丢失文件名的文件

MODEL LINK-BELT 298 HSL
BOOK No. 1113

SERIAL No.
Mitsubishi 6M70 Workshop Manual begins on page 1057
Mitsubishi 6M70 Engine Parts Contact:

Email:
EngineParts@HeavyEquipmentRestorationParts.com
Phone: 2696731638
CRANE SERIAL NUMBER

The crane serial number is on the crane rating manual which is located inside the operator's
cab. The serial number should always be furnished when ordering parts for the crane or when
corresponding with the distributor or factory concerning the crane. Providing the serial
number is the only way of ensuring the correct parts and/or information can be furnished.
In the event the serial number plate is not readable, a number is stamped on the upper revolving
frame which can be used to identify the crane. This number is located on the front face of the
upper frame, between the boom foot mounting lugs.
Link-Belt Construction Equipment Company F00056

General Information and Manual Layout
This manual is divided into 3 Sections separated Tabs.
The front Section is the Workshop Instruction portion of the manual. It contains the
removal/installation (R&I) and the assembly/disassembly (Recondition) instructions for
major crane components. These pages are coded with a “W” in front of the
Section/Group/Page numbers. Example, the pages coded/numbered W2-4-1 through W2-
4-94, contain the instructions for R&I and Recondition of the main pump. (Code W2-4-1
identifies a page in the Workshop Instruction Manual, Section 2, Group 4, and Page 1.)
There are “Contents” pages at the beginning of each sub-section, in front of pages
W1-1-1, W2-1-1, and W3-1-1.
The 2nd and 3rd Sections are the Principles of Operation/Specifications and
Troubleshooting portions of the manual. These pages are coded with a “T” in front of the
Section/Group/Page numbers. Example, the pages coded/numbered T1-3-1 through
T1-3-10, contain the specifications for the engine and engine accessories.The Section
behind Tab 1 contains the specifications and how main components operate to perform
their intended functions. (Code T1-3-1 identifies a page in the Principles of
Operation/Specifications/Troubleshooting Manual, Section 1, Group 3, and Page 1.)
There are “Contents” pages at the beginning of each sub-section, in front of pages T1-2-1,
T2-1-1, and T3-1-1. The Section behind Tab 2 contains Performance Tests/Standards
and Troubleshooting for major components. There are “Contents” pages at the
beginning of each sub-section, in front of pages T4-1-1 and T5-1-1.
BOOK1113 P3091410 Page 1 of 4

Terms/Terminology, Nomenclature, and Abbreviations
The following terms/terminology, nomenclature, and abbreviations are given to help
identify common terms/terminology, nomenclature, and abbreviations used in this
manual that, due to language translations, may not be easily understood.
Auxiliary Hoisting Mechanism = Auxiliary Winch Assembly / Winch Drum

Boom Pendant Rope = Boom Pendants
Center Joint = Rotating Joint
Crawler Shoe = Track Shoe
Derricking = Boom Hoist
Derricking Drum = Boom Hoist Drum
Derricking Mechanism = Boom Hoist System
Derricking Motor = Boom Hoist Motor
Drive Tumbler = Travel Drive Sprocket
Hoisting Drum = Winch Drum
Hoisting Drum Control Valve = Winch Drum Control Valve
Hoisting Mechanism = Winch Assembly / Winch Drum
Hoisting Motor = Winch Motor
Pump Mechanism = Pump Assembly
Screwed-In Connection = Threaded Connection
Slewing = Swing
Slewing Frame = Upper Revolving Frame
Slewing Mechanism = Swing Reduction Unit
Slewing Motor = Swing Motor
Slewing Pump = Swing Pump
Slewing Ring = Turntable Bearing
Stopper = Plug
Take-Up Tumbler = Track Take-Up Idler
Travel Mechanism = Travel Motor and Reduction Gears
Upperstructure = Crane Upper
Page 2 of 4
Conversion Tables
Length Conversion Table
millimeter, mm centimeter, cm meter, m inch, in., " foot, ft., '

1 0.1 0.001 0.03937 0.00328
10 1 0.01 0.3937 0.03281
1000 100 1 39.37 3.281
25.40 2.540 0.0254 1 0.08333
304.8 30.48 0.3048 12 1
mile, mi kilometer, km
1 1.6093
0.6214 1
Area Conversion Table
square millimeter, square centimeter, square meter, m2 square inch, in2 square foot, ft2
mm2 cm2
1 0.01 0.000001 0.00155
100 1 0.0001 0.155 0.001076
1 000 000 1 0000 1 1550 10.764
645.2 6.452 0.000645 1 0.006944
92903.0 929.03 0.09290 144 1
Volume Conversion Table
cubic centimeter, cubic meter, m3 cubic inch, in3 cubic foot, ft3
cm3, cc
1 0.000001 0.0610 0.0000353
1 000 000 1 61024 35.31
16.39 0.0000164 1 0.000579
28320 0.02832 1728 1
gallon, gal. cubic inch, in3 liter, lit., l

1 231 3.785
0.004329 1 0.01639
0.2642 61.02 1
Page 3 of 4
Conversion Tables – (continued)
Weight Conversion Table
gram, g kilogram, kg ounce, oz pound, lb. metric ton, t short ton, s.t.
1 0.001 0.03527 0.0022
1000 1 35.27 2.205 0.001 0.001102
28.349 0.02835 1 0.0625 0.00002835 0.00003125
453.592 0.4536 16 1 0.0004536 0.0005
1 000 000 1 000 35274 2205 1 1.102
907185 907.2 32 000 2000 0.9072 1
Pressure Conversion Table
bar kg/cm3 lb./in2, PSI

1 1.0197 14.50
0.9807 1 14.22
0.06895 0.07031 1
Work, Energy Conversion Table
kg.cm kg.m foot-pound, ft.-lb. inch-pound,.in-lb.

1 0.01 0.0723 0.8681
100 1 7.233 86.81
13.83 0.1383 1 12
1.1525 0.01153 0.08333 1
Centigrade-Fahrenheit Conversion Table
°F °C °F °C °F °C °F °C
-450 -267.78 -200 -128.89 5 -15.00 30 -1.11
-400 -240.00 -150 -101.11 10 -12.22 35 1.67
-350 -212.22 -100 -73.33 15 -9.44 40 4.44
-300 -184.44 -50 -45.56 20 -6.67 45 7.22
-250 -156.67 0 -17.78 25 -3.89 50 10.00
°F °C °F °C °F °C °F °C
55 12.78 80 26.67 150 65.56 400 204.44
60 15.56 85 29.44 200 93.33 450 232.22
65 18.33 90 32.22 250 121.11 500 260.00
70 21.11 95 35.00 300 148.89 550 287.78
75 23.89 100 37.78 350 176.67 600 315.56
Page 4 of 4
INTRODUCTION
TO THE READER
x This manual is written for an experienced technician • If you have any questions or comments, or if you
to provide technical information needed to maintain find any errors regarding the contents of this
and repair this machine. manual, please contact a Link-Belt Distributor.
• Be sure to thoroughly read this manual for cor-

rect product information and service procedures.
ADDITIONAL REFERENCES
x Please refer to the materials listed below in addition • Operation Manual of the Engine
to this manual. • Parts Catalog of the Engine
• The Operator’s Manual

• The Parts Catalog
PAGE NUMBER
x Each page has a number, located on the center
lower part of the page, and each number contains
the following information:
Example : T 1-3-5
Consecutive Page Number for Each Group

Group Number
Section Number
T: Technical Manual W: Workshop Manual
IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and x CAUTION:
signal words are used to alert the reader to the Indicated potentially hazardous situation which
potential for personal injury of machine damage. could, if not avoided, result in personal injury or
death.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury. x IMPORTANT:
Never fail to follow the safety instructions prescribed Indicates a situation which, if not conformed to the
along with the safety alert symbol. instructions, could result in damage to the machine.
The safety alert symbol is also used to draw attention
to component/part weights.
x NOTE:
To avoid injury and damage, be sure to use appropri-
Indicates supplementary technical information or
ate lifting techniques and equipment when lifting
know-how.
heavy parts.

UNITS USED
x SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
this manual.
MKSA system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.
To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
2
Length mm in 0.03937 Pressure MPa kgf/cm 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature qC qF qCu1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
Force N kgf 0.10197 min-1 rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque Nm kgfm 1.0197 mL/rev cc/rev 1.0
Nm lbfft 0.7375
IN-02
SAFETY
RECOGNIZE SAFETY INFORMATION
x This is the SAFETY ALERT SYMBOL.
• When you see this symbol on your machine or in this

manual, be alert to the potential for personal injury.
• Follow recommended precautions and safe operating
practices.
SA-001
001-E01A-0001-2
UNDERSTAND SIGNAL WORDS

x On machine safety signs, signal words designating the
degree or level of hazard - DANGER, WARNING, or
CAUTION - are used with the safety alert symbol.
• DANGER indicates an imminently hazardous situation

which, if not avoided, will result in death or serious
injury.
• WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
• CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.
• DANGER or WARNING safety signs are located
near specific hazards. General precautions are listed
on CAUTION safety signs.
x CAUTION also calls attention to safety messages in this
manual.
x To avoid confusing machine protection with personal SA-1223
safety messages, a signal word IMPORTANT indicates

a situation which, if not avoided, could result in damage
to the machine.
x NOTE indicates an additional explanation for an ele-

ment of information.
002-E01A-0461-6
S-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS
x Carefully read and follow all safety signs on the machine
and all safety messages in this manual.
x Safety signs should be installed, maintained and re-

placed when necessary.
• If a safety sign or this manual is damaged or missing,

order a replacement from your authorized dealer in
the same way you order other replacement parts (be
sure to state machine model and serial number when
ordering). SA-003
x Learn how to operate the machine and its controls cor-

rectly and safely.
x Allow only trained, qualified, authorized personnel to

operate the machine.
x Keep your machine in proper working condition.
• Unauthorized modifications of the machine may impair

its function and/or safety and affect machine life.
x The safety messages in this SAFETY chapter are in-

tended to illustrate basic safety procedures of machines.
However it is impossible for these safety messages to
cover every hazardous situation you may encounter. If
you have any questions, you should first consult your
supervisor and/or your authorized dealer before operat-
ing or performing maintenance work on the machine.
003-E01B-0003-5
PREPARE FOR EMERGENCIES
x Be prepared if a fire starts or if an accident occurs.
• Keep a first aid kit and fire extinguisher on hand.

• Thoroughly read and understand the label attached on
the fire extinguisher to use it properly.
• Establish emergency procedure guidelines to cope
with fires and accidents.
• Keep emergency numbers for doctors, ambulance
service, hospital, and fire department posted near SA-437
your telephone.
004-E01A-0437-3
S-2
SAFETY
WEAR PROTECTIVE CLOTHING
x Wear close fitting clothing and safety equipment appro-
priate to the job.
You may need:

A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear SA-438
Respirator or filter mask.

Be sure to wear the correct equipment and clothing for
the job. Do not take any chances.
• Avoid wearing loose clothing, jewelry, or other items

that can catch on control levers or other parts of the
machine.
x Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating the machine.
005-E01A-0438-4
PROTECT AGAINST NOISE

x Prolonged exposure to loud noise can cause impairment
or loss of hearing.
• Wear a suitable hearing protective mechanism such

as earmuffs or earplugs to protect against objection-
able or uncomfortably loud noises.
SA-434
006-E01A-0434-2
INSPECT MACHINE
x Inspect your machine carefully each day or shift by
walking around it before you start it to avoid personal
injury.

• In the walk-around inspection, be sure to cover all
points described in the “PRE-START INSPECTION”
chapter.
SA-435
007-E01A-0435-2
S-3
SAFETY
USE HANDHOLDS AND STEPS
x Falling is one of the major causes of personal injury.
• When you get on and off the machine, always face the
machine and maintain a three-point contact with the
steps and handrails.
• Do not use any controls as handholds.
• Never jump on or off the machine. Never mount or
dismount a moving machine.
• Be careful of slippery conditions on platforms, steps, SA-439
and handrails when leaving the machine.
008-E01A-0439-3
ADJUST THE OPERATOR’S SEAT

x A poorly adjusted seat for either the operator or for the
work at hand may quickly fatigue the operator leading to
misoperations.
• The seat should be adjusted whenever changing the

operator for the machine.
• The operator should be able to fully depress the ped-
als and to correctly operate the control levers with his
back against the seat back.
• If not, move the seat forward or backward, and check SA-464
again.
009-E01A-0464-3
S-4
SAFETY
FASTEN YOUR SEAT BELT (IF EQUIPPED)
x If the machine should overturn, the operator may be-
come injured and/or thrown from the cab. Additionally
the operator may be crushed by the overturning ma-
chine, resulting in serious injury or death.
• Prior to operating the machine, thoroughly examine

webbing, buckle and attaching hardware. If any item
is damaged or worn, replace the seat belt or compo-
nent before operating the machine.
• Be sure to remain seated with the seat belt securely SA-237
fastened at all times when the machine is in operation
to minimize the chance of injury from an accident.
• We recommend that the seat belt be replaced every
three years regardless of its apparent condition.
010-E02B-0237-3
OPERATE ONLY FROM OPERATOR’S SEAT

x Inappropriate engine starting procedures may cause the
machine to runaway, possibly resulting in serious injury
or death.
• Start the engine only from the operator’s seat.

• NEVER start the engine while standing on the crawler
shoe or on ground.
• Do not start engine by shorting across starter termi-
nals.
SA-444
• Before starting the engine, confirm that all control lev-
ers are in neutral.
012-E01B-0444-3
S-5
SAFETY
JUMP STARTING
x Battery gas can explode, resulting in serious injury.

• If the engine must be jump-started, be sure to follow
the instructions shown in the “OPERATING THE EN-
GINE” chapter.
• The operator must be in the operator’s seat so that the
machine will be under control when the engine starts.
Jump-starting is a two-person operation.
• Never use a frozen battery.
SA-032
• Failure to follow correct jump starting procedures
could result in a battery explosion or a runaway ma-
chine.
013-E01A-0032-3
S-6
SAFETY
PROTECT AGAINST FLYING DEBRIS
x If flying debris hit eyes or any other part of the body, se-
rious injury may result.
• Guard against injury from flying pieces of metal or de-

bris; wear goggles or safety glasses.
• Keep bystanders away from the working area before
striking any object.
SA-432
031-E01A-0432-2
S-7
SAFETY
PARK MACHINE SAFELY •Engage all brake and drum locks. Shutdown the
engine.
To avoid accidents:
•Remove the key from the key switch. Lock the
cab and all access doors.
• Park machine on a firm, level ground.
• Lower the boom to the ground.
033-E04A-0470-3
• In a work site where the boom cannot be lowered to
the ground, secure the boom using guy ropes so as to
minimize the wind effect on the boom,
• Run the engine at slow idle for five (5) minutes to cool
the engine down.
HANDLE FLUIDS SAFELY᧩AVOID FIRES

x Handle fuel with care; it is highly flammable. If fuel ig-
nites, an explosion and/or a fire may occur, possibly re-
sulting in serious injury or death.
• Do not refuel the machine while smoking or when near

open flame or sparks.
• Always shutdown the engine before refueling the ma-
chine.
• Fill the fuel tank outdoors.
SA-018
x All fuels, most lubricants, and some coolants are flam-
mable.
• Store flammable fluids well away from fire hazards.

• Do not incinerate or puncture pressurized containers.
• Do not store oily rags; they can ignite and burn spon-
taneously.
SA-019
034-E01A-0496-4
S-8
SAFETY
SAFE TRANSPORTATION
x The danger of tipping is present when loading/unloading
machine onto/from a truck or trailer bed.
• Be sure to observe local regulations when transporting

the machine on public roads.
• Be sure to have a signal person when loading/unload-
ing the machine.
• Provide an appropriate trailer for transporting the ma-
chine.
Less than 15q SA-475A

Take the following precautions when loading/unloading
the machine:
1) Select firm, level ground.
2) Be sure to use a loading dock or ramp.
3) When using a loading ramp, use one which has
antislip bands on the surface.
4) Drive the machine at very slow speed.
5) Avoid steering while driving up or down the ramp
as it is extremely dangerous. If steering is un-
avoidable, first move back to the ground or flatbed,
modify traveling direction, and begin to drive
again.
6) Do not operate any levers besides the travel lev-
ers when driving up or down the ramp.
7) The top of the ramp where it meets the flatbed is a
sudden bump. Take care when traveling over it.
8) Securely fasten chains or cables to the machine
frame.
035-E03A-0475-᧲
TOWING MACHINE
x When towing the machine, be sure to attach tow wire

ropes around the lower frames as illustrated. To prevent
the wire ropes from being damaged, place protective
material between the lower frames and the wire ropes.
Pulling Rope
SA-605
061-E01A-0605-2
S-9
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
• Understand service procedures before starting work.

Keep the work area clean and dry.
Do not spray water or steam inside cab.
• Never lubricate or service the machine while it is mov-
ing.
• Keep hands, feet and clothing away from
power-driven parts.
• Before servicing the machine:

1) Park machine on a solid, level surface.
2) Lower the boom to the ground. If the boom cannot
be fully lowered, secure the boom with guy ropes
to prevent the boom from being blown by wind.
SA-028
3) Run the engine at slow idle speed without load for

5 minutes.
4) Apply all brakes and locks.
5) Turn the key switch to OFF to shutdown engine.
6) Remove the key from the switch.
7) Move the pilot shut-off lever to the LOCK position.
8) Attach a “Do Not Operate” tag on the cab door.
• If a maintenance procedure must be performed with

the engine running, do not leave machine unattended.
• Securely support any machine elements that must be
raised for service work.
If the machine must be raised, place supporting
blocks under the frame.
• Inspect certain parts periodically and repair or replace
as necessary. Refer to the section discussing that SA-527
part in the “MAINTENANCE” chapter of this manual.
• Keep all parts in good condition and properly installed.
Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil or debris.
• Disconnect battery ground cable (–) before making
adjustments to electrical systems or before perform-
ing welding on the machine.
500-E07A-0497-8
S-10
SAFETY
WARN OTHERS OF SERVICE WORK
x Unexpected machine movement can cause serious in-
jury.
• Before performing any work on the machine, attach a

“Do Not Operate” tag on the control lever.
This tag is available from your authorized dealer.
SA-287
501-E01A-0287-2
SUPPORT MACHINE PROPERLY

x Never attempt to work on the machine without securing
the machine first.
• Always lower the attachment to the ground before you

work on the machine.
• If you must work on a lifted machine or attachment,
securely support the machine or attachment. Do not
support the machine on cinder blocks, hollow tires, or SA-527
props that may crumble under continuous load. Do
not work under a machine that is supported solely by
a jack.
519-E01A-0527-3
STAY CLEAR OF MOVING PARTS

x Entanglement in moving parts can cause serious injury.
• To prevent accidents, care should be taken to ensure

that hands, feet, clothing, jewelry and hair do not be-
come entangled when working around rotating parts.
SA-026
502-E01A-0026-2
S-11
SAFETY
PREVENT BURNS
Hot spraying fluids:
x After operation, engine coolant is hot and under pres-

sure. Hot water or steam is contained in the engine, ra-
diator and heater lines.
Skin contact with escaping hot water or steam can
cause severe burns.
• To avoid possible injury from hot spraying water.

DO NOT remove the radiator cap until the engine is
cool. When opening, turn the cap slowly to the stop. SA-039
Allow all pressure to be release before removing the

cap.
• The hydraulic oil tank is pressurized. Again, be sure
to release all pressure before removing the cap.
Hot fluids and surfaces:
x Engine oil, gear oil and hydraulic oil also become hot
during operation.
The engine, hoses, lines and other parts become hot as
well. SA-225
• Wait for the oil and components to cool before starting

any maintenance or inspection work.
505-E01B-0498-5
REPLACE RUBBER HOSES PERIODICALLY
x Rubber hoses that contain flammable fluids under pres-

sure may break due to aging, fatigue, and abrasion. It is
very difficult to gauge the extent of deterioration due to
aging, fatigue, and abrasion of rubber hoses by inspec-
tion alone.
• Periodically replace the rubber hoses.

SA-019
x Failure to periodically replace rubber hoses may cause
a fire, fluid injection into skin, or the front attachment to
fall on a person nearby, which may result in severe
burns, gangrene, or otherwise serious injury or death.
506-E01A-0019-3
S-12
SAFETY
AVOID HIGH-PRESSURE FLUIDS
x Fluids such as diesel fuel or hydraulic oil under pressure
can penetrate the skin or eyes causing serious injury,
blindness or death.
• Avoid this hazard by relieving pressure before dis-

connecting hydraulic or other lines.
• Relieve the pressure by moving the control levers
several times.
Tighten all connections before applying pressure.
• Search for leaks with a piece of cardboard; take care SA-031
to protect hands and body from high-pressure fluids.

Wear a face shield or goggles for eye protection.
• If an accident occurs, see a doctor familiar with this
type of injury immediately. Any fluid injected into the
skin must be surgically removed within a few hours or
gangrene may result.
SA-292
SA-044
507-E01A-0499-5
NEVER ATTEMPT TO MODIFY SAFETY

MECHANISM, HYDRAULIC COMPONENTS,
OR ELECTRICAL WIRING
x Incorrect modification or adjustment may cause acci-
dent.
• Do not modify or adjust the preadjusted parts of hy-

draulic components or safety mechanism. If read-
justment or modification is required, consult your au-
thorized dealer.
SA-019
x Alternation on electrical wiring may cause fire.
• If modification or alternation of electrical wiring is re-

quired, consult your authorized dealer.
520-E01A-0019-3
S-13
SAFETY
PREVENT FIRES
Check for Oil Leaks: Check Heat Shields:
x Fuel, hydraulic oil and lubricant leaks can lead to fires. x Damaged or missing heat shields may load to
fires.
• Check for oil leaks due to missing or loose clamps,
kinked hoses, lines or hoses that rub against each • Damaged or missing heat shields must be re-
other, damage to the oil-cooler, and loose oil-cooler paired or replaced before operating the ma-
flange bolts. chine.
• Tighten, repair or replace any missing, loose or dam- 508-E02B-0019-9
aged clamps, lines, hoses, oil-cooler and oil-cooler
flange bolts.
• Do not bend or strike high-pressure lines.
• Never install bent or damaged lines, pipes or hoses.
Check for Shorts:
x Short circuits can cause fires.
• Clean and tighten all electrical connections.

• Check before each shift or after eight (8) to ten (10)
SA-019
hours operation for loose, kinked, hardened or frayed
electrical cables and wires.
• Check before each shift or after eight (8) to ten (10)
hours operation for missing or damaged terminal
caps.
• DO NOT OPERATE MACHINE if cable or wires are
loose, kinked, etc.
Clean up Flammables:
x Spilled fuel and oil, and trash, grease, debris, accumu-

lated coal dust, and other flammables may cause fires.
• Prevent fires by inspecting and cleaning the machine

daily, and by removing spilled or accumulated flam-
mables immediately.
Check Key Switch:
x If a fire breaks out, failure to shutdown the engine will

escalate the fire, hampering fire fighting.
• Always check key switch function before operating

the machine every day:
1. Start the engine and run it at slow idle.
2. Turn the key switch to the OFF position to confirm
that the engine stops.
• If any abnormalities are found, be sure to repair them
before operating the machine.
508-E02B-0019-9
S-14
SAFETY
EVACUATING IN CASE OF FIRE
x If a fire breaks out, evacuate the machine in the follow-
ing way:
• Shutdown the engine with turning the key switch to

the OFF position if there is time.
• Use a fire extinguisher if there is time.
• Exit the machine.
SA-393
518-E02A-0393-2
BEWARE OF EXHAUST FUMES

x Prevent asphyxiation. Engine exhaust fumes can cause
sickness or death.
• If you must operate in a building, be sure there is ade-

quate ventilation. Either use an exhaust pipe exten-
sion to remove the exhaust fumes or open doors and
windows to bring enough outside air into the area.
• Be aware of California Proposition 65 Warning which SA-016

reads “Diesel engine exhaust and some of its con-
stituents, and certain vehicle components contain or
emit chemicals known to the State of California to
cause cancer, birth defects, and other reproductive
harm”.
509-E01A-0016-2
S-15
SAFETY
AVOID HEATING NEAR PRESSURIZED FLUID
LINES
x Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to you
and bystanders.
• Do not heat by welding, soldering, or using a torch

near pressurized fluid lines or other flammable mate-
rials.
• Pressurized lines can be accidentally cut when heat
goes beyond the immediate flame area. Install tem- SA-030
porary fire-resistant guards to protect hoses or other
materials before engaging in welding, soldering, etc.
AVOID APPLYING HEAT TO LINES CON-

TAINING FLAMMABLE FLUIDS
• Do not weld or flame cut pipes or tubes that contain
flammable fluids.
• Clean them thoroughly with nonflammable solvent
before welding or flame cutting them.
510-E01B-0030-4
REMOVE PAINT BEFORE WELDING OR

HEATING
x Hazardous fumes can be generated when paint is

heated by welding, soldering, or using a torch. If inhaled,
these fumes may cause sickness.
• Avoid potentially toxic fumes and dust.

• Do all such work outside or in a well-ventilated area.
Dispose of paint and solvent properly. SA-029
• Remove paint before welding or heating:

1) If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
2) If you use solvent or paint stripper, remove
stripper with soap and water before welding.
Remove solvent or paint stripper containers and
other flammable material from area. Allow fumes
to disperse at least 15 minutes before welding or
heating.
511-E01A-0029-4
S-16
SAFETY
PREVENT BATTERY EXPLOSIONS
x Battery gas can explode, resulting in serious injury.
• Keep sparks, lighted matches, and flame away from

the top of battery.
• Never check battery charge by placing a metal object
across the posts. Use a voltmeter or hydrometer.
• Do not charge a frozen battery; it may explode. Warm
the battery to 16 qC (60 qF) first.
• Do not continue to use or charge the battery when SA-032
electrolyte level is lower than specified. Explosion of
the battery may result
• Loose terminals may produce sparks. Securely
tighten all terminals.
x Battery electrolyte is poisonous. If the battery should

explode battery electrolyte may be splashed into eyes,
possibly resulting in blindness.
If splashed in eyes, flush with water for 15 minutes. Get
medical attention immediately.
• Be sure to wear eye protection when checking

electrolyte specific gravity.
512-E01B-0032-4
S-17
SAFETY
HANDLE CHEMICAL PRODUCTS SAFELY
x Direct exposure to hazardous chemicals can cause
serious injury. Potentially hazardous chemicals used
with your machine include such items as lubricants,
coolants, paints, and adhesives.
• A Material Safety Data Sheet (MSDS) provides

specific details on chemical products: physical and
health hazards, safety procedures, and emergency
response techniques.
• Check the MSDS before you start any job using a
hazardous chemical. That way you will know exactly SA-309
what the risks are and how to do the job safely. Then
follow procedures and use recommended equipment.
• See your authorized dealer for MSDS’s on chemical
products used with your machine.
515-E01A-0309-4
DISPOSE OF WASTE PROPERLY
x Improperly disposing of waste can threaten the

environment and ecology. Potentially harmful waste
used with equipment includes such items as oil, fuel,
coolant, brake fluid, filters, and batteries.
• Use leakproof containers when draining fluids. Do not

use food or beverage containers that may mislead
someone into drinking from them.
• Do not pour waste onto the ground, down a drain, or
into any water source.
• Inquire on the proper way to recycle or dispose of
waste from your local environmental or recycling
center, or from your authorized dealer.
516-E01A-0226-4
S-18
SECTION 1
GENERAL
CONTENTS
Group 1 Precautions for Disassembling

and Assembling
Precautions for Disassembling and
Assembling ............................................ W1-1-1
Group 2 Tightening Torque

Tightening Torque Specifications ............. W1-2-1
Standard Torque Specifications ............... W1-2-2
Piping Joint.............................................. W1-2-5
2CNW-1-1
(Blank)
2CNW-1-2
GENERAL INFORMATION / Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING

Precautions for Disassembling and Assembling • Store common parts, such as bolts and nuts with
reference to where they are to be used and in a
x Clean the Machine manner that will prevent loss.
Thoroughly wash the machine before bringing it into • Inspect the contact or sliding surfaces of
the shop. Bringing a dirty machine into the shop disassembled parts for abnormal wear, sticking,
may cause machine components to be or other damage.
contaminated during disassembling/assembling, • Measure and record the degree of wear and
resulting in damage to machine components, as clearances.
well as decreased efficiency in service work.
x Precautions for Assembling
x Inspect the Machine • Be sure to clean all parts and inspect them for
Be sure to thoroughly read and understand all dis- any damage. If any damage is found, repair or
assembling/assembling procedures before starting replace it.
any repair work. Understanding these procedures • Dirt or debris on the contact or sliding surfaces
will help avoid incorrect disassembling of compo- may shorten the service life of the machine. Take
nents as well as the purchasing of unnecessary ser- care not to contaminate any contact or sliding
vice parts. surfaces.
• Before assembling, coat all inner parts with clean
• The machine model, machine serial number, and hydraulic oil or gear oil. Especially coat the slid-
hour meter reading. ing surfaces with clean hydraulic oil or gear oil.
• Be sure to replace O-rings, backup rings, and oil
• Reason for disassembly (symptoms, failed parts,
seals with new ones once they are disassembled.
and causes).
Apply a film of grease before installing.
• Clogging of filters and oil, water or air leaks, if
• Be sure that liquid-gasket-applied surfaces are
any. clean and dry.
• Capacities and condition of lubricants. • If an anti-corrosive agent has been used on a
• Loose or damaged parts. new part, be sure to thoroughly clean the part to
remove the agent.
x Prepare and Clean Tools and Disassembly Area • Utilize matching marks when assembling.
Prepare the necessary tools to be used and the • Be sure to use the designated tools to assemble
area for disassembling work. bearings, bushings and oil seals.
• Keep a record of the number of tools used for
x Precautions for Disassembling disassembly/assembly. After assembling is com-
• To prevent dirt from entering, cap or plug the plete, count the number of tools, so as to make
removed pipes. sure that no tools are missing.
• Before disassembling, clean the exterior of the

components and place it on a work bench.
• Before disassembling, drain gear oil from the
reduction gear.
• Be sure to provide appropriate containers for
draining fluids.
• Use matching marks for easier reassembling.
• Be sure to use the specified special tools, when
instructed.
• If a part or component cannot be removed after
removing its securing nuts and bolts, do not
attempt to remove it forcibly. Find the cause(s),
then take the appropriate measures to remove it.
• Orderly arrange disassembled parts. Mark and
tag them as necessary.

W1-1-1
Bleeding Air from Hydraulic System

When hydraulic oil is drained, the suction filter or the
suction lines are replaced, or the removal and in-
stallation of the pump, swing motor, travel motor or
cylinder is done, bleed air from the hydraulic system
in the following procedures:

IMPORTANT: If the engine is started with air
trapped in the hydraulic pump
housing, damage to the pump may
result.
If the hydraulic motor is operated
with air trapped in the hydraulic
motor housing, damage to the
motor may result.
If the cylinder is operated with air
trapped in the cylinder tube,
damage to the cylinder may result.
Be sure to bleed air before starting
the engine.

x Bleeding Air from Hydraulic Pump

• Remove the air bleeding plug from the top of the
pump and fill the pump housing with hydraulic oil.
• After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the
engine and run at slow idle speed.
• Slightly loosen the plug to bleed air from the
pump housing until hydraulic oil oozes out.
• After bleeding all the air, securely tighten the
plug.

x Bleeding Air from Travel Motor / Swing Motor

• With the drain plug / hose on travel motor / swing
motor removed, fill the motor case with hydraulic
oil.

x Bleeding Air from Hydraulic Circuit

• After refilling hydraulic oil, start the engine. While
operating each cylinder, swing motor and travel W328-01-01-001
motor evenly, operate the machine under light

loads for 10 to 15 minutes. Slowly start each
operation (never fully stroke the cylinders during
initial operation stage). As the pilot oil circuit has
an air bleed device, air trapped in the pilot oil
circuit will be bled while performing the above
operation for approx. 5 minutes.
• Reposition the front attachment to check
hydraulic oil level.
• Stop the engine. Recheck hydraulic oil level. Re-
plenish oil as necessary.
W1-1-2
Floating Seal Precautions
A
1. In general, replace the floating seal with a new
one.
If the floating is to be reused, follow these
procedures:
(1) Keep seal rings together as a matched set

with seal ring faces together. Insert a piece of
cardboard to protect surfaces.
W105-03-05-019
B
(2) Check the seal ring face (A) for scuffing,
scoring, corrosion, deformation or uneven
wear.
(3) Check O-ring (B) for tears, breaks,

deformation or hardening.

2. If incorrectly assembled, oil leakage or damage
will occur. Be sure to do the following, to prevent
trouble.

(1) Clean the floating seal and seal mounting
bores with cleaning solvent. Correct
Use a wire brush to remove mud, rust or dirt.
After cleaning, thoroughly dry parts with
compressed air.

(2) Clean the floating seal and seal mounting Incorrect
bores, as dust on them tends to enter the
floating seal when installing it.

(3) Check that the O-ring is not twisted, and that it
is installed correctly on the seal ring.
D W105-03-05-020
(4) After installing the floating seal, check that

seal surface (C) is parallel with the seal
Correct C Incorrect
a a
mounting bore end face (D) and O-ring (B) as
illustrated. B

b b
a=b
aำ b
W110-03-05-004
W1-1-3
Precautions for Using Nylon Sling

1. Follow the precautions below to use nylon slings
safely.
• Attach protectors (soft material) on the corners of
Correct Eyehole
the load so that the nylon sling does not directly Lifting Method
contact the corners. This will prevent the nylon
sling from damage and the lifted load from slip-
ping.
• Lower the temperature of the lifted load to lower
than 100 qC (212 qF). If unavoidably lifting a load
with a temperature of 100 qC (212 qF) or more,
reduce the load weight.
• Do not lift acid or alkali chemicals.
• Take care not to allow the sling to become wet.
The load may slip.
• When required to use more than one sling, use
slings with the same width and length to keep the W102-04-02-016
lifted load balanced. Incorrect Eyehole

• When lifting a load using an eyehole, be sure to Lifting Method
eliminate any gaps between the sling and load.
(Refer to the right illustration.) Reduce the load
weight so that it is less than 80 % of the sling
breaking force.
• Avoid using twisted, bound, connected, or
hitched slings.
• Do not place any object on twisted or bent slings.
(Refer to the right illustration.)
• When removing the slings from under the load,
take care not to damage the nylon slings. Avoid
contact with protrusions.
• Avoid dragging slings on the ground, throwing W105-04-01-008
slings or pushing slings with a metal piece.

• When using with other types of slings (wire rope)
or accessories (shackle), protect the joint so that
the nylon sling is not damaged.
• Store the nylon slings indoors so they won’t dete-
riorate with heat, sun light, or chemicals.

Bent Sling W162-01-01-009
W1-1-4

Damaged Appearance
CAUTION: If a load is lifted with a damaged Broken Sewing Thread
nylon sling, serious personal injury may re-
sult. Be sure to visually check the nylon sling
for any damage before using.

W162-01-01-002
Scuffing

2. Before using a nylon sling, visually check the ny-
lon sling for any damage corresponding to exam-
ples shown to the right. If any damage is found,
cut and discard the sling. Even if no damage is
found, do not use slings older than 7-years. W162-01-01-003
Fuzz
Broken Sewing
Thread

W162-01-01-004
Broken Sewing
Thread

W162-01-01-005
Broken Sewing
Thread

Scoring Separation of W162-01-01-006
Belt

W162-01-01-007
Fuzz Scuffing

Broken Warp

W162-01-01-008
W1-1-5
Maintenance Standard Terminology
“Standard”
1. Dimension for parts on a new machine.
2. Dimension of components or assemblies ad-
justed to specification. Tolerances are indicated
as necessary.
“Allowable Limit”
1. Machine cannot operate normally with the parts
exceeding this dimension installed.
2. Repair or adjustment is impossible if this dimen-
sion is exceeded.
3. To maintain high machine availability and to save
the repair expense, the machine parts should be
repaired or replaced before reaching the “Allow-
able Limit.”

W1-1-6
GENERAL INFORMATION / Tightening Torque
TIGHTENING TORQUE SPECIFICATIONS
Bolts and Nuts of Machine: Standard Tightening
Torque Chart
Bolt Wrench Torque

No. Descriptions Dia. Q’ty Size
mm Nm kgfm
mm
33 68 50 1640 to 167 to 181
1. Turntable Mounting Bolt
1770
Engine Mounting Bolt Front 14 4 22 60 to 85 6 to 9
2.
and Nut Rear 14 4 22 60 to 85 6 to 9
3. R.H. Platform Mounting Bolt 20 14 30 392 40
4. Cab Mounting Bolt 16 8 24 68 to 79 7 to 8
5. L.H. Platform Mounting Bolt 20 14 30 392 40
6. Live Mast Flip Cylinder Mounting Bolt 20 8 30 359 to 379 35.7 to 38.7
7. Carrier Roller (Front/Rear) Mounting Bolt 12 24 19 60 to 64 6.1 to 6.6
8. Carrier Roller (Center) Mounting Bolt 16 8 24 68 to 79 7 to 8
9. Carrier Roller (To Machine No. 5) Mounting Bolt 24 88 36 498 to 539 50.8 to 55.0
Carrier Roller (From Machine No. 6 and after) 1640 to
10. 33 88 50 167 to 181
Mounting Bolt 1770
11. Travel Mechanism Mounting Bolt (Right/Left) 33 30 Hex.24 1950 200
12. Travel Motor Mounting Bolt (Right/Left) 12 24 Hex.10 106 to 120 10.8 to 13.2
Hoisting Mechanism Mounting Bolt (Front/Rear
13. 22 104 32 540 55
Drum)
Hoist Drum Cover Mounting Bolt (Front/Rear
14. 12 32 19 60 to 64 6.1 to 6.6
Drum)
15. Hoist Motor Mounting Bolt (Front/Rear Drum) 20 8 30 539 55
Boom Raising/Lowering Mechanism Mounting
16. 22 30 32 550 56
Bolt
Boom Raising/Lowering Drum Cover Mounting
17. 10 9 17 34 to 37 3.5 to 3.8
Bolt
18. Boom Raising/Lowering Motor Mounting Bolt 16 4 Hex.14 750 76.5
19. Swing Mechanism Mounting Bolt 20 36 30 350 to 379 35.7 to 38.7
20. Swing Motor Mounting Bolt 16 8 24 235 24
21. Pump Mechanism Mounting Bolt 10 8 17 41 to 45 4.2 to 4.6
22. Main Pump Mounting Bolt 20 4 Hex.17 400 41
23. Swing Pump Mounting Bolt 16 4 Hex.14 240 24
24. Reduction Gear Mounting Bolt 10 4 Hex.12 33 3.4
25. Gear Pump Mounting Bolt 10 2 Hex.8 41 to 45 4.2 to 4.6
26. Hydraulic Oil Tank Mounting Bolt 20 4 30 400 41
27. Fuel Tank Mounting Bolt 16 2 24 148 to 160 15.0 to 16.3
28. Radiator Mounting Bolt 12 4 19 60 to 64 6.1 to 6.6
29. Radiator Stay Mounting Bolt 10 4 17 41 to 45 4.2 to 4.6
30. Hydraulic Hose -
NOTE: (1) Apply lubricant (i.e. white zinc B (3) Apply LOCTITE onto the boom derricking mecha-
dissolved into spindle oil) to reduce nism mounting bolt, boom derricking motor mount-
their friction coefficients. ing bolt, pump mechanism mounting bolt, main
pump mounting bolt and gear pump mounting bolt.
(2) Remove rust, dirt, and dust before in-
stalling fasteners.
W1-2-1
STANDART TORQUE SPECIFICATIONS
CAUTION: Use tools appropriate for the

work to be done. Makeshift tools and
procedures can create safety hazards. For
loosening and tightening nuts and bolts, use
the correct tools. Avoid bodily injury caused
by slipping wrenches.
Bolt Types
Tighten nuts or bolts correctly to torque

specifications. Four kinds of bolts, hexagon bolts T, SA-040
H, M and socket bolts, each made of different
material, are used. Make sure to employ the correct
bolts and tighten them to specification when
assembling the machine or components.
Hexagon T Bolt Hexagon H Bolt Hexagon M Bolt Socket Bolt

W157-01-01-001
Specified Tightening Torque Chart

Bolt Wrench Hexagon T Bolt, Socket Bolt H Bolt M Bolt
Dia. Size Wrench
Size Nm kgfm lbfft Nm kgfm lbfft Nm kgfm lbfft
M 8 13 6 30 3.1 22 20 2.0 15 10 1.0 7.4
M 10 17 8 65 6.6 48 50 5.1 37 20 2.0 15
M 12 19 10 110 11.0 81 90 9.2 66 35 3.6 26
M 14 22 12 180 18.5 133 140 14.0 103 55 5.6 41
M 16 24 14 270 27.5 199 210 21.5 155 80 8.2 59
M 18 27 14 400 41.0 295 300 30.5 221 120 12.0 89
M 20 30 17 550 56.0 406 400 41.0 295 170 17.0 125
M 22 32 750 76.5 553 550 56.0 406 220 22.5 162
M 24 36 950 97.0 701 700 71.5 516 280 28.5 207
M 27 41 1400 143 1033 1050 107 774 400 41.0 295
M 30 46 1950 200 1438 1450 148 1069 550 56.0 406
M 33 50 2600 265 1918 1950 200 1438 750 76.5 553
M 36 55 3200 325 2360 2450 250 1807 950 97.0 701
W1-2-2
IMPORTANT: (1) Apply lubricant (i. e. white zinc B
dissolved into spindle oil) to nuts
and bolts to stabilize their
friction coefficients.
(2) Torque tolerance is s10 %.
(3) Be sure to use bolts of correct
length. Bolts that are too long
cannot be tightened, as the bolt
tip comes into contact with the
bottom of the bolt hole. Bolts
that are too short cannot develop
sufficient tightening force.
(4) The torques given in the chart
are for general use only.
Do not use these torques if a
different torque is given for a
specific application.
(5) Make sure that the nut and bolt
threads are clean before
installing. Remove dirt or
corrosion, if any.
Bolt Tightening Order
When tightening two or more bolts, tighten them

alternately, as shown, to ensure even tightening.
Equally tighten upper Tighten diagonally Tighten from center

and lower alternately and diagonally
1,4 1 12 9 4 1 6 7 14
6 3
4 5
2 13 8 5 2 3 10 11
2,3
W105-01-01-003
W1-2-3
Service Recommendations for Split Flange
IMPORTANT: (1) Be sure to clean and inspect

sealing surfaces. Scratches /
roughness cause leaks and seal
wear. Unevenness causes seal
extrusion. If defects cannot be
removed, replace the W105-01-01-015
component. WRONG
(2) Be sure to use only specified
O-rings. Inspect O-rings for any
damage. Take care not to file
O-ring surfaces. When installing
an O-ring into a groove, use
grease to hold it in place.
(3) Loosely assemble split flange W105-01-01-016
halves. Make sure that the split
is centrally located and
perpendicular to the port.
Hand-tighten the bolts to hold
the parts in place. Take care not
to pinch the O-ring.
(4) Tighten bolts alternately and
diagonally, as shown, to ensure
even tightening. W105-01-01-008
(5) Do not use air wrenches. Using

RIGHT WRONG
an air wrench often causes
tightening of one bolt fully
before tighten the others,
resulting in damage to O-rings or
uneven tightening of bolts. Bend along edge sharply Do not bend it round
RIGHT RIGHT WRONG

Nut and Bolt Lockings
x Lock Plate
IMPORTANT: Do not reuse lock plates. Do not try
to bend the same point twice.
Bend along edge sharply
W105-01-01-009

RIGHT RIGHT WRONG
x Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the
holes in the bolt and nut while WRONG
RIGHT Loosen
tightening, not while loosening.
Tighten
x Lock Wire
IMPORTANT: Apply wire to bolts in the
bolt-tightening direction, not in the W105-01-01-010
bolt-loosening direction.
W1-2-4
PIPING JOINT
Pipe Thread Connection / Union Joint Tightening
Torque Specifications 1 4 3 5 2
Union Joint
Metal sealing faces (4) and (5) of adaptor (1) and

hose (2) fit together to seal pressure oil. Union joints

are used to join small-diameter lines.
Joint Body
IMPORTANT: (1) Do not over-tighten union nut (3). M202-07-051
Excessive force will be applied

to metal sealing surfaces (4) and
(5), possibly cracking adaptor (1). 37q
Be sure to tighten union nut (3)
to specifications. 30q
(2) Scratches or other damage to

sealing surfaces (4) or (5) will Male Union Joint Female Union Joint

cause oil leakage at the joint.
W105-01-01-017
Take care not to damage them
when connecting /disconnecting.
Wrench Size Tightening Torque

Type
Union Nut Joint Body Nm kgfm Ibfft
30q Male Union 17 17 24.5 2.5 18
Joint 19 19 29.5 3.0 22
22 22 39 4.0 29
27 27 93 9.5 69
32 32 137 14.0 101
36 36 175 18.0 129
41 41 205 21.0 151
37q Female Union 17 14 24.5 2.5 18
Joint 19 17 29.5 3.0 22
22 19 39 4.0 29
27 22 93 9.5 69
32 27 137 14.0 101
36 32 175 18.0 129
41 36 205 21.0 151
W1-2-5
O-Ring Seal Joint
7 6 9
O-ring (6) seats against the end face of adaptor (7)
to seal pressure oil.
IMPORTANT: (1) Be sure to replace O-ring (6) with

a new one when reconnecting.
(2) Before tightening union nut (9), Joint Body

confirm that O-ring (6) is seated 8 10
correctly in O-ring groove (8). M104-07-033
Tightening union nut (9) with
O-ring (6) displaced will damage
O-ring (6), resulting in oil Wrench Size Tightening Torque
leakage. Union Nut Joint Body Nm kgfm Ibfft
19 17 29.5 3.0 22
(3) Take care not to damage O-ring 22 19 69 7.0 51
groove (8) or sealing face (10). 27 22 93 9.5 69
Damage to O-ring (6) will cause
32 27 137 14.0 101
oil leakage.
36 30, 32 175 18.0 129
(4) If union nut (9) is found to be 41 36 205 21.0 151
loose, causing oil leakage, do 46 41 205 21.0 151
not tighten it to stop the leak.
Instead, replace O-ring (6) with a
new one, then tighten union nut
(9) after confirming that O-ring
(6) is securely seated in place.
W1-2-6
Screwed-In Connection
PT PF
IMPORTANT: Many types of screwed-in

30q
connec-tions are used for hose
connections.
Be sure to confirm that the thread
pitch and thread type (tapered or
straight) are the correct type before
using any screw-in connection.
Male Tapered Thread Male Straight Thread
W105-01-01-018

Male Tapered Thread
Wrench Tightening Torque
Joint Body Nm kgfm Ibfft
17, 19 59 6 43
19, 22 98 10 72
27, 22 118 12 87
36, 32 235 24 134
41 295 30 215
50 490 50 360
60 670 68 490
70 980 100 720
Seal Tape Application
Internal Thread
Seal tape is used to seal clearances between male

and female threads, so as to prevent any leakage
between threads.
Be sure to apply just enough seal tape to fill up External Thread Clearance
thread clearances. Do not overwrap.
W105-01-01-019
Leave one to two pitch threads uncovered

x Application Procedure
Confirm that the thread surface is clean, free of dirt

or damage.
Apply seal tape around threads as shown. Wrap
seal tape in the same direction as the threads.

M114-07-041
Low-Pressure-Hose Clamp Tightening Torque

T-Bolt Type Worm Gear Type
Low-pressure-hose clamp tightening torque differs
depending on the type of clamp.
See below for correct tightening torque of each type
of low-pressure-hose clamp.
T-Bolt Type Band Clamp:

4.4 Nm (0.45 kgfm, 3.25 lbfft )
Worm Gear Type Band Clamp:
5.9 to 6.9 Nm (0.6 to 0.7 kgfm, 4.3 to 5.1 lbfft )
M114-07-042 M114-07-043
W1-2-7
Connecting Hose
WRONG RIGHT
CAUTION:
(1) When replacing hoses, be sure to use
genuine manufacture parts. Using hoses
other than genuine manufacture parts
may cause oil leakage, hose rupture or
separation of fitting, possibly resulting in
a fire on the machine.
(2) Do not install hoses kinked. Application
of high oil pressure, vibration, or an
impact to a kinked hose may result in oil W105-01-01-011
leakage, hose rupture or separation of
fitting. Utilize print marks on hoses when
installing hoses to prevent hose from
being installed kinked. WRONG RIGHT
(3) If hoses rub against each other, wear to Rubbing Against
the hoses will result, leading to hose Each Other
rupture. Take necessary measures to
protect hoses from rubbing against each
other.
Take care that hoses do not come into
contact with moving parts or sharp
objects.
W105-01-01-012

WRONG RIGHT
Clamp Clamp
Rubbing

W105-01-01-013

WRONG RIGHT

Rubbing

Clamp

W105-01-01-014
W1-2-8
REFERENCE: Major Parts to Be Replaced at
Regular Intervals.
The parts listed below deteriorate as the machine Therefore, these parts should be replaced at regular
ages and are worn out or fatigued by repeated loads, intervals even if no abnormalities are noticed. In
resulting in possible severe personal injury and/or case any abnormalities are found on a part at any
machine trouble. The service life of these parts can time regardless of its specified replacement interval,
not be detected through machine operation or visual immediately replace the part.
inspection.
Part Location Part to be Replaced Q’ty Interval (Hours or Period)

Pendant rope Crane: 400 hrs /2 years
Bucket, Lifting Magnet
Front -
(Heavy Duty Work)
Attachment
: 2000 hrs / 2 years
Ball bearing (oil less bearing in the hook sheave) - 2000 hrs / 2 years
Winch Ball bearing (boom hoist winch pedestal) 1 2000 hrs / 2 years
Fuel hose (between the fuel tank and filter) - 2000 hrs / 2 years
Engine Fuel hose (between the fuel tank and injection - 2000 hrs / 2 years
pump)
IMPORTANT: Each hose has an individual service

life. If any abnormalities are found
during the regular interval check
and/or maintenance service, be sure
to replace with a new one.
W1-2-9
(Blank)
W1-2-10
SECTION 2
SWING MACHINERY
CONTENTS
Group 1 Cab
Remove and Install Cab .......................... W2-1-1 Remove and Install Gear Pump
Dimensions of The Cab Glass ................. W2-1-7 (For Reeving Winch) .......................... W2-4-85
Disassemble Gear Pump
Group 2 Counterweight
(For Reeving Winch) .......................... W2-4-88
Remove and Install Counterweight............ W2-2-1
Assemble Gear Pump
Group 3 Revolving Frame (For Reeving Winch) .......................... W2-4-90

Remove and Install Revolving Frame ...... W2-3-1 Group 5 Control Valve
Remove and Install 4-Unit Control Valve
Group 4 Pump Mechanism
for Front Drum, Rear Drum, Travel,
Remove and Install Main Pump ............... W2-4-1
Boom Raising/Lowering Drum and
Disassemble Main Pump ......................... W2-4-4
Quick Draw .......................................... W2-5-1
Assemble Main Pump............................ W2-4-10
Disassemble 4-Unit Control Valve............ W2-5-4
Maintenance Standard........................... W2-4-16
Assemble 4-Unit Control Valve .............. W2-5-10
Disassemble Front Regulator ................ W2-4-18
Remove and Install 4-Uint Control Valve
Assemble Front Regulator ..................... W2-4-24
for Boom Foot and Lower
Disassemble Rear Regulator................. W2-4-28
Hydraulic Source................................ W2-5-16
Assemble Rear Regulator...................... W2-4-34
Disassemble 4-Unit Control Valve.......... W2-5-18
Remove and Install Swing Pump ........... W2-4-41
Disassemble Swing Pump ..................... W2-4-44
Assemble Swing Pump.......................... W2-4-48
for Counterweight Removal/Installation
Maintenance Standard ......................... W2-4-50
and Live Mast Flip .............................. W2-5-26
Disassemble Regulator ......................... W2-4-52
Assemble Regulator .............................. W2-4-58
Remove and Install Gear Pump
(For Oil Cooler) .................................. W2-4-65
for Swing ............................................ W2-5-36
Disassemble Gear Pump
(For Oil Cooler) .................................. W2-4-68
Assemble Gear Pump (For Oil Cooler) .. W2-4-70
Remove and Install 2-Unit Gear Pump .. W2-4-75
Disassemble 2-Unit Gear Pump ............ W2-4-78
Assemble 2-Unit Gear Pump ................. W2-4-80
2CNW-2-1
Group 6 Swing Mechanism (For Machine No.6 and after)
Remove and Install Swing Mechanism .... W2-6-1 Remove and Install Raising/Lowering
Disassemble Swing Mechanism .............. W2-6-4 Mechanism......................................... W2-8-31
Assemble Swing Mechanism ................... W2-6-8 Disassemble Raising/Lowering
Disassemble Swing Motor ..................... W2-6-12 Mechanism......................................... W2-8-34
Assemble Slewing Motor ....................... W2-6-16 Assemble Raising/Lowering Mechanism W2-8-38
Maintenance Standard ......................... W2-6-20 Disassemble Raising/Lowering Motor .... W2-8-42
Assemble Raising/Lowering Motor ....... W2-8-46
Group 7 Hoisting Mechanism
Remove and Install Hoisting
Disassemble Regulator.......................... W2-8-52
Mechanism .......................................... W2-7-1
Assemble Regulator............................... W2-8-54
Disassemble Hoisting Mechanism ........... W2-7-6
Disassemble Counterbalance Valve....... W2-8-56
Assemble Hoisting Mechanism.............. W2-7-10
Assemble Counterbalance Valve ........... W2-8-58
Disassemble Hoisting Motor .................. W2-7-16
Assemble Hoisting Motor....................... W2-7-20 Group 9 Remote Control Valve
Maintenance Standard ......................... W2-7-24 Remove and Install Boom
Disassemble Regulator ......................... W2-7-26 Raising/Lowering Drums and Travel
Assemble Regulator .............................. W2-7-28 Remote Control Valves......................... W2-9-1
Disassemble Counterbalance Valve ...... W2-7-30 Remove and Install Swing Remote
Assemble Counterbalance Valve ........... W2-7-32 Control Valve........................................ W2-9-5
Disassemble Reeving Winch ...................W2-734 Disassemble Remote Control Valve ......... W2-9-8
Assemble Reeving Winch...................... W2-7-36 Assemble Remote Control Valve............ W2-9-14
Disassemble Reeving Winch Motor ....... W2-7-38
Group 10 Solenoid Valve
Assemble Reeving Winch Motor..............W2-740
Remove and Install Solenoid Valve
Group 8 Raising/Lowering Mechanism Block .................................................. W2-10-1
(To Machine No.5) Disassemble Solenoid Valve Block ........ W2-10-2
Remove and Install Raising/Lowering Assemble Solenoid Valve Block ............. W2-10-4
Mechanism .......................................... W2-8-1
Group 11 Cylinder
Disassemble Raising/Lowering
Remove and Install Flip Cylinder ........... W2-11-1
Mechanism .......................................... W2-8-4
Disassemble Flip Cylinder ..................... W2-11-4
Assemble Raising/Lowering Mechanism . W2-8-8
Assemble Flip Cylinder .......................... W2-11-6
Disassemble Raising/Lowering Motor.... W2-8-12
Remove and Install Counterweight
Assemble Raising/Lowering Motor ...... W2-8-16
Cylinder.............................................. W2-11-9
Disassemble Counterweight Cylinder .. W2-11-12
Disassemble Regulator ......................... W2-8-22
Assemble Counterweight Cylinder ....... W2-11-14
Assemble Regulator .............................. W2-8-24
Remove and Install Boom Foot
Disassemble Counterbalance Valve ...... W2-8-26
Cylinder............................................ W2-11-17
Assemble Counterbalance Valve ........... W2-8-28
Disassemble Boom Foot Cylinder ........ W2-11-18
Assemble Boom Foot Cylinder............. W2-11-20
2CNW-2-2
SWING MACHINERY/ Cab
REMOVE AND INSTALL CAB
2
1
Removal
1. Remove the seat bracket installing bolts (1) (4

used) and remove the seat (2).
: 13 mm

W24X-02-01-001

8
8
2. Loosen the screws (8) (19 used) and bolts (9) (4
5
used) and remove the covers (3 to 7) behind the 3 8
seat.
: 17 mm 8
7
6
4
8 9

M2CN-02-01-001

3. Remove the screws (18) (4 used) and bolts (19) (4 16

used) and remove the covers (16) and (17) on the 14
lower part of the front display. 18 14
12
: 17 mm
4. Remove the screws (14) (14 used) and socket

bolts (15) (2 used) and remove the covers (11) to 13
(13) from the left stand (10). 14
: 4 mm
19
5. Loosen the bolts (20) (4 used) of the left stand
(10). (In order to move the left stand)
: 13 mm
20
11 14
6. Move the left stand (10) approx. 20 mm to the 10 17
15
inside.
W24X-02-01-003

W2-1-1
7. Remove the screws (25) (14 used) and socket 25
bolts (26) (2 used) and remove the covers (22) to 23
(24) from the right stand (21). 26
: 4 mm 27 24 25
26
8. Loosen the bolts (27) (4 used) of the right stand
(21). (In order to move the right stand)
: 13 mm 25
9. Move the right stand (21) approx. 20 mm to the

inside. 25
21
27 22
W2CG-02-01-001
10. Loosen the bolts (33) (22 used) and remove the
under covers (28) to (32) at front of the right bed.
: 17 mm
28
32
29 33
31
33
30
M2CN-02-01-002
33
11. Disconnect all connectors (34) of the electric 35 34
wiring for each equipment installed on the cab.
12. Loosen the hose clamp (36) and remove the air
conditioner hoses (35) (2 used).

36

34

34

34

W24X-02-01-006
W2-1-2
13. Remove the bolt (37) and nuts (38) (8 used).
: 24 mm
38
37

M2CN-02-01-002
14. Attach a wire rope on the lifting position (M12) (4

places) on the top of cab (39) and support it with
the crane.
39
CAUTION: Cab weight: 228 kg
15. Carefully lift the cab (39) in order not to touch the
rear stand, left stand, right stand and other
equipments on the floor plate.

M2CN-02-01-003
W2-1-3
Installation
CAUTION: Cab weight: 228 kg
1. Attach a wire rope on the lifting position (12) (4

places) on the top of cab (39) and lift it with the 39
crane.
2. Carefully lower the cab (39) in order not to touch

the rear stand, left stand, right stand and other
equipments on the floor plate.

3. Install the bolt (37) and nuts (38) (8 used). M2CN-02-01-003
: 24 mm
: 68.1 to 79.4 Nm (6.9 to 8.1 kgfm)
38
37

M2CN-02-01-002
4. Tighten and install the air conditioner hoses (35)

(2 used) to the air conditioner with hose clamp 35 34
(36).
5. Install all connectors (34) of the electric wiring for

each equipment installed on the cab.
36
34
34
34

W24X-02-01-006
W2-1-4
6. Install the under covers (28) to (32) at front of the
right platform with the bolts (33) (25 used).
: 17 mm
: 50 Nm (5.1 kgfm)
28
32
33
29
33
31 30
M2CN-02-01-002
33

7. Push the right stand (21) on the wall in the cab. 25
23
8. Tighten the bolts (27) (4 used) of the right stand 26
(21).
: 13 mm 27 24 25
26
: 10 Nm (1.0 kgfm)
9. Install the covers (22) to (24) on the right stand 25

with the screws (25) (14 used) and socket bolts
(26) (2 used). 25
: 4 mm
21
27 22

W2CG-02-01-001

10. Push the left stand (10) on the wall in the cab.
16
11. Tighten the bolts (20) (4 used) of the left stand 14
(10).
12 18 14
: 13 mm
: 10 Nm (1.0 kgfm)
12. Install the covers (11) to (13) on the left stand (10) 13
with the screws (14) (14 used) and socket bolts 14
(15) (2 used).
: 4 mm 19
13. Install the covers (16) and (17) on the bottom of

the front display with the screws (18) (14 used)
and socket bolts (19) (4 used). 20
: 17 mm 11 14
10 17
: 50 Nm (5.1 kgfm) 15

W24X-02-01-003
W2-1-5
14. Install the covers (3) to (7) on the rear stand with
the screw (8) and bolt (9). 8
: 17 mm 8
5
: 50 Nm (5.1 kgfm) 3 8
8
7
6
4
8 9

M2CN-02-01-001
2
15. Install the seat (2) with the bolt (1). 1
: 13 mm
: 10 Nm (1.0 kgfm)

W24X-02-01-001
W2-1-6
DIMENSIONS OF THE CAB GLASS
NOTE: JIS R3211, 3212 or equivalent Unit: mm
565.2
25
25
R30
R55
810
Thickness :
776
517.7 6.8 mm
26 26
22.5 22 22 22.5
25 25
857.5
166 R53
276.5
466 R5 469.8 (134.7) 53
57.5 I11
64
R75.9 R75.9 42.5
32 88
Thickness : Thickness : 897.5
4 mm 4 mm 122.5
I12.2 Thickness:
763 763 5 mm
40 40
39.5 39.5
312.4 312.4 R5
R5
604.5 768
R5
376.6
Thickness:
5 mm 558.5
R61 R40
758
Thickness :
4 mm 497.7
65.8
498
186.4
R61
R2519
Thickness : 372.6
4 mm
650.8 371.2
802.9
R61
123.2 406.8 735.9 148.3
Thickness :
233.5
4 mm
264.3 R61 R61
648
Thickness : 623 667.7 Thickness : 4 mm
251.6 4 mm 840
530
172.3

W2BC-02-01-001
W2-1-7
(Blank)
W2-1-8
SWING MACHINERY / Counterweight
REMOVE AND INSTALL COUNTERWEIGHT
CAUTION: Never allow the workers enter 1

under and/or between the base machine and
counterweight.
Removal
1. Lower the boom and remove the hook. After

removing the wire rope of the front and rear drum,
remove the pendant rope, extension and top
section. (As for the removal of the pendant rope,
extension and top section, refer to the Operator’s
Manual.)
A
2. Place the power switch on the control box in “ON”

and slightly retract the right and left
removal/installation cylinder (1) with operating the
removal/installation cylinder switch.
M2CN-02-02-001
3. Draw the lever (3) installed on the base

counterweight assembly (2). (Right and left: Each
2 places)
3

M2CN-02-02-002
IMPORTANT: Carefully operate the switch with Detail A

adjusting so that the counterweight
does not tilt to the right and left.
1 B
4. Extend the right and left removal/installation
cylinder (1) with operating the removal/installation
cylinder switch and lower the counterweight on
the ground.

M2CN-02-02-003
W2-2-1
5
5. Pull the lever (4) and draw the pin (5).

4 Detail B M2CN-02-02-004
6. Retract the right and left removal/installation

cylinder (1) with operating the removal/installation 1 C
cylinder switch and lower the removal/installation
frame (6).
9

D
IMPORTANT: Attach a cap so that the dust and

foreign matter does not enter after M2CN-02-02-005
disconnecting the quick couplers.

If the quick couplers come in contact
with other objects, it may be 7
damaged. Handle with care. 9
7. Remove the hose (7) for the removal/installation

cylinder from the piping (9) installed on the
revolving frame (8).

8

Detail C M2CN-02-02-006
8. Push the lever (4) and push the pin (5) into the
removal/installation frame.
5
4
Detail B M2CN-02-02-007
W2-2-2
9. Push in the lever (3) of the base counterweight
assembly (2). (Right and left: Each 2 places)
2 3

Detail D M2CN-02-02-008

IMPORTANT: Take care not to damage the cable of Counterweight Center Approx. 6.1m to
the control box with riding or Rotation Center
pinching it when moving the
machine forward.
10. Move the base machine forward and keep it from

the counterweight.
NOTE: Move the base machine forward so that the

distance between the center of the
counterweight and the rotation center of the
base machine is approx. 6m.

M2CN-02-02-009
W2-2-3
Installation
IMPORTANT: Take care not to damage the cable of

the control box with riding or
pinching it when moving the
machine backward.
1. Move the base machine backward to the direction

of the counterweight at the status that the base
section is supported with the quick draw.
NOTE: Move the base machine backward with

aligning the removal/installation frame (6)
and the revolving frame (8). Align the M2CN-02-02-009
removal/installation (6) at the poison of 5m

8
from the revolving frame (8) and stop B 6
moving the base machine.

Center of
M2CN-02-02-010
Rotating Platform
8
H

M2CN-02-02-005
W2-2-4
2. Move the lock lever (13) to “LOCK” side.

UNLOCK
LOCK
NOTE: When the lock lever (13) is moved to 13

“UNLOCK” position, the counterweight can
not be removed and installed.

3. Draw the lever (3) installed on the base W2CG-02-02-012
counterweight assembly (2). (Right and left: Each

2 places)

2
4. Pull the lever (4) and draw the pin (5). Detail F M2CN-02-02-002
4 Detail G M2CN-02-02-007
7
9
IMPORTANT: Wipe off the dust and foreign from
the quick couplers before
connecting and clean it.
If the quick couplers come in contact
with other objects, it may be
damaged. Handle with care.
Securely connect the hydraulic
hoses. 8 Detail H
M2CN-02-02-006
5. Connect the hose (7) for the removal/installation
cylinder to the piping (9) installed on the revolving
frame (8).
W2-2-5
6. Place the power switch on the control box in “ON”
and extend the right and left removal/installation
cylinder switch. J
1
NOTE: At this time, make sure that the hook (14) of

the removal/installation frame (6) is set to
the pin (15) of the revolving frame (8) side.
M2CN-02-02-003
15

7. Push the lever (4) and push the pin (5) into the
removal/installation frame. 8
14

Detail I M2CN-02-02-011
4
M2CN-02-02-004
Detail J
W2-2-6
IMPORTANT: Carefully operate the switch with
adjusting so that the counterweight
L 1
does not tilt to the right and left.
8. Retract the right and left removal/installation

cylinder switch on the control box and lift the
counterweight.
9. Push in the lever (3) of the base counterweight

assembly (2) and lock the counterweight. (Right M2CN-02-02-001
and left: Each 2 places)
2
Detail K

NOTE: Slightly extend the removal/installation M2CN-02-02-008
cylinder (1) so that the load is not applied to
the removal/installation cylinder (1).

12
10. Install the extension, top section and pendant rope.
(As for the installation of the extension, top section
1
and pendant rope, refer to the Operator’s Manual.)
Detail L
M2CN-02-02-012
W2-2-7
(Blank)
W2-2-8
SWING MACHINERY/ Revolving Frame
REMOVE AND INSTALL REVOLVING
FRAME

CAUTION: Escaping fluid under pressure
may penetrate the skin and eyes, and cause
serious injury. Release the pressure before
removing the hydraulic or other lines.
Hot hydraulic oil just after operation may
spout and cause severe burns. Wait for oil in
order to cool before starting any work.

Removal

removing the wire rope of the front/rear drum,
remove the pendant rope, extension and boom
top section. (As for the removal of the pendant
rope, extension and boom top section, refer to the
Operator’s Manual.)
2. Remove the counterweight. (As for the removal of
the counterweight, refer to W2-2 in this section.)

3. Remove the boom base section, crawler and
lower weight. (As for the removal of the boom
base section, crawler and lower weight, refer to
the Operator’s Manual.)
4. Remove the boom raising/lowering drum wire
rope.

W2-3-1
5. Remove the hose of the center joint of only the

swing machinery side.
1 1
6. Attach the wire rope on the shackle (1). Install the
shackle (1) on the live mast mounting portion of
the revolving frame and counterweight mounting
portion.

M2CN-02-03-001

1 1

M2CN-02-03-002
W2-3-2
CAUTION: Swing machinery weight: Approx.

20 t
7. Balance the swing machinery with using the wire

rope and chain block and support it with the crane.
8. Put the matching marks on the outer race side of

the swing ring and revolving frame side.

M2CN-02-03-003
Center
9. Loosen the bolt (2) 10 mm of the outer race of the
swing ring in both side frames to the direction of
the center in order. Carry out the same procedures
for the rear side. (The illustration is viewed from
the front.)
: 50 mm

10. Lift the swing machinery 10 mm with the crane 2 2
and balance the whole.
W324-02-03-006
11. Remove the bolt (2) from the outer race of the
swing ring in both side frames to the direction of
the center in order.
: 50 mm
12. Lift the swing machinery with the crane and

remove it.

W2-3-3
Installation

CAUTION: Swing machinery weight: Approx.
20 t
1. Balance the swing machinery and lift it with the

crane.
2. Align the matching marks on the outer race of the

swing ring and revolving frame. Lower the swing
machinery slowly and support it at the height of 10
mm with the crane.

M2CN-02-03-003
3. Insert the bolt (2) from the outer race side of the Center
swing ring and tighten the bolt temporarily.
4. Tighten all the bolts temporarily and lower the

swing machinery completely.
5. Tighten the nuts diagonally and alternately.

: 50 mm
: 1640 to 1770 Nm (167.0 to 181.0 kgfm) 2 2

6. Install all hoses on the center joint. (Refer to W3-3 W324-02-03-006
in the following section.)
W2-3-4
7. Install the lower weight, crawler and boom base
section. (As for the installation of the lower weight,
crawler and boom base section, refer to the
8. Install the counterweight. (Refer to W2-2 in this

section.)
9. Install the extension, boom top section and

pendant rope. (As for the installation of the
extension, boom top section and pendant rope,
refer to the Operator’s Manual.)
10. Wind the wire rope on the front/rear drum and

reeve the wire rope through the hook. (Refer to
W2-3-5
(Blank)
W2-3-6
SWING MACHINERY / Pump Mechanism
REMOVE AND INSTALL MAIN PUMP

Before draining hydraulic oil, lower the boom
and apply each brake and drum lock.
Preparation

1. Shutdown the engine. Operate the control lever
several times and release the remaining pressure
in the circuit.
2. Remove the drain plug (1) and drain off the

hydraulic oil with using a container (500 L). After
draining, install the plug (1).
: 19mm

W2CG-02-04-010

Removal 2
1. Remove all hoses, pipings and wire harness from

the pump device. Cap the removed hoses.
: 22 mm, 27 mm, 36 mm
: 8 mm, 10 mm, 14 mm
2. Attach a wire rope on the main pump and support

the main pump with the crane.
CAUTION: Main pump weight: Approx. 304 kg
3. Remove the bolts (2) and (3). Lift the main pump
with the crane and remove it.
: 17mm
: 30 mm
3
M2CN-02-04-001
W2-4-1
Installation

CAUTION: Main pump weight: Approx. 304 kg
2
1. Lift the main pump with the crane and install it to
the coupling and bracket. 4
2. Apply LOCTITE on the bolts (2) and (3) and install

them.
: 17 mm
: 400 Nm (41.0 kgfm)
: 30 mm
: 350 to 379 Nm (35.7 to 38.7 kgfm)
3. Install all hoses, pipings, and wire harness on the

main pump.
᧶22 mm
᧶39 Nm (4.0 kgfm)
᧶27 mm
᧶93 Nm (9.5 kgfm)
᧶36 mm 3
᧶175 Nm (18.0 kgfm) M2CN-02-04-001
᧶8 mm
᧶48 to 50 Nm (4.9 to 5.1 kgfm)

᧶10 mm
᧶90 Nm (9.2 kgfm)
᧶14 mm
᧶210 Nm (21.5 kgfm)
4. Remove the filler port cover of the hydraulic oil

tank. Apply the hydraulic oil to the specified
position of the level gauge.
5. Remove the air bleed plug (4) from the top of main
pump and fill the hydraulic oil. Install the air bleed
plug (4). Start the engine and run at low idling
speed.
: 36 mm
: 170 Nm (17.0 kgfm)
6. Loosen the air bleed plug (4) and release the air in
the pump.
: 36 mm
7. Tighten the air bleed plug (4) after releasing the air.
Do the work at low idling speed. Check the
hydraulic oil level and any oil leaks.
: 36 mm
: 170 Nm (17.0 kgfm)
W2-4-2
(Blank)
W2-4-3
DISASSEMBLE MAIN PUMP

17 18
16
19
14, 15
20
13 21
12 22
11
10
9
8
23
24
25
7 8
5 26
6 45
5 67
4 27
3 44
28 27
2
29 63
43 57 62
10 66
1 42
58
41
40
39
38
37 47 61
36 65
46 48 64
35
10 59
32 33,34
31 60
30
17
55
18 54
53
52
56
50
42
49
40
46 51

W2CG-02-04-002
W2-4-4
1- Socket Bolt (4 Used) 18 - Socket Bolt (4 Used) 35 - Spring (18 Used) 52 - O-Ring
2- Plate 19 - Stopper (2 Used) 36 - Cylinder Block (2 Used) 53 - Oil Seal
3- O-Ring 20 - Backup Ring (2 Used) 37 - Spring (18 Used) 54 - Cover
4- Retaining Ring (2 Used) 21 - O-Ring (2 Used) 38 - Cylinder Block (2 Used) 55 - Socket Bolt (4 Used)
5- Spacer (3 Used) 22 - Servo Piston (2 Used) 39 - Valve Plate 56 - Regulator
6- Bearing (2 Used) 23 - O-Ring (4 Used) 40 - Bearing (2 Used) 57 - Plug(᧮Used)
7- Shaft 24 - Plug (4 Used) 41 - Gear 58 - O-Ring
8- Nut (2 Used) 25 - Pump Casing (2 Used) 42 - O-Ring 59 - Reduction Gear
9- Screw (2 Used) 26 - O-Ring (2 Used) 43 - Block 60 - Flange Socket (4 Used)
10 - Spring Pin (6 Used) 27 - Plug (26 Used) 44 - Screw (2 Used) 61 - O-Ring
11 - Stopper (2 Used) 28 - Support (2 Used) 45 - Eyebolt (2 Used) 62 - Cover
12 - Backup Ring (2 Used) 29 - Socket Bolt (8 Used) 46 - Pin (2 Used) 63 - Socket Bolt (2 Used)
13 - O-Ring (2 Used) 30 - Plate (2 Used) 47 - O-Ring (4 Used) 64 - O-Ring
14 - Feedback Pin (2 Used) 31 - Bushing (2 Used) 48 - Plug (2 Used) 65 - Block
15 - Tilt Pin (2 Used) 32 - Plate (2 Used) 49 - Valve Plate 66 - Socket Bolt (4 Used)
16 - Regulator 33 - Piston (18 Used) 50 - O-Ring (16 Used) 67 - Block (4 Used)
17 - Socket Bolt (4 Used) 34 - Shoe (18 Used) 51 - Shaft
W2-4-5
17 18
16
24
25
28
29 43
41
38
37
36
35
59
33,34
60
30
17
55
18 54
53
56
51

W2CG-02-04-002
W2-4-6
Disassemble Main Pump
• Thoroughly read “PRECAUTIONS FOR

DISASSEMBLING AND ASSEMBLING” (W1-1-1)
before disassembling.
IMPORTANT: Place the rubber plate or cloth on IMPORTANT: Place the rubber plate on the
the workbench not to damage the workbench not to damage the
parts. regulator mounting surface when
placing it down.
1. Select the place to disassemble.
6. Place the pump on the workbench horizontally
NOTE: Select a clean place. with the regulator mounting surface with placing
downward. Separate the pump casing (25) from
2. Remove the dust and rust on the surface of pump the block (43).
with using washing oil.
NOTE: Remove the gear (41) at the same time
3. Remove the plug (24) and drain the oil from the when separating the pump casing (25) from
pump casing (25). the block (43).
: 36 mm
IMPORTANT: Do not damage the sliding surfaces
NOTE: Drain the oil from the plug in front pump of the cylinder block (38), bushing
and rear pump respectively. (36), shoe (34) and plate (30).
4. Remove the socket bolts (17), (18) and flange 7. Remove the cylinder block (38) from the pump
socket (60). Remove the regulators (16), (56) and casing (25) straightly to the shaft. At the same
reduction gear (59). time, remove the piston (33), plate (35), bushing
: 6 mm, 12 mm (36), and spring (37).
NOTE: As for disassembly of the regulators (16) IMPORTANT: Do not damage the oil seal (53) when
and (56), refer to the corresponding removing the cover (54).
section.
8. Remove the socket bolt (55) and remove the
5. Remove the socket bolt (29) that tightens the cover (54).
support (28), pump casing (25) and block (43). : 6 mm
᧶ 17mm
NOTE: If inserting the bolt in the hole (M6) on the
cover (54), the cover (54) can be removed
NOTE: In case the pump is installed behind the easily.
pump, carry out this working after removing
the pump first.
W2-4-7
19
15
11 22
25
7 8
67
28
2
43
40
39
32
30
49
51

W2CG-02-04-002
W2-4-8
9. Remove the socket bolt (1) and block (67).
Remove the plate (2).
: 14 mm
10. Tap the mounting flange part of the support (28)

from the pump casing (25) side and separate the
support (28) from the pump casing (25).
11. Remove the plates (32) and (30) from the pump
casing (25).
12. Tap the ends of the shafts (51) and (7) with using
a plastic hammer and remove the shafts (51) and
(7) from the support (28).
13. Remove the valve plates (39) and (49) from the
block (43).
NOTE: The valve plates (39) and (49) may be

removed at step 6.
IMPORTANT: When removing the tilt pin (15), use

a special tool not to damage the
head of tilt pin (15).
As LOCTITE is applied on the fitting
part between the tilt pin (15) and
servo piston (22), do not damage the
servo piston (22).
Do not remove the bearing (40)
except replacement.
As the setting of flow rate changes,
do not loosen the lock nut (8) of the
block (43) and support (28).
14. If necessary, remove the stoppers (19), (11),

servo piston (22) and tilt pin (15) from the pump
casing (25). Remove the bearing (40) from the
block (43).
W2-4-9
ASSEMBLE MAIN PUMP
56 16
18 18 17
17
9 12 13 22 31 14 15 21 20 19 50 45 57 8 44 42 23,24 33 34 11
8
67
10
26 1
54
55
4
51
53
5
52
6
30
10 40 47,48
28 27 32 35 36 37 29 49 43 41 46 39 38 25 7 3 2
65 64
59
66
68 62
63 60
67
61
66 58
65
69

W2CG-02-04-011
W2-4-10
1- Socket Bolt (4 Used) 19 - Stopper (2 Used) 37 - Spring (18 Used) 55 - Socket Bolt (4 Used)
2- Plate 20 - Backup Ring (2 Used) 38 - Cylinder Block (2 Used) 56 - Regulator
3- O-Ring 21 - O-Ring (2 Used) 39 - Valve Plate 57 - Plug (12 Used)
4- Retaining Ring (2 Used) 22 - Servo Piston (2 Used) 40 - Bearing (2 Used) 58 - O-Ring
5- Spacer (3 Used) 23 - O-Ring (4 Used) 41 - Gear 59 - Reduction Gear
6- Bearing (2 Used) 24 - Plug (4 Used) 42 - O-Ring (2 Used) 60 - Flange Socket (4 Used)
7- Shaft 25 - Pump Casing ᧤2 Used᧥ 43 - Block 61 - O-Ring
8- Nut (2 Used) 26 - O-Ring (4 Used) 44 - Screw (2 Used) 62 - Cover
9- Screw ᧤2 Used᧥ 27 - Plug (26 Used) 45 - Eyebolt (2 Used) 63 - Socket Bolt (2 Used)
10 - Spring Pin (6 Used) 28 - Support (2 Used) 46 - Pin (2 Used) 64 - O-Ring
11 - Stopper (2 Used) 29 - Socket Bolt (8 Used) 47 - O-Ring (4 Used) 65 - Block
12 - Backup Ring (2 Used) 30 - Plate (2 Used) 48 - Plug (2 Used) 66 - Socket Bolt (4 Used)
13 - O-Ring (2 Used) 31 - Bushing (2 Used) 49 - Valve Plate 67 - Block (4 Used)
14 - Feedback Pin (2 Used) 32 - Plate (2 Used) 50 - O-Ring (16 Used) 68 - Seat (4 Used)
15 - Tilt Pin (2 Used) 33 - Piston (18 Used) 51 - Shaft 69 - Steel Ball (4 Used)
16 - Regulator 34 - Shoe (18 Used) 52 - O-Ring (2 Used) 70 - Stopper (2 Used)
17 - Socket Bolt (4 Used) 35 - Plate (2 Used) 53 - Oil Seal 71 - Stopper (2 Used)
18 - Socket Bolt (4 Used) 36 - Bushing (2 Used) 54 - Cover 72 - Reducing Valve
W2-4-11
22 31 14 15 19 33 34 11
67
1
54
55
4
51
53
5
30
28 35 36 37 49 43 46 38 25 7 2

W2CG-02-04-011
W2-4-12
Assemble Main Pump
IMPORTANT: When tightening the servo piston IMPORTANT: Do not damage the oil seal (53) when
(22) and tilt pin (15), use a special installing.
tool not to damage the head of tilt
pin (15) and feedback pin (14). 4. Secure the cover (54) on the pump casing (25)
Apply LOCTITE (medium intensity) with the socket bolt (55).
on the thread part. : 6 mm
: 29 Nm (3.0 kgfm)
1. Install the support (28) on the pump casing (25)
while tapping with using a hammer. NOTE: Slightly apply grease on the oil seal (53) in
the cover (54).
NOTE: When the servo piston (22), the tilt pin (15),
the stoppers (19) and (11) are removed, 5. Secure the plate (2) on the pump casing (25) with
install them on the pump casing (25) first. the socket bolt (1) and block (67).
: 14 mm
2. Place the pump casing (25) with directing the : 430 Nm (44.0 kgfm)
regulator mounting surface downward. Insert the
bushing (31) of the plate (30) in the tilt pin (15). 6. Assemble the piston cylinder sub assembly
Install the plate (30) on the support (28) correctly. (cylinder block (38), piston (33), shoe (34), plate
(35), bushing (36) and spring (37)). As aligning
NOTE: Check if the plate (30) can move smoothly the spline of the bushing (36) and cylinder block
by fingers. (38), insert the piston cylinder sub assembly into
If the grease is applied on the plate (30), the pump casing (25).
support (28) and moving part, the shaft (7)
and (51) can be installed easily. IMPORTANT: Check the direction of the suction
and delivery of the valve plate (49).
IMPORTANT: Do not tap the shaft (51) with using a
hammer. 7. Align with pin (46) and install the valve plate (49)
on the block (42).
3. Install the shaft with the bearing (6), spacer (5)
and retaining ring (4) set on the support (28).
NOTE: Install the outer ring of the bearing (6) while

tapping with using a plastic hammer and
install) the outer ring with using a steel bar
completely.
W2-4-13
56 16
18 18 17
17
14 15 24
51
29 43 41 25 7
59
60

W2CG-02-04-011
W2-4-14
IMPORTANT: Check the direction of the block (42).
(Install the block (42) with the
regulator (56) positioned upward
and the suction flange positioned to
the right.)
8. Install the block (43) on the pump casing (25) and

tighten the socket bolt (29).
: 17mm
: 430 Nm (44.0 kgfm)
NOTE: If assembling the pump at rear side first,

the assembling procedures are easy.
Insert the gear (41) into the block (43) first
and connect to the joint spline of shafts (7)
and (51).
IMPORTANT: Check the regulators (16) and (56)

for the front and rear.
9. Insert the feedback pin (14) of the tilt pin (15) into
the feedback lever of the regulators (16) and (56).
Install the regulators (16), (56) and reduction gear
(59). Tighten the socket bolts (17), (18) and flange
socket (58).
: 6 mm
: 29 Nm (3.0 kgfm)
: 12 mm
: 33 Nm (3.4 kgfm)
10. Install the plug (24).

: 36 mm
: 170 Nm (17.3 kgfm)
W2-4-15
MAINTENANCE STANDARD
1. Clearance between piston outer diameter and

cylinder inner bore.

Standard Allowable Limit
D-d 0.035 mm 0.062 mm d D

W25N-02-04-005

2. Clearance between piston and shoe calking
portion

ˡ 0 to 0.1 mm 0.3 mm
ˡ

3. Shoe thickness W25N-02-04-006

t 4.9 mm 4.7 mm

4. Free length of cylinder spring

L 39.5 mm 38.7 mm
L

W25N-02-04-007
5. Combining height of plate and spherical bushing

H-h 23.0 mm 22.0 mm
H
h

W25N-02-04-008

W2-4-16
(Blank)
W2-4-17
DISASSEMBLE FRONT REGULATOR
3
11
10
9
8
21
7
6 20 12
16 19
5 17 13
4
3 14
2 22
1 15
23
24 16
25
26 18
29
30 44
27
28 43 41
42 45
41
40
36 37 39
38
31
30 32
46
47
47
33
35 48
34
30 49
50
56
54
55 54 53 52 51
58 57 49 50

W2CG-02-04-003
W2-4-18
1- Pin 16 - Pin (2 Used) 31 - Cover 45 - Screw

2- Sleeve 17 - Lever 32 - O-Ring 46 - Casing
3- O-Ring (2 Used) 18 - Pin 33 - O-Ring (3 Used) 47 - Pin (2 Used)
4- O-Ring 19 - Pin 34 - O-Ring 48 - Plug
5- Casing 20 - Feedback Lever 35 - Plug (5 Used) 49 - O-Ring (2 Used)
6- Piston 21 - Lever 36 - Socket Bolt (2 Used) 50 - Retaining Ring (2 Used)
7- Rod 22 - Spool 37 - Socket Bolt (2 Used) 51 - Plug
8- Spring Seat 23 - Sleeve 38 - O-Ring 52 - Pin
9- Spring 24 - Retaining Ring 39 - Adjusting Screw 53 - O-Ring
10 - Spring 25 - Set Spring 40 - Adjusting Screw 54 - O-Ring (9 Used)
11 - Adjusting Rod 26 - Return Spring 41 - Nut (2 Used) 55 - O-Ring
12 - O-Ring 27 - Spring Seat 42 - O-Ring 56 - O-Ring
13 - Adjusting Rod 28 - Retaining Ring 43 - Cover 57 - Cover
14 - Spring 29 - Piston 44 - Lock Nut 58 - Socket Bolt (2 Used)
15 - Spring Seat 30 - Socket Bolt (10 Used)
W2-4-19
11
10
9
8
13
14
15
23
24
25
26
30 44
27
28 43 41
45
40
36 37 39
30
48
30
50
54
54 51
58 57 50

W2CG-02-04-003
W2-4-20
Disassemble Front Regulator
• Thoroughly read “PRECAUTIONS FOR 5. After removing the cover (43) sub assembly, take
DISASSEMBLING AND ASSEMBLING” (W1-1-1) out the springs (9), (10) and spring seat (8) from
before disassembling. the compensating part.Pull out the adjusting rod
(13), spring (14) and spring seat (15) from the
IMPORTANT: Put the rubber plate or cloth on the pilot part.
workbench not to damage the parts.
As the parts are small, take care not
NOTE: The adjusting rod (13) can be removed
to lose the parts.
easily with using the bolt (M4).
6. Remove the socket bolts (58) and (30). Remove
NOTE: Select a clean place. the cover (57).
After removing the cover (57), remove the set
2. Remove the dust and rust on the surface of spring (25) from the pilot part.
regulator with using washing oil. : 5 mm
IMPORTANT: Take care not to lose the O-ring (54). IMPORTANT: When removing the retaining ring
(28), the return spring (26) flies out.
3. Remove the socket bolts (36) and (37). Remove Take care not to lose the return
the regulator from the pump. spring (26).
: 6 mm
7. Remove the retaining ring (28) and remove the
IMPORTANT: The adjusting screws (39), (40), spring seat (27), return spring (26) and sleeve
adjusting rod (11), lock nut (44), nut (23).
(41) and screw (45) are installed on
the cover (43). As the pressure-flow
rate setting is changed, do not NOTE: The retaining ring (24) is installed on the
loosen these screws and nuts. sleeve (23).
4. Remove the socket bolt (30) and remove the 8. Remove the retaining ring (50) and remove the
cover (43). plugs (48) and (51).
: 5 mm
NOTE: The plugs (48) and (51) can be removed
W2-4-21
21
7
6 20
16 19
5 17
22
16
29

W2CG-02-04-003
W2-4-22
IMPORTANT: Do not remove the pin (16).
9. Remove the lever (17).
NOTE: The lever (17) can be removed easily with

using a pair of tweezers.
10. Remove the pin (19) and remove the feedback

lever (20).
NOTE: Push out the pin (19) (pin dia. I4) from the
top with using a thin steel bar not to touch
with the lever (21).
IMPORTANT: Do not remove the pin (16).
12. Pull out the piston (29) and spool (22).
13. Pull out the casing (5), piston (6) and rod (7).
NOTE: When pushing out the rod (7) from the

opposite side of the casing (5), the casing
(5) can be removed.
W2-4-23
ASSEMBLE FRONT REGULATOR
30 32 36 30 14 30
31
45
41
33 56 29 53 15 13 12
35 54 54 55 58
25 34 27 26 24 23 22 46 8 43 44
37 21 18 47 19 49 50
57 39
28 41
48
40
51 3
17 1 11
16 3
2
38
20 4 42
5 6 7 9 10 52

W2CG-02-04-004
1- Pin 16 - Pin (2 Used) 31 - Cover 45 - Screw

2- Sleeve 17 - Lever 32 - O-Ring 46 - Casing
3- O-Ring (2 Used) 18 - Pin 33 - O-Ring (3 Used) 47 - Pin (2 Used)
4- O-Ring 19 - Pin 34 - O-Ring 48 - Plug
5- Casing 20 - Feedback Lever 35 - Plug (5 Used) 49 - O-Ring (2 Used)
6- Piston 21 - Lever 36 - Socket Bolt (2 Used) 50 - Retaining Ring (2 Used)
7- Rod 22 - Spool 37 - Socket Bolt (2 Used) 51 - Plug
8- Spring Seat 23 - Sleeve 38 - O-Ring 52 - Pin
9- Spring 24 - Retaining Ring 39 - Adjusting Screw 53 - O-Ring
10 - Spring 25 - Set Spring 40 - Adjusting Screw 54 - O-Ring (9 Used)
11 - Adjusting Rod 26 - Return Spring 41 - Nut (2 Used) 55 - O-Ring
12 - O-Ring 27 - Spring Seat 42 - O-Ring 56 - O-Ring
13 - Adjusting Rod 28 - Retaining Ring 43 - Cover 57 - Cover
14 - Spring 29 - Piston 44 - Lock Nut 58 - Socket Bolt (2 Used)
15 - Spring Seat 30 - Socket Bolt (10 Used)
W2-4-24
Assemble Front Regulator
1. Insert the rod (7) into the compensating hole of 5. Insert the piston (29) into the hole for the negative
the casing (46). control on the casing (46).
2. Install the pin (16) on the lever (21).Insert the pin NOTE: Check if the piston (29) moves smoothly.
(16) into the groove of the rod (7). Install the pin
(47) on the casing (46).Install the lever (21) into 6. Install the pin (16) on the lever (17).Insert the pin
the pin (47). (16) into the groove of the piston (29).Install the
lever (17).
IMPORTANT: Check if the spool (22) and sleeve
(23) can move in the casing (46) 7. Install the pin (47) to plug (48).Align the pin (47)
smoothly. with the pin hole on the lever (17) and install the
Check the direction of the spool (22). plug (48). Install the retaining ring (50).
IMPORTANT: Check the inserting holes for the

plugs (48) and (51).
8. Insert the plug (51) and install the retaining ring

(50).
22 20
W25N-02-04-011
NOTE: Check if the feedback lever (20) has not too
big play or moves smoothly.
3. Insert the spool (22) and sleeve (23) into the
spool hole on the casing (46). 9. Insert the return spring (26) and spring seat (27)
into the spool hole and install retaining ring (28).
4. Install the feedback lever (20).Align the pin hole
on the feedback lever (20) and insert the pin (19).
NOTE: If the pin (19) is inserted into the feedback

lever (20) first, the inserting procedure is
easy.
IMPORTANT: Check the direction of the feedback

lever (20).
Lever (21) Side Lever (17) Side

(Plugs (48, 51) Side)
W25N-02-04-012
W2-4-25
30 14 30
45
41
58 15 13
25 8 43 44
57 39
41
40
11
5 6 9 10

W2CG-02-04-004
W2-4-26
10. Insert the set spring (25) into the spool hole and
insert the piston (6) and casing (5) into the
compensating hole. Tighten the cover (57) with
the socket bolts (58) and (30).
: 5 mm
: 12 Nᨿm (1.2kgfᨿm)
IMPORTANT: Check the direction of the spring

seat.
11. Insert the spring seat (15), spring (14) and

adjusting rod (13) into the pilot hole. Insert the
spring seat (8) and springs (10) and (9) into the
compensating hole.
12. Install the adjusting screws (39), (40), adjusting

rod (11), lock nut (44), nut (41) and screw (45) on
the cover (43). Install the cover (43) and tighten
socket bolt (30).
: 5 mm
: 12 Nᨿm (1.2kgfᨿm)
W2-4-27
DISASSEMBLE REAR REGULATOR

61 32 60
35
33 33 35
59 36 30 14 30
45
41
56 29 53 15 13 12
31 35 54 54 55 58
34
25 27 26 23 22 46 8 43 44
37 47 19 49 50 24 39
18 57
41
21 48 28 40
51 3
17 1 11
16 3
2
38
20 4 42
5 6 7 9 10 52

W2CG-02-04-005
W2-4-28
1- Pin 17 - Lever 33 - O-Ring (2 Used) 48 - Plug

2- Sleeve 18 - Pin 34 - O-Ring 49 - O-Ring (2 Used)
3- O-Ring (2 Used) 19 - Pin 35 - Plug (7 Used) 50 - Retaining Ring (2 Used)
4- O-Ring 20 - Feedback Lever 36 - Socket Bolt (2 Used) 51 - Plug
5- Casing 21 - Lever 37 - Socket Bolt (2 Used) 52 - Pin
6- Piston 22 - Spool 38 - O-Ring 53 - O-Ring
7- Rod 23 - Sleeve 39 - Adjusting Screw 54 - O-Ring (9 Used)
8- Spring Seat 24 - Retaining Ring 40 - Adjusting Screw 55 - O-Ring
9- Spring 25 - Set Spring 41 - Nut (2 Used) 56 - O-Ring
10 - Spring 26 - Return Spring 42 - O-Ring 57 - Cover
11 - Adjusting Rod 27 - Spring Seat 43 - Cover 58 - Socket Bolt (2 Used)
12 - O-Ring 28 - Retaining Ring 44 - Lock Nut 59 - Socket Bolt (4 Used)
13 - Adjusting Rod 29 - Piston 45 - Screw 60 - O-Ring
14 - Spring 30 - Socket Bolt (6 Used) 46 - Casing 61 - Reducing Valve
15 - Spring Seat 31 - Valve Casing 47 - Pin (2 Used)
16 - Pin (2 Used) 32 - O-Ring
W2-4-29
36 30 14 30
45
15 13
54 54 58
25 27 26 23 8 43 44
37 50 24
57 39
41
48 28 40
51
11
9 10

W2CG-02-04-005
W2-4-30
Disassemble Rear Regulator
before disassembling. the compensating part. Pull out the adjusting rod
(13), spring (14) and spring seat (15) from the
IMPORTANT: Put the rubber plate or cloth on the pilot part.
As the parts are small, take care not
NOTE: The adjusting rod (13) can be removed
to lose the parts.
the cover (57).
NOTE: Select a clean place. After removing the cover (57), remove the set
spring (25) from the pilot part.
: 5 mm
2. Remove the dust and rust on the surface of
regulator with using washing oil. IMPORTANT: When removing the retaining ring
(28), the return spring (26) flies out.
IMPORTANT: Take care not to lose the O-ring (54). Take care not to lose the return
spring (26).
the regulator from the pump. 7. Remove the retaining ring (28) and remove the
: 6 mm spring seat (27), return spring (26) and sleeve
(23).
IMPORTANT: The adjusting screws (39), (40),
adjusting rod (11), lock nut (44), nut
NOTE: The retaining ring (24) is installed on the
sleeve (23).
the cover (43). As the pressure-flow
rate setting is changed, do not
loosen these screws and nuts.
cover (43). NOTE: The plugs (48) and (51) can be removed
: 5 mm easily with using the bolt (M6).
W2-4-31

29
22
19
21
17
16
20
5 6 7

W2CG-02-04-005
W2-4-32
IMPORTANT: Do not remove pin (16).
9. Remove lever (17).


lever (20).
NOTE: Push out the pin (19) (pin dia. I 4) from the

(5) can be remove.
W2-4-33
ASSEMBLE REAR REGULATOR

61 32 60
35
33 33 35
59 36 30 14 30
45
41
56 29 53 15 13 12
31 35 54 54 55 58
34
25 27 26 23 22 46 8 43 44
37 18 47 19 49 50 24
57 39
41
21 48 28 40
51 3
17 1 11
16 3
2
38
20 4 42
5 6 7 9 10 52

W2CG-02-04-005
W2-4-34

4- O-Ring 20 - Feedback Lever 36 - Socket Bolt (2 Used) 51 - Plug
11 - Adjusting Rod 27 - Spring Seat 43 - Cover 58 - Socket Bolt (2 Used)
12 - O-Ring 28 - Retaining Ring 44 - Lock Nut 59 - Socket Bolt (4 Used)
13 - Adjusting Rod 29 - Piston 45 - Screw 60 - O-Ring
14 - Spring 30 - Socket Bolt (6 Used) 46 - Casing 61 - Reducing Valve
15 - Spring Seat 31 - Valve Casing 47 - Pin (2 Used)
16 - Pin (2 Used) 32 - O-Ring
W2-4-35
29
27 26 23 22 46
47 19 50
21 48 28
51
17
16
20
7

W2CG-02-04-005

W2-4-36
Assemble Rear Regulator
1. Insert the rod (7) into the compensating hole of 5. Inert the piston (29) into the hole for the negative
the casing (46). control on the casing (46).
2. Install the pin (16) on the lever (21). Insert the pin NOTE: Check if the piston (29) moves smoothly.
(47) on the casing (46). Install the lever (21) into 6. Install the pin (16) on the lever (17). Insert the pin
the pin (47). (16) into the groove of the piston (29). Install the
lever (17).
(23) can move in the casing (46) 7. Install the pin (47) to plug (48). Align the pin (47)
smoothly. Check the direction of the with the pin hole on the lever (17) and install the
spool (22). plug (48). Install the retaining ring (50).

8. Insert the plug (51) and nstall the retaining ring

(50).
22 20 NOTE: Check if the feedback lever (20) has not too
W25N-02-04-011
9. Insert the return spring (26) and spring seat (27)

3. Insert the spool (22) and sleeve (23) into the spool into the spool hole and install retaining ring (28).
hole on the casing (46).
4. Install the feedback lever (20).Align the pin holes

of the feedback lever (20) and insert the pin (19).


easy.

lever (20).

W25N-02-04-012
W2-4-37

30 14 30
45
15 13
58
25 8 43 44
57 39
41
40
11
5 6 9 10

W2CG-02-04-005

W2-4-38
compensating hole. Tighten the cover (57) with
the socket bolts (58) and (30).
: 5 mm
: 12 Nᨿm(1.2kgfᨿm)

seat.

compensating hole.

socket bolt (30).
: 5 mm
: 12 Nᨿm(1.2kgfᨿm)
W2-4-39
(Blank)
W2-4-40
REMOVE AND INSTALL SWING PUMP

Preparation

1. Operate the control lever several times and
release the remaining pressure in the circuit.

hydraulic oil with using a container (500 L).
: 19mm

W2CG-02-04-010

Removal
1. Remove all hoses, pipings and wire harness from 2

the swing pump. Cap the removed hoses.
: 10 mm
: 22 mm, 27 mm
2. Attach a wire rope on the swing pump and support

the swing pump with the crane.
CAUTION: Swing pump weight: 45 kg
3. Remove the bolt (2). Lift the swing pump with the
crane and remove it.
: 14 mm

M2CN-02-04-002
W2-4-41
Installation

CAUTION: Swing pump weight: 45 kg
1. Lift the swing pump with the crane and install it on
the main pump.
2. Install the bolt (2).

: 14 mm
: 240 Nm (24.0 kgfm)
2
3. Install all hoses, pipings and wire harness on the
swing pump. Fill the hydraulic oil in the swing
pump.
: 10 mm
: 90 Nm (9.2 kgfm)
: 22 mm
: 39 Nm (4.0 kgfm)
: 27 mm
: 93 Nm (9.5 kgfm)
4. Remove the filler port cover of the hydraulic oil.

Apply the hydraulic oil to a specified position of
the level gauge.

5. Start the engine and run at low idling speed. M2CN-02-04-002
Release the air in the swing pump.
6. Do the work at low idling speed after releasing the

air.Check the hydraulic oil level and any oil leaks.
W2-4-42
(Blank)
W2-4-43
DISASSEMBLE SWING PUMP
51
52 53
4 6 10
17
18
45
44
43
39
38
37 35 34 33 32 31 27 26

W2CG-02-04-007
1 - Stopper 15 - O-Ring 28 - O-Ring (2 Used) 41 - Bearing

2 - Backup Ring 16 - Screw 29 - Nut 42 - Spacer (2 Used)
3 - O-Ring 17 - Valve Plate 30 - Eye Bolt 43 - Shaft
4 - Cylinder Block 18 - Cover 31 - Pump Casing 44 - Oil Seal
5 - Servo Piston 19 - Socket Bolt (2 Used) 32 - Socket Bolt (4 Used) 45 - Socket Bolt (4 Used)
6 - Shoe (9 Used) 20 - Cover 33 - Bushing 46 - O-Ring
7 - Bushing 21 - O-Ring (2 Used) 34 - Plate 47 - Spring Pin (2 Used)
8 - Tilt Pin 22 - Bearing 35 - Plate 48 - Lock Nut (2 Used)
9 - Feedback Pin 23 - Plug 36 - Plug (7 Used) 49 - Screw
10 - Piston (9 Used) 24 - O-Ring 37 - Support 50 - Socket Bolt (4 Used)
11 - O-Ring 25 - Pin 38 - Plate 51 - Regulator
12 - Backup Ring 26 - Spring (9 Used) 39 - Cover 52 - Socket Bolt (2 Used)
13 - Stopper 27 - Plug (2 Used) 40 - Retaining Ring 53 - Socket Bolt (2 Used)
14 - O-Ring (9 Used)
W2-4-44
Disassemble Swing Pump

DISASSEMBLING AND ASSEMBLING” before
disassembling.
IMPORTANT: Put the rubber plate and cloth on the IMPORTANT: Do not damage the sliding surfaces
workbench not to damage the parts. of the cylinder block (4), bushing
(34), shoe (6) and plate (38).
7. Pull out the cylinder block (4) from the pump
casing (31) straightly to the shaft (43). At the
NOTE: Select a clean place.
same time, remove the piston (10) (9 used), plate
(34), bushing (33) and spring (26) (9 used).
2. Remove the dust and rust on the surface of the
pump with using washing oil.
IMPORTANT: As the oil seal (44) is installed on the
cover (39), take care not to damage
3. Remove the plug (27) and drain the oil from the the oil seal (44) when removing.
pump casing (31).
: 27 mm 8. Remove the socket bolt (45) (4 used) and remove
the cover (39).
4. Remove the socket bolts (52) (2 used) and (53) (2 : 5 mm
used). Remove the regulator (51).
: 6 mm 9. Tap the mounting flange part of the support (37)
from the pump casing (31) side and separate the
NOTE: As for disassembly of the regulator (51), support (37) from the pump casing (31).
refer to the corresponding section.
10. Remove the plates (35) and (38) from the pump
5. Loosen the socket bolts (32) (4 used) that casing (31).
connect the support (37), pump casing (31) and
cover (18). 11. As tapping the shaft end part of shaft (43) with
: 14 mm using a plastic hammer, remove the shaft (43)
from the support (37).
IMPORTANT: Put the rubber plate or cloth on the
workbench not to damage the 12. Remove the valve plate (17) from the cover (18).
mounting surface of the regulator
when positioning the regulator NOTE: The valve plate (17) may be removed at the
mounting surface downward. step 6.
6. Place the pump onto the workbench horizontally

with positioning the mounting surface downward.
Separate the cover (18) from pump casing (31).
W2-4-45

1 5 8 13
48
18
37 31 22

W2CG-02-04-007
W2-4-46
IMPORTANT: When removing the tilt pin (8), use a
special tool not to damage the head
of the tilt pin (8).
As LOCTITE is applied on the fitting
part between the tilt pin (8) and the
servo piston (5), take care not to
damage the servo piton (5).
Do not remove the bearing (22)
except replacement.
As the setting of flow rate changes,
do not loosen the lock nut (48) of the
cover (18) and support (37).
13. If necessary, remove the stoppers (13), (1), servo

piston (5) and tilt pin (8) from the pump casing
(31) and remove the bearing (22) from the cover
(18).
W2-4-47
ASSEMBLE SWING PUMP

51
52 53
1 4 5 6 7 8,9 10 13
17
18
45
44
42
43
41
40
39
38
37 34 33 32 31 27 26 25

W2CG-02-04-007
1- Stopper 15 - O-Ring 28 - O-Ring (2 Used) 41 - Bearing
2- Backup Ring 16 - Screw 29 - Nut 42 - Spacer (2 Used)
3- O-Ring 17 - Valve Plate 30 - Eye Bolt 43 - Shaft
4- Cylinder Block 18 - Cover 31 - Pump Casing 44 - Oil Seal
5- Servo Piston 19 - Socket Bolt (2 Used) 32 - Socket Bolt (4 Used) 45 - Socket Bolt (4 Used)
6- Shoe (9 Used) 20 - Cover 33 - Bushing 46 - O-Ring
7- Bushing 21 - O-Ring (2 Used) 34 - Plate 47 - Spring Pin (2 Used)
8- Tilt Pin 22 - Bearing 35 - Plate 48 - Lock Nut (2 Used)
9- Feedback Pin 23 - Plug 36 - Plug (7 Used) 49 - Screw
10 - Piston (9 Used) 24 - O-Ring 37 - Support 50 - Socket Bolt (4 Used)
11 - O-Ring 25 - Pin 38 - Plate 51 - Regulator
12 - Backup Ring 26 - Spring (9 Used) 39 - Cover 52 - Socket Bolt (2 Used)
13 - Stopper 27 - Plug (2 Used) 40 - Retaining Ring 53 - Socket Bolt (2 Used)
14 - O-Ring (9 Used)
W2-4-48
Assemble Swing Pump
IMPORTANT: When tightening the servo piston (5) IMPORTANT: Take care not to damage oil seal (44)
and tilt pin (8), use a special tool not when installing.
to damage the head of the tilt pin (8)
and feedback pin (9).Apply LOCTITE 4. Install the cover (39) on the pump casing (31) and
(medium intensity) on the thread secure with the socket bolts (45) (4 used).
part. : 5 mm
: 93 Nm (9.5 kgfm)
1. Install the support (37) on the pump casing (31)
while tapping with using a hammer. NOTE: Slightly apply the grease on the oil seal
(44) in the cover (39).
NOTE: When the servo piston (5), tilt pin (8),
stoppers (1) and (13) are removed, install 5. Assemble the piston cylinder sub assembly
them on the pump casing (31) first. (cylinder block (4), pistons (10) (9 used), shoe (6)
(9 used), plate (34), bushing (33) and springs (26)
2. Place the pump casing (31) with positioning the (9 used)). Align the splines of bushing (33) and
mounting surface for regulator downward. Insert cylinder block (4) and insert the piston cylinder
the bushing (7) of the plate (38) into the tilt pin (8). sub assembly in the pump casing (31).
Install the plate (38) on the support (37) correctly.
IMPORTANT: Check the direction of suction and
NOTE: Check if the plate (38) can move smoothly delivery of the valve plate (17).
by fingers.
If the grease is applied on the plate (38) 6. As aligning with pin (25), install the valve plate
and support (37) and moving portion, the (17) on the cover (18).
shaft (43) can be installed easily.
7. Install the cover (18) on the pump casing (31).
IMPORTANT: Do not hit the shaft (43) with using a Tighten the socket bolts (32) (4 used).
hammer. : 14 mm
: 240 Nm (24.0 kgfm)
3. Install the shaft (43) with the bearing (41), spacer
(42) (2 used) and retaining ring (40) set on the 8. Insert the feedback pin (9) of the tilt pin (8) in the
support (37). feedback lever of the regulator (51) and install the
regulator (51). Tighten the socket bolts (52) (2
used) and (53) (2 used).
NOTE: Tap the outer ring of the bearing (41) with
: 6 mm
using a plastic hammer and insert the
: 29 Nm (3.0 kgfm)
bearing (41) with using a steel bar
completely.
: 27 mm
: 110 Nm (11.0 kgfm)
W2-4-49


Standard Allowable Limit d D

D-d 0.028 mm 0.056 mm

W25N-02-04-005

2. Clearance between piston and shoe calking

portion

ˡ 0 to 0.1 mm 0.3 mm
t
3. Shoe thickness
W25N-02-04-006

t 3.9 mm 3.7 mm

4. Free length of cylinder spring

L 31.3 mm 30.5 mm
L

W25N-02-04-007

5. Combining height of plate and spherical bushing

Standard Allowable Limit H

H-h 19.0 mm 18.3 mm h

W25N-02-04-008
W2-4-50
(Blank)
W2-4-51
DISASSEMBLE REGULATOR
58 62 49
60
61
30 31 36 32 35 14 30
57
49
33
45
41
4 56 29 53 15 13 12
54 55 49,59
25 34 27 26 24 23 22 46 8 43 44
37 21 18 47 19 49 50 39
28 41
51 40
3
48
17 1 11
16 3
2
38
20 4 42
5 6 7 9 10 52

W2CG-02-04-008
W2-4-52
1- Pin 17 - Lever 33 - O-Ring (2 Used) 49 - O-Ring (5 Used)

2- Sleeve 18 - Pin 34 - O-Ring 50 - Retaining Ring (2 Used)
3- O-Ring (2 Used) 19 - Pin 35 - Plug (8 Used) 51 - Plug
4- O-Ring (2 Used) 20 - Feedback Lever 36 - Socket Bolt (2 Used) 52 - Pin
5- Casing 21 - Lever 37 - Socket Bolt (2 Used) 53 - O-Ring
6- Piston 22 - Spool 38 - O-Ring 54 - O-Ring (12 Used)
7- Rod 23 - Sleeve 39 - Adjusting Screw 55 - O-Ring
9- Spring 25 - Set Spring 41 - Nut (2 Used) 57 - Cover
10 - Spring 26 - Return Spring 42 - O-Ring 58 - Reducing Valve
11 - Adjusting Rod 27 - Spring Seat 43 - Cover 59 - Plug
12 - O-Ring 28 - Retaining Ring 44 - Lock Nut 60 - Seat (2 Used)
13 - Adjusting Rod 29 - Piston 45 - Screw 61 - Stopper (2 Used)
14 - Spring 30 - Socket Bolt (8 Used) 46 - Casing 62 - Ball (2 Used)
15 - Spring Seat 31 - Cover 47 - Pin (2 Used)
16 - Pin (2 Used) 32 - Socket Bolt (5 Used) 48 - Plug
W2-4-53

36 32 14 30
57
45
4 15 13
25 27 26 24 23 8 43 44
37 50 39
28 41
51 40
48
11
9 10

W2CG-02-04-008
W2-4-54
Disassemble Regulator
before disassembling. the compensating part. Pull out the adjusting rod
(13), spring (14) and spring seat (15) from the pilot
IMPORTANT: Put the rubber plate or cloth on the part.
As the parts are small, take care not NOTE: The adjusting rod (13) can be removed
to lose the parts. easily with using the bolt (M4).
1. Select the place to disassemble. 6. Remove the socket bolt (32) and remove the
cover (57).
NOTE: Select a clean place. After removing the cover (57), remove the set
spring (25) from the pilot part.
2. Remove the dust and rust on the surface of : 5 mm
regulator with using washing oil.
IMPORTANT: When removing the retaining ring
IMPORTANT: Take care not to lose the O-ring (4). (28), the return spring (26) flies out.
Take care not to lose the return
3. Remove the socket bolts (36) and (37). Remove spring (26).
the regulator from the pump.
: 6 mm 7. Remove the retaining ring (28) and remove the
spring seat (27), return spring (26) and sleeve
IMPORTANT: The adjusting screws (39), (40), (23).
adjusting rod (11), lock nut (44), nut
the cover (43). As the pressure-flow NOTE: The retaining ring (24) is installed on the
rate setting is changed, do not sleeve (23).
loosen these screws and nuts.
4. Remove the socket bolt (30) and remove the plugs (48) and (51).
cover (43).
: 5 mm NOTE: The plugs (48) and (51) can be removed
W2-4-55

29
22
21 19
17
16
20
5 6 7

W2CG-02-04-008
W2-4-56
9. Remove lever (17).


lever (20).
NOTE: Push out the pin (19) (pin dia. I 4) from the

(5) can be remove.
W2-4-57
ASSEMBLE REGULATOR
58 62 49
60
61
30 31 36 32 35 14 30
57
49
33
45
41
4 56 29 53 15 13 12
54 55 49,59
25 34 27 26 24 23 22 46 8 43 44
37 21 18 47 19 49 50 39
28 41
51 40
3
48
17 1 11
16 3
2
38
20 4 42
5 6 7 9 10 52

W2CG-02-04-008
W2-4-58

4- O-Ring (2 Used) 20 - Feedback Lever 36 - Socket Bolt (2 Used) 51 - Plug
11 - Adjusting Rod 27 - Spring Seat 43 - Cover 58 - Reducing Valve
12 - O-Ring 28 - Retaining Ring 44 - Lock Nut 59 - Plug
13 - Adjusting Rod 29 - Piston 45 - Screw 60 - Seat (2 Used)
14 - Spring 30 - Socket Bolt (8 Used) 46 - Casing 61 - Stopper (2 Used)
15 - Spring Seat 31 - Cover 47 - Pin (2 Used) 62 - Ball (2 Used)
16 - Pin (2 Used) 32 - Socket Bolt (5 Used)
W2-4-59
29
27 26 23 22 46
21 47 19 50
28
51
48
17
16
20

W2CG-02-04-008
W2-4-60
Assemble Regulator
1. Insert the rod (7) into the compensating hole of the 5. Inert the piston (29) into the hole for the negative
casing (46). control on the casing (46).
2. Install the pin (16) on the lever (21). Insert the pin NOTE: Check if the piston (29) moves smoothly.
(47) on the casing (46). Install the lever (21) into 6. Install the pin (16) on the lever (17). Insert the pin
the pin (47). (16) into the groove of the piston (29). Install the
lever (17).
(23) can move in the casing (46) 7. Install the pin (47) to plug (48). Align the pin (47)
smoothly. Check the direction of the with the pin hole on the lever (17) and install the
spool (22). plug (48). Install the retaining ring (50).

8. Insert the plug (51) and install the retaining ring

(50).
22 20 NOTE: Check if the feedback lever (20) has not too
W25N-02-04-011
9. Insert the return spring (26) and spring seat (27)

3. Insert the spool (22) and sleeve (23) into the spool into the spool hole and install retaining ring (28).
hole on the casing (46).
4. Install the feedback lever (20). Align the pin holes

of the feedback lever (20) and insert the pin (19).

easy.

lever (20).

W25N-02-04-012
W2-4-61

32 14 30
57
45
41
15 13
25 8 43 44
39
40
11
5 6 9 10

W2CG-02-04-008
W2-4-62
compensating hole.Tighten the cover (57) with the
socket bolts (58) and (30).
: 5 mm
: 12 Nᨿm (1.2 kgfᨿm)

seat.

compensating hole.

socket bolt (30).
: 5 mm
W2-4-63
(Blank)
W2-4-64
REMOVE AND INSTALL GEAR PUMP (FOR
OIL COOLER)


Preparation

in the circuit.

hydraulic oil with using the container (500 L).
: 19mm

W2CG-02-04-010

Removal
1. Remove all hoses and pipings from the gear pump

(for oil cooler). Cap the removed hoses. 2
: 32 mm
2. Support the gear pump (for oil cooler).
CAUTION: Gear pump (for oil cooler) weight:

4.2 kg
3. Remove the bolt (2) and remove the gear pump

(for oil cooler).
: 17 mm

M2CN-02-04-003
W2-4-65
Installation

CAUTION: Gear pump (for oil cooler) weight:
4.2 kg

1. Connect the gear pimp (for oil cooler) to the swing
pump.
2. Apply LOCTITE on the bolt (2) and install.
: 17 mm
: 41 to 45 Nm (4.2 to 4.6 kgfm)
3. Install all hoses and pipings on the gear pump (for

oil cooler). Fill the hydraulic oil in the gear pump 2
(for oil cooler).
: 27 mm
: 93 Nm (9.5 kgfm)
: 32 mm
: 137 Nm (14.0 kgfm)

tank. Fill the hydraulic oil to a specified position of
the level gauge.
5. Start the engine and run at low idling speed.

Release the air in the gear pump (for oil cooler).
6. After releasing the air, do the work at low idling

speed. Check the hydraulic oil level and any oil M2CN-02-04-003
leaks.
W2-4-66
(Blank)
W2-4-67
DISASSEMBLE GEAR PUMP (FOR OIL COOLER)
6 3 4 5 4 3 2 1
13 14
7 8 10 9 11 12

M2CN-02-04-004

1- Drive Gear 5- Body 9- Bushing (4 Used) 13 - Gasket (2 Used)
2- Front Cover 6- Rear Cover 10 - Driven Gear 14 - Backup Ring (2 Used)
3- Gasket (2 Used) 7- Socket Bolt (4 Used) 11 - Oil Seal
4- Side Plate (2 Used) 8- Washer (4 Used) 12 - Retaining Ring
W2-4-68
Disassemble Gear Pump (For Oil Cooler)
• Thoroughly read “PRECAUTIONS FOR 10. Remove the gaskets (3), (13), side plate (4) and
DISASSEMBLING AND ASSEMBLING” backup ring (14).
(W1-11-1) before disassembling.
11. Remove the bushing (9) from the front cover (2).
NOTE: Although the gaskets (3,13), side plate (4)
and backup ring (14) are the same type, 12. Remove the front cover (2) from the vise.
the directions to install are different.
Put a tag on part for reassembly when 13. Remove the retaining ring (12).
disassembling. The driven gear (10) is
symmetrical with respect to the front/rear. 14. Remove the oil seal (11).
Put an identification mark (front or rear) on
the shaft when disassembling.

11
2. Turn the rear cover (6) side upward. Clamp the

mounting part of front cover (2) in a vise.
3. Put the matching marks on the matching part in

the drive side of front cover (2), body (5), and rear 2
cover (6).
4. Remove the socket bolt (7).

M2CN-02-04-005
: 10 mm
5. Remove the rear cover (6).
6. Remove the gaskets (3), (13), side plate (4) and

Backup Ring (14).
7. Remove the bushing (9) from the rear cover (6).
8. Remove the drive gear (1) and driven gear (10).
9. Remove the body (5).
W2-4-69
ASSEMBLE GEAR PUMP (FOR OIL COOLER)
6 3 4 5 4 3 2 1
13 14
7 8 10 9 11 12

M2CN-02-04-004

1 - Drive Gear 5- Body 9- Bushing (4 Used) 13 - Gasket (2 Used)
2 - Front Cover 6- Rear Cover 10 - Driven Gear 14 - Backup Ring (2 Used)
3 - Gasket (2 Used) 7- Socket Bolt (4 Used) 11 - Oil Seal
4 - Side Plate (2 Used) 8- Washer (4 Used) 12 - Retaining Ring
W2-4-70
Assemble Gear Pump (For Oil Cooler)
• Replace all oil seals and gaskets with the new

ones.
Before assembling, clean each part with using
clean washing oil and dry.
Apply the clean hydraulic oil on the inner parts.
Specially, apply the hydraulic oil on the sliding to
prevent it from seizing.
IMPORTANT: Assemble the gaskets (3), (13), side

plate (4) and backup ring (14)
correctly with taking care about the
used places and installing directions
as referring to the tag marked when
disassembling.
Assemble the gears (1) and (10) so
that they mesh each other.
NOTE: Secure the gaskets (3), (13), side plate (4)

and Backup Ring (14) on the groove with
using grease and they are not bitten.
Align the matching marks of each drive
side when assembling the front cover (2),
body (5) and rear cover (6).
Check the direction of the matching mark
on the shaft when installing the driven
gears (10).
1. Secure the front cover (2) with turning the

mounting surface for body (5) upward in a vise.
2. Install the bushing (9) on the front cover (2).
3. Install the gaskets (3), (13), side plate (4) and

backup ring (14) on the front cover (2).
4. Install the body (5) on the front cover (2).
W2-4-71

6 3 4 5 4 3 2 1
13 14
7 8 10 9 11 12

M2CN-02-04-004

1- Drive Gear 5- Body 9- Bushing (4 Used) 13 - Gasket (2 Used)
2- Front Cover 6- Rear Cover 10 - Driven Gear 14 - Backup Ring (2 Used)
3- Gasket (2 Used) 7- Socket Bolt (4 Used) 11 - Oil Seal
4- Side Plate (2 Used) 8- Washer (4 Used) 12 - Retaining Ring
W2-4-72
5. Install the drive gear (1) and driven gear (10) on
the body (5).
7. Install the gaskets (3), (13), side plate (4) and

backup ring (14) on the rear cover (2).
8. Install the rear cover (6) on the body (5).
9. Install the socket bolt (7).

: 10 mm
11
10. Turn over the pump with so that the oil seal (11)
Dust Lip
installing side faces upward. Clamp the pump in a
vise.
Fill grease.
11. Fill the grease between the main lip and the dust
lip of the oil seal (11). Main Lip
W25N-02-04-021
W2-4-73
IMPORTANT: Take care not to damage the oil seal
(11).
14. Install the oil seal (11) on the front cover (2) with Pipe
using a guide and pipe.
Guide
11
M2CN-02-04-006
15. Install the retaining ring (12).
12
M2CN-02-04-007
W2-4-74
REMOVE AND INSTALL 2-UNIT GEAR
PUMP


Preparation

in the circuit.

: 19mm

W2CG-02-04-010

Removal
2
1. Remove all hoses and pipings from the 2-unit gear
pump. Cap the removed hoses.
: 8 mm
: 27 mm
2. Support the 2-unit gear pump.
CAUTION: 2-unit gear pump weight: 7.6 kg
3. Remove the bolt (2) and remove the 2-unit gear

pump.
: 8 mm

M2CN-02-04-008
W2-4-75
Installation

CAUTION: 2-unit gear pump weight: 7.6 kg
1. Connect the gear pump to the reduction gear of
the main pump.

2. Apply LOCTITE on the bolt (2) and install.
: 8 mm
: 25 to 25.6 Nm (2.5 to 2.6 kgfm)
3. Install all hoses and pipings on the 2-unit gear

2
pump. Fill the hydraulic oil in the gear pump.
: 8 mm
: 48 to 50 Nm (4.9 to 5.1 kgfm)
: 27 mm
: 93 Nm (9.5 kgfm)

the level gauge.

Release the air in the gear pump.
6. After releasing the air, do the work at low idling

speed. Check the hydraulic oil level and any oil
leaks.
M2CN-02-04-008
W2-4-76
(Blank)
W2-4-77
DISASSEMBLE 2-UNIT GEAR PUMP

9
6
5
13
4
3
2
1
7 12
6
5
4
10
4 11
16
4 15
5
14

W25N-02-04-017
1- Retaining Ring 5- Gasket (4 Used) 9- Body 13 - Body
2- Oil Seal 6- Side Plate (4 Used) 10 - Adapter Plate 14 - Rear Cover
3- Front Cover 7- Driven Gear 11 - Driven Gear 15 - Washer (4 Used)
4- Gasket (4 Used) 8- Drive Gear 12 - Drive Gear 16 - Socket Bolt (4 Used)
W2-4-78
Disassemble 2-Unit Gear Pump
• Thoroughly read “PRECAUTIONS FOR 9. Remove the gaskets (4), (5) and side plate (6).
DISASSEMBLING AND ASSEMBLING”
(W1-11-1) before disassembling. 10. Remove the adapter plate (10).
NOTE: Although the gaskets (4), (5) and side plate 11. Remove the gaskets (4), (5) and side plate (6).
(6) are the same type, the directions to
install are different. Put a tag on each block 12. Remove the body (9).
for reassembly when disassembling.
The driven gears (7) and (11) are 13. Remove the gaskets (4), (5) and side plate (6).
symmetrical with respect to the front/rear.
Put an identification mark (front or rear) on 14. Remove the drive gear (8) and driven gear (7).
the shaft when disassembling.
15. Remove the front cover (3) from the vise.
pump with using washing oil. 16. Remove the retaining ring (1).
2. Turn the rear cover (14) side upward. Clamp the 17. Remove the oil seal (2).

the drive side of front cover (3), body (9), adapter 2
plate (10), body (13) and rear cover (14).

: 10 mm

3
6. Remove the gaskets (4), (5) and side plate (6).

W25N-02-04-018
8. Remove the body (13).
W2-4-79
ASSEMBLE 2-UNIT GEAR PUMP
8 1 2 9 6 4 10 13 12 15 16
3 7 5 17 11 14 18 19

W25N-02-04-024

1- Retaining Ring 6- Side Plate (4 Used) 11 - Driven Gear 16 - Socket Bolt (4 Used)
2- Oil Seal 7- Driven Gear 12 - Drive Gear 17 - Bushing (8 Used)
3- Front Cover 8- Drive Gear 13 - Body 18 - Plug
4- Gasket (4 Used) 9- Body 14 - Rear Cover 19 - O-Ring
5- Gasket (4 Used) 10 - Adapter Plate 15 - Washer (4 Used)
W2-4-80
Assemble 2-Unit Gear Pump

ones.
IMPORTANT: Install the gasket (5) so that the flat

surface is located at the bottom of
groove.
Assemble the side plate (6) so that
the yellow surface faces the gear Delivery Side Suction Side
side and the long pulling-out hole
faces the suction side. Short Long
The teeth of the gears (7), (8), (11) Pulling-Out Pulling-Out
and (12) are asymmetrical. Mesh Hole Hole
the gears with the small notch each
other and assemble them.
W25N-02-04-022
NOTE: Secure the gaskets (4), (5) and side plate Rotating Direction of
(6) on the groove with using grease and Drive Gear
Large Notch
they are not bitten.
(No Bound Side) Small Notch
(Bound Side)
side when assembling the front cover (3),
body (9), adapter plate (10), body (13) and
rear cover (14). Delivery Suction
Check the direction of the matching mark Side Side
on each shaft when installing the driven
gears (7) and (11).
1. Secure the front cover (3) with turning the Rotating Direction of
mounting surface for body (9) upward in a vise. Driven Gear
W25N-02-04-023
2. Install the gaskets (4), (5) and side plate (6) on

the front cover (3).
3. Install the body (9) on the front cover (3).
W2-4-81

8 1 2 9 6 4 10 13 12 15 16
3 7 5 17 11 14 18 19

W25N-02-04-024

1- Retaining Ring 6- Side Plate (4 Used) 11 - Driven Gear 16 - Socket Bolt (4 Used)
2- Oil Seal 7- Driven Gear 12 - Drive Gear 17 - Bushing (8 Used)
3- Front Cover 8- Drive Gear 13 - Body 18 - Plug
4- Gasket (4 Used) 9- Body 14 - Rear Cover 19 - O-Ring
5- Gasket (4 Used) 10 - Adapter Plate 15 - Washer (4 Used)
W2-4-82
the body (9).
5. Install the gaskets (4), (5) and side plate (6) at the
front and rear surfaces of the adapter plate (10).
6. Install the adapter plate (10) on the body (9).
7. Install the body (13) on the adapter plate (10).

the body (13).
9. Install the gaskets (4), (5) and side plate (6) on

the rear cover (14).
10. Install the rear cover (14) on the body (13).
11. Install the socket bolt (16).

: 10 mm
: 88.2 to 93.1 Nm (9.0 to 9.5 kgfm)
vise.
2
Dust Lip
lip of the oil seal (2).
Fill grease.
Main Lip
W25N-02-04-021
W2-4-83
(2).
14. Install the oil seal (2) on the front cover (3) with Pipe
Guide
W25N-02-04-019
W25N-02-04-020
W2-4-84
REMOVE AND INSTALL GEAR PUMP (FOR
REEVING WINCH)


Preparation

in the circuit.

: 19mm

W2CG-02-04-010

2
Removal
1. Remove all hoses and pipings from the great

pump (for reeving winch). Cap the removed
hoses.
: 27.36mm

2. Support the gear pump (for reeving winch).
CAUTION: Gear pump (for reeving winch)

weight: 2.3 kg
3. Remove the bolt (2) and remove the gear pump

(for reeving winch).
: 8 mm

M2CN-02-04-009
W2-4-85
Installation

CAUTION: Gear pump (for reeving winch)
weight: 2.3 kg

1. Connect the gear pump (for reeving winch) to the
reduction gear of the main pump.
2
2. Install the gear pump (for reeving winch) mounting
bolt (2).
: 8 mm
: 50 Nm (5.1 kgfm)
3. Install all hoses and pipings on the gear pump. Fill

the hydraulic oil in the gear pump.
: 27 mm
: 93 Nm (9.5 kgfm)
: 36 mm
: 175 Nm (18.0 kgfm)

the level gauge.

Release the air in the gear pump (for reeving
winch).

6. After releasing the air, do the work at low idling M2CN-02-04-009
speed. Check the hydraulic oil level and any oil

leaks.
W2-4-86
(Blank)
W2-4-87
DISASSEMBLE GEAR PUMP (FOR REEVING WINCH) 9
3 8
1
14
13
12
11
10
6
7

W23F-02-04-012

1- Retaining Ring 5- Gasket 9 - Drive Gear 12 - Rear Cover
2- Oil Seal 6- Gasket (2 Used) 10 - Bush (2 Used) 13 - Washer (4 Used)
3- Front Cover 7- Side Plate (4 Used) 11 - Ball (2 Used) 14 - Socket Bolt (4 Used)
4- Bush (2 Used) 8- Driven Gear
W2-4-88
Disassemble Gear Pump (For Reeving Winch)
• Thoroughly read “PRECAUTIONS FOR 10. Remove the front cover (3) from the vise.
DISASSEMBLING AND ASSEMBLING”
(W1-11-1) before disassembling. 11. Remove the retaining ring (1).
NOTE: Although the gaskets (5), (6) and side plate 12. Remove the oil seal (2).
(7) are the same type, the directions to
install are different. Put a tag on each block
for reassembly when disassembling.
The driven gears are symmetrical with
2
respect to the front/rear. Put an
identification mark (front or rear) on the
shaft when disassembling.

2. Turn the rear cover (12) side upward. Clamp the

3
W23F-02-04-013
the drive side of front cover (3) and rear cover
(12).

: 10 mm
6. Remove the Bush (10), gaskets (6) and side plate

(7).
8. Remove the gasket (5), (6) and side plate (7).
9. Remove the ball (11) and bushing (4).
W2-4-89
ASSEMBLE GEAR PUMP (FOR REEVING WINCH)
9 3 4 11 7 10
10
6
2
6 7 5 12 8 13 14

W23F-02-04-014

2- Oil Seal 6- Gasket (2 Used) 10 - Bushing (2 Used) 13 - Washer (4 Used)
3- Front Cover 7- Side Plate (2 Used) 11 - %DOO 8VHG 14 - Socket Bolt (4 Used)
4- Bushing (2 Used) 8- Driven Gear
W2-4-90
Assemble Gear Pump (For Reeving Winch)

ones.
IMPORTANT: Install the gasket (6) so that the flat

surface is located at the front cover
(3) and rear cover (12) side.
Assemble the side plate (7) so that
the opposite side against the gasket Delivery Side Suction Side
(6) mounting surface faces the gear
side and the pulling-out hole faces Short
the delivery side. Pulling-Out
The teeth of the gears (7) and (8) are Hole
asymmetrical. Mesh the gears with
the small notch each other and
assemble them. W23F-02-04-015
Rotating Direction of
NOTE: Secure the gaskets (5), (6) and side plate Drive Gear
(7) on the groove with using grease and
Large Notch Small Notch
they are not bitten. (Bound Side)
(No Bound Side)
side when assembling the front cover (3)
and rear cover (12). Delivery Suction
Check the direction of the matching mark Side Side
on each shaft when installing the driven
gears (8).
1. Secure the front cover (3) with turning the Rotating Direction of
mounting surface for rear cover (12) upward in a Driven Gear
vise. W25N-02-04-023
3. Install the gasket (5), (6) and side plate (7) on the
front cover (3).
W2-4-91

9 3 4 11 7 10
10
6
2
6 7 5 12 8 13 14

W23F-02-04-014

2- Oil Seal 6- Gasket (2 Used) 10 - Bushing (2 Used) 13 - Washer (4 Used)
3- Front Cover 7- Side Plate (2 Used) 11 - %DOO 8VHG 14 - Socket Bolt (4 Used)
4- Bushing (2 Used) 8- Driven Gear
W2-4-92
the front cover (3).
5. Install the ball (11) on the front cover (3).
6. Install the bushing (10) on the rear cover (12).
7. Install the gaskets (6) and side plate (7) on the

rear cover (12).
8. Install the rear cover (14) on the front cover (3).
9. Install the socket bolt (14) with washer (13).

: 10 mm
: 88.2 to 93.1 Nm (9.0 to 9.5 kgfm)
vise.
2
lip of the oil seal (2). Dust Lip
Fill grease.
Main Lip
W25N-02-04-021

(2). Pipe
12. Install the oil seal (2) on the front cover (3) with
Guide
W23F-02-04-016
W2-4-93
W23F-02-04-017
W2-4-94
SWING MACHINERY / Control Valve
REMOVE AND INSTALL 4-UNIT CONTROL
VALVE FOR FRONT DRUM, REAR DRUM,
TRAVEL, BOOM RAISING/LOWERING
DRUM AND QUICK DRAW


Removal

in the circuit.
2. Remove all hoses and pipings from the control

valves (1) and (2).
: 22 mm
: 8 mm, 10 mm
NOTE: Attach a cap and an identification tag on the

removed hoses and pipings for
reassembling.
3. Remove the bolt (3).

: 19 mm
CAUTION: Control valve (1) weight: Approx. 1

80 kg
Control valve (2) weight: Approx.
107 kg 3
2

M2CN-02-05-001
4. Lift the control valves (1) and (2) and remove 3
them.
W2-5-1
Installation

CAUTION: Control valve (1) weight: Approx.
80 kg
Control valve (2) weight: Approx.
107 kg
1. Install the control valves (1) and (2) and tighten

with the bolt (3).
: 19 mm
: 60 to 64 Nᨿm (6.1 to 6.6 kgfᨿm)
2. Install all hoses and pipings on the control valves

(1) and (2).
: 22 mm
: 8 mm
: 50 Nᨿm (5.1 kgfᨿm) 1
: 10 mm
3
2
IMPORTANT: After completing the work, check the
M2CN-02-05-001
oil level. Check for any oil leaks. 3
W2-5-2
(Blank)

W2-5-3
DISASSEMBLE 4-UNIT CONTROL VALVE

50 49 38 47 28 49 29 50 45
25 46
39 51
53 48
61 5 26
52 53 39
55 56 36
1
2
18 59
20
17
11
19 E 60
15
85 24
83 E 16 37
10
84 35 30
13 31
43 32
7 33
36 21 6
3 12 41
44 35
54
4 53 42
25 50 53 63 46
40 64 26 34
40
44 52 50 51
14 47 27 48 27 49 45
62
36
87 57
80 67 77 59
69 74 88
58
65 81 60
68 23
75
79
66 86 22 37
59
73 70
60 30
71 78 72 82 76
8 32
41
35
34

W2CG-02-05-006
W2-5-4
1 - Inlet Section 23 - O-Ring 45 - Spring (2 Used) 67 - Spool (2 Used)

2 - Outlet Section 24 - O-Ring (16 Used) 46 - Spring (2 Used) 68 - Spring (2 Used)
3 - Valve Section 25 - End Cover (2 Used) 47 - Spring (2 Used) 69 - Spring (2 Used)
5 - Valve Section 27 - End Cover (2 Used) 49 - Spring (4 Used) 71 - Plug (4 Used)
6 - Valve Section 28 - End Cover 50 - Spring (4 Used) 72 - Plug (4 Used)
7 - Plug 29 - End Cover 51 - Spring Seat (2 Used) 73 - Plug (2 Used)
8 - Plug 30 - Plate (2 Used) 52 - Spring Seat (2 Used) 74 - Plug (2 Used)
9 - Plug 31 - Valve Seat (6 Used) 53 - Spring Seat (4 Used) 75 - Orifice (2 Used)
10 - Plug 32 - Plug (6 Used) 54 - Plug (2 Used) 76 - Steel Ball (2 Used)
11 - Plug 33 - Air Bleed Valve ᧤6 Used᧥ 55 - Plug (2 Used) 77 - O-Ring (4 Used)
12 - Plug (7 Used) 34 - Plug (16 Used) 56 - Valve 78 - O-Ring (4 Used)
13 - O-Ring 35 - O-Ring (12 Used) 57 - Poppet 79 - O-Ring (2 Used)
14 - O-Ring 36 - O-Ring (10 Used) 58 - Spring 80 - Socket%ROW 8VHG
15 - O-Ring 37 - O-Ring (16 Used) 59 - Cap (4 Used) 81 - Socket Bolt (8 Used)
16 - O-Ring 38 - Socket Bolt (8 Used) 60 - O-ring (4 Used) 82 - Filter (2 Used)
17 - O-Ring (7 Used) 39 - Socket Bolt (16 Used) 61 - Relief Valve 83 - Bolt (4 Used)
18 - O-Ring (14 Used) 40 - Socket Bolt (8 Used) 62 - Relief Valve 84 - Nut ᧤8 Used᧥
19 - O-Ring (7 Used) 41 - Solenoid Valve (4 Used) 63 - Casing 85 - Spring Washer (8 Used)
20 - O-Ring 42 - Spool 64 - Casing 86 - Cover
21 - O-Ring (4 Used) 43 - Spool 65 - Cover (2 Used) 87 - O-Ring
22 - O-Ring 44 - Spool (2 Used) 66 - Cover (2 Used) 88 - Socket Bolt (4 Used)
W2-5-5

50 49 38 47 28 49 29 50 45
25 46
51
39 53 48
61 26
52 53 39
55 36
1
E 37
30
43
36 6
41
44
54
4 53 42
25 50 53 63 46
40 26
40
44 52 50 51
47 27 48 27 49 45
36
80 67 77
69
65
68
37
30
41

W2CG-02-05-006
W2-5-6
Disassemble 4-Unit Control Valve
8. Remove the socket bolt (40) and remove the end
• Thoroughly read “PRECAUTIONS FOR cover (27) and plate (30) from the valve sections
DISASSEMBLING AND ASSEMBLING” (W1-1-1) (4) and (6).
before disassembling. : 5 mm
• The disassembling and assembling procedures of 9. Remove the spring seats (52), (53), springs (47)
4-unit control valve for travel (right), boom to (50), O-rings (36) and (37) (2 used) from the
raising/lowering, rear drum (low speed) and front end covers (27) (2 used).
drum (high speed) are explained here. As the
construction is similar, refer to this section when 10. Remove the O-rings (36) and (37) (2 used) from
disassembling and assembling the 4-unit control the plates (30) (2 used).
valve for travel (left), quick draw, rear drum (high
speed) and front drum (low speed).
CAUTION: Do not damage the holes on the

CAUTION: Control valve weight for (travel spool and valve section.
(left), quick draw, rear drum (high speed) and
front drum (low speed)): 80 kg 11. Remove the spools (42) to (44) from each valve
section.
Control valve weight for (travel (right), boom
raising/lowering, rear drum (low speed) and
front drum (high speed)): Approx. 107 kg NOTE: Do not remove the plugs (54) and (55) from
the spools (43) and (44) unnecessarily.
1. Place the control valve assembly on a clean
workbench.
IMPORTANT: Do not adjust the adjusting screw of cover (65), springs (68), (69) and O-ring (77) from
the solenoid valve (41). the casings (63) (2 used).
: 8 mm
2. Remove the solenoid valve (41) from the end
covers (27) (2 used), (28) and (29).
: 32 mm CAUTION: Do not damage the holes on the
spool and casing.
3. Remove the socket bolts (38) and (39) and
remove the end covers (25) (2 used), (26) (2 13. Remove the spool (67) from the casing (63) (2
used), (28) and (29) from each valve section. used).
᧶ 5 mm
4. Remove the spring seat (53), spring (49), (50) IMPORTANT: Do not disassemble the relief valve
and O-ring (36) from the end covers (25) (2 used). (61).
5. Remove the spring seat (51), springs (45), (46), 14. Remove the relief valve (61) from the inlet section
O-rings (36) and (37) (2 used) from the end (1) and remove the O-rings (2 used).
covers (26) (2 used). ᧶ 30 mm
6. Remove the spring seat (52), springs (48), (47),

O-rings (36) and (37) (2 used) from the end cover
(28).
7. Remove the spring seat (53), springs (49), (50),

O-rings (36) and (37) (2 used) from the end cover
(29).
W2-5-7
56
1
2
18 59
17
19 E 60
15
24
83 E 16
10
84
6
3
4
63
64
62
57
59
58
60
23
22
59
60

W2CG-02-05-006
W2-5-8
IMPORTANT: Do not disassemble the relief valve
(62).
15. Remove the relief valve (62) from the valve

section (6) and remove the O-ring.
: 30 mm
16. Remove the valve (56) from the valve section (4)
andremove the O-ring.
17. Remove the plugs (8) and (10) from the valve
sections (4) and (6).
: 30 mm
18. Remove the O-rings (15), (16), (22) and (23) from
the plugs (8) and (10).
19. Turn over the control valve and remove the caps
(59) (4 used).
: 41 mm
20. Remove the poppet (57) and spring (58) from the
valve section (3).
21. Remove the O-ring (60) from the caps (59) (4

used).
22. Turn over the control valve.
23. Remove the nut (84) and remove the bolts (83) (4
used).
: 24 mm
24. Divide each section into the inlet section (1), valve
sections (3) to (6), casing (63), (64) and outlet
section (2).
25. Remove the O-rings (17), (18) (2 used) and (19)

from each section and casings (63) and (64).
26. Remove the O-rings (24) (4 used) from the casing

(64), valve sections (3), (6) and outlet section (2).
W2-5-9
ASSEMBLE 4-UNIT CONTROL VALVE

50 49 38 47 28 49 29 50 45
25 46
39 51
53 48
63 5 26
52 53 39
55 56 36
1
2
18 59
20
17
11
19 E 60
15
85 24
83 E 16 37
10
84 35 30
13 31
43 32
7 33
36 21 6
3 12 41
44 35
54
4 53 42
25 40 53 63 46
40 64 26 34
40
44 52 50 51
14 47 27 48 27 49 45
62
36
87 57
80 67 77 59
69 74 88
58
65 81 60
68 23
75
79
66 86 22 37
59
73 70
60 30
71 78 72 82 76
8 32
41
35
34

W2CG-02-05-006
W2-5-10
1 - Inlet Section 23 - O-Ring 45 - Spring (2 Used) 67 - Spool (2 Used)

2 - Outlet Section 24 - O-Ring (16 Used) 46 - Spring (2 Used) 68 - Spring (2 Used)
5 - Valve Section 27 - End Cover (2 Used) 49 - Spring (4 Used) 71 - Plug (4 Used)
6 - Valve Section 28 - End Cover 50 - Spring (4 Used) 72 - Plug (4 Used)
7 - Plug 29 - End Cover 51 - Spring Seat (2 Used) 73 - Plug (2 Used)
8 - Plug 30 - Plate (2 Used) 52 - Spring Seat (2 Used) 74 - Plug (2 Used)
9 - Plug 31 - Valve Seat (6 Used) 53 - Spring Seat (4 Used) 75 - Orifice (2 Used)
10 - Plug 32 - Plug (6 Used) 54 - Plug (2 Used) 76 - Steel Ball (2 Used)
11 - Plug 33 - Air Bleed Valve ᧤6 Used᧥ 55 - Plug (2 Used) 77 - O-Ring (4 Used)
12 - Plug (7 Used) 34 - Plug (16 Used) 56 - Valve 78 - O-Ring (4 Used)
13 - O-Ring 35 - O-Ring (12 Used) 57 - Poppet 79 - O-Ring (2 Used)
14 - O-Ring 36 - O-Ring (10 Used) 58 - Spring 80 - Socket%ROW 8VHG
15 - O-Ring 37 - O-Ring (16 Used) 59 - Cap (4 Used) 81 - Socket Bolt (8 Used)
16 - O-Ring 38 - Socket Bolt (8 Used) 60 - O-ring (4 Used) 82 - Filter (2 Used)
17 - O-Ring (7 Used) 39 - Socket Bolt (16 Used) 61 - Relief Valve 83 - Bolt (4 Used)
18 - O-Ring (14 Used) 40 - Socket Bolt (8 Used) 62 - Relief Valve 84 - Nut ᧤8 Used᧥
19 - O-Ring (7 Used) 41 - Solenoid Valve (4 Used) 63 - Casing 85 - Spring Washer (8 Used)
20 - O-Ring 42 - Spool 64 - Casing 86 - Cover
21 - O-Ring (4 Used) 43 - Spool 65 - Cover (2 Used) 87 - O-Ring
22 - O-Ring 44 - Spool (2 Used) 66 - Cover (2 Used) 88 - Socket Bolt (4 Used)
W2-5-11

25 50 49
5
53
36
1
2
18 59
17
19 E 60
15
85 24
83 E 16
10
84
43
36 6
3
44
4 42
25 50 53 63
64
44
36
80 57
67 77 59
69
58
65 60
68 23
22
59
60

W2CG-02-05-006
W2-5-12
Assemble 4-Unit Control Valve
1. Install the O-rings (17), (18) (2 used) and (19) on 9. Install the plug (8) on the valve section (6).
each section and casings (63) and (64). : 30 mm
: 70 to 80 Nm (7.1 to 8.2 kgfm)
2. Install the O-rings (24) (4 used) on the casing (64),
valve sections (3), (6) and outlet section (2). 10. Install the plug (10) on the valve section (4).
: 30 mm
3. As for each section and casings (63) and (64), : 100 to 120 Nm (10.0 to 12.0 kgfm)
arrange the inlet section (1), valve section (5),
casing (63), valve section (4), casing (64), valve
sections (6), (3) and outlet section (2) in order.
CAUTION: Do not damage the holes on the
4. Install the bolts (83) (4 used) on each section and
casings (63) and (64). Install the spring washer spool and valve section.
(85) and tighten with the nut (84).
: 24 mm IMPORTANT: Check the positions to insert the
spool (42) to (44).
: 100 to 120 Nm (10.0 to 12.0 kgfm)
5. Turn over the control valve. Install the poppet (57) 11. Insert the spool (44) into the valve sections (4)
and spring (58) on the valve section (3). and (6).Insert the spool (43) into the valve section
(5). Insert the spool (42) into the valve section (3).
6. Install the O-ring (60) on the caps (59) (4 used)
andinstall the cap (59) on the valve sections (3) to
(6). CAUTION: Do not damage the holes on the
: 41 mm spool (67) and casing (63).
: 190 to 210 Nm (19.0 to 21.0 kgfm)
12. Insert the spool (67) into the casings (63) (2 used)
7. Turn over the control valve. and install the springs (68) and (69) on the spool
(67).
8. Install the O-rings (15), (16), (22) and (23) on the
plugs (8) and (10). 13. Install the O-ring (77) on the casings (63) (2 used).
Install the cover (65) on the casings (63) (2 used)
and tighten with the socket bolt (80).
: 8 mm
: 51 to 63 Nm (5.2 to 6.4 kgfm)
14. Install the O-ring (36), spring (49), (50) and spring
seat (53) on the end covers (25) (2 used).
W2-5-13

25 38 47 28 49 29 50 45
39 46
5 51
48
61 26
52 39
56 36
1
E 37
30
36 41
6
3
4 53
25 46
40 26
40
52 50 52
47 27 48 27 49 45
62
36
37
30
41

W2CG-02-05-006
W2-5-14
15. Install the end cover (25) assemblies (2 used) on
the valve section (5) and tighten with the socket 24. Install the O-rings (36), (37) (2 used), springs (49),
bolt (39). (50) and spring seat (53) on the end cover (27).
: 5 mm
: 11 to 13 Nm (1.1 to 1.3 kgfm) 25. Install the end cover (27) assembly and plate (30)
on the valve section (6) and tighten with the
16. Install the O-rings (36), (37) (2 used), springs (48), socket bolt (40).
(47) and spring seat (52) on the end cover (28). : 5 mm
: 11 to 13 Nm (1.1 to 1.3 kgfm)
17. Install the end cover (28) assembly on the valve
section (4) and tighten with the socket bolt (38). 26. Install the O-rings (36), (37) (2 used), springs (45),
: 5 mm (46) and spring seat (51) and (52) on the end
: 15 to 17 Nm (1.5 to 1.7 kgfm) covers (26) (2 used).
18. Install the O-rings (36), (37) (2 used) on the plate 27. Install the end cover (26) assemblies (2 used) on
(30). the valve section (3) and tighten with the socket
bolt (39).
19. Install the O-rings (36), (37) (2 used), springs (47), : 5 mm
(48) and spring seat (52) on the end cover (27). : 11 to 13 Nm(1.1 to 1.3 kgfm)
20. Install the end cover (27) assembly and plate (30) 28. Install the O-rings (2 used) on the relief valve (61)
on the valve section (4) and tighten with the and install the relief valve (61) on the inlet section
socket bolt (40). (1).
: 5 mm : 30 mm
: 11 to 13 Nm (1.1 to 1.3 kgfm) : 69 to 79 Nm (7.0 to 8.1 kgfm)
21. Install the O-rings (36), (37) (2 used), springs (49), 29. Install the O-ring on the relief valve (62) and
(50) and spring seat (53) on the end cover (29). install the relief valve (62) on the valve section (6).
: 30 mm
22. Install the end cover (29) assembly on the valve : 69 to 79 Nm (7.0 to 8.1 kgfm)
section (6) and tighten with the socket bolt (38).
: 5 mm 30. Install the O-ring on the valve (56) and install the
: 15 to 17 Nm (1.5 to 1.7 kgfm) valve (56) on the valve section (4).
: 30 mm
23. Install the O-rings (36) and (37) (2 used) on the : 100 to 120 Nm (10.0 to 12.0 kgfm)
plates (30) (2 used).
31. Install the solenoid valve (41) on the end covers
(27) (2 used), (28) and (29).
: 32 mm
: 39 to 49 Nm (4.0 to 5.0 kgfm)
W2-5-15
VALVE FOR BOOM FOOT AND LOWER
HYDRAULIC SOURCE

Removal

in the circuit.

valve (1).
: 22 mm, 27 mm

reassembling.

: 17 mm
2

22 kg
4. Lift the control valves (1) with the crane and 1

remove it.
M2CN-02-05-002
W2-5-16
Installation

22 kg

1. Install the control valve (1) and tighten with the
bolt (2).
: 17mm
: 34 to 37 Nᨿm (3.5 to 3.8 kgfᨿm)
2. Install all hoses and pipings on the control valve

(1).
: 22 mm
: 27 mm
IMPORTANT: After completing the work, check the 2

oil level.Check for any oil leaks.
1

M2CN-02-05-002
W2-5-17

13
13
21
21 22
16
5 40
4
31 39 24
25
41
33
17
1
27 19
11
2 23
6 14
5
29
3
20 20
36 38 37 18 15
26
34
28 12 7 35
32
9
26
28
30
8
10

M2CN-02-05-003

1 - Inlet Section 12 - O-Ring 23 - Plunger (4 Used) 34 - Plug (4 Used)
2 - Outlet Section 13 - End Cover (8 Used) 24 - Spring (4 Used) 35 - O-Ring (4 Used)
3 - Casing (4 Used) 14 - Plug (24 Used) 25 - Plug (4 Used) 36 - Solenoid Valve (8 Used)
4 - Plug (8 Used) 15 - Plug (8 Used) 26 - Plug (2 Used) 37 - Spool (8 Used)
5 - Plug (10 Used) 16 - O-Ring (8 Used) 27 - O-Ring (4 Used) 38 - Spring (8 Used)
6 - Plug 17 - O-Ring (16 Used) 28 - O-Ring (2 Used) 39 - Bolt (4 Used)
7 - Plug 18 - O-Ring (8 Used) 29 - Relief Valve 40 - Nut (4 Used)
8 - O-Ring (5 Used) 19 - Socket Bolt (32 Used) 30 - Spool 41 - Spring Washer (4 Used)
9 - O-Ring (15 Used) 20 - Spool (4 Used) 31 - Spool
10 - O-Ring (20 Used) 21 - Spring (8 Used) 32 - Spring
11 - O-Ring 22 - Spring Seat (8 Used) 33 - Spring
W2-5-18
• Thoroughly read “PRECAUTIONS FOR 7. Remove the spring seat (22), spring (21), O-ring
DISASSEMBLING AND ASSEMBLING” (W1-1-1) (17) (2 used) and (16) from the end cover (13) (8
before disassembling. used).
CAUTION: Control valve weight: Approx. 22

kg CAUTION: Take care not to damage the hole
of the casing (3).
workbench. 8. Pull out the spool (20) from the casing (3).
9. Remove the plug (25) from the casing (3) and

IMPORTANT: Do not adjust the adjusting screw of removing the O-ring (27).
the solenoid valve (36). : 24 mm
2. Remove the solenoid valve (36) from the end 10. Remove the spring (24) and plunger (23) from the
covers (13) (8 used) and remove the O-ring. casing (3).
: 32 mm
remove the O-ring (28).
: 10 mm
CAUTION: Take care not to damage the hole
of the end cover (13). 12. Remove the plugs (4) (2 used) from the casing
(3).
3. Remove the spools (37) and spring (38) from the : 6 mm
end covers (13) (8 used).
13. Remove the plugs (34) (2 used) from the upper
4. Remove the plug (15) from the end covers (13) (8 surface of the inlet section (1) and remove the
used) and remove the O-ring (18). O-rings (35) (2 used).
: 4 mm : 8 mm
5. Remove the plug (14) (3 used) from the end 14. Remove the spring (32) and (33) from the inlet
covers (13) (8 used). section (1).
: 5 mm
15. Remove the plugs (34) (2 used) from the under
6. Remove the socket bolt (19) and remove the end surface of the inlet section (1) and remove the
cover (13) from the casing (3). O-rings (35) (2 used).
: 4 mm : 8 mm
W2-5-19
6 39
38
30
1
11
7 2
28
3 4
29
8
10

W2CG-02-05-007
W2-5-20

of the inlet section (1).
16. Pull out the spools (30) and (31) from the inlet
section (1)

(29).
Do not adjust the adjusting screw of
the relief valve (29).
17. Remove the relief valve (29) from the inlet section
(1).
: 22 mm
18. Remove the plug (6) from the inlet section (1) and
: 6 mm
19. Remove the plug (5) (6 used) from the inlet

section (1).
: 4 mm
20. Remove the plug (26) (2 used) from the outlet

section (2) and remove the O-ring (28) (2 used).
: 10 mm
21. Remove the plug (7) from the outlet section (2)
and remove the O-ring (12).
:10 mm
22. Remove the plug (5) (4 used) from the outlet

section (2).
:4 mm
23. Remove the nuts (40) (4 used) and pull out the
outlet section (2) and casing (3) from the bolt (39)
in order.
: 13 mm
24. Remove the O-rings (8), (9) and (10) from the inlet
section (1) and casing (3).
W2-5-21
13
13
21
21 22
16
5 40
4
31 39 24
25
41
33
17
1
27 19
11
2 23
6 14
5
29
3
20 20
36 38 37 18 15
26
34
28 12 7 35
32
9
26
28
30
8
10

W2CG-02-05-007

1 - Inlet Section 12 - O-Ring 23 - Plunger (4 Used) 34 - Plug (4 Used)
2 - Outlet Section 13 - End Cover (8 Used) 24 - Spring (4 Used) 35 - O-Ring (4 Used)
3 - Casing (4 Used) 14 - Plug (24 Used) 25 - Plug (4 Used) 36 - Solenoid Valve (8 Used)
5 - Plug (10 Used) 16 - O-Ring (8 Used) 27 - O-Ring (4 Used) 38 - Spring (8 Used)
6 - Plug 17 - O-Ring (16 Used) 28 - O-Ring (2 Used) 39 - Bolt (4 Used)
7 - Plug 18 - O-Ring (8 Used) 29 - Relief Valve 40 - Nut (4 Used)
8 - O-Ring (5 Used) 19 - Socket Bolt (32 Used) 30 - Spool 41 - Spring Washer (4 Used)
9 - O-Ring (15 Used) 20 - Spool (4 Used) 31 - Spool
10 - O-Ring (20 Used) 21 - Spring (8 Used 32 - Spring
11 - O-Ring 22 - Spring Seat (8 Used) 33 - Spring
W2-5-22
1. Install the O-rings (8), (9) and (10) on the inlet IMPORTANT: Do not adjust the adjusting screw of
section (1) and casing (3). the relief valve (29).
2. Install the casing (3) and outlet section (2) on the 8. Install the relief valve (29) on the inlet section
bolt (39) (4 used) attached on the inlet section (1) (1).
in order. Install the spring washer (41) on the bolt : 22 mm
(39) (4 used) and tighten the bolt with the nut (40). : 41 to 47 Nm (4.2 to 4.8 kgfm)
: 13 mm
: 20 to 25 Nm (2.0 to 2.5 kgfm) 9. Install the O-rings (35) on the plugs (34) (2 used)
and install the plug (34) on the under surface of
3. Install the plugs (5) (4 used) on the outlet section the inlet section (1).
(2). : 8 mm
: 69 to 78 Nm (7.0 to 8.0 kgfm)
NOTE: Wrap the seal tape on the plug (5).
: 4 mm IMPORTANT: Check the position to insert the

: 7.8 to 9.8 Nm (0.8 to 1.0 kgfm) spools (30) and (31) and the
direction of the upside and
4. Install the O-ring (12) on the plug (7) andinstall downside.
the plug (7) on the outlet section (2).
: 10 mm 10. Install the spools (30), (31), springs (32) and (33)
: 98 to 118 Nm (10 to 12 kgfm) from the upper surface of the inlet section (1).
5. Install the O-ring (28) on the plug (26) andinstall 11. Install the O-ring (35) on the plugs (34) (2 used)
the plug (26) on the outlet section (2). and install the plug (34) on the upper surface of
: 10 mm the inlet section (1).
: 98 to 118 Nm (10 to 12 kgfm) : 8 mm
: 69 to 78 Nm (7.0 to 8.0 kgfm)
6. Install the plugs (5) (6 used) on the inlet section
(1). 12. Install the plugs (4) (2 used) on the casing (3).
NOTE: Wrap the seal tape on the plug (5). NOTE: Wrap the seal tape on the plug (4).
: 4 mm : 6 mm
: 7.8 to 9.8 Nm (0.8 to 1.0 kgfm) : 20 to 24 Nm (2.0 to 2.4 kgfm)
7. Install the O-ring (11) on the plug (6) (6 used) 13. Install the O-ring (28) on the plug (26) and install
andinstall the plug (6) on the inlet section (1). the plug (26) on the casing (3).
: 6 mm : 10 mm
W2-5-23
12
12
20
20 21
15
23
24
16
18
26
22 13
35 37 36 17 14
3 19

W2CG-02-05-007
W2-5-24
14. Install the plunger (23) and spring (24) on the IMPORTANT: Do not adjust the adjusting screw of
casing (3). the solenoid valve (36).
15. Install the O-rings (27) on the plug (25) and install 22. Install the O-ring on the solenoid valve (36) and
the plug (25) on the casing (3). install the solenoid valve (36) on the end covers
: 24 mm (13) (8 used).
: 49 to 59 Nm (5.0 to 6.0 kgfm) : 32 mm
: 39 to 49 Nm (4.0 to 5.0 kgfm)
IMPORTANT: Check the direction to insert spool

(20).
16. Install the spool (20) on the casing (3).
17. Install the spring (21), spring seat (22), O-rings

(17) (2 used) and (16) on the end covers (13) (8
used).
18. Install the end cover (13) assembly on the casing

(3) and tighten with the socket bolt (19).
: 4 mm
: 5.9 to 7.8 Nm (0.6 to 0.8 kgfm)
19. Install the plugs (14) (3 used) on the end covers

(13) (8 used).
: 5 mm
: 8.3 to 11.0 Nm (0.8 to 1.1 kgfm)
20. Install the O-ring (18) on the plug (15) and install
the plug (15) on the end covers (13) (8 used).
: 4 mm
: 13 to 17 Nm (1.3 to 1.7 kgfm)
21. Install the spool (37) and spring (38) on the end
covers (13) (8 used).
W2-5-25
VALVE FOR COUNTERWEIGHT
REMOVAL/INSTALLTION AND LIVE MAST
FLIP


Removal

in the circuit.

valve (1)
: 22 mm, 27 mm, 36 mm

reassembling.
2
: 17 mm

24.4 kg
4. Lift the control valve (1) and remove it.

1
M2CN-02-05-004

W2-5-26
Installation

24.4 kg

bolt (2).
: 17 mm
: 34 to 37 Nᨿm (3.5 to 3.8 kgfᨿm)

(1).
: 22 mm 2
: 27 mm
: 36 mm
: 175 Nᨿm (18.0 kgfᨿm)

oil level. Check for any oil leaks.
1
M2CN-02-05-004
W2-5-27

15
24
25
43
18 8
6 12
42
13
41 27
28
33
19
35
29
26
1
2 31 21
16
30 7 14 38 40 39 20 17
3 22 23 4 23 4
36
37
34
10
32
9
11 5

W2CG-02-05-008

1 - Inlet Section 12 - O-Ring (2 Used) 23 - Spool (2 Used) 34 - Spring
2 - Outlet Section 13 - O-Ring (2 Used) 24 - Spring (6 Used) 35 - Spring
3 - Casing 14 - O-Ring 25 - Spring (6 Used) 36 - Plug (4 Used)
4 - Casing (2 Used) 15 - End Cover (6 Used) 26 - Plunger (3 Used) 37 - O-Ring (4 Used)
5 - Plug (2 Used) 16 - Plug (18 Used) 27 - Spring (3 Used) 38 - Solenoid Valve (6 Used)
7 - Plug 18 - O-Ring (6 Used) 29 - O-Ring (3 Used) 40 - Spring (6 Used)
8 - Plug (2 Used) 19 - O-Ring (12 Used) 30 - Relief Valve 41 - Bolt (4 Used)
9 - O-Ring (4 Used) 20 - O-Ring (6 Used) 31 - Relief Valve (2 Used) 42 - Nut (4 Used)
10 - O-Ring (12 Used) 21 - Bolt (24 Used) 32 - Spool 43 - Spring Washer (4 Used)
11 - O-Ring (16 Used) 22 - Spool 33 - Spool
W2-5-28
• Thoroughly read “PRECAUTIONS FOR 9. Remove the spool (23) from the casing (4).
before disassembling. 10. Remove the plug (28) from the casings (3) and (4)
and remove the O-ring (21).
: 24 mm
CAUTION: Control valve weight: Approx. 20
kg 11. Remove the spring (27) and plunger (29) from the
casings (3) and (4).
workbench.
12. Remove the plugs (5) (2 used) from the casing
(3).
: 6 mm
IMPORTANT: Do not adjust the adjusting screw of
the solenoid valve (38).
(31).
covers (15) (6 used) and remove the O-ring. Do not adjust the adjusting screw of
: 32 mm the relief valve (31).
13. Remove the relief valve (31) from the casing (4).
CAUTION: Take care not to damage the hole : 24 mm
of the end cover (15).
3. Remove the spools (39) and spring (40) from the remove the O-rings (12) and (13).
end cover (15) (6 used). : 24 mm
4. Remove the plug (17) from the end covers (15) (6 15. Remove the plugs (36) (2 used) from the upper
used) and remove the O-ring (20). surface of the inlet section (1) and remove the
: 4 mm O-rings (37) (2 used).
: 8 mm
5. Remove the plugs (16) (18 used) from the end
covers (15) (6 used). 16. Remove the spring (34) and (35) from the inlet
: 5 mm section (1).
6. Remove the socket bolt (21) and remove the end 17. Remove the plugs (36) (2 used) from the under
cover (15) from the casing (3) and (4). surface of the inlet section (1) and remove the
: 4 mm O-rings (37) (2 used).
: 8 mm
7. Remove the spring seat (25), spring (24), O-rings
(18) and (19) (2 used) from the end cover (15) (6
used).

of the casing (3) and (4).
8. Pull out the spool (22) from the casing (3).
W2-5-29
6 42
41
33
1
2
30 7 14
3 4 4
10
32
9
11

W2CG-02-05-008
W2-5-30

of the inlet section (1).
18. Pull out the spools (32) and (33) from the inlet
section (1)

(30).
Do not adjust the adjusting screw of
(1).
: 22 mm
20. Remove the plug (7) from the inlet section (1) and
: 6 mm
21. Remove the plugs (6) (6 used) from the inlet

section (1).
: 4 mm
22. Remove the plugs (6) (4 used) from the outlet

section (2).
: 4 mm
23. Remove the nuts (42) (4 used) and pull out the
outlet section (2), casings (4) (2 used) and casing
(3) from the bolt (41) in order.
: 13 mm
24. Remove the O-rings (9), (10) and (11) from the
inlet section (1), casings (3) and (4) (2 used).
W2-5-31

15
24
25
43
18 8
6 12
42
13
41 27
28
33
19
35
29
26
1
2 31 21
16
30 7 14 38 40 39 20 17
3 22 23 4 23 4
36
37
34
10
32
9
11 5

W2CG-02-05-008
1 - Inlet Section 12 - O-Ring (2 Used) 23 - Spool (2 Used) 34 - Spring

2 - Outlet Section 13 - O-Ring (2 Used) 24 - Spring (6 Used) 35 - Spring
3 - Casing 14 - O-Ring 25 - Spring (6 Used) 36 - Plug (4 Used)
4 - Casing (2 Used) 15 - End Cover (6 Used) 26 - Plunger (3 Used) 37 - O-Ring (4 Used)
5 - Plug (2 Used) 16 - Plug (18 Used) 27 - Spring (3 Used) 38 - Solenoid Valve (6 Used)
7 - Plug 18 - O-Ring (6 Used) 29 - O-Ring (3 Used) 40 - Spring (6 Used)
8 - Plug (2 Used) 19 - O-Ring (12 Used) 30 - Relief Valve 41 - Bolt (4 Used)
9 - O-Ring (4 Used) 20 - O-Ring (6 Used) 31 - Relief Valve (2 Used) 42 - Nut (4 Used)
10 - O-Ring (12 Used) 21 - Bolt (24 Used) 32 - Spool 43 - Spring Washer (4 Used)
11 - O-Ring (16 Used) 22 - Spool 33 - Spool
W2-5-32
1. Install the O-rings (9), (10) and (11) on the inlet 7. Install the O-rings (37) on the plugs (36) (2 used)
section (1), casings (3) and (4) (2 used). and install the plug (36) on the under surface of
the inlet section (1).
2. Install the casing (3), casings (4) (2 used) and : 8 mm
outlet section (2) on the bolts (41) (4 used) : 69 to 78 Nm (7.0 to 8.0 kgfm)
attached on the inlet section (1) in order. Tighten
with the bolts (41) (4 used) and spring washer
(42). IMPORTANT: Check the position to insert the
: 13 mm spools (32) and (33) and the
: 20 to 25 Nm (2.0 to 2.5 kgfm) direction of the upside and
downside.
3. Install the plugs (6) (4 used) on the outlet section
(2). 8. Install the spools (32), (33), springs (34) and (35)
from the upper surface of the inlet section (1).
9. Install the O-ring (37) on the plugs (36) (2 used)
: 4 mm and install the plug (36) on the upper surface of
: 7.8 to 9.8 Nm (0.8 to 1.0 kgfm) the inlet section (1).
: 8 mm
4. Install the plugs (6) (6 used) on the inlet section : 69 to 78 Nm (7.0 to 8.0 kgfm)
(1).
10. Install the O-rings (12) and (13) on the plug (8)
and install the plug (8) on the casing (4).
: 24 mm
: 39 to 49 Nm (4.0 to 5.0 kgfm)
: 4 mm
: 7.8 to 9.8 Nm (0.8 to 1.0 kgfm)
the plug (7) on the inlet section (1).
: 6 mm
11. Install the relief valve (31) on the casing (4).
: 34 to 38 Nm (3.5 to 3.9 kgfm)
: 24 mm
: 39 to 49 Nm (4.0 to 5.0 kgfm)
IMPORTANT: Do not adjust the adjusting screw of 12. Install the plugs (5) (2 used) on the casing (3).
6. Install the relief valve (30) on the inlet section (1).
: 22 mm : 6 mm
13. Install the plunger (29) and spring (27) on the

casings (3) and (4).
W2-5-33

15
24
25
18
28
19
29
21
16
38 40 39 20 17
3 22 23 4 23 4

W2CG-02-05-008
W2-5-34
14. Install the O-ring (29) on the plug (28) and install IMPORTANT: Do not adjust the adjusting screw of
the plug (28) on the casings (3) and (4). the solenoid valve (38).
: 24 mm
: 49 to 59 Nm (5.0 to 6.0 kgfm) 21. Install the O-ring on the solenoid valve (38) and
install the solenoid valve (38) on the end covers
(15) (6 used).
IMPORTANT: Check the direction to insert spool : 32 mm
(22), (23). : 39 to 49 Nm (4.0 to 5.0 kgfm)
15. Install the spool (22) on the casing (3) and install
the spool (23) on the casing (4).
16. Install the spring (25), spring seat (24), O-rings

(18) and (19) (2 used) on the end covers (15) (6
used).
17. Install the end cover (15) assembly on the casings

(3) and (4) and tighten with the socket bolt (21).
: 4 mm
: 5.9 to 7.8 Nm (0.6 to 0.8 kgfm)
18. Install the plugs (16) (18 used) on the end covers
(15) (6 used).
: 5 mm
: 8.3 to 11.0 Nm (0.8 to 1.1 kgfm)
the plug (17) on the end covers (15) (6 used).
: 4 mm
: 13 to 17 Nm (1.3 to 1.7 kgfm)
20. Install the spool (39) and spring (40) on the end
covers (15) (6 used).
W2-5-35
VALVE FOR SWING


Removal

in the circuit.

valve (1).
: 8 mm, 10 mm
: 22 mm
1

reassembling.
3. Remove the bolt (2). 2

: 19 mm

51 kg

4. Lift the control valve (1) and remove it. M2CN-02-05-005

W2-5-36
Installation

51 kg

bolt (2).
: 19mm
: 60 to 64 Nm (6.1 to 6.6 kgfm)

(1). 1
: 8 mm
: 50 Nm (5.1 kgfm)
: 10 mm
: 90 Nm (9.2 kgfm)
: 22 mm
: 39 Nm (4.0 kgfm) 2

oil level.Check for any oil leaks.
M2CN-02-05-005
W2-5-37

10 18 21 13 12 27 26 20 2
34
11 30
33
31
37 30
32
36
17 33
17 15
35
15 22 19
4 14
23 17
28
16
25 29 24 3
5
7
8
6
W2CG-02-05-009

1 - Inlet Section 11 - O-Ring (3 Used) 21 - Socket Bolt (8 Used) 31 - Spring
2 - Outlet Section 12 - End Cover (2 Used) 22 - Solenoid Valve (2 Used) 32 - Cap (2 Used)
3 - Valve Section 13 - End Cover (2 Used) 23 - Spool 33 - O-Ring (2 Used)
4 - Valve Section 14 - Air Bleed Valve (6 Used) 24 - Spool 34 - Relief Valve
5 - Plug 15 - Valve (6 Used) 25 - Spring (2 Used) 35 - Bolt (4 Used)
6 - Plug 16 - Plug (8 Used) 26 - Spring (2 Used) 36 - Nut (8 Used)
7 - O-Ring 17 - O-Ring (4 Used) 27 - Spring (2 Used) 37 - Spring Washer (8 Used)
8 - O-Ring 18 - O-Ring (4 Used) 28 - Spring Seat (2 Used)
9 - O-Ring (3 Used) 19 - O-Ring (4 Used) 29 - Spring Seat (2 Used)
10 - O-Ring (6 Used) 20 - Socket Bolt (8 Used) 30 - Poppet
W2-5-38
• Thoroughly read “PRECAUTIONS FOR 8. Turn over the control valve and remove the caps
DISASSEMBLING AND ASSEMBLING” (W1-1-1) (32) (2 used).
before disassembling. : 41 mm
9. Remove the poppet (30) and spring (31) from the

CAUTION: Control valve weight: Approx. 51 valve section (4).
kg
10. Remove the O-ring (33) from the caps (32) (2
1. Place the control valve assembly on a clean used).
workbench.
11. Turn over the control valve.
IMPORTANT: Do not adjust the adjusting screw of 12. Remove the nut (36) (2 used) and remove the
the solenoid valve (22). bolts (35) (4 used).
: 24 mm
covers (13) (2 used). 13. Separate each section into the inlet section (1),
: 32 mm valve sections (3), (4) and outlet section (2).
3. Remove the socket bolts (20) and (21) and
remove the end covers (12) (2 used) and (13) (2
14. Remove the O-rings (9), (10) (2 used) and (11)
used) from each valve section
from each section.
: 5 mm
4. Remove the spring seat (28), spring (25), O-rings

(18) and (19) (2 used) from the end covers (13) (2
used).
5. Remove the spring seat (29), springs (26), (27)

and O-ring (18) from the end covers (12) (2 used).
CAUTION: Take care not to damage the

holes of the spool and valve section.
6. Pull out the spools (23) and (24) from each valve
section.

(34).

(1) and remove the O-rings (2 used)
: 30 mm
W2-5-39

10 18 21 13 12 27 26 20 2
34
11 30
33
31
37 30
32
36
17 33
17 15
35
15 22 19
4 14
23 17
28
16
25 29 24 3
5
7
8
6

W2CG-02-05-009

1 - Inlet Section 11 - O-Ring (3 Used) 21 - Socket Bolt (8 Used) 31 - Spring
2 - Outlet Section 12 - End Cover (2 Used) 22 - Solenoid Valve (2 Used) 32 - Cap (2 Used)
3 - Valve Section 13 - End Cover (2 Used) 23 - Spool 33 - O-Ring (2 Used)
4 - Valve Section 14 - Air Bleed Valve (6 Used) 24 - Spool 34 - Relief Valve
5 - Plug 15 - Valve (6 Used) 25 - Spring (2 Used) 35 - Bolt (4 Used)
6 - Plug 16 - Plug (8 Used) 26 - Spring (2 Used) 36 - Nut (8 Used)
7 - O-Ring 17 - O-Ring (4 Used) 27 - Spring (2 Used) 37 - Spring Washer (8 Used)
8 - O-Ring 18 - O-Ring (4 Used) 28 - Spring Seat (2 Used)
9 - O-Ring (3 Used) 19 - O-Ring (4 Used) 29 - Spring Seat (2 Used)
10 - O-Ring (6 Used) 20 - Socket Bolt (8 Used) 30 - Poppet
W2-5-40
1. Install the O-rings (9), (10) (2 used) and (11) on 9. Install the end cover (13) assemblies (2 used) on
each section. the valve section (4) and tighten with the socket
bolt (21).
2. Install each section with the inlet section (1), valve : 5 mm
section (4), valve section (3) and outlet section (2) : 15 to 17 Nm (1.5 to 1.7 kgfm)
in order.
10. Install the O-ring (18) springs (26), (27) and spring
3. Install the bolts (35) (4 used) and spring washer seat (29) on the end cover (12).
(37) on each section and tighten with the nut (36).
: 24 mm 11. Install the end cover (12) assembly on the valve
: 100 to 120 Nm (10.0 to 12.0 kgfm) section (3) and tighten with the socket bolt (20).
: 5 mm
4. Turn over the control valve and install the poppet : 11 to 13 Nm (1.1 to 1.3 kgfm)
(30) and spring (31) on the valve sections (3) and
(4). 12. Install the O-rings (2 used) on the relief valve (34)
and install it on the inlet section (1).
5. Install the O-ring (33) on the caps (32) (2 used) : 30 mm
andinstall the caps (32) on the inlet section (1). : 120 to 140 Nm (12.0 to 14.0 kgfm)
: 41 mm
: 190 to 210 Nm (19.0 to 21.0 kgfm)
13. Install the end covers (13) (2 used) on the
6. Turn over the control valve. solenoid valve (22).
: 32 mm
: 39 to 49 Nm (4.0 to 5.0 kgfm)
CAUTION: Take care not to damage the holes

of the spool and valve section.
IMPORTANT: Check the inserting position of the

spools (23) and (24).
7. Insert the spool (23) into the valve section (4) and
insert the spool (24) into the valve section (3).
8. Install the O-rings (18), (19), spring (25) and

spring seat (28) on the end covers (13) (2 used).
W2-5-41
(Blank)
W2-5-42
SWING MACHINERY / Swing Mechanism
REMOVE AND INSTALL SWING
MECHANISM


Preparation

in the circuit.

Removal
1 2 3 4
1. Remove all hoses (1 to 11) from the swing
12 5
mechanism. Cap the removed hoses.
: 22, 27, 36, 41 mm
2. Remove the bolts (12) (36 used).

᧶ 30 mm
6
7
CAUTION: Swing mechanism assembly
weight: 714 kg 8
10 9
11
3. Lift the swing mechanism with the crane and

remove it.
M2CN-02-06-001

W2-6-1
Installation

CAUTION: Swing mechanism assembly
weight: 714 kg

1. Lift the swing mechanism with the crane and 1 2 3 4
install it on the revolving frame.
12 5
IMPORTANT: When installing the swing
mechanism, apply the liquid packing
on the mounting surfaces of the
reduction gear and revolving frame.
2. Install the bolts (12) (36 used).

: 30 mm
: 350 to 379 Nm (35.7 to 38.7 kgfm) 6
7
3. Install all hoses (1 to 11) on the swing mechanism.
: 22 mm 8
10 9
: 39 Nm (4.0 kgfm) 11
: 27 mm

: 93 Nm (9.5 kgfm)
M2CN-02-06-001
: 36 mm

: 175 Nm (18.0 kgfm)
: 41 mm
: 205 Nm (21.0 kgfm)

W2-6-2
(Blank)
W2-6-3
DISASSEMBLE SWING MECHANISM
33 34 35 36 37
32 1 2 3 4 5 6 7 8 9 10 11
31
30
29
12
13
14
28 27 26 25 24 23 22 21 20 19 18 17 16 15

W2CD-02-06-002
40 39 38
1 - Ring Gear 11 - Motor 21 - Planetary Gear (3 Used) 31 - Sun Gear

2 - Shim 12 - O-Ring 22 - Thrust Washer (6 Used) 32 - Retaining Ring
3 - Bearing 13 - Retaining Ring 23 - Pin (8 Used) 33 - Plug (2 Used)
4 - Socket bolt 14 - Cover 24 - Bearing 34 - Plug
5 - Bearing (2 Used) 15 - Socket Bolt (3 Used) 25 - Casing 35 - Socket Bolt (10 Used)
6 - Casing 16 - Casing 26 - Cover 36 - Pipe
7 - Pinion 17 - Carrier 27 - Bolt (8 Used) 37 - Level Gauge
8 - Pin 18 - Bearing 28 - Shaft 38 - Plug
9 - O-Ring 19 - Spring Pin (3 Used) 29 - Thrust Button 39 - Bolt (6 Used)
10 - Bolt (4 Used) 20 - Knock Pin (2 Used) 30 - Oil Seal 40 - Socket Bolt (4 Used)
W2-6-4
Disassemble Swing Mechanism
• Thoroughly read “PRECAUTIONS FOR 10. Remove the carrier (17) assembly from the casing
DISASSEMBLING AND ASSEMBLING” (W1-1-1) (16).
NOTE: Install the eye bolt (M10) (2 places) on the
CAUTION: Swing mechanism assembly carrier (17). Slowly lift and remove the
weight: 714 kg carrier (17) by hands or with a crane.
1. Remove the plug (33) and drain off the gear oil. 11. Remove the pinion (7) from the casing (6).
Amount of Gear Oil: Approx. 9.2 L 12. Remove the bearing (5) from the pinion (7).
: 8 mm
13. Remove the bearing (3) and shim (2) from the
NOTE: Drain the gear oil in the clean container and carrier (17).
check the metal powder due to wearing.
14. Remove the socket bolt (4) and bolts (39) (6 used)
2. Put the matching mark on the casing (6), (16), from the casing (16) and remove the casing (16).
(25), ring gear (1) and motor (11). : 17 mm
: 30 mm
3. Remove the bolts (10) (4 used) from the swing
motor (11). 15. Remove the sun gear (31) from the planetary gear
: 24 mm (21).
CAUTION: Motor weight: 49 kg 16. Remove the shaft (28) assembly from the casing
(25).
4. Remove the motor (11) from the swing
mechanism. NOTE: Remove the shaft (28) assembly with using
the screw (M12) (3 places) on the end of
NOTE: Lift the motor (11) slightly and tap the swing shaft (28).
mechanism lightly with using a plastic
hammer to remove the motor (11). 17. Remove the ring gear (1) from the casing (25).
5. After removing the level gauge (37) from the pipe NOTE: Remove the ring gear (1) with using the
(36), remove the pipe (36) from the casing (16). pulling-out screw (M8) (2 places) of the ring
gear (1).
6. Remove the O-ring (9) from the casing (16).
18. Remove the bearing (18) and thrust button (29)
7. Remove the socket bolts (40) (4 used), (35) (10 from the shaft (28).
used) and (15) (3 used) from the casing (16) and
remove the casing (16).
: 10 mm
8. Remove the retaining ring (13), cover (14) and

O-ring (12) from the casing (16).
9. Remove the pin (8) from the casing (16).
W2-6-5

28 27 26 25 24 23 22 21 19

W2CD-02-06-002
W2-6-6
19. Remove the pins (23) (3 used) from the planetary Special Tool (A) ˓35 mm
gears (21) (3 used) with using a special tool (A).
Remove the spring pins (19) (3 used) from the
shaft (28).
20. Remove the planetary gears (21) (3 used) and

thrust washers (22) (6 used) from the shaft (28).
21. Remove the bearing (24) from the casing (25).
22. Remove the bolts (27) (8 used) from the cover ˓238 mm
(26) and remove the cover (26) from the casing

(25).
: 13 mm Press
23. Remove the oil seal (30) from the cover (26).
Pillar with
semicircular
section
(3 Places)
284 mm
Special Tool for W2CD-02-06-004

Pin Pulling-Out
W2-6-7
ASSEMBLE SWING MECHANISM
33 34 35 36 37
32 1 2 3 4 5 6 7 8 9 10 11
31
30
29
12
13
14
28 27 26 25 24 23 22 21 20 19 18 17 16 15

W2CD-02-06-002
40 39 38
1 - Ring Gear 11 - Motor 21 - Planetary Gear (3 Used) 31 - Sun Gear

2 - Shim 12 - O-Ring 22 - Thrust Washer (6 Used) 32 - Retaining Ring
3 - Bearing 13 - Retaining Ring 23 - Pin (8 Used) 33 - Plug (2 Used)
4 - Socket bolt 14 - Cover 24 - Bearing 34 - Plug
5 - Bearing (2 Used) 15 - Socket Bolt (3 Used) 25 - Casing 35 - Socket Bolt (10 Used)
6 - Casing 16 - Casing 26 - Cover 36 - Pipe
7 - Pinion 17 - Carrier 27 - Bolt (8 Used) 37 - Level Gauge
8 - Pin 18 - Bearing 28 - Shaft 38 - Plug
9 - O-Ring 19 - Spring Pin (3 Used) 29 - Thrust Button 39 - Bolt (6 Used)
10 - Bolt (4 Used) 20 - Knock Pin (2 Used) 30 - Oil Seal 40 - Socket Bolt (4 Used)
W2-6-8
Assemble Swing Mechanism
1. Install the bearing (24) on the shaft (28).
2. Install the thrust button (29) on the shaft (28).
3. Install the thrust washers (22) (6 used) and

planetary gears (21) (3 used) on the shaft (28)
with the pins (23) (3 used) and lock with the
spring pins (19) (3 used).
NOTE: Caulk the edge (2 places) with using a

punch and lock with the spring pins (19) (3
used). Align the no-semicircular part of the ዘSpecial Tool (B) 2.5mm
thrust washer (22) with the periphery
direction of the shaft (28) when installing.
Lightly tap and insert the pin (23) with using
a plastic hammer so that the holes of pin
(23) and shaft (28) can be aligned. 5mm
The spring pin (19) can be easily inserted
with using a special tool (B).
15mm
4. Install the shaft (28) assembly on the casing (25).
5. Install the bearing (18) on the shaft (28).
6. Install the oil seal (30) inside of the cover (26). ˓5.5mm
NOTE: Insert the oil seal (30) with using a special Special Tool for W2CD-02-06-005
Inserting Spring Pin

tool (C).
7. Install the cover (26) on the casing (25) with the

bolts (27) (8 used).
: 13 mm ዘSpecial Tool (C)
: 29 Nm (3.0 kgfm) ˓11mm
NOTE: Apply ThreeBond #1104 or #1215 on the

mating surfaces of the cover (26) and
casing (25).
˓154mm ˓170mm
W2CD-02-06-006
Special Tool for Inserting
Oil Seal
W2-6-9

33 35 36 37
1 2 3 4 5 6 7 8 10 11
31
30
12
13
14
28 25 24 20 17 16 15

W2CD-02-06-002
40
W2-6-10
IMPORTANT: Wrap a vinyl tape on the spline part 16. Install the O-ring (12), cover (14) and retaining
of the shaft (28) assembly not to ring (13) on the casing (16).
damage the lip of the oil seal (30).
17. Install the casing (16) on the casing (6) with the
8. Install the knock pins (20) (2 used) on the ring socket bolts (40) (4 used), (35) (10 used) and (15)
gear (1). Install it on the casing (25). (3 used).
: 10 mm
NOTE: Align the matching marks on the casing : 98 Nm (10.0 kgfm)
(25) and ring gear (1) when installing.
Apply ThreeBond #1104 or #1215 on the NOTE: Align the matching marks on the casing (6)
mating surfaces of the casing (25) and ring with (16) when installing.
gear (1). Apply ThreeBond #1104 or #1215 on the
mating surfaces of the casing (6) and (16).
9. Install the casing (6) on the ring gear (1) with the
socket bolt (4). 18. Install the O-ring on the casing (16).
: 17 mm
: 430 Nm (44.0 kgfm) 19. Lift the swing motor (11) vertically. Install the
: 30 mm swing motor (11) on the pinion (7) and tighten with
: 430 Nm (44.0 kgfm) the bolts (10) (4 used).
: 24 mm
NOTE: Align the matching marks on the ring gear : 235 Nm (24.0 kgfm)
(1) and casing (6) when installing.
Apply ThreeBond #1104 or #1215 on the 20. Install the plug (33) on the casing (25).
mating surfaces of the ring gear (1) and : 8 mm
casing (6). : 44 Nm (4.5 kgfm)
10. Install the sun gear (31) on the shaft (28). NOTE: Wrap the seal tape on the plug (33).
11. Install the shim (2) and bearing (3) on the carrier 21. Add the gear oil through the oil filler.
(17). Amount of Gear Oil: Approx. 9.2 L
12. Install the bearings (5) (2 used) on the pinion (7). NOTE: Temporarily install the pipe (36) and level
gauge (37) and check the gear oil level.
13. Install the bearing (24) on the casing (16). After installing the swing mechanism on the
machine, install the pipe (36) and level
14. Install the carrier (17) and pinion (7) on the sun gauge (37). At this time, completely remove
gear (31). the seal tape from the screwthread and
wrap the new seal tape when installing
15. Install the pin (8) on the casing (6). after removing grease.
W2-6-11
SWING MECHANISM / Swing Mechanism
DISASSEMBLE SWING MOTOR

1 2 3 4 5 6 7 8 9 10 11 12 13 14
27
26
28
25 29
24 30
31
32
23 22 21 20 19 18 17 15, 16 33

W2CD-02-06-003
1- Shoe 10 - Spring (24 Used) 18 - Pin (2 Used) 26 - Shoe Plate

2- Retainer 11 - Valve Casing 19 - Separator Plate (4 Used) 27 - Plunger (2 Used)
3- Piston (9 Used) 12 - Valve Plate 20 - Friction Plate (3 Used) 28 - Spring (2 Used)
4- Cylinder 13 - Plug 21 - Spring 29 - O-Ring (2 Used)
5- O-Ring 14 - Plug 22 - Casing 30 - Plug (2 Used)
6- Plug 15 - Plug (2 Used) 23 - Shaft 31 - Socket Bolt (4 Used)
7- O-Ring 16 - O-Ring (2 Used) 24 - Oil Seal 32 - O-Ring (2 Used)
8- Brake Piston 17 - Bearing 25 - Bearing 33 - Relief Valve (2 Used)
9- O-Ring
W2-6-12
Disassemble Swing Motor
• Thoroughly read “PRECAUTIONS FOR IMPORTANT: Do not fall off valve plate (12) from
DISASSEMBLING AND ASSEMBLING” (W1-1-1) the valve casing (11). (The valve
before disassembling. plate (12) may be attached at the
cylinder (4) side.)
Do not damage the mating surfaces
CAUTION: Motor weight: 49 kg
when separating the valve casing
(11) from the casing (22) with using a
1. Put the matching marks on the valve casing (11) screwdriver.
and casing (22).
6. Loosen the socket bolts (31) (4 used) and remove
2. Remove the plug (13) from the valve casing (11). the valve casing (11) from the casing (22).
Drain the hydraulic oil. : 17 mm
: 6 mm
3. Place the shaft end of the shaft (23) downward NOTE: When loosening the socket bolt (31), the
and secure the shaft (23) on the workbench to valve casing (11) is floated by the spring
disassemble easily. (10).
7. Remove the O-ring (9), valve plate (12) and pins

NOTE: Place the rubber plate and cloth on the (18) (2 used) from the valve casing (11).
8. Remove the spring (10) from the brake piston (8).
4. Remove the relief valves (33) (2 used) from the
valve casing (11) and remove the O-rings (32) (2
used).
: 41 mm
NOTE: When loosening the relief valve (33), the

O-ring (32) is damaged. Be sure to replace
the O-ring (32).
IMPORTANT: Do not damage the seat part of

plunger (27).
5. Remove the plug (30) from the valve casing (11)

and remove the O-ring (29), spring (28) and
plunger (27).
: 14 mm
W2-6-13

1 2 3 4 5 7 8 11
26
25
24
23 22 21 20 19 17

W2CD-02-06-003
W2-6-14
9. Remove the brake piston (8) from the casing (22). ዘSpecial Tool (A)
NOTE: Attach the claw of a special tool (A) to the

brake piston (8) and pull the brake piston
(8) upward straightly. Special Tool
10. Re-place the motor horizontally.

8
IMPORTANT: Do not damage the sliding surfaces
of the cylinder (4) and shoe (1). 22
11. Remove the cylinder (4), piston (3), retainer (2),

shoe (1) and spring (21) from the shaft (23).
12. Remove the friction plate (20) and separator plate

(19) from the casing (22).
13. Remove the shaft (23) assembly and shoe plate

NOTE: When removing the shaft (23) assembly, W25N-02-06-009
the oil seal (24) is damaged by the spline. 14

Wrap the vinyl tape on the spline of the
85
shaft (23) assembly. 75
30
14. Remove the oil seal (24) from the casing (22). 15
• If necessary, do the following procedures. Do not 35

use the removed bearings (17) and (25) again.
R12.5
15. Remove the inner ring of bearing (25) from the M16 Penetration
shaft (23).
100
30
14
NOTE: Evenly tap and remove the inner ring of

44
bearing (25) with using a steel bar.

8
M16
4
16. Remove the outer ring of bearing (25) from the

˳8
casing (22).
Special Tool for Brake Piston (8)
NOTE: Evenly tap and remove the outer ring of
bearing (25) with using a steel bar.
17. Remove the O-rings (5) and (7) from the casing W25N-02-06-010
(22).
18. Remove the bearing (17) from the valve casing

(11).
W2-6-15
ASSEMBLE SWING MOTOR

1 2 3 4 5 6 7 8 9 10 11 12 13 14
27
26
28
25 29
24 30
31
32
23 22 21 20 19 18 17 15, 16 33

W2CD-02-06-003
1- Shoe 10 - Spring (24 Used) 18 - Pin (2 Used) 26 - Shoe Plate

2- Retainer 11 - Valve Casing 19 - Separator Plate (4 Used) 27 - Plunger (2 Used)
3- Piston (9 Used) 12 - Valve Plate 20 - Friction Plate (3 Used) 28 - Spring (2 Used)
4- Cylinder 13 - Plug 21 - Spring 29 - O-Ring (2 Used)
5- O-Ring 14 - Plug 22 - Casing 30 - Plug (2 Used)
6- Plug 15 - Plug (2 Used) 23 - Shaft 31 - Socket Bolt (4 Used)
7- O-Ring 16 - O-Ring (2 Used) 24 - Oil Seal 32 - O-Ring (2 Used)
8- Brake Piston 17 - Bearing 25 - Bearing 33 - Relief Valve (2 Used)
9- O-Ring
W2-6-16
Assemble Swing Motor
1. Place the casing (22) on the workbench with 8. Install the piston (3) with the shoe (1) installed on
placing the valve casing (11) side upward. the retainer (2) on the cylinder (4).
IMPORTANT: Check the direction of flange of the 9. Align the splines of the cylinder (4) and shaft (23).
inner ring of the bearing (25). Install the cylinder (4) assembly on the shaft (23).
2. Install the bearing (25) on the shaft (23). 10. Re-place the casing (22) with placing the oil seal
(24) side downward.
NOTE: Shrink the inner ring.
11. Install the separator plate (19) and friction plate
IMPORTANT: Check the installing direction of the (20) on the casing (22) in order alternately.
oil seal (24). When tapping the oil
seal (24), do not damage the outer NOTE: Install the separator plates (19) (4 used)
surface of the oil seal. and friction plates (20) (3 used).
3. Insert the oil seal (24) into the casing (22). 12. Install the O-rings (5) and (7) on the casing (22).
NOTE: Apply grease on the lip part of the oil seal NOTE: Apply grease on the O-rings (5) and (7)
(24) thinly. thinly.
Use a special tool.
13. Install the brake piston (8) on the casing (22).
IMPORTANT: Wrap a vinyl tape on the spline part
of the shaft (23) assembly not to 14. Install the spring (10) on the brake piston (8).
damage the lip of the oil seal (24).
15. With tapping the outer ring of the bearing (17)
4. Install the shaft (23) assembly on the casing (22). with using a steel bar lightly, insert the bearing
(17) into the valve casing (11).
5. Re-place the casing (22) horizontally.
6. Insert the shoe plate (26) into the casing (22). NOTE: Evenly tap and insert the outer ring of the
bearing (17) until the outer ring stops at the
step part of the valve casing (11).
NOTE: Direct the larger-chamfered side of the
shoe plate (26) inside of the casing (22).
Apply grease on the mating surface to
prevent from falling off.
7. Install the retainer (2) and spring (21). Install the

piston (3) with the shoe (1).
W2-6-17

9 10 11 12 13
27
28
29
30
31
32
22 33

W2CD-02-06-003
W2-6-18
16. Apply grease on the valve casing (11) mounting
surfaces of the valve plate (12) and install the
valve plate (12) on the valve casing (11).
IMPORTANT: Check the installing direction of the

valve casing (11).
Do not fall off the valve plate (12).
Do not fall the spring (10).
17. After installing the O-ring (9) on the valve casing

(11), install the valve casing (11) on the casing
(22) and tighten the socket bolt (31).
: 17 mm
: 430 Nm (44.0 kgfm)
18. Insert the plunger (27) and spring (28) into the
valve casing (11).
NOTE: Check if the plunger (27) moves smoothly.
19. Install the O-ring (29) on the plug (30) and tighten
the plug (30) to the casing (11).
: 14 mm
: 334 Nm (34.0 kgfm)
20. Install the O-ring (32) on the relief valve (33) and
install the relief valve (33) on the valve casing
(11).
: 41 mm
: 177 Nm (18.0 kgfm)
21. Add the hydraulic oil into the motor. Wrap the seal
tape on the plug (13) and install the plug (13) to
the valve casing (11).
Amount of Hydraulic Oil: Approx. 0.8 L
: 6 mm
: 36 Nm (3.7 kgfm)
W2-6-19
Swing Mechanism
• Replacement Standard for Gear
Replace the parts when the pitting (1 mm or more a pit,

5% or more on the rate of area) occurs on the tooth of
the sun gear (31), planetary gears (21) and ring gear
(1).
When the damage on the appearance is found even if
the pitting does not occur, replace the parts.
Swing Motor

Unit: mm
D-d 0.027 0.052
d D
2. Clearance between piston and shoe shrinking W25N-02-04-005

portion
Unit: mm
ˡ 0 0.3
3. Shoe thickness ˡ
Unit: mm
t
t 5.5 5.3 W25N-02-04-006
4. Friction plate thickness

Unit: mm
2.0 1.8
W2-6-20
SWING MACHINERY / Hoisting Mechanism
REMOVE AND INSTALL HOISTING
MECHANISM


Removal

removing the wire rope of the front and rear drum,
remove the pendant rope, extension, top section
and base section. (As for the removal of the
pendant rope, extension, top section and base 2
section, refer to the Operator’s Manual.) 1
2. Remove the counterweight. (As for the removal of

the counterweight, refer to W2-2 in this section.)
3. Loosen the bolt (3) for the left houses (1) and (2)
on the hoisting motors of the front and rear drums. 3
Lift the left houses (1) and (2) with the crane and
remove them.
: 17mm 3

M2CN-02-07-001
4. Pull out the boom raising/lowering wire rope.
5. Remove the live mast. (As for the removal of the
live mast, refer to W2-3 in this section.)
W2-7-1
6. Remove the bolt (12) and remove the drum
covers (4 to 7) and brackets (8 to 11). 6
: 19 mm 10
7. Move the front and rear drum lock switches in the 4 12

operator’s cab to the “UNLOCK” position (lock 8
disengaged) and disengage the drum lock.
NOTE: In case the pawl is not disengaged, the 7

pawl is disengaged when placing the 10
hoisting lever in “hoisting” position slightly 8
with the drum lock switch kept in the 5
9
“UNLOCK” position (lock disengaged).
11 9
10

M2CN-02-07-002

15 14
8. Remove the wire harness and all hoses from the
hoisting motor (13). Attach a plug on the removed 15 14
hoses.
: 22 mm
: 36 mm
: 10 mm
13
9. Remove the bolt (14) and remove the bracket (15)
from the drum rotation sensor.
: 19 mm 13

M2CN-02-07-003
W2-7-2
CAUTION: Hoisting mechanism (front)

weight: 1770 kg
Hoisting mechanism (rear)
weight: 1770 kg

IMPORTANT: When lifting the hoisting mechanism
with the crane, do not attach a wire
rope on the motor.

10. Attach a wire rope on the drum of the hoisting
mechanism and support it with the crane.
11. Remove the nut (16) and bolt (17).
: 24 mm

12. Remove the bolt (18) and remove the lock plate
(19). Pull out the pin (20) and remove the hoisting
mechanism with the crane.
: 19 mm
Installation
CAUTION: Hoisting mechanism (front)

weight: 1770 kg
Hoisting mechanism (rear) 18
weight: 1770 kg 19
17 16 20 17
IMPORTANT: When lifting the hoisting mechanism
18 16
with the crane, do not attach a wire
rope on the motor. 16 17
19
1. Attach a wire rope on the hoisting mechanism. Lift
it with the crane and align the hoisting mechanism 20 20
with the rotating platform. 19
2. Install the hoisting mechanism on the rotating 18

platform and lock it with the pin (20). Install the
lock plate (19) with the bolt (18).
20
: 19 mm
19
: 60 to 64 Nm (6.1 to 6.6 kgfm)
18 16 17
3. Adjust the right left position of the hoisting
M2CN-02-07-004
mechanism so that the drum flange meshes with

the pawl of the drum lock. Tighten the nut (16).
: 24 mm
: 148 to 160 Nm (15.0 to 16.3 kgfm)
W2-7-3
15 14
4. Install the bracket (15) of the drum rotation 15 14
sensor.
: 19 mm
: 60 to 64 Nm (6.1 to 6.6 kgfm)
13
13

M2CN-02-07-003

6
10
5. Install the wire harness and all hoses on the
hoisting motor (13). 4 12
᧶22 mm ᧶ 39 Nm (4.0 kgfm) 8
᧶36 mm ᧶ 175 Nm (18.0 kgfm)
᧶10 mm ᧶ 90 Nm (9.2 kgfm)
7 10
6. Install the drum covers (4 to 7) and brackets (8 to
11) on the revolving frame with the bolt (12). 8
: 19 mm 5
: 60 to 64 Nm (6.1 to 6.6 kgfm) 9
11 9
10

M2CN-02-07-002
W2-7-4
7. Install the live mast. (As for the installation of the
live mast, refer to W2-3 in this section.)

8. Wind the wire rope on the boom raising/lowering
mechanism.
9. Lift the left houses (1) and (2) with the crane and
tighten the bolt (3). 2
: 17mm 1
: 34 to 37 Nm (3.5 to 3.8 kgfm)

section.)
11. Wind the wire rope on the front and rear drum and 3
reeve the wire rope through the hook. (Refer to
3

M2CN-02-07-001
W2-7-5
DISASSEMBLE HOISTING MECHANISM
3,4 5 6 7 8 9 10 11 12 13 14 17 18 20
15 19 21
16
1 2
65
64 22
63
43
42
41
40
23
39 24
38 27 26 25
28
37 36 35 34 33 32 31 30 29
44 45 46 47 48 49
62
61
50
60 54 51
59 55
58 57 56
53 52

M2CN-02-07-005

1- Drum 18 - Bracket 35 - Needle Bearing (15 Used) 52 - Bolt (12 Used)
2- Cover 19 - Washer (24 Used) 36 - Retaining Ring (5 Used) 53 - Washer (12 Used)
3- Bolt (16 Used) 20 - Bolt (24 Used) 37 - Thrust Plate (3 Used) 54 - Sleeve
4- Washer (16 Used) 21 - Level Gauge 38 - Needle Bearing (6 Used) 55 - Oil Seal
5- Retainer 22 - Motor 39 - Retaining Ring (3 Used) 56 - Bearing
6- Ring Gear 23 - Bolt (4 Used) 40 - Carrier 57 - Bracket
7- Spacer 24 - Washer (4 Used) 41 - Planetary Gear (3 Used) 58 - Washer (6 Used)
8- Sun Gear 25 - O-Ring 42 - Bearing 59 - Bolt (6 Used)
9- Spacer 26 - Plug 43 - Shaft 60 - 1LSSOH
10 - Spacer 27 - Bolt (28 Used) 44 - Bolt (8 Used) 61 - Bolt (4 Used)
11 - Spline Shaft 28 - Washer (28 Used) 45 - Washer (8 Used) 62 - Washer (4 Used)
12 - O-Ring 29 - Plug 46 - Retainer 63 - Retainer
13 - Pedestal 30 - Carrier 47 - Bearing 64 - Plug
14 - Plug 31 - Pin (5 Used) 48 - Bearing 65 - Retainer
15 - Washer (24 Used) 32 - Spacer (5 Used) 49 - Sleeve
16 - Bolt (24 Used) 33 - Thrust Plate (5 Used) 50 - Oil Seal
17 - Casing 34 - Planetary Gear (5 Used) 51 - Retainer
W2-7-6
Disassemble Hoisting Mechanism
CAUTION: Hoisting motor weight: Approx.
DISASSEMBLING AND ASSEMBLING” (W1-1-1) 270 kg
10. Loosen the bolts (23) (4 used) of the hoisting
motor (22). Lift the motor (22) assembly with the
CAUTION: Hoisting mechanism weight: 1770 crane and remove it.
kg ᧶ 30mm
1. Lift the hoisting mechanism with the crane and 11. Remove the O-ring (25) from the reduction gear.
remove put it on a workbench. After removing the
plugs (26) and (29), drain off the gear oil. 12. Loosen the bolts (20) (24 used). Lift the bracket
Gear oil : 12 L (18) with the crane and remove it.
᧶30mm
NOTE: Drain off the gear oil in the clean container
and check the metal powder due to
wearing. CAUTION: Reduction gear weight: Approx.
580 kg
2. Remove the bolts (61) (4 used) and remove the
retainer (63). 13. Loosen the bolts (27) (28 used). Lift the reduction
: 30 mm gear with the crane and remove it from the drum
(1).
3. Remove the bolts (59) (6 used) and remove the ᧶30mm
retainer (65).
: 30 mm 14. Lift the reduction gear with the crane and place it
on the workbench with positioning the hoisting
4. Remove the oil seal (55) from the retainer (65). motor (22) mounting side downward. At this time,
place the wooden block (200 mm square) under
5. Remove the sleeve (54) from the drum (1). the hoisting motor (22) mounting surface and
stabilize the reduction gear.
6. Lift the bracket (57) with the crane and remove it
from the drum (1). 15. Remove the bolts (3) (16 used) and remove the
cover (2).
7. Remove the bearing (56) and oil seal (55) from ᧶19 mm
the bracket (57).
16. Remove the retainer (5) from the cover (2).
8. Remove the sleeve (54) from the drum (1).
17. Remove the bearing (42) from the cover (2).
9. Lift the hoisting mechanism with the crane and
place it on the workbench with positioning the 18. Pull out the shaft (43).
bracket (57) side downward. At this time, place
the wooden block (300 mm square) under the 19. Take out the carrier (40) assembly.
drum (1) and stabilize the hoisting mechanism.
20. Remove the retaining ring (39) (3 used) from the
carrier (40).
21. Remove the planetary gears (41) (3 used), thrust

plates (37) (3 used) and needle bearings (38) (6
used) from the carrier (40).
W2-7-7

6 7 8 9 10 11 12 13 17
16
1
36 35 34 33 32 31 30
44 46 47 48 49
50
51
52

M2CN-02-07-005
W2-7-8
22. Remove the spacer (7) from the sun gear (8).
23. Remove the sun gear (8) and spacer (9).
24. Loosen the bolts (16) (24 used). Remove the ring
gear (6) from the pedestal (13).
: 36 mm
25. Take out the carrier (30) assembly.
26. Remove the retaining ring (36) (5 used) from the

carrier (30).
27. Remove the pin (31) (5 used) from the carrier

(30).
28. Remove the planetary gears (34) (5 used), thrust

29. Remove the spacer (10),(32) (5 used) from the

carrier (30).
30. Remove the spline shaft (11) from the casing (17).
31. Remove the O-ring (12) from the pedestal (13).
32. Loosen the bolts (44) (8 used). Remove the

retainer (46) from the casing (17).
: 24 mm
33. Lift the pedestal (13), bearings (47) and (48),

retainer (51) and oil seal (50) assembled with the
crane and remove it from the casing (17).
34. Remove the bearing (47) from the pedestal (13).
35. Lift the pedestal (13) with the crane and place it
on the workbench with positioning the drum (1)
mounting side downward. At this time, place the
wooden block (200 mm square) under the drum
(1) mounting surface.
36. Loosen the bolts (52) (12 used). Remove the

retainer (51) from the pedestal (13).
: 17 mm
37. Remove the oil seal (50) from the retainer (51).
39. Remove the sleeve (49) from the casing (17).
W2-7-9
ASSEMBLE HOISTING MECHANISM
3,4 5 6 7 8 9 10 11 12 13 14 17 18 20
15 19 21
16
1 2
65
64 22
63
43
42
41
40
23
39 24
38 27 26 25
28
37 36 35 34 33 32 31 30 29
44 45 46 47 48 49
62
61
50
60 54 51
59 55
58 57 56
53 52

M2CN-02-07-005

1- Drum 18 - Bracket 35 - Needle Bearing (15 Used) 52 - Bolt (12 Used)
2- Cover 19 - Washer (24 Used) 36 - Retaining Ring (5 Used) 53 - Washer (12 Used)
3- Bolt (16 Used) 20 - Bolt (24 Used) 37 - Thrust Plate (3 Used) 54 - Sleeve
4- Washer (16 Used) 21 - Level Gauge 38 - Needle Bearing (6 Used) 55 - Oil Seal
5- Retainer 22 - Motor 39 - Retaining Ring (3 Used) 56 - Bearing
6- Ring Gear 23 - Bolt (4 Used) 40 - Carrier 57 - Bracket
7- Spacer 24 - Washer (4 Used) 41 - Planetary Gear (3 Used) 58 - Washer (6 Used)
8- Sun Gear 25 - O-Ring 42 - Bearing 59 - Bolt (6 Used)
9- Spacer 26 - Plug 43 - Shaft 60 - 1LSSOH
10 - Spacer 27 - Bolt (28 Used) 44 - Bolt (8 Used) 61 - Bolt (4 Used)
11 - Spline Shaft 28 - Washer (28 Used) 45 - Washer (8 Used) 62 - Washer (4 Used)
12 - O-Ring 29 - Plug 46 - Retainer 63 - Retainer
13 - Pedestal 30 - Carrier 47 - Bearing 64 - Plug
14 - Plug 31 - Pin (5 Used) 48 - Bearing 65 - Retainer
15 - Washer (24 Used) 32 - Spacer (5 Used) 49 - Sleeve
16 - Bolt (24 Used) 33 - Thrust Plate (5 Used) 50 - Oil Seal
17 - Casing 34 - Planetary Gear (5 Used) 51 - Retainer
W2-7-10
Assemble Hoisting Mechanism
1. Lift the pedestal (13) with the crane and place it 12. Install the spacer (10) and (32) (5 used) on the
on the workbench with positioning the drum (1) carrier (30).
wooden block (200 mm square) under the drum 13. Install the the planetary gears (34) (5 used),
(1) mounting surface. thrust plates (33) (5 used) and needle bearings
(35) (15 used) on the carrier (30).
2. Install the bearing (48) on the pedestal (13).
14. Install the pins (31) (5 used) on the carrier (30)
3. Install the oil seal (50) on the retainer (51). and install the retaining ring (36).
4. Apply the liquid packing (ThreeBond #1215) on 15. Install the carrier (30) assembly on the casing
the mating surface with the retainer (51) of the (17).
pedestal (13).
16. Install the sun gear (8) and spacer (9) on the
5. Install the retainer (51) on the pedestal (13) and carrier (30) assembly.
install the washer (53). Tighten it with the bolts
(52) (12 used) with LOCTITE #242 applied. 17. Install the spacer (7) on the sun gear (8).
: 17mm
: 41 to 45 Nm (4.2 to 4.6 kgfm) 18. Install the ring gear (6) on the pedestal (13) and
6. Lift the casing (17) with the crane and place it on (44) (8 used) with LOCTITE #242 applied.
the workbench with positioning the hoisting motor : 36mm
(22) mounting side downward. At this time, place : 605 to 655 Nm (61.7 to 66.8 kgfm)
the wooden block (200 mm square) under the
hoisting motor (22) mounting surface. 19. Install the planetary gears (41) (3 used), thrust
7. Install the sleeve (49) on the casing (17). used) on the carrier (40) .
8. Install the pedestal (13) on the casing (17). 20. Install the retaining ring (39) (3 used) on the
carrier (40).
9. Install the bearing (47) on the casing (17).
21. Install the carrier (40) assembly on the ring gear
10. Install the retainer (46) on the casing (17) and (6) and sun gear (8).
(44) (8 used) with LOCTITE #242 applied. 22. Install the shaft (43) on the carrier (40) assembly.
: 24mm At this time, make sure that the shaft (43) rotates
: 179 to 194 Nm (18.3 to 19.8 kgfm) by hands.
11. Install the spline shaft (11) on the casing (17). 23. Install the bearing (42) on the shaft (43).
W2-7-11

3,4 6 17 18 20
19
1 2
65
64 22
63
43
23
24
27
28
62
61
60 54
59 55
58 57 56

M2CN-02-07-005
W2-7-12
24. Apply the liquid packing (ThreeBond #1215) on
CAUTION: Hoisting motor weight: Approx.
the mating surface with the cover (2) of the ring
gear (6). 270 kg
25. Install the cover (2) on the ring gear (6) and 31. Lift the motor (22) assembly with the crane and
install it on the casing (17). Tighten with the bolts
tighten with the bolts (3) (16 used) with LOCTITE
#242 applied and washer (4). (23) (4 used) and washer (24).
: 19 mm : 30mm
: 72 to 78 Nm (7.4 to 8.0 kgfm) : 540 Nm (55.0 kgfm)
26. Lift the drum (1) with the crane and place it on the CAUTION: Hoisting mechanism weight: 1770
workbench with positioning the bracket (57) kg
wooden block (300 mm square) under the drum 32. Lift the hoisting mechanism with the crane and
(1) and stabilize the drum (1). place it on the workbench horizontally.
CAUTION: Reduction gear weight: Approx. 33. Install the sleeve (54) on the drum (1).
580kg
34. Install the oil seal (55) and bearing (56) on the
27. Lift the reduction gear with the crane and install it bracket (57).
on the drum (1). Tighten with the bolt (27) (28
used) and washer (28). 35. Lift the bracket (57) with the crane and install it on
: 30 mm the drum (1).
: 540 Nm (55.0 kgfm)
36. Install the sleeve (54) on the drum (1).
28. Hammer in the shaft (43) end surface several
times with a plastic hammer. Make sure that the 37. Install the oil seal (55) on the retainer (65).
dimension “L” between the casing (17) end
surface and the shaft (43) end is 50 mm. 38. Install the retainer (65) on the bracket (57) and
tighten with the bolts (59) (6 used) and washer
29. Lift the bracket (18) with the crane and tighten (58).
with the bolts (20) (24 used) and washer (19) to : 30 mm
the casing (17). : 88 Nm (9.0 kgfm)
: 30 mm
: 750 Nm (76.5 kgfm) 39. Tighten the retainer (63) on the sleeve (54) end
surface with the bolts (61) (4 used) and washer
30. Apply the liquid packing (ThreeBond #1389) on (62).
the mating surface with the motor (22) of the : 30 mm
casing (17). : 88 Nm (9.0 kgfm)
40. Remove the plug (64) and grease through the

nipple (60) until the grease (Shell Alvania EP2)
comes out from the hole removed.
: 7 mm
W2-7-13

13 14
21
64

M2CN-02-07-005
W2-7-14
: 7 mm
42. Add the gear oil to the center of the level gauge
(21) through the filler port of the pedestal (13).
Gear oil : 12 L
43. Install the plug (14) on the filler port of the

pedestal (13).
W2-7-15
DISASSEMBLE HOISTING MOTOR
14 13 32 20 12 10 11 9 8 19 38 27 40 39 44 42
15
8
50
16
51
19
55
18
56
1
54
4
30
6
46
46
57
34
5
3
2
17
33
31
7 53
35 47

36 21 29 28 33 34 23 22 24 25 43 37 26 41 45 52 48 49
M2CN-02-07-006
1- Bolt (4 Used) 16 - Cover 31 - Socket Bolt (12 Used) 46 - Retaining Ring (2 Used)
2- Front Cover 17 - Bearing Spacer 32 - Casing 47 - Casing
3- Oil Seal 18 - O-Ring 33 - O-Ring (5 Used) 48 - Plug (3 Used)
4- O-Ring 19 - O-Ring (4 Used) 34 - Plug (5 Used) 49 - O-Ring (3 Used)
5- Output Shaft 20 - Pin 35 - Front Casing 50 - O-Ring
6- Bearing 21 - Swash Plate 36 - Socket Bolt (14 Used) 51 - O-Ring
7- Retaining Ring 22 - Plunger (9 Used) 37 - O-Ring 52 - Friction Plate (8 Used)
8- Socket Bolt (8 Used) 23 - Holder 38 - Pin 53 - Piston
9- Cover 24 - Spring (9 Used) 39 - Valve Cover 54 - Spring (22 Used)
10 - Stopper 25 - Rotor 40 - Socket bolt 55 - O-Ring
11 - O-Ring 26 - Valve Plate 41 - Shim (1 Unit) 56 - Cover
12 - Piston 27 - Needle Bearing 42 - O-Ring 57 - Plug
13 - Piston 28 - Plate 43 - Socket Bolt (9 Used)
14 - O-Ring 29 - Shoe Plate 44 - Coupling
15 - Stopper 30 - Retaining Ring 45 - Plate (9 Used)
W2-7-16
Disassemble Hoisting Motor IMPORTANT: When removing the valve cover (39),
the valve plate (26) may be removed
• Thoroughly read “PRECAUTIONS FOR together. Do not fall off the valve
DISASSEMBLING AND ASSEMBLING” (W1-1-1) plate (26).
• The procedure starts on the premise that the 10. Remove the socket bolts (40) and (43) (9 used)
regulator, counterbalance valve and solenoid and remove the valve cover (39) from the casing
valve have already been removed. (32).
: 17 mm
CAUTION: Hoisting motor weight: 268 kg
(32).
1. Place the hoisting motor on a workbench and
remove the plug (34) from the casing (32). Drain 12. Remove the valve plate (26) and O-ring (37) from
off the hydraulic oil. the valve cover (39).
: 36 mm
2. Put the matching marks on the front casing (35), NOTE: Do not remove the needle bearing (27)
casing (32), valve cover (39), casing (47) and unnecessarily.
cover (56).
13. Remove the rotor (25), plungers (22) (9 used),
3. Loosen the socket bolts (31) (12 used) evenly and springs (24) (9 used), holder (23) and plate (28)
remove the cover (56) from the casing (47). from the casing (32).
: 10 mm
14. Remove the socket bolts (8) (8 used) and remove
4. Remove the O-ring (55) from the cover (56). the covers (9) and (16) from the casing (32).
: 14 mm
5. Remove the springs (54) (22 used) and piston
(53) from the casing (47). 15. Pull out the stoppers (10), (15), pistons (12) and
6. Remove the casing (47) from the valve cover (39)
and remove the O-rings (50) and (51) from the NOTE: Remove the stoppers (10) and (15) with
casing (47). using a screw (M6).
7. Remove the retaining ring (46), coupling (44) and 16. Remove the O-rings (11) and (14) from the
retaining ring (46) from the output shaft (5). stoppers (10) and (15).
8. Remove the plates (45) (9 used), friction plates 17. Remove the bolts (1) (4 used) and remove the
(52) (8 used), shim (41) and O-ring (42) from the front cover (2) from the front casing (35).
valve cover (39). : 17 mm
18. Remove the oil seal (3) and O-ring (4) from the
9. Remove the retaining ring (30) from the output
front cover (2).
shaft (5).
19. Remove the socket bolts (36) (14 used) and
remove the front casing (35) from the casing (32).
: 12 mm
W2-7-17
32
19
18
17
7
35

21 29

M2CN-02-07-006
W2-7-18
(32) and O-ring (18) from the front casing (35)
respectively.
21. Pull out the output shaft (5) from the front casing
(35).
22. Remove the retaining ring (7) and bearing spacer

(17) from the output shaft (5) and remove the
bearing (5) with using a press.
23. Remove the swash plate (21) from the casing (32)
and remove the shoe plate (29) from the swash
plate (21).
W2-7-19
ASSEMBLE HOISTING MOTOR
14 13 32 20 12 10 11 9 8 19 38 27 40 39 44 42
15
8
50
16
51
19
55
18
56
1
54
4
30
6
46
46
57
34
5
3
2
17
33
31
7 53
35 47

36 21 29 28 33 34 23 22 24 25 43 37 26 41 45 52 48 49

M2CN-02-07-006
1- Bolt (4 Used) 16 - Cover 31 - Socket Bolt (12 Used) 45 - Plate (9 Used)

2- Front Cover 17 - Bearing Spacer 32 - Casing 46 - Retaining Ring (2 Used)
3- Oil Seal 18 - O-Ring 33 - O-Ring (5 Used) 47 - Casing
4- O-Ring 19 - O-Ring (4 Used) 34 - Plug (5 Used) 48 - Plug (3 Used)
5- Output Shaft 20 - Pin 35 - Front Casing 49 - O-Ring (3 Used)
6- Bearing 21 - Swash Plate 36 - Socket Bolt (14 Used) 50 - O-Ring
7- Retaining Ring 22 - Plunger (9 Used) 37 - O-Ring 51 - O-Ring
8- Socket Bolt (8 Used) 23 - Holder 38 - Pin 52 - Friction Plate (8 Used)
9- Cover 24 - Spring (9 Used) 39 - Valve Cover 53 - Piston
10 - Stopper 25 - Rotor 40 - Socket bolt 54 - Spring (22 Used)
11 - O-Ring 26 - Valve Plate 41 - Shim (1 Unit) 55 - O-Ring
12 - Piston 27 - Needle Bearing 42 - O-Ring 56 - Cover
13 - Piston 28 - Plate 43 - Socket Bolt (9 Used) 57 - Plug
14 - O-Ring 29 - Shoe Plate 44 - Coupling
15 - Stopper 30 - Retaining Ring
W2-7-20
Assemble Hoisting Motor
10. Install the O-ring (14) on the stopper (15) and the
1. Install the shoe plate (29) on the swash plate (21) o-ring (11) on the stopper (10) respectively. Install
and install the swash plate (21) on the casing the stoppers (10) and (15) on the end of the
(32). casing (32).
NOTE: Turn the larger chamfered side of the shoe NOTE: Install the stoppers (15) and (10) to the end
plate (29) to the swash plate (21) side. surface of the casing (32).
2. Install the bearing (6) on the output shaft (5) with 11. Install the cover (9) on the casing (32) with the
using a press and install the bearing spacer (17) socket bolts (8) (4 used).
and retaining ring (7). : 14 mm
: 235 Nm (24.0 kgfm)
3. Tap the outer race of the bearing (6) with using a
copper bar and install the output shaft (5) ton the 12. Install the cover (16) on the casing (32) with the
front casing (35). socket bolts (8) (4 used).
: 14 mm
4. Install the O-ring (18) on the front casing (35) and : 235 Nm (24.0 kgfm)
O-rings (19) (4 used) on the casing (32)
respectively. 13. Install the springs (24) (9 used) on the rotor (25)
and install the holder (23).
5. Install the front casing (35) and output shaft (5) on
the casing (32). 14. Install the plungers (22) (9 used) on the plate (28)
and insert the plunger (22) into the rotor (25).
IMPORTANT: Check that swash plate (21) moves
smoothly. 15. Align the spline of the output shaft (5), rotor (25)
and holder (23). Install the rotor (25) assembly on
6. Tighten the socket bolts (36) (14 used). the output shaft (5).
: 12 mm
: 160 Nm (16.3 kgfm) 16. Apply the grease on the valve plate (26). Align
with the pin (38) and install the valve plate (26) on
the valve cover (39). Install the O-ring (37) on the
7. Install the oil seal (3) on the front cover (2) with valve cover (39).
using a press and install the O-ring (4).
17. Install the O-rings (19) (2 used) on the casing
8. Install the front cover (2) on the front casing (35) (32).
and tighten the bolts (1) (4 used).
: 17mm 18. Place the casing (32) on the workbench vertically.
: 57 Nm (5.8 kgfm)
19. Install the valve cover (39) on the casing (32) with
9. Insert the piston (13) into the front casing (35) the socket bolts (40) and (43) (9 used).
side of the casing (32) and the piston (12) into the : 17 mm
valve cover (39) side. : 430 Nm (43.8 kgfm)
W2-7-21
32 27 39 44 42
50
51
55
56
54
30
46
46
34
5
33
31
53
47

33 34 41 45 52

M2CN-02-07-006
W2-7-22
20. Install the retaining ring (30) on the output shaft
(5) and fix the needle bearing (27).

(5).
22. Install the coupling (44) on the output shaft (5)

and install the retaining ring (46).
IMPORTANT: Align the notches on the plate (45)

and friction plate (52). Adjust with
the shims (41) so that the dimension
between the end of the valve cover
(39) and the plate (45) is 3.1 mm.
23. Install the shim (41), plates (45) (9 used) and

friction plates (52) (8 used) on the valve cover
(39) and coupling (44).
24. Install the O-ring (42) on the valve cover (39).
25. Install the O-rings (50) and (51) on the casing (47)
and install the piston (53).
26. Install the springs (54) (22 used) on the piston

(53).
27. Install the O-ring (55) on the cover (56) and install
the cover (56) on the casing (47) with the socket
: 10 mm
: 98 Nm (10.0 kgfm)
the plug (34) on the casing (32).
: 36 mm
: 167 Nm (17.0 kgfm)
W2-7-23
Dial Gauge
1. Secure the plunger with the shoe attached in a

vise.
Install the dial gauge on the shoe. Move the shoe Clearance
upward and downward and measure the
clearance between the shoe and the spherical
part of plunger. In case the measurement value is
Guide
beyond the allowable limit, replace the plunger
and shoe assembly.
Unit: mm

0 to 0.1 0.3 Vise Soft Liner
W309-04-05-002
Remedy: Replace the shoe and the plunger as an
assembly.
2. Measure the plunger diameter at upper, middle,

lower positions (2 places for each) with using a
micrometer. Measure the diameter at the second
position 90 degrees away from the first position.
Measure the rotor bore inner diameter at positions
A and B (2 places for each) with using a cylinder
gauge.
W309-04-05-003
Unit: mm
0.039 0.078
Remedy: Replace the plunger or the rotor.
3. Measure the shoe thickness B with using a

micrometer.
Unit: mm
8.8 8.6
W309-04-05-004
B
W309-04-05-005
W2-7-24
4. Measure the heights of H and h.
C=H-h Plate Holder
Unit: mm
32.2 31.6 H
h
Remedy: Replace the holder and the plate as an

assembly.
W309-04-05-006
5. Measure the dimension A.

Unit: mm
3.1 3.6
A
Remedy: Adjust with the shims.
6. Measure the brake spring length.

Unit: mm
Standard Allowable Limit W309-04-05-007
54 53.2
Remedy: Replace the spring.
7. Measure the thickness of the plate and friction

plate. (17 used)
Unit: mm
32.4 31.7
Remedy: Replace the plate.
W2-7-25

29 2 1 3 4 6 17 16
15
17
7
40
8
41
43
9
42
37 10
13
39
12
38 11
35 25
3
33
34 36 22 23 19 21 20 18 24 27 26
32
14 31 28 30 5

M2CN-02-07-007

1- Plug (2 Used) 12 - Nut (2 Used) 23 - Spool 34 - 3LVWRQ
2- O-ring (2 Used) 13 - Adjusting Screw (2 Used) 24 - Spring seat 35 - Pin
3- Plug 14 - Pin 25 - Spring seat 36 - O-ring
4- Casing 15 - 6SULQJVHDW 26 - O-ring 37 - Socket bolt (6 Used)
5- Socket bolt (2 used) 16 - Spool 27 - Spring 38 - Cover
6- Spacer (2 Used) 17 - Sleeve 28 - O-ring 39 - O-ring
7- Solenoid Valve 18 - Lock pin 29 - O-ring 40 - Sleeve
8- Spring 19 - Spring 30 - O-ring 41 - Piston
9- O-ring 20 - O-ring 31 - Orifice 42 - Lever
10 - Cover (2 Used) 21 - Plug 32 - Plug 43 - Pin
11 - Socket bolt (4 Used) 22 - Sleeve 33 - O-ring
W2-7-26
• Thoroughly read “PRECAUTIONS FOR 10. Remove the plug (32) from the casing (4).
DISASSEMBLING AND ASSEMBLING” (W1-1-1) : 8 mm
11. Remove the O-ring (33) from the plug (32).
1. Remove the solenoid valve (6) from the casing
(4). 12. Remove the lever (42) from the sleeve (17).
: 32 mm
13. Remove the spring seat (9), spring (7), spring seat
2. Remove the socket bolts (5) (4 used) and remove (15), spool (16) and sleeve (17) from the casing
the casing from the hoisting motor (4). (4).
: 6 mm
14. Remove the O-ring (8) from the spring seat (9).
3. Remove the O-rings (28) and (30) from the casing
(4). 15. Remove the plug (21) from the casing (4) and
remove the spring (19) and lock pin (18).
4. Remove the orifice (31) from the casing (4). : 13 mm
: 4 mm
remove the cover (38) from the casing (4). 17. Remove the spring seat (25), spring (27), spring
: 5 mm seat (24), spool (23) and sleeve (22) from the
casing (4).
casing. 18. Remove the O-ring (26) from the spring seat (25).
7. Remove the pin (35) and piston (34) from the

cover (38).
8. Remove the piston (41) and sleeve (40) from the

cover (38).

covers (10) (2 used) from the casing (4).
: 5 mm
IMPORTANT: Do not disassemble the adjusting nut

(13) and nut (12).
W2-7-27
ASSEMBLE REGULATOR

29 2 1 3 4 6 17 16
15
17
7
40
8
41
43
9
42
37 10
13
39
12
38 11
35 25
3
33
34 36 22 23 19 21 20 18 24 27 26
32
14 31 28 30 5

M2CN-02-07-007

W2-7-28
Assemble Regulator
1. Install the sleeve (22), spool (23), spring seat (24) 10. Install the O-ring (8) on the spring seat (9) and
and spring (27) on the casing (4). install it on the casing (4).
2. Install the O-ring (26) on the spring seat (25) and 11. Install the cover (10) on the casing with the socket
install it on the casing (4). bolt (11).
: 5 mm
3. Install the cover (10) on the casing (4) with the : 12 Nm (1.2 kgfm)
socket bolt (11).
: 5 mm 12. Install the piston (34) on the casing (4).
: 12 Nm (1.2 kgfm)
13. Install the O-rings (29), (36) and (39) on the
4. Install the lock pin (18) and spring (19) on the casing (4).
casing (4).
14. Install the pin (35) on the cover (38).
5. Install the O-ring (20) on the plug (21) and install it
on the casing (4). 15. Install the sleeve (40) and piston (41) on the cover
: 13mm (38).
: 29 Nm (3.0 kgfm)
16. Install the cover (38) on the casing with the bolts
6. Install the sleeve (17) and spool (16) on the (37) (6 used).
casing (4). : 5 mm
: 12 Nm (1.2 kgfm)
7. Install the lever (42) on the sleeve (17).
17. Install the orifice (31) on the casing (4) and install
8. Install the O-ring (33) on the plug (32) and install it the O-rings (28) and (30).
on the casing (4). : 4 mm
: 8 mm : 9 Nm (0.9 kgfm)
: 44 Nm (4.5 kgfm)
18. Install the casing (4) on the hoisting motor with the
9. Install the spring seat (15) and spring (7) on the socket bolts (5) (4 used).
casing (4). : 6 mm
: 29 Nm (3.0kgfm)
19. Install the solenoid valve (6) on the casing (4).

: 32mm
: 44 Nm (4.5 kgfm)
W2-7-29
DISASSEMBLE COUNTERBALANCE VALVE
9
19 8
7
21 15 6
20
24 35
5 3
16 4 2
17
18 12 1
13
22 14
23
25
26
12
27 13 10
28 11
29
30
31
32
33
33 34

M2CN-02-07-008
1- Socket Bolt (4 Used) 10 - Plug 19 - Air Bleed Valve 28 - Plunger

2- Spring Washer (4 Used) 11 - O-Ring 20 - O-Ring 29 - Spring
3- Cover 12 - Plug (2 Used) 21 - Plug 30 - O-Ring
4- O-Ring 13 - O-Ring (2 Used) 22 - Socket Bolt (4 Used) 31 - Backup Ring
5- Plug 14 - Casing 23 - Spring Washer (4 Used) 32 - Plug
6- Spool 15 - Socket Bolt (6 Used) 24 - Cover 33 - O-Ring (2 Used)
7- Steel Ball 16 - Spring Washer (6 Used) 25 - O-Ring 34 - Relief Valve
8- Spring 17 - Plug 26 - Spring 35 - Filter
9- Orifice 18 - O-Ring 27 - Seat
W2-7-30
Disassemble Counterbalance Valve 11. Remove the spring (29) and plunger (28) from the
casing (14).
DISASSEMBLING AND ASSEMBLING” (W1-1-1) NOTE: Do not remove the seat (27) except when
before disassembling. replacing the seat.
1. Remove the O-rings (33) (2 used) from the casing 12. Remove the relief valve (34) from the casing (14)
(14). and remove the O-ring and backup ring from the
relief valve (34).
2. Remove the socket bolts (1) and (22) (4 used for : 50 mm
each) and remove the covers (3) and (24) from
the casing (14).
: 10 mm
3. Remove the plug (21) from the cover (24) and

remove the O-ring (20) from the plug (21).
: 6 mm

: 6 mm
5. Remove the spring (26) and O-rings (4) and (25)

from the casing (14).
6. Pull out the spool (6) assembly from the casing

(14).
7. Remove the plug (5) from the spool (6) and

remove the filter (35) from the plug (5).
8. Remove the orifice (9), spring (8) and steel ball

(7) from the spool (6).
9. Remove the plug (32) from the casing (14).

: 50 mm
10. Remove the O-ring (30) and backup ring (31) from
the plug (32).
W2-7-31
ASSEMBLE COUNTERBALANCE VALVE
22 23 24 25 26 9 8 7 14 6 13 12 35 5 4 3
11
20
10
21
1
27 28 29 32 31 30 34
17 18 15
19
16
33

M2CN-02-07-009

W2-7-32
Assemble Counterbalance Valve 12. Install the cover (24) on the casing (14) and
tighten with the socket bolts (22) and spring
1. Install the O-ring and backup ring on the relief washers (23) (4 used for each).
valve (34). : 10 mm
: 88 to 108 Nm (9.0 to 11.0 kgfm)
2. Install the relief valve (34) on the casing (14).
: 50 mm 13. Install the O-ring (11) on the plug (10) and install
: 166 to 186 Nm (17.0 to 19.0 kgfm) the plug (10) on the cover (3).
: 6 mm
3. Install the O-ring (30) and backup ring (31) on the : 34 to 38 Nm (3.5 to 3.9 kgfm)
plug (32).
4. Insert the spring (29) into the plunger (28) and the plug (21) on the cover (24).
install the plunger (28) on the plug (32). : 6 mm
: 34 to 38 Nm (3.5 to 3.9 kgfm)
5. Install the plug (32) on the casing (14).
: 50 mm 15. Install the O-rings (33) (2 used) on the casing
: 181 to 211 Nm (18.5 to 21.5 kgfm) (14).
6. Insert the filter (35) into the plug (5) and install the
plug (5) on the spool (6).
7. Install the steel ball (7), spring (8) and orifice (9)
on the spool (6).
8. Insert the spool (6) into the casing (14).
IMPORTANT: Check if the spool (6) moves

smoothly with pushing the spool.
9. Install the spring (26) on the casing (14).
10. Install O-rings (4) and (25) on the casing (14).
11. Install the cover (3) on the casing (14) and tighten
with the socket bolts (1) and spring washers (2) (4
used for each).
: 10 mm
: 88 to 108 Nm (9.0 to 11.0 kgfm)
W2-7-33
DISASSEMBLE REEVING WINCH

1 2 3 4 5 6 7 8 9 10 11 12 13,14
15
16
17
18
19
30 29 28 27 26 25 24 23 22 21 20

W2CG-02-07-011
1- Drum 9- Planetary Gear (4 Used) 17 - Oil Seal 24 - Coupling

2- Spacer 10 - Needle Bearing (8 Used) 18 - Sleeve 25 - Spring
3- Spacer 11 - Spring Pin (4 Used) 19 - Retaining Ring 26 - Shaft
4- Ring Gear 12 - Carrier 20 - Bearing 27 - O-Ring
5- Carrier Assembly 13 - Plug (2 Used) 21 - O-Ring 28 - End Cover
6- Spacer 14 - O-Ring (2 Used) 22 - Thrust Plate 29 - Plug (2 Used)
7- Pin (4 Used) 15 - Motor 23 - Sun Gear 30 - Socket Bolt (12 Used)
8- Thrust Plate (8 Used) 16 - Retaining Ring
W2-7-34
Disassemble Reeving Winch
11. Take out the carrier (12) assembly.
DISASSEMBLING AND ASSEMBLING” (W1-1-1) 12. Remove the spacer (6) from the Carrier (12).
13. Remove the spring pin (11) and pull out the pins
(7) (4 used) from the carrier (12).
CAUTION: Reeving winch weight: Approx. 93
kg 14. Remove the planetary gears (9) (4 used), thrust
1. Remove the plug (13) and drain off the gear oil. used) from the carrier (12).
Gear oil: 0.5 L
15. Remove the sun gear (23), coupling (24) and
NOTE: Drain the gear oil in the clean container and thrust plate (22) from the motor (15).
16. Remove the retaining ring (19) from the motor
2. Lift the reeving winch with the crane and place it (15) and remove the bearing (20) and sleeve (18).
on a workbench with placing the motor (15)
downward. At this time, place the wooden block 17. Remove the oil seal (17) from the motor (15).
(200 mm square) under the motor (15) mounting
surface to stabilize the reduction gear.
3. Remove the bolts (30) (12 used). Lift the drum (1)
with the crane and remove it.
: 10 mm
4. Remove the retaining ring (16) from the drum (1).
5. Remove the spacers (2) and (3) from the ring

gear (4).
6. Remove the end cover (28) and ring gear (4) from
the reduction gear.
7. Remove the O-ring (27) from the end cover (28).
8. Remove the O-ring (21) from the ring gear (4).
9. Remove the carrier (5) assembly from the shaft.
10. Remove the shaft (26) and spring (25) from the
coupling (24).
W2-7-35
ASSEMBLE REEVING WINCH

1 2 3 4 5 6 7 8 9 10 11 12 13,14
15
16
17
18
19
30 29 28 27 26 25 24 23 22 21 20

W2CG-02-07-011

1- Drum 9- Planetary Gear (4 Used) 17 - Oil Seal 24 - Coupling
2- Spacer 10 - Needle Bearing (8 Used) 18 - Sleeve 25 - Spring
3- Spacer 11 - Spring Pin (4 Used) 19 - Retaining Ring 26 - Shaft
4- Ring Gear 12 - Carrier 20 - Bearing 27 - O-Ring
5- Carrier Assembly 13 - Plug (2 Used) 21 - O-Ring 28 - End Cover
6- Spacer 14 - O-Ring (2 Used) 22 - Thrust Plate 29 - Plug (2 Used)
7- Pin (4 Used) 15 - Motor 23 - Sun Gear 30 - Socket Bolt (12 Used)
8- Thrust Plate (8 Used) 16 - Retaining Ring
W2-7-36
Assemble Reeving Winch
12. Install the O-ring on the end cover (28) and install
1. Lift the motor (15) with the crane and place it on the end cover (28) on the ring gear (4).
the workbench. At this time, place the wooden
block (200 mm square) under the motor (15). 13. Install the spacers (2) and (3) on the ring gear (4).
2. Install the oil seal (17) on the motor (15). 14. Install the retaining ring (16) on the drum (1).
3. Install the sleeve (18) and bearing (20) on the 15. Install the Install the drum (1) on the ring gear (4)
motor (15) and install the retaining ring (19). with the bolts (30) (12 used).
: 10 mm
4. Install the thrust plate (22), coupling (24) and sun : 140 Nዘm (140. Kgfዘm)
gear (23) on the motor (15).
16. Add the gear oil through the plug (13) hole of the
5. Install the planetary gears (9) (4 used), thrust drum (1).
plates (8) (8 used) and needle bearings (10) (8 Gear oil: 0.5 L
used) on the carrier (12).
6. Install the pins (7) (4 used) on the carrier (12) and on the drum (1).
insert the spring pin (11). At this time, turn the slit
portion of the spring pin (11) to the motor side.
7. Install the carrier (12) assembly on the sun gear

(23) and motor (15).
8. Place the spacer (6) on the carrier (12).
9. Install the spring (25) and shaft (26) on the

coupling (24).
10. Install the carrier (5) assembly on the shaft (26).
11. Install the O-ring (21) on the ring rear (4) and
install the ring gear (4) on the carrier (12)
assembly and carrier (5) assembly.

W2-7-37
DISASSEMBLE REEVING WINCH MOTOR

7 8 9 10 11,46 12 13 14 32 33 34 35 36 37

5

6
38
15 39
16 40
17
41
18
42
19
31 43
20
30 21
29 22
28
27 26 25 23 24 23 45 44
W2CG-02-07-012
1- Cylinder 13 - Expander 25 - Spring (8 Used) 37 - Spring (2 Used)

2- Inner Ring 14 - Plug (2 Used) 26 - Housing 38 - Piston (2 Used)
3- Oil Seal 15 - Disk Spring (4 Used) 27 - O-Ring 39 - Plug (2 Used)
4- Bearing 16 - Teflon Ring (4 Used) 28 - Teflon Ring 40 - Spacer (2 Used)
5- Shoe Plate 17 - Bushing (4 Used) 29 - Piston 41 - Plug (2 Used)
6- Collar 18 - Bearing 30 - Plate (3 Used) 42 - Spring (2 Used)
7- Plate 19 - Retaining Ring 31 - Friction Plate (3 Used) 43 - O-Ring (2 Used)
8- Auxiliary Spring 20 - Piston (2 Used) 32 - Socket Bolt (4 Used) 44 - Piston (2 Used)
9- Plunger (7 Used) 21 - Teflon Ring (2 Used) 33 - Cover 45 - Pin (2 Used)
10 - Expander 22 - Balance Plate 34 - Plunger 46 - Teflon Ring
11 - O-Ring 23 - O-Ring (2 Used) 35 - Spacer (2 Used)
12 - Plug 24 - Teflon Ring 36 - O-Ring (2 Used)
W2-7-38
Disassemble Reeving Winch Motor
12. Remove the oil seal (3) from the housing (26).
DISASSEMBLING AND ASSEMBLING” (W1-1-1) 13. Remove the O-ring (23), Teflon ring (46) and
before disassembling. O-ring (11) from the cover (33).

14. Remove the retaining ring (19) from the shaft of
1. Place the reeving winch motor on a workbench the cover (33) and pull out the bearing (18) with
and remove the plug (14) from the casing (33). using a press.
Drain off the hydraulic oil.
: 6 mm 15. Remove the balance plate (22) from the shaft of
the cover (33).
2. Loosen the socket bolts (32) (4 used) evenly and
remove the cover (33) assembly from the housing 16. Remove the pistons (20) (2 used) and Teflon rings
(26). (21) (2 used) from the balance plate (22).
: 8 mm
17. Remove the bushings (17) (4 used), Teflon rings
3. Remove the springs (25) (8 used) from the piston
(16) (4 used) and disk springs (15) (4 used) from
(29). the cover (33).
4. Remove the piston (29) from the housing (26). 18. Remove the plugs (39) (2 used), pistons (38) (2
used), spacers (40) (2 used) and O-rings (36) (2
5. Remove the Teflon ring (24) and O-ring (23) from used) from the cover (33).
the piston (29).
: 41 mm
6. Remove the Teflon ring (28) and O-ring (27) from 19. Remove the springs (37) (2 used) and spacers
the housing (26). (35) (2 used) from the cover (33).
7. Remove the Remove the cylinder (1) assembly 20. Remove the O-rings (36) (2 used), spacers (40) (2
from the housing.
used) and pistons (38) (2 used) from the plug
(39).
8. Remove the inner ring (2) from the cylinder (1)
and pull out the bearing (4) with using a press.
21. Pull out the plunger (34) from the cover (33).
9. Remove the collar (6) from the cylinder (1).
22. Remove the plugs (41) (2 used) from the cover
10. Remove the shoe plate (5), plungers (9) (7 used), (33).
plate (7) and auxiliary spring (8) from the cylinder : 12 mm
(1).
23. Remove the springs (42) (2 used) and pistons
11. Remove the plates (30) (3 used) and friction (44) (2 used) from cover (33).
plates (31) (3 used) from the housing (26).
24. Remove the O-rings (43) (2 used) from the plug
(41).
W2-7-39
ASSEMBLE REEVING WINCH MOTOR

7 8 9 10 11,46 12 13 14 32 33 34 35 36 37

5

6
38
15 39
16 40
17
41
18
42
19
31 43
20
30 21
29 22
28
27 26 25 23 24 23 45 44
W2CG-02-07-012
1- Cylinder 13 - Expander 25 - Spring (8 Used) 37 - Spring (2 Used)

2- Inner Ring 14 - Plug (2 Used) 26 - Housing 38 - Piston (2 Used)
3- Oil Seal 15 - Disk Spring (4 Used) 27 - O-Ring 39 - Plug (2 Used)
4- Bearing 16 - Teflon Ring (4 Used) 28 - Teflon Ring 40 - Spacer (2 Used)
5- Shoe Plate 17 - Bushing (4 Used) 29 - Piston 41 - Plug (2 Used)
6- Collar 18 - Bearing 30 - Plate (3 Used) 42 - Spring (2 Used)
7- Plate 19 - Retaining Ring 31 - Friction Plate (3 Used) 43 - O-Ring (2 Used)
8- Auxiliary Spring 20 - Piston (2 Used) 32 - Socket Bolt (4 Used) 44 - Piston (2 Used)
9- Plunger (7 Used) 21 - Teflon Ring (2 Used) 33 - Cover 45 - Pin (2 Used)
10 - Expander 22 - Balance Plate 34 - Plunger 46 - Teflon Ring
11 - O-Ring 23 - O-Ring (2 Used) 35 - Spacer (2 Used)
12 - Plug 24 - Teflon Ring 36 - O-Ring (2 Used)
W2-7-40
Assemble Reeving Winch Motor
13. Install the plungers (9) (7 used) on the plate (7)
1. Install the O-rings (43) (2 used) on the plugs (41) and insert the auxiliary spring (8) and plunger (9)
(2 used). into the cylinder (1).
2. Install the pistons (44) (2 used) and springs (42) 14. Insert the shoe plate (5) into the cylinder (1).
(2 used) on the cover (33).
15. Insert the collar (6) into the cylinder (1).
3. Install the plugs (41) (2 used) on the cover (33).
: 12 mm 16. Insert the bearing (4) into the output shaft of the
cylinder (1) with using a press and install the inner
4. Insert the plunger (34) into the cover (33). ring (2).
5. Install the spacers (35) (2 used) and springs (37) 17. Insert the cylinder (1) assembly into the housing
(2 used) on the cover (33). (26).
6. Install the pistons (38) (2 used), spacers (40) (2 18. Install the O-ring (23) and Teflon ring (28) on the
used) and O-rings (36) (2 used) on the plugs (39) housing (26).
(2 used) and install the plugs (39) (2 used) on the
cover (33). 19. Install the O-ring (23) and Teflon ring (24) on the
: 41mm piston (29) and install the piston (29) on the
housing (26).
7. Install the disk springs (15) (4 used), Teflon rings 20. Install the springs (25) (8 used) on the piston (29).
(16) (4 used) and bushings (17) (4 used) on the
cover (33). 21. Install the cover (33) assembly on the housing
(26) with the socket bolts (32) (4 used).
8. Install the Teflon rings (21) (2 used) and pistons : 8 mm
(20) (2 used) on the balance plate (22) and insert : 50 Nm (5.1 kgfm)
the balance plate (22) into the shaft of the cover
(33).
22. Install the plug (14) on the cover (33).
9. Insert the bearing (18) into the shaft of the cover : 6 mm
(33) with using a press and install the retaining
ring (19).
10. Install the O-ring (11), Teflon ring (46) and O-ring
(23) on the cover (33).
11. Insert the oil seal (3) into the housing (26) with
using a press.
12. Install the friction plates (31) (3 used) and plates

(30) (3 used) on the housing (26).
W2-7-41
(Blank)
W2-7-42
SWING MACHINERY / Raising/Lowering Mechanism (To Machine No. 5)
REMOVE AND INSTALL RAISING/LOWERING
MECHANISM

Removal
1. Lower the boom and remove the pendant rope,

extension, top section and base section.
(As for removal of the pendant rope, extension,
top section and base section, refer to the
2. Remove the counterweight. (As for removal of the

counterweight, refer to W2-2 in this section.)
2 1
3. Remove the boom raising/lowering wire rope.

4. Loosen the bolts (2) that installs the left house (1)
M2CN-02-08-001
on the raising/lowering motor and remove the

house with lifting it with the crane.
: 17 mm
10 5 6 4 11
11
5. Remove the live mast. (As for removal of the live 11
mast, refer to W2-3 in this section.)
7
6. Remove the bolts (8), (9), (10) and (11). Remove 9
the drum covers (3), (4), (5), bracket (6) and plate 8
10 3
(7). 8
: 19 mm
: 17 mm 9
8 6
10 10
10 6
10

M2CN-02-08-002
W2-8-1
7. Remove all hoses from the raising/lowering motor
(12). Attach a plug on the removed hoses. 12
: 27 mm : 10 mm 13

of the drum speed sensor. 14
: 19 mm
CAUTION: Raising/lowering mechanism

weight: 1670 kg
9. Attach a wire rope on the raising/lowering W2CG-02-08-003
mechanism and support the raising/lowering

10. Remove the nut (15) and remove the bolt (16).
: 24 mm
11. Remove the bolts (17) and remove the lock plate
(18). After removing the pin (19), lift the 17 19 16 15
raising/lowering mechanism with the crane and
remove it.
: 19 mm
18
Installation 17
18
19
weight: 1670 kg 19
1. Attach a wire rope on the raising/lowering
mechanism. Lift the raising/lowering mechanism 17
with the crane and align the raising/lowering 18
mechanism with the revolving frame.
2. Install the raising/lowering mechanism on the

revolving frame. Install the lock plate (18) with the
bolt (18).
16 15 19 17 18 15 16 15 16
:19 mm
:60 to 64 Nm (6.1 to 6.6 kgfm)
M2CN-02-08-003
3. Adjust the raising/lowering mechanism with using

the bolt (16) so that the flange of the drum can be

aligned with the pawl of the drum lock and tighten
it with the nut (15).
: 24 mm 12
: 148 to 160 Nm (15.0 to 16.3 kgfm) 13
4. Install the bracket (14) of the drum speed sensor

on the raising/lowering mechanism with the bolt 14
(13).
: 19 mm
: 60 to 64 Nm (6.1 to 6.6 kgfm)

5. Install all hoses on the raising/lowering motor W2CG-02-08-003
(12).
: 27 mm :93 Nm (9.5 kgfm)
: 10 mm :90 Nm (9.2 kgfm)
W2-8-2
6. Install drum covers (3, 4, 5), bracket (6) and plate

(7) to the revolving frame with bolts (8, 9, 10, 11). 10 5 6 4 11
11
: 19 mm
: 60 to 64 Nm (6.1 to 6.6 kgfm) 11
: 17 mm 7
: 34 to 37 Nm (3.5 to 3.8 kgfm)
9
8
10 3
8
9
8 6
10 10
10 6
10

M2CN-02-08-002
7. Install the live mast. (As for installation of the live

8. Wind the boom raising/lowering wire rope.
9. Lift the left house (1) with the crane. Install the
right house with the bolt (2).
: 17 mm
: 34 to 37 Nm (3.5 to 3.8 kgfm)

section.)
11. Install the base section. (As for installation of the

base section, refer to the Operator’s Manual.)
2 1
12. Install the extension and top section on the base
section and install the pendant rope. M2CN-02-08-001
(Refer to the Operator’s Manual.)
13. Start the engine. After raising/lowering the boom,

check raising/lowering mechanism for any oil
leaks.
W2-8-3
DISASSEMBLE RAISING/LOWERING MECHANISM

14 19 20 24 25 26 27 32 37
13 18 23 28 33
12 16,17 22 29 34 38
11 15 21 30 35 39
7 8 9 10 31 36
5,6
1 2 3 4
40 41 42
43
44
45
46
47
48
49
50
83
51
82
81
80 54 53 52
79 78 77 55
72
56
76 71
75 57
70
74 73 69 68 67 66 65 64 63 62 61 60 59 58
M2CN-02-08-004
1- Motor 22 - Ring Gear 43 - Retainer 64 - Spacer

2- Socket Bolt (4Used) 23 - Sun Gear 44 - Nipple 65 - Pin (5 Used)
3- O-Ring 24 - Bearing 45 - Oil seal (2 Used) 66 - Spacer
4- Sleeve 25 - Bolt (24 Used) 46 - Bolt (4 Used) 67 - Retaining Ring
5- Bolt (12 Used) 26 - Washer (24 Used) 47 - Washer(4 Used) 68 - Retaining Ring (5 Used)
6- Washer (12 Used) 27 - Bracket 48 - Retainer 69 - Retaining Ring (5 Used)
7- Bolt (32 Used) 28 - Washer (24 Used) 49 - Nipple 70 - Planetary Gear (5 Used)
8- Washer (32 Used) 29 - Bolt (24 Used) 50 - Bolt (6 Used) 71 - Needle Bearing (10 Used)
9- Bracket 30 - Retaining Ring 51 - Washer (6 Used) 72 - Retaining Ring (5 Used)
10 - Pedestal 31 - Carrier 52 - Drum 73 - Sleeve (5 Used)
11 - Bolt (30 Used) 32 - Ring Gear 53 - Cover 74 - Plug
12 - Washer (30 Used) 33 - Spacer 54 - Retaining Ring (3 Used) 75 - Pin (5 Used)
13 - Bolt (30 Used) 34 - Sun Gear 55 - Needle Bearing (6 Used) 76 - Nut
14 - Washer (30 Used) 35 - Carrier 56 - Retainer 77 - Spline Shaft
15 - Lock Plate 36 - Spacer 57 - Planetary Gear (5 Used) 78 - Case
16 - Bolt 37 - Washer (16 Used) 58 - Thrust Plate (3 Used) 79 - Bearing (2 Used)
17 - Washer 38 - Bolt (16 Used) 59 - Retaining Ring (5 Used) 80 - Retainer
18 - Spacer 39 - Bearing 60 - Planetary Gear (5 Used) 81 - Oil seal
19 - O-Ring 40 - Sleeve (2 Used) 61 - Needle Bearing (15 Used) 82 - Plug
20 - Carrier 41 - Bracket 62 - Spacer (5 Used) 83 - Shaft
21 - Spacer 42 - Bearing 63 - Thrust Plate (5 Used)
W2-8-4
Disassemble Raising/Lowering Mechanism
CAUTION: Motor (1) weight: Approx. 103 kg
before disassembling. 10. Remove the bolts (2) (4 used). Lift the motor (1)
with the crane and remove it from the case (78).
: 14 mm
weight: Approx. 2000 kg 11. Remove the bolts (58) (4 used). Lift the bracket
(3) with the crane and remove it from the pedestal
1. Lift the raising/lowering mechanism with the crane (9).
and place it on a workbench. Remove the plug : 14 mm
(74) and drain off the gear oil.
Gear oil : 17 L 12. Remove the O-ring (3) from the case (78).
NOTE: Drain the gear oil in the clean container and 13. Put the mark on the head of the case (78) and
check the metal powder due to wearing. bracket (9) and remove the bolts (7) (32 used). Lift
the bracket (9) with the crane and remove it from
2. Loosen the bolts (46) (4 used) and remove the the case (78).
retainer (48). : 36 mm
: 19mm
3. Remove the bolts (50) (6 used) and remove the CAUTION: Reduction gear weight: Approx.
retainer (43). 1060 kg
: 19mm
14. Remove the bolts (13) (30 used). Lift the
reduction gear with the crane and remove it from
4. Remove the oil seal (45) from the retainer (43). the drum (52).
: 32 mm
15. Lift the reduction gear with the crane and place it
6. Lift the bracket (41) with the crane and remove it on a workbench with placing the raising/lowering
from the drum (52). motor (1) mounting side downward. At this time,
7. Remove the bearing (42) and oil seal (45) from the bracket (9) mounting surface of the case (78)
the bracket (41). to stabilize the reduction gear.
8. Remove the sleeve (40) from the drum (52). 16. Remove the bolts (38) (20 used) and remove the
cover (53).
9. Lift the raising/lowering mechanism with the crane : 19 mm
and place it on a workbench with placing the
bracket (41) mounting side downward. At this time, 17. Remove the retainer (56) from the cover (53).
the drum (52) to stabilize the raising/lowering 18. Remove the bearing (39) from the cover (53).
mechanism.
19. Remove the shaft (83).
W2-8-5

19 20 24 25 27 32
18 23 33
16,17 22 29 34
11 15 21 30 35
10 31 36
5,6
4
81
80 54
79 78 77 55
72
76
75 57
70
73 69 68 67 66 65 64 63 62 61 60 59 58
M2CN-02-08-004
W2-8-6
20. Remove the carrier (35) assembly. 35. Remove the carrier (20) assembly.
21. Remove the retaining rings (54) (3 used) from the 36. Remove the retaining rings (69) (5 used) from the
carrier (35). carrier (20).
22. Remove the planetary gears (57) (3 used), thrust 37. Remove the planetary gears (70) (5 used),
plates (58) (3 used) and needle bearings (55) (6 sleeves (73) (5 used), pins (75) (5 used) and
used) from the carrier (35). spacer (21) from the carrier (20).
23. Remove the spacer (36) from the carrier (35). 38. Remove the retaining rings (68) (5 used), and (72)
(5used) from the planetary gears (70) (5 used).
24. Remove the sun gear (34). Remove the needle bearings (70) (10 used).
25. Remove the carrier (31) assembly. 39. Remove the spacer (18) and spline shaft (77)
from the case (78).
26. Remove the retaining rings (59) (5 used) from the
carrier (31). 40. Remove the bolt (16) and remove the lock plate
(15).
27. Remove the planetary gears (60) (5 used) and : 13 mm
thrust plates (63) (5 used), needle bearings (61)
(15 used) and pins (65) (5 used) from the carrier 41. Remove the nut (76) from the case (78).
(31).
42. Remove the pedestal (10) and sleeve (4) from the
28. Remove the spacer (33) and (62) from the carrier case (78).
(31).
29. Remove the spacer (64) and (66) from the sun
gear (23). 44. Remove the bolts (5) (12 used) and remove the
retainer (80).
30. Remove the retaining rings (30) from the bracket : 19 mm
(27).
45. Remove the oil seal (81) from the retainer (80).
31. Remove the sun gear (23) from the bracket (27).
32. Remove the retaining rings (67) from the sun gear
(23). Remove the bearing (24) 47. Remove the bolts (11) (30 used) and remove the
ring gear (22).
33. Remove the bolts (29) (24 used) and remove the : 36 mm
bracket (24).
: 24 mm 48. Remove the O-ring (19) from the pedestal (10).
retaining ring (32).
: 30 mm
W2-8-7
ASSEMBLE RAISING/LOWERING MECHANISM

14 19 20 24 25 26 27 32 37
13 18 23 28 33
12 16,17 22 29 34 38
11 15 21 30 35 39
7 8 9 10 31 36
5,6
1 2 3 4
40 41 42
43
44
45
46
47
48
49
50
83
51
82
81
80 54 53 52
79 78 77 55
72
56
76 71
75 57
70
74 73 69 68 67 66 65 64 63 62 61 60 59 58
M2CN-02-08-004
22 - Motor 43 - Ring Gear 64 - Retainer 84 - Spacer

23 - Socket Bolt (4Used) 44 - Sun Gear 65 - Nipple 85 - Pin (5 Used)
24 - O-Ring 45 - Bearing 66 - Oil seal (2 Used) 86 - Spacer
25 - Sleeve 46 - Bolt (24 Used) 67 - Bolt (4 Used) 87 - Retaining Ring
26 - Bolt (12 Used) 47 - Washer (24 Used) 68 - Washer(4 Used) 88 - Retaining Ring (5 Used)
27 - Washer (12 Used) 48 - Bracket 69 - Retainer 89 - Retaining Ring (5 Used)
28 - Bolt (32 Used) 49 - Washer (24 Used) 70 - Nipple 90 - Planetary Gear (5 Used)
29 - Washer (32 Used) 50 - Bolt (24 Used) 71 - Bolt (6 Used) 91 - Needle Bearing (10 Used)
30 - Bracket 51 - Retaining Ring 72 - Washer (6 Used) 92 - Retaining Ring (5 Used)
31 - Pedestal 52 - Carrier 73 - Drum 93 - Sleeve (5 Used)
32 - Bolt (30 Used) 53 - Ring Gear 74 - Cover 94 - Plug
33 - Washer (30 Used) 54 - Spacer 75 - Retaining Ring (3 Used) 95 - Pin (5 Used)
34 - Bolt (30 Used) 55 - Sun Gear 76 - Needle Bearing (6 Used) 96 - Nut
35 - Washer (30 Used) 56 - Carrier 77 - Retainer 97 - Spline Shaft
36 - Lock Plate 57 - Spacer 78 - Planetary Gear (5 Used) 98 - Case
37 - Bolt 58 - Washer (16 Used) 79 - Thrust Plate (3 Used) 99 - Bearing (2 Used)
38 - Washer 59 - Bolt (16 Used) 80 - Retaining Ring (5 Used) 100 - Retainer
39 - Spacer 60 - Bearing 81 - Planetary Gear (5 Used) 101 - Oil seal
40 - O-Ring 61 - Sleeve (2 Used) 82 - Needle Bearing (15 Used) 102 - Plug
41 - Carrier 62 - Bracket 83 - Spacer (5 Used) 103 - Shaft
42 - Spacer 63 - Bearing 84 - Thrust Plate (5 Used)
W2-8-8
Assemble Raising/Lowering Mechanism 17. Install the spline shaft (77) on the carrier (20)
assembly.
1. Lift the case (78) with the crane and place it on a
workbench. At this time, place the wooden block 18. Apply the liquid packing (ThreeBond #1389B) on
(200 mm square) under the bracket (9) mounting the mating surface on the ring gear (32) of the
surface of the case (78). bracket (27).
2. Install the sleeve (4) on the case (78). 19. Install the ring gear (32) on the bracket (27) with
the bolts (25) (24 used) with LOCTITE #242
3. Install the O-ring (19) on the pedestal (10). applied and the washer (26).
: 30 mm
4. Install the ring gear (12) on the pedestal (10) with : 628 Nm (64 kgfm)
applied and the washer (12). 20. Apply the liquid packing (ThreeBond #1389B) on
: 36 mm the mating surface on the bracket (27) of the ring
: 1079 Nm (105 kgfm) gear (20).
5. Install the bearing (79) on the pedestal (10). 21. Install the bracket (27) on the ring gear (20) with
6. Install the oil seal (81) on the retainer (80). applied and the washer (28).
: 24 mm
7. Apply the liquid packing (ThreeBond #1398B) on : 230 Nm (23.5 kgfm)
the mating surface on the retainer (80) of the
pedestal (10). 22. Install the sun gear (23) on the carrier (20)
assembly.
8. Install the retainer (80) on the pedestal (10) with
the bolts (5) (12 used) with LOCTITE #242 23. Install the bearing (24) on the sun gear (23) and
applied and the washer (6). install the retaining rings (30) and (67).
: 19 mm
: 68 Nm (6.9 kgfm) 24. Install the spacer (66) on the sun gear (23).
9. Install the pedestal (10) on the case (78). 25. Install the spacer (33), (62) (5 used) and thrust
plates (63) (5 used) on the carrier (31) and install
10. Install the bearing (79) on the case (78). the planetary gears (60) (5 used) and needle
bearing (61) (15 used).
11. Install the nut (76) on the case (78).
12. Install the lock plate (15) on the nut (76) with the and install retaining rings (59) (5 used).
bolt (16) with LOCTITE #242 applied and the
washer (17). 27. Install the carrier (31) assembly on the ring gear
: 13 mm (32) and sun gear (23).
: 20 Nm (2.0 kgfm)
28. Install the spacer (64) and sun gear (34) on the
13. Install the spline shaft (77) and spacer (18) on the carrier (31) assembly.
case (78).
29. Install the spacer (36) on the carrier (35) and
14. Install the needle bearings (71) (10 used), install the planetary gears (57) (3 used), thrust
retaining rings (72) (5 used) and (68) (5 used) on plates (58) (3 used) and needle bearings (55) (6
the planetary gears (70) (5 used). used).
15. Install the spacer (21), sleeves (73) (5 usd) and 30. Install the retaining rings (54) (3 used) on the
planetary gears (70) (5 used) on the carrier (20). carrier (35).
16. Install the pins (75) (5 used) on the carrier (20) 31. Install the carrier (35) assembly on the ring gear
and insert the retaining rings (69) (5 used). (32) and sun gear (34).
W2-8-9

14 32 37
13
38
35 39
7 8 9
1 2 3
40 41 42
43
44
45
46
47
48
49
50
83
51
82
53 52
78
56

M2CN-02-08-004

W2-8-10
32. Install the shaft (83) on the carrier (35) assembly. 43. Lift the raising/lowering mechanism with the crane
At this time, Make sure that the shaft (83) rotates and place it on a workbench horizontally.
with turning it by hands.
33. Install the bearing (39) on the cover (53).
34. Install the retainer (56) on the cover (53). bracket (41).
35. Apply the liquid packing (ThreeBond #1389B) on 46. Lift the bracket (41) with the crane and Install it on
the mating surface on the cover (53) of the ring the drum (52).
gear (32).
36. Install the cover (53) on the ring gear (32) with the
bolts (38) (16 used) with LOCTITE #242 applied 48. Install the oil seal (45) on the retainer (43).
and the washer (37).
: 19 mm 49. Install the retainer (43) on the bracket (41) with
: 90 Nm (9.2 kgfm) the bolts (50) (6 used) and the washer (51).
: 19mm
37. Lift the drum (52) with the crane and place it on a : 88 Nm (9.0 kgfm)
workbench with placing the bracket (41) mounting
side downward. At this time, place the wooden 50. Install the retainer (48) on the end surface of the
block (200 mm square) under the drum (52) to sleeve (40) with the bolts (46) (4 used) and the
stabilize the raising/lowering mechanism. washer (47).
: 19mm
: 88 Nm (9.0 kgfm)
CAUTION: Reduction gear weight: Approx.
1060 kg 51. Remove the nipple (44) and apply grease through
the nipple (49) until the grease (Shell Alvania
38. Lift the reduction gear with the crane and install it EP2) comes out
on the drum (52) with the bolts (13) (30 used) with
LOCTITE #262 applied and the washer (14). 52. Remove the plug (82) (level port) from pedstal
: 32 mm and apply the gear oil to the level port.
: 735 Nm (75.0 kgfm) Oil amount : 17 L
39. Install the bracket (9) on the case (78) with the 53. Install the plug (82) (level port).
bolts (7) (32 used) with LOCTITE #262 applied
and the washer (8). At this time, align the marking
of the case (78) and bracket (9). NOTE: Wrap the seal tape on the plug (82).
: 36 mm
: 935 Nm (95.0 kgfm)
40. Install the O-ring (3) on the case (78).
41. Apply the liquid packing (ThreeBond #1389B) on

the mating surface on the motor (1) of the case
(78).
CAUTION: Motor (1) weight: Approx. 103 kg
42. Lift the motor (1) with the crane and install it on
the case (78) with the socket bolts (2) (4 used).
: 14 mm
: 235 Nm (24.0 kgfm)
W2-8-11
DISASSEMBLE RAISING/LOWERING MOTOR

35 18 36 29 28 34 33 23 22 24 25 26 37 27 30 39 50 51

2 37
4 40
6 46
3
33
5
34
41
53
7
44
1 54
19
21 31
33,34 52
9
45
15 9
38
8 8

43
14 13 32 20 49 16 17 48 47 12 11 10 42
M2CN-02-08-005
1- Bolt (3 Used) 15 - Stopper 29 - Shoe Plate 42 - Spring Washer (9 Used)

2- Front Cover 16 - Plug (6 Used) 30 - Retaining Ring 43 - Socket Bolt (9 Used)
3- Oil Seal 17 - O-Ring (6 Used) 31 - Socket Bolt (5 Used) 44 - Coupling
4- O-Ring 18 - O-Ring 32 - Casing 45 - Plate (9 Used)
5- Output Shaft 19 - O-Ring (4 Used) 33 - O-Ring (5 Used) 46 - Retaining Ring (2 Used)
6- Bearing 20 - Pin 34 - Plug (5 Used) 47 - Seat (2 Used)
7- Retaining Ring 21 - Swash Plate 35 - Front Casing 48 - Stopper (2 Used)
8- Socket Bolt (8 Used) 22 - Plunger (9 Used) 36 - Socket Bolt (14 Used) 49 - Steel Ball (2 Used)
9- Cover (2 Used) 23 - Holder 37 - O-Ring (2 Used) 50 - O-Ring
10 - Stopper 24 - Spring (9 Used) 38 - Pin 51 - O-Ring
11 - O-Ring 25 - Rotor 39 - Valve Cover 52 - Friction Plate (8 Used)
12 - Piston 26 - Valve Plate 40 - Socket Bolt (7 Used) 53 - Piston
13 - Piston 27 - Needle Bearing 41 - Cover 54 - Spring (16 Used)
14 - O-Ring 28 - Plate
W2-8-12
Disassemble Raising/Lowering Motor IMPORTANT: Since the valve plate (26) may be
removed together, remove the valve
• Thoroughly read “PRECAUTIONS FOR cover (39) with care. Take care not to
DISASSEMBLING AND ASSEMBLING” (W1-1-1) drop the valve plate (26).
10. Remove the socket bolts (43) (9 used) and spring
washers (42) (9 used) and remove the valve
CAUTION: Raising/lowering motor weight:
cover (39) from the casing (32).
103 kg : 10 mm
1. Place the raising/lowering motor on a workbench.
Remove the plug (34) attached on the casing (32) 11. Remove the valve plate (26) and O-ring (37) from
and drain off the hydraulic oil. the valve cover (39).
: 10 mm
NOTE: Do not remove the needle bearing (27)
2. Put the mating mark on the front casing (35), unnecessarily.
casing (32), valve cover (39) and cover (41).
3. Remove the socket bolts (31) (5 used) and socket springs (24) (9 used), holder and plate (28) from
bolt (40) (7 used). Remove the cover (41) from the casing (32).
the valve cover (39).
: 10mm 13. Remove the socket bolts (8) (8 used) and remove
the cover (9) (2 used) from the casing (32).
4. Remove the O-ring (6) from the cover (41). : 10 mm
5. Remove the springs (54) (16 used) and piston 14. Pull out the stopper (10), (15), piston (12) and (13)
(53) from the valve cover (39). from the casing (32).
6. Remove the O-ring (50) and (51) from the valve
cover (39). NOTE: Pull out the stopper (10) and (15) with
using the screw (M6).
7. Remove the retaining ring (46), coupling (44) and
retaining ring (46) from the output shaft (5). 15. Remove the O-ring (11) and (14) from the stopper
(10) and (15).
8. Remove the plates (45) (9 used) and friction
plates (52) (8 used) from the valve cover (39). 16. Remove the bolts (1) (3 used) and remove the
front cover (2) from the front casing (35).
9. Remove the retaining ring (30) from the output : 17 mm
shaft (5).
17. Remove the oil seal (3) and O-ring (4) from the
front cover (2).

remove the front casing from the casing (32).
: 10 mm
W2-8-13

35 18 29
19
21

32

M2CN-02-08-005
W2-8-14
(32) and remove the O-ring (18) from the front
casing (35).
(35).
21. Remove the retaining ring (7) from the output

shaft (5) and pull out the bearing (6) with using a
press.
plate (21).
W2-8-15
ASSEMBLE RAISING/LOWERING MOTOR

35 18 36 29 28 34 33 23 22 24 25 26 37 27 30 39 50 51

2 37
4 40
6 46
3
33
5
34
41
53
7
44
1 54
19
21 31
33,34 52
9
45
15 9
38
8 8

43
14 13 32 20 49 16 17 48 47 12 11 10 42

M2CN-02-08-005
1- Bolt (3 Used) 15 - Stopper 29 - Shoe Plate 42 - Spring Washer (9 Used)

2- Front Cover 16 - Plug (6 Used) 30 - Retaining Ring 43 - Socket Bolt (9 Used)
3- Oil Seal 17 - O-Ring (6 Used) 31 - Socket Bolt (5 Used) 44 - Coupling
4- O-Ring 18 - O-Ring 32 - Casing 45 - Plate (9 Used)
5- Output Shaft 19 - O-Ring (4 Used) 33 - O-Ring (5 Used) 46 - Retaining Ring (2 Used)
6- Bearing 20 - Pin 34 - Plug (5 Used) 47 - Seat (2 Used)
7- Retaining Ring 21 - Swash Plate 35 - Front Casing 48 - Stopper (2 Used)
8- Socket Bolt (8 Used) 22 - Plunger (9 Used) 36 - Socket Bolt (14 Used) 49 - Steel Ball (2 Used)
9- Cover (2 Used) 23 - Holder 37 - O-Ring (2 Used) 50 - O-Ring
10 - Stopper 24 - Spring (9 Used) 38 - Pin 51 - O-Ring
11 - O-Ring 25 - Rotor 39 - Valve Cover 52 - Friction Plate (8 Used)
12 - Piston 26 - Valve Plate 40 - Socket Bolt (7 Used) 53 - Piston
13 - Piston 27 - Needle Bearing 41 - Cover 54 - Spring (16 Used)
14 - O-Ring 28 - Plate
W2-8-16
Assemble Raising/Lowering Motor
1. Install the shoe plate (29) on the swash plate (21) O-ring (11) on the stopper (10). Install the stopper
and install the swash plate (21) on the casing (15) and (10) on the casing (32).
(32).
NOTE: Install the stopper (15) and (10) to the end
NOTE: Turn the larger chamfered side of the shoe surface of the casing (32).
plate (29) to the swash plate (21) side.
11. Install the cover (9) (2 used) on the casing (32)
2. Install the bearing (6) on the output shaft (5) with with the socket bolts (8) (8 used).
using a press. : 10 mm
: 98 Nm (10.0 kgfm)
3. With lightly tapping the outer race of the bearing
(6) with using the copper bar, install the output 12. Install the springs (24) (9 used) on the rotor (25)
shaft (5) on the front casing (35). and install the holder (23).
4. Install the O-ring (18) on the front casing (35) and 13. Install the plungers (22) (9 used) on the plate (28)
install the O-rings (19) (4 used) on the casing and insert the plunger (22) in the rotor (25).
(32).
14. Install the rotor (25) assembly on the output shaft
5. Install the front casing (35) with the output shaft (5) with aligning the spline of the output shaft (5)
(5) on the casing (32). with the spline of the rotor (25) and holder (23).
IMPORTANT: Make sure that the swash plate (21) 15. Apply grease on the valve plate (26) install it on
moves smoothly. the valve cover (39) as mating with the pin (38).
6. Tighten the socket bolts (36) (14 used). 16. Set up the casing (32) and place it on a
: 10 mm workbench.
: 98 Nm (10.0 kgfm)
17. Install the valve cover (39) on the casing (32) with
7. Install the oil seal (3) on the front cover (2) with the socket bolts (43) (9 used) and spring washers
using a press and install the O-ring (4). (42) (9 used).
: 10 mm
8. Install the front cover (2) on the front casing (35) : 98 Nm (10.0 kgfm)
with the bolts (1) (3 used).
: 17 mm 18. Install the retaining ring (30) on the output shaft
: 57 Nm (5.8 kgfm) (5) and fix the needle bearing (27).
9. Insert the piston (13) in the front casing (35) side 19. Install the retaining ring (46) on the output shaft
of the casing (32) and insert the piston (12) in the (5).
valve cover (39) side.
W2-8-17

34 33 39 50 51

37
40
46
33
5
34
41
53
44
54
31
33,34 52
45

32
M2CN-02-08-005

W2-8-18
20. Installing the coupling (44) on the output shaft (5)
and install the retaining ring (46).
IMPORTANT: Align the notch of the plate (45) and

friction plate (52).
21. Install plate (45) (9 used) and friction plate (52) (8

used) in order on the valve cover (39) and
coupling (44).
22. Install the O-ring (50) and (51) on the valve cover
(39) and install the piston (53).

(53).
the cover (41) on the valve cover (39) with the
socket bolts (31) (5 used) and (40) (7 used).
: 10 mm
: 98 Nm (10.0 kgfm)
on the casing (32).
: 10 mm
: 108 Nm (11.0 kgfm)
W2-8-19
Dial Gauge

vise.
Guide
and shoe assembly.
Unit: mm

W309-04-05-002
assembly.

position 90 raway from the first position.
gauge.
W309-04-05-003
Unit: mm
0.039 0.078

micrometer.
Unit: mm
8.8 8.6
W309-04-05-004
B
W309-04-05-005
W2-8-20
C=H-h Plate Holder
Unit: mm
32.2 31.6 H
h

assembly.
W309-04-05-006

Unit: mm
3.1 3.6
A

Unit: mm
54 53.2

plate. (15 used)
Unit: mm
32.4 31.7
W2-8-21

29 2 1 3 4 6 17 16
15
7 17
40
8
41
9 43
42
37 10
13
39
12
38 11
25
35
33
3 34 36 22 23 19 21 20 18 24 27 26
32
14 31 28 30 5

M2CN-02-08-006

W2-8-22
: 32 mm
the casing (4) from the raising/lowering motor. (4).
: 6 mm
: 4 mm
casing (4).

cover (38).

cover (38).

: 5 mm

(13) and nut (12).
W2-8-23
ASSEMBLE REGULATOR

29 2 1 3 4 6 17 16
15
7 17
40
8
41
9 43
42
37 10
13
39
12
38 11
25
35
33
3 34 36 22 23 19 21 20 18 24 27 26
32
14 31 28 30 5

M2CN-02-08-006

W2-8-24
Assemble Regulator
: 5 mm
socket bolt (11).
: 12 Nm (1.2 kgfm)
casing (4).
: 13mm (38).
: 29 Nm (3.0 kgfm)
casing (4). : 5 mm
: 12 Nm (1.2 kgfm)
: 8 mm : 9 Nm (0.9 kgfm)
: 44 Nm (4.5 kgfm)
18. Install the casing (4) on the raising/lowering motor
9. Install the spring seat (15) and spring (7) on the with the socket bolts (5) (4 used).
casing (4). : 6 mm
: 29 Nm (3.0kgfm)

: 32mm
: 44 Nm (4.5 kgfm)
W2-8-25
9
8
7
21 15 6
20
24 35
5 3
16 4 2
17
18 12 1
13
22 14
23
19 25
26
12
27 13 10
28 11
29
30
31
32
33
33 34

W2CG-02-07-008

W2-8-26
Disassemble Counterbalance Valve
• Thoroughly read “PRECAUTIONS FOR 11. Remove the spring (29) and plunger (28) from the
DISASSEMBLING AND ASSEMBLING” (W1-1-1) casing (14).
NOTE: Do not remove the seat (27) except when
1. Remove the O-rings (33) (2 used) from the casing replacing it.
(14).
12. Remove the relief valve (34) from the casing (14)
2. Loosen the socket bolts (1) and (22) (4 used for and remove the O-ring and backup ring from the
each) and remove the covers (3) and (24) from relief valve (34).
the casing (14). : 50 mm
: 10 mm

: 6 mm

: 6 mm
5. Remove the springs (26) and the O-rings (4, 25)

6. Remove the spool (6) assembly from the casing

(14).



: 50 mm
the plug (32).
W2-8-27
22 23 24 25 26 9 8 7 14 6 13 12 35 5 4 3
11
20
10
21
1
27 28 29 32 31 30 34
17 18 15
16
19 33

M2CN-02-08-007

W2-8-28
Assemble Counterbalance Valve
1. Install the O-ring and backup ring on the relief 12. Install the cover (24) on the casing (14) and
valve (34). tighten with the socket bolts (22) and spring
washers (23) (4 used for each).
2. Install the relief valve (34) on the casing (14). : 10 mm
: 50 mm : 88 to 108 Nm (9.0 to 11.0 kgfm)
: 166 to 186 Nm (17.0 to 19.0 kgfm)
3. Install the O-ring (30) and backup ring (31) on the the plug (10) on the cover (3).
plug (32). : 6 mm
: 34 to 38 Nm (3.5 to 3.9 kgfm)
4. Insert the spring (29) into the plunger (28) and
install the plunger (28) on the plug (32). 14. Install the O-ring (20) on the plug (21) and install
the plug (21) on the cover (24).
5. Install the plug (32) on the casing (14). : 6 mm
: 50 mm : 34 to 38 Nm (3.5 to 3.9 kgfm)
: 181 to 211 Nm (18.5 to 21.5 kgfm)
6. Insert the filter (35) into the plug (5) and install the (14).
on the spool (6).

10. Install the O-rings (4) and (25) on the casing (14).
used for each).
: 10 mm
: 88 to 108 Nm (9.0 to 11.0 kgfm)
W2-8-29
(Blank)
W2-8-30
SWING MACHINERY / Raising/Lowering Mechanism (From Machine No. 6 and after)
REMOVE AND INSTALL RAISING/LOWERING

MECHANISM

Removal
1. Lower the boom and remove the pendant rope,

extension, top section and base section.
(As for removal of the pendant rope, extension,
top section and base section, refer to the
2. Remove the counterweight. (As for removal of the

counterweight, refer to W2-2 in this section.)
2 1
3. Remove the boom raising/lowering wire rope.

4. Loosen the bolts (2) that installs the left house (1)
M2CN-02-08-001
on the raising/lowering motor and remove the

house with lifting it with the crane.
: 17 mm 10 5 6 4 11
11
5. Remove the live mast. (As for removal of the live 11
7
6. Remove the bolts (8), (9), (10) and (11). Remove 9
the drum covers (3), (4), (5), bracket (6) and plate 8
10 3
(7). 8
: 19 mm
9
: 17 mm 8 6
10 10
10 6
10

M2CN-02-08-008
W2-8-31
7. Remove all hoses from the raising/lowering motor

(12). Attach a plug on the removed hoses. 12
: 36 mm : 10 mm
13

of the drum speed sensor.
: 19 mm 14

weight: 1670 kg
mechanism and support the raising/lowering M2CN-02-08-009

10. Remove the nut (15) and remove the bolt (16).
: 24 mm
11. Remove the bolt (17) and remove the lock plate
(18). After removing the pin (19), lift the
raising/lowering mechanism with the crane and 17 19 16 15
remove it.
Installation
18
17
CAUTION: Raising/lowering mechanism 18
weight: 1670 kg 19
mechanism. Lift the raising/lowering mechanism 19
with the crane and align the raising/lowering
mechanism with the revolving frame. 17
18
2. Install the raising/lowering mechanism on the
revolving frame with the pin (19). Install the lock
plate (18) with the bolt (17).
: 19 mm

: 60 to 64 Nm (6.1 to 6.6 kgfm)
16 15 19 17 18 15 16 15 16
3. Adjust the raising/lowering mechanism with using
the bolt (16) so that the flange of the drum can be M2CN-02-08-010
aligned with the pawl of the drum lock and tighten

it with the nut (15).

: 24 mm
: 148 to 160 Nm (15.0 to 16.3 kgfm)
12
4. Install the bracket (14) of the drum speed sensor
on the raising/lowering mechanism with the bolt 13
(13).
: 19 mm
: 60 to 64 Nm (6.1 to 6.6 kgfm) 14
5. Install all hoses on the raising/lowering motor

(12).
: 36 mm :175 Nm (18.0 kgfm)

: 10 mm :90 Nm (9.2 kgfm) M2CN-02-08-009
W2-8-32
6. Install drum covers (3, 4, 5), bracket (6) and plate 10 5 6 4 11

(7) to the revolving frame with bolts (8, 9, 10, 11). 11
: 19 mm
11
: 60 to 64 Nm (6.1 to 6.6 kgfm)
: 17 mm 7
: 34 to 37 Nm (3.5 to 3.8 kgfm)
9
8
10 3
8
9
8 6
10 10
10 6
10

M2CN-02-08-008
7. Install the live mast. (As for installation of the live

8. Wind the boom raising/lowering wire rope.
9. Lift the left house (1) with the crane. Install the
right house with the bolt (2).
: 17 mm
: 34 to 37 Nm (3.5 to 3.8 kgfm)

section.)
11. Install the base section. (As for installation of the

2 1
base section, refer to the Operator’s Manual.)
12. Install the extension and top section on the base

section and install the pendant rope. M2CN-02-08-001
13. Start the engine. After raising/lowering the boom,

check raising/lowering mechanism for any oil
leaks.
W2-8-33
DISASSEMBLE RAISING/LOWERING MECHANISM

8 11 13 14 15 16 17 21 23 24 25 26
7 10 12 18 22 27
1 2 3 4 5 6 9 19
28
20
29
30
31
32
33
34
31
36
32
37
54
53 38
44 39
48
42
49 43 40
56 55 50 51 52 47 46 45 41 35
M2CN-02-08-011
1- Motor 16 - Spacer 31 - Bolt (10 Used) 46 - Spring Pin (4 Used)

2- Bolt (4 Used) 17 - Sun Gear 32 - Washer (10 Used) 47 - Pin (5 Used)
3- Washer (4 Used) 18 - Washer (20 Used) 33 - Retainer 48 - Carrier
4- Plug 19 - Bolt (20 Used) 34 - Nipple 49 - Spring Pin (4 Used)
5- Bolt (32 Used) 20 - Spacer 35 - Drum 50 - Thrust Plate (8 Used)
6- Washer (32 Used) 21 - Shaft 36 - Pin (3 Used) 51 - Pin (4 Used)
7- Bracket 22 - Cover 37 - Carrier 52 - Planetary Gear (4 Used)
8- Pedestal 23 - Bearing 38 - Thrust Plate (6 Used) 53 - Bearing (2 Used)
9- Bolt (30 Used) 24 - Pin 39 - Needle Bearing (3 Used) 54 - Floating Seal
10 - Washer (30 Used) 25 - Sleeve (2 Used) 40 - Planetary Gear (3 Used) 55 - Plug
11 - Drum 26 - Bracket 41 - Spring Pin (3 Used) 56 - Plug
12 - Bolt (18 Used) 27 - Bearing 42 - Carrier
13 - Retainer 28 - Retainer 43 - Thrust Plate (8 Used)
14 - Ring Geaᨮ 29 - Nipple 44 - Pin (4 Used)
15 - Sun Gear 30 - Oil Seal 45 - Planetary Gear (4 Used)
W2-8-34
Disassemble Raising/Lowering Mechanism

CAUTION: Motor᧤1᧥ weight: Approx. 180 kg
before disassembling. 10. Remove the bolts (2) (4 used). Lift the motor (1)
with the crane and remove it from the pedestal
(8).
CAUTION: Raising/lowering mechanism : 30 mm
weight: Approx. 1670 kg
11. Put the mark on the head of the pedestal (8) and
1. Lift the raising/lowering mechanism with the crane bracket (7) and remove the bolts (5) (32 used). Lift
and place it on a workbench. Remove the plug the bracket (7) with the crane and remove it from
(55) and drain off the gear oil. the pedestal (8).
Gear oil : 34 L : 36 mm
: 10 mm
NOTE: Drain the gear oil in the clean container and 735 kg
12. Remove the bolts (9) (30 used). Lift the reduction
2. Loosen the bolts (31) (4 used) and remove the gear with the crane and remove it from the drum
retainer (33). (35).
: 19mm : 32 mm
3. Remove the bolts (31) (6 used) and remove the 13. Lift the reduction gear with the crane and place it
retainer (28). on a workbench with placing the raising/lowering
: 19mm motor (1) mounting side downward. At this time,
4. Remove the oil seal (30) from the retainer (28). the bracket (7) mounting surface of the pedestal
(8) to stabilize the reduction gear.
6. Lift the bracket (26) with the crane and remove it cover (22).
from the drum (35). : 22 mm
7. Remove the bearing (27) and oil seal (30) from 15. Remove the pin (24) from the cover (22).
the bracket (26).
16. Remove the bearing (23) from the cover (22).
17. Remove the shaft (21).
9. Lift the raising/lowering mechanism with the crane
and place it on a workbench with placing the
bracket (26) mounting side downward. At this time,
the drum (35) to stabilize the raising/lowering
mechanism.
W2-8-35
8 11 13 14 15 16 17
12
20
36
37
54
53 38
44 39
48
42
49 43 40
50 51 52 47 46 45 41
M2CN-02-08-011
W2-8-36
18. Remove the carrier (37) assembly. 33. Remove the drum (11) from the pedestal (8).
19. Remove the spring pin (41) and remove the pins 34. Remove the bearing (53) from the drum (11).
35. Remove the bearing (11) and floating seal (54)
20. Remove the planetary gears (40) (3 used), thrust from the pedestal (8).
21. Remove the spacer (20) from the carrier (37).
22. Remove the sun gear (17).
23. Remove the carrier (42) assembly.
24. Remove the spring pin (46) and remove the pins

thrust plates (43) (8 used) from the carrier (42).
26. Remove the spacer (16) from the carrier (42).
27. Remove the sun gear (15).
28. Remove the pins (47) (5 used) and remove the

inner gear (14) from the drum (11).
29. Remove the carrier (48) assembly.
30. Remove the spring pin (49) and remove the pins

thrust plates (50) (8 used) from the carrier (48).
32. Loosen the bolts (12) (18 used) and remove the
retainer (13).
: 12 mm
W2-8-37
ASSEMBLE RAISING/LOWERING MECHANISM

8 11 13 14 15 16 17 21 23 24 25 26
7 10 12 18 22 27
1 2 3 4 5 6 9 19
28
20
29
30
31
32
33
34
31
36
32
37
54
53 38
44 39
48
42
49 43 40
56 55 50 51 52 47 46 45 41 35
M2CN-02-08-011
1- Motor 16 - Spacer 31 - Bolt (10 Used) 46 - Spring Pin (4 Used)

2- Bolt (4 Used) 17 - Sun Gear 32 - Washer (10 Used) 47 - Pin (5 Used)
3- Washer (4 Used) 18 - Washer (20 Used) 33 - Retainer 48 - Carrier
4- Plug 19 - Bolt (20 Used) 34 - Nipple 49 - Spring Pin (4 Used)
5- Bolt (32 Used) 20 - Spacer 35 - Drum 50 - Thrust Plate (8 Used)
6- Washer (32 Used) 21 - Shaft 36 - Pin (3 Used) 51 - Pin (4 Used)
7- Bracket 22 - Cover 37 - Carrier 52 - Planetary Gear (4 Used)
8- Pedestal 23 - Bearing 38 - Thrust Plate (6 Used) 53 - Bearing (2 Used)
9- Bolt (30 Used) 24 - Pin 39 - Needle Bearing (3 Used) 54 - Floating Seal
10 - Washer (30 Used) 25 - Sleeve (2 Used) 40 - Planetary Gear (3 Used) 55 - Plug
11 - Drum 26 - Bracket 41 - Spring Pin (3 Used) 56 - Plug
12 - Bolt (18 Used) 27 - Bearing 42 - Carrier
13 - Retainer 28 - Retainer 43 - Thrust Plate (8 Used)
14 - Ring Geaᨮ 29 - Nipple 44 - Pin (4 Used)
15 - Sun Gear 30 - Oil Seal 45 - Planetary Gear (4 Used)
W2-8-38
Assemble Raising/Lowering Mechanism 12. Install the pins (44) (4 used) on the carrier (42)
and insert the spring pin (46). At this time, turn the
1. Lift the pedestal (8) with the crane and place it on slit portion of the spring pin (46) toward the cover
a workbench. At this time, place the wooden block (22) side.
(200 mm square) under the bracket (7) mounting
surface of the pedestal (8). 13. Install the carrier (42) assembly on the inner gear
(14) and sun gear (15).
2. Install the bearing (53) and floating seal (54) with
grease applied on the pedestal (8). 14. Install the sun gear (17) on the carrier (42)
assembly.
3. Install the drum (11) on the pedestal (8).
15. Install the spacer (20) on the carrier (37) and
4. Install the bearing (53) on the drum (11). install the planetary gears (40) (3 used), thrust
5. Install the retainer (13) on the pedestal (8) with used).
applied. 16. Install the pins (36) (3 used) on the carrier (37)
: 12 mm and insert the spring pin (41). At this time, turn the
: 169 Nm (17.0 kgfm) slit portion of the spring pin (41) toward the cover
(22) side.
6. Install the planetary gears (52) (4 used) and thrust
plates (50) (8 used) on the carrier (48). 17. Install the carrier (37) assembly on the ring gear
(14) and sun gear (17).
and insert the spring pin (49). At this time, turn the 18. Install the shaft (21) on the carrier (37) assembly.
slit portion of the spring pin (49) toward the cover At this time, Make sure that the shaft (21) rotates
(22) side. with turning it by hands.

8. Install the carrier (48) assembly on the pedestal
(8). 20. Install the pin (24) on the cover (22).
9. Install the inner gear (14) on the drum (11) and 21. Apply the liquid packing (ThreeBond #1389B) on
install the pins (47) (5 used). the mating surface on the cover (22) of the drum
(11).
10. Install the sun gear (15) on the carrier (48).
22. Install the cover (22) on the drum (11) with the
11. Install the spacer (16) on the carrier (42) and bolts (19) (20 used) with LOCTITE #262 applied
install the planetary gears (45) (4 used) and thrust and the washer (18).
plates (43) (8 used). : 22 mm
: 176.5 Nm (18.0 kgfm)
W2-8-39
7 98 25 26
26
7 10 27
1 2 3 4 5 6 9 28
29
30
31
32
33
34
31
32
56 35

M2CN-02-08-011
W2-8-40
23. Lift the drum (35) with the crane and place it on a 28. Lift the raising/lowering mechanism with the crane
workbench with placing the bracket (26) mounting and place it on a workbench horizontally.
side downward. At this time, place the wooden
block (200 mm square) under the drum (35) to 29. Install the sleeve (25) on the drum (35).
stabilize the raising/lowering mechanism.
bracket (26).
735 kg 31. Lift the bracket (26) with the crane and Install it on
the drum (35).
24. Lift the reduction gear with the crane and install it
on the drum (35) with the bolts (9) (30 used) with
the washer (10).
: 32 mm 33. Install the oil seal (30) on the retainer (28).
: 735 Nm (75.0 kgfm)
34. Install the retainer (28) on the bracket (26) with
25. Install the bracket (7) on the pedestal (8) with the the bolts (31) (6 used) and the washer (32).
bolts (5) (32 used) with the washer (6) attached.
: 19mm
At this time, align the marking of the pedestal (8) : 88 Nm (9.0 kgfm)
with the bracket (7).
: 36 mm 35. Install the retainer (33) on the end surface of the
: 935 Nm (95.0 kgfm) sleeve (25) with the bolts (31) (4 used) and the
washer (32).
26. Apply the liquid packing (ThreeBond #1389B) on
: 19mm
the mating surface on the motor (1) of the : 88 Nm (9.0 kgfm)
pedestal (8).
36. Remove the nipple (29) and apply grease through
CAUTION: Motor (1) weight: Approx. 180 kg the nipple (34) until the grease (Shell Alvania
EP2) comes out.
27. Lift the motor (1) with the crane and install it on
the pedestal (8) with the bolts (2) (4 used) and the 37. Remove the plug (4) (oil filler port) and plug (56)
washer (3). (level port) from the pedestal (8) and add the gear
: 30 mm oil to the level port.
: 235 Nm (24.0 kgfm) Oil amount : 34 L
38. Install the plug (4) (oil filler port) and plug (56)
(level port).
W2-8-41
DISASSEMBLE RAISING/LOWERING MOTOR

14 13 30 19 12 10 11 9 8 37 36 38 39 43 50 40
48
56
49
15 53
16 51
18
17 52
1
54
4 55
5
44
3 42
7
29
2 45

33 34 20 28 27 32 31 22 21 23 24 35 25 41 26 46 47

M2CN-02-08-012
1- Bolt (4 Used) 16 - Cover 31 - O-Ring (5 Used) 46 - Plug (3 Used)

2- Front Cover 17 - O-Ring 32 - Plug (5 Used) 47 - O-Ring (3 Used)
3- Oil Seal 18 - O-Ring (2 Used) 33 - Front Casing 48 - O-Ring
4- O-Ring 19 - Pin 34 - Socket Bolt (14 Used) 49 - O-Ring
5- Output Shaft 20 - Swash Plate 35 - O-Ring 50 - Friction Plate (7 Used)
6- Bearing 21 - Plunger (9 Used) 36 - Pin 51 - Piston
7- Retaining Ring 22 - Holder 37 - Valve Cover 52 - Spring (16 Used)
8- Socket Bolt (4 Used) 23 - Spring (9 Used) 38 - Socket bolt 53 - O-Ring
9- Cover 24 - Rotor 39 - Shim (1 Unit) 54 - Cover
10 - Stopper 25 - Valve Plate 40 - O-Ring 55 - Plug
11 - O-Ring 26 - Needle Bearing 41 - Socket Bolt (9 Used) 56 - Socket Bolt (4 Used)
12 - Piston 27 - Plate 42 - Coupling
13 - Piston 28 - Shoe Plate 43 - Plate (8 Used)
14 - O-Ring 29 - Socket Bolt (12 Used) 44 - Retaining Ring (2 Used)
15 - Stopper 30 - Casing 45 - Casing
W2-8-42
Disassemble raising/Lowering Motor IMPORTANT: When removing the valve cover (37),
the valve plate (25) may be removed
• Thoroughly read “PRECAUTIONS FOR together. Do not fall off the valve
DISASSEMBLING AND ASSEMBLING” (W1-1-1) plate (25).
• The procedure starts on the premise that the 9. Remove the socket bolts (38) and (41) (9 used)
regulator, counterbalance valve and solenoid and remove the valve cover (37) from the casing
valve have already been removed. (30).
: 14 mm
CAUTION: Raising/lowering motor weight:
10. Remove the valve plate (25) and O-ring (35) from
180 kg
the valve cover (37).
1. Place the raising/lowering motor on a workbench
and remove the plug (35) from the casing (30). NOTE: Do not remove the needle bearing (26)
Drain off the hydraulic oil. unnecessarily.
: 36 mm
2. Put the matching marks on the front casing (33), springs (23) (9 used), holder (22) and plate (27)
casing (30), valve cover (37), casing (45) and from the casing (30).
cover (54).
12. Remove the socket bolts (8) (4 used), (55) (4
3. Loosen the socket bolts (29) (12 used) evenly and used) and remove the covers (9) and (16) from
remove the cover (54) from the casing (45). the casing (30).
: 10 mm : 10 mm
: 12 mm
4. Remove the O-ring (53) from the cover (54).
13. Pull out the stoppers (10), (15), pistons (12) and
5. Remove the springs (52) (16 used) and piston (13) from the casing (30).
NOTE: Remove the stoppers (10) and (15) with
6. Remove the casing (45) from the valve cover (37) using a screw (M6).
and remove the O-rings (48) and (49) from the
casing (45). 14. Remove the O-rings (11) and (14) from the
stoppers (10) and (15).
7. Remove the retaining ring (44), coupling (42)
from the output shaft (5). 15. Remove the bolts (1) (4 used) and remove the
front cover (2) from the front casing (33).
8. Remove the plates (45) (8 used), friction plates : 17 mm
(50) (7 used), shim (39) and O-ring (40) from the
valve cover (37). 16. Remove the oil seal (3) and O-ring (4) from the
front cover (2).

remove the front casing (33) from the casing (30).
: 10 mm
W2-8-43
30
18
17

33 20 28

M2CN-02-08-012
W2-8-44

(30) and O-ring (17) from the front casing (33)
respectively.
(33).
20. Remove the retaining ring (7) and from the output
shaft (5) and remove the bearing (6) with using a
press.
plate (20).
W2-8-45
ASSEMBLE RAISING/LOWERING MOTOR

14 13 30 19 12 10 11 9 8 37 36 38 39 43 50 40
48
56
49
15 53
16 51
18
17 52
1
54
4 55
5
44
3 42
7
29
2 45

33 34 20 28 27 32 31 22 21 23 24 35 25 41 26 46 47

M2CN-02-08-012
1- Bolt (4 Used) 16 - Cover 31 - O-Ring (5 Used) 46 - Plug (3 Used)

2- Front Cover 17 - O-Ring 32 - Plug (5 Used) 47 - O-Ring (3 Used)
3- Oil Seal 18 - O-Ring (2 Used) 33 - Front Casing 48 - O-Ring
4- O-Ring 19 - Pin 34 - Socket Bolt (14 Used) 49 - O-Ring
5- Output Shaft 20 - Swash Plate 35 - O-Ring 50 - Friction Plate (7 Used)
6- Bearing 21 - Plunger (9 Used) 36 - Pin 51 - Piston
7- Retaining Ring 22 - Holder 37 - Valve Cover 52 - Spring (16 Used)
8- Socket Bolt (4 Used) 23 - Spring (9 Used) 38 - Socket bolt 53 - O-Ring
9- Cover 24 - Rotor 39 - Shim (1 Unit) 54 - Cover
10 - Stopper 25 - Valve Plate 40 - O-Ring 55 - Plug
11 - O-Ring 26 - Needle Bearing 41 - Socket Bolt (9 Used) 56 - Socket Bolt (4 Used)
12 - Piston 27 - Plate 42 - Coupling
13 - Piston 28 - Shoe Plate 43 - Plate (8 Used)
14 - O-Ring 29 - Socket Bolt (12 Used) 44 - Retaining Ring (2 Used)
15 - Stopper 30 - Casing 45 - Casing
W2-8-46
Assemble Raising/Lowering Motor

1. Install the shoe plate (28) on the swash plate (20) o-ring (11) on the stopper (10) respectively. Install
and install the swash plate (20) on the casing the stoppers (10) and (15) on the end of the
(30). casing (30).
NOTE: Turn the larger chamfered side of the shoe NOTE: Install the stoppers (15) and (10) to the end
plate (28) to the swash plate (20) side. surface of the casing (30).
2. Install the bearing (6) on the output shaft (5) with 11. Install the cover (9) on the casing (30) with the
using a press and install the retaining ring (7). socket bolts (8) (4 used).
: 12 mm
3. Tap the outer race of the bearing (6) with using a : 160 Nm (16.3 kgfm)
copper bar and install the output shaft (5) ton the
front casing (33). 12. Install the cover (16) on the casing (30) with the
socket bolts (8) (4 used).
4. Install the O-ring (17) on the front casing (33) and : 10 mm
O-rings (18) (4 used) on the casing (30) : 98 Nm (9.9 kgfm)
respectively.
13. Install the springs (23) (9 used) on the rotor (24)
5. Install the front casing (33) and output shaft (5) on and install the holder (22).
the casing (30).
14. Install the plungers (21) (9 used) on the plate (27)
IMPORTANT: Check that swash plate (20) moves and insert the plunger (21) into the rotor (24).
smoothly.
15. Align the spline of the output shaft (5), rotor (24)
6. Tighten the socket bolts (34) (14 used). and holder (22). Install the rotor (24) assembly on
: 10 mm the output shaft (5).
: 98 Nm (9.9 kgfm)
16. Apply the grease on the valve plate (25). Align
with the pin (36) and install the valve plate (26) on
7. Install the oil seal (3) on the front cover (2) with the valve cover (37). Install the O-ring (35) on the
using a press and install the O-ring (4). valve cover (37).
8. Install the front cover (2) on the front casing (33) 17. Place the casing (30) on the workbench vertically.
and tighten the bolts (1) (4 used).
: 17mm 18. Install the valve cover (37) on the casing (30) with
: 57 Nm (5.8 kgfm) the socket bolts (38) and (41) (9 used).
: 14 mm
9. Insert the piston (13) into the front casing (33) : 333 Nm (33.9 kgfm)
side of the casing (30) and the piston (12) into the
valve cover (37) side.
W2-8-47
30 37 39 43 50 40
48
49
53
51
52
54
5
44
42
29
45

32 31

M2CN-02-08-012
W2-8-48

(5).
20. Install the coupling (42) on the output shaft (5).
IMPORTANT: Align the notches on the plate (43)

and friction plate (50). Adjust with
the shims (39) so that the dimension
between the end of the valve cover
(37) and the plate (43) is 3.1 mm.
21. Install the shim (39), plates (43) (8 used) and

friction plates (50) (7 used) on the valve cover
(37) and coupling (42).
22. Install the O-ring (40) on the valve cover (37).
23. Install the O-rings (48) and (49) on the casing (45)
and install the piston (51).

(51).
the cover (54) on the casing (45) with the socket
: 10 mm
: 98 Nm (10.0 kgfm)
the plug (32) on the casing (30).
: 36 mm
: 167 Nm (17.0 kgfm)
W2-8-49
Dial Gauge

vise.
Guide
and shoe assembly.
Unit: mm

W309-04-05-002
assembly.

position 90 raway from the first position.
gauge.
W309-04-05-003
Unit: mm
0.039 0.078

micrometer.
Unit: mm
8.8 8.6
W309-04-05-004
B
W309-04-05-005
W2-8-50
C=H-h Plate Holder
Unit: mm
32.2 31.6 H
h

assembly.
W309-04-05-006

Unit: mm
3.1 3.6
A

Unit: mm
54 53.2

plate. (15 used)
Unit: mm
32.4 31.7
W2-8-51

29 2 1 3 4 6 17 16
15
7 17
40
8
41
9 43
42
37 10
13
39
12
38 11
25
35
33
3 34 36 22 23 19 21 20 18 24 27 26
32
14 31 28 30 5

M2CN-02-08-006

W2-8-52
: 32 mm
the casing (4) from the raising/lowering motor. (4).
: 6 mm
: 4 mm
casing (4).

cover (38).

cover (38).

: 5 mm

(13) and nut (12).
W2-8-53
ASSEMBLE REGULATOR

29 2 1 3 4 6 17 16
15
7 17
40
8
41
9 43
42
37 10
13
39
12
38 11
25
35
33
3 34 36 22 23 19 21 20 18 24 27 26
32
14 31 28 30 5

M2CN-02-08-006

W2-8-54
Assemble Regulator
: 5 mm
socket bolt (11).
: 12 Nm (1.2 kgfm)
casing (4).
: 13mm (38).
: 29 Nm (3.0 kgfm)
casing (4). : 5 mm
: 12 Nm (1.2 kgfm)
: 8 mm : 9 Nm (0.9 kgfm)
: 44 Nm (4.5 kgfm)
18. Install the casing (4) on the raising/lowering motor
9. Install the spring seat (15) and spring (7) on the with the socket bolts (5) (4 used).
casing (4). : 6 mm
: 29 Nm (3.0kgfm)

: 32mm
: 44 Nm (4.5 kgfm)
W2-8-55

9
8
7
21 15 6
20
24 35
5 3
16 4 2
17
18 12 1
13
22 14
23
19 25
26
12
27 13 10
28 11
29
30
31
32
33
33 34

W2CG-02-07-008

W2-8-56
Disassemble Counterbalance Valve
• Thoroughly read “PRECAUTIONS FOR 11. Remove the spring (29) and plunger (28) from the
DISASSEMBLING AND ASSEMBLING” (W1-1-1) casing (14).
NOTE: Do not remove the seat (27) except when
1. Remove the O-rings (33) (2 used) from the casing replacing it.
(14).
12. Remove the relief valve (34) from the casing (14)
2. Loosen the socket bolts (1) and (22) (4 used for and remove the O-ring and backup ring from the
each) and remove the covers (3) and (24) from relief valve (34).
the casing (14). : 50 mm
: 10 mm

: 6 mm

: 6 mm
5. Remove the springs (26) and the O-rings (4, 25)

6. Remove the spool (6) assembly from the casing

(14).



: 50 mm
the plug (32).
W2-8-57

22 23 24 25 26 9 8 7 14 6 13 12 35 5 4 3
11
20
10
21
1
27 28 29 32 31 30 34
17 18 15
16
33
19

M2CN-02-08-013

W2-8-58
Assemble Counterbalance Valve
1. Install the O-ring and backup ring on the relief 12. Install the cover (24) on the casing (14) and
valve (34). tighten with the socket bolts (22) and spring
washers (23) (4 used for each).
2. Install the relief valve (34) on the casing (14). : 10 mm
: 50 mm : 88 to 108 Nm (9.0 to 11.0 kgfm)
: 166 to 186 Nm (17.0 to 19.0 kgfm)
3. Install the O-ring (30) and backup ring (31) on the the plug (10) on the cover (3).
plug (32). : 6 mm
: 34 to 38 Nm (3.5 to 3.9 kgfm)
4. Insert the spring (29) into the plunger (28) and
install the plunger (28) on the plug (32). 14. Install the O-ring (20) on the plug (21) and install
5. Install the plug (32) on the casing (14). : 6 mm
: 50 mm : 34 to 38 Nm (3.5 to 3.9 kgfm)
: 181 to 211 Nm (18.5 to 21.5 kgfm)
6. Insert the filter (35) into the plug (5) and install the (14).
on the spool (6).

10. Install the O-rings (4) and (25) on the casing (14).
used for each).
: 10 mm
: 88 to 108 Nm (9.0 to 11.0 kgfm)
W2-8-59
(Blank)
W2-8-60
SWING MACHINERY / Remote Control Valve
REMOVE AND INSTALL BOOM
RAISING/LOWERING DRUMS AND
TRAVEL REMOTE CONTROL VALVES

Removal

1. Shutdown the engine. Operate the lever several
times and release the remaining pressure in the
circuit. 2
1
seat (2).
: 13 mm

W24X-02-01-001

3. Remove the screws (7) (14 used) and socket bolts 7 13 10 11
(9) (2 used). Remove the covers (4 to 6) from the 5 13 16 17 12
right stand. 13
: 4 mm 7
4. Remove the lever (10 to 12) assemblies, pressure

14
sensors (23) (2 used) and the harness connector
of the panel. 9 8
3
used). Remove the cover (3) from the right stand.
: 10 mm
4
6. Remove the nuts (13) (2 used for each). Remove
15
the lever (10 to 12) assemblies from the remote
control valve (14). Remove the lever (16 to 18) 7 6 7
assemblies from the remote control valve (15). M2CN-02-09-001
: 19 mm
W2-9-1
7. Remove the hoses (21) (10 used) from the elbows
(19) and (20) attached on the remote control valve
(14).
: 22 mm 15 25 25 14 25 20
8. Remove the elbows (19) (8 used) and (20) (2 25

used) from the remote control valve (14).
26
: 19 mm
21
9. Remove the hoses (24) (10 used) from the elbow
(20) and adapter (22) attached on the remote
control valve (15).
: 22 mm 20
10. Remove the elbows (20) (3 used), adapters (22) 19

(7 used) and pressure sensors (23) (2 used) from 20
the remote control valve (15).
: 19 mm 22
21
: 24 mm 23
11. Remove the socket bolts (25) (14 used). Remove 24

the remote control valves (14), (15) and plate (26)
from the right stand. M2CN-02-09-002
: 6 mm

W2-9-2
Installation
1. Install the remote control valves (14), (15) and

plate (26) on the right stand with the socket bolts
(25) (14 used). 15 25 25 14 25 20
: 6 mm
: 20 Nm (2 kgfm) 25
2. Install the elbows (20) (3 used), adapters (22) (7 26

used) and pressure sensors (23) (2 used) on the 21
remote control valve (15).
: 19 mm
: 34.3 to 38.3 Nm (3.5 to 3.9 kgfm)
: 24 mm
20
: 34.3 to 38.3 Nm (3.5 to 3.9 kgfm)
19
3. Install the hoses (24) (10 used) on the elbow (20) 20
and adapter (22) attached on the remote control
valve (15). 22
21
: 22 mm 23
: 39 Nm (4 kgfm)
24
4. Install the elbows (19) (8 used) and (20) (2 used)

on the remote control valve (14).
M2CN-02-09-002
: 19 mm

: 34.3 to 38.3 Nm (3.5 to 3.9 kgfm)
5. Install the hoses (21) (10 used) on the elbows (19)

and (20) attached on the remote control valve (14)
attached.
: 22 mm
: 39 Nm (4.0 kgfm)
W2-9-3
6. Install the lever (10 to 12) assemblies on the
remote control valve (14). Install the lever (16) and 7 13 10 11
(17) assemblies on the remote control valve (15) 12
5 13 16 17
and tighten the nuts (13) (2 used for each).
: 19 mm 13
: 90 Nm (9.2 kgfm) 7
7. Install the cover (3) on the right stand with the 14

screws (7) (2 used) and bolts (8) (2 used).
9 8
: 10 mm 3
: 3.3 to4.2 Nm (0.3 to 0.4 kgfm)
9
8. Connect the lever (10 to 12) assemblies, pressure

sensors (23) (2 used) and the harness connector
of the panel. 4
15
9. Install the covers (4) to (6) on the right stand with
the screws (7) (14 used) and bolts (9) (2 used). 7 6 7
M2CN-02-09-001
: 4 mm

10. Install the seat (2) with the bolts (1) (4 used). 2
: 13 mm
1
: 10 Nm (1.0 kgfm)

W24X-02-01-001
W2-9-4
REMOVE AND INSTALL SWING REMOTE
CONTROL VALVE


Removal 2
1
1. Shutdown the engine. Operate the lever several
times and release the remaining pressure in the
circuit.

seat (2).
: 13 mm

W24X-02-01-001

6 8 3 9 13 11 7 9
3. Remove the screws (9) (14 used) and socket bolts
(10) (2 used) and remove the covers (4) to (6)
from the left stand.
: 4 mm 12
4
4. Remove the harness connector of the panel in the 9 9
left stand.

used) and remove the cover (3) and panel (7)
from the left stand.
9
: 10 mm
6. Remove the nut (11) and remove the lever (13) 10

assembly from the remote control valve (12).
: 19 mm 5

W24X-02-09-003
W2-9-5
7. Remove the hoses (16) (4 used) from the elbow
(14) and adapters (15) attached on the remote
control valve (12).
18
: 22 mm 14
8. Remove the elbows (14) (2 used), adapters (15) 12

(2 used) and plug (17) from the remote control 14
valve (12). 17
: 6 mm
: 19 mm
9. Remove the socket bolts (18) (2 used) and 16

remove the remote control valve (12) from the left
stand.
: 6 mm
15
16
W24X-02-09-004
W2-9-6
Installation
18
14
1. Install the remote control valve (12) on the left
stand with the socket bolts (18) (2 used). 12
: 6 mm
14
: 20 Nm (2 kgfm) 17
2. Install the elbows (14) (2 used), adapters (15) (2

used) and plug (17) on the remote control valve
(12).
16
: 6 mm
: 34.3 to 38.3 Nm (3.5 to 3.9 kgfm)
: 19 mm
: 34.3 to 38.3 Nm (3.5 to 3.9 kgfm) 15
16
3. Install the hoses (16) (4 used) on the elbow (14) W24X-02-09-004
and adapter (15) attached on the remote control
valve (12).
: 22 mm
6 8 3 9 13 11 7 9
: 39 Nm (4.0 kgfm)
4. Install the lever part of the lever (13) assembly on

12
the remote control valve (12) through the panel (7)
and tighten the nut (11). 4
9 9
: 19 mm
: 90 Nm (9.2 kgfm)
9
5. Install the cover (3) and panel (7) on the left stand
with the screws (9) (6 used) and bolts (8) (2 used).
: 10 mm
9
: 3.3 to 4.2 Nm (0.3 to 0.4 kgfm)
6. Connect the harness connector of the panel in the 10

left stand.
5
7. Install the covers (4) to (6) on the left stand with
the screws (9) (14 used) and socket bolts (10) (2 W24X-02-09-003
used)
: 4 mm 2
1
8. Install the seat (2) with the bolts (1) (4 used).
: 13 mm
: 10 Nm (1.0 kgfm)

W24X-02-01-001
W2-9-7
DISASSEMBLE REMOTE CONTROL VALVE

38
36
37
35
8
33ᇬ49
7
6
5
31
1 31
3 1
4 2
2 4
44 3
5
6
30ᇬ48 7
44 8
34 9 29
11
14
12
17 32
16 13 18
4 25
19
39
26
10
22
45
15
21
18
20
24
41
27 40
28 43
42
15 46 47 23
W25N-02-09-004
W2-9-8
1- Steel Ball 14 - Spring Seat 26 - Casing 38 - Boot

2- Holder 15 - Bolt 27 - Socket Bolt 39 - Casing
3- O-Ring 16 - Spring 28 - Bushing 40 - Seat
4- Washer 17 - Spring 29 - Seal 41 - Steel Ball
5- Detent Plug 18 - Nut 30 - Cover 42 - Plug
6- Spring 19 - Spool 31 - Socket Bolt 43 - O-Ring
7- Lock Nut 20 - Plug 32 - Push Rod 44 - Setscrew
8- Adjusting Nut 21 - O-Ring 33 - Disk 45 - Plug
9- Bushing 22 - Casing 34 - Camshaft 46 - Plate
10 - Spring Pin 23 - O-Ring 35 - Setscrew 47 - Socket bolt
11 - Plug 24 - Plate 36 - Socket Bolt 48 - Cover
12 - O-Ring 25 - O-Ring 37 - Lever 49 - Disk
13 - Washer
W2-9-9
Disassemble Remote Control Valve

• As the structure of the remote control valve is
same as for the front drum, rear drum, boom
raising/lowering drum, travel and slewing, the
remote control valve for the rear drum is
explained here. As the spring seat (14), springs
(16), (17), spool (19), cover (30) and disk (33) are
different respectively, indicate each remote
control valve not to confuse the disassembled
parts.
• As the parts are made precisely, handle them
carefully. 38
• Clean the outer surface before disassembling.
1. Remove the lower end of the boot (38) from the

covers (30) and (48) upward. 48
26ᇬ25
2. Loosen the nut (18) and remove the bolt (15). 15ᇬ18
Separate the remote control valve into one unit.
: 13 mm 30
3. Remove the O-ring (25) from the casings (26) and 39ᇬ25
(39).

W25N-02-09-005
31
30
4. Remove the socket bolt (31). Separate the cover
(30) assembly from the casing (39) assembly.
39
: 5 mm

W25N-02-09-006
W2-9-10

CAUTION: The plug (11) may fly out due to
the spring (17) force.
5. Pull out the plug (11) from the casing (39) and 32
remove the push rod (32) from the plug (11).
11
39

W25N-02-09-007
19
6. Pull out the spool (19) assembly and spring (17) 17

39
IMPORTANT: Put the matching mark for the hole
position on the spool (19) assembly,
spring (17) and casing (39).

W25N-02-09-008
39
23
7. Remove the socket bolt (27) and remove the plate
(24). 24
: 6 mm
28
8. Remove the O-ring (23) and bushing (28) from
the casing (39).
27

W25N-02-09-009
W2-9-11
9. Place the spool (19) assembly on the workbench
vertically. Push the spring seat (14) downward 13
and push out the washers (13) (2 used) with using 14
a screwdriver.
19

W324-02-09-011

14
10. Remove the spring seat (14), spring (16) and
washer (4) from the spool (19). 16
IMPORTANT: Handle the parts as an assembly 4

each port.
The washer (4) is used when 19
adjusting the spring (16) for the
setting of secondary pressure and
the thickness is different according
to the spool (19) assembly.
W333-02-09-001

29
11. Remove the O-ring (12) and seal (29) from the
plug (11).
11
IMPORTANT: Take care not to damage the inner
surface of the plug (11). 12

W324-02-09-013

30
12. Remove the detent plug (5) assembly from the
cover (30). 1
2
: 24 mm 4
3
5
NOTE: Slowly remove the detent plug (5) 6
assembly so that the steel ball (1), holder 7
8
(2) and spring (6) does not fly out.

W324-02-09-014
W2-9-12
13. Remove the socket bolt (36) and remove the lever
(37) from the disk (33). 36
: 6 mm
37
33

W324-02-09-015

14. Remove the setscrew (35) from the disk (33).
: 4 mm
35
15. Attach a round bar on the end of the camshaft 33
(34). Tap and remove the camshaft (34) with using
a hammer. Remove the disk (33).
34

W324-02-09-016
16. Remove the plug (42) from the plate (24) and 24
remove the steel ball (41) and seat (40).
: 10 mm 41
40
43
42

W25N-02-09-010
W2-9-13
ASSEMBLE REMOTE CONTROL VALVE

49
48
47
46
38 1 2 4 3 5 7 8
37
36
35
34 6
31
9
33
44 11 10
32 12
13
30
14
29 45
4 16 15
17 18
19
20
21
23
28 42
43
27 41 40 24
22 25 39 26

W25N-02-09-011
W2-9-14
1- Steel Ball 14 - Spring Seat 26 - Casing 38 - Boot

2- Holder 15 - Bolt 27 - Socket Bolt 39 - Casing
3- O-Ring 16 - Spring 28 - Bushing 40 - Seat
4- Washer 17 - Spring 29 - Seal 41 - Steel Ball
5- Detent Plug 18 - Nut 30 - Cover 42 - Plug
6- Spring 19 - Spool 31 - Socket Bolt 43 - O-Ring
7- Lock Nut 20 - Plug 32 - Push Rod 44 - Setscrew
8- Adjusting Nut 21 - O-Ring 33 - Disk 45 - Plug
9- Bushing 22 - Casing 34 - Camshaft 46 - Plate
10 - Spring Pin 23 - O-Ring 35 - Setscrew 47 - Socket Bolt
11 - Plug 24 - Plate 36 - Socket Bolt 48 - Cover
12 - O-Ring 25 - O-Ring 37 - Lever 49 - Disk
13 - Washer
W2-9-15
Assemble Remote Control Valve
1. Install the steel ball (41) and seat (40) on the plate 24
(24).
41
2. Install the O-ring (43) on the plug (42) and install 40
43
the plug (42) on the plate (24). 42
: 10 mm
: 24.5 to 29.4 Nm (2.5 to 3.0 kgfm)

W25N-02-09-010
3. Install the bushing (28) and O-ring (23) on the

casing (39). Tighten the plate (24) with the socket
bolt (27).
: 6 mm
: 27.4 to 31.4 Nm (2.8 to 3.2 kgfm) 39
23
24
28
27

W25N-02-09-009

14
4. Install the washer (4), spring (16) and spring seat
(14) on the spool (19) in order. 16
19

W333-02-09-001

13
5. Place the spool (19) on the workbench vertically.
Push the spring seat (14) upward and install the 14
washers (13) (2 used) on the spring seat (14).
19

W324-02-09-011
W2-9-16
6. Install the washer (13) with the sharp edge side 13 19
with turning upward so that the washer (13) can
mesh with the head of spool (19).
Sharp Edge Side

W324-02-09-018
7. Insert the spring (17) and spool (19) assembly 19

into the casing (39).
17
IMPORTANT: When inserting the spool (19)
assembly, do not attach the lower 39
end of the spool on the corner of the
casing (39) strongly.

W25N-02-09-008
29
8. Install the seal (29) and O-ring (12) on the plug
(11). 11
NOTE: Slightly apply the grease before installing 12

the seal (29).

W324-02-09-013

11
9. Apply the hydraulic oil on the surface of the push
rod (32) and insert the push rod (32) into the plug
(11). 32

W324-02-09-019
W2-9-17
10. Install the push rod (32) assembly on the casing
(39).
32
39

W25N-02-09-007
33
11. Install the disk (33) on the cover (30) and insert
the camshaft (34).
30
34

W324-02-09-020
35

33
12. Apply LOCTITE #241 on the setscrew (35).
Tighten the setscrew (35) to the disk (33).
: 4 mm
: 15.7 to 17.7 Nm (1.6 to 1.8 kgfm)
NOTE: Check if the end of the setscrew (35) is

inserted into the groove of the camshaft W324-02-09-021
(34).
36
13. Install the lever (37) on the disk (33) and tighten 37
with the socket bolt (36).
: 6 mm
: 27.4 to 31.4 Nm (2.8 to 3.2 kgfm) 33

W324-02-09-015
W2-9-18
14. Apply much grease on the holder (2). Secure and
insert the steel ball (1) into the detent plug (5). 30
1
15. Install the O-ring (3) on the detent plug (5). 2
Tighten the detent plug (5) to the cover (30). 4
3
: 24 mm 5
: 38.3 to 44.1 Nm (3.9 to 4.5 kgfm) 6
7
8
16. Insert the washer (4) and spring (6) into the detent
plug (5). Install the lock nut (7) and adjusting nut
(8).
: 24 mm
: 38.3 to 44.1 Nm (3.9 to 4.5 kgfm)
W324-02-09-014

17. Install the cover (30) assembly on the casing (39)

and tighten with the socket bolt (31).
: 5 mm
: 10.8 to 12.8 Nm (1.1 to 1.3 kgfm)
31
30
39

18. Install the boot (38) on the covers (30) and (48). W25N-02-09-012

19. Install the O-ring (25) on the casing (39) of the
remote control valve for rear drum and casing
38
(26) of the remote control valve for front drum.
Place the remote control valve assembly (3 unit)
on the flat workbench. Align the spring pin (10)
30
with the pin hole. Install the bolts (15) (2 used) 48
and tighten with the nut (18). 26ᇬ25
: 13 mm
: 15.7 to 17.7 Nm (1.6 to 1.8 kgfm) 15ᇬ18
22
39ᇬ25

W25N-02-09-005
W2-9-19
(Blank)
W2-9-20
SWING MACHINERY / Solenoid Valve
REMOVE AND INSTALL SOLENOID VALVE
BLOCK


Removal

in the circuit.

2. Remove each harness of the solenoid valve from
the connector.
3. Remove all hoses from the solenoid valve block
(1) and remove the adapter and elbow.
: 19, 22, 27 mm
solenoid valve block (1).
: 13 mm
2
Installation 1
1. Install the solenoid valve block (1) with the bolts

(2) (2 used).
: 13 mm
: 30 Nm (3.1 kgfm)
2. Install the adapter and elbow on the solenoid

valve block (1).
: 19 mm
: 27 to 33 Nm (2.8 to 3.4 kgfm)
: 27 mm
: 86 to 105 Nm (8.7 to 10.7 kgfm)
3. Install all hoses.

: 22 mm M2CN-02-10-001
: 39 Nm (4.0 kgfm)

: 27 mm
: 93 Nm (9.5 kgfm)
4. Connect each harness of the solenoid valve to the

connector.
W2-10-1
DISASSEMBLE SOLENOID VALVE BLOCK
13
11 12
10
9
5
1 3
6
2
17
18
19
4
20
16 15 14 7 8

W2CG-02-10-002
1- Body 6- O-Ring 11 - Solenoid Valve 16 - Spring

2- Plug 7- O-Ring 12 - Nut 17 - O-Ring
3- O-Ring 8- O-Ring 13 - Adjusting Screw 18 - O-Ring
4- Plug 9- Nut 14 - Sleeve 19 - O-Ring
5- Sleeve 10 - Adjusting Screw 15 - Spool 20 - O-Ring
W2-10-2
Disassemble Solenoid Valve Block
• Thoroughly read “PRECAUTIONS FOR 7. Remove the O-ring (17) from the solenoid valve
DISASSEMBLING AND ASSEMBLING” (W1-1-1) (11).
1. Remove the plug (2) from the body (1). sleeve (14).
: 5 mm
9. Remove the sleeve (14) from the solenoid valve
2. Remove the O-ring (3) from the plug (2). (11).
3. Remove the plugs (4) (3 used) from the body (1). 10. Remove the spool (15) and spring (16) from the
: 4 mm sleeve (14).
IMPORTANT: Do not disassemble the sleeve (5)

assembly (reducing valve pilot
portion).
As the reducing set pressure
changes, do not loosen the nut (9).
In case the reducing valve pilot
portion has something wrong,
replace the reducing valve pilot
portion with the sleeve (5) assembly.
4. Remove the sleeve (5) from the body (1).

: 22 mm

sleeve (5).
IMPORTANT: Do not disassemble the solenoid

valve (11) assembly (selecting valve
pilot portion).
As the selecting set pressure
In case the selecting valve pilot
portion has something wrong,
replace the selecting valve pilot
portion with the solenoid valve (11)
assembly.
6. Remove the solenoid valves (11) (5 used) from

the body (1).
: 32 mm
W2-10-3
ASSEMBLE SOLENOID VALVE BLOCK
13
11 12
10
9
5
1 3
6
2
17
18
19
4
20
16 15 14 7 8

W2CG-02-10-002
1- Body 6- O-Ring 11 - Solenoid Valve 16 - Spring

2- Plug 7- O-Ring 12 - Nut 17 - O-Ring
3- O-Ring 8- O-Ring 13 - Adjusting Screw 18 - O-Ring
4- Plug 9- Nut 14 - Sleeve 19 - O-Ring
5- Sleeve 10 - Adjusting Screw 15 - Spool 20 - O-Ring

W2-10-4
Assemble Solenoid Valve Block
1. Apply the grease on the O-rings (18), (19) and

(20) and install the O-rings on the sleeve (14).
2. Install the spool (15) and spring (16) on the sleeve

(14) and install the solenoid valve (11).
3. Apply the grease on the O-ring (17) and install the

O-ring (17) on the solenoid valve (11).
IMPORTANT: As the selecting set pressure

4. Install the solenoid valves (11) (5 used) on the

body (1).
: 32 mm
: 44 Nm (4.5 kgfm)
5. Apply the grease on the O-ring (6), (7) and (8)

and install the O-rings on the sleeve (5).
IMPORTANT: As the reducing set pressure

6. Install the sleeve (5) on the body (1).

: 22 mm
: 44 Nm (4.5 kgfm)
7. Install the plugs (4) (3 used) on the body (1).

: 4 mm
: 8.8 Nm (0.9 kgfm)
8. Apply the grease on the O-ring (3) and install the

O-ring (3) on the plug (2).
9. Install the plug (2) on the body (1).

: 6 mm
: 36 Nm (3.67 kgfm)
W2-10-5
(Blank)
W2-10-6
SWING MACHINERY / Cylinder
REMOVE AND INSTALL FLIP CYLINDER

CAUTION: Remove and install the cylinder
on the level, solid ground.
Escaping fluid under pressure may penetrate
the skin and eyes, and cause serious injury.
Release the pressure before removing the
hydraulic or other lines.

Removal

1. Retract the cylinder (1) fully.

2. Remove the hose (2) (4 used) from the cylinder 4 7 1
5 6
(1). 6 5
: 22 mm 4 2
7
1
3. Remove the bolt (4), washer (5), lock plate (6) and 2
pin (7) from the lever (3). 8
10 9
: 24 mm 2
12
CAUTION: Cylinder (1) weight: 87 kg 2
11
9 10
4. Remove the bolt (8), washer (9), plate (10), 12
11 8
spacer (11) and pin (12). Remove the cylinder (1)
with lifting it with the crane.
: 24 mm

M2CN-02-11-001
W2-11-1
Installation

CAUTION: Cylinder (1) weight: 87 kg
4 7 1
1. Lift the cylinder (1) with the crane and install it on 6
5
the revolving frame with the pin (12), spacer (11), 6 5
4 2
plate (10), washer (9) and bolt (8). 7
: 24 mm 1
: 148 to 160 Nm (15.0 to 16.3 kgfm) 2
8
10 9
2. Install the cylinder (1) on the lever (3) with the pin 2
(7), lock plate (6), washer (5) and bolt (4). 12
: 24 mm 11
: 148 to 160 Nm (15.0 to 16.3 kgfm) 2
9 10
12
11 8
3. Install the hose (2) (4 used) on the cylinder (1).
: 22 mm
: 39 Nm (4.0 kgfm)

M2CN-02-11-001

W2-11-2
(Blank)
W2-11-3
DISASSEMBLE FLIP CYLINDER
16
15
22
14
13
11
19
21
20
18
17
10
9
8
5
4
7
6
3
2
12
1

M2CN-02-11-002

1- Bushing 7- Packing 13 - Valve 18 - Piston Seal
2- Retaining Ring 8- Bushing 14 - Valve 19 - Wear Ring
3- Dust Seal 9- Backup Ring 15 - Valve Cover 20 - Piston
4- Cylinder Head 10 - O-Ring 16 - %ROW 21 - Setscrew
5- O-Ring 11 - Cylinder Tube 17 - O-Ring 22 - Bushing
6- Backup Ring 12 - Piston Rod
W2-11-4
Disassemble Flip Cylinder
• Thoroughly read “PRECAUTIONS FOR 10. Remove the retaining ring (2), dust seal (3),
DISASSEMBLING AND ASSEMBLING” (W1-1-1) packing (7), backup ring (6) and bushing (8) from
before disassembling. the inside of the cylinder head (4).
11. Remove the O-rings (5), (10) and backup ring (9)
CAUTION: Cylinder weight: 87 kg
from the outside of the cylinder head (4).
1. Lift the cylinder with the crane and secure it 12. Remove the bushing (1) from the piston rod (12).
horizontally. Drain off the hydraulic oil from the
cylinder. 13. Remove the bushing (22) from the cylinder tube
(11).
valve cover (15), valves (14) and (13) from the
cylinder tube (11).
: 5 mm
3. Remove the cylinder head (4) assembly from the

cylinder tube (11).
CAUTION: Pull out the piston rod (12)

straightly not to damage the sliding surface.
4. Pull out the piston rod (12) from the cylinder tube
(11).
5. Secure the piston rod (12) horizontally and

remove the setscrew (21) from the piston (20).
: 8 mm
6. Remove the piston (20) assembly from the piston

rod (12).
7. Remove the wear ring (19) and piston seal (18)

from the outside of the piston (20).
8. Remove the O-ring (17) from the piston rod (12).
9. Pull out the cylinder head (4) assembly from the

piston rod (12).
W2-11-5
ASSEMBLE FLIP CYLINDER
16
15
14
22 21 20 19 18 17 13 12 11 10 9 7 6 5 4
2 1
8 3

M2CN-02-11-003

1- Bushing 7- Packing 13 - Valve 18 - Piston Seal
2- Retaining Ring 8- Bushing 14 - Valve 19 - Wear Ring
3- Dust Seal 9- Backup Ring 15 - Valve Cover 20 - Piston
4- Cylinder Head 10 - O-Ring 16 - %ROW 21 - Setscrew
5- O-Ring 11 - Cylinder Tube 17 - O-Ring 22 - Bushing
6- Backup Ring 12 - Piston Rod

W2-11-6
Assemble Flip Cylinder
1. Install the bushing (22) on the cylinder tube (11). 10. Clamp the cylinder tube (11) with a vise. Support
one side with the rest and secure the cylinder tube
2. Install the bushing (1) on the piston rod (12). (11).
3. Install the dust seal (3), retaining ring (2), bushing IMPORTANT: Insert the piston rod (12) straightly
(8), packing (7) and backup ring (6) on the inside with aligning with the center of the
of the cylinder head (4) in order. cylinder tube (11) not to damage the
rings.
NOTE: Apply ThreeBond #1102 on the outer
surface of the dust seal (3) and apply the 11. Insert the piston rod (12) assembly into the
grease (Thickness: 0.2 or less) cylinder tube (11).
(Shin-Nisseki PowerKnock WB2 or
equivalent) on the inside and between the 12. Tighten the cylinder head (4) to the cylinder tube
spaces of the packing (7) and dust seal (3). (11).
: 1062 to 1298 Nm (108.0 to 132.0 kgfm)
4. Install the backup ring (9), O-ring (10) and (5) on
the outside of the cylinder head (4) in order. 13. Install the valves (13), (14) and valve cover (15)
on the cylinder tube (11) and install the bolt (16) (4
5. Install the piston seal (18) and wear ring (19) on used).
the outside of the piston (20) in order. : 5 mm
: 9.72 to 11.88 Nm (0.99 to1.21 kgfm)
6. Install the cylinder head (4) assembly on the
piston rod (12). NOTE: Enclose anticorrosive oil and knuckle oil
#110 with I ml at the extend side and 4 ml at
7. Install the O-ring (17) on the piston rod (12). retract side.

8. Secure the piston rod (12) assembly vertically and
install the piston (20) assembly on the piston rod
(12).
: 1674 to 2046 Nm (171 to 209 kgfm)
9. Apply LOCTITE #242 on the setscrew (21) and

install the setscrew (21) on the piston (20). Lock
the setscrew (21) (2 places) with a punch.
: 8 mm
: 33.57 to 41.03 Nm (3.42 to4.18 kgfm)

W2-11-7
(Blank)
W2-11-8
REMOVE AND INSTALL
COUNTERWEIGHT CYLINDER


Removal

1. Retract the base counterweight assembly. (As for
the removal of the base counterweight assembly,
refer to the Operator’s Manual.)
2. Disassemble the counterweight. (As for the

counterweight disassembling, refer to the
CAUTION: Weight removal/installation device

weight: 4340 kg 2 2
3. Attach the wire rope on the weight

removal/installation device and support the weight 1
removal/installation device with the crane.
4. Draw the lever (1) of the base counterweight.

1
(Refer to the Operator’s Manual.) 2 2
5. Pull out the lock pin (3) from the pin (2) that
secures the weight removal/installation device
and base counterweight.
6. Pull out the pin. Lift the weight removal/installation 3 3

1
device with the crane and remove it. 1
M2CN-02-11-004
W2-11-9
CAUTION: Counterweight cylinder assembly

weight: 1540 kg
7
7
7. Attach the wire rope on the top of the
7 4
counterweight cylinder (4) and support the 7
counterweight cylinder assembly with the crane. 6
8. Pull out the bolt (6) from the pin (5) that secures 5 6 7 7 7 7
the counterweight cylinder (4).
9. Remove the pin and remove the counterweight

cylinder assembly with the crane.
: 17 mm 4
10. Remove the hoses (8) and (9) from the

counterweight cylinder (4).
: 22 mm
5
11. Remove the lock pin (11) from the pin (10) of the
plate that secures the counterweight cylinder (4).
12. Remove the pin (10). After removing the bracket

(12), remove the counterweight cylinder (4) from
the bracket (13).

M2CN-02-11-005
Installation 9
1. Install the counterweight cylinder (4) on the 10

bracket (13) and lock the bracket (12) with the pin
10
(10).
2. Install the lock pin (11) on the pin (10) to lock the
plate (12).
3. Install the hoses (8) and (9) on the counterweight 11

cylinder (4). 11
: 22 mm
12
: 39 Nm (4.0 kgfm)
12
13

M2CN-02-11-006
W2-11-10
CAUTION: Counterweight cylinder assembly

weight: 1540 kg
7
7
4. Lift the counterweight assembly with the crane
7 4
and install it on the weight removal/installation 7
device. 6
5. Lock the counterweight cylinder (4) on the weight 5 6 7 7 7 7

removal/installation device with the pin (5).
6. Install the bolt (6) on the pin (5) that locks the
counterweight cylinder (4).
: 17 mm 4
: 34 to 37 Nm (3.5 to 3.8 kgfm)

CAUTION: Weight removal/installation device M2CN-02-11-005
weight: 16140 kg

7. Lift the weight removal/installation device with the
crane and install it on the base counterweight.
8. Lock the weight removal/installation device on the

base counterweight with the pin (2).
9. Install the lock pin (3) on the pin (2) that locks the
weight removal/installation device.
10. Push in the lever (1) of the base counterweight. 2 2

1
2 2
3 3
1
1
M2CN-02-11-004
W2-11-11
DISASSEMBLE COUNTERWEIGHT CYLINDER
21
22
23
15
19
20
16
17 18
13
12
11
10
9
8
7
6
4
1
3
2
14

M2CN-02-11-007
1- Retaining Ring 7- Backup Ring 13 - O-Ring 19 - Wear Ring

2- Retaining Ring 8- Packing 14 - Piston Rod 20 - Setscrew
3- Bushing 9- Packing 15 - Cylinder Tube 21 - Bolt
4- Dust Seal 10 - Bushing 16 - Piston 22 - Manifold
5- Cylinder Head 11 - O-Ring 17 - O-Ring 23 - Valve
6- Bushing 12 - Backup Ring 18 - Piston Seal
W2-11-12
Disassemble Counterweight Cylinder
• Thoroughly read “PRECAUTIONS FOR 10. Remove the dust seal (4), bushing (6) packing (8),
DISASSEMBLING AND ASSEMBLING” (W1-1-1) backup ring (7), packing (9) and bushing (10) from
before disassembling. the inside of the cylinder head (5).
CAUTION: Cylinder weight: 323 kg 11. Remove the O-rings (11), (13) and backup ring
(12) from the outside of the cylinder head (5).
1. Lift the cylinder with the crane and secure it
horizontally. Drain off the hydraulic oil from the 12. Remove the retaining rings (1), (2) and bushing
cylinder. (3) from the piston rod (14).

manifold (22), valve (23) from the cylinder tube
(15).
: 5 mm

cylinder tube (15).

(15).

remove the setscrew (20) from the piston (16).
: 8 mm

rod (14).

8. Remove the O-ring (17) from the piston rod (14).

piston rod (14).
W2-11-13
ASSEMBLE COUNTERWEIGHT CYLINDER
18
19 16 22 21 23 11
15 14 13 12 8 3
20 5
4 1
17 10 9 7 6 2

M2CN-02-11-008

1- Retaining Ring 7- Backup Ring 13 - O-Ring 19 - Wear Ring
2- Retaining Ring 8- Packing 14 - Piston Rod 20 - Setscrew
3- Bushing 9- Packing 15 - Cylinder Tube 21 - %ROW
4- Dust Seal 10 - Bushing 16 - Piston 22 - Manifold
5- Cylinder Head 11 - O-Ring 17 - O-Ring 23 - Valve
6- Bushing 12 - Backup Ring 18 - Piston Seal
W2-11-14
Assemble Counterweight Cylinder
1. Install the bushing (3) and retaining rings (1) and IMPORTANT: Insert the piston rod (14) straightly
(2) on the piston rod (14). with aligning with the center of the
cylinder tube (15) not to damage the
2. Install the dust seal (4), bushings (6), (10), rings.
packing (8), backup ring (7) and packing (9) on
the inside of the cylinder head (5) in order. 10. Insert the piston rod (14) assembly into the
cylinder tube (15).
NOTE: Apply ThreeBond #1102 on the outer
surface of the dust seal (4) and apply the 11. Tighten the cylinder head (5) to the cylinder
grease (Thickness: 0.2 or less) tube (15).
(Shin-Nisseki PowerKnock WB2 or
: 1323 to 1617 Nm (135.0 to 165.0 kgfm)
equivalent) on the inside and between the
spaces of the packing (9) and dust seal (4).
12. Install the valve (23) and manifold (22) on the
3. Install the backup ring (12), O-rings (13) and (11) cylinder tube (15) and install the bolts (21) (4
on the outside of the cylinder head (5) in order.
used).
4. Install the piston seal (18) and wear ring (19) on : 5 mm
the outside of the piston (16) in order. : 9.72 to 11.88 Nm (0.99 to 1.21 kgfm)
5. Install the cylinder head (5) assembly on the NOTE: Enclose anticorrosive oil and knuckle oil
piston rod (14). #110 with I ml at the extend side and 26 ml
at retract side.
6. Install the O-ring (17) on the piston rod (14).

(14).
: 3528 to 4312 Nm (360 to 440 kgfm)
8. Apply LOCTITE #242 on the setscrew (20) and

install the setscrew (20) on the piston (16). Lock
the setscrew (20) (2 places) with a punch.
: 8 mm
: 33.57 to 41.03 Nm (3.42 to 4.18 kgfm)
9. Clamp the cylinder tube (15) with a vise. Support

(15) horizontally.
W2-11-15
(Blank)

W2-11-16
REMOVE AND INSTALL BOOM FOOT
CYLINDER


Removal

1. Remove the hoses (2) (4 used) from the boom
foot cylinder (1). Attach the plug on the hoses
removed.
: 19 mm

2. Turn the rod of the boom foot cylinder (1) and
remove the rod from the boom foot pin.
: 21 mm
3. Remove the bolt (3) (8 used) of the boom foot

cylinder (1) and remove the boom foot cylinder (1)
from the bracket of the boom foot pin.
: 24 mm
3 4
Installation
1
1. Install the boom foot cylinder (1) on the bracket of
the boom foot pin with the bolt (3) (8 used) and
washer (4).
: 24 mm
: 148 to 160 Nm (15.0 to 16.3 kgfm)
2. Turn the rod of the boom foot cylinder (1) and

1 3 2 2
install the rod on the boom foot pin.
: 21 mm 4
2 2

3. Install the hoses (2) (4 used) on the boom foot
M2CN-02-11-009
cylinder (1).
: 19 mm
: 29.5 Nm (3.0 kgfm)
W2-11-17
DISASSEMBLE BOOM FOOT CYLINDER
4
5
6
10
12
11
13

W2CG-02-11-017
1- Cylinder Tube 5 - Bushing 8 - O-Ring 11 - Wear Ring

2- Piston Rod 6 - Packing 9 - Piston 12 - O-Ring
3- Cylinder Head 7 - O-Ring 10 - Piston Seal 13 - Nylon Nut
4- Dust Seal
W2-11-18
Disassemble Boom Foot Cylinder


horizontally. Drain off the hydraulic oil from the
cylinder.

cylinder tube (1).

(1).
4. Secure the piston rod (2) horizontally and remove

the nylon nut (13) from the piston rod (2).
: 27 mm

rod (2).
6. Remove the O-ring (12) from the inside of the

piston (9).


piston rod (2).
9. Remove the dust seal (4), bushing (5) and

packing (6) from the inside of the cylinder head
(3).
10. Remove the O-rings (8) and (7) from the outside
of the cylinder head (3).
W2-11-19
ASSEMBLE BOOM FOOT CYLINDER
4 3 8 5 6 7 1 2 9 12 10 11 13

M2CN-02-11-010
1- Cylinder Tube 5 - Bushing 8 - O-Ring 11 - Wear Ring

2- Piston Rod 6 - Packing 9 - Piston 12 - O-Ring
3- Cylinder Head 7 - O-Ring 10 - Piston Seal 13 - Nylon Nut
4- Dust Seal
W2-11-20
Assemble Boom Foot Cylinder
1. Install the dust seal (4), bushing (5) and packing

(6) on the inside of the cylinder head (3) in order.
2. Install the O-rings (7) and (8) on the outside of the

cylinder head (3) in order.
3. Install the piston seal (10) and wear ring (11) on

the outside of the piston (9) in order.
4. Install the O-ring (12) on the inside of the piston

(9).

piston rod (2).

(2) with using a special tool.
7. Install the nylon nut (13) on the piston rod (2).

: 27 mm
: 274.5 to 335.5 Nm (29.0 to 35.0 kgfm)
8. Clamp the cylinder tube (1) with a vise. Support

(1) horizontally.
IMPORTANT: Insert the piston rod (2) straightly

with aligning with the center of the
rings.
9. Insert the piston rod (2) assembly into the cylinder

tube (1).
10. Tighten the cylinder head (3) to the cylinder tube

(1).
: 351 to 429 Nm (36.0 to 44.0 kgfm)
W2-11-21
(Blank)
W2-11-22
SECTION 3
LOWER MACHINERY
CONTENTS
Group 1 Swing Ring Group 5 Carrier and Track Rollers

Remove and Install Swing Ring ............... W3-1-1 Remove and Install Carrier Roller
Disassemble Swing Ring ....................... W3-1-4 (Front and Rear) .................................. W3-5-1
Assemble Swing Ring ............................ W3-1-6 Disassemble Carrier Roller
(Front and Rear) .................................. W3-5-4
Group 2 Travel Mechanism Assemble Carrier Roller
Remove and Install Travel Mechanism .. W3-2-1 (Front and Rear) .................................. W3-5-6
Disassemble Travel Mechanism Maintenance Standard ............................. W3-5-8
(Reduction Gear) ................................. W3-2-4 Remove and Install Carrier Roller
Assemble Travel Mechanism (Center)................................................ W3-5-9
(Reduction Gear) ............................... W3-2-12 Disassemble Carrier Roller (Center) ...... W3-5-12
Assemble Carrier Roller (Center)........... W3-5-14
Group 3 Rotating Joint Maintenance Standard ........................... W3-5-16
Remove and Install Rotating Joint ........... W3-3-1 Remove and Install Track Roller ............ W3-5-17
Disassemble Rotating Joint ..................... W3-3-4 Disassemble Track Roller ...................... W3-5-22
Assemble Rotating Joint .......................... W3-3-6 Assemble Track Roller ........................... W3-5-24
Maintenance Standard............................. W3-3-8 Maintenance Standard ........................... W3-5-26
Remove and Install Track Roller ............ W3-5-27
Group 4 Take-Up Tumbler Disassemble Track Roller ...................... W3-5-32
Remove and Install Take-Up Tumbler ...... W3-4-1 Assemble Track Roller ........................... W3-5-34
Disassemble Take-Up Tumbler .............. W3-4-2 Maintenance Standard ........................... W3-5-36
Assemble Take-Up Tumbler..................... W3-4-4
Maintenance Standard............................. W3-4-6
2CNW-3-1
Group 6 Track Shoe
Remove and Install Track Shoe ............... W3-6-1
Maintenance Standard............................. W3-6-4
Group 7 Cylinder
Remove and Install Side Frame
Connecting Cylinder ............................ W3-7-1
Disassemble Side Frame Connecting
Cylinder ............................................... W3-7-4
Assemble Side Frame Connecting
Cylinder ............................................... W3-7-6
Remove and Install Jack-Up Cylinder...... W3-7-9
Disassemble Jack-Up Cylinder.............. W3-7-14
Assemble Jack-Up Cylinder................... W3-7-16
Remove and Install Track Shoe
Tension Cylinder ................................ W3-7-19
Disassemble Track Shoe Tension
Cylinder ............................................. W3-7-20
Assemble Track Shoe Tension
Cylinder ............................................. W3-7-22
Group 8 Control Valve

Remove and Install 6-Unit Control
Valve .................................................. W3-8-1
Disassemble 6-Unit Control Valve ........... W3-8-2
Assemble 6-Unit Control Valve ................ W3-8-4
2CNW-3-2
LOWER MACHINERY / Swing Ring
REMOVE AND INSTALL SWING RING
Before removing/installing the swing ring, the swing

upper structure must be removed and/or installed first.
For removal and installation of the swing upper
structure, refer to the section “Remove and Install
Revolving Frame”.
In this section, the procedure starts at the status with
the swing upper structure removed. 3 2
4
1
Removal 2
2 2
1. Remove the elbows (2) (4 used), clamps (3) (4 4

used), hoses (4) (4 used) and block (5) from the
outer race (1).
NOTE: Remove the bolt (6) and remove the blocks 6 3

(5) (2 used).
5 4
: 17mm 5
2
: 30mm
6 4 3

M2CN-03-01-001

Matching
2. Put a matching mark on the inner race (7) and Mark
7
lower frame (8). 8

M2CN-03-01-002

3. Remove the inner race mounting bolts (9) (68

used).
: 50 mm

M2CN-03-01-003
W3-1-1

CAUTION: Swing ring weight: Approx. 1500
kg
4. Attach the sling tools on the outer race (1) and lift
it. 1

M2CN-03-01-004

W3-1-2
Installation
Clean the mounting surfaces of the lower frame and

slewing ring. Apply ThreeBond #1102.

Matching
CAUTION: Swing ring weight: Approx. 1500 Mark

kg 9
1. Lift the swing ring with the crane and align the 7
matching mark on the lower frame (8) with the 8
inner race (7).
NOTE: If the matching marks do not align, the

position of the soft zone of the inner race
(7) will be dislocated.
2. Tighten the inner race mounting bolts (9) (68

used).
: 50 mm M2CN-03-01-005
: 1640 to 1770 Nᨿm (167 to 181 kgfᨿm)

3. Install the elbows (2) (4 used), clamps (3) (4
used), hoses (4) (4 used) and blocks (5) (2 used). 3 2
4
1
NOTE: Install the block (5) with the bolt (6). 2
2 2
: 17mm
: 34 to 37 Nᨿm (3.5 to 3.8 kgfᨿm) 4
: 30mm
: 288 to 312 Nᨿm (29.4 to 31.8 kgfᨿm)
6 3
5 4
5
2
6 4 3

M2CN-03-01-001
W3-1-3
DISASSEMBLE SWING RING

2 3 2 4 5
1
8 6 7 6

M2CN-03-01-006

1- Pin 3- Inner Race 5- Outer Race 7- Support (89 Used)
2- Seal 4- Ball (89 Used) 6- Seal 8- Plug
W3-1-4
Disassemble Swing Ring

Thoroughly read “PRECAUTIONS FOR
before disassembling. 1
2. Drive out the pin (1) from under the plug (8).
NOTE: After installing the pin (1), grind the punch 8

portion.
W25N-03-01-007

2. Remove the plug (8).
NOTE: Screw the bolt at the pulling-out screw

(M10) portion of the plug (8). Pull or pull out
the plug with tapping the bolt from the 8
inside.

W25N-03-01-008

CAUTION: Swing ring weight: Approx.
1500kg
5
3. Slightly lift the outer race (5) of the turntable 2
bearing horizontally and remove the seal (2) and 4
(6).
A 6
W25N-03-01-009

4. Remove the ball (4) and support (7) from the plug
as rotating the inner race (3). Use a stick-shaped
magnet (A) when removing the ball (4). Take out
the support (7) with the wire (B) bent as hanging.
7
W105-03-01-010

W3-1-5
ASSEMBLE SWING RING
1 2 3 2 4 5
8 7 6

W25N-03-01-006

1- Pin 3- Inner Race 5- Outer Race 7- Support (105 Used)
2- Seal 4- Ball (105 Used) 6- Seal 8- Plug

W3-1-6
Assemble Swing Ring

CAUTION: Swing ring weight: Approx.
1500kg

1. Before assembling the inner race and the outer
race of the swing ring, completely remove the oil
from the groove that the seals (2) and (6) are
inserted. Apply ThreeBond #1735 and install the 2
seals (2) and (6).
4
IMPORTANT: Grease the ball (4) and support (7).

6
W25N-03-01-011

2. Install the balls (4) (89 used) and supports (7) (89
used) and from the plug side in order.
7

W25N-03-01-012
3. Drive the plug (8) into the outer race (5) and drive
in the pin (1).Calk the pin (1) head with the punch.
Fully apply grease (Albania EP2 or equivalent) on
the turntable bearing. 5

W25N-03-01-007

W3-1-7
(Blank)
W3-1-8
LOWER MACHINERY / Travel Mechanism
REMOVE AND INSTALL TRAVEL
MECHANISM


Removal

The procedure starts on the premise that the crawler
shoe has already been removed. As for the removal
and installation of crawler shoe, refer to W3-6-1.

IMPORTANT: After shutting down the engine,
remove and install the quick
coupling.
When the engine is not shutdown,
the quick coupling can not be
inserted or the O-ring in the quick
coupling may be damaged due to the
remaining pressure in the circuit.
Before connecting the coupling,
remove the dusts and clean the
quick coupling.
The quick coupling may be damaged
if the quick coupling is hit.
Handle the quick coupling carefully.

in the circuit. Disconnect the quick couplings (4
places in one side, 8 places in total) of the travel
hydraulic hose.
1
2. Remove all pipings and covers.
: 19 mm, 36 mm
NOTE: Cap the removed pipings.
3
M2CN-03-02-001
2

W3-2-1
CAUTION: Travel mechanism weight: Approx.

2025 kg 4
3. Lift the travel mechanism (4) with the crane.

Remove the bolts (5) (30 used) and remove the 8
travel mechanism (4) from the side frame (7).
: 24 mm 10
9
CAUTION: Drive tumbler weight: Approx. 312
kg
4. Lift the drive tumbler (8) with the crane. Remove

the socket bolts (9) (34 used) and remove the
drive tumbler (8) from the travel mechanism (4).
: 19 mm 7
6

Installation 5 M2CN-03-02-002

CAUTION: Drive tumbler weight: Approx. 312
kg
1. Lift the drive tumbler (8) with the crane and install
it on the travel mechanism (4) with the socket
bolts (9) (34 used) and washers (10) (34 used).
: 19 mm

CAUTION: Travel mechanism weight: Approx.
2025kg

2. Lift the travel mechanism (4) with the crane and

install it on the side frame (7) with the bolts (5) (30
used) and washers (6) (30 used).
: 24 mm
3. Install all the pipings.

1
: 19 mm
: 29.5 Nm (3.0 kgfm)
: 36 mm
: 175 Nm (18.0 kgfm)
: 10 mm
: 90 Nm (9.2 kgfm)
4. Install the cover with the socket bolt (2) and

washer (3).
: 19 mm 3
: 60 to 64 Nm (6.1 to 6.5 kgfm) M2CN-03-02-001
2

W3-2-2
IMPORTANT: After shutting down the engine,
remove and install the quick
coupling.
When the engine is not shutdown,
the quick coupling can not be
inserted or the O-ring in the quick
coupling may be damaged due to the
Before connecting the coupling,
remove the dusts and clean the
quick coupling.
The quick coupling may be damaged
if the quick coupling is hit.
Handle the quick coupling carefully.
5. Connect the travel hydraulic hose to the pipings of

the travel motor side with using the quick
couplings (4 places in one side, 8 places in total).
IMPORTANT: After installing the travel motor, fill

the hydraulic oil in the travel motor.
After installing the travel motor or
travel mechanism, perform the
break-in operation to prevent the
travel motor from initial seizing.
Check for any oil leaks.
W3-2-3
DISASSEMBLE TRAVEL MECHANISM (REDUCTION GEAR)

12 29,30,31 18 35 32 38 37 36 39 34 41 46 54 47 50 48 55 51 60 49 61
9
5
3
1
14
16
27
2
6
4
62
19
15
23
21
25
13
42 52,53 59 56,57 10,11

58
7,8 24 26 22 28 33 17 20 46 45 40 44 43

W2CG-03-02-003

1- Cover 17 - Planetary Gear 33 - Plug 48 - Casing
2- Sun Gear 18 - Carrier 34 - Sun Gear 49 - Casing
3- Ring 19 - Carrier Pin 35 - Ring 50 - Holder
4- Bearing 20 - Spacer 36 - Retaining Ring 51 - Seal Cover
5- O-ring 21 - Bearing 37 - Bearing 52 - Bolt
6- Plug 22 - Bearing 38 - Retaining Ring 53 - Washer
7- Bolt 23 - Retaining Ring 39 - Casing 54 - Socket Bolt
8- Washer 24 - Retaining Ring 40 - Planetary Gear 55 - O-Ring
9- Carrier Pin 25 - Retaining Ring 41 - Carrier 56 - Socket Bolt
10 - Socket Bolt 26 - Retaining Ring 42 - Carrier Pin 57 - Washer
11 - Washer 27 - Retaining Ring 43 - Spacer 58 - O-Ring
12 - Casing 28 - Plug 44 - Bearing 59 - Bearing
13 - Planetary Gear 29 - Bolt 45 - Retaining Ring 60 - Floating Seal
14 - Carrier 30 - Washer 46 - Retaining Ring 61 - Motor
15 - Carrier Pin 31 - Setscrew 47 - Bearing 62 - Spacer
16 - Sun Gear 32 - O-Ring
W3-2-4
Disassemble Travel Mechanism (Reduction Gear)


CAUTION: Travel mechanism weight:
Approx. 1670 kg
There may be pressure accumulated inside of
6
the travel mechanism. Loosen the plug
slowly and release any remaining pressure
completely.
As the plug or gear oil may gush out, do not
loosen the plug suddenly. Keep away from
the plug.
1. Lift the travel mechanism with the crane so that

the plug (28) positions downward. Loosen the Horizontal
plug (6) to the half (2 to 3) turns and release the
remaining pressure in the reduction gear.
: 32 mm
2. Remove the plug (28) and drain off the gear oil.
: 30 mm
3. Put the matching marks on the outside on each 28

mating surface. W2CG-03-02-004

4. Place the travel mechanism on the workbench
with positioning the cover (1) downward.

CAUTION: Motor weight: 134 kg Matching Matching Matching Matching
Mark Mark Mark Mark
5. Install the eyebolt (M12) at the center of the motor Matching
(61). Remove the socket bolts (10) (4 used) and Mark
remove the motor (61) with the crane.
6. Install the eyebolts (M33) (4 used) on the casing

(4). Remove the socket bolts (54) (2 used) and
remove the casings (49) and (48) from the casing
(39) with the crane.
: 19 mm
7. Remove the O-ring (58) from the casing (49).

W2CG-03-02-003
W3-2-5

12 18 35 32 39 41 50 48 51 60 49
14
16
62
52 59 56

W2CG-03-02-003
W3-2-6
8. After turning over the casings (49) and (48), place 17. Remove the inner race of the bearing (59) from
them on the workbench. the casing (48).
9. Remove the bolts (52) (16 used) and remove the 18. Install the eyebolt on the casing (39). Remove the
holder (50). bolts (29) (29 used) and remove the casing (39)
: 30 mm from the casing (12) with the crane.
: 30 mm
10. Lift the casing (48) with the crane and remove it
from the casing (49). NOTE: Lift the casing (39) slightly. Put the metal
pad on the casing (12) and remove the
IMPORTANT: As the outer race of the bearing (59) casing (39) with tapping the casing
is inserted with a press, the outer diagonally upward with using a hammer.
race can not be removed easily. Do

not disassemble unless the
replacement of the bearing (59) is 19. Remove the O-ring (32) from the casing (12).
required.
20. Install the eyebolt on the carrier (41) and remove
the third stage carrier (41) assembly with the
11. Remove the inner race of the bearing (59) from
the casing (48). crane.
12. After turning over the casing (48), place it on the 21. Remove the ring (35) from the casing (12).
workbench with positioning the seal cover (51)
upward. 22. Install the eyebolt on the carrier (18) and remove
the second stage carrier (18) assembly with the
IMPORTANT: Take care not to damage the sliding crane.
surface of the floating seal (60). Do
not disassemble unless the 23. Remove the sun gear (16).
replacement of the floating seal (60)
is required. 24. Remove the sun gear (2) and pull out the spacer
(62).
13. Remove the floating seal (60) of the casing (49)
side. 25. Install the eyebolt on the carrier (14) and remove
the first stage carrier (14) assembly with the
14. Remove the floating seal (60) of the seal cover crane.
(51) side.
15. Remove the socket bolts (56) (24 used) of the

seal cover (51) and remove the seal cover (51)
: 10 mm
16. Remove the O-ring (55) from the seal cover (51).
W3-2-7

12 18 38 37 36 34
3
1
14
16
27
19
15
23
21
25
13
7 24 22 17 20

W2CG03-02-003

W3-2-8
26. Turn over the casing (12) and cover (1) and place IMPORTANT: Replace the carrier pin (19) or the
them on the workbench. planetary gear (17) as 4 units. Put the
mark to use the carrier pin (19) again
27. Remove the bolts (7) (20 used) from the cover (1) so that the carrier pin (19) can be
and remove the cover (1). installed in the former hole on the
: 24 mm carrier (18) before disassembling.

NOTE: Put the metal pad on the cover (1) and 35. Remove the retaining ring (24) from the carrier pin
remove the cover (1) with tapping the cover (19) of the second stage carrier (18) assembly
diagonally upward with using a hammer. and remove the planetary gear (17).
28. Remove the O-ring (5) from the cover (1). 36. Remove the spacer (20) from the carrier pin (19).
29. Remove the bearing (4) from the cover (1). 37. Remove the retaining ring (24) from the planetary
gear (17) and remove the bearing (22).
30. Remove the ring (3) from the cover (1).
38. Remove the retaining ring (36) from the sun gear
IMPORTANT: Replace the carrier pin (15) or the (34) and remove the carrier (18).
planetary gear (13) as 3 units. Put the
mark to use the carrier pin (15) again 39. Remove the carrier pins (19) (4 used) from the
so that the carrier pin (15) can be carrier (18).
installed in the former hole on the
carrier (14) before disassembling. 40. Remove the retaining ring (36) from the sun gear
(34) and remove the carrier (18).
31. Remove the retaining ring (23) from the carrier pin
(15) of the first stage carrier (14) assembly and 41. Remove the retaining ring (38) from the sun gear
remove the planetary gear (13). (34) and remove the bearing (37).
32. Remove the retaining ring (25) from the planetary

gear (13) and remove the bearing (21).
33. Remove the carrier pins (15) (3 used) from the

carrier (14).
34. Remove the retaining ring (27) from the sun gear
(16).
W3-2-9
41 46 47
42
45 40 44 43

W2CG-03-02-003
W3-2-10
IMPORTANT: Replace the carrier pin (42) or the
planetary gear (40) as 5 units. Put
the mark to use the carrier pin (42)
again so that the carrier pin (42) can
be installed in the former hole on the
carrier (41) before disassembling.

42. Remove the retaining ring (45) from the carrier pin
(42) of the third stage carrier (41) assembly and
remove the planetary gear (40).
43. Remove the spacer (43) from the carrier pin (42).
44. Remove the retaining ring (46) from the planetary

gear (40) and remove the bearings (44) (2 used).
45. Remove the carrier pins (42) (5 used) from the

carrier (41).
46. Remove the retaining ring (46) from the carrier

(41) and remove the bearing (47).
W3-2-11
ASSEMBLE TRAVEL MECHANISM (REDUCTION GEAR)

12 29,30,31 18 35 32 38 37 36 39 34 41 46 54 47 50 48 55 51 60 49 61
9
5
3
1
14
16
27
2
6
4
62
19
15
23
21
25
13
42 52,53 59 56,57 10,11

58
7,8 24 26 22 28 33 17 20 46 45 40 44 43

W2CG-03-02-003

1- Cover 17 - Planetary Gear 33 - Plug 48 - Casing
2- Sun Gear 18 - Carrier 34 - Sun Gear 49 - Casing
3- Ring 19 - Carrier Pin 35 - Ring 50 - Holder
4- Bearing 20 - Spacer 36 - Retaining Ring 51 - Seal Cover
5- O-ring 21 - Bearing 37 - Bearing 52 - Bolt
6- Plug 22 - Bearing 38 - Retaining Ring 53 - Washer
7- Bolt 23 - Retaining Ring 39 - Casing 54 - Socket Bolt
8- Washer 24 - Retaining Ring 40 - Planetary Gear 55 - O-Ring
9- Carrier Pin 25 - Retaining Ring 41 - Carrier 56 - Socket Bolt
10 - Socket Bolt 26 - Retaining Ring 42 - Carrier Pin 57 - Washer
11 - Washer 27 - Retaining Ring 43 - Spacer 58 - O-Ring
12 - Casing 28 - Plug 44 - Bearing 59 - Bearing
13 - Planetary Gear 29 - Bolt 45 - Retaining Ring 60 - Floating Seal
14 - Carrier 30 - Washer 46 - Retaining Ring 61 - Motor
15 - Carrier Pin 31 - Setscrew 47 - Bearing 62 - Spacer
16 - Sun Gear 32 - O-Ring

W3-2-12
Assemble Travel Mechanism (Reduction Gear)
1. Install the bearing (47) on the third stage carrier 13. Install the retaining ring (26) on the planetary gear
(41) and install the retaining ring (46). (17) and secure the bearing (22).
2. Insert the carrier pins (42) (5 used) into the third 14. Install the planetary gear (17) on the carrier pin
stage carrier (41). (19) and install the retaining ring (24).
3. Install the retaining ring (46) on the planetary gear 15. Insert the carrier pins (15) (3 used) on the first
(40) and install the bearings (44) (2 used). stage carrier (14).
4. Install the retaining ring (46) on the planetary gear 16. Install the retaining ring (25) on the planetary gear
(40) and secure the bearing (44). (13) and install the bearing (21).

5. Install the spacer (5) on the carrier pin (42). 17. Install the retaining ring (25) on the planetary gear
(13) and secure the bearing (21).
6. Install the planetary gear (40) on the carrier (42)
and install the retaining ring (45). 18. Install the planetary gear (13) on the carrier pin
(15) and install the retaining ring (23).
7. Install the bearing (37) on the sun gear (34) and
install the retaining ring (38).
19. Install the inner race of the bearing (59) at the seal
8. Install the retaining ring (36) on the sun gear (34) cover (51) of the casing (48).
and install the second stage carrier (18).
20. Install the O-ring (55) on the seal cover (51).
9. Install the retaining ring (36) on the sun gear (34)
and secure the second stage carrier (18). 21. Install the seal cover (51) of the casing (48) with
aligning the matching mark. Apply LOCTITE #242
10. Insert the carrier pins (19) (4 used) on the second on the socket bolts (56) (24 used) and tighten the
stage carrier (19). seal cover with the bolts and washers (57) (24
used).
: 10 mm
11. Install the spacer (20) on the carrier pin (19). : 122 to 128 Nm (12.4 to 13.0 kgfm)

12. Install the retaining ring (26) on the planetary gear NOTE: Apply LOCTITE #515 on the mating
(17) and install the bearing (22). surfaces of the casing (48) and seal cover
(51).
IMPORTANT: For handling the floating seal (60),

refer to the section “Floating Seal
Precautions” on page W1-1-3.
W3-2-13

12 18 35 32 39 34 41 50 48 51 60 49
3
1
14
16
27
2
62
52,53 59
7,8 40

W2CG-03-02-003
W3-2-14
22. Install the one side of the floating seal (60) on the 32. Lift the first stage carrier (14) assembly with the
seal cover (51) with using a bamboo spatula. crane. Mesh the first stage carrier (14) assembly
with the casing (12) and install.
23. Install the other side of the floating seal (60) on
the casing (49). 33. Install the retaining ring (27) on the second stage
sun gear (16) and mesh the second stage sun
NOTE: Apply the oil on the sliding surface of the gear (16) with the first stage carrier (14) and
floating seal (60) slightly. install.
24. Lift the casing (48) with the crane and turn over it. 34. Lift the third stage carrier (18) assembly with the
Install the casing (48) on the casing (49). crane. Mesh the second stage sun gear (16) with
the casing (12) and install.
25. Install the inner race of the bearing (59) on the
casing (48). 35. Install the ring (35) on the casing (12).
26. Install the holder (50) on the housing (49). Apply 36. Lift the third stage carrier (41) assembly with the
LOCTITE #242 on the bolts (52) (16 used) and crane. Mesh the third stage carrier (41) assembly
tighten the holder with the bolts and washers (53) with the second stage sun gear (34) and install.
(16 used).
: 30 mm NOTE: Insert the third stage carrier (41) assembly
: 597 to 628 Nm (60.8 to 64.0 kgfm) into the second stage sun gear (34) so that
the position to install the planetary gear
NOTE: Apply LOCTITE #515 on the mating (40) is located as the illustrated to align the
surfaces of the holder (50) and housing oil level position of the planetary bearing.
(49).

Third Stage Planetary Gear
27. Install the ring (3) on the cover (1). Carrier Pin
29. 29. Install the O-ring (5) on the cover (1).
30. Install the cover (1) on the casing (12). Apply

LOCTITE #242 on the bolts (7) (20 used) and
tighten the casing with the bolts and washers (8).
: 24 mm
Horizontal
: 219 to 230 Nm (22.3 to 23.4 kgfm)
NOTE: Apply LOCTITE #515 on the mating

surfaces of the casing (39) and casing (48).
31. Lift the casing (12) with the crane and turn over it.
Install the spacer (62) on the first stage sun gear
(2) and install the bearing (4).
Vertical
W2CG-03-02-005

37. Install the O-ring (32) on the casing (12).
W3-2-15

12 29,30 39 41 54 48 49 61
10,11
58
28

W2CG-03-02-003

W3-2-16
38. Lift the casing (39) with the crane. Mesh the
casing (39) with the planetary gear (4). Align the
matching mark of the casing (39) with the casing
(12). Mesh the casing (39) with the planetary gear
(4) and install.
39. Apply LOCTITE #242 on the holders (29) (29

used) and tighten it with the washer (30).
: 30 mm
: 597 to 628 Nm (60.8 to 64.0 kgfm)

surfaces of the casing (12) and casing (39).

40. Install the O-ring (58) on the casing (48).

41. Lift the casing (48) and casing (49) with the crane.
Align the matching mark of the casing (48) with
the casing (39). Mesh the casing (48) with the
third stage carrier (41) and install.

42. Apply LOCTITE #242 on the socket bolts (54) (2
used) and tighten.
: 19 mm
: 1629 to 1715 Nm (166.0 to 174.0 kgfm)

surfaces of the casing (39) and casing (48). 6
1
43. Lift the motor with the crane and install it with
matching mark with the casing (49). Apply
LOCTITE #242 on the socket bolts (10) (4 used)
and tighten with the washer (11).
: 14 mm
: 371 to 390 Nm (37.7 to 39.7 kgfm)
Horizontal
44. Install the plug (28) on the cover (1) and add the
gear oil through the oil filler port. Wrap the seal
tape on the plug (6) and install the plug (6) on the
cover (1).
Amount of gear oil: 35 L
: 30 mm, 32 mm
28
W2CG-03-02-004
W3-2-17
(Blank)
W3-2-18
LOWER MACINERY / Rotating Joint
REMOVE AND INSTALL ROTATING JOINT


2 3
Removal 4
1
5
1. Shutdown the engine. Operate the control lever 19
in the circuit.
18 6
2. Remove the hoses (1 to 19). 8
: 19, 22, 27, 36, 41, 50 mm 17 7
16
NOTE: Cap the hoses.
14
10 9
15 13
12 11
M2CN-03-03-001

3. Remove the bolt (20) (2 used) and remove the
23 21 20
plate (24).
: 24mm
22
24
plate (25).
: 24mm 25
CAUTION: Rotating joint (23) weight: Approx.

70 kg

5. Lift the rotating joint (23) with the crane and hold M2CN-03-03-002
it.

rotating joint (23) with hoisting the crane.
: 19 mm
W3-3-1
Installation

CAUTION: Rotating joint (23) weight: Approx.
70 kg
23 21 20
1. Lift the rotating joint (23) with the crane and install
it with the bolt (22) (4 used). 22
24
: 19 mm
: 72.0 to 78.0 Nm (6.4 to 8.0 kgfm)
2. Install the plate (24) on the revolving frame with 25

the bolt (20) (2 used).
: 24 mm
: 179.0 to 194.0 Nm (18.3 to 19.8 kgfm)

M2CN-03-03-002

3. Install the hoses (1 to 19).
: 19 mm
: 29.5 Nm (3.0 kgfm) 2 3
: 22 mm 4
1
: 39 Nm (4.0 kgfm)
5
: 27 mm 19
: 93 Nm (9.5 kgfm)
: 36 mm
: 175 Nm (18.0 kgfm) 18 6
: 41 mm 8
: 205 Nm (21.0 kgfm) 17 7
: 50 mm 16
14
10 9
15 13
12 11
M2CN-03-03-001
W3-3-2
(Blank)
W3-3-3
DISASSEMBLE ROTATING JOINT
1 9
3
2
10
11
5
12
7
13
14
15

W25N-03-03-003
1- Scraper 5- O-Ring 9- Seal (8 Used) 13 - Flange

2- O-Ring 6- Socket bolt (4 Used) 10 - O-Ring 14 - Plug
3- Socket bolt (6 Used) 7- Thrust Plate 11 - V-Ring 15 - Plug (4 Used)
4- Cover 8- Body 12 - Shaft
W3-3-4
Disassemble Rotating Joint

CAUTION: Rotating joint weight: Approx. 70

kg
1. Remove the socket bolts (3) (2 used) from the

cover (4) diagonally. Lift the rotating joint with
using the eyebolt (M10) and set it on the vise.
: 8 mm
2. Remove the remained socket bolts (3) (4 used)

and remove the cover (4).
: 8 mm
3. Remove the socket bolts (6) (4 used) and remove

the thrust plate (7).
: 8 mm
IMPORTANT: Take care not to damage the seal 2-I12Hole

sliding surface of the shaft (12). M20350
M20 Tap
4. Completely remove the shaft (12) from the body 2-M10u100
(180)
(8) with using the special tool (A). 151 40
5. Remove the V-ring (11) from the shaft (12).
30
6. Remove the seals (9) (8 used) and O-ring (10)
from the body (8).
57
I25
NOTE: The seal (9) can be removed easily with
using two pins.
12
Spacer
7. Remove the scraper (1), O-ring (2) and (5) from
the cover (4). Protection
Plate
Special Tool (A)

W25N-03-03-004
W3-3-5
ASSEMBLE ROTATING JOINT
2 1 3
7
5
6
10
11
13
12
14
15

W25N-03-03-005
1- Scraper 5- O-Ring 9- Seal (8 Used) 13 - Flange

2- O-Ring 6- Socket bolt (4 Used) 10 - O-Ring 14 - Plug
3- Socket bolt (6 Used) 7- Thrust Plate 11 - V-Ring 15 - Plug (4 Used)
4- Cover 8- Body 12 - Shaft
W3-3-6
Assemble Rotating Joint
IMPORTANT: When installing the seals, apply

grease or hydraulic oil slightly and
install on each groove. After
inserting, apply grease to the inside
(lip portion) of the scraper (1), O-ring
(1), (2) and seal (9).
1. Install the O-ring (2), (5) and scraper (1) on the

cover (4). Apply grease onto the lip part of O-ring
(11), dust seal (10) and seal (9).
I70 or More
NOTE: With using the special tool (B), install the
scraper (1) with using a press. I56
Press
2. Install the O-ring (10) and seal (9) (8 used) on the
body (8).
IMPORTANT: After installing the V-ring (11), apply
20
grease on the lip.
7
3. Install the V-ring (11) on the shaft (12).
1
4. Install the body (8) on the shaft (12) with using a Special Tool (B)
press. W25N-03-03-006
5. Install the thrust plate (7) with the socket bolt (6)
(4 used).
: 8 mm
: 52.0 to 56.8 Nm (5.3 to 5.8 kgfm)
6. Install the cover (4) and tighten with the socket

bolt (3) (6 used).
: 8 mm
: 52.0 to 56.8 Nm (5.3 to 5.8 kgfm)
W3-3-7
Item Allowable limit (Criterion for judgment) Remedy

Body / Shaft Sliding surface and Seizure or serious damage due to Replace
sealed part foreign material biting
Sliding surface of 1) Seizure or abnormal wear due to Replace
body and shaft foreign material biting and damage
except sealed part with 0.1mm or more in depth
2) Damage within 0.1mm in depth Repair and finish
with oil stone
Sliding surface 1) Wear 0.5mm or more and abnormal Replace
with thrust plate wear
2) Wear 0.5mm or less Repair and finish
3) Seizure or damage due to foreign Repair and finish
material biting is within wear limit
(0.5mm) and repairable
Cover Sliding surface 1) Wear 0.5mm or more Replace
with thrust plate 2) Wear 0.5mm or less Repair and finish
3) Seizure or damage due to foreign Repair and finish
material biting is within wear limit
(0.5mm) and repairable
W3-3-8
LOWER MACHINERY / Take-Up Tumbler
REMOVE AND INSTALL TAKE-UP
TUMBLER
• In this section, the procedure starts on the
premise that the track shoe has already been
removed.As for the removal and installation of the
crawler shoe, refer to the “REMOVE AND
INSTALL TRACK SHOE” on W3-6.
Removal
CAUTION: Take-up tumbler weight: 770 kg
1. Prize the take-up tumbler with using a bar and

remove the tumbler together with the bearing from M2CN-03-04-001
the side frame.

Take-Up Tumbler
2. Attach the wire rope on the take-up tumbler. Lift
the take-up tumbler assembly with the crane and
remove it from the side frame.
Bearing

W2CG-03-04-001

3. When storing the take-up tumbler temporarily,
place the take-up tumbler horizontally on the
wooden blocks as illustrated.
Installation
CAUTION: Take-up tumbler weight: 770 kg
IMPORTANT: Check the direction (front/rear) of the

bearing. Clean and apply grease on
the sliding portion of the side frame
and the bearing.

W2CG-03-04-002
1. Lift the take-up tumbler assembly and install it on
the side frame.
W3-4-1
DISASSEMBLE TAKE-UP TUMBLER
5
4
3 6 8
2 7

W2CG-03-04-003

1 - Take-Up Tumbler 3 - Shaft 5 - O-Ring (2 Used) 7 - Bearing (2 Used)
2 - Bushing (2 Used) 4 - Floating Seal (2 Used) 6 - Pin (2 Used) 8 - Plug (4 Used)
W3-4-2
Disassemble Take-Up Tumbler

1. Loosen the plug (8) and drain off the engine oil.
: 6 mm
2. Pull out the pin (6) from the bearing (7) and shaft
(3) with using a bar.
3. Pull out the shaft (3) from the bearing (7) with
using a press. At this time, the shaft (3) and the
bearing (7) are removed from the take-up tumbler
(1).

Precautions ” on page W1-1-3.
4. Remove the floating seal (4) from the take-up

tumbler (1) and bearing (7).
5. Pull out the shaft (3) from the bearing (7) with
using a press.
6. Remove the O-ring (5) from the shaft (3).
7. Remove the bushing (2) from the take-up tumbler

(1).
W3-4-3
ASSEMBLE TAKE-UP TUMBLER
5
4
3 6 8
2 7

W2CG-03-04-003

1 - Take-Up Tumbler 3 - Shaft 5 - O-Ring (2 Used) 7 - Bearing (2 Used)
2 - Bushing (2 Used) 4 - Floating Seal (2 Used) 6 - Pin (2 Used) 8 - Plug (4 Used)
W3-4-4
Assemble Take-Up Tumbler
1. Insert the bushing (2) into the take-up tumbler (1) 10. Apply LOCTITE #503 on the plug (8). Install the
with using a press. plug (8) on the bearing (7).
: 6 mm
2. Install the O-ring (5) on the shaft (3). Align the pin
(6) holes and install the shaft (3) on the bearing
(7).
3. Drive the pin (6) in the bearing (7) and shaft (3).

4. Install a pair of floating seals (4) on the take-up

5. Insert the shaft (3) into the take-up tumbler (1)

from the side that the floating seal (4) was
installed. Install the O-ring (5) on the shaft (3).
6. Install the other floating seals (4) on the take-up

7. Align the pin (6) holes and install the bearing (7)
on the shaft (3).
8. Drive the pin (6) in the bearing (7) and shaft (3).
9. Add the engine oil through the plug (8) hole of the
bearing (7).
Engine oil: Class CD, SAE 30
W3-4-5
Take-Up Tumbler
B A B

W2CG-03-04-004

Unit : mm
Standard Allowable Limit Remedy
A 110 ᧩
B 60 ᧩
Padding and
C 24 ᧩
finishing
D 912 902
E 270 ᧩
(Shaft/Bushing)
Unit : mm
Shaft Outer Dia. 180 179.2
Inner Dia. 180 181
Replace
Bushing Flange
10 ᧩
Thickness
W3-4-6
Drive Tumbler
A B

W2CG-03-04-005

Unit : mm
A 52.2 ᧩
B 105.6 ᧩ Padding and
C 210 ᧩ finishing
D 915.6 ᧩

• If the meshing condition of the drive tumbler and track shoe is faulty, pad and finish to the specified dimension.
W3-4-7
(Blank)
W3-4-8
LOWER MACHINERY / Carrier and Track Rollers
REMOVE AND INSTALL CARRIER
ROLLER(FRONT AND REAR) 1 2
• Remove the carrier roller on the level, solid
ground.
• Before removing the carrier roller, slightly travel
the machine forward. In case the slack of the
track shoe is located at the top of the drive
tumbler, the removing working is easy.
Removal
1. Remove the bolt (1) and remove the cover (2) 2 1

from the side frame.
M2CN-03-06-001
: 19 mm

4
2. Install the jack (4) on the bracket (3) of the side
frame. Tense the track shoe.
When
extending jack
3
When
releasing jack
M2CN-03-06-002

5 6 7
3. Remove the bolt (5) from the side frame and

remove the plate (6). Remove all shims (7). 6
: 24 mm
5
7

M2CN-03-06-003
W3-5-1
4. Remove the jack (4) and lift the track shoe until
the carrier roller (8) keeps away from the track
shoe.
Track Shoe
8

: 19 mm W2CG-03-05-001

CAUTION: Carrier roller (8) weight: 29.4 kg 8 9
6. Remove the carrier roller (8) from the side frame.
Installation
1. Install the carrier roller (8) on the side frame with

the bolt (9).
: 19 mm
: 60 to 64 Nm (6.1 to 6.6 kgfm)
NOTE: Install the carrier roller (8) with positioning

the plug side at the outside.

2. Lower the track shoe lifted with the crane and M2CN-03-05-002
adjust the tension of the track shoe.

NOTE: As for the tension adjustment of the track
shoe, refer to the “Install Track Roller”.
W3-5-2
(Blank)
W3-5-3
DISASSEMBLE CARRIER ROLLER (FRONT AND REAR)
1 2
11
10
12
7
5 4
8
5
7
10
4
3
12
11

6 W2CG-03-05-008

1 - Key Plate 4 - Bushing (2 Used) 7 - Wire (2 Used) 10 - Knock Pin (8 Used)
2 - Collar 5 - O-Ring (2 Used) 8 - Plug 11 - Floating Seal (2 Used)
3 - Roller 6 - Collar 9 - Shaft 12 - Thrust Plate (2 Used)
W3-5-4
Disassemble Carrier Roller (Front and Rear)

1. Loosen the plug (8) and drain off the engine oil.
: 8 mm
2. Remove the wires (7) (2 used) from the collars (2),

(6) and shaft (9) with using a bar.
3. Pull out the shaft (9) from the collars (2) and (6)
with using a press. At this time, the shaft (9) and
the collar (6) are pulled out from the roller (3).
4. Remove the thrust plates (12) (2 used) and knock

pin (10) (8 used) from the roller (3).

5. Remove two pairs of floating seal (11) from the

roller (3), collars (2) and (6).
6. Pull out the shaft (9) from the collar (6) with using
a press.
7. Remove the O-rings (5) (2 used) from the shaft

(9).
8. Remove the bushings (4) (2 used) from the roller

(3).
W3-5-5
ASSEMBLE CARRIER ROLLER (FRONT AND REAR)
12
1 11
10 9
7
6
2 4
5
3

W2CG-03-05-009

1 - Key Plate 4 - Bushing (2 Used) 7 - Wire (2 Used) 10 - Knock Pin (8 Used)
2 - Collar 5 - O-Ring (2 Used) 8 - Plug 11 - Floating Seal (2 Used)
3 - Roller 6 - Collar 9 - Shaft 12 - Thrust Plate (2 Used)
W3-5-6
Assemble Carrier Roller (Front and Rear)
1. Install the O-ring (5) on the shaft (9) and install the
shaft (9) on the collar (6).

2. Install the bushings (4) (2 used) on the roller (3).

3. Install a pair of floating seal (11) on the roller (3)

and collar (6).
4. Install the thrust plate (12) and knock pins (10) (4

used) at the side that the floating seal (11) of the
roller (3) was installed.
5. Insert the shaft (9) on the roller (3) with a press

from the side that the floating seal (11) was
installed and install the other O-ring (5) o the shaft
(9).
6. Install the other floating seal (11) on the roller (3)

and collar (2).
7. Install the thrust plate (12) and knock pins (10) (4

used) on the roller (3).
8. Install the collar (2) on the shaft (9).
9. Drive the wire (7) in the collars (2), (6) and shaft
(9).
shaft (9).
Engine oil amount: 30 to 40 cc
11. Apply LOCTITE #503 on the plug (8) and install

the plug (8) on the shaft (9).
: 8 mm
W3-5-7
Carrier Roller (Front and Rear)

B A B

W2CG-03-05-010
Unit : mm
Allowable
Standard Remedy
Limit
A 152 ᧩
Padding and finish
B 32 ᧩
or replace
C 241 231
(Shaft/Bushing)
Unit : mm
Allowable
Standard Remedy
Limit
Inner Dia. 45 46
Replace
Bushing Flange
᧩ ᧩
Thickness
W3-5-8
REMOVE AND INSTALL CARRIER
ROLLER (CENTER) 1 2
• Remove the carrier roller on the level, solid
ground.
• Before removing the carrier roller, slightly travel
the machine forward. In case the slack of track
shoe is located at the top of the drive tumbler, the
removing working is easy.
Removal
1. Remove the bolt (1) and remove the cover (2)

: 19 mm 2 1
M2CN-03-06-001
When
2. Install the jack (4) on the bracket (3) of the side extending jack
frame. Tense the track shoe (8).
3
When
releasing jack
M2CN-03-06-002


5 6 7
remove the plate (6). Remove all shims (7).
: 24 mm
7

M2CN-03-06-003
W3-5-9
4. Remove the jack (4) and lift the track shoe so that
the carrier roller (8) keeps away from the track
shoe.
Track Shoe
8

M2CN-03-05-003

8 9
: 24 mm
CAUTION: Carrier roller (8) weight: 18.4 kg
6. Remove the carrier roller (8) from the side frame.
Installation
1. Install the carrier roller (8) on the side frame with

the bolt (9).
: 24 mm
: 148 to 160 Nm (15.0 to 16.3 kgfm)
M2CN-03-05-004
2. Lower the track shoe lifted with the crane and

adjust the tension of the track shoe.

NOTE: As for the tension adjustment of the track

shoe, refer to the “Install Track Roller”.
W3-5-10
(Blank)
W3-5-11
DISASSEMBLE CARRIER ROLLER (CENTER)

1
3 5
4 6
10
11
W2CG-03-05-011

1 - Retaining Ring 4 - Socket Bolt (3 Used) 7 - O-Ring 10 - Floating Seal
2 - Roller 5 - Cover 8 - Bushing 11 - Collar
3 - Plug 6 - Thrust Plate 9 - Shaft
W3-5-12
Disassemble Carrier Roller (Center)

1. Loosen the plug (3). Drain off the engine oil.

: 6 mm
2. Remove the retaining ring (1) and cover (5) from

the roller (2).
3. Remove the O-ring (7) from the cover (5).

remove the thrust plate (6) from the shaft (9).
: 6 mm
5. Pull out the shaft (9) from the collar (11) with
using a press. At this time, the shaft (9) and the
collar (11) are removed from the roller (2).

6. Remove the floating seal (10) from the roller (2)

and collar (11).
7. Pull out the shaft (9) from the collar (11) with
using a press.
8. Remove the bushing (8) from the roller (2).
W3-5-13
ASSEMBLE CARRIER ROLLER (CENTER)
7 8 9 10 11

W2CG-03-05-012

1 - Retaining Ring 4 - Socket Bolt (3 Used) 7 - O-Ring 10 - Floating Seal
2 - Roller 5 - Cover 8 - Bushing 11 - Collar
3 - Plug 6 - Thrust Plate 9 - Shaft
W3-5-14
Assemble Carrier Roller (Center) IMPORTANT: Assemble so that the drill hole (6
mm) of the thrust plate (6) aligns
1. Insert the bushing (8) into the roller (2) with using with the groove of the shaft (9).
a press.
Drill Hole (6 mm)
IMPORTANT: Assemble the shaft (9) and collar (11) Thrust Plate (6)
with using a press. The dimension
between the shaft (9) and the collar
(11) is 86.2 s 0.2 mm. When
inserting with using a press, take
care not to damage the seal housing
of the collar (11).
Collar (11)
86.2s0.2 mm
Shaft (9)

W2CG-03-05-014

5. Install the thrust plate (6) on the shaft (9). Apply
LOCTITE #262 on the socket bolts (4) (3 used)
and tighten.
: 6 mm
: 20 Nm (2.0 kgfm)

Shaft (9) W2CG-03-05-013
6. Install the O-ring (7) on the cover (5).

2. Insert the shaft (9) into the collar (11) with using 7. Install the cover (5) on the roller (2) and install
a press. the retaining ring (1).
IMPORTANT: For handling the floating seal (10), 8. Add the engine oil through the plug (3) hole of
refer to the section “Floating Seal the cover (5)
Precautions” on page W1-1-3. Engine oil: Class CD, SAE 30
Engine oil amount: Approx. 50 cc
3. Install the floating seal (10) on the roller (2) and
collar (11). 9. Apply LOCTITE #503 on the plug (3) and install
4. Insert the shaft (9) into the roller (2) with using a : 6 mm
press.
W3-5-15
Carrier Roller (Center)

A

W2CG-03-05-015

Unit : mm
Allowable
Standard Remedy
Limit
A 65.5 ᧩ Padding and finish
B 150 ᧩ or replace
(Shaft/Bushing)
Unit : mm
Allowable
Standard Remedy
Limit
Shaft Outer Dia. 60 ᧩
Inner Dia. 60 ᧩
Replace
Bushing Flange
᧩ ᧩
Thickness
W3-5-16
LOWER MACHINERY / Carrier and Track Rollers (To Machine No. 5)
REMOVE AND INSTALL TRACK ROLLER
1 2
• Remove the track roller on the level, solid ground.
Remove the track roller with the swing machinery
parallel to the track shoe.
• Before removing the track roller, slightly travel the
machine forward. In case the slack of the track
Removal
1. Remove the bolt (1). Remove the cover (2) from

the side frame. 2 1
: 19 mm
M2CN-03-06-001

4
When
extending jack
3
When
releasing jack
M2CN-03-06-002

5 6 7
: 24 mm
4. Remove the jack (4) and loosen the track shoe

with carrying out the travel operation.
7

M2CN-03-06-003
W3-5-17
: 36 mm

6. Extend the jack-up cylinder (9). Jack up until the

track roller (10) keeps away from the track shoe.
10
8 9

M2CN-03-05-005
CAUTION: Track roller (10) weight: 133.4 kg
7. Remove the track roller (10) from the track shoe

with using a bar. Lift it with the crane and remove 10
the track roller (10).

W2CG-03-05-006
W3-5-18
Installation

CAUTION: Track roller (10) weight: 133.4 kg
1. Lift the track roller (10) and install the track roller
10
(10) on the bottom of the side frame.
2. Retract the jack-up cylinder (9). Track the

machine to the extent that the collar of track roller
(10) may keeps a little away from the side frame.
3. Align the bolt holes. Apply the grease containing

molybdenum disulfide on the bolt (8) and tighten
the bolt (8).
: 36 mm
: 605 to 655 Nm (61.7 to 66.8 kgfm)
W2CG-03-05-006
4. When removing the bolts except the bolt (8)

mounting holes (8 places) of the side frame,

waterproof the mounting holes with pouring the
silicon sealant from the upside.

8

M2CN-03-05-006
W3-5-19
5. Retract the jack-up cylinder (9) completely. Group “B”
4 6 5 7 8
IMPORTANT: Tense the track shoe to the specified
dimension.

When
extending jack
IMPORTANT: Adjust so that the shaft of the
take-up tumbler becomes parallel.
7. Install the shim (7) on the side frame. Insert the

shim selected from the group “B” into the
clearance if there is any clearance. 3
When
releasing jack

M2CN-03-06-002
8. Install the plate (6) on the side frame with the bolt
(5) and secure the shim (7).
: 24 mm
: 148 to 160 Nm (15.0 to 16.3 kgfm)

9. Remove the jack (4).

10. Install the cover (2) on the side frame with the bolt
(1). 1 2
: 19 mm
: 60 to 64 Nm (6.1 to 6.6 kgfm)

2 1
M2CN-03-06-001
W3-5-20
(Blank)
W3-5-21
DISASSEMBLE TRACK ROLLER 6

4
3
3
4

W2CG-03-05-016
6

1 - Bushing (2 Used) 3 - Floating Seal (2 Used) 5 - Shaft 7 - Wire (2 Used)
2 - Roller 4 - O-Ring (2 Used) 6 - Collar (2 Used) 8 - Plug (2 Used)
W3-5-22
Disassemble Track Roller


: 6 mm
2. Remove the wire (7) from the collar (6) and shaft
a press. At this time, the shaft (5) and collar (6)
are removed from the roller (2).


roller (2) and collar (6).
a press.

(5).

(2).
W3-5-23
ASSEMBLE TRACK ROLLER

7 6 4
3 1 5 2
W2CG-03-05-017

W3-5-24
Assemble Track Roller
1. Insert the bushings (1) (2 used) into the roller (2).


and collar (6).
4. Insert the shaft (5) into the roller (2) from the side
that the floating seal (3) was installed and install
the other O-ring (4) ton the shaft (5).
5. Install the other pair of floating seal (3) on the

7. Install the wire (7) on the collar (6) and shaft (5).
collar (6).

the plug (8) on the collar (6).
: 6 mm
W3-5-25
Track Roller
B A B

W2CG-03-05-018
Unit : mm
Allowable
Standard Remedy
Limit
A 100 ᧩
B 82.5 ᧩ Padding and finish
C 25 ᧩ or replace
D 330 320
(Shaft/Bushing)
Unit : mm
Allowable
Standard Remedy
Limit
Inner Dia. 100 101
Replace
Bushing Flange
᧩ ᧩
Thickness
W3-5-26
LOWER MACHINERY / Carrier and Track Rollers (Machine No. 6 and after)
REMOVE AND INSTALL TRACK ROLLER
1 2
• Remove the track roller on the level, solid ground.
Remove the track roller with the swing machinery
parallel to the track shoe.
• Before removing the track roller, slightly travel the
Removal
1. Remove the bolt (1). Remove the cover (2) from

the side frame. 2 1
: 19 mm
M2CN-03-06-001

4
When
extending jack
3
When
releasing jack
M2CN-03-06-002

5 6 7
: 24 mm
4. Remove the jack (4) and loosen the track shoe

with carrying out the travel operation.
7

M2CN-03-06-003
W3-5-27
: 50 mm

6. Extend the jack-up cylinder (9). Jack up until the

track roller (10) keeps away from the track shoe.
10
8 9

M2CN-03-05-005
CAUTION: Track roller (10) weight: 138 kg
7. Remove the track roller (10) from the track shoe

with using a bar. Lift it with the crane and remove 10
the track roller (10).

W2CG-03-05-006
W3-5-28

Installation

CAUTION: Track roller (10) weight: 138 kg

10
1. Lift the track roller (10) and install the track roller
(10) on the bottom of the side frame.
2. Retract the jack-up cylinder (9). Lower the

machine to the extent that the collar of track roller
(10) may keeps a little away from the side frame.
3. Align the bolt holes. Apply the grease containing

molybdenum disulfide on the bolt (8) and tighten
the bolt (8).
: 50 mm
: 1640 to 1770 Nm (167.0 to 181.0 kgfm) W2CG-03-05-006

4. When removing the bolts except the bolt (8)

mounting holes (8 places) of the side frame,
waterproof the mounting holes with pouring the
silicon sealant from the upside.

8

M2CN-03-05-007
W3-5-29
5. Retract the jack-up cylinder (9) completely. Group “B”
4 6 5 7 8
IMPORTANT: Tense the track shoe to the specified
dimension.

When
extending jack
IMPORTANT: Adjust so that the shaft of the
take-up tumbler becomes parallel.
7. Install the shim (7) on the side frame. Insert the

shim selected from the group “B” into the
clearance if there is any clearance. 3
When
releasing jack

M2CN-03-06-002
: 24 mm
: 148 to 160 Nm (15.0 to 16.3 kgfm)


(1). 1 2
: 19 mm
: 60 to 64 Nm (6.1 to 6.6 kgfm)

2 1
M2CN-03-06-001
W3-5-30
(Blank)
W3-5-31
DISASSEMBLE TRACK ROLLER 6

4
3
7
8
2
3
4

M2CN-03-05-008
6

W3-5-32
Disassemble Track Roller


: 6 mm
2. Remove the wire (7) from the collar (6) and shaft
a press. At this time, the shaft (5) and collar (6)
are removed from the roller (2).


a press.

(5).

(2).
W3-5-33
ASSEMBLE TRACK ROLLER

8
7 6 4
3 1 5 2
M2CN-03-05-009

W3-5-34
Assemble Track Roller
1. Insert the bushings (1) (2 used) into the roller (2).


and collar (6).
4. Insert the shaft (5) into the roller (2) from the side
that the floating seal (3) was installed and install
the other O-ring (4) ton the shaft (5).
5. Install the other pair of floating seal (3) on the

7. Install the wire (7) on the collar (6) and shaft (5).
collar (6).

the plug (8) on the collar (6).
: 6 mm
W3-5-35
Track Roller

B A B

M2CN-03-05-010
Unit : mm
Allowable
Standard Remedy
Limit
A 100 ᧩
B 82.5 ᧩ Padding and finish
C 25 ᧩ or replace
D 330 320
(Shaft/Bushing)
Unit : mm
Allowable
Standard Remedy
Limit
Inner Dia. 100 101
Replace
Bushing Flange
᧩ ᧩
Thickness
W3-5-36
LOWER MACHINERY / Track Shoe
REMOVE AND INSTALL TRACK SHOE 1 2
• Remove and install the track shoe with the right

procedures safely to prevent an unexpected
serious accident.
• Remove the track shoe on the level, solid ground.
Remove and install the cylinder with the swing
machinery with parallel to the track shoe.
• Before removing the track shoe, slightly travel the
removing working can be done easily.
Removal 2 1

M2CN-03-06-001
1. Remove the bolt (1) and remove the cover (2)
: 19 mm 4

frame. Tense the track shoe (8). When
extending jack
When 3
releasing jack
M2CN-03-06-002

3. Remove the bolt (5) from the side frame and 5 6 7
: 24 mm
7
M2CN-03-06-003
5. Remove the bolt (9) and nut (10) from the track
shoe (8).
8
: 30 mm
9
10
CAUTION: Place the wooden block under the
track shoe (8) and pull out the joint pin (11) 11
after securing the track shoe (8).
6. Pull out the joint pin (11) from the track shoe (8)
with using a bar.
W333-03-07-001
W3-6-1

7. Operate the travel lever backward slowly. Extend
the track shoe (8).
8
CAUTION: Track shoe weight: 3830 kg
8. Jack up the machine with extending the jack-up

cylinder (12) and extend the track shoe (8).

M2CN-03-06-004

Installation
CAUTION: Track shoe weight: 3830 kg
IMPORTANT: Check the direction of the track

shoe.
1. Jack up the machine with extending the jack-up

cylinder (12). Place the track shoe (8) under the
machine so that the drive tumbler can mesh with 12
the end of track shoe (8).
M2CN-03-06-005
2. Lift the track shoe (8) with the crane and mesh the
track shoe (8) with the drive tumbler.
3. With the machine jacked up, slowly operate the Drive Take-Up
travel lever that the track shoe (8) is installed Tumbler Side Tumbler Side
forward. Install the track shoe (8) with turning the
drive tumbler.
M2CN -03-06-006
4. When the connecting part of the track shoe (8)

reaches the take-up tumbler side, lower the
machine. Insert the wooden blocks under the
track shoe (8).

M2CN -03-06-007
Wooden Block
W3-6-2

CAUTION: When aligning the joint pin (11)
hole of the track shoe, do not insert the
fingers into the hole.
5. Align the joint pin (11) hole on the track shoe (8)
and drive in the joint pin (11). 8
9
6. Install the bolt (9) and nut (10) on the joint pin (11).
: 30 mm 10
: 288 to 312 Nm (29.4 to 31.8 kgfm)
11
7. Spot-weld the bolt (9) and nut (10).

W333-03-07-001

Group “B”

IMPORTANT: Tense the track shoe (8) to the 4 6 5 7 8
specified dimension.

frame. Tense the track shoe (8).
When
extending jack
IMPORTANT: Adjust the shaft of the take-up
tumbler parallel.
9. Install the shim (7) on the side frame. If there is

any clearance, insert the shim selected from
3
group “B” into the clearance. When
releasing jack M2CN -03-06-002
: 24 mm
: 148 to 160 Nm (15.0 to 16.3 kgfm)

11. Remove the jack (4). 1 2
(1).
: 19 mm
: 60 to 64 Nm (6.1 to 6.6 kgfm)
2 1
M2CN -03-06-001
W3-6-3
Shoe
G
C
B
I
E

M2CN -03-06-008
Unit: mm
A 110 ᧩
B 70 ᧩
C 100 ᧩
D 15 ᧩
Padding and
E 70 ᧩
finishing or replace
F 158 ᧩
G 58 ᧩
H 56.5 ᧩
I 26.75 ᧩
ዘIf the meshing condition of the drive tumbler and track shoe is faulty, pad and finish to the specified value or
sreplace.
Joint Pin

B W324-03-07-004
Unit: mm
A 55 ᧩
Replace
B 370 ᧩
W3-6-4
LOWER MACINERY / Cylinder
REMOVE AND INSTALL SIDE FRAME
CONNECTING CYLINDER

Removal 3
1. Remove the crawler. (As for the removal of the

crawler, refer to the Operator’s Manual.)
CAUTION: Side frame connecting cylinder

weight: 431 kg
2. Attach the wire rope on the side frame connecting

cylinder (1) and support it with the crane.
3. Remove the hoses (2) (2 used) from the side

frame connecting cylinder (1). Attach the plug on 5
4
the removed hoses.
1
: 22 mm
4
4. Remove the bolt (4) (10 used) and remove the 5
side frame connecting cylinder (1).
M2CN-03-07-001
: 30 mm

8 7 6
covers (8) and (9).
: 17 mm
13
6. Remove the split pin (10) and remove the washer 11
(17).
1
7. Remove the pin (12) and separate the pin (13) 11 7
15 12 9 6
from the cylinder (1).
11
10 10
11 10
10 14

M2CN-03-07-002
W3-7-1
Installation

1. Insert the pin (13) into the brackets (14) and (15). 8 7 6
Connect the cylinder (1) to the pin (13) and insert
the pin (12).
2. Install the washer (11) on the pin (12) and insert 13

11
the split pin (10).
1
3. Install the covers (8) and (9) on the brackets (14) 11 7
and (15) with the bolt (6) (10 used) and washer 15 12 9 6
(7).
: 17 mm
: 34.0 to 37.0 Nm (3.5 to 3.8 kgfm) 11
10 10
CAUTION: Side frame connecting cylinder

weight: 431 kg 11 10
10 14
4. Lift the side frame connecting cylinder (1) with the
crane and install it on the side frame with the bolt
(4) (10 used) and washer (5).
M2CN-03-07-002
: 30 mm
: 288.0 to 312.0 Nm (29.4 to 31.8 kgfm)
5. Connect the hose (2) (2 used) to side frame

connecting cylinder (1).
: 22 mm 2
: 39 Nm (4.0 kgfm)
3
5
4
1
4
5

M2CN-03-07-001
W3-7-2
(Blank)
W3-7-3
DISASSEMBLE SIDE FRAME CONNECTING CYLINDER
1
2
5
6
3
7
4
8
9
12
16
14
17
13
15
11

W2CG-03-07-003

1- Retaining Ring 6- Packing 10 - Piston Rod 14 - Piston Seal
2- Dust Seal 7- Bushing 11 - Cylinder Tube 15 - Wear Ring
3- Cylinder Head 8- Backup Ring 12 - O-Ring 16 - Setscrew
4- O-Ring 9- O-Ring 13 - Piston 17 - Steel Ball
5- Backup Ring
W3-7-4
Disassemble Side Frame Connecting Cylinder
• Thoroughly read “PRECAUTIONS FOR 10. Remove the O-rings (4), (9) and backup ring (8)
DISASSEMBLING AND ASSEMBLING” (W1-1-1) from the outside of the cylinder head (3).

horizontally. Drain off the hydraulic oil in the
cylinder.

cylinder tube (11).

(11).
4. Secure the piston rod (10) horizontally. Remove

the setscrew (16) and steel ball (17) from the
piston (13).
: 17 mm

rod (10).

7. Remove the O-ring (12) from the inside of the

piston (13).

piston rod (10).
9. Remove the retaining ring (1), dust seal (2),

backup ring (5), packing (6) and bushing (7) from
the inside of the cylinder head (3).
W3-7-5
ASSEMBLE SIDE FRAME CONNECTING CYLINDER
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

W2CG-03-07-004

1- Retaining Ring 6- Packing 10 - Piston Rod 14 - Piston Seal
2- Dust Seal 7- Bushing 11 - Cylinder Tube 15 - Wear Ring
3- Cylinder Head 8- Backup Ring 12 - O-Ring 16 - Setscrew
4- O-Ring 9- O-Ring 13 - Piston 17 - Steel Ball
5- Backup Ring
W3-7-6
Assemble Side Frame Connecting Cylinder
1. Install the dust wiper (2), retaining ring (1), 10. Tighten the cylinder head (3) to the cylinder tube
bushing (7), packing (6) and backup ring (6) on (11).
the inside of the cylinder head (3) in order. : 750 to 916 Nm (76.5 to 93.5 kgfm)
2. Install the backup ring (8) and O-rings (9) and (10)
on the outside of the cylinder head (3) in order.
3. Install the wear ring (15) and piston seal (14) on

the outside of the piston (13) in order.

(13).

piston rod (10).
6. Secure the piston rod (10) assembly horizontally

and install the piston (13) assembly on the piston
rod (16).
: 970 to 1186 Nm (99.0 to 121.0 kgfm)
7. Install the steel ball (17) and setscrew (16) on the

piston (13).
: 17 mm
: 22 to 27 Nm (2.3 to 2.8 kgfm)
8. Clamp the cylinder tube (11) in a vise. Support

one side on the workbench and secure the
cylinder tube (11) horizontally.

with aligning with the center of
rings.
9. Insert the piston rod (10) assembly into the

cylinder tube (11).
W3-7-7
(Blank)
W3-7-8
LOWER MACHINERY / Cylinder
REMOVE AND INSTALL JACK-UP
CYLINDER

CAUTION: Remove and install the cylinder
on the level, solid ground.
Escaping fluid under pressure may penetrate
the skin and eyes, and cause serious injury.
Release the pressure before removing the
hydraulic or other lines.
spout and cause severe burns. Wait for oil in 4
5
Removal 3
1. Place the wooden block under the lower frame 2

and lower the lower frame on the wooden block.
2. Operate the jack switch and retract the jack

cylinder to the stroke end.
3. Shutdown the engine. Operate the jack switch on

the switch box several times and release the
6
4. Remove the wing bolt (4) (2 used) and washer (5) 6
that secures the jack beam (1) and cylinder cover
(3).
1
IMPORTANT: Hitting the quick coupling may be
damaged. Handle carefully.

5. Remove the hoses (6) (2 used) from the cylinder M2CN-03-07-003
(2).
: 22 mm
NOTE: Cap the removed hoses. Attach an

identification tag for assembling.
W3-7-9
CAUTION: Jack-up cylinder (7) weight: 365

kg
6. Support the jack-up cylinder (7) with tan assist

crane. Remove the split pin (8), bolts (9), pins (10)
and (11) and remove jack-up cylinder (7). 10 7
: 17 mm
8
11

M2CN-03-07-004

7. Place the jack-up cylinder (7) horizontally and

remove the bolts (12) (4 used) and washer (13) (4
used). Remove the cylinder (2) from the jack
beam (1).
: 14 mm
1
8. Drain off the hydraulic oil in the cylinder (2).
2
9. Remove the other jack-up cylinder (3 places) with
the same manners. 13 12

M2CN-03-07-005
W3-7-10
Installation
1. Insert the valve side of the cylinder (2) into the

bottom of the jack beam (1) and install it with the
washer (13) (4 used) and bolts (12) (4 used).
: 14 mm
: 210 Nm (21.5 kgfm)
1
2
13 12

M2CN-03-07-005
CAUTION: Jack-up cylinder (7) weight: 365

kg 14 10 7
2. Lift the jack-up cylinder (7) with an assist crane. 8

Install it on the lower frame (14) with the pins (10)
and (11) and secure with the split pin (8) , bolts
(9).
: 17 mm
: 34 to 37 Nm (3.5 to 3.8 kgfm)
NOTE: The numbers (1 to 4) are indicated on the

jack-up cylinder (7) and lower frame (14). 9
Install the jack-up cylinder (7) at the
position that the number is matched. 11
The position to secure the jack-up cylinder
(7) is the follows (3 places).
“When retracting the side frame”, “When M2CN-03-07-004
disassembling/assembling the side frame

while working” and “When transporting”.
W3-7-11

IMPORTANT: Remove the dust attached on the 4
coupling and clean before 5
connecting the quick coupling.
Hitting the quick coupling may be 3
damaged. Handle carefully.
Securely connect the hydraulic 2
hose.
3. Connect hoses (6) (2 used) to the cylinder (2).

: 22 mm
: 39 Nm (4.0 kgfm)
4. Install the cylinder cover (3) on the jack beam (1)

with the washer (5) and wing bolt (4) (2 used).
6
5. Install the other jack-up cylinder (3 places) with 6
the same manners.

M2CN-03-07-003
W3-7-12
(Blank)
W3-7-13
DISASSEMBLE JACK-UP CYLINDER
12
23
24
27
25
19 28
20 26
17 18
29
16 31
15 30
14
21 7
22 6
4
11
10
9
8
2
1
13

M2CN-03-07-006

1- Retaining Ring 9 - Rod Packing 17 - Piston Packing 25 - Double Pilot Check Valve
2- Dust Seal 10 - Plate 18 - Piston 26 - Manifold
3- Cylinder Head 11 - Retaining Ring 19 - Setscrew 27 - O-Ring
4- O-Ring 12 - Cylinder Tube 20 - Steel Ball 28 - Plug
5- Bushing 13 - Piston Rod 21 - Steel Ball 29 - Bolt
6- Backup Ring 14 - O-Ring 22 - Setscrew 30 - Piston Packing
7- O-Ring 15 - Bearing Plane 23 - Roll Pin 31 - Backup Ring
8- Backup Ring 16 - Backup Ring 24 - Plug
W3-7-14
Disassemble Jack-Up Cylinder
• Thoroughly read “PRECAUTIONS FOR 10. Remove the piston packings (17), (30), backup
DISASSEMBLING AND ASSEMBLING” (W1-1-1) rings (16), (31) and bearing plane (15) from the
before disassembling outside of the piston (18).
CAUTION: Cylinder weight: 190 kg 11. Remove the O-ring (14) from the inside of the
piston (18).
manifold (26) and double pilot check valve (25)
from the cylinder tube (12).
: 5 mm
2. Remove the O-rings (27) (2 used) from the

manifold (26).
3. Remove the roll pin (23) from the cylinder tube

(12).

cylinder tube (12).
5. Remove the O-rings (4), (7) and backup ring (6).
6. Remove the dust seal (2), retaining ring (1), rod

packing (9), backup ring (8), retaining ring (11),
plate (10) and bushing (5) from the inside of the
cylinder head (3).
CAUTION: Remove piston rod (13) from

cylinder tube (14) straightly in order not to
damage the sliding surface.
(12).

remove the setscrews (19), (22), steel balls (20)
and (21) from the piston (18).
: 17 mm

rod (13).
W3-7-15
ASSEMBLE JACK-UP CYLINDER

18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3
19 2
20
1
21
22
30
31
23 29
28
24 25 26 27

M2CN-03-07-007

1- Retaining Ring 9 - Rod Packing 17 - Piston Packing 25 - Double Pilot Check Valve
2- Dust Seal 10 - Plate 18 - Piston 26 - Manifold
3- Cylinder Head 11 - Retaining Ring 19 - Setscrew 27 - O-Ring
4- O-Ring 12 - Cylinder Tube 20 - Steel Ball 28 - Plug
5- Bushing 13 - Piston Rod 21 - Steel Ball 29 - Bolt
6- Backup Ring 14 - O-Ring 22 - Setscrew 30 - Piston Packing
7- O-Ring 15 - Bearing Plane 23 - Roll Pin 31 - Backup Ring
8- Backup Ring 16 - Backup Ring 24 - Plug
W3-7-16
Assemble Jack-Up Cylinder
9. Install the roll pin (23) on the cylinder tube (12).
(18). 10. Install the O-rings (27) (2 used) on the manifold
(26).
2. Install the bearing plane (15), piston packings (17),
(30), backup rings (16) and (31) on the outside of 11. Install the double pilot check valve (25) and
the piston (18). manifold (26) on the cylinder tube (12) and install
the bolts (29) (4 used).
3. Install the piston (18) assembly on the piston rod : 5 mm
(13).
: 735 to 784 Nm (75.0 to 80.0 kgfm)
4. Apply ThreeBond #1305 on the setscrews (19)

and (22) and install the steel balls (20), (21),
setscrews (19) and (22). Caulk the setscrews (19)
and (22) (2 places) with using a punch.
: 17 mm
: 17.6 to 21.6 Nm (1.8 to 2.2 kgfm)

with aligning with the center of the
rings.
5. Secure the cylinder tube (12) horizontally and

insert the piston rod (13) assembly.
6. Install the bushing (5), plate (10), retaining ring

(11), rod packing (9), backup ring (8), retaining
ring (1) and dust seal (2) on the inside of the
cylinder head (3).
7. Install the backup ring (6), O-rings (7) and (4) on

the outside of the cylinder head (3).

cylinder tube (12).
: 637 to 686 Nm (65.0 to 70.0 kgfm)
W3-7-17
(Blank)
W3-7-18
REMOVE AND INSTALL TRACK SHOE
TENSION CYLINDER


Removal

1. Remove the take-up tumbler. (As for the removal
of the take-up tumbler, refer to W3-4 in this
section.)

2. Remove the bolt (3) and remove the front cover
(2) from the side frame (1).
2
: 19 mm 4
3. Remove the hose (6) from the tension cylinder (5). 3

Attach the plug on the removed hose. 8
: 19 mm 9 1
7
4. Remove the bolt (8) of the plate (7) and remove
the tension cylinder (5) from the side frame (1).
: 24 mm

Installation
6
1. Install the tension cylinder (5) on the side frame
(1) and install the plate (7) with the bolt (8) and
washer (9).
: 24 mm
: 179 to 194 Nm (18.3 to 19.8 kgfm)
5 9
2. Connect the hose (6) to the tension cylinder (5). 7 8
: 19 mm
:29.5 Nm (3.0 kgfm)
M2CN-03-07-008
3. Install the front cover (2) on the side frame (1) with
the bolt (3) and washer (4).
: 19 mm
: 72 to 78 Nm (7.4 to 8.0 kgfm)
W3-7-19
DISASSEMBLE TRACK SHOE TENSION CYLINDER
2
1
3
5
6
7

M2CN-03-07-009
1 - Washer 4 - Piston 6 - Dust Seal 8 - O-Ring

2 - Bolt 5 - Retaining Ring 7 - Backup Ring 9 - Cylinder Tube
3 - Cylinder Head
W3-7-20
Disassemble Track Shoe Tension Cylinder
CAUTION: Cylinder weight: 71 kg

horizontally. Drain off the hydraulic oil in the
cylinder.
2. Remove the bolts (2) (4 used) and washers (1) (4

used) and remove the cylinder head (3) assembly
from the cylinder tube (9).
: 13 mm
3. Remove the retaining ring (5) from the inside of

the cylinder head (3).
CAUTION: Pull out the piston (4) straightly

not to damage the sliding surface.
4. Pull out the piston (4) from the cylinder tube (9).
5. Remove the dust seal (6), O-ring (8) and backup

ring (7) from the inside of the cylinder tube (9).
W3-7-21
ASSEMBLE TRACK SHOE TENSION CYLINDER
4 5 6 7 8 9

M2CN-03-07-010
1 - Washer 4 - Piston 6 - Dust Seal 8 - O-Ring

2 - Bolt 5 - Retaining Ring 7 - Backup Ring 9 - Cylinder Tube
3 - Cylinder Head
W3-7-22
Assemble Track Shoe Tension Cylinder
1. Apply Veseline on the O-ring (8) and dust seal (6)

and install the O-ring (8), backup ring (7) and dust
seal (6) on the cylinder tube (9).
IMPORTANT: Insert the piston (4) straightly with

aligning with the center of the
rings.
2. Apply Veseline on the outer surface of the piston

(4) and insert the piston (4) into the cylinder tube
(9).
3. Install the retaining ring (5) on the inside of the

cylinder head (3).
4. Install the cylinder head (3) on the cylinder tube

(9).
5. Install the washers (1) (4 used) and bolts (2) (4

used) on the cylinder head (3) assembly.
: 13 mm
: 15.7 to 17.7 Nm (1.6 to 1.8 kgfm)
W3-7-23
(Blank)
W3-7-24
LOWER MACHINERY / Control Valve
VALVE

Removal

1. Remove all hoses and wiring connectors from the
control valve (1).
: 22 mm, 27 mm
NOTE: Cap the removed hoses. Attach an

identification tag for assembling.
1
2. Remove the bolt (2) from the control valve (1) and
remove the control valve (1).
: 17mm
Installation 2

bolt (2). M2CN-03-08-001
: 17mm
: 34.0 to 37.0 Nᨿm (3.5 to 3.8 kgfᨿm)
2. Install all hoses and wiring connectors on the

control valve (1).
: 22 mm
: 27 mm

oil level. Check for any oil leaks.
W3-8-1
12,13 1,25,26
14,15,16,17 18,19,20,21
2,25,26
3,25,26
4,25,26
24 22 23
11 10 8 6 5 9 7

W25N-03-08-002
1- Block 8- Bolt (2 Used) 15 - O-Ring (2 Used) 21 - O-Ring

2- Block (4 Used) 9- Bolt (2 Used) 16 - O-Ring 22 - Solenoid Valve (12 Used)
3- Block 10 - Nut (8 Used) 17 - O-Ring 23 - Plate (6 Used)
4- Block 11 - Washer (8 Used) 18 - Reducing Valve 24 - Socket Bolt (36 Used)
5- Plate 12 - Plug 19 - O-Ring 25 - O-Ring (14 Used)
6- Foot (2 Used) 13 - Filter 20 - O-Ring 26 - O-Ring (7 Used)
7- Spacer (2 Used) 14 - Relief Valve
W3-8-2
7. Divide the blocks into (1), (2) (4 used), (3) and (4).
• Thoroughly rear “PRECAUTIONS FOR
DISASSEMBLING AND ASSEMBLING” (W1-1-1) 8. Remove the O-rings (25) (14 used) and (26) (7
before disassembling. used) from each block.
CAUTION: Control valve weight: 25 kg

workbench.

2. Remove the relief valve (14) from the block (1)

and remove the O-rings (15) (2 used), (16) and
(17).
: 27 mm

the reducing valve (18).
3. Remove the reducing valve (18) from the block

(1) and remove the O-rings (19), (20) and (21).
: 27 mm
4. Remove the plug (12) from the block (1) and

remove the filter (13).
: 8 mm

5. Remove the socket bolt (24) and remove the plate

(23) and solenoid valves (22) (2 used) from the
blocks (2) (4 used), (3) and (4).
: 3 mm
6. Remove the nut (10) and remove the bolts (8) (2

used), (9) (2 used), foots (6) (2 used), plate (5)
and spacers (7) (2 used).
: 13 mm
W3-8-3
12,13 1,25,26
14,15,16,17 18,19,20,21
2,25,26
3,25,26
4,25,26
24 22 23
11 10 8 6 5 9 7

W25N-03-08-002
1- Block 8- Bolt (2 Used) 15 - O-Ring (2 Used) 21 - O-Ring

2- Block (4 Used) 9- Bolt (2 Used) 16 - O-Ring 22 - Solenoid Valve (12 Used)
3- Block 10 - Nut (8 Used) 17 - O-Ring 23 - Plate (6 Used)
4- Block 11 - Washer (8 Used) 18 - Reducing Valve 24 - Socket Bolt (36 Used)
5- Plate 12 - Plug 19 - O-Ring 25 - O-Ring (14 Used)
6- Foot (2 Used) 13 - Filter 20 - O-Ring 26 - O-Ring (7 Used)
7- Spacer (2 Used) 14 - Relief Valve
W3-8-4
1. Install the O-rings (25) (2 used) and (26) on the IMPORTANT: Do not adjust the adjusting screw of
blocks (1), (2) (4 used), (3) and (4). the relief valve (14).
2. Arrange the foot (6), block (1), blocks (2) (4 used), 8. Install the O-rings (15) (2 used), (16) and (17) on
block (3), block (4), plate (5), spacers (7) (2 used) the relief valve (14) and install the relief valve (14)
and foot (6) in this order. Pass the bolts (8) (2 on the block (1).
used) and (9) (2 used). : 27 mm
: 68.6 to 78.5 Nm (7.0 to 8.0 kgfm)
3. Install the washer (11) on the bolts (8) (2 used)
and (9) (2 used) with the nut (10).
: 13 mm
: 21.6 to 23.5 Nm (2.2 to 2.4 kgfm)

4. Install the solenoid valves (22) (2 used) and plate

(23) on the blocks (2) (4 used) with the socket bolt
(24).
: 3 mm
: 3.92 to 4.9 Nm (0.4 to 0.5 kgfm)
5. Install the filter (13) on the block (1).
6. Install the plug (12) on the block (1).
: 8 mm
: 34 to 37 Nm (3.5 to 3.8 kgfm)

the reducing valve (18).

reducing valve (18) and install the reducing valve
(18) on the block (1).
: 27 mm
: 68.6 to 78.5 Nm (7.0 to 8.0 kgfm)
W3-8-5
(Blank)
W3-8-6
SECTION 1
GENERAL
—CONTENTS—
Group 1 Specifications
Specifications
(Refer to Link-Belt Technical Data Manual)
Group 2 Component Layout

Main Component Layout .............................. T1-2-1
In Cab ........................................................... T1-2-3
Around Engine.............................................. T1-2-5
Electrical Parts.............................................. T1-2-7
Hydraulic Equipment .................................. T1-2-16
Group 3 Component Specifications

Engine .......................................................... T1-3-1
Engine Accessories ...................................... T1-3-4
Hydraulic Equipment .................................... T1-3-5
Filter............................................................ T1-3-10
2CNT-1-1
(Blank)
2CNT-1-2
GENERAL / Component Layout
MAIN COMPONENTS : LAYOUT 13 14 15 16
Crane Upper
12
11
11
10
9
8
7
6
5
4
3
2
1
30 17
18
19
31
20
21
23
22
29 24
29
25
26
28 27
28
T2CN-01-02-001
1- Gate Lock Solenoid Valve 9- Engine 17 - Fuel Tank 25 - Hydraulic Oil Cooler
Solenoid Valve (under Boom
Hoist Drum)
2- Hydraulic Oil Tank 10 - Front Drum 18 - Rear Control Valve 26 - Turntable Bearing
3- Pilot Filter 11 - EGR Cooler 19 - 3-Spool Solenoid Valve 27 - Rotating Joint
(under Rear Drum)
(Counterweight, Flip)
2
4- Drain Filter 12 - Rear Drum* 20 - 2-Spool Control Valve 28 - Battery
(under Rear Drum)
(Swing, Counterweight,
Flip)
5- Air Cleaner 13 - Reserve Tank 21 - Front Control Valve 29 - Swing Reduction Unit
6- Flip Cylinder 14 - Radiator, Intercooler 22 - Accumulator 30 - Upper Revolving Frame
1
7- Pump Assembly 15 - Boom Hoist Drum* 23 - 4-Spool Solenoid Valve 31 - Foot Pin
(under Rear Drum) Removal/Installation
(Foot Cylinder, Lower Mechanism
Hydraulic Source)
8- Muffler 16 - Boom Hoist Sheave 24 - Hydraulic Oil Cooler
Bearings
*1: The tower boom hoist drum is provided for the tower.
*2: The tower jib boom hoist drum is provided for the tower.
T1-2-1
Base Carrier
2 3
1 4
14
13
7
12
15
11
8
10
9

T2CN-01-02-002
1- Lower Frame 5 - Side Frame Joint Mechanism 9 - Track Take-Up Idler 13 - Travel Mechanism
2- Turntable Bearing 6 - Jack-Up / Side Frame Joint 10 - Upper Roller 14 - Connector Box
Control Valve
3- Track Shoe 7 - Jack-Up Mechanism 11 - Lower Roller 15 - Terminal Box
4- Rotating Joint 8 - Lower Weight 12 - Side Frame
T1-2-2
IN CAB
12
14 5
13
11
10
8
T2CN-01-02-003
1- Rear Overhead Panel 5- Switch Panel 9- Accelerator Pedal 12 - Air Conditioner Control
Panel
2- Side Overhead Panel 6- Monitor Panel 10 - Pilot Shut-Off Lever 13 - Fuse Box
3- Left Stand 7- Swing Lock Pedal 11 - Right Stand 14 - Controller Box
4- Moment Limiter 8- Level Gauge
T1-2-3
• Armchair Lever
1 2 3
T2CN-01-02-004
7 6 5 4
1- Front Drum Lever (with Speed Sensing)

2- Rear Drum Lever (with Speed Sensing)
3- Boom Hoist Lever (with Speed Sensing)
4- Travel Lever (Right)
5- Travel Lever (Left)
6- Third / Quick Draw Lever
7- Swing Lever (with Accelerator Grip,
Swing Brake Switch, Horn Switch)
NOTE: In case of the tower,

Rear Drum ψ Tower Jib Boom Hoist
Boom Hoist ψ Tower Boom Hoist
T1-2-4
AROUND ENGINE
Left Side
1 2 3
T2CG-01-02-011
8 7 6 5 4
Machine Front Machine Rear
T2CG-01-02-012
11 10 9
1- Radiator 4 - Injection Pump 7 - Engine Oil Pressure Switch 10 - Fuel Filter

2- PCV Valve 5 - Engine Oil Restriction Switch 8 - Air Drier (in front of 11 - Air Tank
Radiator)
3- Muffler 6 - Engine Oil Filter 9 - Water Separator
T1-2-5
Right Side
12 13 14
15
16
T2CG-01-02-010
20 19 18 17
Machine Rear Machine Front
12 - Muffler 15 - Coolant Temperature 17 - Alternator 19 - Starter Motor

Sensor
13 - Air Cleaner Restriction 16 - Overheat Switch 18 - Turbocharger 20 - Air Compressor
Sensor
14 - Air Cleaner
T1-2-6
ELECTRICAL PARTS
In Cab
• Left Stand
1 2 3 4 5 6 7

9 8 8 8
T2CN-01-02-005
1 - Master Control Override Key Switch 4- Brake Free Mode Disable/Enable Key 7- Reeving Winch Switch
Switch
2 - Boom Hoist Limit Override Switch 5 - Pilot Control Oil Pressure Override 8- Drum Speed Control Dials
Switch
3 - Hoist Drum Function Limit Override 6 - Live Mast Flip Cylinder Switch 9- Swing Speed Control Dial
Switches
• Right Stand

1 2
T2CN-01-02-006
1- Throttle Lock Switch 2- Drum Pawl Switches
T1-2-7
• Rear Overhead Panel
1 2
T2CN-01-02-007

1- AM / FM Radio 2- Accessory
• Side Overhead Panel
1 2 3 4 5 6 7 8 9 10 11
T2CN-01-02-008

1- Emergency Engine Stop Button 5- Drum Rotation Indicator Switch 9- Roof Wiper Switch
2- Boom Foot Pin Control Switches 6- Travel High Speed Switch 10 - Front Wiper Switch
3- Low Drum Speed Lock Switch 7- Drum Light Switch 11 - Air Conditioning Controls
4- HYD.Tagline Switch (If Equipped) 8- Working Light Switch
T1-2-8
• Inside Rear Cover
Fuse Box 1 2 3 4 5 6
Relay Panel
9 8 7
T2CN-01-02-009
1- ECU 4 - Memory Clear Switch 6 - ECU Lamp (Orange) 8 - MC2 / A

2- Accelerator Lock Switch 5 - ECU Lamp (Red) 7 - MC2 / B 9 - IDU
3- Troubleshooting Switch
• Relay Panel
The relay layout is not fixed.
Check the wiring tag and the electrical circuit
diagram.
T2CN-01-02-010
NOTE: Wiring Tag Name

R1 Mast Cylinder Extend/Retract Relay R6 ............. (Unused)
R2 Engine Oil Pressure Relay R7 ............. Swing Brake Relay 1
R3 Engine Starting Relay R8 ............. Swing Brake Relay 2
R4 Mast Cylinder shrink Relay R9 ............. Glow Lamp Relay
R5 Extra Components Power Source R10 .......... Oil Cooler Fan Relay
Relay
T1-2-9
• Fuse Box
1
2 T2CN-01-02-0011
1 Fuse Box 1
1- Preheat Indicator ..........5A 11 - Air conditioner power . 15A
2- Rear drum 12 - Swing alarm power..... 10A
1 2 3 4 5 6 7 8 9 10 pawl switch ..............10A
3- Optional ........................3A 13 - Audio alarm power ....... 5A
11 12 1314 15 1617 18 1920 4- Dome light.....................5A 14 - Radio............................ 5A
5- IDU................................5A 15 - Pilot control shutoff
2 lever deactivation ...... 5A
Fuse Box 1
6- MCB..............................5A 16 - Glow timer .................... 5A
7- MCA..............................5A 17 - ECU............................ 10A
21 22 2324 25 2627 28 29 30
8- Horn ............................10A 18 - Controller key switch .. 5A
31 3233 34 353637 3839 40 9- Backup power ...............3A 19 - Monitor panel ............... 5A
10 - Fuel pump...................10A 20 - Battery relay ............... 10A
Fuse Box 2 M25N-07-078
Fuse Box 2
21 - Engine start signal ......10A 31 - Air conditioner .............. 3A
22 - Front drum pawl 32 - Optional...................... 10A
switch........................10A
23 - Travel mode 33 - Microphone
/ HYD.Tagline / Speaker amplifier
/ Reeving winch ...........5A / anemometer............ 5A
24 - Air conditioner...............3A 34 - Oil cooler Fan............... 5A
25 - Work light....................20A 35 - Roof wiper .................... 5A
26 - Side light (Optional). ...10A 36 - Swing brake ................. 5A
27 - Solenoid (MCB) ..........15A 37 - Front wiper ................... 5A
28 - Solenoid (MCA) ..........15A 38 - Lighter ........................ 20A
29 - PWM(MCB).................15A 39 - Live mast / jacks......... 10A
30 - PWM(MCA).................15A 40 - ECU Main................... 20A
T1-2-10
• Monitor Panel
4
1- Hour Meter
2- Engine Fuel Level Gauge
3- Engine Water Temperature Gauge
4- Engine Oil Pressure Indicator
5- Hydraulic Oil Pressure
6- Engine Start Protocol Violation Indicator
3 7- Engine Coolant Level Indicator
8- Low Battery Indicator
5 9- Engine Oil Filter Restriction Indicator
10 - Engine Preheater Indicator
11 - Air Filter Restriction Indicator
12 - Controller Malfunction Indicator
6
13 - Engine Overheat Indicator
14 - Cigarette Lighter
7 2 15 - Engine Starter Key Switch
8
9
10
11 1
12
13
T2CN-01-02-012
14 15
T1-2-11
Lower Frame Electrical Parts
Connector Box
Front
Terminal Box
Remote Control Box (Crawler Joint

Cylinder/Counterweight)
T2CN-01-02-013
T1-2-12
Electrical Components (Right Stand)
1 2 3 4 5 6 7 8 9
13
14
Reserve Tank
15
16
10
11
12
Machine Front
Machine Front
T2CN-01-02-014 Receiver Tank T2CN-01-02-015

1- Safety Relay 5- Heater Instruction Relay 9- 3-Color Light Buzzer Relay 13 - Fusible Link (45 A)
2- EDU Relay 6- 3-Color Light (Green) Relay 10 - Flasher Relay 14 - Fusible Link (60 A)
3- Swing Lamp Relay 7- 3-Color Light (Yellow) Relay 11 - Off Delay Relay 15 - Coolant Level Switch
4- Horn Relay 8- 3-Color Light (Red) Relay 12 - Charge Relay 16 - Refrigerant Pressure Switch

Electrical Components (Left Stand)
Machine Front
Machine Front
3
1 2
T2CN-01-02-016 T2CN-01-02-017
1 - Horn 3- Fuel Sensor

2 - Battery (12V)
T1-2-13
Crane Upper Electrical Parts
• Around Winch
Boom Hoist Drum
Rear Drum
Front Drum
3
T2CN-01-02-018
1- Boom Hoist Drum Speed 3 - Front Drum Speed Sensor 4 - Rear Drum Lock Motor 5 - Front Drum Lock Motor
Sensor
2 - Rear Drum Speed Sensor
T1-2-14
• Primary Pilot Pressure Sensor

Left Bed
Accumulator Primary Pilot Pressure Sensor
Machine Front
T2CN-01-02-019
T1-2-15
HYDRAULIC EQUIPMENT
Pump Assembly
2
3
11
6
10
T2CG-01-02-025
7
1- Reeving Winch Pump 4 - Pilot Pump (P6) 7 - Displacement Angle 10 - Power Increase Solenoid
(Optional) Proportional Solenoid Valve Valve (For Main Pump)
(For Swing Pump)
2- PTO Gear Box 5 - Swing Pump (P3) 8 - Displacement Angle 11 - Main Pump 1 (P1)
Proportional Solenoid Valve
(For Main Pump)
3- Boom Foot / Lower 6 - Oil Cooler Pump (P4) 9 - Main Pump 2 (P2)
Hydraulic Power Source
Pump (P5)
T1-2-16
Control Valves (Front, Rear)
Front Control Valve
5
1
Machine Front
2
Machine Rear
3
Rear Control Valve

13 14
12
6
11
Machine Front
Machine Rear 10 9
T2CN-01-02-020

1- Main Relief Valve 5- Front Drum Lowering 9- Rear Drum Hoisting 13 - Boom Hoist Lowering
Proportional Solenoid Valve Proportional Solenoid Valve Remote Control Pressure
Sensor
2- Front Drum Hoisting 6- Main Relief Valve 10 - Rear Drum Hoisting 14 - Boom Hoist Lowering
Proportional Solenoid Valve Remote Control Pressure Proportional Solenoid Valve
Sensor
3- Front Drum Hoisting 7- Boom Hoist Hoisting 11 - Rear Drum Lowering
Remote Control Pressure Proportional Solenoid Valve Remote Control Pressure
Sensor Sensor
4 - Front Drum Lowering 8- Boom Hoist Hoisting 12 - Rear Drum Lowering
Remote Control Pressure Remote Control Pressure Proportional Solenoid Valve
Sensor Sensor
T1-2-17
Swing Control Valve 4-Spool Solenoid Valve (Boom Foot Pin Removal /
Installation, Lower Control Hydraulic Source)
6
18
1 19
20
21
4
2
22
26
25
3 T2CG-01-02-027 24 T2CG-01-02-029
23
1- Hydraulic Oil Source 14 - Counterweight Cylinder
Solenoid Valve in 3-Spool Left Solenoid Valve
Solenoid Valve Unit (Extend)
2- Left Swing Pilot Pressure 15 - Flip Cylinder Solenoid
Sensor Valve (Retract)
3-Spool Solenoid Valve (Counterweight/ Flip 3- Right Swing Pilot 16 - Relief valve
Cylinder) Pressure Sensor
4- Hydraulic Oil Source 17 - Slow Return Valve
Solenoid Valve in 3-Spool
Solenoid Valve Unit
5- Right Swing Spool 18 - (Unused)
6- Left Swing Spool 19 - Lower Hydraulic Supply
7 Solenoid Valve
17 7- Slow Return Valve 20 - Left Boom Foot Cylinder
8
9 Solenoid Valve
10 (Retracting)
8- Flip Cylinder Solenoid 21 - Right Boom Foot Cylinder
Valve (Extend) Solenoid Valve
(Retracting)
9- Counterweight Cylinder 22 - Relief valve
Left Solenoid Valve
16 (Retract)
10 - Counterweight Cylinder 23 - Right Boom Foot Cylinder
Right Solenoid Valve Solenoid Valve
(Retract) (Extending)
11 - Port Relief Valve 24 - Left Boom Foot Cylinder
(Counterweight Cylinder Solenoid Valve
15 Right) (Extending)
14 12 - Port Relief Valve 25 - (Unused)
13 (Counterweight Cylinder
T2CG-01-02-028
Left)
12 11 13 - Counterweight Cylinder 26 - (Unused)
Right Solenoid Valve
(Extend)
T1-2-18

6-Spool Solenoid Valve (Lower Control Valve)
(Jack-Up, Side Frame Joint)
1
14
13
2
4
11
5
10
6
9
7
T2CG-01-02-030
1- Pressure-Reducing Valve 5- Solenoid Valve (Jack-Up 9- Solenoid Valve (Side 12 - Solenoid Valve (Jack-Up
Cylinder (Rear Left) Frame Joint Cylinder Cylinder (Front Left)
Retract) (Right) Extend) Extend)
2- Solenoid Valve (Jack-Up 6 - Solenoid Valve (Side 10 - Solenoid Valve (Jack-Up 13 - Solenoid Valve (Jack-Up
Cylinder (Front Right) Frame Joint Cylinder Cylinder (Rear Left) Cylinder (Front Right)
Retract) (Right) Retract) Extend) Extend)
3 - Solenoid Valve (Jack-Up 7 - Solenoid Valve (Side 11 - Solenoid Valve (Jack-Up 14 - Relief valve:
Cylinder (Front Left) Frame Joint Cylinder (Left) Cylinder (Rear Right)
Retract) Retract) Extend)
4 - Solenoid Valve (Jack-Up 8 - Solenoid Valve (Side
Cylinder (Rear Right) Frame Joint Cylinder (Left)
Retract) Extend)
T1-2-19
(Blank)
T1-2-20
GENERAL / Component Specifications
ENGINE
Manufacturer................................................................. MITSUBISHI FUSO TRUCK & BUS CORPORATION

Model ............................................................................ 6M70-TL
Type .............................................................................. 4-Cycle Water-Cooled In-Line Direct Injection, with
Turbo for Air-Cooling I / C Application
Cyl. No. Bore u Stroke .................................................. 6-135 x 150 mm (5.3 x 5.9 in)
Piston Displacement..................................................... 12.88 L (786 in3)
Rated Output ................................................................ 272 kW / 2000 min-1 (370 PS / 2000 rpm)
Compression Ratio ....................................................... 17.5
Dry Weight .................................................................... 1155 kg excluding accessories
Firing Order................................................................... 1-5-3-6-2-4
Rotational Direction ...................................................... Clockwise, Viewed from Fan
Length × Width × Height............................................... 1473 x 869 x 1259 mm (58 x 34 x 50 in)
Cooling System
Cooling Fan .................................................................. Dia. 850 6-Blade Suction Type
Fan / Pulley Ratio (Flank / Fan).................................... 0.825
Thermostat.................................................................... Cracking Temperature at Atmospheric Pressure:
76.5qC (169.7 qF)
Full-Open Temperature: 90qC (194 qF)
Water Pump .................................................................. Centrifugal Swirl Pump, V Belt Drive
Lubricating System
Lubrication Pump Type ................................................ Gear Pump
Oil Filter........................................................................ Full-Flow / Paper Element Type with Bypass
Oil Cooler..................................................................... Built-In Water-Cooled Flat Tube Type
Oil Capacity ................................................................. Max.27 L (7.1 US gal), Min.24 L (6.3 US gal)
Oil pan Capacity .......................................................... Max.23 L (6.1 US gal), Min.20 L (5.3 US gal)
Starting System
Electric Motor............................................................... Solenoid Depressing Type Speed Reduction
Voltage / Output ........................................................... 24 V / 5.5 kW
Engine Stop System

Method ......................................................................... Fuel Shut-Off Method (Stop Solenoid Method)
Alternator
Method ......................................................................... Alternating Current Type (With Built-In IC Regulator)
Voltage / Output ........................................................... 24 V / 50 A
T1-3-1
Supercharging System
Type .............................................................................. Exhaust Gas Turbo Type TF08L
Fuel System
Type .............................................................................. Common Rail Type
Injector .......................................................................... Electric Control
Injection Control Adjuster.............................................. Electronic Control
Performance
IMPORTANT: This list shows design specifications, which are not servicing standards.
Lubricant Consumption................................................. 100 ml or Less (at Rating Using New Lubricant)
Fuel Consumption Ratio ............................................... 220 g / kW·h (162 g / PS·h) or Less
(At Rating Using New Lubricant)
Maximum Output Torque .............................................. 1510 N·m (154 kgf·m, 1114 lbfft) or more / 1600 min-1
Unloaded Speed ........................................................... Min.: 800r25 min-1
Max.: 2100r25 min-1
T1-3-2
Engine Performance Curve (6M70-TL)
Test conditions
1. JIS D 0006 (Specifications for Diesel Engine for Construction Machinery and Performance Test Method)
under standard atmospheric conditions
2. Fan, and exhaust silencer are not provided.

Torque
Nm (kgfm) (lbfft)
Torque 1600 (163) (1180)
1400 (143) (1033)
1200 (122) (885)
kW 1000 (102) (738)

280
260
240
220 Output Power
200
Output
Power 180
160
140
120
100
80
Fuel Consumption Rate
g / (kWh) (g / PSh)
Fuel Consumption Rate
220 (162)
200 (147)
100 (74)

800 1000 1200 1400 1600 1800 2000 T2CG-01-03-001
-1
Engine Speed min (rpm)
T1-3-3
ENGINE ACCESSORIES
Radiator Assembly
Type ................................................Radiator / Intercooler Parallel Type
Radiator Intercooler
Core Row .......................................4 1
Fin Pitch..........................................4.5 4.0
Fin Shape .......................................Corrugated Louver Corrugated Wave
Radiating Area................................41.43m2 21.76m2
Heat Exchange Capacity................133730 kcal/h 35690 kcal/h
Cap Opening Pressure...................49 kPa (0.5 kgf / cm2, 7.1 psi)
Battery
Model ..............................................195G51-MF(Hybrid Type)
Capacity ..........................................170 Ah (20- Hour Rating)
Voltage ............................................12 V
Discharging Time ............................500 A (-15˚C)
Duration ..........................................4.8 min. or longer
30-Second Voltage .........................9.4 V or more
Height x Width x Length..................257 x 222 x 508 mm (10 x 8.7 x 20 in)
Weight.............................................41 kg (91 lb)
T1-3-4
HYDRAULIC EQUIPMENT
Pumps
Drive Gear Ratio ........................................................... Main Pumps (P1, P2) 1.0
Swing / A-Frame Raise/Lower Pump (P3) 1.0
Oil Cooler Pump (P4) 1.0
Boom Foot / Lower Hydraulic Pump (P5) 1.0
Pilot Pump (P6) 1.0
Main Pumps (1, 2)

Type .............................................................................. Swash Plate Type Variable Displacement Plunger Pump
Model ............................................................................ K3V140DTP
Theoretical Displacement ............................................. 28 to 140 cm3 (1.7 to 8.5 in3) / rev
Maximum Oil Flow Rate (Theoretical Valve) ................ 279 L / min (74 GPM)
Dry Weight .................................................................... 185 kg (408 lb) (P1+P2+P3)
Swing Pump (P3)

Type .............................................................................. Swash Plate Type Variable Displacement Plunger Pump
Model ............................................................................ K5V80S
Theoretical Displacement ............................................. 48 to 80 cm3 (2.9 to 4.9 in3) / rev
Maximum Oil Flow Rate (Theoretical Valve) ................ 160 L / min (42 GPM)
Main Pumps (1, 2) And Swing Pump Wight ................. 185 kg (408 lb) Total
Oil Cooler Pump (P4)

Type .............................................................................. Constant Capacity Type Gear Pump
Model ............................................................................ PHB22RA33
Theoretical Displacement ............................................. 22.2 cm3 (1.4 in3) / rev
Dry Weight .................................................................... 4.2 kg (9.3 lb)
Pilot Pump (P6), Boom Foot / Lower Hydraulic Pump (P5)

Type .............................................................................. Constant Capacity Type Gear Pump
Model ............................................................................ SD1A3020
Theoretical Displacement ............................................. 29.9 cm3 (1.8 in3) / rev (Pilot Pump)
20.4 cm3 (1.2 in3) / rev (Boom Foot / Lower Hydraulic Pump)
Maximum Oil Flow Rate (Theoretical Valve) ................ 59.8 L / min (15.8 GPM) (Pilot Pump)
40.8 L / min (10.8 GPM) (Boom Foot / Lower, Hydraulic Pump)
Front Control Valve

Type .............................................................................. 4-Spool Hydraulic Pilot Type
Model ............................................................................ MWP4253SC773
Main Relief Set-Pressure.............................................. 31.4 MPa (320 kgf / cm2, 4551 psi) @275 L / min (73 GPM)
Weight........................................................................... 80 kg (177 lb)
Rear Control Valve

Model ............................................................................ MWP425S2CT764A
Main Relief Set-Pressure.............................................. 31.4 MPa (320 kgf / cm2, 4551 psi) @ 275 L / min (73 GPM)
Weight........................................................................... 107 kg (236 lb)
Swing Control Valve

Model ............................................................................ MW2252P7209A
Main Relief Set-Pressure.............................................. 31.9 MPa (325 kgf / cm2, 4623 psi) @155 L / min (41 GPM)
Weight........................................................................... 38 kg (84 lb)
T1-3-5
Boom Foot / Lower Hydraulic / Control Valve
Type .............................................................................. Solenoid Select Type
Model ............................................................................ KMC10-4082
Relief Set-Pressure ...................................................... 20.6 MPa (210 kgf / cm2, 2987 psi) @70 L / min (18 GPM)
Weight........................................................................... 22 kg (49 lb)
Flip / Counterweight Control Valve

Type .............................................................................. 3-Spool Solenoid Select Type
Model ............................................................................ KMC10-3059
Weight........................................................................... 20 kg (45 lb)
Jack-Up / Side Frame Control Valve

Type .............................................................................. 6-Spool Solenoid Select Type
Weight........................................................................... 25 kg (56 lb)
T1-3-6
Boom Hoist System (Machine No.5 or earlier)
Weight........................................................................... 2000 kg (4410 lb)
Reduction Gear
Type ...................................................................... 3-Stage Planetary Reduction Gear
Model .................................................................... MRP1703W-500
Reduction Gear Ratio ........................................... 134.6
Boom Hoist Motor
Type ...................................................................... Swash Plate Type Variable Displacement Axial Plunger
Motor
Model .................................................................... M3B280BP / 136-XV030A
Theoretical Displacement ..................................... 136 to 280 cm3 (8.4 to 17 in3) / rev
Overload Relief Set-Pressure ............................... 34.3 MPa (350 kgf / cm2, 4978 psi) @30 L / min (7.9 GPM)
Brake Release Pressure....................................... 2.6 MPa (26.5 kgf / cm2, 377 psi)
Weight ................................................................... 131 kg (289 lb)
Boom Hoist System (Machine No.6 or later)

Weight........................................................................... 1670 kg (3683 lb)
Reduction Gear
Model .................................................................... WT17DS
Boom Hoist Motor
Motor
Model .................................................................... M3B530BP / 178-XV138A
Theoretical Displacement ..................................... 178 to 350 cm3 (11 to 21 in3) / rev
Weight ................................................................... 209 kg (491 lb)
Swing Reduction Unit

Type .............................................................................. M5X130CHB-10A-RG23C34B-T
Weight........................................................................... 325 kg (717 lb)
Reduction Gear
Type ...................................................................... 1-Stage Spur Gear + 1-Stage Planetary Reduction Gear
Reduction Ratio .................................................... 33.88
Swing Motor
Type ...................................................................... Swash Plate Type Constant Displacement Axial Plunger
Motor
Theoretical Displacement ..................................... 129.7 cm3 (7.9 in3) / rev
Winch Assembly (Front / Rear)

Weight (Front / Rear) .................................................... 1770 kg (3903 lb)
Reduction Gear
Winch Motor
Motor
Model .................................................................... M3B800BP-800 / 400-XV079B
Theoretical Displacement ..................................... 400 to 800 cm3 (24 to 49 in3) / rev
Brake Release Pressure....................................... 3.8 MPa (39 kgf / cm2, 555 psi)
Weight ................................................................... 303 kg (669 lb)
T1-3-7
Travel Mechanism
Weight........................................................................... 1670 kg (3683 lb)
Reduction Gear
Model .................................................................... MRP1703W-630
Weight ................................................................... 1550 kg (3418 lb)
Travel Motor
Type ...................................................................... Swash Plate Type Constant Displacement Axial Plunger
Motor
Model .................................................................... MSF-340VP-FL
Theoretical Displacement ..................................... 165.3 to 337.2 cm3 (10.1 to 20.6 in3) / rev
Overload Relief Set-Pressure ............................... 31.4 MPa (320 kgf / cm2, 4551 psi) @275 L / min (73 GPM)
Parking Brake Release ......................................... Self-Pressure Release Method
Weight ................................................................... 125 kg (276 lb)
Counterweigh
Cylinder Boom Foot Flip
t
Cylinder Bore Dia. (mm, in) 㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 50, 2.0 160, 6.3 100, 4.0
Cylinder Outer Dia. (mm, in) 㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 60, 2.4 210, 8.3 120, 4.8
Rod Dia. (mm, in) 㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 25, 1.0 80, 3.2 70, 2.8
Stroke (mm, in) 㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 176, 7.0 1665, 66 890, 36
Fully Retracted Length (mm, in) 㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 379, 15 2150, 85 1280, 51
Weight (kg, lb) 㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 50, 111 323, 713 87, 192
Side Frame
Take-Up Jack-Up
Joint
Cylinder Bore Dia. (mm, in) 㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 110, 4.4 120, 4.8 180, 7.1
Cylinder Outer Dia. (mm, in) 㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 130, 5.2 165, 6.5 220, 8.7
Rod Dia. (mm, in) 㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 65, 2.6 120, 4.8 120, 4.8
Stroke (mm, in) 㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 865, 35 200, 7.9 750, 30
Fully Retracted Length (mm, in) ······················ 1255, 50 407, 17 1070, 43
Weight (kg, lb) 㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 125, 276 71, 157 190, 419
T1-3-8
Remote Control Valve
For Hoisting / Boom Hoist (3-Spool)
Model .................................................................... TH40PC3068
Stroke (mm)㧙Secondary Pilot Pressure (MPa) ... Hoisting Boom Hoist
- 0.6-0.29 0.6-0.39
1-Stage 3.5-1.96 6.5-3.73
2-Stage 6.5-3.73 -
Stroke (in)㧙Secondary Pilot Pressure (kgf / cm2, psi) Hoisting Boom Hoist
- 0.02-3.0, 42 0.02-4.0, 57
1-Stage 0.14-20, 284 0.26-38, 541
2-Stage 0.26-38, 541 -
For Travel / Third (3-Spool)

Model 㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 TH40PC3077A
Stroke (mm)㧙Secondary Pilot Pressure (MPa) Travel Fourth
- 0.6-0.39 0.6-0.29
1-Stage 3.5-1.96 3.5-1.96
2-Stage - 6.5-3.73
Stroke (in)㧙Secondary Pilot Pressure (kgf / cm2, psi) Travel Fourth
- 0.02-4.0, 57 0.02-3.0, 42
1-Stage 0.14-20, 284 0.14-20, 284
2-Stage - 0.26-38, 541
For Swing
Model 㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 TH40PC1042
Stroke (mm)-Secondary Pilot Pressure (MPa) - 0.6-0.39
1-Stage 7.0-2.99
Stroke (in)-Secondary Pilot Pressure (kgf / cm2, psi) - 0.02-4.0, 57
1-Stage 0.28-30, 434
Oil Cooler
Type 㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 Corrugated Wave
Model 㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 1382-636-8010
Outside Dimension (H x W x T) 㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 1130 x 506.5 x 188 mm (44 x 20 x 7.4 in)
Core Dimension (H x W x T) 㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 1040 x 419.4 x 31 mm (41 x 17 x 1.2 in)
Core No. 㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 3
Fin Pitch 㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 3.5 mm (0.14 in)
Radiating Area 㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 13.11 m2 (1 Core)
Heat Exchange Capacity········································ 82130 kcal / h
T1-3-9
Oil Cooler Fan Motor
Type 㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 Constant Displacement Axial Plunger Motor
Model 㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 MSF-18-16
Theoretical Displacement㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 16.4 cm3 / (1.0 in3)rev
Oil Cooler Bypass Check Valve

Model 㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 VA1C007A001A
Cracking Pressure ....................................................... 294 to 392 kPa (3.0 to 4.0 kgf / cm2, 43 to 57 psi)
@40 L / min (11 GPM)
Accumulator
Type 㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 Bladder Type
Delivery Flow Rate 㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 700 cm3
Maximum Set-Pressure 㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 3.9 MPa (40 kgf / cm2, 569 psi)
FILTER
Filtration Remarks
Return Filter 㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 10 Pm (Yamashin Y-467500)
Pilot Filter 㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 10 Pm (Yamashin GT04L-30-15)
Suction Filter 㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 177 Pm (Yamashin SFB32S-177-1220)
(80 mesh)
Drain Filter 㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯㨯 10 Pm (Yamashin SP10-10-10)
T1-3-10
SECTION 2
SYSTEM
—CONTENTS—
Group 1 Control System
Outline.......................................................... T2-1-1
Engine Control ............................................. T2-1-2
Pump Control ............................................... T2-1-8
Other Controls ........................................... T2-1-16
Group 2 Hydraulic System

Outline.......................................................... T2-2-1
Pilot Circuit................................................... T2-2-3
Main Circuit .................................................. T2-2-6
Neutral Circuit .............................................. T2-2-8
Hoisting Circuit(Rear, Front) ...................... T2-2-10
Hoisting Circuit........................................... T2-2-22
Boom Hoist Circuit ..................................... T2-2-25
Quick Draw / Third (Optional) Circuit......... T2-2-27
Travel Circuit.............................................. T2-2-28
Swing Circuit .............................................. T2-2-32
Weight Remove and Install /
Flip Circuit .............................................. T2-2-35
Boom Foot Remove and Install Circuit ...... T2-2-38
Side Frame Connection /
Jack-Up Circuit....................................... T2-2-40
Take-Up Circuit (Optional) ......................... T2-2-42
Reeving Winch Circuit (Optional) .............. T2-2-43
Oil Cooler Circuit........................................ T2-2-44
Group 3 Electric System

Outline.......................................................... T2-3-1
Power Source Circuit ................................... T2-3-2
Preheating Circuit ........................................ T2-3-3
Engine Starting Circuit ............................... T2-3-6
Charging Circuit ........................................... T2-3-8
Engine Stop Circuit .................................... T2-3-10
Surge Voltage Prevention Circuit............... T2-3-12
Accessory Circuit ....................................... T2-3-14
Swing Brake Release Circuit ..................... T2-3-15
Drum Lock Circuit ...................................... T2-3-16
2CNT-2-1
(Blank)
2CNT-2-2
SYSTEM / Control System㩷
OUTLINE㩷
MC (Main Controllers); (2/A and 2/B each incorporated

with a microcomputer), IDU (Information Display Unit),
and ECU (Engine Control Unit) are used to control the
machine.
MC2/A, MC2/B or ECU receives signals from the
engine control accelerator, engine speed sensor and
various switches, computes them, drives the solenoid
valve and controls the engine and pumps.
Engine Control Other Controls

• Engine Speed Control㩷 • Swing Alarm Control㩷
• Fuel Injection Control㩷 • Drum Rotation Sensing Control㩷
• Operation of Injection Nozzle㩷 • Pilot Pressure Drop Alarm Indicator Control㩷
• ECU Failure Diagnosis Control㩷 • Winch Brake Mode Control㩷
• Boom Hoist Lock Control㩷
Pump Control • Engine Start Interlock Control㩷
• Main Pump Displacement Angle Control㩷 • Motor Cut-Off Pressure Control㩷
• Main Pump Power Increase Control㩷 • Front/Rear/Boom Hoist Motor Speed Control㩷
• Calibration of Main Pump Power Increase • Emergency Operation Control㩷
Pressure㩷 • Boom Hoist Drum Auto Stop Control㩷
• Swing Pump Displacement Angle Control㩷 • Front Drum Auto Stop Control㩷
• Rear Drum Auto Stop Control㩷
• Tower Jib Boom Hoist Auto Stop Control
(Optional)㩷
• Second Overhoist Auto Stop Control㩷
• Front Drum Surge Pressure Reduction Control㩷
• 2-Speed Tower Jib Boom Hoist Flow Combining
Control㩷
• External Indication Lamps Control (Optional)㩷
• Audible Output Control㩷
T2-1-1
ENGINE CONTROL㩷
Engine Speed Control
Purpose:㩷 Controls the engine speed by turning the

accelerator grip, depressing the accelerator
pedal and operating the accelerator lock
switch.㩷
Accelerator
Grip
Operation:
1. When turning the accelerator grip, depressing the Accelerator Pedal
accelerator pedal or setting the accelerator lock Accelerator Lock Switch
switch to the accelerator lock position, the voltage
ON
signals are sent to MC2/A from the accelerator
grip, accelerator pedal or accelerator lock switch.㩷
SET
2. When the accelerator lock switch is OFF, the
voltage signal from accelerator lock switch
becomes ineffective and the voltage signals from
accelerator grip and accelerator pedal become
effective.㩷
3. When the accelerator lock switch is in the
accelerator lock position, the voltage signals from
accelerator pedal and accelerator lock switch
become effective and the voltage signal from
accelerator grip becomes ineffective.㩷
4. MC2/A converts the maximum effective voltage
signal to a command speed signal and sends to
ECU.㩷
5. When the voltage signals from accelerator grip, T2CG-02-01-003
accelerator pedal and accelerator lock switch

become ineffective, MC2/A sets the engine speed
㩷
to low idle.㩷
6. Engine speed with an accelerator at lock position
is set by the following procedure.㩷
• Turn the accelerator lock switch OFF.㩷
• Adjust the engine speed by the accelerator grip or
accelerator pedal㩷
• Turn the accelerator lock switch to the accelerator
preset position.㩷
T2-1-2
Fuel Injection Control
Operation: ECU receives the signals from various
Purpose:㩷 ECU sets optimum injected fuel amount sensors as shown below. According to
and fuel injection timing by detecting these signals, ECU operates the TCV
accelerator position, coolant temperature, ADV solenoid valve or TCV RTD solenoid
intake-air temperature, boost pressure and valve in order to regulate engine oil
engine speed by using the various sensors.㩷 pressure which is transmitted to an
electronic timer for control of fuel injection
timing.
Then, ECU computes these signals,
determines the injected fuel amount and
fuel injection timing and sends a
command to the injector.
The injector injects optimum fuel amount
according to this command.
㩷
Injector㩷
Setting the target fuel Accelerator

injected amount Position
Coolant Temperature Intake-Air Boost Pressure Engine Speed

Sensor Temperature Sensor Sensor Sensor
㩷
㪫㪉㪚㪞㪄㪇㪉㪄㪇㪈㪄㪇㪉㪋㩷
T2-1-3
Operation of Injection Nozzle㩷㩷
Valve Spring Magnet
No Injection Operation
• When the magnet is not energized, the armature Armature Plate
plate is pushed downward by the valve spring and
Ball Seat
the ball seat is closed.㩷 Control Chamber
• High-pressure fuel from the Z-orifice is applied to Z-Orifice
the control chamber and the same pressure is
Valve Piston 㪝㫌㪼㫃
applied to the nozzle needle side as well. 㩷 (from Common Rail)
• As fuel at the nozzle needle cannot overcome the
valve piston and nozzle piston, the nozzle needle Nozzle Spring
is pushed downward and no injection will be
made.㩷 Nozzle Needle
Start Injection
• When the magnet is energized, the armature plate
moves upward by magnetic force and the ball seat Nozzle Sheet
opens.㩷
• Fuel in the control chamber is routed to the fuel
tank through the A-orifice and ball seat.㩷 Magnet
• As pressure in the control chamber decreases, Ball
fuel pressure at the nozzle needle overcomes the Armature Plate
valve piston and nozzle piston and pushes the A-Orifice
nozzle needle upward so that fuel injection starts.㩷 Control Chamber
• If the magnet is energized continuously, the Valve Piston 㪝㫌㪼㫃
maximum injection rate is kept.㩷 (from Common Rail)
End of Injection Nozzle Spring

• When the magnet stops energizing, the armature
plate is pushed downward by the valve spring and Nozzle Needle
the ball seat is closed.㩷
• Fuel flows into the control chamber through the High-Pressure Fuel
Z-orifice, the valve piston and nozzle needle are
pushed upward and fuel injection stops.㩷
Valve Spring Magnet
Armature Plate
Ball Seat
Control Chamber
Z-Orifice
Valve Piston 㪝㫌㪼㫃

(from Common Rail)
Nozzle Needle
㩷
㪫㪉㪚㪞㪄㪇㪉㪄㪇㪈㪄㪇㪉㪌㩷
T2-1-4
ECU Failure Diagnosis Control㩷㩷
Purpose: Detects failure of the engine through the 㩷

various sensors connected to ECU and 㩷 Information input to ECU
displays failure information by blinking the 㩷
indicator.
Operation:
1. ECU receives the signals from various sensors.
ECU computes input data and detects failures
when the data is beyond the specified range.㩷
2. When ECU detects a failure, ECU lights the ECU
lamp (orange or red).㩷
3. At this time, when the troubleshooting switch is set
to the ON position, ECU inputs a signal, which
corresponds to failure location, to MC2/A and
makes ECU lamp (red) blink at the same time.㩷
4. MC2/A sends error information to IDU
corresponding to the signal.㩷
5. IDU displays the error code on the connected
display.㩷
NOTE: The red ECU lamp indicates a failure status

that the engine cannot start, and the orange Troubleshooting Unit
ECU lamp indicates a failure status that the (Optional)
Troubleshooting
engine can start. Switch
Red
NOTE: When the troubleshooting switch is in the
ON position, blinking pattern of the red Orange
indicator indicates an error code.
ECU Lamp
Display
㩷
㪫㪉㪚㪞㪄㪇㪉㪄㪇㪈㪄㪇㪉㪍㩷
T2-1-5
x Blinking Pattern of the ECU lamp㩷㩷
Blinking pattern of the ECU lamp indicates an error

code.
The following example indicates error code "1.2".
㩷
Tens Digit Ones Digit
Turn
ON
Turn
OFF
5GE 5GE 5GE
5GE 5GE 5GE 5GE
㩷
㪫㪉㪚㪞㪄㪇㪉㪄㪇㪈㪄㪇㪉㪎㩷
㩷
㩷
㩷
㩷
x Display Items㩷㩷
Two-digit error codes of ECU are displayed on the

right side of page 6/6.
㩷
Error codes are
/%# /%# /%#'%7 㪍㪆㪍 displayed at this
column.
&&.%-4'. 1(( 2+.16.2 1(( '%7'4414
(/$4-4'. 1(( (&$4-.2 1(( '%7'4414
4/$4-4'. 1(( 4&$4-.2 1(( '%7'4414
/$4-4'. 1(( +06.%-.2 1(( '%7'4414
(&$4-4'. 1(( 6*416/# 1(( '%7'4414
'0)+06.%- 1(( 6*416/0# 1(( '%7'4414
4&$4-4'. 1(( 6*416/$ 1(( '%7'4414
&$4-4'. 1(( 6*416/0$ 1(( '%7'4414
㪤㫆㫍㪼㪩㪼㫋㫌㫉㫅
㩷
㪫㪉㪚㪞㪄㪇㪉㪄㪇㪈㪄㪇㪉㪏㩷
T2-1-6
x Error Codes㩷
Error Error
Error Item Error Item
Codes Codes
07 Engine overrun 81 Sensor supply voltage
08 Injector #6 82 Injector Bank 1, 2
11 Common rail pressure sensor 84 EDU relay
12 Segment sensor 89 Air heater lamp
14 Speed sensor 95 CAN 2 communication
15 Increment sensor
16 Accelerator sensor 2
19 Atmospheric pressure sensor
21 Coolant temperature sensor㩷
22 Injection pump no-pressure feeding
23 Injection pump over-pressure feeding
26 Air heater relay
32 Boost pressure sensor
33 ECU
34 Q resistance
36 Faulty injection pump pressure feeding,
Limiter valve open
37 Injector #1
38 Injector #5
39 Injector #3
41 Fuel temperature sensor
44 Intake-air temperature sensor
46 Injector #2
47 Injector #4
48 Starter relay 2
58 Accelerator interdependent diagnosis
63 Fuel supply pump
67 EGR M/V1
68 EGR M/V2
69 EGR M/V3
㩷
T2-1-7
PUMP CONTROL㩷㩷
Main Pump Displacement Angle Control 㩷
㩷
Purpose: Controls delivery flow rate of the main 㩷
pump according to rotation of the
accelerator grip, and slowdown value and 㩷
control direction of the winch motor 㩷
through M/L (Moment Limiter). 㩷
Operation: 㩷
1. MC2/A receives the voltage signal from the 㩷
accelerator grip.㩷㩷
2. MC2/A sends a signal that delivery flow rate is 8. The displacement angle proportional solenoid
controlled from minimum to maximum according valve adjusts pilot pressure oil supplied to the
to rotation (0 to 35%) of the accelerator grip when regulator according to this signal, so that the main
the accelerator lock switch is in the OFF position pump delivery flow rate is returned to the
and delivery flow rate is controlled from minimum accelerator grip delivery flow rate for five seconds
to maximum according to rotation (0 to 100%) of (maximum).㩷As a result, a rapid speed increase is
the accelerator grip when the accelerator is in the prevented.㩷
lock position to the displacement angle 9. Even if returning the accelerator grip rapidly,
proportional solenoid valve. 㩷 MC2/A executes the primary time lag processing
3. The displacement angle proportional solenoid for rotating the accelerator grip and cavitations in
valve supplies pilot pressure oil to the regulator in the winch motor is prevented.㩷(Response time to
main pump according to these signals in order to rapid returning: About two seconds)㩷
change the pump displacement angle.㩷㩷
4. As a result, delivery flow rate of the main pump
becomes proportional to rotation of the
accelerator grip.㩷
5. MC2/A sends a signal to the displacement angle
proportional solenoid valve according to
slowdown value and control direction of each
winch motor that is sent from M/L to MC2/A
through CAN circuit. (Slow Stop Function)㩷
6. The displacement angle proportional solenoid
valve controls pilot pressure oil to the regulator
according to this signal, so that the main pump
delivery flow rate is reduced to 20% of the
accelerator grip delivery flow rate.㩷
7. When operation of the winch motor is completed
or when slowdown value is returned to 100%
through M/L, MC2/A sends a signal to the
displacement angle proportional solenoid valve
for five seconds (maximum) so that the main
pump delivery flow rate is returned to the
accelerator grip delivery flow rate.㩷
T2-1-8
㩷
㩷
㩷 Accelerator Grip
ECU
Accelerator Lock Switch
CAN
MC2/A IDU
(M/L)
5-Spool Solenoid
Valve Unit
Displacement Angle
Proportional Solenoid
Valve
Engine
Pilot
Main Main Pump
Pump 1 Pump 2 㩷
㪫㪉㪚㪞㪄㪇㪉㪄㪇㪈㪄㪇㪇㪈㩷
T2-1-9
Main Pump Power Increase Control㩷㩷
Purpose: Regulates pump delivery flow rate

according to the engine speed and load in
order to use the engine horsepower
effectively.
Operation:
1. The engine speed sensor sends the engine speed
signal to ECU.㩷
2. ECU sends the engine load and engine speed
signal to MC2/A.㩷
3. MC2/A sends the signal according to engine
speed and load to the power increase solenoid
valve.㩷
4. The power increase solenoid valve supplies pilot
pressure oil to the regulator in main pump
according to this signal and increases the pump
absorption horsepower.㩷
5. As a result, pump delivery flow rate increases and
working speed of the actuator increases.㩷
T2-1-10
㩷
㩷
ECU
MC2/A IDU
Power
Increase
Solenoid
Valve 5-Spool Solenoid
Valve Unit
㪤㪸㫀㫅㩷㪤㪸㫀㫅㩷 Pilot

㪧㫌㫄㫇㩷1㩷㪧㫌㫄㫇㩷㪉 Pump 㩷
㪫㪉㪚㪞㪄㪇㪉㪄㪇㪈㪄㪇㪇㪉㩷
Engine
㩷 Speed Sensor
㩷
㩷
T2-1-11
Calibration of Main Pump Power Increase 㩷
Pressure㩷
Purpose: Stores the power increase output

calibration data into MC2/A memory
Operation:
1. Start the engine after completion of basic
calibration operation.㩷
2. When the auto stop release front drum switch and
auto stop release rear drum switch are turned ON,
MC2/B sends a signal to MC2/A.㩷
3. MC2/A lights or blinks the pilot pressure drop
alarm indicator.㩷
4. If the pilot pressure drop alarm indicator blinks
other than the specified cycle of 0.5-second ON
and 0.5-second OFF, turn the auto stop release
front drum switch and auto stop release rear drum
switch OFF.㩷
5. Calibration can be carried out by setting the
accelerator lock switch to the set position and
then turning it OFF.㩷
6. When selecting the power increase pressure
calibration mode, MC2/A changes the power
increase solenoid valve current at the rate of + 7
mA/3 sec.㩷
7. When the power increase pressure becomes the
set pressure [0.3 MPa], MC2/A stores the power
increase output pressure current as a calibration
value by setting the accelerator lock switch to the
set position. (Set positionψOFF)㩷
㩷
㩷
T2-1-12
㩷
㩷
Accelerator
㩷 Lock Switch Auto Stop Release
Front Drum Switch
Pilot Pressure Drop Auto Stop

Alarm Indicator Release Rear
ECU Drum Switch
MC2/A MC2/B
Power
Increase
Solenoid 5-Spool Solenoid
Valve Valve Unit
Main Main
Pump 1㩷 Pump 2 㩷
Pilot Pump
㪫㪉㪚㪞㪄㪇㪉㪄㪇㪈㪄㪇㪇㪋㩷
Engine
㩷 Speed Sensor
T2-1-13
Swing Pump Displacement Angle Control㩷㩷
Purpose: Controls the swing operating speed to 㩷

make Swing operation with long boom
such as tower smooth.
x Swing Speed Control㩷
Operation:
1. MC2/A receives the voltage signal from the swing
speed dial.
2. MC2/A sends a signal in proportion to the position
of swing speed dial to the displacement angle
proportional solenoid valve.
3. The displacement angle proportional solenoid
valve delivers pilot pressure oil to the regulator in
swing pump according to this signal in order to
change the pump displacement angle.
4. As a result, delivery flow rate of the swing pump
becomes delivery flow rate in proportion to the
rotation of swing speed dial.
T2-1-14
㩷
㩷
㩷 Swing Speed Dial
MC2/A
Displacement 5-Spool Solenoid

Angle Valve Unit
Proportional
Solenoid Valve
Swing Pilot
pump Pump 㩷
㪫㪉㪚㪞㪄㪇㪉㪄㪇㪈㪄㪇㪇㪌㩷
㩷
㩷
T2-1-15
OTHER CONTROLS㩷㩷
Swing Alarm Control㩷
Purpose: Lights the swing alarm indicator when the

swing lever is operated.
Operation:
1. When the swing control lever is operated, MC2/A
receives the voltage signal from the swing remote
control pressure sensor in the operated side.㩷
2. MC2/A excites the swing alarm indicator relay.㩷
3. As a result, current from the battery passes
through the battery relay, swing alarm indicator
relay and flasher relay and lights the swing alarm
indicator.㩷
㩷
T2-1-16
㩷
㩷
Swing
Motor
MC2/A
From Battery Swing

Control
Valve
Battery Relay Swing Alarm

Indicator Relay
Swing Alarm Indicator (Left)

Swing Pump
Swing
Control
Lever
Flash Relay
Swing Alarm Indicator (Right)

5-Spool Solenoid
Valve Unit
Pilot Pump
㩷
㪫㪉㪚㪞㪄㪇㪉㪄㪇㪈㪄㪇㪇㪍㩷
㩷
㩷
㩷
T2-1-17
Drum Rotation Sensing Control㩷㩷
Purpose: Detects the rotation of a drum.

This function is useful when a drum
rotation cannot be detected visually during
feathering hoisting or lowering operation
such as alignment.
Operation:
1. When a drum rotates while the drum rotation
sensing switch is in the ON position, MC2/A
receives a signal from the drum rotation detection
sensor.㩷
2. MC2/A sends electrical current to the rotation
sensing solenoid for a specific period of time.
[30 ms (0.03 sec.)]㩷
3. The rotation sensing solenoid notifies drum
rotation to the operator by vibrating the rod of
control lever.㩷
4. When MC2/A receives a signal of specified
frequency of (4 Hz) or less, MC2/A lets 100%
current flow into the rotation sensing solenoid.㩷
5. When MC2/A receives a signal of specified
frequency or higher, MC2/A reduces current
flowing into the rotation sensing solenoid
inversely proportional to the frequency.㩷
㩷
㩷
T2-1-18
NOTE: The following figure shows front drum rotation sensing situation.
Control Lever
Rod Rod Rod
Front Rear Boom Hoist
Front Rotation Vibration

Detection
Sensor A
Front㩷 Front Rotation

Drum Detection
Sensor B
Front Rear Boom Hoist

Rear Rotation Rotation Rotation Rotation
Detection Sensing Sensing Sensing
Sensor A Solenoid Solenoid Solenoid
Rear Rear Rotation

Drum Detection
Sensor B
Boom Hoist Rotation

Detection Sensor A
Boom Hoist MC2/A

Drum
Drum Rotation
Sensing Switch
㩷
㪫㪉㪌㪥㪄㪇㪉㪄㪇㪈㪄㪇㪉㪇㩷
T2-1-19
Pilot Pressure Drop Alarm Indicator Control㩷㩷
Purpose: Notifies the operator the pilot pressure

drop by lighting the pilot pressure drop
alarm indicator.
Operation:
1. MC2/A receives a voltage signal from the primary
pilot pressure sensor.㩷
2. When the pilot pressure reaches the set pressure
of 3 MPa or lower, MC2/A lights the pilot pressure
drop alarm indicator.㩷
㩷
㩷
㩷
㩷
Accumulator
Primary Pilot
Pressure
Sensor
MC2/A
Pilot Pump
Pilot Pressure
Drop Alarm
Indicator
From Battery
㩷
㪫㪉㪚㪞㪄㪇㪉㪄㪇㪈㪄㪇㪇㪎㩷
T2-1-20
(Blank)
T2-1-21
Winch Brake Mode Control㩷㩷
Purpose: Controls the brakes for the front motor and

rear motor.
x Motor Brake Control㩷
Operation:
1. When hoisting or lowering operation is carried out
by using front or rear motor, MC2/A receives a
voltage signal from the remote control pressure
sensor of the corresponding pilot circuit.㩷
2. MC2/A actuates the brake release solenoid valve
for the corresponding motor.㩷
3. Therefore, as pressure oil from the pilot pump
flows to the motor brake through the 5-spool
solenoid valve, the motor brake is released.㩷
㩷
㩷
T2-1-22
㩷
㩷 Brake Release
Solenoid Valve㩷
㩷
Brake㩷
Brake Mode
Selection Key Switch㩷
Front Drum㩷
MC2/A
Release Brake
Solenoid Valve
Brake㩷
Remote Control
Pressure Sensor
Rear
Drum㩷
Front㩷 Rear㩷
Remote
Control Valve
Pilot
Pump㩷
5-Spool Solenoid Valve Unit㩷

T2CG-02-01-008

㩷
T2-1-23
Boom Hoist Lock Control㩷㩷
Purpose: Locks the boom hoist drum and releases 㩷

the brake. 㩷
㩷
Operation
1. When boom hoist hoisting or lowering operation is 㩷
made, MC2/A receives a voltage signal from the 㩷
corresponding remote control pressure sensor.㩷㩷
2. MC2/A actuates the boom hoist drum unlocking
solenoid valve.㩷㩷
3. Therefore, as pressure oil from the pilot pump 㩷
flows to the boom hoist drum lock and boom hoist 㩷
motor bake through the pressure reducing valve
and boom hoist drum unlocking solenoid valve, 㩷
the lock and brake of boom hoist motor are 㩷
released.㩷㩷
㩷
㩷
㩷
㩷
㩷
T2-1-24
㩷
Boom Hoist Drum
Boom Hoist
Motor Brake Boom Hoist
Drum Lock
Boom Hoist
Motor㩷
Rear Control Valve㩷
Boom Hoist
Drum Lowering
Proportional
Solenoid Valve㩷
Remote
From Control
Boom Hoist Pressure
Pedal㩷 Sensor㩷
Boom Hoist Drum
Hoisting Proportional From Boom
Solenoid Valve㩷 Hoist Pedal㩷
Main Pump 1㩷
Boom Hoist㩷
Pilot Pump㩷
Boom Hoist Drum 5-Spool Solenoid 㩷

Unlocking Valve㩷 Valve Unit㩷㩷
㪫㪉㪚㪥㪄㪇㪉㪄㪇㪈㪄㪇㪇㪈㩷
T2-1-25
Engine Start Interlock Control㩷㩷
Purpose: Prevents the engine from starting when

engine start involves a potential hazard.
Front Drum Brake Mode
Selection Switch㩷
Operation:
1. MC2/A activates the engine starting relay when
MC2/A receives an auto brake position signal
Rear Drum Brake Mode
from front and rear drums brake mode selection Selection Switch㩷
switch while the swing brake switch is set in the
MC2/A
brake position.㩷
2. When the key switch is set to the start position,
Swing Brake Switch
the voltage signal passes through the engine
starting relay, the starter relay operates, the
starter motor starts turning and the engine starts.㩷
3. MC2/A lights the brake unapplied indicator for five
seconds when the key switch is turned to the start
position while the engine starting relay is OFF.㩷
Key Switch
Brake Unapplied
Indicator㩷
Engine
Starting
Relay㩷
Starter
Relay㩷㩷
Starter Motor
㩷
㪫㪉㪚㪞㪄㪇㪉㪄㪇㪈㪄㪇㪈㪈㩷
T2-1-26
Motor Cut-Off Pressure Control㩷㩷
Front Lowering
Purpose: Regulates the lowering speed by reducing 㩷 Remote Control
Pressure Sensor
cut-off pressures of the front or rear
motors.
Rear Lowering
Operation: Remote Control
Pressure Sensor㩷
1. MC2/A sends a signal to either front or rear motor
output torque limit solenoid valve when MC2/A
receives a voltage signal that represents
operating pressure of the front or rear lowering
remote control pressure sensor is 0.3 MPa (3.1
kgf/cm2, 43.6 psi) or higher.㩷
2. Therefore, either front or rear motor output torque
limit solenoid valve operates, motor cut-off
pressure is reduced and the lowering speed is
regulated.㩷
㩷
Rear
Drum
Rear Motor Output

Torque Limit
Solenoid Valve㩷
Front
Drum
Front Motor
Output Torque 㩷
㩷 Limit Solenoid
Valve㩷
㪫㪉㪚㪞㪄㪇㪉㪄㪇㪈㪄㪇㪈㪋㩷
T2-1-27
Front, Rear and Boom Hoist Motor Speed Control㩷㩷
Purpose: Controls the speed of front, rear and boom

hoist motors by changing the displacement
angle of motors according to the position of
speed control dial.
Operation:
1. The speed control dial sends a voltage signal to
MC2/B when operating the speed control dial of
the front, rear or boom hoist motor while the low
speed lock switch is in the OFF position.㩷
2. MC2/B sends a signal in proportion to the position
of speed control dial to the front, rear or boom
hoist motor displacement angle proportional
solenoid valve.㩷
3. The front, rear or boom hoist motor displacement
angle proportional solenoid valve delivers pilot
pressure oil according to the signal to each motor
regulator.㩷
4. Therefore, the displacement angle of front, rear or
boom hoist motor is changed and each motor
speed is regulated.㩷
㩷
T2-1-28
NOTE: The following figure shows front motor speed control.㩷

The rear and boom hoist motors use the same control method.
㩷 Slow Speed Lock Switch㩷
Speed Control
Front Dial㩷
Front
Drum㩷
Front Motor
Displacement
Angle
Proportional
Solenoid Valve
㩷
Main Pump 1㩷
Rear Boom Hoist㩷
Front㩷
Remote Control
Valve㩷
Second Overhoist
Solenoid Valve㩷
Pilot Pump㩷
㩷
㪫㪉㪚䌎㪄㪇㪉㪄㪇㪈㪄㪇㪇㪉㩷
T2-1-29
Emergency Operation Control㩷㩷
Purpose: The brake release solenoid valve releases

the drum motor brake by turning an
emergency operation switch ON even if a
failure of MC2/A occurs.
Operation:
1. If a signal between MC2/A and the brake release
solenoid valve is blocked due to the internal logic
circuit failure of MC2/A, the brake release
solenoid valve is switched and pilot pressure oil
acting on the drum motor brake flows to the
hydraulic oil tank.㩷
2. As a result, the drum motor brake is operated
suddenly despite of hoisting, boom hoisting or
swing operation.㩷
3. At this time, when the emergency operation
switch is set to the ON position, electric current
flows from terminal D4 to terminal A23 of MC2/A.㩷
4. Electric current from terminal A23 flows through
the logic circuit of MC2/A and flows to the swing
brake release solenoid valve, boom hoist drum
unlocking solenoid valve and front/rear motor
brake release solenoid valves through terminals
E4, E18, E5 and E17.㩷
Terminal E4:㩷Boom hoist drum unlocking solenoid
valve (5-spool solenoid valve unit)
Terminal E18:㩷Front motor brake release solenoid
valve
Terminal E5:㩷 Rear motor brake release solenoid
valve
Terminal E17:㩷Swing brake release solenoid valve
(5-spool solenoid valve unit)㩷
5. Therefore, when each㩷 motor brake release
solenoid valve of front/rear drums, boom hoist
drum unlocking solenoid valve and swing brake
release solenoid valve are switched, pressure oil
from the pilot pump acts on the drum motor brake.㩷
6. Therefore, the drum motor brake is released.
Then the hoisting, boom hoisting and swing
operations can be done even if a failure of the
logic circuit in MC2/A occurs.㩷
㩷
T2-1-30
㩷
㩷
㩷 Front Motor
Brake Release
Solenoid Valve
Front
Motor㩷
Rear Motor
Brake Release
Solenoid Valve
Emergency
Rear
Operation Switch㩷
Motor㩷
Swing Boom
Motor㩷 Hoist
Motor㩷
Pilot Pump㩷
5-Spool Solenoid Valve Unit㩷㩷
㪫㪉㪚㪞㪄㪇㪉㪄㪇㪈㪄㪇㪈㪊㩷
T2-1-31
Boom Hoist Drum Auto Stop Control㩷㩷
Purpose: Controls pilot pressure by actuating the

boom hoist drum hoisting or lowering
proportional solenoid valve according to a
limit switch signal, IDU data and a
cancellation switch signal.
Operation:
1. MC2/B receives a voltage signal from the limit
switch, IDU and the cancellation switch.㩷
2. MC2/B sends a voltage signal to the boom hoist
drum hoisting or lowering proportional solenoid
valve.㩷
3. Therefore, the boom hoist drum hoisting or
lowering proportional solenoid valve operates and
blocks pilot pressure oil flowing through the boom
hoist spool in rear control valve.㩷
4. As the boom hoist spool returns to the neutral
position and pressure oil from main pump 1 does
not flow, the boom hoist motor stops.㩷
㩷
T2-1-32
㩷
㩷
Boom Hoist Drum Hoisting

Proportional SOL㩷
Auto Stop Release Boom Hoist SW Boom Hoist Drum Lowering

Proportional SOL㩷
Auto Stop Override Key SW
Boom Anti-Two Block
Tower Upper Limiter
Boom Secondary Anti-Two Block
Crane
Terminal Box㩷
Main Hook
Anti-Two
Block Boom Hoist Drum
Hoisting Stop㩷
Aux. Hook Boom Hoist Drum
Anti-Two Lowering Stop㩷
Block
Support
Prevention
Tower Breakage
Tower Prevention㩷
Terminal Box㩷
Tower Jib
Anti-Two
Block
Tower Jib
Back Stop
Alignment
Main Hook
Anti-Two
Block
Aux. Hook
Anti-Two
Block
Tower Jib
Secondary
Anti-Two
Block 㩷
㪫㪉㪚㪥㪄㪇㪉㪄㪇㪈㪄㪇㪇㪊㩷
T2-1-33
Front Drum Auto Stop Control㩷㩷

front drum hoisting or lowering proportional
solenoid valve according to a limit switch
signal, IDU data and a cancellation switch
signal.
Operation:
2. MC2/B sends a voltage signal to the front drum
hoisting or lowering proportional solenoid valve.㩷
3. Therefore, the front drum hoisting or lowering
proportional solenoid valve operates and blocks
pilot pressure oil flowing through the front spool
(low) in rear control valve.㩷
4. As the front spool (low) returns to the neutral
position and pressure oil from main pump 2 does
not flow, the front motor stops.㩷
㩷
T2-1-34
㩷
㩷
Front Drum Hoisting

Proportional SOL㩷
Front Drum Lowering

Proportional SOL㩷
Auto Stop Release Front SW
Boom Secondary Anti-Two Block
Crane Terminal Box㩷
Main Hook
Anti-Two Front Drum
Block Hoisting Stop㩷
Aux. Hook
Anti-Two Front Drum
Block Lowering Stop
Support
Prevention
Tower Terminal Box㩷
Main Hook
Anti-Two
Block
Aux. Hook
Anti-Two
Block
Tower Jib
Secondary
Anti-Two
Block 㩷
㪫㪉㪚㪥㪄㪇㪉㪄㪇㪈㪄㪇㪇㪋㩷
T2-1-35
Rear Drum Auto Stop Control㩷㩷

rear drum hoisting or lowering proportional
solenoid valve according to a limit switch
signal, IDU data and a cancellation switch
signal.
Operation:
2. MC2/B sends a voltage signal to the rear drum
3. Therefore, the rear drum hoisting or lowering
proportional solenoid valve operates and blocks
pilot pressure oil flowing through the rear spool
(low) in rear control valve.㩷
4. As the rear spool (low) returns to the neutral
position, pressure oil from main pump 1 does not
flow, the rear motor stops.㩷
㩷
㩷
㩷
T2-1-36
㩷 Rear Drum Hoisting

Proportional SOL㩷
Rear Drum Lowering

Proportional SOL㩷
Auto Stop Release Front SW
Boom Anti-Two Block
Tower Upper Anti-Two Block
Rear Drum
Main Hook Hoisting Stop㩷
Anti-Two
Block Rear Drum
Lowering Stop㩷
Aux. Hook
Anti-Two Support
Block Prevention㩷
Tower
Breakage
Crane Terminal Box㩷 Prevention
Tower Jib
Anti-Two
Block
Tower Jib
Back Stop
Alignment
Main Hook
Anti-Two
Block
Aux. Hook
Anti-Two
Block
Tower Jib
Secondary
Anti-Two
Block 㩷
T2CN-02-01-005
T2-1-37
Tower Jib Boom Hoist Auto Stop Control 㩷
(Optional)㩷

tower jib hoisting or lowering solenoid
valve according to a limit switch signal, IDU
data and a cancellation switch signal.
Operation:㩷
2. MC2/B sends a voltage signal to the tower jib
hoisting or lowering solenoid valve.㩷
3. Therefore, the tower jib hoisting or lowering
solenoid valve operates and blocks pilot pressure
oil flowing through the spool in front control valve.㩷
4. As the spool returns to the neutral position and
pressure oil from main pump 2 does not flow, the
tower jib boom hoist motor stops.㩷
㩷
㩷
㩷
㩷
㩷
㩷
㩷
㩷
㩷
T2-1-38
Tower Jib
Hoisting SOL
Tower Jib
Lowering SOL
Clamshell Lower
Anti-Two Block
Boom Secondary
Anti-Two Block
Main Hook
Anti-Two Block Tower Jib
Hoisting Stop㩷
Aux. Hook Tower Jib

Anti-Two Lowering Stop㩷
Block
Support
Prevention
Tower Terminal Box
Main Hook
Anti-Two
Block
Aux. Hook
Anti-Two
Block
Tower Jib
Second
Anti-Two
Block
T2CN-02-01-006㩷
T2-1-39
Second Overhoist Auto Stop Control㩷㩷
Purpose: Controls primary pilot pressure for the front,

rear, third and boom hoist by switching the
second overhoist solenoid valve ON/OFF
according to a limit switch signal and a
remote control pressure restoration switch
signal.
Operation:
switch when overhoisting, circuit breaking or
short-circuit occurs.㩷
2. MC2/B turns the second overhoist solenoid valve
OFF and blocks pilot pressure oil flowing through
the front, rear, third and boom hoist pilot valves.㩷
3. Therefore, the corresponding spools in front or
rear control valve return to the neutral position, the
motors operated at front, rear, third and boom
hoist stop.㩷
4. MC2/B receives a signal from the remote control
pressure restoration switch by turning the remote
control pressure restoration switch ON.㩷
5. MC2/B turns the second overhoist solenoid valve
ON and delivers pressure oil from the pilot pump
to the front, rear, third and boom hoist pilot valves.㩷
㩷
㩷
T2-1-40
㩷
㩷
㩷
Second
Overhoist SOL
Boom Secondary
Anti-Two Block
Tower Terminal Box㩷
Tower Jib Second

Anti-Two Block㩷
㩷
㪫㪉㪚㪥㪄㪇㪉㪄㪇㪈㪄㪇㪇㪎㩷
T2-1-41
Front Drum Surge Pressure Reduction Control㩷㩷
Purpose: Slowly reduces pilot pressure applied to the

front spool (low) in front control valve by
controlling the front drum hoisting or
lowering proportional solenoid valve in
order to reduce a surge pressure caused at
auto stop of the front drum.
Operation:
1. MC2/B sends a voltage signal to the front drum
2. At auto stop of the front drum, the front drum
hoisting or lowering solenoid valve delivers
pressure oil from the front pilot valve to the
hydraulic oil tank according to this voltage signal.
This reduces the surge pressure.㩷
㩷
㩷
T2-1-42
㩷
㩷
㩷
㩷 Front Drum Hoisting
Proportional SOL㩷
Front Drum Lowering

Proportional SOL㩷
Support
Prevention㩷
㩷
㪫㪉㪚㪞㪄㪇㪉㪄㪇㪈㪄㪇㪉㪇㩷
T2-1-43
2-Speed Tower Jib Boom Hoist Flow Combining 㩷
Limit Control㩷
㩷
Purpose: When the attachment is a tower and the jib
boom hoist is a rear drum, the rear drum
hoisting or lowering proportional solenoid
valve prevents 2-speed flow combining
from the rear spool.
Also, this control slowly reduces pilot
pressure applied to the rear spool (low) in
front control valve by controlling the rear
drum hoisting or lowering proportional
solenoid valve in order to reduce a surge
pressure caused at auto stop of rear drum.
Operation:
x 2-Speed Flow Combining Prevention㩷
2. The rear drum hoisting or lowering proportional
solenoid valve delivers pressure oil from the rear
pilot valve to the hydraulic oil tank according to
this voltage signal. This prevents 2-speed flow
combining from the rear spool.㩷
㩷
x Surge Pressure Reduction㩷
2. At auto stop of the rear drum, the rear drum
hoisting or lowering proportional solenoid valve
delivers pressure oil from the rear pilot valve to
the hydraulic oil tank according to this voltage
signal. This reduces the surge pressure.㩷
T2-1-44
㩷
㩷
㩷
㩷 Rear Drum Hoisting
Proportional SOL㩷
Rear Drum Lowering

Proportional SOL㩷
㩷
㪫㪉㪚㪞㪄㪇㪉㪄㪇㪈㪄㪇㪉㪈㩷
T2-1-45
External Indication Lamps Control(Optional)㩷㩷
Purpose: Turns ON and OFF the external indication

lamp according to IDU data and a signal
from the auto stop override key switch.
Operation:
1. MC2/B and the auto stop override key switch
send a voltage signal to IDU.㩷
2. IDU turns the moment limiter release indicator ON
and OFF according to the voltage signal.㩷
㩷
Auto stop IDU data (CAN communication data)
Moment limiter
override key Assembly and
Digging mode Overload Pre-indication release indicator
switch disassembly
Release -㩷 -㩷 -㩷 -㩷 Red
Assembly and
No release -㩷 -㩷 -㩷 Red
disassembly
No release Crane Overload -㩷 -㩷 Red
No release Crane No overload Pre-indication -㩷 Yellow
No assembly
No
No release Crane No overload and Green
pre-indication
disassembly
No assembly
No release Digging - -㩷 and Turn OFF
disassembly
㩷
T2-1-46
㩷
㩷
㩷
㩷
Buzzer
Auto Stop Override 3-Color Light

Key Switch Relay (Green)㩷
3-Color
Light
(Green)㩷 3-Color Light
Relay (Yellow)
3-Color
Light
(Yellow)㩷
3-Color Light
Relay (Red)
3-Color
Light
(Red)㩷
㩷
㪫㪉㪚㪥㪄㪇㪉㪄㪇㪈㪄㪇㪇㪏㩷
㩷
㩷
T2-1-47
Audible Output Control㩷
Purpose: Outputs the audio signal from each speaker by writing audio-codes into the audio unit according to IDU
data and operational status.
Operation:
1. MC2/B receives a voltage signal according to IDU data and operational status.㩷
2. MC2/B writes the audio-codes according to the voltage signal to the audio unit.㩷
3. The audio unit operates each speaker and outputs the audio signal.㩷
㩷
㩷
T2-1-48
㩷
㩷
㩷
㩷
㩷
㪫㪉㪚㪥㪄㪇㪉㪄㪇㪈㪄㪇㪇㪐㩷
T2-1-49
(Blank)
㩷
T2-1-50
SYSTEM / Hydraulic System㩷
OUTLINE㩷㩷
The hydraulic system is classified broadly into pilot

circuit and main circuit, and it consists of the following
components.
Pilot Circuit㩷
Hoisting Circuit (Rear, Front)㩷
Hydraulic System㩷 Hoisting Brake Circuit (Optional)㩷
Boom Hoist Circuit㩷
Quick Draw / Third (Optional) Circuit㩷
Main Circuit㩷 Travel Circuit㩷
Swing Circuit㩷
Counterweight / Flip Circuit㩷
Reeving Winch Circuit (Optional)㩷
Boom Foot Remove and Install Circuit㩷
Side Frame Connect / Jack-Up Circuit㩷
Take-Up Circuit (Optional)
Oil Cooler Circuit㩷
㩷
Pilot Circuit:㩷 • Quick Draw / Third (Optional) Circuit
The pilot circuit carries out selection of spool in the The quick draw / third (optional) circuit extends or
control valve as well as control of pump, valve, retracts the quick draw cylinder and drives the jib
motor and parking brake release by using pressure boom hoist motor (optional) by using pressure oil
oil from the pilot pump.㩷 from main pump 2.㩷
㩷 • Travel Circuit
Main Circuit:㩷 The travel circuit drives the machine by driving
The main circuit drives each actuator by using travel mechanism by using pressure oil from
pressure oil from main pumps (pump 1 and pump 2), pumps 1 and 2.㩷
swing pump, oil cooler pump, boom foot / lower • Swing Circuit
control hydraulic source pump, reeving pump, etc.㩷 The swing circuit slews the crane upper by driving
• Hoisting Circuit (Rear, Front) the swing reduction unit by using pressure oil
The hoisting circuit raises or lowers the lifting load from the swing pump.㩷
by driving the front and rear drums by using • Counterweight / Flip Circuit
pressure oil from pumps 1 and 2.㩷 The counterweight /flip circuit removes / installs
• Hoisting Brake Circuit (Optional) the counterweight or raises / lowers the live mast
When the brake mode selection key switch is by driving the counterweight cylinder or flip
operated, the front and rear hoisting brakes are cylinder by using pressure oil from the swing
shifted to “AUTO” or FREE”.㩷 pump.㩷
• Boom Hoist Circuit • Reeving Winch Circuit (Optional)
The boom hoist circuit hoists and lowers the The reeving winch circuit (optional) drives the
boom by driving the boom hoist drum by using reeving winch by using pressure oil from the
pressure oil from pump 1. reeving pump (optional).
T2-2-1
㩷
• Boom Foot Circuit
The boom foot circuit is driven by pressure oil
from the boom foot / lower control hydraulic oil
source pump. This circuit extends or retracts the
boom foot cylinder in order to remove and install
the boom foot.㩷
• Side Frame / Jack-Up Circuit
The side frame / jack-up circuit extends or retracts
the side frame cylinder and jack-up cylinder by
using pressure oil from the boom foot / lower
control hydraulic oil source pump.㩷
• Take-Up Circuit (Optional)
The take-up circuit applies fixed tension to the
track shoe by pushing out the front idler by using
pressure of the travel circuit.㩷
• Oil Cooler Circuit
The oil cooler circuit cools hydraulic oil by driving
the oil cooler motor by using pressure oil from the
oil cooler pump.㩷
T2-2-2
PILOT CIRCUIT㩷㩷
Outline㩷㩷
The pilot circuit is operated by pressure oil from the The pilot circuit carries out delivery flow rate control of
pilot pump, which consists of the following pumps (1, 2) and swing pumps, selection of the control
components. 㩷 valve spool, displacement angle control of the motors
and brake control of the winch drum.㩷
㩷
NOTE: The item with mark* is optional.
㩷
㩷
㩷 Pilot Pump㩷
㩷
㩷
Accumulator㩷 Front Motor Brake Release
Pilot Filter㩷 Solenoid Valve㩷 Front Motor
Gate Rear Motor Brake Release

Pressure Rear Motor
Lock Solenoid Valve㩷
Valve㩷 Reducing
Valve㩷
Regulator Swing Pump㩷
Pilot Relief Swing Pump Displacement Angle

Proportional Solenoid Valve㩷 Regulator Regulator
Valve㩷 (Pump 1) (Pump 2)
Pump Displacement Angle
Proportional Solenoid Valve㩷
Power Increase Solenoid Valve㩷
Swing Remote Control Valve㩷 Swing Control Valve
Right Travel Remote Control Valve
Left Travel Remote Control Valve
Rear Control Front Control

Valve Valve
Second Front Drum Hoisting and Front Control Rear Control

Overhoist Front Remote Lowering Proportional
Control Valve㩷 Valve Valve
Solenoid Valve㩷 Solenoid Valve
Rear Drum Hoisting and
Rear Remote Rear Control Front Control
Lowering Proportional
Control Valve㩷 Valve Valve
Solenoid Valve
Boom hoist Boom hoist Drum

Remote Control Hoisting and Lowering Rear Control
Valve㩷 Proportional Solenoid Valve
Valve
*Third Drum Hoisting
*Third Remote and Lowering Front Control
Control Valve㩷 Proportional Solenoid Valve
Valve
High Travel Speed

Travel Speed Control Valve
Selection Solenoid Valve
Swing Brake Solenoid Swing Brake Valve

Valve㩷
Boom hoist Drum

Boom hoist Drum Lock
Unlocking Solenoid Valve
5-Spool Solenoid Valve Unit
T2-2-3
Gate Lock Circuit
x Gate Lock ON x Gate Lock OFF

The gate lock solenoid valve receives no signal The gate lock solenoid valve receives a signal while
while the gate lock lever is set in the lower position the gate lock lever is set in the upper position (OFF).㩷
(ON).㩷 The passage from the pilot pump to the hydraulic oil
The passage from the pilot pump to the pilot circuit tank is blocked by the gate lock solenoid valve and
is blocked and pressure oil from the pilot pump flows the pilot circuit is kept at the set pressure of pilot
to the hydraulic oil tank through the pilot relief valve.㩷 relief valve.㩷
Therefore, as no pressure oil is applied to the pilot Consequently, each actuator can operate.㩷
circuit, each actuator cannot operate.㩷㩷
㩷㩷
㩷㩷 Gate Lock
Gate Lock Solenoid Valve㩷
㩷 Solenoid Valve㩷㩷
㩷
Pilot
Pilot Pump㩷 Pilot
Pump㩷 Pilot Filter㩷
Filter㩷
To Pilot㩷
To Pilot㩷 Pilot Relief Circuit㩷
㩷 Valve 㩷
Pilot Relief Circuit㩷
㩷 Valve 㩷㪫㪉㪚㪞㪄㪇㪉㪄㪇㪉㪄㪇㪈㪌㩷
㪫㪉㪚㪞㪄㪇㪉㪄㪇㪉㪄㪇㪈㪋㩷㩷
㩷
㩷
T2-2-4
Remote Control Valve Circuit 㩷
The following explains the front drum hoisting.㩷㩷

㩷
When the gate lock is turned OFF, pressure oil from
the pilot pump flows from port P1 in the gate lock
valve to port P in the 5-spool solenoid valve unit.㩷
When front hoisting operation is carried out, pressure
oil reduced by the pressure reducing valve flows to
the end of front drum spool in front control valve
through the second overhoist solenoid valve and
front drum remote control valve.㩷
As a result, pressure oil from the main pump flows to
the front drum motor and the front drum starts
hoisting.㩷
㩷
㩷 from Front To Front
Control Valve Control Valve
㩷
㩷
Front Drum
Remote
Control Valve
Gate Lock
Solenoid Valve
5-Spool Solenoid
Valve Unit㩷
Pressure
Reducing
Valve㩷
Pilot
Pump㩷
Gate Lock Valve㩷
㩷
㩷
Pilot Relief Second Overhoist
Valve 㩷 Solenoid Valve㩷㪫㪉㪚㪞㪄㪇㪉㪄㪇㪉㪄㪇㪇㪈㩷
㩷
㩷
T2-2-5
MAIN CIRCUIT㩷
Pressure oil from pump 1 flows to the right travel motor, Pressure oil from the boom foot / lower control
boom hoist motor, rear and front drum motors through hydraulic oil source pump flows to the 4-spool solenoid
the rear control valve. valve unit. Pressure oil is used for driving pressure of
Pressure oil from pump 2 flows to the left travel motor, the left and right boom foot cylinders as well as
quick draw cylinder or third motor (optional), rear and hydraulic oil source of the lower actuator.
front drum motors through the front control valve. Pressure oil from the lower control section in 4-spool
Pressure oil from both main pumps 1 and 2 flows to solenoid valve unit flows to the lower control valve for
the rear and front drum motors. driving the side frame joint cylinder and jack cylinder.
Pressure oil to the quick draw cylinder is switched by
changing coupling connection and used for the third Pressure oil from the oil cooler pump drives the oil
motor (optional). cooler motor.
㩷
Pressure oil from the swing pump flows to the swing
motor. When the flip / counterweight spool in swing 㩷
control valve activates, pressure oil from the swing 㩷
pump also flows to the flip cylinder and counterweight 㩷
cylinder.
㩷
Return oil from the rear and front control valves, 㩷
3-spool and 4-spool solenoid valve units as well as oil 㩷
cooler returns to the hydraulic oil tank through the oil
cooler. If oil temperature is low (viscosity high), as 㩷
resistance flowing through the oil cooler is large, the 㩷
cooler relief valve opens and return oil flows back 㩷
directly to the hydraulic oil tank.
Return oil from the swing and lower control valves 㩷
flows back directly to the hydraulic oil tank. 㩷
㩷
㩷
㩷
㩷
㩷
㩷
㩷
㩷
T2-2-6
㩷
㩷
Pump 1㩷
Right Travel㩷 Right Travel motor

Pump 2㩷
Boom Hoist㩷
Suction Filter Boom Hoist Motor㩷
㩷 Swing Pump㩷
Rear (Low Speed)㩷
Rear Drum Motor㩷

Boom Foot / Front (High Speed)
Lower Control
Hydraulic Oil
Source Pump㩷 Front Drum Motor㩷
Front Control Valve㩷
Oil Cooler Pump㩷 Left Travel㩷 Left Travel Motor
Quick Draw /
Hydraulic Third motor㩷 Quick Draw Cylinder/
Oil Tank㩷 Third motor㩷
Rear (High Speed)
Rear Drum Motor㩷

Cooler Relief Front (Low Speed)
Valve㩷
Return Filter㩷
Front Drum Motor㩷
Oil Cooler㩷 Swing Control Valve㩷
Swing㩷 Swing Motor㩷
Oil Cooler Motor㩷 Flip / Counterweight 3-Spool Solenoid

Valve Unit㩷
Flip㩷
Left Boom Foot㩷 Left Counterweight
Right Boom Foot㩷

Left Side Frame Right Counterweight
Connecting Cylinder㩷 Lower Control Valve
Lower Control
Left Side Frame Hydraulic Oil Source
Right Side Frame Connecting㩷
Connecting Cylinder㩷 Right Counterweight
Right Side Frame Cylinder㩷
Connecting㩷
Right Front Jack
Cylinder㩷 Right Front Jack㩷 Left Counterweight
Cylinder㩷
Right Boom Foot
Right Rear Jack Right Rear Jack㩷 Cylinder㩷
Cylinder㩷 Right Flip Cylinder
Left Front Jack㩷 Left Boom Foot

Left Front Jack Cylinder㩷
Cylinder㩷
Left Rear Jack㩷 Left Flip Cylinder㩷
Left Rear Jack
Cylinder㩷
T2-2-7
NEUTRAL CIRCUIT㩷㩷
When all the control levers are set to the neutral

position, signal pressure from the remote control valve
does not act on the each spool end in control valve.
Therefore, pressure oil from pump 1 flows through the
rear control valve and pressure oil from pump 2 flows
through the front control valve. Both oil returns to the
hydraulic oil tank through the oil cooler. Pressure oil
from the swing pump returns to the hydraulic oil tank
through the swing control valve.
㩷
Swing Control
Valve㩷
Oil
Cooler
Pump 1㩷 Pump 2㩷 Swing

pump㩷
㩷
Hydraulic Oil Tank㩷㪫㪉㪚㪞㪄㪇㪉㪄㪇㪉㪄㪇㪇㪊㩷
T2-2-8
(Blank)
T2-2-9
HOISTING CIRCUIT(REAR, FRONT)㩷㩷
Single Operation㩷㩷
x Low Speed (First Speed) Operation 㩷
The following explains front low speed. Rear low
speed also works in the same manner.㩷㩷
When the front and rear remote control valves NOTE: The remote control valve is a PPC valve.
equipped with the detent stop at the low speed (first Even if primary pressure is constant,
detent) position, low pressure arises at the secondary pressure arises in proportion to
secondary side of remote control valve and acts on the lever stroke.㩷
the front (low speed) and front (high speed) spool "PPC" stands for "Pressure Proportional
ends. As output pressure is not high enough, only Control".
the front (low speed) spool moves.㩷㩷
As a result, only pressure oil from pump 2 flows to
the front motor. Pressure oil from pump 1 does not
flow to the front motor, but returns to the hydraulic oil
tank through the neutral passage of front (high
speed) spool.
Return oil from the front motor returns to the
hydraulic oil tank through the front (low speed)
spool.㩷
㩷
T2-2-10
Low Speed Operation㩷
Rear Motor Front Motor
㩷
Rear Drum Front Drum

Front
Front (High Speed)
(Low Speed)㩷
Pump 2㩷 Pump 1㩷
Front Remote Control Valve

(1st Detent Position of Lever)
5-Spool Solenoid
Valve Unit㩷
Pilot Pump㩷㩷
㩷 Second Overhoist
Solenoid Valve㩷㪫㪉㪚㪥㪄㪇㪉㪄㪇㪉㪄㪇㪇㪈㩷
T2-2-11
x High Speed (Second Speed) Operation㩷
When the front remote control valve is set in high

(second detent) position, secondary pressure of the
remote control valve increases further and moves the
front (high speed) spool.
Pressure oil from pumps 1 and 2 are combined after
flowing through the front (high speed) and (low
speed) spools and flows to the front motor.
Consequently, the front motor rotes at high speed.
The rear motor works in the same manner.
T2-2-12
High Speed Operation㩷㩷
Rear
㩷 Motor㩷 Front Motor㩷
Front Control Valve㩷 Rear Control Valve㩷
Front Front
(Low Speed)㩷 (High Speed)
Pump 2㩷 Pump 1㩷
Front Remote Control Valve

(2nd Detent Position of Lever)
5-Spool Solenoid
Valve Unit㩷
Pilot Pump㩷㩷
㪫㪉㪚㪥㪄㪇㪉㪄㪇㪉㪄㪇㪇㪉㩷
Second Overhoist Solenoid Valve㩷
㩷
T2-2-13
Combined Operation Circuit
The following explains the combined operation of

front and rear motors.㩷
㩷
NOTE: In case of combined operation of the front
low speed (first speed) and rear high speed
(second speed), as pressure oil is not
supplied to the front motor, the front motor
does not rotate. (Refer to the pages for
combined operation of the front low speed
(first speed) and rear high speed (second
speed).)
㩷
x Front Low Speed (First Speed) + Rear Low Speed
(First Speed)
The front and rear remote control valves are at the
first detent position. Therefore, as secondary
pressure of each remote control valve is low, only
the front and rear low speed spools in the control
valve move. (Refer to the pages for hoisting single
operation.)
Pressure oil from main pump 2 flows to the front
motor through the front low speed spool in front
control valve and the front drum rotates. Pressure oil
from pump 1 flows to the rear motor through the rear
low speed spool in rear control valve and the rear
drum rotates.㩷
Therefore the front drum rotates by pressure oil from
pump 2 and the rear drum rotates by pressure oil
from pump 1.㩷
T2-2-14
Front Low Speed Operation + Rear Low Speed 㩷
Operation㩷
㩷
Front Motor㩷
Rear Motor㩷
Front (Low Speed)㩷
Rear
(Low Speed)㩷

Rear Front
(High Speed)㩷 (High Speed)
Pump 2㩷 Pump 1㩷
Rear Remote Control Valve

Front Remote Control Valve (1st Detent Position of Lever)㩷
(1st Detent Position of Lever)㩷

Second Overhoist
Solenoid Valve㩷
Pilot Pump㩷㩷
㪫㪉㪚㪥㪄㪇㪉㪄㪇㪉㪄㪇㪇㪊㩷
T2-2-15
x Front High Speed (Second Speed) + Rear High 㩷
Speed (Second Speed)
Pressure oil from pumps 1 and 2 is combined and 㩷 Pump 2㩷
rotates the front and rear motors at high speed.㩷㩷
㩷㩷
The front and rear remote control valves are at the Rear (H) Spool㩷
second detent position. Therefore, as secondary 㩷
pressure of each remote control valve is high, both
low speed and high speed front and rear spools in Rear Motor㩷
control valve move. (Refer to the pages for hoisting
single operation.)
㩷
Rear (H) Spool㩷 Rear (L) Spool㩷
Pressure oil from pump 2 flows to the rear motor
through the rear high speed spool in front control
valve. Return oil from the rear motor is divided into Front (L) Spool㩷 Front (H) Spool㩷
two. One flows through the rear high speed and
front low speed spools and the other flows through
the rear low speed and front high speed spools,
Front Motor㩷
which are later combined and flows to the front
motor. Return oil from the front motor is divided into
two. One flows through the front low speed spool
and the other flows through the front high speed
Front (L) Spool㩷 Front (H) Spool㩷
spool so that each oil flows back the hydraulic oil
tank. (Refer to the figure in the right.)
㩷 Hydraulic
Pressure oil from pump 1 flows to the rear motor Oil Tank㩷
through the rear low speed spool in rear control
valve. Return oil from the rear motor is divided into
two. One flows through the rear high speed and
front low speed spools and the other flows through
the rear low speed and front high speed spools, Pump 1㩷
which are later combined and flows to the front
motor. Return oil from the front motor is divided into
Rear (L) Spool
two. One flows through the front low speed spool
and the other flows through the front high speed
spool so that each oil flows back to the hydraulic oil
Rear Motor
tank. (Refer to the figure in the right.)㩷
㩷
㩷
Rear (H) Spool Rear (L) Spool
Front (L) Spool Front (H) Spool
Front Motor
Front (L) Spool Front (H) Spool
Hydraulic
Oil Tank㩷
T2-2-16
Front High Speed Operation + Rear High Speed 㩷
Operation㩷
㩷
Rear Motor Front Motor㩷
Rear (High Speed)

Rear
(Low Speed)㩷
Front Front
(Low Speed)㩷 (High Speed)
Pump 2㩷 Pump 1㩷

Front Remote Control Valve (2nd Detent Position)㩷
(2nd Detent Position)

Second Overhoist
Solenoid Valve㩷
Pilot Pump 㩷
㪫㪉㪚㪥㪄㪇㪉㪄㪇㪉㪄㪇㪇㪋㩷
T2-2-17
x Front Low Speed (First Speed) + Rear High Speed
(Second Speed)
In this case, the rear drum rotates at high speed, but
the front drum does not rotate.㩷
The front remote control valve is set in the first
detent position. Therefore, only the low speed spool
in control valve moves. 㩷
The rear remote control valve is set in the second
detent position. Therefore, both the low speed and
high speed rear spools in control valve move. 㩷
Pressure oil from pumps 1 and 2 is combined after
passing through the front or rear control valve
respectively and flows to the rear motor so that the
rear drum rotates at high speed.㩷
As the front high speed spool is set in the neutral
position, return oil from the rear motor flows into the
tank through the rear low speed and front high
speed spools. Therefore, return oil from the rear
motor flows back to the hydraulic oil tank and the
front drum cannot rotate.㩷
T2-2-18
Front Low Speed Operation + Rear High Speed 㩷
Operation㩷
㩷
Rear Motor Front Motor㩷
Front (Low Speed)㩷
Rear
(Low Speed)
Rear (High Speed)㩷

Front
(High Speed)㩷
Pump 2㩷 Pump 1㩷

Front Remote Control Valve (2nd Detent Position)㩷
(1st Detent Position)

Second Overhoist
Solenoid Valve㩷
Pilot Pump㩷㩷
㪫㪉㪚㪥㪄㪇㪉㪄㪇㪉㪄㪇㪇㪌㩷
T2-2-19
x Front High Speed (Second Speed) + Rear Low
Speed (First Speed)
The front remote control valve is set in the second
detent position and the rear remote control valve is
set in the first detent position. Therefore, as
secondary pressure in the front remote control valve
is high, both the low speed and high speed front and
rear spools in control valve move. (Refer to the
pages for hoisting single operation.)
On the other hand, as secondary pressure in the
rear remote control valve is low, only the low speed
rear spools in control valve move. (Refer to the
pages for hoisting single operation.)
㩷
Pressure oil from pump 2 flows to the front motor
through the front low speed spool in front control
valve.㩷
Pressure oil from pump 1 flows to the rear motor
through the rear low speed spool in rear control
valve. Return oil from the rear motor flows from the
front high speed spool to the front motor.㩷
Consequently, the front drum rotates at high speed
and the rear drum rotates at low speed.
㩷
㩷
㩷
T2-2-20
SYSTEM / Hydraulic System
Front High Speed Operation + Rear Low Speed 㩷
Operation㩷
㩷 Rear motor Front Motor
Front (Low Speed)
Rear (High Speed) Rear

(Low Speed)
Front Control Valve
Rear Control Valve

Front
(High Speed)
Pump 2 Pump 1
Rear Remote Control Valve㩷

Front Remote Control Valve㩷 (First Detent Position)
(Second Detent Position)

Second Overhoist
Solenoid Valve
Pilot Pump
㪫㪉㪚㪥㪄㪇㪉㪄㪇㪉㪄㪇㪇㪍

㩷
T2-2-21
HOISTING CIRCUIT 㩷
Auto Stop Control
㩷
The auto stop control stops the hoisting / lowering
operation automatically when overhoist or overload
arises on the front or rear motor.㩷
The following explains front hoisting operation, The
rear motor also works in the same manner.㩷
㩷
When overhoist or overload arises during front
hoisting operation, MC2/B receives a signal from the
overhoist switch or IDU. MC2/B stops operation of the
hoisting proportional solenoid valve provided in the
circuit located between remote control valve spool
and control valve spool. The hoisting proportional
solenoid valve blocks secondary pressure from the
remote control valve and returns the control valve
spool to the neutral position so that the hoisting
operation stops.㩷
㩷
㩷
㩷
㩷
T2-2-22
Normal Operation State㩷
Front (Low Speed)
Front Control Valve
Rear Control Valve
Pump 1
Overhoist From Front Remote Front (High Speed)
Pump 2 Switch Control Valve
Front Drum Hoisting
Valve Rear Drum Front Drum
Auto-Stop State
Front (Low Speed)
Front Control Valve
Rear Control Valve
Pump 2 Overhoist Pump 1

Switch Front Drum Hoisting From Front Remote Front (High Speed) 㩷
Proportional Control Valve 㪫㪉㪚㪥㪄㪇㪉㪄㪇㪉㪄㪇㪇㪎㩷
Solenoid Valve
T2-2-23
Lowering Operation 㩷
If a lifting load lowering speed is faster than fed oil
During lowering operation, the motor is likely to be amount, pressure at the port B side reduces, the
rotated forcibly by the inertial force and self weight of counterbalance valve is closed and the lifting load
the lifting load. The counterbalance valve prevents stops lowering. At this time, as pressure at the port B
coasting by controlling the lowering speed due to the side increases suddenly, the surge relief valve absorbs
oil feed quantity.㩷 and releases serge pressure to the return circuit. (Fig.
The lowering circuit equips a serge relief valve, which 3)㩷
prevents serge pressure caused by the When pressure at the port B side increases, the
counterbalance valve at lowering stop.㩷 counterbalance valve opens and the lifting load starts
Pressure oil from the control valve, flows to the motor lowering.㩷
through Port B in the counterbalance valve.㩷㩷
The check valve and counterbalance valve block Thus, a lifting load lowers according to fed oil amount
return oil from the motor. (Fig. 1)㩷 from the control valve.㩷
When oil feed pressure rises, the counterbalance During the hoisting operation, as pressure oil flows
valve spool moves and opens the return oil passage from port A to the motor through the check valve, the
routed from the motor so that return oil flows to the hoisting speed is not limited by the counterbalance
hydraulic oil tank through the control valve. As a result, valve.㩷
the motor rotates and a lifting load starts lowering. (Fig. 㩷
2)㩷
㩷
㩷
㩷
Function of Counterbalance Valve
㩷
Fig. 1 Fig. 2 Fig. 3
Counterbalance Valve
Serge Relief
Valve
㩷
㪫㪉㪚㪞㪄㪇㪉㪄㪇㪉㪄㪇㪈㪍㩷
T2-2-24
BOOM HOIST CIRCUIT㩷㩷
Hoisting Operation
When the boom hoist remote control valve is set to

hoisting operation, secondary pressure in the remote
control valve moves the boom hoist spool in rear
control valve. Pressure oil from the pilot pump flows
through the boom hoist drum unlocking solenoid
valve and releases the boom hoist drum lock and
boom hoist motor brake.
Pressure oil from pump 1 flows to the boom hoist
motor through the boom hoist spool so that the boom
hoist drum rotates.㩷
As a result, the boom starts hoisting.
Boom Hoist Drum Lock
㩷 Boom Hoist Drum
Boom Hoist Motor Brake

Boom Hoist Motor
Boom Hoist Spool
Rear Control Valve
Boom Hoist Pedal
From Boom
Pump 1 Hoist Pedal
Boom Hoist Remote

Control Valve
Second
Overhoist SOL㩷
Boom Hoist Drum Lock SOL
Pilot Pump
5-Spool Solenoid Valve Unit 㩷

T2CN-02-02-008
T2-2-25
Auto Stop Control
When the boom hoist is overhoisted or overloaded, NOTE: When the boom hoist auto-stop is operated,
MC2/B receives a signal from the overhoist switch or MC2/A cuts the signal flowing to the boom
IDU. MC2/B stops operation of the boom hoist drum hoist drum lock solenoid valve and the
hoisting proportional solenoid valve provided in the boom hoist drum is locked.
circuit located between boom hoist remote control
valve spool and the front control valve spool. The
㩷
boom hoist drum hoisting proportional solenoid valve
blocks remote control pressure applying to the rear 㩷
control valve spool, returns the boom hoist spool in
rear control valve to the neutral position and the
hoisting operation stops.㩷
㩷
Boom Hoist Drum Boom Hoist Drum Lock
㩷
Boom Hoist Motor Brake

Boom Hoist Motor
Boom Hoist Spool
Rear Control Valve
From Boom Hoist Pedal
Boom Hoist Drum

Hoisting
From Boom
Proportional SOL
Hoist Pedal
Pump 1
Boom Hoist Remote

Control Valve
Second Pilot Pump

Overhoist SOL㩷㩷
T2CN-02-02-009
T2-2-26
QUICK DRAW / THIRD (OPTIONAL)
CIRCUIT㩷
When the quick draw / third remote control valve is Each circuit provides a quick coupler, which selects
operated, secondary pressure in the remote control the operation.
valve moves the quick draw / third spool in rear control
valve. Pressure oil from pump 2 flows to the quick
draw cylinder circuit or third drum circuit through the
quick draw / third spool.
㩷
㩷 Quick Coupler
㩷 Quick Draw Cylinder Third Drum㩷
Quick Draw / Front Control Valve㩷

Third Spool㩷
Pump 2㩷
Quick Draw / Third

Remote Control Valve㩷
Second Overhoist
Solenoid Valve㩷
Pilot Pump㩷
5-Spool Solenoid Valve Unit㩷㩷

T2CN-02-02-010
T2-2-27
TRAVEL CIRCUIT㩷㩷
Delivery pressure oil from pump 1 drives the travel

motor (left), delivery pressure oil from pump 2 drives
the travel motor (right) and both pressure oil releases
the parking brake.
The travel motor is a variable displacement type.
High/Low speed is selected by switching the high/low
travel speed selection switch.
x Low Travel Speed

When the high/low travel speed selection switch is
at the low speed position, electric current does not
flow through the travel high speed solenoid valve of
5-spool solenoid valve unit. The pilot valve in travel
motor is not selected as the travel high speed
solenoid valve is not selected. As pressure oil from
the travel circuit in control valve is not supplied to
the tilt piston, the displacement angle of travel motor
becomes larger and the travel motor rotates at low
speed.㩷
㩷
T2-2-28
Low Travel Speed㩷
㩷
㩷
Tilt Piston㩷 Pilot Valve Pilot Valve㩷 Tilt Piston㩷
㩷
Travel Motor (Left)㩷 Travel Motor (Right)㩷 Parking Brake㩷

Parking Brake㩷
From Boom
Hoist Pedal
From Boom
Hoist Pedal
From From
Travel Travel
Left Travel Remote
Pedal Pedal
Control Valve㩷
Pump 2㩷 Pump 1㩷 Right Travel Remote

Control Valve㩷
Travel High
Speed SOL㩷
Pilot Pump㩷
㩷
T2CN-02-02-011㩷
T2-2-29
x High Travel Speed 㩷
When the high/low travel speed selection switch is
at the high speed position, electric current flows
through the travel high speed solenoid valve in
5-spool solenoid valve unit. The travel high speed
solenoid valve is selected and the pilot valve in
travel motor is selected by pressure oil from the pilot
pump. Pressure oil from the travel circuit is supplied
to the tilt piston and the displacement angle of travel
motor becomes smaller.㩷
Consequently, the travel motor rotates at high
speed.㩷
㩷
T2-2-30
High Travel Speed㩷
㩷
㩷
Tilt Piston㩷 Pilot Valve Pilot Valve㩷 Tilt Piston㩷
㩷
Travel Motor (Left)㩷 Travel Motor (Right)㩷

Parking Brake㩷 Parking Brake㩷
From Boom
Hoist Pedal
From Boom
Hoist Pedal
From From
Left Travel Remote Travel Travel
Control Valve㩷 Pedal Pedal
Right Travel Remote

Control Valve㩷
Pump 2㩷 Pump 1㩷
Travel High
Speed SOL㩷
Pilot Pump㩷
㩷
T2CN-02-02-012㩷
T2-2-31
SWING CIRCUIT㩷㩷
When the swing remote control valve is operated, the

swing control valve spool moves and delivery pressure
oil from the swing pump flows to the swing motor
through the swing control valve.
Return oil from the swing motor flows directly to the
hydraulic oil tank.
When a force such as an inertial force of the swing
frame drives the swing motor during the swing
operation, cavitation occurs in the motor due to motor's
rotation speed exceeding the amount of oil fed from
the pump.
In order to avoid this, a make-up valve is provided,
draws oil from the return circuit and compensates lack
of oil feed.
The swing brake solenoid valve activates and releases
the swing brake by switching the swing brake switch.
㩷
T2-2-32
㩷
㩷
Make-Up Valve㩷
Make-Up Valve㩷
㩷
Swing Brake㩷 Swing Brake㩷
Swing Motor
Swing Control Valve㩷
Swing Remote Swing Pump㩷

Control Valve㩷
Pilot Pump㩷
㩷
Swing Brake 㪫㪉㪚㪞㪄㪇㪉㪄㪇㪉㪄㪇㪉㪈㩷
㩷 Solenoid Valve
T2-2-33
(Blank)
㩷
T2-2-34
㪚㪦㪬㪥㪫㪜㪩WEIGHT / FLIP CIRCUIT㩷㩷
The counterweight cylinder and the flip cylinder use 㩷

pressure oil from the swing pump.
The cylinders switch over to the swing circuit and
counterweight / flip circuit in the swing control valve.
Un-operated state㩷
When the counterweight / flip cylinders are not used,
the counterweight / flip solenoid valve in swing
control valve does not receive a signal.㩷
Therefore, the counterweight / flip spool keeps the
neutral position.㩷
Pressure oil from the swing pump flows to the
hydraulic oil tank through the neutral passage in
counterweight / flip spool.㩷
㩷
㩷
㩷 To Weight Remove
and Install To Flip
㩷 Cylinder㩷 Cylinder
Swing Spool
(To Swing Circuit)㩷
Swing Control Valve㩷
Weight Remove and

Install / Flip Spool㩷
Boom Foot / Lower Control

Hydraulic Oil Source Pump
Weight Remove and

Install / Flip SOL㩷 Swing Pump㩷
㩷
㪫㪉㪚㪞㪄㪇㪉㪄㪇㪉㪄㪇㪉㪊㩷
T2-2-35
Operated state
When either the counterweight switch or the flip NOTE: Pressure reducing valve (3-spool solenoid
switch is operated, the counterweight / flip solenoid valve unit):㩷
valve in swing control valve operates.㩷 This valve reduces inlet pressure to the
As the counterweight / flip spool switches, pressure 3-spool solenoid valve unit and delivers
oil from the swing pump flows to the 3-spool solenoid pressure oil to each spool end of the
valve unit.㩷 solenoid valve for operating the spools.
㩷
NOTE: Sequence valve (3-spool solenoid valve
The following explains with operating the
unit):㩷
counterweight cylinder (right) in the extending
This valve ensures pressure at the primary
direction.㩷
side (pressure reducing circuit) in
When the counterweight switch (right) is operated in
sequence valve.
the extending direction, the counterweight solenoid
valve (right) in 3-spool solenoid valve unit operates in NOTE: Relief valve (3-spool solenoid valve unit):㩷
the extending direction. As a result, pressure oil from This valve limits maximum pressure of the
the 3-spool solenoid valve unit flows to the bottom counterweight / flip cylinder.
side of counterweight cylinder (right) through the NOTE: Port relief valve (3-spool solenoid valve
sequence valve from the spool in counterweight unit):㩷
solenoid valve (right). The counterbalance valve is This valve protects a circuit by limiting the
operated by this pressure oil and the return circuit bottom side circuit pressure in the cylinder
opens. Consequently, the counterweight cylinder while the counterweight solenoid valve is in
(right) extends.㩷 the neutral position.
㩷 NOTE: Slow return valve:㩷
㩷 This valve cushions cylinder start by
restricting inlet pressure oil to the flip
cylinder.
NOTE: Overload relief valve (flip cylinder):㩷
This valve protects a circuit by limiting the
bottom side circuit pressure in the cylinder
while the flip solenoid valve is in the neutral
position.
NOTE: Counterbalance valve (counterweight
cylinder, flip cylinder):㩷
This valve prevents cylinder from extending
and retracting due to a load applied to the
cylinder.
㩷
㩷
T2-2-36
㩷
㩷
Counterweight Cylinder
㩷 Port Relief Valve (R)㩷
Counterweight
SOL (R)㩷
Quick Counterbalance
(L)㩷
Coupler Valve㩷
Counterweight
SOL (L)㩷
Slow Return Valve㩷

Flip Cylinder (L)㩷
Flip SOL㩷
Overload Relief
Valve㩷
Counterbalance
Valve㩷
Relief Valve㩷
Flip Cylinder (R)㩷
Sequence
Valve㩷
Overload
Relief Valve
(To Swing Circuit)
Swing Control
Pressure Valve㩷
Counterbalance
Reducing Valve㩷
Valve㩷 Counterweight /
Flip Spool㩷

Hydraulic Oil Source Pump㩷
Counterweight / Flip SOL Swing Pump㩷

T2CN-02-02-013

㩷
㩷
㩷
㩷
T2-2-37
BOOM FOOT CIRCUIT㩷㩷
The boom foot circuit drives the boom foot cylinder. 㩷

This circuit is controlled by the 4-spool solenoid valve 㩷 4-Spool Solenoid Valve Unit
unit.
The following explains the circuit in left boom foot
cylinder circuit.
When the left boom foot cylinder is operated in the To Lower Lower
extending direction, the spool of 4-spool solenoid valve Control Circuit Oil
Pressure
unit is switched. Control
Pressure oil from the boom foot / lower control SOL㩷
hydraulic oil source pump flows to the 4-spool solenoid
Quick Coupler㩷
valve unit, and flows to the rod side of left boom foot
cylinder through the sequence valve and left boom foot Left
solenoid valve spool. This extends the cylinder. Boom
Foot
SOL㩷
NOTE: Pressure reducing valve (4-spool solenoid
valve unit):㩷 Boom Foot Cylinder
This valve reduces inlet pressure to the (Left)㩷
4-spool solenoid valve unit and delivers Right
pressure oil to each spool end of the Boom
solenoid valve for operating the spools. Foot
Boom Foot Cylinder SOL
NOTE: Sequence valve (4-spool solenoid valve (Right)㩷
unit):㩷 Relief
Valve㩷
side (pressure reducing circuit) in sequence Sequence
Valve㩷
valve.
NOTE: Relief valve (4-spool solenoid valve unit):㩷 Pressure
Reducing
This valve limits maximum pressure of the Valve㩷
boom foot cylinder and lower control circuit.
㩷
Boom Foot / Lower 㩷
Control Hydraulic Oil
㩷
Source Pump㩷
㪫㪉㪚㪥㪄㪇㪉㪄㪇㪉㪄㪇㪈㪋㩷
T2-2-38
(Blank)
㩷
T2-2-39
SIDE FRAME CONNECTING / JACK-UP
CIRCUIT㩷
The lower control valve controls the jack-up cylinder NOTE: Pressure reducing valve:㩷
and the side frame connecting cylinder. This valve reduces inlet pressure to the
Pressure oil from the boom foot / lower control lower control valve and delivers pressure oil
hydraulic oil source pump flows into the lower control to each spool end through each solenoid
valve through the lower control hydraulic oil source valve for operating the spools.
solenoid valve spool in 4-spool solenoid valve unit.
NOTE: Sequence valve:㩷
The following explains hydraulic oil flow when
side (pressure reducing circuit) in sequence
operating the jack-up cylinder (front right) in the
valve.
retracting direction.
NOTE: Relief valve:㩷
When the lower control switch in cab is turned ON, the This valve limits maximum pressure of the
lower control hydraulic oil source solenoid valve in jack-up cylinder and side frame connecting
4-spool solenoid valve unit activates. Pressure oil from cylinder circuit.
the boom foot / lower control hydraulic oil source pump NOTE: Double check valve:㩷
flows to the lower control valve through the 4-spool This valve blocks the jack-up cylinder circuit
solenoid valve unit. in order to prevent the machine from
When the jack-up (front right) is operated in the lowering during jack-up operation.
retracting direction, the jack retract (front right)
solenoid valve in lower control valve activates. Then, 㩷
some pressure oil flowing to the lower control valve is
reduced its pressure by the pressure reducing valve 㩷
and is routed to the spool end in jack-up cylinder (front
right). When the spool moves, pressure oil flows to the
rod side in jack-up cylinder (front right) through the
sequence valve. This time, a passage at cylinder
bottom side in double check valve is open by its
pressure.
As a result, the jack-up cylinder (front right) retracts.
T2-2-40
Jack-Up (Right Front) Retracting Operation㩷
㩷
Left Side Frame Connecting Right Side Frame Connecting Cylinder (R)
Cylinder (L)㩷
Side Frame Connecting
Cylinder Retract Solenoid
Valve (L)
Lower
Cylinder Extend Solenoid
Control
Valve (L)㩷
Valve㩷
Cylinder Retract Solenoid
Valve (R)㩷
Cylinder Extend Solenoid
Jack-Up Cylinder (Left Rear)㩷 Valve (R)㩷
Jack Extend Solenoid
Valve (Left Rear)㩷
Jack Retract Solenoid
Valve (Left Rear)㩷
Jack-Up Cylinder (Right Rear)㩷
Valve (Right Rear)㩷
Valve (Right Rear)㩷
Jack-Up Cylinder (Left Front)㩷
Valve (Left Front)㩷
Valve (Left Front)㩷
Jack-Up Cylinder (Right Front)㩷
Valve (Right Front)㩷
Valve (Right Front)㩷
Double Check Slow Return
Valve㩷 Valve㩷
Relief Valve㩷
Sequence Valve㩷
Filter㩷
Pressure Reducing Valve㩷

Hydraulic Oil Source Pump㩷
㩷
4-Spool Solenoid Valve Unit㩷㪫㪉㪚㪞㪄㪇㪉㪄㪇㪉㪄㪇㪉㪌㩷
Lower Control
㩷 Hydraulic Oil Source
Solenoid Valve㩷
T2-2-41
TAKE-UP CIRCUIT (OPTIONAL)㩷㩷
The take-up mechanism applies fixed tension to the 㩷

truck shoe by pushing out the both left and right front 㩷
idlers by using travel circuit pressure. 㩷
This circuit directs pressure oil in the travel circuit to 㩷

the bottom side in both left and right take-up cylinders 㩷
through the shuttle valve. Consequently, the front 㩷
idlers are pushed out and fixed tension is applied to
the both left and right track shoes. 㩷
If the front idler has a heavy load, the return check 㩷
valve opens and absorbs pressure at bottom side in 㩷
take-up cylinder.
㩷
㩷
㩷
㩷
㩷
㩷
㩷
㩷 Return Check Valve㩷 Return Check Valve Take-Up
Take-Up Cylinder (L)㩷 Cylinder (R)㩷
㩷
Take-Up Mechanism㩷
Front Idler (L)㩷 Front Idler (R)㩷
Travel Mechanism (L)㩷 Shuttle Valve㩷 Travel Mechanism (R)㩷
㩷
㪫㪉㪚㪞㪄㪇㪉㪄㪇㪉㪄㪇㪉㪍㩷
㩷
㩷
T2-2-42
㪩㪜㪜㪭㪠㪥㪞㩷㪮㪠㪥㪚㪟㩷㪚㪠㪩㪚㪬㪠㪫㩷㩿㪦㪧㪫㪠㪦㪥㪘㪣㪀㩷
Reeving Winch㩷
When the reeving winch hoisting switch is turned ON,
the reeving winch hoisting solenoid valve is shifted by
current from the reeving winch hoisting switch. Reeving
Therefore, pressure oil from the pilot pump passes Winch
through the reeving winch hoisting solenoid valve and Brake㩷
shifts the spool in the reeving winch control valve.
Pressure oil from the reeving winch pump flows to the
reeving winch, through the reeving winch control valve.
Then, Pressure oil shifts the spool in the reeving winch,
releases the reeving winch brake and drives the Reeving
Winch
reeving winch motor. Motor㩷
The returning oil from the reeving winch passes
through the reeving winch control valve, and returns to
the hydraulic oil tank .
Spool㩷
From Reeving
Winch Hoisting
Switch㩷
Hydraulic Oil Tank㩷

㩷
Reeving Winch Pump 㩷
㪫㪉㪚㪥㪄㪇㪉㪄㪇㪉㪄㪇㪈㪌㩷
T2-2-43
㪦㪠㪣㩷㪚㪦㪦㪣㪜㪩㩷㪚㪠㪩㪚㪬㪠㪫㩷
The hydraulic oil from each actuator will be cooled by

the oil cooler installed in the return circuit before
returning to the tank. The fan of the oil cooler, which is
driven by the piston motor, is turned on and off by the
temperature sensor installed in the hydraulic oil tank.
The oil cooler fan will stop revolving when the solenoid
valve detects that the temperature of the hydraulic oil is
less than 35ºC and guides the oil from the excited gear
pump through the slip stream to the fan motor. When
the oil temperature increases to 40ºC, the solenoid
valve switches, and the oil cooler fan begins revolving
again.
When ON When OFF
Return Circuit Return Circuit Solenoid Valve㩷

Oil Cooler Solenoid Valve
Switches in
response to
temperature
sensor signal
Piston Motor㩷
Oil Cooler
Fan
Hydraulic Oil Tank

Gear Pump Gear Pump㩷
(with temperature sensor)㩷
㪫㪉㪚㪥㪄㪇㪉㪄㪇㪉㪄㪇㪈㪍㩷㪫㪉㪚㪥㪄㪇㪉㪄㪇㪉㪄㪇㪈㪎
T2-2-44
SYSTEM / Electric System㩷
OUTLINE㩷
The electric system is divided roughly into the main Major functions and constructions of the main circuit is
circuit, the control circuit, the monitor circuit, the brake explained below.
control circuit, the moment limiter and the auto stop
circuit.
x Main circuit:㩷 x Power circuit:㩷 An electric power source for the

Engine-related circuit and accessories-related electric system on the machine.㩷
circuit.㩷 x Preheating circuit:㩷 The circuit that assists engine
x Control circuit starting in cold weather.㩷
Engine and pump control circuit consisting of x Starting circuit:㩷The circuit that starts the engine.㩷
actuators such as solenoid valves, controllers (MC x Charging circuit:㩷 The circuit that charges batteries
and ECU), switch boxes, sensors and switches.㩷 and supplies electricity in order to compensate
x Monitor circuit power consumption.㩷
Circuit that displays operating status of the machine x Engine stop circuit: The circuit that stops the engine
(consisting of monitor display, sensors and by ECU.㩷
switches.)㩷 x Surge voltage prevention circuit: The circuit that
x Moment limiter and auto stop circuit prevents occurrence of serge voltage when the
The circuit that warns of overloading and engine is stopped.㩷
overhoisting, and makes auto stop of hoisting and x Accessories-related circuit: The circuit that is
boom hoist (consisting of the moment limiter that activated when the key switch is turned ON.㩷
displays loading condition during crane operation x Swing brake release circuit: The circuit that releases
and detects overloading, the micro switch that the swing motor brake by delivering pilot pressure oil
detects boom and hook overhoisting, controller (MC) to the brake while the swing brake release solenoid
that performs auto stop, and the solenoid valve).㩷 valve ON.㩷
x Drum lock circuit: The circuit that locks and unlocks
the front lock and rear drum lock.㩷
㩷
T2-3-1
POWER SOURCE CIRCUIT㩷㩷
The negative terminal of battery is connected to the 㩷

machine, When the battery serves backup power for 㩷
the radio and air conditioner while the key switch is in
the OFF position.
Also, the battery serves as a main power supply for
MC2/A, MC2/B, IDU, key switch, fuel feed pump switch
and horn relay.
㩷
㩷
To 12V Power Source
Batteries㩷
Fuel Feed Pump Switch㩷
Horn Switch
Horn㩷
Horn Relay
Radio㩷
Air Conditioner
Key Switch㩷
㩷
㪫㪉㪚㪥㪄㪇㪉㪄㪇㪊㪄㪇㪇㪈㩷
T2-3-2
PREHEATING CIRCUIT
x Preheating operation㩷
When the key switch is turned ON, terminal B is As a result, current from terminal #96 flows through
connected to terminal ACC in the key switch. Current the R-line and excites heater relay 1. Current from
from terminal ACC flows to terminals #158 and #127 terminal ACC in the key switch flows through the coil
of ECU through Z-line and ECU recognizes that the of heater relay 2 while heater relay 1 is excited, and
key switch is ON. In addition, current from terminal turns heater relay 2 ON. The air heater is heated by
ACC excites the battery relay. Then, current from the current from the battery relay.㩷
battery flows to the contact point of the heater relay When terminal #70 in ECU is turned ON, current
through the battery relay while preparing for from terminal ACC in the key switch excites the
excitation of the heater relay coil.㩷 preheat indicator relay and the preheat indicator
ECU sets preheating period by monitoring coolant lights.㩷
and intake-air temperature. Moreover, ECU turns 㩷
terminals #96 and #70 ON during time according to
coolant and intake-air temperature.
Batteries㩷
Key Switch
Battery Relay㩷
Heater Relay 2㩷
Air
Heater
Heater Relay 1
Starter
Motor㩷
Preheat
Preheat Indicator㩷
Indicator Relay
㩷
㪫㪉㪚㪞㪄㪇㪉㪄㪇㪊㪄㪇㪇㪉㩷
T2-3-3
x After-heating operation
When preheating is finished and the engine is not
yet heated sufficiently, the engine start may cause
incomplete combustion.㩷
In order to prevent this, after-heating is carried out
following to preheating.㩷
㩷
Current flows from terminal ACC in the key switch
even after the engine starts.㩷
This current flows to terminals #158, #127, #144,
#129 and #101 in ECU in a similar way of preheating
operation.㩷
As ECU continuously monitors coolant temperature,
air heater is heated in a similar way of preheating
operation if coolant and intake-air is not sufficiently
heated.㩷
(Refer to the pages for Preheating.)㩷
㩷
T2-3-4
(Blank)
㩷
T2-3-5
ENGINE STARTING CIRCUIT㩷
1. When the key switch is turned ON, current from 10. At the same time, ECU sends current to the
terminal ACC in the key switch excites the battery injector and feeds fuel to the engine. Thus, the
relay.㩷 engine starts running.㩷
2. As the battery relay is excited, current from the 11. When the engine starts running, ECU blocks
battery flows to terminal B in the starter motor current from terminal #88 and opens the contact
through the contact point in battery relay.㩷 point in starter relay 2. This blocks current flowing
3. In addition, current from terminal ACC in the key through W-line and terminal SW of the starter
switch flows to terminals #158 and #127 in ECU relay and the starter motor stops.㩷
through Z-line. Then, ECU begins engine starting 12. While the engine is running, the starter does not
procedure.㩷 rotates even if the key switch is turned in the
4. Current from terminal C in the key switch flows to START position as ECU does not send current
terminal #A5 in MCA/2 and MCA/2 recognizes from terminal #88.㩷
that the key switch is in the START position.㩷㩷
5. MC2/A checks that the swing brake switch is in
the brake position and the mode switches of front
and rear drum are in the auto-brake position.
MC2/A excites the engine start relay by using
terminal #E20.㩷
6. Thus, the engine start relay turns ON and current
from terminal C in the key switch flows to terminal
#143 in ECU and terminal #3 in starter relay 2.㩷
7. ECU monitors coolant temperature, fuel
temperature, intake-air temperature, boost
pressure, fuel pressure and engine oil
temperature. If the condition is ready for starting,
ECU outputs a signal from terminal #88. This
excites starter relay 2 and the contact point is
closed.㩷
8. Current flowing from terminal C in the key switch
through W-line flows to terminal SW in the starter
relay through the contact point in starter relay 2
and F-line.㩷
9. Terminals B and S in the starter relay are
connected inside the relay. Current from the
battery flows to terminal S in the starter. The
pinion in starter engages into the ring gear. At the
same time, large-current from the battery flows to
the motor from terminal B in the starter and the
motor rotates.㩷
㩷
T2-3-6
㩷
㩷 Batteries㩷
Swing Brake Switch
Front Drum Brake Mode

Selection Switch㩷
Rear Drum Brake Mode

Selection Switch㩷
Key Switch
Engine Start
Relay㩷
Emergency
Stop Relay㩷
Battery Relay㩷
Starter Relay㩷
Alternator㩷
Starter Relay 2
Starter
Coolant Temp. Sensor㩷
Fuel Temp. Sensor㩷
Intake-Air Temp. Sensor㩷

Injector㩷
Boost Pressure Sensor㩷
Fuel Pressure Sensor㩷
Engine Oil Temp. Sensor㩷

㩷
㪫㪉㪚㪞㪄㪇㪉㪄㪇㪊㪄㪇㪇㪊㩷
T2-3-7
CHARGING CIRCUIT㩷㩷
After the engine starts, the key switch is turned to the

ON position. The battery relay keeps the excitation
condition by current from terminal ACC in the key
switch.
As the engine starts running, the alternator starts
rotating. As current generated by the alternator flows to
a coil in the battery relay through the contact point in
OFF delay relay, the battery relay is kept in ON
condition. In addition, current from terminal B in the
alternator flows to terminal "+" in the battery through
the battery relay. This charges the batteries. At the
same time, current from terminal B in the alternator
flows through the battery relay and fusible link (#30)
and supplies current in these circuits.
When generated voltage of the alternator reaches the
specified value, as current flowing from terminal #4 in
charge relay to terminal L in the alternator is blocked,
the charge relay turns unexcited condition. As a result,
the charge relay turns OFF and the charge indicator
turns OFF.
T2-3-8
㩷
Batteries
Key Switch㩷
OFF Delay Relay㩷
Emergency
Stop Relay㩷
Battery
Relay㩷
Alternator㩷
Charge Relay㩷
Charge
Indicator㩷
Monitor Lamp Unit 㩷

㪫㪉㪚㪥㪄㪇㪉㪄㪇㪊㪄㪇㪇㪉㩷
㩷
㶎The above diagram shows a condition that voltage
generated by the alternator does not reach the
specified value and the charge indicator lights.㩷
T2-3-9
ENGINE STOP CIRCUIT㩷㩷
When the key switch is turned OFF, current from 㩷

terminal ACC in the key switch to terminals #158 and
#127 in ECU is blocked.
Then, ECU blocks current to the injector and stops fuel
supply to the engine.
This stops the engine.
After that, as the contact point in OFF delay relay turns
OFF and current flowing from alternator to a coil in the
battery relay is blocked, the battery relay turns OFF.
(Refer to the pages for Surge voltage prevention
circuit.)
T2-3-10
The illustration shows a condition that the engine runs. 㩷
㩷 Batteries㩷
Key Switch㩷
OFF Delay Relay㩷
Battery
Relay㩷
Alternator㩷
Injector㩷
㩷
㪫㪉㪚㪞㪄㪇㪉㪄㪇㪊㪄㪇㪇㪐㩷
T2-3-11
SURGE VOLTAGE PREVENTION CIRCUIT㩷㩷
When the engine is stopped by turning the key switch

OFF, current from terminal ACC in the key switch stops
and the battery relay turns OFF. Even if turning the key
switch OFF, the engine does not stop at once and
rotates by the inertia, so that the alternator keeps
generating power. Therefore, as the generated power
current does not flow to the battery; surge voltage
occurs in the circuit that may cause damage to the
electronic equipment such as controller and
components. In order to prevent this, the serge voltage
prevention circuit is provided.
The battery relay is excited by the OFF delay relay until

the engine stops. As a result, the generated power
current from terminal B in the alternator flows to the
battery through battery relay and prevents occurrence
of serge voltage.
Current from terminal B in the alternator flows through
the contact point in OFF delay relay and continuously
excites the battery relay. The contact point in battery
relay keeps closed condition and the generated power
current of alternator flows to the battery through the
contact point in battery relay.
Thus, the generated power current of alternator flows
to the battery.
This condition will be kept until the engine is stopped.
NOTE: As the OFF delay relay equips timer

function, it keeps exciting condition for a
specific period even no current flows
through the coil side in order to keep the
contact point ON.
T2-3-12
㩷
㩷
Batteries
Key Switch㩷
OFF Delay Relay
Battery
Relay㩷
㩷
㪫㪉㪚㪞㪄㪇㪉㪄㪇㪊㪄㪇㪇㪏㩷
㩷
㩷
T2-3-13
ACCESSORY CIRCUIT㩷㩷
When the key switch is turned ON, terminals B and 㩷

ACC are connected in the key switch.
Current from terminal ACC excites the battery relay. As
the battery relay is excited, current from the battery
flows to the radio, interior light, working light, drum light
(optional) and cigarette lighter through the battery relay.
Power supply for the horn is not routed through the key
switch but connects directly from the battery.
㩷
Batteries
Radio㩷
Horn Horn
Relay㩷 Switch
Horn
Key Switch㩷
Interior Light㩷
Working
Light㩷
Battery
Relay㩷
Drum Light
(Optional)㩷
Cigarette
Lighter㩷
㩷
㪫㪉㪚㪥㪄㪇㪉㪄㪇㪊㪄㪇㪇㪊㩷
T2-3-14
SWING BRAKE RELEASE CIRCUIT㩷㩷
1. When the swing brake switch is in the OFF

position, the swing brake indicator lights and the
swing brake is applied.㩷
2. When the swing brake switch is turned ON,
current flows from the battery to MC2/A.㩷
3. MC2/A turns the swing brake indicator off.㩷
4. At the same time, MC2/A flows current to the
swing brake release solenoid valve in order to
switch the swing brake release solenoid valve.
Therefore, pressure oil from the pilot pump flows
to the swing break through the swing brake
release solenoid valve and releases the brake.㩷
The illustration shows a condition that the swing brake

switch is in the ON position.
㩷
㩷 Swing Brake
Indicator㩷
㩷
Swing Brake
Switch: ON㩷
To Swing Brake㩷
Pilot Pump㩷
㩷
㪫㪉㪚㪞㪄㪇㪉㪄㪇㪊㪄㪇㪇㪎㩷
㩷
㩷
T2-3-15
DRUM LOCK CIRCUIT㩷㩷
When the key switch is turned ON, terminals B and

ACC are connected in the key switch.
Current from terminal ACC excites the battery relay.
When the battery relay is excited, current from the
battery flows to terminals B of the front, and rear drum
locks through the battery relay.
Under this condition, when the front or rear drum lock
switch is turned OFF, current flows from terminal B in
the corresponding drum lock.
This current flows to terminal P2, the operated lock
switch and terminal A, and unlocks the drum.
Similarly, when the front or rear drum lock switch is
turned ON, current from terminal B in the
corresponding drum lock. This current flows to terminal
A through terminal P1 and the operated lock switch,
and locks the drum.
T2-3-16
NOTE: The following figure shows a condition that the lock switch unlocks.
㩷
㩷
Batteries
Key Switch㩷
Battery Relay
Front Drum Lock㩷
Front Drum
Lock Switch㩷
Rear Drum Lock㩷
Rear Drum
Lock Switch㩷
㩷
㪫㪉㪚㪞㪄㪇㪉㪄㪇㪊㪄㪇㪇㪍㩷
T2-3-17
(Blank)
㩷
T2-3-18

㩷
SECTION 3 㩷
COMPONENT OPERATION㩷
㩷
㩷
—CONTENTS—㩷
Group 1 Pump Assembly Group 4 Boom Hoist System㩷
Outline .......................................................... T3-1-1 Outline........................................................... T3-4-1
Main Pump ................................................... T3-1-2 Boom Hoist Motor ......................................... T3-4-2
Swing Pump ................................................. T3-1-3 Reduction Gear............................................. T3-4-3
Regulator ...................................................... T3-1-5 Boom Hoist Brake ......................................... T3-4-4
Solenoid Valve............................................ T3-1-26 Counterbalance Valve................................... T3-4-6
Pilot Pump, Boom Foot / Lower Control Relief Valve ................................................. T3-4-10
Hydraulic Oil Source Pump, Reeving
Winch Driving Pump (Optional).............. T3-1-28 Group 5 Front and Rear Control Valve㩷
Outline........................................................... T3-5-1
Group 2 Swing Reduction Unit㩷 Configuration................................................. T3-5-2
Outline .......................................................... T3-2-1 Internal Circuit ............................................... T3-5-6
Swing Reduction Gear ................................. T3-2-2 Spool ............................................................. T3-5-8
Swing Motor.................................................. T3-2-3 Main Relief Valve ........................................ T3-5-10
Swing Parking Brake .................................... T3-2-4 Port Relief Valve (with Make-Up Function) . T3-5-12
Valve Unit...................................................... T3-2-6 Make-Up Valve............................................ T3-5-14
Holding Valve .............................................. T3-5-15
Group 3 Winch Assembly㩷 Pressure Compensation Valve ................... T3-5-16
Outline .......................................................... T3-3-1
Motor............................................................. T3-3-2 Group 6 Swing Control Valve㩷
Regulator ...................................................... T3-3-5 Outline........................................................... T3-6-1
Counterbalance Valve ................................ T3-3-10 External View ................................................ T3-6-1
Brake .......................................................... T3-3-15 Internal Circuit ............................................... T3-6-1
Winch Drum................................................ T3-3-16 Configuration................................................. T3-6-2
Reduction Gear .......................................... T3-3-17
Group 7 Lower Control Valve㩷
Outline........................................................... T3-7-1
Configuration................................................. T3-7-2
Internal Circuit ............................................... T3-7-4
Function Block .............................................. T3-7-5
Relief Valve ................................................... T3-7-6
Pressure Reducing Valve.............................. T3-7-8
Sequence Valve .......................................... T3-7-10
Solenoid Valve 㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅㪅 T3-7-11
2CNT-3-1

Group 8 Remote Control Valve㩷
Outline .......................................................... T3-8-1
Configuration ................................................ T3-8-4
Detent Function ............................................ T3-8-8
Operation.................................................... T3-8-10
Group 9 Solenoid Valve Unit㩷

5-Spool Solenoid Valve Unit ......................... T3-9-1
4-Spool Solenoid Valve Unit ......................... T3-9-5
3-Spool Solenoid Valve Unit ........................T3-9-11
Group 10 Travel Mechanism㩷

Outline ........................................................ T3-10-1
Travel Motor................................................ T3-10-2
Parking Brake ............................................. T3-10-4
Travel Reduction Gear ............................... T3-10-6
Travel Brake Valve...................................... T3-10-7
Travel Speed Selection............................. T3-10-10㩷
Group 11 Others (Crane Upper)㩷

Gate Lock Valve ..........................................T3-11-1
Drum Brake Release Solenoid Valve
(Optional) ................................................T3-11-5
Counterweight Cylinder ...............................T3-11-6
Flip Cylinder.................................................T3-11-7
Boom Foot Cylinder.....................................T3-11-8
Accumulator.................................................T3-11-9
Group 12 Others (Base Carrier)㩷

Outline ........................................................ T3-12-1
Turntable Bearing ....................................... T3-12-2
Rotating Joint.............................................. T3-12-3
Slip Ring ..................................................... T3-12-4
Side Frame Connecting Cylinder ............... T3-12-5
Jack-Up Cylinder ........................................ T3-12-6
Take-Up Cylinder (Optional) ....................... T3-12-9
㩷
2CNT-3-2
COMPONENT OPERATION / Pump Assembly
OUTLINE㩷㩷
㩷
The pump assembly consists of main pump (pump 1 Pilot pump (4), boom foot / control hydraulic oil source
(11) and pump 2 (9)), swing pump (5), oil cooler pump pump (3), reeving winch pump (1) and oil cooler pump
(6), pilot pump (4), boom foot / control hydraulic oil (6) are the gear pumps.㩷
source pump (3), reeving winch pump (1) and PTO In addition, PTO gearbox (2) is provided between
gearbox (2).㩷 pump 1 (11) and pump 2 (9).㩷
The main pump is a dual swash plate type variable
displacement plunger pump, and the swing pump is a
single swash plate type variable displacement plunger
pump. These pumps deliver high pressure oil to the
main circuit for operation.㩷
1
2
3
11
10
8

7 T2CG-01-02-025
1 - Reeving Winch Pump 4 - Pilot Pump 7 - Displacement Angle Proportional 10 - Power Increase
(Optional) Solenoid Valve (For Swing Pump) Solenoid Valve
2 - PTO Gearbox 5 - Swing Pump 8 - Displacement Angle Proportional 11 - Main Pump 1 (P1)
Solenoid Valve (For Main Pump)
3 - Boom Foot / Control 6 - Oil Cooler Pump (P4) 9 - Main Pump 2 (P2)
Hydraulic Oil Source Pump
T3-1-1
MAIN PUMP㩷
The main pump is a dual swash plate type plunger

pump.
Two shafts (1) are connected by gear (6). Each shaft
(1) provides a same type of pump.㩷
Cylinder block (5) is splined on shaft (1). Plunger (4) is
inserted into cylinder block (5).㩷
The rotation of engine is transmitted to shaft (1)
through the coupling. When shaft (1) rotates, plunger
(4) rotates with cylinder block (5) together. Plunger (4)
slides over shoe plate (3) and reciprocates in the bore
of cylinder block (5) according to the inclination angle
of swash plate (2). This reciprocating motion suctions
and deliveries hydraulic oil.㩷
Pump 1 (P1)㩷 Pump 2 (P2䋩㩷
㩷
2 3 4 4
5 6 1 5 4 3 2 㩷
T1F3-03-01-003
T3-1-2
SWING PUMP㩷
The swing pump is a single swash plate type plunger

pump.
Shaft (1) is splined to shaft (1) of pump 2. Shaft (1) is
provided with a pump whose type is the same as the
main pump.
Cylinder block (5) is splined on shaft (1). Plunger (4) is
inserted into cylinder block (5).
The rotation of engine is transmitted to shaft (1)
through pump 2. When shaft (1) rotates, plunger (4)
rotates with cylinder block (5) together. Plunger (4)
slides over shoe plate (3) and it reciprocates in the
bore of cylinder block (5) according to the inclination
angle of swash plate (2). This reciprocating motion
suctions and deliveries hydraulic oil.
Splined to
Pump 2㩷
1 2 3 4 5 T25N-03-01-005
T3-1-3
Delivery Flow Rate Adjustment㩷
㩷
The pump delivery flow rate is adjusted by changing
the inclination angle of swash plate (2) in order to
change the stroke of plunger (4).㩷
Pressure oil from the regulator moves the servo piston.
As swash plate (2) is connected to the servo piston,
thus the inclination angle of swash plate (2) is changed
according to the movement of servo piston. This
changes the pump delivery flow rate.㩷
Servo Piston㩷
Valve Plate㩷
5
4
㩷
2 T117-02-01-003
T3-1-4
REGULATOR㩷
The regulator receives the various pressure signals The pump 2 regulator and swing pump regulator
and controls the flow rate of the main pump and the provides a displacement angle proportional solenoid
swing pump in order to prevent from exceeding the valve.㩷
engine horsepower. Each of pump 1, pump 2 and In addition, the PTO gearbox provides a power
swing pump provides one regulator.㩷 increase solenoid valve.㩷
Displacement Angle Proportional

PTO Gearbox㩷 Solenoid Valve㩷
㩷
Pump 1 Power Increase Pump 2 Swing Pump
Regulator㩷 Solenoid Valve Regulator㩷 Regulator㩷 T2CG-03-01-001
Layout㩷
Power Increase Displacement Angle Proportional
Solenoid Valve Solenoid Valve㩷
Pump 2
Regulator㩷
Pump 1
Regulator㩷
Displacement Angle
Valve㩷
Swing Pump
Regulator㩷
㩷
㩷
PTO Gearbox㩷 T2CG-03-01-002
T3-1-5
Sectional View (Main Pump Regulator)㩷
Pump 1㩷 B
Pump 2㩷
B
A A
B A B A
㩷㩷
T25N-03-01-006 T25N-03-01-007
Section A-A㩷 1 2 3 4 5 6
8
㩷
T25N-03-01-011
T3-1-6
Section B-B㩷
9 10 11 12 13 14 15 16
㩷
21 20 19 18 17 T1F3-03-01-008
1- Pilot Piston 7- Feedback Lever 12 - Pin 17 - Servo Piston

2- Pin 8- Pin 13 - Lever 1 18 - Pin
3- Lever 2 9- Return Spring 14 - Pin 19 - Compensating Rod
4- Pin 10 - Sleeve 15 - Outer Spring 20 - Compensating Piston
5- Pin 11 - Spool 16 - Inner Spring 21 - Pistons
6- Pilot Spring
T3-1-7
Sectional View (Swing Pump Regulator)㩷
B
A
B A
㩷
T25N-03-01-014
Section A-A㩷
1 2 3 4 5 6
7
8
㩷
T25N-03-01-012
T3-1-8
Section B-B㩷
9 10 11 12 13 14 15 16
㩷
21 20 19 18 17
T25N-03-01-013
1- Pilot Piston 7- Feedback Lever 12 - Pin 17 - Servo Piston

2- Pin 8- Pin 13 - Lever 1 18 - Pin
3- Lever 2 9- Return Spring 14 - Pin 19 - Compensating Rod
4- Pin 10 - Sleeve 15 - Outer Spring 20 - Compensating Piston
5- Pin 11 - Spool 16 - Inner Spring 21 - Piston
6- Pilot Spring
T3-1-9
Linkage Mechanism (Main Pump)㩷
㩷
The movement of pilot piston (1) is transmitted to Therefore, when lever 1 (13) or lever 2 (3) turns, pin
lever 2 (3) through pin (2). Lever 2 (3) turns about pin (4) contacts the hole of the turned lever. Feedback
(5) which is fixed to the axial plug.㩷 lever (7) rotates around pin (8) attached to servo
The movement of compensating rod (19) is piston (17). In addition, when servo piston (17) moves,
transmitted to lever 1 (13) through pin (18). Lever feedback lever (7) is moved through pin (8). At this
1(13) turns about pin (12) which is fixed to the casing.㩷 time, as neither lever 1 (13) nor lever 2 (3) move,
Pin (4) is attached to feedback lever (7). Both ends of feedback lever (7) turns around pin (4) and spool (11)
pin (4) are inserted into the holes of lever 1 (13) and moves.
lever 2 (3).㩷
12
18 NOTE:
13
Casing Hole Displacement angle
decrease
7 Displacement angle
19
increase
14
4
3
Hole
5
2
11 Axial Plug㩷
1
㩷
17
T142-02-01-005
1- Pilot Piston 5- Pin 12 - Pin 17 - Servo Piston

2- Pin 7- Feedback Lever 13 - Lever 1 18 - Pin
3- Lever 2 8- Pin 14 - Pin 19 - Compensating Rod
4- Pin 11 - Spool
T3-1-10
Linkage Mechanism (Swing Pump)㩷
The movement of pilot piston (1) is transmitted to Therefore, when lever 1 (13) or lever 2 (3) turns, pin
lever 2 (3) through pin (2). Lever 2 (3) is turns about (4) contacts the hole of the turned lever. Feedback
pin (5) which is fixed to the axial plug.㩷 lever (7) rotates around pin (8) attached to servo
The movement of compensating rod (19) is piston (17). In addition, when servo piston (17)
transmitted to lever 1 (13) through pin (18). Lever 1 moves, feedback lever (7) is moved through pin (8).
(13) turns about pin (12) which is fixed to the casing.㩷 At this time, as neither lever 1 (13) nor lever 2 (3)
Pin (4) is attached to feedback lever (7). Both ends of move, feedback lever (7) turns around pin (4) and
pin (4) are inserted into the holes of lever 1 (13) and spool (11) moves.㩷
lever 2 (3).㩷
12
18
13 NOTE:
Casing㩷
Hole Displacement angle
decrease
7
19㩷 Displacement angle
increase
14
4㩷
3㩷
Hole
5㩷
2
11㩷 Axial Plug
1㩷
17㩷
㩷
T117-02-01-009
1- Pilot Piston 5 - Pin 12 - Pin 17 - Servo Piston

2- Pin 7 - Feedback Lever 13 - Lever 1 18 - Pin
3- Lever 2 8 - Pin 14 - Pin 19 - Compensating Rod
4- Pin 11 - Spool
T3-1-11
Regulator Control Functions
The regulator has following three pieces of control

functions.㩷
㩷
x Control by self pump pressure or companion pump
pressure Flow Rate (Q) Pressure Increase㩷
Self pump pressure P1 and companion pump
pressure P2 are applied to the regulator. (The swing Flow Decrease
pump uses only self pump pressure P3.) When the
mean pressure of these two pump pressures exceed
the preset P-Q curve, both pump delivery flow rates
of both pumps are reduced in order to follow the P-Q
curve. This operation prevents overload of the
engine.
In addition, as the P-Q curve is preset by using the 0 Pressure (P)
mean pressure of both pumps, both pump delivery
flow rates become almost equal. Therefore, the
higher pressure pump carries out larger load, while
the lower pressure pump carries out smaller load.
Thus, the total load of pumps is equal to the engine
horsepower. (Summation control)
x Control by pilot pressure from the power increase Flow Rate (Q)㩷
solenoid valve.㩷
(only for the main pump)㩷
MC2/A sends a signal in proportion to the engine
speed and load to the power increase solenoid valve.㩷
The power increase solenoid valve operates
according to this signal and returns the pressure oil
which acts on the compensation piston of regulator
to the hydraulic oil tank. As a result, the delivery flow
rate is increased. (Main pump power increase
control) 0 Pilot Pressure (Pi)
(Refer to the Control System group.)㩷
㩷
T3-1-12
x Control by Pilot Pressure from Displacement Angle Flow Rate (Q)
Proportional Solenoid Valve㩷
Main Pump:㩷
MC2/A sends a signal in proportional to the rotation
of the acceleration grip, to the displacement angle
proportional solenoid valve.㩷
The displacement angle proportional solenoid valve
sends pilot pressure according to this signal to the
regulator in order to increase or decrease the pump
delivery flow rate. (Main pump displacement angle 0 Pilot Pressure (Pi)
control)
(Refer to the Control System group.)
Swing Pump:㩷 Flow Rate (Q)
MC2/A sends a signal in proportional to a position of
the slew speed dial and sends a signal of the initial
setting of pump displacement angle to the
displacement angle proportional solenoid valve.㩷
The displacement angle proportional solenoid valve
sends pilot pressure according to on this signal to the
regulator in order to increase or decrease the pump
delivery flow rate. (Swing pump displacement angle
control) 0 Pilot Pressure (Pi)
(Refer to the Control System group.)㩷
㩷
㩷 Main Pump Regulator Swing Pump Regulator
Pr1 Psv
Pr1 Psv
Pz
P3
P2
P1
㩷
Increase Decrease
Displacement Angle㩷
T25N-03-01-009
㩷
Increase Decrease
T25N-03-01-008
P1 - Pump 1 Delivery Pressure Pz - Power Increase Control Pr1 - Displacement Angle P3 - Swing Pump Delivery
Pressure Proportional Pressure Pressure
(From Power Increase (From Displacement Angle
Solenoid Valve) Proportional Solenoid Valve)
P2 - Pump 2 Delivery Pressure Psv - Pilot Pressure
T3-1-13
(Blank)
T3-1-14
Operation of Regulator㩷
Pr1 Psv
16 10 11
Main Pump
Regulator 13
Pz
P2
20
P1
9
7
17
㩷
Increase Decrease T25N-03-01-008
Displacement Angle
1 3 6
Pr1 Psv
13 16 10 11 9
Swing Pump
Regulator 20
5
P3
7
17㩷
Increase Decrease T25N-03-01-009
Displacement Angle
1 3 6
1 - Pilot Piston 7 - Feedback Lever 10 - Sleeve 16 - Inner Spring

3 - Lever 2 8 - Pin 11 - Spool 17 - Servo Piston
5 - Pin 9 - Return Spring 13 - Lever 1 20 - Compensating Piston
6 - Pilot Spring
P1 - Pump 1 Delivery Pressure Pz - Power Increase Control Pr1 - Displacement Angle P3 - Swing Pump
Pressure Proportional Pressure Delivery Pressure
(From Power Increase (From Displacement Angle
Solenoid Valve) Proportional Solenoid Valve)
P2 - Pump 2 Delivery Pressure Psv - Pilot Pressure
T3-1-15
Control by Self Pump Pressure and Companion
Pump Pressure㩷
NOTE: Control by self pump pressure and 6. When servo piston (17) moves, feedback lever (7)
companion pump pressure is divided into moves through pin (8). As neither compensating
the following two functions.㩷 rod (19) nor lever 1 (13) moves, feedback lever (7)
turns counterclockwise about pin (4) and spool
Flow rate decrease function (overload
(11) moves to the left. The cutouts of spool (11)
prevention)
and sleeve (10) are closed completely, so self
When the load (pressure), the increases,
pump delivery pressure P1 does not act on the
the pump delivery flow rate is decreased
large diameter chamber side of servo piston (17),
and controlled so that the load not to
and the movement of servo piston (17) stops.㩷
exceed the engine horsepower.㩷
7. These movements decrease the pump delivery
Flow rate increase function (flow rate flow rate and reduce the load to the pump.㩷
restoration)
When the load (pressure) decreases, the
pump delivery flow rate is increased and Flow Rate (Q)
controlled in order to efficiently use the
engine horsepower.㩷
㩷
• Flow rate decrease function (overload prevention)㩷
1. When self pump delivery pressure P1 and
companion pump delivery pressure P2 (self pump
delivery pressure P3 in case of the swing pump)
increase, compensating piston (20) moves
compensating rod (19) to the position where outer
0 Pressure (P)㩷
spring (15) force and inner spring (16) forces are
balanced.㩷
2. Compensating rod (19) moves lever 1 (13)
through pin (18). Lever 1 (13) turns
Main Pump
counterclockwise about pin (12) which is fixed to
the casing.㩷
3. Pin (4), which is attached to feedback lever (7), is
inserted into the hole of lever 1 (13). Therefore,
feedback lever (7) turns clockwise about pin (8) by
turning lever 1 (13) and spool (11) moves to the P2
right.㩷 P1
20
4. When spool (11) moves, self pump delivery
pressure P1 acts on the large diameter chamber 11
side of servo piston (17) through spool (11). 13 7
Although self pump delivery pressure P1 acts on 17
the small diameter chamber side, servo piston
(17) moves to the right due to the difference in
area.㩷㩷
5. The pump displacement angle is reduced Increase Decrease
according to the movement of servo piston (17) T25N-03-01-023
and the pump delivery flow rate decreases.㩷

NOTE: The figure shows the main pump.㩷
T3-1-16
10 11 12 13 4 15 16
P1
P2
20 19 18 8 7 17 㩷
T25N-03-01-016
10 11 12 13 4 15 16
20 19 18 8 7 17
㩷
T25N-03-01-016
4- Pin 11 - Spool 15 - Outer Spring 18 - Pin

7- Feedback Lever 12 - Pin 16 - Inner Spring 19 - Compensating Rod
8- Pin 13 - Lever 1 17 - Servo Piston 20 - Compensating Piston
10 - Sleeve
T3-1-17
• Flow rate increase function (flow rate restoration)㩷
1. When self pump delivery pressure P1 and
Flow Rate (Q)
companion pump delivery pressure P2 (self pump
delivery pressure P3 in case of the swing pump)
decrease, compensating piston (20) moves with
compensating rod (19) together leftward to the
position where outer spring (15) force and inner
spring (16) forces are balanced.㩷
2. Compensating rod (19) moves lever 1 (13)
through pin (18). Lever 1 (13) turns clockwise
about pin (12) which is fixed to the casing.㩷
3. Pin (4), which is attached to feedback lever (7), is 0 Pressure (P)㩷
feedback lever (7) turns counterclockwise about
pin (8) by turning lever 1 (13) and spool (11) 㩷
moves to the left.㩷
4. When spool (11) moves, the large diameter
chamber side of servo piston (17) is connected to
the hydraulic oil tank through spool (11). As self
pump delivery pressure P1 acts on the small
diameter chamber side, servo piston (17) moves
to the left.㩷 P2
5. The pump displacement angle increases P1
according to the movement of servo piston (17) 20
and the pump delivery flow rate increases.㩷 11
6. When servo piston (17) moves, feedback lever (7) 13 7
moves through pin (8). As neither compensating
17
rod (19) nor lever 1 (13) moves, feedback lever
(7) turns clockwise about pin (4) and spool (11)
moves, to the right. The cutouts of spool (11) and 㩷
sleeve (10) are closed completely, so the large Increase Decrease
diameter chamber side of servo piston (17) is not Displacement Angle㩷
T25N-03-01-025
connected to the hydraulic oil tank, and the
㩷
movement of servo piston (17) stops.㩷
7. These movements increase the pump delivery NOTE: The figure shows the main pump.㩷
flow rate.㩷㩷
㩷㩷
T3-1-18
10 11 To Hydraulic 12 13 4 15 16
Oil Tank㩷
P1
20 19 18 8 7 17 㩷
T25N-03-01-016
10 11 12 13 4 15 16
20 19 18 8 7 17
㩷
T25N-03-01-016
4- Pin 11 - Spool 15 - Outer Spring 18 - Pin

7- Feedback Lever 12 - Pin 16 - Inner Spring 19 - Compensating Rod
8- Pin 13 - Lever 1 17 - Servo Piston 20 - Compensating Piston
10 - Sleeve
T3-1-19
Control by Pilot Pressure of Power Increase
Solenoid Valve (Main Pump Only)㩷
Power increase control pressure Pz from the power 㩷

increase control solenoid valve acts and increases 㩷
the pump delivery flow rate.㩷㩷 Flow Rate (Q)
㩷㩷
1. When the power increase solenoid valve is 㩷
excited by a signal from MC2/A, the pilot pressure 㩷
acting on pin (21) returns to the hydraulic oil tank.㩷㩷
2. Compensating piston (20) is returned with 㩷
compensating rod (19) together leftward to the 㩷
position where outer spring (15) force and inner 㩷
spring (16) force are balanced.㩷㩷
3. Compensating rod (19) moves lever 1 (13) 㩷 0 Pump Control Pressure (Pi)㩷
through pin (18). Lever 1 (13) turns clockwise 㩷
about pin (12) which is fixed to the casing.㩷㩷
4. Pin (4), which is attached to feedback lever (7), is 㩷
feedback lever (7) turns counterclockwise about
pin (8) by turning lever 1 (13) and spool (11)
moves to the left.㩷 Pz
the hydraulic oil tank through spool (11). As
self-pump delivery pressure P1 acts on the small P1
20
to the left.㩷 11
6. The pump displacement angle increases 13 7
and the pump delivery flow rate increases.㩷
7. When servo piston (17) moves, feedback lever (7)
moves through pin (8). As neither compensating 㩷
Increase Decrease
rod (19) nor lever 1 (13) moves, feedback lever Displacement Angle㩷
(7) turns clockwise about pin (4) and spool (11) T25N-03-01-027
moves to the right. The cutouts of spool (11) and

sleeve (10) are closed completely, so the large
diameter chamber side of servo piston (17) is not
connected to the hydraulic oil tank and the
8. These movements increase the pump delivery
flow rate.㩷
T3-1-20
To Hydraulic Oil Tank㩷 10 11 To Hydraulic 12 13 4 15 16
Pz Oil Tank
21
20 19 18 8 7 17 㩷
T25N-03-01-016
10 11 12 13 4 15 16
21
20 19 18 8 7 17
㩷
T25N-03-01-016
4- Pin 11 - Spool 16 - Inner Spring 19 - Compensating Rod

7- Feedback Lever 12 - Pin 17 - Servo Piston 20 - Compensating Piston
8- Pin 13 - Lever 1 18 - Pin 21 - Pin
10 - Sleeve 15 - Outer Spring
T3-1-21
Control by Pilot Pressure from Displacement
Angle Proportional Solenoid Valve㩷
NOTE: As the axial plug positions are different

between main pump and swing pump, 㩷
operations of the regulators are reversed.㩷㩷 Flow Rate (Q)
㩷
• Main Pump㩷㩷
1. When the displacement angle proportional 㩷
solenoid valve is excited by a signal from MC2/A, 㩷
pilot pressure acts on pilot piston (1).㩷㩷
2. When pilot pressure increases, pilot piston (1) 㩷
moves rightward to the position where pilot 㩷
pressure is balanced with the pilot spring (6) 㩷
force.㩷㩷 0 Pump Control Pressure (Pi)㩷
3. Pilot piston (1) moves lever 2 (3) through pin (2). 㩷
Lever 2 (3) turns counterclockwise about pin (5) 㩷
which is fixed to the axial plug.㩷㩷
inserted into the hole of lever 2 (3). Therefore, 㩷 Pilot Pressure㩷
feedback lever (7) turns clockwise about pin (8)
by turning lever 2 (3) and spool (11) moves to the
right.㩷
5. When spool (11) moves, self pump delivery
pressure P1 acts on the large diameter chamber
side of servo piston (17) through spool (11).
Although self pump delivery pressure P1 acts on
P1
the small diameter chamber side, servo piston
(17) moves to the right due to the difference in
area.㩷 11
6. The pump displacement angle is reduced 7
and the pump delivery flow rate decreases.㩷
7. When servo piston (17) moves, feedback lever (7)
moves through pin (8). As neither compensating 㩷
Increase Decrease
rod (19) nor lever 1 (13) moves, feedback lever Displacement Angle㩷
1 3
(7) turns counterclockwise about pin (4) and spool T25N-03-01-028
(11) moves to the left. The cutouts of spool (11)

and sleeve (10) are closed completely, so self
pump delivery pressure P1 does not act on the
large diameter chamber side of servo piston (17),
and the movement of servo piston (17) stops.㩷
8. These movements decrease the pump delivery
flow rate and reduce the load to the pump.㩷
㩷
T3-1-22
1 2 3 4 5 6
Pilot
Pressure㩷
8
㩷
T25N-03-01-015
10 11 13 4
19 8 7 17 㩷
T25N-03-01-016
1- Pilot Piston 5- Pin 8 - Pin 13- Lever 1

2- Pin 6- Pilot Spring 10 - Sleeve 17- Servo Piston
3- Lever 2 7- Feedback Lever 11 - Spool 19- Compensating Rod
4- Pin
T3-1-23
• Swing Pump㩷
1. When the displacement angle proportional 㩷 Flow Rate (Q)㩷
solenoid valve is excited by a signal from MC2/A, 㩷
pilot pressure acts on pilot piston (1).㩷㩷
2. When pilot pressure increases, pilot piston (1) 㩷
moves rightward to the position where pilot 㩷
pressure is balanced with the pilot spring (6) 㩷
force.㩷㩷
3. Pilot piston (1) moves lever 2 (3) through pin (2). 㩷
Lever 2 (3) turns counterclockwise about pin (5) 㩷
which fixed to the axial plug.㩷㩷
0 Pump Control Pressure (Pi)㩷
inserted into the hole of lever 2 (3). Therefore, 㩷
feedback lever (7) turns counterclockwise about 㩷
pin (8) by turning lever 2 (3) and spool (11) moves 㩷
to the left.㩷㩷 Pilot Pressure
the hydraulic oil tank through spool (11). As self
pump delivery pressure P1 acts on the small
to the left.㩷 P1
6. The pump displacement angle increases
according to the movement of servo piston (17)
and the pump delivery flow rate increases.㩷 11
7. When servo piston (17) moves, feedback lever (7) 7
moves through pin (8). As neither pilot piston (1) 17
nor lever 2 (3) moves, feedback lever (7) turns 㩷
clockwise about pin (4) and spool (11) moves to Increase Decrease
1 3 Displacement Angle㩷
the right. The cutouts of spool (11) and sleeve T25N-03-01-029
(10) are closed completely, so the large diameter

chamber side of servo piston (17) is not
connected to the hydraulic oil tank, and the
8. These movements increase the pump delivery
flow rate.㩷
T3-1-24
1 2 3 4 5 6
Pilot
Pressure㩷
8
㩷
T25N-03-01-017
To Hydraulic
10 11 Oil Tank㩷 4
㩷
T25N-03-01-018
8 7 17
㩷
1- Pilot Piston 5- Pin 8 - Pin 13- Lever 1
2- Pin 6- Pilot Spring 10 - Sleeve 17- Servo Piston
3- Lever 2 7- Feedback Lever 11 - Spool 19- Compensating Rod
4- Pin
T3-1-25
SOLENOID VALVE㩷
The pump 2 regulator and swing pump regulator

provide a displacement angle proportional solenoid
valve.
The power increase solenoid valve is provided to the
PTO gearbox between pump 1 and pump 2.
(Refer to "Control Functions of Regulator".)
Operation of Displacement Angle Proportional Operation of Power Increase Solenoid Valve㩷

Solenoid Valve㩷 1. In neutral state, port P and the output port are
1. In neutral state, port T and the output port are connected through the cutout of spool (4).㩷
connected through the cutout of spool (4), and 2. When electric current from MC2/A goes to
pressure oil from port P is blocked completely by solenoid (1), solenoid (1) is excited and pushes
spool (4).㩷 spool (4) to the right.㩷
2. When electric current from MC2/A goes to 3. The output port is connected to port T through the
solenoid (1), solenoid (1) is excited and pushes cutout of spool (4) and pressure in the output port
spool (4) to the right.㩷 begins to decrease.㩷
3. The output port is connected to port P through the 4. Spring chamber (5) is connected to port T through
cutout of spool (4) and pressure oil from port P hole (3) of spool (4). As left side diameter (A) of
flows to the output port.㩷 notch of spool (4) is larger than right side
4. Spring chamber (5) is connected to port T through diameter (B), spool (4) returns to the left.㩷
hole (3) of spool (4). As left side diameter (A) of
notch of spool (4) is larger than right side
diameter (B), spool (4) returns to the left.㩷
T3-1-26
Displacement Angle Proportional Solenoid Valve Power Increase Solenoid Valve㩷

㩷
In Neutral State㩷㩷
㩷㩷
㩷 1 2 3 4 㩷 1 2 3 4
T Output P 㩷 T Output P 㩷
5 Port㩷 5 Port㩷
T25N-03-01-019 T25N-03-01-021
In Operation㩷
1 2 3 A B 4 1 2 3 4 A B
T Output P 㩷 T Output P 㩷
5 Port㩷 5 Port
T25N-03-01-020 T25N-03-01-022
T3-1-27
PILOT PUMP,
BOOM FOOT / LOWER CONTROL Suction Port㩷
HYDRAULIC OIL SOURCE PUMP,
REEVING WINCH DRIVING PUMP 2
1
(OPTIONAL)㩷
Drive gear (1) is driven through the PTO gearbox and

driven gear (2) engaged with drive gear (1) is also
rotated.
1 - Drive Gear 2 - Driven Gear
Delivery Port㩷
㩷
T137-02-03-005
T3-1-28
COMPONENT OPERATION / Swing Reduction Unit
OUTLINE㩷
The swing reduction unit consists of the valve unit, the The swing reduction gear turns the swing motors with
swing motors and the swing reduction gear.㩷 large torque at a low speed and slews the
The valve unit prevents the cavitation in the swing superstructure.
circuit.㩷
The swing motor is a swash plate type axial plunger
motor (with built-in swing parking brake), which is
driven by pressure oil from the pump and provides the
rotation the swing reduction gear.㩷
㩷
Valve Unit
Swing Motor
Swing
Reduction
Gear㩷
㩷
T2CD-03-02-001
T3-2-1
SWING REDUCTION GEAR㩷
The swing reduction gear is a two-stage reduction gear

comprised of one-stage spur gear and one-stage
planetary gear. Swing motor output shaft (1) rotates
pinion (7) and also rotates sun gear (5) through first
stage gear (2). Sun gear (5) rotates planetary gear (3)
and output shaft (carrier) (6). Output shaft (carrier) (6)
engages with the internal gear of turntable bearing
fixed to the undercarriage in order to slew the
superstructure.㩷
1 2
7 4
㩷
T2CD-03-02-002
1 - Motor Output Shaft 3 - Planetary Gear 5 - Sun Gear 7 - Pinion

2 - First Stage Gear 4 - Ring Gear 6 - Output Shaft (Carrier)
㩷
T3-2-2
SWING MOTOR㩷㩷
㩷
The swing motor consists of swash plate (6), rotor (11), When pressure oil is supplied from the pump, plunger
plungers (10), valve plates (12), housing (8) and swing (10) is pushed. As shoe (9) at the top of plunger (10)
parking brake (spring (1), brake piston (2), plate (3) slides over swash plate (6), rotor (11) rotates.㩷
and friction plate (4)).㩷 The top of shaft (7) is splined to the pinion gear of
Shaft (7) is splined to rotor (11) into which, plunger (10) swing reduction gear. Therefore, the rotation of shaft
is inserted.㩷 (7) is transmitted to the swing reduction gear.㩷
㩷
㩷
12
1
11
10
9 6
㩷
T2CD-03-02-004
1 - Spring 4 - Friction Plate 7 - Shaft 10 - Plunger

2 - Brake Piston 5 - Retainer 8 - Housing 11 - Rotor
3 - Plate 6 - Swash Plate 9 - Shoe 12 - Valve Plate
T3-2-3
SWING PARKING BRAKE㩷
The swing parking brake is a wet type multi-plate disc

brake and a negative mechanism that releases the
brake when the brake release pressure enters in the
brake piston room.
The brake release pressure is supplied from the pilot
pump only when the swing brake switch is operated. In
other cases (including engine stopping), the brake
release pressure returns to the hydraulic oil tank, so
that the brake is applied automatically by spring (1). Swing Brake
Switch
When Brake is Applied㩷
1. When the swing brake switch is set to the ON
position, the swing brake solenoid valve returns to 2
the neutral position, so that the pilot pressure,
which is applied to port Pb, is returned to the 1
2. As a result, the force of spring (1) acts on friction
plate (4), which is engaged with the external Swing Brake
circumference of rotor (11), and on plate (3), Solenoid Valve
which is engaged with the inside of housing (8)
through brake piston (2). Thus, the external
circumference of rotor (11) is secured with friction Hydraulic
force.㩷 Oil Tank㩷
3. When the engine stops, the brake is applied
automatically as pressure is not applied to port 㩷
Pilot Pump㩷
Pb.㩷 T25N-03-02-004
Swing Brake
When Brake is Released㩷 Switch
1. When the swing brake switch is to set the OFF
position, the swing brake solenoid valve is
selected. Then, pilot pressure from the pilot pump 2
is applied to port Pb.㩷
Brake
2. Pilot pressure applied to port Pb acts on the brake Piston
piston chamber.㩷 Chamber
3. Brake piston (2) moves by compressing spring
(1).㩷 1
4. As a result, plate (3) and friction plate (4) are freed Swing
and release the brake.㩷 Brake
㩷 Solenoid
Valve㩷
㩷
Pilot Pump㩷
T25N-03-02-005
T3-2-4
When Brake is Applied:㩷 When Brake is Released:㩷
1 1
2 2
3 3
To Pb Pb
From Pilot
Hydraulic Pump
Oil Tank 4 4
8 㩷 8
Brake Piston Brake Piston
Chamber㩷 11 Chamber㩷 11
T25N-03-02-006 T25N-03-02-006
1 - Spring 3 - Plate 8- Housing 11 - Rotor

2 - Brake Piston 4 - Friction Plate
T3-2-5
VALVE UNIT㩷
The valve unit is provided with a make-up valve.

The make-up valve prevents the cavitation in the Make-Up
circuit. Valve㩷
Make-Up Valve㩷
In swing stopping operation, the swing motor is driven
by the inertial force of superstructure. The swing Port M㩷
motor is turned forcibly in excess of oil pressure from
the pump so that the cavitation will be generated in
the motor.㩷
In order to avoid this, the poppet opens and draws Control Valve㩷
㩷
hydraulic oil when the pressure in the swing circuit
T25N-03-02-007
becomes lower than that in the return circuit (port M)
in order to compensate the lack of oil feed.㩷
㩷
Control Valve㩷
Poppet㩷
Make-Up Valve
Make-Up
Valve㩷
Port M㩷
㩷
T2CD-03-02-003
T3-2-6
COMPONENT OPERATION / Winch Assembly
OUTLINE㩷
The front drum and rear drum are driven separately. Winch motor (2) consists of the motor, counterbalance
When the crane is operated, the front drum uses boom valve (3), regulator (4), the shuttle valve block, the
hook and the rear drum uses jib hook in order to carry drum brake release solenoid valve and the wet type
out hosting and lowering (power lowering and free fall) multi plate brake.
and stopping (holding) operation. (The front drum and Regulator (4) is provided with the motor displacement
rear drum consist of the same parts respectively. The angle proportional solenoid valve and motor cutoff high
following explanation is made in terms of the front pressure solenoid valve.
drum.) Winch drum (1) consists of two-stage planetary
The front drum consists of winch motor (2) and winch reduction gear (5) and brake unit (6), which is built in
drum (1). the drum.
㩷
㩷
Front Drum㩷
Jib Hook㩷
Rear Drum㩷
Boom Hook㩷
㩷
㪫㪉㪚㪞㪄㪇㪊㪄㪇㪈㪄㪇㪇㪊㩷
No lowering free mechanism is provided㩷 With lowering free mechanism (Optional)㩷

㩷 1㩷 2㩷㩷 1 2
㩷㩷
㩷
㩷㪫㪉㪚㪞㪄㪇㪊㪄㪇㪈㪄㪇㪇㪌㩷
㪫㪉㪚㪥㪄㪇㪊㪄㪇㪊㪄㪇㪇㪈㩷㩷
5㩷㩷
㩷 5㩷 4 3 6 㩷 4 3
㩷
㩷
1 - Winch Drum 3 - Counterbalance Valve 5 - Reduction Gear 6- Brake Unit
(Two-Stage Planetary)
2 - Winch Motor 4 - Regulator 㩷㩷
㩷
T3-3-1
MOTOR㩷
The motor is a swash plate type variable displacement Plunger (1) slides over the slope of shoe plate (4) in
axial piston motor capable of selecting high/low order to rotate rotor (2).
speeds. Rotor (2) is splined to output shaft (7) in order to turn
High/low speed selection of the motor is controlled by output shaft (7).
the regulator. Swash plate (5) is located between tilt pistons (8)(2
The wet type multi plate brake is built in the rear case used). The displacement angle is changed by the
(9) side of motor. operation of regulator.
The motor has plungers (1)(9 used). In each plunger
(1), shoe (3) is crimped into rotor (2).
㩷
㩷
㩷
8
Wet Type
Multi plate Brake㩷
7
9
3
2
1
6
㩷
㪫㪊㪉㪋㪄㪇㪉㪄㪇㪋㪄㪇㪇㪊㩷
㩷
1 - Plunger 4- Shoe Plate 6- Valve Plate 8- Tilt Piston
2 - Rotor 5- Swash Plate 7- Output Shaft 9- Rear Case
3 - Shoe
㩷
T3-3-2
Operation㩷㩷
1. Rotation speeds of the front and rear drums are 㩷

changed according to oil flow rate from the pump.㩷㩷
2. Pressure oil from port A of valve plate (6) flows to
rotor (2) and pushes plunger (1).㩷
3. Then, shoe (3) slides over shoe plate (4) on
swash plate (5) in order to rotate rotor (2).㩷
4. The turning torque of rotor (2) is transmitted to the
reduction gear through output shaft (7). Return oil
flows through delivery port B and returns to the
5. When high pressure oil comes in port B, the
rotation is reversed.㩷
㩷
㩷
B A
7
5
6
㩷
㪫㪊㪉㪋㪄㪇㪉㪄㪇㪌㪄㪇㪉㪐㩷
4 3 1 2
㩷
㩷
1 - Plunger 3 - Shoe 5 - Swash Plate 7 - Output Shaft
2 - Rotor 4 - Shoe Plate 6 - Valve Plate 㩷
㩷
㩷
T3-3-3
(Blank)㩷
T3-3-4
REGULATOR㩷
The regulator has two control functions as follows.

Speed
x High/low speed selection control
Motor displacement angle proportional solenoid
valve (7) operates in proportion to operation of
speed set dial for motor (1). The displacement angle
of motor (1) is changed according to pilot pressure
caused when moving the hoisting lever. (Front and
rear motor speed control) (Refer to the Control
0
System group.)㩷
Operation of Speed
Set Dial㩷
x Maximum displacement angle lock control

When self pressure increases, pressure oil to the Speed
large diameter chamber in tilt piston (2) is reduced.
When self pressure increases further, pressure oil in
the large diameter chamber is returned to the
hydraulic oil tank. As a result, the displacement
angle is fixed to the maximum (minimum speed).㩷
In addition, motor cutoff high-pressure solenoid
valve (3) controls the instructions for maximum 0
displacement angle in order to select the set 㩷
pressure to the maximum displacement angles for Self Pressure㩷
hoisting and lowering operations.㩷
㩷
7 8 9 10 11 1
㩷
6
2
㩷
3
T25N-03-03-013
㩷
1 - Motor 4 - Piston 1 7 - Motor Displacement Angle 10 - Orifice
2 - Tilt Piston 5 - Spool 1 8 - Piston 2 11 - Spring 2
3 - Motor Cutoff High-Pressure 6 - Spring 1 9 - Spool 2 㩷
Solenoid Valve
㩷
T3-3-5
High/Low Speed Selection Control㩷
• High speed selection㩷

1. When the speed set dial of front motor is operated, 5. Self pressure also acts on the small diameter
MC2/B sends a signal in proportion to operation chamber side of tilt piston (2).㩷
of the speed set dial to front motor displacement 6. Self pressure, which flows through orifice (10), is
angle proportional solenoid valve (7).㩷 lower than pressure in the small diameter
2. When the hoisting lever is moved, pilot pressure chamber side.㩷
oil from front motor displacement angle 7. Pressure in the large diameter chamber side
proportional solenoid valve (7) acts on piston 2 increases gradually and reaches that in the small
(8).㩷 diameter chamber side. At this time, tilt piston (2)
3. When this pressure is larger than force of spring 2 moves to the right due to the difference in area.㩷
(11), piston 2 (8) pushes spool 2 (9) to the position 8. As a result, motor (1) is set to a small
where pressure is balanced with force of spring 2 displacement angle and results in high speed
(11).㩷 rotation.㩷
4. Self pressure (pressure oil in the main circuit) 9. Thus, motor (1) is protected from rapid changes in
flows to the large diameter chamber side of tilt speed and over speed running.㩷
piston (2) through orifice (10).㩷㩷
㩷
High speed selection (at small displacement angle)㩷
㩷 7 8 9 10 11
㩷
1
Pi1
Bv Av
㩷
2 㪫㪉㪌㪥㪄㪇㪊㪄㪇㪊㪄㪇㪇㪈㩷
㩷
㩷
1 - Motor 7- Motor Displacement Angle 9- Spool 2 11 - Spring 2
2 - Tilt Piston 8 - Piston 2 10 - Orifice 㩷
㩷
T3-3-6
• Low speed selection㩷

1. When the speed set dial of front motor is operated, 5. Self pressure slowly flows to the hydraulic oil tank
MC2/B sends a signal in proportion to operation through orifice (10).㩷
of the speed set dial to front motor displacement 6. As self pressure acts on the small diameter
angle proportional solenoid valve (7).㩷 chamber side of tilt piston (2), tilt piston (2) moves
2. When the hoisting lever is moved, pilot pressure to the left.㩷
oil from front motor displacement angle 7. As a result, motor (1) is set to a large
proportional solenoid valve (7) acts on piston 2 displacement angle and results in low speed
(8).㩷 rotation.㩷
3. When this pressure is lower than force of spring 2 8. Thus, motor (1) is protected from rapid changes in
(11), spool 2 (9) pushes piston 2 (8) to the position speed and overload.㩷
where pressure is balanced with force of spring 2 㩷
(11).㩷
4. Pressure oil acting on piston 2 (8) flows to the 㩷
hydraulic oil tank.㩷㩷
㩷
㩷
Low speed selection (at large displacement angle)㩷
㩷 7 8 9 10 11
㩷
1
Pi1
Bv Av
㩷
2 㪫㪉㪌㪥㪄㪇㪊㪄㪇㪊㪄㪇㪇㪉㩷
㩷
㩷
1 - Motor 7- Motor Displacement Angle 9- Spool 2 11 - Spring 2
2 - Tilt Piston 8 - Piston 2 10 - Orifice 㩷
㩷
㩷
T3-3-7
Maximum Displacement Angle Lock Control㩷
• In Hoisting Operation㩷
1. As no signal comes to motor cutoff high-pressure 6. When self pressure increases further, spool 1 (5)
solenoid valve (3) during hoisting operation, is pushed by piston 1 (4) and pressure oil at the
motor cutoff high-pressure solenoid valve (3) is large diameter chamber side of tilt piston (2) flows
not selected.㩷 to the hydraulic oil tank through spool 1 (5).㩷
2. Pilot pressure acts on piston 1 (4) through motor 7. As a result, tilt piston (2) is pushed leftward and
cutoff high-pressure solenoid valve (3).㩷 motor (1) is set to the maximum displacement
3. Self pressure acts on piston 1 (4).㩷 angle.㩷
4. When self pressure exceeds pilot pressure acting 8. Thus, by setting pressure of spool 1 (5) at higher
on piston 1 (4) and spring 1 (6) force, piston 1 (4) level than that in lowering operation, an
moves leftward to the position when self pressure instruction for maximum displacement angle of
is balanced with those pressures.㩷 motor (1) is retarded in order to retain the
5. As spool 1 (5) is pushed by piston 1 (4), the circuit horsepower for hoisting operation.㩷
to the large diameter chamber side of tilt piston In addition, during the self pressure increasing,
(2) is restricted.㩷 the maximum displacement angle of motor (1) is
retained.㩷
㩷
1
Self pressure: Low Self pressure: High
1
6 6
2 2
5 5
Self Self
Pressure Pressure㩷
4 4
3
㩷 3 㩷
㪫㪉㪌㪥㪄㪇㪊㪄㪇㪊㪄㪇㪈㪋㩷㪫㪉㪌㪥㪄㪇㪊㪄㪇㪊㪄㪇㪈㪌㩷
㩷㩷
㩷
1 - Motor 3- Motor Cutoff High-Pressure 5- Spool 1 6- Spring 1
Solenoid Valve
2 - Tilt Piston 4 - Piston 1 㩷㩷
㩷
㩷
T3-3-8
• In Lowering Operation㩷
1. During lowering operation, motor cutoff 6. When self pressure increases further, spool 1 (5)
high-pressure solenoid valve (3) is selected by a is pushed by piston 1 (4) and pressure oil in the
signal from MC2/A.㩷 large diameter chamber of tilt piston (2) flows to
2. Pressure oil acting on piston 1 (4) flows to the the hydraulic oil tank through spool 1 (5).㩷
hydraulic oil tank through motor cutoff 7. As a result, spool 1 (5) moves by self pressure
high-pressure solenoid valve (3).㩷 lower than that in hoisting operation and motor (1)
3. Therefore, force against self pressure acting on is set at the maximum displacement angle.㩷
piston 1 (4) is only force of spring 1 (6).㩷 8. Thus, by setting pressure for hoisting or lowering
4. When self pressure becomes higher than force of operation, horsepower is retained for hoisting
spring 1 (6), piston 1 (4) moves leftward to the operation, or the motor speed is controlled for
position where self pressure is balanced with lowering operation.㩷
force of spring 1 (6).㩷㩷
5. As spool 1 (5) is pushed by piston 1 (4), the circuit
to the large diameter chamber side of tilt piston 㩷
(2) is restricted.㩷㩷
㩷
1
Self pressure: Low Self pressure: High
1
6 6
2 2
5 5
Self Self
4 Pressure 4 Pressure
3
㩷 3 㩷
㪫㪉㪌㪥㪄㪇㪊㪄㪇㪊㪄㪇㪈㪍㩷㪫㪉㪌㪥㪄㪇㪊㪄㪇㪊㪄㪇㪈㪎㩷
㩷㩷
㩷
1 - Motor 3- Motor Cutoff High-Pressure 5- Spool 1 6- Spring 1
Solenoid Valve
2 - Tilt Piston 4 - Piston 1 㩷㩷
㩷
T3-3-9
COUNTERBALANCE VALVE㩷㩷
2
The counterbalance valve consists of counterbalance 㩷
spool (4), spring (3), check valve (1) and relief valve 1
(2).
Purpose of Counterbalance㩷㩷
A B㩷㩷
1. The counterbalance valve is provided in the 3 4
㪫㪉㪚㪥㪄㪇㪊㪄㪇㪊㪄㪇㪇㪉
lowering circuit.㩷㩷
2. When a load is lifted, as its weight always works 㩷
downward as an external force, the motor carries 㩷 Lowering㩷

a load torque in the lowering direction.㩷
3. At this time, in the hoisting circuit, an internal
pressure corresponding to this external force is
generated.㩷
4. When the control valve is operated in the lowering
direction under this loading condition, internal
pressure of the hoisting circuit that holds the
motor is released.㩷
5. The motor is turned by external force working in
2
lowering direction regardless of oil flow rate from 1
the pump so that coasting phenomenon may
occur.㩷
6. The counterbalance valve prevents this coasting
phenomenon.㩷
㩷
㩷
㪫㪉㪚㪥㪄㪇㪊㪄㪇㪊㪄㪇㪇㪊㩷
㩷
㩷
㩷
1 - Check Valve 2 - Relief Valve 3 - Spring 4 - Counterbalance Spool
㩷
㩷
㩷
T3-3-10
In Hosting Operation㩷㩷
1. During hoisting operation, pressure oil from the 㩷

pump flows through port A, pushes up the poppet 㩷
of check valve (1) and flows to the motor through 㩷
port D.
2. Return oil returns to the hydraulic oil tank through 㩷
ports C and B.㩷㩷
3. During hoisting operation, only check valve (1) 㩷
operates.㩷
㩷
Hoisting㩷㩷
㩷 Hoisting㩷
1 C
C D
B A
A B
4
㩷
㪫㪉㪚㪥㪄㪇㪊㪄㪇㪊㪄㪇㪇㪋㩷
㩷
㪫㪉㪚㪥㪄㪇㪊㪄㪇㪊㪄㪇㪇㪌㩷
㩷
㩷
1 - Check Valve 4 - Counterbalance Spool
㩷
㩷
㩷
㩷
㩷
㩷
T3-3-11
In Lowering Operation㩷
1. During lowering operation, pressure oil from the 8. On the contrary, when oil flow rate decreases,
pump flows to the motor through ports B and C.㩷 passage resistance in counterbalance spool (4)
2. Pressure oil also flows to pilot passage (5) of decreases oil feed pressure is reduced.㩷
counterbalance spool (4). As return oil is blocked 9. Counterbalance spool (4) is returned, the
by check valve (1), the motor does not turn and oil passage is narrowed and the motor speed
feed pressure increases.㩷 decreases.㩷
3. This pressure oil flows through pilot passage (5) 10. When lowering a load, the motor is likely to be
and moves counterbalance spool (4) leftward turned in excess of oil feed amount and oil feed
(rightward in circuit diagram).㩷 pressure decreases.㩷
4. Pressure oil opens ports D and A and return oil 11. The motor speed is restricted not to be faster than
from the motor returns to the hydraulic oil tank oil feed amount by returning counterbalance spool
through the control valve.㩷 (4) and narrowing the flow passage.㩷
5. As a result, the motor turns in the lowering 12. Thus, the lowering speed changes according to oil
direction.㩷 feed amount.㩷
6. When increasing the oil feed amount to the motor, 㩷
passage resistance in counterbalance spool (4)
increases.㩷㩷
7. Oil feed pressure increases so that 㩷
counterbalance spool (4) moves further, the 㩷
passage opens more and the motor speed
increases.㩷㩷
㩷㩷
Lowering㩷 Lowering㩷
㩷㩷
C C 㪛㩷 4
1
5
B A
A B
㩷
㪫㪉㪚㪥㪄㪇㪊㪄㪇㪊㪄㪇㪇㪍㩷㩷
㪫㪉㪚㪥㪄㪇㪊㪄㪇㪊㪄㪇㪇㪎㩷
㩷
㩷
㩷
1 - Check Valve 4- Counterbalance Spool 5 - Pilot Passage
T3-3-12
1. When the spool in control valve is set to the 㩷

neutral position, the hydraulic oil tank pressure is 㩷
applied in port B, counterbalance spool (4) is 㩷
returned and the flow passage is closed.㩷
2. As check valve (1) is closed, internal pressure is 㩷
generated corresponding to the lifting load in 㩷
order to suspend the load in the position.㩷㩷
㩷
㩷
㩷
㩷
㩷
1
B A
㩷
㪫㪉㪚㪥㪄㪇㪊㪄㪇㪊㪄㪇㪇㪏㩷
㩷
㩷
㩷
T3-3-13
Overload Relief Valve㩷㩷
6 2
Overload relief valve (2) that is provided in 㩷
counterbalance valve body (6) absorbs shock
pressure caused by inertial force when the motor
stops.
㩷
1. Overload relief valve (2) is built in the lowering 㪫㪉㪚㪥㪄㪇㪊㪄㪇㪊㪄㪇㪇㪉㩷
circuit.㩷㩷
Poppet (3) in overload relief valve (2) closes the
flow passage due to force of spring (5).㩷
2. When the control lever is set to the neutral
2
position, the motor is likely to be turned in
lowering direction by inertial force of the load.㩷
3. When pressure in port D increases instantly and
reaches the set pressure, poppet (3) in overload
relief valve (2) moves and releases pressure.㩷
5
㩷
㪫㪉㪚㪥㪄㪇㪊㪄㪇㪊㪄㪇㪇㪐㩷
㩷
3 5
Port D
㩷
㪫㪊㪉㪋㪄㪇㪉㪄㪇㪋㪄㪇㪉㪊㩷
㩷
㩷
1 - Overload Relief Valve 3 - Poppet 5 - Spring 6 - Counterbalance Valve
Body
㩷
T3-3-14
BRAKE㩷㩷
1 2
The brake is a wet type multi plate disc brake, and
applied and released by the brake release solenoid
valve.
For releasing the brake, there are two ways: hydraulic
and electric. (Winch brake mode control)
(Refer to the Control System group.) 3
Operation㩷
1. Coupling (5) is splined to output shaft (4).㩷

coupling (5) is splined to friction plates (7).㩷
Disc plates (6) are splined to valve cover (1). Disc 4
plates (6) and friction plates (7) are alternately
installed.㩷
2. While the hoisting lever is set in the neutral
5
position, pressure oil in port PR is routed to the
3. When spring (3) pushes brake piston (2), and
frictions plate (7) and disc plates (6) closely
contact to each other under pressure, the brake is 㩷
PR
applied.㩷㪫㪉㪚㪞㪄㪇㪊㪄㪇㪊㪄㪇㪇㪈㩷
4. When hoisting or lowering with the front (rear) 㩷 7 6
lever, a signal from MC2/A is sent to brake
release solenoid valve (8).㩷
5. When, brake release solenoid valve (8) is
selected, pressure oil from the pilot pump acts on 2 8
brake piston (2) through port PR.㩷
6. Brake piston (2) compresses spring (3) so that
disc plates (6) and friction plates (7) are freed.㩷
7. As a result, the brake is released.㩷
Pilot 㩷
Pump
㪫㪉㪌㪥㪄㪇㪊㪄㪇㪊㪄㪇㪇㪐㩷
㩷
㩷
1 - Valve Cover 3- Spring 5- Coupling 7- Friction Plate
2 - Brake Piston 4- Output Shaft 6- Disc Plate 8- Brake Release Solenoid
Valve
㩷
T3-3-15
WINCH DRUM㩷㩷
The winch drum consists of the reduction gear and the 㩷

brake unit (with free mechanism (optional)).
The reduction gear is a two-stage planetary reduction
gear and converts the rotation transmitted from the
motor to a low-speed large torque so that the drum
rotates.
The brake unit is a wet type multi plate disc brake and
applied with the brake pedal.
No free mechanism is provided With free mechanism (Optional)

Brake Unit㩷
Drum㩷
Reduction Gear㩷
㩷
㩷㩷
㪫㪉㪚㪞㪄㪇㪊㪄㪇㪈㪄㪇㪇㪎㩷
㪫㪉㪚㪥㪄㪇㪊㪄㪇㪊㪄㪇㪈㪇㩷
㩷㩷
Reduction Gear㩷 Drum㩷
㩷㩷
㩷
㩷
㩷
㩷
㩷
㩷
㩷
㩷
㩷
㩷
㩷
㩷
㩷
㩷
㩷
T3-3-16
REDUCTION GEAR㩷㩷
1. The reduction gear is a two-stage planetary 㩷

reduction gear. The motor rotates propeller shaft 㩷
(6).㩷㩷
2. This rotation is transmitted to ring gear (5)
through first stage planetary gear (1), first stage 㩷
carrier (2), sun gear (3), second stage planetary 㩷
gear (4).㩷㩷
3. Ring gear (5) is fixed to drum (8) with bolts (7).㩷
4. Therefore, while rotating ring gear (5), drum (8) is 㩷
also rotated.㩷㩷
㩷
㩷
㩷
㩷
㩷
㩷
3 5 6
8 1 2 4 7
㩷
㪫㪉㪚㪥㪄㪇㪊㪄㪇㪊㪄㪇㪈㪈㩷
㩷
1 - First Stage Planetary Gear 3- Sun Gear 5- Ring Gear 7- Bolt
2 - First Stage Carrier 4- Second Stage Planetary 6- Propeller Shaft 8- Drum
Gear
㩷
㩷
T3-3-17
(Blank)
T3-3-18
COMPONENT OPERATION / Boom Hoist System
OUTLINE㩷
The boom hoist system consists of boom hoist motor Reduction gear (3) is a three-stage planetary reduction
(5), reduction gear (3), brake valve (1) and boom hoist gear that converts the rotation transmitted from boom
drum (4). hoist motor (5) to a low-speed large torque in order to
Boom hoist motor (5) is an axial plunger motor that rotate boom hoist drum (4).
incorporates a parking brake (wet type multi plate Brake valve (1) prevents overload and cavitation of the
brake). Boom hoist motor (5) is driven by pressure oil boom hoist circuit.
from the pump and transmits the rotation to reduction
gear (3).
㩷
㩷
㩷 1 2 3 4
㩷
㩷
㪫㪉㪚㪥㪄㪇㪊㪄㪇㪋㪄㪇㪇㪈㩷㩷
5
㩷
㩷
1 - Brake Valve 3 - Reduction Gear 4- Boom Hoist Drum 5- Boom Hoist Motor
2 - Regulator 㩷㩷㩷
* This illustration represents the boom hoist system of Machine No.5 or earlier.
㩷
㩷
㩷
㩷
㩷
T3-4-1
BOOM HOIST MOTOR㩷
The boom hoist motor is a swash plate type variable Pressure oil supplied from the pump pushes plunger
displacement axial plunger motor and consists of valve (6). Shoe (5) at the top of plunger (6) slides on swash
plate (1), swash plate (4), rotor (2), plunger (6) and plate (4) according to the inclination. Therefore, rotor
shaft (3). (2) rotates.
Shaft (3) is splined to rotor (2). Plunger (6) is inserted
into rotor (2).
㩷
㩷
Machine No.5 or earlier
1 2
3
㩷
6 5 4 㪫㪉㪚㪥㪄㪇㪊㪄㪇㪋㪄㪇㪇㪉㩷㩷
1- Valve Plate 3- Shaft 5- Shoe 6- Plunger

2- Rotor 4- Swash Plate 㩷㩷
㩷
㩷
Machine No.6 or later
1 2
3
㩷
6 5 4 㪫㪉㪚㪥㪄㪇㪊㪄㪇㪋㪄㪇㪇㪊㩷㩷
㩷
1 - Valve Plate 3- Shaft 5- Shoe 6- Plunger
2 - Rotor 4- Swash Plate 㩷㩷
㩷
T3-4-2
REDUCTION GEAR㩷
The reduction gear is a three-stage planetary reduction Housing (11) in the boom hoist motor is fixed to the
gear. swing frame. Ring gear (1) is fixed to the boom hoist
The boom hoist motor rotates propeller shaft (7). This drum by using the bolts. Therefore, when ring gear (1)
rotation is transmitted to ring gear (1) through first rotates, the boom hoist drum rotates.
stage planetary gear (8), first stage carrier (6), second 㩷
stage sun gear (5), second stage planetary gear (9),
second stage carrier (4), third stage sun gear (3), third
stage planetary gear (10) and third stage carrier (2).
㩷
Machine No.5 or earlier 11 2 1 3 4 5 6
10 9 8
㩷
T2CN-03-04-004
1 - Ring Gear 4- Second Stage Carrier 7- Propeller Shaft 10 - Third Stage Planetary Gear
2 - Third Stage Carrier 5- Second Stage Sun Gear 8- First Stage Planetary Gear 11 - Housing
3 - Third Stage Sun Gear 6- First Stage Carrier 9- Second Stage Planetary 㩷
Gear
㩷
Machine No.6 or later 1 2 3 4 5
11 10 9
㩷
8
㪫㪉㪚㪥㪄㪇㪊㪄㪇㪋㪄㪇㪇㪌㩷㩷
1 - Ring Gear 4- Second Stage Carrier 7- Propeller Shaft 10 - Third Stage Planetary Gear
2 - Third Stage Carrier 5- Second Stage Sun Gear 8- First Stage Planetary Gear 11 - Housing
3 - Third Stage Sun Gear 6- First Stage Carrier 9- Second Stage Planetary
Gear
㩷
T3-4-3
BOOM HOIST BRAKE㩷㩷
The boom hoist brake is a wet type multi plate disc 㩷

brake and a negative mechanism that releases the 㩷
brake when brake release pressure enters the brake 㩷
piston chamber.
The wet type multi plate disc brake and the hoist drum 㩷
lock are provided in the same circuit, and work at the 㩷
same time. 㩷
When Brake is Applied㩷㩷 Boom Hoist Drum Unlocking

㩷 Solenoid Valve㩷
1. When the boom hoist lever is set in the neutral
position, as the boom hoist drum unlocking 㩷
solenoid valve is not selected, pilot pressure fed
to the boom hoist drum lock returns to the
hydraulic oil tank through the boom hoist drum Pilot Pump
lock solenoid valve.㩷
2. As a result, force of disc spring (1) acts on plates Hydraulic Oil
(3) engaged with the inside of housing (6) and on Tank㩷
friction plates (4) engaged with the external
circumference of brake coupling (5) through brake
piston (2). Thus, the external circumference of 㩷
brake coupling (5) is retained with friction force.㩷 Boom Hoist 㩷
Drum Lock㩷
3. In the boom hoist drum lock, pawl (9) is moved by 㩷
torsion spring (8) and the boom hoist drum is 㪫㪉㪌㪥㪄㪇㪊㪄㪇㪋㪄㪇㪇㪍㩷
locked.㩷㩷
㩷
When Brake is Released㩷
1. When the boom hoist lever is moved, the boom 㩷
hoist drum lock solenoid valve is selected by a 㩷
signal from MC2/A.㩷
㩷
2. Then, pilot pressure from the pilot pump is
Boom Hoist Drum Unlocking
supplied to the boom hoist drum lock through the 㩷 Solenoid Valve㩷
boom hoist drum lock solenoid valve.㩷㩷
3. Furthermore, pilot pressure acts on the brake
piston chamber.㩷
Pilot Pump
4. Brake piston (2) moves by compressing disc
spring (1).㩷
5. As a result, plate (3) and friction plate (4) are
freed and the brake is released.㩷
6. The boom hoist drum lock retracts by pilot
pressure and pawl (9) moves.㩷
7. As a result, pawl (9) is removed from the boom 㩷
Boom Hoist Drum 㩷
hoist drum and the lock is released.㩷 Lock㩷
㩷
㩷
㪫㪉㪌㪥㪄㪇㪊㪄㪇㪋㪄㪇㪇㪌㩷
㩷
㩷
㩷
㩷
㩷
T3-4-4
When Brake is Applied㩷㩷
㩷 1 2 3 4 5 㩷
Boom Hoist Drum㩷
㩷㩷
㩷㩷
Boom Hoist Drum Lock

9
Brake Piston Chamber㩷 8
7
㩷 To Hydraulic Oil 㩷
㪫㪉㪚㪞㪄㪇㪊㪄㪇㪋㪄㪇㪇㪌㩷 Tank㩷㪫㪉㪚㪥㪄㪇㪊㪄㪇㪋㪄㪇㪇㪍㩷
To Hydraulic Oil 㩷
㩷 Tank㩷 6
㩷㩷
㩷㩷
When Brake is Released㩷㩷
㩷 2 3 4 5 㩷
1
㩷㩷
㩷㩷 Boom Hoist Drum㩷
㩷
㩷
Brake Piston Chamber㩷 Boom Hoist Drum Lock

9
㩷
From Pilot
㪫㪉㪚㪞㪄㪇㪊㪄㪇㪋㪄㪇㪇㪌㩷 7
㩷 Pump㩷 6 From Pilot 㩷
㩷 Pump㩷㪫㪉㪚㪥㪄㪇㪊㪄㪇㪋㪄㪇㪇㪍㩷
㩷
㩷
1 - Disc Spring 4 - Friction Plate 6- Housing 8- Torsion Spring
2 - Brake Piston 5 - Brake Coupling 7- Pawl Joint 9- Pawl
3 - Plate 㩷㩷㩷
* This illustration represents the boom hoist brake of Machine No.5 or earlier.
㩷
T3-4-5
COUNTERBALANCE VALVE㩷㩷
The counterbalance valve consists of counterbalance 㩷

spool (4), spring (3), check valve (1) and relief valve 1 2
(2).
Purpose of Counterbalance㩷㩷
1. The counterbalance valve is provided in the 㪫㪉㪚㪥㪄㪇㪊㪄㪇㪋㪄㪇㪇㪎㩷
3 4
lowering circuit.㩷㩷
2. When a load is lifted, as its weight always works 㩷
downward as an external force, the motor carries 㩷 Lowering
a load torque in the lowering direction.㩷
3. At this time, in the hoisting circuit, an internal
pressure corresponding to this external force is
generated.㩷
4. When the control valve is operated in the lowering 2
direction under this loading condition, internal
pressure of the hoisting circuit that holds the
motor is released.㩷
5. The motor is turned by external force working in
lowering direction regardless of oil flow rate from
the pump so that coasting phenomenon may
occur.㩷
6. The counterbalance valve prevents this coasting
phenomenon.㩷 1
㩷
㪫㪉㪚㪥㪄㪇㪊㪄㪇㪋㪄㪇㪇㪏㩷
㩷
㩷
㩷
㩷
1 - Check Valve 2 - Relief Valve 3 - Spring 4 - Counterbalance Spool
㩷
㩷
㩷
T3-4-6
In Hosting Operation㩷㩷
1. During hoisting operation, pressure oil from the 㩷

pump flows through port A, pushes up the poppet 㩷
of check valve (1) and flows to the motor through 㩷
port D.㩷
2. Return oil returns to the hydraulic oil tank through 㩷
ports C and B.㩷㩷
3. During hoisting operation, only check valve (1) 㩷
operates.㩷
㩷
㩷
㩷
㩷
Hoisting㩷
㩷
㩷
㩷
㩷 Hoisting㩷
1 C
D
D C
A
A B
4 A B
㩷
㪫㪉㪚㪥㪄㪇㪊㪄㪇㪋㪄㪇㪇㪐㩷
㩷
㩷㪫㪉㪚㪥㪄㪇㪊㪄㪇㪋㪄㪇㪈㪇㩷
㩷㩷
1 - Check Valve 4 - Counterbalance Spool 㩷
㩷㩷
㩷㩷
㩷
㩷
T3-4-7
In Lowering Operation㩷
1. During lowering operation, pressure oil from the 8. On the contrary, when oil flow rate decreases,
pump flows to the motor through ports B and C.㩷 passage resistance in counterbalance spool (4)
2. Pressure oil also flows to pilot passage (5) of decreases oil feed pressure is reduced.㩷
counterbalance spool (4). As return oil is blocked 9. Counterbalance spool (4) is returned, the
by check valve (1), the motor does not turn and oil passage is narrowed and the motor speed
feed pressure increases.㩷 decreases.㩷
3. This pressure oil flows through pilot passage (5) 10. When lowering a load, the motor is likely to be
and moves counterbalance spool (4) leftward turned in excess of oil feed amount and oil feed
(rightward in circuit diagram).㩷 pressure decreases.㩷
4. Pressure oil opens ports D and A and return oil 11. The motor speed is restricted not to be faster than
from the motor returns to the hydraulic oil tank oil feed amount by returning counterbalance spool
through the control valve.㩷 (4) and narrowing the flow passage.㩷
5. As a result, the motor turns in the lowering 12. Thus, the lowering speed changes according to oil
direction.㩷 feed amount.㩷
6. When increasing the oil feed amount to the motor,
passage resistance in counterbalance spool (4)
increases.㩷
7. Oil feed pressure increases so that
counterbalance spool (4) moves further, the
passage opens more and the motor speed
increases.㩷
Lowering㩷 Lowering㩷
C 4 5
1
D C
D
A B
4 A B
㩷
㪫㪉㪚㪥㪄㪇㪊㪄㪇㪋㪄㪇㪈㪉㩷
㩷
㪫㪉㪚㪥㪄㪇㪊㪄㪇㪋㪄㪇㪈㪈㩷
㩷
1 - Check Valve 4- Counterbalance Spool 5 - Pilot Passage
T3-4-8
1. When the spool in control valve is set to the 㩷

neutral position, the hydraulic oil tank pressure is 㩷
applied in port B, counterbalance spool (4) is 㩷
returned and the flow passage is closed.㩷
2. As check valve (1) is closed, internal pressure is 㩷
generated corresponding to the lifting load in 㩷
order to suspend the load in the position.㩷㩷
㩷
㩷
㩷
㩷
㩷
B A
㩷
㪫㪉㪚㪥㪄㪇㪊㪄㪇㪋㪄㪇㪈㪊㩷
㩷
㩷
㩷
㩷
T3-4-9
RELIEF VALVE㩷㩷
Relief valve (2) that is provided in counterbalance 㩷 6 2

valve body (6) absorbs shock pressure caused by
inertial force when the motor stops.
1. Relief valve (2) is built in the lowering circuit.㩷㩷

㪫㪉㪚㪥㪄㪇㪊㪄㪇㪋㪄㪇㪇㪎㩷
Poppet (3) in relief valve (2) closes the flow
passage due to force of spring (5).㩷㩷
2. When the control lever is set to the neutral
position, the motor is likely to be turned in
lowering direction by inertial force of the load.㩷
3. When pressure in port D increases instantly and
reaches the set pressure, poppet (3) in relief 2
valve (2) moves and releases pressure.㩷
㩷
㪫㪉㪚㪥㪄㪇㪊㪄㪇㪋㪄㪇㪈㪋㩷
㩷
3 5
Port D
㩷
㪫㪊㪉㪋㪄㪇㪉㪄㪇㪋㪄㪇㪉㪊㩷
㩷
㩷
2- Relief Valve 3 - Poppet 5 - Spring 6 - Counterbalance Valve
Body
㩷
㩷㩷
㩷
T3-4-10
COMPONENT OPERATION / Front and Rear Control Valves㩷
OUTLINE㩷㩷
The control valve controls the pressure, flow rate, and 㩷

flow direction in the hydraulic circuit.
The front and rear control valves are 4-spool type,

which consist of the main relief valve, port relief valve,
make-up valve, holding valve, pressure compensation
valve, proportional solenoid valve, remote control
pressure sensor and spools.
The front control valve has the spools for travel (left),
rear drum (high speed) and front drum (low speed).
The rear control valve has the spools for travel (right),
boom hoist, rear drum (low speed) and front drum
(high speed).
The spool is switched by pressure oil from the solenoid
valve and delivers pressure oil from main pumps 1 and
2 to each actuator.
T3-5-1
CONFIGURATION㩷㩷
㩷
2 3 4 5 6
7
1
㩷
T2CG-03-05-004
㩷
㩷 12 11 10 9
㩷 1 2 4 11 6 㩷
㩷 10
㩷
㩷
㩷
㪫㪉㪚㪥㪄㪇㪊㪄㪇㪌㪄㪇㪇㪈㩷
8 9
㩷㪫㪉㪚㪥㪄㪇㪊㪄㪇㪌㪄㪇㪇㪉㩷
1- Main Relief Valve 4- Rear Drum (High Speed) 7- Pressure Compensation 10 - Front Drum Hoisting
Spool Valve Remote Control Pressure
Sensor
2- Left Travel Spool 5- Port Relief Valve (with 8- Front Drum Lowering 11 - Front Drum Hoisting
Make-Up Function) Proportional Solenoid Valve Proportional Solenoid Valve
3- Make-Up Valve 6 - Front Drum (Low Speed) 9 - Front Drum Lowering 12 - Holding Valve
Spool Remote Control Pressure
Sensor
T3-5-2
㩷
㩷
㩷
7
1
11
2
12 6
㩷
㪫㪉㪚㪥㪄㪇㪊㪄㪇㪌㪄㪇㪇㪊㩷
T3-5-3
㩷
㩷
2 3 4 5 6 4 7 8
㩷
1
9
㩷
㪫㪉㪙㪚㪄㪇㪊㪄㪇㪉㪄㪇㪇㪉㩷
㩷
㩷 17 16 15 14 13 12 11 10
㩷
㩷
㩷 1 2 5 17 7 13 8
㩷 12 16
㩷
㩷
㩷
㪫㪉㪌㪥㪄㪇㪊㪄㪇㪌㪄㪇㪊㪇㩷
㩷
㪫㪉㪙㪚㪄㪇㪊㪄㪇㪉㪄㪇㪇㪈㩷
㩷 14 10
㩷 11 15
㩷
㩷
1 - Main Relief Valve 6- Port Relief Valve (with 10 - Rear Drum Lowering 14 - Boom Hoist Lowering
make-up function) Proportional Solenoid Valve Proportional Solenoid Valve
2 - Right Travel Spool 7 - Rear Drum (Low Speed) 11 - Rear Drum Lowering 15 - Boom Hoist Lowering
Spool Remote Control Pressure Remote Control Pressure
Sensor Sensor
3 - Make-Up Valve 8- Front Drum (High Speed) 12 - Rear Drum Hoisting 16 - Boom Hoist Hoisting
Spool Remote Control Pressure Remote Control Pressure
Sensor Sensor
4 - Pressure Compensation 9- Holding Valve 13 - Rear Drum Hoisting 17 - Boom Hoist Hoisting
Valve (2 Used) Proportional Solenoid Valve Proportional Solenoid Valve
5 - Boom Hoist Spool
T3-5-4
COMPONENT OPERATION / Front and Rear Control Valves
17
1 3
14
13
4 2 8
7
10
㩷
㪫㪉㪙㪚㪄㪇㪊㪄㪇㪉㪄㪇㪇㪊㩷
T3-5-5
INTERNAL CIRCUIT㩷㩷
Pilot Pressure Control Circuit㩷
Pilot Pressure oil from the remote control valve acts

on a spool in the control valve and the spool moves.

㩷 9 10
㩷
㩷
㪫㪉㪙㪚㪄㪇㪊㪄㪇㪉㪄㪇㪈㪎㩷
㩷
1 2 3 4 㩷
㩷
4 3
㩷
㩷
㪫㪉㪙㪚㪄㪇㪊㪄㪇㪉㪄㪇㪈㪍㩷
㩷 5 6 7 8 9 10
㩷
㩷
㩷
1 - Travel (Left Reverse) 4- Front Drum (Low Speed) 7- Boom Hoist Hoisting 10 - Rear Drum (Low Speed)
Lowering Lowering
2 - Travel (Left Forward) 5 - Travel (Right Reverse) 8- Boom Hoist Lowering
3 - Front Drum (Low Speed) 6 - Travel (Right Forward) 9- Rear Drum (Low Speed)
Hoisting Hoisting
㩷
㩷
T3-5-6
Main Circuit㩷
Internal circuit of the control valve is a series circuit.
1. Each section is connected by a passage.㩷

2. When the spool is set in neutral, oil from the pump
flows to the next section through a passage.㩷
3. When the spool moves, pressure oil from port P
flows to the actuator through port B or A.㩷 Passage㩷
4. Return oil from the actuator flows to the
downstream passage through the spool from port A B
A or B.㩷
5. Therefore, all the oil through upstream section
and the actuator flows to the downstream section.㩷 P T
㩷
㪫㪊㪉㪋㪄㪇㪉㪄㪇㪍㪄㪇㪉㪐㩷
㩷
㩷

㩷 Passage㩷 Port A㩷㩷 Passage㩷 Port A㩷
㩷㩷
㩷㩷
㪫㪉㪚㪥㪄㪇㪊㪄㪇㪌㪄㪇㪇㪋㩷㪫㪉㪚㪞㪄㪇㪊㪄㪇㪌㪄㪇㪇㪊㩷
Port P㩷 Port B㩷
㩷 Port P Port B
T3-5-7
SPOOL㩷㩷
A closed center type, open center type and semi-open 㩷

P
center type spools are used. T
B A
x Closed Center Type Spool㩷 2
When the spool is set in neutral, oil in ports A and B is

blocked by spool (2). Therefore, oil in ports A and B
does not flow to port T.
• Front drum (high speed)㩷
• Rear drum (high speed)㩷㩷
㪫㪊㪉㪋㪄㪇㪉㪄㪇㪍㪄㪇㪈㪉㩷
㩷
㩷
x Open Center Type Spool㩷㩷
T B A
T
When the spool is set in neutral, oil in port A or port B,
1
and flows to the hydraulic oil tank through passage (1) 1
in the spool and port T.
• Travel (right)㩷
• Travel (left)㩷
2
㩷
㪫㪊㪉㪋㪄㪇㪉㪄㪇㪍㪄㪇㪈㪊㩷
x Semi-Open Center Type Spool㩷㩷
Oil in port A flows to the hydraulic oil tank through 㩷 T
B A
passage (1) in the spool and port T. Oil in port B is
1
blocked by spool (2).
• Boom hoist㩷
• Rear drum (low speed)㩷
• Front drum (low speed)㩷
㩷
2
㩷
㪫㪊㪉㪋㪄㪇㪉㪄㪇㪍㪄㪇㪈㪋㩷
㩷
㩷
1 - Passage 2- Spool
㩷
㩷
T3-5-8
Operation of Spool㩷
NOTE: The rear drum spool in rear control valve

(low speed) is explained as an example.
1. When spool (2) moves to the right by

compressing spring (1), pressure oil from port P
Port T㩷 A B
flows to the actuator through passage (3) and port
B.㩷 1
2. Return oil from the actuator flows to port T
through port A and passage (5).㩷
NOTE: For two upstream spools form a series

circuit, when spools (2 and 4) are moved
simultaneously, for instance, and if the
actuator for upstream spool (4) stops due to 2
㩷
overload, the actuator for downstream 5 3 㪫㪊㪉㪋㪄㪇㪉㪄㪇㪍㪄㪇㪈㪌㩷
spool (2) also stops simultaneously.
Port P㩷
4
㩷
㪫㪉㪌㪥㪄㪇㪊㪄㪇㪌㪄㪇㪇㪉㩷
1- Spring 3- Passage 4 - Spool (Boom Hoist) 5 - Passage

2- Spool 㩷㩷㩷
(Rear Drum Low Speed)
㩷
T3-5-9
MAIN RELIEF VALVE㩷
The main relief valve prevents pressure in the main

circuit from exceeding the set pressure while the
actuators such as motor or cylinder are operated.
Thus, oil leak from hose and pipe joints and breakage
of the actuator are prevented.
Relief Operation㩷
1. Pressure in port HP (main circuit) acts on pilot
poppet (4) through orifice (6) in main poppet (1).㩷
2. When pressure in port HP reaches the set
pressure of spring B (5), pilot poppet (4) opens a
passage and pressure oil flows to port LP
(hydraulic oil tank).㩷
3. At this time, a pressure difference is generated
between port HP and spring chamber (2) due to
orifice (6).㩷
4. When this pressure difference reaches the set
pressure of spring A (3), main poppet (1) opens a
passage and pressure oil from port HP flows to
port LP.㩷
5. As a result, pressure in the main circuit
decreases.㩷
6. When pressure in the main circuit decreases to
the fixed level, main poppet (1) is closed by force
of spring A (3).㩷
T3-5-10
Normal State㩷
㩷
㩷 1 2 3 4 5
HP
LP
6 㩷
㪫㪉㪙㪚㪄㪇㪊㪄㪇㪉㪄㪇㪇㪏㩷
㩷
Relief State㩷
㩷
㩷 1 2 3 4 5
HP
6 LP 㩷
㪫㪉㪙㪚㪄㪇㪊㪄㪇㪉㪄㪇㪇㪐㩷
㩷
㩷 1 2 3 4 5
HP
6 LP 㩷
㪫㪉㪙㪚㪄㪇㪊㪄㪇㪉㪄㪇㪈㪇㩷
㩷
1 - Main Poppet 3 - Spring A 5 - Spring B 6- Orifice
2 - Spring Chamber 4 - Pilot Poppet 㩷㩷
㩷
T3-5-11
PORT RELIEF VALVE
(with Make-Up Function)㩷
The port relief valve with make-up function is provided

in the lowering circuit for front drum (low speed) and
rear drum (low speed). The port relief function
prevents pressure in each actuator circuit from
increasing too high when an actuator is operated by
external force while the control valve spool is set in
neutral.
In addition, the make-up function prevents cavitation
by supplying oil from the hydraulic oil tank when
pressure in an actuator circuit is reduced.
Relief Operation㩷 Make-Up Operation㩷

1. Pressure in port HP (actuator circuit) flows to 1. When pressure in port HP (actuator circuit)
spring chamber (5) through orifice (10) in piston becomes lower than pressure in port LP
(1) and acts on pilot poppet (6).㩷 (hydraulic oil tank), pressure of port LP pushes
2. When pressure in port HP reaches the set sleeve (3) rightward and opens the seat surface
pressure of spring B (7), pilot poppet (6) opens of sleeve (3).㩷
the passage and pressure oil from spring 2. Hydraulic oil from port LP flows to port HP and
chamber (5) flows to port LP (hydraulic oil tank) prevents cavitation.㩷
through passage (8) and the external 3. When pressure in port HP rises to the fixed level,
circumference of sleeve (3).㩷 the seat surface of sleeve (3) is closed by force of
3. At this time, a pressure difference is caused spring A (4).㩷
between port HP and spring room (5) due to 㩷
orifice (10).㩷
4. When this pressure difference reaches the set
pressure of spring A (4), main poppet (2) opens a
port LP.㩷
5. As a result, pressure in the actuator circuit
decreases.㩷
6. When pressure in the actuator circuit decreases
to the fixed level, pilot poppet (6) closes the
passage by force of spring B (7) and pressure in
spring chamber (5) increases. Then, main poppet
(2) closes the passage by force of spring A (4).㩷
㩷
T3-5-12
Normal State㩷
㩷 1 2 3 4 5 6 7
LP
㩷
㪫㪉㪙㪚㪄㪇㪊㪄㪇㪉㪄㪇㪈㪈㩷
10 9 8
Relief State㩷
1 2 3 4 5 6 7
㩷
㪫㪉㪙㪚㪄㪇㪊㪄㪇㪉㪄㪇㪈㪉㩷
10 9 8
㩷
㩷 3 4
㩷
㪫㪉㪙㪚㪄㪇㪊㪄㪇㪉㪄㪇㪈㪊㩷
㩷
1 - Piston 4 - Spring A 7 - Spring B 9 - Spring C
2 - Main Poppet 5 - Spring Chamber 8 - Passage 10 - Orifice
3 - Sleeve 6 - Pilot Poppet 㩷㩷
T3-5-13
MAKE-UP VALVE㩷㩷 Port T㩷
The lowering circuits of boom hoist, provides a 㩷

make-up valve.
The make-up valve prevents cavitation by supplying oil
from port T when pressure in port B becomes
negative. Port B
Operation㩷
1. When pressure in port B becomes negative, the
poppet that is pushed rightward due to the
pressure reeving area difference (Y > X) is moved
leftward by pressure in port T.㩷
2. As a result, oil is fed from port T to port B in order
to prevent cavitation.㩷
㩷
㩷㪫㪉㪙㪚㪄㪇㪊㪄㪇㪉㪄㪇㪈㪋㩷
㩷 Port B㩷 Port T㩷
㩷
Area Y
Poppet Area X㩷
㩷
㪫㪊㪊㪈㪄㪇㪊㪄㪇㪌㪄㪇㪈㪉㩷
T3-5-14
HOLDING VALVE㩷㩷
Holding valve (3) maintains the unidirectional flow and 㩷

prevents reverse flow. 㩷
The front and rear high speed circuits provides this
valve.
Low Speed Hoisting㩷

During low speed hoisting, only low speed spool (1)
works. High speed pool (2) is kept closed.㩷
㩷
㩷
㩷 2
㩷
㩷
㩷
㩷
㩷
1
High Speed Hoisting㩷
When shifting the hoisting lever from low speed to 㩷
high speed position, pressure oil tends to flow 3 㪫㪉㪙㪚㪄㪇㪊㪄㪇㪉㪄㪇㪉㪉㩷
backward from the motor side to the pump side as 㩷
pressure at the pump side is lower than pressure at
the motor side at the start of opening of higher speed 㩷
spool (2).㩷
In order to avoid this, holding valve (3) is provided.㩷
㩷
㩷
㪫㪉㪙㪚㪄㪇㪊㪄㪇㪉㪄㪇㪉㪊㩷
3
㩷
㩷
1 - Spool 3 - Holding Valve
(Low Speed Side)
2 - Spool 㩷
(High Speed Side)
㩷
T3-5-15
PRESSURE COMPENSATION VALVE㩷
The pressure compensation valves are pressure

compensated flow rate control valves that are located
in the boom hoist, rear drum (low speed), and front
drum (low speed) circuits.
The pressure compensation valve maintains desired
flow rate to an actuator regardless of its carrying load.
NOTE: Boom hoist operation is explained in this

section as an example.
Operation (with small lever stroke)㩷

1. Pressure oil from port P flows to chamber C Spring㩷 To Actuator㩷
through internal passage. Then, pressure oil flows
To
to chamber E through the passage of Downstream
compensation spool and acts on the Section㩷
Pressure
compensation spool end.㩷 Compensation
2. When the boom hoist lever is moved, pressure oil Valve
that flows through the spool acts on spring Spool
chamber B through passage A.㩷 (Boom Hoist)㩷
From Port P
3. If the lever is at small shift, as the spool severely
narrows pressure oil acting on spring chamber B,
differential pressure between chamber C
(chamber E) and chamber B becomes larger.㩷
4. When a differential pressure between chamber A 㩷
(chamber E) and chamber B increases, the 㪫㪉㪌㪥㪄㪇㪊㪄㪇㪌㪄㪇㪋㪈㩷
compensation spool moves upward while pushing 㩷

the spring in spring chamber.㩷 Spring Chamber Spring㩷
㩷
5. As a result, pressure oil from port P flows to the
downstream section through chambers C to D.㩷
6. Thus, by releasing excess pressure, an optimum
flow rate to the actuator is obtained.㩷
㩷
㩷
㩷
㩷
Compensation Spool㩷
㪫㪉㪙㪚㪄㪇㪊㪄㪇㪉㪄㪇㪉㪋㩷
T3-5-16
Operation (with Large Lever Stroke)㩷㩷
1. Pressure oil from port P flows to chamber C 㩷
through internal passage of control valve. Then, Spring㩷 To Actuator㩷
㩷
pressure oil flows to chamber B through the
Pressure
passage in compensation spool and acts on the Compensation
compensation spool end.㩷 Valve
2. When the boom hoist lever is moved, pressure oil
that flows through the spool acts on the spring
chamber B through passage A.㩷 Spool
(Boom Hoist)
3. If the lever is at large shift, as the spool does not From Port P
narrow oil flow rate so much, differential pressure
between chamber C (chamber E) and chamber B
becomes smaller.㩷
4. When a differential pressure between chamber C
㩷
(chamber E) and chamber B becomes small, the
㪫㪉㪌㪥㪄㪇㪊㪄㪇㪌㪄㪇㪋㪇㩷
compensation spool is pushed downward by force
㩷
of spring in spring chamber B.㩷
5. As a result, as a passage between chamber C 㩷
Spring Chamber Spring㩷
and D is blocked, large amount of oil flows 㩷
through the actuator.㩷
6. Thus, oil flow rate is delivered to the actuator
according to the lever stroke.㩷
㩷
㩷
㩷
㩷
Compensation Spool㩷
㩷
㪫㪉㪙㪚㪄㪇㪊㪄㪇㪉㪄㪇㪉㪌㩷
T3-5-17
(Blank)
㩷
T3-5-18
COMPONENT OPERATION/ Swing Control Valve㩷
OUTLINE㩷
The swing control valve consists of swing spool (5) NOTE: Refer to the Front/Rear Control Valve group
(controlled by the hydraulic pilot pressure), 3-spool as for operation of main relief valve (4) and
solenoid valve unit hydraulic oil source spool (2) the spools.
(controlled by the solenoid) and relief valve (4).
Swing spool (5) is selected by pressure oil from the
swing remote control valve in order to deliver pressure
oil from the swing pump to the swing motor.
3-spool solenoid valve unit hydraulic oil source spool
(2) is switched by a signal transmitted to solenoid valve
(1) and supplies pressure oil from the swing pump to
the counterweight cylinder and the flip cylinder through
the 3-spool solenoid valve unit.
㩷
EXTERNAL VIEW㩷
㩷 1
2
1
4
㩷
3 㪫㪉㪚㪞㪄㪇㪈㪄㪇㪉㪄㪇㪉㪎㩷
㩷
INTERNAL CIRCUIT
5 2
㩷
㪫㪉㪚㪞㪄㪇㪊㪄㪇㪍㪄㪇㪇㪈㩷
1
1- 3-Spool Solenoid Valve 3- Swing Pilot Pressure 4- Relief Valve 5- Swing Spool
Unit Hydraulic Oil Source Sensor
Solenoid Valve
2 - 3-Spool Solenoid Valve 㩷㩷㩷
Unit Hydraulic Oil Source
Spool
T3-6-1
COMPONENT OPERATION/ Swing Control Valve㩷
CONFIGURATION㩷
㩷 4
A
A
B B
2
1 1
Section: A-A
5
㩷
Section: B-B 㪫㪉㪚㪞㪄㪇㪊㪄㪇㪍㪄㪇㪇㪉㩷
㩷
1- 3-Spool Solenoid Valve 2- 3-Spool Solenoid Valve 4- Relief Valve 5- Swing Spool
Unit Hydraulic Oil Source Unit Hydraulic Oil Source
Solenoid Valve Spool
㩷
T3-6-2
COMPONENT OPERATION / Lower Control Valve㩷
OUTLINE㩷
The lower control valve provides the The function block consists of the jack-up (right front),
electromagnetic-hydraulic pilot type spool and jack-up (left front), jack-up (right rear), jack-up (left
direct-acting spool, which consists of the RGB block rear), side frame connecting (right) and side frame
and function block. connecting (left) viewing from the RGB block.
The RGB block provides the relief valve, pressure
reducing valve and sequence valve.
The function block provides the spool, holding valve
and solenoid valve.
The spool is switched by electric current from each
control switch and delivers pressure oil from port P to
the jack-up cylinder and the side frame connecting
cylinder.
㩷
Port P㩷
㩷
Solenoid Valve
RGB Block
Jack-Up (Right Front)㩷
Jack-Up (Left Front)㩷
Function Jack-Up (Right Rear)㩷

Block
Jack-Up (Left Rear)㩷

(Right)㩷

(Left)㩷
㩷
㪫㪉㪚㪞㪄㪇㪊㪄㪇㪎㪄㪇㪇㪈㩷

㩷
T3-7-1
CONFIGURATION㩷 1 2
㩷
3
5
18 6
7
10
18
11
12
13
18 14
15
16
㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷㩷
㪫㪉㪚㪞㪄㪇㪊㪄㪇㪎㪄㪇㪇㪉㩷
㩷
㪫㪉㪚㪞㪄㪇㪊㪄㪇㪎㪄㪇㪇㪈㩷
T3-7-2
㩷㩷
㩷
㩷㩷
㩷 Section A
㩷
㩷
2 3 1
㩷
6 5
8
7
10
9
12
11
14
13
㩷
16 㪫㪉㪌㪥㪄㪇㪊㪄㪇㪌㪄㪇㪉㪇㩷
15
㩷 4
㩷
㩷
㩷㩷
㪫㪉㪌㪥㪄㪇㪊㪄㪇㪌㪄㪇㪈㪐㩷㩷
㩷
㩷
Section B㩷
18
㩷
㪫㪉㪌㪥㪄㪇㪊㪄㪇㪌㪄㪇㪉㪊㩷
㩷
17
㩷
1 - Pressure Reducing Valve 6 - Jack Extend Solenoid Valve 11 - Jack Retract Solenoid 15 - Side Frame Connecting
(Right Front) Valve (Left Rear) Cylinder Extend Solenoid
Valve (Left)
2 - Relief Valve 7 - Jack Retract Solenoid 12 - Jack Extend Solenoid Valve 16 - Side Frame Connecting
Valve (Left Front) (Left Rear) Cylinder Retract Solenoid
Valve (Left)
3 - Orifice 8 - Jack Extend Solenoid Valve 13 - Side Frame Connecting 17 - Spool
(Left Front) Cylinder Extend Solenoid
Valve (Right)
4 - Sequence Valve 9 - Jack Retract Solenoid 14 - Side Frame Connecting 18 - Holding Valve
Valve (Right Rear) Cylinder Retract Solenoid
Valve (Right)
5 - Jack Retract Solenoid 10 - Jack Extend Solenoid Valve 㩷㩷
Valve (Right Front) (Right Rear)
㩷
T3-7-3
INTERNAL CIRCUIT㩷㩷
㩷 Filter㩷 Circuit A 1 2
Pressure oil through port P is divided into two in the
RGB block. 㩷
3
One flow flows to each solenoid valve through the filter,
pressure reducing valve (1) and orifice (3). (Circuit A) RGB Block
The other flow flows to main spool (17) through P
4
sequence valve (4). (Circuit B)
Circuit B provides relief valve (2) which prevents its 5
pressure from exceeding the set level. 6
In addition, circuit B consists of a parallel circuit and Circuit B 7
makes the combined operation capable.
Neutral 8
The parallel circuit provides holding valve (18) which
Circuit
prevents the back flow of pressure oil from the output
port during fine-control operation. Parallel
Circuit 9
10
11
12
13
14
15
18
16
17 㩷
㪫㪉㪚㪞㪄㪇㪊㪄㪇㪎㪄㪇㪇㪉㩷
1 - Pressure Reducing Valve 6- Jack Extend Solenoid 11 - Jack Retract Solenoid 15 - Side Frame Connecting
Valve (Right Front) Valve (Left Rear) Cylinder Extend Solenoid
Valve (Left)
2 - Relief Valve 7- Jack Retract Solenoid 12 - Jack Extend Solenoid 16 - Side Frame Connecting
Valve (Left Front) Valve (Left Rear) Cylinder Retract Solenoid
Valve (Left)
3 - Orifice 8- Jack Extend Solenoid 13 - Side Frame Connecting 17 - Spool
Valve (Left Front) Cylinder Extend Solenoid
Valve (Right)
4 - Sequence Valve 9- Jack Retract Solenoid 14 - Side Frame Connecting 18 - Holding Valve
Valve (Right Rear) Cylinder Retract Solenoid
Valve (Right)
5 - Jack Retract Solenoid 10 - Jack Extend Solenoid 㩷㩷
Valve (Right Front) Valve (Right Rear)
T3-7-4
FUNCTION BLOCK㩷
NOTE: Jack retract (right front) operation is

explained in this section as an example.
1. Pressure oil in circuit A flows through the internal 6. The piston and spool (17) are connected.㩷
passage and acts on jack retract solenoid valve 7. Therefore, spool (17) is moved leftward by
(5) (right front) and jack extend solenoid valve (6) pressure of chamber C.㩷
(right front).㩷 8. When the notch of spool (17) reaches the
2. Pressure oil in circuit B flows through the internal passage, pressure oil in the passage flows to port
passage and flows to the neutral circuit and B and increases pressure in port B.㩷
parallel circuit.㩷 9. Port A is connected to the tank passage and
3. Pressure oil in the parallel circuit pushes and pressure oil in port A returns to the hydraulic oil
opens holding valve (18) and flows to the tank.㩷
passage.㩷 10. Thus, each actuator is operated.㩷
4. When the jack-up switch (right front) is set to the 㩷
retract position, jack retract solenoid valve (5) 㩷
(right front) is selected and pressure oil in circuit A
flows to chamber C of the piston.㩷㩷
5. Chamber D of the piston is connected to port T
(hydraulic oil tank) through jack extend solenoid
valve (6) (right front).㩷
㩷
㩷 6 5
㩷
Parallel Circuit 18 Passage Circuit A㩷

(Circuit B)㩷
A B
D Piston C
㩷
17 Tank Neutral Port T 㪫㪉㪌㪥㪄㪇㪊㪄㪇㪌㪄㪇㪌㪍㩷
Passage Circuit (To Hydraulic Oil Tank)
㩷 (Circuit B)
㩷
㩷
5- Jack Retract Solenoid 6- Jack Extend Solenoid 17 - Spool 18 - Holding Valve
Valve (Right Front) Valve (Right Front)
㩷
T3-7-5
RELIEF VALVE㩷
The main relief valve prevents that pressure in the

lower control circuit exceeds the set pressure while
operating an actuator such as motor or cylinder.
Thus, oil leak from hose and pipe joints and breakage
of the actuator are protected.
Relief Operation㩷
1. Pressure in port HP (main circuit) acts on pilot
poppet (2) through orifice (7) in main poppet (6)
and orifice (4) in seat (3).㩷
2. When pressure in port HP reaches the set
pressure of spring (1), pilot poppet (2) opens the
passage and pressure oil flows to port LP
(hydraulic oil tank) through passage (8).㩷
3. At this time, a differential pressure is generated
between port HP and spring chamber (9) due to
orifice (7).㩷
4. When the differential pressure reaches the set
pressure of spring (5), main poppet (6) opens the
port LP.㩷
5. As a result, pressure in the lower control circuit
decreases.㩷
6. When pressure in the main circuit decreases to
the fixed level, force of spring (5) closes main
poppet (6).㩷
㩷
T3-7-6
Normal State:㩷
㩷 LP
1 2 3 4 5 6 7
HP
8 㩷
㪫㪉㪌㪥㪄㪇㪊㪄㪇㪌㪄㪇㪌㪊㩷
Relief State:㩷 9
㩷 LP
1 2
HP
8
㩷
㪫㪉㪌㪥㪄㪇㪊㪄㪇㪌㪄㪇㪌㪋㩷
㩷 LP
5 6 7
HP
㩷
㪫㪉㪌㪥㪄㪇㪊㪄㪇㪌㪄㪇㪌㪌㩷
9
㩷
1 - Spring 4 - Orifice 6- Main Poppet 8- Passage
2 - Pilot Poppet 5 - Spring 7- Orifice 9- Spring Chamber
3 - Seat 㩷㩷㩷
㩷
T3-7-7
PRESSURE REDUCING VALVE㩷
The pressure reducing valve reduces oil pressure of

port P to the fixed level and delivers pressure oil to the
solenoid valve of function block. Thus, rapid
movement of the spool is prevented.
Operation㩷
1. Pressure oil from port P flows to the output port
through the notch and inside of the spool.㩷
2. The spring chamber connects to port T (hydraulic
oil tank) through the hole of retainer.㩷
3. When pressure in port P increases and exceeds
spring force, the spool moves rightward until
pressure is balanced with spring force.㩷
4. When the notch of spool reaches the hole in
retainer, port P and port T are connected, and
pressure in port P decreases.㩷
5. When pressure in port P becomes lower than
spring force, the spool moves leftward until
pressure is balanced with spring force.㩷
6. Thus, rapid movement of the spool is prevented
by reducing pressure of oil from port P and
controlling pressure of the output port constant.㩷
㩷
㩷
㩷
㩷
㩷
T3-7-8
Normal State:㩷
㩷
㩷
㩷 Output Port㩷 Spool㩷 Hole Retainer
㩷
Port P㩷 Port T㩷 Spring㩷 Spring Chamber㩷㪫㪉㪌㪥㪄㪇㪊㪄㪇㪌㪄㪇㪌㪈㩷
㩷
㩷
Pressure Reducing State:㩷
㩷
㩷 Output Port㩷 Spool㩷 Notch Hole㩷 Retainer
㩷
㪫㪉㪌㪥㪄㪇㪊㪄㪇㪌㪄㪇㪌㪉㩷
Port P㩷 Port T㩷 Spring㩷
㩷
㩷
T3-7-9
SEQUENCE VALVE㩷
The sequence valve blocks pressure oil from port P

and controls the pressure reducing valve to move prior
to the sequence valve in order to maintain operating
pressure of the main spool.
Operation㩷
1. Pressure oil from port P is divided into two. one 5. When pressure in port P is larger than forces of
flow acts on the sequence valve, and the other springs A and B, the sequence valve moves
flow acts on the pressure reducing valve.㩷 downward while compressing springs A and B.
2. Force of spring A and B push up the sequence 㩷
valve.㩷 6. Pressure oil from port P flows to the main spool
3. Therefore, when pressure in port P is smaller than through the internal passage.㩷
forces of spring A and B, the sequence valve is 7. Thus, primary pressure (output pressure) of the
not selected.㩷 pressure reducing valve is maintained by setting a
4. Pressure oil from port P flows to the pressure time lag in operation between pressure reducing
reducing valve and is routed to each solenoid valve and sequence valve.㩷
valve.㩷㩷
㩷
㩷
㩷
㩷
To Main
㩷 Spool㩷 To Solenoid Valve㩷
T P
㩷
Spring B㩷 Spring A㩷 Sequence Valve㩷 Pressure 㪫㪉㪌㪥㪄㪇㪊㪄㪇㪌㪄㪇㪌㪎㩷
Reducing Valve㩷
㩷
㩷
T3-7-10
SOLENOID VALVE㩷
Each solenoid valve is an ON/OFF solenoid valve.

When operating the switch corresponding to each
actuator, the solenoid valve is excited and switches the
rod. As a result, pressure oil from the pressure
reducing valve acts on the main spool and the spool is
selected.
Operation㩷
1. When the switch is set to the OFF position, 5. Rod (3) pushes steel ball (4) to make close
pressure oil from port P (pressure reducing valve) contact with seat (5) and the passage between
is blocked by steel ball (7).㩷 the output port and port T is blocked.㩷
2. The output port is connected to port T (hydraulic 6. Steel ball (4) pushes steel balls (6, 7) and port P is
oil tank) through steel ball (6).㩷 connected to the output port.㩷
3. When the switch is set to the ON position, 7. Pressure oil from port P flows to the output port
solenoid (2) is excited.㩷 through the external circumference of steel ball
4. Plunger (1) moves downward and pushes rod (3).㩷 (7).㩷
㩷 8. As a result, pressure in the output port increases
and the main spool is selected.㩷
Neutral State: Exciting State:
1 1
2 2
3 3
4 4
Port T Port T
5 5
Output Port 6 Output Port 6
7 7
㩷㩷
Port P 㪫㪉㪌㪥㪄㪇㪊㪄㪇㪌㪄㪇㪌㪏㩷
Port P㩷㪫㪉㪌㪥㪄㪇㪊㪄㪇㪌㪄㪇㪌㪐㩷
㩷㩷
㩷
㩷
1 - Plunger 3 - Rod 5 - Seat 7 - Steel Ball
2 - Solenoid 4 - Steel Ball 6 - Steel Ball 㩷
㩷
T3-7-11
(Blank)
㩷
㩷
T3-7-12
COMPONENT OPERATION / Remote Control Valve㩷
OUTLINE㩷
The remote control valve controls pilot pressure oil that The hoisting and travel remote control valves provide
is used to move the spools in control valve. detent plug (10) respectively.
There are three remote control valves: 3-spool hoisting The travel remote control valve provides remote
valve, 3-spool travel valve and 1-spool swing valve (7). control pressure sensors (8, 9).
The hoisting remote control valve consists of boom
hoist valve (1), rear drum valve (2) and front drum NOTE: These remote control valves have the same
valve (3). structure except for detent plug (10) and the
The travel remote control valve consists of third drum shuttle block.
(4) (optional), left travel (5), and right travel (6).
㩷
The hoisting and travel remote control valves are made
of three section for each, which are connected which 㩷
the spring pins.
㩷
㩷
1 2 3 4 5 6 7
㩷
㩷
10
Shuttle Valve Block㩷
9 8
㩷
㪫㪉㪚㪞㪄㪇㪊㪄㪇㪏㪄㪇㪇㪈㩷
Hoisting Travel Swing
㩷 Remote Control Remote Control Remote Control
Valve㩷 Valve㩷 Valve㩷
㩷
㩷
1 - Boom Hoist Remote 4 - Third Remote Control Valve 7- Swing Remote Control 9- Travel Remote Control
Control Valve (Optional) Valve Pressure Sensor (L)
2 - Rear Drum Remote Control 5 - Left Travel Remote Control 8 - Travel Remote Control 10 - Detent Plug
Valve Valve Pressure Sensor (R)
3 - Front Drum Remote 6 - Right Travel Remote 㩷㩷
Control Valve Control Valve
㩷
㩷
T3-8-1
x Hoisting Remote Control Valve㩷㩷
㩷 Boom Hoist㩷 Rear㩷 Front㩷
Parts Name Port No. Connected to
1 Boom Raise 㩷
Boom 2 Boom Lower
Hoist 7 Displacement Angle
Control Signal Pressure T
3 Hoisting P
4 Lowering
Rear
8 Displacement Angle
Control Signal Pressure
5 Hoisting
6 Lowering 8 4㩷
Front
9 Motor Displacement Angle 2 6㩷
Control Signal Pressure
9㩷
㩷 Boom Hoist㩷 Rear㩷 Front㩷 7 5㩷
㩷 2 7 1 4 8 3 6 9 5
1 㩷
㩷㪫㪉㪚㪞㪄㪇㪊㪄㪇㪏㪄㪇㪇㪉㩷
㩷 3㩷
㩷
㩷
㩷㩷
P T 㪫㪉㪚㪞㪄㪇㪊㪄㪇㪏㪄㪇㪇㪊㩷
x Travel Remote Control Valve㩷㩷 Third Travel Travel

(Optional) (Left)㩷 (Right)㩷
㩷
Parts Port 㩷
Connected to
Name No.
Third 1 Hoisting
(Optional) 2 Lowering T
3 Forward
P
Travel 4 Reverse P
(Left) 7 Remote Control Pressure
Sensor
5 Forward
Travel 6 Reverse
7 4㩷
(Right) 8 Remote Control Pressure
Sensor 6㩷
2
Third 8㩷
(Optional)㩷 Travel (Left)㩷 Travel (Right)
2 1 4 7 3 6 8 5 5㩷
1 㩷
㪫㪉㪌㪥㪄㪇㪊㪄㪇㪍㪄㪇㪇㪍㩷
㩷 3
㩷
P P T 㪫㪉㪌㪥㪄㪇㪊㪄㪇㪍㪄㪇㪇㪊㩷
T3-8-2
x Swing Remote Control Valve㩷㩷
㩷
Parts Name Port No. Connected to
1 Right Swing 㩷
Swing
2 Left Swing
㩷
T
㩷
P
㩷 1 2
2
㩷
P T 㪫㪉㪌㪥㪄㪇㪊㪄㪇㪍㪄㪇㪇㪋㩷
1
㩷
㩷㩷
㩷㪫㪉㪙㪚㪄㪇㪊㪄㪇㪍㪄㪇㪇㪊㩷
㩷㩷
㩷㩷
㩷㩷
㩷
㩷
T3-8-3
CONFIGURATION㩷
The remote control valve consists of screw joint (1),

cam (2), detent plug (3), pusher (4), balance spring (6),
return spring (7) and spool (8).
Remote control valves for hoisting and travel are each
made of three sections combined though spring pins
(10).The control lever is attached to screw joint (1) that
is bolted to cam (2) so that they move together.
The bottom surface of head of spool (8) is supported

by the top surface of spring guide (5). The two
surfaces contact through balance spring (6).
Pusher (4) is lifted by return spring (7) through spring
guide (5).
Detent plug (3) maintains the control lever in the fixed
position even when releasing the control lever and lets
the actuator operate at a constant speed.
Shuttle block (9) selects secondary pilot pressure on
the control side and lets pressure oil flow to another
output port.
T3-8-4
Hoisting Remote Control Valve㩷
㩷
1
2
3
5
6
7
1
2
㩷
㪫㪉㪙㪚㪄㪇㪊㪄㪇㪍㪄㪇㪇㪌㩷
㩷
1 - Screw Joint 4 - Pusher 6- Balance Spring 8- Spool
2 - Cam 5 - Spring Guide 7- Return Spring 9- Shuttle Valve Block
3 - Detent Plug 㩷㩷㩷
T3-8-5
Travel Remote Control Valve㩷
㩷
2
3
㩷
㪫㪉㪙㪚㪄㪇㪊㪄㪇㪍㪄㪇㪇㪍㩷
㩷
㩷
1- Screw Joint 4- Pusher 6- Balance Spring 8- Spool
2- Cam 5- Spring Guide 7- Return Spring 9- Shuttle Valve Block
3- Detent Plug 㩷㩷㩷
㩷
㩷
㩷
T3-8-6
Swing Remote Control Valve㩷㩷
㩷㩷
㩷 D
㩷 Section D㩷
㩷㩷
1
㩷
㪫㪉㪌㪥㪄㪇㪊㪄㪇㪍㪄㪇㪈㪈㩷
㩷
㪫㪉㪌㪥㪄㪇㪊㪄㪇㪍㪄㪇㪈㪉㩷
㩷
㩷
㩷
㩷
1 - Screw Joint 4 - Pusher 6- Balance Spring 8- Spool
2 - Cam 5 - Spring Guide 7- Return Spring 9- Shuttle Valve Block
㩷
㩷
㩷
T3-8-7
DETENT FUNCTION㩷
The front and rear remote control valves for hoisting NOTE: The first detent of front and rear remote
provide two detent plugs respectively. control valves is provided for low-speed
The boom hoist and travel remote control valves for operation and its second detent is for
hoisting provide one detent plug respectively. high-speed operation.㩷
The detent plug keeps the control lever in the fixed (Refer to the pages for Hoisting Circuit in
position even when releasing the control lever and lets Hydraulic System group). As the boom
the actuator operate at a constant speed. hoist, left travel and right travel provide a
detent plug, combined operations is made
Operation㩷 easily.
1. When control lever (1) is set in neutral, ball (3)
and holder (4) are pushed to cam (2) due to
㩷
spring (5).㩷
2. When control lever (1) is tilted and notch A of cam 㩷
(2) reaches ball (3), ball (3) and holder (4) are 㩷
pushed at a distance of notch A by force of spring
㩷
(5).㩷
3. While control lever (1) is tilted, pusher (6) always
pushes cam (2) upward due to return spring (7).㩷
4. However, as notch A of cam (2) is engaged with
ball (3), cam (2) does not move.㩷
5. As a result, control lever (1) is held in the first
detent position even if control lever (1) is
released.㩷
6. When control lever (1) is tilted further from the first
detent position and notch B of cam (2) reaches
ball (3), ball (3) and holder (4) are pushed at a
distance of notch B by force of spring (5).㩷
7. As a result, cam (2) is engaged with ball (3) again
and control lever (1) is held in the second detent
position even if control lever (1) is released in a
manner similar to the first detent position.㩷
8. Thus, as control lever (1) is held in the fixed
position, an actuator is operated at a constant
speed and combined operations is made easily.㩷
㩷
T3-8-8
㩷
When Operating the Control Lever㩷
㩷
㩷
㩷 1
A (First Detent Position)㩷
3
B (Second Detent
Position)㩷
3
4
5 4
㩷
㪫㪉㪌㪥㪄㪇㪊㪄㪇㪍㪄㪇㪈㪌㩷
㩷
㩷
㩷
1 - Control Lever 3 - Ball 5 - Spring 7 - Return Spring
2 - Cam 4 - Holder 6 - Pusher 㩷
㩷
㩷
T3-8-9
OPERATION㩷㩷
When control lever (1) in the operator's cab is 㩷

operated, secondary pilot pressure is delivered in 㩷
response to stroke of the control lever in remote 㩷
control valve (2). This delivered pilot pressure acts on
spool (4) in control valve (3) so that spool (4) is moved 㩷
until pilot pressure force balances with spring (5) force. 㩷
㩷
㩷
㩷
3 4 5
Port T
(To Hydraulic Oil
Tank)㩷
Port P
(From Pilot Pump)㩷
From Main To Hydraulic

Pump㩷 Oil Tank㩷
Output Port㩷
㩷
㪫㪊㪉㪋㪄㪇㪉㪄㪇㪎㪄㪇㪈㪇㩷
㩷
1 - Control Lever 3 - Control Valve 4 - Spool 5- Spring
2 - Remote Control Valve 㩷㩷㩷㩷㩷
㩷
㩷
T3-8-10
Neutral Position㩷
1. When the control lever is set in the neutral

position, as spool (2) is raised upward by force of
return spring (1), primary pilot pressure from port
P is blocked.㩷
2. The output port (secondary pilot pressure) is
connected to port T (hydraulic oil tank).㩷
Port T (Hydraulic Oil Tank)㩷
Port P (Primary Pilot Pressure)㩷
㩷
Output Port (Secondary 㪫㪊㪉㪋㪄㪇㪉㪄㪇㪎㪄㪇㪇㪏㩷
Pilot Pressure)㩷
㩷
1 - Return Spring 2- Spool
㩷
T3-8-11
Beginning to Deliver Output (Increasing 㩷
Secondary Pressure)㩷
㩷
1. When control lever (3) is operated and cam (4) is 㩷
tilted, pusher (5) moves downward according to 㩷
tilt angle of cam (4) and a passage to port T is
closed by spool (2).㩷㩷
2. Pressure oil from port P (primary pilot pressure 㩷
side) is routed to the output port (secondary pilot 㩷
pressure side) through the clearance of spool (2).㩷
Port T 2
Primary Pilot Pressure

Port P
㩷
Output Port
㪫㪊㪉㪋㪄㪇㪉㪄㪇㪎㪄㪇㪈㪈㩷
㩷 Clearance Secondary Pilot

㩷 Pressure
㩷
2 - Spool 3 - Control Lever 4 - Cam 5 - Pusher
T3-8-12
Maintaining Secondary Pilot Pressure㩷
1. Pressure oil from port P (primary pilot pressure) 5. After repeating these procedures, pressure
acts on diameters d1 and d2 in spool (2).㩷 according to stroke of control lever (3) is routed to
2. This pressure pushes spool (2) upward due to the the output port.㩷
difference of area (d1!d2).㩷 6. As described above, balance spring (6) is
3. Spool (2) is pushed upward and the output port is compressed while the spool moves downward,
connected to port T.㩷 until force of balance spring (6) and oil pressure
4. As pressure in the output port decreases, spool are balanced out. This is pressure of the output
(2) is pushed downward again by the reaction port.㩷
force of balance spring (6).㩷㩷
Port T
2
Clearance
Primary Pilot Pressure

Port P
㩷
Output Port 㪫㪊㪉㪋㪄㪇㪉㪄㪇㪎㪄㪇㪈㪉㩷
㩷
Secondary Pilot
㩷
Pressure
㩷
2- Spool 3 - Control Lever 6 - Balance Spring
T3-8-13
(Blank)
㩷
T3-8-14
COMPONENT OPERATION / Solenoid Valve Unit㩷
5-SPOOL SOLENOID VALVE UNIT㩷
㩷㩷
Outline㩷 x Boom Hoist Drum Unlocking Solenoid Valve㩷
The 5-spool solenoid valve unit consists of the This valve is switched by a signal from MC2/A and
following valves.㩷 delivers pressure oil to the boom hoist brake and
boom hoist drum lock.㩷
x Pressure Reducing Valve㩷 x Third Drum Unlocking Solenoid Valve (Optional)㩷
This valve reduces pressure in the pilot circuit and This valve is switched by a signal from MC2/A and
delivers pressure oil.㩷 delivers pressure oil to the third brake and third drum
x Second Overhoist Solenoid Valve㩷 lock.㩷
This valve is switched by a signal from MC2/B and 㩷
blocks pressure oil flowing through front, rear, boom
hoist and third (optional) remote control valves.㩷
x High Travel Speed Selection Solenoid Valve㩷
This valve is switched by the high/low travel speed
selection switch and delivers pressure oil to the
travel motor displacement angle control valve.㩷
x Swing Brake Solenoid Valve㩷
1
This valve is switched by the swing brake switch and
2
delivers pressure oil to the parking brake in swing
3
motor.㩷
4
㩷 5 㩷
㪫㪉㪚㪞㪄㪇㪊㪄㪇㪐㪄㪇㪇㪉
6
㩷
㩷
㩷
To Front, Rear, Boom Hoist and Third Remote Control Valves㩷
To Travel Displacement Angle Control Valve 㩷
To Swing Parking Brake㩷
To Boom Hoist Drum Lock㩷
To Third Drum Lock㩷
㩷
1 2 3 4 5 6 㪫㪉㪚㪞㪄㪇㪊㪄㪇㪐㪄㪇㪇㪈㩷
1 - Second Overhoist Solenoid 3- Swing Brake Solenoid 5- Third Drum Unlocking 6- Pressure Reducing Valve
Valve Valve Solenoid Valve (Optional)
2 - High Travel Speed 4 - Boom Hoist Drum
Selection Solenoid Valve Unlocking Solenoid Valve
T3-9-1
Internal Configuration㩷
1 2 3 4 5 6
A5 A4 A3 A2 A1
P1
P
㩷
P2 㪫㪉㪚㪞㪄㪇㪊㪄㪇㪐㪄㪇㪇㪊㩷
㩷
㩷
1- Second Overhoist Solenoid 3- Swing Brake Solenoid 5- Third Drum Unlocking 6- Pressure Reducing Valve
Valve Valve Solenoid Valve (Optional)
2 - High Travel Speed 4 - Boom Hoist Drum
Selection Solenoid Valve Unlocking Solenoid Valve
㩷
T3-9-2
Solenoid Valve㩷㩷
The solenoid valve is a normal close type with 㩷

ON/OFF operation. 㩷
㩷
Operation㩷 5-Spool Solenoid
1. When a valve is set in neutral state (unexcited 㩷 Valve Unit㩷
state), port T and output port A connect through 㩷
the notch of a spool. As the spool blocks pressure In Neutral
㩷 State㩷
oil from port P, pressure oil is not supplied to
output port A.㩷
2. When electric current flows through the solenoid, Solenoid
Valve㩷
the solenoid is excited and pushes the spool.㩷
3. Port T is blocked by the spool and output port A
and port P are connected through the notch of a
spool.㩷
4. As a result, pressure oil from port P flows to the
output port.㩷
5. When electric current flowing through the
solenoid is cut, the spool moves back to the
original position and output for the output port A is
cut.㩷
㩷
㩷
㪫㪉㪚㪞㪄㪇㪊㪄㪇㪐㪄㪇㪇㪋㩷
㩷
㩷 Unexcited State㩷 Excited State㩷
㩷
㪫㪉㪚㪞㪄㪇㪊㪄㪇㪐㪄㪇㪇㪌㩷
㩷
㩷
T3-9-3
(Blank)
㩷
㩷
㩷
㩷
㩷
㩷
㩷
T3-9-4
Outline㩷 NOTE: As for detailed information of the relief valve,

The 4-spool solenoid valve unit is an holding valve and spool operation, refer to
electromagnetic-hydraulic pilot spool type, which the Front and Rear Control Valves group.
consists of main relief valve, sequence valve,
㩷
pressure reducing valve, holding valve, solenoid
valve and spool.㩷
The spool is a parallel circuit and semi-open center
type.㩷
㩷
㩷
㩷 1 2 3 4 5 6
㩷
㩷
㪫㪉㪚㪥㪄㪇㪊㪄㪇㪐㪄㪇㪇㪈㩷
㩷
㩷 7 10 7 9 7 8
㩷
1 - Pressure Reducing Valve 4 - Foot Cylinder Solenoid 7 - Holding Valve 10 - Foot Cylinder Solenoid
Valve (Right/Retracting) Valve (Right/Extending)
2 - Sequence Valve 5 - Foot Cylinder Solenoid 8- (Unused)
Valve (Left/Retracting)
3 - Relief Valve 6 - Lower Hydraulic Pressure 9 - Foot Cylinder Solenoid
Control SOL Valve (Left/Extending)
㩷
T3-9-5
Configuration㩷
㩷
㩷
4 5 6
㩷
㩷
10 9 8 㩷㪫㪉㪚㪥㪄㪇㪊㪄㪇㪐㪄㪇㪇㪉㩷
㩷
㩷
1 - Pressure Reducing Valve 4 - Foot Cylinder Solenoid 7 - Holding Valve 10 - Foot Cylinder Solenoid
Valve (Right/Retracting) Valve (Right/Extending)
2 - Sequence Valve 5 - Foot Cylinder Solenoid 8 - (Unused)
Valve (Left/Retracting)
3 - Relief Valve 6 - Lower Hydraulic Pressure 9- Foot Cylinder Solenoid
Control SOL Valve (Left/Extending)
㩷
T3-9-6
㩷
㩷
㩷
2 7
㩷
㪫㪉㪚㪞㪄㪇㪊㪄㪇㪐㪄㪇㪇㪏㩷
T3-9-7
Pressure Reducing Valve㩷㩷 Pressure Reducing Valve㩷 Sequence Valve
The pressure reducing valve reduces oil pressure of 㩷

port P to the fixed level and delivers pressure oil to
the solenoid valve. Spool (1)
Spring (1)
x Operation㩷
1. Pressure oil from port P flows to chamber E Spool (2)㩷
through passage (C).㩷 Spring (2)㩷
2. Pressure oil flows to chamber G through notch (E)
of spool (1) and acts on the solenoid valve.㩷
3. Pressure oil in chamber G acts on chamber D at
spool (1) end through internal passage of spool
To Solenoid
(1). Then, pressure oil flows to spring chamber (A) Valve
of the sequence valve through passage (B) and
pushes spool (2) downward with force of spring
(2).㩷
4. When pressure acting on the bottom surface of
spool (1) exceeds force of spring (1), spool (1)
moves upward until pressure is balanced with
force of spring (1).㩷
5. Spring chamber (J) is connected to the hydraulic
oil tank. Pressure oil from chamber G flows to the
hydraulic oil tank through notch (H) of spool (1)
and pressure in chamber G is reduced.㩷
6. When pressure in chamber G decreases,
pressure in chamber D that acts on the surface of
spool (1) decreases.㩷
7. Spool (1) moves downward by force of spring (1)
until force at the surface of spool (1) is balanced
and pressure in chamber G increases again.㩷 Spool (1)
8. Thus, pressure flowing to a solenoid valve is
Spring (1)
maintained constant by controlling pressure from
port P as the set pressure or less.㩷 Spool (2)㩷
㩷 Spring (2)㩷

Pressure Reducing Valve㩷
To Solenoid Valve㩷
To Solenoid
Valve
To Control Valve
Spool㩷
Sequence Valve㩷
㩷
㪫㪉㪙㪚㪄㪇㪊㪄㪇㪌㪄㪇㪇㪋㩷
To Solenoid Valve㩷㩷
㪫㪉㪙㪚㪄㪇㪊㪄㪇㪌㪄㪇㪇㪌㩷
T3-9-8
Sequence Valve㩷㩷
Pressure Reducing Sequence
The sequence valve blocks pressure oil from port P 㩷 Valve㩷 Valve㩷
so that the pressure reducing valve operates prior to 㩷
the sequence valve and secures the operation of a
solenoid valve by maintaining primary pilot pressure
of the sequence valve (primary pilot pressure of the
pressure reducing valve) even if the main circuit
pressure suddenly drops. Spring (2)㩷
Spool (2)㩷
x Operation㩷
1. Pressure in the pressure reducing valve circuit
always flows to spring chamber (A) of the
sequence valve through passage B.㩷 To Control
2. Spool (2) in the sequence valve is pushed To Solenoid Valve Spool
Valve
downward by the pressure-reduced oil and force
of spring (2). Thus, pressure at port P (primary
pilot pressure of the sequence valve and the
pressure reducing valve) is maintained at a
pressure that is force of spring (2) adding the
secondary pilot pressure of the pressure reducing
valve. As a result, operation pressure of the
solenoid valve is always maintained.㩷
3. Pressure oil from port P flows to chamber D in the
sequence valve.㩷
4. Pressure oil in chamber D passes through spool
(2) and acts on chamber E at the end spool (2).㩷
5. When pressure in chamber D exceeds pressure in
spring chamber (A) and force of spring (2), spool
(2) compresses spring (2) and moves upward.㩷
6. Pressure oil flows from chamber D to chamber K
and flows to the control valve spool.㩷
Spring (2)㩷
7. In this manner, primary pilot pressure (output
pressure) of pressure reducing valve is Spool (2)㩷
maintained by setting a time lag in operation
between the pressure reducing valve and
sequence valve.㩷
㩷
To Control
㩷 To Solenoid Valve Spool
㩷 Pressure Reducing Valve㩷 Valve
To Solenoid Valve㩷
㩷
To Control Valve
Spool㩷
㩷
Sequence Valve㩷
㩷㪫㪉㪙㪚㪄㪇㪊㪄㪇㪌㪄㪇㪇㪍㩷
㪫㪉㪙㪚㪄㪇㪊㪄㪇㪌㪄㪇㪇㪋㩷㩷
To Solenoid
㩷 Valve㩷
T3-9-9
Solenoid Valve㩷㩷
Each solenoid valve in a 4-spool control valve is an 㩷 In Neutral State

ON/OFF solenoid valve. 㩷
Solenoid Control Valve Spool
When a selection switch is turned ON, the solenoid 㩷
valve is excited and switches the solenoid valve
spool.
As a result, pressure oil from the pressure reducing
valve acts on the control valve spool and the spool is
Spring
selected.
Solenoid
x Operation㩷 Valve
1. When the switch is set to the OFF position, Spool
pressure oil from port P (pressure reducing valve)
is blocked by the spool.㩷
Furthermore, chambers A and C connects to the
2. When the control switch is set to the ON position,
the solenoid is excited.㩷
3. The solenoid valve spool moves downward by
compressing the spring.㩷
4. Chambers B and C are connected, and pressure
oil from port P flows to chamber D in the control
valve.㩷 Energized State
5. As a result, the control valve spool switches.㩷
㩷
Solenoid Control Valve Spool
Spring
Solenoid
Valve
Spool
㩷
㪫㪉㪙㪚㪄㪇㪊㪄㪇㪌㪄㪇㪇㪎㩷
T3-9-10
The 3-spool solenoid valve unit is an 㩷 NOTE:㩷As for detailed information of the relief valve,
electromagnetic-hydraulic pilot spool type, which port relief valve and spool operation; refer
consists of main relief valve, sequence valve, pressure to the Front/Rear Control Valves group.㩷
reducing valve, holding valve, port relief valve, Also, refer to the 4-Spool Solenoid Valve
solenoid valve and spool. group as for information of the pressure
The spool is a parallel circuit and semi-open center reducing valve, sequence valve and
type. solenoid valve.㩷
㩷
㩷
㩷
㩷 1 2 3 4 5 4 6 4 7
㩷
㩷
㪫㪉㪚㪞㪄㪇㪊㪄㪇㪐㪄㪇㪈㪇㩷
㩷
11 10 8 9 8
㩷
1 - Pressure Reducing Valve 4 - Holding Valve 7 - Counterweight Cylinder 10 - Counterweight Cylinder
Solenoid Valve Solenoid Valve
(Right/Retract) (Left/Extend)
2 - Sequence Valve 5 - Flip Cylinder (Extend) 8 - Port Relief Valve 11 - Flip Cylinder Solenoid
Valve (Retract)
3 - Relief Valve 6 - Counterweight Cylinder 9 - Counterweight Cylinder 㩷
(Left/Retract) (Right/Extend)
㩷
T3-9-11
Configuration㩷
5 6 7
11 10 9
4 4
㩷
㩷㪫㪉㪚㪞㪄㪇㪊㪄㪇㪐㪄㪇㪇㪐㩷
㩷
1 - Pressure Reducing Valve 4 - Holding Valve 7 - Counterweight Cylinder 9 - Counterweight Cylinder
(Right/Retract) (Left/Extend)
2 - Sequence Valve 5 - Flip Cylinder (Extend) 8 - Port Relief Valve 10 - Flip Cylinder Solenoid
Valve (Retract)
3 - Relief Valve 6 - Counterweight Cylinder 9 - Counterweight Cylinder 㩷
(Left/Retract) (Right/Extend)
T3-9-12
COMPONENT OPERATION/ Travel Mechanism㩷
OUTLINE㩷
The travel mechanism consists of travel motor, travel The travel reduction gear is a 3-stage planetary
reduction gear and travel brake valve. reduction gear, converts the rotation transmitted from
The travel motor is an axial plunger motor and the travel motor to a low-speed high torque, and
incorporates the parking brake of negative type wet rotates the drive tumblers and crawler shoes.
multi plate type. The travel motor is driven by pressure The travel brake valve prevents overload to the travel
oil from the pump and transmits the rotation to the circuit as well as cavitation.
travel reduction gear.
㩷
㩷
㩷
㩷
㩷 Travel Reduction Gear㩷 Travel Brake Valve㩷
㩷
㩷
㩷
㪫㪉㪚㪛㪄㪇㪊㪄㪇㪎㪄㪇㪇㪈㩷
㩷
㩷 Travel Motor㩷
㩷
㩷
㩷
T3-10-1
TRAVEL MOTOR㩷
The travel motor is a swash plate type variable Four tilt pistons (1) are provided and switches
displacement axial plunger motor and consists of valve displacement angle of swash plate (7) by using balls
plate (4), plunger (2), shoe (6), shaft (9), swash plate (8).
(7) and rotor (3). Rotor (3) is pushed onto valve plate (4) by force of
Shaft (9) is splined to rotor (3). Plunger (2) is inserted spring (5).
into rotor (3).
㩷
㩷
㩷 1 2 3
㩷
㪫㪉㪚㪛㪄㪇㪊㪄㪇㪎㪄㪇㪇㪉㩷
9 8 7 6 5 4
㩷
㩷
㩷
1 - Tilt Piston 4- Valve Plate 6- Shoe 8- Ball
2 - Plunger 5- Spring 7- Swash Plate 9- Shaft
3 - Rotor 㩷㩷㩷
㩷
㩷
T3-10-2
Operation㩷㩷
1. When pressure oil is delivered to port A of valve 㩷

plate (4), it flows to one side of rotor (3) and 㩷
pushes plunger (2).㩷
2. Due to this force and inclination of swash plate (7),
shoe (6) slides over swash plate (7), and rotor (3)
and shaft (9) rotate.㩷
3. When plunger (2) reaches port B while rotor (3) is
rotating, oil returns back to the hydraulic oil tank.㩷
4. Whether pressure oil flows to port A or B,
determines switching operation of forward or
reverse travel.㩷
㩷
㩷
㩷
㩷
㩷
Port B㩷 Port A㩷
Port B㩷
Port A㩷
4
3㩷
2㩷
6
9㩷 7
Valve Plate㩷㩷
㪫㪈㪏㪊㪄㪇㪊㪄㪇㪌㪄㪇㪇㪐㩷
㩷
㩷
2- Plunger 4- Valve Plate 7- Swash Plate 9- Shaft
3- Rotor 6- Shoe 㩷㩷
㩷
㩷
T3-10-3
PARKING BRAKE㩷㩷
The parking brake is a negative type that releases the 㩷

brake when self pressure is applied to brake chamber 㩷
M. The parking brake is always applied except when 㩷
traveling.
Friction plate (4) is splined to rotor (5) and plate (3) is 㩷
splined to casing (6) respectively. 㩷

1. When the travel lever is in neutral, brake chamber
M is connected to the hydraulic oil tank.㩷
2. Brake piston (2) is pushed down by force of spring
(1).㩷
3. As a result, as plate (3) is pushed on to friction
plate (4), rotor (5) does not rotate.㩷 Hydraulic
Oil Tank㩷
4. Thus, the parking brake is applied.㩷
1
㩷
㪫㪉㪚㪞㪄㪇㪊㪄㪈㪇㪄㪇㪇㪈㩷
2
㩷
When Brake is Released㩷㩷
1. When the travel lever is shifted, self pressure in
the main circuit acts on brake chamber M.㩷
2. Brake piston (2) moves up by compressing spring
(1).㩷
3. As a result, plate (3) and friction plate (4) become
free and the parking brake is released.㩷
㩷
㩷
㩷
㩷
㩷
2 㪫㪉㪚㪞㪄㪇㪊㪄㪈㪇㪄㪇㪇㪉㩷
㩷
㩷
T3-10-4
1
To Hydraulic
Oil Tank㩷
M
2
5 6
㩷
㪫㪈㪈㪈㪄㪇㪊㪄㪇㪋㪄㪇㪇㪎㩷
㩷
When Brake is Released
㩷
㩷 1
M
2
5 6 㩷
㪫㪈㪈㪈㪄㪇㪊㪄㪇㪋㪄㪇㪇㪏㩷
㩷
㩷
1 - Spring 3 - Plate 5 - Rotor 6- Casing
2 - Brake Piston 4 - Friction Plate 㩷㩷
㩷
㩷
T3-10-5
TRAVEL REDUCTION GEAR㩷
The travel reduction gear is a three-stage planetary As third stage carrier (5) is fixed to housing (1) of the
reduction gear. travel motor, it does not rotate. Ring gear (4) and travel
The travel motor rotates shaft (10) and its turning drive sprocket (2) are both bolted to drum (3) and they
torque is transmitted to third stage carrier (5) and ring rotates together.
gear (4) through first stage planetary gear (11), first
stage carrier (9), second stage sun gear (8), second
stage planetary gear (12), second stage carrier (7),
third stage sun gear (6) and third stage planetary gear
(13).
㩷㩷
㩷1 2 3 4 5 6 7 8
㩷
㩷
㩷
9
㩷
10
Third㩷 Second㩷 First㩷
㩷
11 㪫㪈㪈㪈㪄㪇㪊㪄㪇㪋㪄㪇㪈㪈㩷
㩷
㩷
㪫㪉㪚㪛㪄㪇㪊㪄㪇㪎㪄㪇㪇㪍㩷㩷
㩷 13 12 㩷
㩷
㩷
㩷
㩷
1 - Housing (Travel Motor) 5- Third Stage Carrier 8- Second Stage Sun Gear 11 - First Stage Planetary Gear
2 - Travel Drive Sprocket 6- Third Stage Sun Gear 9- First Stage Carrier 12 - Second Stage Planetary
Gear
3 - Drum 7- Second Stage Carrier 10 - Shaft 13 - Third Stage Planetary Gear
4 - Ring Gear 㩷㩷㩷
㩷
㩷
㩷
㩷
T3-10-6
TRAVEL BRAKE VALVE㩷
The travel brake valve is located at the head of travel

motor and consists of the following valves.
x Overload Relief Valve㩷 x Check Valve㩷

This valve prevents overload of the motor circuit and This valve assists the counterbalance valve in
surge pressure.㩷 operation, and prevents cavitation in the motor
x Counterbalance Valve㩷 circuit.㩷
This valve smoothly starts and stops travel operation, x Travel Motor Displacement Angle Control Valve㩷
and prevents coasting while traveling a descending This valve controls the tilt piston by pilot pressure
slope.㩷 from the high speed selection solenoid valve.㩷
㩷㩷
㩷
㩷 Travel Motor Displacement
Angle Control Valve㩷
㩷
Overload Relief Overload Relief

Valve Valve㩷
Counterbalance
Valve㩷
㩷
㪫㪉㪚㪛㪄㪇㪊㪄㪇㪎㪄㪇㪇㪊㩷
㩷
㩷 Check Valve㩷
㩷
㩷
㩷
T3-10-7
When Traveling㩷 Circuit Protection㩷
1. When pressure oil from the control valve flows to 1. When internal pressure of the circuit exceeds the
port VA, check valve (2) opens and oil flows to set pressure of overload relief valve (4), this valve
motor port MA.㩷 opens and releases high pressure oil to the low
2. On the other hand, return oil from the travel motor pressure side. This protects the travel motor from
flows back to motor port MB, but oil is blocked by overloading.㩷
check valve (2).㩷 2. In addition, the circuit protection releases serge
3. When pressure in port VA increases further, pressure caused by the inertial force when
pressure oil flows through check valve (orifice) (3) stopping the travel motor.㩷
and acts on the surface of spool (1). This moves 3. When the travel motor draws oil by pumping
spool (1) leftward.㩷 action, check valve (2) opens (by make-up
4. As a result, return oil from the travel motor flows function) and cavitation is prevented.㩷
through the notch of outer surface of spool (1) and 㩷
flows to port VB. Now, pressure oil flows and the Shuttle Function㩷
travel motor rotates.㩷 1. When spool (1) moves, port VA or VB connects to
5. When the travel lever is shifted to the neutral the parking brake release passage. Pressure oil is
position, spool (1) returns to the original position routed to the parking brake chamber and the
by the spring force; blocks the circuit and the parking brake is released.㩷
travel motor stops rotating.㩷 2. When the travel motor stops, spool (1) returns
back to the neutral position and the parking brake
When Descending Slope㩷 release passage is closed.㩷
1. The travel motor forced rotates and acts like a Pressure oil in the parking brake chamber flows to
pump while traveling downhill due to own weight.㩷 the drain port and the parking brake is applied.㩷
2. When the travel motor draws oil in, pressure at
port VA and right end of spool (1) decrease. This 㩷
moves spool (1) rightward and it limits the return 㩷
oil from the travel motor.㩷㩷
3. Therefore, pressure at the motor port MB side
increases and the brake is applied to the travel 㩷
motor.㩷
4. When the return circuit is reduced, pressure in
port VA increases again and spool (1) moves
leftward.㩷
By repeating these steps (hydraulic braking),
coasting is prevented.㩷
T3-10-8
㩷
㩷
Control Valve㩷
㩷
1 2 2 3
VB VA
MA
MB㩷
Parking Brake Travel High/Low

Release Passage㩷 Speed Selecting
Passage㩷
㩷
Travel Motor 㪫㪉㪚㪛㪄㪇㪊㪄㪇㪎㪄㪇㪇㪎㩷
㩷
1 - Spool (Counterbalance 2- Check Valve 3- Check Valve 4- Overload Relief Valve
Valve)
㩷
㩷
㩷
㩷
㩷
T3-10-9
TRAVEL SPEED SELECTION㩷
Piston (7) is located next to swash plate (4), which 3. Pressure oil from port VA on high pressure side is
selects the travel speed by changing the displacement blocked by spool (1) and oil in piston (7) returns to
angle of swash plate (4) according to movement of the hydraulic oil tank through spool (1).㩷
piston (7). 4. Plunger (3) of the travel motor pushes swash
plate (4) and the displacement angle of swash
x Low Speed 㩷 plate (4) becomes maximum.㩷
1. When the high/low travel speed selection switch 5. As a result, stroke of plunger (3) becomes larger,
is set to the low speed position, as high travel the travel motor runs at low speed.㩷
speed selection solenoid valve is not selected, 㩷
pressure oil from the pilot pump is not fed to port
P.㩷
2. As a result, spool (1) is pushed by spring (2)
leftward.㩷
㩷
Control Valve㩷
㩷
1 2
VB VA
High Travel Speed

Selection Solenoid Valve㩷
P
Hydraulic
Oil Tank㩷
Pilot Pump㩷
㩷
㩷
7 6 5 4
㪫㪉㪚㪛㪄㪇㪊㪄㪇㪎㪄㪇㪇㪏㩷
㩷
1 - Spool 3 - Plunger 5 - Steel Ball 7 - Piston
2 - Spring 4 - Swash Plate 6 - Steel Ball 㩷
㩷
T3-10-10
x High Speed
1. When the high/low travel speed selection switch 4. Piston (7) pushes swash plate (4) and the
is set to the high speed position, the high travel displacement angle of swash plate (4) decreases.㩷
speed selection solenoid valve is selected.㩷 5. Plunger (3) stroke in the travel motor is reduced
2. As a result, pressure oil from the pilot pump is fed and the travel motor runs at high speed.㩷
from port P and moves spool (1) rightward.㩷㩷
3. Pressure oil in port VA on high pressure side acts
on piston (7) through spool (1).㩷
㩷
㩷 Control Valve㩷
1 2
VB VA
High Travel Speed

Selection Solenoid Valve㩷
P
Hydraulic
Oil Tank㩷
Pilot Pump㩷
㩷
㪫㪉㪚㪛㪄㪇㪊㪄㪇㪎㪄㪇㪈㪇㩷
7 6 5 4
㩷
1 - Spool 3 - Plunger 5 - Steel Ball 7 - Piston
2 - Spring 4 - Swash Plate 6 - Steel Ball 㩷
㩷
㩷
T3-10-11
(Blank)
㩷
㩷
㩷
㩷
㩷
㩷
㩷
㩷
㩷
㩷
T3-10-12
COMPONENT OPERATION/ Others (Crane Upper)㩷
GATE LOCK VALVE㩷㩷
The gate lock valve consists of the gate lock solenoid 㩷

valve and pilot relief valve. 㩷
The gate lock solenoid valve switches the pilot circuit 㩷
ON/OFF. The pilot relief valve secures the pilot circuit
pressure. 㩷
㩷 Gate Lock Solenoid Valve

㩷
Gate Lock Valve㩷
㩷
㪫㪉㪚㪞㪄㪇㪊㪄㪈㪈㪄㪇㪈㪇㩷
Pilot Relief Valve㩷
㩷
㩷 Gate Lock Solenoid Valve㩷
Pilot Relief Valve㩷
㩷
㪫㪉㪚㪞㪄㪇㪊㪄㪈㪈㪄㪇㪈㪊㩷
T3-11-1
Gate Lock Solenoid Valve㩷
The gate lock solenoid valve is activated by operating When the gate lock lever is set to "Unlock" position,
the gate lock lever, which controls flow rate of pressure the gate lock solenoid valve activates and the solenoid
oil flowing from the pilot pump to the pilot circuit. valve spool switches to the "Open" position.
As a result, all of pressure oil from the pilot pump flow
When the gate lock lever is set in "Lock" position, the to the pilot circuit through the spool of solenoid valve.
spool of solenoid valve is in "Closed" position. Thus, as oil is fed to the pilot circuit, the operation
Pressure oil from the pilot pump acts on the pilot relief system becomes operable.
valve and opens the relief valve. As a result, all of
pressure oil from the pilot pump flow to the hydraulic
oil tank through the relief valve. Thus, as no oil is fed to
the pilot circuit, the operation system is inoperable.
㩷
Gate lock is in "Lock" state Gate lock is in "Unlock" state
㩷
㩷
Gate Lock Solenoid Valve㩷 Gate Lock Solenoid Valve㩷
㩷
Pilot Pilot
Pump㩷 Pump㩷
㩷
To Pilot 㪫㪉㪚㪞㪄㪇㪊㪄㪈㪈㪄㪇㪈㪋㩷㩷
Pilot Relief Valve㩷 Circuit㩷 Pilot Relief
Valve㩷㩷
T3-11-2
Pilot Relief Valve㩷㩷
The pilot relief valve is a relief valve which secures 㩷

pressure in the pilot circuit. When pressure in the 㩷
pilot circuit exceeds set pressure of the pilot relief 㩷
valve, the pilot relief valve flows pressure oil from the
pilot pump to port T and reduces pressure in the pilot 㩷
circuit.
On the other hand, if pressure in the pilot circuit is
lower than set pressure of the pilot relief valve, the
pilot relief valve closes and pressure oil from the pilot
pump is routed to the pilot circuit.
㩷
Gate Lock
㩷 Solenoid Valve㩷
Pilot Pump
㩷
To Pilot Circuit 㪫㪉㪚㪞㪄㪇㪊㪄㪈㪈㪄㪇㪈㪉㩷
㩷 To Pilot Relief
Valve㩷
㩷
㩷
㩷
T3-11-3
(Blank)
㩷
㩷
T3-11-4
DRUM BRAKE RELEASE SOLENOID
VALVE (OPTIONAL)㩷
The drum unlocking solenoid valve is a normal close 㩷 NOTE:㩷 As for operation of the drum unlocking
type with ON/OFF operation. solenoid valve, refer to the 4-Spool
The drum unlocking solenoid valves are located in the Solenoid Valve Unit group.㩷
front, rear, and third (optional) drums.
㩷
Depress the brake pedal and turn the free mode 㩷
switch of a drum ON while the brake mode switch is 㩷
set in the auto-brake position.
The solenoid of drum unlocking solenoid valve
receives a signal from MC2/A.
As a result, the solenoid is excited and the drum
unlocking solenoid valve is switched.
Port 3
(From Pilot Pump)
Port 2
(Output Port)㩷
㩷
Port 1 㪫㪉㪌㪥㪄㪇㪊㪄㪇㪏㪄㪇㪇㪏㩷
(Hydraulic Oil Tank)
㩷
㩷
㩷
㩷
T3-11-5
COUNTERWEIGHT CYLINDER㩷㩷
The counterweight cylinder is used to remove and 㩷

install the counterweight which is extended and 㩷
retracted by pressure oil from the 3-spool solenoid 㩷
valve unit.
The piping provides valve block (14) which includes a
down safety valve.
The down safety valve shuts down the circuit and
prevents the counterweight from dropping when the
hoses are damaged.
㩷
1 2 3 4 5 6 7 8 9 10
㩷 11
12
13 14 15 16 17
㩷
㪫㪉㪚㪥㪄㪇㪊㪄㪈㪈㪄㪇㪇㪈㩷
㩷
1- Set Screw 6- Backup Ring 10 - Backup Ring 14 - Valve Block
2- Ring 7- Bushing 11 - Bushing 15 - Cylinder Tube
3- Packing 8- Seal 12 - Dust Seal 16 - Piston Rod
4- O-Ring 9- Packing 13 - Piston 17 - Cylinder Head
5- O-Ring 㩷㩷㩷
㩷
㩷
T3-11-6
FLIP CYLINDER㩷㩷
The flip cylinder is extended and retracted by pressure 㩷

Down Safety Valve㩷
oil from the 3-spool solenoid valve unit in order to raise 㩷
or lower the live mast.
The piping provides valve block (12) which includes a Relief
Valve㩷
down safety valve and a relief valve.
The down safety valve shuts down the circuit and
prevents the live mast from dropping when the hoses
are damaged.
㩷
㪫㪉㪚㪞㪄㪇㪊㪄㪈㪈㪄㪇㪇㪋㩷
㩷 Flip Cylinder㩷
㩷
㩷
㩷
㩷
㩷 1 2 3 4 5 6 7 8
㩷
㩷
9 10 11 13
12
㩷
㪫㪉㪚㪥㪄㪇㪊㪄㪈㪈㪄㪇㪇㪉㩷
1- Wear Ring 5- O-Ring 8 - Dust Seal 11 - Piston Rod
2- Packing 6- Packing 9 - Piston 12 - Valve Block
3- Wear Ring 7- Backup Ring 10 - Tube 13 - Cylinder Head
4- O-Ring 㩷㩷㩷
㩷
T3-11-7
BOOM FOOT CYLINDER㩷
The boom foot cylinder is extended and retracted by

pressure oil from the 4-spool solenoid valve unit in
order to remove and install the boom foot pin.
㩷
㩷
㩷 1 2 3 4 5
㩷
㪫㪉㪚㪥㪄㪇㪊㪄㪈㪈㪄㪇㪇㪊㩷
㩷
㩷
1- Piston Rod 3- Cylinder Tube 4- Piston 5- Nut
2- Cylinder Head 㩷㩷㩷
㩷
㩷
㩷
T3-11-8
ACCUMULATOR㩷㩷
㩷
The accumulator is provided in the pilot circuit. The 㩷
accumulator absorbs hydraulic surge and maintains 㩷
pilot pressure (for a short time) immediately after the
engine stop. Accumulator㩷
The accumulator mainly consists of body (5), holder
(4), poppet (1) and bladder (2) that contains nitrogen
gas (N2) hermetically.
The pilot pressure sensor attached with the
accumulator sends pressure in the pilot circuit to 㩷
MC2/A. 㪫㪉㪚㪞㪄㪇㪊㪄㪈㪈㪄㪇㪇㪌㩷
㩷
x Pressure oil from the pilot pump passes through port 㩷 Pilot Pressure
Sensor㩷
A, enters the accumulator and compresses bladder 㩷
(2) until pressure oil is balanced with nitrogen gas in 㩷
bladder (2).㩷㩷 6
㩷 1
x If pressure oil is not obtained in circuit due to engine
stalling or the like, compressed bladder (2) expands
and delivers the accumulated oil to pilot circuit Nitrogen Gas
through port A.㩷 5 (N2)㩷 2
㩷
4
Pilot Pressure Oil㩷

3
A
㩷
㪫㪈㪇㪌㪄㪇㪉㪄㪈㪇㪄㪇㪇㪊㩷
㩷
1 - Poppet 4- Holder
2 - Bladder 5- Body
3 - Oil Port 6- Gas Plug
㩷
㩷
㩷
㩷
T3-11-9
(Blank)
T3-11-10
COMPONENT OPERATION/ Others (Base Carrier)㩷
OUTLINE㩷㩷
㩷
The undercarriage drives the machine and carries
weight of the superstructure.
The undercarriage mainly consists of lower frame (8),
side frame (13), rotating joint (1), turntable bearing (17),
track take-up idler (10), upper roller (12) lower roller
(11), track shoe (4), travel mechanism (14), side frame
connecting cylinder (3) and jack-up cylinders (5, 9, 15
and 18).
㩷
㩷 1
㩷 2
18
3
6
17 4
16 5
15
6 6
14
7
13 8
12
9
11 6
10 㩷
㪫㪉㪚㪥㪄㪇㪊㪄㪈㪉㪄㪇㪇㪈㩷

㩷
㩷
1 - Rotating Joint 6- Float 11 - Lower Roller 15 - Jack-Up Cylinder
(Right Rear)
2 - Jack-Up/Side Frame 7- Lower Weight (Front) 12 - Upper Roller 16 - Lower Weight (Rear)
Connecting Control Valve
3 - Side Frame Connecting 8- Lower Frame 13 - Side Frame 17 - Turntable Bearing
Cylinder
4 - Track Shoe 9- Jack-Up Cylinder 14 - Travel Mechanism 18 - Jack-Up Cylinder
(Right Front) (Left Rear)
5 - Jack-Up Cylinder 10 - Track Take-Up Idler 㩷㩷
(Left Front)
㩷
T3-12-1
TURNTABLE BEARING㩷㩷
The turntable bearing carries weight of the 㩷

superstructure and swivels it smoothly. 㩷
This bearing is a single row type ball bearing, and 㩷
consists of outer race (1), inner race (3), ball (7),
supports (5, 6) and seals (2, 4). 㩷
Outer race (1) is bolted to the superstructure and inner 㩷
race (3) is bolted to the undercarriage. The internal 㩷
teeth of inner race (3) engage with the output shaft of
swing reduction gear. 㩷
㩷
㩷
㩷
㩷
1
6
7
㩷
㪫㪈㪊㪌㪄㪇㪊㪄㪇㪉㪄㪇㪇㪈㩷
㩷
㩷
1 - Outer Race 3 - Inner Race 5 - Support 7- Ball
2 - Seal 4 - Seal 6 - Support 㩷
㩷
㩷
T3-12-2
ROTATING JOINT㩷
The rotating joint is a full 360q turn joint and delivers Pressure oil from each port of the body passes through
pressure oil to the travel motors while preventing the spindle and flows to the left and right travel motors,
hoses from kinking when the superstructure slews. lower control valves, side frame connecting cylinder
The spindle is fixed at the center of slew of the and jack-up cylinder. The seal is provided and
undercarriage. prevents oil leakage between spindle and body.
㩷
㩷
㩷
㩷
Body
H
A Seal㩷
C A
B
D
E
F B
G
C
Seal
B D D
A C
G E H F E
F
Seal
Spindle
㩷
㪫㪉㪌㪥㪄㪇㪊㪄㪇㪐㪄㪇㪇㪌㩷
㩷
㩷
Port A - Right Travel Forward Port D - Left Travel Forward Port G - High/Low Travel Speed Selection
Pilot Pressure
Port B - Right Travel Reverse Port E - Lower Control Hydraulic Oil Port H - Travel Mechanism Drain
Source Pilot Pressure
Port C - Left Travel Reverse Port F - Control Circuit Drain 㩷
㩷
T3-12-3
SLIP RING㩷㩷
The slip ring is provided at the top of spindle of rotating 㩷

joint. 㩷
The slip ring is a full 360q turn joint and sends electric 㩷
current to the undercarriage while preventing the
wiring from kinking when the superstructure slews. 㩷
㩷㩷
㩷㩷
㩷 Slip Ring㩷㩷
㩷㩷
Brush Ring
㩷㩷
㩷
㪫㪉㪌㪥㪄㪇㪊㪄㪇㪐㪄㪇㪈㪇㩷
㩷
㩷
㩷
㩷
㪫㪉㪌㪥㪄㪇㪊㪄㪇㪐㪄㪇㪇㪐㩷
㩷
㩷
㩷
T3-12-4
SIDE FRAME CONNECTING CYLINDER㩷㩷
Side Frame Connecting Cylinder
The side frame connecting cylinder is a hydraulic 㩷
cylinder and the side frame can be removed and 㩷
installed smoothly by extending and retracting the side
frame connecting cylinder.
The side frame connecting extracting/retracting

solenoid valve of lower control valve controls the side
frame connecting cylinder.
When the side frame connecting extract/retract
solenoid valve switches, pressure oil flows to the side
frame connecting cylinder through a spool of the lower
Side Frame㩷
control valve.
㩷
㪫㪉㪚㪞㪄㪇㪊㪄㪈㪉㪄㪇㪇㪉㩷
㩷
Configuration㩷
㩷 1 2 3 4 5 6 7 8 9 10 11 12
㩷
㪫㪉㪚㪞㪄㪇㪊㪄㪈㪉㪄㪇㪇㪊㩷
㩷
1 - Piston Rod 4 - Cylinder Head 7 - Spacer 10 - Wear Ring
2 - Dust Wiper 5 - Bushing 8 - Piston 11 - Set Screw
3 - U-Ring 6 - Cylinder Tube 9 - Piston Seal 12 - Steel Ball
㩷
T3-12-5
JACK-UP CYLINDER㩷
The jack-up cylinder consists of cylinder and pilot Jack-Up Cylinder㩷

check valve. In addition, the slow return valve is
provided in the return circuit on jack-up cylinder retract
side.
The jack-up cylinders are used to disassemble and
assemble the lower frame into upper and lower
sections when transporting the machine. The jack up
cylinder lifts up the lower frame in order to remove and
install the side frame and load and unload the lower
frame to the trailer.
The jack extend/retract solenoid valves at lower

control valves controls the jack-up cylinders.
When selecting the jack extend/retract solenoid valves, 㩷
pressure oil passes through a spool of the lower 㪫㪉㪚㪥㪄㪇㪊㪄㪈㪉㪄㪇㪇㪉㩷
control valves and flows to the jack-up cylinder. 㩷
㩷 Side Frame㩷
Lower Frame㩷
㩷
㩷
1 2
㩷
㩷
㪫㪉㪚㪥㪄㪇㪊㪄㪈㪉㪄㪇㪇㪊㩷
㩷
1 - Pilot Check Valve Block 3 - Piston 4- Piston Rod 5 - Cylinder Head
2 - Cylinder Tube 㩷㩷㩷
㩷
T3-12-6
Pilot Check Valve㩷㩷
㩷㩷
The pilot check valve maintains pressures on rod Jack-Up Cylinder㩷
side and bottom side of the jack-up cylinder.㩷㩷
Thus, even if the jack-up cylinders are subjected to
external forces, extension and retraction of the
jack-up cylinders are prevented.㩷
㩷
Operation㩷
1. Pressure oil from port A (jack-up cylinder extend
side) opens the check valve in slow return check
Check Valve Check Valve
valve and acts on the pilot check valve.㩷
2. Pressure oil opens the check valve on jack-up
cylinder extend side, flows to the bottom side of
jack-up cylinder and also acts on the check valve
on jack-up cylinder retract side.㩷
3. As pressure oil also opens the check valve on rod Check Valve
side (return side), pressure oil on the rod side
passes through the check valve and flows to the
4. As a result, the jack-up cylinder extends.㩷 B
5. When setting the jack-up switch to the OFF
A 㩷
position, the jack extend/retract solenoid valve
㪫㪉㪌㪥㪄㪇㪊㪄㪇㪐㪄㪇㪇㪍㩷
returns to neutral.㩷
6. The main spool in lower control valve also returns 㩷
to neutral and the extension/retraction of the Jack-Up Cylinder㩷
㩷
jack-up cylinder stops.㩷
7. At this time, even if the jack-up cylinders are
subjected to external forces, the jack-up cylinders
are kept in position as return circuit is blocked by
the check valve.㩷
㩷
Check Valve Check Valve㩷
㩷
㪫㪉㪌㪥㪄㪇㪊㪄㪇㪐㪄㪇㪇㪏㩷
㩷
㩷
㩷
T3-12-7
Slow Return Valve㩷㩷
The slow return valve is provided in the jack-up 㩷

cylinder extend circuit. 㩷 Jack-Up Cylinder㩷
By reducing the return circuit on jack-up cylinder
retract side in order to deliver pressure oil slowly,
rapid lowering of the machine by self weight is
prevented.
Operation㩷
1. Pressure oil from port B flows to the rod side of
jack-up cylinder.㩷
2. On the other hand, pressure oil in return circuit
passes through the pilot check valve and acts on
the check valve in slow return valve.㩷
3. As return oil is blocked by the check valve, return Orifice㩷
oil flows to port A through the orifice.㩷
Check Valve
4. As a result, as the jack-up cylinder retract speed
is reduced, rapid lowering of the machine is
prevented.㩷
㩷 B A
㩷
㪫㪉㪌㪥㪄㪇㪊㪄㪇㪐㪄㪇㪇㪎㩷
㩷
㩷
㩷
㩷
㩷
㩷 Orifice Check Valve Slow Return
㩷 Valve㩷
㩷
To Lower From Jack-Up

Control Valve㩷 Cylinder㩷
㩷
㪫㪉㪌㪥㪄㪇㪊㪄㪇㪐㪄㪇㪇㪊㩷
㩷
㩷
㩷
㩷
㩷
㩷
T3-12-8
TAKE-UP CYLINDER (OPTIONAL)
The take-up cylinder pushes the left and right front

idlers forward by using the travel circuit pressure in
order to set at a specified tension on the track shoe.
The travel circuit pressure is routed to the bottom side

of the left and right take-up cylinders. Consequently,
the front idler is pushed and a specified pressure acts
on the left and right track shoes.
When a strong force acts on the front idler, the return
check valve is opened and the bottom side pressure
oil in the take-up cylinder is released, so that shock is
reduced.
From Travel
1 2 3 4 5 6 Hydraulic Circuit
㪫㪉㪚㪥㪄㪇㪊㪄㪈㪉㪄㪇㪇㪋㩷
1 - Cylinder Head 3- Dust Seal 5- Cylinder Tube

2 - Dust Seal 4- O-ring 6- Piston
T3-12-9
SECTION 4
OPERATIONAL
PERFORMANCE TEST
—CONTENTS—
Group 1 Introduction Group 5 Component Test
Operational Performance Tests.................... T4-1-1 Primary Pilot Pressure (Pilot Circuit) ............T4-5-1
Preparation for Performance Tests............... T4-1-3 Secondary Pilot Pressure .............................T4-5-2
Precautions for Starting Engine.................... T4-1-4 Traveling Mode Control Pressure .................T4-5-4
Swing Brake Release Pressure ....................T4-5-5
Group 2 Standard Main Relief Valve Pressure...........................T4-5-6
Performance Standards ............................... T4-2-1 Swing Control Valve......................................T4-5-8
Main Pump P-Q Diagram ............................. T4-2-4 3-Spool Solenoid Valve (Counter Weight,
Swing Pump P-Q Diagram ........................... T4-2-6 Live Mast Flip Cylinders)...........................T4-5-10
4-Spool Solenoid Valve (Boom Foot Pin,
Group 3 Engine Test Lower Hydraulic Power Source) ...............T4-5-11
Engine Speed............................................... T4-3-1 Lower Control Valve....................................T4-5-12
Overload Relief Valve Set Pressure ...........T4-5-13
Group 4 Crane Test Main / Swing Pump Flow Rate
Traveling Speed ........................................... T4-4-1 Measurement............................................T4-5-14
Mistrack Check............................................. T4-4-2 Regulator Adjustment (Main Pump)............T4-5-18
Travel Motor Leakage .................................. T4-4-3 Regulator Adjustment (Swing Pump) ...........T4-5-21
Swing Speed ................................................ T4-4-4 Swing Motor Drainage ................................T4-5-24
Turntable Bearing Play................................. T4-4-5 Travel Motor Drainage ................................T4-5-26
Hoisting / Lowering Speed Derricking Motor Drainage..........................T4-5-28
(Front / Rear Drums) .................................. T4-4-6
Regulator Adjustment................................... T4-4-7 Group 6 Adjustment
Boom Derricking Speed .............................. T4-4-8 Power Increase Pressure Calibration ...........T4-6-1
Jack-Up Speed............................................. T4-4-9 Brake Pedal Unit Adjustment ........................T4-6-4
Load Lowering by Front / Rear Drums ....... T4-4-10
Control Lever Operating Control Force ...... T4-4-11
Control Lever Stroke .................................. T4-4-11
C-4-1
(Blank)
C-4-2
OPERATIONAL PERFORMANCE TEST / Introduction
OPERATIONAL PERFORMANCE TESTS
Use operational performance test procedures to
quantitatively check all systems and functions on the
machine.
Kinds of Operational Performance Tests

1. System performance and function test
each system such as engine, travel, slewing, and
hydraulic cylinder is individually tested.
2. Component performance and function test
each component such as hydraulic pump, motor,
and various valves is individually tested.
Purpose of Operational Performance Tests

1. To evaluate the performance and function of a
system or component by comparing the test
results to the standard specifications.
2. According to the evaluation above, repair, adjust,
or replace the system or component as
necessary to restore the systems and functions
to the required performance level.
3. To ensure safety and high efficiency operation.
Standard Specifications
“Performance Standard” and “Allowable Limit” are
shown in tables to evaluate the performance test
data.
Precautions for the Test Result Evaluation

1. Besides determining whether the test results
meet the standard specifications or not, check
which level of standards the test results
correspond to.
2. In compliance with how long and under what type
of work or conditions the machine has operated,
or the machine maintenance condition, the extent
of deterioration of the machine’s performance
may differ. Decide the degree of repair,
adjustment, and/or replacement corresponding to
the machine operation hours.
With the passage of time, the machine's operational

performance deteriorates, so that the machine needs
to be serviced periodically. Before servicing the
machine, conduct performance tests to check the
extent of deterioration and to decide what kind of
service needs to be done referring to the standard
specifications.
T4-1-1
Definition
Definition of “Performance Standard”

1. Operation speed values and dimension of the
new machine.
2. Operational performance of new components
adjusted to specifications.
Allowable errors will be indicated as necessary.
Definition of “Allowable Limit”

1. Normal machine performance cannot be
accomplished after exceeding this limit.
2. Repair or adjustment is impossible after
exceeding this limit.
3. Therefore, in consideration of operation efficiency
and maintenance expense.
Proper maintenance shall be carried out before
reaching the Allowable Limit
T4-1-2
PREPARATION FOR PERFORMANCE
TESTS
Observe the following rules in order to carry out

performance tests accurately and safely.
The Machine
1. Before starting performance tests, perform a
sight-inspection of the machine. Then, if any
abnormalities such as oil or coolant leaks, loose
bolts, or cracks are found, repair them.
2. Confirm the status of the implementation of daily
and monthly checks before performing the
measurement.
Test Area and Measuring Instrument

1. Select a hard and level surface.
2. Secure enough space to allow the machine to run
straight for more than 10 m.
3. Secure enough space to allow the machine to
make a full swing with the front attachment
extended.
4. Provide equipment and measuring instruments
suitable to the test to be performed.
5. If required, rope off the test area and provide
signboards to keep unauthorized personnel away. T105-06-01-003
6. Provide measuring weights or equivalent ones.
7. Coordinate work signals and procedures with
co-workers.
Precautions
1. Pay attention to the peripheral working
environment at all times while measuring to
ensure safety (foundation, space, high voltage
power lines and etc.).
2. Always give first priority to safety. Be sure to
adhere to work signals and operate the machine
carefully.
3. Avoid contaminating the machine and the ground
with leaking oil. When removing hydraulic pipings,
use oil pans to catch escaping oil.
4. After completing the measurements, be sure to
clean up to prevent contamination of the
environment (bring back waste oils and other
wastes).
Precise Measurement
1. Accurately calibrate test instruments in advance
to obtain correct data.
2. Carry out tests under the exact test conditions
prescribed for each test item. SA-331
3. Repeat the same test and confirm that the test
data obtained can be repeated. Use the average
values of the measurements.
4. Make efforts to improve your measuring
techinique.
T4-1-3
LOCK Position
PRECAUTIONS FOR STARTING ENGINE

1. Check that lock lever (1) is placed in the LOCK 1
position.
2. Check that each control lever is in the NEUTRAL M2CE-03-007
position.
3. Using free winch specification, verify that the

front and rear brake pedals (4) and (5) locks are
engaged, that the front and rear drum brake
mode switches (2) and (3) are set to "Automatic 5 4 2 3 1
Brake" mode.
1
4. Check that swing brake switch (6) is in the ON 6
(brake) position.
NOTE: If the front and rear drum mode switches

(2) and (3) are not set to "Automatic Brake"
mode, or the swing brake switch (8) is not
in the ON (brake) position, the engine does
not start.
5. Before operating the machine, thoroughly read

and understand the operator’s manual.
T25U-04-01-001
T4-1-4
OPERATIONAL PERFORMANCE TEST / Standards
PERFORMANCE STANDARDS
The performance standards show the required per- Measuring conditions:
formance measurements. Engine speed : Fast Idle
For details including measuring method, refer to T4-3 . Hydraulic oil temperature : 50r5 qC (122r9qF)
Data in ( ) is given for reference.
Reference
Performance Test Designation Performance Standard Remarks
Page
Engine Speed min-1 T4-3-1
Fast Idle Speed 2075 to 2125
Slow Idle Speed 775 to 825
2,
Engine Compression Pressure MPa (kgf/cm , psi) 2.94 (30, 426) After warming up
Valve Clearance mm With the cold engine
IN 0.04
EX 0.08
Traveling Speed sec/10 m T4-4-1
Slow Speed 53 to 60
Fast Speed 26 to 30
Mistrack mm/10 m 60 or less At fast travel speed T4-4-2
Travel Motor Leakage T4-4-3
Slippage Until Brake is Applied turn (1/6 or less)
Motor Slippage When Parking mm/5 min (0)
Swing Speed sec/3 turn T4-4-4
Min 158 to 180
Dial
Max 95 to 106
Turntable Bearing Wear mm (5 to 6) T4-4-5
Hoisting and Lowering Speed sec/Drum 6 turns T4-4-6
Slow Speed Holding Speed 1 21 to 24
Slow Speed Holding Speed 2 10 to 12
Front/Rear
Normal Speed 1 11 to 13
Normal Speed 2 5.6 to 6.4
Boom Derricking Speed sec/Drum 6 turns T4-4-8
Fast 24 to 27
Slow ---
T4-2-1
Performance Reference
Performance Test Designation Remarks
Standard Page
Jack-up Speed (When stroke : 450mm) sec Engine speed:Slow idle T4-4-9
Extend 28 to 31
Retract 15 to 17
Load Lowering by Front / Rear Drums mm/2 min (0) T4-4-10
Control Lever Operating Force N (kgf, lbf) T4-4-11
Front / Rear Drum Lever 1st. Detent 5.9 to 11.3
(0.6 to 1.2,
1.3 to 2.5)
2nd. Detent 11.3 to 18.6
(1.2 to 1.9,
2.5 to 4.2)
Boom Derricking Lever 5.9 to 18.6
(0.6 to 1.9,
1.3 to 4.2)
Traveling Lever 7.6 to 15.7
(0.8 to 1.6,
1.7 to 3.5)
Swing Lever 10.9 to 23.3
(1.1 to 2.4,
2.5 to 5.2)
Control Lever Stroke mm T4-4-11
Front / Rear Drum Lever 1st. Detent 57 to 64
2nd. Detent 99 to 106
Boom Derricking Lever 99 to 106
Traveling Lever 44 to 51
Swing Lever 93 to 103
T4-2-2
Re- Reference
Performance Test Designation Performance Standard
marks Page
Hydraulic System
Primary Pilot Pressure MPa (kgf/cm2, psi) T4-5-1
Gate lock valve (without free fall winches) 9.80.50 (10050, 1421730)
Gate lock valve (with free fall winches) 6.90.50 (7050, 1000730)
Pilot Circuit 4.90.50 (5050, 711730)
Secondary Pilot Pressure MPa (kgf/cm2, psi) T4-5-2
Front/Rear Lever 1st. Detent (2.0r0.2 (20.4r2, 290r29))
2nd. Detent (3.4r0.2 (34.7r2, 493r29))
Boom Derricking (3.4r0.2 (34.7r2, 493r29))
Traveling (2.0r0.2 (20.4r2, 290r29))
Swing (2.90.50 (29.60.50,
421730))
Brake pedal (front and rear drum with free fall) (5.88r0.2 (60.0r2,
853r29))
Traveling Mode Control Pressure MPa (kgf/cm2, psi) (2.45 to 5.88 (25 to 60,
T4-5-4
356, to 853))
Swing Brake Release Pressure MPa (kgf/cm2, psi) (4.90.50 (5050, 711730)) T4-5-5
Main Relief Valve Pressure MPa (kgf/cm2, psi) T4-5-6
Front/Rear Control Valve 28.3 to 31.4 (288 to 320,
4100 to 4550)
Swing Control Valve 28.7 to 31.4 (288 to 320,
4160 to 4550)
3-spool solenoid valve(Live mast, counter weightcylinder) 26.5 to 29.4 (270 to 300,
3840 to 4260)
4-spool solenoid valve (Boom foot pin, lower hydraulic) 18.5 to 20.6 (189 to 210,
2680 to 2990)
Hydraulic fluid cooling fan relief valve 8.8 to 9.8 (9 to 10,
1280 to 1420)
Leaving winch relief valve 18.5 to 20.6 (189 to 210,
2680 to 2990)
Lower Control Valve 18.5 to 20.6 (189 to 210,
189 to 210)
Overload Relief Valve Pressure MPa (kgf/cm2, psi) T4-5-13
Front/Rear 34.3 (350, 4970)
Boom Derricking 34.3 (350, 4973)
Traveling 32.4 (330, 4700)
Main / Swing Pump Flow Rate - T4-5-14
Swing Motor Drainage L/min - T4-5-24
Travel Motor Drainage L/min - T4-5-26
Boom Derricking Drainage L/min - T4-5-28
T4-2-3
MAIN PUMP P-Q DIAGRAM
x P-Q Control (Torque Control)
(Reference: Bench measurement)
• Rated pump speed: 2000 min-1 (rpm)

• Hydraulic oil temperature: 50r5 qC (122r9 qF)
• Power increase proportional solenoid valve current: “I” mA
Flow Rate
L/min 400
300 I=800 mA
A B C
D
E
F
200
I=0 mA
G H
100
0 5 10 15 20 25 30 35 T2CG-04-02-001
Delivery Pressure MPa
P-Q Point: I=800 mA P-Q Point: I=0 mA

Delivery Pressure Flow Rate Delivery Pressure Flow Rate
2 2
MPa (kgf/cm ) L/min MPa (kgf/cm ) L/min
A 7.8 (80) 275 F 3.9 (40) 200
B 12.4 (127) 274 G 26.3 (2.7) 57
C 22.3 (216) 270 H 31.4 (320) 54
D 26.1 (266) 217 Data in ( ) is given for reference.
E 31.4 (320) 183
T4-2-4
x P-Q Control by Pump Control Pilot Pressure Signal

Flow Rate
L/min
300
A
200
100
B
0 1 2 3 4 T2CG-04-02-002
Pilot Pressure MPa
P-Q Point
Pilot Control Pressure Flow Rate
Solenoid Valve Current
2
MPa (kgf/cm ) L/min
mA
+10
A 0.86 (8.8) 276r1.5 315 0
+77
B 2.92 (29.8) 67r3 586 -33
T4-2-5
SWING PUMP P-Q DIAGRAM
x P-Q Control (Torque Control)

Flow Rate 200

L/min
A
150
B
C
100
50
0 5 10 15 20 25 30 35 T2CG-04-02-003
Delivery Pressure MPa
P-Q Point
Delivery Pressure Flow Rate
2
MPa (kgf/cm ) L/min
A 25.8 (263) 154
B 28.0 (286) 137
C 31.9 (325) 123
T4-2-6
x P-Q Control by Pump Control Pilot Pressure Signal
• Specified pump speed: 2000 min-1 (rpm)

B
Flow Rate
L/min 150
A
100
50
0 1 2 3 T2CG-04-02-004
Pilot Pressure MPa
P-Q point
Pilot Control Pressure Flow Rate
Solenoid Valve Current
2
MPa (kgf/cm ) L/min
mA
A 1.11r0.2 (11.3r2) 94r3 340r30
B 1.96r0.2 (20r2) 158r3 457r30
T4-2-7
(Blank)
T4-2-8
OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE SPEED
Summary:
1. Measure the engine speed using the moment lim-
iter speed indicator.
NOTE: 1.If the engine speed is out of specification,

all other measured performance data will
also be out of specification. Accordingly,
always measure the engine speed before
performing any tests.
Preparation:
Sufficiently warm up the machine until the engine
coolant temperature reaches 50 qC (122 qF) or more,
also, keep the hydraulic oil temperature at
50r5 qC (122r9 qF).
Measurement:
Measure the slow and fast idle speeds.
Evaluation:
Refer to T4-2 Performance Standards.
Remedy:
Refer to the engine shop manual.
T4-3-1
OPERATIONAL PERFORMANCE TEST / Engine Test
(Blank)
T4-3-2
OPERATIONAL PERFORMANCE TEST / Crane Test
TRAVELING SPEED
Summary:
1. Measure the time to travel 10 m to check the op-
erational performance of the travel power system
(from the hydraulic pump to the travel motor)
comprehensively.
2m
Preparations:
1. Adjust both the right and left track sags equally. (6.5ft)
2. Prepare a level and solid test track 10 m long,
60q
with an extra length of 3 to 5 m on both ends of
the test track for machine acceleration and de-
celeration.
3. The machine should be equipped with the basic
boom and hook. Set the boom angle to 60q, and T25N-04-04-001
hoist the hook until it reaches 2 m below the
height at which the hoisting limiter buzzer starts
to operate.
(Or dismount the front attachment and counter-
weight)
4. After raising the hydraulic oil temperature to the
range of 50r5 qC (122r9 qF), let the hydraulic oil
flow into the circuits to be measured for more
than two minutes before starting the test.
Measurement:
Measure in both fast and slow travel modes.
1. Run the engine at the fast idle speed.
2. Start driving the machine from the acceleration
zone with both the right and left travel levers at
full stroke.
3. Measure the time required to travel the 10 m test Deceleration
track. Zone 3 to 5 m
4. After measuring forward travel time, turn the up- Acceleration End
per 180q. Then, measure the reverse travel time. Zone 3 to 5 m
Start 10 m
5. Repeat the measurement three times in each di-
rection. Calculate the average values. T324-06-03-002
Evaluation:
Notes
Remedy: 10m = 33ft
Refer to T5-4 Troubleshooting.
3 to 5m = 9.8 to 16ft
2m = 6.5ft
T4-4-1
MISTRACK CHECK
Summary:
1. Measure the maximum distance from the 10 m
straight line connecting the travel start and end
points to the actual rut line to check the variation
between the right and left travel power line (from
the hydraulic pump to the travel motor) perform- 2m
ance.
2. Mistrack is generally reduced when measured on (6.5ft)
a concrete surface.
60q
Preparations:
1. Adjust both the right and left track sags equally.
2. Prepare a level and solid test track 10 m long,
with an extra length of 3 to 5 m on both ends of T25N-04-04-001
the test track for machine acceleration and de-
celeration.
3. The machine should be equipped with the basic
boom and hook. Hoist the hook to approx. 2 m
below the height, which the hoisting limiter
buzzer starts to operate.
(Or dismount the front attachment and counter- 2m
Maximum Distance
weight)
flow into the circuits to be measured for more 10 m
than two minutes before starting the test. Acceleration
Zone 3 to 5 m
T324-06-03-003
Measurement:
Measure in both fast and slow travel modes.
1. Run the engine at the fast idle speed. Notes
2. Start driving the machine from the acceleration
zone with both the right and left travel levers at 10m = 33ft
full stroke. 3 to 5m = 9.8 to 16ft
3. Measure the maximum distance from a straight 2m = 6.5ft
10 m line to the machine rut.
4. After measuring in forward travel, measure in re-
verse travel.
rection. Calculate the average values.
Evaluation:
Remedy:
T4-4-2
TRAVEL MOTOR LEAKAGE
Summary:
1. Measure the travel parking brake drift on a speci-
fied angle slope.
Preparations:
2m
1. The test slope shall be smooth with a gradient of
20 % (11.31 q). (6.5ft)
2. Put a mark on the travel reduction gear cover. 60q
3. Use the basic boom with the hook. Set the boom
angle to 60 q. 20 %
weight) T25N-04-04-006
4. Keep the hydraulic oil temperature at 50r5 qC
(122r9 qF).
Position where the machine
Measurement: stops.
Measure in both fast and slow travel speed modes. Position when the travel levers
are in neutral.
Movement
x Track movement (sprocket rotation) until the park- (Rotation Angle)
ing brake is applied. Mark
1. Climb the slope and place the travel levers in
neutral.
2. Measure the travel reduction gear cover mark
movement from the position when the lever is
placed in neutral to the position when the ma-
chine stops (when the brake is applied).
T107-06-03-002
x Travel motor slip while parking

1. Climb the slope and place the travel levers in
neutral.
2. Stop the engine.
3. After parking the machine, put the matching
marks on the shoe and side frame.
4. After 5 minutes have passed, measure the dif-
ference (3) between mark (1) on the side frame
and mark (2) on the shoe.
Evaluation:
T324-06-03-005
2 3 1
T4-4-3
SWING SPEED
Summary:
1. Measure the time to swing three complete turns
to check the operational performance of the sw-
ing system (from the hydraulic pump to the swing
2m
motor) comprehensively.
Preparations: (6.5ft)
1. Check the lubrication of the swing gear and turn- 60q
table.
2. Place the machine on a level and solid ground
with ample space for swing. Do not test on a
slope.
3. Use the basic boom with the hook. Set the boom T25N-04-04-001
angle to 60q.
weight)
range of 50r5 qC
(122r9 qF), let the hydraulic oil flow into the cir- Accelerator
Grip
cuits to be measured for more than two minutes
before starting the test. Swing Brake
Switch
Measurement:
Turn the swing brake switch at ON position and Swing
Lever
measure the swing speed under the following condi-
tions: With the swing speed control dial in SLOW
position or in FAST position. Left
1. Using accelerator dial (or accelerator grip), run Swing
the engine at the fast idle speed.
IMPORTANT: Do not operate the control lever

rapidly. Otherwise, a large swing of Right
Swing
the hook may result, potentially
causing the hook to come in contact
with the boom.
Swing Speed
Control Dial
2. Operate the swing control lever fully.
3. After the swing speed becomes constant, meas-
T25N-04-01-001
ure the time required for the upper to rotate three
turns in one direction.
4. Measure on the right and left swing.
Evaluation:
Remedy:
T4-4-4
TURNTABLE BEARING PLAY
Summary:
1. Measure the turntable bearing play using a dial
gauge to check the wear of ring races and balls.
Preparation:
1. Check the turntable bearing mounting bolts for
looseness. Counterweight
2. Check the lubrication of the swing ring. Check 60q
that the turntable bearing rotation is smooth and
without noise.
3. Install the dial gauge onto the center on upper
surface in carbody, at the counterweight side (po-
sition A). T324-06-03-012
Position A
4. Secure the dial gauge by using a magnetic base.
5. Position the upper in the same direction as trav-
eling the carbody.
6. Position the dial gauge so that its needle point
comes into contact with the bottom surface of
turntable bearing outer race.
7. Perform the measurement on level and solid
Needle Point
ground. Use the basic boom with the hook. Set
the boom angle to 60q. Apply a maximum lifting
load (100 %) to the hook.
Detailed Position A
NOTE: Refer to the GENERAL / SPECIFICATION T324-06-03-013
section or the Operator’s Manual for the

lifting load value equivalent to the 100% Measurement of (h1)
lifting load.
(122r9 qF).
Measurement:
1. Before lifting a load, read the dial gauge indica-
tion (h1).
2. Lift up a weight (100 % load) until the bottom of
the weight leaves the ground. Then, read the dial
gauge indication (h2).
3. Obtain the turntable bearing play (H) by calculat-
ing the difference between (h1) and (h2).
That is, H = h2-h1 T25N-04-04-007
Evaluation: Measurement of (h2)

T25N-04-04-008
T4-4-5
HOISTING / LOWERING SPEED (FRONT /
REAR DRUMS)
Summary:
1. Measure the time required for the front and rear
drum to rotate six complete turns to comprehen-
sively check the operational performance of the
hydraulic pump and the front and rear drum mo-
tors in the front and rear drum drive system.
Preparation:
1. Use the basic boom with the hook.
weight)
2. Set the boom angle to 60q. Lower the hook until it
comes close to the ground surface.
range of 50r5 qC (122r9 qF) by operating the
drum motors, let the hydraulic oil flow into the
circuits to be measured for more than two min- 60q
utes before starting the test.
4. Check that the weight of the hoisting limiter func-
tions at the specified position.
T25N-04-04-009
NOTE: Depending on the number of the wire rope
falls, the hook travel for six turns of the Front Drum Rear Drum x Speed 2
hoist drum varies. Start the measurement Lever Lever
x Speed 1 Lowering
from the position having enough margin in
stroke. x Neutral
Measurement: x Speed 1 Hoisting

1. Using accelerator dial (or accelerator grip), run
x Speed 2
the engine at the fast idle speed.
2. Operate the hoist lever (front and rear drum
lever) corresponding to the drum to be measured.
3. After the drum rotation speed becomes constant, M25N-04-008
measure the time required to rotate six turns.

4. Repeat the measurements three times in each
direction. Calculate the average values.
5. Measure the times in all operations.
Evaluation:
T4-4-6
REGULATOR ADJUSTMENT
x Displacement Angle Set Pressure and Power Set
Pressure Adjustment.
Motor speed can be adjusted with adjusting screws
(1) and (2) at regulator.
T25N-03-03-024
Adjustment Item Adjustment Procedure Remarks

1. Displacement angle set Loosen nut (1), and adjust pressure 1) Other control characteristics are
pressure with adjusting screw (2). not influenced.
One turn of adjusting screw (2) 2) Securely retighten lock nut (1)
Flow Rate
changes the pressure as follows: after adjustment.
Front/Rear drum:
2
530 kPa (5.4 kgf/cm )
: 13 mm
: 16 Nm (1.6 kgfm)
Pilot Pressure
2. Power set pressure Loosen lock nut (4), and adjust 1) Other control characteristics are
pressure with adjusting screw (3). not influenced.
Pressure One turn of adjusting screw (3) 2) Securely retighten lock nut (4)
changes the pressure as follow: after adjustment.
2
21.5 MPa (219 kgf/cm )
: 13 mm
: 16 Nm (1.6 kgfm) Notes
530 kPa = 77 psi
21.5 MPa = 3130 psi
Torque 16 Nm = 12 lbfft
T4-4-7
BOOM DERRICKING SPEED
Summary:
1. Measure the time required for the boom derrick-
ing drum to rotate six complete turns to compre-
hensively check the operational performance of
the hydraulic pump and the boom derricking
drum motors in the boom derricking drum drive
system. 2m
Preparations: (6.5ft)
(Or dismount the front attachment and counter- 60q
weight)
flow into the circuits to be measured for more
T25N-04-04-001
than two minutes before starting the test.
3. Check that the boom derricking drum brake func-
tions properly.
4. Check that the derricking limiter functions prop-
erly.
Measurement:
Measure the boom derricking speed under the fol-
lowing conditions: With the speed control dial in
SLOW position and in FAST position.
1. Using accelerator dial (or accelerator grip), run
the engine at the fast idle speed. Boom Derricking
Lever
2. Operate the boom derricking lever. Accelerator
3. After the boom derricking drum rotation speed Grip
becomes constant, measure the time required to
Lowering
rotate six turns.
4. Repeat the measurements three times in both
hoisting and lowering directions. Calculate the x Neutral
average values.
Hoisting
Evaluation: Boom Derricking Drum
Speed Control Dial
Remedy:
T25U-04-01-001
T4-4-8
JACK-UP SPEED
Summary:
1. Measure the extension time of jack-up cylinder
from minimum retraction length to maximum ex-
tension length in order to judge overall perform-
ance of drive system for jack-up cylinder ranging
from pump for gantry raise/lower, jack-up and
crawler frame joint to jack-up cylinders.
Preparation:
1. Deliver oil into the measured hydraulic circuit for
two minutes or longer while making jack-up op-
eration at hydraulic oil temperature of 50±5qC
(122±9 qF).
2. Carry out measurement after extending jack-up
cylinder fully.
Measurement:
Make measurement at each measuring point.
1. Set the engine speed to the fast idle speed.
2. Set the jack-up switch to the extend position.
3. Measure the extension time of jack-up cylinder
from fully retracted position (minimum length) to
ground contact position.
4. With jack-up switch at the retract position, and
jack-up cylinder resting on the ground, measure
the retraction time of jack-up cylinder to the
minimum retraction length.
5. Carry out measurement three times, and deter-
mine the average of measurements.
Evaluation: T2CD-04-04-001
Refer to T4-2 Performance Standards. Jack-up Cylinder
T4-4-9
LOAD LOWERING BY FRONT / REAR
DRUMS
Summary:
1. To check front/rear motor performance, measure
slippage at the drum flange for two minutes while
idling the engine.
1 2
Preparations:
2. Number of rope reeving at the boom hook is four
or less.
3. Set the front/rear drum brake mode switches (1
and 2) to the “Auto Brake” position.
range of 50r5 qC
(122r9 qF), let the hydraulic oil flow into the cir-
cuits to be measured for more than two minutes
before starting the test.
5. Hoist the weight, stop it, and make measurement.
Measurement:
1. Set boom angle to 60q.
2. Set the load to about 13.5 t when converted to
line pull with a single wrap on the drum. (at boom
hook, about 54 t at 4 rope reeving, and about
40.5 t at 3 rope reeving) T25U-04-01-001
3. Lift and suspend the weight 0.5 m above the

ground.
4. Set engine speed to slow idle.
5. Measure slippage length at outer surface of the
drum flange. Measure for two minutes.
6. Restore number of rope reeving as it was.
Evaluation:
Remedy:
60q
0.5 m (20 in)
T25N-04-04-010
T4-4-10
CONTROL LEVER OPERATING CONTROL
FORCE
Summary:
1. Check the operating function of each control
lever and measure the operating force.
2. Measure the maximum operating force of the
front attachment control lever.
3. Measure the operating force under the grip of Drum Lever
each control lever.
Preparations:
Swing
1. Keep the hydraulic oil temperature at 50r5 qC Lever
(122r9 qF).
Measurement:
2. Measure on each control lever.
3. Stop the engine.
4. Operate each lever full stroke to measure the
maximum operating force.
Evaluation: Drum Lever

Travel Lever
T25U-04-01-001
CONTROL LEVER STROKE
Main points:
1. Check for play in each of the operating levers
and the operating condition, and measure the
stroke.
2. Measure the stroke at the center of the grip for
each of the operating levers.
3. Measure separately if there is rattling in neutral.
Measurements:
1. Stop the engine.
2. Measure the stroke of each operating lever at the
top center of the grip, while the lever is in the
neutral position to the end of the stroke.
3. The measurement is performed in straight line.
4. Measure the stroke three times, and the calcu-
lated average is the measurement value.
Judgment:
Refer to the Performance Standards List in Chapter
T4-2.
T4-4-11
(Blank)
T4-4-12
OPERATIONAL PERFORMANCE TEST / Component Test
PRIMARY PILOT PRESSURE (PILOT
CIRCUIT)
5-Spool Solenoid
Preparations: Valve Block
1. Stop the engine.
2. Detach adapter 1 from port P1(PF3/8) of the
5-spool solenoid valve block.
: 22 mm
Port P1
3. Attach a pressure gauge to port P1. (Adapter 1)
4. Start the engine. Check for oil leaks at the pres-
sure gauge unit connector.
(122r9 qF).
Measurement:
1. Run the engine at the fast idle speed.
2. Measure the pilot oil pressure under no load con-
dition by using a pressure gauge.
Evaluation: M2CG-07-063
Adjustment of Primary Pilot Pressure (Pilot Cir-

cuit)
Adjustment:
Adjust the set pressure of pressure reducing valve
provided on the 5-spool solenoid valve block while
checking the pressure gauge if necessary.
1. Loosen the lock nut. Adjustment Screw

: 14 mm Lock Nut
2. Turn the adjusting screw.
: 6 mm
3. Tighten the lock nut.
: 14 mm
: 7.8 Nm (0.8 kgfm)
4. Check the set pressure after adjustment.
Notes
T T
7.8 Nm = 5.8 lbfft
P1 P
T4-5-1
SECONDARY PILOT PRESSURE Boom Derricking Rear Drum Front Drum
Drum
Preparations:
1. Stop the engine.
2. Install a pressure gauge unit to the circuit to be
measured.
2-1. Front / Rear / Boom Derricking Drums Circuit
• Remove the hoses and adapters from port 8
(G1/4) in the front drum remote control valve, port
7 (G1/4) in the rear drum remote control valve and
ports 1 and 2 (G1/4) in the boom derricking re-
mote control valve. Install the tee and pressure
gauge.
: 19 mm
2-2. Third drum / Quick Draw Circuit Port 2 Port 8
• Remove the travel remote control pressure sen-
sors from ports 8 and 9 (G1/4) in the right and left
travel remote control valve. Install the tee and Port 1
pressure gauge.
: 24 mm Port 7
T25N-03-06-005
: 16r1.6 Nm (1.6 to 0.16 kgfm) Third Drum Left Travel Right Travel
• Remove the hose and adapter from the quick / Quick Draw
draw remote control valve port 7 (G1/4) and at-
tach the tee and pressure gauge.
: 19 mm
2-3. Swing Circuit
• Remove the plug from port 3 (G1/4) in the slewing
remote control valve. Install the tee and pressure
gauge.
: 6 mm
Tee : ST 6069
Pressure Gauge Unit : ST 6932

sure gauge unit connector. Port 9
4. Keep the hydraulic oil temperature at 50r5 qC Port 7
(122r9 qF).
T25N-03-06-006
Port 8
Swing
Notes
16r1.6 Nm = 12r1.2 lbfft
Plug
Port 3
T25N-03-06-007
T4-5-2
Measurement:
1. In case of measurement in the front/rear and
boom derricking circuits, engage the respective STD lever
drum locks.
Swing Lock
In case of measurement in the swing circuit, turn Pedal Lock Lever
the swing lock pedal in the LOCK position and
turn the swing brake switch in ON.
CAUTION: When measuring in the travel

circuit near the rotating parts, take care not to
allow your hand, foot, and/or clothes to be-
come entangled in the rotating parts.
2. Lower the lock lever to the UNLOCK position. Control

Operate the control lever corresponding to the Lever
circuit in which the secondary pilot pressure is to
be measured at each detent position. Then,
measure the pilot pressure at each detent position
by using a pressure gauge.
3. Repeat the measurement three times at each
detent position. Calculate the average value.
T25U-04-01-001
Evaluation:
Remedy:
In case the measured results are out of specifications,
check the primary pilot pressure. When the primary
pilot pressure is normal, the remote control valve may
be faulty.
T4-5-3
TRAVELING MODE CONTROL PRESSURE
Preparations:
Traveling Speed
1. Stop the engine. Control Hose
2. Remove the travel speed control hose.
: 19 mm
3. Install adapter1 to the adapter.
Install the removed hose and tee to the adapter 1.
Install the pressure gauge unit to the tee.
: 19 mm
Adapter 1 : ST 6451
Tee : ST 6069
(122r9 qF).
Adapter
Measurement: M2CG-07-058
1. Measure the pressures by using a pressure

gauge while the machine is traveling at both slow NOTE: The illustration shows the right travel.
and fast speeds.
2. Repeat the measurement three times. Calculate
the average value. Pressure Gauge
Evaluation:
Remedy:
In case the measured results are out of specifications,
pilot pressure is normal, the solenoid valve or elec- Tee 7/16-20UNF
trical system may be faulty. (For Adapter)
Adapter 1
7/16-20UNF
(For Hose)
T324-06-04-025
T4-5-4
SWING BRAKE RELEASE PRESSURE
Swing Motor
Preparations:
1. Stop the engine.
2. Remove the swing brake release hose from port
PR in the slewing motor. Tee
: 22 mm
3. Install the adapter to the tee.
Install the hose and tee to the adapter. Install the
pressure gauge unit to the tee.
: 22 mm, 19 mm
Adapter : ST 6485
Tee : ST 6069
Hose
Pressure Gauge Unit : ST 6932 T2CD-04-05-002

5. Keep the hydraulic oil temperature at 50r5 qC Pressure Gauge
(122r9 qF).
Measurement:
1. With the swing brake switch turned to both the ON
and OFF positions, measure the swing brake re-
lease pilot pressure.
rection. Calculate the average values. Nipple 9/16-18UNF
(For Tee)
Evaluation:
Adapter
9/16-18UNF
Remedy: (For Hose)
In case the measured results are out of specifications, T324-06-04-025
pilot pressure is normal, the solenoid valve or elec-
trical system may be faulty.
T4-5-5
MAIN RELIEF VALVE PRESSURE
Front / Rear Control Valves
Preparations:
1. Stop the engine.
2. Remove the plug from pressure check ports (a1
and a2) (G1/4) at the main pump delivery port. Main Pump 1 Main Pump 2
: 6 mm
3. Install the tee and pressure gauge unit to check
ports (a1 and a2).
: 19 mm
Tee : ST 6069
4. Measurement of the main relief valve set pressure
on the front control valve (connected to main
pump 1):
Remove the right travel motor forward hydraulic T25N-04-05-001
hose (3). Port a1 Port a2

Measurement of the main relief valve set pressure
on the rear control valve (connected to main
pump 2):
Remove the left travel motor forward hydraulic 4
hose (1).
5. Start the engine. Check for oil leaks at the pipe
connection part.
(122r9 qF). 3
Measurement:
1. Run the engine at high idle. 2
2. Measure the main relief valve set pressure on the
front control valve (connected to main pump 1)
with the right travel lever stroked in the FOR-
WARD position.
Measure the main relief valve set pressure on the
3
rear control valve (connected to main pump 2) 1 4
M2CG-05-034
with the left travel lever stroked in the FORWARD
position. Read the pressure when the relief valve 1- Pipe for Left Travel 3- Pipe for Right Travel
relieves. Forward Forward
3. Repeat the measurement three times in each di- 2 - Pipe for Left Travel Re- 4 - Pipe for Right Travel
rection. Calculate the average values. verse Reverse
T4-5-6
Evaluation:
Refer to T4-2 Performance Standards. Main Relief
Valve
Remedy:
Adjustment:
Adjust the set pressure of main relief valve if neces-
sary.
1. Loosen the lock nut.

: 22 mm
: 6 mm
: 22 mm
: 16.7 to 19.6 Nm (1.7 to 2.0 kgfm)
Front Control Valve T25N-03-05-030
Notes
16.7 to 19.6 Nm = 12 to 14 lbfft Main Relief
Valve
Lock Nut
Adjusting
Screw
Pressure Increase Pressure Decrease
W107-02-05-129
Rear Control Valve

T2CD-01-02-005
Lock Nut
Adjusting
Screw
T326-06-04-002
T4-5-7
SWING CONTROL VALVE Swing Pump
Preparations:
1. Stop the engine.
2. Remove the plug from pressure check port a4
(G1/4) at the swing pump delivery port.
: 6 mm
3. Install the tee and pressure gauge unit to pres-
sure check port a4.
: 19 mm Port a4
Tee : ST 6069 T25N-04-05-001
Pressure Gauge Unit : ST 6934 STD lever

(122r9 qF).
Swing Lock Pedal
Measurement:
1. Turn the swing lock pedal in the LOCK position
and lock the swing function.
2. Run the engine at the fast idle speed. Swing
Lever
3. Move the swing lever backward or forward slowly
to relieve the oil pressure. Read the pressure at
this time.
Evaluation:
T25U-04-01-001
T4-5-8
Adjustment:
Adjust the set pressure of the main relief valve while
checking the pressure gauge if necessary.

: 22mm
: 6 mm
: 22 mm
: 16.7 to 19.6 Nm (1.7 to 2.0 kgfm)
Relief Valve
Notes
T2CG-01-02-027
16.7 to 19.6 Nm = 12 to 14 lbfft
Adjusting Screw Lock Nut
T326-06-04-002
Lock Nut
Adjusting
Screw
W107-02-05-129
T4-5-9
3-SPOOL SOLENOID VALVE (COUNTER
WEIGHT, LIVE MAST FLIP CYLINDERS)
Preparations:
1. Stop the engine.
2. Remove the plug from pressure check port P (G
1/4) on the gantry raise / lower hydraulic source
selection control valve.
: 6 mm
sure check port P.
: 19 mm
Tee : ST 6069 Port P
(122r9 qF).
Measurement:
Relief Valve
1. Run the engine at high idle.
T2CG-01-02-028
2. Turn the gantry raise/lower switch to the LOWER
position and relieve the gantry raise/lower cylinder.
Read the pressure at this time.
Lock Nut
Evaluation: Adjusting
Refer to T4-2 Performance Standards. Screw
Adjustment:
sary.
2. Turn the adjusting screw. W107-02-05-129

T4-5-10
4-SPOOL SOLENOID VALVE (BOOM FOOT
PIN CYLINDERS, LOWER HYDRAULIC
POWER SOURCE)
Preparations:
1. Stop the engine.
2. Remove the plug from pressure check port P (G
1/4) on the gantry raise / lower hydraulic source
selection control valve. Port P
: 6 mm
sure check port P.
: 19 mm
Tee : ST 6069
Relief Valve
5. Keep the hydraulic oil temperature at 50r5 qC T2CG-01-02-029
(122r9 qF).
Measurement:
1. Run the engine at high idle.
2. Operate one arbitrary switch to relieve the pres-
sure from the cylinder. Check the pressure at this
time with the pressure gauge.
Evaluation:
Refer to T4-2 Performance Standards. Lock Nut
Adjusting
Adjustment: Screw
sary.

4. Check the set pressure after adjustment. W107-02-05-129
T4-5-11
LOWER CONTROL VALVE Lower Control Valve
Relief Valve Port PG
Preparation:
1. Stop the engine.
2. Remove plug from the pressure check port PG A
(R3/8) on the lower control valve. B
: 6 mm
3. Install tee and pressure gauge unit to the re-
moved plug port.
: 17 mm
Tee : ST 6068

(122r9 qF).
Measurement: T25N-03-05-019
1. Run the engine at high idle. Section A

Plug
2. While relieving the jack-up cylinder oil pressure by
operating the remote control box to jack-up the
cylinder, take a pressure gauge reading.
3. Repeat the measurement three times. Calculate
the average value.
Evaluation:
Adjustment:
Adjust the set pressure of the relief valve while
T25N-03-05-060
checking the pressure gauge if necessary. Section B
1. Loosen lock nut. Adjusting

Screw
2. Turn adjusting screw to adjust the set pressure.
3. Tighten lock nut.
4. Recheck the set pressure.
Lock Nut
T25N-03-05-021
Lock Nut
Adjusting
Screw
Pressure Pressure
Increase Decrease
W107-02-05-129
T4-5-12
OVERLOAD RELIEF VALVE SET PRES-
SURE
Summary:
1. No safe and reliable method to measure the
overload relief valve set pressure is available,
because the circuit oil pressure must be raised by
blocking the return circuit of the control valve and
applying an external load to a hydraulic actuator.
Doing so would create a high potential to easily
damage the machine.
2. Comparing the oil flow rate delivered from the
main pump, the quantity of relieving oil flow from
the overload relief valve is very small. Therefore,
checking the overload relief pressure by letting
the main pump deliver oil to the overload relief
valve does not meet the test conditions. Accord-
ingly, if the check is required, remove the over-
load relief valve from the machine, and perform
the unit test of the overload relief valve on a
specified test bench using the correct oil flow rate.
3. As explained above, checking the overload relief
valve pressure setting on the machine is not
recommended. Therefore, when the main circuit
relief pressure is normal, the overload relief
pressure setting is also considered to be normal.
T4-5-13
MAIN / SWING PUMP FLOW RATE
MEASUREMENT
x P-Q Control (Torque Control) Measurement:
Summary: 1. Keep the hydraulic oil temperature at 50r5 qC
Main / swing pump performance is checked by (122r9 qF).
measuring the pump flow rate with a hydraulic tester 2. Measure the maximum and minimum flow rates
installed at the main / swing pump delivery port (one under no load.
side) to be measured. Use the moment limiter and a 3. Select each switch position as follows:
pressure gauge at the same time. Slewing Speed Accelerator
Accelerator Grip
Control Dial Holding Switch
IMPORTANT: This measurement procedure is a Fast Idle Slow Idle Fast Speed ON
simple method. The measured data
will be lower by approx. 5 % than the
4. Adjust the main relief valve set-pressure in the
accurately measured value. To
front / rear / slewing control valve to each pres-
measure accurately, disconnect the
sure point specified along the main / slewing
return circuit from the control valve
pump P-Q curve. (Refer to T4-2-4, 6)
and connect it to the sump tank.
Slowly close the loading valve of the hydraulic
tester. Measure the flow rates and engine speeds
Preparations:
at the pressure points specified in the P-Q curve.
1. Stop the engine. Push the air bleed valve to bleed
air. Install a vacuum pump to the oil filler port.
NOTE: Operate the vacuum pump while connect-
ing the pump flow rate test line.
2. Remove the delivery hose from the main pump

(one side) to be measured. Install pipe (1) to the
pump delivery port by using the split flanges and
bolts, which were used to connect the removed
delivery hose.
: 41 mm
: 8 mm
3. Connect pipe (1) to hydraulic tester (4) with test
hose (2) and adapter (3). Install adapter (5), test
hose (6) and flange (7) to hydraulic tester (4).
: 8 mm
4. Install the delivery hose to flange (7) with split
flanges (8) and bolt (9).
: 8 mm
5. Install a pressure gauge to the main pump to be
measured. (Refer to T4-5-8 and 10.)
: 6 mm
: 19 mm
6. Remove the connector from displacement angle
7. Remove the vacuum pump. Loosen plug (10) on
the top of pump casing. Bleed air from the pump
casing until oil only comes out of the plug.
8. Fully open the loading valve of hydraulic tester.
T4-5-14
Evaluation:
1. Convert the measured flow rates to those at the 2. Standard Flow Rate
specified pump speed using the following formu- Refer to T4-2 Performance Standards.
las:
NOTE: When actually measuring, install pipe (1)
Qc = Ns × Q/Ne only to the pump to be measured.
Qc: Converted Flow Rate

Q: Measured Flow Rate
-1
Ns: Specified Pump Speed: 2000 min
Ne: Measured Engine Speed: Moment Limiter
1 2 3 4 5 6 7 8 9
Delivery Hose
(To Control Valve)
T1F3-04-05-010
Displacement Angle Propor-

Power Increase Solenoid Valve tional Solenoid Valve
T25N-04-05-001
10
1- Pipe (ST 6192) 4- Hydraulic Tester (ST 6299) 7- Flange (ST 6121) 10 - Plug
2- Test Hose (ST 6145) 5- Adapter G1 u UNF1-7/8 8- Split Flange (4506459)
(ST 6146)
3- Adapter G1 u UNF1-7/8 6 - Test Hose (ST 6145) 9- Bolt (J781030) (4 Used)
(ST 6146)
T4-5-15
x Pilot Characteristics
Summary: Measurement:
Main / slewing pump performance is checked by 1. Keep the hydraulic oil temperature at 50r5 qC
measuring the pump flow rate with a hydraulic tester (122r9 qF).
installed at the main / slewing pump delivery port 2. The pump flow rate in response to the external
(one side) to be measured. Use the moment limiter command pilot pressure is measured.
and a pressure gauge at the same time. 3. Select each switch position as follows:
Slewing Accelerator
IMPORTANT: This measurement procedure is a Accelerator Grip Speed Holding
simple method. The measured data Control Dial Switch
will be lower by approx. 5 % than the Fast Idle Fast Speed ON
accurately measured value. To
measure accurately, disconnect the
4. Adjust the reducing valve set-pressure to each
return circuit from the control valve
pressure point specified along the main / slewing
and connect it to the hydraulic oil
pump P-Q curve. (Pilot Characteristics) (Refer to
tank.
T4-2-5,7)
Measure the flow rates and engine speeds at the
Preparations:
pressure points specified in the P-Q curve.
1. Referring to steps 1 to 4 on page T4-5-16, con-
nect a hydraulic tester to the main pump to be
measured.
2. Remove the hose from displacement angle pro-
Evaluation:
portional solenoid valve port Pr1 of the main
1. Convert the measured flow rates to those at the
pump (displacement angle proportional solenoid
specified pump speed using the following formu-
valve port Psv3) to be measured. Install plug
las:
(4174545) (9/16 UNF) to the removed hose.
Qc = Ns u Q/Ne
: 19 mm
Qc: Converted Flow Rate
3. Install adapters (14) (3 used) to pressure reducing
Q: Measured Flow Rate
valve (15). Remove the hose from P1 (Refer to -1
Ns: Specified Pump Speed: 2000 min
T4-5-1) port in pressure reducing valve of the
Ne: Measured Engine Speed: Moment Limiter
4-unit solenoid valve and install hose (13).
Connect the other end of hose (13) to port P1 on
2. Standard Flow Rate
pressure reducing valve (15).
: 19 mm
4. Install tee (16) to port P2 in pressure reducing
valve (15). Install pressure gauge (17) and hose NOTE: When actually measuring, install pipe (1)
(13) to tee (16). Install hose (13) to the displace- only to the pump to be measured.
ment angle proportional solenoid valve.
: 19 mm
5. Install hose (13) and adapter (14) to port T in
pressure reducing valve (15). Remove plug L
from the return pipe. Install hose (13).
: 19 mm
6. Remove the connector from displacement angle
7. Remove the vacuum pump. Loosen plug (10) on
the top of pump casing. Bleed air from the pump
casing until oil only comes out of the plug.
8. Fully open the loading valve of hydraulic tester.
9. Start the engine. Check for oil leaks at the pipe
connection part.
T4-5-16
1 2 3 4 5 6 7 8 9
Delivery Hose
(To Control Valve)㩷
T1F3-04-05-010
Displacement Angle
Proportional Sole-
Port Pr1㩷 noid Valve㩷 View A
Port Psv3㩷
T25N-04-05-011 T25N-04-05-001
A 10
Pressure Reducing Valve

Port Position㩷
Pressure Re-
Return Pipe㩷
ducing Valve㩷
T
L
14
17 13㩷
P1 P2
14
To Displacement Angle
Valve㩷
T25N-04-05-010
13㩷 16 14 15 14 13
1 - Pipe E (ST 6192) 5 - Adapter G1 u UNF1-7/8 9 - Bolt (J781030) (4 Used) 15 - Pressure Reducing Valve
(ST 6146) (4325439)
2 - Test Hose (ST 6145) 6 - Test Hose (ST 6145) 10 - Plug 16 - Tee 9/16 UNF x G1/4
(ST6450)
3 - Adapter G1 u UNF1-7/8 7 - Flange (ST 6121) 13 - Hose 9/16 UNF 17 - Pressure Gauge
(ST 6146) (4304905) (ST 6931)
4 - Hydraulic Tester (ST 6299) 8 - Split Flange (4506459) 14 - Adapter 9/16 UNF x G3/8
(A852133)
T4-5-17
REGULATOR ADJUSTMENT (MAIN PUMP)
x Minimum and Maximum Flow Rate Adjustment

This regulator can adjust minimum and maximum
flow rates with adjusting screws (1) and (2) at each
main pump body.
3 4 2 4 3
1 1
Main Pump1 Main Pump2 T1F3-03-01-003
1 - Adjusting Screw (For 2- Adjusting Screw (For Maxi- 3- Lock Nut (For Minimum 4- Lock Nut (For Maximum
Minimum Flow Adjustment) mum Flow Adjustment) Flow Adjustment) Flow Adjustment)

1. Minimum Flow Rate Loosen lock nut (3) and turn ad- • Other control characteristics remain
justing screw (1). unchanged. Notice that the required
Q Rotating adjusting screw (1) 1/4 a power is increased at maximum de-
turn clockwise increases the mini- livery pressure if tightened exces-
mum pump flow rate by 5.0 L/min. sively.
: 24 mm • Securely retighten lock nut (3) after
: 130 Nm (13.3 kgfm) the adjustment.
I
2. Maximum Flow Rate Loosen lock nut (4) and turn ad- • Other control characteristics remain
justing screw (2). unchanged, except that only maxi-
Q Rotating adjusting screw (2) 1/4 a mum oil rate varies.
turn clockwise decreases the • Securely retighten lock nut (4) after
maximum pump flow rate by 6.2 the adjustment.
L/min.
: 30 mm
: 240 Nm (24.5 kgfm) Notes
130 Nm = 961 lbfft
240 Nm = 177 lbfft
I
T4-5-18
x Torque Adjustment (P-Q Control)
For torque adjustment, similarly adjust both the ad-
justing screws (5) and (6) at the main pumps 1 and
2. Pressure change due to adjustment is that when
both the pumps are pressurized at the same time.
9 8
5
10
T1F3-03-01-008

1. Outer Spring Adjustment Loosen lock nut (7) and turn adjust- • When adjusting screw (5) is turned,
ing screw (5). inner spring (8) set-force varies.
Q
Therefore, when adjusting screw
Rotating adjusting screw (5) 1/4 a (5) is turned clockwise, turn ad-
turn clockwise: justing screw (6) 2.17 times turns
• Compensating Starting Pressure: of adjusting screw (5) counter-
2
+ 1.74 MPa (17.8 kgf/cm ) clockwise to keep inner spring (8)
• Torque: set-force unchanged.
+ 84.3 Nm (8.6 kgfm) • Securely retighten lock nut (7) and
: 46 mm:Lock Nut (7) nut (10) after the adjustment.
P1+P2 Pd : 160 Nm (16.5 kgfm)
2. Inner Spring Adjustment Loosen lock nut (10) and turn ad- • Securely retighten lock nut (10) af-
justing screw (6). ter the adjustment.
Q
Rotating adjusting screw (6) 1/4 a Notes
turn clockwise: 1.74 MPa = 254 psi
• Pump flow rate: 84.3 Nm = 62 lbfft
+ 10.2 L/min
• Torque: 160 Nm = 118 lbfft
+ 56.9 Nm (5.8 kgfm) 10.2 L/min = 622 in3/min
P1+P2 Pd : 13 mm:Lock Nut (10) 56.9 Nm = 42 lbfft
: 16 Nm (1.6 kgfm)
16 Nm = 12 lbfft
T4-5-19
x Pilot Pressure Characteristics
11
12
T25N-03-01-011

1. Pilot Pressure Characteris- Loosen lock nut (11) and turn ad- • Securely retighten lock nut (11)
tics justing screw (12). after the adjustment.
Rotating adjusting screw (12) 1/4 a
Q
turn clockwise:
• Pump flow rate:
16.2 L/min
• Flow rate control starting pres-
sure: Notes
2
+ 150 kPa (1.5 kgf/cm )
16.2 L/min = 988 in3/min
: 13 mm:Lock Nut (11)
: 16 Nm (1.6 kgfm) 150 kPa = 21 psi
Pi 16 Nm = 12 lbfft
T4-5-20
REGULATOR ADJUSTMENT (SWING
PUMP)
x Minimum and Maximum Flow Rate Adjustment

This regulator can adjust minimum and maximum
flow rates with adjusting screws (1) and (2) at each
main pump body.
4
3
1 2
T25N-03-01-005
1- Adjusting Screw (For 2- Adjusting Screw (For Maxi- 3- Lock Nut (For Minimum 4- Lock Nut (For Maximum
Minimum Flow Adjustment) mum Flow Adjustment) Flow Adjustment) Flow Adjustment)

1. Minimum Flow Rate Loosen lock nut (3) and turn ad- • Other control characteristics re-
justing screw (1). main unchanged. Notice that the
Q
Rotating adjusting screw (1) 1/4 a required power is increased at
turn clockwise increases the mini- maximum delivery pressure if
mum pump flow rate by 3.2 L/min. tightened excessively.
: 24 mm • Securely retighten lock nut (3) after
: 130 Nm (13.3 kgfm) the adjustment.
Pi
2. Maximum Flow Rate Loosen lock nut (4) and turn ad- • Other control characteristics re-
justing screw (2). main unchanged, except that only
Q
Rotating adjusting screw (2) 1/4 a maximum oil rate varies.
turn clockwise decreases the • Securely retighten lock nut (4) after
maximum pump flow rate by 3.2 the adjustment.
L/min.
: 24 mm
: 130 Nm (13.3 kgfm)
Notes
130 Nm = 96 lbfft
Pi
T4-5-21
x Torque Adjustment (P-Q Control)
9 8
5
10
T25N-03-01-013

1. Outer Spring Adjustment Loosen lock nut (7) and turn ad- • When adjusting screw (5) is
justing screw (5). turned, inner spring (8) set-force
varies. Therefore, when adjusting
Q Rotating adjusting screw (5) 1/4 a screw (5) is turned clockwise, turn
turn clockwise: adjusting screw (6) 1.61 times
• Compensating Starting Pressure: turns of adjusting screw (5) coun-
2
+ 1.9 MPa (19 kgf/cm ) terclockwise to keep inner spring
• Torque: (8) set-force unchanged.
+ 26 Nm (2.6 kgfm) • Securely retighten lock nut (7) and
: 46 mm:Lock Nut (7) nut (10) after the adjustment.
P1+P2 Pd
: 160 Nm (16.5 kgfm)
2. Inner Spring Adjustment Loosen lock nut (10) and turn ad- • Securely retighten lock nut (10)
justing screw (6). after the adjustment.
Q Rotating adjusting screw (6) 1/4 a
turn clockwise:
• Pump flow rate: Notes
+ 5.8 L/min 1.9 MPa = 276 psi
• Torque: 26 Nm = 19 lbfft
+ 16 Nm (1.6 kgfm)
: 13 mm:Lock Nut (10) 160 Nm = 118 lbfft
P1+P2 Pd : 16 Nm (1.6 kgfm) 5.8 L/min = 354 in3/min
16 Nm = 12 lbfft
T4-5-22
x Pilot Pressure Characteristics
11
12
T25N-03-01-012

1. Pilot Pressure Characteristics Loosen lock nut (11) and turn ad- • Securely retighten lock nut (11)
justing screw (12). after the adjustment.
Q
Rotating adjusting screw (12) 1/4 a
turn clockwise:
• Pump flow rate: 14 L/min
• Flow rate control starting pres-
2
sure: + 180 kPa (1.8 kgf/cm ) Notes
: 13 mm:Lock Nut (11) 14 L/min = 854 in3/min
: 16 Nm (1.6 kgfm) 180 kPa = 26 psi
Pi 16 Nm = 12 lbfft
T4-5-23
SWING MOTOR DRAINAGE
Summary: Drain Hose Swing Motor
Turn the swing lock pedal to the LOCK position and
turn the swing brake switch in ON. Operate the sw-
ing lever and relieve the swing relief valve. Under
this condition, measure the drain oil amount from the
swing motor to check the swing motor performance.
1. Secure the inspectors’ safety during the meas-

urement. Take care not to damage any sur-
rounding buildings or vegetation.
2. The amount of drain oil from the swing motor will
be greatly affected by the oil temperature. Keep T2CD-04-05-002
the oil temperature in the proper range.
Preparations:
1. Place the machine on a level and solid ground
with ample space for slewing. Do not measure on
a slope.
(122r9 qF). Rotate the swing motor and warm the
inside of motor.
3. Stop the engine. Remove drain hose (1) from the
swing motor at the return oil port to the sump
tank. Install plug (1-3/16-12UN) to the removed
return oil ports to the sump tank.
: 36 mm
T4-5-24
Measurement:
Amount of Oil Drained While Relieving Swing
1. Attach the basic boom with the boom angle set at
60q. (Or dismount the front attachment and
counterweight.)
2. Turn the swing lock pedal to the LOCK position
and turn the swing brake switch in ON.
3. Start the engine and run it at high idle. While op-
erating the swing lever full stroke, receive the hy- 2m
draulic oil coming out of the drain hose and
measure the time and the volume at the same
time. (6.5ft)
4. Repeat the measurement three times each in
both clockwise and counterclockwise directions
and calculate the average value. 60q㩷
5. Take the measurement for more than 45 sec-
onds.
Evaluation:
*Conversion of the Measured Values T25N-04-05-013
Receive the drain oil with a measuring vessel such

as a measuring cylinder or cup. Obtain the converted
drain oil amount using the formula below:
UQ= 60 u q / t
Where
UQ : Amount of drain oil per minute (L/min)
t : Time measuring Time (seconds)
q : Total amount of drain oil Amount (L)
T107-06-05-008
T4-5-25
TRAVEL MOTOR DRAINAGE
Summary:
1. The travel motor performance is checked by Drain Hose Travel Motor
measuring the drain oil amount from the travel
motor while driving the machine straight on a
level solid surface to rotate the travel motor.
2. Secure the inspectors’ safety during the meas-
urement. Take care not to damage any sur-
rounding buildings or vegetation. Be sure to use
a guide to check the safety in the front of and the
rear of the machine.
3. The travel motor performance should be judged
comprehensively while referring to the check re-
sults of travel speeds, mistrack amount together
with the drain oil amount.
4. Drain oil amount from the travel motor will be
greatly affected by the oil temperature. Keep the
oil temperature in the proper range. M2CG-07-010
Preparations: NOTE: The illustration shows the right travel.

(122r9 qF). Rotate the travel motor to warm the
inside of the motor.
2. Stop the engine. Remove drain hose from the
travel motor. Install plug (3/4-16UNF) to the re-
moved hose end.
Install drain measuring hose (3/4-16UNF) to the
travel motor.
: 27 mm
T4-5-26
Measurement:
CAUTION: When doing any work near the

rotating parts, take care not to allow your
hand, foot, and/or clothes to become entan-
gled in the rotating parts.

60q. (Or dismount the front attachment and
counterweight.)
2. Insert a round bar (Dia.: 100 mm, Length: 200 2m
mm) between drive tumbler and track link.
3. Start the engine. Run the engine at fast idle (6.5ft)
speed. Operate the travel lever to FORWARD
according to the guide and relieve the travel.
4. Receive the hydraulic oil coming out of the drain
60q㩷
hose and measure the time at the same time.
5. Repeat the measurement three times each side
and calculate the average value.
onds.
T25N-04-05-013
Evaluation:
*Conversion of the Measured Values
UQ= 60 u q / t
Where
T4-5-27
DERRICKING MOTOR DRAINAGE
Summary:
1. Engage the boom derricking drum lock. Operate
the boom derricking lever to LOWER slowly in
order to relieve. Under this condition, measure
the drain oil amount from the boom derricking
motor and check the boom derricking motor per-
formance.
2. Secure the inspectors’ safety during measure-
ment. Take care not to damage any surrounding
buildings or vegetation.
3. Drain oil amount from the boom derricking motor
will be greatly affected by the oil temperature.
Maintain the oil temperature in the proper range.
Preparations:
CAUTION: Check around the drum, the con-
dition of boom and hook, and the safety
around machine.

(122r9 qF). Rotate the boom derricking motor Drain Port
and warm the inside of motor.
Boom Derricking
2. Stop the engine. Remove the drain hose from the Motor㩷
boom derricking motor at the return oil port to the M2CG-07-057
hydraulic oil tank. Install plug (1-3/16-12UN) to
the removed return oil ports to the hydraulic oil
tank.
: 36 mm
T4-5-28
Measurement:
60q.
weight.)
2. Start the engine and engage the boom derricking
drum lock. Run the engine at the fast idle speed.
Operate the boom derricking lever to LOWER
slowly in order to relieve.
3. Receive the hydraulic oil coming out of the drain
hose and measure the time at the same time. 2m
4. Repeat the measurements three times. Calculate
the average values. (6.5ft)
onds.
Evaluation: 60q㩷
*Conversion of the Measured Values
T25N-04-05-013
UQ= 60 u q / t
Where
T4-5-29
(Blank)
T4-5-30
OPERATIONAL PERFORMANCE TEST / Adjustment
POWER INCREASE PRESSURE
CALIBRATION
MC2/A is used to store the adjusted value of the

horsepower output. Adjust horsepower and pressure in
the following cases:
x When MC2/A is replaced.

x When the main pump or power shift solenoid valve is
replaced.
x When the engine speed has changed.
T4-6-1
Preparation:
1. Install the pressure measuring hose (4622751)
and pressure gauge (5 MPa) to quick coupler (1).
Adjustment:
1. Turn drum rotation sensor switch (7) for front / rear
/ boom derricking drums to ON position.
2. Turn accelerator holding switch (6) to accelerator
preset position (SET) (9) and turn key switch (3) to
Power Increase Solenoid Valve
ON position under this condition. 1
T25N-04-06-001
NOTE: After this, the pilot oil pressure indicator at
monitor panel (2) blinks every 0.5 second.
3. After the pilot oil pressure indicator blinks, turn

accelerator holding switch (6) to accelerator 2
unlock position (OFF) (8).
3
M25N-03-344
4
5
6
T25U-04-01-001
6 8
M25N-03-084
T4-6-2
Calibration Starting
1. Start the engine.
2. Turn front / rear drum auto stop override switches
(4, 5) to ON position.
NOTE: Now, MC2/A blinks the pilot oil pressure 2
indicator at monitor panel (2). (Refer to
Control System.) 3
3. If the pilot oil pressure indicator blinks other than

every 0.5 second, turn front / rear drum auto stop
override switches (4 and 5) to OFF position.
4. Turn accelerator holding switch (6) to accelerator
preset position (SET) (9) and turn accelerator
unlock switch to OFF position (8).
NOTE: Now, the power shift decreases gradually.
The pilot oil pressure indicator blinks a cy- 6
cle of 0.4 second ON and 0.1 second OFF
during this time. 4
5. When the power shift pressure reaches the set 5

pressure (0.3 MPa), turn accelerator holding
switch (6) to accelerator preset position (SET) (9)
and turn accelerator unlock switch to OFF position
(8). T25U-04-01-001
NOTE: Normal completion:

Pilot oil pressure indicator: ON
Abnormal completion:
Pilot oil pressure indicator: Blinking every
0.1 second
Normal completion condition:

• Power shift electric current offset d Offset adjust- 6 8
ing range (r150 mA)
[Power shift electric current offset Output current
- Adjustment point power shift electric current (608
mA)]
• Output current d Upper limit electric current (800
M25N-03-084
mA)
9
IMPORTANT: When turning the key switch (3) to

OFF position, record the completed
calibration to EEPROM (MC2/A) for
five seconds. Do not operate key
switch (3) during this time.
6. Turn the key switch (3) to OFF position and wait

for five seconds or longer.
7. Remove the pressure gauge.
Notes
5 MPa = 51 kgf/cm2 = 725 psi
0.3 MPa = 3 kgf/cm2 = 44 psi
T4-6-3
BRAKE PEDAL UNIT ADJUSTMENT
IMPORTANT: After repairing or inspecting the

brake pedal unit, adjust the brake
pedal unit.
If failing to make this adjustment, the
brake is unlikely to work.
Adjustment:
A
x Adjusting brake pedal position
1. Tighten locknut (1) so that dimension A becomes C
specification.
Dimension A: 45 mm
2. Loosen lock nut (2). Tighten stopper bolt (3) until
lever (4) is clear of stopper bolt (3).
3. At this time, check if rod (8) of the pressure
reducing valve is pushed to its stroke end.
4. Check if height of floor plate (6) and pin (5) B
T25N-04-06-005
(dimension C) is set to specification.
Dimension C: 72r2 mm Brake
Pedal
5. If dimension C is different from specification,
adjust as follows. 5 6 1
5-1. Loosen lock nut (7).
: 17 mm
5-2. Attach a spanner onto width across flats (9) of
rod (8) and turn rod (8) in the adjusting direction.
: 14 mm
5-3. When dimension C becomes specification,
tighten lock nut (7).
: 17 mm
: 19.5r2.0 Nm (2.0r0.2 kgfm)
6. Loosen stopper bolt (3) until stopper bolt (3) gets 4 3 2
in contact with lever (4).
T25N-04-06-005
7. When stopper bolt (3) contacts lever (4), loosen
stopper bolt (3) a half turn from that position and
7 8
lock it with lock nut (2).
IMPORTANT: When if dimensions B and C are dif-

ferent from specification, return to
step 2 for adjustment.
8. Check if dimensions B and C are specification.

Dimension B: 27 to 28 mm
Notes Pressure Reducing

Valve
A: 45mm = 1.77 in T25N-04-06-002
C: 72r2 mm = 2.83r0.08 in
B: 27 to 28mm = 1.06 to 1.10 in
19.5r2.0 Nm = 14.3r1.5 lbfft
T4-6-4
9. Loosen lock nut (10) and tighten stopper bolt (11) Lock Pedal
sufficiently. 4 8
10. Lower lever (4) until rod (8) of the pressure
reducing valve reaches its stroke end. Hold it in
position.
11. Loosen stopper bolt (11) until stopper bolt (11)
gets in contact with lever (4). 14
12. When stopper bolt (11) contacts lever (4), loosen
stopper bolt (11) a half turn from that position and
lock it with lock nut (10). 13
x Adjusting pedal lock position

13. Loosen 2 bolts (13). 12 11 10 Pressure Reducing
Valve
T25N-04-06-006
IMPORTANT: If lock position is too low, unlocking
is unlikely to be made.
Adjust it with care.
14. By changing the thickness of shim (14) and by

repositioning latch (12), make adjustment so that
stroke required for unlocking the pedal is obtained
and locking at stroke end is achieved.
Thicknesses of shims (14): 4.5 mm
6.0 mm
9.0 mm
12.0 mm
15. In pedal lock position, check if dimensions D is

specification.
Dimension D: 40 mm or more D T25N-04-06-006
Notes
4.5mm = 0.18 in
6.0mm = 0.24 in
9.0mm = 0.35 in
12.0mm = 0.47 in
40mm = 1.6 in
T4-6-5
(Blank)
T4-6-6
SECTION 5
TROUBLESHOOTING
—CONTENTS—
Group 1 Diagnosing Procedure Group 3 Troubleshooting A
Introduction .................................................. T5-1-1 Troubleshooting A Procedure .......................T5-3-1
Diagnosing Procedure.................................. T5-1-2 Failure of MC2/A or MC2/B Battery and
Troubleshooting Monitor............................... T5-1-4 Sensor System Power Supply ....................T5-3-2
Failure of Engine Control System ...............T5-3-17
Group 2 Component Layout Failure of Brake Control System.................T5-3-20
Main Components ........................................ T5-2-1 Failure of Main Pump Delivery Flow
Control System .........................................T5-3-32
Failure of Main Pump Power Increase
Control System .........................................T5-3-36
Failure of Swing Pump Discharge Rate
Control System .........................................T5-3-38
Failure of Swing Alarm Control System ......T5-3-41
Failure of Drum Rotation Sensor
Control System .........................................T5-3-44
Failure of Engine Start Interlock
Control System .........................................T5-3-48
Failure of Pilot Oil Pressure Indicator
Control System .........................................T5-3-52
Failure of Winch Motor Cutoff Pressure
Control System .........................................T5-3-54
Failure of Boom Derricking Drum Automatic
Stop Control system..................................T5-3-56
Failure of Front Drum Automatic Stop
Control System .........................................T5-3-66
Failure of Rear Drum Automatic Stop
Control System .........................................T5-3-70
Failure of Third Drum Automatic Stop
Control System .......................................T5-3-74
Failure of Second Overhoist Automatic Stop
Control System .........................................T5-3-78
Failure of Front and Rear Motor Speed
Control System .........................................T5-3-82
Failure of Boom Derricking Drum Speed
Control System .........................................T5-3-86
Failure of Tower Jib Derricking
2-Speed (Flow Combining) Restricting
System......................................................T5-3-88
Failure of External Moment Limiter
Indicator Control System ..........................T5-3-90
Failure of Oil Cooling Fan Rotation
Control System .........................................T5-3-92
C-5-1
Group 4 Troubleshooting B
Troubleshooting B Procedure....................... T5-4-1 Fault Code W48..........................................T5-6-27
Troubleshooting List ..................................... T5-4-2 Fault Code W49..........................................T5-6-28
Engine System Troubleshooting .................. T5-4-4 Fault Code W90..........................................T5-6-30
Actuator System Troubleshooting .............. T5-4-11 Fault Code W91..........................................T5-6-31
Hoisting Drum System Troubleshooting ..... T5-4-12 Fault Code WA1 .........................................T5-6-32
Boom Derricking Drum System Fault Code WA2 .........................................T5-6-32
Troubleshooting........................................ T5-4-15 Fault Code WA3 .........................................T5-6-32
Swing System Troubleshooting.................. T5-4-16 Fault Code WB1 .........................................T5-6-33
Travel System Troubleshooting.................. T5-4-18 Fault Code WB2 .........................................T5-6-33
Other Troubleshooting................................ T5-4-20 Fault Code WB3 .........................................T5-6-34
Group 5 Troubleshooting C Group 7 Troubleshooting E

Troubleshooting C Procedure Troubleshooting E Procedure .......................T5-7-1
(Troubleshooting For Monitor)...................... T5-5-1
Malfunction of Coolant Temperature Group 8 Electrical System Inspection
Gauge ........................................................ T5-5-2 Precautions for Inspection
Malfunction of Fuel Gauge ........................... T5-5-3 and Maintenance ........................................T5-8-1
Malfunction of Engine Oil Pressure Battery Voltage Check ..................................T5-8-3
Indicator ..................................................... T5-5-4 Fusible Link Inspection .................................T5-8-3
Malfunction of Glow Lamp............................ T5-5-5 Fuse Inspection ............................................T5-8-4
Malfunction of Coolant Level Indicator ......... T5-5-6 Alternator Inspection.....................................T5-8-5
Malfunction of Abnormal Controller Continuity Check ..........................................T5-8-6
Indicator ..................................................... T5-5-7
Malfunction of Air Filter Restriction
Indicator ..................................................... T5-5-8
Malfunction of Overheat Indicator ................ T5-5-9
Malfunction of Alternator Indicator.............. T5-5-10
Malfunction of Brake Unapplied Indicator .. T5-5-11
Malfunction of Hour Meter.......................... T5-5-12
Malfunction of Pilot Oil Pressure
Indicator ................................................... T5-5-12
Group 6 Troubleshooting D
Troubleshooting D Procedure ...................... T5-6-1
Fault Code Table .......................................... T5-6-2
Fault Code E20, E22.................................... T5-6-4
Fault Code E21, E26.................................... T5-6-6
Fault Code E30 ............................................ T5-6-8
Fault Code E31 .......................................... T5-6-10
Fault Code E40 .......................................... T5-6-13
Fault Code E43 .......................................... T5-6-13
Fault Code E44 .......................................... T5-6-13
Fault Code E45 .......................................... T5-6-14
Fault Code E50 .......................................... T5-6-16
Fault Code E51 .......................................... T5-6-18
Fault Code E52 .......................................... T5-6-20
Fault Code W47 ......................................... T5-6-24
C-5-2
TROUBLESHOOTING / Diagnosing Procedure
INTRODUCTION
Inspection procedures for troubleshooting are

presented in an orderly fashion in this section so as to
enable you locate the source of any problems that may
arise.
The troubleshooting section consists of 8 groups.
• Diagnosing procedure
• Component layout
• Troubleshooting A (Control System)

Use this group when a controller failure indicator
on the monitor panel is blinking.
Example: Abnormal accelerator control.
• Troubleshooting B (Base Machine Operation

System)
Use this group when any trouble exists in the
base machine operation system except the main
controller and/or auto-stop controller system.
Example: Hoist and/or lower function is
inoperable.
• Troubleshooting C (Monitor System)

Use this group when any trouble regarding
monitors such as gauges and/or indicators occur.
Example: Fuel gauge is inoperable.
• Troubleshooting D (IDU System)

Use this group when auto-stop is performed
although auto-stop is not required.
• Troubleshooting E (Engine Control System)

Use this group when the ECU lamp blinks and
displays the fault code.
(ECU records the situation of faulty electrical
signal system as the fault code according to the
self-diagnosis function.)
• Electrical System Check Method

Refer to this group when precautions and/or
inspection data for the electrical system check is
required.
T5-1-1
DIAGNOSING PROCEDURE
These six basic steps are essential for efficient

troubleshooting:
1. Study the system
• How is the machine configured

• What types of devices are being used
(Configuration, function and etc)
T107-07-01-001
2. Ask the operator

Ask the operator how he/she perceives about the
circumstances of the trouble to clarify the details,
as the perception of troubles is different
depending on the person.
• How is the machine being used? (Find out if the

machine is being operated correctly)
• When was the trouble noticed, and what types of
work the machine doing at that time?
• What are details of the trouble? Is the trouble
getting worse, or did it appear suddenly for the
first time?
• Did the machine have any other troubles
previously? If so, which parts were repaired
before?
T107-07-01-002
3. Inspect the machine

Before starting the troubleshooting procedure,
check the machine’s daily maintenance points, as
shown in the operator’s manual.
Also, check the electrical system, including the

batteries, as troubles in the electrical system such
as low battery voltage, loose connections and
blown fuses will result in malfunction of the
controllers, causing total operational failure of the
machine.
If troubleshooting is started without noticing a

blown fuse, incorrect diagnosis may result along
with a large amount of lost time. Be sure to check
if any fuse has blown before starting T107-07-01-003
troubleshooting.
Fuse failure is often caused by a fine crack in the
fuse, and such fine cracks are very hard to detect
by visual inspection.
Always check fuses using a tester.
T5-1-2
4. Operate the machine yourself
Try to identify the trouble by operating the
machine yourself.
If the trouble cannot be confirmed, stop the
engine and obtain further details of the
malfunction from the operator.
Also, check for any incomplete connections of the
wire harnesses.
5. Perform troubleshooting
CAUTION: Never attempt to disconnect

harnesses or hydraulic lines
while the engine is running. The T324-07-01-002
machine may malfunction or

pressurized oil may spout,
possibly resulting in personal
injury. Be sure to stop the engine
before disconnecting harnesses
or hydraulic lines.
First identify in which group the trouble is

present. Then, perform the troubleshooting,
system by system, in accordance with the
classification of Troubleshooting A, B, C, D and
E as described in this group.
6. Trace possible causes

Before reaching a conclusion, check the most
likely causes again. Try to identify the actual
cause of the trouble.
Based on your conclusion, make a plan for
appropriate repairs to avoid consequent
malfunctions.
T324-07-01-003
T5-1-3
TROUBLESHOOTING MONITOR
Outputs the diagnostic results of analog inputs, digital

inputs and digital outputs of MC2/A, MC2/B and the
IDU.
The diagnostic results are indicated on the display
connected to the IDU.
Maintenance
Key Switch
Indication
T2CD-01-02-012
1. Turn ON the maintenance key switch, and press
key on the ML window to indicate the
maintenance menu.
T2CD-05-01-001
2. Select “Monitor” by pressing or key,

then press key to indicate the monitor
menu.
T2CD-05-01-002
3. Select the item you want to display in the

monitor menu using or key, then
press key.
T2CD-05-01-003
T5-1-4
MC2/A Analog Inputs
Display
MC2/A Input/Output Monitor
1/6
MC2/A AI1 MC2/A AI2 MC2/A AI3
THROT.GRIP x.xx V DD HST PRS x.xx V SL RGT PRS x.xx V x.
THROT.FOOT x.xx V DD LWR PRS x.xx V SL LFT PRS x.xx V L
DD_CTRL_SP x.xx V FD HST PRS x.xx V PILOT PRS x.xx V N
THROL.M.P. x.xx V FD LWR PRS x.xx V FD BRK PRS x.xx V LO
SL_CTRL_SP x.xx V RD HST PRS x.xx V RD BRK PRS x.xx V H
THROT.3RD x.xx V RD LWR PRS x.xx V 3D BRK PRS x.xx V N
TR_RGT_PRS x.xx V 3D HST PRS x.xx V AN_IN22 x.xx V **
TR_LFT_PRS x.xx V 3D LWR PRS x.xx V DAN_IN23 OFF **
Ĺ Ļ Page Selection ×Return
Item
Item Signal name Display Normal range

THROT.GRIP Accelerator grip signal x.xx V 0.95 to1.05
THROT.FOOT Accelerator pedal signal x.xx V 0.05 to 0.70
DD_CTRL_SP Boom derricking speed dial x.xx V 0.64 to 0.93
THROL.M.P. No connection x.xx V
MC2/A_AI1
SL_CTRL_SP Slewing speed dial signal x.xx V 0.64 to 0.93
THROT.3RD No connection x.xx V
TR_RGT_PRS Right travel remote control pressure x.xx V 0.40 to 0.84
TR_LFT_PRS Left travel remote control pressure x.xx V 0.40 to 0.84
DD HST PRS Boom derricking drum hoisting remote control pressure x.xx V 0.40 to 0.84
DD LWR PRS Boom derricking drum lowering remote control pressure x.xx V 0.40 to 0.84
FD HST PRS Front drum hoisting remote control pressure x.xx V 0.40 to 0.84
FD LWR PRS Front drum lowering remote control pressure x.xx V 0.40 to 0.84
MC2/A_AI2
RD HST PRS Rear drum hoisting remote control pressure x.xx V 0.40 to 0.84
RD LWR PRS Rear drum lowering remote control pressure x.xx V 0.40 to 0.84
3D HST PRS Third drum hoisting remote control pressure x.xx V 0.40 to 0.84 * Option
3D LWR PRS Third drum lowering remote control pressure x.xx V 0.40 to 0.84 * Option
SL RGT PRS Right slewing remote control pressure x.xx V 0.40 to 0.84
SL LFT PRS Left slewing remote control pressure x.xx V 0.40 to 0.84
PILOT PRS Primary pilot pressure x.xx V 0.40 to 0.72
FD BRK PRS Front drum brake depressing pressure x.xx V 0.40 to 0.72 * Option
MC2/A_AI3
RD BRK PRS Rear drum brake depressing pressure x.xx V 0.40 to 0.72 * Option
3D BRK PRS No connection x.xx V
AN_IN22 No connection x.xx V
DAN_IN23 No connection ON/OFF
Conditions of the normal range

1. The engine is running.
2. The auto stop is not operating.
3. The gate lock is in the lock position.
4. All the levers are in the neutral positions.
5. All the dials and pedals are in theminimum positions.
6. All the switches are in the normal or OFFpositions.
T5-1-5
MC2/A Analog Inputs/Outputs
Display
2/6
MC2/A_AI4 MC2/A_AI5 MC2/A_AIO
M_PMP_CUR xxxx mA MAIN_B xx.xx V THROT.OUT xx.xx V
INC._TQ._CUR xxxx mA 24V_1 xx.xx V
RM_CUT_OFF 24V_2 xx.xx V
DM_CAP_CUR xxxx mA 24V_3 xx.xx V
SL_PMP_CUR xxxx mA 5V x.xx V
FM_CUT_OFF OFF
3M_CAP_CUR xxxx mA
SL_ALAM_LP OFF ENG.TORQUE xxxxx
Item

M_PMP_CUR Main pump displacement angle proportional solenoid valve: xxxx mA 680 to 720
Control current
INC._TQ._CUR Torque increase proportional solenoid valve: Control current xxxx mA 0 to 720
RM_CUT_OFF No connection
DM_CAP_CUR Derricking motor absorption volume proportional solenoid xxxx mA 630 to 670
MC2/A_AI4 valve: Control current
SL_PMP_CUR Slewing pump displacement angle proportional solenoid xxxx mA 0 to 60
valve: Control current
FM_CUT_OFF No connection
3M_CAP_CUR No connection
SL_ALAM_LP No connection
MAIN_B Main power supply voltage xx.xx V 24.00 to 32.00
24V_1 Sensor power supply voltage (for detection switches) xx.xx V 21.60 to 26.40
MC2/A_AI5 24V_2 Throttle control switch power supply voltage xx.xx V 21.60 to 26.40
24V_3 Emergency operation switch power supply voltage xx.xx V 21.60 to 26.40
5V Sensor power supply voltage x.xx V 4.97 to 5.03
THROT.OUT Accelerator output voltage xx.xx V 0.90
MC2/A_AIO
ENG.TORQUE Engine load xxxxx OFF

5. All the dials and pedals are in the minimum positions.
6. All the switches are in the normal or OFF positions.
T5-1-6
MC2/A Digital Inputs
Display
3/6
MC2/A DI1 MC2/A DI2 MC2/A DI3
3D_SEL. OFF GATE_LOCK OFF M_PMP_FIX. OFF
AUX_SEL. OFF ATTACHMENT * S_PMP_FIX. OFF
FREE_ALARM OFF DG_IN10 OFF FREE_MD_SW OFF
DM_FIX_SW OFF OVERH2_SIG ON FD_FREE_SW OFF
DG_IN4 OFF ENG.START OFF RD_FREE_SW OFF
DG_IN5 OFF DG_IN13 ON 3D_FREE_SW OFF
DG_IN6 OFF THROT.FIX OFF SL_BRK_SW OFF
D_R._IND. OFF THROT.PRE OFF DG_IN23 OFF
Item

3D_SEL. No connection ON/OFF
AUX_SEL. No connection ON/OFF
FREE_ALARM No connection ON/OFF
DM_FIX_SW No connection ON/OFF
MC2/A DI1
DG_IN4 No connection ON/OFF
D_R._IND. Drum rotation sensing stop switch ON/OFF OFF
GATE_LOCK Gate lock lever position signal ON/OFF OFF
*Crane operation: CRANE,
CRANE/TOWER Tower operation: TOWER
ATTACHMENT Attachment signal
/ALLON/ALLOFF ALLON: Both contacts closed
ALLOFF: Both contacts open
MC2/A DI2 DG_IN10 No connection ON/OFF
OVERH2_SIG Boom 2nd overhoist switch signal ON/OFF ON
ENG.START Engine start signal ON/OFF OFF
THROT.FIX Throttle lock switch ON/OFF OFF
THROT.PRE Throttle preset switch ON/OFF OFF
M_PMP_FIX. No connection ON/OFF
S_PMP_FIX. Slewing pump discharge rate lock switch ON/OFF OFF
FREE_MD_SW Brake mode switch ON/OFF OFF * Option
FD_FREE_SW Front drum free mode switch ON/OFF OFF * Option
MC2/A DI3
RD_FREE_SW Rear drum free mode switch ON/OFF OFF * Option
3D_FREE_SW No connection ON/OFF
SL_BRK_SW Slewing brake switch ON/OFF OFF

T5-1-7
MC2/A Digital Inputs
Display
4/6
MC2/A DI4 MC2/A DI5 MC2/A DPI
FD_BRK_SW ON DD_PLS OFF FD_PLS_CNT 0
RD_BRK_SW ON DG_IN33 OFF RD_PLS_CNT 0
3D_BRK_SW ON ECU_ERR. OFF DD_PLS 0
SD_CAN.SW OFF ECU_WAR. OFF
FD_PLS_A OFF DG_IN36 OFF
FD_PLS_B OFF DG_IN37 OFF
RD_PLS_A OFF
RD_PLS_B OFF
Item

FD_BRK_SW Front drum brake pedal limit switch ON/OFF OFF * Option
RD_BRK_SW Rear drum brake pedal limit switch ON/OFF OFF * Option
3D_BRK_SW No connection ON/OFF
SD_CAN.SW No connection ON/OFF
MC2/A DI4
FD_PLS_A No connection ON/OFF
FD_PLS_B No connection ON/OFF
RD_PLS_A No connection ON/OFF
RD_PLS_B No connection ON/OFF
DD_PLS No connection ON/OFF
ECU_ERR. ECU error signal ON/OFF OFF
MC2/A DI5
ECU_WAR. ECU warning signal ON/OFF OFF
FD_PLS_CNT Front drum pulse counter -xxxx 0 (288/1rotation) 0:when drum is stopped
MC2/A DPI RD_PLS_CNT Rear drum pulse counter -xxxx 0 (288/1rotation) 0:when drum is stopped
DD_PLS Derricking drum pulse counter 0/1 0 0: when drum is stopped

T5-1-8
MC2/A Digital Outputs
Display
5/6
MC2/A DO1 MC2/A DO2
M_PMP_CUR xxxx mA FD_PLS_SOL xxxx mA
INQ._TQ_CUR xxxx mA RD_PLS_SOL xxxx mA
RM_CUT_OFF ON DD_PLS_SOL xxxx mA
DM_CAP_CUR xxxx mA SL_BRK_REL OFF
SL_PMP_CUR xxxx mA
FM_CUT_OFF ON
3M_CAP_CUR xxxx mA
SL_ALAM_LP OFF
Item

M_PMP_CUR Main pump displacement angle actual current xxxx mA 680 to 720
INQ._TQ_CUR Torque increase proportional solenoid valve xxxx mA 0 to 720
RM_CUT_OFF Rear motor cut-off ON/OFF ON
DM_CAP_CUR Boom derricking motor absorption volume xxxx mA 630 to 670
MC2/A DO1 proportional solenoid valve: Control current
SL_PMP_CUR Slewing pump displacement angle actual current xxxx mA 0 to 60
FM_CUT_OFF Front motor cut-off ON/OFF ON
3M_CAP_CUR No connection xxxx mA
SL_ALAM_LP Slewing alarm lamp relay ON/OFF OFF
FD_PLS_SOL Front drum rotation indicator solenoid xxxx mA 0 0: when drum is stopped
RD_PLS_SOL Rear drum rotation indicator solenoid xxxx mA 0 0: when drum is stopped
MC2/A DO2
DD_PLS_SOL Derricking drum rotation indicator solenoid xxxx mA 0 0:when drum is stopped
SL_BRK_REL Slewing brake release solenoid valve ON/OFF OFF

T5-1-9
MC2/A Digital Output/ECU Status
Display
6/6
MC2/A DO3 MC2/A DO4 MC2/A ECU
DD_LCK_REL OFF PILOT_LP ON ECU_ERROR0 ----
FM_BRK_REL OFF FD_BRK_LP OFF ECU_ERROR1 ----
RM_BRK_REL OFF RD_BRK_LP OFF ECU_ERROR2 ----
3M_BRK_REL OFF INTLCK_LP OFF ECU_ERROR3 ----
FD_BRK_REL OFF THROT.M.A OFF ECU_ERROR4 ----
ENG._INTLCK ON THROT.M.NA OFF ECU_ERROR5 ----
RD_BRK_REL OFF THROT.M.B OFF ECU_ERROR6 ----
3D_BRK_REL OFF THROT.M.NB OFF ECU_ERROR7 ----
Item

DD_LCK_REL Boom derricking drum unlocking solenoid valve ON/OFF OFF
FM_BRK_REL Front motor brake release solenoid valve ON/OFF OFF
RM_BRK_REL Rear motor brake release solenoid valve ON/OFF OFF
MC2/A 3M_BRK_REL Third drum motor brake release solenoid valve ON/OFF OFF * Option
DO3 FD_BRK_REL Front drum brake release solenoid valve ON/OFF OFF * Option
ENG._INTLCK Engine start interlock ON/OFF ON
RD_BRK_REL Rear drum brake release solenoid valve ON/OFF OFF * Option
3D_BRK_REL No connection ON/OFF
PILOT_LP Pilot oil pressure indicator ON/OFF ON
FD_BRK_LP Front drum free mode lamp (red) ON/OFF OFF * Option
RD_BRK_LP Rear drum free mode lamp (red) ON/OFF OFF * Option
MC2/A INTLCK_LP Start interlock lamp ON/OFF OFF
DO4 THROT.M.A No connection ON/OFF
THROT.M.NA No connection ON/OFF
THROT.M.B No connection ON/OFF
THROT.M.NB No connection ON/OFF
ECU_ERROR0 ECU error number xxxx/---- ----
MC2/A ECU_ERROR3 ECU error number xxxx/---- ----
ECU ECU_ERROR4 ECU error number xxxx/---- ----

T5-1-10
MC2/B Analog Inputs
Display
MC2/B Input/Output Monitor
MC2/B_AI1 MC2/B_AI2 MC2/B_AI3

1/6
FD_CTRL_SP x.xx V TR_RGT_PRS x.xx V 3D_ROPE_ED ON
RD_CTRL_SP x.xx V TR_LET_PRS x.xx V DAN_IN17 OFF
DD_CTRL_SP x.xx V MAST_ANGLE x.xx V DAN_IN18 OFF
AN_IN3 x.xx V AN_IN11 x.xx V DAN_IN19 OFF
AN_IN4 x.xx V AN_IN12 x.xx V DAN_IN20 OFF
AN_IN5 x.xx V AN_IN13 x.xx V PENDANT ALLOFF
DD_HST_PRS x.xx V FD_ROPE_ED ON DAN_IN22 OFF
DD_LWR_PRS x.xx V RD_ROPE_ED ON DAN_IN23 OFF
Item
FD_CTRL_SP Front dum speed control dial x.xx V 0.64 to 0.93
RD_CTRL_SP Rear drum speed control dial x.xx V 0.64 to 0.93
DD_CTRL_SP Derricking drum speed control dial x.xx V 0.64 to 0.93
MC2/B_AI1
DD_HST_PRS Derricking drum hoisting remote control pressure x.xx V 0.40 to 0.84
DD_LWR_PRS Derricking drum lowering remote control pressure x.xx V 0.40 to 0.84
TR_RGT_PRS Right travel remote control pressure x.xx V 0.40 to 0.84
TR_LET_PRS Left travel remote control pressure x.xx V 0.40 to 0.84
MAST_ANGLE Live mast angle sensor x.xx V 0.98 to 4.02
MC2/B_AI2
ON/OFF/ALLON/
FD_ROPE_ED Front drum rope end (three-winding) detection ON *Option
ALLOFF
ON/OFF/ALLON/
RD_ROPE_ED Rear drum rope end (three-winding) detection ON *Option
ALLOFF
ON/OFF/ALLON/
3D_ROPE_ED No connection
ALLOFF
MC2/B_AI3
ON/OFF/ALLON/
PENDANT Pendant rope tension detectionswitch OFF
ALLOFF

T5-1-11
MC2/B Analog Inputs
Display
MC2/B_AI4 MC2/B_AI5 2/6

DD_HST_CUR xxxx mA MAIN_B xx.xx V
DD_LWR_CUR xxxx mA 24V_1 xx.xx V
FD_HST_CUR xxxx mA 24V_2 xx.xx V
FD_LWR_CUR xxxx mA 24V_3 xx.xx V
RD_HST_CUR xxxx mA 5V x.xx V
RD_LWR_CUR xxxx mA
FM_CAP_CUR xxxx mA
RM_CAP_CUR xxxx mA
Item

DD_HST_CUR Derricking drum hoisting proportional solenoid valve xxxx mA 739 to 779
DD_LWR_CUR Derricking drum lowering proportional solenoid valve xxxx mA 739 to 779
FD_HST_CUR Front drum hoisting proportional solenoid valve xxxx mA 702 to 742
FD_LWR_CUR Front drum lowering proportional solenoid valve xxxx mA 702 to 742
RD_HST_CUR Rear drum hoisting proportional solenoid valve xxxx mA 702 to 742
MC2/B_AI4
RD_LWR_CUR Rear drum lowering proportional solenoid valve xxxx mA 702 to 742
Front drum motor absorption volume proportional solenoid
FM_CAP_CUR xxxx mA 649 to 689
valve
Rear drum motor absorption volume proportional solenoid
RM_CAP_CUR xxxx mA 649 to 689
valve
24V_1 Power supply for three-winding layer detector xx.xx V 21.60 to 26.40
MC2/B_AI5 24V_2 Power supply voltage for overhoist switch on machine xx.xx V 21.60 to 26.40
24V_3 Power supply voltage for overhoist switch with attachment xx.xx V 21.60 to 26.40
5V Sensor power supply voltage x.xx V 4.97 to 5.03

T5-1-12
MC2/B Digital Inputs
Display
MC2/B_DI1 MC2/B_DI2 MC2/B_DI3

3/6
DD_REL_SW OFF DG_IN8 OFF DG_IN16 OFF
FD_REL_SW OFF BM_OVERH ON JB_OVERH ON
RD_REL_SW OFF DG_IN10 OFF ATTACHMENT *
3D_REL_SW OFF TH_OVERH ON DG_IN19 OFF
REL_KEY_SW OFF DG_IN12 OFF HK_OVERH ON
OH2_REL_SW OFF BT_LOWER_L ON JB_OVERH2 ON
DG_IN6 ON DG_IN14 OFF F.POST ON
HM_FIX_SW OFF BT_OVERH2 ON FLIP_CYL. OFF
Item
DD_REL_SW Derricking drum auto stop release switch ON/OFF OFF
FD_REL_SW Front drum auto stop release switch ON/OFF OFF
RD_REL_SW Rear drum auto stop release switch ON/OFF OFF
3D_REL_SW Third drum auto stop release switch ON/OFF OFF * Option
MC2/B_DI1
REL_KEY_SW Auto stop release control key switch ON/OFF OFF
OH2_REL_SW Boom 2nd over hoist stop release switch ON/OFF OFF
HM_FIX_SW Winch motor low speed locking switch ON/OFF OFF
BM_OVERH Boom over hoist switch ON/OFF/ALLON/ALLOFF ON
TH_OVERH Tower over hoist switch ON/OFF/ALLON/ALLOFF ON
MC2/B_DI2
BT_LOWER_L No connection ON/OFF/ALLON/ALLOFF
DG_IN14 No connection1 ON/OFF
BT_OVERH2 Boom second over hoist switch ON/OFF/ALLON/ALLOFF ON
JB_OVERH Tower jib over hoist switch ON/OFF/ALLON/ALLOFF ON
*Crane operation: CRANE,
CRANE/TOWER/ Tower operation: TOWER,
ATTACHMENT Attachment detection signal Both signal Close: ALL_ON,
ALLON/ALLOFF
Both signal Open: ALL_OFF
MC2/B_DI3
HK_OVERH Hook over hoist switch ON/OFF/ALLON/ALLOFF ON
JB_OVERH2 Jib second over hoist switch ON/OFF/ALLON/ALLOFF ON
F.POST No connection ON/OFF/ALLON/ALLOFF
FLIP_CYL. Mast flip cylinder storing detection ON/OFF/ALLON/ALLOFF ON

T5-1-13
MC2/B Digital Inputs
Display
MC2/B_DI4 MC2/B_DI5 4/6

DG_IN24 OFF RD_HST_STP ON
DG_IN25 OFF RD_LWR_STP ON
SWL_OVERH ON 3D_HST_STP ON
JB_FOLD OFF 3D_LWR_STP ON
DD_HST_STP ON B/J_LOW_T. ON
DD_LWR_STP ON JB_OVER_T. ON
FD_HST_STP ON
FD_LWR_STP ON
Item

SWL_OVERH No connection ON/OFF/ALLON/ALLOFF
JB_FOLD No connection ON/OFF/ALLON/ALLOFF
MC2/B_DI4
DD_HST_STP Boom derricking drum hoisting stop signal ON/OFF ON
DD_LWR_STP Boom derricking drum lowering stop signal ON/OFF ON
FD_HST_STP Front drum hoisting stop signal ON/OFF ON
FD_LWR_STP Front drum lowering stop signal ON/OFF ON
RD_HST_STP Rear drum hoisting stop signal ON/OFF ON
RD_LWR_STP Rear drum lowering stop signal ON/OFF ON
3D_HST_STP Third drum hoisting stop signal ON/OFF ON * Option
MC2/B_DI5
3D_LWR_STP Third drum lowering stop signal ON/OFF ON * Option
B/J_LOW_T. Boom/jib loading stop signal ON/OFF ON
JB_OVER_T. Tower breakage prevention signal ON/OFF ON

T5-1-14
MC2/B Digital Outputs
Display
MC2/B_DO1 MC2/B_DO2 5/6

DD_HST_CUR xxx mA FLIP_EXT. OFF
DD_LWR_CUR xxx mA FLIP_RET. OFF
FD_HST_CUR xxx mA PWM_OUT2
FD_LWR_CUR xxx mA OVERH2_SOL ON
RD_HST_CUR xxx mA
RD_LWR_CUR xxx mA
FM_CAP_CUR xxx mA
RM_CAP_CUR xxx mA
Item

DD_HST_CUR Boom dericking drum hoisting proportional solenoid valve xxxx mA 739 to 779
DD_LWR_CUR Boom derricking drum lowering proportional solenoid valve xxxx mA 739 to 779
FD_HST_CUR Front drum hoisting proportional solenoid valve xxxx mA 702 to 742
FD_LWR_CUR Front drum lowering proportional solenoid valve xxxx mA 702 to 742
MC2/B_DO1
RD_HST_CUR Rear drum hoisting proportional solenoid valve xxxx mA 702 to 742
RD_LWR_CUR Rear drum lowering proportional solenoid valve xxxx mA 702 to 742
FM_CAP_CUR Front drum motor absorptionvolume proportional solenoid valve xxxx mA 649 to 689
RM_CAP_CUR Rear drum motor absorption volume proportional solenoid valve xxxx mA 649 to 689
FLIP_EXT. Mast flip cylinder extending solenoid valve ON/OFF OFF
FLIP_RET. Mast flip cylinder retracting solenoid valve ON/OFF OFF
MC2/B_DO2
PWM_OUT2 No connection
OVERH2_SOL Boom second over hoist solenoid valve ON/OFF ON

T5-1-15
MC2/B Digital Outputs
Display
MC2/B_DO3 MC2/B_DO4 6/6

SOL_OUT0 SHORT ALARM_0 OFF
SOL_OUT1 OFF ALARM_1 OFF
3D_HST_SOL ON ALARM_6 OFF
3D_LWR_SOL ON ALARM_7 OFF
Item

SOL_OUT0 No connection ON/OFF
MC2/B_DO1
3D_HST_SOL Third drum hoisting stop ON/OFF ON * Option
3D_LWR_SOL Thlrd drum lowering stop ON/OFF ON * Option
ALARM_0 No connection ON/OFF
MC2/B_DO2 ALARM_3 No connection ON/OFF

T5-1-16
IDU Analog Inputs
Display
IDU Input/Output Monitor
1/3
IDU_AI1 IDU_AI2 IDU_AI3
AN_IN120 x.xx V AN_IN0 x.xx V AN_IN8 x.xx V
BM_LOAD x.xx V AN_IN3 x.xx V AN_IN11 x.xx V
JB_LOAD x.xx V HYD_THM x.xx V MAIN_B xx.xx V
JB_ANGLE x.xx V AN_IN5 x.xx V 24V xx.xx V
JB_ANGLE2 x.xx V AN_IN6 x.xx V 5V x.xx V
BM_ANGLE x.xx V AN_IN7 x.xx V 10V xx.xx V
Item

BM_LOAD Boom derricking rope tension x.xx V 0.46 to 4.58
IDU_AI1
JB_LOAD Jib derricking rope tension x.xx V 0.46 to 4.58
JB_ANGLE Tower jib angle (when working position) x.xx V 0.64 to 4.82
JB_ANGLE2 Tower jib angle (when assembling position) x.xx V 0.64 to 4.82
BM_ANGLE Boom angle x.xx V 0.64 to 4.82
IDU_AI2
HYD_THM Hydraulic oil temperature sensor x.xx V 0.24 to 4.34
IDU_AI3
24V Power supply for switch xx.xx V 21.60 to 26.40
5V Sensor power supply x.xx V 4.97 to 5.03
10V Load cell power supply xx.xx V 9.98 to 10.02

T5-1-17
IDU Digital Inputs
Display
IDU_DI1 IDU_DI2 IDU_DI3

2/3
CLAMSHELL OFF DEC_CH2 OFF OVERHEAT OFF
DRAGLINE OFF DEC_CH3 OFF PLS_IN1 OFF
DG_IN2 ON DEC_CH4 OFF PLS_IN2 OFF
JB_CATCH OFF BM_OH_LINE ON PLS_IN3 OFF
REAR OFF JB_OH_LINE ON PLS_IN4 OFF
ADD_CH1 OFF JB_OH2_L. OFF PLS_IN5 OFF
ADD_CH2 OFF MAINTE.KEY ON PLS_IN6 OFF
DEC_CH1 OFF PLS_IN7 OFF
Item

CLAMSHELL Clamshell mode switch, No connection ON/OFF OFF
DRAGLINE Dragline mode switch, No connection ON/OFF OFF
JB_CATCH No connection ON/OFF/ALLOFF/ALLON
IDU_DI1
REAR No connection ON/OFF
ADD_CH1 No connection ON/OFF
ADD_CH2 No connection ON/OFF
DEC_CH1 No connection ON/OFF
IDU_DI2 BM_OH_LINE Boom hook wiring detection (main hook) ON/OFF ON
JB_OH_LINE Jib hook wiring detection (sub hook) ON/OFF ON
JB_OH2_L. No connection ON/OFF
MAINTE.KEY Maintenance key switch ON/OFF ON
OVERHEAT Thermo switch ON/OFF OFF
PLS_IN1 No connection ON/OFF
IDU_DI3

T5-1-18
IDU Digital Outputs
Display
3/3
IDU_DO1 IDU_DO2 IDU_DO3
DD_HST_STP ON B/J_LOW_T. ON DD_HST_SD% xxx %
DD_LWR_STP ON JB_OVER_T. ON DD_LWR_SD% xxx %
FD_HST_STP ON GREEN_LMP ON FD_HST_SD% xxx %
FD_LWR_STP ON YELLOW_LMP OFF FD_LWR_SD% xxx %
RD_HST_STP ON RED_LMP OFF RD_HST_SD% xxx %
RD_LWR_STP ON OIL_CL.FAN ON RD_LWR_SD% xxx %
3D_HST_STP ON LAMP_CHK OFF 3D_HST_SD% xxx %
3D_LWR_STP ON BUZZER OFF 3D_LWR_SD% xxx %
Item

DD_HST_STP Boom derricking drum hoisting stop ON/OFF ON
DD_LWR_STP Boom derricking drum lowering stop ON/OFF ON
FD_HST_STP Front drum hoisting stop ON/OFF ON
FD_LWR_STP Front drum lowering stop ON/OFF ON
IDU_DO1
RD_HST_STP Rear drum hoisting stop ON/OFF ON
RD_LWR_STP Rear drum lowering stop ON/OFF ON
3D_HST_STP Third drum hoisting stop ON/OFF ON
3D_LWR_STP Thlrd drum lowering stop ON/OFF ON
B/J_LOW_T. Boom/jib shouldering prevention ON/OFF ON
JB_OVER_T. Tower breakage prevention ON/OFF ON
GREEN_LMP External moment limiter indicator: green ON/OFF ON
YELLOW_LMP External moment limiter indicator: yellow ON/OFF OFF
IDU_DO2
RED_LMP External moment limiter indicator: red ON/OFF OFF
OIL_CL.FAN Hydraulic oil cooling fan operating relay ON/OFF ON
LAMP_CHK Lamp check relay ON/OFF OFF
BUZZER Buzzer ON/OFF OFF
DD_HST_SD% Boom derricking drum hoisting slowdown ratio xxx % 100
DD_LWR_SD% Boom derricking drum lowering slowdown ratio xxx % 100
FD_HST_SD% Front drum hoisting slowdown ratio xxx % 100
FD_LWR_SD% Front drum lowering slowdown ratio xxx % 100
IDU_DO3
RD_HST_SD% Rear drum hoisting slowdown ratio xxx % 100
RD_LWR_SD% Rear drum lowering slowdown ratio xxx % 100
3D_HST_SD% Third drum hoisting slowdown ratio xxx % 100
3D_LWR_SD% Third drum lowering slowdown ratio xxx % 100

T5-1-19
(Blank)
T5-1-20
TROUBLESHOOTING / Component Layout
MAIN COMPONENTS
Refer to T1-2 Operational Principles.
Crane Upper

7
8
6
5
4
3
2
1
10
11
20
12
13
14
15
16
17
18
19
1- Gate Lock Solenoid Valve 9 - Fuel Tank 17 - Hydraulic Oil Cooler

2- Sump Tank 10 - Rear Control Valve 18 - Hydraulic Oil Cooler Solenoid Valve
3- Pilot Filter 11 - 3-Spool Solenoid Valve (under Rear Drum) 19 - Rotating Joint
(Counterweight, Flip)
4- Drain Filter 12 - 2-Spool Control Valve (under Rear Drum) 20 - Foot Pin Removal/Installation
(Swing, Counterweight, Flip) Mechanism
5- Flip Cylinder 13 - Front Control Valve
6- Pump Assembly 14 - 4-Spool Solenoid Valve (under Rear Drum)
(Foot Cylinder, Lower Hydraulic Source)
7- Reserve Tank 15 - Accumulator and Primary Pilot Pressure
Sensor
8- Radiator and Intercooler 16 - 5-Spool Solenoid Valve Unit
T5-2-1
T5-2-2
TROUBLESHOOTING / Troubleshooting A
TROUBLESHOOTING A PROCEDURES
x Use troubleshooting A when error is indicated as a result that IDU diagnoses MC2/A and MC2/B.
x How to read troubleshooting flowchart
YES(OK)
(2)
Perform inspection or measurement in box (1), and select YES (OK) or
࡮ (1) NO (NOT OK) according to (1), and go to the next box (2) or (3).
(3)
NO(NOT OK)
࡮ Under the box is inspection or measuring method or references.

Be careful that if inspection or measuring method is incorrect, finding the cause of failure
½Key switch: ON becomes difficult or the equipment may be damaged.
࡮ The bold line box shows a cause of failure.

The bold line tells a location where possible cause of failure is present.
NOTE: All connector drawings show the connecting

side of the harness end connector. (as seen
from the arrows)
Harness
T6L4-05-03-001
T5-3-1
FAILURE OF MC2/A OR MC2/B BATTERY
AND SENSOR SYSTEM POWER SUPPLY
Abnormality
x Using the power supply monitor, check if the
batteries and sensor power supplies of MC2/A and
MC2/B are all normal.
MC2/A, MC2/B
Normal range
Countermeasure for
Item Signal name Description (under the following
abnormality
conditions)
MAIN_B Main power supply voltage xx.xx V 24.00 to 32.00 Harness check
24V_1 Sensor power supply (for each xx.xx V 21.60 to 26.40 Harness check
24V_2 detection switch)
24V_3
5V Analog sensor power supply x.xx V 4.97 to5.03 Harness check

4. All the levers are in the neutral
positions.
5. All the dials and pedals are in the
minimum positions.
6. All the switches are in the normal or
OFF positions.
T5-3-2
Battery
Battery Relay
264
Key Switch
206
15A
MC2/A MC2/B
D1 X1
MAIN_B MAIN_B
M18 M18
KEY_SW KEY_SW
E12 Y12
SOL_VB SOL_VB
E13 Y13
PWM_VB PWM_GND E26 PWM_VB PWM_GND Y26
D12 D12
MAIN_GND MAIN_GND
D5 X5
SENSOR_5V SENSOR_5V
D16 X16 IDU

SENSOR_5V SENSOR_5V
D2 X2
SENSOR_24V_1 SENSOR_24V_1
D3 SENSOR_24V_2 X3 SENSOR_24V_2
D4 X4
SENSOR_24V_3 SENSOR_24V_3
CAN
D21 D10 X21 X10 J1 J2
T25N-05-03-001
T5-3-3
Check of Battery System
MC2/A side
x Check the fuse. (Refer to the fuse list for MCA/5A.)

x Check the wiring connections first.
In case where the fuse has blown
YES Short circuit between D1
Disconnect connector MCA-1 of MC2/A. and machine
Check for continuity between terminal D1
of harness end and machine. Faulty MC2/A
· Key switch: OFF NO
In case where the fuse has not blown

YES Faulty MC2/A
Disconnect connector YES

MCA-1 of MC2/A. Disconnect harness from Faulty battery
Check if voltage between YES terminal (-) of battery.
terminal D1 of harness end Disconnect harness from Check for continuity
and machine is 24V. terminal (+) of battery and between terminal (-) and Broken harness between
connect it to machine. machine. battery and ground, or
· Key switch: ON NO faulty ground
NO Check for continuity between · Key switch: OFF
D1 of harness end of MCA-1
and machine. Broken harness between
NO MC2/A and battery
· Key switch: OFF
Connector
MC2/A MC2/B
Connector MCA-1 (Harness End) Connector MCB-1 (Harness End)
D1 X1
MC2/B side
x Check the fuse. (Refer to the fuse list for MCB/5A.)

YES Short circuit between X1
Disconnect connector MCB-1 of MC2/B. and machine
Check for continuity between terminal X1
of harness end and machine. Faulty MC2/B

YES Faulty MC2/B
Disconnect connector
MCB-1 of MC2/B. Disconnect harness from YES Faulty battery
Check if voltage between terminal (-) of battery.
YES
terminal X1 of harness end Disconnect harness from Check for continuity
and machine is 24V. terminal (+) of battery and between terminal (-) and Broken harness between
connect it to machine. machine. battery and ground, or
· Key switch: ON NO faulty ground
NO Check for continuity between · Key switch: OFF
X1 of harness end of MCB-1
and machine. Broken harness between
NO MC2/B and battery
· Key switch: OFF
T5-3-4
Check of Key Switch
MC2/A side
x Check the fuse. (Refer to the fuse list for the controller main power supply 5A.)
x Check the wiring connections.
· In cases the fuse has blown
YES Short circuit between line
Disconnect connector MCA-1 of MC2/A. M18 and machine
Check for continuity between terminal
M18 of harness end and machine. Faulty MC2/A
· In cases the fuse has not blown

YES Faulty MC2/A
Disconnect connector MCA-1. YES Faulty key switch

Check if voltage between
terminal M18 of harness end YES Check if voltage between
and machine is 24V. Connect terminal ACC of key key switch terminal B
· Key switch: ON switch to machine. and machine is 24V. Broken harness between
Check for continuity between · Key switch: ON NO key switch and battery
NO M18 of harness end of
MCA-1 and machine. Broken harness between
· Key switch: OFF NO MC2/A and key switch
MC2/A
Connector
Connector MCA-1 (Harness End)
Monitor Panel Connector 6P
(Harness End)
Key Switch Terminal B
M18
201
MC2/B
204 Key Switch Terminal Connector MCB-1 (Harness End)
ACC
MC2/B side M18
x Check the fuse. (Refer to the fuse list for the controller main power supply 5A.)
· In cases the fuse has blown
YES Short circuit between
Disconnect connector MCB-1 of MC2/B. line M18 and machine
M18 of harness end and machine. Faulty MC2/B
· In cases the fuse has not blown

YES Faulty MC2/B
Disconnect connector MCB-1. YES Faulty key switch

terminal M18 of harness end YES Check if voltage between
and machine is 24V. key switch terminal B and
Connect terminal ACC of key machine is 24V. Broken harness between
· Key switch: ON switch to machine. NO key switch and battery
· Key switch: ON
Check for continuity between
NO M18 of harness end of
Broken harness between
MCB-1 and machine. MC2/B and key switch
T5-3-5
Check of Solenoid and PWM Power Supply
MC2/A side
x Check the fuse. (Refer to the fuse list for SOL (MCA) 15A, PWM (MCA) 15A.)
In case where the fude has blown
YES Short circuit between either
Disconnect connector MCA-6 of MC2/A. lines E12 or E13 and machine
Check for continuity between terminal E12 (E13)
of harness end connector and machine.
Faulty MC2/A
YES Faulty MC2/A
Disconnect connector Broken harness

MCA-6. YES between battery relay
Check if voltage Connect harness 206 to and ground, or faulty
between terminal E12 battery relay, and connect (-) harness
(E13) of harness end YES terminal of battery relay to
connector and machine.
Check if voltage between Disconnect harness 264 of
machine is 24V. battery relay and connect it
Disconnect harness 206 E12 (E13) of harness end of
· Key switch: ON of battery relay and MCA-6 and machine is 24V. to machine.
A
connect it to machine. NO Check for continuity
· Key switch: ON between key switch terminal
Check for continuity
NO between E12 (E13) of ACC and machine.
harness end of MCA-6 · Key switch: OFF
and machine.
· Key switch: OFF Broken harness E12
(E13) between battery
NO relay and MCA-6
Disconnect harness from (+) YES Faulty battery relay

terminal of battery and connect it
YES to machine.
Check for continuity between Broken harness
60sq red wire of primary terminal between battery relay
of battery relay and machine. NO and battery
A
Broken harness
between key switch
NO and battery relay
Connector
MC2/A
E12 E13
T5-3-6
MC2/B side
x Check the fuse. (Refer to the fuse list for SOL (MCB) 15A, PWM (MCB) 15A.)
YES Short circuit between either
Disconnect connector MCB-6 of MC2/B. lines Y12 or Y13 and machine
Check for continuity between terminal Y12 (Y13)
of harness end connector and machine. Faulty MC2/B

YES Faulty MC2/B
Broken harness
Disconnect connector YES between battery relay
Connect harness 206 to
MCB-6 of MC2/B. and ground, or faulty
battery relay, and connect (-)
Check if voltage between harness
terminal Y12 (Y13) of YES terminal of battery relay to
machine.
harness end connector Disconnect harness 264 of
and machine is 24V. battery relay and connect it
Disconnect harness 206 Y12 (Y13) of harness end of
· Key switch: ON of battery relay and MCB-6 and machine is 24V. to machine.
A
connect it to machine. NO Check for continuity
· Key switch: ON between key switch
NO between Y12 (Y13) of terminal ACC and machine.
harness end of MCB-6 · Key switch: OFF
and machine.
Broken harness Y12
· Key switch: OFF (Y13) between battery
NO relay and MCB-6
Disconnect harness from (+) YES Faulty battery relay

terminal of battery and connect it
YES to machine.
60sq red wire of primary terminal between battery relay
of battery relay and machine. NO and battery
A
Broken harness
between key switch
NO and battery relay
Connector
MC2/B
Connector MCB-6 (Harness End)
Y12 Y13
T5-3-7
Check of Sensor Power Supply (5V system 1) of MC2/A
YES Faulty sensor

Disconnect sensor connector.
terminal R (D5) of harness end YES Broken harness between
connector and machine is 5V. MC2/A and sensor
Check if voltage of terminal D5 of
· Key switch: ON NO connector MCA-1 of MC2/A is 5V.
Faulty MC2/A
· Key switch: ON NO
· Connector MCA-1 is plugged into controller.
Sensor Harness end connector

Accelerator grip D5
B W R
Accelerator pedal D5
W R
B
Swing speed
control dial
D5 Left Stand Panel Connector
R
Boom Derricking
B R
Speed Control Dial
W
Speed Control Dial Connector
Connector
MC2/A
D5
T5-3-8
Check of Sensor Power Supply (5V system 2) on of MC2/A
YES Faulty sensor

terminal R (D16) of harness end YES Broken harness between
connector and machine is 5V. MC2/A and sensor
Check if voltage of terminal D16 of
· Key switch: ON connector MCA-1 of MC2/A is 5V.
NO
Faulty MC2/A
· Key switch: ON
NO
· Connector MCA-1 is plugged into controller.
Connector

Boom derricking drum hoisting remote
control pressure
Boom derricking drum lowering remote
control pressure R W B
Front drum hoisting remote control
pressure
Front drum lowering remote control
pressure
Rear drum hoisting remote control
pressure
Rear drum lowering remote control
pressure
Third drum hoisting remote control
pressure
Third drum lowering remote control
pressure
Right swing remote control pressure
Left swing remote control pressure
Primary pilot pressure

Front drum brake depressing pressure R B
W
Rear drum brake depressing pressure
MC2/A
D16
T5-3-9
Check of Sensor Power Supply (5V system 1) on of MC2/B
YES Faulty sensor

Check if voltage between terminal R (X5) of
harness end connector and machine is 5V. YES Broken harness between
MC2/B and sensor
͊Key switch: ON Check if voltage of X5 of
NO connector MCB-1 of MC2/B is 5V.
Faulty MC2/B
͊Key switch: ON NO
͊Connector MCB-1 is plugged into controller.
Connector
Front drum speed control dial X5 Left Stand Panel Connector
B R
Rear drum speed control dial
W
Speed Control Dial Connector
MC2/B
X5
Check of Sensor Power Supply (5V system 2) of MC2/B

YES Faulty sensor

Check if voltage between terminal R (X16) of
YES Broken harness between
harness end connector and machine is 5V.
MC2/B and sensor
NO connector MCB-1 is 5V.
Faulty MC2/B
͊Key switch: ON NO
͊Connector MCB-1 is plugged into controller.
Connector
Right travel remote control

pressure
R W B
Left travel remote control

pressure
MC2/B
X16
T5-3-10
Brake mode key switch YES Faulty switch
Disconnect connector 16P of left control panel.

Check if voltage between terminal D2 of
MC2/A and switch
͊Key switch: ON Check if voltage of D2 of
NO connector MCA-1 is 24V.
͊Key switch: ON Faulty MC2/A
͊Connector MCA-1 is plugged NO
into controller.
Front / rear drum free mode switches

Front / rear pedal limit switches
Disconnect connector of switch.

Check if voltage between terminal D2 of
͊Key switch: ON
Connector
Left control panel MC2/A

Connector 16P (Harness End) Connector MCA-1 (Harness End)
D2
D2
Front drum free mode switch
D2
Rear drum free mode switch
Front drum pedal limit switch

D2
Rear drum pedal limit switch
T5-3-11
Accelerator control switch

YES Faulty accelerator control
switch
Disconnect connector 12P of right control panel.
Check if voltage between terminal D3 of harness
end connector and machine is 24V. YES Broken harness between
MC2/A and switch
NO connector MCA-1 is 24V.
Faulty MC2/A
͊Key switch: ON NO
͊Connector MCA-1 is plugged
into controller.
Connector
Right control panel MC2/A

Connector 12P (Harness End) Connector MCA-1 (Harness End)
D3 D3
Emergency operation switch (insaide of rear stand)
YES Faulty emergency

operation switch
Disconnect connector of emergency operation switch.
Check if voltage between terminal D4 of harness end YES Broken harness between
connector and machine is 24V. MC2/A and switch
NO connector MCA -1 is 24V.
Faulty MC2/A
͊Key switch: ON NO
͊Connector MCA-1 is plugged
into controller.
Connector
emergency operation switch MC2/A
Connector of (Harness End) Connector MCA-1 (Harness End)
D4
D4
T5-3-12
Front, Rear drum rope end detection switch

Pendant angle detection switch
YES Faulty detection switch
Disconnect connector of detection switch.

Check if voltage between terminal X2 of YES Broken harness between
MC2/B and detection
͊Key switch: ON Check if voltage of X2 of connector
NO MCB-1 of MC2/B is 24V.
Faulty MC2/B
͊Key switch: ON NO
͊Connector MCB-1 is plugged
into controller.
Connector
Sensor Connector (Harness End)
Pendant Angle Detection Switch X2
Front Drum Rope End Detection Switch

X2
Rear Drum Rope End Detection Switch
MC2/B
X2
T5-3-13
Boom / Tower overhoist switch

Boom lowering limit switch
YES Faulty switch

Check if voltage between terminal X3 of
MC2/B and switch
NO connector MCB-1 is 24V.
Faulty MC2/B
͊Key switch: ON NO
͊Connector MCB-1 is plugged
into controller.
Boom / Tower second overhoist switch
Disconnect connector of second overhoist switch.

Check if voltage between terminal #1 of harness
end connector and machine is 24V.
͊Key switch: ON
Connector
Boom overhoist switch X3
Tower overhoist switch X3
Boom lowering limit switch X3
Terminal (1)
㽳
㽴㽲
Boom / tower second overhoist switch
㽶㽵
MC2/B
X3
T5-3-14
Jib overhoist limit switch

Jib second overhoist limit switch YES Faulty limit switch
Jib back stop alignment switch
Disconnect connector of limit switch.
Check if voltage between terminal #1 of
MC2/B and limit switch
· Key switch: ON Check if voltage of terminal X4
NO of connector MCB-1 is 24V.
Faulty MC2/B
· Key switch: ON
Hook overhoist switch NO
· Connector MCB-1 is plugged
Disconnect connector of limit switch. into controller
Check if voltage between terminal #1 of
· Key switch: ON
Live mast flip cylinder limit switch

Disconnect connector of limit switch.
Check if voltage between terminal X4 of
· Key switch: ON
Connector

Jib overhoist switch
㽳㽲
Jib second overhoist

㽳㽲
switch
㽵㽴
Jib back stop

alignment Switch 㽳㽲
Hook overhoist switch

㽳㽲㽲㽳
㽶㽵㽴
㽸㽷 Junction box 㽴㽵
Limit switch harness
receptacle (Harness End)
Live mast flip cylinder
(1) R23 X4 (2)
limit switch
(3) B25 (4)
MC2/B
X4
T5-3-15
Check of CAN communication between MC2/A and IDU

x Check the continuity between terminal D10 of connector MCA-1
of MC2/A and terminal J1 of connector IDU-4 of IDU.
x Check the continuity between terminal D21 of connector MCA-1
of MC2/A and terminal J2 of connector IDU-4 of IDU.
Check of CAN communication between MC2/B and IDU

x Check the continuity between terminal X10 of connector MCB-1
of MC2/B and terminal J1 of connector IDU-4 of IDU.
x Check the continuity between terminal X21 of connector MCB-1
of MC2/B and terminal J2 of connector IDU-4 of IDU.
Connector
MC2/A IDU
Connector MCA-1 (Harness End) Connector IDU-4 (Harness End)
D10 J1 J2
D21
MC2/B
X10
X21
T5-3-16
FAILURE OF ENGINE CONTROL SYSTEM
Abnormality
• Using the power supply monitor, check if the battery and sensor power supply of MC2/A are all normal.
If any errors are indicated, refer to "Failure of MC2/A Batteries and Sensor Power Supply".
• Using the MC2/A input/output monitor, confirm the sensor signal.
Normal range (under Countermeasure for
Item Signal name Description
the following conditions) abnormality
THROT._GRIP Accelerator grip signal x.xx V 0.95 to 1.05 Harness check
Sensor check
THROT._FOOT Accelerator pedal signal x.xx V 0.50 to 0.70 Harness check
Sensor check
THROT._3RD Third accelerator signal x.xx V 0.50 to 0.70 Harness check
Sensor check
THROT._FIX Throttle holding switch ON/OFF OFF Harness check
Sensor check
THROT._PRE Throttle preset switch ON/OFF OFF Harness check
Sensor check
THROT._OUT Accelerator output voltage x.xx V 0.90 Harness check
MC2/A hard check

3. The gate lock is in the lock
position.
MC2/A
D1 MAIN_B positions.
M18 KEY_SW minimum positions.
+24V 6. All the switches are in the normal
E12 SOL_VB or OFF positions.
E13 PWM_VB
MAIN_GND
E26 PWM_GND
D5 SENSOR_5V
D14 SENS_GND_5
Accelerator
㨻㩂㩈㩣 B5 AN_IN0
Grip 㩂㩨㩢㨹㩖㩩 ECU
DA_OUT B6
DA_GND B14
Accelerator
㨻㩂㩈㩣 B13 AN_IN1
Pedal㩗㩩㩊㩨㩣
D3 SENSOR_24V_2
Accelerator
䍏䍖䍜䍷࿕ቯ Holding A6 DG_IN14
Accelerator
䍏䍖䍜䍷䍪䍽䍶䍜䍍䍢 Preset A19 DG_IN15
T5-3-17
Check of Accelerator SensorGrip / Pedal
x Check the wiring connections first. Normal range of accelerator sensor

x If voltage from the accelerator sensor is 4.9 V output voltage
or more, the cause of trouble may be failure of
Grip sensor min. 0.95 to 1.05 v
sensor, or broken harness between terminal
D14 of MC2/A and D14 (ground) of accelerator max. 2.4 to 3.1 v
sensor connector. Pedal sensor min. 0.5 to 0.7 v
x If voltage from the accelerator sensor is 0.1V max. 4.3 to 4.5 v
or less, the cause of the trouble may be a
broken harness between sensor and MC2/A, or
a short circuit between line D5 (SENSOR_5V)
and ground line.
Connect disconnected YES Faulty MC2/A

connector.
YES Check if voltage
Disconnect connector between SIG of MCA-3
Faulty sensor
MCA-3 of MC2/A. and machine is in the
normal range. NO
YES Check for continuity
between terminal SIG ½Insert a test bar into the rear
of harness end face of the connector.
connector of sensor ½Turn key switch ON. Broken harness
and B5 of MCA-3.
Check if voltage SIG between
NO
YES between D5 and Key switch: OFF MC2/A and sensor
D14 of harness
end connector of Check for continuity
YES Faulty MC2/A
sensor is 5±0.5V.
YES between D14 of
Key switch: ON. harness end
Disconnect connector Broken harness
Check if voltage connector of sensor
of accelerator sensor. D14 between
between D5 of harness and machine.
Check for continuity NO MC2/A and sensor
between terminals D5 NO end connector of sensor Key switch: OFF
and D14 of sensor and machine is 5±0.5V.
Broken harness D5
side connector.
Keep key switch ON. between MC2/A
NO
Key switch: OFF and sensor
Faulty sensor
NO
Connector
Accelerator Grip Sensor MC2/A

(Harness End) Connector MCA-1 (Harness End)
+24v
D14 B5 D5 D5
D14
SIG GND
Accelerator Pedal Sensor MC2/A

SIG SIG (Grip) SIG (Pedal)

B13 D5
B5
D14
B13
T5-3-18
Check of Accelerator Holding Switch
Accelerator
Holding Switch: Check for continuity YES Faulty switch
holding side between terminal A6
of harness end
connector and A6 of Broken A6 harness
connector 12P. between switch and
NO
YES Disconnect ͊Key switch: OFF MC2/A
connector MCA-4
of MC2/A. YES Faulty switch
Disconnect connector ͊Key switch: OFF between terminal
12P of right stand panel. A19 of harness end
Accelerator connector and A19 Broken A19 harness
between D3 of harness Holding Switch: of connector 12P. between switch and
Check if voltage end connector and preset side NO MC2/A
between terminal machine is 24V. ͊Key switch: OFF
D3 of connector ͊Key switch: ON Broken D3 harness
MCA-1 of MC2/A between switch and
and machine is NO MC2/A
24V.
͊Key switch: ON Faulty MC2/A
͊Insert test bar into rear NO
face of connector.
Connector
Right Stand Control Panel

Connector 12P (Harness End)
A19 D3 A6
MC2/A MC2/A
Connector MCA-1 (Harness End) Connector MCA-4 (Harness End)
D3 A6
A19
T5-3-19
FAILURE OF BRAKE CONTROL SYSTEM
Abnormality
x Using the power supply monitor, check if the battery and sensor power supply of MC2/A are all normal.
x If any errors are indicated, refer to "Failure of MC2/A Batteries and Sensor Power Supply".
x Using the MC2/A input/output monitor, confirm the sensor signals.
Normal range
Item Signal name Description (under the following Countermeasure for
conditions) abnormality
Remote Control Pressure x.xx V 0.40 to 0.84 Harness check
DD_HST_PRS Boom derricking drum hoisting Sensor check
DD_LWR_PRS Boom derricking drum lowering
FD_HST_PRS Front drum hoisting
FD_LWR_PRS Front drum lowering
RD_HST_PRS Rear drum hoisting
RD_LWR_PRS Rear drum lowering
3D_HST_PRS Third drum hoisting
3D_LWR_PRS Third drum lowering
PILOT_PRS Primary pilot pressure x.xx V 0.40 to 0.72 Harness check
Sensor check
FD_BRK_PRS Front brake depressing pressure x.xx V 0.40 to 0.72 Harness check
RD_BRK_PRS Rear brake depressing pressure Sensor check
FREE_MD_SW Brake mode key switch ON/OFF OFF
FD_FREE_SW Front drum mode switch ON/OFF OFF Harness check
RD_FREE_SW Rear drum mode switch Switch check
FD_BRK_SW Front brake pedal limit switch ON/OFF OFF Harness check
RD_BRK_SW Rear brake pedal limit switch Switch check
FD_BREK_REL Front drum brake release solenoid valve ON/OFF OFF Harness check
RD_BRK_REL Rear drum brake release solenoid valve Solenoid valve check
Solenoid valve ON/OFF OFF Harness check
DD_LCK_REL Boom derricking drumlock release
FM_BRK_REL Front motor brake release Solenoid valve check
RM_BRK_REL Rear motor brake release
3M_BRK_REL Third drum motor brake release
FD_BRK_LP Front free mode lamp ON/OFF OFF Harness check
RD_BRK_LP Rear free mode lamp
x For checks of the harness between MC2/A and IDU, refer to

"Check of CAN communication between MC2/A and IDU"
in the chapter on "Failure of MC2/A Batteries and Sensor 1. The engine is running.
Power Supply".
minimum positions.
6. All the switches are in the normal or OFF
positions.
T5-3-20
Failure of Brake Control System
MC2/A
D1 MAIN_B
SOL_OUT4 E6 㩖㩥㩧㩎㩎㩨㩡㩛㩖㩨㩤㨺㩁
Front Drum Brake Release
M18 KEY_SW Solenoid
+24V ⸃㒰㔚⏛ᑯ
E12 SOL_VB
SOL_OUT6 E7 Rear Drum Brake Release
E13 PWM_VB Solenoid
MAIN_GN
E26 PWM_GND
D16 SENSOR_5V
E4
D15
SOL_OUT0 Derricking drum lock release
⿠ફ㩎㩨㩡㩛㩥㨹㩂
Pressure sensor SENS_GND_5 Solenoid
⸃㒰㔚⏛ᑯ
Boom derricking hoisting
⿠ફᏎ਄ B1 AN_IN8 SOL_OUT1 E18
remote control pressure Front motor brake release
㩖㩥㩧㩎㩝㨺㩊㩖㩨㩤㨺㩁
㩢㩝㩄㩧࿶ Solenoid
Boom derricking lowering ⸃㒰㔚⏛ᑯ
⿠ફᏎਅ B9 AN_IN9
remote control pressure E5
㩢㩝㩄㩧࿶ SOL OUT2
㩢㩞㩝㨺㩊㩖㩨㩤㨺㩁
Rear motor brake release
Front hoisting remote control
㩖㩥㩧㩎Ꮞ਄ C6 AN_IN10 Solenoid
⸃㒰㔚⏛ᑯ
pressure 㩢㩝㩄㩧࿶ SOL OUT3 E19
Front lowering remote control 㩆㩨㩖㩨⿠ફ㩝㨺㩊㩖㩨
Third drum motor brake
㩖㩥㩧㩎Ꮞਅ C12 AN_IN11 release Solenoid
pressure
㩢㩝㩄㩧࿶ 㩤㨺㩁⸃㒰㔚⏛ᑯ
Rear hoisting remote
㩢㩞Ꮞ਄control C5 AN_IN12
pressure
㩢㩝㩄㩧࿶
Rear lowering remote
㩢㩞Ꮞਅ control C11 AN_IN13 224
pressure
㩢㩝㩄㩧࿶
Third drum hoisting remote
㩆㩨㩖㩨⿠ફᏎ C4 AN_IN14
control pressure OC_OUT1 E22
Front drum free mode indicator
਄
Third drum lowering remote
㩆㩨㩖㩨⿠ફᏎ C10 AN_IN15 RED
control pressure
ਅ OC_OUT2 E9 Rear drum free mode indicator
Primary pilot pressure
㩔㩩㨼㩥㨹㩎 C2 AN_IN18
RED
㧝ᰴ࿶
Front brake pedal㩖㩥㩧㩎㩖㩨㩤㨺㩁
depressing C8 AN_IN19
detection 〯ㄟᬌ಴
Rear brake pedal 㩢㩞㩖㩨㩤㨺㩁
depressing C1 AN_IN20
detection 〯ㄟᬌ಴
D2 SENSOR_24V_1
A8 DG_IN18
224 Brake mode key switchSW
㩖㩨㩤㨺㩁㩝㨺㩎㩨ಾᦧ߃㩁㨺
293 Green
Front auto brake
mode indicator A21 DG_IN19
Front mode switch SW
㩖㩥㩧㩎㩝㨺㩎㩨ಾᦧ߃
Rear auto brake 294 Green
mode indicator
A9 DG_IN20
㩢㩞㩝㨺㩎㩨ಾᦧ߃
Rear SW
mode switch
Front pedal limit switch

A11 DG_IN24
Rear pedal limit switch
A24 DG_IN25
T5-3-21
Check of Remote Control Pressure Sensor System
(Boom Derricking drum)

x If voltage from the pressure sensor is 4.6V or more, pressure sensormay be faulty, or harness may be
broken between terminal D15 of MC2/A and terminal D15 (ground) of pressure sensor.
x If voltage from the pressure sensor is 0.4V or less, harness D16 (SENSOR_5V) may be a broken between
MC2/A and pressure sensor, or a short circuit between line D16 and ground.
Note
“sensor” shows “remote control pressure sensor”
YES
Connect disconnected Faulty MC2/A
YES
connector.
Disconnect connector Check if voltage between
MCA-3 of MC2/A. SIG of MCA-3 and Faulty sensor
machine is 0.5 to 4.5V. NO
between terminal SIG ½ Key switch: ON
of harness end ½Insert a test bar into rear face
connector of sensor of connector.
Broken harness
Check if voltage and SIG of MCA-3.
SIG between
͊Key switch: OFF NO
YES between D16 and MC2/A and sensor
D15 of harness
end connector of YES Faulty MC2/A
sensor is 5±0.5V. Check for continuity
YES between D15 of
͊Key switch: ON
Disconnect connector harness end connector Broken D15
of pressure sensor. Check if voltage of sensor and machine. harness between
Check for continuity between D16 of harness ͊Key switch: OFF NO
MC2/A and sensor
between terminals NO end connector of sensor
D16 and D15 of and machine is 5±0.5V.
sensor side connector. Broken D16
͊Key switch: ON
harness between
͊Key switch: OFF NO MC2/A and sensor
Faulty sensor
NO
Connector
MC2/A
Boom Derricking Drum Connector MCA-1 (Harness End)
Remote Control Pressure Sensor
(Harness End)
D15 D16
D16 SIG D15
+5V GND
MC2/A
Hoist : B1 Connector MCA-3 (Harness End)
Lower : B9 Hoist : B1
B1
B9
Lower : B9
T5-3-22
Check of Remote Control Pressure Sensor System
(Front, Rear, Third drum)

x If voltage from the pressure sensor is 4.6V or more, pressure sensor may be faulty of, or harness may be
broken between terminal D15 of MC2/A and terminal D15 (ground) of pressure sensor.
x If voltage from the pressure sensor is 0.4V or less, harness D16 (SENSOR_5V) may be broken between
MC2/A and the pressure sensor, or a short circuit between line D16 and ground.
Note
“sensor” shows “remote control pressure sensor”
YES Faulty MC2/A

Connect disconnected
YES connector.
Disconnect connector Check if voltage between
MCA-2 of MC2/A. SIG of MCA-2 and Faulty sensor
YES Check for continuity machine is 0.5 to 4.5V. NO
between terminal SIG ½ Key switch: ON
of harness end ½Insert a test bar into rear face
connector of sensor of connector.
and SIG of MCA-2. Broken harness
YES between D16 and
D15 of harness
YES between D15 of
͊Key switch: ON
Disconnect connector harness end connector Broken harness
of pressure sensor. Check if voltage of sensor and machine. D15 between
Check for continuity between D16 of harness NO
͊Key switch: OFF MC2/A and sensor
between terminals NO end connector of sensor
D16 and D15 of and machine is 5±0.5V.
sensor side connector. Broken harness
͊Key switch: ON D16 between
NO
͊Key switch: OFF MC2/A and sensor
Faulty sensor
NO
Connector
Drum Hoisting / Lowering
MC2/A
(Harness End)
D16 SIG D15 D15 D16
+5V GND
Drum Hoist Lower MC2/A

Front C6 C12 Connector MCA-2 (Harness End)
Rear C5 C11
C4 C5 C6
Third C4 C10 C10 C11 C12
T5-3-23
Check of Pressure Sensor: Primary Pilot Pressure

x If voltage from pressure sensor is 4.6V or more,
cause of trouble may be failure of pressure sensor,
or broken harness of D15 (ground) line between
MC2/A and sensor.
x If voltage from pressure sensor is less than 0.4V, Note
cause of trouble may be a broken harness of D16 “sensor” means “primary pilot pressure sensor “.
(SENSOR_5V) line between MC2/A and sensor, or a
short circuit between D16 and ground.

YES connector.
Disconnect connector C2 of MCA-2 and Faulty sensor
MCA-2 of MC2/A. machine is 0.5 to 4.5V. NO
YES Check for continuityof
½Key switch: ON
C2 line between MCA-2
½Insert test bar into the rear
and harness end
face of the connector Broken harness C2
connector of sensor.
between MC2/A and
Check if voltage ͊Key switch: OFF NO terminal of sensor
YES between D16 and
D15 of harness
YES between D15 of
Disconnect connector ͊Key switch: ON harness end connector
of pressure sensor. Broken harnessD15
Check if voltage of sensor and machine. between MC2/A and
Check for continuity between D16 of harness NO sensor
between terminals ͊Key switch: OFF
D16 and D15 of NO end connector of sensor
and machine is 5±0.5V.
pressure sensor side Broken harness D16
connector. ͊ Key switch: ON between MC2/A and
NO sensor
͊Key switch: OFF
Faulty sensor
NO
Connector
Primary Pilot Pressure Sensor
(Harness End)
+5V GND
D16 D15
C2
Primary Pilot
Pressure Sensor
MC2/A
Accumulator
D15 D16
MC2/A
C2
Left Bed
T5-3-24
Check of Pressure Sensor: Front / Rear Drum
brake depressing pressure (free fall winch)

x If voltage from pressure sensor is 4.6V or more,
cause of trouble may be failure of pressure sensor,
or broken harness of D15 (ground) line between
MC2/A and sensor.
x If voltage from pressure sensor is less than 0.4V,
cause of trouble may be a broken harness of D16 Note
“sensor” means “drum brake depressing pressure sensor “
(SENSOR_5V) line between MC2/A and sensor, or a
short circuit between D16 and ground.

YES connector.
Disconnect connector SIG of MCA-2 and Faulty sensor
MCA-2 of MC2/A. machine is 0.5 to 4.5V. NO
YES Check for continuityof
SIG line between MCA-2 ½Key switch: ON
and harness end ½Insert test bar into rear face
of connector Broken harness
connector of sensor.
between D16 and
YES
D15 of harness
YES between D15 of harness
Disconnect connector ͊Key switch: ON end of sensor connector
of brake depressing Check if voltage between Broken harness
and machine. D15 between
pressure sensor. D16 of harness end of NO MC2/A and sensor
Check for continuity ͊Key switch: OFF
NO sensor connector and
between terminals machine is 5±0.5V.
D16 and D15 of Broken harness
pressure sensor side ͊Key switch: ON D16 between
NO
connector. MC2/A and sensor
͊Key switch: OFF Faulty sensor
NO
Connector
Brake Depressing Pressure Sensor

(Harness End)
+5V GND
D16 D15
SIG
MC2/A MC2/A
Front brake : C8 Connector MCA-2 (Harness End)
Rear brake : C1
Rear SIG
C1
D15 D16 C8
Front SIG
T5-3-25
Check of Motor Brake Release Solenoid Valve
(Boom derricking, Front, Rear, Third drum)

x Cause of trouble may be failure of hoisting or
lowering remote control pressure sensor system.
x At first, check drum hoisting and lowering remote
control pressure sensor.
YES Faulty brake release

solenoid valve
Disconnect connector of motor
brake release solenoid valve. YES
Faulty harness between
Connect MCA-6. solenoid and ground, or
terminals SIG and GND of YES Check if voltage between faulty ground
SIG of harness end
harness end connector is 24V. Disconnect connector MCA-6 connector of solenoid
of MC2/A. Faulty MC2/A
½Operate winch hoisting or lowering. and machine is 24V.
Check for continuityof SIG line NO
NO between MCA-6 and harness ½Operate winch hoisting or
end connector of solenoid. lowering.
Faulty harness between
͊Key switch: OFF NO MC2/A and solenoid
Connector
Solenoid Valve (Harness End) MC2/A

Boom Derricking Rear

SIG E26
GND
Boom derricking E4 E4 E5
Front E18 E18 E19
Rear E5
Third E19
Front Third
T5-3-26
Check of Brake Mode Key Switch (free fall winch)
YES Faulty MC2/A
Disconnect connector MCA-4 of MC2/A. Trouble of power supply of

Check if voltage of terminal A8 of brake mode key switch.
harness end connector is 24V. YES
Disconnect MCA-4 and connector 16P Refer to "Check of Sensor
͊Key switch: ON of left stand panel. Power Supply (24V System 1)
Check for continuityof A8 line between of MC2/A."
NO MCA-4 and harness end of connector
16P of left stand panel. Faulty harness between MC2/A
NO and brake mode key switch
͊Key switch: OFF
Connector
Left Stand Panel Connector 16P
(Harness End)
A8
MC2/A
A8
T5-3-27
Check of Drum Brake Mode Switch (free fall winch)
YES Faulty MC2/A
Disconnect connector MCA-4 of MC2/A. Trouble of power supply

Check if voltage of terminal A21 (A9) of YES of brake mode switch.
harness end connector is 24V. Refer to "Check of
Disconnect MCA-4 and brake mode switch Sensor Power Supply
½Key switch ON, connector 06P. (24V System 1) of
Free switch ON
NO Check for continuityof A21 (A9) line between
Terminal MCA-4 and harness end of connector 06P. Faulty harness between
½A21: front MC2/A and brake mode
͊Key switch: OFF
½A9 : rear NO switch
In case brake mode indicator lamp (green) does not

blink by switching drum brake mode switch.
Terminal YES Blown bulb of auto brake
½293 : front Check for continuity of
indicator (green)
½294 : rear YES harness end terminals
293 (294) between
connector 06P and brake Broken harness between
Check for continuity between right stand panel and
YES indicator connector.
terminals 224 and 293 (294) of NO brake mode indicator
connector06P of switch side. ͊Key switch: OFF
terminal 224 of harness end of ͊Key switch: OFF Faulty drum brake mode
brake mode switch connector NO switch
06P and machine is 24V.
͊Key switch: ON
fuse and brake mode
NO switch, or blown fuse
Connector
Right stand
Brake mode switch connector 06P Brake Indicator LampConnector
Rear drum (Harness End) (Harness End)
Front drum (Harness End)
SIG2 SIG2
293 294
224 293 224 294
A21 A9
SIG1 Front drum Rear drum

SIG1
SIG2 SIG2
MC2/A
Rear drum SIG1
Front drum SIG1
A9
A21
T5-3-28
Check of Drum Brake Pedal Limit Switch, Front / Rear Drum (free fall winch)
x Check the wiring connections first
YES Faulty MC2/A
Disconnect connector MCA-4 of MC2/A. Trouble of power supply of

Check if voltage of terminal A11 (A24) of brake pedal limit switch.
harness end is 24V. YES
Disconnect MCA-4 andconnector of Refer to "Check of Sensor
½Key switch ON. brake pedal limit switch. Power Supply (24V system 1)
½Depress drum brake pedal. Check for continuityof A11 (A24) of MC2/A."
NO between MCA-4 and harness end
connector of brake pedal limit switch. Faulty harness between MC2/A
½Key switch OFF. NO and brake pedal limit switch
Terminal
½Keep MCA-4 disconnected.
½A11 : front
½A24 : rear
Connector
Brake pedal limit switch connector

(Harness End) MC2/A
Connector MCA-4 (Harness End) Front: A11
Front drum Rear drum
A11
A11 A12 A24
Rear: A24
T5-3-29
Check of Drum Brake Release Solenoid Valve
(free fall winch)

YES Faulty solenoid valve
Disconnect connector of drum

brake release solenoid. YES Faulty harness between
Check if voltage between Connect MCA-6. solenoid and ground, or
terminals E6 (E7) and GND of YES Check if voltage of E6 faulty ground
harness end connector is 24V. (E7) of harness end
connector of solenoid Faulty MC2/A
Key switch ON,
Disconnect connector MCA-6 of is 24V.
Brake mode key switch ON. NO
MC2/A and solenoid connector. Key switch: ON
Depress brake pedal.
Check for continuity of terminal E6 Brake mode key switch ON.
Free mode switch ON NO (E7) between MCA-6 and harness
Depress brake pedal.
end of solenoid connector. Free mode switch ON
Terminal
͊Key switch: OFF Faulty harness between
E6: front drum
NO MC2/A and solenoid
E7: rear drum
Connector
Front / Rear Drum
Brake Release Solenoid Valve MC2/A
E6 E7
SIG (B)
Front : E6
GND
Rear : E7
Check of Drum Brake Mode Indicator Lamp

(free fall winch)
Free mode indicator (red) does not Terminal

blink by switching free mode switch. E22 : Front drum brake
E9 : Rear drum brake
Key switch ON,
Brake mode key switch ON.
Brake pedal depressed. YES Faulty MC2/A
Free mode switch ON. Disconnect connector MCA-6 of MC2/A.
YES Check for continuity of E22 (E9) between
harness end connector of indicator and Faulty harness between
Disconnect connector of brake MCA-6.
mode indicator. MC2/A and free mode
NO
Check if voltage between terminal ͊Key switch: OFF indicator
224 of harness end connector of
indicator and machine is 24V. Broken harness
between fuse and brake
½Key switch ON
NO mode indicator, or
blown fuse
Connector
Brake Mode Indicator Lamp Connector MC2/A
E22 E9
224 E9 E22
T5-3-30
Check of Harness between IDU and MC2/B

Connector
x Check the continuity between terminal R13 of the
harness end connector of connector IDU-4 of IDU
and terminal R13 of the harness end connector of
connector MCB-4 of MC2/B. IDU
(Boom derricking drum hoisting stop signal) Connector IDU-4 (Harness End)
x Check the continuity between terminal R26 of the

R13 Z12 Z13 Z14 Z4
harness end connector of IDU-4 and terminal R26 of
R26 Z1 Z2 Z3 Z15
the harness end connector of MCB-4.
(Boom derricking drum lowering stop signal)
x Check the continuity between terminal Z12 of the

harness end connector of IDU-4 and terminal Z12 of
(Front drum hoisting stop signal)
MC2/B
x Check the continuity between terminal Z1 of the Connector MCB-4 (Harness End)
the harness end connector of MCB-5. R13
(Front drum lowering stop signal) R26

(Rear drum hoisting stop signal)
x Check the continuity between terminal Z2 of the MC2/B

harness end connector of IDU-4 and terminal Z2 of Connector MCB-5 (Harness End)
(Rear drum lowering stop signal)
Z1 Z2 Z3 Z4
x Check the continuity between terminal Z14 of the Z12 Z13 Z14 Z15
(Third drum hoisting stop signal)

(Third drum lowering stop signal)

(Boom shouldering prevention signal)

(Tower breakage prevention signal)
T5-3-31
FAILURE OF MAIN PUMP DELIVERY FLOW
CONTROL SYSTEM
Abnormality
x Using the power supply monitor, check if the battery
and sensor power supply of MC2/A are all normal.
x If any errors are indicated, refer to "Failure of MC2/A
Batteries and Sensor Power Supply".
x Using the MC2/A input/output monitor, confirm the
sensor and solenoid valve signals.
Normal range (under the Countermeasure for

following conditions) abnormality
THROT._GRIP Accelerator grip signal x.xx V 0.95 to 1.05 Harness check
Sensor check
Remote control pressure x.xx V 0.40 to 0.84 Harness check
DD_HST_PRS Boom derricking drum hoisting Sensor check
DD_LWR_PRS Boom derricking drum lowering
FD_HST_PRS Front drum hoisting
FD_LWR_PRS Front drum lowering
RD_HST_PRS Rear drum hoisting
RD_LWR_PRS Rear drum lowering
3D_HST_PRS Third drum hoisting
3D_LWR_PRS Third drum lowering
M_PMP_CUR Main pump displacement angle xxxx mA 680 to 720 Harness check
proportional solenoid valve Solenoid valve check
x For check of remote control pressure sensors, refer Conditions of the normal range
to Section "Failure of Brake Control System." 1. The engine is running.
x For check of the accelerator grip, refer to Section 2. The auto stop is not operating.
“Failure of Engine Control System”.
positions.
minimum positions.
6. All the switches are in the normal or
OFF positions.
T5-3-32
Failure of Main Pump Delivery Flow Control System
MC2/A
D1 MAIN_B
PWMOUT0+ F9 Main Pump
M18 KEY_SW Displacement
Angle Proportional
+24V PWMOUT0- F5
Solenoid Valve
E12 SOL_VB
E13 PWM_VB
MAIN_GND
E26 PWM_GND
D5 SENSOR_5V
D14 SENS_GND_5
Accelerator B5 AN_IN0
Grip
D16 SENSOR_5V
D15 SENS_GND_5
Boom Derricking Drum

B1 AN_IN8
Hoisting Remote
Control Pressure
Boom Derricking Drum B9 AN_IN9

Lowering Remote
Control Pressure
Front Drum Hoisting
Remote Control C6 AN_IN10
Pressure
Front Drum Lowering
Pressure
Rear Drum Hoisting

C5 AN_IN12
Remote Control
Pressure
Rear Drum Lowering
Remote Control
C11 AN_IN13
Pressure
Third Drum Hoisting
C4 AN_IN14
Remote Control
Pressure
Third Drum Lowering
C10 AN_IN15
Remote Control
Pressure
T5-3-33
Check of Main Pump Displacement Angle
• Check the wiring connections first.
Note
“solenoid” means “main pump displacement angle
proportional solenoid”
YES Faulty solenoid

Disconnect connector of
main pump displacement
angle proportional solenoid YES Harness short circuit between
and Insert an ammeter. Check for continuity
Disconnect connector MCA-5 of YES between F5 and F9 solenoid and MC2/A
Check if electric current is
700 to 0mA with turning MC2/A and solenoid connector. of harness end of
accelerator grip from 0 to Check for continuity between MCB-5 or solenoid Faulty MC2/A
100%. terminal F9 of solenoid connector connector. NO
and F9 of MCA-5.
Key switch: ON. NO Check for continuity between
terminal F5 of solenoid connector Broken harness F9 or F5
and F5 of MCA-5. NO between MC2/A and solenoid
½ Key switch OFF

½ Remove the ammeter
Connector
Main Pump Displacement Angle MC2/A

Proportional Solenoid Valve Connector MCA-5 (Harness End)
(Harness End)
F5 F9
F9 F5
T5-3-34
Check of Remote Control Pressure Sensor
System Traveling)

• If voltage from pressure sensor is 4.6V or more,
pressure sensor may be faulty, or harness may be
broken between terminal X15 of MC2/B and
terminal X15 (ground) of pressure sensor.
• If voltage from the pressure sensor is 0.4V or less,
Note
harness X16 (SENSOR_5V) may be broken “sensor” means “traveling right or left remote
between MC2/B and the pressure sensor, or a control pressure sensor”
short circuit between line X16 and ground.
Terminal
Right : S1
Connect disconnected YES Faulty MC2/B
Left : S9
YES connector.
Disconnect connector terminal S1 (S9) of MCB-3
MCB-3 of MC2/B. Faulty sensor
and machine is 0.5 to 4.5V. NO
YES between terminal S1 ½ Key switch: ON
½ Insert test bar into rear face
(S9) of harness end of connector.
connector of sensor
and terminal S1 (S9) Broken harness S1
of MCB-3. (S9) between MC2/B
Check if voltage NO and sensor
Key switch: OFF.
YES between X15 and
X16 of harness
end connector of YES Faulty MC2/B
sensor is 5 ± 0.5V. YES between X15 of
Key switch: ON. harness end connector Broken harness X15
Disconnect connector of sensor and machine.
of pressure sensor. Check if voltage between MC2/B and
between X16 of harness NO sensor
Check for continuity Key switch: OFF.
between terminals X15 NO end connector of sensor
and X16 of sensor side and machine is 5 ± 0.5V.
Broken harness X16
connector. Key switch: ON. between MC2/B and
NO sensor
Key switch: OFF.
Faulty sensor
NO
Connector
MC2/B
Traveling Connector MCB-1 (Harness End)
(Harness End)
X15 X16
D5 SIG D14
X16 GND +5V
(D5) X15
(D14)
S1: right MC2/B
S9 : left Connector MCB-3 (Harness End)
S1
S9
T5-3-35
FAILURE OF MAIN PUMP POWER
INCREASE CONTROL SYSTEM
When abnormal
• Using the power supply monitor, check if the
batteries and sensor power supply of MC2/A are
all normal.
• If any errors are indicated, refer to "Failure of
MC2/A Batteries and Sensor Power Supply".
• Using the MC2/A input/output monitor, confirm the
sensor and solenoid valve signal statuses.
Normal range
Countermeasure for
abnormality
conditions)
INC._TQ_CUR Power shift proportional xxxx mA 0 to 720 Harness check
solenoid valve Solenoid valve check


MC2/A
D1 MAIN_B
PWMOUT1+ F21 Main pump
M18 KEY_SW power shift
+24V PWMOUT1- F17 proportional
E12 SOL_VB solenoid valve
E13 PWM_VB
MAIN_GND
E26 PWM_GND ECU
DA_OUT B6 ACCEL2 SIG
DA_GND B14 ACCEL1 SIG
T5-3-36
Check of Main Pump Power Shift Proportional
Solenoid Valve
• Check the wiring connections first. Note

“solenoid” means “main pump power shift
proportional solenoid”.
YES Faulty solenoid
Disconnect connector of main

pump power shift proportional
YES Harness short circuit
solenoid and Insert an ammeter. Check for continuity between MC2/A and
Operate throttle. YES between terminals F21 solenoid
Check if electric current changes Disconnect connector MCA-5 of
and F17 of harness
as engine speed. MC2/A, and solenoid connector.
end of MCB-5 or Faulty MC2/A
solenoid connector.
Engine: Start. terminal F21 of solenoid NO
connector and F21 of MCA-5. Key switch: OFF.
NO
Check for continuity between Broken harness F21
terminal F17 of solenoid or F17 between
connector and F17 of MCA-5. NO MC2/A and solenoid
½ Key switch OFF
Connector
Main Pump Power Shift MC2/A

(Harness End)
F21 F17 F17 F21
T5-3-37
FAILURE OF SWING PUMP
DISCHARGE RATE CONTROL SYSTEM
When abnormal
all normal.
Normal range
Countermeasure for
abnormality
conditions)
SL_CTRL_SP Swing speed control dial x.xx V 0.64 to 0.93 Harness check
Sensor check
SL_PMP_CUR Swing pump displacement angle xxxx mA 0 to 60 Harness check
Conditions of normal range


MC2/A
D1 MAIN_B
PWMOUT4+ Swing Pump
F11
Displacement Angle
M18 KEY_SW
Proportional
+24V PWMOUT4- F7 Solenoid Valve
E12 SOL_VB
E13 PWM_VB
MAIN_GND
E26 PWM_GND
D5 SENSOR_5V
D14 SENS_GND_5
Swing Speed B3 AN_IN4

Control Dial
T5-3-38
Check of Swing Speed Control Dial

• If voltage from the speed control dial is 4.1V or
more, the speed control dial may be faulty, or
there may be a broken harness between terminal
D14 of MC2/A and the speed control dial.
• If voltage from the speed control dial is 0.1V or
less, there may be a broken harness between
MC2/A and the speed control dial, or a short
circuit between ground and D5 (Sensor 5V).

YES connector.
Disconnect connector B3 of MCA-3 and
MCA-3 of MC2/A. Faulty dial
machine is 1.0 to 4.0V. NO
between B3 of harness ½ Key switch: ON
end connector of dial ½ Insert test bar into rear face of
and B3 of MCA-3. connector. Broken harness
between MC2/A and
Check if voltage Key switch: OFF NO dial
YES between D14 and
D5 of harness
dial is 5 ± 0.5V. Check for continuity
Disconnect connector YES between D14 of
of swing speed Key switch: ON harness end connector Broken harness
control dial. Check if voltage of dial and machine. between MC2/A and
Check for continuity between D5 of harness Key switch: OFF NO dial
between terminals D5 NO end connector of dial
and D14 of dial side and machine is 5 ± 0.5V.
Broken harness
connector.
Key switch: ON between MC2/A
Key switch: OFF NO and dial
Faulty dial
NO
Connector
Swing Speed Control Dial
(Harness End)
D14 D5
B3
MC2/A MC2/A
D5 B3
D14
T5-3-39
Check of Swing Pump Displacement Angle

Note
“solenoid” means “swing pump displacement angle
proportional solenoid”
YES Faulty solenoid

swing pump displacement
angle proportional solenoid, YES Harness short circuit
and insert an ammeter. Check for continuity between MC2/A and
Check if electric current YES between F11 and F7 of solenoid
changes from 0 to 700mA, harness end of MCA-5
Disconnect connector MCA-5 of
as swing speed control dial or solenoid connector. Faulty MC2/A
MC2/A and solenoid connector.
is turned from 0 to 100%. NO
Check for continuity of F11 between Key switch: OFF
Engine: Start NO MCA-5 and solenoid connector.
Check for continuity of F7 between Broken harness F11
MCA-5 and solenoid connector. or F7 between
NO MC2/A and solenoid
½ Key switch OFF
Connector
Swing Pump Displacement Angle MC2/A

(Harness End)
F11 F7 F7 F11
T5-3-40
FAILURE OF SWING ALARM CONTROL
SYSTEM
When abnormal
all normal.
sensor and relay signal statuses.
Normal range
Countermeasure for
abnormality
conditions)
SL_RGT_PRS Right swing remote control pressure x.xx V 0.40 to 0.84 Harness check
SL_LFT_PRS Left swing remote control pressure Sensor check
SL_ALAM_LP Swing alarm lamp relay ON/OFF OFF Harness check
Relay check

MC2/A
D1 MAIN_B
PWMOUT7+ E15
Swing Alarm
M18 KEY_SW
Relay
+24V
E12 SOL_VB
E13 PWM_VB
MAIN_GND
E26 PWM_GND
D16 SENSOR_5V
D15 SENS_GND_5
Right Swing
Pressure
Left Swing C9 AN_IN17
Remote Control
Pressure
T5-3-41
Check of Remote Control Pressure Sensor
System(Swing)

• If voltage from the pressure sensor is 4.6V or more, Note
the pressure sensor may be faulty, or there may “sensor” means “swing remote control pressure sensor”
be a broken harness between terminal D15 of
MC2/A and the ground of the pressure sensor.
• If voltage from the pressure sensor is 0.4V or less,
there may be a broken harness between MC2/A Terminal
and the pressure sensor, or a short circuit Right: C3
between ground line and line D16 (SENSOR_5V). Left : C9

connector.
Disconnect connector between C3 (C9) of

MCA-2 and machine is Faulty sensor
MCA-2 of MC2/A.
0.5 to 4.5V. NO
between C3 (C9) of ½ Key switch: ON
harness end connector ½ Insert a test bar into rear face
of sensor and C3 (C9) of the connector.
of MCA-2. Broken C3 (C9)
Check if voltage harness between
Key switch: OFF NO MC2/A and sensor
YES between D15 and
D16 of harness
sensor is 5 ± 0.5V.
YES between D15 of
Key switch: ON harness end
Disconnect connector connector of sensor Broken D15 harness
of pressure sensor. Check if voltage between between MC2/A and
and machine.
Check for continuity D16 of harness end NO sensor
NO connector of sensor and Key switch: OFF
between terminals D15
and D16 of sensor. machine is 5 ± 0.5V.
Broken D16 harness
Key switch: ON between MC2/A and
Key switch: OFF
NO sensor
Faulty sensor
NO
Connector
Swing Remote Control MC2/A
Pressure Sensor Connector MCA-1 (Harness End)
(Harness End)
+5V D15 D16

D16 D15
GND
Right : C3 MC2/A
Left : C9 Connector MCA-2 (Harness End)
C3
C9
T5-3-42
Check of Swing Alarm Relay System
YES Faulty relay

YES
GND of swing alarm relay socket and
machine. Broken GND harness between
Key switch: OFF relay and machine, or faulty
Disconnect swing alarm NO ground
relay from socket.
Check if voltage of terminal
E15 of relay socket is +24V. YES Faulty MC2/A
½ Key switch: ON Disconnect connector MCA-6 of MC2/A.
½ Operate swing leverright or left. Check for continuity between E15 of
NO relay socket and E15 of MCA-6.
Broken E15 harness between
NO MC2/A and relay
Key switch: OFF
Connector
Swing Alarm Relay Socket (R24) MC2/A

(B) E15
GND E15
T5-3-43
FAILURE OF DRUM ROTATION SENSOR
CONTROL SYSTEM
When abnormal
all normal.
sensor and solenoid signal statuses.
Normal range
Countermeasure for
abnormality
conditions)
FD_PLS_A Front drum rotation sensor A ON/OFF ON/OFF (*1) Harness check
FD_PLS_B Front drum rotation sensor B Sensor check
RD_PLS_A Rear drum rotation sensor A
RD_PLS_B Rear drum rotation sensor B
DD_PLS Boom derricking drum rotation sensor
FD_PLS_CNT Front drum pulse counter -xxxxx 0 (*2) Harness check
RD_PLS_CNT Rear drum pulse counter Sensor check
DD_PLS Boom derricking drum pulse counter MC2/A hardware check
D_R._IND. Drum rotation sensor cancel switch ON/OFF OFF Harness check
Switch check
FD_PLS_SOL Front drum rotation indicating solenoid xxxx mA 0 Harness check
RD_PLS_SOL Rear drum rotation indicating solenoid Solenoid check
DD_PLS_SOL Boom derricking drum rotation indicating
solenoid

*1Depends on the position of the sensor and the fin of the drum.
*2 288/hoisting 1rotation
T5-3-44
Failure of Drum Rotation Sensor Control System
MC2/A
D1 MAIN_B
PWMOUT0 E2
M18 KEY_SW Front Drum Rotation
E26 Indicator Solenoid
+24V
E12 SOL_VB
E13 PWM_VB PWMOUT1 E16

Rear Drum Rotation
MAIN_GND E26 Indicator Solenoid
E26 PWM_GND
PWMOUT2 E3
Boom Derricking
Drum Rotation
E26 Indicator Solenoid
Front Drum A13 DG_IN28

Rotation Sensor B
A26 DG_IN29
Front Drum PWMGND
Rotation Sensor A
F12 DG_IN30
Rear Drum
Rotation Sensor B
F1 DG_IN31
Rear Drum
Rotation Sensor A
F13
Boom Derricking DG_IN32
Drum Rotation
Sensor
F16 DG_GND
A15 DG_IN7
㩎㩨㩡㩛࿁ォᗵ⍮㩁㨶㩧㩈㩣㩇㨼㨹㩋
Drum Speed Feedback
Cancel Switch
T5-3-45
Check of Drum Rotation Indicating Solenoid System
YES Faulty drum rotation

indicating solenoid
Disconnect front drum
lever connector. Harness short circuit
Check if voltage between Check for continuity YES
between MC2/A and
terminals E26 and E2
YES between E2 (E16, E3) drum lever
(E16, E3) of harness end and E26 of harness end
connector is +24V. Disconnect connector MCA-6. of MCA-6 or drum lever
Check for continuity of E2 (E16, E3) Faulty MC2/A
½ Key switch ON. connector.
between MCA-6 and connector of NO
½ Operate drum hoisting Key switch: OFF
or lowering. NO drum lever.
Check for continuity of E26 between Broken harness E2
MCA-6 and connector of drum lever. (E16, E3) or E26
NO between MC2/A and
Terminal Key switch: OFF
drum lever
Front : E2
Rear : E16
Derricking: E3
Connector
Front Drum Lever (Harness End) Rear Drum Lever (Harness End) Boom Derricking Drum Lever
(Harness End)
E26 E2 E26 E16 E3 E26
GND SIG GND SIG SIG GND
MC2/A
Front drum SIG Derricking drum SIG
E2 E3
E16 E26
Rear drum SIG
T5-3-46
Check of Drum Rotation Sensor System
YES Faulty sensor or faulty

adjustment
Disconnect connector of drum rotation
sensor. Connect terminals F16 and
Disconnect connectors MCA-4 and MCA-5. YES Faulty MC2/A
SIG of harness end connector.
Check for continuity of SIG between MCA-4
Check if monitor indicator comes ON.
(or MCA-5) and harness end connector of
½ Key switch: ON
NO rotation sensor. Broken harness of SIG
Check for continuity of F16 between MCA-5 or F16 between MC2/A
and harness end connector of rotation sensor. NO and sensor
Key switch: OFF
Check of Drum Rotation Sensor Cancel Switch System
YES Faulty MC2/A
Disconnect connectors MCA-5 and MCA-4.

Check for continuity between terminals F16 Disconnect connector 16F-W of side YES Faulty cancel switch
and A15 of harness end connector. overhead panel.
½ Key switch ON Check for continuity of A15 between MCA-4
½ Drum rotation sensor cancel switch: ON and side overhead panel connector.
NO Broken harness A15 or
Check for continuity of F16 between MCA-4
F16 between MC2/A and
and side overhead panel connector. NO side overhead panel
Key switch: OFF
MCA-4 and MCA-5 are disconnected.
Connector
Drum Speed Feedback Sensor Side Overhead Panel Connector 16F-W

(Harness End) (Harness End)
SIG Connector
Front A A26 MCA-4
F16 SIG B A13 MCA-4 F16 A15
Rear A F1 MCA-5
GND SIG
B F12 MCA-5 Cancel switch
Derricking A F13 MCA-5
MC2/A MC2/A
Connector MCA-4 (Harness End) Front B SIG Rear A SIG Connector MCA-5 (Harness End)
A13 F1
A15 A26 F12 F13 F16
Front A SIG Rear B SIG Derricking SIG

Cancel switch
T5-3-47
FAILURE OF ENGINE START INTERLOCK
CONTROL SYSTEM
When abnormal
all normal.
• Using MC2/A input/output monitor, confirm the
relay signal status.
Normal range
Countermeasure for
abnormality
conditions)
FD_FREE_SW Front drum free switch ON/OFF OFF Harness check
RD_FREE_SW Rear drum free switch Switch check
SL_BRK_SW Swing brake switch ON/OFF OFF Harness check
Switch check
ENG._START Engine start signal ON/OFF OFF Harness check
ENG._INTLCK Engine start interlock ON/OFF ON Harness check
Relay check
INTLCK_LMP Start interlock lamp ON/OFF OFF Harness check

MC2/A
D1 MAIN_B 5. All the dials and pedals are in the minimum positions.
M18 KEY_SW 6. All the switches are in the normal or OFF positions.
+24V
E12 SOL_VB
E13 PWM_VB
MAIN_GND
E26 PWM_GND
D2 SENSOR_24V_1
224 Green
A21 DG_IN19
Front Drum Free Mode Switch
Green
A9 DG_IN20
Rear Drum Free Mode Switch E20
SOL_OUT5 Engine Start
Relay
A18 DG_IN22
Swing Brake Switch Red
OC_OUT3 E23 224
203 A5 Engine Start Interlock

10A DG_IN12
Start Key Switch Indicator
T5-3-48
Check of Engine Start Relay System
YES Faulty engine start relay
YES
GND terminal of harness end of
engine start relay and machine. Broken GND harness
Key switch: OFF between engine start relay
NO and machine, or faulty ground
Disconnect engine start relay from socket.
Check if voltage of terminal E20 of relay
socket is +24V.
YES Faulty MC2/A
½Key switch: ON Disconnect connector MCA-6 of MC2/A.
Swing brake switch: Brake applied Check for continuity of E20 line between
Front drum brake mode switch: Auto Brake NO engine start relay and MCA-6.
Rear drum brake mode switch: Auto Brake Broken harness E20 between
Key switch: OFF NO MC2/A and engine start relay
Connector
Engine Start Relay (R3) MC2/A

(B) E20
E20
GND
T5-3-49
Check of Swing Brake Switch System
YES Faulty MC2/A
Disconnect connector MCA-4. Broken harness 301

YES between fuse and
Check if voltage of terminal
A18 of harness end connector Check for continuity swing lever, or blown
YES between 301 and A18 of fuse
is +24V.
switch side connector of
½Key switch: ON Disconnect MCA-4. swing lever. Faulty swing brake
Swing brake switch: Brake released Check for continuity of A18 line NO switch
½Key switch: OFF
between harness end connector
NO Swing brake switch: Brake
of swing lever and MCA-4.
release Broken harness A18
Key switch: OFF between MC2/A and
NO swing lever
Connector
Swing Lever Connector MC2/A

301 A18
A18
T5-3-50
Check of Drum Brake Free Mode Switch System
(free fall winch)
YES Faulty MC2/A
Trouble in the power

Disconnect connector MCA-4. supply to brake mode
Check if voltage of terminal YES switch o Refer to
A21 (A9) of harness end "Check of Sensor
connector is +24V. Check for continuity Power Supply (24V
YES between D2 and A21 (A9)
system 1) of MC2/A".
½Key switch: ON of switch side connector of
½Brake mode switch: Free mode Disconnect MCA-4. brake mode switch.
Check for continuity of A21 Faulty brake mode
(A9) line between harness ½Key switch: OFF NO switch
NO end connector of front (rear) ½Brake mode switch: Free mode
Terminal drum lever and MCA-4.
Broken harness A21
½Front drum : A21 (A9) between MC2/A
Key switch: OFF NO
½Rear drum : A9 and brake mode switch
Connector
Front Drum Lever Rear Drum Lever
A21 D2 A9 D2
+24V +24V
MC2/A
A9
A21
T5-3-51
FAILURE OF PILOT OIL PRESSURE
INDICATOR CONTROL SYSTEM
When abnormal
all normal.
sensor signal status.
Normal range
Countermeasure for
abnormality
conditions)
PILOT_PRS Primary pilot pressure x.xx V 0.40 to 0.72 Harness check
Sensor check
PILOT_LP Pilot oil pressure indicator ON/OFF ON Harness check


MC2/A
D1 MAIN_B
M18 KEY_SW
+24V
E12 SOL_VB
E13 PWM_VB
MAIN_GND RED
OC_OUT0 E8 224
E26 PWM_GND
Pilot Oil Pressure Indicator
D16 SENSOR_5V
D15 SENS_GND_5
Primary Pilot
Oil Pressure
C2 AN_IN18
Sensor
For checks of the primary pilot oil pressure sensor, refer to

"Check of Primary Pilot Oil Pressure Sensor" in the chapter
on "Failure of Brake Control System".
T5-3-52
Check of Pilot Oil Pressure Indicator
The indicator does not illuminate, even when the pilot

oil pressure is below the set pressure.
YES Faulty MC2/A

Disconnect connector MCA-6 of MC2/A.
YES Check for continuity of E8 line between
terminals of harness end connector of
monitor panel and MCA-6. Broken harness E8 between
Disconnect monitor panel connector.
Key switch: OFF NO MC2/A and monitor panel
Check if voltage of terminal 224 of
harness end connector is +24V.
½Key switch: ON Broken harness between fuse and
½Engine start monitor panel, or blown fuse
NO
½Gate lock lever: Lock position
The indicator does not go off, even though the pilot oil
pressure reaches the set pressure.
YES Short circuit line E8 and ground

Disconnect monitor panel connector. between MC2/A and monitor panel
Check for continuity between terminal E8

of harness end connector and machine.
Short circuit line E8 and ground
Key switch: OFF NO inside monitor panel
Connector
MC2/A
Monitor Panel (Harness End) Connector MCA-6 (Harness End)
E8 E8
GD1 224
GND
T5-3-53
FAILURE OF WINCH MOTOR CUTOFF
PRESSURE CONTROL SYSTEM
When abnormal
all normal.
relay signal status.
Normal range
Countermeasure for
abnormality
conditions)
FD_LWR_PRS Front drum lowering remote x.xx V 0.40 to 0.84 Harness check
control pressure Sensor check
RD_LWR_PRS Rear drum lowering remote
control pressure
FM_CUT_OFF Front motor cutoff ON/OFF ON Harness check
RM_CUT_OFF Rear motor cutoff Solenoid valve check
• Refer to the chapter on the "Failure of Brake Conditions of the normal range
Control System" to check pressure sensors. 1. The engine is running.

MC2/A
D1
PWMOUT2+ F10 Rear motor cutoff
M18 KEY_SW solenoid valve
+24V
E12 SOL_VB
E13 PWM_VB
MAIN_GND
E26 PWM_GND
PWMOUT5+ E14
Front motor cutoff
solenoid valve
D16 SENSOR_5V
D15 SENS_GND_5
Front drum lowering

C12
remote control AN_IN11
pressure sensor
Rear drum lowering C11 AN_IN13

remote control
pressure sensor
T5-3-54
Check of Front Motor Cut off Solenoid Valve System

YES Faulty solenoid
YES
GND of harness end connector of the
solenoid and machine. Broken harness GND between
harness end connector of the
Disconnect connector of front Key switch: OFF NO solenoid and machine, or faulty
motor cut off solenoid. ground
Check if voltage of terminal E14 of
harness end connector is 24V.
YES Faulty MC2/A
½Key switch: ON. Disconnect connector MCA-6.
½Front drum lowering operation Check for continuity of E14 line
NO between MCA-6 and harness
end connector of the solenoid. Broken harness E14 between
NO MC2/A and the solenoid
Key switch: OFF
Connector MC2/A
Front motor cut off solenoid valve Connector MCA-6 (Harness End)
(Harness End)
E14 (B) E14
GND
Check of Rear Motor Cutoff Solenoid Valve System

YES Faulty solenoid
YES
GND of harness end connector of the
solenoid and machine. Broken harness GND between
harness end connector of the
Disconnect connector of rear motor Key switch: OFF solenoid and machine, or faulty
NO
cut off solenoid. ground
Check if voltage of terminal F10 of
harness end is 24V. YES Faulty MC2/A
½Key switch: ON. Disconnect connector MCA-5.
½Rear drum lowering operation Check for continuityof F10 line
NO between MCA-5 and harness end
connector of the solenoid. Broken harness F10 between
NO MC2/A and the solenoid
Key switch: OFF
Connector
Rear motor cut off solenoid valve MC2/A

F10
F10 (B)
GND
T5-3-55
FAILURE OF BOOM DERRICKING DRUM
AUTOMATIC STOP CONTROL SYSTEM
When abnormal
batteries and sensor power supply of MC2/B are
all normal.
MC2/B Batteries and Sensor Power Supply".
• Using the MC2/B input/output monitor, confirm the
switch and solenoid signal statuses.
Normal range
Countermeasure for
abnormality
conditions)
DD_REL_SW Boom derricking drum automatic stop ON/OFF OFF Harness check
override switch Switch check
REL_KEY_SW Automatic stop override key switch ON/OFF OFF Harness check
Switch check
BM_OVERH Boom overhoist ON For non-overhoist Harness check
BM_OVERH2 Boom/tower second overhoist OFF operations: ON Switch check
TH_OVERH Tower overhoist ALLOFF When overhoisting:
BT_LOWER_L Boom/tower lower limit ALLON OFF
JB_OVERH Jib overhoist
JB_OVERH2 Jib second overhoist
HK_OVERH Hook overhoist
ATTACHMENT Attachment detection signal CRANE For crane operation: Harness check
TOWER CRANE Junction box check
ALLOFF For tower operation:
ALLON TOWER
Proportional solenoid valve xxxx mA 739 to 779 Harness check
DD_HST_CUR Boom derricking drum hoisting Solenoid valve check
DD_LWR_CUR Boom derricking drum lowering MC2/B hardware check
DD_HST_STP Boom derricking drum hoisting stop signal ON/OFF ON Harness check
DD_LWR_STP Boom derricking drum lowering stop signal
B/J_LOW_T. Boom/jib shouldering prevention signal
JB_OVER_T. Tower damage prevention signal
• For checks of the harness between the IDU and Conditions of the normal range
MC2/B, refer to "Check of harness between IDU
and MC2/B" in the chapter on "Failure of Brake
Control System". 2. The auto stop is not operating.

T5-3-56
Failure of Boom Derricking Drum Auto Stop Control System
MC2/B
D1 MAIN_B
PWMOUT0+ Z9 Boom Derricking Drum
PWMOUT0- Z5 Hoisting Proportional
M18 KEY_SW Solenoid Valve
+24V
E12 SOL_VB
E13 PWM_VB
PWMOUT1+ Z21 Boom Derricking Drum
Z17
PWMOUT1-
MAIN_GND Solenoid Valve
E26 PWM_GND
Resistance
Boom Derricking Drum
Automatic Stop Override S7 DG_IN0 Resistance
Switch
Automatic Stop R1 DG_IN4
SOL_OUT0 Y4 329
Override Key Switch
Z16 DG_GND Y18 330
SOL_OUT1
X3 SENSOR_24V_2
R3 DG_IN8
Boom Overhoist
R16 DG_IN9
R4 DG_IN10
Tower Overhoist
R17 DG_IN11
R18 DG_IN13
Clamshell:
Lower Limit R7 DG_IN16
R5 DG_IN12
Boom/Tower Second
Overhoist R19 DG_IN15
X4
R8
X4 SENSOR_24V_3
R21
R8 DG_IN18
R21 DG_IN19
R6 DG_IN14
Jib Overhoist With Crane
Jib Backstop IDU

Alignment
R20 DG_IN17 Boom Derricking Drum
DG_IN28 R13 OC_OUT0 Hoisting Stop
DG_IN29 R26 OC_OUT1 Boom Derricking Drum
Main Hook Lowering Stop
R11 DG_IN24
Overhoist
DG_IN36 Z4 OC_OUT8 Shouldering Prevention
DG_IN37 Z15 OC_OUT9 Tower Damage Prevention

Aux. Hook
Overhoist
R9 DG_IN20 CAN_0H X10 CAN_0H
CAN_0L X21 CAN_0L
Jib Second R24 DG_IN25

Overhoist
R22 DG_IN21
Tower Junction Box

Resistance Resistance
T5-3-57
Check of Wiring Detection Signal System

When the error indication is "ALL_ON"
YES Faulty junction box
Disconnect connector of front structure

harness from boom top junction box.
Check for continuity between terminals YES Short circuit in lines R8 and
R8 and R21 of junction box receptacle. R21 between boom top and
Disconnect connector MCB-4 of MC2/B. MC2/B
Key switch: OFF Check for continuity between terminals
NO R8 and R21 of MCB-4.
Faulty MC2/B
½Key switch: OFF NO
½Leave front structure harness connector of
boom top end disconnected.
When the error indication is "ALL_OFF" Terminal

½Crane: R8
½Tower: R21
YES Faulty MC2/B
Disconnect MCB-4.
YES Check for continuity of R8 (R21)
line between MCB-4 and boom Broken harness R8 (R21)
Check if voltage of top junction box. between boom top and
YES terminal X4 of front NO MC2/B
Disconnect connector of structure harness Key switch: OFF
front structure harness from connector of boom
boom top junction box. top end is 24V.
Check for continuity Broken harness X4 between
Key switch: ON boom top and MC2/B
between terminals X4 and NO
R8 of receptacle of boom
top junction box. Faulty junction box
NO
Key switch: OFF
Connector Cable Reel Harness

Cable Reel Harness (Harness End Connector) (Receptacle of Boom (Tower) Top Junction Box)
24P (32P) (24P)

32P
A (R8) #2(R8)
T (R21) A (R8) T (R21)
#2 R8 #3 R21 #3(R21)
U (X4) #㧝(X4)
U (X4) #1 X4
ԘԙԚԛ
Ԝ ԝ Ԟ ԟ Ԡ
ԡ Ԣ ԣ Ԥ ԥ Ԧ
ԧԨԩԪԫ
㪉㪈㩷㪉㪉㩷㪉㪊㩷㪉㪋㩷
MC2/B MC2/B
Connector MCB-1 (Harness End) Connector MCB-4 (Harness End)
X4 R8
R21
T5-3-58
Check of Boom / Tower Overhoist Switch System
(Boom overhoist, Tower overhoist, Boom/Tower second overhoist)
When the error indication is "ALL OFF"

YES Faulty MC2/B
Disconnect connector MCB-4.
YES Check for continuity of line S(b)
between MCB-4and machine
Check if voltage of X3 side connector of switch. Broken harness between
YES of machine end NO MC2/B and switch
Key switch: OFF
connector of overhoist
switch is 24V. Trouble of power supply
Disconnect connector of to the switch o Refer to
overhoist switch. ½Key switch: ON "Check of Sensor Power
Check for continuity between NO Supply (24V system 2)"
terminals X3 and S(b) of of MC2/B.
switch end connector.
½Key switch: OFF Faulty switch
½Overhoist switch: Neutral
NO
When the error indication is "ALL ON"

YES Faulty switch
Disconnect connector of boom switch.

Check for continuity between terminals Harness short circuit S(a)
YES
S(a) and S(b) of switch side connector. and S(b) between MC2/B
½Key switch: OFF and the switch
½Overhoist switch: Neutral NO S(a) and S(b) of MCB-4.
Faulty MC2/B
Key switch: OFF NO
S(a) S(b)
Boom overhoist R3 R16
Tower overhoist R4 R17
Boom / Tower R5 R19
second overhoist
Connector
Tower Overhoist Switch Boom/Tower Second Overhoist
Boom Overhoist Switch
(Machine Harness End) (Receptacle of Junction Box)
(Machine Harness End)
S(b) #2(R19)
R3 R16 X3 S(a) #3(R5) S(b)
R17 X3 S(a) 㽳
S(a) R4 㽴㽲
S(b)
㽶㽵
#1(X3)
MC2/B
R3 R4 R5
R16 R17 R19
T5-3-59
Check of Jib Overhoist Switch System
When the error indication is "ALL OFF" Disconnect connector YES Faulty MC2/B
MCB-4 .
YES Check for continuity between
terminal S(b) of MCB-4 and
terminal #3 of machine side Harness open circuit
YES
Check if voltage of terminal connector of switch. NO between switch and MC2/B
#1 of machine side
connector of switch is 24V. Key switch: OFF
Trouble of power supply to
Disconnect connector of ½Key switch: ON the switch o Refer to
switch.
"Check of Sensor Power
Check for continuity NO
Supply (24V system 3)" of
between terminals #1 and
MC2/B.
#3 of switch side connector.
½Jib overhoist switch: Neutral NO

YES Faulty switch

Check for continuity between terminals YES Harness short circuit
#2 and #3 of switch end connector. Disconnect connector MCB-4. between switch and MC2/B
½Key switch: OFF Check for continuity between terminals
NO S(a) and S(b) of MCB-4.
½Jib overhoist switch: Neutral Faulty MC2/B
Key switch: OFF NO
S(a) S(b)
Jib overhoist R6 R20
Jib second R24 R22
overhoist
Connector Jib Second Overhoist Switch

Jib Overhoist Switch (Junction Box Receptacle)
(Junction Box Receptacle)
#2(R24)
#1(X4)
#2(R6) #1(X4)
ԙ Ԙ
ԙ Ԙ ԛ Ԛ
Ԛ #3(R22)
#3(R20)
MC2/B
R6
R20 R22 R24
T5-3-60
Check of Hook Overhoist Switch System
When the error indication is "ALL OFF"

Disconnect connector MCB-4. YES Faulty MC2/B
terminal #4 of machine side
Check if voltage of connector of switch and Harness open circuit
YES terminal #2 of machine terminal R9 of MCB-4. NO between MC2/B and switch
side connector of Key switch: OFF
Disconnect connector of switch is 24V. Trouble of power supply of
hook overhoist switch. ½Key switch: ON switcho Refer to "Check of
Check for continuity NO Sensor Power Supply (24V
between terminals #2 and system 3)" of MC2/B.
#4 of switch end connector.
½Hook overhoist switch: NO
Non-overhoist position

YES Faulty switch
Disconnect connector of hook overhoist switch.

Check for continuity between terminals #3 and YES Harness short circuit
#4 of switch side connector. Disconnect connector MCB-4. between MC2/B and switch
½Key switch: OFF Check for continuity between
NO terminals R9 and R11 MCB-4.
½Hook overhoist switch: Non-overhoist position Faulty MC2/B
Key switch: OFF NO
Connector
Hook Overhoist Switch Connector Hook Overhoist Switch Connector
(Junction Box Receptacle) (Machine side Connector)
#2(X4) #1(X4) #2 X4
#1 X4
㽳㽲 Ԙ ԙ
㽶㽵㽴 Ԛ ԛ
㽸㽷 #3(R11)
#4(X9)
#3 R11 #4 R9
MC2/B
R9 R11
T5-3-61
Check of Tower Jib Limit Switch System (Swing Lever overhoist, Jib folded detection)
With error indicators "ALL_OFF" YES Faulty MC2/B

terminal #3 of machine side
connector of switch and terminal Broken harness between
Check if voltage of R10 of MCB-4. NO switch and MC2/B
YES terminal #1 of machine
Key switch: OFF
side connector of
Disconnect connector of switch is 24V. Trouble of power supply
limit switch. of switch o Refer to
Check for continuity Key switch: ON "Check of Sensor Power
between terminal #1 and NO Supply (24V System 3)
terminal #3 of switch side of MC2/B."
connector.
½Limit switch: Neutral NO
With error indicators "ALL_ON"
YES Faulty switch (short)

Disconnect limit switch connector.
terminals #2 and #3 of switch side YES Harness short between
connector. Disconnect MCB-4. switch and MC2/B
½Key switch: OFF NO terminal S(a) and S(b) of MCB-4.
½Limit switch: Neutral Faulty MC2/B
Key switch: OFF NO
S(a) S(b)
Swing lever overhoist R12 R10
Jib folded detection R25 R23
Jib Folded Detection Switch Connector

(Junction Box Receptacle)
Connector
#3(R23) #2 (R25)
Swing Lever overhoist Detection Switch
Connector (Junction Box Receptacle) ԙ
Ԛ Ԙ
Ԝ ԛ #1(X4)
#2(R12) #1(X4)
㽳㩷㽲㩷
㽴㩷
MC2/B
#3(R10) Connector MCB-4 (Harness side)
R10 R12
R23 R25
T5-3-62
Check of Boom Derricking Drum Hoisting / Lowering Proportional Solenoid Valve
YES Faulty solenoid
Insert an ammeter between

harness end connector and
connector of boom derricking YES Harness short circuit
between MC2/B and
drum hoisting (or lowering) YES Check for continuity solenoid
proportional solenoid. Disconnect connector MCB-5 and between SIG(+) and
Check if electric current is solenoid connector. SIG(-) of MCB-5.
739 to 779mA. Check for continuity of SIG(+) line Faulty MC2/B
between MCB-5 and solenoid ½Key switch: OFF NO
½Key switch: ON
½All overhoist switches: NO connector.
And check for continuity of SIG(-)
Non-overhoist position Broken harness SIG(+)
line between MCB-5 and solenoid
connector. or SIG(-) between
NO MC2/B and solenoid
½Key switch: OFF
½Remove the ammeter.
Connector
Boom Derricking Drum Hoisting MC2/B

Proportional Solenoid Valve Connector MCB-5 (Harness End)
(Harness End)
SIG(+) SIG(-) Z5 Z9
Z17 Z21
Hoisting Z9 Z5
Lowering Z21 Z17
T5-3-63
Check of Auto Stop Override Select Key Switch System

YES Faulty MC2/B
Disconnect connectors MCB-4
and MCB-5.
Check for continuity between Disconnect connector 16P of left stand panel, YES Faulty auto stop override
terminals Z16 and R1 of MCB-4 and MCB-5. select key switch
harness end connector. Check for continuity of R1 line between MCB-4
½Key switch: OFF NO and connector 16P of left stand panel. Broken harness R1 or Z16
½Auto stop override select key switch: ON Check for continuity of Z16 line between between MC2/B and left
MCB-5 and connector 16P of left stand panel. NO stand panel
Key switch: OFF
Check of Boom Derricking Drum Auto Stop Override Switch System
• Check wiring connections first.

YES Faulty MC2/B
and MCB-5.
Check for continuity between YES Faulty boom derricking drum
terminals Z16 and S7 of Disconnect connector 16P of left stand panel,
MCB-3 and MCB-5. auto stop override switch
harness end connector.
Check for continuity of S7 line between MCB-3
½Key switch: OFF NO and connector 16P of left stand panel.
½Boom derricking drum auto stop Check for continuity of Z16 line between Broken harness S7 or Z16
override switch: ON MCB-5 and connector 16P of left stand panel. between MC2/B and left
NO stand panel
Key switch: OFF
Connector
MC2/B
Left stand panel Connector MCB-3 (Harness End)
Connector 16P (Harness End)
S7
R1 S7 Z16
MC2/B MC2/B
R1
Z16
T5-3-64
(Blank)
T5-3-65
FAILURE OF FRONT DRUM AUTOMATIC
STOP CONTROL SYSTEM
When abnormal
all normal.
switch and solenoid valve signal statuses.
Normal range
Countermeasure for
abnormality
conditions)
FD_REL_SW Front drum automatic stop override switch ON/OFF OFF Harness check
REL_KEY_SW Automatic stop override key switch ON/OFF OFF Switch check
BM_OVERH2 Boom/tower second overhoist ON For non-overhoist
OFF operations: ON
ALLOFF When overhoisting:
ALLON OFF
FD_ROPE_END Front drum rope end detector ON 3 windings or less: ON
OFF More than 3windings:
ALLOFF OFF
ALLON
SHORT For tower operation:
OPEN TOWER
JB_OVERH2 Jib second overhoist ON For non-overhoist Harness check
HK_OVERH Hook overhoist OFF operations: ON Switch check
ALLOFF When overhoisting:
ALLON OFF
FD_HST_CUR Front drum hoisting Solenoid valve check
FD_LWR_CUR Front drum lowering MC2/B hardware check
FD_HST_STP Front drum hoisting stop signal ON/OFF ON Harness check
FD_LWR_STP Front drum lowering stop signal
• For checks of the harness between the IDU and Conditions of the normal range
MC2/B, refer to "Check of harness between IDU
and MC2/B" in the chapter on "Failure of Brake
Control System".

T5-3-66
Failure of Front Drum Auto Stop Control System
MC2/B
PWMOUT2+ Z10
X1 MAIN_B Front Drum
Hoisting Proportional
PWMOUT2- Z6
Solenoid Valve
M18 KEY_SW
+24V
Y12 SOL_VB Drum Lock Switch
PWMOUT3+ Z22
Y13 PWM_VB 383 Front Drum
PWMOUT3- Z18 Lowering Proportional
Y26 PWM_GND
Resistance
Front Drum S15 DG_IN1 Resistance

Automatic Stop
Override Switch
R1 DG_IN4
SOL_OUT2 Y5 331
Automatic Stop Z16 DG_GND
Override Key Switch SOL_OUT3 Y19 332
X3 SENSOR_24V_2
R5 DG_IN12
Boom/Tower R19 DG_IN15

Second Overhoist
Switch
X2 SENSOR_24V_1
Front Drum T9 AN_IN17

Rope End
Detection Switch T4 AN_IN14
X4 SENSOR_24V_3
(Crane) R8 DG_IN18 IDU
(Tower) R21 DG_IN19

Front Drum
DG_IN30 Z12 OC_OUT2 Hoisting Stop
Jib Overhoist R6 DG_IN14

DG_IN31 Z1 OC_OUT3 Front Drum
Prevention Lowering Stop
R20 DG_IN17
Shouldering
DG_IN36 Z4 OC_OUT8 Prevention
Hook
R11 DG_IN24
Overhoist
CAN_0H X10 CAN_0H
R9 DG_IN20
CAN_0L X21 CAN_0L

Overhoist
R22 DG_IN21
Tower Junction Box Resistance Resistance
T5-3-67
Check of Front Drum Hoisting / Lowering Proportional Solenoid Valve
YES Faulty solenoid
Insert an ammeter to the

connector of front drum YES Harness short circuit between
hoisting (or lowering)
MC2/B and solenoid
proportional solenoid. YES Check for continuity
Check if electric current between SIG(+) and
Disconnect connector MCB-5 and
is 702 - 742mA. SIG(-) of MCB-5. Faulty MC2/B
solenoid connector.
½Key switch: ON Check for continuity of SIG(+) line NO
½All overhoist switches: NO between MCB-5 and solenoid.
Non-overhoist position Check for continuity of SIG(-) line Broken harness SIG(+) or
between MCB-5 and solenoid. SIG(-) between MC2/B and
NO solenoid
Key switch: OFF
Connector
Front Drum Hoisting / Lowering

Proportional Solenoid Valve MC2/B
(Harness End) Connector MCB-5 (Harness End)
SIG(+) SIG(-) Z6 Z10

Z18 Z22
Hoisting Z10 Z6
Lowering Z22 Z18
(383)
T5-3-68
Check of Front Drum Automatic Stop Override Switch System
YES Faulty MC2/B
Disconnect connectors MCB-3 and MCB-5.

Check for continuity between terminals Z16 YES Faulty switch
and S15 of harness end connector. Disconnect connector 16P of left
stand panel.
½Key switch: OFF Check for continuity of S15 line
½Front drum automatic stop override switch: ON NO between MCB-3 and connector 16P.
Check for continuity of Z16 line Broken harness S15 or S16
between MCB-5 and connector 16P. between MC2/B and left
NO stand panel
Key switch: OFF
MCB-3 and MCB-5 are disconnected.
Connector

(Harness End)
S15 Z16
MC2/B
MC2/B
S15 Z16
T5-3-69
FAILURE OF REAR DRUM AUTOMATIC
STOP CONTROL SYSTEM
When abnormal
all normal.
Normal range (under the Countermeasure for

following conditions) abnormality
RD_REL_SW Rear drum automatic stop override switch ON/OFF OFF Harness check
RD_ROPE_END Rear drum rope end detector (for EN) ON 3 windings or less: ON
OFF More than 3 windings:
ALLOFF OFF
ALLON
ALLON TOWER
TH_OVERH Tower over-hoist ON For non-over-hoist Harness check
BM_OVERH2 Boom/tower second over-hoist OFF operations: ON Switch check
JB_OVERH Jib over-hoist ALLOFF When over-hoisting:
JB_OVERH2 Jib second over-hoist ALLON OFF
HK_OVERH Hook over-hoist
RD_HST_CUR Rear drum hoisting Solenoid valve check
RD_LWR_CUR Rear drum lowering MC2/B hardware check
RD_HST_STP Rear drum hoisting stop signal ON/OFF ON Harness check
RD_LWR_STP Rear drum lowering stop signal
JB_OVER_T. Tower damage prevention signal

• For checks of the limit switch, the attachment
wiring and the auto stop override select key switch, 1. The engine is running.
refer to the chapter on "Failure of Boom Derricking 2. The auto stop is not operating.
Drum Auto Stop Control System". 3. The gate lock is in the lock position.

T5-3-70
Failure of Rear Drum Automatic Stop Control System
MC2/B
X1 MAIN_B PWMOUT4+ Z11 Rear Drum
M18 KEY_SW
Hoisting Proportional
PWMOUT4- Z7
+24V Solenoid Valve
Y12 SOL_VB
Drum Lock Switch
Y13 PWM_VB
PWMOUT5+ Y14 384 Rear Drum
MAIN_GND Lowering Proportional
PWMOUT5- Z19
Y26 PWM_GND Solenoid Valve
Resistance
Resistance
Rear Drum Automatic
Stop Override Switch S8 DG_IN2
SOL_OUT4 Y6 333
Automatic Stop R1 DG_IN4 SOL_OUT5 Y20 334
Override Key Switch

Z16 DG_GND
X3 SENSOR_24V_2
R4 DG_IN10
Tower Overhoist
R17 DG_IN11
Second Overhoist R19 DG_IN15
X2 SENSOR_24V_1
Rear Drum T2 AN_IN18

Rope End Detector
T10 AN_IN15
(for EN)
X4 SENSOR_24V_3
R8 DG_IN18
R21 DG_IN19
Jib Over-hoist R6 DG_IN14
Jib Backstop
Alignment IDU
R20 DG_IN17
DG_IN32 Z13 OC_OUT4
Rear Drum
Hoisting Stop
DG_IN33 Z2 OC_OUT5 Rear Drum
R11 DG_IN24
Lowering Stop
Main Hook
Over-hoist DG_IN36 Z4 OC_OUT8 Shouldering
Prevention
DG_IN37 Z15 OC_OUT9 Tower Damage
Aux. Hook Prevention
Over-hoist
R9 DG_IN20
CAN_0H X10 CAN_0H
CAN_0L X21 CAN_0L

Over-hoist
R22 DG_IN21
Tower Junction Box

T5-3-71
Check of Rear Drum Hoisting / Lowering Proportional Solenoid Valve
YES Failure solenoid
Insert an ammeter to the

connector of rear drum YES Harness short circuit between
hoisting (or lowering) YES Check for continuity MC2/B and solenoid
proportional solenoid. between SIG(+) and
Check if electric current Disconnect connector MCB-5 (and
MCB-6) and solenoid connector. SIG(-) of MCB-5
is 702 - 742mA. (and MCB-6). Faulty MC2/B
Check for continuity of SIG(+) line
½Key switch: ON between MCB-5 (MCB-6, Y14: in NO
½All over-hoist switches: NO case of lowering) and solenoid.
Non-over-hoist position And check for continuity of SIG(-) Broken harness SIG(+) or
line between MCB-5 and solenoid. SIG(-) between MC2/B and
NO solenoid
Key switch: OFF
Connector
Rear Drum Hoisting / Lowering

(Harness End)
SIG(+) SIG(-)
Hoisting Z11 Z7
Lowering Y14 Z19
(384)
MC2/B MC2/B
Z7 Z11
Z19 Y14
T5-3-72
Check of Rear Drum Automatic Stop Override Switch System
YES Faulty MC2/B
Disconnect connectors MCB-3 and MCB-5.

Check for continuity between terminals Z16 Disconnect MCB-3, MCB-5 and YES Faulty rear drum auto
and S8 of harness end connector. connector 16P of left stand panel. stop override switch
½Key switch: OFF Check for continuity of S8 line between
½Rear drum automatic stop override switch: ON NO MCB-3 and connector 16P.
Broken harness S8 or
Check for continuity of Z16 line
Z16 between MC2/B
between MCB-5 and connector 16P. NO and left stand panel
Key switch: OFF
Connector

(Harness End)
S8 Z16
MC2/B MC2/B
S8
Z16
T5-3-73
FAILURE OF THIRD DRUM AUTOMATIC
STOP CONTROL SYSTEM (OPTIONAL)
When abnormal
all normal.
MC2/B Batteries and Sensor Power Supply."
Normal range
Countermeasure for
abnormality
conditions)
3D_REL_SW Third drum automatic stop override switch ON/OFF OFF Harness check
ALLON TOWER
BT_OVERH2 Boom/tower second overhoist ON For non-overhoist Harness check
JB_OVERH2 Jib second overhoist OFF operations: ON Switch check
HK_OVERH Hook overhoist ALLOFF When overhoisting:
TW_OVERH Tower overhoist ALLON OFF
JB_OVERH Jib overhoist switch
3D_HST_SOL Third drum hoisting stop solenoid ON ON Harness check
3D_LWR_SOL Third drum lowering stop solenoid OFF Solenoid check
MC2/B hardware check
3D_HST_STP Third drum hoisting stop signal ON/OFF ON Harness check
3D_LWR_STP Third drum lowering stop signal
• For check of the limit switch, the attachment wiring

and the automatic stop override select key switch,
refer to the chapter on "Failure of Boom Derricking 1. The engine is running.
Drum Automatic Stop Control System." 2. The auto stop is not operating.
T5-3-74
Failure of Third Drum Automatic Stop Control System (Optional)
MC2/B
X1 MAIN_B
Y7
SOL_OUT6
M18 KEY_SW Third Drum Hoisting
+24V Solenoid Valve
Y12 SOL_VB
Y13 PWM_VB
Y21
SOL_OUT7
MAIN_GND Third Drum Hoisting
Solenoid Valve
GD2
Third Drum Automatic

Stop Override Switch S16 DG_IN3
Automatic Stop R1 DG_IN4

Override Key Switch
Z16 DG_GND
X3 SENSOR_24V_2
Second Overhoist
R19 DG_IN15
X4 SENSOR_24V_3
(Crane) R8 DG_IN18
(Tower) R21 DG_IN19
R6 DG_IN14
Jib
Overhoist R20 DG_IN17
Hook R11 DG_IN24

IDU
Overhoist
R9 DG_IN20
DG_IN34 Z14 OC_OUT6 Third Drum Hoisting Stop
DG_IN35 Z3 OC_OUT7 Third Drum Lowering Stop

Overhoist
R22 DG_IN21 DG_IN36 Z4 OC_OUT8 Shouldering Prevention
CAN_0H
CAN_0L
CAN_0H
CAN_0L
Tower Junction Box
X21 X10 J2 J1
T5-3-75
Check of Third Drum Hoisting / Lowering Solenoid Valve
YES Faulty solenoid
Disconnect connector of third YES Harness short between

drum hoisting (or lowering) Check for continuity
solenoid valve. YES between SIG(+) and
solenoid and MC2/B
Check if voltage between GND of MCB-6 or
terminals SIG(+) and GND of Disconnect connector MCB-6 harness end of Faulty MC2/B
harness end connector is 24V. and connector of solenoid. solenoid connector. NO
Check for continuity of SIG(+) Key switch: OFF
½Key switch: ON line between MCB-6 and
½Over-hoist switches: NO connector of solenoid. In case of no
Non-over-hoist position Check for continuity of GND continuity at SIG(+) Broken harness SIG(+)
line between connector of between MC2/B and
solenoid and machine. solenoid
Key switch: OFF NO

Broken harness GND
between solenoid and
In case of no machine
continuity at GND
Connector
Rear Drum Hoisting / Lowering
(Harness End)
MC2/B
SIG(+) (B)
Hoisting Y7 GND Y7
Lowering Y21 GND Y21
T5-3-76
Check of Third Drum Automatic Stop Override Switch System
YES Faulty MC2/B

Disconnect connectors MCB-3 and
MCB-5.
Check for continuity between terminals Disconnect MCB-3, MCB-5 and YES Faulty third drum auto
S16 and Z16 of harness end connector. connector 16P of left stand panel. stop override switch
Check for continuity of S16 line
½Key switch: OFF NO between MCB-3 and connector 16P.
½Third Drum automatic stop release switch: ON Broken harness S16or
Check for continuity of Z16 line Z16 between MC2/B and
between MCB-5 and connector 16P. NO
left stand panel
Key switch: OFF
Connector

(Harness End)
S16 Z16
MC2/B MC2/B
S16 Z16
T5-3-77
FAILURE OF SECOND OVERHOIST
AUTOMATIC STOP CONTROL SYSTEM
When abnormal
all normal.
Normal range
Countermeasure for
abnormality
conditions)
OH2_REL_SW Second over-hoist recovery switch ON/OFF OFF Harness check
Switch check
ALLON TOWER
BM_OVERH2 Boom/tower second over-hoist ON For non-over-hoist Harness check
JB_OVERH2 Jib second over-hoist OFF operations: ON Switch check
ALLOFF When over-hoisting: OFF
ALLON
OVERH2_SOL Second over-hoist solenoid valve ON/OFF ON Harness check
Solenoid valve check
• For checks of the limit switch, the attachment Conditions of the normal range
wiring and the auto stop override select key switch,
refer to the chapter on "Failure of Boom Derricking
Drum Automatic Stop Control System". 2. The auto stop is not operating.

T5-3-78
Failure of Second Over-hoist Auto Stop Control System
MC2/B
X1 MAIN_B MC2/A
M18 KEY_SW DG_IN11

+24V
Y12 SOL_VB
Y13 PWM_VB
PWM_OUT3 Y17
Second Over-hoist
PWM_GND Y26
GND
Second Over-hoist R14 DG_IN5

Recovery Switch
Z16 DG_GND
X3 SENSOR_24V_2
R5 DG_IN12
Boom/Tower
Second Over-hoist R19 DG_IN15
X4 SENSOR_24V_3
(Crane) R8 DG_IN18
IDU
(Tower) R21 DG_IN19

Over-hoist R22 DG_IN21
CAN_0H
CAN_0H
CAN_0L
CAN_0L
Tower Junction Box
X21 X10 J2 J1
T5-3-79
Check of Second Over-hoist Solenoid Valve System
YES Faulty solenoid
Disconnect second over-hoist

YES Short circuit in
solenoid connector. harness between
Check if voltage between Check for continuity
YES between Y17 and Y26 of MC2/B and solenoid
terminals Y26 and Y17 of
harness end connector is harness end of MCB-6 or
Disconnect MCB-6. Faulty MC2/B
+24V. solenoid connector.
Check for continuity of Y17 line
NO
½Key switch: ON between MCB-6 and harness ½Key switch: OFF
½Second over-hoist limit switch: end of solenoid connector. In case of no
NO Check for continuity of Y26 line Broken harness Y17
Non-over-hoist position continuity at Y17
between harness end of solenoid between MC2/B and
connector and machine. solenoid
½Key switch: OFF NO Broken harness Y26
In case of no machine
continuity at Y26
Connector
Second over-hoist solenoid valve MC2/B

(Harness End) Connector MCB-6 (Harness End)
Y17 Y26
Y17 Y26
T5-3-80
Check of Second Over-hoist Recovery Switch System
YES Faulty MC2/B

and MCB-5.
Check for continuity between YES Faulty second over-hoist
terminals Z16 and R14 of Disconnect connector 16P of left stand panel. recovery switch
harness end connector. Check for continuity of R14 line between
½Second over-hoist MCB-4 and connector 16P.
NO Check for continuity of Z16 line between
recovery switch: ON Broken harness R14 or
MCB-5 and connector 16P. Z16 between MC2/B and
NO left stand panel
½Key switch: OFF
½MCB-4 and MCB-5 are disconnected.
Connector
(Harness End)
R14 Z16
MC2/B MC2/B
R14 Z16
T5-3-81
FAILURE OF FRONT AND REAR MOTOR
SPEED CONTROL SYSTEM
When abnormal
all normal.
Normal range
Countermeasure for
abnormality
conditions)
HM_FIX_SW Slow speed fix switch ON/OFF OFF Harness check
Switch check
FD_CTRL_SP Front speed control dial x.xx V 0.64 to 0.93 Harness check
RD_CTRL_SP Rear speed control dial
FM_CAP_CUR Front motor displacement angle xxxx mA 649 to 689 Harness check
control proportional solenoid valve Solenoid valve check
RM_CAP_CUR Rear motor displacement angle
control proportional solenoid valve

MC2/B 6. All the switches are in the normal or OFF positions.
X1 MAIN_B
M18 KEY_SW
+24V
Y12 SOL_VB
Y13 PWM_VB PWMOUT6+ Y1 Front Motor Displacement

Angle Control Proportional
MAIN_GND PWMOUT6- Z8
Solenoid Valve
Y26 PWM_GND
PWMOUT7+ Y15 Rear Motor Displacement

Angle Control Proportional
PWMOUT7- Z20 Solenoid Valve
R15 DG_IN7
Slow Speed Fix
Switch Z16 DG_GND
X5 SENSOR_5V
X14 SENSOR_GND_5 IDU

Front Speed S5 AN_IN0
Control Dial
Rear Speed S13 AN_IN1

Control Dial
CAN_0H
CAN_0H
CAN_0L
CAN_0L
X21 X10 J2 J1
T5-3-82
Check of Front / Rear Drum Speed Control Dial
Connect disconnected YES Faulty MC2/B

YES connector.
Check if voltage
Disconnect connector between terminal S5 of
MCB-3. MCB-3 and machine is Faulty dial
YES Check for continuity of 0.64 to 0.93V. NO
S5 line between MCB-3
½Key switch: ON
and harness end Broken harness S5
connector of the dial. between MC2/B and
NO dial
Check if voltage ½Key switch: OFF
YES
between X14 and
X5 of harness YES Faulty MC2/B
end connector of Check for continuity
Disconnect connector the dial is 5±0.5V. YES between terminal
X14 of harness end
of front (or rear) drum ½Key switch: ON Broken harness X14
Check if voltage between connector of the dial
speed control dial. between MC2/B and
X5 of harness end and machine.
Check for continuity NO dial
between terminals NO connector of the dial and ½Key switch: OFF
X14 and X5 of speed machine is 5±0.5V.
control dial connector Broken harness X5
½Key switch: ON between MC2/B and
of dial side. NO dial
½Key switch: OFF
Faulty dial
NO
Connector
Front / Rear Drum Speed Control Dial
(Harness End)
GND +5V
X14 X5
S5
Front S5
Rear S13
MC2/B MC2/B
X5 S5
X14 S13
T5-3-83
Check of Front / Rear Motor Displacement Angle Proportional Solenoid Valve
YES Faulty solenoid
Insert an ammeter to front

(or rear) motor proportional YES
Harness short circuit
solenoid connector. Check for continuity of between MC2/B and
Check if electric current is YES SIG(+) and SIG(-) of solenoid
Disconnect MCB-5, MCB-6 and
649 to 689mA. solenoid connector. harness end connector
Check for continuity of SIG(+) line of solenoid. Faulty MC2/B
½Key switch: ON
between MCB-6 and connector of NO
½Key switch: OFF
solenoid.
NO
Check for continuity of SIG(-) line
between MCB-5 and connector of Broken harness SIG(+)
solenoid. or SIG(-) between
NO MC2/B and solenoid
½Key switch: OFF
½Remove the ammeter.
Connector
Winch Motor Displacement Angle
(Harness End)
SIG(+) SIG(-)
SIG(+) SIG(-)
Front Y1 Z8
Rear Y15 Z20
MC2/B MC2/B
Z8 Y1
Z20 Y15
T5-3-84
Check of Slow Speed Fix Switch System
YES Faulty MC2/B
Disconnect connectors MCB-4 and

MCB-5 of MC2/B.
Check for continuity between terminals YES Faulty switch
Disconnect side overhead panel connector.
R15 and Z16 of harness end connector.
Check for continuity of R15 line between
½Key switch: ON side overhead panel and MCB-4.
NO Check for continuity of Z16 line between Broken harness R15 or Z16
½Slow speed fix switch: ON
side overhead panel and MCB-5. between MC2/B and side
NO overhead panel
½Key switch: OFF
½MCB-4 and MCB-5 are disconnected.
Connector
Side Overhead Panel Connector 16F-W

(Harness End)
Z16 R15
MC2/B MC2/B
R15 Z16
T5-3-85
FAILURE OF BOOM DERRICKING DRUM
SPEED CONTROL SYSTEM
When abnormal
all normal.
• Using the MC2/A, MC2/B input/output monitor,
confirm the sensor and solenoid valve signal
statuses.
Normal range
Countermeasure for
abnormality
conditions)
DD_CTRL_SP Boom derricking drum speed control dial x.xx V 0.64 to 0.93 Harness check
(MC 2/A)
DD_HST_CUR Boom derricking drum hoisting xxxx mA 739 to 779 Harness check
DD_LWR_CUR Boom derricking drum lowering MC2/B hardware check
proportional solenoid valve
• Refer to the chapter "Failure of Boom Derricking Conditions of the normal range
Drum Automatic Stop Control System" to check
the boom derricking drum hoisting / lowering
proportional solenoid valves.
MC2/B
X1 MAIN_B
PWMOUT0+ Z9 Derricking Drum
M18 KEY_SW Hoisting Proportional
PWMOUT0- Z5
+24V Solenoid Valve
Y12 SOL_VB
Y13 PWM_VB PWMOUT1+ Z21

Derricking Drum
PWMOUT1- Z17
Y26 PWM_GND
Resistance
Resistance
MC2/A
SOL_OUT0 Y4 329
D5 SENSOR_5V
Derricking B4 SOL_OUT1 Y18 330
Speed Control AN_IN12
Dial D14
SENSOR_GND_5
IDU
CAN_0H
CAN_0L
CAN_0H
CAN_0H
CAN_0L
CAN_0L
D21 D10
X21 X10 J2 J1
T5-3-86
Check of Boom Derricking Drum Speed Control Dial
Note
• Check the wiring connections first. The “dial” means “boom derricking
drum speed control dial”.
YES Faulty MC2/A

Connect disconnected
YES connector.
Disconnect connector B4 of MCA-3 and Faulty dial
MCA-3. machine is 0.64 to 0.93V. NO
YES Check for continuity of
½Key switch: ON
B4 line between
½Insert a test bar into the rear
MCA-3 and harness
face of the connector.
end connector of dial. Broken harness B4
½Key switch: OFF between MC2/A and
Check if voltage NO
dial
YES between D14 and
D5 of harness
dial is 5±0.5V. Check for continuity
YES between D14 of
Disconnect ½Key switch: ON
connector of boom harness end connector
Check if voltage Broken harness D14
derricking drum of dial and machine.
between D5 of harness between MC2/A and
speed control dial. ½Key switch: OFF NO dial
NO end connector of dial
Check for continuity and machine is 5±0.5V.
between terminals Broken harness D5
D14 and D5 of dial. ½Key switch: ON between MC2/A and
NO dial
½Key switch: OFF
Faulty dial
NO
Connector
Boom Derricking Drum Speed

Control Dial (Harness End)
+5V
GND
D14 D5
B4
MC2/A MC2/A
D5 B4
D14
T5-3-87
FAILURE OF TOWER JIB DERRICKING
2-SPEED (FLOW COMBINING)
RESTRICTING SYSTEM
When abnormal
all normal.
Normal range
Countermeasure for
abnormality
conditions)
ALLON TOWER
RD_HST_CUR Rear drum hoisting proportional xxxx mA 702 to 742 Harness check
solenoid valve Solenoid valve check
RD_LWR_CUR Rear drum lowering proportional MC2/B hardware
solenoid valve check
• For checks of the rear drum hoisting proportional

solenoid valve and the rear drum lowering
proportional solenoid valve, refer to the chapter on
"Failure of Rear Drum Automatic Stop Control 1. The engine is running.
System". 2. The auto stop is not operating.
T5-3-88
Failure of Tower Jib Derricking 2-Speed (Flow Combining) Restricting System
MC2/B
X1 MAIN_B
PWMOUT4+ Z11 Rear Drum Hoisting
M18 KEY_SW
Proportional
+24V PWMOUT4- Z7
Y12 SOL_VB Solenoid Valve
Drum Lock Switch
Y13 PWM_VB
PWMOUT5+ Y14
384 Rear Drum Lowering
MAIN_GND
PWMOUT5- Z19 Proportional Solenoid
Y26 PWM_GND Valve
Resistance
Resistance
SOL_OUT4 Y6 333
SOL_OUT5 Y20 334
(Crane) X4 SENSOR_24V_3
R8 DG_IN18
(Tower) R21 DG_IN19 IDU
Tower Junction
CAN_0L
CAN_0H
Box
CAN_0L
CAN_0H
X21 X10 J2 J1
T5-3-89
FAILURE OF EXTERNAL MOMENT
LIMITER INDICATOR CONTROL SYSTEM
When abnormal
batteries and sensor power supply of the IDU are
all normal.
• If any errors are indicated, refer to "Failure of IDU
Batteries and Sensor Power Supply".
• Using the IDU input/output monitor, confirm the
Normal range
Countermeasure for
abnormality
conditions)
External moment limiter indicator ON/OFF Harness check
GREEN_LMP Green ON
YELLOW_LMP Yellow OFF
RED_LMP Red OFF
REL_KEY_SW Auto stop override key switch ON/OFF OFF Harness check
(MC2 / B) Switch check

390
IDU
External Moment Limiter
M1 MAIN_B Indicator Relay
DC_OUT10 N1 External 3-color indicator
M18 KEY_SW
+24V Green
391
MAIN_GND1
MAIN_GND2 Green
DC_OUT11 N14
Yellow
392
Yellow
DC_OUT12 N2
Red
393
Red
T5-3-90
Check of External Moment Limiter Indicator
System
YES Faulty IDU

Connect relay.
YES Connect terminal N( )
of relay to machine. YES
Check if external A
indicator illuminates. Check if voltage
Disconnect connector
of terminal SIG
YES IDU-5. ½Key switch: ON NO of relay is 24V.
Check for continuity of ½Insert test bar into rear Faulty relay
line N( ) between relay face of the connector. ½Key switch: ON
NO
Disconnect relay of socket and IDU-5. ½Connect terminal
external indicator. ½Key switch: OFF N( ) to ground.
Check if voltage of Broken harness
terminal 390 of relay NO between IDU and relay
socket is +24V.
½Key switch: ON Broken harness
between fuse and
NO relay, or blown fuse
YES Faulty external indicator

Check for continuity (blown bulb)
of line SIG between
A external indicator Broken harness
and relay. between external
NO indicator and relay
½Key switch: OFF
Connector
External Moment Limiter Indicator IDU

Relay Socket (Harness End) Connector IDU-5 (Harness End)
N( ) 390
N1 N2
SIG
N14
390
N( ) SIG
Green N 391
Yellow N14 392
Red N2 393
T5-3-91
FAILURE OF OIL COOLING FAN
ROTATION CONTROL SYSTEM
When abnormal
• Using the power supply monitor, check if the IDU
batteries and sensor power supply are all normal.
• Using the IDU input/output monitor, confirm the
IDU
Normal range
Countermeasure
Item Signal Name Description (under the following
for abnormality
conditions)
MAIN_B Main battery voltage xx.xx V 24.00 to 32.00 Harness check
24V Switch power supply xx.xx V 21.60 to 26.40
5V Analog sensor power supply x.xx V 4.97 to 5.03
10V Load cell power supply xx.xx V 9.98 to 10.02
HYD_THM Hydraulic oil temperature sensor x.xx V 0.24 to 4.34 Harness check
OIL_CL_FAN Oil cooling fan operating relay ON / OFF ON Harness check
Normal signal states

IDU input
IDU output Solenoid
Oil temperature temperature Fan
fan stop power supply
sensor
Over 40°C Under 1.7V OFF OFF Rotating
Up to 40°C Over 1.7V ON ON Stopped
(NOTE) The conditions may not match the above
table between 35°C (95 qF) and 40°C (104 qF). Normal range conditions
IDU
M15 SENS_GND_5
Hydraulic oil
temperature
sensor N10 ANL_IN4
OC_OUT13
210 309 N15

+24V
Fuse (#34)
394 Oil cooling
fan solenoid
Oil cooling fan relay (R10)
T5-3-92
Check of Oil Cooling Fan Operating System
If the oil cooling fan does not rotate: Connect cooling fan
• Check the wiring connections first. solenoid connector.
• Check fuse (31). YES Swap oil cooling fan
A
• Check temperature of hydraulic oil. relay (R10) and mast
Check if voltage lowering relay (R4).
Cooling fan rotates over about 40 degrees C.
YES between terminal N15 Check if fan rotates.
of harness end of ½Engine: start
solenoid connector
Disconnect oil and machine is 24V.
YES cooling fan solenoid Faulty solenoid
½Key switch: ON
connector. ½Fan solenoid connector is NO
Check if fan rotates. disconnected.
Check if oil cooling
YES fan relay signal on ½Engine: started Faulty cooling fan motor,
the IDU output NO pump or solenoidvalve
Check if oil monitor is OFF.
temperature ½Key switch: ON Faulty IDU
sensor output NO
is 1.7V or less.
½Key switch: ON Faulty sensor or harness
½Read IDU input
monitor. NO
YES Faulty relay
YES Short circuit harness

N15 and ground
Disconnect IDU-5.
A YES Check for continuity between relay and IDU.
between N15 of relay
Disconnect cooling socket and machine. Faulty IDU
fan relay. NO
Check for continuity ½Key switch: OFF
NO between terminal
N15 of relay socket YES Short circuit harness 394
Disconnect cooling fan with 24V between relay
and machine. solenoid connector. and solenoid.
½Key switch: OFF Check if voltage
NO between 394 of relay
Faulty relay
socket is 24V.
Connector NO
½Key switch: ON
Oil cooling fan relay (R10) Oil cooling fan solenoid valve
(Harness End) connector (Harness End)
(2) N15 309 (1)

394 (B)
394 (5)
309 (1) (2)
GND
(3)
Oil temperature sensor output

Temperature Output voltage IDU
120°C (248qF) 0.25V Connector IDU-5 (Harness End)
70°C (158qF) 0.8V
40°C (104qF) 1.7V
20°C (68qF) 2.5V
-30°C (-22qF) 4.3V N15
T5-3-93
(Blank)
T5-3-94
TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURE
Troubleshooting B procedures are used for failure
diagnosis based on trouble phenomena.
x How to read troubleshooting flowchart
YES (OK)
(2)
According to the result of inspection or measurement in (1), select
࡮ (1) YES (OK) or NO (NOT OK), and go to the next step (2) or (3).
(3)
NO (NOT OK)
࡮ Under the box, inspection or measurement method, or reference may be added. Be

careful that if incorrect inspection or measuring method will make it difficult to find the
· Key switch: ON cause of failure, or may damage the equipment.
࡮ A bold line box shows a cause of failure.

The description in the bold-lined box helps you locate a possible cause of failure.
NOTE: All connector drawings show the

connecting side of the harness end
connector. (as seen from the arrow)
Harness
T6L4-05-03-001
T5-4-1
TROUBLESHOOTING LIST
Failure sections Failure phenomena

E-1 Starter does not run.
E-2 Poor engine starting ability at low temperature. (no preheating)
Engine system
E-3 Engine continues to idle, and the accelerator cannot be operated.
E-4 Engine does not stop.
A-1 Two or more actuators do not work.
Actuator system
A-2 An actuator does not stop, even when the control lever is moved to neutral.
M-1 Drum does not rotate.
M-2 When the hoisting lever is neutral, the load lowers (in automatic brake
Hoisting drum
mode).
system
M-3 Unable to perform free-fall when setting brake mode switch to the Free
Mode position. (free fall winch)
Boom derricking B-1 Drum does not rotate.
drum system
Swing system S-1 The swing speed is too slow, or swing is does not move.
T-1 One of the tracks does not move, the traveling speed is too slow, or the
Traveling system path of traveling is not straight.
T-2 Travel speed cannot be shifted.
O-1 Drum lock does not work.
O-2 Live mast cylinder cannot be extended or retracted.
O-3 Counterweight cylinder cannot be extended or retracted.
Others
O-4 Jack cylinderor side frame connecting cylinder cannot be extended or
retracted.
O-5 Boom foot pin cylinder cannot be extended or retracted.
T5-4-2
(Blank)
T5-4-3
ENGINE SYSTEM TROUBLESHOOTING
E-1 Starter does not run.

• The engine will not start unless the following
conditions are met for the sake of safety when
starting the engine. Please verify these
conditions.
• Turning the key with brake (2) or (3) released will
cause the brake caution lamp to light up.
1) Emergency engine stop switch: released
2) Swing brake switch: brake position
3) Front drum and rear drum brake mode
switch: auto brake (with free fall winch).
• The engine can be started when a start
allowance signal (E20) to the starter relay from
MC2/A.
• Controller signals can be checked at the input
monitor:
Front drum mode switch FD_FREE_SW
Rear drum mode switch RD_FREE_SW
Swing brake switch SL_BRK_SW
Engine-start interlock ENG.INTLCK
Start interlock lamp INTLCK_LP
YES Go to engine system

troubleshooting.
Check if voltage
YES
of starter motor
YES Check if ECU
error is terminal B is 24V.
displayed. YES Check if voltage of
key switch C · Key switch: ON
½Key switch: START terminal is 24V.
Faulty key switch
Check if fusible link Check if voltage of ½Key switch: start
NO
65A, 45A and fuses second end of ½Insert a test bar into the
NO battery relay is 24V. rear of connector
(17), (20), (21), and
(40) are normal. Go to power source
½Key switch: ON
system
NO troubleshooting.
Blown fuse
NO
Connector
Key switch connector (Harness End)
Key switch
terminal C
203
T5-4-4
Connector
Safety relay (R17) Engine start relay (R3)
Starter relay
206 215
E E20
72 212 88
143
E 212 A5
143
(L) (SW)
(B) (S)
Faulty starter relay, or

YES
faulty ground
Check if voltage (terminal L)
YES of starter relay
terminal SW is
over 24V. Check if voltage of
Check if voltage · Key switch: START safety relay terminal A
YES of starter relay NO 212 is over 24V.
terminal S is · Key switch: START

over 24V.
Check if voltage · Key switch: START
YES of starter relay Broken harness
terminal B is between starter relay
NO and starter motor
over 24V.
Check if voltage · Key switch: ON Broken harness
YES of starter motor
between battery relay
terminal S is over NO and starter motor
24V.
· Key switch: START Faulty starter motor,
faulty connection of
NO cables, or faulty
ground
Broken harness of
starter main cable, or
NO faulty connection
YES Broken harness line

212
YES Faulty safety relay

A
Check if voltage of
terminal 143 of safety YES Go to faulty engine
NO relay is over 24V. start interlock control
Check if voltage of system.
· Key switch: START
terminal 143 of · Key switch: START
NO engine start relay is
over 24V.
Broken harness line
· Key switch: START
NO 143
T5-4-5
Power Supply System Failure
Broken harness
YES
between battery relay
and starter motor
YES
Broken harness
between battery and
Disconnect ground
harness 206 of
battery relay Connect harness 206.
Check if voltage Connect (-) terminal of
of relay terminal YES battery to machine. Disconnect harness
is 24V or more. Check if voltage YES 264 of battery relay.
between machine and Connect it to machine.
· Key switch: ON terminal B of starter Disconnect harness Check for continuity
motor is 24V or more. from (+) terminal of between terminal ACC
A
battery, and connect it of harness end of key
· Key switch: ON to machine.
Check if battery switch connector and
Disconnect connector machine.
fluid and voltage
NO are normal. NO of key switch.
between terminal B of Broken harness
harness end connector between battery and
NO key switch
and machine.
Faulty battery
NO
Connector
Key Switch (Harness End)
Terminal B
YES
Broken harness
203 201 between battery relay
Connect ground terminal of
and ground
204 YES battery relay to machine.
Connect disconnected Check if voltage between
connector. machine and terminal B of
starter motor is 24V or more. Faulty battery relay
Terminal ACC · Key switch: ON NO
between machine and
terminal ACC of key
switch is 24V or more. Faulty key switch
A · Key switch: ON NO
· Insert a test bar into the
back side of connector.
Broken harness
between key switch
NO and battery relay, or
blown fuse
T5-4-6
Check of key switch and battery system
YES
battery and ground or
faulty ground.

Connect (-) terminal
battery relay and ground.
of battery to machine. Connect ground terminal
YES Check if voltage of battery relay to
between terminal 206 YES machine.
of harness end of Check if voltage between
battery relay and terminal206 of harness Disconnect line 264
machine is 24V. end of battery relay and harness of battery
· Key switch: ON machine is 24V. relay.
Check if voltage · Key switch: ON
Check if voltage A
Check if battery NO between terminal of
between terminal of
voltage and line 200 harness end harness end and
specific gravity NO of battery relay and machine is 24V.
of battery fluid machine is 24V. · Key switch: ON
are normal.
· Key switch: ON
NO battery and battery relay
Faulty battery
NO
YES Faulty battery relay

A YES
key switch and battery
relay
Check if voltage
between ACC
YES Faulty key switch
NO terminal of key switch
and machine is 24V. Check if voltage
between terminal B of
· Key switch: ON
· Insert test bar into rear of NO key switch and
machine is 24V. Broken harness between
connector
· Key switch: ON NO key switch and battery
· Insert test bar into rear of
connector
Connector
Key switch connector
(Harness End)
Terminal B
203 201 Terminal ACC

204
T5-4-7
E-2Poor engine starting ability at low
temperature (no preheating)
• Turning key switch to ON when coolant is under

0°C will automatically start preheating.
• If coolant is warmer than 0°C, it will not preheat.
• Preheating time changes with coolant
temperature.
• The preheat lamp will light up 5 to 20 seconds
after turning the key switch to ON.
• If an abnormality is indicated by the ECU lamp,
proceed to engine system troubleshooting.
• Check heater relay fuses.
Faulty heater,
YES
faulty ground or
broken harness
between heater relay
and heater
Faulty heater relay,

YES Check if voltage of YES
faulty relay ground or
heater relay output
terminal is 24V. Check if voltage of faulty heater fuse
YES
· Heater lamp lit. heater relay signal
terminal is 24V. Check if voltage of
· Key switch: ON heater relay drive
A
Check if coolant Check if voltage of NO relay output terminal
temperature is input terminal of (216) is 24V.
NO heater relay is 24V.
below 0°C. · Heater lamp lit
· Key switch: ON
Broken heater
NO power source line
Check again with

NO coolant below 0°C.
YES Broken harness line

216
A
YES Faulty heater relay
Check if voltage of
drive relay
Connector heater relay drive relay
NO input terminal (208) is
24V. Broken harness line
Heater relay drive relay (R26) NO 208
· Key switch: ON
(Harness End)
(4)
(1)
(2) 18 96
216 (5)
208
(3)
T5-4-8
E-3Engine continues to idle, and the accelerator
cannot be operated.
• If there is no signal from the accelerator MC2/A

does not output the accelerator signal to ECU
and ECU error 16 and 24 are displayed.
• If the controller abnormality warning lamp is lit,
errors other than "accelerator signal" may also be
problems. Check ECU error codes.
• If the ECU error code is "Accelerator Sensor
Abnormality," operating the accelerator setting
switch will save the internal engine speed. (This
function only operates when abnormality
present.)
Over 4.9V
Harness is shorting with
power supply
Disconnect ECU From 0.9V to 4.1V
YES connector and Refer to engine
check accelerator troubleshooting.
signal voltage of
harness end. Disconnect connector YES
Faulty MC2/A
Check if ECU error · Key switch: ON MCA-3 of MC2/A.
lamp indicates · Turn accelerator grip Check for continuityof
YES
accelerator sensor or depress pedal. Under B6 line between MCA-3 Broken harness between
abnormality 0.2V and ECU2 connector. NO ECU and MC2/A
(code 16, 24).
Check if ECU
error lamp is lit. Go to engine
NO troubleshooting.
· Key Switch: ON
Check accelerator grip
(and pedal), and MC2/A.
NO Go to engine control
system troubleshooting.
Connector
ConnectorECU2 (Harness End)

MC2/A
Connector MCA-3 (Harness End) Grip
Pedal Grip
(115) (101)
B6
B14
B14 B6
B14 B6
Pedal
(158) (144)
Pedal Grip
T5-4-9
E-4 Engine does not stop
• Turning off the rotation allowance circuit (line

158) to the ECU with the key switch stops the
engine.
• To emergency stop the engine, disconnecting the
connector connected to ECU will stop fuel
injection stopping the engine.
YES Go to engine
troubleshooting.
YES Faulty key switch

Reset emergency engine
Check if ECU YES stop switch.
error lamp is lit. Turn key switchOFF.
Check if engine stopped. Harness short of
· Key switch: OFF NO line 204and +24V.
Press emergency · Key switch: OFF
engine stop switch.
YES Harness short of
NO Check if engine
stopped. line 208and +24V.
· Key switch: OFF Reset emergency
engine stopNO
switch. Harness short of
Remove fuse (20). YES line 224 or
NO Check if engine following harness,
stopped. Remove fuse and +24V line.
· Key switch: OFF (19).
NO Check if engine YES Harness short of
stopped. Remove fuse line 202 and +24V.
· Key switch: OFF (17).
NO Check if engine
stopped. Harness short of
· Key switch: OFF NO line 158 and +24V.
T5-4-10
ACTUATOR SYSTEM TROUBLESHOOTING
A-1 Two or more actuators do not work.
• The pilot circuit (pilot pump, gate lock valve, etc.)

or relief valves may be faulty.
• If the hoisting, lowering and boom derricking
(lowering) drums do not work, refer to
“Troubleshooting A” and “Troubleshooting D”.
YES Faulty main pump
YES
Check if main relief pressure
of valve for abnormal
operation is normal. Incorrect main relief valve
· Refer to "Performance Measurement". NO pressure setting
YES Check if primary pilot
circuit pressure is normal. Faulty gate lock valve,
· Refer to "Performance YES faulty pressure reducing
Measurement".
valve or second over
Check if gate lock valve, hoist solenoid valve of
Check if gate lock lever pressure reducing valve and
on and emergency stop solenoid unit
NO second over hoist solenoid valve
switches are in unlock of the solenoid unit is normal.
positions. Faulty pilot pump
· Disassemble. NO
· Gate lock lever: Pulled
· Emergency stop switch: OFF
Turn gate lock lever and
emergency stop switches
NO to unlocked positions.
A-2 An actuator does not stop, even when the

control lever is moved to neutral.
• The spool in the remote control valve or the

control valve may be stuck.
YES Faulty remote control

valve
· Although control lever is in neutral, pilot oil pressure

Check if the actuator stops is being transmitted to control valve (spool).
when the gate lock lever is
moved to the locked position.
Faulty control valve

NO
· Although pilot oil pressure is not being transmitted to

control valve (spool), oil passage is open, due to
sticking, etc.
T5-4-11
HOISTING DRUM SYSTEM TROUBLESHOOTING
M-1 Drum does not rotate.

• If the pilot pump, the pressure-reducing valve of
the 5-spool solenoid valve unit, or the gate lock Notes
valve are faulty, not only drum rotation, but also 28.3MPa = 4100psi
travel and swing, are deactivated. 31.4MPa = 4550psi
4.9MPa = 711psi
• When the safety device or the drum lock motor is
operating, the drum stops.
Refer to "Troubleshooting A” and “Troubleshooting D".

YES Faulty hoisting motor
YES Check if pressure of

port PR of hoisting
motor is 4.9MPa.
Faulty motor brake
YES Check if output pressure NO release valve
from control valve is
28.3 to 31.4MPa.
· Attach a pressure gauge to Stuck spool in control
port a or b of the counter valve or proportional
YES Check if secondary balance valve of the hoisting NO solenoid valve
pilot pressure is motor.
normal. Port a: During hoisting
Remove piping from · Refer to Port b: During lowering
solenoid unit port A5, "Performance
and attach pressure Measurement".
gauge. Faulty remote control
Check if output NO valve
pressure is 4.9MPa.
Faulty second
over-hoist solenoid
NO valve

Port PR (G1/4)
Second over-hoist
solenoid valve
Port A5 Port a (G3/8)
Port b (G3/8)
M2CG-07-063
T2CG-05-04-001
T5-4-12
M-2 When the hoisting lever is neutral, the load
lowers.
(When in automatic brake mode)
• The hoisting drum brake or the hoisting motor

multi-disc brake may not be engaged.
• Refer to "Troubleshooting A".
Winch with free fall Faulty drum brake

YES
release solenoid
valve
Check if output pressure
YES
of drum brake release
solenoid valve is 0MPa. YES Faulty hoisting motor
multi-disc brake
· Attach a pressure gauge to Check if pressure of
port A of the drum brake port PR of hoisting
release solenoid valve. NO motor is 0MPa.
Depress brake pedal. Faulty hoisting motor
Check if load lowers. brake release
NO solenoid valve
Faulty drum brake

NO
Winch without free fall
Port PR (G1/4)
Drum Brake Release Solenoid Valve
Port P (G3/8)
Port A (G3/8)
1
Hoisting Motor
T
3 T2CG-05-04-001
T5-4-13
M-3 Unable to perform free-fall when setting
brake mode switch to the Free Mode position
(free fall winch)

Notes
• Cannot switch into free mode when tower 6.9MPa = 1000psi
derricking drum or secondary hoist solenoid valve
are stopped.
• Check troubleshooting A as well.
YES Faulty drum brake
YES Check if pressure of A port

of brake release solenoid
valve is 6.9MPa.
Faulty brake release
· Disconnect piping from drum brake NO solenoid valve
release solenoid valve A port and
attach a pressure gauge.
YES Check if primary pressure · Engine on
of brake circuit is normal · Brake mode switch: ON (free position)
(6.9MPa). · Brake pedal: not depressed
· Refer to property · Drum free mode switch: ON
measurement guide
Check if brake mode switch
procedure is correct.
Check pilot pump or
· Engine on NO gate lock valve.
· Gate lock lever: pulled
(operating position)
· Brake mode key switch: ON Try again using the
(free position) correct free mode
NO setting procedure.
· Brake pedal depressed
· Brake mode switch: ON
Drum brake solenoid valve
Port P (G3/8)
Port A (G3/8)
1 3
T 2
T5-4-14
BOOM DERRICKING DRUM SYSTEM Boom Derricking Drum Lock
TROUBLESHOOTING
B-1 Drum does not rotate.

the 5-spool solenoid valve unit, or the gate lock
valve are faulty, not only drum rotation, but also
travel and swing, are deactivated.
• When the safety device is operating, the drum
stops. M2CG-07-062
Ball Joint
Refer to "Troubleshooting A” and From Port A5 of
“Troubleshooting D". Torsion Spring
5-spool Solenoid Valve Unit
Notes YES Faulty boom

28.3MPa = 4100psi derricking motor
34.5MPa = 5000psi YES Check if
4.9MPa = 711psi Remove piping from derricking drum
solenoid unit port A2, lock is normal.
YES and attach pressure Faulty boom
NO derricking drum lock
gauge.
Check if pressure is
Check if pressure 4.9MPa. Faulty derricking drum
YES of derricking NO release solenoid valve
motor is 28.3 to
Remove piping 34.5MPa. Faulty proportional
from solenoid unit · Attach pressure solenoid valve of
YES port A5, and attach gauge to boom remote control line, or
pressure gauge. derricking motor. NO faulty boom derricking
Check if pressure Port AM: hoisting remote control valve
Check if is 4.9MPa. Port BM: lowering
primary circuit
pressure is Faulty second
normal. NO overhoist solenoid
· Refer to
"Performance
Faulty pressure
Measurement".
reducing valve of
NO solenoid unit
5-Spool Solenoid Valve Unit Boom Derricking Drum
Port A2
Port A5
Pressure reducing valve
Port b M2CG-07-057
(G3/8)
Port a
M2CG-07-063
(G3/8)
T5-4-15
Port b (G1/4) Port a (G1/4)
SWING SYSTEM TROUBLESHOOTING
Port b (G1/4)
S-1 The swing speed is too slow, or swing is
does not move. Port a (G1/4)

valve are faulty, not only swing, but also travel
and drum rotation, are deactivated.
Notes M2CG-07-059
28.7MPa = 5610psi
31.9MPa = 4630psi
4.9MPa = 711psi
YES Faulty swing motor
YES
Check if pressure of
5-spool solenoid unit
port A3 is 4.9MPa. Check if voltage
· Attach a pressure gauge between terminal #2 of
to port A3 of 5-spool NO swing lever connector
YES Check if motor input solenoid valve unit. and machine is 24V.
pressure is 28.7 to · Insert a test bar into rear of
· Swing brake switch: ON
31.9MPa. the connector.
· Attach a pressure gauge · Key switch: ON
Check if relief to swing motor.
YES pressure of swing · Port b: right swing
Faulty swing control
control valve is 28.7 · Port a: left swing
NO valve
to 31.9MPa.
· Attach a pressure gauge YES Faulty swing pump
Check if to pressure gauge port
Check if the swing pump
secondary pilot of swing control valve.
displacement angle proportional
pressure of swing NO solenoid valve is normal. Faulty MC2/A, or harness
remote control between MC2/A and
valve is normal. Refer to the chapter on "Failure of swing pump proportional
NO
Swing Pump Control System". solenoid valve
· Refer to
"Performance
Measurement". Faulty swing remote
NO control valve
Swing Control Valve 5-Spool Solenoid Valve Unit

b2
(Right Swing) Swing Brake
Pressure Gauge Solenoid Valve
Port G 1/4
a2
(Left Swing) T2CG-01-02-027
Port A3
M2CG-07-063
T5-4-16
YES Faulty swing brake

switch
swing lever. YES Faulty swing brake
YES Connect terminals #2 and #8 Check for continuity solenoid valve
of harness end connector. YES between terminal #2 of
Check if pressure of solenoid harness end connector
unit port A2 is 4.9MPa. of swing brake solenoid Broken harness
Connect disconnected connector.
and machine. between swing brake
· Key switch: ON Disconnect connector of swing
brake solenoid. NO solenoid and ground, or
faulty ground
NO Check if voltage between
terminal #1 of harness end
connector and machine is 24V. Broken harness
· Key switch: ON between swing brake
· Swing brake switch: ON NO solenoid and swing
brake switch
Broken harness
between swing brake
NO switch and battery
Connector
Swing Pump Displacement Angle

Swing Lever (Harness End) Swing Brake Solenoid Valve
(Harness End)
(Harness End)
+24V
GND
1 4) E17 䋨 B 䋩 E11 F7
301
(1) (1) (2)
(2)
) A18
MC2/A
(1) (13)
(14) E17 (26)
T5-4-17
TRAVELING SYSTEM
TROUBLESHOOTING
T-1 One of the tracks does not move, the

traveling speed is too slow, or the path of
traveling is not straight.
• If the pilot pump, the pressure reducing valve of

valve are faulty, not only travel, but also swing
and drum rotation, are deactivated.
• If one of the tracks does not move, the remote
control valve, the control valve, the travel motor,
the rotating joint or the pump may be faulty.
YES Stuck spool in the

control valve
Disassemble and YES Faulty travel motor

Swap left and clean servo piston or travel speed
right travel hoses YES of travel motor. reduction gear
YES on rotating joint. Disassemble and Check if failure
Check if failure clean counterbalance phenomenon Faulty travel motor
phenomenon is YES valve of travel motor. NO servo piston
occurs again.
reversed. Check if failure
phenomenon occurs Faulty
Check if travel again. counterbalance
Check if NO
secondary relief pressure valve
travel pilot NO of slower track
pressure is is normal.
Swap left and right travel YES Faulty relief valve
normal.
relief valves.
· Refer to NO Check if failure phenomenon
"Performance Faulty rotating joint
is reversed.
Measurement". NO
Faulty remote
NO control valve
Rotating Joint
Right Travel
Left Travel A (Forward)
(Reverse)
D
B
Left Travel Right Travel

(Forward) C (Reverse)
T25N-05-04-006
T5-4-18
T-2 Travel speed cannot be shifted.
Notes
4.9MPa = 711psi
• Check wiring and hose connections first.
YES
Faulty travel motor
turn switch
YES Check if input pressure composition
of travel motor port PS
is 4.9MPa. Loose quick coupling
Check if output · Attach tee and pressure NO of hydraulic hose
YES pressure of port A4 gauge to travel motor
of solenoid unit is port PS.
4.9MPa. · Travel speed switch:
Check for continuity high speed
YES between terminal #2 of · Attach pressure gauge Faulty travel high
harness end connector to solenoid unit port A4.
NO speed solenoid valve
of travel high speed · Travel speed switch:
solenoid and machine. high speed
Broken harness
between travel high
Disconnect connector of NO speed solenoid and
travel high speed ground.
solenoid of solenoid unit.
Check if voltage of Broken harness
terminal #1 of harness YES between travel speed
end connector is 24V. Check for continuity between switch and battery, or
· Travel speed switch: high YES terminals 265 and 266 of blown fuse.
speed Disconnect connector 16P of harness end of connector 16P
side overhead panel. of side overhead panel. Faulty travel speed
Check if voltage between · 7UDYHOVSHHG VZLWFKKLJKVSHHG NO switch
NO terminal 265 of harness end
connector and machine is 24V. Broken harness line
NO 265
Connector
Travel high speed solenoid valve Side overhead panel connector 16P
GND
266 䋨B䋩 (1) 265 266 (7)

(1) (2) (8) (16)
5-spool solenoid valve unit

Travel motor
M2CG-07-010
High speed switch port Port A4
(G 1/4)
M2CG-07-063
T5-4-19
OTHER TROUBLESHOOTING
0-1 Drum lock does not work
(front drum, rear drum)
Check power supply for drum lock motor.
YES
A
YES
#4 of harness end connector of drum
lock motor and machine. Faulty ground of
Check if voltage between · Key switch: OFF NO drum lock motor
terminal #6 of drum lock
motor and machine is 24V. Broken harness
· Key switch: ON between drum lock
· Insert a test bar into the motor and battery,
NO or blown fuse (front:
rear of the connector.
#22, rear: #2)
In case Drum Lock cannot be activated.

YES Faulty drum lock
Connect disconnected connector. motor.
YES Disconnect connector of drum lock motor.
Check for continuity between terminals #1 Broken harness
Disconnect connector 12P of right and #3 of harness end connector. between drum lock
A
stand panel. · Key switch: OFF NO switch and drum
Check for continuity between · Drum lock switch: Lock lock motor
terminals of machine end connector.
Faulty drum lock
· Drum lock switch: ON
· Measure following terminals. NO switch
· Front drum: between terminals 274 and 272.
· Rear drum: between terminals 278 and 276.
In case Drum Lock cannot be released.

YES Faulty drum lock
Connect disconnected connector. motor
YES Disconnect connector of drum lock motor.
Check for continuity between terminals #2 Broken harness
Disconnect connector 12P of right and #3 of harness end connector. between drum lock
stand panel. · Key switch: OFF NO switch and drum
A Check for continuity between lock motor
· Drum lock switch: Unlock
terminals of machine end connector.
Faulty drum lock
· Drum lock switch: OFF
NO switch
· Measure following terminals.
· Front drum: between terminals 274 and 273.
· Rear drum: between terminals 278 and 276.
Connector
Drum Rock Motor (Harness End)
Right Stand Panel (Harness End)
Front Rear
(2) (2)
273 272 (1) 272 273 274 (3) (1) 276 277 278 (3)
278 277 276 274 (4) (B) 271 (6) (4) (B) 275 (6)
GND
GND
T5-4-20
T5-4-21
0-2 Live mast flip cylinder cannot be extended
or retracted
• Check wiring connections first. Left Stand Panel Connector 12P

• Check fuse (39) (mast / jack). (Harness End)
• When measuring voltage, turn key switch to ON
283
and put gate lever in the lock position.
Connector

Left Stand Panel Connector 16P (Harness End) (Panel Side)
285 284 283

Connect disconnected YES between terminal #2
connector. of harness end of
Disconnect live mast solenoid valve
YES flip solenoid connector. connector.
Check for continuity Check if voltage
between terminal #5 between terminal #1 of Broken harness
YES (283) of harness end harness end connector between live mast flip
connector 12P and and machine is 24V. NO switch and solenoid
Check for continuity terminal #2 (285) of · Live mast flip switch:
between terminal #5 connector 16P. extend or retract
YES (283) of harness end · Live mast flip switch:
connector 12P and retract
Disconnect
terminal #1 (284) of
connector 12P of
connector 16P. NO
left stand panel.
Check if voltage · Live mast flip switch:
between terminal extend Faulty live mast flip
#5 (283) of harness NO switch
end connector and
machine is 24V. Broken harness
· Key switch ON between fuse #39
NO and connector 12P

Live Mast Flip

Cylinder Extend
(Live Mast Hoisting)
(284,GND)
Connector
Live Mast Flip
3-spool Solenoid Valve Cylinder Retract
(Harness End) (Live Mast Lowering)
(285,GND)
Live Mast
Hoisting: 284 GND
Lowering: 285
(B) PC Port
(G1/4)
(1) (2)
T2CG-01-02-028
3-spool Solenoid Valve
T5-4-22
Disconnect and plug hydraulic hose
connected to live mast flip port of
YES
3-spool solenoidvalve.
Operate live mast switch.
Check if pressure is 26.5 to 32.3MPa.
Connect disconnected · Attach pressure gauge to PG port of
connector. 3-spool solenoidvalve. (G1/4)
Disconnect quick coupling
YES of hydraulic hose of YES Faulty live mast flip
counterweight cylinder
retracting line. cylinder
Check for
continuity Operate cylinder to retract.
YES between terminal Check if relief pressure is Faulty 3-spool solenoid
#2 of harness 26.5 to 32.3MPa. NO valve
Connect disconnected end connector · Attach pressure gauge to Set swing lock and operate
connector.Disconnect and machine. PG port of 3-spool solenoid swing lever.
hydraulic source valve. (G1/4) Check if relief pressure of A
solenoid connector of NO swing control valve is 28.7
YES
swing control valve. to 35.1MPa.
Check if voltage
between terminal #1 of · Attach pressure gauge to PG port
harness end connector of 3-spool solenoid valve. (G1/4)
and machine is 24V.
Broken harnessof ground
· Live mast flip switch: line between solenoid and
extend or retract NO ground

live mast flip switch and
NO solenoid
Broken harnessof ground

line between solenoid valve
NO and ground
Plughydraulic source YES Faulty 3-spool solenoid

port of swing control valve
YES valve and operate flip.
Check if relief pressure Check if the pilot YES Faulty hydraulic source port
of swing control valve is pressure of the of swing control valve
28.3 to 34.5MPa. hydraulic pressure
NO source port is
· Attach pressure gauge to Faulty pilot pressure of
A 1.5MPa or more.
PG port of 3-Spool NO 4-spool solenoid valve
solenoid valve. (G1/4) · Attach pressure gauge to
a1 port of swing control
valve.
Faulty swing control valve
NO or pump
Swing control valve
PG Port (G1/4)
Notes
Connector 26.5MPa = 3840psi
Hydraulic Source Solenoid Valve 32.3MPa = 4680psi
(Harness End) 28.7MPa = 4160psi
35.1MPa = 5100psi
GND 28.3MPa = 4100psi
34.5MPa = 5000psi
A20 (B) 1.5MPa = 218psi
(1) (2)
Hydraulic Source
(A20,GND)
T2CG-01-02-027
T5-4-23
0-3 Counterweight cylinder cannot be extended

or retracted

• Check fuse (39) (mast/jack).
• Connect control box.
YES Faulty Lower hydraulic

source relay
Check if continuity of
Swap lower YES all pair of terminals are
hydraulic source normal, when another
relay (R5) and mast switches of control box
lowering relay (R4). are operated.
Check if Refer to control box
counterweight YES of terminals of control
box end connector continuity check
cylinder moves.
Connectlower between #1(490) and
· Key switch: ON hydraulic source relay. #2(388).
· Lock lever: lock Disconnect control Control box power Broken harness in
· Counterweight cylinder YES box joint connector. switch: ON control box or faulty
switch: extend or retract Check if voltage NO power switch
Disconnect lower between machine end
hydraulic source connector terminal#1
relay from socket. and machine is 24V. Broken harness
Check if voltage between lower hydraulic
NO of terminal#3 of NO source relayand control
socket and box joint connector
machine is 24V.
Broken harness
between lower hydraulic
NO source relay and battery
Connector
Lower Hydraulic Relay (R5) Control Box Joint Connector
Socket (Harness End) (Machine End)
(3)375 (2)388
(4)376 (1)490
(2) (4) (1)
(B) 490 A3
OP12 (5)
GND 225 (5)373
(3)
(13)367
(6)374
(15)GND
T5-4-24
Notes
26.5MPa = 3840psi
32.3MPa = 4680psi
Disconnect quick
coupling of hydraulic
hose connected to
YES counterweight cylinder.
Operate counterweight
cylinder switch, and
Check for check if relief pressure
continuity is 26.5 to 32.3MPa.
YES between · Attach pressure gauge to
terminal #2 of
Connect disconnected PG port of 3-spool solenoid
harness end
connector. Disconnect valve (G1/4)
connector and
connector of solenoid · Engine on
machine.
YES of swing control valve.
Check if voltage
Check for continuity Broken harness
between terminal#1 of
YES between terminal#2 between solenoid and
harness end connector NO ground, or faulty ground
Connect disconnected of harness end of and machine is 24V.
connector. Disconnect counterweight
counterweight solenoid solenoidconnector Counterweight cylinder
Broken harness
of 3-spool solenoid and machine. switch: extend or retract
YES between control box
valve. NO connector and solenoid
Check if voltage
between terminal#1 of
harness end connector Broken harness
and machine is 24V. between solenoid and
NO ground, or faulty ground
Counterweight cylinder
switch: extend or retract.
Broken harness
between control box
NO joint connector and
solenoid valve
Faulty wiring inside

NO control box
Connector
Live Mast Flip Cylinder Extend
(284,GND)
3-Spool Solenoid Valve
(Harness End)
GND Left Retract (376,GND)
(B)
PG Port (G1/4)
(1) (2)
Right Retract (374,GND)
Live Mast Flip Cylinder
Retract (285,GND)
Counterweight
Cylinder Left Extend (375,GND)
Counterweight
Cylinder Right Extend (373,GND)
3-Spool Solenoid Valve T2CG-01-02-028
T5-4-25
YES Faulty counterweight

cylinder
YES Faulty 3-spool

solenoid valve
YES
Operate live mast Plug hydraulic source

flip cylinder. port of swing control
Check if relief YES valve and operate
NO pressure is 26.5 counterweight cylinder.
to 32.3MPa. Check if relief pressure
of swing control valve
Attach pressure gauge is 28.7 to 35.1MPa. YES Faulty hydraulic
to PG port of 3-spool
Set swing lock pin Check if pilot source port of swing
solenoid valve. (G1/4) Attach pressure gauge to control valve
and operate swing. pressure for hydraulic
PG port of swing control
Check if relief source solenoid of
valve. (G1/4) NO swing control valve is
NO pressure of swing Pilot pressure of
control valve is 28.7 1.5MPa or more. 4-spool solenoid
to 35.1MPa. Attach pressure gauge to NO valveis low.
Attach pressure gauge a1 port of swing control
to PG port of swing valve.
control valve. (G1/4)
Faulty swing control
NO valve or pump
Notes
26.5MPa = 3840psi
32.3MPa = 4680psi
28.7MPa = 4160psi
35.1MPa = 5100psi
1.5MPa = 218psi
PG Port
(G1/4)
Connector
Solenoid Valve Connector

(Harness End) Hydraulic
Source
(A20,E)
GND
A20 (B)
(1) (2)
a1 Port
(G1/4)
Swing Control Valve

T2CG-01-02-027
T5-4-26
0-4 Jack cylinderorside frame connecting

cylinder cannot be extended or retracted.

• Check if quick couplings of hydraulic hoses are
correctly connected.
• Connect control box wiring to machine connector.
YES Faulty lower hydraulic

source relay (R5)

Swap lower between terminal
hydraulic source YES #15 of machine end
relay (R5) and mast of control box
lowering relay (R4). Check if voltage connecting socket
Check if cylinder between terminal #1 and machine is
YES (490) of machine end
moves.
connector of control
· Lock lever: lock Connect lower hydraulic
box joint connector Broken harness
· Engine is running. source relay. Disconnect
and machine is 24V. between rotatingjoint
· Jack switch: extend upper side connector of
YES rotating joint. and control box joint
or retract NO connector, or faulty
terminal #4 of upper rotatingjoint
Disconnect lower
hydraulic source harness end connector
relay from socket. and machine is 24V. Broken harness between
Check if voltage lower hydraulic source
NO of terminal #3of NO relay and rotating joint
socket and
machine is 24V.
lower hydraulic source
NO relay and battery
Connector Control Box Joint Connector

(Machine End)
(4)495 (3)496 (2)429

Lower Hydraulic Relay Rotating Joint Upper (1)490
(R5) (Socket) Connector (8)428 (6)493
(Upper Harness End)
(2) (4) (1) (9)425 (5)494
1
(B) 490 A3 429
OP12 (5) 490 (7)427

) 4) (10)426
GND 225 (13)421
(11)423
(3) (12)424
(15)GND (14)422
T5-4-27
Disconnect solenoid
connector of lower
control valve.
YES
Check if voltage
between terminal #3 of
Check for continuity harness end connector
Connect disconnected YES between harness and machine is 24V.
connector. Disconnect end connector
terminal #2 and Switch: extend
lower hydraulic source
YES solenoid connector. machine. Broken harness between
Check if voltage lower hydraulic source
YES Check if control between harness end
box power NO solenoid and ground, or
connector terminal #1 faulty ground
lamp is lit.
YES
Check if and machine is 24V.
control box is Control box power switch: Broken harness between
normal. ON YES lower hydraulic source
Disconnect rotating
Refer to control solenoid and rotating
joint upper connector.
box continuity joint
check
NO between rotating joint Broken harness between
connector terminals
#2 and #3. rotating joint and control
NO box power switch, or
Control box power switch: faulty rotating joint
ON
Broken lamp line of
NO control box or blown bulb
Faulty control box

NO
Broken groundline or
NO faulty ground
Check for broken line in
lower junction box.
Lower Control Valve
PG Port (G3/8)
Connector
Solenoid Valve Distribution
Lower Control Valve
xJack Right Front Extend/Retract
(Harness End) 427/428
xJack Left Front Extend/Retract
425/426
Retract xJack Right Rear Extend/Retract
Retract
GND 423/424
xJack Left Rear Extend/Retract
1 2 421/422
xSide Frame Connecting Cylinder
3 4
Right Extend/Retract 495/496
xSide Frame Connecting Cylinder
Extend
Extend Left Extend/Retract 493/494
GND
T25N-03-05-019
T5-4-28
Check if another
YES jack or side frame
Check for continuity connecting cylinder
A
YES between terminal #2 of moves.
harness end connector
Check if voltage of solenoid valve and
machine. Broken harness
YES between terminal #1 of
harness end connector between solenoid and
NO
Check for continuity of solenoid valve and ground
YES between terminal #4 machine is 24V.
of harness end Broken harness
Switch: extend
connector of solenoid between switch and
valve and machine. NO
solenoid
Broken harness
NO
ground
Broken harness
between switch and
NO solenoid
YES Faulty jack cylinder

Disconnect quick coupling
of hydraulic hose
YES connected to the cylinder
and operate switch. Connect disconnected YES Faulty lower control
Check if relief pressure is quick coupling. Operate valve
18.5 to 22.7MPa. boom foot pin cylinder.
NO Check if relief pressure
Attach the pressure gauge to Faulty pump or 4-spool
A PG port of lower control valve. is 18.5 to 22.7MPa. NO solenoid
Attach pressure gauge to PG
port of 4-spool solenoid valve. YES Faulty lower control
valve
Check if boom foot pin
NO cylinder move normally.
Faulty pump or 4-spool
NO solenoid valve
Connector
Lower Hydraulic Source Solenoid Valve

(Harness End)
GND
Lower Hydraulic Source
(429,GND) Notes
429 (B)
18.5MPa = 2680psi
(1) (2)
22.7MPa = 3290psi
b1 PG (G1/4)
a1
4-Spool Solenoid Valve
T2CG-01-02-029
T5-4-29
0-5 Boom foot pin cylindercannot be extended

or retracted.

Upper cab side pin cylinder cannot be moved.
YES Faulty lower hydraulic

source relay(R5)
Connect removed relay.

Disconnect connector 16P
YES of left side overhead panel.
Swap lower YES between terminal connector and machine is
hydraulic source 24V.
#2 of relay socket
relay (R5) and mast (R5) and machine.
lowering relay (R4).
Check if boom foot Broken ground line or
pin cylinder moves. NO faulty ground
Check if voltage of
· Engine on YES terminal #1 of relay
· Lock lever: released socket (R5) and
· Boom foot pin switch: machine is 24V. Broken harness between
YES terminal #1 of l relay (R5)
on or off
and battery (through the
Remove relay (R5) lock lever switch)
from socket. Check if lock
Check if voltage of Check lock lever,
lever is release
NO position. relay (R2), and fuse (15).
NO terminal #3 of relay
socket and machine
is 24V. Release lock lever and
· Engine off NO check again
· Key switch ON
· Lock lever: released Broken harness between
NO relay (R5) and battery
Connector
Lower Hydraulic Source Relay (R5) Left Side Overhead Panel Connector 16P
Socket (Harness End) (Harness End)
(2) (4) (1)

(B) 490 A3
1 OP12 OP13 OP14 OP15 OP16
OP12 (5)
8
GND 225
(3)
T5-4-30

between terminal #2 of
Connect disconnected YES
harness end connector A
connector. Disconnect of solenoid and
connector of boom foot pin machine.
YES right insert solenoid.
connector and machine is Broken harness
Check for continuity between switch and
YES between terminals #1 24V. NO solenoid
and #3 of connector Boom foot pin (upper cab side)
16P of panel end. switch insert: ON
YES between terminals #1 Boom foot pin (upper cab
and #2 of connector side) release switch: ON
NO
16P of panel end.
Boom foot pin (upper Faulty switch contact
cab side) insert switch: NO
ON
Broken harness
between fuse (39) and
NO connector
Notes Connect harness end of YES Faulty boom foot pin

18.5MPa = 2680psi solenoid connector of left solenoid valve
YES boom foot pin to solenoid
22.7MPa = 3290psi
of cab side foot pin.
Check if cab side cylinder Faulty cylinder or
YES Operate boom foot pin left. hydraulic piping
Check if relief pressure is moves. NO
18.5 to 22.7MPa. Turn opposite side pin switch:
ON
Attach pressure gauge to PG Faulty 4-spool solenoid
A port of 4-spool solenoid valve. NO valve or pump
(G1/4)
Broken harness of
NO ground line
Boom Foot Pin

Connector Upper Cab Side
Release
Boom Foot Pin Cylinder (OP14,GND)
Solenoid Valve (Harness End)
Boom Foot Pin
Opposite Side
GND Boom Foot Pin Release
Upper Cab Side (OP16,GND)
(B) Insert b1
(OP13,GND) PG Port
(1) (2) (G1/4)
P
OP13 – OP16
Boom Foot Pin a1

Opposite side 4-Spool Solenoid Valve
Insert
(OP15,GND)
T2CG-01-02-029
T5-4-31
(Blank)
T5-4-32
TROUBLESHOOTING / Troubleshooting C
TROUBLESHOOTING C PROCEDURE
(TROUBLESHOOTING FOR MONITOR)
Use troubleshooting C when any monitors, such as • Monitor Panel
gauges or indicators malfunction.
4
x How to Read Troubleshooting Flow Charts

YES (OK)
(2)
࡮ (1)
(3)
NO (NOT OK) 3
5
After checking or measuring item (1), select either
YES (OK) or NO (NOT OK) and proceed to item
(2) or (3), as appropriate. 6
7
2
࡮ 8
· Key switch: ON 9
Special instructions or reference item are 10

indicated in the spaces under the box. Incorrect
11
measuring or checking methods will render
12 1
troubleshooting impossible, and may damage
components as well.
13
Causes are stated in a thick-line box. Scanning

through thick-line boxes, possible causes can be
seen without going through the flow chart.
14 15
1- Hour Meter
NOTE: All connector drawings illustrated in this 2- Fuel Level Gauge
group are connection ends of harness end 3- Engine Water Temperature Gauge
connector. (Seen from arrow direction.) 4- Engine Oil Pressure Indicator
5- Hydraulic Oil Pressure
6- Engine Start Protocol Violation Indicator
7- Engine Coolant Level Indicator
Harness 8- Low Battery Indicator
9- Engine Oil Filter Restriction Indicator
10 - Engine Preheating Indicator
11 - Air Filter Restriction Indicator
12 - Controller Malfunction Indicator
13 - Engine Overheat Indicator
14 - Cigarette Lighter
15 - Engine Starter Key Switch
T5-5-1
MALFUNCTION OF COOLANT
TEMPERATURE GAUGE
Check the wiring connections first.

Gauge needle does not swing
YES Faulty sensor
YES
coolant temperature sensor
and connect to machine. Disconnect connector of sensor YES Faulty monitor panel
Check if needle swings to and connector 16P of monitor
Check if coolant (H) side. panel.
temperature sensor · Key switch: ON NO Check for continuity of terminal Broken harness
connector is 230 between 16P connector and between monitor panel
correctly connected. temperature sensor connector. NO and sensor
Faulty connection
NO
Gauge needle swings over scale

YES Faulty sensor
Check if needle
returns when
coolant temperature YES
Short-circuited harness
sensor connector is between monitor panel
disconnected. Disconnect connector of the sensor and
and sensor.
connector 16P from monitor panel.
· Key switch: ON NO Check for continuity between terminal 230
of harness end connector and machine. Faulty monitor panel
NO
Gauge needle swings unstably
Disconnect connector of the sensor. YES Faulty sensor

YES Connect terminal #1(230) of harness end
connector to machine.
Check if coolant Check if needle swings to (H) side and Faulty monitor panel
temperature stays in that position. NO
sensor is correctly
· Key switch: ON
connected.
Faulty connection
NO
Monitor panel
Coolant Temperature Sensor
224 Meter 230
Connector
Coolant Temperature Sensor(Harness End)
Coolant Temperature and Electrical Resistance
230 (1) Coolant Temperature Electrical Resistance
(B) (2) qC :
GND
50 (122qF) (153.9)
80 (176qF) 51.9±4.0
Monitor Panel Connector 16P (Harness End) 100 (212qF) 27.4±1.9
120 (248qF) (16.1)
1
8 230
NOTE: Values in ( ) are reference only.
T5-5-2
MALFUNCTION OF FUEL GAUGE
Check the wiring connections first.

Gauge pointer does not move at all.
YES Faulty sensor
fuel sensor. Connect
YES terminals #1 and #2 of
harness end connector. Disconnect connector of fuel YES Faulty monitor panel
Check if gauge pointer sensor and connector 16P of
swings to (F) side. monitor panel.
Check if fuel
NO Check for continuity of terminal Broken harness
sensor is correctly · Key switch: ON 232 between connector 16P between monitor panel
connected. · Connect by using a clip. and fuel sensor connector. NO and sensor
Faulty connection
NO
Gauge pointer swings over scale. YES Faulty sensor

Disconnect fuel sensor
connector. Short-circuited harness
Disconnect connector of fuel sensor, YES
Check if pointer swings between monitor panel
and connector 16P of monitor panel.
back to zero. and sensor
· Key switch: ON NO 232 of harness end connector of fuel
sensor and machine. Faulty monitor panel
NO
Gauge pointer swings unstably. Disconnect connector of fuel sensor. YES Faulty sensor
YES Connect terminals #1 and #2 of
Check if gauge pointer swings to (F) Faulty monitor panel
Check if fuel sensor is side and stays in that position. NO
connected correctly. · Key switch: ON
· Insert a test bar into rear face of connector.
Faulty connection
NO
Monitor panel
Fuel Sensor
224 Meter 232
Float
Fuel Sensor (Harness End) FULL
Connector 257 mm
GND
(B) 232 3/4 Fuel Sensor
(Harness End) 1 2
138.5 mm 22q
1 232 R370 33q
8 70.5 mm
Float Position and Electrical Resistance 27q

1/2
Float Position Resistance (:) 228 mm 28q
Full 10 +1.0
- 0.5 Electrical Resistor
1/4
3/4 (19.5) 338 mm
1/2 32r3
1/4 (49.5)
EMPTY
Empty 80r2
T107-04-03-020
T5-5-3
MALFUNCTION OF ENGINE OIL
PRESSUREINDICATOR

Check key switch: ON
Engine stop
Engine has insufficient hydraulic pressure

but warning lamp does not light up.
· Key switch: ON YES Faulty pressure switch

· Engine stop Disconnect connector of engine
YES
oil pressure switch.
Connect terminal 223 of harness
end connector to machine. Broken harness between
Check if warning lamp lights up.
NO pressure switch and monitor
Leaving monitor panel connector
16P connected, connect terminal
223 to machine.
Check if warning lamp lights up.
Disconnect connector 16P of YES Faulty monitor panel or
· Key switch: ON monitor panel. blown warning lamp bulb
· Insert test bar into rear face of Check if voltage between
connector to connect. NO terminal 224 of harness end
connector and machine is 24V. Broken power supply line of
NO monitor panel or blown fuse
Connector
Monitor Panel Connector 16P Engine Oil Pressure Switch

1 223 223
8 224
Monitor panel Engine Oil Pressure Switch
202 224 223
Fuse
The monitor warning lamp lights up when the pressure switch㵭s

contact point connects at 0.05 MPa or less.
T5-5-4
MALFUNCTION OF GLOW LAMP
Key switch during the check: ON

During engine preheating warning lamp does not turn ON.
YES Faulty ECU

Disconnect ECU
connector.
Connect terminal 70 YES Faulty relay
of harness end
connector to machine. Connect ECU
Check if the warning connector. Swap
lamp turns ON. preheating lamp Check for YES
relay and mast Faulty monitor panel
· Key switch: ON NO lowering relay. continuity between or blown bulb of lamp
Disconnect connector YES ground terminal
Check if warning 16P of monitor panel. (GD1) of harness
lamp turns ON. Check if voltage end connector and Broken ground line or
between terminal 236 machine. NO faulty ground
· Any relay can be used NO of harness end
instead of mast lowering
relay.
connector and Broken line 236 or
machine is 24V. NO blown fuse
Connector
Connector ECU1(Harness End) Preheating Lamp Relay
(Harness End)
70 214
236
70
214

(Harness End)
ECU
210 214 70
1
Fuse
8 GD1 236
Preheating Lamp Monitor panel

Relay
GND
236
T5-5-5
MALFUNCTION OF COOLANT LEVEL
INDICATOR

Indicator is not turned ON.
· Check if water level is above Low level.
YES Faulty level switch
coolant level switch.
YES Connect terminals 226
YES Faulty monitor panel
and GE1 of harness end Disconnect connector 16P of monitor
connector. panel.
Check if indicator is NO Check for continuity between machine Broken harness
Turn key switch ON. turned ON. and 226 of harness end connector. between level switch
Check if indicator is · Key switch: ON · Keep terminals 226 and GE1 connected. NO and monitor panel
turned ON.
· Key switch: OFF ļ ON YES Blown indicator bulb
between machine and Disconnect connector IDU-5 of IDU
YES Faulty IDU
NO terminal N3 of connector and 16P connector of monitor panel.
16P of monitor panel. Connect terminal N3 of harness end
· Key switch: ON connector to machine.
· Insert a test bar into the rear NO Check for continuity between Broken harness
face of connector. machine and terminal N3 of harness between monitor panel
· Check within 3 seconds after NO and IDU
end of IDU-5.
turning key switch ON.
Indicator is turned ON although water level is

below the specified level. Short-circuited harness
YES
Disconnect coolant level between level switch
switch connector and and monitor panel
connector 16P of Connect
YES monitor panel. YES Short-circuited harness
disconnected between monitor panel
Check for continuity YES connector.
between machine and and IDU
Check for continuity Disconnect IDU-5.
terminal 226 of harness Check if indicator
Disconnect connector end connector. between machine Faulty IDU
of coolant level switch. and terminal N3 of is turned ON. NO
Check if indicator is NO harness end of 16P · Key switch: ON
turned ON. connector. Faulty monitor panel
NO
· Key switch: ON
Faulty level switch
NO
Monitor Panel Connector 16P Coolant Level Switch

GND
1 N3
8 226 226 䋨B䋩
IDU Connector IDU-5 (Harness End) Reserve Tank
N3
ON
FULL
LOW
Monitor panel Coolant level switch
224 226 Radiator
OFF
N3 Coolant Level Switch

IDU
T107-04-03-012
T5-5-6
MALFUNCTION OF ABNORMAL
CONTROLLER INDICATOR

• If a malfunction occurs in the ECU system, the
controller malfunction indicator illuminates.
Indicator is not turned ON even if abnormality is indicated
by troubleshooting monitor or ECU lamp.
YES Faulty ECU
Disconnect ECU2 connector,
YES and connect terminal 114 or Disconnect monitor panel
connector. Connect terminal YES Faulty monitor panel
115 of harness end of ECU-2
229 of harness end connector
to machine.
to machine.
Check if warning lamp turns
NO Check for continuity between
Turn key switch ON. Broken harness between
terminals 114 or 115 of
ON. · Key switch: ON harness end connector of NO monitor panel and ECU
Check if indicator
ECU and machine.
is turned ON.
YES Indicator bulb is burned out
· Key switch: OFFlON Check for continuity between
machine and terminal N3 of
NO connector 16P of monitor Disconnect connector IDU-5 YES
panel. of IDU. Connect N3 of harness Faulty IDU
end connector to machine.
· Key switch: ON
· Insert a test bar into the rear face NO Check for continuity between
N3 of harness end connector Broken harness between
of connector. of monitor panel and machine. NO monitor panel and IDU
· Check within 3 seconds after
turning key switch ON.
Indicator is turned ON even if failure is not indicated

by troubleshooting monitor or ECU lamp.
YES Faulty ECU
Disconnect ECU2 Short-circuited harness

connector. YES
between monitor panel and
Check if indicator Disconnect monitor ECU
is turned OFF. panel connector 16P.
· Key switch: ON Check for continuity Connect
YES Short-circuited harness
between machine and disconnected
NO terminal 229 of YES connector. between monitor and IDU
harness end Check for continuity Disconnect IDU-5.
connector. between terminal Check if indicator Faulty IDU
N3 of harness end is turned ON. NO
· Keep ECU2 connector NO connector and · Key switch: ON
disconnected. machine. Faulty monitor panel
NO
114 ECU
Monitor panel
Monitor Panel Connector 16P 224 229 115
(Harness End)
1 N3 N3
IDU
8 229
ECU2 Connector(Harness End)

IDU
Connector IDU-5 (Harness End)
115 114
N3
T5-5-7
MALFUNCTION OF AIR FILTER
RESTRICTION INDICATOR

Indicator is not turned ON although air filter is clogged.
YES Faulty air filter restriction
Disconnect terminals of air filter switch.
restriction switch. Connect
YES
terminal 228 of harness end YES Faulty monitor panel
Disconnect connector 16P of
connector to machine.
monitor panel.
Check if indicator is turned ON.
· Key switch: ON NO machine and 228 of harness Broken harness between
Turn key switch ON. end connector. monitor panel and air
Check if indicator is NO filter restriction switch.
· Keep terminal of air filter restriction
turned ON
switch connected to machine.
· Key switch: OFFlON YES Blown indicator bulb
machine and terminal N3 of Disconnect connector IDU-5 of IDU YES
and connector 16P of monitor panel. Faulty IDU
NO connector 16P of monitor panel.
Connect terminal N3 of harness end
· Key switch: ON to machine.
· Insert a test bar into the rear face of NO Check for continuity between N3 of Broken harness between
connector. harness end connector and
· Check within 3 seconds after turning NO monitor panel and IDU.
machine.
key switch ON.
Indicator is turned ON although air filter is not clogged.

· Disassembly and visual check
· Confirm that air filter is not dampened.
YES
between monitor panel
and air filter switch.
Disconnect
terminals of air filter
YES Faulty air filter restriction
restriction switch.
switch.
Check if indicator is Disconnect connector
turned OFF. 16P of monitor panel.
Connect YES Short-circuited harness
· Key switch: ON Check for continuity between monitor panel
disconnected
NO between machine YES connector. and IDU.
and terminal 228 of Check for continuity Disconnect IDU-5.
harness end. between machine Check if indicator Faulty IDU
· Keep air filter restriction and terminal N3 of is turned ON. NO
switch disconnected. NO harness end
· Key switch: ON
connector. Faulty monitor panel
NO
Monitor Panel Connector 16P IDU

(Harness End) Connector IDU-5 (Harness End)
1 N3 N3
8 228
Air filter restriction switch

Monitor panel
Pressure Indicator operation Air filter restriction switch
6.25r0.5kPa or less OFF +24V 224 228
(635r58 mm H2O or less)
(0.91r0.07psi or less) Fuse
6.25r0.5kPa or more N3 IDU
(635r58 mm H2O or more) ON
(0.91r0.07psi or more)
T5-5-8
MALFUNCTION OF OVERHEAT
INDICATOR
Indicator is not turned ON when overheating. YES Faulty overheat switch

Disconnect terminal 335 of
YES overheat switch. Connect harness With terminal of overheat
end terminal 335 to machine. YES Faulty monitor panel
switch connected to machine,
Check if indicator is turned ON. disconnect connector 16P of
· Key switch: ON monitor panel.
NO Check for continuity between Broken harness
Turn key switch ON. between monitor panel
machine and 335 of harness
Check if indicator is NO and overheat switch
end connector.
turned ON.
· Key switch: OFFlON YES Blown indicator bulb
Disconnect connector 16P of
machine and terminal N3 of YES Faulty IDU
NO connector 16P of monitor panel. monitor panel, and connector
IDU-5 of IDU. Connect N3 of
· Key switch: ON harness end of IDU-5 to
· Insert a test bar into the rear face of NO machine. Broken harness
connector. Check for continuity between between monitor panel
· Check within 3 seconds after turning machine and N3 of harness NO and IDU
key switch ON. end of connector 16P.
Indicator is turned ON although coolant temperature is low.

YES Faulty overheat switch
Disconnect
terminal of YES
overheat switch. between monitor panel
Disconnect terminal and overheat switch
Check if indicator 335 of overheat
is turned OFF. switch and connector
· Key switch: ON 16P of monitor panel. YES Short-circuited harness
Connect disconnected between monitor panel
NO Check for continuity YES connector. Disconnect and IDU
between machine IDU-5.
and 335 of harness Check for continuity Check if indicator is
end connector. between machine Faulty IDU
turned ON.
NO
NO and N3 of harness
end connector. · Key switch: ON
Faulty monitor panel
NO
(Harness End)
Overheat Switch Terminal
1 N3 (Harness End)
8 335
335 GE4
IDU
(GND)
Connector IDU-5 (Harness End)
N3
Monitorpanel
Overheat switch
+24V
224 335
Overheat switch
Fuse
Indicator
Coolant temperature N3
operation IDU
Lower than 101 qC (214 qF) OFF
K5
101 qC (214 qF) or higher ON
T5-5-9
MALFUNCTION OF ALTERNATOR
INDICATOR
Alternator indicator is not turned ON although charging is insufficient. Broken harness
YES between charge relay
and ground, or faulty
ground
Broken harness
YES
Disconnect charge between charge relay
relay. Connect terminal and monitor panel
219 of harness end
connector to machine. Disconnect charge relay
Check if alternator YES
and alternator connector.
indicator illuminates. Check for continuity
· Key switch: ON Connect 219 of between 213 of both
monitor panel harness end connectors.
connector to Connect charge relay. · Key switch: OFF
NO machine. Connect terminal 213
Check if alternator
indicator illuminates. YES of harness end YES Faulty alternator
connector of charge
· Key switch: ON relay to machine.
· Insert a test bar into Check if alternator
indicator illuminates. Broken harness
the rear of connector. Check if voltage between alternator
of terminal 206 of · Key switch: ON NO and charge relay
harness end of · Insert a test bar into the
NO charge relay rear of connector.
connector is 24V. Faulty charge relay
NO
· Key switch: ON
Broken harness
between charge relay
NO
and battery relay
Alternator indicator is not turned OFF even when engine runs.

Short-circuited
YES harness to ground
between charge relay
Check for continuity and monitor panel
between 219 of
YES
harness end Short-circuited
connector of charge YES harness to ground
Disconnect
Disconnect charge relay and machine. alternator connector. between alternator
relay and connector Check for continuity and charge relay
of monitor panel. between terminal Disconnect charge
Check for continuity NO 213 of harness end YES Faulty charge relay
relay.
between terminal connector and Check for continuity
219 of harness end machine. NO between terminal Faulty alternator
connector of monitor GND and 219 of
· Key switch: ON NO
panel and machine. relay connector.
· Key switch: ON

NO
Alternator
Charge relay
Connector Monitor panel 206 213
224 219
Charge Relay Alternator Monitor Panel Connector 16P
(Harness End) (Harness End) (Harness End)
GND
1 219
206 219 (B) 213 206
213 218 8
T5-5-10
MALFUNCTION OF BRAKE UNAPPLIED
INDICATOR
• Turn the swing brake switch ON. Then set the
Indicator lighting conditions front/rear/third brake mode switches to "Auto
If key switch is set to “START” position under one or brake mode", and confirm that the engine starts.
more conditions mentioned below, engine does not
start and indicator is turned ON.
• Slewing brake switch: OFF
With "free mount winch specification" (optional)
the following as well:
• Front drum brake mode switch: Free mode
• Rear drum brake mode switch: Free mode
Indicator does not turn ON under

indicator lighting conditions.
Disconnect connector MCA-6 YES Faulty MC2/A
x Key switch: START of MC2/A and connector 16P
YES of monitor panel.
Connect terminal E23 of connector terminals E23 of both harness between monitor panel
16P of monitor panel to machine. end connectors. NO and MC2/A
Check if indicator is turned ON.
· Key switch: ON Faulty monitor panel or

· Connect to machine from rear NO burnt indicator bulb
face of connector.
Indicator is not turned OFF

even when engine runs.
· Engine: Running
· Key switch: ON YES Faulty MC2/A
Disconnect connector MCA-6.

Check if indicator is turned YES Short-circuited harness
OFF. Disconnect connector 16P of between monitor panel
monitor panel. and MC2/A
· Key switch: ON Check for continuity between
NO machine and terminal E23 of Faulty monitor panel
NO
Monitor panel
224 E23 MC2/A
Connector
MC2/A
Monitor Panel Connector 16P Connector MCA-6(Harness End)
(Harness End)
8 E23 E23
T5-5-11
MALFUNCTION OF HOUR METER
Hour meter does not work.

YES Faulty monitor panel
· Key switch: ON (hour meter)
Disconnect connector 16P of monitor panel.
Check for continuity between machine and
terminal GD1 of harness end connector.
monitor panel and ground,
NO or faulty ground
Connector

(Harness End)
Monitor panel
1 224 Meter GD1

8 GD1
GND
MALFUNCTION OF PILOT OIL PRESSURE

INDICATOR
x If pilot oil pressure indicator is faulty, refer to “Check

of Pilot Oil Pressure Indicator” in Troubleshooting A.
T5-5-12
TROUBLESHOOTING / Troubleshooting D
TROUBLESHOOTING D PROCEDURE
If IDU itself or sensors connected to IDU fail, failure

codes will be displayed on the monitor window of IDU.
If error code is indicated, find a page showing
troubleshooting procedures corresponding to an error
code from table on the next page and follow the
flowchart for inspection.
Troubleshooting precautions:
• Turn OFF machine key switch and turn OFF IDU Connector
power, before disconnecting connector.
• Use a digital voltmeter for measurement of voltage
or resistance.
• “Measure XX between A and B” described in the
flowchart implies that red tester stick of digital
voltmeter is connected to A and black tester stick
to B.
• When measuring, be careful to make connection
to connector side and receptacle side correctly. T331-05-07-001
Receptacle
T331-05-07-002
Note: All connector drawings illustrated in this

group are connection ends of harness end
connector. (Seen from arrow direction.)
Harness
T6L4-05-03-001
T5-6-1
FAULT CODE TABLE
Function Failure Fault Failure explanation Judgment and conditions Reference

code page
Auto stop Boom angle E20 Boom angle upper limit failure Boom angle > Upper limit T5-6-4
E21 Boom angle lower limit failure Boom angle < Lower limit T5-6-6
Tower angle E22 Tower angle upper limit failure Tower angle > Upper limit T5-6-4
E26 Tower angle lower limit failure Tower angle < Lower limit T5-6-6
Jib angle E30 Jib angle upper limit failure Jib angle > Upper limit T5-6-8
E31 Jib angle lower limit failure Jib angle < Lower limit T5-6-10
Specification E40 No ML data available No data available corresponding to auto T5-6-13
selection specification selection
E43 Mode selection failure (tower) Crane is selected with tower attachment. T5-6-13
E44 Mode selection failure (crane) Tower is selected with crane attachment. T5-6-13
E45 Attachment wiring short circuit Wiring short circuit in non-disassembly position T5-6-14
Loads E50 Boom / jib derricking force upper limit Boom / jib derricking force > Upper limit T5-6-16
failure
E51 Boom / jib no-load derricking force Boom / jib derricking force < No-load criterion T5-6-18
failure
E52 Boom / jib derricking force lower limit Boom / jib derricking force < Lower limit T5-6-20
failure
E52 Jib derricking force lower limit failure
Jib derricking force < Lower limit T5-6-22
E53 Load cell power supply upper limit failure
10 V power supply monitoring voltage > Upper -
limit
E54 Load cell power supply lower limit failure 10 V power supply monitoring voltage < Lower -
limit 1
E55 Load cell power supply short circuit 10 V power supply monitoring voltage < Lower -
failure limit 2
Monitorling Communication W90 Control A communication failure MC2/A communication status T5-6-30
only W91 Control B communication failure MC2/B communication status T5-6-31
Specification W47 Attachment wiring failure (open circuit) Wiring failure (open circuit) in non-disassembly T5-6-24
selection position
W48 Counterweight detection failure Abnormal counterweight detection T5-6-27
W49 Hook overhoist wiring failure No hook overhoist wiring available on selection T5-6-28
side
Power supply W10 Main power supply upper limit failure Monitoring voltage > Upper limit -
W11 Main power supply lower limit failure Monitoring voltage < Lower limit -
W14 Switch power supply short circuit failure 24V power supply monitoring voltage < lower -
limit 2
WA1 Switch power supply 1 short circuit (Control A) 24V1 power supply monitoring T5-6-32
(control A) voltage < Lower limit 2
WA2 Switch power supply 2 short circuit (control A) 24V2 power supply monitoring T5-6-32
WA3 Switch power supply 3 short circuit (Control A) 24V3 power supply monitoring T5-6-32
WA5 Sensor power supply short circuit (Control A) 5V power supply monitoring voltage -
(control A) < Lower limit 2
WB1 Switch power supply 1 short circuit (Control B) 24V1 power supply monitoring T5-6-33
(control B) voltage < Lower limit 2
WB5 Sensor power supply short circuit (Control B) 5V power supply monitoring voltage -
(control B) < Lower limit 2
T5-6-2
Failure Indication (Title Bar)
Function Failure Fault Failure indication (title bar)

code Red: Auto stop, Orange: Monitoring and warning
Auto stop Boom angle E20 E20: Boom angle is abnormal
E21 E21: Boom angle is abnormal
Angle E27 E27: Angle failure (open circuit)
Tower angle E22 E22: Tower angle is abnormal
E26 E26: Tower angle is abnormal
Jib angle E30 E30: Jib angle is abnormal
E31 E31: Jib angle is abnormal
E37 E37: Jib angle wiring failure (open circuit)
Specification E40 E40: No data available
selection E43 E43: Tower selection
E44 E44: Crane selection
E45 E45: Cable reel short circuit
Loads E50 E50: Load cell failure
E51 E51: Rope tension failure
E52 E52: Load cell failure
E53 E53: Load cell power supply failure
E54 E54: Load cell power supply drop
E55 E55: Load cell power supply short circuit
Monitoring Communication W90 W90: Communication A failure
only W91 W91: Communication B failure
Angle wiring W38 W38: Jib angle wiring failure (open circuit)
Specification W47 W47: Cable reel failure (open circuit)
selection W48 W48: Counterweight detection failure
W49 W49: Hook overhoist wiring failure
Power supply W10 W10: Power supply voltage failure
W11 W11: Power supply voltage drop
W14 W14: Sensor power supply short circuit (24V)
WA1 WA1: Sensor power supply short circuit (24V1A)
WA5 WA5: Sensor power supply short circuit (5VA)
WB1 WB1: Sensor power supply short circuit (24V1B)
WB5 WB5: Sensor power supply short circuit (5VB)
T5-6-3
FAULT CODE E20, E22
Connector (IDU-1)
E22 E20

M6

Check if NO

attachment of
machine is crane.

YES On the operation setting
window, select tower Controller (IDU)
attachment.
Disconnect connector “1” (5P) of boom IDU-1
angle detector from machine junction box.
Check if E20 YES (E21 or E26 indicated) Machine Harness

disappears.
“2”16P ( black)
NO
Boom B
Boom angle detector “1” 5P
With connector “1” (5P) disconnected, failure
measure voltage between terminals
N20 and M6 of connector "2" (16P).
N20: Angle detection sensor output
M6: GND

Between N20 and YES
M6 = 0.2V Boom Angle Detector Machine Junction Box
NO
(over 4V)
Machine junction box
failure Connector "2" (16P Black) Boom B
Disconnect connector IDU-1 of IDU.
Measure resistance between terminals N20 M6 M4

M4: Sensor power supply, 5V


Resistance ? M6 of IDU-1 and terminal M6 of
connector “2” (16P).

0: to1M:

No continuity

Continuity ?
Continuity
Machine harness
failure
IDU failure
T5-6-4
(Blank)
T5-6-5
FAULT CODE E21, E26

E21, E26

Controller (IDU)
Check if connector “1” (5P) of boom

angle detector is correctly connected.
Check if “2” 5P
YES
connection is
correct. “1” 5P
NO
Connect connector of boom angle

detector correctly. Boom Angle Detector Machine Junction Box
T25N-05-06-004

Measure voltage between terminals Receptacle “2” (5P)

#1 and #4 of receptacle "2" (5P) of
machine junction box. M6
2 1
3 M4
4 5

N20

Between #1 NO
and #4 = 4.4V

YES A

Boom angle detector
failure
T5-6-6
Connector (IDU-1)
A E21, E26
M4 M6

Connector (IDU-5)
Measure voltage between terminals
N20: Angle detection sensor output N20
M4: Sensor power supply

YES
Between N20
Controller (IDU)
and M4 = 4.4V
IDU-5 IDU-1
NO
failure
Disconnect connectors IDU-1 and IDU-5

of IDU.
Measure resistance between terminal M6
of IDU-1 and terminal N20 of IDU-5.
M6: GND “3” 16P (black)
Boom B
0: to Several M:
Resistance ?

Boom Angle Detector Machine Junction Box
Make a short circuit between terminals

N20 and M4 of connector “3” (16P).

M4 of IDU-1 and terminal N20 of IDU-5. Connector "3" (16P Black) Boom B

N20 M4

No continuity
Continuity ?

Continuity

Machine harness
IDU failure failure
T5-6-7
FAULT CODE E30
Receptacle “2” (5P)

E30
M6
2 1
3 M4
Disconnect connector “1” (5P) of jib angle 4 5
detector from tower top junction box. N19
Measure voltage between terminals #2
and #4 of receptacle "2" (5P).
#2: M6:GND
#4: N19 Angle detection sensor output
Between #2 YES
and #4 0.2 V
NO Jib angle detector

(over 4V) failure Cable reel wiring
“3”
Disconnect connector “3” of cable reel wiring

of tower top junction box side. “5”
Measure voltage between terminals #17(K)
and #19(Y).
“4”
#17(K): M6 GND
#19(Y): N19 Angle detector output
Machine Junction Box
“1” 5P
“2” 5P
Tower Top Junction Box

Between #17(K) YES
and #19(Y) 0.2 V

NO Boom top junction box
(over 4V) failure
Connector “3” (32P) Connector “3” (24P)

Disconnect connector “4” of cable reel A
wiring of machine junction box.
Measure voltage between terminals 1 2 3 4
#17(K) and #19(Y) of receptacle "5". 5 6 7 8 9

10 11 12 13 14 15
16 17 18 19 20
21 22 23 24
Y
K
Between
#17(K) YES
and #19(Y) 0.2 V Receptacle “5” (32P) Receptacle “5” (24P)
A
NO
(over 4V)
Cable reel wiring
failure
B
Y
K

T5-6-8

B Connector "6" (12P) Boom C

E30

N19 M6 M4

Connect connector “4” to machine Controller (IDU)
junction box. IDU-5 IDU-1
Between N19 YES

and M6 = 0.2V Boom C
“6” 12P (black)
NO
failure
(over 4V)
Disconnect connector IDU-1 and IDU-5 of IDU. “4”

Measure resistance between terminal M4 of
IDU-1 and N19 of IDU-5. Machine Junction Box

0: to Several M: T25N-05-06-009
Resistance ?

Connector (IDU-1)
Measure resistance between terminal M6
of connector "6" (12P) and terminal M6 of
IDU-1. M4 M6

Connector (IDU-5)

No continuity
Continuity ? N19

Continuity
Machine harness
failure
IDU failure
T5-6-9
FAULT CODE E31

E31
Check if connector “1” (5P) of jib angle

detector is correctly connected.
Check if YES
connection is
correct.
NO “1” 5P
Connect connector of jib angle

detector correctly.
Jib Angle Detector
“2” 5P

T25N-05-06-007

Receptacle “2” (5P)

Disconnect connector “1” (5P). M6 M4

Measure voltage between terminals #1
and #4 of receptacle "2" (5P). 2 1
3
4 5

N19

Between #1 YES
and #4 4.8 V

NO
Jib angle detector
failure
T5-6-10
E31
C

Controller (IDU)
Disconnect connector “3” of cable reel
wiring of tower top junction box.
Measure voltage between terminals #16( f ) : M4, Sensor power supply
#16( f ) and #19(Y). #19(Y) : N19, Angle detector output
Cab rear harness

Between #16( f ) YES
and #19(Y) = 4.8 V Boom C
“3” “6” 12P (black)
Cable Reel Wiring
NO Tower top junction
box failure
“5”
“4”
Disconnect connector “4” of cable reel

wiring from machine junction box. Machine Junction Box
#16( f ) and #19(Y) of receptacle “5”.

YES T25N-05-06-010
Between #16( f )
and #19(Y) 4.8 V
Connector "6" (12P) Boom C
N19 M4
NO
Cable reel wiring

failure
Measure voltage between
terminals N19 and M4 of Connector “3” (32P) Connector “3” (24P)
connector "6" (12P).
f A 1 2 3 4
5 6 7 8 9
10 11 12 13 14 15

16 17 18 19 20
21 22 23 24
Between N19 YES Y
and M4 4.8 V
Receptacle “5” (32P) Receptacle “5” (24P)

A
NO
Machine junction box f
failure
D
Y
T5-6-11
Connector (IDU-1)

D E31

M4 M6
Connector (IDU-5)
With connector “6” (12P) disconnected,
disconnect connector IDU-1 of IDU.
Measure voltage between terminals M4 N19
and M6 of IDU-1.

Controller (IDU)
IDU-5 IDU-1
0: to Several M:
Resistance ?
Machine harness
Boom C
failure
“6” 12P (black)
Disconnect
Disconnectconnector
connectorIDU-5
IDU-5ofofIDU.
IDU.
Check
Measure
for continuity
continuitybetween
betweenterminal
N19
terminal
of IDI-5
N19andandterminal
terminal
N19
N19
of of
connector
connector"6""6"(12P).
(12P).

No continuity
Continuity ?
Connector "6" (12P) Boom C

N19
Continuity

Machine harness
failure

IDU failure
T5-6-12
FAULT CODE E40
E40
IDU failure.
FAULT CODE E43, 44
E43 E44
Check if Check if
attachment of NO attachment of NO
field machine is field machine is
“tower”. “crane”.
YES YES
IDU failure IDU failure
On the operation setting window, On the operation setting window,

check the selected attachment. check the selected attachment.
heck if “tower”
C NO Check if “crane” NO
is selected. is selected.
YES YES
On the operation setting On the operation setting

window, select “tower”. window, select “crane”.
IDU failure IDU failure
T5-6-13
FAULT CODE E45
Connector “1" (32P) Connector “1" (24P)
E45
T
A 1 2 3 4
U
5 6 7 8 9
Disconnect connector “1” of cable reel wiring 10 11 12 13 14 15
from machine junction box. 16 17 18 19 20
Check for continuity between terminals #1 (U)
and #2(A) of connector “1”. #1 (U) : X4
21 22 23 24
Check for continuity between terminals #1(U) #2 (A) : R8
and #3(T) of connector “1”. #3 (T) : R21

Controller (MC2/B)
MCB-4

Crane
Between #1(U) and #2(A) = closed
Between #1(U) and #3(T) = open NO
Tower
Between #1(U) and #2(A) = open “3” 16P (white)
Between #1(U) and #3(T) = closed E Boom A
“2” 16P (white)

Cable Reel Wiring
YES
Connect connector “1” of cable reel wiring.

Check for continuity between terminals R8
and X4 of connector "2" (16P).
Check for continuity between terminals R21
and X4 of connector "2" (16P). “1”

Boom Top Junction Box T25N-05-06-013
(Tower Top Junction Box)

Crane Connector "3" (16P White)
BoomA
Between R8 and X4 = closed
Between R21 and X4 = open YES R21 R8 X4

Tower
Between R8 and X4 = open
Between R21 and X4 = closed Connector "2" (16P White) Boom A
With connector “2” (16P) disconnected,
disconnect connector MCB-4 of MC2/B. X4 R8 R21
Measure resistance at connector "3"
(16P).
NO

Resistance between (open circuit)
either terminals R21
and X4, or R8 and X4
Resistance: over 500 k:

failure Machine harness failure MC2/B failure
T5-6-14

E E45
T
A U
Disconnect connector “4” of cable reel wiring from

boom top junction box.
Check for continuity between terminals #1(U) and
#2(A) of receptacle "5".
Check for continuity between terminals #1(U) and
#3(T) of receptacle "5".
#1 (U) : X4
#2 (A) : R8
#3 (T) : R21

Crane
Between #1(U) and #2(A) =closed
Between #1(U) and #3(T) = open
NO
Tower
Between #1(U) and #2(A) = open Controller (MC2/B)
Between #1(U) and #3(T) = closed
Boom top junction box

failure
YES
Cable reel wiring “5”

failure
“4”
Cable Reel Wiring


Boom Top Junction Box
T25N-05-06-013

T5-6-15
FAULT CODE E50

E50

Controller (IDU)
IDU-5
Disconnect connector “1” (7P)
from the load cell.
Check if E50 YES (E52 indicated)

disappears.
Load Cell
NO
Load cell failure
“2” 4P

Connect connector “1” (7P) to “1” 7P
the load cell. Load Cell Harness
Disconnect connector “2”. T25N-05-06-015

Check if E50 YES (E52 indicated) Connector “2" (4P)
disappears.
M14 M3
NO N18
Load cell harness
failure
Connect connector “2”.
Disconnect connector IDU-5
of IDU.
Check if E50 YES (E52 indicated)

disappears.
NO
Machine harness
failure
IDU failure
T5-6-16
(Blank)

T5-6-17
FAULT CODE E51

E51

Check the setting of boom (tower)
length, jib length, number of hoist
rope reeved and hook capacity.

Check if the NO
setting is correct.

YES On the operation setting window,
make the setting depending on
field machine.
Check the difference between
actual load and indication load at
boom upper and boom lower.
Check if the
YES
difference is large
(1t or more).
NO Grease derricking mechanism:

boom foot pin, live mast foot pin,
Release derricking rope tension to boom stop inner etc.
remove load cell tension completely.
Select the IDU monitor window.

Operation:
1. Turn ON maintenance key switch.
2. Press “‫ ޚ‬key” on the ML window. IDU Monitor Window
3. Select the monitor in the
maintenance menu window.
4. Select the IDU monitor in the
monitor menu window.
Load Cell Output
(Crane)
Check “BM LOAD” value in the IDU

monitor window.
Check “JB LOAD” in case of tower.
Load Cell Output
(Tower Jib)
NO
0.5 Vr0.04 V
YES F
IDU failure
T5-6-18
F E51 Load Cell Zero Point Correction Window
Load cell zero point correction Load factor 30%
Load cell output voltage 8

Corrected output voltage 8
Select the load cell zero point correction window.
Operation: Standard correction voltage 8
1. Turn ON maintenance key switch. Correctable voltage range 8
2. Press “ż key” on the ML window. Detach the load cell from the hoist rope to completely
3. Select the adjustment menu in the maintenance eliminate the load ratio from the load cell.
menu window. After detaching the load cell, press <START> key.
4. Select the load cell zero point correction in the Pay attention.
adjustment menu window. Don̉t disconnect the connector from the load cell.
In case of tower, select the jib load cell zero Cancel Start
point correction.
Load Cell Zero Point Correction Completion Window
Press ż key once.

Load cell zero point correction is completed.
Select the IDU monitor window.

Operation:
1. Turn ON maintenance key switch
2. Press “ż key” in the ML window.
3. Select the monitor in the maintenance menu
window.
4. Select the IDU monitor in the monitor menu
window.
IDU Monitor Window
Check “BM LOAD” in the IDU monitor window. Load Cell Output
In case of tower, check “JB LOAD”. (Crane)
Load Cell Output

(Tower Jib)
Vr0.04 V ? NO
0.5
YES
Load cell failure
Check if E51 NO
disappears.
YES
IDU failure
Completion
T5-6-19
FAULT CODE E52
Crane
E52
Controller (IDU)
Check if connector “1” (7P) is

correctly connected to the load cell.
Check if YES
connection is Load cell
correct.

NO
Load Cell Harness

Connect correctly connector “1” 7P
“1” (7P) to the load cell. T25N-05-06-016
Connector “1” (7P)
A F

Disconnect connector “1” from the B G E
load cell.
Measure voltage between terminals C D
#A and #D of connector “1” (7P).

#A : M3, 10V
#D : N18, Load Cell Output

Between #A YES
and #D = 9.8 V
NO
Load cell failure
T5-6-20
G E52 (crane)
Controller (IDU)
Disconnect connector “2” (4P) of the load IDU-5 IDU-1

cell harness.
Measure voltage between terminals M3
and N18 of connector "3" (4P).
Between #1 YES
“3” 4P
and #3 = 9.8 V

NO
Load cell harness
failure “2” 4P
of IDU. “1” 7P Load Cell
Measure resistance between terminal
T25N-05-06-017
M14 of IDU-1 and terminal N18 of IDU-5. Load Cell Harness
M14: Sensor Ground

N18: Load Cell Output
0: to several M:
Resistance ? Connector "3" (4P)
(no resistance) M3
N18
Make a short circuit between terminal M3

and terminal N18 of connector "3" (4P). Connector (IDU-1)
M3
M14
M3 of IDU-1 and terminal N18 of IDU-5.
Connector (IDU-5)
N18
No continuity
Continuity ?
Continuity
Machine harness
failure
IDU failure
T5-6-21
Tower
E52
Controller (IDU)
Check if connector “1” (7P) is correctly
connected to the load cell.
Check if connector “2” (7P) is correctly

connected to the machine junction box.
Check if YES
connection is “1” 7P
correct. “2” 7P
NO
Connect correctly connector “1”

and connector “2”. Machine Junction Box
Jib Load Cell
T25N-05-06-018
Disconnect connector “1” from jib load cell. Connector “1” (7P)
Measure voltage between terminals #A
and #D of connector “1” (7P).
#A: M3, 10V A F
#D: N6, Load Cell Output B G E
C D
Between #A YES
and #D 9.8 V
NO
Load cell failure
T5-6-22
H E52 (tower) Receptacle “3” (7P)
A F
B G E
Disconnect connector “2” (4P) from machine
Controller (IDU)
junction box. C D IDU-1
Measure voltage between terminals #A and #D IDU-5
of receptacle “3” (7P) of machine junction box.
#A: M3, 10V
#D: N6, Load Cell Output
“4” 16P (black)

Between #A YES
Boom B
and #D = 9.8V
NO Load cell harness

failure
“2” 7P
M3 and N6 of connector "4" (16P).
“3” 7P
YES
Between M3
and N6 = 9.8V Machine Junction Box
Jib Load Cell
T25N-05-06-019
NO Load Cell Harness
Load cell harness
failure
of IDU.
Measure resistance between terminal
M14 of IDU-1 and terminal N6 of IDU-5.
0: to several M: Connector "4" (16P) Boom B

Resistance ?
M3
N6
Make a short circuit between terminal M3

and terminal N6 of connector "4" (16P). Connector (IDU-1)
M3
Check for continuity between terminal M3 M14
of IDU-1 and terminal N6 of IDU-5.
Connector (IDU-5)

No continuity N6
Continuity ?
Continuity
Machine harness
IDU failure failure
T5-6-23
FAULT CODE W47
W47 Connector “1” (32P) Connector “1” (24P)
T A
1 2 3 4
Check connection of connector “1” and U
5 6 7 8 9
connector “2” of cable reel wiring.
10 11 12 13 14 15
16 17 18 19 20
21 22 23 24
NO
Check if
connected.
YES A
Disconnect connector "1" of cable reel wiring

from machine junction box.
Check for continuity between terminals #1(U)
and #2(A) of connector "1".
#1 (U): X4
Check for continuity between terminals #1(U) #2 (A): R8
and #3(T) of connector "1". #3 (T): R21
Controller (MC2/B)
Crane

Between #1(U) and #3(T) = open NO
“3” 16P (white)
Tower Boom A
Between #1(U) and #2(A) = open
B
“4” “1”
“2”
YES
Connect connector “1” of cable reel wiring.

Check for continuity between terminals R8 and
X4 of connector “3” (16P).
Check for continuity between terminals R21 and
X4 of connector “3” (16P). Cable Reel Wiring

Crane
Between R8 and X4 = closed
YES
Tower
Between R21 and X4 = closed Connector "3" (16P White) Boom A
X4 R8 R21
C
NO
Machine junction box failure
T5-6-24

A W47

Disassembly position YES
(for transport) ?

NO
30q or more
Boom angle ?

Connect cable reel wiring Less than 30q or no signal
correctly from angle detector

Set boom angle at
IDU failure less than 30q.

B W47
Disconnect connector "2" of cable reel Receptacle “4” (32P) Receptacle “4” (24P)
wiring from boom top junction box. T
A
U
Check for continuity between terminals

#1(U) and #2(A) of receptacle "4". #1 (U): X4
Check for continuity between terminals #2 (A): R8
#1(U) and #3(T) of receptacle "4". #3 (T): R21 T25N-05-03-028
Crane

Between #1(U) and #3(T) = open
NO
Tower
Between #1(U) and #2(A) = open
Boom top junction box

YES failure
Cable reel wiring failure
T5-6-25
C W47
Connector (MCB-1)
X4
Connect connector "3" (16P).

Disconnect connectors MCB-1 and MCB-4 of MC2/B.
Connector (MCB-4)
Check for continuity between terminal X4 of MCB-1

R8
and terminal R8 of MCB-4.
Check for continuity between terminal X4 of MCB-1 R21
and terminal R21 of MCB-4.
Crane

Between X4 and R8 = closed
Between X4 and R21 = open
YES
Tower
Between X4 and R8 = open
Between X4 and R21 = closed
MC2/B failure
Controller (MC2/B)
NO
MCB-4 MCB-1
Machine harness
failure
“3” 16P (white)

Cable Reel Wiring
Boom A
T25N-05-06-033
T5-6-26
FAULT CODE W48
W48
Check limit switch and wiring are set in

counterweight mounted position.
NO
Normal ?
YES Wiring failure
IDU failure
T5-6-27
FAULT CODE W49
W49
Check
Check
connection
connection
of connector
of connector
“1” (7P)
of hook
“1” (7P)
overhoist
of hook
switch
overhoist
harness
withwith Controller (IDU)
boomboom
top top
junction
junction
box.box.
Check if NO
connected.
Connect correctly
YES
“2”
“3”
Disconnect connector “1” (7P) of hook
overhoist switch harness.
#5 and #6 of connector “1” (7P).
“1” 7P

No continuity
Continuity ?
Continuity Hook overhoist switch

connector failure Connector “1” (7P)

1 2

3 4 5
Connect connector "1" (7P). Disconnect #1 (U): X4
connector “3”. #14 (W): K10 6 7
Check for continuity between terminals #15 (d): K3
#1(U) and #14(W) of receptacle "2" of
Check for continuity between terminals Without short jib, no need to
#1(U) and #15(d) of receptacle "2". check for continuity between
terminals #1(U) and #15(d).
A d
No continuity W
Continuity ?
Continuity Boom top junction box

failure
T25N-05-03-028
T5-6-28
Connector (MCB-1)
D W49
X4
Connector (IDU-3)
Connect connector “3” to the boom top #1 (U): X4
junction box. #14 (W): K10
#15 (d): K3 K3
#1(U) and #14(W) of connector "4". K10
#1(U) and #15(d) of connector "4".
Without short jib, no need to
check for continuity between Controller (MC2/B) Controller (IDU)
terminals #1(U) and #15(d). IDU-3
MCB-1
No continuity
Continuity ?
Continuity Cable reel wiring

failure
“2”
“5” 16P (white)
Connect connector “4” of machine junction Boom A
“3”
box. Disconnect connector "5" (16P).
Check for continuity between terminals X4
and K10 of connector "5" (16P).
Check for continuity between terminalsX4
and K3 of connector "5" (16P).
Without short jib, no need to “4”
check for continuity between
terminals X4 and K3. Cable Reel Wiring
No continuity
Continuity ?
Continuity

failure
Connect connector “5” (16P). Connector "5" (16P White) Boom A
Disconnect connector IDU-3 of IDU and
connector MCB-1 of MC2/B. X4
Check for continuity between terminal K10
K10 K3
of IDU-3 and terminal X4 of MCB-1. Without short jib, no need to
Check for continuity between terminal K3 check for continuity between
of IDU-3 and terminal X4 of MCB-1. terminals X4 and K3 of IDU-3.
Connector “4” (32P) Connector “4” (24P)
No continuity A
Continuity ? 1 2 3 4
d W 5 6 7 8 9
10 11 12 13 14 15
Continuity
16 17 18 19 20
Machine harness 21 22 23 24
IDU failure failure
T5-6-29
FAULT CODE W90
W90
Controller (MC2/A) Controller (IDU)
Disconnect CAN connectors ("1" and "2").

Check for continuity between terminal #A of
connector “1” and #A of connector “2”.
Check for continuity between terminal #B of
connector “1” and #B of connector "2".
MCA-1
“1” 3P Machine Harness IDU-4
“2” 3P
No continuity
Continuity ?
CAN Cable
CAN connector (Connected to All Controllers)
Continuity
T25N-05-06-028
CAN cable failure

Connect CAN connectors ("1" and "2").
Disconnect connectors IDU-4 of IDU
and MCA-1 of MC2/A.
T25N-05-06-029
View A

Check for continuity between terminal J1 CAN connector
of connector IDU-4 and terminal D10 of
connector MCA-1.
No continuity
Continuity ? IDU-4
View B
J1 J2
Continuity
Check for continuity between terminal J2

of IDU-4 and terminal D21 of MCA-1. View C MCA-1
D10
D21
No continuity
Continuity ?
Continuity
Machine harness
IDU or MC2/A failure failure
T5-6-30
FAULT CODE W91
W91 Controller (MC2/B) Controller (IDU)
Disconnect CAN connectors ("1" and "2").

Check for continuity between terminal #A of
connector “1” and #A of connector “2”.
Check for continuity between terminal #B of
connector “1” and #B of connector "2".
MCB-1
“1” 3P Machine Harness IDU-4

“2” 3P
No continuity
Continuity ?
CAN Cable
CAN connector (Connected to All Controllers)
T25N-05-06-028
Continuity
Connect CAN connectors ("1" and "2"). CAN cable failure

Disconnect connectors IDU-4 of IDU
and MCB-1 of MC2/B.
T25N-05-06-029
View A
Check for continuity between terminal J1 CAN connector
of connector IDU-4 and terminal X10 of
connector MCB-1.

No continuity
Continuity ?
View B IDU-4
Continuity
J1 J2
Check for continuity between terminal J2

of IDU-4 and terminal X21 of MCB-1.
View C MCB-1

X10
X21
No continuity
Continuity ?
Continuity
Machine harness
failure
IDU or MC2/B failure
T5-6-31
FAULT CODE WA1
WA1
Disconnect connector of brake

mode selection switch.
Check if WA1 YES

disappears.
NO
Brake mode selection
switch wiring failure
MC2/A failure
FAULT CODE WA2

WA2
accelerator control switch.
Check if WA2 YES

disappears.
NO
Accelerator control switch
wiring failure
MC2/A failure
FAULT CODE WA3

WA3
emergency operation switch.
Check if WA3 YES

disappears.
NO
Emergency operation
switch wiring failure
MC2/A failure
T5-6-32
FAULT CODE WB1
WB1
Disconnect the connectors for the

three winding detection limit switches.
Check if WB1 YES

disappears.
NO
Failure of wiring for three winding

detection limit switches
MC2/B failure
FAULT CODE WB2
WB2
Disconnect all connectors connected to

the following switches.
boom overhoist
tower overhoist
clamshell lower limit
boom second overhoist
(short circuit connectors)
Check if WB2 YES

disappears.
NO
Failure of wiring to following switches.
boom overhoist
tower overhoist
MC2/B failure clamshell lower limit
boom second overhoist
T5-6-33
FAULT CODE WB3
WB3
Disconnect connector “1” from

Controller (MC2/B)
Check if WB3 YES

disappears.
“3” 16P (white)
Boom A
NO Boom top junction box
failure
“2”
Disconnect connector “2” from “1”

machine junction box.
Cable Reel Wiring

Machine Junction
Box

Check if WB3 YES
T25N-05-06-030
disappears.
NO Cable reel wiring

failure
Disconnect connector “3” (16P).
Check if WB3 YES

disappears.
NO Machine junction box

failure
MC2/B failure
T5-6-34
TROUBLESHOOTING / Troubleshooting E
TROUBLESHOOTING E PROCEDURE
Use troubleshooting E when the ECU lamp in the cab

illuminates or blinks after the activation of the ECU
troubleshooting control (refer to the chapter on
"Operating Principle/System").
Refer to T2-1-1 operating principles.
Error Codes㩷
Error
Error Item
Codes
07 Engine overrun
08 Injector #6
11 Common rail pressure sensor
12 Segment sensor
14 Speed sensor
15 Increment sensor
19 Atmospheric pressure sensor
21 Coolant temperature sensor㩷
22 Injection pump no-pressure feeding
23 Injection pump over-pressure feeding
26 Air heater relay
32 Boost pressure sensor
33 ECU
34 Q resistance
36 Faulty injection pump pressure
feeding, Limiter valve open
37 Injector #1
38 Injector #5
39 Injector #3
41 Fuel temperature sensor
44 Intake-air temperature sensor
46 Injector #2
47 Injector #4
48 Starter relay 2
58 Accelerator interdependent diagnosis
63 Fuel supply pump
67 EGR M/V1
68 EGR M/V2
69 EGR M/V3
81 Sensor supply voltage
82 Injector Bank 1, 2
84 EDU relay
89 Air heater lamp
95 CAN 2 communication
㩷
T5-7-1
TROUBLESHOOTING / Troubleshooting E
(Blank)
T5-7-2
TROUBLESHOOTING / Electrical System Inspection
PRECAUTIONS FOR INSPECTION AND
MAINTENANCE
1. Disconnect the power source.

Be sure to remove the ground earth terminals
from the batteries first when taking wire
harnesses and connectors off for repair or
replacement work.
Failure to do so can result in damage to the wire
harnesses, fuses, and fusible links and, in some
cases, cause fire due to short circuiting.
2. Color coding of wire harnesses.
The color codes of the wire harnesses in the
electrical system are shown in the table below.
In cases on the design sheet where two colors
are indicated for one wire, the left initial stands for
the base color, while the right initial stands for the
marking color.
Code Color Code Color

R Red W White
L Blue G Green
Or Orange Lg Light green
Y Yellow B Black
Br Brown P Pink
Gr Gray V Violet
NOTE: 1) Code BW indicates a black base wire

with white fine-line marking.
2) Initials “O” and “Or” both stand for the
color orange.
3) Wires with longitudinal stripes printed
on them are not color coded. Be sure
not to confuse them with color coded
wires.
T5-8-1
3. Precautions for connecting and disconnecting
terminal connectors.
1) When disconnecting harnesses, grasp them Right Wrong
by their connectors. Do not pull on the wire
itself.
2) Water-resistant connectors keep water out
so that if water enters them, water will not
easily drain from them. When checking
T107-07-06-001
water-resistant connectors, take extra care
not to allow water to enter the connectors. In
case water should enter the connectors,
reconnect only after the connectors are
thoroughly dried. Right
3) Before connecting terminal connectors, Rust
check that no terminals are bent or coming Deformation
off. In addition, as most connectors are
made of brass, check that no terminals are
Separation
rusting.
4) Be sure to release the lock first before
attempting to separate connectors, if a lock T107-07-06-002
is provided.
5) When connecting terminal connectors
provided with a lock, be sure to insert them
together until the lock “clicks”
6) If the connector is secured with a screw,
remove the screw. Tighten a screw until the
torque mark (protruded mark) appears.
4. Precautions for using a circuit tester.

1) Before using a circuit tester, refer to the
instructions in the circuit tester manual.
Then, set the circuit tester to meet the object
to be measured, voltage range and current
polarity.
2) Before starting the connector test, always
check the connector terminal numbers, Protruded Mark
referring to the circuit diagram.
When the connector size is very small, and
the standard probe size is too large to be
used for testing, wind a fine piece of
sharpened wire or a pin around the probe to
make the test easier.
3) When checking the connector using a teater,
insert the tester probe from the harness side
of the connector wherever possible, to
protect the terminal inside the connector
from damage.
Wind a Piece of Wire Tester Probe
Sharpen the end of the Wire

T107-07-06-003
T5-8-2
BATTERY VOLTAGE CHECK
1. Turn the key switch OFF. Check voltage between
the battery positive terminal and the vehicle
frame (ground earth).
Normal Voltage: 24 V or more
NOTE: If voltage is abnormal, recharge or replace

the battery.
2. Start the engine. Check voltage between the

battery positive terminal and the vehicle frame
(ground earth).
Normal Voltage: 26 to 28.5 V
NOTE: If voltage is abnormal, check the charging

system.
T107-04-05-006
T105-07-01-006
FUSIBLE LINK INSPECTION
Open the cap of the fusible link (slow blow fuse) to

disconnect the fuse, and visually inspect it.
Number Capacity Connected to

Key Switch
(1) 45A Fuse Box1
(#5 to 10)
Fuse Box1
(#1 to 4, #11, #16)
(2) 65A
Fuse Box2
(#22 to 30)
T324-04-05-002
T5-8-3
FUSE INSPECTION
Cracks in a fuse are so fine that it is very difficult or

impossible to find by visual inspection. Use a tester to
correctly inspect fuse continuity by following the in-
structions described below.
1. Turn Key Switch ON

When the key switch is turned ON, current from
key switch terminal M activates the battery relay
so that electric power is supplied to all circuits.
(Refer to the circuit diagram.)
2. Remove the fuse box cover. Set the tester volt-

age to meet the circuit specification to be meas-
ured. (Measurement Range: 0 to 30 V)
3. Ground the negative probe of the tester to the

vehicle frame. Touch the terminals located away
from the center of the fuse box with the positive
probe of the tester one at a time. When normal
continuity of a fuse is intact, the tester will indi-
cate 20 to 25 V (battery voltage).
NOTE: In both fuse boxes 1 and 2, all terminals

located along the lengthwise centerline are
connected to the power source (primary),
while terminals located away from the
Power Source Side()
center are connected to loads (accesso-
ries) (secondary).
Accessory side ()
T105-07-01-008
T5-8-4
ALTERNATOR INSPECTION
In general, the alternator indicator remains off when
the alternator is generating power.
If the alternator indicator comes on while the engine is
running, the alternator might be defective.
How to check the alternator
1. Turn the key switch to the ON position. Confirm

that the alternator indicator comes on.
2. Measure the voltage between teminals B and E

terminals of the alternator. If the measured
voltage is around 24 V, the alternator circuit can
Terminal E
be considered normal. If the measured voltage
is low, a shortage in battery capacity or looseness
of the wire connectors of the alternator circuit
might be the cause of the malfunction. When the
Terminal B
voltage is 0 V, the wiring between the battery
relay and alternator might be disconnected, or
the ground line of the alternator might be
disconnected.
3. Next, start the engine and measure the voltage

generated as the alternator operates.
As described above, measure the voltage
T333-05-07-001
between terminals B and E on the side of the
alternator. If the voltage is around 28 V (voltage
generated by alternator), the alternator is
operating normally.
If the measured voltage remains at around 24V
(voltage of battery), there is some trouble with the
alternator or the regulator.
T5-8-5
CONTINUITY CHECK Harness
A a
Single-line continuity check
Disconnect both end connectors of the harness
(open) and check continuity (measure resistance)
between both ends:
If the ohm-meter reading is: 0 : Continuity :
f : Discontinuity
NOTE: When the one end connector is far apart Connect to A a

from the other, connect one end of the vehicle
frame.
connector (A) to the machine chassis using
a clip. Then, check continuity of the
harness through the vehicle frame.
Connect to
:
the vehicle
If the ohm-meter reading is: 0 : Continuity frame.
f: Discontinuity
Single-line short-circuit check (Short-circuit with A a

vehicle frame)
u Short-circuit
Disconnect both end connectors of the harness and between the
check continuity between one end connector of the harness and
the vehicle
harness and the vehicle frame: : frame.
If the ohm-meter reading is:
0 : Short circuit is present.
f : No short circuit is present.
T107-07-05-003
Multi-line continuity check

Disconnect connectors at both ends of the harness First connection (clip)
and connect terminals (A) and (B) at one end with a
clip, etc., and check for continuity between termi-
A a
nals (a) and (b) at the other end of the connector. B b
f : means that either (A)-(a) or (B)-(b) is broken. C c
To find out which line is broken, either check each
line individually or change the connected terminals Second connection (clip)
and test again.
NOTE: By conducting the multi-line continuity :

check twice, it is possible to find out which
line is broken. Check continuity between
terminals (a) and (c) with terminals (A) and
T107-07-05-004
(C) connected.
0ȍ means (B)-(b) is broken. Short-circuit between harnesses.
f : means that (A)-(a) is broken.
A a
Multi-line short-circuit check (Short-circuit in B
u
b
harness) C c
Disconnect both end connectors of the harness,
and check continuity between terminals (A) and (B)
or (C).
0 : Short-circuit exists between the harnesses. :
f : No short-circuit exists between the
harnesses.
T107-07-05-005
T5-8-6
Mitsubishi 6M70
GROUP INDEX
Workshop GENERAL ............................................. 00
Manual ENGINE ................................................. 11
diesel engine LUBRICATION ...................................... 12
FUEL AND ENGINE CONTROL ........... 13
COOLING .............................................. 14
INTAKE AND EXHAUST....................... 15
EMISSION CONTROL .......................... 17
Mitsubishi 6M70 Engine Parts Contact:

Email:
EngineParts@HeavyEquipmentRestorationParts.com
Phone: 2696731638
Applicable models
Mitsubishi 6M70
DIAGNOSIS CODES
1. Diagnosis Codes
• Diagnosis codes indicate the faulty sections of the vehicle.
• A fault can be repaired by reading out the diagnosis code(s) stored in the control unit and performing the remedy
for that code(s).
• Diagnosis codes can be displayed in the following two methods. Select either of them according to the system to
be diagnosed.
• Using a Multi-Use Tester
• Using flashing of a warning lamp on meter cluster
• The table below indicates the systems for which diagnosis codes can be displayed and the methods usable for in-
dividual systems.
1.1 Systems and diagnosis code displaying methods

Diagnosis codes
Warning displaying methods Reference
System
lamp Multi-Use Flashing of Gr
Tester warning lamp
Common rail 13
Turbocharger 15
O O
Exhaust gas recirculation 17
Starter continuous energizing preventing function 54
Vehicle speed limiting (SLD)
O O 54
Auto cruise
– Full auto air conditioner O O 55
1.2 Types of diagnosis codes

• There are two types of diagnosis code output method depending on the system: one has a distinction of present
and past codes, and the other does not have such a distinction.
Diagnosis code
System
With distinction of present and past Without distinction
Except below O –
Full auto air conditioner – O
(1) The system that has a distinction of present and past diagnosis codes
(1.1) Present diagnosis code
• Fault developed in the vehicle after the starter switch is set to ON is indicated by corresponding diagnosis code.
• The fault warning lamp is lit at the same time.
(1.2) Past diagnosis code

• Past fault developed in the vehicle is indicated by corresponding diagnosis code stored in the memory of the elec-
tronic control unit.
• With the vehicle restored to its normal condition or the starter switch turned from OFF to ON after inspection or re-
pair against present diagnosis codes, the present diagnosis code is stored as past diagnosis codes in the memory
of the electronic control unit.
• When reading out the past diagnosis codes, the warning lamp does not illuminate as such codes do not indicate
the current fault.
(2) The system that does not have a distinction of present and past diagnosis codes
• The present and past diagnosis codes are displayed together without distinction.
00-22
00
2. Reading and Erasing the Diagnosis Code
2.1 Using a Multi-Use Tester
(1) Connecting a Multi-Use Tester
Special tools
Mark Tool name and shape Part No. Application
SOFTWARE DISC
FMS-E07-3* Installation of the Muti-Use-Tester-III
Multi-Use Tester III (Multi-Use or version-up of the current version
SOFTWARE DISC Tester-III ver- into Multi-Use Tester-III SOFTWARE
sion) DISC (Pub. No. SG0705A)
Data transmission between electronic

V.C.I. MH062927
control unit and PC
Multi-Use Tester test

Harness E
A: Harness for inspec-
MH063659
tion and drive recorder
A: MH063661
B: Harness for drive re- Power supply to V.C.I. and communi-
B: MH063663
corder cation with electronic control unit
C: MH063665
C: Drive recorder har-
D: MH063666
ness
D: Cigarette lighter
plug harness
Multi-Use Tester test

Multi-Use Tester test harness B ex-
harness D MH062951
tension
(used for extension)
Communication between V.C.I. and

USB cable MH063668
PC
00-23
DIAGNOSIS CODES
(1.1) To perform system inspection
• Move the starter switch to the LOCK position.
• Connect PC installed , , -A and as shown.
• Connect -A connector to the Multi-Use Tester connector on
the vehicle.
(1.2) To use drive recorder function

• Move the starter switch to the LOCK position.
• Connect PC installed , , -A, -C, -D and
as shown.
• Connect -C connector to the Multi-Use Tester connector on
the vehicle.
• Connect the cigarette lighter plug of -D to the cigarette light-
er socket on the vehicle.
(1.3) To extend the Multi-Use Tester test harness

• Connect to -A to extend the test harness to use the
Multi-Use Tester outside the vehicle.
00-24
00
(2) Access of diagnosis code
• Set the starter switch to ON.
• Operate the Multi-Use Tester for a display of necessary diagnosis code stored in the memory of the electronic
control unit and identify the location of the fault.
(3) Clearing of diagnosis code

• Set the starter switch to ON (the engine not to be started).
• Operate the Multi-Use Tester to delete all the diagnosis codes stored in the memory of the electronic control unit.
2.2 Using flashing of a warning lamp on meter cluster

(1) Engine control, vehicle speed limiting (SLD), auto cruise
• Using the diagnosis and memory clear switches, display diagnosis codes.
CAUTION
• Opening the memory clear switch followed by its reconnection will erase the stored diagnosis codes from
the memory. To avoid inadvertently erasing necessary codes, be sure to read well the procedure de-
scribed below before handling diagnosis codes.
00-25
DIAGNOSIS CODES
(1.1) Reading diagnosis codes
• To read a diagnosis code, observe how may times the warning
lamp flashes and how long each illumination lasts.
• The duration of illumination differs between the first and second
digits.
• Second digit: 1.2 sec.
• First digit: 0.4 sec.
• A diagnosis code consists of the flashing of second digit and the
flashing of first digit in that order. If a diagnosis code has “0” in
the second digit, only the first digit will be displayed.
• The diagnosis code 01 will be displayed if the system is normal.
• The same diagnosis code will be displayed 3 times in a row be-
fore moving to the display of the next code.
• After the last diagnosis code is displayed, the first code will be
displayed again 3 times in a row and then the subsequent
codes. This will be repeated.
(1.2) Present diagnosis codes

• Turn the starter switch ON.
• Remove the diagnosis switch.
• Present diagnosis codes will be displayed by flashing of the
warning lamp.
• When the diagnosis switch is connected, electronic control unit
will stop (terminate) displaying diagnosis codes.
(1.3) Present and past diagnosis codes

• Turn the starter switch to the ON position.
• Open the diagnosis switch.
• Present diagnosis codes will be displayed by flashing of the
warning lamp.
• Open the memory clear switch.
• Present and past diagnosis codes will be displayed by flashing
of the warning lamp.
• Turn the starter switch to the OFF position and connect the
memory clear switch and diagnosis switch to terminate the diag-
nosis code displaying mode.
(1.4) Erasing diagnosis codes

• Turn the starter switch to the ON position (do not start the en-
gine).
• Open the memory clear switch and reconnect it; all diagnosis
codes stored in electronic control unit memory will be erased.
To cancel diagnosis code erasure after opening the memory
clear switch, turn the starter switch to the OFF position and then
reconnect the memory clear switch.
00-26
00
(2) Full automatic air conditioner
(2.1) Connection of LED for inspec-
tion
• Move the starter switch to the LOCK
position.
• Connect the LED for inspection to the
Multi-Use Tester connector.
CAUTION
• Air conditioner electronic control
unit and control panel has a backup
power supply to keep diagnostic
check results in memory. If this
power supply is cut off, with battery
cables disconnected, for example,
stored data are erased.
• Air conditioner electronic control
unit and control panel enters into
the mode of control during fault im-
mediately a fault occurs. In this
mode, control is effected to mini-
mize trouble arising from the fault.
(2.2) Reading and erasing diagnosis codes

• To read a diagnosis code, observe how may times the LED for
inspection flashes and how long each illumination lasts.
• The duration of illumination differs between the first and second
digits.
• Second digit: 1.5 sec.
• First digit: 0.5 sec.
• A diagnosis code consists of the flashing of second digit and the
flashing of first digit in that order. If a diagnosis code has “0” in
the second digit, only the first digit will be displayed.
• When two or more faults occur at a time, relevant diagnosis
codes are displayed repeatedly starting from the first Code.
• To erase a diagnosis code from the memory after inspection,
disconnect negative (–) battery cable and leave it disconnected
for more than 30 seconds.
00-27
TABLE OF STANDARD TIGHTENING TORQUES
• Use specified bolts and nuts. Tighten them to the torques shown below as appropriate, unless otherwise speci-
fied.
• Threads and bearing surfaces shall be dry.
• If the mating nut and bolt (or stud bolt) are different in level of strength, tighten them to the torque specified for the
bolt.
Hexagon Head Bolts and Stud Bolts (Unit: N·m {kgf·m})

Strength 4T 7T 8T
Identification
symbol
Nominal
diameter (stud) (stud) (stud)
2 to 3 4 to 6 5 to 7
M5 {0.2 to 0.3}
–
{0.4 to 0.6}
–
{0.5 to 0.7}
–
4 to 6 7 to 10 8 to 12
M6 {0.4 to 0.6}
–
{0.7 to 1.0}
–
{0.8 to 1.2}
–
9 to 13 16 to 24 19 to 28
M8 {0.9 to 1.3}
–
{1.7 to 2.5}
–
{2.0 to 2.9}
–
18 to 27 17 to 25 34 to 50 32 to 48 45 to 60 37 to 55
M10 {1.8 to 2.7} {1.8 to 2.6} {3.5 to 5.1} {3.3 to 4.9} {4.5 to 6.0} {3.8 to 5.7}
34 to 50 31 to 45 70 to 90 65 to 85 80 to 105 75 to 95
M12 {3.4 to 5.1} {3.1 to 4.6} {7.0 to 9.5} {6.5 to 8.5} {8.5 to 11} {7.5 to 10}
60 to 80 55 to 75 110 to 150 100 to 140 130 to 170 120 to 160
M14 {6.0 to 8.0} {5.5 to 7.5} {11 to 15} {11 to 14} {13 to 17} {12 to 16}
90 to 120 90 to 110 170 to 220 160 to 210 200 to 260 190 to 240
M16 {9 to 12} {9 to 11} {17 to 23} {16 to 21} {20 to 27} {19 to 25}
130 to 170 120 to 150 250 to 330 220 to 290 290 to 380 250 to 340
M18 {14 to 18} {12 to 16} {25 to 33} {23 to 30} {30 to 39} {26 to 35}
180 to 240 170 to 220 340 to 460 310 to 410 400 to 530 360 to 480
M20 {19 to 25} {17 to 22} {35 to 47} {32 to 42} {41 to 55} {37 to 49}
250 to 330 230 to 300 460 to 620 420 to 560 540 to 720 490 to 650
M22 {25 to 33} {23 to 30} {47 to 63} {43 to 57} {55 to 73} {50 to 67}
320 to 430 290 to 380 600 to 810 540 to 720 700 to 940 620 to 830
M24 {33 to 44} {29 to 39} {62 to 83} {55 to 73} {72 to 96} {63 to 85}
Hexagon Head Flange Bolts (Unit: N·m {kgf·m})

Strength 4T 7T 8T
Identification
symbol
Nominal
diameter
4 to 6 8 to 12 10 to 14
M6 {0.4 to 0.6}
–
{0.8 to 1.2}
–
{1.0 to 1.4}
–
10 to 15 19 to 28 22 to 33
M8 {1.0 to 1.5}
–
{2.0 to 2.9}
–
{2.3 to 3.3}
–
21 to 31 20 to 29 45 to 55 37 to 54 50 to 65 50 to 60
M10 {2.1 to 3.1} {2.0 to 3.0} {4.5 to 5.5} {3.8 to 5.6} {5.0 to 6.5} {5.0 to 6.5}
38 to 56 35 to 51 80 to 105 70 to 95 90 to 120 85 to 110
M12 {3.8 to 5.5} {3.5 to 5.2} {8.0 to 10.5} {7.5 to 9.5} {9 to 12} {8.5 to 11}
00-28
00
Hexagon Nuts (Unit: N·m {kgf·m})
Strength 4T 6T
Identification
symbol
Nominal Standard screw Coarse screw

Standard screw thread Coarse screw thread
diameter thread thread
2 to 3 4 to 6
M5 {0.2 to 0.3}
–
{0.4 to 0.6}
–
4 to 6 7 to 10
M6 {0.4 to 0.6}
–
{0.7 to 1.0}
–
9 to 13 16 to 24
M8 {0.9 to 1.3}
–
{1.7 to 2.5}
–
18 to 27 17 to 25 34 to 50 32 to 48
M10 {1.8 to 2.7} {1.8 to 2.6} {3.5 to 5.1} {3.3 to 4.9}
34 to 50 31 to 45 70 to 90 65 to 85
M12 {3.4 to 5.1} {3.1 to 4.6} {7.0 to 9.5} {6.5 to 8.5}
60 to 80 55 to 75 110 to 150 100 to 140
M14 {6.0 to 8.0} {5.5 to 7.5} {11 to 15} {11 to 14}
90 to 120 90 to 110 170 to 220 160 to 210
M16 {9 to 12} {9 to 11} {17 to 23} {16 to 21}
130 to 170 120 to 150 250 to 330 220 to 290
M18 {14 to 18} {12 to 16} {25 to 33} {23 to 30}
180 to 240 170 to 220 340 to 460 310 to 410
M20 {19 to 25} {17 to 22} {35 to 47} {32 to 42}
250 to 330 230 to 300 460 to 620 420 to 560
M22 {25 to 33} {23 to 30} {47 to 63} {43 to 57}
320 to 430 290 to 380 600 to 810 540 to 720
M24 {33 to 44} {29 to 39} {62 to 83} {55 to 73}
Hexagon Flange Nuts (Unit: N·m {kgf·m})

Strength 4T
Identification
symbol
Nominal Standard screw Coarse screw

diameter thread thread
4 to 6
M6 {0.4 to 0.6}
–
10 to 15
M8 {1.0 to 1.5}
–
21 to 31 20 to 29
M10 {2.1 to 3.1} {2.0 to 3.0}
38 to 56 35 to 51
M12 {3.8 to 5.6} {3.5 to 5.2}
00-29
TABLE OF STANDARD TIGHTENING TORQUES
Tightening Torque for General-Purpose Flare Nut (Unit: N·m {kgf·m})
Pipe diameter φ4.76 mm φ6.35 mm φ8 mm φ10 mm φ12 mm φ15 mm
Tightening torque 17 {1.7} 25 {2.6} 39 {4.0} 59 {6.0} 88 {9.0} 98 {10}
Tightening Torque for General-Purpose Air Piping Nylon Tube (DIN Type) (Unit: N·m
{kgf·m})
Nominal diameter
6 × 1 mm 10 × 1.25 mm 12 × 1.5 mm 15 × 1.5 mm
× wall thickness
+6 +0.6 +10 +1.0 +10 +1.0 +5 +0.5
Tightening torque 20 0 {2.0 0 } 34 0 {3.5 0 } 49 0 {5.0 0 } 54 0 {5.5 0 }
Tightening Torque for General-Purpose Air Piping Nylon Tube (SAE Type) (Unit: N·m
{kgf·m})
Nominal diameter 1/4 in. 3/8 in. 1/2 in. 5/8 in.
+4 +0.4 +5 +0.5 +5 +0.5 +5 +0.5
Tightening torque 13 0 {1.3 0 } 29 0 {3.0 0 } 49 0 {5.0 0 } 64 0 {6.5 0 }
00-30
GROUP 11 ENGINE
SPECIFICATIONS .............................................................................. 11-2
STRUCTURE AND OPERATION

1. Engine Proper .................................................................................... 11-3
2. Rocker and Shaft, Camshaft, Rocker Case and
Cylinder Head Gasket ....................................................................... 11-4
3. Valve Mechanism ............................................................................... 11-4
4. Connecting Rod ................................................................................. 11-5
5. Piston .................................................................................................. 11-5
6. Timing Gears ...................................................................................... 11-6
7. Flywheel ............................................................................................. 11-6
8. Flywheel PTO ..................................................................................... 11-7
9. Powertard Brake System .................................................................. 11-8
TROUBLESHOOTING ..................................................................... 11-12
ON-VEHICLE INSPECTION AND ADJUSTMENT

1. Measuring Compression Pressure ................................................ 11-14
2. Inspection and Adjustment of Valve Clearances .......................... 11-16
3. Inspection and Adjustment of Powertard Clearances ................. 11-20
ENGINE REMOVAL AND INSTALLATION ...................................... 11-22
ROCKER COVER, ROCKER AND SHAFT ..................................... 11-26
CAMSHAFT AND ROCKER CASE ................................................. 11-30
CYLINDER HEAD AND VALVE MECHANISM ................................ 11-38
PISTON, CONNECTING ROD AND CYLINDER LINER ................. 11-54
FLYWHEEL PTO <WITH FLYWHEEL PTO> ................................... 11-68
FLYWHEEL ...................................................................................... 11-72
TIMING GEARS
<WITHOUT FLYWHEEL PTO>...................................................... 11-78
<WITH FLYWHEEL PTO> ............................................................ 11-82
CRANKSHAFT AND CRANKCASE ................................................. 11-88
11-1
SPECIFICATIONS
Item Specifications
Engine type 6M70T2 6M70T4
Type 6-cylinder, in-line, water-cooled, 4-cycle diesel engine
Combustion chamber Direct injection type
Valve mechanism Overhead camshaft (OHC) system
Maximum output kW {PS} /rpm 257 {350} / 2000 309 {420} / 2000
Maximum torque N·m {kgf·m} /rpm 1620 {165} / 1100 1810 {185} / 1100
Cylinder bore × stroke mm φ135 × 150
3
Total displacement cm {L} 12882 {12.882}
Compression ratio 17.5
Mitsubishi 6M70 Engine Parts contact:

email: EngineParts@HeavyEquipmentRestorationParts.com
Phone: 269 673 1638
11-2
STRUCTURE AND OPERATION 11
1. Mitsubishi 6M70 Engine Proper
• The 6M70 engine employs an overhead camshaft (OHC) system, with the valve mechanism and the timing
gears arranged as shown above.
11-3
2. Rocker and Shaft, Camshaft, Rocker Case and Cylinder Head Gasket
• The camshaft journals are directly
supported by the rocker case and the
camshaft cap, without using any cam-
shaft bearings. The rocker case and
camshaft caps have been machined
together, meaning that they all need to
be replaced for a new set when one of
them becomes defective.
3. Valve Mechanism
• Each valve has a valve stem seal, which regulates the flow of lubricating oil to the contact surface between the
valve and the valve guide.
• The valve springs have a variable pitch to prevent abnormal vibration at high engine speed. The exhaust valves
use a double spring, with the inner and outer springs coiled in different directions to prevent them from jamming
each other.
11-4
11
4. Mitsubishi 6M60 Connecting Rod
• Weight mark: “A” to “H”, “J” to “M”
• “A” indicates the greatest connecting
rod mass.
5. Mitsubishi 6M70 Piston
11-5
6. Mitsubishi 6M70 Timing Gears
• The timing gears are provided with
timing marks to help ensure correct
assembly.
• Timing marks are provided on the fol-
lowing gears.
• Camshaft gear: stamped line
• Crankshaft gear: “A”
• Idler gear A, B: “A”, “B”
• Idler gear C: “B”, “C”
• Supply pump gear: “C”
7. Flywheel
11-6
11
8. Flywheel PTO
• The flywheel PTO is located in the upper part of the flywheel housing and is driven by the PTO drive gear.
11-7
9. Powertard Brake System
• The Powertard is activated when all of the following conditions are met with the combination switch placed in the
first stage or second stage.
• Engine speed: 800 to 2400 rpm
• Clutch pedal released (clutch pedal switch: OFF)
• Accelerator pedal released (accelerator pedal switch: ON)
• Transmission in gear (transmission neutral switch: ON)
• Anti-lock brake system not activated (ABS) (Control unit: OFF) (See Gr35E.)
• If any of the above conditions are not met, operation of the Powertard system will be temporarily canceled.
If the engine speed is less than 700 rpm or higher than 2500 rpm although all the other conditions (clutch pedal,
accelerator pedal, and transmission conditions) are met, operation of the Powertard system will be canceled.
• When the vehicle speed exceeds the auto cruise set vehicle speed during driving with the auto cruise engaged,
the Powertard is activated by the control of the engine electronic control unit even if the Powertard switch (combi-
nation switch) is not turned ON. (See Gr13.)
• When the Powertard switch is placed in the first stage, the Powertard is activated to enhance the engine braking
power.
• When the Powertard switch is placed in the second stage, the turbocharger magnetic valve is activated to control
the turbocharger and generate stronger braking power than the first stage.
11-8
11
9.1 Operation of Powertard brake system
• The Powertard brake system is a device to enhance the engine brake performance. It opens and closes the ex-
haust valve (one side only) to control the volume of compressed air in the combustion chamber in accordance
with the movement of the piston, thereby providing a boosted braking force. Powertard components are located in
the cylinder head.
• The valve bridge is provided with an adjusting screw and a pin that allow the exhaust valve to be opened and
closed under the control of the Powertard, in addition to ordinary valve control.
• The pin is free to move in the adjusting screw. Its movement is controlled by the control valve.
• The adjusting screw is used to adjust the timing (Powertard clearance) for the control valve to press the pin.
(1) Operating principle

• In the ordinary engine brake, the piston is forced up during its
compression stroke when compressed air A develops a counter
force B to press the piston. This force works as a braking force.
However, the piston is forced down during its expansion stroke
to let compressed air expand. This causes an accelerating force
C to work on the piston downward, resulting in the braking force
obtained during the compression period being lost largely.
11-9
• When the Powertard system is activated, the piston pressing
force works as a braking force during the compression stroke as
when the Powertard system is not activated. During the expan-
sion period, the exhaust valve is opened by the working of the
system to let some of the compressed air out through the ex-
haust port.
• This causes the piston pressing force to be no longer generated.
As a result, the braking force obtained during the compression
period is maintained for effective use.
• After letting out more compressed air, the exhaust valve is

closed, which causes the combustion chamber to be closed up.
As a result, during the expansion period, a new force is generat-
ed which hinders the movement of piston when it goes down.
This force, following the braking force obtained during the previ-
ous compression period, also acts as a braking force, enhancing
greatly the vehicle’s engine brake capacity.
The operation of the system which causes the valve to be
opened and closed in agreement with the successive piston
strokes is called synchronized operation.
• As shown above, when the Powertard system is activated, the
engine brake provides more power than the ordinary engine
brake.
(2) Hydraulic pressure control

• When the solenoid valve is activated,
engine oil (oil pressure produced by
ordinary engine oil pump) is let in from
A to flow through the oil passage and
forces open the check valve in the
control valve.
• Oil pressure proceeds through the oil
passage to move the master piston
into contact with the dedicated Power-
tard cam.
• This allows the rotation of the dedicat-
ed Powertard cam to be transmitted to
the master piston. As the cam lobe top
is reached, oil pressure in the oil pas-
sage further builds up, forcing the
check valve in the control valve to
close and working on the slave piston
at the same time.
• The slave piston pushes the pin, which
in turn forces the exhaust valve to
open. As a result, the pressure in the
combustion chamber is released to
maintain effective braking force.
11-10
11
• As the Powertard cam further rotates
and the cam lobe top leaves the mas-
ter piston, the oil pressure in the oil
passage is reduced.
• As a result, the exhaust valve is
closed by its spring force, which allows
the valve to open and close according
to ordinary valve timing. At the same
time, the check valve in the control
valve opens to let engine oil (oil pres-
sure produced by ordinary engine oil
pump) work through the oil passages
and, allowing the exhaust valve to be
forced open again through the move-
ment of the Powertard cam.
• When the Powertard release condi-

tions are met, the following sequence
of operation is followed.
• When the solenoid valve is de-ener-
gized, the control valve shuts the in-
coming path (A) for engine oil from
the rocker case and opens the out-
going path (B) to the cylinder head.
• Engine oil in the oil passage is let
out through B, relieving the control
valve of oil pressure.
• The control valve opens the path
(C) that has been closed by oil pres-
sure to let out engine oil in the
chamber of the slave piston and oil
passage.
• As the oil pressure is removed, the
master piston is lowered to leave
the Powertard cam.
• At the same time, the slave piston is
forced up by the spring force. As a
result, the exhaust valve is closed
and the Powertard is turned off.
(3) Powertard brake control (Power-

tard: Switch is placed in the sec-
ond stage)
• The turbocharger magnetic valve
feeds air A to the air cylinder, narrow-
ing turbine vane B.
• The number of revolutions of the tur-
bocharger increases, taking more air
into the combustion chamber.
• Compressed air C increases and the
braking force of the Powertard be-
comes stronger.
11-11
TROUBLESHOOTING
Symptoms
Abnormal engine noise

Reference Gr
Low power output

Possible causes
Valve clearance incorrect O O
Defective cylinder head gasket O O
Cylinder head and valve Valve and valve seat worn and carbon deposits O O
mechanism Valve spring fatigued O O
Defective rocker shaft and bracket O
Poor lubrication of rocker shaft and bracket assembly O
Defective backlash between gears O
Timing gears
Poor lubrication of gearts and idler shaft O
Camshaft end play excessive O
Camshaft
Camshaft worn O
Piston ring groove(s) worn and damaged O O
Pistons and connecting
Piston ring(s) worn and damaged O O
rods
Piston pin and connecting rod small end worn O
Crankshaft end play excessive O
Fan pulley improperly mounted O
Crankshaft Crankshaft pins and connecting rod bearings worn or
O
damaged
Crankshaft journals and main bearings worn or damaged O
Defective supply pump O O
Fuel system Defective injector O O Gr13
Air trapped in fuel system O
Cooling system malfunction O
Cooling system Gr14
Belts loose/damaged O
Air cleaner colgged O O
Intake and exhaust Gr15
Turbocharger malfunction O O
system
Diesel particulate filter colgged O O Gr15
Oil viscosity unsuitable O Gr12
Improper fuel O
Incorrectly fitted piping and hoses O
Defective/incorrectly fitted alternator and other auxiliaries O Gr54
11-12
11
Powertard Brake System
Symptoms
Turning Powertard switch OFF does not

Powertard brake fails to operate
cancel Powertard braking

Reference Gr
Possible causes
Lubrication oil is cold and too viscous O O
Powertard clearance too large O
Blown fuse O
Improper connection of harnesses and connectors O
Defective clutch switch O O
Defective accelerator switch O O
Defective transmission neutral switch O O
Gr13
Electrical system Defective powertard switch (combination switch) O O
Defective meter cluster O O
Defective engine speed sensor O O
Defective powertard solenoid valve O O
Defective engine control unit O O
Defective ABS exhaust brake cut relay <ABS/ASR> O O Gr35
Defective Powertard O O
Broken or weak exhaust valve springs O
Valve mechanism Exhaust valve sticky or not smooth in operation O
Improperly adjusted powertard clearance O
Oil leakage in Powertard system O
Engine oil pressure too low O
Air present in engine oil O
Oil leakage from around cylinder head and rocker case O
Insufficient engine oil flow Oil passage leading to powertard assembly clogged O
Oil leakage from powertard brake system O
Gr12
Defective control valve O
11-13
1. Measuring Compression Pressure
Service standards
Location Maintenance item Standard value Limit Remedy
2,940 kPa 1,960 kPa
Each cylinder (at 200 rpm) Inspect
{30 kgf/cm2} {20 kgf/cm2}
– Mitsubishi 6M70 390 kPa
Pressure difference be-
Compression pressure – {4 kgf/cm2} Inspect
tween each cylinder
or less
Special tools (Unit: mm)

Compression gauge
adapter MH062180 Measuring of compression pressure
A
M14 × 1.5
• A drop in compression pressure can be used as a guide to determine when the engine should be overhauled.
• Measure the compression pressure at regular intervals. Keeping track of its transitions can provide a useful tool
for troubleshooting. On new vehicles and vehicles with newly replaced parts, the compression pressure will be
somewhat higher depending on the break-in condition of piston rings, valve seats, etc., but this will return to nor-
mal as the parts wear down.
• Before the compression measurement, confirm that the engine oil, starter, and battery are in normal condition.
• Place the vehicle in the following conditions.
• Warm up the engine until the coolant temperature reaches approximately 75 to 85°C.
• Turn off the lights and accessories.
• Place the transmission in N range.
• Turn the steering wheel in neutral position.
• Remove the fuse (M25) from the fuse box in the cab to prevent
fuel from being injected while the engine is cranked using the
starter.
CAUTION
• When cranking the engine, never shut off the power sup-
plied to the engine electronic control unit by disconnecting
the engine electronic control unit connector or other similar
methods. If the engine is cranked with the power to the en-
gine electronic control unit shut off, the supply pump will
not be controlled by the electronic control unit, causing the
supply pump to be malfunctioned.
11-14
11
• Remove all the injectors. (See Gr13.)
• Cover the injector mounting holes with shop towels or other sim-
ilar cloth. Crank the engine using the starter. Ensure that no for-
eign matter is attached on the shop towels.
CAUTION
• If cracks or any other damage are evident in the cylinders,
this means that the coolant, engine oil or fuel, or other sub-
stances, has entered the cylinders. If this is the case, it is
extremely dangerous to crank the engine as these sub-
stances will gush out at high temperature from the injector
mounting holes. Stay away from the engine when cranking
it.
• Attach the nozzle gasket and to one of the mounting holes.

Then, connect a compression gauge to .
• Crank the engine and measure the compression pressure.
• Measure the compression pressure for all the cylinders one after
another. Determine the compression pressure difference be-
tween the cylinders.
• If the compression pressure is below the limit or the pressure dif-
ference between each cylinder is not within the limit, pour a
small amount of engine oil into the corresponding mounting hole
and measure the compression pressure again.
• If the compression pressure increases, the piston rings and
inner surfaces of cylinder may be badly worn or otherwise
damaged.
• If the compression pressure remains unchanged, there may
be seizure in the valves, the valves may be incorrectly seated
or the cylinder head gasket may be defective.
• Install the injector. (See Gr13.)

• Install the rocker cover and the gasket. (See “ROCKER COV-
ER, ROCKER AND SHAFT”.)
11-15
2. Mitsubishi 6M70 Inspection and Adjustment of
Valve Clearances Service standards (Unit: mm)

Mitsubishi 6M70 Intake side 0.4 – Adjust
–
Valve clearance (when engine is cold) Exhaust side 0.6 – Adjust
Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
– Lock nut ( 6M70 valve bridge adjusting screw tightening) 68 {7} –
– Lock nut ( 6M70 rocker arm adjusting screw tightening) 60 {6} –
• Mitsubishi 6M70 Valve clearances should be checked and

adjusted as follows while the engine is still cold.
[Inspection]
• Remove the rocker cover.
10 5 16
• Bring the No. 1 or No. 6 cylinder piston to the top dead center
(TDC) on the compression stroke according to the following pro-
cedure:
• Crank the engine until the pointer is aligned with the “1 6”
mark on the flywheel.
• This will place either the No. 1 or No. 6 cylinder piston at TDC
on the compression stroke. The cylinder in which the rocker
arms for both the intake and exhaust valves can be pushed
down by hand by the valve clearance amounts has its piston
at TDC. Rotate the engine by one full turn to switch the TDCs
of the No. 1 and No. 6 cylinder pistons.
• With the No. 1 or No. 6 cylinder piston at TDC, measure the

clearance of the valves (clearance between valve bridge and
pad) marked with a circle in the table below.
Cylinder No. 1 2 3 4 5 6
Valve IN EX IN EX IN EX IN EX IN EX IN EX
No. 1 cylinder
piston at TDC on O O O – – O O – – O – –
compression stroke
No. 6 cylinder
piston at TDC on – – – O O – – O O – O O
compression stroke
• Any attempt to insert a feeler gauge without first securing suffi-

cient space, as described above, between the pad and the valve
bridge will fail, as the pad will tilt as shown in the illustration, thus
blocking the entry of a feeler gauge.
11-16
11
• Before inserting a feeler gauge, push the adjusting screw pad on
the side opposite from where a feeler gauge is to be inserted, as
shown in the illustration, using a flat-blade screwdriver or other
similar tool. This will create space necessary for the gauge to be
inserted.
• The measurement is correct when the feeler gauge feels slightly
resisted as it is inserted.
• The measurement is not yet correct if the feeler gauge can still
be inserted smoothly.
• If the measurement deviates from the standard value, adjust as
follows.
[Adjustment]
• Loosen the lock nuts and adjusting screws on the valve bridge
and rocker arm.
• While holding the valve bridge by hand, screw in the adjusting

screw until it lightly contacts the valve stem end.
• Then, further screw in the adjusting screw by 45°.
• While holding the adjusting screw in this position, tighten the

lock nuts to the specified torque.
CAUTION
• After adjusting the adjusting screw, be sure to tighten the
lock nut to the specified torque. Insufficient torquing will
compromise the parallelism of the valve bridge, damaging
the valve mechanism.
11-17
• Screw in or out the adjusting screw on the rocker arm until the
correct feeler gauge can be inserted with a slight resistance.
• After adjustment, while holding the adjusting screw in this posi-
tion with a screwdriver, tighten the lock nuts to the specified
torque.
• Recheck the valve clearance using the correct feeler gauge.
CAUTION
• If the valve clearance has been adjusted, be sure to check
and adjust the Powertard clearance. (See later section.)
• After the adjustment is complete, install the rocker cover and the
gasket. (See “ROCKER COVER, ROCKER AND SHAFT”.)

Phone: 269 673 1638
11-18
11
M E M O
11-19
3. Inspection and Adjustment of Powertard Clearances
Service standards (Unit: mm)
– Powertard clearance (when engine is cold) 1.0 ± 0.05 – Adjust

– Lock nut (for locking Powertard assembly adjusting screw) 25 {2.6} –

Feeler gauge MH063474 Adjustment of Powertard Clearances
P11605
Inspection and adjustment of the Powertard clearance must be car-

ried out after the inspection and adjustment of the valve clearance
while the engine is cold.
Inspection and adjustment of valve clearances (See 2. “Inspection
and Adjustment of Valve Clearances”.)
[Inspection]
• Remove the rocker cover.
10 5 16
• Bring the No. 1 or No. 6 cylinder piston to the top dead center
(TDC) on the compression stroke according to the following pro-
cedure:
• Crank the engine until the pointer is aligned with the “1 6”
mark on the flywheel.
• This will place either the No. 1 or No. 6 cylinder piston at TDC
on the compression stroke. The cylinder in which the rocker
arms for both the intake and exhaust valves can be pushed
down by hand by the valve clearance amounts has its piston
at TDC. Rotate the engine by one full turn to switch the TDCs
of the No. 1 and No. 6 cylinder pistons.
11-20
11
• When the No. 1 or No. 6 piston is at the TDC position of its com-
pression stroke, measure Powertard clearance for the valve
marked O in the following table.
Cylinder No.
Powertard 1 2 3 4 5 6
clearance measuring point
No. 1 piston at TDC of compression
O O O
stroke
No. 6 piston at TDC of compression
O O O
stroke
• For proper measurement, some resistance must be felt when in-
serting the in the clearance.
• Accurate measurements cannot be expected if the gauge moves
loosely in the clearance.
• If any measurement is out of specification, make adjustment as
follows.
[Adjustment]
• To adjust Powertard clearance, loosen the lock nut, then tighten
the adjusting screw until the moves somewhat stiffly in the
gap.
• Holding the adjusting screw in that position with a screwdriver,
tighten the lock nut to lock the adjusting screw. Recheck the
Powertard clearance using the .
11-21
ENGINE REMOVAL AND INSTALLATION
Removal sequence
1 Engine
2 Rear mounting : Locating pin
3 Front mounting
Installation sequence
Follow the removal sequence in reverse.

Nut (front mounting installation) 300 to 400 {30 to 40} –
Nut (rear mounting installation) 120 to 160 {12 to 16} –
Bolt (rear mounting installation) 70 to 95 {7.0 to 9.5} –
11-22
11
Removal procedure
Removal: Engine
• Hook a lifting device onto front hanger, rear hanger RH and rear
hanger LH, and lift the device with a crane until it is taut.
WARNING
• Use a lifting device that can comfortably withstand the
mass of the engine (approx. 1000 kg).
• Ensure that the harnesses, piping and other relevant parts have
been disconnected.
• Remove the bolts and nuts from the engine mounts. Slowly lift
the engine, taking care not to hit the engine against the frame or
cab.
• Once the bottom of the engine is out of the frame, turn the en-
gine by 90° and remove it out of the vehicle.
Inspection procedure
Inspection: Mounting
• Check the entire circumference of the rubber cushion of the
mountings for a crack, breakage and adhesion of oil.
• If there is any abnormality, replace the mounting.
11-23
ENGINE REMOVAL AND INSTALLATION
Installation procedure
Installation: Rear mounting
• Install the rear mounting on the engine in the illustrated direc-
tion.
Installation: Engine
• Loosen cross member and support mounting bolts and nuts.
• Hook a lifting device onto front hanger, rear hanger RH and rear
hanger LH, and lift the device with a crane to install the engine.
• Make sure that the stud of the rear mounting is placed at the il-
lustrated position (lowermost part of the slot on the support
side).
• The slot on the cross member side needs not necessarily be on
the lowermost part.
• If the stud is not placed at the illustrated position, adjust the posi-
tion with the cross member and support.
• Tighten cross member and support mounting bolts and nuts to
the torque of 120 to 160 N·m {12 to 16 kgf·m}.
• Tighten front and rear mounting nuts to the specified torque.
11-24
11
M E M O
11-25
MITSUBISHI 6M70 ROCKER COVER, ROCKER AND SHAFT
11-26
11
Disassembly sequence
1 Oil filler cap 7 Harness 12 O-ring
2 Rubber 8 Slave piston housing
3
4
Rocker cover
Rocker cover gasket
9
10
Rocker shaft cap
Rocker and shaft
*a:: Rocker case
Locating pin
5 Packing (See later section.) : Non-reusable parts
6 Oil pipe 11 Bushing connector
Assembly sequence
Follow the disassembly sequence in reverse.

Bolt (rocker cover mounting) 8.8 {0.9} 6.5 Ft Lbs –
Oil pipe 44 {4.5} –
M10 bolt (slave piston housing mounting) 55 {5.5} –
Bolt (rocker shaft mounting) 98 {10} –
M12 bolt (slave piston housing mounting) 80 {8.0} –
Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Rubber portion of oil filler cap
O-ring Engine oil As required
Rocker cover gasket
Periphery and top surface of packing ThreeBond 1211 As required
Work before removal

Releasing valve spring force
• Before loosening the rocker and shaft mounting bolts, check
whether the valve springs are compressed by the rockers. If so,
loosen the adjusting screws on the rockers to relieve the spring
force. This will eliminate the possibility of compressed springs
damaging parts when they are released.
Installation: Packing
• Apply sealant over the periphery of the packing and immediately
install it on the rocker case.
• After installing it on the rocker case, apply sealant over the top of
the packing.
• Install the rocker gasket and rocker cover on it immediately after
applying sealant.
CAUTION
• Never run the engine for one hour after installation.
• If the rocker cover is removed after installation, never fail to
replace the packing and apply the sealant again.
11-27
ROCKER COVER, ROCKER AND SHAFT
Rocker and Shaft
1 Adjusting screw
2 Rocker bushing
3 Intake rocker
4 Rocker shaft spring
5 Adjusting screw
6 Rocker bushing
7 Exhaust rocker
8 Rocker shaft
Assembly sequence
Follow the disassembly sequence in re-
verse.

2, 6, 8 Clearance between rocker shaft and bushing 0.027 to 0.088 0.2 Replace
3, 7 Radial clearance of rocker (roller) 0.068 to 0.112 – Replace

Lock nut (adjusting screw tightening) 60 {6} –

Inside surface of rocker bushing Engine oil As required

Rocker bushing puller Removal and installation of rocker

ME350053
A B C bushing
φ 27.6 φ 30.5 φ 28
11-28
11
Inspection: Radial clearance of rocker (roller)
• If the measurement deviates from the standard value, replace
the defective part(s).
Inspection: Clearance between rocker shaft and bushing

• If the measurement exceeds the limit, replace the bushing.
Replace of rocker bushing

[Removal]
[Installation]
• Assemble the bushing onto the rocker such that the oil holes are
aligned as shown in the illustration.
• After assembly, measure the clearance again.
• If the measurement is less than the standard value, ream the
bushing.
11-29
MITSUBISHI 6M70 CAMSHAFT AND ROCKER CASE
11-30
11
1 Camshaft cap 6 O-ring
*b:
a: Cylinder head
2 Camshaft 7 Connector
* Idler gear D
(See later section.)
3 Master piston
8
9
Rocker case
O-ring
*c:: Timing gear case
Locating pin
4 Master piston housing 10 Rocker case gasket : Non-reusable parts
5 Powertard solenoid valve
CAUTION
• The rocker case and the camshaft caps have been machined together, which means that they all must be
replaced together. The removed camshaft caps must be identified by attaching tags with their cylinder
numbers because they must be reinstalled to their original positions on the rocker case.
• Do not remove the Powertard solenoid valve unless necessary for replacement.
Assembly sequence

– Camshaft end play 0.1 to 0.2 0.4 Replace
*
2, b Backlash between idler gear D and camshaft gear 0.112 to 0.165 0.35 Replace
Powertard solenoid valve resistance (at temperature
5 32.6 to 39.8 Ω – Replace
25°C)

Bolt (camshaft cap mounting) 80 {8} –
Nut (connector mounting) 49 {5.0} –
Bolt (rocker case mounting) 19 {1.9} –
Bolt (master piston housing mounting) 54 {5.5} –

Camshaft journals and cams
Outer periphery of master piston
O-ring
Engine oil As required
Camshaft journal supports on rocker case
Camshaft journal supports on camshaft cap
Rocker case gasket
Top mating surfaces of cylinder head and timing gear
ThreeBond 1211 As required
case
11-31
CAMSHAFT AND ROCKER CASE
Work before removal
Inspection: Backlash between idler gear D and camshaft
gear
• Measure the backlash at least at three different locations. If the
measurement exceeds the limit, replace the defective part(s).
Inspection: Camshaft end play

• If the measurement exceeds the limit, replace the defective
part(s).
Inspection: Resistance in Powertard solenoid valve

the Powertard solenoid valve.
Removal procedure
Removal: Rocker case gasket
CAUTION
• Be careful not to scratch the cylinder head and timing gear
case when removing the rocker case gasket.
Cleaning procedure
Cleaning: Powertard solenoid valve
• Brush the oil screen clean and dry it with compressed air.
CAUTION
• Do not use a wire brush for cleaning. It could damage the oil
screen.
11-32
11
Installation: Rocker case
• Remove oil or any other contamination from the surfaces where
sealant is to be applied.
• Apply sealant onto the areas (shown in the illustration) on the
top surfaces of the cylinder head and timing gear case. Take
care not to spread the sealant beyond the application areas dur-
ing installation.
• Within three minutes following the application, install the rocker
case together with the rocker case gasket on the cylinder head.
CAUTION
• Do not start the engine for at least an hour after installation.
• Whenever the rocker case mounting bolts are subsequently
loosened or removed, the rocker case gasket must be re-
placed and sealant reapplied upon reassembly.
Installation: Camshaft
• Make sure that each alignment mark is aligned.
• Install the camshaft such that the stamped line on the camshaft
gear is level with the top surface of the rocker case.
11-33
Camshaft
1 Camshaft gear
2 Key
3 Camshaft
: Non-reusable parts
Assembly sequence
verse.

1, 3 Interference between camshaft gear and camshaft 0.017 to 0.058 – Replace
Lobe diame-
ter : 61.233
Intake side Base circle 8.233 7.74
diameter :
Differ- 53.000
ence of Lobe diame-
cam lobe ter : 61.367
diameter Exhaust side Base circle 8.234 7.72 Replace
and base diameter :
3 Camshaft
circle di- 53.133
ameter
Lobe diame-
ter : 60.147
Powertard Base circle 7.017 6.52
diameter :
53.130
Bend 0.05 0.08 Replace
Oil clearance at journal 0.082 to 0.127 0.28 Replace
Removal procedure
Removal: Camshaft gear
• Remove the camshaft gear by pushing on the end of the cam-
shaft with a press or other similar tool.
CAUTION
• Do not attempt to remove the camshaft gear with a hammer
as damage will result. Use a press or other similar tool.

Phone: 269 673 1638
11-34
11
Inspection: Interference between camshaft gear and cam-
shaft
Inspection: Camshaft
(1) Difference of cam lobe diameter and base circle diameter
• If the measurement is less than the limit, replace the camshaft.
(2) Bend
• Measure the camshaft at the center journal for bend while sup-
porting the shaft at the end journals.
• A half of the dial gauge reading obtained as the camshaft is ro-
tated by a full turn represents the bend of the camshaft.
• If the measurement exceeds the limit, replace the camshaft.
(3) Oil clearance at journal

part(s).
CAUTION
• The camshaft cap and rocker case have been machined to-
gether, which means that they all must be replaced togeth-
er.
11-35
Installation: Camshaft gear
• Heat the camshaft gear to approximately 150°C using a gas
burner.
• While facing the camshaft gear as shown in the illustration,
press it onto the camshaft until it seats snugly on the camshaft.
WARNING
• You may burn yourself if you touch the heated camshaft
gear.
CAUTION
• When installing the camshaft gear, be sure to apply the load
with the press at the center of the gear. Apply the load on
the gear may damage the gear.
11-36
11
M E M O
11-37
MITSUBISHI 6M70 CYLINDER HEAD AND VALVE MECHANISM
11-38
11
1 Nozzle bridge 8 Timing gear case 14 6M70 Cylinder head gasket
2 Injector (See Gr13.) 9 Idler shaft
3 O-ring 10 Idler gear bushing *b:
a: Idler gear C
4 Nozzle tip gasket 11 Idler gear D * Flywheel housing
5 Cylinder head bolt 12 Thrust plate *c:: Crankcase
Locating pin
6 Plate 13 Cylinder head
7 O-ring (See later section.) : Non-reusable parts
Assembly sequence
CAUTION
• The cylinder head bolt is tightened within the plastic region. The number of punch marks indicates the
number of times the bolt has been tightened. If there are 3 punch marks (tightened 3 times in the past), re-
place the bolt.

9, 10 Clearance between idler shaft and idler gear bushing 0.03 to 0.068 0.2 Replace
11 Idler gear D end play 0.1 to 0.2 0.4 Replace
11, a
* Backlash between idler gear D and idler gear C 0.094 to 0.181 0.35 Replace
Mitsubishi 6M70 Tightening torque (Unit: N·m {kgf·m})

Bolt (nozzle bridge mounting) 54 {5.5} –
• Wet
Mitsubishi 6M70 Cylinder head bolt 180 NM {18 kgfm} 133 Ft Lbs • Can be reusable
Plus + 90° up to 3 times
Bolt (idler shaft mounting) 55 {5.5} –

O-ring
Threaded of bolt
Outer periphery of idler shaft
Inside surface of idler gear bushing
Top mating surfaces of flywheel housing and crankcase
Mating surfaces of cylinder head on cylinder head gasket ThreeBond 1211 As required
top surface and timing gear case
Mating surfaces of cylinder head and timing gear case ThreeBond 1207C As required

Phone: 269 673 1638
11-39
CYLINDER HEAD AND VALVE MECHANISM
Socket wrench MH063388 Installation of cylinder head
Idler gear bushing-puller Removal and installation of idler gear

ME350196
A B C bushing
φ 56 φ 62 φ 57
Work before removal

Inspection: Idler gear D end play
part(s).
Inspection: Backlash between idler gear D and idler gear C

part(s).
Removal procedure
Removal: Cylinder head
• Remove the bolts (× 4).
• Progressively loosen the cylinder head bolts in the order shown
in the illustration, going over them several times, before eventu-
ally removing them.
11-40
11
Removal: Idler shaft
• Remove the idler shaft together with idler gear D as a unit with a
slide hammer.
Removal: Cylinder head gasket

CAUTION
• Be careful not to scratch the cylinder head, crankcase and
flywheel housing when removing the cylinder head gasket.
Inspection: Clearance between idler shaft and idler gear
bushing
Replacement of idler gear bushing

[Removal]
[Installation]
• Press in the bushing until contacts the end face of idler
gear D.
• After installation, measure the clearance again.
• If the measurement is less than the specified value, ream the
bushing.
11-41
Installation: Timing gear case
• Apply a sealant to the illustrated section of the timing gear case.
• Install the timing gear case to the cylinder head within 3 minutes
following the application of the sealant. Take care not to spread
the sealant beyond the application areas during installation.
CAUTION
• After reassembly, if the timing gear case mounting bolts are
subsequently loosened or removed, be sure to apply seal-
ant again upon reassembly.
Installation: Cylinder head

CAUTION
• Before installing the Mitsubishi 6M70 cylinder head bolt,
check the number of punch marks on the bolt head.
(Bolts with up to two punch marks can be reused.)
The number of punch marks indicates the number of times
the bolt has been tightened in the past within the plastic re-
gion. If there are three punch marks (tightened three times
in the past), replace the bolt.

• Apply sealant onto the areas (shown in the illustration) on the
top surfaces of the flywheel housing and crankcase.
• Within three minutes following the application, install the cylinder
head gasket onto the crankcase. Take care not to spread the
sealant beyond the application areas during installation.
CAUTION
• Be careful not to scratch the cylinder head gasket when in-
stalling the cylinder head gasket.
• After reassembly, if the cylinder head bolts are subsequent-
ly loosened or removed, be sure to replace the cylinder
head gasket and apply sealant again upon reassembly.
11-42
11
• Install the cylinder head gasket onto the crankcase and apply
sealant to the illustrated section of the cylinder head gasket.
• Within three minutes following the application, install the cylinder
head onto the cylinder head gasket. Take care not to spread the
sealant beyond the application areas during installation.
CAUTION
• Whenever the cylinder head bolts are subsequently loos-
ened or removed, the cylinder head gasket must be re-
placed and sealant reapplied upon reassembly.
• If pistons, connecting rods or other relevant parts are re-
placed, measure to check the pistons for any change in pro-
trusion. (See “PISTON, CONNECTING ROD AND CYLINDER
LINER”.)
• Tighten the cylinder head bolts to a torque of 180 N·m {18 kgf·m}
in the order shown in the illustration.
• Install the bolts.
• Further tighten the bolts, in the order shown and as follows.
• Turn the holder of counterclockwise to pretension the inter-

nal spring.
• Set the tool such that the rod (extension) is pressed against the
rocker shaft bracket by the force of the spring.
• Align any line on the holder scale with any line on the socket
scale. (This will be used as the reference point = 0°.)
• From the reference point, turn the socket by 90° in the direction
shown. Each division on the holder scale represents 5°.
• After tightening the cylinder head bolt within the plastic region,
make a punch mark on the bolt head to record the number of
times that they have been tightened.
CAUTION
• The bolts should be tightened within the plastic region.
Never tighten them further than the specified angle.
11-43
MITSUBISHI 6M70 CYLINDER HEAD AND VALVE MECHANISM
Cylinder Head
1 Adjusting screw 7 Inner valve spring 15 Intake valve seat
2 Valve bridge <Exhaust> 16 Nozzle tube
3 Pin 8 Valve stem seal 17 O-ring
4 Valve cotter 9 Exhaust valve 18 Cylinder head
5 Upper retainer 10 Intake valve
6 Valve spring 11 Valve bridge guide : Non-reusable parts
<Intake> 12 Exhaust valve guide
Outer valve spring 13 Intake valve guide
<Exhaust> 14 Exhaust valve seat
Assembly sequence
CAUTION
• When an exhaust valve or intake valve has been removed, make sure to replace the valve stem seal.

Phone: 269 673 1638
11-44
11
Mitsubishi 6M70 Service standards (Unit: mm)
2, 11 6M70 Valve bridge-to-valve bridge guide clearance 0.01 to 0.048 0.1 Replace
6M70 Valve springFree length 89.3 87.9 Replace
<Intake>,
Installed load 490.4 ± 24.5 N
6 6M70 outer valve – Replace
(Installed length 61.325) {50.0 ± 2.5 kgf}
spring
<Exhaust> Squareness – 2.0 Replace
Free length 76.0 74.9 Replace
6M70 Inner valve
Installed load 98.1 ± 4.9 N
7 spring – Replace
(Installed length 54.325) {10.0 ± 0.5 kgf}
<Exhaust>
Squareness – 2.0 Replace
Stem outer diameter 9.925 to 9.940 9.85 Replace
Sinkage from cylinder head
0.2 ± 0.25 0.7 Replace
9 6M70 bottom surface
Exhaust valve Valve margin 2.5 2.0 Replace
Seat angle 45° ± 15° – Rectify
9, 12 6M70 Exhaust valve stem-to-valve guide clearance 0.07 to 0.10 0.2 Replace
Stem outer diameter 9.96 to 9.975 9.85 Replace
Sinkage from cylinder head bottom
0.5 ± 0.25 1.0 Replace
10 6M70 surface
Intake valve Valve margin 2.83 2.33 Replace
Seat angle 60° ± 15° – Rectify
10, 13 6M70 Intake valve stem-to-valve guide clearance 0.035 to 0.065 0.2 Replace
11 6M70 Outer diameter of valve bridge guide 10.989 to 11 10.988 Replace
Rectify or
14 6M70 Exhaust valve seat width 3.5 ± 0.2 4.2
replace
Rectify or
15 6M70 Intake valve seat width 2.8 ± 0.2 3.5
replace
Rectify or
Bottom surface distortion 0.07 0.2
replace
18 6M70 Height from top surface to
130 ± 0.05 129.5 Replace
Cylinder head bottom surface
Valve seat hole diameter φ 49 +0.025
0 – Replace

Lock nut (valve bridge adjusting screw tightening) 68 {7.0} –
Stud bolt 20 {2.0} –

Lip of valve stem seal
Stem and end of valve
Nozzle tube end ThreeBond 1211 As required
11-45
Valve lifter
A MH061668
φ 42 Removal and installation of valve cot-
ters
Valve lifter hook MH061679
Valve stem seal installer

MH062806 Installation of valve stem seals
A B
φ 22 φ 11
Valve lapper 30091-07500 Lapping valves and valve seats
Valve bridge guide

installer ME350051 Installation of valve bridge guides
A B
φ 11 56
Valve guide remover MH062177 Removal of valve guides
Valve guide installer

ME350052 Installation of Mitsubishi 6M70
A B C
valve guides
φ 25 φ 15 16.8
Caulking tool body MH062174
Installation of Mitsubishi 6M70

intake valve seats ,
Installer ring MH062175 exhaust valve seats ,
A B
φ 10 φ 51
11-46
11
Nozzle tube remover

MH061232 Removal of nozzle tube
A B
φ 8.7 φ 12.5
Nozzle tube installer

bolt
MH061231
A B
φ 8.5 M18 × 1.5
Nozzle tube installer

body
ME350195 Installation of Mitsubishi 6M70
A nozzle tube
M18 × 1.5
Nozzle tube stamp

A MH061229
φ8
Removal procedure
Removal: Valve cotter
• Using and , evenly compress the valve cotter to re-
move so that the valve spring does not lean to one side.
Removal: Nozzle tube
11-47
Inspection: Valve bridge and valve bridge guide
(1) Valve bridge-to-guide clearance
part(s).
(2) Outer diameter of valve bridge guide
• If the measurement is less than the limit or if the parts are un-
evenly worn, replace the valve bridge guide.
Replacement of valve bridge guide

[Installation]
• Before installation, ensure that no water, oil or other foreign mat-
ter is in the installation hole.
• Using , install the valve bridge guide until it securely contacts
the cylinder head.
CAUTION
• The valve bridge guide must be installed to the specified
depth of the cylinder head. Correct installation can only be
possible by using .
Inspection: Mitsubishi 6M70 Intake and exhaust valve (1)

Valve stem outer diameter
• If the measurement is less than the limit or the valve is worn ex-
tremely unevenly, replace the valve.
• When the valve has been replaced with a new one, make sure to
lap the valve and valve seat.
(2) Valve seat angle

• If the measurement deviates from the standard value, rectify the
valve.
(3) Valve margin
• If the measurement is less than the limit, replace the valve.
Refacing valve
• Limit grinding to a necessary minimum.
• If the valve margin is below the limit after grinding, replace the
valve.
• After grinding, make sure to lap the valve and valve seat.
11-48
11
Inspection: Valve-to-valve guide clearance
• If the clearance exceeds the specified limit, replace the defective
part(s).
Replacement of valve guides

[Removal]
[Installation]
• Using , install the valve guide until it securely contacts the
cylinder head.
CAUTION
• The valve guide must protrude from the cylinder head by
the specified amount. Correct installation can only be pos-
sible by using .
• The valve guides for the exhaust valves are longer than the
valve guides for the inlet valves.
Inspection: Contact between valve and valve seat

• Before starting inspection, check that the valve and valve guide
are intact.
• Apply an even coat of red lead to the valve contact surface of
the valve seat.
• Strike the valve once against the valve seat. Do not rotate the
valve during this operation.
• If the red lead deposited on the valve indicates a poor contact

pattern, take either of the following corrective actions.
Contact pattern Corrective action
Minor defect Lapping valve
Serious defect Reface or replace valve and valve seat
11-49
Lapping valve
• Lap the valve in the following sequence.
• Apply a thin coat of lapping compound to the contact surface of
the valve seat. Adding a small amount of engine oil to the lap-
ping compound can facilitate even application.
• Start with an intermediate-grit compound (120 to 150 grit) and
finish with a fine-grit compound (200 grit or more).
CAUTION
• Do not put any compound on the stem.
• Strike the valve several times against the valve seat while rotat-
ing the valve a little at a time.
• Wash away the compound with diesel fuel.
• Apply engine oil to the contact surface of the valve seat and rub
in the valve and seat well.
• Inspect the contact pattern between valve and valve seat again.
• If the contact pattern is still defective, replace the valve seat.
Inspection: Mitsubishi 6M70 Valve seats

• If the valve seat is refaced or replaced after performing the fol-
lowing inspection, make sure to lap the valve and valve seat.
(1) Valve seat width
• If the measurement exceeds the limit, reface or replace the
valve seat.
(2) Valve sinkage from cylinder head bottom surface

• Perform measurement keeping the valve in close contact with
the valve seat.
• If the measurement exceeds the limit, reface or replace the de-
fective part(s).
Refacing the valve seat

• Grind the valve seat using a valve seat cutter or valve seat
grinder.
• Place a piece of sandpaper of approximately #400 between the
cutter and valve seat and grind the valve seat lightly.
• Use a 15° or 75° cutter to cut the valve seat width within the
standard range. Replace the valve seat if it cannot be refaced
within the standard range.
CAUTION
• Make sure that the valve seat refacing does not cause the
valve sinkage to exceed the limit.
11-50
11
• After refacing, make sure to lap the valve and valve seat.
Replacement of valve seat

[Removal]
• The valve seats are installed by expansion fitting. To remove a
valve seat, grind inside the metal stock to reduce the wall thick-
ness, then remove the valve seat at room temperature.
[Installation]
• Measure the diameter of the valve seat hole in the cylinder
head.
the cylinder head.
• Chill the valve seat thoroughly by immersing in it in liquid nitro-

gen.
• Drive in the valve seat using with the chamfered side of
facing the cylinder head.
• After driving in, reverse the direction of and crimp the valve
seat.
• After reassembly, make sure to lap the valve and valve seat.
Inspection: Cylinder head bottom surface distortion

• If the distortion exceeds the limit, rectify it using a surface grind-
er.
CAUTION
• Make sure that the height of the cylinder head from the top
surface to the bottom surface is not reduced to a value be-
low the limit.
11-51
Installation: Mitsubishi 6M70 Nozzle tube
• Apply a sealant to the perimeter A of the tip of the nozzle tube.
• Push in the nozzle tube by hand until it contacts surface B of the
cylinder head.
• Tighten with the bolt and press the nozzle tube onto sur-
face B of the cylinder head.
• Apply engine oil to section C of .
• Screw in until can be pulled out from the bottom of
the cylinder head.
• After installing the nozzle tube, be sure to perform a leak test to
check for airtightness.
Installation: Mitsubishi 6M70 Valve stem seal

• Apply engine oil to the lip of the valve stem seal.
• Install the valve stem seal until sits snugly on the cylinder
head.
• After assembly, check that its spring is not deformed or dam-
aged.
Installation: Mitsubishi 6M70 Valve spring

• Install the outer and inner valve springs onto the cylinder head
while facing them as shown in the illustration.
Installation: Mitsubishi 6M70 Valve cotter

• Using and , install the valve cotter while compressing
the valve spring(s) evenly.
CAUTION
• Do not compress the valve spring(s) too much, or the upper
retainer will contact the valve stem seal and damage will re-
sult.
11-52
11
M E M O
11-53
MITSUBISHI 6M70 PISTON, CONNECTING ROD AND
CYLINDER LINER Disassembly sequence
1 Lower connecting rod bearing
2 Connecting rod cap
3 Upper connecting rod bearing
4 Piston and connecting rod
5 Cylinder liner
Assembly sequence
verse.

– Piston protrusion from crankcase top surface –0.321 to –0.111 – Replace
– End play of connecting rod 0.2 to 0.5 1.0 Replace
Oil clearance 0.06 to 0.122 0.25
1, 3 Connecting rod bearing Replace
Span when free – 90.5
4, 5 Piston and cylinder liner clearance 0.247 to 0.277 – Replace
Flange protrusion 0.01 to 0.07 –
Inner diameter φ135 to 135.03 φ135.25
5 Cylinder liner Cylindricity 0.03 or less – Replace
Difference in protrusion of
0.04 or less –
adjacent flange

Nut (connecting rod cap mounting) 49 {5} + 120° Wet

Nut thread
Inside surface of connecting rod bearing
Outside periphery of cylinder liner
Outer periphery of piston
11-54
11
Piston guide clamp MH061667
Piston guide lever MH061658
Installation of piston and connecting

rod
Socket wrench MH061560
Cylinder liner extractor

A MH062194 Removal of cylinder liner
φ134.5
Adapter ME350054
Bolt MF130651 Measurement of cylinder liner flange

protrusion and step height between
adjacent cylinder liners
Washer A B MF450009
40 M16 × 2
Work before removal

Retaining of cylinder liners
• The cylinder liners may move up when the crankcase is turned
over, or the crankshaft is rotated after the pistons are installed.
To prevent this, retain the cylinder liners by holding their flanges
with bolts and washers.
11-55
PISTON, CONNECTING ROD AND CYLINDER LINER
Inspection: Piston protrusion from crankcase top surface
• The amount of piston protrusion affects engine performance and
must therefore be inspected without fail.
• Set the piston at the top dead center.
• Make the measurement at the two measurement points on the
top face of the piston and calculate the average value.
• If the average value deviates from the standard value, check the
clearances between all relevant parts.
Inspection: Connecting rod end play

• Measure the end play for every connecting rod.
part(s).
Inspection: Cylinder liner flange protrusion and step height

between adjacent cylinder liners
• Install so that it does not run onto the cylinder liner flange
and tighten and to the torque of 49 N·m {5 kgf·m}.
• Measure the cylinder liner flange protrusion.

• If the measurement deviates from the standard value, inspect
the installation and replace the defective part(s).
• If the difference in the adjacent flange protrusion deviates from
the standard value, replace the defective part(s) upon checking
the installed condition.
CAUTION
• If the cylinder liner flange protrusion is not within the speci-
fied value, the contact pressure of the cylinder head gasket
against the bore of the cylinder will not be high enough to
prevent gas leakage.
11-56
11
Inspection: Connecting rod bearing span when free
CAUTION
• Do not attempt to manually expand the bearings.
• If the measurement is less than the limit, replace the upper and
lower connecting rod bearings.
Inspection: Connecting rod bearing-to-crankshaft clearance

(oil clearance)
• Fit the lower bearing to the connecting rod cap and the upper
bearing to the connecting rod, then tighten the nut to a torque of
115 N·m {12 kgf·m}.
• Measure the inner diameter of the bearing and the outer diame-
ter of the crankshaft pin.
• If the clearance exceeds the limit, replace the defective part(s).
• If a bearing has to be replaced with an undersized one, machine
the crankshaft pin to the specified undersize diameter.
(See “CRANKSHAFT AND CRANKCASE”.)
Inspection: Mitsubishi 6M70 Piston and cylinder liner clearance

• If the value calculated from the measurement deviates from the
standard value, replace the defective part(s).
A: Measuring point on the crankcase (in direction of the crank-
case axis).
B: Measuring point on the crankcase (vertical to the crankcase
axis).
C: Measuring point on the piston (vertical to the piston pin hole).
CAUTION
• Because the cylinder liner is a thin-walled liner, the boring
process cannot be preformed on an oversized liner. Do not
remove the cylinder liner except for replacement to prevent
deformation.
11-57
Replacement of cylinder liner
[Removal]
CAUTION
• If the cylinder liners will need to be reused for some reason
or other, make alignment marks to ensure correct reassem-
bly.
[Installation]
• When replacing the cylinder liner, use the size mark on the
crankcase and the size mark on the piston to select the appro-
priate size of the cylinder liner.
Size mark Size mark Size mark

on crankcase on cylinder liner on piston
“1” “1A” “A”

“1B”
“2A”
“2” “2B” “B”
“3A”
“3” “3B”
CAUTION
• Using a piston with the size mark different from the size
mark of cylinder liner can lead to engine seizure.
• Apply a thin coat of engine oil onto the outer periphery (hatched
area) of the cylinder liner.
• While pushing the cylinder liner evenly with hands, gently insert
the cylinder liner into the crankcase.
CAUTION
• Cylinder liners are thinly structured. Therefore, they must
be handled with extreme care.
11-58
11
Installation: Connecting rod bearings
CAUTION
• Do not reverse the positions of the lower bearing and the
upper bearing (with oil hole) when installing, as this may
cause seizure in the engine.
Installation: Piston and connecting rod

• Check that the piston ring end gaps are in their correct positions.
A: 1st compression ring gap
B: 2nd compression ring gap
C: Oil ring gap
D: Oil ring expander spring gap
“ ”: Front mark on piston
• Ensure that the size mark (“A”, “B”) on the piston is the same as
that on the cylinder liner.
• Face the front mark “ ” of the piston toward the front of the en-
gine.
• With and installed around the piston skirt, tighten the
adjusting bolt of until the inside diameter of matches
the outside diameter of the piston skirt.
• After adjustment, remove and from the piston. Apply
engine oil to the following areas. Then, install and
over the rings of the piston.
• Outer periphery of piston
• Inner periphery of
• Inner periphery of cylinder liner
CAUTION
• Cover the connecting rod bolt with a vinyl hose to prevent
the connecting rod bolt from damaging the inside surface
of the cylinder and crankshaft.
11-59
CAUTION
• Be careful not to scratch or damage head of the piston (a
part of the combustion chamber).
• Make sure that the connecting rod does not hit oil jet.
• After installing the piston and connecting rod, install the connect-
ing rod cap onto the connecting rod, ensuring that the their align-
ment marks (projection) are aligned with the weight mark. Then,
tighten the nut to the torque of 49 N·m {5 kgf·m}.
• Further tighten the bolts in the following procedure.

nal spring.
crankshaft by the force of the spring.
shown. Each division on the socket scale represents 5°.
• After assembly of the connecting rod cap, perform the following
test.
• End play of connecting rod
• Piston protrusion

Phone: 269 673 1638
11-60
11
M E M O
11-61
Mitsubishi 6M70 Piston and Connecting Rod
1 1st compression ring
2 2nd compression ring
3 Oil ring
4 Snap ring
5 Piston pin
6 Connecting rod bushing
7 Connecting rod bolt
8 Connecting rod
9 Piston
Assembly sequence
verse.

1st compression ring 0.4 to 0.55
1 to 3 Piston ring end gap 2nd compression ring 0.5 to 0.65 1.5 Replace
Oil ring 0.4 to 0.6
1st compression ring 0.015 to 0.06 0.15
Clearance between
1 to 3, 9 piston ring and piston 2nd compression ring 0.085 to 0.125 0.25 Replace
ring groove
Oil ring 0.025 to 0.065 0.15
5, 6 Clearance between piston pin and connecting rod bushing 0.02 to 0.055 0.1 Replace
5, 9 Clearance between piston pin and piston 0.004 to 0.022 0.1 Replace
Bend – 0.05
8 Connecting rod Replace
Twist – 0.1

Outer periphery of piston pin
Outer periphery of connecting rod bushing
Connecting rod bushing mounting surface of connecting Engine oil As required
rod
Connecting rod bolt mounting hole
11-62
11
Special tools
Removal and installation of piston

Piston ring tool 31191-02900
rings
Connecting rod bushing Removal and installation of connect-

MH062185
puller kit ing rod bushings
Removal procedure
Removal: Piston ring
Removal: Piston pin

• Remove the piston pin by striking it with a rod and hammer.
• If the piston pin is difficult to remove, first heat the piston in hot
water or with a piston heater.
Inspection: Mitsubishi 6M70 Piston ring end gap
• Using the crown of a piston, push the piston ring horizontally into
a cylinder in the crankcase until it reaches the lower part of the
cylinder liner, where there is relatively small wear.
• Taking care not to move the piston ring, measure the end gap.
• If the measurement exceeds the limit, replace all the piston rings
as a set.
11-63
Inspection: Mitsubishi 6M70 Clearance between piston
ring and piston ring groove
• Remove any carbon deposits from the ring groove in the piston.
• Measure the side clearance of each ring around the piston’s en-
tire periphery of the ring groove.
part(s). If any of the piston rings is defective, replace all the pis-
ton rings as a set.
• The clearance of the 1st compression ring must be measured
using a thickness gauge while holding the ring against the piston
ring groove with a straight edge.
Inspection: Clearance between piston pin and piston

part(s).
Inspection: Mitsubishi 6M70 Clearance between piston

pin and connecting rod bushing
Replacement of connecting rod bushing

• Replace the connecting rod bushing using .
11-64
11
[Removal]
• If the upper connecting rod bearing is installed on the big end of
the connecting rod, remove the bearing.
• Secure the connecting rod to the base with a bracket and plate.
• Set collar A on the puller in the direction shown in the illustration
and gradually remove the bushing with a press load of approxi-
mately 49 kN {5000 kgf}.
[Installation]
• Apply engine oil to the outer periphery of the connecting rod
bushing and the bushing fitting surface of the connecting rod.
• Fit collar B, the bushing, and collar A over the puller in the direc-
tion shown in the illustration and lock this arrangement together
with the nut.
• Align the oil holes in the bushing and the connecting rod. Then,
use a press to slowly apply a pressure of approximately 49 kN
{5,000 kgf} to the puller until the bushing is forced into place.
• After assembly, measure the clearance again.
bushing.
Inspection: Connecting rod bend and twist

• Mount the connecting rod on the connecting rod aligner. Also
mount the connecting rod bearings, piston pin, and connecting
rod cap to create the same conditions as are expected when the
connecting rod is mounted on a crankshaft. Tighten the nuts of
the connecting rod cap to a torque of 115 N·m {12 kgf·m}.
• Measure the extent of bend and twist in the connecting rod.
• If either measurement exceeds the limit, replace the connecting
rod.
Installation: Mitsubishi 6M70 Connecting rod bolt
• Make sure that bolt holes of the connecting rod are free of flaws
and burrs.
• Apply engine oil to the knurled portion of the connecting rod bolt
and press fit it in the illustrated direction with the maximum press
load of 5880 N {600 kgf}.
11-65
Installation: Mitsubishi 6M70 Piston and connecting rod
• When the piston and connecting rods are replaced, install each
part as follows;
• Select all the connecting rods with the same weight mark on the
same engine (‘‘A to H’’, ‘‘J to M’’).
• Apply engine oil to the piston pin, and assemble the piston and
connecting rod with their marks facing in the illustrated direc-
tions.
“ ”:Front mark
• If the piston pin is difficult to insert, first heat the piston in hot wa-
ter or with a piston heater. Then, install the piston.
Installation: Mitsubishi 6M70 Piston rings

• With the manufacturer’s marks (found near the piston ring end
gaps) facing up, install the piston rings so that the end gap of
each ring is positioned as shown in the illustration.
A: 1st compression ring end gap
B: 2nd compression ring end gap
C: Oil ring end gap
D: Oil ring expander spring end gap
“ ”: Front mark on piston
The manufacturer’s marks are present only on the 1st and 2nd
compression rings.
11-66
11
M E M O
11-67
FLYWHEEL PTO <WITH FLYWHEEL PTO>
1 Eyebolt 7 Flange 13 Ball bearing
2 Oil pipe 8 Oil seal 14 PTO head
3 PTO bracket 9 Cover 15 O-ring
4 Washer 10 Gasket
5 PTO gear 11 Roller bearing
*a: Flywheel housing
6 Washer 12 PTO shaft : Non-reusable parts
Assembly sequence

– Total backlash of gears 0.19 to 0.62 0.8 Replace

Eyebolt 21 {2.1} –
Nut (PTO gear installation) 220 {22} –
Nut (flange installation) 178 {17.8} –
11-68
11
O-ring
Oil seal lip
Multipurpose grease
Sliding contact surfaces of flange and oil seal As required
[NLGI No.2 (Ca soap)]
Multipurpose grease
Fitting surfaces of flange and PTO shaft As required
[NLGI No.2 (Ca soap)]
Inspection before removal

Inspection: Total backlash of gears
• “Total backlash of gears” is the gear backlash produced when
the PTO gear, PTO idler gear A, PTO idler gear B and drive gear
are all in mesh with each other.
• Measure the total backlash of gears by inserting a lever type dial
gauge into the threaded holes A in the flange of the PTO head
assembly.
• If the measurement is out of specification, check each gear for
wear and replace if necessary.
• Check the PTO idler gear A, PTO idler gear B and drive gear for
wear. (See TIMING GEARS <WITH FLYWHEEL PTO>.)
Removal procedure
Removal: Roller bearing and PTO shaft
• Remove the roller bearing and PTO shaft in the direction shown
in the illustration.
11-69
FLYWHEEL PTO <WITH FLYWHEEL PTO>
Removal: Ball bearing
• Remove the ball bearing in the direction shown in the illustration.
Installation: Oil seal
• Fit the oil seal oriented as shown in the illustration.
Installation: Split pin

• After fitting, bend the split pin in the illustrated direction.
Installation: PTO head

• Make sure that the PTO shaft turns lightly by hand before install-
ing the PTO head onto the flywheel housing.
11-70
11
M E M O
11-71
FLYWHEEL
1 Snap ring 11 O-ring 22 Eyebolt
2 Pilot bearing 12 Collar 23 Water inlet pipe
3 Ring gear 13 Engine speed sensor 24 Eyebolt
4 Flywheel 14 Stiffener 25 Oil pipe
5 Rear oil seal 15 Air suction hose 26 Air compressor
6 Power steering oil hose 16 Eyebolt 27 O-ring
7 O-ring 17 Air suction pipe 28 Flywheel housing
8 Suction hose 18 Eyebolt
9 Power steering oil pump 19 Air outlet pipe : Locating pin
(See Gr37.) 20 Eyebolt : Non-reusable parts
10 O-ring 21 Water outlet pipe
Assembly sequence
CAUTION
• The flywheel mounting bolt is tightened within the plastic region. The number of punch marks indicates
the number of times the bolt has been tightened. If there are 3 punch marks (tightened 3 times in the
past), replace the bolt.
11-72
11
Rectify or
Friction surface distortion 0.05 0.2
replace
Friction surface height 48 ± 0.2 49.5 Replace
4 Flywheel Friction surface runout Rectify or
– 0.2
(when fitted) replace
Rectify or
Friction surface parallelism 0.1 or less –
replace
Eccentricity of flywheel housing measured at spigot joint sec- Inspect or
28 – 0.2
tion (when fitted) replace

Without PTO 100 {10} + 90° • Wet

Bolt (flywheel mounting) • Can be reused
up to 3 times
With PTO 100 {10} + 150°
Power steering oil hose 68 {7.0} –

Bolt (power steering oil pump mounting) 74 {7.5} –
Nut (collar mounting) 100 {10} –
Engine speed sensor 25 {2.5} –
Bolt (rear oil seal mounting) 12 {1.2} –
Bolt (flywheel housing mounting) 80 {8.0} –
Eyebolt (oil pipe mounting) 21 {2.1} –
Eyebolt (air outlet pipe mounting) 100 {10} –
Eyebolt (water inlet pipe mounting)
50 {5.1} –
Eyebolt (water outlet pipe mounting)
Eyebolt (air suction pipe mounting) 155 {16} –

Thread of bolts
Rear oil seal lip
Rear oil seal surface to be mated with flywheel housing
ThreeBond 1207C As required
Engine mounting surface of flywheel housing
Special tools
Socket wrench ME350193
Installation of flywheel
Magnet base MH062356
11-73
FLYWHEEL

Inspection: Flywheel friction surface runout when fitted
• If the measurement exceeds the limit, check if the bolts are cor-
rectly tightened as well as the crankshaft mounting surface. Cor-
rect or replace the flywheel as required.
Removal procedure
Removal: Flywheel
• To remove the flywheel, use bolts inserted into the dedicated
holes in the flywheel.
Removal: Ring gear

• Heat the ring gear evenly with a gas burner or the like until it
reaches approximately 200°C, then remove it from the flywheel.
WARNING
• You may burn yourself if you touch the heated ring gear.
Removal: Collar
• Install bolts (M4 x 0.7 mm) into the dedicated holes in the collar,
and pull the bolts to remove the collar.
Inspection: Flywheel
(1) Friction surface height
• If the measurement exceeds the limit, replace the flywheel.
11-74
11
(2) Friction surface distortion
• If the measurement exceeds the limit, rectify or replace the fly-
wheel.
• If the ring gear is evidently defective, replace the ring gear be-
fore inspecting the friction surface for distortion.
Rectification of friction surface

• Rectify the friction surface so that its height is not above the
specified limit, and it is parallel with surface A within specifica-
tion.
Installation: Flywheel housing
[Installation]
• Clean the flywheel housing surface where sealant is to be ap-
plied.
• Apply an even and continuous bead of sealant onto the flywheel
housing surface where the crankcase is to be mounted.
• Within three minutes following the application, install the fly-
wheel housing onto the crankcase. When installing the flywheel
housing, take care not to spread the sealant beyond the applica-
tion area.
CAUTION
• Do not start the engine at least for an hour after the flywheel
housing has been installed.
• If the flywheel housing mounting bolts are subsequently
loosened, be sure to apply sealant again upon reassembly.
[Inspection]
• While turning the crankshaft, measure the flywheel housing for
any eccentricity at the location indicated in the illustration.
• If the eccentricity exceeds the limit, reassemble the flywheel.
• If the eccentricity still exceeds the limit after reassembly, replace
11-75
FLYWHEEL
Installation: Air compressor
• Set the No. 1 cylinder piston at the top dead center of the com-
pression stroke.
• Align the stamped mark “1” on the air compressor gear with the
projection on the air compressor.
• While keeping this condition, align the stamped mark “1” with the
scribed line on the rear plate and install the air compressor to
the flywheel housing.
Installation: Rear oil seal

• Clean the rear oil seal surface where sealant is to be applied.
• Apply an even and continuous bead of sealant on the rear oil
seal as shown in the illustration.
• Install the rear oil seal onto the flywheel housing within 3 min-
utes following the application of the sealant. Be careful not to
dislodge the sealant.
CAUTION
• Do not start the engine at least for an hour after the rear oil
seal has been installed.
• If the rear oil seal mounting bolts are subsequently loos-
ened, be sure to apply sealant again upon reassembly.
Installation: Ring gear

• Heat the ring gear evenly with a gas burner or the like until it
reaches approximately 200°C.
WARNING
• You may burn yourself if you touch the heated ring gear.
• Fit the ring gear with the side having non-chamfered portions to-
ward the flywheel.
Installation: Flywheel
CAUTION
• Before installing a bolt, check the number of punch marks
on the bolt head. (Bolts with up to two punch marks can be
reused.)
The number of punch marks indicates the number of times
11-76
11
• Tighten the flywheel mounting bolts to a torque of 100 N·m {10
kgf·m}.
• Further tighten the bolts in the following procedure.
• Turn the holder of counterclockwise to preload the built-
in spring.
• Set the tool such that the rod (extension) is pressed against
by the force of the spring.
• From the reference point, turn the socket by 90° <Without fly-
wheel PTO>, 150° <With flywheel PTO> clockwise. Each divi-
sion on the socket scale represents 5°.
• After tightening the bolt within the plastic region, make a
punch mark on the bolt head for subsequent identification.
CAUTION

Phone: 269 673 1638
11-77
MITSUBISHI 6M70 TIMING GEARS
<WITHOUT FLYWHEEL PTO>
1 Idler shaft C 6 Idler shaft bolt
*b:
a: Supply pump gear
2 Idler gear bushing 7 Thrust plate A, B
* Crankshaft gear
3 Idler gear C 8 Idler gear bushing : Non-reusable parts
4 Thrust plate C 9 Idler gear A, B : Locating pin
5 O-ring 10 Idler shaft A, B
Assembly sequence

Idler gear C and supply
0.096 to 0.198 0.35 Replace
pump gear
Idler gear C and idler gear
– Backlash between gears 0.089 to 0.181 0.35 Replace
A, B
Idler gear A, B and crank-
0.076 to 0.196 0.35 Replace
shaft gear
1, 2 Clearance between idler shaft C and idler gear bushing 0.036 to 0.08 0.2 Replace
3, 9 Idler gear end play 0.1 to 0.2 0.4 Replace
Clearance between idler shaft A, B and idler gear bush-
8, 10 0.025 to 0.066 0.2 Replace
ing

Bolt (idler gear C mounting) 80 {8.0} –
Idler shaft bolt (idler gear A, B mounting) 155 {16} –
11-78
11
O-ring
Inside surface of bushing of gears

Idler gear bushing

puller ME350197 Removal of idler gear bushing
A B
φ 105 φ 100
Idler gear bushing in-

staller ME350198 Installation of idler gear bushing
A
φ 99.3
Idler gear bushing Removal and installation of idler gear

puller MH062046
bushing
A B C
φ 45.5 φ 50 φ 46

Inspection: Backlash between gears
• For each pair of gears, measure the backlash at more than three
teeth.
• If any of the measurements exceeds the limit, replace the defec-
tive part(s).
Inspection: Idler gear end play

part(s).
11-79
TIMING GEARS <WITHOUT FLYWHEEL PTO>
Inspection: Clearance between idler shaft C and idler gear
bushing
[Inspection]

[Removal]
[Installation]
• Install until it contacts the idler gear with idler gear C facing
in the illustrated direction.
bushing.
Inspection: Clearance between idler shaft A, B and idler

gear bushing
[Inspection]

[Removal]
11-80
11
[Installation]
• Install until it contacts the idler gear with idler gear A, B fac-
ing in the illustrated direction.
bushing.
Installation: idler gear
• Install idler gear A, B such that the alignment mark “A” on the
gear is aligned with the alignment mark “A” on the crankshaft
gear.
• When installing idler gear C, ensure that the alignment mark “B”
on the gear is aligned with the alignment mark “B” on idler gear
A, B and that the alignment mark “C” on idler gear C is aligned
with the alignment mark “C” on the supply pump gear.
11-81
MITSUBISHI 6M70 TIMING GEARS <WITH FLYWHEEL PTO>
1 O-ring 9 PTO idler gear B 17 PTO drive gear
2 Idler shaft bolt 10 Idler shaft C
3 Thrust plate A, B 11 Idler gear bushing
*a: Supply pump gear
4 PTO idler gear bushing 12 Idler gear C
*b: Rear plate
5 PTO idler gear A 13 Thrust plate C
*d:
c: Crankcase
6 Idler shaft B 14 Idler gear bushing
* Crankshaft gear
7 Thrust plate C 15 Idler gear A, B : Locating pin
8 PTO idler gear bushing 16 Idler shaft A : Non-reusable parts
Assembly sequence

Phone: 269 673 1638
11-82
11
Between idler gear C and supply
0.096 to 0.198 0.35 Replace
pump gear
Between idler gear C and idler gear
0.089 to 0.181 0.35 Replace
A, B
Between idler gear A, B and crank-
– Gear backlash 0.076 to 0.196 0.35 Replace
shaft gear
Between PTO idler gear A and PTO
0.07 to 0.2 0.35 Replace
idler gear B
Between PTO idler gear A and drive
0.07 to 0.2 0.35 Replace
gear
4, 6 PTO idler gear bushing-to-idler shaft B clearance 0.03 to 0.068 0.2 Replace
5, 9, 12,
Idler gear end play 0.1 to 0.2 0.4 Replace
15
8, 10 PTO idler gear bushing-to-idler shaft C clearance 0.036 to 0.08 0.2 Replace
10, 11 Idler gear bushing-to-idler shaft C clearance 0.04 to 0.08 0.2 Replace
14, 16 Idler gear bushing-to-idler shaft A clearance 0.03 to 0.06 0.2 Replace

Idler shaft bolt (for installing PTO idler gear A, idler gear A, B) 155 {16} –
Bolt (for installing PTO idler gear B, idler gear C assembly) 80 {8.0} –

O-ring
Gear bushing inner surface

Idler gear bushing

puller ME350197 Removal of idler gear bushing
A B
φ 105 φ 100
Idler gear bushing

installer ME350198 Installation of idler gear bushing
A
φ 99.3
Idler gear bushing Removal and installation of idler gear

puller MH062046
bushing
A B C
φ 45.5 φ 50 φ 46
11-83
TIMING GEARS <WITH FLYWHEEL PTO>
Idler gear bushing Removal and installation idler gear

puller MH061256
bushings
A B C
φ 57.3 φ 62 φ 58

Inspection: Backlash between gears
• For each pair of gears, measure the backlash at more than three
teeth.
• If any of the measurements exceeds the limit, replace the defec-
tive part(s).
Inspection: Idler gear end play

part(s).
Inspection: Clearance between PTO idler gear bushing and
idler shaft B
[Inspection]
Replacement of PTO idler gear bushing

[Removal]
11-84
11
[Installation]
• Install until it contacts the PTO idler gear A with PTO idler
gear A facing in the illustrated direction.
bushing.
Inspection: Clearance between PTO idler gear bushing and

idler shaft C
[Inspection]
• If the clearance exceeds the limit, replace the bushing.
Replacement of PTO idler gear bushing

[Removal]
[Installation]
• Install until it contacts the PTO idler gear B with PTO idler
gear B facing in the illustrated direction.
bushing.
Inspection: Clearance between idler shaft C and idler gear

bushing
[Inspection]
11-85
TIMING GEARS <WITH FLYWHEEL PTO>
[Removal]
[Installation]
• Install until it contacts the idler gear with idler gear C facing
in the illustrated direction.
bushing.
Inspection: Clearance between idler gear bushing and idler

shaft A
[Inspection]

[Removal]
[Installation]
• Install until it contacts the idler gear with idler gear A, B fac-
ing in the illustrated direction.
bushing.
11-86
11
Installation: Idler gear
• Install idler gear A, B such that the alignment mark “A” on the
gear is aligned with the alignment mark “A” on the crankshaft
gear.
• When installing idler gear C, ensure that the alignment mark “B”
on the gear is aligned with the alignment mark “B” on idler gear
A, B and that the alignment mark “C” on idler gear C is aligned
with the alignment mark “C” on the supply pump gear.
11-87
MITSUBISHI 6M70 CRANKSHAFT AND CRANKCASE
11-88
11
1 Crankshaft pulley 9 Ring 17 Oil jet
2 Front oil seal 10 Rear oil seal slinger 18 Oil spray plug
3 Front cover 11 Crankshaft gear 19 Crankcase
4 Front cover gasket 12 Crankshaft
5 Thrust plate 13 Rear plate : Locating pin
6 Lower main bearing 14 Gasket : Non-reusable parts
7 Main bearing cap 15 Upper main bearing
8 Front oil seal slinger 16 Check valve
CAUTION
• The check valve has been tightened using thread-locking compound and so, may deform during removal.
Once removed, the check valve must not be reused. Therefore, do not remove the check valve unless any
fault is found.
Assembly sequence
CAUTION
• If overtightened, the check valve will not operate properly, leading to engine seizure. Be sure to tighten
the check valve to the specified torque.
• The main cap bolt is tightened within the plastic region. The number of punch marks indicates the num-
ber of times the bolt has been tightened. If there are 3 punch marks (tightened 3 times in the past), replace
the bolt.

Oil clearance 0.06 to 0.122 0.25 Replace
6, 15 Main bearing
Span when free – 106.5 Replace
Replace thrust
End play 0.09 to 0.23 0.4
plate
Bend 0.04 or less 0.1 Replace
Roundness 0.01 or less 0.03 Rectify or replace
Pins and journals
Cylindricity 0.006 or less – Rectify or replace
12 Crankshaft
Center-to-center distance between
75 ± 0.07 – Replace
the journal and pin
Journal width 42 ± 0.3 – Replace
+0.2
Pin width 54 0 – Replace
Fillet R5 – Replace
Distortion of top surface 0.07 or less 0.2 Rectify or replace
19 Crankcase Roundness 0.005 or less –
Cylinder block Replace
Cylindricity 0.015 or less –

Bolt (crankshaft pulley installation) 240 {24} –
Bolt (front cover installation) 45 {4.6} –
• Wet
Bolt (main bearing cap installation) 100 {10} + 130 ± 2° • Can be reused
up to 3 times
Check valve 34 {3.5} –
11-89
CRANKSHAFT AND CRANKCASE
Front oil seal lip
Thread of bolts Engine oil As required
Inside surface of main bearing

Socket wrench MH063365 Installation of main bearing cap
Front oil seal slinger

installer
MH061817 Installation of front oil seal slinger
A
φ 108
Rear oil seal slinger in-

staller
MH061652 Installation of ring
A
φ 123
Gear puller MH061061 Removal of crankshaft gear
Inspection before disassembly

Inspection: Crankshaft end play
• If the measurement exceeds the specified limit, replace the
oversized thrust plates.
Oversizes available: 0.15, 0.30, 0.45 mm
• Replace the crankshaft if the end play cannot be adjusted within
the standard range.

Phone: 269 673 1638
11-90
11
Removal procedure
Removal: Main bearing caps
• The main bearing cap on the rearmost part is located by locating
pins. Use a slide hammer to remove it.
Removal: Front oil seal slinger

• Taking care not to damage the crankshaft, split the slinger using
a chisel or a similar tool.
Removal: Ring
• Taking care not to damage the crankshaft, split the slinger using
a chisel or a similar tool.
Removal: Crankshaft gear

CAUTION
• Do not tap off the crankshaft gear as this can damage it.
Inspection: Main bearing
(1) Main bearing span when free
• If the measurement less than the limit, replace the upper and
lower bearings as a set.
CAUTION
• Do not attempt to manually expand the bearings.
11-91
(2) Main bearing oil clearance
• Fit the upper main bearing into the crankcase and the lower
main bearing into the main bearing cap.
• Tighten the bolts to a torque of 100 N·m {10 kgf·m}.
• Measure the inner diameter of the main bearing and the outer di-
ameter of the corresponding crankshaft journal.
• If the difference between the measurements exceeds the speci-
fied limit, machine the crankshaft journal to one of the specified
undersize dimensions.
Inspection: Crankshaft
(1) Bend
• Measure the crankshaft at the center journal for bend while sup-
porting the shaft at the end journals.
• A half of the dial gauge reading obtained as the crankshaft is ro-
tated by a full turn represents the bend of the crankshaft.
• If the measurement exceeds the limit, replace the crankshaft.
(2) Roundness and cylindricity of crankshaft journals and

pins
• If any of the measurements exceeds the limits, grind the crank-
shaft journal(s) and/or pin(s) to undersize(s) or replace the
crankshaft.
11-92
11
Grinding of crankshaft
CAUTION
• If the crankshaft pins and journals are ground to undersiz-
es, be sure to use bearings of corresponding undersizes.
• Check the measurement in the table of service standards and

correct the crankshaft as follows.
• Do not change the center-to-center distance A between the
journal and pin.
• Do not change the journal width B and the pin width C.
• Finish the fillets D smoothly.
• Carry out a magnetic inspection to check for cracks possibly
caused by grinding. Also, check that the hardness of the sur-
face has not dropped below Shore hardness number (Hs) 75.
• If there is any abnormality, replace the crankshaft.
Mitsubishi 6M70 Crankshaft undersize dimensions (Unit: mm)

Undersizes
0.25 0.50 0.75 1.00
-0.08 -0.08 -0.08 -0.08
Finished journal outside diameter 99.75 -0.10 99.50 -0.10 99.25 -0.10 99.00 -0.10
-0.06 -0.06 -0.06 -0.06
Finished pin outer diameter 83.75 -0.09 83.50 -0.09 83.25 -0.09 83.00 -0.09
Roundness 0.01 or less
Cylindricity 0.006 or less
• When grinding, turn both the crankshaft and the grinder counter-
clockwise as viewed from the crankshaft front end.
• When finishing the crankshaft with whestone or sandpaper, ro-
tate the crankshaft clockwise.
Inspection: Distortion of crankcase top surface

• If the measurement exceeds the limit, correct the crankcase top
surface with a surface grinder.
CAUTION
• Do not grind the crankcase top surface so much as to com-
promise the correct piston protrusion.
11-93
Installation: Oil spray plug
• Install the oil spray plug in the illustrated direction.
CAUTION
• Be careful that if the direction of the oil spray plug is not ap-
propriate, oil supply to the timing gear becomes insuffi-
cient, causing seizure.
Installation: Gasket
• Lower parts of the gasket (oil pan mounting surface) protrude af-
ter installation. Cut the protruding parts after installing the fly-
wheel housing.
Installation: Crankshaft gear

• Heat the crankshaft gear to approximately 100°C with a burner
or the like.
WARNING
• You may burn yourself if you touch the heated crankshaft
gear.
• Align the locating pin fitted in the crankshaft with the notch in the
crankshaft gear. Drive the gear into position by lightly striking its
end face with a plastic hammer.
Installation: Rear oil seal slinger

• Install the rear oil seal slinger so that it is in close contact with
the crankshaft gear.
Installation: Ring
• To install the ring, push it in with until it comes into positive
contact with the slinger end face.
11-94
11
Installation: Front oil seal slinger
• Install the front oil seal slinger onto the crankshaft until the end
of face of securely contacts the guide.
Installation: Mitsubishi 6M70 Main bearing

• Install the main bearings with their lugs aligned as shown in the
illustration. When the crankshaft journals have been ground to
an undersize, use undersized main bearings.
Undersizes available: 0.25 mm, 0.50 mm, 0.75 mm, 1.00 mm
CAUTION
• The upper main bearing has an oil hole. The lower main
bearing has no oil hole. Do not confuse the upper and lower
bearings, as this can cause seizure in the engine.
Installation: Mitsubishi 6M70 Thrust plate

• Install thrust plates on both sides of the main bearing cap and
the rear end of the crankcase, ensuring that the oil grooves face
outside.
• If oversized thrust plates are to be used, those with and
marks must be the same in size. Oversizes available: 0.15 mm,
0.30 mm and 0.45 mm.
CAUTION
• If thrust plates are installed with the oil grooves facing in-
side, the engine may seize.
Installation: Main bearing cap

CAUTION
• Before installing bolts, check the number of punch marks
on the bolt head. (Bolt with up to two punch marks can be
reused.)
• The number of punch marks indicates the number of times
• Install locating pins in the illustrated direction for the main bear-
ing cap on the rearmost part.

Phone: 269 673 1638
11-95
• Starting at the front of the engine, fit the main bearing caps in the
order of the embossed numbers with the embossed numbers
and front marks facing in the illustrated direction.
• Tighten all the bolts to 100 N·m {10 kgf·m}, then additionally
tighten them according in the following procedure.
nal spring.
crankcase by the force of the spring.
shown. Each division on the socket scale represents 5°.
• After tightening the bolt within the plastic region, make a punch
mark on the bolt head to record the number of times that they
have been tightened
CAUTION
• After tightening the bolt, rotate the crankshaft by hand. If it can-

not be rotated smoothly, inspect the main bearing cap for mount-
ing surface.
Installation: Mitsubishi 6M70 Front oil seal
• Install the front oil seal onto the front cover while pressing the
seal’s entire periphery evenly to prevent it from tilting.
• Install the front oil seal until its flange comes into positive contact
with the front cover.
11-96
GROUP 12 LUBRICATION
SPECIFICATIONS.............................................................................. 12-2

1. Lubrication System ........................................................................... 12-3
2. Oil Pump ............................................................................................. 12-4
3. Oil Cooler ........................................................................................... 12-5
4. Full-flow Oil Filter ........................................................................ 12-6
5. Bypass Oil Filter ........................................................................... 12-7
6. Engine Oil Pressure Switch .............................................................. 12-7
7. Regulator Valve .................................................................................. 12-7
8. Lubrication of Engine Components ................................................. 12-8
TROUBLESHOOTING ...................................................................... 12-11

1. Oil Filter Replacement ..................................................................... 12-12
2. Engine Oil Replacement ................................................................. 12-14
3. Oil Pressure Measurement ............................................................. 12-15
OIL PAN, OIL JETS ......................................................................... 12-16
OIL PUMP, OIL STRAINER ............................................................. 12-18
OIL FILTER ...................................................................................... 12-22
OIL COOLER ................................................................................... 12-24
REGULATOR VALVE ....................................................................... 12-26
12-1
SPECIFICATIONS
Item Specifications
Method of lubrication Oil pump type
Oil filter Filter paper element center bolt type
Oil cooler Shell and plate type (multiple-plate type)
API classification CD, CD/SF, CE, CE/SF, CF-4 or JASO
Grade
classification DH-1, DH-2
Engine oil
Oil pan Approx. 31.5 {31.5}
Quantity dm3 {L}
Oil filter 4 to 4.5 {4 to 4.5}
12-2
1. Lurication System
1 Rocker shaft 14 Powertard solenoid valve 27 Bypass oil filter

2 Camshaft journal (No.2 to 7) 15 Main oil gallery 28 Oil cooler bypass valve
3 Camshaft journal (No.1) 16 Regulator valve 29 Oil cooler
4 Rocker case (No.1) 17 Check valve for oil jet 30 Full-flow oil filter
5 Slave piston (No.1 to 5) 18 Piston 31 Engine oil bypass
6 Camshaft cap (No.2 to 6) 19 Air compressor alarm switch
7 Rocker case (No.2 to 6) 20 Turbocharger 32 Relief valve
8 Cylinder head sub oil gallery 21 Main bearing 33 Oil pump
9 Master piston (No.1 to 5) 22 Connecting rod bearing 34 Oil strainer
10 Slave piston (No.6) 23 Connecting rod bushing 35 Supply pump
11 Camshaft cap (No.7) 24 Idler gear A, B 36 Idler gear C
12 Rocker case (No.7) 25 Oil spray plug 37 Idler gear D
13 Master piston (No.6) 26 Oil spray plug 38 Flywheel PTO
39 Oil pan
12-3
2. Mitsubishi 6M70 Oil Pump
• This engine uses a gear-type oil pump
driven by the rotation of the crankshaft
transmitted through the engagement
of the crankshaft gear and the oil
pump gear.
The oil pump has a relief valve, which
prevents excessive pressure from
building up inside the lubricating sys-
tem by allowing part of the engine oil
to escape to the oil pan when the oil
pressure exceeds a specified level.
12-4
12
3. Mitsubishi 6M70 Oil Cooler
3.1 Mitsubishi 6M70 Bypass valve

• When the engine oil is cool and its vis-
cosity is high, or when the oil cooler el-
ement becomes clogged and restricts
the flow of the engine oil, the bypass
valve opens to let the engine oil by-
pass the oil cooler and flow directly to
the main oil gallery.
12-5
4. Full-flow Oil Filter
• The filter elements use elements
made of filter paper.
4.1 Engine oil bypass alarm switch

• If the full-flow oil filter elements clog
up, this will restrict the flow of engine
oil, causing various parts of the engine
to seize. To prevent this, the engine oil
bypass alarm switch is installed.
• If the full-flow oil filter clogs up, the en-
gine oil bypass alarm switch trips in
such a way as to direct the engine oil
straight on to the oil cooler, bypassing
the filter elements. When the engine
oil bypass alarm switch trips, the rele-
vant warning lamp illuminates to alert
the operator to the clogged full-flow oil
filter elements.
12-6
12
5. Bypass Oil Filter
• The oil filter elements use elements
made of filter paper.
6. Mitsubishi 6M70 Engine Oil Pressure Switch

• If the oil pressure of the engine oil fed
to the main oil gallery drops below the
specified value, the engine oil pres-
sure switch trips and illuminates the
relevant warning lamp to alert the op-
erator to the abnormal oil pressure.
7. Mitsubishi 6M70 Regulator Valve

• If the oil pressure in the main oil gal-
lery exceeds the specified value, the
regulator valve opens and returns a
portion of the engine oil to the oil pan
to adjust the oil pressure.
12-7
8. Lubrication of Engine Components
• The engine oil in the main oil gallery lubricates the engine components in the following ways.
8.1 Mitsubishi 6M70 Main bearing and connecting rod bearing
• Engine oil supplied through an oil passage in the crankshaft lubricates the big end (connecting rod bearing) of
each connecting rod. Simultaneously, engine oil supplied through an oil passage in the connecting rod lubricates
the connecting rod’s small end (connecting rod bushing). Beside, engine oil is sprayed out of the oil jet in the head
of the connecting rod into the piston to cool the piston.
8.2 Mitsubishi 6M70 Timing gears
• Engine oil in the main oil gallery is directed through the oil passages in the crankcase and cylinder head and is
used to lubricate the various gear shafts. After lubricating the gear shafts, the oil is used to lubricate the gears be-
fore returning the oil pan. Engine oil also lubricates the gears by the oil spray plugs. The oil spray plug has an ar-
row showing the installed direction on its head.
12-8
12
8.3 Mitsubishi 6M70 Valve mechanism
• Engine oil in the main oil gallery is directed through the oil passages in the cylinder head, rocker case and cam-
shaft cap, and lubricates the No. 1 journal of the camshaft before being fed to the rocker shaft. The oil flowing
through the oil passages in the rocker shaft lubricates No. 2 to No. 7 journals of the camshaft and also lubricates
the rockers. The oil flowing to the adjusting screws on the rockers lubricates the valve bridges. After lubricating
the various parts, the oil returns to the oil pan.
8.4 Mitsubishi 6M70 Check valves and
oil jets
• An oil jet is fitted in the lower part of
the main oil gallery for each cylinder.
• Engine oil is sprayed out of the oil jet
into the piston to cool the piston.
• Each oil jet is fitted with a check valve
that opens and closes at predeter-
mined oil pressure levels. At low en-
gine speeds, the check valve closes to
maintain the required volume of oil in
the lubrication system and prevent re-
ductions in oil pressure.

Phone: 269 673 1638
12-9
8.5 Mitsubishi 6M70 Turbocharger
• Engine oil in the main oil gallery is di-
rected through a pipe to the bearing
housing to lubricate the inner compo-
nents.
• A piston ring is provided on each end
of the turbine wheel shaft. The rings
function as oil sealing.
8.6 Mitsubishi 6M70 Supply pump

• The engine oil supplied to the supply
pump lubricates the inside of the pump
and supply pump gear.
• After lubricating the inside of the
pump, the oil is directed through the
timing gear train from the rear of the
pump and returns to the oil pan.
8.7 Mitsubishi 6M70 Air compressor

• The engine oil in the main oil gallery
lubricates the inside of the air com-
pressor, is directed through the timing
gear train from the air compressor
gear side, and returns to the oil pan.
12-10
TROUBLESHOOTING 12
Symptoms
Excessive oil consumption (oil leakage)

Engine is difficult to start
Reference Gr
Low oil pressure

Overheating
Possible causes
Incorrectly mounted element O O O
Defective gasket O O O
Defective O-ring O O O
Oil cooler
Clogged element O O
Damaged element O O O
Weakened bypass valve spring O
Malfunctioning oil pump O O
Interference between oil pump gear and oil pump case
O O
and/or cover
Oil pump
Incorrectly connected oil pipe O O
Clogged oil strainer O O
Weakened relief valve spring O
Incorrect installation O
Oil filter Clogged element O O
Defective O-ring O
Defective front oil seal O
Front cover
Incorrectly mounted front cover O
Gr11
Defective rear oil seal O
Flywheel housing
Incorrectly mounted flywheel housing O
Weakened regulator valve spring O
Defective piston cooling oil jet(s) O O
Oil working its way up into combustion chamber(s) through piston rings O
Gr11
Oil working its way down into combustion chamber(s) through valves O
Too high oil viscosity O
Poor oil quality O
Deterioration of oil O
Excess of oil O
Fuel mixed with oil O
12-11
1. Oil Filter Replacement
– Drain plug (oil filter) 24.5 ± 4.9 {2.5 ± 0.5} –
– Center bolt 63.7 ± 4.9 {6.5 ± 0.5} –

Engine oil
API classification CD, CD/SF, CE, 4 to 4.5 dm3
– Oil filter
CE/SF, CF-4 or JASO classification {4 to 4.5 L}
DH-1, DH-2
WARNING
• Wipe up any spilled engine oil, as it can cause fires.
• To avoid any risk of burns, take care not to touch the engine oil when the engine is hot.
CAUTION
• Make sure not to put any engine oil on the belt when working on the oil filter. Belts soiled with oil or
grease may easily slip, resulting in deteriorated performance of the cooling system.
• Do not reuse the oil filter elements by washing.
• Install the gasket, taking care not to twist it.
[Removal]
• Remove the drain plug and drain the oil out of the oil filter.
12-12
12
• Clean other parts than the element, O-ring and gasket to be re-
placed with washing oil.
[Installation]
• Replace the element, O-ring and gasket with new ones, respec-
tively.
• Install the oil filter case so that the drain plug is positioned as
shown in the illustration.
• With the oil filter installed, start the engine and ensure that there
is no oil leakage through the gasket.
• If oil is leaking, remove and reinstall the oil filter.
• Stop the engine and check the engine oil level.
• Add engine oil if the engine oil level is low.
12-13
2. Engine Oil Replacement
– Drain plug (oil filter) 24.5 ± 4.9 {2.5 ± 0.5} –
– Drain plug (oil pan) 68 {7} –

Engine oil 4 to 4.5 dm3
– Oil filter
API classification CD, CD/SF, CE, {4 to 4.5L}
CE/SF, CF-4 Approx. 31.5 dm3
– Oil pan or JASO classification DH-1, DH-2 {31.5L}
WARNING
CAUTION
• Make sure not to put any engine oil on the belt when working on the oil filter. Belts soiled with oil or
grease may easily slip, resulting in deteriorated performance of the cooling system.
[Draining]
• Remove the filler cap.
• Remove the drain plugs of the oil filter or oil pan to drain out the
engine oil.
[Refilling]
• Tighten the drain plug to the specified torque, then pour a speci-
fied amount of new engine oil into the engine.
• Wait at least for 6 minutes after installing the filler cap and check
the engine oil level.
• Start the engine and ensure that there is no oil leakage.
• Stop the engine, wait at least for 30 minutes and check the en-
gine oil level.
• Add engine oil if the engine oil level is low.
CAUTION
• Do not add engine oil too much. An excessive oil level can
only lead to increased oil consumption or make the positive
crankcase ventilation system less efficient.
12-14
12
3. Oil Pressure Measurement
Service standards
49 kPa
135 to 295 kPa
No-load minimum speed {0.5 kgf/
Oil pressure (oil tempera- {1.4 to 3 kgf/cm2}
– cm2} Inspect
ture at 70 to 90°C)
295 to 490 kPa 195 kPa
No-load maximum speed
{3 to 5 kgf/cm2} {2 kgf/cm2}

– Engine oil pressure switch 24.5 ± 4.9 {2.5 ± 0.5} With cold engine
• Remove the Mitsubishi 6M70 engine oil

pressure switch.
• Using an adapter, connect an oil pressure gauge to the engine

oil pressure switch mounting hole.
• Warm up the engine until the oil temperature reaches 70 to
90°C.
• Measure the oil pressure while running the engine at a minimum
speed and then at maximum speed, both under no load.
• If the measurements are below the specified limits, overhaul the
lubrication system.
CAUTION
• Reinstall the oil pressure switch only when the engine is
cold.
12-15
MITSUBISHI 6M70 OIL JETS, OIL PAN,
1 Drain plug
2 Oil pan
3 Check valve
4 Oil jet
: Locating pin
CAUTION
• The check valve has been tightened
using thread-locking compound
and so, may deform during remov-
al. Once removed, the check valve
must not be reused. Do not remove
the check valve unless defects are
evident.
Assembly sequence
CAUTION
• If overtightened, the check valve will not operate properly, leading to engine seizure. Be sure to tighten
the check valve to the specified torque.

Drain plug 68 {7} –
Check valve 34 {3.5} –

Crankcase mounting surface of oil pan ThreeBond 1207C As required
12-16
12
Installation: Oil pan
• Clean the mating surfaces of each part.
• Apply a bead of sealant to the mating surface of the oil pan
evenly and without any breaks.
Change the amount of application to A and B at four locations
• Mount the oil pan within three minutes of applying the sealant.
Make sure that the sealant stays in place.
CAUTION
• Do not start the engine less than an hour after installation. If
the oil pan mounting bolts were loosened or removed, be
sure to reapply sealant.
12-17
MITSUBISHI 6M70 OIL PUMP, OIL STRAINER
1 Oil strainer 8 Relief valve spring
*b:
a: Crankshaft gear
2
3
Gasket
Oil pipe
9
10
Relief valve
Idler shaft
* Oil pump gear
4 Gasket 11 Idler gear : Locating pin

5 Cover 12 Gear and case : Non-reusable parts
6 Driven gear 13 Gasket
7 Ring
• The oil strainer, the oil pipe and the oil pump must all be removed together as an assembly.
• Do not disassemble the oil pump unless defects are evident.
• The gear and case assembly is not serviceable. If the gear and case assembly appears defective, replace it.
Assembly sequence
Follow the disassembly procedure in reverse.

5, 12 Clearance between drive gear shaft and cover 0.04 to 0.07 0.15 Replace
Clearance between driven gear shaft and case, and
5, 6, 12 0.04 to 0.07 0.15 Replace
that between the shaft and cover
Clearance between case and tooth tips of each gear 0.2 to 0.29 0.35
6, 12 Replace
Difference between case depth and height of each gear 0.05 to 0.12 0.15
190 ± 11 N 179 N
8 Relief valve spring installed load (installed length 47.7) Replace
{19.4 ± 1.1 kgf} {18.3 kgf}
0.9 +0.1 MPa 0.9 MPa
9 Relief valve opening pressure 0 Replace
{9 +10 kgf/cm2} {9 kgf/cm2}
10, 11 Clearance between idler shaft and idler gear 0.03 to 0.06 0.15 Replace
*
11, a Backlash between idler gear and crankshaft gear 0.08 to 0.2 0.35 Replace
11, *b Backlash between idler gear and oil pump gear 0.076 to 0.196 0.35 Replace
12-18
12
Bolt (oil pump cover mounting) 44 ± 4.9 {4.5 ± 0.5} –
Thread-locking
Nut (idler shaft mounting) 69 ± 10 {7 ± 1}
compound

Nut thread Loctite 262 As required
Sliding parts of oil pump Engine oil As required

Inspection: Backlash of each gear
part(s).
Inspection: Driven gear, Gear and case assembly
• Perform the following inspections. Replace the defective part(s)
as required.
(1) Difference between case depth and height of each gear
(2) Clearance between case and tooth tips of each gear

Phone: 269 673 1638
12-19
OIL PUMP, OIL STRAINER
(3) Clearance between drive gear shaft and cover
(4) Clearance between driven gear shaft and case, and that
between the shaft and cover
Installation: Idler shaft
• Install the idler shaft so that “↑” is positioned within the area
12-20
12
M E M O
12-21
OIL FILTER
1 Drain plug
2 Center bolt
3 Washer
4 O-ring
5 Oil filter case
6 Gasket
7 Oil filter element
8 Spring
9 Engine oil bypass alarm switch
10 Oil filter head
11 O-ring
*a:: Oil cooler

Non-reusable parts
Assembly sequence
verse.
WARNING
CAUTION
• When adding engine oil, be careful not to allow engine oil to smear the belt. A belt smeared with oil will
slip, resulting in reduced cooling efficiency.
• Do not reuse the oil filter elements by washing.
• Install the gasket, taking care not to twist it.

Drain plug 24.5 ± 4.9 {2.5 ± 0.5} –
Center bolt 63.7 ± 4.9 {6.5 ± 0.5} –
Engine oil bypass alarm switch 49 ± 4.9 {5.0 ± 0.5} –
12-22
12
M E M O
12-23
MITSUBISHI 6M70 OIL COOLER
Removal sequence
1 Bypass valve
2 O-ring
3 Water pipe
4 O-ring
5 Oil cooler element
6 O-ring
7 Oil cooler cover
8 Oil cooler plug
9 O-ring
10 O-ring
11 Gasket
12 Regulator valve
13 O-ring

244 kPa
294 ± 50 kPa
1 Bypass valve opening pressure {2.5 kgf/ Replace
{3.0 ± 0.5 kgf/cm2}
cm2}
Air leakage from oil cooler element
5 0 cm3 {0 mL} – Replace
(air pressure: 1.47 MPa {15 kgf/cm2}, 15 seconds)

Bypass valve 15 to 20 {1.5 to 2.0} –
Bolt (oil cooler cover mounting) 54 {5.5} –
Regulator valve 98 to 118 {10 to 12} –
Nut (oil cooler element mounting) 24.5 to 32.3 {2.5 to 3.3} –
Oil cooler plug 21 {2.1} –

Mark Points of application Lubricant and/or sealant Quantity
12-24
12
Inspection: Oil cooler element
• Plug the outlet of the oil cooler element and connect a hose to
the engine oil inlet port. Then, immerse the oil cooler element in
a tank of water.
• Apply a specified air pressure for 15 seconds through the hose,
and check for any air leaks.
• Replace the element if it leaks air.
12-25
MITSUBISHI 6M70 REGULATOR VALVE
1 Snap ring
2 Valve
3 Spring
4 Body
Assembly sequence
verse.

0.49 ± 0.03 MPa
– Regulator valve opening pressure – Replace
{5.0 ± 0.3 kgf/cm2}
78 ± 2 N
3 Spring installed load (installed length 48.3) – Replace
{8.0 ± 0.2 kgf}
12-26
GROUP 13
FUEL AND ENGINE CONTROL
SPECIFICATIONS................................. 13-2 SUPPLY PUMP.................................... 13-66
STRUCTURE AND OPERATION INJECTOR........................................... 13-70

1. Common Rail System ....................... 13-4
2. Engine Control ................................ 13-20 FUEL TANK ......................................... 13-74
3. Fuel Filter ......................................... 13-21
4. Water Separator............................... 13-22 FUEL FILTER ...................................... 13-76
WATER SEPARATOR ......................... 13-80

TROUBLESHOOTING
<FUEL SYSTEM> ............................... 13-24
ENGINE CONTROL ............................ 13-84
<DIAGNOSIS USING Multi-Use Tester>
1. Diagnosis Procedure ...................... 13-26 INSPECTION OF ELECTRICAL
2. Diagnostic Precautions .................. 13-27 EQUIPMENT........................................ 13-88
3. Inspections Based on
Diagnosis Codes ............................. 13-28 INSTALLED LOCATIONS OF
4. Multi-Use Tester Service Data ........ 13-50 PARTS ................................................. 13-94
5. Actuator Tests Performed
Using Multi-Use Tester.................... 13-52 ELECTRIC CIRCUIT DIAGRAM ....... 13-102
6. Inspections Performed at Electronic
Control Unit Connectors ................ 13-54
ON-VEHICLE INSPECTION AND

ADJUSTMENT
1. Inspecting No-load Minimum
and Maximum Speeds.................... 13-58
2. Inspection of Fuel Leakage ............ 13-59
3. Inspection of Injection Pipe and
Fuel Pipe Mounting Clamp ............. 13-59
4. Draining of Deposit in Fuel Tank .... 13-59
5. Air-bleeding of Fuel System........... 13-60
6. Fuel Filter Replacement ................. 13-61
7. Cleaning of Gauze Filter ................ 13-62
8. Water Separator Element
Replacement.................................... 13-63
COMMON RAIL................................... 13-65
13-1
MITSUBISHI 6M70 FUEL SYSTEM SPECIFICATIONS
Item Specifications
Manufacturer Bosch
Model CP2L4
Control method Electronic
Type In-Line 4 barrel type
Supply pump Feed pump type External gear
Rail pressure Model MPROP
control valve Rated voltage V 24
Max. common rail pressure
160 {1631}
MPa {kgf/cm2}
Manufacturer Bosch
3
Common rail volume cm {mL} 20 {20}
Common rail Pressure limiting valve opening pressure
185 to 195 {1886 to 1988}
MPa {kgf/cm2}
Common rail pressure sensor supply
5
voltage V
Manufacturer Bosch
Control method Electronic
Injectors Max. operating pressure
160 {1631}
MPa {kgf/cm2}
Min. operating pressure
25 {255}
MPa {kgf/cm2}
Common rail Manufacturer Bosch
electronic control
unit Rated voltage V 24

Phone: 269 673 1638
13-2
13
M E M O
13-3
1. Mitsubishi 6M70 Common Rail System
• In the common rail system, an electronic control unit monitors various aspects of the engine (engine speed, accel-
erator position coolant temperature, etc.) using information from sensors. In accordance with these data, the elec-
tronic control unit effects control over the fuel injection quantity, fuel injection timing, and fuel injection pressure in
order to optimize the engine’s operation.
• The electronic control unit has a diagnosis function that enables it to recognize abnormalities in the common rail
system’s major components and alert the driver to them.
• The common rail system consists mainly of an electronically controlled supply pump; injectors; a common rail;
and the electronic control unit and sensors that are used to control the other components.
13-4
13
• When the engine is cranked by means of the starter switch, the feed pump (this is located inside the supply pump)
simultaneously draws fuel from the fuel tank and feeds it via the water separator, gauze filter and fuel filter to the
MPROP (rail pressure control valve). A quantity of fuel metered by the MPROP is supplied via the inlet valves to
the plunger chambers.
• The fuel in the plunger chambers is pressurized. The outlet valves are then opened, and the fuel is fed under
pressure to the common rail.
• The pressurized fuel is held in the common rail and then uniformly fed to the injectors.
• In response to signals from the engine electronic control unit, a magnetic valve in each injector causes the injector
to inject fuel into the relevant combustion chamber at the optimal timing and in the optimal quantity.
• If fuel leakage occurs through any of the fuel line connections between the common rail and injectors, the relevant
flow limiter(s) will close, shutting off fuel supply and thus preventing any further fuel leakage out of the system.
• If the pressure of fuel in the common rail rises above the specified level, the pressure limiting valve opens to allow
fuel to return to the fuel tank.
• If the pressure of fuel in the supply pump rises above the specified level, the overflow valve opens to allow fuel to
return to the fuel tank.
• Excess fuel in the injector returns to the fuel tank through passages in the cylinder head.
13-5
1.1 Mitsubishi 6M70 Supply pump
13-6
13
• The supply pump pressurizes fuel and supplies it in a highly pressurized state.
• Fuel drawn from the fuel tank by the feed pump is not supplied directly to the plungers. It is supplied first to the
MPROP (rail pressure control valve), which controls the amount of fuel reaching the plungers.
• If the fuel pressure exceeds a certain level, the overflow valve returns fuel to fuel tank. This operation keeps the
pressure of the fuel constant.
• Rotation of the camshaft causes (via the tappets) up-down movement of the plungers. Fuel in the plunger cham-
bers is thus highly pressurized.
13-7
(1) MPROP (rail pressure control valve)
CAUTION
• Be sure to connect the MPROP (rail pressure control valve)
connector to the engine harness before starting the engine.
If the engine were started with the MPROP connector not
connected, control of the supply pump by the engine elec-
tronic control unit would not be possible and a fault would
ensue.
• The MPROP receives fuel from the feed pump and feeds fuel to-
ward the plungers of the supply pump in such a quantity that the
fuel pressure (target common rail pressure) corresponds to that
required by the engine electronic control unit.
• When the MPROP is not operating, i.e., when current is not flow-
ing, fuel flows at its maximum rate. When current flows, the pis-
ton in the MPROP is pressed down such that fuel is not fed
toward the plungers.
• The engine electronic control unit controls the ratio of current-off
time (duty ratio).

Phone: 269 673 1638
13-8
13
1.2 Mitsubishi 6M70 Common rail
• The common rail distributes to the injectors high-pressure fuel that has been fed from the supply pump.
• Each flow limiter prevents an abnormal outflow of fuel. It does so by blocking the fuel passage in the event of fuel
leakage from the injection pipe or excessive injection of fuel from the injector.
• The common rail pressure sensor is used in feedback control. It senses the fuel pressure (actual common rail
pressure) inside the common rail and feeds a corresponding signal to the electronic control unit.
• If the fuel pressure in the common rail exceeds a certain, set level, the piston in the pressure limiting valve pushes
and compresses the spring such that fuel is able to escape. The pressure limiting valve thus prevents the fuel
pressure from becoming higher than the set pressure. When the pressure limiting valve is activated, the common
rail system is faulty and needs an inspection of fuel supply system.
(1) Flow limiter

• During normal operation, the piston moves (thus pushing and compressing the spring) to the extent necessary for
one injection quantity to pass through. The piston does not make contact with the seat at this time. When injection
is complete, the piston is returned to its initial position by the spring.
• If the amount of fuel passing through the flow limiter becomes excessively great, the piston presses against the
seat, thereby closing the fuel passage and preventing an abnormal outflow of fuel.
When the piston has pressed against the seat, it does not return to its original position until the engine has been
stopped and the pressure in the common rail has come down.

Phone: 269 673 1638
13-9
1.3 Mitsubishi 6M70 Injector
• In accordance with electrical signals from the engine electronic control unit, each injector supplies high-pressure
fuel from the common rail to the relevant combustion chamber of the engine at the optimal timing and in the opti-
mal quantity.
• The Mitsubishi 6M70 injector is divided into the control section and the injector section.
• The control section consists of the control chamber, magnet, valve spring, armature plate, valve ball, valve
body, valve piston, orifice A, and orifice Z. The valve piston is located between the control section and the injec-
tion section.
• The injection section consists of the nozzle body, nozzle needle, nozzle spring, and nozzle nut.

Phone: 269 673 1638
13-10
13
(1) Operation
(1.1) Injection not taking place
• With the magnet not energized, the ar-
mature plate is pushed down by the
valve spring such that the ball seat is
closed.
• The high-pressure fuel acts upon the
control chamber via orifice Z. The
same pressure acts upon the nozzle
needle.
• The fuel pressure acting on the nozzle
needle cannot overcome the valve pis-
ton and nozzle spring, so the nozzle
needle stays in its downward-pushed
position and injection does not take
place.
(1.2) Start of injection

• When the magnet is energized, the re-
sulting electromagnetic force draws
the armature plate upward, causing
the ball seat to open.
• Fuel in the control chamber passes
through the orifice A and ball seat and
flows to the fuel tank.
• With the pressure in the control cham-
ber reduced, the fuel acting on the
nozzle needle overcomes the valve
piston and nozzle spring, pushing up
the nozzle needle such that injection
starts.
• If the magnet remains energized, the
injection reaches its maximum level.
13-11
(1.3) End of injection
• When energization of the magnet is
stopped, the armature plate is pushed
downward by the valve spring such
that the ball seat closes. At this time,
fuel flows into the control chamber via
orifice Z, pushing down the valve pis-
ton and nozzle needle such that injec-
tion finishes.

Phone: 269 673 1638
13-12
13
1.4 Electronic control system
(1) System block diagram
Input signals Engine electronic control unit Output signals
Engine speed sensor Injector magnetic valve

Cylinder recognition sensor Fuel injection control MPROP1, 2 (rail pressure
control valve)
Water temperature sensor
Engine
Boost pressure sensor Warm-up acceleration Fuel injection

function pressure control
Common rail pressure sensor
Fuel temperature sensor Fuel injection quantity
Intake air temperature sensor Auxiliary brake control
function
Fuel injection timing
Idle-up function control
Starter switch
Accelerator pedal position sensor Turbocharger control
Accelerator pedal switch function Engine warning lamp
Pulse converter (vehicle speed sensor) (See Gr15.)
Tachometer
Idling speed adjustment potentiometer
Fuel injection rate adjustment resistor Exhaust gas
recirculation valve Safety relay
Clutch switch control function
Vehicle
Transmission neutral switch (See Gr17.) Powertard

Powertard switch solenoid valve
Memory clear switch Starter continuous
Diagnosis switch energization Turbocharger
Governor control switch prevention function magnetic valve
(See Gr54.)
Power take-off resistor
Electronic drive
Power take-off load sensor Fault diagnosis unit relay
Pulse converter & Turbine speed sensor function
Multi-Use Tester connector
MVCU (See Gr54.) EGR EDU (See Gr17.)
: Electrical signal EGR magnetic valve

: CAN signal (See Gr17.)
ABS: Anti-lock brake system

ASR: Anti spin regulator
CAN: Controller area network
ECU: Electronic control unit
EDU: Electronic drive unit
EGR:Exhaust gas recirculation
MVCU: Multifunction vehicle control unit
13-13
Mitsubishi 6M70 Parts Main function/operation
Engine speed sensor Sensing of engine speed
Cylinder recognition sensor Cylinder recognition
Water temperature sensor Sensing of coolant temperature
Boost pressure sensor Sensing of boost pressure
Common rail pressure sensor Sensing of common rail pressure
Fuel temperature sensor Sensing of fuel temperature
Intake air temperature sensor Sensing of intake air temperature
Senses that the engine is in starting condition with the starter switch in
Starter switch
START position.
Accelerator pedal position sensor Sensing of extent of accelerator pedal depression
Sensing of released/pressed condition of accelerator pedal (ON with
Accelerator pedal switch
pedal released)
Pulse converter (vehicle speed sensor) Sensing of vehicle speed
Idling speed adjustment potentiometer Acceleration of warm-up
Fuel injection rate adjustment resistor Correction of fuel injection rate
Sensing of released/Pressed condition of clutch pedal (OFF with pedal
Clutch switch
released)
Transmission neutral switch Detection of transmission neutral condition
Powertard switch Operation of auxiliary brake
Diagnosis switch Output of diagnosis codes
Memory clear switch Deletion of diagnosis codes; output of past diagnosis codes
Governor control switch Idle up when power take-off is in operation
Power take-off resistor Selection of power take-off map
Power take-off load sensor Sensing of extent of accelerator pedal depression
Pulse converter & Turbine speed sensor Sensing of turbine wheel speed
Control of fuel injection rate, fuel injection quantity, and fuel injection
Injector magnetic valve
timing
MPROP1, 2 (rail pressure control valve) Control of fuel injection pressure
Engine warning lamp Indication of system abnormalities
Tachometer Indication of engine speed (in meter cluster)
Powertard solenoid valve ON/OFF control of Powertard magnetic valve
Turbocharger magnetic valve Selection of turbocharger control
Safety relay Control of starter continuous energization prevention function
Electronic drive unit relay Supply of power to exhaust gas recirculation electronic drive unit
Engine data recognized by the engine electronic control unit are output-
ted to the CAN bus to enable systems to obtain data that they need for
CAN communication
control. Multifunction Vehicle Control Unit system issues signals to the
(MVCU)
engine electronic control unit via the CAN bus to enable it to effect en-
gine control appropriate for type of system control.
Multi-Use Tester connector Communication between Multi-Use Tester and common rail system
Engine data recognized by the engine electronic control unit are output-
ted to the CAN bus to enable systems to obtain data that they need for
CAN communication
control. Exhaust gas recirculation electronic drive unit issues signals to
(EGR EDU)
the engine electronic control unit via the CAN bus to enable it to effect
engine control appropriate for type of system control.
EGR: Exhaust gas recirculation Mitsubishi 6M70 engine parts contact:

EDU: Electronic drive unit email:
MVCU: Multifunction vehicle control unit EngineParts@HeavyEquipmentRestorationParts.com
phone: 269 673 1638
13-14
13
(2) Fuel injection control
(2.1) Pilot injection
• Pilot injection entails the injection of an extremely small amount
of fuel ahead of the main injection.
• This suppresses hasty heat generation early in the injection cy-
cle and thus suppresses NOx generation and noise at the start
of combustion.
• The post injection added after the main injection reduces partic-
ulate matter (PM) generation in the exhaust gas.
(3) Fuel injection quantity control

(3.1) Fuel injection quantity during engine startup
• During engine startup, the fuel injection quantity is determined in
accordance with the engine speed and coolant temperature.
(3.2) Basic fuel injection quantity

• The basic fuel injection quantity is determined in accordance
with the engine speed and throttle opening.
(3.3) Maximum injection quantity

• The maximum injection quantity is calculated from the engine
speed and boost pressure.
(3.4) Fuel injection rate adjustment resistor correction

amount
• To limit inconsistency in the injection quantity, the injection quan-
tity is corrected by the fuel injection rate adjustment resistor.
13-15
(4) Fuel injection timing control
(4.1) Main injection timing
• The main injection timing is calculated from the fuel injection
quantity and engine speed.
(4.2) Pilot injection timing (pilot interval)

• The pilot injection timing is calculated from the fuel injection
(5) Fuel injection pressure control

• The fuel injection pressure is calculated from the fuel injection
(6) Warm-up acceleration function
Engine electronic
control unit
Input signals
Comparison
Water temperature sensor operations Output signals
Accelerator pedal position
sensor Idling speed
control
Idling speed adjustment
potentiometer Target injection
quantity
• The warm-up acceleration function increases engine warm-up by varying the engine’s idling speed in accordance
with the engine’s coolant temperature. It can operate either automatically or manually. Selection is made using the
idling speed adjustment potentiometer.
13-16
13
(7) Auxiliary brake function
Input signals Engine electronic Output signals

control unit
Accelerator pedal position sensor

Clutch switch Auxiliary brake
function Powetard solenoid valve
Transmission neutral switch
Powertard switch
• The auxiliary brake function activates or deactivates the Powertard solenoid valve according to the vehicle condi-
tion to control the auxiliary brake.
(8) Idle-up function

• The idle-up function increases the engine idling speed when a load is applied to the engine by other system or
when the warm-up acceleration function is activated.
(9) Fault diagnosis function

• When the starter switch is in the ON position, the system continuously monitors the sensors and other system
components. If any fault is detected, the system warns the driver of this by displaying the relevant fault information
on the meter cluster. At the same time, the system also stores a relevant diagnosis code in the memory and starts
operation in the fault mode.
• While the control during fault is taking place, the system’s functionality is limited to ensure vehicle and driver safe-
ty. It is possible to read the memorized diagnosis code using a Multi-Use Tester or from flashing of the warning
lamp.
• Diagnosis codes shown by the Multi-Use Tester and those indicated by flashing of the warning lamp are different.
• The Multi-Use Tester is capable of showing more detailed diagnosis codes.
13-17
(10)Electronic control unit connection diagram
13-18
13
13-19
2. Engine Control
2.1 Accelerator pedal switch

• The accelerator pedal switch is used to monitor whether or not the accelerator pedal is pressed.
2.2 Accelerator pedal position sensor

• The accelerator pedal position sensor monitors for change in the position of the accelerator pedal and sends rele-
vant electric signals to the common rail electronic control unit. The lever is constantly pulled towards the idling po-
sition by a return spring.
13-20
13
3. Fuel Filter
• The fuel filter removes foreign matter from fuel via the filter element. The fuel filter also incorporates a water sep-
arator which separates any water from fuel.
• Water separated from fuel accumulates at the bottom of the fuel filter assembly.
• The water which has collected can be drained through the drain hole by loosening the drain plug.
• To bleed air from the fuel system, a manually operated pump and plug are provided on the fuel filter head.
13-21
4. Water Separator
• A water separator is installed between
the fuel tank and the feed pump. It is
designed to remove impurities from
fuel and also separates water from fu-
el.
• Water separated from fuel is collected
at the bottom of the water separator
and is drained when the float reaches
the level line.
• To drain water collected, loosen the
drain cock. This allows the water to be
discharged through the drain hole.
13-22
13
M E M O
13-23
TROUBLESHOOTING <MITSUBISHI 6M70 FUEL SYSTEM>
Symptoms
Engine does not reach maximum speed
Engine control warning lamp illuminates

Engine stalls immediately after start
Engine maximum speed too high
Engine output not sufficient
Engine output inconsistent
Reference
Gr
Fuel supply insufficient

Engine idling unstable
Engine does not start
Engine does not stop

Engine hard to start
Engine knocks
Possible causes
Defective electronic control fuel system O
Defective feed pump O O O O
*
Supply pump
Defective sealing of supply pump overflow valve O O O O
*
Defective MPROP O O O O O
Defective base supply pump O O O O
*
Common rail pressure sensor open-circuited,
O O O O O O
Common rail short or intermittent connection; defective sensor
Pressure limiting valve malfunction O O O
*
Incorrect injector Defective injector magnetic valve O O O O O
fuel injection Defective injector O O O O
*
Gauze filter clogged O O O O O O
Fuel filter clogged O O O O
Water separator clogged O O O O
No fuel in fuel tank O
Fuel pipe clogged and fuel leak from joint O
Air or water in fuel system O O O O
Poor quality fuel is used O O O O
Fuel leak from high-pressure joint O O O O O
Incorrectly adjusted accelerator pedal stopper bolt O O
Engine control
Defective accelerator position sensor O O O
Engine speed sensor and cylinder recognition sensor open-circuited,
O O O
short, or intermittent connection
Boost pressure sensor open-circuited, short, or intermittent connec-
O O O O O
tion
Water temperature sensor open-circuited, short, or intermittent con-
O O O
nection
Defective fuel injection volume adjusting resistor O O O
Idling speed adjustment knob intermittent connection O O O
Fuel pipe and hose cracked O
MPROP: Rail pressure control valve
*: Contact Bosch Service Station for repair.
13-24
13
Symptoms
Engine does not reach maximum speed
Engine control warning lamp illuminates

Engine stalls immediately after start
Engine maximum speed too high
Engine output not sufficient
Engine output inconsistent
Reference
Gr
Fuel supply insufficient

Engine idling unstable
Engine does not start
Engine does not stop

Engine knocks
Possible causes
Oil viscosity unsuitable O O Gr12
Valve clearance incorrect O O
Defective cylinder head gasket O O
Valve and valve seat worn and carbon deposits O O
Valve spring fatigued O O Gr11
Piston ring worn and damaged O O
Piston ring groove worn and damaged O
Piston and cylinder liner worn O O
Cooling system malfunction O O Gr14
Defective starter switch O O Gr54
Blown fuse O O O O Gr54
13-25
TROUBLESHOOTING <DIAGNOSIS USING Multi-Use Tester>
1. Diagnosis Procedure
• Perform the inspection in accordance with the following flowchart.
Warning lamp lit
Vehicle in service shop
Read all (past and present) diagnosis codes by Multi-Use Tester. (See Gr00.)
Perform inspection based on diagnosis codes. (See later section.)
NO Response to transient fault

Was able to identify the fault?
(See Gr00.)
YES
Rectify or replace with new parts.
Clear stored diagnosis code. (See Gr00.)
Test drive
Code issued
Read diagnosis code(s) by Multi-Use Tester. (See Gr00.)
No code issued
End of inspection
13-26
13
2. Diagnostic Precautions
• Before measuring voltage, check the battery for charged condition and specific gravity. If system inspection is per-
formed with the battery uncharged or reduced in specific gravity, accurate measurements cannot be achieved.
• Before disconnecting battery cables, harnesses and connectors, set the starter switch to LOCK or OFF, then allow
at least 20 seconds.
• To avoid having electrical parts damaged, set the starter switch and lighting switch to LOCK or OFF before recon-
necting battery cables, harnesses and connectors.
• When performing measurement with the tester, handle the test bar carefully so that it does not damage internal
circuit and other electrical parts of the electronic control unit to result in a short-circuit failure between terminals in
connector or between connector and car body.
• Resistance is affected by temperature. Determine the necessity of resistance measurement following given tem-
perature specification as a guide. Otherwise, use normal temperature (10 to 35°C) as the measuring condition.
• To start the engine, be sure to connect the connector of the MPROP (rail pressure control valve) to the engine
harness. If the engine is started without connecting the MPROP connector, the engine electronic control unit can-
not control the supply pump and the fault of the engine may result.
13-27
3. Inspections Based on Diagnosis Codes
3.1 Diagnosis code list
• Diagnosis codes shown by the Multi-Use Tester and those indicated by warning lamp display are different.
Warning lamp indication

Code Message Remarks
Flashes Red Orange
P0107 Atmospheric Pressure Sensor 19 – O
P0108 Atmospheric Pressure Sensor 19 – O
P0112 INT Air Temp SNSR (Low) 44 – O
P0113 INT Air Temp SNSR (High) 44 – O
P0117 Water Temp SNSR (Low) 21 – O
P0118 Water Temp SNSR (High) 21 – O
P0121 Accel Pedal Check (Plausibility) 58 – O
P0122 Accel Pedal Sensor 1 24 – O
P0182 Fuel Temp Sensor (inlet) Low 41 – O
P0183 Fuel Temp Sensor (inlet) High 41 – O
P0192 CRS Pressure SNSR (Low) 11 – O
P0193 CRS Pressure SNSR (High) 11 – O
P0200 Injector Circuit 1 82 – O
P0201 Injector M/V-Cylinder 1 (Load) 37 – O
P0219 Engine Overrunning 7 O –
P0227 PTO Accel Sensor 61 – O
P0228 PTO Accel Sensor 61 – O
P0234 Over Boost 54 – O Gr15
P0237 Boost Press SNSR (Low) 32 – O
P0238 Boost Press SNSR (High) 32 – O
P0251 Common Rail Pressure Defect 36 – O
P0253 Common Rail Pressure Defect 22 O –
P0254 Common Rail Pressure Defect 23 O O
P0335 Engine Revolution SNSR 15 – O
P0340 Camshaft Position SNSR 12 – O
P0500 Vehicle Speed Sensor 25 – O
P0506 Idle Volume 31 – –
P0507 Idle Volume 31 – –
P0510 Accel SW 65 – –
P0560 M/V Supply Voltage 79 – O
P0600 CAN Communication – O –
P0605 ECU System (Hardware) 33 O O
P0615 Starter Safety Relay (Over Load) 48 – O Gr54
P0616 Starter Safety Relay (Low) 48 – O Gr54
13-28
13
Flashes Red Orange
P0617 Starter Safety Relay (High) 48 – O Gr54
P1130 VGT 1 51 – O Gr15
P1132 VGT 1 51 – O Gr15
P1133 VGT 1 51 – O Gr15
P1135 VGT 2 52 – O Gr15
P1137 VGT 2 52 – O Gr15
P1138 VGT 2 52 – O Gr15
P1140 VGT 3 53 – O Gr15
P1142 VGT 3 53 – O Gr15
P1143 VGT 3 53 – O Gr15
P1171 Q Adjustment Resistor (Low) 34 – O
P1172 Q Adjustment Resistor (High) 34 – O
P1176 PTO Adjustment Resistor (Low) 62 – O
P1177 PTO Adjustment Resistor (High) 62 – O
P1200 Injector Circuit 2 82 – O
P1236 Turbine Revolution SNSR (Low) 57 – O Gr15
P1237 Turbine Revolution SNSR (High) 57 – O Gr15
P1238 Turbine Overrunning 59 – O Gr15
P1251 Common Rail Pressure M/V 1 63 – O
P1254 PRV Opening 36 – O
P125A Rail Pressure M/V 1 (Over Load) 63 O –
P125B Rail Pressure M/V 1 (Long Short) 63 O –
P125C Rail Pressure M/V 2 (Over Load) 63 O –
P125D Rail Pressure M/V 2 (Long Short) 63 O –
P1267 EGR 1 67 – O Gr17
P1268 EGR 1 67 – O Gr17
P1272 EGR 2 68 – O Gr17
P1273 EGR 2 68 – O Gr17
P1277 EGR 3 69 – O Gr17
P1278 EGR 3 69 – O Gr17
P1335 Revolution & Position Sensor 14 O –
P1460 Auxiliary Brake M/V 1 93 – O
P1562 Sensor Supply Voltage 1 81 – –
P1572 Sensor Supply Voltage 3 81 – O
P1573 Sensor Supply Voltage 3 81 – O
P1605 ECU System (EEPROM) 33 – O
P1606 ECU System (Software) 33 O –
P1625 EDU Relay 84 – O Gr17
13-29
Flashes Red Orange
P1630 CAN (EGR 1) 95 – O Gr17
3.2 Diagnosis code generation conditions and inspection items
P0107: Atmospheric Pressure Sensor (warning lamp flashes: 19)

Atmospheric pressure sensor (incorporated into engine electronic control unit)
Generation condition
voltage remains less than 2 V for 3 seconds.
System recovers when atmospheric pressure sensor (incorporated into engine
Recoverability
electronic control unit) remains 2 V or more for 1 second.
• Control is effected using backup value of 101.3 kPa {1.03 kgf/cm2}.
Control effected by electronic control unit (Exhaust emissions worsen.)
• Exhaust gas recirculation control is stopped.
Service data 30: Atmospheric Pressure
Inspection
Other Replace engine electronic control unit.
P0108: Atmospheric Pressure Sensor (warning lamp flashes: 19)

Atmospheric pressure sensor (incorporated into engine electronic control unit)
voltage remains higher than 4.7 V for 3 seconds.
System recovers when atmospheric pressure sensor (incorporated into engine
Recoverability
electronic control unit) voltage remains 4.7 V or less for 1 second.
• Control is effected using backup value of 101.3 kPa {1.03 kgf/cm2}.
Control effected by electronic control unit (Exhaust emissions worsen.)
Service data 30: Atmospheric Pressure
Inspection
Other Replace engine electronic control unit.
P0112: INT Air Temp SNSR (Low) (warning lamp flashes: 44)
Generation condition Intake air temperature sensor 1 voltage remains less than 0.15 V for 3 seconds.
System recovers when intake air temperature sensor 1 voltage remains 0.15 V or
Recoverability
more for 1 second.
Control effected by electronic control unit Control is effected using backup value (25°C).
Service data 2B: Intake Air Temperature
Electronic control unit connector 01 : Intake air temperature sensor 1
Inspection
Electrical equipment #305: Intake air temperature sensor 1
Electric circuit diagram Intake air temperature sensor 1 system
P0113: INT Air Temp SNSR (High) (warning lamp flashes: 44)
Intake air temperature sensor 1 voltage remains higher than 4.85 V for 3 sec-
onds.
System recovers when intake air temperature sensor 1 voltage remains 4.85 V or
Recoverability
less for 1 second.
Inspection
Electrical equipment #305: Intake air temperature sensor 1
13-30
13
P0117: Water Temp SNSR (Low) (warning lamp flashes: 21)
Generation condition Water temperature sensor voltage remains less than 0.2 V for 3 seconds.
System recovers when water temperature sensor voltage remains 0.2 V or more
Recoverability
for 1 second.
• Control is effected using backup value (at engine startup: –20°C; when engine
Control effected by electronic control unit is running: 80°C).
Service data 2E: Water Temperature
Electronic control unit connector 02 : Water temperature sensor
Inspection
Electrical equipment #262: Water temperature sensor
Electric circuit diagram Water temperature sensor system
P0118: Water Temp SNSR (High) (warning lamp flashes: 21)

Generation condition Water temperature sensor voltage remains higher than 4.85 V for 3 seconds.
System recovers when water temperature sensor voltage remains 4.85 V or less
Recoverability
for 1 second.
• Control is effected using backup value (at engine startup: –20°C; when engine
Control effected by electronic control unit is running: 80°C).
Service data 2E: Water Temperature
Electronic control unit connector 02 : Water temperature sensor
Inspection
Electrical equipment #262: Water temperature sensor
Electric circuit diagram Water temperature sensor system
P0121: Accel Pedal Check (Plausibility) (warning lamp flashes: 58)

The difference in output voltage between accelerator pedal position sensors 1
and 2 remains 70% or more for 6 seconds when the sensors are normal.
System recovers if difference in output voltage between accelerator pedal posi-
Recoverability tion sensors 1 and 2 remains less than 70% for 3 seconds when the sensors are
normal.
Control effected by electronic control unit – (Low output)
22: Accel Pedal Position (unfiltered), 23: Accel Pedal Position (filtered)
Service data
24: Accel Pedal Sensor Voltage 1, 25: Accel Pedal Sensor Voltage 2
Inspection Electronic control unit connector 03 : Accelerator pedal position sensor
Electrical equipment #324: Accelerator pedal position sensor
Electric circuit diagram Accelerator pedal position sensor system
P0122: Accel Pedal Sensor 1 (warning lamp flashes: 24)

Generation condition Accelerator pedal position sensor 1 voltage remains less than 0.5 V for 1 second.
System recovers when accelerator pedal position sensor 1 voltage remains 0.5 V
Recoverability
or more for 1 second.
• If accelerator pedal position sensor 1 alone is faulty
Control is effected using accelerator pedal position sensor 2.
• If both accelerator pedal position sensors 1 and 2 are faulty
Control effected by electronic control unit • Auto cruise control is stopped.
• Turbocharger control is stopped.
• Control is effected using backup value (when accelerator pedal switch is
ON: accelerator pedal is not pressed (0%); when the switch is OFF: the
pedal is pressed 30%).
Service data
24: Accel Pedal Sensor Voltage 1
Electric circuit diagram Accelerator pedal position sensor 1 system
13-31
Accelerator pedal position sensor 1 voltage remains higher than 4.5 V for 1 sec-
ond.
Recoverability
or less for 1 second.
Service data
P0182: Fuel Temp Sensor (inlet) Low (warning lamp flashes: 41)
Generation condition Fuel temperature sensor voltage remains less than 0.15 V for 3 seconds.
System recovers when fuel temperature sensor voltage remains 0.15 V or more
Recoverability
for 1 second.
Service data 2F: Fuel Temperature (Inlet)
Electronic control unit connector 04 : Fuel temperature sensor
Inspection
Electrical equipment #323: Fuel temperature sensor
Electric circuit diagram Fuel temperature sensor system
P0183: Fuel Temp Sensor (inlet) High (warning lamp flashes: 41)
Generation condition Fuel temperature sensor voltage remains higher than 4.8 V for 3 seconds.
System recovers when fuel temperature sensor voltage remains 4.8 V or less for
Recoverability
1 second.
Service data 2F: Fuel Temperature (Inlet)
Electronic control unit connector 04 : Fuel temperature sensor
Inspection
Electrical equipment #323: Fuel temperature sensor
Electric circuit diagram Fuel temperature sensor system
P0192: CRS Pressure SNSR (Low) (warning lamp flashes: 11)

Generation condition Common rail pressure sensor voltage remains less than 0.2 V for 0.25 second.
System recovers (power is re-supplied to electronic control unit) if signal becomes
Recoverability
normal when starter switch is turned OFF (2 minutes or more) → ON.
• Common rail pressure open loop control is effected.
(Output is reduced, and exhaust emissions worsen.)
Control effected by electronic control unit
• Auto cruise control is stopped.
• Actuator tests “B9: Fuel Leak Check, BB to C0: Injector Test, BA: VGT Test”
are stopped.
Service data 0C: Difference Common Rail Pressure
Inspection Electrical equipment #319: Common rail pressure sensor
Electric circuit diagram Common rail pressure sensor system
13-32
13
P0193: CRS Pressure SNSR (High) (warning lamp flashes: 11)
Generation condition Common rail pressure sensor voltage remains higher than 4.8 V for 0.25 second.
Recoverability
• Common rail pressure open loop control is effected.
(Output is reduced, and exhaust emissions worsen.)
are stopped.
Inspection Electrical equipment #319: Common rail pressure sensor
Electric circuit diagram Common rail pressure sensor system
P0200: Injector Circuit 1 (warning lamp flashes: 82)

Injector circuit (No. 1, 2 or 3 cylinder) is short-circuited, open-circuited, or over-
loaded.
System recovers (power is re-supplied to electronic control unit) if signal be-
Recoverability
comes normal when starter switch is turned OFF (2 minutes or more) → ON.
• Injector magnetic valve (No. 1, 2 or 3 cylinder) control is stopped. (Output is
reduced due to three-cylinder operation, and exhaust emissions worsen.)
are stopped.
Actuator test BB: Injector Test 1, BC: Injector Test 2, BD: Injector Test 3,
Electronic control unit connector 05 : Injector magnetic valve
Inspection
Electrical equipment #582: Injector magnetic valve
Electric circuit diagram Injector magnetic valve (No. 1, 2 or 3 cylinder) system
P0201: Injector M/V-Cylinder 1 (Load) (warning lamp flashes: 37)

Injector magnetic valve (No. 1 cylinder) is short-circuited, open-circuited or over-
loaded.
• When short-circuited or overloaded
• System recovers (power is re-supplied to electronic control unit) if signal
becomes normal when starter switch is turned OFF (2 minutes or more) →
Recoverability ON.
• When open-circuited
• System recovers if signal becomes normal with starter switch in ON posi-
tion.
• Injector magnetic valves (No. 1, 2 and 3 cylinder) are stopped.
Control effected by electronic control unit (Output is reduced, and exhaust emissions worsen.)
• Actuator test “BA: VGT Test” is stopped.
Actuator test BB: Injector Test 1
Inspection
Electric circuit diagram Injector magnetic valve (No. 1 cylinder) system
13-33
loaded.
Recoverability ON.
tion.
Actuator test BF: Injector Test 5
Inspection

loaded.
Recoverability ON.
tion.
Actuator test BD: Injector Test 3
Inspection

loaded.
Recoverability ON.
tion.
Actuator test C0: Injector Test 6
Inspection
13-34
13
loaded.
Recoverability ON.
tion.
Actuator test BC: Injector Test 2
Inspection

loaded.
Recoverability ON.
tion.
Actuator test BE: Injector Test 4
Inspection
P0219: Engine Overrunning (warning lamp flashes: 07)

Generation condition Engine speed is 2900 rpm or higher.
Recoverability System recovers if engine speed is 2500 rpm or less.
• No feed from MPROP (rail pressure control valve)
• Exhaust gas recirculation control
• Check for occurrences of diagnosis code "P0335: Engine Revolution SNSR".
Inspection Other • If the diagnosis code is redisplayed with the pointer of the tachometer not
reaching the red zone, replace the engine electronic control unit.
13-35
Generation condition Accelerator pedal position sensor 2 voltage remains less than 0.5 V for 1 second.
Recoverability
or more for 1 second.
Service data

Accelerator pedal position sensor 2 voltage remains higher than 4.5 V for 1 sec-
ond.
Recoverability
or less for 1 second.
Service data
P0227: PTO Accel Pedal Sensor (warning lamp flashes: 61)

Voltage of power take-off load sensor remains less than 0.5 V for 1 second when
governor control switch is ON.
System recovers when voltage of power take-off load sensor remains 0.5 V or
Recoverability
more for 1 second when governor control switch is ON.
• When governor control switch is ON
Control effected by electronic control unit • Engine warning lamp (orange) display
• Control is effected using backup value (output: 0%).
Service data 34: PTO Accel Position, 35: PTO Accel Sensor Voltage
Electronic control unit connector 06 : Power take-off load sensor
Inspection
Electrical equipment #317: Power take-off load sensor
Electric circuit diagram Power take-off load sensor system
13-36
13
P0228: PTO Accel Sensor (warning lamp flashes: 61)
Voltage of power take-off load sensor remains higher than 3.5 V for 1 second
when governor control switch is ON.
System recovers when voltage of power take-off load sensor remains 3.5 V or
Recoverability
less for 1 second when governor control switch is ON.
• When governor control switch is ON
• Control is effected using backup value (output: 0%).
Service data 34: PTO Accel Position, 35: PTO Accel Sensor Voltage
Inspection
Electrical equipment #317: Power take-off load sensor
Electric circuit diagram Power take-off load sensor system
P0237: Boost Press SNSR (Low) (warning lamp flashes: 32)

Generation condition Boost pressure sensor voltage remains less than 0.3 V for 3 seconds.
System recovers when boost pressure sensor voltage remains 0.3 V or more for
Recoverability
1 second.
• Control is effected using backup value of 101.3 kPa {1.03 kgf/cm2}. (Output is
Control effected by electronic control unit reduced, and fuel economy worsens.)
Service data 26: Boost Pressure
Inspection Electrical equipment #318: Boost pressure sensor
Electric circuit diagram Boost pressure sensor system
P0238: Boost Press SNSR (High) (warning lamp flashes: 32)

Generation condition Boost pressure sensor voltage remains higher than 4.7 V for 3 seconds.
System recovers when boost pressure sensor voltage remains 4.7 V or less for 1
Recoverability
second.
• Control is effected using backup value of 101.3 kPa {1.03 kgf/cm2}. (Output is
Control effected by electronic control unit reduced, and fuel economy worsens.)
Inspection Electrical equipment #318: Boost pressure sensor
Electric circuit diagram Boost pressure sensor system
13-37
P0251: Common Rail Pressure Defect (warning lamp flashes: 36)
Diagnosis code is generated under either of the following conditions.
(1) MPROP (rail pressure control valve) power supply remains low for 1 second.
(2) The difference between target common rail pressure and actual common rail
pressure remains 30% or more for 10 seconds.
Recoverability
• In the case of above problem (1)
• No specific control is effected.
• Injection quantity is limited. (Output is reduced.)
Actuator test B9: Fuel Leak Check
• Air-bleeding of fuel system (See “ON-VEHICLE INSPECTION AND ADJUST-
MENT”.)
Inspection • Inspection of fuel piping (See “COMMON RAIL”.)
• Fuel filter (See “FUEL FILTER”.)
Other
• Gauze filter (See “ON-VEHICLE INSPECTION AND ADJUSTMENT”.)
• Supply pump (Have work performed by Bosch.)
• Pressure limiting valve (Have work performed by Bosch.)
• Injectors (Have work performed by Bosch.)

(1) Common rail pressure sensor voltage remains less than 0.74 V for 30 sec-
onds.
pressure is 30% or more, and MPROP (rail pressure control valve) discharge
rate remains above the specified value for 60 seconds.
• System recovers when common rail pressure sensor voltage remains 0.74
V or more for 5 seconds.
Recoverability • In the case of above problem (2)
• System recovers when the difference between target rail pressure and ac-
tual rail pressure is 30% or less, or MPROP (rail pressure control valve)
discharge rate remains less than the specified value for 5 seconds.
Control effected by electronic control unit Engine is stopped.
Service data C0: Difference Common Rail Pressure
• Air-bleeding of fuel system (See “ON-VEHICLE INSPECTION AND ADJUST-
MENT”.)
Inspection • Inspection of fuel piping (See “COMMON RAIL”.)
Other
13-38
13
(1) Common rail pressure sensor voltage remains 4.4 V or more for 10 seconds
when common rail pressure is controlled without feedback value.
(2) When above problem (1) is not occurred, common rail pressure sensor volt-
age remains 2.96 V or more for 10 seconds when common rail pressure is
controlled without feedback value.
(3) Common rail pressure sensor voltage remains 4.4 V or more for 5 seconds.
pressure is 30% or more, and MPROP (rail pressure control valve) discharge
rate remains above the specified value for 10 seconds.
Recoverability
• In the case of above problems (1) and (2)
• Engine warning lamp (red) display
• Engine is stopped.
• In the case of above problems (3) and (4)
• Injection quantity is limited. (Output is reduced, and exhaust emissions
worsen.)
Service data C0: Difference Common Rail Pressure
Inspection
Other Supply pump (Have work performed by Bosch.)
P0335: Engine Revolution SNSR (warning lamp flashes: 15)

(1) Signals from engine speed sensor are not input while signals from cylinder
Generation condition recognition sensor are recognized.
(2) Engine speed recognized by engine speed sensor is higher than 6000 rpm
when engine speed is higher than 450 rpm.
• System recovers if signals from engine speed sensor are input while sig-
nals from cylinder recognition sensor are recognized.
Recoverability
• System recovers if engine speed recognized by engine speed sensor is
6000 rpm or less when engine speed is higher than 450 rpm.
• Control is effected using cylinder recognition sensor.
Control effected by electronic control unit (Output decreases owing to reduced control accuracy.)
Service data 01: Engine Revolution
Electronic control unit connector 07 : Engine speed sensor
Inspection
Electrical equipment #263: Engine speed sensor
Electric circuit diagram Engine speed sensor system
13-39
P0340: Camshaft Position SNSR (warning lamp flashes: 12)
(1) Phase difference between cylinder recognition sensor and engine speed sen-
sor deviates from the standard value when engine speed is 20 rpm or more.
(2) No signal from the cylinder recognition sensor during the 132-pulse inputs of
the engine speed sensor signal after recognition of the gap of the engine
speed sensor.
(3) Abnormal signal (timing) of cylinder recognition sensor signal during the 240-
pulse inputs of the engine speed sensor signal.
• System recovers when phase difference between cylinder recognition sen-
sor and engine speed sensor is within the standard value when engine
speed is 20 rpm or more.
Recoverability
• System recovers when signals from cylinder recognition sensor are input.
• System recovers when the signal (timing) of cylinder recognition sensor
signal during the 240-pulse inputs of the engine speed sensor signal be-
comes normal.
• Control is effected using engine speed sensor.
Control effected by electronic control unit • In the case of above problems (2) and (3)
• Control is effected using engine speed sensor.
Electronic control unit connector 08 : Cylinder recognition sensor
Inspection
Electrical equipment #320: Cylinder recognition sensor
Electric circuit diagram Cylinder recognition sensor system
P0500: Vehicle Speed Sensor (warning lamp flashes: 25)

Vehicle speed remains 2 km/h or less for 20 seconds when engine speed is 1000
Generation condition rpm or more, clutch pedal is released and transmission neutral signal indicates
that transmission is in gear.
System recovers when vehicle speed remains 2 km/h or more for 3 seconds
Recoverability when engine speed is 1000 rpm or more, clutch pedal is released and transmis-
sion neutral signal indicates that transmission is in gear.
• Vehicle speed limiting control is stopped. (Engine speed is also limited.)
Service data 29: Vehicle Speed
Electronic control unit connector 09 : Vehicle speed sensor
Inspection
Electrical equipment #265: Vehicle speed sensor
Electric circuit diagram Vehicle speed sensor system
P0506: Idle Volume (warning lamp flashes: 31)

Idling speed adjustment potentiometer voltage remains less than 0.7 V for 3 sec-
onds.
System recovers when idling speed adjustment potentiometer voltage remains
Recoverability
0.7 V or more for 1 second.
• Control is effected with auto idle permanently selected.
Service data 28: Idle Volume Voltage
Electronic control unit connector 10 : Idling speed adjustment potentiometer
Inspection
Electrical equipment #157: Idling speed adjustment potentiometer
Electric circuit diagram Idling speed adjustment potentiometer system
13-40
13
P0507: Idle Volume (warning lamp flashes: 31)
Idling speed adjustment potentiometer voltage remains higher than 4.6 V for 3
seconds.
System recovers when idling speed adjustment potentiometer voltage remains
Recoverability
4.6 V or less for 1 second.
• Control is effected with auto idle permanently selected.
Service data 28: Idle Volume Voltage
Electronic control unit connector 10 : Idling speed adjustment potentiometer
Inspection
Electrical equipment #157: Idling speed adjustment potentiometer
Electric circuit diagram Idling speed adjustment potentiometer system
P0510: Accel SW (warning lamp flashes: 65)

Accelerator pedal switch remains ON for 1 second when accelerator pedal posi-
tion is higher than 30%.
System recovers if accelerator pedal switch is turned OFF when accelerator ped-
Recoverability
al position is 30% or lower.
Control effected by electronic control unit No specific control is effected.
Service data 73: Accel SW
Electronic control unit connector 11 : Accelerator pedal switch
Inspection
Electrical equipment #029: Accelerator pedal switch
Electric circuit diagram Accelerator pedal switch system
P0560: M/V Supply Voltage (warning lamp flashes: 79)

Generation condition Magnetic valve power supply remains low for 0.5 second.
Recoverability
• Turbocharger magnetic valve control is stopped.
• Safety relay control is stopped.
• Powertard magnetic valve control is stopped.
• Electronic drive unit relay control is stopped.
• Following controls are stopped by stopping electronic drive unit relay control.
Replace engine electronic control unit. (See “6. Registration or Change of the
Inspection Other
Engine Electronic Control Unit Information”.)
P0600: CAN Communication (warning lamp flashes: –)

• No controller area network signals from multi function vehicle control unit are
Generation condition received for 1.8 seconds.
• Controller area network signal from MVCU indicating “vehicle speed limitation
device (SLD) is abnormal” is received.
Recoverability
• Engine speed is limited.
• Vehicle speed limiting control is stopped.
Controller area network communication system between engine electronic con-
Electric circuit diagram
trol unit and multi function vehicle control unit
Inspection
Check the combination of engine electronic control unit and multi function vehicle
Other
control unit
13-41
P0605: ECU System (Hardware) (warning lamp flashes: 33)
(1) Power supply circuit or power supply in electronic control unit is abnormal.
(2) Devices (analog-digital converter, IC for driving injector or timer IC) in electron-
ic control unit or CPU gate array communication are abnormal.
• System recovers if power supply circuit or power supply in electronic con-
trol unit becomes normal.
Recoverability
becomes normal when starter switch is turned OFF → ON.
• Engine warning lamp (orange) display
Control effected by electronic control unit • In the case of above problem (2)
• Engine warning lamp (red) display
• Engine is stopped.
Inspection Other Replace the engine electronic control unit.
P1171: Q Adjustment Resistor (Low) (warning lamp flashes: 34)

Fuel injection rate adjustment resistor voltage remains less than 0.2 V for 3 sec-
onds.
System recovers when fuel injection rate adjustment resistor voltage remains 0.2
Recoverability
V or more for 1 second.
Control effected by electronic control unit Control is effected using backup value (No. 1). (Output is slightly reduced.)
Service data 33: Q Adjustment Resistor No.
Electronic control unit connector 12 : Fuel injection rate adjustment resistor
Inspection
Electrical equipment #828: Fuel injection rate adjustment resistor
Electric circuit diagram Fuel injection rate adjustment resistor system
P1172: Q Adjustment Resistor (High) (warning lamp flashes: 34)

Fuel injection rate adjustment resistor voltage remains higher than 4.8 V for 3
seconds.
System recovers when fuel injection rate adjustment resistor voltage remains 4.8
Recoverability
V or less for 1 second.
Control effected by electronic control unit Control is effected using backup value (No. 1). (Output is slightly reduced.)
Service data 33: Q Adjustment Resistor No.
Electronic control unit connector 12 : Fuel injection rate adjustment resistor
Inspection
Electrical equipment #828: Fuel injection rate adjustment resistor
Electric circuit diagram Fuel injection rate adjustment resistor system
P1176: PTO Adjustment Resistor (Low) (warning lamp flashes: 62)

Power take-off resistor voltage remains less than 0.2 V for 3 seconds when gov-
ernor control switch is ON.
System recovers when power take-off resistor voltage remains 0.2 V or more for
Recoverability
1 second when governor control switch is ON.
Control effected by electronic control unit Control is effected using backup value (not resistor).
Service data 36: PTO Adjustment Resistor No.
Electronic control unit connector 13 : Power take-off resistor
Inspection
Electrical equipment #828: Power take-off resistor
Electric circuit diagram Power take-off resistor system
13-42
13
P1177: PTO Adjustment Resistor (High) (warning lamp flashes: 62)
Power take-off resistor voltage remains higher than 4.8 V for 3 seconds when
governor control switch is ON.
System recovers when power take-off resistor voltage remains 4.8 V or less for 1
Recoverability
second when governor control switch is ON.
Control effected by electronic control unit Control is effected using backup value (not resistor).
Service data 36: PTO Adjustment Resistor No.
Electronic control unit connector 13 : Power take-off resistor
Inspection
Electrical equipment #828: Power take-off resistor
Electric circuit diagram Power take-off resistor system
P1200: Injector Circuit 2 (warning lamp flashes: 82)

Injector circuit 2 (No. 4, 5 or 6 cylinder) is short-circuited, open-circuited, or over-
loaded.
Recoverability
• Injector magnetic valve (No. 4, 5 or 6 cylinder) control is stopped. (Output is
reduced due to three-cylinder operation, and exhaust emissions worsen.)
are stopped.
BE: Injector Test 4, BF: Injector Test 5
Actuator test
C0: Injector Test 6
Inspection Electronic control unit connector 05 : Injector magnetic valve
Electric circuit diagram Injector magnetic valve (No. 4, 5 or 6 cylinder) system
P1251: Common Rail Pressure M/V 1 (warning lamp flashes: 63)

Current flowing to MPROP1 (rail pressure control valve) remains above the spec-
ified value for 0.3 second.
Recoverability
• Injection quantity is limited. (Output is reduced, and exhaust emissions wors-
en.)
Electronic control unit connector 14 : MPROP1 (rail pressure control valve)
Inspection
Electrical equipment #574: MPROP1 (rail pressure control valve)
Electric circuit diagram MPROP1 (rail pressure control valve) system

Current flowing to MPROP2 (rail pressure control valve) remains above the spec-
ified value for 0.3 second.
Recoverability
en.)
Inspection
13-43
P1254: PRV Opening (warning lamp flashes: 36)
Diagnosis code is generated under either of the following conditions
• Common rail pressure is abnormally large.
(except forced opening of pressure limiting valve by electronic control unit
Generation condition control)
• Pressure limiting valve is faulty.
(Limiting valve opens even though the common rail pressure is normal.)
• Abnormal common rail pressure due to leakage or clogging of fuel system
Recoverability
en.)
Electronic control unit connector 14 : MPROP (rail pressure control valve)
Electrical equipment #574: MPROP (rail pressure control valve)
Electric circuit diagram MPROP (rail pressure control valve) system
Inspection • Air-bleeding of fuel system (See “ON-VEHICLE INSPECTION AND ADJUST-
MENT”.)
• Inspection of fuel piping (See “COMMON RAIL”.)
Other

MPROP1 (rail pressure control valve) circuit shorted to ground or open-circuited
(low level when turned OFF) as detected for 0.3 second.
Recoverability
en.)
Inspection
13-44
13
(1) MPROP1 (rail pressure control valve) circuit shorted to battery (high level
Generation condition when turned ON) as detected for 0.3 second.
(2) MPROP1 (rail pressure control valve) driving voltage remains abnormal for 1
second.
Recoverability ON.
• MPROP1 (rail pressure control valve) driving voltage remains normal for 1
second.
worsen.)
Control effected by electronic control unit • Exhaust gas recirculation control is stopped.
Inspection

(1) MPROP2 (rail pressure control valve) circuit shorted to battery (high level
Generation condition when turned ON) as detected for 0.3 second.
(2) MPROP2 (rail pressure control valve) driving voltage remains abnormal for 1
second.
Recoverability ON.
• MPROP2 (rail pressure control valve) driving voltage remains normal for 1
second.
worsen.)
Control effected by electronic control unit • Exhaust gas recirculation control is stopped.
Inspection
13-45
MPROP2 (rail pressure control valve) circuit shorted to ground or open-circuited
(low level when turned OFF) as detected for 0.3 second.
Recoverability
en.)
Inspection
P125A: Rail Pressure M/V 1 (Over load) (warning lamp flashes: 63)
MPROP1 (rail pressure control valve) driving current value remains higher than
2A for 10 seconds.
Recoverability
en.)
Inspection Electronic control unit connector 14 : MPROP1 (rail pressure control valve)
P125B: Rail Pressure M/V 1 (Long Short) (warning lamp flashes: 63)
MPROP1 (rail pressure control valve) circuit remains shorted to ground as detect-
ed for 10 seconds.
Recoverability
Control effected by electronic control unit Engine is stopped 50 seconds after the diagnosis code is generated.
P125C: Rail Pressure M/V 2 (Over Load) (warning lamp flashes: 63)
MPROP2 (rail pressure control valve) driving current value remains higher than
2A for 10 seconds.
Recoverability
en.)
13-46
13
P125D: Rail Pressure M/V 2 (Long Short) (warning lamp flashes: 63)
MPROP2 (rail pressure control valve) circuit remains shorted to ground as detect-
ed for 10 seconds.
Recoverability
Control effected by electronic control unit Engine is stopped 50 seconds after the diagnosis code is generated.
P1335: Revolution & Position Sensor (warning lamp flashes: 14)

No signal from engine speed sensor and cylinder recognition sensor while starter
switch (S signal) is input for 10.2 seconds.
System recovers when signals are input from engine speed sensor or cylinder
Recoverability
recognition sensor.
Electronic control unit connector 07 : Engine speed sensor, 08 : Cylinder recognition sensor
Inspection
Electrical equipment #263: Engine speed sensor, #320: Cylinder recognition sensor
Electric circuit diagram Engine speed sensor and cylinder recognition sensor systems
P1460: Auxiliary Brake M/V 1 (warning lamp flashes: 93)

Current flowing to Powertard solenoid valve remains above the specified value
for 1 second.
System recovers when the current flowing to Powertard solenoid valve remains
Recoverability
below the specified value for 1 second.
• Operation of auxiliary brake is stopped.
Service data 80: Powertard M/V
Actuator test AC: Powertard M/V
Inspection Electronic control unit connector 15 : Powertard solenoid valve
Electrical equipment #571: Powertard solenoid valve
Electric circuit diagram Powertard solenoid valve system

Powertard solenoid valve circuit shorted to ground or open-circuited (driving ter-
minal is at low level when turned OFF) as detected for 1 second.
System recovers when Powertard solenoid valve circuit remains normal (driving
Recoverability
terminal is at high level when turned OFF) for 1 second.
13-47
Powertard solenoid valve circuit shorted to battery (driving terminal is at high lev-
el when turned ON) as detected for 1 second.
System recovers when Powertard solenoid valve circuit remains normal (driving
Recoverability
terminal is at low level when turned ON) for 1 second.
P1562: Sensor Supply Voltage 1 (warning lamp flashes: 81)

Circuit voltage (sensor supply voltage 1) in electronic control unit remains abnor-
mally low for 0.5 second.
System recovers when circuit voltage (sensor supply voltage 1) in electronic con-
Recoverability
Control effected by electronic control unit No specific control is effected. Failure occurs only to circuit abnormality.
Service data 24: Accel Pedal Sensor Voltage 1, 28: Idle Volume Voltage
03 : Accelerator pedal position sensor 1,
Electronic control unit connector
10 : Idling speed adjustment potentiometer
Inspection #157: Idling speed adjustment potentiometer, #324: Accelerator pedal position
Electrical equipment
sensor 1
Accelerator pedal position sensor 1 and idling speed adjustment potentiometer
systems

mally high for 0.5 second.
Recoverability
Service data 24: Accel Pedal Sensor Voltage 1, 28: Idle Volume Voltage
03 : Accelerator pedal position sensor 1,
Electronic control unit connector
10 : Idling speed adjustment potentiometer
Inspection #157: Idling speed adjustment potentiometer, #324: Accelerator pedal position
Electrical equipment
sensor 1
Accelerator pedal position sensor 1 and idling speed adjustment potentiometer
systems

Recoverability
Service data 25: Accel Pedal Sensor Voltage 2, 26: Boost Pressure
Electronic control unit connector 03 : Accelerator pedal position sensor 2
Inspection
Electrical equipment #318: Boost pressure sensor, #324: Accelerator pedal position sensor 2
Electric circuit diagram Boost pressure sensor and accelerator pedal position sensor 2 systems
13-48
13
Recoverability
Service data 25: Accel Pedal Sensor Voltage 2, 26: Boost Pressure
Electronic control unit connector 03 : Accelerator pedal position sensor 2
Inspection
Electrical equipment #318: Boost pressure sensor, #324: Accelerator pedal position sensor 2
Electric circuit diagram Boost pressure sensor and accelerator pedal position sensor 2 systems

Recoverability
Service data 0C: Difference Common Rail Pressure, 35: PTO Accel Sensor Voltage
Inspection
Electrical equipment #317: Power take-off load sensor, #319: Common rail pressure sensor
Electric circuit diagram Power take-off load sensor and common rail pressure sensor systems

Recoverability
Service data 0C: Difference Common Rail Pressure, 35: PTO Accel Sensor Voltage
Inspection
Electrical equipment #317: Power take-off load sensor, #319: Common rail pressure sensor
Electric circuit diagram Power take-off load sensor and common rail pressure sensor systems
P1605: ECU System (EEPROM) (warning lamp flashes: 33)

Generation condition Reading or writing error occurs during access.
Recoverability
normal when starter switch is turned OFF → ON.
Inspection Other Replace engine electronic control unit.
P1606: ECU System (Software) (warning lamp flashes: 33)

• System overload occurs.
• Data processing time of engine electronic control unit has exceeded time-out
period (0.0655 second).
Recoverability
Control effected by electronic control unit Engine is stopped.
Inspection Other Replace engine electronic control unit.
13-49
4. Multi-Use Tester Service Data
• It is possible to see service data and actuator tests simultaneously.
No. Item Data Inspection condition Requirement

Engine speed after engine
01 Engine Revolution .rpm Racing (engine running)
warm-up: 500 ± 25 rpm
02 Reference Injection Quantity . % Engine idling 5 to 20%
Fuel injection quantity af-
Difference Common Rail
0C . % Engine idling ter engine warm-up:
Pressure
Less than 30%
20 Actual EGR Position 1 . See Gr17. –
21 VGT Position . % See Gr15. –

Accelerator pedal not pressed 0%
Accel Pedal Position
22 . % Accelerator pedal gradually pressed Value gradually increases.
(unfiltered)
Accelerator pedal fully pressed 100%
Accelerator pedal not pressed 0%
Accel Pedal Position
23 . % Accelerator pedal gradually pressed Value gradually increases.
(filtered)
Accelerator pedal fully pressed 100%
Accel Pedal Sensor Accelerator pedal gradually pressed
24 . V 0.85 to 4.15 V
Voltage 1 from released position
Accel Pedal Sensor Accelerator pedal gradually pressed
25 . V 0.85 to 4.15 V
Voltage 2 from released position
Value matches atmospher-
Starter switch ON (engine is stopped)
ic pressure indication.
26 Boost Pressure . kPa
Accelerator pedal pressed after engine
Value gradually increases.
has started
1 V <altitude: 0 m>
Boost Pressure Sensor 0.92 V <altitude: 600 m>
27 . V
Voltage Accelerator pedal pressed after engine
has started
28 Idle Volume Voltage . V SLOW to FAST 3 to 1 V
Value matches speedome-
29 Vehicle Speed .km/h Vehicle in motion
ter indication.
2A Turbine Revolution .rpm See Gr15. –
Value matches ambient
2B Intake Air Temperature . °C Engine cold
temperature indication.
Engine cold
2E Water Temperature . °C Engine in process of warming up Value gradually increases.
Engine stopped after warming up Value gradually decreases.
Engine cold
2F Fuel Temperature (Inlet) . °C Engine in process of warming up Value gradually increases.
Engine stopped after warming up Value gradually decreases.
Altitude: 0 m 101 kPa
30 Atmospheric Pressure . kPa
Altitude: 600 m 95 kPa
Number matches number
1/2/3/4/5/6/7/8/9/10/
33 Q Adjustment Resistor No. – marked on fuel injection
11/NON
rate adjustment resistor.
When power take-off is used (MIN to
34 PTO Accel Position . % 0 to 100%
MAX)
When power take-off is used (MIN to
35 PTO Accel Sensor Voltage . V 1 to 3.0 V
MAX)
Number matches number
36 PTO Adjustment Resistor No. 1/2/3/4/5/6/7/8/NON Governor control switch ON marked on power take-off
resistor.
Value matches battery
37 Power Supply Voltage . V Starter switch ON
voltage.
13-50
13
Engine cranked by means of starter
ON
switch
71 Starter SW (S) ON/OFF
Starter switch in position except
OFF
START
Starter switch in ON position ON
72 Starter SW (M) ON/OFF
Starter switch in position except ON OFF
Accelerator pedal not pressed ON
73 Accel SW ON/OFF
Accelerator pedal pressed OFF
Powertard switch (1st step): ON ON
74 Powertard SW 1 ON/OFF
Powertard switch (1st step): OFF OFF
Powertard switch (2nd step): ON ON
75 Powertard SW 2 ON/OFF
Powertard switch (2nd step): OFF OFF
Clutch pedal pressed ON
76 Clutch SW ON/OFF
Clutch pedal not pressed OFF
Transmission not in neutral ON
77 Neutral SW ON/OFF
Transmission in neutral OFF
ON (5 times, for 1.5 sec.
Actuator test is performed
each)
78 Idle Up Cancel SW ON/OFF
Actuator test is not performed OFF
[Actuator test] B8: Idle Up Cancel SW
Governor control switch ON ON
7C PTO SW ON/OFF
Governor control switch OFF OFF
Diagnosis switch OFF
ON
(with connector connected)
7D Diagnosis SW ON/OFF
Diagnosis switch ON
OFF
(with connector disconnected)
Memory clear switch OFF
ON
(with connector connected)
7E Memory Clear SW ON/OFF
Memory clear switch ON
OFF
(with connector disconnected)
Operated under following conditions
• Accelerator and clutch pedals are
ON
7F Auxiliary Brake SW 1 ON/OFF pressed
• Transmission in neutral position
Other than above conditions OFF
Powertard operating ON
80 Powertard M/V ON/OFF Powertard not operating OFF
[Actuator test] A6: Powertard M/V
82 VGT M/V 1 ON/OFF See Gr15. –
Auxiliary brake operating ON
85 Auxiliary Brake Indicator Lamp ON/OFF Auxiliary brake not operating OFF
[Actuator test] AE: Auxiliary Brake Indicator Lamp
88 Starter Safety Relay ON/OFF See Gr54. –
89 EDU Power Relay ON/OFF See Gr17. –
Starter switch ON (engine not started) ON
8A MIL LAMP ON/OFF No error after engine startup OFF
[Actuator test] B3: MIL Lamp
Starter switch ON (engine not started) ON
8B Diagnosis Lamp ON/OFF No error after engine startup OFF
[Actuator test] B4: Diagnosis Lamp
13-51
5. Actuator Tests Performed Using Multi-Use Tester
No. Item Explanation Confirmation method
A1 EGR 1
A2 EGR 2 See Gr17. –
A3 EGR 3
A9 VGT M/V 1
AA VGT M/V 2 See Gr15. –
AB VGT M/V 3
Repeatedly turn each valve ON and OFF (5 times, for Check by the operating
1.5 sec. each). sound when Powertard so-
[Can be executed when the following conditions are lenoid valve is turned ON/
AC Powertard M/V satisfied] OFF.
• Vehicle: stationary (vehicle speed 0 km/h) [Service data]
• Starter switch: ON 80: Powertard M/V
• Engine: stopped
Repeatedly turn Auxiliary brake indicator lamp ON and Check that the indicator
OFF (5 times, for 1.5 sec. each). lamp surely illuminates or
[Can be executed when the following conditions are goes out as commanded.
AE Auxiliary Brake Indicator Lamp satisfied] [Service data]
• Vehicle: stationary (vehicle speed 0 km/h) 85: Auxiliary Brake Indica-
• Starter switch: ON tor Lamp
• Engine: stopped
B1 Starter Safety Relay See Gr54. –
B2 EDU Relay See Gr17. –
Repeatedly turn the engine control warning lamp ON ON/OFF condition of warn-
and OFF (5 times, for 1.5 sec. each). ing lamp (orange)
B3 MIL LAMP
[Can be executed when the following conditions are [Service data]
satisfied] 8A: MIL LAMP
• Starter switch: ON ON/OFF condition of warn-
• Engine: stopped ing lamp (red)
B4 Diagnosis Lamp
[Service data]
8B: Diagnosis Lamp
Repeatedly turn idle up cancel switch ON and OFF (5 Check that the engine
times, for 1.5 sec. each). idling speed remains at low
[Can be executed when the following conditions are idling.
B8 Idle Up Cancel SW
satisfied] [Service data]
• Vehicle: stationary (vehicle speed 0 km/h) 78: Idle Up Cancel SW
• Transmission: Neutral
Increase rail pressure for a certain period of time Check that no fuel leaks
[Can be executed when the following conditions are from fuel system (pipe and
satisfied] hose).
B9 Fuel Leak Check
• Vehicle: stationary (vehicle speed 0 km/h)
• Transmission: Neutral
• Engine: idling
BA VGT Test See Gr15. –
Selected injector magnetic valve forcibly deactivated Check that injector mag-
BB Injector Test 1 [Can be executed when the following conditions are netic valve for No. 1 cylin-
satisfied] der stops operating.
• Vehicle: stationary (vehicle speed 0 km/h) Check that injector mag-
BC Injector Test 2 • Engine speed: Below 1500 rpm netic valve for No. 2 cylin-
• Transmission: Neutral der stops operating.
• No active diagnosis code generated
Check that injector mag-
BD Injector Test 3 netic valve for No. 3 cylin-
der stops operating.
BE Injector Test 4 netic valve for No. 4 cylin-
BF Injector Test 5 netic valve for No. 5 cylin-
C0 Injector Test 6 netic valve for No. 6 cylin-
13-52
13
M E M O
13-53
6. Inspections Performed at Electronic Control Unit Connectors
• These inspections aid troubleshooting by enabling you to check whether electronic control unit signals are being
correctly transmitted via the vehicle harness and connectors.
The white-on-black numbers ( 01 , 02 , and so on) correspond to the similarly printed reference numbers in
section “3. Inspections Based on Diagnosis Codes”.
6.1 Electronic control unit connector terminal layout
6.2 Inspection instructions

• Some inspections are performed with the connectors removed. Others are performed with the connectors fitted.
Observe the following caution:
CAUTION
• Do not touch any terminal except those specified for the inspection. Be particularly careful not to cause
short circuits between terminals using the tester probes.
Check item Measurement method

01 [Conditions]
• Starter switch OFF
Resistance of intake air temperature sensor 1 • Disconnect connector. Perform inspection on vehicle-side connector.
[Requirements]
Terminals: A63-A32
• 0°C: 15 +3.78
–2.94 kΩ
• 20°C: 6.514 +1.437
–1.147 kΩ
• 80°C: 0.874 +0.136
–0.115 kΩ
13-54
13
02 [Conditions]
Resistance of water temperature sensor • Disconnect connector. Perform inspection on vehicle-side connector.
[Requirements]
Terminals: A40-A41
• 20°C: 2.45 ± 0.14 kΩ
• 80°C: 0.32 kΩ (reference value)
• 110°C: 147.1 ± 2 kΩ
03 [Conditions]
• Starter switch ON
Output voltage of accelerator pedal position • Vehicle-side harness connected (Perform inspection on back of connector.)
sensor [Requirements]
Terminals (+)-(–):
B34-B33 (accelerator pedal position sensor 1)
B46-B45 (accelerator pedal position sensor 2)
• With accelerator pedal not pressed: 0.85 ± 0.1 V
• With accelerator pedal pressed: 4.15 ± 0.1 V
04 [Conditions]
Resistance of fuel temperature sensor • Disconnect connector. Perform inspection on vehicle-side connector.
[Requirements]
Terminals: A89-A65
• 20°C: 2.5 ± 0.25 kΩ
• 80°C: 0.32 ± 0.02 kΩ
• 110°C: 0.144 ± 0.01 kΩ
05 [Conditions]
Resistance of injector magnetic valve • Disconnect connector. Perform inspection on vehicle-side connector.
[Requirements]
Terminals:
A72-A23 (injector magnetic valve: No. 1 cylinder)
• 0.21 to 0.295 Ω
06 [Conditions]
Output voltage of Power take-off load sensor • Vehicle-side harness connected (Perform inspection on back of connec-
tor.)
[Requirements]
Terminals (+)-(–): A15-A16
• Idling: 0.85 ± 0.1 V
• Full-load: 3.0 ± 0.1 V
07 [Conditions]
Resistance of engine speed sensor • Disconnect connector. Perform inspection on vehicle-side connector.
[Requirements]
Terminals: A10-A9
• 2.2 ± 0.2 Ω (25°C)
08 [Conditions]
Resistance of cylinder recognition sensor • Disconnect connector. Perform inspection on vehicle-side connector.
[Requirements]
Terminals: A59-A83
• 860 ± 86 Ω
09 [Conditions]
Output voltage of vehicle speed sensor • Vehicle-side harness connected (Perform inspection on back of connector.)
• Turn wheels slowly using chassis dynamometer.
[Requirements]
Terminals (+)-(–): A67-chassis ground
• High pulse voltage: 8 ± 1 V
• Low pulse voltage: 0.5 V or lower
13-55
10 [Conditions]
Output voltage of idling speed adjustment • Vehicle-side harness connected (Perform inspection on back of connector.)
potentiometer [Requirements]
Terminals (+)-(–): A12-A36
• AUTO position: 4.0 ± 0.1 V
• SLOW position: 3.0 ± 0.2 V
• FAST position: 1.0 ± 0.1 V
11 [Conditions]
Operating voltage of accelerator pedal switch • Disconnect connector. Perform inspection on vehicle-side connector.
[Requirements]
Terminals (+)-(–): A20-chassis ground
• With accelerator pedal pressed: There is no continuity.
• With accelerator pedal not pressed: There is continuity.
12 [Conditions]
Resistance of fuel injection rate adjustment • Disconnect connector. Perform inspection on vehicle-side connector.
resistor [Requirements]
Terminals: A35-A88
• No. 1 resistor: 270 ± 13.5 Ω
• No. 2 resistor: 510 ± 25.5 Ω
• No. 3 resistor: 820 ± 41 Ω
• No. 4 resistor: 1300 ± 65 Ω
• No. 5 resistor: 2000 ± 100 Ω
• No. 6 resistor: 3300 ± 165 Ω
• No. 7 resistor: 5600 ± 280 Ω
• No. 8 resistor: 15000 ± 750 Ω
• No. 9 resistor: 390 ± 19.5 Ω
• No. 10 resistor: 4300 ± 215 Ω
• No. 11 resistor: 9100 ± 455 Ω
13 [Conditions]
Resistance of Power take-off resistor • Disconnect connector. Perform inspection on vehicle-side connector.
[Requirements]
Terminals: A43-A19
• No. 1 resistor: 270 ± 13.5 Ω
• No. 2 resistor: 510 ± 25.5 Ω
• No. 3 resistor: 820 ± 41 Ω
• No. 4 resistor: 1300 ± 65 Ω
• No. 5 resistor: 2000 ± 100 Ω
• No. 6 resistor: 3300 ± 165 Ω
• No. 7 resistor: 5600 ± 280 Ω
• No. 8 resistor: 15000 ± 750 Ω
14 [Conditions]
Resistance of MPROP • Disconnect connector. Perform inspection on vehicle-side connector.
(rail pressure control valve) [Requirements]
Terminals:
• A69-A21, A69-A2, A3-A21, A3-A2 (MPROP1)
• A27-A4, A27-B38, B52-A4, B52-B38 (MPROP2)
• 2.6 to 3.15 Ω
15 [Conditions]
Voltage of Powertard solenoid valve • Disconnect connector. Perform inspection on vehicle-side connector.
[Requirements]
Terminals: A74-A5
• 32.6 to 39.8 Ω (engine oil temperature: 25°C)
16 [Conditions]
Resistance of controller area network resistor • Disconnect connector. Perform inspection on vehicle-side connector.
[Requirements]
Terminals: B11-B12, B5-B6
• 120 ± 6 Ω
13-56
13
M E M O
13-57
1. Inspecting No-load Minimum and Maximum Speeds
Service standards
– No-load minimum speed (idling speed) 450 to 500 rpm – Inspect
– No-load maximum speed 2330 to 2370 rpm – Inspect
1.1 Work before inspection

• Before starting the inspection and adjustment, carry out the fol-
lowing preparatory steps.
• Put the transmission in neutral.
• Turn off all lamps and accessories.
• Attach a Multi-Use Tester.
• Warm up the engine until the engine coolant temperature is ap-
proximately 80 to 95°C.
(Verify from Service Data “2E: Water Temperature”)
1.2 No-load minimum speed

[Inspection]
• With the accelerator pedal released, measure the engine speed.
• If the measurement deviates from the standard value, check for
an installed condition of the accelerator control cable and accel-
erator link. (See “ENGINE CONTROL”.)
• If the cable and link are found to be normal, check for the accel-
erator pedal switch*a, accelerator pedal position sensor*a, sup-
ply pump*b and engine electronic control unit*b.
(*a: See “ENGINE CONTROL”, *b: Contact Bosch Service Sta-
tion for repair.)
1.3 No-load maximum speed

[Inspection]
• Measure the engine speed with the accelerator pedal pressed
against the stopper bolt.
• If the measurement deviates from the standard value, check for
an installed condition of the accelerator control cable and accel-
erator link. (See “ENGINE CONTROL”.)
tion for repair.)
[Adjustment]
• If the measurement deviates from the standard value, adjust the
stopper bolt to change the accelerator pedal travel until the opti-
mum engine speed is reached with the pedal pressed.
• If it cannot be adjusted within the standard value by using the
stopper bolt, check for an installed condition of the accelerator
control cable and accelerator link. (See “ENGINE CONTROL”.)
tion for repair.)
• After the adjustment, make sure that the accelerator pedal
moves smoothly by firmly pressing the pedal 10 to 15 times until
it contacts the stopper bolt.
13-58
13
• If it does not move smoothly, check for an installed condition of
the accelerator control cable and accelerator link. (See “EN-
GINE CONTROL”.)
2. Inspection of Fuel Leakage

• Check if there is no fuel leakage from the fuel tank, fuel filter, supply pump, common rail, injector and fuel piping.
If there is a fuel leakage, replace the pipe or hose and tighten to the specified torque. If fuel leaks from joint, re-
tighten the bolts, nuts and clamps to the specified torque. (See later section.)
3. Inspection of Injection Pipe and Fuel Pipe Mounting Clamp

– Bolt or nut (clamp mounting) 17.6 to 21.6 {1.8 to 2.2} –
• Visually check the clamp appearance and make sure there is no

cracks or damages at the rubber part of the clamps.
• If there is any abnormality, replace the clamp.
• Check for looseness in the clamp mounting bolt or nuts. If there
is looseness, tighten the bolts and nuts to the specified torque.
4. Draining of Deposit in Fuel Tank

DANGER
• Do not allow any flames or sources of heat near the fuel tank, as it may explode.
WARNING
• Fuel is highly flammable. Keep it away from flames and sources of heat.
• Thoroughly wipe up any spilled fuel, otherwise it may catch fire.

– Drain plug 127 {13} Sealant

Location Points of application Specified lubricant and/or sealant Quantity
– Seat surface of drain plug Seal end No. 22 As required
[Removal]
• Drain the deposit in the fuel tank by removing the drain plug,
gasket and strainer from the fuel tank.
[Installation]
• Install the strainer and gasket to the fuel tank. Tighten the drain
plug to the specified torque.
13-59
5. Air-bleeding of Fuel System
– Plug 9.8 ± 2.0 {1.0 ± 0.2} –
• Loosen one of the plugs on the fuel filter.

• Turn the knob of the manually operated pump counterclockwise.
When the knob jumps out, push the knob to feed fuel.
• Continue pumping until fuel with no bubbles of air comes out of
the plug.
• With no air bubbles coming out with fuel, tighten the plug to the
specified torque.
• Continue operating the pump until there is strong pumping resis-
tance.
• While pushing the knob of the manually operated pump, screw it

in to the right to fix.
• Wipe up all spilled fuel, then start the engine.
• Check that no fuel leakage occurs.
WARNING
• Fuel is highly flammable. Keep it away from flames and
sources of heat.
• Be sure to wipe up all spilled fuel. Unless it is wiped up, it
could catch fire.
13-60
13
6. Fuel Filter Replacement
– Drain plug 2 ± 0.5 {0.2 ± 0.05} –
– Case 18 to 20 {1.8 to 2.0} –

– O-ring Engine oil As required
Special tools
Filter wrench MH063201 Removal and installation of case
[Removal]
• Drain fuel from the case by loosening the drain plug.
• Using , remove the case.
WARNING
sources of heat.
• Thoroughly wipe up any spilled fuel. Otherwise, it may
catch fire.
CAUTION
• Be careful not to damage the case.
[Installation]
• Clean the surface of the fuel filter head and case where the O-
ring is to be mounted.
13-61
• Replace the filter element and O-rings with new parts.
• Apply a thin coat of engine oil to the O-rings. Install the O-rings
onto the case.
CAUTION
• The use of non-genuine filter elements will lead to engine
problems. Be sure to use only genuine parts.
• To help prevent fuel injection problems, keep the fuel filter
and hoses free from contamination.
• Install a torque wrench to and tighten the case to the spec-

ified torque.
• Tighten the drain plug to the specified torque. With the plug cor-
rectly installed, bleed air from the fuel system.
• Start the engine and ensure that there is no fuel leakage.
• If there is fuel leakage, remove and install the fuel filter correctly.
7. Cleaning of Gauze Filter

– Eyebolt 25 to 29 {2.5 to 3.0} –
• Remove the eyebolt in the middle of fuel piping.

• Pull out the gauze filter from the removed eyebolt.
• Wash the gauze filter with light oil.
• After washing, install the gauze filter in the reverse order.
• Bleed air from the fuel system.
• Start the engine and check for fuel leakage.
WARNING
• Thoroughly wipe up any spilled fuel, otherwise it may catch
fire.
sources of heat.
13-62
13
8. Water Separator Element Replacement
– Drain plug 1.47 ± 0.3 {0.15 ± 0.03} –
– Cover 19.6 ± 2.5 {2.0 ± 0.3} –
– Plug A 12.3 ± 2.5 {1.25 ± 0.3} –
– Plug B 17.2 ± 2.5 {1.75 ± 0.3} –

Special tools
Filter wrench MH063201 Removal and installation of cover
[Removal]
• Loosen plugs A and B and then loosen the drain plug. Next, dis-
charge fuel from the water separator.
• Using , remove the cover.
WARNING
sources of heat.
• Thoroughly wipe up any spilled fuel. Otherwise, it may
catch fire.
CAUTION
• Use care not to damage the cover.
13-63
[Installation]
• Clean the surface of the water separator body, against which O-
ring abuts, and the O-ring groove in the cover.
• Replace the filter element and O-ring with new parts.

• Apply a thin coat of engine oil to the O-ring. Install the O-ring
onto the case.
CAUTION
• To help prevent fuel injection problems, keep the water sep-
arator and fuel hoses free from contamination.
• Install torque wrench to and tighten the case to the speci-

fied torque.
• Tighten the drain plug and plugs A, B to the specified torque.
With the plug correctly installed, bleed air from the fuel system.
• If there is fuel leakage, remove and install the water separator
correctly.
13-64
MITSUBISHI 6M70 COMMON RAIL 13
Removal sequence
1 Eyebolt
2 Fuel return pipe
3 Fuel pipe
4 Injection pipe
5 Common rail
*a: Crankcase
: Locating pin
WARNING
• Fuel is highly flammable. Do not
handle it near flames or heat.
• Spilled fuel may catch fire and
therefore, must be wiped off com-
pletely.
CAUTION
• Any contamination of the common
rail, even if it is minor, will greatly
affect the performance of the en-
gine. After removing pipes or other
parts, plug the openings with cov-
ers. Wash eyebolts and gaskets in
light oil and keep them away from
contaminants.
• Contact Bosch Service Station for any

service needs of the common rail.

Fuel pipe
29 to 34 {3.0 to 3.5} –
Injection pipe
Bolt (common rail mounting) 54 {5.5} –
Eyebolt (fuel return pipe mounting) 30 to 35 {3.1 to 3.6} –
Installation: Mitsubishi 6M70 Fuel pipe and injection pipe
• Ensure that the pipe and mounting surfaces of the connector are
flat and free from damage.
• Bring the pipe into intimate contact with mounting surfaces of the
connector evenly, and temporarily tighten it without applying an
excessive force.
• Tighten it to the specified torque after temporary tightening.
13-65
MITSUBISHI 6M70 FUEL SUPPLY PUMP
Removal sequence
1 Fuel pipe 7 Fuel feed pipe 13 O-ring
2 Eyebolt 8 Over flow valve
3 Fuel suction pipe 9 Fuel return pipe
*b:
a: Flywheel housing
4 Eyebolt 10 Eyebolt
* Rear plate
5 Fuel feed pipe 11 Oil pipe : Non-reusable parts
6 Eyebolt 12 Supply pump
WARNING
• Fuel is highly flammable. Do not handle it near flames or heat.
• Spilled fuel may catch fire and therefore, must be wiped off completely.
CAUTION
• Any contamination of the supply pump, even if it is minor, will greatly affect the performance of the en-
gine. After removing pipes, hoses, or other parts, plug the openings with covers. Wash eyebolts and new
gaskets in light oil and keep them away from contaminants.
• Contact Bosch Service Station for any service needs of the supply pump.
CAUTION
• Make sure that the harness (marked with “ ”) of MPROP (rail pressure control valve) is connected to the
supply pump before starting the engine. Starting the engine without connection causes a malfunction.
13-66
13
Service standards
0.23 ± 0.07 MPa
8 Overflow valve – Replace
{2.3 ± 0.7 kgf/cm2}

Bolt (supply pump mounting) 54 {5.5} –
Eyebolt (fuel suction pipe mounting)
25 to 29 {2.6 to 3.0} –
Eyebolt (fuel feed pipe mounting)
Eyebolt (oil pipe mounting) 21 {2.1} –
Overflow valve mounting 30 to 40 {3.1 to 4.1} –
Fuel pipe 29 to 35 {3.0 to 3.6} –
Bolt (supply pump mounting) 125 {12.7} –


Timing bolt
A ME350296 Installation of supply pump
φ10
Open end spanner

A B Removal and installation of fuel suc-
ME355665
tion pipe and fuel feed pipe
15 24
Removal procedure
Removal: Fuel suction pipe and fuel feed pipe
• Apply (width across flats: 24 mm) to the connector of the
supply pump as a stopper, and then loosen the eyebolt to re-
move the fuel suction pipe and fuel feed pipe.
CAUTION
• Do not use except for a stopper of the fuel suction pipe
and fuel feed pipe, otherwise the open end section may be
broken.

Phone: 269 673 1638
13-67
SUPPLY PUMP
Installation: Mitsubishi 6M70 Fuel Supply pump
• Position the No. 1 piston to the top dead center in the compres-
sion stroke in the following manner.
• Crank the engine to align the pointer with the “1 6” mark on
the flywheel.
• This will bring either the No. 1 piston or the No. 6 piston to the
top dead center in the compression stroke. If both the inlet
and exhaust rockers can be moved by hand by the amount of
valve clearance, that cylinder is at the top dead center in the
compression stroke. From that position, every turn of the
crankshaft will alternately bring the No.1 and No. 6 pistons to
the top dead center in the compression stroke. (See Gr11.)
• Install the supply pump while ensuring that the stamped line on
the supply pump gear is aligned with the stamped line on rear
plate.
• Insert into the timing checking hole of the flywheel housing.

• If the seat surface of is securely fitted, the timing is aligned.
If the seat surface lifts, the gears are not properly engaged. Re-
install the supply pump.
CAUTION
• Remember to remove after it is used.
• Install bolt A from the supply pump side and bolt B from the fly-
wheel housing side.
Installation: Fuel suction pipe and fuel feed pipe

supply pump as a stopper, and then tighten the eyebolt to install
the fuel suction pipe and fuel feed pipe.
CAUTION
• Do not use except for a stopper of the fuel suction pipe
and fuel feed pipe, otherwise the open end section may be
broken.
13-68
13
Installation: Fuel pipe
excessive force.

Phone: 269 673 1638
13-69
MITSUBISHI 6M70 INJECTOR
Removal sequence
1 Injection pipe
2 Injection pipe seal
3 Nozzle bridge
4 O-ring
5 Injector
6 O-ring
7 O-ring
8 Nozzle tip gasket
9 Eyebolt
10 Fuel return pipe
11 Fuel return pipe
WARNING
• Fuel is highly flammable.
Do not handle it near flames or
heat.
• Spilled fuel may catch fire and
therefore, must be wiped off com-
pletely.
CAUTION
• The harnesses and connectors between the injectors and common rail electronic control unit are under
high voltage. Be careful not to receive an electric shock. Before attempting to remove the injectors, turn
the starter switch to the LOCK position.
• Carefully handle the injector, taking care not to damage the threaded portion and nozzle as high pressure
is applied to the injector.
• To eliminate fuel injection and other problems, protect the injectors and pipes, that have been removed,
from the ingress of contaminants.
• Contact Bosch Service Station for any service needs of the injector.
CAUTION
• Do not attempt to clean the nozzle hole with a wire brush or other similar tools, or the hole can be dam-
aged.
• Be sure to tighten the nozzle bridge bolts to the specified torque. Overtightening the bolts can deform the
injectors, resulting in incorrect fuel injection.

Bolt (nozzle bridge mounting) 54 nm {5.5 kgfm} 40 Ft Lbs –
Mitsubishi 6M70 Injection pipe 29 to 34 {3.0 to 3.5} –
Eyebolt (fuel return pipe mounting) 40 {4} –
Phone: 269 673 1638
13-70
13

Injector extractor Removing injector

adapter ME165088
(use with MH061071)
Nozzle extractor
A MH061071 Removing injector
M8 × 1.25
Open end spanner Removal and installation of injection

A B ME355665
pipe
15 24
Removal procedure
Removal: Mitsubishi 6M70 Injection pipe
injector as a stopper, and then loosen the union nut to remove
the injection pipe.
CAUTION
• Do not use except for a stopper of the injection pipe,
otherwise the open end section may be broken.

Phone: 269 673 1638
13-71
INJECTOR
Removal: Mitsubishi 6M70 Injector
• Tighten the nut so that a hook of can be hung on section A
of the injector.
• Attach to and remove the injector.
Installation: Mitsubishi 6M70 Injection pipe
injector as a stopper.
CAUTION
• Do not use except for a stopper of the injection pipe,
otherwise the open end section may be broken.
excessive force.
13-72
13
M E M O
13-73
FUEL TANK
Removal sequence
1 Drain plug 6 Fuel level sensor 10 Fuel tank
2 Strainer 7 Fuel tank strap 11 Fuel tank bracket
3 Connecting plug 8 Fuel tank strap 12 Fuel tank bracket
4 Suction hose <Except FV51> <Except FV51>
5 Return hose 9 Fuel tank strap 13 Fuel tank bracket
DANGER
• Do not allow any flames or sources of heat near the fuel tank, as it may explode.
WARNING
• Fuel is highly flammable. Keep it away from flames and sources of heat.
• Thoroughly wipe up any spilled fuel, otherwise it may catch fire.
13-74
13
Drain plug 127 {13} –
Connecting plug 20 {2.0} –
Nut (fuel tank strap mounting) 11.7 to 12.7 {1.2 to 1.3} –
Bolt (fuel tank bracket mounting) 54 to 72 {5.5 to 7.3} Wet
FV51 54 to 72 {5.5 to 7.3}
Bolt (fuel tank bracket mounting) Wet
Except FV51 150 to 204 {15 to 21}

Location Points of application Specified lubricant and/or sealant Quantity
Seat surface of drain plug Seal end No. 22 As required
Contact area between fuel tank strap and fuel tank Soapy water As required
Thread area of bolt Engine oil As required
13-75
FUEL FILTER
1 Cap
2 Fuel return pipe
3 Overflow valve
4 Fuel feed pipe
5 Eyebolt
6 Fuel feed pipe
7 Plug
8 Drain plug
9 O-ring
10 Case
11 Float
12 O-ring
13 Element
14 Fuel filter head
Assembly sequence
verse.
WARNING
• Fuel is highly flammable. Keep it
away from flames and sources of
heat.
• Thoroughly wipe up any spilled fu-
el. Otherwise, it may catch fire.
CAUTION
Service standards
1.14 ± 0.03 MPa
3 Overflow valve – Replace
{12 ± 0.3 kgf/cm2}

Eyebolt 30 {3.0} –
Drain plug 2 ± 0.5 {0.2 ± 0.05} –
Case 18 to 20 {1.8 to 2.0} –
Plug 9.8 ± 2.0 {1.0 ± 0.2} –
Overflow valve
20 to 29 {2.0 to 3.0} –
Cap

13-76
13
Special tools
Filter wrench MH063201 Removal and installation of case
Removal procedure
Removal: Case
• Drain fuel from the case by loosening the drain plug.
• Using , remove the case.
Installation: Case
• Clean the surface of the fuel filter head and case where the O-
ring is to be mounted.
13-77
FUEL FILTER
• Replace the filter element and O-rings with new parts.
• Apply a thin coat of engine oil to the O-rings. Install the O-rings
onto the case.
CAUTION
• To help prevent fuel injection problems, keep the fuel filter
and hoses free from contamination.
• Install a torque wrench to and tighten the case to the spec-

ified torque.
• Tighten the drain plug to the specified torque. With the plug cor-
rectly installed, bleed air from the fuel system.
• Start the engine and check that there is no fuel leakage.
• If there is fuel leakage, remove and install the fuel filter correctly.
13-78
13
M E M O
13-79
WATER SEPARATOR
1 Fuel hose
2 Fuel cut valve
3 Connector
4 Plug A
5 O-ring
6 Plug B
7 O-ring
8 Drain plug
9 O-ring
10 Cover
11 O-ring
12 Float
13 Element
14 Body
Assembly sequence
verse.
WARNING
• Fuel is highly flammable. Keep it
away from flames and sources of
heat.
• Thoroughly wipe up any spilled fu-
el. Otherwise, it may catch fire.
CAUTION

Fuel cut valve 35 {3.6} –
Plug A 12.3 ± 2.5 {1.3 ± 0.3} –
Plug B 17.2 ± 2.5 {1.8 ± 0.3} –
Drain plug 1.47 ± 0.3 {0.15 ± 0.03} –
Cover 19.6 ± 2.5 {2.0 ± 0.25} –
Connector 40 {4.0} –

Special tools
Filter wrench MH063201 Removal and installation of cover
13-80
13
Removal procedure
Removal: Cover
• Loosen plugs A and B and then loosen the drain plug. Next, dis-
charge fuel from the water separator.
• Using , remove the cover.
WARNING
• Do not bring an open flame or heat near to fuel, which can
catch fire easily.
• Thoroughly wipe the surface clean of spilled fuel that could
otherwise lead to a fire.
CAUTION
• Use care not to damage the cover.
Installation: Cover
• Clean the surface of the water separator body, against which O-
ring abuts, and the O-ring groove in the cover.
• Replace the filter element and O-ring with new parts.

• Apply a thin coat of engine oil to the O-ring. Install the O-ring
onto the case.
CAUTION
• To help prevent fuel injection problems, keep the water sep-
arator and fuel hoses free from contamination.
13-81
WATER SEPARATOR
• Install torque wrench to and tighten the case to the speci-
fied torque.
• Tighten the drain plug and plugs A, B to the specified torque.
With the plug correctly installed, bleed air from the fuel system.
• If there is fuel leakage, remove and install the water separator
correctly.
13-82
13
M E M O
13-83
ENGINE CONTROL
Removal sequence
1 Cover 6 Accelerator pedal bracket
2 Accelerator pedal control cable 7 Accelerator link (See later section.)
3 Accelerator pedal pin 8 Accelerator pedal position sensor
4 Accelerator pedal
5 Stopper bolt : Non-reusable parts
• After the installation, check the no-load minimum speed and no-load maximum speed for normal state and adjust
them if required. (See “ON-VEHICLE INSPECTION AND ADJUSTMENT”.)
• Make sure that the accelerator pedal moves smoothly.
Installation: Accelerator pedal control cable
• Connect the accelerator pedal control cable to the accelerator
link.
13-84
13
• Install the other end of the accelerator pedal control cable onto
the accelerator position sensor control lever.
• Adjust tension of the accelerator pedal control cable with the ac-
celerator link stopper bolt so that accelerator link B contacts the
stopper.
• Press the accelerator pedal until the control lever of the acceler-
ator pedal position sensor contacts the full load stopper bolt.
• Adjust the stopper bolt so that clearance between the accelera-
tor pedal and stopper bolt is to the dimension shown in the illus-
tration.
13-85
ENGINE CONTROL
Accelerator Link
Removal sequence
1 Accelerator pedal switch
2 Bushing
3 Accelerator link A
4 Bushing
5 Accelerator link B
6 Collar
7 Return spring
8 Bushing
9 Accelerator link bracket

Sliding surfaces of bushing and accelerator link bracket Chassis grease
As required
Sliding surfaces of collar and return spring [NLGI No. 1 (Li soap)]
Installation: Accelerator pedal switch
• Place accelerator link B against the stopper.
• Place the push rod of the accelerator pedal switch against accel-
erator link B and install the accelerator pedal switch so that the
stroke of the push rod is to the dimension shown in the illustra-
tion.
13-86
13
M E M O
13-87
INSPECTION OF MITSUBISHI 6M70 ELECTRICAL PARTS
#001 Inspection of combination switch
DD15B connector connection table
Switch position Terminals with continuity
OFF –
Powertard
1st step 6 – 11
switch
2nd step 6 – 11, 3 – 9
• For other inspections than shown above, see Gr54.
• If there is any abnormality, replace the switch.
#029 Inspection of accelerator pedal switch

OFF –
ON 1–2
#031 Inspection of clutch switch

OFF –
ON 1–2
#157 Inspection of idling speed adjustment potentiometer

• Apply 5 volts DC to terminals 1 and 2 of the idling speed adjust-
ment potentiometer.
• Turn the knob fully counterclockwise. Then, measure the output
voltage across terminals 2 and 3 (see the diagrams on the left)
while slowly turning the knob clockwise.
Knob position Output voltage
AUTO (0°) 4.0 ± 0.1 V
Standard value
SLOW (30°) 3.0 ± 0.2 V
FAST (300°) 1.0 ± 0.1 V
• If any measurement is out of specification, replace the idling
speed adjustment potentiometer.
13-88
13
#201 Inspection of relay (normally open 5-pin)
• Check continuity and operating condition of the relay. Replace
the relay if necessary.
#262 Inspection of Mitsubishi 6M70 water temperature sensor

• Place the water temperature sensor in a container filled with en-
gine oil.
• Heat the oil to each of the specified temperatures. Stir the oil
well while doing so.
• Measure the resistance between terminals 1 and 2.
20°C 2.45 ± 0.14 kΩ
0.32 kΩ
Standard value 80°C
(reference value)
110°C 147.1 ± 2 Ω
• If either measurement is out of specification, replace the sensor.
#263 Inspection of Mitsubishi 6M70 engine speed sensor

Standard value (at 25°C) 2.2 ± 0.2 kΩ
• If the measurement is out of specification, replace the sensor.
CAUTION
• The signal may not output if the sensor tightening torque is
insufficient. Check if the sensor is tightened with the cor-
rect tightening torque. (See Gr11.)
#265 Inspection of vehicle speed sensor

• With the 24 volts DC applied to terminals 1 and 2, slowly turn the
shaft of the vehicle speed sensor.
• Measure the maximum voltage (high pulse voltage) and mini-
mum voltage (low pulse voltage) occurring at each specified pair
of terminals.
Low pulse voltage 0.5 V or lower
Standard value
High pulse voltage 8±1V
• If any measurement is out of specification, replace the sensor.
13-89
INSPECTION OF ELECTRICAL EQUIPMENT
#305 Inspection of Misubishi 6M70 intake air temperature sensor
• The intake air temperature sensor 1 may output false signals if
its tip is contaminated. Clean it if necessary. (See Gr15.)
• Place the sensor in a container filled with engine oil.
0°C 15 +3.78
–2.94 kΩ
Standard value 20°C 6.514 +1.437
–1.147 kΩ
80°C 0.874 +0.136
–0.115 kΩ
#317 Inspection of power take-off load sensor

• Apply 5 volts DC to terminals 4 and 6.
• Measure the output voltage across terminals 5 and 6 with the le-
ver at idling position A and at full-load position B.
Lever position Output voltage
Standard value Idling position A 0.85 ± 0.1 V
Full-load position B 3.0 ± 0.1 V
• If measurement of full-load position B deviates from standard
value, adjust with full load stopper bolt.
• If measurement of idling position A deviates from standard val-
ue, replace the sensor.
#318 Inspection of Mitsubishi 6M70 boost pressure sensor

• Apply 5 volts DC to terminals 3 and 1.
• Apply air pressure. Gradually increase it and, while doing so,
measure the output voltage occurring at terminals 2 and 1.
Air pressure (gauge pressure) Voltage
Standard value 99 kPa {1.0 kg/cm2} Approx. 2.5 V
232.2 kPa {2.3 kg/cm2} Approx. 4.5 V
#319 Inspection of Mitsubishi 6M70 common rail pressure sensor

• The sensor cannot easily be inspected in isolation, so you must
evaluate it indirectly by inspection of system harnesses and re-
lated parts.
• If there is no abnormality in any related part but the system is ab-
normal, replace the common rail.
13-90
13
#320 Inspection of Mitsubishi 6M70 cylinder recognition sensor
Standard value 860 ± 86 Ω
• If the measurement is out of specification, replace the sensor.
#323 Inspection of Mitsubishi 6M70 fuel temperature sensor

• Place the fuel temperature sensor in a container filled with en-
gine oil.
20°C 2.5 ± 0.25 kΩ
Standard value 80°C 0.32 ± 0.02 kΩ
110°C 0.144 ± 0.01 kΩ
#324 Inspection of accelerator pedal position sensor

• Apply 5 volts DC to terminals 4 and 6 and terminals 1 and 3 of
the accelerator pedal position sensor connector.
• Measure the output voltage at terminals 5 and 6 (sensor 1) and
the output voltage at terminals 2 and 3 (sensor 2) with the lever
in each specified position.
Lever position Output voltage
Standard value Idling position A 0.85 ± 0.1 V
Full load position B 4.15 ± 0.1 V
A: Position in which accelerator pedal switch is fully pushed in
by lever
B: Position in which lever is touching stopper bolt
• If any output voltage is out of specification, make an adjustment.
• If any output voltage is still out of specification when you have
made an adjustment, replace the sensor.
#571 Inspection of Powertard solenoid valve

Standard value Engine oil temperature: 25°C 32.6 to 39.8 Ω
• If the measurement is out of specification, replace the Powertard
solenoid valve.
13-91
INSPECTION OF ELECTRICAL EQUIPMENT
#574 Inspection of MPROP
(rail pressure control valve)
• Measure the resistance between terminals 1 and 2. Identify
MPROP1 and 2 by “M/P-1” and “M/P-2” labeled on the harness.
Standard value
2.6 to 3.15 Ω
(at 20°C)
• If the measurement is out of specification, replace the supply
pump.
#582 Inspection of Mitsubishi 6M70 injector magnetic valve

Standard value (at 20 to 70°C) 0.21 to 0.295 Ω
• If the measurement is out of specification, replace the injector.
#828 Inspection of fuel injection rate adjustment resistor

• Measure the resistance of the resistor number marked on the
fuel injection rate adjustment resistor.
1 270 ± 13.5 Ω
2 510 ± 25.5 Ω
3 820 ± 41 Ω
4 1300 ± 65 Ω
5 2000 ± 100 Ω
Standard value
Resistor No. 6 3300 ± 165 Ω
(at 20°C)
7 5600 ± 280 Ω
8 15000 ± 750 Ω
9 390 ± 19.5 Ω
10 4300 ± 215 Ω
11 9100 ± 455 Ω
• If the measurement is out of specification, replace the fuel injec-

tion rate adjustment resistor with one that has the same resistor
number and same specified resistance.
CAUTION
• The fuel injection rate adjustment resistor is matched to the
engine. If you replace it, be sure to replace it with one that
has the same resistor number.
13-92
13
M E M O
13-93
INSTALLED LOCATIONS OF PARTS
13-94
13
13-95
13-96
13
13-97
13-98
13
13-99
MITSUBISHI 6M70 INSTALLED LOCATIONS OF PARTS
13-100
13
13-101
ELECTRIC CIRCUIT DIAGRAM
13-102
13
13-103
13-104
13
13-105
13-106
GROUP 14 COOLING
SPECIFICATIONS ............................................................................. 14-2

1. Cooling System (Flow of Coolant) ................................................... 14-3
2. Thermostat ......................................................................................... 14-4
3. Water Pump ........................................................................................ 14-4
TROUBLESHOOTING ...................................................................... 14-5

1. Inspection and Adjustment of Belt Tension ................................. 14-6
2. Inspection of Belts ....................................................................... 14-8
3. Coolant Replacement and Cleaning of Cooling System ................ 14-9
4. Air Bleeding of Cooling System ..................................................... 14-11
5. Gas Leakage Test ............................................................................ 14-11
6. Coolant Leakage Test....................................................................... 14-11
DISCONNECTION AND CONNECTION

OF HOSES AND PIPES .................................................................. 14-12
RADIATOR AND FAN SHROUD ..................................................... 14-16
SURGE TANK .................................................................................. 14-24
COOLING FAN AND BELT............................................................... 14-26
WATER PUMP................................................................................... 14-28
THERMOSTAT .................................................................................. 14-34
14-1
SPECIFICATIONS
Item Specifications
Cooling system Forced water circulation system
Water pump Belt-driven type
Thermostat Wax pellet, bottom bypass type (with jiggle valve)
Automatic cooling fan coupling Continuous control type
Radiator Tube and corrugated fin type
Coolant capacity dm3 {L} 41 {41}
14-2
1. Mitsubishi 6M70 Cooling System (Flow of Coolant)
14-3
2. Mitsubishi 6M70 Thermostat
• The thermostat is a bottom bypass
type that uses a wax-filled pellet as its
flow-regulating element. When the
wax is heated, it melts from solid to liq-
uid, changing its total volume. This al-
lows the valve to open or close in
accordance with the coolant tempera-
ture, regulating and adjusting the flow
of coolant to the radiator and to the
water pump (bypassing the radiator).
3. Mitsubishi 6M70 Water Pump

• The water pump has a drain hole to
prevent coolant from entering the unit
bearing in case of a defect in the unit
seal.
14-4
TROUBLESHOOTING 14
Symptoms
Overheating (poor cooling)
Excessive coolant loss

Reference Gr
Abnormal noise
Overcooling
Possible causes
Loose or damaged O O
Belt Excessive tension O
Oil on belt O
Incorrectly mounted water pump O O
Defective gasket O O
Defective bearing unit O O
Water pump
Defective impeller O
Defective unit seal O O
Fit of bearing unit on flange and impeller too loose O O
Incorrectly mounted case O O
Valve opening temperature too high
Thermostat O
(valve remains closed)
Valve opening temperature too low (valve remains open) O
Leakage from coolant temperature sensor O O
Clogged core O
Radiator
Cracked core and/or separation in welds O O
Defective bearing O O
Automatic cooling fan Damaged bimetal O
coupling Contaminated bimetal O O
Silicon oil leakage O O
Incorrectly mounted oil cooler O O
Oil cooler Gr12
Incorrectly mounted cylinder head O O
Cylinder head Gr11
Poorly airtight pressure cap O
Insufficient coolant amount, contaminated coolant O
Clogged or scaled coolant passage O
Incorrectly connected hoses O O
Excessively low exterior temperature O
Exhaust gas recircula- Defective gasket O O
Gr17
tion related Incorrectly mounted exhaust gas recirculation piping O O
Air compressor Gr11
Incorrectly mounted water pipe O O
14-5
1. Inspection and Adjustment of Belt Tension
CAUTION
• Be careful not to allow engine oil to smear the belt. A belt smeared with oil slips, resulting in reduced
cooling efficiency.
• When replacing the belts, replace them as a set to prevent differences in tension between the two belts.

For air conditioner 15 to 20 – Adjust
– Belt tension For alterna- When new 19 to 24
– Adjust
tor When reused 25 to 30

– Nut (for alternator retention) 82 {8.4} –
– Bolt (for cooler compressor retention) 19.6 to 24.5 {2.0 to 2.5} –
Special tools
Belt tension gauge MH062345 Measurement of tension of belt
Inspection after installation

Inspection: Tension of belts
• Press each belt at a central portion between pulleys with a force
of approximately 98 N {10 kgf} as shown in the illustration and
measure the amount of deflection of the belt.
A: Alternator pulley
B: Compressor pulley (for air conditioner)
C: Water pump pulley
D: Crankshaft pulley
• Place the small O-ring on at the scale mark corresponding

to 98 N {10 kgf} (press force).
• Place the large O-ring on at the scale mark corresponding
to the maximum permissible deflection value specified for the
belt.
14-6
14
• Place at a central portion between pulleys of the V-belt and
push the handle (indicated by the arrow in the illustration) until
indicated by arrow touches the O-ring.
• Measure the amount of deflection of the V-belt.

• If the measurement deviates from the standard value, adjust as
follows.
Adjustment of belt
(1) Belt for alternator
• Loosen the alternator mounting nuts (2 locations) and adjust the
tension of the belt with the adjusting bolt.
• When the adjustment is completed, tighten the bolts and nuts
securely.
CAUTION
• Excessive tension in belts may damage the belts and relat-
ed bearings.
(2) Belts for air conditioner

• Loosen the cooler compressor mounting bolts (4 places) and ad-
just the tension of the belt with the adjusting bolt.
• When the adjustment is completed, tighten the bolts securely.
CAUTION
• Excessive tension in belts may damage the belts and relat-
ed bearings.
14-7
2. Inspection of Belts
• Visually check the belt for a crack or damage.
• If there is any abnormality, replace the belt.
Belt condition Remaining service life (reference)

• The driving distance over the
which the belt can still be used is
at least as long as that over which
the belt has been used since the
vehicle was new or since the belt
was replaced (whichever is more
recent).

about half of that over which the
belt has been used since the vehi-
cle was new or since the belt was
replaced (whichever is more re-
cent).

about a quarter of that over which
the belt has been used since the
vehicle was new or since the belt
was replaced (whichever is more
recent).
• The belt has reached the end of

its service life and must be re-
placed.
14-8
14
3. Coolant Replacement and Cleaning of Cooling System

– Radiator drain cock 2.0 {0.2} –
– Crankcase drain cock 37 {3.8} –
• Using the radiator for extended periods of time without cleaning can increase chance of rust and scale formation,
which may cause engine overheating. The cooling system must be cleaned periodically.
Use a coolant containing the FUSO DIESEL LONGLIFE COOLANT additive and soft water in the specified pro-
portions. (See the Owner’s Handbook for instructions on the use of the additive.)
3.1 Draining of coolant
• Before draining the coolant, loosen the pressure cap to reduce the pressure in the cooling system. Remember to
drain the coolant out of the reservoir tank as well.
WARNING
• Drain the coolant only after it has cooled sufficiently to avoid getting scalded.
• Opening the pressure cap while the coolant temperature is still high can cause hot coolant to spray
out. Cover the pressure cap with a cloth, and loosen it slowly to let the pressure out before opening it
fully.
3.2 Cleaning procedure

CAUTION
• Water used for flushing the cooling system must be soft water that has a property meeting the require-
ments indicated below. Using hard water will cause scale and rust to form in the system.
Required properties of soft water
Total hardness .......................... 300 ppm or less
Sulfate SO 4 .............................. 100 ppm or less
Chloride CI ............................. 100 ppm or less
Total dissolved solids .............. 500 ppm or less
pH .............................................. 6 to 8
• Keep the coolant temperature at approximately 90°C so that the thermostat valve remains open and coolant con-
tinues to circulate in the radiator.
• For the sake of convenience you can raise the coolant temperature quickly by covering the front of the radiator
with corrugated cardboard or something similar.
• In cases where a great amount of rust has accumulated it is common for the radiator to leak as a result of clean-
ing. Conduct a through check for leakage after cleaning.
• Select an appropriate cleaning method according to the condition of the cooling system as shown below.
14-9
• Ordinary condition • Coolant extremely dirty • Radiator clogged
Cleaning using FUSO RADIATOR CLEANER (RADIPET-7)

Flushing with water
Drain out coolant
Make water solution of FUSO RADIATOR CLEANER

(RADIPET-7) at 5 to 10% concentration in volume.
Pour solution into surge tank.
Let the engine idle for 30 minutes with the water at approxi-
mately 90°C.
CAUTION
• Limit the engine idling period to one hour. Operating
an engine containing the cleaning solution for long-
er time may lead to damage of the cooling system.
Drain out coolant
Pour tap water (preferably hot) into the surge tank.
Let the engine idle for 10 minutes with the water

at approximately 90°C.
Drain out water
Cleaning is complete if drained water is clear

Repeat procedure if drained water is not clear
• After cleaning the cooling system using cleaning solu-
tion, fill it with coolant containing the specified additive as
soon as possible.
• To prevent freezing of the coolant and corrosion of the
cooling system, add the specified portion of FUSO DIE-
SEL LONGLIFE COOLANT to the coolant. (See the
Owner’s Handbook for instructions on the use of the ad-
ditive.)
WARNING
• FUSO DIESEL LONGLIFE COOLANT is flammable. Keep it away from heat and flames.
CAUTION
• If you accidentally splash FUSO DIESEL LONGLIFE COOLANT in your eyes, wash it out immediately with
water and seek medical attention.
14-10
14
4. Air Bleeding of Cooling System
• If the engine is started with the coolant filled up to the neck of the surge tank, the coolant temperature rises and
the expanded coolant overflows from the neck little by little. To avoid this, fill the surge tank with a slightly smaller
quantity of the coolant.
• With the pressure cap removed and the coolant temperature at 90°C, let the engine idle in order to bleed air com-
pletely out of the cooling system.
• After air bleeding is completed, refill the reservoir tank with coolant as needed.
5. Gas Leakage Test

• Presence of air or exhaust gas in coolant accelerates corrosion
of the cooling system components. To prevent this, carry out air/
gas leakage tests in accordance with the following procedure.
• Remove the pressure cap.
WARNING
• If the engine is hot, boiling coolant may spurt out from the
filler port when the pressure cap is loosened. To avoid
burning yourself, make sure to remove the pressure cap
only when the coolant is cold.
• Run the engine until the coolant temperature rises to approxi-

mately 90°C.
• If air bubbles appear continuously through the filler port, there is
air or exhaust gas penetrating into the cooling system.
• Presence of air in coolant can be an indication of loose cylinder
head bolts, loose water pump mounting bolts, loose hose con-
nections, and/or a damaged hose.
• Presence of exhaust gas in coolant can be an indication of a
damaged cylinder head gasket and/or cracks in the cylinder
head.
6. Coolant Leakage Test

• Ensure that there is no coolant leakage from coolant system during idling.
• If any leakage is found, check for the mounting condition. If there is looseness, tighten the part to the specified
torque. If there are cracks or damages, replace the defective part with a new one. (See later section.)
14-11
DISCONNECTION AND CONNECTION OF HOSES AND PIPES
Periphery of Radiator
Removal sequence
1 Supply hose 6 Water hose
2 Inlet hose 7 Hose
3 Overflow hose 8 Water hose
4 Heater hose 9 Water pipe
5 Heater hose 10 Outlet hose
• Install each hose clamp to the angle indicated in the illustration so that sufficient clearance is assured between the
hose clamp and its surrounding parts.
14-12
14
Hose clamp 4.0 ± 0.5 {0.4 ± 0.05} –
Hose clamp 5.0 ± 0.5 {0.5 ± 0.05} –
Hose clamp 3.5 to 4.5 {0.35 to 0.45} –
Hose clamp 4.4 {0.45} –
Hose clamp 6.5 ± 0.5 {0.7 ± 0.05} –
Installation: Outlet hose
• Install the outlet hose so that its marking faces the stopper of the
water pipe.
Installation: Hose
• Install the hose marked with a white line so that this white line is
placed in the center of the clamp.
14-13
DISCONNECTION AND CONNECTION OF HOSES AND PIPES
Periphery of Engine
14-14
14
Removal sequence
1 Air pipe 10 Eyebolt 19 Water pipe
2 Water pipe 11 Eyebolt 20 Water pipe
3 Water hose 12 Water pipe 21 Water hose
4
5
Water hose
Eyebolt
13
14
Eyebolt
Eyebolt
*a: Exhaust gas recirculation
cooler
6
7
Eyebolt
Water pipe
15
16
Water pipe
Water hose
* b: Exhaust gas recirculation
valve
8 Water hose 17 Water hose
* c: Water pump
9 Water pipe 18 Water hose
• Install each hose clamp to the angle indicated in the illustration so that sufficient clearance is assured between the
hose clamp and its surrounding parts.

Clamp 3.9 {0.4} –
Eyebolt (water pipe mounting) 39 {4.0} –
14-15
RADIATOR AND FAN SHROUD
Removal sequence
1 Cushion rubber 6 Cushion rubber 10 Radiator support
2 Front thrust rod bracket 7 Radiator 11 Shroud seal
3 Cushion rubber (See later section.) 12 Fan shroud
4 Cushion rubber 8 Radiator bracket
5 Thrust rod 9 Cushion rubber
• Refer to the previous section “DISCONNECTION AND CONNECTION OF HOSES AND PIPES” for the correct
insertion depth of radiator hoses into the pump as well as the correct tightening torque of clamps.
14-16
14
Tip clearance
spacer Adjusting clearance between fan
ME294842
A B shroud and cooling fan blades
50 7
Installation: Thrust rod
• Tighten nuts so that the thickness of cushion rubbers on both
ends of the thrust rod is to the dimension shown in the illustra-
tion.
Installation: Fan shroud

• Using , adjust the clearance between the fan shroud and
cooling fan blades to the dimension shown in the illustration over
the entire circumference.
Installation: Shroud seal and fan shroud

• Install the shroud seal and fan shroud while aligning the section
A as shown in the illustration.
14-17
Radiator
1 Thrust rod bracket 5 Side member 9 Packing
2 Radiator shroud 6 Upper tank 10 Core
3 Cross stay 7 Packing
4 Drain cock 8 Lower tank : Non-reusable parts
CAUTION
• Gently handle upper tank and lower tank, since they are made of a resin that can break on impact.
• If there are two paint marks on the joint between the core and upper tank or on the joint between the core
and lower tank (which indicates that the tank retaining tabs have been crimped twice before), replace the
core with a new part.
• Do not disassemble radiator unless there is an abnormality.
Assembly sequence
Service standards
Air leakage from radiator
– 0 cm3 {0 mL} – Rectify or replace
(air pressure: 177 kPa {1.8 kgf/cm2})

Drain cock 2 {0.2} –
Bolt (side member mounting) 13 {1.3} –
14-18
14
Special tools
J94-Z013
Lock-and-break tool Removal of upper and lower tanks
-10000
The indicated part number is T.RAD’s part number.

Inspection: Air leakage from radiator
• Install hose and radiator cap tester and plug to upper tank.
• Insert plug in lower tank, and immerse the entire body of the ra-
diator in water.
• Apply a specified air pressure using radiator cap tester, and
check for any air leakage.
• If any leakage is found, repair or replace radiator.
• Replace the following parts according to the leakage location.

Area of leakage Cause
Tank Cracked tank
Upper tank Defective crimping
Lower tank Tank joint Defective packing
Cracked tank
Tube; Tube joint Cracked tube
• If there are two paint marks on the joint between the core and
upper tank or on the joint between the core and lower tank
(which indicates that the tank retaining tabs have been crimped
twice before), replace the core with a new part.
• Paint a mark for each core replacement. The upper and lower
core replacement should be counted and marked separately.
Removal procedure
Removal: Upper tank and lower tank
• Use , for removal and reinstallation of the tanks.
14-19
• Adjust the stopper bolt until the gap dimension shown in the il-
lustration is obtained on the attachment of .
CAUTION
• Before using , be sure to set the gap to the specified di-
mension by adjusting the stopper bolt. Otherwise, damaged
will result.
• Use to bend open tabs of retain tank in place.

• After tabs are bent open, squeeze the handle of to straight-
en tabs as illustrated.
• After straightening all tabs in the perimeter, hold the pipes con-
nected to the inlet/outlet, and remove tank.
• If it is difficult to remove tank lightly hit with rubber hammer (or

plastic hammer) to remove.
CAUTION
• Gently handle tanks, since they are made of a resin that can
break on impact.
Inspection: Tank surface where core is to be mounted
• Check and clean the tank surface where the core is to be mount-
ed for cleanliness, damage, etc.
• If any abnormality is found, replace the tank.
CAUTION
• To prevent adhesion of foreign substances on mounting
surface, conduct work with bare hands.
14-20
14
Inspection: Core groove where tank is to be mounted
• Check the groove on the core where the tank is to be mounted
for adhesion of foreign substances or cracks.
• If foreign substances are found, rub the area with #1000 sand-
paper or the like gently so as to avoid scratching the surface, or
use compressed air to remove them.
• If there are cracks in the groove, repair or replace.
CAUTION
• If the packing and tank are installed onto the core without
removing foreign substances from the groove, coolant leak-
age will result. Be sure to inspect and clean the tank mount-
ing groove along the entire periphery (even a hair can cause
leakage).
Repairing core
CAUTION
• The core is repaired by means of tungsten inert-gas arc
welding (TIG welding), which should only be performed by a
skilled welder.
• It is extremely dangerous to weld on a wet core. Before
welding, ensure that the core is completely dry.
• Using a stainless wire brush, brush both ends A of the leaky

tube and the areas B around the tube ends until the base alumi-
num is exposed.
• Before closing the tube at both ends by welding, drill a small

breather hole in the tube.
CAUTION
• If a breather hole is not provided, the tube may develop
small pinholes due to escaping air.
• Ground the core at the support.

CAUTION
• If welding is performed without the core properly grounded,
this can lead to short-circuit where the base metal may
melt.
14-21
• Close both end of the tube by tungsten inert-gas arc welding
(TIG welding).
Welding conditions
• Welding rod: A4043 (approx. φ2 mm)
• Welding current: AC80A
• After welding, check for the following problems. If any of them
exist, repair again or replace the core.
• Undercut
• Bead crack
• Base metal crack
CAUTION
• Improper weld can lead to recurrence of coolant leakage.
Installation: Upper tank, Lower tank
• With the tank installed, eliminate any clearance between the
tank and core plate by tapping with a rubber (or plastic) hammer.
CAUTION
• To prevent adhesion of foreign substances, use bare hands
to install the packing and tank.
• Adjust the stopper bolt until the gap dimension shown in the il-
lustration is obtained on the attachment of .
• Follow the sequence shown in the diagram, bend tabs for crimp-
ing tank.
1 to 4: Bend two tabs at the center.
5 to 8: Bend other tabs following the direction of the arrow.
CAUTION
• Since cannot be used to crimp sides 1 and 2, use pli-
ers with the tips wrapped in vinyl tape.
• After crimping the tabs onto the tank, check for coolant
leakage.
14-22
14
• Paint a mark on the core where it can be easily noticed to indi-
cate that the core has been crimped.
CAUTION
• Paint a mark on the core where it can be easily noticed to
indicate that the core has been crimped.
14-23
SURGE TANK
1 Supply hose
2 Air bleeder hose
3 Overflow hose
4 Supply pipe
5 Supply hose
6 Pressure cap
7 Water level sensor
8 O-ring
9 Surge tank
Assembly sequence
verse.

49 ± 9.8 kPa
6 Pressure valve opening pressure – Replace
{0.5 ± 0.1 kgf/cm2)

Clamp 3 to 5 {0.3 to 0.5} –
Water level sensor 3 to 4 {0.3 to 0.4} –
Inspection: Pressure cap
(1) Pressure valve opening pressure
the pressure cap.
14-24
14
(2) Inspection of vent valve
• Check the water level of the reservoir tank in advance.
• Run the engine at high rpm. When the engine coolant overflows
to the reservoir tank to some extent, stop the engine.
• Leave the engine in this condition for a while. When the engine
coolant temperature becomes the atmospheric temperature,
check that the water level in the reservoir tank returns to the wa-
ter level before the engine start.
• If the water level does not lower, the vent valve is defective. Re-
place the pressure cap.
CAUTION
• Do not remove the pressure cap before the engine coolant
temperature drops to the atmospheric temperature. Other-
wise, vacuum in the radiator is lost and the engine coolant
cannot return to the reservoir tank.
Installation: Hose
• The insertion depth of each hose is as shown in the illustration.
14-25
MITSUBISHI 6M70 COOLING FAN AND BELT
Removal sequence
1 Belt (for air conditioner)
*b:
a:Alternator
2
3
Belt (for alternator)
Automatic cooling fan coupling
* Cooler compressor
(for air conditioner)
4 Cooling fan
*c: Water pump
5
6
Fan coupling
Torsional damper
*d: Crankshaft pulley
• The automatic cooling fan coupling cannot be disassembled. If it is found faulty, replace the whole assembly.
CAUTION
• Be careful not to allow engine oil to smear the belt. A belt smeared with oil slips, resulting in reduced
cooling efficiency.
• When replacing the belts, replace them as a set to prevent differences in tension between the two belts.
• After installation, perform the inspection and adjustment of belt tension. (See “ON-VEHICLE INSPECTION AND
ADJUSTMENT.”)

Phone: 269 673 1638
14-26
14
Bolt (fan coupling mounting) 115 {12} –
Nut (automatic cooling fan coupling mounting) 50 {5.0} –
Inspection and cleaning procedure

Inspection: Automatic cooling fan coupling
• Perform the following inspection. If any abnormality is found, re-
place the automatic cooling fan coupling.
• Check for leakage of oil from the coupling body.
• Rotate the automatic cooling fan coupling by hand and check
for irregular movement or abnormal noise caused by a defect
in the bearing.
• Check for excessive axial play in the automatic cooling fan
coupling when the engine is cool.
Cleaning: Automatic cooling fan coupling

• If any foreign particles have adhered to the bimetal, remove
them carefully without applying excessive force.
14-27
MITSUBISHI 6M70 WATER PUMP
1 Snap ring
2 Water pump cover
3 O-ring
4 Water pump pulley
5 Flange
6 Impeller
7 Wire
8 Bearing unit
9 Unit seal
10 Connector
11 Water pump case
12 O-ring
Assembly sequence
verse except for the following.
11 → 8 → 7 → 9 → 6
• See the previous section “DISCON-

NECTION AND CONNECTION OF
HOSES AND PIPES” for the correct
insertion depth of water pump hoses
into the pump as well as the correct
tightening torque of clamps.

Reassembly
5, 8 Interference between flange and bearing unit 0.05 to 0.08 – allowed only
twice
Reassembly
6, 8 Interference between impeller and bearing unit 0.03 to 0.06 – allowed only
twice

Connector 39 {4.0} –

Thread of connector Threebond Sealock 2310 As required

Phone: 269 673 1638
14-28
14
Bolt
A B
MH001102
M6 × 1 60
Removal and installation of snap ring
Nut
A
MF434103
M6 × 1
Water pump pully

puller
MH062411
A B
60 13
Removal of flange
Bolt
A B C
MH000715
26 35 M10 × 1.5
Impeller puller
A B
MH062192 Removal of impeller
φ 10 48
Unit seal installer

A B C
MH062195 Installation of unit seal
9.6 ± φ 12.5±
φ 28
0.03 0.1
Removal procedure
Removal: Snap ring
• Install the and into bolt hole of snap ring, then tighten
and remove the snap ring.
14-29
WATER PUMP
Removal: Flange
Removal: Impeller
Removal: Bearing unit

• Remove the bearing unit using a press. Heating the water pump
case to approximately 80°C will facilitate the removal.
CAUTION
• The ram load applied to remove the bearing unit should not
exceed 9800 N {1000 kgf}.
• When the bearing unit is replaced, always replace the unit
seal.
Inspection: Interference between flange and bearing unit
CAUTION
• Even if the measurement complies with the standard value,
reassembly must not be carried out more than twice.
Inspection: Interference between impeller and bearing unit

CAUTION
• Even if the measurement complies with the standard value,
reassembly must not be carried out more than twice.
14-30
14
Installation: Bearing unit
• Install the bearing unit by ramming down its outer race with the
press until the end face A of the outer race and the end face B of
water pump case meet flush.
CAUTION
• Before installing, check the rotating condition of the bear-
ing unit.
• When installing, do not press the shaft end of the bearing
unit.
Installation: Wire
• Align the groove on the water pump case side with the groove
on the bearing side at the wire inlet before inserting the wire into
the water pump case.
Installation: Unit seal

• Using , install the unit seal until it securely contacts the wa-
ter pump case.
Installation: Impeller
CAUTION
• Before installing an impeller, make sure that there is no or
only one punch mark in the shown location on the impeller.
Make an additional punch mark on the flange to indicate
that it undergoes the disassembly and reassembly process
you are doing now.
• Punch mark(s) indicate the number of times the impeller
was disassembled and reassembled in the past. If there are
two marks, the impeller must be replaced.
• With a press installed against the impeller end face, press fit the
impeller onto the bearing unit until the impeller end face is flush
with the shaft end face of the bearing unit.
14-31
WATER PUMP
Installation: Flange
CAUTION
• Before installing a flange, make sure that there is no or only
one punch mark in the shown location on the flange. Make
an additional punch mark on the flange to indicate that it
undergoes the disassembly and reassembly process you
are doing now.
• Punch mark(s) indicate the number of times the flange was
disassembled and reassembled in the past. If there are two
marks, the flange must be replaced.
• Stand the shaft of the bearing unit on a block as illustrated.

• Place a fixture on the flange and apply the load of a press to it.
• Press the fixture down until the shaft of the bearing unit contacts
the fixture.
CAUTION
• If the flange is installed without the fixture, the water pump
case will be damaged.
Inspection after assembly

Inspection: Flange rotation
• Rotate the flange by hand. The flange should rotate smoothly
without any binding.
• If the flange does not rotate freely, disassemble and check.
14-32
14
M E M O
14-33
MITSUBISHI 6M70 THERMOSTAT
1 Water hose 8 Thermostat 11 Water temperature sensor
2 Bypass pipe (Valve opening temperature <for thermometer>
3 O-ring 82°C) 12 Overheat switch
4 Eyebolt 9 Thermostat 13 Water joint
5 Air bleeding pipe (Valve opening temperature 14 Thermostat case
6 Thermostat cover 88°C) 15 Gasket
7 Rubber ring 10 Water temperature sensor
(for engine control) : Non-reusable parts
• Do not remove the thermostat case unless it has a water leak or any other defect.
• Refer to the previous section “DISCONNECTION AND CONNECTION OF HOSES AND PIPES” for the correct
insertion depth of thermostat cover and case hoses into the pump as well as the correct tightening torque of
clamps.

Phone: 269 673 1638
14-34
14
Valve opening
82 ± 2°C –
8 Thermostat temperature
Valve lift/temperature 10 or more/95°C –
Replace
Valve opening
88 ± 2°C –
9 Thermostat temperature
Valve lift/temperature 10 or more/100°C –

For engine control
Water temperature sensor 39 {40} –
For thermometer
Overheat switch 27 to 41 {2.8 to 4.2} –
Water joint 34 {3.5} Sealant
Eyebolt 25 {2.6} –

Winding around threaded portion of water joint Teflon tape 3.5 turns
Inspection: Thermostat
• Stir the water using a stirring rod to maintain an even water tem-
perature in the container, then conduct the tests indicated below.
the thermostat.
(1) Valve opening temperature
• Hold the thermostat with wire to keep it away from the heat
source.
• Heat the water gradually to the valve opening temperature.
• Maintain this temperature for five minutes and make sure that
the valve is completely open.
• Make sure that the valve closes completely when the water tem-
perature drops below 65°C.
(2) Valve lift
• Maintain the coolant temperature at the specified temperature
for five minutes to keep the valve fully open.
• Measure the valve lift.
14-35
GROUP 15 MITSUBISHI 6M70 INTAKE
AND EXHAUST
SPECIFICATIONS ................................ 15-2 AIR CLEANER ................................... 15-34
STRUCTURE AND OPERATION TURBOCHARGER ............................... 15-36

1. Air Cleaner ...................................... 15-3
2. Turbocharger .................................. 15-4 INTERCOOLER ................................... 15-48
3. Turbocharger Control System ......... 15-5
4. Diesel Particulate Filter .................... 15-8 INTAKE MANIFOLD ............................ 15-50
TROUBLESHOOTING ......................... 15-9 EXHAUST MANIFOLD........................ 15-52
ON-VEHICLE INSPECTION AND ADJUST- EXHAUST PIPE

<FS> ...................................................... 15-54
MENT
<EXCEPT FS>....................................... 15-56
1. Measurement and Adjustment of
Turbocharger Boost Pressure ....... 15-10
DIESEL PARTICULATE FILTER
2. Cleaning and Inspection of
<FS>................................................... 15-58
Air Cleaner Element ...................... 15-12
<EXCEPT FS> .................................... 15-60
3. Check for Looseness in Intake
Manifold Mounting Bolts and
Nuts .............................................. 15-12
4. Check for Cracks and Gas
Leakage in Exhaust Manifold ........ 15-12
5. Check for Cracks and Gas
Leakage in Turbocharger .............. 15-12
TURBOCHARGER CONTROL SYSTEM

1. Diagnosis Procedure ..................... 15-14
2. Diagnostic Precautions ................. 15-14
3. Inspections Based on
Diagnosis Codes .......................... 15-15
4. Multi-Use Tester
Service Data ................................. 15-20
5. Actuator Tests by
Multi-Use Tester ............................ 15-20
6. Inspection of
Electrical Equipment ..................... 15-21
7. Installed Locations of Parts .......... 15-22
8. Electric Circuit Diagram ................ 15-30
15-1
SPECIFICATIONS
/
Item Specifications
Air cleaner element Cyclone filter paper type
Dust indicator type Mechanical
TF08
Model (VG (Variable Geometry: Variable nozzle vane
Turbocharger type) Turbocharger)
Manufacturer Mitsubishi Heavy Industries
Intercooler type Tube and corrugated fin (air cooled)
DPF (Diesel Particulate Filter) Continuous regeneration type
15-2
1. Air Cleaner
• The air cleaner is a single element
type.
• The air cleaner is provided with an un-
loader valve and a vacuator valve.
• When the engine speed drops below a
specified level, the vacuator and un-
loader valves are shaken by a conse-
quent change in internal vacuum to
automatically force out accumulated
water and dust.
15-3
2. Mitsubishi 6M70 Turbocharger
• TF08 model is equipped with turbocharger, which is a variable nozzle vane type turbocharger with adjustable,
heat-resistive alloy turbine vanes provided at the turbine exhaust gas inlet port.

Phone: 269 673 1638
15-4
15
3. Turbocharger Control System
3.1 General description

• The turbocharger control system uses various sensors to detect the status of the engine and controls the turbo-
charger magnetic valves according to sensor output data by means of the engine electronic control unit.
• The turbocharger magnetic valves control the air cylinder movement to optimize the opening of the turbine vanes
according to operating conditions.
• When powertard brake (2nd step) is activated, the turbine vanes are closed, the turbocharger speed is increased
and more air is supplied to the combustion chamber.
15-5
3.2 Electronic Control System

Input signals Engine-electronic control unit Output signals
Starter switch (S) Engine warning lamp

Turbocharger control
Water temperature sensor function
Turbocharger magnetic
Vehicle speed sensor valve
Diagnosis function
Accelerator pedal position sensor
Clutch switch
Engine speed sensor
Boost pressure sensor
Turbine speed sensor
Powertard switch (2nd stage)
Memory clear switch
Diagnosis switch
15-6
15
(2) Diagnosis function
• While the starter switch is on, the diagnosis function is constantly activated to find faults in various sensors. Upon
any sensor being found faulty, the driver is informed of the fault through the display in the meter cluster. At the
same time, the fault is memorized in the form of a diagnosis code and the system starts to effect necessary at-
fault control(s).
• During at-fault control(s), the system is limited in the workings to ensure the safety of the vehicle and driver. The
memorized diagnosis code can be accessed on the Multi-Use Tester screen or through blinking of warning lamp.
• Diagnosis codes are different in the way of indication between the Multi-Use Tester and blinking of the warning
lamp.
• The Multi-Use Tester provides more specific diagnosis codes.
3.3 Electronic control unit connection diagram
15-7
4. Diesel Particulate Filter
• Diesel particulate filter is a large-ca-
pacity system consisting of an ultra-ef-
ficient oxidation catalyst and a filter.
Diesel particulate filter is designed to
efficiently break and capture PM emit-
ted by engines running on low-sulfur
fuel, and the filter is continuously re-
generated.
• The new environmentally-friendly en-
gine has drastically-reduced PM emis-
sion levels. In addition, the ultra-
efficient oxidation catalyst breaks and
treats most of PM emitted from the en-
gine, minimizing PM loading/deposit
onto the subsequent filter. As a result,
the filter is unlikely to clog up even un-
der the driving conditions that require
long hours of drive with relatively low
exhaust gas temperature. Also, active
regeneration, which increases fuel
consumption, is not required.
• The size of the filtration openings has
been optimized to eliminate the de-
posit of ash (product of combustion)
generated in the engine. The filter re-
quires no maintenance, including peri-
odical cleaning.
15-8
TROUBLESHOOTING 15
Symptoms
Abnormal noise or vibration in intake/exhaust

Reference Gr
Excess oil consumption

Poor engine power

White exhaust gas
Black exhaust gas
system
Possible causes
Air cleaner Clogged air cleaner element O O O O
Defective bearing O O O
Carbon deposits on shaft and turbine wheel
O O
unit
Interference between shaft and turbine
O O O
wheel unit and turbine back plate
Interference between shaft and turbine
O O O
wheel unit and turbine housing
Bent shaft and turbine wheel unit O O O
Cartridge assembly
Damaged shaft and turbine wheel unit O O O

Interference between compressor wheel
O O O
and compressor cover
Turbocharger
Seized thrust sleeve and/or thrust bearing O O O
Damaged compressor wheel O O O
Oil leakage due to worn piston ring and/or
O O O
insert
Piston ring fitted poorly O
Defective sliding action between parts due
O O O
to clogged lubrication oil pipe and eyebolt
Oil seals damaged due to clogged oil return
O O
pipe
Compressor cover fitted poorly O O O O
Turbine housing fitted poorly O O
Foreign substances deposited on intercooler front
Intercooler O
core
Front pipe/DPF/tail pipe deformed O O
Front pipe/DPF/tail pipe fitted poorly O O
Incorrect valve clearances O
Head gasket defective O
Wear/carbon deposits on valves and valve seats O
Gr11
Valve spring weakened O
Piston rings worn/damaged O O
Piston ring grooves worn/damaged O O
Cooling system malfunctioning O Gr14
Engine oil quantity excessive O Gr12
Major moving parts seized O O Gr11
Uneven or excessive fuel injection O Gr13
15-9
1. Measurement and Adjustment of Turbocharger Boost Pressure
Service standards
Boost pressure
– (when VGT test performed with ambient temperature at 157 ± 7 kPa – Adjust
25°C and atmospheric pressure at 101.5 kPa)
(1) Preparation
• Put the transmission in N range.
• Turn off all lamps and accessories.
• Connect the Multi-Use Tester.
• Check diagnosis code of each electronic control system. If any
fault exists, rectify it.
• Warm up the engine until the engine coolant has been heated to
more than 60°C. (verify from Service Data “2E: Water Tempera-
ture”)
• Check that the non-load minimum speed (idling speed) is as
specified. (See Gr13.)
(2) Measurement and correction of boost pressure
• Turn the idle adjust dial to any position within the illustrated
range of Mode 1.
• Select [Engine Control] on the system select screen of the Multi-
Use Tester, then execute [BA: VGT Test] from [Actuator Tests].
• When [BA: VGT Test] is executed, the engine speed should be
automatically increased to 1600 rpm (No. 2 magnetic valve acti-
vated).
• Maintain the state of [BA: VGT Test] having been executed (for 5
to 15 minutes) until boost pressure is stabilized.
• Measure the following items from among [Service Data].
26: Boost pressure (actual boost pressure)
2B: Intake air temperature (actual intake air temperature)
30: Atmospheric pressure (actual atmospheric pressure)
• Obtain corrected boost pressure by calculating above Service
Data.
[Correction with intake air temperature]

Corrected boost pressure [kPa] = Measured boost pressure + 0.43
(measured intake air temperature - 25)
[Correction with boost temperature (Exhaust gas recirculation

temperature)]
Corrected boost pressure [kPa] = Measured boost pressure + 0.02
(measured boost temperature - 33)
[Correction with atmospheric pressure]

Corrected boost pressure [kPa] = Measured boost pressure -
(measured atmospheric pressure - 101.5)
• If corrected boost pressure in any case above deviates from the
standard value, adjust the turbocharger.
CAUTION
• If the adjusting range of the air cylinder shaft exceeds ±1.5
turns, check the turbocharger.
15-10
15
(3) Adjustment of turbocharger
WARNING
• The turbocharger is hot for a while after the engine is
stopped. Take care not to burn yourself during adjustment
work.
• To adjust the turbocharger, turn the joint.

• Make sure that the air cylinder is in the state of zero stroke when
the engine is stopped.
• Loosen the position bolts A and B.
• Remove the connecting levers from the air cylinder joint.

• With a wrench put on the flats of the air cylinder shaft, loosen the
nut.
• Turning the joint part of the air cylinder, adjust the length of the
shaft.
Decreased by ap-
Direction A
Adjusting guide: One turn prox. 17 kPa
(with engine speed at 1600 rpm) Increased by approx.
Direction B
17 kPa
CAUTION
• If boost pressure exceeds the standard value, the engine
may malfunction or break down. Boost pressure must be
within the specified range.
• After adjustment, secure the shaft with nut and refit the levers to
the joint.
• Measure boost pressure again.
• If the boost pressure deviates from the standard value, readjust
it.
• Make sure that the air cylinder is in the state of zero stroke when
the engine is stopped.
• Tighten the position bolt A for the illustrated clearance between
the bolt and lever.
• After adjustment, secure the bolt with the lock nut.
• Introduce specified pressure in the air cylinder from the port A,

B, C to bring the air cylinder into the state of full stroke.
• Tighten the position bolt B for the illustrated clearance between
the bolt and lever.
• After adjustment, secure the bolt with the lock nut.
15-11
2. Cleaning and Inspection of Air Cleaner Element
[Cleaning: Element]
• Blow a jet of compressed air at a pressure not higher than 685
kPa {7 kgf/cm2} against the inside surfaces of the element.
CAUTION
• For the frequency and timing of cleaning, refer to the rele-
vant instruction manual. More frequent cleaning than nec-
essary could damage the element or cause dust and foreign
matter to be sucked into the engine.
• Do not strike the element or hit it against another object to
remove dust.
• Do not blow compressed air against outside surfaces of the
element.
[Inspection: Element]
• Shine some electric light inside the element.
• Replace the element if thin spots or broken parts are evident in
the filter paper, or if the packing at the top of the element is dam-
aged.
Also replace the element if the dust on the element is damp with
oily smoke or soot, regardless of the replacement schedule.
3. Check for Looseness in Intake Manifold Mounting Bolts and Nuts

• Check for looseness in the intake manifold and air inlet pipe mounting bolts and nuts. If there is looseness, tighten
the bolts and nuts to the specified torque. (See “INTAKE MANIFOLD”.)
4. Check for Cracks and Gas Leakage in Exhaust Manifold

• Inspect the exhaust manifold visually. If there is any trace of gas leakage or cracks, replace the exhaust manifold.
(See “EXHAUST MANIFOLD”.)
• Check for looseness in the exhaust manifold mounting nuts. If there is looseness, tighten the nuts to the specified
torque. (See “EXHAUST MANIFOLD”.)
5. Check for Cracks and Gas Leakage in Turbocharger

• Inspect the turbocharger visually. If there is any trace of gas leakage or cracks, replace the turbocharger. (See
“TURBOCHARGER”.)
• Check for looseness in the turbocharger mounting bolts and nuts. If there is looseness, tighten the bolts and nuts
to the specified torque. (See “TURBOCHARGER”.)
15-12
15
M E M O
15-13
Warning lamp lit

(See Gr00.)
YES
Test drive
Code issued
No code issued
End of inspection
15-14
15
Code Message
Flashes Red Orange
P0234 Over Boost 54 – O
P1130 VGT1 51 – O
P1132 VGT1 51 – O
P1133 VGT1 51 – O
P1135 VGT2 52 – O
P1137 VGT2 52 – O
P1138 VGT2 52 – O
P1140 VGT3 53 – O
P1142 VGT3 53 – O
P1143 VGT3 53 – O
P1236 Turbine Revolution SNSR (Low) 57 – O
P1237 Turbine Revolution SNSR (High) 57 – O
P1238 Turbine Overrunning 59 – O
P0234: Over Boost (warning lamp flashes: 54)

Boost pressure remaining above the specified value for 10 seconds is repeated
five times when engine speed is at 600 rpm up to 2300 rpm.
• In the case of above problem
• System recovers if boost pressure is below the specified value when en-
gine speed is at 600 rpm up to 2300 rpm.
Recoverability • In the case where above problem is repeated five more times
becomes normal when starter switch is turned OFF (2 minutes or more)
→ ON.
• In the case of above problem
Control effected by electronic control unit • In the case where above problem is repeated five more times
worsen.)
Inspection
Other Turbocharger
15-15
P1130: VGT1 (warning lamp flashes: 51)
Current flowing in the turbocharger magnetic valve (No. 1 magnetic valve) re-
mains above the specified value for 1 second.
System recovers when current flowing in the turbocharger magnetic valve (No.
Recoverability
1 magnetic valve) becomes normal for 1 second.
en.)
Service data 21: VGT position, 82: VGT M/V1
Actuator test A9: VGT1
Inspection
Electrical equipment #566: Turbocharger magnetic valve
Electric circuit diagram Turbocharger magnetic valve (No. 1 magnetic valve) system

Turbocharger magnetic valve (No. 1 magnetic valve) circuit shorted to ground
or open-circuited (low level when turned OFF) as detected for 1 second.
Recoverability
1 magnetic valve) becomes normal (high level when turned OFF) for 1 second.
en.)
Inspection

Turbocharger magnetic valve (No. 1 magnetic valve) circuit shorted to battery
(high level when turned ON) as detected for 1 second.
Recoverability
1 magnetic valve) becomes normal (low level when turned ON) for 1 second.
en.)
Inspection
15-16
15
Recoverability
en.)
Actuator test AA: VGT2
Inspection

Recoverability
en.)
Inspection

Recoverability
en.)
Inspection
15-17
Recoverability
en.)
Actuator test AB: VGT3
Inspection

Recoverability
en.)
Inspection

Recoverability
en.)
Inspection
15-18
15
P1236: Turbine Revolution SNSR (Low) (warning lamp flashes: 57)
Turbine speed remains 3000 rpm or less for 10 seconds when engine speed is
1000 rpm or more.
System recovers if turbine speed remains higher than 3000 rpm for 1 second
Recoverability
when engine speed is 1000 rpm or more.
Service data 2A: Turbine Revolution
Inspection Electrical equipment #835: Turbine speed sensor and pulse converter
Electric circuit diagram Turbine speed sensor and pulse converter system
P1237: Turbine Revolution SNSR (High) (warning lamp flashes: 57)

Generation condition Turbine speed remains 125000 rpm or more for 10 seconds.
System recovers when turbine speed remains less than 125000 rpm for 1 sec-
Recoverability
ond.
Control effected by electronic control unit Turbocharger control is stopped.
Inspection Electrical equipment #835: Turbine speed sensor and pulse converter
P1238: Turbine Overrunning (warning lamp flashes: 59)

Generation condition Turbine speed remains 105000 rpm or more for 1 second.
System recovers if signal becomes normal when starter switch is turned from
Recoverability OFF (2 minutes or more) to ON (power supply resumed to electronic control
unit).
• Injection quantity is stopped. (Output is reduced, and exhaust emissions
Control effected by electronic control unit worsen.)
Electrical equipment #835: Turbine speed sensor and pulse converter
Inspection
Other Turbocharger unit
15-19

VGT opening degrees displayed according to VGT M/V operations
21 VGT Position . %
shown below.
Value matches atmospheric
pressure indication.
26 Boost Pressure . kPa
Accelerator pedal pressed after en-
gine has started
2A Turbine Revolution .rpm Engine speed: 2280 to 2320 rpm 50000 to 80000 rpm
No. 1 magnetic valve ON ON
82 VGT M/V1 ON/OFF No. 1 magnetic valve OFF OFF
[Actuator test] A9: VGT1
[Actuator test] AA: VGT2
[Actuator test] AB: VGT3
VGT opening (%) 0 to 12.5 to 25 to 37.5 to 50 to 62.5 to 75 to 87.5 to 100

M/V1 ON OFF ON OFF ON OFF ON OFF
M/V2 ON ON OFF OFF ON ON OFF OFF
M/V3 ON ON ON ON OFF OFF OFF OFF
5. Actuator Tests by Multi-Use Tester

No. Item Description Check method
Magnetic valve operating sound
A9 VGTM/V1 No. 1 magnetic valve activated [Service data]
82: VGT M/V1
AA VGTM/V2 No. 2 magnetic valve activated [Service data]
83: VGT M/V2
AB VGTM/V3 No. 3 magnetic valve activated [Service data]
84: VGT M/V3
Used for turbo boost pressure measurement/ad- See On-Vehicle Inspection and Ad-
BA VGT Test
justment justment.
15-20
15
6. Inspection of Electrical Equipment
#566 Inspection of turbocharger magnetic valve

• Perform the following tests on the turbocharger magnetic valve.
Replace the valve if found faulty.
(1) Valve activation test
• Gradually increasing from 0 V, apply voltage to the turbocharger
magnetic valve between the following terminals.
1-3 No. 1 magnetic valve
4-pin connector
Terminals 2-4 No. 2 magnetic valve
2-pin connector 1-2 No. 3 magnetic valve
• Measure voltage when turbocharger magnetic valve is activated.
(Listen to the operating sound for ON/OFF of the magnet valve.)
Reference value
18 V or less
(minimum activation voltage)
(2) Continuity and air tight test

• Test air pressure: 981 kPa {10 kgf/cm2}
#835 Inspection of turbine speed sensor and pulse converter

unit
• Test the turbine speed sensor and pulse converter unit as con-
nected to the turbocharger.
• Disconnect the turbine speed sensor and pulse converter unit
from the electronic control unit harness at connectors. Then,
prepare and fit the test harness in place.
• The sensor does not respond to manual rotation of the turbo-
charger compressor wheel. To make the sensor responsive,
start the engine to be idling.
• Measure the maximum level (high-pulse voltage) and minimum
level (low-pulse voltage) of voltage appearing between test con-
nector terminals 4 and 1.
Low-pulse voltage 0V
Standard value
High-pulse voltage 5V
• If the measurement deviates the standard value, replace the tur-
bine speed sensor and pulse converter unit.
15-21
7. Installed Locations of Parts
15-22
15
15-23
15-24
15
15-25
15-26
15
15-27
15-28
15
M E M O
15-29
8. Electric Circuit Diagram
15-30
15
15-31
15-32
15
M E M O
15-33
AIR CLEANER
Removal sequence
1 Dust indicator 5 Duct joint hose 9 Safety element
2 Air tube 6 Air intake hose 10 Body
3 Vacuator valve 7 Cover
4 Lower air duct 8 Outer element
CAUTION
• Do not remove the safty element except for replacement.
• Never clean the safty element.
Service standards
9.12 ± 0.69 kPa
1 Dust indicator activating negative pressure – Replace
{930 ± 70 mmH2O}

Clamp 3.0 to 3.5 {0.3 to 0.35} –
15-34
15
Cleaning procedure
Cleaning: Element
• Blow a jet of compressed air at a pressure not higher than 685
kPa {7 kgf/cm2} against the inside surfaces of the element.
CAUTION
• For the frequency and timing of cleaning, refer to the rele-
vant instruction manual. More frequent cleaning than nec-
essary could damage the element or cause dust and foreign
matter to be sucked into the engine.
• Do not strike the element or hit it against another object to
remove dust.
• Do not blow compressed air against outside surfaces of the
element.
Inspection: Element
• Shine some electric light inside the element.
• Replace the element if thin spots or broken parts are evident in
the filter paper, or if the packing at the top of the element is dam-
aged.
Also replace the element if the dust on the element is damp with
oily smoke or soot, regardless of the replacement schedule.
Inspection: Operation of dust indicator under specified neg-

ative pressure
• Apply negative pressure to the dust indicator, and take the read-
ing when the red signal appears in the dust indicator window.
• Replace the dust indicator if found faulty.
15-35
MITSUBISHI 6M70 TURBOCHARGER ATTACHING PARTS
Removal sequence
1 Air inlet pipe 11 Gasket 20 Turbocharger magnetic valve
2 Air hose 12 Turbine speed sensor bracket
3 Air pipe 13 O-ring 21 Bracket
4 Air hose 14 Eyebolt 22 Turbocharger (See later sec-
5 Turbocharger coupler bracket 15 Eyebolt tion.)
6 Turbocharger coupler 16 Air pipe 23 Gasket
7 Seal ring 17 Air hose
8 Eyebolt 18 Connector
*a: Exhaust manifold
9 Oil feed pipe 19 Turbocharger magnetic valve : Non-reusable parts
10 Oil return pipe

Phone: 269 673 1638
15-36
15
Clamp 7.0 to 8.0 {0.7 to 0.8} –
Eyebolt (oil pipe mounting)
21 {2.1} –
Eyebolt (air pipe mounting)
Eyebolt (air pipe mounting) 25 {2.5} –
Nut (turbocharger mounting) 36 {3.7} –
Nut (turbocharger mounting) 45 {4.6} –
Nut (turbocharger coupler bracket mounting) 90 {9.0} –
Bolt (turbocharger magnetic valve bracket mounting) 75 {7.6} –

Turbocharger (to be filled with engine oil) Engine oil As required
Installation: Mitsubishi 6M70 Turbocharger
• Before installing the turbocharger assembly, pour engine oil into
the oil hole of the bearing housing to ensure smooth operation of
the internal parts.
Installation: Mitsubishi 6M70 Seal ring

• Fit the seal rings onto the turbocharger coupler, with their end
gaps positioned 180 degrees apart from each other.
Installation: Bracket
• Temporarily tighten the bracket on the air pipe and exhaust man-
ifold.
• Tighten the bolts after temporary tightening while ensuring that
there is no clearance at the joints between the bracket and air
pipe, and bracket and exhaust manifold.
• After installing the bracket, ensure that there is no gas leakage
from the joint of turbocharger with exhaust manifold.

Phone: 269 673 1638
15-37
TURBOCHARGER
Mitsubishi 6M70 Turbocharger
1 Connecting lever 7 Nozzle 13 Turbine housing
2 Spacer 8 Flange 14 Cartridge assembly
3 Joint 9 Snap ring (See later section.)
4 Air cylinder 10 Compressor cover
5 Bracket 11 O-ring : Non-reusable parts
6 Clamp bolt 12 Clamp plate
Assembly sequence

2 Spacer outside diameter – φ11.5 Replace
3 Joint inside diameter – φ12.5 Replace
Stroke Port A 12 –
(operating air pressure:
Port B 6 –
390 to 785 kPa {4 to 8 kgf/
2} when compressed air
4 Air cylinder cm Replace
Port C 3 –
introduced)
Airtight test (390 to 785 kPa {4 to 8 No air leakage of 25 cm2 –
kgf/cm2}) {25 mL} for 1 minute
7 Play between nozzle lever plate and link 0.05 to 0.40 1.0 Replace
Clearance between compressor cover and compressor
10, 14 0.08 to 0.28 – Check parts
wheel
Play in axial direction of shaft and tur-
0.075 to 0.155 – Check parts
Cartridge as- bine wheel
14
sembly Shaft and turbine wheel-to-turbine
0.48 to 0.92 – Check parts
back plate clearance
15-38
15
Bolt (bracket mounting) 34 to 38 {3.5 to 3.9} Wet
Clamp bolt 6.4 to 7.4 {0.65 to 0.75} Wet
Bolt (clamp plate mounting) 25.5 to 27.4 {2.6 to 2.8} Wet

Threads of clamp bolt Seizure preventive compound
As required
Threads of mounting bolt (FEL-PRO CA-5)
Work before removal

Alignment mark
• Put alignment marks on the coupling, turbine housing, compres-
sor cover and cartridge assembly.
Removal procedure
Removal: Nozzle
• Remove the flange and nozzle in one unit from the turbine hous-
ing.
• Remove the clamp bolt, then remove the nozzle from the flange.

Phone: 269 673 1638
15-39
TURBOCHARGER
Removal: Snap ring
• Tighten the bolt to contract the snap ring and remove the ring.
Removal: Compressor cover

• Lightly tap around the entire periphery of the compressor cover
with a rubber-faced hammer, taking care not to cause damage.
CAUTION
• The blades on the cartridge assembly are easily bent. Make
sure that they do not strike the compressor cover.
Removal: Turbine housing

• Lightly tap around the entire periphery of the turbine housing
with a rubber-faced hammer, taking care not to cause damage.
CAUTION
• The blades of the turbine wheel on the cartridge assembly
are easily bent. Make sure that they do not strike the turbine
housing.
Work after disassembly

Cleaning
• Before cleaning, visually check the disassembled parts for
scorches, abrasion and other marks that may be difficult to see
after cleaning. Replace any part that appears defective.
• Immerse the disassembled parts in a non-flammable solvent (a
5 to 10 aqueous solution of Oil Clean from New Hope Co., Ltd.).
Take out the parts and blow them dry with compressed air. Re-
move any hard deposits with a stiff brush or plastic scraper.
• Again, immerse the parts in the solvent.
• Blow them dry using compressed air.
Inspection: Spacer outside diameter
• If the measurement is less than the specified limit, replace the
spacer.
15-40
15
Inspection: Joint inside diameter
• If the measurement exceeds the specified limit, replace the joint.
Inspection: Air cylinder

(1) Stroke
• Apply specified air pressure to the ports (A to C) in the air cylin-
der, one at a time, and measure the corresponding strokes of
the air cylinder.
the air cylinder.
(2) Airtight test

• Apply specified air pressure to the ports (A to C) in the air cylin-
der, one at a time, and measure air leakage per minute using an
air breather.
• If the measurement exceeds the standard value, replace the air
cylinder.
Inspection: Nozzle
• Move the ring assembly of the nozzle all the way by hand from
“full opening” to “full closing” and measure its travel with a dial
gauge A.
• Position the ring assembly roughly in the middle of measured
length of its travel.
• To center and hold the ring assembly and mount in place, use
appropriate shims equally spaced at 3 places between them.
Type of shim
• Width × length: 5 mm × 10 mm
• Thickness: 0.1 mm to 0.4 mm
• Measure the play between each lever plate and ring with the dial
gauge B. If any of the measurements exceeds the specified limit,
replace the nozzle.
Inspection: Clearance between compressor cover and com-
pressor wheel
• Measure the maximum runout A of the compressor wheel when
the wheel is moved in vertical direction.
• Measure the outside diameter B of the compressor wheel.
CAUTION
• Do not rotate the compressor wheel for axial play measurement.
15-41
TURBOCHARGER
• Measure the inside diameter C of the compressor cover.
• Calculate the clearance between compressor wheel and com-
pressor cover as follows.
Clearance=
C-B-A
2
• If the clearance deviates from the specified standard value
range, disassemble and correct.
Inspection: Cartridge assembly

(1) Play in axial direction of shaft and turbine wheel
• If the measurement exceeds the specified limit, disassemble
and check the parts.
(2) Shaft and turbine wheel-to-turbine back plate clearance

• Measure the clearance between the turbine back plate and shaft
and turbine wheel unit.
• Be sure to measure the clearance at the periphery of the blades
using two feeler gauges.
• If the measurement deviates from the standard value, disassem-
ble the cartridge assembly, inspect and check the parts.
Installation: Turbine housing
• Install the cartridge assembly into the turbine, then perform the
following test.
(1) Rotating condition of cartridge assembly
• Turn the wheels of the cartridge assembly. They should turn
smoothly.
• If not, disassemble the cartridge assembly, inspect and check
the parts.
Installation: Nozzle
• Fit the nozzle in the flange.
• In fitting, turn the nozzle and flange so that the control crank and
ring properly engage each other
15-42
15
Installation: Snap ring
• Turn the snap ring in its mounting groove to confirm proper seat-
ing of the ring. After confirmation, loosen the bolt and fit the ring
securely.
Work after installation

Adjustment: Positioning of air cylinder
(1) Full closing position
• Remove the position bolt B, then move the lever all the way in
the illustrated direction.
(2) Temporary tightening of position bolt

• Reinstall the position bolt B, and drive it in until it contacts the le-
ver.
• Mark the position bolt B at that position, give it 5 and half turns,
then tighten the lock nut to secure the position bolt B.
(3) Readjustment for full closing position

• Introduce specified pressure in the air cylinder from the port A,
B, C and bring the air cylinder into the state of full stroke, then
connect the lever to the joint.
• Make sure that the lever is in slight contact with the position bolt
B. If there is an open space between the lever and position bolt
B or the lever is pushing the position bolt B, loosen the lock nut
and make necessary adjustment by turning the shaft. Then,
tighten the lock nut.
• Back up the position bolt B a half turn for a clearance of approxi-
mately 0.5 mm between the bolt and lever, then tighten the lock
nut to secure the position bolt B in that position.
(4) Full opening position
• Release compressed air to bring the air cylinder into the sate of
zero stroke. Adjust the position bolt A for a clearance of 0.5 mm
between the bolt and lever, then tighten the lock nut to secure
the bolt in that position.
15-43
MITSUBISHI 6M70 TURBOCHARGER PARTS
Cartridge Assembly
1 Lock nut 8 Thrust ring 15 Snap ring
2 Compressor wheel 9 Thrust bearing 16 O-ring
3 Snap ring 10 Thrust ring 17 Bearing housing
4 Insert 11 Shaft and turbine wheel
5 Piston ring 12 Piston ring : Non-reusable parts
6 Thrust sleeve 13 Turbine back plate
7 Oil deflector 14 Bearing
Assembly sequence

Turbine housing-to-shaft and tur-
0.39 to 1.0 – Replace
bine wheel clearance
Shaft and turbine
11
wheel Bearing journal outside diameter – 11.996 Replace
Shaft bend – 0.015 Replace
Outside diameter – 20.382 Replace
14 Bearing Inside diameter – 12.042 Replace
Length – 11.94 Replace
Inside diameter of bearing insertion bore in bearing
17 – 20.506 Replace
housing

Phone: 269 673 1638
15-44
15
Thread-locking
Lock nut 20 {2.0}
compound

Thread of lock nut Molykote BR-2 Plus As required
O-ring
Piston ring Engine oil As required
Bearing
Removal procedure
Removal: Compressor wheel
• Secure the turbine housing in a vise.
• Fit the turbine wheel side of the cartridge assembly into the tur-
bine housing.
• Hold the boss on the shaft and turbine wheel unit to prevent the
cartridge assembly from turning.
• Loosen and remove the lock nut.
Inspection: Turbine housing-to-shaft and turbine wheel

clearance
the defective part.
Removal: Snap ring

• Remove the snap ring.
CAUTION
• Remove the snap ring while holding it with your hand to
prevent it from springing off.
15-45
TURBOCHARGER
Removal: Insert
Inspection: Shaft and turbine wheel
[Inspection]
(1) Journal outside diameter
• If the measurement exceeds the specified limit or uneven wear
is excessive, replace the shaft and turbine wheel unit.
• Inspect the journal visually and recondition it if roughened.
(2) Shaft bend

• Set a dial gauge at the illustrated position on the shaft. Turning
the shaft slowly, measure the extent of bending.
• If the measurement exceeds the specified limit, replace the shaft
[Reconditioning]
• Attach the shaft and turbine wheel unit to a lathe, supporting it at
both centers.
• With the shaft and turbine wheel unit turning at 300 to 600 rpm,
smooth the journal using sandpaper (#400) and engine oil.
• Measure the outside diameter of the bearing contact portion. If
the measurement exceeds the specified limit, replace the shaft
Inspection: Bearing
bearing.
15-46
15
Inspection: Bearing housing
bearing housing.
Installation: Thrust bearing
• Install the shaft and turbine wheel unit, fitted in the bearing hous-
ing, in the turbine housing. Fasten it in place temporarily with the
coupling.
CAUTION
• When installing the shaft and turbine wheel unit, make sure
that its blades are not damaged by striking the turbine
housing because they are easily bent.
• Fit the thrust bearing onto the shaft and turbine wheel unit.
CAUTION
• Before installing the thrust bearing, wipe off dirt and oily
substance completely from the stepped area of the shaft
and both sides of the thrust ring using dry tissue paper or
the like.
Installation: Insert
• Fit the piston ring onto the thrust sleeve, then fit it into the insert,
its end gap first, taking care that it is not damaged.
CAUTION
• When fitting the piston ring, use care not to open it exces-
sively or twist its end gap portion.
• Fit necessary parts in the insert first, then fit the insert into the
bearing housing.
CAUTION
• Before installing the insert, wipe off dirt and oily substance
completely from both end faces of the thrust sleeve using
dry tissue paper or the like.
Installation: Snap ring

• Place the snap ring in the bearing housing in the illustrated di-
rection using a pair of snap ring pliers.
• Then, using a screwdriver, tap the snap ring at its break ends
into place in the mating groove of the bearing housing.
CAUTION
• Fit the snap ring while holding it with your hand to prevent
it from springing off.
15-47
INTERCOOLER
Removal sequence
1 Air inlet hose
2 Air outlet hose
3 Intercooler
*a: Turbocharger
*b: Intake throttle
CAUTION
• When removing the air inlet hose,
do not try to pry it off with strong
force using a screwdriver or other
similar tools. Doing that can dam-
age the fluorolayer on the inner sur-
face of the hose, possibly
compromising the oil resistance of
the hose.
Service standards
Intercooler air leakage
3 0 cm3 {0 mL} – Replace
(at air pressure of 147 kPa {1.5 kgf/cm2})

Clamp 7 to 8 {0.7 to 0.8} –
Inspection: Intercooler
• Plug one of the air ports of the intercooler and immerse it in a
tank of water. Apply the specified air pressure to the intercooler
through the other air port.
• If leakage is apparent, replace the intercooler.
15-48
15
Installation: Air inlet hose
• Fit the air inlet hose to the intercooler and air inlet pipe to the il-
lustrated dimension.
Installation: Air outlet hose

• Fit the air outlet hose to the intercooler and air inlet pipe to the il-
15-49
MITSUBISHI 6M70 INTAKE MANIFOLD
1 Eyebolt 5 Bracket 10 Intake manifold
2 Boost pressure sensor 6 Air inlet pipe 11 Gasket
3 Intake air temperature sensor 7 Gasket
4 Intake air temperature sensor
(dummy)
8
9
Spacer
Gasket
*a:: Cylinder head (See Gr11.)
Non-reusable parts
Assembly sequence

Bolt (intake manifold mounting)
Bolt (air inlet pipe mounting)
54 {5.5} –
Bolt (bracket mounting)
Nut (air inlet pipe mounting)
Eyebolt 21 {2.1} –
Bolt (boost pressure sensor mounting) 4 to 6 {0.4 to 0.6} –
Intake air temperature sensor 1 20 {2.0} –
Intake air temperature sensor 2 25 ± 5 {2.5 ± 0.5} –
15-50
15
Inspection: Intake air temperature sensor
• Check that the sensor portion is free of soot, oily substance, etc.
• If not, clean the sensor portion as follows.
• Spray a cleaner on the sensor portion from 2 or 3 cm away.
Recommended cleaners:
Wako Chemical brake and parts cleaner from Wako Chemical
Trusco Nakayama brake and parts cleaner ALP-BP
Chemsearch Lexite LO
• In 20 to 30 seconds after spraying, wipe the sensor portion clear
of the sprayed cleaner using a soft waste cloth or the like.
CAUTION
• Be sure to wait for 20 or 30 seconds before wiping. It takes
the cleaner that long to dissolve foreign matter.
• If the sensor portion is fouled excessively, the positive crankcase

ventilation (PCV) may be faulty. Inspect the PCV valve and filter
to locate the cause and remove it.
15-51
MITSUBISHI 6M70 EXHAUST MANIFOLD
1 Insulator 5 Rear exhaust manifold 9 Exhaust Manifold Gaskets
2 Front exhaust manifold 6 Seal ring
3 Seal ring
4 Exhaust Manifold Expansion rings
7
8
Expansion ring
Center exhaust manifold
*a:: Cylinder head (See Gr11.)
Non-reusable parts
Assembly sequence

Nut (exhaust manifold mounting) 42 {4.2} –

Torque wrench
A MH063080 Installation of exhaust manifold

Double flat
surfaced 14

Phone: 269 673 1638
15-52
15
Installation: Mitsubishi 6M70 Expansion rings and seal rings
• Fit the seal rings with their end gaps positioned 120 degrees
apart from each other.
• Fit the expansion rings so that their crests do not meet the end
gaps of the seal rings.
• Fit the seal rings with their chamfered sides facing the center ex-
haust manifold.
Installation: Mitsubishi 6M70 Exhaust manifold
15-53
EXHAUST PIPE <FS>
1 Lower front pipe 7 Clamp 13 Clamp
2 Gasket 8 Exhaust pipe cover 14 Upper front pipe
3 Gasket 9 Clamp
4
5
Rubber cushion
Exhaust pipe hanger
10
11
Center front pipe
Gasket
*a:: Diesel Particulate Filter
Non-reusable parts
6 Stay 12 Rubber cushion

Nut (upper front pipe mounting)
Nut (center front pipe mounting) 85 to 110 {8.7 to 11.0} –
Nut (lower front pipe mounting)
Bolt (clamp mounting) 20 ± 3 {2.1 ± 0.3} –
15-54
15
Installation: Rubber cushions
• Tighten the rubber cushions until they are compressed to the
thickness A.
Location of rubber cushion Compressed thickness

Upper front pipe 10 mm
Lower front pipe 23 mm
15-55
EXHAUST PIPE <EXCEPT FS>
1 Spring 6 Seal ring 11 Exhaust pipe clamp bracket
2 Washer 7 Gasket
3 Clamp 8 Upper front pipe
*a: Diesel Particulate Filter
4
5
Lower front pipe
Washer
9
10
Gasket
Rubber cushion
*b:: Turbocharger coupler
Non-reusable parts

Bolt (lower front pipe mounting) 44 ± 10 {4.5 ± 1.0} –
Nut (upper front pipe mounting) 85 to 110 {8.7 to 11.0} –
• Tighten the rubber cushions until they are compressed to the il-
15-56
15
M E M O
15-57
DIESEL PARTICULATE FILTER <FS>
1 Clamp 6 Gasket 11 DPF
2 Tail pipe 7 DPF band
3
4
Stay
Rubber cushion
8
9
Stay
Rubber cushion
*a::Front pipe
Non-reusable parts
5 Collar 10 Collar DPF: Diesel Particulate Filter
Assembly sequence

Nut (clamp tightening) 54 ± 10 {5.5 ± 1.0} –
Nut (front pipe mounting) 85 to 110 {8.6 to 11.0} –
Bolt (clamp tightening) 20 ± 3 {2.1 ± 0.3} –
15-58
15
Inspection: DPF
• Check the inner exhaust channel of DPF for clogging with for-
eign material.
• If clogged, the inner exhaust channel must be cleaned with com-
pressed air or DPF must be replaced.
• If DPF is clogged, this may be due to problems with the engine.
Check the engine and adjust as required. Also check the engine
oil and fuel.
Installation: DPF
• Insert the DPF pipe into the tail pipe until the DPF pipe bottoms
out against the expanded portion of the tail pipe.

• Compress the rubber cushions until the dimensions shown in
the illustration are achieved.
Installation: Clamps
• Tighten the nuts just enough to loosely retain the clamps so that
they can easily be moved.
• Tighten the nut at A until the ends of the clamps at A contact with
each other.
• Completely tighten the nut at B.
CAUTION
• Do not overtighten the nut at B, or the clamps and DPF may
become damaged.
15-59
DIESEL PARTICULATE FILTER <EXCEPT FS>
1 Spring 7 Muffler plate
*a: Front pipe
2 Washer 8 DPF cover : Non-reusable parts
3 Seal ring 9 DPF insulator
4 Clamp 10 DPF DPF: Diesel Particulate Filter
5 Tail pipe 11 Bracket
6 Muffler plate
Assembly sequence

Bolt (front pipe mounting) 34 to 54 {3.5 to 5.5} –
Nut (DPF mounting) 70 to 95 {7.1 to 9.7} –
Nut (bracket mounting) 306 to 360 {31 to 37} –
Nut (bracket mounting) 20 ± 3 {2.1 ± 0.3} –
15-60
15
Inspection: DPF
• Check the inner exhaust channel of DPF for clogging with for-
eign material.
• If clogged, the inner exhaust channel must be cleaned with com-
pressed air or DPF must be replaced.
• If DPF is clogged, this may be due to problems with the engine.
Check the engine and adjust as required. Also check the engine
oil and fuel.
Installation: Clamps and rubber cushions

• Tighten the nuts just enough to loosely retain the clamps so that
they can easily be moved.
• Tighten the nut at A until the ends of the clamps at A contact with
each other.
• Completely tighten the nut at B.
CAUTION
• Do not overtighten the nut at B, or the clamps and DPF may
become damaged.
15-61
GROUP 17 MITSUISHI 6M70
EMISSION CONTROL
1. Exhaust Gas Recirculation System ............................................... 17-2
2. Blowby Gas Return System .......................................................... 17-7

1. Replacement of Positive Crankcase Ventilation Valve Element ..... 17-8
2. Check for Cracks and Damages in Piping of Blowby Gas
Return System .............................................................................. 17-8
3. Check for Cracks, Damages and Looseness in Piping of
Exhaust Gas Recirculation System ............................................... 17-8
EXHAUST GAS RECIRCULATION SYSTEM

1. Diagnosis Procedure .................................................................. 17-10
2. Diagnostic Precautions .............................................................. 17-10
3. Inspections Based on Diagnosis Codes ......................................17-11
4. Multi-Use Tester Service Data ..................................................... 17-14
5. Actuator Tests Performed Using Multi-Use Tester....................... 17-14
6. Inspections Performed at Electronic Control Unit Connectors.... 17-14
7. Inspection of Electrical Equipment ............................................. 17-16
8. Installed Locations of Parts ........................................................ 17-18
9. Electric Circuit Diagram .............................................................. 17-24
EGR VALVE, EGR MAGNETIC VALVE, EGR PIPE AND

EGR COOLER................................................................................... 17-26
BLOWBY GAS RETURN SYSTEM .................................................. 17-29
17-1
1. Exhaust Gas Recirculation System
1.1 Overview
• In the exhaust gas recirculation system, various engine-related information (engine speed, water temperature, ac-
celerator position) is collected by the relevant sensors and is sent to the engine electronic control unit and EGR
EDU which then control the EGR magnetic valves based on the information received.
• EGR achieves lower combustion temperatures by reintroducing combusted exhaust gas (which contains inert
gases) into the intake manifold. This has the effect of reducing the amount of harmful NOx (nitrogen oxides)
formed in the engine. The EGR cooler enhances the NOx (nitrogen oxides) reducing performance of the EGR
system by cooling the mixed exhaust gas to lower maximum combustion temperature.
17-2
17
(1) EGR magnetic valves
• The EGR magnetic valves are each turned ON/OFF by drive signals from the engine electronic control unit to re-
alize a 7-stage supply of air to the EGR valve.
(2) Mitsubishi 6M70 EGR valve
• The EGR valve realizes 7 stages of valve lift in accordance with the supply of air to its input ports from the EGR
magnetic valves.
17-3
1.2 Electronic control system
Input signals Engine electronic control unit Output signals
Engine speed sensor Engine warning lamp

Exhaust gas recircula-
Water temperature sensor tion control function
Accelerator pedal position

sensor Fault diagnosis
function
Intake air temperature
sensor
Electronic drive unit relay
Memory clear switch
Diagnosis switch
Multi-Use Tester connector
EGR EDU
EGR: Exhaust gas recirculation
EDU: Electronic drive unit
EGR magnetic valve
: Electrical signal
: Controller area network signal
17-4
17
(2) Exhaust gas recirculation valve control function
• Based on inputs from various sensors, the engine electronic control unit determines the degree of opening of the
exhaust gas recirculation valve and sends corresponding control signals to the exhaust gas recirculation electron-
ic drive unit to activate the exhaust gas recirculation magnetic valve.
In the case of black smoke emission or engine speed instability, which may occur when the engine is heavily load-
ed or lightly loaded, or when the auxiliary brake is operating, the engine electronic control unit stops exhaust gas
recirculation valve control.
(3) Fault diagnosis function
• While the starter switch is in the ON position, the engine electronic control unit continuously monitors exhaust gas
recirculation electronic drive unit, the sensors and other control elements for faults. In the event that the engine
electronic control unit finds a component faulty, it causes an indication to be made in the meter cluster to alert the
driver. At the same time, it memorizes the fault location in the form of a diagnosis code.
• While the engine is running, the exhaust gas recirculation electronic drive unit continuously monitors the status of
communication with the exhaust gas recirculation magnetic valve and engine electronic control unit. When the ex-
haust gas recirculation electronic drive unit detects a fault, it sends the information to the engine electronic control
unit.
• While the control during fault is taking place, the system’s functionality is limited to ensure vehicle and driver safe-
ty. It is possible to read the memorized diagnosis code using a Multi-Use Tester or from flashing of the warning
lamp.
17-5
1.3 Electronic control unit connection diagram
17-6
17
2. Blowby Gas Return System
• The blowby gas return system is designed to introduce blowby gases into the intake air duct for reburning, thus
preventing the gases from being released to the atmosphere.
• The positive crankcase ventilation valve keeps constant the pressure inside the crankcase.
• The oil in the blowby gas is separated by the wire mesh and the element in the oil separator and the positive
crankcase ventilation valve and is returned to the oil pan.
• When the element is clogged, the regulator valve opens and the blowby gas flows to the positive crankcase venti-
lation hose without passing through the element.
17-7
1. Replacement of Positive Crankcase Ventilation Valve Element

CAUTION
• For information on the element replacement interval, refer
to the element instruction manual. If the element is used be-
yond its replacement interval, it may become clogged,
causing the pressure inside the engine to increase such
that oil leakage occurs.
[Removal]
• Loosen the cap by hand.
CAUTION
• Do not use any tools to loosen the cap. Otherwise, the cap
may become damaged.
[Installation]
• Clean the thread on the cap.
• Lightly smear the O-ring with engine oil and fit it on the cap.
• Securely tighten the cap until it stops slightly above the positive
crankcase ventilation body.
CAUTION
• Be sure to use a genuine Mitsubishi Fuso element. Using an
inappropriate element could result in engine trouble.
• When replacing the element, be sure to replace the O-ring
also.
2. Check for Cracks and Damages in Piping of Blowby Gas Return System
• Inspect the piping of blowby gas return system visually. If there is any cracks or damages, replace the piping.
(See “BLOWBY GAS RETURN SYSTEM”.)
3. Check for Cracks, Damages and Looseness in Piping of Exhaust Gas Recircula-
tion System
• Inspect the exhaust gas recirculation pipe visually. If there is any cracks or damages, replace the pipe. (See “EGR
VALVE, EGR PIPE AND EGR COOLER”.)
• Check for looseness in the exhaust gas recirculation pipe mounting bolts and nuts. If there is looseness, tighten
the bolts and nuts to the specified torque. (See “EGR VALVE, EGR PIPE AND EGR COOLER”.)
17-8
17
M E M O
17-9
Warning lamp lit

(See Gr00.)
YES
Test drive
Code issued
No code issued
End of inspection
17-10
17
• Diagnosis codes shown by the Multi-Use Tester and those indicated by warning lamp display are different.
Code Message
Flashes Red Orange
P0112 INT Air Temp SNSR (Low) 44 – O
P0113 INT Air Temp SNSR (High) 44 – O
P1267 EGR 1 67 – O
P1268 EGR 1 67 – O
P1272 EGR 2 68 – O
P1273 EGR 2 68 – O
P1277 EGR 3 69 – O
P1278 EGR 3 69 – O
P1625 EDU Relay 84 – O
P1630 CAN (EGR 1) 95 – O
P0112: INT Air Temp SNSR (Low) (warning lamp flashes: 44)
Generation condition Intake air temperature sensor 1 voltage remains lower than 0.15 V for 3 seconds.
System recovers if intake air temperature sensor 1 voltage remains higher than
Recoverability
0.15 V for 1 second.
Control effected by electronic control unit Carries out control using a backup value (25°C).
Inspection
Electrical equipment #305: Intake air temperature sensor
P0113: INT Air Temp SNSR (High) (warning lamp flashes: 44)
Intake air temperature sensor 1 voltage remains higher than 4.85 V for 3 sec-
onds.
System recovers if intake air temperature sensor 1 voltage remains lower than
Recoverability
4.85 V for 1 second.
Control effected by electronic control unit Carries out control using a backup value (25°C).
Inspection
Electrical equipment #305: Intake air temperature sensor
P1267: EGR1 (warning lamp: 67)

Controller area network signal from exhaust gas recirculation electronic drive unit
Generation condition indicating “magnetic valve (M/V-1) circuit shorted to ground or open” remains be-
ing received for 2 seconds.
System recovers if controller area network signal from exhaust gas recirculation
Recoverability electronic drive unit indicating “magnetic valve (M/V-1) is normal” remains being
received for 1 second.
Control effected by electronic control unit Exhaust gas recirculation control is stopped.
Service data 20: Actual EGR Position
Actuator test A1: EGR1
Inspection
Electrical equipment #530: Exhaust gas recirculation magnetic valve
Electric circuit diagram Exhaust gas recirculation magnetic valve system
17-11
Generation condition indicating “magnetic valve (M/V-1) circuit shorted to power source” remains being
received for 2 seconds.
Inspection

Inspection

Inspection

Inspection
17-12
17
Inspection
P1625: EDU Relay (warning lamp flashes: 84)

Either of the following occurs.
(1) Current flowing in the electronic drive unit relay remains exceeds the speci-
fied value for 1 second.
Generation condition (2) Electronic drive unit relay circuit remains shorted to ground or open (driving
terminal low level when turned OFF) as detected for 1 second.
(3) Electronic drive unit relay circuit remains shorted to power supply (high level
when turned ON) as detected for 1 second.
• System recovers if current flowing in the electronic drive unit relay remains
lower than the specified value.
Recoverability • System recovers if current flowing in the electronic drive unit relay remains
normal (driving terminal high level when turned OFF) for 1 second.
• System recovers if current flowing in the electronic drive unit relay remains
normal (driving terminal low level when turned ON) for 1 second.
Service data 89: EDU Power Relay
Actuator test B2: EDU Relay
Inspection Electronic control unit connector 02 : Electronic drive unit relay
Electrical equipment #201: Inspection of relay
Electric circuit diagram Electronic drive unit relay system
P1630: CAN (EGR 1) (warning lamp flashes: 95)

Any of the following occurs.
(1) Controller area network signal from exhaust gas recirculation electronic drive
unit 1 indicating “target exhaust gas recirculation opening received from en-
Generation condition gine electronic control unit is wrong” remains being received for 2 seconds.
(2) No controller area network signal from exhaust gas recirculation electronic
drive unit is received for 1 second.
(3) Engine controller area network signal abnormal state lasts for 0.5 second.
• System recovers if controller area network signal from exhaust gas recircu-
lation electronic drive unit 1 indicating “target exhaust gas recirculation
opening received from engine electronic control unit is normal” remains be-
ing received for 1 second.
Recoverability • In the case of above problem (2)
• System recovers if controller area network signal from exhaust gas recircu-
lation electronic drive unit remains being received for 0.5 second.
• System recovers if normal engine controller area network signal lasts for
0.5 second.
Service data 20: Actual EGR Position 1
Actuator test A1: EGR 1
Inspection Electrical equipment Exhaust gas recirculation electronic drive unit and engine electronic control unit
Controller area network communication system between engine electronic con-
trol unit and exhaust gas recirculation electronic drive unit
17-13
Position as commanded by
Perform actuator test
20 Actual EGR Position . actuator test
[Actuator test] A1: EGR 1
Equal to ambient tempera-
2B Intake Air Temperature . °C On a cold engine
ture
Starter switch ON ON
89 EDU Power Relay ON/OFF Starter switch OFF OFF
[Actuator test] B2: EDU relay
5. Actuator Tests Performed Using Multi-Use Tester

No. Item Explanation Confirmation method
A0 EGR 1 Maintain exhaust gas recirculation valve 1 opening indicated Actual position of service
by Multi-Use Tester. data matches target value
[Can be executed when the following conditions are satisfied] commanded by actuator
A1 EGR 2
• Vehicle: stationary (vehicle speed 0 km/h) test
• Starter switch: ON [Service data]
A3 EGR 3 • Engine: stopped 20: Actual EGR Position
ON/OFF switchover of electronic drive unit relay Operating sound of elec-
(automatically reset after 15 seconds) tronic drive unit relay
[Can be executed when the following conditions are satisfied] [Service data]
AC EDU Relay
• Vehicle: stationary (vehicle speed 0 km/h) 89: EDU Power Relay
• Starter switch: ON
• Engine: stopped
6. Inspections Performed at Electronic Control Unit Connectors

• These inspections aid troubleshooting by enabling you to check whether electronic control unit signals are being
correctly transmitted via the vehicle harness and connectors.
The white-on-black numbers ( 01 , 02 , and so on) correspond to the similarly printed reference numbers in
section “3. Inspections Based on Diagnosis Codes”.
17-14
17
6.1 Electronic control unit connector terminal layout
6.2 Inspection instructions

• Some inspections are performed with the connectors removed. Others are performed with the connectors fitted.
Observe the following caution:
CAUTION
• Do not touch any terminal except those specified for the inspection. Be particularly careful not to cause
short circuits between terminals using the tester probes.

01 [Conditions]
Resistance of intake air temperature sensor 1 • Disconnect connector. Perform inspection on vehicle-side connector.
[Requirements]
Terminals: A63-A32
• 0°C: 15 +3.78
–2.94 kΩ
• 20°C: 6.514 +1.437
–1.147 kΩ
• 80°C: 0.874 +0.136
–0.115 kΩ
02 [Conditions]
Voltage of electronic drive unit relay
• Vehicle-side harness connected (Perform inspection on back of connector.)
[Requirements]
Terminals (+)-(–): B14-ground
• With relay operating: 0 V
• With relay not operating: Corresponding to battery voltage
17-15
7. Inspection of Electrical Equipment
#201 Inspection of relay (normally open, 5 pins)
• Perform a continuity check and an operation check. If there is
any abnormality, replace the relay.
#305 Inspection of intake air temperature sensor

• Place the sensor in a container filled with engine oil.
0°C 15 +3.78
–2.94 kΩ
Standard value 20°C 6.514 +1.437
–1.147 kΩ
80°C 0.874 +0.136
–0.115 kΩ
#530 Inspection of exhaust gas recirculation magnetic valve

• Perform the following checks. If there is any abnormality, replace
the exhaust gas recirculation magnetic valve.
(1) Check of operation
• Gradually increase from zero the voltage applied to terminals 3
and 6 (magnetic valve 1), 2 and 5 (magnetic valve 2) and 1 and
4 (magnetic valve 3).
• Observe the voltage when the exhaust gas recirculation magnet-
ic valve operates.
(Determine the magnetic valve’s OFF-ON operation from the op-
erating sound.)
Standard value
18 V or lower
(min. operating voltage)
(2) Check of continuity and airtightness
• Air pressure applied during check: 930 kPa {9.5 kgf/cm2}
17-16
17
M E M O
17-17
8. Installed Locations of Parts
17-18
17
17-19
17-20
17
17-21
17-22
17
17-23
9. Electric Circuit Diagram
17-24
17
17-25
MITSUBISHI 6M70 EGR VALVE, EGR MAGNETIC VALVE, EGR PIPE
AND EGR COOLER
17-26
17
Removal sequence
1 Upper EGR pipe clamp 11 EGR water pipe 21 Gasket
2 Lower EGR pipe clamp 12 Eyebolt 22 Air pipe
3 Spacer 13 EGR water pipe 23 Connector
4 EGR pipe 14 Eyebolt 24 EGR magnetic valve
5 Gasket 15 EGR air pipe
6
7
Gasket
Rubber hose
16
17
EGR valve
Gasket
*a::Air inlet pipe (see Gr15.)
Non-reusable parts
8 EGR cooler 18 EGR pipe Arrows A to C indicate points to or
9 Gasket 19 Gasket from which pipes are connected.
10 Eyebolt 20 Plate
Perform installation by following the removal sequence in reverse.

Exhaust gas passage side
0 cm3 {0mL} – Replace
Air leakage of (Air pressure: 400 kPa {4 kgf/ cm2})
8
EGR cooler Coolant passage side
0 cm3 {0mL} – Replace
(Air pressure: 300 kPa {3 kgf/ cm2})
1 0 –
2 1.3 ± 0.3 –
3 2.6 ± 0.3 –
EGR valve lift 4 4.6 ± 0.3 –
Operating
16 (Air pressure: 637 to 932 kPa {6.5 Replace
2 stage 5 5.7 ± 0.4 –
to 9.5 kgf/ cm })
6 7.7 ± 0.4 –
7 9.0 ± 0.3 –
8 11.0 ± 0.3 –

Bolt (EGR pipe clamp mounting)
Bolt (EGR pipe mounting)
54 {5.5} –
Bolt (Bracket mounting)
Bolt (EGR cooler mounting)
Nut (EGR pipe mounting) 42 {4.2} –
Clamp (water hose mounting) 3.9 {0.4}
Eyebolt (EGR water pipe mounting)
40 {4.1} –
Connector (air pipe mounting)
Bolt (EGR magnetic valve mounting) 24 {2.4}
Eyebolt (EGR air pipe mounting) 25 {2.6} –
Bolt (EGR pipe mounting) 59 {6.0} –
17-27
EGR VALVE, EGR MAGNETIC VALVE, EGR PIPE AND EGR COOLER
Inspection procedures
Inspection: EGR valve lift
• While applying specified air pressure to the ports in accordance
with the table below, measure the valve lift in operating steps 1
to 8 on each valve.
• Replace the EGR valve if it does not conform to the standard
value.
Input port
Operating step
M/V-1 M/V-2 M/V-3
1 – – –
2 O – –
3 – O –
4 O O –
5 – – O
6 O – O
7 – O O
8 O O O
O: Air applied
–: Air not applied
Inspection: EGR cooler

(1) Exhaust gas passage side
• Fit a cover over the exhaust gas outlet of the EGR cooler, and
connect a hose to the exhaust gas inlet. Then, submerge the
EGR cooler in a container of water. Make sure the coolant pas-
sage is full of water.
• Apply specified air pressure through the hose. Check that air
does not leak from any part.
• If there is any leakage, replace the EGR cooler.
(2) Coolant passage side

• Fit covers over the EGR cooler’s exhaust gas inlet, exhaust gas
outlet, and coolant outlet, and connect a hose to the coolant in-
let. Then, submerge the EGR cooler in a container of water.
• Apply specified air pressure through the hose. Check that air
does not leak from any part.
• If there is any leakage, replace the EGR cooler.
17-28
BLOWBY GAS RETURN SYSTEM 17
Removal sequence
1 PCV hose 7 PCV hose 13 Element
2 PCV pipe 8 Oil hose 14 PCV body
3
4
PCV hose
PCV hose
9
10
Oil separator
Oil hose
*
a:
:
Rocker cover
Non-reusable parts
5 PCV pipe 11 Cap PCV: Positive crankcase ventilation
6 O-ring 12 O-ring
CAUTION
• For information on the element replacement interval, refer to the element instruction manual. If the ele-
ment is used beyond its replacement interval, it may become clogged, causing the pressure inside the en-
gine to increase such that oil leakage occurs.
Perform installation by following the removal sequence in reverse.

Clamp 4.0 {0.4} –
Bolt (PCV pipe mounting)
54 {5.5} –
Bolt (oil separator mounting)
Bolt (PCV valve mounting) 24 {2.4} –
17-29
BLOWBY GAS RETURN SYSTEM

Phone: 269 673 1638
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MODEL LINK-BELT 298 HSL

BOOK No. 1113

Mitsubishi 6M70 Workshop Manual begins on page 1057

Mitsubishi 6M70 Engine Parts Contact:

CRANE SERIAL NUMBER

Link-Belt Construction Equipment Company F00056

BOOK1113 P3091410 Page 1 of 4

Auxiliary Hoisting Mechanism = Auxiliary Winch Assembly / Winch Drum

Length Conversion Table

millimeter, mm centimeter, cm meter, m inch, in., " foot, ft., '

Area Conversion Table

Volume Conversion Table

gallon, gal. cubic inch, in3 liter, lit., l

Weight Conversion Table

Pressure Conversion Table

bar kg/cm3 lb./in2, PSI

Work, Energy Conversion Table

kg.cm kg.m foot-pound, ft.-lb. inch-pound,.in-lb.

Centigrade-Fahrenheit Conversion Table

• Be sure to thoroughly read this manual for cor-

• The Operator’s Manual

Consecutive Page Number for Each Group

• When you see this symbol on your machine or in this

UNDERSTAND SIGNAL WORDS

• DANGER indicates an imminently hazardous situation

x To avoid confusing machine protection with personal SA-1223

safety messages, a signal word IMPORTANT indicates

x NOTE indicates an additional explanation for an ele-

x Safety signs should be installed, maintained and re-

• If a safety sign or this manual is damaged or missing,

x Learn how to operate the machine and its controls cor-

x Allow only trained, qualified, authorized personnel to

x Keep your machine in proper working condition.

• Unauthorized modifications of the machine may impair

x The safety messages in this SAFETY chapter are in-

PREPARE FOR EMERGENCIES

x Be prepared if a fire starts or if an accident occurs.

• Keep a first aid kit and fire extinguisher on hand.

You may need:

Respirator or filter mask.

• Avoid wearing loose clothing, jewelry, or other items

PROTECT AGAINST NOISE

• Wear a suitable hearing protective mechanism such

x Falling is one of the major causes of personal injury.

ADJUST THE OPERATOR’S SEAT

• The seat should be adjusted whenever changing the

• Prior to operating the machine, thoroughly examine

OPERATE ONLY FROM OPERATOR’S SEAT

• Start the engine only from the operator’s seat.

• Guard against injury from flying pieces of metal or de-

HANDLE FLUIDS SAFELY᧩AVOID FIRES

• Do not refuel the machine while smoking or when near

• Store flammable fluids well away from fire hazards.

• Be sure to observe local regulations when transporting

Less than 15q SA-475A

x When towing the machine, be sure to attach tow wire

• Understand service procedures before starting work.

• Before servicing the machine:

3) Run the engine at slow idle speed without load for

• If a maintenance procedure must be performed with

• Before performing any work on the machine, attach a

SUPPORT MACHINE PROPERLY