SM4480203

CONTENTS
CHAPTER 1
GENERAL CAUTIONS FOR MAINTENANCE WORK
1-1 Correct Work ...........................................................................................................................................................................1-1
1-2 Safety Precautions ..................................................................................................................................................................1-1
1-3 Preparations ............................................................................................................................................................................1-1
1-4 Cautions for Disassembly and Reassembly............................................................................................................................1-1
1-5 Cautions for Removal and Installation of Hydraulic Equipment ..............................................................................................1-2
1-6 Cautions for Removal and Installation of Hydraulic Piping......................................................................................................1-2
1-7 Cautions for Handling Seals....................................................................................................................................................1-3
1-8 Correct Installation of Hydraulic Hose .....................................................................................................................................1-3
1-9 Specifications of Hydraulic Hose.............................................................................................................................................1-6
1-10 Air Release of Hydraulic Equipment....................................................................................................................................1-11
CHAPTER 2
TECHNICAL DATA
2-1 Specifications ...................................................................................................................................................................... 2-1-1
2-2 Outline Drawing and Working Area ..................................................................................................................................... 2-2-1
2-3 Weight List of Main Parts .................................................................................................................................................... 2-3-1
2-4 Lifting Capacity List ............................................................................................................................................................. 2-4-1
CHAPTER 3
SERVICE STANDARDS
3-1 Machine Performance ......................................................................................................................................................... 3-1-1
3-2 Engine ................................................................................................................................................................................. 3-2-1
3-3 Undercarriage ..................................................................................................................................................................... 3-3-1
3-3-1 Rubber Crawler Specifications ................................................................................................................................... 3-3-1
3-4 Controls ............................................................................................................................................................................... 3-4-1
3-5 Hydraulic Equipment ........................................................................................................................................................... 3-5-1
3-5-1 Hydraulic Cylinders .................................................................................................................................................... 3-5-1
3-6 Implement ........................................................................................................................................................................... 3-6-1
3-6-1 Front Attachments ...................................................................................................................................................... 3-6-1
3-6-2 Blade Moving Device.................................................................................................................................................. 3-6-2
3-6-3 Bucket Teeth .............................................................................................................................................................. 3-6-2
3-7 List of Tightening Torque .................................................................................................................................................... 3-7-1
3-7-1 Machine...................................................................................................................................................................... 3-7-1
3-7-2 Engine ........................................................................................................................................................................ 3-7-4
3-7-3 Tightening Torque for General Bolts and Nuts........................................................................................................... 3-7-4
CHAPTER 4
ENGINE
4-1 Measurement, Inspection and Adjustment .......................................................................................................................... 4-1-1
4-1-1 Measuring the Compression Pressure ....................................................................................................................... 4-1-1
4-1-2 Adjusting the Valve Clearance ................................................................................................................................... 4-1-2
4-1-3 Checking the V-belt Tension ...................................................................................................................................... 4-1-3
4-1-4 Checking the Fuel Injection Valve .............................................................................................................................. 4-1-3
4-1-5 Checking and adjusting the Fuel Injection Timing...................................................................................................... 4-1-5
4-1-6 Adjusting the Maximum (or Minimum) Idling Speed................................................................................................... 4-1-7
4-1-7 Checking the Cooling Water System and Radiator for Water Leakage ..................................................................... 4-1-7
4-1-8 Checking the Sensors ................................................................................................................................................ 4-1-8
4-2 Measurement Procedure, Service Data and Corrective Action........................................................................................... 4-2-1
4-2-1 Cylinder Head............................................................................................................................................................. 4-2-1
4-2-2 Cylinder Block ............................................................................................................................................................ 4-2-6
4-2-3 Valve Rocker Arm ...................................................................................................................................................... 4-2-8
4-2-4 Piston and Piston Rings ........................................................................................................................................... 4-2-10
4-2-5 Connecting Rod........................................................................................................................................................ 4-2-13
4-2-6 Cam shaft ................................................................................................................................................................. 4-2-16
4-2-7 Crank shaft ............................................................................................................................................................... 4-2-17
4-2-8 Gears........................................................................................................................................................................ 4-2-20
4-2-9 Trochoid Pump ......................................................................................................................................................... 4-2-21
4-3 Precautions for Reassembly ............................................................................................................................................... 4-3-1
4-4 Fuel Injection System .......................................................................................................................................................... 4-4-1
4-4-1 Fuel Injection Pump.................................................................................................................................................... 4-4-1
4-4-2 Fuel Injection Valve .................................................................................................................................................... 4-4-1
4-4-3 Governor Mechanism ................................................................................................................................................. 4-4-2
4-4-4 Specifications of Fuel Injection Pump ........................................................................................................................ 4-4-4
4-4-5 Service Date for Fuel Injection Equipment ................................................................................................................. 4-4-5
4-5 Electrical Equipment ........................................................................................................................................................... 4-5-1
4-5-1 Starter Motor .............................................................................................................................................................. 4-5-1
4-5-2 Alternator.................................................................................................................................................................... 4-5-2
4-5-3 Glow Plug ................................................................................................................................................................... 4-5-4
CHAPTER 5
HYDRAULIC SYSTEM
5-1 Outline................................................................................................................................................................................. 5-1-1
5-1-1 Control Valve Operation ............................................................................................................................................. 5-1-4
5-1-2 Additional Operation of Control Valve ........................................................................................................................ 5-1-6
5-2 Hydraulic Circuit Schematic ................................................................................................................................................ 5-2-1
5-2-1 For Standard Type Machines ..................................................................................................................................... 5-2-1
5-3 Circuit Operation ................................................................................................................................................................. 5-3-1
5-3-1 Boom .......................................................................................................................................................................... 5-3-1
5-3-2 Arm............................................................................................................................................................................. 5-3-3
5-3-3 Bucket ........................................................................................................................................................................ 5-3-5
5-3-4 Swing.......................................................................................................................................................................... 5-3-7
5-3-5 Boom Swing ............................................................................................................................................................... 5-3-9
5-3-6 Blade ........................................................................................................................................................................ 5-3-11
5-3-7 Travel ....................................................................................................................................................................... 5-3-13
5-3-8 Track Gauge Change .............................................................................................................................................. 5-3-15
5-3-9 Simultaneous Operation of Blade and Travel........................................................................................................... 5-3-17
5-3-10 Simultaneous Operation of Boom and Arm............................................................................................................ 5-3-19
5-3-11 Simultaneous Operation of Boom and Bucket ....................................................................................................... 5-3-21
5-3-12 Simultaneous Operation of Arm and Swing ........................................................................................................... 5-3-23
5-3-13 Simultaneous Operation of Arm and Bucket .......................................................................................................... 5-3-25
5-3-14 Simultaneous Operation of Boom, Arm and Swing ................................................................................................ 5-3-27
5-3-15 Hydraulic P.T.O. ..................................................................................................................................................... 5-3-29
5-4 Pressure Adjustment ........................................................................................................................................................... 5-4-1
5-4-1 Relief Valves .............................................................................................................................................................. 5-4-1
5-4-2 Swing Brake Valve ..................................................................................................................................................... 5-4-3
5-4-3 Cut-Off Valve.............................................................................................................................................................. 5-4-4
CHAPTER 6
HYDRAULIC EQUIPMENT
6-1 Hydraulic Pump ................................................................................................................................................................... 6-1-1
6-2 Control Valve...................................................................................................................................................................... 6-2-1
6-3 Pilot Valve ........................................................................................................................................................................... 6-3-1
6-4 Swing Motor ........................................................................................................................................................................ 6-4-1
6-5 Travel Motor ........................................................................................................................................................................ 6-5-1
CHAPTER 7
ADJUSTMENT AND REPAIR
7-1 Electric Equipment of Machine............................................................................................................................................ 7-1-1
7-1-1 Parts Layout of Electrical Equipment ......................................................................................................................... 7-1-1
7-1-2 Monitor and Alarm Systems ....................................................................................................................................... 7-1-2
7-1-3 Wiring Diagram........................................................................................................................................................... 7-1-5
7-1-4 Circuit Description of Engine Start and Stop, and Battery Charging .......................................................................... 7-1-6
7-1-5 Removal and Reinstallation of Engine ....................................................................................................................... 7-1-8
7-1-6 Removal and Reinstallation of Starter Motor............................................................................................................ 7-1-14
7-1-7 Removal and Reinstallation of Fuel Injection Pump................................................................................................. 7-1-15
7-1-8 Removal and Reinstallation of Fuel Tank................................................................................................................. 7-1-17
7-1-9 Removal and Reinstallation of Radiator ................................................................................................................... 7-1-20
7-2 Undercarriage ..................................................................................................................................................................... 7-2-1
7-2-1 Outline ........................................................................................................................................................................ 7-2-1
7-2-2 Points of Reassembly................................................................................................................................................. 7-2-2
7-2-3 Crawler Tension Adjustment Procedure..................................................................................................................... 7-2-3
7-2-4 Removal and Reinstallation of Crawler ...................................................................................................................... 7-2-4
7-2-5 Disassembly and Reassembly of Idler ....................................................................................................................... 7-2-5
7-2-6 Disassembly and Reassembly of Track Roller........................................................................................................... 7-2-7
7-2-7 Removal and Reinstallation of Track Gauge Change Cylinder .................................................................................. 7-2-9
7-3 Controls ............................................................................................................................................................................... 7-3-1
7-3-1 Control Train............................................................................................................................................................... 7-3-1
7-3-2 Mechanical Control Linkage ....................................................................................................................................... 7-3-2
7-3-3 Adjustment of Control Levers ..................................................................................................................................... 7-3-4
7-3-4 Adjustment of Travel Levers....................................................................................................................................... 7-3-5
7-3-5 Adjustment of Boom Swing Pedal .............................................................................................................................. 7-3-6
7-3-6 Adjustment of Blade Lever ......................................................................................................................................... 7-3-6
7-3-7 Adjustment of Lock Lever Switch ............................................................................................................................... 7-3-7
7-3-8 Adjustment of Track Gauge Change Control Lever ................................................................................................... 7-3-7
7-3-9 Adjustment of Accelerator Lever ................................................................................................................................ 7-3-8
7-3-10 Adjustment of P.T.O. Pedal...................................................................................................................................... 7-3-9
7-3-11 Adjustment Procedure of Travel Alarm Switch (Left and Right) ............................................................................. 7-3-10
7-4 Swing Bearing ..................................................................................................................................................................... 7-4-1
7-5 Hydraulic Equipment ........................................................................................................................................................... 7-5-1
7-5-1 Removal and Reinstallation of Hydraulic Pump ......................................................................................................... 7-5-1
7-5-2 Removal and Reinstallation of Control Valve ............................................................................................................. 7-5-4
7-5-3 Removal and Reinstallation of Swing Motor............................................................................................................... 7-5-7
7-5-4 Removal and Reinstallation of Swivel Joint.............................................................................................................. 7-5-10
7-5-5 Disassembly and Reassembly of Swivel Joint ......................................................................................................... 7-5-13
7-5-6 Disassembly and Reassembly of Hydraulic Cylinders ............................................................................................. 7-5-16
7-5-7 Hydraulic Oil Tank .................................................................................................................................................... 7-5-20
7-5-8 Piping Layout............................................................................................................................................................ 7-5-26
7-6 Implement ........................................................................................................................................................................... 7-6-1
7-6-1 Removal and Reinstallation of Implement.................................................................................................................. 7-6-1
CHAPTER 8
PERIODIC INSPECTION AND SERVICING
8-1 List of Periodic Inspection and Servicing.................................................................................................................................8-1
CHAPTER 9
FUEL, LUBE OIL AND GREASE RECOMMENDED
9. Fuel, Lube Oil and Grease Recommended ...............................................................................................................................9-1
CHAPTER 10
TROUBLESHOOTING
10-1 Non-Breakdowns............................................................................................................................................................. 10-1-1
10-1-1 Natural Release of Bucket...................................................................................................................................... 10-1-1
10-1-2 Discontinuous Arm Movement ............................................................................................................................... 10-1-1
10-1-3 Drifting of Upperstructure on Quick Travel Operation ............................................................................................ 10-1-2
10-1-4 Thermal Shock of Travel Motor .............................................................................................................................. 10-1-3
10-1-5 Change of Blade Speed in Loaded Condition ........................................................................................................ 10-1-4
10-1-6 Time Lag on Travel Speed Switching..................................................................................................................... 10-1-5
10-1-7 Fluctuation in Oil Level of Hydraulic Oil Tank Due to Temperature Change.......................................................... 10-1-6
10-2 Troubleshooting .............................................................................................................................................................. 10-2-1
10-2-1 Machine and Engine............................................................................................................................................... 10-2-1
10-2-2 Electrical Equipment on Panel ............................................................................................................................. 10-2-22
CHAPTER 11
REFERENCE DATA
11-1 Specifications for Attachment..............................................................................................................................................11-1
CHAPTER 1
GENERAL CAUTIONS FOR MAINTENANCE WORK
1-1 Correct Work............................................................................................1-1

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

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

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

Take care not to twist the hoses. (Judge whether or not the hose is twisted by Metal fitting
the hose mark.) For hoses with a metal fitting, use two wrenches to prevent
twisting.
Pipe or
Use one to fix the hose, and the other to tighten the fitting to the specified Hose connector
tightening torque. Carefully check that the hoses do not come in contact after Fixed side
tightening. If any contact is found, correct it or use tubes.
(2) When installing hoses, first tighten to the specified torque and then loosen
them a little. Then retighten to the specified torque.
• Break in the installed parts before tightening (except those using seal tapes).
(3) When installing pipes, turn the nuts more 1/4 to 1/2 turn after they reach the sharp torque rise point.
(4) When installing or removing hoses, use two wrenches, one to fasten the hose and the other to tighten or loosen
the hose to prevent twisting.
(5) Check for oil leakage by applying max. pressure 5 to 6 times after attaching hydraulic hoses or pipes.
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MAINTENANCE WORK
1-7 Cautions for Handling Seals
(1) Clean out grooves of O-rings. Remove burrs or dust if any.
Burrs
Dust
(2) Take care not to twist O-rings. Correct by your finger if it is twisted.
(3) Take care not to damage seals when inserting.
(4) Handling of floating seals :
• Completely wipe off all the oil from the O-ring and housing after detaching the floating seals.
• Before installing, apply a little gear oil to the matching face of the housing.
• Turn the seals two or three times after installation to break them in.
(5) Apply grease to the lip of the oil seals to prevent wear.
Grease
1-8 Correct Installation of Hydraulic Hose
In order to mount the hydraulic hose most effectively and economically, observe the following cautions.
(1) When a hose is used at the minimum bending radius, use elbows to avoid sharp bending.
Not good Good
(2) To prevent twisting, the hose should be bent in the same direction as it moves.
Not good Good
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MAINTENANCE WORK
(3) When the hose is pressurized, the hose length varies slightly at the bend. Allow this change to occur and do not
try to fasten the bend.
Not pressurized
When pressurized
(4) It is necessary for the hose to have ample slackness for elongation and contraction, because its length will
change by +2 % to -4 % when used at high pressure.
Not good
Good
(5) Use the proper adapters, not pipes, in order to reduce the number and length of joints and improve the external
appearance.
Not good Good
(6) Use an elbow to prevent excessive twisting or bending of the hose.
Not good Good
(7) Use adapters to make the hose as straight as possible. The outside appearance can be improved by avoiding
the use of hoses that are too long.
Not good Good
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MAINTENANCE WORK
(8) The hose should be slightly longer than is absolutely necessary. The extra allows smoother movement of the
hose and prevents sharp bending.
Not good Good
(9) When a bent hose is attached to two different planes, fix as shown in the diagram to prevent twisting.
Not good Good
(10) Use the marking on the hose as a guide to prevent twisting during installation.
Twisting of metal fitting with union nuts should be with a wrench on the hexagonal parts.
Hose mark Hose mark

Not good Good
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MAINTENANCE WORK
1-9 Specifications of Hydraulic Hose
Two types of hydraulic hoses are used in Yanmar Construction Machinery : the standard parts specified in the
Yanmar Industrial Standards (YIS) and special parts for the respective models. Specifications of the hydraulic hoses
can be known by the code number or part descriptions as explained below. (For the parts number, please refer to
our Parts Catalog.)
(1) Yanmar Standard Type

The part code consists of 11-digit numbers :
Hose material code Fittings combination code

Hose type code Nominal length code
Nominal dia. code
Description Hose material Type of hose Hose dia. Hose length Combination
of fittings
Part code No.
Hose material
02 1
1 (SAE J517,100R1) 3
Rubber hose
2320 03 Unit : cm 4
(High pressure type) 5
2 (SAE J517,100R2)
04 6
02 1
1 (SAE J517,100R7) 03
Plastic hose 4
2327 04
(High pressure type) 5
03
2 (SAE J517,100R7) 7
04
02
03 1
04
Rubber hose 05
2325 1 (SAE J517,100R6) 4
(Medium pressure type) 06
10
12 5
14
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MAINTENANCE WORK
1) Type of Hose (Hose Dia. & Recommended Working Pressure)
Working
Inner dia. Outer dia.
Type of hose Hose dia. pressure
[in. (mm)] [in. (mm)]
[PSI (MPa)]
02 0.25 (6.3) 0.53 (13.5) 2489 (17.2)
1
03 0.37 (9.5) 0.69 (17.5) 1991 (13.7)
(SAE J517, 100R1)
04 0.50 (12.7) 0.81 (20.6) 1564 (10.8)
02 0.25 (6.3) 0.59 (15.1) 4266 (29.4)
2
03 0.37 (9.5) 0.75 (19.1) 3484 (24.0)
(SAE J517,100R7)
04 0.50 (12.7) 0.87 (22.2) 2986 (20.6)
02 0.25 (6.3) 0.49 (12.5) 2986 (20.6)
1
03 0.37 (9.5) 0.65 (16.6) 2489 (17.2)
(SAE J517, 100R6)
04 0.50 (12.7) 0.81 (20.7) 1991 (13.7)
2 03 0.37 (9.5) 0.68 (17.2) 2986 (20.6)
(SAE J517,100R7) 04 0.50 (12.7) 0.84 (21.4) 2986 (20.6)
02 0.25 (6.3) 0.50 (12.7) 427 (2.9)
03 0.37 (9.5) 0.63 (15.9) 427 (2.9)
04 0.50 (12.7) 0.78 (19.8) 427 (2.9)
1 05 0.63 (15.9) 0.91 (23.0) 427 (2.9)
(SAE J517,100R6) 06 0.75 (19.0) 1.25 (31.8) 427 (2.9)
10 1.00 (25.4) 1.50 (38.1) 427 (2.9)
12 1.25 (31.8) 1.75 (44.5) 427 (2.9)
14 1.50 (38.1) 2.04 (51.9) 427 (2.9)
2) Total Length of Hose [Unit : in. (cm)]
L L L
3 digit indication in cm. (Example) Nominal length 065 : Full length 25.6 in. (65 cm)
3) Hose Dia. (Unit : inch)
02....1/4'' 05....5/8'' 12....1 1/4''

03....3/8'' 06....3/4'' 14....1 1/2''
04....1/2'' 10....1
Note :
Please note that these code numbers are different from those for the equivalent diameters for special parts on the
next page.
1-7 4480203
MAINTENANCE WORK
4) Combination of Fitting
Fitting 60 degrees bent type.

Code No. R(PT) 60
type Taper pipe thread Straight pipe thread
A D
R (PT) G (PF) with male 30
1 A·B G(PF) degrees seat
3 A·E
G(PF) Straight pipe thread 45 45 degrees bent type.
G (PF) with male 30 Straight pipe thread
B E
4 B·B degrees seat G (PF) with male 30
30
G(PF) degrees seat
5 B·C
90 90 degrees bent type.
6 B·E Straight pipe thread
C
G (PF) with male 30
7 B·D G(PF) 30 degrees seat
(Example) Part code 2 3 2 0 2 0 3 0 8 5 5
Rubber hose, high pressure type List of pipe threads

SAE J517, 100R2 Symbol Name
Straight pipe
G (PF)
Nominal dia., 3 / 8" thread
Male taper pipe
Hose length, 33.5 in. (85 cm) R (PT)
thread
Straight pipe thread G (PF) with Female taper
Rc (PT)
male 30 degrees seat and 90 degrees bent type. pipe thread
Straight pipe thread G (PF) with
male 30 degrees seat
Note :
All the hoses with fittings other than those listed above are special parts.
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MAINTENANCE WORK
(2) Special Parts
Description ..................... Hose P 2 06 AB 075 W

1 2 3 4 5 6 7 8
8 Other accessories
1 Part name No accessories...Blank
O-ring ....................... 1
2 Hose material 6 Total length 7 Hose protector

Rubber hose ............ G (Unit : cm) Coil spring ............... W
Wear-resistant high Coil tube .................. S
pressure rubber Wire braid ................ B
5 Combination of fitting Tube (Rubber) .......... R
hose ......................... H
Plastic hose ............. P Tube (Vinyl) .............. V
Wear-resistant Fitting type Code Sponge rubber ......... P
R(PT) Hose cover ............... K
plastic hose............... F No protection ..... Blank
Taper pipe A
thread R (PT)
3 Recommended G(PF) Straight pipe

working pressure thread G (PF)
with male 30 B
PSI(Mpa) 30
Over 2986 (20.6) ..................... 1 degrees seat
2489 to 2986 (17.2 to 20.6) ..... 2 90 degrees
1991 to 2489 (13.7 to 17.2) ..... 3 90 bent type.
Straight pipe
1564 to 1991 (10.8 to 13.7) ..... 4 thread G (PF) C
995 to 1564 (6.9 to 10.8) ......... 5 with male 30
427 to 995 (2.9 to 6.9) ............. 6 G(PF) 30 degrees seat
213 to 427 (1.5 to 2.9) ............. 7
Below 213 (1.5) ....................... 8
4 Nominal dia. (inch) Without fitting Y

List of pipe threads
1 / 8" ......................... 02
For the combination of fitting, Symbol Name
3 / 16" ....................... 03
refer to the list on the following G (PF) Straight pipe thread
1 / 4" ......................... 04
page. R (PT) Male taper pipe thread
3 / 8" ......................... 06
1 / 2" ......................... 08 Rc (PT) Female taper pipe thread
5 / 8" ......................... 10
3 / 4" ......................... 12
1" .............................. 16
The example hose, P 2 06 AB 075 W stands for :

2 3 4 5 6 7
2 Material : Plastic
3 Working pressure : 2489 to 2986 PSI (17.2 to 20.6 MPa)
4 Nominal dia. : 3 / 8"
5 Fitting type : Taper pipe thread R (PT) and straight pipe thread G (PF) with male 30 degrees seat.
6 Length : 29.5 in. (75 cm)
7 Hose protector : Coil spring
1-9 4480203
MAINTENANCE WORK
5 Combination of fitting
Fitting type Code Fitting type Code

90
R (PT) 90 degrees bent type.
Taper pipe thread R (PT) A UNF thread with female P
UNF 37 degrees seat
37
Straight pipe thread G 60 60 degrees bent type.
G (PF)
(PF) with male 30 B UNF thread with female Q
degrees seat 37 degrees seat
30 UNF
90 degrees bent type.
90 Straight pipe thread G 45 degrees bent type.
45
(PF) with male 30 C UNF thread with female R
degrees seat 37 degrees seat
UNF
G (PF) 30
60 60 degrees bent type. UNF UNF, thread with O-ring

Straight pipe thread G groove
D S
(PF) with male 30
G (PF) degrees seat O-ring

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

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

PF nut
G (PF) Straight pipe thread, jam nut female 30
30
30 female 30 degrees seat K degrees seat X
with O-ring groove
G (PF)

Straight pipe thread G 90 Gauge port
L
(PF) with male 30 90 degrees elbow straight
G (PF) degrees seat G (PF) pipe thread with gauge Z
port plug male 30
NPTF
Taper pipe thread NPTF M degrees seat
30
Without fitting Y
UNF
37
UNF, thread with female Note :
37 degrees seat N
According to the combination of bending or elbow fittings, some
hoses require drawings or original hoses to locally manufacture.
1-10 4480203
MAINTENANCE WORK
1-10 Air Release of Hydraulic Equipment
When operating the machine after disassembly or parts replacement of the hydraulic equipment, piping, etc., be
sure to release air from the hydraulic system. This is necessary to prevent seizure and cavitation of the hydraulic
equipment. If the air is left in the hydraulic system, the air is compressed or expanded depending on the load, having
an adverse effect on the smooth operation of the hydraulic equipment and shortening the service life.
1. Air Release of Each Hydraulic Component

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

1) Set the Engine Speed at Low Idling Range.
2) Extend and Retract the Cylinder Up to 1.97 to 3.9 in. (50 to 100 mm) from Each Stroke End Slowly 4 or 5
Times.
1.97 to 3.9 in. 1.97 to 3.9 in.

(50 to 100 mm) (50 to 100 mm)
Retraction stroke end Retraction stroke end
Note :
The extension and retraction stroke is up to 1.97 in. (50 mm) from each stroke end for the blade cylinder.
3) Then, Fully Extend and Retract the Cylinder 3 or 4 Times.
1-11 4480203
CHAPTER 2
TECHNICAL DATA
2-1 Specifications....................................................................................... 2-1-1

2-2 Outline Drawing and Working Area ..................................................... 2-2-1
2-3 Weight List of Main Parts..................................................................... 2-3-1
2-4 Lifting Capacity List.............................................................................. 2-4-1
2. TECHNICAL DATA
2. Technical Data
2-1 Specifications
Item Unit ViO15-2
Main specifications of machine
Dimensions
Overall length (Transportation position) in. (mm) 133.9 (3410)
Transportation position in. (mm) -
Overall height
Cabin Traveling position in. (mm) -
Overall width Full machine width in. (mm) -
Transportation position in. (mm) 90.4 (2295)
Overall height
Traveling position in. (mm) 90.4 (2295)
Canopy
Full machine width
Overall width in. (mm) 47.2 (1200) / 37.4 (950)
(Maximum/Minimum)
Tumbler center distance in. (mm) 46.7 (1185)
Track gauge (Maximum/Minimum) in. (mm) 38.2 (970) / 28.3 (720)
Minimum ground clearance in. (mm) 7.1 (180)
Traveling performance
Low speed (Forward/Reverse) MPH (km/hr) -
Steel crawler
Travel High speed (Forward/Reverse) MPH (km/hr) -
speed Low speed (Forward/Reverse) MPH (km/hr) 1.30 (2.1)
Rubber crawler
High speed (Forward/Reverse) MPH (km/hr) 2.67 (4.3)
Climbing ability degrees 30
Permissible water depth limit in. (mm) 14.2 (360)
Work performance
Width (Standard) in. (mm) 17.7 (450)
Bucket (Standard. JIS heaped capacity) cu.ft. (cu.m) 1.77 (0.05)
Number of teeth / Installation method pcs. 3 / rubber pin lock type
Maximum With blade raised in. (mm) 82.7 (2100)
digging
depth With blade on the ground in. (mm) 87.4 (2220)
Maximum depth of vertically digging in. (mm) 68.9 (1750)

Maximum dumping height in. (mm) 100.8 (2560)
Minimum front swing radius (with boom in front) in. (mm) 59.1 (1500)
Minimum front swing radius Cabin in. (mm) -
(at 75 degrees right boom swing) Canopy in. (mm) 49.2 (1250)
Rear end swing radius in. (mm) 23.6 (600)
Left degrees -
Cabin
Right degrees -
Boom swing angle
Left degrees 42
Canopy
Right degrees 65
Bucket lbs. (kN) 3087 (13.7)
Maximum digging force
Arm lbs. (kN) 1985 (8.8)
Maximum tractive force (Oil pressure force) (rubber) lbs. (kN) 4198 (18.7)
Maximum swing inclination angle (with standard bucket) degrees 23 (at loading)
2-1-1 4480203
2. TECHNICAL DATA
Item Unit ViO15-2

Main specifications of machine
Work performance
Swing speed rpm 8.5
Fuel consumption in practical operation Gals/h (L/h) 0.48 (1.8)
Blade
47.2 (1200)!9.3 (235)/
Width!Height (Side open/close) in. (mm)
37.4 (950)!9.3 (235)
Blade Capacity (Side open/close) cu.ft. (cu.m) 2.12 (0.06)/1.70 (0.048)
Lift above ground level in. (mm) 8.9 (225)
Digging depth in. (mm) 8.7 (220)
Mean contact pressure
Cabin PSI (KPa) -
Steel crawler
Canopy PSI (KPa) -
JIS
Cabin PSI (KPa) -
Rubber crawler
Canopy PSI (KPa) 4.0 (27.3)
Mass
Cabin lbs. (kg) -
Steel crawler
Canopy lbs. (kg) -
Operating mass
Cabin lbs. (kg) -
Rubber crawler
Canopy lbs. (kg) 3704 (1680)
Cabin lbs. (kg) -
Steel crawler
Canopy lbs. (kg) -
Base machine dry mass
Cabin lbs. (kg) -
Rubber crawler
Canopy lbs. (kg) 2800 (1270)
Hydraulic equipment
Hydraulic pump
Engine → Coupling →
Drive method
Pump (Direct drive)
Variable displacement piston pump
Type of main pump
+ Gear pump
Variable displacement piston pump : 2
Number of pumps
+ Gear pump : 1
cu.in./rev 0.55 (9)!2,
Theoretical discharge volume
(cu.cm/rev) 0.27 (4.5)!1
Maximum allowable pressure PSI (MPa) -
Control valve
Number of connected valves pcs.
P1, P2 PSI (MPa) 2986 (20.6)
System relief set pressure
P3 PSI (MPa) 427 (2.9)
Boom (at rod end) PSI (MPa) 3413 (23.5)
Boom (at bottom end) PSI (MPa) -
Circuit relief set pressure
Arm (at rod end) PSI (MPa) -
Arm (at bottom end) PSI (MPa) 3413 (23.5)
2-1-2 4480203
2. TECHNICAL DATA
Item Unit ViO15-2

Hydraulic equipment
Control valve
Bucket (at rod end) PSI (MPa) -
Bucket (at bottom end) PSI (MPa) 3555 (24.5)
Boom swing (at rod end) PSI (MPa) -
Circuit relief set pressure
Boom swing (at bottom end) PSI (MPa) -
Blade (at rod end) PSI (MPa) -
Blade (at bottom end) PSI (MPa) -
Cylinder
Stroke in. (mm) 17.0 (431)
Inside diameter in. (mm) Ø2.17 (Ø55)
Boom Piston rod diameter in. (mm) Ø1.18 (Ø30)
Up (Ground → Max.) sec. 2.4
Speed
Down (Max. → Ground) sec. 2.3
Stroke in. (mm) 15.91 (404)
Arm Piston rod diameter in. (mm) Ø1.38 (Ø35)
Full stroke for digging sec. 3.0
Speed
Full stroke for dumping sec. 2.1
Stroke in. (mm) 10.9 (278)
Bucket Piston rod diameter in. (mm) Ø1.18 (Ø30)
Full stroke for digging sec. 2.2
Speed
Full stroke for dumping sec. 1.5
Stroke in. (mm) 4.17 (106)
Blade Piston rod diameter in. (mm) Ø1.18 (Ø30)
Up (Ground → Max.) sec. 1.1
Speed
Down (Max. → Ground) sec. 1.2
Stroke in. (mm) 11.6 (295)
Boom swing Piston rod diameter in. (mm) Ø1.38 (Ø35)
Full stroke to the right sec. 2.7
Speed
Full stroke to the left sec. 3.8
Stroke in. (mm) 10.2 (260)
Track gauge
Piston rod diameter in. (mm) Ø1.18 (Ø30)
change
Max. track gauge sec. 3.5
Speed
Min. track gauge sec. 2.7
Swivel joint
Swivel joint port diameter!Number inch!pcs. 1/4!21
2-1-3 4480203
2. TECHNICAL DATA
Item Unit ViO15-2

Hydraulic equipment
Motor
Type Orbit motor
cu.in./rev
Displacement 14.9 (244)
Swing motor (cu.cm/rev)
Type Cross relief valve
Brake valve
Relief set pressure PSI (MPa) 1465 (10.1) to 1564 (10.8)
Type Variable displacement piston motor
cu.in./rev
Displacement (Low/High) 0.94 (15.4)/0.47 (7.70)
(cu.cm/rev)
Travel motor Type Counterbalance valve
Brake valve
Relief set pressure PSI (MPa) -
Planetary gear
Type of reduction gear
(with double-reduction mechanism)
Hydraulic oil tank
4.83 (18.3)
Tank capacity Gals (L)
[tank : 3.65 (13.8), others : 1.19 (4.5)]
Type Wire gauze
Suction filter Filtration area sq.in. (sq.cm) 51.1 (330)
Filtration accuracy Meshes 100
Type Cartridge (Paper filter)
Filtration area sq.in. (sq.cm) 341.0 (2200)
Return filter
Filtration accuracy µ 10
By-pass valve opening pressure PSI (MPa) 21.3 (0.15)
Locking device
Lever lock Oil pressure controlled
Boom swing lock Pedal guard
Swing lock Mechanical brake
Swing device
Planetary gear
Swing bearing
(with reduction mechanism)
Swing motor shaft gear →
Power transmission
Swing gear
Type of brake Oil pressure controlled
Brake mounting position Swing motor
Undercarriage
Shoe width in. (mm) -
Type -
Grouser
Height in. (mm) -
Steel
Shoe and link mounting method -
crawler
Link pitch in. (mm) -
Number of shoes (One side) pcs. -
Crawler drive method -
2-1-4 4480203
2. TECHNICAL DATA
Item Unit ViO15-2

Undercarriage
Shoe width in. (mm) 9.06 (230)
Rubber
Lug height in. (mm) 0.71 (18)
crawler
Core metal pitch in. (mm) 2.83 (72)
Manner of support -
Carrier roller Quantity (One side) pcs. -
(Upper
roller) Bearing -
Sealing -
Number of shoe slide plates (One side) pcs. 2
Track roller Quantity (One side) pcs. 3

(Lower Bearing Ball bearing
roller) Sealing QLF
Quantity (One side) pcs. 1
Idler Bearing Ball bearing
Sealing QLF
Number of Steel crawler pcs. 19
sprocket
teeth Rubber crawler pcs. 14
Crawler tension adjustment Grease adjuster

Engine
Main specifications
Engine model 3TNE68-EBVA
Vertical type series water-cooled
Type
4 cycle diesel engine
Combustion system Special swirl pre-combustion chamber
pcs. - in.!in.
Number of cylinders - Bore!Stroke 3 - 2.68!2.83 (68!72)
(mm!mm)
Total displacement cu.in. (cu.cm) 47.8 (784)
HP/rpm
Rated output / engine speed 11.4/2000 (8.5/2000)
(KW/rpm)
ft•lbf/rpm 33.3 to 36.2/1650
Maximum torque / engine speed
(N•m/rpm) (45.1 to 49.0/1650)
lbs./HP•h
Specific fuel consumption 0.441 (200)
(g/PS•h)
Maximum idling speed rpm 2100 to 2150
Minimum idling speed rpm 1125 to 1175
Engine dry mass (excluding air cleaner and silencer) lbs. (kg) 185.2 (84)
Lubricating method Forced lubrication by trochoid pump
lbs./HP•h
Specific lubricating oil consumption 0.0003 to 0.0015 (0.136 to 0.68)
(g/PS•h)
Compression pressure PSI (MPa) 469 (3.2) at 300 rpm
Cylinder head
Open bTDC degrees 5 to 15
Intake valve
Close aBDC degrees 37 to 47
Open bBDC degrees 37 to 47
Exhaust valve
Close aTDC degrees 5 to 15
2-1-5 4480203
2. TECHNICAL DATA
Item Unit ViO15-2

Engine
Cylinder head
Intake valve clearance (Cold engine) in. (mm) 0.006 to 0.010 (0.15 to 0.25)
Exhaust valve clearance (Cold engine) in. (mm) 0.006 to 0.010 (0.15 to 0.25)
Intake valve seat angle degrees 120
Exhaust valve seat angle degrees 90
Piston
Ring shape Barrel face (chrome-plated)
First compression ring
Ring quantity pcs. 1
Ring shape Taper face
Second compression ring
Ring shape Bevel cutter (with coil expander)
Oil-ring
Governor
Name Mechanical all speed type
Type Centrifugal type
Fuel feed system
Filter paper with automatic
Fuel filter
air release device
Fuel filter filtration area sq.in. (sq.cm) 67.0 (432)
Oil/water separator Mesh filter screen (100 mesh)
Feed pump Electrolical
Lubrication system
Lubrication pump Trochoid pump
LO pressure regulating valve opening pressure PSI (MPa) 28.4 to 42.7 (0.20 to 0.29)
LO filter Full flow filter
LO filter filtration area sq.in. (sq.cm) 124.1 (800)
Filter valve opening pressure PSI (MPa) 11.4 to 17.1 (0.08 to 0.12)
Operating pressure of alarm switch PSI (MPa) 5.69 to 8.53 (0.04 to 0.06)
Cooling device
Cooling system Water-cooling (Radiator)
Fan belt size HM 34
Thermostat opening temperature ºF (ºC) 159.8 (71)
Thermostat full-open temperature ºF (ºC) 185 (85)
Radiator cap pressure PSI (MPa) 12.80 (0.089)
pcs.!Øin.
Radiator fan 5!Ø11.4 (Ø290)
(mm)
Operating temperature of water temperature alarm switch ºF (ºC) 224.6 to 235.4 (107 to 113)
Air cleaner
Type Cyclone type
Filtration area sq.ft. (sq.m) 4.7 (0.44)
2-1-6 4480203
2. TECHNICAL DATA
Item Unit ViO15-2

Engine
Fuel injection pump
Injection pump type YPFR
Injection pump plunger diameter in. (mm) Ø0.20 (Ø5.0)
Injection pump cam lifting height in. (mm) 0.28 (7.0)
Fuel injection timing (FID) degrees 13 to 15
Firing order 1→3→2
Nozzle
Type YDN-OPD2
Øin.
Nozzle hole diameter!Number of holes Ø0.04 (Ø1.0)!1
(mm)!pcs.
Spray angle degrees 5 to 10
Fuel injection pressure PSI (MPa) 1706 to 1836 (11.8 to 12.7)
Turbocharger
Type -
Revolution speed rpm -
Turbocharging pressure PSI (MPa) -
Starting device
Cold starting aids Super quick glow
Starting aids capacity V-W DC 12-120
Battery type SY110-S6
Battery voltage - 5 hrs rate capacity V-Ah 12-36
Electrical equipment
Type AC generator magnet
Alternator Nominal output V-A 12-20
Rated speed rpm 3230
Type RS5121
Regulator
Regulation voltage V 14.0 to 16.0
Type Reduction type
Starter motor Nominal output V-kW 12-1.2
Engagement Magnet shift
Type - -
Stop motor
Nominal output V-A -
Hour meter V-W 12-12
Horn V-W 12-48
Fuse A!pcs. 15!3
Battery charge alarm lamp V-W 12-2
Monitor lamps Engine oil pressure alarm lamp V-W 12-2
Water temperature alarm lamp V-W 12-2
Headlight V-W -
Boom light V-W 12-27
Room lamp (for cabin) V-W -
Wiper motor (for cabin) V-W -
Cabin heater (for cabin) V-W -
2-1-7 4480203
2. TECHNICAL DATA
2-2 Outline Drawing and Working Area
in. (mm)
/ 9.85 (250)
4.92 (125)
15.75
(400)
17.21 (450)
47.26 (1200)
/ 37.41 (950)
25.20
(640)
R2
/ 11.42 (290)
3.
63
6.50 (165)
(6
00
)
59.07 (1500)
(54.15 (1375) : at Boom Swing)
142.56 (3620)
100.82 (2560)
90.38 (2295 )
40.56 (1030)
8.86 (225)
7.09 (180)
8.66 (220)
9.06 (230) 61.24 (1555)

220)
133.89 (3410)
87.42 (2
38.20 (970)
64.98 (1750)
/ 28.35 (720) 102.00 (2590)

82.70 (2100)
142.56 (3620)
47.26 (1200)
/ 37.41 (950) 146.49 (3720) 40.56 (1030)
2-2-1 4480203
2. TECHNICAL DATA
2-3 Weight List of Main Parts

[Unit : lbs. (kg)]
ViO15-2
Equipment No. Part Canopy
Rubber crawler
Front implement
1 Bucket Ass’y 73.9 (33.5)
5 2 Bucket arm & link Ass’y 22.1 (10)
3 3 Bucket cylinder Ass’y 23.2 (10.5)
4 Arm Ass’y 59.5 (27)
2 5 Arm cylinder Ass’y 29.8 (13.5)
4 6 Boom Ass’y 112.5 (51)
7 Boom cylinder Ass’y 41.9 (19)
7 6 8 Boom bracket Ass’y 71.7 (32.5)
1 9 Quick coupler Ass’y −
8
9
Undercarriage
1 Idler Ass’y 18.5 (8.4) × 2
2 Crawler guard Ass’y −
3 Crawler adjuster Ass’y 13.2 (6)
7 12 6 13 9 10
4 Track roller Ass’y 7.7 (3.5) × 6
5 Sprocket Ass’y 14.3 (6.5) × 2
6 Carrier roller Ass’y 2.2 (1) × 4
7 Track frame Ass’y 496.1 (225)
8 Steel crawler & Rubber crawler Ass’y 103.1 (59)
9 Blade cylinder Ass’y 19.8 (9)
10 Blade Ass’y 145.5 (66)
11 5 8 4 3 2 1 11 Travel motor Ass’y 52.9 (24) × 2
12 Swing bearing Ass’y 43.0 (19.5)
13 Swivel & hose or fitting Ass’y 30.9 (14)
Upperstructure
1 Engine hood Ass’y 27.6 (12.5)
2 Hydraulic oil tank & filters Ass’y 46.3 (21)
10 3 Engine 231.5 (105)
4 Operator's seat & mount Ass’y 129.0 (58.5)
8 5 Counter weight Ass’y −
2 6 Turning frame Ass’y 639.5 (290)
9 7 4 7 Controls (4 cables) Ass’y 55.1 (25)
8 Battery Ass’y 30.9 (14)
11 1 9 Fuel tank & piping Ass’y 24.3 (11)
10 Canopy & mount Ass’y 67.3 (30.5)
5 11 Swing lock, covers, steps and panels 77.2 (35)
12 Swing motor Ass’y 52.9 (24)
12 6 3 13 13 Pump & mount and hoses Ass’y 77.2 (35)
14 Control valve & fitting and hoses Ass’y 55.1 (25)
15 Boom swing cylinder Ass’y 32.0 (14.5)
2-3-1 4480203
2. TECHNICAL DATA
2-4 Lifting Capacity List
ViO15-2
With:
(" Cabin# Canopy) Type
A
(" Steel # Rubber) Crawler
Quick coupler
W/O Bucket
P
A : Reach from swing center line [in. (m)]

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

A [in. (m)] Max. 98.4 (2.5) 78.7 (2.0) Min.
B [in. (m)]
* 662 474 * 650 * 650 * 650
78.7 (2.0) − − −
(300) (215) (295) (295) (295)
* 673 408 * 684 584 * 783 * 783
59.1 (1.5) − −
(305) (185) (310) (265) (355) (355)
* 673 397 * 805 584 * 1058 805 * 915 * 915
39.4 (1.0)
(305) (180) (365) (265) (480) (365) (415) (415)
* 684 386 * 904 562 * 1268 761 * 1378 1003
19.7 (0.5)
(310) (175) (410) (255) (575) (345) (625) (455)
* 706 397 * 992 551 * 1378 739 * 1643 915
0 (0)
(320) (180) (450) (250) (625) (335) (745) (415)
* 728 452 * 959 551 * 1323 728 * 1786 1103
-19.7 (-0.5)
(330) (205) (435) (250) (600) (330) (810) (500)
* 717 540 * 1125 750
-39.4 (-1.0) − − − −
(325) (245) (510) (340)
2-4-1 4480203
2. TECHNICAL DATA
Blade above ground Unit : lbs. (kg)

A [in. (m)] Max. 98.4 (2.5) 78.7 (2.0) Min.
B [in. (m)]
474 441 * 650 * 650 * 650 * 639
78.7 (2.0) − −
(215) (200) (295) (295) (295) (290)
430 386 * 684 551 * 722 * 783 * 904 * 915
59.1 (1.5)
(195) (175) (310) (250) (350) (355) (410) (415)
408 375 595 551 827 761 1036 948
39.4 (1.0)
(185) (170) (270) (250) (375) (345) (470) (430)
397 364 584 540 805 706 992 860
19.7 (0.5)
(180) (165) (265) (245) (365) (320) (450) (390)
408 386 573 518 772 684 1158 1036
0 (0)
(185) (175) (260) (235) (350) (310) (525) (470)
441 419 562 518 761 673
-19.7 (-0.5) − −
(200) (190) (255) (235) (345) (305)
573 507 783 706
-39.4 (-1.0) − − − −
(260) (230) (355) (320)
Note :
The lifting load with the asterisk (*) mark is limited by hydraulic lifting capacity rather than tipping. The lifting capacity
shown in the above list is based on the ISO Standard No. 10567 and represents either 87 % of hydraulic lifting
capacity or 75 % of tipping load, which is smaller.
2-4-2 4480203
CHAPTER 3
SERVICE STANDARDS
3-1 Machine Performance.......................................................................... 3-1-1

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

Applicable model ViO15-2
Item Measuring condition Unit Standard Allowance
Machine performance
Working speed
Boom speed Machine position
Max. cylinder extension Up 2.4 2.6
sec.
• Engine : rated speed

• Hydraulic oil temp. : 122 to 140 °F (50 to 60 °C) Down 2.3 2.5
Bucket teeth grounded • Site : Firm, flat ground
• Excluding cushion
Arm speed Machine position
Max. cylinder retraction Extend 2.1 2.3
sec.
• Engine : rated speed Retract 3.0 3.2

Max. cylinder extension • Hydraulic oil temp. : 122 to 140 °F (50 to 60 °C)
• Site : Firm, flat ground
Bucket speed Machine position
Max. cylinder retraction Dump 1.5 1.7
sec.
• Engine : rated speed Curl 2.2 2.4

Max. cylinder extension • Hydraulic oil temp. : 122 to 140 °F (50 to 60 °C)
Boom offset speed Machine position
Right swing 2.7 3.0

Max. cylinder retraction
sec.
• Hydraulic oil temp. : 122 to 140 °F (50 to 60 °C) Left swing 3.8 4.1
Max. cylinder extension • Full stroke
Blade speed Machine position
Max. cylinder retraction Up 1.1 1.2
sec.
• Engine : rated speed Down 1.2 1.3

Blade grounded • Hydraulic oil temp. : 122 to 140 °F (50 to 60 °C)
3-1-1 4480203

Machine performance
Machine position
High speed
18.0 20.5
sec./
Travel speed 787.4 in.
(20 m)

• Hydraulic oil temp. : 122 to 140 °F (50 to 60 °C) Low speed
• Traveling time for 787.4 in. (20 m) after an 34.3 39.0
approach run of 196.9 in. (5 m) or more.
Machine position
High speed
90 to 105
degrees 9.0 10.4

• Hydraulic oil temp. : 122 to 140 °F (50 to 60 °C) sec./
Track speed • Site : Firm, flat ground 3 rev.
• Travel lever : Full throttle
(Floating crawler side)
• Float one side of the crawler. Low speed
Make a mark on the crawler.
After turning the floating crawler side more 17.0 19.6
than once at full throttle, measure the time
needed for 3 turns of the crawler.
Machine position

in. (mm)/
• Hydraulic oil temp. : 122 to 140 °F (50 to 60 °C) 19.7 (500)
Track deviation 787.4 in. 23.6 (600)
• Site : Firm, flat ground or less
(20 m)
• Measure the deviation (χ) in a travel distance
of 787.4 in. (20 m) after an approach run of
196.9 in. (5 m) or more.
10
3-1-2 4480203

Machine performance
Machine position
in.
(mm) 4.72 (120)
Traveling drift 7.09 (180)
15 degrees / or less
5 min.
• Engine : stopped
• Hydraulic oil temp. : 122 to 140 °F (50 to 60 °C)
• Drift of the machine after 5 min. on a slope with
an inclination of 15 degrees.
Drift of cylinders
Machine position
Boom drift 0.31 (8) 0.59 (15)
(Cylinder rod retraction) or less
Arm drift 0.31 (8) 0.59 (15)

(Cylinder rod extension) in. or less
• Engine : stopped (mm)
• Hydraulic oil temp. : 122 to 140 °F (50 to 60 °C) /
Bucket drift • Site : Firm, flat ground 10 min.
0.20 (5) 0.35 (9)
(Cylinder rod extension) • Make the boom and bucket pins the same
or less
height.
• Measure the retraction or extension of each cyl-
inder rod after leaving the machine at the above
Blade drift position for 10 min. 0.20 (5) 0.35 (9)
(Cylinder rod extension) • Lift the blade to the highest position, and mea- or less
sure the cylinder rod extension after 10 min.
Machine position
15 degrees in.
Boom offset drift (mm) 0.20 (5)
0.30 (7.5)
(Cylinder rod extension) / or less
• Engine : stopped
10 min.
• Make the boom and bucket pins the same
height.
• Park the machine on a slope with an inclination
of 15 degrees and turn the upperstructure 90
degrees to the crawler and engage the swing
lock.
• Measure the cylinder rod extension after 10 min.
3-1-3 4480203

Machine performance
Machine position
in. 4.65 6.89

Swing drift at stopping (mm) or (118) or less, (175)
• Engine : rated speed degrees 30 or less 45
• Make the boom and bucket pins the same height.
• Make match marks on the outer race and the
inner race of the swing bearing (or the track
frame).
• Measure shifted distance between both marks
after making one turn with no load.
Machine position
sec. /
Swing time 35 40
5 turns

• Make one idling turn with no load, then mea-
sure the time necessary to make 5 turns.
Machine position
( at engine
stop ) 0
15 degrees
in.
Swing drift • Engine : stopped
(mm)
• Make the boom and bucket pins the same height.
• Park the machine on a slope with an inclination
of 15 degrees and turn the upperstructure 90
degrees to the crawler.
• Make match marks on the outer race and the
inner race of the swing bearing (or the track
( at engine
operating ) !1.77 (45)
(!10 degrees)
frame).
• Measure shifted distance or angle between
both marks after 5 min.
3-1-4 4480203
3-2 Engine
1) Nominal and Allowable Values

ViO15-2
Applicable model 3TNE68-EBVA
Item Unit Standard Wear limit
Cylinder head
Cylinder head distortion in. (mm) 0.0020 (0.05) or less 0.0059 (0.15)
Intake degrees 120 −
Valve seat angle
Exhaust (°) 90 −
Intake 0.045 (1.15) 0.065 (1.65)
Valve seat width in. (mm)
Exhaust 0.056 (1.41) 0.075 (1.91)
Ø0.215 to 0.216
Stem outside dia. 0.213 (5.4)
(Ø5.460 to 5.475)
Ø0.2165 to 0.2171
Intake valve Guide inside dia. in. (mm) 0.220 (5.58)
(Ø5.500 to 5.515)
0.0010 to 0.0022
Oil clearance 0.007 (0.18)
(0.025 to 0.055)
Ø0.2144 to 0.2150
Stem outside dia. 0.213 (5.4)
(5.445 to 5.460)
Ø0.2165 to 0.2171
Exhaust valve Guide inside dia. in. (mm) 0.220 (5.58)
(Ø5.500 to 5.515)
0.0016 to 0.0028
(0.040 to 0.070)
Valve guide projection in. (mm) 0.276 (7)
0.012 to 0.020
Intake
(0.3 to 0.5)
Valve sinkage in. (mm) 0.039 (1.0)
0.030 to 0.037
Exhaust
(0.75 to 0.95)
0.033 to 0.045
Intake
Valve head (0.85 to 1.15)
in. (mm) 0.020 (0.5)
thickness 0.037 to 0.049
Exhaust
(0.95 to 1.25)
Intake valve Open b. TDC degrees 5 to 15 −
operating timing Close a. BDC (°) 37 to 47 −
Exhaust valve Open b. BDC degrees 37 to 47 −
operating timing Close a. TDC (°) 5 to 15 −
Free length in. (mm) 1.102 (28) −
Valve spring Inclination in. (mm) − 0.031 (0.8)
Tension [0.0394 in. (1 mm) compressed] lbs. (kg) 2.51 to 3.09 (1.14 to 1.40)
0.006 to 0.010
Intake / exhaust valve clearance in. (mm) −
(0.15 to 0.25)
Cylinder block
2.6772 to 2.6783
Cylinder bore dia.
(68.000 to 68.030)
2.6780 to 2.6783
L mark
(68.020 to 68.030)
2.6850 (68.20)
2.6776 to 2.6780
Cylinder bore dia. M mark in. (mm) (68.010 to 68.020)
2.6772 to 2.6776
S mark
(68.000 to 68.010)
Roundness of cylinder sleeve bore 0 to 0.00039 (0 to 0.01) 0.00118 (0.03)
Cylindricity of cylinder sleeve bore 0 to 0.00039 (0 to 0.01) 0.00118 (0.03)
3-2-1 4480203

Valve
Ø0.3926 to 0.3932
Shaft outside dia. Ø0.3917 (Ø9.95)
(Ø9.972 to 9.987)
Intake / exhaust Ø0.3937 to 0.3945
Bush inside dia. Ø0.3972 (Ø10.09)
valve rocker arm (Ø10.000 to 10.020)
0.0005 to 0.0019
(0.013 to 0.048)
Push rod bend in. (mm) 0.00118 (0.03) or less −
Ø0.7067 to 0.7074
Stem outside dia. Ø0.7059 (Ø17.93)
(17.950 to 17.968)
Ø0.7087 to 0.7094
Tappet Guide hole inside dia. Ø0.7106 (Ø18.05)
(Ø18.000 to 18.018)
0.0013 to 0.0027
(0.032 to 0.068)
Piston
2.6748 to 2.6760
Piston outside dia.
(67.940 to 67.970)
2.6764 to 2.6768
L mark
(67.980 to 67.990)
2.6762 to 2.6764
ML mark 2.6732 (67.90)
(67.975 to 67.980)
Piston outside dia.
2.6760 to 2.6762
MS mark
(67.970 to 67.975)
2.6756 to 2.6760
S mark
(67.960 to 67.970)
in. (mm)
0.0018 to 0.0030
Minimum clearance between piston and cylinder −
(0.045 to 0.075)
0.0240 to 0.0287
Top clearance −
(0.610 to 0.730)
Ø0.7870 to 0.7874
Outside dia. Ø0.7835 (Ø19.90)
(Ø19.991 to 20.000)
Ø0.7874 to 0.7877
Piston pin Bush inside dia. Ø0.7882 (Ø20.02)
(Ø20.000 to 20.008)
0 to 0.00067
(0.000 to 0.017)
Piston ring
0.0610 to 0.0618
Ring groove width −
(1.550 to 1.570)
0.0579 to 0.0587
Ring width −
(1.470 to 1.490)
Top ring
0.0024 to 0.0039
Clearance between groove and ring −
(0.060 to 0.100)
0.0039 to 0.0098
End gap 0.0591 (1.5)
(0.100 to 0.250)
in. (mm)
0.0606 to 0.0612
(1.540 to 1.555)
0.0563 to 0.0571
Ring width −
(1.430 to 1.450)
Second ring
0.0035 to 0.0049
(0.090 to 0.125)
0.0059 to 0.0138
End gap 0.0591 (1.5)
(0.150 to 0.350)
3-2-2 4480203

Piston ring
0.1185 to 0.1191
(3.010 to 3.025)
0.1169 to 0.1177
Ring width −
(2.970 to 2.990)
Oil ring in. (mm)
0.0008 to 0.0022
(0.020 to 0.055)
0.0059 to 0.0138
End gap 0.0591 (1.5)
(0.150 to 0.350)
Connecting rod
Ø1.5354 to 1.5361
Crank pin metal inside dia. −
(Ø39.000 to 39.016)
0.0585 to 0.0591
Crank pin metal thickness −
(1.487 to 1.500)
Crank pin side
Ø1.4161 to 1.4165
Crank pin outside dia. 1.4141 (35.91)
(Ø35.970 to 35.980)
0.0013 to 0.0023
(0.033 to 0.059)
in. (mm)
Ø0.7884 to 0.7889
Bush inside dia. 0.7913 (20.10)
(Ø20.025 to 20.038)
Ø0.7870 to 0.7874
Piston pin side Piston pin outside dia. 0.7835 (19.90)
(Ø19.991 to 20.000)
0.0010 to 0.0019
(0.025 to 0.047)
0.0012 (0.03) or less
Twist and parallelism 0.0031 (0.08)
for 3.937 (100)
Cam
1.4150 to 1.4157
Cam shaft outside dia. 1.4114 (35.85)
(35.940 to 35.960)
Gear side
0.0016 to 0.0033
Oil clearance −
(0.040 to 0.085)
1.4138 to 1.4148
(35.910 to 35.935)
Intermediate
0.0026 to 0.0045
Oil clearance −
(0.065 to 0.115)
in. (mm) 1.4150 to 1.4157
(35.940 to 35.960)
Flywheel side
0.0016 to 0.0049
Oil clearance −
(0.040 to 0.125)
Bend 0.00079 (0.02) or less 0.00197 (0.05)
1.1799 to 1.1823
Intake cam 1.1713 (29.75)
(29.970 to 30. 030)
Cam height
1.1799 to 1.1823
Exhaust cam 1.1713 (29.75)
(29.970 to 30.030)
Crank shaft
1.5736 to 1.5740
Outside dia. 1.5709 (39.90)
(39.970 to 39.980)
0.0585 to 0.0591
Journal Main metal thickness −
in. (mm) (1.487 to 1.500)
0.0013 to 0.0023
(0.033 to 0.059)
Bend 0.00079 (0.02) or less −
3-2-3 4480203

0.0035 to 0.0107
Crank shaft −
(0.090 to 0.271)
0.0020 to 0.0098
Cam shaft −
(0.05 to 0.25)
Side gap in. (mm)
0.0079 to 0.0157
Connecting rod −
(0.2 to 0.4)
0.0039 to 0.0118
Idle gear −
(0.1 to 0.3)
Crank gear, cam gear, idle gear and fuel 0.0016 to 0.0047
−
injection pump drive gear (0.04 to 0.12)
Backlash in. (mm)
0.0043 to 0.0075
Lubricating oil pump gear −
(0.11 to 0.19)
Others
3.14 (11.9)
High speed −
Lube oil pump GPM at 3600 min-1 (rpm)
discharge volume (L/min) 0.66 (2.5)
Low speed −
at 750 min-1 (rpm)
PSI 42.66 to 56.88
Oil pressure regulating valve opening pressure −
(kPa) (294.2 to 392.3)
PSI 5.69 to 8.53
Oil pressure switch operating pressure −
(kPa) (39.2 to 58.8)
8.45 (32)
GPM at 3320 to 3380
Cooling water pump discharge volume −
(L/min)
min-1 (rpm)
157.1 to 162.5
Thermostat valve Temperature °F (°C) −
(69.5 to 72.5)
opening tempera-
ture 0.18 (4.5) or more
Lift at opening in. (mm) −
at 185°F (85°C) or higher
Thermo-switch 224.6 to 235.4
ON −
operating tempera- °F (°C) (107 to 113)
ture OFF 212 (100) or more −
3-2-4 4480203
3-3 Undercarriage
3-3-1 Rubber Crawler Specifications
[Unit : in. (mm)]

Measuring
Part Standard Wear limit
position
Rubber crawler specifications
(1) Rubber crawler
A 0.71 (18) 0.31 (8)

A
(2) Idler & shaft

A Ø1.18 (Ø30) −
B
B Ø1.26 (Ø32) Ø1.02 (Ø26)
C Ø11.61 (Ø295) Ø11.42 (Ø290)

C
A
3-3-1 4480203
[Unit : in. (mm)]

Measuring
Part Standard Wear limit
position
(3) Track roller & shaft
B
A Ø0.98 (Ø25) -
C
B 2.72 (69) 2.48 (63)
C 5.12 (130) 4.88 (124)

A
(4) Sprocket
B
A 0.79 (20) 0.39 (10)
A
C
B 0.71 (18) 0.51 (13)
C 3.19 (81) −
(5) Slide plate
A 1.97 (50) 1.77 (45)

A
3-3-2 4480203
3-4 Controls

Item Measuring conditions Unit Standard Allowable limit
Controls
Operating force
Right control lever • Engine : stopped
2.87 (1.3) 3.97 (1.8)
(Boom & Bucket) • Hydraulic oil temp. : 122 to 140 °F (50 to 60 °C)
• Lever operating force : Measure the force by
Left control lever
hanging the spring scale on the lever grip. 2.87 (1.3) 3.97 (1.8)
(Arm & Swing)
• Pedal operating force : Measure the force by
Blade lever applying load as shown below. 4.41 (2.0) 5.52 (2.5)
Press
Forward Forward
Spring scale
lbs. (kg) 4.85 (2.2) 5.95 (2.7)
Travel levers
Reverse Reverse
2.87 (1.3) 3.97 (1.8)
Boom swing lever Pull − −
Boom swing pedal 12.1 (5.5) 14.3 (6.5)
P.T.O. pedal − −
Play of control lever & pedal

Right control lever • Engine : stopped 0.79 (20)
−
(Front & rear / left & right) • Hydraulic oil temp. : 122 to 140 °F (50 to 60 °C) or less
• Play of each control lever and pedal :
Left control lever 0.79 (20)
Measure the total play (front & rear and left & −
(Front & rear / left & right) or less
right) at the lever grip end or the pedal end.
0.59 (15)
Blade lever Play −
Play or less
in. (mm)
0.79 (20)
Travel levers −
or less
0.16 (4)
Boom swing pedal −
or less
P.T.O. pedal − −
Control valve
Spool stroke
Boom A B
Stroke
Bucket
Arm
in. (mm) 0.24 (6) −
Swing
Parallel-flow divider
Right travel
A B
Left travel Stroke
Blade in. (mm) 0.24 (6) −

Boom swing
Offset
3-4-1 4480203
3-5 Hydraulic Equipment
3-5-1 Hydraulic Cylinders

ViO15-2
1 (Max. retraction length)

3 2 (Stroke)
8
7-1 7-2
5 4
6-1 6-2
Unit : in. (mm)

No. 7-1 / 7-2 8
6-1 / Tightening
1 2 3 4 5 Nut size
6-2 Standard Allowable limit torque
Cylinder (mm)
ft•lbf (N•m)
27.2 17.0 2.60 Ø2.17 Ø1.18 361.7 to 434.0
Boom G1/4 Ø1.38 (Ø35) Ø1.40 (Ø35.5) M24
(690) (431) (66) (Ø55) (Ø30) (490.0 to 588.0)
25.7 15.9 2.52 Ø2.17 Ø1.38 361.7 to 434.0
Arm G1/4 Ø1.18 (Ø30) Ø1.20 (Ø30.5) M24
(652) (404) (64) (Ø55) (Ø35) (490.0 to 588.0)
20.2 10.9 2.48 Ø2.17 Ø1.18 217.0 to 253.2
Bucket G1/4 Ø1.18 (Ø30) Ø1.20 (Ø30.5) M20
(514) (278) (63) (Ø55) (Ø30) (294.0 to 343.0)
21.7 11.6 2.52 Ø2.56 Ø1.38 Rc1/4 361.7 to 434.0
Boom swing Ø1.57 (Ø40) Ø1.59 (Ø40.5) M24
(550) (295) (64) (Ø65) (Ø35) G1/4 (490.0 to 588.0)
15.7 4.17 4.76 Ø2.17 Ø1.18 217.0 to 253.2
Blade Rc1/4 Ø1.18 (Ø30) Ø1.20 (Ø30.5) M20
(400) (106) (121) (Ø55) (Ø30) (294.0 to 343.0)
Track gauge 19.1 10.2 2.48 Ø2.17 217.0 to 253.2
(Ø30) G1/4 Ø1.57 (Ø40) Ø1.59 (Ø40.5) M20
change (485) (260) (63) (Ø55) (294.0 to 343.0)
Nut for pipe
Symbol Name
G (PF) Straight pipe thread
R (PT) Taper pipe thread (male)
Rc (PT) Taper pipe thread (female)
3-5-1 4480203
3-6 Implement
3-6-1 Front Attachments

ViO15-2
8
9 4
1
6
15
10 7
2
16
5
3
11
12
13
14
Unit : in. (mm)

Applicable model : ViO15-2 Wear limit
No. Standard
Measuring point Pin Bore of bush or hole
1 Boom swing fulcrum Ø1.97 (Ø50)
2 Boom fulcrum Ø1.38 (Ø35)
3 Boom swing cylinder, rod Ø1.57 (Ø40)
4 Boom swing cylinder, bottom Ø1.57 (Ø40)
5 Boom cylinder, bottom Ø1.38 (Ø35)
6 Boom cylinder, rod Ø1.38 (Ø35)
7 Arm fulcrum Ø1.38 (Ø35)
8 Arm cylinder, bottom Ø1.18 (Ø30)
-0.02 (-0.5) +0.02 (+0.5)
9 Arm cylinder, rod Ø1.18 (Ø30)
10 Bucket cylinder, bottom Ø1.18 (Ø30)
11 Bucket cylinder, rod Ø1.18 (Ø30)
12 Link “A” arm Ø1.18 (Ø30)
13 Bucket fulcrum Ø1.18 (Ø30)
14 Bucket “link A” Ø1.18 (Ø30)
15 Track gauge change cylinder, bottom Ø1.57 (Ø40)
16 Track gauge change cylinder, rod Ø1.57 (Ø40)
Note : Allowable clearance is 0.04 in. (1.0 mm).
3-6-1 4480203
3-6-2 Blade Moving Device
2 3
Unit : in. (mm)

Applicable model : ViO15-2 Wear limit
No. Standard
Measuring point Pin Bore of bush or hole
1 Blade cylinder, rod Ø1.18 (Ø30)
2 Blade cylinder, bottom Ø1.18 (Ø30) -0.02 (-0.5) +0.02 (+0.5)
3 Blade fulcrum Ø1.18 (Ø30)
Note : Allowable clearance between pin and bore of bush or hole is 0.04 in. (1.0 mm).
3-6-3 Bucket Teeth
Unit : in. (mm)

Measuring point Standard Wear limit Measure
A
7.40 (188) 5.20 (132) Replace
3-6-2 4480203
3-7 List of Tightening Torque
3-7-1 Machine
Unit : ft•lbf (N•m)
Applicable model: ViO15-2
Equipment
Thread size Tightening torque Adhesive
No. Tightening part
Engine / Electrical equipment
18.1 to 23.9
1 Engine mount vibroisolating rubber Nut M10 4T torque
(24.5 to 32.3)
32.6 to 43.4
2 Engine × Engine mount M10 Three Bond 1324
(44.1 to 58.8)
32.6 to 43.4
3 Engine stopper × Engine mount M10 Three Bond 1324
(44.1 to 58.8)
1.63 to 1.85
4 Hose clip 60 (Intake hose installation) −
(2.2 to 2.5)
Lock nut
1.45 to 2.17
5 Battery holding rod Nut M6 3.62 to 4.34 ft•lbf
(1.96 to 2.94)
(4.9 to 5.88 N•m)
0.89 to 1.11
6 Fuel gauge unit Pan head screw M5
(1.2 to 1.5)
1.63 to 1.85
7 CW-T (A-B) Hose clip
(2.2 to 2.5)
2.17 to 2.89
8 Battery cable terminals Nut M6
(2.94 to 3.92)
14.5 to 16.6
9 Air cleaner M8
(19.6 to 22.6)
18.1 to 23.9 ft•lbf
1.85 to 2.15
10 Fuel tank band Nut M10 (24.5 to 32.4 N•m)
(2.5 to 2.9)
<Lock nut side>
Lock nut M18 21.7 to 25.3
11 Safety starter switch
(Fine screw thread) (29.4 to 34.3)
Driving system
32.6 to 43.4
1 Sprocket M10 Three Bond 1324
(44.1 to 58.8)
Travel device
6.51 to 7.23
1 Plugs (idler, adjust cylinder) PT 1/8 Loctite 572
(8.83 to 9.81)
32.6 to 43.4
2 Idler seal cover × Crawler spring M10 Three Bond 1324
(44.1 to 58.8)
57.9 to 72.3
3 Track roller tightening nut M12 Three Bond 1324
(78.4 to 98.0)
4 Nipple valve M16 36.2 (49.0)
32.6 to 43.4
5 Shoe slide plate M10 Three Bond 1324
(44.1 to 58.8)
3-7-1 4480203

Equipment
No. Tightening part
Controls
Nut M14 54.3 to 61.5
1 Levers (L, R) × Pilot valve Three Bond 1324
(Fine screw thread) (73.6 to 83.4)
1.48 to 1.92
2 Knobs (L, R) × Levers (L, R) Binding head screw M4 Three Bond 1324
(2.0 to 2.6)
9.4 to 12.3
3 L-ball 8 × Link ball 8 Nut M8
(12.7 to 16.7)
5.79 to 7.23
4 L-ball 8 × Rod Nut M8
(7.84 to 9.8)
14.5 to 18.8
5 Valve mount × Turning frame Flange bolt M10 Three Bond 1324
(19.6 to 25.5)
2.89 to 3.62
6 Accelerator cable Nut M6
(3.92 to 4.9)
14.5 to 18.1
7 Blade cable Nut M12
(19.6 to 24.5)
14.5 to 18.1
8 Track gauge change cable Nut M12
(19.6 to 24.5)
Frame
79.6 to 94.0
1 Swing bearing × Frame M12 Loctite 262
(107.8 to 127.4)
57.9 to 72.3
2 Crawler guard (steel crawler only) M12 Three Bond 1324
(78.5 to 98.1)
Hydraulic equipment
Hexagon socket 36.2 to 43.4
1 CF Coupling Three Bond 1324
head bolt M10 (49.0 to 58.8)
32.6 to 43.4
2 Swivel joint × Track frame M10 Three Bond 1324
(44.1 to 58.8)
57.9 to 72.3
3 Swing motor × Turning frame M12 Three Bond 1324
(78.4 to 98.0)
32.6 to 43.4
4 Travel motor × Track frame M10 Three Bond 1324
(44.1 to 58.8)
43.4
5 Drain plug M14 × Hydraulic oil tank M14
(58.8)
10.9 to 12.3
6 Oil level gauge × Hydraulic oil tank M10
(14.7 to 16.7)
1.11 to 1.85
7 Hose clip 13 − Drain
(1.5 to 2.5)
1.85 to 2.52
8 Hose clip 16 − Drain
(2.5 to 3.4)
2.89 to 3.62 Return BL-Hydraulic oil
9 Hose clip 35 −
(3.92 to 4.90) tank
3.62 to 4.34
10 Hose clip 25 − Hydraulic oil tank drain
(4.90 to 5.88)
3.62 to 4.34
11 Hose clip 41 − Suction
(4.90 to 5.88)
2.17 to 2.89
12 Breather cover (for hydraulic oil tank) M5
(2.94 to 3.92)
18.1 to 23.9
13 Flange (PIN pump) M10
(24.5 to 32.4)
3-7-2 4480203

Equipment
No. Tightening part
Rigging
Canopy pole × Seat mount 57.9 to 72.3
1 M12 (10.9T) 7T torque
(canopy type) (78.4 to 98.0)
Work implements
32.6 to 43.4
1 Slide cover M10 Three Bond 1324
(44.1 to 58.8)
32.6 to 43.4
2 Lock plate (swing cyl. bottom pin) M10 Three Bond 1324
(44.1 to 58.8)
32.6 to 43.4
3 Lock plate (blade arm fulcrum pin) M10 Three Bond 1324
(44.1 to 58.8)
32.6 to 43.4
4 Implement cylinder pin lock M10 Three Bond 1324
(44.1 to 58.8)
57.9 to 72.3
5 Swing cylinder connecting rod pin M12 Three Bond 1324
(78.5 to 98.1)
3-7-3 4480203
3-7-2 Engine
Tightening torque for major bolts and nuts
No Thread size × Tightening torque Lubricating

Item
. Pitch Unit : ft•lbf (N•m) oil
1 Cylinder head bolt (class 1) M8 × 1.25 27.5 to 30.4 (37.2 to 41.2) Yes
2 Connecting rod bolt (class 1) M7 × 1.0 16.6 to 20.3 (22.5 to 27.4) Yes
3 Flywheel mounting bolt M10 × 1.25 59.3 to 63.7 (80.4 to 86.2) Yes
4 Metal cap bolt M9 × 1.25 38.3 to 41.2 (51.9 to 55.9) Yes
5 Crankshaft pulley fastening bolt M12 × 1.5 61.5 to 68.7 (83.3 to 93.1) Yes
6 Fuel injection nozzle retainer clamp nut M20 × 1.5 36.2 to 39.1 (49.0 to 52.9) No
7 Glow plug M10 × 1.25 10.9 to 14.5 (14.7 to 19.6) No
8 Governor weight support nut M12 × 1.25 50.6 to 54.3 (68.6 to 73.5) Yes
9 High pressure pipe nut M12 × 1.5 21.7 to 25.3 (29.4 to 34.3) No
3-7-3 Tightening Torque for General Bolts and Nuts

Tightening torque
Item Thread size × Pitch Remarks
[Unit : ft•lbf (N•m)]
7.23 to 8.68
M6 × 1
(9.8 to 11.8)
16.6 to 21.0
M8 × 1.25
(22.6 to 28.4)
32.6 to 43.4
M10 × 1.5
(44.1 to 58.8)
57.9 to 72.3
M12 × 1.75
Coarse (78.5 to 98.1)
1) Apply 80% of tightening torque
thread 86.8 to 108.5 when tightened to aluminum.
M14 × 2
Hexagon head bolt (7T) (117.7 to 147.1) 2) Apply 60% of tightening torque
Nut 123.0 to 151.9 for 4T bolts and lock nuts.
M16 × 2 3) Use fine screw threads for
(166.7 to 205.9)
engine only.
173.6 to 209.8
M18 × 2.5
(235.4 to 284.4)
238.7 to 296.6
M20 × 2.5
(323.6 to 402.1)
94.0 to 108.5
M14 × 1.5
Fine (127.5 to 147.1)
thread 155.5 to 177.2
M16 × 1.5
(210.9 to 240.3)
1/8 7.23 (9.8)
1/4 14.5 (19.6)
PT plug
3/8 21.7 (29.4)
1/2 43.4 (58.8)
M8 9.4 to 12.3 (12.7 to 16.7)
M12 18.1 to 25.3 (24.5 to 34.3)
Pipe joint bolt
M14 28.9 to 36.2 (39.2 to 49.0)
M16 36.2 to 43.4 (49.0 to 58.8)
3-7-4 4480203
CHAPTER 4
ENGINE
4-1 Measurement, Inspection and Adjustment .......................................... 4-1-1

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

Compression pressure at 300 rpm PSI (MPa) Variations of compression
pressure among cylinders
Standard Limit PSI (MPa)
482.9 to 511.9 (3.33 to 3.53) 362.5 (2.5) 28.4 to 42.7 (0.2 to 0.3)
2) Trouble Diagnosis Through Measurement of Compression Pressure

Reduction in the compression pressure of the cylinder is one of the major causes of the increase in blow-by gas
(which causes contamination and increased consumption of lubricating oil, and other trouble) and the engine start-
ing failure. The compression pressure is influenced by the following factors :
(1) Degree of the clearance between the piston and the cylinder ;
(2) Degree of the clearance around the intake / exhaust valve seats ; and
(3) Gas leak through the nozzle gasket or the cylinder head gasket.
This means that the compression pressure decreases as the engine parts are worn and lose durability through the
use of the engine over a long period of time.
In addition, the compression pressure is also decreased by scratches on the cylinder or the piston which are caused
by dust or other foreign matters drawn in through the soiled filter element of the air cleaner, and wear or breakage of
any piston rings. Therefore, the condition of the engine should be diagnosed by measuring the compression pres-
sure.
4-1-1 4480203
4. ENGINE
Causes and countermeasures to be taken when the compression pressure is less than the limit value.
No. Item Causes Countermeasures
• Filter element of air cleaner • Clogged filter element • Clean the filter element.
1 • Broken filter element • Replace the filter element.
• Defective filter element seal portion
• Valve clearance • Excessive or no valve clearance • Adjust the valve clearance.
2
(Refer to Section 4-1-2.)
• Valve timing • Improper valve timing • Adjust the valve clearance.
• Improper valve clearance (Refer to Section 4-1-2.)
3
• Inspect and adjust the valve rocker arm.
(Refer to Sections 4-2-3, 4-2-6 and 4-2-8.)
• Cylinder head gasket • Gas leak through the gasket • Replace the gasket.
• Nozzle gasket • Re-tighten the cylinder head and the nozzle at the
4
specified torque.
(Refer to Section 3-7-2 of Chapter 3.)
• Intake/exhaust valve • Gas leak due to worn valve seats or • Lap the valve seats.
5 • Valve seat trapped foreign matters (Refer to Section 4-2-1 2).)
• Sticking of valves • Replace the intake/exhaust valves.
• Piston • Gas leak due to scratches or wear of • Do the honing and use oversize parts.
6 • Piston ring the piston, piston ring or cylinder (Refer to Sections 4-2-2 3) and 4-2-4 8).)
• Cylinder
4-1-2 Adjusting the Valve Clearance
(1) Inspect and adjust the intake / exhaust valve clear-

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

clearance Adjust screw
and Allowable Values".
Notes : Valve clearance Lock nut

1. If the valve cap is worn or otherwise damaged in the
head, replace it with a new one.
2. Check that the valve cap is fitted on the head of
intake/exhaust valve.
Valve cap (Adjusting the valve clearance)
Normal Abnormal
4-1-2 4480203
4. ENGINE
4-1-3 Checking the V-belt Tension
Push the center of the V-belt between the alternator

and the cooling water pump with a finger. If the slack
is 0.39 to 0.59 in. (10 to 15 mm), the V-belt tension is
proper. If not, adjust the V-belt tension using the
adjuster at the alternator.
Adjust the tension of

the V-belt using a bar.
Adjuster 0.39 to 0.59 in.

(10 to 15mm)
Alternator
Cooling water pump
Crank pulley
Alternator
(Adjusting the V-belt tension)
4-1-4 Checking the Fuel Injection Valve
1) Measuring the Fuel Injection Pressure
Note :
Thoroughly remove carbon deposits from the injection
nozzle hole before the measurement.
(1) Connect the fuel injection valve to the high pressure

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

Fuel injection pressure adjustment
[in. (mm)]
0.0039 (0.1) 0.0079 (0.2) Increase the pressure adjusting shim thickness by 0.0039 in. (0.1 mm) to
0.0118 (0.3) 0.0157 (0.4) increase the fuel injection pressure by about
0.0197 (0.5) 99.5 to 128.0 PSI (686.5 to 882.6 KPa).
4-1-3 4480203
4. ENGINE
[Reference : Structure of fuel injection valve]

(Special swirl pre-combustion chamber)
Nozzle holder
Pressure adjusting shim
Nozzle spring
Nozzle spring seat
Valve stop spacer
Nozzle valve
Nozzle
Nozzle body
Nozzle case nut
2) Checking the Spray Pattern

While pumping the lever of the nozzle tester once or twice per second at the specified fuel injection pressure (Refer
to Section "2-1 Specifications".), check the spray pattern. If the spray pattern is not normal, clean or replace the noz-
zle.
(1) Check that the pattern is neither like a stream nor slivered.
(2) Check that fuel is sprayed conically around the nozzle center line and that the spray angle is 5 to 10 degrees.
[Normal spray pattern] [Abnormal spray pattern]
5 to 10 degrees
(3) Spray fuel on a sheet of white paper placed about 11.8 in. (30 cm) below the nozzle. The injection spray should
form a perfect circle.
(4) No fuel should drip from the nozzle after injection.
(5) Fuel should not ooze from the nozzle hole when the fuel injection pressure rises to a value that is a little lower
than the specified value : 284 PSI (1.96 MPa).
(6) Test the injection with a nozzle tester ; retighten the nozzle holder and test it again if there is excessive fuel leak
from the overflow coupling. Replace the nozzle as a set if the fuel leak is still excessive.
4-1-4 4480203
4. ENGINE
3) Nozzle Valve Sliding Test

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

Y DN - O S D YD1
Design code
No code : Pintle type

Code D : Throttle type
Size : Size P (or S)
Spray angle Identification

number
Type : Pintle type
YANMAR
4-1-5 Checking and adjusting the Fuel Injection Timing
1) Replacing the Fuel Injection Pump

Adjusting shim
When the pump has become old and worn, replace the pump.
Replacing only the fuel pump

As with the standard engine, injection timing adjusting shims are
inserted between the gear case and the fuel pump for adjustment.
Check the injection timig with the FID method.
Note :
Do not separate the FIP coupling and driving gear.
Marking for adjustment shim
(Shim thickness differs for each fuel pump.) 45
No.1 cylinder
Timing seal line
End nut
FIP driving gear
4-1-5 4480203
4. ENGINE
2) Checking and Adjusting the Fuel Injection Timing

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

Cylinder No.1
fuel level rises at the tip of the delivery valve spring holder.
At that time, stop turning the crankshaft.
(3) Check the timing mark imprinted on the flywheel through the Flywheel housing
peep hole in the flywheel housing.
(For the fuel injection timing, refer to Section "2-1 Specifica-
tions".
Peep hole
Timing mark
(4) If the fuel injection timing differs from the specified timing,
remove the fuel injection pump to adjust the timing by
increasing or reducing the adjusting shim thickness
between the fuel injection pump and the gear case.
• Increase the shim thickness to delay the injection timing.
• Reduce the shim thickness to advance the injection timing. Adjusting shim
4-1-6 4480203
4. ENGINE
4-1-6 Adjusting the Maximum (or Minimum) Idling Speed
(1) First warm up the engine. Then, gradually increase the Maximum idling speed adjusting bolt
engine speed up to the maximum idling speed. (Refer to Decrease Increase
Section "2-1 Specifications".)
(2) If the maximum idling speed differs from the specified one,
adjust the maximum idling speed using the maximum
idling speed adjusting bolt.
(3) Set the minimum idling speed to the specified value, Minimum idling speed
(Refer to Section "2-1 Specifications".) by turning the mini- adjusting bolt
mum idling speed adjusting bolt.

Note : Increase
The illustration shows the partial perspective view of the gover- Regulator handle Decrease
nor for the direct injection system.
4-1-7 Checking the Cooling Water System and Radiator for Water Leakage
1) Checking the Cooling Water System for Water Leakage

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

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

Attach the radiator cap to a cap tester. Set the pressure of the
tester to 10.67 to 14.93 PSI (0.073 to 0.103 MPa). Check if the
cap is opened at the set pressure. If not, replace the cap,
because it is defective.
Radiator cap
(Checking the radiator cap)
4-1-7 4480203
4. ENGINE
4-1-8 Checking the Sensors
1) Checking the Thermostat and the Thermoswitch

(1) Thermostat
Put the thermostat into the water in a container. While To radiator
measuring the water temperature, heat the water. Check
that the thermostat functions at a temperature of 157.1
to 162.5 °F (69.5 to 72.5 °C). Cover
Thermometer
Thermostat
Thermostat
Thermoswitch
(2) Thermoswitch
Put the thermoswitch into the antifreeze or oil in a con- Thermometer
tainer. While measuring the liquid temperature, heat the
liquid. If the tester shows continuity at a temperature of
224.6 to 235.4 °F (107 to 113 °C), the thermoswitch is
normal.
Tester probes
2) Hydraulic Switch
Cylinder block
Remove the connector from the hydraulic switch. While (Flywheel side)
running the engine, bring the tester probes into contact Tester probes
with the switch terminal and the cylinder block. If the

tester shows continuity, the hydraulic switch is defective.
(Continuity test)
4-1-8 4480203
4. ENGINE
4-2 Measurement Procedure, Service Data and Corrective Action
For the maintenance of all parts, make measurements according to the following measurement procedure. If any
part is found to be defective or if any part is not within the allowable value, replace it with a new one. However, if it is
expected that any part within the allowable value will exceed the value before the next maintenance based on the
record of its use, be sure to replace such a part beforehand.
4-2-1 Cylinder Head
1) Checking the Combustion Surface for Distortion

(1) Remove the intake / exhaust valves and the fuel
Straight-edge
injection valve from the engine. Clean the surface of
the cylinder head.
(2) Place a straight-edge along each of the four sides
and each diagonal of the cylinder head. Measure
the clearance between the straight-edge and the
combustion surface with a thickness gauge.
Cylinder head
combustion Standard Wear limit Thickness gauge
surface distortion
Refer to Section "3-2 1) Nominal and Allowable Values". ( Measuring the combustion
surface distortion )
(3) Visually check if the combustion surface is free from
discoloration, cracks, and crazing. In addition, use the color check kit for cracks and crazing.
2) Intake / Exhaust Valve Seat

(1) Valve sinkage
Over long periods of use and repeated lappings, combustion efficiency may drop. Measure the sinking depth and
replace the valve and valve seat if the valve sinking depth exceeds the standard value.
Standard. Wear limit
Intake
Valve valve Refer to Section "3-2 1) Nominal and
sinkage Exhaust Allowable Values".
valve
Valve sinkage
Depth micrometer
(Measuring the valve sinkage)
4-2-1 4480203
4. ENGINE
(2) Width and angle of the valve seat

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

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

(1) Correct the roughened seat surface with a seat
grinder or a seat cutter.
70
Seat grindstone Angle θ (degrees)

Intake valve 30
15
Seat width
Exhaust valve 45
(2) When the seat width is enlarged from the initial

value, correct it by grinding the seat surface with a
Valve seat
70 degrees seat grinder or a seat cutter. Then, grind
the seat surface with a 15 degrees grinder so that
the seat width should be the standard value. (Valve seat correction angle)
Note :
When using a seat cutter, apply pressure evenly taking
care not to cut the seat surface unevenly.
(3) Knead a valve compound with oil and finish the valve seat by lapping with the compound.
Note :
If any valve requires correction, be sure to measure the oil clearance between the valve stem outside dia. and the
valve guide inside dia. If the oil clearance exceeds the wear limit, replace the valve or the valve guide before correct-
ing the valve seat surface. (For the oil clearance between the valve and the valve guide, refer to the subsection 3 in
this section.)
4-2-2 4480203
4. ENGINE
(4) Last, lap the valve using only oil.

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

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

Measure the thickness of the valve head with a micrometer.
If the measured value is near the wear limit, replace the
valve with a new one.
Standard Wear limit
Intake
Thickness valve Refer to Section "3-2 1) Nominal
of valve
Exhaust and Allowable Values".
head
valve Seat width
Thickness
Valve diameter
Seat angle
4-2-3 4480203
4. ENGINE
[Valve guide replacement procedure]

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

(4) Check the projection of the valve guide.
Projection
Standard Wear limit
Refer to Section "3-2 1) Nominal

Valve guide projection
(Valve guide projection)

4) Valve Stem Seal Valve stem seal
[Time of replacement]
(1) When oil loss is found excessive.
Valve guide
(2) When the valve stem seal is removed.
Cylinder head
(3) When the intake / exhaust valve is removed.
[Precautions on installation]
Before reinstalling the intake / exhaust valve, thoroughly
remove the burrs on the valve stem surface and then apply
sufficient lubricating oil to the valve stem.
Hatched portion indicates
( where to apply lubricating oil. )
4-2-4 4480203
4. ENGINE
5) Checking the Valve Spring

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

Check the contact of the inner surface of the valve
spring holder with the outer surface of the cotter as well Square
as the contact of the inner surface of the cotter with the Free length
notch in the head of the valve stem. If such contact is
uneven or if the cotter has sunk due to wear, replace the
cotter with a new one. Surface plate
(Measuring the inclination of valve spring)
4-2-5 4480203
4. ENGINE
4-2-2 Cylinder Block

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

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

Refer to Section "3-2 1) Nominal a, b and c in the directions of A and B
Roundness of cylinder
Cylindricity of cylinder Cylinder bore measuring
( points )
4-2-6 4480203
4. ENGINE
3) Honing
(1) Application of honing
Apply honing or boring to the cylinder if it is partially
worn, flawed, or otherwise damaged. If the partial wear,
flaw or other damage is minor, it can be repaired only by
honing with a Flex-Hone. However, if it is not minor,
apply honing after boring. In this case, taking the maxi-
mum wear into consideration, it is important to examine
whether the cylinder can attain perfect roundness after
honing and / or boring, and whether prepared oversized
pistons and piston rings can be used. (For the oversized (Flex-Hone)
pistons and piston rings, refer to Section "4-2-4 Piston
and Piston Rings".)
(2) Procedure for using the Flex-Hone Flex-Hone
It is common practice to use the Flex-Hone for honing.
The procedure for using it is described below. Any mate-
rial needs a honing allowance of approx. 0.00004 in. (1 /
1000 mm) for honing with the Flex-Hone.
[1] Items to be prepared Power drill
Flex-Hone, power drill, and honing liquid

Engine oil Light oil
Flex-Hone Applicable bore dia.
50% 50%
Yanmar code No. [in. (mm)]
129400-92420 2.48 to 2.76 (63 to 70)
Honing liquid
[2] Handling procedure
Soak the Flex-Hone in the honing liquid. Insert the Flex-
Hone into the cylinder and move it up and down for about
30 seconds while turning it at a cross hatch angle of about
30 to 40 degrees. Then, extract the Flex-Hone while turn- 30 to 40 degrees
ing it.
Notes :
1. Use the Flex-Hone at a speed of 300 to 1200 rpm. Use
of the Flex-Hone at a higher speed may be hazardous.
2. Never insert into or extract from the cylinder the Flex-
Hone, with the power drill stopped.
4-2-7 4480203
4. ENGINE
4) Overhaul of Cylinder (Reference)

Service life of cylinder block (H3)
(H3 = 3H1)
Time for boring and honing (H2)

(H2 = 1.5H1)
Time for honing (H1)
Increase in L.O.C* Increase in L.O.C Increase in L.O.C Increase in L.O.C

and blow-by and blow-by and blow-by and blow-by
Honing Boring
Examine the applicability
( of oversized
pistons and piston rings.
)
*L.O.C = lubricating oil consumption
4-2-3 Valve Rocker Arm
1) Measuring the Rocker Arm Shaft Outside Diame-

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

busu inside diameter )
4-2-8 4480203
4. ENGINE
2) Checking the Push Rod Bend, Measuring the Tappet

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

Thickness gauge
Stem outside
diameter Refer to Section "3-2 1)
Guide hole Nominal and Allowable Val-
Tappet ues".
inside
diameter
Oil clearance (Measuring the push rod bend)
3) Other Inspections
(1) Valve rocker arm shaft spring
Check if the rocker arm shaft spring is free from corro-
sion and wear. If not, replace it with a new one.
(2) Wear of intake/exhaust valve rocker arm and valve cap
Check the intake / exhaust valve rocker arm for the con-
tact surface with the valve cap. If any of them is exces-
sively worn or partially flaked, replace it.
(3) Check the portion where the valve clearance adjust
screw is in contact with the push rod. If the portion is (Measuring the tappet stem outside diameter)
worn or flaked, replace the push rod or the adjust screw.
Adjust screw
Check of contact surface
Check of contact
surface of rocker arm
Push rod
Abnormal contact surface Normal contact surface
(Checking the tappet contact surface)
4-2-9 4480203
4. ENGINE
4-2-4 Piston and Piston Rings
1) Checking the Piston

(1) Remove carbon deposits from the head and com-
bustion surface of the piston while taking care not to
damage the piston. Check if there are any cracks or
damage.
(2) Check the outer surface and ring grooves of the pis-
ton, and replace it if worn or damaged.
Measuring
position
0.87 to 0.98 in
(22 to 25 mm )
2) Measuring the Piston Outside Diameter

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

Minimum clearance Refer to Section "3-2 1) Nominal
between piston and Allowable Values".
and cylinder
(Measuring the piston outside diameter)
3) Shapes of Piston Rings
Top ring
Top ring
Second ring
Oil ring
4-2-10 4480203
4. ENGINE
4) Measuring the Ring Groove Width, the Ring Width (B), and the End Gap
To measure the piston ring groove width, first measure the
width (B) of the piston ring. Then, fit the piston ring into
the ring groove after cleaning the groove carefully. Insert a
thickness gauge between the piston ring and the groove
to measure the clearance between them. Obtain the ring
groove width by adding the ring width to the measured
clearance.
Width
(B)
Thickness
(Measuring the ring groove width)
To measure the end gap, push the piston ring into the End gap
sleeve using the piston head, insert a thickness gauge
between both ends of the piston ring. If the sleeve is worn,
Approx. 1.18 in. (30 mm)
measure the end gap after pushing the piston ring into the
sleeve to the portion which is less worn (approx. 1.18 in.
Piston ring
(30 mm) from the lower end of the sleeve).
Standard Wear limit
Ring groove Cylinder block

width
Ring width (B)
Top
ring Clearance
between
groove and ring
End gap
Ring groove
width
Second
Ring width (B)
( Measuring the end gap
of piston ring )
ring Clearance and Allowable Values".
between
groove and ring
End gap
Ring groove
width
Ring width (B)
Oil ring Clearance
between
groove and ring
End gap
4-2-11 4480203
4. ENGINE
5) Installation of Piston Rings

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

Inside Diameter of the Piston Pin
Measure the outside diameter and bush hole inside
diameter of the piston pin. Replace the piston pin if one Oil ring
or both of the measured values exceed the wear limit.
Apply lubricating oil to the piston pin before inserting it
Top ring
into the piston.
120
120
Second ring
120
Oil ring
(Measuring points of the piston pin

outside diameter )
Standard Wear limit
Outside dia.
Piston Bush hole Refer to Section "3-2 1) Nomi-
pin inside dia. nal and Allowable Values".
Oil clearance
Apply oil to piston pin
(Measuring the piston pin outside diameter) Circlip
(Inserting piston pin)
4-2-12 4480203
4. ENGINE
7) Top Clearance (Reference)
Top clearance
Refer to Section "3-2 1) Nominal and Allowable Values".
8) Oversized Piston and Piston Ring
(0.250S : Oversized by 0.0098 in. (0.25 mm))
Piston assembly code

Size classification Piston ring assembly code
(including piston ring assembly)
0.250S 119265-22900 119265-22950
4-2-5 Connecting Rod
1) Visual Inspection
Inspect the following portions for cracks, distortion and discoloration :
(1) Portions close to the boundaries between the chamfered parts of the large and small ends, and the I-beam sec-
tion of the connecting rod
(2) Portion around the oil hole in the bush at the small end
2) Measuring the Twist and Parallelism

Measure the twist and parallelism of the connecting rod with a connecting rod aligner.
Twist and parallelism
Refer to Section "3-2 1) Nominal and Allowable Values".
n.
4i )
3.9 mm
0
(10
n.
4i )
3.9 mm
0
(10 Parallelism
Connecting
rod aligner
Twist
Reference axis
( Measuring the twist with

connecting rod aligner )
(Measuring the twist and parallelism)
4-2-13 4480203
4. ENGINE
3) Measuring the Clearance Between the Crank Pin and Bush

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

Pin Bush and the Piston Pin
To measure the oil clearance between the piston pin
bush and the piston pin, measure the inside diameter of
the piston pin bush and the outside diameter of the pis-
ton pin, and calculate the difference between them.
Standard Wear limit
Bush
inside dia. Cylinder gauge
Piston Refer to Section "3-2 1) Nomi-
Piston pin
pin side. nal and Allowable Values".
outside dia
Oil clearance
( Measuring the inside diameter of

the piston pin bush
)
4-2-14 4480203
4. ENGINE
5) Checking the Contact of the Crank Pin Metal

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

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

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

Undersized by 0.0098 in. (0.25 mm)
Crank pin metal
Metal thickness in. (mm)
Part code No.
Standard
119810-23350 0.064 (1.625)
Crank shaft
Thickness gauge
(Measuring the connecting rod side gap)
4-2-15 4480203
4. ENGINE
4-2-6 Cam shaft
1) Side Gap Around the Cam Shaft

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

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

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

Cam shaft bend
4) Measuring the Intake / Exhaust Cam Height
V-block
Standard Wear limit
Intake (Measuring the cam shaft bend)

Cam cam Refer to Section "3-2 1) Nominal and
height Exhaust Allowable Values".
cam
Micrometer
Cam height
(Measuring the cam height)
4-2-16 4480203
4. ENGINE
5) Measuring the Outside Diameters of the Cam Shaft

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

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

Before extracting the crank shaft and when installing it,
contact a dial gauge with the end of the crank shaft.
Press the crank shaft to each of the right and left sides in
the axial direction to measure the side gap. Alternatively,
insert a thickness gauge directly into the clearance
between the thrust metal in the reference part and the
thrust face of crank shaft to measure the side gap. If the
measured value exceeds the wear limit, replace the
thrust metal with a new one.
ues".
Dial gauge
Crank shaft
4-2-17 4480203
4. ENGINE
2) Color Check of Crank Shaft

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

Check the metals for flaking, melting, seizure, and the
state of the contact spur face. Replace any of the metals
if it is damaged.
(Inspection by color check)
4) Bend of the Crank Shaft
Support the journals of the crank shaft with V-blocks at
both ends. Measure the runout at the center journal with Bend
a dial gauge while rotating the crank shaft to check the
bend of the crank shaft.
Bend Nominal and Allowable Val- Runout
ues".
Dial gauge
5) Measuring the of Crank Pin and Journal

Measure the outside diameters, roundness, taper angles
of the crank pin and journal. If the partial wear or the
roundness exceeds the wear limit but the measured out-
side diameter is within the limit, correct it by regrinding.
V-block V-block
Replace the crank shaft with a new one, if it is
(Measuring the crank shaft bend)
unreparable. An under sized crank pin metal by 0.0098
in. (0.25 mm) is available. (Refer to Section 4-2-5, 4-2-8
in this chapter.)
Crank journal
Crank pin
( Measuring
and journal
points of the crank pin
)
4-2-18 4480203
4. ENGINE
Standard Wear limit
Crank Crank pin

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

(1) The lower half of the metal on the cap side has no oil groove.
(2) The upper half of the metal on the cylinder block side has an oil groove.
(3) Check the cylinder block alignment No.
(4) Place the embossed mark "FW" of the cap on the flywheel side.
(5) Place the main metal as a reference one on the flywheel side.
Main metal (reference)
Thrust metal (flywheel side)
Main metal
Metal cap (reference)
Metal cap
Metal cap
7) Undersized Main Metal by 0.0098 in. (0.25 mm) and Oversized Thrust Metal by 0.0098 in. (0.25 mm)
Main metal Thrust metal
Metal thickness Metal thickness
Part code No. in. (mm) Part code No. in. (mm)
Standard Standard
719260-02870 0.064 (1.625) 119260-02940 0.084 (2.125)
4-2-19 4480203
4. ENGINE
4-2-8 Gears
1) Checking the Gears

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

Apply a dial gauge onto the pitch circle of the gear, and measure the backlash.
Standard Wear limit
Crank gear, cam gear,

idle gear and fuel injec- Refer to Section "3-2 1)
Backlash tion pump drive gear Nominal and Allowable
Lubricating oil pump Values".
gear
3) Checking and Measuring the Idle Gear Shaft and the Idle Gear
(1) Measure the idle gear bush inside diameter and the
idle gear shaft outside diameter, and replace the bush
or the idle gear shaft if the oil clearance exceeds the
wear limit.
(2) Check that the oil holes in the idle gear shaft and the
bush are aligned.
Idle gear
Standard Wear limit Bush
Idle gear shaft
Shaft outside dia.
Idle gear Bush inside dia. Nominal and Allowable
Values".
Oil clearance
4) Gear Train
After installing all the gears, check that the matchmarkes A, B and C on the idle gear are aligned with those on the
crank gear the fuel injection pump drive gear and the cam gear respectively.
(From the gear case side)

Fuel injection pump drive gear
Cam gear
B
B C
C
A
Idle gear
A *P.T.O. (Option)
Crank gear
Lubricating oil pump gear
Direction of rotation
4-2-20 4480203
4. ENGINE
4-2-9 Trochoid Pump
1) Clearance Between Outer Rotor and Pump Body

Insert a thickness gauge between the outer rotor and the Outer rotor
pump body to measure the clearance.
Pump body
Standard Wear limit
Clearance between Thickness gauge

outer rotor and
pump body
(Measuring the clearance between

outer rotor and pump body )
2) Clearance Between Outer Rotor and Inner Rotor
Insert a thickness gauge between the top of the inner
rotor tooth and the top of the outer rotor tooth to mea-
sure the clearance.
Inner rotor
Standard Wear limit

Outer rotor
Clearance between
outer rotor and
inner rotor
Thickness gauge
3) Distortion Between Pump Body and Inner Rotor,

Outer Rotor
Place a straight edge on the end face of the pump body
and insert a thickness gauge between the straight edge
and the rotors to measure the distortion.
Standard Wear limit (Measuring the clearance between

outer rotor and inner rotor )
Distortion between
the pump body and Refer to Section "3-2 1) Nominal and
the inner and outer Allowable Values".
rotors
4) Clearance Between Rotor Shaft and Side Cover

Shaft Hole
Measure the rotor shaft outside diameter and the side
cover shaft hole diameter, and calculate the difference
between the hole diameter and the outside diameter.
Standard Wear limit
Clearance between
Refer to Section "3-2 1) Nominal and
rotor shaft and
Allowable Values".
side cover shaft hole
5) Others
(1) Check for looseness of the engagement of the drive gear and the rotor shaft, and replace the entire assembly if
there is looseness or play.
(2) Push the oil pressure regulating valve piston from the drill hole side to check if the piston returns normally.
Replace the entire assembly if the piston does not return due to the broken spring or any other trouble.
(3) Check that the rotor shaft rotates smoothly when the drive gear is rotated.
4-2-21 4480203
4. ENGINE
4-3 Precautions for Reassembly
Reassemble the engine components in the reverse order of the disassembly procedure. Follow the precautions
below particularly before and during the reassembly.
1) Cleaning the Components

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

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

Apply a dial gauge to the end of the crank shaft. Press the
crank shaft to each of the right and left sides in the axial
direction to measure the side gap. Alternatively, insert a
thickness gauge directly into the clearance between the ref-
erence thrust metal and the thrust surface of the crank shaft
to measure the side gap. If the measured value exceeds the
wear limit, replace the thrust metal with a new one.
Dial gauge
Refer to Section "3-2 1) Nom-
Side gap
inal and Allowable Values". Crank shaft
4) Gear Train
After installing all the gears, check (From the gear case side)
that the match marks A, B and C on Fuel injection pump drive gear
the idle gear are aligned with those
Cam gear
on the crank gear, the fuel injection
pump drive gear and camshaft
gear respectively, as shown below.
B
B C
C
A
Idle gear
A *P.T.O. (Option)
Crank gear
Lubricating oil pump gear
Direction of rotation
4-3-1 4480203
4. ENGINE
5) Where to Use Liquid Packing

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

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

(1) Fit the piston ring into the ring groove, with the manu-
facturer's mark near the end of the piston ring facing
upward (to the combustion chamber side), using a
piston ring replacer. After fitting the piston ring, check
that it moves smoothly. The side with manufacturer’s
mark shall face upward
(2) Install the piston their end gaps rings into their
respective ring grooves so that their end gaps are
shifted at 120 degrees intervals, making sure that
Top ring
they are not aligned along the piston. Apply lubricat-
ing oil to the outside surface of the piston.
Second ring
Oil ring
Top ring
120
120
Second ring
120
Oil ring
4-3-2 4480203
4. ENGINE
8) Applying Lubricating Oil to the Push Rod Adjust Screw Contact Portion
Apply lubricating oil to the hatched portion of the push rod as shown in the figure, before reassembly.
Apply lubricating oil
9) Installation Direction of the Piston and the Connecting Rod
I.D. mark
Cam shaft side
Nozzle side
Piston
Cylinder Flywheel side

size mark
Embossed mark
(Flywheel side)
Connecting
rod
Alignment mark
10) Tightening Order and Tightening Torque of the Cylinder Head Bolts
Tighten the cylinder head bolts at a specified tightening torque in the numerical order as shown below.
Cam shaft side
7 1 10
(Three cylinders) 13 3 6 12
Flywheel side Gear case side
11 5 4 14
9 2 8
Fuel pump side
Refer to Section "3-7-2

Tightening torque Engine Tightening torque for
major bolts and nuts".
11) After Completing the Reassembly, Carry Out a Verification Run of the Engine to Check That There is No
Water or Oil Leakage.
4-3-3 4480203
4. ENGINE
4-4 Fuel Injection System
4-4-1 Fuel Injection Pump
The fuel injection pump is a Yanmar YPFR Bosch type. It

is an integrated inline pump equipped with a built-in gov- Delivery valve
ernor. spring
The cam shaft has a fuel feed pump drive cam and a
tappet drive cam for the plunger. A drive gear is mounted
Delivery valve
on the drive side of the cam shaft, and a governor weight
is installed on the opposite side.
As the plunger rises, the fuel opens the delivery valve
and goes through the high pressure pipe to the fuel
injection valve. Fuel control
rack
When the control rack connected to the governor lever Plunger
moves, the pinion rotates the plunger. This changes the

positions of the plunger notch and the fuel hole, and in
Plunger spring
turn controls the fuel injection quantity.
Note :
Pumps are numbered from No.1, No.2, No.3 ···from the
governor side to match them with the numbers of the cyl-
inders.
Plunger guide roller
(Sectional view of fuel injection pump)

4-4-2 Fuel Injection Valve
Applicable Model 3TNE68-EBVA

Nozzle type YDN-OPD2
Valve seat type Single cone
Fuel injection pressure PSI (Mpa) 1706 to 1849 (11.8 to 12.7)
Diameter of nozzle hole ! Number of nozzle holes in. (mm) ! pcs. Ø0.039 (1.0) ! 1
Spray angle degrees 5 to 10
Part code number (Assembly) D19255-53100
4-4-1 4480203
4. ENGINE
4-4-3 Governor Mechanism
The governor is a mechanical all speed type and installed in the YPFR type of fuel injection pump. For the structure
of the governor works in the lower part of the tension lever with the centrifugal force of the governor weight transmit-
ted through the sleeve. An excess fuel spring for increasing the fuel injection quantity at the starting of the engine is
installed at the bottom end of the tension lever. The tension lever, which is supported by the bearing for the governor
lever shaft, has free vibration.
One end of the governor spring is hung to the upper right end of the tension lever, and the other end of the governor
spring is hung to the spring lever of the control lever shaft.
A governor lever, which can be rotated smoothly, is installed on the governor lever shaft. The bottom end of the gov-
ernor lever contacts with the shifter contacting with the sleeve and also contacts with the excess fuel spring contact-
ing with the lower part of the tension lever, and therefore, the governor lever vibrates in synchronism with the
vibration of the tension lever as the revolution of the pump increases or decreases.
The top end of the governor lever is connected to the control rack of the fuel injection pump via the governor link.
Maximum speed adjusting bolt
Fuel limit bolt
Governor link
Shifter
Excess fuel spring
(Structure of governor)
4-4-2 4480203
4. ENGINE
1. Adjustment of governor
(by using a pump tester and referring to the adjustment service data for the standard values)
1) Adjusting the maximum idling speed Maximum speed

adjusting bolt
(1) Set the governor control lever to the fuel increase position
end.
(2) Adjust the tightening volume of the maximum speed adjust-
ing bolt.
Increase the idling speed. Check that the maximum idling
speed is within the specified range.
Maximum idling speed
Refer to Section "2-1 Specifica-
ViO15-2
tions".
FU
Note : LL
Adjustment after mounting the engine to the machine:
Refer to Section "7-3-10 Adjustment of Accelerator Lever". IDLE
ST 60 UN
OP R
2) Adjusting the minimum idling speed

(Adjusting the idling)
(1) Measure the idling speed while lowering the governor con-
trol lever to the idling position and adjust the position of the
control lever to the position where the specified minimum
Idling adjusting bolt
idling speed is attained, with the idling adjusting bolt.
Maximum idling speed
Refer to Section "2-1 Specifica-
ViO15-2
tions".
Note :
Adjustment after mounting the engine to the machine:
Refer to Section "7-3-10 Adjustment of Accelerator Lever".
4-4-3 4480203
4. ENGINE
4-4-4 Specifications of Fuel Injection Pump
Applicable model
3TNE68-EBVA
Item
(1)+(2)+(3) 719233-51770
Fuel injection pump assembly
code number
(1)+(2)+(3)+(4) -
Assembly code number 719225-51100
Part code number 119225-51100
Plunger diameter Dp in. (mm) Ø0.20 (Ø6)

Plunger barrel
assembly
Lead angle degrees 45
Fuel injection pump
Identification mark M-2

(1)
cu. in. / St
Suck back volume QR 0.0010 (16.2)
Delivery valve (cu. mm / St)
assembly
Angleich cut in. (mm) 0
Identification mark -
Cam shaft Part code number -
Assembly code number -
Governor weight Part code number 119600-51200
lbs. / in.
Governor spring Spring constant 30.47 (5.33)
(N / mm)
Item
Governor
(2) Free length in. (mm) 1.59 (40.3)
Tension lever shape

in. (mm) -
(Length between the supporting points)
Type FO limiter Angleich spring

Torque rise device
Part code number 119223-61450 119610-66700
Engine stop device 119233-66500
Assembly code number 119255-52102

(3) Fuel feed pump
Type Magnetic feed pump
4-4-4 4480203
4. ENGINE
4-4-5 Service Date for Fuel Injection Equipment
Model
3TNE68-EBVA
Item

Fuel injection pump assembly code number

Adjustment specification Engine spec. Calibration spec.
Nozzle type YDN-OPD2 DN-12SD12
1635 to 1778 2346 to 2489
Injection start pressure PSI (kpa)
(11278 to 12259) (16182 to 17162)
Ø0.06!11.02 Ø0.08!23.62
Fuel injection pipe D / d!L in. (mm)
(Ø1.6!280) (Ø2.0!600)
Top clearance [prestroke] in. (mm) 0.037 to 0.041 (0.95 to 1.05) [0.098 (2.5)]
Pump speed : N1 rpm 1000
Rack position
in. (mm) R = 0.30 (7.5)
(indicator scale) : R1
Rated load Measuring stroke St 
cu. in.
Injection volume : Q1 0.0946 (15.8) 
(cu. cm)
Variation % ±3
No load
maximum speed Rack position
in. (mm) 
Idling or Measuring stroke St 
at R1-2 mm position
cu. in.
Injection volume : Q3 
(cu. cm)
Rack position
in. (mm) R = 0.55 (14)
Starting
Measuring stroke St 
cu. in. 2.990 to 3.356
Injection volume : Q4 
(cu. cm) (49 to 55)
Pump
rpm 
speed : N5
Screw in
degrees 
Angleich angle : θ
spring Measuring
St 
stroke
Injection cu. in.
 
volume : Q5 (cu. cm)
Torque rise
Pump
rpm 
speed : N5
Torque
Torque in. (mm) 
rise stroke
rise
spring Measuring
St 
stroke
Injection cu. in.
 
volume : Q5 (cu. cm)
4-4-5 4480203
4. ENGINE
4-5 Electrical Equipment
4-5-1 Starter Motor

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

Yanmar code 119233-77010
Starter motor model S114-816
Nominal output / Weight kW / lbs. (kg) 1.2 / 6.4 (2.9)
Rotation direction (Viewed from pinion side) Clockwise
Engagement method Magnetic shift
Terminal voltage / Current V/A 11 / !90
No load
Speed rpm "2750
Terminal voltage / Current V/A 8.4 / 250
Load
characteris- ft•lbf "7.2
tics Torque / speed (N•m) (0.73)
/ rpm / "1200
Clutch type Ø6!6 roller
Pinion coming out voltage V !8
Pinion DP or module
DP10/12
/ Number of pinion teeth
Standard spring force lbs. (kg) 3.64 (1.65)
Brush Standard height 0.61 (15.5)
in. (mm)
/ Wear limit / 0.37 (9.5)
Magnetic switch
resistance at Series coil / Shunt coil Ω 0.34 / 0.72
68 °F (20 °C)
Outside Standard Ø1.14 (29)
diameter / Wear limit / Ø1.10 (28)
Difference
between Correction limit 0.004 (0.1)
Commutator max. and / Precision in. (mm) / 0.002 (0.05)
min. dia.
0.0079 (0.2) /
Mica Correction limit
0.020 (0.5) to Starter Performance
undercut / Precision
0.031 (0.8)
Voltage
Speed
Brush Shaft diameter Ø0.4714 (11.973)

to Ø0.4703 (11.945)
side / Bearing inside / Ø0.4735 (12.027)
bearing diameter to Ø0.4724 (12.000) (r/min) (V)
12 D
Interme- Shaft diameter Starter Performance JIS D5004 12 C
diate / Bearing inside - 6000 12
Voltage
bearing diameter
Standard
in. (mm) Ø0.4903 (12.454)
diameters Pinion Shaft diameter 5000 10
to Ø0.4898 (12.440)
sliding / Bearing inside / Ø0.4941 (12.550)
section diameter to Ø0.4933 (12.530) 4000 8
Output
Pinion Shaft diameter Ø0.4903 (12.454)
to Ø0.4898 (12.440) 3000 6
side / Bearing inside / Ø0.4932 (12.527)
bearing diameter to Ø0.4921 (12.500) 2000 4 Torque
0.012 (0.3) to
Gap between pinion and pinion stopper in. (mm) Speed
0.098 (2.5) 1000 2
0 0
0 200 400 600 800
Current (A)
Standard output characteristic curves
4-5-1 4480203
4. ENGINE
4-5-2 Alternator
The alternator is a revolving-field type three-phase AC generator. The AC electricity generated by the alternator is
converted to DC through the full-wave rectification by the diode and is stored in the battery.
Specification Regulator specifications

Nominal output voltage Yanmar code of current limiter 119653-77710
V/A 12 / 20
(Full-wave rectification) Adjusted voltage (V) 14 to 15
Alternator model GP9186 Yanmar code of safety relay 119247-77100
Operating speed rpm 1400 to 6600
Maximum speed rpm 6600
!22.5 / 12
Nominal output current A/V
(at 6600 rpm)
Permissible ambient -13 to 176
°F (°C)
temperature (-25 to 80)
Ground polarity Negative
Applicable models 3TNE68-EBVA
Air heater circuit
Alternator Key switch

GEN
Charge warning lamp
Battery
Regulator
Load
Tightening torque M10 nut

21.70 to 25.32 ft lbf
(29.40 to 34.30 N m)
n
ctio
ire
al d
ion
tat
Ro
2-pole connector
4-5-2 4480203
4. ENGINE
Disassembly procedure
(1) Disconnect the generator from the engine.
(2) Remove the cap and the M10 hexagonal nut. 2
(3) Fix the end of the shaft. Do not fix the flywheel. 4 1
(4) Pull out the rotor magnet.
1 Stator coil
Tap the threaded end (M10) of the shaft with a mal- 2 Rotor magnet
3 Ball bearing
let or the like. 4 Fly wheel
(5) Clamp the lead-wire to the coil plate.
Remove an M4 screw and the coupler.
(6) Remove the stator coil from the coil plate.
3
Remove 2-M4 screws. 3
Reassembly procedure
(1) To reassembly the magneto-generator, reverse the
steps indicated in disassembly procedure.
(2) Tighten the M10 hexagonal nut to a torque of 29.40
to 34.30 N•m (21.70 to 25.32 ft•lbf)
Generator check
Follow the next directions to see if the generator works normally.
(1) Disconnect the generator output wiring to the regulator, with the generator left coupled with the engine.
(2) Extend the generator output wiring and connect it to a volt / ammeter.
(3) Set the volt / ammeter to the 100 V AC range.
(4) Start the engine and check the volt / ammeter for readings.
(5) When the specified voltage is proven on the volt / ammeter, the generator is in normal operation.
4-5-3 4480203
4. ENGINE
4-5-3 Glow Plug
The air heater is available for warming combustion chamber during starting in cold weather. The glow plug is
mounted on the cylinder head.
The device is operated by the key switch on the instrument panel.
Specifications
Rated voltage DC10 V
Rated current 8.5 to 11.5 A
Rated operating time 4 sec.
Applicable model 3TNE74-ENBV
Dimensions
Tightening torque :
Unit : in. (mm) Body : 10.8 to 14.5 ft•lbs. (14.7 to 19.6 N•m)
0.551 (14)
M4 0.7
Nut : 0.72 to 1.08 ft•lbs. (1.0 to 1.5 N•m)
Width 0.472 (12)

0.709 (18) 0.728 (18.5) 0.335 (8.5)
0.433 (11)
2.677 (68)
0.236 (6) 0.079 (2)
M10 1.25
0.173 (4.4)
0.323 (8.2)
4-5-4 4480203
CHAPTER 5
HYDRAULIC SYSTEM
5-1 Outline ................................................................................................. 5-1-1

5-1-1 Control Valve Operation............................................................. 5-1-4
5-1-2 Additional Operation of Control Valve........................................ 5-1-6
5-2 Hydraulic Circuit Schematic................................................................. 5-2-1
5-2-1 For Standard Type Machines..................................................... 5-2-1
5-3 Circuit Operation.................................................................................. 5-3-1
5-3-1 Boom.......................................................................................... 5-3-1
5-3-2 Arm ............................................................................................ 5-3-3
5-3-3 Bucket ........................................................................................ 5-3-5
5-3-4 Swing ......................................................................................... 5-3-7
5-3-5 Boom Swing............................................................................... 5-3-9
5-3-6 Blade........................................................................................ 5-3-11
5-3-7 Travel ....................................................................................... 5-3-13
5-3-8 Track Gauge Change .............................................................. 5-3-15
5-3-9 Simultaneous Operation of Blade and Travel .......................... 5-3-17
5-3-10 Simultaneous Operation of Boom and Arm ........................... 5-3-19
5-3-11 Simultaneous Operation of Boom and Bucket ....................... 5-3-21
5-3-12 Simultaneous Operation of Arm and Swing ........................... 5-3-23
5-3-13 Simultaneous Operation of Arm and Bucket.......................... 5-3-25
5-3-14 Simultaneous Operation of Boom, Arm and Swing................ 5-3-27
5-3-15 Hydraulic P.T.O...................................................................... 5-3-29
5-4 Pressure Adjustment ........................................................................... 5-4-1
5-4-1 Relief Valves .............................................................................. 5-4-1
5-4-2 Swing Brake Valve..................................................................... 5-4-3
5-4-3 Cut-Off Valve ............................................................................. 5-4-4
5. HYDRAULIC SYSTEM
5. Hydraulic System
5-1 Outline
The hydraulic system consists of an engine, variable displacement piston pumps, a control valve, a boom cylinder,
an arm cylinder, a bucket cylinder, a boom swing cylinder, a blade cylinder, a swing motor, a swivel joint, track gauge
change cylinder, two travel motors, 2 way valve and a hydraulic oil tank. The oil discharged from the variable dis-
placement piston pumps flows to the actuators through the control valve.
The hydraulic pilot control system comprises a pilot pump, a cut-off valve mounted on the hydraulic pump and two
pilot valves. The oil discharged from the pilot pump flows into the pilot ports of the control valve through the cut-off
valve, the pilot valves and the 2 way valve to control the valve spool movement in proportion to the pressure at the
port.
Pilot valve
Swivel joint
Swing motor
Right
Boom swing cylinder

Hydraulic oil tank
Arm cylinder
Rear
Hydraulic pump
Boom cylinder
Travel motor
2 way valve
Track gauge change

Front cylinder
Left
Control valve
Bucket cylinder Bucket cylinder
5-1-1 4480203
5. HYDRAULIC SYSTEM
1) Hydraulic Pump
The variable displacement piston pumps and the pilot
pump are linked to the flywheel of the engine through the
coupling. The number of revolutions of each hydraulic
pump is identical to the engine speed.
Discharge volume of each pump

cu. in. (cu. cm) / rev
No. Pump Discharge volume
1 Piston pump P1 0.549 (9.0) a10 a8 a7 B5 a3 a2
A11 B11 A10 B10 A9 B9 A8 B8 A7 B7 A6 B6 A5 B4 A4 B3 A3 B2 A2 B1 A1
2 Piston pump P2 0.549 (9.0) Track gauge change Swing Travel (L) Arm swing 2 P.T.O. Blade Travel (R) Bucket Boom Boom swing Control valve
3 Pilot pump P3 0.275 (4.5) 1.0
1.0
1.4 1.0
0.8
2) Oil Flow P2 P1
(1) Piston pumps P1 and P2 (when the lock levers are
in the unlock position)
The pumps take in oil through the suction filter from the MRV-1
MRV-2
hydraulic oil tank and discharge it. The discharged oil R2 ACV
ACV
R1
CRV-A3
flows to the ports P1 and P2 of the control valve and ACV
T2 CRV-A8 CRV-B2 T1
returns from the ports T1 and T2 to the hydraulic oil tank
through the return filter. This circulation is repeated. b10 b8 b7 b3 b2
The bypass valve in the return filter opens at a differen-

tial pressure of 21.3 PSI (0.147 MPa).
(2) Pilot pump P3

P T P T
The oil from the pilot pump P3 flows back to the hydrau-
Solenoid
lic oil tank through the ports B1 and B2 of the cut-off valve
valve integrated into the pump and the pilot valves. B1 B2 PA P3 P2 P1
SOL B SOL A 4 Swing 2 3 Arm 1 3 Boom 1 4 Bucket 2

Hydraulic pump
Left
Right
Extend
Retract
Down
Up
Dump
Curl
3) System Relief Valve Hydraulic oil
tank
The system relief valves R1 and R2 of the control valve
Pilot valve (LH) 1 2 4 3 Pilot valve (RH)
control the discharge pressure of the pumps.
2 way valve
A B D C
P3 P2 P1 Engine
Return filter
M
Suction filter
O
S1
Pilot pump P3 Piston pump P1, P2
5-1-2 4480203
5. HYDRAULIC SYSTEM
P2
P1
Hydraulic pump
B2 S1
B1
Hydraulic oil tank
Pilot valve (RH)
Pilot valve (LH)
P
T1
T
P1
P
P2
T2
Control valve
5-1-3 4480203
5. HYDRAULIC SYSTEM
5-1-1 Control Valve Operation
1) Oil Flow from Hydraulic Pump

(1) Piston pump P1
Track gauge change section

The oil from the piston pump P1 is fed to the track gauge
change, swing, arm cylinders, travel (L) motor and P.T.O.
Boom swing section

Travel (R) section
through the port P2 of the inlet section, the track gauge
Travel (L) section
Swing 2 section
Bucket section
P.T.O. section
Swing section
Boom section
change, swing, travel (L), arm, swing 2 and P.T.O. sec-
Blade section
Arm section
tions. Also the oil from the piston pump P1 is fed to the
blade cylinder through the parallel passage and the
blade section.
(2) Piston pump P2

Switching section of oil
The oil from the piston pump P2 is fed to the boom flow from piston pump P2
swing, boom, bucket, blade, arm cylinders, travel (R)
a10 a8 a7 B5 a3 a2
motor and P.T.O. through the port P1 of the inlet section, A11 B11 A10 B10 A9 B9 A8 B8 A7 B7 A6 B6 A5 B4 A4 B3 A3 B2 A2 B1 A1
Control valve
the boom swing, boom, bucket, travel (R), blade, arm, Track gauge change Swing Travel (L) Arm swing 2 P.T.O. Blade Travel (R) Bucket Boom Boom swing
High-speed travel 1.0

swing 2 and P.T.O. sections. pilot line
1.0
1.4 1.0
0.8
P2 P1
2) Simultaneous Operation of Boom and Bucket
A parallel passage is provided for the boom and bucket
sections so that the boom and the bucket can be oper-
ated simultaneously. MRV-2
ACV
MRV-1
R2 ACV R1
CRV-A3
ACV
3) Simultaneous Operation of Blade and Travel T2 CRV-A8 CRV-B2 T1
The left and right travel sections are fed with the oil from Combined oil flow from piston
b10 b8 b7 b3 b2
Swing motor mechanical
the piston pumps P1 and P2, respectively. Meanwhile, brake release pilot line
pumps P1 and P2
the oil from the piston pump P1 and that from the piston
pump P2 are regulated through the throttles (Ø0.04 in.
[1.0 mm]) in the parallel passage and are also fed to the
blade section. Therefore, the blade can be operated
P T P T
while the machine is traveling.
Solenoid The throttles ( 0.04 in. (1.0 mm))
valve for simultaneous operation of
Boom priority orifice
4) Simultaneous Operation of Boom, Arm and B1 B2 PA P3 P2 P1 blade and travel
( 1.4)
Swing SOL B SOL A
Hydraulic pump
4 Swing 2 3 Arm 1 3 Boom 1 4 Bucket 2
Left
Right
Extend
Retract
Down
Up
Dump
Curl
The oil from the piston pump P2 flows to the arm section Hydraulic oil
tank
through the boom section, the notch in the boom spool
and the bypass passage. Pilot valve (LH) 1 2 4 3 Pilot valve (RH)
When the swing operation is performed, the pilot pres-
sure flows to the swing 2 section to move its spool so A B D C
2 way valve
P3 P2 P1 Engine
that all the oil from the port P1 circuit flows into the port
Return filter
P2 circuit. M
The oil from the piston pump P1 flows through the notch Suction filter
O
in the swing spool to combine with the oil from the port S1
P1 circuit before flowing to the arm section. Therefore, Pilot pump P3 Piston pump P1, P2
the boom, arm and swing operation can be performed
simultaneously.
5-1-4 4480203
5. HYDRAULIC SYSTEM
AI
Arm AO
Boom swing Track gauge change
BSL
BSR
Boom
BKI BKO BD
BU
BLD BLU
Blade
Bucket
Hydraulic pump
P2
Hydraulic oil tank
P1
P3
B1
A1
B2 P Swing motor
S1
B1
A1
B1
A2
B2 Pilot valve (LH)
B3 Pilot valve (RH)
A5 T
B5
2
A4 1
A8 T 2
B8 4 P 3
B4 A10 3
1
A3 B10 P
A11
T1 B11 4
P1 A9
b2 B9
b3
Travel motor (R)

b7
b8
b10 P2
a2 P1 P1
T2
a3
P2 P2
a7
Travel motor (L)
a8
a10
Control valve
5-1-5 4480203
5. HYDRAULIC SYSTEM
5-1-2 Additional Operation of Control Valve
Simultaneous Operation of Travel and Blade

When the blade lever is operated while the machine is traveling, the
oil from the piston pump P1 and that from the piston pump P2 flow
to the blade section through the parallel passage. The parallel pas-
sage has throttles ( 0.04 in. [1.0 mm]) so that the oil from the pis-
ton pump P1 and that from the piston pump P2 evenly flow to the re-
spective travel sections and the blade section. Therefore, the ma-
Simultaneous Operation of Boom, Arm and chine travels without deviation.
Swing
When the control levers are moved to simultaneous- Simultaneous Operation of Boom and Bucket
ly operate the boom and the arm and swing the up- A parallel passage is provided for the bucket section
per structure, the pilot pressure flows to the port a7 so that the boom and the bucket can be operated si-
or the port b7 of the swing 2 section to move its multaneously. The parallel passage has a throttle (
spool at the swing operation. The oil from the piston 0.06 in. [1.4 mm]) so that oil can flow to the boom
pump P2 flows to the arm section through the notch section more smoothly than to the bucket section
in the boom spool. even when the boom is given a heavier load.
The oil from the piston pump P1 flows through the
notch in the swing spool to combine with the oil from
the piston pump P2 before flowing to the arm sec-
tion.
a10 a8 a7 B5 a3 a2
Track gauge change Swing Travel (L) Arm swing 2 P.T.O. Blade Travel (R) Bucket Boom Boom swing Control valve
1.0 1.0
1.4 1.0
0.8
P2 P1
P1 P2
MRV-2 MRV-1
ACV
R2 ACV R1
CRV-A3
ACV
T2 CRV-A8 CRV-B2 T1
b10 b8 b7 b3 b2
Combined Oil Flow for Arm Operation Simultaneous Operation of Boom and Arm
When the arm control lever is operated, the oil from the piston pump When the arm control lever is operated while the boom
P2 flows through the parallel passage to combine with the oil from is being operated, the oil from the piston pump P2 flows
the piston pump P1. However, all the oil from the piston pump P2 through the notch in the boom spool and the bypass
does not, as the regulated oil by the throttle in the swing 2 section passage to combine with the oil from the piston pump
flows back to the hydraulic oil tank. P1 before flowing to the arm section. However, all the oil
from the piston pump P2 does not, as a part of the oil
flows back to the hydraulic oil tank through the swing 2
section.
5-1-6 4480203
5. HYDRAULIC SYSTEM
5-2 Hydraulic Circuit Schematic
5-2-1 For Standard Type Machines

Swing motor Travel motor (L) Travel motor (R)
Blade cylinder
R/G R/G Boom swing cylinder Bucket cylinder
( 55X 30-106)
B2 ( 65X 35-295) ( 55X 30-278)
A2 T Track gauge change

cylinder GJ Arm cylinder Boom cylinder
P PS FC JH
PS
( 55X 30-260) E ( 55X 35-404) ( 55X 30-431)
B D
A I
a1 a2 a2 a1
A I
SR2 6 B D
P1 P2 T1 EF T2 P2 P1
C GJ H
SR1
A1 B1
B
P.T.O.
A
a10 a8 a7 B5 a3 a2
Track gauge change Swing Travel (L) Arm swing 2 P.T.O. Blade Travel (R) Bucket Boom Boom swing Control valve [PSI (MPa)]
1.0 1.0
1.4 1.0 1 2986.2 (20.6)
0.8 2 3412.8 (23.5)
P2 P1 3 3555.0 (24.5)
4 3412.8 (23.5)
5 2986.2 (20.6)
6 1493.1 (10.3)
5 7 426.6 (2.9)
MRV-2 MRV-1 8 21.3 (0.15)
3 ACV
R2 4 ACV 1 R1
CRV-A3
ACV 2
T2 CRV-A8 CRV-B2 T1
b10 b8 b7 b3 b2
P T P T
Solenoid
valve
B1 B2 PA P3 P2 P1
Hydraulic pump
Left
Right
Extend
Retract
Down
Up
Dump
Curl
P1 = 0.55 cu.in. (9.0 cu.cm) / rev
Hydraulic oil
tank
P2 = 0.55 cu.in. (9.0 cu.cm) / rev
P3 = 0.27 cu.in. (4.5 cu.cm) / rev 1 2 4 3
Pilot valve (LH) Pilot valve (RH)
8
Engine 2 way valve
A B D C
P3 P2 P1 3TNE68-EBVA
7
8.6 kW / 2000 rpm
Return filter
(11.7 PS / 2000 rpm)
M
Suction filter
O
S1
5-2-1 4480203
5. HYDRAULIC SYSTEM
5-3 Circuit Operation
5-3-1 Boom Boom cylinder
1) Boom “Up”
BD
(1) Pilot oil flow
When the boom control lever is pulled back to raise the
boom, the oil from the pilot pump P3 flows through the
cut-off valve and the port 2 of the pilot valve (RH) to the
port b2 of the boom section to move its spool. BU
(2) Oil flow from hydraulic pump

The oil discharged from the piston pump P2 flows to the
boom section through the port P1 of the inlet section and
the parallel passage and flows through the port B2 to BU a10 a8 a7 B5 a3 a2
of the boom cylinder to extend its cylinder rod, raising A11 B11 A10 B10 A9 B9 A8 B8 A7 B7 A6 B6 A5 B4 A4 B3 A3 B2 A2 B1 A1
Control valve
Track gauge change Swing Travel (L) Arm swing 2 P.T.O. Blade Travel (R) Bucket Boom Boom swing
the boom. The return oil from BD of the boom cylinder 1.0 1.0 1.4
1.0
flows back to the hydraulic oil tank through the port A2 of 0.8
the boom section and the ports T1 and T2 of the control P2 P1
valve.
Meanwhile, a part of the oil from the piston pump P2
flows back to the hydraulic oil tank through the notch in MRV-2 MRV-1
ACV
the boom spool and the swing 2 and P.T.O. sections. R2
CRV-A3 ACV R1
ACV
T2 CRV-A8 CRV-B2 T1
2) Boom "Down"
b10 b8 b7 b3 b2
(1) Pilot oil flow
When the boom control lever is pushed forward to lower
the boom, the oil from the pilot pump P3 flows through
the cut-off valve and the port 4 of the pilot valve (RH) to
the port a2 of the boom section to move its spool. P T P T
Solenoid
valve
B1 B2 PA P3 P2 P1
The oil flows in the opposite direction to the oil flow in the
boom up operation with regard to the boom cylinder. Hydraulic pump
Left
Right
Extend
Retract
Down
Up
Dump
Curl
Hydraulic oil
tank
<OPT> pattern Pilot valve (LH) 1 2 4 3 Pilot valve (RH)
The boom control lever and the arm control lever
changes mutually operation from standard pattern. 2 way valve
A B D C
The oil from port 1 of the pilot valve (LH) flows to port C P3 P2 P1 Engine
Return filter
of the 2 way valve to move the boom section spool in M
boom up position. Suction filter
O
The oil from port 3 of the pilot valve (LH) flows to port D S1
of the 2 way valve to move the boom section spool in Pilot pump P3 Piston pump P1, P2
boom down position.
5-3-1 4480203
5. HYDRAULIC SYSTEM
Boom cylinder
BD
BU
Hydraulic oil tank

Hydraulic pump P2
B2
S1
Pilot valve (RH)

A2 T1 B2
P1
b2
T2
T
a2
1
3
P
Control valve
5-3-2 4480203
5. HYDRAULIC SYSTEM
5-3-2 Arm
1) Arm “Retract”
Arm cylinder
(1) Pilot oil flow
When the arm control lever is pulled back to retract the
AO
arm, the oil from the pilot pump P3 flows through the cut-
off valve and the port 1 of the pilot valve (LH) to the port
a8 of the arm section to move its spool.
(2) Oil flow from hydraulic pump AI
The oil from the piston pump P1 flows through the port
P2 of the inlet section to the arm section. The oil from
the piston pump P2 flows through the bypass passage to
combine with the oil from the piston pump P1 before
flowing to the arm section. However, all the oil from the a10 a8 a7 B5 a3 a2
piston pump P2 does not, as the oil is regulated, or A11 B11 A10 B10 A9 B9 A8 B8 A7 B7 A6 B6 A5 B4 A4 B3 A3 B2 A2 B1 A1
Control valve
reduced at the swing 2 section before the arm section. 1.0 1.0
1.4 1.0
The combined oil flows through the port A8 of the arm 0.8
section to AI of the arm cylinder to extend its cylinder P2 P1
rod.
The return oil from AO of the arm cylinder flows back to
the hydraulic oil tank through the port B8 of the arm sec- MRV-2 MRV-1
ACV
tion and the ports T1 and T2 of the control valve. R2
CRV-A3 ACV R1
ACV
T2 CRV-A8 CRV-B2 T1
2) Arm "Extend"
b10 b8 b7 b3 b2
(1) Pilot oil flow
When the arm control lever is pushed forward to extend
the arm, the oil from the pilot pump P3 flows through the
cut-off valve and the port 3 of the pilot valve (LH) to the
port b8 of the arm section to move its spool. P T P T
Solenoid
valve
B1 B2 PA P3 P2 P1
The combined oil flows in the opposite direction to the oil
flow in the arm retract operation with regard to the arm Hydraulic pump
Left
Right
Extend
Retract
Down
Up
Dump
Curl
Hydraulic oil
cylinder. tank

<OPT> pattern
The boom control lever and the arm control lever 2 way valve
A B D C
changes mutually operation from standard pattern. P3 P2 P1 Engine
Return filter
The oil from port 1 of the pilot valve (RH) flows to port B M
of the 2 way valve to move the arm section spool in arm Suction filter
O
retract position. S1
The oil from port 3 of the pilot valve (RH) flows to port A Pilot pump P3 Piston pump P1, P2
of the 2 way valve to move the arm section spool in arm
extend position.
5-3-3 4480203
5. HYDRAULIC SYSTEM
AI
Arm cylinder AO
Hydraulic oil tank P2
P1
Hydraulic pump
B1 S1
Pilot valve (LH)
T1
P1
A8 B8
b8
T2
T
P2 3
1
P
a8
Control valve
5-3-4 4480203
5. HYDRAULIC SYSTEM
5-3-3 Bucket
1) Bucket “Curl”
Bucket cylinder
(1) Pilot oil flow
When the bucket control lever is moved to the left to curl
BKO
the bucket, the oil from the pilot pump P3 flows through
the cut-off valve and the port 2 of the pilot valve (RH) to
the port a3 of the bucket section to move its spool.
(2) Oil flow from hydraulic pump BKI
P1 of the inlet section and the port A3 of the bucket sec-
tion to BKI of the bucket cylinder to extend its cylinder
rod.
The return oil from BKO of the bucket cylinder flows a10 a8 a7 B5 a3 a2
back to the hydraulic oil tank through the port B3 of the A11 B11 A10 B10 A9 B9 A8 B8 A7 B7 A6 B6 A5 B4 A4 B3 A3 B2 A2 B1 A1
Control valve
bucket section and the ports T1 and T2 of the control 1.0 1.0
1.4 1.0
valve. 0.8
P2 P1
2) Bucket "Dump"
(1) Pilot oil flow
When the bucket control lever is moved to the right to MRV-2 MRV-1
ACV
dump the bucket, the oil from the pilot pump P3 flows R2
CRV-A3 ACV R1
ACV
through the cut-off valve and the port 4 of the pilot valve CRV-B2
T2 CRV-A8 T1
(RH) to the port b3 of the bucket section to move its
b10 b8 b7 b3 b2
spool.

bucket curl operation with regard to the bucket cylinder. P T P T
Solenoid
valve
B1 B2 PA P3 P2 P1

Hydraulic pump
Left
Right
Extend
Retract
Down
Up
Dump
Curl
Hydraulic oil
tank
2 way valve
A B D C
P3 P2 P1 Engine
Return filter
M
Suction filter
O
S1
5-3-5 4480203
5. HYDRAULIC SYSTEM
BKI BKO
Bucket cylinder
Hydraulic oil tank

P2
Hydraulic pump B2
S1
Pilot valve (RH)

T1 A3 B3
P1
b3
T2
4 2
a3
P
Control valve
5-3-6 4480203
5. HYDRAULIC SYSTEM
5-3-4 Swing Swing motor

1) Right Swing
(1) Pilot oil flow B2
When the swing control lever is moved to the right, the A2 T

oil from the pilot pump P3 flows through the cut-off valve P
and the port 4 of the pilot valve (LH) to the port b10 of
the swing section and the port b7 of the swing 2 section
to move their spools.
(2) Oil flow from hydraulic pump SR2

P2 of the inlet section, the parallel passage and the port SR1
B10 of the swing section to the port A1 of the brake
valve, so that the swing motor can be rotated.
The return oil from the port B1 of the brake valve flows
back to the hydraulic oil tank through the port A10 of the
swing section and the ports T1 and T2 of the control A1 B1
valve.
Meanwhile, a part of the oil from the piston pump P1
flows back to the hydraulic oil tank through the notch in
the swing spool.
a10 a8 a7 B5 a3 a2
2) Left Swing A11 B11 A10 B10 A9 B9 A8 B8 A7 B7 A6 B6 A5 B4 A4 B3 A3 B2 A2 B1 A1
(1) Pilot oil flow Shockless valve Track gauge change Swing Travel (L) Arm swing 2 P.T.O. Blade Travel (R) Bucket Boom Boom swing Control valve
When the swing control lever is moved to the left, the oil 1.0 1.0
from the pilot pump P3 flows through the cut-off valve 1.4 1.0
and the port 2 of the pilot valve (LH) to the port a10 of 0.8
the swing section and the port a7 of the swing 2 section P2 P1
to move their spools.

The oil flows in the opposite direction to the oil flow in the MRV-2 MRV-1
right swing operation with regard to the swing motor. R2
ACV
R1
CRV-A3 ACV
ACV
3) Release and Operation of Swing Motor Mechani- T2 CRV-A8 CRV-B2 T1
cal Brake
When the engine is started, the oil from the pilot pump b10 b8 b7 b3 b2
P3 flows to the port P of the swing motor and presses
the piston (with a spring) of the swing motor mechanical
brake to release the brake.
When the engine is stopped, the oil from the pilot pump
P3 does not flow to the swing motor so that the spring
force causes the brake to be applied.
P T P T
4) Swing Motor Hydraulic Brake Operation Solenoid

When the swing control lever is released (i.e., returned valve
to the neutral position), the oil flow to the swing motor is B1 B2 PA P3 P2 P1
blocked and the pressures at the ports A1 and B1 of the SOL B SOL A 4 Swing 2 3 Arm 1 3 Boom 1 4 Bucket 2
brake valve become equal and consequently the brake Hydraulic pump
Left
Right
Extend
Retract
Down
Up
Dump
Curl
is applied. However, the swing motor continues to rotate Hydraulic oil
tank
in a short time due to its inertia. This causes the motor to
act like a pump and increase the B1-B2 line pressure in Pilot valve (LH) 1 2 4 3 Pilot valve (RH)
case of rotation for the right swing operation. The brake
valve is of shockless type. The increased pressure
opens the relief valve SR1 to let the oil on the higher 2 way valve
pressure side escape to the A1-A2 line, so that the cir- P3 P2 P1 Engine A B D C
cuit pressure is absorbed and cavitation is prevented on Return filter

the port A2 side. M
The port T of the swing motor has the drain function and Suction filter
a circuit which directly takes in the return oil flowing from O
the port T1 to the hydraulic oil tank to prevent negative S1
pressure in the swing motor. Pilot pump P3 Piston pump P1, P2
5-3-7 4480203
5. HYDRAULIC SYSTEM
Swing motor
B1
A1
Hydraulic oil tank
Hydraulic pump
P1
P3
B1 S1
Pilot valve (LH)
T1
A10
B10
b7
T2
b10
T 2
P2
4 P
a7
a10
Control valve
5-3-8 4480203
5. HYDRAULIC SYSTEM
5-3-5 Boom Swing
The boom swing pedal is linked to the spool of the con-

Boom swing cylinder
trol valve through an L-ball and a rod.
BSR
1) Right Boom Swing
Oil Flow from Hydraulic Pump
When the boom swing pedal is moved on the right, the
spool is pulled. The oil from the piston pump P2 flows
through the port P1 of the inlet section and the port B1 of BSL
the boom swing section to BSR of the boom swing cylin-

der to retract its cylinder rod.
The return oil from BSL of the boom swing cylinder flows
back to the hydraulic oil tank through the port A1 of the
boom swing section and the ports T1 and T2 of the con- a10 a8 a7 B5 a3 a2
trol valve. A11 B11 A10 B10 A9 B9 A8 B8 A7 B7 A6 B6 A5 B4 A4 B3 A3 B2 A2 B1 A1

Control valve
1.0
1.0
1.4 1.0
2) Left Boom Swing 0.8
Oil Flow from Hydraulic Pump P2 P1
When the boom swing pedal is moved on the left, the

spool is pressed. The oil flows in the opposite direction
to the oil flow in the right boom swing operation with MRV-2 MRV-1
ACV
regard to the boom swing cylinder. R2
CRV-A3 ACV R1
ACV
T2 CRV-A8 CRV-B2 T1
b10 b8 b7 b3 b2
P T P T
Solenoid
valve
B1 B2 PA P3 P2 P1

Hydraulic pump
Left
Right
Extend
Retract
Down
Up
Dump
Curl
Hydraulic oil
tank
2 way valve
A B D C
P3 P2 P1 Engine
Return filter
M
Suction filter
O
S1
5-3-9 4480203
5. HYDRAULIC SYSTEM
BSL
Boom swing cylinder
BSR
P2
S1
Hydraulic pump
Hydraulic oil tank
T1
A1 B1
P1
T2
Control valve
5-3-10 4480203
5. HYDRAULIC SYSTEM
5-3-6 Blade
The blade lever is linked to the spool of the control valve Blade cylinder
BLU
through an L-ball and a blade cable.
1) Blade "Down"
BLD
When the blade lever is pushed forward to lower the
blade, the spool is pressed. The oil from the piston pump
E
F
P1 and that from the piston pump P2 are regulated by
the respective throttles in the parallel passage and then
combine in the blade section. The combined oil flows
through the port B5 of the blade section and the port F of
F
the swivel joint to BLD of the blade cylinder to extend its E
cylinder rod, lowering the blade.

The return oil from BLU of the blade cylinder flows back a10 a8 a7 B5 a3 a2
to the hydraulic oil tank through the port E of the swivel Track gauge change Swing Travel (L) Arm swing 2 P.T.O. Blade Travel (R) Bucket Boom Boom swing Control valve
joint, the port A5 of the blade section and the ports T1 1.0 1.0
1.4 1.0
and T2 of the control valve. 0.8
P2 P1
2) Blade "Up"
When the blade lever is pulled back to raise the blade, MRV-2
ACV
MRV-1
the spool is pulled. The oil flows in the opposite direction R2

CRV-A3 ACV R1
ACV
to the oil flow in the blade down operation with regard to T2 CRV-A8 CRV-B2 T1
the blade cylinder.
b10 b8 b7 b3 b2
P T P T
Solenoid
valve
B1 B2 PA P3 P2 P1

Hydraulic pump
Left
Right
Extend
Retract
Down
Up
Dump
Curl
Hydraulic oil
tank
2 way valve
A B D C
P3 P2 P1 Engine
Return filter
M
Suction filter
O
S1
5-3-11 4480203
5. HYDRAULIC SYSTEM
P2
Hydraulic oil tank
P1
Hydraulic pump S1
T1 A5 F E
P1
Swivel joint
B5
P2 F
T2
Control valve E
Blade cylinder
BLD
BLU
5-3-12 4480203
5. HYDRAULIC SYSTEM
5-3-7 Travel Travel motor (L) Travel motor (R)
Each travel lever is linked to the spool of the control R/G R/G
valve through an L-ball and a rod.
1) Forward Travel (Right) PS

C G J J H
D PS
Oil Flow from Hydraulic Pump I
When the right travel lever is pushed forward, the spool a1 a2 a2 a1

of the right travel section is pressed.
P1 of the inlet section, the port A4 of the right travel sec- I
tion and the port I of the swivel joint to the port P2 of the P1 P2 T1
C G J
H
D T2 P2 P1
right travel motor to rotate it. The return oil from the port
P1 of the right travel motor flows back to the hydraulic oil
tank through the port D of the swivel joint, the port B4 of
the right travel section and the ports T1 and T2 of the
control valve.
2) Forward Travel (Left)

P2 of the inlet section, the port A9 of the left travel sec-
tion and the port C of the swivel joint to the port P1 of the a10
A11 B11 A10 B10 A9 B9
a8
A8 B8
a7
A7 B7 A6 B6
B5
A5 B4 A4 B3 A3
a3
B2 A2
a2
B1 A1
left travel motor to rotate it. The return oil from the port Track gauge change Swing Travel (L) Arm swing 2 P.T.O. Blade Travel (R) Bucket Boom Boom swing Control valve
P2 of the left travel motor flows back to the hydraulic oil 1.0
1.0
tank through the port G of the swivel joint, the port B9 of 1.4 1.0
the left travel section and the ports T1 and T2 of the con- 0.8
P2
trol valve. P1
3) Reverse Travel (Right and Left)

When the right or left travel lever is pulled back, the MRV-2
ACV
MRV-1
spool of the travel section is pulled. The oil flows in the R2

CRV-A3 ACV R1
opposite direction to the oil flow in the forward travel ACV
operation with regard to the right or left travel motor. T2 CRV-A8 CRV-B2 T1
b10 b8 b7 b3 b2
4) High-Speed Function
When the high-speed pedal is moved, the signal is
transmitted from the high-speed travel switch to the sole-
noid valve A to increase the travel speed.
(1) Pilot oil flow

When the high-speed pedal is moved, the signal is P T P T
transmitted from the high-speed travel switch to the cut- Solenoid

off valve and the solenoid valve A is opened. The oil valve
from the pilot pump P3 flows through the port PA of the B1 B2 PA P3 P2 P1
solenoid valve A to the port H of the swivel joint and is SOL B SOL A 4 Swing 2 3 Arm 1 3 Boom 1 4 Bucket 2
divided into two flows to the port PS of each travel motor. Hydraulic pump
Left
Right
Extend
Retract
Down
Up
Dump
Curl
Hydraulic oil
tank
(2) Increase in output speed of travel motor
The pilot oil from the pilot pump P3 moves the swash Pilot valve (LH) 1 2 4 3 Pilot valve (RH)
plate control piston to incline the swash plate to its mini-
mum angle, which shortens the piston stroke of the
2 way valve
travel motor and decreases the travel motor capacity to A B D C
P3 P2 P1 Engine
increase its output speed. This increases the travel
Return filter
speed. M
Meanwhile, the travel driving force weakens as the out- Suction filter
put torque of the travel motor becomes smaller due to O
the shortened piston stroke. S1
5-3-13 4480203
5. HYDRAULIC SYSTEM
P2
P1
Hydraulic pump
PA
S1
Hydraulic oil tank
T1 A4 B4
P1
A9 B9
P2
T2
Control valve
Travel motor (R)
J
I
G
D
Travel motor (L)
H C PS
T2
I P1 PS T1
D
P2
G P1
H
P2
JR
Swivel C JL
joint
5-3-14 4480203
5. HYDRAULIC SYSTEM
5-3-8 Track Gauge Change
The track gauge change lever is connected to the spool Track gauge change cylinder
of the track gauge change section through an L-ball and

a cable.
1) Widening of Track Gauge

When the track gauge change lever is pulled up to widen
the track gauge, the spool of the track gauge change
section is pressed. B
A

The oil from the piston pump P1 flows to the bottom side A
B
of the track gauge change cylinder through the port P2
of the inlet section, the port B11 of the track gauge
change section and the port B of the swivel joint to a10 a8 a7 B5 a3 a2
extend its cylinder rod, widening the track gauge. Track gauge change Swing Travel (L) Arm swing 2 P.T.O. Blade Travel (R) Bucket Boom Boom swing Control valve
The return oil from the rod side of the track gauge 1.0 1.0
1.4 1.0
change cylinder flows back to the hydraulic oil tank 0.8
through the port A of the swivel joint, the port A11 of the P2 P1
track gauge change section and the ports T1 and T2 of

the control valve.
MRV-2 MRV-1
ACV
2) Narrowing of Track Gauge R2
CRV-A3 ACV R1
ACV
When the track gauge change lever is pushed down to T2 CRV-A8 CRV-B2 T1
narrow the track gauge, the spool of the track gauge
b10 b8 b7 b3 b2
change section is pulled.

track gauge widening operation with regard to the track P T P T
gauge change cylinder. Solenoid

valve
B1 B2 PA P3 P2 P1

Hydraulic pump
Left
Right
Extend
Retract
Down
Up
Dump
Curl
Hydraulic oil
tank
2 way valve
A B D C
P3 P2 P1 Engine
Return filter
M
Suction filter
O
S1
5-3-15 4480203
5. HYDRAULIC SYSTEM
Hydraulic oil tank
P1
Hydraulic pump S1
A
T1
B
Swivel joint
A11
P2 B11
T2
A
Control valve
Track gauge change cylinder
5-3-16 4480203
5. HYDRAULIC SYSTEM
5-3-9 Simultaneous Operation of Blade and Travel

Blade cylinder Travel motor (L) Travel motor (R)
Oil Flow from Hydraulic Pump R/G R/G
1) Oil Flow to Blade Section

The oil from the piston pump P1 and that from the piston pump BLU
PS PS
P2 flow to the blade section through the ports P2 and P1 of the
inlet sections and the parallel passages, respectively. The oil is a1 a2
F E
C G J J H D
a2 a1
I
regulated evenly by the throttle (Ø0.04 in. [1.0 mm]) in each
parallel passage before the blade section. BLD
P1 P2 T1 T2 P2 P1
2) Oil Flow to Travel Sections F E H D

I
C G J
The oil from the piston pump P1 flows to the travel (L) section
through the port P2 of the inlet section, and the oil from the pis-
ton pump P2 flows to the travel (R) section through the port P1
of the inlet section.
The oil is fed to each travel section evenly after being reduced
by the throttle (Ø0.04 in. [1.0 mm]) in the parallel passage.
Therefore, even when the blade lever is operated while the
a10 a8 a7 B5 a3 a2
machine is traveling, the machine travels without deviation, as A11 B11 A10 B10 A9 B9 A8 B8 A7 B7 A6 B6 A5 B4 A4 B3 A3 B2 A2 B1 A1
Control valve
the oil is securely fed into the travel sections. Track gauge change Swing Travel (L) Arm swing 2 P.T.O. Blade Travel (R) Bucket Boom Boom swing
1.0 1.0
Refer to Section "5-3-6. Blade" and Section "5-3-7. Travel" for 1.4 1.0
0.8
the oil flow with regard to the blade cylinder and the travel P2 P1
motors.
MRV-2 MRV-1
ACV
R2 ACV R1
CRV-A3
ACV
T2 CRV-A8 CRV-B2 T1
b10 b8 b7 b3 b2
P T P T
Solenoid
valve
B1 B2 PA P3 P2 P1

Hydraulic pump
Left
Right
Extend
Retract
Down
Up
Dump
Curl
Hydraulic oil
tank
2 way valve
A B D C
P3 P2 P1 Engine
Return filter
M
Suction filter
O
S1
5-3-17 4480203
5. HYDRAULIC SYSTEM

Hydraulic pump
P1
PA
S1
E
F J
I B4
G A4 B5
Swivel T1 A5
joint D
P1
H C A9 B9
F
P2
I
D T2
E
G
H
JR
JL
C
Control valve
Travel motor (R)
BLD T2
BLU
P1 PS Travel motor (L)
PS
P2
T1
P1
P2
Blade cylinder
5-3-18 4480203
5. HYDRAULIC SYSTEM
5-3-10 Simultaneous Operation of Boom and Arm

Arm cylinder Boom cylinder
1) Oil Flow to Boom Section
The oil from the piston pump P2 flows to the boom section
AO BD
through the port P1 of the inlet section and the parallel pas-
sage.
2) Oil Flow to Arm Section

The oil from the piston pump P1 flows to the arm section AI BU
sage.
The oil from the piston pump P2 flows through the bypass
passage of the notch in the boom spool and the parallel
passage to combine with the oil from the piston pump P1 a10 a8 a7 B5 a3 a2
before flowing to the arm section. However, all the oil from A11 B11 A10 B10 A9 B9 A8 B8 A7 B7 A6 B6 A5 B4 A4 B3 A3 B2 A2 B1 A1
Control valve
the piston pump P2 does not, as the oil regulated by the 1.0 1.0
1.4 1.0
throttle in the swing 2 section flows back to the hydraulic oil 0.8
tank. P2 P1
Refer to Section "5-3-1. Boom" and Section "5-3-2. Arm" for

the oil flow with regard to the boom and arm cylinders.
MRV-2 MRV-1
ACV
R2 ACV R1
CRV-A3
ACV
T2 CRV-A8 CRV-B2 T1
b10 b8 b7 b3 b2
P T P T
Solenoid
valve
B1 B2 PA P3 P2 P1

Hydraulic pump
Left
Right
Extend
Retract
Down
Up
Dump
Curl
Hydraulic oil
tank
2 way valve
A B D C
P3 P2 P1 Engine
Return filter
M
Suction filter
O
S1
5-3-19 4480203
5. HYDRAULIC SYSTEM
AI
AO
Arm cylinder
Boom cylinder
BD
Hydraulic pump
Hydraulic oil tank BU
P2
P1
B2
S1
B1
Pilot valve (RH)

A2 T1 B2
P1 b2
Pilot valve (LH)
A8 B8
b8
T2
T
a2 P2
1
3
P
a8
T
3
1
P
Control valve
5-3-20 4480203
5. HYDRAULIC SYSTEM
5-3-11 Simultaneous Operation of Boom and Bucket

1) Oil Flow to Boom Section Bucket cylinder Boom cylinder
The oil from the piston pump P2 flows to the boom section
through the port P1 of the inlet section and the parallel pas- BKO BD
sage.
2) Oil Flow to Bucket Section

The oil from the piston pump P2 flows to the bucket section BKI BU
sage.
A throttle (Ø0.06 in. [1.4 mm]) is installed in the parallel pas-
sage to the bucket section to regulate the oil feeding into the
bucket section. Thus the oil can flow more smoothly to the a10 a8 a7 B5 a3 a2
boom section even when the bucket control lever is moved A11 B11 A10 B10 A9 B9 A8 B8 A7 B7 A6 B6 A5 B4 A4 B3 A3 B2 A2 B1 A1
while the boom with a heavy load is being raised. Therefore, 1.0
1.0
the boom and the bucket can be operated simultaneously. 0.8
1.4 1.0
Refer to Section "5-3-1. Boom" and Section "5-3-3 Bucket" for P2 P1
the oil flow with regard to the boom and bucket cylinders.
MRV-2 MRV-1
ACV
R2 ACV R1
CRV-A3
ACV
T2 CRV-A8 CRV-B2 T1
b10 b8 b7 b3 b2
P T P T
Solenoid
valve
B1 B2 PA P3 P2 P1

Hydraulic pump
Left
Right
Extend
Retract
Down
Up
Dump
Curl
Hydraulic oil
tank
2 way valve
A B D C
P3 P2 P1 Engine
Return filter
M
Suction filter
O
S1
5-3-21 4480203
5. HYDRAULIC SYSTEM
Boom cylinder
BD
BKI BKO
BU
Bucket cylinder
Hydraulic oil tank

P2
Hydraulic pump
B2
S1
B2
T1
A2 A3 B3
P1
b2
b3
T2
a2 T
1
a3 2
4
3
P
Control valve Pilot valve (RH)
5-3-22 4480203
5. HYDRAULIC SYSTEM
5-3-12 Simultaneous Operation of Arm and Swing Swing motor Arm cylinder

B2
1) Oil Flow to Arm Section A2 T
AO
The oil from the piston pump P1 flows through the port P2 P
of the inlet section and partly flows to the arm section

through the notch in the swing spool.
The oil from the piston pump P2 flows through the port P1 AI
SR2
of the inlet section and the bypass passage to combine with
the oil from the piston pump P1 before flowing to the arm SR1
section.
2) Oil Flow to Swing Section A1 B1
The oil from the piston pump P1 flows to the swing section
sage.
The spool of the swing 2 section is moved when the swing a10 a8 a7 B5 a3 a2
control lever is operated, so that all the oil from the piston Track gauge change Swing Travel (L) Arm swing 2 P.T.O. Blade Travel (R) Bucket Boom Boom swing Control valve
pump P2 flows to the arm section when the arm is simulta- 1.0 1.0
1.4 1.0
neously operated. 0.8
Also the spool of the swing 2 section has the function of P2 P1
smoothing the implement speed change with the oil quantity

fed depending on the patterns of the arm and swing simul-
taneous operation. MRV-2 MRV-1
ACV
Refer to Section "5-3-2. Arm" and Section "5-3-4 Swing" for R2
CRV-A3 ACV R1
ACV
the oil flow with regard to the arm cylinder and the swing T2 CRV-A8 CRV-B2 T1
motor.
b10 b8 b7 b3 b2
P T P T
Solenoid
valve
B1 B2 PA P3 P2 P1

Hydraulic pump
Left
Right
Extend
Retract
Down
Up
Dump
Curl
Hydraulic oil
tank
2 way valve
A B D C
P3 P2 P1 Engine
Return filter
M
Suction filter
O
S1
5-3-23 4480203
5. HYDRAULIC SYSTEM
Swing motor
AI
T
AO
Arm cylinder
B1
A1

P1
P3
Hydraulic pump
B1 S1
Pilot valve (LH)

T1
P1 A10
A8 B8 B10
b7
b8
T2
b10 T 2
1 3
P2
4 P
a7
a8
a10
Control valve
5-3-24 4480203
5. HYDRAULIC SYSTEM
5-3-13 Simultaneous Operation of Arm and Bucket

Arm cylinder Bucket cylinder
The oil from the piston pump P1 flows to the arm section AO BKO
through the port P2 of the inlet section.
The oil from the piston pump P2 flows through the port P1
of the inlet section and the parallel passage to combine with
the oil from the piston pump P1 before flowing to the arm
AI BKI
section. The oil from the piston pump P2 is regulated by the
throttle (Ø0.03 in. [0.8 mm]) before combining with the oil
from piston pump P1.
2) Oil Flow to Bucket Section

The oil from the piston pump P2 flows to the bucket section a10 a8 a7 B5 a3 a2
through the port P1 of the inlet section and the bypass pas- Track gauge change Swing Travel (L) Arm swing 2 P.T.O. Blade Travel (R) Bucket Boom Boom swing Control valve
sage. 1.0 1.0
1.4 1.0
Refer to Section "5-3-2. Arm" and Section "5-3-3. Bucket" 0.8
P2 P1
for the oil flow with regard to the arm and bucket cylinders.
MRV-2 MRV-1
ACV
R2 ACV R1
CRV-A3
ACV
T2 CRV-A8 CRV-B2 T1
b10 b8 b7 b3 b2
P T P T
Solenoid
valve
B1 B2 PA P3 P2 P1

Hydraulic pump
Left
Right
Extend
Retract
Down
Up
Dump
Curl
Hydraulic oil
tank
2 way valve
A B D C
P3 P2 P1 Engine
Return filter
M
Suction filter
O
S1
5-3-25 4480203
5. HYDRAULIC SYSTEM
AI
Arm cylinder AO
Bucket cylinder
BKI BKO
Hydraulic oil tank
P2
P1
Hydraulic
pump
B2
S1
B1
Pilot valve (RH)

T1 A3 B3
P1 Pilot valve (LH)
A8 b3
B8
b8
T2
T
P2
a3
2
4
P T
a8 3
1
P
Control valve
5-3-26 4480203
5. HYDRAULIC SYSTEM
5-3-14 Simultaneous Operation of Boom, Arm and Swing
Oil Flow from Hydraulic Pump Swing motor Arm cylinder Boom cylinder
1) Oil Flow to Boom Section B2

AO BD
The oil from the piston pump P2 flows to the boom section through A2 T
the port P1 of the inlet section and the parallel passage. Also the oil P
from the piston pump P2 flows to the arm section through the notch in
the boom spool and the bypass passage.
AI BU
SR2
SR1
The oil from the piston pump P1 flows to the arm section through the
port P2 of the inlet section and the notch in the swing spool.
The oil from the piston pump P2 flows through the notch in the boom
A1 B1
spool and the bypass passage to combine with the oil from the piston
pump P1 before flowing to the arm section.
3) Oil Flow to Swing Section

a10 a8 a7 B5 a3 a2
The oil from the piston pump P1 flows to the swing section through A11 B11 A10 B10 A9 B9 A8 B8 A7 B7 A6 B6 A5 B4 A4 B3 A3 B2 A2 B1 A1
the port P2 of the inlet section and the parallel passage. Also the oil 1.0
1.0
from the piston pump P1 flows to the arm section through the notch in 1.4 1.0
0.8
the swing spool and the bypass passage. P2 P1
The spool of the swing 2 section is moved when the swing control
lever is operated, so that all the oil from the piston pump P2 flows to
the arm section. MRV-2
ACV
MRV-1
Also the spool of the swing 2 section has the function of smoothing R2
CRV-A3 ACV R1
ACV
the implement speed change in the simultaneous operation of the T2 CRV-A8 CRV-B2 T1
arm, boom and swing. b10 b8 b7 b3 b2

Refer to Section "5-3-1. Boom", Section "5-3-2. Arm" and Section "5-
3-4 Swing" for the oil flow with regard to the boom and arm cylinders
and the swing motor.
P T P T
Solenoid
valve
B1 B2 PA P3 P2 P1

Hydraulic pump
Left
Right
Extend
Retract
Down
Up
Dump
Curl
Hydraulic oil
tank
2 way valve
A B D C
P3 P2 P1 Engine
Return filter
M
Suction filter
O
S1
5-3-27 4480203
5. HYDRAULIC SYSTEM
Swing motor
AI
AO T
Arm cylinder
B1
A1
Boom cylinder
P
BD
Hydraulic oil tank BU
P2
P1
P3
Hydraulic
pump
B2
S1
B1
A2 T1 B2 Pilot valve (RH)

P1 A10
b2
A8 Pilot valve (LH)
B8 B10
b7
b8
b10
T2
a2 P2 T
T 2
a7 1
3 1 3
a8 P
a10 4 P
Control valve
5-3-28 4480203
5. HYDRAULIC SYSTEM
5-3-15 Hydraulic P.T.O.
The P.T.O. pedal is linked to the spool of the P.T.O. sec-

tion through an L-ball and a rod.
Combined oil / Double acting P.T.O.
When the P.T.O. pedal is moved on the left side, the

spool of the P.T.O. section is pulled.
B A
Combined flow
Oil Flow from Hydraulic Pump Double action
The oil from the piston pump P1 flows to the P.T.O. sec-
tion through the port P2 of the inlet section. The oil from
the piston pump P2 flows through the bypass passage to a10 a8 a7 B5 a3 a2
combine with the oil from the piston pump P1 before Track gauge change Swing Travel (L) Arm swing 2 P.T.O. Blade Travel (R) Bucket Boom Boom swing Control valve
flowing to the arm section. The combined oil flows to A 1.0 1.0
1.4 1.0
of the P.T.O. through the port B6 of the P.T.O. section. 0.8
The return oil from B of the P.T.O. flows back to the P2 P1
hydraulic oil tank through the port A6 of the P.T.O. sec-

tion and the ports T1 and T2 of the control valve.
When the P.T.O. pedal is moved on the right side, the MRV-2
ACV
MRV-1
spool of the P.T.O. section is pressed. R2

CRV-A3 ACV R1
ACV
T2 CRV-A8 CRV-B2 T1
b10 b8 b7 b3 b2
spool pull operation with regard to the P.T.O.
P T P T
Solenoid
valve
B1 B2 PA P3 P2 P1

Hydraulic pump
Left
Right
Extend
Retract
Down
Up
Dump
Curl
Hydraulic oil
tank
2 way valve
A B D C
P3 P2 P1 Engine
Return filter
M
Suction filter
O
S1
5-3-29 4480203
5. HYDRAULIC SYSTEM
P.T.O.
B A
P2
P1
Hydraulic pump S1
Hydraulic oil tank
T1 A6
P1
B6
P2
T2
Control valve
5-3-30 4480203
5. HYDRAULIC SYSTEM
5-4 Pressure Adjustment

5-4-1 Relief Valves
1) Conditions
(1) Engine : rated speed
(2) Hydraulic oil temperature : 122 to 140 °F (50 to 60 °C)
(3) Pressure gauge capacity : 5688.1 PSI (39.2 MPa)
2) Relief Valve Specifications (Set Pressure)

Set pressure
Valve Pump
PSI (MPa) GPM (L/min)
R1 Piston pump P2 2986.2 (20.6)
System relief valve R2 Piston pump P1 2986.2 (20.6) at 4.22 (16)
R3 Gear pump P3 426.6 (2.9)
Boom (rod end) Piston pump P2 3412.8 (23.5)
Circuit relief valve Arm (bottom end) Piston pump P1 3412.8 (23.5) at 1.32 (5)
Bucket (bottom end) Piston pump P2 3555.0 (24.5)
(1) Remove the step A 1 and the side cover L 2.
(2) Remove the plugs R (PT1/8) 3 and 4 and install the oil pressure gauges.
3
4
P1
P2
5-4-1 4480203
5. HYDRAULIC SYSTEM
4) Adjustment Procedure
(1) To check the pressure of the system relief valve P1 (for the piston pump P2) of the control valve, retract the
bucket cylinder to its stroke end, hold the lever and read the gauge. Adjust the pressure if necessary.
(2) To check the pressure of the system relief valve P2 (for the piston pump P1), extend the boom swing cylinder to
its stroke end, hold the lever and read the gauge. Adjust the pressure if necessary.
Relief valve (P1)

(Piston pump P2)
Relief valve (P2)

(Piston pump P1)
(3) To adjust the pressure of each circuit relief valve, extend or retract the cylinder to its stroke end, hold the lever
and read the gauge. Whether the pressure of the circuit relief valve is lower than that of the system relief valve
can be read on the gauge.
Increase the pressure of the system relief valve and that of the circuit relief valve by turns, and lock the adjust
screw when the specified pressure of the circuit relief valve is obtained. Then lower the pressure of the system
relief valve to the specified pressure and lock the adjust screw.
Boom cylinder (rod)
Bucket cylinder (bottom)
Arm cylinder (bottom)
5) Pressure Change by One Turn of Adjust Screw

Tightening torque
Pressure change Number of adjust
for lock nut
PSI (MPa) screw turns
ft·lbf (N·m)
System relief valve
1877.1 (12.9) 1/1 14.47 (19.6)
Circuit relief valve
5-4-2 4480203
5. HYDRAULIC SYSTEM
5-4-2 Swing Brake Valve
1) Conditions
(2) Hydraulic oil temperature : 122 to 140 °F (50 to 60
°C)
1
(3) Pressure gauge capacity : 4977.1 PSI (34.3 MPa)
(4) Set pressure : 1493.1 PSI (10.3 MPa)
2) Measuring Procedure
(1) Remove the step A 1 and the side cover L 2.
(2) Remove the plug R (PT1/8) 3 to install the pressure
gauge.
(3) Fix the upperstructure and move the swing control
lever to the right or the left, hold the lever when
relief pressure is applied to the relief valve and read 2
the gauge.
3) Adjustment Procedure
(1) Since this relief valve is not adjustable, replace the
relief valve assembly with a new one if the relief
pressure needs to be adjusted.
3
P1
P2
Swing motor
Relief valve A
Relief valve B
5-4-3 4480203
5. HYDRAULIC SYSTEM
5-4-3 Cut-Off Valve
1) Conditions
(2) Hydraulic oil temperature : 122 to 140 °F (50 to 60
°C)
(3) Pressure gauge capacity : 1422 PSI (9.8MPa)
(4) Set pressure : 426.6 PSI (2.9MPa)
(1) Remove the side cover L 1.
(2) Remove the plug R (PT1/8) 2 and install the pres-
sure gauge.
(3) Move the lock levers to the "lock" position, and read 1
the gauge.
3) Pressure Adjustment Procedure

(1) Loosen the lock nut 3.
(2) Turn the adjust screw 4 to adjust the pressure to the
specified pressure. 2
(3) After adjustment, hold the adjust screw 4 to tighten
P3
the lock nut 3.
Note :
Fully loosen the lock nut to prevent the O-ring from being
damaged.
4) Pressure Change by One Turn of Adjust Screw
Pressure change Tightening torque for lock nut
19.5 to 23.9 ft·lbf

108.1 PSI (0.75 MPa)
(26.5 to 32.4 N·m)
Clockwise
(Pressure goes up)
3 Counterclockwise
(Pressure goes down)
5-4-4 4480203
CHAPTER 6
HYDRAULIC EQUIPMENT
6-1 Hydraulic Pump ................................................................................... 6-1-1

6-2 Control Valve ...................................................................................... 6-2-1
6-3 Pilot Valve............................................................................................ 6-3-1
6-4 Swing Motor ......................................................................................... 6-4-1
6-5 Travel Motor......................................................................................... 6-5-1
6. HYDRAULIC EQUIPMENT
6. Hydraulic Equipment
6-1 Hydraulic Pump
1. Outline
1) Piston Pump
The piston pump consists of a drive shaft, a swash plate, a rotary group, body H, a control spring, a control rod, a
gear pump, body S, a valve block assembly, a relief valve, and other components. It is a variable displacement pis-
ton pump that discharges two equivalent volumes by means of a rotary group.
• One rotary group is divided into one intake port and two discharge ports.
• Gear pump (the pilot pump) is connected to the piston pump with a coupling and the gear pump and the piston
pump share one intake port.
• Control system : Simultaneous incline angle full horsepower control.
5
4 6
2 7 3
9
8
6
4
No. Part
5
1 Drive shaft
2 Swash plate 3
3 Rotary group
2
4 Body H 7
9
5 Control spring
6 Gear pump 1
7 Body S
8 Valve block assembly 8
9 Relief valve
6-1-1 4480203
2) Valve Block Assembly and Relief Valve

The valve block comprises a body, a relief valve and two solenoid valves A and B. It has the following three functions
and is installed on the body H :
[1] The relief valve for regulating the pilot oil pressure :
[2] Shifting between the two travel speeds by the solenoid valve A : and
[3] Turning on and off the pilot oil supplied to the pilot valves by the solenoid valve B.
Solenoid valve B Solenoid valve A
B1 B2 PA P3 P2 P1
SOL B SOL A
X
(PD)
Body O
Check valve Relief valve S1

(SOL B) (SOL A
Relief valve
Body
6-1-2 4480203
2. Theory of Operation
1) Pump Function
• The cylinder barrel, which is splined to the drive shaft, revolves with the shaft.
• The pistons installed into the cylinder barrel, following the swash plate, make a reciprocating motion, which causes
the volume of the cylinder to change, thereby enabling the intake and discharge pump operations.
• As the pistons move from the top dead center to the bottom dead center, thereby increasing the volume, oil flowing
from the intake port runs through the valve plate into the cylinder barrel. (Intake stroke)
• As the pistons move from the bottom dead center to the top dead center, thereby decreasing the volume, the oil in
the cylinder barrel is discharged to the discharge port, (Discharge stroke)
• By changing the inclination of the swash plate, the piston stroke is changed and thus the displacement of the pis-
ton can be changed.
• Oil taken in from the inner port of the cylinder barrel is discharged from the inner discharge port of the valve plate.
• Oil taken in from the outer port of the cylinder barrel is discharged from the outer discharge port of the valve plate.
Piston Swash plate
Top dead center
Cylinder barrel
Valve plate
Discharge port
P1
P2
Bottom dead center
Discharge
stroke
Intake port Intake stroke
6-1-3 4480203
2) Control Function
• The discharge volume of the pump is regulated by the inclination of the swash plate angle. The swash plate angle
is controlled by a direct variable mechanism using a spring.
• The swash plate pivots on the ball behind it and the load F1 applied from the piston is in the direction as shown in
the below figure, which creates a clockwise moment with regard to the swash plate. To counteract this force, the
spring force F2 is applied in the opposite direction by the spring installed to set the horsepower at a constant level,
so that a specified load can be obtained.
• With increase in the pressure, the above clockwise moment increases, and when it overcomes the counterclock-
wise moment by the spring force, it compresses the spring to reduce the swash plate angle. Thus, the discharge
volume is decreased to maintain the horsepower at a constant level.
Moment Spring
caused by F2
Spring force F2
Load F1
Ball
Moment
created by F1
P-Q characteristic curve (Total horsepower control)
Q1, Q2
Discharge volume
P1 + P2
Discharge pressure
6-1-4 4480203
3) Function of Valve Block Assembly and Relief Valve

The oil from the pilot pump P3 flows through the body H of the piston pump to the valve block and is supplied to the
solenoid valves after its pressure is regulated by the relief valve. The solenoid valve A (SOL A) supplies the oil to the
port PA when it is turned on, and causes the oil in the port PA to escape into the housing of the piston pump from the
port S1 as shown in the below figure when it is turned off.
The solenoid valve B (SOL B) supplies the oil to the ports B1 and B2 when it is turned on, and causes the oil in the
ports B1 and B2 to escape into the housing of the piston pump from the port S1 when it is turned off.
B1 B2 PA P3 P2 P1
SOL B SOL A
X
(PD)
Body O
Check valve Relief valve S1

(SOL B) (SOL A)
Relief valve
Port B1, B2
Port PA
SOL B
SOL A
Body
6-1-5 4480203
25
30
5 24
29
20
14
20 3
4
26
9
38 8 28
33
10 34
45 21
46 11 27
3. Exploded View and Component Parts
42 19 13
1
6-7
43 37
44 31 36
48 12
47 22
40
6-1-6
27
39
41 18
2
4480203
17
35 15
23
32
32 48 16
49
51
50
No. Part Q'ty No. Part Q'ty

1 Body S 1 27 Coned disc spring 3
2 Body H 1 28 Internal snap ring 1
3 Drive shaft 1 29 Internal snap ring 1
4 Cylinder barrel 1 30 External snap ring 1
5 Valve plate 1 31 O-ring 1
6 Piston 10 32 O-ring 3
7 Shoe 10 33 O-ring 1
8 Shoe holder 1 34 Plug 1
9 Barrel holder 1 35 Hexagon socket head bolt 5
10 Swash plate 1 36 Hexagon socket head plug 4
11 Needle 3 37 Plug 1
12 Ball 2 38 Spring pin 1
13 Packing 1 39 Hexagon socket head set screw 1
14 Spring C 1 40 Hexagon nut 1
15 Spring T1 1 41 Seal washer 1
16 Spring holder 1 42 Gear pump kit 1
17 Spring guide 1 43 Coupling 1
18 Pin 1 44 Collar 1
19 Washer 1 45 Hexagon socket head bolt 2
20 Retainer 2 46 Washer 2
21 Stopper pin A 1 47 O-ring 1
22 Stopper pin B 1 48 O-ring 2
23 Pin 1 49 Valve block assembly 1
24 Ball bearing 1 50 Hexagon socket head bolt 3
25 Needle bearing 1 51 Spring washer 3
26 Oil seal 1
6-1-7 4480203
4. Special Tool
[Unit : in. (mm)]
Oil seal installation jig 51)
31)
2.01 (
1.22 (
2.05 (52)
2.76 (70)
6-1-8 4480203
5. Disassembly and Reassembly

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

Tools No. Nominal size Q’ty
1 Width across flats : 0.16 in. (4 mm) 1
Hexagon bar wrench 2 Width across flats : 0.24 in. (6 mm) 1
3 Width across flats : 0.32 in. (8 mm) 1
Wrench 4 Width across flats : 0.52 in. (13 mm) 1
Snap ring pliers 5 For internal snap ring 1
Plastic hammer 6 1
Hexagon socket head bolts 7 M10!65 (2 pcs.) 2
Grease 8 Little
6-1-9 4480203
3) Disassembly
Procedure
1. Removal of the valve block assembly
Remove the three hexagon socket head bolts 50
(M8!75) to remove the valve block assembly 49. 49
Tool :
Hexagon bar wrench 2
50
2. Removal of the gear pump kit

Remove the two hexagon socket head bolts 45 (M8!25)
to remove the gear pump kit 42, the collar 44 and the cou-
pling 43.
Tool :
Wrench 4
45
42
3. Removal of the hexagon socket head set screw

Loosen nut 40 sufficiently to remove hexagon socket
head set screw 39.
Tools :
Wrench 4
Note :
Do not disassemble when there are no 39
trouble around these parts, such as oil
leak. It makes horsepower control 39
change. When disassembly is done,
measure the dimension of a before a
removal, and adjust it to the same
dimension when reinstallation.
4. Separation of the body S kit and the body H kit

Remove the upper two of the five hexagon socket head
bolts 35 (M10!45).
Install and tighten the two hexagon socket head bolts

(M10!65) for temporary installation by about 10 mm in
place of the two bolts to loosen the remaining three hexa-
gon socket head bolts 35.
Then, loosen the two bolts for temporary installation to
separate the body S and the body H.
Tool :
Hexagon bar wrench 3 35
6-1-10 4480203
Procedure
Tap the spring installation area of the body H 2 with a plastic
hammer for easy separation of the bodies.
Tool :
Plastic hammer 6
5. Disassembly of the body S kit

(1) Remove the spring T1 15 and spring holder 16 from the 1
body S kit.
15
(2) Remove the cylinder barrel kit.
(3) Remove the swash plate 10 and the balls 12.
10
6-1-11 4480203
Procedure
(4) Remove the stopper pin A 21, the two coned disc springs
27 and the washer 19, then the stopper pin B 22, the two
coned disc springs 27.
21
27
(5) Remove the internal snap ring 28 on the engine side of

the drive shaft from the body S 1.
Tool :
Snap ring pliers 5
(6) Tap the drive shaft 3 on the body H lightly with a plastic
hammer to remove the oil seal 26 and the drive shaft with
the ball bearing 24 from the body S 1.
6. Disassembly of the body H kit

Remove the spring guide 16 from the body H 2.
16
6-1-12 4480203
Procedure
7. Disassembly of the cylinder barrel kit
(1) Remove the shoe holder 8 with assembly of the pistons 6
and the shoes 7 installed and barrel holder 9 from the cyl-
inder barrel 4. 9
8
6, 7
(2) Remove the needles 11 from the cylinder barrel 4.
11
(3) Remove the internal snap ring 29 and then remove the
retainer 20, the spring C 14 and the retainer 20 in order
29 20
from the cylinder barrel 4. 14
20
4
6-1-13 4480203
4) Reassembly
Procedure
1. Installation of the cylinder barrel kit
(1) Install the retainer 20, the spring C 14, the retainer 20 and
29 20
the internal snap ring 29 in order into the shaft hole of the 14
cylinder barrel 4. 20
4
(2) Install the needles 11 into the cylinder barrel 4.
11
(3) Install the barrel holder 9 and the shoe holder 8 with
assembly of the pistons and the shoes inserted, carefully
into the cylinder barrel 4.
Note :
Do not tap the pistons with a hammer or the like for installa-
tion.
2. Installation of the stopper pins A and B kits

Install one coned disc springs 28 and the washer 19 onto 22 21
the stopper pin A 21 to assemble the stopper pin A kit.
Install the two coned disc springs 27 onto the stopper pin
B 22 to assemble the stopper pin B kit.
Note :
Take care not to install the coned disc springs 27 in the wrong
direction. 27
27 19
22.8 22.4
Stopper pin B kit Stopper pin A kit
6-1-14 4480203
Procedure
3. Installation of the body S kit
(1) Installation of the oil seal and the drive shaft
Install the drive shaft 3 with the ball bearing 24, the oil
seal 26 and the internal snap ring 28 in order into the body
S 1.
Note : 3
Replace the removed oil seal with a new one in reassembly.
24
1
Apply a small quantity of grease to the lip and outer side

face of the oil seal 26, and tap it lightly with a hammer us-
ing a special installation jig to install it into the body S.
For easy installation, place body S 1 on body H 2 tempo-

rarily.
Tools :
Plastic hammer 6
Oil seal installation jig 1
(2) Install the stopper pin A kit and the stopper pin B kit into
the body S 1.
Stopper pin
6-1-15 4480203
Procedure
(3) Put the balls 12 into the holes in the swash plate 10, and
install it with the balls fitted into the holes in the body S 1.
10 12
1
(4) Install the cylinder barrel kit into the body S 1.
Cylinder barrel kit

1
(5) Install the spring holder 16 on the spring T1 15, and fit the
globular part of the spring holder 16 into the hole of the
swash plate 10. 15
4. Installation of the body H kit

(1) Install the spring guide 17 into the body H 2.
17
6-1-16 4480203
Procedure
(2) Place the valve plate 5 on the body H 2 softly with the
spring pin 38 on the body H 2 fitted into the thin groove of
the valve plate 5.
Note : 5
Take care not to place the valve plate on the wrong side on
body H 2. The thin-grooved side of the valve plate is con-
tacted with the cylinder barrel.
2
5. Assembling the body S and the body H

(1) Install the packing 13 on the mating surface of the body S
1 aligning the pin 23.
Note :
Replace the remove packing with a new one.
13
(2) To put the body S 1 and the body H 2 together, install and
quietly tighten two hexagon socket head bolts (M10!65)
for temporary installation in place of the upper two hexa-
gon socket head bolts 35 (M10!45). When the clearance
between the mating surfaces of the body S 1 and the
body H 2 gets narrow to 0.2 to 0.4 in. (5 to 10 mm), install
and tighten the other three hexagon socket head bolts 35 1
(M10!45).
Remove the hexagon socket head bolts for temporary
installation, and instead, install and tighten the two hexa- 35
gon socket head bolts 35 (M10!45).
Tool : Hexagon bar wrench 3
Tightening torque : 37.6 to 47.7 ft lbf 2
(51.0 to 64.7 N m)
6. Installation of hexagon socket head set screw

Fasten hexagon socket head set screw 39 with hexagon
nut 40 so that the set screw has the same projection
height as that before disassembly.
Tools :
Wrench 4
Hexagon bar wrench 1 39 40
6-1-17 4480203
Procedure
7. Installation of the gear pump kit
(1) Install the O-rings 47 and 48 on the mating surface of the
piston pump kit for the gear pump kit.
Note :
Replace the removed O-rings with new ones.
47 48
(2) Install the collar 44 and the coupling 43 in the area cou-
pled with the gear pump kit of the piston pump kit.
43 44
(3) Install the gear pump kit 42 onto the piston pump kit with
two hexagon socket head bolts 45 (M8!20) and washers
46.
Tool :

(9.8 to 14.2 N m)
45, 46
8. Installation of the valve block assembly

(1) Install the O-rings 32 and 48 on the mating surface of the
piston pump kit for the valve block assembly.
Note :
Replace the removed O-rings with new ones.
32, 48
6-1-18 4480203
Procedure
(2) Install the valve block assembly 49 onto the piston pump
kit with the three hexagon socket head bolts 50 (M8!75)
and the spring washers 51.
Tool :
Hexagon bar wrench 2 49
51
Tightening torque : 14.5 to 18.1 ft lbf
(19.6 to 24.5 N m)
50
9. Operation check after reassembly

• After the assembly of the hydraulic pump, check that the pump shaft rotates smoothly.
• Install the hydraulic pump in the machine and release air from the pump before starting the engine.
• Apply system relief set pressure to the hydraulic pump and check that the pump operates normally.
6-1-19 4480203
Clean the parts to be checked and completely dry them
Check the major parts carefully and replace any ones on which excessive wear or damage that may cause malfunc-
tion is found.
Replace deformed or damaged seals.
Procedure
(1) Piston assembly and cylinder barrel
• Perform visual inspections for any flaws, scuffing or exces-
sive wear (especially on the sliding parts). Piston assembly Cylinder barrel
• Check the clearance between the outside diameter of each
piston and the inside diameter of the cylinder barrel.
D - d ! 0.00197 in. (0.05 mm)
D
(2) Piston shoes and pistons d
• Check the axial play of each and shoe.
Shoe Piston
ε ! 0.00787 in. (0.2 mm)
(3) Drive shaft

• Check the oil seal installation area.
Wear ! 0.00098 in. (0.025 mm)
(Difference between contact and noncontact parts with oil Oil seal installation area
seal in radius.)
D
6-1-20 4480203
7. Troubleshooting
Trouble Cause Measure

1. Overload applied to (1) Engine speed higher than specified value Adjust engine speed to specified value
engine
(2) Pressure higher than specified value Adjust voltage to specified value
(3) Seizing or breakage of pump internal parts Repair or replace pump
2. Extreme low pump dis- (1) Low engine speed Adjust engine speed
charge volume or dis-
(2) Damaged pump coupling Repair or replace pump coupling
charge pressure not
increased (3) Seizing or breakage of pump internal parts Repair or replace pump
3. Abnormal sound or (1) Air or water in hydraulic oil Retighten relevant parts in circuit, especially suc-
vibration tion pipe. If there is water in hydraulic oil, replace
(Cavitation) it
(2) Clogged suction strainer Clean or replace suction strainer
(3) Clogged or squeezed suction pipe Repair suction pipe
(4) Breakage of caulked area of piston shoes Replace piston assembly
(5) Loosened pump installation Tighten pump installation area
(6) Damaged coupling Replace coupling
4. Oil leak (1) Malfunction of O-ring or seat packing Replace O-ring or seat packing and install new
ones correctly
(2) Loosened cap ring or insufficient tightening Retighten cap ring and specified tightening
of it torque
(3) Oil leak from oil seal edge Replace oil seal, or repair or replace drive shaft
6-1-21 4480203
6-2 Control Valve
1. Outline
This control valve is a mono-block valve comprising eleven-series connected three-position directional control
valves which control the operation of the actuators by switching the circuit, system relief valves which control the cir-
cuit pressure, circuit relief valves, an anti-cavitation valve, load check valves, throttles and others.
1) Circuit Configuration
There are two pump ports at both right and left ends of the circuit. Oil from the port P2 flows to the track gauge
change, swing, left travel, arm, swing 2 and P.T.O. spool sections, which are connected via parallel passages.
The parallel passage allows simultaneous operation of more than one spool, however, they cannot always operate
in the same motion. Specifically, due to the differences in load and capacity between the actuators, pressures to be
generated vary and the spool with a smaller load pressure operates earlier.
To allow the simultaneous operation of the spools in the same motion as a single operation, the spool stroke of the
spool section with a heavier load needs to be adjusted to the full stroke while that of the spool section with a lighter
load needs to be adjusted to half a stroke or smaller.
Oil from the port P1 flows to the boom swing, boom, bucket, right travel and blade spool sections, which are also
connected via parallel passages.
Track gauge change
Boom swing
Right travel
Left travel
Swing 2
Bucket
P.T.O.
Swing
Boom
Blade
Arm
A8
B8
A7
B7
A6
B6
B5
A5
B4
A4
B3
A3
B2
A2
B1
A1
A11
B11
A10 Pa10
B10
A9
B9
Pa8
Pa7
Pa3
Pa2
1.0
1.0
0.9
1.4
1.0
P2
P1
Pb3
Pb2
Pb10
Pb8
Pb7
Pump P1 Pump P2
T1
T2
T4
T3
6-2-1 4480203
2. Operation of Directional Control Valves (Pilot Controlled Directional Control Valves)

1) Spool in Neutral
When the spool is in neutral, the oil fed by the
pump flows through the unloaded passage and Actuator ports
returns to the tank through the tank passage. Load check valve
(Unloaded state) The actuator ports A and B are

Parallel passage A B
blocked. Unloaded passage
A B T
a b
P Spool Tank passage Return spring

T
2) Pressurizing Port b
The unloaded passage is closed, and the oil fed
by the pump passes through the parallel pas-
A B
sage, opens the load check valve and flows to
the actuator port B.
The return oil from the actuator port A returns to
Pressurize
the tank through the tank passage. port b.
The spool is returned to the neutral position by

the return spring.
3) Pressurizing Port a
The unloaded passage is closed, and the oil fed
by the pump passes through the parallel pas- A B
sage, opens the load check valve and flows to
the actuator port A.
Pressurize
The return oil from the actuator port B returns to port a.
the tank through the tank passage.
The spool is returned to the neutral position by
the return spring.
6-2-2 4480203
4) Single Operation of Blade

When the blade spool is pushed in, the oil from the port P1 is regulated to a specified quantity through the throttle
and the specified quantity of oil flows to the port B5. The return oil from the port A5 returns to the tank through the
tank passage.
The oil from the port P2 returns to the tank through the tank passage because the unloaded passage for the pump
port P2 is open.
When the blade spool is pulled out, the specified quantity of oil flows to the port A5 and returns from the port B5 to
the tank.
Blade
Tank port
Port A5
Pump port P2
Pump port P1
Port B5
Tank port
Push in.
port P2
Pump
Port B5
port P1
Pump
Tank port
Tank port
6-2-3 4480203
5) Simultaneous Operation of Blade and Travel

When the both travel spools are pulled out and the blade spool is pushed in, the oil from the port P1 and that from
the port P2 flow to the travel section ports B4 and B9 respectively, while some of each oil flow is regulated to a spec-
ified quantity through the throttle and the specified quantity of oil flows to the blade section. These divided oil flows
which have come into the blade section are combined after passing through the load check valve, and the combined
oil flows to the port B5.
The return oil from the port A5 returns to the tank through the tank passage.
The blade section is supplied with the same specified quantity of divided oil from the ports P1 and P2 ; therefore, the
both travel sections are also supplied with the same quantity of oil. Thus, the machine can travel without deviation
even when the blade is operated during traveling.
When the travel spools are pushed in and the blade spool is pulled out, the oil from the port P1 and that from the port
P2 flow to the travel section ports A4 and A9 respectively and the specified quantity of divided oil flows through the
blade section to the port A5. Then, the oil returns from the port B5 to the tank through the tank passage.
Left travel
Right travel
Blade
Tank port
Pull out.
Pull out.
Port A5
Pump port P2
Pump port P1
Tank port
Port B5
Push in.
port P1
Pump
Port B9
Port B5
Port B4
port P2
Pump
Tank port
Tank port
6-2-4 4480203
6) Pulling P.T.O. Spool Out

When the P.T.O. spool is pulled, the oil from the port P1 and that from the port P2 are combined and the combined oil
flows to the port B6.
The return oil from the port A6 flows to the hydraulic oil tank through the tank passage.
When the P.T.O. spool is pressed, the oil flows to the port A6 and returns from the port B6 to the hydraulic oil tank.
P.T.O.
Tank port
Pull out.
Port A6
Pump port P2
Pump port P1
Tank port
combined
P1,P2
Port B6
Port B6
port P2
Pump
port P1
Pump
Tank port
Tank port
6-2-5 4480203
3. System Relief Valves

These relief valves are of a balance piston type and also a cartridge type.
The relief valves are located between the pump ports P1 and P2 in the inlet sections, and the tank port T1 and T2.
They operate as follows:
1) Relief Operation
(1) Pressure oil flows through the inside of the
Socket Throttle B Piston Regulating valve spring
piston installed in the pressure control
valve (the parent valve) and the throttle B
to the inner chamber A, so that it is filled
with oil. The pressure control valve and the P
socket are securely seated, and so are the
socket and the regulating body seat.
Tank passage
Regulating body seat Pressure control valve Regulating valve
Inner chamber A
(2) When the oil pressure in the port P
reaches the set pressure of the regulating
valve spring, the pressure oil flows through
the piston to the regulating valve to open it.
At this time, the pressure oil passes through
the inside of the piston, the throttle B, the
inner chamber A, the ring-shaped throttle C
and the drill hole D in sequence, and flows
outside the socket to the tank passage.
Ring-shaped throttle C Drill hole D
(3) When the regulating valve opens, the pres-

sure in the inner chamber A is lowered, and
consequently, the pressure control valve is
opened and the pressure oil in the port P
flows directly to the tank passage through
the drill hole E.
Drill hole E
(4) When the pressure in the port P lowers to less than the set pressure of the regulating valve spring, the regulating
valve is pressed on the seat with the force of the regulating valve spring and the pressure in the inner chamber A
becomes equal to that in the port P. Therefore, the pressure control valve is also pressed on the seat portion of
the socket and returned to the original state.
6-2-6 4480203
4. Balance Piston Type

(It is installed at the rod end of the boom cylinder and at the bottom end of the bucket cylinder and arm cylinder.)
1) Relief Operation
(1) Pressure oil flows through the inside of the
Throttle B Piston Regulating valve spring
piston installed in the pressure control
valve (the parent valve) and the throttle B Tank passage
to the inner chamber A, so that it is filled
with oil. The pressure control valve and the
P
socket are securely seated, and so are the
socket and the section body seat. Section body
seat
Pressure control
Socket valve Inner chamber A Regulating valve
(2) When the oil pressure in the port P
reaches the set pressure of the regulating
valve spring, the regulating valve is
opened.
At this time, the pressure oil passes
through the inside of the piston, the throttle
B, the inner chamber A, the ring-shaped
throttle C and the drill hole D in sequence,
Ring-shaped throttle C Drill hole D
and flows outside the socket to the tank
passage.
(3) When the regulating valve opens, the pres-

sure in the inner chamber A is lowered,
and consequently, the pressure control
valve is opened and the pressure oil in the
port P flows directly to the tank passage
through the drill hole E.
Drill hole E
(4) When the pressure in the port P lowers to less than the set pressure of the regulating valve spring, the regulating
valve is pressed on the seat with the force of the regulating valve spring and the pressure in the inner chamber A
becomes equal to that in the port P. Therefore, the pressure control valve is also pressed on the seat portion of
the socket and returned to the original state.
6-2-7 4480203
2) Suction Operation
When the pressure in the tank passage exceeds that in
the port P, upward force is applied to the socket. This
creates an opening between the section body seat and
the socket and oil flows from the tank passage to the
port P, so that the space in the port P is filled with oil.
Thus, when negative pressure is generated in the port P,
the port P is supplied with oil from the tank passage to
prevent negative pressure.
6-2-8 4480203
5. Anti-Cavitation Valve
(It is installed at the rod end of the boom swing cylinder and arm cylinder and at the bottom end of the boom cylin-
der.)
This anti-cavitation valve consists of a body, a piston and a spring. The valve is located between the actuator port P
and the tank port T in the section. It operates as follows:
(1) The pressure oil in the port P flows through the
Spring
inside of the piston to the piston chamber, so that it is
Tank passage
filled with oil. The balance is kept with the spring
T
force in the piston chamber and the oil flow to the
tank passage is being blocked. P
Section body seat

(2) When the pressure in the tank passage exceeds that
Piston
in the port P, upward force is applied to the piston.
This creates an opening between the section body
seat and the valve and oil flows from the tank pas-
sage to the port P, so that the space in the port P is
filled with oil.
(Operating State)
6-2-9 4480203
6. Shut-Off Valve
This shut-off valve is a cartridge type.
The shut-off valve is installed between the actuator port P and the tank port T in the valve section.
1) When the Shut-Off Valve is Closed :

With the hexagon socket head bolt tightened, the oil
passage between the actuator port P and the tank port T
is blocked and the oil flows to the actuator port P.
P
T
Hexagon socket head bolt
2) When the Shut-Off Valve is Open :

With the hexagon socket head bolt loosened, the oil pas-
sage between the actuator port P and the tank port T is
open and the oil flows to the tank port T.
(The pressure at the actuator port P is equal to the pres-
sure in the tank passage.)
P
T
Hexagon socket head bolt
6-2-10 4480203

• Precautions for disassembly
(1) Since the parts of the hydraulic equipment are generally precision-made for tight clearances, be sure to perform
disassembly and reassembly in a clean place that is free from dust.
(2) Prepare clean tools and treated oil, and handle the parts carefully.
(4) Before beginning disassembly, review the drawings of the internal structure and prepare the required parts
In principle, replace the removed seals and O-rings with new ones. Since some replacement parts are available
only as subassemblies, refer to the parts catalog to prepare the necessary subassemblies in advance.
• Precautions for reassembly
[2] The O-rings may not have any defects in molding or be damaged in handing or distorted by heat.
[3] Do not extend any O-rings with such great force as to permanently deform them.
A distorted O-ring may not return to its original shape, and therefore, may cause oil leakage.
(2) Before beginning reassembly, check that there is no treated oil or hydraulic oil on the outer surface of the O-ring
groove in the mating face of each section. If reassembly is performed without cleaning such oil, it may be mis-
taken for oil leakage.

Tool Nominal Size Remarks
3 For hexagon socket set screw M6.
4 For hexagon socket head bolt M5.
Hexagon screw socket key (mm) 5 For hexagon socket head plug R (PT) 1 / 8.
6 For hexagon socket head plug G (PF) 1 / 4.
8 For hexagon socket head plug G (PF) 3 / 8.
Wrench or box wrench (mm) 8, 10, 13, 21 and 22
Screwdriver for cross recessed
For cross recessed pan-head screw M5.
head screws
Rod (in. [mm]) Ø0.18 × 3.94 (Ø4.5 × 100) For disassembly and reassembly of spring center.
14.5 to 72.4 (19.6 to 98.1)
Torque wrench (ft·lbf [N·m]) For nut M8. For system and circuit relief valves and spring cases.
Smaller than 14.5 (19.6)
6-2-11 4480203
3) Exploded View and Component Parts

Exploded view
1 18
2 7
10 9
11
12
3 13
9
10 7
7 11
7 6 31 3 5 12
8 3 13
1617 10
15
14 7 32 3 5 11
18 12
3 13
7
10 19 18
11 23 33 3 7
5 3
10 20 7
11 22 19
12 1514 10
23 34 3 5 24 25
3 13
11 20 22
12
3 5 16 13 26
17 35 17
27
1516 3 10
14
30 11
7 12
3
28 29 36 5 3 13
3 26
27
4
10 7 9
10 11
17 37 3 5 12
11 16
12 7 1415 3 13
13 30 22
10
11
3 5 4
1617
12 23 38
15 3 13 3
14 20 7
10
11 39 3 5 3
40 3 5 12 23
3 13
19 20
14 22
15
41 3 16
22 23 5 17
21
3 18
7
42 3 5
43
6 1
7
8
6-2-12 4480203
Component Parts

1 Nut M8 6 23 O-ring AS1A016 10
2 Bolt 3 24 Check valve (Bucket section) 1
3 O-ring 1BP10.0 26 25 Check valve spring (Bucket section) 1
4 O-ring 1BP4.0 2 26 Plug G (PF) 1 / 4 4
5 O-ring AS1B127 12 27 O-ring 1BP11.0 4
6 O-ring 1BP10.0 2 28 Spring case 6
7 O-ring 1BP14.0 13 29 Hexagon socket head bolt M5 × 45 12
8 System relief valve 2 30 Shut-off valve 2
9 Anti-cavitation valve 3 31 P1 section 1
10 Check valve holder 11 32 Boom swing section 1
11 O-ring 1BP11.0A 11 33 Boom section 1
12 Check valve spring 10 34 Bucket section 1
13 Check valve 10 35 Travel section (R) 1
14 Pan head screw M5 × 10 12 36 Blade section 1
15 Spring seat 12 37 P.T.O. section 1
16 Backup ring T3P10A 12 38 Swing 2 section 1
17 O-ring 1A P10A 12 39 Arm section 1
18 Plug G (PF) 3 / 8 4 40 Travel section (L) 1
19 Circuit relief valve 3 41 Swing section 1
20 Pilot case (A1) 5 42 Variable track section 1
21 Pilot case (B1) 5 43 P2 section 1
22 Hexagon socket head bolt M5 × 20 20
6-2-13 4480203
4) Disassembly
Procedure
(1) Put the control valve assembly on a clean working table.
(2) Remove circuit relief valves 19, shut-off valve 30 and anti-
cavitation valve 9.
9
30
9
19
30
19
(3) Remove plug G3 / 8 18 on the side of each section.
18
(4) Remove spring case 28 of each section.
28
6-2-14 4480203
Procedure
(5) Remove pilot cases A1 20 and B1 21 of each section.
21
20
(6) Remove the boom spool, the bucket spool, the arm spool,
the swing 2 spool and the swing spool. Swing spool
Swing 2 spool
Arm spool
Boom spool
Bucket spool
(7) Remove the boom swing spool, the right travel spool, the P.T
P.T.O.
.T.O.
.O. spool Track
Track gauge change spool
blade spool, the P.T.O. spool, the left travel spool and the
Left travel spool
track gauge change spool.
Note :
Each spool is installed into the valve body with a specified
clearance between them. Make matchmarks on them so that
each spool can be reinstalled in its original position.
Blade spool
Right travel spool

Boom swing spool
(8) Remove the seal plates 15, the backup rings 16 and the
O-rings 17 on the spool link side.
15, 16, 17
6-2-15 4480203
Procedure
(9) Remove the system relief valves 8.
Note :
Make matchmarks on the valves and the control valve body
before removing the valves.
(10) Remove the check valve holder 10 (with the O-ring 11),
the check valve spring 12 and the check valve 13 of each
section. 10
10
11
12
13
(11) While holding the nut on one inlet section side, loosen the
nut on the other inlet section side to separate the sec-
tions from each other.
(12) Remove the check valve 24 and the check valve spring
25 of the bucket section.
24
25
6-2-16 4480203
Procedure
(13) Remove the O-rings 3 and 5 from the mating face of each
section.
Note :
Put all the sections in order for reassembly.
5 3
6-2-17 4480203
5) Reassembly
Procedure
(1) After installing the O-rings 3, 4 and 5 to each section, put
the sections in the specified order and the insert bolts 2
into them.
2
Note :
Do not apply grease to the O-rings.
(2) Install the check valve 24 and the check valve spring 25
into the bucket section.
24 25
(3) Put all the sections together and tighten the nuts at a
specified tightening torque.

(13.7 to 14.7 N m)
(4) Install the check valve 13, the check valve spring 12 and
the check valve holder 10 (with the O-ring 5) to each sec-
tion, and tighten the check valve holder at a specified tight- 10
ening torque
Tightening torque : 18.1 to 21.7 ft lbf (24.5 to 29.4 N m)
Note : 10
Both travel (R) sections have no check
valve 13 or check valve spring 12.
5
12
13
6-2-18 4480203
Procedure
(5) Install the boom swing spool, the right travel spool, the P.T.O. spool Track gauge change spool
blade spool, the P.T.O. spool, the left travel spool and the
Left travel spool
track gauge change spool in their original positions.
Note :
Replace any spool as a spool assembly if necessary.
Blade spool
Right travel spool

Boom swing spool
(6) Install the boom spool, the bucket spool, the arm spool,
the swing 2 spool and the swing spool in their original posi- Swing spool
Swing 2 spool
tions.
Arm spool
Note :
Replace any spool as a spool assembly if necessary.
Boom spool
Bucket spool
(7) Install the pilot cases A1 20 and B1 21.

(5.9 to 6.9 N m)
21
20
(8) Install the spring cases 28.

(5.9 to 6.9 N m)
28
6-2-19 4480203
Procedure
(9) Install the O-rings 17, the backup rings 16 and the seal
plates 15 on the spool link side.

(2.0 to 3.0 N m)
15, 16, 17
(10) Install the system relief valves 8.

Tightening torque : 28.9 ft lbf (39.2 N m)
Note :
Apply grease thinly to the O-rings 6 and 7.
(11) Install the circuit relief valves 19, the shut-off valve 30
and the anti-cavitation valve 9.
9
30
9
Note :
Apply grease thinly to the O-rings 9.
19
30
19
(12) Install the plug G3 / 8 18 (with the O-ring 7) on the side of

each section.
18
Note :
Apply grease thinly to the O-rings 7.
6-2-20 4480203
6) Troubleshooting
1. Oil leak from spool (1) Damaged oil seal (1) Replace oil seal.
(2) Damaged spool surface (2) - 1. Flaw ··· Replace spool.
(2) - 2. Foreign substances ··· Remove.
2. Spool does not work smoothly or (1) Foreign substances caught inside (1) Clean hydraulic circuit and valves.
return to neutral position. (2) Bent spool (2) Replace spool.
(3) Off-center of control valve linkage (3) Check linking condition of linkage.
(4) Excessive tightening of bolt (4) Retighten tie rod at specified tightening
torque.
Tightening torque:
10.1 to 10.8 ft·lbf
(13.7 to 14.7 N•m)
(5) Distortion of valve contact face. (5) Repair distortion of contact face.
(6) Too high temperature of hydraulic oil. (6) Keep oil temperature within specified
range.
3. Actuator does not operate or oper- (1) Spool stroke is not full. (1) Check spool linked portion.
ates slowly (at low pressure). (2) Foreign substances caught between reg- (2) Disassemble and clean parts.
ulating valve and seat surface.
(3) Improper set pressure, or sticking or (3) Adjust set pressure or disassemble and
breakage of relief valve clean parts.
4. Actuator does not operate or oper- (1) Overload (1) Check load applied.
ates slowly (at high pressure). (2) High resistance of piping (2) Replace piping with proper sized one.
5. Oil pressure can not be main- (1) Neutral position of spool is not in right (1) Adjust neutral position of spool.
tained in neutral position of spool. place.
(2) Oil leak from clearance between spool (2) Replace spool or valve section.
and body
(3) Internal leakage of hydraulic cylinder (3) Repair or replace hydraulic cylinder.
6. Oil pressure lowers when spool is (1) Dust or foreign substances caught (1) Disassemble and clean parts.
moved from neutral position. between load check valve and seat sur-
face.
(2) Sticking or breakage of poppet. (2) Replace poppet.
(3) Damaged seat surface. (3) Replace valve section.
6-2-21 4480203
6-3 Pilot Valve
1. Outline
The pilot valve outputs pilot pressure according to the stroke of the control levers from the corresponding output
ports to move the control valve spools.
Structural drawing Specifications
Primary pressure Highest pressure :

1001.1 PSI (6.9 MPa)
14 Secondary pressure Highest control pressure :
6 0 to 355.5 PSI (0 to 2.45 MPa)
Allowable back pressure Highest : 44.1 PSI (0.3 MPa)
7 Rated capacity 4 GPM (15 L / min)
8 Operating angle ±19 degrees, ±25 degrees

4 9 Dry mass 3.5 lbs (1.6 kg)
5
Part
No. Part No. Part
10
1 1 Casing 8 Push rod
11
2 Port plate 9 Spring seat
13
3 Spring (for secondary
12 3 Bushing 10
pressure)
4 Plate 11 Return spring
5 Plug 12 Spool
2 6 Joint 13 Washer 2
Adjusting nut (for lever
7 Disc 14
joint)
A
Port arrangement
P T
3 2
P
1 3 2 4
Hydraulic symbol
P. Port P (from the pilot pump)
T. Port T (to the hydraulic oil tank)
1. Port 1
2. Port 2
T 3. Port 3
4. Port 4
4
1
Viewed from arrow A
6-3-1 4480203
2. Structure
A pilot valve comprises casing 1 with four vertical shaft
holes in it and four pressure reducing valves installed 14
into the holes.
6
A pressure reducing valve consists of spool 12, spring
(for secondary pressure) 10, return spring 11, spring
7
seat 9 and washer 2 13. The force of the spring (for sec-
8
ondary pressure) 10 is set for secondary pressure : 72.5
4 9
to 145 PSI (0.5 to 1.0 MPa). The spool 12 is pressed
against the push rod 8 by the return spring 11. 5
When the control lever is moved and the push rod 8 is
pushed down, the spring seat 9 is also moved downward 10
1
and the setting of the spring (for secondary pressure) 10 11
is changed. 13
The casing 1 and the port plate 2 have an oil inlet port 3
12
(port P) and an oil discharge port (port T), and also have
output ports 1, 2, 3 and 4, at which secondary pressure
is generated. 2
3. Function
When the port P receives the supply oil pressure from
the hydraulic pump, the spool 12 switches the oil pas-
sage to lead the pressure oil at the port P to the output
port (1, 2, 3, or 4) or to lead the pressure oil at the output A
port to the port T. The spring (for secondary pressure) 10
acts on the spool 12 to decide the output pressure. The
push rod 8, which is inserted in the plug 5, can slide to
change the amount of compression of the spring (for
secondary pressure) 10.
The return spring 11 acts on the casing 1 and the spring
seat 9 to return the push rod 8 to the original position,
irrespective of the output pressure, so that the spool 12
can surely be returned to the neutral position. The return
spring 11 also acts as a reaction force spring which
gives a feeling of using adequate operating force to the
operator.
6-3-2 4480203
1) Control Lever in Neutral Position
The force of the spring (for secondary pressure) 10
which decides the output pressure of the pilot valve does
not work on the spool 12. Therefore, the spool 12 is
pushed up by the spring seat 9 pressed by the return
spring 11 and the output ports 2 and 4 are connected to
the port T. Consequently, the output pressure is equal to
the pressure of the hydraulic oil tank. 9
10
11
12
Ports 2 and 4
2) Control Lever Moved to One Side
When the control lever is moved to one side and the
push rod 8 on the side is pushed down, the spring seat 9
and the spool 12 move downward and the port P is con-
nected to the output port (2 or 4). Consequently, the oil 8
fed from the pilot pump flows to the output port (2 or 4)
and generates pressure.
9
12
Ports 2 and 4
3) Control Lever Held in that Position
When the control lever is moved to one side and the
pressure at the output port (2 or 4) on the side rises to
the pressure equivalent to the preset force of the spring
10, the oil pressure is balanced with the force of the
spring 10. If the pressure at the output port (2 or 4) rises
to above the preset pressure, the output port (2 or 4) and
the port P are closed, and the output port (2 or 4) and
10
the port T are opened. If the pressure at the output port
(2 or 4) drops to below the preset pressure, the output
Port T
port (2 or 4) and the port P are opened, and the output
Port P
port (2 or 4) and the port T are closed. Thus, the second-
ary pressure is kept constant.
Ports 2 and 4
6-3-3 4480203
5. Sectional View and Component Parts
18 20
19 21
12
11
10
8
13
14
16 17
Pressure reducing
valve assembly
15
9
7 1
6 4
2
3
No. Part No. Part

1 Casing 12 Seal
2 Port plate 13 O-ring
3 Seal washer 14 Spring seat
4 O-ring 15 Washer 2
5 Hexagon socket head bolt 16 Return spring
6 Spring pin 17 Spring (for secondary pressure)
7 Bushing 18 Joint
8 Plate 19 Disc
9 Spool 20 Adjusting nut
10 Plug 21 Boot
11 Push rod
6-3-4 4480203
6. Special Tools
1) Drawing of Jig 2) Bushing (2 pcs.)
)
(R135
R0.
Unit : in. (mm)
15 degrees
0.606 to 0.614 0.25 to 0.26
(15.4 to 15.6) (6.4 to 6.6)
0.02 (0.5)
R
0.
R0
2
.2
(R
(R C0.02 (C0.5)
5.
4.5
8)
)
1.1 ( 2.9) Material : SCM415(N)
(12.5)
0.5
(9.5)
Carburizing and quenching
0.4
1.0 ( 26.5)
0.9 ( 23.5)
(Width across flats) C0.02 (C0.5)
Material : S45C 0.45 to 0.46
(11.5 to 11.7)
13)
0.5
Detail drawing of bushing

0.7 ( 19)
(
Material : SCM415 (N) Carburizing and quenching

69)
Surface heat treatment

54)
2.7 (
50)
46)
Method Gas carburizing and quenching

2.1 (
2.0 (
Surface hardness HRC HRC 56 to 60

1.8 (
1.0 ( 25)
Effective case Hmv 550 or more

( 17)
0.7
hardness
Effective case 0.02 to 0.03 in. (0.5 to 0.8 mm)
0.906 to 0.913 depth
( 23 to 23.2)
1.063 to 1.064 Quenching area Overall
( 27.000 to 27.013)
1.221 to 1.222
( 31.015 to 31.028)
Bushing
Section A-A
0.63 to 0.64
( 16.0 to 16.2)
Detail drawing of jig
1 and 2 should be press-fitted
A A
Joint in mounted state
6-3-5 4480203

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

Tool Q'ty Nominal size Remarks
Hexagon socket screw key (Hexagon
1 6
wrench)
1 22
Wrench
1 32
Small-sized screwdriver 1 -
Special jig 1 - Refer to the drawing of special jig.
Kerosene, oil stone, high-temperature grease
Others
Volatile rust inhibitor, sand paper (#1000, #2000)
6-3-6 4480203
3) Disassembly
Procedure
(1) Clean the pilot valve with kerosene.
(2) Fasten the pilot valve with a copper plate (or a lead plate)
in a vise.
(3) Remove the boot 21.
Note :
Plug up all the ports. Take care not to break the boot 21.
21
(4) Hold the adjusting nut 20 and the disc 19 by their width
across flats with wrenches and loosen to remove them.
20
19
(5) Loosen the joint 18 by turning it counterclockwise with a

jig.
Note : 18
Jig
If the return springs 16 are strong, the plate 8, the plugs 10,
and the push rods 11 come up as the joint 18 is loosened. Be
careful when removing the joint 18 as they may jump out.
(6) Remove the plate 8.
6-3-7 4480203
Procedure
(7) If the return springs 16 are weak, the plugs 10 remain in
the casing 1 due to the sliding friction of the O-rings.
Remove them with a screwdriver.
Notes :
• To remove the plug 10, hold it by the groove in its external
surface with the screwdriver to prevent it from being dam-
aged due to unbalanced load.
• Be careful when removing the plug 10 as it may jump out
due to the spring force of the return spring 16.
10
1
(8) Remove the push rods 11, the plugs 10, the pressure
reducing valve assemblies and the return springs 16 from
the casing 1.
11
11
Note : 10 Pressure reducing

Make notes of the physical relationship with the respective valve assembly
holes in the casing.
16
1
(9) Put the pilot valve with the port plate 2 side up and fasten
it in the vise.
(10) Remove the hexagon socket head bolts 5 with a hexa-

gon socket screw key (hexagon wrench). 2
(11) Remove the port plate 2, the O-ring 4 and the bushing 7
from the casing 1.
7
4
6-3-8 4480203
Procedure
(12) When disassembling the pressure reducing valve
assembly, move the spring seat 14 sideward while press-
ing it to bend the secondary pressure spring 17 and then
take the spool 9 out of the spring seat 14 through the
larger hole.
Notes :
• Be careful not to damage the surface of the spool 9. 18
• Do not press the spring seat 14 over 0.2 in. (6 mm).
(13) Remove the spring seat 14, the secondary pressure

spring 17 and the washer 2 15 from the spool 9.
9 14
15 17
(14) Remove the push rod 11 from the plug 10.
11
11 10
(15) Remove the O-ring 13 and the seal 12 from the plug 10.
10
Note :
To remove the seal 12, use a small-sized screwdriver or the
like.
12
13 10
6-3-9 4480203
4) Reassembly
Procedure
(1) Install the bushing 7 and the O-ring 4 in the casing 1.
4 1 7
(2) Install the port plate 2 and the hexagon socket head bolts
5 with the seal washer 3 to the casing 1. 5
Notes:
• Make sure that the mounting position of the spring pin 6 in
the port plate 2 is aligned to that of the casing 1.
• Replace the seal washers 3 with new ones.
1 2
(3) Tighten the hexagon socket head bolts 5.
Tightening torque : 14.1 to 16.3 ft bf

(19.1 to 22.1 N m)
Note :
Slowly tighten the hexagon socket head bolts alternately.
(4) Install the washer 2 15 and the secondary pressure spring

17 onto the spool 9 in this order.
14
9 15 17
6-3-10 4480203
Procedure
(5) Put the spool 9 through the larger hole in the spring seat
14 while pressing the spring seat 14 to bend the second- 9
ary pressure spring 17, and then move the spring seat
14 to set the spool 9 in the center of the spring seat 14. 14
Note :
Do not press the spring seat 14 over 0.2 in. (6 mm).
17
(6) Install the return springs 16 into the casing 1.
(7) Install the pressure reducing valve assemblies into the

casing 1.
16
Note :
Be sure to reinstall them to the positions where they were
before disassembly.
Pressure reducing
valve assembly 1
(8) Install the O-ring 13 onto the plug 10.

13
10
(9) Install the seal 12 into the plug 10.
Note :
Install the seal 12 so that its lip is set as shown in the figure 10
below.
Plug
Seal
13
12
6-3-11 4480203
Procedure
(10) Install the push rod 11 into the plug 10.
Note :
Apply hydraulic oil to the surface of the push rod. 10
11
Push rod Apply hydraulic oil
(11) Install the plug assemblies into the casing 1.

If the return springs 16 are weak, the plug assemblies
will stop due to the sliding friction of the O-rings.
If the return springs 16 are strong, install the four plug
assemblies together using the plate 8 and temporarily
fasten it with the joint 18.
Plug assembly
(12) Install the plate 8 and the joint 18.
Notes :
18
• Install the plug assemblies while keeping them straight,
being careful not to press the spools and damage the inner
surface of the holes in the casing 1.
• Be careful as the plug assemblies and the plate 8 may jump
out.
(13) With a jig, fasten the joint 18 to the casing 1 at the speci-
fied torque.

(44.1 to 50.0 N m)
Adhesive : Apply Loctite #262 or its equivalent.
Jig
6-3-12 4480203
Procedure
(14) Install the disc 19 onto the joint 18.
Notes :
• Screw in the disc 19 until it comes into contact with the four
push rods 11 evenly. 18
• Screwing it too much can cause the secondary pressure
when the control lever is in neutral and the malfunction of
the implement. Take care of the adjustment of the disc 19 19
position.
(15) Install the adjusting nut 20 and hold the disc 19 by the
width across flats with a wrench. Tighten the adjusting
nut at the specified torque.

(63.7 to 73.6 N m) 20
Adhesive : Apply Loctite #262 or its equivalent.
Note :
Do not move the disc 19 when tightening the adjusting nut. 19
(16) Apply grease to the moving part of the joint 18 and the
top of the push rod 11.
18
11
(17) Install the boot 21.
Note :
Be careful not to break the boot 21.
21
6-3-13 4480203
Clean the removed parts, dry them with compressed air and repair or replace them, if necessary, according to the
following service standards :
Notes :
• It is advisable that the seals such as O-rings are replaced with new ones if once removed; however, they can be
reused if it is confirmed that there is no damage on them.
• Be sure to replace the seal washer 3 with a new one each time the hexagon socket head bolt 5 is loosened.
No. Inspection Item Standard Value Remarks
1 Amount of oil leak Control lever in neutral condition : Conditions :
over 61 (1000) cu.in (cu.cm) / min control lever in Primary pressure
operated condition : 426.6 PSI (2.94 MPa)
over 122 (2000) cu.in (cu.cm) / min replace spool Oil viscosity :
when either of above conditions is obtained. If not 0.036 (23) sq.in (sq.mm) / sec.
effective, replace pilot valve with new one.
2 Spool Replace if wear of sliding part is over 393.7 µin. (10 Amount of oil leak in this spool condi-
µm) larger than that of non-sliding part. tion will be about the same as above.
3 Push rod Replace if top part is worn over 0.04 in. (1 mm).
4 Play in control section Replace if disc 19 and joint 18 in control section Adjust if play is due to loosened
have play of over 0.08 in. (2 mm) due to wear. adjusting nut.
5 Operation stability Replace pilot valve with new finished product if
abnormal sound, hunting, fall in primary pressure,
etc. occur during operation and are beyond recovery
according to Section "9. Troubleshooting".
6-3-14 4480203
9. Troubleshooting
No. Trouble Cause Measure
1 Secondary pressure 1. 1. Insufficient primary pressure. 1. 1. Secure primary pressure.
does not rise 2. Breakage or permanent set of secondary pres- 2. Replace spring 17 with new one.
sure spring 17.
3. Too large clearance between spool 9 and casing 3. Replace spool 9 with new one.
1.
4. Play in handle section. 4. Adjust or replace handle section.
2 Secondary pressure is 1. Sliding part is caught. 1. Repair defective part.
unstable 2. Fluctuation of tank passage pressure. 2. Connect port T with hydraulic oil
tank by exclusive tank passage.
3. Air leaked in piping. 3. Operate control lever several
times to release air.
3 Secondary pressure is 1. Too high tank passage pressure. 1. Connect port T with hydraulic oil
too high tank by exclusive tank passage.
2. Sliding part is caught. 2. Repair defective part.
6-3-15 4480203
6-4 Swing Motor
1. Structure and Functions
11 1 14 2 20 22 30 24
Mechanical brake mechanism 21 23

This hydraulic swing motor consists of an orbit motor and a pinion gear assembly.
The swing motor with a mechanical brake has friction plates splined to the pinion gear 3 and steel plates splined to
the bearing housing 1. In this structure, the brake is operated under the brake torque which is produced by frictional
force generated by the piston ring and the coil springs.
The hydraulic motor has six holes in the valve 24 and seven holes in the valve plate 22, and the displacement per
revolution is 14.9 cu. in. (244 cu. cm).
The pinion gear assembly consists of the pinion gear 3 and the two bearings 11 and 14 supporting the pinion gear.
The hydraulic oil which flows in through the brake valve is fed to the valve housing 30.
No. Part
1 Bearing housing
2 Flange mounting
3 Pinion gear
11 Front bearing
14 Rear bearing
20 Roller
21 Drive
22 Valve plate
23 Valve drive
24 Valve
30 Valve housing
6-4-1 4480203
High pressure
1 2
21 Front : Port A Back : Port B
Low pressure (High pressure) (Low pressure)
Drain 20 22 30
23 24
Drain line
When hydraulic oil is fed to the port A, the oil flows into the oil hole in the valve 24 corresponding to the port A and
runs through the oil hole in the valve plate 22 to rotate the roller 20. When the valve 24 is rotated via the valve drive
23, the positional relation between the six holes in the valve 24 and the seven holes in the valve plate 22 is changed
and, in turn, the relative position of the hydraulic oil which flows into the roller 20 is shifted successively. The oil flow
is converted into rotational force and outputted to the drive 21 splined to the roller 20. Then, the rotational force is
transmitted to the pinion gear 3.
The oil which has leaked in the motor lubricates the parts, and then, is drained from the drain port.
6-4-2 4480203
2. Mechanical Brake
The friction plates are splined to the pinion gear and the steel plates are splined to the bearing housing. When no
hydraulic oil flows into the brake release port, the springs press the piston against the end face of the bearing hous-
ing through the steel plates and the friction plates which causes the pinion gear (output shaft) to be locked.
When hydraulic oil flows into the piston chamber through the brake release port, the piston is moved up against the
springs to the bottom of the flange mounting and the friction plates and the steel plates are disengaged, which
causes the mechanical brake to be released.
Flange mounting Coil spring
Piston
Piston chamber
Blake release
port
Friction plate
Steel plate
Ring
Bearing housing
Pinion gear
6-4-3 4480203
3. Theory of Operation for Brake Valve (Super Shockless Valve)

At starting or stopping, high pressure oil flows through the orifice of the orifice plug 50 into the damper chamber and
opens the plunger 43.
Then, the high pressure oil flows through the oil hole in the plunger 43, the oil hole in the piston 45 and the orifice of
the orifice plug 49, and finally into the other side of the piston 45.
The high pressure oil moves the piston 45 to the direction in which the spring load of the spring 53 increases.
The movement of the piston 45 causes the set pressure to change from 953 to 1635 PSI (6.6 to 11.3 MPa) continu-
ously.
When the piston 45 reaches the stroke end, the set pressure becomes 1635 PS1 (11.3 MPa).
53 43 50
45
Piston chamber
Damper chamber 49
No. Part
43 Plunger
45 Piston
49 Orifice plug
50 Orifice plug
53 Spring
6-4-4 4480203

(2) Prepare clean tools and treated oil and handle the parts carefully.
parts are available only as subassemblies, see the parts catalogue to prepare the necessary subassemblies in
advance.
[3] Do not extend any O-rings with such great force as to permanently deform them.
2) Tools for Disassembly

Tool Remarks
Torque wrench Capacity : 7.2 to 72.3 ft•lbf (9.8 to 98.0 N•m)
Socket Width across flats : 0.55 in. (14 mm)
Hexagon sockets Width across flats : 0.20 in. (5 mm)
Width across flats : 0.31 in. (8 mm)
Retaining pliers Internal snap ring : Ø1.85 in. (47 mm), Ø4.72 in. (120 mm)
External snap ring : Ø1.77 in. (45 mm)
Screw driver
Plastic hammer
Press !3 ton
Vice
6-4-5 4480203
44
56
56
47
46
51 57 55
43 52
53 49 46
47
54
48 45 48
42 45
54
3) Exploded View and Parts Names
47 53
46 2
43 10
49 19
A B 5152
16
14 18
51 7
52 16
50
5644 5
56 16
6-4-6
47 6
46 17 35 A B
39
40
4480203
8 9 26
28 35
1 33
15
13 31 3432
41 30
11 38 4
12 29
27
25
43 24
37
22
2338
20 36
38
21
36
No. Parts Q’ty No. Parts Q’ty

1 Bearing housing 1 30 Valve housing 1
2 Flange mounting 1 31 Steel ball 2
3 Pinion gear 1 32 Plug 2
4 Blind plug 4 33 O-ring 2
5 Piston 1 34 Spring 2
6 Ring 1 35 Blind plug 2
7 Internal snap ring 1 36 O-ring 2
8 Friction plate 6 37 O-ring 1
9 Steel plate 7 38 O-ring 3
10 Spring 8 39 O-ring 2
11 Front bearing 1 40 Hexagon head bolt 4
12 Internal snap ring C 1 41 Collar 1
13 External snap ring C 1 42 Valve body 1
14 Rear bearing 1 43 Plunger 2
15 X-ring 1 44 Seat 2
16 O-ring 3 45 Piston 2
17 O-ring 1 46 Plug (M27) 4
18 Hexagon socket head bolt 8 47 O-ring 4
19 Shaft face seal 1 48 Seal set 2
20 Roller 1 49 Orifice plug 2
21 Drive 1 50 Orifice plug 2
22 Valve plate 1 51 Filter 4
23 Valve drive 1 52 Collar 4
24 Valve 1 53 Spring 2
25 Balancing ring 1 54 Shim 2
26 Spring 2 55 Blind plug 6
27 Inner face seal 1 56 O-ring 4
28 Pin 2 57 Hexagon socket head bolt 2
29 Outer face seal 1
6-4-7 4480203
4) Disassembly
Procedure
(1) Remove the shockless valve from the motor body.
Note :
Do not remove the shockless valve if not required. Shockless valve
Motor body
(2) Hold the flange part in a vice with the pinion gear 3 side
down.
Remove the hexagon head bolts 40.
40
30
(3) Remove the valve housing 30. When removing it, take
care not to lose pins 28 and springs 26. 26
Note :
Do not disassemble the valve housing 30 if not required. 28
(4) Remove the balancing ring 25, the valve 24, the valve
plate 22 and the valve drive 23.
22
20
23
6-4-8 4480203
Procedure
(5) Remove the roller 20 and the drive 21.
20
21
(6) Remove the hexagon socket head bolts 18.
18
(7) Remove the flange mounting 2, and then remove the

springs 10. 2
Note :
Do not remove the shaft face seal 19, the rear bearing 14 and 10
the internal snap ring 7, if not required.
(8) Remove the piston 5.
6-4-9 4480203
Procedure
(9) Remove the ring 6.
6
(10) Remove one of the steel plates 9.
(11) Remove one of the friction plates 8. Alternately remove

the rest of the steel plates 9 and the friction plates 8.
8
(12) Remove the internal snap ring 12 to remove the pinion

gear assembly such as the bearing from the bearing Pinion gear assembly 15 1
housing 1.
Remove the blind plug 4 and the X-ring 15 from the bear- 3
ing housing 1. 11
11
6-4-10 4480203
Procedure
(13) Remove the external snap ring 13 from the pinion gear 3
to remove the collar 41 and the front bearing 11.
3
Note :
Do not remove them, if not required.
11
41
12 13
6-4-11 4480203
5) Reassembly
Procedure
(1) Press-fit the front bearing 11 and the collar 41 into the pin-
ion gear 3.
At this time, pay attention to the direction of press-fitting.
(2) Install the external snap ring 13. 3
13 11
41
Collar Chamfered
No shield
Front
bearing
Shield
(3) Install the X-ring 15 into the bearing housing 1.
15
(4) Install the pinion gear assembly into the bearing housing
1.
After installation, install the internal snap ring 12, and then
tighten the blind plug 4 into the bleeder.
Pinion gear assembly
6-4-12 4480203
Procedure
(5) Insert one of the seven steel plates 9 into the bearing
housing 1. 1
9
(6) Insert one of the six friction plates 8 into the bearing hous-
ing 1.
8
Note :
Alternately install the steel plates and the friction plates.
Finally, the steel plate should be seen on the top.
(7) Install the O-rings (for inner and outer faces) 17 and 16
onto the ring 6.
17
6
(8) Insert the ring 6 with O-rings into the bearing housing 1.
1
(9) Install the O-ring (for outer face) 16 onto the piston 5.
(10) Insert the piston 5 into the bearing housing 1. 5
6-4-13 4480203
Procedure
(11) Install the shaft face seal 19 into the flange mounting 2.
10
2
(12) Insert the rear bearing 14 and fasten it with the internal 14
snap ring 7. 19
(13) Apply grease to the springs 10, and install them into the
flange mounting 2. 7
(14) Install the O-ring 16 into the flange mounting 2.
16
(15) Install the flange mounting 2

on the bearing housing 1.
Pilot port 2
Notes :
• Take care not to drop the
springs 10.
• The drain hole should be posi-
tioned as shown in the figure at 1
the right.
Position of drain hole
(16) Tighten the hexagon socket head bolts 18.
Note :
Apply Loctite #242 or its equivalent to the hexagon socket
head bolts 18.
18
(17) Install the two types of O-rings 36 and 38 into the O-ring
grooves in the flange mounting 2.
21
(18) Insert the drive 21.
38
36
6-4-14 4480203
Procedure
(19) Install the roller 20.
Note :
20
The drain hole in the roller 20 must be aligned with the drain
hole in the flange mounting 2.
(20) Insert the valve drive 23 into the roller.
23
grooves in the valve plate 22.
(22) Install the valve plate 22 on the roller 20. 22
Note :
The drain hole in the valve plate 22 must be aligned with the
drain hole in the roller 20. 20
(23) Install the valve 24.
24
6-4-15 4480203
Procedure
Note :
Valve
The installation of the valve is important because the position
Valve drive
of the valve determines the revolving direction of the motor.
Refer to the right figure for the installation of the valve.
External gear tooth Horizontal hole

Roller star 15
(24) Install the steel balls 31, the springs 34 and the plugs 32
into the valve housing 30. 32 34
31 30
(25) Install the springs 26 and the pins 28 into the valve hous-
Outer face seal 29
ing 30.
Valve housing 30
(26) Install the outer face seal 29 and the inner face seal 27
Inner face seal 27
into the balancing ring 25.
Note :
When installing the balancing ring 25 into the valve housing
30, the notches in the balancing ring 25 must be aligned with
the pins 28. Spring 26
Balancing Pin 28
ring 25
grooves in the valve housing 30.
(28) Insert a slender bar such as a driver into the port B side
of the valve housing 30, and install the valve housing 30
on the valve 24 while holding the balancing ring 25 to
prevent it from coming off. 38
Note : 24
The drain hole in the valve housing 30 must be aligned with
the drain hole in valve 24.
6-4-16 4480203
Procedure
(29) Tighten the hexagon head bolts 40.
Note :
Apply Loctite #242 or its equivalent to the bolts 40.
40
Tightening torque : 39.1 ft lbf (53 N m)
(30) Install the O-ring 39 into the O-ring groove in the valve
housing 30. 57
Shockless valve
(31) Install the shockless valve in the motor body.
Tighten the hexagon socket head bolts 57.
Tightening torque : 39.8 ft lbf (54 N m)
(32) The procedure for reassembling the swing motor is com-

pleted.
Make sure that the swing motor rotates in the correct
direction before being installed to the actual device.
Rotation direction viewed from the pinion shaft side :
When pressure is applied to the port A : Clockwise
When pressure is applied to the port B : Counterclock-
wise
6-4-17 4480203
6) Troubleshooting
1. Motor does not rotate (1) Insufficient hydraulic oil volume in Supply hydraulic oil to the specified level.
hydraulic oil tank.
(2) Breakage of pump. Replace the pump.
(3) Malfunction of relief valve or low set Disassemble and clean the relief valve and set the
pressure of it. pressure to the specified value.
(4) Excessive wear or scuffing of motor. Disassemble the motor to check the parts. Replace
any damaged parts.
(5) Short-circuit inside motor. The face seals or other parts may be damaged.
Disassemble the motor to check the parts. Replace
any damaged parts.
(6) Insufficient brake release pressure. Apply a pilot pressure of 145 PSI (1.0 MPa) to the
brake release port.
2. Unstable rotation (1) Low relief set pressure. Check whether the specified volume of hydraulic oil
is fed to the motor suction side. Then, check and
repair each part.
(2) Air in pump on the suction side. Check the piping of the suction side. Tighten the
piping if necessary.
3. Reverse rotation (1) Reversed piping. Correct the piping.
(2) Reversed valve timing of motor. Correct the valve timing.
4. Oil leak from joint (1) Loosened bolt. Tighten the bolt at the specified tightening torque.
(2) Caught or damaged O-ring. Replace the O-ring.
5. Low brake torque (1) Worn friction plates. Replace the friction plates.
(2) Pressure remaining in pilot line. Check the piping of the pilot line.
6-4-18 4480203
6-5 Travel Motor
1. Structure
The travel motor consists of a swash plate type axial piston motor, anti-cavitation valve, 2-speed switching mecha-
nism and a reduction gear.
The swash plate type axial piston motor has 9 pistons and a 2-speed (low and high) switching mechanism.
The counter balance valve and the anti-cavitation valve are integrated with the piston motor which is housed in the
reduction gear.
The reduction gear reduces the output revolutions of the piston motor through the planetary double-reduction mech-
anism and increases the output torque to transmit it to the sprocket.
Counter balance valve
Swash plate type axial piston motor
Reduction gear
Anti-cavitation valve
2-speed switching mechanism
Structure of travel motor
6-5-1 4480203
1) Motor
When the travel control valve is switched to "Travel", the hydraulic oil flows through the counter balance valve to the
port A of the valve plate.
When the pressure at the port A rises, the hydraulic oil flows into the bores corresponding to the port A in the cylin-
der barrel.
When the hydraulic oil flows into the bores, the pistons are pressed against the sliding surface of the swash plate,
and the shoes fitted on the pistons slide on the sliding surface of the swash plate towards the circumference. That
motion of more than one piston on the high pressure side is converted into the rotational motion of the cylinder bar-
rel.
The output shaft splined to this cylinder barrel also starts to rotate together with the rotation of the cylinder barrel.
When the pistons move to the low pressure side, the pistons are pushed into the bores and discharge hydraulic oil
from them. The hydraulic oil discharged from the cylinder barrel flows through the port B of the valve plate to the
return passage.
When the travel control valve is switched to the opposite side, the pressure at the port B becomes high and the pres-
sure at the port A becomes low, so that the rotation of the output shaft is reversed.
Piston assembly
Cylinder barrel
Valve plate
Output shaft
Swash plate
Port A
Port B
6-5-2 4480203
2) Counter Balance Valve

The counter balance valve works to reduce the shock caused when the piston motor stops and to prevent it from
overrunning a specified speed due to external loading.
When the control valve is moved to the neutral position, the hydraulic oil flow to the ports P1 and P2 is blocked. This
causes the pressures in the chambers R and L to fall to nearly zero, and the spool is returned to the neutral position
by the force of the springs on both sides. When the spool is returned to the neutral position, the ports M1 and M2 of
the piston motor are blocked by the plunger and the check valve, and the motor is stopped rotating.
Control valve
Orifice L Orifice R
P1 P2
Spring L Spring R
Chamber L
Chamber R
Spring L Spring R
Check valve L M1 M2 Check valve R
Plunger Motor Plunger notch
Structure of counter balance valve
6-5-3 4480203
(1) Counter Balance Function

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

M1 M2
Counter balbance valve (Counter balancing operation)
6-5-4 4480203
(2) Brake Function

When the control valve is returned to the neutral position, the flow of pressure oil from the pump is blocked and the
pressures at the ports P1 and P2 become equal. Consequently, the plunger starts returning to the neutral position
through the force of the spring R. When the plunger moves, the opening of the plunger notch becomes small, and
since the piston motor still continues to rotate through the inertial force (the pumping of the motor), the pressure at
the port M2 rises. The relief valve R2 is activated by this pressure and lets the oil escape to the port M1 so that the
shock due to the inertial force at the port M2 is absorbed, and at the same time, the cavitation at the port M1 is pre-
vented.
Orifice L Control valve Orifice R
P1 P2
Spring L Spring R
Spring L Spring R
Check valve L Check valve R

M1 M2
Counter balance valve (Braking operation)
6-5-5 4480203
3) Anti-Cavitation Valve
This anti-cavitation mechanism works together with the counter balance valve.
Compared with conventional counter valance mechanism, this mechanism has oil passages A, B and C and check
valves B and C in addition.
Throttle B Throttle C
Port P1 Port P2
Counter balance valve spool
Spring Spring
Oil passage B Oil passage C
Check valve B Check valve C
Oil passage A
Oil passage M1 Oil passage M2
Motor
Anti-cavitation valve (in neutral state)
6-5-6 4480203
(1) Motor Stop → Start

When the oil pressure force is applied to the port P1, the counter balance valve spool exceeds the force of the spring
and moves to the right. This causes the hydraulic oil in the port P1 to flow thorough the oil passage M1 to the
hydraulic motor and rotate it. (normal counter balance operation) Although the high pressure oil flows to the oil pas-
sage A at the same time of this, the pressure oil does not leak to the low pressure side (the oil passage C side) due
to the operation of the check valve C.
Inflow Discharge
(high pressure) (low pressure) Throttle C
P1 P2
Spring
Oil passage A
(High pressure) (Low pressure)
Motor
Anti-cavitation valve (in starting)
(2) In Regular Rotation of Motor

Although the high pressure also flows to the oil passage A while the motor is rotating regularly, the pressure oil does
not leak to the low pressure side due to the operation of the check valve C. Therefore, the anti-cavitation has no
effect on the motor operation.
Inflow Discharge
(high pressure) (low pressure) Throttle C

P1 P2
Oil passage B Check valve C
Check valve B Oil passage C
Oil passage A
Oil passage M2
Oil passage M1
(High pressure) (Low pressure)
Motor
Anti-cavitation valve (in starting)
6-5-7 4480203
(3) Regular Rotation of Motor → In Speed Reduction

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

(Low pressure) (High pressure)
Motor
Anti-cavitation valve (in speed reduction)

(4) In Motor Speed Reduction → Stop
The anti-cavitation mechanism works until the oil flow from the passage A to the P1 port is blocked at the point
shown in the figure below.
Position to block between oil passage A and port P1
Inflow Discharge
Throttle C
P1 P2
Oil passage A
(Low pressure) (High pressure)
Motor
Anti-cavitation valve in stop
6-5-8 4480203
4) 2-Speed Switching Mechanism

(1) 1st Speed (Low Speed)
The swash plate has three surfaces a, b and c, as shown in the figure below, and is installed on the flange holder
with two steel balls so that it can move. When the control valve is in the low speed position, since the spool is located
in the position as shown in the figure below by the force of the spring and oil passage is connected to the port T via
Pi 1 and Pi 2, the low pressure of the return passage only works on the swash plate control piston. In this condition,
the swash plate control piston does not push up the swash plate. Accordingly, the surface a at the rear of the swash
plate is pressed against the vertical surface by the thrust force of the motor and the force of the spring with the steel
balls as the inclination axis. The inclination angle of the swash plate is "α" as shown in the figure.
M1 M2
P1 (Driving pressure)
Pi1 Pi2
Spring
Spring
Surface c
Valve plate Piston assembly Surface b
Steel ball
L1
F Fs1
Low pressure
Lo
High pressure
Fp Fs2
Spring
Port B (Low pressure) Spring Surface a
Swash plate control piston
Swash plate
Port A (High pressure)
6-5-9 4480203
(2) 2nd Speed (High Speed)

When the control valve is switched to the high speed position, the pressure oil from the pump is led to the end face
of the spool and the spool is shifted to the position as shown in the figure below. This causes the ports M1 and M2 to
open and the hydraulic oil from the port A (high pressure) in the valve plate of the motor is supplied to the swash
plate control piston though the valve port M1. This pressure oil pushes up the swash plate control piston, which over-
comes the motor thrust force and the spring force, and the surface a of the swash plate is detached from the vertical
surface to cause the surface b to be contacted with the vertical surface tightly. When the surface b contacts with the
vertical surface, the inclination angle of the surface c, which is the sliding surface of the swash plate, is reduced to
"β". Accordingly, the stroke of the piston is reduced to lower the motor displacement. The motor with smaller dis-
placement rotates faster (high speed).
When the motor revolves in reverse, the same action as the above occurs, except that the high and low pressure
ports are reversed.
When the engine is stopped, since no pumps work, no pressure oil is supplied to the end face of the spool and the
spool returns to the 1st speed position by the spring force. Accordingly, no force is applied to the swash plate control
piston to press the swash plate, and the swash plate maintains its low inclination angle "α" through the spring force.
Thus, the low speed condition is always maintained at starting.
M1 M2
Pi1 Pi2
Spring
Spring
Surface c
Valve plate Surface b
Piston assembly
Steel ball
L1
F Fs1
Lo
Low pressure
High pressure
Fp Fs2
Spring
Port B (Low pressure) Spring Surface a
Port A (High pressure) Swash plate Swash plate control piston
6-5-10 4480203
5) Reduction Gear
The reduction gear comprises a planetary double-reduction mechanism.
4 3
Z2 2
Z4
Z1
1
Z5
Z6 Z3
6 5 7
Structure
The drive gear 1 engages with the 1st-stage planetary gear 2 and the 2nd-stage sun gear 4 engages with the 2nd-
stage planetary gear 5. The 2nd-stage planetary carrier 6 is fastened to the machine body. The planetary gears 2
and 5 engage with the ring gear (housing) 7.
The driving force from the piston motor is transmitted to the drive gear 1 and reduced by the gears. The reduced
driving force is then transmitted to the ring gear 7 though the planetary gear 5 of the 2nd-stage planetary carrier 6
fastened to the machine body. (Driving force is also transmitted from the 1st-stage planetary gear 2.) The input and
output revolutions are opposite to each other.
6-5-11 4480203
3. Exploded View and Parts Comprised

6
9
10
11
12
13
14
15
16
17
18
22 8
39
24
38
25 37
26
28 36
27
33
19 32
20
21 31
30
1
35
2 34
7
3
4
70
69
68
67
29
47
46
45
44
43 77
5 42 79
40
41 74 52 71
73
51
50 76
53 75 78
58 80
5960 81
61 82
83
48 54
55
72
49 62
56 6364
57 65
66
6-5-12 4480203

1 Flange holder 1 43 Spring 1
2 Floating seal 2 44 Washer 1
3 Angular bearing 1 45 Snap ring 1
4 Ring nut 1 46 Valve plate 1
5 Plug PT1/4 2 47 Ball bearing 1
6 Housing 1 48 O-ring 1B P7 2
7 Steel ball 109 49 Pin 1
8 Plug PT1/8 2 50 Pin 2
9 Thrust washer 4 51 O-ring 1B P11 2
10 Collar 4 52 Plug 2
11 Cage & roller 4 53 Base plate 1
12 Planetary gear B 4 54 Orifice 4
13 Thrust plate 1 55 Plug 2
14 Screw 4 56 O-ring 1B P11 1
15 Sun gear 1 57 Plug 1
16 External snap ring 1 58 Plunger 1
17 Drive gear 1 59 Check valve 2
18 Holder 1 60 Spring 2
19 Inner race 3 61 O-ring S8 A1 2
20 Cage & roller 3 62 Plug 2
21 Planetary gear A 3 63 Spring seat 2
22 Thrust plate 1 64 Spring 2
24 Wire 1 65 O-ring 1B P24 2
25 O-ring 1B P130 1 66 Cap 2
26 Cover 1 67 Spool 1
27 Plug PF1/4 2 68 Spring 1
28 O-ring 1B P11 2 69 O-ring 1B P11 1
29 O-ring 1A (AS568-245) 1 70 Plug 1
30 Oil seal 1 71 Hexagon socket head bolt 6
31 Ball bearing 1 72 Plug 2
32 Shaft 1 73 Orifice 2
33 Steel ball 2 74 Plug 1
34 Spring 2 75 O-ring 1B P8 2
35 Piston assembly 2 76 Plug 2
36 Swash plate 1 77 Valve body 1
37 Piston assembly 9 78 O-ring 1B P12 2
38 Retainer plate 1 79 Hexagon socket head bolt 3
39 Retainer holder 1 80 Check valve 2
40 Cylinder barrel 1 81 Spring 2
41 Pin 3 82 O-ring 1B P 14 2
42 Collar 1 83 Plug PF 3/8 2
6-5-13 4480203
4. Special Tools
Unit : in. (mm)
S-2 : Eye bolt S-2 : Housing disassembly jig
0.83 0.51
(21) (13)
0.157 0.354
(4) (9)
0.098
1.61 (2.5) 6.6
(
( 41) 16 1
8)
0.98
( 25)
87
7. 00)
2
(
0.24
G(PF)1/4 (6)
Two pieces divided
Weld
S-3 : Ring nut tightening jig

0.16 to 0.63 (4 to 16)
130)
4.96 ( 126)
(12.8 to 13.0)
0.50 to 0.51
3.54 (90)
5.12 (
0.39
(10)
Weld
3.94 (100)
0.35
(9)
S-4 : Ball bearing disassembly jig S-5 : Angular bearing press-fitting jig
5.25196 to 5.25983
5.33070 to 5.33857
5.48818 to 5.49605
( 133.4 to 133.6)
( 135.4 to 135.6)
( 139.4 to 139.6)
3.94 (100)
(24.2 to 24.4)
1.14 ( 29)
0.95 to 0.96
0.98 0.039 (1)

(25)
1.18 (30)
6-5-14 4480203
Unit : in. (mm)

S-6 : Floating seal installation jig
0.27165 to 0.28740
(6.9 to 7.3) 0.2 (5)
1.6 Ra
5.62204 to 5.62991 ( 142.8 to 143.0)
15 1
6.05904 to 6.06692
1.6 Ra
( 153.9 to 154.1)
5.63385 to 5.64172
R0.0079 15 1
5.57086 to 5.57873
( 143.1 to 143.3)
(R0.2)
( 141.5 to 141.7)
170)
160)
Slight-
5.19684 to 5.23621
chamfering
( 132.0 to 133.0)
1.6 Ra
6.69 (
6.30 (
R0.012 (R0.3)
Extended figure of circled area
0.31102 to 0.31890
0.25591 to 0.29528 (7.9 to 8.1)
( 6.5 to 7.5)
0.79134
(20.1)
Guide jig Installation jig
S-7 : Flange holder press-fitting jig

200)
7.87 (
0.39
(10)
S-13 : Oil seal press-fitting jig
4.33 (110)
0.42913 to 0.43701 0.47
(10.9 to 11.1) (12)
0.4685 to 0.47638
(11.9 to 12.1)
0.079 (2)
1.65118 to 1.65236
0.77165 to 0.77953
( 41.94 to 41.97)
30
( 19.6 to 19.8)
1.34 ( 34)
30)
R0.00394 to 0.01181
(R0.1 to 0.3)
1.18 (
1.18 (30)
0.62992 to 0.63779
( 16.0 to 16.2)
C0.06 (C1.5)
6-5-15 4480203
Unit : in. (mm)

S-9 : Ball bearing press-fitting jig S-10 : Shaft assembly press-fitting jig
0.98 ( 25)
4.33 (110)
0.079 (2)
1.6555 to 1.6575
1.38 (35)
42.05 to 42.1)
47)
35)
1.85 (
1.38 (
0.20
(5)
1.6555 to 1.6575
(
( 42.05 to 42.1)
2.36 ( 60)
S-11 : Snap ring installation jig S-12 : Ball bearing press-fitting jig
0.97 (50) 0.79 (20)

0.079 (2)
0.39
1.57 (40) (10)
1.2618 to 1.2637
32.05 to 32.1)
27)
36)
0.28
(7)
1.06 (
1.42 (
(
1.02 ( 26) 1.18 ( 30)
S-13 : Pin Ø0.14!1.18 (Ø3.5!30)

S-14 : Round rod Ø0.39!5.9 (Ø10!150)
S-15 : Round rod Ø0.79!39.4 (Ø20!1000)
S-16 : Piano wire Ø0.0079!27.6 (Ø0.2!700)
S-17 : Spring scale
6-5-16 4480203

(3) First clean the external surfaces of the removed assemblies.
parts are available only as subassemblies, see the parts catalog to prepare the necessary subassemblies in
advance.
(6) Handling O-rings
(7) Before beginning reassembly, check the mating surface of each section to be sure that there is no cleaning oil or
hydraulic oil on the surface of the outer side from the O-ring groove. If reassembly is performed without cleaning
such oil, it may be mistaken for oil leak.Tools for disassembly and reassembly
2) Tool for Disassembly and Reassembly

No. Tool Nominal size Applicable part
1 Torque wrench 230 Plug 5, 8, Screw 14, Socket head bolt 79
(Preset type)
2 450 Plug 27, 52, 57, 62, 70, 83
3 (kgf·cm) 1800 Socket head bolt 71, Ring nut 4
4 2800 Cap 66
5 Hexagon bit for torque wrench 4 Screw 14
(Width across flats)
6 5 Plug 8, 62, Socket head bolt 79
7 (mm) 6 Plug 5, 27, 52, 57, 70, 83
8 8 Socket head bolt 71
9 12 Cap 66
10 Socket for torque wrench 19 Plug 57
(Width across flats)
(mm)
11 Screwdriver Floating seal 2, Wire 24, Base plate 53
12 Hammer Angular bearing 3, Plug 5, Oil seal 30, Shaft 32,
Pin 49
13 Plastic hammer Base plate 53
14 Pliers Wire 24
15 Snap ring pliers Snap ring 45
16 Punch Plug 5, Pin 49
6-5-17 4480203
3) Disassembly
Procedure
(1) Hold the motor with a vice and remove the three hexagon
socket head bolts 79 to remove the valve body assembly.
79
Tools :
• Torque wrench 1 Valve body assembly
• Hexagon bit 6
(2) Hold the valve body 77 with a vice and remove the plugs
83 to remove the relief valve assembly.
77 83
Notes :
• When removing the relief valve assembly, cover it with
waste cloth or the like.
• Do not disassemble the valve body assembly if not
required.
Tools :
• Torque wrench 2
• Hexagon bit 7
(3) Remove the plugs 52 and the caps 66.
Tools : 66
• Torque wrench 2, 4
• Hexagon bit 7, 9
(4) Remove the springs 64 and the spring seats 63.
64 63
6-5-18 4480203
Procedure
(5) Turn the plunger assembly slowly to remove it.
Plunger assembly
Note :
Take care not to damage or dent the outside of the plunger
58.
(6) Insert a pin of approx. Ø0.14!1.18 in. (Ø3.5!30 mm)

into the through hole of Ø0.16 in. (Ø4 mm) in the plunger
assembly. Hold it with a vice and remove the plug 62. 62
Note :
Do not disassemble the plunger assembly if not required.
Tools :
• Torque wrench 2 58
• Hexagon bit 6
• Pin Ø0.14!1.8 in. (Ø3.5!30 mm) (S-13)
(7) Remove the springs 60 and the check valves 59.
Note : 58
Keep the right and left check valves separately to identify
them with regard to the plunger for correct reassembly.
62 60 59
(8) Remove the plugs 70 and 57.
Tools :
• Torque wrench 2
• Hexagon bit 7
• Socket 10
6-5-19 4480203
Procedure
(9) Remove the spring 68 and the spool 67.
Note :
Take care not to damage or dent the outside of the spool.
(10) Remove the six hexagon socket head bolts 71.
Tools :
• Torque wrench 3
• Hexagon bit 8 71
(11) Remove the base plate 53.
Notes :
• When the base plate cannot be removed easily, tap it in the
53
pulling-out direction with a plastic hammer. If it is still not be
removed, pry it up lightly with a screwdriver.
• Take care that the cylinder barrel is not pulled out.
Tools :
• Plastic hammer 13
• Screwdriver 11
(12) Remove the valve plate 46, the O-ring 29 and the pin 49.
49 29
46
6-5-20 4480203
Procedure
(13) Remove the cylinder barrel assembly, the pins 41, the
retainer holder 39, the retainer plate 38 and the piston
assemblies 37. 38 37 41 39 Cylinder barrel assembly
Note :
Take care not to damage the sliding surface of the cylinder
barrel.
(14) Remove the internal snap ring 45 from the cylinder barrel
40.
Note :
Take care not to damage the sliding surface of the cylinder
barrel.
Tool :
• Snap ring pliers 15
(15) Remove the washer 44, the spring 43 and the collar 42.
45 43
44 42 40
(16) Remove the swash plate 36, the steel balls 33, the piston
assemblies 35 and the springs 34.
36 34
33 35
6-5-21 4480203
Procedure
(17) Remove the plugs 8 and 27.
Tools :
• Torque wrench 1, 2
• Hexagon bit 6, 7 27
(18) Fit the eye bolts G (PF) 1/4 into the tapped holes for the
plugs 27 and put a round rod [approx. 39.37 in. (1 m) in
length] through the eye bolt holes. Turn the cover 26 until Round rod
the wire 24 can be seen from the tapped hole for the plug
8.
Tools :
• Eye bolt (S-1)
• Round rod (S-15)
26
(19) When the end of the wire 24 comes in sight, draw the
wire outside the hole with a screwdriver.
Eye bolt
24 Screwdriver
Tool :
• Screwdriver 11
(20) Turn the cover 26 while pulling the end of the wire 24
with pliers to draw the wire out.
Tool :
• Pliers 14
26
24
(21) Put a hook through the eye bolt holes to lift and remove
the cover 26 (or remove the cover using a round rod).
Tools :
• Eye bolt (S-1)
6-5-22 4480203
Procedure
(22) When the cover 26 has rusted and is hard to remove, fol-
low the disassembly procedure below.
Remove the plugs 8. 26
Tools :
• Hexagon bit 7, 6
(23) Take all the steel balls 7 out of the tapped hole for the
plug 8.
Notes :
• After removing oil and grease with thinner, white gasoline or
the like, blow compressed air over the steel balls to remove
them.
• It is hard to remove them, tap the outside of the housing 6
with a hammer.
• Insert a piano wire from the tapped hole for the plug 8 to
make sure that all the steel balls 7 have been removed.
Tools :
• Hammer 12 7 6
• Piano wire (S-16)
(24) Put a metal plate or a jig between the flange holder 1 and
the housing 6, and tighten the three M14 bolts evenly
from the housing side.
Tools :
• Torque wrench 3
• Hexagon bit 8 6
• Metal plate or housing disassembly jig (S-2)
Bolt M14
(25) Remove the housing 6.
6-5-23 4480203
Procedure
(26) Remove the sun gear 15, the holder 18, the planetary
gear 21, the cage & rollers 20, the drive gear 17 and the 15
thrust plate 22.
18
22
21 17
20
(27) Pull out the wire 24 by holding its end with pliers and
remove the cover 26.
Tool :
• Pliers 14
(28) Remove the thrust plate 13 and the four screws 14.
Tools :
• Hexagon bit 5
14
(29) Remove the thrust washers 9, the planetary gears B 12,

the collar 10 and the cage & rollers 11.
Note :
Take care not to damage the gear tooth surface and the roll-
ing contact surfaces of the collars.
9 11 10 12
6-5-24 4480203
Procedure
(30) Remove the two plugs 5.
Tools :
• Torque wrench 1
• Hexagon bit 7
(31) Remove the ring nut 4.
Tools : Ring nut tightening jig

• Torque wrench 3
• Ring nut tightening jig (S-3)
(32) Place a round rod on the groove for the steel balls 7 and
tap it lightly with a hammer to remove the angular bear-
ing 3.
Tools :
• Hammer 12
(33) Remove the floating seal 2 and the angular bearing 3.
3
2
6-5-25 4480203
Procedure
(34) Remove the other floating seal 2 using two screwdrivers.
Tool :
• Screwdriver 11
(35) Place a round rod on the hole for the shaft 32 and tap the
rod lightly with a hammer to remove it.
Tools :
• Hammer 12
(36) Remove the oil seal 30.
Tools : 30
• Hammer 12
• Screwdriver 11
(37) Remove the ball bearing 31 from the shaft 32.
Tool :
• Ball bearing disassembly jig (S-4) Ball bearing disassembly jig
31
6-5-26 4480203
4) Reassembly
Procedure
(1) Apply grease to one floating seal 2 and install it onto the
flange holder 1.
Tool :
• Floating seal installation jig (S-6)
Floating seal installation jig
(2) Press-fit the angular bearing 3 into the housing 6.
Tool :
• Angular bearing press-fitting jig (S-5) Angular bearing
press-fitting jig
(3) Apply grease to the other floating seal 2 and install it to

the housing 6.
Floating seal
Tool : installation jig
• Floating seal installation jig (S-6)
(4) Press-fit the flange holder 1 into the housing 6.

Flange holder
Tool : press-fitting jig
• Flange holder press-fitting jig (S-7)
6-5-27 4480203
Procedure
(5) Tighten the ring nut 4 so that there is no clearance
between the housing and the angular bearing. Turn the
housing several times and then measure the starting load.
Assume the measured load is "F" ft•lbf (N•m). Tighten the
ring nut to adjust the starting load to F+[12.3 to 18.0 ft•lbf
(16.7 to 24.5 N•m)]
Tools : Spring scale

• Torque wrench 3
• Ring nut tightening jig (S-3)
• Spring scale (S-17)
(6) Tighten the plugs 5.

(9.8 to 19.6 N m)
Note :
Do not wind a seal tape onto these plugs.
Tools :
• Torque wrench 1
• Hexagon bit 7 5
(7) Caulk each plug 5 at the two places with a punch to pre-
vent it from loosing.
Tools :
• Hammer 12
• Punch 16
Punch
(8) Insert steel balls 7 (109 pcs.)
6-5-28 4480203
Procedure
(9) Wind a seal tape onto the plugs 8 and tighten them.

(6.9 to 8.8 N m)
Tools :
• Torque wrench 1
8
• Hexagon bit 6
(10) Install the thrust washers 9, the collars 10, the cage &
rollers 11 and the planetary gears B 12.
9
10
11
12
12 10 11
(11) Put the thrust plate 13 on the trunnion of the flange

holder 1, apply adhesive (Loctite #262 or its equivalent)
to the four screws 14 and tighten them.
13
(4.1 to 8.0 N m)
Note :
Before applying adhesive, remove oil and grease completely
from the screws, and use hardening accelerator.
Tools :
• Torque wrench (1)
• Hexagon bit (6) for above
(12) Install the sun gear 15 fitted with the external snap ring
16, the inner races 19, the holder 18, the planetary gears
A 21, the cage & rollers 20 and the drive gear 17.
23 18 17 1615
19
21 20
6-5-29 4480203
Procedure
(13) Install the thrust plate 22.
22
(14) Apply grease to the O-ring 25 and install it to the cover

26.
Install the cover on the housing 6 with the U-groove
aligned with the tapped hole for the plug 8 in the housing
6.
26
25
(15) Bend the end of the wire 24 by about 0.32 in. (8 mm) at
an angle of 90 degrees and insert it into the tapped hole
in the housing 6. Turn the cover 26 to draw in the wire
24.
Tools :
• Eye bolt (S-1)
(16) Tighten the plugs 8. 26

(6.86 to 8.82 N m)
Tools :
• Torque wrench 1
• Hexagon bit 6
(17) Press-fit the oil seal 30 into the flange holder 1.
Tool : 1
• Oil seal press-fitting jig (S-8)
6-5-30 4480203
Procedure
(18) Press-fit the ball bearing 31 onto the shaft 32.
Tool :
• Ball bearing press-fitting jig (S-9)
32
31
Ball bearing
press-fitting jig
(19) Press-fit the shaft assembly into the flange holder 1.

Shaft assembly
Tool : press-fitting jig 1
• Shaft assembly press-fitting jig (S-10)
(20) Install the steel balls 33, the spring 34, the piston assem-
blies 35 and the swash plate 36 into the flange holder 1.
Note :
Apply hydraulic oil to the sliding surface of
the swash plate before installation. 36
33
34 35
(21) Install the collar 42, the spring 43, the washer 44 and the
snap ring 45 into the cylinder barrel 40.
Tools :
• Snap ring pliers 15 Snap ring
• Snap ring installation jig (S-11) installation jig
40 42 43 44 45
40
6-5-31 4480203
Procedure
(22) Apply grease to the pins 41 and install them into the
three holes in the cylinder barrel 40.
41 40
(23) Install the retainer holder 39, the retainer plate 38 and
the piston assemblies 37.
37
Note :
Apply hydraulic oil to the nine bores in the cylinder barrel. 38
39
(24) Place the motor on its side and install the cylinder barrel
assembly using the spline of the shaft as a guide.
Cylinder barrel assembly
(25) Press the cylinder barrel 40 by hands to check that the

spring force works normally.
(26) Apply hydraulic oil to the sliding area of the cylinder bar-
40
rel.
6-5-32 4480203
Procedure
(27) Install the O-ring 29 and the pins 50 into the flange
holder 1.
50
Note :
Apply a small amount of grease to the O-ring.
29
(28) Press-fit the ball bearing 47 into the base plate 53.
Tool :
• Ball bearing press-fitting jig (S-12)
Ball bearing
press-fitting jig
53
(29) Install the pin 49 and caulk it at two places.
Tools :
• Hammer 12
• Punch 16
49
(30) Apply grease to the rear of the valve plate 46 and install
it onto the base plate 53. 46
(31) Install the O-rings 48 onto the base plate 53.
Note :
Apply a small amount of grease to the O-rings 48 before
installation.
53
6-5-33 4480203
Procedure
(32) Install the base plate 53 onto the flange holder 1.
53
(33) Tighten the six hexagon socket head bolts 71.

(35.3 to 39.2 N m)
Tools :
• Hexagon bit 8
(34) Install the spool 67 and the spring 68.

67
Notes :
• Install the spool straight while turning it.
• Apply hydraulic oil to the spool before installation.
(35) Install the plugs 70 and 57 fitted with the O-ring.

(34.3 to 39.2 N m)
Tools :
• Torque wrench 2
• Hexagon bit 7
• Socket 10
6-5-34 4480203
Procedure
(36) Install the check valves 59, the springs 60 and the plugs
62 fitted with the O-ring 61 to the plunger 58.

(24.5 to 29.4 N m)
58
Tools :
• Torque wrench 2
• Hexagon bit 6
58 59 60 6162
(37) Install the plunger assembly to the base plate 53.
Notes :
• Apply hydraulic oil to the plunger assembly before installa-
tion.
• Install the plunger assembly straight while turning it.
(38) Install the spring seats 63 and the springs 64.

64
63
(39) Tighten the caps 66 fitted with the O-ring 65.
Note :
Apply a small amount of grease to the O-rings.

(149.1 to 164.8 N m)
Tools :
• Torque wrench 4
• Socket 9
6-5-35 4480203
Procedure
(40) Install the relief valve assembly into the valve body 77.
(41) Tighten the plugs 83.

77 83

(34.3 to 39.2 N m)
Tools :
• Torque wrench 2
• Socket 7
(42) Install the O-rings 78 to the valve body 77, and fasten the
valve body assembly to the base plate 53 with the three
socket head bolts 79.
79
(14.4 to 15.9 N m)
53
Tools :
• Torque wrench 1
• Hexagon bit 6
(43) Tighten the plug 52 fitted with the O-ring 51.

(21.6 to 23.5 N m)
Tools :
• Torque wrench 2
• Hexagon bit 7
(44) Put gear oil of approx. 0.37 Qts. (0.35 L) through the
tapped holes for the plugs 27.
(45) Wind a seal tape onto the plugs 27 and tighten them.

(21.6 to 23.5 N m)
27
Tools :
• Torque wrench 2
• Hexagon bit 7
6-5-36 4480203
Procedure
(46) This completes the reassembly.
6-5-37 4480203
Clean the removed parts, dry them with compressed air and repair or replace them, if necessary, according to the
following service standards :
Standard value
No. Parts Inspection item (recommended value for Measure
replacement
1 Floating seal 2 Sliding surface No excessive flaws, wear or Replace.

seizure
2 Angular bearing 3 Moving surface o excessive flaws, wear or Replace.

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

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

A 21 Rolling contact surface of No excessive flaws, wear or
cage & roller flaking on the rolling contact
surface
5 Needle bearing 20 Cage & roller (needle bear- No excessive flaws, wear or Replace.
Cage & roller 11 ing) surface flaking
6 Thrust washer 9 Sliding surface No excessive flaws, wear or Replace.

seizure
7 Thrust plates 13 and 22 Sliding surface No excessive flaws, wear or Replace.

seizure
8 Sun gear 15 Gear tooth surface Same as No.3 Replace.
9 Inner races 10 and 19 Cage & roller (needle bear- No excessive flaws, wear or Replace.
ing) surface flaking
10 Drive gear 17 Gear tooth surface Same as No.3 Replace.
11 Holder 18 Sliding surface against plane- No excessive flaws, or wear Replace planetary gear B
tary gear B and holder together
12 O-rings 23, 25, 29, 48, 51, Surface condition and hard- No flaws or distortion. Rubber seal members
56, 61, 65, 69, 73, 80, ness Not hardened deteriorate with the lapse
and 83 of time.
Replacement with new
seals is recommended
every time they are reas-
sembled.
13 Shaft 32 Oil seal surface No flaws or excessive wear Replace.
14 Ball bearings 31 and 47 Moving surface Same as No.2 Replace.
15 Oil seal 30 Lip surface and hardness No flaws, distortion or exces- Replace.
sive wear.
Not hardened
16 Swash plate 36 Sliding surface against piston No excessive flaws 0.00079 When sliding surface has
assembly in. over [0.02 mm], wear or roughened, repair it by
Surface roughness seizure 0.4 Ra (0.8 Ra) lapping (#1000).
Replace it if the damage
is beyond repair.
6-5-38 4480203
Standard value
No. Parts Inspection item (recommended value for Measure
replacement
17 Cylinder barrel 40 Clearance between it and 0.02 mm (0.04 mm) Replace cylinder barrel
piston assembly. 0.00079 in. (0.02 mm) and piston assembly
[0.00157 in. (0.04 mm)] together.
Sliding surface against valve No excessive flaws (over When sliding surface has
plate. 0.02 mm), wear or seizure. roughened, repair it by
Surface roughness 0.4 Ra (0.8 Ra) lapping (#1000).
If the damage is beyond
repair, replace the cylin-
der barrel and piston
assembly together.
18 Springs 34, 43, 60, 64, 68 Breakage or distortion Replace.

and 82
19 Piston assembly 37 Clearance between it and cyl- Same as No.17 Same as No.17
inder barrel.
Sliding surface against Same as No.16 Same as No.16
swash plate and surface
roughness.
Play between pistons and 0.00591 in. [0.15 mm] Replace.
shoes 0.01575 in. [0. 4 mm])
20 Piston assembly 35 Clearance between it and Same as No.17 Same as No.17

flange holder.
Sliding surface against Same as No.16 Same as No.16
swash plate and surface
roughness.
21 Valve plate 46 Sliding surface against cylin- Same as No.17 Same as No.17
der barrel and surface rough-
ness.
Thickness : 5 mm 0.189 in. [4.8 mm] Replace.
22 Base plate 53 Sliding surface against No excessive flaws, wear or Replace base plate and
plunger. seizure. plunger together.
Sliding surface against spool. No excessive flaws, wear or Replace base plate and
seizure. spool together.
23 Plunger 58 Sliding surface against base No excessive flaws, wear or Replace base plate and
plate. seizure. plunger together.
Sliding surface against check No excessive flaws, wear or Replace plunger and
valve. seizure. check valve together.
24 Check valve 59 Sliding surface against No excessive flaws, wear or Replace plunger and
plunger. seizure. check valve together.
Seat surface against plunger. The plunger is seated com- Replace plunger and
pletely. check valve together.
25 Spool 67 Sliding surface against base No excessive flaws, wear or Replace base plate and
plate. seizure. spool together.
26 Valve body 76 Sliding surface against check No excessive flaws, wear or Replace check valve and
valve. seizure. valve body together.
Seat surface against check The check valve is seated

valve. completely.
27 Check valve 81 Sliding surface against valve No excessive flaws, wear or Replace check valve and
body. seizure. valve body together.
Seat surface against valve The valve body is seated

body. completely.
6-5-39 4480203
7. Troubleshooting
1) Motor
1. Motor does not rotate. 1) Malfunction of equipment other than Check whether the specified volume of hydraulic oil
motor, counter balance valve and is fed to the motor suction side.
reduction gear. Then, check and repair each part.
2) Escape of pressure oil due to exces- Replace any excessively worn parts.
sive wear of motor’s sliding parts. Repair any flaws or burrs on the surfaces, clean all
the parts and reassemble them.
3) Malfunction due to breakage of Disassemble the motor and replace any broken
motor’s sliding parts. parts.
(In this case, motor makes an abnor- Clean all the parts and reassemble them.
mal sound).
4) Relief valve operates due to too much Check the load and regulate it to the value corre-
load applied to motor. sponding to the set relief pressure.
2. Motor speed is low. 1) Specified volume of oil is not being Check whether the specified volume of hydraulic oil
supplied to motor due to failure of is fed to the motor suction side.
hydraulic pump, system relief valve, Then, check and repair each part.
etc.
2) Specified speed is not obtained due to After disassembling the motor, check them for
drop of motor’s displacement. excessive wear of the sliding parts. Repair or
replace any worn parts.
3. Large fluctuation in 1) A large volume of high pressure oil After disassembling the motor, check the parts and
motor revolutions leaks and flows out from drain port replace any worn parts.
due to wear of motor’s parts, causing Clean all the parts and reassemble them.
a large drop and fluctuation in motor
revolutions.
The fluctuation is also caused by worn
bearing.
4. Oil leak 1) Breakage of oil seals or O-rings. Replace any broken oil seals and O-rings. Take
care not to damage the lip of the oil seal.
Apply a small amount of grease to O-rings before
assembly.
6-5-40 4480203
2) Counter Balance Valve

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

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

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

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

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

(1) Foreign substances caught inside. Remove al the foreign substances, repair any dam-
aged area, clean the parts and reassemble them.
the part.
(2) Broken spring. Replace the spring. Remove all the foreign sub-
stances, repair any damaged area, clean the parts
and reassemble them.
(3) Clogged orifice. Clean the part with cleaning oil and reassemble it.
6-5-41 4480203
3) Anti-Cavitation Valve
1. Motor does not turn or 1) Seat of check valve is defective.

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

on traveling. (1) Foreign substances caught between Remove all the foreign substances, repair any
check valve and valve body. damaged area, clean the parts and reassemble
them.
the part.
6-5-42 4480203
4) 2-Speed Switching Mechanism

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

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

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

Remove all the foreign substances, repair any
them.
6-5-43 4480203
CHAPTER 7
ADJUSTMENT AND REPAIR
7-1 Electric Equipment of Machine................................... 7-1-1 7-3-8 Adjustment of Track Gauge Change
7-1-1 Parts Layout of Electrical Equipment ................ 7-1-1 Control Lever..................................................... 7-3-7
7-1-2 Monitor and Alarm Systems .............................. 7-1-2 7-3-9 Adjustment of Accelerator Lever ....................... 7-3-8
7-1-3 Wiring Diagram.................................................. 7-1-5 7-3-10 Adjustment of P.T.O. Pedal............................. 7-3-9
7-1-4 Circuit Description of Engine Start and Stop, 7-3-11 Adjustment Procedure
and Battery Charging ........................................ 7-1-6 of Travel Alarm Switch (Left and Right)......... 7-3-10
7-1-5 Removal and Reinstallation of Engine .............. 7-1-8 7-4 Swing Bearing ............................................................ 7-4-1
7-1-6 Removal and Reinstallation 7-5 Hydraulic Equipment .................................................. 7-5-1
of Starter Motor ............................................... 7-1-14 7-5-1 Removal and Reinstallation
7-1-7 Removal and Reinstallation of Hydraulic Pump............................................. 7-5-1
of Fuel Injection Pump .................................... 7-1-15 7-5-2 Removal and Reinstallation
7-1-8 Removal and Reinstallation of Fuel Tank........ 7-1-17 of Control Valve................................................. 7-5-4
7-1-9 Removal and Reinstallation of Radiator .......... 7-1-20 7-5-3 Removal and Reinstallation
7-2 Undercarriage ............................................................ 7-2-1 of Swing Motor .................................................. 7-5-7
7-2-1 Outline ............................................................... 7-2-1 7-5-4 Removal and Reinstallation of Swivel Joint..... 7-5-10
7-2-2 Points of Reassembly........................................ 7-2-2 7-5-5 Disassembly and Reassembly
7-2-3 Crawler Tension Adjustment Procedure............ 7-2-3 of Swivel Joint ................................................. 7-5-13
7-2-4 Removal and Reinstallation of Crawler ............. 7-2-4 7-5-6 Disassembly and Reassembly
7-2-5 Disassembly and Reassembly of Idler .............. 7-2-5 of Hydraulic Cylinders ..................................... 7-5-16
7-2-6 Disassembly and Reassembly 7-5-7 Hydraulic Oil Tank ........................................... 7-5-20
of Track Roller................................................... 7-2-7 7-5-8 Piping Layout................................................... 7-5-26
7-2-7 Removal and Reinstallation 7-6 Implement................................................................... 7-6-1
of Track Gauge Change Cylinder...................... 7-2-9 7-6-1 Removal and Reinstallation of Implement ......... 7-6-1
7-3 Controls ...................................................................... 7-3-1
7-3-1 Control Train...................................................... 7-3-1
7-3-2 Mechanical Control Linkage .............................. 7-3-2
7-3-3 Adjustment of Control Levers ............................ 7-3-4
7-3-4 Adjustment of Travel Levers.............................. 7-3-5
7-3-5 Adjustment of Boom Swing Pedal ..................... 7-3-6
7-3-6 Adjustment of Blade Lever ................................ 7-3-6
7-3-7 Adjustment of Lock Lever Switch ...................... 7-3-7
7. ADJUSTMENT AND REPAIR
7. Adjustment and Repair

7-1 Electric Equipment of Machine
7-1-1 Parts Layout of Electrical Equipment
1) Electric Wiring
17 7 8
6
22 11 9
23
21 10
20
18
19
12
13
1
16
2
5 3
15 24 14
No. Part No. Part No. Part

1 Harness A 9 Timer (1 sec.) 17 Battery cable (positive)
2 Harness B 10 Safety relay 18 Battery cable (negative)
3 Harness (for boom light) 11 Current limiter 19 Battery
4 Slow blow fuse (40A) 12 Engine ground cable 20 Safety switch (lever lock R)
5 Fuse box 13 Safety switch (lever lock L) 21 Indicator box
6 Starter switch 14 Safety switch (high-speed travel) 22 Starter motor
7 Glow register 15 Horn 23 Travel alarm
8 Glow relay 16 Head light 24 Safety switch
7-1-1 4480203
7-1-2 Monitor and Alarm Systems
For safer machine operation, the operator needs to have a clear understanding of the machine’s condition. However,
it is difficult for the operator to keep an eye on every aspect of the machine he/she operating.
Therefore, gauges and alarms are installed to warn the operator of any trouble of the machine at the early stage.
Note :
The monitors do not give a full assurance of the machine’s condition. The indications shown on them should be used
as a guide for daily check and periodic maintenance according to the operation and maintenance manual.
1) Part Name
Panel
ON
OFF
6 1 Engine oil pressure alarm lamp

F HOUR METER
FUEL
1/10h
2 Water temp. meter
5 3 Water temp. alarm lamp
4 Battery charge alarm lamp
E
H 5 Fuel gauge
W.TEMP
3 6 Hour meter
2
C
4 1
2) Function of Alarm Sensor
• All the lamps should go on for a few seconds when the starter switch is turned on.
• All the lamps should go off when the engine is running.
• The engine oil pressure and battery charge alarm lamps should go on when the engine is stopped.
• The buzzer should sound when a lamp goes on while the engine is running.
3) Alarm Sensor Operation

(1) Lube oil pressure drop monitoring (engine oil pressure switch)
When the engine oil pressure falls, the lamp goes on and the buzzer sounds.
Starter SW Engine start

ON Lamp
Lamp OFF
Engine oil ON Lamp
ON Alarm sound
pressure
Normal
Pressure drop
<5.69 to 8.53 PSI
(<0.04 to 0.06 MPa)
The switch monitors the lube oil pressure drop of the engine and
causes the engine oil pressure alarm lamp to go on and the alarm PT 1/8
buzzer to sound.
Working pressure : 5.69 to 8.53 PSI (0.04 to 0.06 MPa)
Installation position : Engine block Terminal
0.945 in.
(24 mm)
7-1-2 4480203
When the alarm buzzer sounds, check the following items.

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

The water temp. meter indicates the engine cooling water temperature.
The pointer should be within the white range while the engine is running.
If the pointer goes up to the red range, the engine is overheating.
Red
Starter SW
ON White
2 to 3 seconds later, Engine start
lamp out Lamp
ON Alarm sound
Engine Lamp Lamp
cooling water ON OFF
temperature Water temperature rise
>224.6 to 235.4 F
Normal (>107 to 113 )
Turned on : Cooling water temp. : 224.6 to 235.4°F (107 to 113°C) 0.827 in.
(21 mm)
Turned off : Cooling water temp. : 212°F (100°C) or less 16 1.5
Installation position : Cooling water pump on engine
Terminal

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

When there occurs a potential difference between the output voltage of the alternator and the voltage of the battery,
the lamp goes on and the buzzer sounds.
Starter SW Engine start

Lamp
ON Lamp ON Alarm sound
OFF
Terminal Lamp
voltage of ON Voltage of
alternator battery
Normal Potential difference

(Voltage drop)

[1] Degeneration or malfunction of battery.
[2] Refer to Section "7-1-4 Circuit Description of Engine Start and Stop, and Battery Charging".
7-1-3 4480203
(4) Fuel gauge

When the starter switch is turned on, the fuel gauge starts to work to
indicate the oil level in the fuel tank.
• It is normal for the fuel gauge to take some time to indicate the cor-
rect level after the starter switch is turned on.
• The remaining oil level indication can change depending on the incli-
nation of the machine body.
Fuel gauge unit
FULL
3/4
(104.8 to 112.8 mm)
4.13 to 4.44 in.
(94.7 mm)
3.73 in.
1/2
(44.9 to 52.9 mm)
1.77 to 2.08 in.
55
55
1/4
(48.7 to 56.7 mm)
(1.2 mm)
1.92 to 2.23 in.
0.05 in.
EMPTY
Float position Resistance (Ω)

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

When the starter switch is turned on, the hour meter starts to work.
HOUR METER
1/10h
7-1-4 4480203
7-1-3 Wiring Diagram
1) Standard Specifications
Work lamp switch Glow relay
Horn switch Current limiter Timer Glow register
Cut-off switch Cut-off switch One touch decel L Timer relay
left left Safety relay (NC)
Sb
Sb
Or
Br
B
Y
49 50 46 39A 44 43 45 47
B
0.75 Or
4 3 2 1
0.75 Br
1.25 YW
0.85 YW
0.75 Y
0.85 YB
2.0 R
2.0 B
2.0 L
2.0 L
3.0 RL
3 1
1.25 B
0.85 L
0.5 Lg
0.5 Lg
0.5 W
2 1
2.0 B
4 3
4 2
RW
R
Decel switch
B
3 1
Y
4 2 13 14 11 5A
B Or Sb Sb R Br Y 12 6A
30 29A 29 9A 47A 45A 25 26 23 8A 15 16 4A 17A 22 21 20 19 18 17 36A 65 64 60A61A 60 61 63 62
3.0 WB
1.25 B
3.0 W
3.0 W
3.0 W
3.0 R
0.85 YW
0.85 YW
0.85 YB
0.85 YB
0.85 GW
1.25 YG
0.85 YR
0.85 YB
0.85 Or
0.5 RW
0.5 RW
3.0 RG
3.0 RB
3.0 RL
0.85 B
1.25 B
0.85 B
0.85 L
1.25 L
0.5 Br
0.5 Br
3.0 G
3.0 R
0.5 B
0.5 Y
0.5 Y
0.5 Y
2.0 L
2.0 L
Travel alarm
0.85 B
68
55A 0.85 YW
3.0 WB 3.0 WB
6 19 19
3.0 W 3.0 W
5 17 17
3.0 RL
2A 30
3.0 R
30
Starting switch
Travel alarm 3.0 RB
4 50
3.0 RB
50 AC
switch left 3.0 RW 3.0 RW
3 AC
57
56 0.85 Y
3.0 RW 3.0 RW 1 15A

3A 3
1.25 YR 1.25 YR 2 15A
7 2
Travel alarm 1.25 YG
8 5 1.25 YG
switch right 1.25 YB 1.25 YB 3 15A
9 6
3.0 RL 3.0RL
55 0.85 YW 2 4
0.85 Y 0.85 YB 3.0 R 3.0R
69A 0.85 Y 1 1
15A reserve
58 0.85 YG Fuse box

59A 0.85 G
Two speed switch
27 Slow blow fuse (40A)

Horn
25A 0.85 GW
53 0.85 YG + -
0.5 YB 0.5 YB
27 13
0.5 B
28 14
0.5 B Hour meter
Work lamp
L H Temp meter
23A 1.25 YL
3.0 B
24 1.25 B
14
1.25 YR
1.25 YR
0.85 YB
0.5 LgR
3.0 RG
0.85 G
1.25 B
0.5 LB
0.5 Lg
3.0 W
3.0 G
3.0 B
2.0 L
2.0 L
Frame earth E F Fuel meter
1.25YL
51 15A 30A 59 7A 67 12A 64A 10 66 33A 41A 40A 20A 19A
1.25B
52 9 15 13 12 14 11 5 1 4 6 7 8 2 3
1.25 YR
1.25 YR
0.85 YB
0.5 LgR
3.0 RG
0.85 G
1.25 B
0.5 LB
0.5 Lg
3.0 W
2.0 G
2.0 B
2.0 L
2.0 L
4 3 Lamp
0.5 B 0.85 YB Decel (option)

48 35 5
0.5 L 0.5 LB
33 3
0.5 L
34 4
0.5 YL
Fuel sensor 31 1 Oil
0.5 W
39 9
34A 6A 7A 8A 0.5 LgR
0.5 Lg
41 11
0.85 YR 40 10 Temp
1.25 YR
0.5 LgR
0.5 B
0.5 LB
1.25 B
32 2
0.5 Lg
0.5 Y
37 6
0.5 YB
0.85 B 42 12 Lamp
0.5 B Buzzer
2.0 L
2.0 L
38 8 checker
1.25 YR
12A 14A 6A 7A 8A
0.85 YB
0.5 Y
0.85 G
0.85 B
0.85 B
36 7
2.0 G
2.0 B
2A 3A
7 11 Charge
15A 16 13A 17 5A 1A 4A
P G H
L R
Indicator box
3.0 RG
3.0 W
Y Yellow R Red
3.0 R
B.E. B.E. B.E. YB Yellow Black RL Red Blue

Temp sensor YR Yellow Red RW Red White
S Temp switch Dynamo YL Yellow Blue
AVf 30 Fuel pump Oil pressure RB Red Black
EB 20 B
Cut off Travel two YW Yellow White RG Red Green
Engine stop switch YG Yellow Green G Green
valve speed valve
20 solenoid YB Yellow Black GW Green White
W White B Black
WB White Black LgR Young Leaves Red
65B24L L Blue Or Orange
Starter motor Glow plug
LB Blue Black Br Brown
Lg Young Leaves
Battery B.E.
7-1-5 4480203
7-1-4 Circuit Description of Engine Start and Stop, and Battery Charging
3.0 RG
1. Start Engine 0.5 B
15
16
S
E
3.0 RB
4A 50
The starter switch 30 is always supplied with electric current from 0.5 Br
Turn on the starter switch. 17A Br
the battery. (Battery -Slow blow fuse-Starter switch 30)
↓ Safty relay (NC)
Starter switch 30, AC-Lead wire RW-Fuse 15 A-Lead wire YR-

The timer is supplied with electric current. 1.25 B
22 B 2.0 B B
Timer R (Lead wire) 0.85 Or
2.0 L
21 Or 0.75 Or
2.0 L
Or
20 Sb Sb
↓ 2.0 L
3.0 R
19 Sb 2.0 L
2.0 R
Sb
18 R R
0.5 Br 0.75 Br
The relay is supplied with electric current Timer RW-Relay 2, Relay 1-Timer Y 17 Br
0.75 Y
Br
Y
from the timer and the 1 and 2 are con- 0.5 Y
36A Y
nected. Y Yellow R Red Current limiter
YB Yellow Black RL Red Blue
↓ YR Yellow Red RW Red White
3.0 RL
YL Yellow Blue RB Red Black 65 4 3 4
3
The relay operates, and the 3 and 4 are The relay 4 is always supplied with electric current from the battery YW Yellow White RG Red Green 3.0 G
0.5 RW
64
YG Yellow Green G Green 60A 2
connected. through the slow blow fuse. YB Yellow Black GW Green White
0.5 Y
61A
2 1
1
W White
↓ WB White Black
B Black
LgR Young Leaves Red
Timer relay
L Blue Or Orange
The engine stop solenoid P (pull) is sup- The engine stop solenoid H (hold) is supplied with electric current LB Blue Black Br Brown 0.5 RW RW
60
plied with electric current from the relay 3 when the starter switch is turned on. Lg Young Leaves 0.5 Y
61 Y
0.85 B B
to press the engine control lever. 0.85 YR
63
62 R
↓
Timer
The engine stop solenoid P is stopped In about one second after the starter switch is turned on, the timer
being supplied with electric current. operates to stop electric current from flowing to the engine stop 3.0 WB
6 19
3.0 WB
19
3.0 W 3.0 W
solenoid P. 3.0 RL
5
2A
17
30
3.0 R
17
30
However, the engine stop solenoid H is still supplied with electric 3.0 RB
4 50
3.0 RB
50 AC
↓
3.0 RW 3.0 RW
3 AC
current when the starter switch is on, so that the control lever stays
pushed. Starting switch
Turn the starter switch to "START" position. The starter motor B is always supplied with electric current from the
3.0 RW 1 15A
↓ battery. 1.25 YR
3A 3 3.0 RW
1.25 YR
7 2 2 15A
1.25 YG 1.25 YG
8 5
The electric current is supplied from the The magnet switch of the starter motor operates to allow the pinion 1.25 YB
3.0 RL
9 6 1.25 YB
3.0RL
3 15A
2 4
starter switch 50 to the safety relay, and to jump out. At the same time, the crankshaft of the engine rotates 3.0 R
1 1
3.0R
from safety relay S to the starter motor S to and the engine starts to run.
1.25 YR
1.25 YR
0.85 YB
0.5 LgR
15A Reserve
3.0 RG
0.85 G
1.25 B
0.5 LB
0.5 Lg
3.0 W
3.0 G
rotate the starter motor.
3.0 B
2.0 L
2.0 L
Fuse box
↓ 15A 30A 59 7A 67 12A 64A 10 66 33A 41A 40A 20A 19A
9 15 13 12 14 11 5 1 4 6 7 8 2 3
The safety relay operates. When the engine speed reaches the rated speed, the dynamo L, R
1.25 YR
1.25 YR
0.85 YB
0.5 LgR
3.0 RG
0.85 G
1.25 B
0.5 LB
0.5 Lg
and current limiter sb, sb are connected. And also current limiter Br
3.0 W
2.0 G
Slow blow fuse (40A)
2.0 B
2.0 L
2.0 L
and safety relay Br are connected.
Therefore, the dynamo, the current limiter and the safety relay are
supplied with electric current.
The signal from the current limiter Br flows to the safety relay Br
and cuts off the connection between the safety relay s and starter
motor S, which causes the pinion to be pulled back and the engine 0.85 YR
1.25 YR
1.25 B
to be prevented from overrunning.
0.85 B
2.0 L
2.0 L
1.25 YR
12A 14A
2. Stop Engine
2.0 G
2.0 B
2A 3A
Turn off the starter switch. 5A 1A 4A L R
↓ P G H
3.0 RG
The engine stop solenoid H is stopped The control lever blocks a flow of fuel oil to stop the engine. 3.0 R
being supplied with the electric current to
S Fuel pump Dynamo
pull back the control lever. EB 20 AVf 30 B
Engine stop
solendoid
20
(-) (+)
65B24L Starter motor
Battery B.E.
7-1-6 4480203
3. Charge Battery
The electric current flows from the dynamo L, R to the battery
The electric current generated by the
through the current limiter sb, sb, R and the slow blow fuse to
dynamo flows to the battery to be charged. 3.0 RG
15 S
charge the battery. Y Yellow 0.5 B
16 E
YB Yellow Black 3.0 RB
4A 50
↓ YR Yellow Red 0.5 Br
17A Br
YL Yellow Blue
When the voltage generated by the dynamo is low, the circuit in the YW Yellow White
YG Yellow Green Safety relay (NC)
alternator is turned on, and the electric current flows from the bat- YB Yellow Black
When the battery charge alarm lamp goes
tery charge alarm lamp in the indicator box to the alternator to light W White 1.25 B 2.0 B
on, the battery charges poorly. the alarm lamp.
WB White Black 0.85 Or
22
21
B
Or 0.75 Or
B
Or
L Blue 2.0 L 2.0 L
20 Sb Sb
(Indicator box→Lead wire WG→Alternator L) LB Blue Black 2.0 L
19 Sb 2.0 L
Sb
Lg Young Leaves 3.0 R
18 R 2.0 R
R
R Red 0.5 Br 0.75 Br
17 Br Br
RL Red Blue 0.75 Y
0.5 Y Y
RW Red White 36A Y
RB Red Black Current limiter
RG Red Green
G Green
GW Green White
B Black
LgR Young Leaves Red
Or Orange
Br Brown 3.0 RW 3.0 RW 1 15A
3A 3
1.25 YR 1.25 YR 2 15A
7 2
1.25 YG 1.25 YG
8 5
1.25 YB 1.25 YB 3 15A
9 6
3.0 RL 3.0RL
2 4
3.0 R 3.0R
1 1
15A reserve
Fuze box
Slow blow fuze (40A)
0.5YB
27 13
0.5 YB + - Hour meter
0.5 B 0.5 B
28 14
L H Temp meter
1.25 YR
1.25 YR
0.85 YB
0.5 LgR
3.0 RG
0.85 G
1.25 B
0.5 LB
0.5 Lg
3.0 W
3.0 G
3.0 B
2.0 L
2.0 L
15A 30A 59 7A 67 12A 64A 10 66 33A 41A 40A 20A 19A
9 15 13 12 14 11 5 1 4 6 7 8 2 3 E F Fuel meter
1.25 YR
1.25 YR
0.85 YB
0.5 LgR
3.0 RG
0.85 G
1.25 B
0.5 LB
0.5 Lg
3.0 W
2.0 G
2.0 B
2.0 L
2.0 L
Lamp
0.85 YB Decel (option)

35 5
0.5 LB
33 3
0.5 L
34 4
0.5 YL
31 1 Oil
0.5 W
39 9
0.5 LgR
41 11
0.5 Lg Temp
40 10
0.5 B
32 2
0.85 YR 0.5 Y 37 6
0.5 YB
42 12 Lamp Buzzer
0.5 B checker
38 8
0.85 B 0.5 Y 36 7
1.25 YR
Charge
2.0 G
2.0 B
2.0 L
2.0 L
3.0 RG
3.0 R
5A 1A 4A 2A 3A Indicator box
P G H
S L R
EB 20 AVf 30 B
20
(-) (+)
65B24L Engine stop Dynamo

Starter motor solenoid
Battery B.E.
7-1-7 4480203
7-1-5 Removal and Reinstallation of Engine
1) Removal
Procedure
(1) Swing the upperstructure so that the drain plug 1 of the
hydraulic oil tank and the cooling water drain plug 2 are
positioned halfway between the right and left crawlers.
Then, lower the bucket to the ground and stop the engine. 1
(2) Remove the drain plug 1 from the hydraulic oil tank and 2
drain the hydraulic oil.
Type YANMAR SUPER HYDRO OIL (VG 46

class) or its equivalent
Quantity 3.6 Gals. (13.8 L)
(3) Remove the drain plug 2 from the two-way cock for cool-
ing water and drain the cooling water.
Cooling water quantity 2.3 Qts. (2.2 L)
2 1
(4) Remove the step A 3, the panel (UP) 4, the panel L 7

(LOW) 5 and the panel R 6. 4
(5) Remove the indicator box 7, and then disconnect the har-
ness connectors. 6
(6) Disconnect the battery cable (negative) 8 and the battery

cable (positive) 9 and remove the battery clamp 10. Then 9 8
remove the battery 11.
(7) Remove the battery mount 12. 10

11
12
7-1-8 4480203
Procedure
(8) Remove the side cover R 13, the frame R cover 14 and
the bonnet R 15.
(9) Remove the step rib 16, the frame L cover 17, the covers
A 18 and B 19, the hydraulic oil tank cover 20 and the
bonnet L 21. 21
15 20
Note :
Remove the plate a before removing the step rib 16.
a
18
14
19
13 17
16
(10) Remove the operator's seat bracket 22 (with the opera-

tor's seat), and then remove the operator's seat plate 23. 22
25 26
(11) Remove the snap pin 25 and disconnect the accelerator
cable 24 from the accelerator lever 26.
24
23
(12) Remove the nuts 29 from the L-balls of the cable 27 con-
nected to the blade lever and the cable 28 connected to 27 29 28
the track gauge change lever, and disconnect those
29
cables from the levers.
7-1-9 4480203
Procedure
(13) Disconnect the harnesses 30, 31 and 32 from the lock
lever switches L and R and the horn switch respectively.
33 44
(14) Disconnect the harnesses 33 and 34 from the starter
switch and the fuel gauge unit respectively. 32
(15) Disconnect the connectors 37 of the harnesses A 35 and
B 36 from each other. 31
(16) Disconnect the connectors 39 of the fuse wire 38 and the
34
harness B 36 from each other, and disconnect the body
ground terminal 40. 30
(17) Disconnect the connectors 41, 42 and 43 of the high- 39
speed travel switch, the horn and the boom light (working
35
lamp) respectively.
(18) Remove the bracket 44 from the operator's seat mount 38

50. 37 36
40
43 42 41
(19) Remove the canopy 45.
(20) Remove the bracket UP 46 and the filler 47.
(21) Loosen the hose clip 49 on the intake manifold side and
remove the air cleaner hose B 48 from the intake mani-
fold.
(22) Rope the operator's seat mount 50 (with the bonnet A

and the air cleaner assembly 51) and lift it up, to remove 45
it.
46 47 51
Note :
Take care that the harnesses and clamps do not catch on any
other parts when lifting up the operator's seat mount.
48
49
50
7-1-10 4480203
Procedure
(23) Remove the hoses connected to the hydraulic oil tank
52. 55
a. Suction hose 56
b. Return hose (control valve to hydraulic oil tank) 54
c. Return hose (joint to hydraulic oil tank)
57
Note : To full tank
Remove the return hose from the joint.
d. Hydraulic oil drain hose
(24) Remove the feed pump 53, and then remove the fuel
hose 54 (the fuel tank to the water separator 55) from the 52
water separator 55. 53
(25) Remove the fuel return hose 56 (the fuel filter 57 to the
fuel tank) from the fuel tank.
d
(26) Remove the hydraulic oil tank 52, and then remove the
hydraulic oil tank stay B 58.
a
c
58
b
(27) Remove the hydraulic hoses from the hydraulic pump.

a. Hose P1 a
b. Hose P2
c. Hose P3 P2 P1
b c
d. Hose PA
e. Hose PB1
f. Hose PB2 P3
d
PB1 PB2
PA f
(28) Remove the hoses A 59 and C 60 from the engine.

62
(29) Remove the cooling water drain hose 61. 63
(30) Remove the radiator 62 (with the shroud 63) from the 59
fuel tank mount 64.
61
60
64
7-1-11 4480203
Procedure
(31) Remove the engine ground cable 65.
70 67 70
(32) Remove the engine stopper 66.
66
(33) Remove the stopper plate 67 and the plate E 68.
68
70
(34) Remove the nuts 70 from the vibroisolating rubbers 69.
69
70 69
69
69
65
(35) Rope the engine using its lifting lugs and lift it up, to
remove it.
2) Reinstallation
Reinstall the engine in the reverse order of the removal procedure.
Adhesive and tightening torque
No. Parts Size Adhesive Tightening torque
1.8 to 2.2 ft•lbf
59 Hose band (CW-T) 38 
(2.5 to 2.9 N•m)
1.6 to 1.8 ft•lbf
 Hose clip (CW-T) 25 
(2.2 to 2.5 N•m)
Apply Three Bond 1324 or its 32.6 to 43.4 ft•lbf
68 Plate E M10!25
equivalent. (44.1 to 58.8 N•m)
7-1-12 4480203
57.9 to 72.3 ft•lbf

45 Canopy pole M12!35 
(78.5 to 98.1 N•m)
18.1 to 23.8 ft•lbf
69 Vibroisolating rubber M10 nut 
(24.5 to 32.3 N•m)
Apply Three Bond 1324 or its 32.6 to 43.4 ft•lbf
66 Engine stopper M10!25
equivalent. (44.1 to 58.8 N•m)
1.6 to 1.8 ft•lbf
49 Hose clip 60 
(2.2 to 2.5 N•m)
14.5 to 16.6 ft•lbf
 Air cleaner mount M8!16 
(19.6 to 22.6 N•m)
7-1-13 4480203
7-1-6 Removal and Reinstallation of Starter Motor
1) Removal
Procedure
(1) Lower the bucket to the ground and stop the engine.

cable (positive) 2 and remove the battery clamp 3 from 2 1
the battery 4. Then remove the battery 4.

4
(4) Disconnect the wire harness 7 from the starter motor 6.
(5) Remove the mounting bolts 8 and remove the starter

motor 6. 7 8
6
8
2) Reinstallation
Reinstall the starter motor in the reverse order of the removal procedure.
Note :
Secure the harness with a band.
Starter motor mounting bolt (M10)

Tightening torque 32.6 to 43.4 ft•lbf (44.1 to 58.8 N•m)
7-1-14 4480203
7-1-7 Removal and Reinstallation of Fuel Injection Pump
1) Removal
Procedure
(1) Remove the water separator 1. 6
1
(2) Remove the air cleaner bracket 2, and remove the air
cleaner assembly 3.
(3) Remove the hose connector bolt 4 and remove the hose 5
(the fuel filter to the fuel pump).
(4) Remove the steady retainer 5, and then remove the fuel 4
injection pipes (No.1, No.2 and No.3) 6.
12
(5) Remove the fuel injection pump chamber cover 7, and

then take off the snap pins 8 and remove the link 9.
Note :
Take care not to drop the snap pins 8 inside the fuel pump 9
case 10. 12
(6) Remove the nuts (with washer 8) 11 and remove the fuel
injection pump 12. 8
11
10
7-1-15 4480203
2) Reinstallation
Reinstall the fuel injection pump in the reverse order of
the removal procedure.
Note :
Measure the total thickness of the adjusting shims. Shims
Replace them with new ones that have the same thick-
ness altogether. 10
3) Checking of Fuel Injection Timing

(1) Check the fuel injection timing in the FID method.
(2) Adjust the fuel injection timing by changing the total
thickness of shims.
• Increase the thickness to delay the fuel injection tim-
ing.
• Reduce the thickness to advance the fuel injection tim-
ing.
Note :
For the proper fuel injection timing, refer to the specifica-
tion on page 2-1-5.
7-1-16 4480203
7-1-8 Removal and Reinstallation of Fuel Tank
1) Removal
Procedure
(1) Swing the upperstructure so that the drain cock 2 of the
fuel tank 1 is positioned halfway between the right and left
crawlers. Then, lower the bucket to the ground and stop
the engine.
(2) Open the drain cock 2 and drain the fuel.
Fuel quantity 5.3 Gals. (20 L)

(when the tank is filled up)
1
2
(3) Remove the bonnet R 3, the frame R cover 4, the indica-

tor box 5, the panel R 6 and the side cover 7. 5
Note:
Do not disconnect the harness connectors from the indicator
box 5.
7-1-17 4480203
Procedure
(4) Remove the hose clips 11 of the fuel hose 8 (the fuel filter
to the fuel tank), the fuel drain hose 9 and the fuel hose 10 8
(the fuel tank to the water separator), and remove the
hoses. 1
11
(5) Remove the fuel tank clamp 12 and the stand R 13, and
then remove the fuel tank 1.
12
11
10
11
9
13
7-1-18 4480203
2) Reinstallation
Reinstall the fuel tank in the reverse order of the removal procedure.
Note :
Before reinstalling the fuel tank, clean up the inside of it. In particular, remove the deposits on the bottom of the fuel
tank completely.
7-1-19 4480203
7-1-9 Removal and Reinstallation of Radiator
1) Removal
Procedure
(1) Swing the upperstructure so that the cooling water drain
plug 1 is positioned halfway between the right and left
crawlers. Then, lower the bucket to the ground and stop
the engine.
(2) Remove the drain plug 1 from the two-way cock 2 for cool-
ing water and drain the cooling water.
1
Cooling water quantity : 2.7 Qts. (2.6 L)

(including the cooling water in the sub-tank)
(3) Remove the indicator box 3, the panel R 4, the bonnet R 5

and the bracket UP 6.
5
(4) Remove the filler 7.
7-1-20 4480203
Procedure
(5) Remove the hoses A 8 and C 9 from the engine.
11
(6) Remove the cooling water drain hose 10. 12
(7) Remove the radiator 11 (with the shroud 12) from the fuel 8
tank mount 13.
10
9
13
7-1-21 4480203
2) Reinstallation
Reinstall the radiator in the reverse order of the removal procedure.
Hose clip 60
Table of Mixing Ratio of Anti-freeze to Water

°F 23 14 5 -4 -13 -22 -31 -40
Lowest temperature
(°C) (-5) (-10) (-15) (-20) (-25) (-33) (-35) (-40)
Qts. 0.42 0.74 0.85 0.95 1.06 1.27 1.37 1.48
Amount of anti-freeze
(L) (0.4) (0.7) (0.8) (0.9) (1.0) (1.2) (1.3) (1.4)
Qts. 2.33 2.01 1.90 1.80 1.69 1.48 1.37 1.27
Amount of water
(L) (2.2) (1.9) (1.8) (1.7) (1.6) (1.4) (1.3) (1.2)
Note :
At the delivery from the factory, water and anti-freeze are mixed in the ratio shown above for the -31 °F (-35 °C) tem-
perature.
7-1-22 4480203
7-2 Undercarriage
7-2-1 Outline
The undercarriage consists of travel motors, a track frame (crawler frames and a lower center frame), track rollers,
front idlers, rubber crawlers and other parts. Hydraulic oil fed through the control valve and the swivel joint from the
hydraulic pump causes the travel motors to rotate, so that the power is transmitted to the crawlers via the sprockets.
The track frame can be widened and narrowed by the track gauge change cylinder.
Viwed from the top

Slide plate
Rubber crawler
Idler Stopper bolt Track gauge Travel motor
change cylinder
Track roller
Swivel joint
A Section A-A
A
Grease adjuster Track roller Sprocket
7-2-1 4480203
7-2-2 Points of Reassembly

Bolt 10 25
Apply Three Bond 1324 or its
equivalent.
Tightening torque: 32.6 to 43.4 ft lbf
(44.1 to 58.8 N m)
Install rubber crawler

so that lug is set in di-
rection as shown in
top view below.
Hexagon socket head bolt 10 25

Apply Three Bond 1324 or its
equivalent.
Tightening torque: 32.6 to 43.4 ft lbf
(44.1 to 58.8 N m)
Check that track roller

moves smoothy after
Section A-A installing it into frame.
Idler should smoothly

move back and forth. A
A
Apply heavy-duty Check that track roller moves
grease to moving smoothly after installing it into
area of idler. frame.
Track gauge change cylinder
Stopper bolt
Stopper bolt setting procedure Nut M16

Apply Three Bond 1324 or its equivalent.
After fully screwing stopper nut Tightening torque : 123.0 to 151.9 ft lbf
onto stopper bolt, loosen nut one (166.7 to 205.9 N m)
turn. Then tighten bolt.
Bolt 10 16
0.47 in. Apply Three Bond 1324 or its equivalent.
(12 mm) Tightening torque : 32.6 to 43.4 ft lbf
Setting length (44.1 to 58.8 N m)
at the widest track gauge
4.92 in. (125 mm)
Shoe slide plate
7-2-2 4480203
7-2-3 Crawler Tension Adjustment Procedure
(1) Raise one crawler using the boom.

(2) Position the mark on the inside surface of the rub- Track roller
ber crawler on the slide plate.
(3) Measure the clearance H shown in the figures
below, and adjust the crawler tension so that the
clearance H will be within the specified range.
Crawler
Clearance to be measured for
tension sdjustment
H : 0.31 to 0.51 in.

(8 to 13 mm)
7-2-3 4480203
7-2-4 Removal and Reinstallation of Crawler
! When rasing the machine, support it with safety blocks of sufficient strength.
When loosening or removing the nipple valve 1, the high internal pressure could cause grease to eject or the nipple valve
! to blow. Do not bring your face close to the nipple valve 1.
1) Removal of Rubber Crawler

Handle the rubber crawlers with great care, as they are heavy.
!
Rubber crawler : 130 lbs. (59 kg) each
Procedure
(1) Lower the bucket to the ground, and remove the nipple
valve 1 to loosen the rubber crawler tension.
Note :
Move the machine back and forth if the grease is not dis-
charged smoothly.
(2) Swing the upperstructure to position the implement in the

direction opposite to the blade, and raise the machine
slightly with the implement.
Rubber crawler
to remove
(3) Insert steel pipes between the crawler frame and the rub-
ber crawler 2, as shown in the figure at the right, and turn
the sprocket in the reverse direction. Slide the rubber
crawler off when the rubber crawler is separated from the
idler by the steel pipes.
2
Rotating direction
Steel pipes
2) Reinstallation of Rubber Crawler

Install the rubber crawler in the reverse order of the removal procedure.
7-2-4 4480203
7-2-5 Disassembly and Reassembly of Idler
1) Structure and Component Parts
Projection Form of Idler
2
7 8
For rubber crawlers For steel crawlers
3
4
9
10
6
11
No. Part Q’ty No. Part Q’ty

1 Idler 1 7 Internal snap ring C62 1
2 Internal snap ring C62 1 8 Idler fork R 1
3 Idler fork L 1 9 External snap ring C25 1
4 Seal QLN306213.2Y 1 10 Seal QLN306213.2Y 1
5 Shaft 1 11 Bearing 6206 1
6 Bearing 6206 1
The procedures for disassembling and reassembling the idler for the steel crawler and that for the rubber crawler are
the same, though the two idlers are different in their external dimension.
2) Disassembly
Procedure
(1) Remove the idler assembly from the crawler frame.
Crawler frame
Idler assembly
7-2-5 4480203
Procedure
(2) Remove the mounting bolts to remove the crawler adjust-
ing spring.
(3) Remove the snap ring C 9 and then remove the idler fork
Mounting bolt
R 8, the seal 10 and the snap ring C 7.
(4) Drain the lube oil inside the idler. Then, pull out the shaft 5 Crawler adjusting
(with the bearing 11) using a press. spring
Oil quantity 0.026 Qts. (25 mL)
(5) Remove the seal 4, and then remove the snap ring C 2
and the bearing 6. 98
Note : 10
7
The shaft 5 is press-fitted into the idler fork L 3. 11
1
5
6
24
3
Idler assembly for rubber crawlers
3) Reassembly
Reassemble the idler in the reverse order of the disas-
sembly procedure.
Notes :
[1] Clean all the parts and check them for damage or
defects.
[2] Replace the seals with new ones.
[3] Apply multipurpose grease to the lips of seals 4 and 4, 10
10.
[4] When installing the seal 10, to release air from the
inside of the idler, remove the sleeve from the seal
and install the seal, then install the sleeve.
Crawler adjusting spring mounting bolt (M10)
Adhesive Three Bond 1324 or its equivalent.
[5] Oil to be used for idler:

Sleeve
Type Engine oil SAE 30
Quantity 0.026 Qts. (25 mL)
7-2-6 4480203
7-2-6 Disassembly and Reassembly of Track Roller
1 2 3 4 5 6 7
For rubber crawlers

8

1 Seal TW 25 52 18 1 5 Shaft 1
2 Roller 1 6 Bearing 6205 1
3 Internal snap ring C52 1 7 Internal snap ring C52 1
4 Bearing 6205 1 8 Seal TW 25 52 18 1
2) Disassembly
Procedure
(1) Remove the mounting bolts and remove the track roller Mounting bolt
from the crawler frame.
Crawler frame
Track frame
7-2-7 4480203
Procedure
(2) Remove the seal 1 from the track roller 2 and drain the
lube oil.
Oil quantity 0.042 Qts. (40 mL)
(3) Remove the snap ring C 3 and pull out the shaft 5 (with
the bearing 4) using a press. 1
3
(4) Remove the seal 8, and then remove the snap ring C 7 4
and the bearing 6.
5
2
6
7
8
3) Reassembly
Reassemble the track roller in the reverse order of the
disassembly procedure.
1, 8
Notes :
[1] Clean all the parts and check them for damage or
defects.
[2] Replace the seals with new ones.
[3] Apply multipurpose grease to the lips of seals 1 and
8.
[4] When installing the seal 1, to release air from the
inside of the track roller, remove the sleeve from the
seal and install the seal, then install the sleeve.
Track roller mounting bolt (M12)
[5] Oil to be used for track rollers : Sleeve
Type Engine oil SAE 30
Quantity 0.042 Qts. (40 mL)
7-2-8 4480203
7-2-7 Removal and Reinstallation of Track Gauge Change Cylinder
1) Removal of Track Gauge Change Cylinder

Procedure
(1) Widen the track frame fully by operating the track gauge
change cylinder, and then remove the right rubber crawler
1.
Note :
Refer to Section "7-2-5 Removal and Reinstallation of
Crawler".
1
Rotating direction
Steel pipes
(2) Raise the machine using the implement and the blade,
and then place blocks under the lower center frame 2.
2
Note :
Place blocks which have sufficient height to allow work under
the lower center frame 2.
Blocks

hydraulic oil tank is positioned halfway between the right
and left crawlers, and then stop the engine.
(4) Remove the drain plug 3 from the hydraulic oil tank and
drain the hydraulic oil. 3
Hydraulic oil quantity 3.6 Gals. (13.8 L)
7-2-9 4480203
Procedure
(5) Remove the hose cover 4 and the motor cover 5, and
then remove the hydraulic hoses 7 from the right travel
motor 6.
6
Note : 7 5
Mark the hydraulic hoses 7 to identify their respective fitting T
positions.
P2 PS
7
(6) Remove the under cover (SJ) 8. P1
(7) Remove the plates 12 for the pin 10 at the rod end and
the pin 11 at the bottom end of the track gauge change 11
cylinder 9, and pull out the pins.
12
(8) Remove the right stopper bolt 13, and then pull out the 14 16
crawler frame (R) 14 from the lower center frame 2.
(9) Pull out the track gauge change cylinder 9 and remove
the hydraulic hose 15 on the bottom side. 13 9
(10) Turn the track gauge change cylinder 9 about 90
degrees, and then remove the hydraulic hose 16 on the A
rod side of the cylinder from the lower part of the lower
center frame 2.
2
15
(11) Remove the track gauge change cylinder 9 from the
lower center frame 2.
10
A
12
7-2-10 4480203
2) Reinstallation of Track Gauge Change Cylinder

Reinstall the track gauge change cylinder in the reverse order of the removal procedure.
Notes :
[1] Clean the square pipes of the crawler frames and the square pipe holes of the lower center frame.
[2] Apply heavy-duty grease to the four sides of each square pipe hole of the lower center frame over 7.9 in. (200
mm) from the entrance.
[3] Stopper bolt setting procedure:
After fully screwing the stopper nut onto the stopper bolt, loosen the nut one turn. Then tighten the bolt.
Setting length at the

widest track gauge : 0.47 in.
4.92 to in. (125mm) (12mm)
Stopper bolt and stopper nut (M16)

Tightening torque 123.0 to 151.9 ft•lbf
(166.7 to 205.9 N•m)
[4] Place the hoses for the track gauge change cylinder
in the outermost and undermost position of all the Track gauge change
cylinder
hoses connected to the swivel joint.
(This prevents the hoses from catching on any other Stopper bolt
hose when narrowing the track frame.)

[5] Check that the clearance between the stopper bolt
head and the hose fitting is 0.2 in. (5 mm) or more
when the track frame is narrowed fully.
[6] Hydraulic oil to be used :
Type YANMAR SUPER HYDRO OIL (VG

Hose
46 class) or its equivalent
Clearance :
0.2 in. (5 mm)
Swivel joint
7-2-11 4480203
7-3 Controls
7-3-1 Control Train
1) Control Lever (R) 2) Travel Levers (Travel Pedals) 3) Boom Swing Pedal
Control Lever (L) and High-Speed Pedal 4) Blade Lever
5) Lock Levers 6) Track Gauge Change Lever 7) Accelerator Lever
8) P.T.O.
7-3-1 4480203
7-3-2 Mechanical Control Linkage
1) Points of Assembly
(1) Use a jig to install the bushing into the link.
Bushing installation
Bushing press-fitting jig Press-fit

Unit : in. (mm)
Jig
Jig No.
L1
F-001 F-002 Bushing
L2
D 1.18 (30)
d 0.55 (14) 0.79 (20)
D
L1 4.72 (120) Link

L2 0.55 (14)
C0.0394
Notes : F-001 : Boom swing pedal link
C0.0394 (C1) (C1) P.T.O. pedal
R0.00787 (R0.2)
Operator’s seat mount
Bracket for high-speed travel
F-002 : Others
(2) Set the crevices of the control valve spools horizontally.

(3) However, the crevices of the travel (R) and (L) valve spools must be set vertically.
Spool
Crevice
Rod Travel (R) and (L)
Others
Crevice
(4) Apply grease to the links and take care not to damage the O-rings A when installing the links.
(5) Add grease to the grease nipples B after installation.
7-3-2 4480203
2) Tightening Torque and Mounting Angle for Rod Joints
Tightening torque : L-ball 8A
Tightening torque :
5.79 to 7.23 ft lbf
(7.8 to 9.8 N m)
Tightening torque :
9.40 to 12.3 ft
(12.7 to 16.7 N m)
L-ball mounting angle
s
ree
deg
90
The angle should be 90 degrees.
A
A
Joints for P.T.O. pedal
7-3-3 4480203
7-3-3 Adjustment of Control Levers

Adjust nut 5
1) Adjustment of Control Levers 2 (Width across flats : 22)
(1) Move the lever boot 1 upward and loosen the
lock nut 2. 1
(2) Adjust the right and left control levers 3 so that
the distance between them will be 18.7 in.
(476 mm) and also adjust the right control
lever 3 so that the distance between it and the
blade lever 4 will be 6.5 in. (165 mm).
(3) Adjust the right and left control levers 3 so that Tightening torque for lock nut
they will be in a straight line when viewed from Tightening torque : 54.3 to 61.5 ft lbf
(73.6 to 83.4 N m
the side.
(4) Holding the adjustable nut 5, tighten the lock
nut 2 at a specified torque (for each control In neutral position
lever). 6.5 in. (165 mm)
3
7.3 deg
rees
Lock lever
3 3
18.7 in. (476 mm)
The values in the figure sare reference ones.)
7-3-4 4480203
7-3-4 Adjustment of Travel Levers
1) Position of Travel Lever Grips Frame cover front end

Remove the step A and the frame L cover.
(1) Difference in side level between the right and
left lever grips : Within 0.12 in. (3 mm) 8.96 in.
(227.5 mm) Difference in side lever between both
(2) Adjustment lever grips : within 0.12 in. (3 mm)
2.44 in. 2.40 in. (in neutral and full stroke position)
Difference in side level (62 mm) (61 mm)
• Loosen the nut 1 of the L-ball and rotate the rod
2 to adjust the position of the lever grip to 8.96
in. (227.5 mm) from the frame cover front end
(for each lever grip).
• After adjusting the difference in side level
between both levers to 0.12 in. (3 mm) or less,
tighten the nuts 1.
2) Adjustment of Stopper Bolts

(For Forward Travel and Reverse)
(1) Loosen the lock nuts 4 of the stopper bolts 3.
(2) Screw in the stopper bolts 3 so that the travel 3
lever will not touch them. 4
(3) Move the travel lever to its stroke end, and
loosen the stopper bolt 3 until the bolt head
touches the travel lever (for each stopper
bolt). 4 1 2
(4) Loosen the stopper bolt 3 half a turn further
and tighten the lock nut 4 to fix it. 3
Mounting angle of L-ball Tightening torque :
s 9.40 to 12.3 ft lbf

ree (12.7 to 16.7 N m)
deg
90
Tightening torque :
5.79 to 7.23 ft lbf
(7.8 to 9.8 N m)
7-3-5 4480203
7-3-5 Adjustment of Boom Swing Pedal Boom swing pedal
1) Setting Pedal Level

Remove the frame L cover.
(1) Loosen the nut 2 of the L-ball 1.
(2) Adjust the boom swing pedal by turning the
rod 3 so that the pedal will be level.
(3) Tighten the nut 2 of the L-ball 1.
2) Adjustment of Stopper Bolts (For Right and

Left Boom Swing)
(1) Loosen the lock nuts 4 and screw in the stop-
per bolts 5 so that they will not touch the boom
swing pedal.
3.78 to 3.86 in.

(96 to 98 mm)
(2) Move the boom swing pedal to its stroke end,
and loosen the stopper bolt 5 until the bolt 5
head touches the pedal (for each stopper 4
bolt).
(3) Loosen the stopper bolt 5 one more turn and Adjust the length of the rod
for boom swing so that the pedal
tighten the lock nut 4 to fix it. will be level in the neutral position
1 2 3
In neutral position
7-3-6 Adjustment of Blade Lever

7.3 deg
rees
Remove the indicator box and the panel R, and
then remove the pilot valve (RH).
(1) Loosen the nut 1 and adjust the blade lever so
that it will be inclined forward at 7.3 degrees to Pirot valve (RH) Blade lever
the vertical line in the neutral position.
Indicater box
(2) Adjustment of stopper bolts 3 (for the blade up
and down)
[1] Loosen the lock nuts 2 and loosen the stopper
bolts 3 so that they will not touch the blade
lever.
[2] Move the blade lever to its stroke end, and
tighten the stopper bolt 3 until the bolt end Lock lever (R)
touches the blade lever (for each stopper 2 3
Panel (R)
bolt).
[3] Tighten the stopper bolt 3 one more turn and
tighten the lock nut 2 to fix it. 1
(124.7 mm)
4.91 in.
7-3-6 4480203
7-3-7 Adjustment of Lock Lever Switch

Lock
(1) Remove the panel L (UP) 1 and the pane L (LOW) 2. 1
(2) Move the lock lever 3 to the unlock position.
(3) Loosen the bolt 6 of the bracket 5 to adjust the
switch 4 so that the length shown in the figure will be
within the range from 0.18 to 0.22 in. (4.5 to 5.5 mm)
2
when the switch is fully pressed in.
Note : Unlock A
The implement should not operate even if the control
3
lever is moved when the lock lever is in the lock position.
4
m .
5 in
)
m
Tightening torque :
5. .22
21.7 to 25.3 ft lbf

to 0
.5 to
(29.4 to 34.3 N m)
(4 .18
Note : Overtorque may cause

0
damage to the switch.

Detail of A
Lock lever switch operation
Cut-off Imple-
Lever Switch Switch
valve ment
position state circuit 5
operation operation
6
Pushed
Unlock ON Operate Operate
Normal
Can not
Lock OFF Stop
operate
7-3-8 Adjustment of Track Gauge Change Con- 1

trol Lever
(1) Remove the side cover L 1.

(2) Loosen the nut 3 of the track gauge change cable 2.
(124.7 mm)
4.91 in.
In neutral position
4
10 degrees
3
5.2 in.
(132 mm) 2
7-3-7 4480203
7-3-9 Adjustment of Accelerator Lever
1. Adjustment of Minimum Idling Speed 4

(1) Loosen the stopper bolt 1, and then move the accel-
erator lever 4 forward. 5 A
(2) When the regulator handle 7 on the engine side 2
touches the stopper bolt 6 for the minimum idling 1
speed, check whether the minimum idling speed is
within a specified range (1125 to 1175 rpm).
(3) If the minimum idling speed is not within the range,
make adjustments to the speed by tightening or
loosening the stopper bolt 6 for the regulator handle
7. 3 9
(4) After the adjustment of the minimum idling speed,
screw in the stopper bolt 1 for the accelerator lever 4
until the bolt end touches the accelerator arm 3 and
fix it with the nut 2.
2. Adjustment of Maximum Idling Speed

(1) Move the accelerator lever 4 back until the regulator
handle 7 on the engine side touches the adjusting
bolt 8 for the maximum idling speed in the governor
case.
(2) Check that the maximum idling speed is within a
specified range (2125 to 2175 rpm).
(3) Make adjustments with the accelerator cable 5 in the
part A shown in the figure so that the stopper 9 for 8
the maximum idling speed for the accelerator lever 4
will touch the accelerator arm 3.
6
7-3-8 4480203
7-3-10 Adjustment of P.T.O. Pedal ln neutral position
1) Setting Pedal Level
3.78 to 3.86 in.

(1) Loosen the nut 2 of the L-ball 1.
(96 to 98 mm)
5
(2) Adjust the P.T.O. pedal by turning the rod 3 so that
the pedal will be level.
(3) Tighten the nut 2 of the L-ball 1.
4
2) Adjustment of Stopper Bolts (on Both Sides)

(1) Loosen the lock nuts 4 and screw in the stopper
bolts 5 so that they will not touch the P.T.O. pedal.
(2) Move the P.T.O. pedal to its stroke end, and loosen
the stopper bolt 5 until the bolt head touches the
pedal. (for each stopper bolt)
(3) Loosen the stopper bolt 5 half a turn further and
tighten the lock nut 4 to fix it. 1
3) Adjustment of Pedal Lock
5.04 in
(1) After the adjustment of the pedal stroke, move the 2
. (128
P.T.O. pedal to its stroke end on the left and place
3
the P.T.O. pedal lock 6 on the P.T.O. pedal. mm)
(2) Adjust the clearance H between the P.T.O. pedal
lock 6 and the P.T.O. pedal to 0.08 in. (2 mm) or less
with the nut 7.
(3) Adjust the operating force for the P.T.O. pedal lock 6
at the end A, with the U nut 8, to a value within a
specified range : 2.2 to 4.4 lbs. (1.0 to 2.0 kg). 5.31 in. (135 mm)
P.T.O pedal
Pedal
8
9
7-3-9 4480203
7-3-11 Adjustment Procedure of Travel Alarm

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

(2) Loosen bolt 4 (2 pcs.) of bracket 3 of travel alarm
switch 2.
(3) Adjust the distance between the travel lever arm 5
and the travel alarm switch 2 to 0.02 in. (0.5 mm) or
less.
Note :
Make the clearances A and B equal.
Travel lever
A Travel lever
2 1 neutral position
B
5 4
0 to 0.02 in.
(0 to 0.5 mm)
3
Tightening torque :
21.7 to 25.3 ft lbs.
29.4 to 34.3 N m
7-3-10 4480203
7-4 Swing Bearing 1 3 2

1) Removal and Reinstallation of Swing Bearing
4
(1) Remove the implement.
Refer to Section "7-6-1 Removal and Reinstallation
of Implement".
(2) Remove the engine.
of Engine".
(3) Remove the swing motor.
of Swing Motor".
(4) Remove the hydraulic hoses from the swivel joint.
of Swivel Joint".
2
(5) Rope the turning frame 1 at three points and sus-
pend it temporarily.
1
(6) Remove the seven mounting bolts 2 with which the
turning frame 1 is mounted on the outer race of the
swing bearing.
(7) Lift up the turning frame 1.
(8) Remove the eighteen mounting bolts 3 with which
the inner race of the swing bearing is mounted on
the track frame.
(9) Remove the swing bearing 4.
2) Points of Installation
The inner and outer races of the swing bearing have a Soft zone S
3 Soft zone of
soft zone, and the soft zone of the inner race is marked of inner race outer race
with "S".
The soft zone of the outer race is located at the steel ball
insertion port.
To reduce the load to be applied to the soft zones, as 4 Steel ball
insertior port
shown in the figure at the right, install the swing bearing
with the "S" mark on the right side of the track frame and
the steel ball insertion port on the left side of it.
7-4-1 4480203
3) Service Standards
Standard Wear limit
Axial clearance B
Outer race
Dial gauge Load 441 lbs. (200 kgf)
0.0012 to 0.0059 in. 0.0157 in.
B
(0.03 to 0.15 mm) (0.4 mm)
Outer race PCD
Radial clearance A
Load 55 lbs. 0.0012 to 0.0098 in. 0.0197 in.
A
(25 kgf) (0.03 to 0.25 mm) (0.5 mm)
Inner race
Ø0.6946 in.
Steel ball diameter 
(Ø17.6425 mm)
M12!25
Tuning frame!outer race 79.6 to 94.0 ft·lbf Apply Loctite 262
Tightening torque (10.9 T) M12!40
Track frame!inner race (107.9 to 127.5 N·m) or its equivalent.
M12!45
Note :
Put multipurpose grease into the swing bearing.
4) Parts of Swing Bearing

5 7 1, 4 2 6
No. Part Q'ty
1 Steel ball 66
2 Seal A 1
3 Seal B 1
8
4 Support 66
5 Outer race 1
6 Inner race 1
7 Taper pin 1
8 Plug 1
3
5) Inspection
(1) Check the gear teeth surfaces for nicks, flaws, cracks, wear and breakage. Replace the swing bearing if the
damage is excessive.
(2) Check for abnormal sound. Clean, grease or replace the swing bearing if necessary.
(3) Check the inner and outer races for play and irregular rotation. Refer to the service standards for repair or
replacement.
(4) Check for grease leak from the swing bearing seal. Replace the swing bearing if the leakage is excessive.
7-4-2 4480203
7-5 Hydraulic Equipment
7-5-1 Removal and Reinstallation of Hydraulic Pump

1) Removal
Procedure
and left crawlers. Then, lower the bucket to the ground
and stop the engine. 1
2
(2) Remove the under cover 2.
(4) Remove the step A 3, the frame L cover 4, the bonnet L 5

and the covers A 6 and B 7.
7-5-1 4480203
Procedure
(5) Remove the mounting bolts 9 for the drain block 8, and
then remove the hose 10 (the drain block to the hydraulic 10
oil tank).
11
(6) Remove the hydraulic oil tank stay B 11.
8 9
(7) Remove the hydraulic hoses from the hydraulic pump 12.
a. Hose P1 b a
b. Hose P2
c. Hose P3
d. Hose PA
13
e. Hose PB1
f. Hose PB2
P1
(8) Disconnect the harness connector of the cut-off valve.
P2
(9) Remove the mounting bolts 13 and remove the hydraulic P3
pump 12.
c
PA 12
d PB2
PB1
7-5-2 4480203
2) Reinstallation
Reinstall the hydraulic pump in the reverse order of the removal procedure.
Notes :
• Apply heavy-duty grease to the spline shaft of the hydraulic pump.
Hydraulic pump installation bolt M12
• Hydraulic oil to be used :

46 class) or its equivalen
• After the installation of the hydraulic pump, make a test run and operate the relief valves to check for oil leak or
other abnormality.
7-5-3 4480203
7-5-2 Removal and Reinstallation of Control Valve
1) Removal
Procedure
hydraulic oil tank and the under cover (CV) 2 are posi-
tioned halfway between the right and left crawlers. Then,
lower the bucket to the ground and stop the engine. 1
(2) Remove the under cover (CV) 2.

2
1
2
(4) Remove the step A 3, the frame L cover 4 and the step rib 5
5.
Note :
Remove the plate a before removing the step rib 5. a
3 4
(5) Remove the hydraulic hoses and the pilot hoses from the P1 P1 P1
control valve 6. 6 A1 B1 Boom sming
A2 B2 Boom
Notes : A3 B3 Bucket
• Remove the hydraulic hoses and the pilot hoses from the A4 B4 Travel (R)
control valve in left-to-right order. A5 B5 Blade
• Mark the removed hoses to identify their respective fitting A6 B6 P.T.O.
positions. Front A7 B7 Swing 2
A8 B8 Arm Hose
A9 B9 Travel (L) removal
A10 B10 Swing order
A11 B11 Track gauge change
P2 T2 P2
7-5-4 4480203
Procedure
(6) Remove the nuts 12 from the L-balls 11 connected to the
boom swing section 7, the travel (R) section 8, the P.T.O. 14
section 9 and the travel (L) section 10, to disconnect
those sections from the links 13.
13
(7) Remove the pins 16 to disconnect the cable 14 connected 12
to the blade lever and the cable 15 connected to the track
15
gauge change lever from the spools of the control valve 6. 16
7 16
11 8
13
6
11 9
12 11
13
12
11
13 10
12
(8) Remove the mounting bolts 17, and then remove the con-
trol valve 6 from the valve plate 18.
18
17
7-5-5 4480203
2) Reinstallation
Reinstall the control valve in the reverse order of the removal procedure.
Notes :
[1] Install the hoses so that each of them is not in contact with any other hoses or parts.

[3] After the installation of the control valve, raise the hydraulic oil temperature to 122 to 140 °F (50 to 60 °C) and
operate the relief valves, to check for oil leak.
Connector and joint setting angle
P1 T1
es
egre
A1 B1
35 d
Pa 2 A2 B2 Pb 2
Pa 3 A3 B3 Pb 3
A4 B4
es
A5 B5 30 degre
Machine
front
A6 B6
Pb 7
es
Pa7
gre
A7 B7
de
45
Pa8 A8 B8 Pb 8
A9 B9
Pa 10
A10 B10 Pb 10
A11 B11
P2 T2
7-5-6 4480203
7-5-3 Removal and Reinstallation of Swing Motor
1) Removal
Procedure
and stop the engine.
1
4.
Note :
Remove the plate 5 before removing the step rib 4. 5
2 3
(4) Remove the joint 6 (with the hose) from the pedal mount
7.
7
7-5-7 4480203
Procedure
(5) Remove the hydraulic hoses from the swing motor 8.
* Hose 9 (control valve to swing motor)
* Hose 10 (control valve to swing motor)
* Pilot hose 11 (cut-off valve to swing motor)
(6) Remove the drain hose 12 from the T-elbow nipple 3/8 13. T
AV
BV
P
10 11
9
12 13
(7) Remove the mounting bolts 14 and remove the swing

motor 8. 14
7-5-8 4480203
2) Reinstallation
Reinstall the swing motor in the reverse order of the removal procedure.
Notes :
Swing motor mounting bolt (M12)
Adhesive Apply three bond 1324 or its equivalent.
[1] Install the hoses so that each of them is not in contact with any other hoses or parts.

[3] After the installation of the swing motor, raise the hydraulic oil temperature to 122 to 140 °F (50 to 60 °C) and
operate the relief valves, to check for oil leak.
7-5-9 4480203
7-5-4 Removal and Reinstallation of Swivel Joint
1) Removal
Procedure
(1) Operate the implement and the blade to raise the
machine.
(2) After raising the machine, place blocks under the

machine.
Notes :
• To prevent the machine from dropping down, be sure to
place blocks under it.
• Place blocks which have sufficient height to allow work
under the machine.
Blocks

1
(4) Remove the under cover (SJ) 2.
1
2
5.
Note :
Remove the plate a before removing the step rib 5. a
3 4
7-5-10 4480203
Procedure
(7) Remove the hydraulic hoses from the swivel hub of the
swivel joint. D I Swivel joint
I : For travel motor (R) (reverse)
D : For travel motor (R) (forward travel) J I
J (L) : For travel motor (R) (drain) (L) F G
F: For blade cylinder (bottom side) J
H (K) : For high-speed (R) D
F B
H : For high-speed (L) H G
B : For track gauge change cylinder (bottom side)
A : For track gauge change cylinder (rod side) H J
J
E : For blade cylinder (rod side) (K) A C
E
C : For travel motor (L) (reverse)
J : For travel motor (L) (drain) C
H
G : For travel motor (L) (forward travel) A
E
Notes :
• Remove the hydraulic hoses from the swivel hub in bottom-
to-top order.
• Mark the removed hoses to identify their respective fitting
positions.
(8) Remove the mounting bolts for the swivel joint.
(9) Remove the hydraulic hoses from the control valve.

A : For track gauge change cylinder (rod side)
C : For travel motor (L) (reverse)
I : For travel motor (R) (reverse) D F
E : For blade cylinder (rod side) E
D : For travel motor (R) (forward travel) G
F : For blade cylinder (bottom side) I B
G : For travel motor (L) (forward travel)
B : For track gauge change cylinder (bottom side)
Note :
Mark the removed hoses to identify their respective fitting C
positions.
A B4 B5
A5
(10) Take down the swivel joint (with the hydraulic hoses con-
nected to the swivel shaft) to the lower center frame and A4 B9
remove it.
B11
A9
A11
Control valve
7-5-11 4480203
2) Reinstallation
Reinstall the swivel joint in the reverse order of the removal procedure.
Notes :
[1] Wrap seal tape around the connectors before installing them.
[2] Install each connector at a specified mounting angle.
Swivel joint mounting bolt (M10)
Adhesive Apply Three Bond 1324 or its equivalent.

Deveropment connecter mounting angles

Travel motor side
J B
A G
I
E
F C
D H
F E
J I D C G
A H B
F
45
deg
E
s
ree
ree
I
deg
s
10
rees
45
deg
5 deg
ree
G
H
s
D
C
B 15 degrees
15 degrees A
Viewed from blade
7-5-12 4480203
7-5-5 Disassembly and Reassembly of Swivel Joint

The swivel joint is used to prevent the hydraulic piping from twisting when the upperstructure swings. The swivel
joint consists of a shaft, a hub, a seal kit and other parts. The shaft and hub have holes and grooves, and the oil
which flows in from the port of the shaft, passing through the hub groove, is fed to the actuators of the undercarriage.
13
9
7
8
2
4
2
11
12 6
10
5
14

1 Swivel seal kit 1 8 Swivel shaft 1
2 O-ring 55.76!5.7 2 9 Dowel pin 10!25 1
3 Swivel seal 9 10 Swivel flange 1
4 Back-up ring EL 1 11 Thrust washer 40!66!2.5 1
5 O-ring 1A G70.0 NBR 1 12 External snap ring C40 1
6 Swivel hub 1 13 Screw plug R (PT) 1/8 8
7 Swivel shaft 1 14 Bolt (with spring washer) 8!35 3
7-5-13 4480203
2) Disassembly and Reassembly of Swivel Joint

13
• Disassembly
(1) Remove the bolts 14.
(2) Remove the swivel flange 10 and the O-ring 5.
(3) Remove the external snap ring C 12 and the thrust 7
washer 11 from the swivel shaft 7.
(4) Pull the swivel shaft 7 out of the swivel hub 6 and
remove the O-ring 2.
(5) Remove the swivel seals 3, O-ring 2 and back-up 2
ring 4 from the swivel hub 6. 4
2
• Reassembly
(1) Install the swivel seals 3, O-ring 2 and back-up ring
4 into the swivel hub 6.
3
(2) Apply multipurpose grease to the inner surface of
the swivel hub 6.
(3) Install the O-ring 2 onto the swivel shaft 7 and
insert the shaft into the swivel hub 6 slowly.
• Use a jig (E-004 B).
11 6
• Apply multipurpose grease to the outer surface
of the shaft. 12
(4) Install the thrust washer 11 and the external snap
ring C 12 to the swivel shaft 7. 10
(5) Install the O-ring 5 and then the swivel flange 10 5
on the swivel hub 6, and install and tighten and
bolts 14. 14
Insertion of shaft
Shaft insertion jig No.E-004B
Unit : in. (mm)
)
1
(R
2.756 (70)
3 94
.0
0.87(22)
R0
Swivel shaft 7
C0.02 (C0.5)
Insertion jig
Swivel seal 3
Swivel hub 6
R0.00394 (R0.1)
Note : The areas must be hard chromium plated.
7-5-14 4480203
3) Precautions for Handling and Storing Seals

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

• Fitting
(1) Use lithium soap base multipurpose grease (cone penetration
No.1 or No.2).
(2) To fit a swivel seal, make it heart-shaped as shown in the fig-
ures at the right and press one end of it into the groove.
Then, fit the whole swivel seal, pressing it with your finger
(Figs. 1 and 2). Fig. 1 Fig. 2
(3) When using a jig for fitting swivel seals, use a jig with round
edges to avoid damaging the seals. (Fig. 3)
(4) If the swivel seal is distorted after fitted, correct the distortion
with a jig before assembly. (Fig. 4)
5) Repair and Replacement of Parts

(1) Disassemble and reassemble the swivel joint at a place free
from dust. Fig. 3 Fig. 4
(2) Completely remove the contamination, foreign matter
(sludge), etc. from the removed parts.
(3) Check the seal surface of the shaft for flaws and nicks.
Repair or replace the shaft when necessary.
(4) Replace the shaft if it is worn.
(5) Replace all seals in reassembly.
7-5-15 4480203
7-5-6 Disassembly and Reassembly of Hydraulic Cylinders
1) Sectional View and Component Parts
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16
Track gauge
Boom Arm Bucket Boom swing Blade
No. Part change
cylinder cylinder cylinder cylinder cylinder
cylinder
1 Dust seal $ $ $ $ $ $
2 Lock washer $ $ $ $ $ $
3 O-ring $ $ $ $ $ $
4 Head $ $ $ $ $ $
5 O-ring $     
6 ISI packing $ $ $ $ $ $
7 Back-up ring $     
8 O-ring $ $ $ $ $ $
9 Cylinder tube $ $ $ $ $ $
10 Cushion collar $     
11 Cushion plunger $     
12 RGU packing $ $ $ $ $ $
13 RWL bearing $ $ $ $ $ $
14 Piston $ $ $ $ $ $
15 U-nut $ $ $ $ $ $
16 Rod $ $ $ $ $ $
7-5-16 4480203

(1) Parts are high precision-made. Be careful not to damage any parts by dropping them or knocking them together
when handling them.
(2) If there are any burrs on the surface of seal installation parts or O-ring grooves, remove them.
(3) Never use the lock washer removed once.
(4) Replace once removed seals and O-rings with new ones.
(5) Clean all the parts and dry them by air blow.
3) Disassembly
Procedure
(1) Drain the oil from the hydraulic cylinder. Pipe
Cylinder
(2) Hold the cylinder at the bottom end or using the pin hole Jig
Hook wrench
at the bottom end, and put the rod side of the cylinder on
a block.
(3) Raise the pawl of the lock washer 2 on the head 4 and
loosen the head 4.
Note : 4 2
Use a hook wrench or a jig to loosen the head 4. Bolt
Adjuster
(4) Pull out the rod assembly 16 from the cylinder tube 9, and
then hold the cylinder rod assembly at the rod end or
using the pin hole at the rod end.
16
Hold cylinder rod assembly
(5) Disassembly of boom cylinder

Remove the U-nut 15, and then the piston 14, the cushion
plunger 11, the cushion collar 10, and the head 4 in that 14
order. 11
10
4
9
16 15
7-5-17 4480203
Procedure
(6) Disassembly of bucket, arm, boom swing, blade and track
gauge change cylinders
Remove the U-nut 15, and then the piston 14 and the 15
head 4 in that order. 14
4
16
9
(7) Remove the O-rings 3, 5 and 8, the dust seal 1, the ISI
packing 6, the RGU packing 12 and the PWL bearing 13. 7
5
Note : 3
Use a sharp tool to raise each of the O-rings, the ISI packing,
the RGU packing or the PWL bearing, and then insert a spat- 4 6
ula to remove it.
8
1
12, 13
14
7-5-18 4480203
4) Reassembly
Reassemble the hydraulic cylinder in the reverse order of the disassembly procedure.
Notes :
• Take care not to install the cushion plunger 11 of the boom cylinder in the wrong direction.
• Replace the O-rings, packings and seals with new ones.
11
Head side
U-nut Size end Tightening Torque

No. Cylinder U-nut size U-nut tightening torque Adhesive
361.7 to 434.0 ft•lbf
1 Boom M24
(490.4 to 588.4 N•m)
361.7 to 434.0 ft•lbf
2 Arm M24
(490.4 to 588.4 N•m)
217.1 to 253.3 ft•lbf
3 Bucket M20
(294.3 to 343.4 N•m)
Three Bond 1324 or its equivalent
361.7 to 434.0 ft•lbf
4 Boom swing M24
(490.4 to 588.4 N•m)
217.1 to 253.3 ft•lbf
5 Blade M20
(294.3 to 343.4 N•m)
217.1 to 253.3 ft•lbf
6 Track gauge change M20
(294.3 to 343.4 N•m)
7-5-19 4480203
7-5-7 Hydraulic Oil Tank
1. Structure and Component Parts
12
6 7
5 6 8
13 12
13 9
10
11

1 Return flange 1 8 Bolt M10 1
2 Return filter 1 9 O-ring 1A G75.0 1
3 Oil supply port cap 1 10 Suction filter 1
4 O-ring 1A G85.0 1 11 Suction flange 1
5 Hydraulic oil tank 1 12 Bolt (with spring washer) 8!16 7
6 O-ring 4 13 Bolt (with spring washer) 12!25 3
7 Oil level gauge 1
7-5-20 4480203
2. Removal and Reinstallation of Hydraulic Oil Tank

1) Removal
Procedure
(2) Remove the drain plug 1 from the hydraulic oil tank and 1
(3) Remove the step A 2, the panel L (UP) 3, the panel L 5

(LOW) 4, the indicator box 5 and the panel R 6, and then 3
disconnect the harness connectors.

cable (positive) 8 and remove the battery clamp 9. Then 8 7
remove the battery 10.

10
11
7-5-21 4480203
Procedure
(6) Remove the side cover 13, the frame R cover 14 and the
bonnet R 15.
(7) Remove the step rib 16, the frame L cover 17, the covers
A 18 and B 19, the hydraulic oil tank cover 20 and the
bonnet L 21.
15 21
20
Note :
Remove the plate a before removing the step rib 16.
a
18
14
19
13 17
16
(8) Remove the operator's seat plate 23 (with the operator's

seat 22), and then remove the operator's seat plate 23. 22 26
25
(9) Remove the snap pin 25 and disconnect the accelerator
cable 24 from the accelerator lever 26.
24
23
(10) Remove the nuts 29 from the L-balls of the cable 27 con-
nected to the blade lever and the cable 28 connected to 27 29 28 29
the track gauge change lever, and disconnect those
cables from the levers.
7-5-22 4480203
Procedure
(11) Disconnect the harnesses 30, 31 and 32 from the lock
lever switches L and R and the horn switch respectively.
33 45
(12) Disconnect the harnesses 33 and 34 from the starter
switch and the fuel gauge unit respectively. 32
(13) Disconnect the connectors 37 of the harnesses A 35 and
B 36 from each other. 31
34
(14) Disconnect the connectors 39 of the fuse wire 38 and the
harness B 36 from each other, and disconnect the body
ground terminal 40. 30
(15) Disconnect the connectors 41, 42, 43 and 44 of the high- 39
speed travel switch, the horn, the boom light (working
35
lamp) and travel alarm switches respectively.
(16) Remove the bracket 45 from the operator's seat mount 38

51. 37 36
40
43 42 41
44
(17) Remove the canopy 46.
(18) Remove the bracket UP 47 and the filler 48.
(19) Loosen the hose clip 50 on the intake manifold side and
remove the air cleaner hose B 49 from the intake mani-
fold.
(20) Rope the operator's seat mount 51 (with the bonnet A

and the air cleaner assembly 52) and lift it up, to remove 46
it.
47 48 52
Note :
Take care that the harnesses and clamps do not catch on any
other parts when lifting up the operator's seat mount.
49
50
51
7-5-23 4480203
Procedure
(21) Remove the hoses connected to the hydraulic oil tank
53. 53
a. Suction hose
b. Return hose (control valve to hydraulic oil tank)
c. Return hose (joint to hydraulic oil tank)
Note :
Remove the return hose from the joint.
d. Hydraulic oil drain hose 54
(22) Remove the feed pump 54 (with the fuel hose) from the
hydraulic oil tank 53.
(23) Remove the mounting bolts 55 and remove the hydraulic 55

oil tank 53.
d
2) Reinstallation
Reinstall the hydraulic oil tank in the reverse order of the
removal procedure.
Notes :
[1] Completely drain the oil from the hydraulic oil tank and
wipe off the deposits from the bottom of the tank.
2
[2] Replace the return filter 2 with a new one.
[3] Clean the suction filter 10. Replace it if the wire gauze is
damaged.
[4] Replace the oil when it reaches the replacement time or
it has been deteriorated. If reusing the oil, maintain the
oil quality so that it has no impurities.
[5] Check the O-rings 6 of the oil level gauge 7 for oil leak.
If any oil leak is found, replace the O-ring. 6 76

10
7-5-24 4480203
3) Oil Level Check

(1) Place the machine on firm and flat ground when check-
ing the hydraulic oil level. Upper limit
(2) Check the hydraulic oil level with the oil level gauge 0.394 in. (10 mm) Float
when the oil temperature is between 32 °F (0°C) and
Middle
86°F (30°C).
(3) The proper oil level is 0.394 in. (10 mm) above the mid-
dle of the oil level gauge. The hydraulic oil level Lower limit
increases or decreases depending on the hydraulic oil

temperature due to its nature; therefore, check it when
the oil is cooled. Oil level gauge
4) Machine Position for Oil Level Check

(1) Retract the bucket and arm cylinder rods fully to lower
the bucket to the ground.
(2) Lower the blade to the ground.
Machine position
7-5-25 4480203
7-5-8 Piping Layout

1) Upperstructure
(Hydraulic oil tank → Hydraulic pump → Control valve)
P2 P1
A
B
Hydraulic tank
Hydraulic pump
D
5 degrees
C
P1
P2 P3
45 degrees 45 degrees
Viewed from D
B
Control valve
P1 P1 P1
A1 B1 Boom swing
A2 B2 Boom
A3 B3 Bucket P1
A4 B4 Travel (R)
A5 B5 Blade P2
A6 B6 P.T.O.
A7 B7 Swing 2
Front
A8 B8 Arm
A9 B9 Travel (L)
A10 B10 Swing
A11 B11 Track gauge change
P2 T2 P2
7-5-26 4480203
2) Upperstructure
(Control valve ←→ Swing motor)
(Control valve ←→ Boom cylinder)
BV AV G
F
35 degrees
P
H
AV B
BV
P L
Viewed from Y
A
E K B2
Y
B3
B C B6
J
A6
A B8
A3 B10
A2
D A8 A10
K D
E F G Hydraulic pump Z
L Swing moter
Control valve
C
P3
5 degrees
P1
J
P2 P3
H
45 degrees 45 degrees
Boom cylinder
Viewed from Z
7-5-27 4480203
3) Upperstructure
(Implement)
I
E F G H
Arm cylinder
L
A B C D
I
J K
J L
K
M
E
N
F
G H
A
B
M C
N O D
Bucket cylinder
7-5-28 4480203
4) Upperstructure
(Hydraulic pump → Swivel joint)
(Control valve → Swivel joint)
(Control valve → Boom swing cylinder)
A
E
F
I
B
G
D A E
F
I PA
B H
G
D
C
H
C
H
Hydraulic pump
Swing cylinder
Swivel joint
Control valve
F
D
G
K
J
B
J
E
I
B5
B1 B4
C
A1 B9
K
A
A5 B11
A4
A9 A11
7-5-29 4480203
5) Upperstructure
(Control valve, Swivel joint → Hydraulic oil tank)
(Hydraulic pump → Swing motor → Control valve)
B
A
Swivel joint
Swing motor
C
D
Hydraulic oil tank
E D
Control valve
H
F
B E
A
T1 F
b7
b10
H
T2
a7 a10
7-5-30 4480203
6) Pilot Control for Implements

(Hydraulic pump → Pilot valves → Control valve)
Viewed from top
T 2 T 2
3 3
1 1
T
2 2 4 P 4 P
1 3 T P 3
4 1 4 Right Front Left
P
N E
4
C D H 2 C
B P O G
A M E
F K C
1
3 B
D
A
A G
Pilot valve (R)

J
I
Pilot valve (L)
L
B2
B1
Hydraulic pump
2 way valve O
K B
F
L
b2
b3
Control valve I
b7
b8
P a2
D
a3 J
a8
a10
H
N
7-5-31 4480203
7) Undercarriage
(Swivel joint → Travel motor)
(Swivel joint → Blade cylinder)
(Swivel joint → Track gauge change cylinder)
L I
D
T I
F
J
L P2
PS
D
G
P1 D F B
H G
I K
D J C
B A
C
H E
F A
E
Travel motor (R) Z
M E
N
Travel motor (L)
Swivel joint
Track gauge
change cylinder
H PS
Blade cylinder
T P1
P2
M
N J
A C
45 degrees E
F
G 45 degrees
I
5 degrees G 10 degrees
H
D
C
15 degrees
B
15 degrees A
J
B
Viewed from Z
7-5-32 4480203
7-6 Implement
7-6-1 Removal and Reinstallation of Implement
Notes :
• When removing a pin, check the number of shims installed and their positions.
• When removing a hose, put a plug into the hose connection port to keep the oil from flowing out.
1) Removal of Bucket
Procedure
(1) Lower the bucket 1 to the ground with its back face down.
(2) Remove the bolts 2 (M10) and remove the pins 3.
(3) Remove the bucket 1. 2 3
7-6-1 4480203
2) Removal of Arm
Procedure
(1) Remove the bucket.
1
(2) Remove the bolts 1 (M10) and pull out the pins 2. Then 5
remove the bucket link 3 and the bucket arms 4.
(3) Lightly place the top end of the arm 5 on the ground per- 5
pendicularly to the ground.
2 Approximately
90 degrees
4
3 4
(4) Remove the hydraulic hoses from the bucket cylinder 6,

and remove the bolt 7 (M10) to pull out the pin 8. Then
remove the bucket cylinder 6. Rope
Note : 8
Rope the bucket cylinder and remove it using a lifting device.
(5) After roping the arm 5, remove the bolt 10 (M10) and
remove the pin 12 from the arm cylinder 11 (on the rod Rope Block 11
side).
Note :
Place a block under the arm cylinder.
(6) Remove the bolt 13 (M10) and pull out the arm pin 14.
Then remove the arm 5 using a lifting device.
14
12 13
10
5
7-6-2 4480203
3) Removal of Boom
Procedure
(1) After raising the boom 12 fully, remove the slide cover 2
from the boom cylinder 1. 1
(2) Place the top end of the boom 12 on the ground.

12
Note :
Install an expansion plug to the connector from which the 2
hydraulic hose has been removed and start the engine.
(3) After roping the arm cylinder 3, remove the hydraulic

hoses from the arm cylinder. 5
Rope
(4) Remove the bolt 4 (M10) and pull out the pin 5. Then
remove the arm cylinder 3. 4
Note : 3
Remove the arm cylinder using a lifting device.
(5) After roping to the boom cylinder 1, remove the hydraulic

hoses from the boom cylinder. 7 Rope 7
6
(6) Remove the bolts 6 (M10) and pull out the pins 7. Then
remove the boom cylinder 1.
6
Note :
Remove the boom cylinder using a lifting device.
(7) Disconnect the connectors 8 of the boom light wiring har-

ness.
7-6-3 4480203
Procedure
(8) Remove the mounting bolts for the bucket L tube 9 and
the bucket R tube 10.
(9) Remove the hose A clamp 11.

11
10
(10) After roping the boom 12, remove the bolt 13 (M10) and
pull out the pin 14. Then remove the boom 12. Rope
Notes : 12
• Remove the boom using a lifting device.
• Take care that the hoses do not catch on any other parts.
14
13
7-6-4 4480203
4) Removal of Blade
Procedure
(1) Turn the implement to the blade side, lower the bucket
and the blade 1 to the ground and stop the engine. 6
3
(2) Remove the protector 2 and remove the hydraulic hoses. 7
4
(3) Remove the bolts 3 (M10) and pull out the pins 4. Then
remove the blade cylinder 5.
(4) After roping the blade 1, remove the bolts 6 (M10) and
pull out the pins 7. Then remove the blade. 2
Note : 3
Remove the blade using a lifting device. 4 5
7-6-5 4480203
5) Removal of Boom Bracket

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

Refer to Section "7-6-1 2) Removal of Arm". 3
(3) Remove the boom 3.

Refer to Section "7-6-1 3) Removal of Boom".
2
(4) Remove the bolt 4 (M12) and pull out the pin 5 (for the
boom swing cylinder).
1
(5) Remove the bolt 6 (M12) and the snap ring C 7, and pull
out the pin 8. Then remove the boom bracket 9.
Note :
Rope the boom bracket and remove it using a lifting device. 7
5
9
4 6
7-6-6 4480203
6) Removal of Boom Swing Cylinder

Procedure
(1) Swing the upperstructure so that the pin 1 at the bottom
end of the boom swing cylinder is positioned halfway
between the right and left crawlers. Then, lower the
bucket to the ground and stop the engine.
(2) Remove the frame R cover 2, and then remove the

hydraulic hoses 4 from the boom swing cylinder 3.
(3) Remove the bolt 5 (M12) and pull out the pin 6 at the rod
2
end of the boom swing cylinder 3.
(4) Remove the plate 7 and pull out the pin 1 at the bottom
end of the boom swing cylinder 3.
(5) Remove the boom swing cylinder 3 from the turning frame
8.
3
1
5 8
7-6-7 4480203
7) Reinstallation
Reinstall the implement in the reverse order of the removal procedure.
3
1
10
9
8
6
7
Tightening Torque and Adhesive
No. Size Tightening torque Adhesive
1 M10
2 M10
3 M10
32.6 to 43.4 ft·lbf (44.1 to 58.8 N·m)
4 M10 Apply Three Bond 1324 or its equivalent.
5 M10
6 M10
7 M12
57.9 to 72.3 ft·lbf (78.5 to 98.1 N·m)
8 M12 
9 M10 32.6 to 43.4 ft·lbf (44.1 to 58.8 N·m) Apply Three Bond 1324 or its equivalent.
10 M10 
7-6-8 4480203
CHAPTER 8
PERIODIC INSPECTION AND SERVICING
8-1 List of Periodic Inspection and Servicing .................................................8-1

8. PERIODIC INSPECTION AND SERVICING
8. Periodic Inspection and Servicing
8-1 List of Periodic Inspection and Servicing
% : Check $ : Supply & : Replace " : Adjust (clean) # : Oil & grease
Every Every Every Every Every
Check & service items Daily
50 100 250 500 1000 hrs
Check falling off, breakage of parts %
Check loosened bolts & nuts, retighten %
General
Check engine condition %
Clean "
Check, resupply %/'
*Swing gear case oil
Replace &1st time &
Check, resupply %/'
Travel reduction gear oil
Replace &1st time &
Lube oil
Check, resupply %/'
*Transmission oil
Replace &1st time &
Check, resupply %/"
*Differential gear oil
Replace &1st time &
Check, resupply %/'
Hydraulic oil
Replace &
Hydraulic Clean suction filter "1st time "
system &
Replace return filter &
1st time
Check for abnormality of hydraulic pump %
Check grease-up positions, grease #
Greasing the swing gears and the swing bear-
#
Grease ings
Greasing the track gauge change cylinder and
#
the link fulcrum
Undercar- Check, adjust track tension %/"
riage *Check air pressure, wear, flaw in tyres %
*Check performance, play of steering lever %
Check performance, play of travel lever %
*Check performance of speed change lever %
*Check performance of forward/reverse pedal %
Steering *Check performance, play of steering wheel %
equipment Stroke %
*Brake pedal
Performance %
Stroke %
*Parking brake
Performance %
Check performance of accel. lever %
Check front & work lights, horn %
Check hourmeter function %
Check function of change, oil and pilot lamps %
Electric Check wire breakage, short-circuits, loosened
%
equipment terminals retighten
Check, resupply battery fluid %/'
Check specific gravity of electrolyte "As required
Check function of OK monitor %
8-1 4480203
8. PERIODIC INSPECTION AND SERVICING
% : Check $ : Supply & : Replace " : Adjust (clean) # : Oil & grease
Every Every Every Every Every
Check & service items Daily
50 200 400 1000 2000 hrs
Check & supply of oil to the tank %/'
Drain the fuel tank "
Fuel oil
Clean the oil/water separator "
Replace the fuel filter element, pre-filter &
Check the quantity of engine oil %/'
& &
Replace the engine oil
Lube oil 1st time
& &
Replace the engine oil filter element
1st time
Check & supply of cooling water %/'
Clean radiator fins "
Cooling
Check the fan-belt tension %/"
water
Replace the cooling water &
Clean & check the cooling water system &within one year
Rubber hose Check & replace fuel oil pipe, cooling water pipe &
Operation
Check & adjust governor lever, accelerator % "
system
Intake sys- Clean air cleaner & replace element " &
tem *Check turbocharger, adjust "
Cylinder Adjust the intake and exhaust valve clearance "
head Lapping the intake and exhaust valve "
Check fuel valve nozzle, clean "
Fuel pump &
Check & adjustment of fuel injection pressure &
injection "
atomizing condition
valve
Check fuel pump, adjust "
*Applicable to models with the relevant equipment
Note :
• When machine is used at dusty worksites clean and replace filter element twice or more frequently than specified
in the table.
• Execution of periodic inspection and servicing is indispensable to conform the EPA emission control regulations.
Keep a record of the results.
8-2 4480203
CHAPTER 9
FUEL, LUBE OIL AND GREASE RECOMMENDED
9. Fuel, Lube Oil and Grease Recommended ...............................................9-1

9. REFERENCE DATA
9. Fuel, Lube Oil and Grease Recommended
Item Type
Engine oil Engine oil SAE 10W30, CD class
Travel reduction gear oil Gear oil SAE90 (GL-4)
Hydraulic oil ISO VG46
Fuel Diesel light oil
Engine cooling water YANMAR genuine long-life coolant (LLC) 51 % added water
Recommendations based on temperature ranges

Prescribed Amount of oil
Part be refilled Oil type (°F) -4 14 32 50 68 86 amount of oil to be changed
(°C) (-20) (-10) (0) (10) (20) (30)
SAE 10WCD
Engine oil pan Engine oil SAE 10W-30CD 3.2 Qts. (3.0 L) 3.2 Qts. (3.0 L)
SAE 15W-40CD
0.37 Qts. (0.35 0.37 Qts. (0.35

Travel reduction gear Gear oil SAE 90 (GL-4) L) L)
(For right and left each) (For right and left each)
In the tank 3.6 Gals. (13.8 L)

Hydraulic oil system Hydraulic oil ISO VG46 Other parts 1.6 Gals. (6.2 L)
3.6 Gals. (13.8 L)
No. 2-D
Fuel tank Light oil No. 3-D 5.3 Gals. (20.0 L) 
No. 3-D (S)
Radiator 2.3 Qts. (2.2 L)

Cooling system Water YANMAR genuine long-life coolant (LLC) added 
Subtank 0.42 Qts. (0.4 L)
°F 23 14 5 -4 -13 -22 -31 -40

Lowest temperature
°C (-5) (-10) (-15) (-20) (-25) (-30) (-35) (-40)
Qts. 0.42 0.74 0.85 0.95 1.06 1.27 1.37 1.48
Amout of anti-freeze
(L) (0.4) (0.7) (0.8) (0.9) (1.0) (1.2) (1.3) (1.4)
Qts. 2.33 2.01 1.90 1.80 1.69 1.48 1.37 1.27
Amout of water
(L) (2.2) (1.9) (1.8) (1.7) (1.6) (1.4) (1.3) (1.2)
Note :
At the delivery, water and antifreeze are mixed at the ratio for -31 °F (-35 °C) temperature above.
9-1 4480203
CHAPTER 10
TROUBLESHOOTING
10-1 Non-Breakdowns ............................................................................. 10-1-1

10-1-1 Natural Release of Bucket ..................................................... 10-1-1
10-1-2 Discontinuous Arm Movement ............................................... 10-1-1
10-1-3 Drifting of Upperstructure on Quick Travel Operation............ 10-1-2
10-1-4 Thermal Shock of Travel Motor.............................................. 10-1-3
10-1-5 Change of Blade Speed in Loaded Condition........................ 10-1-4
10-1-6 Time Lag on Travel Speed Switching .................................... 10-1-5
10-1-7 Fluctuation in Oil Level of Hydraulic Oil Tank Due
to Temperature Change......................................................... 10-1-6
10-2 Troubleshooting ............................................................................... 10-2-1
10-2-1 Machine and Engine .............................................................. 10-2-1
10-2-2 Electrical Equipment on Panel ............................................. 10-2-22
10. TROUBLESHOOTING
10. Troubleshooting
10-1 Non-Breakdowns
10-1-1 Natural Release of Bucket
Phenomenon
When the arm is extended while scooping with the
bucket, the scooping side of the bucket is restricted by
the arm and causes back pressure because oil cannot
be supplied to the bucket cylinder in time.
When the boom is raised immediately in this condition,
the bucket is released naturally because of the back
pressure in the piston side of the cylinder
Operation
This problem can be solved by using a sequence of
three actions of bucket scooping, arm extension and
boom raising.
(For the models that cannot make the triple sequence
actions, extend the arm after raising the boom.)
10-1-2 Discontinuous Arm Movement
When scooping with the arm, the arm tends to move

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

speed is in the low to medium speed range.
Advise your users fully that this will happen in hydraulic
equipment and that this is not a breakdown.
Discontinuous phenomenon appears in this range.
10-1-1 4480203
10. TROUBLESHOOTING
10-1-3 Drifting of Upperstructure on Quick Travel Operation
Phenomenon
The upperstructure drifts on quick travel operation (especially, on spin-or pivot-turning).
Drift
Reason
Inertial force is given to the upperstructure through the quick operation of the undercarriage, and high pressure is
applied to the swing motor. The relief valve is activated to turn the swing motor.
(The mechanical brake is released when the engine is running.)
Inertial force
Mechanical brake
release port
Relief valve
P2
10-1-2 4480203
10. TROUBLESHOOTING
10-1-4 Thermal Shock of Travel Motor
Phenomenon
When the travelling operation is made for pivot turning in cold temperatures after raising the hydraulic oil to more
than 140°F (60°C) higher than the ambient temp. through relief valve operation, etc., without travelling after starting
the engine, the machine may travel straight instead of making a pivot turn.
(Travel straight in spite of turning operation.)

Reason
Spool
Motor
Brake valve
Swivel joint
Motor
When the hot hydraulic oil is suddenly fed to the cold brake valve and motor, the spool in the brake valve sticks
momentarily due to thermal expansion, canceling the braking force.
Evaluation
Since the phenomenon disappears in 20 to 30 seconds and this situation is generally rare, this phenomenon pre-
sents no problem.
10-1-3 4480203
10. TROUBLESHOOTING
10-1-5 Change of Blade Speed in Loaded Condition
Phenomenon
When the blade is being used to raise the machine or do
other operations by which the blade is loaded, the blade
speed becomes slower than that when the blade is
unloaded.
Reason
The oil from the port P1 of the inlet section flows to the
blade cylinder through the throttle in the parallel passage
and the blade section.
Meanwhile, the circuit pressure of the port P1 increases due to the load on the blade cylinder and the resistance at
the throttle until it reaches the set pressure of the relief valve. Consequently, some oil flows back to the hydraulic oil
tank, so that the blade cylinder is fed with less oil to slow down the blade speed.
Blade cylinder
Throttle
B5 A5 B4 A4 B3 A3 B2 A2 B1 A1
a3 a2
Blade Bucket Boom Boom swing
1.0
1.4 1.0
P1
MRV-1
Relief valve
T1
b3 b2
10-1-4 4480203
10. TROUBLESHOOTING
10-1-6 Time Lag on Travel Speed Switching
Phenomenon
In cold temperatures, there is a time lag in switching from the high-travel speed to low-travel speed (with the high-
speed pedal released).
Reason
The shock caused during switching from the high-speed to low-speed is lightened by the throttles of A. In cold tem-
peratures, however, the passage resistance of the throttles becomes larger and it takes more time for the swash
plate of the travel motor to return to the low speed.
Swash plate angel switch piston
Travel motor High-speed pedal
R/G
Travel motor swash plate A
PS
a1 a2
High-speed switch valve
P1 P2 T1,T2
10-1-5 4480203
10. TROUBLESHOOTING
10-1-7 Fluctuation in Oil Level of Hydraulic Oil Tank Due to Temperature Change
Phenomenon
The oil level of the hydraulic oil tank varies between before operation (the machine is cool) and after operation (the
machine is warm).
After operation (machine warm)
Before operation (machine cool)
Reason
The oil level changes because the thermal expansion factor of oil is far larger (about 20 times) than that of steel.
1. Liner thermal expansion factor of steel : 11.7×10 -6

2. Cubical thermal expansion factor of steel : 3.51×10 -5
3. Cubical thermal expansion factor of hydraulic oil : 7.7×10 -4
(Example)
0.14 Gals. (0.531 L)

Expansion by temp. rise
68 F (20
Hydraulic oil
3.6 Gals. (13.8 L) 158 F (70
3.6 Gals. (13.8 L)
0.006 Gals. (0.024 L)

Hydraulic oil Expansion by temp. rise
68 F (20
tank (Steel)
3.6 Gals. (13.8 L) 158 F (70
3.6 Gals. (13.8 L)
10-1-6 4480203
10. TROUBLESHOOTING
10-2 Troubleshooting
10-2-1 Machine and Engine
(How to use the charts)
Trouble
A Aa Ab
B Ba Bb Bc
C Ca Cb Cc Ce
Factors related to the trouble are enumerated

in the columns and instructions for corrective
procedures are given below. It is recommended
that the troubles be inspected and corrected
one by one according to the chart.
Inspection item
Remedy for failure
10-2-1 4480203
10. TROUBLESHOOTING
Low output
Does the work Hydraulic Set relief pressure

implement work power
normally? source of control valve
Excessive in- Clogging of Clogging of

take resistance air cleaner intake pipe
Clean Clean
Excessive Clogging of Clogging of Clogging of

exhaust exhaust port of
resistance muffler exhaust pipe cylinder head
Clean or replace Clean Clean
Defective fuel Air in fuel Clogging of Clogging of

system system fuel filter fuel pipe
Release the air Clean or replace Clean
Clogging of air release port in

fuel tank
Insufficient fuel
discharge from
feed pump
Improper ad- Fuel injection Clogging of fuel Sticking of fuel

Governor injection nozzle
justment pressure hole injection valve
Adjust Adjust Clean or replace Replace
Defective lever Improper Malfunction of Defective deliv- Wear of

injection plunger
link timing fuel pump rack ery valve barrel
Repair or replace Adjust Repair or replace Repair or replace Replace
Low compres- Improper clear- Defective seat Seizing of intake Deterioration or

ance of intake of intake or or exhaust valve breakage of
sion pressure or exhaust valve exhaust valve stem valve spring
Adjust Smooth or Replace Replace
replace seat
Compression leak from
head gasket
Replace
Sticking, damage, or Scuffing or Scuffing or

wear of
wear of piston ring piston wear of liners
Replace Replace Replace
Overheating Refer to Overheating
10-2-2 4480203
10. TROUBLESHOOTING
Overheating

implement work
normally? power source of control valve
Cooling water Low cooling Damage or Clogging of Excessive

Loose fan belt wear of fan exhaust
system water level belt radiator resistance
Supply Adjust Replace Clean Clean
Clogging or Defective Clogging of Malfunction Malfunction

defect of of cooling
radiator cap thermostat radiator hose water pump of radiator
Clean or replace Replace Clean Replace Replace
Excessive intake Clogging of Clogging of

resistance air cleaner intake pipe
Clean or replace Clean
Excessive exhaust Clogging of Clogging of Clogging of

cylinder head
resistance muffler exhaust pipe exhaust port
Clean Clean Clean
Gas leak from Crack of

Cylinder head
head gasket cylinder head
Replace Replace
Improper Defective fuel

Fuel system
injection timing injection valve
Correct Repair or replace
Intake or exhaust Improper clear- Improper valve

valve opening/ ance of intake or opening/closing
closing timing exhaust valve timing
Adjust Adjust
Piston Seizing
Replace
10-2-3 4480203
10. TROUBLESHOOTING
Black smoke
emission

implement work
normally? power source of control valve
Low output See Low output
Fuel Improper fuel
Replace
Fuel injection Advanced Excessive Uneven injec-

pump injection timing injection volume tion volume
Adjust Adjust Adjust or replace
Improper Defective lever or

Governor
adjustment link
Adjust Repair or replace
White smoke
emission
Mixing with low

Fuel Water in fuel quality fuel or
impurities
Replace Replace
Lubricating oil Improper grade
Replace
Excessive intake Clogging of air Clogging of
resistance cleaner intake pipe
Clean or replace Clean or replace
Fuel injection Delayed injection

pump timing
Adjust
Defective valve Damage or Damage or

Oil down wear of valve wear of valve
stem seal stem guide
Sticking, damage Scuffing or Scuffing or
Oil up or wear of piston
ring wear of piston wear of liners
Gas leak from
head gasket
Excessive Replace
Malfunction of thermostat
cooling
Replace
10-2-4 4480203
10. TROUBLESHOOTING
Starter motor does not turn Except seizure of engine and

or output is low. trouble of any work implement
Disconnection Disconnection Connection

or connection Battery terminal Ground terminal failure of
failure of wire coupler
Repair Repair Repair Repair
Battery Specific gravity Voltage Damaged battery
Recharge Supply electrolyte Replace

or recharge
Damage or rust of Internal contact Damaged

Starter switch
terminal failure of switch switch
Replace or repair Replace Replace
Damage or rust Malfunction of

Safety relay
of terminal relay
Replace or repair Replace
Malfunction or
Damage or rust Defective Burnout of Layer
Starter motor poor contact of
of terminal magnetic switch brushes coil short-circuit
Replace or repair Replace Replace starter Replace starter

motor motor
Clutch slipping
Replace
Inspection procedures
When the starter motor cannot be started by turning the starter switch on, check it as follows.
(Battery, starter switch and wiring assumed to be normal.)
(1) Safety relay & starter motor magnetic switch
Connect the S-and B-terminals of the starter motor directly.
[1] When the starter motor turns : The safety relay is faulty.
[2] When the starter motor does not turn : Either the starter motor magnetic switch or the starter motor is faulty.
(2) Starter motor
Connect the B-and M-terminals of the starter motor directly. S
[1] When the starter motor turns : Magnetic switch is faulty. M
B
[2] When the starter motor does not turn : Starter motor is faulty.
10-2-5 4480203
10. TROUBLESHOOTING
Battery dies or battery

cannot be charged (during operation)
Charging failure Discharges
Disconnection Battery Ground Discon- Connection Starter

or connection nection of failure of ON
failure terminal terminal wire coupler switch
Repair Repair Repair Repair Turn off
Damaged
Battery Wiring Short-circuit
battery
Replace Replace
Starter Damage Internal contact

or rust of Electrical
switch failure of switch Alternator
terminal equipment
Repair or Replace
replace
Electrical Damaged
Alternator Regulator
equipment diode
Replace
Short-circuit or Short-circuit
Loose fan belt
breakage of lead wire of coil
Adjust Replace Replace
alternator
Damaged diode Defective IC regulator

Replace Replace alternator
Defective
brushes
Repalace or replace
Burnout
of coil
Replace alternator
Layer short-circuit
Replace alternator
10-2-6 4480203
10. TROUBLESHOOTING
Work implement does not move

at all or its operation is slow.
Hydraulic oil
Insufficient Deterioration Viscosity
quantity
Supply Replace Specified
hydraulic oil
Piping Faulty joint (Aeration or cavitation)
Repair
Hydraulic Insufficient dis- Wear of spline of Breakage Inner part

Oil leak
pump charge volume joint of shaft failure
Repair or replace Replace Replace Replace Replace
Filter Clogging
Clean or replace
10-2-7 4480203
10. TROUBLESHOOTING
Work Implements
Weak digging force Boom, arm and bucket cylinders
Hydraulic Do other
implements work
power source normally?
Pump P4 Relief valve

pressure
Check the pressure
and adjust it. Refer
to section 5-4 Pres-
sure Adjustment
Inspect pilot valve by switching

Internal leakage or malfunction
Pilot valve Lever stroke hose with hose of other normal
of valve spool
circuit
Replace Replace
System relief Dust in Malfunction of Improper Defective pilot

Control valve system relief circuit relief
valve pressure control valve valve valve pressure poppet seat
Check the pressure Clean Replace Adjust Replace system
and adjust it. Refer relief valve
sure Adjustment
Movement of
Internal leakage
valve spool
Replace Repair of parts
Movement of main valve
Hydraulic Internal spool in inlet section
Oil leak
cylinder leakage
Replace
Repair or replace Replace seal or
whole assembly
Unintended descent of hydraulic cylinder Boom and arm cylinders]
Anti-drift Dust in
valve control valve
Clean
Circuit relief Dust in Defective seat of
Control valve circuit relief
valve pressure control valve valve
Check the pressure Clean Replace circuit
and adjust it. Refer relief valve
sure Adjustment
Hydraulic Internal
Oil leak
cylinder leakage
Repair or Replace seal or
replace whole assembly
Inspection procedure
Switch the hose with the hose of the other circuit using the control valve.
[1] No descent : Control valve is faulty.
[2] Descent : Cylinder is faulty.
10-2-8 4480203
10. TROUBLESHOOTING
Slow implement working speed Boom, arm and bucket cylinders
Relief valve
Pump P4
pressure
Check the pressure
sure Adjustment
Internal leakage or malfunction Inspect by switching hose

Pilot valve Lever stroke with hose of other normal
of valve spool
circuit
Replace Replace
System relief Movement of Internal Movement of valve

Control valve spool in parallel-
valve pressure valve spool leakage flow divider
Check the pressure Repair or replace Repair or Replace
and adjust it. Refer replace
sure Adjustment
Movement of main valve

Hydraulic spool in inlet section
cylinder Oil leak Internal leakage
Replace
whole assembly
Hydraulic Insufficient oil discharge

pump volume from pump
Replace
Control lever cannot be held at

neutral position Travel, blade and boom swing cylinders
Wear of
Control valve Cap Spring
spring seat
10-2-9 4480203
10. TROUBLESHOOTING
Drifting of boom swing
Extent of Measure telescopic motion amount of

drifting cylinder rod on 15-degrees slope
Steering Boom swing Sticking of swing

equipment pedal pedal link
Adjust neutral Repair pedal link or apply grease
position Replace bush
Control Circuit relief Dust in circuit Wear of circuit relief

valve valve pressure relief valve valve seat surface
Check the pressure
and adjust it. Refer Clean or replace Replace circuit
to section 5-4 Pres- relief valve
sure Adjustment
Dust in control Wear of anti-void valve

valve seat surface
Clean or replace Replace
Defective spool
fitting
Replace spool section
Hydraulic Internal
Oil leak
cylinder leakage

whole assembly
Inspection procedure
Switch the hose with the hose of the other circuit using the control valve.
[1] No boom swing drifting : Control valve is faulty.
[2] Boom swing drifting : Hydraulic cylinder is faulty.
10-2-10 4480203
10. TROUBLESHOOTING
Boom swing cannot be made or is slow
Hydraulic Do other work implements

source work normally?
Boom swing Sticking of swing Wear of

Controls
pedal pedal link link joint
Adjust neutral Repair pedal link or apply grease Replace
position Replace bush
Circuit relief Dust in circuit relief Permanent set of circuit relief

Control valve
valve pressure valve valve seat surface
Check the pressure Clean or replace Replace circuit relief valve
to section 5-4 "Pres-
sure Adjustment"
Malfunction Fall or wear of

of spool spool link pin
Adjust lever stroke. Install or replace
Internal
Hydraulic cylinder Oil leak
leakage
whole assembly
10-2-11 4480203
10. TROUBLESHOOTING
Upperstructure cannot swing or

swing speed is slow
No outside Remove the

resistance? resistance source
Hydraulic Do other implements

power source work normally?
Operation of Relief valve

Cut-off valve
solenoid pressure
Replace Check pressure. Refer
sure Adjustment
Movement of [Inspect by switching hose with

Pilot valve
valve spool hose of other normal circuit.]
Repair or replace
Relief valve Movement of Dust in

Control valve
pressure valve spool control valve
Check pressure. Refer Repair or replace Clean
sure Adjustment
Relief valve Dust in Wear of relief
Swing brake valve
pressure relief valve valve seat surface
Check pressure. Refer Clean Replace
sure Adjustment
Brake release
Mechanical brake Internal leakage
pressure
Check brake Replace seal
release pressure
Hydraulic motor Oil leak Internal leakage Internal breakage
Replace seal or Replace Replace motor

whole assembly
Swing reduction
Internal breakage
gear
Replace
Breakage of swing Wear or rust of

Swing braring
bearing gear swing bearing ball
Replace Replace
10-2-12 4480203
10. TROUBLESHOOTING
Swing only to one side
Relief valve Dust in Wear of relief

Swing brake valve
pressure relief valve valve seat surface
Check pressure. Refer Clean or replace
sure Adjustment
Relief valve
Cut-off valve
pressure
Check pressure. Refer
sure Adjustment
Movement of [Inspect pilot by switching hose with
Pilot valve
valve spool hose of other normal circuit]
Repalr or replace
Movement of
Control valve
valve spool
Repalr or replace
Drifting of swing [Brake does not work]
Extent of drifting Measure drifting
Compare with service

standard valve
Is valve spool
Pilot valve
returned to neutral?
Repair or replace
Oil leak from brake Relief valve Dust in Wear of relief

Swing brake valve
valve fitted area pressure relief valve valve seat surface
Replace Check pressure. Refer Clean or replace Replace
sure Adjustment
Hydraulic motor Oil leak Internal leakage
Replace seal or Replace

whole assembly
10-2-13 4480203
10. TROUBLESHOOTING
Drifting of swing [Unintended drifting on slopes]
Measure motion amount of swing bearing

Extent of drifting
outer race on 15 degrees slope.
Refer to 3-1 "Machine Performance"
Is valve spool
Pilot valve
returned to neutral?
Repair of replace
Defective spool
Control valve
fitting

whole assembly
Wear or breakage Operation Wear of friction

Mechanical brake
of coil spring brake piston plate or steel plate
Relief valve Dust in relief Wear of relief

Swing brake valve
pressure valve valve seat surface
Check pressure. Refer Clean or replace Replace
sure Adjustment
Swing
Internal breakage
reduction gear
Replace
10-2-14 4480203
10. TROUBLESHOOTING
Travel Equipment
No travelling
Crawler tension Before making checks, remove dirt from

and clogging undercarriage and adjust crawler tension

lock lever
Release
R and L relief Dust in

Control valve
valves pressure control valve
Check the pressure and Clean
adjust it. Refer to sec-
tion 5-4 Pressure Ad-
justment
Spool link pin

comes off
Install
Swivel joint Internal leakage
Replace seal
Driving Lift machine body and check undercar-

mechanism riage turns under external force
Brake valve (or Loosen ports P1 and P2 Dust in plunger Plunger plug
Sticki of plunger
counterbalance valve) joints and check oil flow orifice loosened
Clean Retighten Repair or replace
Hydraulic motor
Oil leak Internal leakage Internal breakage
and reduction gear
Replace seal or Replace Replace motor
whole assembly
10-2-15 4480203
10. TROUBLESHOOTING
Cannot travel straight
Crawler tension, Before making checks, remove dirt from

clogging undercarriage, and adjust crawler tension.
Hydraulic Do other implements work Lift machine body and Check hydraulic
power source normally? check R and L revolutions pump
Replace hydraulic
pump
Improper adjustment of
lever stopper bolt
Readjust
Controls Link operation Wear of link joint
Repair or replace Replace
R and L relief valves Dust in Wear of relief

Control valve
pressure control valve valve seat surface
Check the pressure and Clean Replace
adjust it. Refer to section
5-4 Pressure Adjustment"
Internal
Swivel joint Oil leak
leakage
Replace seal Replace seal
Brake valve Sticking of Dust in Wear of check

(or counter balance valve) plunger check valve valve seat surface
Repair or replace Clean Repair or replace
Hydraulic Internal Malfunction of

Oil leak
motor leakage 2-speed spool
Replace seal or Replace motor Replace
whole assembly 2-spool valve
10-2-16 4480203
10. TROUBLESHOOTING
1. When the hydraulic tester is not used :
(1) Reverse the hoses of the hydraulic pumps P1 and P2.
Phenomenon : Reversed ...................Replace the hydraulic pump.
(2) Reverse the hoses between the control valve and the swivel joint.
Phenomenon : Reversed ...........................................Overhaul or replace the control valve.
(3) Reverse the hoses between the swivel joint and the brake valve (or counter balance valve).
Phenomenon : Reversed ...................Overhaul or replace the swivel joint.
(4) Reverse the left and right hydraulic motors.
Phenomenon : Reversed ...........................................Replace the counter balance valve (or counter balance
valve) or the motor.
2. When the hydraulic tester is used :

(1) Flow volume at no load (Check the difference between the right and left motors.)
(2) Flow volume when loaded (Check the difference between the right and left motors.)
Conditions :
(1) Discharge volume at no load
Make judgment by reading the difference
between the right and left motors.
(2) Discharge volume when loaded
(3) Engine at rated speed.
(4) Hydraulic oil temp. at 122 to 140 F (50 to 60 C)
10-2-17 4480203
10. TROUBLESHOOTING
Cannot make spin

turning
Site condition Dry ground Wet ground Sndy
Crawler tension Before making checks, remove dirt from

and clogging under carriage and adjust crawler tension.

R and L relief Wear of relief valve

Control valve Dust in control valve
valves pressure seat surface
Lift machine body Clean Replace
Check the pressure and
R and L relief Wear of relief valve

Brake valve Dust in brake valve
valves pressure spring and seat surface
Lift machine body Clean Replace
Check the pressure and

whole assembly
10-2-18 4480203
10. TROUBLESHOOTING
Drift of machine
body on slopes
Check the drift with machine

Extent of drift
placedon a 15 degrees slope.
Hydraulic Internal
Oil leak
motor leakage
whole assembly
Brake valve (or counter Leakage from Dust in check Wear of check Breakage of
balance valve plunger valve valve seat surface spring
Replace valve Clean Repair or replace Replace
Check the drift with the machine placed on a slope with an inclination angle below 15 degrees.
[1] Continuous drift : Brake valve (or counter balance valve) is faulty.
[2] Discontinuous drift : Hydraulic motor is faulty.
10-2-19 4480203
10. TROUBLESHOOTING
No switching to high-speed
One side? Both side?
Switch
Safety switch
operation
Repair or replace
Solenoid Relief valve

Cut-off valve
operation pressure
Replace Check the pressure
Oil leak
Pipings
from joint
Repair or replace
Internal
Swivel joint Oil leak
leakage
Repair or replace Replace seal
Hydraulic Operation of Internal

Oil leak
motor high-speed spool failure of motor
Repair or replace Overhaul or replace
assembly
Breakage
Orifice clogged Dust in spool
of spring
Clean Clean Replace
Note :
When the oil temp. is still very low, switching to high-speed may not be made immediately when treading on the
high-speed pedal. This problem disappears as the oil temperature rises.
(Refer to Section "10-1-7 Time Lag on Travel Speed Switching".)
10-2-20 4480203
10. TROUBLESHOOTING
Travelling speed is switched to high-speed naturally

or high-speed cannot be cancelled
One side? Both side?
Switch
Safety switch
operation
Repair or replace
Solenoid Spool
Cut-off valve
operation operation
Replace Repair or replace
Hydraulic Operation of Internal

motor high-speed spool failure of motor
Faulty spool
Dust in spool
movement
Clean or replace Repair or replace
10-2-21 4480203
10. TROUBLESHOOTING
10-2-2 Electrical Equipment on Panel
(1) How to read the chart
Trouble
Inspection/repair instructions
Check item
Factors in trouble or treatment
(2) Refer to the wiring diagram for the number of the connector terminal and lead wire color.
(3) Color marks of leads

W (White) B(Black) R (Red) Y (Yellow)
G (Green) L (Blue) Br (Brown) Lg (Light green)
O (Orange) Gr (Grey)
Combination of colors
Example : W R ..............(Red stripes on white background)
Marking color
Background color
10-2-22 4480203
10. TROUBLESHOOTING
Monitor Lamps
Starter switch is turned on, but monitor lamp does not go on
Failure of YES
all lamps?
NO Check the power line :

Replace fuse
Check wire harness
Check connector contact
Check starter switch
Others
Only one lamp does not go on
YES
Filament blown?
NO Replace bulb
Check :
Rapair according to the trou-
bleshooting procedure for the
relevant lamp.
10-2-23 4480203
10. TROUBLESHOOTING
Hourmeter
Hourmeter does not work while engine is running
YES
Fuse blown?
NO Replace fuse
Disconnect the bipole connecter on the back

of the instrument panel, and check whether a
voltage of 10V or more is applied to the termi-
nal No.22B (YB) with the starter switch turned
on.
YES
Voltage rises?
NO Replace wire harness B
Disconnect the terminal No.14 (B) on the back

of the instrument panel and ground it.
(Keep the terminal No.22B connected.)
YES
Activated?
NO Grounding cable is defective
Replace hourmeter
10-2-24 4480203
10. TROUBLESHOOTING
Water Temp. Alarm Lamp
Failure of water temp. alarm lamp
Lamp does not go on Lamp goes on even when

even on overheating. water temp. is low.
Disconnect the wire harness

YES
Fuse blown? No.14A (Lg) from the water
temp. switch terminal.
NO Replace fuse
YES
YES
Filament blown? Lamp goes off?
NO Replace lamp NO Replace water temp. switch
Disconnect the wire harness Replace wire harness A or B

No.14A (Lg) from the water
temp. switch terminal and
ground it.
(Turn on the starter switch.)
YES
Lamp goes on?
NO Replace water temp. switch
Replace wire harness A or B
10-2-25 4480203
10. TROUBLESHOOTING
Battery Charge Alarm Lamp
Failure of battery charge alarm lamp
Starer switch is turned on, Lamp goes on while running

but lamp does not go on the engine
YES
Fuse blown?
Replace fuse Stop the engine

NO
YES
Filament blown?
Replace bulb Disconnect the L-terminal of the

NO
alternator.
(Turn on the starter switch)
Disconnect the L-terminal of the
alternator and ground it.
YES YES
Lamp goes on? Lamp goes on?
Check the alternator Check the alternator

NO NO
Disconnect the terminal No.7 Disconnect the terminal No.7

(WG) of the 12-pole connector in (WG) of the 12-pole connector in
the indicator box and ground it. the indicator box.
YES YES
Replace wire harness A or B Replace wire harness A or B

NO NO
Replace the indicator box Replace the indicator box
10-2-26 4480203
10. TROUBLESHOOTING
Engine Oil Pressure Alarm Lamp
Failure of engine oil pressure alarm lamp
Starer switch is turned on, Lamp goes on while running

but lamp does not go on the engine
YES
Fuse blown?
Stop the engine
Replace fuse
NO
YES YES
Insufficient
Filament blown? engine oil?
Replace bulb Supply engine oil
NO NO
Disconnect the terminal No.13A Disconnect the terminal No.13A

(LgR) from the oil pressure (LgR) from the oil pressure
switch terminal and ground it. switch terminal.
YES YES
Replace oil pressure switch Replace oil pressure switch

NO NO
Replace wire harness A or B Disconnect the terminal No.11

(LgR) of the 12-pole connector
on the monitor lamp side.
YES
Lamp goes on?
Replace wire harness A or B

NO
Replace indicator box
10-2-27 4480203
10. TROUBLESHOOTING
Warning Buzzer
Buzzer sounds while Starter switch is turned on,

running engine but buzzer does not sound
Is engine oil NO Is engine oil NO

pressure alarm pressure alarm
lamp on? lamp on?
YES Normal YES Repair the lamp according

to the troubleshooting
procedure for engine oil
pressure alarm lamp.
Is battery NO
charge alarm
lamp on?
YES Normal
Is water NO
temp. alarm
lamp on?
YES Normal
Replace the indicator box Replace the indicator box
10-2-28 4480203
10. TROUBLESHOOTING
Fuel Level Gauge
Fuel level gauge is faulty
Pointer indicates a value

Pointer does not work Unstable pointer
larger than the real fuel level
Check the connection of the Disconnect the terminal No.11A Check if the fuel in the fuel
terminal No.10A of the fuel of the fuel level sensor, connect tank is shaking.
lever sensor. 80 resistance to the female
terminal (harness side) and
ground it.
(Turn on starter switch)
Is the fuel
Is the terminal YES Does the pointer YES level gauge pointer YES
unstable due to the shaking
No.10A loosened? move to "E"? of fuel in the fuel
tank?
Contact failure of Replace the fuel
the terminal No.11A level sensor Normal
NO NO NO
Disconnect the terminal No.11A Disconnect the terminal No.4 Check the connection of the
(L) of the fuel level sensor, (L) of the female connecter of terminal No.11A of the fuel
connect 10 resistance to the the fuel level gauge, connect lever sensor.
female terminal (harness side) 80 resistance and ground it.
and ground it.
Does the pointer YES Does the pointer YES Is the terminal YES
move to "F"? move to "E"? loosened?
Replace the fuel Harness is faulty Contact failure of
NO level sensor NO (Short-circuit) NO the terminal
Replace the fuel

level gauge
Disconnect the terminal No.4 Disconnect the terminal No.11A

(L) of the female connecter of of the fuel level sensor, connect
the fuel level gauge, connect 10 resistance to the female
10 resistance and ground it. terminal (harness side) and
ground it.
Does the pointer YES Does the pointer YES

move to "F"? move to "F"?
Replace wire harness Replace the fuel
NO A or B (Wire breakage) level sensor
NO
Replace the fuel level gauge Replace the fuel level gauge
10-2-29 4480203
10. TROUBLESHOOTING
Water Temperature
Water temperature gauge is faulty
Pointer indicates a value

Pointer does not work
larger than the real temperature
Check the connection of the Disconnect the terminal No.15A

terminal No.15A (LB) of the of the water temp. sensor,
water temp. sensor. connect 80 resistance to the
female terminal (harness side)
and ground it.
Is the terminal Does the

YES YES
No.15A loosened? pointer move to the
bottom?
Contact failure of Replace the water
NO the terminal No.15A NO temp. sensor
Disconnect the terminal No.15A Disconnect the terminal No.3

(LB) of the water temp. sensor, (LB) of the female connecter of
connect 10 resistance to the the water temp. gauge, connect
female terminal (harness side) 80 resistance and ground it.
and ground it.
Does the Does the

YES YES
pointer move to the pointer move to the
red zone? bottom?
Replace the water Harness is faulty
NO temp. sensor NO (Short-circuit)
Replace the water

temp. gauge
Disconnect the terminal No.3

(LB) of the female connecter of
the water temp. gauge, connect
10 resistance and ground it.
Does the
YES
pointer move to the
red zone?
Replace wire harness
NO A or B (Wire breakage)
Replace the water temp. gauge
10-2-30 4480203
CHAPTER 11
REFERENCE DATA
11-1 Specifications for Attachment ..............................................................11-1

11. REFERENCE DATA
11.Reference Data
11-1 Specifications for Attachment
Min. J
D
Max. K
A
a
b M
C
B
G’ G
Arm
E’
F
b a
Unit : in. (mm)

Model
ViO15-2
Item
Specifications for bucket installation
A (Distance between bucket pins) 4.13 (105)
B (Distance between bucket and bucket arm pivot pins) 3.74 (95)
C (Distance between bucket arm pins) 6.50 (165)
D (Distance between bucket link pins) 6.69 (170)
E (External width of arm-stick end boss) 4.13 (105)
E' (Internal width of bucket pin boss) 4.17 (106)
F (External width of bucket pin boss) 5.79 (147)
G / G' (Outer diameter of bucket pin) Ø1.18 (Ø30) / Ø1.18 (Ø30)
J (Cylinder length when it is fully retracted) 20.24 (514)
K (Cylinder length when it is fully extended) 31.18 (792)
M (Bucket arm pin height from arm-stick and bucket pivot pins) 0.20 (5)
11-1 4480203
ViO15-2
Service Manual
First Edition : Jul. 2002
Published by : Engineering & Development Dept.

Edited by : Construction Equipment Division
Products Support Group
Finished by : Yanmar Technical Service Co., Ltd.
All rights reserved.

This manual may not be reproduced or copied
in whole or in part, without the written consent
of YANMAR CO., LTD.

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CONTENTS

GENERAL CAUTIONS FOR MAINTENANCE WORK

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

1. General Cautions for Maintenance Work

1-1 Correct Work

1-2 Safety Precautions

1-4 Cautions for Disassembly and Reassembly

(1) Clean the machine before disassembly.

One and a half threads

1-5 Cautions for Removal and Installation of Hydraulic Equipment

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

1-6 Cautions for Removal and Installation of Hydraulic Piping

(1) Installation of hydraulic hose

1-7 Cautions for Handling Seals

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

1-8 Correct Installation of Hydraulic Hose

Not good Good

Not good Good

Not good Good

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

Not good Good

Not good Good

Not good Good

Not good Good

Hose mark Hose mark

1-9 Specifications of Hydraulic Hose

(1) Yanmar Standard Type

Hose material code Fittings combination code

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

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

3) Hose Dia. (Unit : inch)

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

Fitting 60 degrees bent type.

(Example) Part code 2 3 2 0 2 0 3 0 8 5 5

Rubber hose, high pressure type List of pipe threads

(2) Special Parts

Description ..................... Hose P 2 06 AB 075 W

2 Hose material 6 Total length 7 Hose protector

3 Recommended G(PF) Straight pipe

4 Nominal dia. (inch) Without fitting Y

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

Fitting type Code Fitting type Code

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

45 45 degrees bent type.

90 90 degrees bent O-ring

Straight pipe thread with

30 30 degrees bent type.

1-10 Air Release of Hydraulic Equipment

1. Air Release of Each Hydraulic Component

2. Air Release of Hydraulic Cylinders

1.97 to 3.9 in. 1.97 to 3.9 in.

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

Maximum depth of vertically digging in. (mm) 68.9 (1750)

Item Unit ViO15-2

Item Unit ViO15-2

Item Unit ViO15-2

Item Unit ViO15-2

Track roller Quantity (One side) pcs. 3

Crawler tension adjustment Grease adjuster