ZX450 470 500 520LC-3 Full Technical Manual

INTRODUCTION
TO THE READER
• This manual is written for an experienced technician • If you have any questions or comments, at if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact using “Service Manual
Revision Request Form” at the end of this man-
• Be sure to thoroughly read this manual for cor- ual.
rect product information and service procedures. (Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-29-832-7084
FAX: 81-29-831-1162
E-mail: dc@hitachi-kenki.com
• This manual contains the revision information
to the 29, April 2010.
ADDITIONAL REFERENCES
• Please refer to the other materials (operator’s

manual, parts catalog, engine technical material
and Hitachi training material etc.) in addition to this
manual.
MANUAL COMPOSITION
• This manual consists the Technical Manual and the • Information included in the Workshop Manual:
Workshop Manual. technical information needed for maintenance
and repair of the machine, tools and devices
• Information included in the Technical Manual: needed for maintenance and repair, maintenance
technical information needed for redelivery and standards, and removal/installation and assem-
delivery, operation and activation of all devices ble/disassemble procedures.
and systems, operational performance tests, and
troubleshooting procedures.
PAGE NUMBER
• Each page has a number, located on the center

lower part of the page, and each number contains
the following information:
Example : T 1-3-5
Consecutive Page Number for Each Group

Group Number
Section Number
T: Technical Manual W: Workshop Manual
IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and • CAUTION:
signal words are used to alert the reader to the Indicated potentially hazardous situation which
potential for personal injury of machine damage. could, if not avoided, result in personal injury or
death.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury. • IMPORTANT:
Never fail to follow the safety instructions prescribed Indicates a situation which, if not conformed to the
along with the safety alert symbol. instructions, could result in damage to the machine.
The safety alert symbol is also used to draw attention
to component/part weights.
• NOTE:
To avoid injury and damage, be sure to use appropri-
Indicates supplementary technical information or
ate lifting techniques and equipment when lifting
know-how.
heavy parts.
UNITS USED
• SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
this manual.
MKSA system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.
To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
Length mm in 0.03937 Pressure MPa kgf/cm2 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature °C °F °C×1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
Force N kgf 0.10197 min-1 rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N⋅m kgf⋅m 1.0197 mL/rev cc/rev 1.0
N⋅m lbf⋅ft 0.7375
IN-02
SECTION AND GROUP
SECTION 1 GENERAL
CONTENTS Group 1 Specification
Group 2 Component Layout
Group 3 Component Specifications
SECTION 2 SYSTEM
Group 1 Controller
TECHNICAL MANUAL Group 2 Control System
Group 3 ECM System
(Operational Principle)
Group 4 Hydraulic System
Group 5 Electrical System
SECTION 3 COMPONENT OPERATION
Group 1 Pump Device
Group 2 Swing Device
Group 3 Control Valve
Group 4 Pilot Valve
Group 5 Travel Device
Group 6 Signal Control Valve
Group 7 Others (Upperstructure)
Group 8 Others (Undercarriage)
TECHNICAL MANUAL (Troubleshooting)
SECTION 4 OPERATIONAL PER- SECTION 5 TROUBLESHOOTING
FORMANCE TEST Group 1 Diagnosing Procedure
All information, illustrations and speci- Group 1 Introduction Group 2 Monitor Unit
fications in this manual are based on Group 2 Standard Group 3 Dr. ZX
the latest product information available Group 3 Engine Test Group 4 ICF
at the time of publication. The right is Group 4 Excavator Test Group 5 Component Layout
reserved to make changes at any time Group 5 Component Test Group 6 Troubleshooting A
without notice. Group 6 Adjustment Group 7 Troubleshooting B
Group 8 Electrical System Inspection
COPYRIGHT(C)2009
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
SECTION 1
GENERAL
―CONTENTS―
Group 1 Specifications
Specifications ........................................... T1-1-1
Working Ranges ....................................... T1-1-3
Shoe Types and Applications ................... T1-1-6
Bucket Types and Applications
(Backhoe) ............................................... T1-1-8

Main Component Layout........................... T1-2-1
Electrical Component Layout.................... T1-2-3
Engine ...................................................... T1-2-9
Pump Device .......................................... T1-2-10
Swing Device.......................................... T1-2-10
Travel Device.......................................... T1-2-10
Control Valve ...........................................T1-2-11
Signal Control Vale ................................. T1-2-22
Group 3 Component Specifications

Engine ...................................................... T1-3-1
Engine Accessories .................................. T1-3-4
Hydraulic Component ............................... T1-3-5
Electrical Component ............................... T1-3-9
1J1T-1-1
(Blank)
1J1T-1-2
GENERAL / Specifications
SPECIFICATIONS
ZAXIS450-3, ZAXIS450LC-3, ZAXIS500LC-3
A
C
G
L
B F
E
D
K J
I H
M1J1-12-001
Model ZX450-3 ZX450LC-3 ZX500LC-3

Type of Front-End Attachment 3.4 m (11 ft 2 in) Arm
PCSA 1.9 m3 (2.5 yd3), PCSA 2.1 m3 (2.7 yd3), PCSA 2.1 m3 (2.7 yd3),
Bucket Capacity (Heaped)
CECE 1.7 m3 CECE 1.8 m3 CECE 1.8 m3
Operating Weight 45700 kg (100750 lb) 46600 kg (102734 lb) 49500 kg (109128 lb)
Basic Machine Weight 35600 kg (78484 lb) 36500 kg (80468 lb) 39400 kg (86861 lb)
Engine ISUZU AH-6WG1X 260 kW/1800 min-1(353 PS/1800 rpm)
A: Overall Width 3740 mm (12 ft 3 in) 3740 mm (12 ft 3 in) 3860 mm (12 ft 8 in)
B: Cab Height 3330 mm (10 ft 11 in) 3330 mm (10 ft 11 in) 3410 mm (11 ft 2 in)
C: Rear End Swing Radius 3560 mm (11 ft 8 in) 3560 mm (11 ft 8 in) 3560 mm (11 ft 8 in)
D: Minimum Ground Clearance *760 mm (2 ft 6 in) *760 mm (2 ft 6 in) *840 mm (2 ft 9 in)
E: Counterweight Clearance *1400 mm (4 ft 7 in) *1400 mm (4 ft 7 in) *1470 mm (4 ft 10 in)
F: Engine Cover Height 3080 mm (10 ft 1 in) 3080 mm (10 ft 1 in) 3160 mm (10 ft 4 in)
G: Overall Width of Upperstructure 3530 mm (11 ft 7 in) 3530 mm (11 ft 7 in) 3530 mm (11 ft 7 in)
H: Undercarriage Length 5040 mm (16 ft 6 in) 5470 mm (17 ft 11 in) 5330 mm (17 ft 6 in)
I: Undercarriage Width 3490 mm (11 ft 5 in)/ 3490 mm (11 ft 5 in)/ 3520 mm (11 ft 7 in)/
(Extended/Retracted) 2990 mm (9 ft 10 in) 2990 mm (9 ft 10 in) 3020 mm (9 ft 11 in)
J: Sprocket Center to Idler Center 4040 mm (13 ft 3 in) 4470 mm (14 ft 8 in) 4250 mm (13 ft 11 in)
K: Track Shoe Width 600 mm (24 in) (Grouser shoe)
L: Overall Height 3460 mm (11 ft 4 in) 3460 mm (11 ft 4 in) 3540 mm (11 ft 7 in)
85 kPa 79 kPa 87 kPa
Ground Pressure
(0.87 kgf/cm2, 12 psi) (0.81 kgf/cm2, 11 psi) (0.89 kgf/cm2, 13 psi)
Swing Speed 9.0 min-1 (rpm)
5.5 km/h (3.4 mph)/ 4.0 km/h (2.5 mph)/
Travel Speed (fast/slow)
3.4 km/h (2.1 mph) 2.9 km/h (1.8 mph)
Gradeability 35 ° (tanθ = 0.70)
NOTE: “*” The dimensions do not include the height of the shoe lug.
T1-1-1
ZAXIS470H-3, ZAXIS470LCH-3, ZAXIS520LCH-3
A
C
G
B L
F
E
D
K J
I H
M1J1-12-003
Model ZX470H-3 ZX470LCH-3 ZX520LCH-3

Type of Front-End Attachment H front (with 3.4 m (11 ft 2 in) Arm)
Bucket Capacity (Heaped) PCSA 1.9 m3 (2.5 yd3), CECE 1.7 m3
Operating Weight 47100 kg (103837 lb) 48100 kg (106041 lb) 51700 kg (113978 lb)
Basic Machine Weight 36100 kg (79586 lb) 37100 kg (81791 lb) 40600 kg (89507 lb)
Engine ISUZU AH-6WG1X 260 kW/1800 min-1(353 PS/1800 rpm)
A: Overall Width 3770 mm (12 ft 4 in) 3770 mm (12 ft 4 in) 3860 mm (12 ft 8 in)
B: Cab Height 3450 mm (11 ft 4in) 3450 mm (11 ft 4 in) 3520 mm (11 ft 7 in)
C: Rear End Swing Radius 3560 mm (11 ft 8 in) 3560 mm (11 ft 8 in) 3560 mm (11 ft 8 in)
D: Minimum Ground Clearance *760 mm (2 ft 6 in) *760 mm (2 ft 6 in) *840 mm (2 ft 9 in)
E: Counterweight Clearance *1400 mm (4 ft 7 in) *1400 mm (4 ft 7 in) *1470 mm (4 ft 10 in)
F: Engine Cover Height 3080 mm (10 ft 1 in) 3080 mm (10 ft 1 in) 3160 mm (10 ft 4 in)
G: Overall Width of Upperstructure 3530 mm (11 ft 7 in) 3530 mm (11 ft 7 in) 3530 mm (11 ft 7 in)
H: Undercarriage Length 5040 mm (16 ft 6 in) 5470 mm (17 ft 11 in) 5330 mm (17 ft 6 in)
I: Undercarriage Width 3490 mm (11 ft 5 in)/ 3490 mm (11 ft 5 in)/ 3520 mm (11 ft 7 in)/
(Extended/Retracted) 2990 mm (9 ft 10 in) 2990 mm (9 ft 10 in) 3020 mm (9 ft 11 in)
J: Sprocket Center to Idler Center 4040 mm (13 ft 3 in) 4470 mm (14 ft 8 in) 4250 mm (13 ft 11 in)
K: Track Shoe Width 600 mm (24 in) (Grouser shoe)
L: Overall Height 3460 mm (11 ft 4 in) 3460 mm (11 ft 4 in) 3540 mm (11 ft 7 in)
88 kPa 82 kPa 91 kPa
Ground Pressure
(0.89 kgf/cm2, 13 psi) (0.83 kgf/cm2, 12 psi) (0.93 kgf/cm2, 13 psi)
Swing Speed 9.0 min-1 (rpm)
5.5 km/h (3.4 mph)/ 4.0 km/h (2.5 mph)/
Travel Speed (fast/slow)
3.4 km/h (2.1 mph) 2.9 km/h (1.8 mph)
Gradeability 35 ° (tanθ = 0.70)
NOTE: “*” The dimensions do not include the height of the shoe lug.
T1-1-2
WORKING RANGES
ZAXIS450-3, ZAXIS450LC-3
G
F
A
M1J1-12-002
Category 7.0 m (22 ft 12 in) Boom 8.2 m (26 ft 11 in) Boom

2.9 m (9 ft 6 in) Arm 3.4 m (11 ft 2 in) Arm 3.9 m (12 ft 10 in) Arm 4.9 m (16 ft 1 in) Arm 4.9 m (16 ft 1 in) Arm
Backhoe Backhoe Backhoe Backhoe Backhoe
Item ZX450-3 ZX450LC-3 ZX450-3 ZX450LC-3 ZX450-3 ZX450LC-3 ZX450-3 ZX450LC-3 ZX450-3 ZX450LC-3
A:Maximum Digging
11400 (37’5”) 12060 (39’7”) 12490 (40’12”) 13340 (43’9”) 14510 (47’7”)
Reach mm (ftxin)
B:Maximum Digging
7280 (23’11”) 7770 (25’6”) 8270 (27’2”) 9110 (29’11”) 10230 (33’7”)
Depth mm (ftxin)
C: Maximum Cutting
10250 (33’8”) 11060 (36’3”) 11160 (36’7”) 11730 (38’6”) 12240 (40’2”)
Height mm (ftxin)
D: Maximum Dumping
7030 (23’1”) 7650 (25’1”) 7770 (25’6”) 8670 (28’5”) 9220 (30’3”)
Height mm (ftxin)
E:Transport Height
*3600 (11’10”) *3480 (11’5”) *3500 (11’6”) *4550 (14’11”) *4430 (14’6”)
mm (ftxin)
F: Overall Transport
*12000 (39’4”) *11910 (39’1”) *11910 (39’1”) *11900 (39’1”) *13130 (43’1”)
Length mm (ftxin)
G: Minimum Swing
5020 (16’6”) 4840 (15’11”) 4810 (15’10”) 4850 (15’11”) 5870 (19’3”)
Radius mm (ftxin)
NOTE: “*” The dimensions include the height of the shoe lug.
T1-1-3
ZAXIS500LC-3
G
F
A
M1J1-12-002
Category 7.0 m ( 22 ft 12 in) Boom 8.2 m (26 ft 11 in) Boom

2.9 m (9 ft 6 in) Arm 3.4 m (11 ft 2 in) Arm 3.9 m (12 ft 10 in) Arm 4.9 m (16 ft 1 in) Arm 4.9 m (16 ft 1 in) Arm
Backhoe Backhoe Backhoe Backhoe Backhoe

Item
A:Maximum Digging
11400 (37’5”) 12060 (39’7”) 12490 (40’12”) 13340 (43’9”) 14510 (47’7”)
Reach mm (ftxin)
B:Maximum Digging
7200 (23’7”) 7690 (25’3”) 8200 (26’11”) 9030 (29’8”) 10150 (33’4”)
Depth mm (ftxin)
C: Maximum Cutting
10330 (33’11”) 11130 (36’6”) 11240 (36’11”) 11810 (38’9”) 12310 (40’5”)
Height mm (ftxin)
D: Maximum Dumping
7100 (23’4”) 7730 (25’4”) 7840 (25’9”) 8750 (28’8”) 9290 (30’6”)
Height mm (ftxin)
E:Transport Height
*3620 (11’11”) *3500 (11’6”) *3510 (11’6”) *4540 (14’11”) *4440 (14’7”)
mm (ftxin)
F: Overall Transport
*11980 (39’4”) *11890 (39’) *11890 (39’) *11940 (39’2”) *13150 (43’2”)
Length mm (ftxin)
G: Minimum Swing
5020 (16’6”) 4840 (15’11”) 4810 (15’10”) 4850 (15’11”) 5870 (19’3”)
Radius mm (ftxin)
NOTE: “*” The dimensions include the height of the shoe lug.
T1-1-4
ZAXIS470H-3, ZAXIS470LCH-3, ZAXIS520LCH-3

G
F
A
M1J1-12-004
Category 3.4 m (11 ft 2 in) H Arm

Backhoe
Item
ZX470H-3 ZX470LCH-3 ZX520LCH-3
A:Maximum Digging Reach
12060 (39’7”)
mm (ftxin)
B:Maximum Digging Depth
7770 (25’6”) 7690 (25’3”)
mm (ftxin)
C: Maximum Cutting Height
11060 (36’3”) 11130 (36’6”)
mm (ftxin)
D: Maximum Dumping Height
7650 (25’1”) 7730 (25’4”)
mm (ftxin)
E:Transport Height mm (ftxin) *3480 (11’5”) *3500 (11’6”)
F: Overall Transport Length
*11910 (39’1”) *11890 (39’)
mm (ftxin)
G: Minimum Swing Radius
4840 (15’11”)
mm (ftxin)
NOTE: “*” The dimensions do not include height of the shoe lug.
T1-1-5
SHOE TYPES AND APPLICATIONS
ZX450-3
Shoe Width mm (in) 600 mm (24") 750 mm (30")
Grouser Shoe Grouser Shoe
Application For Ordinary Ground (Standard) For Weak Footing (Option)
Operating Weight kg 45700 46400
(lb) (100800) (102300)
Base Machine Weight kg 35600 36300
(lb) (78500) (80000)
Cab Height mm 3330 3330
(ft•in) (10’11”) (10’11”)
Minimum Ground mm *720 *720
Clearance (ft•in) (28”) (28”)
Undercarriage mm 5040 5040
Length (ft•in) (16’6”) (16’6”)
Undercarriage Width mm 3490/2990 3640/3140
(ft•in) (11’5”/9’10”) (11’11”/10’4”)
(Extended/Retracted)
Ground Pressure kPa 85 69
(kgf/cm2, psi) (0.87, 12) (0.70, 10)
ZX450LC-3
Shoe Width mm (in) 600 mm (24") 750 mm (30") 900 mm (35")
Grouser Shoe Grouser Shoe Grouser Shoe
Application For Ordinary Ground For Weak Footing For Weak Footing
(Standard) (Option) (Option)
Operating Weight kg 46600 47400 48100
(lb) (102700) (104500) (106000)
Base Machine Weight kg 36500 37300 37900
(lb) (80500) (82200) (83600)
Cab Height mm 3330 3330 3330
(ft•in) (10’11”) (10’11”) (10’11”)
Minimum Ground mm *720 *720 *720
Clearance (ft•in) (28”) (28”) (28”)
Undercarriage mm 5470 5470 5470
Length (ft•in) (17’11”) (17’11”) (17’11”)
Undercarriage Width mm 3490/2990 3640/3140 3790/3290
(ft•in) (11’5”/9’10”) (11’11’’/10’4’’) (12’5’’/10’10’’)
(Extended/Retracted)
Ground Pressure kPa 79 64 54
(kgf/cm2, psi) (0.81, 11) （0.65, 9） (0.55, 8)
NOTE: ･ The specification foe the front-end attachment are for 3.4 m(11 ft 2 in) arm with PCSA 1.9
m3(2.5yd3)bucket for ZX450-3 or PCSA 2.1 m3(207 yd3) for ZX450LC-3.
･750 mm(30in) and 900 mm(35in) grouser shoe should not be used on gravel or rocky ground.
･*The dimensions do not include the height of the shoe lug.
T1-1-6
ZX500LC-3
Shoe Width mm (in) 600 mm (24") 750 mm (30") 900 mm (35")
Grouser Shoe Grouser Shoe Grouser Shoe
Application For Ordinary Ground For Weak Footing For Weak Footing
(Standard) (Option) (Option)
Operating Weight kg 49500 50300 51100
(lb) (109100) (110900) (112700)
Base Machine Weight kg 39400 40200 40900
(lb) (86900) (88600) (90200)
Cab Height mm 3410 3410 3410
(ft･in) (11’2’’) (11’2’’) (11’2’’)
Minimum Ground mm *840 *840 *840
Clearance (ft･in) (33’’) (33’’) (33’’)
Undercarriage mm 5330 5330 5330
Length (ft･in) (17’6’’) (17’6’’) (17’6’’)
Undercarriage mm 3520/3020 3670/3170 3820/3320
Width (ft･in) (11’7’’/9’11’’) (12’1’’/10’5’’) (12’6’’/10’11’’)
(Extended/Retracted) (Extended/Retracted) (Extended/Retracted)
Ground Pressure kPa 87 71 60
(kgf/cm2, psi) (0.89, 13) (0.73, psi) (0.61, 8.7)
NOTE: ･ The specification foe the front-end attachment are for 3.4 m(11 ft 2 in) arm with PCSA 2.1
m3(2.7yd3)bucket for ZX500LC-3
･750 mm(30in) and 900 mm(35in) grouser shoe should not be used on gravel or rocky ground.
･*The dimensions do not include the height of the shoe lug.
T1-1-7
BUCKET TYPES AND APPLICATIONS (BACKHOE)
ZX450-3, ZX450LC-3
Bucket Capacity
Front-End Attachment
m3 (yd3)
Bucket ZX450-3 ZX450LC-3
Width 8.2 m 8.2 m
Bucket mm (in) 7.0 m (23’0’’) Boom (26’10’’) 7.0 m (23’ 0’’) Boom (26’10’’)
PCSA CECE
(With side Boom Boom
(Heaped) (Heaped)
cutter) 2.9 m 3.4 m 3.9 m 4.9 m 4.9 m 2.9 m 3.4 m 3.9 m 4.9 m 4.9 m
(9'6") (11’2”) (12’10”) (46’1”) (46’1”) (9'6") (11’2”) (12’10”) (46’1”) (46’1”)
Arm Arm Arm Arm Arm Arm Arm Arm Arm Arm
1.15
(1.5)
1.0 1210
(48”)
※ ※ ※ ◎ ◎ ※ ※ ※ ◎ ◎
1.4
(1.8)
1.2 1410
(56”)
※ ※ ※ ◎ × ※ ※ ※ ◎ ×
Hoe
1.6
(2.1)
1.4 1360
(54”)
◎ ◎ ◎ ※ ※ ◎ ◎ ◎ ※ ※
Bucket
1.9
(2.5)
1.7 1540
(61”)
◎ ◎ ○ ※ ※ ◎ ◎ ◎ ※ ※
2.1
(2.7)
1.8 1630
(64”)
◎ ○ × ※ ※ ◎ ◎ ○ ※ ※
2.3
(3.0)
2.0 1660
(65”)
○ × × ※ ※ ◎ ○ × ※ ※
ZX500LC-3
Bucket Capacity
m3 (yd3)
Bucket
8.2 m
Width
Bucket 7.0 m (23’0”) Boom (26’ 10”)
mm (in)
PCSA CECE Boom
(With side
(Heaped) (Heaped) 2.9 m 3.4 m 3.9 m 4.9 m 4.9 m
cutter)
(9'6") (11’2”) (12’10”) (46’1”) (46’1”)
Arm Arm Arm Arm Arm
1.15
(1.5)
1.0 1210
(48”)
※ ※ ※ ◎ ◎
1.4
(1.8)
1.2 1410
(56”)
※ ※ ※ ◎ ×
Hoe
1.6
(2.1)
1.4 1360
(54”)
◎ ◎ ◎ ※ ※
Bucket 1.9
(2.5)
1.7 1540
(61”)
◎ ◎ ◎ ※ ※
2.1
(2.7)
1.8 1630
(64”)
◎ ◎ ○ ※ ※
2.3
(3.0)
2.0 1660
(65”)
◎ ○ × ※ ※
NOTE: Symbols in the above table have the following meaning.

◎: General excavating.
○: Light duty excavating.
×: Not applicable (not warrantable)
※: Impossible to install.
T1-1-8
ZX470H-3, ZX470LCH-3, ZX520LCH-3

Bucket Capacity
m3 (yd3) Bucket Width
Bucket mm (in) ZX470H-3 ZX470LCH-3 ZX520LCH-3
PCSA CECE
(With side cutter) 3.4 m(11’2”) 3.4 m(11’2”) 3.4 m(11’2”)
(Heaped) (Heaped)
H Arm H Arm H Arm
Rock Bucket 1.9 (2.5) 1.7 1480 (58”) ■ ■ ■
1170 (46”)
Ripper Bucket 1.3 (1.7) 1.2 ■ ■ ■
(Without side cutter)
One Point
------ ------ ------ ■ ■ ■
Ripper
ZX470R-3, ZX470LCR-3, ZX520LCR-3

Bucket Capacity
m3 (yd3) Bucket Width
Bucket mm (in) ZX470R-3 ZX470LCR-3 ZX520LCR-3
PCSA CECE
(With side cutter) 3.4 m(11’2”) 3.4 m(11’2”) 3.4 m(11’2”)
(Heaped) (Heaped)
R Arm R Arm R Arm
Rock Bucket 1.9 (2.5) 1.7 1480 (58”) ■ ■ ■
1170 (46”)
Ripper Bucket 1.3 (1.7) 1.2 ■ ■ ■
(Without side cutter)
One Point
------ ------ ------ ■ ■ ■
Ripper
NOTE: Symbols in the above table have the following meanings.

■: Rock digging
For diging/loading operation gravels, blasted, hard clay, soft rock and so on.
T1-1-9
(Blank)
T1-1-10
GENERAL / Component Layout
MAIN COMPONENT LAYOUT
28
27 2
3
4
5
26 6
7
8
9
10
25
A
24
23
22
21
11
20
19 12
18 13
17
16 15 14 T1J1-01-02-002
1 - Arm Cylinder 8- Control Valve 15 - Fan Pump 22 - Hydraulic Oil Tank

2 - Washer Tank 9- Signal Control Valve 16 - Travel Device 23 - Pilot Shut-Off Solenoid
Valve
3 - Swing Bearing 10 - Air Cleaner 17 - Drain Filter 24 - Shockless Valve
4 - Center Joint 11 - Fan Motor 18 - Pilot Filter/ Pilot Relief 25 - Travel Pilot Valve
Valve
5 - Swing Device 12 - Engine 19 - Solenoid Valve Unit 26 - Front Attachment / Swing
Pilot Valve
6 - Fuel Tank 13 - Engine Oil Filter 20 - Check Valve 27 - Boom Cylinder
7 - Reserve Tank 14 - Pump Device 21 - Track Adjuster 28 - Bucket Cylinder
T1-2-1
View A (Around the Radiator)
4
3 5 M1J1-07-034
M1J1-07-032
Above of Control Valve

6
T1J1-01-02-013
1 - Inter Cooler 3 - Air Conditioner Condenser 5 - Oil Cooler 6 - Accumulator

2 - Fuel Cooler 4 - Radiator
T1-2-2
ELECTRICAL COMPONENT LAYOUT
Overview
Around Horn (Refer to T1-2-7)

• Horn
• Boom Bottom Pressure Sensor
• Auto-Lubrication Distribution Valve
1 (Optional)
2
Around Battery (Refer to T1-2-7)
• Battery
• Battery Relay
• Fusible Link
• Starter Relay
• Glow Plug Relay
• Auto-Lubrication System
(Optional)
3
4
Around Radiator
(Refer to T1-2-7)
• Receiver Tank
• Fresh Air
Temperature
Sensor
Pressure Sensor Block (Refer to T1-2-8)
• Pressure Sensor (Boom Raise) 11
• Pressure Sensor (Boom Lower) 10
• Pressure Sensor (Arm Roll-Out) 9 Engine
• Pressure Sensor (Arm Roll-In) 8 6 (Refer to T1-2-9)
• Pressure Sensor (Bucket Roll-Out)
• Pressure Sensor (Bucket Roll-In) 7 T1J1-01-02-002
• Pressure Sensor (Right Travel)
• Pressure Sensor (Left Travel) Pump Device (Refer to T1-2-10)
• Pump 1, 2 Delivery Pressure Sensor
• Pump 1, 2 Regulator Pressure Sensor
• Pump 1, 2 Control Solenoid Valve
• Fan Pump Control Solenoid Valve
1 - Monitor Unit 4- Fuel Sensor 7- Air Cleaner Restriction Switch 10 - Washer Motor
2 - Atmosphere Pressure 5- Pressure Sensor (Swing) 8- Solenoid Valve Unit 11 - ECM (Engine Controller)
Sensor (Refer to T1-2-8) (Refer to T1-2-8)
3 - Coolant Level Switch 6 - Intake Air Temperature 9 - Hydraulic Oil Temperature
Sensor Sensor
T1-2-3
(In Cab
Rear Tray
(Refer to T1-2-5)
11
12 View B
13
1
B
2
3
4
5
6
7
8
9
Switch Panel 10
(Refer to T1-2-6) T1J1-01-02-016
1 - Fan Rotation Direction 4 - Auto-Lubrication Switch 7 - Overload Alarm Switch 10 - Engine Stop Switch
Switch (Optional) (Optional) (Optional)
2 - Rotating Light Switch 5 - Level Check Switch 8 - Seat Heat Switch 11 - Radio
(Optional) (Engine Oil Level / Coolant (Optional)
Level)
3 - Rear Light Switch 6 - Boom Mode Selector 9 - Travel Alarm Deactivation 12 - Blower Main Relay
(Optional) Switch Switch (Optional)
13 - Compressor Clutch Relay
T1-2-4
Rear Tray 1 2
T1J1-01-02-003
7 6 5
10 11 12 13
9
14
8
15
16
T1V1-01-02-009
21 20 19 18 17
1 - MCF (Main Controller) 7 - Satellite Communication 12 - Auto-Lubrication Relay 17 - Light Relay 3 (R13)
Terminal (Optional) (R11) (Optional) (Optional)
2 - Overload Alarm Relay 8 - Security Relay (R5) 13 - Lock Relay (R2) 18 - Light Relay 2 (R8)
(Optional)
3 - Fuse Box 9 - Starter Cut Relay (R4) 14 - Load Damp Relay (R1) 19 - ECM Main Relay (R14)
4 - Dr. ZX Connector (Use as 10 - Hour Mater Relay (R12) 15 - Wiper Relay (R6) 20 - Washer Relay (R9)
Download Connector) (Optional)
5 - Pump Learning Switch 11 - Security Horn Relay (R3) 16 - Light Relay 1 (R7) 21 - Horn Relay (R10)
6 - ICF (Information Controller)
T1-2-5
Switch Panel
T1V1-04-02-001
6 5
1- Engine Control Dial 3 - Power Mode Switch 5- Key Switch 7- Wiper/Washer Switch
2- Auto-Idle Switch 4 - Travel Mode Switch 6- Work Light Switch
T1-2-6
Around Horn Around Radiator
3
M1J1-07-032
T1J1-01-02-015
Around Battery
7 8 9
6 10
5 11
12
T1J1-01-02-012
1 - Horn 4 - Fresh Air Temperature 7- Starter Relay 10 - Auto-Lubrication Pump

Sensor
2 - Boom Bottom Pressure 5 - Battery 8- Battery Relay 11 - Fuel Filler System Switch
Sensor (Optional)
3 - Receiver Tank 6 - Glow Plug Relay 9- Fusible Link 12 - Fuel Filler Pump
T1-2-7
Pressure Sensor Brock
1 2 3 4 5 6 7 8
Front Side
Main Frame
T1J1-01-02-008
Swing Device Side
Solenoid Valve Unit
Control Valve
Signal Control Valve
13
12
11 9
10
T1J1-01-02-007
1 - Pressure Sensor (Travel 5 - Pressure Sensor (Bucket 8- Pressure Sensor (Boom 11 - Solenoid Valve Unit (SI)
Right) Roll-In) Lower)
2 - Pressure Sensor (Travel 6 - Pressure Sensor (Bucket 9 - Pressure Sensor (Swing) 12 - Solenoid Valve Unit (SF)
Left) Roll-Out)
3 - Pressure Sensor (Arm 7 - Pressure Sensor (Boom 10 - Solenoid Valve Unit (SG) 13 - Solenoid Valve Unit (SC)
Roll-Out) Raise)
4 - Pressure Sensor (Arm
Roll-In)
T1-2-8
ENGINE
1 3
5
4
2
7 8 9 10
11
20
12
19
18
13
17
14
16
15
T1J1-01-02-014
1 - Fuel Main Filter 6 - EGR Valve 11 - Common Rail Pressure 16 - Fuel Temperature Sensor
Sensor
2 - Fuel Pre Filter 7 - Glow Plug Connector 12 - Crank Speed Sensor 17 - Cam Angle Sensor
Terminal
3 - Injector Connector 8 - Coolant Temperature 13 - Engine Oil Pressure 18 - Supply Pump
Sensor Sensor
4 - Boost Pressure Sensor 9 - Suction Control Valve 14 - Starter 19 - Overheat Switch
5 - Boost Temperature Sensor 10 - Priming Pump 15 - Engine Oil Level Switch 20 - Alternator
T1-2-9
PUMP DEVICE
1 2 3 4
11
T1J1-01-02-004
10 9 8 7
SWING DEVICE TRAVEL DEVICE
12 13
14
M1J1-07-048
M1J1-07-053
12
1 - Pump 2 Regulator Pressure 5- Pump 1 9- Pump 2 Delivery Pressure 12 - Swing Relief Valve
Sensor Sensor
2 - Pump 2 Control Solenoid Valve 6 - Pump 1 Delivery 10 - Fan Pump 13 - Counterbalance Valve
Pressure Sensor
3 - Pump 1 Regulator Pressure 7 - Pilot Pump 11 - Fan Pump Control 14 - Travel Relief Valve
Sensor Solenoid Valve
4 - Pump 1 Control Solenoid Valve 8 - Pump 2
T1-2-10
CONTROL VALVE
1
2
3
5 T1J1-03-03-003
4
8
7
6
10 9
T1J1-03-03-004
1 - Overload Relief Valve 4 - Overload Relief Valve 7 - Overload Relief Valve 9 - Overload Relief Valve
(Boom Lower) (Bucket Roll-In) (Boom Mode) (Arm Roll-In)
(Bucket Roll-Out) (Boom Raise) (Arm Roll-Out) (Auxiliary)
3 - Main Relief Valve 6 - Overload Relief Valve
(Auxiliary)
T1-2-11
COMPONENTS IN CONTROL VALVE
1 2 3 4 5
45 7
8
44
43 9
42 10
41
11
40
39
38
12
37
13
14
15
16
36
17
35 18
19
34
20
33
32
31 30 29 28 27 26 25 24 23 22 21
T450-03-03-025
T1-2-12
A B
C
C
D
D
E
E
F
F
G
G
H
H
T450-03-03-001
A B
Cross Section A-A Cross Section B-B
14
34
28 31
T450-03-03-011 T450-03-03-010
1- Bypass Shut-Out Valve 13 - Load Check Valve (Boom 2 24 - Check Valve (Main Relief 35 - Overload Relief Valve
Parallel Circuit) Pressure Flow Combining (Bucket Roll-Out)
Circuit)
2- Arm Regenerative Valve 14 - Boom Regenerative Valve 25 - Check Valve (Bucket Flow 36 - Overload Relief Valve
(Switch Valve) Combining Circuit) (Bucket Roll-In)
3- Check Valve (Arm 1 15 - Overload Relief Valve 26 - Check Valve (Auxiliary 37 - Boom Flow Rate Control
Roll-Out Parallel Circuit) (Boom Mode) Flow Combining Circuit) Valve (Switch Valve)
4- Load Check Valve (Arm 1 16 - Boom Overload Relief 27 - Check Valve (Bucket Flow 38 - Boom Flow Control Valve
Roll-In Parallel Circuit) Control Valve Combining Circuit) (Poppet Valve)
5- Load Check Valve (Swing 17 - Load Check Valve 28 - Flow Combiner Valve 39 - Overload Relief Valve
Tandem Circuit) (Auxiliary Tandem Circuit) (Boom Lower)
6- Load Check Valve (Arm 1 18 - Overload Relief Valve 29 - Check Valve (Flow 40 - Overload Relief Valve
Tandem Circuit) (Auxiliary) Combiner Valve Circuit) (Boom Raise)
7- Arm Regenerative Valve 19 - Overload Relief Valve 30 - Check Valve (Main Relief 41 - Boom Anti-Drift Valve
(Check Valve) (Auxiliary) Pressure Flow Combining (Switch Valve)
Circuit)
8- Arm Anti-Drift Valve (Check 20 - Load Check Valve 31 - Main Relief Valve 42 - Boom Anti-Drift Valve
Valve) (Auxiliary Parallel Circuit) (Check Valve)
9- Arm Anti-Drift Valve (Switch 21 - Load Check Valve (Left 32 - Load Check Valve (Bucket 43 - Check Valve (Arm
Valve) Travel Tandem Circuit) Parallel Circuit) Make-Up Circuit)
10 - Overload Relief Valve (Arm 22 - Bypass Shut-Out Valve 33 - Bucket Regenerative Valve 44 - Arm Flow Rate Control
Roll-Out) (Switch Valve) Valve (Switch Valve)
11 - Overload Relief Valve (Arm 23 - Load Check Valve (Left 34 - Bucket Regenerative Valve 45 - Arm Flow Rate Control
Roll-In) Travel Parallel Circuit) (Check Valve) Valve (Poppet Valve)
12 - Load Check Valve (Boom 2
Tandem Circuit)
T1-2-13
1 2 3 4 5
45 7
8
44
43 9
42 10
41
11
40
39
38
12
37
13
14
15
16
36
17
35 18
19
34
20
33
32
31 30 29 28 27 26 25 24 23 22 21
T450-03-03-025
T1-2-14
Cross Section C-C Cross Section D-D
Swing
Arm 2 Arm 1
3 10 2
8
44
45
T450-03-03-016
40 11
T450-03-03-023
Parallel Circuit) Pressure Flow combining (Bucket Roll-Out)
Circuit)
Circuit)
Tandem Circuit)
T1-2-15
1 2 3 4 5
45 7
8
44
43 9
42 10
41
11
40
39
38
12
37
13
14
15
16
36
17
35 18
19
34
20
33
32
31 30 29 28 27 26 25 24 23 22 21
T450-03-03-025
T1-2-16
Cross Section E-E Cross Section F-F
Boom 1 Boom 2 Bucket Auxiliary

33
39 13 15, 16 35 25 19
38
37
17
12
32
41 42 36 34 18
T450-03-03-015 T450-03-03-014
Circuit)
Circuit)
Tandem Circuit)
T1-2-17
1 2 3 4 5
45 7
8
44
43 9
42 10
41
11
40
39
38
12
37
13
14
15
16
36
17
35 18
19
34
20
33
32
31 30 29 28 27 26 25 24 23 22 21
T450-03-03-025
T1-2-18
Cross Section G-G Cross Section H-H
Travel Travel
(right) (left)
31
30
21
22
29
T450-03-03-013
T450-03-03-012
28
Circuit)
Roll-In Parallel Circuit) Control Valve} Combining Circuit) (Poppet Valve)
Circuit)
Tandem Circuit)
T1-2-19
1 2 3 4 5
45 7
8
44
43 9
42 10
41
11
40
39
38
12
37
13
14
15
16
36
17
35 18
19
34
20
33
32
31 30 29 28 27 26 25 24 23 22 21
T450-03-03-025
T1-2-20
Cross Section I-I
T450-03-03-008
24
T450-03-03-001
T450-03-03-006
Circuit)
Circuit)
Tandem Circuit)
T1-2-21
SIGNAL CONTROL VALVE
Pilot Port
Pilot Valve Side

Port Name Connecting to Remark
Port A Right Pilot Valve Boom Raise Pilot Pressure
Port B Right Pilot Valve Boom Lower Pilot Pressure
Port C Left Pilot Valve Arm Roll-Out Pilot Pressure
Port D Left Pilot Valve Arm Roll-In Pilot Pressure
Port E Left Pilot Valve Left Swing Pilot Pressure
Port F Left Pilot Valve Right Swing Pilot Pressure
Port G Right Pilot Valve Bucket Roll-In Pilot Pressure
Port H Right Pilot Valve Bucket Roll-Out Pilot Pressure
Port I Travel Pilot Valve Left Travel Forward Pilot Pressure
Port J Travel Pilot Valve Left Travel Reverse Pilot Pressure
Port K Travel Pilot Valve Right Travel Forward Pilot Pressure
Port L Travel Pilot Valve Right Travel Reverse Pilot Pressure
Port M Auxiliary Pilot Valve Auxiliary Open Pilot Pressure
Port N Auxiliary Pilot Valve Auxiliary Close Pilot Pressure
Port SA - Plug
Port SB - Plug
Port PI Check Valve Primary Pilot Pressure
Port PH Pilot Shut-Off Solenoid Valve Primary Pilot Pressure (Heat Circuit)
Port SH Swing Parking Brake Brake Release Pressure
Port DF Hydraulic Oil Tank Returning to Hydraulic Oil Tank
T1-2-22
Pilot Valve Side
PH
C
A
E
M
D
H B
SB
F
G
Pilot Valve
Side
PI
K
I
SH J
DF
SA L
T1J1-03-06-002
Control Valve Side

SM 3
5
1
13
2 4
SK SE
8
S3
14
Control Valve 7
Side
9 6
10
SN
SL
11
TR 12 SP T1J1-03-06-003
T1-2-23
Control Valve Side

Port 1 Control Valve Boom Raise Pilot Pressure
Port 2 Control Valve Boom Lower Pilot Pressure
Port 3 Control Valve Arm Roll-Out Pilot Pressure
Port 4 Control Valve Arm Roll-In Pilot Pressure
Port 5 Control Valve Left Swing Pilot Pressure
Port 6 Control Valve Right Swing Pilot Pressure
Port 7 Control Valve Bucket Roll-In Pilot Pressure
Port 8 Control Valve Bucket Roll-Out Pilot Pressure
Port 9 Control Valve Left Travel Forward Pilot Pressure
Port 10 Control Valve Left Travel Reverse Pilot Pressure
Port 11 Control Valve Right Travel Forward Pilot Pressure
Port 12 Control Valve Right Travel Reverse Pilot Pressure
Port 13 Control Valve Auxiliary Open Pilot Pressure
Port 14 Control Valve Auxiliary Close Pilot Pressure
Port S3 - Pressure Sensor (Swing)
Port SE - Plug
Port SM Hydraulic Oil Tank Returning to Hydraulic Oil Tank
Port SN - Plug
Port SP Hydraulic Oil Tank Returning to Hydraulic Oil Tank
Port SL Control Valve Flow Combiner Valve Control Pressure
Port SK Control Valve Arm Flow Rate Control Valve Control Pressure
Port TR - Plug
T1-2-24
Pilot Valve Side
PH
C
A
E
M
D
H B
SB
F
G
Pilot Valve
Side
PI
K
I
SH J
DF
SA L
T1J1-03-06-002
Control Valve Side

SM 3
5
1
13
2 4
SK SE
8
S3
14
Control Valve 7
Side
9 6
10
SN
SL
11
TR 12 SP T1J1-03-06-003
T1-2-25
(Blank)
T1-2-26
GENERAL / Component Specifications
ENGINE
Manufacturer............................................. ISUZU
Model ........................................................ AH-6W41XYSA-01
Type .......................................................... Diesel, 4-Cycle, Water-cooled, Inline, Direct Injection
Cyl. No.- Bore × Stroke ............................. 6-147 mm×154 mm (5.79 in×6.06 in)
Piston Displacement ................................. 15681 cm3 (957 in3)
Rated Output............................................. 260±5.2 kW/1800 min-1 (353±7 PS/ 1800 rpm)
Compression Ratio ................................... 16.0
Dry Weight ................................................ 1153 kg (2542 lb)
Firing Order............................................... 1-5-3-6-2-4
Rotation Direction ..................................... Clockwise (Viewed from fan side)
COOLING SYSTEM
Cooling Fan............................................... Dia. 1120 mm (44.1 in), 6 Blades Draw-in Type
Thermostat ................................................ Cracking Temperature at Atmospheric Pressure: 83 °C (181 °F)
Full Open (Stroke: 10 mm or more) Temperature: 95 °C (203 °F)
Water Pump .............................................. Centrifugal Gear Driven Type
LUBRICATION SYSTEM
Lubrication Pump Type ............................. Gear Pump
Oil Filter..................................................... Combined System of Full Flow and Bypass Type
Oil Cooler .................................................. Water Cooled Integral Type
STARTING SYSTEM
Motor ......................................................... Reduction Type
Voltage / Output ........................................ 24 V / 7 kW (9.5 PS)
PREHEAT SYSTEM
Preheating Method.................................... Glow Plug (QOS Type)
ENGINE STOP SYSTEM

Stop Method.............................................. Fuel Shut-Off
T1-3-1
ALTERNATOR
Type ............................................................... AC Type (With IC Regulator)
Voltage / Output ............................................. 24 V / 50 A
SUPERCHARGING SYSTEM
Type ............................................................... Exhaust-Turbocharger Type TD08H
FUEL SYSTEM
Type ...............................................................Common Rail 6HD Type
Governor ........................................................Electrical Centrifugal All Speed Control
Injection Nozzle ............................................Electrical Multi-Hole Type
EXHAUST RECIRCULATION SYSTEM

EGR Valve...................................................... Electrical Valve
Cooling System.............................................. Water Cooled, Diameter 80x300 mm (3.2x11.8 in)
PERFORMANCE (at New engine)

Lubricant Consumption.................................. Less than 100 mL/h (0.03 US gal/h) at 1800 min-1 (rpm)
Fuel Consumption Ratio ................................ Less than 214±13.6 g/kW/h (157±10 g/PS/h) at 1800 min-1
(rpm) (without Fan)
Injection Timing .............................................. 7 ° before T.D.C.
Maximum Output Torque................................ 1580±79 N⋅m (161±8 kgf⋅m) at approx. 1500 min-1 (rpm)
Compression Pressure .................................. 2.94 MPa (30 kgf/cm2, 427 psi)
Valve Clearance (Inlet / Exhaust) .................. 0.4 / 0.4 mm (when cool)
No Load Speed ............................................ Slow: 900±25 min-1 (rpm)
Fast: 1850±15 min-1 (rpm)
T1-3-2
Engine Performance Curve (AH-6WG1XYSA-01)
Test Condition: 1. In conformity with JIS D1005 (Performance Test Method for Diesel Engine Used for Construc-
tion Machinery) under standard atmospheric pressure.
2. Equipped with alternator and without fan.
1 1
1370±96 N⋅m/1000 min− 1580±79 N⋅m/1500 min−
Torque
(N⋅m)
1
260±5.2 kW/1800 min−
Output
(kW)
1
1850±30 min−
Fuel Consumption
Ratio (g/kW⋅h)
1
214±13.6 g/kW⋅h/1800 min−
-1 T1J1-01-03-001
Engine Speed min (rpm)
T1-3-3
ENGINE ACCESSORIES
RADIATOR ASSEMBLY
Type ...............................................................Radiator/Oil Cooler Parallel,
Inter Cooler Tandem Type Assembly
Weight ............................................................300 kg (661 lb)
Radiator Oil Cooler

Core Row ....................................................... 5 1
Fin Pitch ......................................................... 3.5/2P mm 3.5/2P mm
Fin Type ......................................................... ALW-4 CF40-1×3line
Radiating Area ............................................... 70.82 m2 (762 ft2) 60.81 m2 (655 ft2)
Capacity ......................................................... 15 L (4 US gal) 15.6 L (4.1 US gal)
Air-Tight Test Pressure .................................. 100 kPa (1.0 kgf/cm2, 14 psi) 1 MPa (10 kgf/cm2, 287 psi)
Cap Opening Pressure .................................. 49 kPa (0.5 kgf/cm2, 7 psi) −
Inter Cooler
Core Row ....................................................... −
Fin Pitch ......................................................... 4.0/2P mm
Fin Type ......................................................... 10 Hole Pipe
Radiating Area ............................................... 29.16 m2 (314 ft2)
Capacity ......................................................... 20 L (5.3 US gal)
Air-Tight Test Pressure .................................. −
Cap Opening Pressure .................................. −
FUEL COOLER
Weight ............................................................ 0.7 kg (1.5 lb)
Fin Pitch ......................................................... 4.0 mm
Fin Type ......................................................... Wave Fin
Capacity ......................................................... 0.2 L (0.05 US gal)
Radiating Area ............................................... 0.865 m2 (9.3 ft2)
Air-Tight Test Pressure .................................. 45 kPa (0.46 kgf/cm2, 6.5 psi)
Cap Opening Pressure .................................. −
BATTERY
Type ............................................................... 195G51-MF
Capacity ......................................................... 170 Ah (20-Hour Rate)
Voltage ........................................................... 12 V
Height × Width × Length ................................ 257×222×508 mm (10×8.7×20 in)
Weight ............................................................ 41.0 kg (90 lb)× 2
T1-3-4
HYDRAULIC COMPONENT
PUMP DEVICE
Drive Gear Ratio ............................................ Engine: 1, Pump 1: 32/31, Pump 2: 1
Engine: 1, Fan Pump: 1
Engine: 1, Pilot Pump: 32/31
MAIN PUMP
Type ............................................................... Variable Displacement Swash Plate Tandem Plunger Pump
Maximum Flow (Theoretical Value) ............... 367 L/min (97 US gpm) ×2
FAN PUMP
Type ............................................................... Variable Displacement Swash Plate Tandem Plunger Pump
Maximum Flow (Theoretical Value) ............... 65 L/min (17 US gpm)
PILOT PUMP
Model ............................................................. HY/ZFS 11/16.8 R
Type ............................................................... Fixed Displacement Type Gear Pump
Maximum Flow (Theoretical Value) ............... 33.6 L/min (8.88 US gpm)
HP Mode: 35.3 L/min (9.33 US gpm)
CONTROL VALVE
Backhoe
Model ............................................................. UH36-104
Type ............................................................... Pilot Pressure Operated Type (4-Spools + 5-Spools)
Main Relief Set-Pressure .............................. Normal: 31.9 MPa (325 kgf/cm2, 4638 psi) at 340 L/min
(90 US gpm)
Power Digging: 34.3 MPa (350 kgf/cm2, 4987 psi) at 340
L/min (90 US gpm)
Overload Relief Set-Pressure ........................ 35.3 MPa (360 kgf/cm2, 5132 psi) at 110 L/min (29 US gpm)
(Arm, Bucket, Boom, Auxiliary Close)
27.9 MPa (285 kgf/cm2, 4053 psi) at 110 L/min (29 US gpm)
(Auxiliary Open)
Loading Shovel
Model ............................................................. UH36-104C
Type ............................................................... Pilot Pressure Operated Type (4-Spools + 5-Spools)
Main Relief Set-Pressure .............................. Normal: 27.9 MPa (285 kgf/cm2, 4050 psi) at 340 L/min
(90 US gpm)
Overload Relief Set-Pressure ........................ 35.3 MPa (360 kgf/cm2, 5130 psi) at 110 L/min (29 US gpm)
(Boom Raise, Arm Extend/Retract, Bucket Open)
（Bucket Tilt-in/Tilt-out）
（Bucket Close）
T1-3-5
SWING DEVICE
Type ............................................................... Two-Stage Reduction Planetary Gear
Reduction Gear Ratio .................................... 16.563
SWING MOTOR
Model ............................................................. M5X130CHB
Type ............................................................... Swash-Plate Type, Fixed Displacement Axial Plunger Motor
VALVE UNIT
Type ............................................................... Non Counterbalance Valve Type
Relief Set-Pressure........................................ 27.9 MPa (285 kgf/cm2, 4053 psi) at 74 L/min (19.5 US gpm)
SWING PARKING BRAKE

Type ............................................................... Multi-Disc-Wet Negative Type
Release Pressure ........................................ 1.9 to 2.8 MPa (19 to 29 kgf/cm2, 276 to 407 psi)
TRAVEL DEVICE
Type ............................................................... Three-Stage Reduction Planetary Gear
Reduction Gear Ratio .................................... 55.318
TRAVEL MOTOR
Type ............................................................... Swash-Plate Type Variable Displacement Axial Plunger Motor
TRAVEL BRAKE VALVE

Type ................................................................Counterbalance Valve Type
Relief Set Pressure .........................................36.8 MPa (375 kgf/cm2, 5350 psi) @ 120 L/min (32 US gpm)
TRAVEL PARKING BRAKE

Type ................................................................Multi-Disc-Wet Negative Type
Cracking Pressure for Release.......................1.7 MPa (17 kgf/cm2, 242 psi)
FAN MOTOR
Model ..............................................................M5BF-045-1N03
Type ................................................................Fixed Displacement Trochoid Motor
T1-3-6
CYLINDER
Backhoe
Boom Arm
Rod Diameter......................................... 115 mm (4.5”) 130 mm (5.1”)
Cylinder Bore ......................................... 170 mm (6.7”) 190 mm (7.5”)
Stroke ..................................................... 1590 mm (5’3”) 1940 mm (6’4”)
Fully Retracted Length........................... 2260 mm (7’5”) 2710 mm (8’11”)
Plate Thickness...................................... 30 μm (1.18 μin) 30 μm (1.18 μin)
Weight .................................................... 420 kg (930 lb) 656 kg (1450 lb)
Bucket Counterweight Removal (Optional)

Rod Diameter......................................... 120 mm (4.7”) 65mm (2.6”)
Stroke ..................................................... 1325 mm (4’4”) 360 mm (1’2”)
Weight .................................................... 401 kg (885 lb) 82 kg (181 lb)
Loading Shovel
Boom Arm Bucket
Rod Diameter......................................... 115 mm (4.5”) 115 mm (4.5”) 115 mm (4.5”)
Cylinder Bore ......................................... 170 mm (6.7”) 170 mm (6.7”) 150 mm (5.9”)
Stroke ..................................................... 1590 mm (5’3”) 1205 mm (3’11”) 1230 mm (4’0”)
Fully Retracted Length........................... 2260 mm (7’5”) 1985 mm (6’6”) 2060 mm (6’9”)
Plate Thickness...................................... 30 μm (1.18 μin) 30 μm (1.18 μin) 30 μm (1.18 μin)
Weight .................................................... 420 kg (930 lb) 360 kg (794 lb) 320 kg (705 lb)
Level Dump
Rod Diameter......................................... 115 mm (4.5”) 65 mm (2.6”)
Stroke ..................................................... 560 mm (1’10”) 285 mm (11.2”)
Weight .................................................... 220 kg (485 lb) 57 kg (126 lb)
T1-3-7
FRONT ATTACHMENT PILOT VALVE

Model ............................................................. HVP06A-040-101
TRAVEL PILOT VALVE

Model ............................................................. HVP05S-040-101
AUXILIARY/ COUNTER WEIGHT REMOVAL PILOT VALVE (Optional)

Model ............................................................. HVP05M-040-101
SOLENOID VALVE UNIT

Function ......................................................... ⋅ SG : Power Digging Control
⋅ SI : Travel Motor Swash Angle Control
⋅ SF : Boom Flow Rate Control Valve Control
⋅ SC : Boom Mode Selector Control
PILOT PRESSURE SIGNAL CONTROL VALVE

Function ......................................................... ⋅ Shock Reducing (Boom Raise)
⋅ Arm Flow Rate Control Valve Control
⋅ Swing Parking Brake Release
⋅ Flow Combiner Valve Control
PILOT SHUT-OFF SOLENOID VALVE

Type ............................................................... ON/OFF Solenoid Valve
BYPASS CHECK VALVE

Cracking Pressure ......................................... 100±30 kPa (1.0±0.3 kgf/cm2, 14.5±4.4 psi)
@ 15 L/min (4 US gpm)
OIL COOLER BYPASS CHECK VALVE

Relief Set Pressure ........................................ 250±37 kPa (2.6±0.4 kgf/cm2, 36.3±5.4 psi)
T1-3-8
ELECTRICAL COMPONENT
BATTERY RELAY
Voltage / Current ............................................24 V / 100 A
GLOW PLUG RELAY

Voltage ........................................................... 24 V
HORN
Voltage / Current ............................................ 24 V⋅3 A
Sound Pressure ............................................. 110±5 dB (A)
ILLUMINATION
Specification................................................... Work/Boom Light: Halogen 24V, 70 W
Cab Light: 24 V, 10 W
AIR CONDITIONER
Refrigerant ................................................... 134a
Cooling Ability ................................................ 16.7 MJ/h (4000 kcal/h)
Cool Air Volume ............................................. 550 m3/h (718 yd3/h) or More
Heating Ability ................................................ 21.0 MJ/h (5000 kcal/h) or More
Warm Air Volume ........................................... 400 m3/h (523 yd3/h) or More
Temperature Adjusting System ...................... Electronic Type
Refrigerant Quantity....................................... 1150±50 g (2.5±0.11 lb)
Compressor Oil Quantity ............................... 180+150 cm3 (0.047+0.0040 US gal)
T1-3-9
(Blank)
T1-3-10
MEMO
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SECTION 2
SYSTEM
—CONTENTS—
Group 1 Controller Group 5 Electrical System
Outline ...................................................... T2-1-1 Outline ...................................................... T2-5-1
Can: Controller Area Network Main Circuit............................................... T2-5-2
(Network Provided for Machine) ............. T2-1-2 Electric Power Circuit
MCF: Main Controller ............................... T2-1-3 (Key Switch: OFF)................................... T2-5-4
ECM: Engine Control Module ................. T2-1-12 Accessory Circuit ...................................... T2-5-5
ICF: Information Controller ..................... T2-1-14 Starting Circuit (Key Switch: START) ........ T2-5-6
Monitor Unit ............................................ T2-1-16 Charging Circuit (Key Switch: ON) ............ T2-5-8
Serge Voltage Prevention Circuit ............ T2-5-12
Group 2 Control System
Pilot Shut-Off Circuit (Key Switch: ON) ... T2-5-14
Outline ...................................................... T2-2-1
Security Lock Circuit ............................... T2-5-16
Engine Control.......................................... T2-2-4
Engine Stop Circuit (Key Switch: OFF) ... T2-5-18
Pump Control ......................................... T2-2-21
Security Horn Circuit ............................... T2-5-19
Valve Control .......................................... T2-2-42
Working Light Circuit............................... T2-5-20
Other Controls ........................................ T2-2-54
Wiper / Washer Circuit ............................ T2-5-22
Group 3 ECM System
Outline ...................................................... T2-3-1
Fuel Injection Control ............................... T2-3-2
Engine Start Control ............................... T2-3-10
EGR (Exhaust Gas Recirculation)
Control.................................................. T2-3-12
Fuel Injection Amount Correction............ T2-3-14
Fuel Filter Restriction Indicator
Control.................................................. T2-3-15
Engine Stop Control................................ T2-3-16
Group 4 Hydraulic System

Outline ...................................................... T2-4-1
Pilot Circuit ............................................... T2-4-2
Main Circuit ............................................ T2-4-14
Counterweight Removal / Installation
Circuit (Optional) .................................. T2-4-24
1J1T-2-1
(Blank)
1J1T-2-2
SYSTEM / Controller
OUTLINE
The controllers are provided for each control respec-

tively.
Each controller is connected by using CAN (Controller
Area Network) in order to display on the monitor unit in
the cab or the monitoring of the machine overall con-
dition including the engine.
• MCF：Main Controller
• ECM：Engine Control Module
• ICF：Information Controller
• Monitor Unit
Dr.ZX
Satellite Terminal
(Optional)
Monitor Unit ICF
CAN Bus Line
MCF
ECM
CAN Bus Line

T1J1-02-01-004
NOTE: CAN (CAN Bus Line)
T2-1-1
SYSTEM / Controller
CAN: CONTROLLER AREA NETWORK
(NETWORK PROVIDED FOR MACHINE)
MCF, ECM, ICF and the monitor unit are connected by
using the CAN bus line and communicate the signal
and the data each other.
The CAN bus line consists of two harnesses, CAN

High and CAN Low.
Each controller judges the CAN bus line level due to
potential difference between CAN High and CAN Low.
Each Controller arranges the CAN bus line level and
sends the signal and the data to other controllers.
Dr.ZX
Satellite Terminal
(Optional)
Monitor Unit ICF
CAN Bus Line
CAN High
MCF
CAN Low
ECM
T1V1-02-01-050
T2-1-2
SYSTEM / Controller
MCF: MAIN CONTROLLER
Function Outline
The signals from engine control dial, sensors and NOTE: As for details on each control, refer to the
switches are input to MCF. Information from ECM, Control System group / SYSTEM.
ICF and monitor unit are input to MCF by using CAN.
MCF processes the input signals in the logic circuit
and sends the signal equal to target engine speed to
ECM (Engine Control Module) by using CAN com-
munication in order to control the engine.
MCF drives the solenoid valve unit and pump control
solenoid valve in order to control the pump and valve.
MCF has the controls as follows.

• Engine Control • Valve Control (Solenoid Valve Unit)
• Engine Control Dial Control • Pressure Increase Selection Control When Trav-
• ECO Control eling
• HP Mode Control • Power Digging Control
• Travel Speed Increase Control • Auto-Power Lift Control
• E Mode Control • Travel Motor Swash Angle Control
• Auto-Idle Control • Boom Mode Selector Control
• Attachment Operation Speed Increase Control • Boom Flow Rate Control Valve Control
(Optional)
• Attachment Operation Speed Decrease Control • Other Control
(Optional) • Work Mode Control
• Rear Monitoring Display Selection Control
• Pump Control • Level Check Control
• Pump Flow Rate Control • Auto Lubrication Control (Optional)
• Speed Sensing Control • Travel Alarm Control (Optional)
• E Mode Control • Overload Alarm Control (Optional)
• Horsepower Control
• Relief Flow Rate Reducing Control
• Swing Horsepower Reducing Control
• Overheat Prevention Control
• Attachment Mode Control (Optional)
• Counterweight Removal and Installation Control
(Optional)
• Fan Pump Flow Rate Control
• Pump Learning Control
T2-1-3
SYSTEM / Controller
• Engine Control
• Engine Control Dial Control, ECO Control
Controls the engine speed according to the rota-
tion angle of engine control dial. (Engine Control
Dial Control)
Reduces the engine speed to 1600 min-1 in 1
second in order to reduce fuel consumption and
noise level when all the control levers are in neu-
tral. (ECO Control)
• HP Mode Control
Slightly increases digging power such as arm
roll-in operation while excavating deeply.
• Travel Speed Increase Control

Increases the engine speed and travels faster
during travel single operation.
• E Mode Control
Reduces the target engine speed to 1580 min-1 in
maximum in order to reduce fuel consumption.
• Auto-Idle Control
Reduces the engine speed to 1030 min-1 in 3.5
seconds when all the control levers are in neutral
with the auto-idle switch ON. Therefore, fuel
consumption and noise level can be reduced.
• Attachment Operation Speed Increase Control

(Optional)
Set attachment operation speed (breaker) to in-
crease (+) with Dr. ZX. When operating the at-
tachment, engine speed increases to the attach-
ment operating speed set by Dr. ZX.
• Attachment Operation Speed Decrease Control

(Optional)
Set attachment operation speed (breaker) to de-
crease (-) with Dr. ZX. When the attachment
mode is selected, engine speed decreases to the
attachment operating speed set by Dr. ZX.
T2-1-4
SYSTEM / Controller
Hydraulic Oil
Temperature
Sensor
Pressure Sensor
Boom Raise
Boom Lower
Arm Roll-Out
Arm Roll-In
Bucket Roll-Out
Bucket Roll-In
Swing
Key Switch
Travel (Right)
Travel (Left)
Attachment (Optional)
Engine Con- Counterweight (Optional)
trol Dial CAN Communication
Monitor Unit
Auto-Idle
Switch MCF
Dr. ZX Digging Attachment Mode

Mode 1 to 3
Power Mode
Switch
HP Mode
E Mode
Pump 2 Delivery Pump 1 Delivery

P Mode Pressure Sensor Pressure Sensor
T1J1-02-02-021
Pump 2 Regulator Pump 1 Regulator

Pressure Sensor Pressure Sensor
T2-1-5
SYSTEM / Controller
• Pump Control
• Pump Flow Rate Control • Overheat Prevention Control
Delivers oil required for the actuator according to Reduces maximum flow rate and suction torque
the control lever stroke from the main pump. of the main pump, reduces the engine load and
prevents overheating when temperature of cool-
• Speed Sensing Control ant or hydraulic oil increases beyond the specified
Controls the pump flow rate in response to engine level.
speed changes due to variations in load so that
the engine output can be utilized more efficiently. • Attachment Mode Control (Optional)
(Engine stall is prevented when the machine op- Limits the upper of maximum flow rate of pump 2
erates under adverse conditions such as operat- and controls the appropriate flow rate for the at-
ing at high altitude.) tachment when operating the attachment with the
work mode in attachment mode.
• E Mode Control
Decreases the pump suction torque to 85 % in • Counterweight Removal and Installation Control
order to reduce the engine load and improve fuel (Optional)
consumption rate. Engine stall is prevented when Applies back-pressure to the main relief valve,
inferior fuel is used or the machine operates un- increases main relief pressure and the hoist /
der adverse conditions such as operating at high lower power improves. Or, Controls pump delivery
altitude. flow rate and makes fine operation easy.
• Horsepower Control • Fan Pump Flow Rate Control

Controls delivery flow rate of each main pump Controls delivery flow rate of the fan pump ac-
and uses engine power effectively so that sum of cording to boost temperature (intake air tem-
pump torques divided to two main pumps and fan perature passing by the intercooler), coolant
pump does not exceed the engine output torque. temperature, hydraulic oil temperature and intake
air temperature), and controls fan rotation speed
• Relief Flow Rate Reducing Control in order to make temperature of oil cooler, radiator
Controls hydraulic energy loss and prevents hy- and intercooler appropriate.
draulic oil temperature from rising. (Flow Rate
Reducing Control (Relief Cut Off)) • Pump Learning Control
Detects pressure, which is necessary to pump
• Swing Horsepower Reducing Control control, when the pump control solenoid valve is
Decreases delivery flow rate of main pump 2 in- activated.
cluding the swing circuit, increases delivery flow
rate of main pump 1 and uses the engine power
effectively when the swing control lever is oper-
ated and the pressure sensor (swing) detects
swing pilot pressure.
T2-1-6
SYSTEM / Controller
Pressure Sensor
Boom Raise
Boom Lower
Arm Roll-Out
Arm Roll-In
Bucket Roll-Out
Bucket Roll-In Pump 2 Delivery
Travel (Right) Pressure Sensor
Travel (Left)
Pump 1 Delivery
Swing
Pressure Sensor
Engine Con- Attachment (Optional)
trol Dial Counterweight (Optional)
Boom Mode
Selector Switch
MCF Pump 1
Regulator
Pressure
Sensor
Boost Tem-
perature Pump 2
Sensor Regulator
Pressure
Sensor
Coolant Intake-Air
temperature Temperature CAN Communication
sensor Sensor Pump 2 Control Pump 1 Control
Solenoid Valve Solenoid Valve
Monitor Unit
HP Mode (Work Mode)
Digging Attachment
E Mode
Mode Mode
P Mode
Hydraulic Oil
Power Mode Temperature T1J1-02-02-001
Switch Sensor
T2-1-7
SYSTEM / Controller
• Valve Control (Solenoid Valve Unit)
• Pressure Increase Selection Control When Trav-
eling, Power Digging Control
MCF drives solenoid valve unit (SG) temporarily,
supplies back-pressure to the main relief valve
and increases main relief pressure.
• Auto-Power Lift Control

When operating boom raise, MCF drives solenoid
valve unit (SG) temporarily, supplies
back-pressure to the main relief valve and in-
creases main relief pressure.
• Travel Motor Swash Angle Control

When shifting the travel mode switch, MCF drives
solenoid valve unit (SI) and selects the travel
mode.
• Boom Mode Selector Control

MCF drives solenoid valve unit (SC) and selects
the overload relief control valve. Therefore, as re-
lief set-pressure of the overload relief valve at the
boom lower side decreases, vibration of the ma-
chine is reduced during digging and grading work.
• Boom Flow Rate Control Valve Control

During combined operation of boom lower and
arm or boom lower and bucket, MCF drives so-
lenoid valve unit (SF).
Therefore, the switch valve of boom flow rate
control valve is shifted and oil through the boom
cylinder is restricted.
When the boom is lowered due to own weight with
the regenerative circuit and pressure oil from the
pump is used for other actuator, operating speed
of actuator increases.
T2-1-8
SYSTEM / Controller
Pressure Sensor
Boom Raise
Boom Lower
Arm Roll-Out
Arm Roll-In
Bucket Roll-Out
Bucket Roll-In
Boom Bottom Swing Pump 2 Delivery Pump 1 Delivery
Travel (Left)
Engine Control Attachment (Optional)
Dial
Counterweight (Optional)
Power Digging
Switch
MCF
Pump 1 Regulator
Fast Pressure Sensor
Pump 2 Regulator
Slow
Pressure Sensor
Travel Mode
Switch
Solenoid Valve
Unit
Pump 2 Control Pump 1 Control
Boom Mode
Selector Switch
Travel Motor
Boom Overload T1J1-02-02-012

Main Relief Relief Control
Valve Valve
T2-1-9
SYSTEM / Controller
• Other Control
• Work Mode Control
The work mode control consists of two modes,
digging and attachment.
The mode can be selected by using the monitor
unit.

Switches the screen of monitor unit to that of the
back-screen.
• Level Check Control

Checks levels of coolant and engine oil when
starting the work. This result is displayed on the
monitor unit.
• Auto Lubrication Control (Optional)

Controls the auto lubrication system correctly.
• Travel Alarm Control (Optional)

Sounds the buzzer while traveling.
• Overload Alarm Control (Optional)

Sounds the buzzer and indicates the warning of
overload while overloaded operation of boom
raise including lifting work.
T2-1-10
SYSTEM / Controller
Monitor Unit
Overload Alarm
Switch (Optional) MCF
Auto Lubrication
Switch (Optional) Back-Screen Buzzer
Level Check
Switch
Rear View Switch

(Optional)
To ICF
CAN Bus Line
Key Switch
Travel Alarm System

(Optional)
Pressure Sensor
Travel (Right) Travel Alarm
Buzzer Deactivation Switch
Travel (Left) (Optional)
Swing
Boom Bottom
Pressure Sensor
Auto Lubrication
Relay (Optional)
Proximity Switch
Engine Oil
Level Switch
Coolant Level
Switch
T1J1-02-01-001
T2-1-11
SYSTEM / Controller
ECM: ENGINE CONTROL MODULE
Function Outline
ECM (Engine Control Module) receives the signals
from sensors and MCF
ECM processes and drives the two-way valve, suc-
tion control valve and EGR (Exhaust Gas Recircula-
tion) motor in order to control the supply pump, in-
jector pump and EGR valve.
ECM has the controls as follows.

• Fuel Injection Control
ECM detects the engine operating condition ac-
cording to the signals from each sensor and MCF
and controls the fuel injection.
• Fuel Injection Amount Correction

ECM adjusts fuel injection amount according to
the signal of atmospheric pressure sensor.
• Preheating Control
ECM controls time for continuity of electrical cur-
rent for the glow plug according to coolant tem-
perature and improves the starting of engine.
• EGR Control
ECM decides EGR gas amount according to en-
gine speed, fuel flow rate, coolant temperature,
atmospheric pressure and intake-air temperature.
ECM opens EGR valve and re-circulates exhaust
gas, amount of which is equal to EGR gas amount,
in the intake manifold. EGR gas is combined with
intake-air so that combustion temperature is low-
ered and NOx is reduced.
• Engine Stop Control

When the emergency stop switch is turned to the
ON position, ECM stops the fuel injection of in-
jector and stops the engine.
NOTE: As for details on each control, refer to the

ECM System group / SYSTEM.
T2-1-12
SYSTEM / Controller
ECM
Crank Speed Sensor
Engine Stop
Cam Angle Sensor
Switch
From Terminal M
in Key Switch Atmospheric Pressure Sensor
Fuel Temperature Sensor
Coolant Temperature Sensor

Fuse Box
Intake-Air Temperature Sensor
To ICF, Mo-
tor Unit Boost Pressure Sensor
Boost Temperature Sensor

CAN Bus Line
Engine Oil Pressure Sensor
EGR Motor Position Sensor
EGR Motor
From Battery
MCF
Two-Way Valve
Glow Plug Relay Common Rail
Pressure Sensor
Suction
Control
Valve Common Rail
Supply Pump
Glow Plug
Fuel Tank
Injector
T1J1-02-01-002
T2-1-13
SYSTEM / Controller
ICF: INFORMATION CONTROLLER
Function Outline
• Operating Hours Management
The built-in clock is provided for ICF.
ICF sends data of the built-in clock to the monitor
unit by using CAN bus line.
• Alarm, Fault Code Memory

ICF memorizes the alarm and the fault code from
each controller by using the CAN bus line in the
time series.
The memorized alarm and fault code are sent to
the center server by the satellite terminal (op-
tional).
Engine oil pressure alarm and overheat alarm are
sent to the center server whenever these occur.
Other alarm and fault code are sent to the center
server once a day.
• Fault Code Display

ICF displays the fault code sent from each con-
troller by using the CAN bus line on Dr. ZX.
• Maintenance History
When the maintenance key is pushed on the
monitor unit, time is recorded.
• Daily Report Data Making

ICF records operating hours, fuel level and fuel
amount of use during daily operation, and makes
the daily report data.
The daily report data can be sent to the center
server by using the satellite terminal (optional).
• Frequency Distribution Data Making

ICF makes the frequency distribution data every
100 hours.
The frequency distribution data can be sent to the
center server by using the satellite terminal (op-
tional).
• Cumulative Operating Hours Record

ICF records all hours when the machine is oper-
ated.
The cumulative operating hours can be
downloaded to Dr. ZX.
• Mail Data Making (Optional)

ICF records the mails sent from the monitor unit
and sends them to the center server by the satel-
lite terminal.
T2-1-14
SYSTEM / Controller
ICF
CAN Bus Line
MCF Communication
• Built-In Clock
ECM
Satellite Terminal
(Optional)
• GPS
Monitor Unit
Center Server
Dr. ZX
T1V1-02-01-049
T2-1-15
SYSTEM / Controller
MONITOR UNIT
Function Outline
Primary Screen
1 2 3 4 5 6 7 8
22 10
11
12
13
14
15
21 20 19 18 17 16
T1J1-02-01-003
1 - Work Mode Display 7 - Work Mode Display 13 - Fuel Consumption Gauge 18 - Mail Selection (Optional)
2 - Auto-Idle Display 8 - Hour Meter 14 - Clock 19 - Auxiliary Selection
3 - Overload Alarm Display 9 - Auxiliary 15 - Back-Screen Selection 20 - Work Mode Selection
(Optional)
4 - Auto Lubrication Display 10 - Fuel Gauge 16 - Menu 21 - Return to Primary Screen
(Optional)
5 - Auxiliary 11 - Mail Display (Optional) 17 - Auxiliary Selection 22 - Coolant Temperature
Gauge
6 - Glow Display 12 - Auto Lubrication Display
(Optional)
T2-1-16
SYSTEM / Controller
• Display of Meters
Work Mode 2
Data to be displayed on each meter are received
from other controllers (MCF, ICF and ECM) by using
CAN, and are displayed on the monitor unit.
1 3
• Work Mode Display
The attachments being used are displayed accord-
ing to the signals received from MCF by using CAN.
Digging Mode 4
T1V1-05-01-108
Attachment Mode
Breaker
M1J1-01-003
M1J1-01-004 1 - Coolant Temperature 3 - Fuel Gauge

2 - Hour Meter 4 - Clock
T2-1-17
SYSTEM / Controller
• Auto-Idle Display (1)
When turning the auto-idle switch ON in the switch
panel, the monitor displays the auto-idle. 1 2 3 4
When the key is turned ON with the auto-idle switch
ON, auto-idle display (1) blinks for 10 seconds.
• Overload Alarm Display (2) (Optional)

MCF detects suspended load according to the sig-
nal from the bottom pressure sensor in boom cylin- 5
der. When overload is detected, the monitor unit
displays the alarm and sounds the buzzer according
to the signal received from MCF by using CAN bus
line. (Refer to T2-1-34.) (Refer to the Control Sys-
tem group / SYSTEM.)
• Auto Lubrication Display (3) (Optional)

When the auto lubrication switch (optional) is turned M1J1-01-003
ON, the auto lubrication is displayed according to

the signal received from MCF by using CAN bus
line.
• Glow Display (4)

While ECM is supplying current to the glow plug, the
data is displayed according to the signal from ECM.
(Refer to the ECM System group / SYSTEM.)
• Fuel Consumption Gauge Display (5)

Fuel consumption is displayed according to the sig-
nal from ECM, which is received through MCF by
using CAN.
T2-1-18
SYSTEM / Controller
• Fuel Sensor Error Display Coolant Temperature Fuel Sensor Error
When the fuel sensor is faulty or if the harness be- Sensor Error Display Display
tween fuel sensor and monitor unit is broken, the
data is displayed on the fuel gauge.
• Coolant Temperature Sensor Error Display

When the coolant temperature sensor is faulty or if
the harness between coolant temperature sensor
and monitor unit is broken, the data is displayed on
the coolant temperature gauge.
• Alarm and Remedy Displays against Alarm M1J1-01-010
Alarm marks are displayed on the lower part of

screen according to the alarm signals received from
each controller by using CAN. The remedy for each
alarm is displayed by key operation.
Alarm Display M1J1-01-008
Remedy Display against Alarm T1V5-05-01-013
T2-1-19
SYSTEM / Controller
• Troubleshooting
This screen displays fault codes according to the
signals received from ICF by using CAN.
Fault Code Display T1V5-05-01-097
• Controller Version
This screen displays the version of controller.
• Monitoring Controller Version Display T1V5-05-01-122
This screen displays temperature and pressure data

received from each controller by using CAN.
By key operation, the displayed data is hold.
T1V5-05-01-087
Monitoring Screen
• Operating Conditions
This screen displays machine hour, fuel usage and
fuel consumption rate registered by the monitor unit.
Operating Condition Screen T1V5-05-01-025
T2-1-20
SYSTEM / Controller
• Pump 2 Flow Rate Adjustment
(Only machines equipped with optional parts)
When using the attachments, fine adjust flow rate of
pump 2 by keys 1 and 2 operation.
(Adjusting range: -50 to 50 L/min)
The signals from the monitoring unit are sent to
MCF by using CAN.
MCF adjusts flow rate of pump 2 while controlling
pump 2 control solenoid valve. (Refer to Attachment
Mode Control in the Control Systems group / SYS-
TEM.) Key 1
Key 2
• Attachment Selection
When using Breaker 1
(Only machines equipped with optional parts) M1J5-01-014
On this screen, select digging mode and attachment

mode set by Dr. ZX.
NOTE: In attachment mode, the following four

modes are set at the time of shipping from
the factory.
1 - Digging
2 - Breaker 1
3 - Breaker 2
4 - Breaker 3
1 2 3 4 M1J5-05-003
Attachment Selection Screen
T2-1-21
SYSTEM / Controller
• Back Monitor Settings
By key operation, image display ON and OFF of
Auto-Control for switching image of the back monitor
while traveling pilot time and display format on the
screen of the rear view camera can be set.
IMPORTANT: the rear view camera is set in mirror

image mode. Therefore, if image dis-
play is set as mirror image, normal
image is displayed on the screen of
monitor unit.
If image display is set as normal
image, mirror image is displayed on
the screen of monitor unit.
T1V5-05-01-134
Back Monitor Setting Screen
T1V1-05-01-126
Normal Image Screen
T1V1-05-01-127
Mirror Image Screen
T2-1-22
SYSTEM / Controller
• Maintenance Settings
This screen displays the hour meter reading at re-
placement time and the remaining hours until the
next replacement.
As the items to be replaced are displayed in a list,
record performed replacement by selecting an item
from the list.
• Interval ON/OFF Settings

Set change interval for each item to be replaced.
• Items included in Maintenance Settings

Engine Oil
Engine Oil Filter Maintenance Setting Screen T1V5-05-01-049
Hydraulic Oil
Hydraulic Oil Pilot Filter
Hydraulic Oil Full-Flow Filter
Travel Device Oil
Swing Device Oil
Swing Bearing Grease
Air Cleaner Filter
Engine/Air Conditioner V-belt
Fuel Filter
Air Conditioner Filter
Interval ON/OFF Setting Screen T1V5-05-01-052
• Language Settings
Select a language to be used in screens from
among preset languages, according to work envi-
ronment.
Language Setting Screen T1V1-05-01-137

• Mail (Optional Function)
Send requests such as requests of forwarding (1),
service maintenance (2), fuel replenishment (3) and
general (4) in the mail switch screen.
Contents of mails are registered in ICF, and are sent
to the central server by a satellite terminal.
Mail Switch Screen T1V5-05-01-037
T2-1-23
SYSTEM / Controller
• Overload Alarm
Alarm
IMPORTANT: When using overload alarm, make

overload alarm available by using Dr.
ZX.
MCF detects suspended load according to the signal

from the bottom pressure sensor in boom cylinder.
When overload is detected, the monitor unit displays
the alarm and sounds the buzzer according to the
signal received from MCF by using CAN bus line.
If overload of the suspended load is dissolved, the
alarm message disappears and the buzzer stops
ringing. (Refer to the Control System group / SYS-
TEM.) T1V1-05-01-128
Primary Screen
NOTE: Even if the work is done while displaying a
Overload Alarm Switch (Optional)
screen except the primary screen, when an
overload condition is reached, the screen
of monitor unit is switched to the primary
screen, an alarm message is displayed,
and a buzzer is rung.
Even after the overload alarm is dissolved,
the monitor unit keeps on displaying the
primary screen without returning to the
screen while the work is done.
M1J1-03-001
T2-1-24
SYSTEM / Control System
OUTLINE
MCF (Main Controller) is used to control the machine

operations. The signals from engine control dial, vari-
ous sensors and switches are sent to MCF and proc-
essed in the logic circuit.
MCF sends the signals equivalent to the target engine
speed to ECM (Engine Control Module) by using CAM
communication in order to control the engine.
(Refer to ECM System / SYSTEM.) MCF drives the
solenoid valve unit and pump control solenoid valve in
order to control the pump and valve.
Satellite Terminal
(Optional)
Engine Con-
trol Dial Sensor Switch
CAN
Communication
Monitor Unit MCF

Fan Pump
Control
Solenoid
Valve
Pump Con-
trol Sole-
noid Valve
Solenoid
Valve Unit
T1J1-02-02-032
T2-2-1
Input Signal Output
• Engine Control Dial → Engine Control
• Pump 1 Regulator Pressure Sensor → Engine Control Dial Control
• Pump 2 Regulator Pressure Sensor → ECO Control
• Pump 1 Delivery Pressure Sensor → HP Mode Control
• Pump 2 Delivery Pressure Sensor → Travel Speed Increase Control
• Pressure Sensor (Boom Raise) → E Mode Control
• Pressure Sensor (Boom Lower) → Auto-Idle Control
•Pressure Sensor (Arm Roll-Out) → Attachment Operation Speed Increase
Control (OP)
• Pressure Sensor (Arm Roll-In) → Attachment Operation Speed Decrease
Control (OP)
• Pressure Sensor (Bucket Roll-Out) →
• Pressure Sensor (Bucket Roll-In) → Pump Control
• Pressure Sensor (Swing) → Pump Flow Rate Control
• Pressure Sensor (Travel) → Speed Sensing Control
• Pressure Sensor (Left Travel) → E Mode Control
• Pressure Sensor (Attachment) (OP) → Horsepower Control
• Pressure Sensor (Counterweight) (OP) → Relief Flow Rate Reducing Control
• Hydraulic Oil Temperature Sensor → Swing Hosepower Reducing Control
• Auto-Idle Switch → Overheat Prevention Control
• Power Digging Switch → Attachment Mode Control (OP)
• Power Mode Switch (HP/E/P) → Counterweight Removal and Installation
Control (OP)
• Travel Mode Switch (Fast/Slow) → MCF Fan Pump Flow Rate Control
• Learning Switch → Pump Learning Control
• Pilot Shut-Off Switch →
• Boom Mode Selector Switch → Valve Control (Solenoid Valve Unit)
• Boom Bottom Pressure Sensor → Pressure Increase Selection Control When
Traveling
• Key Switch → Power Digging Control
• Rear View Switch (OP) → Auto-Power Lift Control
• Overload Alarm Switch (OP) → Travel Motor Swash Angle Control
• Auto Lubrication Switch (OP) → Boom Mode Selector Control
• Proximity Switch (OP) → Boom Flow Rate Control Valve Control
• Engine Oil Level Switch →
• Coolant Level Switch → Other Control
Work Mode Control
CAN Communication Rear Monitoring Display Selection Control
• Crank Speed Sensor ← Target Engine Speed Level Check Control
• Cam Angle Sensor Actual Engine Speed → Auto Lubrication Control (OP)
• Coolant Temperature E Coolant Temperature → Travel Alarm Control (OP)
Sensor C
• Boost Temperature M Boost Temperature → Overload Alarm Control (OP)
Sensor
• Intake-Air Tempera- Intake-Air Tempera-
ture Sensor ture →
• Work Mode Switch (From Monitor Unit) →
(Digging/Attachment)
NOTE: OP: This control is for only the machine

with optional parts equipped.
T2-2-2
(Blank)
T2-2-3
ENGINE CONTROL
The engine control consists of the following functions.
• Engine Control Dial Control

• ECO Control
• HP Mode Control
• Travel Speed Increase Control
• E Mode Control
• Auto-Idle Control
• Attachment Operation Speed Increase Control
(Optional)
• Attachment Operation Speed Decrease Control
(Optional)
NOTE: (Optional): This control is for only the ma-

chine with optional parts equipped.
T2-2-4
Engine Control System Layout
Hydraulic Oil
Temperature
Sensor
Pressure Sensor
Boom Raise
Boom Lower
Arm Roll-Out
Arm Roll-In
Bucket Roll-Out
Bucket Roll-In
Swing
Key Switch
Travel (Right)
Travel (Left)
Engine Con-
trol Dial
CAN Communication
Monitor Unit
Auto-Idle MCF
Switch
Dr.ZX Digging Attachment Mode

Mode 1 to 3
Power Mode
Switch
HP Mode
E Mode
P Mode Pump 2 Delivery Pump 1 Delivery

T1J1-02-02-021

T2-2-5
Engine Control Dial Control, ECO Control
Engine speed is
Purpose: Controls the engine speed according to the reduced to 1600
rotation angle of engine control dial. (Engine Engine -1
min when the
Speed
control dial control) control levers are in
neutral.
Reduces the engine speed to 1600 min-1 in
order to reduce fuel consumption and noise
level when all the control levers are in neutral.
(ECO control)
Operation:
1. MCF sends the signals equivalent to target en-
gine speed to ECM by using CAN communication
Engine Con-
according to rotation angle of the engine control trol Dial Posi-
dial. Slow Idle Fast Idle tion
2. ECM controls the engine speed according to the
signal received by using CAN communication. NOTE: MCF sends the target engine speed to
3. When the engine control dial is beyond 1600 min-1 ECM every 10 ms (0.01 second). MCF
and all the control levers are turned to the neutral changes the data to send to ECM accord-
position (all pressure sensors: OFF), MCF ing to the status.
changes the signal to send to ECM as 1600 min-1
after one second.
4. ECM reduces the engine speed to 1600 min-1.
NOTE: When the engine speed set by the engine

control dial is slower than 1600 min-1, the
engine speed does not change as this
speed is slower than the engine speed in
ECO control.
This control is done regardless of whether
the auto-idle control is done or not.
The fast idle speed (P mode engine speed)
of engine can be corrected by Dr. ZX.
NOTE: The control (ECO control) in operation

steps 3, 4 is deactivated by Dr. ZX tempo-
rarily or permanently.
T2-2-6
Pressure Sensor
Boom Raise
Boom Lower
Arm Roll-Out
Arm Roll-In
Bucket
Bucket Roll-In
Swing
Travel (Right)
Travel (Left)
trol Dial
CAN Commu-
nication
MCF
Dr.ZX
P Mode
T1J1-02-02-022
T2-2-7
HP Mode Control
Purpose: Slightly increases digging power such as

arm roll-in operation while excavating deeply. Engine
Speed
-1
1210 min Increasing
Operation: Range of Fast
1. When the power mode switch is in the HP mode -1
Idle
1020 min
position and all the following conditions exist,
MCF sends the signals equivalent to the target
engine speed to ECM by using CAN communica-
tion.
2. ECM slightly increases the engine speed set by
the engine control dial.
Engine Con-
Condition: trol Dial Posi-
tion
• Engine Control Dial: Set at 1020 min-1 or faster. Slow Idle Fast Idle
• Boom Raise or Arm Roll-In Operation: Operated
• Average Delivery Pressure of Pumps 1 and 2:
High
NOTE: HP mode control is deactivated by Dr. ZX

temporarily or permanently. When HP
mode is selected with HP mode deacti-
vated, the engine speed can become 1800
min-1 by using the engine control dial.
T2-2-8
Pressure Sensor
Boom Raise
Arm Roll-In
Engine
Control Dial
CAN Communi-
cation
MCF
Dr.ZX
Power Mode
Switch
HP Mode

T1J1-02-02-023
T2-2-9
Travel Speed Increase Control
Purpose: Increases the engine speed and travels

faster during travel single operation. Engine
Speed
Engine speed
Operation: increases from
1. When the following conditions exist, MCF sends the fast idle
-1
1220 min speed by 100
the signals equivalent to the target engine speed -1
min .
to ECM by using CAN communication. -1
1120 min
2. ECM increases the engine speed by 100 min-1
-1
from the speed set by the engine control dial and 1070 min
travels faster.
Condition: Engine Con-

• Engine Control Dial: Set the engine speed at trol Dial Posi-
1070 min-1 or faster. Slow Idle Fast Idle tion
• Travel Operation: Operated
T2-2-10
Pressure Sensor
Travel (Right)
Travel (Left)
Engine Con-
trol Dial
CAN Communi-
cation
MCF

Travel Mode Switch
Slow
T1J1-02-02-024
NOTE: The illustration shows when the travel

mode switch is in the SLOW position.
T2-2-11
E Mode Control
Purpose: Reduces the target engine speed to 1580

min-1 in maximum in order to reduce fuel
consumption. Engine
Speed
Operation:
1. When the following conditions exist, MCF sends
the signal equivalent to the target engine speed
regulated at 1580 min-1 to ECM by using CAN 1580 min
-1
communication.
2. ECM adjusts the engine speed to the target en-
gine speed received from MCF.
Condition: Engine Con-

trol Dial Posi-
• Engine Control Dial: Set the engine speed at Slow Idle Fast Idle tion
1580 min-1 or faster.
• Power Mode Switch: E mode
NOTE: MCF sends the target engine speed to

ECM every 10 ms (0.01 second). MCF
changes the data to send to ECM accord-
ing to the status.
T2-2-12
Engine Con-
trol Dial CAN Communi-
cation
MCF
Power Mode
Switch
E Mode

T1J1-02-02-025

T2-2-13
Auto-Idle Control
Purpose: Reduces the engine speed when all the

control levers are in neutral in order to re-
duce fuel consumption and noise level.
Operation:
1. When the following conditions exist and approx.
3.5 seconds after the control lever is turned to
neutral, MCF sends the signals equivalent to the Engine Engine speed is
reduced to the
auto-idle speed to ECM by using CAN communi- Speed
auto-idle speed
cation. after 3.5 seconds.
2. ECM changes the engine speed into the auto-idle Fast Idle
speed.
3. As soon as either control lever is moved (pres-
sure sensor: ON), MCF returns the signals send- Auto-Idle
-1
ing to ECM into those equivalent to the target en- 1030 min Speed
gine speed set by the engine control dial.
4. ECM returns the engine speed into the original
engine speed. Slow Idle
Engine Con-
trol Dial Posi-
Condition: Slow Idle Fast Idle tion
• Engine Control Dial: Set the engine speed at
1030 min-1 or faster.
• Auto-Idle Switch: ON
Auto-Idle Deactivation Requirements:

• Control Lever: Operated (pressure sensor: ON)
• Power Mode Switch: When the E mode is
changed to P mode or P mode is changed to E
mode
• Engine Control Dial: When the engine speed is
changed
NOTE: Auto-idle speed can be adjusted by Dr. ZX.
T2-2-14
Pressure Sensor
Boom Raise
Boom Lower
Arm Roll-Out
Arm Roll-In
Bucket Roll-Out
Bucket Roll-In
Swing
Travel (Right)
Travel (Left)
trol Dial
CAN Communi-
cation
Auto-Idle MCF
Switch
Dr.ZX
Power Mode Switch
P Mode
T1J1-02-02-026
T2-2-15
Attachment Operation Speed Increase Control
(Only Machine Equipped with Front Attachment
Parts) Engine
Speed
When all condi-
tions exist, the
Purpose: Increases the maximum engine speed to maximum en-
the attachment (breaker) operating engine gine speed is
speed set by Dr. ZX when the attachment is increased to the
speed set by Dr.
operated. ZX.
Operation:
1. When the following conditions exist and the at-
tachment is operated, the MCF sends the signals
equivalent to the target engine speed set by Dr. Engine Con-
trol Dial Posi-
ZX to ECM by using CAN communication. tion
Slow Idle Fast Idle
2. ECM increases engine speed to the attachment
operating speed set by Dr. ZX.
Conditions:
• Dr. ZX: Resets the maximum engine speed to a
faster (+) attachment (breaker) operating speed in
the service mode.
• Engine Control Dial: Fast Idle Speed Position
• Power Mode Switch: HP Mode
• Attachment: Operated
• Work Mode: Attachment Mode
Set the attachment selected by Dr. ZX to faster
(+).
NOTE: When the P mode engine speed is preset

to a slower speed in Dr. ZX service mode,
the maximum engine speed will not be in-
creased when operating the attachment.
T2-2-16
Pressure Sensor
Engine Con-
trol Dial CAN Communi-
cation
Monitor Unit
MCF
Dr.ZX
Attachment Mode
1 to 3
Power Mode Switch
HP Mode
T1J1-02-02-030
T2-2-17
Attachment Operation Speed Decrease Control
(Only Machine Equipped with Front Attachment
Parts) Engine
Speed
Purpose: Decreases the maximum engine speed to When all condi-

the attachment (breaker) operating engine tions exist, the
maximum en-
speed set by Dr. ZX when the attachment gine speed is
mode is selected. reduced to the
speed set by Dr.
ZX.
Operation:
1. When the following conditions exist and the front
attachment is operated, MCF sends the signals
equivalent to the target engine speed set by Dr. Engine Con-
trol Dial Posi-
ZX to ECM by using CAN communication. tion
Slow Idle Fast Idle
2. ECM increases engine speed to the attachment
operating speed set by Dr. ZX.
Conditions:
• Dr. ZX: Resets the maximum engine speed to a
slower (-) attachment (breaker) operating speed
in the service mode.
• Work Mode: Attachment Mode
Set the attachment selected by Dr. ZX to slower
(-)
T2-2-18
CAN Com- Monitor Unit

munication
MCF
Dr.ZX
Attachment Mode
1 to 3
T1J1-02-02-031
T2-2-19
(Blank)
T2-2-20
PUMP CONTROL
The pump control system has the following functions:
• Pump Flow Rate Control • Overheat Prevention Control

• Speed Sensing Control • Attachment Mode Control (Optional)
• E Mode Control • Pump Control for Counterweight (Optional)
• Horsepower Control • Fan Pump Flow Rate Control
• Relief Flow Rate Decrease Control • Pump Learning Control
• Swing Horsepower Reducing Control
NOTE: (Optional): This control is for only the ma-
chine with optional parts equipped.
Pump Control System Layout

Pressure Sensor
Boom Raise
Boom Lower
Arm Roll-Out
Arm Roll-In
Bucket Roll-Out
Travel (Left)
Swing Pump 1 Delivery
Pressure Sensor
Engine Con- Attachment (Optional)
trol Dial Counterweight (Optional)
Boom Mode
Selector Switch
Boost Tem-
perature Pump 1
Sensor MCF Regulator
Pressure
Sensor
Pump 2
Regulator
Pressure
Sensor
Coolant Intake-Air
Temperature Temperature CAN Communication
Sensor Sensor Pump 2 Control Pump 1 Control
Monitor Unit Solenoid Valve Solenoid Valve
HP Mode (Work Mode)
E Mode
Digging Attachment
Mode Mode
P Mode
Hydraulic Oil
Power Mode Temperature T1J1-02-02-001
Switch Sensor
T2-2-21
Pump Flow Rate Control
Purpose: Delivers oil required for the actuator from the

main pump according to the control lever
stroke.
Operation:
• Control Lever: Operated
1. When the control lever is operated, pressure oil NOTE: The boom is lowered due to own weight by
from the pilot valve according to the control the boom regenerative valve during boom
pressure acts on each pressure sensor. lower operation.
2. Each pilot pressure sensor detects this pressure Therefore, during boom lower operation,
and sends the signal to MCF. delivery flow rate of the main pump does
3. MCF compares with the actual pump swash angle not increase.
detected by the pump 1 regulator sensor or pump
2 regulator sensor, calculates the required oil
amount and drives the pump control solenoid
valve.
4. Consequently, swash angle of the main pump
becomes large and delivery flow rate of the main
pump increases.
• Control Lever: In Neutral

1. When the control lever is in neutral, pilot pressure
oil to each pressure sensor disappears.
2. Each pilot pressure sensor detects no pressure
and sends the signal to MCF.
3. MCF compares with the actual pump swash angle
detected by the pump 1 regulator sensor or pump
2 regulator sensor, calculates the required oil
amount and drives the pump control solenoid
valve.
4. Consequently, swash angle of the main pump
becomes minimum and delivery flow rate of the
main pump becomes minimum.
T2-2-22
Pressure Sensor
Boom Raise
Boom Lower
Arm Roll-Out
Arm Roll-In Pump 2 Delivery
Pressure Sensor
Bucket Roll-Out
Travel (Left)
Engine Con-
trol Dial Swing
Pump 1
MCF Regulator
Pressure
Sensor
Pump 2
Regulator
Pressure
Sensor
T1J1-02-02-002

T2-2-23
Speed Sensing Control
Purpose: Controls the pump flow rate in response to

engine speed changes due to variations in
load so that the engine output can be utilized
more efficiently. (Engine stall is prevented
when the machine operates under adverse
conditions such as operating at high alti-
tude.)
Operation:
Q
1. The target engine operating speed is set by con- HP Mode
trolling the engine control dial.
2. MCF calculates the difference in speed between
the target engine speed and the actual engine Increase
speed input from ECM. Then, MCF sends signals
to the pump control solenoid valve.
3. The pump control solenoid valve delivers pilot Basic
Decrease Torque
pressure oil in response to the received signals to
the pump regulator and controls the pump deliv-
ery flow rate.
4. If the engine load increases and the actual engine
Pressure P
speed becomes slower than the target engine T111-05-02-004
speed, the pump swash angle is reduced so that
Pump P-Q Curve
pump flow rate will be reduced. Therefore, the
engine load is reduced and engine stall is pre-
vented.
Q
5. If the actual engine speed becomes faster than
the target engine speed, the pump swash angle is P/E Mode
Flow Rate
increased so that pump flow rate will increase.
Therefore, the engine output can be utilized more
efficiently.
NOTE: As for the actual engine speed, ECM cal-

culates the signals from crank speed sen- Decrease
Basic
sor and cam angle sensor and sends to Torque
MCF.
Pressure P
T166-02-01-014
T2-2-24
Pump 2 Delivery
Pressure Sensor
Pump 1 Delivery
Pressure Sensor
Engine
Control Dial
MCF
CAN Com-
munication
T1J1-02-02-003
Crank Speed Cam Angle Pump 2 Control Pump 1 Control

Sensor Sensor Solenoid Valve Solenoid Valve
T2-2-25
E Mode Control
Purpose: Decreases the pump suction torque to 85 %

in order to reduce the engine load and im-
prove fuel consumption rate. Engine stall is
prevented when inferior fuel is used or the
machine operates under adverse conditions
such as operating at high altitude.
Q
Operation:
1. When the E mode switch is turned ON, MCF re-
ceives the signal.
2. MCF calculates a target pump displacement an- Flow
gle according to the signal from the pump delivery Rate Decrease
Base Torque
pressure sensor.
MCF compares the target pump displacement E Mode
angle with the actual pump displacement angle
detected by the pump regulator pressure sensor.
3. MCF actuates the pump control solenoid valve in Pressure P
order to compensate for the difference between T166-02-01-006
the actual and target pump displacement angles,

and reduces the main pump displacement angle.
Then, the main pump flow rate decreases.
T2-2-26
Pump 2 Delivery
Pressure Sensor
Pump 1 Delivery
Pressure Sensor
Engine
Control Dial
MCF Pump 1
Regulator
Pressure
Sensor
Pump 2
Regulator
Pressure
Power Mode Switch Sensor
E Mode
T1J1-02-02-004
T2-2-27
Horsepower Control
Purpose: Controls delivery flow rate of each main NOTE: Delivery flow rate of the fan pump is con-
pump and uses engine power effectively so trolled by the fan pump flow rate control
that sum of pump torques divided to two regardless with engine output power. (Re-
main pumps and fan pump does not ex- fer to T2-2-38.)
ceed the engine output torque.
Operation:
1. In normal, delivery pressure difference between 5. MCF compares actual pump displacement angle
main pumps 1 and 2 occurs with two pumps op- detected by the pump regulator pressure sensor
erated. with the target pump displacement angle.
2. Larger load is applied to the main pump with 6. MCF activates the pump control solenoid valve at
higher delivery pressure and smaller load is ap- the side with larger load in order to compensate
plied to that with lower delivery pressure. for the difference between the actual and target
3. The pump delivery pressure sensor and pump pump displacement angles, and increases deliv-
regulator pressure sensor detect this status and ery flow rate of the main pump with larger load.
send the signal to MCF.
4. MCF calculates the maximum target pump dis-
placement angle according to the signals from
two main pump delivery pressure sensors so that
sum of pump torques of main pumps 1, 2 and fan
pump does not exceed the engine output power.

Engine
Control Dial
MCF Pump 1
Regulator
Pressure
Sensor
Pump 2
Regulator
Pressure
Sensor
T1J1-02-02-038

T2-2-28
Relief Flow Rate Reducing Control (Relief Cut
Off)
Purpose: Reduces hydraulic energy loss and prevents

hydraulic oil temperature from rising. (Flow
Rate Reducing Control (Relief Cut Off))
Operation:
1. When an actuator is operated, the pump delivery 4. If the pressure sensor (travel right or left) detects
pressure varies due to changing load applied to travel pilot pressure or the pressure sensor
each actuator. (swing) detects swing pilot pressure, MCF can-
2. The pump delivery pressure sensor detects de- cels the relief flow rate reducing control to the
livery pressure and sends the signals to MCF. main pump (relief cut off override).
3. When pump delivery pressure reaches 30.9 MPa
(315 kgf/cm2, 4490 psi), MCF compares pump
delivery pressure with the actual pump displace-
ment angle detected by the pump regulator
pressure sensor, and activates the pump control
solenoid valve. Therefore, pump delivery flow rate
decreases and becomes the minimum flow rate.
Qm
Relief Cut Off Override
Flow Rate
Relief Cut Relief Flow Rate
Off Reducing
Qo
Pressure Pc Pr P
Travel (Right)
Travel (Left)
Pump 2 Delivery
Swing Pressure Sensor
Pump 1 Delivery
Pressure Sensor
Engine Con-
trol Dial
Pump 1
MCF Regulator
Pressure
Sensor
Pump 2
Regulator
Pressure
Sensor
T1J1-02-02-005
T2-2-29
Swing Horsepower Reducing Control
Purpose: Decreases delivery flow rate of main pump 2

including the swing circuit, increases delivery
flow rate of main pump 1 and uses the en-
gine power effectively when the swing con-
trol lever is operated and the pressure sen-
sor (swing) detects swing pilot pressure.
Operation:
1. The pressure sensor (swing) detects swing pilot
pressure and sends a signal to MCF when the
swing function is operated. Q
2. MCF calculates the target pump displacement
angle according to a signal from the pump deliv-
ery pressure sensor. Then, MCF compares the Flow Rate
target displacement angle with the actual pump
displacement angle detected by the pump regu-
lator pressure sensor.
3. MCF activates the pump control solenoid valve in
main pump 2 in order to compensate the differ- Pressure P
ence between the actual and target displacement Main Pump 2
angles, and decreases pump delivery flow rate.
4. If the combined operation of swing and travel, or
Q
swing and front attachment is operated, the
pressure sensors (swing, travel, boom raise/lower,
arm roll-out/in, bucket roll-out/in and attachment)
detect pilot pressure respectively and send a Flow Rate
signal to MCF.
5. MCF activates the control solenoid valve in main
pump 1 and increases pump delivery flow rate.
Pressure P
Main Pump 1
T2-2-30
Pressure Sensor
Travel (Right) Pump 2 Delivery

Travel (Left) Pressure Sensor
Swing
Pump 1 Delivery
Pressure Sensor
Engine Con-
trol Dial
MCF Pump 1
Regulator
Pressure
Sensor
Pump 2
Regulator
Pressure
Sensor
Pump 2 Control Pump 1 Control T1J1-02-02-006

NOTE: The illustration shows during combined

operation of swing and travel.
T2-2-31
Overheat Prevention Control
Purpose: Prevents the engine from overheating by

reducing the main pump maximum flow
rate and pump torque, reducing the load
applied to the engine when coolant and
hydraulic oil temperatures increase beyond
the specified level.
Operation:
1. The signal from coolant temperature sensor is
Q
sent to MCF via ECM and CAN.
2. When coolant temperature is 99 °C (210 °F) or
higher, MCF calculates the target pump dis-
placement angle according to the signal from the Flow Rate
pump delivery pressure sensor. MCF compares
the actual pump displacement angle detected by
the pump regulator pressure sensor with the tar-
get pump displacement angle.
order to compensate the difference between the Pressure P
actual and target displacement angels, and de-
creases 7 % of pump torque.
4. The signal from the hydraulic oil temperature
Q
sensor is sent to MCF.
5. When hydraulic oil temperature is 100 °C (212 °F)
or higher, MCF calculates the target pump dis-
placement angle according to the signal from the
Flow Rate
pump delivery pressure sensor. MCF compares
the actual pump displacement angle detected by
the pump regulator pressure sensor with the tar-
get pump displacement angle.
order to compensate the difference between the Pressure P
actual and target displacement angels, and de-
creases maximum flow rate and 7 % of pump
torque.
Completion Condition for Overheat Control

• Coolant temperature 95 °C (203 °F) or lower
• Hydraulic oil temperature: 95 °C (203 °F) or lower
T2-2-32
Pump 2 Delivery
Pressure Sensor
Pump 1 Delivery
Pressure Sensor
Engine Con-
trol Dial
Pump 1
MCF Regulator
CAN Commu-
Pressure
nication
Sensor
Pump 2
Regulator
Pressure
Sensor

Coolant Tem- Hydraulic Oil Solenoid Valve Solenoid Valve T1J1-02-02-007
perature Sen- Temperature
sor Sensor
T2-2-33
Attachment Mode Control (Only Machine
Equipped with Front Attachment)
Purpose: Limits the upper of maximum flow rate of Operation:

pump 2 and controls the appropriate flow 1. When the work mode is in the attachment mode
rate for the attachment when operating the position and the breaker (attachment pilot valve)
attachment with the work mode in attach- is operated, the pressure sensor (attachment)
ment mode. detects attachment pilot pressure and sends the
signal to MCF.
2. At the same time, the selection information of at-
NOTE: When the attachment mode is shifted, the tachment mode is sent to MCF.
maximum flow rate setting (367 L/min (97 3. MCF always detects the displacement angle de-
gpm)) at normal control (digging mode) can tected by the pump regulator pressure sensor.
be selected as the table below. 4. MCF activates the pump 2 control solenoid valve
and keeps the displacement angle when the dis-
Mode Maximum Breaker placement angle of pump 2 increases to the posi-
Flow Rate tion for maximum flow rate indicated at the at-
Breaker 1 200 L/min tachment mode.
Mitsubishi (MKB2500SS)
(53 gpm) 5. As the attachment is controlled by the auxiliary
Breaker 2 250 L/min NPK (E-220) spool at 5-spool section in control valve, only
(66 gpm) Furukawa (F-45) maximum flow rate of pump 2 is controlled.
Mitsubishi (MKB3000V)
Breaker 3 280 L/min Hitachi (HSB90S) NOTE: If operating the attachment at digging mode,
(74 gpm) NPK (E-225) flow rate of pump 2 is kept minimum.
Okada (OUB524)
NOTE: As return oil from the breaker flows to the
hydraulic oil tank directly without flowing
Q
(L/min) through the oil cooler, hydraulic oil tem-
perature increases.
367 In order to prevent this, when operating the
breaker, MCF activates pump 1 flow rate
280 control solenoid valve and increases deliv-
250 ery flow rate of pump 1.
200 Consequently, as oil amount through the oil
cooler increases, hydraulic oil temperature
does not increase and overheating is pre-
vented when operating the breaker.
Pressure P
T2-2-34
Control Valve
Auxiliary
Spool
(For
Attachment)
Pressure Sensor
4-Spool 5-Spool
Section Section
Front Attachment Pump 2

Delivery Pump 1 Delivery
Pressure Pressure Sensor
Engine Con- Sensor
trol Dial
MCF
Pump 1 Regulator
Pressure Sensor
Pump 2 Regulator
Pressure Sensor
CAN
Cummunication

Monitor Unit Solenoid Valve Solenoid Valve
(Work Mode)
Digging Attachment
mode Mode
T1J1-02-02-008
T2-2-35
Counterweight Removal and Installation Control
(Optional)
Purpose: Applies back-pressure to the main relief

valve, increases main relief pressure and the
hoist / lower power improves. Or, Controls
pump delivery flow rate and makes fine op-
eration easy.
Operation:
1. When the counterweight hoist / lower lever (op-
tional) is operated, the pressure sensor (coun-
terweight) detects pilot pressure and sends the
signal to MCF.
2. MCF activates solenoid valve unit (SG).
3. Pressure oil from the pilot pump flows to the back
of main relief valve.
4. Pressure oil compresses the spring of main relief
valve and relief pressure increases. (Refer to the
Control Valve group / COMPONENT OPERA-
TION.)
5. MCF compares actual pump displacement angle
detected by the pump 1 or 2 regulator pressure
sensor with the target pump displacement angle.
MCF calculates required oil amount and activates
the pump control solenoid valve.
6. Delivery flow rates of pumps 1, 2 become mini-
mum.
NOTE: Main Relief Pressure:

During normal operation: 31.9 MPa (325
kgf/cm2, 4638 psi)
During pressure increasing operation: 34.3
MPa (350 kgf/cm2, 4987 psi)
T2-2-36
Pressure Sensor

Counterweight
MCF
Pump 1 Regulator
Pressure Sensor
Pump 2 Regulator
Pressure Sensor
Solenoid Valve Unit

Pilot Pump
T1J1-02-02-009
Main Relief
Valve
T2-2-37
Fan Pump Flow Rate Control
Purpose: Controls delivery flow rate of the fan pump

according to boost temperature, coolant
temperature, hydraulic oil temperature and
intake air temperature.Controls deliver flow
rate of the fan pump in order not to decrease
although engine speed is slow with the air
conditioner ON. Therefore, controls fan rota-
tion speed in order to make temperature of
oil cooler, radiator and intercooler appropri-
ate.
Operation:
• Blower Motor Relay (Air Conditioner Switch): OFF • Blower Motor Relay (Air Conditioner Switch): ON
1. The signals from boost temperature sensor and 1. The signals from boost temperature sensor,
coolant temperature sensor are sent to MCF via coolant temperature sensor and in-take air tem-
ECM and CAN. perature sensor are sent to MCF via ECM and
2. The signal from hydraulic oil temperature sensor CAN.
is sent to MCF. 2. The signal from hydraulic oil temperature sensor
3. MCF calculates fan rotation speed according to is sent to MCF.
each signal. 3. The signal of target engine speed from engine
4. MCF sends the fastest value of fan rotation speed control dial is sent to MCF.
to the fan pump control solenoid valve and con- 4. MCF calculates fan rotation speed according to
trols delivery flow rate of the fan pump. each signal.
5. Consequently, fan rotation speed is controlled 5. MCF sends the fastest value of fan rotation speed
properly. to the fan pump control solenoid valve and con-
trols delivery flow rate of the fan pump
6. Consequently, fan rotation speed is controlled
properly regardless with engine speed.
T2-2-38
Hydraulic Oil
Temperature
Sensor
Engine
Control
Dial
MCF
CAN
Fan Pump Control

Boost Tem- Coolant Intake-Air Solenoid Valve
perature temperature Temperature
Sensor sensor Sensor
Blower Motor T1J1-02-02-010
Relay
T2-2-39
Pump Learning Control
Purpose: Detects pressure which is necessary to

pump control, when the pump control sole-
noid valve is activated.
Operation:
1. When the following conditions exist and the
learning switch in the rear console is turned to the
pump learning position (opposite to E), MCF ac-
tivates the pump control solenoid valve.
2. Therefore, the spool in pump control solenoid
valve is operated.
3. The regulator pressure sensor detects variable
pressure at this time and sends the signal ac-
cording to each pressure to MCF.
4. MCF records electrical current and pressure
when the pump control solenoid valve is acti-
vated.
Condition:
• Engine: Running
• Engine Control Dial: Fast Idle
• Auto-Idle Switch: OFF
• Power Mode Switch HP Mode
• Pressure Sensor: Output zero. (The control lever
is in neutral.)
• Hydraulic Oil Temperature: 50±5 °C (122±41 °F)
• Pilot Shut-Off Lever: LOCK Position
IMPORTANT: Perform the pump learning if the

following work is done. (Refer to the
T/M [Troubleshooting] section.)
• Replace the pump, pump regulator and pump
control solenoid valve
• Replace MCF
NOTE: The pump learning is not required when the

batteries are replaced.
T2-2-40
Pilot Shut-Off
Lever
Pressure Sensor
Learning Switch
Key Switch
Engine Con-
trol Dial
Pump 1
Auto-Idle MCF Regulator
Switch Pressure
Sensor
Pump 2
Regulator
Pressure
Power Mode Switch Sensor
HP Mode

T1J1-02-02-033
T2-2-41
VALVE CONTROL
The valve control system functions as follows:
• Pressure Increase Selection Control When Trav-

eling
• Power Digging Control
• Travel Motor Swash Angle Control
• Boom Flow Rate Control Valve Control
T2-2-42
Pressure Sensor
Boom Raise
Boom Lower
Arm Roll-Out
Arm Roll-In
Pump 2 Delivery
Bucket Roll-Out Pressure Sensor
Bucket Roll-In
Boom Bottom Pump 1 Delivery
Swing
Travel (Right)
Engine Con- Travel (Left)
trol Dial Attachment (Optional)
Power Digging
Switch
MCF
Fast Pump 1 Regulator

Pressure Sensor
Slow Pump 2 Regulator
Pressure Sensor
Travel Mode
Switch
Solenoid Valve Unit

Boom Mode
Selector Switch
Pilot Pump
Travel Motor
T1J1-02-02-012
Main Relief Boom Overload
Valve Relief Control Valve
T2-2-43
Pressure Increase Selection Control When Trav-
eling, Power Digging Control
Purpose: Applies back-pressure to the main relief

valve and increases main relief pressure.
Operation:
1. When the pressure sensor (travel right or left)
detects travel pilot pressure or when the power
digging switch is turned in the ON position, MCF
activates solenoid valve unit (SG) (for eight sec-
onds with the power digging switch ON).
valve and increases relief pressure. (Refer to the
TION.)
NOTE: Main Relief Pressure:

kgf/cm2, 4638 psi)
During pressure increasing operation: 34.3
T2-2-44
Pressure Sensor
Travel (Right)
Travel (Left)
Power Digging
Switch
MCF
Solenoid Valve
Unit
Pilot Pump
T1J1-02-02-013
Main Relief
Valve
T2-2-45
Auto-Power Lift Control
Purpose: Increases pressure when raising the boom.
Operation:
1. MCF activates solenoid valve unit (SG) when the
signals from pressure sensors (boom raise, arm
roll-in) and pump 1 delivery pressure sensor meet
the following conditions.
valve and increases relief pressure (Refer to the
TION.)
Conditions:
• Boom Raise Pressure Sensor: Output 1.7 MPa
(17 kgf/cm2, 247 psi)) or higher
• Pump 1 Delivery Pressure Sensor: Output 29
• Arm Roll-In Pressure Sensor: Output zero. (0.5
MPa (5.1 kgf/cm2, 73 psi))
NOTE: This control system is activated during

combined operations (except for the arm
roll-in combined operation).
T2-2-46

Pressure Sensor
Boom Raise
Arm Roll-In
MCF
Pump 1 Regulator
Pressure Sensor
Pump 2 Regulator
Pressure Sensor
Solenoid Valve Unit

Pilot Pump
T1J1-02-02-015
Main Relief Valve
T2-2-47
Travel Motor Swash Angle Control
Purpose: Selects the travel mode.

Operation:
• Slow Travel Mode
1. With the travel mode switch the (SLOW)
position, no electrical current flows to solenoid
valve unit (SI).
2. As solenoid valve unit (SI) is not activated
(shifted), pressure oil from the pilot pump is not
supplied to the travel mode selection valve.
3. For this reason, the travel mode selection valve is
not shifted, and pressure oil in the travel circuit in
control valve is not supplied to the tilt pistons.
Consequently, the travel motors rotate in the slow
speed mode.
(Refer to the Travel Device group / COMPONENT
OPERATION.)
From Main Pump
Brake Valve
Solenoid Valve
Unit (SI)
Pilot
Pump
Travel Mode
Contlr Valve
Travel Motor
MCF
Travel Mode Tilt Piston
Switch Parking Brake
T2-2-48
• Fast Travel Mode
1. With the travel mode switch turned to the
(FAST) position, electrical current flows to sole- Condition:
noid valve unit (SI). • Left, right travel pilot pressure: Either travel pilot
2. As solenoid valve unit (SI) is activated (shifted), pressure is high. (Reference: 2.1 MPa or more)
pressure oil from the pilot pump is supplied to the • Pump 1, 2 delivery pressure sensor: Delivery pres-
travel mode selection valve. sure of either pump is low. (Reference: 29 MPa or
3. For this reason, pressure oil in the travel circuit in less)
control valve is supplied to the tilt pistons. Con-
sequently, the travel motors rotate in the fast
speed mode.
(Refer to Travel Device group / COMPONENT
OPERATION.)
From Main Pump
Brake Valve
Solenoid Valve
Unit (SI)
Pilot
Pump
Travel Motor Travel Mode

Control Valve
MC
Travel Mode
Switch Parking Brake
Tilt Piston
Pump 1 Delivery
Travel (Left)
ENG.
Pump 2 Delivery
Pressure Sensor
T2-2-49
Boom Mode Selector Control
Purpose: Reduces vibration of the machine at digging

and grading work.
Operation:
1. The signals from each pressure sensor are sent
to MCF.
Boom Mode
2. When the following conditions exist, MCF acti- Selector Switch
vates solenoid valve unit (SC).
3. Pressure oil from the pilot pump flows through
solenoid valve unit (SC) and acts on the boom
overload relief control valve.
4. When the boom overload relief control valve is
shifted, relief set pressure of the overload relief
valve decreases.
5. Consequently, as holding pressure at the boom
cylinder rod side decreases, vibration of the ma-
chine is reduced during boom lower operation.
(Refer to the Control Valve group, Boom Overload
TION.)
M1J1-03-001
Condition:
• Work Mode: Digging mode
• Boom Mode Selector Switch: ON
• Pressure Sensor (Travel Right/Left) No output
• Pressure Sensor (Boom, Arm, Bucket, Swing and
Attachment): Output from either pressure sensor
NOTE: Overload Relief Pressure:

kgf/cm2, 5132 psi) @110 L/min
During operation: 11.8 MPa (120 kgf/cm2,
1715 psi) @110 L/min
NOTE: When output of each pressure sensor

(boom raise/lower, arm roll-out/in, bucket
roll-out/in, swing, travel right/left, attach-
ment (optional) or counterweight (optional))
becomes 0.7 MPa (7.1 kgf/cm2, 102 psi) or
higher, MCF recognizes that the control
lever is operated.
T2-2-50
Main Pump 2
Boom
Cylinder
Solenoid Valve Unit
SC
Boom Mode
Selector Switch Pilot Pump
Boom Overload
MCF Main Pump 1 Relief Control Valve
CAN Com-
munication Pressure Sensor
Boom Raise
Monitor Unit Boom Lower
(Work Mode) Arm Roll-Out
Arm Roll-In
Bucket Roll-Out
Bucket Roll-In
Swing
Travel (Right)
Travel (Left)
Digging Mode
T1J1-02-02-016
NOTE: The illustration shows during boom lower

operation.
T2-2-51
Boom Flow Rate Control Valve Control
Purpose: Restricts pressure oil to the boom cylinder

from the pump during combined operation of
boom lower and arm or boom lower and
bucket.
When the boom is lowered due to own
weight with the regenerative circuit and
pressure oil from the pump is used for other
actuator, operating speed of actuator in-
creases.
(Refer to the Control Valve group / COM-
PONENT OPERATION.)
Operation:
1. When the pressure sensor sends the signal to
MCF during combined operation of boom lower
and arm or boom lower and bucket, MCF acti-
vates solenoid valve unit (SF).
2. Pressure oil from the pilot pump acts on the
switch valve in boom flow rate control valve.
3. Therefore, the switch valve in boom flow rate
control valve is shifted and pressure oil which
flows to the boom cylinder from the pump is re-
stricted.
4. Consequently, pressure oil from the pump flows to
the actuator and operating speed of actuator in-
creases.
T2-2-52
Pressure Sensor
Boom Raise
Boom Lower
Arm Roll-Out
Arm Roll-In
Bucket Roll-Out
Bucket Roll-In
MCF
Solenoid Valve
Unit
Pilot Pump
Boom
Cylinder
Arm
Cylinder
Boom Flow Rate

Control Valve
(Switch Valve)
Pump 1 Pump 2
T1J1-02-02-017
NOTE: The illustration shows during combined

operation of boom lower and arm roll-in.
T2-2-53
OTHER CONTROLS
The valve control system functions as follows:
• Work Mode Control

• Level Check Control
• Auto Lubrication Control (Optional)
• Travel Alarm Control (Optional)
• Overload Alarm Control (Optional)
T2-2-54
Work Mode Control
The work mode consists of two modes, digging and

attachment.
The mode can be selected by using the monitor unit.
• Digging Mode:
Normal control is performed.
• Attachment Mode:
Functions only when a front attachment in the op-
tional kit is operated.
Flow rate of the pump increases or decreases in
proportion to control pressure of the auxiliary
valve (refer to T2-2-34).
The pump flow rate control settings are made by
using the monitor unit and Dr. ZX.
T2-2-55
Rear View Image Selection Control
Purpose: Changes the display of monitor unit into the

image of rearview monitor.
Operation:
1. When the signal from travel pressure sensor or
rear view switch (optional) is sent to MCF, MCF
sends the signal to select the display to the
monitor unit by using CAN communication.
2. Monitor unit changes the display into the image of
rearview monitor.
3. Push the rearview monitor selection switch on
monitor unit and change the image of rearview
monitor.
NOTE: The function of image selection on monitor

unit can be turned OFF in the setting menu.
T2-2-56
Pressure Sensor
Travel
Rear Monitoring Switch
(Optional)
MCF
CAN Communication
Monitor Unit
Rearview Monitor
Image
T1J1-02-02-036
Setting Menu Rearview Moni-

tor Selection
Switch
T2-2-57
Level Check Control
Level Check Switch
Purpose: Checks levels of coolant and engine oil when
starting the work. This result is displayed on
the monitor unit.
Operation:
1. When the level check switch is turned ON with the
key switch ON, MCF receives the signal.
2. MCF outputs the signals of coolant level switch
and engine oil level switch to the monitor unit.
3. The monitor unit displays the coolant level and
engine oil level.
NOTE: Display Color to Monitor Unit:

During normal: Green M1J1-03-001
During lack: Red
T2-2-58
Engine Oil Coolant Level

Level Switch Switch
Key Switch
CAN Communication
Level Check MCF
Switch
Monitor Unit
Engine Oil Level Coolant Level

(During Lack: Red) (During Normal:
Green)
T1J1-02-02-035
T2-2-59
Auto Lubrication Control (Optional)
Purpose:Controls the auto lubrication system correctly.

(Refer to the Others (Upperstructure) group,
distribution valve group / COMPONENT
OPERATION.)
Operation:
1. When the auto lubrication switch is turned ON, 13. After the preset interval, MCF activates the
terminal B24 is connected to the ground inside grease pump and starts auto lubrication in order
MCF. to connect terminal #B24 to the ground.
2. Therefore, auto lubrication relay (R11) is excited. 14. Within five minutes after auto lubrication relay
3. Electrical current from fuse #30 flows to terminal (R11) is turned ON, if the signal from the proximity
#3 in the grease pump and proximity switch. switch is not sent to terminal #5 in MCF, MCF
4. Therefore, the grease pump is activated and auto recognizes that the auto lubrication circuit is faulty
lubrication starts. (no grease, faulty grease pump). Then, the auto
5. While auto lubrication relay (R11) is turned ON, lubrication alarm is displayed on the monitor unit.
the grease pump is activated and delivers grease.
6. When the grease pump delivers grease, the pis- NOTE: Lubrication time and interval can be set by
ton in distribution valve is operated. using the monitor unit and the service
7. The proximity switch is provided in distribution mode in Dr.ZX.
valve and is turned ON or OFF by the piston
stroke of distribution valve.
8. When the piston of distribution valve comes up to
the proximity switch, the proximity switch is turned
ON and the transistor in proximity switch is turned Auto Lubrication
Switch (Optional)
ON. Therefore, terminal #B5 in MCF is connected
to the ground via the proximity switch.
9. In opposite, when the piston of distribution valve
becomes away from the proximity switch, the
proximity switch is turned OFF and the transistor
in proximity switch is turned OFF. Therefore,
electrical current from terminal #3 flows to termi-
nal #B5 in MCF.
10. MCF detects operating number (stroke number) of
distribution valve according to the signal input to
terminal #B5.
11. When operating number (stroke number) reaches
the setting, MCF blocks the grounding connection
of terminal #B24.
M1J1-03-001
12. Consequently, auto lubrication relay (R11) is
turned OFF and no electrical current flows to the
grease pump, so that the grease pump stops.
T2-2-60
From Battery
29 30
Fuse Box 2
Auto Lubrica-
tion Relay
(R11)
Grease Pump
Auto Lubrication
Switch
Distribution
Transistor
Valve
3
Proximity Switch
B5 B24 B3
MCF
Monitor Unit
T1J1-02-02-020
T2-2-61
Travel Alarm Control (Only Machine Equipped
with Optional Parts)
Travel Alarm
Purpose: Sounds the buzzer while traveling. Deactivation Switch
(Optional)
Operation: MCF receives the signals from travel pres-

sure sensor (travel right or left) when travel
operation is made. As long as MCF re-
ceives this signal, MCF sends the signals
to the travel alarm device and sounds the
buzzer.
NOTE: After traveling continuously for more than

13 seconds, the buzzer can be stopped by
using the travel alarm deactivation switch.
M1J1-03-001
Pressure Sensor
Travel (Right)
Travel (Left)
MCF
Travel Alarm
System (Optional)
Travel Alarm
Deactivation Switch
(Optional)
Buzzer
T1J1-02-02-018
T2-2-62
Overload Alarm Control (Only Machines
Equipped with Optional Parts)
Purpose: Sounds the buzzer and indicates the warning NOTE: The overload alarm in monitor unit should
of overload while overloaded operation of become enable by using Dr.ZX.
boom raise including lifting work.
NOTE: The pressure setting of overload alarm in
Operation:
MCF can be adjusted by using Dr.ZX.
1. When the following conditions exist, MCF sends
the signal to the monitor unit.
2. While the monitor unit receives the signal from
MCF, terminal A9 is connected to the ground in- Overload Alarm
side the monitor unit. Switch (Optional)
3. The monitor unit sounds the buzzer and indicates
the warning of overload.
Condition:
• Boom Bottom Pressure Sensor: Output beyond
the constant value
• Overload Alarm Switch: ON
M1J1-03-001
Boom Bottom Pressure Sensor
Overload
Alarm Switch Monitor Unit
MCF
(Optional)
CAN Com- A9
munication
Buzzer T1J1-02-02-019
T2-2-63
(Blank)
T2-2-64
SYSTEM / ECM System
OUTLINE
ECM (Engine Control Module) receives the signals • The supply pump is driven by the engine and
from sensors and MCF produces high-pressure fuel.
ECM processes and drives the two-way valve, suction • The common rail distributes high-pressure fuel
control valve and EGR motor in order to control the produced by the supply pump to the injector in
supply pump, injector pump and EGR (Exhaust Gas each engine cylinder.
Recirculation) valve. • The injector injects high-pressure from the
common rail.
• Fuel Injection Control
• Engine Start Control
• EGR Control
• Fuel Injection Amount Correction
• Fuel Filter Restriction Indicator Control
• Engine Oil Pressure Indicator Control
• Engine Stop Control
Fuel Filter Differential
Pressure Sensor
Crank Speed Sensor
Cam Angle Sensor
Atmospheric Pressure Sensor
Boost Pressure Sensor

CAN EGR Motor Position Sensor
EGR Motor
ECM
MCF
Two-Way Valve
Common Rail
Pressure
Sensor
Suction Control
Valve
Common Rail
Supply Pump
Injector
Fuel Tank
T1V1-02-02-013
T2-3-1
SYSTEM / ECM System
FUEL INJECTION CONTROL
ECM detects the engine running condition according to
the signals from each sensor and MCF and controls
fuel injection amount, injection pressure, injection
timing and injection rate.
Two-way valve controls: Crank Speed Sensor

• Fuel Injection Amount Control Cam Angle Sensor
• Fuel Injection Timing Control
• Fuel Injection Rate Control Atmospheric Pressure Sensor
Suction control valve controls:
• Fuel Injection Pressure Control
Boost Pressure Sensor

EGR Motor
ECM
MCF
Common Rail Two-Way Valve

Pressure
Suction Control
Valve
Common Rail
Supply Pump
Injector
Fuel Tank
T1GR-02-02-001
T2-3-2
SYSTEM / ECM System
(Blank)
T2-3-3
SYSTEM / ECM System
Fuel Injection Amount Control
Purpose: Controls the best fuel injection amount.
Operation:
1. ECM detects the engine speed according to the
signals from the crank speed sensor and cam
angle sensor.
2. MCF calculate the target engine speed according
to the signals from the engine control dial,
sensors and switches and sends the signals to
ECM by using CAN communication.
(Refer to SYSTEM / Control System.)
3. ECM mainly controls fuel injection amount by
turning ON/OFF for two-way valve in injector
according to the engine speed and the signals
from MCF.
T2-3-4
SYSTEM / ECM System
Pressure Sensor
Travel Crank Speed Sensor
Front Attachment
Cam Angle Sensor
Swing
Boom Raise Atmospheric Pressure Sensor
Arm Roll-In
Auxiliary (Optional)
Engine
Control Dial Intake-Air Temperature Sensor
Auto-Idle Boost Pressure Sensor

Switch

EGR Motor
Power Mode MCF
ECM
Switch
HP Mode
E Mode Common Rail

Two-Way Valve
CAN Pressure Sensor
P Mode
Monitor Unit
Common Rail
Digging Attachment
Mode Mode
Pump 2 Delivery
Pressure Sensor
Fuel Tank Supply Pump Injector
Pump 1 Delivery
Pressure Sensor
Oil Temperature
Sensor
Pump 1 Control
Pressure Sensor
T1V1-02-02-001
Pump 2 Control
Pressure Sensor
T2-3-5
SYSTEM / ECM System
Fuel Injection Pressure Control
Purpose: Controls fuel injection pressure according to

fuel pressure in the common rail.
Operation:
1. ECM calculates fuel injection amount according to
the engine speed and the signals from MCF by
using CAN communication. (Refer to the page on
Fuel Injection Amount Control.)
2. The common rail pressure sensor sends the
signals according to pressure in the common rail
to ECM.
3. ECM calculates the best fuel pressure in common
rail according to the engine speed, fuel injection
amount and the signals of common rail pressure.
ECM drives the suction control valve in supply
pump and supplies the best amount of fuel to the
common rail.
4. Fuel according to fuel pressure in the common rail
is supplied to the injector from the common rail so
that fuel injection pressure is controlled.
T2-3-6
SYSTEM / ECM System
Pressure Sensor
Travel Crank Speed Sensor
Front
Cam Angle Sensor
Swing
Boom Raise Atmospheric Pressure Sensor
Arm Roll-In
Auxiliary (Optional)
Engine
Control Dial
Auto-Idle
Switch Boost Pressure Sensor

CAN EGR Motor Position Seonsor
EGR Motor
Power Mode MCF
ECM
Switch
HP Mode
E Mode Common Rail Pressure Two-Way Valve

Sensor
P Mode
Monitor Unit
Common Rail
Suction Control
Digging Valve
Attachment
Mode
Mode
Pump 2 Delivery
Pressure Sensor
Fuel Tank Supply Pump Injector
Pump 1 Delivery
Pressure Sensor
Oil Temperature
Sensor
Pump 1 Control
Pressure Sensor
T1V1-02-02-012
Pump 2 Control
Pressure Sensor
T2-3-7
SYSTEM / ECM System
Fuel Injection Timing Control
Purpose: Calculates the best fuel injection timing.
Operation:
1. ECM calculates the fuel injection timing according
to engine speed and fuel injection amount.
2. ECM controls the two-way valve in injector by
turning ON/OFF according to fuel injection timing.
Fuel Injection Rate Control
Purpose: Improves combustion in the engine cylinder.
Operation:
1. The injector injects small amount of fuel (pilot
injection) first and ignites.
2. After igniting, the injector injects fuel (main
injection). ECM controls fuel injection timing and
fuel injection amount by turning the two-way valve
in injector ON/OFF.
Fuel Injection
1. The nozzle in injector is always pressured.
2. When turning the electromagnetic coil in two-way
valve ON, high-pressure fuel in the control
chamber returns to the fuel tank through orifice 1.
3. Therefore, the hydraulic pressure piston is raised
and the nozzle opens so that the injection starts.
4. When turning the electromagnetic coil in two-way
valve OFF, the valve is closed and the circuit to
fuel tank is closed. High-pressure fuel from the
common rail flows to the control chamber through
orifice 2.
5. Therefore, when high-pressure flows to the
control chamber, the hydraulic pressure piston is
lowered by pressure difference of movement of
hydraulic pressure piston so that injection stops.
T2-3-8
SYSTEM / ECM System
1. Two-Way Valve: ON 2. Injection Start
From ECM From ECM
Electromagnetic Coil Electromagnetic Coil

Two-Way Valve
Two-Way Valve
Valve
Returning to Fuel Tank Returning to Fuel Tank

From Common From Common
Rail Rail
Orifice 1
Control
Chamber
Hydraulic
Pressure Piston
Spring
Nozzle Nozzle
3. Two-Way Valve: OFF 4. Injection Stop
From ECM From ECM
Electromagnetic Coil
Two-Way Valve Two-Way Valve
Valve
From Common From Common

Rail Rail
Control
Chamber
Orifice 2
Hydraulic Hydraulic
Pressure Piston Pressure Piston
Nozzle Nozzle
T1GR-02-02-012
T2-3-9
SYSTEM / ECM System
ENGINE START CONTROL
Coolant From Terminal
Temperature Sensor #5 in Key Switch
Purpose: Controls time for continuity of electrical
current for the glow plug according to coolant
temperature and improves the starting of
engine.
Operation: Fuse Box

1. The coolant temperature sensor sends the ECM
signals according to coolant temperature to ECM.
2. ECM connects the ground circuit of glow plug
relay according to the signals and controls time
for continuity of electrical current for the glow
plug.
From Battery
Glow Plug Relay
Glow Plug T1V7-02-02-001
T2-3-10
SYSTEM / ECM System
(Blank)
T2-3-11
SYSTEM / ECM System
EGR (EXHAUST GAS RECIRCULATION)
CONTROL
Purpose: Re-circulates a part of exhaust gas in the
intake manifold and combines it with
intake-air. Therefore, combustion
temperature is lowered and generation of
oxide of nitrogen (NOx) is controlled.
Operation:
• EGR Gas Amount Control
1. ECM decides EGR gas amount according to
engine speed, fuel flow rate, coolant temperature,
atmospheric pressure and intake-air temperature.
2. ECM drives EGR motor, opens EGR valve and
sends EGR gas to the intake manifold in
response to engine condition so that EGR gas is
combined with intake-air.
3. At the same time, ECM detects the opening
amount of EGR valve by using EGR motor
position sensor.
• EGR Gas Cooling

EGR gas is cooled by the cooling system in EGR
gas passage.
Cooled EGR gas is combined with intake-air so
that combustion temperature is lowered and NOx
is generated lower than normal EGR gas.
• Lead Valve
Lead valve prevents fresh air from entering into
the EGR gas passage and EGR gas from flowing
in reverse direction.
Therefore, EGR gas flows to one direction and
EGR gas amount increases.
T2-3-12
SYSTEM / ECM System
To Intercooler
Exhaust
From Air Cleaner
Outlet of Coolant
Cooling System
Engine
Inlet of Coolant
EGR Valve
Intake Manifold
EGR Motor
Position
From Suction Sensor
Intercooler EGR Motor
Lead Valve
ECM
Crank Speed Sensor
Cam Angle Sensor
Atmospheric Pressure Sensor
Common Rail Pressure Sensor

T1V1-02-02-007
T2-3-13
SYSTEM / ECM System
FUEL INJECTION AMOUNT CORRECTION
Atmospheric
Pressure Sensor
Operation:
1. The atmospheric pressure sensor sends the
signals according to atmospheric condition to
ECM.
2. ECM calculates atmospheric pressure according
to the signals, controls the two-way valve in
injector and corrects fuel injection amount.
ECM
Two-Way
Valve
T1GR-02-02-002
T2-3-14
SYSTEM / ECM System
FUEL FILTER RESTRICTION INDICATOR
CONTROL Fuel Filter Differential
Pressure Sensor
Operation:
1. The fuel filter differential pressure sensor sends
the signal according to the fuel flow rate pressure
to ECM.
2. ECM sends the signal to the monitor unit.
3. The monitor unit displays the fuel filter restriction ECM
alarm.
Monitor Unit
Fuel Filter Restriction T1V1-02-02-015
Alarm
T2-3-15
SYSTEM / ECM System
ENGINE STOP CONTROL
Operation:
1. When turning the engine stop switch ON,
electrical current from the battery flows to the
Engine Oil Pressure
terminal #1-47 in ECM through ECM main relay. Sensor
2. ECM stops injection of the injector and stops the
engine.
3. ECM is turned OFF after turning ECM main relay
OFF.
ECM
Monitor Unit
T1V1-02-02-015
Engine Oil Pressure
Alarm
T2-3-16
SYSTEM / ECM System
Key Switch
Battery
Fuse Box
ECM Main
Relay
OFF
ECM
Engine Stop
Switch
T1JK-02-013
T2-3-17
SYSTEM / ECM System
(Blank)
T2-3-18
SYSTEM / Hydraulic System
OUTLINE
The hydraulic system is broadly divided into two cir-

cuits, the main circuit and the pilot circuit.
Pilot Circuit:
Power Source Controller Pilot Circuit

Pilot Pump → Pilot Valves → Operation Control Circuit
Pump Regulators Pump Control Circuit
Solenoid Valve Unit Valve Control Circuit
Signal Control Valve Swing Parking Brake Release Circuit
Accumulator Travel Motor Swash Angle Control Circuit
Hydraulic Oil Heat Circuit
Emergency Boom Lower Circuit
Main Circuit:
Power Source Controller Actuator

Main Pumps → Control Valves → Motors
Cylinders
Front Attachmens (Optional)
Fan Pump → Fan Motor

(For Oil Cooler / Radiator)
T2-4-1
PILOT CIRCUIT
Outline
• Pressure oil from the pilot pump is used to oper-
ate the operation control circuit, pump control
circuit, valve control circuit, swing parking brake
release circuit, travel motor swash angle control
circuit, hydraulic oil heat circuit and emergency
boom lower circuit.
T2-4-2
Operation Control Circuit
Swing Parking Brake
Release Circuit
Left Pilot Valve Travel Pilot Right Pilot Valve Auxiliary Pilot
Valve Valve Swing Motor
Shockless
Valve
Pilot Shut-Off Pump Control Circuit

Solenoid Valve
Pump Control
Solenoid Valve 2 1
Hydraulic Oil
Heat Circuit
To Control
Valve Spool Pump
Regulator 2 1
Emergency Boom
Lower Circuit
Flow Combiner Valve
Arm Flow Rate Control Valve
Accumulator Bypass Shut-Out Valve
Boom Anti-Drift Valve

Fan Pump
Arm Anti-Drift Valve Control Solenoid
Valve
SG Main Relief Valve
SI Boom Flow Rate Control Valve Fan Pump

Regulator
Valve Control SF Boom Overload Relief Control Valve
Circuit
SC Control Valve Hydraulic

Oil Tank
Solenoid
Valve Unit
Travel Motor Swash

Angle Control Circuit Suction Filter
Travel Motor Travel Motor Pilot Relief

Valve
Pilot Pump
Pilot Filter
T1J1-02-04-001
T2-4-3
Operation Control Circuit
• The pilot valves control pressure oil from the pilot
pump and operates the control valve spools.
• The signal control valve is provided between the
pilot valves and the control valve. The shockless
valve (in boom raise circuit) built in the signal
control valve dampens quick spool movement in
the control valve. (Refer to the COMPONENT
OPERATION / Signal Control Valve group.)
• The shockless valve (in boom lower circuit) pro-
vided between the right pilot valve and the signal
control valve dampens quick spool movement in
the control valve.
T2-4-4
Travel Pilot Valve Left Pilot Valve Right Pilot Valve
Shockless Valve
Signal Control
Valve
Shockless Valve 11 12 9 10 7 8 4 3 2 1 6 5
(In Signal Control
Valve)
6 5
4 3
3 4
1 2
2 1
Auxiliary
8 7
10 9
11 12
Control Valve
Pilot Pump T1J1-02-04-002
1- Boom Raise 4 - Arm Roll-In 7 - Bucket Roll-In 10 - Travel (Left Reverse)

2- Boom Lower 5 - Left Swing 8 - Bucket Roll-Out 11 - Travel (Right Forward)
3- Arm Roll-Out 6 - Right Swing 9 - Travel (Left Forward) 12 - Travel (Right Reverse)
T2-4-5
Pump Control Circuit
• Main Pump Delivery Flow Rate Control

• Pressure oil from the pilot pump flows to the
pump control solenoid valve in regulator.
• The pilot sensor in the controlled circuit sends
the signal to MCF.
• The signal from pump regulator pressure sensor
is always sent to MCF.
• MCF sends the signals according to each signal
to the pump control solenoid valve and controls
the pump control solenoid valve.
Therefore, the pump flow rate is controlled. (Re-
fer to the Control System group / SYSTEM.)
• Fan Pump Delivery Flow Rate Control

• Pressure oil from the pilot pump flows to the fan
pump control solenoid valve in fan pump regula-
tor.
• MCF activates the fan pump control solenoid
valve and controls delivery flow rate of fan pump
in order to adjust temperatures in oil cooler, ra-
diator and intercooler properly.
(Refer to Fan Pump Flow Rate Control in the
Control System group / SYSTEM.)
T2-4-6
Fan Pump Pump 2 Pump 1
Fan Pump Control

Solenoid Valve
Pilot Pump
Pump 2 Regulator Pump 1 Control Pump 1 Regulator

Pressure Sensor Solenoid Valve Pressure Sensor
CAN
Communication Pump 2 Control
Solenoid Valve
ECM MCF Engine Control Dial
Hydraulic Oil Temperature

Intake-Air Sensor
Temperature
Sensor
Coolant Pressure Sensor
Temperature Boom Raise
Sensor
Boom Lower
Boost
Temperature Arm Roll-Out
Sensor
Arm Roll-In
Bucket Roll-Out
Bucket Roll-In
Swing
Travel (Right)
Travel (Left)
T1J1-02-04-003
T2-4-7
Valve Control Circuit (Refer to the Control Valve
group / COMPONENT OPERATION.)
• The following valves are shifted by primary pilot

pressure from the pilot pump, secondary pilot pres-
sure from the pilot valve, solenoid valve units (SG,
SF, SC), flow combiner valve spool in signal control
valve and arm flow rate control valve control spool.
• Pilot pressure from pilot pump: Boom anti-drift
valve and arm anti-drift valve
• Attachment pilot pressure (optional): Bypass
shut-out valve (4-spool section)
• Solenoid Valve Unit SG: Main relief valve
• Solenoid valve unit SF: Boom flow rate control
valve (switch valve)
• Solenoid valve unit SC: Boom overload relief
control valve
• Flow combiner valve spool: Flow combiner valve
• Arm flow rate control valve spool: Arm flow rate
control valve (switch valve)
T2-4-8
Attachment
Pilot Valve
Arm Flow Rate Con-
trol Valve Spool
Pilot Shut-Off
Solenoid
Valve
Flow Combiner Valve

Spool
Bypass Shut-Out Valve
Arm Flow Rate

Control Valve
(Switch Valve)
Boom Anti-Drift
Valve
Arm Anti-Drift
Valve
Boom Overload
Relief Control Valve
Solenoid
Valve Unit
SG
SF
SC
Boom Flow Rate

Flow Control Valve
Main Relief (Switch Valve)
Valve Combiner
Valve
T2-4-9
Swing Parking Brake Release Circuit (Refer to
the Swing Device group / COMPONENT OPERA-
TION.)
• When the front attachment and/or swing function

is operated, pilot pressure selected by the shuttle
valves in signal control valve shifts the swing
parking brake release spool.
• Consequently, release signal pressure is routed
to the swing motor and releases the swing park-
ing brake.
Travel Motor Swash Angle Control Circuit (Refer

to the Travel Device group / COMPONENT OP-
ERATION.)
• Pilot pressure from solenoid valve unit (SI) regu-

lates the travel motor swash angle control valve.
(Refer to the Valve Control in Control System
group / SYSTEM.)
Hydraulic Oil Heat Circuit (Refer to the Others

(Upperstructure) group / COMPONENT OPERA-
TION.)
• When the pilot shut-off solenoid valve is closed,

pilot pressure oil is routed to the signal control
valve so that hydraulic oil is warmed while pass-
ing through the orifice in signal control valve.
• This warmed hydraulic oil flows to the signal con-
trol valve and pilot valves so that the pilot system
components are warmed.
T2-4-10
Swing Arm Boom Bucket
Hydraulic Oil
Pilot Heat Circuit
Shut-Off
Solenoid
Valve
Signal Control
Valve
Swing Parking Brake

Shuttle Valve
Release Spool
Swing Motor
Solenoid Valve Unit
SI
Swash Angle
Control Valve
Travel Motor T1J1-02-04-005
T2-4-11
Emergency Boom Lower Circuit (Refer to the
Others (Upperstructure) / COMPONENT OPERA-
TION.)
• The accumulator is provided between pilot pump NOTE: Immediately after the engine stops (the key
and pilot shut-off solenoid valve for boom lower switch is turned OFF), the battery relay is
at emergency. The accumulator accumulates kept ON for a specified time due to load
pressure oil from the pilot pump. damp relay operation. (Refer to the Surge
• When the engine stops suddenly and the control Voltage Prevention Circuit in Electrical
lever is operated with the pilot shut-off lever in System group / SYSTEM.) Therefore, elec-
UNLOCK position, pressure oil from the accu- trical current from the battery (fuse #4) flow
mulator flows to each spool in the control valve to the pilot shut-off solenoid valve and the
through each pilot valve. pilot shut-off solenoid valve is kept ON.
• Therefore, as the spool in operated control valve
is operated, the circuit between main pump and
actuator is connected through the control valve
spool.
• As pressure oil between control valve and actua-
tor flows to the hydraulic oil tank through the con-
trol valve spool, pressure between control valve
and actuator decreases.
• Consequently, when the engine stops suddenly,
by operating the control lever (boom lower) right
away, the front attachment can be lowered onto
the ground (due to own weight).
NOTE: Immediately after the engine stops, by op-

erating all the control levers, any pressure
in the circuit between control valve and
actuator can be released.
T2-4-12
Travel Pilot Valve Left Pilot Valve Boom Lower Right Pilot Valve
Pilot
Shut-Off
Solenoid
Valve
11 12 9 10 7 8 4 3 2 1 6 5
Control Valve
6
Accumulator
5
3 4 4
3
2 1 1
2
7
8
11 12
10 9
T2-4-13
MAIN CIRCUIT
Outline
• Main pumps (1, 2) and fan pump draw hydraulic
oil from the hydraulic oil tank. Main pump 1 and
main pump 2 deliver pressure oil to the 4-spool
control valve and the 5-spool control valve re-
spectively.
• The fan pump delivers hydraulic oil to the fan
motor and derives the fan motor.
• Delivered pressure oil from the main pump is
routed to the motor or cylinder in response to op-
eration of the spool in the control valve.
• Return oil from the motor and/or cylinder flows
back to the hydraulic oil tank via the control valve,
low-pressure relief valve and oil cooler.
• The low-pressure relief valve is provided in the
return circuit (between control valve and oil
cooler) of main circuit, and keeps a constant
pressure in the main circuit.
• Therefore, actuator operation is improved when
cavitation occurs.
• When oil temperature is low (high viscosity), oil
flow resistance increases in the oil cooler, which
opens the bypass check valve, so that hydraulic
oil returns directly to the hydraulic oil tank.
T2-4-14
Low-Pressure Swing Motor

Relief Valve
5-Spool
Section
Swing
Arm 2 Arm 1
Boom 1 Boom 2
Bucket Auxiliary
Travel (Right) Travel (Left)
4-Spool Sec- Arm Cylinder

tion
Boom Control Valve

Cylinder
Main Main
Fan Pump Pump 1 Pump 2
Attachments
Bucket Cylinder
Hydraulic
Suction Filter Oil Tank
Bypass
Check Valve
Travel Motor Travel Motor
(Right) (Left)
Oil Cooler
Fan Motor T1J1-02-04-008
T2-4-15
Neutral Circuit
• When the control lever is in neutral, pressure oil
from the main pump passes through the control
valve and returns to the hydraulic oil tank.
Single Operation Circuit

• Pressure oil from main pump 1 is routed to the
4-spool control valve and is further routed to
each spool of the travel (right), bucket, boom 1
and arm 2.
• Pressure oil from main pump 2 is routed to the
5-spool control valve and is further routed to
each spool of the swing, arm 1, boom 2, auxiliary
and travel (left).
• The boom and arm are actuated by pressure oil
from two main pumps. Pressure oil from each
main pump is combined and supplied together.
T2-4-16
Flow Combining
Circuit
Swing
Motor
4-Spool Section 5-Spool Section
Swing
Boom
Cylinder
Arm 1
Arm 2 Arm
Cylinder
Boom 2
Boom 1
Bucket
Cylinder
Bucket Auxiliary
Auxiliary
Travel Motor
(Right)
Travel (right)
Travel Motor
Travel (Left)
(left)
Pump 1 Pump 2
T450-03-03-029
T2-4-17
Combined Operation Circuit
• Swing and Boom Raise Operation

1. When the boom is raised while swinging, pilot
pressure shifts the swing, boom 1 and boom 2
spools.
2. Pressure oil from pump 1 flows into the boom cyl-
inders through the parallel circuit and the boom 1
spool, and raises the boom.
3. Pressure oil from pump 2 flows into the swing
motor through the swing spool.
4. At the same time, pressure oil from pump 2 flows
through the parallel circuit and flows into the
boom cylinders is combined with pressure oil
from pump 1, and raises the boom.
T2-4-18
Swing Motor
Parallel Circuit
Boom
Cylinder
Swing
Boom 1
Boom 2
Parallel Circuit
Pump 1 Pump 2
T1J1-02-04-006
T2-4-19
• Travel and Arm Roll-In Operation
1. When the arm is rolled in while traveling, pilot
pressure shifts the travel, arm 1 and 2 spools.
2. At the same time, right travel pilot pressure shifts
the flow combiner valve control spool in the sig-
nal control valve. Pressure oil from the flow com-
biner valve control spool is routed to the flow
combiner valve and shifts the flow combiner
valve.
3. Pressure oil from pump 1 drives the right travel
motor through the right travel spool.
4. At the same time, pressure oil from pump 1
passes through the flow combiner valve and the
left travel spool and drives the left travel motor.
5. Pressure oil from pump 2 flows into the arm cyl-
inder through the arm 1 spool and moves the
arm.
6. Consequently, pressure oil from pump 2 is used
only to operate the arm. Pressure oil from pump
1 is equally routed to both the right and left travel
motors and ensures that the machine can travel
straight.
T2-4-20
Arm 2
Arm 1 Arm
Cylinder
Travel Motor
(Right) Travel (Right)
Travel Motor
Travel
(Left)
(Left)
Flow Combiner
Valve
From Flow Combiner

Valve Control Spool
in Signal Control
Valve
Pump 1 Pump 2 T1J1-02-04-007
T2-4-21
• Boom Raise / Arm Roll-In
(Arm Regenerative Circuit)
1. Pressure oil from pump 1 is routed to the boom 1 Operation in Arm Regenerative Circuit:
spool and arm 2 spool through the 4-spool paral- 1. When arm is rolled in with the arm rolled-out po-
lel circuit. sition, arm speed becomes faster comparing with
2. Pressure oil from pump 2 is routed to the boom 2 pressure oil amount from pump 2 due to arm own
spool through the arm 1 spool and 5-spool paral- weight.
lel circuit. 2. Therefore, pressure between pump 2 and arm
3. During combined operation of boom raise and cylinder bottom decreases.
arm roll-in, arm roll-in pilot pressure shifts the 3. When pressure in the cylinder bottom side is
arm flow rate control valve control spool in signal lower than that in rod side, the check valve is
control valve. opened.
4. Boom raise pilot pressure flows to the arm flow 4. Therefore, return oil from the cylinder rod side is
rate control valve control spool and acts on the routed to the bottom side, is combined with oil
switch valve in arm flow rate control valve. from pump 2, and combined oil is routed to the
5. When the switch valve is shifted, the poppet cylinder bottom side.
valve in arm flow rate control valve moves to the 5. Consequently, the regenerative operation is op-
direction to restrict the passage in arm 2 in re- erated and cylinder speed increases.
sponse to the boom raise control pressure.
6. Consequently, more pressure oil from pump1 NOTE: Refer to the Flow Rate Control Valve in
flows to the boom 1 side and boom operating Control Valve group / COMPONENT OP-
speed is kept. ERATION.
7. As return oil from the arm cylinder rod side is
routed to the arm cylinder bottom side due to the
regenerative circuit in arm 1 spool, arm roll-in
speed increases.
Arm Regenerative Circuit
Arm Regenerative
Valve (Switch Valve) Pump 2
Pressure Oil
from Pilot Pump
Arm Cylinder
Arm 2 Arm 1
From Arm
Flow Rate
Control Valve
Control Spool
Arm Regenerative
in Signal Con-
Valve (Check Valve)
trol Valve
Arm Flow Rate Arm Flow Rate
Control Valve Control Valve
(Poppet Valve) (Switch Valve)
Pump 1 T1J1-02-04-012
T2-4-22
Arm Boom
Roll-In Roll-Out Lower Raise
Pilot Pump
Arm Flow Control
Valve Control Spool
4 1
Arm Regenerative Arm Flow Rate 5-Spool Section

Valve (Switch Valve) Control Valve Parallel Circuit
(Poppet Valve)
Arm 2
Boom
Cylinder
4 4
Arm
Cylinder
1 1 Arm 1
Boom 1
Boom 2
Arm Flow Rate

Control Valve
(Switch Valve)
4-Spool Section
Parallel Circuit
Pump 1 Pump 2
T1J1-02-04-009
T2-4-23
COUNTERWEIGHT REMOVAL /
INSTALLATION CIRCUIT (OPTIONAL)
1. When the counterweight hoist/lower control lever 4. When lowering the counterweight, pressure oil is
(optional) is operated, pressure oil from the pilot divided into two directions. One flows to the cyl-
pump flows through the counterweight pilot valve inder rod side. Another flows to the holding valve.
and shifts the auxiliary spool in the 5-spool con- 5. The holding valve is opened by pressure in the
trol valve to remove/install the counterweight. rod side and flows return oil from the bottom side.
2. Pressure oil from main pump 2 flows into the 6. Return oil flow from the cylinder bottom is regu-
counterweight removal / installation cylinder lated by the slow return valve.
through the auxiliary spool from the neutral circuit 7. Return oil flows to the hydraulic oil tank through
in 5-spool control valve. the holding valve.
3. When hoisting the counterweight, pressure oil
flows into the cylinder bottom through the check NOTE: During counterweight removal and installa-
valves in holding valve and slow return valve. tion operation, flow rates of pumps 1, 2 are
minimum. (Refer to the Pump Control dur-
ing Counterweight Removal and Installa-
tion in Control System group / SYSTEM.)
Holding Valve
Pilot Shut-off Valve
Lowering Operation
Counterweight
Removal Cylinder
Auxiliary
Slow Return Valve
Main Pump 2 T1J1-02-04-011
T2-4-24
SYSTEM / Electrical System
OUTLINE
The electrical circuit is broadly divided into the main

circuit, monitor circuit and control circuit.
• Main Circuit
The engine and accessory operation related circuit.
• Monitor Circuit
The electrical circuit group consists of the monitors,
sensors and switches, and displays the machine
operation status.
• Control Circuit (Refer to Control System / SYS-

TEM.)
The control circuit is categorized into the engine,
pump and valve control circuits. Each circuit con-
sists of the actuators such as solenoid valves, MCF
(main controller), ECM (engine control module),
switch boxes, sensors and pressure switches.
T2-5-1
MAIN CIRCUIT
The major functions and circuits in the main circuit are
as follows.
• Electric Power Circuit: Supplies all electric power

to all electrical systems on this machine. [Key
Switch, Batteries, Fuses (Fuse Boxes, Fusible
Links), Battery Relay]
• Accessory Circuit
Becomes operative when the key switch is turned
to the ACC position.
• Starting Circuit
Starts the engine. [Key Switch, Starter, Starter
Relay]
• Charging Circuit
Charges the batteries. [Alternator, (Regulator)]
• Serge Voltage Prevention Circuit

Prevents the occurrence of serge voltage devel-
oped when stopping the engine. [Load Damp
Relay]
• Pilot Shut-Off Circuit (Key Switch: ON)

Supplies pressure oil to the pilot valve from the
pilot pump by the pilot shut-off solenoid valve.
• Security Lock Circuit

Cut electrical current for starting from the key
switch according to the signals from external
alarm system or monitor unit. Turns the pilot
shut-off solenoid valve OFF and blocks the pilot
circuit.
• Engine Stop Circuit (Key Switch: OFF)

Stops the engine by using ECM. (MCF, ECM)
• Security Horn Circuit

Operate the security horn according to the sig-
nals from external alarm system or monitor unit.
• Working Light Circuit

Turn on the work light and cab light.
• Wiper Circuit
Operate the intermittent operation of wiper and
the washer.
T2-5-2
(Blank)
T2-5-3
ELECTRIC POWER CIRCUIT (KEY
SWITCH: OFF)
The battery ground terminal is connected to the vehi-
cle frame. Current from the battery plus terminal flows
as shown below when the key switch is turned OFF.
Battery
↓ →Glow Plug Relay (Power)
Fusible Link →Terminal #8: ECM Main Relay (Power)
→Key Switch Terminal B
→Terminal #9: Radio (Backup Power)
→Load Damp Relay (Power)
Security Horn (Backup Power)
→Fuse Box
Security Horn Relay (Power)
→Terminal #10: MCF (Power), ICF (Power)
→Terminal #11: Horn Relay (Power)
→Terminal #19: Monitor Unit (Power)
→Terminal #20: Optional
Key Switch
Glow Plug
Relay
Fusible Link
(45 A)
Battery
Relay
Battery
Fuse Fuse
Box Box
Load Damp
Relay
Horn Relay
Radio, Security Horn, Security Horn Relay
MCF, ICF
ECM Main Relay
Optional
T1J1-02-05-010
T2-5-4
ACCESSORY CIRCUIT
1. When the key switch is turned to the ACC posi-
tion, terminal B is connected to terminal ACC in
the key switch.
2. Current from key switch terminal ACC flows to
radio (#12), cab light (#12), lighter (#13) and aux-
iliary (#15) through the fuse box and makes each
accessory operable.
Key Switch
Glow Plug
Relay
Fusible Link
(45 A)
Battery
Relay
Fuse
Battery Box
Load Damp
Relay
Cab Light, Radio
Cigarette Lighter
Auxiliary
T1J1-02-05-011
T2-5-5
STARTING CIRCUIT (KEY SWITCH:
START)
1. When the key switch is turned to the START po-
sition, terminal B is connected to terminals M and
ST in the key switch.
2. As current from terminal M excites the battery
relay, battery current is routed to starter terminal
B and starter relay terminal B through the battery
relay.
3. Current from terminal ST flows to starter relay
terminal S through the starter cut relay.
4. Current flows to the starter relay coil and starter
relay is turned ON.
5. Current flows to starter terminal C from starter
relay terminal C.
6. Consequently, the relay in starter is turned ON so
that the starter begins rotating.
7. On the other hand, current from key switch ter-
minal M flows to MCF, ICF, the monitor unit and
ECM through fuse #18 as a signal indicating that
the key switch is in the ON or START position.
8. As soon as ECM receives this signal, ECM turns
the ECM main relay ON.
9. Current from the battery flows to ECM through
fuse #8, the ECM main relay and fuse #14 and
the main power is turned ON.
10. ECM makes the engine starting condition.
T2-5-6
Key Switch
Starter Cut
Fusible Link Relay
(45 A)
Battery
Relay
Battery
Fuse Fuse
Box Box
Starter
Relay
ECM
Main Relay
Starter
Monitor ICF ECM

MCF Unit
T1J1-02-05-018
T2-5-7
CHARGING CIRCUIT (KEY SWITCH: ON)
1. After the engine starts and the key switch is Monitor Unit
released, the key switch moves to the ON
position.
2. Key switch terminal B is connected to terminals
ACC and M in the key switch with the key switch
ON.
3. The alternator starts generating electricity with
the engine running. Current from alternator
terminal B flows to the batteries through the
battery relay and charges the batteries.
4. Current from alternator terminal L flows to the
monitor unit, turns the alternator alarm OFF and
flows to ICF.
T1J1-05-01-007
NOTE: Monitor unit detects the alternator charging Alternator
according to power from the alternator and Alarm
turns the Alternator Alarm OFF.
T2-5-8
Key Switch
Battery
Relay
Battery
Alternator
Monitor Unit ICF
T1J1-02-05-013
T2-5-9
Alternator Operation
• The alternator consists of field coil FC, stator coil • At the beginning, no current is flowing through
SC and diode D. The regulator consists of tran- field coil FC. When the rotor starts rotating, al-
sistors T1 and T2, Zener diode ZD and resis- ternate current is generated in stator coil SC by
tances R1 and R2. the rotor remanent magnetism.
• Alternator terminal B is connected to base B of • When current flows through field coil FC, the ro-
transistor T1 through the circuit [B → R → RF tor is further magnetized so that the generating
→ (R) → (R1)]. voltage increases. Thereby, current flowing
• When the battery relay is ON, the battery voltage through field coil FC increases. Therefore, gen-
is applied to base B of transistor T1 so that col- erating voltage increases further and the batter-
lector C is connected to emitter E. Therefore, ies start charging.
field coil FC is grounded through transistor T1.
Alternator
B R L Regulator
Battery RF (R) R3 R4 R5
Relay
R6
D
ZD
R2
Battery SC B
E
R1 C
T2
FC B
D1 C E
T1
(F)
(E)
E
T157-04-02-008
T2-5-10
Regulator Operation
• When generating voltage increases more than • When generating voltage decreases lower than
the set-voltage of Zener diode ZD, current flows the set-voltage of Zener diode ZD, transistor T2
to base B of transistor T2 and collector C is con- is turned OFF and transistor T1 is turned ON
nected to emitter E. again.
• Current which was routed to base B of transistor • Current flows through field coil FC and generat-
T1 disappears due to transistor T2 operation so ing voltage at stator coil SC increases. The
that transistor T1 is turned OFF. above operation is repeated so that the alternator
• No current flows through filed coil FC and gener- generating voltage is kept constant.
ating voltage at stator coil SC decreases.
RF R3 R4 R5
Battery Relay
R6
ZD
R2
Battery B
SC
A E
C
FC T2
B
R1 C E
T1
(F) D1
(E)
E
T157-04-02-009
T2-5-11
SERGE VOLTAGE PREVENTION CIRCUIT
1. When the engine is stopped (key switch: OFF),
current from key switch terminal M is discon-
nected and the battery relay is turned OFF.
2. The engine continues to rotate due to inertia
force just after the key switch is turned OFF so
that the alternator continues to generate electric-
ity.
3. As the generating current cannot flow to the bat-
tery, surge voltage arises in the circuit and fail-
ures of the electronic components, such as the
controller, possibly cause. In order to prevent the
occurrence of surge voltage, the surge voltage
prevention circuit is provided.
4. When the alternator is generating electricity, gen-
erating current from alternator terminal L flows to
monitor unit terminal #C7. The monitor unit con-
nects terminal #A12 to ground.
5. Current flows through the load damp relay excit-
ing circuit and the load damp relay is turned ON.
6. Accordingly, even if the key switch is turned OFF
while the engine is rotating, battery current con-
tinues to excite the battery relay through the load
damp relay.
7. When the alternator stops generating, the battery
relay is turned OFF.
T2-5-12
Key Switch
Battery
Relay
Battery
Load Damp
Relay
Alternator
C7 A12
Monitor Unit
T1J1-02-05-014
T2-5-13
PILOT SHUT-OFF CIRCUIT (KEY SWITCH:
ON)
1. When the pilot shut-off lever is turned to the
UNLOCK position, the pilot shut-off switch is
turned ON.
2. Electrical current from fuse #4 flows to the
ground through the pilot shut-off relay and pilot
shut-off switch so that the pilot shut-off relay is
excited.
3. At the same time, the starter cut relay is con-
nected to the ground circuit.
4. When the pilot shut-off relay is excited, the
ground in pilot shut-off solenoid valve is con-
nected to the ground through the pilot shut-off
relay and security relay.
5. Therefore, the pilot shut-off solenoid valve is
turned ON, pressure oil from the pilot pump is
routed to the pilot valve.
6. When the key switch is turned to the START po-
sition, the starter cut relay is excited.
7. When the starter cut relay is excited, the circuit
between terminal ST in the key switch and ter-
minal S in starter relay is blocked.
8. Therefore, when the pilot shut-off lever is in the
UNLOCK position the key switch is turned to the
START position, the engine does not start.
T2-5-14
Key Switch
Battery
Relay
Battery
4
Fuse
Security Pilot Box
Relay Starter Cut Shut-Off
Starter Relay Lever
Relay
Pilot
Shut-Off
Solenoid
Valve Pilot
Shut-Off Pilot Shut-Off
Switch Relay
MCF Monitor ICF ECM

Unit
T1J1-02-05-015
T2-5-15
SECURITY LOCK CIRCUIT
1. When the external alarm signal or password in-
put error signal from ICF is input to the monitor
unit, terminal #A4 is connected to the ground in-
side the monitor unit.
2. Therefore, the security relay and starter cut relay
are excited.
3. When the security relay is excited, the ground
circuit in pilot shut-off solenoid valve is blocked
and the pilot shut-off solenoid valve is turned
OFF.
4. Therefore, pressure oil which flows to the pilot
valve from the pilot pump is blocked by the pilot
shut-off solenoid valve.
5. When the starter cut relay is excited, the circuit
between terminal ST in the key switch and ter-
minal S in starter relay is blocked.
6. Therefore, when the key switch is turned to the
START position, the engine does not start.
T2-5-16
Key Switch
Battery
Relay
Battery
Fuse
Security Box
Relay Pilot Shut-Off
Starter Cut Lever
Starter Relay
Relay
Pilot
Shut-Off
Relay
Pilot Shut-Off
Solenoid Valve
A4
MCF Monitor Unit ICF ECM
T1J1-02-05-016
T2-5-17
ENGINE STOP CIRCUIT (KEY SWITCH:
OFF)
1. When the key switch is turned from the ON posi-
tion to the OFF position, the signal current indi-
cating that the key switch is ON stops flowing
from terminal M to ECM terminal #V24.
2. ECM stops injection of injector and the engine
stops.
3. When the engine stops, ECM turns the ECM
main relay OFF.
Key Switch
Fusible Link
(45 A)
Battery
Fuse
Box
ECM
Main Relay
ECM
V24
T1J1-02-05-017
T2-5-18
SECURITY HORN CIRCUIT
From Battery
1. When the external alarm signal or password in-
put error signal from ICF is input to the monitor Fuse #9
unit, terminal #A3 is connected to the ground in-
side the monitor unit.
2. Therefore, the security horn relay is excited.
3. When the security horn relay is excited, electrical
current from fuse #9 operates the security horn. Signal from ICF
A3
Monitor Unit
Security Horn
Security Horn
Relay
T1V1-02-05-006
T2-5-19
WORKING LIGHT CIRCUIT
Working Light and Cab Light Circuit
1. When the working light switch moves to position
1, monitor unit terminal #B20 receives the signal.
2. Terminal #A1 is connected to the ground inside
the monitor unit.
3. Therefore, light relay 1 is excited, current from
fuse #29 flows to the working light and cab light,
and turns on the working light and cab light.
Boom Light Circuit

1. When the working light switch moves to position
2, monitor unit terminal #A6 receives the signal.
2. Terminal #A5 is connected to the ground inside
the monitor unit.
3. Therefore, light relay 2 is excited, current from
fuse #1 flows to the boom light, and turns on the
boom light.
T2-5-20
Boom Light Monitor Unit

Input
B-20 A-5
1
Working Light A-6 A-1
Switch 2
Working Light
Input
From Battery
Fuse #29
Fuse #1
Light Relay 1 Light Relay 2
Cab Light
Working Light
Boom Light
T1J1-02-05-009
T2-5-21
WIPER / WASHER CIRCUIT
Wiper Circuit
1. The wiper / washer switch sends the electrical
signal on position the INT. in response to the set Fast
intervals to the monitor unit. Speed
2. The monitor unit connects terminal #A2 to the
ground according to the input intervals.
3. Therefore, the wiper relay repeats to turn ON and
OFF. Middle
Speed
4. When the wiper relay is turned ON, current from
fuse #2 flows to the wiper motor and the wiper Slow
Speed
moves.
Washer Circuit M178-01-016
1. While pushing the wiper/washer switch, the

monitor unit receives the electrical signal from Position INT. Set Time
the wiper/washer switch. Slow 8 seconds
2. The monitor unit connects terminal #A10 to the Middle 6 seconds
ground and the washer relay is excited. Fast 3 seconds
3. Current from fuse #2 flows to the washer motor
and washer liquid jets.
T2-5-22
From
Battery
Wiper / Washer Switch Wiper
Fuse #2
Monitor Unit
Washer
Washer Relay
Wiper Motor
Washer Motor
Wiper Relay
T1V1-02-05-005
T2-5-23
(Blank)
T2-5-24
MEMO
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SECTION 3
COMPONENT OPERATION
CONTENTS
Group 1 Pump Device Group 4 Pilot Valve
Outline ...................................................... T3-1-1 Outline ...................................................... T3-4-1
Main Pump, Fan Pump ............................. T3-1-2 Operation .................................................. T3-4-4
Regulator for Main Pump.......................... T3-1-4 Shockless Function
Regulator for Fan Pump ......................... T3-1-12 (Only for Travel Pilot Valve) ................. T3-4-14
Pump 1, 2 Control Solenoid Valve
Group 5 Travel Device
Fan Pump Control Solenoid Valve ........ T3-1-28
Outline ...................................................... T3-5-1
Pilot Pump .............................................. T3-1-30
Travel Reduction Gear .............................. T3-5-2
Pump Delivery Pressure Sensor............. T3-1-30
Travel Motor.............................................. T3-5-3
Pump Regulator Pressure
Travel Brake Valve .................................... T3-5-5
(Flow Rate Control Pressure) Sensor ... T3-1-30
Parking Brake ......................................... T3-5-12
Outline ...................................................... T3-2-1
Outline ...................................................... T3-6-1
Swing Reduction Gear.............................. T3-2-2
Pilot Port ................................................... T3-6-2
Swing Motor ............................................. T3-2-3
Shuttle Valve............................................. T3-6-6
Swing Parking Brake ................................ T3-2-4
Shockless Valve...................................... T3-6-10
Valve Unit ................................................. T3-2-6
Arm Flow Rate Control Valve Control Spool,
Group 3 Control Valve Flow Combiner Valve Control Spool,
Outline ...................................................... T3-3-1 Swing Parking Brake Release Spool ..... T3-6-14
Hydraulic Circuit ..................................... T3-3-16
Main Relief Valve.................................... T3-3-20
Overload Relief Valve
(with Make-Up Function)....................... T3-3-22
Boom Overload Relief Control Valve ...... T3-3-24
Flow Combiner Valve.............................. T3-3-26
Anti-Drift Valve........................................ T3-3-28
Regenerative Valve ................................ T3-3-32
Flow Rate Control Valve ......................... T3-3-36
Bypass Shut-Out Valve ........................... T3-3-40
1J1T-3-1
Group 7 Others (Upperstructure)
Pilot Shut-Off Solenoid Valve.................... T3-7-1
4-Spool Solenoid Valve Unit ..................... T3-7-3
Pilot Relief Valve ...................................... T3-7-5
Fan Motor ................................................. T3-7-6
Fan Valve ................................................. T3-7-7
Shockless Valve ....................................... T3-7-8
Accumulator ............................................. T3-7-9
Distribution Valve (Optional) ................... T3-7-10
Group 8 Others (Undercarriage)

Swing Bearing .......................................... T3-8-1
Center Joint .............................................. T3-8-2
Track Adjuster .......................................... T3-8-3
1J1T-3-2
COMPONENT OPERATION / Pump Device
OUTLINE
The pump device consists of main pumps (1, 2), pilot

pump and fan pump.
The engine output is transmitted via the coupling. Af-
ter being distributed by the gear, the engine power
drives the pumps respectively. The reduction gear
ratio of engine and main pump (2) is 1:1, engine and
main pump 1 / pilot pump is 1:32/31, and engine and
fan pump is 1:1.
The main pump is a swash plate type variable dis-
placement plunger pump.
The two main pumps arranged in parallel supply
high-pressure oil for work to the main circuit.
The pilot pump is a gear pump and supplies pressure
oil to the pilot circuit.
The fan pump is a swash plate type variable dis-
placement plunger pump and supplies pressure oil to
the fan motor.
Regulator
Main Pump 1
Regulator
T1J1-03-01-028
Fan Pump Main Pump 2 Pilot Pump
T3-1-1
MAIN PUMP, FAN PUMP
The main pump and fan pump are swash plate type When shaft (1) rotates, plunger (2) rotates with cylin-
variable displacement plunger pump. der block (3) together. Plunger (2) slides on shoe
Shaft (1) is splined to cylinder block (3). Plunger (2) is plate (4) and reciprocate in the bore of cylinder block
inserted into cylinder block (3). (3) due to inclination of swash plate (5). By this recip-
The engine output is transmitted to shaft (1) via the rocation, suction and delivery of hydraulic oil are car-
pump transmission. ried out.
2 3
Main Pump
5 4
2 3 T1J1-03-01-002
Fan Pump
T1J1-03-01-003
5 4
1 - Shaft 3- Cylinder Block 4- Shoe Plate 5- Swash Plate

2 - Plunger
T3-1-2
Delivery Rate Increase/Decrease Operation
The main pump delivery rate is changed by changing

the swash plate (3) angle (displacement angle) and
changing plunger stroke.
Servo piston (2) is moved by pressure oil from the
regulator and the swash plate (3) angle (displacement
angle) is controlled.
As swash plate (3) is connected to servo piston (2),
the swash plate (3) angle is changed by the
movement of servo piston (2).
5
4
T142-02-01-001
3
1 - Shaft 3 - Swash Plate 5 - Cylinder Block 6 - Valve Plate

2 - Servo Piston 4 - Plunger
T3-1-3
REGULATOR FOR MAIN PUMP
The regulators are provided on the top of main pumps As pump control solenoid valve (4) is activated, servo
and control the pump delivery flow rate. Pump assist pressure Psv from the pilot pump is reduced
delivery flow rate is controlled as flow rate control and acts on pilot piston (3) as flow rate control pres-
pressure from pump control solenoid valve (4) sure.
increases or decreases. Also, servo assist pressure Psv is combined with self
Self pump delivery pressure P1 is routed to spool (2) pump delivery pressure P1 through check valve (5).
through check valve (6) and acts on spool (2). Main
pump delivery pressure P1 is also routed into the
small chamber of servo piston (11) all the time.
5 To Control
Valve
Psv
4 6
7
3 8
9
2 10
1
P1
Pilot Pump
11 Main Pump T1J1-03-01-004
T3-1-4
5 2 1 4
8 7
Psv
10
Small
Chamber
Large
Chamber
P1
11
Pilot Pump
Main Pump
Increase←Displacement Angle→Decrease
T1J1-03-01-024
1 - Sleeve 4 - Pump Control Solenoid 7 - Spring 10 - Feedback Lever

Valve
2 - Spool 5 - Check Valve 8 - Pin 11 - Servo Piston
3 - Pilot Piston 6 - Check Valve 9 - Pin
T3-1-5
Control by Flow Rate Control Pressure of Pump
Control Solenoid Valve
• Minimum Flow Rate (Regulator Operation with

Flow Rate Control Pressure 0)
1. When flow rate control pressure from pump 3. As servo piston (11) moves, feedback lever (10)
control solenoid valve (4) is 0, spool (2) is rotates counterclockwise around pin (9).
pushed to the left by spring (7). 4. As the top end of feedback lever (10) is
2. As a result, own pump delivery pressure P1 is connected to sleeve (1) by pin (8), sleeve (1)
routed into the large chamber in servo piston (11) moves to the left.
through check valve (6), sleeve (1) and spool (2). Servo piston (11) continues to move until the
Although own pump delivery pressure P1 is also notches on sleeve (1) and spool (2) and closed
routed into the small chamber in servo piston (11), completely.
servo piston (11) moves to the right due to the 5. With the above operation, the pump
difference in pressure receiving areas. displacement angle becomes the minimum so
that pump delivery flow rate become minimum.
5 To Control
Valve
Psv
4 6
3
7
8
2
9
10
1
P1
Pilot Pump
11 Main Pump T1J1-03-01-005
T3-1-6
5 2 1 4
8 7
Psv
10
Small
Chamber
Large
Chamber
P1
9
11
Pilot Pump
Main Pump
Increase←Displacement Angle→Decrease T1J1-03-01-025
T3-1-7
• Increasing Flow Rate (Regulator Operation with
Flow Rate Control Pressure Increasing)
1. When pump control solenoid valve (4) is actuated, 4. As servo piston (11) moves to the left, feedback
flow rate control pressure Pi in proportion to the lever (10) rotates clockwise around pin (9).
movement of pump control solenoid valve (4) 5. As the top end of feedback lever (10) is
acts on pilot piston (3) and moves spool (2) to the connected to sleeve (1) by pin (8), sleeve (1)
right until spool (2) balances with spring (7). moves to the right.
2. When spool (2) moves to the right, the large Servo piston (11) continues to move until the
chamber of servo piston (11) is connected to the notches on sleeve (1) and spool (2) are closed
hydraulic oil tank through passage in spool (2). completely.
3. As own pump delivery pressure P1 is routed into 6. With the above operation, the pump
the small chamber of servo piston (11) all the displacement angle is increased, and pump
time, servo piston (11) moves to the left and oil in delivery flow rate increases. Increasing amount
the large chamber is returned to the hydraulic oil of pump delivery flow rate is proportional to the
tank. that of flow rate control pressure Pi.
5 To Control
Psv Valve
4 6
Pi
3
7
8
2
9
10
1
P1
Pilot Pump
11 Main Pump T1J1-03-01-006
T3-1-8
5 2 1 4
8 7
Psv
Pi
10
Small
Chamber
Large
Chamber
P1
9
11
Pilot Pump
Main Pump
T1J1-03-01-026
T3-1-9
• Decreasing Flow Rate (Regulator Operation with
Flow Rate Control Pressure Decreasing)
1. When flow rate control pressure Pi from pump 4. As servo piston (11) moves to the right, feedback
control solenoid valve (4) decreases, spool (2) is lever (10) rotates counterclockwise around pin
returned to the left until spool (2) balances with (9).
spring (7). 5. As the top end of feedback lever (10) is
2. Pressure oil acting on pilot piston (3) is returned connected to sleeve (1) by pin (8), sleeve (1)
to the hydraulic oil tank via through pump control moves to the left.
solenoid valve (4). Servo piston (11) continues to move until the
3. As spool (2) moves to the left, own pump delivery notches on sleeve (1) and spool (3) are closed
pressure P1 is routed into the large chamber in completely.
servo piston (11) through check valve (6), sleeve 6. With the above operation, the pump
(1) and spool (2). displacement angle is reduced and pump
Although own pump delivery pressure P1 is also delivery flow rate decreases. Decreasing amount
routed into the small chamber in servo piston (11), of pump delivery flow rate is proportional to that
servo piston (11) moves to the right due to the of flow rate control pressure Pi.
difference in pressure receiving areas.
5 To Pilot
Valve
Psv
4 6
Pi
3
7
8
2
9
10
1
P1
Pilot Pump
11 Main Pump T1J1-03-01-005
T3-1-10
5 2 1 4
8 7
Psv
10
Small
Chamber
Large
Chamber
P1
9
11
Pilot Pump
Main Pump
Increase←Displacement Angle→Decrease T1J1-03-01-025
T3-1-11
REGULATOR FOR FAN PUMP
The regulator is provided on the top of the fan pump As fan pump control solenoid valve (17) is activated,
and control the fan pump delivery flow rate. Pump pilot pressure Pr from the pilot pump is reduced and
delivery flow rate is controlled as flow rate control acts on pilot piston (22) as flow control pressure Pi.
pressure from fan pump control solenoid valve (17)
increases or decreases.
Own pump delivery pressure P3 is routed to
compensating piston (1), spool (2) and the small
chamber in servo piston (15) all the time.
17
To Fan Motor
Pr
Pi
22 2
P3
Pilot Pump
15 Fan Pump T1J1-03-01-013
T3-1-12
Section A
2 3 4 5 6 7
B A
1 9
Small
Chamber
P3
Large Chamber
15 14 13 12 11 10
Fan Pump
Section B T1J1-03-01-011
16 17 18 19 7
Pr
23
Pilot Pump
22 14 13 21 20 T1J1-03-01-012
1- Compensating Piston 7- Pin 13 - Feedback Lever 19 - Pin

2- Spool 8- Hole 14 - Pin 20 - Spring
3- Sleeve 9- Inner Spring 15 - Servo Piston 21 - Pin
4- Lever 2 10 - Outer Spring 16 - Spool 22 - Pilot Piston
5- Pin 11 - Compensating Rod 17 - Fan Pump Control 23 - Hole
Solenoid Valve
6 - Pin 12 - Pin 18 - Lever 1
T3-1-13
Link Mechanism
• The movement of pilot piston (22) is transmitted • Therefore, when lever 1 (18) or lever 2 (4) turns,
through pin (21) to lever 1 (18). Lever 1 (18) is pin (7) contacts the hole of the turned lever.
turned about pin (19), which is fixed to the axial Feedback lever (13) turns about pin (14) at-
plug. tached to servo piston (15).
• The movement of pilot piston (11) is transmitted • In addition, when servo piston (15) moves, feed-
through pin (12) to lever 2 (4). Lever 2 (4) is back lever (13) is moved through pin (14).
turned about pin (5), which is fixed to the hous- • At this time, as neither lever 1 (18) nor lever 2 (4)
ing. move, feedback lever (13) turns about pin (7).
• Pin (7) is attached to feedback lever (13). Both
ends of pin (7) are inserted into holes (23, 8) on
lever 1 (18) and lever 2 (4).
Housing
5
12 NOTE : Displacement Angle: Small
4 : Displacement Angle: Large
11 8
13
6
7
18
23
19
2 21
Axial Plug
14
22
15
T1J1-03-01-007
2- Spool 7- Pin 13 - Feedback Lever 19 - Pin

4- Lever 2 8- Hole 14 - Pin 21 - Pin
5- Pin 11 - Compensating Rod 15 - Servo Piston 22 - Pilot Piston
6- Pin 12 - Pin 18 - Lever 1 23 - Hole
T3-1-14
(Blank)
T3-1-15
Control by Flow Rate Control Pressure of Fan
Pump Control Solenoid Valve
• Decreasing Flow Rate (Regulator Operation with

Flow Rate Control Pressure Increasing)
1. When fan pump control solenoid valve (17) is ac- 7. With the above operation, pump delivery flow rate
tivated, flow rate control pressure Pi in proportion decreases according to increasing amount of
to the movement of fan pump control solenoid flow rate control pressure Pi.
valve (17) is routed to pilot piston (22) through
spool (16). When pilot pressure Pi increases, pi- NOTE: Refer to the pilot circuit in Hydraulic Sys-
lot piston (22) moves to the right until pilot piston tem group / SYSTEM.
(22) balances with spring (20).
2. Pilot piston (22) moves lever 1 (18) through pin Q
(21). Lever 1 (18) rotates counterclockwise about
(Flow
pin (19) fixed to the axial plug. Rate)
3. Pin (7), which is attached to feedback lever (13),
is inserted into hole (23) of lever 1(18). Therefore,
feedback lever (13) rotates clockwise about pin
(14) by the turning of lever 1 (18) and moves
spool (2) to the right.
4. When spool (2) moves, own pump delivery pres-
sure P3 acts on the large chamber in servo pis-
ton (15) through spool (2). Although own pump Pi (Flow Rate Control
delivery pressure P3 acts on the small chamber, Pressure)
servo piston (15) moves to the right due to the 16
To Fan Motor
difference in pressure receiving area.
Pr
5. As the pump displacement angle reduces ac-
cording to the movement of servo piston (15), Pi
pump delivery flow rate decreases.
17
6. When servo piston (15) moves, feedback lever
(13) moves through pin (14). As neither pilot pis- 22 3
ton (22) nor lever 1 (18) moves, feedback lever 2
(13) rotates counterclockwise about pin (7) and
moves spool (2) to the left. When the notches on 13
sleeve (3) and spool (2) are closed completely,
own pump delivery pressure P3 does not act on
the large chamber in servo piston (15) and servo
piston (15) stops moving.
P3
15 14
Pilot Pump
Fan Pump
T1J1-03-01-022
T3-1-16
Section A 2 3 4 5 6 7
1 9
Small Chamber
P3
Large Chamber 15 14 13 12 11 10
Increase←Displacement Angle→Decrease Fan Pump
T1J1-03-01-030
16 17 18 19 7
Section B
Pi
Pr 23
Pilot Pump
T1J1-03-01-019
22 14 13 21 20
T3-1-17
13
7
18
23
19
2 21
Axial Plug
14
22
15
T1J1-03-01-007
T3-1-18
(Blank)
T3-1-19
• Increasing Flow Rate (Regulator Operation with
Flow Rate Control Pressure Decreasing)
1. When fan pump control solenoid valve (17) is ac- 7. With the above operation, pump delivery flow rate
tivated, flow rate control pressure Pi in proportion decreases according to increasing amount of
to the movement of fan pump control solenoid flow rate control pressure Pi.
valve (17) is routed to pilot piston (22) through
spool (16). When pilot pressure Pi decreases,
pilot piston (22) moves to the left until pilot piston NOTE: Refer to the pilot circuit in Hydraulic Sys-
(22) balances with spring (20). tem group / SYSTEM.
2. Pilot piston (22) moves lever 1 (18) through pin
Q
(21). Lever 1 (18) rotates clockwise about pin
(19) fixed to the axial plug. (Flow
Rate)
is inserted into hole (23) of lever 1(18). Therefore,
feedback lever (13) rotates counterclockwise
about pin (14) by the turning of lever 1 (18) and
moves spool (2) to the left.
4. When spool (2) moves, the large chamber in
servo piston (15) is connected to the hydraulic oil
tank though spool (2). As own pump delivery Pi (Flow Rate Control
pressure P3 acts on the small chamber, servo Pressure)
piston (15) moves to the left. 16
5. As the pump displacement angle increases ac- To Fan Motor
cording to the movement of servo piston (15), Pr
pump delivery flow rate increases. Pi
(13) moves through pin (14). As neither pilot pis- 17
ton (22) nor lever 1 (18) moves, feedback lever 3
22
(13) rotates clockwise about pin (7) and moves
spool (2) to the right. When the notches on 2
sleeve (3) and spool (2) are closed completely, 13
the large chamber in servo piston (15) is not
connected and servo piston (15) stops moving.
P3
15 14
Pilot Pump Fan Pump
T1J1-03-01-023
T3-1-20
Section A 2 3 4 5 6 7
9
1
Small Chamber
P3
Large Chamber 15 14 13 12 11 10
Increase←Displacement Angle→Decrease Fan Pump
T1J1-03-01-016
Section B 16 17 18 19 7
23
Pi
Pr
Pilot Pump
T1J1-03-01-031
22 14 13 21 20
T3-1-21
13
7
18
23
19
2 21
Axial Plug
14
22
15
T1J1-03-01-007
T3-1-22
(Blank)
T3-1-23
Control by Own Pump Delivery Pressure
NOTE: This control is performed in case speed

increases beyond the rated speed when
starting.
• Decreasing Flow Rate

1. When own pump delivery pressure P3 increases 8. The notches on spool (2) and sleeve (3) are
from C to D, compensating piston (1) moves closed completely and own pump delivery pres-
compensating rod (11) to the right until compen- sure P3 does not act on the large chamber in
sating piston (1) balances with outer spring (10) servo piston (15), so that the movement of servo
and inner spring (9). piston (15) stops moving.
2. Compensating rod (11) moves lever 2 (4) through 9. With the above operation, pump delivery flow rate
pin (12). Lever 2 (4) rotates counterclockwise is decreased from A to B, and load of the pump is
about pin (5) fixed to the housing. reduced.
(Flow
is inserted into hole (8) of lever 2 (4). Therefore, Rate)
feedback lever (13) rotates clockwise about pin
(14) by the turning of lever 2 (4) and moves spool A
(2) to the right. B
4. When spool (2) moves, own pump delivery pres-
sure P3 acts on the large chamber in servo pis-
ton (15) through spool (2). Although own pump
delivery pressure P3 acts on the small chamber,
servo piston (15) moves to the right due to the
difference in pressure receiving area. C D (Delivery
5. The pump displacement angle reduces according Pressure)
to the movement of servo piston (15) and the
pump delivery flow rate decreases.
To Fan Motor
6. As own pump delivery pressure P3 acts on com-
Pr
pensating piston (1), although piston (15) moves,
compensating rod (11) and lever 2 (4) do not
move.
(13) moves through pin (14). As neither com- 22 3
pensating rod (11) nor lever 2 (4) moves, 2
feedback lever (13) rotates counterclockwise
about pin (7) and move spool (2) to the left. 13
P3
9, 10 15 14
Pilot Pump Fan Pump
T1J1-03-01-015
T3-1-24
Section A 2 3 4 5 6 7
9
1
Small Chamber
P3
Large Chamber
15 14 13 12 11 10
Increase←Displacement Angle→Decrease Fan Pump T1J1-03-01-014
Housing
5
12
4
11 8
13
14
15
T1J1-03-01-007
T3-1-25
• Increasing Flow Rate
1. When own pump delivery pressure P3 decreases 6. When servo piston (15) moves, feedback lever
from D to C, compensating piston (1) and com- (13) moves through pin (14). As neither com-
pensating rod (11) are returned to the left until pensating rod (11) nor lever 2 (4) moves,
compensating piston (1) balances with outer feedback lever (13) rotates clockwise about pin
spring (10) and inner spring (9). (7) and moves spool (2) to the right. The notches
2. Compensating rod (11) moves lever 2 (4) through on spool (2) and sleeve (3) are closed completely
pin (12). Lever 2 (4) rotates clockwise about pin and the large chamber in servo piston (15) is not
(5) fixed to the housing. connected to the hydraulic oil tank, so that the
3. Pin (4), which is attached to feedback lever (7), is movement of servo piston (15) stops moving.
inserted into the hole of lever 2(13). Therefore, 7. With the above operation, pump delivery flow rate
feedback lever (13) rotates counterclockwise increases from B to A.
about pin (14) by the turning of lever 2 (4) to (Flow
move spool (2) to the left. Rate)
4. When spool (2) moves, the large chamber in
servo piston (15) is connected to the hydraulic oil A
tank through spool (2). As own pump delivery B
pressure P3 acts on the small chamber, servo
piston (15) moves to the left.
5. The pump displacement angle increases accord-
ing to the movement of servo piston (15) and
pump delivery flow rate increases.
C D (Delivery
Pressure)
To Fan Motor
Pr
3
2
11
13
P3
9, 10 15 14
Pilot Pump Fan Pump
T1J1-03-01-017
T3-1-26
Section A 2 3 4 5 6 7
9
1
Small Chamber
P3
Large Chamber 15 14 13 12 11 10
Fan Pump T1J1-03-01-016
Housing
5
12
4
11 8
13
14
15
T1J1-03-01-007
T3-1-27
PUMPS 1, 2 CONTROL SOLENOID VALVE,
FAN PUMP CONTROL SOLENOID VALVE
The pump control solenoid valve is quipped with the
regulator for pumps 1, 2 and fan pump.
The pump control solenoid valve supplies the flow
rate control pressure to the regulator and controls the
pump delivery flow rate.
Operation
1. In neutral, port Pi and the output port are blocked
by spool (1). The output port is connected to port
T through the notch in spool (1).
2. When current from MC (main controller) flows to
solenoid (4), solenoid (4) is excited and pushes
spring 2 (3).
3. Spring 2 (3) pushes spool (1) to the left. Port Pi is
connected to the output port through the notch in
spool (1). Therefore, pressure in the output port
increases.
4. There is the pressure receiving area difference in
the notch in spool (1). The area of right side (B) is
larger than that of left side (A).
5. When pressure in the output port starts to in-
crease, Pi1×A+S2 (force pushing spool (1) to the
left) becomes stronger than Pi1×B+S1 (force
pushing spool (1) to the right). Therefore, spool
(1) moves to the left.
6. When pressure in the output port increase further,
Pi1×B+S1 (force pushing spool (1) to the right)
becomes stronger than Pi1×A+S2 (force pushing
spool (1) to the left). Therefore, spool (1) returns
to the right.
7. Consequently, as port Pi and the output port are
blocked by spool (1), pressure in the output port
stops increasing.
Pi1: Pressure in the output port

A, B: Pressure receiving area on spool (1)
S1: Spring 1 (2) force
(Force pushing spool (1) to the left side)
S2: Spring 2 (3) force
(Force pushing spool (1) to the right side)
T3-1-28
Neutral state:
2 3 4
Port Pi Port T
T1J1-03-01-032
Output Port
Operating state:
2 3 4
A B
Port Pi Port T
T1J1-03-01-033
Output Port
1 - Spool 2- Spring 1 3- Spring 2 4- Solenoid
T3-1-29
PILOT PUMP Inlet
Port
Drive gear (1) is driven by the engine through the 2 1
transmission, which in turn rotates driven gear (2) as
they are meshed together.
1- Drive Gear
2- Driven Gear
Outlet
Port
T137-02-03-005
PUMP DELIVERY PRESSURE SENSOR

This sensor detects pump delivery pressures, which
are used in order to control various operations. When
oil pressure is applied onto diaphragm (6), diaphragm
(6) is deformed. The deformation of diaphragm (6) is
detected as the electrical signals. 3 4 5 6
3- Ground 5- Power Source (5V)

T157-02-03-010
4- Output 6- Pressure Receiving Area
(Diaphragm)
PUMP REGULATOR PRESSURE (FLOW

RATE CONTROL PRESSURE) SENSOR
This sensor detects pump control pressures, which
are used in order to control various operations. When
oil pressure is applied onto diaphragm (7), diaphragm 7 8 9 10
(7) is deformed. The deformation of diaphragm (7) is
T1J1-03-01-029
detected as the electrical signals.
7- Pressure Receiving Area 9- Output

(Diaphragm)
8 - Ground 10 - Power Source (5V)
T3-1-30
COMPONENT OPERATION / Swing Device
OUTLINE
The swing device consists of the valve unit, the swing

motor and the swing reduction gear.
The valve unit prevents the cavitation and overloads
in the swing circuit.
The swing motor is a swash plate type axial plunger
motor (with built-in swing parking brake), which is
driven by pressure oil from the pump and is provided
with the swing reduction gear.
The swing reduction gear turns the swing motor with
large torque at slow speed and swings the upper-
structure.
Valve Unit
Swing Motor
Swing Reduction
Gear
T16J-03-02-001
T3-2-1
SWING REDUCTION GEAR
The swing reduction gear is a two-stage planetary
gear type.
Ring gear (8) is provided on inside of the housing, is
fixed to the upperstructure with the bolt, and does not
rotate.
Shaft (6) in the swing motor drives first stage sun gear
(5).
Then, rotary power is transmitted to second stage sun
gear (3) via first stage planetary gear (7) and first
stage carrier (4). Second stage sun gear (3) rotates
shaft (1) via second stage planetary gear (9) and
second stage carrier (2).
As shaft (1) meshes with the internal gear of swing
bearing fixed to the undercarriage, the upperstructure
is rotated.
6
5
4 7
8
3
9
2
T16J-03-02-002
1 - Shaft 4- First Stage Carrier 6- Shaft in Swing Motor 8- Ring Gear

2 - Second Stage Carrier 5- First Stage Sun Gear 7- First Stage Planetary Gear 9- Second Stage Planetary
Gear
3 - Second Stage Sun Gear
T3-2-2
SWING MOTOR
The swing motor consists of swash plate (1), rotor (4), When pressure oil is supplied from the pump, plunger
plunger (10), valve plate (5), housing (3) and swing (10) is pushed. Shoe (2) at the top of plunger (10)
parking brake (springs (6), brake piston (7), plate (8), slides over swash plate (1) so that rotor (4) rotates.
friction plate (9)). The top of shaft (12) is splined to the first stage sun
Shaft (12) is splined to rotor (4) into which plunger gear of swing reduction gear. Therefore, the rotation
(10) is inserted. of shaft (12) is transmitted to the swing reduction
gear.
5
6
7
4
8
3
2 9
1 10
11
12
T178-03-02-002
1- Swash plate 4- Rotor 7- Brake Piston 10 - Plunger

2- Shoe 5- Valve Plate 8- Plate 11 - Retainer
3- Housing 6- Spring 9- Friction Plate 12 - Shaft
T3-2-3
SWING PARKING BRAKE
The swing parking brake is a wet type multiplate disc
brake and a negative mechanism that releases the
brake when brake release pressure acts in brake pis-
ton chamber (8).
The brake release pressure is supplied from the pilot
pump only when either swing or front attachment is
operated.
In other cases (including engine stopping), the brake
release pressure returns to the hydraulic oil tank, so
that the brake is applied automatically by spring (4).
When Brake is Applied

1. When the swing or front attachment control lever
is returned to neutral, the swing parking brake
release spool in signal control valve is returned to
neutral and pilot pressure to port SH disappears.
2. Check valve (7) is closed and the brake release
pressure through orifice (6) is released to the
swing motor housing.
3. As a result, the force of spring (4) acts on plate
(2), which is engaged with the external circum-
ference of rotor (1), and on friction plate (3),
which is engaged with the inside of housing (9)
through brake piston (5). Thus, the external cir-
cumference of rotor (1) is secured with friction
force.
When the engine stops, the brake is applied
automatically as pressure is not applied to port
SH.
When Brake is Released

1. When the swing or front attachment control lever
is operated, the swing parking brake release
spool in signal control valve is shifted. Then, pilot
pressure from the pilot pump is applied to port
SH.
2. Pilot pressure to port SH pushes to open check
valve (7), and acts in brake piston chamber (8).
3. As a result, as brake piston (5) is pushed upward,
plate (2) and friction plate (3) are freed, so that
the brake is released.
T3-2-4
3
Port SH (Brake
Release Pressure)
2
8
T178-03-02-003
1 9
1- Rotor 4- Spring 6- Orifice 8- Brake Piston Chamber

2- Plate 5- Brake Piston 7- Check Valve 9- Housing
3- Friction Plate
T3-2-5
VALVE UNIT
The valve unit consists of make-up valve and relief
valve.
The make-up valve prevents cavitation in the circuit
and the relief valve prevents surge pressure and Relief valve
overloads in the circuit.
Make-Up Valve
Make-Up Valve
During swing stopping operation, the swing motor is
driven by the inertial force of swing frame. The swing
motor is turned forcibly in excess of oil pressure from
the pump, so that cavitation may be generated in the
motor. Port M
In order to avoid this cavitation, when pressure in the
swing circuit becomes lower than that in the return
Control Valve
circuit (port M), the poppet opens to draw hydraulic
oil and compensates the lack of oil feed.
T1J1-03-02-001
Control Valve
Poppet
Make-Up Valve Make-Up Valve
Port M
T178-03-02-004
Relief Valve
T3-2-6
Relief Valve
During starting or stopping swing operation, pressure
in the swing circuit becomes high. The relief valve
prevents the circuit pressure from rising higher than
the set-pressure.
Low Pressure Relief Operation (Shockless Function): High Pressure Relief Operation (Overload Preven-
1. Pressure at port HP (swing circuit) is routed into tion):
oil chamber C (9) through orifice (2) in poppet 1. After piston (6) is moved to full stroke, spring (3)
(1). is compressed and the circuit pressure becomes
2. When pressure oil in chamber C (9) flows to oil the relief set-pressure.
chamber A (8) through passage A (4) and to oil 2. If pressure at port HP increases more than the
chamber B (7) through passage B (5). spring (3) set-pressure, poppet (1) is unseated
3. As the receiving area in oil chamber B (7) is lar- and pressure oil flows to port LP from port HP.
ger than that in oil chamber A (8), piston (6) 3. When pressure at port HP is reduced to the
moves to the left. specified level, poppet (1) is seated by the spring
4. As long as piston (6) keeps moving, a pressure (3) force.
difference is developed between the front and the
rear of poppet (1). When this pressure difference
is increased more than the spring (3) force, pop-
pet (1) is unseated and pressure oil flows to port
LP from port HP.
5. When piston (6) is moved to full stroke, the pres-
sure difference between the front and the rear of
poppet (1) disappears and poppet (1) is seated.
1 2 3 4 5 6
HP
LP
9 8 7 T178-03-02-005
1- Poppet 4- Passage A 6- Piston 8- Oil Chamber A

2- Orifice 5- Passage B 7- Oil Chamber B
9- Oil Chamber C
3- Spring
T3-2-7
(Blank)
T3-2-8
COMPONENT OPERATION / Control Valve
OUTLINE
The control valve controls the pressure, flow rate and

flow direction in the hydraulic circuit. The main control
valve consists of two rows of 4-spool section and
5-spool section.
The major parts are main relief valve, flow combiner
valve and spools, and are operated by pilot oil pres-
sure.
As for the spools, in the 4-spool section of control valve,
right travel, bucket, boom 1 and arm 2 are arranged in
that order as viewed from the machine front. In the
5-spool section, left travel, auxiliary, boom 2, arm 1 and
swing are arranged in that order as viewed from the
machine front.
Swing 5-Spool Section

Arm 1
Boom 2
Auxiliary
Travel (Left)
Main Relief Valve

Arm 2
Boom 1
Bucket
Travel (Right)
4-Spool Section
T1J1-03-03-010
T3-3-1
Layout
1 2 3 4 5
45 7
8
44
42 10
41
11
40
39
38
12
37
13
14
15
16
36
17
35 18
19
34
20
33
32
31 30 29 28 27 26 25 24 23 22 21
T450-03-03-053
T3-3-2
4-Spool Section
44, 45 1 2
40 37, 38
41, 42 39
36
29
35
27, 33
T450-03-03-026
30
28 32 31
Circuit)
5- Load Check Valve (Swing 17 - Load Check Valve (Auxil- 28 - Flow Combiner Valve 39 - Overload Relief Valve
Tandem Circuit) iary Tandem Circuit) (Boom Lower)
6- Load Check Valve (Arm 1 18 - Overload Relief Valve 29 - Check Valve (Flow Com- 40 - Overload Relief Valve
Tandem Circuit) (Auxiliary) biner Valve Circuit) (Boom Raise)
Circuit)
8- Arm Anti-Drift Valve (Check 20 - Load Check Valve (Auxil- 31 - Main Relief Valve 42 - Boom Anti-Drift Valve
Valve) iary Parallel Circuit) (Check Valve)
9- Arm Anti-Drift Valve (Switch 21 - Load Check Valve (Left 32 - Load Check Valve (Bucket
Valve) Travel Tandem Circuit) Parallel Circuit)
Tandem Circuit)
T3-3-3
1 2 3 4 5
45 7
8
44
9
42 10
41
11
40
39
38
12
37
13
14
15
16
36
17
35 18
19
34
20
33
32
31 30 29 28 27 26 25 24 23 22 21
T450-03-03-053
T3-3-4
5-Spool Section
3 5
10
4, 6
26 11
12, 13
15, 16
18
17, 20
19
25 21, 23 22
24
T450-03-03-027
Circuit)
Roll-In Parallel Circuit) Control Valve Combing Circuit) (Poppet Valve)
Circuit)
Tandem Circuit)
T3-3-5
1 2 3 4 5
45 7
8
44
9
42 10
41
11
40
39
38
12
37
13
14
15
16
36
17
35 18
19
34
20
33
32
31 30 29 28 27 26 25 24 23 22 21
T450-03-03-053
T3-3-6
A B
C
C
D
D
E
E
F
F
G
G
H
H
T450-03-03-001
A B
Cross Section B-B
Cross Section A-A
14
34
28 31
T450-03-03-010
T450-03-03-011
Circuit)
Circuit)
Tandem Circuit)
T3-3-7
1 2 3 4 5
45 7
8
44
9
42 10
41
11
40
39
38
12
37
13
14
15
16
36
17
35 18
19
34
20
33
32
31 30 29 28 27 26 25 24 23 22 21
T450-03-03-053
T3-3-8
Swing Arm 2 Arm 1

3 10 2
8
44
4, 6
45
7
5
T450-03-03-016
40 11
T450-03-03-023
Circuit)
Circuit)
Tandem Circuit)
T3-3-9
1 2 3 4 5
45 7
8
44
9
42 10
41
11
40
39
38
12
37
13
14
15
16
36
17
35 18
19
34
20
33
32
31 30 29 28 27 26 25 24 23 22 21
T450-03-03-053
T3-3-10

33
39 26 15, 16 35 25 19
38
37
17, 20
12, 13
32
14 34
41 42 36 27 18
T450-03-03-015 T450-03-03-014
Circuit)
Circuit)
Tandem Circuit)
T3-3-11
1 2 3 4 5
45 7
8
44
9
42 10
41
11
40
39
38
12
37
13
14
15
16
36
17
35 18
19
34
20
33
32
31 30 29 28 27 26 25 24 23 22 21
T450-03-03-053
T3-3-12
Travel Travel
(right) (left)
31
30
21, 23
22
29
T450-03-03-013 T450-03-03-012
28
Circuit)
Circuit)
Tandem Circuit)
T3-3-13
1 2 3 4 5
45 7
8
44
9
42 10
41
11
40
39
38
12
37
13
14
15
16
36
17
35 18
19
34
20
33
32
31 30 29 28 27 26 25 24 23 22 21
T450-03-03-053
T3-3-14
Cross Section I-I
T450-03-03-008
24
T450-03-03-001
T450-03-03-006
Circuit)
Circuit)
Tandem Circuit)
T3-3-15
HYDRAULIC CIRCUIT
Main Circuit
Pressure oils from pump 1 and pump 2 flow to the
4-spool section and 5-spool section of the control
valve respectively.
The parallel circuit is provided in both right and left
main circuits and makes the combined operation pos-
sible. The flow combining circuit is provided in both
boom and arm circuits so that pressure oils from
pump 1 and pump 2 are combined during a single
operation.
The main relief valve is provided in the main circuit

(between pump and actuator). The main relief valve
works so that pressure in main circuit does not ex-
ceed the set pressure when the spool is in operation
(or when the control lever is in operation).
The overload relief valve is provided in the actuator
circuits (between control valve and actuator) of boom,
arm, bucket and auxiliary. The overload relief valve
prevents surge pressure caused by external force in
the actuator circuit does not exceed the set pressure
when the spool is in neutral (with the control lever in
neutral).
The boom overload relief control valve is provided in
the boom lower circuit of boom 2. The boom overload
relief valve decreases relief set pressure of the over-
load relief valve and reduces vibration of machine
during boom lowering operation.
T3-3-16
Flow
Combining
Circuit Boom 2 Swing
Spool Motor
Boom
Cylinder
Arm
Cylinder
Overload
Relief Valve
Boom Overload
Bucket Relief Control
Cylinder Valve
Auxiliary
Travel
Motor
(Right)
Travel
Motor (Left)
Overload
Relief Valve

Parallel Circuit Parallel Circuit Overload
Relief Valve
Main Relief
Valve
Pump 1 Pump 2
T450-03-03-029
T3-3-17
Pilot Control Circuit
Pressure oil (indicated with numbers) from the pilot
valve acts on the spool in control valve in order to
move the spool.
In the following operations, pressure oil moves the
spool and acts on the valves as follows.
• During auxiliary operation, pressure oil moves the

auxiliary spool and shifts the bypass shut-out
valve in 4-spool section. (Optional)
The air bleed circuit is located on the upper section of

control valve and bleeds any air trapped inside auto-
matically.
External Pilot Pressure Circuit

• As the boom 1 spool is shifted during boom lower
operation, pressure oil from the pilot pump acts
on the boom anti-drift valve and releases the lock
of boom anti-drift valve.
• As the arm 1 spool is shifted during arm roll-in
operation, pressure oil from the pilot pump acts
on the arm anti-drift valve and releases the lock of
arm anti-drift valve.
• Pressure in the main relief valve is increased by
pilot pressure from solenoid valve (SG)
• The boom overload relief control valve is shifted
by pilot pressure from solenoid valve unit (SC).
• The boom flow rate control valve is shifted by pilot
pressure from solenoid valve unit (SF).
• The flow combiner valve is shifted by pilot pres-
sure from the flow combiner valve control spool in
signal control valve.
• The arm flow rate control valve is shifted by pilot
pressure from the arm flow rate control valve
control spool in signal control valve.
T3-3-18
Bypass
Arm Flow Shut-Out Valve
Rate Control
Valve
Air Bleed
Circuit
Boom Anti-Drift
Valve
6 5
Auxiliary
(Attachment) Arm 1 Spool
Pilot Pressure
Pilot Pressure
Pressure Oil
from Arm 3 4 from Pilot
Flow Rate
4 3 Pump
Control Valve
Control Spool
in Signal
Control Valve
Arm Anti-Drift
2 Valve
Pressure Oil 2 1
from Pilot Pump 1
Pilot Pressure
from Solenoid Pilot Pressure
Valve Unit from Solenoid
(SF) Valve Unit
8 (SC)
7 14 13
Boom 1
Spool
Boom Flow Boom

Rate Control 11 12 Overload
Valve 10 9 Relief
Control Valve
Main Relief Pilot Pressure Pilot Pressure from Flow Combiner Bypass
Valve from Solenoid Flow Combiner Valve Valve Shut-Out Valve
Valve Unit Control Spool in
(SG) Signal Control Valve
T1J1-03-03-001
1- Boom Raise 5- Left Swing 9- Travel (Left Forward) 13 - Auxiliary (Open)

2- Boom Lower 6- Right Swing 10 - Travel (Left Reverse) 14 - Auxiliary (Close)
3- Arm Roll-Out 7- Bucket Roll-In 11 - Travel (Right Forward)
4- Arm Roll-In 8- Bucket Roll-Out 12 - Travel (Right Reverse)
NOTE: Yellow line : Pilot Control Circuit

Orange line : External Pilot Pressure Circuit
T3-3-19
MAIN RELIEF VALVE
The main relief valve serves so that pressure in the
main circuit does not exceed the set pressure when
the actuator such as motor or cylinder is in operation.
Thus, oil leak from hose and pipe joints and breakage
of the actuator are prevented.
Relief Operation
1. Pressure in port HP (main circuit) acts on pilot
poppet (6) through orifice A (1) in main poppet (3)
and orifice B (4) in seat (5).
2. When pressure in port HP reaches the set pres-
sure of spring (7), pilot poppet (6) opens and
pressure oil flows to port LP (hydraulic oil tank)
through passage (9).
3. At this time, a pressure difference is caused be-
tween port HP and spring chamber (10) due to
orifice A (1).
4. When this pressure difference reaches the set
pressure of spring (10), main poppet (3) opens
and pressure oil from port HP flows to port LP.
5. As a result, pressure in the main circuit de-
creases.
6. When pressure in the main circuit decreases to
the fixed level, main poppet (3) is closed by force
of spring (10).
Set Pressure Increasing Operation

1. When pilot pressure from solenoid valve unit (SG)
acts on port PF, spring (7) is compressed by pis-
ton (8).
2. Therefore, force of spring (7) becomes stronger.
3. Consequently, as pressure required in order to
open pilot poppet (6) is increased, the relief set
pressure is increased.
T3-3-20
During Relief Operation:
1 2 3 4 5 6 7 8
HP
LP 10 9 T450-03-03-031
During Set Pressure Increasing Operation:
1 2 3 4 5 6 7 8
HP
PF
LP 10 9 T450-03-03-032
From Solenoid
Valve Unit
(SG)
1- Orifice A 4 - Orifice B 7 - Spring 9 - Passage

2- Sleeve 5 - Seat 8 - Piston 10 - Spring
3- Main Poppet 6 - Pilot Poppet
T3-3-21
OVERLOAD RELIEF VALVE (WITH
MAKE-UP FUNCTION)
The overload relief valves are located in the boom,
arm, bucket and auxiliary circuits. The overload relief
valve prevents each actuator circuit pressure from
rising excessively when the actuators are moved by
external force.
In addition, when the actuator circuit pressure is re-
duced, the overload relief valve draws hydraulic oil
from the hydraulic oil tank and prevents the occur-
rence of cavitation. (make-up function)
Relief Operation Make-Up Operation

1. Pressure in port HP (actuator circuit) acts on pilot 1. When pressure in port HP (actuator circuit) de-
poppet (6) through orifice (1) in piston (9). creases lower than pressure in port LP (hydraulic
2. When pressure in port HP reaches the set pres- oil tank), main poppet (2) moves to the right.
sure by spring (7), pilot poppet (6) opens, and 2. Hydraulic oil flows to port HP from port LP and
pressure oil from passage (5) flows along the ex- cavitation is prevented.
ternal circumference of main poppet (2), and 3. When pressure in port HP rises to the fixed level,
flows to port LP (hydraulic oil tank). main poppet (2) is closed by force of spring (4).
3. At this time, a pressure difference is caused be-
tween port HP and spring chamber (8) due to ori-
fice (1).
4. When this pressure difference reaches the set
pressure of spring (8), piston (9) and main poppet
(2) open and pressure oil from port HP flows to
port LP.
5. Thereby, the actuator circuit pressure decreases.
6. When pressure in the actuator circuit decreases
to the fixed level, piston (9) and main poppet (2)
are closed by force of spring (8).
T3-3-22
Relief Operation:
1 2 3 4 5 6 7
HP
LP T450-03-03-033
9 8
Make-Up Operation:
2 4
HP
T450-03-03-034
LP
1- Orifice 4 - Spring 6- Pilot Poppet 8- Spring

2- Main Poppet 5 - Passage 7- Spring 9- Piston
3- Sleeve
T3-3-23
BOOM OVERLOAD RELIEF CONTROL
VALVE
The boom overload relief control valve is provided in
the boom lower circuit of boom 2. The boom overload
relief control valve is shifted by pilot pressure from
solenoid valve unit (SC) and decreases the set pres-
sure in overload relief valve of boom cylinder rod side
circuit.
Therefore, during boom lower operation, vibration of
the machine is reduced. (Refer to the Control System
group / SYSTEM.)
Operation
1. In normal, pressure oil in port HP flows to cham-
ber C through piston (6) and acts on main poppet
(5). Thereby, main poppet (5) is closed and the
set pressure in overload relief valve is kept high.
2. When pilot pressure from solenoid valve unit (SC)
acts on piston (1), piston (1) opens poppet (2).
When poppet (2) opens, chambers a, b are con-
nected to port LP through the external circumfer-
ence of sleeve (7).
3. When pressure in chamber c reaches the set
pressure of spring (3), pilot poppet (4) opens.
When pilot poppet (4) opens, pressure in cham-
ber c decreases, and piston (6) and main poppet
(5) move to the left.
4. As main poppet (5) opens, pressure oil flows to
port LP from port HP and the set pressure of
overload relief valve decreases.
5. Consequently, as force in the boom cylinder rod
side decreases, vibration of the machine during
boom lower operation is reduced.
T3-3-24
1 2 a 3 4 5 6
Pilot Pressure HP
LP
7 d b c T1J1-03-03-005
1 2 a 3 4 5 6
Pilot Pressure HP
LP
b c
T1J1-03-03-006
1 2 a 3 4 5 6
Pilot Pressure HP
b LP
T1J1-03-03-007
1- Piston 3 - Spring 5 - Main Poppet 7 - Sleeve

2- Poppet 4 - Pilot Poppet 6 - Piston
T3-3-25
FLOW COMBINER VALVE
1. During combined operation of front attachment
and travel, the flow combiner valve control spool
in signal control valve is shifted and pilot pressure
shifts the spool in flow combiner valve.
2. When the spool in flow combiner valve is shifted,
pressure oil from pump 1 flows to the spools in
right and left travels.
3. Therefore, pressure oil from pump 1 is routed to
both right travel and left travel spools.
4. Pressure oil from pump 2 is routed to the front
attachment and swing.
Consequently, during combined operation of
travel, front attachment and swing, the machine
can travel straight.
Pilot Pressure from

Flow Combiner Valve
Control Spool
Spool
Pressure Oil from

Pump 1
To Left Travel Spool
T450-03-03-035
T3-3-26
Flow Combiner
Valve
Pilot Pressure from Flow Combiner

Valve Control Spool in Signal
Control Valve
Travel Motor Travel Motor

(Right) Pump 1 (Left) T450-03-03-036
T3-3-27
ANTI-DRIFT VALVE
The anti-drift valve is provided in the circuits of boom
cylinder bottom side and arm cylinder rod side, and
prevents the cylinders from drifting.
NOTE: Both boom and arm anti-drift valves are

identical in construction. Therefore, the
boom anti-drift valve is explained as an From Port 4Pc3
(Pressure Oil
example. from Pilot Pump)
Holding Operation
1. Pressure oil from the boom cylinder bottom side
flows to the spring (5) chamber and the spring (4) Boom 1 Anti-Drift Valve
Spool (Switch Valve)
chamber in switch valve (3) through orifice (7) in
check valve (6). Boom
Cylinder
2. When the control lever in neutral (boom 1 spool
(8): neutral), pressure oil from port 4Pc3 is
blocked so that switch valve (3) in the anti-drift
valve is not shifted.
3. Consequently, as check valve (6) is pushed by
force of spring (5) and pressure of the spring (5) Anti-Drift Valve
chamber, and the return circuit is blocked, drift (Check Valve)
amount of the cylinder is reduced. T450-03-03-037
T3-3-28
Holding Operation:
2 3 4
6
7
4Pc3 From Boom

Pressure Oil from
Cylinder Bottom
Pilot Pump
(Return) Side
8
T450-03-03-017
1- Check Valve 3 - Switch Valve 5 - Spring 7 - Orifice

2- Piston 4 - Spring 6 - Check Valve 8 - Boom 1 Spool
T3-3-29
Releasing Operation
1. During boom lower operation (arm roll-in opera- From Port 4Pc3
tion in case of the arm anti-drift valve), spool (8) in (Pressure Oil
boom 1 moves to the left. Pressure oil from port From Pump 1 from Pilot Pump)
4Pc3 acts on piston (2) through the inner pas-
sage.
Anti-Drift Valve
2. As piston (2) pushes switch valve (3), switch Boom 1 (Switch Valve)
valve (3) is shifted. Spool
3. Pressure oil in the spring (5) chamber of check Boom
valve (6) pushes to open check valve (1) through To Boom 2 Cylinder
the external circumference of switch valve (3) so Spool
that pressure oil flows to the hydraulic oil tank. (Hydraulic
Oil Tank)
4. Therefore, pressure in the spring (5) chamber
decreases. At this time, a pressure difference
between port 4A3 and the spring (5) chamber
arises due to orifice (7) in check valve (6). Check Valve Anti-Drift Valve
(Check Valve)
5. When this pressure difference becomes stronger
than the spring (5) force, check valve (6) opens. T450-03-03-038
Consequently, return oil from the boom cylinder

bottom side flows to the hydraulic oil tank.
T3-3-30
Releasing Operation:
2 3 4
Pressure Oil 4Pc3 From Boom

from Pilot Cylinder Bottom
Pump (Return) Side
4Ａ3
8
To Hydraulic Oil
Tank
T450-03-03-028
1- Check Valve 3 - Switch Valve 5 - Spring 7 - Orifice

2- Piston 4 - Spring 6 - Check Valve 8 - Boom 1 Spool
T3-3-31
REGENERATIVE VALVE
The regenerative valves are provided in the boom
lower, arm roll-in and bucket roll-in circuits. The re-
generative valve increases cylinder speeds in order to
cylinder hesitation, and improve machine controllabil-
ity.
Operation of Boom Regenerative Valve

1. During boom lower operation, return oil from the Boom Cylinder
cylinder bottom side enters hole on the spool and
acts on the check valve.
2. During boom lower operation, the boom is low-
ered faster as compared with amount of supply
from the pump due to boom own weight.
3. Therefore, pressure in the circuit between pump Boom
and boom cylinder rod decreases. Lower Pilot
4. When pressure in the cylinder rod side becomes Pressure
lower than that in the bottom side, the check valve
opens. Pressure Oil
from Pump 1
5. Consequently, return oil from the cylinder bottom
side flows to the rod side, is combined with pres-
sure oil from pump 1, and is supplied to the cyl- T450-03-03-041
inder rod side so that the regenerative operation

is done.
6. Therefore, speed of the cylinder increases.
7. When the cylinder is moved full stroke or the load
increases, pressure in the cylinder rod side circuit
increases more than that in the bottom side.
8. Consequently, the check valve is closed and re-
generative operation stops.
T3-3-32
Boom Lower
Pilot Pressure
Boom Cylinder
Spool
Hole
Check Valve
T450-03-03-052
T3-3-33
Arm Regenerative Valve and Bucket Regenerative
Valve
NOTE: Operational principle of the arm regenera-

tive valve is identical to that of the bucket
regenerative valve. Therefore, the bucket
generative valve is explained as an exam-
ple.
Operation
1. During bucket roll-in operation (arm roll-in opera-
During Regenerative Operation:
tion in case of the arm regenerative valve), return
Bucket Cylinder
oil from the cylinder rod side flows to the hydraulic
oil tank through external circumference of the
plunger in switch valve and hole on the sleeve. Check Valve
2. Return oil from the cylinder rod enters hole on the
spool and acts on the check valve through spool
inside.
3. When roll-in operation is done with the bucket Bucket Roll-In
Pilot Pressure
roll-out, the bucket moves faster as compared
with pressure oil supply from the pump.
4. Therefore, pressure in the circuit between pump
and bucket cylinder bottom decreases.
5. When pressure in the cylinder bottom side be-
comes lower than that in the rod side, the check Pressure Oil
valve opens. Switch Valve from Pump 1
T450-03-03-043
6. Therefore, return oil from the cylinder rod side
flows to the bottom side, is combined with pres-
sure oil from the pump, and is supplied to the During Normal Operation:
cylinder bottom side. Bucket Cylinder
7. Consequently, the regenerative operation is done
and speed of the cylinder increases. Check Valve
8. When the cylinder is moved full stroke or the
roll-in load increases, pressure in the cylinder
bottom side circuit increases more than the rod
side. Bucket Roll-In
Pilot Pressure
9. Therefore, the check valve is closed and the re-
generative operation stops.
10. As pressure in the cylinder bottom side circuit in-
creases, the piston of switch valve pushes the
plunger.
11. Consequently, as amount of oil which flows to the Pressure Oil
hydraulic oil tank from the cylinder rod side in- Switch Valve from Pump 1
T450-03-03-039
creases, speed of the cylinder is kept increasing
in spite of overload state.
T3-3-34
During Regenerative Operation: During Normal Operation:
Swich Valve
Switch Valve
Bucket Cylinder Bucket Cylinder
Plunger Plunger
Piston
Sleeve
Spool Spool
Check Valve Check

Valve
T450-03-03-044 T450-03-03-045
Bucket Roll-In Bucket Roll-In

Pilot Pressure Pilot Pressure
T3-3-35
FLOW RATE CONTROL VALVE
The flow rate control valve is provided in the boom and
arm circuits, restricts oil flow rate in the circuit during
combined operation, and gives priority to other actua-
tors. (Refer to the Control System, Hydraulic System
groups / SYSTEM.)
Each flow rate control valve is operated during com-

bined operation as shown below.
Flow Rate Combined Operation
Control Valve
Boom Boom Lower + Arm (Roll-Out / In)
Boom Lower + Bucket (Roll-In / Out)
Arm Boom Raise and Arm Roll-In
NOTE: The boom flow rate control valve is ex-

plained here.
Boom Cylinder
Normal Operation
1. Pressure oil which flows to the 4-spool section
parallel circuit from pump 1 is divided into the two
directions.
2. One acts on the check valve A in the poppet valve.
The other pushes to open check valve B and acts To Boom 2 Spool
on the switch valve.
3. In normal, as the switch valve is kept closed,
pressure oil from pump 1 is blocked by the switch Poppet
Pressure
valve. Oil from
4. Pressure oil from pump 1 pushes to open check Pilot
valve A and the poppet, and flows to the boom 1 Pump Switch
Valve
spool.
Pressure Oil
from Pump 1
(Parallel Circuit)
T450-03-03-046
T3-3-36
During Normal Operation:
Section A
A
Switch Valve
Switch Valve
Poppet
Check Valve A
Check
Valve B
To Boom 1 To Boom 1
Spool Spool
From Pump 1 T450-03-03-048
T3-3-37
Flow Rate Control Operation
1. Pilot pressure from solenoid valve unit (SF) shifts Boom Cylinder
the switch valve in boom flow rate control valve.
2. As pressure oil from pump 1 acts on the piston
through switch valve, the piston moves downward
(upward in the circuit diagram).
3. Therefore, back pressure in the poppet increases
To Regenerative
and the force to close the poppet valve appears. Circuit in Boom 2
4. Consequently, the poppet restricts flow rate to the Spool
boom 1 spool and pressure oil is supplied to other Poppet
actuators which load pressure is higher at. Pressure
Oil from
Pilot
Pump Switch
Valve
Pressure Oil Pressure Oil

from Solenoid from Pump 1
Valve Unit (SF) (Parallel Circuit)
T450-03-03-047
T3-3-38
During Flow Rate Control Operation:
A From Solenoid Section A

Valve Unit (SF)
Switch Valve
Switch Valve
Piston
Poppet
Check Valve A
Check
Valve B
To Boom 1 To Boom 1
Spool Spool
From Pump 1
T450-03-03-049
T3-3-39
BYPASS SHUT-OUT VALVE
The bypass shut-out valve is provided in the rear of
4-spool and 5-spool section circuits. The bypass
shut-out valve blocks the neutral circuit (return circuit
to hydraulic oil tank) in 4-spool and 5-spool sections so
that pressure oils in pumps 1 and 2 are combined.
Therefore, amount of oil which flows to the cylinder
increases and speed of the cylinder increases.
NOTE: The bypass shut-out valve in 5-spool sec-

tion is not used for the machine control.
From Pump 1
Operation
1. When the attachment is operated on the machine
equipped with the attachment (optional), pilot
pressure from the pilot valve (optional) shifts the
bypass shut-out valve in 4-spool section. Attachment
2. Therefore, as the neutral circuit in 4-spool section Pilot
Pressure
is blocked, pressure oil from pump 1 flows to the (Optional)
5-spool section, is combined with pressure oil
from pump 2 so that combined pressure oil is
supplied to the auxiliary spool.
3. Consequently, speed of the attachment (optional)
increases. T450-03-03-050
To Hydraulic
Oil Tank
NOTE: The illustration shows the bypass shut-out

valve in 4-spool section.
T3-3-40
Bypass Shut-Out
Valve (4-Spool
Section)
Attachment
Pilot
Pressure
(Optional)
Auxiliary
Spool
Attachment
(Optional)
Bypass Shut-Out
Valve (5-Spool
Section)
Pump 1 Pump 2
T1J1-03-03-002
T3-3-41
(Blank)
T3-3-42
COMPONENT OPERATION / Pilot Valve
OUTLINE
The pilot valve controls pilot pressure oil in order to NOTE: As for the pilot valves for front attach-
move spool in control valve. The pilot valve outputs ment/swing and for travel, the structure of
pressure according to the control lever stroke by PPC cam to push in the pusher is different and
(Pressure Proportional Control Valve) function and that of pressure-reducing valve is same.
moves the spool in control valve.
The 4-port pilot valves for front attachment/swing and
for travel are standard.
The 2-port pilot valve is for counterweight (optional)
and for auxiliary (optional).
• Front Attachment / Swing Pilot Valve

Port ISO Control Hitachi Pattern
No. Pattern
1 Bucket Roll-Out ←
2 Boom Lower ←
Right
3 Bucket Roll-In ←
4 Boom Raise ←
1 Right Swing Arm Roll-In
2 Arm Roll-Out Right Swing
Left
3 Left Swing Arm Roll-Out
4 Arm Roll-In Left Swing
Hydraulic P T
Symbol
P 4
1 3 2 4
T105-02-07-020
3 1
2 T1V1-03-04-001
T
T3-4-1
• Travel Pilot Valve
Port No.
1 Travel (Right Reverse)
2 Travel (Right Forward)
3 Travel (Left Forward)
T
4 Travel (Left Reverse)
P
Hydraulic
Symbol
B T1M9-03-05-004
View B 3 4
3 P T 4 2 1
T178-03-04-017
2
1
T1M9-03-05-005
• Counterweight (Optional), Auxiliary (Optional) Pilot

Valves
Port No.
1 Lower
Counterweight
2 Raise
T
1 Open
Auxiliary
2 Close
P
P T
T1CF-03-04-002
1 2 T1CF-03-04-001 1 2
T3-4-2
(Blank)
T3-4-3
OPERATION
• Front Attachment / Swing and Travel Pilot Valves

Spool (6) head comes in contact with the upper sur-
face of spring guide (3), which is kept raised by return
spring (5).
Neutral (Output Curve: A to B):

1. When in neutral, spool (6) totally blocks pressure
oil from port P (the pilot pump). The output port is E F
opened to port T (hydraulic oil tank) through the
inner passage in spool (6). D
2. Therefore, pressure in the output port is equal to Pilot
that in port T. Pressure
3. When the control lever is slightly tilted, cam (1) is
tilted and pusher (2) is downward. Pusher (2) C
compress return spring (5) along with spring
guide (3) together.
4. At this time, as pressure in the output port is equal A B
Lever Stroke
to that in port T, spool (6) moves downward while T523-02-05-001
keeping the lower surface of spool (6) head in
contact with spring guide (3).
5. This status continues until hole (7) on spool (6) is
opened to port P.
T3-4-4
Front Attachment / Swing Pilot Valve
1 1
2 2
6
3 3 Port T
4 4 7
5 5 Port P
6 Output Port
6
Port T Port T
7 Port P 7 Port P
Output Port T1V1-03-04-007

Travel Pilot Valve

1 1
2 2 Port T
7
Port P
3 3 6
4 4
5 Output Port
5
6
Port T Port T
6
Port P Port P
7 7

1 - Cam 3 - Spring Guide 5 - Return Spring 7 - Hole

2 - Pusher 4 - Balance Spring 6 - Spool
T3-4-5
During Metering or Decompressing
(Output Curve: C to D)
1. When the control lever is further tilted in order to
move pusher (2) downward more, hole (7) on E F
spool (6) is opened to port P and pressure oil in
port P flows into the output port. D
2. Pressure in the output port acts on the bottom Pilot
surface of spool (6) so that spool (6) is pushed Pressure
upward.
3. Until upward force acting on the bottom surface of C
spool (6) overcomes the balance spring (4) force,
balance spring (4) is not compressed so that
spool (6) is not raised and pressure in the output A B
Lever Stroke
port increases. T523-02-05-001
4. As pressure in the output port increases, the force
to push spool (6) upward increases. When this
force overcomes the balance spring (4) force,
balance spring (4) is compressed so that spool (6)
is moved upward.
5. As spool (6) is moved upward, hole (7) is closed
so that pressure oil from port P stops flowing into
the output port and pressure in the output port
stops increasing.
6. As spool (6) is moved downward and balance
spring (4) is compressed, pressure acting on the
bottom surface of spool (6) increases until pres-
sure balances with the increasing spring force.
This increasing pressure becomes pressure at
the output port.
T3-4-6
1 1
2 2
3 3
4 4
5 5
6
6
Port T Port T
7 Port P 7 Port P
Output Port T1V1-03-04-009 Output Port T1V1-03-04-010
Travel Pilot Valve

1 1
2 2
3 3
4 4
5 5
6 6
Port T Port T
7 Port P 7 Port P
Output Port T1V1-03-04-004 Output Port T1V1-03-04-005

T3-4-7
Full Stroke (Output Curve: E to F)
1. When the control lever is fully stroked, pusher (2)
is moved downward until pusher (2) on the front E F
attachment / swing pilot valve comes in contact
with the casing shoulder, or cam (1) on the travel D
pilot valve comes in contact with the casing. Pilot
2. At this time, the bottom surface of pusher (2) di- Pressure
rectly pushes spool (6). Therefore, even if pres-
sure in the output port increases further, hole (7) C
on spool (6) is kept open.
3. Consequently, pressure in the output port is equal
to that in port P. A B
Lever Stroke
T523-02-05-001
NOTE: Total lever strokes for front attachment and

swing controls are determined by stroke
dimension (E) of pusher (2). Total lever
stroke for travel control is determined by
stroke dimension (E) of cam (1).
T3-4-8
2 2
4
5
6
Port T
7 Port P

T1V1-03-04-007
Travel Pilot Valve

1
1
2
E
4
5
6
Port T
Port P
7

T1V1-03-04-002

T3-4-9
• Counterweight (Optional) / Auxiliary (Optional) Pilot
Valves
During Metering or Decompressing
In Neutral (Output Curve: A to B) (Output Curve: C to D)
1. When the control lever is in neutral, spool (7) 1. When the control lever is tilted further, the hole on
completely blocks pressure oil from port P. spool (7) is connected to the notch.
2. As the output port is connected to port T through 2. Pressure oil in port P flows into the output port
the passage in spool (7), pressure in the output through the notch and the hole on spool (7), and
port is equal to that in the hydraulic oil tank. pressure in the output port increases.
3. When the control lever is slightly tilted, cam (1) is 3. Pressure in the output port acts on the bottom
moved and pusher (2) compresses return spring surface of spool (7) and spool (7) is moved up-
(6) downward with spring guide (4) together. ward.
4. At this time, spool (7) is pushed by balance spring 4. When the force to move spool (7) upward is
(5) and moved downward until dimension (A) be- smaller than balance spring (5), balance spring (5)
comes zero (port P is aligned with the hole). is not compressed.
5. During this movement, the output port is con- 5. Therefore, as port P is kept connected to the
nected to port T so that pressure oil is not supplied output port, pressure in the output port continues
to the output port. to increase.
6. When pressure in the output port increases further,
NOTE: The lever stroke while pressure at dimen- the force to move spool (7) upward increases.
sion (A) becomes zero is play. 7. When this force becomes larger than balance
spring (5), spool (7) compresses balance spring
(5) and moves upward.
8. When spool (7) moves upward, the notch is
closed. As pressure oil from port P does not flow
to the output port, pressure in the output port stop
increasing.
9. As spool (7) is moved downward and balance
spring (5) is compressed, pressure acting on the
bottom surface of spool (7) increases until pres-
sure balances with the increasing spring force.
This increasing pressure becomes pressure at the
output port.
E F
Pilot
Pressure
A B Pusher Stroke
T523-02-05-001
T3-4-10
In Neutral (Output Curve: A to B) During Metering or Decompressing (Output Curve: C
to D)
4
3
5 5
Port T Port T
6
(A)
Port P Port P
Hole Hole 7
Passage 7
Output Port T1M7-03-04-022

Port T
(A)
Port P
1- Cam 3- Plate 5 - Balance Spring 7 - Spool

2- Pusher 4- Spring Guide 6 - Return Spring
T3-4-11
1. When the control lever is fully stroked, pusher (2)
is moved downward until cam (1) comes in con- E F
tact with the casing.
2. At this time, the bottom surface of pusher (2) di- D
rectly pushes spool (7). Therefore, even if pres- Pilot
sure in the output port increases further, the hole Pressure
on spool (7) is kept open.
3. Consequently, pressure in the output port is equal C
to that in port P.
A B
Pusher Stroke
T523-02-05-001
T3-4-12
3 4
5
Port T
6
Port P
Hole
7
Output Port T1J1-03-04-001
1 - Cam 3- Plate 5 - Balance Spring 7 - Spool

2 - Pusher 4- Spring Guide 6 - Return Spring
T3-4-13
SHOCKLESS FUNCTION
(ONLY FOR TRAVEL PILOT VALVE) Damper Spring Pin Travel Pedal
The travel pilot valve has the damper enabling damp- A

ing of the speed change shock by the travel lever. Travel Lever
The damper is composed of support, gears 1 and 2
and others. Gear 1 is connected with the support.
Support
The support is secure to the bracket by using a spring
pin. The travel lever and travel pedal are secure to the
bracket. Bracket
Therefore, the support swings transversely around the Pin
pin in line with the movement of the travel lever.
Operation Gear 2
1. If the travel lever is released from the hand during A
traveling, spring force of the return spring returns Gear 1
the travel lever to the neutral position.
2. At this time, gears 1 and 2 inside the damper re-
ceive opposing force due to friction.
3. Therefore, as the travel lever gradually returns to
the neutral position, the extent of sudden stop at
the time of abrupt release of the travel lever is
damped down.
T1M7-03-04-002
Section A-A
Spring Pin
Damper
Support
Pin
T1M7-03-04-003
T3-4-14
COMPONENT OPERATION / Travel Device
OUTLINE
The travel device consists of the travel motor, travel The travel reduction gear is a three-stage reduction
reduction gear and travel brake valve. The travel mo- planetary gear type, converts rotary power transmitted
tor is a swash plate type variable displacement axial from the travel motor to slow large torque, and rotates
plunger motor and equipped with the parking brake the sprocket and track. The travel brake valve pre-
(with built in a wet-type negative multi-disc brake). vents the travel circuit from being overloaded and
The travel motor is driven by pressure oil from the prevents the occurrence of cavitation.
pump and transmits its rotary power to the travel re-
duction gear.
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3 ZAXIS500LC-3, 520LCH-3
Travel Motor Travel Reduction Gear Travel Motor Travel Reduction Gear
Travel Brake Travel Brake

T1J1-03-05-002
Valve Valve
Sprocket T1J1-03-05-009
Sprocket
T3-5-1
TRAVEL REDUCTION GEAR
The travel reduction gear is a three-stage reduction
planetary gear type.
The travel motor rotates shaft (7). This rotation is
transmitted to third stage carrier (2) and ring gear (1)
via first stage planetary gear (8), first stage carrier (6),
second stage sun gear (5), second stage planetary
gear (9), second stage carrier (4), third stage sun gear
(3) and third stage planetary gear (10).
Third stage carrier (2) is fixed to by housing (13) and
does not rotate.
Ring gear (1) is secured to drum (12) with the bolt or
pin.
Third Second First
Sprocket (11) is bolted to drum (12), and are rotated Stage Stage Stage
with ring gear (1) together.
T111-03-04-011
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3 ZAXIS500LC-3, 520LCH-3
1 2 3 4
1 2 3 4
5
5
6
6
7
7
8
8
Pin
13 12 10 9
13 12 10 9
11 11
T1J1-03-05-002
T1J1-03-05-009
1- Ring Gear 5- Second Stage Sun Gear 8- First Stage Planetary Gear 11 - Sprocket
2- Third Stage Carrier 6- First Stage Carrier 9- Second Stage Planetary 12 - Drum
Gear
3- Third Stage Sun Gear 7- Shaft 10 - Third Stage Planetary Gear 13 - Housing
4- Second Stage Carrier
T3-5-2
TRAVEL MOTOR
The travel motor is a swash plate type variable dis- Four tilt pistons (9) shift the swash angle of swash
placement axial plunger motor and equipped with plate (7) due to a fulcrum as ball (13). Rotor (16)
parking brake (3) (with built in a wet-type negative sticks on valve plate (1) due to the spring (14) force.
multi-disc brake). The travel motor consists of swash
plate (7), rotor (16), plunger (4) with the shoe, valve
plate (1), output shaft (11), tilt piston (9) and casing
(8).
1 2 3 4 5 6 7 8 9 10
11
17
16
T1J1-03-05-003
15 14 13 12
1- Valve Plate 6- Retainer Plate 10 - Spring 14 - Spring

2- Spring 7- Swash Plate 11 - Output Shaft 15 - Brake Piston
3- Parking Brake 8- Casing 12 - Roller Bearing 16 - Rotor
4- Plunger 9- Tilt Piston 13 - Ball 17 - Valve Cover
5- Holder
T3-5-3
1. Pressure oil in valve plate (1) flows to port A, en-
ters into one side in rotor (2), and pushes plunger
(3).
2. This force and inclination of swash plate (5)
make shoe (4) slide on swash plate (5) in order
to rotate rotor (2) and output shaft (6).
3. As rotor (2) rotates, when plungers (3) reach port
B, oil is routed to the hydraulic oil tank.
4. Whether pressure oil is supplied to port A or port
B determines the travel direction.
Port B Port A
Port B
Port A
4
6 5
Valve Plate
T183-03-05-009
1 - Valve Plate 3 - Plunger 5 - Swash Plate 6 - Output Shaft

2 - Rotor 4 - Shoe
T3-5-4
TRAVEL BRAKE VALVE
The travel brake valve is located on the travel motor
head and consists of the following valves.
• Overload Relief Valve: • Check Valve:

Prevents the occurrence of overload and surge Assists the counterbalance valve operation and
pressure in the motor circuit. prevents cavitation in the motor circuit.
• Counterbalance Valve: • Travel Mode Selection Valve:
Makes starting and stopping travel operations Controls the tilt piston when selecting travel
smooth and prevents the machine from running mode.
away while descending slopes.
Section A-A
Overload Relief Counterbalance

Valve Valve
Travel Mode
Selection Valve
Check
Valve
A A
Overload Relief Counterbalance
Valve Valve
T1J1-03-05-004
T3-5-5
Counterbalance Valve, Check Valve
While Traveling: While Descending:

1. When pressure oil from the control valve flows to 1. While descending a slope, the travel motor is
port P1, pressure oil flows unseats the check forcibly rotated by the machine weight so that the
valve, flows to port BM and the travel motor. motor operates like a pump.
2. On the other hand, return oil from the travel mo- 2. If the travel motor draws oil, oil pressure in port
tor is routed to port AM. However, return oil is P1 and chamber G decrease and the spool
blocked by the spool in counterbalance valve. moves upward, so that return oil from the travel
3. When pressure in port P1 increases further, motor is restricted. Therefore, pressure in port
pressure oil from port P1 pushes to open the AM increases and brakes the travel motor.
check valve in spool through oil passage F in 3. Once return oil from the travel motor is restricted,
spool, and flows to chamber G. Pressure oil from pressure in port P1 increases again and moves
port P1 flows to chamber G through the orifice the spool downward.
and orifice A in the spool. 4. As this operation (hydraulic braking operation) is
4. Therefore, the spool moves to the lower. At this repeated, the machine is prevented from running
time, pressure oil from port P1 flows to port A and away.
is supplied to the parking brake, so that the park-
ing brake is released.
5. Return oil from the travel motor flows to port P2
through notch H on the spool. Then, pressure oil
is allowed to flow so that the travel motor starts
rotating.
6. When the travel lever is returned to neutral, oil in
ports P1 and P2 flows to the hydraulic oil tank
through the control valve.
7. Oil in chamber G flows to port P1 through the ori-
fice and pressure in chamber G is reduced.
8. Therefore, the spool is returned to the original
position by spring force and blocks the oil pas-
sage, so that the travel motor rotation is stopped.
T3-5-6
While Traveling:
Port BM Check Valve
Chamber G
Orifice A
Orifice
From Port P1
Port P1
Check Valve
Spool
From Port P1
To Port BM
Oil Passage F
Port A
To Port P2
From
Port AM
Port P2 Spool
H
Spring
Port AM Counterbalance Valve
T1J1-03-05-005
While Descending:
Port BM Chamber G
Port P1
Spool
From Port P1
To Port BM
Port P2 To Port P2
From Port
AM Spool
Port AM
T1J1-03-05-006
T3-5-7
Circuit Protection Operation: Overload

Relief Valve
1. When pressure in the circuit increases over the
set-pressure of overload relief valve, the poppet
is opened and high pressure oil relieves to the
low pressure side, so that the travel motor is pro-
tected from being overloaded.
2. In addition, the overload relief valve relieves the
shock loads developed due to inertia force when
stopping the travel motor. Poppet
Low
Pressure
High
Pressure T183-03-05-011
T3-5-8
(Blank)
T3-5-9
Travel Mode Selection Valve
The travel speed mode changes as the displacement
angle of swash plate (3) is changed by tilt piston (5).
• Slow Speed (Maximum Displacement Angle)

1. Spool (8) in travel mode selection valve (1) is 3. Therefore, as the displacement angle of swash
held in neutral by the spring (2) force. plate (3) is fixed to the larger side, the plunger (6)
2. As pressure oil from the control valve is blocked stroke becomes maximum. As amount of oil re-
by spool (8) through the counterbalance valve. quired to rotate the travel motor becomes maxi-
The circuit to tilt pistons (5) is opened to the hy- mum, the travel motor rotates at low speed.
draulic oil tank. (Refer to the Control System group/SYSTEM as
for the control circuit.)
1 8 7 2
5 6
To Hydraulic
Oil Tnak
4 3
Counterbalance
3 Valve
From Control
Valve T1J1-03-05-007
1 - Travel Mode Selection 3 - Swash Plate 5 - Tilt Piston 7 - Pilot Pressure (From So-
Valve lenoid Valve Unit (SI))
2 - Spring 4 - Ball 6 - Plunger 8 - Spool
T3-5-10
• Fast Speed (Minimum Displacement Angle)
1. When pilot pressure (7) from solenoid valve unit 4. Consequently, the travel motor rotates at high
(SI) is supplied to travel mode selection valve (1), speed.
pilot pressure (7) is supplied to chamber A (10) (Refer to the Control System group/SYSTEM as
through orifice (9) in spool (8) and moves spool for the control circuit.)
(8) to the right.
2. As spool (8) moves, pressure oil from the control
valve acts on tilt pistons (5) through the counter
balance valve and spool (8).
3. Therefore, tilt pistons (5) pushes swash plate (3)
and the displacement angle is reduced to the
minimum.
8 9 7 1 2
5 6
From Travel Mode 10

Selection Valve
4 3
Counterbalance
3 Valve
From Control
T1J1-03-05-008
Valve
1 - Travel Mode Selection 4- Ball 7- Pilot Pressure (From So- 9- Orifice

Valve lenoid Valve Unit (SI))
2 - Spring 5- Tilt Piston 8 - Spool 10 - Chamber A
3 - Swash Plate 6- Plunger
T3-5-11
PARKING BRAKE
The parking brake is a negative-type brake released When spring (1) pushes piston (3) and friction plate
when pilot pressure oil is applied to piston chamber (5) comes into contact with plate (4), the parking
(2). The parking brake is automatically applied except brake is applied.
during travel operation. (Refer to the pilot circuit in the Hydraulic System
Friction plate (5) is connected to rotor (7) and plate (4) group / SYSTEM as for pilot oil flow.)
is connected to casing (6) via spline couplings respec-
tively.
1 2 3 4 5 6
T1J1-03-05-003
1 - Spring 3 - Piston 5- Friction Plate 7- Rotor

2 - Piston Chamber 4 - Plate 6- Casing
T3-5-12
When Brake is Applied Spring
When the travel lever is in the neutral position, the
friction plate and plate come in contact tightly, so that
the parking brake is applied. At this time, oil in the
piston chamber returns to the hydraulic oil tank.
Piston
Chamber
Piston
Plate
Friction Plate
Casing
Rotor
T111-03-04-007
When Brake is Released Spring

When the travel lever is operated, pilot pressure oil
flows to the piston chamber and acts on the piston. Piston
Therefore, the piston is pushed and moves upward. Chamber
Consequently, the friction plate is separated from the
plate and the parking brake is released.
Piston
Plate
Friction Plate
Casing
Rotor
T111-03-04-008
T3-5-13
(Blank)
T3-5-14
COMPONENT OPERATION / Signal Control Valve
OUTLINE
The signal control valve is provided in the pilot circuit

Section A-A
between pilot valve and control valve, and controls
various signal pressure used to regulate the pumps Shockless
and valves. Valve (For
The major components of signal control valve are Boom Raise)
shuttle valve, shockless valve, flow combiner valve

control spool, arm flow rate control valve control spool Auxiliary Arm Flow Rate
Control Valve
and swing parking brake release spool.
Control Spool
Auxiliary
Auxiliary
Swing Parking Flow Combiner

Brake Release Valve Control
Spool Spool
A, B T178-03-06-002
Section B-B (Shuttle Valve)
11
Pilot Valve
Side 4
5
9
8
6 10
13 3
T1J1-03-06-004
15 16
12
2
1
14
17
T178-03-06-009
1 - Left Travel 6- Swing 11 - Arm / Boom Raise 16 - Boom / Arm / Bucket / Left
Travel / Swing
2 - Right Travel 7- Auxiliary 12 - Boom / Arm / Bucket / 17 - Left Travel / Right Travel
Swing / Auxiliary
3 - Bucket 8- Swing / Auxiliary 13 - Boom / Arm / Bucket
4 - Arm 9- Boom / Arm 14 - Boom / Arm / Bucket / Left
Travel
5 - Boom 10 - Arm / Boom Raise / Swing 15 - Boom / Arm / Bucket /
/ Auxiliary Right Travel
T3-6-1
PILOT PORT
Pilot Valve Side

Port SA - Plug
Port SB - Plug
T3-6-2
Pilot Valve Side
PH
C
A
E
M
D
H B
SB
F
G
Pilot Valve
Side
PI
K
I
SH J
DF
SA L
T1J1-03-06-002
Control Valve Side

SM 3
5
1
13
2 4
SK SE
8
S3
14
Control Valve 7
Side
9 6
10
SN
SL
11
TR 12 SP T1J1-03-06-003
T3-6-3
Control Valve Side

Port SE - Plug
Port SN - Plug
Port TR - Plug
T3-6-4
Pilot Valve Side
PH
C
A
E
M
D
H B
SB
F
G
Pilot Valve
Side
PI
K
I
SH J
DF
SA L
T1J1-03-06-002
Control Valve Side

SM 3
5
1
13
2 4
SK SE
8
S3
14
Control Valve 7
Side
9 6
10
SN
SL
11
TR 12 SP T1J1-03-06-003
T3-6-5
SHUTTLE VALVE
The shuttle valve selects pilot pressure used to per-
form each operation and routes pilot pressure to the
corresponding control valves and/or control spools.
The spools corresponding to each operation are as
follows:
Arm Flow Rate Flow Combiner Swing Parking

Control Valve Valve Control Brake Release
Control Spool Spool Spool
Boom Raise { ⎯ {
Boom Lower ⎯ ⎯ {
Arm Roll-Out ⎯ ⎯ {
Arm Roll-In { ⎯ {
Bucket Roll-In ⎯ ⎯ {
Bucket Roll-Out ⎯ ⎯ {
Right Swing ⎯ ⎯ {
Left Swing ⎯ ⎯ {
Right Travel ⎯ { ⎯
Left Travel ⎯ ⎯ ⎯
Auxiliary ⎯ ⎯ {
T3-6-6
Left Right
Travel Travel Swing Arm Boom Bucket
1 2 3 4 5 6 7
Shockless Valve
(For Boom Raise)
8
Arm Flow Rate
Control Valve
Control Spool 9
Swing Parking Flow Combiner 17 16 15 14 13 12 11 10 T1J1-03-06-001

Brake Release Valve Control
Spool Spool
T3-6-7
COMPONENT OPERTATION / Signal Control Valve
Pilot Valve
Side
T1J1-03-06-004
Section B-B
11
4
5
9
8
6 10
13 3
15 16
12
2
1
14
17
T178-03-06-009
1- Left Travel 6- Swing 11 - Arm / Boom Raise 16 - Boom / Arm / Bucket / Left
Travel / Swing
2- Right Travel 7- Auxiliary 12 - Boom / Arm / Bucket / 17 - Left Travel / Right Travel
Swing / Auxiliary
3- Bucket 8- Swing / Auxiliary 13 - Boom / Arm / Bucket
4- Arm 9- Boom / Arm 14 - Boom / Arm / Bucket / Left
Travel
5- Boom 10 - Arm / Boom Raise / Swing 15 - Boom / Arm / Bucket /
/ Auxiliary Right Travel
T3-6-8
(Blank)
T3-6-9
SHOCKLESS VALVE
The shockless valve is provided in the boom raise
Port A
circuit and functions when returning the boom raise Spool
control lever suddenly.
During Boom Raising Operation

1. Boom raise pilot pressure is routed into port A
and acts on the spool.
2. Immediately after operation is started, low pilot
pressure flows into the spring B chamber through
clearance C between spool and housing. At the Clearance C
same time, pilot pressure flows to port 1 through
inner passage 2. Port 1 T1V1-03-06-003
3. When pilot pressure increases, pressure in the
spring B chamber increases, and the spool
pushes spring A and moves to the left.
4. As the spool is moved, port A is connected to port
1 and pressure in port 1 increase, so that the Port A
spool in control valve is moved. Spring A Spool Spring B
Port 1 T1V1-03-06-002
T3-6-10
During boom raising operation
Spring A Spool Port A
Clearance C
Inner Passage 2
Spring B
Port 1 T183-03-06-003
Spool Port A
Port 1 T183-03-06-004
Detail of Housing
Clearance C
Spool T1V1-03-06-008
T3-6-11
During Boom Raising Operation (Shockless Op-
eration)
Spring A Spool Port A Spring B
1. When the boom is returned suddenly, port A is
connected to the hydraulic oil tank through the
pilot valve. Return oil from the boom raise spool
in the control valve acts on port 1.
2. Pressure oil from port 1 flows to spring chamber
A through inner passage 1 and to port A through
the spool. Oil in spring chamber B flows to port A
through the spool.
3. Pressure acting on the spring A side moves the
spool to the right.
4. Therefore, clearance C between spool and hous- Port 1 T1V1-03-06-002
ing is closed, so that pressure oil is blocked.

5. When clearance C is closed, pressure in spring Port A
chamber B increases and moves the spool to the Spring A Spool Spring B
left. Then, clearance C is opened again and
pressure oil flows to the port A side.
6. As operations in steps (2 to 5) are repeated,
pressure oil is gradually returned to port A, so
that the control valve spool returns slowly.
Clearance C
Port 1
T1V1-03-06-004
Spring A Spool Port A Spring B
Port 1 T1V1-03-06-002
T3-6-12
During boom raising operation (Shockless operation)
Spring A Inner Passage 1 Clearance C Spool

Port A
Spring B
Inner Passage 2 Oil Chamber

Port 1 T183-03-06-005
Spool
Port A
Inner Passage 2 Oil Chamber

Port 1 T183-03-06-004
Detail of Clearance C
Housing
Spool T1V1-03-06-008
T3-6-13
ARM FLOW RATE CONTROL VALVE CON-
TROL SPOOL,
FLOW COMBINER VALVE CONTROL
SPOOL, Arm Flow Rate Control Valve Control Spool:
SWING PARKING BRAKE RELEASE
SPOOL To Hydraulic Boom Raise Control
Oil Tank Pilot Pressure
Spool Spring
NOTE: The spools above are identical in opera-
tional principle.
1. The arm flow rate control valve control spool is

shifted by arm roll-in pilot pressure and supplies
boom raise pilot pressure to the arm flow rate T178-03-06-014
control valve in control valve. Arm Roll-In To Arm Flow Rate
2. The flow combiner valve control spool is shifted Pilot Pressure Control Valve
by right travel pilot pressure and supplies primary
pilot pressure to the flow combiner valve in con- Flow Combiner Valve Control Spool:
trol valve.
3. The swing parking brake release spool is shifted To Hydraulic Primary Pilot
by the boom, arm, bucket, swing or auxiliary pilot Oil Tank Pressure
Spool Spring
pressure and supplies primary pilot pressure to
the swing motor.
T178-03-06-014
Right Travel To Flow Combiner
Pilot Pres- Valve
sure
Swing Parking Brake Release Spool:

To Hydraulic Primary Pilot
Oil Tank Pressure
Spool Spring
T178-03-06-014
Boom, Arm, To Swing
Bucket or Aux- Motor
iliary Pilot
Pressure
T3-6-14
COMPONENT OPERATION / Others (Upperstructure)
PILOT SHUT-OFF SOLENOID VALVE
Cross Section Z-Z Pilot Shut-Off
Solenoid Valve
The pilot shut-off solenoid valve is a solenoid
valve-operated switch valve.
The spool in pilot shut-off solenoid valve is shifted by
To Ports T1
the pilot shut-off lever and turns on or off pilot pres- to T4
sure oil to the pilot valve and signal control valve.
To Ports A1
to A4
Port P
Spool
T1J1-03-07-011
Port H
A1
P T1
T2
A2
A3
Z
T3
T4
A4
HT
T1V1-03-07-011
A1 - Travel / Auxiliary Pilot A4 - Unused T1 - Travel / Auxiliary Pilot T3 - Left Pilot Valve
Valve Valve
A2 - Right Pilot Valve HT - Signal Control Valve (Port T2 - Right Pilot Valve T4 - Hydraulic Oil Tank
PH)
A3 - Left Pilot Valve P - Primary Pilot Pressure
T3-7-1
• Pilot Shut-Off Lever: LOCK Position Pilot Shut-Off Lever: LOCK Position
1. When the pilot shut-off lever is in the LOCK posi-
tion, the pilot shut-off relay is turned OFF and the Pilot Shut-Off
pilot shut-off solenoid valve is turned OFF. (Refer Solenoid Valve
to Electrical System group / SYSTEM.)
To Hydrau-
2. Pressure oil from the pilot pump flows to the sig- lic Oil Tank
nal control valve through the spool in pilot
shut-off solenoid valve.
3. Oil from the pilot valve flows to the hydraulic oil
From Pilot
tank. Pump
4. Therefore, although the control lever is operated,
the pilot valve is not operated. To Pilot
Valve
• Pilot Shut-Off Lever: UNLOCK Position

1. When the pilot shut-off lever is in the UNLOCK
position, the pilot shut-off relay is turned ON and
the pilot shut-off solenoid valve is activated. (Re-
fer to Electrical System group / SYSTEM.)
2. Therefore, the Circuit to signal control valve and Spool
hydraulic oil tank are blocked by the spool in pilot To Signal T1J1-03-07-011
shut-off valve. Control Valve
3. Pressure oil from the pilot pump flows to the pilot
valve.
Pilot Shut-Off Lever: UNLOCK Position
4. Consequently, when the control lever is operated,
the pilot valve is operated. Pilot Shut-Off
Solenoid Valve
To Hydrau-
lic Oil Tank
From Pilot
Pump
To Pilot
Valve
Spool
To Signal T1J1-03-07-001
Control Valve
T3-7-2
4-SPOOL SOLENOID VALVE UNIT
Controls the control valve and the valve in travel mo-
tor by the signal from MC (main controller). (Refer to
Control System / SYSTEM.) The 4-spool solenoid
valve unit consists of proportional solenoid valves (SC, SC SF SI SG
SF, SI and SG).
• SC: Control the boom overload relief control

valve in control valve
• SF: Control the boom flow rate control valve
(switch valve) in control valve
• SI: Control the travel motor swash angle control
valve
• SG: Increase pressure of the main relief valve in
control valve
T1V1-03-07-007
T3-7-3
Proportional Solenoid Valve
Controls by an electric current signal from MC and

outputs pressure in proportional to degree of the
electric current.
• When not energized (In neutral): • When energized:

1. Spring (2) pushes spool (1) to the right and 1. Solenoid (3) pushes spool (1) to the left due to
output port S is connected to tank port T. force in proportional to the electric current flowing
through solenoid (3).
2. Pilot oil pressure from port P flows into output
port S and pressure at output port S increases.
3. Pressure at outpur port S acts on step part a on
spool (1).
Because of difference in the pressure receiving
area between step part a, spool (1) is pushed to
the right.
4. When pressure at port S increases and the force
to push spool (1) to the right overcomes the force
to push spool (1) to the left by solenoid (3), spool
(1) moves back to the right side and the passage
between output port S and port P is closed. As a
result, pressure increase at port S stops.
1 2 3
T S P
a
T107-02-07-005
1- Spool 2- Spring 3- Solenoid
T3-7-4
PILOT RELIEF VALVE Pilot Relief
Valve
The pilot relief valve has a pilot filter incorporated. Port P
The pilot relief valve functions to regulate pilot pump
pressure oil routed to port P to a set constant
pressure.
Pilot Filter
T178-03-07-001
T3-7-5
FAN MOTOR
The fan motor, a vane motor is operated by pressure
oil from the fan pump and rotates the fan in oil cooler.
The fan motor consists of cap end (1), cartridge (2),
plate (3), bearing (4), housing (5) and shaft (6).
2 3 4 5
T1J1-03-07-002
1- Cap End 3 - Plate 5 - Housing 6- Shaft

2- Cartridge 4 - Bearing
T3-7-6
FAN VALVE
Fan Valve (Standard)
The fan valve (standard) consists of make-up valve Port M1 Port M2
and relief valve.
The make-up valve prevents cavitation in the circuit
and the relief valve prevents surge pressure and
Relief Valve
T1J1-03-07-003
Port P1 Port T1
Fan Valve (Optional)

The fan valve (optional) consists of make-up valve,
relief valve and solenoid valve. Solenoid
Valve
The make-up valve prevents cavitation in the circuit Port M1 Port M2
and the relief valve prevents surge pressure and
When the solenoid valve is shifted, pressure oil from
the fan pump (port P1) is shifted to port M1 or M2. Port PP
Therefore, rotation of the fan motor is switched to for-
ward or reverse rotation.
Port P1 Port T1
T1J1-03-07-004
Relief Valve
T3-7-7
SHOCKLESS VALVE
The shockless valve is provided in the boom lower
circuit and operated when the boom lower control
lever is suddenly returned.
Operation
1. When the boom lower control lever is returned, 4. As pressure difference between front and rear of
return oil from the spool in control valve (boom orifice (6) occurs, spool (5) is move to the left by
lower side) acts on port A. pressure acting on the spring (3) side. Therefore,
2. Oil in port A flows to chamber D (1) through ori- passage (2) in spool (5) and housing (4) is closed
fice (6). and pressure oil is blocked.
3. Pressure in chamber D (1) is routed to port B 5. When passage (2) is closed, pressure in cham-
through passage (2) in spool (5) and housing (4), ber D (1) increases and spool (5) moves to the
so that pressure in chamber D (1) decreases. right. Passage (2) is open again and pressure oil
flows to port B.
6. By repeating steps 3 to 5, pressure oil returns to
the port B side gradually, so that the spool in con-
trol valve is slowly returned.
2 3
Port B
Port A T1J1-03-07-012
6 5
1- Chamber D 3 - Spring 5 - Spool 6- Orifice

2- Passage 4 - Housing
T3-7-8
ACCUMULATOR
The accumulator is provided in the pilot circuit in order 6
to buffer fluctuations in oil pressure, and to maintain
1
pilot pressure for a short time period after the engine
is stopped.
The accumulator mainly consists of body (5), holder 5 Nitrogen
(4), bladder (2), which encloses nitrogen gas (N2), and Gas (N2) 2
poppet (1).
4
• Pressure oil from the pilot pump enters into the
accumulator through port A pilot pressure com-
Pilot Pres-
presses bladder (2) until the nitrogen gas bal- sure Oil
ances against with bladder (2).
• When pressure supply is stopped due to engine 3
stall or any other reasons, bladder (2) starts ex-
panding and accumulated oil is supplied to the
pilot circuit through port A.
A
T105-02-10-003
1- Poppet 4 - Holder
2- Bladder 5 - Body
3- Oil Port 6 - Gas Plug
T3-7-9
DISTRIBUTION VALVE (OPTIONAL)
Distribution
Valve
The distribution valve is provided in the auto lubrica-
tion circuit and distributes grease from the grease
pump to each lubrication position.
The proximity switch detects grease amount to be
distributed and outputs the signal to MC.
(Refer to Auto Lubrication Control in SYSTEM / Con-
trol System group.)
Proximity Switch
T1J1-03-07-005
From
Grease
Pump Piston
Operation
1. Grease from the grease pump acts on the right Port 11 A Port 12
side of piston A through passage G.
2. Therefore, piston A moves to the left. Grease at Port 9 B Port 10
the left side of piston A flows to port 2 through
passage H and piston F. Port 7 C Port 8
Port 5 D Port 6
Port 3 E Port 4
Port 1 F Port 2
T1J1-03-07-006
Passage H Passage G
From
Grease
Passage J Pump Passage I
3. When piston A moves to the left, grease from the Port 11 A Port 12
grease pump acts on the right side of piston B
through passage I. Port 9 B Port 10
4. Therefore, piston B moves to the left. Grease at
the left side of piston B flows to port 11 through Port 7 C Port 8
passage J and piston A.
Port 5 D Port 6
Port 3 E Port 4
Port 1 F Port 2
T1J1-03-07-007
T3-7-10
5. When piston B moves to the left, grease from the From
grease pump acts on the right side of piston C Grease
through passage K. Passage L Pump Passage K
6. Therefore, piston C moves to the left. Grease at
the left side of piston C flows to port 9 through Port 11 A Port 12
passage L and piston B.
7. By repeating steps 3 to 6, grease is supplied to Port 9 B Port 10
ports 11, 9, 7, 5 and 3 in this order.
Port 7 C Port 8
Port 5 D Port 6
Port 3 E Port 4
Port 1 F Port 2
T1J1-03-07-008
From
Grease
Pump
Port 11 A Port 12
8. When piston F moves to the left, grease from the
grease pump acts on the left side of piston A
Port 9 B Port 10
through passage H.
9. Therefore, piston A moves to the right. Grease at
the right side of piston A flows to port 1 through Port 7 C Port 8
passage G and piston F.
Port 5 D Port 6
Port 3 E Port 4
Port 1 F Port 2
T1J1-03-07-009
Passage H Passage G
From
Grease
Passage J Pump Passage I
10. When piston A moves to the right, grease from Port 11 A Port 12
the grease pump acts on the left side of piston B
through passage J. Port 9 B Port 10
11. Therefore, piston B moves to the right. Grease at
the right side of piston B flows to port 12 through Port 7 Port 8
C
passage I and piston A.
12. By repeating steps 10, 11, grease is supplied to
Port 5 D Port 6
ports 12, 10, 8, 6 and 4 in this order.
Port 3 E Port 4
Port 1 F Port 2
T1J1-03-07-010
T3-7-11
(Blank)
T3-7-12
COMPONENT OPERATION / Others (Undercarriage)
SWING BEARING
The swing bearing supports the upperstructure weight Outer race (1) is bolted to the upperstructure and
and functions to rotate the upperstructure smoothly. inner race (3) is bolted to the undercarriage. The
This bearing is a single-row shear ball-type bearing internal gear of inner race (3) engages with the output
and consists of outer race (1), inner race (3), ball (6), shaft of swing reduction gear.
support (5) and seals (2, 4).
T135-03-02-001
1 - Outer Race 3 - Inner Race 5 - Support 6- Ball

2 - Seal 4 - Seal
T3-8-1
CENTER JOINT
The center joint is a 360° rotating joint. The center Pressure oil flows to the right and left travel motors
joint allows pressure oil to flow smoothly to the travel from each port of the body through the spindle. The
motor without twisting the hoses while the seal prevents oil leaks between spindle and body.
upperstructure is rotated.
The spindle is fixed to the upperstructure, and the
body is fixed to the swing center of undercarriage.
Spindle
Body
Seal
T16J-03-07-001
T3-8-2
TRACK ADJUSTER
The track adjuster consists of spring (5) and adjuster
cylinder (6), and is supported by the side frame.
Spring (5) absorbs loads applied to the front idler.
Piston rod (8) adjusts track sag.
Hexagonal Part 1
• Grease is applied through the grease fitting into
part a of adjuster cylinder (6). Grease pushes
piston rod (8) and decreases track sag. Grease Fitting
• In order to increases track sag, loosen the
hexagonal part of valve (1) 1 to 1.5 turns
counterclockwise and release grease.
CAUTION: Adjuster cylinder (6) is highly

pressurized. As valve (1) may fly out and the
highly pressurized grease may spout out, do
not loosen valve (1) quickly and/or Grease Discharge Hole
excessively.
Keep face and body parts away from valve
(1) and loosen valve (1) slowly and gradually. T1J1-03-08-002
In addition, do not loosen the grease fitting.
1 2 3 4 a 5 6 7 8
T1J1-03-08-001
1 - Valve 3 - Washer 5 - Spring 7 - Flange

2 - Nut 4 - Spacer 6 - Adjuster Cylinder 8 - Piston Rod
T3-8-3
(Blank)
T3-8-4
MEMO
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Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Tel: 81-29-982-7084
Fax: 81-29-831-1162
SERVICE MANUAL REVISION REQUEST FORM
COMPANY NAME: MODEL:

PUBLICATION PART NO.:
YOUR NAME: (Located at the left top corner in the cover page)
DATE: PAGE NO.:

(Located at the bottom center in the page. If two or more revi-
FAX: sions are requested, use the comment column)
E-mail:
YOUR COMMENTS / SUGGESTIONS:

Attach photo or sketch if required.
If your need more space, please use another sheet.
REPLY:
(Copy this form for usage)

INTRODUCTION
TO THE READER
age.):
TEL: 81-29-832-7084
FAX: 81-29-831-1162
to the 21, April 2009.

manual.
MANUAL COMPOSITION
PAGE NUMBER

Example : T 1-3-5

Group Number
Section Number
IN-01
INTRODUCTION
NOTATIONS

death.
• NOTE:
know-how.
heavy parts.
UNITS USED
this manual.
From From
mm ft 0.003281 MPa psi 145.0
L US qt 1.057 kW HP 1.341
IN-02
SAFETY
RECOGNIZE SAFETY INFORMATION
• These are the SAFETY ALERT SYMBOLS.
• When you see these symbols on your machine or

in this manual, be alert to the potential for per-
sonal injury.
• Follow recommended precautions and safe oper-
ating practices.
001-E01A-0001
SA-688
UNDERSTAND SIGNAL WORDS

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

situation which, if not avoided, will result in death
or serious injury.
• WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
• CAUTION indicates a potentially hazardous
situation which, if not avoided, may result in minor
or moderate injury.
• DANGER or WARNING safety signs are located
near specific hazards. General precautions are
listed on CAUTION safety signs.
• Some safety signs don't use any of the desig-
nated signal words above after the safety alert
symbol are occasionally used on this machine.
• To avoid confusing machine protection with personal

safety messages, a signal word IMPORTANT indi-
cates a situation which, if not avoided, could result in
damage to the machine. SA-1223
• NOTE indicates an additional explanation for an

element of information.
002-E01A-1223
SA-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS
• Carefully read and follow all safety signs on the
machine and all safety messages in this manual.
• Safety signs should be installed, maintained and
replaced when necessary.
• If a safety sign or this manual is damaged or

missing, order a replacement from your author-
ized dealer in the same way you order other re-
placement parts (be sure to state machine model
and serial number when ordering).
• Learn how to operate the machine and its controls
correctly and safely.
• Allow only trained, qualified, authorized personnel to
operate the machine. SA-003
• Keep your machine in proper working condition.
• Unauthorized modifications of the machine may

impair its function and/or safety and affect ma-
chine life.
• Do not modify any machine parts without au-
thorization. Failure to do so may deteriorate the
part safety, function, and/or service life. In addi-
tion, personal accident, machine trouble, and/or
damage to material caused by unauthorized
modifications will void Hitachi Warranty Policy.
• Do not use attachments and/or optional parts or
equipment not authorized by Hitachi. Failure to do
so may deteriorate the safety, function, and/or
service life of the machine. In addition, personal
accident, machine trouble, and/or damage to
material caused by using unauthorized attach-
ments and/or optional parts or equipment will void
Hitachi Warranty Policy.
• The safety messages in this SAFETY chapter are
intended to illustrate basic safety procedures of
machines. However it is impossible for these safety
messages to cover every hazardous situation you
may encounter. If you have any questions, you
should first consult your supervisor and/or your au-
thorized dealer before operating or performing
maintenance work on the machine.
003-E01B-0003
SA-2
SAFETY
PREPARE FOR EMERGENCIES
• Be prepared if a fire starts or if an accident occurs.
• Keep a first aid kit and fire extinguisher on hand.

• Thoroughly read and understand the label at-
tached on the fire extinguisher to use it properly.
• To ensure that a fire-extinguisher can be always
used when necessary, check and service the
fire-extinguisher at the recommended intervals as
specified in the fire-extinguisher manual.
• Establish emergency procedure guidelines to
cope with fires and accidents.
• Keep emergency numbers for doctors, ambu-
lance service, hospital, and fire department
posted near your telephone. SA-437
004-E01A-0437
WEAR PROTECTIVE CLOTHING

• Wear close fitting clothing and safety equipment
appropriate to the job.
You may need:

A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear
Respirator or filter mask.
Be sure to wear the correct equipment and clothing
for the job. Do not take any chances. SA-428
• Avoid wearing loose clothing, jewelry, or other

items that can catch on control levers or other
parts of the machine.
• Operating equipment safely requires the full atten-
tion of the operator. Do not wear radio or music
headphones while operating the machine.
005-E01A-0438
SA-3
SAFETY
PROTECT AGAINST NOISE
• Prolonged exposure to loud noise can cause im-
pairment or loss of hearing.
• Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against objec-
tionable or uncomfortably loud noises.
006-E01A-0434
SA-434
INSPECT MACHINE
• Inspect your machine carefully each day or shift by
walking around it before you start it to avoid per-
sonal injury.
• In the walk-around inspection be sure to cover all

points described in the "RE-START INSPEC-
TION" chapter in the operator's manual.
007-E01A-0435
SA-435
SA-4
SAFETY
GENERAL PRECAUTIONS FOR CAB
• Before entering the cab, thoroughly remove all dirt
and/or oil from the soles of your work boots. If any
controls such as a pedal is operated while with
dirt and/or oil on the soles of the operator's work
boots the operator's foot may slip off the pedal,
possibly resulting in a personal accident.
• Do not leave parts and/or tools lying around the
operator's seat. Store them in their specified loca-
tions.
• Avoid storing transparent bottles in the cab. Do
not attach any transparent type window decora-
tions on the windowpanes as they may focus
sunlight, possibly starting a fire.
• Refrain from listening to the radio, or using music
headphones or mobile telephones in the cab
while operating the machine.
• Keep all flammable objects and/or explosives
away from the machine.
• After using the ashtray, always cover it to extin-
guish the match and/or tobacco.
• Do not leave cigarette lighters in the cab. When
the temperature in the cab increases, the lighter
may explode.
524-E01A-0000
SA-5
SAFETY
USE HANDHOLDS AND STEPS
• Falling is one of the major causes of personal injury.
• When you get on and off the machine, always

face the machine and maintain a three-point
contact with the steps and handrails.
• Do not use any controls as hand-holds.
• Never jump on or off the machine. Never mount or
dismount a moving machine.
• Be careful of slippery conditions on platforms,
steps, and handrails when leaving the machine.
008-E01A-0439
SA-439
ADJUST THE OPERATOR'S SEAT

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

the operator for the machine.
• The operator should be able to fully depress the
pedals and to correctly operate the control levers
with his back against the seat back.
• If not, move the seat forward or backward, and
check again.
• Adjust the rear view mirror position so that the
best rear visibility is obtained from the operator's
seat. If the mirror is broken, immediately replace it SA-462
with a new one.
009-E01A-0462
SA-6
SAFETY
ENSURE SAFETY BEFORE RISING FROM
OR LEAVING OPERATOR'S SEAT
• Before rising from the operator's seat to open/close
either side window or to adjust the seat position, be
sure to first lower the front attachment to the ground
and then move the pilot control shut-off lever to the
LOCK position. Failure to do so may allow the ma-
chine to unexpectedly move when a body part un-
intentionally comes in contact with a control lever,
possibly resulting in serious personal injury or death.
• Before leaving the machine, be sure to first lower

the front attachment to the ground and then move
the pilot control shut-off lever to the LOCK posi-
tion. Turn the key switch OFF to stop the engine.
• Before leaving the machine, close all windows,
doors, and access covers and lock them up.
FASTEN YOUR SEAT BELT

• If the machine should overturn, the operator may
become injured and/or thrown from the cab. Addi-
tionally the operator may be crushed by the over-
turning machine, resulting in serious injury or death.
• Prior to operating the machine, thoroughly ex-

amine webbing, buckle and attaching hardware. If
any item is damaged or worn, replace the seat
belt or component before operating the machine.
• Be sure to remain seated with the seat belt se-
curely fastened at all times when the machine is
in operation to minimize the chance of injury from
an accident.
・We recommend that the seat belt be replaced SA-237
every three years regardless of its apparent con-

dition.
010-E01A-0237
SA-7
SAFETY
MOVE AND OPERATE MACHINE SAFELY
• Bystanders can be run over.
• Take extra care not to run over bystanders. Con-

firm the location of bystanders before moving,
swinging, or operating the machine.
• Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
• Use a signal person when moving, swinging, or
operating the machine in congested areas. Coor-
dinate hand signals before starting the machine.
• Use appropriate illumination. Check that all lights
are operable before operating the machine. If any
faulty illumination is present, immediately repair it.
SA-426
011-E01A-0398
HANDLE STARTING AIDS SAFELY

Starting fluid:
• Starting fluid is highly flammable.
• Keep all sparks and flame away when using it.

• Keep starting fluid well away from batteries and
cables.
• Remove container from machine if engine does
not need starting fluid.
• To prevent accidental discharge when storing a
pressurized container, keep the cap on the con-
tainer, and store it in a cool, well-protected loca-
tion.
• Do not incinerate or puncture a starting fluid con-
SA-293
tainer.
036-E01A-0293-3
SA-8
SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT
• Inappropriate engine starting procedures may cause
the machine to runaway, possibly resulting in seri-
ous injury or death.
• Start the engine only when seated in the opera-

tor's seat.
• NEVER start the engine while standing on the
track or on ground.
• Do not start engine by shorting across starter
terminals.
• Before starting the engine, confirm that all control
levers are in neutral.
• Before starting the engine, confirm the safety SA-444
around the machine and sound the horn to alert

bystanders.
012-E01B-0431
JUMP STARTING
• Battery gas can explode, resulting in serious injury.
• If the engine must be jump started, be sure to

follow the instructions shown in the "OPERATING
THE ENGINE" chapter in the operator's manual.
• The operator must be in the operator's seat so
that the machine will be under control when the
engine starts. Jump starting is a two-person op-
eration.
• Never use a frozen battery.
• Failure to follow correct jump starting procedures
could result in a battery explosion or a runaway
machine.
SA-032
S013-E01A-0032
SA-9
SAFETY
KEEP RIDERS OFF MACHINE
• Riders on machine are subject to injury such as be-
ing struck by foreign objects and being thrown off
the machine.
• Only the operator should be on the machine.

Keep riders off.
• Riders also obstruct the operator's view, resulting
in the machine being operated in an unsafe
manner.
014-E01B-0427
SA-379
PRECAUTIONS FOR OPERATIONS

• Investigate the work site before starting operations.
• Be sure to wear close fitting clothing and safety

equipment appropriate for the job, such as a hard
hat, etc. when operating the machine.
• Clear all persons and obstacles from area of op-
eration and machine movement.
Always beware of the surroundings while operat-
ing. When working in a small area surrounded by
obstacles, take care not to hit the upperstructure
against obstacles.
• When loading onto trucks, bring the bucket over
the truck beds from the rear side. Take care not to
swing the bucket over the cab or over any person.
M104-05-015
SA-10
SAFETY
INVESTIGATE JOB SITE BEFOREHAND
• When working at the edge of an excavation or on a
road shoulder, the machine could tip over, possibly
resulting in serious injury or death.
• Investigate the configuration and ground condi-
tions of the job site beforehand to prevent the
machine from falling and to prevent the ground,
stockpiles, or banks from collapsing.
• Make a work plan. Use machines appropriate to
the work and job site.
• Reinforce ground, edges, and road shoulders as
necessary. Keep the machine well back from the
edges of excavations and road shoulders.
• When working on an incline or on a road shoulder, SA-380
employ a signal person as required.
• Confirm that your machine is equipped a FOPS
cab before working in areas where the possibility
of falling stones or debris exist.
• When the footing is weak, reinforce the ground
before starting work.
• When working on frozen ground, be extremely
alert. As ambient temperatures rise, footing be-
comes loose and slippery.
• Beware the possibility of fire when operating the
machine near flammable objects such as dry
grass.
• Make sure the worksite has sufficient strength to
firmly support the machine.
When working close to an excavation or at road
shoulders, operate the machine with the tracks po-
sitioned perpendicular to the cliff face with travel
motors at the rear, so that the machine can more
easily evacuate if the cliff face collapses.
• If working on the bottom of a cliff or a high bank is
required, be sure to investigate the area first and
confirm that no danger of the cliff or bank collapsing
exists. If any possibility of cliff or bank collapsing
exists, do not work on the area.
• Soft ground may collapse when operating the ma-
chine on it, possibly causing the machine to tip over.
When working on a soft ground is required, be sure
to reinforce the ground first using large pieces of
steel plates strong and firm enough to easily support
the machine.
• Note that there is always a possibility of machine
tipping over when working on rough terrain or on
slopes. Prevent machine tipping over from occurring.
When operating on rough terrain or on slopes:
• Reduce the engine speed.
• Select slow travel speed mode.
• Operate the machine slowly and be cautious with
machine movements.
SA-11
SAFETY
EQUIPMENT OF HEAD GUARD, ROPS,
FOPS
In case the machine is operated in areas where the
possibility of falling stones or debris exist, equip a
head guard, ROPS, or FOPS according to the poten-
tial hazardous conditions. (The standard cab for this
machine corresponds to ROPS and FOPS.)
ROPS: Roll-Over Protective Structure

FOPS: Falling Object Protective Structure
SA-490
PROVIDE SIGNALS FOR JOBS INVOLV-

ING MULTIPLE NUMBERS OF MACHINES
• For jobs involving multiple numbers of machines,
provide signals commonly known by all personnel
involved. Also, appoint a signal person to coordinate
the job site. Make sure that all personnel obey the
signal person's directions.
018-E01A-0481
SA-481
CONFIRM DIRECTION OF MACHINE TO

BE DRIVEN
• Incorrect travel pedal/lever operation may result in
serious injury death.
• Before driving the machine, confirm the position

of the undercarriage in relation to the operator's
position. If the travel motors are located in front of
the cab, the machine will move in reverse when
travel pedals/levers are operated to the front.
017-E01A-0491
SA-491
SA-12
SAFETY
DRIVE MACHINE SAFELY
• Before driving the machine, always confirm that the
travel levers/pedals direction corresponds to the di-
rection you wish to drive.
• Be sure to detour around any obstructions.

• Avoid traveling over obstructions. Soil, fragments
of rocks, and/or metal pieces may scatter around
the machine. Don't allow personnel to stay around
the machine while traveling.
• Driving on a slope may cause the machine to slip or

overturn, possibly resulting in serious injury or
death. SA-657
• Never attempt to ascend or descend 35 degrees

or steeper slopes.
• Be sure to fasten the seat belt.
• When driving up or down a slope, keep the bucket
facing the direction of travel, approximately 0.5 to
1.0 m (A) above the ground.
• If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and
stop.
SA-658
SA-441
SA-442
SA-13
SAFETY
• Driving across the face of a slope or steering on a
slope may cause the machine to skid or turnover.
If the direction must be changed, move the ma-
chine to level ground, then, change the direction
to ensure safe operation.
• Avoid swinging the upperstructure on slopes.
Never attempt to swing the upperstructure down-
hill. The machine may tip over. If swinging uphill is
unavoidable, carefully operate the upperstructure
and boom at slow speed. Travel Motor
• If the engine stalls on a slope, immediately lower
the bucket to the ground. Return the control lev-
M104-05-008
ers to neutral. Then, restart the engine.
• Be sure to thoroughly warm up the machine be-
fore ascending steep slopes. If hydraulic oil has
not warmed up sufficiently, sufficient performance
may not be obtained.
• Use a signal person when moving, swinging or
• Before moving machine, determine which way to
move travel pedals/levers for the direction you
Arrow-Mark
want to go. When the travel motors are in the rear,
pushing down on the front of the travel pedals or M178-03-001
pushing the levers forward moves the machine

forward, towards the idlers.
An arrow-mark seal is stuck on the inside surface
of the side frame to indicate the machine front
direction.
• Select a travel route that is as flat as possible.
Steer the machine as straight as possible, making
small gradual changes in direction.
• Before traveling on them, check the strengths of
bridges and road shoulders, and reinforce if nec-
essary.
SA-14
SAFETY
• Use wood plates in order not to damage the road
surface. Be careful of steering when operating on
asphalt roads in summer.
• When crossing train tracks, use wood plates in
order not to damage them.
• Do not make contact with electric wires or
bridges.
• When crossing a river, measure the depth of the
river using the bucket, and cross slowly. Do not
cross the river when the depth of the river is
deeper than the upper edge of the upper roller.
• When traveling on rough terrain, reduce engine
speed. Select slow travel speed. Slower speed
will reduce possible damage to the machine.
• Avoid operations that may damage the track and SA-011
undercarriage components.
• During freezing weather, always clean snow and
ice from track shoes before loading and unloading
machine, to prevent the machine from slipping.
SA-15
SAFETY
AVOID INJURY FROM ROLLAWAY ACCI-
DENTS
• Death or serious injury may result if you attempt to
mount or stop a moving machine.
To avoid rollaways:
• Select level ground when possible to park ma-
chine.
• Do not park the machine on a grade.
• Lower the bucket and/or other work tools to the
ground.
• Turn the auto-idle switch and the H/P mode
switch off.
• Run the engine at slow idle speed without load for
5 minutes to cool down the engine. SA-391
• Stop the engine and remove the key from the key
switch.
• Pull the pilot control shut-off lever to LOCK posi-
tion.
• Block both tracks and lower the bucket to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade.
• Position the machine to prevent rolling.
• Park a reasonable distance from other machines.
SA-392
020-E02A-0493
SA-16
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
• If any person is present near the machine when
backing or swinging the upperstructure, the machine
may hit or run over that person, resulting in serious
injury or death.
To avoid back-over and swing accidents:

• Always look around BEFORE YOU BACK UP
AND SWING THE MACHINE. BE SURE THAT
ALL BYSTANDERS ARE CLEAR.
• Keep the travel alarm in working condition (if
equipped).
ALWAYS BE ALERT FOR BYSTANDERS MOV-
ING INTO THE WORK AREA. USE THE HORN SA-383
OR OTHER SIGNAL TO WARN BYSTANDERS

BEFORE MOVING MACHINE.
• USE A SIGNAL PERSON WHEN BACKING UP
IF YOUR VIEW IS OBSTRUCTED. ALWAYS
KEEP THE SIGNAL PERSON IN VIEW.
Use hand signals, which conform to your local
regulations, when work conditions require a signal
person.
• No machine motions shall be made unless signals
are clearly understood by both signalman and
operator.
• Learn the meanings of all flags, signs, and mark-
ings used on the job and confirm who has the SA-384
responsibility for signaling.
• Keep windows, mirrors, and lights clean and in
good condition.
• Dust, heavy rain, fog, etc., can reduce visibility. As
visibility decreases, reduce speed and use proper
lighting.
• Read and understand all operating instructions in
the operator's manual.
021-E01A-0494
SA-17
SAFETY
KEEP PERSON CLEAR FROM WORKING
AREA
• A person may be hit severely by the swinging front
attachment or counterweight and/or may be crushed
against an other object, resulting in serious injury or
death.
• Keep all persons clear from the area of operation

and machine movement.
• Before operating the machine, set up barriers to
the sides and rear area of the bucket swing radius
to prevent anyone from entering the work area.
022-E01A-0386
SA-386
NEVER POSITION BUCKET OVER ANY-

ONE
• Never lift, move, or swing bucket above anyone or a
truck cab.
Serious injury or machine damage may result due to
bucket load spill or due to collision with the bucket.
023-E01A-0487
SA-487
AVOID UNDERCUTTING
• In order to retreat from the edge of an excavation if
the footing should collapse, always position the un-
dercarriage perpendicular to the edge of the exca-
vation with the travel motors at the rear.
• If the footing starts to collapse and if retreat is not

possible, do not panic. Often, the machine can be
secured by lowering the front attachment, in such
cases.
024-E01A-0488 SA-488
SA-18
SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING
MACHINE---SERIOUS OR FATAL CRUSHING IN-
JURIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU
CAN JUMP FREE
• The danger of tipping is always present when oper-
ating on a grade, possibly resulting in serious injury
or death.
To avoid tipping:
• Be extra careful before operating on a grade.
SA-012
• Prepare machine operating area flat.

• Keep the bucket low to the ground and close to
the machine.
• Reduce operating speeds to avoid tipping or slip-
ping.
• Avoid changing direction when traveling on
grades.
• NEVER attempt to travel across a grade steeper
than 15 degrees if crossing the grade is un-
avoidable.
• Reduce swing speed as necessary when swing-
ing loads.
SA-440
• Be careful when working on frozen ground.
• Temperature increases will cause the ground to

become soft and make ground travel unstable.
025-E03B-0463
NEVER UNDERCUT A HIGH BANK

• The edges could collapse or a land slide could occur
causing serious injury or death.
026-E01A-0519
SA-489
SA-19
SAFETY
DIG WITH CAUTION
• Accidental severing of underground cables or gas
lines may cause an explosion and/or fire, possibly
• Before digging check the location of cables, gas

lines, and water lines.
• Keep the minimum distance required, by law, from
cables, gas lines, and water lines.
• If a fiber optic cable should be accidentally sev-
ered, do not look into the end. Doing so may re-
sult in serious eye injury.
• Contact your local "diggers hot line" if available in
SA-382
your area, and/or the utility companies directly.
Have them mark all underground utilities.
027-E01A-0382
OPERATE WITH CAUTION

• If the front attachment or any other part of the ma-
chine hits against an overhead obstacle, such as a
bridge, both the machine and the overhead obstacle
will be damaged, and personal injury may result as
well.
• Take care to avoid hitting overhead obstacles with

the boom or arm.
SA-389
028-E01A-0389
SA-20
SAFETY
AVOID POWER LINES
• Serious injury or death can result if the machine or
front attachments are not kept a safe distance from
electric lines.
• When operating near an electric line, NEVER

move any part of the machine or load closer than
3 m plus twice the line insulator length.
• Check and comply with any local regulations that
may apply.
• Wet ground will expand the area that could cause
any person on it to be affected by electric shock.
Keep all bystanders or co-workers away from the
site.
SA-381
029-E01A-0381
PRECAUTIONS FOR LIGHTENING

• The machine is vulnerable to lighting strikes.
• In the event of an electrical storm, immediately

stop operation, and lower the bucket to the
ground. Evacuate to a safe place far away from
the machine.
• After the electrical storm has passed, check all of
the machine safety devices for any failure. If any
failed safety devices are found, operate the ma-
chine only after repairing them.
SA-1088
OBJECT HANDLING
• If a lifted load should fall, any person nearby may be
struck by the falling load or may be crushed under-
neath it, resulting in serious injury or death.
• When using the machine for craning operations,

be sure to comply with all local regulations.
• Do not use damaged chains or frayed cables,
sables, slings, or ropes.
• Before craning, position the upperstructure with
the travel motors at the rear.
• Move the load slowly and carefully. Never move it
suddenly.
• Keep all persons well away from the load.
• Never move a load over a person's head.
• Do not allow anyone to approach the load until it
is safely and securely situated on supporting
blocks or on the ground. SA-014
• Never attach a sling or chain to the bucket teeth.

They may come off, causing the load to fall.
032-E01A-0132
SA-21
SAFETY
PROTECT AGAINST FLYING DEBRIS
• If flying debris hit eyes or any other part of the body,
serious injury may result.
• Guard against injury from flying pieces of metal or

debris; wear goggles or safety glasses.
• Keep bystanders away from the working area
before striking any object.
031-E01A-0432
SA-432
PARK MACHINE SAFELY

To avoid accidents:
• Park machine on a firm, level surface.
• Lower bucket to the ground.
• Turn auto-idle switch and H/P mode switch OFF.
• Run engine at slow idle speed without load for 5
minutes.
• Turn key switch to OFF to stop engine.
• Remove the key from the key switch.
• Pull the pilot control shut-off lever to the LOCK
position.
• Close windows, roof vent, and cab door. SA-390
• Lock all access doors and compartments.
HANDLE FLUIDS SAFELY-AVOID FIRES

• Handle fuel with care; it is highly flammable. If fuel
ignites, an explosion and/or a fire may occur, possi-
bly resulting in serious injury or death.
• Do not refuel the machine while smoking or when

near open flame or sparks.
• Always stop the engine before refueling the ma-
chine.
• Fill the fuel tank outdoors.
• All fuels, most lubricants, and some coolants are

flammable.
• Store flammable fluids well away from fire haz- SA-018
ards.
• Do not incinerate or puncture pressurized con-
tainers.
• Do not store oily rags; they can ignite and burn
spontaneously.
• Securely tighten the fuel and oil filler cap.
034-E01A-0496
SA-019
SA-22
SAFETY
TRANSPORT SAFELY
• Take care the machine may turn over when loading
or unloading the machine onto or off of a truck or
trailer.
• Observe the related regulations and rules for safe

transportation.
• Select an appropriate truck or trailer for the ma-
chine to be transported.
• Be sure to use a signal person.
• Always follow the following precautions for load-
ing or unloading:
1. Select solid and level ground.
2. Always use a ramp or deck strong enough to
support the machine weight. SA-395
3. Turn auto-idle switch OFF.

4. Always select the slow speed mode with the
travel mode switch.
5. Never load or unload the machine onto or off a
truck or trailer using the front attachment func-
tions when driving up or down the ramp.
6. Never steer the machine while on the ramp. If the
traveling direction must be changed while the
ramp, unload the machine from the ramp, repo-
sition the machine on the ground, and then try
loading again.
7. The top end of the ramp where it meets the flat-
bed is a sudden bump. Take care when traveling
over it.
8. Place blocks in front of and behind the tracks.
Securely hold the machine to the truck or trailer
deck with wire ropes.
Be sure to further follow the details described in the

TRANSPORTING section in the operator's manual.
035-E07A-0454
SA-23
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
• Understand service procedures before starting
work.
• Keep the work area clean and dry.
• Do not spray water or steam inside cab.
• Never lubricate or service the machine while it is
moving.
• Keep hands, feet and clothing away from
power-driven parts.
Before servicing the machine:

1. Park the machine on a level surface.
2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.
4. Run the engine at slow idle speed without load
for 5 minutes.
5. Turn the key switch to OFF to stop engine.
6. Relieve the pressure in the hydraulic system by SA-028
moving the control levers several times.

7. Remove the key from the switch.
8. Attach a "Do Not Operate" tag on the control
lever.
9. Pull the pilot control shut-off lever to the LOCK
position.
10. Allow the engine to cool.
500-E02C-0520
SA-527
SA-24
SAFETY
• If a maintenance procedure must be performed
with the engine running, do not leave machine
unattended.
• If the machine must be raised, maintain a 90 to
100° angle between the boom and arm. Securely
support any machine elements that must be
raised for service work.
• Inspect certain parts periodically and repair or re-
place as necessary. Refer to the section discuss-
ing that part in the "MAINTENANCE" chapter of
this manual.
•
SA-037
Keep all parts in good condition and properly in-
stalled.
• Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or de-
bris.
• When cleaning parts, always use nonflammable
detergent oil. Never use highly flammable oil such
as fuel oil and gasoline to clean parts or surfaces.
• Disconnect battery ground cable (-) before mak-
ing adjustments to electrical systems or before
performing welding on the machine.
• Sufficiently illuminate the work site. Use a main-
tenance work light when working under or inside
the machine.
• Always use a work light protected with a guard. In
case the light bulb is broken, spilled fuel, oil, anti-
freeze fluid, or window washer fluid may catch
fire.
WARN OTHERS OF SERVICE WORK

• Unexpected machine movement can cause serious
injury.
• Before performing any work on the machine, at-

tach a "Do Not Operate" tag on the control lever.
This tag is available from your authorized dealer.
501-E01A-0287
T1J1-01-01-001
SA-25
SAFETY
SUPPORT MACHINE PROPERLY
• Never attempt to work on the machine without se-
curing the machine first.
• Always lower the attachment to the ground before

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

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

ensure that hands, feet, clothing, jewelry and hair
do not become entangled when working around
rotating parts.
502-E01A-0026
SA-026
SA-26
SAFETY
PREVENT PARTS FROM FLYING
• Grease in the track adjuster is under high pressure.
Failure to follow the precautions below may result in
serious injury, blindness, or death.
• Do not attempt to remove GREASE FITTING or

VALVE ASSEMBLY.
• As pieces may fly off, be sure to keep body and
face away from valve.
• Never attempt to disassemble the track adjuster.
Inadvertent disassembling of the track adjuster
may cause the parts such as a spring to fly off,
possibly resulting in severe personal injury or
death.
SA-344
• Travel reduction gears are under pressure.

face away from AIR RELEASE PLUG to avoid
injury.
• GEAR OIL is hot. Wait for GEAR OIL to cool, and
then gradually loosen AIR RELEASE PLUG to
release pressure.
503-E01B-0344
STORE ATTACHMENTS SAFELY

• Stored attachments such as buckets, hydraulic
hammers, and blades can fall and cause serious
injury or death.
• Securely store attachments and implements to

prevent falling. Keep children and bystanders
away from storage areas.
504-E01A-0034
SA-034
SA-27
SAFETY
PREVENT BURNS
Hot spraying fluids:
• After operation, engine coolant is hot and under

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

DO NOT remove the radiator cap until the engine
is cool. When opening, turn the cap slowly to the
stop. Allow all pressure to be released before
removing the cap. SA-039
• The hydraulic oil tank is pressurized. Again, be

sure to release all pressure before removing the
cap.
Hot fluids and surfaces:
• Engine oil, gear oil and hydraulic oil also become

hot during operation.
The engine, hoses, lines and other parts become
hot as well.
• Wait for the oil and components to cool before SA-225

starting any maintenance or inspection work.
505-E01B-0498
REPLACE RUBBER HOSES PERIODI-

CALLY
• Rubber hoses that contain flammable fluids under
pressure may break due to aging, fatigue, and
abrasion. It is very difficult to gauge the extent of
deterioration due to aging, fatigue, and abrasion of
rubber hoses by inspection alone.
• Periodically replace the rubber hoses. (See the

page of "Periodic replacement of parts" in the
operator's manual.)
• Failure to periodically replace rubber hoses may

cause a fire, fluid injection into skin, or the front
attachment to fall on a person nearby, which may SA-019
result in severe burns, gangrene, or otherwise

serious injury or death.
S506-E01A-0019
SA-28
SAFETY
AVOID HIGH-PRESSURE FLUIDS
• Fluids such as diesel fuel or hydraulic oil under
pressure can penetrate the skin or eyes causing se-
rious injury, blindness or death.
• Avoid this hazard by relieving pressure before

disconnecting hydraulic or other lines.
• Tighten all connections before applying pressure.
• Search for leaks with a piece of cardboard; take
care to protect hands and body from
high-pressure fluids. Wear a face shield or gog-
gles for eye protection.
• If an accident occurs, see a doctor familiar with
this type of injury immediately. Any fluid injected
into the skin must be surgically removed within a SA-031
few hours or gangrene may result.
507-E03A-0499
SA-292
SA-044
SA-29
SAFETY
PREVENT FIRES
Check for Oil Leaks:
• Fuel, hydraulic oil and lubricant leaks can lead to
fires.
• Check for oil leaks due to missing or loose clamps,
kinked hoses, lines or hoses that rub against each
other, damage to the oil-cooler, and loose
oil-cooler flange bolts.
• Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and
• Do not bend or strike high-pressure lines.
• Never install bent or damaged lines, pipes, or
hoses.
SA-019
Check for Shorts:

• Short circuits can cause fires.
• Clean and tighten all electrical connections.
• Check before each shift or after eight(8) to ten(10)
hours operation for loose, kinked, hardened or
frayed electrical cables and wires.
hours operation for missing or damaged terminal
caps.
• DO NOT OPERATE MACHINE if cable or wires
are loose, kinked, etc..
Clean up Flammables:
• Spilled fuel and oil, and trash, grease, debris, ac-
cumulated coal dust, and other flammables may
cause fires.
• Prevent fires by inspecting and cleaning the ma-
chine daily and by removing spilled or accumu-
lated flammables immediately.
Check Key Switch:
• If a fire breaks out, failure to stop the engine will
escalate the fire, hampering fire fighting.
Always check key switch function before operating
the machine every day:
1. Start the engine and run it at slow idle.
2. Turn the key switch to the OFF position to con-
firm that the engine stops.
• If any abnormalities are found, be sure to repair
them before operating the machine.
508-E02B-0019
Check Heat Shields:

• Damaged or missing heat shields may lead to fires.
• Damaged or missing heat shields must be re-
paired or replaced before operating the machine.
508-E02A-0393
SA-30
SAFETY
EVACUATING IN CASE OF FIRE
• If a fire breaks out, evacuate the machine in the fol-
lowing way:
• Stop the engine by turning the key switch to the

OFF position if there is time.
• Use a fire extinguisher if there is time.
• Exit the machine.
• In an emergency, if the cab door or front window
cannot be opened, break the front or rear window
panes with the emergency evacuation hammer to
escape from the cab. Refer the explanation pages SA-393
on the Emergency Evacuation Method in the op-

erator's manual.
18-E02B-0393
SS-1510
BEWARE OF EXHAUST FUMES

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

adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open
doors and windows to bring enough outside air
into the area.
509-E01A-0016
SA-016
PRECAUTIONS FOR WELDING AND

GRINDING
• Welding may generate gas and/or small fires.
• Be sure to perform welding in a well ventilated

and prepared area. Store flammable objects in a
safe place before starting welding.
• Only qualified personnel should perform welding.
Never allow an unqualified person to perform
welding.
• Grinding on the machine may create fire hazards.
Store flammable objects in a safe place before
starting grinding.
• After finishing welding and grinding, recheck that
there are no abnormalities such as the area sur- SA-818
rounding the welded area still smoldering.
523-E01A-0818
SA-31
SAFETY
AVOID HEATING NEAR PRESSURIZED
FLUID LINES
• Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to
yourself and bystanders.
• Do not heat by welding, soldering, or using a torch

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

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

HEATING
• Hazardous fumes can be generated when paint is
heated by welding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.
• Avoid potentially toxic fumes and dust.

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

1. If you sand or grind paint, avoid breathing the
dust.
Wear an approved respirator. SA-029
2. If you use solvent or paint stripper, remove

stripper with soap and water before welding.
Remove solvent or paint stripper containers and
other flammable material from area. Allow fumes
to disperse at least 15 minutes before welding or
heating.
511-E01A-0029
SA-32
SAFETY
BEWARE OF ASBESTOS DUST
• Take care not to inhale dust produced in the work
site. Inhalation of asbestos fibers may be the cause
of lung cancer.
• Depending on the wok site conditions, the risk of

inhaling asbestos fiber may exist. Spray water to
prevent asbestos from becoming airborne. Don't
use compressed air.
• When operating the machine in a work site where
asbestos might be present, be sure to operate the
machine from the upwind side and wear a mask
rated to prevent the inhalation of asbestos.
• Keep bystanders out of the work site during op-
eration. SA-029
• Asbestos might be present in imitation parts. Use

only genuine Hitachi Parts.
PREVENT BATTERY EXPLOSIONS

• Battery gas can explode.
• Keep sparks, lighted matches, and flame away

from the top of battery.
• Never check battery charge by placing a metal
object across the posts. Use a voltmeter or hy-
drometer.
• Do not charge a frozen battery or start engine with
frozen battery.
There is fear of explosion. If battery electrolyte is
frozen, wait until it is liquefied completely in an
atmospheric temperature room.
• Do not continue to use or charge the battery when
electrolyte level is lower than specified. Explosion SA-032
of the battery may result.

• Loose terminals may produce sparks. Securely
tighten all terminals.
• Battery electrolyte is poisonous. If the battery should

explode, battery electrolyte may be splashed into
eyes, possibly resulting in blindness.
• Be sure to wear eye protection when checking

electrolyte specific gravity.
512-E01B-0032
SA-33
SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY
• If spilled onto skin, refrigerant may cause a cold
contact burn.
• Refer to the instructions described on the con-

tainer for proper use when handling the refriger-
ant.
• Use a recovery and recycling system to avoid
leaking refrigerant into the atmosphere.
• Never touch the refrigerant.
513-E01A-0405
SA-405
HANDLE CHEMICAL PRODUCTS SAFELY

• Direct exposure to hazardous chemicals can cause
serious injury. Potentially hazardous chemicals used
with your machine include such items as lubricants,
coolants, paints, and adhesives.
• A Material Safety Data Sheet (MSDS) provides

specific details on chemical products: physical
and health hazards, safety procedures, and
emergency response techniques.
• Check the MSDS before you start any job using a
hazardous chemical. That way you will know ex-
actly what the risks are and how to do the job
safely. Then follow procedures and use recom- SA-309
mended equipment.
• See your authorized dealer for MSDS's (available
only in English) on chemical products used with
your machine.
515-E01A-0309
SA-34
SAFETY
DISPOSE OF WASTE PROPERLY
• Improperly disposing of waste can threaten the en-
vironment and ecology. Potentially harmful waste
used with HITACHI equipment includes such items
as oil, fuel, coolant, brake fluid, filters, and batteries.
• Use leakproof containers when draining fluids. Do

not use food or beverage containers that may
mislead someone into drinking from them.
• Do not pour waste onto the ground, down a drain,
or into any water source.
• Air conditioning refrigerants escaping into the air
can damage the Earth's atmosphere. Govern-
ment regulations may require a certified air condi- SA-226
tioning service center to recover and recycle used

air conditioning refrigerants.
• Inquire on the proper way to recycle or dispose of
waste from your local environmental or recycling
center, or from your authorized dealer.
516-E01A-0226
BEFORE RETURNING THE MACHINE TO

THE CUSTOMER
• After maintenance or repair work is complete,
confirm that:
• The machine is functioning properly, especially

the safety systems.
• Worn or damaged parts have been repaired or
replaced
S517-E01A-0435
SA-435
SA-35
SAFETY
(Blank)
SA-36
SECTION AND GROUP SECTION 4 OPERATIONAL PER-
CONTENTS FORMANCE TEST
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Excavator Test
TECHNICAL MANUAL Group 5 Component Test
SECTION 5 TROUBLESHOOTING
(Troubleshooting)
Group 1 Diagnosing Procedure
Group 2 Monitor Unit
Group 6 Troubleshooting A
Group 7 Troubleshooting B
TECHNICAL MANUAL (Operational Principle)
SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION
Group 1 Specifications Group 1 Pump Device
Group 2 Component Layout Group 2 Swing Device
Group 3 Component Specifications Group 3 Control Valve
SECTION 2 SYSTEM Group 4 Pilot Valve
Group 1 Controller Group 5 Travel Device
Group 2 Control System Group 6 Signal Control Valve
Group 3 ECM System Group 7 Others (Upperstructure)
Group 4 Hydraulic System Group 8 Others (Undercarriage)
All information, illustrations and speci-

fications in this manual are based on
the latest product information available
at the time of publication. The right is
reserved to make changes at any time
without notice.
COPYRIGHT(C)2008
Tokyo, Japan
All rights reserved
←これ以下
記載しない
WORKSHOP MANUAL
SECTION 1 GENERAL INFORMATION SECTION 3 UNDERCARRIAGE
Group 1 Precautions for Disassem- Group 1 Swing Bearing
bling and Assembling Group 2 Travel Device
Group 2 Tightening Torque Group 3 Center Joint
Group 3 Painting Group 4 Track Adjuster
Group 4 Bleeding Air from Hydrau- Group 5 Front Idler
lic Oil Tank Group 6 Upper and Lower Roller
SECTION 2 UPPERSTRUCTURE Group 7 Track
Group 1 Cab SECTION 4 FRONT ATTACHMENT
Group 2 Counterweight Group 1 Front Attachment
Group 3 Main Frame Group 2 Cylinder
Group 4 Pump Device
Group 7 Pilot Valve
Group 8 Pilot Shut-Off Solenoid Valve
Group 9 Solenoid Valve
Group 11 Shockless Valve
Group 12 Fan Valve
Group 13 Fan Motor
SECTION 4
OPERATIONAL
PERFORMANCE TEST
CONTENTS
Group 1 Introduction Group 4 Excavator Test
Operational Performance Tests ................ T4-1-1 Travel Speed............................................. T4-4-1
Preparation for Performance Tests ........... T4-1-2 Track Revolution Speed ............................ T4-4-2
Mistrack Check ......................................... T4-4-3
Group 2 Standard
Travel Motor Leakage ............................... T4-4-4
Operational Performance Standard
Swing Speed............................................. T4-4-5
Table....................................................... T4-2-1
Swing Function Drift Check....................... T4-4-6
Main Pump P-Q Diagram.......................... T4-2-5
Swing Motor Leakage ............................... T4-4-7
Fan Pump P-Q Diagram ........................... T4-2-6
Maximum Swingable Slant Angle .............. T4-4-8
Fan Pump I-Q Diagram............................. T4-2-7
Swing Bearing Play................................. T4-4-10
Monitor Unit Indicating Values (MC) ......... T4-2-8
Hydraulic Cylinder Cycle Time ................ T4-4-12
Monitor Unit Indicating Values (ECM) ..... T4-2-14
Dig Function Drift Check ......................... T4-4-14
Sensor Activating Range ........................ T4-2-15
Control Lever Operating Force................ T4-4-15
Group 3 Engine Test Control Lever Stroke ............................... T4-4-16
Engine Speed ........................................... T4-3-1 Boom Raise/Swing Combined
Engine Compression Pressure ................. T4-3-3 Operation Check ................................... T4-4-17
Valve Clearance ....................................... T4-3-4
Lubricant Consumption............................. T4-3-7
1J1T-4-1
Group 5 Component Test
Primary Pilot Pressure.............................. T4-5-1
Secondary Pilot Pressure ......................... T4-5-3
Solenoid Valve Set Pressure .................... T4-5-4
Main Pump Delivery Pressure .................. T4-5-6
Fan Pump Delivery Pressure .................... T4-5-7
Main Relief Valve Set Pressure ................ T4-5-8
Overload Relief Valve Set Pressure........ T4-5-12
Main Pump Flow Rate Measurement ...... T4-5-14
Fan Pump Flow Rate Measurement ....... T4-5-16
Swing Motor Drainage ............................ T4-5-22
Travel Motor Drainage ............................ T4-5-24
1J1T-4-2
OPERATIONAL PERFORMANCE TEST / Introduction
OPERATIONAL PERFORMANCE TESTS
Use operational performance test procedure to quan- The machine performance does not always deterio-
titatively check all system and functions on the ma- rate as the working hours increase. However, the
chine. machine performance is normally considered to re-
duce in proportion to the increase of the operation
Purpose of Performance Tests hours. Accordingly, restoring the machine perform-
1. To comprehensively evaluate each operational ance by repair, adjustment, or replacement shall con-
function by comparing the performance test data sider the number of the machine’s working hours.
with the standard values.
2. According to the evaluation results, repair, adjust, Definition of “Performance Standard”
or replace parts or components as necessary to 1. Operation speed values and dimensions of the
restore the machine’s performance to the desired new machine.
standard. 2. Operational performance of new components
3. To economically operate the machine under op- adjusted to specifications. Allowable errors will be
timal conditions. indicated as necessary.
Kinds of Tests
1. Base machine performance test is to check the
operational performance of each system such as
engine, travel, swing, and hydraulic cylinders.
2. Hydraulic component unit test is to check the op-
erational performance of each component such
as hydraulic pump, motor, and various kinds of
valves.
Performance Standards
“Performance Standard” is shown in tables to evalu-
ate the performance test data.
Precautions for Evaluation of Test Data

1. To evaluate not only that the test data are correct,
but also in what range the test data are.
2. Be sure to evaluate the test data based on the
machine operation hours, kinds and state of work
loads, and machine maintenance conditions.
T4-1-1
OPERATIONAL PERFORMANCE TEST / Introduction
PREPARATION FOR PERFORMANCE
TESTS
Observe the following rules in order to carry out

performance tests accurately and safely.
THE MACHINE
1. Repair any defects and damage found, such as
oil or water leaks, loose bolts, cracks and so on,
before starting to test.
TEST AREA
1. Select a hard and flat surface.
2. Secure enough space to allow the machine to
run straight more than 20 m (65 ft 7 in), and to
make a full swing with the front attachment ex-
tended.
3. If required, rope off the test area and provide
signboards to keep unauthorized personnel
away.
PRECAUTIONS
1. Before starting to test, agree upon the signals to
be employed for communication among cowork-
ers. Once the test is started, be sure to commu-
nicate with each other using these signals, and to
follow them without fail.
2. Operate the machine carefully and always give
first priority to safety.
3. While testing, always take care to avoid acci-
dents due to landslides or contact with
high-voltage power lines. Always confirm that
there is sufficient space for full swings.
4. Avoid polluting the machine and the ground with T105-06-01-003
leaking oil. Use oil pans to catch escaping oil.

Pay special attention to this when removing hy-
draulic pipings.
MAKE PRECISE MEASUREMENT

1. Accurately calibrate test instruments in advance
to obtain correct data.
2. Carry out tests under the exact test conditions
prescribed for each test item.
3. Repeat the same test and confirm that the test
data obtained can be produced repeatedly. Use
mean values of measurements if necessary.
T105-06-01-004
T4-1-2
OPERATIONAL PERFORMANCE TEST / Standard
OPERATIONAL PERFORMANCE STAN-
DARD TABLE
The standard performance values are listed in the ta- Test procedure:
ble below. • Engine Control Dial: Fast Idle
Refer to the group T4-3 to T4-5 for performance test • Power Mode Switch: HP Mode
procedures. • Auto-Idle Switch: OFF
Values indicated in parentheses are reference values. • Work Mode: Digging Mode
• Hydraulic Oil Temperature: 50±5 °C (122±9 °F)
Performance Reference
Performance Test Remarks
Standard Page
-1
ENGINE SPEED min T4-3-1
Slow Idle 900±50 With the lever in neutral
Fast Idle (P mode) 1650±50 ↑
Fast Idle (E mode) 1630±50 ↑
Auto-Idle 1180±50 ↑
Fast Idle With boom raise and re-
1750±50
(P mode) lief operation
Fast Idle With boom raise and arm
1850±50
(HP mode) roll-in relief operation
2 2.94 (30) With the engine speed
ENGINE COMPRESSION PRESSURE MPa (kgf/cm ) T4-3-3
or less 200 min-1
VALVE CLEARANCE (IN, EX) mm 0.4 With the engine cold T4-3-4
LUBRICANT CONSUMPTION mL/h 100 or less At new machine T4-3-7
(At rated operation)
TRAVEL SPEED sec/20 m T4-4-1
Fast Speed 13.0±2.0 500LC-3/520LCH-3: 18.0±2.0
Slow Speed 20.0±2.0 500LC-3/520LCH-3: 25.0±2.0
TRACK REVOLUTION SPEED sec/3 rev T4-4-2
450LC-3/470LCH-3: 22.0±2.0
Fast Speed 20.5±2.0
500LC-3/520LCH-3: 29.5±2.0
450LC-3/470LCH-3: 34.0±2.0
Slow Speed 31.5±2.0
500LC-3/520LCH-3: 41.5±2.0
MISTRACK CHECK
mm/20 m 200 or less T4-4-3
(With fast and travel speed modes)
TRAVEL MOTOR LEAKAGE mm/5 min 0 T4-4-4
SWING SPEED sec/3 rev 20.0±1.5 Bucket empty T4-4-5
SWING FUNCTION DRIFT CHECK mm/180° 1267 or less Bucket empty T4-4-6
SWING MOTOR LEAKAGE mm/5 min 0 Bucket loaded T4-4-7
MAXIMUM SWINGABLE SLANT ANGLE deg. 17 or more Bucket loaded T4-4-8
SWING BEARING PLAY mm 0.6 to 1.85 Allowable limit: 3.1 to 4.35 T4-4-10
T4-2-1
Perform-
Reference
Performance Test ance Stan- Remarks
Page
dard
HYDRAULIC CYLINDER CYCLE TIME sec T4-4-12
3.4 m Arm
Backhoe 1.9 m3 (PCSA heaped)
Bucket, Bucket empty
Boom Raise 3.6±0.3
Boom Lower 2.5±0.3
Arm Roll-In 4.5±0.3
Arm Roll-Out 3.1±0.3
Bucket Roll-In 3.5±0.3
Bucket Roll-Out 2.9±0.3
2.3 m3 Rock Bucket, Bucket
Loading Shovel
empty
Boom Raise 4.9±0.3
Boom Lower 3.6±0.3
Arm Extend 2.7±0.3
Arm Retract 2.0±0.3
Bucket Tilt-In 2.7±0.3
Bucket Tilt-Out 3.1±0.3
Bucket Open 1.1±0.3
Bucket Close 1.0±0.3
DIG FUNCTION DRIFT CHECK mm/5 min T4-4-14
3.4 m Arm
Backhoe 1.9 m3 (PCSA heaped)
Bucket, Bucket loaded
Boom Cylinder 15 or less
Arm Cylinder 20 or less
Bucket Cylinder 20 or less
Bucket Bottom 100 or less
2.3 m3 Rock Bucket, Bucket
Loading Shovel
loaded
Boom Cylinder 10 or less
Arm Cylinder 20 or less
Bucket Cylinder 20 or less
Bucket Bottom 100 or less
T4-2-2
Performance
Standard
CONTROL LEVER OPERATING FORCE N (kgf) Hitachi lever pattern T4-4-15
16.0 (1.6)
Boom Lever
or less
13.0 (1.3)
Arm Lever (ISO Lever Pattern: Swing Lever)
or less
13.0 (1.3)
Bucket Lever
or less
16.0 (1.6)
Swing Lever (ISO Lever Pattern: Arm Lever)
or less
28.0 (2.9)
Travel Lever
or less
60.0 (6.1)
Bucket Open Pedal
or less
60.0 (6.1)
Bucket Close Pedal
or less
CONTROL LEVER STROKE mm Hitachi lever pattern T4-4-16
Boom Lever 97±10
Arm Lever (ISO Lever Pattern: Swing Lever) 82±10
Bucket Lever 82±10
Swing Lever (ISO Lever Pattern: Arm Lever) 97±10
Travel Lever 120±10
Backhoe: 3.4 m Arm
BOOM RAISE/SWING COMBINED
sec 5.0 or less 1.9 m3 (PCSA heaped) T4-4-17
OPERATION CHECK
Bucket, Bucket empty
Bucket Teeth Height: H mm 7000 or more
COMPONENT TEST
2
PRIMARY PILOT PRESSURE MPa (kgf/cm ) T4-5-1
3.9+0.7−0.2
Engine: Slow Idle
(40+7.0−2.0)
3.9±0.2
Engine: Fast Idle
(39±2)
2 3.4 to 4.0 Value indicated on Dr. ZX
SECONDARY PILOT PRESSURE MPa (kgf/cm ) T4-5-3
(34 to 40) (Lever: Full Stroke)
±0.2 (2)
2
SOLENOID VALVE SET PRESSURE MPa (kgf/cm ) Value indicated on Dr. ZX T4-5-4
MAIN RELIEF VALVE SET PRES- 2
MPa (kgf/cm ) T4-5-6
SURE
Backhoe
When each Boom Lower, Arm, Bucket 31.9+1.0−1.5
Relief Operation (325+10−15)
34.3+1.0−1.5
When Power Digging
(350+10−15)
Loading Shovel
When each Boom Raise / Lower, Arm Extend /
27.9+2.5−0
Retract, Bucket Tilt-In / Tilt-Out, Bucket Open /
Close Relief Operation (285+25−0)
T4-2-3
Performance Reference
Standard Page
2
RELIEF PRESSURE MPa (kgf/cm )
Backhoe
28.4+2.0−0
When relieving swing
(290+20−0)
34.3+1.0−1.5
When relieving travel
(350+10−15)
Loading Shovel
27.9+2.5−0
When relieving swing
(285+25−0)
34.3+1.0−1.5
When relieving travel
(350+10−15)
OVERLOAD RELIEF VALVE SET PRES- 2
MPa (kgf/cm ) T4-5-12
SURE
Backhoe
35.3+1.00
Boom, Arm, Bucket, and Auxiliary Close
(360+100)
27.9+1.00
Auxiliary Open
(280+100)
Boom (Lower) 12.0+1.00
(When operating boom mode selector) (120+100)
Loading Shovel
35.3+1.00
Boom Raise, Arm Extend / Retract, Bucket Open
(360+100)
30.9+1.00
Bucket Tilt-In / Tilt-Out
(315+100)
15.5+1.50
Bucket Close
(158+150)
MAIN PUMP FLOW RATE MEASUREMENT L/min − Refer to page T4-2-5 T4-5-14
FAN PUMP FLOW RATE MEASUREMENT L/min − Refer to page T4-2-6 T4-5-16
SWING MOTOR DRAINAGE
L/min 0.2 to 0.3 T4-5-22
With constant maximum speed
TRAVEL MOTOR DRAINAGE
L/min 5 or less Allowable limit: 10 T4-5-24
With the track jacked up
T4-2-4
MAIN PUMP P-Q DIAGRAM
• Hydraulic P-Q Control

Delivery Pressure Flow Rate
(REFERENCE: Measured at Test Stand) MPa (kgf/cm2, psi) L/min (US gpm)
A 20 (205, 2908) Approx. 250 (66)
• Rated Pump Speed: 1750 min-1 (rpm)
• Power Mode Switch: P Mode B 25 (255, 3635) Approx. 190 (50)
• Hydraulic Oil Temperature: 50±5°C
C 30 (305, 4361) Approx. 160 (42)
NOTE: Refer to T4-5-14.
L/min
400
350
300
A
Flow 250
Rate
B
200
C
150
100
50
0
0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 MPa T1J1-04-02-001
(51) (102) (153) (204) (255) (306) (357) (kgf/cm2)
Delivery Pressure
T4-2-5
FAN PUMP P-Q DIAGRAM
• Hydraulic P-Q Control

Delivery Pressure Flow Rate
(REFERENCE: Measured at Test Stand) MPa (kgf/cm2, psi) L/min (US gpm)
A 7.8 (80, 1134) Approx. 63 (17)
• Power Mode Switch: P Mode B 23.2 (235, 3373) Approx. 59 (16)
C 26.2 (265, 3809) Approx. 52 (14)
NOTE: Refer to T4-5-16.
L/min
75
A
B
C
50
Flow
Rate
25
0
0 5.0 10.0 15.0 20.0 25.0 MPa T1J1-04-02-002
(51) (102) (153) (204) (255) (kgf/cm2)
Delivery Pressure
T4-2-6
FAN PUMP I-Q DIAGRAM
• Hydraulic I-Q Control

Fan Pump Control Flow Rate
(REFERENCE: Measured at Test Stand) Solenoid Valve Oper- L/min (US gpm)
ating Signal mA
A 381±30 Approx. 63±3 (17±0.8)
• Power Mode Switch: P Mode
• Hydraulic Oil Temperature: 50±5°C B 597±40 Approx. 15±3 (4±0.8)
L/min
75
50
Flow
Rate
25
0
300 400 500 600 700 mA T1J1-04-02-003
Fan Pump Control Solenoid Valve Operating Signal
T4-2-7
MONITOR UNIT INDICATING VALUES
(MC)
Unless specified, test under the following conditions.

• Power Mode Switch: P mode
• Work Mode: Digging Mode
Reference Measured Value

Item Remarks
Value First Second Third Average
REQUESTED ENGINE SPEED (min-1)
Fast Idle (HP Mode) 1600
Fast Idle
1700
(When operating a control lever)
Fast Idle (HP Mode) 1800 When boom
raise reliev-
ing
Fast Idle (E Mode) 1580
Auto-Idle 1030
Slow Idle 750
ACTUAL ENGINE SPEED -1
(min )
Fast Idle 1650
Fast Idle
1750
(When operating a control lever)
Fast Idle (HP Mode) 1850 When boom
raise reliev-
ing
Fast Idle (E Mode) 1630
Auto-Idle 1180
Slow Idle 900
EC DIAL ANGLE (V)
Minimum 0.56
Maximum 4.42
T4-2-8

Item Remarks
PUMP 1 DELIVERY
PRESSURE (MPa)
Control Lever in Neutral 0.7
Boom Raise 34.3 When relieving
Boom Lower -
Arm Roll-In 31.9 When relieving
Arm Roll-Out 31.9 When relieving
Bucket Roll-Out 31.9 When relieving
Bucket Roll-In 31.9 When relieving
Boom Raise + Arm
Roll-In + Bucket Roll-In 31.9 When relieving
Combined Operation
PUMP 2 DELIVERY
PRESSURE (MPa)
Boom Lower -
Boom Raise + Arm
Roll-In + Bucket Roll-In 31.9 When relieving
Combined Operation
T4-2-9

Item Remarks
PUMP 1 REGULATOR
PRESSURE (MPa)
Boom Lower -
Boom Raise + Arm Roll-In
+ Bucket Roll-In Combined 0.5 When relieving
Operation
PUMP 2 REGULATOR
PRESSURE (MPa)
Boom Lower -
Operation
T4-2-10

Item Remarks
PUMP 1 FLOW CONTROL
PRESSURE (MPa)
Boom Lower -
Operation
PUMP 2 FLOW CONTROL
PRESSURE (MPa)
Boom Lower -
Operation
T4-2-11

Item Remarks
FRONT PILOT PRESSURE When relieving
4.0
(MPa)
TRAVEL PILOT When relieving
4.0
PRESSURE (MPa)
BOOM RAISE PILOT When relieving
4.0
PRESSURE (MPa)
ARM ROLL-IN (BH) When relieving
4.0
PILOT PRESSURE (MPa)
SWING PILOT
4.0 When relieving
PRESSURE (MPa)
ATT. CONTROL PILOT When relieving
4.0
PRESSURE (MPa)
POWER BOOST CONTROL
PRESSURE (MPa)
Power Digging Switch: ON,
2.15
Lever in Neutral
When Boom Raise Reliev-
2.15
ing
TRAVEL MOTOR CONTROL When fast speed
4.0
PRESSURE (MPa) traveling
T4-2-12
(Blank)
T4-2-13
MONITOR UNIT INDICATING VALUES
(ECM)
Unless specified, test under the following conditions.

• Power Mode Switch: P mode
• Work Mode: Digging Mode

Item Remarks
ENGINE TORQUE (MPa) 47 When boom raise
relieving
ACTUAL ENGINE 1750 When boom raise
SPEED (min-1) relieving
TARGET ENGINE 1700 When boom raise
SPEED (min-1) relieving
ENGINE OIL 444 When boom raise
PRESSURE (kPa) relieving, When
Neutral: 428 kPa
BOOST PRESSURE (kPa) 128 When boom raise
relieving
T4-2-14
SENSOR ACTIVATING RANGE
1. Checking Method
• Hydraulic Oil Temperature: 50±5 °C

• Unless specified:
Engine Power Auto-Idle
Work Mode
Control Dial Mode Switch Switch
Maximum Digging
P Mode OFF
Speed Mode
• Monitor each sensor using monitor unit (service

mode).
2. Sensor Activating Range
Sensor Operation Specification

Slow Idle Speed 0.3 to 1.0 V
Engine Control Dial
Fast Idle Speed 4.0 to 4.7 V
Control Lever: Neutral 0 to 0.049 MPa (0 to 0.5 kgf/cm2)
Pilot Operation Pilot Control Shut-Off Lever: LOCK
Pressure Sensor Control Lever: Full Stroke 2.45 to 3.9 MPa (25 to 40 kgf/cm2)
Pilot Control Shut-Off Lever: UNLOCK
Pump Regulator Control Lever: Neutral Pump 1: *0.49 MPa (5.0 kgf/cm2)
Pressure Sensor Pump 2: *0.44 MPa (4.5 kgf/cm2)
Jack-up, Travel Lever: Full Stroke (Jack-up *1.76 to 2.55 MPa (18 to 26 kgf/cm2)
Side)
Pump Delivery Control Lever: Neutral *0.3 to 0.5 MPa (3 to 5 kgf/cm2)
Pressure Sensor When Boom Raise Relieving 31.9+1-0 MPa (325+10-0 kgf/cm2)
(Boom Bottom
Pressure Sensor)
*: Reference Value
T4-2-15
(Blank)
T4-2-16
OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE SPEED
Summary
1. Measure the engine speed by using the monitor
unit (service mode).
2. Measure the engine speeds in each mode.
NOTE: If the engine speed is not adjusted cor-

rectly, all other performance data will be
unreliable. Consequently, measure the en-
gine speed before performing all other
tests in order to check that the engine
speed meets specification.
Preparation:
1. Select the service menu of monitor unit.
2. Warm up the machine until coolant temperature
reaches 50 °C (122 °F) or more, and hydraulic oil
temperature is 50±5 °C (122±41 °F).
T4-3-1
Measurement: Evaluation:
1. Measure the items as shown in the table below. Refer to Operational Performance Standard in Group
2. When measuring, set the switch and test condi- T4-2.
tion as shown in the table below in response to
the engine speed to be measured. Remedy:
Refer to Troubleshooting B in Group T5-7.
NOTE: ECO stands for the auto engine speed re-

duction system by 1600 min-1.
Engine Power
Auto-Idle
Item Control Mode Work Mode Test Conditions
Switch
Dial Switch
Slow Idle Min. Speed P OFF Digging Mode
Fast Idle Slightly operate the bucket out
(With ECO deac- function for ECO deactivated.
Max. Speed P OFF Digging Mode
tivated) Measure engine speed with the
lever in neutral.
Fast Idle Measure engine speed while
Max. Speed P OFF Digging Mode
(Relief operation) relieving the boom raise circuit.
Fast Idle
Max. Speed E Mode OFF Digging Mode
(E mode)
Fast Idle Measure engine speed while
Max. Speed HP Mode OFF Digging Mode
(HP mode) relieving the boom raise circuit.
Check engine speed 4 seconds
Auto-Idle Max. Speed P ON Digging Mode after returning all control levers
to neutral.
Switch Panel: Monitor Unit:
Digging Mode
Engine Control Dial
Auto-Idle Switch
Power Mode Switch
M1J1-01-002
T1V1-04-03-001
T4-3-2
ENGINE COMPRESSION PRESSURE
Summary:
1. Measure compression pressure in the cylinders
and check for a decline in engine power.
2. Check exhaust gas color. Keep track of engine oil
consumption.
3. Check for abnormalities in the intake system, in-
cluding the air filter.
Preparation:
1. Confirm that valve clearances are correct.
2. Confirm that the batteries are charged properly.
3. Run the engine until the coolant temperature
gauge reaches the operating range.
4. Remove the negative terminal of battery. Remove
all the glow plugs from each cylinder.
： 25 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
Injector
IMPORTANT: If disconnecting the connector of Connector
injector, fuel cannot be jetted.
Therefore, ECM judges that the fuel
system is faulty and the fault code
is displayed. After measurement,
delete the displayed fault code.
5. Disconnect the connector of injector which is in-

stalled to the lower head cover.
6. Install the negative terminal of battery.
7. Turn the starter. Exhaust foreign subjects from Lower Head Cover
the cylinder.
8. Install a pressure gauge (Isuzu 5-8840-2675-0) T1J1-04-03-001
and an adaptor (Isuzu 1-8531-7019-0) to the Pressure
Gauge
glow plug mounting part. (Sufficiently install them
in order to prevent air leakage.)
Measurement:
1. Turn the starter and measure compression pres-
sure of each cylinder.
2. Repeat the measurement three times and calcu-
late the mean values.
Evaluation:
Refer to Operational Performance Standard in Group
T4-2.
Remedy:
Refer to the engine workshop manual. T1J1-04-03-002
T4-3-3
VALVE CLEARANCE
Summary: Terminal Nut Harness

1. Perform the measurement when the engine is
cold.
2. Before starting any work, clean the head cover
mounting area and avoid contamination in the
engine.
Preparation:
1. Remove the head cover.
2. Remove the terminal nut which secures the har-
ness to the injector.
: 2 N⋅m (0.2 kgf⋅m, 1.5 lbf⋅ft)
3. Remove the bolts (2 used). Remove the harness
Injector T1J1-04-03-006
assembly from the injector.
: 22 N⋅m (2.2 kgf⋅m, 16 lbf⋅ft)
4. Remove the leak off pipe. Bolt
Bolt:
: 15 N⋅m (1.5 kgf⋅m, 11 lbf⋅ft)
5. Rotate the crank pulley. Align the T/C mark on
flywheel with the pointer on gear case in order to
get TDC in the compression stroke.
NOTE: When rotating the crank pulley, remove the

fan guard. Then, rotate the fan while hold-
ing the fan belt. If it is difficult to rotate, Harness
remove all glow plugs and release com- Assembly T1J1-04-03-007
pression pressure.
Leak Off Pipe
6. Check if piston No.1 (or piston No.6) is now posi-
tioned at the T/C in the compression stroke.
NOTE: Move push rods for the intake and exhaust

valves on the No.1 cylinder up and down
by hand. If any clearances on the both
ends of the push rods are found, piston
No.1 is positioned at T/C in the compres-
sion stroke. (If the exhaust valve of cylin- T1J1-04-03-008
der No.1 is pushed down, piston No.6 is

positioned at T/C in the compression
stroke.
T/C Mark Pointer
7. Start measurement from the cylinder (No.1 or
No.6) positioned at T/C in the compression
stroke.
Flywheel Gear Case
T1J1-04-03-003
T4-3-4
Measurement:
1. Insert a thickness gauge into the clearance be- Rocker Arm Thickness Gauge
tween rocker arm and cam, and measure the
valve clearance.
NOTE: The cylinders are aligned from No.1 to

No.6 in that order, as viewed from the fan
side. Injection Order: 1-5-3-6-2-4
2. When measurement is started from No.1 cylinder,

perform the same measurement to all valves in-
dicated with the mark “○” in the table below.
(When measurement is started from No.6 cylin- Cam T1J1-04-03-004
der, perform the measurement in the valves

shown with mark “×”.)
Cylinder No. No.1 No.2 No.3 No.4 No.5 No.6

Valve locations E I E I E I E I E I E I
When the measurement is
{ { { { { {
started from No.1 cylinder
When the measurement is
× × × × × ×
started from No.6 cylinder
3. Rotate the crankshaft 360°. Align the T/C mark

with the pointer. Continue measurement of other
valves in the same way.
Evaluation:
T4-2.
T4-3-5
Adjustment:
If the measurement results are out of specification, Lock Nut
adjust the valve clearance in the same order of
measurement. Adjusting
Screw
IMPORTANT: Touch the bridge to the end of valve
heads (2 used) horizontally and ad-
just the valve clearance carefully.
1. Loosen the lock nuts (12 used) and adjusting

screws (12 used), which secure the bridge and
rocker arm.
2. Insert a thickness gauge into the clearance be-
tween rocker arm and cam. Bridge T1J1-04-03-005
3. Tighten the adjusting screw of rocker arm until Rocker Arm
condition for the thickness gauge is proper.
4. Tighten the lock nut of rocker arm. Rocker Arm Thickness Gauge
: 78 N⋅m (8.0 kgf⋅m, 58 lbf⋅ft)
5. Tighten the adjusting screw of bridge until the
thickness gauge does not move
6. Tighten the adjusting screw of bridge until condi-
tion for the thickness gauge is proper.
7. Tighten the lock nut of bridge.
: 54 N⋅m (5.5 kgf⋅m, 40 lbf⋅ft)
8. Check the valve clearance after the lock nuts are
tightened.
Cam T1J1-04-03-004
T4-3-6
LUBRICANT CONSUMPTION
Measuring Method
1. Place the machine on level firm ground and leave
the machine for at least one hour in order to let
the lubricant lower to the oil pan when the engine
stops.
At this time, confirm that the machine is level by
using a leveler.
2. Record read-out A (unit: hour) of the hour meter.
3. Replenish the lubricant up to the high-level.
4. Operate the machine for at least 100 hours or un-
til the oil level lowers to the low-level.
IMPORTANT: Keep the machine-leaving time in

Step 1 above.
5. Place the machine on level firm ground and leave
the machine for at least one hour in order to let
the lubricant lower to the oil pan when the engine
stops.
At this time, confirm that the machine is level by
using a leveler.
6. Record read-out B (unit: hour) of the hour meter.
7. Replenish the lubricant up to the high-level
gauge while measuring the oil-replenishing vol-
ume C.
NOTE: When measuring, use a high-precision
measuring cylinder or the like.
8. Determine lubricant consumption from the fol-

lowing equation:
Oil replenishing volume (C) [mL] / Operating
hours (B-A) [hr]
Evaluation:
T4-2.
T4-3-7
(Blank)
T4-3-8
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL SPEED
Summary:
Measure the time required for the excavator to travel
a 20 m (65.6 ft) test track.
Preparation:
1. Adjust the track sag on both side tracks equally.
2. Prepare a flat and solid test track 20 m (65.6 ft) in
length with extra length of 3 to 5 m (9.8 to 16 ft)
Arm Rolled-In, Bucket Rolled-In
on both ends for machine acceleration and de- End
celeration. Bucket Height: 0.3 to 0.5 m
IMPORTANT: The bucket teeth will hit the boom if Start

20 m Deceleration
the bucket is rolled-in with the arm Zone
fully rolled-in. 3 to 5 m
As for this condition: arm fully Acceleration
rolled-in + Bucket fully rolled-in, set Zone
3 to 5 m
the bucket at fully rolled-in and a
perform arm roll-in operation. T105-06-03-001
3. Hold the bucket 0.3 to 0.5 m (12 to 20 in) above

the ground with the arm and bucket rolled in.
4. Maintain hydraulic oil temperature at 50±5 °C
(122±41 °F).
Measurement:
1. Measure both the slow and fast speeds of the
machine.
2. Measurement conditions are as below.
Travel Engine Power Work
Auto-Idle
Mode Control Mode Mode
Switch
Switch Dial Switch
Slow Digging
Fast Idle HP Mode OFF
Mode Mode
Fast Digging
Mode Mode
3. Start traveling the machine in the acceleration

zone with the travel levers to full stroke.
4. Measure the time required to travel 20 m (65.6
ft).
5. After measuring the forward travel speed, turn
the upperstructure 180° and measure the reverse
travel speed.
6. Perform the measurement three times and cal-
culate the average values.
Evaluation:
Refer to the Operational Performance Standard in
Group T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-7.
T4-4-1
TRACK REVOLUTION SPEED
Summary:
Measure the track revolution cycle time with the
track raised off ground.
Preparation:
1. Adjust the track sag of both side tracks to be
equal.
2. Put the mark on the track to be measured, by
using a piece of chalk.
3. Swing the upperstructure 90° and lower the 90° to 110°
bucket to raise the track off ground. Keep the
boom-arm angle between 90 to 110° as shown.
Place blocks under the machine frame.
M104-07-067
CAUTION: Securely support the raised track

using wooden blocks.
4. Maintain the hydraulic oil temperature at 50±5 °C

(122±41 °F).
90° to 110°
Measurement:
1. Measure the both tracks on forward and reverse
directions at each travel mode.
2. Measurement conditions are as below. T1J1-04-04-001

Auto-Idle
Switch
Switch Dial Switch
Slow Digging
Mode Mode
Fast Digging
Mode Mode
3. Operate the travel control lever of the raised
track to full stroke.
4. Measure the time required for 3 revolutions in
both directions after a constant track revolution
speed is obtained.
Evaluation:
Group T4-2.
NOTE: The measurement data obtained through

the raised track revolution test may have
wide variations. Therefore, the evaluation
based on the results obtained from the 20
m travel speed check described before is
more recommendable.
Remedy:
T4-4-2
MISTRACK CHECK
Summary: Evaluation:
1. Allow the machine to travel 20 m (65.6 ft). Meas- Refer to the Operational Performance Standard in
ure the maximum tread deviation from the tread Group T4-2.
chord line drawn between the travel start and end
points to check the performance equilibrium be- Remedy:
tween both sides of the travel device systems Refer to the Troubleshooting B in Group T5-7.
(from the main pump to the travel motor).
2. If measured on a concrete surface, the tread de-
viation has a trend to decrease.
Preparation:
1. Adjust the track sag of both tracks to be equal. Maximum Distance
2. Provide a flat, solid test yard 20 m (65.6 ft) in
length, with extra length of 3 to 5 m (9.8 to 16 ft)
on both ends for machine acceleration and de- Acceleration
celeration. Zone:
3 to 5 m
20 m
IMPORTANT: The bucket teeth will hit the boom if
the bucket is rolled-in with the arm
fully rolled-in.
As for this condition: arm fully
rolled-in + Bucket fully rolled-in, set
the bucket at fully rolled-in and a T105-06-03-022
perform arm roll-in operation.

3. Hold the bucket 0.3 to 0.5 m (12 to 20 in) above
the ground with the arm and bucket rolled in.
(122±41 °F).
Measurement:
1. Measure the amount of mistracking in both fast,
and slow travel speeds.
Auto-Idle
Switch
Switch Dial Switch
Slow Digging
Mode Mode
Fast Digging
Mode Mode
3. Start traveling the machine in the acceleration

zone with the travel levers at full stroke.
4. Measure the maximum distance between a
straight 20 m (65.6 ft) tread chord line and the
tread made by the machine.
5. After measuring the tracking in forward travel,
turn the upperstructure 180° and measure in re-
verse travel.
T4-4-3
TRAVEL MOTOR LEAKAGE
Summary:
To measure the parking brake function on a specified
slope.
Preparation:
1. The surface of the test slope shall be even with a
gradient of 20 % (11.31°).
2. Hold the bucket 0.2 to 0.3 m (8 to 12 in) above 0.2 to 0.3 m
the ground with the arm and bucket fully rolled in.
IMPORTANT: The bucket teeth will hit the boom if

the bucket is rolled-in with the arm
fully rolled-in. T105-06-03-004
As for this condition: arm fully
rolled-in + Bucket fully rolled-in, set
the bucket at fully rolled-in and a
perform arm roll-in operation.
(122±41 °F).
Measurement:
1. Measure the travel parking brake slip amount
while parked.
2. Climb the slope and place the travel levers in
neutral.
3. Stop the engine. Alignment marks on the track side frame
4. After the machine stops, put the matching marks and shoe when the machine comes to a stop.
on a track link or shoe, and the track side frame. Displacement measured after 5 minutes.
5. After 5 minutes, measure the distance between
the marks on the track link or shoe and the track T105-06-03-006
side frame.
Evaluation:
Group T4-2.
T4-4-4
SWING SPEED
Summary:
Measure the time required to swing three complete
turns.
Preparation:
1. Check the lubrication of the swing gear and
swing bearing.
2. Place the machine on flat, solid ground with am-
ple space for swinging. Do not conduct this test
on slopes.
3. With the bucket empty, position the front attach-
ment as follows: The height as the
Backhoe: boom foot pin height.
With the arm cylinder fully retracted, and the
bucket cylinder fully extended, raise the boom so T105-06-03-013
that the arm tip pin height is flush with the boom
foot pin height.
Loading Shovel:
With the arm cylinder and the bucket cylinder
fully extended, raise the boom so that the arm tip The height as the
pin height is flush with the boom foot pin height. boom foot pin height.
NOTE: In case of no place to be measured, meas- TBAR-04-04-001
ure with the boom raised and the arm

rolled-in.
(122±41 °F).
CAUTION: Prevent personal injury. Always
make sure that the area is clear and that
co-workers are out of the swing area before
starting the measurement.
Measurement:
Engine Power Mode Work Mode Auto-Idle
Control Dial Switch Switch
Digging
Mode
2. Operate swing control lever fully.
3. Measure the time required to swing 3 turns in
one direction.
4. Operate swing control lever fully in the opposite
direction and measure the time required for 3
turns.
Evaluation:
Group T4-2.
Remedy:
T4-4-5
SWING FUNCTION DRIFT CHECK
Summary:
Measure the swing drift on the bearing outer cir-
cumference when stopping after a 180° full-speed
swing.
Preparation:
swing bearing.
2. Place the machine on flat, solid ground with am-
ple space for swinging. Do not conduct this test
Two Matching Marks
on a slope.
3. With the bucket empty, position the front attach- T105-06-03-008
ment as follows:
Backhoe:
bucket cylinder fully extended, raise the boom so
foot pin height.
Loading shovel:
fully extended, raise the boom so that the arm tip
pin height is flush with the boom foot pin height.
4. Put the matching marks on the swing bearing and
on the track frame by using a tape, as illustrated. T105-06-03-009
5. Swing the upperstructure 180°.

(122±41 °F).
Measure Difference Between Marks

Measurement: Mark on Track Frame

1. Measurement conditions are as below. Mark on Swing Bearing
Engine Power Mode Auto-Idle
Work Mode
T105-06-03-010
Digging
Mode
2. Operate the swing control lever fully and return it
to the neutral position when the mark on upper-
structure aligns with that on track frame after
swinging 180° .
3. Measure the distance between the two marks.
4. Align the marks again, swing 180°, and then test
in the opposite direction.
Evaluation:
Group T4-2.
Remedy:
T4-4-6
SWING MOTOR LEAKAGE
Summary:
Check for upperstructure drift while suspending a
load on a slope.
Preparation:
swing bearing.
2. Load bucket fully. In lieu of loading the bucket,
weight (W) of the following specification can be
used.
Backhoe: W=2850 kg (6280 lb)
Loading shovel: W=3900 kg (8600 lb)
3. Position the front attachment as follows:
Backhoe: T105-06-03-011
bucket cylinder fully extended, raise the boom so
foot pin height.
Loading shovel:
4. Park the machine on a smooth slope with a gra-
dient of 26.8% (15°).
5. Swing the upperstructure to position it 90° to the
slope. Put the matching marks on the swing Measure Difference Between Marks
bearing periphery and track frame by using a
tape, as illustrated.
(122±41 °F).
Measurement: Mark on Track Frame

Power Mode Auto-Idle Mark on Swing Bearing
Work Mode
Switch Switch
HP Mode Digging Mode OFF T105-06-03-010
2. Maintain the engine at slow idle. After five min-

utes, measure the difference between the marks
along the swing bearing periphery and the track
frame.
3. Perform the measurement in both right and left
swing directions.
Evaluation:
Group T4-2.
Remedy:
T4-4-7
MAXIMUM SWINGABLE SLANT ANGLE
Summary:
With the upperstructure swung 90° to the slope,
check the maximum slant angle on which the upper-
structure can swing to the uphill side.
Preparation:
1. Check that the swing gear and bearing are well
lubricated.
2. Load bucket fully. In lieu of loading the bucket,
used.
Backhoe: W=2850 kg (6280 lb)
Loading shovel: W=3900 kg (8600 lb)
Backhoe: T105-06-03-011
With the arm cylinder fully retracted and the
bucket cylinders fully extended.
Loading shovel:
With the arm cylinder fully extended and the
bucket cylinders fully extended. Hold the arm tip
pin to the position flush with the boom foot pin
height.
4. Climb a slope and swing the upperstructure 90°
to the slope.
(122±41 °F).
Measurement:
Engine
Power Mode Auto-Idle
Control Work Mode
Switch Switch
Dial
Fast Idle HP Mode Digging Mode OFF
2. Operate the swing lever to full stroke to swing the

upperstructure to the uphill side.
3. If the machine can swing, measure the cab floor
slant angle.
4. Increase the slope angle and repeat the meas-
urement. Check both clockwise and counter-
clockwise.
Evaluation:
Group T4-2.
Remedy:
T4-4-8
(Blank)
T4-4-9
SWING BEARING PLAY
Summary:
Measure the swing bearing play using a dial gauge
to check the wear of bearing races and balls.
Preparation:
1. Check swing bearing mounting bolts for loose-
ness.
2. Check the lubrication of the swing bearing. Con-
firm that bearing rotation is smooth and without
noise.
3. Install a dial gauge on the track frame as shown
Magnetic Base Dial Gauge
by using a magnetic base.
T105-06-03-014
4. Position the upperstructure so that the boom
aligns with the tracks facing towards the front
idlers.
5. Position the dial gauge so that its needle point
comes into contact with the bottom face of the
bearing outer race.
6. Bucket should be empty.
Round Trunk
NOTE: The measured value will vary depending
on where the magnet base is secured.
Secure the magnet base onto the round
trunk or in a position as close to the round
trunk as possible.
T105-06-03-015
T4-4-10
Measurement:
Backhoe:
With the arm cylinders fully retracted and the
bucket cylinders fully extended, position the arm
tip pin height is flush with the boom foot pin
height.
Loading shovel:
With the arm cylinder fully extended and the
bucket cylinders fully extended, position the arm
top pin height is flush with the boom foot pin
height.
2. Lower the bucket to the ground and use it to
raise the front idler 0.5 m (20 in). Record the dial
gauge reading (h2).
3. Calculate bearing play (H) from this data (h1 and
h2) as follows:
H=h2−h1
Evaluation:
Group T4-2.
Backhoe Front Measurement: (h2)

Measurement: (h1)
The height as the

boom foot pin height
T105-06-03-017
T105-06-03-013
Loading Shovel Front Measurement: (h2)

Measurement: (h1)
The height as the

boom foot pin height
TBAR-04-04-002
TBAR-04-04-001
T4-4-11
HYDRAULIC CYLINDER CYCLE TIME
Summary:
1. Check the overall operational performance of the
front attachment hydraulic system (between the
hydraulic pumps and each cylinder) by measur-
ing the cycle time of the boom, arm, bucket, and
bucket dump (open/close) cylinders with the
empty bucket.
2. Bucket should be empty.
Preparation:
(122±41°F).
Measurement:
Engine
Control Work Mode
Switch Switch
Dial
T105-06-03-018
2. Position the front attachment as described in the

following. Then, measure the operating time until
the cylinder reaches the stroke end by fully mov-
ing the control lever.
• Backhoe
Boom Cylinder:
With the bucket cylinder fully extended and the
arm cylinder fully retracted, lower the bucket to
the ground.
Arm Cylinder:
Retract the bucket cylinder so that the arm and 0.5 m
bucket teeth are vertical to the ground.
Adjust the boom cylinder stroke so that the
bucket bottom height is 0.5 m (20 in) above the T1V1-04-05-005
ground with the bucket cylinder fully extended.

Set the arm so that the center of arm operation is
vertical.
Bucket Cylinder:
Adjust the boom and arm cylinder so that the
center of full stroke movement of the bucket is
positioned vertically.
T105-06-03-018
T4-4-12
• Loading Shovel Loading Shovel
Boom Cylinder:
With the bucket cylinder and the arm cylinder
fully extended, lower the bucket to the ground.
Arm Cylinder:
With the arm fully retracted, position the bucket
so that the rear bucket does not come in contact
with the arm stopper. Then, adjust the boom cyl- Boom Cylinder
inder stroke to position the bucket bottom 1 m
(39 in) above the ground.
Bucket Cylinder:
With the bucket closed and held in a load dump
position, adjust the boom cylinder stroke so that
bucket bottom height is approx. 1 m (39 in) above
the ground.
TBAR-04-04-003
Bucket Open-Close Cylinder:
With the bucket cylinder and arm cylinder fully
extended, adjust the boom cylinder stroke so that
the bucket bottom height approx. 1 m (39 in)
above the ground.
Evaluation: Arm Cylinder

Group T4-2. TBAR-04-04-004
Remedy:
Bucket
Cylinder
TBAR-04-04-005
Bucket
Open-Close Cyl-
inder
TBAR-04-04-006
T4-4-13
DIG FUNCTION DRIFT CHECK
Summary:
Measure dig function drift, which can be caused by
oil leakage in the control valve and boom, arm, and
bucket cylinders, with the loaded bucket.
NOTE: When testing the dig function drift just after

Extended
cylinder replacement, slowly operate each Retracted
Distance
Distance
cylinder to its stroke end to release air. Retracted
Distance
Preparation:
1. Load bucket fully. In lieu of loading the bucket, Same Height
used.
Backhoe: W=2850 kg (6280 lb) Bucket Bottom
Loading Shovel: W=3900 kg (8600 lb)
Backhoe: T105-06-03-021
With the arm cylinder fully retracted and the

bucket cylinder fully extended. Backhoe:
Loading shovel: Boom and Bucket Cylinder Retraction
With the arm cylinder and the bucket cylinder Loading Shovel:
fully extended. Boom, Arm and Bucket Cylinder Retraction
Raise the boom so that the arm tip pin height is
flush with the boom foot pin height concerning Mark Mark
backhoe and loading shovel.
3. With the arm rolled out and the bucket rolled in,
hold the bucket so that the height of the bucket
pin is the same as the boom foot pin.
(122±41 °F).
T110-06-03-002
Measurement:
1. Stop the engine. Backhoe:
2. Five minutes after the engine has been stopped, Arm Cylinder Extension
measure the change in the position of the bottom
of the bucket, as well as the boom, arm and
bucket cylinders.
Mark
Evaluation:
Group T4-2.
Remedy:
T110-06-03-001
T4-4-14
CONTROL LEVER OPERATING FORCE
Summary:
1. Measure each lever operating force using a
spring scale
2. Measure the maximum lever operating force at
the grip center of each control lever.
3. Check the control lever condition.
Preparation:
Maintain the hydraulic oil temperature at 50±5 °C
(122±41 °F).

make sure that the area is clear and that T107-06-03-003

Measurement:
1. Measure each control lever.
Engine
Control Work Mode
Switch Switch
Dial
3. Operate each boom (raise) arm and bucket lever
to the fully and measure the maximum operating
force for each with each actuator relieved.
4. Operate boom (lower) lever and measure the T107-06-03-004
maximum operating force with the boom lower

relieved by jacking up the machine in a safe
area.
5. Operate swing lever and measure the maximum
operating force with swing relieved after securing
the front attachment to prevent swinging.
6. Lower the bucket to the ground to raise one track
off the ground. Operate the travel lever to full
stroke and measure the maximum operating
force required. When finished, lower the track
and then jack-up the other track.
Evaluation:
Group T4-2.
T4-4-15
CONTROL LEVER STROKE
Summary:
1. Check the lever stroke play and the lever operat-
ing condition. Measure each lever stroke at the
lever top using a ruler.
2. Measure the lever stroke at the grip center of
each control lever.
3. In case lever stroke play is present in the neutral
position, add half (1/2) the play present to both
side lever strokes.
NOTE: When the lever has play, take a half of this

value and add it to the measured stroke.
Preparation: T107-06-03-005
Maintain the hydraulic oil temperature at 50±5 °C

(122±41 °F).
Measurement:
1. Stop the engine.
2. Measure each lever stroke at the lever top from
neutral to the stroke end using a ruler.
Evaluation:
Group T4-2.
T4-4-16
BOOM RAISE/SWING COMBINED OP-
ERATION CHECK
Summary:
Check boom raise and swing movement speeds
while operating both functions simultaneously.
Preparation:
1. Start the engine and run it at fast idle. Operate
the boom raise function and check to be sure that
the cylinder movement is smooth, with out stick-
ing. M104-07-021
2. Position the machine with front attachment posi-

tioned as illustrated and with the bucket empty.
(122±41 °F).

make sure that the area is clear and that co-
workers are out of the swing area before
Measurement:
Engine
Power Mode Auto-Idle T107-06-03-010
Control Work Mode
Switch Switch
Dial
2. Raise the boom and swing simultaneously.

3. When the upperstructure rotates 90°, release the
control levers to stop both functions. Measure the
time required to swing 90° and the height (H) of
H
the bucket teeth.
Evaluation:
Refer to the Operational Performance Standard in T107-06-03-011
Group T4-2.
Remedy:
T4-4-17
(Blank)
T4-4-18
OPERATIONAL PERFORMANCE TEST / Component Test
PRIMARY PILOT PRESSURE
Preparation:
1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic
oil tank and release any remaining pressure.
3. Remove the plug from the pilot filter. Install
adapter (ST 6069) and pressure gauge (ST
6942) to the pressure check port.
: 14 mm
Plug
4. Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection.
(122±41 °F).
T178-03-07-001
Measurement:
Work Mode
Digging
Mode
Digging
Slow Idle HP Mode OFF
Mode
2. Measure pilot pressure in each specified setting

above without load.
late the average values.
Evaluation:
Group T4-2.
T4-5-1
Primary Pilot Pressure Adjustment Procedure
Adjustment:
Adjust the relief valve set pressure if necessary.
Relief Valve
1. Remove plug (1) from the relief valve.

: 22 mm
2. Install the estimated number of shims (2). T178-03-07-001
3. After adjustment, tighten plug (1).

: 25+2 N⋅m (2.5+0.2 kgf⋅m, 18.4+1.5 lbf⋅ft) 1
2
4. After adjustment, check the set pressure.
NOTE: Standard Change in Pressure (Reference)

Shim Thickness Change in Relief Pressure
(mm) kPa (kgf/cm2, psi)
0.25 78 (0.8, 11.3)
0.5 157 (1.6, 22.8)
1.0 304 (3.1, 44.2)
T111-06-04-004
T4-5-2
SECONDARY PILOT PRESSURE
Preparation:
1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic Pilot Valve Signal Control Valve
3. Measure pressure at the location between pilot
Hose
valve and signal control valve. Remove the pilot
hose from the circuit to be measured. Install the Nipple
hose (9/16-18UNF, Length: approx. 400 mm (16
in)) to the signal control valve side. Install tee
(4351843), adapter (ST 6460), nipple (ST 6069),
coupling (ST 6332) and pressure gauge (ST 6315)
between the hoses. Pressure
Gauge
: 17 mm, 19 mm
Tee
Adapter
NOTE: When removing the lines from signal con-
trol valve, use tool (SNAP-ON
GAN850812B: size 19.05 mm) in order to
easily remove the lines.

(122±41 °F). T1F3-04-05-008
Measurement:
Work Mode
Digging
Mode
Digging
Mode
2. Measure pilot pressure by using a pressure
gauge with the corresponding control lever oper-
ated to full stroke.
Evaluation:
Group T4-2.
Remedy:
T4-5-3
SOLENOID VALVE SET PRESSURE
Solenoid Valve
Preparation:
Pressure Gauge
1. Stop the engine.
3. Remove the line from the solenoid valve to be
measured. Install tee (ST 6451), hose (Parts
Number: 4216453), adapter (ST 6461) and pres-
sure gauge (ST 6942).
: 17 mm, 19 mm, 22 mm
Hose Tee Adapter T157-05-04-002

(122±41 °F).
Measurement:
Work Mode
Digging
Mode
Digging
Mode
2. Operate as instructed below for each measuring

solenoid valve:
Solenoid Valve SG: Turn the power digging
switch ON and OFF.
Solenoid Valve SI: Turn the travel mode switch
ON and OFF.
Solenoid Valve SF: Combined operation of boom SC SF SI SG
lower and arm, or boom lower and bucket.
Solenoid Valve SC: Turn the boom mode selector
switch ON. Operate the front and swing opera-
tion.
3. Read the values on the pressure gauge.
Evaluation:
Refer to the Operational Performance Standard in T1V1-03-07-007
Group T4-2.
T4-5-4
Solenoid Valve Adjustment Procedure
7 O-Ring
IMPORTANT: As O-ring is damaged and oil leak-
8
age may cause, do not loosen ad-
justing screw (8) excessively.
Do not loosen adjusting screw (8)
more than 2 turns.
1. Loosen lock nut (7). Turn adjusting screw (8) and
adjust the set pressure.
2. After adjustment, tighten lock nut (7).
: 10 mm
: 3 mm T1V1-04-05-004
: 3 N⋅m (0.3 kgf⋅m, 2.2 lbf⋅ft) 2.0 mm (0.079 in) or less

from end of Lock Nut
3. After adjustment, check the set pressure.
Screw Turns 1/4 1/2 3/4 1
Change kPa 69 137 206 275
in Pres- (kgf/cm2) (0.7) (1.4) (2.1) (2.8) 7
sure (psi) (10) (20) (30) (40)
T1V1-04-05-003
7 8
Pressure Pressure
Increase Decrease
W107-02-05-129
T4-5-5
MAIN PUMP DELIVERY PRESSURE
Preparation:
1. Stop the engine.
oil tank and release any remaining pressure. Main Pump 1 Side
3. Remove the plug of pressure check port from the
main pump delivery port. Install adapter (ST
6069), hose (ST 6943) and pressure gauge (ST Plug
6941).
: 6 mm
(122±41 °F).
Measurement:
1. Measurement Conditions are below. T1J1-04-05-001

Work Mode
Digging
Mode
2. Measure pressure with the control levers in neu- Main Pump 2 Side
tral without load.
3. Repeat the measurement three times and calcu- Plug
Evaluation:
Group T4-2.
Remedy:
T1J1-04-05-002
T4-5-6
FAN PUMP DELIVERY PRESSURE
Preparation:
1. Stop the engine.
fun pump delivery port. Install adapter (ST 6069),
hose (ST 6943) and pressure gauge (ST 6941).
: 6 mm
Plug
(122±41 °F).
Measurement:
1. Measurement Conditions are below.
Work Mode
Digging
Mode
T1J1-04-05-003
2. Measure pressure with the control levers in neu- Fan Pump

tral without load.
Evaluation:
Group T4-2.
Remedy:
T4-5-7
MAIN RELIEF VALVE SET PRESSURE
Summary:
Measure the main relief valve set pressure at the de-
livery port in main pump.
Main Pump 1 Side
Preparation:
1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic Plug
main pump delivery port. Install adapter (ST
6069), hose (ST 6943) and pressure gauge (ST
6941).
: 6 mm
5. Maintain the hydraulic oil temperature at 50±5 °C T1J1-04-05-001
(122±41 °F).
Measurement:
Engine Power Mode Auto-Idle Main Pump 2 Side
Work Mode
Digging Plug
Mode
2. First, slowly operate the bucket, arm and boom

control levers to the stroke end and relieve each
function.
3. As for the swing function, secure the upperstruc-
ture so it is immovable. Slowly operate the swing
lever and relieve the swing function.
4. As for the travel function, secure the tracks
against an immovable object. Slowly operate the
T1J1-04-05-002
travel levers and relieve the travel function.
5. With the power digging switch pushed, slowly
operate the bucket, arm and boom control levers
to the stroke ends and relieve each function
within eight seconds.
Evaluation:
Group T4-2.
NOTE: If the measure pressures for all functions

are lower than the specified range, the
probable cause is a decrease of main relief
valve setting pressure.
If relief pressure of a particular function is
lower, the probable cause is other than
main relief valve.
T4-5-8
NOTE: In case pressures of all circuits are low, the
pressure of the main relief valve may de- Main Relief
Valve
crease. In case pressures of specified cir-
cuits are low, pressures of some other
parts except the main relief valve may de-
crease.
Main Relief Valve Setting Adjustment Procedure

When adjusting the increased pressure (when travel
or power digging switch is ON), adjust the
high-pressure side of main relief pressure.
When adjusting the normal main relief pressure, ad-
just the low-pressure side of main relief pressure.
When adjusting the high-pressure side of main relief
pressure, the low-pressure side of main relief pres-
sure setting is changed accordingly. Therefore, be
sure to adjust the low-pressure side of main relief
pressure after adjusting the high-pressure side of T1J1-03-03-008
main relief pressure.
• High-pressure side of relief pressure adjustment

1
procedure.
1. Loosen nut (2). 2
Lightly tighten plug (1) until the end of plug (1)
3
comes into contact with sleeve A.
Tighten lock nut (2). 4
: 30 mm
5 A
Lock Nut (2)
: Less then 59 N⋅m (6 kgf⋅m, 44 lbf⋅ft)
2. Loosen lock nut (4).
Turn Plug (3) clockwise to adjust the relief pres-
sure setting referring to the table below.
: 41 mm
Lock Nut (4)
• Low-pressure side of relief pressure adjustment

procedure.
Turn plug (1) counter clockwise to adjust the re-
T16J-04-04-003
lief pressure setting referring to the table below.
Tighten lock nut (2).
: 30 mm
Lock Nut (2) 1, 3
4. Check the set pressure again.
NOTE: Approx. 4.5 MPa (46 kgf/cm2, 654 psi)

increase/decreases at a quarter turning. Pressure Pressure
Increase Decrease
W107-02-05-127
T4-5-9
Swing Relief Valve Set-Pressure Adjustment Pro-
cedure
1. Loosen the lock nut to adjust the adjusting plug.

: 38 mm
Swing Relief Valve
3. Turn adjusting plug (1) to adjust.
: 30 mm
4. Tighten lock nut (2).

: 38 mm
: 118 N⋅m (12.0 kgf⋅m, 87 lbf⋅ft)
5. Check the set pressure.
T178-03-02-001
2
1
Adjusting Plug
1
Turns
MPa 10.0
(kgf/cm2) (102)
(psi) (1450) T16J-04-05-001
Pressure Pressure
Increase Decrease
T157-05-04-023
T4-5-10
Travel Relief Pressure Setting Adjustment
Procedure
Adjustment:
Adjust the set pressure of the travel relief valve using
the adjusting screw after loosening the lock nut.
1. Loosen the lock nut.

: 19 mm
2. Turn the adjusting screw to adjust the pressure

setting, referring to the table below.
Travel Relief
: 6 mm Valve
3. Retighten the lock nut. T183-01-02-012
: 19 mm Lock Nut
: 34.3 to 44.1 N⋅m
(3.5 to 4.5 kgf⋅m, 25 to 32 lbf⋅ft)
4. Recheck the set pressure.
Adjusting Screw
T142-05-04-007
Reference : Change in Pressure Setting

Screw Turns 1/4 1/2 3/4 1 Lock Nut
Change MPa 1.96 3.92 5.88 7.85 Adjusting Screw

in (kgf/cm ) 2
(20) (40) (60) (80)
Pressure
(psi) (280) (570) (850) (1140)
Pressure Increase Pressure Decrease
W107-02-05-129
T4-5-11
OVERLOAD RELIEF VALVE SET PRES-
SURE
Summary: Preparation:
1. The circuit pressure must be increased by apply- 1. Stop the engine.
ing an external force while blocking the return cir- 2. Push the air bleed valve on top of the hydraulic
cuit from the control valve. This measuring oil tank and release any remaining pressure.
method is hazardous and the results obtained 3. Remove the plug from pressure check port of
with this method are unreliable. main pump delivery port. Install adapter (ST
2. The oil flow rate used to set the overload relief 6069), hose (ST 6943) and pressure gauge (ST
pressure is far less than that used to set the main 6941).
relief pressure. Therefore, measuring the over- Start the engine. Confirm that no oil leakage is
load pressure in the main circuit by increasing observed at the pressure gauge connection
the main relief set pressure more than the over- : 6 mm
load valve set-pressure is not a proper method.
In addition, in case a main relief valve designed
to leak a small quantity of oil before reliving is Main Pump 1 Side
used, its pre-leaking start pressure must be in-
creased more than the overload relief valve set
Plug
pressure. However, the pre-leaking start pressure
is not always increased more than the overload
relief valve set-pressure as the adjustable upper
limit of the main relief valve set-pressure is pro-
vided. Accordingly, the overload relief valve as-
sembly should be removed from the machine and
checked on a specified test stand at a correct oil
flow rate. Some overload relief valves come in
contact with the control valve body to block the oil T1J1-04-05-001
passage. When this type of overload relief valve Main Pump 2 Side
is checked, the control valve body must be pre-
cisely finished as the test unit. Provide one con- Plug
trol valve other than that on the machine as a test
kit.
3. If the overload relief valve performance must be
checked on the machine, however, measure the
main relief pressure while releasing each front
function respective to the measuring overload re-
lief valve. And, assume that the overload relief
valve is functioning correctly if the obtained main
relief pressure is within the specified value range.
Measure the main pressure of the front functions
as follows. T1J1-04-05-002

(122±41 °F).
T4-5-12
Measurement:
Work Mode
Digging
Mode
2. Slowly operate the bucket, arm and boom control

levers to the stroke ends and relieve each func-
tion.
3. Read pressures at this time.
4. Perform the measurement for the bucket, arm
and boom in that order.
late the average value for each.
Evaluation:
1. Performance of the overload relief valves are
normal if the measured main relief pressures are
within the specified value range.
Refer to the Operational Performance Standard

in Group T4-2.
Overload Relief Valve Pressure Adjustment Pro-

cedure 1
NOTE: In principle, adjust the overload relief valve

pressure on a test stand.
Loosen lock nut (1) and adjust pressure by using

adjusting screw (2).
2
: 19 mm
T162-04-04-004
2. Turn adjusting screw (2) in order to adjust pres-

sure.
: 6 mm
3. Tighten lock nut (1).

: 19 mm 2
: 31.5 N⋅m (3.2 kgf⋅m, 23 lbf⋅ft)
4. Check the set pressure.

Pressure Pressure
Increase Decrease
Screw Turns 1/4
MPa 5.0
Change in
(kgf/cm2)
W107-02-05-129
(51)
Pressure
(psi) (725)
T4-5-13
MAIN PUMP FLOW RATE MEASUREMENT
• P-Q Control (Torque Control)

Summary:
Main pump performance is checked by measuring 5. Install a pressure gauge to the main pump to be
the pump flow rate by using a hydraulic tester in- measured. (Refer to “Main Relief Set Pressure”.)
stalled at the main pump delivery port (one side) to : 6 mm
be measured. Use monitor unit (service mode) and 6. Disconnect the pipe from the port Psv (12). Con-
a hydraulic tester at the same time. nect hose (ST 6339) (14) to the disconnected the
pipe hole on regulator to be measured. Install
IMPORTANT: This measurement procedure is a plug (ST 6212) to the disconnected the pipe hole
simple method. The measured data on regulator not to be measured.
will be lower by approx. 5 % than 7. Remove the vacuum pump. Loosen plug (13) on
the accurately measured value. In top of the pump casing. Bleed air from the casing
order to measure accurately, dis- until oil only comes out.
connect the return circuit from the 8. Fully open the loading valve of hydraulic tester
control valve and connect it to the (5).
hydraulic oil tank. 9. Start the engine. Check the pressure gauge and
hydraulic tester (5) connection for any oil leaks.
Preparation:
1. Stop the engine. Push the air bleed valve and Measurement:
bleed air. Connect a vacuum pump to the oil filler 1. Maintain the hydraulic oil temperature at 50±5 °C
port. (122±41 °F).
NOTE: Operate the vacuum pump while connect- 2. Measure the maximum flow rate.
ing the pump flow rate test line. 3. Measurement conditions are below.
2. Disconnect the delivery hose from main pump Engine Power Mode Auto-Idle
Work Mode
(one side) to be measured. Connect pipe (1 or 2) Control Dial Switch Switch
by using the split flanges and bolts which were Digging
Fast Idle P Mode OFF
used for the disconnected delivery hose. Mode
: 41 mm
: 10 mm 4. Adjust the relief set pressure of main relief valve
3. Connect pipe (1 or 2) to hydraulic tester (5) by in control valve to each pressure point specified
using test hose (3) and adapter (4). Install along the main pump P-Q curve. (Refer to
adapter (6), joint (7), test hose (8) and flange (9) T4-2-5) Slowly restrict the loading valve of hy-
to hydraulic tester (5). draulic tester while relieving pressure in the arm
: 41 mm roll-in circuit. Measure the flow rates and engine
: 10 mm speeds at each pressure point specified in the
4. Connect the delivery hose to flange (9) with split P-Q curve.
flanges (10) and bolt (11). 5. Repeat the measurement three times and calcu-
: 10 mm late the average values.
T4-5-14
Evaluation:
1. Convert the measured flow rates to those at the 2. Standard Flow Rate
specified pump speed by using the following for- Refer to Operational Performance Standard in
mulas: Group T4-2.
NOTE: When actually measuring, install pipe (1 or
Qc = (Np × Q) ⁄ (Ne × i) 2) only to the pump to be measured.
Qc : Converted Flow Rate

Q : Measured Flow Rate
Np : Specified Pump Speed:
1803 min-1 (Main Pump 1)
1750 min-1 (Main Pump 2)
Ne : Measured Engine Speed:
Values indicated on monitor unit (service mode)
i: Pump Speed Ratio:
Main Pump 2 Side = 1.0
Main Pump 1 Side = 1.03 (32/31)
1, 2 3 4 5 6 7 8 9 10 11
Delivery Hose
(To Control Valve)
T173-04-04-002
12
13
Main Pump 2
Main Pump 1
14 T1J1-04-05-003
1- Pipe E (ST 6144) 5 - Hydraulic Tester (ST 6299) 9 - Flange (ST 6118) 12 - Port Psv
2- Pipe B (ST 6143) 6 - Adapter PF1 × UNF1-7/8 10 - Split Flange (ST 6130) 13 - Plug
(ST 6146)
3- Test Hose (ST 6145) 7 - Joint (ST 6330) 11 - Bolt (ST 6409) (4 Used) 14 - Hose (ST 6339)
4- Adapter PF1 × UNF1-7/8 8 - Test Hose (ST 6320)
(ST 6146)
T4-5-15
FAN PUMP FLOW RATE MEASUREMENT
• P-Q Control (Torque Control)

Summary:
Fan pump performance is checked by measuring 5. Disconnect the pipe from the port Pr (12). Con-
the pump flow rate by using a hydraulic tester in- nect hose (ST 6339) (14) to the disconnected
stalled at the fan pump delivery port (one side) to be pipe hole on regulator to be measured. Install
measured. Use a hydraulic tester. plug (ST 6212) to the disconnected pipe hole on
regulator not to be measured.
IMPORTANT: This measurement procedure is a 6. Remove the vacuum pump. Loosen plug (13) on
simple method. The measured data top of the pump casing. Bleed air from the casing
will be lower by approx. 5 % than until oil only comes out.
the accurately measured value. In 7. Fully open the loading valve of hydraulic tester
order to measure accurately, dis- (5).
connect the return circuit from the 8. Start the engine. Check the pressure gauge and
control valve and connect it to the hydraulic tester (5) connection for any oil leaks.
hydraulic oil tank.
Measurement:
Preparation: 1. Maintain the hydraulic oil temperature at 50±5 °C
1. Stop the engine. Push the air bleed valve and (122±41 °F).
bleed air. Connect a vacuum pump to the oil filler 2. Measure the maximum flow rate.
port. 3. Measurement conditions are below.
NOTE: Operate the vacuum pump while connect- Engine Power Mode Auto-Idle
Work Mode
ing the pump flow rate test line. Control Dial Switch Switch
2. Disconnect the delivery hose from fan pump to Digging
Fast Idle P Mode OFF
be measured. Connect pipe (1 or 2) by using the Mode
split flanges and bolts which were used for the
disconnected delivery hose. 4. Adjust the set pressure of relief valve in fan valve
: 41 mm to each pressure point specified along the fan
: 10 mm pump P-Q curve. (Refer to T4-2-6) Slowly restrict
3. Connect pipe (1 or 2) to hydraulic tester (5) by the loading valve of hydraulic tester. Measure the
using test hose (3) and adapter (4). Install flow rates and engine speeds at each pressure
adapter (6), joint (7), test hose (8) and flange (9) point specified in the P-Q curve.
to hydraulic tester (5). 5. Repeat the measurement three times and calcu-
: 41 mm late the average values.
: 10 mm
4. Connect the delivery hose to flange (9) with split
flanges (10) and bolt (11).
: 10 mm
T4-5-16
Evaluation:
1. Convert the measured flow rates to those at the 2. Standard Flow Rate
specified pump speed by using the following for- Refer to Operational Performance Standard in
mulas: Group T4-2.
Qc = (Np × Q) ⁄ (Ne × i)
Qc : Converted Flow Rate

Q: Measured Flow Rate
Np : Specified Pump Speed:1750 min-1
Ne : Measured Engine Speed:
Values indicated on monitor unit (service mode)
i: Pump Speed Ratio: 1.0 (31/31)
1, 2 3 4 5 6 7 8 9 10 11
Delivery Hose
(To Control Valve)
T173-04-04-002
Lower Side of Pump Upper Side of Pump
Fan Pump
12
13
14
T1J1-04-05-004
T1J1-04-05-003
Fan Pump
1- Pipe E (ST 6144) 5- Hydraulic Tester (ST 6299) 9 - Flange (ST 6118) 12 - Port Pr
2- Pipe B (ST 6143) 6- Adapter PF1 × UNF1-7/8 10 - Split Flange (ST 6130) 13 - Plug
(ST 6146)
3- Test Hose (ST 6145) 7 - Joint (ST 6330) 11 - Bolt (ST 6409) (4 Used) 14 - Hose (ST 6339)
4- Adapter PF1 × UNF1-7/8 8 - Test Hose (ST 6320)
(ST 6146)
T4-5-17
Adjustment of Max. Flow Rate and Min. Flow
Rate
NOTE: Illustration shows the main pump.
The flow rate is adjusted by changing the servo piston
max. stroke. Adjustment of max flow rate. Loosen nut 3 4
1 2
(2) on the large chamber side end of the servo piston
and turn adjusting screw (1). Adjustment of min. flow
rate. Loosen nut (3) on the small chamber side end of
the servo piston and turn adjusting screw (4).
NOTE: Change in Flow Rate (Reference)

Main Pump 1 Speed: 1803 min-1
Main Pump 2 Speed: 1750 min-1 T1J1-04-05-007
Fan Pump Seed: 1750 min-1

Adjusting Screw Turn 1/4
Flow Rate Change
6.9 L/min
(Main Pump 1)
Flow Rate Change
6.7 L/min
(Main Pump 2)
Flow Rate Change
2.8 L/min
(Fan Pump)
1 Adjustment of Max. Flow Rate
Flow Rate Flow Rate

Decrease Increase
W107-02-05-129
I
4
Adjustment of Min. Flow Rate
Flow Rate Flow Rate

Increase Decrease
W107-02-05-129
NOTE: I: The signal current of pump control sole-

noid valve.
T4-5-18
Adjustment of Main Pump Flow Rate Control
The flow rate control is performed by signal current (I)
of pump control solenoid valve. The flow rate control
is adjusted by changing the set-force of spring (1).
Adjustment: Loosen nut (2) and turn adjusting screw
(3).
1 2 3
T16J-04-04-006

Main Pump 1 Speed: 1803 min-1 Flow Rate Control
Main Pump 2 Speed: 1750 min-1 Q
Flow Rate Change
38.0 L/min
(Main Pump 1)
Flow Rate Change
36.9 L/min
(Main Pump 2)
3
I
NOTE: I: The signal current of pump control sole-

noid valve.
Flow Rate Flow Rate
Decrease Increase
W107-02-05-129
T4-5-19
Adjustment of fan pump flow rate control
The flow rate control is performed by signal current
(I) of pump control solenoid valve. The flow rate con-
trol is adjusted by changing the set-force of spring
(1).
Adjustment:
Loosen nut (2) and turn adjusting screw (3).
T1J1-04-05-005

Pump Speed: 1750 min-1 Flow Rate Control
Adjusting Screw Turn 1/4 Q
Flow Rate Change 6.5 L/min
Flow Rate Flow Rate

Increase Decrease NOTE: I: The signal current of pump control sole-
noid valve.
W107-02-05-129
T4-5-20
Adjustment of Torque Control (Fan Pump Regu-
lator Only) NOTE: When adjusting screw (4) is turned, inner
The torque control is performed by pump delivery spring (2) set-force varies. Therefore,
pressure P. Therefore, the torque constant control is when adjusting screw (4) is turned, turn
adjusted by changing the set-force of inner spring (2) adjusting screw (6) 2.24 times the turns of
and outer spring (1). adjusting screw (4) in the opposite direc-
(Before adjusting screws (4) and (6), mark the end of tion to keep inner spring (2) set-force un-
the adjusting screw with a white marker for the re- changed.
cord of the original position.)
When resetting inner spring (2), loosen nut (5) and
When resetting outer spring (1), loosen nut (3) and
1 2 3 4
T1J1-04-05-006
NOTE: Change in pressure when adjusting outer

spring pump speed: 1750 min-1
Q
Outer Spring Adjustment Data
Flow Rate Change 8.9 L/min
(2.4 US gal/min)
Pressure Change 1.9 MPa (19.4 kgf/cm2)
(276 psi)
Engine Torque Change 15.1 N⋅m (1.5 kgf⋅m)
(11.1 lbf⋅ft)
P
4, 6
Increase Decrease
T157-05-04-023
T4-5-21
SWING MOTOR DRAINAGE
Summary:
1. Measure amount of oil draining from the swing
motor while swinging the upperstructure and
check the swing motor performance.
2. The amount of drain oil from the swing motor will
change depending on hydraulic oil temperature.
Preparation:
1. Maintain hydraulic oil temperature at 50±5 °C
(122±41 °F). Rotate the swing motor in order to 1
warm inside of the motor.
2. Stop the engine. Push air bleed valve (1) on top A
of the hydraulic oil tank and release any remain-
ing pressure. B
: 4 mm
3. Measure the left swing motor drainage:
Disconnect drain hose (2) at part B. Connect the
test drain hose (3/4-16UN) to the motor side and
plug (ST 6637) to drain hose (2).
Measure the right swing motor drainage: 2
Disconnect right drain hose (1) at part A. Install
plug (ST 6491) on the tee side.
: 27 mm
: 93 Nxm (9.5 kgfxm, 70 lbfxft)
Machine
Front Side

starting machine operation.
Also, take care not to fall off the machine T16J-04-04-007
Preconditions for Measurement:
1. Measurement conditions are below.

Work Mode
Digging
Mode
T4-5-22
Measurement:
• Amount of Oil Drained While Swinging the
Upperstructure
1. With the bucket empty, position the front
attachment as follows:
• Backhoe:
bucket cylinder fully extended, raise the boom so The height as the
that the arm tip pin height is flush with the boom boom foot pin height.
foot pin height.
• Loading Shovel: T105-06-03-013

2. Start the engine. Operate and hold the swing
lever full stroke. Start draining oil measurement The height as the
after the swing speed eaches a constant boom foot pin height.
maximum speed. The measuring time should be TBAR-04-04-001
more than 20 seconds.

3. Repeat the measurement three times in both
clockwise and counterclockwise directions, and
calculate the average values.
• Amount of Oil Drained While Relieving Swing Motor
Circuit
1. Thrust the bucket teeth into the ground as
illustrated so that the upperstructure does not
rotate when the swing lever is operated full
stroke.
2. Start the engine. Operate and hold the swing
lever full stroke. Start drain oil measurement
when drain oil starts coming out of the drain
hose end. The measuring time should be more
than 20 seconds.
3. Repeat the measurement three times in both
clockwise and counterclockwise directions, and
calculate the average values.
NOTE: Because the left swing motor drain hose is
connected to the right swing motor drain
port, the total of the left and right swing
motor drainage will be measured when
measuring the right swing motor drainage
according to step 4 in Preparation. For this
reason, be sure to deduct the amount of
left swing motor oil drainage (step 3 in
Preparation) from that total amount.
Evaluation: T107-06-05-008
Refer to the Oprational Performance Standard in

Group T4-2. ΔQ = 60 × q / t
∗ Conversion of the amount of drain oil measured Where:
into the per-minute value ΔQ : Amount of drain oil per minute (L/min)
First measure the amount of drain oil by using a t : Measured time (seconds)
calibrated container. Then, convert the measured q : Total amount of drain oil (L)
drain oil into the per-minute value by using the
formula below:
T4-5-23
TRAVEL MOTOR DRAINAGE
Summary:
1. While rotating the travel motor with the track to
be measured jacked up, measure amount of oil
draining from the travel motor and check travel
motor performance.
2. During measuring check in order to prevent per-
sonal injury.
3. Judge travel motor performance from the results Drain Hose
including travel speed, mistrack and so on over-
all.
4. The amount of drain oil from the travel motor will
change depending on hydraulic oil temperature.
Preparation:
1. Main hydraulic oil temperature at 50±5 °C
(122±41 °F). Rotate the travel motor and warm
inside of the motor.
2. Stop the engine. Push air bleed valve on top of
the hydraulic oil tank and release any remaining
M183-01-001
pressure.
3. Disconnect the drain hose in the travel motor at
the travel motor end. Install plug (ST 6637) to the
disconnected end. Connect test drain hose
(3/4-16UN) to the travel motor.
: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 70 lbf⋅ft) Test Drain Hose
Preconditions for Measurement:

Work Mode
Digging
Mode
T157-05-04-019
Drain Hose
ST 6637
T183-04-04-011
T4-5-24
Measurement:
CAUTION: When working around moving

parts is unavoidable, pay special attention to
ensure that hands, feet, and clothing do not
become entangled. Securely support the
raised track by using the blocks.
1. Start the engine. Jack up the track to be meas-

ured.
2. Rotate the track to be measured. Start drain oil
90° to 110°
measurement when drain oil starts coming out of
the drain hose end.
3. Repeat the measurement at least three times in
both forward and reverse directions, and calcu-
late the average values. M104-07-067
4. The measuring time should be more than 20

seconds.
Evaluation:
Refer to the Operational Performance Standard in 90° to 110°
Group T4-2.
∗ Conversion of the amount of drain oil measured

into the paramount value T1J1-04-04-001
First measure the amount of drain oil using a

calibrated container. Then, convert the measured
drain oil into the paramount value using the
formula below:
ΔQ = 60 × q / t
Where:
ΔQ : Amount of drain oil per minute (L/min)
t : Time measured (seconds)
q : Total amount of drain oil (L)
T157-05-04-019
T4-5-25
(Blank)
T4-5-26
MEMO
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SECTION 5
TROUBLESHOOTING
CONTENTS
Group 1 Diagnosing Procedure Group 6 Troubleshooting A
Introduction .............................................. T5-1-1 Troubleshooting A Procedure .................... T5-6-1
Diagnosing Procedure .............................. T5-1-2 MC Fault Code List ................................... T5-6-2
ECM Fault Code List............................... T5-6-22
Group 2 Monitor Unit
ICF Fault Code List ................................. T5-6-34
Outline ...................................................... T5-2-1
Monitor Unit Fault Code List ................... T5-6-36
How to Use Screens ............................... T5-2-10
MC Fault Code 11000 to 11002............... T5-6-37
Screen Display
MC Fault Code 11003 ............................. T5-6-38
When An Alarm is Issued ...................... T5-2-18
MC Fault Code 11004 ............................. T5-6-39
Contents of Alarms ................................. T5-2-20
CAN Harness Check ............................... T5-6-40
Troubleshooting...................................... T5-2-22
MC Fault Code 11101 ............................. T5-6-60
Controller Version ................................... T5-2-24
MC Fault Code 11200 ............................. T5-6-61
Monitoring .............................................. T5-2-26
MC Fault Code 11202 ............................. T5-6-62
Displaying Operating Conditions ............ T5-2-29
MC Fault Code 11301 ............................. T5-6-63
Pump 2 Flow Rate Adjustment................ T5-2-30
MC Fault Code 11302 ............................. T5-6-64
Attachment Selection.............................. T5-2-32
MC Fault Code 11303 ............................. T5-6-65
Time Set ................................................. T5-2-35
MC Fault Code 11400 ............................. T5-6-66
Fuel Rate Display/No Display ................. T5-2-36
MC Fault Code 11402 ............................. T5-6-67
Back Monitor Settings............................. T5-2-40
MC Fault Code 11404 ............................. T5-6-68
Maintenance Settings ............................. T5-2-47
MC Fault Code 11405 ............................. T5-6-69
Language Settings.................................. T5-2-52
MC Fault Code 11410 ............................. T5-6-70
Group 5 Component Layout MC Fault Code 11412 ............................. T5-6-71
Main Component Layout........................... T5-5-1 MC Fault Code 11802 ............................. T5-6-72
Electrical Component Layout.................... T5-5-3 MC Fault Code 11901 ............................. T5-6-73
Engine ...................................................... T5-5-9 MC Fault Codes 11910, 11911, 11914,
Pump Device .......................................... T5-5-10 11918, 11920, 11983, 11984 ................. T5-6-75
Swing Device.......................................... T5-5-10 MC Fault Codes 11910, 11911, 11914,
Travel Device.......................................... T5-5-10 11918, 11920, 11983, 11984
Control Valve ...........................................T5-5-11 CAN Harness Check ............................. T5-6-76
Components in Control Valve ................. T5-5-12 MC Fault Code 11989 ............................. T5-6-79
Pilot Port................................................. T5-5-22 MC Fault Code 11991 ............................. T5-6-80
MC Fault Code 11992 ............................. T5-6-81
MC Fault Code 11993 ............................. T5-6-82
MC Fault Code 11994 ............................. T5-6-83
1J1T-5-1
MC Fault Code 11995............................. T5-6-84 Continuity Check....................................... T5-8-8
MC Fault Code 11997............................. T5-6-85 Voltage and Current Measurement ......... T5-8-10
MC Fault Code 11998............................. T5-6-86 Check by False Signal ............................ T5-8-17
MC Fault Code 11999............................. T5-6-87 Test Harness........................................... T5-8-18
ICF Fault Codes 14000 to 14003............ T5-6-89
ICF Fault Codes 14006, 14008............... T5-6-93
Monitor Unit Fault Code 13303 ............... T5-6-95
Monitor Unit Fault Codes
13306, 13308........................................ T5-6-97
Pilot Shut-Off Lever Alarm .....................T5-6-100
Group 7 Troubleshooting B
Troubleshooting B Procedure ................... T5-7-1
Relationship between Machine Trouble
Symptoms and Related Parts ................. T5-7-2
Correlation between Trouble
Symptoms and Part Failures................. T5-7-20
Engine System Troubleshooting ............. T5-7-36
All Actuator System Troubleshooting ...... T5-7-54
Front Attachment System
Troubleshooting .................................... T5-7-64
Swing System Troubleshooting............... T5-7-74
Travel System Troubleshooting .............. T5-7-77
Other System Troubleshooting ............... T5-7-82
Work After Replacing Components ........T5-7-108
Charge Air Conditioner
with Refrigerant ...................................T5-7-109
Exchange Inspection .............................T5-7-118

Precautions for Inspection and
Maintenance ........................................... T5-8-1
Instructions for Disconnecting
Connectors ............................................. T5-8-3
Fuse Inspection ........................................ T5-8-4
Fusible Link Inspection
and Replacement.................................... T5-8-6
Battery Voltage Check .............................. T5-8-6
How to Troubleshooting
Alternator Malfunctions ........................... T5-8-7
1J1T-5-2
TROUBLESHOOTING / Diagnosing Procedure
INTRODUCTION
Refer to the inspection and troubleshooting proce-

dures after any machine trouble has occurred. The
inspection and troubleshooting procedures are pre-
sented in an orderly fashion in this section to quickly
find the cause of the machine trouble and solution.
The troubleshooting section in this manual consists of

6 groups; Diagnosing Procedure, Monitor Unit, Com-
ponent Layout, Troubleshooting A (base machine di-
agnosis by using fault codes), Troubleshooting B
(base machine diagnosis starting with inspection of
abnormal operational status) and Electrical System
Inspection.
• Diagnosing Procedure • Troubleshooting A (base machine diagnosis by

using fault codes)
• Monitor Unit Refer to these procedures if any fault codes are
Refer to this group as for the display screen and displayed when each controller (MC, ECM, ICF
operating procedures of monitor unit. and monitor unit) is diagnosed by using service
menu of monitor unit.
• Component Layout
IMPORTANT: ICF receives and retains a record of
the electrical signal system mal-
function of each controller in the
form of fault codes by using CAN
communication. In addition, ICF
self-diagnosing function records the
electrical signal system malfunction
in the form of fault codes
Ex.) Fault Code 11004-2: Failure of CAN Com-
munication
• Troubleshooting B (base machine diagnosis

starting with inspection of abnormal operational
status)
Refer to these procedures when no fault codes
are displayed after diagnosing the machine with
service menu of monitor unit.
Ex.) Although the engine control dial is turned,
engine speed does not change.
• Electrical System Inspection

Refer to this group when required to obtain pre-
cautions and/or information for the electrical sys-
tem inspection.
Ex.) Fuse Check
T5-1-1
DIAGNOSING PROCEDURE
These six basic steps are essential for efficient

troubleshooting:
1. Study the System

Study the machine’s technical manuals. Know the
system and how it works, and what the
construction, functions and specifications of the
system components are.
2. Ask the operator

Before inspecting, get the full story of
malfunctions from the operator below.
T107-07-01-001
(a) How is the machine being used? (Find out if

the machine is being operated correctly)
(b) When was the trouble noticed, and what

types of work the machine doing at that
time?
(c) What are the details of the trouble? Is the

trouble getting worse, or did it appear
suddenly for the first time?
(d) Did the machine have any other troubles

previously? If so, which parts were repaired
before?
3. Inspect the machine

Before starting the troubleshooting procedure, T107-07-01-002
check the machine’s daily maintenance points, as
shown in the operator's manual.
Also, check the electrical system, including the

batteries, as troubles in the electrical system
such as low battery voltage, loose connections
and blown fuses will result in malfunction of the
controllers, causing total operational failure of the
machine.
If troubleshooting is started without checking for
blown fuses, a wrong diagnosis may result,
wasting time. Check for blown fuses before
troubleshooting. Even if a fuse looks normal by
visual inspection, a fine crack is difficult to find.
Always use a tester when checking the fuses.
T107-07-01-003
T5-1-2
4. Operate the machine yourself

Try to identify the trouble by operating the
machine yourself.
If the trouble cannot be confirmed, stop the
engine and obtain further details of the
malfunction from the operator.
Also, check for any incomplete connections of
the wire harnesses correponding to the trouble.
T5-1-3
5. Perform troubleshooting
CAUTION: Do not disconnect harnesses or

hydraulic lines while the engine is running.
The machine may malfunction or pressurized
oil may spout, possibly resulting in personal
injury. Stop the engine before disconnecting
harnesses or hydraulic lines.
Perform diagnosis by using the service menu of

monitor unit. In case any fault code has been dis-
played by diagnosis by using service menu of
monitor unit, check the cause of the trouble by T107-07-01-007
referring to Troubleshooting A in this section. In

case any fault code has been displayed by diag-
nosis by using service menu of monitor unit, write
the fault code. Delete the fault code once and re-
try self-diagnosis again. If the fault code is dis-
played again, check the cause of the trouble by
referring to Troubleshooting A in this section.
In case the fault code is not displayed, check

operating condition of each component by refer-
ring to Troubleshooting B in this section and by
using service menu of monitor unit.
NOTE: Note that the fault codes displayed do not

necessarily indicate machine trouble. The
controller stores even temporary electrical
malfunctions, such as a drop in battery
output voltage or disconnections of the
switches, sensors, etc., for inspections.
For this reason, the “RETRIAL” is required
to erase the accumulated fault codes from
the controller memory and to confirm if any
fault codes are indicated after the
“RETRIAL”.
IMPORTANT: “RETRIAL” or “RETRY” means once

turned off the key switch then check
the fault code again with using the
monitor unit (Refer to page T5-2-22)
T5-1-4
6. Trace possible causes

Before reaching a conclusion, check the most
likely causes again. Try to identify the actual
cause of the trouble.
Based on your conclusion, make a plan for
appropriate repairs to avoid consequent
malfunctions.
T5-1-5
(Blank)
T5-1-6
TROUBLESHOOTING / Monitor Unit
OUTLINE
Primary Screen
1 2 3 4 5 6 7 8
22 10
12
13
14
15
21 20 19 17 16
T1J1-02-01-003
1 - Work Mode Display 6 - Glow Display 12 - Auto Lubrication Display 17 - Auxiliary Selection
(Optional)
2 - Auto-Idle Display 7 - Work Mode Display 13 - Fuel Consumption Gauge 19 - Auxiliary Selection
3 - Overload Alarm Display 8 - Hour Meter 14 - Clock 20 - Work Mode Selection
(Optional)
4 - Auto Lubrication Display 9 - Auxiliary 15 - Back-Screen Selection 21 - Return to Primary Screen
(Optional)
5 - Auxiliary 10 - Fuel Gauge 16 - Menu 22 - Coolant Temperature
Gauge
T5-2-1
• Display of Meters
Work Mode 2
Data to be displayed on each meter are received
from other controllers (MC, ICF and ECM) by using
CAN, and are displayed on the monitor unit.
1 3
• Work Mode Display
The attachments being used are displayed accord-
ing to the signals received from MC by using CAN.
Digging Mode 4
T1V1-05-01-108
Attachment Mode
Breaker
M1J1-01-003
M1J1-01-004 1 - Coolant Temperature 3 - Fuel Gauge

2 - Hour Meter 4 - Clock
T5-2-2
• Auto-Idle Display (1)
When turning the auto-idle switch ON in the switch
panel, the monitor displays the auto-idle. 1 2 3 4
When the key is turned ON with the auto-idle switch
ON, auto-idle display (1) blinks for 10 seconds.
• Overload Alarm Display (2) (Optional)

MC detects suspended load according to the signal
from the bottom pressure sensor in boom cylinder. 5
signal received from MC by using CAN bus line.
(Refer to T2-1-34.) (Refer to the Control System
group / SYSTEM.)
• Auto Lubrication Display (3) (Optional)

When the auto lubrication switch (optional) is turned M1J1-01-003
ON, the auto lubrication is displayed according to the

• Glow Display (4)

While ECM is supplying current to the glow plug, the
data is displayed according to the signal from ECM.
(Refer to the ECM System group / SYSTEM.)
• Fuel Consumption Gauge Display (5)

Fuel consumption is displayed according to the sig-
nal from ECM, which is received through MC by us-
ing CAN.
T5-2-3
• Fuel Sensor Error Display Coolant Temperature Fuel Sensor Error
When the fuel sensor is faulty or if the harness be- Sensor Error Display Display
tween fuel sensor and monitor unit is broken, the
data is displayed on the fuel gauge.
• Coolant Temperature Sensor Error Display

When the coolant temperature sensor is faulty or if
the harness between coolant temperature sensor
and monitor unit is broken, the data is displayed on
the coolant temperature gauge.
• Alarm and Remedy Displays against Alarm M1J1-01-010
Alarm marks are displayed on the lower part of

screen according to the alarm signals received from
each controller by using CAN. The remedy for each
alarm is displayed by key operation.
Alarm Display M1J1-01-008
Remedy Display against Alarm T1V5-05-01-013
T5-2-4
• Troubleshooting
This screen displays fault codes according to the
signals received from ICF by using CAN.
Fault Code Display T1V5-05-01-097
• Controller Version
This screen displays the version of controller.
• Monitoring Controller Version Display T1V5-05-01-122
This screen displays temperature and pressure data

received from each controller by using CAN.
By key operation, the displayed data is hold.
T1V5-05-01-087
Monitoring Screen
• Operating Conditions
This screen displays machine hour, fuel usage and
fuel consumption rate registered by the monitor unit.
Operating Condition Screen T1V5-05-01-025
T5-2-5
• Pump 2 Flow Rate Adjustment
When using the attachments, fine adjust flow rate of
pump 2 by keys 1 and 2 operation.
(Adjusting range: -50 to 50 L/min)
The signals from the monitoring unit are sent to MC
by using CAN.
MC adjusts flow rate of pump 2 while controlling
pump 2 control solenoid valve. (Refer to Attachment
Mode Control in the Control Systems group / SYS-
TEM.) Key 1
Key 2
• Attachment Selection
When using Breaker 1
(Only machines equipped with optional parts) M1J5-01-014
On this screen, select digging mode and attachment

mode.
NOTE: In attachment mode, the following four

modes are set at the time of shipping from
the factory.
1 - Digging
2 - Breaker 1
3 - Breaker 2
4 - Breaker 3
1 2 3 4 M1J5-05-003
Attachment Selection Screen
T5-2-6
• Back Monitor Settings
By key operation, image display ON and OFF of
Auto-Control for switching image of the back monitor
while traveling pilot time and display format on the
screen of the rear view camera can be set.
IMPORTANT: the rear view camera is set in mirror

image mode. Therefore, if image
display is set as mirror image, nor-
mal image is displayed on the screen
of monitor unit.
If image display is set as normal
image, mirror image is displayed on
the screen of monitor unit.
T1V5-05-01-134
Back Monitor Setting Screen
T1V1-05-01-126
Normal Image Screen
T1V1-05-01-127
Mirror Image Screen
T5-2-7
• Maintenance Settings
This screen displays the hour meter reading at re-
placement time and the remaining hours until the
next replacement.
As the items to be replaced are displayed in a list,
record performed replacement by selecting an item
from the list.
• Interval ON/OFF Settings

Set change interval for each item to be replaced.
• Items included in Maintenance Settings

Engine Oil
Engine Oil Filter
Maintenance Setting Screen T1V5-05-01-049
Hydraulic Oil
Hydraulic Oil Pilot Filter
Hydraulic Oil Full-Flow Filter
Travel Device Oil
Swing Device Oil
Swing Bearing Grease
Air Cleaner Filter
Engine/Air Conditioner V-belt
Fuel Filter
Air Conditioner Filter
Interval ON/OFF Setting Screen T1V5-05-01-052
• Language Settings
Select a language to be used in screens from among
preset languages, according to work environment.
Language Setting Screen T1V1-05-01-137
T5-2-8
• Overload Alarm Alarm
MC detects suspended load according to the signal

from the bottom pressure sensor in boom cylinder.
If overload of the suspended load is dissolved, the
alarm message disappears and the buzzer stops ring-
ing. (Refer to the Control System group / SYSTEM.)
NOTE: Even if the work is done while displaying a

screen except the primary screen, when an
overload condition is reached, the screen of
T1V1-05-01-128
monitor unit is switched to the primary Primary Screen
screen, an alarm message is displayed,
and a buzzer is rung. Overload Alarm Switch (Optional)
Even after the overload alarm is dissolved,
the monitor unit keeps on displaying the
primary screen without returning to the
screen while the work is done.
M1J1-03-001
T5-2-9
HOW TO USE SCREENS
Displaying Primary Screen
IMPORTANT: Start the engine after the primary

screen is displayed.
When the key switch is turned to the ON position, the

starting screen appears for about two seconds and the
primary screen appears.
Key Switch: ON T1V1-05-01-115
Primary Screen T1V1-05-03-001
IMPORTANT: After the engine starts and the al-

ternator starts generating power, al-
ternator alarm is displayed on the
primary screen.
Alternator Alarm
M1J1-03-005
T5-2-10
Displaying Primary Screen by Password Input
(Optional)
1. When the key switch is turned to the ON position,

the starting screen appears and the password
input screen appears.
Starting Screen T1V1-05-01-115
T1V5-05-01-093
Password Input Screen
2. Input a password by using the keys located under

the screen. If pushing the confirm key, the monitor
unit matches the input password to the registered
one. If they match, the primary screen appears.
NOTE: When inputting the password again, the

entered characters can be erased by
pushing the erase key.
T1V5-05-01-002
Confirm Key Erase Key
T5-2-11
In Case of Inputting an Incorrect Password
1. If inputting an incorrect password, the message

"password is incorrect." appears by pushing the
confirm key.
T1V5-05-01-093
Password Input Screen
T1V5-05-01-002
2. Return to the password input screen, by pushing

the back key.
NOTE: When inputting the password again, the

entered characters can be erased by
pushing the erase key.
T1V5-05-01-004
Back Key
T1V5-05-01-093
T5-2-12
3. If inputting an incorrect password three times, a
screen appears informing that the security lock
has been applied, and a buzzer rings for thirty
seconds. During that time, the buzzer does not
stop ringing even if turning of the key switch
ON/OFF.
T1V5-05-01-005
Security Lock Screen
4. After thirty seconds, if the key switch is turned to

the ON position, the starting screen appears and
the password input screen appears again. Then a
password can be input again. If inputting an in-
correct password even once this time, the security
lock screen appears again and a buzzer rings for
thirty seconds. The buzzer does not stop ringing
for thirty seconds even if turning the key switch
ON/OFF.
Starting Screen T1V1-05-01-115
5. After the buzzer stops ringing, a password can be

input again. Turn the key switch to the ON position
and input a password after the password input
screen appears. (Refer to T5-2-11).
6. If inputting an incorrect password again, the secu-

rity lock screen appears again. The buzzer does
not stop ringing for thirty seconds even if turning
the key switch ON/OFF.
Password Input Screen T1V5-05-01-093
T5-2-13
Extending Password Duration Time
IMPORTANT: This operation is applicable only to

those machines that display the
primary screen based upon pass-
word input.
By using the password duration screen, password du-

ration time can be set. When you restarting the ma-
chine, a password need not be input within that time-
frame.
1. When turn the key switch to the OFF position,
the monitor unit displays the password duration Key 1 Key 2 Key 3 Key 4 Key 5 T1V1-05-01-012
screen for ten seconds.

Password Duration Screen (Key Switch: OFF)
2. While the password duration screen is still dis-

played, push a relevant key, and password dura-
tion time is set. Duration time assigned to each
key is as follows:
key 1: 0 minute
key 2: 30 minutes
key 3: 60 minutes
key 4: 90 minutes
key 5: 120 minutes
NOTE: If password duration time is not set ex-

plicitly, 0 minute on duration time is as-
Key Switch: ON T1V1-05-01-115
sumed.
3. If turning the key switch to the ON position within

password duration time, the monitor unit displays
the primary screen after the starting screen.
T5-2-14
Password Change (Optional)
1. After the primary screen is displayed, push the

menu key in order to display the main menu.
Menu Key
2. Select password change from main menu by us-

ing keys1 and 2. Push the confirm key. Then, the
password change screen appears.
T1V5-05-01-129
Key 1 Key 2 Confirm Key
T1V5-05-01-041
Registered Password
3. Input the registered password and push the con-
firm key.
4. If inputting the password again, the entered

characters can be erased. By pushing the erase
key.
T1V5-05-01-042
T5-2-15
NOTE: If inputting an incorrect password after

pushing the confirm key, the message
"Password is incorrect." appears.
Push the back key and go back to the pre-
vious screen, Input the password again.
T1V5-05-01-044
Back Key
5. The message "Enter password to be registered."

appears. Then, input a new password with three
or four digits and push the confirm key.
T1V5-05-01-130
A New Password
6. If inputting the password again, push the erase

key.
T1V5-05-01-131
T5-2-16
7. The message "Re-enter password." appears.
Then, input a new password again and push the
confirm key.
8. If inputting the password again, push the erase

key in order to erase the entered characters.
T1V5-05-01-132
Confirm Key Erase Key T1V5-05-01-133
9. The message "New password has been regis-

tered." appears. This completes the password
change process.
T1V5-05-01-043
Key 6
10. Push key 6 and the primary screen appears.
T5-2-17
SCREEN DISPLAY WHEN AN ALARM IS
ISSUED
When an alarm is issued, the alarm marks are dis-

played at the bottom of screen.
• When the number of alarms is two or less
M1J1-01-007
• When the number of alarms is three or more
M1J1-01-008
T5-2-18
When an alarm is issued, if the key under a relevant
alarm mark is pushed, the remedy against the alarm is
displayed.
Push a Relevant Key M1J1-01-007
T1V5-05-01-013
IMPORTANT: When the engine warning alarm
blinks and the key under the alarm
mark is pushed, the remedy for
alarm is not displayed.
Drain water from the fuel tank.
Blink
M1J1-01-009
T5-2-19
CONTENTS OF ALARMS
Display Contents of Alarms Remedy

Overheat Alarm Temperature of engine coolant is going up abnormally higher.
Stop the work and turn the engine into low idle in order to lower
the coolant temperature.
M178-01-036
Engine Warning Alarm Failure of the engine or its related parts.

Please contact our authorized distributor or dealer.
M183-01-080
Engine Oil Pressure Alarm Pressure of engine lubricant oil is decreasing.

Stop the engine immediately and inspect the hydraulic system
and oil volume of the engine.
M178-01-037
Alternator Alarm Fault in the electronic system.

Inspect the alternator and battery system.
M183-01-071
Remaining Fuel Alarm Volume of remaining oil is becoming less.

Refuel oil earlier.
M178-01-034
Auto-Lubrication Alarm Fault in the auto-lubrication system.

T1J1-05-01-005
Air Filter Clogged Alarm The air filter is clogged.

Clean or replace the air filter.
M183-01-067
Work Mode Alarm Fault in the network system.

T1V1-05-01-102
Pilot Shut-Off Lever Alarm Fault in the pilot shut-off lever system.
T1V1-05-01-103
T5-2-20
(Blank)
T5-2-21
TROUBLESHOOTING
1. Displaying service menu

Turn the key switch to the ON position while
pushing the key at upper right corner of the
monitor unit. Therefore, service menu is added to
main menu.
T1V1-05-01-115
Turn key switch ON while pushing the key
2. When the primary screen appears, push the menu

key and display main menu.
Menu Key
3. Select service menu from main menu by using

keys 1 and 2. Push the confirm key. Then, the
service menu screen appears.
NOTE: When pushing the back key, return to the

previous screen.
T1V5-05-01-114
Key 1 Key 2 Confirm Key Back Key
Back Key T1V5-05-01-083
T5-2-22
4. Select troubleshooting by using keys 1 and 2.
Push the confirm key. Then, the troubleshooting
screen appears.
5. Results of trouble analyses for each controller are

displayed on the screen.
6. Select abnormal of a faulty controller by using

keys 1 and 2. Push the confirm key. Then, failure
code screen appears.
For details of trouble analyses, refer to "Trouble-
shooting A."
Key 1 Key 2 Confirm Key Back Key T1V5-05-01-083
IMPORTANT: Up to twenty failure codes can be
displayed. But, one screen can con- A figure enclosed in ( ) indicates the number of failure codes.
tain only ten failure codes maximum.
If the screen is fully filled with ten
items, push key 1 and check other
failure codes on the next page.
When returning to the previous page,
push key 2.

previous screen.
7. Push key 6, and the primary screen appears.
Key 1 Key 6 Key 2 Back Key T1V5-05-01-097
T5-2-23
CONTROLLER VERSION
1. Displaying Service Menu

pushing the key at upper right of the monitor unit.
Therefore, service menu is added to main menu.
T1V1-05-01-115
Turn the key switch ON while pushing the key
2. When primary screen appeared, push menu key
to display main menu.
Menu Key

NOTE: When pushing the back key, return back to

the previous screen.
T1V5-05-01-114
Back Key T1V5-05-01-083
T5-2-24
4. Select controller version by using keys 1 and 2.
Push the confirm key. Then, the controller version
screen appears.
NOTE: The version of ECM is not displayed.

previous screen.
T1V5-05-01-083
T1V5-05-01-122
Key 6 Back Key
T5-2-25
MONITORING
1. Displaying Service menu

pushing the key at upper right of the monitor unit.
Therefore, the service menu is added to main
menu.
T1V1-05-01-115
Turn the key switch ON while pushing the key
2. When the primary screen appeared, push the

menu key and display main menu.
Menu Key


previous screen.
T1V5-05-01-114
Back Key T1V5-05-01-083
T5-2-26
4. Select monitoring by using keys 1 and 2. Push the
confirm key. Then, the monitoring screen appears.
For items to be monitored, refer to the next sec-
tion.
T1V5-05-01-083
5. Select an item to be monitored by using keys 1
and 2. Push the confirm key. Then, the selected
item is brought up to the top.
6. Push key 3, and the displayed data are put on

hold.
Push key 3 again, and the records are updated
with the displayed data.
7. The monitoring item order is reset to the initial

state by pushing key 4.
When key 4 is pushed and a confirmation mes- Back Key
sage appears, push the confirm key.
T1V5-05-01-087
Key 1 Key 2 Key 3 Key 4 Confirm Key

previous screen.
Back Key
T1V5-05-01-088
Key 6 Confirm Key
T5-2-27
A List of Items to be Monitored
Items Units Remarks

Engine Torque %
Coolant Temperature (E) °C
Fuel Temperature °C
Engine Oil Pressure kPa
Atmospheric Pressure kPa
Intake Air Temperature °C
Boost Pressure kPa
Boost Temperature °C
Coolant Temperature (M) °C
Target Engine Speed min-1
Actual Engine Speed min-1
Pump 1 Delivery Pressure MPa
Pump 1 Pump Control Pressure MPa
Pump 1 Target Flow Rate L/min
Pump 2 Delivery Pressure MPa
Pump 2 Pump Control Pressure MPa
Pump 2 Target Flow Rate L/min
Front Pilot Pressure MPa
Boom Raise Pilot Pressure MPa
Arm Roll-In Pilot Pressure MPa
Swing Pilot Pressure MPa
Travel Pilot Pressure MPa
Att. Control Pilot Pressure MPa
EC Dial Angle V
Hydraulic Oil Temperature °C
Pump Torque Proportional Valve MPa
Digging Regeneration Valve MPa Pump 1 Regulator Pressure
Arm Regeneration Valve MPa Pump 2 Regulator Pressure
Travel Motor Control Pressure MPa
Power Boost Control Pressure MPa
Power Mode -
Travel Mode Switch -
Power Digging Switch -
Radio Signal Strength -
T5-2-28
DISPLAYING OPERATING CONDITIONS

Menu Key
2. Select operating conditions from main menu by

using keys 1 and 2. Push the confirm key. Then,
the operating conditions screen appears.
T1V5-05-01-019
3. Push the reset key, and a screen appears to con-

firm if it's OK to reset data.
If it’s OK to reset data, push the confirm key.

previous screen.
IMPORTANT: Total fuel consumption and fuel

consumption rate depend on the
operating environment and the op-
eration method of machine.
The values shown on the screen are
just for reference. Reset Key Back Key T1V5-05-01-025
There could arise ± 20% of differ-

ences between actual fuel consump-
tion and fuel consumption which is
displayed by the monitor unit.
Back Key
T1V5-05-01-026
Key 6 Confirm Key
T5-2-29
PUMP 2 FLOW RATE ADJUSTMENT
(Only Machines Equipped with Optional
Parts)
IMPORTANT: This operation is effective when at-

tachments are used.

2. Select attachment adjustment from main menu by

using keys 1 and 2. Push confirm key. Then, the Menu Key
attachment adjustment screen appears.
3. Push key 2. Then, the attachment adjustment

screen for currently installed attachments ap-
pears.
T1V5-05-01-019
4. Adjust flow rate of pump 2 by using keys 1 and 2.

When using breaker 1, breaker 2 or breaker 3,
pushing key 1 will decrease flow rate of pump 2
and pushing key 2 will increase respectively.

previous screen.
M1J5-01-014
Key 1 Key 2 Back Key
T5-2-30
(Blank)
T5-2-31
ATTACHMENT SELECTION
(Only Machines Equipped with Optional
Parts)
IMPORTANT: Select the attachments from the

work mode screen.
In order to display the work mode
screen, push key F1 after primary
screen appears, or select from main
menu.
Selecting an Attachment by Using Key F1
1. When the primary screen appears, push key F1 Key F1

Primary Screen M1J1-01-002
and display the work mode screen.
2. Push a relevant key under an attachment mark to

be used in order to select the attachment.
(In the right example, Breaker 1 is selected.)
NOTE: When selecting Digging, return to the pri-

mary screen.
3. On the attachment specification screen, confirm if

specification of the installed attachment agrees
with that displayed on the screen. Digging
Back Key
Breaker 1
previous screen. Work Mode Screen M1J5-05-003
4. Push confirm the key, and the primary screen

appears.
Confirm
Key
Attachment Specification Screen M1J5-01-011
T5-2-32
Selecting an Attachment from Main Menu

Menu Key
2. Select work mode from main menu by using keys

1 and 2. Push confirm key. Then, the work mode
screen appears.
Back Key
T1V5-05-01-019
3. Push the relevant key under an attachment mark

to be used in order to select the attachment.
(In the right example, Breaker 1 is selected.)
NOTE: When selecting digging, return to main

menu.
4. On the attachment specification screen, confirm if

specification of the installed attachment agrees
with that displayed on the screen.
Digging
For details of the attachment specification screen,
refer to T5-2-38 and 39. Back Key
Breaker 1
Work Mode Screen M1J5-05-003

previous screen.
5. Push the confirm key, and the primary screen

appears.
Confirm
Key
Attachment Specification Screen M1J5-01-011
T5-2-33
Attachment Specification Screen
Maximum Pump 2 Flow Rate
Maximum Engine Speed
Flow Combining Switching Valve: OFF
M1J5-01-011
M1J5-01-012
M1J5-01-013
T5-2-34
TIME SET

Menu Key
Primary Screen
T1V1-05-03-001
2. Select time set from main menu by using keys 1
and 2. Push the confirm key. Then, the time set
screen appears.
Back Key
T1V5-05-01-019
3. On the time set screen, select the items to be set

(Year, Month, Day and Time) by using keys 1 and
2, and set the figures by using keys 3 and 4.
Move the
4. By using key 2, move the item to . Push the item to
this icon
confirm key. Then, system time is updated with
the values you specified on the screen.

previous screen.
Back Key
5. Push key 6, and return to the primary screen.
T1V5-05-01-021
Key 1 Key 2 Key 3 Key 4 Confirm Key
Back Key
Key 6 T1V5-05-01-022
T5-2-35
FUEL RATE DISPLAY/NO DISPLAY
Fuel Rate Display

Menu Key
2. Select fuel rate display/no display from main

menu by using keys 1 and 2. Push the confirm key.
Then, the fuel rate display/no display screen ap-
pears.
T1V5-05-01-118
3. Push the confirm key, and fuel rate display will be

set to ON.

previous screen.
Back Key
T1V5-05-01-164
Confirm Key
Back Key
T1V5-05-01-119
T5-2-36
4. Push key 6, and the fuel gauge will be added to
primary screen.
Key 6 T1V5-05-01-119
T1V1-05-03-001
Fuel Gauge
T5-2-37
Fuel Rate No Display

Fuel Gauge
Menu Key
2. Select fuel rate display/no display from main

menu by using keys 1 and 2. Push the confirm key.
Then, the fuel rate display/no display screen ap-
pears.
3. Push the confirm key, and fuel rate display will be

set to OFF.

previous screen.
Back Key
Confirm Key T1V5-05-01-119
Back Key
T1V5-05-01-164
T5-2-38
Key 6
T1V5-05-01-164
T5-2-39
BACK MONITOR SETTINGS
IMPORTANT: Image displayed on the back monitor

is of auxiliary nature at best. When
the machine is operated pay thor-
ough attention to surrounding situa-
tion.
Auto-Control: ON
Image on the monitor unit when traveling is automati-

cally switched to that of the back monitor.
Menu Key
1. When the primary screen appears, push the menu Primary Screen T1V1-05-03-001
2. Select back monitor settings from main menu by

the back monitor settings screen appears.
Back Key
T1V5-05-01-114
3. Select auto-control by using keys 1 and 2. Push

the confirm key. Then, auto-control is set to ON.

primary screen.
5. If travel operation is done, backward image is

displayed on the screen of monitor unit.
Back Key
Key 1 Key 2 Confirm Key T1V5-05-01-134
Back Key
Key 6
T1V5-05-01-120
T5-2-40
Auto-Control: OFF
Set automatic switching function of images between

monitor unit and back monitor when traveling to OFF.

Menu Key

T1V5-05-01-118
3. Select auto-control by using keys 1 and 2. Push

the confirm key. Then, auto-control is set to OFF.

previous screen.
T1V5-05-01-120
Back Key
Key 6 T1V5-05-01-134
T5-2-41
Switching Image Display
• From mirror image to normal image

Menu Key

Back Key
T1V5-05-01-114
3. Select mirror image by using keys 1 and 2. Push

the confirm key. Then, the setting is switched to
normal image.

previous screen.
Back Key
Key 1 Key 2 Confirm Key T1V5-05-01-120
Back Key
T1V5-05-01-120
T5-2-42
4. Push the back monitor switching key, and normal
image is displayed on the screen.
Back Monitor Switching Key T1V5-05-01-120
T1V1-05-01-126
Normal Image
T5-2-43
• From normal image to mirror image
Menu Key

T1V5-05-01-114
3. Select normal image by using keys 1 and 2. Push

the confirm key. Then, the setting is switched to
mirror image.

previous screen.
T1V5-05-01-120
T1V5-05-01-135
T5-2-44
4. Push the back monitor switching key, and mirror
image is displayed on the screen.
T1V5-05-01-135
Back Monitor Switching Key
T1V1-05-01-127
Mirror Image
T5-2-45
Switching Image Format
IMPORTANT: If changing the rear view camera to

one with PAL image format, change
the image format of the back monitor
to PAL.

Menu Key

3. Select "PAL" for image format by using keys 1 and

2. Push the confirm key. Then, the setting of im-
age format is switched to "PAL".

previous screen.
T1V5-05-01-114
T1V5-05-01-120
Back Key
Key 6
T1V5-05-01-136
T5-2-46
MAINTENANCE SETTINGS

Menu Key
2. Select maintenance settings from main menu by

the maintenance settings screen appears.
T1V5-05-01-019
3. Select an item to be set from among the list of

maintenance settings screen by using keys 1 and
2. Push the confirm key. Then, the Interval
ON/OFF settings screen appears.
(In the right example, Engine Oil is selected.)
T1V5-05-01-049
Maintenance Information Display ON/OFF
1. Select ON or OFF for maintenance information

display by using keys 1 and 2. Push the confirm
key.
ON: When time comes to change, an informa-
tion message is displayed on the screen.
OFF: No information message is displayed.
Key 1
Confirm
2. In order to complete setting, push key 6. Then, the Key
Key 2
primary screen appears.
Key 6
Interval ON/OFF Settings Screen T1V5-05-01-052
T5-2-47
Change Interval Settings
IMPORTANT: Change interval can only be set

when maintenance information dis-
play is set to ON.
1. Select change interval by using keys 1 and 2.
Key 1
Key 2 Interval ON/OFF Settings Screen T1V5-05-01-052
2. Set time for change interval by using keys 3 and 4.
3. Select remaining hours by using keys 1 and 2,

and push confirm key.
Key 1
T1V5-05-01-138
Key 2 Key 3 Key 4 Confirm Key
4. The message "Adjust remaining hours to new

change interval. OK?" appears. Then, push the
confirm key.
Key 6 Confirm Key T1V5-05-01-139
Menu Key
T5-2-48
Resetting Data
1. If data is reset, push key 5 on the Interval ON/OFF

settings screen.
Key 5
Interval ON/OFF Settings Screen T1V5-05-01-052
2. The message "Reset Data. OK?" appears. Then,

push the confirm key.
3. The value of remaining hours is reset to that of

change interval. Previous change date/hour is
updated with current date and time.
Confirm Key T1V5-05-01-140
T5-2-49
Screen Display when Maintenance Information
Display is ON
• When only one item applies

1. If turning the key switch to the ON position, the
starting screen appears. Then, the scheduled
maintenance screen for the item whose change
interval has expired appears for three to ten sec-
onds. Finally the primary screen appears.
(In the right example, Hydraulic Oil applies.)
NOTE: for a machine which the primary screen is

displayed according to a password on, the T1V1-05-01-115
Starting Screen
scheduled maintenance screen for the item
whose change interval has expired appears
for three to ten seconds, after the password
is input successfully and the confirm key is
pushed. And then the primary screen ap-
pears.
2. If data is rest, push the reset key while the

scheduled maintenance screen is displayed. Back Key
The message "Reset Data. OK?" appears. Then,
The value of remaining hours is reset to that of Reset Key
change interval. Previous change date/hour is
updated with current date and time. T1V5-05-01-170
Maintenance Information Display Screen
NOTE: When pushing the back key while the

maintenance information display screen is
displayed, return to the primary screen.
NOTE: When pushing the back key while reset

screen is displayed, return to the mainte-
nance information display screen.
Back Key
Confirm Key
T1V5-05-01-171
Reset Screen
Menu Key
T5-2-50
• When more than two items apply
1. If turning the key switch to the ON position, the
starting screen appears. Then, the scheduled
maintenance screen for the items whose change
interval has expired appears for three to ten sec-
onds. Finally the primary screen appears.
NOTE: For a machine which the primary screen is

displayed according to a password on, the
scheduled maintenance screen for the
items whose change interval has expired
appears for three to ten seconds, after the
password is input successfully and the con- T1V1-05-01-115
Starting Screen
firm key is pushed. And then the primary
screen appears.
2. If data is reset, while the scheduled maintenance

screen is displayed, select desired item by using
maintenance information display screen for the
selected item appears.
(In the right example, Hydraulic Oil is selected.) Key 1 Back Key
NOTE: When pushing the back key while the

scheduled maintenance screen is displayed, Key 2
Confirm
the primary screen appears. Key
T1V5-05-01-169
Scheduled Maintenance Screen
3. Push the reset key while the maintenance infor-
mation display screen is displayed.
The message "Reset Data. OK?" appears. Then,
The value of remaining hours is reset to that of
change interval. previous change date/hour is
updated with current date and time.
NOTE: When pushing the back key while the Back Key
maintenance information display screen is
displayed, return to the scheduled mainte-
nance screen. Reset Key
NOTE: When pushing the back key while the reset Maintenance Information Display Screen T1V5-05-01-170
screen is displayed, return to the mainte-

nance information display screen.
Back Key
T1V5-05-01-171
Reset Screen
T5-2-51
LANGUAGE SETTINGS

2. Select language from main menu by using keys 1

and 2. Push the confirm key. Then, the language
settings screen appears.
3. Select a desired language by using keys 1 and 2.

Push the confirm key.
NOTE: Languages to be displayed on the screen Menu Key

of monitor unit have been selected from Primary Screen T1V1-05-03-001
twelve languages, namely display lan-
guages 1 or 2, at the time of shipping from
the factory.
(Refer to the next section)

previous screen.
T1V5-05-01-114
Back Key
T1V1-05-01-137
Key 1 Key 6 Key 2 Confirm Key
T5-2-52
Lists of Display Languages
Display Languages 1
Language Screen Display
Japanese
T1V1-05-01-141
English
T1V1-05-01-142
Chinese (Simplified)
T1V1-05-01-143
Chinese (Traditional)
T1V1-05-01-144
Korean
T1V1-05-01-145
Indonesian
T1V1-05-01-146
Thai
T1V1-05-01-147
Vietnamese
T1V1-05-01-148
Myanmarese
T1V1-05-01-149
Arabic
T1V1-05-01-150
Persian
T1V1-05-01-151
Turkish
T1V1-05-01-152
Display Languages 2
Language Screen Display
English
T1V1-05-01-142
Spanish
T1V1-05-01-153
Italian
T1V1-05-01-154
French
T1V1-05-01-155
German
T1V1-05-01-156
Dutch
T1V1-05-01-157
Russian
T1V1-05-01-158
Portuguese
T1V1-05-01-159
Finnish
T1V1-05-01-160
Swedish
T1V1-05-01-161
Norwegian
T1V1-05-01-162
Danish
T1V1-05-01-163
T5-2-53
(Blank)
T5-2-54
TROUBLESHOOTING / Component Layout
MAIN COMPONENT LAYOUT
28
27 2
3
4
5
26 6
7
8
9
10
25
A
24
23
22
21
11
20
19 12
18 13
17
16 15 14 T1J1-01-02-002
1 - Arm Cylinder 8- Control Valve 15 - Fan Pump 22 - Hydraulic Oil Tank

2 - Washer Tank 9- Signal Control Valve 16 - Travel Device 23 - Pilot Shut-Off Solenoid
Valve
3 - Swing Bearing 10 - Air Cleaner 17 - Drain Filter 24 - Shockless Valve
4 - Center Joint 11 - Fan Motor 18 - Pilot Filter/ Pilot Relief 25 - Travel Pilot Valve
Valve
5 - Swing Device 12 - Engine 19 - Solenoid Valve Unit 26 - Front Attachment / Swing
Pilot Valve
6 - Fuel Tank 13 - Engine Oil Filter 20 - Check Valve 27 - Boom Cylinder
7 - Reserve Tank 14 - Pump Device 21 - Track Adjuster 28 - Bucket Cylinder
T5-5-1
View A (Around the Radiator)
4
3 5 M1J1-07-034
M1J1-07-032
Lower of Control Valve
T1J1-01-02-009
1 - Inter Cooler 3 - Air Conditioner Condenser 5 - Oil Cooler 6 - Accumulator

2 - Fuel Cooler 4 - Radiator
T5-5-2
ELECTRICAL COMPONENT LAYOUT (Overview)
Around Horn (Refer to T1-2-7)

• Horn
• Boom Bottom Pressure Sensor
• Auto-Lubrication Distribution Valve
1 (Optional)
2
Around Battery (Refer to T1-2-7)
• Battery
• Battery Relay
• Fusible Link
• Starter Relay
• Glow Plug Relay
• Auto-Lubrication System
(Optional)
3
4
Around Radiator
(Refer to T1-2-7)
• Receiver Tank
• Fresh Air
Temperature
Sensor
Pressure Sensor Block (Refer to T1-2-8)
• Pressure Sensor (Boom Raise) 11
• Pressure Sensor (Boom Lower) 10
• Pressure Sensor (Arm Roll-Out) 9 Engine
• Pressure Sensor (Arm Roll-In) 8 6 (Refer to T1-2-9)
• Pressure Sensor (Bucket Roll-In) 7 T1J1-01-02-002
• Pressure Sensor (Right Travel)
• Pressure Sensor (Left Travel) Pump Device (Refer to T1-2-10)
• Pump 1, 2 Delivery Pressure Sensor
• Pump 1, 2 Regulator Pressure Sensor
• Pump 1, 2 Control Solenoid Valve
• Fan Pump Control Solenoid Valve
1 - Monitor Unit 4- Fuel Sensor 7- Air Cleaner Restriction Switch 10 - Washer Motor
2 - Atmosphere Pressure 5- Pressure Sensor (Swing) 8- Solenoid Valve Unit 11 - ECM (Engine Controller)
Sensor (Refer to T1-2-8) (Refer to T1-2-8)
3 - Coolant Level Switch 6 - Intake Air Temperature 9 - Hydraulic Oil Temperature
Sensor Sensor
T5-5-3
Electrical Component Layout (In Cab)
Rear Tray
(Refer to T1-2-5)
11
View B
B
2
3
4
5
6
7
8
9
Switch Panel 10
(Refer to T1-2-6) T1J1-01-02-010
1 - Fan Rotation Direction 4 - Auto-Lubrication Switch 7 - Overload Alarm Switch 10 - Engine Stop Switch
Switch (Optional) (Optional) (Optional)
2 - Rotating Light Switch 5 - Level Check Switch 8 - Seat Heat Switch 11 - Radio
(Optional) (Engine Oil Level / Coolant (Optional)
Level)
3 - Rear Light Switch 6 - Boom Mode Selector 9 - Travel Alarm Deactivation
(Optional) Switch Switch (Optional)
T5-5-4
Electrical Component Layout (Rear Tray)
1 2
T1J1-01-02-003
6 5
10 11 12 13
9
14
8
15
16
T1V1-01-02-009
21 20 19 18 17
1 - MC (Main Controller) 8 - Security Relay (R5) 13 - Lock Relay (R2) 18 - Light Relay 2 (R8)
2 - Overload Alarm Relay 9 - Starter Cut Relay (R4) 14 - Load Damp Relay (R1) 19 - ECM Main Relay (R14)
(Optional)
3 - Fuse Box 10 - Hour Mater Relay (R12) 15 - Wiper Relay (R6) 20 - Washer Relay (R9)
(Optional)
5 - Pump Learning Switch 11 - Security Horn Relay (R3) 16 - Light Relay 1 (R7) 21 - Horn Relay (R10)
6 - ICF (Information Controller) 12 - Auto-Lubrication Relay (R11) 17 - Light Relay 3 (R13)
(Optional) (Optional)
T5-5-5
Electrical Component Layout (Switch Panel)
T1V1-04-02-001
6 5
1- Engine Control Dial 3 - Power Mode Switch 5- Key Switch 7- Wiper/Washer Switch
2- Auto-Idle Switch 4 - Travel Mode Switch 6- Work Light Switch
T5-5-6
Around Horn Around Radiator
5
2
4
M1J1-07-032
3 T1J1-01-02-006
Around Battery
8 9 10
7 11
6 12
13
T1J1-01-02-005
1 - Horn 5 - Fresh Air Temperature 8- Starter Relay 11 - Auto-Lubrication Pump

Sensor
2 - Distribution Valve 6 - Battery 9- Battery Relay 12 - Fuel Filler System Switch
3 - Boom Bottom Pressure 7 - Glow Plug Relay 10 - Fusible Link 13 - Fuel Filler Pump
Sensor
4 - Receiver Tank
T5-5-7
Pressure Sensor Brock
1 2 3 4 5 6 7 8
Front Side
Main Frame
T1J1-01-02-008
Swing Device Side
Solenoid Valve Unit
Control Valve
13
12
11 9
10
T1J1-01-02-007
1 - Pressure Sensor (Travel 5 - Pressure Sensor (Bucket 8- Pressure Sensor (Boom 11 - Solenoid Valve Unit (SI)
Right) Roll-In) Lower)
2 - Pressure Sensor (Travel 6 - Pressure Sensor (Bucket 9 - Pressure Sensor (Swing) 12 - Solenoid Valve Unit (SF)
Left) Roll-Out)
3 - Pressure Sensor (Arm 7 - Pressure Sensor (Boom 10 - Solenoid Valve Unit (SG) 13 - Solenoid Valve Unit (SC)
Roll-Out) Raise)
4 - Pressure Sensor (Arm
Roll-In)
T5-5-8
ENGINE
1 2
20
4 3
5 6 7 8 9
10
19
11
18
17
12
16
13
15
14
T1J1-01-02-011
1 - EGR Valve 6 - Coolant Temperature 11 - Crank Revolution Sensor 16 - Cam Angle Sensor
Sensor
2 - Injector Connector 7 - Suction Control Valve 12 - Engine Oil Pressure 17 - Supply Pump
Sensor
3 - Boost Pressure Sensor 8 - Priming Pump 13 - Starter 18 - Overheat Switch
4 - Boost Temperature Sensor 9 - Fuel Main Filter 14 - Engine Oil Level Switch 19 - Alternator
5 - Glow Plug Connector 10 - Common Rail Pressure 15 - Fuel Temperature Sensor 20 - Fuel Pre Filter
Terminal Sensor
T5-5-9
PUMP DEVICE
1 2 3 4
11
T1J1-01-02-004
10 9 8 7
SWING DEVICE TRAVEL DEVICE
12 13
14
M1J1-07-048
M1J1-07-053
12
1 - Pump 2 Regulator Pressure 5- Pump 1 9- Pump 2 Delivery Pressure 12 - Swing Relief Valve
Sensor Sensor
2 - Pump 2 Control Solenoid Valve 6 - Pump 1 Delivery 10 - Fan Pump 13 - Counterbalance Valve
Pressure Sensor
3 - Pump 1 Regulator Pressure 7 - Pilot Pump 11 - Fan Pump Control 14 - Travel Relief Valve
Sensor Solenoid Valve
4 - Pump 1 Control Solenoid Valve 8 - Pump 2
T5-5-10
CONTROL VALVE
1
2
3
5 T1J1-03-03-003
4
8
7
6
10 9
T1J1-03-03-004
(Boom Lower) (Bucket Roll-In) (Boom Mode) (Arm Roll-In)
(Bucket Roll-Out) (Boom Raise) (Arm Roll-Out) (Auxiliary)
3 - Main Relief Valve 6 - Overload Relief Valve
(Auxiliary)
T5-5-11
COMPONENTS IN CONTROL VALVE
1 2 3 4 5
45 7
8
44
43 9
42 10
41
11
40
39
38
12
37
13
14
15
16
36
17
35 18
19
34
20
33
32
31 30 29 28 27 26 25 24 23 22 21
T450-03-03-025
T5-5-12
A B
C
C
D
D
E
E
F
F
G
G
H
H
T450-03-03-001
A B
Cross Section A-A Cross Section B-B
14
34
28 31
T450-03-03-011 T450-03-03-010
Circuit)
Circuit)
Tandem Circuit)
T5-5-13
1 2 3 4 5
45 7
8
44
43 9
42 10
41
11
40
39
38
12
37
13
14
15
16
36
17
35 18
19
34
20
33
32
31 30 29 28 27 26 25 24 23 22 21
T450-03-03-025
T5-5-14
Swing
Arm 2 Arm 1
3 10 2
8
44
45
T450-03-03-016
40 11
T450-03-03-023
Circuit)
Circuit)
Tandem Circuit)
T5-5-15
1 2 3 4 5
45 7
8
44
43 9
42 10
41
11
40
39
38
12
37
13
14
15
16
36
17
35 18
19
34
20
33
32
31 30 29 28 27 26 25 24 23 22 21
T450-03-03-025
T5-5-16

33
39 13 15, 16 35 25 19
38
37
17
12
32
41 42 36 34 18
T450-03-03-015 T450-03-03-014
Circuit)
Circuit)
Tandem Circuit)
T5-5-17
1 2 3 4 5
45 7
8
44
43 9
42 10
41
11
40
39
38
12
37
13
14
15
16
36
17
35 18
19
34
20
33
32
31 30 29 28 27 26 25 24 23 22 21
T450-03-03-025
T5-5-18
Travel Travel
(right) (left)
31
30
21
22
29
T450-03-03-013
T450-03-03-012
28
Circuit)
Circuit)
Tandem Circuit)
T5-5-19
1 2 3 4 5
45 7
8
44
43 9
42 10
41
11
40
39
38
12
37
13
14
15
16
36
17
35 18
19
34
20
33
32
31 30 29 28 27 26 25 24 23 22 21
T450-03-03-025
T5-5-20
Cross Section I-I
T450-03-03-008
24
T450-03-03-001
T450-03-03-006
Circuit)
Circuit)
Tandem Circuit)
T5-5-21
PILOT PORT
Pilot Valve Side

Port SA - Plug
Port SB - Plug
T5-5-22
Pilot Valve Side
PH
C
A
E
M
D
H B
SB
F
G
Pilot Valve
Side
PI
K
I
SH J
DF
SA L
T1J1-03-06-002
Control Valve Side

SM 3
5
1
13
2 4
SK SE
8
S3
14
Control Valve 7
Side
9 6
10
SN
SL
11
TR 12 SP T1J1-03-06-003
T5-5-23
Control Valve Side

Port SE - Plug
Port SN - Plug
Port TR - Plug
T5-5-24
Pilot Valve Side
PH
C
A
E
M
D
H B
SB
F
G
Pilot Valve
Side
PI
K
I
SH J
DF
SA L
T1J1-03-06-002
Control Valve Side

SM 3
5
1
13
2 4
SK SE
8
S3
14
Control Valve 7
Side
9 6
10
SN
SL
11
TR 12 SP T1J1-03-06-003
T5-5-25
(Blank)
T5-5-26
TROUBLESHOOTING / Troubleshooting A
TROUBLESHOOTING A PROCEDURE
Refer to troubleshooting A procedure in case any fault

codes are displayed after diagnosing by using service
menu of monitor unit.
• How to Read Troubleshooting Flow Charts
YES (OK)
(2)
After completing the checking and/or measuring procedures in box (1),
・ (1) select YES (OK) or NO (NOT OK) and proceed to box (2) or (3).
(3)
NO (NOT OK)
Instructions, reference, and/or inspection methods and/or measurements are occasionally

・
described under the box. If incorrectly checked or measured, not only will troubleshooting
· Key switch: ON be unsuccessful but also damage to the components may result.
・ Refer to “Electrical System Inspection” group (group 8) for descriptions in the dotted-line
box.
・ Use monitor unit (service mode) for descriptions in the double-line box.
・ Causes of machine problems are stated in the thick-line box. Scanning quickly through the
thick-line boxes allows you to estimate the possible causes before actually following the
flow chart.
NOTE: Harness end connector viewed from the

open end side by the all connectors image
shown in this section.
Harness End
Connector Harness
Open End Side T6L4-05-03-001
T5-6-1
MC FAULT CODE LIST
Fault
Trouble Cause Influenced Control
Code
11000-2 Abnormal EEPROM Faulty MC • All Control
11001-2 Abnormal RAM Faulty MC • All Control
11002-2 Abnormal A/D Converter Faulty MC • All Control
11003-3 Abnormal Sensor Voltage Faulty MC • All Control
11004-2 CAN Communication Error Faulty MC • Engine Control

Shorted Circuit in CAN Bus • Work Mode Control
Line • Attachment Mode Control
• Horsepower (Speed Sensing)
Control
• Fan Pump Flow Rate Control
• CAN Cycle Data Communi-
cation
• Overheat Prevention Control
11101-3 EC Dial sensor Circuit High In- Voltage: 4.75 V or higher • Engine Control Dial Control
put
11101-4 EC Dial sensor Circuit Low In- Voltage: Less than 0.25 V • Engine Control Dial Control
put
11200-3 Pump 1 Delivery Pressure Sen- Voltage: 4.75 V or higher • HP Mode Control
sor Circuit High Input • Horsepower Control
• Relief Flow Rate Reducing
Control (Relief Cut Off)
11200-4 Pump 1 Delivery Pressure Sen- Voltage: Less than 0.25 V • HP Mode Control
sor Circuit Low Input • Horsepower Control
11202-3 Pump 2 Delivery Pressure Voltage: 4.75 V or higher • HP Mode Control
Sensor Circuit High Input • Horsepower Control
11202-4 Pump 2 Delivery Pressure Voltage: Less than 0.25 V • HP Mode Control
Sensor Circuit Low Input • Horsepower Control
T5-6-2
Symptoms in Machine Operation Reference

Remedy
When Trouble Occurs. Page
• Replace MC T5-6-37
-
-
-
• Engine speed is kept at backup • Replace MC T5-6-38
speed (1200 min-1). • Check Harness (Sensor Power)
• Check Sensor to connected to
MC
• No Speed sensing • Replace MC T5-6-39
• All abnormal signals via CAN • Check CAN Harness
communication
• Engine speed is kept at slow idle
speed.
• Target engine speed is kept at • Check Harness T5-6-60

1200 min-1. • Replace Engine Control Dial
• Target engine speed is kept at • Check Harness T5-6-60
1200 min-1. • Replace Engine Control Dial
• Increasing speed at HP mode is • Check Harness T5-6-61
difficult. • Replace Pump 1 Delivery
• Less flow rate at 19.6 MPa Pressure Sensor
• Relief cut is not operated.
• Auto-power lift does not function.
• Relief cut is not operated.
• Auto-power lift does not function.

T5-6-3
Fault
Code
11301-3 Swing Pilot Pressure Sensor Voltage: 4.75 V • Engine Control
Circuit High Input or higher • Relief Flow Rate Reducing
• Swing Horsepower Reducing
Control
11301-4 Swing Pilot Pressure Sensor Voltage: Less than 0.25 V • Engine Control
Circuit Low Input • Relief Flow Rate Reducing
Control
11302-3 Boom Raise Pilot Pressure Voltage: 4.75 V or higher • Engine Control
Sensor Circuit High Input • HP Mode Control
T5-6-4

Remedy
• Cut off override is not impossible. • Check Harness T5-6-63
• A/I cannot be released by swing • Replace Swing Pilot Pressure
operation. Sensor
• Flow rate of lever regulated pump
control becomes maximum by
swing operation.
• Reducing operation of swing
torque is impossible.
• Boom mode selector control is
impossible by swing operation.
• Engine speed is lower than
speed at E mode.
• Cut off override is not impossible. • Check Harness T5-6-63

• A/I cannot be released by swing • Replace Swing Pilot Pressure
operation. Sensor
swing operation.
• Reducing operation of swing
torque is impossible.
impossible by swing operation.
speed at E mode.
• Speed at HP mode does not in- • Check Harness T5-6-64

crease by boom raise operation. • Replace Boom Raise Pilot Pres-
• A/I cannot be released by boom sure Sensor
raise operation.
boom raise operation.
impossible by boom raise opera-
tion.
• Auto-power lift does not function
by boom raise operation.
• Boom flow rate control valve
control is not operated.
speed at E mode.
T5-6-5
Fault
Code
11302-4 Boom Raise Pilot Pressure Voltage: Less than 0.25 V • Engine Control
Sensor Circuit Low Input • HP Mode Control
11303-3 Arm Roll-in Pilot Pressure Voltage: 4.75 V or higher • Engine Control
Sensor Circuit High Input • HP Mode Control
• Boom Flow Rate Control
Valve Control
11303-4 Arm Roll-in Pilot Pressure Voltage: Less than 0.25 V • Engine Control
Sensor Circuit Low Input • HP Mode Control
• Boom Flow Rate Control
Valve Control
T5-6-6

Remedy
crease by boom raise operation. • Replace Boom Raise Pilot Pres-
• A/I cannot be released by boom sure Sensor
raise operation.
boom raise operation.
impossible by boom raise opera-
tion.
by boom raise operation.
speed at E mode.
crease by arm roll-in operation. • Replace Arm Roll-In Pilot Pres-
• A/I cannot be released by arm sure Sensor
roll-in operation.
arm roll-in operation.
impossible by arm roll-in opera-
tion.
by arm roll-in operation.
speed at E mode.
crease by arm roll-in operation. • Replace Arm Roll-In Pilot Pres-
• A/I cannot be released by arm sure Sensor
roll-in operation.
arm roll-in operation.
impossible by arm roll-in opera-
tion.
by arm roll-in operation.
• Boom flow rate control valve con-
trol is not operated.
speed at E mode.
T5-6-7
Fault
Code
11400-3 Pump 2 Regulator Valve FB Current: Higher than 920 mA • All Pump Controls
High Current
11400-4 Pump 2 Regulator Valve FB Current: Less than 56 mA • All Pump Controls
Low Current
11402-3 Boom Flow Control Valve FB Current: Higher than 920 mA • All Pump Controls
High Current
11402-4 Boom Flow Control Valve FB Current: Less than 56 mA • All Pump Controls
Low Current
11404-3 Power Boost P/S Valve FB Current: Higher than 920 mA • Counterweight Removal and
High Current Installation Control
• Pressure Increase Selection
Control When Traveling
11404-4 Power Boost P/S Valve FB Low Current: Less than 56 mA • Counterweight Removal and
Current Installation Control
11405-3 Travel Swash Angle P/S Valve Current: Higher than 920 mA • Travel Motor Swash Angle
FB High Current Selection Control
11405-4 Travel Swash Angle P/S Valve Current: Less than 56 mA • Travel Motor Swash Angle
FB Low Current Selection Control
11410-3 Pump 1 Regulator Valve FB Current: Higher than 920 mA • All Pump Controls
High Current
11410-4 Pump 1 Regulator Valve FB Current: Less than 56 mA • All Pump Controls
Low Current
11412-3 Hyd. Fan P/S Valve FB High Current: Higher than 920 mA • Fan Pump Flow Rate Control
Current
11412-4 Hyd. Fan P/S Valve FB Low Current: Less than 56 mA • Fan Pump Flow Rate Control
Current
11802-3 Boom Bottom Pressure Sensor Voltage: 4.5 V or higher • Overload Alarm Control
Circuit High Input
11802-4 Boom Bottom Pressure Sensor Voltage: Less than 0.25 V • Overload Alarm Control
Circuit Low Input
11901-3 Hyd. Oil Temp Sensor Circuit Intake air temperature: 21 °C • Engine Control
High Input or higher (higher than 20 °C) • Overheat Prevention Control
Voltage: 4.10 V or higher • Fan Pump Flow Rate Control
This condition is continued
beyond 30 seconds.
11901-4 Hyd. Oil Temp Sensor Circuit Voltage: Less than 0.23 V • Engine Control
Low Input This condition is continued • Overheat Prevention Control
beyond 30 seconds. • Fan Pump Flow Rate Control
T5-6-8

Remedy
• Pump 2 control is impossible. • Check Harness T5-6-66
• Boom flow rate control valve • Check Harness T5-6-67

• Boom flow rate control valve • Check Harness T5-6-67
• Increasing pressure selection is • Check Harness T5-6-68
impossible.
• Increasing pressure selection is • Check Harness T5-6-68

impossible.
• Travel mode selection is impos- • Check Harness T5-6-69

sible.
• Travel mode selection is impos- • Check Harness T5-6-69
sible.
• Fan control is impossible. • Check Harness T5-6-71
• Fan control is impossible. • Check Harness T5-6-71
• Check Harness T5-6-72

- • Replace Boom Bottom Pressure
Sensor
• Check Harness T5-6-72
- • Replace Boom Bottom Pressure
Sensor
• Overheat prevention control of • Check Harness T5-6-73
hydraulic oil is impossible. • Replace Hydraulic Oil Tempera-
• Maximum fan speed ture Sensor
• Drive torque of pump is reduced.
• Overheat prevention control of • Check Harness T5-6-73

hydraulic oil is impossible. • Replace Hydraulic Oil Tempera-
• Maximum fan speed ture Sensor
T5-6-9
Fault
Code
11910-2 Actual Engine Speed Receive Faulty Harness
-
Error
11911-2 Security Signal receive Error Faulty Harness
-
11914-2 Radiator Water Temp Receive Faulty Harness • Overheat Prevention Control
Error • Fan Pump Flow Rate Control
11918-2 Work Mode Receive Error Faulty Harness • Work Mode Control
• Attachment Mode Control
11920-2 Fuel Flaw Receive Error Faulty Harness
-
11976-3 Auxiliary Valve 2 FB High Cur- Current: Higher than 920 mA
-
rent
11976-4 Auxiliary Valve 2 FB Low Cur- Current: Less than 56 mA
-
rent
11977-3 Auxiliary Valve 1 FB High Cur- Current: Higher than 920 mA
-
rent
11977-4 Auxiliary Valve 1 FB Low Cur- Current: Less than 56 mA
-
rent
11980-3 ATT Relief Change Valve FB Current: Higher than 920 mA
-
High Current
11980-4 ATT Relief Change Valve FB Current: Less than 56 mA
-
Low Current
11981-3 Fan Reverse Valve 2 FB High Current: Higher than 920 mA
-
Current
11981-4 Fan Reverse Valve 2 FB Low Current: Less than 56 mA
-
Current
11982-3 Fan Reverse Valve 1 FB High Current: Higher than 920 mA
-
Current
11982-4 Fan Reverse Valve 1 FB Low Current: Less than 56 mA
-
Current
11983-2 Intake Air Temperature Receive Faulty Harness • Fan Pump Flow Rate Control
Error
11984-2 Boost Temperature Receive Faulty Harness • Fan Pump Flow Rate Control
Error
11989-3 Boom Mode Control Valve FB Current: Higher than 920 mA • Boom Mode Selector Control
High Current
11989-4 Boom Mode Control Valve FB Current: Less than 56 mA • Boom Mode Selector Control
Low Current
T5-6-10

Remedy
• Stop speed sensing. • Check Harness T5-6-75
• Pump learning is impossible.
• When engine control security and • Check Harness T5-6-75
pump control security are turned
ON, security is activated.
• Maximum fan speed • Check Harness T5-6-75
• The value received last time is • Check Harness T5-6-75
effective.
• The value received last time is • Check Harness T5-6-75
effective.
• Check Harness -
-
• Check Harness -
-
• Check Harness -
-
• Check Harness -
-
• Attachment relief selection is im- • Check Harness -
possible.
• Attachment relief selection is im- • Check Harness -
possible.
• Fan reverse is impossible. • Check Harness -
• Maximum fan speed (with blower • Check Harness T5-6-75

motor relay ON)
• Maximum fan speed • Check Harness T5-6-75
• Boom mode selector control is • Check Harness T5-6-79

impossible.
• Boom mode selector control is • Check Harness T5-6-79
impossible.
T5-6-11
Fault
Code
Right Travel Pilot Pressure Voltage: 4.75 V or higher • Travel Speed Increase Con-
Sensor Circuit High Input trol
Control
• Rear Monitoring Display Se-
11991-3 lection Control
• Travel Alarm Control
• Engine Control
Right Travel Pilot Pressure Voltage: Less than 0.25 V • Travel Speed Increase Con-
Sensor Circuit Low Input trol
Control
• Engine Control
T5-6-12

Remedy
• Increasing travel speed is impos- • Check Harness T5-6-80
sible by right travel operation. • Replace Right Travel Pilot Pres-
• A/I cannot be released by right sure Sensor
travel operation.
• Cut off override is impossible by
right travel operation.
impossible by right travel opera-
tion.
• Pressure increase when traveling
is impossible by right travel op-
eration.
• Rear monitoring display selection
eration.
• Travel alarm outputs.
speed at E mode.

sible by right travel operation. • Replace Right Travel Pilot Pres-
• A/I cannot be released by right sure Sensor
travel operation.
right travel operation.
impossible by right travel opera-
tion.
eration.
eration.
speed at E mode.
T5-6-13
Fault
Code
Pump 2 Regulator Pressure Voltage: 4.75 V or higher • Pump 2 Flow Rate Control
Sensor Circuit High Input • Pump 2 Regulator Pressure
11992-3 Learning
Pump 2 Regulator Pressure Voltage: Less than 0.25 V • Pump 2 Flow Rate Control
Sensor Circuit Low Input • Pump 2 Regulator Pressure
11992-4 Learning
Left Travel Pilot Pressure Sen- Voltage: 4.75 V or higher • Travel Speed Increase Con-
sor Circuit High Input trol
Control
• Engine Control
Left Travel Pilot Pressure Sen- Voltage: Less than 0.25 V • Travel Speed Increase Con-
sor Circuit Low Input trol
Control
• Engine Control
T5-6-14

Remedy
• No secondary pressure feedback • Check Harness T5-6-81
of pump 2 proportional solenoid • Replace Pump 2 Regulator Pres-
valve (bad response) sure Sensor


sible by left travel operation.
• A/I cannot be released by left
travel operation.
left travel operation.
impossible by left travel opera-
tion.
is impossible by left travel opera-
tion.
tion.
speed at E mode.

sible by left travel operation.
• A/I cannot be released by left
travel operation.
left travel operation.
impossible by left travel opera-
tion.
tion.
tion.
speed at E mode.
T5-6-15
Fault
Code
Pump 1 Regulator Pressure Voltage: 4.75 V or higher • Pump 1 Flow Rate Control
Sensor Circuit High Input • Pump 1 Regulator Pressure
11994-3 Learning
Pump 1 Regulator Pressure Voltage: Less than 0.25 V • Pump 1 Flow Rate Control
Sensor Circuit Low Input • Pump 1 Regulator Pressure
11994-4 Learning
Arm Roll-Out Pilot Pressure Voltage: 4.75 V or higher • Boom Mode Selector Control
Sensor Circuit High Input • Boom Flow Rate Control
Valve Control
• Engine Control
11995-3
Arm Roll-Out Pilot Pressure Voltage: Less than 0.25 V • Boom Mode Selector Control
Sensor Circuit Low Input • Boom Flow Rate Control
Valve Control
• Engine Control
11995-4
T5-6-16

Remedy

• A/I cannot be released by arm • Check Harness T5-6-84

roll-out operation. • Replace Arm Roll-Out Pilot
• Flow rate of lever regulated pump Pressure Sensor
arm roll-out operation.
impossible by arm roll-out opera-
tion.
speed at E mode.
• A/I cannot be released by arm • Check Harness T5-6-84

roll-out operation. • Replace Arm Roll-Out Pilot
arm roll-out operation.
impossible by arm roll-out opera-
tion.
speed at E mode.
T5-6-17
Fault
Code
11997-3 Bucket Roll-Out Pilot Pressure Voltage: 4.75 V or higher • Boom Mode Selector Control
Valve Control
• Engine Control
11997-4 Bucket Roll-Out Pilot Pressure Voltage: Less than 0.25 V • Boom Mode Selector Control
Valve Control
• Engine Control
11998-3 Boom Lowering Pilot Pressure Voltage: 4.75 V or higher • Boom Mode Selector Control
Valve Control
• Engine Control
11998-4 Boom Lowering Pilot Pressure Voltage: Less than 0.25 V • Boom Mode Selector Control
Valve Control
• Engine Control
T5-6-18

Remedy
• A/I cannot be released by bucket • Check Harness T5-6-85
roll-out operation. • Replace Bucket Roll-Out Pilot
bucket roll-out operation.
impossible by bucket roll-out op-
eration.
speed at E mode.

roll-out operation. • Replace Bucket Roll-Out Pilot
bucket roll-out operation.
impossible by bucket roll-out op-
eration.
speed at E mode.

crease by boom lower operation. • Replace Boom Lower Pilot
• A/I cannot be released by boom Pressure Sensor
lower operation.
impossible by boom lower opera-
tion.
speed at E mode.

crease by boom lower operation. • Replace Boom Lower Pilot
• A/I cannot be released by boom Pressure Sensor
lower operation.
impossible by boom lower opera-
tion.
speed at E mode.
T5-6-19
Fault
Code
11999-3 Bucket Roll-In Pilot Pressure Voltage: 4.75 V or higher • Boom Mode Selector Control
Valve Control
• Engine Control
11999-4 Bucket Roll-In Pilot Pressure Voltage: Less than 0.25 V • Boom Mode Selector Control
Valve Control
• Engine Control
T5-6-20

Remedy
roll-in operation. • Replace Bucket Roll-In Pilot
bucket roll-in operation.
impossible by bucket roll-in op-
eration.
speed at E mode.

roll-in operation. • Replace Bucket Roll-In Pilot
bucket roll-in operation.
impossible by bucket roll-in op-
eration.
speed at E mode.
T5-6-21
ECM FAULT CODE LIST
Fault
Trouble Cause
Code
91-2 Accelerator Sensor 1-2 Comparison Fault • Difference in opening angle between accelerator
sensors 1-2 is 45 % or more.
100-3 Engine Oil Pressure Sensor Fault (Low Voltage: Less than 0.1 V
Voltage Fault)
100-4 Engine Oil Pressure Sensor Fault (High Voltage: More than 4.85 V
Voltage Fault)
102-3 Boost Pressure Sensor Fault (Low Volt- Voltage: Less than 0.1 V
age Fault)
102-4 Boost Pressure Sensor Fault (High Volt- Voltage: More than 4.9 V
age Fault)
105-3 Boost Temperature Sensor Fault (High Voltage: More than 4.94 V
Voltage Fault)
105-4 Boost Temperature Sensor Fault (Low Voltage: Less than 0.1 V
Voltage Fault)
108-3 Barometric Pressure Sensor Fault (Low Voltage: Less than 0.5 V
Voltage Fault)
108-4 Barometric Pressure Sensor Fault (High Voltage: More than 3.8 V
Voltage Fault)
T5-6-22
Reference Page on
Presumptive Symptoms in Assumptive
Engine Trouble-
Real Machine Operation Conditions at Back-up
shooting Manual
• 1 system fault: No back-up • 1 system fault: No back-up 1E-474
• 2 system fault: Accelerator opening an- • 2 system fault: Accelerator
gle is controlled to 0 %. opening angle is controlled
to 0 %.
• Operationality is not affected. • No back-up 1E-365
• Operationality is affected • Boost pressure default set- 1E-305

ting (200 kPa)
• Boost pressure correction/
EGR stopped
• Black smoke emission • Boost pressure default set- 1E-312

ting (200 kPa)
• Boost pressure correction/
EGR stopped
• Operationality is affected. • No back-up 1E-437
• Operationality is affected. • No back-up 1E-429
• Black smoke emitted at high altitude • Barometric pressure default 1E-204

• Output shortage at low altitude setting 80 kPa (equivalent to
altitude 2500 m)
• Black smoke emitted at high altitude • Barometric pressure default 1E-211

• Output shortage at low altitude setting 80 kPa (equivalent to
altitude 2500 m)
T5-6-23
Fault
Trouble Cause
Code
110-3 Engine Coolant Temperature Sensor Voltage: More than 4.85 V

Fault (High Voltage Fault)
110-4 Engine Coolant Temperature Sensor Voltage: Less than 0.1 V

Fault (Low Voltage Fault)
157-0 Common Rail Pressure Fault (First Rail pressure: More than 150 MPa
Stage)
157-0 Common Rail Pressure Fault (Second Common rail pressure fault (first stage) + rail pressure:
Stage) More than 155 MPa or higher
157-2 Common Rail Pressure Fault (Excessive Actual rail pressure higher than target rail pressure for
Pressure Feed in Pump) 10 MPa or more holds 8 seconds or more. Or actual
rail pressure higher than target rail pressure for 10
MPa or more holds 8 seconds or more, during indica-
tion of no pressure feed.
157-3 Common Rail Pressure Sensor Fault Voltage: More than 4.5 V
(High Voltage Fault)
157-3 Common Rail Pressure Sensor Fault Voltage: Less than 0.7 V.
(Low Voltage Fault)
T5-6-24
Reference Page on
Presumptive Symptoms in Assumptive
Engine Trouble-
Real Machine Operation Conditions at Back-up
shooting Manual
• At normal temperature: Black smoke • Coolant temperature de- 1E-238
emission at starting, greater engine com- fault setting. (at starting:
bustion noise are possible. -20 °C, at running: 80 °C)
• During idling at atmospheric tempera-
ture: Rough idling, engine stall, white
smoke emission
• Start ability deteriorates at low tempera- • Coolant temperature de- 1E-232
ture fault setting. (at starting:
• Black smoke emission is possible -20 °C, at running: 80 °C)
• Output lowering depending on conditions
• Intense engine vibration • Limited injection amount 3 1E-183

• Rough idling (Multi-injection stopped)
• Output lowering • Target rail pressure: Upper
• Blow up fault limit (80 MPa)
• Black smoke emission
• Excessive output
• Output lowering • Actual rail pressure default 1E-266
• Black smoke emission setting (80 MPa)
• Engine stall is possible. • Rail pressure feedback
control stopped
• Limited injection amount 2
(Multi-injection stopped)
• Engine blow up • Actual rail pressure default 1E-260
setting (80 MPa)
• Rail pressure feedback
control stopped
T5-6-25
Fault
Trouble Cause
Code
172-3 Intake Air Temperature Sensor Fault Voltage: More than 4.95 V
(High Voltage Fault)
172-4 Intake Air Temperature Sensor Fault (Low Voltage: Less than 0.1 V.
Voltage Fault)
174-3 Fuel Temperature Sensor Fault (High Voltage: More than 4.85 V
Voltage Fault)
174-4 Fuel Temperature Sensor Fault (Low Voltage: Less than 0.1 V.
Voltage Fault)
190-0 Overrun Engine Speed: More than 1970 min-1
628-2 ROM Fault ROM is faulty.

Re-flash failure
633-7 Pressure Limiter Open Pressure limiter is opened.
636-2 G Sensor Fault (No Signal) The crank signal exists but no G sensor signal.
636-2 G Sensor Fault (Signal Fault) Number of pulse for G sensor signal is mismatched.
636-7 Cam Sensor out of Phase Correct G sensor pulse does not exist in crank gap po-
sition.
T5-6-26
Reference Page on
Presumptive Symptoms in Assumptive Conditions at
Engine Trouble-
Real Machine Operation Back-up
shooting Manual
• White smoke emission is possible when • Intake air temperature de- 1E-224
starting at low temperature. fault setting (at starting: -10
°C, at running: 25 °C)
• White smoke emission is possible when • Intake air temperature de- 1E-218
starting at low temperature. fault setting (at starting: -10
°C, at running: 25 °C)
• Not in particular • Fuel temperature default 1E-252
setting (at starting: -20 °C,
at running: 70 °C)
• Operationality is affected. • Fuel temperature default 1E-246
setting (at starting: -20 °C,
at running: 70 °C)
• Output lowering • Limited injection amount 1 1E-303
(Limitation is lifted if the
speed decreases.)
• Engine stopped • Engine stopped 1E-379

• Hunting
• Symptom does not change during en- • Engine running based on 1E-331
gine running. crank when crank is normal
• After engine stalls, engine will not start. • After engine stops: Unable
to identify cylinder (unable
to restart)
to restart)
to restart)
T5-6-27
Fault
Trouble Cause
Code
639-2 CAN Bus Fault Bus-off is detected.
639-3 CAN Timeout Fault CAN data reception does not complete at a set time.
651-3 Open Circuit in Injection Nozzle #1 Drive No injector 1 monitor input signal exists.
System
System
System
System
System
System
723-2 Crank Sensor Fault (No Signal) G sensor signal exists but no crank signal.
723-2 Crank Sensor Fault (Signal Fault) Number of pulse for crank signal is mismatched.
987-3 Check Engine Lamp Fault No check engine lamp monitor signal exists.
T5-6-28
Reference Page on
Engine Trouble-
shooting Manual
Vary depending on setting Switched to drive control by 1E-529
accelerator sensor input volt-
age
Vary depending on setting Switched to drive control by 1E-534
accelerator sensor input volt-
age
• Intense engine vibration • Injection for cylinder #5 1E-273
• Rough idling
• Output lowering
• Blow up fault

• Rough idling
• Output lowering
• Blow up fault

• Rough idling
• Output lowering
• Blow up fault

• Rough idling
• Output lowering
• Blow up fault

• Rough idling
• Output lowering
• Blow up fault
• Intense engine vibration • Common 1 stop (#1, #2, #3 1E-298

• Rough idling cylinders stopped)
• Output lowering
• Blow up fault
• Output lowering • Control based on G sensor 1E-319

• White smoke emission when G sensor is normal
• Intense engine vibration is possible.
• Engine stall is possible (restart is possi-
ble when G sensor is normal.)
• Output lowering • Control based on G sensor 1E-325
• White smoke emission when G sensor is normal
• Intense engine vibration is possible.
• Engine stall is possible (restart is possi-
ble when G sensor is normal.)
T5-6-29
Fault
Trouble Cause
Code
1077-2 CPU Fault Sub-CPU detects main CPU fault in 100 msec after
key switch ON. (Sub-CPU resets CPU.)
1079-2 Voltage Fault in 5 V Power Supply 1 5 V 1 power supply voltage: 5.5 V or more, 4.5 V or
less
less
1239-1 No Pump Pressure Feed (First Stage) Actual rail pressure lower than target rail pressure for
10 MPa or more holds 8 seconds or more. Or pressure
feed indication is limit +1 °C or less, and actual rail
pressure lower than target rail pressure for 10 MPa or
more holds 8 seconds or more.
1240-1 No Pump Pressure Feed (Second Stage) Actual rail pressure lower than target rail pressure for
10 MPa or more holds 8 seconds or more, when
judgment of “No pump pressure feed (first stage)” is
completed. Or pressure feed indication is limit +1 °C or
less, and actual rail pressure lower than target rail
pressure for 10 MPa or more holds 8 seconds or more.
1347-0 PCV1 Open Circuit or Ground Short PCV1 monitor signal is fixed to Low side.
1347-4 PCV1+B Short Circuit PCV1 monitor signal is fixed to High side.
1348-0 PCV2 Open Circuit or Ground Short PCV2 monitor signal is fixed to Low side.
1348-4 PCV2+B Short Circuit PCV2 monitor signal is fixed to High side.
1485-2 Main Relay System Fault Main relay voltage is 1 V or less. In spite of relay OFF
command, relay is connected.
10001-3 EGR Position Sensor Fault (Brushless EGR position output signal is abnormal.
Specification)
10002-2 EGR Valve Control Fault Difference between target valve lift and actual position
is more than 20 %.
T5-6-30
Reference Page on
Engine Trouble-
shooting Manual
Output lowering • Limited injection amount 2 1E-383
• Sub-CPU stops control.
Accelerator opening angle is controlled to Same to accelerator sensor 1E-514
0 %. fault
• Black smoke emitted at high altitude • Same to barometric pres- 1E-517
• Output lowest at low altitude sure and intake air
temperature sensor fault
• Output lowering • Target rail pressure upper

• Engine stall
• Intense engine vibration • PCV1 stop 1E-199
• Rough idling
• Output lowering
• Blow up fault
• Intense engine vibration • PCV2 stop 1E-199
• Rough idling
• Output lowering
• Blow up fault
Engine does not start. No back-up 1E-505
• Operationality is not affected. • Instruction to fully close 1E-353

EGR valve
• Operationality is not affected. • Instruction to fully close 1E-359
EGR valve
T5-6-31
Fault
Trouble Cause
Code
10003-2 Injection Nozzle Common 1 Drive System No injector 1, 2, 3 monitor input signal exists.
Fault
10004-2 Injection Nozzle Common 2 Drive System No injector 4, 5, 6 monitor input signal exists.
Fault
10005-1 Charge Circuit Fault (Bank 1) When charge circuit bank 1 voltage inside ECM is
low.
10006-1 Charge Circuit Fault (Bank 2) When charge circuit bank 2 voltage inside ECM is
low.
10007-2 CPU Monitoring IC Fault RUN-SUB pulse does not change for 20 msec or
more.
10008-2 A/D Conversion Fault A/D conversion failure
less
less
less
10013-2 EEPROM Fault EEPROM is faulty.
T5-6-32
Reference Page on
Engine Trouble-
shooting Manual
• Output lowering
• Blow up fault
• Engine stall is possible.
• Output lowering
• Blow up fault
• Output lowering
• Blow up fault
• Output lowering
• Blow up fault
• Output lowering • Analog sensor system de- 1E-512

• Black smoke emission fault processing
• Target rail pressure upper
limit (80 MPa)
• Deterioration of start ability • Same to oil pressure, cool- 1E-520
• Black smoke emission is possible. ant temperature, and
• Operationality is affected. combustion temperature
sensor fault
• Operationality is affected. • Same to boost pressure 1E-523

sensor fault
• Engine blow up • Same to rail pressure sen- 1E-526
• Output lowering sor fault and EGR position
• Black smoke emission sensor fault
T5-6-33
ICF FAULT CODE LIST
Reference
Fault Code Trouble Cause Remedy
Page
14000-2 Abnormal CAN Data cannot be received Check for CAN communication bus line. T5-6-89
Communication due to the noise on the
CAN bus line.
14001-2 Flash Memory: In case the internal Replace ICF. T5-6-89
Read / Write memory is abnormal
Error when the key is turned
ON
14002-2 External RAM: In case the internal Replace ICF. T5-6-89
Read / Write memory is abnormal
Error when the key is turned
ON
14003-2 EEPROM: Sum In case the internal Replace ICF. T5-6-89
Check Error memory is abnormal
when the key is turned
ON
14006-2 Satellite Com- In case communication to Check for the items below. T5-6-93
munication the satellite terminal 1. Check if the communication line is
Terminal: cannot be done over 30 abnormal.
Communication seconds. 2. Check if the electrical power source
Error of communication terminal is ab-
normal.
• Electrical power source
• Fuses
3. Check if the satellite terminal is bro-
ken.
14008-2 Abnormal In- In case the internal Replace ICF. T5-6-93

ternal RAM memory is abnormal
when the key is turned
ON
T5-6-34
(Blank)
T5-6-35
MONITOR UNIT FAULT CODE LIST
Reference
Fault Code Trouble Cause Remedy
Page
13303-2 Abnormal Thermistor temperature is Cool the monitor unit and so on until T5-6-95
Thermistor 85 °C (185 °F) or higher. temperature inside the monitor unit is
Temperature less than 85 °C (185 °F).
13304-2 Abnormal REG During REG input H level (Refer to the Troubleshooting flow T5-6-96
Input H Level chart.)
13306-2 Abnormal When failure reading If this fault code is displayed after T5-6-97
EEPROM EEPROM occurs retarial, replace the monitor unit.
13308-2 Abnormal CAN Bus off occurs beyond Refer to “CAN Harness Check” on page T5-6-97
Communication five times. T5-6-40 to 59.
13310-2 Shorted circuit The state, input 105±30 Ω Check coolant temperature sensor and T5-6-98
in Coolant or less, is kept over 60 harness.
Temperature seconds.
Sensor
13311-2 Shorted circuit The state, input 3±1 Ω or Check fuel level sensor and harness. T5-6-99
in Fuel Level less, is kept over 60
Sensor seconds.
13311-4 Open circuit in The state, input 135±20 Ω Check fuel level sensor and harness. T5-6-99
Fuel Level or less, is kept over 60
Sensor seconds.
T5-6-36
MC FAULT CODE 11000 to 11002
Fault Code Trouble Cause

11000-2 Abnormal EEPROM Faulty MC
11001-2 Abnormal RAM Faulty MC
11002-2 Abnormal A/D Converter Faulty MC
YES *Faulty MC.

Check if operation of engine
and machine is normal.
Faulty MC.
NO
* When the fault code is displayed in the result of
retrial and if operation of engine and machine is
normal, the machine can be used.
T5-6-37
MC FAULT CODE 11003

11003-3 Abnormal Sensor Voltage Faulty MC
IMPORTANT: If fault code 11003-3 (Abnormal

sensor voltage) is displayed with
other fault codes together, perform
the diagnosing for fault code
11003-3 first.
YES Faulty sensor.
Disconnect connectors of
all sensors corresponding
to the displayed fault code Short-circuited harness
and retry. Check if fault Disconnect all YES
connectors at MC between MC and sensor in
code 11003-3 disappears. the harness with continuity.
end. Check for
continuity between
NO terminals #1 and #3
of harness end
connector of each Faulty MC.
sensor. NO
· Key switch: OFF
Connector (Harness end of connector viewed from the

open side)
• Pressure Sensor (Right Travel) • Pump 1 Delivery Pressure Sensor
• Pressure Sensor (Left Travel) • Pump 2 Delivery Pressure Sensor
• Pressure Sensor (Swing)
• Pressure Sensor (Boom Raise)
• Pressure Sensor (Boom Lower)
• Pressure Sensor (Arm Roll-In)
• Pressure Sensor (Arm Roll-Out)
• Pressure Sensor (Bucket Roll-In)
T1J1-05-06-002
• Pressure Sensor (Counterweight) (Optional)

• Pressure Sensor (Attachment) (Optional)
• Pump 1 Regulator Pressure Sensor
• Pump 2 Regulator Pressure Sensor
T1J1-05-06-001
T5-6-38
MC FAULT CODE 11004

11004-2 Abnormal CAN Communication Faulty MC
Dr.ZX
Satellite
Terminal
(Optional)
Monitor Unit ICF
CAN Harness
MC
ECM
T1J1-02-01-004
• Check CAN harness between each controller.

(Refer to “CAN Harness Check (T5-6-40 to 59)”).
T5-6-39
CAN HARNESS CHECK
• Check the wiring connections first.
NO Open circuit in CAN

harness between
MC and ECM.
Check for continuity in
YES
CAN harness between
MC and ECM. Check for continuity
· Key switch: OFF in CAN harness
· Refer to Continuty YES between MC and
Check for continuity in Check in CAN monitor unit.
YES
CAN harness between Harness on T5-6-44. · Key Switch OFF
MC and ICF. · Refer to Continuty
· Key switch: OFF Check in CAN
· Refer to Continuty Harness on T5-6-46.
Check in CAN
Check if fault code Harness on T5-6-45. Open circuit in CAN
11004-2 is displayed harness between
after retry. NO MC and ICF.
Normal.
NO
T5-6-40
Short-circuited CAN
Disconnect all YES
harness between ground
connectors in MC, circuit and CAN circuit.
ICF, ECM and
monitor unit.
YES Check for continuity YES Short-circuited CAN
between CAN circuit
harness between power
and ground circuit in
circuit and CAN circuit.
MC, ICF, ECM and
monitor unit.
Check for continuity Short-circuited CAN
· Key switch: OFF YES harness between key
· Refer to NO between CAN circuit
and power circuit in Check for continuity signal circuit and CAN
“Discontinuity Check
MC, ICF, ECM and between CAN circuit circuit.
between CAN Circuit
and Ground Circuit” monitor unit. and key signal circuit
NO in MC, ICF, ECM and Check for continuity
on T5-6-47 to 50. · Key switch: OFF
monitor unit. between High side and To A
· Refer to
“Discontinuity Check NO Low side in CAN
· Key switch: OFF harness.
between CAN Circuit · Refer to “Discontinuity
and Power Circuit” Check between CAN · Key switch: OFF
on T5-6-51 to 54. Circuit and Key · Refer to “Discontinuity
Signal Circuit” on Check in CAN
T5-6-55 to 57. Harness on T5-6-58
to 59.
Open circuit in CAN

harness between MC and
NO monitor unit.
T5-6-41
YES Short-circuited CAN

harness.
NO Check the
Connect connector connection of MC
YES in MC. and connector.
A Check if fault code
Connect all 11004-2 is
connectors except displayed. Faulty MC.
connector MC-C in YES
MC. · Key switch: ON
Check if resistance
between terminals NO Check the
Connect connector connection of ICF
#C4 and #C15 of in ICF.
NO harness end of YES and connector.
Connect connector in Check if fault code
connector MC-C is MC. Disconnect 11004-2 is
within 60±10 Ω. connector ICF-C in displayed. Faulty ICF.
ICF. YES
· Key switch: OFF · Key switch: ON
Check if resistance
between terminals
#C5 and #C11 of Connect connector
NO harness end of Connect connector in YES in ECM. Check if
connector is within ICF. fault code 11004-2
60±10 Ω. Disconnect is displayed.
· Key switch: OFF connector in ECM.
Check if resistance · Key switch: ON
between terminals
NO #18 and #37 of
Connector harness end of Connect connector in
connector is within ECM.
MC Disconnect
Connector MC-C 120±10 Ω.
connector monitor-B
(Harness end) · Key switch: OFF in monitor unit.
NO
#C4 #C15 Check if resistance
C1 C10 between terminals
#B6 and #B7 of
harness end of
connector is within
120±10 Ω.
C23 C31
· Key switch: OFF
ICF
Connector ICF-C
(Harness end)
#C5
T1V1-05-04-002
#C11
Monitor Unit
ECM Connector Monitor-B Connector
Connector (Harness end)
(Harness end) #18 #37 #B7 #B6
T1GR-05-04-002
T183-05-04-013
T5-6-42
NO Adjust the connection of

ECM and connector.
Faulty ECM.
YES
NO Check the connection

Connect connector in of monitor unit and
YES monitor unit. connector.
Check if fault code
11004-2 is displayed. Faulty monitor unit.
YES
· Key switch: ON
Failure in any controller

of MC, ICF, ECM and
NO monitor unit.
T5-6-43
Continuity Check in CAN Harness
IMPORTANT: Before continuity check, turn the key

switch OFF.
• Between MC and ECM

CAN Harness (High Side)
Check for continuity between terminal #C4 of
harness end of connector MC-C in MC and
terminal #18 of harness end of connector in ECM.
CAN Harness (Low Side)

terminal #37 of harness end of connector in ECM.
Connector
MC
Connector MC-C
(Harness end)
#C4 #C15
C1 C10
C23 C31
ECM
Connector
(Harness end)
#18 #37
T1GR-05-04-002
T5-6-44
• Between MC and ICF
terminal #C5 of harness end of connector ICF-C
in ICF.

terminal #C11 of harness end of connector ICF-C
in ICF.
Connector
MC
Connector MC-C
(Harness end)
#C4 #C15
C1 C10
C23 C31
ICF
Connector ICF-C
(Harness end)
#C5
#C11 T1V1-05-04-002
T5-6-45
• Between MC and Monitor Unit
terminal #B7 of harness end of connector
monitor-B in the monitor unit.

terminal #B6 of harness end of connector
monitor-B in the monitor unit.
Connector
MC
Connector MC-C
(Harness end)
#C4 #C15
C1 C10
C23 C31
Monitor Unit
Connector Monitor-B
(Harness end)
#B7 #B6
T183-05-04-013
T5-6-46
Discontinuity Check between CAN Circuit and
Ground Circuit Connector
IMPORTANT: Before continuity check, turn the key Connector MC-C
(Harness end)
switch OFF.
• In case of continuity, the circuit between #C4
CAN circuit and ground circuit is C1 C10
shorted.
• In case of discontinuity, the circuit is
normal.
C23 C31
• MC
Between CAN Circuit (High Side) and Ground Connector MC-A
Circuit (Harness end)
harness end of connector MC-C and terminal #A2 #A2
of harness end of connector in MC-A.

harness end of connector MC-C and terminal
#A13 of harness end of connector in MC-A.
#A13
T183-05-04-008
harness end of connector MC-C and terminal #B8 Connector MC-B
of harness end of connector in MC-B. (Harness end)
#B8
#B18 of harness end of connector in MC-B.
#B18
T183-05-04-021
T5-6-47
Between CAN Circuit (Low Side) and Ground
Circuit Connector
harness end of connector MC-C and terminal #A2
Connector MC-C
of harness end of connector in MC-A. (Harness end)
Check for continuity between terminal #C15 of #C15

harness end of connector MC-C and terminal C1 C10
#A13 of harness end of connector in MC-A.

C23 C31
harness end of connector MC-C and terminal #B8
of harness end of connector in MC-B.
Connector MC-A
(Harness end)
harness end of connector MC-C and terminal #A2
#B18 of harness end of connector in MC-B.
#A13
T183-05-04-008
Connector MC-B
(Harness end)
#B8
#B18
T183-05-04-021
T5-6-48
• ECM
Between CAN Circuit (High Side) and Ground
Circuit ECM
Check for continuity between terminals #18 and Connector
#1 of harness end of connector. (Harness end)
#18 #43
Check for continuity between terminals #18 and
#4
#3 of harness end of connector.
#3
T1GR-05-04-002
#62 #1

Between CAN Circuit (Low Side) and Ground ECM

Circuit Connector
Check for continuity between terminals #37 and (Harness end)
#37 #43
#4
#3
Check for continuity between terminals #37 and T1GR-05-04-002

#4 of harness end of connector. #62 #1


T5-6-49
• ICF
Between CAN Circuit (High Side) and Ground ICF
Circuit Connector ICF-C
Check for continuity between terminals #C5 and (Harness end)
#C14 of harness end of connector ICF-C.
#C5
Check for continuity between terminals #C5 and
T1V1-05-04-002
#C14 #C15
Between CAN Circuit (Low Side) and Ground ICF

(Harness end)

T1V1-05-04-002
#C14 #C15 #C11
• Monitor Unit Monitor Unit

Between CAN Circuit (High Side) and Ground Connector Monitor-B
(Harness end)
Circuit
Check for continuity between terminals #B7 and
#B11 of harness end of connector in the monitor #B7
unit.
T183-05-04-013
#B11
Between CAN Circuit (Low Side) and Ground Monitor Unit

Circuit Connector Monitor-B
(Harness end)
Check for continuity between terminals #B6 and
#B11 of harness end of connector in the monitor
#B6
unit.
T183-05-04-013
#B11
T5-6-50
Power Circuit Connector
switch OFF. (Harness end)
CAN circuit and power circuit is shorted. C1 C10
normal.
• MC C23 C31
Between CAN Circuit (High Side) and Power
Circuit
Check for continuity between terminal #C4 of Connector MC-A
harness end of connector MC-C and terminal #A1 (Harness end)
of harness end connector MC-A.
#A1
#A12 of harness end connector MC-A.
#A12
Check for continuity between terminal #C4 of T183-05-04-008
of harness end connector MC-B. Connector MC-B
(Harness end)
Check for continuity between terminal #C4 of #B7
#B17 of harness end connector MC-B.
#B17
T183-05-04-021
T5-6-51
Between CAN Circuit (Low Side) and Power
Circuit Connector
harness end of connector MC-C and terminal #A1 Connector MC-C
of harness end connector MC-A. (Harness end)
#C15
Check for continuity between terminal #C15 of C1 C10
#A12 of harness end connector MC-A.
Check for continuity between terminal #C15 of C23 C31

of harness end connector MC-B. Connector MC-A
(Harness end)
#B17 of harness end connector MC-B. #A1
#A12
T183-05-04-008
Connector MC-B
(Harness end)
#B7
#B17
T183-05-04-021
T5-6-52
• ECM
ECM
Circuit Connector

T1GR-05-04-002
#2
Between CAN Circuit (Low Side) and Power ECM

Connector
Check for continuity between terminals #37 and #37 #5

T1GR-05-04-002
#2
• ICF
ICF
Between CAN Circuit (High Side) and Power Connector ICF-C
#C1 of harness end of connector ICF-C. #C5
#C2
Check for continuity between terminals #C5 and #C1
T1V1-05-04-002
Between CAN Circuit (Low Side) and Power ICF

(Harness end)
#C2
T1V1-05-04-002
#C11
T5-6-53
• Monitor Unit
Circuit Monitor Unit
Connector Monitor-A
Check for continuity between terminal #B7 of (Harness end)
harness end of connector monitor-B in the monitor
unit and terminal #A16 of harness end of
connector monitor-A in the monitor unit.
#A16
T183-05-05-001
Monitor Unit
Connector Monitor-B
(Harness end)
#B7
T183-05-04-013
Between CAN Circuit (Low Side) and Power Monitor Unit

Circuit Connector Monitor-A
unit and terminal #A16 of harness end of
connector monitor-A in the monitor unit.
#A16
T183-05-05-001
Monitor Unit
Connector Monitor-B
(Harness end)
#B6
T183-05-04-013
T5-6-54
Key Signal Circuit Connector
switch OFF. (Harness end)
CAN circuit and key signal circuit is C1 C10
shorted.
normal.
C23 C31
• MC
Between CAN Circuit (High Side) and Key Signal Connector MC-B
Check for continuity between terminal #C4 of #B16
#B16 of harness end of connector MC-B.
T183-05-04-021
Between CAN Circuit (Low Side) and Key Signal Connector

Circuit
Check for continuity between terminal #C15 of Connector MC-C
harness end of connector MC-C and terminal (Harness end)
#B16 of harness end of connector MC-B.
#C15
C1 C10
C23 C31
Connector MC-B
(Harness end)
#B16
T183-05-04-021
T5-6-55
• ECM
Between CAN Circuit (High Side) and Key Signal ECM
Circuit Connector
T1GR-05-04-002
Between CAN Circuit (Low Side) and Key Signal ECM

Circuit Connector
T1GR-05-04-002
• ICF
ICF
Between CAN Circuit (High Side) and Key Signal Connector ICF-C
#C7
T1V1-05-04-002
Between CAN Circuit (Low Side) and Key Signal ICF

Connector ICF-C
Check for continuity between terminals #C11

and #C7 of harness end of connector ICF-C.
#C7
T1V1-05-04-002
#C11
T5-6-56
• Monitor Unit
Monitor Unit
unit and terminal #A7 of harness end of connector #A7
monitor-A in the monitor unit.
T183-05-05-001
Monitor Unit
Connector Monitor-B
(Harness end)
#B7
T183-05-04-013
Between CAN Circuit (Low Side) and Power

Monitor Unit
unit and terminal #A7 of harness end of connector
monitor-A in the monitor unit. #A7
T183-05-05-001
Monitor Unit
Connector Monitor-B
(Harness end)
#B6
T183-05-04-013
T5-6-57
Discontinuity Check in CAN Harness
IMPORTANT: Before continuity check, turn the key

switch OFF.
• In case of continuity, the circuit between
CAN (high side) circuit and CAN (low
side) circuit is shorted.
normal.
• Connector MC-C
Check for continuity between terminals #C4 and MC
Connector MC-C
#C15 of harness end of connector MC-C in MC. (Harness end)
#C4 #C15
C1 C10
C23 C31
• Connector ECM
ECM
Check for continuity between terminals #18 and Connector
(Harness end)
#37 of harness end of connector in ECM.
#18 #37
T1GR-05-04-002
T5-6-58
• Connector ICF-C
#C11 of harness end of connector ICF-C in ICF. ICF
Connector ICF-C
(Harness end)
#C5
#C11 T1V1-05-04-002
• Connector Monitor-B in Monitor Unit Monitor Unit

Check for continuity between terminals #B6 and Connector Monitor-B
(Harness end)
#B7 of harness end of connector monitor-B in the
#B7 #B6
monitor unit.
T183-05-04-013
T5-6-59
MC FAULT CODE 11101

11101-3 Abnormal Engine Control Dial Sensor High Voltage Voltage: 4.75 V or higher
11101-4 Abnormal Engine Control Dial Sensor Low Voltage Voltage: Less than 0.25 V
Check if harnes
between terminal YES Faulty harness
between MC and
#D15 of harness end engine control dial.
YES of connector MC-D in
MC and terminal #2 in
Disconnect connector switch panel is open
of switch panel. or shorted. Faulty MC.
Disconnect connector of Check if voltage NO
switch panel. between terminals #1
YES
Check fi resistance and #3 of harness end Open circuit in
between terminals #1 and of connector is 5±0.5 Check fi voltage harness between MC
V. between terminal #1 YES and engine control
#3 of switch panel end of
connector is 5±0.5 kΩ. of harness end of dial (terminal #3).
· Key switch: ON connector in switch
Insert a probe of tester
from the back of connector panel and machine is
NO specification.
in terminal #2 with switch Open circuit in
panel connector harness between MC
connected. · Key switch: ON NO and engine control
When rotating engine · Specification: 5±0.5 V dial (terminal #1).
control dial, chack if
voltage becomes
specification. Faulty engine control
NO dial.
· Specification: Refer to
the table below.
Specification of Engine Control Dial

Slow Idle 0.3 to 1.0 V
Fast Idle 4.0 to 4.7 V

open side)
MC
Connector MC-D
T183-05-04-009
#C15
Switch Panel
#3 #2 #1
T5-6-60
MC FAULT CODE 11200

11200-3 Abnormal Pump 1 Delivery Pressure Sensor High Voltage Voltage: 4.75 V or higher
11200-4 Abnormal Pump 1 Delivery Pressure Sensor Low Voltage Voltage: Less than 0.25 V
YES Faulty harness between

Check if harnes MC and pump 1 delivery
between terminal #C3 pressure sensor.
YES of harness end of
connector MC-C in MC
Disconnect connector and terminal #2 in
of pump 1 delivery pump 1 delivery Faulty MC.
pressure sensor. pressure sensor is NO
Check fi voltage open or shorted.
NO
between terminals #1
and #3 of harness end
of connector is 5±0.5 YES Open circuit in harness
Check fi voltage between MC and pump 1
V. between terminal #1 delivery pressure sensor
Switch pump 1 delivery of harness end of (terminal #3).
pressure sensor with · Key switch: ON connector in pump 1
NO
pump 2 delivery delivery pressure Open circuit in harness
pressure sensor and sensor and machine between MC and pump 1
retry. is specification. NO delivery pressure sensor
Check if fault code is (terminal #1).
· Key switch: ON
switched.
· Refer to the table
upward.
Faulty pump 1 delivery
YES pressure sensor.

open side)
MC Pump 1 Delivery
Connector MC-C Pressure Sensor
#C3
C1 C10
C23 C31
T1J1-05-06-002
T5-6-61
MC FAULT CODE 11202

11202-3 Abnormal Pump 2 Delivery Pressure Sensor High Voltage Voltage: 4.75 V or higher
11202-4 Abnormal Pump 2 Delivery Pressure Sensor Low Voltage Voltage: Less than 0.25 V

Check if harnes MC and pump 2 delivery
between terminal #C12 pressure sensor.
Disconnect connector and terminal #2 in
of pump 2 delivery pump 2 delivery Faulty MC.
pressure sensor. pressure sensor is NO
NO
of connector is 5±0.5
Check fi voltage YES Open circuit in harness
between terminal #1 between MC and pump 2
V. of harness end of delivery pressure sensor
Switch pump 1 delivery
pressure sensor with connector in pump 2 (terminal #3).
· Key switch: ON
pump 2 delivery NO delivery pressure
pressure sensor and sensor and machine Open circuit in harness
retry. is specification. between MC and pump 2
NO delivery pressure sensor
Check if fault code is · Key switch: ON
switched. (terminal #1).
upward.
Faulty pump 2 delivery

open side)
MC Pump 2 Delivery
Connector MC-C Pressure Sensor
#C12
C1 C10
C23 C31
T1J1-05-06-002
T5-6-62
MC FAULT CODE 11301

11301-3 Abnormal Swing Pilot Pressure Sensor High Voltage Voltage: 4.75 V or higher
11301-4 Abnormal Swing Pilot Pressure Sensor Low Voltage Voltage: Less than 0.25 V

MC and pressure sensor.
Check if harnes
YES between terminal #D16
of harness end of
connector MC-D in MC
Disconnect connector and terminal #2 in Faulty MC.
of pressure sensor. pressure sensor is NO
NO and #3 of harness end
V. Open circuit in harness
· Key switch: ON Check fi voltage YES between MC and
between terminal #1 pressure sensor (terminal
of harness end of #3).
Switch pressure sensor connector in pressure
with other pressure NO sensor and machine
sensor and retry. is specification. Open circuit in harness
Check if fault code between MC and
disappears. · Key switch: ON NO pressure sensor (terminal
#1).
upward.
Faulty pressure sensor.

YES

open side)
MC Pilot Pressure Sensor

Connector MC-D (Swing)
#D16
T1J1-05-06-001
T183-05-04-009
T5-6-63
MC FAULT CODE 11302

11302-3 Abnormal Boom Raise Pilot Pressure Sensor High Voltage Voltage: 4.75 V or higher
11302-4 Abnormal Boom Raise Pilot Pressure Sensor Low Voltage Voltage: Less than 0.25 V
Check if harnes YES Faulty harness between

between terminal #C13 MC and pressure sensor.
of harness end of
YES
and terminal #2 in
pressure sensor is Faulty MC.
open or shorted.
Disconnect connector NO
of pressure sensor.
NO Check fi voltage
Open circuit in harness
between MC and
V.
YES pressure sensor (terminal
Check fi voltage
· Key switch: ON #3).
between terminal #1 of
harness end of
Switch pressure sensor NO connector in pressure
with other pressure sensor and machine is Open circuit in harness
sensor and retry. specification. between MC and
Check if fault code NO pressure sensor (terminal
disappears. · Key switch: ON #1).
upward.
YES

open side)
MC
Pilot Pressure Sensor (Boom Raise)
Connector MC-C
#C13
C1 C10
C23 C31 T1J1-05-06-001
T5-6-64
MC FAULT CODE 11303

11303-3 Abnormal Arm Roll-In Pilot Pressure Sensor High Voltage Voltage: 4.75 V or higher
11303-4 Abnormal Arm Roll-In Pilot Pressure Sensor Low Voltage Voltage: Less than 0.25 V

and terminal #2 in
Disconnect connector open or shorted. NO
of pressure sensor.
Check fi voltage
NO
YES between MC and
Check fi voltage
· Key switch: ON pressure sensor (terminal
between terminal #1
#3).
of harness end of
with other pressure sensor and machine Open circuit in harness
sensor and retry. is specification. between MC and
disappears. · Key switch: ON
· Refer to the table #1).
upward.
YES

open side)

Connector MC-C (Arm Roll-In)
C1 C10
#C23
C23 C31 T1J1-05-06-001
T5-6-65
MC FAULT CODE 11400

11400-3 Abnormal Feedback High Current of Pump 2 Control Solenoid Current: Higher than 920 mA
Valve
11400-4 Abnormal Feedback Low Current of Pump 2 Control Solenoid Current: Less than 56 mA
Valve
IMPORTANT: In case switching the connector in

solenoid valve and performing the
diagnosing, check for continuity in
the solenoid before switching. When
the connector is switched and the
engine starts with the solenoid
shorted, normal solenoid valve and
MC may be damaged.
Reference value:
Pump control solenoid valve: 17.5 Ω
at 20 °C
4-spool solenoid valve unit: 18.5 Ω
at 20 °C
Switch connectors of YES Faulty pump 2 control

pump 2 control solenoid solenoid valve.
valve and control
YES solenoid valve.
Check if fault code in
torque control solenoid Faulty MC.
valve is displayed. NO
harness between MC
and pump 2 control
solenoid valve.
· Between terminal #A30

of connector MC-A in
MC and terminal #1 of Open circuit in harness.
connector in pump 2 NO
control solenoid valve.
MC and terminal #2 of
connector in pump 2

open side)
MC
Connector MC-A Pump 2 Control Solenoid Valve
#A19
T1J1-05-06-003
#A30 T183-05-04-008
T5-6-66
MC FAULT CODE 11402

11402-3 Abnormal Feedback High Current of Solenoid Valve Unit Current: Higher than 920 mA
(SF) (Boom Flow Rate Control Valve Control)
11402-4 Abnormal Feedback Low Current of Solenoid Valve Unit Current: Less than 56 mA
(SF) (Boom Flow Rate Control Valve Control)

MC may be damaged.
Reference value:
at 20 °C
at 20 °C
Switch connectors of YES Faulty solenoid valve unit

solenoid valve unit (SF) (SF).
and other solenoid valve
YES
unit (SC, SG or SI).
switched solenoid valve Faulty MC.
unit is displayed. NO
harness between MC and · After switching connectors,
solenoid valve unit (SF). operate combined operation
of boom lower and bucket or
· Between terminal #A20 arm, and check by using
of connector MC-A in monitor unit (service mode).
connector in solenoid Open circuit in harness.
valve unit (SF). NO
· Between terminal #A3 of
connector MC-A in MC
and terminal #2 of
connector in solenoid
valve unit (SF).

open side)
MC
Connector MC-A
Solenoid Valve Unit (SF)
#A3 #A20
T1V1-05-04-003
T183-05-04-008
T5-6-67
MC FAULT CODE 11404

11404-3 Abnormal Feedback High Current of Solenoid Valve Unit (SG) Current: Higher than 920 mA
(Main Relief Pressure Control)
11404-4 Abnormal Feedback Low Current of Solenoid Valve Unit (SG) Current: Less than 56 mA
(Main Relief Pressure Control)

MC may be damaged.
Reference value:
at 20 °C
at 20 °C

solenoid valve unit (SG) (SG).
YES
unit (SF, SC or SI).
harness between MC · After switching connectors,
and solenoid valve unit operate boom raise relieved,
(SG). and check by using monitor
unit (service mode).
NO
valve unit (SG).
valve unit (SG).

open side)
MC Solenoid Valve Unit (SG)

Connector MC-A
#A7
T1V1-05-04-003
#A23
T183-05-04-008
T5-6-68
MC FAULT CODE 11405

11405-3 Abnormal Feedback High Current of Solenoid Valve Unit (SI) Current: Higher than 920 mA
(Travel Motor Displacement Angle Control)
11405-4 Abnormal Feedback Low Current of Solenoid Valve Unit (SI) Current: Less than 56 mA
(Travel Motor Displacement Angle Control)

MC may be damaged.
Reference value:
at 20 °C
at 20 °C
solenoid valve unit (SI) (SI).
YES unit (SF, SC or SG).
harness between MC · After switching connectors,
and solenoid valve unit turn travel mode switch to
(SI). FAST, and check by using
monitor unit (service
· Between terminal #A11 mode).
connector in solenoid NO
valve unit (SI).
valve unit (SI).

open side)
MC Solenoid Valve Unit (SI)
Connector MC-A
#A17
#A11
T1V1-05-04-003
T183-05-04-008
T5-6-69
MC FAULT CODE 11410

11410-3 Abnormal Feedback High Current of Pump 1 Control Solenoid Current: Higher than 920 mA
Valve
11410-4 Abnormal Feedback Low Current of Pump 1 Control Solenoid Current: Less than 56 mA
Valve

MC may be damaged.
Reference value:
at 20 °C
at 20 °C
Switch connectors of YES Faulty pump 1 control
pump 1 control solenoid solenoid valve.
valve and pump 2 control
YES solenoid valve.
harness between MC
and pump 1 control
solenoid valve.

connector in pump 1 NO
connector in pump 1

open side)
Pump 1 Control Solenoid Valve
MC
Connector MC-A
#A16 #A22
T1J1-05-06-003
T183-05-04-008
T5-6-70
MC FAULT CODE 11412

11412-3 Abnormal Feedback High Current of Fan Pump Control Solenoid Current: Higher than 920 mA
Valve
11412-4 Abnormal Feedback Low Current of Fan Pump Control Solenoid Current: Less than 56 mA
Valve

MC may be damaged.
Reference value:
at 20 °C
at 20 °C
Switch connectors of fan YES Faulty fan pump control

pump control solenoid solenoid valve.
valve and pump 2 control
YES solenoid valve.
harness between MC
and maximum pump 1
flow rate limit control
solenoid valve.
connector in fan pump NO
connector in fan pump
open side)
Fan Pump Control Solenoid Valve
MC
Connector MC-A
#A15 #A9
T1J1-05-06-003
T183-05-04-008
T5-6-71
MC FAULT CODE 11802

11802-3 Abnormal Boom Bottom Pressure Sensor High Voltage Voltage: 4.5 V or higher
11802-4 Abnormal Boom Bottom Pressure Sensor Low Voltage Voltage: Less than 0.25 V
Check if harnes
between terminal #C24 YES Faulty harness between
MC and boom bottom
of harness end of pressure sensor.
YES connector MC-C in MC
and terminal #2 in
boom bottom pressure
sensor is open or Faulty MC.
Disconnect connector shorted. NO
of boom bottom
pressure sensor.
NO Check fi voltage
of connector is 5±0.5 Open circuit in harness
V. Check fi voltage YES between MC and boom
between terminal #1 bottom pressure sensor
· Key switch: ON of harness end of (terminal #3).
Switch boom bottom connector in boom
pressure sensor and NO bottom pressure
pump 2 delivery sensor and machine
between MC and boom
pressure sensor. is specification. NO bottom pressure sensor
Check if fault code
· Key switch: ON (terminal #1).
(11202) disappears.
upward.
Faulty boom bottom

open side)
MC Boom Bottom Pressure Sensor

Connector MC-C
C1 C10
C23 C31 T1J1-05-06-001

#C24
T5-6-72
MC FAULT CODE 11901

11901-3 Hydraulic Oil Temperature Sensor High Voltage Intake Air Temp.: 21 °C or higher
Voltage: 4.10 V or higher
The above condition holds 30 seconds or more.
11901-4 Hydraulic Oil Temperature Sensor Low Voltage Voltage: Less than 0.23 V
The above condition holds 30 seconds or more.
Connect terminals #1
YES Faulty MC.
of connector in
hydraulic oil
temperature sensor by Connect terminal #D6
YES using a clip. Open circuit in harness
of harness end of YES between MC and
Disconnect connector connector MC-D in
MC-D from MC. hydraulic oil temperature
MC to machine. sensor (terminal #1).
Check for continuity Check for continuity
Disconnect connector of between terminals #D2
hydraulic oil temperature NO between terminals #2
and #D6 of harness of harness end of
sensor. Open circuit in harness
end of connector connector in hydraulic
Check if resistance at between MC and
MC-D. oil temperature NO
sensor end connector is hydraulic oil temperature
specification. sensor and machine. sensor (terminal #2).
· Specification: Refer to
the table below. Faulty hydraulic oil
NO temperature sensor.
Specification of Hydraulic Oil Temperature Sensor

Hydraulic Oil Temperature Resistance
(°C) (kΩ)
-20 16.2±1.6
0 (5.88)
20 2.45±0.24
40 (1.14)
60 (0.534)
80 0.322

open side)
MC Hydraulic Oil Temperature

Connector MC-D Sensor
#D2
1 2
#D6
T183-05-04-009
T5-6-73
(Blank)
T5-6-74
MC FAULT CODES 11910,11911, 11914, 11918, 11920, 11983, 11984

11910-2 Actual Engine Speed Receive Error Faulty CAN Harness
Sent from ECM
11911-2 Security Signal Receive Error Faulty CAN Harness
Sent from monitor unit
11914-2 Radiator Water Temperature Receive Error Faulty CAN Harness
Sent from ECM
11918-2 Work Mode Receive Error Faulty CAN Harness
Sent from monitor unit
11920-2 Fuel Flow Receive Error Faulty CAN Harness
Sent from ECM
11983-2 Intake Air Temperature Receive Error Faulty CAN Harness
Sent from ECM
11984-2 Boost Temperature Receive Error Faulty CAN Harness
Sent from ECM
Dr. ZX
Satellite Terminal
(Optional)
Monitor Unit ICF
CAN Harness
MC
ECM
T1J1-02-01-004
T5-6-75
MC FAULT CODES 11910, 11911, 11914,
11918, 11920, 11983, 11984
(CAN HARNESS CHECK)
Disconnect all
connectors of MC, ICF, YES Open circuit in CAN
ECM and monitor unit. harness between ground
YES Check for continuity circuit and CAN circuit.
between ground circuit
(MC, ICF, ECM, Check for continuity
monitor unit) and CAN between power
circuit. circuit (MC, ICF,
NO ECM, monitor unit)
Check for continuity in · Key switch: OFF and CAN circuit.
YES · Refer to
CAN harness between
MC and ECM. “Discontinuity Check · Key switch: OFF
between CAN Circuit · Refer to “Discontinuity
· Key switch: OFF and Ground Circuit” Check between CAN
· Refer to “Continuity on T5-6-47 to 50. Circuit and Power Circuit”
Retry by using monitor Check in CAN on T5-6-51 to 54.
unit (service mode). Harness” on T5-6-44.
Check if fault code Open circuit in CAN
11004-2 is displayed. harness between MC and
NO ECM.
Normal.
NO
T5-6-76
Shorted circuit in CAN

YES
circuit and CAN circuit.
Shorted circuit in CAN

YES harness between key
signal circuit and CAN
circuit.
Check for continuity
between key signal
circuit (MC, ICF, YES Shorted circuit in CAN
NO ECM, monitor unit) harness.
and CAN circuit.
· Key switch: OFF Check for continuity
· Refer to between High side Connect all
“Discontinuity and Low side in CAN connectors except YES
NO harness. To A
Check between connector MC-C in
CAN Circuit and · Key switch: OFF MC.
Check if resistance Disconnect
Key Signal Circuit” · Refer to
between terminals connector in ECM.
on T5-6-55 to 57. “Discontinuity Check NO
#C4 and #C5 of Connect MC-C
in CAN Harness” on connector in MC.
T5-6-58-to 59. harness end of
connector MC-C is Check if resistance To B
within 60±10 Ω. NO between terminals
#18 and #37 of
· Key switch: OFF harness end of
connector in ECM is
Connector within 120±10 Ω.
MC · Key switch: OFF
Connector MC-C
(Harness end)
#C4 #C15
C1 C10
C23 C31
Monitor Unit
Connector Monitor-B
(Harness end)
#18 #37
T1GR-05-04-002
T5-6-77
NO Check the connections of

Connect connector MC and connector.
in MC. Check if fault
A code 11004-2 is
displayed. Faulty MC.
· Key switch: ON YES
Check the connections of

Connect connector NO
ECM and connector.
ECM.
YES Check if fault code
11004-2 is
displayed. Faulty ECM.
YES
· Key switch: ON
Connect connector NO Check the connections of

B in ICF. ICF and connector.
YES Check if fault code
Connect connector in
11004-2 is
ECM.
displayed. Faulty ICF.
Disconnect
connector ICF-C in · Key switch: ON YES
ICF.
Check if resistance
NO Check the connections of
between terminals Connect connector in Connect connector monitor unit and
NO #C5 and #C11 of in monitor unit.
ICF. YES connector.
harness end of Disconnect Check if fault code
connector is within connector monitor B 11004-2 is
Faulty monitor unit.
120±10 Ω. in monitor unit. displayed.
Check if resistance YES
· Key switch: OFF · Key switch: ON
between terminals
NO #B6 and #B7 of
harness end of
connector is within Failure in any controller in
120±10 Ω. MC, ICF, ECM or monitor
NO unit.
· Key switch: OFF
Connector
ECM
Connector
ICF
(Harness end)
Connector ICF-C
(Harness end)
#B7 #B6
#C5
T183-05-04-013
#C11 T1V1-05-04-002
T5-6-78
MC FAULT CODE 11989

11989-3 Abnormal Feedback High Current of Solenoid Valve Unit (SC) Current: Higher than 920 mA
(Boom Mode Control)
11989-4 Abnormal Feedback Low Current of Solenoid Valve Unit (SC) Current: Less than 56 mA
(Boom Mode Control)

MC may be damaged.
Reference value:
at 20 °C
at 20 °C

solenoid valve unit (SC) (SC).
YES
unit (SF, SG or SI).
Check for continuity in · After switching connectors,
harness between MC and operate combined
solenoid valve unit (SC). operation of boom lower
and bucket or arm, and
· Between terminal #A10 of
check by using monitor unit
connector MC-A in MC and
(service mode).
terminal #1 of connector in
solenoid valve unit (SC). Open circuit in harness.
· Between terminal #A6 of NO
connector MC-A in MC and
terminal #2 of connector in
solenoid valve unit (SC).

open side)
MC
Connector MC-A
#A6 #A10
Solenoid Valve Unit (SC)
T1V1-05-04-003
T183-05-04-008
T5-6-79
MC FAULT CODE 11991

11991-3 Abnormal Travel Right Pilot Pressure Sensor High Voltage Voltage: 4.75 V or higher
11991-4 Abnormal Travel Right Pilot Pressure Sensor Low Voltage Voltage: Less than 0.25 V

Check if harnes
of harness end of
#1).
upward.

YES

open side)

Connector MC-D (Travel Right)
#D9
T1J1-05-06-001
T183-05-04-009
T5-6-80
MC FAULT CODE 11992

11992-3 Abnormal Pump 2 Regulator Pressure Sensor High Voltage Voltage: 4.75 V or higher
11992-4 Abnormal Pump 2 Regulator Pressure Sensor Low Voltage Voltage: Less than 0.25 V
Check if harnes Faulty harness between

YES MC and pump 2 regulator
between terminal #D4
YES connector MC-D in MC
and terminal #2 in
pump 2 regulator
of pump 2 regulator
pressure sensor.
NO Check fi voltage
V. Check fi voltage YES between MC and pump 2
Switch pump 1 regulator between terminal #1 regulator pressure sensor
pressure sensor with of harness end of
pump 2 regulator connector in pump 2
pressure sensor and NO regulator pressure
retry. sensor and machine Open circuit in harness
Check if fault code is specification. between MC and pump 2
NO regulator pressure sensor
disappears.
upward. Faulty pump 2 regulator

open side)
MC
Connector MC-D Pump 2 Regulator Pressure Sensor
#D4
T1J1-05-06-001
T183-05-04-009
T5-6-81
MC FAULT CODE 11993

11993-3 Abnormal Travel Left Pilot Pressure Sensor High Voltage Voltage: 4.75 V or higher
11993-4 Abnormal Travel Left Pilot Pressure Sensor Low Voltage Voltage: Less than 0.25 V

Check if harnes
of harness end of
#1).
upward.

YES

open side)

Connector MC-D (Travel Left)
T1J1-05-06-001
#D14
T183-05-04-009
T5-6-82
MC FAULT CODE 11994

11994-3 Abnormal Pump 1 Regulator Pressure Sensor High Voltage Voltage: 4.75 V or higher
11994-4 Abnormal Pump 1 Regulator Pressure Sensor Low Voltage Voltage: Less than 0.25 V
Check if harnes Faulty harness between

YES MC and pump 1 regulator
between terminal #D11
YES connector MC-D in MC
and terminal #2 in
pump 1 regulator
of pump 1 regulator
pressure sensor.
NO Check fi voltage
V. Check fi voltage YES between MC and pump 1
Switch pump 1 regulator between terminal #1 regulator pressure sensor
pressure sensor with of harness end of
pump 2 regulator connector in pump 1
pressure sensor and NO regulator pressure
retry. sensor and machine Open circuit in harness
Check if fault code is specification. between MC and pump 1
NO regulator pressure sensor
disappears.
upward. Faulty pump 1 regulator

open side)
MC
Connector MC-D Pump 1 Regulator Pressure Sensor
#D11
T1J1-05-06-001
T183-05-04-009
T5-6-83
MC FAULT CODE 11995

11995-3 Abnormal Arm Roll-Out Pilot Pressure Sensor High Voltage Voltage: 4.75 V or higher
11995-4 Abnormal Arm Roll-Out Pilot Pressure Sensor Low Voltage Voltage: Less than 0.25 V

Check if harnes
of harness end of
#1).
upward.

YES

open side)

Connector MC-D (Arm Roll-Out)
#D5
T1J1-05-06-001
T183-05-04-009
T5-6-84
MC FAULT CODE 11997

11997-3 Abnormal Bucket Roll-Out Pilot Pressure Sensor High Voltage: 4.75 V or higher
Voltage
11997-4 Abnormal Bucket Roll-Out Pilot Pressure Sensor Low Voltage: Less than 0.25 V
Voltage

of harness end of
YES
and terminal #2 in
open or shorted.
of pressure sensor.
NO Check fi voltage
between MC and
V.
Check fi voltage
harness end of
upward.
YES

open side)
MC Pilot Pressure Sensor (Bucket Roll-Out)

Connector MC-C
#C11
C1 C10
C23 C31 T1J1-05-06-001
T5-6-85
MC FAULT CODE 11998

11998-3 Abnormal Boom Lower Pilot Pressure Sensor High Voltage Voltage: 4.75 V or higher
11998-4 Abnormal Boom Lower Pilot Pressure Sensor Low Voltage Voltage: Less than 0.25 V

of harness end of
YES
and terminal #2 in
open or shorted.
of pressure sensor.
NO Check fi voltage
between MC and
V.
Check fi voltage
harness end of
upward.
YES

open side)
MC Pilot Pressure Sensor (Boom Lower)

Connector MC-C
#C1
C1 C10
C23 C31 T1J1-05-06-001
T5-6-86
MC FAULT CODE 11999

11999-3 Abnormal Bucket Roll-In Pilot Pressure Sensor High Voltage Voltage: 4.75 V or higher
11999-4 Abnormal Bucket Roll-In Pilot Pressure Sensor Low Voltage Voltage: Less than 0.25 V

of harness end of
YES
and terminal #2 in
open or shorted.
of pressure sensor.
NO Check fi voltage
between MC and
V.
Check fi voltage
harness end of
upward.
YES

open side)
MC Pilot Pressure Sensor (Bucket Roll-In)

Connector MC-C
#C2
C1 C10
C23 C31 T1J1-05-06-001
T5-6-87
(Blank)
T5-6-88
ICF FAULT CODES 14000 to 14003
Fault Code Trouble Remedy

14000-2 Abnormal CAN Communication Execute retry B.
If this error code is displayed after retry, check the following
item.
• Check the CAN communication line (harness).
14001-2 Flash Memory: Read / Write Error Not necessary
14002-2 External RAM: Read / Write Error
14003-2 EEPROM: Sum Check Error Not necessary
T5-6-89
(Blank)
T5-6-90
(Blank)
T5-6-91
(Blank)
T5-6-92
ICF FAULT CODES 14006, 14008

14006-2 ICF: Satellite Communication Execute retry.
Terminal: Communication Error If this error code is displayed after retry, check the following
item.
• Check the communication line.
• Check the power source line of satellite terminal.
• Check the fuse.
Then, execute self-diagnosing and execute retry.

14008-2 ICF: Abnormal Internal RAM Execute retry.
If this error code is displayed after retry, replace the
controller.
Fault Code 14006-2
• Check the communication line Connector (Harness end of connector viewed from the
1. Check for continuity between terminal #A8 of open end)
harness end of connector ICF-A in ICF and
terminal #10 of harness end of connector A in
satellite terminal. ICF
2. Check for continuity between terminal #A9 of Connector ICF-A
harness end of connector ICF-A in ICF and #A8
terminal #20 of harness end of connector A in #A9
satellite terminal.
3. Check for continuity between terminal #A31 of #A31
harness end of connector ICF-A in ICF and
Satellite
terminal #2 of harness end of connector B in Connector A
satellite terminal.
10 9 8 7 6 5 4 3 2 1
• Check the power source line of satellite terminal
20 19 18 17 16 15 14 13 12 11
1. Check the battery power
Check voltage between terminal #2 of harness
end of connector A in satellite terminal and Satellite
Connector B
machine is 24 V.
2. Check the main power
With the key switch ON, check voltage between 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
terminal #1 of harness end of connector A in
satellite terminal and machine is 24 V.
3. Check the ground power
#12 of harness end of connector A in satellite
terminal.
T5-6-93
(Blank)
T5-6-94
MONITOR UNIT FAULT CODE 13303
13303-2 Abnormal Thermistor Temperature Cool the monitor unit until temperature inside the monitor unit
becomes less than 85 °C.
The screen of monitor unit becomes dark.
YES Normal.
Cool monitor unit. Check

YES if the screen of monitor
unit becomes normal.
Check if temperature
NO
around monitor unit is
high.

NO
T5-6-95

13304-2 Abnormal REG Input H Level Refer to the following.
NOTE: As terminal L in the regulator is a

waterproof type connector, it is difficult to
measure voltage. Measure voltage at
terminal R in starter relay. Check for
continuity at terminal R in starter relay and
terminal L in regulator.
Less than 33.5 V Faulty monitor unit.

Less than Measure voltage at
33.5 V terminal #C7 of
connector monitor-C.
· Engine: Running between terminal L in
Measure voltage at 33.5 V or higher regulator and monitor
terminal L in unit.
regulator.
Faulty regulator or faulty
alternator.
33.5 V or higher

open end)
Starter Relay
E
S R
Monitor Unit
Connector Monitor-C
6 1
12 7
#C7
T5-6-96
MONITOR UNIT FAULT CODES 13306, 13308
13306-2 Abnormal EEPROM If this error code is displayed after re-try, replace the monitor
unit.
13308-2 Abnormal CAN Communication Refer to “Check CAN Harness” (T5-6-44 to 59).
T5-6-97
13310-3 Shorted Circuit in Coolant Check the coolant temperature sensor and harness.
Temperature Sensor
With terminal of coolant

temperature sensor Shorted circuit in harness
YES between monitor unit and
disconnected, disconnect
connector monitor-C in sensor.
YES
monitor unit.
Check for continuity between
terminal #C8 of harness end Faulty monitor unit.
Check if resistance of of connector in monitor unit NO
coolant temperature and machine.
sensor is specification.
Faulty coolant temperature

NO sensor.

Coolant Temperature Resistance
(°C) (kΩ)
25 7.6
40 4.0±0.35
50 2.7±0.216
80 0.98
95 0.60
105 0.45
120 0.30

open end)
Monitor Unit Coolant Temperature Sensor
Connector Monitor-C
#1 #2
6 1
1 7
#C8
#3 T1J1-05-06-004
T5-6-98
13311-3 Shorted Circuit in Fuel Level Sensor Check the fuel level sensor and harness.
13311-4 Open Circuit in Fuel Level Sensor Check the fuel level sensor and harness.
Shorted circuit in harness

YES
With connector of fuel between monitor unit and
level sensor sensor.
disconnected, disconnect
connector monitor-C in
YES monitor unit.
Check for continuity Connect terminal #1 of
between terminal #C2 of harness end of YES Faulty monitor unit.
harness end of connector in fuel level
connector in monitor unit sensor to machine.
and machine. Check for continuity
Check if resistance of NO between terminal #C2 of
fuel level sensor is harness end of Open circuit in harness
specification. connector in monitor unit NO between monitor unit and
and machine. sensor.
Faulty fuel level sensor.

NO
Fuel Level Sensor
Float
Float Position Resistance (Ω)
Upper Limit (FULL) 10+0-4
FULL
3/4 26
R381.9 1/2 38±5
257 mm 1/4 53
3/4
Alarm Level 85±3
93 mm Lower Limit (EMPTY) 90+10-0
70.5 mm
204 mm 1/2 open end)
Monitor Unit
Connector Moniter-C Fuel Sensor
338 mm 1/4 #C2
6 1 1 2
1 7
EMPTY
T178-05-05-001
T5-6-99
PILOT SHUT-OFF LEVER ALARM
Pilot shut-off lever alarm is displayed on the

monitor unit screen.
YES Faulty pilot shut-off

switch.
Check if pilot shut-off
switch is bent or
damaged.
Faulty harness.
NO
Pilot Shut-Off Pilot Shut-Off

Lever Switch
T1V1-05-06-005
T5-6-100
TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURE
Apply troubleshooting B procedure when no fault code

is displayed on the service mode in monitor unit
although the machine operation is abnormal.
When the fault code is displayed, refer to
Troubleshooting A and start the troubleshooting.
On the front section pages of this group are the tables
indicating the relationship between machine trouble
symptoms and related parts which may cause such
trouble if failed.
Start the troubleshooting with more probable causes
selected by referring to these tables.
• How to Read the Troubleshoting Flow Charts
YES (OK)
(2)
• After checking or measuring item (1), select either YES (OK) or
・ (1) NO (NOT OK) and proceed to item (2) or (3), as appropriate.
(3)
NO (NOT OK)
・ • Special instructions or reference item are indicated in the spaces under the box.
Incorrect measuring or checking methods will render troubleshooting impossible,
· Key switch: ON and may damage components as well.
• Explanation of how to use test harness kit required. Refer to “Electrical System
・
Inspection” group (group 8) in this section.
・ • Use the service mode in monitor unit.
・ • Causes are stated in a thick-line box. Scanning through thick-line boxes, possible
causes can be seen without going through the flow chart.
T5-7-1
RELATIONSHIP BETWEEN MACHINE
TROUBLE SYMPTOMS AND RELATED
PARTS
This table indicates the relationship between machine
trouble symptoms and the potential problem parts,
which may cause trouble if failed, and the evaluation
methods of these components.
Parts Pump 1 Delivery Pump 2 Delivery
Engine Control Dial
• Instructs engine target speed. • Monitors pump delivery • Monitors pump delivery pres-
pressure to control HP mode, sure to control HP mode,
horsepower relief flow rate horsepower, swing horse-
reducing and auto-power lift power reducing and attach-
Function controls. ment mode controls.
• Engine speed does not • If pump delivery pressure • If pump delivery pressure
change even if engine control sensor output is 0.25 V or sensor output is 0.25 V or
dial is turned. 4.75 V, following symptoms 4.75 V, following symptoms
Symptoms in control sys- • If discontinuity or shorted will be presented by back-up will be presented by back-up
circuit occurs in engine con- mode function. mode function.
tem when trouble occurs. trol dial, target speed of 1200
-1
min is used as back-up
value.
• Engine speed is kept un-

-1
• HP mode is inoperable. • HP mode is inoperable.
changed from 1200 min . (Even if operating arm roll-in (Even if operating arm roll-in
(Auto-idle system functions. and boom raise with power and boom raise with power
Engine can be stopped by mode switch in HP mode po- mode switch in HP mode po-
key switch.) sition, engine speed does not sition, engine speed does not
increase.) increase.)
• As delivery pressure and flow • As delivery pressure and flow
rate of pump 1 are limited, rate of pump 2 are limited,
operating speed is slow and operation speed is slow and
Symptoms in machine power is weak except swing power is weak except bucket
operation when trouble operation. operation.
• Engine easily stalls. • Engine easily stalls.
occurs. • Under swing combined op-
erations, swing power is
weak.
• During boom raise single op-
eration, pressure does not
increase (power is weak).
By MC Fault Fault code 11101 is displayed. Fault code 11200 is displayed. Fault code 11202 is displayed.
Code
Monitor Item: Requested Engine Monitor Item: Pump 1 Delivery Monitor Item: Pump 2 Delivery
Speed, EC Dial Angle Pressure (Displayed by built-in Pressure (Displayed by built-in
By Monitor (Displayed by built-in diagnosing diagnosing system) diagnosing system)
Evaluation Function system)
Using Test
- - -
Harness
Others - - -
• Judge if pressure sensor is • Judge if pressure sensor is
faulty or harness is discon- faulty or harness is discon-
NOTE - nected by switching with nected by switching with
pump 2 delivery pressure pump 1 delivery pressure
sensor. sensor.
Descriptions of Control T2-1 T2-1 T2-1
(Operational Principle
Section in T/M)
T5-7-2
Pressure Sensor Pressure Sensor Pressure Sensor

(Boom Raise) (Boom Lower) (Arm Roll-Out)
• Monitors boom raise pilot pressure. (HP • Monitors boom lower pilot pressure. • Monitors arm roll-out pilot pressure.
mode control, auto-power lift control and (Boom mode selector control and boom (Boom mode selector control and boom
boom mode selector control) mode flow rate control valve control) mode flow rate control valve control)
• Abnormal low voltage: No signals arrive • Abnormal low voltage: No signals arrive • Abnormal low voltage: No signals arrive
to MC. to MC. to MC.
• Abnormal high voltage: As the sensor is • Abnormal high voltage: As the sensor is • Abnormal high voltage: As the sensor is
detected as fully operated, the sensor is detected as fully operated, the sensor is detected as fully operated, the sensor is
controlled. controlled. controlled.
• Engine speed becomes below E mode

-1
-1
-1
speed (1580 min ). speed (1580 min ). speed (1580 min ).
Abnormal high voltage: Abnormal high voltage: Abnormal high voltage:

• Even if lever is in neutral with auto-idle • Even if lever is in neutral with auto-idle • Even if lever is in neutral with auto-idle
switch ON, engine speed does not de- switch ON, engine speed does not de- switch ON, engine speed does not de-
crease. crease. crease.
Abnormal low voltage: Abnormal low voltage: Abnormal low voltage:
• Even if boom is raised with auto-idle • Even if boom is lowered with auto-idle • Even if arm is rolled out with auto-idle
switch ON, engine speed does not in- switch ON, engine speed does not in- switch ON, engine speed does not in-
crease. crease. crease.
• Even if boom is raised with power mode • During combined operation of boom • During combined operation of boom
switch in HP mode position, engine lower and arm or bucket, speed of arm or lower and arm roll-out, speed of arm
speed does not increase. bucket is slow. roll-out is slow.
• During boom raise single operation, • Even if boom is lowered with boom mode • Even if arm is rolled out with boom mode
pressure does not increase (power is selector switch ON, boom mode selector selector switch ON, boom mode selector
weak). control is inoperable. (Machine vibrations control is inoperable. (Machine vibrations
• Even if boom is raised with boom mode are many.) are many.)
selector switch ON, boom mode selector
control is inoperable. (Machine vibrations
are many.)
Fault Code 11302 is displayed. Fault Code 11998 is displayed. Fault Code 11995 is displayed.
Monitor Item: Boom Raise Pilot Pressure Monitor Item: Boom Lowering Pilot Pressure Monitor Item: Arm Roll-Out (BH) Pilot Pres-
(Displayed by built-in diagnosing system) sure
- - -
- - -
• Judge if pressure sensor is faulty or port • Judge if pressure sensor is faulty or port • Judge if pressure sensor is faulty or port
is clogged by switching pressure sensor is clogged by switching pressure sensor is clogged by switching pressure sensor
with another pressure sensor. with another pressure sensor. with another pressure sensor.
T2-1 T2-1 T2-1
T5-7-3
Parts Pressure Sensor Pressure Sensor Pressure Sensor

(Arm Roll-In) (Bucket Roll-Out) (Bucket Roll-In)
• Monitors arm roll-in pilot • Monitors bucket roll-out pilot • Monitors bucket roll-in pilot
pressure. (HP mode control, pressure. (Boom mode se- pressure. (Boom mode se-
boom mode selector control lector control and boom mode lector control and boom
and boom mode flow rate flow rate control valve control) mode flow rate control valve
Function control valve control) control)
• Abnormal low voltage: No • Abnormal low voltage: No • Abnormal low voltage: No

signals arrive to MC. signals arrive to MC. signals arrive to MC.
Symptoms in control • Abnormal high voltage: As the • Abnormal high voltage: As the • Abnormal high voltage: As
system when trouble sensor is detected as fully sensor is detected as fully the sensor is detected as
occurs. operated, the sensor is con- operated, the sensor is con- fully operated, the sensor is
trolled. trolled. controlled.
• Engine speed becomes be- • Engine speed becomes be- • Engine speed becomes be-
low E mode speed (1580 low E mode speed (1580 low E mode speed (1580
-1 -1 -1
min ). min ). min ).
Abnormal high voltage: Abnormal high voltage: Abnormal high voltage:

• Even if lever is in neutral with • Even if lever is in neutral with • Even if lever is in neutral with
auto-idle switch ON, engine auto-idle switch ON, engine auto-idle switch ON, engine
speed does not decrease. speed does not decrease. speed does not decrease.
Abnormal low voltage: Abnormal low voltage: Abnormal low voltage:
• Even if arm is rolled in with • Even if bucket is rolled out • Even if bucket is rolled in
Symptoms in machine auto-idle switch ON, engine with auto-idle switch ON, en- with auto-idle switch ON, en-
operation when trouble speed does not increase. gine speed does not in- gine speed does not in-
• Even if arm is rolled in with crease. crease.
occurs. power mode switch in HP • During combined operation of • During combined operation of
mode position, engine speed boom lower and bucket boom lower and bucket
does not increase. roll-out, speed of bucket roll-in, speed of bucket roll-in
• Even if arm is rolled in with roll-out is slow. is slow.
boom mode selector switch • Even if bucket is rolled out • Even if bucket is rolled in
ON, boom mode selector with boom mode selector with boom mode selector
control is inoperable. (Ma- switch ON, boom mode se- switch ON, boom mode se-
chine vibrations are many.) lector control is inoperable. lector control is inoperable.
(Machine vibrations are (Machine vibrations are
many.) many.)
By MC Fault Fault Code 11303 is displayed. Fault Code 11997 is displayed. Fault Code 11999 is displayed.
Code
Monitor Item: Arm Roll-In (BH) Monitor Item: Bucket Roll-Out Monitor Item: Bucket Roll-In
Pilot Pressure (BH) Pilot Pressure (BH) Pilot Pressure
(Displayed by built-in diagnosing
By Monitor system)
Evaluation Function
Using Test - - -
Harness
Others - - -
• Judge if pressure sensor is • Judge if pressure sensor is • Judge if pressure sensor is
faulty or port is clogged by faulty or port is clogged by faulty or port is clogged by
NOTE switching pressure sensor switching pressure sensor switching pressure sensor

Section in T/M)
T5-7-4
Pressure Sensor Pressure Sensor Pressure Sensor

(Swing) (Right Travel) (Left Travel)
• Monitors swing pilot pressure. (Relief flow • Monitors right travel pilot pressure. • Monitors left travel pilot pressure. (Travel
rate reducing control (relief cut off), swing (Travel speed increase control, relief flow speed increase control, relief flow rate
horsepower reducing control and boom rate reducing control (relief cut off), reducing control (relief cut off), pressure
mode flow rate control valve control) pressure increase selection control when increase selection control when traveling
traveling and travel alarm control (op- and travel alarm control (optional))
tional))
• Abnormal low voltage: No signals arrive • Abnormal low voltage: No signals arrive • Abnormal low voltage: No signals arrive
to MC. to MC. to MC.
• Abnormal high voltage: As the sensor is • Abnormal high voltage: As the sensor is • Abnormal high voltage: As the sensor is
detected as fully operated, the sensor is detected as fully operated, the sensor is detected as fully operated, the sensor is
controlled. controlled. controlled.

-1
-1
-1
speed (1580 min ). speed (1580 min ). speed (1580 min ).
• Travel alarm (optional) outputs. • Travel alarm (optional) outputs.
Abnormal high voltage:
• Even if lever is in neutral with auto-idle Abnormal high voltage: Abnormal high voltage:
switch ON, engine speed does not de- • Even if lever is in neutral with auto-idle • Even if lever is in neutral with auto-idle
crease. switch ON, engine speed does not de- switch ON, engine speed does not de-
Abnormal low voltage: crease. crease.
• Even if swing is operated with auto-idle Abnormal low voltage: Abnormal low voltage:
switch ON, engine speed does not in- • Even if right travel is operated with • Even if left travel is operated with
crease. auto-idle switch ON, engine speed does auto-idle switch ON, engine speed does
• Even if swing is operated at full stroke, not increase. not increase.
swing speed is slow. • Even if right travel is operated, engine • Even if left travel is operated, engine
• During combined operation of swing and speed does not increase. speed does not increase.
bucket, bucket speed is slow. • Even if right travel is operated, pressure • Even if left travel is operated, pressure
• Even if swing is operated with boom does not increase. does not increase.
mode selector switch ON, boom mode
selector control is inoperable. (Machine
vibrations are many.)
Fault Code 11301 is displayed. Fault Code 11991 is displayed. Fault Code 11993 is displayed.
Monitor Item: Swing Pilot Pressure Monitor Item: Right Travel Pilot Pressure Monitor Item: Left Travel Pilot Pressure
(Displayed by built-in diagnosing system)
- - -
- - -
• Judge if pressure sensor is faulty or port • Judge if pressure sensor is faulty or port • Judge if pressure sensor is faulty or port
is clogged by switching pressure sensor is clogged by switching pressure sensor is clogged by switching pressure sensor
T2-1 T2-1 T2-1
T5-7-5
Parts Pressure Sensor Pressure Sensor

Boom Bottom Pressure
(Attachment) (Counterweight Removal)
Sensor
• Monitors attachment pilot • Monitors counterweight re- • Monitors boom cylinder bot-
pressure. (Attachment mode moval pilot pressure for tom pressure. (Overload
control) counterweight lifting lever. alarm control (optional))
(Pump control in counter-
Function weight removal)
• Abnormal low voltage: No • No signals arrive to MC. • No signals arrive to MC.

signals arrive to MC.
Symptoms in control sys- • Abnormal high voltage: As
tem when trouble occurs. the sensor is detected as fully
operated, the sensor is con-
trolled.
Abnormal high voltage: • Even if lever is operated, • Condition is always over-
• Even if lever is in neutral with pressure does not increase loaded.
auto-idle switch ON, engine and flow rate does not de- • Overload alarm is displayed
speed does not decrease. crease. on the monitor unit.
Abnormal low voltage: • Overload alarm sounds.
• Even if attachment is oper-
ated with auto-idle switch ON,
engine speed does not in-
Symptoms in machine crease.
operation when trouble • Even if attachment is oper-
occurs. ated, pump 2 flow rate is kept
unchanged.
Fault Code 11802 is displayed.

By MC Fault
- -
Code
Monitor Item: Att. Control Pilot Monitor Item: C/W Removal Pi- Monitor Item: Boom Bottom
By Monitor Pressure lot Pressure Pressure
Function (Displayed by built-in diagnosing Monitor pressure change while
Evaluation system) lifting counterweight.
Using Test
- - -
Harness
Others - - -
• Judge if pressure sensor is • Judge if pressure sensor is
faulty or port is clogged by faulty or port is clogged by
switching pressure sensor switching pressure sensor
with another pressure sensor. with another pressure sensor.
NOTE -

Section in T/M)
T5-7-6

Hydraulic Oil Temperature Sensor
• Monitors swash angle control pressure • Monitors swash angle control pressure • Monitors hydraulic oil temperature.
of main pump 1. of main pump 2. (Overheat prevention control and fan
pump flow rate control)
• No signals arrive to MC. (Pump control • No signals arrive to MC. (Pump control • No signals arrive to MC.
is inoperable.) is inoperable.)
• Machine mistracks. • Machine mistracks. • Fan pump is fixed at maximum swash

• Engine is overloaded. • Engine is overloaded. angle (fan rotation speed becomes
• Work speed is lowered. • Work speed is lowered. maximum).
• Main pump drive torque decreases.
Fault Code 11994 is displayed. Fault Code 11992 is displayed. Fault code 11901 is displayed.
Monitor Item: Pump 1 Regulator Pressure Monitor Item: Pump 2 Regulator Pressure Monitor Item: Hydraulic Oil Temperature
(Displayed by built-in diagnosing system) (Displayed by built-in diagnosing system) (Displayed by built-in diagnosing system)
- - -
- - -
• Judge if sensor is faulty or harness is • Judge if sensor is faulty or harness is
faulty by switching with pump 2 sensor. faulty by switching with pump 1 sensor.
T2-1 T2-1 T2-1
T5-7-7
Parts
Solenoid Valve Unit (SG) Solenoid Valve Unit (SI) Solenoid Valve Unit (SF)
• Temporarily increases relief • Controls travel mode selec- • Shifts boom flow rate control
pressure of main relief valve tion. valve (switch valve) during
when operating power dig- combined operation of boom
ging and travel. lower and arm or bucket.
Function (Boom flow rate control valve
control)
• If solenoid valve unit (SG) is • As swash angle of travel mo- • If solenoid valve unit (SF) is
not activated, pressure at tor cannot be changed, travel not activated, pressure at
port SG becomes 0 MPa. motor is fixed at large swash port SF becomes 0 MPa.
angle position (slow speed).
Symptoms in control sys-
tem when trouble occurs.
Solenoid valve unit (SG) is closed: • Even if travel mode switch is • Arm speed is slow when op-
• Relief pressure stays at2 normal turned to FAST position, fast erating boom lower and arm.
31.4 MPa (325 kfg/cm ). Even travel mode cannot be se- • Bucket speed is slow when
if power digging switch is lected. operating boom lower and
pushed, relief pressure does bucket.
not increase. Power does not
increase.
Solenoid valve unit (SG) is open:
• Pressure always increases.
Every operation makes power
Symptoms in machine increase.
operation when trouble
occurs.
By MC Fault Fault code 11404 is displayed. Fault code 11405 is displayed. Fault code 11402 is displayed.
Code
Monitor Item: Power Boost Monitor Item: Travel Motor Monitor Item: Boom Flow Con-
By Monitor Control Pressure Control Pressure trol Pressure
Function (Displayed by built-in diagnos- (Displayed by built-in diagnos-
Evaluation ing system) ing system)
Using Test
Harness - - -
Others - - -
• Judge if solenoid valve is • Judge if solenoid valve is • Judge if solenoid valve is
broken or harness is discon- broken or harness is discon- broken or harness is discon-
NOTE nected by switching with an- nected by switching with an- nected by switching with an-
other solenoid valve unit other solenoid valve unit other solenoid valve unit
harness. harness. harness.
Section in T/M)
T5-7-8
Solenoid Valve Unit (SC) Pump 1 Control Solenoid Valve Pump 2 Control Solenoid Valve
• Controls boom mode selector control. • Changes pump 1 swash angle. • Changes pump 2 swash angle.
Reduces boom overload relief pressure
2
to 11.8 MPa (120 kgf/cm ) at 110 L/min.
• Boom overload relief pressure is not re- • Pump control is inoperable. • Pump control is inoperable.
duced.
• Even if boom mode selector switch is • If harness is disconnected and solenoid • If harness is disconnected and solenoid
turned ON, boom lower power and vibra- valve is faulty, flow rate of pump 1 be- valve is faulty, flow rate of pump 2 be-
tion cannot be controlled. comes minimum. comes minimum.
Fault code 11989 is displayed. Fault code 11410 is displayed. Fault code 11400 is displayed.
Monitor Item: Boom Mode Control Pressure Monitor Item: Pump 1 Regulator Valve Cur- Monitor Item: Pump 2 Regulator Valve Cur-
rent rent
• Install lamp harness (ST 7130). Check

output signals from MC and harness
condition.
- -
- - -
• Judge if solenoid valve is broken or har- • Judge if solenoid valve is broken or har- • Judge if solenoid valve is broken or har-
ness is disconnected by switching with ness is disconnected by switching with ness is disconnected by switching with
another solenoid valve unit harness. another solenoid valve harness. (Switch another solenoid valve harness. (Switch
harness of delivery pressure sensor and harness of delivery pressure sensor and
regulator pressure sensor.) regulator pressure sensor.)
T2-1 T2-1 T2-1
T5-7-9
Parts Fan Pump Control Pilot Shut-Off

Solenoid Valve MC
Solenoid Valve
• Controls delivery flow rate of • Opens and closes the pilot • Controls engine, pump and
fan pump. (Fan pump flow circuit. valve operation.
rate control)
Function
• Fan pump flow rate control is Solenoid valve is closed: • Depending on trouble situa-
not operated. • All actuators are not oper- tions, control system mal-
ated. (Pilot pressure oil is not function may differ. (The fol-
supplied to pilot valve.) lowing symptoms in machine
Solenoid valve is open: operation indicates that MC
• Pilot pressure oil is always logic circuit has failed.)
supplied to pilot valve.
Symptoms in control sys- • When lever is operated with
tem when trouble occurs. pilot shut-off lever in LOCK
position, actuator is operated.
• Pilot pressure oil is not sup-
plied to heat circuit in signal
control valve. (Actuator con-
trollability becomes bad.)
Solenoid valve is closed: Solenoid valve is closed: • Even though engine starts,
• Fan pump is fixed at maxi- • All actuators are not oper- speed stays slow.
mum swash angle (maximum ated. (Pilot pressure oil is not • As pump displacement is
flow rate). supplied to pilot valve.) held at minimum, all actuator
• As fan pump overload in- Solenoid valve is open: speeds are slow.
creases, delivery flow rates of • Pilot pressure oil is always
pumps 1, 2 decrease. Every supplied to pilot valve.
operation speed becomes • When lever is operated with
Symptoms in machine slow. pilot shut-off lever in LOCK
operation when trouble Solenoid valve is open: position, actuator is operated.
occurs. • Fan pump is fixed at mini- • Pilot pressure oil is not sup-
mum swash angle (minimum plied to heat circuit in signal
flow rate). control valve. (Actuator con-
• Overheating easily occurs. trollability becomes bad.)
• Hydraulic oil temperature
easily increases.
• Air conditioner does not work
easily.
By MC Fault Fault code 11412 is displayed.

- -
Code
Monitor Item: Fan Pump Valve
By Monitor
Current - -
Evaluation Function
Using Test
- - -
Harness
Others - - -
• Before suspecting a failure in

MC, check the fuses in con-
NOTE - - trol system. If any sensor in 5
V system is short-circuited,
fault code 11003 is displayed.

Section in T/M)
T5-7-10
Power Digging Switch Travel Mode Switch Auto-Idle Switch

• Activates power digging control. • Changes travel mode. • Activates auto-idle control.
ON: 0 V→Increasing Pressure Fast Mode: 0 V ON: 0 V → Auto-idle is operable.
OFF: 5 V→ Not increasing Pressure Slow Mode: 5 V OFF: 5 V → Inoperable
• Open Circuit: Pressure does not in- • Open circuit in switch: Travel speed re- • Open circuit: Auto-idle system is inoper-
crease. mains unchanged in slow mode (5 V). able.
• Shorted Circuit: Pressure increases for 8 • Shorted circuit in switch: Travel speed • Shorted circuit: Even if auto-idle switch is
seconds after turning key switch ON, and remains unchanged in fast mode (0 V). OFF, auto-idle control is always per-
stops increasing. formed.
• Power digging control does not operate if • Even if travel mode switch is turned to • Open circuit: Auto-idle system is inoper-
open circuit or shorted circuit occurs. FAST position, fast travel mode cannot able.
be selected. • Shorted circuit: Even if auto-idle switch is
• Even if travel mode selector is turned to OFF, auto-idle control is always per-
SLOW position, slow travel mode cannot formed.
be selected.
- - -
Monitor Item: Power Boost SW Monitor Item: Travel Mode SW Monitor Item: Auto-Idle SW
(Displayed by built-in diagnosing system) (Displayed by built-in diagnosing system)
- - -
- - -
- - -
T2-1 T2-1 T2-1
T5-7-11
Parts Power Mode Switch Power Mode Switch Power Mode Switch
(HP Mode) (E Mode) (P Mode)
• Activates HP mode control. • Selects E mode. • Selects P mode.
ON: 0 V → HP mode is op- ON: 0 V → E mode ON: 0 V
erable. OFF: 5 V → Normal OFF: 0 V
OFF: 5 V → Normal. (If E mode and HP mode are
Function not selected, MC judges as P
mode is selected.)
• Open circuit: Even if HP • Open circuit: Even if E mode • Open circuit: P mode
mode is selected, HP mode is selected, engine speed • Shorted circuit: E mode or HP
is inoperable. does not decrease. mode
• Shorted circuit: Even if HP • Shorted circuit: Engine speed
mode switch is turned OFF, does not increase to the
HP mode is not deactivated. maximum. Auto-idle control is
inoperable.
• Open circuit: Even if HP • Open circuit: Even if E mode • Open circuit: P mode
mode is selected, HP mode is selected, engine speed • Shorted circuit: E mode or HP
is inoperable. does not decrease. mode
• Shorted circuit: Even if HP • Shorted circuit: Engine speed
mode switch is turned OFF, does not increase to the
HP mode is not deactivated. maximum. Auto-idle control is
inoperable.
Symptoms in machine
occurs.
By MC Fault
- - -
Code
Monitor Item: HP Mode SW Monitor Item: E/P SW Monitor Item: E/P SW
By Monitor
Evaluation Function
Using Test
- - -
Harness
Others - - -
NOTE - - -

Section in T/M)
T5-7-12
Boom Mode Auto Lubrication Switch

Pilot Shut-Off Switch Selector Switch (Optional)
• Activates pilot shut-off solenoid valve. • Reduces overload relief pressure at the • Activates auto lubrication.
(Turns pilot shut-off relay ON.) boom cylinder rod side. ON: 0 V → Auto lubrication control is op-
erable.
OFF: 5 V → Inoperable
• Open circuit: Pilot shut-off switch is al- • Open circuit: Boom mode selector control • No signals arrive to MC.
ways turned OFF. is not performed.
• Pilot shut-off solenoid valve is not shifted. • Shorted circuit: Overload relief pressure
• Even if lever is operated with pilot at the boom cylinder rod side remains low
shut-off lever in UNLOCK position, all constantly so that machine cannot be
actuator are not operated. raised off ground with front attachment
• Shorted circuit: Pilot shut-off switch is
always turned ON.
• Engine does not start.
If shorted circuit occurs while starting en-
gine, operate lever with pilot shut-off
lever in LOCK position so that actuator is
operated.
Open circuit: • Open circuit: Boom mode selector control • Open circuit, shorted circuit: Auto lubrica-
• Pilot shut-off switch is always turned is not performed. tion is operable.
OFF. • Shorted circuit: Overload relief pressure
• Pilot shut-off solenoid valve is not shifted. at the boom cylinder rod side remains low
• Even if lever is operated with pilot constantly so that machine cannot be
shut-off lever in UNLOCK position, all raised off ground with front attachment
actuator are not operated.
Shorted circuit:
• Pilot shut-off switch is always turned ON.
• Engine does not start.
If shorted circuit occurs while starting en-
gine, operate lever with pilot shut-off
lever in LOCK position so that actuator is
operated.
- - -
Monitor Item: Gate Lock SW Monitor Item: Boom Mode SW Monitor Item: Lubricating Mode
- - -
- - -
- - -
T2-5 T2-1 T2-1
T5-7-13
Parts Boom Overload Relief

Learning Switch Flow Combiner Valve
Control Valve
• Starts pump learning • Supplies oil to both right and • Reduces pressure in boom
ON: 0 V → Learning left travel spools from pump 1 lower circuit.
OFF: 5 V → Normal control during combined operation of
Function travel and front/swing.
• Pump learning is not per- • During combined operation of • If valve is bound at fully
formed. travel and front/swing, oil is closed, when boom lower is
not supplied to left travel operated with boom mode
spool, or insufficient oil is selector switch ON, machine
supplied to left travel spool. can be raised off ground with
front attachment.
• If spool is bound at fully
Symptoms in control sys- open, when boom lower is
tem when trouble occurs. operated with boom mode
selector switch OFF, machine
cannot be raised off ground
with front attachment. (Power
is weak.)
• If problem is caused by open • While traveling, when • If valve is bound at fully

circuit or discontinuity of front/swing lever is operated, closed, when boom lower is
switch, machine operates machine mistracks to the left. operated with boom mode
normally. (Only learning can- selector switch ON, machine
not be performed.) can be raised off ground with
• If shorted circuit occurs, front attachment.
learning mode operation • If spool is bound at fully
starts when key switch is open, when boom lower is
Symptoms in machine turned ON. Therefore, engine operated with boom mode
operation when trouble will stall at 2 second or 20 selector switch OFF, machine
occurs. seconds after engine starts. cannot be raised off ground
with front attachment. (Power
is weak.)
By MC Fault
- - -
Code
Monitor Item: Pump 1 Regulator
By Monitor Learning Condition, Pump 2
Regulator Learning Condition - -
Evaluation Function
Using Test
- - -
Harness
Others - - -
NOTE - - -

Section in T/M)
T5-7-14

Boom Flow Rate Control Valve Arm Flow Rate Control Valve
(4-Spool Side)
• Restricts boom lower circuit when operat- • Restricts arm roll-in circuit during combined • Supplies pressure oil from pump 1 to
ing boom lower and arm or boom lower operation of boom raise and arm roll-in, so auxiliary spool when auxiliary spool is
and bucket, so that other actuator speed that boom raise speed increases. operated.
increases.
• If control valve is bound at fully closed, • If control valve is bound at fully closed, arm • If spool is bound at fully open, single
boom raise speed is slow. roll-out speed is slow. attachment operation speed be-
• If control valve is bound at fully open, arm • If control valve is bound at fully open, comes slow.
speed is slow during combined operation of boom raise speed is slow during combined • If spool is bound at fully closed, main
boom lower and arm. operation of boom raise and arm roll-in. relief valve continues to relieve with
• If control valve is bound at fully open, all control levers positioned in neu-
bucket speed is slow during combined op- tral.
eration of boom lower and bucket. • When all control levers are in neutral,
pump 1 pressure is higher than pump
2 pressure according to the spool
bound conditions.
• If control valve is bound at fully closed, • If control valve is bound at fully closed, • If spool is bound at fully open, single
boom raise speed is slow. boom raise speed is slow. attachment operation speed be-
• If control valve is bound at fully open, arm • If control valve is bound at fully open, comes slow.
speed is slow during combined operation of boom raise speed is slow during combined • If spool is bound at fully closed, main
boom lower and arm. operation of boom raise and arm roll-in. relief valve continues to relieve with
• If control valve is bound at fully open, all control levers positioned in neu-
bucket speed is slow during combined op- tral.
eration of boom lower and bucket. • When all control levers are in neutral,
pump 1 pressure is higher than pump
2 pressure according to the spool
bound conditions.
- - -
- - -
- - -
- - -
- - -
T2-1, T3-3 T2-4 T3-3
T5-7-15
Parts Boom Regenerative Bucket Regenerative

Arm Regenerative Valve
Valve Valve
• Routes return oil from boom • Routes return oil from arm • Routes return oil from bucket
cylinder bottom side to rod cylinder rod side to bottom cylinder rod side to bottom
side and prevents boom cyl- side and prevents arm cylin- side and prevents bucket
Function inder hesitation. der hesitation if rod side cylinder hesitation.
pressure in arm cylinder is
higher.
• If check valve is kept closed, • If the switch valve is kept • If the switch valve is kept
boom is not smoothly low- closed, arm is weak when closed, bucket is weak when
ered. heavy load is applied. heavy load is applied.
• If check valve is kept open, • If the switch valve is kept • If the switch valve is kept
machine cannot be raised off open, arm speed is slow. open, bucket speed is slow.
ground with front attachment.

• If check valve is kept closed, • If the switch valve is kept • If the switch valve is kept
boom is not smoothly low- closed, arm is weak when closed, bucket is weak when
ered. heavy load is applied. heavy load is applied.
• If check valve is kept open, • If the switch valve is kept • If the switch valve is kept
machine cannot be raised off open, arm speed is slow. open, bucket speed is slow.
ground with front attachment.
Symptoms in machine
occurs.
By MC Fault
- - -
Code
By Monitor
- - -
Evaluation Function
Using Test
- - -
Harness
Others - - -
NOTE - - -

Section in T/M)
T5-7-16
Flow Combiner Valve

Boom Anti-Drift Valve Arm Anti-Drift Valve
Control Spool
• Forcibly open check valve in boom lower • Forcibly open check valve in arm roll-in • Be shifted by right travel pilot pres-
return circuit and allows boom to move only return circuit and allows arm to move only sure and supplies control pressure to
when boom is lowered. Prevents boom when arm is rolled in. Prevents arm from flow combiner valve in control valve.
from drifting due to oil leaks in control drifting due to oil leaks in control valve.
valve.
• If switch valve is bound, check valve does • If switch valve is bound, check valve does • If spool is bound at fully open, when
not open. not open. boom, arm, bucket or swing and
travel is operated, flow combiner
valve is shifted.
• If spool is bound at fully closed, when
combined operation of travel and
front/swing is made, machine mis-
tracks to the left. (Left travel speed
becomes slow.)
• If check valve is kept closed, boom does • If check valve is kept closed, arm roll-in • If spool is bound at fully open, when
not lower. speed becomes slow. boom, arm, bucket or swing and
• If check valve is kept open, front attach- • If check valve is kept open, front attach- travel is operated, flow combiner
ment drift increases due to oil leaks in con- ment drift increases due to oil leaks in con- valve is shifted.
trol valve. trol valve. • If spool is bound at fully closed, when
• Boom moves jerky or boom speed be- • Arm moves jerky or arm speed becomes combined operation of travel and
comes slow depending on valve bound slow depending on valve bound conditions. front/swing is made, machine mis-
conditions. tracks to the left. (Left travel speed
becomes slow.)
- - -
- - -
- - -
- - -
- - -
T 3-3 T3-3 T3-6
T5-7-17
Parts Swing Parking Brake Arm Flow Rate Control Proximity Switch
Release Spool Valve Control Spool (Auto Lubrication System)
• Be shifted by boom, arm, • Shifts arm flow rate control • Sets lubricating time and its
bucket, swing or auxiliary pi- valve (switch valve) during interval. (Auto lubrication
lot pressure and supplies combined operation of boom control)
Function swing parking brake release raise and arm roll-in.
pressure.
• If spool is bound at fully • If spool is bound at fully • No signals arrive to MC.

open, swing parking brake is closed, boom raise speed is
kept released. (Machine vi- slow during combined opera-
brates while traveling.) tion of boom raise and arm
• If spool is bound at fully roll-in.
closed, swing parking brake • If spool is bound at fully
is kept applied. (Dragging is open, arm roll-out speed is
felt.) slow during combined opera-
Symptoms in control sys- tion of boom raise and arm
roll-out.
• If spool is bound at fully • If spool is bound at fully • Auto lubrication is not oper-
open, swing parking brake is open, arm speed decreases ated correctly.
kept released. (Machine vi- during single arm operation.
brates while traveling.) (Arm flow rate control is al-
• If spool is bound at fully ways operable.)
closed, swing parking brake • If spool is bound at fully
is kept applied. (Dragging is closed, swing power be-
felt.) comes insufficient during
Symptoms in machine combined operation of swing
operation when trouble and arm roll-in. (Arm flow rate
occurs. control is inoperable.)
By MC Fault
- - -
Code
Monitor Item: Auto Lubrication
By Monitor
- - Counting SW
Evaluation Function
Using Test
- - -
Harness
Others - - -
NOTE - - -
Descriptions of Control T3-3 T2-4, T3-6 T2-1

Section in T/M)
T5-7-18
(Blank)
T5-7-19
CORRELATION BETWEEN TROUBLE
SYMPTOMS AND PART FAILURES
This table indicates the relationship between machine z : Related, required to check
{ : Related. However, in case this component fails, other trouble
troubles and parts contributing to the cause of the symptom will be more noticeable so that this component will not
trouble if failed. be the direct cause of the trouble concerned.
Engine System Troubleshooting

E-1 E-2 E-3
Starter does not rotate. Even if starter rotates, engine When engine control dial is
Trouble does not start. fully rotated, engine stalls.
Symptom When engine control dial is
fully rotated with P mode or
HP mode, engine speed is
slow.
Parts
MC (Main Controller) z
ECM z {
ICF {
Monitor Unit {
Pump 1 Delivery Pressure Sensor
Pump 1 Regulator Pressure Sensor
Starter Cut Relay (R4) z
ECM Main Relay (R14)
Pressure Sensor (Boom Raise)
Pressure Sensor (Arm Roll-In)
Pressure Sensor (Attachment)
Pilot Shut-Off Switch z
Engine Stop Switch z
Key Switch z
Engine Control Dial
Auto-Idle Switch
Power Mode Switch {
Battery Relay z
Starter Relay z
Engine Electrical Equipment z {
Engine Unit z z
Check batteries. Check fuel system (Filters and
piping).
Remarks
T5-7-20
NOTE: The trouble symptoms in this table are de-

scribed provided that each trouble occurs
independently.
In case more than one trouble occurs at
the same time, find out all faulty compo-
nents while checking all suspected com-
ponents in each trouble symptom.
E-4 E-5 E-6 E-7

Even if engine control dial is Faulty HP mode. Faulty E mode. Faulty auto-idle system.
rotated, engine speed remains
unchanged.
z z z z
z { { {
z z
z z
z
z
z
z
z { z
z
z z {
z
Open circuit in CAN harness Check pilot pressure sensor.
(Connector is disconnected.)
T5-7-21
z : Related, required to check
symptom will be more noticeable so that this component will not
be the direct cause of the trouble concerned.
E-8
Even if key switch is turned
Trouble OFF, engine does not stop.
Symptom
Parts
MC (Main Controller)
ECM z
ICF
Monitor Unit
Starter Cut Relay (R4)
ECM Main Relay (R14) z
Pilot Shut-Off Switch
Engine Stop Switch
Key Switch z
Engine Control Dial
Auto-Idle Switch
Power Mode Switch
Battery Relay
Starter Relay 2
Engine Electrical Equipment
Engine Unit
Remarks
T5-7-22

independently
E-11 E-12
Engine stalls during operation Engine is difficult to start at
Trouble under adverse condition such low temperature.
Symptom as at high altitude.
Parts
ECM { z
ICF
Monitor Unit
Pump 1 Delivery Pressure Sensor {
Pump 1 Regulator Pressure Sensor {
Pump 1 Control Solenoid Valve {
Glow Plug Relay z
Engine Electrical Equipment z
Engine Unit
Pump Regulator z
Check fuel system for clog-
ging.
Remarks
T5-7-23
All Actuator System Troubleshooting

A-1 A-2 A-3
All actuators are not operated. All actuator speeds are slow. Left travel is inoperable during
Trouble single travel operation. Single
Symptom swing operation speed becomes
slow. Arm speed is slightly slow
during arm level crowding.
Parts
MC (Main Controller) z z
ECM {
Monitor Unit {
Pilot Shut-Off Relay (R2) z
Security Relay (R5) {
Main Relief Valve z
Main Pump { z
Main Pump Regulator { z
Pilot Pump z
Pilot Relief Valve z
Pilot Shut-Off Switch {
Pilot Shut-Off Solenoid Valve z
Pump 1 Control Solenoid
{
Valve
{ z
Valve
Pump 1 Regulator Pressure
{
Sensor
{ z
Sensor
Pump 1 Delivery Pressure
{
Sensor
{ z
Sensor
Refer to F-1.
Remarks
NOTE: The trouble symptoms in this table are de- z : Related, required to check
scribed provided that each trouble occurs { : Related. However, in case this component fails, other trouble
independently. In case more than one trou- be the direct cause of the trouble concerned.
ble occurs at the same time, find out all
faulty components while checking all sus-
pected components in each trouble symp-
tom.
T5-7-24
A-4
Right travel is inoperable during
single travel operation. Single
bucket operation speed be-
comes slow. Boom is not raised
properly during arm level
crowding.
z
z
T5-7-25

A-5 A-6 A-7

Actuator does not stop even if Actuator speed is faster than Fan rotation speed remains un-
Trouble control lever is turned to neutral. normal. changed at maximum.
Symptom Machine mistracks when travel
lever is operated at half stroke.
Precise control cannot be per-
formed.
Parts
MC (Main Controller) z z
ECM {
Monitor Unit
Main Pump
Main Pump Regulator
Fan Pump z
Fan Pump Regulator z
z
Sensor
z
Sensor
z
Sensor
z
Sensor
z
Valve
z
Valve
Fan Pump Control Solenoid
z
Valve
Engine Control Dial {
Air Conditioner Switch (Blower
Motor Relay)
Hydraulic Oil Temperature
{
Sensor
Intake Air Temperature Sensor {
Boost Temperature Sensor {
Coolant Temperature Sensor {
Spool z
Fan Motor
Fan Valve
Pilot Valve z
Oil Cooler Bypass Check
Valve
Low-Pressure Relief Valve
Pilot Pump
Refer to A-2.
Remarks
T5-7-26

independently
A-8 A-9 A-10 A-11

Overheating occurs. Flow rate of pump2 is not re- Attachment operating speed is Overheating easily occurs when
Fan rotation speed is slow. duced to specification when op- too slow. operating breaker.
erating attachment.
z z z z
z z z
z
z
z
z z
z
z
z
z
z {
z {
{
Refer to A-2 or A-3. Refer to A-4 or A-8.
T5-7-27

Front Attachment System Troubleshooting

F-1 F-2 F-3
All front attachment actuator Even if power digging switch Some cylinder is inoperable or
Trouble power is weak. is pushed, power does not speeds are slow.
Symptom increase. Boom raise power is
weak when digging.
Parts
MC z
Pressure Sensor (Boom Lower)
Pressure Sensor (Arm Roll-Out)
Pressure Sensor (Bucket Roll-Out)
Pressure Sensor (Bucket Roll-In)
Pressure Sensor (Swing)
Solenoid Valve Unit (SG) z
Power Mode Switch z
Boom Mode Selector Switch
Spool z
Main Relief Valve z z
Overload Relief Valve { z
Boom Overload Relief Control Valve
Load Check Valve
Anti-Drift Valve
Boom Flow Rate Control Valve
Boom Regenerative Valve
Bucket Regenerative Valve
Shockless Valve (Signal Control Valve) {
Arm Flow Rate Control Valve Control
Spool
Shuttle Valve z
Pilot Valve z
Shockless Valve {
Cylinder
Refer to A-1 or A-2. Refer to A-3.
Remarks
T5-7-28
NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at
scribed provided that each trouble occurs the same time, find out all faulty compo-
independently nents while checking all suspected com-
F-4 F-5 F-6 F-7

Arm speed or bucket speed is Boom raise speed is slow during Even if boom mode selector When boom raise or arm roll-out
slow during combined operation arm crowding operation (during switch is pushed, machine is is operated, boom or arm starts
of boom lower and arm or boom combined operation of boom raised off ground. to move after slightly moving
lower and bucket. raise and arm roll-in) downward.
Arm moves jerky.
z
{
{
{
{
z
z
z z
z
z
z
z
z
{
z
{
{ {
{
z
Refer to A-3.
T5-7-29
{ : Related. However, in case this component fails, other trouble NOTE: The trouble symptoms in this table are de-
symptom will be more noticeable so that this component will not scribed provided that each trouble occurs
be the direct cause of the trouble concerned. independently
F-8 F-9
Front attachment drifts remarka- Front attachment speed is slow
Trouble bly. during combined operation of
Symptom front attachment and swing.
Parts
Pressure Sensor (Boom Raise) {
Pressure Sensor (Boom Lower) {
Pressure Sensor (Arm Roll-Out) {
Pressure Sensor (Arm Roll-In) {
Pressure Sensor (Bucket Roll-Out) {
Pressure Sensor (Bucket Roll-In) {
Pressure Sensor (Swing) z
Pressure Sensor (Auxiliary) {
Solenoid Valve Unit (SG)
Power Mode Switch
Pump 1 Delivery Pressure Sensor z
Pump 1 Regulator Pressure Sensor z
Pump 1 Control Solenoid Valve z
Spool z
Main Relief Valve
Boom Overload Relief Control Valve
Load Check Valve
Anti-Drift Valve z
Boom Flow Rate Control Valve
Boom Regenerative Valve
Bucket Regenerative Valve
Shockless Valve (Signal Control
Valve)
Arm Flow Rate Control Valve Control
Spool
Shuttle Valve
Pilot Valve
Shockless Valve
Cylinder z
Remarks
T5-7-30
(Blank)
T5-7-31
Swing/Travel System Troubleshooting

S-1 S-2 T-1
Swing is slow or unmoving. Swing is fast. Both right and left tracks do
Trouble When swing is operated fully, not rotate or rotate slowly.
Symptom swing speed is slow.
Parts
MC (Main Controller) z {
Pressure Sensor (Swing) z
Pressure Sensor (Right Travel) {
Pressure Sensor (Left Travel) {
Solenoid Valve Unit (SI) {
Main Pump
Main Pump Regulator
Pilot Pump z
Pilot Relief Valve z
Spool z {
Main Relief Valve z
Load Check Valve
Flow Combiner Valve
Pilot Valve z {
Swing Device z
Travel Device {
Center Joint
Flow Combiner Valve Control Spool
Swing Parking Brake Release Spool z
Shuttle Valve z
Travel Mode Switch
Refer to A-1 or A-2. Refer to A-1, F-2 or T-4.
Remarks

T5-7-32
T-2 T-3 T-4

One side track does not rotate Machine mistracks during com- Fast travel is inoperable. Travel
or rotates slowly. Machine mis- bined operation of travel and mode does not change from slow
tracks. front attachment. mode to fast mode.
{ z
{
{
{ z
{
{
{ {
z {
{
{
{
{
{
{
{ z
z
z
z z
z z
z
{
z
In case either bucket or swing is
also slow, refer to A-3 or A-4.

independently
T5-7-33
Other System Troubleshooting

O-1 O-2 O-3
Wiper is inoperable or not re- Counterweight removal / in- Counterweight removal / in-
Trouble tracted. stallation device is not operated stallation speed is fast.
Symptom or power is weak. Precise operation cannot be
performed.
Parts
MC z z
Monitor Unit z
Wiper Relay (R6) z
Auto Lubrication Relay (R11)
Pressure Sensor (Counterweight) z z
Solenoid Valve Unit (SG) z
Fan Pump Control Solenoid Valve
Auto Lubrication Device
Engine Oil Level Switch
Coolant Level Switch
Wiper/Washer Switch z
Level Check Switch
Auto Lubrication Switch
Key Switch
Wiper Motor z
Air Conditioner
Main Pump {
Main Pump Regulator {
Fan Pump
Pilot Pump {
Pilot Relief Valve {
Main Relief Valve {
Pilot Valve {
Counterweight Removal Device z z
Distribution Valve
Refer to A-1, F-1 or F-2.
Remarks

T5-7-34
O-4 O-5 O-6

Auto lubrication is faulty. Level check is faulty. Air conditioner malfunction
z z {
{ z
z
z
{
{
z
z
z
Refer to T5-7-96.

independently
T5-7-35
ENGINE SYSTEM TROUBLESHOOTING
E-1 Starter does not rotate.
IMPORTANT: As electric current from the key

switch is not routed to starter relay
with the pilot shut-off lever in
UNLOCK position, the starter does
not rotate. (Refer to Electrical Sys-
tem.)
• This trouble has nothing to do with the electronic

control system such as MC.
• Check the wiring connections first. YES Faulty starter cut relay.
Switch starter cut relay
YES with other general re-
lay. Remove starter cut relay.
Check if starter rotates. Check if voltage at ter-
minal #3 of harness end
Check if both voltages · Key switch: START NO of connector is 24 V.
YES at key switch termi- · Key switch: START
nals #5 and #6 are 24
V.
· Key switch: START
YES Faulty key switch.
Check if battery voltage Check for continuity
and electrolyte density is between battery posi-
normal, and fusible link (45 tive terminal and key
A) is not blown. NO
switch terminal #1.
Faulty harness between
· Voltage: 24 V or more battery and key switch.
Density: 1.26 or more NO
Faulty battery or faulty

NO fusible link.
Key Switch: Battery Relay:

Terminal A
T178-05-04-001
T105-07-04-002
T5-7-36
Faulty starter, or faulty

YES harness between starter
and battery relay.
NO Check if voltage at
terminal A in battery
relay is 24 V.
Check if voltage at
· Key switch: ON Faulty battery relay.
YES terminal #2 of har- NO
ness end of con-
Disconnect connector nector in starter cut
of starter relay. relay is 0 V. Shorted circuit in harness
Connect terminal S of
between starter cut relay
harness end of con-
YES nector to machine. and pilot shut-off switch,
YES or faulty pilot shut-off
switch.
harness end of con-
nector in starter cut
relay and machine. Open circuit in harness
between starter cut relay
NO and starter relay.

between key switch and
NO starter cut relay.

open side)
Starter Cut Relay Starter Relay
E
S R
T183-05-04-003
T5-7-37
E-2 Even if starter rotates, engine does not start.
YES Faulty ECM main relay.
Connect terminal #1
of harness end of
connector in ECM
Switch ECM main main relay to ma-
relay with other gen- Connect terminal #5 of YES
chine.
eral relay. harness end of connec- Check for continuity
Check if engine tor in ECM main relay to between terminals
starts. machine. #21 and #40 of har-
YES Disconnect connector in ness end of connec-
ECM. tor in ECM.
Disconnect ECM main Check for continuity
relay from connector. between terminals #2
and #5 of harness end Open circuit in harness
Check if voltage at ter- between ECM main relay
NO minal #3 of harness of connector. NO and ECM.
end of connector is
24V.
NO
ECM main relay.
· Check if fuse #8 is
blown.

open side)
ECM Main Relay Connector ECM #21 #24 #5
T183-05-04-003
T1GR-05-04-002
#40 #2
T5-7-38
Disconnect con- YES Open circuit in harness

nector ICF-C in between key switch and
ICF. monitor unit.
YES Check if voltage
between terminal Check if fuse #18 is blown.
Disconnect
#C7 of harness
connector MC-B
end of connector Open circuit in harness
in MC.
and machine is between key switch and
YES Check if voltage
24V. NO ICF.
between terminal
#B16 of harness · Key switch: ON Check if fuse #18 is blown.
end of connector
Check if voltage
and machine is
between terminal Open circuit in harness
YES #24 of harness 24V.
end of connector · Key switch: ON NO
Check for conti- MC.
in ECM and ma-
nuity between Check if fuse #18 is blown.
chine is 24V.
YES terminal #2 of · Key switch: ON
harness end of
connector in ECM Open circuit in harness
main relay and between key switch and
machine. NO ECM.
Check if fuse #18 is blown.
Faulty ground in ECM

NO main relay.

between ECM main relay
NO and ECM.
Connector MC-B Connector ICF-C

#B16
B1 B8 1 6
7 12
T1GR-05-04-002
B19 B25 #C7
T5-7-39
E-3 When engine control dial is fully rotated,
engine stalls.
When engine control dial is fully rotated,
engine speed becomes slow.
Related Fault Code Trouble Reference Page

11003 Abnormal Sensor Voltage T5-6-38
MC
11004 CAN Communication Error T5-6-39
YES
Refer to Troubleshooting
Monitor unit (service mode) A.
Cannot be displayed the
<Pump/Delivery Pressure>
and/or <Coolant Temperature>
Refer to engine trouble-
NO shooting manual.
T5-7-40
E-4 Even if engine control dial is rotated, engine
speed remains unchanged.

MC
11101 Abnormal Engine Control Dial T5-6-60
• If the CAN harness between ECM and MC is

open, the symptom occurs that engine speed in-
creases or decreases.
Faulty engine control dial,
YES or open circuit in harness
between engine control
dial and MC.
Check if fault code 11101-3 or
11101-4 is displayed.
Check if engine control stan-
YES Faulty CAN between MC
dard voltage is normal.
and ECM.
· Standard voltage
Slow idle position: 0.3 to 1.0 V Check if fault code 11004-2 is
Fast idle position: 4.0 to 4.7 V displayed at the same time.
NO
· Monitor item:
EC dial angle · Monitor unit (service mode)
Cannot be displayed the Faulty MC.
· Possible to display by built-in
diagnosing system. <Pump/Delivery Pressure> NO
T5-7-41
E-5 Faulty HP mode
• Even if power mode switch is turned to the HP

mode position, HP mode is inoperable. (General
mode normally operates.)

11200 Abnormal Pump 1 Delivery Pressure Sensor T5-6-61
MC 11202 Abnormal Pump 2 Delivery Pressure Sensor T5-6-62
11302 Abnormal Boom Raise Pilot Pressure Sensor T5-6-64
11303 Abnormal Arm Roll-In Pilot Pressure Sensor T5-6-65
• The sensors detect the conditions necessary to • Refer to the pages for HP Mode Control in the
operate HP mode. Therefore, if any of these sen- SYSTEM / Control System group in the T/M (Op-
sors fails, HP mode becomes inoperable. erational Principle).
• Pressure sensors (arm roll-in and boom raise) • Check the wiring connections first.
and pump 1 and 2 delivery pressure sensors are
also engaged in the HP mode control. However, if
these sensors fail, other operating functions will
be also affected.
Faulty power mode
NO switch or open circuit in
mode switch and MC.
Monitor power mode

switch.
NO Check if indication HP
is highlighted when
power mode switch is
turned to “HP mode”.
Faulty MC.
· Monitor item: HP YES
mode SW
Check if fault code is
displayed.
YES A.
T5-7-42
• Even if the power mode switch is not turned to HP
mode, HP mode is operable.

MC 11004 CAN Communication Error T5-6-39
• Boom raise and arm roll-in must be operated

when the average delivery pressures of pump 1
and 2 are high, if HP mode control is performed.
The sensors related to this condition may not be
faulty at the same time.

YES between MC and power
mode switch.
Monitor the power

mode switch.
Check if “ON” is dis- YES Faulty ECM.
played.
· Monitor item: HP
mode SW Check if fault code
· Power mode switch: NO 11004-2 is displayed.
P mode
Faulty MC.
NO
T5-7-43
E-6 Faulty E mode
• Even if power mode switch is turned to the E mode

position, engine speed remains unchanged. (En-
gine speed does not decrease.)

MC 11202 Abnormal Pump 2 Delivery Pressure Sensor T5-6-62
11992 Abnormal Pump 2 Regulator Pressure Sensor T5-6-81
• In case trouble symptoms E-1 to E-5 and E-7 are • Pump 1, 2 regulator pressure sensors and pump
recognized, perform the troubleshooting of these 1, 2 delivery pressure sensors are also engaged
troubles first. in the E mode control. However, if these sensors
• The sensors detect the conditions necessary to fail, other operating functions will be also af-
operate E mode. Therefore, if any of these sen- fected.
sors fails, E mode becomes inoperable. • Refer to the pages for E Mode Control in the
SYSTEM / Control System group in the T/M (Op-
erational Principle).
Faulty power mode

NO switch, or open circuit in
mode switch and MC.
Monitor power mode

switch.
NO When power mode
switch is shifted to E
mode, check if display
is changed.
Faulty MC.
· Monitor item: E/P SW
YES
Check if fault code is

displayed.
YES A.
T5-7-44
• Even if power mode switch is not turned to E mode,
engine speed decreases.

• Required engine speed from the engine control

dial must be beyond 1580 min-1 when the pump
control pressures of pump 1 and 2 are low or the
average delivery pressures of pump 1 and 2 are
high, if E mode control is performed. The sensors
related to this condition may not be faulty at the
same time.

NO between MC and power mode
switch, or faulty power mode
switch.
Monitor power mode switch.
Check if “E” is displayed. YES Refer to Troubleshooting A.
· Monitor item: E/P SW

· Power mode switch: P mode Check if fault code
YES 11004-2 is displayed.
Faulty MC.
NO
T5-7-45
E-7 Faulty auto-idle system
• Even if control lever is turned to neutral, auto-idle

system is inoperable.

11301 Abnormal Swing Pilot Pressure Sensor T5-6-63
11991 Abnormal Right Travel Pilot Pressure Sensor T5-6-80
MC
11993 Abnormal Left Travel Pilot Pressure Sensor T5-6-82
11995 Abnormal Arm Roll-Out Pilot Pressure Sensor T5-6-84
11997 Abnormal Bucket Roll-Out Pilot Pressure Sensor T5-6-85
11998 Abnormal Boom Lower Pilot Pressure Sensor T5-6-86
11999 Abnormal Bucket Roll-In Pilot Pressure Sensor T5-6-87
ECM 639 Abnormal CAN T5-6-28, 29
• In case trouble symptoms E1 to E6 are recog- • Refer to the pages for Auto-Idle Control in the
nized, perform the troubleshooting of these trou- SYSTEM / Control System group in the T/M (Op-
bles first. erational Principle).
• Even if failure in each pilot pressure sensor may • Check the wiring connections first.
have relevance to malfunction of the auto-idle
control. However, if these sensors fail, other op-
erating functions will also be affected.
YES Faulty MC.

Monitor auto-idle switch.
YES Switch auto-idle switch.
Check if ON-OFF is
changed. Open circuit in harness
between auto-idle
Check if Auto-Idle is · Monitor Item: Auto-idle NO switch and MC.
displayed on monitor SW
unit.
Disconnect connector moni- YES Faulty auto-idle switch.
· Auto-idle switch: ON tor-B.
Check for continuity between
NO terminal #B18 of harness Open circuit in harness
end of connector and ma- between auto-idle
chine. NO switch and monitor unit.
· Auto-idle switch: ON

open side)
Connector Monitor-B
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
#B18
T5-7-46
• Even if auto-idle switch is turned OFF, auto-idle is
operable.

YES Shorted circuit in

Disconnect connector harness between
MC-B in MC and switch MC and auto-idle
panel connector.
Check for continuity be-
tween terminal #B13 of
harness end of connector
MC-B and machine.
Faulty MC.
· Auto-idle switch: OFF NO

open side)
Connector MC-B
B1 B8
B19 B25
#B13
T5-7-47
E-8 Even if key switch is turned OFF, engine
does not stop. (In case engine does not stop,
stop engine by pulling engine stop handle
located under seat stand. Then, begin in-
spection.)
• Probably the symptoms such as “Engine speed is

slower than specification in all operating ranges”
or “Even if engine control dial is rotated, engine
speed remains unchanged” may come up. Per-
form troubleshooting for these symptoms.
YES Faulty key switch.
Check if voltage at
terminal #5 in key
switch is 24 V.
NO Shorted circuit in
· Key switch: OFF harness between key
Disconnect
connector in ECM. switch and ECM.
Check if voltage
between terminal #24
NO of harness end of
connector and
machine is o V. Faulty ECM.
· Key switch: OFF YES
Key Switch:
#24
ECM Connector
(Harness end)
T1GR-05-04-002
T105-07-04-002
T5-7-48
(Blank)
T5-7-49
(Blank)
T5-7-50
E-11 Engine stalls during operation under ad-
verse condition such as at high altitude.

11200 Pump 1 Delivery Pressure Sensor T5-6-61
11202 Pump 2 Delivery Pressure Sensor T5-6-62
MC 11400 Pump 2 Control Solenoid Valve Circuit T5-6-66
11410 Pump 1 Control Solenoid Valve Circuit T5-6-70
11992 Pump 2 Regulator Pressure Sensor T5-6-81
11994 Pump 1 Regulator Pressure Sensor T5-6-83
• If speed sensing control is inoperable, the engine

will stall under adverse operating conditions.
• As pump control solenoid valve, pump regulator
pressure sensor and regulator are 2 used for
each, both may not become faulty at the same
time. Or, if one is faulty, machine mistracks.
NO Faulty MC or faulty
adjustment of regulator.
· Refer to Operational
Performance Test.
Measure pump flow rate.
Check if P-Q curve of
pump is normal.
Performance Test.
Faulty engine unit.
YES
· Refer to Engine
Troubleshooting Manual.
T5-7-51
E-12 Engine is difficult to start at low tempera-
ture. (During cold weather or in cold dis-
tricts, engine is difficult to start or does not
start even if pre-heated.)
• Check if electricity is routed to the glow plugs. • Check the battery.

Check the glow plugs for any abnormality. • Check the wiring connections first.
• The pre-heat system operates only when coolant
temperature is below 20 °C (68 °F).
YES Faulty sensor.
Disconnect connector of
coolant temperature sensor.
Check if voltage at glow plug YES Faulty ECM.
is 20 to 24 V.
· Key switch: ON Disconnect connector in
ECM. Connect terminal #10
of harness end of connector
NO to machine. Check if prob-
lem is corrected.
· Connect to machine from Measure each glow plug
the back of connector by NO resistance.
using a clip with the con-
nector connected. · Key switch: OFF
· Before measuring, re-
move copper plates
connecting each glow
plug.
• Measurement of Glow Plug Voltage and Resistance

Voltage Check Resistance Check
Remove
the
copper
plate.
Specification: 20 to 24 V Specification: Below 10 Ω

T105-07-04-006 T105-07-04-007
T5-7-52

open end side)
Glow Plug Relay
ECM
Connector
#10 1
4
3
2
T1GR-05-04-002
∞Ω Faulty glow plug.
Faulty glow plug relay, or

NO faulty harness between
glow plug relay and glow
Connect connector in plug.
glow plug relay. Connect
YES terminal #4 of harness
end of connector to ma-
chine. Check if voltage at
glow plug is 20 to 24 V.
· Key switch: ON
between glow plug relay
YES and ECM.
Disconnect connector in
glow plug relay.
Check if voltages at ter-
Below 10 Ω minals #1 and #3 of
harness end of connector
in glow plug relay are 20 to
24 V
· Key switch: ON If terminal #1 is 0 V, open
circuit in harness be-
tween glow plug relay
and battery. If terminal #3
NO is 0 V, open circuit in
harness between glow
plug relay and terminal M
in key switch.
· Check if fuse #16 is
blown.
T5-7-53
ALL ACTUATOR SYSTEM TROUBLE-
SHOOTING
A-1 All actuators are not operated.
YES Faulty pilot shut-off

relay (R2).
Switch pilot
YES shut-off relay (R2) YES Faulty security relay
with other general (R5).
relay. Check if fault
code is improved.
Switch security re-
lay (R5) with other Disconnect con-
general relay. nector of pilot
NO Check if fault code shut-off solenoid
is improved. valve.
Check if voltage at A
Monitor pilot NO
terminal #2 of har-
shut-off switch. ness end of con-
Check if ON is nector is 24 V.
changed.
· Key switch: ON
· Monitor Item (MC):
Gate lock SW
· Pilot shut-off lever: Faulty pilot shut-off
UNLOCK position NO switch.
Disconnect connector YES Faulty monitor unit.

of pilot shut-off solenoid
YES valve.
Faulty pilot shut-off
and #2 of solenoid
NO solenoid valve.
valve end of connector.
A
Faulty fuse #4 or open
circuit in harness be-
tween fusible link (75
NO A) and pilot shut-off
solenoid valve.
Connector (Harness end of connector viewed from the open
side)
Pilot Shut-Off Solenoid Valve Pilot Shut-Off Solenoid Valve (So-

lenoid Valve End)
T183-05-04-010 T1J1-05-07-006
T5-7-54
A-2 All actuator speeds are slow.
• Reduction in pump 1 and 2 flow rate due to some

reasons or faulty pilot system may cause this
trouble.
• Although speed is satisfactory, in case power is
weak, refer to the troubleshooting faulty relief
valve (F-1).
• As for the machine equipped with the counter-
weight removal / installation device (optional),
check the pilot pressure (counterweight).
Faulty pilot pump or

YES clogged pilot filter.
Check if same
symptom still ap-
NO pears after disas-
sembling, cleaning,
and adjusting pilot
relief valve. End.
NO
Check if primary pilot

pressure is normal. Refer to Engine
YES
Troubleshooting
· Specification: Refer to Manual.
Operational Perform-
ance Test.
· Fully boom raised or Monitor actual en-
arm roll-in gine speed.
· Monitor item: Boom NO Faulty main relief
raise pilot pressure, YES Check if abnormal
speed is indicated. valve.
arm roll-in (BH) pilot
pressure · Monitor item: Actual
· Possible to display by engine speed Check if main relief
built-in diagnosing · Possible to display by pressure is normal.
system NO
using built-in diag-
nosing system · Refer to Operational
Performance Test Faulty Pump device.
for pressure meas-
YES
urement procedure.
T5-7-55
A-3 Left travel is inoperable during single travel
operation. Single swing operation speed is
slow. Arm is slightly slow during arm level
crowding. (All problems occur at the same
time.)
• The pump 2 flow rate is minimized due to some • If swing operation speed is normal, monitor swing
reasons. Accordingly, the left travel and swing pilot pressure and, check if the pressure is 0 MPa
motors, which are driven by pressure oil from while swing control lever is in neutral.
pump 2, moves very slow. • Check the wiring connections first.
• Pressure oil from pump 1 is also routed to the • Refer to the SYSTEM / Hydraulic System group
arm and boom cylinders so that the arm and in the T/M (Operational Principle).
boom can move at a slightly slow speed in single
operation. However, in level crowd operation,
pressure oil is routed to the boom prior to the arm
so that arm speed becomes very slow.
YES Faulty pump 2 delivery

Switch pump 2 pressure sensor.
Check
deliveryif pressure
any fault
codes are
NO sensor withdis-
pump
played.
1 delivery pres-
sure sensor.
Check if symptom Faulty pump 2.
is improved.
Monitor pump 2 deliv- NO
ery pressure with con- · Left travel operation
trol lever in neutral.
Check if pressure is
minimum. When oper-
ating control lever, YES Faulty pump 2 regulator
check if pump 2 deliv- regulator pressure
ery pressure is sensor with pump
NO
changed. 1 regulator pres-
Monitor pump 2 sure sensor.
· Monitor item: Pump 2
regulator pres- Check if symptom Stuck pump 2 control
delivery pressure
sure. Check if is improved. solenoid valve or faulty
· Possible to display by NO
built-in diagnosing sys- pressure with con- · Left travel opera- MC.
tem trol lever in neutral tion
· Control lever operation: YES is changed to
Except right travel and pressure when
bucket operating control
· Monitor item:
Pump 2 regulator Faulty pump 2 regulator.
pressure
YES
· Possible to dis-
play by built-in
diagnosing sys-
tem
· Jack up left track
and fully operate
left travel control
lever.
T5-7-56
A-4 Right travel is inoperable during single
travel operation. Single bucket operation
speed is slow. Boom is not raised properly
during arm level crowding. (All problems
occur at the same time.)
• The pump 1 flow rate is minimized due to some • Check the wiring connections first.
reasons. Accordingly, the right travel motor and • Refer to the SYSTEM / Hydraulic System group
bucket cylinder, which are actuated by pressure in the T/M (Operational Principle).
oil from pump 1, moves very slow.
• Pressure oil from pump 2 is also routed to the
arm and boom cylinders so that the arm and
boom can move at a slightly slow speed in single
operation. However, in level crowd operation,
pressure oil is routed to the arm prior to the boom
so that boom is scarcely raised.
YES Faulty pump 1 delivery

Check
deliveryif pressure
any fault
codes are
NO sensor withdis-
pump
played.
2 delivery pres-
sure sensor.
Check if symptom Faulty pump 1.
is improved.
Monitor pump 1 deliv- NO
ery pressure with con- · Right travel operation
trol lever in neutral.
minimum. YES Faulty pump 1 regulator
When operating con- Switch pump 1 pressure sensor.
trol lever, check if regulator pressure
pump 1 delivery pres- NO sensor with pump
sure is changed. 2 regulator pres-
Monitor pump 1 sure sensor.
· Monitor item: Pump 1 Check if symptom Stuck pump 1 control
delivery pressure regulator pres-
sure. Check if is improved. solenoid valve or faulty
· Possible to display by NO MC.
built-in diagnosing sys- pressure with con- · Right travel operation
tem trol lever in neutral
· Control lever operation: YES is changed to
Except left travel and pressure when
swing operating control
· Monitor item:
Pump 1 regulator Faulty pump 1 regulator.
pressure YES
· Possible to dis-
play by built-in
diagnosing sys-
tem
· Jack up right
track and fully
operate right
travel control
lever.
T5-7-57
A-5 Actuator does not stop even if control lever
is returned to neutral.
• Bound spool in the pilot valve or bound main

spool in the control valve is suspected.
YES Faulty pilot valve.
· When control lever is in neu-

Check if actuator stops when tral, pilot pressure is routed to
pilot shut-off lever is raised. spool end in control valve.
Faulty control valve.

NO
· Although pilot pressure is not
routed to spool end in control
valve, spool is kept opened
due to binding of spool.
A-6 Actuator speed is faster than normal.

Machine mistracks when travel lever is op-
erated at half stroke. Precise control cannot
be performed.
• The pump 1 or 2 flow rate is maximized due to

some reasons.
• If the fault code is not displayed, the pump device
is displayed, the pump device is faulty.
• If the fault code is displayed, refer to Trouble-
shooting A.
T5-7-58
A-7 Fan rotation speed remains unchanged at
maximum.
• Check if the fault code is not displayed first.

• If the sensor corresponding to fan pump flow rate
control is abnormal, fan rotation speed becomes
maximum.
• If all actuator speeds are slow, refer to A-2.
YES Faulty fan pump or faulty

fan pump regulator.
Install a pressure
gauge to port Pr in
fan pump regulator.
When following con-
ditions exist, check if
pressure is changed. Faulty fan pump control
· Air conditioner switch: NO solenoid valve (stuck).
ON
· Engine control dial:
Slow→Fast
Port Pr
T1J1-05-07-001
T5-7-59
A-8 Overheating occurs.
Fan rotation speed is slow.

MC 11412 Abnormal Fan Pump Control Solenoid Valve T5-6-71
11901 Abnormal Hydraulic Oil Temperature Sensor T5-6-73
ECM 110 Abnormal Coolant Temperature Sensor T5-6-24, 25
YES Faulty oil cooler bypass

check valve or faulty
C
Disconnect connector
of fan control solenoid
valve.
Check if fan rotation YES Faulty fan pump control
speed becomes fast. solenoid valve (stuck).
Install a pressure
gauge to port Pr in
fan pump regulator.
YES Faulty fan pump or faulty
NO Check if pressure at
fan pump regulator.
port Pr is 3.9 MPa
(40 kgf/cm2, 570 psi).
Measure drain
· Engine control dial: amount of fan motor.
Fast Check if drain
NO
amount is normal.
Faulty fan motor.

NO
Port Pr
T1J1-05-07-001
T5-7-60
A-9 Flow rate of pump 2 is not reduced to speci-
fication when operating attachment.
Related Fault Code Trouble Reference

Page
11400 Abnormal Pump 2 Control Solenoid Valve T5-6-66
MC
11918 Work Mode Receive Error T5-6-75, 76
• Although the attachment is operated with work

mode in digging, pump 2 flow rate remains kept
minimum.
YES Refer to Troubleshoot-

ing A.
Check if fault code

is displayed. YES Faulty monitor unit.
Check if swing speed

is within specification.
NO
· Refer to Operational Faulty MC.
Performance Test. NO
T5-7-61
A-10 Attachment operating speed is too slow.
• If all actuator speeds are slow or operating speed

at pump 2 side (5-spool side) is slow, refer to A-2
or A-3.
• Although the attachment is operated with work
mode in digging, pump 2 flow rate remains kept
minimum.
YES Faulty control valve

spool.
Check if auxiliary
YES spool in control
valve is stuck or
bound.
Monitor ATT pilot Faulty MC or faulty
pressure. NO monitor unit.
within specification.
· Monitor item:
Att. Control Pilot
Pressure
· Possible to display
Faulty pilot valve.
by built-in diagnosing
system NO
· Engine control dial:
Fast
· Control pedal: Full
stroke
T5-7-62
A-11 Overheating occurs easily when operating
breaker.
Related Fault Code Trouble Reference

Page
MC 11918 Work Mode Receive Error T5-6-75, 76
• Refer to Attachment Mode Control in the Control

System group/ SYSTEM in T/M (Operational
Principle).
• If overheating occurs when operating except the
breaker, refer to A-8.
• If operating speed at pump 1 side (4-spool side)
is slow, refer to A-4.
YES Faulty pump 1 or faulty

pump 1 regulator.
Monitor target pump 1

flow rate.
Select attachment mode
(breaker) in work mode.
Check if flow rate in-
creases.
· Monitor item: Pump 1 Faulty MC.
target flow rate NO
· Attachment operation
T5-7-63
FRONT ATTACHMENT SYSTEM TROU-
BLESHOOTING
F-1 All front attachment actuator power is weak.
• In case operating speeds are extremely slow,

pump control may be malfunctioning (A-1 and/or
A-2). Faulty pilot system may also cause this
trouble.
31.9 to 34.3 MPa Main relief valve should be

2
(325 to 350 kgf/cm , 4640 to 4990 psi) normal. Find out cause of
trouble by tracing other trou-
ble symptoms.
Monitor pump 1 and 2 delivery
pressures.
· Monitor item: Pump 1 and 2 Adjust main relief valve.
delivery pressure Less than 31.9 MPa
· Possible to display by using (325 kgf/cm2, 4640 psi)
built-in diagnosing system
· Relieve boom, arm and bucket
circuits.
· Power mode switch: HP
· Work mode: Digging
T5-7-64
F-2 Even if power digging switch is pushed,
power does not increase.
Boom raise power is week when digging.

MC
11404 Abnormal Solenoid Valve Unit (SG) T5-6-68
• Refer to the pages for the SYSTEM / Power Dig-

ging Control group in T/M (Operational Principle).
YES Refer to Trouble-

shooting A.
Check if fault code Faulty power digging

is displayed. switch, or open cir-
NO
cuit in harness be-
tween power digging
Monitor Power digging switch and MC.
switch.
When pushing power
NO digging switch, check if
ON is displayed. YES Faulty main relief
Monitor main relief valve.
· Monitor item: Power control pressure.
boost SW Check if pressure is
YES approx. 31.9 MPa (325
· Possible to display by
using built-in diagnos- kgf/cm2, 4640 psi) Faulty MC.
ing system NO
· Monitor item: Power
boost control pressure
using built-in diagnosing
system
T5-7-65
F-3 Some cylinders are inoperable or speeds are
slow.
• When other actuators (travel and swing motors)

operate normally, the pilot pump (primary pilot
pressure) is considered to be normal.
• Refer to F-6 if boom lowering is slow.
Bound control valve
YES spool or faulty cylinder
(faulty seal kit).
YES Check if overload

Monitor pump control relief pressure is
pressure. normal.
YES Check if pump control
pressure changes Faulty overload relief
smoothly while mov- NO valve.
ing control lever
slowly.
· Monitor item:
Monitor or measure Faulty shuttle valve in
Pump 1 flow control
secondary pilot pres- signal control valve.
pressure, pump 2 flow NO
sure. control pressure
Check if secondary pi- · Possible to display by
lot pressure is normal. using built-in diagnosing
· Secondary pilot pressure: system
Refer to Operational Per-
formance Test.
· Monitor item:
Boom raise pilot pressure Faulty pilot valve or
(Possible to display by bound shockless
using built-in diagnosing valve spool (during
system), NO abnormal boom op-
boom lowering pilot pres- eration).
sure,
arm roll-in (BH) pilot
pressure (Possible to dis-
play by using built-in di-
agnosing system),
arm roll-out (BH) pilot
pressure,
bucket roll-out (BH) pilot
pressure,
bucket roll-in (BH) pilot
pressure
T5-7-66
F-4 Arm speed or bucket speed is slow during
combined operation of boom lower and arm
or boom lower and bucket.

11402 Abnormal Solenoid Valve Unit (SF) T5-6-67
11995 Abnormal Arm Roll-Out Pilot Pressure Sensor T5-6-84
MC
11997 Abnormal Bucket Roll-Out Pilot Pressure Sensor T5-6-85
11998 Abnormal Boom Lower Pilot Pressure Sensor T5-6-86
11999 Abnormal Bucket Roll-In Pilot Pressure Sensor T5-6-87
• Refer to the pages for Boom Flow Rate Control

Valve Control in SYSTEM in Control System
group in T/M (Operational Principle).
• If arm or bucket speed during single operation is
slow, refer to A-3.

shooting A.
Check if fault code

is displayed. YES Faulty boom flow
Monitor solenoid valve rate control valve.
unit (SF). Check if pres-
NO sure is approx. 3.9 MPa
(40 kgf/cm2, 570 psi). Faulty MC.
· Monitor item: Boom flow NO
control pressure
· Combined operation of
boom lower and arm or
bucket.
T5-7-67
F-5 Boom raise speed is slow during arm
crowding operation (during combined op-
eration of boom raise and arm roll-in) Arm
moves jerky.
• Refer to the SYSTEM / Hydraulic System group in

T/M.
Faulty arm regen-
YES
erative valve (switch
Check if arm regen- valve).
YES erative valve (switch
Install a pressure valve) is bound or
gauge to port SK in scored.
signal control valve. Faulty arm flow rate
YES Check if pressure is NO control valve.
approx. 3.9 MPa (40
kgf/cm2, 570 psi).
· Engine control dial: Bound arm flow rate
Measure and monitor Fast control valve control
secondary pilot · Boom raise and NO spool in signal con-
pressure. arm roll-in are re- trol valve.
lieved.
· Secondary pilot pres-
sure: Refer to Opera-
tional Performance Faulty pilot valve.
Test.
· Monitor item: Boom NO
raise pilot pressure, arm
roll-in (BH) pilot pres-
sure
using built-in diagnosing
system

(Control Valve Side)
Port SK
T1J1-05-07-002
T5-7-68
F-6 Even if the boom mode selector switch is
pushed, machine is raised off ground.

MC 11989 Abnormal Solenoid Valve Unit (SC) T5-6-79
• Refer to the pages for Boom Mode Selector Con-

trol in SYSTEM / Control System group in T/M
(Operational Principle).
Disconnect boom mode

selector switch and con-
nector B in MC. YES Faulty MC.
Check for continuity be-
NO tween terminal #9 of
harness end connector of Open circuit in har-
Exchange boom mode boom mode selector ness between con-
selector switch with level switch and terminal #2 of nector B in MC and
NO check switch. NO
harness end connector B boom mode selector
Check if system operates in MC. switch.
properly.
Faulty boom mode
Monitor boom mode selector switch.
YES
selector switch.
Check if ON is dis-
played.
· Monitor item: Boom NO Faulty MC.

mode SW Monitor solenoid valve
unit (SC).
YES approx. 3.9 MPa (40
Faulty boom overload
kgf/cm2, 570 psi).
relief valve or boom
· Monitor item: boom YES overload control valve
mode control pressure in control valve.
· Boom mode selector
switch: ON
· Boom lower operation
Connector (Harness end connector viewed from the

open end side)
Boom Mode Selector MC Connector B

Switch
#2
B1 B8
T1J1-05-07-003
#9
B19 B25
T5-7-69
F-7 When boom raise or arm roll-out is operated,
boom or arm starts to move after moving
slightly downward.
Damaged control valve

NO spool, broken spring, or
loose spool end.
Check if excessive
YES cylinder internal leak-
age is found.
Check if load check Faulty cylinder seal.

valve in control YES
valve is normal.
· Disassemble / Faulty Load check valve.

visual inspection NO
NOTE: 1. During the initial stage of operation, oil

pressure and flow rate from the pump is
low. Therefore, if the load check valve is
malfunctioning, the oil in the bottom side (B)
of the boom cylinder flows back into the
circuit through the load check valve. When the load check
Therefore, the boom cylinder is tempo- valve is faulty: (A)
rarily retracted.
2. As oil pressure and flow rate from the
pump is low, if oil leaks from bottom side
(A) to rod side (B) due to faulty boom
cylinder piston or cylinder barrel, the
boom cylinder is temporarily retracted
during the initial stage of operation. In
addition, when cylinder force is reduced,
the cylinder drift increases in this case. T105-07-04-012
T5-7-70
F-8 Front attachment drifts remarkably.
YES Faulty pilot valve.
YES Faulty corresponding

Check if cylinder
cylinder.
drift is reduced
when pilot shut-off Check if cylinder in-
valve is closed. YES
ternal leakage is
found. Faulty corresponding
control valve (damaged
Check if correspond- NO spring or loose spool
ing overload relief end).
NO pressure is normal.
Performance Test Faulty corresponding
section for pressure NO overload relief valve.
measurement pro-
cedure.
• Boom Cylinder Internal Leakage Check
1. With the bucket cylinder fully retracted and the

arm cylinder slightly extended from the fully re-
tracted position, lower the bucket tooth tips onto
the ground.
2. Disconnect hoses from the boom cylinder rod side.

Drain oil from the hoses and cylinders. (Plug the
disconnected hose ends.)
T105-07-04-009
3. Retract the arm cylinder and lift the bucket off the
ground. If oil flows out of the hose disconnected
pipe ends and the boom cylinders are retracted at
this time, oil leaks in the boom cylinders. In case
no oil flows out of the hose disconnected pipe
ends but the boom cylinders are retracted, oil
leaks in the control valve.
T5-7-71
F-9 Front attachment speed is slow during com-
bined operation of front attachment and
swing.

11301 Abnormal Swing Pilot Pressure Sensor T5-6-63
MC
• If other operations except the front/swing are

normal, the pressure sensor (swing) may be
faulty.
• Refer to the pages for Swing Horse Power Re-
ducing Control in SYSTEM / Control System
group in T/M (Operational Principle).
• Check the wiring connection first.

shooting A.
Check if fault code
is displayed.
Faulty MC.
NO
T5-7-72
(Blank)
T5-7-73
SWING SYSTEM TROUBLESHOOTING
S-1 Swing is slow or unmoving.
• Check whether the pilot system is faulty or the

main circuit is faulty.
• In case other functions (front attachment and
travel) operate normally, the pilot pump is con-
sidered to be normal. If the pilot system is dis-
playing a problem, the cause of trouble may exist
in the circuit after the pilot valve.
• In case the left travel speed is also slow, refer to
A-2.
Check if swing motor

Install a pressure gauge to YES parking brake release
port SH. Measure parking valve is bound or
brake release pressure. scored.
YES
Check if pressure is be-
tween 3.4 to 4.9 MPa (35 to
50 kgf/cm2, 495 to 710 psi). Faulty swing parking brake
Monitor secondary release valve spool in sig-
pilot pressure. · Arm relief operation NO nal control valve.
Check if secondary
pilot pressure is
normal.
· Specification: Refer to NO Faulty pilot valve.
Operational Perform-
ance Test. Disassemble and clean
· Monitor item: Swing pilot valve.
pilot pressure NO Check if trouble occurs.
· Possible to display by Faulty swing shuttle valve.
using built-in diagnosing YES
system

(Pilot Valve Side)
Port SH
T1J1-05-07-005
T5-7-74
YES Faulty swing reduction gear.

Check if swing motor drain
YES oil amount is normal.
Check if swing relief Faulty swing motor.
NO pressure is normal. · Measurement: NO
formance Test Section.
· Swing relief operation.
· Monitor item: Pump 2 de-
livery pressure
· Possible to display by using Faulty swing relief valve.
built-in diagnosing system NO
· Specification:
formance Test Section.
Faulty swing motor parking

YES brake release valve.
T5-7-75
S-2 Swing is fast.
When swing is operated fully, swing speed is
slow.

MC 11301 Abnormal Swing Pilot Pressure Sensor T5-6-63
• Refer to F-9 “Front attachment speed is slow

during combined operation of front attachment
and swing”.
• If swing speed is fast, the swing horsepower re-
ducing control may be abnormal. If swing speed is
slow when swing is operated fully, the relief flow
rate decrease control may be faulty. The cause is
malfunction of the pressure sensor (swing).
• Refer to the pages for Swing Horsepower Re-
ducing Control and Relief flow Rate Reducing
Control in SYSTEM / Control System group in
T/M (Operational Principle).
YES Refer to Trouble

shooting A.
Check if fault code
is displayed.
Faulty MC.
NO
T5-7-76
TRAVEL SYSTEM TROUBLESHOOTING
T-1 Both right and left tracks do not rotate or

rotate slowly.
• Both right and left pilot valves, travel motors,

and/or control valve spools are unlikely to be
faulty at the same time.
• In case both travel systems do not operate, the
pilot system, which is applied to both side travel
motors, may be faulty. If the primary pilot pressure
is lower than specification, the front attachment
operating speed becomes slow as well. Refer to
A-1.
• In case the fast travel mode cannot be selected,
refer to T-4.
• If the power is insufficient, it seems that pressure
is not built up, check pressure sensor (travel) cir-
cuit, and refer to F-2.
T5-7-77
T-2 One side track does not rotate or rotates
slowly. Machine mistracks.
• Check that both side track sags are equally ad-

justed.
• Faulty pump control will cause the machine to
mistrack. In this case, other trouble symptoms
such as slow bucket or swing single operation
speed, or slow arm roll-in and boom raise speed
in level crowd operation will occur at the same
time. If both mistrack and other symptoms as
described above occurs at the same time, refer to Check if travel motor
A-3 and A-4. NO drain oil amount is nor-
• In one side track only does not rotate, the pilot mal.
valve, control valve, travel motor, or center joint
may be faulty. Check if symptom is · Measurement: Refer to
reversed when right Operational Perform-
YES and left travel line ance Test section.
hoses are switched
each other at the top of
center joint.
Check if travel relief
YES
pressure in slow speed Bound control valve spool.
side is normal.
· Travel relief operation. YES
· Monitor item: Pump 1
and 2 delivery pressure
using built-in diagnosing Switch forward travel
Check if secondary
system relief valve with reverse
travel pilot pressure is
· Measurement: Refer to travel one, or right travel
normal.
Operational Perform- NO relief valve with left one.
· Monitor item: Travel ance Test section. Check if symptom is
pilot pressure reversed.
· Possible to display
by using built-in di- Faulty pilot valve.
agnosing system NO
Relationship between Faulty Seal Location Seal Location
and Mistrack Direction
Seal When pivot turn is
When traveling straight
NO. performed
1 External Oil Leak ←
Pi (Travel Speed Change) 1
2 ←
Oil Leak
2
3 3
4 Right Travel
(Reverse)
Left Travel 4
(Reverse) 5
5
Right Travel
(Forward)
Left Travel
6 6
(Forward)
7
and External oil leak and External Leak T16J-03-07-001
T5-7-78
NO Faulty travel motor.
NO Faulty travel reduction

Disassemble and clean gear.
YES travel motor swash an-
gle control mechanism.
Check if any abnormal-
Disassemble and ity is found. Faulty travel motor swash
clean travel motor YES angle control mechanism.
counterbalance valve.
YES Check if same symp-
tom occurs. Faulty counterbalance
valve.
NO
NO Faulty center joint.
Faulty travel relief valve.

YES
Arrangement of Pipe Line
Front
1 2 3
6
5
T1J1-05-07-004
1 - Drain 3 - Right Travel (Reverse) 5 - Left Travel (Reverse) 6 - Left Travel (Forward)
2 - Right Travel (Forward) 4 - Pilot (Travel Speed Change)
T5-7-79
T-3 Machine mistracks during combined opera-
tion of travel and front attachment.
Disconnect hose (SL) Faulty flow combiner

YES
connecting to flow com- valve control spool in
biner valve from signal signal control valve.
control valve.
NO Install a pressure gauge
to signal control valve. YES Faulty load check valve.
Check if signal pressure
Check load check
is approx. 3.9 MPa (40
valve for any abnor-
Check flow combiner kgf/cm2, 570 psi). NO mality. Find out cause of trouble
valve in control valve by tracing other trouble
for any abnormality. NO symptoms.
Faulty flow combiner

YES valve.

(Control Valve Side)
Port SL
T1J1-05-07-002
T5-7-80
T-4 Fast travel is inoperable.
Travel mode does not change from slow
mode to fast mode.

11405 Abnormal Solenoid Valve Unit (SI) T5-6-69
MC 11991 Abnormal Right Travel Pilot Pressure Sensor T5-6-80
11993 Abnormal Left Travel Pilot Pressure Sensor T5-6-82
• Refer to the pages for Travel Motor Swash Angle

Control in SYSTEM / Control section in the T/M
(Operational Principle).
Faulty travel mode

NO switch or open circuit
in harness between
travel mode switch
and MC.
Monitor travel mode
switch.
Check if displayed in- Faulty travel motor
YES
dication is highlighted in swash angle control
response to travel Check if travel motor mechanism.
YES swash angle control
mode switch operation. Monitor travel motor
mechanism is abnor-
· Monitor item: Travel Speed Control Pres- Faulty travel motor or
mal.
mode SW sure. faulty travel reduction
· Possible to display by Check if pressure is gear.
YES approx. 3.9 MPa (40 NO
using built-in diagnos-
ing system kgf/cm2, 570 psi).
Faulty MC.
· Monitor item: Travel NO
motor control pressure
using built-in diagnos-
ing system
· Travel mode: Fast
T5-7-81
OTHER SYSTEM TROUBLESHOOTING
O-1 Wiper is inoperable or not retracted.
Checking Instructions
• The wiper is driven by electric power routed via
the relay circuit controlled by the monitor assem-
bly. In case the wiper is inoperable, first check the
wiper motor and links for any abnormality by us-
ing an auxiliary electric power and the test har-
ness.
• If the front window is open, the wiper does not
operate. Check that the front window is securely
closed.
YES Faulty wiper relay.
Disconnect monitor A
Switch wiper relay with connector in monitor unit.
NO other general relay. Connect terminal #A2 of YES Faulty monitor unit.
Check if wiper is oper- harness end of connector
ated. to machine.
Disconnect wiper relay.
· Key switch: ON NO Check for continuity be-
Check if wiper relay tween terminal #2 of har- Open circuit in harness
is turned ON or OFF ness end of connector between wiper relay
in response to INT. NO and monitor unit.
and machine.
position of wiper
switch. YES Faulty wiper motor.
Shut front window.
· Key switch: ON
Open front window. Disconnect wiper motor
· Wiper switch: INT YES
Measure voltage be- connector.
tween terminals B and Measure voltage between Open circuit in harness
L of window contact terminals B and L of har- between window con-
YES point (cab side). ness end of connector. NO tact point and wiper
Check if voltage is 24 Check if voltage is 24 V. motor.
V. · Key switch: ON
· Key switch: ON · Wiper switch: ON
· Wiper switch: ON Open circuit in harness
between wiper relay
NO and window contact
Window Contact Point Connector

(Cab Side) Wiper Motor (Harness end)
INT. Position Set Time
Slow 8 second
Middle 6 second B L
Fast 3 second
S E
T1V1-05-07-005
Monitor Unit
Monitor A Connector (Harness end) #A2
T183-05-05-001
T5-7-82
Wiper Drive Circuit
Wiper Motor Wiper Relay
Main
↑
Window T1V1-05-07-004
Contact
Point
T5-7-83
O-2 Counterweight removal/installation device is
not operated or power is weak.

MC 11404 Abnormal Solenoid Valve unit (SG) T5-6-68
• Refer to the page for Pump Control for Counter-

weight Removal and Installation in Control Sys-
tem group/ SYSTEM in T/M (Operational Princi-
ple).
• If other actuator is not operated or slow, the pilot
system may be faulty. Refer to A-1.
• If power is weak, refer to F-1 and F-2.
YES Faulty pressure sensor
(counterweight).
Switch pressure sen-
sor (counterweight)
NO with other pilot pres- Open circuit in harness
sure sensor. NO between terminal #1 of
Check if symptom is connector of pressure
improved. sensor (counterweight)
and MC, or faulty MC.
Monitor secondary Disconnect connector of

pilot pressure. pressure sensor (coun-
Check if secondary terweight). Disconnect connector
pilot pressure is nor- Check if voltage at ter- D in MC.
NO
mal. minal #1 of harness end Connect terminal #3 of
of connector is 5±0.5 V. connector D to ma-
· Monitor item: C/W chine.
removal pilot pressure · Key switch: ON Check for continuity
· Counterweight re- YES between terminal #2 of
moval/installation op- harness end of con-
eration nector of pressure
sensor (counterweight)
and machine.
Refer to F-1 and F-2.

YES

Connector MC-D (Counterweight)
#D3
T1J1-05-06-001
T183-05-04-009
T5-7-84
YES Faulty spool in control

valve.
YES Check if spool in control

valve is bound or scored.
Faulty pilot valve for
counterweight re-
moval/installation, or
NO faulty counterweight re-
moval/installation device.

NO pressure sensor (coun-
terweight) and MC.
T5-7-85
O-3 Counterweight removal/installation speed is
fast. Precise operation cannot be per-
formed.

MC
• Refer to the page for Pump Control for Counter-

weight Removal and Installation in Control Sys-
tem group / SYSTEM in T/M (Operational Princi-
ple).
• When operating counterweight removal / installa-
tion, flow rates of pumps 1 and 2 are minimum.
Therefore, if other actuator speed is fast, the
pump control may be faulty. Refer to A-6.
YES Faulty pressure sen-
sor (counterweight).
Switch pressure sen-
sor (counterweight)
NO with other pilot pres-
sure sensor.
Check if symptom is Open circuit in har-
improved. ness between terminal
#1 of connector of
Monitor secondary pressure sensor
pilot pressure. NO (counterweight) and
Check if secondary MC, or faulty pilot
pilot pressure is nor- valve.
mal.
· Monitor item: C/W
removal pilot pressure
· Counterweight re-
moval/installation op- Faulty MC.
eration YES

open side)
Pilot Pressure Sensor
(Counterweight)
T1J1-05-06-001
T5-7-86
(Blank)
T5-7-87
O-4 Auto lubrication is faulty.
• Even if the auto lubrication switch is turned ON,

auto lubrication is not operated.
• Interval: 90 minutes (The interval setting can be Damaged lubrication
changed between 10 and 90 minutes.), Lubricat- Monitor auto lubrica- YES
tion proximity switch. pipings on front at-
ing time: 5 minutes tachment.
YES Check if ON/OFF is
switched and dis-
played alternately Check if grease pump
during monitoring. NO is operated.
· Monitor item: Auto lu-
brication counting SW
· Auto lubrication switch:
ON
Monitor lubrication
YES pump status.
Check if “Comp.” is
displayed.
· Monitor item: Lubrica-

tion control output
Monitor auto lubrica- · Auto lubrication switch:
tion device switch. ON
Check if “auto” is dis- YES Faulty auto lubrication
played. Switch auto lubrication relay (R11).
relay (R11) with other
· Monitor item: Lubri- general relay.
cating mode NO Check if symptom is
· Auto lubrication improved.
switch: ON NO
Disconnect auto lubri-

cation switch and
connector MC-B in YES
MC. Faulty auto lubrication
Check for continuity switch.
NO harness end of con-
nector in auto lubrica- Open circuit in har-
tion switch and termi- ness between auto
nal #B3 of harness NO lubrication switch and
end of connector in MC.
MC.

open side)
MC
Auto Lubrication Switch Connector B
#B3
B1 B8
T1J1-05-07-003
#9 B19 B25
T5-7-88
Damaged lubrication
pipings between grease
pump and distribution
YES
valve on upperstructure
(attached proximity
switch), or faulty distri-
bution valve on upper-
structure, or no grease.
Faulty proximity switch,

Disconnect proximity YES or open circuit in har-
switch. ness between proximity
YES Check if voltage at terminal switch and ground.
#3 of harness end of con-
Disconnect connector in nector is 24 V. Open circuit in harness
grease pump. between auto lubrica-
Check if voltage at terminal · Key switch: ON
NO tion relay (R11) and
NO #2 of harness end of con- · Auto lubrication switch: ON
proximity switch.
nector is 24 V.
· Key switch: ON Open circuit in harness
· Auto lubrication switch: ON between auto lubrica-
tion relay (R11) and
grease pump, or dam-
NO
aged lubrication pipings
on upperstructure.
Faulty fuse #30, or

Disconnect auto lubrication YES open circuit in harness
relay (R11). between fuse #30 and
Check for continuity be- auto lubrication relay
tween terminal #2 of har- (R11).
ness end connector in auto
lubrication relay (R11) and Open circuit in harness
terminal #B24 of harness between auto lubrica-
end connector in MC. NO tion relay (R11) and

open side)
Grease Pump Auto Lubrication Relay (R11)

Proximity Switch
1 2 3
T183-05-04-003
T5-7-89
• Even if auto lubrication time is over, auto lubrication
does not stop.
• Even if auto lubrication switch is turned OFF, auto
lubrication does not stop.
• Interval: 60 minutes (The interval setting can be
changed between 10 and 90 minutes.), Lubricat-
ing time: 5 minutes
YES Faulty auto lubrication re-

lay (R11).
Switch auto lubrication
relay (R11) with other
general relay. Check if YES Faulty MC.
auto lubrication stops.
MC-B in MC.
NO Check if auto lubrication
stops. Shorted circuit in harness
between auto lubrication
NO relay (R11) and MC.
• At the same time when the auto lubrication device

stops, auto lubrication alarm is displayed.
• There is a possibility that no grease or faulty
proximity switch.
In this case, check the following:
1. Grease amount in the cartridge
2. Air mixed into the circuit
3. Plug at the cartridge
4. Failure of the proximity switch
T5-7-90
Procedure to fill up grease to lubrication pipe (air
bleed procedure)
• Filling up grease to lubrication pipe at upperstruc-

ture side
1. Disconnect lubrication hoses (1, 4). Attach a plug 6. Remove the plug from the end of lubrication
to the disconnected hoses. hoses (1, 4).
2. Remove the adapter at the distribution valve (2) 7. Apply grease through the nipple attached with
side in hose (3) between grease pump (5) and distribution valve (2) by using a grease gun.
distribution valve (2). 8. Check if grease comes out of the end of lubrica-
3. Install the nipple to the port where the adapter in tion hoses (1, 4).
distribution valve (2) was removed. 9. Install the plug to the end of removed lubrication
4. Apply grease through the nipple on the upper of hoses (1, 4).
grease pump (5) by using a grease gun. 10. Remove the nipple from distribution valve (2). In-
5. Start grease pump (5). Release any pressure stall the adapter and hose (3).
between grease pump (5) and distribution valve
(2).
Air bleeding time: Approx. 4 to 5 minutes
• Turn the key switch ON.
• Turn the auto lubrication switch ON.
• Check if grease comes out of the disconnected
hose.
• Turn the auto lubrication switch OFF.
• Turn the key switch OFF.
NOTE: If the auto lubrication alarm is displayed on
the monitor unit, turn the key switch OFF
and perform step 5 again.
5 3
T1J1-05-07-007
T5-7-91
• Filling up grease to boom lubrication pipe
1. Remove elbows (2, 3).
2. Install the nipple (J75482) to the port where el-
bows (2, 3) were removed.
3. Apply grease through the nipple by using a
grease gun.
4. When filling up grease to the port (2) side:
Check if grease comes out of adapter (1) in the
boom end and check for any leakage of grease
from the lubrication pipe.
5. When filling up grease to the port (3) side:
Check if grease is supplied to each pin and
check for any leakage of grease from distribution
valve (4) and the lubrication pipe.
6. Remove the nipple. Install elbows (2, 3).
Boom
1
A
3 2 T1J1-05-07-008
View A
T1J1-05-07-009
T5-7-92
• Filling up grease to arm lubrication pipe
1. Remove adapter (6).
2. Install the nipple (J75482) to the port where
adapter (6) was removed.
3. Apply grease through the nipple by using a
grease gun.
4. Check if grease is supplied to each pin and
check for any leakage of grease from distribution
valve (5) and the lubrication pipe.
5. Remove the nipple. Install adapter (6).
View B
B
5 6
T1J1-05-07-011
Arm
T1J1-05-07-010
T5-7-93
O-5 Level check is faulty.
• Even if the level check switch is turned ON, the

alarm (green or red) is not displayed on the monitor
unit.

MC 11004 Can Communication Error T5-6-39
Monitor Unit 13308 Can Communication Error T5-6-97
YES Faulty MC, or faulty

monitor unit.
Monitor level check

switch.
Check if “ON” is dis-
played.
· Monitor item: Level
check SW YES
Switch connector of level Faulty level check
· Level check switch: ON check switch with that of switch.
· Key switch: ON boom mode selector
switch.
NO Check if symptom is im- Faulty MC, or open
proved. circuit in harness be-
· Boom mode selector NO tween level check
switch: ON switch and MC.
· Key switch: ON

open side)
Coolant Level Switch Engine Oil Level Switch MC

MC-C Connector C
#C9
C1 C10
#C21
T183-05-04-010 C23 C31
T5-7-94
• Even if the level check switch is turned OFF, the
alarm (green or red) is displayed on the monitor
unit.

MC 11004 Can Communication Error T5-6-39
Monitor Unit 13308 Can Communication Error T5-6-97
YES Faulty level switch.
Connect disconnect
connector.
YES Disconnect connectors of
coolant level switch and
engine oil level switch. Shorted circuit in har-
YES
Check if alarm disap- ness between MC and
pears. Disconnect connector each level switch.
C in MC.
NO Check if alarm disap-
pears. Faulty monitor unit.
B in monitor unit. NO
Check if alarm dis-
appears.

NO
T5-7-95
O-6 Malfunction of Air Conditioner
The air conditioner has a self-diagnosis function.

The self-diagnosis functions to:
• Display Fault Codes
• Change Displayed Fault Codes
• Delete Fault Code
• End Fault Code Display
• Display Fault Code

1. Press the fan OFF switch to turn the fan OFF.
2. Press and hold both the upper and lower sides of
the temperature control switch on the air condi-
tioner control panel at the same time for more Temperature
than 3 seconds with the key switch ON. Fan OFF Switch Control Switch
NOTE: After operation has been performed, the

buzzer will sound.
3. If any fault codes are found, the LCD displays the

fault codes as ⎡E{{⎦.
M178-01-017
NOTE: If more than one fault code is found, the LCD

lower number fault code will be displayed
first.
T5-7-96
Fault Code List
Fault
Location in Trouble Cause Symptom
Code
Abnormal circulation E11 Broken circuit in air circulation Y value (air flow-in temperature) cannot
air sensor sensor be adjusted in response to the
E12 Short-circuited circulation air set-temperature.
sensor
Abnormal fresh air E13 Broken circuit in fresh air sensor Operation is controlled under such cir-
sensor E14 Short-circuited fresh air sensor cumstance as no fresh air sensor is pro-
vided.
Abnormal solar E18 Short-circuited solar radiation Operation is controlled under such cir-
radiation sensor sensor cumstance as no solar radiation sensor is
provided.
Abnormal evapora- E21 Broken circuit in evaporator sen- Operation is controlled under such cir-
tor sensor sor cumstance as the evaporator temperature
E22 Short-circuited evaporator sen- is set to 10 °C (50 °F).
sor
Abnormal damper E43 Abnormal air vent damper Corresponding damper servo becomes
E44 Abnormal air mix damper inoperable.
E45 Abnormal circulation/fresh air
damper
Water temperature E15 Broken circuit in water tempera- Operation is controlled under such cir-
sensor ture sensor cumstance as the water temperature is
E16 Short-circuited water tempera- set to 60 °C (140 °F). (Warm-up control is
ture sensor not performed.)
Abnormal refrigerant E51 Abnormal high/low refrigerant The compressor clutch is disengaged.
pressure (The compressor stops.)
T5-7-97
• Change Displayed Fault Code
When displaying more than one fault code, press Temperature
either the upper or bottom side of the temperature Control Switch
control switch key. The following fault code is dis-
played.
NOTE: Each time the displayed fault code is

changed, the buzzer sounds. In case only
one fault code exists, the displayed fault
code remains unchanged. M178-01-017
LCD
LCD
• Delete Fault Code
1. Press and hold both the circulation air switch and
the fresh air switch for more than 3 seconds at
the same time to delete the fault code.
NOTE: After the fault code is deleted, the buzzer

will sound.
M178-01-017
Circulation Fresh Air
2. After the fault code has been deleted, the LCD Air Switch Switch
displays ⎡E{{⎦.
Fan OFF Switch
• End Fault Code Display

Press the fan OFF switch, or press the upper side
of the fan switch key. The self-diagnostic mode is
complete.
M178-01-017
Fan Switch
T5-7-98
※ Please fill in all sections and return this AIR CONDITIONER TROUBLE REPORT to the related post / after experiencing a problem with
your machine’s air conditioning system.
< AIR CONDITIONER TROUBLE REPORT > File No.
(1) What Checked by:
Model (Serial No. )
Operation Type Manual Semi-Auto Full-Auto
Delivery Date Year Month
(2) When
Date Year Month Day Operating Hour ( h)
Time Morning Daytime Evening Night
Frequency Every Day Once a Week Once a Month Times per
(3) Where
Job Site Address State County Town
Access Road Condition Paved Not Paved (Gravel Sand Soil)
(4) How (Operating Conditions)
Weather Fine Cloudy Rain Snow
Atmospheric Temperature Very Hot Hot Cold Very Cold
Operating Conditions Parking Traveling Working
Temperature Control Paint blanks equal to red indicators. / Fill in set-temperature when
full-auto operation
A/C ON OFF
Control Air Induction Re-Circulation Fresh Air Circulation
Panel AUTO ON OFF Not Available
Fill following items when operated in manual mode or when manual control type unit is used.
Vent Position Front Front / Rear Foot Front / Rear and Foot
Fan First Second Third Fourth Fifth Sixth
(5) How (Problem Symptom)
Abnormal Compressor Operation
Symptom Not turned ON <Check Result>
Not turned OFF (1) Is problem reproducible ?
Others Reproducible
Uncontrollable air temperature Not reproducible
(2) Pressure (To be measured at gauge manifold)
Symptom No cool air
Low Pressure
No warm air
High Pressure
Others
(3) Which parts have been replaced ?
Uncontrollable air volume
1
Symptom Air flows in Hi mode only
No air flows
2
Small air volume
Others
Uncontrollable vent hole
∗ Before replacing the control amplifier, be sure to
check that the connectors are correctly connected
Symptom Vent hole isn’t selected
while repeatedly disconnecting and reconnecting
Others connectors.
Abnormal panel indication
Faulty Indicator Vent Hole
A/C
AUTO
Fresh Air Circulation
Fan OFF
Fan (Lo • •• Hi)
Temperature Control
Symptom Stays OFF
Stays ON
Blinks
Others
T5-7-99
Cooling Circuit
Refrigerant pressure Bubbles can be seen in sight Piping and/or parts are stained with oil,
in both high and glass. respond to gas detector.
low-pressure sides is
low.
No oil stain is found or gas detector
does not respond. Refrigerant has not
been refilled for longer than one sea-
son.
No bubbles are seen in sight
glass.
After cooling at fast speed continu-

ously, cooling power is reduced. Air
flow volume remains unchanged.
Air flow volume is reduced.
Refrigerant pressure
in low-pressure side Bubbles can be seen in sight Compressor cylinder is extremely hot,
Insuffi- is high. glass. emitting a smell.
cient
Cooling
Power
Refrigerant pressure in Compressor cylinder is extremely hot,
high-pressure side is low. emitting a smell.
Heater unit emits hot air.
Refrigerant pressure
in high-pressure side Bubbles can be seen in sight Refrigerant pressure in low-pressure
is high. glass. side is low.
Condenser is stained and clogged.
Even if condenser is sprayed with water, few bubbles appear. Receiver dryer tem-
perature is low.
After cooling at fast speed continu-

ously, cooling power is reduced. Air Frost forms. Thermistor does not cool.
flow volume is reduced.
Thermistor cools.
T5-7-100
Gas leaks from pipe joints and/or parts. Re-tighten or replace parts.
Normal leakage of refrigerant from hoses. Refill refrigerant.
Improper adjustment (excessive restriction) of expansion Readjust or replace expansion valve.

valve.
Clogged expansion valve. Remove clog, or replace receiver and/or expansion

valve.
Clogged low-pressure circuit and/or evaporator. Remove clog, or replace parts.
Frozen expansion valve or water in circuit. After evacuation, refill refrigerant and/or replace re-
ceiver dryer.
Gas leaks from case. Seal gaps by using vinyl tape or packing compound.
Poor contact of expansion valve temperature sensing cylinder. Make good contact. Replace temperature sensing
stay.
Improper adjustment (excessive open) of expansion valve. Readjust or replace.
Insufficient compressor discharge (faulty gasket and/or valve). Replace.
Improper water stop valve wire adjustment and/or faulty stop

valve. Check and readjust or replace.
Poor airtight fitting of outside air damper (outside air induction

Repair.
type).
Clogged high-pressure circuit before receiver dryer. Remove clog, or replace parts.
Clean Condenser.
Excessive refrigerant. Remove excessive refrigerant to proper level.
After evacuation, refill refrigerant and/or replace re-

Air is mixed in system.
ceiver dryer.
Incorrect thermistor location. Correct thermistor location.
Gas leaks from case. Seal gaps by using vinyl tape or packing compound.
Faulty thermistor (stays ON). Disconnected thermistor cord.
Even if function and performance are normal, when Instruct user on correct air-conditioner operation.
air-conditioner is kept operated for a long time with thermistor (Reset thermistor to either minimum or middle cooling
in max. cooling position and air flow in M or L mode, frost may position or increase air flow.)
form.
T5-7-101
Cooling Circuit
Case connection. Louver resonance.
Fan contacts case, or foreign matter enters case.

Blower fan connection.
Brush friction noise, metal and/or thrust washer con-
tact noise.
Gas blowing sound (roaring). Gas vibration noise (compressor discharge and/or
suction gas noise).
Expansion valve connection, whistle Abnormal noise from expansion valve (Expansion
Noise sound, gas blowing sound. valve is normally functioning.).
Faulty clutch bearing, and/or idle pulley bearing.
Clutch disengaging sound.

Contact of clutch amature due to resonance, or loose
belt and/or screws.
Noisy compressor.
Compressor rotating sound.
Vibration and/or loose screws due to excessive drive
belt looseness.
Broken heater core and/or hose.

Water leak and/or splash.
Clogged case drain port and/or drain hose.
Others
Absorbed cigarette and dust smell on evaporator fins.

Abnormal smell.
T5-7-102
Repair or replace.
Remove foreign matter. Readjust fan motor location.
Slight noise is unavoidable.

Replace if loud.
No functional problem exists.

Provide silencer if intolerable.
Replace expansion valve if whistle sound is heard. Gas flow noise can be slightly heard.
Replace.
Repair or replace clutch. Re-tighten screws.
Repair or replace.
Re-adjust drive belt.
Replace.
Clean.
Clean evaporator. When humidity is high, open door. While rotating fan at approx. 1500 min-1 in
L mode for more than 10 minutes, flush smell out by condensed water.
T5-7-103
Compressor
Compressor does not rotate. Clutch terminal voltage is normal 24 V.
Inoperable
cooling Clutch terminal voltage is low.
system.
Clutch terminal voltage is 0 V.
Bubbles exist even after refrigerant is refilled.
Both high and

low side Check for oil and refrigerant leaks from parts other than
pressures are compressor and pipe joints by using gas detector.
low.
Both com- Check for oil and refrigerant leaks from compressor (no
pressor and leaks from parts other than compressor) by using gas
blower mo- detector.
tor rotate. (Refer to NOTE 1,
2 on page
Stain on exterior.
Refrigerant has not been refilled for longer

than one season.
Refrigerant is discharged within 1 to 2

months after being recharged. Check for
refrigerant leaks using gas detector.
Refrigerant is kept charged for longer than

2 years.
Compressor cylinder is not hot. (Refrigerant returns to com-

High-pressure side is pressor in liquid form.)
slightly low and
low-pressure side is high.
No refrigerant returns in liquid form. High-pressure side is low.
Bubbles can be seen through Others

sight glass.
High-pressure side is high.
Refer to the Cooling Circuit Troubleshooting
Table on page T5-7-100.
Temperature is not cooled when compressor is
operated at fast speed continuously.
Air flow from blower is insufficient.
T5-7-104
Seized clutch. Replace.
Improper gap between amature and rotor (improper air gap).

Replace.
Open or shorted circuit in core cable.
Shaft does not rotate (internally locked). Replace.
Faulty Electrical System.
Faulty Electrical System.
Oil leaks from mechanical seal, gasket, and/or charge valve.

Replace.
Oil leaks from oil plug.
Oil and refrigerant leaks from front housing, and/or cylinder block joint. Replace.
Normal leaks from hoses. Charge

refrigerant.
No leaks (normal).
Refer to the Cooling Circuit Troubleshooting Table on page T5-7-100.
Broken valve (Refer to NOTE 3 on page T5-7-107.)
Replace.
Blown gasket (Refer to NOTE 3 on page T5-7-107.)
Check and adjust

Excessive oil. oil level.
T5-7-105
Compressor
Compressor rotation is abnormally draggy.

Overheating
is susceptible
to occur.
Trouble other than compressor. Refer to the Cooling Circuit Troubleshooting Ta-
ble on page T5-7-100.
Noise is heard when clutch is OFF.
Abnormal
noise
Noise is heard when clutch is ON.
T5-7-106
Broken clutch bearing due to overly tightened belt. Replace.
Shaft does not rotate.

Replace.
Shaft rotates draggy.
Broken clutch bearing.

Replace.
Contact or slip due to poor air gap.
Faulty idle pulley bearing.
Refer to the Cooling Circuit

Saggy belt. Troubleshooting Table on
page T5-7-102.
Loose screws.
Broken valve.
Replace.
Blown gasket.
Abnormal internal noise. Replace.
Vibration due to saggy belt.

Refer to the Cooling Circuit
Troubleshooting Table on
Loose screws. page T5-7-102.
NOTE:
1. Do not quickly decide that oil is leaking when a stain around the clutch and/or gasket is found. A
slight oil seepage will appear due to the seal construction. However, this oil seepage will not
cause malfunction. Accurately check whether oil is leaking or seeping only.
2. When gas detector is used in the high sensitivity range, normal gas leaks from rubber hose sur-
face may be detected. As long as the specified rubber hoses are used, the problem should not
occur. (In case a large leaks is detected, the hose may be broken.)
3. After allowing the compressor to idle for 10 to 15 minutes, normal pressure difference between
high-pressure side and low-pressure side is 0.5 MPa (5 kgf/cm2) or less. When the clutch is
turned OFF, the pressure difference between high-pressure side and low-pressure side will dis-
appear within about 10 seconds.
T5-7-107
WORK AFTER REPLACING COMPO-
NENTS
The following work is required after replacing

compressor, high pressure hose, low pressure hose,
condenser, receiver tank, liquid hose and air
conditioner unit.
The same work is required when gas leakage is found.
1. Add compressor oil

3
Oil amount: 180 cm (0.19 qt)
2. Charge air conditioner with refrigerant

• Purging
• Charge air conditioner with refrigerant
• Warm up operation
• Inspection
T5-7-108
CHARGE AIR CONDITIONER WITH
REFRIGERANT
Necessity of Purging
Make sure to purge the air conditioner circuit with a
vacuum before charging with refrigerant (R134a)
because the following problems can arise if air or
other gases remain in the A/C circuit. Air
1. Pressure rise in the high pressure side:

If air remains in the air conditioner circuit, this
disturbs the heat exchange between refrigerant
and air in the condenser, causing pressure to rise
in the high pressure side (compressor side).
Usually, refrigerant gas is easily liquefied,
however, air cannot be liquefied and remains as a
gas in the condenser because the temperature at
which air liquefies is extremely low. That is, Pressure increases if air
W115-02-10-001
liquidation of the refrigerant gas in the condenser remains in the air
conditioner circuit.
decreases by the amount of air in the circuit, and
the gas pressure in the high pressure side
increases accordingly.
2. Metal corrosion:
If air remains in the air conditioner circuit, a
chemical reaction between refrigerant and
moisture in the air takes place, and as a result,
hydrochloric acid, that corrodes metals such as
aluminum, copper and iron, is produced.
Hydrochloric acid Hydrochloric Acid W115-02-10-002

corrodes metals if
moisture exists.
Metal Corrosion
3. Plugging of the expansion valve by moisture:

When high pressure refrigerant gas passes
through the expansion valve, gas pressure
decreases and temperature drops. Moisture
included in high pressure refrigerant gas in the air
conditioner circuit freezes at the expansion valve
orifice, plugging refrigerant flow. Operation of the
air conditioner becomes unstable and cooling Plugged Refrigerant
efficiency lowers. Flow
Ice produced at the
expansion valve disturbs
W115-02-10-003
refrigerant flow, lowering
cooling efficiency.
Low Cooling
Efficiency
T5-7-109
Purging Procedure Gauge Manifold
IMPORTANT: Never mistake the charge hose Low Pressure

Valve
connections.
Low Pressure
Charge Hose High Pressure
1. Close the high and low pressure valves on the Valve
gauge manifold (Parts Number 4360564).
Connect the high-pressure-side charge hose and High Pressure
Charge Hose
the low-pressure-side charge hoses to the
high-pressure-side charge valve (“D” marked) and Center Pressure
Charge Hose
to the low-pressure-side charge valve (“S” Vacuum Pump
marked) located on the compressor, respectively.
Connect the charge hose located on the center of
the manifold bottom to the vacuum pump (Parts
Number 4360565).
NOTE: Vacuum Pump Joint Adapter (Parts

Number 4360566).
W115-02-10-005
Low Pressure
Side S
Compressor
D
High Pressure
Side
T142-02-05-018
Fully Open
IMPORTANT: Remove refrigrant remained in the
air conditioner circuit and operate
Fully Open
the vacumu pump.
2. Open the high pressure and low pressure valves

in the gauge manifold. Perform purging for 10
minutes or more by operating the vacuum pump.
In Operation
W115-02-10-005
T5-7-110
IMPORTANT: If the pointer returns to 0, retighten
the line connections and perform
purging again. Close
3. When the low pressure gauge reading falls below Close

-100 kPa (-755 mmHg), stop the vacuum pump
and close the high and low pressure valves. Wait
for approximately five minutes and confirm that
the pointer does not return to 0.
In Operation
W115-02-10-005
4. With the high pressure and low pressure valves of

the gauge manifold closed, connect the charge
hose to the refrigerant container (Parts Number
4347644).
Refrigerant
Container
W115-02-10-007
5. Loosen the charge hose connection to the gauge

manifold and open the refrigerant container valve
to purge air in the charge hose with the refrigerant Loosen
pressure.
Open
W115-02-10-007
T5-7-111
IMPORTANT: Always stop the engine when
High
charging the air conditioner with Pressure
refrigerant. Do not position the Gauge
refrigerant container upside down Tighten
during charging operation. When
changing the refrigerant container
during charging operation, purge air Open
from the charge hose, as shown in
step 10. Charge the low pressure
side hose first.
6. Fully tighten the charge hose connection to the Open

gauge manifold. Open the high pressure valve
and refrigerant container valve to charge with
refrigerant (R134a).
Close the high pressure valve and refrigerant
container valve when the high pressure gauge
2
reading reaches 98 kPa (1 kgf/cm , 14 psi).
W115-02-10-007
NOTE: Use warm water of 40 °C (104 °F) or less to
warm the refrigerant container to aid in
charging operation.
W115-02-10-008
IMPORTANT: Use the leak tester for R134a.
7. After charging, check the line connections for gas

leaks by using leak tester (Parts Number
4360567).
T5-7-112
8. Confirm that the high pressure and low pressure
valves in the gauge manifold and the refrigerant
container valve are closed.
Start the engine and operate the air conditioner.
Operating Conditions of the Air Conditioner:

Engine Speed : Slow Idle
Cab Window : Fully Open
Cooler Switch : ON
Airflow Volume : Maximum
Thermo Switch : Maximum
IMPORTANT: Do not open the high pressure valve Open

in the gauge manifold.
9. Open the low pressure valve in the gauge

manifold and the refrigerant container valve to
charge with refrigerant until the bubbles seen in
the receiver tank sight glass disappear.
NOTE: The required refrigerant quantity is 1150 Open

g±50 g (2.53±0.01 lb).
W115-02-10-007
Close
10. If the refrigerant container becomes empty during
the charging work, replace it with a new refrigerant
container as follows:
• Close the high pressure and low pressure valves
on the manifold gauge.
• Replace the empty container with a new one.
• Tighten, then slightly loosen the refrigerant
container joint.
• Slightly open the low pressure valve on the Close
manifold gauge.
• When the refrigerant container joint starts to leak,
immediately tighten the refrigerant container joint
and close the low pressure valve on the manifold
gauge.
11. After charging, close the low pressure valve in the

gauge manifold and the refrigerant container valve.
W115-02-10-007
Stop the engine.
T5-7-113
IMPORTANT: If the air conditioner is operated with
very low refrigerant, a bad load will
be exerted on the compressor. If the
air conditioner is overcharged with
refrigerant, cooling efficiency will
lower and abnormal high pressure
will arise in the air conditioner circuit, Sight Glass
causing danger.
12. Start the engine and operate the air-conditioner

again.
Observe the sight glass of the receiver tank and
check refrigerant quantity.
Receiver Tank
Cooler Switch : ON
W115-02-10-009
NOTE: As the bubbles in the sight glass vary

depending on the ambient temperature,
check refrigerant quantity confirming the
changes in pressure .
Checking procedures: Stop the air
conditioner and wait until refrigerant returns
to the balanced pressure. Then, start the air
conditioner again.
T5-7-114
Relation between Refrigerant Quantity and Refrigerant
Flow in Sight Glass:
Refrigerant Flow in Sight Glass

Refrigerant
(approx. 1 min. after air conditioner Explanation for Refrigerant Flow in Sight Glass
Quantity
switch is turned ON)
(immediately after) (approx. 1 mm after) Immediately after the air conditioner is turned ON, few
bubbles are seen. Then the flow becomes transparent
Adequate
and shows thin milk white color.
W115-02-10-016
No bubbles are seen after the air conditioner is turned

Overcharged ON.
W115-02-10-017
Bubbles are seen continuously after the air condi-

Not Enough tioner is turned ON.
W115-02-10-018
W115-02-10-019
Bubbles exist: Bubbles are seen in refrigerant flow as

both liquid refrigerant and refrigerant gas exist, being
mixed.
W115-02-10-020
Transparent: Refrigerant flow is transparent as only

liquid refrigerant exists.
115-02-10-021
Milk white: Refrigerant flow shows thin milk white

as oil and refrigerant are separated.
CAUTION: Wait until the high-pressure-side

pressure drops to less than 980 kPa (10
kgf/cm2, 142 psi) before attempting to dis-
connect the high-pressure-side charge hose.
Otherwise, refrigerant and compressor oil
may spout.
13. After checking refrigerant quantity, disconnect the

low-pressure-side charge hose first. Wait for the
high-pressure-side pressure to drop to less than
980 kPa (10 kgf/cm2, 142 psi). Disconnect the
high-pressure-side charge hose.
NOTE: Do not discharge refrigerant in the charge

hose in order not to discharge refrigerant
into the atmosphere for the environmental
protection.
T5-7-115
Warm-up Operation
After charting the air conditioner, carry out warm-up
operation five minute to lubricate system with
compressor oil.

Cooler Switch : ON
Inspection
After warm-up operation, carry out gas leak check
and performance check.
CAUTION: Refrigerant will produce

poisonous material if exposed to heat of 1000
°C (1800 °F) or more. Never bring refrigerant
close to a fire. Leak Tester
1. Check the air conditioner for gas leaks by using a

leak tester.
• Perform checking under well-ventilated
conditions.
• Thoroughly wipe off dust from the charge hose
connections of the compressor.
• Pay special attention to check the line
connections.
• If any gas leaks are found, retighten the line
connections.
W115-02-10-013
2. Performance Check
Carry out performance check of the air
conditioner after checking each air conditioner
component.
• Check each component for abnormalities.
• Carry out ON-OFF check of the compressor
clutch. Retighten Line
• Check compressor fan belt tension. Connection
• Check coolant level in the radiator.
• Operate the air conditioner and check the
performance.
W115-02-10-014
T5-7-116
3. The checklist before the summer season is as
follows:
• Check each air conditioner component for
abnormalities.
• Check the line connections for oil leaks.
• Check refrigerant quantity.
• Check the engine cooling circuit.
• Check belts for wear. Replace if necessary.
4. Off-Season Maintenance
• During off-season, operate the idler pulley and
compressor at least once a month for a short time
in order to check for any abnormal sounds.
• Do not remove the compressor belts during
off-season. Operate the compressor occasionally
at slow speed for 5 to 10 minutes with the belt
slightly loosened in order to lubricate the machine
parts.
T5-7-117
EXCHANGE INSPECTION
Exchange inspection method is a troubleshooting

method to find the trouble location by exchanging the
suspected part / component with another part / com-
ponent having identical characteristics.
Many sensors and solenoid valves used on this ma-

chine are identical. Therefore, using this switch-check
method, faulty part / component, and/or harness can
be easily found.
Example: Abnormal pump 1 delivery pressure sensor

(Fault code: 11200)
Check Method:
1. Switch connector of two delivery pressure sen-
sors.
2. Retry troubleshooting.
Result:
In case the pump 2 delivery pressure sensor is ab-
normal (fault code 11202), the pump 1 delivery pres-
sure sensor is considered to be faulty.
In case the pump 1 delivery pressure sensor is ab-

normal (fault code 11200), the pump 1 delivery pres-
sure sensor harness is considered to be faulty.
Pump 1 Delivery
Pressure Sensor
Pump 2 Delivery
Pressure Sensor
T1J1-05-07-012
T5-7-118
Applicability of Switch-Check Method
Fault Code Trouble Applicability

11000-2 Abnormal EEPROM Not Applicable
11001-2 Abnormal RAM
11002-2 Abnormal A/D Converter
11003-3 Abnormal Sensor Voltage
11004-2 CAN Communication Error Not Applicable
11101-3 EC Dial sensor Circuit High Input Not Applicable
11101-4 EC Dial sensor Circuit Low Input
11200-3 Pump 1Delivery Pressure Sensor Circuit High Input Applicable (Harness / Sensor)
11200-4 Pump 1 Delivery Pressure Sensor Circuit Low Input
11202-3 Pump 2 Delivery Pressure Sensor Circuit High Input
11202-4 Pump 2 Delivery Pressure Sensor Circuit Low Input
11301-3 Swing Pilot Pressure Sensor Circuit High Input Applicable (Harness / Sensor)
11301-4 Swing Pilot Pressure Sensor Circuit Low Input
11302-3 Boom Raise Pilot Pressure Sensor Circuit High Input
11302-4 Boom Raise Pilot Pressure Sensor Circuit Low Input
11303-3 Arm Roll-in Pilot Pressure Sensor Circuit High Input
11303-4 Arm Roll-in Pilot Pressure Sensor Circuit Low Input
11400-3 Pump 2 Regulator Valve FB High Current Applicable (Harness / Solenoid Valve)
11400-4 Pump 2 Regulator Valve FB Low Current
11402-3 Boom Flow Control Valve FB High Current Applicable (Harness / Solenoid Valve)
11402-4 Boom Flow Control Valve FB Low Current
11404-3 Power Boost P/S Valve FB High Current
11404-4 Power Boost P/S Valve FB Low Current
11405-3 Travel Swash Angle P/S Valve FB High Current
11405-4 Travel Swash Angle P/S Valve FB Low Current
T5-7-119

11410-3 Pump 1 Regulator Valve FB High Current Applicable (Harness / Solenoid Valve)
11410-4 Pump 1 Regulator Valve FB Low Current
11412-3 Hyd. Fan P/S Valve FB High Current
11412-4 Hyd. Fan P/S Valve FB Low Current
11802-3 Boom Bottom Pressure Sensor Circuit High Input Not Applicable
11802-4 Boom Bottom Pressure Sensor Circuit Low Input
11901-3 Hyd. Oil Temp Sensor Circuit High Input Not Applicable
11901-4 Hyd. Oil Temp Sensor Circuit Low Input
11910-2 Actual Engine Speed Receive Error Not Applicable
11911-2 Security Signal Receive Error
11914-2 Radiator Water Temp Receive Error
11918-2 Work Mode Receive Error
11920-2 Fuel Flaw Receive Error
11976-3 Auxiliary Valve 2 FB High Current Applicable (Harness / Solenoid Valve)
11976-4 Auxiliary Valve 2 FB Low Current
11977-3 Auxiliary Valve 1 FB High Current
11977-4 Auxiliary Valve 1 FB Low Current
11980-3 ATT Relief Change Valve FB High Current Not Applicable
11980-4 ATT Relief Change Valve FB Low Current
11981-3 Fan Reverse Valve 2 FB High Current Not Applicable
11981-4 Fan Reverse Valve 2 FB Low Current
11982-3 Fan Reverse Valve 1 FB High Current
11982-4 Fan Reverse Valve 1 FB Low Current
11983-2 Intake Air Temperature Receive Error Not Applicable
11984-2 Boost Temperature Receive Error Not Applicable
11989-3 Boom Mode Control Valve FB High Current Applicable (Harness / Solenoid Valve)
11989-4 Boom Mode Control Valve FB Low Current
T5-7-120

11991-3 Right Travel Pilot Pressure Sensor Circuit High Input Applicable (Harness / Sensor)
11991-4 Right Travel Pilot Pressure Sensor Circuit Low Input
11992-3 Pump 2 Regulator Pressure Sensor Circuit High Input Applicable (Harness / Sensor)
11992-4 Pump 2 Regulator Pressure Sensor Circuit Low Input
11993-3 Left Travel Pilot Pressure Sensor Circuit High Input Applicable (Harness / Sensor)
11993-4 Left Travel Pilot Pressure Sensor Circuit Low Input
11994-3 Pump 1 Regulator Pressure Sensor Circuit High Input Applicable (Harness / Sensor)
11994-4 Pump 1 Regulator Pressure Sensor Circuit Low Input
11995-3 Arm Roll-Out Pilot Pressure Sensor Circuit High Input Applicable (Harness / Sensor)
11995-4 Arm Roll-Out Pilot Pressure Sensor Circuit Low Input
11997-3 Bucket Roll-Out Pilot Pressure Sensor Circuit High In-
put
11997-4 Bucket Roll-Out Pilot Pressure Sensor Circuit Low Input
11998-3 Boom Lowering Pilot Pressure Sensor Circuit High In-
put
11998-4 Boom Lowering Pilot Pressure Sensor Circuit Low Input
11999-3 Bucket Roll-In Pilot Pressure Sensor Circuit High Input
11999-4 Bucket Roll-In Pilot Pressure Sensor Circuit Low Input
T5-7-121
(Blank)
T5-7-122
TROUBLESHOOTING / Electrical System Inspection
PRECAUTIONS FOR INSPECTION AND
MAINTENANCE
1. Disconnect the power source.

Remove the harness from the negative terminal
side in battery first when taking wire harnesses
and connectors off for repair or replacement work.
Failure to do so can result in damage to the wire
harnesses, fuses and fusible links and, in some
cases, cause fire due to short circuiting.
2. Color coding of wire harnesses.
As for the color codes of wire harnesses in the
electrical system, refer to the table below.
In cases on the design sheet where two colors
are indicated for one wire, the left initial stands
for base color, while the right initial stands for
marking color.
Code Color Code Color

R Red W White
L Blue G Green
Or Orange Lg Light
green
Y Yellow B Black
Br Brown P Pink
Gr Gray V Violet
NOTE: • Code BW indicates a black base wire

with white fine-line marking.
• Initials “O” and “Or” both stand for the
color orange.
• Wires with longitudinal stripes printed
on them are not color coded. Do not
confuse them with color coded wires.
T5-8-1
3. Precautions for connecting and disconnecting
terminal connectors.
• When disconnecting the harnesses, grasp them
Right Wrong
by their connectors. Do not pull on the wire itself.
Release the lock first before attempting to
separate connectors, if a lock is provided. (Refer
to “Instructions for Disconnecting Connector” on
page T5-8-3.)
• The water-resistant connectors keep water out. If T107-07-06-001
water enters them, water will not easily drain from

them. When checking the water-resistant
connectors, take extra care not to allow water to
enter the connectors. In case water should enter
the connectors, reconnect only after the
connectors are thoroughly dried. Right
• Before connecting terminal connectors, check
Rust
that no terminals are bent or coming off. In
addition, as most connectors are made of brass, Wrong
(Deformation)
check that no terminals are rusting.
• When connecting terminal connectors provided Wrong
with a lock, insert them together until the lock (Separation)
“clicks.” T107-07-06-002
• Pull the harness near the connector in order to
check if it is correctly connected.
4. Precaution for using a circuit tester.

• Before using a circuit tester, refer to the
instructions in the circuit tester manual.
Then, set the circuit tester to meet the object to
Wind a Piece of Wire Tester Probe
be measured, voltage range and current polarity.
• Before starting the connector test, always check
the connector terminal numbers, referring to the
circuit diagram.
When the connector size is very small, and the Sharpen the end of the Wire
standard probe size is too large to be used for T107-07-06-003
testing, wind a fine piece of sharpened wire or a

pin around the probe to make the test easier.
• When checking the connector by using a tester,
insert a tester probe from the harness end of
connector in order not to damage the terminal
inside connector.
T5-8-2
INSTRUCTIONS FOR DISCONNECTING
CONNECTORS
• Push to Unlock and Separate Type

(Most of connectors are “Push, Unlock and Sepa-
rate Type”.)
NOTE: 1. Connectors will not be easily separated

even if the lock is pushed while being
pulled. Push the lock first before pulling
the connectors.
2. The lock is located on female side con
nector (harness end side).
T107-04-05-002
• Raise Lock, Pull and Separate Type
Locations of This Type Connector

Starter Relay
T107-04-05-003
• Pull and Separate Type
IMPORTANT: Before pulling and separating, re-

lease the wire lock in the hydraulic
oil temperature sensor by using a
pair of pincers.

Hydraulic Oil Temperature Sensor
T107-04-05-004
• Push Lock and Switch Lever Type

Cab Harness to Main Harness
ECM
T1J1-05-08-003
T5-8-3
FUSE INSPECTION
Cracks in a fuse are so fine that it is very difficult or NOTE: All terminals located along the lengthwise
impossible to find by visual inspection. Use a tester in centerline of the fuse box are connected to
order to correctly inspect fuse continuity by following the power source, while terminals located
the instructions described below. away from center of the fuse box are con-
nected to loads (accessories). Therefore,
1. Turn the key switch ON. test all fuses in the same method except
When the key switch is turned ON, current from for the glow relay circuit fuse. Check the
key switch terminal M activates the battery relay glow relay circuit fuse with the key switch
so that electric power is supplied to all circuits turned to the ON position and follow the
except the glow plug relay circuit. (Refer to the procedure in step 3.
circuit diagram.)
2. Remove the fuse box cover. Set the tester.
(Measurement Range: 0 to 30 V)
3. Ground the negative probe of tester to the vehicle
frame. Touch the terminals located away from
center of the fuse box with the positive probe of
tester one at a time. When normal continuity of a
fuse is intact, the tester will indicate 20 to 25 V
(battery voltage).
T5-8-4
10 20 30 40
9 19 29 39
8 18 38
28
7 17 27 37
26
6 16 36
25
5 15 35
24
4 14 34
23
3 13 33
22
2 12 32
21
1 11 31
M178-07-034 M178-07-034
Fuse Fuse
Capacity Connected to Capacity Connected to
No. No.
1 20 A Light Relay 2 21 10 A Seat Heater (Optional)
2 10 A Wiper Relay, Washer Relay, 22 10 A Light Relay 3 (Optional)
Wiper Motor
3 20 A Heater (Air Conditioner Unit) 23 10 A Rear Light (Optional)
4 10 A Pilot Shut-Off Relay, Pilot 24 10 A Auxiliary Power (Optional)
Shut-Off Solenoid Valve, MC
Solenoid Valve Power
5 5A Optional 1, Attachment Power, 25 5A Immobilizer (Optional)
Travel Alarm (Optional)
6 10 A Optional 2 26 5A Quick Hitch (Optional)
7 10 A Electronic Grease Gun 27 5A Auxiliary 3
8 30 A ECM Main Relay 28 - -
9 5A Radio (Backup Power), Secu- 29 20 A Light Relay 1, Fan Rotation
rity Horn, Security Horn Relay Direction Switch (Optional),
Auto Lubrication Switch, Travel
Alarm Deactivation Switch (Op-
tional), Level Check Switch,
10 5A MC/ICF Main Power 30 10 A Auto Lubrication Relay
11 10 A Horn Relay 31 10 A Seat Heater (Optional)
12 5A Cab Light, Radio Power 32 10 A Front Work Light (Optional)
13 10 A Cigarette Lighter 33 10 A Indicator (Optional)
14 15 A Suction Control Valve (Engine) 34 10 A Auxiliary 2
15 10 A Auxiliary 35 - -
16 5A Glow Plug Relay 36 - -
17 5A Air Conditioner Unit 37 - -
18 5A Engine Stop Switch, Monitor 38 - -
Unit/MC/ICF/ECM Power ON
Signal
19 5A Monitor Unit Power 39 - -
20 10 A Optional 3 40 - -
T5-8-5
FUSIBLE LINK INSPECTION AND RE-
PLACEMENT Fusible Link
Inspection
1. Visually check if fusible links have blown.
Replacement
1. Remove the negative cable from the battery.
2. Push (to unlock) and pull to disconnect fusible

link connector. Replace the fusible link.
3. Reconnect the negative cable to the battery. Battery Relay

M1J1-07-015
Fusible Link
T111-04-05-015
To Battery Relay
BATTERY VOLTAGE CHECK
1. Turn the key switch OFF. Check voltage between

the battery positive terminal and the vehicle.
Normal Voltage: 24 V
NOTE: If voltage is abnormal, recharge or replace

V
the battery.
2. Start the engine. Check voltage between the

battery positive terminal and the vehicle frame.
Normal Voltage: 26 to 28 V T162-05-06-005
NOTE: If voltage is abnormal, check the charging

system.
T5-8-6
HOW TO TROUBLESHOOT ALTERNATOR Monitor Unit
MALFUNCTIONS
In general, the alternator alarm remains off when the

alternator is generating power.
If the alternator alarm is displayed while the engine is
running, the alternator might be defective.
How to check the circuit
1. Stop the engine. Turn the key switch to the ON

position. Confirm that the alternator alarm comes
on.
Alternator Alarm T1J1-05-01-007
2. Measure the voltage between the B and the

vehicle frame. If the measured voltage is around
24 V, the alternator circuit can be considered
B Connector (L, R)
normal. If the measured voltage is low, a
shortage in battery capacity or looseness of the
wire connectors of the alternator circuit might be
the cause of the malfunction. When the voltage is
0 V, the wiring between the fuse box and
alternator might be loose or disconnected.
Also, the alternator cannot generate electricity if
the ground line is disconnected.
3. Next, start the engine and measure the voltage

generated while as the alternator rotates.
As described above, measure the voltage
between terminals B and the vehicle frame. If the
voltage is around 28 V, the alternator is operating
normally.
If the rated voltage is not being generated, there
is some trouble with the alternator or the regula-
tor.
T16J-05-06-001
T5-8-7
CONTINUITY CHECK
Harness
Single-line continuity check A a
Disconnect both end connectors of the harness and
check continuity between both ends:
If the ohm-meter reading is: 0 Ω = Continuity
∞ Ω = Discontinuity
Ω
NOTE: When the one end connector is far apart

from the other, connect one end of Connect to
A a
connector (A) to the machine chassis the vehicle
using a clip. Then, check continuity of the frame.
harness through the vehicle frame as
illustrated.
Connect to
Ω
the vehicle
If the ohm-meter reading is: 0 Ω = Continuity frame.
∞ Ω = Discontinuity
A a
Single-line short-circuit check
Disconnect both end connectors of the harness and × Short-circuit
check continuity between one end connector of the between the
harness and
harness and the vehicle frame: the vehicle
If the ohm-meter reading is: Ω frame.
0 Ω = Short circuit is present.
∞ Ω = No short circuit is present.
T107-07-05-003
T5-8-8
Multi-line continuity check
Disconnect both end connectors of the harness, First short-circuit (Clip)
and short-circuit two terminals, (A) and (B), at one
end connector, as illustrated. Then, check continuity
A a
between terminals (a) and (b) at the other connector. B b
If the ohm-meter reading is ∞ Ω, either line (A) - (a), C c
or (B) - (b) is in discontinuity. To find out which line
is discontinued, conduct the single line continuity Second short-circuit
check on both lines individually, or, after changing
the short-circuit terminals from (A) - (B) to (A) - (C),
check continuity once more between terminals (a)
Ω
and (c).
NOTE: By conducting the multi-line continuity T107-07-05-004

check twice, it is possible to find out which
line is discontinued. With terminals (A) and
(C) short-circuited, check continuity
between terminals (a) and (c).
If the ohm-meter reading is:
0 Ω = Line (B) - (b) has discontinuity.
∞ Ω = Line (A) - (a) has discontinuity.
Multi-line short-circuit check

Disconnect both end connectors of the harness, Short-circuit between harnesses.
and check continuity between terminals (A) and (B)
or (C). A a
×
If the ohm-meter reading is: B b
C c
0 Ω = Short-circuit exists between the lines.
∞ Ω = No short-circuit exists between the lines.
T107-07-05-005
T5-8-9
VOLTAGE AND CURRENT MEASURE-
MENT
Turn key switch ON so that the specified voltage (cur-

rent) is supplied to the location to be measured.
Judge if the circuit is normal by evaluating whether
the measured voltage (current) matches the specifica-
tion.
24-Volt Circuit
Start checking the circuit in order up to the loca-
tion to be measured from either power source or
actuator side. Thereby, the faulty location in the
circuit will be found.
Black Probe (Negative) of Tester:
To ground to the vehicle frame
Red Probe (Positive) of Tester:
To touch the location to be measured
Engine Key Switch Location to be Measured Specification

Power Source
Circuit
Stopped OFF Between (2) and (1): One Battery 10 to 12.5 V
Stopped OFF Between (3) and (2): One Battery 10 to 12.5 V
Stopped OFF Between (3) and (1): Two Batteries 20 to 25 V
Stopped OFF Between (4) and Ground: Battery Power 20 to 25 V
Stopped OFF Between (5) and Ground: Fusible Link 20 to 25 V
Stopped OFF Between (1) and Ground: Backup Current * 6 mA
Preheat Circuit
Stopped ON or START Between (6) and Ground: Key Switch 20 to 25 V
Stopped ON or START Between (7) and Ground: Glow Plug 20 to 25 V
Charging Circuit
Fast Speed ON Between (8) and Ground: Alternator (B) / Generating 26 to 30 V
Voltage
Fast Speed ON Between (9) and Ground: Battery Relay / Generating 26 to 30 V
Voltage
Fast Speed ON Between (10) and Ground: Fuse Box / Starter Relay (R) / 26 to 30 V
Generating Voltage
Fast Speed ON Between (11) and Ground: Generating Voltage 13 to 30 V
Fast Speed ON Between (12) and Ground: Monitor Unit (C7) 13 to 30 V
Surge Voltage
Prevention Circuit
Idle Speed ON Between (8) and Ground: Alternator (B) 26 to 30 V
Idle Speed ON Between (11) and Ground: Starter Relay (R) 13 to 30 V
Idle Speed ON Between (13) and Ground: Load Damp Relay 26 to 30 V
Idle Speed ON Between (9) and Ground: Battery Relay 26 to 30 V
Accessory Circuit
Stopped ON Between (14) and Ground: Auxiliary 20 to 25 V
Stopped ON Between (15) and Ground: Cigarette Lighter 20 to 25 V
Stopped ON Between (16) and Ground: Radio, Cab Light 20 to 25 V
Stopped ON Between (17) and Ground: Battery Relay 20 to 25 V
NOTE: *: Before measurement, disconnect the negative cable from the battery.
T5-8-10
7
Glow
Plug Key Switch
Glow Plug
Relay
Fuse Box
1 2 3 4 9 5
Battery Relay
6
10
Battery
17
Load Damp 16 15
Starter 14
13 Relay
Relay
11
Alternator
Monitor
C7 Unit
T1J1-05-08-002
12
T5-8-11

Starting Circuit
Started START Between (18) and Ground: Key Switch 20 to 25 V
Started START Between (19) and Ground: Battery Relay (Coil) 20 to 25 V
Started START Between (20) and Ground: Battery Relay (Switch) 20 to 25 V
Started START Between (21) and Ground: Starter (B) 20 to 25 V
Started START Between (22) and Ground: Starter (C) 20 to 25 V
Started START Between (23) and Ground: Starter Relay (S) 20 to 25 V
Started START Between (24) and Ground: Starter Cut Relay 20 to 25 V
Started START Between (25) and Ground: Fuse Box 20 to 25 V
Started START Between (26) and Ground: Fuse Box 20 to 25 V
Started START Between (27) and Ground: ICF (C7) 20 to 25 V
Started START Between (28) and Ground: Monitor Unit (A7) 20 to 25 V
Started START Between (29) and Ground: MC (B16) 20 to 25 V
Started START Between (30) and Ground: ECM (1-24) 20 to 25 V
Started START Between (31) and Ground: ECM Main Relay 5V
Started START Between (32) and Ground: ECM Main Relay 20 to 25 V
T5-8-12
Battery Starter Cut Re-

Relay 20 lay
25
19
26
Battery
23 ECM Main
24 Relay
Starter
Relay
31 32
21
Starter
22
MC Monitor Unit ICF ECM
B16 A7 C7 V24
T1J1-05-08-002
29 28 27 30
T5-8-13

Pilot Shut-Off Cir-
cuit
Stopped ON Between (33) and Ground: Fuse Box 20 to 25 V
Stopped ON Between (34) and Ground: Pilot Shut-Off Relay 20 to 25 V
Stopped ON Between (35) and Ground: Pilot Shut-Off Solenoid Valve 20 to 25 V
Stopped ON Between (36) and Ground: Pilot Shut-Off Relay 20 to 25 V
Stopped ON Between (37) and Ground: Security Relay 20 to 25 V
T5-8-14
Key Switch
37
Battery
Relay
33
Fuse
Box
Battery
Security
Relay
Pilot Shut-Off 35
Solenoid Valve Pilot Shut-Off
Switch
Pilot
Shut-Off
Relay
36 34
T1J1-05-08-002
T5-8-15
5 Voltage Circuit
Power Signal or
• Voltage between terminal #1 and the vehicle Two Polarities Source Ground
frame 1 2
Disconnect the connector with the key switch OFF.
Measure voltage between terminal #1 on the
machine harness end connector and the vehicle
frame (ground).
• Key switch: ON V
• Tester black terminal (negative):
Connected to the vehicle frame (ground)
• Tester red terminal (positive):
Connected to terminal #1
T107-07-05-006
Power
Evaluation: Three Polarities
Source Signal Ground
If the measuring voltage is within 5±0.5 volts, the 1 2 3
circuit up to terminal #1 is normal.
• Voltage between terminal #1 and the ground

terminal T107-07-05-007
Disconnect the sensor connector with the key

switch OFF. Two Polarities
1 2
Measure voltage between terminal #1 on the
machine harness end connector and the ground
terminal (terminal #2 for two polarities, or terminal
#3 for three polarities).
V
• Key switch: ON
• Tester black terminal (negative):
Connected to the ground terminal
(terminal #2 or #3)
• Tester red terminal (positive):
Connected to terminal #1 T107-07-05-008
Evaluation: Three Polarities

If the measured voltage is within 5±0.5 volt, the 1 2 3
circuit up to terminal #1 or the ground terminal
(terminal #2 or #3) is normal.
T107-07-05-009
T5-8-16
CHECK BY FALSE SIGNAL
Two Polarities
Turn the key switch OFF. Disconnect the sensor con- (Hydraulic Oil Temperature Sensor)
nector. Turn the key switch ON. Connect terminal #1 (Fuel Sensor)
1 2
(power source) of machine harness end connector to
terminal #2 (signal). (Power voltage is used as a false
signal.) Check this state by using the monitor unit
(service mode). When the maximum value is dis-
played, MC and the circuit up to the machine harness
end connector are normal. If “ON” is displayed, the
pressure switch circuits are normal.
Connect
IMPORTANT: Do not connect terminal #1 or #2 to
terminal #3 or to the vehicle frame
(ground) when checking a Three Polarities
T107-07-05-010
three-polarity connector.
(Pressure Sensor)
(Pump Delivery Pressure Sensor)
NOTE: Some kinds of sensors can be monitored (Pump Regulator Pressure Sensor) 1 2 3
by the service menu of monitor (the built-in (Boom Bottom Pressure Sensor)
diagnosing system).
Connect
T107-07-05-011
T5-8-17
TEST HARNESS
Install a test harness between connectors. Check the

circuit condition depending on whether the test har-
ness lamp lights or extinguishes during operation.
Parts Number 4283594 (ST 7126)

Use in order to check a single-line (discontinuity
and/or voltage).
During Operation: Lamp is ON.
To Location to be Measured.
To Ground
Parts Number 4283594 (ST 7126) T107-07-05-012
T5-8-18
MEMO
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Tel: 81-29-982-7084
Fax: 81-29-831-1162
COMPANY NAME: MODEL:

PUBLICATION PART NO.:
YOUR NAME: (Located at the left top corner in the cover page)
DATE: PAGE NO.:

(Located at the bottom center in the page. If two or more revi-
FAX: sions are requested, use the comment column)
E-mail:

REPLY:

THE ATTACHED DIAGRAM LIST
(The following diagrams are attached to this manual.)
1. ZAXIS450-3/500LC-3/520LCH-3 ELECTRICAL CIRCUIT DIAGRAM

ZAXIS450-3/500LC-3/520LCH-3 CONNECTORS
2. ZAXIS450-3/500LC-3/520LCH-3/650LC-3/850-3 CAB HARNESS
ZAXIS450-3/500LC-3/520LCH-3 MAIN HARNESS
3. ZAXIS450-3/500LC-3/520LCH-3 ENGINE HARNESS

ZAXIS450-3/500LC-3/520LCH-3 CONTROL VALVE HARNESS
4. ZAXIS450-3/500LC-3/520LCH-3 PUMP HARNESS
ZAXIS450-3/500LC-3/520LCH-3/650LC-3/850-3 MONITOR HARNESS
5. ZAXIS450-3/500LC-3/520LCH-3/650LC-3/850-3 AIR CONDITIONER HARNESS
ZAXIS450-3/500LC-3/520LCH-3/650LC-3/850-3 FUSE BOX 2 HARNESS
6. ZAXIS450-3/500LC-3/520LCH-3/650LC-3/850-3 PILOT SHUT-OFF SOLENOID VALVE HARNESS
ZAXIS450-3/500LC-3/520LCH-3/650LC-3/850-3 CAB SWITCH HARNESS
(BOOM MODE SELECTOR SWITCH, LEVEL CHECK SWITCH, SEAT HEAT SWITCH (OPTIONAL))
7. ZAXIS450-3/500LC-3/520LCH-3/650LC-3/850-3 OVERLOAD ALARM HARNESS (OPTIONAL)
ZAXIS450-3/500LC-3/520LCH-3/650LC-3/850-3 OVERLOAD ALARM SUB HARNESS (OPTIONAL)
8. ZAXIS450-3/500LC-3/520LCH-3/650LC-3/850-3 BREAKER HOUR METER HARNESS
(CAB HARNESS SIDE) (OPTIONAL)
ZAXIS450-3/500LC-3/520LCH-3/650LC-3/850-3 BREAKER HOUR METER HARNESS
(CONSOLE SIDE) (OPTIONAL)
9. ZAXIS450-3/500LC-3/520LCH-3/650LC-3/850-3 ATT. SENSOR HARNESS (OPTIONAL)

ZAXIS450-3/500LC-3/520LCH-3/650LC-3/850-3 SEAT HEATER HARNESS (OPTIONAL)
10. ZAXIS450-3/500LC-3/520LCH-3 AUTO-LUBRICATION HARNESS 1 (MACHINE SIDE) (OPTIONAL)
ZAXIS450-3/500LC-3/520LCH-3/650LC-3/850-3 AUTO-LUBRICATION HARNESS 1
(CAB SWITCH HARNESS SIDE) (OPTIONAL)
11. ZAXIS450-3/500LC-3/520LCH-3/650LC-3/850-3 AUTO-LUBRICATION HARNESS 2
(CAB SWITCH HARNESS SIDE) (OPTIONAL)
ZAXIS450-3/500LC-3/520LCH-3/650LC-3/850-3 CAB SWITCH HARNESS
(TRAVEL ALARM DEACTIVATION SWITCH) (OPTIONAL)
12. ZAXIS450-3/500LC-3/520LCH-3/650LC-3/850-3 CAB SWITCH HARNESS

(FAN ROTATION DIRECTION SWITCH) (OPTIONAL)
ZAXIS450-3/500LC-3/520LCH-3/650LC-3/850-3 REAR VIEW CAMERA RELAY HARNESS
13. ZAXIS450-3/500LC-3/520LCH-3 HYDRAULIC CIRCUIT DIAGRAM (BACKHOE)
ZAXIS450-3/500LC-3/520LCH-3 HYDRAULIC CIRCUIT DIAGRAM
(BREAKER/CRUSHER/TWO SPEED FLOW COMBINER) (OPTIONAL)
14. ZAXIS450-3/500LC-3/520LCH-3 HYDRAULIC CIRCUIT DIAGRAM (HOSE-RUPTURE) (OPTIONAL)
ZAXIS450-3/500LC-3/520LCH-3 HYDRAULIC CIRCUIT DIAGRAM (WITH COUNTERWEIGHT REMOVAL
AND INSTALLATION DEVICE) (OPTIONAL)
15. ZAXIS450-3/470H-3 HYDRAULIC CIRCUIT DIAGRAM (LOADING SHOVEL)

DB
TR/MO (L) TR/MO (R)
SW/MO
FR
N 14
SM SH Pi Pi
M 13
5
BUCKET E SW L
S3
F SW R
3 G 6
IN 7
G BKT IN
A B
OUT Dr(R)
1 H H BKT OUT
8
4 A Dr(L)
SE
UP
T T6
P P3
Attach to Part No. : TT1JK-E-00
DOWN SL
2 B
SH
BOOM A BOOM UP P2 P1 P2 P1
1
ARM SK
3 C A B
OUT
SB
IN 1 D
4 E B BOOM DWN
2 SI
L ARM OUT 3 DT
T T5 C
P P2
SP
R
2 F SN SM
SWING SG T3
SA
PROPEL RH D
1 L
ZX400R-3、ZX400LCH-3 HYDRAULICCIRCUIT DIAGRAM
4
RR 12
L
P1
RF K
2 K 11 SL
TR SN
4 J J
10 B8
LR TR A VEL;R RF
T A8 TO 11
9 TR A VEL;L
I DC
P LF RR
LF TO12
DF TO 9 TO 10 B1
PH V A LVE SHU TTLE LR
3 I HT A1
T3
PROPEL LH T4 DK
T1 B7
A7 SK
T2 AUX
A1 P
BKT OUT
A2 AUX B TO 14 BKT IN TO 8
TO 13 AUX A TO 7
A3
BUCKET
B2
A4 G A TE LOCK
V A LVE A2
PI7
SEC.BOOM
PI9
PI1
PI8
DZ BKT CYL.
BM UP
TO 1
PM2
PRIM.BOOM
TO 2
BM DWN B3
PI6
B6 A3
ARM CYL.
A6
PRIM.ARM SF
ARM OUT ARM IN

TO 3 TO 4
DD
PI2 SD
DS
DM SW R
SE TO 6 BOOM CYL.
DN PI3
DY SG DE
RELIEF PRES.
SEC.ARM
DK B5
SI A4
TR.SPEED
DP A5
SWING DH
PE SF SW L
DIG REG TO 5
DE
SC SC
ARM.FLOW SC2
DH DD
T1 T2
PD A9 SJ2 SJ
P2
DZ PF V A LVE SOL.
TAIL HOSE TAIL HOSE
PD2 PD1
PA
DT
DB
(4)
(3)
(2)
(1)
PA
4
3
2
1
PE
PF
DY PUMP FL PUMP PQ
PG
PC
−
−
−
−
for the relief valve prssure setting valve.
PD
PI2
PI8
PI1
Pi3
SB TA
Cotrol Valve
SA
PC1 PC2 A1 ST
・Positions below are connected respectively inside.
TA
NOTE：Refer to the PEFORMANCE STANDARD in the tachnical manual
Attach to Part No.:TT1JK-E-00
ZX400R-3, ZX400LCH-3 HYDRAURIC CIRCUIT DIAGRAM
SPECIFICATIONS
・Breaker and Crusher Piping
・2-Speed Flow Combining Piping
Pi
Dr(R)
P1
TR/MO (R)
P2
Pi
Dr(L)
P1
TR/MO (L)
P2
DB
TR/MO (L) TR/MO (R)
SW/MO
FR
N 14
SM SH Pi Pi
SPECIFICATION
M 13
5
BUCKET E SW L
S3
F SW R
3 G 6
IN 7
G BKT IN
A B
・Arm Hose Rupture Valve
OUT Dr(R)
1 BKT OUT
・Boom Hose Rupture Valve
H H
8
4 A Dr(L)
SE
Attach to Part No. : TT1JK-E-00
UP
T T6
P P3
DOWN SL
2 B
SH
BOOM A BOOM UP P2 P1 P2 P1
1
ARM SK
3 C A B
OUT
SB
IN 1 D
4 E B BOOM DWN
2 SI
L ARM OUT 3 DT
T T5 C
P P2
SP
R
2 F SM
ZX400R-3、ZX400LCH-3 HYDRAULIC CIRCUIT DIAGRAM
SN
SWING SG T3
SA
PROPEL RH D
1 L 4
RR 12
L
P1
RF K
2 K 11 SL
TR SN
4 J J
10 B8
LR TR A VEL;R RF
T A8 TO 11
9 TR A VEL;L
I DC
P LF RR
LF TO12
DF TO 9 TO 10 B1
PH V A LVE SHU TTLE LR
3 I HT A1
T3
PROPEL LH T4 DK
T1 B7
A7 SK BKT CYL.
T2 AUX
A1 P
BKT OUT
A2 AUX B TO 14 BKT IN TO 8
TO 13 AUX A TO 7
A3
BUCKET BOOM CYL.
B2
A4 G A TE LOCK
V A LVE A2
PI7
SEC.BOOM
PI9
PI1
PI8
DZ
BM UP
TO 1
PM2
PRIM.BOOM
BM DWN
B3
TO 2
PI6
B6 A3
A6
PRIM.ARM SF
ARM OUT TO 4
TO 3 ARM IN
DD
PI2 SD
DS
DM SW R
SE TO 6
DN PI3
DY SG DE
RELIEF PRES.
SEC.ARM
DK B5
SI A4
TR.SPEED
DP A5
SWING DH
PE SF SW L
DIG REG TO 5
DE
SC SC
ARM.FLOW SC2
DH DD
T1 T2
PD A9 SJ2 SJ
P2
DZ PF V A LVE SOL.
for the relief valve prssure setting valve.
TAIL HOSE TAIL HOSE

NOTE：Refer to the PEFORMANCE STANDARD in the tachnical manual
PD2 PD1
PA
DT
DB
PA
(4)
(3)
(2)
(1)
PE
PF
4
3
2
1
DY PUMP FL PUMP PQ
PG
PC
PD
−
−
−
−
SB TA
SA
PI2
PI8
PI1
Pi3
PC1 PC2 A1 ST
TA
Cotrol Valve
・Positions below are connected respectively inside.
Attach to Part No.:TT1JK-E-00
ZX400R-3、ZX400LCH-3 ELECTRICAL DIAGRAM
CAB OUTSIDE CAB INSIDE
CAB INSIDE CAB OUTSIDE CCD

AEX WB 1-31 0.3WB
R 1-18 R Vcc
SATELLITE TERMINAL or GSM TERMINAL SATELLITE TERMINAL AERIAL B 1-26 B GND
STARTERーSWITCH (BUILT-IN AERIAL) (When installing satellilte terminal) GPS AERIAL
W 1-34 B Signal
B 1-44 Gy S GND
THEF PREVENTION RELEASE PULSE

THEFT PREVENTION CONNECTION DETECTION
B G1 G2 ACC M ST
COMMUNICATION GND
Trem A
OPTIONAL
H
0.3WL 1-40 WL BY
OFF MONITOR＿Ｈ CAB_H
BATT POWER
ACC W WIPER SPECIFICATION ANT HYDRAULIC OIL FILTER ALARM
WAKE UP
ON AIR CONDITIONER＿Ｈ JOINT5,6 MONITOR
POWER ON SIGNAL
JOINT8 Dr. 0.3GL 1-39 GL F M B
KEY ON
AEX 3B 3-2 JOINT1 START
REG INPUT
+5V
1 2 3 4 5 6 CCD CAMERA POWER（＋５Ｖ） A8 0.3R 1 R
AIR CLEANER ALARM SW
RXD
REG
GND
GND
GND
TXD
RTS
CTS
CCD CAMERA GND
RXD
1.25WR A13 0.3B 2 B
VCC
GND
TXD
RTS
CTS
LY 5-16 0.3GB C7 ＲＥＧINPUT
3R 2-1 3R 3R BATT DISPLAY SIGANL A15 W 3 W GPS 0.3Br 1-22 Br 1 2 B
FUSIBLE RB 6-11 0.3RB A7 POWER ON SIGNAL ＧＮＤ A14 B 4 B
LINK(45A) AVSS 2W 1-37 2W AVSS K A 2LW 3LW KEY-ON FUEL GAUGE
JOINT5,6,7
123456 1 2 3 9 10 11 12 15 18 19 20 1 2 9
3W
5W 3-1 5W D3 YR
0.3RL 1-49 AEX RL
AUTORE-FUELING WK ACC
ＣＡＮ COMMUNICATION Ｈ B7 G 7-1 G AVSSCS LR
60B 60R 60R W OPT_FUSE +24V
SYSTEM R4 1 3 ＣＡＮ COMMUNICATION Ｌ B6 L 7-8 L AVSSCS Trem B M4
B
A PILOT SHUT-OFF +5V
L
1.25R
ENG B
5R
B
5W
3B
STARTER
0.3RW
0.3BW
RL
LB 0.3LB A16 POWER INPUT +5V
0.3RB
0.3BG
6-12 POWER ＥＣ DIAL SIGNAL INPUT
0.3BL
C4 0.3BrW 6-7 0.3BrW 3-4
2R
0.3R
0.3G
0.3Y
0.3B
0.3B
0.3L
CUT RELAY 8 9 10 4 18 19 17 5 6 20 0.3WB C1 GLOW INPUT
RB
6-13 CIRCUIT
LY
OPT_LIGHT ＥＣ DIAL SIGNAL INPUT（ＧＮＤ） C10 0.3WY 6-6 0.3WY
BP
BATTERY １２Ｖ×２ 1 2 3 11 12 13 14 15 16 7 1 2 OVERHEAT SW
30A
10A
10A
10A
3R
5A
5A
5A
5A
5A
5A
B 6-16 0.3B B11 ＧＮＤ
20A
10A
20A
10A
10A
10A
10A
254 R1 K
5A
5A
5A
BATTERY M6 1 3 0.85RY 1-8 RY
WIPER SIGNAL （＋５Ｖ） C6 0.3R 6-14 0.3R
C8
A21
A31
C1
C2
C7
A28
A17
A7
A6
A18
A5
A20
A9
C4
A8
RELAY B S
ECM
CONTROLLER
RB POWER ON SIGNAL
SWITCH BOX
WG AIR CONDITIONER
1.25WY OPT.1(ALT)
OPT.2(ALT)
OPT.3(BATT)
2R 2 LOAD DUMP WIPER SIGNAL INPUT C3 0.3RB 0.3RB 0.85BY 1-52
PuG
1 6-5 BY
SOLENOID
A
BACK-UP
LIGHT
WIPER
HEATER
HORN
LIGHTER
FUEL_PUMP
AUX
GLOW／Ｒ
1.25 OELECTRIC GREASE GUN
RADIO／ROOM LIGHT
2B PREVENTION RELAY K A +24V WIPER SIGNAL INPUT（ＧＮＤ） C9 0.3RW 6-15 0.3RW MAIN POWER
ICF
OPT AEX 2BW 1-27 1.25BW BUZZER RY AVSS
A E 1
254
+
1 3 2 1 2 W 5-8 0.3W A9
CAN D15
0.3YB 1-33 BL AVSS 2
CBH BOOM RAISE
3 S
CONTROL CIRCUIT
FUSIBLE 2B BW
K B R EXTERNAL MAIN GND COMMUNICATION CONTROLLER BY AVSS
0.3 O
60R
GATE_SW -
LINK(45A) AEX 8fW
D7 POWER CIRCUIT
A10
C14
C15
C11
A
AEX 0.85W
C5
B
RY AVSS 1
+
GY 1-38 GY 0.3RB 1-42 RB AVSS 2
1.25LgR
C3 BY AVSS 3
S CAI ARM ROLL-IN
1.25R
Connection state of theft prevention is detected B13 0.3YR 7-12
0.85L
STARTER 3 1 5.8inch LCD YR -
0.85BR
2R
1.25LY
B
G
B
L
3G
RL
LB
M GLOWRELAY THEFT PREVENTION CONNECTION DETECTION C5 0.3LY 7-13 LY
2RB
B
RY AVSS 1
YR
3G
S
+
SERIAL COMMUNICATION ＴＤＸ B8 0.3R 7-2 R 1 0.3R 1-24 R AVSS 2
4 2 REFRESH THE C12 FRT FRONT PRESSURE SENSOR (LOW-PRESSURE)
5RL
S
5R
AEX LY 1-36 LY SERIAL COMMUNICATION ＲＸＤ B9 0.3W 7-9 W 2 BY AVSS 3
MONITOR DISPLAY -
AEX 8fW
STARTER RELAY 3 AVSSCS
C B
SERIAL AVSSCS RY AVSS 1
CAB_H MONITOR_Ｈ
+
GATE_VAL 0.3BR 1-43 BR AVSS 2
B HYDRAULIC OIL FILTER SW INPUT B15 0.3WL 5-11 0.3WL C13 S X
BY AVSS 3 SWING
S AEX 2BW -
1.25RL
PULL-UP
1.25R
FUEL FILTER ALARM SW INPUT B1 0.3GR 7-6
E 1.25B 1 1 PW OPTION_CON. RY AVSS 1
3B
+
1 2 3 4 5
PILOT AIR FILTER ALARM SW INPUT B4 0.3GL 5-9 0.3GL 0.3YR 1-32 YR AVSS 2
1.25WY
C2 S TRAVEL TRAVEL
AEX 3BY
BLOCKVALVE 2 2 R R 1 2 3 4 5 6 OPT(ROOF SKYLIGHT WIPER SPECIFICATION) GLOW ＥＸＩＴ B10 0.3G 6-10 0.3G BY AVSS 3
-
0.85R 6 7 8 9 0
2 1-51 LY 1 2 BY
A K 0.85B F1 F2 F3 F4 FUEL SIGNAL C2 0.3BrW 7-3 0.3Br D2 0.3LY
2B
ALTERNATOR ENG R
1
-5 GLOW PLUG K R2 OIL TEMPERATURE／Ｓ
ACG R5 13 1 3 COOLANT TEMPERATURE SIGNAL C8 0.3WB 7-10 0.3WB
OPT.3(BATT)
1-50
OPT.1(ALT)
OPT.2(ALT)
LIGHT１
B
GND
LIGHT２
STARTER PILOT SHUT-OFF C16
E B D5 RELAY
3 A RELAY OVERHEAT SW 1-41
R HORN LED B5 0.3RL 5-10 0.3RL W
254 254 C5
L RL ! ENGINE OIL PRESSURE B16 0.3WR 5-12 0.3WR CAB_H 12 0.85RY R SF2 1
E F JOINT2 PRESSURE SENSOR
+
DELIVERY
Pu PG SWITCH BOX 0.3RG 1-16 RG 3 Gy SF2 2 S PRESSURE PUMP
PuR
REGULATOR
RL ENGINE ABNORMAL C11 0.3WY 5-13 0.3WY D10 16 0.85BY B SF2 3 - SENSOR 1 (HIGH-PRESSURE)
1
PL
1-50 BrY OFF AIR CONDITIONER＿Ｈ
1 3 AUTO-IDLE SW INPUT B18 0.3G 6-4 0.3G 0.3G 12 L POWER R SF2 1
AUTO-IDLE
PRESSURE SENSOR
+
R3 Ａ／ＩＳＷ 0.3WG 1
3G
1-7 WG O SF2 2 S
DIGGINGＳＷ PD D11 PUMP CONTROL 1
PuW
LIGHT SW2 INPUT A6 0.3LB 6-2 0.3LB 0.3LB 16 BrW 2 B SF2 3 - (LOW-PRESSURE)
R14 HORN RELAY
LIGHT SW1 INPUT 0.3GW 0.3GW 15 BrY
PULL-UP
ENG3-6 M4 1 3 B20 6-1 0.3GW 1
FUEL_PUMP 0.3O A12 LOAD DUMP RELAY OUTPUT LIGHT SW S GB 7 0.3GB
ＥＣＵ 254 O 5-7 OFF
B4
FUELFILTER A 3
RELAYDRIVING CIRCUIT
0.3R LIGHT ２ RELAY OUTPUT 0.3R 9 GR +
GB
ＭＡＩＮ R 5-5 A5 B
B
INTAKE-AIR - DIFFERENTIAL PRESSURE SENSOR G 5-1 0.3G A1 LIGHT 1 RELAY OUTPUT 0.3RB 10 GY SIGNAL
S
2 1 RELAY WIPER VR
TEMPERATURE SENSOR JOINT GB 5-3 0.3GB A3 HORN RELAY OUTPUT 0.3RW 11 GB - R SF2 1
254 D4 K PRESSURE SENSOR
+
+ S - -FFS Br 1 2 GL GL 5-4 0.3GL A4 STARTERRELAY OUTPUT WASHER SW INPUT B3 0.3G 6-3 0.3G 0.3G 8 GL WASHER SW 0.3GY 1-25 GY 4 L SF2 2 S DELIVERY PUMP
D4
B SF2
PRESSURE (HIGH-PRESSURE)
R SF2
B
A K B 5-6 0.3B A10 WASHER RELAY OUTPUT B SF2 3 - SENSOR 2
- 3 2 1 JOINT3 2
FUEL TEMPERATURE S PUMP GW 5-2 0.3GW A2 WIPER RELAYー OUTPUT
LIGHTER AUX GW 6-8 GW A11 SUB WIPER RELAYー OUTPUT ＨＭＳＴＳＷ INPUT B14 R SF2
SENSOR 9 15 13 ROOM LAMP 1
PRESSURE SENSOR
+
＋４７Ｖ PILOT SHUT-OFF DETECTION B19 0.3R 6-9 R R 5 R 0.3YB 1-17 YB 2 W SF2
18 17 2 S
S 1.25B - +1.25LY AVS 0.85G AUX B17 0.3GY 5-15 ROOM LAMP POWER INPUT D14 B SF2 3 -
PUMP CONTROL ２ (LOW-PRESSURE)
3L
COOLANT
PL
RB
GB
B12 0.3Gy 7-16 PL 0.3Y 1 WR +

B
-
TEMPERATURE SENSOR ENG_1
＋ K B2 0.3GB 7-7 PuW 0.3BrW 2 WG SIGNAL
GW
GW
S R 1-28 R
BrY
GR ENGINE SPEED CONTROL DIAL

BW
0.3WY 3 WB - LB 1-1 LB 5 SF2 W

D6 1
PUMP −
A 0.85BY A22
A16
LR 1-10 LR 6 SF2 R 2 SB PUMP 2
+ 0.3BR 14 P FAST SPEED D13 DISPLACEMENT ANGLE LIMIT
0.85B
CRANK ANGLE 1 B TRAVEL MODE SW 0.85RY PUMP
2-85
1-46
1-14
RB 1-35 RB
KEY 1-24 SLOW SPEED
1-10
2-106 CRANK+
SENSOR - 2 W D7 BrW 1-2 BrW 7 SF2 B 1 PUMP SOLENOID
2-107 CRANK- SIGNAL B 0.3YL A30
STARTER CONTROL
MCF SOLENOID
3 Gy 0.3G 6 Y HP GW 1-11 GW 8 SF2 G 2 ST TORQUE
2-108 CRANK_SLD YG YR 2 1 0.3BG 7 YW E
A19 ATT OPTIONAL
+ 4 W
2-99 CAM+
1-21 MBES NORMAL OPEN
4 B P
CAM ANGLE - 5 B 1-40
YG YG 4-27 YG
ROOM LAMP ＧＮＤ O 10 K A
2-98 CAM- MAIN B
SENSOR 6 Gy POWER 1-2
1.25L 3L 2-2 3L CONTROLLER RG 11
L 2
2-100 CAM_SLD
7 YG AEX 1.25L
2-84 WATER TEMP 1-5 1 SELECTOR VALVE SELECTION
8 O AEX
2-95 BOOST+ PUMP
9 BY AEX RW 4- 20 0.3G
+ 1-80 OIL PRESS+ 1-11
RW
ADDITIONAL SWITCH BOX(ROOF SKYLIGHT WIPER SPECIFICATION) K A
PRESSURESENSOR S 10 O AEX 2
B 1 RADIO L
- 11 W AEX
1-67 OIL PRESS ANT SECONDARY PILOT
1-79 OIL PRESS- PW 2 0.85B 1 ROOF SKYLIGHT WIPER SW 1
+ 12 W 1-32 0.85BR 2 RELIEF SELECTION
2-87 COM RAIL PRESS+ Y 3
COMMON RAIL S 13 R
2-82 COM RAIL PRESS 1-52 DIAG ACC 3 0.3 YR 4 YR K A
R 4 4 0.3 RL 13 0.3RL 2
PRESSURESENSOR - B
2-90 COM RAIL PRESS
B.UP W
0.85B 3 WASHER SW ATT L
14 B 1-38
GB 5
CONNECTOR
1 0.3 Gy 6 Gy 2 BR
R9 0.85BY 4 1 ACC SELECTION
2-101 COM RAIL PRESS- SPR+ SPEAKER−Ｒ
+ 15 BR AEX
1-74 BOOST TEMP SPR-
5 0.3 W 5 W 1 ASHER R10 1 3 1.25L 14 1.25L ATT POWER
S 16 LB AEX RELAY HORN 2 RY 1
ＢＯＯＳＴSENSOR
+
17 P AEX
2-91 BOOST PRESS
1-61
GB 3 SPL+
2 0.3 GyB 15 GyR 2
SPEAKER−Ｌ 1 3 RELAY A3
RG 4-8 RG 13 1 LgB 2 S ARM DUMP
- 6 0.3 WB 14 WB 1
2-109 BOOST- BrL 2 ATM SPL- O 4-3 O 12 3 BY 3 - PILOT（Ｓ）
1.25 G
1.25 G
1-60 0.3G
7 0.3 B 16 B A20
ECM
1 LB AEX
2-83 FUEL_TEMP PL 1 PRESS. GND 254 B6 YB 4-4 YB 11 YB
K A
3G
3G
SCV Hi 2 0.85BrG AEX 1-71 R7 OPTIONAL
B25
Lo 0.85BrG AVSS
2-105 SUCTION CONTROL Hi LIGHT 1 3 LIGHT 1 3 R8 B
254 SWING ALARM 1 3 OPTION 2 12 A27
YB 4-10 YB 10 YB
L 5 L 2
SUPPLY PUMP 2-113 SUCTION CONTROL Hi RELAY2 B LW 4-9 LW 9 LW
B A RELAY1 HORN ＳＷ OPTIONAL SWING ALARM 11 0.3BR BR A26 1 MODE SELECTION
3 0.85GB AEX
2-89 SUCTION CONTROL Lo 1-72
RL
0.3 9 A25 LB 4-5 LB 8 LB 4 LB
ENG_3 0.85Gy AVSS
IA_T B
GyR EG_STOP JOINT3 0.3 SWING ALARM POWER (PATROL LIGHT) 10 0.3GR B23
2-97 SUCTION CONTROL Lo 2 WPu 7 2
EMERGENCY 254 2 5 4 1.25RL 254 BUCKET ADJACENT SW 9 0.3L A7
YG 4-7 YG YG 7 YG
PuG
1 1.25Y AEX 1-47

PG 4-11 1 B2 AUXILIARY FLOW
Br
1 STOPＳＷ 1
R
R 4-1 R 6 R 6 R
INJ-1
2
2-121 INJ-COM1 G R
B 8 SWING ALARM POWER (BUZZER) 8 LB
A23 RATE ADJUSTMENT
2 1.25P AEX BY 5 BY SENSOR GND
2-116 INJ-COM2 2 5 6 1 BOOM VIBRATION CONTROL SW2 7 0.3GL
INJ-3 3 HORN SW TRAVEL ALARM DEACTIVATION SW B11 RY 4 RY +5V
4 5 1.25RG AEX TRAVEL ALARM DEACTIVATION SW 6 GB
2-119 INJ-1 COUPLED OPTIONAL LOAD ALARM SW 5 0.3WG 0.3BG 4-12 BG 3
INJ-2 5 6 1.25BW AEX B20 D3
6 7 1.25LW AEX
2-118 INJ-2
8 REAR MONITORING SW 4 0.3GR D9
0.3WL 4-17 LgB 2 LgB
1
B15
+
2-120 INJ-3
7 8 1.25WG AEX
ENG_STOP 9 BOOM VIBRATION CONTROL SW1 3 0.3GW 0.3WPu 4-13 RW 1 RW 2 S
2-117 INJ-4 SW B12 D5 3 - ATT PRESSURE SENSOR
8 9 WY 4-21 0.3WY 2 Y Y
10
2-114 （ONLY 6H ENGINE） ENGINEABNORMAL 1-6
WR 4-22 0.3WR EC11 2 2 EC2 DEACTIVATION SW OPTIONAL POWER WY
B B5
2-115 （ONLY 6H ENGINE） B 1
INJ-4 ＥＮＧPRESSUREＳＷ 1-17
1 GR 1-30 GR ML SENSOR
ENG_2 FUELFILTERCLEANER 1-7
2 2 YR AEX ST_ 1 2 2 ST_ OPT2 INITIAL SETINGＳＷ
INJ-6 2-92 EGR_SENS_W 1-63 NORMAL ＯＰＥＮ
3 0.3BG
3 GW AEX
2-93 EGR_SENS_V ENGINE 1-42
OL 4-18 0.3OL EC1 EC2 B13
4 4 V AEX 0.3G
INJ-5 2-94 EGR_SENS_U CAN CONTROL DIAL1-64 LB 4-15 0.3LB B21
5 6 0.85LR AEX MAIN BACK UP COMMUNICATION EM_EC1 0.3BR
6 7 0.85LY AEX
2-110 EGR_MOT_W
GND GND 1-41
BrG 4-6 0.3GY 2 1 B14 ML ML OPTIONAL
1-18
1-37
2
2-103 EGR_MOT_V
1-43
7
1-62
8 0.85YL AEX EM_EC2

1-1
1-3
0.85BY 1
1-4
2-111 EGR_MOT_U 0.85BY
2RL AVSS
8 WG D6
2R AVSS
0.3W 0.3G 4-24 G 1 RG 2 BOOM ANGLE SENSOR
0.3W C23
0.5BrR
C1
1.25B
3
0.5B
0.85RY 0.85RY
ENG_4 D1
+
W
2 G AVSSCS G AVSSCS 4-29 G AVSSCS AVSSCS G
V ＣＡＮ C4 CAN 1
1 L AVSSCS L AVSSCS 4-28 L AVSSCS AVSSCS L 0.3P 4-23 P Lg 2
ＥＧＲ U
2L
C15 COMMUNICATION D16
2 ARM ANGLE SENSOR
0.85W 3
VALVE S
2B
0.3WG 4-14 WG 3
W
SUNSENSOR
SUN
JOINT7 R13 1 3
R12 1 3 R11 1 3 D12 BOOM OFF-SET ANGLE（Ｓ）
V
Ｍ MONITOR＿ＨＭＡＸＨＩRELAY AIRRELAYRELAY 1
U ＯＦＦRELAY W 0.3Y 4-16 Y 4 Br 2
2B K C24 BOOM ROD PRESSURE SENSOR
1 0.3BrL 5 0.3BrL D8 3
AMBIENTSENSOR BrB 2 5 4 254 254 A
2 0.3RB 14 0.3RB 2R 2RB 0.3OB 4-19 OB 5 RB 1
BrR B C11 2
2 1 RW 1-46 0.3BrY P D2 R 6
3
BOOM BOTTOM PRESSURE SENSOR
BR 1-45 A K WY RY 7 +5V RY
0.3BR
BY 8 BY
1-21
1-29
1-9
1.25WY
A/C-CONT1 10 3 1 2 11 9 12 2 3 1 1-23
JOINT3
2RL
JOINT4 R 4-2
2R WASHER B24
V
WG
IGN 1 0.3WY 1 COOLANTSENSOR
・ 2 0.3BR 2 (WT) LB
M
L R6
・ 3 B WIPER RELAY
W B WORK LIGHT OPTIONAL(ONLY ROOF SKYLIGHT WIPER K SPECIFICATION) WATER PROOF PLUG
MODE(V/V) 4
GW
BL YL 5 (24)
CAB OUTSIDE CAB INSIDE MODE(V/CL) 5
R
BR RW 1-3 RW AVX 1
0.3GL ＩＮＴ． HORN SIDE MALE SHURE PLUG A10 BW 1-12 BW AVX 2 SF ARM REGENERATION
BR
BR
BR
IN-CABTEMPERATURESENSOR 6 1 3 BY Y R
R
0.3BrL RG 1 (32) ＡＣＴ WATERPROOF CAP A6
SOLAR RADIATION SENSOR 7 1 3 1 3 1 3 1 3 1 3
7 (1-B) W 1-4 W AVX 1
0.85BR
WL WG LUBRICATOR FEMALE RECEPTACLE A32
MIX PBR 8 Ｍ R15 R17 G 1-13 G AVX 2 SC DIGGING REGENERATION VALVE
0.3B
2RL
25 4 R16 R22 R21 BODY EARTH WATERPROOF CAP A29
0.85BR
0.85BY
GND2 9 OPT（３３０）
1 SOLENOID
0.85B
1-19 Y 1-5 Y AVX
0.3B LY 6 (35) BOOM LIGHT B
GW
2 5 4 2 5 4 2 5 4 254 254 A11
GND1 10 Ｍ 1.25 O 1.25 1 + CONNECTOR A17
WG 1-14 WG AVX 2 SG POWER DIGGING
4 (27) G
0.85LG
0.85BY
RY
・ 11 FLAT TERMINAL
B
0.85B BW
5 (8) ＭＩＸ． LUBRICATOR L 1-6 L AVX 1
0.85B
WL HORN （Ｈ）
・ 12 1.25 A31 2 SI TRAVEL MODE
BW
2 - R 1-15 R AVX
BR 2 (20-D) ＡＣＴ 0.85B
SCREW TERMINAL FLAT TERMINAL WITH LOCK A5
・ 13
BP WY 1 (19) 0.85B WR
MODE(FOOT) 14 WIPER A28
WPu
MODE(Bi/L) 15 RB 1.25B
CONTROL UNIT
0.3BrY BP 1 (14-A) 2 1 4 3 B16 KEY SIGNAL SOLENOID A2

AMBIENTTEMPERATURESENSOR 16 HORN（Ｌ） 0.85BR
0.3WY WPu 2 (15) P5
2 1.25R
COOLANT TEMPERATURE SENSOR 17 1-47 0.85W
1
0.85WR 0.85BW K A A1 SOLENOID GND A13
BL 6 (5-A) P4 RG 1-20 RG 0.85B POWER
・ 18 0.85B A12 0.85B
BR
Y BP 7 (14-B) P3 0.85L
MAIN MAIN B8
0.85WL
W B7
0.85RG
MIX 5V 19 TRAVEL
GW
0.85R
0.85B
0.3BR W 3 (4) P2 ＭＯＤＥ B S L E L B17 POWER GND B18 OPTIONAL
SENSOR ＧＮＤ 20 R18 1
0.85BW
R19 1
0.85BR
8 (5-B) ＡＣＴ PRESSURE SWITCH
0.85BY
BL P1 WIPER 3 1 3 3
1.25WY 4-32 WY 1 B
BR 5 (20-E) R20 2 1 4 3 4-26 WR 2 TRAVEL
・ (21) 1 1B 1A 2B 2A C
TRAVEL ALARM
0.3YB Lg 4 (36) 3 D ALARM
BLW BASE (22) 2 Ｍ ROOF SKYLIGHT 4-31 GB 4 A
ＯＦＦ RELAY (23) 3
0.3Br LB 9 (28) CAB INSIDE WASHER CAB INSIDE DOOR ＳＷ
2 5 4 W
BW
2 5 4
L
2 5 4
R
B
YL Y
INTAKE (REC) (24) 4 B S L E C.B. OPTIONAL
1 (30-B) B LG
A/C ON (25) 5
0.3YG 2RB
0.3YB 2 (22)
CAB OUTSIDE COMPRESSOR M 2 1 4 3
・ (26)
6 ＰＴｒ WIPERMOTOR M
RY 2B 3 (9-C) B S L E 1-48 RW 3
ＭＩＸ（ＨＯＴ→ＣＯＯＬ） (27) 7
LB 2B
WIPER OUT
NOTE 4 BEACON LIGHT
ＭＯＤＥ（ＦＯＯＴ→Ｖ／Ｖ） (28) 8 1B 1A 2A
LG
4 (30-C) ROOF SKYLIGHT WIPER MOTOR 1. Separate harness ground lines to 3 lines (Accessory, Control power,
B
2RB B
・ (29) 9 SWING ALARM
0.3RB
System control).
C.B.
BLW F-BACK (30) 10 RESISTER DOOR ＳＷ 4-30 LB 1
0.3BrW
ＭＡＸＨｉ RELAY (31) 11 (REG) B S L E
INTAKE(FRESH) (32) 12
RG 2B 1 (9-D) M Do not connect the lines each other, and fix them together. 4-25 BR 2
SWING
ALARM
・ (33) 13 WIPER MOTOR 2. GND line for connection of cab floor and cab should be 8mm2 wire.
2L 1 (38) WIPERMOTOR
・ (34) 14 FAN 3. Wire should be 0.5mm2 , unless otherwise specified.
LY CAB INSIDE CAB OUTSIDE
ＭＩＸ（ＣＯＯＬ→ＨＯＴ） (35) 15 Ｍ MOTOR C.B.
ＭＯＤＥ（Ｖ／Ｖ→ＦＯＯＴ） (36) 16
Lg 2RB 2 (30-D)
(FUN) 4. 0.5 to 1.25mm2 wires are CAVS wire, 2 to 5mm2 wires are AVS,
M SWING
A/C-CONT2 0.3WG 1 (1-H) more than 8mm2 wires are AV wire, unless otherwise specified for wires
IN-CABTEMPERATURE 0.3GL 0.3YG 2 (25) THERMOSTAT Ｗ WIPER inside cab.
SENSOR (20-C) 1 0.3BR 0.3P 3 (39)
(AT) (6) 2
(TH) WIPER MOTOR 0.5 to 1.25mm2 wires are AVS wire, more than 2mm2 wires are AV wire,
unless otherwise specified for wires outside cab.
AIR CONDITIONER UNIT 5.
6.
marked wire is AEX wire.
marked wire is CHAVX wire.
Attach to Part No.：TT1JK-E-00
ZX400R-3/400LCH-3 ENGINE HARNESS 1
1 2 3
1 2 3
1 2 3
180
220
1 2 3 1 2 3
1 2 3
250 150
ZX400R-3/400LCH-3 ENGINE HARNESS 2

CRANK SPEED SENSOR CAM ANGLE SENSOR
ENG_1 WATER HYDRAULIC COMMON RAIL INTAKE-AIR
TEMPERATURE BOOST PRESSURE PRESSURE TEMPERATURE
1 2 3 2 1 SENSOR SENSOR SENSOR SENSOR SENSOR
CRANK+ 106 1
CRANK- 107 2
CRANK_SLD 108 3
CAM+ 99 4 1 2 3 1 2 3 1 2 3 1 2 3 1 2
CAM- 98 5
CAM_SLD 100 6
WATER TEMP 84 7
BOOST+ 95 8
OIL PRESS+ 80 9
OIL PRESS 67 10
OIL PRESS- 79 11
COM RAIL PRESS+ 87 12
COM RAIL PRESS 82,90 13
COM RAIL PRESS- 101 14
BOOST TEMP 74 15
BOOST PRESS 91 16
BOOST- 109 17
18
19
20
1 FUEL SCV
INJ-COM1 121 1 2 TEMPERATURE SUPPLI
INJ-COM2 116 2 3 SENSOR PUMP OVERHAET SW
3 4
4 5 TO INJECTOR
INJ-1 119 5 6
INJ-4 118 6 7 1 2 1 2
INJ-2 120 7 8
INJ-3 117 8
INJ-5 114 ※６ＨＯｎｌｙ 9
INJ-6 115 ※６ＨＯｎｌｙ 10
11
12
ENG_2
FUEL_TEMP 83 1
SUCTION CONTROL Hi 105,113 2
SUCTION CONTROL Lo 89,97 3
モニタへ 4
5
モニタへ 6
1 ENG_3 1
EGR_SENS_W 92 2 2
EGR_SENS_V 93 3 3
EGR_SENS_U 94 4 4
5 5 TO EGR VALVE
EGR_MOT_W 110 6 6
EGR_MOT_V 103 7 7
EGR_MOT_U 111 8 8
ENG_4
Attach to Part NO.：TT1JK-E-00
ZX400R-3/400LCH-3 CAB HARNESS
ENG/H_1
1 3 7 5 9 11 15 64 51 8 FRAME_GND DETAIL
CIRCUIT CIRCUIT JOINT_E
No. SIZE COL. COMMENT No. SIZE COL. COMMENT 9 536 4 8 6 10 14 16 58 70 995 18
FROM TO FROM TO 19 660 542 537 235 664 78 61 996 26 501 502
1 1.25 R MCF-A-1 FUSE-4- 586 0.5 R JOINT2-5 537 ALT_GND CAB_EARTH1
27 505 823 546 234 60 59 998 34
2 1.25 R MCF-A-12 1 587 0.5 B JOINT2-4 CAB_EARTH2 512
35 764 202 508 516 223 250 101 62 71 997 44 CAB_EARTH2
3 0.5 LB MCF-A-22 ENG/H_1-1 588 0.3 BrY ENG/H_1-46 JOINT3-10 ENG/H_2
45 597 588 583 993 222 102 81 53 52 587
200
4 0.5 LR MCF-A-16 ENG/H_1-10 589 0.85 B WIPER_STD-1 R6-4 (CO
T) 794
5 0.5 BrW MCF-A-30 ENG/H_1-2 590 0.85 BY WIPER_STD-4 R6-3
6 0.5 GW MCF-A-19 ENG/H_1-11 591 0.85 BR WIPER_STD-2 FUSE-2- 810 511 795
7 0.5 RW MCF-A-10 ENG/H_1-3 592 0.85 B WIPER_STD-3 CAB_EARTH4 50 2 1
8 0.5 BW MCF-A-6 ENG/H_1-12 593 0.5 BR R6-1 591 ENG/H_4 Ａ 796
200(COT)
9 0.5 W MCF-A-32 ENG/H_1-4 594 0.85 B R6-5 CAB_EARTH3
871
10 0.5 G MCF-A-29 ENG/H_1-13 595 0.5 BR R9-1 591 ENG/H_3
11 0.5 Y MCF-A-11 ENG/H_1-5 596 0.5 BR R9-3 591 T) 50 978
25 0(CO
12 1.25 B MCF-A-2 CAB_EARTH3 597 0.3 BR ENG/H_1-45 JOINT3-11 1 17 653 21 655 652 5
501 506
509
13 1.25 B MCF-A-13 12 598 3 G R7-3 FUSE-1- 6 766 18 22 650 651 10 CAB_EARTH3
14 0.5 WG MCF-A-17 ENG/H_1-14 599 1.25 G R7-1 598 2 1 12
11 768 72 69 100 14
15 0.5 L MCF-A-31 ENG/H_1-6 600 3 G R8-3 598 15 769 76 68 17 40
16 0.5 R MCF-A-5 ENG/H_1-15 601 1.25 G R8-1 598 18 767 73 762 760 254 22
250(COL)
17 0.5 R MCF-A-23 ENG/H_4-1 602 0.5 W R10-1 603 23 80 74 27 26 763 27 503
18 0.5 YG MCF-A-7 ENG/H_4-7 603 0.5 W R10-3 FUSE-11- 28 801 800 149 138 141 32
21 0.5 513
O MCF-A-20 ENG/H_4-3 604 0.5 B GATE_SW-3 CAB_EARTH4
22 0.5 RG MCF-A-3 ENG/H_4-8 605 0.5 B HORN_SW CAB_EARTH4 521
ＣＡＢＥＡＲＴＨ１ SERIAL
26 0.5 WR MCF-A-28 ENG/H_4-26 606 2 LW D3-A 522
27 0.5 BR MCF-A-25 ENG/H_4-25 607 3 W JOINT1-4 FUSE-12+ 539
MCF_A MCF_B MCF_C MCF_D 1 3
609 2 RB R11-5 FUSE-3- 540
34 0.3 BG MCF-B-13 JOINT2-7 610 1.25 WY OPT-1 FUSE-5-
Ｂ 860(COT) 825 826 827
35 0.3 BR MCF-B-14 JOINT2-14 611 2 R OPT-2 FUSE-6- M10 502 594

38 0.3 G MCF-B-21 JOINT2-6 612 1.25 LgR OPT-3 FUSE-20- A1 A11 B1 B8 C1 C10 D1 D5 773
39 0.85 80
L MCF-B-7 FUSE-10- 615 3 B OPT-6 CAB_EARTH4 1 12 22 16 8 18 7 11 103 41 44 48 39 40 63 60 62 800 101 51 81 72 61 69
40 0.85 B MCF-B-8 CAB_EARTH3 616 1.25 R OPT-4 537 2 13 4 14 6 21 3 17 43 45 34 35 47 88 42 50 73 78 71 801 102 53 52 68 58 64 100 774
41 0.3 GB MCF-B-4 JOINT3-7 617 1.25 RL OPT-5 536 27 650 651 26 10 5 15 9 65 38 652 653 655 74 76 54 70 59 80 ST_EC1 779
42 0.85 L MCF-B-17 39 618 0.5 RL 536 OPT_LIGHT A25 A32 B19 B25 C23 C31 D13 D16 ST_EC2
43 0.3 FLAG 983
GL MCF-B-11 OPT2-7 631 0.5 YR 566 ROOM EC1
44 0.5 250
Y MCF-B-5 ML INITIALIZE 632 1.25 LY LIGHTER ＋ FUSE-13- AVS 230 230
507
45 0.3 GW MCF-B-12 OPT2-3 633 1.25 B CAB_EARTH4 250 S1
220
LIGHTER ー CAB_EARTH4
47 0.3 GR MCF-B-15 OPT2-4 650 0.5 LW MCF_A-26 ENG/H_4-9 Ｉ 80 55 63
FLAG 79
1 2
48 0.3 G MCF-B-6 JOINT2-12 651 0.5 YB MCF_A-27 ENG/H_4-10 Assy
592
49 0.3 G JOINT6-4 48 652 0.5 LB MCF_B-23 ENG/H_4-5 80 1
S2 56 80
50 0.85 B MCF-B-18 40 653 0.5 R MCF_B-24 ENG/H_4-2 Ｄ 130(
COT) FLAG 2 1
902 901 604
51 0.85 RY MCF-D-1 ENG/H_1-8 655 0.5 YB MCF_B-25 ENG/H_4-4 2 1 GATE_VAL LIGHTER
Assy ROOM 605
52 0.85 RY MCF-D-7 51 660 1.25 O ENG/H_1-19 FUSE-7- DIODE5 ALL DIODES SHOULD 2 80 631 SET-1P(B)
53 0.85 BY MCF-D-6 ENG/H_1-52 661 0.85 G AUX+ FUSE-15- 2 BE ASSEMBLED. 80 E1 903 633 615
767 769 632
54 0.85 BY MCF-D-13 53 662 0.85 B AUX- CAB_EARTH4 1 3 1 2 EC2
1 2 - + 633
528 530 550
55 0.85 RY 51 ST-EC1-1 664 1.25 WY ENG/H_1-23 610 R12 R11
RELAY BOX
SP_L 100(VT)
Ｃ DIODE4 80 532 531
56 0.85 BY 53 ST-EC2-2 665 0.5 WY 610 OPT2-1 2 Assy
766 662
58 0.3 1 572 1 3 E2 2 1
RG MCF-D-10 ENG/H_1-16 666 0.85 B 662 D6-A 2 1
50 50
Ｌ
59 0.3
2 571 517 853 527 EM_EC1 827
YB MCF-D-15 ENG/H_1-33 667 0.85 G 661 D6-K )
(VT EM_EC2 EG_STOP
60 0.3 YR MCF-C-2 ENG/H_1-32 668 0.5 R 653 D2-A 100
SP_R
61 0.3 GY MCF-D-4 ENG/H_1-25 669 0.5 WY 664 D2-K 4 4
2 1
2 1 2 1 1 570
62 0.3 RB MCF-C-3 ENG/H_1-42 760 0.3 WY ENG/H_4-21 JOINT5-13 DIODE1
Ｒ
955 981 975 980 OPT. 768 770
80
A K
70
2 569 70 661
63 0.3 W MCF-C-1 ST-EC1-2 5 941 5 609 513 510 FLAG 517 526
R12 R11
0
64 0.3 WG MCF-D-11 ENG/H_1-7 762 0.3 G ENG/H_4-20 JOINT6-10
25
3 972 3 583 6 3 HORN_SW
150(COT)
65 0.3 WG MCF-B-20 OPT2-5 763 0.5 YG ENG/H_4-27 R14-1 FLAG 70
500(COT)
)
100 662
OT
68 0.3 WL MCF-D-9 ENG/H_4-17 764 0.5 RB ENG/H_1-35 FUSE-18-
0(C
69 0.3 WPu MCF-D-5 ENG/H_4-13 766 0.3 GY ENG/H_4-6 EM_EC2-2 4 4 4 4 4 JOINT_E X+
15
2 1 2 1 2 1 2 1 2 1 70 AU CAP 545 605
70 0.3 EM_EC1-1 T)
YB MCF-D-14 ENG/H_1-17 767 0.3 OL ENG/H_4-18 527 525 523 526 505 900 852 543 529 533 856 519 501 502 507 -
150
(CO 2 1
AUX GATE_SW
71 0.3 BR MCF-C-13 ENG/H_1-43 768 0.3 GyR ENG/H_4-11 EG_STOP-2 5 5 5 540 5 525 5 524 70 509 512 562
72 0.3 BG MCF-D-3 ENG/H_4-12 769 0.3 LB ENG/H_4-15 EM_EC1-2 3 521 R5 3 910 R4 3 541 R3 3 531 R2 3 520 R1 100 ＮＰ
73 0.3 OB MCF-C-11 ENG/H_4-19 770 0.5 R EG_STOP-1 810 50 90 Ｊ 70 Ｋ 190
280(COT) 250(COT) 150(COT) 1 3
530 821 604
74 0.3 G MCF-C-23 ENG/H_4-24 771 0.5 L ICF_C-1 39
76 0.3 Y MCF-C-24 ENG/H_4-16 772 0.5 L ICF_C-2 39 2
4
1 2
4
1 2
4
1 2
4
1 2
4
1 BZ 70 ＥＬ
100
(CO
T)
70
78 0.3 R MCF-C-12 ENG/H_1-24 773 0.5 B ICF_C-14 CAB_EARTH3 545 602 855 595 854 601 850 599 851 589 593 861 860 70 WIPER_STD 70
A K
79 0.5 B ML INITIALIZE 774 0.5 B ICF_C-15 CAB_EARTH3 5 542 5 546 5 536 5 537 5 594 1 2 )
CAB_EARTH4
R10 R9 R8 R7 R6 OT 668 669 FLAG
80 0.3 P MCF-D-16 ENG/H_4-23 775 0.5 LY ICF_C-8 202 3 603 3 596 3 600 3 598 3 590 0( C
15
70
ML
81 0.3 LY MCF-D-2 ENG/H_1-51 776 0.5 RB ICF_C-7 764 1 5 589 591 592 590 50
88 0.5 RB MCF-B-16 764 777 0.3 RW ICF_C-4 Trem_A-19 665 45 47 65 1 4 CAP
4 4
160
2 1 2 1 50
100 0.3 WG MCF-D-12 ENG/H_4-14 779 0.5 B ICF_A-10 CAB EARTH3 138 43 149 103 993 105 503 DIODE6
70
44
280(COT)
539 763 961 982 6 12
101 0.5 W MCF-C-5 ENG/H_1-41 INNER_OF_SHIERD 780 0.3 R ICF_A-7 Dr-1 DIODE2
5 810 5 979
R14 R13
120(COT)
102 0.5 B MCF-C-16 ENG/H_1-50 OUTER_OF_SHIERD 781 0.3 RB ICF_A-6 Dr-2
3 538 3 983 A K
103 0.3 L MCF-B-2 OPT2-9 782 0.3 B ICF_A-18 Dr-5 OPT2 79
OT) 666 667 ML INITIALIZE
105 0.3 BR 27 OPT2-11 783 0.3 BG ICF_A-17 Dr-6 R14 R13 170(C 100
138 0.5 GB ENG/H_4-31 OPT2-6 784 0.3 BL ICF_A-28 Dr-3 T) 1 3 OPT
CO
0(
340(COT)
141 0.5 WY ENG/H_4-32 610 785 0.5 BP ICF_A-5 Dr-4
14 100 610 611 612
149 0.5 LB ENG/H_4-30 OPT2-8 786 0.3 BW ICF_A-8 Trem_A-10 616 617 615
202 0.5 LY ENG/H_1-36 JOINT5-16 787 0.3 L ICF_A-9 Trem_A-20 8 1 10 1 4 6
205 0.3 R JOINT2-9 JOINT6-14 788 0.3 G ICF_A-20 Trem_B-9 M6
206 0.3 RB JOINT2-10 JOINT6-5 789 0.3 Y ICF_A-21 Trem_B-1 790 789 786 991 791 793 792 OPT_LIGHT
M8
207 0.3 JOINT2-11 JOINT6-15 788 787 777 990 796 795 794
RW 790 0.3 B ICF_A-31 Trem_B-2 1 6
222 0.3 RL ENG/H_1-49 JOINT5-10 791 0.5 LY Trem_A-3 202 16 9 20 11
1 771 772 6
615 507 ＣＡＢＥＡＲＴＨ４
777 804
223 0.3 GL ENG/H_1-39 JOINT5-9 792 0.5 RB Trem_A-1 764 Trem_B Trem_A Ｍ 80
7 776 775 805 12 618
228 0.3 JOINT2-8 JOINT6-3 39 ＣＡＢＥＡＲＴＨ３ 633 79
G 793 0.5 L Trem_A-2 13 773 774 17
229 0.3 GW JOINT2-15 JOINT6-1 794 0.5 B Trem_A-11 CAB_EARTH2 13 17 160 80
230 0.3 LB JOINT2-16 JOINT6-2 795 0.5 B Trem_A-12 CAB_EARTH2 ＣＡＢＥＡＲＴＨ２ 662 592
ICF_C OPT_FUSE
234 0.3 WB ENG/H_1-31 JOINT7-10 796 0.5 B Trem_A-15 CAB_EARTH2 Dr
540 509 1 3
235 0.3 Br ENG/H_1-22 JOINT7-3 800 0.5 G MCF_C-4 ENG/H_4-29 AVSSCS
250 0.3 WL ENG/H_1-40 JOINT5-11 801 0.5 L MCF_C-15 ENG/H_4-28 ８００TWIST 120 Ｆ 780 781 784
60 827 604
978 871 796 795 794 587 512 M8
594 12
785 782 783 561
254 0.3 WR ENG/H_4-22 JOINT5-12 802 0.5 G 804 JOINT7-1 AVSSCS 4 6 562
501 3 B ENG/H_3-2 JOINT_E 803 0.5 L 805 JOINT7-8 ８０２TWIST COT) 1 9 605
400( 1
502 3 B CAB_EARTH1 JOINT_E 804 0.5 G ICF_C-5 800 AVSSCS 40 785 781 780 786 787 9
773
503 0.5 B OPT2-12 CAB_EARTH3 805 0.5 L ICF_C-11 801 ８０４TWIST SEC_HONE 10 779 783 782 788 789 21
80 22 784 790 31
505 1.25 BW ENG/H_1-27 R4-4 810 3 L ENG/H_2-2 R14-5 503
774
70
22
506 5 W ENG/H_3-1 FUSE-1+ 821 0.5 R GATE_SW-2 JOINT6-9
507 3 B CAB_EARTH4 JOINT_E 823 0.5 R FUSE-14- ENG/H_1-28 541 80 5A 5A
508 2 779 513 C/U 10 39 560 612 20 OPT.3
W ENG/H_1-37 D3-K ＡＶＳＳ 824 0.5 RB JOINT6-11 764 DIODE3 ICF_A
10A 5A
509 3 B CAB_EARTH3 JOINT_E 825 0.5 R JOINT7-2 SERIAL-1 BACK.UP 9 543 870 19 SW.BOX
510 0.5 W D1-K 508 826 0.5 W JOINT7-9 SERIAL-2 983 521 30A 5A COVE
544
A K ECM 8 538 764 18 POW.ON
511 3 R ENG/H_2-1 JOINT1-1 827 0.5 B SERIAL-3 CAB_EARTH4 606 508 10A 5A
512 3 B CAB_EARTH2 JOINT_E 850 0.5 G JOINT5-1 R7-2 LUBRICATOR 7 660 522 940 17 AIRCON
539
60(COT)
513 0.5 B D1-A CAB_EARTH3 851 0.5 GW JOINT5-2 R6-2

OPT.2 6 611
10A 5A
516 16 GLOW_RELAY
516 0.5 GY ENG/H_1-38 FUSE-16- 852 0.5 GB JOINT5-3 R3-2 5A 10A
517 0.5 Br EG_STOP-6 D4-1 853 0.5 GL JOINT5-4 D4-2 OPT.1 5 610 661 15 AUXLIALY
506
519 1.25 10A 5A
R R1-1 511 854 0.5 R JOINT5-5 R8-2 SOLENOID 4 1 551 823 14 FUEL_PUMP
520 2 R R1-3 511 855 0.5 B JOINT5-6 R9-2 FUSE BOX
20A 10
HEATER 3 609 632 13 LIGHTER
521 2 B CAB_EARTH3 R5-3 856 0.5 O JOINT5-7 R1-2
522 3 LW JOINT1-5 FUSE-18+ 860 0.5 W JOINT5-8 BZ-2 WIPER 2 591
10A
607
5A
566 12 RADIO NOTES
523 0.5 R 532 R5-1 861 0.5 LB BZ-1 870 20A 10A 1. EACH WIRE TYPE IS AS FOLLOWS.
LAMP 1 598 603 11 HORN
524 0.5 W R1-5 508 870 0.5 LB JOINT6-12 FUSE-19- 1.25 mm2 OR LESS : CAVS or AVSS
525 0.5 Pu R5-4 R2-5 871 0.5 B JOINT6-16 CAB_EARTH2 MORE THAN 2mm2 : AVS
526 0.5 PuG R4-2 EG_STOP-5 900 1.25 WR JOINT1-6 R4-1 BUT, IN THE CASE OF THE WIRE WITH COMMENTS,
527 0.5 PuR R5-2 D4-3 901 0.3 Y JOINT2-1 EC1-1 THE WIRE TYPE OF COMMENTS IS ADOPTED.
528 0.5 Br D5-1 517 902 0.3 BrW JOINT2-2 EC1-2 2. THE SIDES OF PIN ARRANGEMENTS ARE LOOKED AT FROM
529 0.5 PuW JOINT7-7 R2-2 903 0.3 WY JOINT2-3 EC2-2 THE OTHER CONNECTOR.
530 0.3 O D5-2 GATE_SW-1 904 0.3 BrW JOINT6-7 902 1 7 3. ELECTRIC WIRE BETWEEN FG' AND LN SHOULD NOT HAVE
531 0.5 PW R2-3 GATE_VAL-1 905 0.3 WY JOINT6-6 903 850 851 852 853 854 855 856
240(COT)
Ｇ ElECTRIC BRANCHES OR JUNCTIONS.
532 0.5 R GATE_VAL-2 1 910 1.25 WR R4-3 900 860 223 222 250 254 760 202 4. PUT THE PART NO. LABEL ON THE HARNESS.
533 0.5 R R2-1 532 940 0.5 WG JOINT3-12 FUSE-17- 8 16 5. CB TYPE CONNECTORS ARE MADE OF PURE BRASS WITH NO CLOTHING.
536 2 RL ENG/H_1-9 R8-5 ＡＶＳＳ 941 2 RB R12-5 609 6. COLOR ABBREVIATIONS ARE DRAWN BASED ON JASO D607.
537 2 R ENG/H_1-21 R7-5 944 0.3 BrL JOINT3-3 JOINT7-5 JOINT5
D
ＡＶＳＳ 15
0( WIPER_STD,OPT,ROOM,SEC_OPT
7. DIAMETER OF THE CORRUGATED TUBE (COT) FOR CAB EARTH1,
538 3 G FUSE-8- R14-3 953 0.3 RB JOINT7-14 597 CO
R14-2
T) CAB EARTH2,G-LIGHTER SHOULD BE SMALLER THAN 20mm.
539 0.5 B CAB_EARTH3 955 0.5 BrR JOINT3-1 R12-2
R3-5 CAB_EARTH3
8. USE LEAD -FREE PARTS. (WIRE, COT, TAPE AND etc.)
540 0.5 B 961 0.5 BrB JOINT3-2 R13-2
)
OT
R3-3 COT)
RELAY BOX C
0(C
541 0.5 PG SEC_HONE 972 2 L JOINT4-1 R12-3 240( FUSE_BOX1,2

24
T)
542 0.5 RG ENG/H_1-20 R10-5 975 0.5 P JOINT3-9 R11-2 (CO
543 0.5 R3-1
240 Ｈ
RL FUSE-9- 978 2 B JOINT4-2 CAB_EARTH2
544 0.5 RL SEC_HONE 543 979 2 R JOINT4-3 R13-5 E
545 0.3 WPu HORN_SW R10-2 980 0.5 WG R11-1 940
546 0.5 BrR ENG/H_1-29 R9-5 981 0.5 WG R12-1 940 170
(CO J K L
T)
550 0.5 PL D5-3 JOINT7-16 982 0.5 WG R13-1 940
250(COT
T)
551 0.5
1 7 1 7 0(
CO
W FUSE-14+ 508 983 2 B R13-3 CAB_EARTH3 25
17
0(
229 230 228 49 206 905 904 802 825 235 944 529 CO
560 3 R FUSE-10+ 511 990 0.5 YR JOINT7-12 Trem_A-18
)
T)
999 821 762 824 870 205 207 871 803 826 234 990 991 953 550 995 996 998 997
F
561 5 W OPT_FUSE-1 506 991 0.5 LY JOINT7-13 Trem_A-9 ICF-A
8 16 8 16 1 4
562 3 B OPT_FUSE-2 JOINT_E 993 0.3 GR OPT2-10 2
N
ENG/H_1-48 7 1 7 1 1 2
4 6 ICF-C
566 0.5 YR JOINT3-4 FUSE-12- 995 0.5 R JOINT8-1 ENG/H_1-18 JOINT8 34 38 586 587 903 902 901
JOINT6 607 900 41 569 570 566 944 961 955 972 978
568 0.3 RL JOINT3-13 543 996 0.5 B JOINT8-2 ENG/H_1-26 JOINT7 230 229 35 48 207 206 205 228 573 571 572 568 940 597 588 975 CAB_EARTH3 OPT2
522 511 979
569 0.5 Gy JOINT3-6 SP_R-2 997 0.5 B JOINT8-4 ENG/H_1-44 OUTER_OF_SHIERD NO.2 1 8
5 3 16 8 16 3 4
570 0.5 W JOINT3-5 SP_R-1 998 0.5 W JOINT8-3 ENG/H_1-34 INNER_OF_SHIERD NO.2
571 0.5 GyB JOINT3-15 SP_L-2 999 0.5 GW 851 JOINT6-8 JOINT1 JOINT2 JOINT3 JOINT4
572 0.5 WB JOINT3-14 SP_L-1
573 0.5 B JOINT3-16 501
583 0.85 W ENG/H_1-47 R11-3
ZX400R-3/400LCH-3 MONITOR UNIT HARNESS
JOINT6
JOINT7
JOINT5 C16MB
C16MBR
C16MW
CIRCUIT
No. SIZE COL. COMMENT
FROM TO
7 1 7 1 7 1
49 0.3 G CN1_2-18 JOINT6-4
856 855 854 853 852 851 850 904 905 206 49 228 230 229 529 993 944 235 825 802 4 1
202 0.3 LY CN2-7 JOINT5-16
202 820 760 254 250 222 223 860 871 207 205 872 870 824 762 821 999 550 953 991 990 234 826 803 997 998 996 995
205 0.3 R CN2-6 JOINT6-14
16 8 16 8 16 8
206 0.3 RB CN2-3 JOINT6-5
10 C04MW
207 0.3 RW CN2-9 JOINT6-15 0( T)
CO CO )
100(
COT)
T)
10
0( (COT JOINT8
222 0.3 RL CN1_2-5 JOINT5-10 100
223 0.3 GL CN1_2-4 JOINT5-9
228 0.3 G CN1_2-3 JOINT6-3
229 0.3 GW CN1_2-20 JOINT6-1
230 0.3 LB CN1_1-6 JOINT6-2
234 0.3 WB CN2-8 JOINT7-10 70
235 0.3 Br CN2-2 JOINT7-3 880

250 0.3 WL CN1_2-15 JOINT5-11 WSTOP 70
254 0.3 WR CN1_2-16 JOINT5-12 881
529 0.3 GB CN1_2-2 JOINT7-7
550 0.3 Gy CN1_2-12 JOINT7-16 8 1
760 0.3 WY CN2-11 JOINT5-13
OPEN
CN2-12 995 824 230 854 853 852 851 850
980(COT)
762 0.3 G CN1_2-10 JOINT6-10 870 998 997 996 856 999 855 860
802 0.5 G CN1_2-7 JOINT7-1 AVSSCS 803 TWIST 16 9
803 0.5 L CN1_2-6 JOINT7-8 AVSSCS 802 TWIST
820 0.3 GY CN1_2-17 JOINT5-15
T)
821 0.3 R CN1_2-19 JOINT6-9 CN1_1
CO
0(
825 0.3 R CN1_2-8 JOINT7-2
15
826 0.3 W CN1_2-9 JOINT7-9
824 0.3 RB CN1_1-7 JOINT6-11
850 0.3 G CN1_1-1 JOINT5-1 10 1
851 0.3 GW CN1_1-2 JOINT5-2
150(COT)
852 0.3 GB CN1_1-3 JOINT5-3 762 826 825 802 803 222 223 228 529 993
853 0.3 GL CN1_1-4 JOINT5-4 229 821 49 820 254 250 880 990 550 871
854 0.3 R CN1_1-5 JOINT5-5 20 11
855 0.3 B CN1_1-10 JOINT5-6
856 0.3 O CN1_1-12 JOINT5-7
860 0.3 W CN1_1-9 JOINT5-8 CN1_2
15
0(
870 0.3 LB CN1_1-16 JOINT6-12
CO
T)
871 0.3 B CN1_2-11 JOINT6-16
872 0.3 WB CN2-1 JOINT6-13
880 0.5 YL CN1_2-14 WSTOP 6 1
350
881 0.5 BL WSTOP 871
904 0.3 BrW CN2-4 JOINT6-7 205 991 904 206 235 872
905 0.3 WY CN2-10 JOINT6-6 760 905 207 234 202
944 0.3 BrL SUN-1 JOINT7-5 12 7
953 0.3 RB SUN-2 JOINT7-14
990 0.3 YR CN1_2-13 JOINT7-12
SUN
991 0.3 LY CN2-5 JOINT7-13 CN2
993 0.3 GR CN1_2-1 JOINT7-6
995 0.3 R CN1_1-8 JOINT8-1
953 944
996 0.3 B CN1_1-13 JOINT8-2
2 1
997 0.5 B CN1_1-14 JOINT8-4 APEXSP-1A OUTER
998 0.5 W CN1_1-15 JOINT8-3 APEXSP-1A INNER
999 0.5 GW CN1_1-11 JOINT6-8
Atatch to Part No.：TT1JK-E-00
ZX400R-3/400LCH-3 CONNECTORS (HARNESS END CONNECTOR WITHOUT COMMENT)
OUTSIDE CAB INSIDE CAB
PART NO. W1J1-E-00
ZAXIS450-3 • 450LC-3 • 470H-3 • 470LCH-3 • 500LC-3 • 520LCH-3 class

Workshop Manual
450-3
450LC-3
HYDRAULIC EXCAVATOR
470H-3
470LCH-3
WORKSHOP MANUAL
URL:http://www.hitachi-c-m.com
500LC-3
520LCH-3
Hydraulic Excavator
Service Manual consists of the following separate Part No;
Technical Manual (Operational Principle) : Vol. No.TO1J1-E
Technical Manual (Troubleshooting) : Vol. No.TT1J1-E
PRINTED IN JAPAN (E) 2006, 02 Workshop Manual : Vol. No.W1J1-E
W1J1-E-00 Page 1 2006.2.20, 12:25 Adobe PageMaker 7.0J/PPC

INTRODUCTION
TO THE READER
age.):
TEL: 81-29-832-7084
FAX: 81-29-831-1162
to the 29, Mayl 2009.

manual.
MANUAL COMPOSITION
PAGE NUMBER

Example : T 1-3-5

Group Number
Section Number
IN-01
INTRODUCTION
NOTATIONS

death.
• NOTE:
know-how.
heavy parts.
UNITS USED
this manual.
From From
mm ft 0.003281 MPa psi 145.0
L US qt 1.057 kW HP 1.341
IN-02
SAFETY
RECOGNIZE SAFETY INFORMATION
• These are the SAFETY ALERT SYMBOLS.
• When you see these symbols on your machine or

in this manual, be alert to the potential for per-
sonal injury.
• Follow recommended precautions and safe oper-
ating practices.
001-E01A-0001
SA-688
UNDERSTAND SIGNAL WORDS

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

situation which, if not avoided, will result in death
or serious injury.
• WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
• CAUTION indicates a potentially hazardous
situation which, if not avoided, may result in minor
or moderate injury.
• DANGER or WARNING safety signs are located
near specific hazards. General precautions are
listed on CAUTION safety signs.
• Some safety signs don't use any of the desig-
nated signal words above after the safety alert
symbol are occasionally used on this machine.
• To avoid confusing machine protection with personal

safety messages, a signal word IMPORTANT indi-
cates a situation which, if not avoided, could result in
damage to the machine. SA-1223
• NOTE indicates an additional explanation for an

element of information.
002-E01A-1223
SA-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS
• Carefully read and follow all safety signs on the
machine and all safety messages in this manual.
• Safety signs should be installed, maintained and
replaced when necessary.
• If a safety sign or this manual is damaged or

missing, order a replacement from your author-
ized dealer in the same way you order other re-
placement parts (be sure to state machine model
and serial number when ordering).
• Learn how to operate the machine and its controls
correctly and safely.
• Allow only trained, qualified, authorized personnel to
operate the machine. SA-003
• Keep your machine in proper working condition.
• Unauthorized modifications of the machine may

impair its function and/or safety and affect ma-
chine life.
• Do not modify any machine parts without au-
thorization. Failure to do so may deteriorate the
part safety, function, and/or service life. In addi-
tion, personal accident, machine trouble, and/or
damage to material caused by unauthorized
modifications will void Hitachi Warranty Policy.
• Do not use attachments and/or optional parts or
equipment not authorized by Hitachi. Failure to do
so may deteriorate the safety, function, and/or
service life of the machine. In addition, personal
accident, machine trouble, and/or damage to
material caused by using unauthorized attach-
ments and/or optional parts or equipment will void
Hitachi Warranty Policy.
• The safety messages in this SAFETY chapter are
intended to illustrate basic safety procedures of
machines. However it is impossible for these safety
messages to cover every hazardous situation you
may encounter. If you have any questions, you
should first consult your supervisor and/or your au-
thorized dealer before operating or performing
maintenance work on the machine.
003-E01B-0003
SA-2
SAFETY
PREPARE FOR EMERGENCIES
• Be prepared if a fire starts or if an accident occurs.
• Keep a first aid kit and fire extinguisher on hand.

• Thoroughly read and understand the label at-
tached on the fire extinguisher to use it properly.
• To ensure that a fire-extinguisher can be always
used when necessary, check and service the
fire-extinguisher at the recommended intervals as
specified in the fire-extinguisher manual.
• Establish emergency procedure guidelines to
cope with fires and accidents.
• Keep emergency numbers for doctors, ambu-
lance service, hospital, and fire department
posted near your telephone. SA-437
004-E01A-0437
WEAR PROTECTIVE CLOTHING

• Wear close fitting clothing and safety equipment
appropriate to the job.
You may need:

A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear
Respirator or filter mask.
Be sure to wear the correct equipment and clothing
for the job. Do not take any chances. SA-428
• Avoid wearing loose clothing, jewelry, or other

items that can catch on control levers or other
parts of the machine.
• Operating equipment safely requires the full atten-
tion of the operator. Do not wear radio or music
headphones while operating the machine.
005-E01A-0438
SA-3
SAFETY
PROTECT AGAINST NOISE
• Prolonged exposure to loud noise can cause im-
pairment or loss of hearing.
• Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against objec-
tionable or uncomfortably loud noises.
006-E01A-0434
SA-434
INSPECT MACHINE
• Inspect your machine carefully each day or shift by
walking around it before you start it to avoid per-
sonal injury.
• In the walk-around inspection be sure to cover all

points described in the "RE-START INSPEC-
TION" chapter in the operator's manual.
007-E01A-0435
SA-435
SA-4
SAFETY
GENERAL PRECAUTIONS FOR CAB
• Before entering the cab, thoroughly remove all dirt
and/or oil from the soles of your work boots. If any
controls such as a pedal is operated while with
dirt and/or oil on the soles of the operator's work
boots the operator's foot may slip off the pedal,
possibly resulting in a personal accident.
• Do not leave parts and/or tools lying around the
operator's seat. Store them in their specified loca-
tions.
• Avoid storing transparent bottles in the cab. Do
not attach any transparent type window decora-
tions on the windowpanes as they may focus
sunlight, possibly starting a fire.
• Refrain from listening to the radio, or using music
headphones or mobile telephones in the cab
while operating the machine.
• Keep all flammable objects and/or explosives
away from the machine.
• After using the ashtray, always cover it to extin-
guish the match and/or tobacco.
• Do not leave cigarette lighters in the cab. When
the temperature in the cab increases, the lighter
may explode.
524-E01A-0000
SA-5
SAFETY
USE HANDHOLDS AND STEPS
• Falling is one of the major causes of personal injury.
• When you get on and off the machine, always

face the machine and maintain a three-point
contact with the steps and handrails.
• Do not use any controls as hand-holds.
• Never jump on or off the machine. Never mount or
dismount a moving machine.
• Be careful of slippery conditions on platforms,
steps, and handrails when leaving the machine.
008-E01A-0439
SA-439
ADJUST THE OPERATOR'S SEAT

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

the operator for the machine.
• The operator should be able to fully depress the
pedals and to correctly operate the control levers
with his back against the seat back.
• If not, move the seat forward or backward, and
check again.
• Adjust the rear view mirror position so that the
best rear visibility is obtained from the operator's
seat. If the mirror is broken, immediately replace it SA-462
with a new one.
009-E01A-0462
SA-6
SAFETY
ENSURE SAFETY BEFORE RISING FROM
OR LEAVING OPERATOR'S SEAT
• Before rising from the operator's seat to open/close
either side window or to adjust the seat position, be
sure to first lower the front attachment to the ground
and then move the pilot control shut-off lever to the
LOCK position. Failure to do so may allow the ma-
chine to unexpectedly move when a body part un-
intentionally comes in contact with a control lever,
possibly resulting in serious personal injury or death.
• Before leaving the machine, be sure to first lower

the front attachment to the ground and then move
the pilot control shut-off lever to the LOCK posi-
tion. Turn the key switch OFF to stop the engine.
• Before leaving the machine, close all windows,
doors, and access covers and lock them up.

• If the machine should overturn, the operator may
become injured and/or thrown from the cab. Addi-
tionally the operator may be crushed by the over-
turning machine, resulting in serious injury or death.
• Prior to operating the machine, thoroughly ex-

amine webbing, buckle and attaching hardware. If
any item is damaged or worn, replace the seat
belt or component before operating the machine.
• Be sure to remain seated with the seat belt se-
curely fastened at all times when the machine is
in operation to minimize the chance of injury from
an accident.
・We recommend that the seat belt be replaced SA-237
every three years regardless of its apparent con-

dition.
010-E01A-0237
SA-7
SAFETY
MOVE AND OPERATE MACHINE SAFELY
• Bystanders can be run over.
• Take extra care not to run over bystanders. Con-

firm the location of bystanders before moving,
swinging, or operating the machine.
• Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
• Use a signal person when moving, swinging, or
• Use appropriate illumination. Check that all lights
are operable before operating the machine. If any
faulty illumination is present, immediately repair it.
SA-426
011-E01A-0398
HANDLE STARTING AIDS SAFELY

Starting fluid:
• Starting fluid is highly flammable.
• Keep all sparks and flame away when using it.

• Keep starting fluid well away from batteries and
cables.
• Remove container from machine if engine does
not need starting fluid.
• To prevent accidental discharge when storing a
pressurized container, keep the cap on the con-
tainer, and store it in a cool, well-protected loca-
tion.
• Do not incinerate or puncture a starting fluid con-
SA-293
tainer.
036-E01A-0293-3
SA-8
SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT
• Inappropriate engine starting procedures may cause
the machine to runaway, possibly resulting in seri-
ous injury or death.
• Start the engine only when seated in the opera-

tor's seat.
• NEVER start the engine while standing on the
track or on ground.
• Do not start engine by shorting across starter
terminals.
• Before starting the engine, confirm that all control
levers are in neutral.
• Before starting the engine, confirm the safety SA-444
around the machine and sound the horn to alert

bystanders.
012-E01B-0431
JUMP STARTING
• Battery gas can explode, resulting in serious injury.
• If the engine must be jump started, be sure to

follow the instructions shown in the "OPERATING
THE ENGINE" chapter in the operator's manual.
• The operator must be in the operator's seat so
that the machine will be under control when the
engine starts. Jump starting is a two-person op-
eration.
• Never use a frozen battery.
• Failure to follow correct jump starting procedures
could result in a battery explosion or a runaway
machine.
SA-032
S013-E01A-0032
SA-9
SAFETY
KEEP RIDERS OFF MACHINE
• Riders on machine are subject to injury such as be-
ing struck by foreign objects and being thrown off
the machine.
• Only the operator should be on the machine.

Keep riders off.
• Riders also obstruct the operator's view, resulting
in the machine being operated in an unsafe
manner.
014-E01B-0427
SA-379
PRECAUTIONS FOR OPERATIONS

• Investigate the work site before starting operations.
• Be sure to wear close fitting clothing and safety

equipment appropriate for the job, such as a hard
hat, etc. when operating the machine.
• Clear all persons and obstacles from area of op-
eration and machine movement.
Always beware of the surroundings while operat-
ing. When working in a small area surrounded by
obstacles, take care not to hit the upperstructure
against obstacles.
• When loading onto trucks, bring the bucket over
the truck beds from the rear side. Take care not to
swing the bucket over the cab or over any person.
M104-05-015
SA-10
SAFETY
INVESTIGATE JOB SITE BEFOREHAND
• When working at the edge of an excavation or on a
road shoulder, the machine could tip over, possibly
• Investigate the configuration and ground condi-
tions of the job site beforehand to prevent the
machine from falling and to prevent the ground,
stockpiles, or banks from collapsing.
• Make a work plan. Use machines appropriate to
the work and job site.
• Reinforce ground, edges, and road shoulders as
necessary. Keep the machine well back from the
edges of excavations and road shoulders.
• When working on an incline or on a road shoulder, SA-380
employ a signal person as required.
• Confirm that your machine is equipped a FOPS
cab before working in areas where the possibility
of falling stones or debris exist.
• When the footing is weak, reinforce the ground
before starting work.
• When working on frozen ground, be extremely
alert. As ambient temperatures rise, footing be-
comes loose and slippery.
• Beware the possibility of fire when operating the
machine near flammable objects such as dry
grass.
• Make sure the worksite has sufficient strength to
firmly support the machine.
When working close to an excavation or at road
shoulders, operate the machine with the tracks po-
sitioned perpendicular to the cliff face with travel
motors at the rear, so that the machine can more
easily evacuate if the cliff face collapses.
• If working on the bottom of a cliff or a high bank is
required, be sure to investigate the area first and
confirm that no danger of the cliff or bank collapsing
exists. If any possibility of cliff or bank collapsing
exists, do not work on the area.
• Soft ground may collapse when operating the ma-
chine on it, possibly causing the machine to tip over.
When working on a soft ground is required, be sure
to reinforce the ground first using large pieces of
steel plates strong and firm enough to easily support
the machine.
• Note that there is always a possibility of machine
tipping over when working on rough terrain or on
slopes. Prevent machine tipping over from occurring.
When operating on rough terrain or on slopes:
• Reduce the engine speed.
• Select slow travel speed mode.
• Operate the machine slowly and be cautious with
machine movements.
SA-11
SAFETY
EQUIPMENT OF HEAD GUARD, ROPS,
FOPS
In case the machine is operated in areas where the
possibility of falling stones or debris exist, equip a
head guard, ROPS, or FOPS according to the poten-
tial hazardous conditions. (The standard cab for this
machine corresponds to ROPS and FOPS.)
ROPS: Roll-Over Protective Structure

FOPS: Falling Object Protective Structure
SA-490
PROVIDE SIGNALS FOR JOBS INVOLV-

ING MULTIPLE NUMBERS OF MACHINES
• For jobs involving multiple numbers of machines,
provide signals commonly known by all personnel
involved. Also, appoint a signal person to coordinate
the job site. Make sure that all personnel obey the
signal person's directions.
018-E01A-0481
SA-481
CONFIRM DIRECTION OF MACHINE TO

BE DRIVEN
• Incorrect travel pedal/lever operation may result in
serious injury death.
• Before driving the machine, confirm the position

of the undercarriage in relation to the operator's
position. If the travel motors are located in front of
the cab, the machine will move in reverse when
travel pedals/levers are operated to the front.
017-E01A-0491
SA-491
SA-12
SAFETY
• Before driving the machine, always confirm that the
travel levers/pedals direction corresponds to the di-
rection you wish to drive.
• Be sure to detour around any obstructions.

• Avoid traveling over obstructions. Soil, fragments
of rocks, and/or metal pieces may scatter around
the machine. Don't allow personnel to stay around
the machine while traveling.
• Driving on a slope may cause the machine to slip or

overturn, possibly resulting in serious injury or
death. SA-657
• Never attempt to ascend or descend 35 degrees

or steeper slopes.
• Be sure to fasten the seat belt.
• When driving up or down a slope, keep the bucket
facing the direction of travel, approximately 0.5 to
1.0 m (A) above the ground.
• If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and
stop.
SA-658
SA-441
SA-442
SA-13
SAFETY
• Driving across the face of a slope or steering on a
slope may cause the machine to skid or turnover.
If the direction must be changed, move the ma-
chine to level ground, then, change the direction
to ensure safe operation.
• Avoid swinging the upperstructure on slopes.
Never attempt to swing the upperstructure down-
hill. The machine may tip over. If swinging uphill is
unavoidable, carefully operate the upperstructure
and boom at slow speed. Travel Motor
• If the engine stalls on a slope, immediately lower
the bucket to the ground. Return the control lev-
M104-05-008
ers to neutral. Then, restart the engine.
• Be sure to thoroughly warm up the machine be-
fore ascending steep slopes. If hydraulic oil has
not warmed up sufficiently, sufficient performance
may not be obtained.
• Use a signal person when moving, swinging or
• Before moving machine, determine which way to
move travel pedals/levers for the direction you
Arrow-Mark
want to go. When the travel motors are in the rear,
pushing down on the front of the travel pedals or M178-03-001
pushing the levers forward moves the machine

forward, towards the idlers.
An arrow-mark seal is stuck on the inside surface
of the side frame to indicate the machine front
direction.
• Select a travel route that is as flat as possible.
Steer the machine as straight as possible, making
small gradual changes in direction.
• Before traveling on them, check the strengths of
bridges and road shoulders, and reinforce if nec-
essary.
SA-14
SAFETY
• Use wood plates in order not to damage the road
surface. Be careful of steering when operating on
asphalt roads in summer.
• When crossing train tracks, use wood plates in
order not to damage them.
• Do not make contact with electric wires or
bridges.
• When crossing a river, measure the depth of the
river using the bucket, and cross slowly. Do not
cross the river when the depth of the river is
deeper than the upper edge of the upper roller.
• When traveling on rough terrain, reduce engine
speed. Select slow travel speed. Slower speed
will reduce possible damage to the machine.
• Avoid operations that may damage the track and SA-011
undercarriage components.
• During freezing weather, always clean snow and
ice from track shoes before loading and unloading
machine, to prevent the machine from slipping.
SA-15
SAFETY
AVOID INJURY FROM ROLLAWAY ACCI-
DENTS
• Death or serious injury may result if you attempt to
mount or stop a moving machine.
To avoid rollaways:
• Select level ground when possible to park ma-
chine.
• Do not park the machine on a grade.
• Lower the bucket and/or other work tools to the
ground.
• Turn the auto-idle switch and the H/P mode
switch off.
• Run the engine at slow idle speed without load for
5 minutes to cool down the engine. SA-391
• Stop the engine and remove the key from the key
switch.
• Pull the pilot control shut-off lever to LOCK posi-
tion.
• Block both tracks and lower the bucket to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade.
• Position the machine to prevent rolling.
• Park a reasonable distance from other machines.
SA-392
020-E02A-0493
SA-16
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
• If any person is present near the machine when
backing or swinging the upperstructure, the machine
may hit or run over that person, resulting in serious
injury or death.
To avoid back-over and swing accidents:

• Always look around BEFORE YOU BACK UP
AND SWING THE MACHINE. BE SURE THAT
ALL BYSTANDERS ARE CLEAR.
• Keep the travel alarm in working condition (if
equipped).
ALWAYS BE ALERT FOR BYSTANDERS MOV-
ING INTO THE WORK AREA. USE THE HORN SA-383
OR OTHER SIGNAL TO WARN BYSTANDERS

BEFORE MOVING MACHINE.
• USE A SIGNAL PERSON WHEN BACKING UP
IF YOUR VIEW IS OBSTRUCTED. ALWAYS
KEEP THE SIGNAL PERSON IN VIEW.
Use hand signals, which conform to your local
regulations, when work conditions require a signal
person.
• No machine motions shall be made unless signals
are clearly understood by both signalman and
operator.
• Learn the meanings of all flags, signs, and mark-
ings used on the job and confirm who has the SA-384
responsibility for signaling.
• Keep windows, mirrors, and lights clean and in
good condition.
• Dust, heavy rain, fog, etc., can reduce visibility. As
visibility decreases, reduce speed and use proper
lighting.
• Read and understand all operating instructions in
the operator's manual.
021-E01A-0494
SA-17
SAFETY
KEEP PERSON CLEAR FROM WORKING
AREA
• A person may be hit severely by the swinging front
attachment or counterweight and/or may be crushed
against an other object, resulting in serious injury or
death.
• Keep all persons clear from the area of operation

and machine movement.
• Before operating the machine, set up barriers to
the sides and rear area of the bucket swing radius
to prevent anyone from entering the work area.
022-E01A-0386
SA-386
NEVER POSITION BUCKET OVER ANY-

ONE
• Never lift, move, or swing bucket above anyone or a
truck cab.
Serious injury or machine damage may result due to
bucket load spill or due to collision with the bucket.
023-E01A-0487
SA-487
AVOID UNDERCUTTING
• In order to retreat from the edge of an excavation if
the footing should collapse, always position the un-
dercarriage perpendicular to the edge of the exca-
vation with the travel motors at the rear.
• If the footing starts to collapse and if retreat is not

possible, do not panic. Often, the machine can be
secured by lowering the front attachment, in such
cases.
024-E01A-0488 SA-488
SA-18
SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING
MACHINE---SERIOUS OR FATAL CRUSHING IN-
JURIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU
CAN JUMP FREE
• The danger of tipping is always present when oper-
ating on a grade, possibly resulting in serious injury
or death.
To avoid tipping:
• Be extra careful before operating on a grade.
SA-012
• Prepare machine operating area flat.

• Keep the bucket low to the ground and close to
the machine.
• Reduce operating speeds to avoid tipping or slip-
ping.
• Avoid changing direction when traveling on
grades.
• NEVER attempt to travel across a grade steeper
than 15 degrees if crossing the grade is un-
avoidable.
• Reduce swing speed as necessary when swing-
ing loads.
SA-440
• Be careful when working on frozen ground.
• Temperature increases will cause the ground to

become soft and make ground travel unstable.
025-E03B-0463
NEVER UNDERCUT A HIGH BANK

• The edges could collapse or a land slide could occur
causing serious injury or death.
026-E01A-0519
SA-489
SA-19
SAFETY
DIG WITH CAUTION
• Accidental severing of underground cables or gas
lines may cause an explosion and/or fire, possibly
• Before digging check the location of cables, gas

lines, and water lines.
• Keep the minimum distance required, by law, from
cables, gas lines, and water lines.
• If a fiber optic cable should be accidentally sev-
ered, do not look into the end. Doing so may re-
sult in serious eye injury.
• Contact your local "diggers hot line" if available in
SA-382
your area, and/or the utility companies directly.
Have them mark all underground utilities.
027-E01A-0382
OPERATE WITH CAUTION

• If the front attachment or any other part of the ma-
chine hits against an overhead obstacle, such as a
bridge, both the machine and the overhead obstacle
will be damaged, and personal injury may result as
well.
• Take care to avoid hitting overhead obstacles with

the boom or arm.
SA-389
028-E01A-0389
SA-20
SAFETY
AVOID POWER LINES
• Serious injury or death can result if the machine or
front attachments are not kept a safe distance from
electric lines.
• When operating near an electric line, NEVER

move any part of the machine or load closer than
3 m plus twice the line insulator length.
• Check and comply with any local regulations that
may apply.
• Wet ground will expand the area that could cause
any person on it to be affected by electric shock.
Keep all bystanders or co-workers away from the
site.
SA-381
029-E01A-0381
PRECAUTIONS FOR LIGHTENING

• The machine is vulnerable to lighting strikes.
• In the event of an electrical storm, immediately

stop operation, and lower the bucket to the
ground. Evacuate to a safe place far away from
the machine.
• After the electrical storm has passed, check all of
the machine safety devices for any failure. If any
failed safety devices are found, operate the ma-
chine only after repairing them.
SA-1088
OBJECT HANDLING
• If a lifted load should fall, any person nearby may be
struck by the falling load or may be crushed under-
neath it, resulting in serious injury or death.
• When using the machine for craning operations,

be sure to comply with all local regulations.
• Do not use damaged chains or frayed cables,
sables, slings, or ropes.
• Before craning, position the upperstructure with
the travel motors at the rear.
• Move the load slowly and carefully. Never move it
suddenly.
• Keep all persons well away from the load.
• Never move a load over a person's head.
• Do not allow anyone to approach the load until it
is safely and securely situated on supporting
blocks or on the ground. SA-014
• Never attach a sling or chain to the bucket teeth.

They may come off, causing the load to fall.
032-E01A-0132
SA-21
SAFETY
PROTECT AGAINST FLYING DEBRIS
• If flying debris hit eyes or any other part of the body,
serious injury may result.
• Guard against injury from flying pieces of metal or

debris; wear goggles or safety glasses.
• Keep bystanders away from the working area
before striking any object.
031-E01A-0432
SA-432
PARK MACHINE SAFELY

To avoid accidents:
• Park machine on a firm, level surface.
• Lower bucket to the ground.
• Turn auto-idle switch and H/P mode switch OFF.
• Run engine at slow idle speed without load for 5
minutes.
• Turn key switch to OFF to stop engine.
• Remove the key from the key switch.
• Pull the pilot control shut-off lever to the LOCK
position.
• Close windows, roof vent, and cab door. SA-390
• Lock all access doors and compartments.
HANDLE FLUIDS SAFELY-AVOID FIRES

• Handle fuel with care; it is highly flammable. If fuel
ignites, an explosion and/or a fire may occur, possi-
bly resulting in serious injury or death.
• Do not refuel the machine while smoking or when

near open flame or sparks.
• Always stop the engine before refueling the ma-
chine.
• Fill the fuel tank outdoors.
• All fuels, most lubricants, and some coolants are

flammable.
• Store flammable fluids well away from fire haz- SA-018
ards.
• Do not incinerate or puncture pressurized con-
tainers.
• Do not store oily rags; they can ignite and burn
spontaneously.
• Securely tighten the fuel and oil filler cap.
034-E01A-0496
SA-019
SA-22
SAFETY
TRANSPORT SAFELY
• Take care the machine may turn over when loading
or unloading the machine onto or off of a truck or
trailer.
• Observe the related regulations and rules for safe

transportation.
• Select an appropriate truck or trailer for the ma-
chine to be transported.
• Be sure to use a signal person.
• Always follow the following precautions for load-
ing or unloading:
1. Select solid and level ground.
2. Always use a ramp or deck strong enough to
support the machine weight. SA-395
3. Turn auto-idle switch OFF.

4. Always select the slow speed mode with the
travel mode switch.
5. Never load or unload the machine onto or off a
truck or trailer using the front attachment func-
tions when driving up or down the ramp.
6. Never steer the machine while on the ramp. If the
traveling direction must be changed while the
ramp, unload the machine from the ramp, repo-
sition the machine on the ground, and then try
loading again.
7. The top end of the ramp where it meets the flat-
bed is a sudden bump. Take care when traveling
over it.
8. Place blocks in front of and behind the tracks.
Securely hold the machine to the truck or trailer
deck with wire ropes.
Be sure to further follow the details described in the

TRANSPORTING section in the operator's manual.
035-E07A-0454
SA-23
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
• Understand service procedures before starting
work.
• Keep the work area clean and dry.
• Do not spray water or steam inside cab.
• Never lubricate or service the machine while it is
moving.
• Keep hands, feet and clothing away from
power-driven parts.
Before servicing the machine:

1. Park the machine on a level surface.
2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.
4. Run the engine at slow idle speed without load
for 5 minutes.
5. Turn the key switch to OFF to stop engine.
SA-028
6. Relieve the pressure in the hydraulic system by
moving the control levers several times.
7. Remove the key from the switch.
8. Attach a "Do Not Operate" tag on the control
lever.
9. Pull the pilot control shut-off lever to the LOCK
position.
10. Allow the engine to cool.
500-E02C-0520
SA-527
SA-24
SAFETY
• If a maintenance procedure must be performed
with the engine running, do not leave machine
unattended.
• If the machine must be raised, maintain a 90 to
100° angle between the boom and arm. Securely
support any machine elements that must be
raised for service work.
• Inspect certain parts periodically and repair or re-
place as necessary. Refer to the section discuss-
ing that part in the "MAINTENANCE" chapter of
this manual.
•
SA-037
Keep all parts in good condition and properly in-
stalled.
• Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or de-
bris.
• When cleaning parts, always use nonflammable
detergent oil. Never use highly flammable oil such
as fuel oil and gasoline to clean parts or surfaces.
• Disconnect battery ground cable (-) before mak-
ing adjustments to electrical systems or before
performing welding on the machine.
• Sufficiently illuminate the work site. Use a main-
tenance work light when working under or inside
the machine.
• Always use a work light protected with a guard. In
case the light bulb is broken, spilled fuel, oil, anti-
freeze fluid, or window washer fluid may catch
fire.
WARN OTHERS OF SERVICE WORK

• Unexpected machine movement can cause serious
injury.
• Before performing any work on the machine, at-

tach a "Do Not Operate" tag on the control lever.
This tag is available from your authorized dealer.
501-E01A-0287
T1J1-01-01-001
SA-25
SAFETY
SUPPORT MACHINE PROPERLY
• Never attempt to work on the machine without se-
curing the machine first.
• Always lower the attachment to the ground before

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

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

ensure that hands, feet, clothing, jewelry and hair
do not become entangled when working around
rotating parts.
502-E01A-0026
SA-026
SA-26
SAFETY
PREVENT PARTS FROM FLYING
• Grease in the track adjuster is under high pressure.
Failure to follow the precautions below may result in
serious injury, blindness, or death.
• Do not attempt to remove GREASE FITTING or

VALVE ASSEMBLY.
face away from valve.
• Never attempt to disassemble the track adjuster.
Inadvertent disassembling of the track adjuster
may cause the parts such as a spring to fly off,
possibly resulting in severe personal injury or
death.
SA-344
• Travel reduction gears are under pressure.

face away from AIR RELEASE PLUG to avoid
injury.
• GEAR OIL is hot. Wait for GEAR OIL to cool, and
then gradually loosen AIR RELEASE PLUG to
release pressure.
503-E01B-0344
STORE ATTACHMENTS SAFELY

• Stored attachments such as buckets, hydraulic
hammers, and blades can fall and cause serious
injury or death.
• Securely store attachments and implements to

prevent falling. Keep children and bystanders
away from storage areas.
504-E01A-0034
SA-034
SA-27
SAFETY
PREVENT BURNS
Hot spraying fluids:
• After operation, engine coolant is hot and under

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

DO NOT remove the radiator cap until the engine
is cool. When opening, turn the cap slowly to the
stop. Allow all pressure to be released before
removing the cap. SA-039
• The hydraulic oil tank is pressurized. Again, be

sure to release all pressure before removing the
cap.
Hot fluids and surfaces:
• Engine oil, gear oil and hydraulic oil also become

hot during operation.
The engine, hoses, lines and other parts become
hot as well.
• Wait for the oil and components to cool before SA-225

starting any maintenance or inspection work.
505-E01B-0498
REPLACE RUBBER HOSES PERIODI-

CALLY
• Rubber hoses that contain flammable fluids under
pressure may break due to aging, fatigue, and
abrasion. It is very difficult to gauge the extent of
deterioration due to aging, fatigue, and abrasion of
rubber hoses by inspection alone.
• Periodically replace the rubber hoses. (See the

page of "Periodic replacement of parts" in the
operator's manual.)
• Failure to periodically replace rubber hoses may

cause a fire, fluid injection into skin, or the front
attachment to fall on a person nearby, which may SA-019
result in severe burns, gangrene, or otherwise

serious injury or death.
S506-E01A-0019
SA-28
SAFETY
AVOID HIGH-PRESSURE FLUIDS
• Fluids such as diesel fuel or hydraulic oil under
pressure can penetrate the skin or eyes causing se-
rious injury, blindness or death.
• Avoid this hazard by relieving pressure before

disconnecting hydraulic or other lines.
• Tighten all connections before applying pressure.
• Search for leaks with a piece of cardboard; take
care to protect hands and body from
high-pressure fluids. Wear a face shield or gog-
gles for eye protection.
• If an accident occurs, see a doctor familiar with
this type of injury immediately. Any fluid injected
into the skin must be surgically removed within a SA-031
few hours or gangrene may result.
507-E03A-0499
SA-292
SA-044
SA-29
SAFETY
PREVENT FIRES
Check for Oil Leaks:
• Fuel, hydraulic oil and lubricant leaks can lead to
fires.
• Check for oil leaks due to missing or loose clamps,
kinked hoses, lines or hoses that rub against each
other, damage to the oil-cooler, and loose
• Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and
• Do not bend or strike high-pressure lines.
• Never install bent or damaged lines, pipes, or
hoses.
SA-019
Check for Shorts:

• Short circuits can cause fires.
• Clean and tighten all electrical connections.
hours operation for loose, kinked, hardened or
frayed electrical cables and wires.
hours operation for missing or damaged terminal
caps.
• DO NOT OPERATE MACHINE if cable or wires
are loose, kinked, etc..
Clean up Flammables:
• Spilled fuel and oil, and trash, grease, debris, ac-
cumulated coal dust, and other flammables may
cause fires.
• Prevent fires by inspecting and cleaning the ma-
chine daily and by removing spilled or accumu-
lated flammables immediately.
Check Key Switch:
• If a fire breaks out, failure to stop the engine will
escalate the fire, hampering fire fighting.
Always check key switch function before operating
the machine every day:
1. Start the engine and run it at slow idle.
2. Turn the key switch to the OFF position to con-
firm that the engine stops.
• If any abnormalities are found, be sure to repair
them before operating the machine.
508-E02B-0019
Check Heat Shields:

• Damaged or missing heat shields may lead to fires.
• Damaged or missing heat shields must be re-
paired or replaced before operating the machine.
508-E02A-0393
SA-30
SAFETY
EVACUATING IN CASE OF FIRE
• If a fire breaks out, evacuate the machine in the fol-
lowing way:
• Stop the engine by turning the key switch to the

OFF position if there is time.
• Use a fire extinguisher if there is time.
• Exit the machine.
• In an emergency, if the cab door or front window
cannot be opened, break the front or rear window
panes with the emergency evacuation hammer to
escape from the cab. Refer the explanation pages SA-393
on the Emergency Evacuation Method in the op-

erator's manual.
18-E02B-0393
SS-1510
BEWARE OF EXHAUST FUMES

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

adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open
doors and windows to bring enough outside air
into the area.
509-E01A-0016
SA-016
PRECAUTIONS FOR WELDING AND

GRINDING
• Welding may generate gas and/or small fires.
• Be sure to perform welding in a well ventilated

and prepared area. Store flammable objects in a
safe place before starting welding.
• Only qualified personnel should perform welding.
Never allow an unqualified person to perform
welding.
• Grinding on the machine may create fire hazards.
Store flammable objects in a safe place before
starting grinding.
• After finishing welding and grinding, recheck that
there are no abnormalities such as the area sur- SA-818
rounding the welded area still smoldering.
523-E01A-0818
SA-31
SAFETY
AVOID HEATING NEAR PRESSURIZED
FLUID LINES
• Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to
yourself and bystanders.
• Do not heat by welding, soldering, or using a torch

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

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

HEATING
• Hazardous fumes can be generated when paint is
heated by welding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.
• Avoid potentially toxic fumes and dust.

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

1. If you sand or grind paint, avoid breathing the
dust.
Wear an approved respirator. SA-029
2. If you use solvent or paint stripper, remove

stripper with soap and water before welding.
Remove solvent or paint stripper containers and
other flammable material from area. Allow fumes
to disperse at least 15 minutes before welding or
heating.
511-E01A-0029
SA-32
SAFETY
BEWARE OF ASBESTOS DUST
• Take care not to inhale dust produced in the work
site. Inhalation of asbestos fibers may be the cause
of lung cancer.
• Depending on the wok site conditions, the risk of

inhaling asbestos fiber may exist. Spray water to
prevent asbestos from becoming airborne. Don't
use compressed air.
• When operating the machine in a work site where
asbestos might be present, be sure to operate the
machine from the upwind side and wear a mask
rated to prevent the inhalation of asbestos.
• Keep bystanders out of the work site during op-
eration. SA-029
• Asbestos might be present in imitation parts. Use

only genuine Hitachi Parts.
PREVENT BATTERY EXPLOSIONS

• Battery gas can explode.
• Keep sparks, lighted matches, and flame away

from the top of battery.
• Never check battery charge by placing a metal
object across the posts. Use a voltmeter or hy-
drometer.
• Do not charge a frozen battery or start engine with
frozen battery.
There is fear of explosion. If battery electrolyte is
frozen, wait until it is liquefied completely in an
atmospheric temperature room.
• Do not continue to use or charge the battery when
electrolyte level is lower than specified. Explosion SA-032
of the battery may result.

• Loose terminals may produce sparks. Securely
tighten all terminals.
• Battery electrolyte is poisonous. If the battery should

explode, battery electrolyte may be splashed into
eyes, possibly resulting in blindness.
• Be sure to wear eye protection when checking

electrolyte specific gravity.
512-E01B-0032
SA-33
SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY
• If spilled onto skin, refrigerant may cause a cold
contact burn.
• Refer to the instructions described on the con-

tainer for proper use when handling the refriger-
ant.
• Use a recovery and recycling system to avoid
leaking refrigerant into the atmosphere.
• Never touch the refrigerant.
513-E01A-0405
SA-405
HANDLE CHEMICAL PRODUCTS SAFELY

• Direct exposure to hazardous chemicals can cause
serious injury. Potentially hazardous chemicals used
with your machine include such items as lubricants,
coolants, paints, and adhesives.
• A Material Safety Data Sheet (MSDS) provides

specific details on chemical products: physical
and health hazards, safety procedures, and
emergency response techniques.
• Check the MSDS before you start any job using a
hazardous chemical. That way you will know ex-
actly what the risks are and how to do the job
safely. Then follow procedures and use recom- SA-309
mended equipment.
• See your authorized dealer for MSDS's (available
only in English) on chemical products used with
your machine.
515-E01A-0309
SA-34
SAFETY
DISPOSE OF WASTE PROPERLY
• Improperly disposing of waste can threaten the en-
vironment and ecology. Potentially harmful waste
used with HITACHI equipment includes such items
as oil, fuel, coolant, brake fluid, filters, and batteries.
• Use leakproof containers when draining fluids. Do

not use food or beverage containers that may
mislead someone into drinking from them.
• Do not pour waste onto the ground, down a drain,
or into any water source.
• Air conditioning refrigerants escaping into the air
can damage the Earth's atmosphere. Govern-
ment regulations may require a certified air condi- SA-226
tioning service center to recover and recycle used

air conditioning refrigerants.
• Inquire on the proper way to recycle or dispose of
waste from your local environmental or recycling
center, or from your authorized dealer.
516-E01A-0226
BEFORE RETURNING THE MACHINE TO

THE CUSTOMER
• After maintenance or repair work is complete,
confirm that:
• The machine is functioning properly, especially

the safety systems.
• Worn or damaged parts have been repaired or
replaced
S517-E01A-0435
SA-435
SA-35
SAFETY
(Blank)
SA-36
SECTION 1 GENERAL INFORMATION
SECTION AND GROUP
CONTENTS Group 1 Precautions for disassembling
and Assembling
Group 2 Tightening Torque
Group 3 Painting
Group 4 Bleeding Air from Hydraulic Oil
Tank
WORKSHOP MANUAL SECTION 2 UPPERSTRUCTURE
Group 1 Cab
Group 2 Counterweight
Group 3 Main Frame
Group 4 Pump Device
Group 7 Pilot Valve
Group 12 Fan Valve
Group 13 Fan Motor
Group 14 Engine
SECTION 3 UNDERCARRIAGE
Group 1 Swing Bearing
All information, illustrations and speci-
fications in this manual are based on Group 2 Travel Device
the latest product information available
at the time of publication. The right is
Group 3 Center Joint
reserved to make changes at any time Group 4 Track Adjuster
without notice.
Group 5 Front Idler
Group 6 Upper and Lower Roller
Group 7 Track
COPYRIGHT(C)2006 SECTION 4 FRONT ATTACHMENT
Tokyo, Japan
Group 1 Front Attachment
All rights reserved
Group 2 Cylinder
TECHNICAL MANUAL (Operational Principle)
SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION
Group 1 Specification Group 1 Pump Device
Group 2 Component Layout Group 2 Swing Device
Group 3 Component Specifications Group 3 Control Valve
SECTION 2 SYSTEM Group 4 Pilot Valve
Group 1 Controller Group 5 Travel Device
Group 2 Control System Group 6 Signal Control Valve
Group 3 ECM System Group 7 Others (Upperstructure)
Group 4 Hydraulic System Group 8 Others (Undercarriage)
TECHNICAL MANUAL (Troubleshooting)

SECTION 4 OPERATIONAL PER- SECTION 5 TROUBLESHOOTING
FORMANCE TEST Group 1 Diagnosing Procedure
Group 1 Introduction Group 2 Monitor Unit
Group 2 Standard Group 3 Dr. ZX
Group 3 Engine Test Group 4 ICF
Group 4 Excavator Test Group 5 Component Layout
Group 5 Component Test Group 6 Troubleshooting A
Group 6 Adjustment Group 7 Troubleshooting B
SECTION 1
GENERAL
 CONTENTS 
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling.............................................T1-1-1
Group 2 Tightening Torque

Tightening Torque Specification .............. W1-2-1
Torque Chart .......................................... W1-2-3
Piping Joint ............................................ W1-2-6
Periodic Replacement of Parts ............. W1-2-10
Group 3 Painting
Painting .................................................. W1-3-1
Group 4 Bleeding Air from Hydraulic Oil

Tank
Bleeding Air from Hydraulic Oil Tank....... W1-4-1
1J1W-1-1
(Blank)
1J1W-1-2
GENERAL / Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING
Precautions for Disassembling and Assembling
• Clean the Machine • Precautions for Disassembling
Thoroughly wash the machine before bringing it into • To prevent dirt from entering, cap or plug the
the shop. Bringing a dirty machine into the shop removed pipes.
may cause machine components to be • Before disassembling, clean the exterior of the
contaminated during disassembling/assembling, components and place on a work bench.
resulting in damage to machine components, as • Before disassembling, drain gear oil from the
well as decreased efficiency in service work. reduction gear.
• Be sure to provide appropriate containers for
draining fluids.
• Inspect the Machine • Use matching marks for easier reassembling.
• Be sure to use the specified special tools, when
Be sure to thoroughly understand all disassem-bling instructed.
/ assembling procedures beforehand, to help avoid • If a part or component cannot be removed after
incorrect disassembling of components as well as removing its securing nuts and bolts, do not
personal injury. attempt to remove it forcibly. Find the cause(s),
Be sure to and record the items listed below to then take the appropriate measures to remove it.
prevent problems from occurring in the future. • Orderly arrange disassembled parts. Mark and
tag them as necessary.
• The machine model, machine serial number, and • Store common parts, such as bolts and nuts with
hour meter reading. reference to where they are to be used and in a
• Reason for disassembly (symptoms, failed parts, manner that will prevent loss.
and causes). • Inspect the contact or sliding surfaces of
• Clogging of filters and oil, water or air leaks, if disassembled parts for abnormal wear, sticking,
any. or other damage.
• Capacities and condition of lubricants. • Measure and record the degree of wear and
• Loose or damaged parts. clearances.
• Prepare and Clean Tools and Disassembly Area
Prepare the necessary tools to be used and the

area for disassembling work.
W1-1-1
• Precautions for Assembling Bleeding Air from Hydraulic System
• Be sure to clean all parts and inspect them for When hydraulic oil is drained, the suction filter or the
any damage. If any damage is found, repair or suction lines are replaced, or the removal and instal-
replace part. lation of the pump, swing motor, travel motor or cyl-
• Dirt or debris on the contact or sliding surfaces inder is done, bleed air from the hydraulic system in
may shorten the service life of the machine. Take the following procedures:
care not to contaminate any contact or sliding
surfaces. IMPORTANT: If the engine is started with air
• Before assenbling, coat all inner parts with clean trapped in the hydraulic pump hous-
hydraulic oil or gear oil. Especially coat the sliding ing, damage to the pump may result.
surfaces with clean hydraulic oil or gear oil. If the hydraulic motor is operated
• Be sure to replace O-rings, backup rings, and oil
with air trapped in the hydraulic
seals with new ones once they are disassembled.
motor housing, damage to the motor
Apply a film of grease before installing.
may result.
• Check that liquid-gasket-applied surfaces are
clean and dry. If the cylinder is operated with air
• If an anti-corrosive agent has been used on a trapped in the cylinder tube, damage
new part, be sure to thoroughly clean the part to to the cylinder may result.
remove the agent. Be sure to bleed air before starting
• Utilize matching marks when assembling. the engine.
• Be sure to use the designated tools to assemble
bearings, bushings and oil seals. • Bleeding Air from Hydraulic Pump
• Keep a record of the number of tools used for
disassembly / assembly. After assembling is • Remove the air bleeding plug from the top of the
complete, count the number of tools, so as to pump and fill the pump housing with hydraulic oil.
make sure that no forgotten tools remain in the • After the pump housing is filled with hydraulic oil,
assembled machine. temporarily tighten the plug. Then, start the en-
gine and run at slow idle speed.
• Slightly loosen the plug to bleed air from the
pump housing until hydraulic oil oozes out.
• After bleeding all the air, securely tighten the plug.
• Bleeding Air from Travel Motor / Swing Motor
• With the drain plug / hose on travel motor / swing

motor removed, fill the motor case with hydraulic
oil.
W1-1-2
• Bleeding Air from Hydraulic Circuit
• After refilling hydraulic oil, start the engine. While

operating each cylinder, swing motor and travel
motor evenly, operate the machine under light
loads for 10 to 15 minutes. Slowly start each op-
eration (never fully stroke the cylinders during ini-
tial operation stage). As the pilot oil circuit has an
air bleed device, air trapped in the pilot oil circuit
will be bled while performing the above operation M104-07-021
for approx. 5 minutes.
• Reposition the front attachment to check hydrau-
lic oil level.
• Stop the engine. Recheck hydraulic oil level. Re-
plenish oil as necessary.
W1-1-3
Floating Seal Precautions
A
1. In general, replace the floating seal with a new
one after disassembling.
If the floating seal is to be reused, follow these
procedures:
(1) Keep seal rings together as a matched set with

seal ring faces together. Insert a piece of
cardboard to protect surfaces.
(2) Check the slide surface on seal ring (A) for

scuffing, scoring, corrosion, deformation or B W105-03-05-019
uneven wear.
(3) Check O-ring (B) for tears, breaks,

deformation or hardening.
2. If incorrectly assembled, oil leakage or damage

will occur. Be sure to do the following, to prevent
trouble.
(1) Clean the floating seal and seal mounting

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

bores. Check the bore surface for scuffing or
scoring by touching the surface with touch.
(3) Check that the O-ring is not twisted, and that it

is installed correctly on the seal ring.
W105-03-05-020
Correct C Incorrect
(4) After installing the floating seal, check that seal
ring surface (A) is parallel with seal mating a a
face (C) by measuring the distances (A) and
A
(C) at point (a) and (b), as illustrated. If these
distances differ, correct the O-ring seating.
B
b b
a=b a≠b
W110-03-05-004
W1-1-4
Precautions for Using Nylon Sling
1. Follow the precautions below to use nylon slings

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

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

• When using with other types of slings (wire rope)
or accessories (shackle), protect the joint so that
the nylon sling is not damaged.
• Store the nylon slings indoors so they won’t dete-
riorate with heat, sun light, or chemicals.
Bent Sling W162-01-01-009
W1-1-5
Damaged Appearance
CAUTION: If a load is lifted with a damaged Broken Sewing Thread
nylon sling, serious personal injury may re-
sult. Be sure to visually check the nylon sling
for any damage before using.
W162-01-01-002
Scuffing
2. Before using a nylon sling, visually check the ny-
lon sling for any damage corresponding to exam-
ples shown to the right. If any damage is found,
cut and discard the sling. Even if no damage is
found, do not use slings older than 7-years. W162-01-01-003
Fuzz
Broken Sewing
Thread
W162-01-01-004
Broken Sewing
Thread
W162-01-01-005
Broken Sewing
Thread
Separation of W162-01-01-006
Scoring
Belt
W162-01-01-007
Fuzz Scuffing
Broken Warp
W162-01-01-008
W1-1-6
MAINTENANCE STANDARD TERMINOLOGY
“Standard”
1. Dimension for parts on a new machine.
2. Dimension of new components or assemblies

adjusted to specification.
“Allowable Limit”
1. Normal machine performance cannot be accom-
plished after exceeding this limit.
2. Repair or adjustment is impossible after exceed-

ing this limit.
3. Therefore, in consideration of operation efficiency

and maintenance expense, proper maintenance
shall be carried out before reaching the “Allow-
able Limit”.
W1-1-7
(Blank)
W1-1-8
GENERAL / Tightening
TIGHTENING TORQUE SPECIFICATION
Bolt Dia Wrench Torque

No. Descriptions Q’ty
mm Size (mm) Nxm (kgfxm) (lbfxft)
Engine cushion Front 27 2 41 1050 (105) (775)
1 rubber mount- Engine - cushion rubber 22 2 32 750 (76.5) (550)
Rear
ing bolt Cushion rubber-machine 18 4 27 400 (41.0) (295)
2 Engine bracket mounting bolt 14 8 22 210 (21) (155)
3 Radiator mounting bolt 20 4 30 550 (56) (405)
4 Hydraulic oil tank mounting bolt 16 8 24 210 (21.5) (155)
5 Fuel tank mounting bolt 16 8 24 210 (21.5) (155)
1− 3 −12UNF 180 (18.0) (135)
16 36
6 ORS fittings for hydraulic hoses and piping
1 − 7 −12UNF 41 210 (21.0) (155)
16
7 Pump device mounting bolt 12 12 19 98 (9.2) (66)
8 Fan pump mounting bolt 18 4 14 holes 230 (23) (170)
9 Fan motor mounting nut 12 2 19 110 (11) (81.0)
10 Control valve mounting bolt 20 4 30 400 (41.0) (295)
11 Control valve bracket mounting bolt 20 6 30 400 (41.0) (295)
12 Swing device mounting bolt 22 26 32 750 (76.5) (550)
13 Swing motor mounting bolt 18 24 14 300 (30.5) (220)
14 Battery mounting nut 12 2 19 35 (3.5) (26)
15 Cab mounting nut 16 6 24 210 (21.5) (155)
16 Cab anchor bolt 22 2 32 550 (55) (405)
Swing bearing mounting bolt to upperstructure 30 36 46 1950 (195) (1440)
17
Swing bearing mounting bolt to undercarriage 27 36 41 1400 (143) (1030)
Travel device mounting bolt 22 48 32 750 (76.5) (550)
18 Travel motor mounting bolt 18 8 27 300 (30.5) (220)
Sprocket mounting bolt 22 48 32 750 (76.5) (550)
450-3, 470H-3,
Upper roller mounting 18 24 27 400 (41.0) (295)
19 450LC-3, 470LCH-3
bolt
500LC-3, 520LCH-3 20 24 30 550 (55) (405)
450-3, 470H-3 22 64 32 750 (76.5) (550)
Lower roller mounting
20 450LC-3, 470LCH-3 22 72 32 750 (76.5) (550)
bolt
500LC-3, 520LCH-3 24 64 36 950 (95) (700)
450-3, 470H-3 24 392 32 1400 (143) (1030)
21 Track shoe bolt 450LC-3, 470LCH-3 24 424 32 1400 (143) (1030)
500LC-3, 520LCH-3 24 392 32 1400 (143) (1030)
450-3, 450LC-3 22 16 32 750 (76.5) (550)
470H-3 22 28 32 750 (76.5) (550)
Track guard mount-
22 470LCH-3 22 40 32 950 (95) (700)
ing bolt
500LC-3 22 16 36 750 (76.5) (550)
520LCH-3 24 28 36 950 (95) (700)
(LC, LCH) 33 36 50 1750 (178) (1290)
23 Track mounting bolt
MT, MTH 33 36 50 2200 (224) (1620)
8 13 205 to (1.05 to (7.7 to
Flex master coupling
24 Low-pressure piping 12.5 1.26) 9.2)
T bolt clamp 1/4-28 UNF 11 10 (1.0) (7.4)
W1-2-1
Bolt Dia Wrench Torque

No. Descriptions Q’ty
mm Size (mm) Nxm (kgfxm) (lbfxft)
45 2 65 2400 (240) (1730)
25 Counterweight mounting bolt
24 4 36 450 (45.0) (325)
26 Signal control valve mounting bolt 10 4 8 holes 50 (5.1) (37)
Front pin-retaining bolt 20 15 30 400 (41.0) (295)
27
Front pin-retaining nut 20 7 30 400 (41.0) (295)
NOTE: 1. Apply lubricant (e.g. white zinc B dis-

solved into spindle oil) to bolts and nuts to
reduce friction coefficient of them.
2. Make sure bolt and nut threads are
clean before installing.
W1-2-2
TORQUE CHART
CAUTION: Use tools appropriate for the

work to be done. Makeshift tools and proce-
dures can create safety hazards. For loosen-
ing and tightening nuts and bolts, use cor-
rect size tools. Otherwise, tightening tools
may slip, potentially causing personal injury.
Bolt Types
Tighten nuts or bolts correctly to torque specifications.

Make sure to employ correct bolts and tighten them SA-040
correctly when assembling the machine or compo-

nents.
Hexagon T Bolt Hexagon H Bolt Hexagon M Bolt Socket Bolt
W162-01-01-001
Specified Tightening Torque Chart
Hexagon
Wrench
Bolt Dia. Wrench
Size
Size M552-07-091 M552-07-090 M552-07-092
Socket Bolt
N⋅m (kgf⋅m) (lbf⋅ft) N⋅m (kgf⋅m) (lbf⋅ft) N⋅m (kgf⋅m) (lbf⋅ft)
M6 10 5 3.3 to 4.2 (0.3 to 0.4) (2.4 to 3.0)
M8 13 6 30 (3.0) (21.5) 20 (2.0) (14.5) 10 (1.0) (7.2)
M10 17 8 65 (6.5) (47) 50 (5.0) (36) 20 (2.0) (14.5)
M12 19 10 110 (11) (80) 90 (9.0) (65) 35 (3.5) (25.5)
M14 22 12 180 (18) (130) 140 (14) (101) 55 (5.5) (40)
M16 24 14 270 (27) (195) 210 (21) (152) 80 (8.0) (58)
M18 27 14 400 (40) (290) 300 (30) (215) 120 (12) (87)
M20 30 17 550 (55) (400) 400 (40) (290) 170 (17) (123)
M22 32 750 (75) (540) 550 (55) (400) 220 (22) (159)
M24 36 950 (95) (690) 700 (70) (510) 280 (28) (205)
M27 41 1400 (140) (1010) 1050 (105) (760) 400 (40) (290)
M30 46 1950 (195) (1410) 1450 (145) (1050) 550 (55) (400)
M33 50 2600 (260) (1880) 1950 (195) (1410) 750 (75) (540)
M36 55 3200 (320) (2310) 2450 (245) (1770) 950 (95) (690)
W1-2-3
IMPORTANT: The following items are applied to
both fine and coarse pitch threads.
1. Apply lubricant (i. e. white zinc B
dissolved Into Spindle oil) to
nuts and bolts to reduce their
friction coefficients.
The plated bolts require no lu-
bricant.
2. Torque tolerance is ±10 %.
3. Be sure to use bolts of correct
length. Bolts that are too long
cannot be tightened, as the bolt
tip comes into contact with the
bottom of the bolt hole. Bolts
that are too short cannot develop
sufficient tightening force.
4. The torques given in the chart
are for general use only. Do not
use these torques if a different
torque is given for a specific ap-
plication.
5. Make sure that nut and bolt
threads are clean before install-
ing.
Remove dirt or corrosion, if any.
Bolt Tightening Order
When tightening two or more bolts, tighten them al-

ternately, as shown, to ensure even tightening.
Tighten from center and diagonally
Equally tighten upper and lower alternately Tighten diagonally
1 12 9 4 1 6 7 14
6 3
1st to 4th
4 5
2 13 8 5 2 3 10 11
2nd to 3rd
W105-01-01-003
W1-2-4
Service Recommendations for Split Flange
IMPORTANT: 1. Be sure to clean and inspect

sealing surfaces. Scratches /
roughness cause leaks and seal
wear.
Unevenness causes seal extru-
sion. If defects cannot be pol-
ished out, replace the compo-
W105-01-01-015
nent.
WRONG
2. Be sure to use only specified
O-rings. Inspect O-rings for any
damage. Take care not to file
O-ring surfaces. When installing
an O-ring into a groove, use
grease to hold it in place.
3. While lightly tightening split
flange halves, check that split is
W105-01-01-016
centered and perpendicular to
the port. Hand-tighten bolts to
hold parts in place. Take care not
to pinch the O-ring.
4. Tighten bolts alternately and di-
agonally, as shown, to ensure
even tightening.
5. Do not use air wrenches. Using W105-01-01-008
an air wrench often causes RIGHT WRONG

tightening of one bolt fully before
tightening of the others, resulting
in damage to O-rings or uneven
tightening of bolts. Do not bend it round
Bend along edge sharply
Nut and Bolt Locking RIGHT RIGHT WRONG
• Lock Plate
IMPORTANT: Do not reuse lock plates. Do not try
to bend the same point twice.
• Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the Bend along edge sharply
W105-01-01-009
holes in the bolt and nut while tight-
RIGHT RIGHT WRONG
ening, not while loosening.
• Lock Wire
IMPORTANT: Apply wire to bolts in the
bolt-tightening direction, not in the
bolt-loosening direction. Do not re-
Loosen WRONG
use lock wires. RIGHT
Tighten
W105-01-01-010
W1-2-5
PIPING JOINT
IMPORTANT: The torques given in the chart are 1 4 3 5 2

for general use only.
Do not use these torques if a differ-
ent torque is given for a specific ap-
plication.
Union Joint
M202-07-051
Joint Body
Metal sealing surfaces (4) and (5) of adapter (1) and
hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines.
IMPORTANT: 1. Do not over-tighten union nut (3). 37°

Excessive force will be applied to
30°
metal sealing surfaces (4) and (5),
possibly cracking adapter (1). Be
sure to tighten union nut (3) to
specifications. Male Union Joint Female Union Joint
2. Scratches or other damage to
sealing surfaces (4) or (5) will W105-01-01-017
cause oil leakage at the joint.

Take care not to damage them
when connecting/disconnecting.
Wrench Size Wrench Size mm Tightening Torque

Description mm
Union Nut Joint Body N⋅m (kgf⋅m, lbf⋅ft)
30°male 17 17 24.5 (2.5,18)
19 19 29.5 (3.0, 21.5)
22 22 39 (4.0, 28.5)
27 27 78 (8.0, 58)
32 32 137 (14.0,101)
36 36 175 (18.0,129)
41 41 205 (21.0,151)
37°female 17 14 24.5 (2.5,18)
19 17 29.5 (3.0, 21.5)
22 19 39 (4.0, 28.5)
27 22 78 (8.0, 58)
32 27 137 (14.0,101)
36 32 175 (18.0,129)
41 36 205 (21.0,151)
NOTE: Tightening torque of 37° male coupling without union is similar
to tightening torque of 37° female.
W1-2-6
O-ring Seal Joint 9
7 6
O-ring (6) seats against the end surface of adapter (7)

to seal pressure oil.
IMPORTANT: 1. Be sure to replace O-ring (6) with

a new one when reconnecting.
2. Before tightening union nut (9),
confirm that O-ring (6) is seated Joint Body
8 1
correctly in O-ring groove (8). M104-07-033
Tightening union nut (9) with

O-ring (6) displaced will damage
O-ring (6), resulting in oil leak-
age. Wrench Size Wrench Size Tightening Torque
3. Take care not to damage O-ring mm mm
groove (8) or sealing surface Union Nut Joint Body N⋅m (kgf⋅m, lbf⋅ft)
(10). 19 17 29.5 (3.0, 21.5)
Damage to O-ring (6) will cause 22 19 69 (7.0, 51)
oil leakage. 27 22 93 (9.5, 69)
4. If union nut (9) is loose and oil is 32 27 137 (14.0,101)
leaking, do not re-tighten union 36 30,32 175 (18.0,129)
nut (9). Replace O-ring (6) with a 41 36 205 (21.0,151)
new one and check that O-ring 46 41 205 (21.0,151)
(6) is correctly seated in place,
tighten union nut (9).
W1-2-7
Screw-In Connection
PT PF
Depending on types of screw and sealing, different 30°
types of screw fittings are used.
IMPORTANT: Be sure to confirm that the thread

pitch and thread type (tapered or
straight) are the correct type before Male Tapered Thread Male Straight Thread
using any screw-in connection.
W105-01-01-018
Male Tapered Thread

Wrench Size Tightening Torque
mm N⋅m (kgf⋅m, lbf⋅ft)
Joint Body FC material SS material
19 14.5 (1.5,10.5) 34 (3.5, 25)
22 29.5 (3.0, 21.5) 49 (5.0, 36)
27 49 (5.0, 36) 93 (9.5, 69)
36 69 (7.0, 51) 157 (16,116)
41 108 (11, 80) 205 (21,151)
50 157 (16,116) 320 (33, 235)
60 195 (20,144)
Seal Tape Application
Internal Thread
Seal tape is used to seal clearances between male
and female threads, so as to prevent any leaks be-
tween threads.
Be sure to apply just enough seal tape to fill up thread External Thread
Clearance
clearances. Do not overwrap.
• Application Procedure W105-01-01-019
Leave one to two pitch threads uncovered

Confirm that the thread surface is clean and, free of
dirt or damage.
Apply seal tape around threads as shown. Wrap seal
tape in the same direction as the threads.
Low-Pressure-Hose Clamp Tightening Torque
Low-pressure-hose clamp tightening torque differs

depending on the type of clamp. M114-07-041
T-Bolt Type Band Clamp:
4.4 N⋅m (0.45 kgf⋅m, 3.25 lbf⋅ft)
T-Bolt Type Worm Gear Type
Worm Gear Type Band Clamp:
5.9 to 6.9 N⋅m (0.6 to 0.7 kg⋅m, 4.3 to 5.1 lbf⋅ft)
M114-07-043 M114-07-042
W1-2-8
Connecting Hose
WRONG RIGHT
CAUTION: When replacing hoses, be sure to
use only genuine Hitachi service parts. Using
hoses other than genuine Hitachi hoses may
cause oil leaks, hose rupture or Separation of
fitting, possibly resulting in a fire on the ma-
chine.
Do not install hoses kinked. Application of W105-01-01-011

high oil pressure, vibration, or an impact to a
kinked hose may result in oil leaks, hose
rupture or separation of fitting. Utilize Print WRONG RIGHT
marks on hoses when installing to prevent Rubbing Against
hose from being kinked. Each Other
If hoses rub against each other, wear to the

hoses will result, leading to hose rupture.
Take necessary measures to protect hoses
from rubbing against each other. W105-01-01-012
WRONG RIGHT
Take care so that hoses do not come into
contact with moving parts or sharp objects. Clamp Clamp
Rubbing Against
Each Other
W105-01-01-013
WRONG RIGHT
Rubbing Against
Each Other Clamp
W105-01-01-014
W1-2-9
PERIODIC REPLACEMENT OF PARTS
The parts listed below deteriorate as the machine

ages and are worn out or fatigued by repeated loads,
resulting in possible severe personal injury and/or
machine trouble. The service life of these parts can-
not be detected through machine operation or visual
inspection.
Therefore, these parts should be replaced at regular
intervals even if no abnormalities are noticed. In case
any abnormalities are found on a part at any time
regardless of its specified replacement interval, im-
mediately replace the part.
Replacement
Periodic Replacement Parts
Intervals
Fuel hose (Fuel tank to filter) Every 2 years or 6000 hours
Engine Fuel hose (Fuel tank to injection pump) Every 2 years or 6000 hours
Heater hose (Heater to engine) Every 2 years or 6000 hours
Pump suction hose Every 2 years or 6000 hours
Pump delivery hose Every 2 years or 6000 hours
Basic Machine
Swing hose Every 2 years or 6000 hours
Hydraulic Travel hose Every 2 years or 6000 hours
System Boom cylinder line hose Every 2 years or 6000 hours
Front-End Arm cylinder line hose Every 2 years or 6000 hours
Attachment Bucket cylinder line hose Every 2 years or 6000 hours
Pilot hose Every 2 years or 6000 hours
NOTE: Be sure to replace seals, such as O-rings

and gaskets, when replacing hoses.
W1-2-10
GENERAL / Painting
PAINTING
Painting specification
Surfaces to Be Painted Painting Colour
• Main surface of upperstructure YR-01 [TAXI yellow]
Bed cover YR-01[TAXI yellow]
Inner surface Grey
• Front attachment YR-01 [TAXI yellow]
• Track (undercarriage) N1.0 [Black]
• A part of rear left of cab Shining silver
Final painted color

• Inside and outside surface of cab High Grade Beige Deep
• Right window beam, U-Bolt [KASAI PAINT LF-113-230B
(Charcoal series black, half glossy)]
• Suspension lifter (chair bottom) [N2.0 (Black)]
• Lever (travel, pilot shut-off, foot rest) High Frade Black
• Floor plate Grey [Cation]
• Grid plate Deep Black
• Handrail and ladder High Grade Beige Deep
• Mirror stay High Grade Black
• Camera cover High Grade Beige Deep
Specified masked position

• Control valve plate • Engine cover catch
• Swing motor plate • Battery cable terminal cover
• Pump plate (main pump / fan pump) • Air cleaner indicator
Camera
Ladder Cover
Handrail
W1J1-01-03-002
W1J1-01-03-001
Front Step including

Handrail, Rear Step
W1-3-1
GENERAL / Painting
Shaded Part: Shining Silver
Align with the panel.
Panel
W1J1-01-03-003
Left Side of Cab
W1J1-01-03-004
(Door) (Rear Panel of Door)
10 W1J1-01-03-005
Painted Range of Door
Track (Undercarriage)
N1.0 (Black)
W178-01-03-008
Engine Cover
(TAXI Yellow)
W1J1-01-03-006
W1-3-2
GENERAL / Bleeding Air from Hydraulic Oil Tank
BLEED AIR FROM HYDRAULIC OIL TANK
CAUTION: Escaping fluid under pressure

may penetrate the skin and eyes, and cause
serious injury. Release the pressure before
removing hydraulic or other lines.
Hot hydraulic oil just after operation may
spout and cause severe burns. Wait for oil in
order to cool before starting any work.
Do not turn the cap on hydraulic oil tank
quickly. The cap may fly off by internal
pressure. Release any remaining pressure
and remove the cap.
Preparation
1. Park the machine on a solid, level surface. Lower

the front attachment onto the ground.
2. Stop the engine. Push the air bleed valve on the

hydraulic oil tank and release any remaining
pressure in the hydraulic oil tank.
3. Remove the cap on the hydraulic oil tank. Install

an adapter of vacuum pump to the cap mounting W104-07-021
part in hydraulic oil tank. Operate the vacuum
pump.
NOTE: Run the vacuum pump continuously while

working in order to maintain negative Vacuum pump
pressure in the hydraulic oil tank.
Hose
Adapter
Air Bleed Valve

W562-02-03-008
W1-4-1
GENERAL / Bleeding Air from Hydraulic Oil Tank
(Blank)
W1-4-2
MEMO
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SECTION 2
UPPERSTRUCTURE
— CONTENTS —
Group 1 Cab Group 5 Control Valve
Remove and Install Cab ......................... W2-1-1 Remove and Install Control Valve...........W2-5-1
Dimensions of Cab Glass....................... W2-1-9 Disassemble Control Valve
(4-Spool Housing Side) .........................W2-5-4
Group 2 Counterweight Assemble Control Valve
Remove and Install Counterweight ........ W2-2-1
(4-Spool Housing Side) .......................W2-5-10
Group 3 Main Frame Disassemble Control Valve
Remove and Install Main Frame ............ W2-3-1 (5-Spool Housing Side) .......................W2-5-16
Assemble Control Valve
Group 4 Pump Device (5-Spool Housing Side) .......................W2-5-20
Remove and Install Pump Device .......... W2-4-1 Disassemble Control Valve (4-Spool
Disassemble Pump Device .................. W2-4-14 Housing Upper and Lower Sides) .......W2-5-26
Assemble Pump Device ....................... W2-4-24 Assemble Control Valve (4-Spool
Maintenance Standard ......................... W2-4-37 Housing Upper and Lower Sides) .......W2-5-32
Allowable Limits for Cylinder Block .. W2-4-38 Disassemble Control Valve (5-Spool
Disassemble Regulator ........................ W2-4-39 Housing Upper and Lower Sides) .......W2-5-40
Assemble Regulator............................. W2-4-42 Assemble Control Valve (5-Spool
Disassemble Fan Pump ....................... W2-4-46 Housing Upper and Lower Sides) .......W2-5-46
Assemble Fan Pump............................ W2-4-53 Disassemble Control Valve
Maintenance Standard (Fan Pump) ..... W2-4-59 (4-Spool Control Valve) .......................W2-5-52
Disassemble Regulator (Fan Pump) .... W2-4-60 Assemble Control Valve
Assemble Regulator (Fan Pump)......... W2-4-64 (4-Spool control Valve)........................W2-5-56
Structure of Pilot Pump ........................ W2-4-70 Disassemble Control Valve
(5-Spool Control Valve) .......................W2-5-58
(5-Spool control Valve)........................W2-5-62
Disassemble Control Valve
(Housing Front and Rear Sides) .........W2-5-64
(Housing Front and Rear Sides) .........W2-5-66
Disassemble Housing...........................W2-5-68
Assemble Housing................................W2-5-70
1J1W-2-1
Group 6 Swing Device Group 12 Fan Valve
Remove and Install Swing Device.......... W2-6-1 Remove and Install Fan Valve ..............W2-12-1
Disassemble Swing Device.................... W2-6-4 Structure of Fan Valve ..........................W2-12-4
Assemble Swing Device....................... W2-6-14
Disassemble Swing Motor .................. W2-6-24
Group 13 Fan Motor
Remove and Install Fan Motor..............W2-13-1
Assemble Swing Motor ........................ W2-6-28
Structure of Fan Motor ........................W2-13-25
Maintenance Standard ......................... W2-6-32
Group 14 Engine
Group 7 Pilot Valve
Remove and Install Engine.................W2-14-1
Remove and Install Pilot Valve............... W2-7-1
Disassemble Right and Left
Pilot Valves ......................................... W2-7-18
Assemble Right and Left
Pilot Valves ......................................... W2-7-22
Disassemble Travel Pilot Valve ............ W2-7-26
Assemble Travel Pilot Valve ................. W2-7-30

Remove and Install
Pilot Shut-Off Solenoid Valve ............... W2-8-1
Structure of
Pilot Shut-Off Solenoid Valve ............... W2-8-3

Remove and Install Solenoid Valve........ W2-9-1
Structure of Solenoid Valve .................... W2-9-3
Disassemble and Assemble Proportional
Solenoid Valve...................................... W2-9-4

Remove and Install Signal
Control Valve ...................................... W2-10-1
Structure of Signal Control Valve.......... W2-10-3

Remove and Install Shockless Valve ... W2-11-1
Structure of Shockless Valve................ W2-11-3
1J1W-2-2
UPPERSTRUCTURE / Cab
REMOVE AND INSTALL CAB
Removal
CAUTION: Seat (1) weight: 40 kg (88 lb)
1. Remove bolts (2) (2 used). Remove the seat belt 1

from bracket (4).
: 16 mm
2
W1JB-02-01-008
2. Remove socket bolts (3) (4 used) from seat (1).

Remove seat (1) from bracket (4). 1 3
: 6 mm
W1JB-02-07-007
3. Remove mat (6) from the cab inside.

5
6 W1JB-02-07-015
W2-1-1
4. Remove bolts (8) (3 used) and washers (9) (3 7 8, 9 5
used) from bracket (7). Remove bracket (7) from
bracket (10) and cab (5).
: 19 mm
10 W1JB-02-01-003
5. Remove bolts (12) (2 used) from cover (11).

: 13 mm
11
12
W1JB-02-01-004
6. Remove caps (13) (6 used) from cover (11).

Remove screws (14) (6 used) from cover (11). 5
7. Remove cover (11) from cab (5). 13, 14
11
W1JB-02-01-005
13, 14
8. Remove bolts (15) (2 used) from bracket (16) and
cover (17). 15
: 13 mm
9. Remove bolts (19) (2 used) from cover (17). 16

Remove cover (17) from bracket (18).
: 17 mm
17
18
15 19 W1JB-02-01-040
W2-1-2
10. Remove screws (21) (2 used) from cover (20).
20 21
Remove cap (22) and screw (23) from cover (20).
Remove cover (20) from cab (5).
W1JB-02-01-001
22, 23 5
11. Remove bolt (24) from duct (25). Remove duct

(25) from bracket (26). 24 16
: 13 mm
25
26
W1JB-02-01-041
12. Remove bolts (27, 29) (6 used for each). Remove

under covers (28, 30) from the main frame.
: 19 mm
27
28
29
30
W1J1-02-01-002
W2-1-3
13. Remove bolts (33) (2 used), washers (32) (2 Cab
used) and spacers (31) (2 used) from the cab.
: 32 mm
W1J1-02-01-003
31, 32, 33
Bracket 36 5
CAUTION: Cab (5) weight: 550 kg (1210 lb) Bracket
14. Attach a nylon sling onto the bracket and hold cab
(5).
15. Remove nuts (34) (6 used) and washers (35) (6

used) from cab (5).
: 24 mm
34, 35
34, 35
16. Remove socket bolts (36) (6 used) from cab (5).
: 8 mm
36
17. Remove bolts (37) (5 used) and washers (38) (5 34, 35
used) from cab (5). W1JB-02-01-006
: 17 mm
37, 38 36
18. Remove all connectors, plugs and vinyl hoses
from cab (5).
CAUTION: Cab (5) weight: 550 kg (1210 lb)
19. Remove cab (5) from main frame (39).
W1J1-02-01-001
39
W2-1-4
Installation
CAUTION: Cab (5) weight: 550 kg (1210 lb)
1. Attach a nylon sling onto cab (5) and hoist cab (5).
Align cab (5) with the mounting hole on main
frame (39).
W1J1-02-01-001
39
2. Install cab (5) to main frame (39) with bolts (34) (6 Bracket 36 5 Bracket
used) and washers (35) (6 used).
: 24 mm
: 210 N⋅m (21.5 kgf⋅m, 155 lbf⋅ft)
3. Install cab (5) to main frame (39) with socket bolts

(36) (6 used).
: 8 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 34, 35
34, 35
4. Install cab (5) to main frame (39) with bolts (37) (5
used) and washers (38) (5 used). 36
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 34, 35
W1JB-02-01-006
5. Install cab (5) to the lower side of main frame (39) 37, 38 36
with bolts (33) (2 used), washers (32) (2 used)
and spacers (31) (2 used).
: 32 mm
Cab
: 400 N⋅m (40.8 kgf⋅m, 295 lbf⋅ft)
W1J1-02-01-003
31, 32, 33
W2-1-5
6. Install covers (28, 30) to the lower side of main
frame (39) with bolts (27, 29) (6 used for each).
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
27
28
29
30
W1J1-02-01-002
7. Install duct (25) to brackets (16, 26) with bolt (24).

: 13 mm 24 16
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
25
8. Install the connector, plug and vinyl hose to cab
(5).
26
W1JB-02-01-041
W2-1-6
9. Install cover (20) to cab (5) with screws (21) (2 20 21
used). Install cover (20) to cab (5) with screw (23).
Install cap (22) to screw (23).
10. Install bracket (16) to bracket (18) with bolts (15)

(2 used). Install cover (17) to bracket (18) with
bolts (19) (2 used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
W1JB-02-01-001
22, 23 5
15
16
17
18
15 19 W1JB-02-01-040
11. Install cover (11) to cab (5) with bolts (14) (5 used). 5
Install caps (13) (6 used) to screws (14) (6 used).
13, 14
11
13, 14 W1JB-02-01-005
12. Install cover (11) to cab (5) with bolts (12) (2

5
used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
11
12
W1JB-02-01-004
W2-1-7
13. Install bracket (7) to bracket (10) and cab (5) with
bolts (8) (3 used) and washers (9) (3 used). 7 8, 9 5
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
10 W1JB-02-01-003
CAUTION: Seat (1) weight: 40 kg (88 lb) 1 3

Seat Belt
14. Install seat (1) to bracket (4) with socket bolts (3)
(4 used).
: 6 mm
4
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
W1JB-02-07-007
15. Install the seat belt to bracket (4) with bolts (2) (2
used).
: 16 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
Seat Belt
2
W1JB-02-01-008
16. Install mat (6) to the cab (5) inside.

5
6 W1JB-02-07-015
W2-1-8
DIMENSIONS OF THE CAB GLASS
NOTE: Unit: mm (1 mm=0.039 in) Black Ceramic

115 Coating Range
70
21
107
60 2-R50
C0.5 2-R50
2-R250
2-R127 2-R20
2-R10
70
C0.5
Black Ceramic W1JB-02-01-013 106.6 A
Coating Surface 1081
R50
Section A R2975 (4 mm) R800
φ28
R75 B
Black R120
Ceramic R40 20 70
268
Coating
Surface
50 16.5 W1JB-02-01-011
2R-5
271 21
214 21
847
Black Ceramic
Coating Range
R1075
C
372.9
(4 mm)
W1JB-02-01-009 22
50
54.1 25 W1JB-02-01-012
25 84
865
C0.5
W1JB-02-01-014
R2
C0.5
W1JB-02-01-019
Black Ceramic
Section B
Coating Surface
Section C
W2-1-9
NOTE: Unit: mm (1 mm=0.039 in)

375 214
R155
(4 mm) (4 mm)
796.5 796.5 2-φ12.2 +0.5
-0
40
R2852
34.2
267.5
3-R4
50 50
50 234.5 W1JB-02-01-015 W1JB-02-01-016

390 50
13.9
434.5
C0.5
Black Ceramic C0.5

Coating Surface
W1JB-02-01-013
Section A
W1JB-02-01-010
860.8
Black Ceramic 833
Coating Range 506
63.5 581
50 438.5 26.5
2-φ21 353.5
2-R4
R150 64.5
R2854
R50 109.5 336
R25 102.5
A
498.5 448 1
R58 R75 (4 mm) R60 152.5
R250 185
R964 R103
R5031 34
R42 R329
R10
118
R5004 82
327.5
R10 R60 W1JB-02-01-018
173
17
W2-1-10
Black Ceramic
Coating Range
R30 30
39
29
652
87.5 (4 mm) R200
87.5
R200
R500 R500 A
R50 185 185
45
70
R50
205
848
4-R10
W1JB-02-01-021
W1JB-02-01-010
567.5 Black Ceramic

496
Coating Range
C0.5
123.5 80 59.5
3-R4 85
75.5 100 R25
Black Ceramic C0.5
W1JB-02-01-013 R25
Coating Surface
R20 R25 R25 B
87.7° R75
Section A
R4139.5
887 1008
1099
1145.5
(4 R4044.5
mm)
1127.3 19.5
C0.5
R40
R35
R100
R35
W1JB-02-01-014 R550
φ83
C0.5 R135
13°
A
228
112 109°
Section B 105
65° R250
R20 102°
W1JB-02-01-017
R70 R60
76
140
78.5 57 195
447
483
W2-1-11
C1
C1
Black Ceramic W1JB-02-01-013
Coating Surface
Section A
W1JB-02-01-009
1646.47
1599.44
Black Ceramic
187 313.6
Coating Range
R20
80 50
106 R300
2-R25
R2145 50
R30
696.73 R75
50
1230
R2940
900
(5 mm) A
1205
R25
1496.7
R30 90
40 R3025
R30 R50 1636.3
R20 158 R10
873.14
R2875
150 145
R575 R50
R125
R1040 R30 R50
R1525 28°
W1JB-02-01-020
R55 R30
393
400
807.65
963.7
W2-1-12
Procedure to Remove Cab Glass Right-Hand
Glass
Procedures to Remove Right-Hand Glass, Rear Left
Glass, Lower Door Glass and Rear Glass
CAUTION: When removing the broken or
cracked glass, the glass shards may cause
serious injury.
Before removing, use the gummed tape or
something like in order to paste the broken or
cracked glass and reinforce them. Remove
the glass pieces away.
W1JB-02-01-009
1. Remove the resin panel, garnish, spacer or etc.
around the glass.
Rear Glass
Rear
Left-Hand
Garnish Glass
Garnish
Lower Glass Resin Panel W1JB-02-01-010

of Door
Cab
2. Prick a hole in the adhesive by using an awl (or Cab Glass
cutter knife). Awl
Adhesive W1SE-02-01-033
3. Pass a piano wire (or a wire) through the hole.

Piano Wire
(or Metal Wire)
W1SE-02-01-034
W2-1-13
4. Wind the both ends of piano wire onto the
screwdriver. Draw the wire back and forth in order
to cut the adhesive between cab and glass.
Remove the glass from the cab. Cab Glass (Cab Outside)
NOTE: Cut off the middle of adhesive between Cab Glass

glass and cab.
Piano wire is easily broken if a part of piano
wire turns hot. Change the position and cut
the adhesive.
Adhesive
(Cab Inside)
W1SE-02-01-035
W2-1-14
Procedure to Install Cab Glass
Right-Hand Glass
Procedures to Install Right-Hand Glass, Rear

Left-Hand Glass, Lower Door Glass and Rear Glass
1. Cut off the residual adhesive from cab side by 1 to

2 mm deep all around by using a cutter knife or
similar.
NOTE: Do not damage the cab paint.
W1JB-02-01-009
Rear Glass
2. Clean the cutting edge of adhesive at cab side by

using white spirit.
Lower Glass Rear Left-Hand W1JB-02-01-010
of Door Glass
IMPORTANT: Primer should be shaken for about 1

minute and mix thoroughly before Cab
opening the cap.
After opening Primer, apply Primer
Cut Knife
as quickly as possible and replace
the cap immediately after using.
After opening Primer, all the
contents should be used within 180 Cut off Adhesive by 1 to 2
mm Deep
days (or 2 hours with the cap off). W1SE-02-01-036
3. Apply Primer for paint (Sika Aktivator DM-1) to the
cutting edge of adhesive at cab side by using a
brush. Wait for about 15 minutes in order to let it
dry by itself.
NOTE: The painting primer should be applied
evenly in order to leave no blemishes. Cab
Apply Primer 24
Cutting Edge of
Adhesive at Cab
Side
W1SE-02-01-038
W2-1-15
4. Clean the mating edge of new glass by using
clean rag and ethylalcohol.
IMPORTANT: Primer （ Sika Primer Z06G+P ）

should be shaken for about 1 minute
and mix thoroughly before opening
the cap.
After opening Primer, apply Primer
as quickly as possible and replace
the cap immediately after using.
After opening Primer, all the
contents should be used within 180
days (or 2 hours with the cap off).
5. Apply Primer for glass (Sika Primer Z06G+P) to
the cutting edge of adhesive at cab side by using
a brush. Wait for about 15 minutes in order to let it
dry by itself.
(As for the position to apply Primer, refer to
W2-1-14.)
6. Install the spacer with facing to the glass surface

by using the instant adhesive.
(As for the positions to install spacers A, B and C
dam rubber, refer to W2-1-17.)
7. Cut off the nozzle of adhesive cartridge (Sika

Tack-Drive) into V-shaped by using a knife. (Refer
to W2-1-17.)
8. Remove the seal of cartridge. Install the V-shaped

nozzle.
9. Install the cartridge to the manual coking gun.
10. Apply adhesive to the adhesive position at cab

side so that the bead triangle may be even.
(As for the position to apply adhesive refer to
W2-1-14.)
11. Suck, raise the glass by using sucker lifter

4355282 (refer to W2-1-17), and adhere it to the
cab within 5 minutes.
NOTE: Install the glass while aligning the spacer
position on the glass. Remove all adhesive
except the mounting surface, before
solidifying by using white spirit.
12. Secure the glass by using the gummed tape until

the adhesive becomes solid in order to prevent
them from being mispositioned or coming off.
NOTE: Time for adhesive (Sika Tack-Drive) to
become solid: 8 hours (just for reference)
W2-1-16

Right-Hand Glass
Rear Glass
250 300 350 500
100
200
200 200
500
200
200 200
250 300
W1JB-02-01-029
200
200
100
100 W1JB-02-01-030
Rear Left-Hand Glass
150 200
Lower Glass of Door

200
500
200
W1JB-02-01-035
W1JB-02-01-038
W2-1-17
NOTE: Unit: mm Spacer B Spacer C

(1 mm=0.039 in)
Spacer A
20 6 20 6
2
20 6
4 4 R0.5
R8 75°
4 R0.5
6 8 78°
3
R5 84° R10
6 R0.5
12
3 Apply Adhesive 10.5
Apply Adhesive to Both Sides

10.5 W1JB-02-01-023 W1JB-02-01-024
to Both Sides
W1JB-02-01-022
Dam Rubber
30 6.4
W1JB-02-01-025
Lower Grass of Door

Rear Left-Hand Glass
Right-Hand Glass
Rubber Spacer A
Dam
Rubber
Spacer B Spacer A
Spacer A Dam Spacer B
Rubber
W1JB-02-01-039
Spacer B
Rear Glass
W1JB-02-01-027
W1JB-02-01-026 Spacer C
8 to 9 mm
W1JB-02-01-042
Adhesive
Apply Bead Hear 13 to 15 mm
Cut Nozzle
End into
V-Shaped
W1SE-02-01-027
9
Apply bead should
12
from Even Triangle.
Remove
the Seal
W1JB-02-01-031
Adhesive
Cartridge
W1SE-02-01-043
Panel
W1SE-02-01-028
W2-1-18
13. The required amount (just for reference) of adhesive and primer
Painted Surface or Adhesive

Glass Surface
Surface
Adhesive Primer Primer
Sika Tack-Drive Sika Aktivator DM-1 Sika Primer 206G+P
310 ml Cratridge 250 ml Can 30 ml Bottle
Upper Front
310 ml 0.75 ml 0.67 ml
Glass
Lower Glass of
150 ml 0.5 ml 0.45 ml
Door
Rear Left-Hand
250 ml 0.65 ml 0.6 ml
Glass
Rear
Right-Hand 100 ml 1 ml 0.9 ml
Glass
Rear Glass 210 ml 0.5 ml 0.45 ml
W2-1-19
Procedures to Install Upper Door Glass
Sash
1. Before installing the glass, remove the garnish Assembly
around sash assembly from the cab inside for
easy removal. Push the sash assembly by hands
and remove the sash outside.
Garnish
2. Install glass A and glass B into the sash grooves.
3. Install the sash assembly, which the glass is

Glass A Glass B
installed on, onto the door from the outside of cab.
Secure the sash assembly at the inside of cab by W1JB-02-01-010
using the garnish.
W2-1-20
Procedures to Install Upper Front Glass
Adhere the glass in the same
1. Stick seal (1) to the lower side of front upper glass method as right-hand glass.
by using Cemedine Super X.
Stick and secure both right and left ends (the
thicker part) of seal (1) to the glass by using
Cemedine Super X.
Stick the mating surface of seal (1) and the glass
by using Cemedine Super X so that no visible
undulation or boss can be found.
NOTE: Cemedine Super X Black No.8008

Glue-state adhesive, tubed
IMPORTANT: The upper front glass is

arched-fringed. When replacing the
glass, contact with the nearest
HITACHI Office and replace it as an
assembly.
W1JB-02-01-034
Cemedine Super X Upper Glass Cemedine Super X Upper Glass

Seal Here
Seal (1) Seal (1)
Lower Glass Lower Glass

W1JB-02-01-032 W1JB-02-01-033
W2-1-21
(Blank)
W2-1-22
UPPERSTRUCTURE / Counterweight
REMOVE AND INSTALL COUNTERWEIGHT
Removal
CAUTION: Counterweight weight: 9150 kg

(20200 lb)
1. Attach a lifting tool, wire rope and chain block to

the lifting hole on counterweight in order to hold.
Adjust the wire rope length by using the chain
block and make the counterweight horizontal.
CAUTION: Do not stay under the lifted

counterweight.
W1J1-02-02-001
2. Remove bolts (13), spring washers (14) and

washers (11) (11 used for each). Remove covers 1
(11, 12) from the main frame. 2
3
4
CAUTION: When using a power wrench, do 5 6
7
not injure hands by the reaction bar. 8
3. Loosen bolt (10) by using a power wrench.

Remove bolts (10) (2 used), washers (9) (2 used), 1
nuts (7) (2 used), shim (6) and washers (8) (2 2
3
used). 4
: 65 mm 5
NOTE: Shim (6) is installed in the clearance 7 9
8
between nut (7) and the bracket. 10
12
4. Remove bolts (1) (4 used), lock washers (2) (2 15
used), plates (3) (2 used) and shims (4, 5) from 11 14
the counterweight. 13
15
: 36 mm 14 W1J1-02-02-002
13
5. Hoist and remove the counterweight from the
main frame.
8
1
7
9
3
1, 2
W1J1-02-02-003
4, 5
W2-2-1
UPPERSTRUCTURE / Counterweight
Installation

(20200 lb)
1. Attach a lifting tool, wire rope and chain block to

the lifting hole on counterweight in order to hoist.
Adjust the wire rope length by using the chain
block and make the counterweight horizontal.
CAUTION: Do not stay under the lifted
counterweight.
2. Install the projection of counterweight to the hole

on bracket.
W1J1-02-02-001
CAUTION: When using a power wrench, do

not injure hands by the reaction bar. 1
2
3. Apply lubricant onto bolts (10) (2 used). Install the 3
4
counterweight to the main frame with bolts (10) (2 5 6
used), washers (9) (2 used), washers (8) (2 used), Bracket 7
nuts (7) (2 used) and shims (6). Tighten bolt (10) 8
by using a power wrench.
: 65 mm 1
: 2350 N⋅m (240 kgf⋅m, 1730 lbf⋅ft) 2
3
4. Install the counterweight to the main frame with 4
5
shims (5, 4), plate (3), lock washer (2) and bolt 7
(1). 9
8
: 36 mm 10
12
: 440 N⋅m (45 kgf⋅m, 325 lbf⋅ft) 15
NOTE: Shims (4, 5) are installed in the clearance 11 14
between plate (3) and the bracket 13
15
14
5. Install covers (11, 12) with bolts (13), spring W1J1-02-02-002
13
washers (14) and washers (15) (11 used for
each).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
8
1
7
9
3
1, 2
W1J1-02-02-003
4, 5
Bracket Projection
W2-2-2
UPPERSTRUCTURE / Main Frame
REMOVE AND INSTALL MAIN FRAME
Removal
CAUTION: Release any pressure in the

hydraulic oil tank before doing any work.
(Refer to BLEED AIR FROM HYDRAULIC OIL
TANK on W1-4-1.)
W1J1-02-01-001
CAUTION: Cab weight: 560 kg (1235 lb)
1. Remove the cab from the main frame.

(Refer to the Remove and Install Cab section on
W2-1.)

(20200 lb)
2. Hoist and remove the counterweight from the

main frame.
(Refer to the Remove and Install Counterweight
section on W2-2.)
W1J1-02-02-001
CAUTION: Standard front attachment

assembly weight: 7920 kg (17470 lb)
3. Remove the front attachment assembly from the

main frame. W1JB-02-03-003
(Refer to the Remove and Install Front
Attachment section on W4-1.)
W2-3-1
4. Remove all hoses from center joint (2). Remove
lock plate (1). 1
(Refer to the Remove and Install Center Joint
section on W3-3.)
CAUTION: Upperstructure weight: 10800 kg

(23800 lb) 2
Upperstructure weight with removal / Rear W1J1-02-03-001
installation device: 11200 kg (24700 lb)
5. Install special tools (ST 0234, ST 0235) to the

Shackle
bracket at the mounting position for
counterweight with the bolts (M45, Pitch 3.0 mm)
and the nuts (2 used). ST 0235 ST 0234
Install the shackle (for 4.8 ton) to special tools Bolt
(ST 0234, ST 0235) and attach a wire rope.
Attach a wire rope onto the boom bracket. Hoist
each wire rope by using a chain block.
: 70 mm
Bracket W1J1-02-03-002
ST 0234, ST 0235
Nut
Bolt
W166-02-03-010
Front
Wire Rope
Boom Bracket
W105-02-03-005
W2-3-2
6. Remove bolts (3) (29 used) and (4) (7 used) from
the outer race of swing bearing.
7. Adjust the wire rope length by using a chain block

(6) in order to make the counterweight horizontal.
Hoist and remove the main frame from the track
frame.
3,4 W1JB-02-03-002
Main Frame
Track Frame W157-02-03-002
W2-3-3
Installation
CAUTION: Upperstructure weight: 10800 kg 6

(23800 lb)
Upperstructure weight with removal /
installation device: 11200 kg (24700 lb)
1. Attach a wire rope onto special tools (ST 0234,

ST 0235) and the boom bracket. Main Frame
Adjust the wire rope length by using a chain block Track Frame
(6) and make the counterweight horizontal. Hoist
and install the main frame to the track frame.
W157-02-03-002
2. Hoist the main frame. Align knock pin holes (5) (2

used) on the main frame with the knock pins (2 Front
used) of outer race in swing bearing. Wire Rope
3. Apply LOCTITE #262 to bolts (3) (29 used) and

(4) (7 used). Boom Bracket
Install the main frame with bolts (3) (29 used) and
(4) (7 used).
: 46 mm
: 1950 (199 kgf⋅m, 1440 lbf⋅ft)
4. Install all hoses to the upper of center joint (2). 5

: 19 mm 4 W105-02-03-005
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) 4

: 27 mm
4
: 78 N⋅m (8 kgf⋅m, 58 lbf⋅ft)
4
: 41 mm
: 205 N⋅m (21 kgf⋅m, 151 lbf⋅ft) 3
5. Install lock plate (1) to center joint (2). (Refer to 4

the Remove and Install Center Joint section on 4
4
W3-3.)
: 22 mm
: 140 N⋅m (14 kgf⋅m, 103 lbf⋅ft)
5
W1J1-02-03-004
2
W1J1-02-03-001
W2-3-4
CAUTION: Cab weight: 560 kg (1235 lb)
6. Install the cab to the center frame.

(Refer to the Remove and Install Cab section on
W2-1.)
W1J1-02-01-001

(20200 lb)
7. Install the counterweight to the main frame.

(Refer to the Remove and Install Counterweight
section on W2-2.)
CAUTION: Front attachment assembly

weight: 7920 kg (17470 lb)
8. Install the front attachment assembly to the main

frame. (Refer to the Remove and Install Front
Attachment section on W4-1.) W1J1-02-02-001
9. Add hydraulic oil into the hydraulic oil tank. Start

the engine. Set the front attachment in posture for
checking hydraulic oil level in its tank. Check the
hydraulic oil level and any oil leakage.
W1JB-02-03-003
M104-07-021
W2-3-5
(Blank)
W2-3-6
UPPERSTRUCTURE / Pump Device
REMOVE AND INSTALL PUMP DEVICE

TANK on W1-4-1.)
Removal
1 2
1. Open engine cover (2). Remove lock pins (5) (2
used) and washers (4) (2 used). Remove stays
(3) (2 used) from the bracket. Lay down engine
cover (2) to the muffler cover (1) side.
W1J1-02-13-001
CAUTION: Engine cover (2) weight: 32kg (70

lb) 8 3
2. Remove bolts (7) (8 used) from hinges (6) (4

used). Remove engine cover (2) from bracket (8). 4
: 17 mm
5
7 Bracket
6
W1J1-02-13-020 W1J1-02-13-015
1 10
3. Remove bolts (10) (8 used). Remove Muffler
cover (1).
: 19 mm
W1J1-02-13-003
W2-4-1
CAUTION: Cover (15) weight: 32 kg (70 lb)

15
4. Remove catches (2). Open cover (11). Remove
Rain Cover
bolts (16) (11 used). Remove cover (15).
: 19 mm
16
NOTE: Remove cover (15) with cover (11) and the
rain cover attached. 11
Catch W1J1-02-04-038
17 18 19
5. Remove bolts (21) (4 used). Remove bracket (8)
from bracket (22). 8
: 19 mm
21
6. Remove bolts (18) (3 used). Remove bracket
(22). 22
: 19 mm

(17).
: 19 mm
W1J1-02-04-040
23 24 25 26

under covers (24, 26) from the main frame.
: 19 mm
W1J1-02-04-039
Main Frame
W2-4-2
9. Loosen nut (29) and move band (28) to the center
of hose (31). Remove the terminals (2 used) of 27
contamination sensor (27). Remove hose (31)
from air cleaner (30). 28
: 11 mm
Terminal
29
30
31
W1J1-02-04-042
10. Remove bolts (34) (2 used). Remove clamps (35)

(2 used) from bracket (32).
: 17 mm
32
W1J1-02-04-045
Main Frame
33
34
35
32
W1J1-02-04-046
W2-4-3
11. Open and lock the pump cover.
36 37 38 37 37 39
12. Remove bolts (40) (2 used). Remove the harness
from cover (39). 40
: 17 mm
41
13. Remove bolts (37) (18 used) and (42). Remove
covers (36, 38, 39, 41). 37
: 19 mm 42
W1J1-02-04-041
CAUTION: Air cleaner (38) weight: 35 kg (77 Harness
lb)
14. Remove bolts (45) (4 used) from the bolt

mounting hole at pump space side. Attach a nylon
sling onto air cleaner (43). Hoist and remove air 43
cleaner (43) from bracket (32).
: 17 mm
32
W1J1-02-04-044
45
32
Bolt Mounting
W1J1-02-04-043
Hole
W2-4-4
(32).
: 19 mm
32
45
W1J1-02-04-045
Main Frame
46 47, 48 49, 50 52, 53

16. Remove socket bolts (52, 57) (4 used for each).
Remove pipes (53, 58) from the pump device.
: 14 mm
17. Remove socket bolts (47, 49, 60) (4 used for

each). Remove hoses (48, 50, 61) from the pump
device.
: 10 mm 5
18. Remove hoses (46, 51, 54, 55, 56, 59). Cap the
hose and pump. Attach identification tags to the
removed hoses for reassembling. 5
: 17 mm, 19 mm, 27 mm, 36 mm, 41 mm
5
19. Remove all the connectors from the pump device.
60, 61
5
57, 58 56 W1J1-02-04-001
W2-4-5
CAUTION: Pump device weight: 290 kg (640

lb)
20. Attach a wire rope onto eyebolts (2 used) in the

pump device and hold the pump device.
IMPORTANT: The engine is connected to the

pump device through the coupling.
When removing the pump device
from the engine, slide the pump
device to 50 mm (2.0 in) in parallel to
the shaft.
21. Put the matching marks on the mating surfaces
on engine and pump device. Remove bolts (62)
(8 used), (65) (2 used), spring washers (63) (10 Eyebolt
used) and washers (64) (10 used). Hoist and
remove the pump device from the engine. W1J1-02-04-002
: 19 mm
IMPORTANT: When removing the pump device 62, 63, 64

from the engine, remove the
coupling of engine and pump device
together. Do not reuse the coupling.
22. Remove socket bolts (67) (2 used) from coupling
(66) in the pump device. Remove coupling (66)
from the pump device.
: 12 mm
23. Remove socket bolts (69) (10 used) from

coupling (68) in the engine. Remove coupling (68)
from the engine.
: 8 mm
W1J1-02-04-003
63, 64, 65
Pump Device
66 67 67 W1J1-02-04-047
68 69 W1J1-02-04-048
W2-4-6
Installation
IMPORTANT: When removing the pump device

from the engine, replace the
coupling of engine and pump device.
Do not reuse the coupling.
1. Apply LOCTITE #262 to socket bolts (69) (10
used). Install coupling (68) to the engine with
socket bolts (69) (10 used).
: 8 mm
: 49 N⋅m (5.0 kgf⋅m, 36 lbf⋅ft)
2. Insert coupling (66) until spline end surface (A) in

68 69 W1J1-02-04-048
the pump device comes in contact with hub end
surface (B) in coupling (66). Install coupling (66)
to the pump device with socket bolts (67) (2
used).
: 12 mm
: 150 N⋅m (15.3 kgf⋅m, 110 lbf⋅ft)
Pump Device
66 A 67 67 B W1J1-02-04-047
W2-4-7
CAUTION: Pump device weight: 290 kg (640

lb) 62, 63, 64
3. Attach a wire rope onto eyebolts (2 used) in the

upper surface on pump. Hoist the pump device
and insert coupling (66) in the pump device into
coupling (68) in the engine. Align the matching
marks made when disassembling on engine and
pump device.
4. Apply LOCTITE #262 to socket bolts (62) (8

used) and (65) (2 used). Install the pump device
to the engine with bolts (62) (8 used), (65) (2
used), spring washers (63) (10 used) and
washers (64) (10 used).
: 19 mm
W1J1-02-04-003
: 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft) 63, 64, 65
5. Install pipes (53, 58) with socket bolts (52, 57) (4

used for each). Install hoses (48, 50, 61) with
socket bolts (47, 49, 60) (4 used for each).
: 10 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
: 14 mm
: 210 N⋅m (21.5 kgf⋅m, 155 lbf⋅ft)
6. Install hoses (46, 51, 54, 55, 56, 59) and the
connector.
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
Eyebolt
: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)
: 36 mm W1J1-02-04-002
: 180 N⋅m (18 kgf⋅m, 133 lbf⋅ft)

: 41 mm 46 47, 48 49, 50 52, 53
: 210 N⋅m (21 kgf⋅m, 155 lbf⋅ft)
60, 61
5
57, 58 56 W1J1-02-04-001
W2-4-8
7. Install bracket (44) to the main frame with bolts
(45) (5 used).
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
32
45
W1J1-02-04-045
Main Frame
CAUTION: Air cleaner (38) weight: 35 kg (77

lb)
43
8. Apply LOCTITE #262 to bolts (45) (4 used).
Attach a nylon sling onto air cleaner (38). Hoist
and move air cleaner (38) to the mounting
position for bracket (44). Install air cleaner (43) to
bracket (32) with bolts (45) (4 used).
32
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
NOTE: Install bolts (45) (4 used) through the bolt
mounting hole at pump space side.
W1J1-02-04-044
45
32
Bolt Mounting
W1J1-02-04-043
Hole
W2-4-9
9. Install covers (36, 38, 39, 41) with bolts (37) (18
used) and (42). 36 37 38 37 穴 37 39
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 40
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft) 41
10. Install harness (33) and the clamps (2 used) with 33

bolts (40) (2 used). Pass harness (33) through the 42
hole on cover (39). 37
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
11. Install harness (33) with clamp (35) and bolts (34)
(2 used). W1J1-02-04-041
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
32
W1J1-02-04-045
Main Frame
33
34
35
32
W1J1-02-04-046
W2-4-10
12. Install hose (31) to air cleaner (27). Tighten band 27
(29) with nut (30).
: 11 mm 28
13. Install the terminals (2 used) of contamination

sensor (28). Terminal 29
30
31
W1J1-02-04-042
17 18 19
8
14. Install bracket (17) with bolts (19) (4 used).
: 19 mm
21
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
22
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
16. Install bracket (8) to bracket (22) with bolts (21) (4

used).
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
W1J1-02-04-040
17. Install covers (11, 15) with bolts (16) (11 used).
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
15
NOTE: Cover (11) and the rain cover are attached Rain Cover
to cover (15).
16
11
W1J1-02-04-038
W2-4-11
18. Install muffler cover (1) with bolts (10) (8 used). 1 10
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
CAUTION: Engine cover (2) weight: 32 kg (70

W1J1-02-13-003
lb)
19. Place engine cover (2) onto muffler cover (1).

1 2
Install hinges (6) (4 used) to bracket (8) with bolts
(7) (8 used).
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
20. Install stays (3) (2 used) to bracket (8) with

washers (4) (2 used) and lock pins (5) (2 used).
W1J1-02-13-001
8 3
4
5
8
6
W1J1-02-13-020 W1J1-02-13-015
W2-4-12
21. Install under covers (24, 26) to the main frame
with bolts (23, 25) (5 used for each). 23 24 25 26
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
W1J1-02-04-039
Main Frame
W2-4-13
DISASSEMBLE PUMP DEVICE
56
64 63 57
63 15 D
64 58 A
57 59
67 E
68
69 B
55 60
61
65 19
84 56
66
19
73 57
76 74
75 57
83 64 62
63 16
70 18
71 62 26
72
77 71 16 27
78 70
79 38 29 G
80 110 C
37 30
F 31, 32
D
33
36 37 28 H
81
31, 32
C
39 38 25
E 27
28
45 36 29
34 50 48
30
41 52
42 40 41 33 54
111 49
42 34
41 44 51
46 46 39
47 40 C 53
47 42 4
43 3
2
A 22 7
21
20 6
106 B 5 8
112 109 1
104 108 23
112
102 107
19
F 87 11
24 10
92 9
93
101 94 12
95 17 13
96
100 95 18 16
G 86
98 24
99 H 85 90
91
15 88
14 89 W1J1-02-04-004
W2-4-14
1- Valve Cover 31 - Shoe (18 Used) 62 - Tapered Screw with Orifice 93 - Transmission Cover
(4 Used)
2- Nut (2 Used) 32 - Plunger (18 Used) 63 - Plug (3 Used) 94 - O-Ring
3- Set Screw (2 Used) 33 - Shoe Plate (2 Used) 64 - O-Ring (3 Used) 95 - Needle Bearing (2 Used)
4- Socket bolt 34 - Swash Plate (2 Used) 65 - Socket Bolt (8 Used) 96 - Drive Gear
5- Booster 36 - Tilt Bushing (2 Used) 66 - Socket Bolt (8 Used) 98 - Transmission Housing
6- O-Ring 37 - Tilt Pin (2 Used) 67 - Servo Cover (2 Used) 99 - Pin (2 Used)
7- Booster Cover 38 - Feedback Pin (2 Used) 68 - Nut (2 Used) 100 - Socket Bolt (8 Used)
8- Socket Bolt (5 Used) 39 - Swash Plate Stand (2 69 - Set Screw (2 Used) 101 - Eyebolt
Used)
9- O-Ring 40 - Pin (2 Used) 70 - Retaining Ring (2 Used) 102 - Relay Gear
10 - Cover 41 - Retaining Ring (3 Used) 71 - Spacer (2 Used) 104 - Needle Bearing
11 - Socket Bolt (2 Used) 42 - Bearing Spacer (3 Used) 72 - Drive Gear 106 - Retaining Ring
12 - Socket Bolt (2 Used) 43 - Roller Bearing 73 - Driven Gear 107 - O-Ring
13 - Socket Bolt (9 Used) 44 - Drive Shaft 74 - Spacer 108 - Shaft
14 - Plug (2 Used) 45 - Driven Shaft 75 - Retaining Ring 109 - Retaining Ring
15 - O-Ring (2 Used) 46 - Bearing Spacer (2 Used) 76 - Front Casing 110 - O-Ring
16 - Plug (12 Used) 47 - Retaining Ring (2 Used) 77 - O-Ring 111 - Roller Bearing
17 - Valve Plate Pin (2 Used) 48 - Backup Ring (2 Used) 78 - Oil Seal 112 - Bearing Spacer (3 Used)
18 - Seat Packing (2 Used) 49 - O-Ring (2 Used) 79 - Front Cover
19 - Pin (4 Used) 50 - Stopper S (2 Used) 80 - Retaining Ring
20 - Stopper 1 (2 Used) 51 - Servo Piston (2 Used) 81 - Socket Bolt (11 Used)
21 - Steel Ball (2 Used) 52 - Stopper L (2 Used) 83 - Pin (4 Used)
22 - Seat (2 Used) 53 - O-Ring (2 Used) 84 - Pin
23 - Plug (2 Used) 54 - Backup Ring (2 Used) 85 - Inner Spacer
24 - Needle Bearing (2 Used) 55 - Pump Casing 86 - Stop Ring
25 - Valve Plate R 56 - Eyebolt (2 Used) 87 - Pin (4 Used)
26 - Valve Plate L 57 - Plug (20 Used) 88 - O-Ring (2 Used)
27 - Cylinder Block (2 Used) 58 - O-Ring (5 Used) 89 - Plug (2 Used)
28 - Cylinder Spring (18 Used) 59 - O-Ring (2 Used) 90 - O-Ring (2 Used)
29 - Spherical Bushing (2 60 - Name Plate 91 - Plug (2 Used)
Used)
30 - Retainer (2 Used) 61 - Rivet (2 Used) 92 - Socket Bolt (3 Used)
W2-4-15
D
A
E
B
55
63
G
C
F
D
C
4
A 7
B 8
1
F 11
10
12
13
G
H
W1J1-02-04-004
W2-4-16
Disassemble Pump Device
CAUTION: The pump assembly weight: 290

kg (640 lb)
1. Remove plug (63). Drain oil from pump casing

(55).
2. Remove the regulators (2 used) in pumps 1, 2

from pump casing (55).
NOTE: As for removal and disassembly of the
regulator, refer to the regulator section on
W2-4-39.
The structures of pumps 1, 2 are identical.
Put the marks on the regulator in pumps
1,2 in order not to confuse.
3. Remove the gear pump (pilot pump) from booster

cover (7).
NOTE: As for removal and disassembly of the gear
pump, refer to the gear pump section on
W2-4-59.
4. Remove socket bolts (8) (5 used). Remove

booster cover (7) from valve cover (1).
: 6 mm

cover (10) from valve cover (1).
: 8 mm
CAUTION: Valve Cover (1) weight: 60 kg (130

lb)
6. Install eyebolt (M12, pitch 1.75 mm) to the bolt

hole on valve cover (1). Hoist and hold the
eyebolt.
7. Remove socket bolts (4) (1 used), (12) (2 used)

and (13) (9 used) from valve cover (1). Tap and
remove valve cover (1) from pump casing (55) by
using a plastic hammer.
: 17 mm
W2-4-17
D
A
68 E
67
69 B
55
76
26
27
79 29 G
80 C
37 30
F 31, 32
D
33
28 H
81
32,
C 31
37 25
E 27
45 28
34 29
30
33
50
34
51
52
C
3
2
A 44
B
1
F
24
86
G
24
H 85
W1J1-02-04-004
W2-4-18
IMPORTANT: Do not remove needle bearing (24)
unless replacing needle bearing (4).
8. Remove stop ring (86), inner spacer (85) and
valve plate (25) from drive shaft (44). Remove
valve plate (26) from driven shaft (45).
9. Remove plungers (32, 31), retainer (30),

spherical bushing (29) and the cylinder block (27)
assembly attached with cylinder spring (28) from
drive shaft (44) and driven shaft (45) in pump
casing (55).
10. Remove shoe plates (33) (2 used) from swash

plates (34) (2 used).
11. Remove swash plates (34) (2 used) from pump

casing (55).
IMPORTANT: Adhesive (THREEBOND #1305N) is

applied to the mating part of tilt pin
(37) and servo piston (51).
Do not loosen nuts (2, 68). When
loosen nuts (2, 68) and rotating set
screws (3, 69), flow rate is changed.
12. Remove stopper L (52), stopper R (50), servo
piston (51), tilt pin (37) and servo cover (67) from
pump casing (55).
: 10 mm
13. Remove retaining ring (80) and front cover (79)

from front casing (76).
NOTE: Attach a screwdriver to the outer surface
groove and pull out front cover (79).
W2-4-19
D
A
E
B
55
65
19
84
73
76 74
75
83
70
71
72
71
70
G
C
F
D
H
81
39 C
E
45
41 41
42
111
42
41
46 46 39
47 C
42
43
A 44
B
47
G
H
W1J1-02-04-004
W2-4-20
CAUTION: Front casing (76) weight: 32 kg
swash plate stands (39) (2 used) from pump
(70 lb)
casing (55).
: 6 mm
14. Attach a lifting tool onto the bolt hole mounting the
engine and hold front casing (76). Remove socket
bolts (81) (12 used). Hoist and remove front
casing (76) from pump casing (55).
: 10 mm
NOTE: Pins (19) (2 used), (83, 84) are located
between front casing (76) and pump casing
(55). When the mating part of front casing
(76) and pump casing (55) is secured tight,
tap and remove front casing (76) by using
a plastic hammer.
15. Remove retaining rings (70) (2 used), bearing

spacers (71) (2 used) and drive gear (72) from
drive shaft (44).
16. Remove retaining ring (75), bearing spacer (74)

and driven gear (73) from driven shaft (45).
17. Remove retaining ring (47) and bearing spacer

(46) from drive shaft (44). Remove retaining ring
(47), bearing spacer (46), retaining ring (41) and
bearing spacer (42) from driven shaft (45).
18. Tap the shaft end by using a plastic hammer and

remove drive shaft (44) and driven shaft (45) from
pump casing (55).
IMPORTANT: Do not remove roller bearings (43,

111) unless replacing roller bearings
(43, 111). Attach a plate onto the
outer ring of roller bearings (43, 111)
and push out by using a press.
19. When replacing roller bearings (43, 111) in drive
shaft (44) or driven shaft (45), remove retaining
ring (41), bearing spacer (42) and roller bearing
(43, 11).
W2-4-21
D
A
E
B
76
G
110 C
F
D
H
106 B
112 108 109
104 107
112
102
F
92
93
101 94
95
96
100 95
98 G
99 H
W1J1-02-04-004
W2-4-22
CAUTION: Fan pump Transmission weight:

28 kg (62 lb)
Fan pump weight: 51 kg (112 lb)
21. Hoist and hold eyebolt in the fan pump. Remove

the socket bolts (4 used) mounting the fan pump.
Remove the fan pump from transmission housing
(98). (Refer to “Disassemble Fan Pump” on
W2-4-49.)
22. Hoist and hold eyebolt (101).

transmission housing (98) from front casing (76).
: 10 mm
24. Remove retaining ring (109) and shaft (108) from

transmission housing (98).
25. Remove the relay gear (102) assembly attached

with bearing spacers (112) (3 used) and needle
bearing (104) from transmission housing (98).
26. Remove bearing spacers (112) (3 used). Remove

retaining ring (106) from relay gear (102).
27. Remove needle bearing (104) from relay gear

(102).

transmission cover (93) from transmission
housing (98).
: 14 mm

from transmission cover (93) and
transmission housing (98) unless
replacing.
29. Remove drive gear (96).
W2-4-23
ASSEMBLE PUMP DEVICE
52 53, 54 51 38 37 55 56 2 3 17 4 1
66
68
69 20 21
67
15 22
81
58
65
59
10 Section X-X
34
9
36 11
76
16
39 57 29 33 28 31 30 15 14 27 32 18 13 23 16
58
40
62 26
41 73 47 46 42 111 42 41 45 5 6 8 7
74
75
47
71
71
77 19
44
80 86
70
24
79
25
80
12
78
18 46 43 42 41 85 88 89 91 90
72
Section A-A
W1J1-02-04-005
W2-4-24
102
104
110
100
42
107
108 109
106
112
98
95
95
96
94 W1J1-02-04-013
Fan Pump
93 92
Transmission Section for Fan Pump
1- Valve Cover 31 - Shoe (18 Used) 62 - Tapered Screw with 93 - Transmission Cover
Orifice (4 Used)
2- Nut (2 Used) 32 - Plunger (18 Used) 63 - Plug (3 Used) 94 - O-Ring
3- Set Screw (2 Used) 33 - Shoe Plate (2 Used) 64 - O-Ring (3 Used) 95 - Needle Bearing (2 Used)
4- Socket bolt 34 - Swash Plate (2 Used) 65 - Socket Bolt (8 Used) 96 - Drive Gear
5- Booster 36 - Tilt Bushing (2 Used) 66 - Socket Bolt (8 Used) 98 - Transmission Housing
6- O-Ring 37 - Tilt Pin (2 Used) 67 - Servo cover (2 Used) 99 - Pin (2 Used)
7- Booster Cover 38 - Feedback Pin (2 Used) 68 - Nut (2 Used) 100 - Socket Bolt (8 Used)
8- Socket Bolt (5 Used) 39 - Swash Plate Stand (2 Used) 69 - Set Screw (2 Used) 101 - Eyebolt
9- O-Ring 40 - Pin (2 Used) 70 - Retaining Ring (2 Used) 102 - Relay Gear
10 - Cover 41 - Retaining Ring (3 Used) 71 - Spacer (2 Used) 104 - Needle Bearing
11 - Socket Bolt (2 Used) 42 - Bearing Spacer (3 Used) 72 - Drive Gear 106 - Retaining Ring
12 - Socket Bolt (2 Used) 43 - Roller Bearing 73 - Driven Gear 107 - O-Ring
13 - Socket Bolt (9 Used) 44 - Drive Shaft 74 - Spacer 108 - Shaft
14 - Plug (2 Used) 45 - Driven Shaft 75 - Retaining Ring 109 - Retaining Ring
15 - O-Ring (2 Used) 46 - Bearing Spacer (2 Used) 76 - Front Casing 110 - O-Ring
16 - Plug (12 Used) 47 - Retaining Ring (2 Used) 77 - O-Ring 111 - Roller Bearing
17 - Valve Plate (2 Used) 48 - Backup Ring (2 Used) 78 - Oil Seal 112 - Bearing Spacer (3 Used)
18 - Seat Packing (2 Used) 49 - O-Ring (2 Used) 79 - Front Cover
19 - Pin (4 Used) 50 - Stopper S (2 Used) 80 - Retaining Ring
20 - Stopper 1 (2 Used) 51 - Servo Piston (2 Used) 81 - Socket Bolt (11 Used)
21 - Steel Ball (2 Used) 52 - Stopper L (2 Used) 83 - Pin (4 Used)
22 - Seat (2 Used) 53 - O-Ring (2 Used) 84 - Pin
23 - Plug (2 Used) 54 - Backup Ring (2 Used) 85 - Inner Spacer
24 - Needle Bearing (2 Used) 55 - Pump Casing 86 - Stop Ring
25 - Valve Plate R 56 - Eyebolt (2 Used) 87 - Pin (4 Used)
26 - Valve Plate L 57 - Plug (20 Used) 88 - O-Ring (2 Used)
27 - Cylinder Block (2 Used) 58 - O-Ring (5 Used) 89 - Plug (2 Used)
28 - Cylinder Spring (18 Used) 59 - O-Ring (2 Used) 90 - O-Ring (2 Used)
29 - Spherical Bushing (2 Used) 60 - Name Plate 91 - Plug (2 Used)
30 - Retainer (2 Used) 61 - Rivet (2 Used) 92 - Socket Bolt (3 Used)
W2-4-25
65 Apply adhesive
(THREEBOND #1305N).
55
Section X-X
39 18
41 73 47 42 111 42 41 45
74
75
47
71
71
Apply adhesive
(SEALAND L101) to 19
outer surface of oil
seal.
44
70
46 43 42 41
72
Section A-A
W1J1-02-04-005
W2-4-26
Assemble Pump Device
1. Apply adhesive (THREEBOND #1305N) onto the

CAUTION: Front casing weight: 32 kg (70 lb)
thread part of socket bolts (65) (8 used).
10. Install pins (19) (2 used), (83, 84) to pump casing
2. Install swash plate stand (39) to pump casing (55)
(55).
with socket bolts (65) (8 used).
: 6 mm
11. Apply grease onto the seat packing (18) mounting
: 34 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft)
surface of pump casing (55). Install seat packing
(18) to pump casing (55).
3. Install roller bearing (43), bearing spacer (42) and
retaining ring (41) to drive shaft (44).
4. Install drive shaft (44) to pump casing (55). Tap

the outer ring by using a plastic hammer and
install roller bearing (43) completely. Install
bearing spacer (46) and retaining ring (47).
5. Install retaining ring (70), spacer (71), drive gear

(72), bearing spacer (71) and retaining ring (70)
to drive shaft (44).
6. Install retaining ring (41), bearing spacer (42),

roller bearing (111), bearing spacer (42) and
retaining ring (41) to driven shaft (45).
7. Install driven shaft (45) to pump casing (55). Tap

the outer ring by using a plastic hammer and
install roller bearing (111) completely.
8. Install bearing spacer (46) and retaining ring (47)

to driven gear (45).
9. Install driven gear (73), spacer (74) and retaining

ring (75) to driven shaft (45).
W2-4-27
51 Apply adhesive (THREEBOND #1305N).

52
37 55
66
67
81
Section X-X
34
36
76
39
80
79
78
76
Section A-A
W1J1-02-04-005
W2-4-28
12. Install front casing (76) to pump casing (55) with 18. Install servo cover (67) onto pump casing (55)
socket bolts (81) (8 used). with socket bolt (66).
: 10 mm : 10 mm
: 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft) : 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)
NOTE: When it is difficult to install front casing (76),
tap and install front casing (76) by using a 19. Install tilt bushing (36) of swash plate (34) to tilt
plastic hammer. pin (37). Install swash plate (34) onto swash plate
stand (39). Check if swash plate (34) moves
13. Apply grease to the lip part in oil seal (78). Install smoothly.
oil seal (78) to front cover (79).
14. Install front cover (79) and retaining ring (80) to

front casing (76).
15. Apply adhesive (THREEBOND #1305N) to the

thread part in servo piston (51).
16. Apply adhesive (THREEBOND #1305N) to the

mounting position for tilt pin in servo piston (51).
17. Install servo piston (51), tilt pin (37), stopper L

(52) and stopper R (50) to pump casing (55).
Tilt Pin Mounting Position
50
51
37 52
36
39
34
W16J-02-04-007
W2-4-29
55 17 1
20 21
15 22
58
59
Section X-X
29 28 31 30 27 32
45 26
44
24
25
18
Section A-A
W1J1-02-04-005
W2-4-30
20. Install the plunger assemblies (31, 32), retainer
(30), spherical bushing (29) and cylinder spring
(28) to cylinder block (27) in drive shaft (44) and
driven shaft (45).
21. Align the splines and install spherical bushings

(29) (2 used) and the cylinder block (27)
assembly to pump casing (55).
IMPORTANT: The directions to install valve plates

(25, 26) at the drive shaft (44) side
and driven shaft (45) side are
different.
Drive side: Clockwise
Drivenside: Counterclockwise
Notch Notch
26: Counterclockwise 25: Clockwise

W16J-02-04-015
Valve Plate Check
22. Align the valve plate pin (17) positions and install
valve plates (25, 26) to valve cover (1).
23. Install check valves (21, 20, 22) to valve cover

(1).
24. When replacing needle bearing (24), install

needle bearing (24) to valve cover (1) in drive
shaft (44) and driven shaft (45).
25. Install O-rings (15, 58, 59) and seat packing (18)
to valve cover (1) in pump casing (55).
W2-4-31
38 37 55 4 1
10 Section X-X
11
13
45 5 8 7
19
Gear Pump
44
12
Section A-A
W1J1-02-04-005
W2-4-32
29. Install booster (5) to valve cover (1). Install O-ring
CAUTION: Valve cover (1) weight: 60 kg (130
(6) to booster cover (7). Install booster cover (7)
lb)
to valve cover (1) with socket bolts (8) (4 used).
Install O-ring (9) to cover (10). Install cover (10) to
26. Install special tool to the end of drive shaft (44)
valve cover (1) with socket bolts (11) (2 used).
and driven shaft (45).
: 8 mm
: 57 N⋅m (5.8 kgf⋅m, 42 lbf⋅ft)
148 mm
30. Install feedback pin (38) in tilt pin (37) to the
φ34.5 +0.05
φ387
130.7 mm feedback lever in regulator. Install the regulator to

97.7 mm pump casing (55) with the socket bolts (8 used).
+0.15
-0.075
0
: 6 mm
: 29 N⋅m (3.0 kgf⋅m, 21 lbf⋅ft)
R30
R2
30° R10
151 mm
133.7 mm
φ387
φ32 +0.05
43.9 mm
-0.075
+0.15
0
R30
R1
30° R10
Special Tool (Unit: mm) W16J-02-04-009
27. Install pins (19) (2 used) to valve cover (1). Tap

and install valve cover (1) to pump casing (55) by
using a plastic hammer.
28. Install valve cover (1) to pump casing (55) with

socket bolts (4) (1 used), (12) (2 used) and (13)
(9 used).
: 17 mm
: 630 N⋅m (64 kgf⋅m, 465 lbf⋅ft)
W2-4-33
Transmission Housing Side
102
104
110
100
42
107
108 109
106
112
98
95
95
96
94 W1J1-02-04-013
93 92 Fan Pump
W2-4-34
CAUTION: Fan pump transmission weight: CAUTION: Fan pump weight: 51 kg (112 lb)
28 kg (62 lb)
40. Hoist eyebolt in the fan pump and install the fan
31. Install needle bearing (95) to transmission pump to transmission housing (98). Install the
housing (98). socket bolts (4 used).
: 14 mm
32. Install drive gear (96) to needle bearing (95) at : 235 N⋅m (24 kgf⋅m, 175 lbf⋅ft)
the transmission housing (98) side.
33. Install needle bearing (95) and O-ring (94) to

transmission cover (93).
34. Install transmission cover (93) to transmission

housing (98) with socket bolts (92) (3 used).
: 14 mm
: 240 N⋅m (24.5 kgf⋅m, 175 lbf⋅ft)
35. Install needle bearing (104) to relay gear (102).

Insert retaining ring (106) into relay gear (102).
36. Install bearing spacers (112) (3 used) to relay

gear (102). Install relay gear (102) to transmission
housing (98).
37. Install O-ring (107) to shaft (108). Install shaft

(108) to transmission housing (98).
38. Install retaining ring (109) to transmission housing

(98).
39. Install O-ring (110) to front casing (76). Install

transmission housing (98) to front casing (76)
: 10 mm
: 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)
W2-4-35
(Blank)
W2-4-36
MAINTENANCE STANDARD
Allowable Limits for vulnerable Parts
1. Clearance between plunger (32) outer diameter
(d) and cylinder block (27) bore diameter (D).
d D
D-d Unit: mm (in)
Standard Allowable Limit
0.038 (0.001) 0.078 (0.003)
W117-02-02-009
2. Free length (L) of cylinder spring (28)
L Unit: mm (in)
40.9 (1.61) 40.1 (1.58)
3. Clearance (e) between plunger (32) and shoe L

(31) bottom and shoe (31) thickness (t)
W117-02-02-010
e Unit: mm (in)
0 to 0.1 (0 to 0.35 (0.014)
0.004)
t Unit: mm (in)
Standard Allowable Limit e
t
5.4 (0.21) 5.0 (0.20)
W117-02-02-011
4. The difference between the surface of retainer

(30) to the top of spherical bushing (29)
Base
H-h Unit: mm (in)
Standard Allowable Limit h H
13.5 (0.53) 12.5 (0.49)

W117-02-02-012
W2-4-37
ALLOWABLE LIMITS FOR CYLINDER BLOCK
The Repair Limits for Cylinder, Valve Plate and Swash Plate (Shoe Plate)
Roughness when repair is
Valve plate (sliding portion) 3-Z
necessary
Swash plate (shoe plate portion)
Cylinder (sliding portion) Standard roughness (values
Less than 0.4Z (by lapping)
after being repaired)
W2-4-38
DISASSEMBLE REGULATOR
7
6
5
4
3
2 8
1 9
26
34
33
32
31
28 30
11
10
29 13
27
26 5 14
15
18
25 16
19
20 17
21
22
35 23
24
W16J-02-04-002
1- Regulator Casing 10 - Support Plug 20 - Pilot Piston 29 - Socket Bolt (2 Used)

2- Spring Seat 11 - O-Ring (2 Used) 21 - Pf Sleeve 30 - O-Ring (2 Used)
3- Pilot Spring 13 - Pin 22 - O-Ring 31 - Seat
4- Adjusting Disc Q 14 - O-Ring (5 Used) 23 - Plug 32 - Steel Ball
5- O-Ring (2 Used) 15 - O-Ring 24 - Socket Bolt (4 Used) 33 - Stopper
6- Cover 16 - Pin 25 - Socket Bolt 34 - Socket Bolt (6 Used)
7- Socket Bolt (4 Used) 17 - Feedback Lever 26 - Plug (9 Used) 35 - O-Ring
8- Nut 18 - Spool 27 - Valve Casing
9- Adjusting Screw 19 - Sleeve 28 - Proportional Pressure
Reducing Valve
W2-4-39
7
6
4
3
2
1
34
33
32
31
28
10
27
18
25
19
20 17
21
24
W16J-02-04-002
W2-4-40
Disassemble Regulator
IMPORTANT: The same type regulator is installed

to pumps 1 and 2. As these
characteristics are different each
other, do not confuse them. These
procedures are for the pump 1
regulator.
1. Remove socket bolts (34) (6 used). Remove the
regulator from the pump casing.
: 5 mm
2. Remove socket bolts (24, 25). Remove valve

casing (27) attached with proportional pressure
reducing valve (28) from casing (1).
: 6 mm
3. Remove socket bolts (7) (4 used). Remove cover

(6) from casing (1).
: 5 mm
4. Remove Pf sleeve (21) and pilot piston (20) from

casing (1).
5. Remove support plug (10) from casing (1).

Remove feedback lever (17).
: 6 mm
6. Remove spool (18) and sleeve (19) from casing

(1).
7. Remove adjusting disc Q (4), pilot spring (3) and

spring seat (2) from casing (1).
NOTE: Remove adjusting disc Q (4) by using the
bolt (M4).
8. Remove seat (31), steel ball (32) and stopper

(33) from casing (1).
W2-4-41
ASSEMBLE REGULATOR
Section A-A
29
16 34
10
26
1
35
30
15
17
A
27 26 31 32 33 28
2 4 3
9
25
11, 23 8
24 7
21
6
20
5
22
14
5
13
19 18
A
W16J-02-04-010
W2-4-42
1- Regulator Casing 10 - Support Plug 20 - Pilot Piston 29 - Socket Bolt (2 Used)

2- Spring Seat 11 - O-Ring (2 Used) 21 - Pf Sleeve 30 - O-Ring (2 Used)
3- Pilot Spring 13 - Pin 22 - O-Ring 31 - Seat
4- Adjusting Disc Q 14 - O-Ring (5 Used) 23 - Plug 32 - Steel Ball
5- O-Ring (2 Used) 15 - O-Ring 24 - Socket Bolt (4 Used) 33 - Stopper
6- Cover 16 - Pin 25 - Socket Bolt 34 - Socket Bolt (6 Used)
7- Socket Bolt (4 Used) 17 - Feedback Lever 26 - Plug (9 Used) 35 - O-Ring
8- Nut 18 - Spool 27 - Valve Casing
9- Adjusting Screw 19 - Sleeve 28 - Proportional Pressure
Reducing Valve
W2-4-43
Section A-A
16
Pin Hole
10
30
17
A
27 31 32 33 16
2 4 3
25
24
21
6
20
22
19 18 Support Hole
A
W16J-02-04-010
W2-4-44
Assemble Regulator
IMPORTANT: Spread the rubber sheet or cloth or

etc. on the workbench in order not
to damage the parts.
1. Install spool (18) and sleeve (19) to casing (1).
Check if spool (18) and sleeve (19) move inside
casing (1) smoothly.
2. Insert pin (16) in feedback lever (17) into the pin

hole on sleeve (19). Slide feedback lever (17) so
that the support hole on feedback lever (17) can
be seen through the mounting hole on support
plug (10). Install support plug (10). Check if
feedback lever (17) moves smoothly.
: 6 mm
: 36 N⋅m (3.7 kgf⋅m, 27 lbf⋅ft)
3. Install spring seat (2), pilot spring (3) and

adjusting disc Q (4) to casing (1).
4. Install cover (6) to casing (1) with socket bolt (7).

: 5 mm
: 12 N⋅m (1.2 kgf⋅m, 8.9 lbf⋅ft)
5. Install Pf sleeve (21), pilot piston (20) and check

valve assemblies (33, 32, 31) to casing (1).
6. Install O-rings (30, 22) to valve casing (27). Install

valve casing (27) to casing (1) with socket bolts
(24, 25).
: 5 mm
: 12 N⋅m (1.2 kgf⋅m, 8.9 lbf⋅ft)
W2-4-45
DISASSEMBLE FAN PUMP
51
50 45
49
48
16
19
B 20
14 21
13 22
12
11 A 54
10
9 23
24
5
15
54
26
7
6 55
7 27
8
4 44
3 28 43
2
1 59
58
40 47
39 46
38 3
55
37
36
35
B 34 42
56
32, 33 57
30
29
A 31
W1J1-02-04-006
W2-4-46
1- Socket Bolt (4 Used) 15 - Housing 32 - Shoe (9 Used) 47 - Socket Bolt (2 Used)

2- Cover 16 - Tilt Pin 33 - Plunger (9 Used) 48 - O-Ring (2 Used)
3- O-Ring (2 Used) 19 - Stopper L 34 - Retainer Plate 49 - Plug (2 Used)
4- Oil Seal 20 - Backup Ring 35 - Spherical Bushing 50 - Nut
5- Shaft 21 - O-Ring 36 - Spring (9 Used) 51 - Eyebolt
6- Bearing 22 - Servo Piston 37 - Cylinder Block 54 - O-Ring (9 Used)
7- Spacer (2 Used) 23 - O-Ring (2 Used) 38 - Valve Plate 55 - Plug (8 Used)
8- Retaining Ring 24 - Plug (2 Used) 39 - Bearing 56 - Pin (2 Used)
9- Nut (2 Used) 26 - O-Ring 40 - O-Ring 57 - Pin
10 - Adjusting Screw 27 - Swash Plate Stand 42 - Cover 58 - O-Ring
11 - Spring Pin (2 Used) 28 - Socket Bolt (4 Used) 43 - Adjusting Screw 59 - Plug
12 - Stopper 29 - Swash Plate 44 - Nut (2 Used)
13 - Backup Ring 30 - Bushing 45 - Feedback Pin
14 - O-Ring 31 - Shoe Plate 46 - Cover
W2-4-47
A
10
9
24
15
4 44
28 43
47
39 46
38
37
36
35
B 34 42
32, 33
A
W1J1-02-04-006
W2-4-48
Disassemble Fan Pump
IMPORTANT: Do not remove oil seal (4) unless

CAUTION: Fan pump weight: 51 kg (110 lb)
replacing oil seal (4).
8. Remove spherical bushing (35) and springs (36)
IMPORTANT: Do not remove adjusting screws (10,
(9 used) from cylinder block (37).
43) and nuts (9, 44). If removing
adjusting screws (10, 43) and nuts (9,
44), the characteristics are changed.
1. Remove plug (24) from housing (15). Drain
hydraulic oil from the pump.
: 13 mm
2. Remove the socket bolts (4 used). Remove the

regulator from housing (15).
: 6 mm

cover (46) from cover (42).
: 10 mm

unless replacing needle bearing
(39).
cover (42) and valve plate (38) from housing (15).
: 17 mm
5. Remove the cylinder block (37) assembly

attached with plungers (33) (9 used), shoes (32)
(9 used), spherical bushing (35) and retainer plate
(34).
6. Remove the retainer plate (34) assembly

attached with plunger (33) (9 used) and shoes
(32) (9 used).
7. Remove plungers (33) (9 used) and shoes (32) (9

used) from the retainer plate (34) assembly.
W2-4-49
45
16
19
22
12
A
5
15
7
6
7 27
8
B
31
29
A
W1J1-02-04-006
W2-4-50
9. Remove socket bolts (1) (4 used). Remove cover
(2) from swash plate stand (27).
: 6 mm
10. Remove swash plate stand (27) from housing

(15). When swash plate stand (27) cannot be
removed, tap and remove swash plate stand (27)
by using a plastic hammer.
11. Remove swash plate (29) and shoe plate (31)

from housing (15).
12. Remove shaft (5) from swash plate stand (27).

When shaft (5) cannot be removed, tap and
remove shaft (5) by using a plastic hammer.
IMPORTANT: LOCTITE has been applied onto the

contacting part between tilt pin (16)
and servo piston (22). When
disassembling, do not damage
servo piston (22).
13. Remove stoppers (12, 19), servo piston (22) and
tilt pin (16) from housing (15).
14. Remove retaining ring (8), spacers (7) (2 used)

and bearing (6) from shaft (5).
W2-4-51
(Blank)
W2-4-52
ASSEMBLE FAN PUMP
27 12 13, 14 22 32 16 15 30 20, 21 19 41 44 43
9
10
40
11
26
23, 24
3
5
2
4
47
8
7
7 46
1
3
28
6 29 31 34 35 32, 33 36 37 38 56 39 42 57 58, 59
48, 49, 50, 51
W1J1-02-04-007
1- Socket Bolt (4 Used) 15 - Housing 32 - Shoe (9 Used) 47 - Socket Bolt (2 Used)

2- Cover 16 - Tilt Pin 33 - Plunger (9 Used) 48 - O-Ring (2 Used)
3- O-Ring (2 Used) 19 - Stopper L 34 - Retainer Plate 49 - Plug (2 Used)
4- Oil Seal 20 - Backup Ring 35 - Spherical Bushing 50 - Nut
5- Shaft 21 - O-Ring 36 - Spring (9 Used) 51 - Eyebolt
6- Bearing 22 - Servo Piston 37 - Cylinder Block 54 - O-Ring (9 Used)
7- Spacer (2 Used) 23 - O-Ring (2 Used) 38 - Valve Plate 55 - Plug (8 Used)
8- Retaining Ring 24 - Plug (2 Used) 39 - Bearing 56 - Pin (2 Used)
9- Nut (2 Used) 26 - O-Ring 40 - O-Ring 57 - Pin
10 - Adjusting Screw 27 - Swash Plate Stand 42 - Cover 58 - O-Ring
11 - Spring Pin (2 Used) 28 - Socket Bolt (4 Used) 43 - Adjusting Screw 59 - Plug
12 - Stopper 29 - Swash Plate 44 - Nut (2 Used)
13 - Backup Ring 30 - Bushing 45 - Feedback Pin
14 - O-Ring 31 - Shoe Plate 46 - Cover
W2-4-53
27 12 13, 14 22 32 16 15 20, 21 19
11
26
3
5
2
4
8
7
7
6 29 31 34 35 32, 33 36 37 38
W1J1-02-04-007
W2-4-54
Assemble Fan Pump
1. Apply LOCTITE onto the contacting part between 11. Install plungers (33) (9 used) and shoes (32) (9
servo piston (22) and tilt pin (16). used) to retainer plate (34). Install retainer plate
(34) to cylinder block (37).
2. Install tilt pin (16) and servo piston (22) to housing
(15). 12. Install cylinder block (37) to shaft (5).
3. Install O-ring (21) and backup ring (20) to stopper NOTE: Apply grease to valve plate (38).
(19). Install stopper (19) to housing (15).
4. Install O-ring (13) and backup ring (14) to stopper

(12). Install stopper (12) to housing (15).
5. Install spacer (7), bearing (6), spacer (7) and

retaining ring (8) to shaft (5).
6. Install spring pin (11) and O-ring (26) to swash

plate stand (27). Install swash plate stand (27) to
housing (15).
7. Install shoe plate (31) to swash plate (29). Align

swash plate (29) with tilt pin (16) and install
swash plate (29) to housing (15). Check if swash
plate (29) moves smoothly.
8. Install O-ring (3) and oil seal (4) to cover (2).
9. Install shaft (5) to swash plate stand (27). Install

cover (2) to swash plate stand (27) with socket
bolts (1) (4 used).
: 6 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
10. Install springs (36) (9 used) and spherical bushing

(35) to cylinder block (37).
W2-4-55
16 15 41
40
23, 24
47
46
3
28
38 42
W1J1-02-04-007
W2-4-56
13. Install pins (56, 57) and O-ring (40) to cover (42).
NOTE: Align the pin hole on valve plate (38) with

pin (54) and install valve plate (38).
14. Install cover (42) to housing (15) with socket bolts

(28) (4 used).
: 17 mm
: 400 N⋅m (41 kgf⋅m, 295 lbf⋅ft)
15. Install O-ring (3) to cover (46). Install cover (46) to

cover (42) with socket bolts (47) (2 used).
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
16. Align the feedback lever in regulator with tilt pin

(16). Install the regulator to housing (15) with the
socket bolts (4 used).
: 6 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
17. Install O-ring (23) to plug (24). Install plug (24) to

housing (15).
: 36 mm
: 147 N⋅m (15 kgf⋅m, 108 lbf⋅ft)
W2-4-57
(Blank)
W2-4-58
1. Clearance between plunger (33) outer diameter

(d) and cylinder block (37) bore diameter (D).
d D
D-d Unit: mm (in)
0.028 (0.001) 0.056 (0.002)
W117-02-02-009
2. Free length (L) of spring (36)
L Unit: mm (in)
31.3 (1.23) 30.2 (1.19)
3. Clearance (e) between plunger (33) and shoe L

(32) bottom and shoe (31) thickness (t)
W117-02-02-010
e Unit: mm (in)
0 to 0.1 0.3 (0.012)
(0 to 0.004)
t Unit: mm (in)
Standard Allowable Limit e
t
3.9 (0.15) 3.7 (0.14)
W117-02-02-011
4. The difference between the surface of retainer

plate (34) to the top of spherical bushing (35)
Base
H-h Unit: mm (in)
Standard Allowable Limit h H
19.0 (0.75) 18.3 (0.72)

W117-02-02-012
W2-4-59
DISASSEMBLE REGULATOR (FAN PUMP)
3
11
10
9
8
7
6 D
B 22
5 F 23
24
4 25
3 20
2
1 20
19 21 A 31
G 30
18
17 CE 29
16 28 44
15
14 32
13 27
43
42
41
40
39 41
38 46
37
32 33 34
36
66 65
D
E 48
49
35
49
F 51
G 52
64 53
64 57
61 58
A
B
63 C
60 67 54
59 52 52
69 53
67
62
W1J1-02-04-008
W2-4-60
1- Pin 18 - Sleeve 35 - O-Ring (3 Used) 54 - Adjusting Plug

2- Sleeve 19 - Spool 36 - Socket Bolt (2 Used) 57 - Pin
3- O-Ring (2 Used) 20 - Pin (2 Used) 37 - Socket Bolt (2 Used) 58 - O-Ring
4- O-Ring 21 - Lever 38 - O-Ring 59 - O-Ring
5- Sleeve 22 - Feedback Lever 39 - Adjusting Screw 60 - O-Ring
6- Compensating Piston 23 - Pin 40 - Adjusting Screw 61 - O-Ring
7- Compensating Rod 24 - Pin 41 - Nut (2 Used) 62 - Cover
8- Spring Seat 25 - Lever 42 - O-Ring 63 - Socket Bolt (4 Used)
9- Spring 27 - Pilot Piston 43 - Cover 64 - Plug (11 Used)
10 - Spring 28 - Spring Seat 44 - Nut 65 - Solenoid Valve
11 - Adjusting Disc 29 - Spring 46 - Adjusting Screw 66 - Socket Bolt (2 Used)
13 - Retaining Ring 30 - Adjusting Disc 48 - Housing 67 - O-Ring (9 Used)
14 - Spring Seat 31 - O-Ring 49 - Pin (2 Used) 69 - Plug
15 - Spring 32 - Socket Bolt (8 Used) 51 - Adjusting Plug
16 - Spring 33 - Cover 52 - O-Ring (3 Used)
17 - Retaining Ring 34 - O-Ring 53 - Retaining Ring (2 Used)
W2-4-61
11
10
9
8
7
6 D
B 22
5 F 23
25
2 20
1 20
19 21 A
G 30
18
CE 29
16 28 44
15
14 32
13 27
43
41
40
39 41
46
37
32 33
36
66 65
D
E 48
49
49
F 51
G
53
A
B
63 C
54
52
53
62
W1J1-02-04-008
W2-4-62
Disassemble Regulator (Fan Pump)
1. Remove socket bolts (36) (2 used) and (37) (2 IMPORTANT: Do not remove pin (49) from
used). Remove housing (48) from the pump. adjusting plug (51). Put the mark on
: 6 mm adjusting plugs (51, 54) in order not
to confuse.
IMPORTANT: Do not remove adjusting screws (39, 8. Remove retaining ring (53) from housing (48).
40, 46) and nuts (41) (2 used), (44). If Remove adjusting plugs (51, 54) by using the bolt
adjusting screws (39, 40, 46) and (M6).
nuts (41) (2 used), (44) are removed,
the pump characteristics are IMPORTANT: Do not remove pin (20) from lever
changed. (25).
2. Remove socket bolts (32) (4 used). Remove 9. Remove lever (25) and pilot piston (27) from
cover (33) from housing (48). housing (48).
: 5 mm
10. Remove pin (23) in feedback lever (22) through
3. Remove socket bolts (63) (4 used). Remove the mounting hole on adjusting plug (51). Remove
cover (62) from housing (48). feedback lever (22), sleeve (18) and spool (19)
: 5 mm from housing (48).
4 mm
solenoid valve (65) from cover (62). IMPORTANT: Do not remove pins (20, 49) from
lever (21).
5. Remove pin (1), sleeves (2, 5) and compensating 11. Remove lever (21) and compensating rod (7)
piston (6) from housing (48). from housing (48).
6. Remove retaining ring (13), spring seat (14) and

springs (15, 16) from housing (48).

cover (43), adjusting disc (11), springs (9, 10),
spring seat (8), adjusting disc (30), spring (29)
and spring seat (28) from housing (48).
: 5 mm
W2-4-63
ASSEMBLE REGULATOR (FAN PUMP)
62 51
48 49 23 52
B
53
A
25
48 37
49
36
32 21 24
34
B 56
33 A
35 52, 69 55
20 22 26 54
64 67 63 59
64 66
65
29
30
Section A-A 32
31
45
46
43
60 68, 69 58 27 20 22 28 37
15 16 17 18 19
9 10 42 11 43
13 44
Section B-B 39
3 41
1 40
2
3
38
4
6 5 7 22 20 8
W1J1-02-04-009
W2-4-64
1- Pin 18 - Sleeve 35 - O-Ring (3 Used) 54 - Adjusting Plug

2- Sleeve 19 - Spool 36 - Socket Bolt (2 Used) 57 - Pin
3- O-Ring (2 Used) 20 - Pin (2 Used) 37 - Socket Bolt (2 Used) 58 - O-Ring
4- O-Ring 21 - Lever 38 - O-Ring 59 - O-Ring
5- Sleeve 22 - Feedback Lever 39 - Adjusting Screw 60 - O-Ring
6- Compensating Piston 23 - Pin 40 - Adjusting Screw 61 - O-Ring
7- Compensating Rod 24 - Pin 41 - Nut (2 Used) 62 - Cover
8- Spring Seat 25 - Lever 42 - O-Ring 63 - Socket Bolt (4 Used)
9- Spring 27 - Pilot Piston 43 - Cover 64 - Plug (11 Used)
10 - Spring 28 - Spring Seat 44 - Nut 65 - Solenoid Valve
11 - Adjusting Disc 29 - Spring 46 - Adjusting Screw 66 - Socket Bolt (2 Used)
13 - Retaining Ring 30 - Adjusting Disc 48 - Housing 67 - O-Ring (9 Used)
14 - Spring Seat 31 - O-Ring 49 - Pin (2 Used) 69 - Plug
15 - Spring 32 - Socket Bolt (8 Used) 51 - Adjusting Plug
16 - Spring 33 - Cover 52 - O-Ring (3 Used)
17 - Retaining Ring 34 - O-Ring 53 - Retaining Ring (2 Used)
W2-4-65
48 49 23 51 52 53
25
48
49
21
20 26 54 55 56
29
30
Section A-A 32
31
27 28
17 18 19
9 10 42 11 43
Section B-B
7 22 8
W1J1-02-04-009
W2-4-66
Assemble Regulator (Fan Pump)
1. Insert compensating rod (7) and lever (21) into 9. Install O-ring (55) to adjusting plug (54). Install
housing (48). adjusting plug (54) to housing (48). Install
retaining ring (56) to housing (48).
2. Align the pin (49) hole on lever (21) with the pin
hole on housing (48). Align pin (20) in lever (21) 10. Install O-ring (31) to stopper (30).
with the stepped part on compensating rod (7).
Install lever (21) to housing (48). 11. Install spring seat (28), spring (29) and stopper
(30) to housing (48).
3. Install retaining ring (17) to sleeve (18). Install
sleeve (18) and spool (19) to housing (48). 12. Install O-ring (3) to stopper (11).
IMPORTANT: Before installing feedback lever (22), 13. Install O-ring (42) to housing (48). Install spring
check if spool (19) moves smoothly. seat (8), springs (9, 10) and stopper (11) to
Check the directions of spool (19) housing (48). Install cover (43) to housing (48)
and feedback lever (22). with socket bolts (32) (4 used).
4. Align the pin hole on spool (19) with that on : 5 mm
feedback lever (22). Install pin (23) through the : 12 N⋅m (1.2 kgf⋅m, 8.9 lbf⋅ft)
mounting hole of support plug (51).
5. Insert pilot piston (27) and lever (25) into housing

(48).
IMPORTANT: Before installing lever (25), check if

pilot piston (27) moves smoothly.
6. Align pin (26) in lever (25) with the stepped part
on pilot piston (27) and install lever (25).
7. Install O-ring (52) and pin (49) to adjusting plug

(51).
8. Align pin (49) in adjusting plug (51) with the pin

hole on lever (25) and install adjusting plug (51).
Install retaining ring (53) to housing (48).
W2-4-67
62
48
48 37
36
32
34
33
35
63
66
65
Section A-A
16 15 17 18 19
14
13
Section B-B
4
6 5
W1J1-02-04-009
W2-4-68
14. Install spring (15), spring seat (14) and retaining
ring (13) to spool (19).
15. Install O-ring (4) to sleeve (5). Install sleeve (5),

compensating piston (6), O-ring (3), sleeve (2)
and pin (1) to housing (48).
16. Install spring (16) and O-rings (59, 60, 61) to

housing (48). Install cover (62) with socket bolts
(63) (4 used).
: 5 mm
: 12 N⋅m (1.2 kgf⋅m, 8.9 lbf⋅ft)
17. Install O-rings (34) and (35) (3 used) to cover

(33).
18. Install cover (33) to housing (48) with socket bolts

(32) (4 used).
: 5 mm
: 12 N⋅m (1.2 kgf⋅m, 8.9 lbf⋅ft)
19. Install solenoid valve (65) to cover (62) with

20. Install the regulator to the pump with socket bolts

(36) (2 used) and (37) (2 used).
: 6 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
W2-4-69
STRUCTURE OF PILOT PUMP
27
13
26
10
10
12
1
9
6
26
14
27
6
9
2
3
5
16
15
7
12
W137-02-04-034
W2-4-70
Wrench Tightening Torque

Item Part Name Q’ty Size Remarks
(mm) N⋅m (kgf⋅m) (Ibf⋅ft)
1 Housing 1
2 Flange 1
3 Oil Seal 1 Apply grease to the oil seal
lip when installing
5 Retaining Ring 1
6 Seal 2 Apply grease to seal when
installing
7 Cover 1
9 Backup Ring 2 Apply grease to backup
ring when installing
10 Key 2
12 O-Ring 2 Apply grease to O-ring
when installing
13 Gear 1
14 Gear 1
15 Washer 2
16 Bolt 2 : 17 39 to 44 (4 to 4.5) (29 to 33)
26 Bushing 4 Apply a film of hydraulic oil
to bushing when installing
27 Bushing 4 Apply a film of hydraulic oil
to bushing when installing
W2-4-71
(Blank)
W2-4-72
UPPERSTRUCTURE / Control Valve
REMOVE AND INSTALL CONTROL VALVE
1 2
Removal

TANK on W1-4-1.)
1. Remove bolts (2) (4 used) from covers (1) (2

used). Remove covers (1) (2 used) from the main
frame.
: 19 mm W1J1-02-05-061
2. Remove solenoid valve (3) and signal control 3 5

valve (4) from control valve (5). Move solenoid
valve (3) and signal control valve (4) outside the
space for removal and installation of control valve
(5). (Refer to “Remove and Install Solenoid Valve”
on W2-9 and “Remove and Install Signal Control 4
Valve” on W2-10.)
3. Remove all hoses and connectors from control

valve (5). Cap the hoses and control valve (5).
Attach identification tags to the removed hoses for
reassembling.
: 17 mm, 19 mm, 36 mm
: 8 mm, 10 mm W1J1-02-10-001
4. Install eyebolts (M12, Pitch 1.75 mm) (4 used) to

control valve (5). Eyebolt Mounting Position
(M12, Pitch 1.75 mm) 5
Swing
Arm 2
Arm 1
Boom 1
Boom 2
Bucket
Auxiliary
Right Travel
Left Travel
W1J1-02-05-058
Eyebolt Mounting Position
(M12, Pitch 1.75 mm)
W2-5-1
5. Remove bolts (6) (4 used) and spacers (7) (4
used) from control valve (5).
: 30 mm
CAUTION: Control valve (5) weight: 400 kg
(880 lb)
6. Hoist and remove control valve (5) from the main

frame.
Installation
1. Install eyebolts (M12, Pitch 1.75 mm) (4 used) to 6, 7 6, 7

control valve (5).
CAUTION: Control valve (5) weight: 400 kg

(880 lb)
2. Hoist and align control valve (5) with the mounting 5 W1J1-02-05-059
Lower Side of Control Valve
position.
3. Apply LOCTITE #262 to bolts (6) (4 used). Install

control valve (5) to the main frame with bolts (6) (4
used) and spacers (7) (4 used).
: 30 mm
: 400 N⋅m (41 kgf⋅m, 295 lbf⋅ft) Eyebolt Mounting Position 5
4. Remove eyebolts (M12, Pitch 1.75 mm) (4 used)
from control valve (5).
5. Install all hoses and connectors to control valve

(5).
: 17 mm
: 39 N⋅m (4.0 kgf⋅m, 29 lbf⋅ft)
: 19 mm
: 29.5 N⋅m (3.0 kgf⋅m, 22 lbf⋅ft)
: 36 mm
: 175 N⋅m (18.0 kgf⋅m, 130 lbf⋅ft)
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
: 10 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
W1J1-02-05-058
Eyebolt Mounting Position

Upper Side of Control Valve
W2-5-2
6. Install solenoid valve (3) and signal control valve
(4). (Refer to “Remove and Install Solenoid Valve” 3 5
on W2-9 and “Remove and Install Signal Control
Valve” on W2-10.)
7. Install covers (1) (2 used) to the main frame with

bolts (2) (4 used).
: 19 mm W1J1-02-10-001
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft) 1 2
IMPORTANT: After completing the work, check the

oil level. Start the engine and check
for any oil leaks.
W1J1-02-05-061
W2-5-3
DISASSEMBLE CONTROL VALVE (4-SPOOL HOUSING SIDE) 15
Boom Anti-Drift Valve 14
13
12
10 11
19
8
9 18
8 17
7 16
6
5
4 8
3 20
2
1
21
22
Load Check Valve

23
24
25 Bypass Shut-Out Valve
26 31
30 27 35
28 32
29 24
25
33
36
34 37
Boom Flow Rate

Control Valve 44
38
43
10 42
41
40
19 10
8 39 15
17 45 14
45
52 17
14 41 39 8
15 46 51
43 19
8
44
35
8
46 55
47
47
48
49 48
49 54
50
53 37
Arm Flow Rate
Control Valve
W1Ｊ1-02-05-051
W2-5-4
1- Cap 15 - Cap (2 Used) 29 - O-Ring 43 - O-Ring (2 Used)

2- O-Ring 16 - Cover 30 - Cap 44 - Cap (2 Used)
3- Spring 17 - Check Valve (3 Used) 31 - Cap 45 - Cover (2 Used)
4- Poppet 18 - Spring 32 - O-Ring 46 - O-Ring (2 Used)
5- O-Ring 19 - Cap (3 Used) 33 - Spool 47 - Piston (2 Used)
6- Backup Ring 20 - O-Ring 34 - Spring 48 - Spring (2 Used)
7- Sleeve 21 - Spring 35 - Socket Bolt (8 Used) 49 - Check Valve (2 Used)
8- O-Ring (10 Used) 22 - Poppet 36 - Flange 50 - Poppet
9- Backup Ring 23 - Cap 37 - O-Ring (2 Used) 51 - Spring
10 - Socket Bolt (12 Used) 24 - Backup Ring (2 used) 38 - Housing (4-Spool Side) 52 - Spool
11 - Piston 25 - O-Ring (2 Used) 39 - Spring (2 Used) 53 - Poppet
12 - O-Ring 26 - Spring 40 - Spool 54 - O-Ring
13 - Cap 27 - Check Valve 41 - Guide (2 Used) 55 - Flange
14 - O-Ring (3 Used) 28 - Cap 42 - Spring
W2-5-5
15
14
Boom Anti-Drift Valve 13
12
10 11
19
8
9 18
8 17
7 16
6
5
4 8
3 20
2
1
21
22

31
32
33
34
Boom Flow Rate

Control Valve 44
38
43
10 42
41
40
19 10
8 39 15
17 45 14
45
52 17
14 41 39 8
15 46 51
43 19
8
44
8
46
47
47
48
49 48
49
50
53 54
Arm Flow Rate
Control Valve
W1Ｊ1-02-05-051
W2-5-6
Disassemble Control Valve (4-Spool Housing
Side)
• Disassemble Bypass Shut-Out Valve • Disassemble Boom Anti-Drift Valve

1. Remove cap (31) from housing (38). 11. Remove socket bolts (10) (4 used). Remove
: 46 mm cover (16) and O-rings (8) (4 used), (20) from
housing (38).
2. Remove spool (33) and spring (34) from housing : 12 mm
(38).
12. Remove spring (21) and poppet (22) from housing
• Disassemble Arm Flow Rate Control Valve (38).
cover (45) and O-rings (8, 46) from housing (38). 13. Remove cap (1), spring (3) and poppet (4) from
: 12 mm cover (16).
: 8 mm
4. Remove piston (47), spring (48), check valve (49)
and poppet (53) from housing (38). 14. Remove cap (13) and piston (11) from cover (16).
: 30 mm
5. Remove cap (44), spring (51), guide (41) and NOTE: When replacing O-ring (14), remove cap
spool (52) from cover (45). (15) from cap (13).
: 30 mm
15. Insert the pipe (inner dia.: 7 mm, outer dia.: 10
6. Remove cap (19), spring (39) and check valve mm, length: 15 mm) into the hole on cap (13). Tap
(17) from cover (45). and remove sleeve (7) through the hole on cap
: 5 mm (1).
• Disassemble Boom Flow Rate Control Valve 16. Remove cap (19), spring (18) and check valve
7. Remove socket bolts (10) (4 used). Remove (17) from cover (16).
cover (45) and O-rings (8, 46) from housing (38). : 5 mm
: 12 mm
8. Remove piston (47), spring (48), check valve (49)

and poppet (50) from housing (38).
9. Remove cap (44), spring (42), guide (41) and

spool (40) from cover (45).
: 30 mm
10. Remove cap (19), spring (39) and check valve

(17) from cover (45).
: 5 mm
W2-5-7
Load Check Valve

23
24
25
26
30 27 35
28
29 24
25
36
37
38
35
55
54
37
W1Ｊ1-02-05-051
W2-5-8
• Disassemble Load Check Valve
(27) from housing (38).
: 14 mm
18. When replacing O-ring (25), remove cap (30) from

housing (38).
19. When replacing O-ring (29), remove cap (28) from

housing (38).
20. When replacing O-rings (37, 54), remove flanges

(36, 55) from housing (38).
W2-5-9
ASSEMBLE CONTROL VALVE (4-SPOOL HOUSING SIDE)
Boom Flow Rate Bypass Shut-Out
38 10 Control Valve 10 33 34 32 31 Valve 38
Bypass
Shut-Out
Valve
Load Check Valve
10
Arm Flow Section of Bypass Shut-Out Valve

Rate Control Figure of Control Valve (Right)
Valve Arm Flow Rate Boom Anti-Drift Valve Boom Flow Rate
Control Valve (Refer to Close-Up.) Control Valve
(Refer to Close-Up.) (Refer to Close-Up.)
38 38
Section of Arm Flow Rate Section of Boom Flow Rate Control Valve,
Control Valve Boom Anti-Drift Valve
42 (51) 40 (52) 45 12 16 11 9, 8 7 6, 5 3
45 45 13
2
14 14
44 1
15 15
41 19 4
19
48 8
8 39 17 46 8
47 18 21
49 ( ): No. at Arm Side
50 (53) 17
Close-Up of Boom Flow Rate Control Valve, 22
8
25, 24 23 Load Check Valve
26 27 38 20
Close-Up of Boom Anti-Drift Valve
Section of Load Check Valve

W1J1-02-05-044
W2-5-10
1- Cap 15 - Cap (2 Used) 29 - O-Ring 43 - O-Ring (2 Used)

2- O-Ring 16 - Cover 30 - Cap 44 - Cap (2 Used)
3- Spring 17 - Check Valve (3 Used) 31 - Cap 45 - Cover (2 Used)
4- Poppet 18 - Spring 32 - O-Ring 46 - O-Ring (2 Used)
5- O-Ring 19 - Cap (3 Used) 33 - Spool 47 - Piston (2 Used)
6- Backup Ring 20 - O-Ring 34 - Spring 48 - Spring (2 Used)
7- Sleeve 21 - Spring 35 - Socket Bolt (8 Used) 49 - Check Valve (2 Used)
8- O-Ring (10 Used) 22 - Poppet 36 - Flange 50 - Poppet
9- Backup Ring 23 - Cap 37 - O-Ring (2 Used) 51 - Spring
10 - Socket Bolt (12 Used) 24 - Backup Ring (2 used) 38 - Housing (4-Spool Side) 52 - Spool
11 - Piston 25 - O-Ring (2 Used) 39 - Spring (2 Used) 53 - Poppet
12 - O-Ring 26 - Spring 40 - Spool 54 - O-Ring
13 - Cap 27 - Check Valve 41 - Guide (2 Used) 55 - Flange
14 - O-Ring (3 Used) 28 - Cap 42 - Spring
W2-5-11
Boom Flow Rate

38 10 Control Valve 10 33 34 32 31 38
Bypass
Shut-Out
Valve
Arm Flow Section of Bypass Shut-Out Valve

Rate Control Figure of Control Valve (Right)
Valve Arm Flow Rate
Control Valve
(Refer to Close-Up.)
38
Section of Arm Flow Rate Section of Boom Flow Rate Control Valve,
Control Valve Boom Anti-Drift Valve
42 (51) 40 (52) 45
43 45
44
41
19
48
8 39 17 46 8
47
49 ( ): No. at Arm Side
50 (53)
Close-Up of Boom Flow Rate Control Valve,
Section of Load Check Valve

W1J1-02-05-044
W2-5-12
Assemble Control Valve (4-Spoo Housing Side)
• Assemble Bypass Shut-Out Valve • Assemble Boom Flow Rate Control Valve
1. Install spool (33) and spring (34) to housing (38). 7. Install poppet (50), check valve (49), spring (48)
and piston (47) to housing (38).
2. Install O-ring (32) to cap (31). Install cap (31) to
housing (38). 8. Install O-ring (43) to cap (44). Install spool (40),
: 46 mm guide (41), spring (42) and cap (44) to cover (45).
: 250 N⋅m (25.5 kgf⋅m, 185 lbf⋅ft) : 30 mm
: 60 N⋅m (6.1 kgf⋅m, 44 lbf⋅ft)
• Assemble Arm Flow Rate Control Valve
3. Install poppet (53), check valve (49), spring (48) 9. Install O-ring (8) to cap (19). Install check valve
and piston (47) to housing (38). (17), spring (39) and cap (19) to cover (45).
: 5mm
4. Install O-ring (43) to cap (44). Install spool (52), : 20 N⋅m (2.0 kgf⋅m, 15 lbf⋅ft)
guide (41), spring (51) and cap (44) to cover (45).
: 30 mm 10. Install O-rings (46, 8) to cover (45). Install cover
: 60 N⋅m (6.1 kgf⋅m, 44 lbf⋅ft) (45) to housing (38) with socket bolts (10) (4
used).
5. Install O-ring (8) to cap (19). Install check valve : 12 mm
(17), spring (39) and cap (19) to cover (45). : 180 N⋅m (18.3 kgf⋅m, 130 lbf⋅ft)
: 5 mm
: 20 N⋅m (2.0 kgf⋅m, 15 lbf⋅ft)
6. Install O-rings (46, 8) to cover (45). Install cover

(45) to housing (38) with socket bolts (10) (4
used).
: 12 mm
: 180 N⋅m (18.3 kgf⋅m, 130 lbf⋅ft)
W2-5-13
Load Check Valve
10 Section of Bypass Shut-Out Valve

Figure of Control Valve (Right)
38
Section of Arm Flow Rate Control Valve Section of Boom Flow Rate Control Valve
12 16 11 9, 8 7 6, 5 3
13
2
14
15 1
19 4
18 21
17
Close-Up of Boom Flow Rate Control 22
Valve, Arm Flow Rate Control Valve
8
25, 24 23 26 27 38
20
Section of Load Check Valve W1J1-02-05-044
W2-5-14
• Assemble Boom Anti-Drift Valve

11. Install poppet (22) and spring (21) to housing (38).
12. Install O-rings (8, 5) and backup rings (9, 6) to

sleeve (7). Install sleeve (7) to cover (16).
13. Install O-ring (2) to cap (1). Install poppet (4),

spring (3) and cap (1) to cover (16).
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
14. Install O-ring (12) to cap (13). Install piston (11)

and cap (13) to cover (16).
: 30 mm
: 60 N⋅m (6.1 kgf⋅m, 44 lbf⋅ft)
15. Install O-ring (8) to cap (19). Install check valve

(17), spring (18) and cap (19) to cover (16).
: 5 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
16. Install O-rings (20) and (8) (4 used) to cover (16).

Install cover (16) to housing (38) with socket bolts
(10) (4 used).
: 12 mm
: 180 N⋅m (18.3 kgf⋅m, 130 lbf⋅ft)
• Assemble Load Check Valve

17. Install O-ring (25) and backup ring (24) to cap (23).
Install check valve (27), spring (26) and cap (23)
to housing (38).
: 14 mm
: 350 N⋅m (36 kgf⋅m, 260 lbf⋅ft)
W2-5-15
DISASSEMBLE CONTROL VALVE
(5-SPOOL HOUSING SIDE)
Arm Anti-Drift Valve

13
12
10 11
9 18
8 17
7 16
6 15
5
4 14
3
2
1 17
19
20
Bypass Shut-Out Valve 21
Load Check Valve-1

22 Load Check Valve-2
26
23 32 Load Check Valve-3
27
27 33
24 28
27 34
29
30 28
25 30 35
31 29 27
31
28 27
30
31 29 28 36
30
30
31 37
38 31
39
40
41
W1Ｊ1-02-05-052
W2-5-16
1- Cap 12 - O-Ring 23 - O-Ring 34 - Cap

2- O-Ring 13 - Cap 24 - Spool 35 - Cap
3- Spring 14 - Cover 25 - Spring 36 - Cap
4- Poppet 15 - Check Valve 26 - Cap 37 - O-Ring
5- O-Ring 16 - Spring 27 - Backup Ring (5 Used) 38 - Socket Bolt (16 Used)
6- Backup Ring 17 - O-Ring (5 Used) 28 - O-Ring (5 Used) 39 - Flange (4 Used)
7- Sleeve 18 - Cap 29 - Check Valve (4 Used) 40 - O-Ring (4 Used)
8- O-Ring 19 - O-Ring 30 - Spring (5 Used) 41 - Housing (5-Spool Side)
9- Backup Ring 20 - Spring 31 - Check Valve (5 Used)
10 - Socket Bolt (4 Used) 21 - Poppet 32 - Cap
11 - Piston 22 - Cap 33 - Cap
W2-5-17

13
12
10 11
9 18
8 17
7 16
6 15
5
4 14
3
2
1 17
19
20
Bypass Shut-Out Valve 21
Load Check Valve-1

26
23 32 Load Check Valve-3
27
27 33
24 28
27 34
29
30 28
25 30 35
31 29 27
31
28 27
30
31 29 28 36
30
30
31 37
38 31
39
40
41
W1Ｊ1-02-05-052
W2-5-18
Side)
• Disassemble Bypass Shut-Out Valve • Disassemble Arm Anti-Drift Valve

1. Remove cap (22) from housing (41). 8. Remove socket bolts (10) (4 used). Remove
: 46 mm cover (14), O-rings (17) (4 used), (19) from
housing (41).
2. Remove spool (24) and spring (25) from housing : 12 mm
(41).
9. Remove spring (20) and poppet (21) from housing
• Disassemble Load Check Valve-1 (41).
3. Remove cap (26), check valve (29), spring (30)
and check valve (31) from housing (41). 10. Remove cap (1), spring (3) and poppet (4) from
: 14 mm cover (14).
: 8 mm
• Disassemble Load Check Valve-2
4. Remove cap (32), check valve (29), spring (30) 11. Remove cap (13) and piston (11) from cover (14).
and check valve (31) from housing (41). : 30 mm
: 14 mm
12. Insert the pipe (inner dia.: 7 mm, outer dia.: 10
• Disassemble Load Check Valve-3 mm, length: 15 mm) into the hole on cap (13). Tap
5. Remove cap (33), check valve (29), spring (30) and remove sleeve (7) through the hole on cap
and check valve (31) from housing (41). (1).
: 14 mm
• Disassemble Load Check Valve-4 (15) from cover (14).
6. Remove cap (34), check valve (29), spring (30) : 5 mm
and check valve (31) from housing (41).
: 14 mm 14. When replacing O-rings (40) (4 used), remove
socket bolts (38) (16 used) from flanges (39) (4
• Disassemble Load Check Valve-5 used).
(31) from housing (41). 15. When replacing O-ring (37), remove cap (36) from
: 14 mm housing (41).
W2-5-19
ASSEMBLE CONTROL VALVE (5-SPOOL
HOUSING SIDE)
Load Check Arm Anti-Drift
Load Check Valve-3 Valve
Valve-2 10
3 4 5 6 1
41
Load Check
Load Check Valve-4
Valve-1
Load Check
Valve-5
Bypass
Shut-Out
Valve Section of Bypass Shut-Out Valve
31 30 32 29 27, 28 41
31 30 29 26 27, 28 41
Section of Load Check Valve-1 Section of Load Check Valve-2

31 30 29 29 34 41 27, 28
33 41 27, 28
30
31
Section of Load Check Valve-3 Section of Arm Anti-Drift Valve, Load Check Valve-4
14 11 9, 8 7 6, 5 3
27, 28 35 30 31
13 2
12
1
18 4
17
16 20
15
17 21
Section of Load Check Valve-5
19
Close-Up of Arm Anti-Drift Valve
W1J1-02-05-045
W2-5-20
1- Cap 12 - O-Ring 23 - O-Ring 34 - Cap

2- O-Ring 13 - Cap 24 - Spool 35 - Cap
3- Spring 14 - Cover 25 - Spring 36 - Cap
4- Poppet 15 - Check Valve 26 - Cap 37 - O-Ring
5- O-Ring 16 - Spring 27 - Backup Ring (5 Used) 38 - Socket Bolt (16 Used)
6- Backup Ring 17 - O-Ring (5 Used) 28 - O-Ring (5 Used) 39 - Flange (4 Used)
7- Sleeve 18 - Cap 29 - Check Valve (4 Used) 40 - O-Ring (4 Used)
8- O-Ring 19 - O-Ring 30 - Spring (5 Used) 41 - Housing (5-Spool Side)
9- Backup Ring 20 - Spring 31 - Check Valve (5 Used)
10 - Socket Bolt (4 Used) 21 - Poppet 32 - Cap
11 - Piston 22 - Cap 33 - Cap
W2-5-21
Load Check Arm Anti-Drift

Load Check
Valve-3 Valve 10
Valve-2 24 25 23 22 41
41
Load Check
Load Check Valve-4
Valve-1
Load Check
Valve-5
Bypass
Shut-Out
Valve Section of Bypass Shut-Out Valve
31 30 32 29 27, 28 41
31 30 29 26 27, 28 41

31 30 29 29 34 41 27, 28
33 41 27, 28
30
31

Section of Arm Anti-Drift Valve, Load Check Valve-4
27, 28 35 30 31 41
Close-Up of Arm Anti-Drift Valve W1J1-02-05-045
W2-5-22
Assemble Control Valve (5-Spool Housing Side)
• Assemble Bypass Shut-Out Valve • Assemble Load Check Valve-5

1. Install spool (24) and spring (25) to housing (41). 7. Install O-ring (28) and backup ring (27) to cap (35).
Install check valve (31), spring (30) and cap (35)
2. Install O-ring (23) to cap (22). Install cap (22) to to housing (41).
housing (41). : 14 mm
: 46 mm : 350 N⋅m (35.7 kgf⋅m, 260 lbf⋅ft)
: 250 N⋅m (25.5 kgf⋅m, 185 lbf⋅ft)
• Assemble Load Check Valve-1

Install check valves (31, 29), spring (30) and cap
: 14 mm
: 350 N⋅m (35.7 kgf⋅m, 260 lbf⋅ft)

: 14 mm
: 350 N⋅m (35.7 kgf⋅m, 260 lbf⋅ft)

5. Install O-ring (28) and backup ring (27) to cap
(33). Install check valves (31, 29), spring (30)
and cap (33) to housing (41).
: 14 mm
: 350 N⋅m (35.7 kgf⋅m, 260 lbf⋅ft)

: 14 mm
: 350 N⋅m (35.7 kgf⋅m, 260 lbf⋅ft)
W2-5-23
Arm Anti-Drift
Valve
10
41
Section of Bypass Shut-Out Valve


41

Section of Arm Anti-Drift Valve
14 11 9, 8 7 6, 5 3
13 2
12
1
18 4
17
16 20
15
17 21
19
Close-Up of Arm Anti-Drift Valve
W1J1-02-05-045
W2-5-24
• Assemble Arm Anti-Drift Valve

8. Install poppet (21) and spring (20) to housing
(41).
9. Install O-rings (8, 5) and backup rings (9, 6) to

sleeve (7). Install sleeve (7) to cover (14).
10. Install O-ring (2) to cap (1). Install poppet (4),

spring (3) and cap (1) to cover (14).
: 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
11. Install O-ring (12) to cap (13). Install piston (11)

and cap (13) to cover (14).
: 30 mm
: 60 N⋅m (6.1 kgf⋅m, 44 lbf⋅ft)
12. Install O-ring (17) to cap (18). Install check valve

(15), spring (16) and cap (18) to cover (14).
: 5 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
13. Install O-rings (19) and (17) (4 used) to cover (14).

Install cover (14) to housing (41) with socket bolts
(10) (4 used).
: 12 mm
: 180 N⋅m (18.3 kgf⋅m, 130 lbf⋅ft)
W2-5-25
DISASSEMBLE CONTROL VALVE (4-SPOOL HOUSING UPPER AND LOWER SURFACES)
Bucket
Regenerative Valve Main Relief Valve
19
20 38
21 39
40
41
30
42
Arm Regenerative 43
Overload Relief Valve 31
44
Valve 19
45 Check Valve-1
20 46 56
2 24
21 47
3
25 48
4 57
22 49
5 26 50 35
6 27 51 34
7 23 28 52 36
9 53 37
33 54
10 35 34 55
11 24
8 36
25 37
12
13 26
14 27
28
15
29
16
17
18 37
36
57
59
61
60
1
62
Check Valve-2
18
17 63
65 16
66 57
15
67 14
13 64
68 12
Flow Combiner
8 Valve
11
10
9
7
6
5
4
3
2
Overload Relief W1Ｊ1-02-05-053
Valve
W2-5-26
1- Housing (4-Spool Side) 18 - O-Ring (4 Used) 36 - Spring (3 Used) 53 - Spring

2- Lock Nut (4 Used) 19 - Cap (2 Used) 37 - Check Valve (3 Used) 54 - Main Poppet
3- Adjusting Screw (4 Used) 20 - O-Ring (2 Used) 38 - Adjusting Screw 55 - Sleeve
4- O-Ring (4 Used) 21 - Spring Seat (2 Used) 39 - O-Ring 56 - Cap
5- Spring (4 Used) 22 - Spring 40 - Lock Nut 57 - O-Ring (3 Used)
6- Pilot Poppet (4 Used) 23 - Sleeve 41 - Piston 58 - Backup Ring
7- Seat (4 Used) 24 - O-Ring (2 Used) 42 - Sleeve 59 - Cap
8- Spring (4 Used) 25 - Spool (2 Used) 43 - O-Ring 60 - Spool
9- O-Ring (4 Used) 26 - Piston (2 Used) 44 - O-Ring 61 - Spacer
10 - Backup Ring (8 Used) 27 - Backup Ring (2 Used) 45 - Lock Nut 62 - Spring
11 - O-Ring (4 Used) 28 - O-Ring (2 Used) 46 - Cap 63 - Cap
12 - Spring (4 Used) 29 - Sleeve 47 - O-Ring 64 - O-Ring
13 - Piston (4 Used) 30 - Spring 48 - Spring 65 - Cap
14 - Main Poppet (4 Used) 31 - Sleeve 49 - Pilot Poppet 66 - O-Ring
15 - Sleeve (4 Used) 32 - Sleeve 50 - Pilot Seat 67 - Cap
16 - O-Ring (4 Used) 33 - Backup Ring (2 Used) 51 - Backup Ring
17 - Backup Ring (4 Used) 34 - O-Ring (3 Used) 52 - O-Ring
W2-5-27
Bucket
Regenerative Valve
Main Relief Valve
19
20 38
21 39
40
41
30
42
Arm Regenerative
Valve 43
31
Overload Relief 44
Valve 19 Check Valve-1
45
20 46 56
2 24
21 47
3
25 48
4 57
22 49
5 26 50 35
6 27 51 34
7 23 28 52 36
9 53
33 37
10 35 54
34 55
11 24
8 36
25 37
12
13 26
14 27
28
15
29
16
17
18
1
Check Valve-2
65
66
67
68
Overload Relief W1Ｊ1-02-05-053

Valve
W2-5-28
Upper and Lower Surfaces)
• Disassemble Overload Relief Valve • Disassemble Bucket Regenerative Valve

IMPORTANT: Do not disassemble the overload 8. Remove the sleeve (31) assembly (19 to 37) from
relief valve. When the overload relief housing (1).
valve is disassembled, pressure : 36 mm
must be adjusted.
1. Remove the sleeve (15) assembly (2 to 18) from 9. Clamp sleeve (31) into a vise. Remove cap (19).
housing (1). : 14 mm
: 41mm NOTE: Cap (19) is pushed outside by spring (30).
While pushing cap (19) to sleeve (31),
2. Clamp sleeve (15) into a vise. Remove the seat remove cap (19).
assembly (2 to 7, 9, 10) from sleeve (15). Remove
springs (8, 12), piston (13) and poppet (14) from 10. Remove spring seat (21), spring (30) and spool
sleeve (15). (25) from sleeve (31).
: 36 mm
11. Remove sleeve (33) from housing (1) by using
IMPORTANT: Put the matching marks on adjusting special tool (ST 1489).
screw (3) and seat (7). Record the Remove piston (26) from sleeve (33).
rotation number of adjusting screw
(3). 12. Remove check valve (37) and spring (36) from
3. Loosen lock nut (2). Remove adjusting screw (3), sleeve (33).
spring (5) and pilot poppet (6) from seat (7).
: 19 mm • Disassemble Check Valve-1
: 6 mm, 10 mm 13. Remove cap (56), check valve (37) and spring
• Disassemble Arm Regenerative Valve : 14 mm
4. Remove the sleeve (23) assembly (19 to 29) from
housing (1).
: 46 mm
5. Clamp sleeve (23) into a vise. Remove cap (19).

: 14 mm
NOTE: Cap (19) is pushed outside by spring (22).
While pushing cap (19) to sleeve (23),
remove cap (19).
6. Remove spring seat (21), spring (22) and spool

(25) from sleeve (23).
7. Remove sleeve (29) and piston (26) from sleeve

(23).
W2-5-29
Main Relief Valve
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
37
36
57
59
61
60
1
62 Check Valve-2
63
57
64
Flow Combiner
Valve
W1Ｊ1-02-05-053
W2-5-30
• Disassemble Check Valve-2

14. Remove cap (60), check valve (37) and spring
: 14 mm
• Disassemble Main Relief Valve

IMPORTANT: Do not disassemble the main relief
valve. When the main relief valve is
disassembled, pressure must be
adjusted.
15. Remove the cap (46) assembly (38 to 55) from
housing (1).
: 41mm
IMPORTANT: As pilot seat (50) is installed to cap

(46), do not disassemble pilot seat
(50).
16. Remove sleeve (55) from cap (46) . Remove
spring (53) and main poppet (54) from sleeve
(55).
IMPORTANT: Put the matching marks on adjusting

screw (38), lock nut (40) and sleeve
(42). Record the rotation number of
17. Loosen lock nut (40). Remove adjusting screw
(38) from sleeve (42). Remove piston (41), spring
(48) and poppet (49) from sleeve (42).
： 30 mm, 22 mm
IMPORTANT: Put the matching marks on sleeve

(42), lock nut (45) and cap (46).
Record the rotation number of
sleeve (42).
18. Loosen lock nut (45). Remove sleeve (42) from
cap (46).
: 41 mm
• Disassemble Flow Combiner Valve

19. Remove cap (64), spring (63), spacer (62) and
spool (61) from housing (1).
: 46 mm
W2-5-31
ASSEMBLE CONTROL VALVE (4-SPOOL HOUSING UPPER AND LOWER SURFACES)
Arm Flow Combiner
Check Overload Regenerative Overload Check
1 1 Relief Valve Valve 2
Valve-1 Relief Valve Valve Valve-2 3
4
7
Main Relief 9
Valve
15
5
6
8
Bucket 11, 10
Regenerative 16
Valve 12
13
Figure of Control Valve (Upper) Figure of Control Valve (Lower) 18, 17 14
Arm Regenerative Close-Up of Overload Relief Valve

Valve Bucket
(Refer to Close-Up.) Overload Overload Regenerative Valve
1 Relief Valve 1 Relief Valve (Refer to Close-Up.)
Overload Overload
Relief Valve Relief Valve
Section of Arm Section of Overload Relief Valve Section of Bucket Regenerative
Regenerative Valve Valve, Overload Relief Valve
Main Relief Valve
19
38 19
Check Valve-1
20 42 40 20
56 23 45 31
57
21 46 21
36 39
34, 35 41 30 24
22 47
24 43
37 25
48
44 49
37 25
61 27, 28
36 50 26
62 53
57, 59 51, 52
27, 28 34, 35
54 36
60 57 26
63 55 33
Check Valve-2
64 29 37
Flow Combiner Close-Up of Main Close-Up of Bucket
Valve Close-Up of Arm
Regenerative Valve Relief Valve Regenerative Valve
Section of Check Valve-1, Main Relief W1J1-02-05-046
Valve, Check Valve-2, Flow Combiner

Valve
W2-5-32
1- Housing (4-Spool Side) 18 - O-Ring (4 Used) 36 - Spring (3 Used) 53 - Spring

2- Lock Nut (4 Used) 19 - Cap (2 Used) 37 - Check Valve (3 Used) 54 - Main Poppet
3- Adjusting Screw (4 Used) 20 - O-Ring (2 Used) 38 - Adjusting Screw 55 - Sleeve
4- O-Ring (4 Used) 21 - Spring Seat (2 Used) 39 - O-Ring 56 - Cap
5- Spring (4 Used) 22 - Spring 40 - Lock Nut 57 - O-Ring (3 Used)
6- Pilot Poppet (4 Used) 23 - Sleeve 41 - Piston 58 - Backup Ring
7- Seat (4 Used) 24 - O-Ring (2 Used) 42 - Sleeve 59 - Cap
8- Spring (4 Used) 25 - Spool (2 Used) 43 - O-Ring 60 - Spool
9- O-Ring (4 Used) 26 - Piston (2 Used) 44 - O-Ring 61 - Spacer
10 - Backup Ring (8 Used) 27 - Backup Ring (2 Used) 45 - Lock Nut 62 - Spring
11 - O-Ring (4 Used) 28 - O-Ring (2 Used) 46 - Cap 63 - Cap
12 - Spring (4 Used) 29 - Sleeve 47 - O-Ring 64 - O-Ring
13 - Piston (4 Used) 30 - Spring 48 - Spring 65 - Cap
14 - Main Poppet (4 Used) 31 - Sleeve 49 - Pilot Poppet 66 - O-Ring
15 - Sleeve (4 Used) 32 - Sleeve 50 - Pilot Seat 67 - Cap
16 - O-Ring (4 Used) 33 - Backup Ring (2 Used) 51 - Backup Ring
17 - Backup Ring (4 Used) 34 - O-Ring (3 Used) 52 - O-Ring
W2-5-33
Overload Overload
Relief Valve Relief Valve 2
3
4
7
9 15
5
6
8
11, 10
16
12
13
18, 17 14
Figure of Control Valve (Upper) Figure of Control Valve (Lower)
Close-Up of Overload Relief Valve
Arm Regenerative Valve Bucket
(Refer to Close-Up.) Overload Relief Valve
1 Overload Relief Valve Regenerative
1 (Refer to Close-Up.) (Refer to Close-Up.) Valve
Overload
Section of Arm Relief Valve
Section of Overload Relief Valve,
Regenerative Valve Section of Overload Relief Valve Bucket Regenerative Valve
19
20
23
21
22
24
25
27, 28
26
29
Section of Check Valve-1, Main Relief Close-Up of Arm Close-Up of Main Close-Up of Bucket
Valve, Check Valve-2, Flow Combiner Regenerative Valve Relief Valve Regenerative Valve
W1J1-02-05-046
Valve
W2-5-34
Assemble Control Valve (4-Spool Housing Upper
and Lower Surfaces)
• Assemble Overload Relief Valve • Assemble Arm Regenerative Valve

IMPORTANT: Align the matching marks and 6. Install O-ring (28) and backup ring (27) to sleeve
tighten adjusting screw (3) to the (29). Install piston (26) and sleeve (29) to sleeve
same turns when disassembling. (23).
1. Install pilot poppet (6), spring (5), adjusting screw
(3) and lock nut (2) to seat (7). 7. Install spool (25), spring (22) and spring plate (21)
to sleeve (23).
2. Install O-ring (16), backup ring (17) and O-ring IMPORTANT: Cap (19) is pushed outside by spring
(18) to sleeve (15). (22). While pushing cap (19) to
sleeve (23), install cap (19).
3. Install piston (13) to main poppet (14). Install main 8. Install O-ring (20) to cap (19). Clamp sleeve (23)
poppet (14) to sleeve (15). into a vise. Install cap (19) to sleeve (23).
: 14 mm
4. Clamp sleeve (15) into a vise. Install springs (8, : 180 N⋅m (18.3 kgf⋅m, 133 lbf⋅ft)
12) to the seat (7) assembly. Install the seat (7)
assembly to sleeve (15). 9. Install O-ring (24) to sleeve (23). Install sleeve
: 36 mm (23) to housing (1).
: 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft) : 46 mm
: 180 N⋅m (18.3 kgf⋅m, 133 lbf⋅ft)
IMPORTANT: Install the overload relief valve to the
original position before
disassembling. Adjust pressure of
the overload relief valve by using a
test bench.
(Refer to the Operational
Performance Test section /
TROUBLESHOOTING in the
separated volume, T/M.)
5. Install the overload relief valves (4 used) to
housing (1).
: 41 mm
: 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft)
NOTE: Tighten the hexagonal part of sleeve (15).
W2-5-35
Main Relief
Valve
Bucket
Regenerative
Valve

Bucket
Regenerative Valve
Section of Arm Section of Overload Relief Valve Section of Overload Relief Valve,
Regenerative Valve Bucket Regenerative Valve
Main Relief Valve
38 19
42 40 20
45 31
39 46 21
41 30
24
43 47
25
48
44 49
27, 28
50 26
53
51, 52
54 34, 35
36
55 33
37
Section of Check Valve-1, Main Relief Close-Up of Arm Close-Up of Main Relief Close-Up of Bucket
Valve, Check Valve-2, Flow Combiner Regenerative Valve Valve Regenerative Valve
Valve W1J1-02-05-046
W2-5-36
• Assemble Bucket Regenerative Valve

10. Install piston (26), spring (36) and check valve 16. Install poppet (49), spring (48) and piston (41) to
(37) to sleeve (33). cap (46).
11. Install O-rings (28, 35) and backup rings (27, 34) IMPORTANT: Align the matching marks and
to sleeve (33). Install sleeve (33) to sleeve (31). tighten adjusting screw (38) to the
same turns when disassembling.
12. Install spool (25), spring (30) and spring seat (21) 17. Install lock nut (40) and O-ring (39) to adjusting
to sleeve (31). screw (38). Install adjusting screw (38) to sleeve
(42). Tighten lock nut (40).
IMPORTANT: Cap (19) is pushed outside by spring : 30 mm
(30). While pushing cap (19) to : 60 N⋅m (6 kgf⋅m, 44 lbf⋅ft)
sleeve (31), install cap (19).
13. Install O-ring (20) to cap (19). Clamp sleeve (31) 18. Install backup ring (51) and O-ring (52) to pilot
into a vise. Install cap (19) to sleeve (31). seat (50).
: 14 mm
: 180 N⋅m (18.3 kgf⋅m, 133 lbf⋅ft) 19. Install main poppet (54) and spring (53) to sleeve
(55).
14. Install O-ring (24) to sleeve (31). Install sleeve
(31) to housing (1). 20. Install the sleeve (55) assembly to cap (46).
: 36 mm
: 180 N⋅m (18.3 kgf⋅m, 133 lbf⋅ft) 21. Install O-ring (47) to cap (46).
• Assemble Main Relief Valve IMPORTANT: Adjust pressure of the main relief
IMPORTANT: Align the matching marks and valve. (Refer to the Operational
tighten sleeve (42) to the same turns Performance Test section /
when disassembling. TROUBLESHOOTING in the
15. Install lock nut (45) and O-rings (43, 44) to separated volume, T/M.)
sleeve (42). Install sleeve (42) to cap (46). 22. Install the main relief valve to housing (1).
: 41 mm
Tighten lock nut (45). : 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft)
: 41 mm
NOTE: Tighten the hexagonal part of cap (46).
: 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft)
W2-5-37
Check
Check
1 Valve-1
Valve-2

Section of Overload Relief Valve Section of Bucket Regenerative

Section of Arm
Regenerative Valve Valve, Overload Relief Valve
Check Valve-1
56
57
36
34, 35
37
37
61
36
62
57, 59
60 57
63
Check Valve-2
64
Flow Combiner Close-Up of Arm Close-Up of Main Close-Up of Bucket
Valve Regenerative Valve Relief Valve Regenerative Valve
W1J1-02-05-046
Section of Check Valve-1, Check Valve-2,
Flow Combiner Valve
W2-5-38
• Assemble Flow Combiner Valve

23. Install O-ring (57) to cap (64). Install spool (61),
spacer (62), spring (63) and cap (64) to housing
(1).
: 46 mm
: 250 N⋅m (26 kgf⋅m, 184 lbf⋅ft)
• Assemble Check Valve-1

24. Install O-rings (57, 34) and backup ring (35) to cap
(56). Install spring (36), check valve (37) and cap
: 14 mm
: 350 N⋅m (35.7 kgf⋅m, 258 lbf⋅ft)
• Assemble Check Valve-2

Install spring (36), check valve (37) and cap (60)
to housing (1).
: 14 mm
: 350 N⋅m (35.7 kgf⋅m, 258 lbf⋅ft)
W2-5-39
DISASSEMBLE CONTROL VALVE (5-SPOOL HOUSING UPPER AND LOWER SURFACES)
Overload Relief Valve-1
46
Overload Relief 47
Valve-2
48
49
1
50
2
53
3
4 51
Check Valve-2 Check Valve-3 52
44
5 38 45
6 24
7 39
36 23
8 40 54
9 Check Valve-1
10 55
32 41
11 56
31 33 42
12
43 57
13 37
14 32 34
28
15 33 35 29
16
37 30
6
5 34
19 35
20
21
22
23 64
24
26
27
28 30
29
29
30 28
57
58 56
59 55
54
23
60
24
61 52
51
62
53
63 50
49
48
47
46

W1Ｊ1-02-05-054
W2-5-40
1- Cap 19 - Pilot Seat 36 - Cap 52 - O-Ring (4 Used)

2- O-Ring 20 - Spring 37 - O-Ring 53 - Seat (4 Used)
3- Piston 21 - Spring 38 - Cap 54 - Spring (4 Used)
4- Sleeve 22 - Piston 39 - O-Ring 55 - Piston (4 Used)
5- Backup Ring (2 Used) 23 - O-Ring (4 Used) 40 - Spacer 56 - Main Poppet (4 Used)
6- O-Ring (2 Used) 24 - Backup Ring (10 Used) 41 - O-Ring 57 - Sleeve (4 Used)
7- Poppet 25 - Main Poppet 42 - Spring 58 - O-Ring
8- Spring 26 - Sleeve 43 - Check Valve 59 - Cap
9- Spring Seat 27 - O-Ring (5 Used) 44 - Cap 60 - O-Ring
10 - Spring 28 - Backup Ring (5 Used) 45 - O-Ring 61 - O-Ring (2 Used)
11 - Pilot Poppet 29 - O-Ring (5 Used) 46 - Lock Nut (4 Used) 62 - Flange
12 - Lock Nut 30 - Cap 47 - Adjusting Screw (4 Used) 63 - Socket Bolt (4 Used)
13 - Backup Ring 31 - O-Ring (2 Used) 48 - O-Ring (4 Used) 64 - Housing (5-Spool Side)
14 - O-Ring 32 - Backup Ring (2 Used) 49 - Spring (4 Used)
15 - Sleeve 33 - Spring (2 Used) 50 - Pilot Poppet (4 Used)
16 - O-Ring 34 - Check Valve (2 Used) 51 - Spring (4 Used)
W2-5-41
46
Overload Relief 47
Valve-2 48
49
1
50
2
53
3
4 51
Check Valve-2 Check Valve-3 52
44
5 38 45
6 24
7 39
36 23
8 40 54
9 Check Valve-1
10 55
32 41
11 56
31 33 42
12
43 57
13 37
14 32 34
28
15 33 35 29
16
37 30
6
5 34
19 35
20
21
22
23 64
24
26
27
28 30
29
29
30 28
57
58
56
59
55
54
23
24
52
51
53
50
49
48
47
46

W1Ｊ1-02-05-054
W2-5-42
Disassemble Control Valve
(5-Spool Housing Upper and Lower Surfaces)
• Disassemble Overload Relief Valve-1 6. When replacing O-ring (58), remove cap (59) from
IMPORTANT: Do not disassemble the overload housing (64).
relief valve. When the overload relief
valve is disassembled, pressure 7. When replacing O-ring (45), remove cap (44) from
must be adjusted.(Refer to the housing (64).
Operational Performance Test
section / TROUBLESHOOTING in the
Attach the identification tag onto the
overload relief valves (4 used) in
order to install to the original
position.
1. Loosen sleeve (57). Remove overload relief

valves-1 from housing (64).
: 41 mm
2. Clamp the hexagonal part of sleeve (57) into a

vise. Loosen the hexagonal part of seat (53).
Remove the seat assembly (46 to 50, 52, 23, 24).
Remove springs (51, 54), piston (55) and poppet
(56) from sleeve (57).
: 36 mm
IMPORTANT: Put the matching marks on adjusting

screw (47) and seat (53). Record the
rotation number of adjusting screw
(47).
3. Remove lock nut (46). Remove adjusting screw
(47), spring (49) and pilot poppet (50) from seat
(53).
: 19 mm
: 6 mm
• Disassemble Check Valve-1, Check Valve-2

4. Remove caps (31, 36), check valve (35) and
spring (34) from housing (64).
: 14 mm
• Disassemble Check Valve-3

5. Remove cap (38), spacer (40), spring (42) and
check valve (43) from housing (64).
: 8 mm
W2-5-43
Overload Relief
Valve-2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
6
5
19
20
21
22
23 64
24
26
27
28
29
30
W1Ｊ1-02-05-054
W2-5-44
• Disassemble Overload Relief Valve-2
IMPORTANT: Do not disassemble the overload
relief valve. When the overload relief
valve is disassembled, pressure
must be adjusted. Refer to the
Operational Performance Test
section / TROUBLESHOOTING in the
8. Rotate sleeve (27) and remove the overload relief

valve assembly (1 to 30) from housing (64).
: 41 mm
IMPORTANT: Put the matching marks on sleeves
(27, 15). Record the rotation number
of adjusting sleeve (15).
9. Clamp sleeve (27) into a vise. Loosen sleeve (15).
Remove the sleeve (15) assembly (1 to 14) from
sleeve (27).
: 36 mm
10. Remove spring seat (9), spring (10), pilot poppet

(11), pilot seat (19), springs (21, 20), piston (22)
and main poppet (26) from sleeve (27).
NOTE: Push and remove main poppet (26) from
the housing (64) side in sleeve (27) by
using a round bar.
11. Remove spring (8) and poppet (7) from sleeve

(15).
IMPORTANT: Put the matching marks on sleeves

(4, 15) and lock nut (12). Record the
rotation number of sleeve (4).
12. Clamp sleeve (15) into a vise. Loosen lock nut
(12). Remove sleeve (4) and lock nut (12) from
sleeve (15).
: 36 mm
13. Clamp sleeve (4) into a vise. Remove cap (1).

Remove piston (3) from sleeve (4).
: 27 mm
NOTE: Push a round bar (Dia.: 3 mm) into the
poppet (7) hole on sleeve (4) and remove
piston (3).
W2-5-45
ASSEMBLE CONTROL VALVE (5-SPOOL HOUSING UPPER AND LOWER SURFACES)
Overload Relief
Valve-2
Check Valve-2
Check Valve-3
Check Valve-1
64
Overload Relief
Figure of Control Valve (Upper)
Overload Relief 64 Valve-1
Valve-1 Figure of Control Valve (Lower)
Overload Relief
Check Valve-3 Overload Relief Valve-1 Valve-2
(Refer to Close-Up.) (Refer to Close-Up.) (Refer to Close-Up.)
Check Valve-2
(Refer to
Close-Up.)
Overload Relief
Valve-1
Overload Relief (Refer to Close-Up.)
Valve-1
Section of Check Valve-3, Section of Check Valve-2, Section of Overload Relief Valve-1
Overload Relief Valve-1 Overload Relief valve-2
38
1
Check Valve-1
Overload Relief Valve-1 39 4 2
(Refer to Close-Up.) 46
47 3
40 12
53 13
48 41
57 42 15 14
52 7
49 51 43 8
50 16 5, 6
24, 23
Close-Up of 9
28 54
Check Valve-3 27 10
31 (36) 11
55 32 5, 6 19
29, 30 56 34 21, 20 28
24, 23
Close-Up of Overload 33, 37 22 26
Relief Valve-1 35
29, 30
Section of Check Valve-1, ( )：For Check Valve-2
Close-Up of Overload
Overload Relief valve-1 Close-Up of Check Relief Valve-2 W1J1-02-05-047
Valve-1, Check Valve-2
W2-5-46
1- Cap 19 - Pilot Seat 36 - Cap 52 - O-Ring (4 Used)

2- O-Ring 20 - Spring 37 - O-Ring 53 - Seat (4 Used)
3- Piston 21 - Spring 38 - Cap 54 - Spring (4 Used)
4- Sleeve 22 - Piston 39 - O-Ring 55 - Piston (4 Used)
5- Backup Ring (2 Used) 23 - O-Ring (4 Used) 40 - Spacer 56 - Main Poppet (4 Used)
6- O-Ring (2 Used) 24 - Backup Ring (10 Used) 41 - O-Ring 57 - Sleeve (4 Used)
7- Poppet 25 - Main Poppet 42 - Spring 58 - O-Ring
8- Spring 26 - Sleeve 43 - Check Valve 59 - Cap
9- Spring Seat 27 - O-Ring (5 Used) 44 - Cap 60 - O-Ring
10 - Spring 28 - Backup Ring (5 Used) 45 - O-Ring 61 - O-Ring (2 Used)
11 - Pilot Poppet 29 - O-Ring (5 Used) 46 - Lock Nut (4 Used) 62 - Flange
12 - Lock Nut 30 - Cap 47 - Adjusting Screw (4 Used) 63 - Socket Bolt (4 Used)
13 - Backup Ring 31 - O-Ring (2 Used) 48 - O-Ring (4 Used) 64 - Housing (5-Spool Side)
14 - O-Ring 32 - Backup Ring (2 Used) 49 - Spring (4 Used)
15 - Sleeve 33 - Spring (2 Used) 50 - Pilot Poppet (4 Used)
16 - O-Ring 34 - Check Valve (2 Used) 51 - Spring (4 Used)
W2-5-47
Overload Relief
Valve-2
Check Valve-2
Check Valve-3
Check Valve-1
64
Overload Relief
Figure of Control Valve (Upper) Valve-1 64
Figure of Control Valve (Lower)
Overload Relief
Check Valve-3 Valve-1
(Refer to Close-Up.) (Refer to Close-Up.)
Check Valve-2
Overload Relief
Valve-1
Overload Relief (Refer to Close-Up.)
Valve-1
Overload Relief Valve-1 Overload Relief Valve-2
38
Check Valve-1
(Refer to Close-Up.) Overload Relief
Valve-1 39
(Refer to Close-Up.) 46
47 40
53
48 41
57 42
52
49 51 43
50 24, 23
Close-Up of Check
28 54 Valve-3
31 (36)
55 32
29, 30 56 34
Close-Up of Overload 33, 37
Relief Valve-1 35
Section of Check Valve-1, ( )：For Check Valve-2 Close-Up of

Overload Relief Valve-1 Overload Relief W1J1-02-05-047
Close-Up of Check Valve-2
W2-5-48
(5-Spool Housing Upper and Lower Surfaces)
• Assemble Overload Relief Valve-1 • Assemble Check Valve-1, Check Valve-2

1. Install O-ring (52), backup rings (24) (2 used) and 7. Install O-rings (32, 37) and backup ring (33) to cap
O-ring (23) to seat (53). Install O-ring (48) to (check valve-1: 31, check valve-2: 36). Install
adjusting screw (47). spring (34), check valve (35) and cap (check
valve-1: 31, check valve-2: 36) to housing (64).
IMPORTANT: Align the matching marks and : 14 mm
tighten adjusting screw (47) to the : 350 N⋅m (36 kgf⋅m, 258 lbf⋅ft)
same turns when disassembling.
2. Install pilot poppet (50), spring (49), adjusting • Assemble Check Valve-3
screw (47) and lock nut (46) to seat (53). 8. Install O-ring (39) to cap (38). Install O-ring (41) to
spacer (40). Install check valve (43), spring (42),
3. Install O-ring (28), backup ring (29) and O-ring spacer (40) and cap (38) to housing (64).
(30) to sleeve (57). : 8 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
4. Install piston (55) to main poppet (56). Install main
poppet (56) to sleeve (57).
5. Install springs (54, 51) to the seat (53) assembly.

Install the seat (53) assembly to sleeve (57).
: 36 mm
: 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft)
IMPORTANT: Install overload relief valve-1 to the

original position before
disassembling.
Adjust pressure of the overload
relief valve by using a test bench.
(Refer to the Operational
Performance Test section /
6. Install overload relief valves-1 (4 used) to
housing (64).
: 41 mm
: 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft)
NOTE: Tighten the hexagonal part of sleeve (57).
W2-5-49
Overload Relief
64 Valve-2
Figure of Control Valve (Upper) 64

Overload Relief Valve-1 Overload Relief Valve-2
4 2
3
12
13
15 14
7
8
16 5, 6
Close-Up of 9
Check Valve-3 27 10
11
5, 6 19
21, 20 28
24, 23
Close-Up of Overload 22
Relief Valve-1
26
29, 30
Section of Check Valve-1, ( )：For Check Valve-2
Close-Up of Overload
Overload Relief Valve-1 Close-Up of Check Relief Valve-2 W1J1-02-05-047
W2-5-50
• Assemble Overload Relief Valve-2 17. Install springs (21, 20) to main poppet (26). Install
9. Install O-ring (2) to cap (1). Install piston (3) and pilot seat (19) to sleeve (27). Install pilot poppet
cap (1) to sleeve (4). (11) to pilot seat (19).
: 27 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 18. Align the sleeve (15) assembly with the sleeve
(27) assembly before temporarily tightening.
10. Install lock nut (12), backup ring (13) and O-ring Clamp sleeve (27) into a vise. Tighten sleeve (15).
(14) to sleeve (4). Install backup ring (5), O-ring : 36 mm
(6) and poppet (7) to sleeve (4). : 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft)
IMPORTANT: Align the matching marks and IMPORTANT: Install overload relief valve-2 to the
tighten sleeve (4) to the same turns original position before
when disassembling. disassembling.
11. Install the sleeve (4) assembly to sleeve (15). Adjust pressure of overload relief
Tighten lock nut (12). valve-2 by using a test bench.
: 36 mm (Refer to the Operational
: 80 N⋅m (8 kgf⋅m, 59 lbf⋅ft) Performance Test section /
12. Install O-ring (16), spring (8), spring seat (9) and separated volume, T/M.)
spring (10) to the sleeve (15) assembly. 19. Install overload relief valve-2 to housing (64).
: 41 mm
13. Install O-rings (28, 30) and backup ring (29) to : 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft)
sleeve (27). NOTE: Tighten the hexagonal part of sleeve (27).
14. Install backup rings (24) (2 used), O-ring (23) and

piston (22) to main poppet (26).
15. Install the main poppet (26) assembly to sleeve

(27).
16. Install backup ring (5) and O-ring (6) to pilot seat
(19).
W2-5-51
(4-SPOOL CONTROL VALVE)
4
1
5
2 4
6
5
3
7
6 5
4
7 20
5
5
4
6
5
7 12
6
5 13
14
7 10
15
5 16
17 21
8 18
19
11
22
3
3
24
23 1
1
W1J1-02-05-055
W2-5-52
1- Socket Bolt (13 Used) 7- Spring (4 Used) 13 - Check Valve 19 - Spool (Bucket)
2- Cover 8- Spool 14 - Spring 20 - Spool
3- O-Ring (8 Used) 9- Spool (Arm 2) 15 - Spacer 21 - Spool (Travel)
4- Cap (4 Used) 10 - Spool 16 - O-Ring 22 - Housing (4-Spool Side)
5- Spring Guide (8 Used) 11 - Spool (Boom 2) 17 - Backup Ring 23 - Cover
6- Sleeve (4 Used) 12 - Spool 18 - Cap 24 - Cover
W2-5-53
4
1
5
2 4
6
5
3
7
6 5
4
7 20
5
5
4
6
5
7 12
6
5 13
14
7 10
15
5 16
17 21
8 18
19
11
22
3
3
24
23 1
1
W1J1-02-05-055
W2-5-54
Disassemble Control Valve (4-Spool Control
Valve)
• Disassemble Spool
1. Remove socket bolts (1) (6 used) from cover (2).
Remove cover (2) and O-rings (3) (4 used) from
housing (22).
: 10 mm
2. Remove socket bolts (1) (7 used) from covers (23,

24). Remove covers (23, 24) and O-rings (3) (4
used) from housing (22).
: 10 mm
IMPORTANT: Rotate and remove spool (9, 11, 19,

21) assemblies.
Do not disassemble spool (9, 11, 19,
21) assemblies unless necessary.
3. Remove spool (9, 11, 19, 21) assemblies from
housing (22).
4. Remove bolts (4) (4 used), spring guide (12) (4

used), springs (7) (4 used), sleeves (6) (4 used)
and spring guides (5) (4 used) from spools (8, 10,
12, 20).
: 10 mm

check valve (13) from spool (12).
: 10 mm
W2-5-55
CONTROL VALVE)
22 1 2 23 1 1 24

5
8 10 12 7
2
4
22 1 6
20
13
14 18
15 16, 17
W1J1-02-05-048
3 23 9 11 19 3 21 24 1
Section of 4-Spool
1- Socket Bolt (13 Used) 7- Spring (4 Used) 13 - Check Valve 19 - Spool (Bucket)
2- Cover 8- Spool 14 - Spring 20 - Spool
3- O-Ring (8 Used) 9- Spool (Arm 2) 15 - Spacer 21 - Spool (Travel)
4- Bolt (4 Used) 10 - Spool 16 - O-Ring 22 - Housing (4-Spool Side)
5- Spring Guide (8 Used) 11 - Spool (Boom 2) 17 - Backup Ring 23 - Cover
6- Sleeve (4 Used) 12 - Spool 18 - Cap 24 - Cover
W2-5-56
Assemble Control Valve (4-Spool Control Valve)
1. Install O-rings (3) (8 used) to housing (22). Install

cover (24) to housing (22) with socket bolts (1) (2
used). Install cover (23) to housing (22) with
: 10 mm
: 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft)
2. Apply LOCTITE #262 to the thread part of bolts

(4) (4 used). Install spring guide (5), sleeve (6),
spring (7) and spring guide (5) to spools (20, 12,
10, 8) with bolt (4) respectively.
: 10 mm
: 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft)

Install check valve (13), spring (14) and spacer
(15) to spool (12). Install cap (18) to spool (12).
: 10 mm
: 80 N⋅m (8 kgf⋅m, 59 lbf⋅ft)
IMPORTANT: Apply hydraulic oil onto the surface

of spools (9, 11, 19, 21).
4. Rotate and install spools (8, 10, 12, 20) to
housing (22) slowly.
5. Install O-rings (3) (8 used) to housing (22). Install

cover (2) to housing (22) with bolts (1) (6 used).
: 10 mm
: 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft)
W2-5-57
(5-SPOOL CONTROL VALVE)
1 5
4
6
2 5
4 7
6
3 12 5
5
7 28
6
4 5
7
20
5
4 5
6
5
7 21
6 13 22
5 14 23
7
10 15 24
25 29
5 16
8 17 26
18
27
19 30
11
31
3
3
31
32
1
W1J1-02-05-056
W2-5-58
1- Socket Bolt (15 Used) 9- Spool (Travel) 17 - Backup Ring 25 - Backup Ring
2- Cover 10 - Spool 18 - Cap 26 - Cap
3- O-Ring (10 Used) 11 - Spool (Auxiliary) 19 - Spool (Boom 2) 27 - Spool (Arm 2)
4- Bolt (5 Used) 12 - Spool 20 - Spool 28 - Spool
5- Spring Guide (10 Used) 13 - Check Valve 21 - Check Valve 29 - Spool (Swing)
6- Sleeve (5 Used) 14 - Spring 22 - Spring 30 - Housing (5-Spool Side)
7- Spring (5 Used) 15 - Spacer 23 - Spacer 31 - Cover (2 Used)
8- Spool 16 - O-Ring 24 - O-Ring 32 - Cover
W2-5-59
1 5
4
6
2 5
4 7
6
3 12 5
5
7 28
6
4 5
7
20
5
4 5
6
5
7 21
14 13 22
5 14 23
6
10 15 24
25 29
7 16
8 17 26
18
27
19 30
11
31
3
3
31
32
1
W1J1-02-05-056
W2-5-60
Disassemble Control Valve (5-Spool Control
Valve)
Disassemble Spools (6 to 10)

1. Remove socket bolts (1) (6 used) from cover (2).
Remove cover (2) and O-rings (3) (5 used) from
housing (30).
: 10 mm
2. Remove socket bolts (1) (9 used) from covers (31)

(2 used) and (32). Remove covers (31) (2 used)
and (32) from housing (30).
: 10 mm
IMPORTANT: Slowly rotate and straightly remove

spool (9, 11, 19, 27, 29) assemblies.
Do not disassemble the spool (9, 11,
19, 27, 29) assemblies unless
necessary.
3. Remove spool (9, 11, 19, 27, 29) assemblies from
housing (30).
4. Remove bolt (4), spring guide (5), spring (7),

sleeve (6) and spring guide (5) from spools (9, 11,
19, 27, 29).
: 10 mm

: 10 mm

: 8 mm
W2-5-61
CONTROL VALVE)
30
1
1
1
2 31
31
32 1
3 2 9 11 19 27 29 5 4
6
7
1
5
30
8 28
10 20
12
13 21
14 22
15 23
18 24, 25
26
W1J1-02-05-049
3 31 3 16, 17 32 3 31
Section of 5-Spool
1- Socket Bolt (15 Used) 9- Spool (Travel) 17 - Backup Ring 25 - Backup Ring
2- Cover 10 - Spool 18 - Cap 26 - Cap
3- O-Ring (10 Used) 11 - Spool (Auxiliary) 19 - Spool (Boom 2) 27 - Spool (Arm 2)
4- Cap (5 Used) 12 - Spool 20 - Spool 28 - Spool
5- Spring Guide (10 Used) 13 - Check Valve 21 - Check Valve 29 - Spool (Swing)
6- Sleeve (5 Used) 14 - Spring 22 - Spring 30 - Housing (5-Spool Side)
7- Spring (5 Used) 15 - Spacer 23 - Spacer 31 - Cover (2 Used)
8- Spool 16 - O-Ring 24 - O-Ring 32 - Cover
W2-5-62
Assemble Control Valve (5-Spool Control Valve)
1. Install O-rings (3) (5 used) to housing (30). Install 6. Install O-rings (3) (5 used) to housing (30). Install
covers (31) (2 used) and (32) to housing (30) with cover (2) to housing (30) with bolts (1) (6 used).
socket bolts (1) (9 used). : 10 mm
: 10 mm : 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft)
: 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft)
IMPORTANT: Apply LOCTITE #262 to the thread

part of bolt (4).
2. Install spring guide (5), sleeve (6), spring (7) and
spring guide (5) to spools (8, 10, 12, 20, 28) with
bolt (4).
: 10 mm
: 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft)

Install check valve (13), sleeve (15) and spring
: 10 mm
: 80 N⋅m (8 kgf⋅m, 59 lbf⋅ft)

Install check valve (21), sleeve (23) and spring
: 8 mm
: 80 N⋅m (8 kgf⋅m, 59 lbf⋅ft)
IMPORTANT: Apply hydraulic oil onto the surface

of the spool (8, 10, 12, 20, 28)
assemblies.
5. Rotate and install spools (8, 10, 12, 20, 28) to
housing (30) slowly.
W2-5-63
(HOUSING FRONT AND REAR
SURFACES)
3
4
6
W1Ｊ1-02-05-062
1- Housing (4-Spool Side) 3- Check Valve 5- O-Ring, Backup Ring 6- Cap

2- Housing (5-Spool Side) 4- Spring
W2-5-64
Disassemble Control Valve (Housing Front and
Rear Surfaces)
1. Remove cap (6), spring (4) and check valve (3)

from housing (2).
: 14 mm
W2-5-65
ASSEMBLE CONTROL VALVE (HOUSING
FRONT AND REAR SURFACES)
2 1 1 2
Check Valve
Figure of Control Valve (Rear) Figure of Control Valve (Front)

6
Section of Check Valve
W1J1-02-05-050
1- Housing (4-Spool Side) 3- Check Valve 5- O-Ring, Backup Ring 6- Cap

2- Housing (5-Spool Side) 4- Spring
W2-5-66
Assemble Control Valve (Housing Front and Rear
Surfaces)
1. Install O-ring and backup ring (5) to cap (6). Install

check valve (3), spring (4) and cap (6) to housing
(2).
: 14 mm
: 350 N⋅m (36 kgf⋅m, 258 lbf⋅ft)
W2-5-67
DISASSEMBLE HOUSING 3
4
2 3
5
1
6
4
3
8
10
5
4
3
8
8
10
9
8
9
W1Ｊ1-02-05-057
1- Housing (4-Spool Side) 4- O-Ring (3 Used) 8 - Washer (14 Used)

2- Housing (5-Spool Side) 5- O-Ring (3 Used) 9 - Socket Bolt (8 Used)
3- O-Ring (6 Used) 6- O-Ring (6 Used) 10 - Socket Bolt (6 Used)
W2-5-68
Disassemble Housing
1. Remove all valves from the upper and lower

surfaces at 5-spool side and 4-spool side.
CAUTION: Control valve weight: 400 kg (880

lb)
IMPORTANT: When placing housing (2) at 5-spool

side or housing (1) at 4-spool side
on the workbench, use the cloth in
order not to damage.
2. Install eyebolts (M12, Pitch 1.75 mm) (2 used)
into the hole on control valve. Hoist and place the
control valve onto the workbench with housing (1)
facing downward.
3. Remove socket bolt (9) and washer (8) from

housing (2).
: 14 mm
CAUTION: Control valve weight: 400 kg (880

lb)
4. Hoist and place the control valve onto the

workbench with housing (2) facing downward.
5. Remove socket bolts (9) (7 used), (10) (6 used)

and washers (8) (13 used) from housing (1).
: 14 mm
CAUTION: Housing (1) weight: 200 kg (440

lb)

into the hole on housing (1). Hoist and remove
housing (1) from housing (2) slowly.
7. Remove O-rings (3) (6 used), (4) (6 used), (5) (3

used) and (9) (3 used) from housing (2 or 1).
W2-5-69
ASSEMBLE HOUSING 10, 8 1
9, 8
9, 8
9, 8
10, 8
3
2
5 6
3 3
4 W1J1-02-05-060
1- Housing (4-Spool Side) 4- O-Ring (3 Used) 8 - Washer (14 Used)

2- Housing (5-Spool Side) 5- O-Ring (3 Used) 9 - Socket Bolt (8 Used)
3- O-Ring (6 Used) 6- O-Ring (6 Used) 10 - Socket Bolt (6 Used)
W2-5-70
Assemble Housing
IMPORTANT: When placing housing (2) or

housing (1) on the workbench, use
the cloth in order not to damage.

lb)

into the hole (2 places) on housing (2). Hoist and
place housing (2) onto the workbench with the
side facing downward.
2. Apply grease to O-rings (6) (6 used), (7) (6 used),

(8) (3 used) and (9) (3 used). Install O-rings (6) (6
used), (7) (6 used), (8) (3 used) and (9) (3 used)
to housing (2).

lb)

into the hole on housing (1). Hoist and install
housing (1) to housing (2). Install housing (1) to
housing (2) with socket bolts (3) (7 used), (5) (6
used) and washers (4) (13 used).
: 14 mm
: 250 N⋅m (25.5 kgf⋅m, 184 lbf⋅ft)
4. Hoist and place the control valve onto the

workbench with the side of housing (1) facing
downward.
5. Install socket bolt (3) and washer (4) to housing

(2).
: 14 mm
: 250 N⋅m (25.5 kgf⋅m, 184 lbf⋅ft)
W2-5-71
(Blank)
W2-5-72
UPPERSTRUCTURE / Swing Device
REMOVE AND INSTALL SWING DEVICE
There are swing devices (9, 10). These procedures

are for swing device (9). Swing device (10) can be
removed and installed in the same procedures.

TANK on W1-4-1.)
2 1 2
Removal
1. Remove bolts (2) (4 used). Remove covers (1) (2

used) from the main frame.
: 19 mm
2. Remove socket bolts (4) (8 used) from swing

device (9). Remove hoses (5, 6).
: 8 mm
3. Remove hoses (3, 7, 8) from swing device (9).

Cap the hoses and swing device (9).
: 17 mm, 19 mm, 27 mm, 36 mm
W1J1-02-05-061
6 7 3
4. Put the matching marks on housing (13) in swing
device (9) and the main frame.
Remove adapter (15), bolts (11) (13 used) and 5
Adapter: PT1/2
: 32 mm 4
6
5. Remove corks (14) (2 used) from housing (13) by
using a screwdriver. Do not reuse cork (14). 3
NOTE: Other cork (14) is located diagonally. 5
10 9
W1J1-02-06-001
11
12
13
14 14
15
W1J1-02-06-002
W2-6-1
CAUTION: Swing device (9) weight: 230 kg

(510 lb)
Nylon Sling
1. Install the bolts (M20, Pitch 2.5 mm) (2 used) to
the hole (2 places) for cork (14). Attach a nylon
sling onto the motor outer surface in swing device
(9).
2. Rotate the bolt and raise off swing device (9) from
the main frame. Hoist and remove swing device
Motor
(9) from the main frame.
: 30 mm
Installation
1. Apply liquid packing (THREEBOND #1215) to the 9 W155-02-06-012

mounting surface for main frame in swing device
(9).
11
CAUTION: Swing device (9) weight: 230 kg 12
(510 lb)
13
2. Align the matching marks on main frame and the
knock pin (15) position. Install swing device (9).
Tap and install knock pins (15) (2 used) to the
14 14
main frame.
15
NOTE: Other knock pin (15) is located diagonally.
3. Install swing device (9) to the main frame with

W1J1-02-06-002
bolts (11) (13 used) and washers (12) (13 used).
Install new corks (14) (2 used) to the pulling-out
hole. Install adapter (15).
: 32 mm
: 750 N⋅m (76.5 kgf⋅m, 555 lbf⋅ft)
Adapter: PT1/2
: 50.5 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
W2-6-2
4. Install hoses (5, 6) to swing device (9) with socket
bolts (4) (8 used). 6 7 3
: 8 mm
: 57 N⋅m (5.8 kgf⋅m, 42 lbf⋅ft)
5
5. Install hoses (3, 7, 8) to swing device (9).
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft) 4
: 19 mm 6
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 27 mm 3
: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft) 5
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft) 4
6. Release any pressure in the pump device. (Refer 8

to W1-1.) Check the hydraulic oil level. Start the
engine and check for any oil leaks. 10 9
W1J1-02-06-001
7. Install covers (1) (2 used) to the main frame with 2 1 2

the bolts (2) (4 used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
W1J1-02-05-061
W2-6-3
DISASSEMBLE SWING DEVICE
24 3
25
26
27
4
28 23
5
22
21
6
20
19
7
18 8
29 17
16
9
30
15
31 10
14
32
11
33
12
34
13
35
W16J-02-06-001
1- Motor 10 - Bolt (2 Used) 19 - Thrust Plate (3 used) 28 - Cork (2 Used)

2- Socket Bolt (8 Used) 11 - Lock Plate 20 - Planetary Gear (3 Used) 29 - Oil Seal
3- Ring Gear 12 - Bearing Nut 21 - Needle Bearing (3 Used) 30 - Roller Bearing
4- First Stage Sun Gear 13 - Roller Bearing 22 - Spring Pin (3 Used) 31 - Screw (4 Used)
5- Thrust Plate 14 - Thrust Plate (3 used) 23 - Pin (3 Used) 32 - Magnet (4 Used)
6- First Stage Carrier 15 - Planetary Gear (3 Used) 24 - Socket Bolt (12 Used) 33 - Sleeve
7- Second Stage Sun Gear 16 - Thrust Plate (3 used) 25 - Drain Plug 34 - O-Ring
8- Thrust Plate 17 - Spring Pin (3 Used) 26 - Cock 35 - Shaft
9- Second Stage Carrier 18 - Pin (3 Used) 27 - Housing
W2-6-4
Disassemble Swing Device
CAUTION: Swing device weight: 230 kg (510 CAUTION: Swing motor (1) weight: 50 kg
lb) (110 lb)
1. Install bracket (ST 5101) onto the workbench. 6. Remove socket bolts (2) (8 used). Remove motor
(1) from ring gear (3).
2. Attach a nylon sling onto the swing device and : 10 mm
hoist the swing device. NOTE: THREEBOND is applied to the mating
surfaces on ring gear (3) and motor (1).
Eyebolt
Mounting Insert a screwdriver into the notch in
Positions mating part and raise off motor (1).
7. Remove first stage sun gear (4) from first stage

carrier (6).
8. Remove the first stage carrier (6) assembly from

ring gear (3).
9. Remove socket bolts (24) (12 used) from ring

gear (3).
W16J-02-06-003 : 14 mm
3. Install the swing device to bracket (ST 5101) so

that the stopper of bracket (ST 5101) can be CAUTION: Ring gear (3) weight: 22.5 kg (50
inserted between the teeth in pinion gear in the lb)
swing device. Install the swing device to bracket
(ST 5101) with the bolts (M20) (2 used). 10. Install eyebolt (M12, Pitch 1.75 mm) into the
: 30 mm socket bolt hole (2 places) on ring gear (3). Hoist
Bolt Swing Device and remove ring gear (3) from housing (27).
NOTE: THREEBOND is applied to the mating
surfaces on ring gear (3) and housing (27).
Insert a screwdriver into the notch in
ST 5101
Stopper mating part and raise off ring gear (3).
Pinion Gear
W178-02-06-012
4. Remove drain plug (25). Rotate cock (25) and

drain oil in the swing device.
Plug: PT1/2
5. Put the matching marks on the mating part

between motor (1) and ring gear (3), between ring
gear (3) and housing (27).
W2-6-5
24
27
23
5
22
21
6
20
19
7
18 8
17
16
9
15
10
14
11
12
35
W16J-02-06-001
W2-6-6
11. Remove second stage sun gear (7) from second 18. Remove bearing nut (12) from shaft (35) by using
stage carrier (9). special tool (ST 2926).
ST 2926
CAUTION: The second stage carrier (9) 12
12. Remove the second stage carrier (9) assembly

from shaft (35).
13. Remove spring pins (22) (3 used) from first stage

carrier (6) by using special tool (ST 1462).
14. Remove pins (23) (3 used), planetary gears (20)

(3 used), needle bearings (21) (3 used) and thrust
plates (19) (3 used) from first stage carrier (6).
15. Remove thrust plate (5) from first stage carrier W178-02-06-008
(6).
CAUTION: The housing (27) assembly
16. Remove the second stage carrier (9) assembly in
weight: 120 kg (265 lb)
the same procedures as steps 11 to 14.
Special tool when removing spring pin (17): ST
19. Install eyebolt (M16, Pitch 2.0 mm) into the
1463
socket bolt (24) hole (2 places) on housing (27).
NOTE: The needle bearing is not used for second Remove the bolts (M20) (2 used) securing
stage carrier (9). Thrust plates (14, 16) (3 housing (27) and bracket (ST 5101).
used for each) are located above and Hoist and remove housing (27) from bracket (ST
under planetary gear (15). 5101).
: 30 mm
17. Remove bolts (10) (2 used). Remove lock plate
(11) from bearing nut (12).
: 17 mm
W2-6-7
27
13
35
W16J-02-06-001
W2-6-8
20. Install the housing (27) assembly to bracket (ST
CAUTION: The shaft (35) assembly weight:
7298). Set the housing (27) assembly to the
50 kg (110 lb)
press.
Press 21. Remove the shaft (35) assembly from housing
(27) by using a press.
Press
27
Cover
ST 7298 27
W178-02-06-006
CAUTION: When pressing shaft (35), cover W157-02-06-011

housing (27) with the cover (outer dia.: 290
mm (11.4 in), inner dia.: 90 mm (3.5 in),
thickness: 25 to 30 mm (1.0 to 1.2 in)).
When housing (27) and/or roller bearing (13)
are broken and flown off without the cover,
the metal fragments may result in personal
injury.
Press at 30 ton or less.
Degrease the housing (27) inside before
heating roller bearing (13). Failure to
degrease may cause a fire.
35
13
27
Cover
W157-02-06-010
W2-6-9
27
30
13
35
W16J-02-06-001
W2-6-10
22. Install the shaft (35) assembly to the guide. 23. Set shaft (35) to the press.
Special Tool when Removing Bearing
Shaft
Hose Clamp Press
35
30
33
Guide
W157-02-06-012
35
30 W157-02-06-014
33
NOTE: Remove roller bearing (30) by using
special tools (ST 7297, ST 7299).
Place special tool (ST 7299) onto the
stepped part of special tool (ST 7297).
Insert the pinion gear of shaft (35) into the
tooth-hole of special tool (ST 7299). Push
shaft (35) by using the press and remove
Shaft roller bearing (30) from shaft (35).
W157-02-06-013
Guide
Press
NOTE: Use the following parts as special tools for

removing roller bearing (30).
Part Specification 35
Shaft Length: 270 mm (10.6 in)
(Bolt) Diameter: 19 mm (0.7 in)
Number: 8 used (All should be in same 30
length with no wear and deformation on ST 7299
both ends) 33
ST 7297
Material: S35C
Hose Standard Diameter: 8-1/2
Clamp Tightening Range: 185 to 215 mm
(7.3 to 8.5 in)
Number: 2 used W178-02-06-009
Guide Height: 230 mm (9.1 in)

Outer Dia. : 230 mm (9.1 in)
Inner Dia. : 210 mm (8.3 in)
W2-6-11
27
Body
29
30
33
34
13
35
W16J-02-06-001
W2-6-12
24. Remove the inner race of roller bearing (30) and
sleeve (33) from shaft (35).
25. Remove O-ring (34), screws (30) (4 used) and

magnets (31) (4 used) from sleeve (33).
IMPORTANT: Do not remove roller bearings (13,

30) and the outer race from housing
(27) unless replacing the parts.
26. Remove the inner race of roller bearing (13) from
housing (27).
Insert a round bar into the oil passage in housing
(27). Tap by using a hammer and remove the
outer race of roller bearing (30).
13 27
Oil Passage
Outer Race
30
W178-02-06-001

lb)
27. Attach a nylon sling onto the body of housing (27).

Hoist and place housing (27) with the pinion gear
of shaft (35) facing upward.
28. Insert a screwdriver into the notch on housing

(27) where oil seal (29) is mounted. Remove oil
seal (29).
NOTE: Oil seal (29) is secured by using
THREEBOND. Do no reuse oil seal (29).
29. Remove roller bearing (13) from housing (27).

Attach a bar, tap the outer race by using a
hammer and remove roller bearing (13).
W2-6-13
ASSEMBLE SWING DEVICE
4
22
21 5
23
20 6
19 3
17 7
16
9
18 24
15
8
14
10
13 11
26
12
25
27
32
30
31 29
33
35
34
W16J-02-06-002
1- Motor 10 - Bolt (2 Used) 19 - Thrust Plate (3 used) 28 - *Cork (2 Used)

2- Socket Bolt (8 Used) 11 - Lock Plate 20 - Planetary Gear (3 Used) 29 - Oil Seal
3- Ring Gear 12 - Bearing Nut 21 - Needle Bearing (3 Used) 30 - Roller Bearing
4- First Stage Sun Gear 13 - Roller Bearing 22 - Spring Pin (3 Used) 31 - Screw (4 Used)
5- Thrust Plate 14 - Thrust Plate (3 used) 23 - Pin (3 Used) 32 - Magnet (4 Used)
6- First Stage Carrier 15 - Planetary Gear (3 Used) 24 - Socket Bolt (12 Used) 33 - Sleeve
7- Second Stage Sun Gear 16 - Thrust Plate (3 used) 25 - Drain Plug 34 - O-Ring
8- Thrust Plate 17 - Spring Pin (3 Used) 26 - Cock 35 - Shaft
9- Second Stage Carrier 18 - Pin (3 Used) 27 - Housing
NOTE: As for the item with * mark, refer to

W2-6-1.
W2-6-14
Assemble Swing Device IMPORTANT: Apply THREEBOND #1215 to the
outer surface of oil seal (29) and
1. Apply LOCTITE to screws (30) (4 used). Install grease to the lip part respectively.
magnets (31) (4 used) to sleeve (33) with screws Install oil seal (29) with the lip part
(30) (4 used). Install O-ring (34) to sleeve (33). facing to the motor side.
5. Install oil seal (29) to housing (27) by using
special tool (ST 7300).
CAUTION: Shaft (35) weight: 36 kg (80 lb)
2. Install sleeve (33) and the inner race of roller

bearing (30) to shaft (35). Install sleeve (33) and ST 7300
29
the inner race by using special tool (ST 7295) and
a press.
27
Press
W178-02-06-007
ST 7295
NOTE: When replacing oil seal (29), install oil seal
30 (29) by using special tools (ST 7300, ST
33 7296).
35
ST 7300 35
W178-02-06-013 33
ST 7296
CAUTION: Housing (27) weight: 70 kg (130 27

29
lb)
3. Attach a nylon sling onto the body of housing (27).

Hoist and place housing (27) with the sleeve (33)
mounting side facing upward. W16J-02-06-004
4. Tap and install the outer race of roller bearing 6. Apply grease to the inner surface of oil seal (29)
(30) by using a bar and hammer to housing (27). and the outer surface of sleeve (33).
NOTE: Grease prevents the lip from curling.
W2-6-15
24
13
12
27
29
33
35
W16J-02-06-002
W2-6-16
CAUTION: The housing (27) assembly CAUTION: The housing (27) assembly
weight: 90 kg (200 lb) weight: 130 kg (290 lb)
7. Attach a nylon sling onto the body of housing (27). 12. Install eyebolt (M16, Pitch 2.0 mm) into the socket
Hoist and place housing (27) with the ring gear bolt (24) hole (2 places) on housing (27). Hoist
(3) side facing upward. and place housing (27) on a press.
8. Tap by using a bar and hammer and install the 13. Remove bearing nut (12) from shaft (35).
outer race of roller bearing (13) to housing (27).
14. Install the inner race of roller bearing (13) to
housing (27) by using special tool (ST 2924) and
CAUTION: The housing (27) assembly
a press.
IMPORTANT: Check and align carefully in order to

ST 2924
prevent the oil seal (29) lip from
curling.
9. Install eyebolt (M16, Pitch 2.0 mm) into the 13
socket bolt (24) hole (2 places) on housing (27).
Hoist and install housing (27) to shaft (35).
10. Install the inner race of roller bearing (13) to shaft

(35) by using a bar and hammer. Tap the inner
race until two threads of shaft (35) for bearing nut
(12) appear.
11. Install bearing nut (12) to shaft (35).

W178-02-06-011
NOTE: Bearing nut (12) prevents shaft (35) from

falling off.
W2-6-17
17
16 9
18
15
8
14
10
13 11
12
27
35
W16J-02-06-002
W2-6-18
15. Secure bracket (ST 5101) on a workbench. Place 17. Apply LOCTITE to the thread part of bolts (10) (2
the housing (27) assembly on bracket (ST 5101) used). Install lock plate (11) to bearing nut (12)
so that the stopper in bracket (ST 5101) is with bolts (10) (2 used). If the spline in lock plate
inserted between the teeth of pinion gear. Install (11) is not aligned with that in shaft (35), tighten
the housing (27) assembly to bracket (ST 5101) bearing nut (12) until the splines are aligned.
with bolts (M20) (2 used). : 17 mm
： 30 mm : 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
18. Install thrust plate (8) to second stage carrier (9)

27
with the oil groove side facing to the outside.
19. Apply grease onto the upper and lower sides of

ST 5101 planetary gear (15). Install thrust plates (14, 16).
Stopper Install planetary gear (15) to second stage carrier
(9).
20. Install pin (18) to second stage carrier (9).
W178-02-06-012
NOTE: Align the spring pin (17) holes on second
Pinion Gear stage carrier (9) and pin (18).
IMPORTANT: Install bearing nut (12) with the

stepped side facing to the roller
bearing (13) side.
16. Apply grease to the thread part of bearing nut
(12). Install bearing nut (12) to shaft (35).
Tighten bearing nut (12) to the specified torque
by using special tool (ST 2926).
: 490 N⋅m (50 kgf⋅m, 360 lbf⋅ft)
12
ST 2926
W178-02-06-008
W2-6-19
22 6
23 3
20
19 7
17 9
16
18
15
14 8
13
11
27
35
W16J-02-06-002
W2-6-20
21. Install spring pin (17) into the hole on second
stage carrier (9) by using special tool (ST 1463).
Concave 9
NOTE: Install spring pin (17) with the slit facing to
the motor side. 11
35
17
18 Motor Side
Slit
W178-02-06-002
W178-02-06-014
22. Install planetary gears (15) (2 used), thrust plates

26. Install second stage sun gear (7) to the second
(14) (2 used), (16) (2 used), pins (18) (2 used)
stage carrier (9) assembly. Install second stage
and spring pins (17) (2 used) to other hole (2
sun gear (7) with the thinner side facing upward
places) on second stage carrier (9) in the same
(the motor side).
procedures as steps 19, 20.
27. Remove old adhesive and clean housing (27) and
23. Install thrust plate (5) to first stage carrier (6) with
the ring gear (3) mounting surface. Apply
the oil groove side facing upward.
THREEBOND #1215 onto this surface.
24. Install needle bearings (21) (3 used) to planetary
gears (20) (3 used). Install planetary gear (20),
thrust plates (19) (3 used), pins (23) (3 used) and
spring pins (22) (3 used) to first stage carrier (6)
in the same procedures as steps 19 to 22.
NOTE: When removing and installing spring pin
(22), use special tool (ST 1462).
CAUTION: The second stage carrier (9)

25. Install the second stage carrier (9) assembly to

the spline in shaft (35).
W2-6-21
6
3
7
24
26
25
27
W16J-02-06-002
W2-6-22
CAUTION: Ring gear (3) weight: 22.5 kg (50

lb) Eyebolt Mounting
Positions
28. Install eyebolt (M12, Pitch 1.75 mm) into the
socket bolt (2) hole (2 places) on ring gear (3).
Align the matching marks made when
disassembling and install ring gear (3). Install ring
gear (3) to housing (27) with socket bolts (24) (12
used).
: 14 mm
: 205 N⋅m (21 kgf⋅m, 150 lbf⋅ft)
29. Align with the spline of second stage sun gear (7)
and install the first stage carrier (6) assembly. W16J-02-06-003
NOTE: Install first stage sun gear (4) with the

stepped side facing downward (the thrust
plate (5) side).
30. Install first stage sun gear (4) to the first stage
carrier (6) assembly.
31. Install cock (26) to housing (27). Place the handle

of cock (26) horizontally and close the port hole.
32. Wind the seal tape onto drain plug (25) and install
drain plug (25) to cock (26).
Plug: PT1/2
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
33. Add gear oil #90 (6.7 L (1.8 US gal.)) into ring
gear (3).
34. Remove old adhesive and clean ring gear (3) and
the motor (1) mounting surface. Apply
THREEBOND #1212 onto this surface.
CAUTION: Swing motor weight: 50 kg (110

lb)
35. Install eyebolts (M10, Pitch 1.5 mm) (2 used) to

motor (1). Align the matching marks made when
disassembling. Hoist and install motor (1). Install
motor (1) to ring gear (3) with socket bolts (2) (8
used).
: 10 mm
: 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)
W2-6-23
DISASSEMBLE SWING MOTOR
11
8
7
6
5
4 10
3
2
24
25 29
26 30
1 27 31
28
23 27
26
25
24
12
13
14 22
15 21 32
16 20
W178-02-06-015
19
18
17
1- Casing 9- Rotor 17 - O-Ring 25 - O-Ring (2 Used)

2- Oil Seal 10 - Plate (4 Used) 18 - O-Ring 26 - Spring (2 Used)
3- Bearing 11 - Friction Plate (3 Used) 19 - Brake Piston 27 - Poppet (2 Used)
4- Shaft 12 - O-Ring 20 - Spring (24 Used) 28 - Valve Casing
5- Shoe Plate 13 - Piston 21 - Valve Plate 29 - Socket Bolt (4 Used)
6- Plunger (9 Used) 14 - Spring 22 - Bearing 30 - O-Ring (2 Used)
7- Plate 15 - Ball 23 - O-Ring 31 - Plug (2 Used)
8- Retainer 16 - Plug (2 Used) 24 - Plug (2 Used) 32 - Relief Valve (2 Used)
W2-6-24
Disassemble Swing Motor 28
19
CAUTION: Swing motor weight: 50 kg (110
lb) Notch A
1
IMPORTANT: Do not disassemble relief valve (32).
1. Remove relief valves (32) (2 used) from valve
casing (28).
: 41 mm
2. Remove plugs (24) (2 used) from valve casing Port B

(28).
: 14 mm
3. Remove springs (26) (2 used) and poppets (27)

(2 used) from valve casing (28).
IMPORTANT: Record the clearance dimension T178-03-02-003

between valve casing (28) and
casing (1).
4. Put the matching marks at the jointed surfaces
between valve casing (28) and casing (1).
Remove socket bolts (29) (4 used).
: 17 mm
5. Remove valve casing (28) from casing (1).

NOTE: Valve plate (21) may be removed with
valve casing (28) together. Do not drop
valve plate (21).
6. Remove valve plate (21) and springs (20) (24

used) from rotor (9).
7. Install special tool (ST 1468) to notch A and

remove brake piston (19) from casing (1).
8. Remove O-rings (17, 18) from casing (1).
W2-6-25
11
8
7
6
5
4 10
3
2
24
25 29
26 30
1 27 31
28
23 27
26
25
24
12
13
14 22
15 21 32
16 20
W178-02-06-015
19
18
17
W2-6-26
9. Hoist and set casing (1) horizontally. Remove
rotor (9), retainer (8), plate (7) and plungers (6) (9
used) from shaft (4).
10. Remove plates (10) (4 used) and friction plates

(11) (3 used) from casing (1).
11. Remove shoe plate (5) from casing (1).
12. Remove shaft (4) from casing (1) by using a

plastic hammer.
13. Remove oil seal (2) from casing (1) by using a bar
and hammer.
14. Remove the outer race of bearing (3) from casing

(1) by using a bar and hammer.

shaft (4) by using a press.
IMPORTANT: The filter and orifice are installed to

piston (13). Do not disassemble
piston (13) unless they are clogged
or deformed.
When replacing the inner parts,
replace them as an assembly.
16. Remove piston (13) from casing (1) by using a
pair of pliers.
17. Remove spring (14) and ball (15) from casing (1).
W2-6-27
ASSEMBLE SWING MOTOR
27 26 25 24
12
13
14
15
16
29
T178-03-02-004
T178-03-02-003
31
30
28 32
22 21
20
23
19
18
10
17
6
11
9 8
7 3
5
1
4 T178-03-02-002
1- Casing 9- Rotor 17 - O-Ring 25 - O-Ring (2 Used)

2- Oil Seal 10 - Plate (4 Used) 18 - O-Ring 26 - Spring (2 Used)
3- Bearing 11 - Friction Plate (3 Used) 19 - Brake Piston 27 - Poppet (2 Used)
4- Shaft 12 - O-Ring 20 - Spring (24 Used) 28 - Valve Casing
5- Shoe Plate 13 - Piston 21 - Valve Plate 29 - Socket Bolt (4 Used)
6- Plunger (9 Used) 14 - Spring 22 - Bearing 30 - O-Ring (2 Used)
7- Plate 15 - Ball 23 - O-Ring 31 - Plug (2 Used)
8- Retainer 16 - Plug (2 Used) 24 - Plug (2 Used) 32 - Relief Valve (2 Used)
W2-6-28
Assemble Swing Motor
IMPORTANT: Install the inner race of bearing (3) 8. Hoist and set casing (1) horizontally. Install the
with the flange facing to the stepped rotor (9) assembly to shaft (4).
side of shaft (4). IMPORTANT: There are four notches on the outer
1. Install the inner races of bearings (3, 22) to shaft side of plate (10) and on the spline
(4) by using a press. side of friction plate (11) respectively.
Align each notch at the same place
IMPORTANT: Install oil seal (2) with the lip part when installing.
facing upward (the rotor (9) side). 9. Hoist and set casing (1) vertically. Alternately
2. Install oil seal (2) to casing (1) by using a plate. install plates (10) (4 used) and friction plates (11)
(3 used) to casing (1) and rotor (9).
3. Install the outer race of bearing (3) to casing (1)
by using a bar and hammer. 10. Install O-rings (17, 18) to casing (1).
IMPORTANT: Wind the tape onto the spline at the 11. Align the matching mark and install brake piston
end of shaft (4) in order not to (19) into casing (1).
damage oil seal (2).
NOTE: If it is difficult to install brake piston (19),
4. Install shaft (4) with casing (1) in horizontal.
tap brake piston (19) by using a plastic
hammer evenly.
5. Hoist valve casing (28) and set casing (1)
vertically with the mounting surface facing upward.
12. Install springs (20) (24 used) to brake piston (19).
Install shoe plate (5) to casing (1) with the
chamfered side of inside facing inside.
IMPORTANT: Install retainer (8) to plunger (6) with

the notch on retainer (8) facing to
the shoe plate (5) side.
6. Align the notch and install retainer (8) to plate (7).
Install plungers (6) (9 used).
IMPORTANT: After applying hydraulic oil to the

plunger hole on rotor (9), install
plunger (6).
7. Install the plunger (6) assemblies (9 used) to rotor
(9).
W2-6-29
27 26 25 24
12
13
14
15
16
29
T178-03-02-004 T178-03-02-003
31
30
28 32
22 21
20
23
19
18
10
17
6
11
9 8
7 3
5
1
4 T178-03-02-002
W2-6-30
IMPORTANT: When replacing the inner parts in 19. Install poppets (27) (2 used) and springs (26) (2
piston (13), replace them as an used) to valve casing (28). Install O-ring (25).
assembly. Install plug (24) to valve casing (28).
Install so that the ends of piston (13) : 14 mm
and casing (1) may be in the same : 330 N⋅m (34 kgf⋅m, 245 lbf⋅ft)
position.
13. Install ball (15), spring (14) and piston (13) to 20. Install relief valves (32) (2 used) to valve casing
casing (1). (28).
: 41 mm
IMPORTANT: Tap the type indicated surface on : 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
bearing (22) by using a plastic
hammer.
14. Install the outer race of bearing (22) to valve
casing (28) by using a plastic hammer.
IMPORTANT: Install valve plate (21) with the notch

on port facing to the rotor (9) side.
15. Install O-ring (23) to valve casing (28). Apply
grease to valve plate (21). Install valve plate (21)
to valve casing (28).
16. Apply grease to the needle part of bearing (22).
IMPORTANT: Check that the clearance between

valve casing (28) and casing (1) is
equal to that before disassembling.
If the clearance is larger than that
before disassembling, repeat the
installation from step 5.
17. Align the matching marks and install valve casing
(28) to casing (1).
18. Install valve casing (28) to casing (1) with socket

: 17 mm
: 430 N⋅m (44 kgf⋅m, 320 lbf⋅ft)
W2-6-31
Swing Motor
1. Clearance between plunger outer diameter and

rotor inner bore d
D-d Unit: mm (in)

0.027 (0.0011) 0.052 (0.0020)
W107-02-06-138
D D
W107-02-06-139
2. Clearance (δ) between plunger and shoe bottom

Unit: mm (in)
0 (0) 0.3 (0.0118)
W107-02-06-140
W107-02-06-141
W2-6-32
3. Shoe thickness
Unit: mm (in)
5.5 (0.22) 5.3 (0.21)
W107-02-06-142
4. Friction plate thickness

Unit: mm (in)
2.0 (0.08) 1.8 (0.07)
W107-02-06-143
W2-6-33
(Blank)
W2-6-34
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL PILOT VALVE

TANK on W1-4-1.)
Remove Left Pilot Valve

1
CAUTION: Seat (1) weight: 40 kg (88 lb)
1. Remove bolts (2) (2 used).

: 16 mm
2
W1JB-02-01-008
2. Remove socket bolts (3) (4 used). Remove seat 1 3

(1) from bracket (4).
: 6 mm
W1JB-02-07-007
W2-7-1
3. Remove cap (7) from lever (5). Remove screw (8).
Remove cover (6) from lever (5). 5 6
W1JB-02-07-013
7, 8
4. Remove bolts (10) (2 used). Remove lever (5)
5
from bracket (9).
: 13 mm
9
10 W1JB-02-07-012
11
5. Remove screws (12) (4 used). Move boot (11) up
from bracket (9).
9
12
W1JB-02-07-002
6. Remove screw (13). 13 11
W1JB-02-07-014
W2-7-2
7. Remove bolts (14) (2 used) and screw (17).
Remove covers (15, 16) from bracket (9).
: 10 mm
14 15 16
17
9
W1JB-02-07-011
8. Remove clip bands (20) (2 used). Disconnect the

connector of wire (21). 18 19 20
9. Loosen lock nut (19). Remove the lever (18)

assembly from pilot valve (22).
: 19 mm, 22 mm
21
W1JB-02-07-005
22
10. Remove hoses (23) (6 used) from pilot valve (22).

Attach an identification tag onto the removed 22
hoses for assembling. Cap the open ends.
: 19 mm
W1JB-02-07-006
23
W2-7-3
11. Remove bolt (24). Remove pilot valve (22) from
bracket (9).
: 13 mm 24 9
22
W1JB-02-07-005
24
W2-7-4
Install Left Pilot Valve
24 9
1. Install pilot valve (22) to bracket (9) with bolts (24)
(4 used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft) 22
W1JB-02-07-005
24
2. Install hoses (23) (6 used) onto pilot valve (22). 22

: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
W1JB-02-07-006
23
3. Install the lever (18) assembly to pilot valve (22).

Secure the lever (18) assembly to pilot valve (22) 18 19 20
with lock nut (19).
: 22 mm
: 55 N⋅m (5.5 kgf⋅m, 41 lbf⋅ft)
21
4. Connect the connector of wire (21).
5. Install wire (21) to bracket (9) in pilot valve (22)

with clip bands (20) (2 used). 9
W1JB-02-07-005
22
W2-7-5
6. Install covers (15, 16) to bracket (9) with bolts (14)
(2 used) and screw (17).
: 10 mm
: 3.3 to 4.2 N⋅m
(0.3 to 0.4kgf⋅m, 2.4 to 3.1 lbf⋅ft)
14 15 16
17
9
W1JB-02-07-011
7. Install covers (15, 16) to bracket (9) with screw

(13).
13 9 16
15
W1JB-02-07-014
11 9
8. Install boot (11) to bracket (9) with screws (12) (4
used).
12
W1JB-02-07-002
9. Install lever (5) to bracket (9) with bolts (10) (2 5

used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft) 9
10 W1JB-02-07-012
W2-7-6
10. Install cover (6) to lever (5) with screw (8). Attach
cap (7) to cover (6). 5 6
W1JB-02-07-013
CAUTION: Seat (1) weight: 40 kg (88 lb) 7, 8
(4 used).
: 6 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)) 1
used). 3
: 16 mm 2
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) W1JB-02-01-008
1 3
W1JB-02-07-007
W2-7-7
Remove Right Pilot Valve
1. Remove the seat. (Refer to W2-7-1.)
2. Remove caps (1) (2 used). Remove screws (2, 4)

(2 used for each). Remove cover (3) from bracket 1, 2
(5).
5 4 W1JB-02-07-009
3. Remove screw (6).
1, 2
7 6 5
W1JB-02-07-008
4. Remove screws (9) (4 used). Move boot (8) up

from bracket (5). Remove screw (10). 5
5. Remove cover (7) from bracket (5). 9
W1JB-02-07-002
10
8
W1JB-02-07-016
W2-7-8
6. Remove clip bands (13) (2 used). Disconnect the 11 12 13
connector of wire (14).
7. Loosen lock nut (12). Remove the lever (11)

assembly from pilot valve (15). 14
: 19 mm, 22 mm
8. Remove bolts (17) (3 used). Remove the bracket

(5) assembly from stand (16). Lay down the
bracket (5) assembly with the bracket (5)
assembly facing downward. W1JB-02-07-005
15
: 17 mm
9. Remove bolt (19). Remove cover (18) from

bracket (5). 5
: 10 mm
17
16
W1JB-02-07-008
18 19
10. Remove hoses (20) (6 used) from pilot valve (15).
Attach an identification tag onto the removed
hoses for reassembling. Cap the open ends.
: 19 mm
5
W1JB-02-07-010
15
W1JB-02-07-006
20
W2-7-9
11. Remove bolts (21) (4 used). Remove pilot valve
21 5
(15) from bracket (5).
: 13 mm
15
W1JB-02-07-005
21
W2-7-10
Install Right Pilot Valve
21 5
1. Install pilot valve (15) to bracket (5) with bolts (21)
(4 used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft) 15
W1JB-02-07-005
21
2. Install hoses (20) (6 used) to pilot valve (15).

: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 220 lbf⋅ft)
15
W1JB-02-07-006
20
W2-7-11
3. Install the lever (11) assembly to pilot valve (15). 11 12 13
Secure the lever (11) assembly to pilot valve (15)
with lock nut (12).
: 22 mm
: 55 N⋅m (5.5 kgf⋅m, 41 lbf⋅ft) 14
4. Connect the connector of wire (14).
5. Install wire (14) to pilot valve (15) and bracket (5) 15

with clip bands (13) (2 used).
W1JB-02-07-005
18 19
6. Install cover (18) to bracket (5) with bolt (19).
: 10 mm
: 3.3 to 4.2 N⋅m
(0.3 to 0.4 kgf⋅m, 2.4 to 3.1 lbf⋅ft)
5
W1JB-02-07-010
7. Install cover (7) to bracket (5) with screw (6).
8. Install the bracket (5) assembly to stand (16) with

7
bolts (17)(3 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
5
17
16
W1JB-02-07-008
9. Install covers (18, 7) to bracket (5) with screw

(10). 10
5
7 18
W1JB-02-07-016
W2-7-12
10. Install boot (8) to bracket (5) with screws (9) (4 8
used).
5
W1JB-02-07-002
11. Install cover (3) to bracket (5) with screws (2, 4) (2

used for each). Attach caps (1) (2 used) to cover
(3).
1, 2
5 4
W1JB-02-07-009
CAUTION: Seat (1) weight: 40 kg (88 lb) 1 3
(4 used).
4
: 6 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
W1JB-02-07-007
used). 1
: 16 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
2
W1JB-02-01-008
W2-7-13
Remove Travel Pilot Valve
1 2
1. Remove bolts (3) (7 used). Remove cover (2) from
main frame (1).
: 19 mm
W1J1-02-08-001
2. Remove hoses (5) (6 used) from pilot valve (6). 5 5

Attach identification tags to the removed hoses for
reassembling. Attach a cap onto pilot valve (6)
and hoses (5) (6 used).
: 17 mm, 19 mm
W1JB-02-07-001
3. Remove floor mat (7) from the cab.
W1JB-02-07-015
7
W2-7-14
4. Remove bolts (10) (4 used). Remove levers (9) (2
used) and pedals (8) (2 used) from pilot valve (6).
: 17 mm 9
8
10 6 W1JB-02-07-003
5. Remove socket bolts (11) (2 used). Remove pilot 1

valve (6) from main frame (1).
: 8 mm
6 11
W1JB-02-07-004
W2-7-15
Install Travel Pilot Valve
1
1. Install pilot valve (6) to main frame (1) with socket
: 8 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
6 11
W1JB-02-07-004
2. Install levers (9) (2 used) and pedals (8) (2 used)

to pilot valve (6) with bolts (10) (4 used).
: 17 mm 9
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft) 8
3. Install hoses (5) (6 used) to pilot valve (6).

: 17 mm 10 6 W1JB-02-07-003
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
5 5
W1JB-02-07-001
W2-7-16
4. Install cover (2) onto main frame (1) with bolts (3)
(7 used). 1 2
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
W1J1-02-08-001
5. Install floor mat (7) to the cab.
W1JB-02-07-015
7
W2-7-17
DISASSEMBLE RIGHT AND LEFT PILOT
VALVES
17
16
15
14
13
12
11
10
9 18
7
6 19
5 20
4 21
3 22
W178-02-07-064
1- Spacer (4 Used) 7- Spring Guide (4 Used) 13 - O-Ring (4 Used) 18 - Casing

2- Shim (Several) 8- Retaining Ring (4 Used) 14 - Plate 19 - Spool (4 Used)
3- Balance Spring A (2 Used) 9- Pusher A (2 Used) 15 - Universal Joint 20 - O-Ring
4- Balance Spring B (2 Used) 10 - Pusher B (2 Used) 16 - Cam 21 - Plug
5- Return Spring A (2 Used) 11 - Oil Seal (4 Used) 17 - Screw Joint 22 - Retaining Ring
6- Return Spring B (2 Used) 12 - Sleeve (4 Used)
W2-7-18
Disassemble Right and Left Pilot Valves
IMPORTANT: Casing (18) is made of aluminium. 3. Attach a spanner onto the upper part of universal
Too strong a force can deform or joint (15) and remove universal joint (15).
damage them. Be careful while : 17 mm
handling them. NOTE: Universal joint (15) has been secured on
IMPORTANT: Spool (19) has been selected to casing (18) by using LOCTITE #262.
match the hole of casing (18). The
dimensions of balance springs A (3), 4. Remove plate (14).
B (4) and return springs A (5), B (6)
as well as those of pushers A (9), B IMPORTANT: Do not damage the surface of sleeve
(10) are different. Indicate the port (12). Insert a soft rubber between
number from which it is removed. sleeve (12) and the tool. Oil seal (11)
Port numbers are stamped on the cannot be removed from sleeve (12).
outer surface of casing (18). Sleeve (12) and oil seal (11) must be
replaced as an assembly.
IMPORTANT: Do not remove screw joint (17) while 5. Pull out sleeve (12) upward by using a pair of
clamping casing (18) in a vise. The pliers.
strong torque may act on screw joint
(17). IMPORTANT: The dimensions of pushers (9, 10)
1. Clamp screw joint (17) in a vise. Turn cam (16) by for ports (1, 3) and ports (2, 4) are
using a spanner. Remove screw joint (17). different. Indicate the port number
: 19 mm, 32 mm from which it is removed in order to
keep by the port number.
2. Clamp the flat surface of casing (18) in a vise 6. Remove pushers (9, 10) from casing (18).
lightly. Remove cam (16) from universal joint (15).
: 32 mm
W2-7-19
18
7
6 19
5
4 21
3 22
W178-02-07-064
W2-7-20
7. When compressing the spring, do not lower the IMPORTANT: Spool (19) has been selected to
match the hole of casing (18).
spool. Install special tool (ST 4145) to the port Replace spool (19) and casing (18)
hole on casing (18) as illustrated. as an assembly.
: 6 mm 11. Remove special tool (ST4145) from casing (18).
Slowly turn and remove spool (19) from casing
8. Install special tool (ST 4146) to the pusher hole (18).
on casing (18). Push special tool and compress
the spring. Tighten special tool (ST 4146) by IMPORTANT: Retaining ring (22) may come off
using the socket bolt (M14, Pitch 2.0 mm). while disassembling. Do not drop
Remove retaining rings (8)(4 used) from spools retaining ring (22) inside the casing.
(19) (4 used) by using a screwdriver. If retaining ring (22) falls inside the
: 12 mm casing, remove retaining ring (22)
completely. Retaining ring (22)
cannot be reused.
ST 4146 12. Remove retaining ring (22) by using a screwdriver.
Install the bolt (M8, Pitch 1.25 mm) to plug (21) in
order to pull out.
: 13 mm
22
W178-02-07-048
ST 4145
IMPORTANT: The quantity of shims (2) has been

determined for each port during the
performance testing at the factory.
Do not lose the shims. Keep the
shim carefully in order to install the
shim to each former port when
assembling.
9. Remove special tool (ST4146). Remove spring
guides (7)(4 used), return springs A (5) (2 used),
B (6) (2 used), balance springs A (3) (2 used), B
(4) (2 used) from spools (19) (4 used).
10. Remove shim (2) and spacers (1) (4 used) from

spools (19) (4 used).
W2-7-21
ASSEMBLE RIGHT AND LEFT PILOT VALVES
17
15
16
11 9, 10
14
12
13
8
7
3, 4
5, 6
2
21
1
20
18 19
22
W1V1-02-07-001
1- Spacer (4 Used) 7- Spring Guide (4 Used) 13 - O-Ring (4 Used) 18 - Casing

2- Shim (Several) 8- Retaining Ring (4 Used) 14 - Plate 19 - Spool (4 Used)
3- Balance Spring A (2 Used) 9- Pusher A (2 Used) 15 - Universal Joint 20 - O-Ring
4- Balance Spring B (2 Used) 10 - Pusher B (2 Used) 16 - Cam 21 - Plug
5- Return Spring A (2 Used) 11 - Oil Seal (4 Used) 17 - Screw Joint 22 - Retaining Ring
6- Return Spring B (2 Used) 12 - Sleeve (4 Used)
W2-7-22
Assemble Right and Left Pilot Valves
IMPORTANT: The pilot valve is susceptible to IMPORTANT: Refer to the table in left in order to
contamination. Keep the parts clean assemble them correctly.
when assembling. 3. Install spacers (1) (4 used), shim (2) and balance
springs (3, 4) (2 used for each) to spools (19) (4
NOTE: Table below shows the relations between used). Install return springs (5, 6) (2 used for
each port and the components. Do not each) to casing (18).
confuse them when assembling.
4. Install spring guides (7) (4 used) onto return
Port Spool Shim Pushers A, B springs (5, 6) (2 used for each) with the protrusion
No. (19) (2) (9, 10) facing upward.
Outer grooves
1 5. Install special tool (ST 4146) to the pusher (9, 10)
Same to the Same to the (3 used)
hole on casing (18). Secure special tool (ST 4146)
former one former one Without outer
2 by using the bolts (M14, Pitch 2.0 mm).
groove
: 12 mm
Outer grooves
3
(3 used)
ST 4146
Without outer
4
groove
ST 4144
Port Return Springs Balance Springs A, B

No. (5, 6) (3, 4)
1 Short Short
2 Long Long
3 Short Short
4 Long Long
1. Insert same spools (19) (4 used) before

W178-02-07-049
disassembling to the port hole (4 places) on ST 4145
casing (18).
6. Install retaining ring (8) to ring holder (ST 4144).
NOTE: Spool (19) and casing (18) must be
2. Install special tool (ST 4145) to the port hole on

casing (18).
: 6 mm
W2-7-23
17
15
16
11 9, 10
14
12
13
8
3, 4
18
W1V1-02-07-001
W2-7-24
7. Install retaining rings (8) (4 used) to ring holder IMPORTANT: Check the tightness of cam (16).
(ST 4144). Install retaining rings (8) (4 used) to 15. Install cam (16) to universal joint (15). The
the groove on the head of spool (21) out of clearance between cam (16) and pushers (9, 10)
special tool (ST 4146). (2 used for each) should be 0 to 0.2 mm (0 to
0.008 in).
IMPORTANT: Check the mounting positions of
pushers (9, 10) (2 used for each). 16. Secure cam (16) by using a spanner. Tighten
8. Install pushers (9, 10) (2 used for each). screw joint (17) by using a spanner.
After pushing pushers (9, 10) (2 used for each) by : 19 mm, 32 mm
hand, remove them. Check if retaining ring (8) : 68.4 N⋅m (6.98 kgf⋅m, 50 lbf⋅ft)
falls off or balance springs (3, 4) (2 used for each)
are located correctly.
After checking, install pushers (9, 10) (2 used for
each) to casing (18).
9. Apply grease to the ball at the ends of pushers (9,

10) (2 used for each).
10. Apply grease to the joint part of universal joint

(15).
11. Apply grease to the inner surface of oil seals

(11) (4 used).
NOTE: Spool (12) and oil seal (11) must be
12. Install oil seals (11) (4 used) to sleeves (12) (4

used). Push the sleeves (12) (4 used) assembly
by hand until O-ring (13) is inserted into the hole
on sleeves (12) (4 used).
13. Clamp casing (18) in a vise lightly.
IMPORTANT: Align the bolt hole on plate (14) with

the screw hole on casing (18).
14. Apply LOCTITE #262 to the thread part of
universal joint (15). Place plate (14) on casing
(18) and install universal joint (15).
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
W2-7-25
DISASSEMBLE TRAVEL PILOT VALVE
3
4
35
7 34
33
32
8
9 31
30
10
29
11
28
14 27
26
12
13 15
25
16
24
17
18
23
19
20
21 22
W178-02-07-063
1- Bolt (2 Used) 10 - Spring Pin 19 - O-Ring (2 Used) 28 - Oil Seal (4 Used)

2- Cover 11 - Bracket (2 Used) 20 - Plug (2 Used) 29 - Spring Washer (2 Used)
3- Spring Pin (2 Used) 12 - Spring Pin (2 Used) 21 - Plug (2 Used) 30 - Socket Bolt (2 Used)
4- Spring Pin (2 Used) 13 - Spring Pin (2 Used) 22 - O-Ring (2 Used) 31 - Rubber Seat (2 Used)
5- Cam (2 Used) 14 - O-Ring (4 Used) 23 - Casing 32 - Damper (2 Used)
6- Bushing (4 Used) 15 - Bushing (4 Used) 24 - Spool 33 - O-Ring (2 Used)
7- Holder 16 - Pusher (4 Used) 25 - Return Spring (4 Used) 34 - O-Ring (2 Used)
8- Spring Washer (4 Used) 17 - Spring Guide (16 Used) 26 - Spacer (4 Used) 35 - Pin
9- Socket Bolt (4 Used) 18 - Balance Spring (4 Used) 27 - Shim (12 Used)
W2-7-26
Disassemble Travel Pilot Valve IMPORTANT: The quantity of shim has been
determined during the performance
IMPORTANT: Casing (23) is made of aluminium. testing at the factory. Keep the shim
Too strong a force can deform or together with the spool.
damage them. Be careful while 6. Push balance spring (18). Remove spring guides
handling them. (17) (4 used), balance springs (18) (4 used),
shims (27) (12 used) and spacers (26) (4 used)
IMPORTANT: Spool (24) has been selected to from spools (24) (4 used).
match the hole of casing (23).
Indicate the port number from which 7. Remove return springs (25) (4 used) from casing
it is removed. (23).
Port numbers are stamped on the
outer surface of casing (23).
1. Clamp casing (23) in a vise. Remove bolts (1) (2
used). Remove cover (2) from holder (7).
: 10 mm
2. Remove bolts (30) (2 used) and spring washers

(29) (2 used). Remove the holder (7) assembly
from casing (23).
: 8 mm
3. Pull out the pusher (16) assemblies (4 used) from

casing (23).
4. Remove pushers (16) (4 used) from bushings (15)

(4 used). By using a bamboo spatula, remove oil
seals (28) (4 used) and O-rings (14) (4 used) from
bushings (15) (4 used).
IMPORTANT: Put the mark on spools (24) (4 used)
in order to easily install spool (24)
into the original hole.
5. Turn and remove the spools (24) (4 used)

assembly from casing (23).
Spring guides (17) (4 used), balance springs (18)
(4 used), shims (27) (12 used) and spacers (26)
(4 used) are removed with spools (24) (4 used)
together.
NOTE: Spool (24) has been selected to match the
hole of casing (23). Replace spool (24) and
casing (23) as an assembly.
W2-7-27
3
4
6
3
4
5 10
11
5 12
6 13
6
35
7 34
33
32
9 31
10
31
11 32
33
34
35
12
13
23
19
20
21 22
W178-02-07-063
W2-7-28
IMPORTANT: Place the stand under bracket (11) 12. Remove spring pins (3, 4) (2 used for each) from
and form the reaction force. If holder cams (5) (2 used) at the same time by using
(7) bears the reaction force, a strong special tool (ST 1237).
force acts on pin (35) and pin (35) The hole insides of spring pins (3, 4) (2 used for
may be deformed. each) in cam (5) are in stepped-shape. Tap the
8. Place a stand under bracket (11). bottom of cam (5). As the holes of spring pins (3,
The hole insides of spring pins (12, 13) (2 used 4) (2 used for each) are crimped, spring pins (3, 4)
for each) in bracket (11) are in stepped-shape. may feel tight when removing.
The spring pin can only be removed in one
direction. 13. Remove pin (35) by using a bar and hammer. At
Remove both spring pins (12, 13) (2 used for the same time cams (5) (2 used) are also
each) from bracket (11) at the same time by using removed.
special tool (ST 1237). Remove bracket (11) from Do not remove bushings (6) (4 used) in holder (7)
pin (35). unless necessary. When removing, tap bushings
Do not remove spring pin (10) attached with (6) (4 used) by using special tool (ST 7256).
bracket (11) unless necessary.
The outside end of spring pin (10) has been 14. Remove plugs (20) (2 used) from casing (23).
crimped. O-rings (19) (2 used) are removed with plugs (20)
(2 used) together.
12, 13 : 5 mm
11
35 15. Remove plugs (21) (2 used) from casing (23).
10
O-rings (22) (2 used) are removed with plugs (21)
Crimped Here (2 used) together.
: 6 mm
Stand
W176-02-07-019
9. Remove socket bolts (9) (4 used) and spring

washers (8) (4 used). Remove dampers (32) (2
used) and rubber seats (31) (2 used) from pin (35).
O-rings (34) (2 used) are removed together.
: 5 mm
10. Remove O-rings (33) (2 used) from pin (35).
11. Place holder (7) with the casing (23) mounting

surface facing upward.
W2-7-29
ASSEMBLE TRAVEL PILOT VALVE
11 32 31 1 2 35 6 12 10 13 5 3, 4 30
29
34 15
9 33 28
17
8 18
14
25
27
16
26
24
23
W178-02-11-316
1- Bolt (2 Used) 10 - Spring Pin 19 - *O-Ring (2 Used) 28 - Oil Seal (4 Used)

2- Cover 11 - Bracket (2 Used) 20 - *Plug (2 Used) 29 - Spring Washer (2 Used)
3- Spring Pin (2 Used) 12 - Spring Pin (2 Used) 21 - *Plug (2 Used) 30 - Socket Bolt (2 Used)
4- Spring Pin (2 Used) 13 - Spring Pin (2 Used) 22 - *O-Ring (2 Used) 31 - Rubber Seat (2 Used)
5- Cam (2 Used) 14 - O-Ring 23 - Casing 32 - Damper (2 Used)
6- Bushing (4 Used) 15 - Bushing (4 Used) 24 - Spool (4 Used) 33 - O-Ring (2 Used)
7- Holder 16 - Pusher (4 Used) 25 - Return Spring (4 Used) 34 - O-Ring (2 Used)
8- Spring Washer (4 Used) 17 - Spring Guide (16 Used) 26 - Spacer (4 Used) 35 - Pin
9- Socket Bolt (4 Used) 18 - Balance Spring (4 Used) 27 - Shim (12 Used)
NOTE: As for the parts with mark *, refer to

W2-7-24.
W2-7-30
Assemble Travel Pilot Valve
IMPORTANT: Check the direction to install spring

NOTE: Bushings (6)(4 used) are identical.
guide (17).
1. Assemble spools (24) (4 used) into the assembly.
• Insert bushings (6) (4 used) into special tool (ST
7256). Tap special tool (ST 7256) and install
• Insert spacers (26) (2 used), shims (27) (12 used)
bushing (6) into the hole of holder (7) by using a
and balance springs (18) (4 used) into spools (24)
hammer.
(4 used) in this order. Install the shim as the same
Stop tapping when the bushing (6) end is flush
condition before disassembling.
with the inside wall.
• Push balance springs (18) (4 used) by hand.
7 ST 7256
Install spring guides (17) (4 used) to spools (24)
(4 used) with the stepped-end facing downward.
IMPORTANT: Before inserting the parts into holder

(7) and casing (23), apply hydraulic
oil onto the parts. 6
W176-02-11-310
2. Insert return springs (25) (4 used) into casing
(23). • Install bushing (6) on the opposite side in the
same procedure. 6
3. Insert the spool (24) assembly into the former port 7
before disassembling. Turn and install the spools ST 7256
(24) (4 used) assembly into casing (23).
4. Assemble pushers (16) (4 used) into the

assembly.
• Install oil seals (28) (4 used) to bushings (15) (4 W176-02-11-311
used).
• Apply grease to the inner surface of oil seals (28) • Install bushing (6) in near side as illustrated. Stop
(4 used). tapping when the bushing (6) end is flush with the
• Install O-rings (14) (4 used) to bushings (15) (4 outside of holder (7).
used). 6
• Insert pushers (16) (4 used) into bushings (15) (4
7 ST 7256
used).
• Apply grease to the head of pushers (16) (4
used).
Outside of
Holder
5. Insert the pushers (16) (4 used) assembly into
casing (23). W176-02-11-312
6. If bushing (6) has been removed from holder (7), • Install bushing (6) in the near and opposite side
install bushings (6) (4 used) to holder (7) by using as illustrated.
special tool (ST 7256) in the following procedures. 6
7
ST 7256
W176-02-11-313
W2-7-31
32 31 35 31 32 5 3, 4 30
29
34
9 33
23
W178-02-11-316
W2-7-32
7. Install O-rings (33) (2 used) to pin (35). IMPORTANT: Check the direction of damper (32).
Apply grease to O-rings (33) (2 used). Assemble The inner bore of damper (32) is
pin (35) and cams (5) (2 used) to holder (7). edged-shape. If damper (32) is pried
when installing, O-ring (33) will be
IMPORTANT: Check the direction to install spring damaged.
pins (3, 4) (2 used for each). 12. Install dampers (32) (2 used) to pin (35) with the
8. Install spring pins (3, 4) (2 used for each) to cams lever facing upward.
(5) (2 used) by using special tool (ST 1237).
Secure cams (5) (2 used) and pin (35). At this 13. Secure damper (32) and rubber seat (31) to
time, spring pins (3, 4) (2 used for each) should holder (7) with socket bolts (9) (4 used) and spring
be displaced with their slits at 90°. washers (8) (4 used).
Tap and install spring pins (3, 4) (2 used for each) : 5 mm
until spring pins (3, 4) make contact with the : 6.9 N⋅m (0.7 kgf⋅m, 5.1 lbf⋅ft)
stepped part in the hole.
14. Apply grease to O-ring (34). Push O-rings (34) (2
3 Slit Slit used) to the endmost of pin (35).
W178-02-07-050
4
9. Crimp the hole edge (2 places) of cams (5) (2

used), where spring pins (3, 4) are inserted, by
using a punch.
10. Place holder (7) on the casing (23) assembly.

Install holder (7) to casing (23) with socket bolts
(30) (2 used) and spring washers (29) (2 used).
Check the mark direction and install holder (7).
: 8 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
11. Install rubber seats (31) (2 used) to pin (35).
W2-7-33
11 32 1 2 35 12 10 13 1 1
19, 20
21, 22
W178-02-11-316
W2-7-34
15. As for the direction to install bracket (11), refer to 21. Install O-rings (19) (2 used) to plugs (20) (2 used).
the figure in the disassemble section. Install Install plugs (20) (2 used) to casing (23).
bracket (11) to pin (35). Align the inserting holes of : 5 mm
spring pins (12, 13) (2 used for each). : 10 N⋅m (1 kgf⋅m, 7.4 lbf⋅ft)
IMPORTANT: Place a stand under bracket (11) and 22. Install O-rings (22) (2 used) to plugs (21) (2 used).
form a reaction force. If holder (7) Install plugs (21) (2 used) to casing (23).
bears the reaction force, a strong : 6 mm
force acts on pin (35) and pin (35) : 19.6 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
may be deformed.
16. Place a stand under bracket (11).
Tap spring pins (12, 13) into bracket (11) until
spring pins (12, 13) come to the stepped end by
using special tool (ST 1237). The spring pins (2
used) are displaced with their slits in 90°.
Crimped Crimped
Here Here
11 35
Stand 12, 13
W176-02-07-011
17. Crimp the hole edge of bracket (11), where spring

pins (12, 13) are inserted, by using a punch.
18. Install bracket (11) on the opposite side to pin (35)

in the same procedures as steps 16, 17.
19. Install cover (2) to holder (7) with bolts (1) (2 used).
: 10 mm
: 4.9 N⋅m (0.5 kgf⋅m, 3.6 lbf⋅ft)
20. Apply grease to the spring pin (10) contact part of

dampers (32) (2 used).
W2-7-35
(Blank)
W2-7-36
UPPERSTRUCTURE / Pilot Shut-Off Solenoid Valve
REMOVE AND INSTALL PILOT SHUT-OFF
SOLENOID VALVE
1 2
TANK on W1-4-1.)
Removal 3
1. Remove bolts (3) (7 used) from cover (2). Remove
cover (2) from main frame (1).
: 19 mm
W1J1-02-08-001
Bottom of Main Frame
2. Remove bolt (6). Remove wiring connector (7). 5 6

: 17 mm
3. Remove hoses (5) (9 used) from pilot shut-off

solenoid valve (8). Attach identification tags to the
removed hoses for reassembling. Cap hose (5)
and pilot shut-off solenoid valve (8).
: 17mm, 19 mm
7
5
5 8 W1JB-02-08-003
Footrest Travel Pilot Valve
4. Remove bolts (10) (2 used) and washers (11) (2

used) from plate (9). Remove pilot shut-off
solenoid valve (8) from plate (9).
: 17 mm 9
W1JB-02-08-004
10, 11
W2-8-1
Installation Footrest Travel Pilot Valve
1. Install pilot shut-off solenoid valve (8) to plate (9)
with bolts (10) (2 used) and washers (11) (2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
6
W1JB-02-08-004
10, 11
2. Install hoses (5) (9 used) to pilot shut-off solenoid 5 6

valve (8).
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
3. Install wiring connector (7).
4. Install bolt (6).

: 17 mm 7
: 50 N⋅m (5 kgf⋅m, 66 lbf⋅ft) 5
5 8 W1JB-02-08-003
1 2
(7 used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
Bottom of Main Frame W1J1-02-08-001
W2-8-2
STRUCTURE OF PILOT SHUT-OFF SOLENOID VALVE
W1JB-02-08-001
3 4 5 6 7 8
Section A W1JB-02-08-002
Wrench Size Tightening Torque Remark

Item Part Name Q’ty
(mm) N⋅m (kgf⋅m) (lbf⋅ft)
1 Plug 1 : 6 26.5 (2.7) (19.5)
2 O-Ring 1 （1B P11）
3 Spring 1
4 Spool 1
5 Filter 1
6 Body 1
7 O-Ring 1 （1A P16）
8 Solenoid 1
9 Socket bolt 2 : 4 3.92 (0.4) （2.9）
W2-8-3
(Blank)
W2-8-4
UPPERSTRUCTURE / Solenoid Valve
REMOVE AND INSTALL SOLENOID VALVE

TANK on W1-4-1.)
2 1 2
Removal

: 19 mm
W1J1-02-05-061
Signal Control
2. Remove all hoses, pipes and connectors (5) (4 3 Valve
used) from solenoid valve (3). Attach an
identification tag onto the removed hoses for
assembling. Cap the hose and solenoid valve (3).
: 17 mm, 19 mm
W1J1-02-10-001
3
3. Remove bolts (6) (2 used). Remove solenoid
valve (3) from control valve (4).
: 17 mm
6 W1JB-02-09-005
W2-9-1
Installation 4
1. Install solenoid valve (3) to control valve (4) with

bolts (6) (2 used). 3
: 17 mm
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
6 W1JB-02-09-005
Signal Control
3 Valve
2. Install all hoses, pipes and connectors (5) (4

used) to solenoid valve (3).
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
W1J1-02-10-001
2 1 2
3. Install covers (1) (2 used) onto the main frame

with bolts (2) (4 used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
W1J1-02-05-061
W2-9-2
STRUCTURE OF SOLENOID VALVE
Housing
W800-02-09-001
Proportional
Solenoid Valve
Proportional
Solenoid Valve
W800-02-09-002
Filter Plug Plug Filter
W800-02-09-004
W800-02-09-003
Section B
View A
W2-9-3
DISASSEMBLE AND ASSEMBLE
PROPOTIONAL SOLENOID VALVE
1
2
3
4
5
7
8
9
12
13 14
10
15
11 16
17
18
19
W18G-02-08-012
4 2 3, 5 6 1 8 12 13 17 10 18
19
W18G-02-08-013
7 9 14 15 16 11
1- Socket Bolt (2 Used) 6- Solenoid 11 - Orifice 16 - O-Ring

2- Lock Nut 7- Spring 12 - Washer 17 - Sleeve
3- O-Ring 8- O-Ring 13 - Spring 18 - Plate
4- Adjusting Bolt 9- Diaphragm 14 - O-Ring 19 - Wave Spring
5- Spring 10 - Spool 15 - O-Ring
W2-9-4
Disassemble Proportional Solenoid Valve Assemble Proportional Solenoid Valve
IMPORTANT: Do not disassemble lock nut (2) and 1. Install wave spring (19) and plate (18) to the
adjusting bolt (4) for pressure housing.
adjustment.
1. Remove socket bolts (1) (2 used). Remove 2. Install O-rings (14, 15, 16) on sleeve (17). Insert
solenoid (6) and O-ring (8) from the housing. sleeve (17) into the housing.
: 4 mm
IMPORTANT: When inserting spool (10) into
sleeve (17), do not damage the edge
2. Remove spool (10), diaphragm (9), washer (12) inside sleeve (17).
and spring (13) from sleeve (17). After inserting spool (10), push
spool (10) by 3 to 5 mm. Check if
3. Remove sleeve (17), plate (18) and wave spring spool (10) moves smoothly.
(19) from the housing.
3. Install diaphragm (9), washer (12) and spring (13)
IMPORTANT: Do not remove orifice (11) from to spool (10). Install spool (10) to sleeve (17).
sleeve (17).
4. Remove O-rings (14, 15, 16) from sleeve (17). 4. Install spring (7) to solenoid (6). Install solenoid
(6) to the housing with socket bolts (1) (2 used).
： 4 mm
+2 +0.2 +0.15
：5 -0 N⋅m (0.5 -0 kgf⋅m, 3.7 -0 lbf⋅ft)
W2-9-5
(Blank)
W2-9-6
UPPERSTRUCTURE / Signal Control Valve
REMOVE AND INSTALL SIGNAL
CONTROL VALVE

TANK on W1-4-1.)
2 1 2
Removal
: 19 mm
W1J1-02-05-061
4-Spool Solenoid Valve

2. Remove all hoses and the connectors (2 used)
from signal control valve (3). Attach an
identification tag onto the removed hoses for
assembling. Cap signal control valve (3) and the 3
hose.
: 17 mm, 19 mm
W1JB-02-05-004
3. Remove socket bolts (6) (4 used). Remove signal

control valve (3) from bracket (5).
5
： 8 mm
W1JB-02-10-001
W2-10-1
Installation
3
1. Install signal control valve (3) to bracket (5) with
: 8 mm
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
W1JB-02-10-001
2. Install all hoses and the connector to signal

control valve (3). 4-Spool Solenoid Valve
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) 3
W1JB-02-09-004
2 1 2
3. Install covers (1) (2 used) onto the main frame
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
W1J1-02-05-061
W2-10-2
STRUCTURE OF SIGNAL CONTROL VALVE
4 13
12
11
7
4
10
9
7 8
7 7
4
4
W1JB-02-10-002
W2-10-3
15
14 16
17
18
19
16 20
17
21
19
16 20
17
18
19
20
14
22
23
24
25
26
27
19
28
17
16
20 29
19
18 14
5 17
20 16
19
21
17
20 16
19
18
17
16 W1JB-02-10-003
Detail of Body 2
1- Bolt (3 Used) 9- Body 3 17 - O-Ring (7 Used) 25 - O-Ring

2- Body 1 10 - Gasket 18 - Spring (4 Used) 26 - Spring
3- Gasket 11 - Body 4 19 - Spring Guide (7 Used) 27 - Spool
4- Filter (17 Used) 12 - Gasket 20 - Spool (6 Used) 28 - Spring
5- Body 2 13 - Body 5 21 - Spring (2 Used) 29 - Plate
6- Gasket 14 - Socket Bolt (11 Used) 22 - Plate
7- Shuttle Valve (2 Used) 15 - Plate 23 - O-Ring
8- Spring (4 Used) 16 - Plug (7 Used) 24 - Shuttle Valve
W2-10-4
UPPERSTRUCTURE / Shockless Valve
REMOVE AND INSTALL SHOCKLESS
VALVE

TANK on W1-4-1.) 1
Removal
1. Remove bolts (3) (6 used). Remove cover (2) from
main frame (1).
: 19 mm
W1J1-02-08-001
3 2
2. Remove hoses (8) (2 used) from shockless valve

(7). Cap hose (8) and shockless valve (7). 6
: 19 mm
3. Remove bolts (5) (2 used). Remove shockless 7

valve (7) from bracket (6).
: 13 mm
W1JB-02-11-001
8
W2-11-1
Installation
5
1. Install shockless valve (7) to bracket (6) with bolts
(5) (2 used).
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft) 6
2. Install hoses (8) (2 used) to shockless valve (7).

: 19 mm 7
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
W1JB-02-11-001
8
(6 used). 1
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
W1J1-02-08-001
3 2
W2-11-2
STRUCTURE OF SHOCKLESS VALVE
4 5 6 7
T183-03-07-008
Wrench Size Tightening Torque

Item Part Name Q’ty Remark
(mm) N⋅m (kgf⋅m) (lbf⋅ft)
1 Plug 2 : 8 39 (4) (29)
2 O-Ring 2
3 Body 1
4 Spring 2
5 Plunger 1
6 Ring 1
7 Orifice 1
W2-11-3
(Blank)
W2-11-4
UPPERSTRUCTURE / Fan Valve
REMOVE AND INSTALL FAN VALVE
2 1 2

TANK on W1-4-1.)
Removal

: 19 mm Engine Cover
W1J1-02-05-061
2. Open and lock the engine cover. Remove bolts (3) 3 Fan Motor
(4 used) from cover (4). Remove cover (4) from
the bracket.
: 19 mm
4
W1J1-02-12-001
3. Remove hoses (5) (2 used) and (6) (2 used) from

fan valve (7). Cap fan valve (7) and hoses (5, 6).
5
: 36 mm
W1J1-02-12-002
W2-12-1
4. Remove bolts (9) (2 used) from fan valve (7).
Remove fan valve (7) from bracket (8).
: 17 mm
8
W1J1-02-12-002
W2-12-2
Installation
1. Install fan valve (7) to bracket (8) with bolts (9) (2 5

used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
8
2. Install hoses (5) (2 used) and (6) (2 used) to fan 6

valve (7).
: 36 mm 7
: 175 N⋅m (18 kgf⋅m, 129 lbf⋅ft)
W1J1-02-12-002
9
3 Fan Motor
3. Install cover (4) to the bracket with bolts (3) (4

used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
4
W1J1-02-12-001
2 1 2
bolts (2) (4 used).
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
W1J1-02-05-061
W2-12-3
STRUCTURE OF FAN VALVE
View A W1JB-02-13-003
A W1JB-02-13-002
1 2 3 4 5 6
7 8 9 10 11 12
13
14
18 17 16 15
Section B W1JB-02-13-001
Wrench Size Wrench Size

Item Part Name Q’ty Item Part Name Q’ty
(mm) (mm)
1 Pin 2 10 O-Ring 1
2 Poppet 2 11 Spring 1
3 Poppet 1 12 O-Ring 1
4 Backup Ring 2 13 Lock Nut 1 : 17
5 O-Ring 1 14 Screw 1
6 O-Ring 1 15 Body 1 : 32
7 Spring 1 16 Poppet 1
8 O-Ring 1 17 Adapter 1 : 32
9 Spring 1 18 Backup Ring 2
W2-12-4
UPPERSTRUCTURE / Fan Motor
REMOVE AND INSTALL FAN MOTOR
2
hydraulic oil tank before doing any work. 1 3
Counterweight
TANK on W1-4-1.)
Removal Machine
Front
1. Drain half of hydraulic oil through the oil filler on
hydraulic oil tank by using a pump. Remove plug
(4). Drain hydraulic oil in the hydraulic oil cooler
(16 L, 4.2 US gal.) and drain pipe. After draining
hydraulic oil, install plug (4).
: 19 mm
: 30 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
W1J1-02-13-007
6 5 Main Frame
2. Remove bolts (6) (6 used) and the washers (6
used). Remove cover (5) from the main frame.
: 19 mm
3. Remove bolts (7) (2 used). Remove cover (8)

from the radiator.
: 19 mm
4. Remove the radiator cap. Open valve (9) and Counterweight 4

drain coolant (15 L, 4.2 US gal.) from the radiator.
W1J1-02-13-011
After draining coolant, install the radiator cap and
close valve (9).
Radiator Assembly
5. Remove bolts (1, 3) (2 used for each) and the
washers (4 used). Open and secure dust cover
(2).
: 19 mm
Machine
Front
8, 9 7 W1J1-02-13-008
Valve (9) is located behind cover (8).
W2-13-1
6. Remove refrigerant in the air conditioner. Remove Radiator Assembly
hoses (14) (2 used) from condenser (10). Cap the
adapter in condenser and hose (14). As for the
procedures to remove refrigerant, refer to the
operator’s manual.
: 19 mm
7. Remove the bands (2 used) from hoses (12) (2

used). Remove hoses (12) (2 used) from fuel
cooler (11). Drain fuel in the hoses between
engine and fuel cooler (11) and between fuel
cooler (11) and fuel tank. Cap fuel cooler (11) and
hose (12).
W1J1-02-13-008
10
14
11
8. Remove connector (15) from fresh air

temperature sensor (16).
13 12 W1J1-02-13-013
16
15
W1J1-02-13-014
W2-13-2
IMPORTANT: Insert the protective material
17 18
between engine cover (18) and
muffler cover (17) in order not to
damage the cover.
9. Open and hold engine cover (18). Remove lock
pins (21) (2 used) and washers (20) (2 used) from
stays (19) (2 used). Lay down engine cover (18)
to the muffler cover (17) side.
W1J1-02-13-001
19
20
CAUTION: Engine cover (18) weight: 32 kg 21
(70 lb)
W1J1-02-13-015
used). Remove engine cover (18) from the main
frame. 18
: 17 mm
22
23
W1J1-02-13-020
W2-13-3
11. Remove bolts (28) (18 used). Remove radiator
covers 1, 2 (24, 29) from the main frame. 24 17 25
： 19 mm
Ａ
12. Remove bolts (25) (8 used). Remove muffler

cover (17) from the main frame.
: 19 mm
28
13. Remove bolts (26) (4 used). Remove covers (27)
(2 used) from the main frame.
: 19 mm 29
W1J1-02-13-003
28 27 26
View A
24
28
17 25 W1J1-02-13-002
Radiator Assembly
covers (31, 34) from the main frame.
: 19 mm
31
32
W1J1-02-13-007
Counterweight 34 33 Main Frame
W2-13-4
15. Loosen nuts (42, 44, 46) (2 used for each). Move 35 36, 37
bands (43, 45, 48) (2 used for each) to the center
of hoses (41, 47).
: 11 mm
16. Remove bolts (49, 53). Remove clamps (50, 52) B

A Machine
from pipe (51). Front
: 17 mm
17. Remove pipe (51) from hoses (41, 47).

44, 45
42, 43
W1J1-02-13-005
41
46 47 48
49, 50
51
18. Loosen nuts (36, 54) (2 used for each). Move

bands (37, 56) (2 used for each) to the center of
52
hoses (35, 55).
: 11 mm
53
19. Remove bolts (57, 61). Remove clamps (58, 60)
from pipe (59). Detail for Part A W1J1-02-13-017
: 17 mm
61
20. Remove pipe (59) from hoses (35, 55).
60
54
59
58
57
W1J1-02-13-016
56 55
Detail for Part B
W2-13-5
21. Loosen nuts (65) (2 used). Move bands (66) (2
used) to the center of hose (67). Remove hose
(67) from the radiator.
: 11 mm
22. Loosen nuts (62) (2 used). Move bands (63) (2

used) to the center of hose (64). Remove hose
(64) from the radiator.
: 11 mm
62, 63
64
Machine W1J1-02-13-004
Front
65
66
67 W1J1-02-13-017
W2-13-6
23. Remove bolts (68) (4 used). Remove bracket (69)
from the main frame.
: 19 mm
68, 69
24. Remove hose (70) from the coolant reservoir.
70
Coolant
Reservoir
Front
25. Remove bolt (72). Remove coupler holder (71)

from the coupler.
: 11 mm
71
72
Coupler
W1J1-02-13-018
26. Remove bolts (74) (4 used) from flange (73). Machine

Front
: 19 mm
73
74
W1J1-02-13-008
W2-13-7
27. Remove hoses (76 to 78) from fan valve (75).
: 27 mm, 36 mm
Machine
W1J1-02-13-004
Front
78
75
77
76
W1J1-02-13-021
Machine
28. Remove bolts (80) (4 used), washers (81) (4 Front
used) and nuts (82) (4 used).
: 30 mm
80, 81, 82
79
W1J1-02-13-008
W2-13-8
29. Close dust cover (2). Temporarily tighten dust Lifting Hole
cover (2) with bolts (3) (2 used) and the washers
(2 used).
: 19 mm
Machine
NOTE: While hoisting radiator, do not open dust Front
cover (2).
CAUTION: The radiator assembly weight: 3

570 kg (1260 lb)
2
30. Attach a wire rope onto the lifting hole on radiator
assembly and hold the radiator assembly.
31. Hoist the radiator assembly and check if the W1J1-02-13-005
hydraulic hose is removed. Place the radiator

assembly onto the flat place. Cap the hydraulic oil
cooler and hose.
86
32. Remove bolts (90) (6 used). Remove cover (89)
from bracket (88). 87
: 19 mm
88
33. Remove bolts (86) (8 used) from fan guard (87).
: 19 mm 89
90
CAUTION: The bracket (88) assembly

weight: 90 kg (200 lb) 91
34. Attach a nylon sling onto the hole on bracket (88)

and hold bracket (88). Remove bolts (91) (6 used) W1J1-02-13-004
from bracket (88). Hoist and remove the bracket

(88) assembly from the radiator. Place the bracket
(88) assembly onto the flat place with fan (94)
facing upward. 94 87
: 19 mm
88
W1JB-02-12-010
93 92
W2-13-9
35. Remove socket bolts (92) (4 used). Remove fan 95
Shaft
(94) from coupling (93). 99 96
: 8 mm 92
94
36. Remove lock pin (95) and nut (96) from the shaft
in fan motor (98). 93
: 24 mm
97
IMPORTANT: Key (97) is attached with the shaft in
fan motor (98). Do not lose key (97). 88 98
37. Remove coupling (93) and fan guard (87) from
the shaft in fan motor (98).
NOTE: When it is difficult to remove coupling (93),
use special tool when removing the
bearing.
W1J1-02-13-010

94 87
38. Hoist and place the bracket (88) assembly with
the shaft in fan motor (98) facing downward.
88
Remove hoses (105, 106) from fan motor (98).
Remove hose (102) from fan motor (98).
: 8 mm
: 36 mm
W1JB-02-12-010
93 92
100, 101 102 103, 104
W1J1-02-13-019
106 105 98
W2-13-10
40. Remove bolts (107) (2 used), washers (108) (2
used) and nuts (109) (2 used). Remove fan motor
(98) from bracket (88). 98
: 19 mm
NOTE: Replace fan motor (98) with the assembly.
W1JB-02-12-011
107, 108, 109 88
W2-13-11
Installation
CAUTION: Bracket (88) weight: 41 kg (90 lb)
1. Attach a nylon sling onto the hole on bracket (88).

Hoist and place bracket (88) with the mounting
surface for fan motor (98) facing downward.
98
2. Install fan motor (98) to bracket (88) with bolts
(107) (2 used), washers (108) (2 used) and nuts
(109) (2 used).
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
W1JB-02-12-011
107, 108, 109 88
100, 101 102 103, 104

3. Install hoses (105, 106) to fan motor (98) with
socket bolts (101, 104) (4 used for each). Install
hose (102) to fan motor (98).
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
: 8 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
W1J1-02-13-019
106 105 98
W2-13-12

4. Hoist and place the bracket (88) assembly with

the shaft in fan motor (98) facing upward.
98
W1JB-02-12-011
107, 108, 109 88
95
5. Apply LOCTITE #262 to nut (96). Install key (97), 99
Shaft
96
coupling (93), washer (99), nut (96) and lock pin
92
(95) to the shaft in fan motor (98).
: 24 mm 94
: 100 N⋅m (10 kgf⋅m, 75 lbf⋅ft) 93
6. Apply LOCTITE #262 to socket bolt (92). Install 97

fan guard (87) between bracket (88) and coupling
(93). Install fan (94) to coupling (93) with socket 98
88
: 8 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
W1J1-02-13-010
W2-13-13

weight: 90 kg (200 lb) 94 87
7. Hoist and install bracket (88) to the radiator with

88
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
W1JB-02-12-010
93 92
8. Install cover (89) onto bracket (88) with bolts (90)

(6 used).
88
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
98
91
W1J1-02-13-009
9. Install fan guard (87) to the radiator with bolts (86)

(8 used). 86
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft) 87
88
89
90
91
W1J1-02-13-004
W2-13-14
CAUTION: The radiator assembly weight: Lifting Hole

570 kg (1260 lb)
IMPORTANT: Before installing the radiator Machine

assembly to the main frame, check Front
the connections in hydraulic oil
cooler and hoses.
10. Temporarily tighten dust cover (2) with bolts (3) (2 3
used). Attach a wire rope to the lifting hole on the
radiator assembly. Hoist and move the radiator 2
assembly to the mounting position for radiator in
the main frame.
W1J1-02-13-005
11. Apply LOCTITE #262 to bolts (80) (4 used). Install Machine

the radiator assembly to bracket (79) with bolts Front
(80) (4 used), washers (81) (4 used) and nuts (83)
(4 used).
: 30 mm 80, 81, 82
: 550 N⋅m (56 kgf⋅m, 405 lbf⋅ft)
79
W1J1-02-13-008
12. Apply LOCTITE #262 to bolt (68). Install bracket

(69) to the main frame with bolts (68) (4 used).
68, 69
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
Front
W2-13-15
13. Install hoses (76 to 78) to fan valve (75).
: 27 mm
: 137 N⋅m (14 kgf⋅m, 100 lbf⋅ft)
: 36 mm
: 175 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
14. Install hose (70) to the coolant reservoir.
70
Coolant
Reservoir
Machine
W1J1-02-13-004
Front
78
75
77
76
W1J1-02-13-021
W2-13-16
15. Install coupler holder (71) with bolt (72).
: 11 mm
Machine
W1J1-02-13-004
Front
71
72
16. Install flange (73) with bolts (74) (4 used). Coupler

: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
W1J1-02-13-018
Machine
Front
73
74
W1J1-02-13-008
W2-13-17
17. Install hose (67) to the radiator. Tighten bands
(66) (2 used) with nuts (65) (2 used).
: 11 mm
18. Install hose (64) to the radiator. Tighten bands

(63) (2 used) with nuts (62) (2 used).
: 11 mm
62, 63
64
Front
65
66
67 W1J1-02-13-017
W2-13-18
19. Install pipe (51) to hose (47). Install hose (41) to
pipe (56). Tighten bands (43, 45, 48) (2 used for 35 36, 37
each) with nuts (42, 44, 46) (2 used for each).
: 11 mm
20. Install clamps (50, 52) to pipe (51) with bolts (49,
53). B
A Machine
: 17 mm Front
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
44, 45
42, 43
W1J1-02-13-005
41
46 47 48
49, 50
51
Machine 52
Front
53
W1J1-02-13-017
Detail for Part A
21. Install pipe (59) to hose (35). Install hose (55) to 61

pipe (59). Tighten bands (37, 56) (2 used for 60
each) with nuts (36, 54) (2 used for each). 54
: 11 mm 59
22. Install clamps (58, 60) to pipe (59) with bolts (57, 58
61). 57
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
W1J1-02-13-016
56 55
Detail for Part B
W2-13-19
23. Remove bolts (3) (2 used). Open and secure dust 2
cover (2) to the counterweight side.
: 19 mm
3
W1J1-02-13-012
Radiator Assembly
Machine
Front
24. Install hoses (12) (2 used) to fuel cooler (11).
Secure hoses (12) (2 used) with the bands (2
used).
25. Install hoses (14) (2 used) to condenser (13).

: 19 mm
W1J1-02-13-008
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
14
11
13 12 W1J1-02-13-013
10, 11 Close-Up
W2-13-20
26. Install cover (8) to the radiator with bolts (7) (2
used). Radiator Assembly
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
8 7 W1J1-02-13-008
27. Install connector (15) to fresh air temperature

sensor (16).
16
15
12 Close-Up W1J1-02-13-014
W2-13-21
the bolts (26) (4 used). 24 17 25
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft) Ａ
29. Install radiator covers (24, 29) to the main frame

with the bolts (28) (18 used).
: 19 mm
28
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
30. Install muffler cover (17) to the main frame with 29

: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft) W1J1-02-13-003
28 27 26
31. Install covers (5, 31, 34) to the main frame with
bolts (6, 32, 33) (6 used for each) and the
washers (24 used). View A
: 19 mm 24
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
28
32. Shut dust cover (2). Install dust cover (2) with
bolts (1, 3) (2 used for each) and the washers (4
used). 17 25 W1J1-02-13-002
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
Radiator Assembly 2
1 3
31
32
W1J1-02-13-007
Counterweight 5 34 33 Main Frame
W2-13-22
33. Place engine cover (18) onto muffler cover (17).
17 18
Install engine cover (18) to the main frame with
hinges (23) (4 used) and bolts (22) (8 used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
34. Insert the end of stays (19) (2 used) in engine

cover (18) into the bracket and install with
washers (20) (2 used) and lock pin (21).
W1J1-02-13-001
19
Bracket
20
21
W1J1-02-13-015
22
23
W1J1-02-13-020
W2-13-23
35. Add coolant into the radiator.
36. Add refrigerant in the air conditioner.

NOTE: As for type and amount of refrigerant, refer
to the operator’s manual.
37. Add hydraulic oil into the hydraulic oil tank.

Release any pressure in the main pump and fan
pump.
38. Start the engine. Keep the engine idling for

several minutes in order to circulate the coolant
and hydraulic oil.
39. Stop the engine. Check coolant in coolant

reservoir. Add coolant to the specification.
40. Check hydraulic oil in the hydraulic oil tank. If

hydraulic oil is lack, release any pressure and add
hydraulic oil.
W2-13-24
STRUCTURE OF FAN MOTOR
7
21
22
23
W1JB-02-12-002
1 2 3 4 5 6 7 8 9 10 11
W1JB-02-12-001
20 19 18 17 16 15 14 13 12
1- End Cap 7- Pressure Port Plate 13 - Retaining Ring 19 - Needle Bearing

2- Rotor Insert Assembly 8- O-Ring 14 - Retaining Ring 20 - Socket Bolt (4 Used)
3- Vane Spring (24 Used) 9- Housing 15 - Seal 21 - Ball
4- Mount (12 Used) 10 - Ball Bearing 16 - Seal 22 - Valve
5- Vane (12 Used) 11 - Key 17 - Pin (2 Used) 23 - Screw
6- Cam Ring 12 - Shaft 18 - Seal
NOTE: Tightening Torque

20- Socket bolt 100 N⋅m (10 kgf⋅m, 75 lbf⋅ft)
23- Screw 11.5 to 12.6 N⋅m (1.2 to 1.3 kgf⋅m, 8.5 to 9.3 lbf⋅ft)
W2-13-25
(Blank)
W2-13-26
UPPERSTRUCTURE / Engine
REMOVE AND INSTALL ENGINE

hydraulic oil tank before doing any work. 1 2
TANK on W1-4.)Remove the grounding wire
from the battery.
Removal
1. Drain off coolant (max. 55 L (14.5 US gal)) from

the radiator.
: 19 mm
W1J1-02-13-001
2. Open engine cover (2). Remove lock pins (5) (2
used) and washers (4) (2 used) from the stay and
cylinder (3). Lay down engine cover (2) to the
muffler cover (1) side.
3
CAUTION: Engine cover (2) weight: 32 kg (71

lb)
4
5
used). Attach a nylon sling to engine cover (2).
Hoist and remove engine cover (2).
: 17 mm 7
Bracket
4. Remove bolts (9) (8 used). Remove muffler cover 6
(1).
: 19 mm W1J1-02-14-023
1 9
W1J1-02-13-003
W2-14-1
CAUTION: Air cleaner cover (10) weight: 32

kg (71 lb) 10
Rain Cover
5. Unlock the catch. Open air cleaner cover (12).
Remove bolts (11) (11 used). Attach a nylon sling
11
to air cleaner cover (10). Hoist and remove air
cleaner cover (10). 12
: 19 mm
NOTE: Remove air cleaner cover (10) with cover
(12) and the rain cover attached.
Catch W1J1-02-04-038
13
6. Remove bolts (14) (18 used). Remove radiator
Ａ
covers (13, 15).
: 19 mm
14
15
14 W1J1-02-13-003
7. Remove bolts (17, 19) (5 used for each) and (20) 16

(4 used). Remove under covers (16, 18, 21) from
the main frame. 17
: 19 mm
18
19
21 20 W1J1-02-14-015
W2-14-2
8. Remove bolts (23) (4 used) from both ends of

22
bracket (24). Attach a nylon sling to bracket (24).
Hoist and remove bracket (24).
: 19 mm
23
(22). 24
: 19 mm
25
10. Remove bolts (26) (3 used). Remove bracket 27
(25).
: 19 mm
CAUTION: Muffler (28) weight: 31 kg (68 lb)

26 W1J1-02-14-001
11. Remove bolts (32) (4 used) and washers (33) (4
used) from exhaust pipe (31). Remove nuts (35)
(8 used) and washers (34) (4 used) from U-bolts
(30) (2 used). Remove U-bolts (30) (2 used) from
muffler (28). Attach a nylon sling to muffler (28).
Hoist and remove muffler (28).
: 17 mm, 19mm
CAUTION: Bracket (27A) weight: 30 kg (66

lb)
12. Attach a nylon sling to bracket (27A) and hold

bracket (27A). Remove bolts (36) (4 used). Hoist
and remove bracket (27A). 32, 33 31 30 29 28 27A W1J1-02-14-004
: 19 mm
13. Remove nuts (29) (8 used). Remove exhaust pipe 30

(31) from the engine.
: 19 mm
32, 33
28
34
35
27A
31
36
W1J1-02-14-005
W2-14-3
14. Loosen nuts (38) (2 used) in bands (39) (2 used). 37 38, 39 40, 41
Remove bolts (41) (4 used) from clamps (40) (2
used). Remove pipe (42) from hose (37).
: 11 mm, 17 mm
15. Loosen nuts (43) (2 used) in bands (44) (2 used). Pipe 42

Remove hose (45) from the pipe in radiator.
: 11 mm 43
44
40
41
45 W1J1-02-13-017
49
16. Loosen nuts (47) (2 used) in bands (46) (2 used).
Remove bolts (49) (4 used) from clamps (50) (2 50 46, 47
used). Remove pipe (51) from hose (48).
: 11 mm, 17 mm 51
50
49
W1J1-02-13-016
48
17. Loosen nuts (54) (2 used) in bands (53) (2 used).

52
Remove hose (52) from the pipe in engine.
18. Loosen nuts (57) (2 used) in bands (56) (2 used). 53, 54

Remove hose (55) from the pipe in engine.
55
56, 57
W1J1-02-13-004
W2-14-4
19. Remove terminals (67) (2 used) from air cleaner
restriction switch (61). Remove clip (66). Loosen 61
nut (63) in band (62).
: 11 mm 62
67
63
64
65
66
W1J1-02-04-042
20. Disconnect connector (70) from intake-air

temperature sensor (68).
70
68
W1J1-02-14-021
71 72 65 64
21. Remove bolts (71) (2 used). Remove clamp (72)
from bracket (73).
: 17 mm
21. Loosen nut (75) in band (74). Remove the 69

hose/pipe assembly (76, 69, 65) from the pipe in
engine.
: 11 mm 76
75
74
73
W1J1-02-14-006
W2-14-5
77
W1J1-02-04-045
Main Frame
23. Remove bolts (79) (2 used).

: 17 mm 78
79
80
77
W1J1-02-04-046
24. Open and lock the pump cover. Remove bolts 81 82 83 82 82 84

(85) (2 used). Pull out harness (78) to the pump
space from cover (84). 85, 86
: 17 mm
87
25. Remove bolts (82) (18 used) and (89). Remove
covers (81, 83, 84, 87). 82
: 17 mm, 19 mm 89
78 W1J1-02-04-041
W2-14-6
64

77
lb)
26. Remove bolts (90) (4 used). Attach a nylon sling

onto air cleaner (64). Hoist and remove air
cleaner (64).
: 17 mm W1J1-02-04-044
NOTE: Remove bolts (90) (4 used) from the

mounting hole on pump space.
90
77
(77).
: 19 mm
Bolt Mounting
W1J1-02-04-043
Hole
77
91
W1J1-02-04-045
Main Frame
W2-14-7
28. Remove nut (93). Remove harness (92) from Radiator Pipe
overheat switch (94).
: 6.6 mm
29. Disconnect connector (97). Attach a nylon sling to

air compressor (99) and hold air compressor (99). 94 93 92 W1J1-02-14-022
Loosen bolt (96) fully. Remove bolts (100) (4

used). Remove air compressor (99) from the Engine
95 96
engine.
: 12 mm, 13 mm
NOTE: Remove and install the engine with air
compressor (99) hoisted inside the
machine. Do not remove hose (98).
97
30. Remove terminal covers (101, 107). Remove nut

(102) and screw (108) from the terminal in
alternator. Disconnect connector (103). Remove 98
bolts (104) (2 used) from clamps (105) (2 used) in
harness (106). Remove harness (106). 100 99 W1J1-02-14-003
: 12 mm, 13 mm, 17 mm Alternator
101, 102 103
31. Loosen bands (109) (2 used). Close the cock in

fuel pipe. Remove fuel hoses (110) (2 used) from
the pipe in engine. Cap the open ends of hose
and pipe.
107, 108 106 104, 105 W1J1-02-14-010
109, 110 109, 110

W1J1-02-14-011
W2-14-8
IMPORTANT: Before removing nut (111) from the
terminal in starter motor (112),
remove the grounding wire in
battery. If the work is continued with 111
the grounding wire connected, the
circuit may be shorted. 112
32. Remove nuts (111) (2 used). Remove harness
(114) from the terminal in starter motor (112). Bracket
Remove nut (113). Remove the grounding wire
from the bracket. 113
: 17 mm, 22 mm
114 Grounding Wire W1J1-02-14-009
33. Remove bolts (115) (3 used). Remove clips (116)

(3 used) from harness (118). Disconnect
connectors (119 to 123). Disconnect connector
Engine
(117) in the oil level switch. 115, 116 117
: 17 mm 123
115, 116
122
121
120
34. Remove bolts (125) (5 used). Remove clips (126) 119
(5 used) from harness (124). Disconnect 115, 116
connectors (127, 128, 129).
: 17 mm 118 W1J1-02-14-007
124 125, 126 125, 126
127
125, 126
125, 126
125, 126
129 128
W1J1-02-14-008
Pump
W2-14-9
35. Loosen nuts (130) (2 used) in bands (131) (2 Pipe
used). Remove hose (132) from the pipe in
engine.
: 11 mm 130
131
132
36. Remove hoses (133) (2 used) from the engine.

Cap the open ends of hose and pump. Attach an Engine W1J1-02-14-002
identification tag to the hose.

: 41 mm
133

Remove pipes (141, 145) from the pump device.
Cap the open ends of hose and pump. Attach an
identification tag to the hose.
: 14 mm
38. Remove socket bolts (136, 138, 146) (4 used for

each). Remove hoses (137, 139, 147) from the W1J1-02-14-012
Engine
pump device. Cap the open ends of hose and
pump. Attach an identification tag to the hose.
: 10 mm
134 135 136, 137 138, 139 140, 141
39. Remove hoses (134, 135, 142, 143, 148) from
the pump device. Cap the open ends of hose and
pump. Attach an identification tag to the hose.
: 17 mm, 19 mm, 27 mm, 36 mm, 41 mm
148
146, 147
144, 145 143 142 W1J1-02-04-001
W2-14-10
40. Remove bolts (150) (2 used), washers (151) (4
used), plates (149) (2 used), cushions (152) (2
used) and nuts (155) (2 used) from brackets
(153) (2 used).
: 41 mm
NOTE: After removing the engine from the main
frame, remove cushions (154) (2 used).
150, 151 149 W1J1-02-14-013
Air Compressor
150
151
149
152
153
154
152
155
W1J1-02-14-020
Details when installing
41. Remove bolts (157) (2 used) and washer (158) or

the spacer from brackets (156) (2 used).
: 32 mm
NOTE: The spacer instead of washer (158) is
installed to bolt (157) at the muffler side. 156
W1J1-02-14-014
Starter Motor 157, 158
W2-14-11
CAUTION: Engine/pump weight: 1630 kg

(3590 lb)
42. Attach a wire rope to the lifting hole (3 places) on

engine. Hoist and remove the engine.
Lifting Hole
153
IMPORTANT: Secure the wooden block in order to

attach on the engine. Place the
engine horizontally. Hold the engine
in order not to fall down. W1J1-02-14-016
43. After placing the wooden blocks (300 mm×600
mm, 11.8 in×23.6 in) (2 used) under brackets Wooden 153
(153) (2 used) at the engine radiator side and the Block
wooden block (300 mm×300 mm, 11.8 in×11.8 in) Wooden
Block
under the pump device, place the engine.
Lower Surface on
Engine Wooden Block Position W1J1-02-14-017
W2-14-12
Installation
1. Install cushion (154) to the place for brackets

(153) (2 used) in the main frame.
CAUTION: Engine/pump weight: 1630 kg

(3590 lb)
2. Attach a wire rope to the lifting hole (3 places) on

engine. Hoist and move the engine to the
mounting position for engine in the main frame.
152
153
154
W1J1-02-14-016
3. Install brackets (153) (2 used) which are installed

to the engine with bolts (150) (2 used), washers
(151) (4 used), plates (149) (2 used), cushions
(152) (2 used) and nuts (155) (2 used).
: 41 mm
: 1050 N⋅m (107 kgf⋅m, 774 lbf⋅ft)
150, 151 149 W1J1-02-14-013
Air Compressor
150
151
149
152
153
154
152
155
W1J1-02-14-020
Details when installing
W2-14-13
4. Install brackets (156) (2 used) with bolts (157) (2
used), washer (158) or the spacer. Install the
spacer instead of washer (158) to bracket (156)
at the muffler side.
: 32 mm
: 750N⋅m (77 kgf⋅m, 553 lbf⋅ft) 156
Starter Motor 157, 158 W1J1-02-14-014
5. Install hoses (133) (2 used) to the engine.

: 41 mm
: 300 N⋅m (31 kgf⋅m, 221 lbf⋅ft)
133
6. Tighten nuts (130) (2 used). Tighten hose (132) to

the pipe in engine with bands (131) (2 used).
: 11 mm W1J1-02-14-012
Engine
Pipe
130
131
132
W1J1-02-14-002
Engine
W2-14-14
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
77
91
W1J1-02-04-045
Main Frame

lb)
8. Attach a nylon sling onto air cleaner (64). Hoist 64

and move air cleaner (64) to the mounting
position on bracket (77). Apply LOCTITE #262 to
bolts (90) (4 used). Install air cleaner (64) with
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft) 77
NOTE: Install bolts (90) (4 used) to the bolt
mounting hole on pump space.
W1J1-02-04-044
90
77
Bolt Mounting
W1J1-02-04-043
Hole
W2-14-15
9. Install hose (76) to the pipe in engine. Tighten nut
(75). Tighten hose (76) with band (74). Install pipe 71 72 65 64
(69) to bracket (73) with clamp (72) and bolts (71)
(2 used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
: 11 mm 69
76
75
74
73
W1J1-02-14-006
10. Install connector (70) to intake-air temperature

sensor (68).
70
68
W1J1-02-14-021
11. Pull in harness (78) through the pump space.

78
Install clips (80) (2 used) in harness (78) to
bracket (77) with bolts (79) (2 used).
: 17 mm 79
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
80
77
W1J1-02-04-046
W2-14-16
12. Install hose (65) to the pipe in air cleaner (64).
Tighten nut (63). Tighten hose (65) with band (62). 61
Install clip (66).
: 11 mm 62
13. Connect terminals (67) (2 used) in air cleaner

restriction switch (61). 67
63
64
65
66
W1J1-02-04-042
14. Install covers (81, 83, 84, 87) with bolts (82) (18 81 82 83 82 82 84
used) and (89).
: 17 mm 85, 86
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
: 19 mm 87
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
82
15. Install clips (86) (2 used) in harness (78) with 89
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
78 W1J1-02-04-041
124 125, 126 125, 126

16. Install clips (126) (5 used) in harness (124) with
bolts (125) (5 used). Install connectors (127, 128,
129).
: 17 mm 127
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
125, 126
125, 126
125, 126
Pump 129 128
W1J1-02-14-008
W2-14-17
17. Install pipes (141, 145) to the pump device with 134 135 136, 137 138, 139 140, 141
socket bolts (140, 144) (4 used for each). Install
hoses (137, 139, 147) to the pump device with
socket bolts (136, 138, 146) (4 used for each).
: 10 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
: 14 mm
: 210 N⋅m (21.5 kgf⋅m, 155 lbf⋅ft)
18. Install hoses (134, 135, 142, 143, 148) to the

pump device.
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
148
: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft) 146, 147
: 36 mm
: 180 N⋅m (18 kgf⋅m, 133 lbf⋅ft) 144, 145 143 142 W1J1-02-04-001
: 41 mm
: 210 N⋅m (21 kgf⋅m, 155 lbf⋅ft)
19. Install clips (116) (3 used) in the harness with 115, 116 Engine 117
bolts (115) (3 used). Install connectors (119 to
123
123). 115, 116
: 17 mm 122
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
121
20. Install connector (117) in the engine oil level 120

switch.
119 115, 116
118 W1J1-02-14-007
W2-14-18
21. Install hoses (110) (2 used) to the fuel pipes (2
used) in engine. Tighten hoses (110) (2 used)
with bands (109) (2 used) by using a screwdriver.
22. Install air compressor (99) to the engine with bolts 109, 110 109, 110
(100) (4 used). Adjust a slack in belt (95) by using W1J1-02-14-011
bolt (96).
: 13 mm 95 96 Engine
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
97
98
100 99 W1J1-02-14-003
Slack
Push Here 6 to 10 mm
Approx. 98 Ｎ (10 kgf） Idle Pulley (0.2 to 0.4 in)
Crank Pulley
95 Air Compressor Pulley W1J1-02-14-018
W2-14-19
23. Install harness (106) to the terminals (2 used) in
alternator with nut (102) and screw (108). Install Alternator 101, 102 103
terminal covers (101, 107). Install connector (103).
Install clips (104) (2 used) in harness (106) with
: 12 mm
: 13 mm
: 20 N⋅m (2 kgf⋅m, 15 lbf⋅ft)
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
107, 108 106 104, 105 W1J1-02-14-010
IMPORTANT: Before installing harness (114) to the

terminal in starter motor (112),
remove the grounding wire in 111
battery. If the work is continued with
the grounding wire connected, the 112
circuit may be shorted.
24. Install harness (114) to the terminals (2 used) in
Bracket
starter motor (112) with nuts (111) (2 used). Install
the grounding wire to the bracket with nut (113). 113
Connect the grounding wire in battery.
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
114 Grounding Wire W1J1-02-14-009
: 22 mm
: 140 N⋅m (14.3 kgf⋅m, 103 lbf⋅ft)
Radiator Pipe
25. Install harness (92) to overheat switch (94) with

nut (93).
: 6.6 mm
94 93 92 W1J1-02-14-022
W2-14-20
26. Install hose (55) to the pipe in engine. Tighten
nuts (56) (2 used). Tighten hose (55) with bands
(57) (2 used). 52
: 11mm
53, 54
27. Install hose (52) to the pipe in engine. Tighten
nuts (53) (2 used). Tighten hose (52) with bands
55
(54) (2 used).
: 11mm 56, 57
28. Install pipe (42) to hose (37). Tighten nuts (38) (2

used). Tighten hose (37) with bands (39) (2
used).
: 11mm W1J1-02-13-004
37 38, 39 40, 41
29. Secure pipe (42) with clamps (40) (2 used) and
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
Pipe 42
30. Install hose (45) to the pipe in radiator. Tighten
nut (43). Tighten hose (45) with bands (44) (2
used). 43
: 11mm
31. Install pipe (51) to hose (48). Tighten nuts (46) (2

44
used). Tighten hose (48) with bands (47) (2
used).
: 11 mm 40
32. Install pipe (51) with clamps (50) (2 used) and 41

: 17 mm 45 W1J1-02-13-017
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)

49
50 46, 47
51
50
49
W1J1-02-13-016
48
W2-14-21
33. Install exhaust pipe (31) to the engine with nuts
(29) (8 used).
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
CAUTION: Bracket (27A) weight: 30 kg (66

lb)
34. Hoist and hold bracket (27A). Install bracket

(27A) to the main frame with bolts (36) (4 used).
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
32, 33 31 30 29 28 27A W1J1-02-14-004
CAUTION: Muffler (28) weight: 30 kg (66 lb)

30
35. Hoist and place muffler (28) onto bracket (27).

Install the pipe in muffler (28) to exhaust pipe (31)
with bolts (32) (4 used) and washers (33) (4
used).
: 19 mm 32, 33
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft) 28
36. Install muffler (28) to bracket (27A) with U-bolts

(30) (2 used), washers (34) (4 used) and nuts
(35) (8 used).
: 19 mm 34
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft) 35
27A
31
36
W1J1-02-14-005
W2-14-22
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft) 22

: 19 mm 23
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
24
25
39. Hoist and hold bracket (24). Install bracket (24) to 27
brackets (22, 25) with bolts (23) (4 used).
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
26 W1J1-02-14-001
40. Install covers (16, 18, 21) with bolts (17, 19) (5 16
used for each) and (20) (4 used).
: 19 mm 17
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
18
19
21 20 W1J1-02-14-015
W2-14-23
CAUTION: Air cleaner cover (10) weight: 32

kg (71 lb) 10
Rain Cover
41. Hoist and move air cleaner cover (10) to the
mounting position. Install air cleaner cover (10)
11
: 19 mm 12
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
Catch W1J1-02-04-038
13
42. Install radiator covers (13, 15) with bolts (14) (18
used).
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
14
15
14 W1J1-02-13-003
1 9
43. Install muffler cover (1) with bolts (9) (8 used).

: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
W1J1-02-13-003
W2-14-24
44. Hoist and place engine cover (2) onto muffler
1 2
cover (1). Install hinges (6) (4 used) in engine
cover (2) with bolts (7) (8 used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
45. Insert the end of stay and cylinder (3) into the
bracket and install with washers (4) (2 used) and
lock pins (5) (2 used).
W1J1-02-13-001
4
5
Bracket
7
6
W1J1-02-14-023
46. Connect the grounding wire to the negative

terminal in battery.
47. Add coolant (max. 55 L, 14.5 US gal.) into the

radiator.
48. Open the cock in fuel pipe.
W2-14-25
(Blank)
W2-14-26
MEMO
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SECTION 3
UNDERCARRIAGE
— CONTENTNS —
Group 1 Swing Bearing Group 4 Track Adjuster
Remove and Install Remove and Install Track Adjuster .........W3-4-1
Swing Bearing ........................................ W3-1-1 Disassemble Track Adjuster ...................W3-4-2
Disassemble Swing Bearing .................. W3-1-4 Assemble Track Adjuster ......................W3-4-10
Assemble Swing Bearing ....................... W3-1-6
Group 5 Front Idler
Group 2 Travel Device Remove and Install Front Idler................W3-5-1
Remove and Install Travel Device.......... W3-2-1 Disassemble Front Idler..........................W3-5-4
Disassemble Travel Device.................... W3-2-4 Assemble Front Idler ............................W3-5-10
Assemble Travel Device....................... W3-2-18 Maintenance Standard..........................W3-5-14
Disassemble Travel Motor.................... W3-2-34
Assemble Travel Motor ........................ W3-2-38 Group 6 Upper and Lower Roller
Disassemble Brake Valve .................... W3-2-44 Remove and Install Upper Roller............W3-6-1
Assemble Brake Valve ......................... W3-2-46 Remove and Install Lower Roller............W3-6-4
Maintenance Standard ......................... W3-2-48 Disassemble Lower Roller ......................W3-6-8
Assemble Lower Roller.........................W3-6-10
Group 3 Center Joint Maintenance Standard..........................W3-6-12
Remove and Install Center Joint ............ W3-3-1
Disassemble Center Joint ...................... W3-3-4 Group 7 Track
Assemble Center Joint ........................... W3-3-6 Remove and Install Track .......................W3-7-1
Maintenance Standard ......................... W3-3-11 Maintenance Standard..........................W3-7-13
1J1W-3-1
(Blank)
1J1W-3-2
UNDERCARRIAGE / Swing Bearing
REMOVE AND INSTALL SWING BEARING
Before removing and installing the swing bearing, the

upperstructure must be removed first. For removal
1
and installation of the upperstructure, refer to “Re- Matching Mark
move and Install Frame”, “Remove and Install Front
Attachment” and “Remove and Install Counterweight”
sections.
In this section, the procedure starts on the premise
that the upperstructure has already been removed.
3 2
Removal
1. Put the matching marks on inner race (3) of W142-03-01-001
swing bearing (1) and track frame (2).
2. Remove all grease pipes from swing bearing (1). 1 4

: 17 mm
3. Remove bolts (4) (40 used) from swing bearing

(1).
: 41 mm
W105-03-01-002
CAUTION: Swing bearing (1) weight: 642 kg

(1420 Ib)
4. Install lifting tool (ST 9050) to swing bearing (1).

Hoist and remove swing bearing (1) from track
frame (2).
ST 9050
1 W105-03-01-003
2
W3-1-1
Installation
1
Clean the mounting surfaces of track frame (2) and
swing bearing (1).
1. Apply THREEBOND #1102 to the mounting sur-

face for swing bearing (1) on track frame (2). 2
3
W105-03-01-003
CAUTION: Swing bearing (1) weight: 642 kg

(1420 Ib)
IMPORTANT: Check sure to align the matching

marks. Otherwise, the inner race
soft zone will be in wrong position.
2. Hoist swing bearing (1). Align the matching marks
made when disassembling on inner race (3) of
swing bearing (1) and track frame (2).
Plug Position
Soft Zone Position
(Outer Race)
Greasing Hole Positions
(3 Places)
W1J1-03-01-002
W3-1-2
3. Apply LOCTITE #262 to bolts (4) (40 used).

Tighten swing bearing (1) to track frame (2) with
bolts (4) (40 used). 4
: 41 mm
: 1375 N⋅m (140 kgf⋅m, 1015 Ibf⋅ft)
4. Install all grease pipes to swing bearing (1).

: 17 mm
: 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
1 W105-03-01-002
2
5. After installing the swing bearing, fill the grease
bath with grease until the pinion of swing bear- Swing Bearing Grease Level Pinion
ing is covered clearance A or B in grease.
Grease amount: 18 L (4.76 US gal.)
Clearance A: 10 mm (0.4 in)

Clearance B: 25 mm (1.0 in)
A mm
B
W175-03-01-002
Grease Bath
W3-1-3
DISASSEMBLE SWING BEARING
1 2 3
W1J1-03-01-001
7 6 5
7
6
W157-03-01-002
1 - Outer Race 4 - Plug 6- Ball (86 Used) 8- Support (86 Used)
2 - Seal 5 - Seal 7- Inner Race 9- Grease Fitting (3 Used)
3 - Pin
W3-1-4
Disassemble Swing Bearing
CAUTION: Swing bearing weight: 642 kg

1. Remove pin (3) from the bottom side of plug (4).
(1420 Ib)
NOTE: As pin (3) head was crimped after installa-
tion, grind off the crimped part. 3. Hoist outer race (1) of the swing bearing horizon-
tally and slightly. Remove seals (2 and 5) from
outer race (1) and inner race (7).
3
4. Place inner race (7) of the swing bearing on the
wooden blocks. Hoist outer race (1).
5. While rotating inner race (7), remove balls (6) (86

used) and supports (8) (86 used) from the plug
hole.
Use round-bar magnet (A) and remove the balls.
Use tip-bent wire (B) and remove support (8).
4
W105-03-01-007 1
2
2. Remove plug (4).
NOTE: Screw bolt (M10, Pitch 1.5 mm) in the
threaded hole in plug (4). Tap the bolt head
from the bottom side or pull the bolt in or- A
der to remove plug (4). 7
W105-03-01-009
6 5
4
W105-03-01-008
8 W105-03-01-010
W3-1-5
ASSEMBLE SWING BEARING
1 2 3
W1J1-03-01-001
7 6 5
7
6
W157-03-01-002
1 - Outer Race 4 - Plug 6- Ball (86 Used) 8- Support (86 Used)

2 - Seal 5 - Seal 7- Inner Race 9- Grease Fitting (3 Used)
3 - Pin
W3-1-6
Assemble Swing Bearing
3. Clean the groove part for seals (2, 5) completely.
Apply THREE BOND #1530D and install seal (2)
CAUTION: Swing bearing weight: 642 kg
to outer race (1). Install seal (5) to the groove part
(1420 lb)
on inner race (7).
Outer race (1) weight: 289 kg (640 lb)
4. Install plug (4) into outer race (1). Secure plug (4)
1. Align inner race (7) of the swing bearing with the
with pin (3). Crimp the head of pin (3) by using a
ball groove on outer race (1).
punch.
IMPORTANT: Apply grease to balls (6) and 5. Apply much grease to the swing bearing.
support (8).
2. Install balls (6) (86 used) and support (8) (86
used) alternately from the plug hole. Install ball
(6) first.
3
4
5 W142-03-01-005
W142-03-01-007
W142-03-01-006
35±5 mm
6 8
W142-03-01-004
NOTE: Dia. of support (8): 26 mm

Dia. of support (9): 50.8 mm
W3-1-7
(Blank)
W3-1-8
UNDERCARRIAGE / Travel Device
REMOVE AND INSTALL TRAVEL DEVICE
5. Put the matching marks on travel device (10) and
IMPORTANT: Release any pressure in the track frame (1).
hydraulic oil tank before doing any Remove bolts (8) and washers (9). Hoist and
work. remove travel device (10) from track frame (1).
(Refer to “BLEED AIR FROM : 32 mm
HYDRAULIC OIL TANK” on W1-4-1.)
Bolts (8) and washers (9)
Removal ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
Before removing the travel device, the tracks must be 20 used
removed first. For removal and installation of the tracks, ZAXIS500LC-3, 520LCH-3: 24 used
refer to “Remove and Install Tracks” section on W3-7-1.
In this section, the procedure starts on the premise that 1 2, 3
the track have already been removed.
CAUTION: Cover (4) weight: 4

ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
32 kg (71 lb)
ZAXIS500LC-3, 520LCH-3: 40 kg (88 lb)
1. Remove bolts (2) (6 used) and washer (3) (6

used) from cover (4). Remove cover (4) from track
frame (1). W16J-03-02-006
: 24 mm
2. Remove hoses (6, 7) from travel device (10). 5 1 6

Attach an identification tag onto the removed
hoses for reassembling. Cap the open ends.
: 22 mm, 27 mm
7
3. Remove split flanges (11) (4 used) and socket
bolts (12) (8 used) from travel device (10).
8, 9
Remove hoses (5) (2 used) from travel device (10).
Cap the open ends.
: 10 mm 10
12 11
CAUTION: Travel Device (10) weight: W16J-03-02-005
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:

671 kg (1479 lb)
ZAXIS500LC-3, 520LCH-3: 855 kg (1885 lb)
4. Attach a nylon sling to travel device (10). Hoist

and hold travel device (10).
W111-03-02-002
W3-2-1
Installation
CAUTION: Travel device (10) weight:

ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
671 kg (1480 lb) 5 1 6
ZAXIS500LC-3, 520LCH-3: 855 kg (1885 lb)
IMPORTANT: Align the matching marks made

when disassembling. If the matching 7
marks are not aligned, it is difficult to
install hoses (6, 7).
8, 9
1. Install travel device (10) to track frame (1) with
bolts (8) and washers (9).
: 32 mm 10
: 750 N⋅m (76.5 kgf⋅m, 550 Ibf⋅ft)
12 11
Bolts (8) and washers (9) W16J-03-02-005
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:

20 used
ZAXIS500LC-3, 520LCH-3: 24 used
1 2, 3
2. Install hoses (5) (2 used) to travel device (10) with
split flanges (11) (4 used) and socket bolts (12) (8
used).
: 10 mm
: 90 N⋅m (9 kgf⋅m, 66 Ibf⋅ft) 4
3. Install hoses (6, 7) to travel device (10).

: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 Ibf⋅ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m, 58 Ibf⋅ft) W16J-03-02-006
CAUTION: Cover (4) weight:

ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
32 kg (71 lb)
ZAXIS500LC-3, 520LCH-3: 40 kg (88 lb)
4. Install cover (4) to track frame (1) with bolts (2)

(6 used) and washers (3) (6 used).
: 24 mm
: 210 N⋅m (21 kgf⋅m, 155 Ibf⋅ft)
IMPORTANT: After completing the work, check the

oil level. Start the engine and check
for any oil leaks.
In order to prevent the travel motor
from seizing, perform the break in
operation after installation.
W3-2-2
(Blank)
W3-2-3
DISASSEMBLE TRAVEL DEVICE
(ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3) 10
9
8
6
5
4
3
26
2 25
24
23
22 27
1
21
19 20
18
17
16 28
15
29
30
14
31
32
33
12 13 34
11 36 35
37
38
39
40 51
41
42
50
49
48
47
46
45
43
44 W1J1-03-02-006
1- Motor 14 - Sprocket 27 - Spring Pin (3 Used) 40 - Needle Bearing (4 Used)
2- Bolt (4 Used) 15 - Washer (24 Used) 28 - Spacer 41 - Needle Bearing (4 Used)
3- Spring Washer (4 Used) 16 - Bolt (24 Used) 29 - First Stage Carrier 42 - Thrust Plate (4 used)
4- O-Ring 17 - Third Stage Carrier 30 - Thrust Plate (3 used) 43 - Shaft
5- Housing 18 - Third Stage Sun Gear 31 - Spring Pin (3 Used) 44 - Ring Gear
6- Floating Seal 19 - Second Stage Carrier 32 - Second Stage Planetary 45 - Bolt (30 Used)
Gear (3 used)
7- Roller Bearing 20 - Spacer 33 - Pin (3 Used) 46 - Retaining Ring
8- Drum 21 - Second Stage Sun Gear 34 - Needle Bearing (3 Used) 47 - Stopper Pin
9- Roller Bearing 22 - Thrust Plate (3 used) 35 - Thrust Plate (3 used) 48 - Ball Bearing
10 - O-Ring 23 - Needle Bearing (3 Used) 36 - Thrust Plate (4 used) 49 - Cover
11 - Bearing Nut 24 - Pin (3 Used) 37 - Third Stage Planetary Gear 50 - Bolt (16 Used)
(4 Used)
12 - Lock Plate 25 - First Stage Planetary Gear 38 - Spring Pin (4 Used) 51 - Plug (3 Used)
(3 used)
13 - Bolt (2 Used) 26 - Thrust Plate (3 Used) 39 - Pin (4 Used)
W3-2-4
(ZAXIS500LC-3, 520LCH-3)
53
13
12
7 11
6
5 9
16
15
51
4
14
1
50
26
25
27 48
24 47 52
23
22 49
29
3
2 21 44
20 43
19
28
18
30
32
31
33
34
35
36
37
39
38
17 40
41 W17P-03-02-001
42
1- Motor 15 - Washer (24 Used) 28 - Spacer 41 - Needle Bearing (4 Used)
2- Bolt (4 Used) 16 - Bolt (24 Used) 29 - First Stage Carrier 42 - Thrust Plate (4 used)
3- Spring Washer (4 Used) 17 - Third Stage Carrier 30 - Thrust Plate (3 used) 43 - Shaft
4- O-Ring 18 - Third Stage Sun Gear 31 - Spring Pin (3 Used) 44 - Ring Gear
5- Housing 19 - Second Stage Carrier 32 - Second Stage Planetary 47 - Stopper Pin
Gear (3 used)
6- Floating Seal 20 - Spacer 33 - Pin (3 Used) 48 - Ball Bearing
7- Roller Bearing 21 - Second Stage Sun Gear 34 - Needle Bearing (3 Used) 49 - Cover
8- Drum 22 - Thrust Plate (3 used) 35 - Thrust Plate (3 used) 50 - Bolt (20 Used)
9- Roller Bearing 23 - Needle Bearing (3 Used) 36 - Thrust Plate (4 used) 51 - Plug (3 Used)
11 - Bearing Nut 24 - Pin (3 Used) 37 - Third Stage Planetary Gear 52 - Spring Washer (20 Used)
(4 Used)
12 - Lock Plate 25 - First Stage Planetary Gear 38 - Spring Pin (4 Used) 53 - Knock Pin (8 Used)
(3 used)
13 - Bolt (2 Used) 26 - Thrust Plate (3 Used) 39 - Pin (4 Used)
14 - Sprocket 27 - Spring Pin (3 Used) 40 - Needle Bearing (4 Used)
W3-2-5
(ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3)
10
9
8
6
5
4
3
26
2 25
24
23
22 27
1
21
19 20
18
17
16 28
15
29
30
14
31
32
33
12 13 34
11 36 35
37
38
39
40 51
41
42
50
49
48
47
46
45
43
44 W1J1-03-02-006
W3-2-6
Disassemble Travel Device
CAUTION: Motor (1) weight: 130 kg (290 lb)
The disassembling procedures of travel device for
ZAXIS450-3, 450LC-3, 470H-3 and 470LCH-3 are 2. Put the matching marks on the mating positions of
same to ZAXIS500LC-3 and 520LCH-3 except ring motor (1) and housing (5).
gear (44). Install eyebolts (M12, Pitch 1.75 mm) (2 used) to
This is explained according to the illustration of motor (1). Attach a nylon sling to eyebolt. Hoist
ZAXIS450-3, 450LC-3, 470H-3 and 470LCH-3. and hold motor (1). Remove bolts (2) (4 used) and
spring washers (3) (4 used) from motor (1).
CAUTION: There may be pressure Remove motor (1) from housing (5).
accumulated inside of the travel device. : 27 mm
Slowly loosen the air bleed plug and
completely release the residual pressure. 5
Remove the drain plug and drain gear oil. 2, 3
If the air bleed plug is loosened quickly, the
plug may fly off and/or gear oil may spurt.
Keep away from the plug.
1
CAUTION: Travel device weight:

ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
671 kg (1479 lb)
Eyebolt
ZAXIS500LC-3, 520LCH-3: 855 kg (1885 lb) Mounting
Position
1. Hoist and hold the travel device. Loosen plug
(51-B) 2 to 3 turns. Remove plug (51-A). Drain W16J-03-02-002
gear oil from the travel device. Place the travel

device on a workbench with the motor (1) side
facing upward. CAUTION: Travel reduction gear weight:
: 14 mm ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
540 kg (1190 lb)
ZAXIS500LC-3, 520LCH-3: 720 kg (1587 lb)
51-B
3. Wind a nylon sling to the body of drum (8) and
ring gear (44). Hoist and place the travel device
on the workbench with the cover (49) side facing
upward.
51-A
W111-03-02-006
W3-2-7
(ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3)
10
51
50
49
45
44 W1J1-03-02-006
W3-2-8
Procedure to Remove Ring Gear (44)
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3
4. Put the matching marks on the mating positions of

cover (49) and ring gear (44).
Install eyebolt (PT 3/4) into the plug (51) hole (2
places).
Remove bolts (50) (16 used) from cover (49).
Hoist and remove cover (49) from ring gear (44).
: 22 mm
NOTE: THREEBOND has been applied to the
mating surfaces of ring gear (44) and cover
(49). Insert a screwdriver between ring
gear (44) and cover (49). Raise cover (49)
for easier removal.
CAUTION: Ring gear (44) weight: 70 kg

(154 lb)

ring gear (44) and drum (8).
Install eyebolt (M14, Pitch 2.0 mm) into the bolt
(50) hole (2 places) on ring gear (44).
Attach a nylon sling to eyebolt. Hoist and hold ring
gear (44).
6. Remove bolts (45) (30 used) from ring gear (44).

Remove ring gear (44) from drum (8). Remove
O-ring (10) from drum (8).
: 27 mm
W3-2-9
53
51
50
52
49
44
W17P-03-02-001
W3-2-10
Procedure to Remove Ring Gear (44)
ZAXIS500-3LC-3, 520LCH-3

cover (49) and drum (8).
Install eyebolt (M10, Pitch 1.5 mm) into the plug
(51) hole (2 places).
Remove bolts (50) and spring washers (52) (2
used for each from cover (49). Hoist and remove
cover (49) from drum (8).
: 22 mm
NOTE: THREEBOND has been applied to the
mating surfaces of drum (8) and cover (49).
Insert a screwdriver between drum (8) and
cover (49). Raise cover (49) for easier
removal.
CAUTION: Ring gear (44) weight: 75 kg

(165 lb)

ring gear (44) and drum (8).
Install eyebolt (M10, Pitch 1.5 mm) into the bolt
(50) hole (2 places) on ring gear (44).
Attach a nylon sling to eyebolt. Hoist and hold ring
gear (44). Remove ring gear (44) and knock pins
(53) (8 used) from drum (8).
W3-2-11
(ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3)
26
25
24
23
22 27
21
19 20
18
17
28
29
30
31
32
33
12 13 34
11 36 35
37
38
39
40
41
42
43
W1J1-03-02-006
W3-2-12
9. Remove shaft (43) from first stage carrier (29).
Remove first stage carrier assemblies (22 to 29)
and second stage sun gear (21) from second
stage carrier (19).

assembly weight:
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
25 kg (55 lb)
ZAXIS500LC-3, 520LCH-3: 30 kg (66 lb)
10. Wind the nylon slings (2 used) onto second stage

carrier (19). Hoist and remove second stage
carrier assemblies (19, 20, 30 to 35) and third
stage sun gear (18).
CAUTION: The third stage carrier (17)

assembly weight:
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
70 kg (154 lb)
ZAXIS500LC-3, 520LCH-3: 85 kg (187 lb)
11. Wind the nylon slings (2 used) onto third stage

carrier (17). Hoist and remove third stage carrier
(17) assemblies (17, 36 to 42) from drum (8).
12. Remove bolts (13) (2 used) from lock plate (12).

Remove lock plate (12) from bearing nut (11).
: 19 mm
13. Install special tool (ST 3136) to bearing nut (11).

Remove bearing nut (11) from housing (5).
ST 3136
W1JB-03-02-003
W3-2-13
(ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3)
9
8
6
5
16
15
14
45
W1J1-03-02-006
W3-2-14
CAUTION: Drum (8), sprocket (14) and other CAUTION: Sprocket (14) weight:
parts weight: ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: 85 kg (187 lb)
180 kg (400 lb) ZAXIS500LC-3, 520LCH-3: 115 kg (254 lb)
ZAXIS500LC-3, 520LCH-3: 855 kg (1885 lb)
IMPORTANT: The mating parts of drum (8) and sprocket (14) and drum (8).
housing (5) are sliding surface. Attach a nylon sling to sprocket (14). Hoist and
Place the drum (8) assembly on the hold sprocket (14).
wooden blocks in order not to
damage the sliding surface. 19. Remove bolts (16) (24 used) and washers (15)
14. Put the matching marks on the mating positions of (24 used) from sprocket (14). Remove sprocket
drum (8) and housing (5). (14) from drum (8).
Install eyebolt (A) into the bolt (45) hole (2 places) : 32 mm
on drum (8). Attach a nylon sling to eyebolt. Hoist
and hold drum (8). IMPORTANT: Do not remove the outer race of
roller bearings (7, 9) from drum (8)
Eyebolt (A) unless necessary.
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: If the bearing is pressed in
M18, Pitch 2.5 mm insufficiently, the service life of
ZAXIS500LC-3, 520LCH-3: M14, Pitch 2.0 mm bearing may be affected. In case the
outer race has been removed,
15. Remove the drum (8) assembly from housing (5). replace with a new one.
At this time, the inner race of roller bearing (9) is 20. Remove the outer race of roller bearing (7) drum
also removed together. (8) by using a bar and hammer.
16. Remove floating seals (6) from housing (5) and

drum (8).
IMPORTANT: Do not remove the inner race of

roller bearing (7) from housing (5)
unless necessary. In case the inner
race of roller bearing (7) has been
removed, replace with a new one.
housing (5) by using a bar and hammer.
NOTE: If the inner race of roller bearing (7) cannot
be removed, cut the inner race by using a
gas torch. At this time, do not damage
housing (5).
W3-2-15
(ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3)
9
8
27
19 20
17
16 28
29
31
36
37
38
39
40
41
42
W1J1-03-02-006
W3-2-16
CAUTION: Drum (8) and other parts weight:

ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
100 kg (221 lb)
ZAXIS500LC-3, 520LCH-3: 185 kg (408 lb)
21. Install eyebolt (M22, Pitch 2.5 mm) into the bolt
(16) hole (2 places) on drum (8) from the motor
(1) side. Attach a nylon sling to eyebolt.
Hoist and turn over drum (8). Remove the outer
race of roller bearing (9) from drum (8) by using a
bar and hammer.
22. Remove spring pin (38) from third stage carrier

(17) by using a round bar. Remove pin (39).
Remove third stage planetary gear (37) and thrust
plates (36, 42) from third stage carrier (17).
Remove needle bearings (40, 41) from the third
stage planetary gear (37).
Round Bar Dia.:

ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
8 mm (0.32 in)
ZAXIS500LC-3, 520LCH-3: 10 mm (0.39 in)
23. Remove spring pins (38) (4 used), pins (39) (4

used), third stage planetary gears (37) (4 used),
thrust plates (36, 43) (4 used for each), needle
bearings (40, 41) (3 used for each) from third
stage carrier (17) according to step 20.
24. Disassemble the first stage carrier (29) assembly

and the second stage carrier (19) assembly
according to steps 20, 21.
Diameter of round bar for spring pin (27): A

Diameter of round bar for spring pin (31): B
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
A=4 mm (0.16 in). B=5 mm (0.20 in)
ZAXIS500LC-3, 520LCH-3:
A=5 mm (0.20 in). B=6 mm (0.24 in)
25. Remove spacer (28) from first stage carrier (29).

Remove spacer (20) from second stage carrier
(19).
W3-2-17
ASSEMBLE TRAVEL DEVICE
(ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3)
14 15 16
5 6 8 7 9 11 10
45 44 17 18 20
19
2 3 4 21
28
1 29
51
49
46
48
47
43
25
26
27
24
23
22
50
35 32 34 33 30 31
36 38
T16J-03-05-001
12 13 42 37 41 40 39
1- Motor 14 - Sprocket 27 - Spring Pin (3 Used) 40 - Needle Bearing (4 Used)

2- Bolt (4 Used) 15 - Washer (24 Used) 28 - Spacer 41 - Needle Bearing (4 Used)
3- Spring Washer (4 Used) 16 - Bolt (24 Used) 29 - First Stage Carrier 42 - Thrust Plate (4 used)
4- O-Ring 17 - Third Stage Carrier 30 - Thrust Plate (3 used) 43 - Shaft
5- Housing 18 - Third Stage Sun Gear 31 - Spring Pin (3 Used) 44 - Ring Gear
6- Floating Seal 19 - Second Stage Carrier 32 - Second Stage Planetary 45 - Bolt (30 Used)
Gear (3 used)
7- Roller Bearing 20 - Spacer 33 - Pin (3 Used) 46 - Retaining Ring
8- Drum 21 - Second Stage Sun Gear 34 - Needle Bearing (3 Used) 47 - Stopper Pin
9- Roller Bearing 22 - Thrust Plate (3 used) 35 - Thrust Plate (3 used) 48 - Ball Bearing
10 - O-Ring 23 - Needle Bearing (3 Used) 36 - Thrust Plate (4 used) 49 - Cover
11 - Bearing Nut 24 - Pin (3 Used) 37 - Third Stage Planetary Gear 50 - Bolt (16 Used)
(4 Used)
12 - Lock Plate 25 - First Stage Planetary Gear 38 - Spring Pin (4 Used) 51 - Plug (3 Used)
(3 used)
13 - Bolt (2 Used) 26 - Thrust Plate (3 used) 39 - Pin (4 Used)
W3-2-18
18 8 17 44 52
14
50
5 51
19
29
21
20
28
49
43
1
47
48
25
23
24
26
2
22
3
4 30 33 27
6 7 9 11 12 13 42 35 32 34
37 40 36 31 53
39 38 15 16 T17P-03-05-001
1- Motor 15 - Washer (24 Used) 28 - Spacer 41 - Needle Bearing (4 Used)

2- Bolt (4 Used) 16 - Bolt (24 Used) 29 - First Stage Carrier 42 - Thrust Plate (4 used)
3- Spring Washer (4 Used) 17 - Third Stage Carrier 30 - Thrust Plate (3 used) 43 - Shaft
4- O-Ring 18 - Third Stage Sun Gear 31 - Spring Pin (3 Used) 44 - Ring Gear
5- Housing 19 - Second Stage Carrier 32 - Second Stage Planetary 47 - Stopper Pin
Gear (3 used)
6- Floating Seal 20 - Spacer 33 - Pin (3 Used) 48 - Ball Bearing
7- Roller Bearing 21 - Second Stage Sun Gear 34 - Needle Bearing (3 Used) 49 - Cover
8- Drum 22 - Thrust Plate (3 used) 35 - Thrust Plate (3 used) 50 - Bolt (20 Used)
9- Roller Bearing 23 - Needle Bearing (3 Used) 36 - Thrust Plate (4 used) 51 - Plug (3 Used)
11 - Bearing Nut 24 - Pin (3 Used) 37 - Third Stage Planetary Gear 52 - Spring Washer (20 Used)
(4 Used)
12 - Lock Plate 25 - First Stage Planetary Gear 38 - Spring Pin (4 Used) 53 - Knock Pin (8 Used)
(3 used)
13 - Bolt (2 Used) 26 - Thrust Plate (3 used) 39 - Pin (4 Used)
14 - Sprocket 27 - Spring Pin (3 Used) 40 - Needle Bearing (4 Used)
W3-2-19
(ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3)
14 15 16
5 6 8 7 9
45 44
T16J-03-05-001
W3-2-20
Assemble Travel Device
The disassembling procedures of travel device for 5. Install eyebolt (A) into the bolt (45) hole (2 places)
ZAXIS450-3, 450LC-3, 470H-3 and 470LCH-3 are on drum (8).
same to ZAXIS500LC-3 and 520LCH-3 except ring Hoist and place drum (8) with the ring gear (44)
gear (44). side facing upward.
This is explained according to the illustration of Tap and install the outer race of roller bearing (9)
ZAXIS450-3, 450LC-3, 470H-3 and 470LCH-3. to drum (8) by using a bar and hammer evenly.
Eyebolt (A)
CAUTION: Housing (5) weight:
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
M18, Pitch 2.5 mm
90 kg (198 lb)
ZAXIS500LC-3, 520LCH-3: M14, Pitch 2.0 mm
ZAXIS500LC-3, 520LCH-3: 100 kg (221 lb)
1. Wind a nylon sling to the body of housing (5). NOTE: Tap and listen to ring in order to check if the
Hoist and place housing (5) with the motor (1) outer race is installed to drum (8)
side facing downward. completely.
2. Install one half of floating seal (6) to housing (5) CAUTION: Sprocket (14) weight:
by using a wooden spatula or similar tool. ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
Tap and install the inner race of roller bearing (7) 85 kg (187 lb)
to housing (5) by using a bar and hammer evenly. ZAXIS500LC-3, 520LCH-3: 115 kg (254 lb)
NOTE: Tap and listen to ring in order to check if the
inner race is installed to housing (5) 6. Attach nylon slings (2 used) to sprocket (14).
completely. Hoist and place sprocket (14) onto drum (8).
CAUTION: Drum (8) weight: 7. Apply LOCTITE #262 to bolt (16). Install sprocket
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: (14) to drum (8) with bolts (16) (24 used) and
100 kg (221 lb) spring washers (15) (24 used).
ZAXIS500LC-3, 520LCH-3: 185 kg (408 lb) : 32 mm
: 750 N⋅m (76.5 kgf⋅m, 550 lbf⋅ft)
(16) hole (2 places) on drum (8) from the motor
(1) side.
Hoist and place drum (8) with the ring gear (44)
side facing downward.
Tap and install the outer race of roller bearing (7)
to drum (8) by using a bar and hammer evenly.
NOTE: Tap and listen to ring in order to check if the
outer race is installed to drum (8)
completely.
4. Apply grease to O-ring of floating seal (6) on the

drum (8) side. Install one half of floating seal (6) to
drum (8).
W3-2-21
(ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3)

14
5 8 9 11
T16J-03-05-001
W3-2-22
CAUTION: Drum (8), sprocket (14) and other

part weight:
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
180 kg (397 lb)
ZAXIS500LC-3, 520LCH-3: 300 kg (661 lb)

when disassembling. Check the
clearance all around drum (8) in
housing (5) shall be equal.
8. Hoist and place the drum (8) assembly to housing
(5).
9. Tap and install the inner race of roller bearing (9)

to housing (5) by using a bar and hammer evenly.
IMPORTANT: Install bearing nut (11) with the

stepped part facing to roller bearing
(9).
Apply a film of grease to the
threaded part of bearing nut (11).
10. Install bearing nut (11) to housing (5). Tighten
bearing nut (11) by hand.
NOTE: Apply a film of grease to the threaded part
of bearing nut (11) in order to tighten to the
specified torque.
W3-2-23
(ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3)
14
5 8 9 11 10
17
49
36 38
T16J-03-05-001
12 13 42 37 41 40 39
W3-2-24
11. Install special tool (ST 3136) to bearing nut (11). IMPORTANT: There is an identification groove on
Tighten bearing nut (11) by using a torque wrench. one half of third stage planetary gear
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: (37). Install third stage planetary
: 500 N⋅m (51 kgf⋅m, 369 lbf⋅ft) gear (37) with the identification
ZAXIS500LC-3, 520LCH-3 groove facing to cover (49).
: 780 N⋅m (80 kgf⋅m, 575 lbf⋅ft) 15. Install needle bearings (40, 41) (4 used for each) to
third stage planetary gears (37) (4 used). Clamp
ST 3136 third stage planetary gear (37) with thrust plates
(36, 42) (4 used for each). Install third stage
planetary gear (37) to third stage carrier (17).
16. Align the spring pin (38) holes on third stage

carrier (17) and pins (39) (4 used). Install pin (39).
IMPORTANT: Install spring pin (38) with the slit of

pin (38) facing to the end of pin (39).
17. Tap and install spring pins (38) (4 used) into third
stage carrier (17) and pin (39) by using a round bar.
W1JB-03-02-003
Round Bar Dia.:

12. Hold and rotate sprocket (14) both clockwise and ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
counterclockwise 4 to 5 turns. Tap drum (8) by 8 mm (0.32 in)
using a plastic hammer in order to secure ZAXIS500LC-3, 520LCH-3: 10 mm (0.39 in)
appropriate play. 38
13. Perform steps 11 and 12 twice and tighten bearing 39

nut (11) to the specified torque.
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
Slit
: 500 N⋅m (51 kgf⋅m, 369 lbf⋅ft)
ZAXIS500LC-3, 520LCH-3 W178-02-06-002
: 780 N⋅m (80 kgf⋅m, 575 lbf⋅ft)
IMPORTANT: If the spline of lock plate (12) is not

align with that of housing (5), tighten
bearing nut (11) further in the
tightening direction in order to align
with the spline.
14. Apply LOCTITE #262 to bolt (13). Install lock plate
(12) to bearing nut (11) with bolts (13) (2 used).
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
: 19 mm
: 90 N⋅m (9 kgf⋅m, 66 lbf⋅ft)
ZAXIS500LC-3, 520LCH-3
: 19 mm
: 71 N⋅m (7.2 kgf⋅m, 52 lbf⋅ft)
W3-2-25
(ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3)
5 8
45 44 17 18 19 21
28
29
49
43
25
26
27
24
23
22
50
35 32 34 33 30 31
36 38
T16J-03-05-001
42 37 41 40 39
W3-2-26
18. Install spacer (28) to first stage carrier (29).
assembly weight:
19. Install needle bearings (23) (3 used) to first stage
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
planetary gears (25) (3 used). Clamp first stage
25 kg (55 lb)
planetary gear (25) with thrust plates (26, 22) (3
ZAXIS500LC-3, 520LCH-3: 30 kg (66 lb)
used for each). Install first stage planetary gear
(25) to first stage carrier (29).
24. Wind nylon slings (2 used) onto second stage
carrier (19) assemblies (19, 20 and 30 to 35).
IMPORTANT: Install spring pin (27) with the slit of
Hoist and lower the second stage carrier (19)
spring pin (27) facing to the end of
assemblies onto third stage sun gear (18).
pin (24).
20. Install spring pins (27) (3 used) into first stage
25. Install second stage sun gear (21) to second
carrier (29) and pin (24) by using a round bar.
stage carrier (19) with the thinner end facing to
cover (49).
Round Bar Dia.:
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: Upper
4 mm (0.16 in)
ZAXIS500LC-3, 520LCH-3: 6 mm (0.24 in)
27
24 W1JB-03-02-005
21
Slit
26. Install first stage carrier (29) assemblies (22 to 29)
W178-02-06-002
to second stage carrier (19).
21. Assemble second stage carrier (19) according to 27. Insert shaft (43) into the center of carrier. Let it
the steps 19 to 21. engage with first stage planetary gears (25) (3
Round Bar Dia.: 5 mm (0.20 in) used).
CAUTION: The third stage carrier (17)

assembly weight:
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
70 kg (154 lb)
ZAXIS500LC-3, 520LCH-3: 85 kg (187 lb)
22. Wind nylon slings (2 used) onto third stage carrier

(17) assemblies (15 and 34 to 40). Hoist and
lower the third stage carrier (17) assemblies onto
housing (5).
23. Install third stage sun gear (18) to third stage

carrier (17) with the thinner end facing to cover
(49).
Upper
W1JB-03-02-004
18
W3-2-27
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3
51 46 47 48 49 50
44
45
10
W1J1-03-02-007
W1J1-03-02-008
W3-2-28
Procedure to Install Ring Gear (44)
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3
28. Install O-ring (10) to drum (8).

CAUTION: Ring gear (44) weight: 70 kg IMPORTANT: Apply THREEBOND #1389B to the
(150 lb) cover (49) mounting surface of ring
gear (44).
IMPORTANT: Align the matching marks made 34. Install eyebolt (PT 3/4) into the plug (51) hole (2
when disassembling. places) on cover (49).
29. Install eyebolts (M14, Pitch 2.0 mm) into the bolt Hoist and lower cover (49) onto ring gear (44).
(50) hole on ring gear (44). Hoist and lower ring
gear (44) onto drum (8). IMPORTANT:
35. Apply LOCTITE #262 to bolt (50). Install cover
30. Apply LOCTITE #262 to bolt (45). Install ring gear (49) to ring gear (44) with bolts (50) (16 used).
(44) to drum (8) with bolts (45) (30 used). : 22 mm
: 27 mm : 180 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
: 400 N⋅m (41 kgf⋅m, 295 lbf⋅ft)
36. Wind the seal tape onto plugs (51) (3 used).
31. Attach a tube bar onto ball bearing (48). Tap a Install plugs (51) (3 used) to cover (49).
tube bar by using a hammer and install ball : 14 mm
bearing (48) to cover (49). : 70 N⋅m (7 kgf⋅m, 51 lbf⋅ft)
Ball Bearing (48) Inner Diameter: 45 mm (1.77 in)
Outer Diameter: 68 mm (2.68 in)
32. Attach a tube bar onto stopper pin (47). Tap a

tube bar by using a hammer and install stopper
pin (47) to ball bearing (48).
Stopper Pin (47) Inner Diameter: 26 mm (1.02 in)
IMPORTANT: Install retaining ring (46) with the

chamfered surface facing to cover
(49).
33. Install retaining ring (46) to cover (49).
W3-2-29
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3
W1J1-03-02-007
51 47 48
50
52 49
53
44
W1J1-03-02-008
W3-2-30
Procedure to Install Ring Gear (44)
CAUTION: Ring gear (44) weight: 75 kg (165

lb)

when disassembling.
(50) hole on ring gear (44). Hoist and lower ring
gear (44) onto drum (8).
38. Install knock pin (53) between drum (8) and ring
gear (44).
39. Attach a tube bar onto ball bearing (48). Tap the
tube bar by using a hammer and install ball
bearing (48) to cover (49).
Ball Bearing (48) Inner Diameter: 45 mm (1.77 in)
40. Attach a tube bar onto stopper pin (47). Tap the
tube bar by using a hammer and install stopper
pin (47) to ball bearing (46).
Stopper Pin (47) Inner Diameter: 26 mm (1.02 in)
IMPORTANT: Apply THREEBOND #1389B onto the

cover (49) mounting surface on ring
gear (44).
41. Install eyebolts (PF1/4) into the plug (51) holes (2
places) on cover (49).
Hoist and lower cover (49) onto drum (8).
42. Apply LOCTITE #262 to bolt (50). Install cover

(49) to drum (8) with bolts (50) (20 used) and
: 22 mm
: 180 N⋅m (18 kgf⋅m, 133 lbf⋅ft)
43. Wind the seal tape onto plugs (51) (3 used).

Install plugs (51) (3 used) to cover (49).
: 14 mm
: 70 N⋅m (7 kgf⋅m, 52 lbf⋅ft)
W3-2-31
5
44
2 3 4
T16J-03-05-001
W3-2-32
CAUTION: Travel device weight: ZAXIS450-3,

450LC-3, 470H-3, 470LCH-3:
540 kg (1191 lb)
ZAXIS500LC-3, 520LCH-3: 720 kg (1587 lb)
44. Install eyebolt (B) into the bolt hole (2 places) on

the housing (5) flange part. Hoist and turn over
the travel device.
Eyebolt (B)
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
M18, Pitch 2.5 mm
ZAXIS500LC-3, 520LCH-3: M22, Pitch 2.5 mm
45. Fill gear oil (C) into the travel device.
Gear oil (C)

ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
11.5 L (3.0 US gal.)
ZAXIS500LC-3, 520LCH-3: 14.0 L (3.7 US gal.)
46. Install O-ring (4) to motor (1).
CAUTION: Motor (1) weight: 130 kg (290 lb)

into the bolt hole on motor (1). Hoist motor (1)
align the spline on shaft (43) with that on motor
(1) and install motor (1) to housing (5).
5
2, 3
Eyebolt
Mounting
Position
W16J-03-02-002
48. Install motor (1) to housing (5) with bolts (2) (4

used) and spring washers (3) (4 used).
: 27 mm
: 300 N⋅m (31 kgf⋅m, 220 lbf⋅ft)
W3-2-33
DISASSEMBLE TRAVEL MOTOR
4
1 3
2
7
6
5
2
17
15 16
14
13
11 12
10
25
9
24
8 23
22
21
20
18
30
29
19 28
27
26
W1J1-03-02-002
1- Case 9- Swash Plate 17 - Roller Bearing 25 - O-Ring
2- O-Ring (4 Used) 10 - Piston (9 Used) 18 - *Disc Plate 26 - Spring (10 Used)
3- Spring (2 Used) 11 - Retainer 19 - *Friction Plate 27 - Pin
4- Piston (2 Used) 12 - Holder 20 - Backup Ring 28 - Pin (4 Used)
5- Oil Seal 13 - Spring (9 Used) 21 - O-Ring 29 - Valve Housing
6- Roller Bearing 14 - Cylinder Block 22 - O-Ring 30 - Socket Bolt (9 Used)
7- Shaft 15 - Valve Plate 23 - Backup Ring
8- Steel Ball (2 Used) 16 - Collar 24 - Brake Piston
NOTE: ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
18-*Disc Plate (5 Used)
19-*Friction Plate (4 Used)
W3-2-34
Disassemble Travel Motor
IMPORTANT: Secure case (1) onto the workbench.
CAUTION: Valve housing (29) weight: 39 kg 4. Install eyebolt (M12, Pitch 1.75 mm) to the pin
(90 lb) (28) hole (2 places) on brake piston (24). Attach a
nylon sling onto eyebolt. Hoist and remove brake
IMPORTANT: Loosen socket bolts (30) (9 used) piston (24) from case (1).
evenly. When socket bolts (30) are
loosened, valve housing (29) will 5. Remove O-rings (21, 22), backup rings (20, 23)
raise from case (1) under the from brake piston (24).
reaction force from springs (13, 26).
Take down the clearance between 6. Remove disc plates (18) and friction plates (19)
case (1) and valve housing (29). from case (1) one by one alternately.
When removing valve housing (29)
from case (1), valve plate (15) may ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
be removed with valve housing (29) Disc plates (18): 5 used
together. Do not drop valve plate Friction plates (19): 4 used
(15). ZAXIS500LC-3, 520LCH-3: 24 used
1. Put the matching marks on the mating positions of Disc plates (18): 6 used
valve housing (29) and case (1). Install eyebolt Friction plates (19): 5 used
(M12, Pitch 1.75 mm) to valve housing (29).
Attach a nylon sling onto eyebolt. Hoist and hold
valve housing (29). Remove socket bolts (30) (9
used) from valve housing (29). Remove valve
housing (29) from case (1).
: 14 mm
1 29
30
Eyebolt Mounting
Position
W16J-03-02-002
2. Remove springs (26) (10 used), O-rings (2) (4

used), pins (28) (4 used) and O-ring (25) from
case (1).
IMPORTANT: Do not damage valve plate (15).

3. Remove collar (16) and valve plate (15) from
cylinder block (14).
W3-2-35
4
1 3
7
6
5
W1J1-03-02-002
W3-2-36
IMPORTANT: Do not remove the inner race of

CAUTION: The cylinder block (14) assembly
roller bearing (6) from shaft (7) and
the outer race of roller bearing (6)
from case (1) unless necessary.
IMPORTANT: If cylinder block (14) needs to be
replaced, cylinder block assemblies
shaft (7) by using a press.
(10 to 15) with valve plate (15)
should be replaced.
IMPORTANT: Keep the outer race of roller bearing
7. Remove cylinder block (14) assemblies (10 to 15)
(6) properly so that it can be
from case (1).
installed in the same direction
NOTE: Hold and rotate cylinder block (14) left and before disassembling.
right lightly by both hands in order to 12. Remove the outer race of roller bearing (6) from
remove slowly. case (1) by using a bar and hammer.
8. Remove retainer (11), pistons (10) (9 used), 13. Remove oil seal (5) from case (1).
holder (12) and springs (13) (9 used) from
cylinder block (14).
IMPORTANT: Do not damage the sliding surface of

swash plate (9).
Piston (4) and steel ball (8) may be
removed with swash plate (9)
together. Do not drop piston (4) and
steel ball (8).
9. Remove swash plate (9), pistons (4) (2 used),
springs (3) (2 used) and steel balls (8) (2 used)
from case (1).
NOTE: If it is difficult to remove steel ball (8), that

means steel ball (8) has been set in case
(1), so use some kerosene or thinner, etc.
in order to clean grease first. Then remove
steel ball (8) from case (1) by using a
magnet.
IMPORTANT: Do not damage the spline part of

shaft (7) and contact part of oil seal
(5). Oil leakage will occur if they are
damaged.
10. Remove shaft (7) from case (1). At this time, the
inner race of roller bearing (6) is removed with
shaft (7) together.
W3-2-37
ASSEMBLE TRAVEL MOTOR
27 30 26 22, 23 24 20, 21 7 4 3
16
29 8
17
15
28
25
W1J1-03-02-003
2
Brake Release Circuit 14 10 18 19 13 11 12 9 6 5
1- Case 9- Swash Plate 17 - Roller Bearing 25 - O-Ring

2- O-Ring (4 Used) 10 - Piston (9 Used) 18 - *Disc Plate (5 Used) 26 - Spring (10 Used)
3- Spring (2 Used) 11 - Retainer 19 - *Friction Plate (4 Used) 27 - Pin
4- Piston (2 Used) 12 - Holder 20 - Backup Ring 28 - Pin (4 Used)
5- Oil Seal 13 - Spring (9 Used) 21 - O-Ring 29 - Valve Housing
6- Roller Bearing 14 - Cylinder Block 22 - O-Ring 30 - Socket Bolt (9 Used)
7- Shaft 15 - Valve Plate 23 - Backup Ring
8- Steel Ball (2 Used) 16 - Collar 24 - Brake Piston

W3-2-38
Assemble Travel Motor
IMPORTANT: Align the spherical hole in swash
IMPORTANT: Apply grease to the inner periphery plate (9) with steel ball (8) and install
of oil seal (5) for case (1) at the swash plate (9).
pressed-in part and the outer pe- Apply grease to the contact part of
riphery of oil seal (5). case (1) for swash plate (9).
In addition, oil seal (5) should be 6. Install swash plate (9) to case (1) with its thicker
pressed in straight in order not to side facing downward.
deform.
1. Install oil seal (5) to case (1). IMPORTANT: Apply hydraulic oil to the piston (10)
mounting hole of cylinder block (14).
IMPORTANT: Install the outer race of roller bear- Check the mounting direction of re-
ing (6) with the stamped mark facing tainer (11).
to the swash plate (9) side.
2. Tap the outer race of roller bearing (6) evenly by 7. Install springs (13) (9 used) and holder (12) to
using a bar and hammer and install the outer race cylinder block (14).
to case (1). Install pistons (10) (9 used) to retainer (11). Install
NOTE: Tap and listen to ring in order to check if the retainer (11) to cylinder block (14).
outer race is installed to case (1) com-
pletely.
CAUTION: The cylinder block (14) assembly
IMPORTANT: Install the inner race of roller bearing
(6) with its collar facing to the swash IMPORTANT: Apply hydraulic oil to the piston (10)
plate (9) side. sliding surface of swash plate (9)
3. Tap the inner race of roller bearing (6) evenly by and the spherical surface of holder
using a bar and hammer and install the inner race (12).
to shaft (7). There is the inner race of roller
Tap and install the shaft (7) assembly to case (1) bearing (17) on the tip of shaft (7).
by using a hammer. Do not damage them. Align the
spline of shaft (7) with that of cylin-
IMPORTANT: Apply hydraulic oil on outside pe- der block (14).
riphery of steel ball (8) and piston (4). 8. Install the cylinder block (14) assembly to shaft
Apply hydraulic oil to the piston and (7).
the steel ball mounting surface of
case (1).
4. Install springs (3) (2 used), pistons (4) (2 used) CAUTION: The case (1) assembly weight:
and steel balls (8) (2 used) to case (1). 54 kg (120 lb)
CAUTION: The case (1) assembly weight:

54 kg (120 lb)
5. Install eyebolts (M18, Pitch 2.5 mm) into the

socket bolts (30) hole (2 places) on case (1). At-
tach a nylon sling onto eyebolt. Hoist and place
the case (1) assembly with the brake release cir-
cuit facing downward.
W3-2-39
27 26 22, 23 24 20, 21
16
29
17
15
28
W1J1-03-02-003
14 18 19
W3-2-40
9. Install eyebolt (M18, Pitch 2.5 mm) into the socket 12. Lightly tap and install brake piston (24) to case (1)
bolt (30) hole (2 places) on case (1). Attach a ny- by using a plastic hammer.
lon sling to eyebolt. Hoist and place case (1) ver-
tically. IMPORTANT: As for springs (26) (10 used), there
are twelve spring (25) mounting
10. Install disc plates (18) and friction plates (19) al- holes on brake piston (24). Check
ternately case (1). the correct hole to install spring (26).
24
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: Free Hole
Disc plates (18): 5 used
Friction plates (19): 4 used
ZAXIS500LC-3, 520LCH-3: 26
Disc plates (18): 6 used
Friction plates (19): 5 used
NOTE: When installing, align with the notch on
case (1).
26
When installing disc plate (18), its inner
splines shall be aligned with those of cyl-
inder block (14).
W16J-03-02-003
Free Hole
IMPORTANT: Apply grease to O-rings (21, 22) and
backup rings (20, 23). 13. Install springs (26) (10 used) to brake piston (24).
11. Install O-rings (21, 22) and backup rings (20, 23)
to brake piston (24).
IMPORTANT: Check the mounting direction for

brake piston (24). When installing,
the notch shall be square to the pin
(28) hole on case (1).
1
24
Notch
W16J-03-02-003
28
W3-2-41
30 24
29
28
25
W1J1-03-02-003
2
W3-2-42
IMPORTANT: Install the outer race of roller bear- 17. Install eyebolt (M12, Pitch 1.75 mm) into the bolt
ing (17) with the stamped mark fac- hole on valve housing (29). Attach a nylon sling
ing to the valve plate (15) side. onto eyebolt.
14. Tap the outer race of roller bearing (17) evenly by Hoist valve housing (32). Align with the pin (28)
using a bar and hammer and install the outer race hole on brake piston (24) and place valve housing
to valve housing (29). (29) onto the case (1).
NOTE: Tap and listen to ring in order to check if the Install valve housing (29) to case (1) with socket
outer race is installed to valve housing (29) bolts (30) (9 used).
completely. : 14 mm
: 439±22 N⋅m
IMPORTANT: Apply grease to the contact surfaces (45±2.2 kgf⋅m, 325±16 lbf⋅ft)
of valve plate (15) and valve housing NOTE: Tighten socket bolts (30) (9 used) evenly.
(29).
15. Install collar (16) to valve housing (29). Align the 1 29
pin holes on pin (27) and valve plate (15). Install
valve plate (15) to valve housing (29). 30
IMPORTANT: Apply grease to O-rings (2, 25).

16. Install O-rings (25) and (2) (4 used) to case (1).
Install pins (28) (4 used) to valve housing (29).
CAUTION: Valve housing (29) weight: 39 kg

(90 lb) Eyebolt
Mounting Position
IMPORTANT: When installing valve housing (29)
to case (1), check if the clearance W16J-03-02-002
between case (1) and valve housing

(29) is equal to that noted when dis-
assembling. If the value is different,
disassemble them and reassemble
again.
when disassembling. If the matching
marks cannot be aligned with each
other, brake piston (24) may be in-
stalled in wrong direction.
W3-2-43
DISASSEMBLE BRAKE VALVE
2
1 5 7 9
3 Plug
4 6 8 10
11
9
10 12
35
36 51
37
38
39
40
41
42
43
44
48
47
49 46
10
9
13
16
17 14
18 15
19
20
21
51 22
24
26
4 27
3 28
30
2 23 31
1 25 32
45 33
34
44 29
43
42
41 36
50 40 5
39 35
38
37
W1J1-03-02-004
1- Plug (2 Used) 14 - O-Ring 27 - Spring (2 Used) 40 - Spring Seat (2 Used)

2- O-Ring (2 Used) 15 - Plug 28 - Spring Guide (2 Used) 41 - Plug (2 Used)
3- Spring (2 Used) 16 - Poppet Seat (2 Used) 29 - O-Ring (2 Used) 42 - O-Ring (2 Used)
4- Check Valve (2 Used) 17 - Backup Ring (2 Used) 30 - Backup Ring (2 Used) 43 - Spring (2 Used)
5- Relief Valve (2 Used) 18 - O-Ring (2 Used) 31 - O-Ring (2 Used) 44 - Check Valve (2 Used)
6- Plug 19 - Backup Ring (2 Used) 32 - Plug (2 Used) 45 - Spool
7- O-Ring 20 - Poppet (2 Used) 33 - Nut (2 Used) 46 - Valve Housing
8- Spring 21 - Relief Housing (2 Used) 34 - Set Screw (2 Used) 47 - Pin (4 Used)
9- Plug (6 Used) 22 - Piston (2 Used) 35 - Socket Bolt (8 Used) 48 - Pin
10 - O-Ring (6 Used) 23 - Backup Ring (2 Used) 36 - Cap (2 Used) 49 - Orifice
11 - Orifice (2 Used) 24 - O-Ring (2 Used) 37 - O-Ring (2 Used) 50 - Spool Assembly
12 - Socket Bolt (9 Used) 25 - Backup Ring (2 Used) 38 - Spring Seat (2 Used) 51 - Orifice (2 Used)
13 - Valve Assembly 26 - Spring Seat (2 Used) 39 - Spring (2 Used)
W3-2-44
Disassemble Brake Valve
IMPORTANT: Do not disassemble relief valves (5)
CAUTION: The valve housing (46) assembly
(2 used). Relief valve (5) should be
replaced as assembly. Attach an
identification tag to each relief valve
1. Secure the valve housing (46) assembly on a firm
(5) in order to install to their original
workbench.
position.
In addition, do not rotate set screw
2. Remove plugs (6, 15), O-rings (7, 14) and spring
(34). The setting pressure can
(8) from valve housing (46).
change.
: 10 mm
5. Remove relief valves (5) (2 used) from valve
housing (46).
IMPORTANT: Remove valve assembly (13) while
: 36 mm
rotating. If a little resistance is felt
while removing, do not try to remove
6. Push cap (36) and remove socket bolts (35) (8
it by force, return to original position
used). Remove caps (36) (2 used) from valve
and retry.
housing (46).
In addition, do not disassemble
: 10 mm
valve assembly (13). In case re-
placement should be carried out to NOTE: In case cap (36) cannot be removed, tap
any parts of it, replace it with the cap (36) by using a plastic hammer. While
valve housing (46) assembly in- tapping, loosened socket bolt (35) should
cluding spool assembly (50), valve be still on cap (36).
assembly (13), orifices (11, 49, 51)
and the plug. 7. Remove spring seats (38) (2 used), springs (39)
3. Push valve assembly (13) lightly. Rotate and re- (2 used) and spring seats (40) (2 used) from valve
move valve assembly (13) by hand from valve housing (46).
housing (46).
IMPORTANT: Remove spool assembly (50) while
4. Remove plugs (1) (2 used), O-rings (2) (2 used), rotating. In case a little resistance is
springs (3) (2 used) and check valves (4) (2 used) felt while removing, do not try to
from valve housing (46). remove it by force, return to original
: 14 mm position and retry.
8. Push spool assembly (50) lightly. Rotate and re-
move spool assembly (50) by hand from valve
housing (46).
9. Clamp spool assembly (50) in a vise by using chip

of wood inserted at both side.
10. Remove plugs (41) (2 used) from spool (45).

Remove springs (43) (2 used) and check valves
(44) (2 used) from spool (45).
W3-2-45
ASSEMBLE BRAKE VALVE
Relief Valve (5)
16 18 21 26 24 27 31 29 32 33
34
17、19 20 22 23、25 28 30
10 11 6 7 36 38
41
37
39
35
51
A A
42
A
9 40
8 43
44
13 45
14 50
48 47
12
15
46
5 2 1 3 4
Section A-A-A W1J1-03-02-005
1- Plug (2 Used) 14 - O-Ring 27 - Spring (2 Used) 40 - Spring Seat (2 Used)

2- O-Ring (2 Used) 15 - Plug 28 - Spring Guide (2 Used) 41 - Plug (2 Used)
3- Spring (2 Used) 16 - Poppet Seat (2 Used) 29 - O-Ring (2 Used) 42 - O-Ring (2 Used)
4- Check Valve (2 Used) 17 - Backup Ring (2 Used) 30 - Backup Ring (2 Used) 43 - Spring (2 Used)
5- Relief Valve (2 Used) 18 - O-Ring (2 Used) 31 - O-Ring (2 Used) 44 - Check Valve (2 Used)
6- Plug 19 - Backup Ring (2 Used) 32 - Plug (2 Used) 45 - Spool
7- O-Ring 20 - Poppet (2 Used) 33 - Nut (2 Used) 46 - Valve Housing
8- Spring 21 - Relief Housing (2 Used) 34 - Set Screw (2 Used) 47 - Pin (4 Used)
9- *Plug (6 Used) 22 - Piston (2 Used) 35 - Socket Bolt (8 Used) 48 - Pin
10 - *O-Ring (6 Used) 23 - Backup Ring (2 Used) 36 - Cap (2 Used) 49 - *Orifice
11 - *Orifice (2 Used) 24 - O-Ring (2 Used) 37 - O-Ring (2 Used) 50 - Spool Assembly
12 - Socket Bolt (9 Used) 25 - Backup Ring (2 Used) 38 - Spring Seat (2 Used) 51 - Orifice
13 - Valve Assembly 26 - Spring Seat (2 Used) 39 - Spring (2 Used)
NOTE: As for parts with mark *, refer to W3-2-30.
W3-2-46
Assemble Brake Valve
1. Install O-rings (7, 14) to plugs (6, 15) respectively.
Install valve assembly (13), spring (8) and plugs
(6, 15) to valve housing (46).
: 10 mm
: 67.3±4.9 N⋅m
(6.9±0.5 kgf⋅m, 50±3.6 lbf⋅ft)
2. Install O-rings (2) (2 used) to plugs (1) (2 used)

Install check valves (4) (2 used), springs (3) (2
used) and plugs (1) (2used) to valve housing (46).
: 14 mm
: 412±20 N⋅m
(42±2 kgf⋅m, 304±15 lbf⋅ft)
IMPORTANT: Install relief valve (5) to the former

position before disassembling.
3. Install relief valves (5) (2 used) to valve housing
(46).
: 36 mm
: 412±22 N⋅m
(42±2.2 kgf⋅m, 304±16 lbf⋅ft)
4. Slowly rotate and insert spool assembly (50) into

valve housing (46).
5. Install O-rings (37) (2 used) to caps (36) (2 used).
6. Install spring seats (40) (2 used), springs (39) (2

used) and spring seats (38) (2 used) to valve
housing (46). Install caps (36) (2 used) with
: 10 mm
: 108±4.9 N⋅m
(11±0.5 kgf⋅m, 80±3.6 lbf⋅ft)
W3-2-47
1. Clearance between inner diameter of cylinder

Cylinder
block and outer diameter of piston: Block
(D-d): 0.06 mm (0.002 in) or less

D d
W507-02-04-009
Piston
2. Clearance between piston and shoe engaging:

Piston
δ: 0.4 mm (0.016 in) or less
Shoe
δ
W107-02-06-140
3. Clearance between inner diameter and outer di-
ameter at the mounting position of case and pis- Piston
ton:
(D-d): 0.03 mm (0.001 in) or less D
Case
4. Wear amount on the sliding surfaces of cylinder

block and valve plate:
W162-03-02-005
Check there is no abnormal scratch, wear or
score.
Damage and wear amount within 0.02 mm (0.001
in) or less.
W3-2-48
Sprocket
C
D
E
A
W105-03-07-042
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3 Unit: mm (in)

Standard Allowable Limit Remedy
A 92 (3.6) [82 (3.2)]
B 131.6 (5.2) 126.6 (4.9)
Build up and
C 167.6 (6.6) -
finishing
D 177.5 (7.0) 172.5 (6.8)
E 215.9 (8.5) -
ZAXIS500LC-3, 520LCH-3 Unit: mm (in)

A 102 (4.0) [92 (3.6)]
B 91.4 (3.6) 86.4 (3.4)
Build up and
C 132.3 (5.2) -
finishing
D 143.9 (5.6) 138.9 (5.5)
E 228.6 (9) -
NOTE: Value in [ ] is just for reference.
W3-2-49
(Blank)
W3-2-50
UNDERCARRIAGE / Center Joint
REMOVE AND INSTALL CENTER JOINT
IMPORTANT: Release any pressure in the hydrau-

lic oil tank before doing any work. Machine Front
(Refer to “Bleed Air from Hydraulic
Oil Tank” on page W1-4-1.)
Removal
7 8 1
2
IMPORTANT: Attach an identification tag to all the 6
hoses of center joint for reassem-
bling.
IMPORTANT: Remove all the hoses and adapters
from center joint. Attach a cap to the
removed hoses.
1. Remove hoses (1, 2, 5, 6) and adapters (4 used) 5 3
from the upper side of spindle on the center joint. W16J-03-03-002
4
: 41 mm Spindle
2. Remove hoses (3, 4) from the spindle.

: 19 mm, 27 mm
3. Remove bolts (8) (2 used) and spring washers (2

used) from the spindle. Remove stopper (7)
from the spindle. At this time, remove the wash-
ers (2 used) between stopper (7) and spindle.
: 22 mm
CAUTION: Center joint weight: 52 kg (110 lb)

17 Center Joint
4. Install eyebolts (G1) to the adapter holes (2 16 9
10
places) on the upper side of spindle. Attach a
nylon sling onto eyebolt. Take up slack of the
nylon sling. Track
Frame
5. Remove hoses (9 to 16) from the lower side of
center joint.
: 22 mm, 27 mm, 41 mm 15
14 11
6. Put the matching marks on the track frame and 13
W16J-03-03-003
12
the center joint.
Remove bolts (17) (4 used) and spring washers
(4 used). Hoist and remove the center joint slow-
ly. Machine Front
: 24 mm
W3-3-1
Installation
CAUTION: Center joint weight: 52 kg (110 lb)
IMPORTANT: Align the matching marks made 16 17 Center Joint

9
when disassembling. 10
1. Install the center joint to the track frame with bolts 18
(17) (4 used) and spring washers (4 used).
: 24 mm Track
Frame
: 210 Nm (21.5 kgfm, 154 Ibfft)
2. Install the adapters (18) (4 used) to the lower

15
side of center joint.
: 41 mm 14 11
: 400 Nm (41 kgfm, 295 Ibfft) 13 12
W16J-03-03-003
3. Install hoses (9 to 16) to the lower side of center

joint. Machine Front
: 22 mm
: 39 Nm (4 kgfm, 29 Ibfft)
: 27 mm
Machine Front
: 78 Nm (8 kgfm, 58 Ibfft)
: 41 mm
: 205 Nm (21 kgfm, 152 Ibfft)
7 8 1
4. Insert the washer between stopper (7) and the 2
spindle. Install stopper (7) to the spindle with 6
bolts (8) (2 used) and spring washers (2 used).
: 22 mm
: 140 Nm (14 kgfm, 101 Ibfft)
5. Install hoses (3, 4) to the spindle.

5 3
: 27 mm
: 93 Nm (9.5 kgfm, 69 Ibfft) 4
W16J-03-03-002
Spindle
: 19 mm
: 29.5 Nm (3 kgfm, 21.5 Ibfft)
6. Install the adapters (4 used) to the upper side of

spindle. Install hoses (1, 2, 5, 6) to the adapters
(4 used).
: 41 mm
: 205 Nm (21 kgfm, 152 Ibfft)
IMPORTANT: After completing the work, check

the oil level. Start the engine and
check for any oil leaks.
W3-3-2
(Blank)
W3-3-3
DISASSEMBLE CENTER JOINT
3
4
9
6
10
11
12
W16J-03-03-001
1 - Plug 4 - O-Ring 7 - Body 10 - O-Ring

2 - Spindle 5 - Bushing 8 - Ring 11 - Cover
3 - Dust Seal 6 - Oil Seal (6 Used) 9 - Retaining Ring 12 - Bolt (4 Used)
W3-3-4
Disassemble Center Joint
CAUTION: Spindle (2) weight: 22 Kg (50 lb)

CAUTION: Center joint weight: 52 kg (110 lb) Body (7) weight: 29 kg (60 lb)
1. Remove bolts (12) (2 used) in diagonal position 6. Tighten bolt (ST 1020) of special tool (ST 1033)
from cover (11). Install eyebolts (M12, Pitch 1.75 and remove body (7) from spindle (2) upward.
mm) into the bolt holes. Just before spindle (2) is separated from body (7),
Attach a nylon sling onto eyebolt. Place the cen- remove special tool. Install eyebolt (M12, Pitch
ter joint on the workbench. 1.75 mm) into the bolt (12) holes (2 places) on
: 19 mm body (7). Attach a nylon sling onto eyebolt. Push
spindle (2). Hoist and remove body (7).
2. Remove bolts (12) (2 used) and eyebolts (2
used) from body (7). Remove cover (11) from IMPORTANT: It is easier to remove oil seal (6) if
body (7). two pins are used. Do not damage
: 19 mm the seal groove with the pins.
7. Remove oil seals (6) (6 used) from body (7).
3. Remove O-ring (10), retaining ring (9) and ring
(8) from body (7).
4. Put the matching marks on body (7) and spindle

(2).
5. Install special tool (ST 1033) to body (7) with 7

: 19 mm
ST 1020 6
ST 1033 12
W105-03-03-015
7 8. Remove dust seal (3) and O-ring (4) from body

(7).
IMPORTANT: While welding, cover the seal sur-

face in order to prevent it from be-
ing spattered.
W183-03-03-004 9. When replacing bushing (5), build-up weld at 90
(4 places) in its inner diameter by using a welding
rod. Shrink and remove bushing (5).
W3-3-5
ASSEMBLE CENTER JOINT
8
10
12
9
11
W183-03-08-001
1 - *Plug 4 - O-Ring 7 - Body 10 - O-Ring

2 - Spindle 5 - Bushing 8 - Ring 11 - Cover
3 - Dust Seal 6 - Oil Seal (6 Used) 9 - Retaining Ring 12 - Bolt (4 Used)
NOTE: As for the item with mark*, refer to W3-3-4.
W3-3-6
Assemble Center Joint
IMPORTANT: Apply grease to the bushing (5) IMPORTANT: The clearance between body (7) and
mounting part on body (7). spindle (2) is not much. Align the
1. If bushing (5) has been removed, first install center of body (7) and spindle (2)
bushing (5) to body (7). (Refer to page W3-3-10.) and install body (7) straightly.
As the seal may be damaged, slowly
install body (7).
IMPORTANT: Apply grease to the dust seal (3) Install body (7) in order not to form
mounting part on body (7). Face the the step at position A (the mounting
metal part of dust seal (3) to the position for ring (8)) shown below.
body (7) side.
2. Install O-ring (4) and dust seal (3) to body (7).
Metal Part 3 2
A
W800-03-03-001
7
3. Install oil seals (6) (6 used) to body (7).
W800-03-03-002
W3-3-7
8
10
12
9
11
W183-03-08-001
W3-3-8
CAUTION: Spindle (2) weight: 22 kg (50 lb)

Body (7) weight: 29 kg (60 lb)
IMPORTANT: Apply grease to the sliding surface

of dust seal (3) on spindle (2) and
inner surfaces of oil seal (6) and
bushing (5).
4. Place spindle (2) on a workbench with its upside
down. Install eyebolt (M12, Pitch 1.75 mm) into
the bolt (12) holes (2 places) on body (7). Hoist
and place body (7) while aligning the matching
mark with that of spindle (2).
5. Tap the circumference of body (7) evenly by us-

ing a plastic hammer and insert body (7) into
spindle (2).
IMPORTANT: Install ring (8) with the chamfered

edge facing to the inner surface of
body (7).
6. Install ring (8) to body (7).
IMPORTANT: Install retaining ring (9) with its

chamfered edge facing to the ring
(8) side.
7. Install retaining ring (9) to spindle (2).
8. Install O-ring (10) to body (7). Install cover (11) to

body (7) with bolts (12) (4 used).
: 19 mm
: 88 Nm (9 kgfm, 65 Ibfft)
W3-3-9
When replacing body (7) with a new one, the following
procedures are required.
ST 2670
IMPORTANT: When installing bushing (5) to body

(7), grease and molybdenum di- 7
sulphide should be applied to the
fitting surface.
5
Push and install bushing (5) to body (7).
1. Clean body (7) and bushing (5).
2. Push bushing (5) to body (7) by using a press.
Pushing force: 0.5 to 1.5 ton
Pushing tool: ST 2670
W105-03-03-029
W3-3-10
Item Allowable Limit (basis of judgment) Remedy

1. Wear more than 0.2 mm (0.008 in) Replace
2. Seizure and abnormal wear Replace
3. Uneven wear within 180 Replace
Wear Area Within Half
Range
Bushing
T157-01-01-040
Sliding surface with Heavily damaged one by seizure or foreign mat- Replace
seals ter
1) Excessively worn one by seizure or foreign Replace
Sliding surface be- matter, or one having the score of 0.1 mm
tween body and spin- (0.004 in) or more
dle other than sliding 2) One having the score of less than 0.1 mm Repair the surface
surfaces with seals (0.004 in) smooth by using
an oil stone
Body, Spindle
1) One that has worn 0.5 mm (0.02 in) or Replace
more, or excessively worn
2) One that has worn 0.5 mm (0.02 in) or less Repair the surface
Sliding surface with smooth
ring 3) One that has scores due to seizure or Repair the surface
foreign matter but the damage is less than smooth
the allowable wear limit 0.5 mm (0.02 in)
and is repairable
1) One that has worn 0.5 mm (0.02 in) or Replace
more
2) One that has worn less than 0.5 mm (0.02 Repair the surface
Sliding surface with in) smooth
Cover
ring 3) One that has scores due to seizure or Repair the surface
foreign matter but the damage is less than smooth
the allowable wear limit 0.5 mm (0.02 in)
and is repairable
W3-3-11
(Blank)
W3-3-12
UNDERCARRIAGE / Track Adjuster
REMOVE AND INSTALL TRACK AD-
JUSTER
Before removing and installing the track adjuster, the

tracks and the front idler must be removed first. For
removal and installation of the tracks and the front
idler, refer to “Remove and Install Track” and “Re-
move and Install Front Idler” sections. In this section,
the procedure starts on the premise that the tracks
and the front idler have already been removed.
CAUTION: When removing track adjuster (1),

track adjuster (1) may fly off due to spring
force. 2
Do not stand in the same direction to remove 1
track adjuster (1) or where track adjuster (1)
may fly out. The rod screw is always loaded
by spring force.
Be alert that if the rod or screw section is
broken, the broken pieces may fly out by
spring force.
W142-03-04-002
Removal
3 4
CAUTION: Track adjuster (1) weight:
ZAXIS450-3, 470H-3: 235 kg (518 lb)
ZAXIS450LC-3, 470LCH-3: 239 kg (527 lb)
ZAXIS500LC-3, 520LCH-3: 365 kg (805 lb)
1. Pry and remove track adjuster (1) from track

frame (2) by using a pry bar. A
W16J-03-04-002
Installation
2
CAUTION: Track adjuster (1) weight: 3
ZAXIS450-3, 470H-3: 235 kg (518 lb)
ZAXIS450LC-3, 470LCH-3: 239 kg (527 lb)
ZAXIS500LC-3, 520LCH-3: 365 kg (805 lb)
1. As illustrated, install track adjuster (1) into spring

guide (3) on track frame (2).
Check that the end face of track adjuster (1)
W1J1-03-04-003
comes into contact with that of plate (4) at this View Ａ
time.
W3-4-1
DISASSEMBLE TRACK ADJUSTER
(ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3)
2
3
4
5
1 6
7
9
10
11
12
13
14
15 W1J1-03-04-002
16
1- Socket Bolt (4 Used) 5- Wear Ring 9- O-Ring 13 - Nut

2- O-Ring 6- U-Ring 10 - Spacer 14 - Bolt
3- Guide 7- Retaining Ring 11 - Spring 15 - Rod
4- Piston Rod 8- Cylinder 12 - Bracket 16 - Valve
W3-4-2
2
3
5
17
1 6
18
7
15
10 8
9
11
12
13
16
14 W1J1-03-04-004
1- Socket Bolt (4 Used) 6- U-Ring 11 - Spring 15 - Rod

2- O-Ring 7- Retaining Ring 12 - Bracket 16 - Valve
3- Guide 8- Cylinder 13 - Nut 17 - Backup Ring
4- Piston Rod 9- O-Ring 14 - Bolt 18 - Plate
5- Wear Ring (2 Used) 10 - Spacer
W3-4-3
2
3
4
5
1 6
7
9
10
11
12
13
14
15 W1J1-03-04-002
16
W3-4-4
Disassemble Track Adjuster
• Use a pump unit which has the maximum pres-
2
sure of 69 MPa (700 kgf/cm , 9950 psi) and the IMPORTANT: Compress the spring until the clear-
flow rate of 8 to 10 liters (2.1 to 2.6 US gal). Set ance between bracket (12) and nut
the main relief pressure to 49 MPa (500 (13) is approximately 10 mm (0.4 in).
2
kgf/cm , 7110 psi) (80 tons) or lower. 2. Loosen valve (16). Compress spring (11) of the
track adjuster by using special tool (ST 4932).
IMPORTANT: Use special tool (ST4932) when as- : 24 mm
sembling and disassembling the
track adjuster. Clearance 10 mm (0.4 in)
CAUTION: As the spring force of track ad-

juster is extremely large, carry out the dis-
assembly and assembly work carefully. 12 15
Thoroughly inspect the special tool for any 13
damage in order to perform the work safely. 14
16
CAUTION: Track adjuster weight:
ZAXIS450-3, 470H-3: 235 kg (518 lb)
ZAXIS450LC-3, 470LCH-3: 239 kg (527 lb)
ZAXIS500LC-3, 520LCH-3: 365 kg (805 lb)
W142-03-04-020
1. Hoist and place the track adjuster on the rest of

IMPORTANT: Put the matching marks on rod (15)
special tool (ST 4932).
and nut (13).
Track Adjuster 3. Remove valve (16) from rod (15).
ST 4932
: 24 mm
4. Remove bolt (14) from nut (13). Remove nut (13)

from rod (15).
: 17 mm, 100 mm
Rest
W142-03-04-019
W3-4-5
(ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3)
10
11
12
W1J1-03-04-002
10 8
11
12
W1J1-03-04-004
W3-4-6
5. Slowly return the piston of special tool (ST 4932) 7. Install eyebolt (M16, Pitch 2.0 mm) to piston rod
until spring (11) extends to its free length. (4). Attach a nylon sling to spring (11). Pass a ny-
NOTE: Spring (11) free length: lon sling through eyebolt. Hoist and place the as-
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: sembly on the rest.
782 mm (31 in)
ZAXIS500LC-3, 520LCH-3: 733 mm (29 in)
Eyebolt
CAUTION: Track adjuster weight:

4
ZAXIS450-3, 470H-3: 235 kg (518 lb)
ZAXIS450LC-3, 470LCH-3: 239 kg (527 lb)
ZAXISS500LC-3, 520LCH-3: 365 kg (805 lb)
11
6. Secure bracket (12) and spring (11) together by

using a wire. Attach a nylon sling to spring (11) of
the track adjuster. Hoist and remove the track
adjuster from special tool (ST 4932). Rest
11 ST 4932 W142-03-04-006
CAUTION: The cylinder (8) assembly weight:

ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
12
75 kg (165 lb)
ZAXIS500LC-3, 520LCH-3: 102 kg (225 lb)
8. Hoist and remove cylinder (8) assemblies (1 to 9,

15) from spring (11).
W142-03-04-005 8
11
Rest
W142-03-04-007
W3-4-7
(ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3)
2
3
4
5
1 6
7
9
10
11
12
2 15 W1J1-03-04-002
3
5
17
1 6
18
7
15
10 8
9
11
12
W1J1-03-04-004
W3-4-8
CAUTION: Spring (11) weight: ZAXIS450-3, CAUTION: Cylinder (8) weight: ZAXIS450-3,
450LC-3, 470H-3, 470LCH-3: 122 kg (269 lb) 450LC-3, 470H-3, 470LCH-3: 39 kg (86 lb)
ZAXIS500LC-3, 520LCH-3: 150 kg (331 lb) ZAXIS500LC-3, 520LCH-3: 52.4 kg 115.5 lb)
Rod (15) weight: 21 kg (50 lb)
9. Remove wire fastening spring (11) and bracket
(12). Hoist and remove spring (11) from the rest. 14. Install eyebolt (M16, Pitch 2.0 mm) to rod (15).
Attach a nylon sling. Hoist and remove rod (15)
from cylinder (8).
CAUTION: Bracket (12) weight: ZAXIS450-3,
Remove O-ring (9) from inside of cylinder (8).
450LC-3, 470H-3, 470LCH-3: 22 kg (48.5 lb)
ZAXIS500LC-3, 520LCH-3: 21.5 kg (47.4 lb)
15. Remove the following parts below from piston rod
(4).
10. Remove spacer (10) and bracket (12) from the
rest.
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
Wear ring (5), retaining ring (7) and U-ring (6)
11. Remove socket bolts (1) (4 used) from guide (3).
Remove guide (3) from piston rod (4).
Wear ring (5) (2 used), backup ring (17), U-ring
: 12 mm
(6), plate (18) and retaining ring (7)
2
3
1
15
W142-03-04-010
12. Remove piston rod (4) from cylinder (8).
13. Remove O-ring (2) from guide (3).
W3-4-9
ASSEMBLE TRACK ADJUSTER
16 13 12 11 9 6 5 8 3 4
Grease Outlet
W1J1-03-04-001
14 15 10 Chamber B 7 1 2 Chamber A
1- Socket Bolt (4 Used) 6- U-Ring 11 - Spring 15 - Rod

2- O-Ring 7- Retaining Ring 12 - Bracket 16 - Valve
3- Guide 8- Cylinder 13 - Nut 17 - **Backup Ring
4- Piston Rod 9- O-Ring 14 - Bolt 18 - **Plate
5- *Wear Ring 10 - Spacer
NOTE: *: ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: 1 used
ZAXIS500LC-3, 520LCH-3: 2 used
**: The parts are used for ZAXIS500LC-3, 520LCH-3.
W3-4-10
Assemble Track Adjuster
IMPORTANT: Apply grease to wear ring (5) and IMPORTANT: Fill chamber (B) in cylinder (8) with
U-ring (6). grease. Push piston rod (4) and
Install U-ring (6) with the lip facing completely release pressure in
to rod (15). chamber (B) and rod (15).
1. After cleaning all parts, install the following parts Apply hydraulic oil to the inner sur-
below to piston rod (4). face of cylinder (8) and piston rod
(4).
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: 3. Install eyebolt (M16, Pitch 2.0 mm) to piston rod
Wear ring (5), retaining ring (7) and U-ring (6) (4). Attach a nylon sling. Hoist and install piston
ZAXIS500LC-3, 520LCH-3: rod (4) to cylinder (8).
Wear ring (5) (2 used), backup ring (17), U-ring
(6), plate (18) and retaining ring (7) IMPORTANT: Fill chamber (A) in guide (3) with
grease.
4 Apply grease to O-ring (2) and apply
LOCTITE #262 to socket bolts (1) (4
5 used).
6 4. Install O-ring (2) to guide (3). Install guide (3) to
7 cylinder (8) with socket bolts (1) (4 used).
: 12 mm
: 140 N⋅m (14 kgf⋅m, 103 Ibf⋅ft)
2
3
W166-03-04-001 1
4
CAUTION: Rod (15) weight: 21 kg (50 lb)
2. Apply grease to O-ring (9). Install O-ring (9) to

cylinder (8). Install eyebolt (M16, Pitch 2.0 mm) to
rod (15). Attach a nylon sling. Hoist and install rod
(15) to cylinder (8).
9
W142-03-04-018
15
9
W142-03-04-012
W3-4-11
12 11 8 4
Grease Outlet
W1J1-03-04-001
15 10
W3-4-12
CAUTION: Bracket (12) weight: CAUTION: Track adjuster weight:

ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: 22 ZAXIS450-3, 470H-3: 235 kg (518 lb)
kg (48.5 lb) ZAXIS450LC-3, 470LCH-3: 239 kg (527 lb)
ZAXIS500LC-3, 520LCH-3: 21.5 kg (47.4 lb) ZAXIS500LC-3, 520LCH-3: 365 kg (805 lb)
Spring (11) weight: ZAXIS450-3, 450LC-3,
470H-3, 470LCH-3: 122 kg (270 lb) 7. Attach a nylon sling to spring (11) and pass it
ZAXIS500LC-3, 520LCH-3: 150 kg (331 lb) through eyebolt on piston rod (4). Hoist and place
spring (11) horizontally and slowly.
5. Attach a nylon sling to bracket (12). Hoist and
place bracket (12) and spacer (10) on the rest.
Attach the nylon sling to spring (11). Hoist and
place spring (11) onto bracket (12). Secure
bracket (12) and spring (11) together by using 4
pieces of wire.
CAUTION: The Cylinder (8) assembly 11

weight: ZAXIS450-3, 450LC-3, 470H-3,
470LCH-3: 75 kg (165 lb)
ZAXIS500LC-3, 520LCH-3: 102 kg (225 lb)
6. Install eyebolt (M16, Pitch 2.0 mm) to piston rod

(4). Hoist the cylinder (8) assembly. Align spacer
(10) and bracket (12) and install the cylinder (8) W142-03-04-006
assembly.
IMPORTANT: Set rod (15) with its grease outlet
facing downward.
8. Hoist and set the track adjuster on special tool
8
(ST 4932). Remove eyebolt from piston rod (4).
ST 4932
10
11
Rest
12
W142-03-04-007
W142-03-04-005
W3-4-13
16 13 12 11 15
Grease Outlet
A mm (Free Length B mm) W1J1-03-04-001
14 C mm

A=620 mm (24.4 in), B=782 mm (30.8 in),
C=830 mm (32.7 in)
A=590 mm (23.2 in), B=733 mm (28.9 in),
C=885 mm (34.9 in)
W3-4-14
IMPORTANT: Slowly compress spring (11) while IMPORTANT: Align the matching marks made
aligning the center of rod (15) with when disassembling. Check that the
that of bracket (12) by using a pry grease outlet in rod (15) is aligned
bar. with that in nut (13).
Do not damage the threads on rod 10. Install nut (13) to rod (15). Secure nut (13) to rod
(15). (15) with bolt (14).
9. Operate the cylinder of special tool (ST 4932) and : 100 mm
remove a wire. Compress spring (11) until speci- : 17 mm
fied spring (11) length (A) is obtained. : 39 N⋅m (4 kgf⋅m, 29 Ibf⋅ft)
NOTE: Specified Spring Length (A)
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
782 mm (30.8 in) 13
733 mm (28.9 in) 15
11
14
ST 4932
16
12
W142-03-04-020
11. Install valve (16) to rod (15).

Wire : 24 mm
: 147 N⋅m (15 kgf⋅m, 108 Ibf⋅ft)
12. Retract the cylinder of special tool (ST 4932).
W142-03-04-015 CAUTION: Track adjuster weight:

ZAXIS450-3, 470H-3: 235 kg (518 lb)
ZAXIS450LC-3, 470LCH-3: 239 kg (527 lb)
ZAXIS500lc-3, 520lch-3: 365 kg (805 lb)
13. Attach a nylon sling to the track adjuster. Hoist

and remove the track adjuster from special tool.
CAUTION: If only the spring assembly is

transported, use a firm steel box and take
any other precautions in order to carry the
track adjuster safely.
W3-4-15
(Blank)
W3-4-16
UNDERCARRIAGE / Front Idler
REMOVE AND INSTALL FRONT IDLER
Before removing and installing the front idler, the

tracks must be removed first. For removal and instal-
lation of the tracks, refer to “Remove and Install Track”
section (W3-7-1).
In this section, the procedure starts on the premise that
the tracks have already been removed.
Removal
CAUTION: Front idler weight:
W142-03-05-002
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
281 kg (619 lb)
ZAXIS500LC-3, 520LCH-3: 353 kg (778 lb)
The front idler may fly off due to the strong 1

spring force when removing the track ad-
juster. Do not stand in the same direction to
remove the front idler or where the front idler
flies off.
5
1. Pry and remove the front idler and yoke (4) from
4
track frame (1) by using a pry bar.
3
2 W17P-03-05-001
2. Attach a nylon sling to bearing (5) and yoke (4)
sections. Hoist and remove the front idler assem-
bly from track frame (1).
3. Remove socket bolts (2) and remove guard (3) Wooden Block
from yoke (4).
: 19 mm
: 90 N⋅m (9.2 kgf⋅m, 66 Ibf⋅ft)
4. When storing the front idler, place the front idler

on wooden block as illustrated.
W105-03-05-003
W3-5-1
Installation
CAUTION: Front idler weight: Direction to Install

ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
1
281 kg (619 lb)
ZAXIS500LC-3, 520LCH-3: 353 kg (778 lb)
1. Install the front idler in reverse procedures when

removing.
• Clean and apply grease to the bearing (5) sliding 5
surface on track frame (1).
W17P-03-05-001
W3-5-2
(Blank)
W3-5-3
DISASSEMBLE FRONT IDLER
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3
1
3 8
5
7 6
10
11
6 9
5
2 4
12
3
14
13
8 W1J1-03-05-001
1- Bearing (2 Used) 5- Floating Seal (2 Used) 9 - Guard 12 - Yoke

2- Pin (2 Used) 6- Bushing (2 Used) 10 - Bolt (3 Used) 13 - Bolt (4 Used)
3- O-Ring (2 Used) 7- Idler 11 - Spring Washer (3 Used) 14 - Spring Washer (4 Used)
4- Axle 8- Plug (2 Used)
W3-5-4
1
5
7 8
6
3 6
3 9
2 10
11
8
1
14 12 W1J1-03-05-003
13

W3-5-5
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3
2
1
3 8
5
7 6
10
11
6 9
5
2 4
12
3
14
13
8 W1J1-03-05-001
ZAXIS500LC-3, 520LCH-3 2
1
5
7 8
6
3 6
3 9
2 10
11
8
1
14 12 W1J1-03-05-003
13
W3-5-6
Disassemble Front Idler
1. Loosen bolts (10) (3 used), and spring washers 6. Remove bearing (1) from the upper side of idler
(11) (3 used) from guard (9). Remove guard (9) (7). Remove floating seals (5) (2 used) from both
from yoke (12). sides of idler (7) and bearing (1).
: 19 mm
1
CAUTION: Yoke (12) weight:
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: 5
44 kg (97 lb)
ZAXIS500LC-3, 520LCH-3: 70 kg (154 lb) 7
2. Attach a nylon sling to yoke (12) and hold yoke

(12). Remove bolts (13) (4 used) and spring
5
washers (14) (4 used). Hoist and remove yoke
(12) from bearings (1) (2 used). 3
: 30 mm
3. Remove plug (8) from bearing (1). Drain off oil. 4

: 6 mm
1
4. Remove pin (2) from bearing (1) by using a bar
and hammer.
W105-03-05-009
CAUTION: The idler (7) assembly weight:

ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
232 kg (511 lb)
ZAXIS500LC-3, 520LCH-3: 183 kg (403 lb)
Axle (4) weight:
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
28 kg (62 lb)
ZAXIS500LC-3, 520LCH-3: 31.4 kg (69 lb)
Bearing (1) weight:
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
27 kg (60 lb)
ZAXIS500LC-3, 520LCH-3: 18 kg (40 lb)
5. Put the matching marks on bearing (1) and axle

(4). Remove the axle (4) assembly from idler (7)
by using press.
1 4
W105-03-05-008
W3-5-7
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3

2
1
3
5
6
6 9
5
2 4
W1J1-03-05-001
ZAXIS500LC-3, 520LCH-3 2
1
5
7
6
3 6
3 9
W1J1-03-05-003
W3-5-8
CAUTION: The axle (4) assembly weight: IMPORTANT: Do not remove bushing (6) unless
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: necessary.
54 kg (119 Ib) 9. When replacing bushing (6), remove bushing (6)
ZAXIS500LC-3, 520LCH-3: 50 kg (110 lb) by using special tool (ST 1973) and a press.
IMPORTANT: Place wooden blocks or etc. under

the lower part of bearing (1) in order
not to damage bearing (1).
7. Wind a nylon sling to the axle (4) assembly. Hoist
and place bearing (1) onto wooden blocks. ST 1973
8. Remove pin (2) from bearing (1) by using a bar

and hammer.
Put the matching marks on bearing (1) and axle
(4). Remove axle (4) from bearing (1) by using a
press. 6
Remove O-rings (3) (2 used) from axle (4).
3
2 W105-03-05-011
Wooden Block
3
W105-03-05-010
W3-5-9
ASSEMBLE FRONT IDLER
1 2 5 7 4 6 3 7 8 9 10 11
14 13 12
W1J1-03-05-002

W3-5-10
Assemble Front Idler
CAUTION: Idler (7) weight: CAUTION: The axle (4) assembly weight:
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
150 kg (331 lb) 54 kg (119 lb)
ZAXIS500LC-3, 520LCH-3: 208 kg (459 lb) ZAXIS500LC-3, 520LCH-3: 50 kg (110 lb)
1. Install bushing (6) to idler (7). 5. Wind a nylon sling to bearing (1) of the axle (4)
assembly. Hoist and insert the axle (4) assembly
into idler (7) from the side where floating seal (5)
CAUTION: Axle (4) weight: has already been installed.
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
28 kg (62 lb) 6. Apply LOCTITE #503 to plug (8). Install plug (8) to
ZAXIS500LC-3, 520LCH-3: 31.4 kg (69 lb) bearing (1).
Bearing (1) weight: : 6 mm
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: : 20 N⋅m (2 kgf⋅m, 15 Ibf⋅ft)
27 kg (60 lb)
ZAXIS500LC-3, 520LCH-3: 18 kg (40 lb)
CAUTION: The idler (7) assembly weight:
2. Wind a nylon sling to axle (4). Hoist and place ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
axle (4) vertically. Install O-ring (3) (1 used) onto the 183 kg (403 lb)
upper side of axle (4). ZAXIS500LC-3, 520LCH-3: 286 kg (631 lb)
7. Wind a nylon sling to the idler (7) assembly. Hoist

IMPORTANT: Align the matching marks made and turn over the idler (7) assembly.
when disassembling. Install O-ring (3) to axle (4).
3. Evenly tap and install bearing (1) into axle (4) by
using a plastic hammer. Insert pin (2) into bearing
2
4
3 W105-03-05-014
4. Apply grease to O-ring (3) on the floating seal (5).

Install a pair of floating seals (5) to idler (7) and
bearing (1).
W3-5-11
1 2 4 8 9 10 11
14 13 12
W1J1-03-05-002
W3-5-12
8. Apply grease to O-ring (3) of floating seal (5). In-

stall the other floating seal (5) to idler (7) and
bearing (1).
1 5 3 7
W157-03-05-005

when disassembling.
9. Evenly tap and install bearing (1) into axle (4) by
using a plastic hammer. Insert pin (2) into bearing
10. Add engine oil (API CD grade SAE30) 450 mL

(0.12 US gal.) via the plug (8) hole on bearing (1).
11. Apply LOCTITE #503 to plug (8). Install plug (8) to

bearing (1).
: 6 mm
: 20 N⋅m (2 kgf⋅m, 15 Ibf⋅ft)
CAUTION: Yoke (12) weight:

ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
44 kg (97 lb)
ZAXIS500LC-3, 520LCH-3: 70 kg (154 lb)
12. Wind a nylon sling to yoke (12). Hoist and align

the bolt (13) hole on the yoke (12) and bearing
(1).
13. Install yoke (12) to bearings (1) (2 used) with bolts

(13) (4 used) and spring washers (14) (4 used).
: 30 mm
: 392 N⋅m (40 kgf⋅m, 290 Ibf⋅ft)
14. Install guard (9) to yoke (12) with bolts (10) (3

used) and spring washers (11) (3 used).
: 19 mm
: 88⋅m (9 kgf⋅m, 65Ibf⋅ft)
W3-5-13
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3
C D
E
A W166-03-05-001
Unit: mm (in)
A 116 (4.6) [88.4 (3.5)]
B 234 (9.2) -
Cladding by welding
C 716 (28.2) [689 (27.1)]
and finish or replace
D 761 (30) -
E (22.5 (0.9) 32.5 (1.3)
Axle and Bushing
Unit: mm (in)
Axle Outside Dia. 110 (4.33) [109.2 (4.30)]
Inside Dia. 111 (4.37) [112 (4.41)] Replace
Bushing
Flange Thickness 6 (0.24) [5.2 (0.21)]
NOTE: Values in [ ] are just for reference.
W3-5-14
C D
E
A W166-03-05-001
Unit: mm (in)
A 116 (4.6) [88.4 (3.5)]
B 234 (9.2) -
Cladding by welding
C 716 (28.2) [689 (27.1)]
and finish or replace
D 761 (30) -
E (22.5 (0.9) 32.5 (1.3)
Axle and Bushing
Unit: mm (in)
Axle Outside Dia. 110 (4.33) [109.2 (4.30)]
Bushing
NOTE: Values in [ ] are just for reference.
W3-5-15
(Blank)
W3-5-16
UNDERCARRIAGE / Upper and Lower Roller
REMOVE AND INSTALL UPPER ROLLER
Removal
CAUTION: Grease pressure in the adjuster

cylinder is high. Do not loosen valve (1)
quickly or too much as valve (1) may fly off
or high-pressure grease in the adjuster cyl-
inder may gush out.
Keep body parts and face away from valve (1)
and loosen valve (1) carefully. Do not loosen
grease fitting (2). W105-03-06-001
IMPORTANT: Remove any mud or gravel between 2 1

sprockets and tracks before loos-
ening valve (1). It is enough to
loosen valve (1) by 1 to 1.5 turns.
1. Loosen valve (1) on the track adjuster. Drain
grease and release the tension of track link.
: 24 mm
Grease Outlet
W800-03-07-002
4
2. Insert the wooden block and an oil jack between
track frame (5) and track (4). Jack up track (4) in
order to get enough clearance between upper
Oil Jack
roller (3) and track (4).
3. Insert the wooden blocks under upper roller (3).

Wooden Block
5 3
W116-03-06-001
Wooden Block
W116-03-06-002
W3-6-1
4. Remove bolts (6) (4 used) from upper roller (3).
: 27 mm
3
6
W116-03-06-002
CAUTION: Upper roller (3) weight:

ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
39 kg (86 lb)
ZAXIS500LC-3, 520LCH-3: 46.5 kg (102.5 lb)
5. Attach a nylon sling to the roller part of upper

roller (3). Hoist and remove upper roller (3) from
track frame (5).
3 5
W116-03-06-003
Installation
CAUTION: Upper roller (3) weight:

ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
39 kg (86 lb)
ZAXIS500LC-3, 520LCH-3: 46.5 kg (102.5 lb)
3
1. Hoist and insert upper roller (3) between track 5 W116-03-06-003
frame (5) and track (4).

Insert the wooden blocks between upper roller (3)
and track frame (5) and hold upper roller (3).
Align the holes for bolt (6) and install upper roller
(3) with bolts (6) (4 used).
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
: 27 mm
: 400 N⋅m (41 kgf⋅m, 295 lbf⋅ft)
: 30 mm
: 550 N⋅m (41 kgf⋅m, 406 lbf⋅ft)
6
2. Remove the wooden blocks and oil jack. W116-03-06-002
W3-6-2
3. Tighten valve (1) on the track adjuster.
: 24 mm
: 147 N⋅m (15 kgf⋅m, 108 lbf⋅ft)
2 1
CAUTION: If track sag should be measured

with the machine raised, support the jacked
up machine firmly by using the wooden
blocks.
4. Jack up the track to be measured. Apply grease

via grease fitting (2) and adjust track tension.
Track sag specifications (A):

ZAXIS450-3, 470H-3: 380 to 430 mm W800-03-07-002
(15 to 17 in)
ZAXIS450LC-3, 470LCH-3: 390 to 440 mm
(15.4 to 17.3 in)
ZAXIS500LC-3, 520LCH-3: 430 to 480 mm
(17 to 19 in)
NOTE: Before measuring track sag, clean the

track frame and tracks and rotate the track
by a half turn in reverse direction.
W800-03-06-001
IMPORTANT: Replace the upper roller as an as-

sembly.
5. Add engine oil (API CD class SAE 30) through
7
the plug (8) hole on cover (7).
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
120 mL (0.03 US gal.))
ZAXIS500LC-3, 520LCH-3: 8
150 mL (0.04 US gal.)
6. Apply LOCTITE #503 to plug (8). Install plug (8)

to cover (7).
: 6 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
W1J1-03-06-001
W3-6-3
REMOVE AND INSTALL LOWER ROLLER
Removal
CAUTION: Track guard weight:

1
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
40 kg (88 lb)
ZAXIS500LC-3, 520LCH-3: 56 kg (123 lb)
1. Remove the track guard.

ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
: 32 mm W105-03-06-008
: 36 mm
2. Remove bolts (1) (4 used) from the lower roller.

ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
: 32 mm 90° to 110°
: 36 mm
W800-03-07-003
2
3. Raise the machine by using the front attachment

and insert the wooden blocks under track frame
(2).
W105-03-06-001

cylinder is high. Do not loosen valve (3) 4 3
quickly or too much as valve (3) may fly off
or high-pressure grease in the adjuster cyl-
inder may gush out.
and loosen valve carefully.
Do not loosen grease fitting (4).
IMPORTANT: It is enough to loosen valve (3) by 1

to 1.5 turns. Do not loosen valve (3) Grease Outlet
over that degree.
4. Loosen valve (3) on the track adjuster. Drain
W800-03-07-002
enough grease and permit the lower roller to be
removed.
: 24 mm
W3-6-4
CAUTION: Lower roller (5) weight:

ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
80 kg (176 lb)
ZAXIS500LC-3, 520LCH-3: 108 kg (238 lb)
5. Remove lower roller (5) by using a fork lift.
5
W105-03-06-010
Installation

ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
80 kg (176 lb) 2
ZAXIS500LC-3, 520LCH-3: 108 kg (238 lb)
1. Set lower roller (5) under track frame (2) by using

a fork lift.
5 W105-03-06-011
2. Lower the machine so that track frame (2) may

keep a little clearance away from the collar of
lower roller (5). Align lower roller (5) with the
mounting hole for track frame (2). Install lower
roller (5) to track frame (2) with bolts (1) (4 used).
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
: 32 mm 5
: 750 N⋅m (77 kgf⋅m, 553 lbf⋅ft) W105-03-06-012
: 36 mm
: 950 N⋅m (97 kgf⋅m, 700 lbf⋅ft)
W105-03-06-008
W3-6-5
CAUTION: Track guard weight:

ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
80 kg (176 lb)
ZAXIS500LC-3, 520LCH-3: 108 kg (238 lb) 2
3. Install the track guard to track frame (2).

ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
: 32 mm
: 750 N⋅m (77 kgf⋅m, 553 lbf⋅ft)
: 36 mm
: 950 N⋅m (97 kgf⋅m, 700 lbf⋅ft)
5
4. Tighten valve (3) on the track adjuster. W105-03-06-012
: 24 mm
: 147 N⋅m (15 kgf⋅m, 108 lbf⋅ft)
CAUTION: If track sag should be measured 4 3

with the machine raised, support the jacked
up machine firmly by using the wooden
blocks.
5. Apply grease via grease fitting (4) and adjust

track tension.
ZAXIS450-3, 470H-3: 380 to 430 mm
(15 to 17 in)
ZAXIS450LC-3, 470LCH-3: 390 to 440 mm
(15.4 to 17.3 in)
ZAXIS500LC-3, 520LCH-3: 430 to 480 mm W800-03-07-002
(17 to 19 in)
NOTE: Before measuring track sag, clean the

track frame and tracks and rotate the track
by a half turn in reverse direction.
W800-03-06-001
W3-6-6
(Blank)
W3-6-7
DISASSEMBLE LOWER ROLLER
5
4
3 6
7
5
6 7
1
3
4
W166-03-06-006
1 - Floating Seal (2 Used) 3 - O-Ring (2 Used) 5 - Pin (2 Used) 7 - Bushing (2 Used)

2 - Axle 4 - Collar (2 Used) 6 - Plug (2 Used) 8 - Roller
W3-6-8
Disassemble Lower Roller
5. Remove floating seal (1) from roller (8) and collar
IMPORTANT: Put the matching marks on collar (4) (4).
and axle (2).
4 1 8 1
1. Remove plug (6) from the end of collar (4). Drain
oil. (2 places). Remove pin (5) from collar (4) (2
places) by using a bar (Dia. 25 mm (1.0 in)) and
hammer. 1
: 6 mm
4

ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
80 kg (176 lb)
ZAXIS500LC-3, 520LCH-3: 108 kg (238 lb)
2. Set the roller (8) assembly to the press. Push W105-03-06-026
axle (2) until O-ring (3) is removed from collar (4) 6. Set the axle (2) assembly to a press. Remove
by using a press. Remove collar (4) from axle (2). axle (2) from collar (4).
NOTE: Collar (4) can be removed if axle (2) is 4
pushed in by approx. 55 mm (2.2 in) by
using a press.
3. Remove floating seal (1) from collar (4) and roller

(8).
Remove O-ring (3) from axle (2). 2
CAUTION: Axle (2) weight + collar (4) weight:

ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
25 kg (55 lb)
ZAXIS500LC-3, 520LCH-3: 38 kg (84 lb)
W105-03-06-027
4. Remove the axle (2) assembly from roller (8). 7. Remove O-ring (3) from axle (2).
8. When replacing bushing (7), remove bushing (7)

by using special tool (ST 1955) and a press.
ST 1955
W105-03-06-028
W3-6-9
ASSEMBLE LOWER ROLLER
4 5 6
8 2 7 1 3
W162-03-06-002
1 - Floating Seal (2 Used) 3 - O-Ring (2 Used) 5 - Pin (2 Used) 7 - Bushing (2 Used)

2 - Axle 4 - Collar (2 Used) 6 - Plug (2 Used) 8 - Roller
W3-6-10
Assemble Lower Roller
CAUTION: Lower roller (8) weight: CAUTION: The axle (2) assembly weight:
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
47 kg (104 lb) 25 kg (55 lb)
ZAXIS500LC-3, 520LCH-3: 61 kg (134 lb) ZAXIS500LC-3, 520LCH-3: 38 kg (84 lb)
Axle (2) weight:
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3: 4. Insert axle (2) into roller (8). Install O-ring (3) with
20 kg (44 lb) grease applied to axle (2). Install other collar (4)
ZAXIS500LC-3, 520LCH-3: 29 kg (62 lb) and floating seal (1) in the same procedures and
secure with pin (5).
1. Install bushings (7) (2 used) to roller (8). Do not
dent the flange surface of bushing (7). 5 1 2 8
Apply much grease to O-ring (3) and install O-ring
(3) to axle (2).

when disassembling.
2. Install one of collar (4) to axle (2). Do not damage
O-ring (3). Tap pin (5) into the pin hole and se- 4 3
cure collar (4) on axle (2).
5 W157-03-06-009
2
5. Fill engine oil (API CD class SAE30) 1.0 L (0.26
3 US gal.) via the plug (6) hole on collar (4) on both
sides.
6. Apply LOCTITE #503 or equivalent to plug (6).

Install plugs (6) (2 used) to collars (4) on both
4 W16J-03-06-001 sides.
: 6 mm
: 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)
CAUTION: Lower roller (8) assembly weight:
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
5 8
80 kg (176 lb)
ZAXIS500LC-3, 520LCH-3: 108 kg (238 lb)
3. Apply grease to the O-ring part on floating seal 6

(1). Install floating seal (1) to roller (8) and collar
(4).
8 1
1 4 W105-03-06-024
W157-03-06-008
W3-6-11
Upper Roller
• Roller
B
W166-03-06-007

A 103 (4.1) -
B 210 (8.3) - Replace
C 170 (6.7) 160 (6.3)
A 114 (4.5) -
B 220 (8.7) - Replace
C 180 (7.1) [170 (6.7)]
• Axle and Bushing

Standard Allowabel Limit Remedy
Axle Outside Dia. 60 (2.4) [59.2 (2.3)]
Bushing
Flange Thickness 4.5 (0.2) [3.7 (0.1)]

Standard Allowabel Limit Remedy
Axle Outside Dia. 68 (2.7) [67.2 (2.6)]
Bushing
Flange Thickness 4.5 (0.2) [3.7 (0.1)]
NOTE: The values in [ ] are just for reference.
W3-6-12
Lower Roller
• Roller
W157-03-06-003

A 214 (8.4) [249 (9.8)]
B 284 (11.2) - Clad by welding and
C 35 (1.4) [17.5 (0.7)] finish or replace
D 200 (7.9) 180 (7.1)

A 246 (9.7) [283 (11.1)]
B 320 (12.6) - Clad by welding and
C 37 (1.5) [18.5 (0.7)] finish or replace
D 220 (8.7) [202 (8.0)]
• Axle and Bushing

Axle Outside Dia. 85 (3.3) [84.2 (3.3)]
Inside Dia. 86 (3.4) [87.0 (3.4)] Replace
Bushing

Axle Outside Dia. 100 (3.9) [99.2 (3.9)]
Bushing
NOTE: The values in [ ] are just for reference.
W3-6-13
(Blank)
W3-6-14
UNDERCARRIAGE / Track
REMOVE AND INSTALL TRACK
Removal

cylinder is high. Do not loosen valve (2)
quickly or too much as valve (2) may fly off 1 2 Adjuster Cylinder
or high-pressure grease in the cylinder may
gush out.
and loosen valve (2) carefully. Do not loosen
grease fitting (1).
1. Loosen valve (2) in the track adjuster and drain

grease.
2. Rotate the track so that master pin (3) is W800-03-07-027

positioned at the upper of front idler (4). Place a
wooden block under shoe (5) and support shoe
(5).
4
Wooden Block W105-03-07-006
NOTE: The heads in both ends of master pin (3)

are the stepped-shape. The heads of other
pins are the flat-shape. As master pin (3) is
symmetrical, master pin (3) can be
removed from and installed to both
directions.
Flat
3 With Step Pin W800-03-07-004
W3-7-1
CAUTION: Shoe (5) weight:

6
ZAXIS450-3, 450LC-3, 470H-3, 470LCH-3:
600 mm: 28 kg (62 lb)
5
750 mm: 36 kg (79 lb)
900 mm: 42 kg (93 lb) 7
3
600 mm: 32 kg (71 lb)
600 mm (WG): 31 kg (68 lb) 5
750 mm: 40 kg (88 lb) 7
900 mm: 48 kg (106 lb)
3. Remove bolts (7) (8 used) from shoes (5) (2

used) at front and rear of master pin (3). Remove
shoes (5) (2 used) from track link (6).
: 41 mm
W105-03-07-006
4. Secure shoes (5) (2 used) at front and rear of

master pin (3) by using a chain block. 5
W1J7-03-07-002
Chain Block
W3-7-2
(Blank)
W3-7-3
ASSEMBLE SPECIAL TOOL WHEN REMOVING AND INSTALLING MASTER PIN
13 14
12
11
10
9
Master Pin When

Removing
8
10
15
19
18
12
11
17
16
*Hose 15
10
*: Electric Pump 9
(ST 1531) Accessory
Master Pin When

Installing
16
W1J7-03-07-001
10
9
8- Hydraulic Cylinder 11 - Frame (ST 1513) 14 - Adapter (ST 1518) 17 - Pilot (ST 1517)
(ST 1512)
9 - Screw (2 Used) (ST 1516) 12 - Pusher (ST 1521) 15 - Extension (3 Types) 18 - Guide (ST 1525)
(ST 1514)
10 - Nut (2 Used) (ST 1515) 13 - Handling Screw (ST 1530) 16 - Nut (2 Used) (ST 1515) 19 - Guide Pin (ST 1529)
W3-7-4
Assemble Special Tool (ST 1532) When
Removing and Installing Master Pin
The procedures (steps 5 to 11) are for assembly of 11. Install the hoses (2 used) of electric pump (ST
special tool (ST 1532) when removing and installing 1531) to hydraulic cylinder (8).
master pin. If special tool (ST 1532) when removing
and installing master pin has already been assembled,
these procedures are unnecessary.
IMPORTANT: Insert screws (9) (2 used) into the 10

screw hole on hydraulic cylinder (8) 9
completely. If screws (9) (2 used) are
not inserted completely, screw (9)
may be removed from hydraulic
8
cylinder (8) when removing and
installing master pin (3).
5. Install screws (9) (2 used) to hydraulic cylinder
(8). A
IMPORTANT: If lengths (A) of nut (10) at both

sides are different, screw (9) may be
deformed when removing and
installing master pin (3). Install nuts
(10) (2 used) to the position, same
length (A) away from hydraulic
cylinder (8). W1J7-03-07-005
6. Install nuts (10) (2 used) to screws (9) (2 used),

where same length (A) away from hydraulic
cylinder (8).
CAUTION: Frame (11) weight: 74 kg (163 lb)
7. Insert frame (11) into the position for nut (10) in

screws (9) (2 used) and tighten with nut (16).
8. Install extension (15) to hydraulic cylinder (8).
NOTE: Extension (15) consists of three types. The

length for each is different. When the
stroke of hydraulic cylinder (8) is
insufficient during removal / installation
work, add extension (15) in order to extend
the stroke.
9. Install pilot (17) and pusher (12) to extension (15).
10. Install adapter (14) to frame (11) with handling

screw (13).
W3-7-5
CAUTION: Special tool (ST 1532) when

removing and installing master pin weight:
150kg (330 lb)
12. Attach a nylon sling to screws (9) (2 used) in Nylon Sling

special tool (ST 1532) when removing and
installing master pin and hoist special tool. Move
installing master pin to the mounting position for
master pin (3). Adjust length of the nylon sling and
align adapter (14) and pusher (12) in special tool
B
(ST 1532) when removing and installing master
pin with master pin (3).
ST 1532
IMPORTANT: Align the centers of adapter (14) and 9
pusher (12) with that of master pin W1J7-03-07-003
(3). If the centers are not aligned and

master pin (3) is removed, special
tool (ST 1532) when removing and 14
installing master pin may be
deformed or damaged.
12
13. Align the end of master pin (3) with the hole of
adapter (14) in special tool (ST 1532) when
removing and installing master pin. Adjust
hydraulic cylinder (8) and push pusher (12) to the
end of master pin (3). Check for the installation 3
conditions of master pin (3) and special tool (ST
1532) when removing and installing master pin.
ST 1532
14. Extend hydraulic cylinder (8) and push out master Detail B
pin (3). W1J7-03-07-004
NOTE: When the stroke of hydraulic cylinder (8) is

insufficient, retract hydraulic cylinder (8)
once. Add extension (15) between 16
extension (15) and pilot (17) in order to 10
extend the stroke. When extensions (15) (3 9
used) are added and the stroke of
hydraulic cylinder (8) is insufficient, move
the positions to install nuts (10, 16) (2 used 8
for each) to the hydraulic cylinder (8) side.
17
15 (Inside)
W1J7-03-07-005
W3-7-6
15. Remove special tool (ST 1532) when removing
and installing master pin and a chain block from
track link (6). Chain Block
IMPORTANT: After raise the machine, support the ST 1532

6
W1J7-03-07-003
machine by using a block securely.
16. Turn the upperstructure 90° to the direction to
remove the track. Set the angle between boom
and arm in 90° to 110° and lower the bucket
onto the ground. Raise the machine and support
the machine by using a block.
90° to 110°
CAUTION: The track assembly weight:
ZAXIS450-3, 470H-3:
600 mm: 2450 kg (5401 lb)
750 mm: 2810 kg (6195 lb) W800-03-07-003
ZAXIS450LC-3, 470LCH-3: Block
600 mm: 2470 kg (5445 lb)
750 mm: 3040 kg (6702 lb)
900 mm: 3380 kg (7452 lb)
600 mm: 2975 kg (6559 lb)
600 mm (WG): 2915 kg (6426 lb)
750 mm: 3380 kg (7452 lb)
900 mm: 3745 kg (8256 lb)
17. Turn the travel device to the reverse direction and

extend the track.
Travel
Device
W105-03-07-011
W3-7-7
Installation
CAUTION: The track assembly weight:

ZAXIS450-3, 470H-3:
600 mm: 2450 kg (5401 lb)
750 mm: 2810 kg (6195 lb)
600 mm: 2470 kg (5445 lb)
750 mm: 3040 kg (6702 lb)
900 mm: 3380 kg (7452 lb)
600 mm: 2975 kg (6559 lb) W800-03-07-003
600 mm (WG): 2915 kg (6426 lb) Block
750 mm: 3380 kg (7452 lb)
900 mm: 3745 kg (8256 lb)
5
IMPORTANT: Check the direction of track. 6

1. Raise the machine and support the machine by
using a block. Place the track under the machine
so that the track end can mesh with sprocket
(20). Idler Side Sprocket
Side
2. Hoist the track at sprocket (20) side and mesh
the tack with sprocket (20).
W105-03-07-013
3. Operate the travel lever for the side to attach the

track and rotate travel device (21) slowly. Attach
the track to sprocket (20).
20
W105-03-07-014
4. While rotating travel device (21) slowly, pass the
track over the upper rollers (2 used) and attach
the track to front idler (4).
21
4 Upper Roller 20
W105-03-07-011
W3-7-8
5. After the track is attached to front idler (4), raise 4
the machine. Remove the block. Lower the
machine.
W1J7-03-07-007
IMPORTANT: Insert the tapered side of guide pin

(19) first.
6. Secure shoe (5) of both ends of the track by
using a chain block. Adjust the chain length by
using the chain block and align with the master
5
pin (3) mounting hole on track link (6). Insert
guide pin (19) into the master pin (3) mounting
hole.
W1J7-03-07-002
Chain Block
7. Install extension (15), pilot (17), pusher (12) and 19

master pin (3) to special tool (ST 1532) when
18
removing and installing master pin. 12
NOTE: Master pin (3) is symmetrical. Master pin 17
6
(3) can be installed to both directions. 15
8. Install guide (18) to master pin (3).
ST 1532 W1J7-03-07-006
W3-7-9
CAUTION: Special tool (ST 1532) when

removing and installing master pin weight:
Nylon Sling
150 kg (330 lb)
9. Attach a nylon sling to screws (9) (2 used) in

installing master pin and hoist special tool. Move
installing master pin to the mounting position for
master pin (3). Adjust length of the nylon sling
and align the master pin (3) mounting hole with
adapter (14) hole and of position C in master pin
(3) in special tool (ST 1532) when removing and
9
installing master pin.
ST 1532 W1J7-03-07-003
19 14
IMPORTANT: Align the centers of adapter (14) and
C
master pin (3) with that of master
pin (3) mounting hole. If the centers
are not aligned and master pin (3) is
installed, special tool (ST 1532)
when removing and installing A
master pin may be deformed or B
damaged. 6
10. Align position A of guide pin (19) with the hole
3
center of adapter (14) in special tool (ST 1532)
when removing and installing master pin. Adjust
hydraulic cylinder (8) and push master pin (3) to W1J7-03-07-006
position B of guide pin (19). Check for the

installation conditions of guide pin (19) and
installing master pin.
16
10
9
11. Extend hydraulic cylinder (8) and insert master
pin (3) until guide pin (19) is pushed out from the
master pin mounting hole on track link (6). 8
NOTE: When the stroke of hydraulic cylinder (8) is
insufficient, retract hydraulic cylinder (8)
once. Add extension (15) between
extension (15) and pilot (17) in order to 15 17
(Inside)
extend the stroke. When extensions (15) (3
used) are added and the stroke of
hydraulic cylinder (8) is insufficient, move
the positions to install nuts (10, 16) (2 used
for each) to the hydraulic cylinder (8) side. W1J7-03-07-005
W3-7-10
12. Remove special tool (ST 1532) when removing
and installing master pin and a chain block from Nylon Sling
track link (6).
Chain Block
ST 1532 6
W1J7-03-07-003
13. Install shoes (5) (2 used) with bolts (7) (8 used).

: 32 mm 5
: 750 N⋅m (77 kgf⋅m, 553 lbf⋅ft) 7
7
5
W105-03-07-006
14. Tighten valve (2). Apply grease through grease 1 2

fitting (1) and adjust the track tension.
: 24 mm
: 147 N⋅m (15 kgf⋅m, 108 lbf⋅ft)

ZAXIS450-3, 470H-3: 380 to 430 mm
(15 to 17 in)
ZAXIS450LC-3, 470LCH-3: 390 to 440 mm
(15.4 to 17.3 in)
ZAXIS500LC-3, 520LCH-3: 430 to 480 mm W800-03-07-027
(17 to 19 in)
W800-03-06-001
W3-7-11
15. Remove extension (15), pilot (17), pusher (12)
and guide (18) from special tool (ST 1532) when 19
removing and installing master pin.
18
12
17
15
W1J7-03-07-006
16. Remove the hoses (2 used) of electric pump (ST

1531) from hydraulic cylinder (8). If special tool 10
(ST 1532) when removing and installing master 9
pin is disassembled and stored, disassemble
according to the assembling procedures on
W3-7-5 in reverse. 8
NOTE: Put the matching marks on screw (9) and
nut (10) before removing screws (9) (2 10
used) and nuts (10) (2 used). 9
W1J7-03-07-005
Hose
W3-7-12
Link
Measure the length of four links.
1. Do not measure the part included the master pin.
2. Measure the length with tension on the track.
A
W155-03-07-001

A 863.6 (34) [905.3 (35.6)] Cladding by welding and
B 129 (5.1) [122 (4.8)] finish or replace
A 915.5 (36) [944.3 (37.2)] Cladding by welding and
B 134.6 (5.3) [127.6 (5.0)] finish or replace
[ ]：Reference
Master Pin
C B C
W800-03-07-028
A

A 254 (10) -
B 47.3 (1.86) [44.3 (1.74)] Replace
C 47.57 (1.87) -
A 290 (11.4) -
B 48.5 (1.91) [45.5 (1.79)] Replace
C 48.83 (1.92) -
[ ]：Reference
W3-7-13
Master Bushing
W105-03-07-023

A 160.8 (6.3) -
B 47.9 (1.89) [59.9 (2.36)] Replace
C 71.35 (2.81) [66.4 (2.61)]
A 181.4 (7.1) -
B 49.2 (1.94) [52.2 (2.06)] Replace
C 79.0 (3.11) [74.0 (2.91)]
[ ]：Reference
Grouser Shoe
W105-03-07-024

A 247 (9.7) -
B 15 (0.6) - Replace
C 36 (1.4) 24 (0.9)
A 254.5 (10) -
B 18 (0.7) - Replace
C 37 (1.5) 24 (0.9)
[ ]：Reference
W3-7-14
Bushing
W105-03-07-023

A 169 (6.7) -
B 48.4 (1.91) [49.4 (1.95)] Replace
C 71.35 (2.81) [66.4 (2.61)]
A 192.4 (7.6) -
B 49.6 (1.95) [50.6 (1.99)] Replace
C 79.0 (3.11) [74.0 (2.91)]
[ ]：Reference
Pin
W142-03-07-004
A

A 254 (10) - Cladding by welding and
A 290 (11.4) - Cladding by welding and
[ ]：Reference
W3-7-15
(Blank)
W3-7-16
MEMO
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SECTION 4
FRONT ATTACHMENT
 CONTENTS 
Group 1 Front Attachment
Hydraulic Circuit Pressure Release
Procedure............................................. W4-1-1
Remove and Install Front Attachment ........ W4-1-2
Remove and Install Bushing .................... W4-1-10
Maintenance Standard............................... W4-1-12
Standard Dimensions for
Arm and Bucket Connection .................... W4-1-15
Standard Dimensions for
Arm and Boom Connection .................. W4-1-16
Group 2 Cylinder
Remove and Install Cylinder ................... W4-2-1
Disassemble Cylinders ......................... W4-2-14
Assemble Cylinders.............................. W4-2-22
Maintenance Standard.......................... W4-2-28
1J1W-4-1
(Blank)
1J1W-4-2
FRONT ATTACHMENT / Front Attachment
HYDRAULIC CIRCUIT PRESSURE
RELEASE PROCEDURE
NOTE: Operate the pilot pump by using the power

from battery without starting the engine and
deliver the pilot pressure to the spool of
control valve.
3
1. Turn pilot shut-off lever (1) to the UNLOCK
position.
2. Turn engine stop switch (2) ON.

NOTE: Perform steps 1, 2 and turn the key switch
to the START position. Although the starter
rotates, the engine does not start.
IMPORTANT: Battery will deplete. Operate the key

switch for short period.
3. With the key switch in the START position,
operate the lever in order to release any pressure
in hydraulic circuit 4 to 5 times.
2 1
4. Turn pilot shut-off lever (1) to the LOCK position.
M1U1-01-029
5. Turn engine stop switch (2) OFF.
W4-1-1
REMOVE AND INSTALL FRONT
ATTACHMENT
Removal
1. Park the machine on a solid, level surface. Fully

retract the bucket and arm cylinders and lower
the front attachment onto the ground. W1J1-04-01-001
2. Remove the connector in boom light between cab 2

and main frame.
3. Remove lubrication hose (2) from the rod side of

boom cylinder (1). (2 places on both right and left)
: 19 mm
1
4. Remove bolts (5) (4 used). Remove washer (3)
and stopper (4). (2 places on both right and left)
: 30 mm
W105-04-01-002
1
CAUTION: Boom cylinder weight: 430 kg
(950 lb) 3
CAUTION: Metal fragments may fly off when 4
a hammer is used. Wear necessary
protection, such as goggles, hard hats, etc in
order to prevent personal injury. 5
5. Hoist the tube end of boom cylinder (1). By using

a bar and hammer, pull out pin (6) to the position
where the cylinder rod can be removed. 6
NOTE: When pin (6) cannot be removed, start the

engine and operate the boom lever in order
to adjust the hole position of boom cylinder W166-04-01-005
(1) piston rod end.
IMPORTANT: The grease fitting is equipped for

the tube in boom cylinder (1). Insert
a plate in order not to touch the
grease fitting.
6. Insert a plate between the boom cylinder and
main frame. Hold and lower the boom cylinder.
7. Remove the other boom cylinder in the same

procedures as steps 5, 6.
Plate
W157-04-01-005
W4-1-2
8. Start the engine. Operate the boom lever and
retract the rod of boom cylinder (1). In order not
to extend the rod, pass a wire through the rod
hole and secure the rod to the cylinder tube. Stop
the engine.
9. Operate the control lever several times with the

pilot shut-off lever in the UNLOCK position and
release any pressure in the circuit.
NOTE: The accumulator is equipped for the pilot
circuit.
After the engine stops and when the control
lever is operated with the pilot shut-off
lever in the UNLOCK position, any
pressure can be released in the front
attachment circuit.
10. Release any pressure in the front attachment pipe

and bleed air in the hydraulic oil tank.
(Refer to W4-1-1, W1-4-1.)
NOTE: Steps 10 to 12 are for the machine

attached with the auto lubrication device
(optional).
11. Remove lubrication hose (7). Cap the removed

hoses.
: 19 mm
12. Remove bolt (8) and remove clip (9).

: 17 mm
13. Remove the clip bands (10) (2 used). 7
14. Remove socket bolts (12) (16 used). Remove 8

hoses (11) (4 used). Cap the removed hoses.
: 12 mm 9
15. Remove bolts (13) (2 used) from plate (14) in 12

boom foot pin (15). 10
: 30 mm
11 11 M1J1-07-049
13
15 14
W105-04-01-007
W4-1-3

weight: 8000 kg (17650 lb)
16. Attach a wire rope to the boom. Hoist the boom

and take up slack of wire ropes.
W105-04-01-008
17. Install a bar of special tool (ST 1975) into the hole
on boom foot pin (15). Install the nut. Remove 15
boom foot pin (15).
: 36 mm ST 1975
Bar
Nut
W105-04-01-022
18. Hoist the front attachment and operate the

machine in reverse.
W157-04-01-004
W4-1-4
Installation

weight: 8000 kg (17650 lb)
1. Hoist the front attachment. Align the boom foot

with the mounting hole of main frame.
Insert the shim into the left and right sides of
boom foot and adjust the clearance between the
boom foot and main frame within 1.5 mm.
Shim thickness: 3.2 mm, 2.3 mm or 1.0 mm
Boom Foot Position
CAUTION: Metal fragments may fly off when Mounting Hole of

Main Frame
W157-04-01-004
order to prevent personal injury.
2. Install boom foot pin (15). Install plate (14) with

: 30 mm
: 400 N⋅m (41 kgf⋅m, 295 lbf⋅ft) 13
3. Install hoses (11) (4 used) with socket bolts 15 14

(12) (16 used).
: 12 mm
W105-04-01-007
: 140 N⋅m (14 kgf⋅m, 103 lbf⋅ft)
NOTE: Steps 4 to 6 are for the machine attached

with the auto lubrication device (optional).
4. Install lubrication hose (7).

: 19 mm
7
: 30 N⋅m (3.0 kgf⋅m, 22 lbf⋅ft)
8
5. Install clip (9) with bolt (8).
: 17 mm 9
: 50 N⋅m (5.1 kgf⋅m, 37 lbf⋅ft)
12
6. Secure lubrication hose (7) to hose (11) in the 10
outside with clip bands (10) (2 used).
11 11 M1J1-07-049
W4-1-5
CAUTION: Boom cylinder weight: 430 kg

(950 lb)
IMPORTANT: Fill hydraulic oil to specified level.

Start the engine. Check for any oil 1
leaks of each hose.
7. Hoist boom cylinder (1). Start the engine. Extend
the boom cylinder and align with the pin hole.
CAUTION: Metal fragments may fly off when

protection, such as goggles, hard hats, etc in W157-04-01-006

1
8. Install pin (6) and install boom cylinder (1) to both 3
sides. 4
9. Install washer (3) and stopper (4) and tighten with

bolts (5) (4 used). (2 places on both right and left) 5
: 30 mm
: 400 N⋅m (41 kgf⋅m, 295 lbf⋅ft)
10. Install lubrication hose (2) to the rod side of boom 6

cylinder (1).
: 19 mm
: 30 N⋅m (3.0 kgf⋅m, 22 lbf⋅ft)
W166-04-01-005
11. Install the connector to the boom light.

2
W105-04-01-002
W4-1-6
12. Apply grease into the boom foot position and the
Boom
rod side of boom cylinder by using a grease gun. Cylinder
As for the machine attached with the auto Rod Side
lubrication device (Optional), turn the auto
lubrication switch ON. Boom
Foot
Side
13. After completing the work, add hydraulic oil to the
specified level.
14. Operate every cylinder fully to the stroke end

several times and release the pressure in the
circuit. Check for any oil leaks of each hose.
W166-04-01-102
Auto Lubrication Switch
M1J1-03-001
W4-1-7
IMPORTANT: When the arm has been removed Arm
from the boom, perform the 14
followings when installing the arm.
Boom
15. Install shim (14) to the left and right sides of arm.
Shim (14) thickness: 8.0 mm
16. Insert the shim between the arm and shim (14) so
that the clearance between shim and arm is
within 1.5 mm.
Shim thickness: 1.0 mm or 2.0 mm
17. After installing the arm, apply grease into the

boom/arm joint pin and the rod side of arm
cylinder by using a grease gun.
As for the machine attached with the auto
lubrication device (Optional), turn the auto W166-04-01-100
lubrication switch ON
IMPORTANT: For handling of HN bushing for the

front attachment, check the
followings.
• Precautions when installing the bushing
When installing the bushing and if a hammer is
used, the bushing may be damaged. Install the
bushing by using a press.
• Precautions when reinforcing the arm
Boom / Arm
The heat when welding in order to reinforce the Joint Pin
arm may cause oil leakage and decrease
Arm Cylinder
lubrication performance. Rod Side
When lubrication oil leaks, replace the bushing.
Boom / Arm
Joint Pin
W166-04-01-101
W4-1-8
(Blank)
W4-1-9
REMOVE AND INSTALL BUSHING
d c
b
a
W166-04-02-005
Bucket
Arm
Link A 2 1 2 f 3
1 2 Link A
1 2 1
a: Bucket and Link A

W166-04-02-012 Boom
1 2 3
Link B
b: Link A c: Boom and Arm
W166-04-02-014
W166-04-02-013 2 1 2 3
Arm
1 2 3
2 Bucket
Boom
Main Frame
d: Boom and Main Frame Link B

f: Arm and Bucket
W166-04-02-010
e: Arm and Link B
W166-04-02-016
W166-04-02-015
1- Dust Seal 2 - Bushing 3 - Spacer
W4-1-10
Removal
1. Remove dust seal (1) and bushing (2).

NOTE: If bushing (2) cannot be removed, burn off
bushing (2).
Installation
1. Cool bushing (2) by using dry ice.
2. Install bushing (2) and dust seal (1).

When installing bushing (2), use the following
plate.
Plate when installing bushing

a: Bucket side .....................................ST 2881
Link A side.......................................ST 2873
b: Link A ..............................................ST 2873
c: Arm .................................................ST 2877
d: Boom side.......................................ST 2877
Main frame side ..............................ST 2886
e: Arm .................................................ST 2882
f: Bucket side .....................................ST 2881
Armside...........................................ST 2873
W4-1-11
Pin and Bushing
f
d
c g
h
b i
e
a
k
j
W105-04-01-018
Unit: mm (in)
Position Item Standard Allowable Limit
Pin Outer Dia. 110 (4.33) 109 (4.29)
Bushing Inner Dia. (Frame Side) 110 (4.33) 111.5 (4.39)
a: Boom Cylinder and Main Frame
Bushing Outer Dia. 130 (5.12) -
Bearing Inner Dia. (Cylinder Side) 110 (4.33) 111.5 (4.39)
Pin Outer Dia. 120 (4.72) 119 (4.69)
Bushing Inner Dia. (Frame Side) 120 (4.72) 121.5 (4.78)
b: Boom and Main Frame Bushing Outer Dia. 140 (5.51) -
Bushing Inner Dia. (Boom Side) 120 (4.72) 121.5 (4.78)
Pin Outer Dia. 120 (4.72) 119 (4.69)
c: Boom Cylinder and Boom Pin Hole Inner Dia. (Boom Side) 120 (4.72) -
W4-1-12
Unit: mm (in)
Position Item Standard Allowable Limit
Pin Outer Dia. 110 (4.33) 109 (4.29)
d: Boom and Arm Cylinder Pin Hole Inner Dia. (Boom Side) 110 (4.33) -
Pin Outer Dia. 120 (4.72) 119 (4.29)
Bushing Inner Dia. (Boom Side) 120 (4.72) 121.5 (4.78
e: Boom and Arm Bushing Outer Dia. 140 (5.51) -
Bushing Inner Dia. (Arm Side) 120 (4.72) 121.5 (4.78)
Pin Outer Dia. 110 (4.33) 109 (4.29)
f: Arm Cylinder and Arm Pin Hole Inner Dia. (Arm Side) 110 (4.33) -
Pin Outer Dia. 100 (3.94) 99 (3.90)
g: Arm and Bucket Cylinder Pin Hole Inner Dia. (Arm Side) 100 (3.94) -
Pin Outer Dia. 110 (4.33) 109 (4.29)
Bushing Inner Dia. (Link A Side) 110 (4.33) 111.5 (4.39)
h: Bucket Cylinder and Link
Pin Outer Dia. 110 (4.33) 109 (4.29)
Bushing Inner Dia. (Link A Side) 110 (4.33) 111.5 (4.39)
i: Link and Bucket Bushing Outer Dia. 130 (5.12) -
Bushing Inner Dia. (Bucket Side) 110 (4.33) 109 (4.29)
Pin Outer Dia. 110 (4.33) 109 (4.29)
Bushing Inner Dia. (Arm Side) 110 (4.33) 111.5 (4.39)
j: Arm and Bucket Bushing Outer Dia. 130 (5.12) -
Bushing Inner Dia. (Bucket Side) 110 (4.33) 111.5 (4.39)
Pin Outer Dia. 100 (3.94) 99 (3.90)
k: Arm and Link Bushing Inner Dia. (Arm Side) 100 (3.94) 101.5 (4.00)
IMPORTANT: When replacing HN bushing for the

front attachment, install it by using a
press.
W4-1-13
Side Cutter
B A
W166-04-01-011
Unit: mm (in)
A 305 (12.0) 200 (7.9)
Replace
B 40 (1.6) -
Point
B C
W1J1-04-01-002
Unit: mm (in)
A 254 (10.0) 127 (5.0)
B 140 (5.5) -
Replace
C 137 (5.4) -
D 129 (5.1) -
W4-1-14
STANDARD DIMENSIONS FOR ARM AND
BUCKET CONNECTION
IMPORTANT: If the front attachment of a previous
model machine is used, use the
grease intervals for previous model
machine.
Without Without
bushing bushing
Section B
Section A
W187-04-01-003
Unit: mm (in)
Model ZX450-3/500LC-3 ZX450 EX400-5
NOTE: Dimension h: 470 mm (5.51 in) includes
a 520 (20.47) ← ←
the clearance for shims to adjust bucket
b 10 (0.39) ← ← clearance.
c 750 (29.53) ← ← Dimensions o and p: 45° means the angle
d 710 (27.95) ← ← for the bolt hole.
e - - -
f 1911 (75.24) 1896 (74.65) ←
g - 643 (25.32) ←
470.5 to 471.0
h ← ←
(18.52 to 18.54)
i 130 (5.12) ← ←
j 558 (21.97) ← ←
k 106 (4.17) ← ←
l 648 (25.51) 643 (25.32) ←
m 471 (18.54) ← ←
n 130 (5.12) ← ←
o 45° ← ←
p 45° ← ←
q 680 (26.77) ← ←
W4-1-15
STANDARD DIMENSIONS FOR ARM AND
BOOM CONNECTION
IMPORTANT: If the front attachment of a previous

model machine is used, use the
grease intervals for previous model
machine.
Without
bushing
Section C
W187-04-01-002
Unit: mm (in)
Model ZX450-3/500LC-3 ZX450 EX400-5
s 140 (5.51) ← ←
t 471 (18.54) ← ←
u 632 (24.88) ← ←
W4-1-16
FRONT ATTACHMENT / Cylinder
REMOVE AND INSTALL CYLINDER
Preparation
1. Park the machine on a solid, level surface. Fully

retract the bucket and arm cylinders and lower
the front attachment onto the ground.
2. Stop the engine. Operate the control lever several

W1J1-04-01-001
time with the pilot shut-off lever in the UNLOCK
position and release any pressure in the circuit.
NOTE: The accumulator is equipped for the pilot
circuit.
After the engine stops, when the control
lever is operated several time with the pilot
shut-off lever in the UNLOCK position, any
pressure can be released in the circuit.
3. Release any pressure in the front attachment pipe.

(Refer to the HYDRAULIC CIRCUIT PRESSURE
RELEASE PROCEDURE on W4-1-1.)
4. Release the pressure in the hydraulic oil tank.

TANK on W1-4-1.)
W4-2-1
Remove and Install Boom Cylinder
A
B
W1J1-04-01-003
A: Rod Side B: Bottom Side Hydraulic Hose

Lubrication Hose
6
1
2
3 7
4 W166-04-01-003 W166-04-01-002
5
6
7
2
3
8
5, 4
6
9
1
10
W162-04-01-025
12 11
W166-04-01-005
1- Pin 4 - Spring Washer (8 Used) 7 - Pin (2 Used) 10 - Spring Washer (2 Used)

2- Washer (2 Used) 5 - Bolt (8 Used) 8 - Washer (2 Used) 11 - Spacer
3- Stopper (2 Used) 6 - Boom Cylinder (2 Used) 9 - Bolt (2 Used) 12 - Shim
W4-2-2
Removal
1. Remove the lubrication hoses (4 used) from the

CAUTION: Pin (7) weight: 24 kg (53 lb)
rod side and bottom side in boom cylinder (6) on
both sides.
6. Remove bolt (9) from the bottom side of boom
: 19 mm
cylinder (6). Remove spring washer (10) and
washer (8).
CAUTION: Boom cylinder weight: 430 kg Pry and remove pin (7) by using a pry bar.
(950 lb) Remove boom cylinder (6). Remove spacer (11)
Pin (1) weight: 90 kg (200 lb) and shim (12). (Shim (12) may not be installed.)
: 30 mm
7. Remove other boom cylinder (6) in the same
procedures.
2. Attach a wire rope onto boom cylinder (6) and

hold boom cylinder (6).
Remove bolts (5) (4 used) from the cylinder rod
side. Remove spring washers (4) (4 used),
stopper (3) and washer (2).
Remove pin (1) from the cylinder rod hole.
Place boom cylinder (6) on a stand.
: 30 mm
3. Remove other boom cylinder (6) in the same

procedures.
4. Start the engine. Retract the cylinder rod to the

stroke end. Pass a wire through the cylinder rod
hole and secure the rod in order not to extend
boom cylinder (6).
5. Stop the engine. Release any remaining pressure

in the hydraulic lines and air in oil tank. Remove
the hydraulic hoses (4 used). (Refer to W4-1-1,
W1-4-1.)
： 41 mm
W4-2-3
A
B
W1J1-04-01-003
A: Rod Side B: Bottom Side Hydraulic Hose

Lubrication Hose
6
1
2
3 7
4 W166-04-01-003 W166-04-01-002
5
6
7
2
3
8
5, 4
6
9
1
10
W162-04-01-025
12 11
W166-04-01-005
1- Pin 4 - Spring Washer (8 Used) 7 - Pin (2 Used) 10 - Spring Washer (2 Used)

2- Washer (2 Used) 5 - Bolt (8 Used) 8 - Washer (2 Used) 11 - Spacer
3- Stopper (2 Used) 6 - Boom Cylinder (2 Used) 9 - Bolt (2 Used) 12 - Shim
W4-2-4
Installation
CAUTION: Boom cylinder weight: 430 kg CAUTION: Metal fragments may fly off when
(950 lb) a hammer is used. Wear necessary
Pin (7) weight: 24 kg (53 lb) protection, such as goggles, hard hats, etc in
7. Hoist the boom cylinder rod side on other side.
While adjusting the height, extend the cylinder
rod. Align the pin hole on cylinder rod side with
that on boom side. Install pin (1) into the hole on
1. Hoist boom cylinder (6) and align with the pin hole
the boom cylinder rod side.
on cylinder bottom side. Install spacer (11) to
inside and install shim (12) to outside. Install pin
8. Install bolts (5) (4 used for each), spring washers
(7). Install washer (8), spring washer (10) and bolt
(4) (4 used for each), stopper (3) and washer (2)
(9).
to both sides of pin (1).
: 30 mm
: 30 mm
: 400 N⋅m (41 kgf⋅m, 295 lbf⋅ft)
: 400 N⋅m (41 kgf⋅m, 295 lbf⋅ft)
2. Install other boom cylinder (6) in the same
9. Install the lubrication hoses (2 used).
procedures.
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
3. Install the hydraulic hoses (4 used). Remove the
wire to secure the cylinder rod.
10. When all work is completed, operate the boom
: 41 mm
cylinder for several times to stroke end and bleed
: 210 N⋅m (21 kgf⋅m, 155 lbf⋅ft)
air from the circuit.
4. Install the lubrication hoses (2 used) to the
bottom side of boom cylinder (6) on both sides.
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
5. Hoist the cylinder rod side. While adjusting the

height, extend the cylinder rod. Align the pin hole
on cylinder rod side with that on boom side.

6. Install pin (1) from the cylinder rod side.
W4-2-5
Remove and Install Arm Cylinder
W1J1-04-01-003
Lubrication Hose Hydraulic Hose
2
1 Lubrication Hose
3 2
4
5
Wooden Block 1
Boom
W166-04-01-004
W162-04-01-008
W166-04-01-006
1- Pin (2 Used) 3- Bolt (2 Used) 4 - Stopper (2 Used) 5 - Lock Nut (4 Used)

2- Arm Cylinder
W4-2-6
Removal
1. Remove the lubrication hose from the rod side of

CAUTION: Pin weight: 25 kg (55 lb)
arm cylinder (2).
: 19 mm CAUTION: Metal fragments may fly off when
CAUTION: Arm cylinder weight: 660 kg (1455
lb)
Pin weight: 25 kg (55 lb)
5. Remove lock nuts (5) (2 used) from the bottom
CAUTION: Metal fragments may fly off when side of arm cylinder (2). Remove bolt (3).
a hammer is used. Wear necessary Remove pin (1). Hoist and remove arm cylinder
protection, such as goggles, hard hats, etc in (2).
order to prevent personal injury. : 30 mm
2. Insert the wooden blocks between the boom and

arm cylinder (2). Attach a wire rope onto arm
cylinder (2) and hold arm cylinder (2). Remove
lock nuts (5) (2 used) from the cylinder rod side.
Remove bolt (3). Remove pin (1).
: 30 mm

arm cylinder (2).

in the hydraulic lines and oil tank. Remove the
hydraulic hoses (2 used) and the lubrication hose
from the bottom side.
(Refer to W4-1-1, W1-4-1.)
: 12 mm
: 19 mm
W4-2-7
W1J1-04-01-003
Lubrication Hose Hydraulic Hose

2
Lubrication Hose
1
3 2
4
5
Wooden Block 1
W166-04-01-004 Boom
W162-04-01-008
W166-04-01-006
1- Pin (2 Used) 3- Bolt (2 Used) 4- Stopper (2 Used) 5- Lock Nut (4 Used)

2- Arm Cylinder
W4-2-8
Installation
CAUTION: Arm cylinder weight: 660 kg (1455 CAUTION: Pin weight: 25 kg (55 lb)
lb)
1. Hoist arm cylinder (2). Align the pin hole on the
mounting part for cylinder bottom side.
CAUTION: Pin weight: 25 kg (55 lb) 5. Hoist pin (1). Insert pin (1) into the pin hole on
cylinder rod side and install pin (1) to the arm.
Install bolt (3) and lock nuts (5) (2 used) to
stopper (4) in the arm.
: 30 mm
: 400 N⋅m (41 kgf⋅m, 295 lbf⋅ft)
2. Hoist pin (1). Insert pin (1) into the pin hole on
6. Install the lubrication hose to pin (1) at the rod
cylinder bottom side. Align the bolt holes on pin
side of arm cylinder (2).
and stopper (4) in boom. Install bolt (3) and lock
: 19 mm
nuts (5) (2 used) to stopper (4). Insert the wooden
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
blocks between the boom and arm cylinder (2).
: 30 mm
7. When completing the work, operate the arm
: 400 N⋅m (41 kgf⋅m, 295 lbf⋅ft)
cylinder several times to the stroke end and
release the pressure in the circuit.
3. Install the hydraulic hoses (2 used) and the
lubrication hose to the bottom side.
: 12 mm
: 140 N⋅m (14 kgf⋅m, 103 lbf⋅ft)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
4. Hoist the cylinder rod. Remove the wire to secure

the rod.
Start the engine. Extend the cylinder rod. Align the
pin hole on cylinder rod side with that on arm.
W4-2-9
Remove and Install Bucket Cylinder
W1J1-04-01-003
Hydraulic Hose
1 2 3 4
Lubrication Hose
4
8
5 Arm
Wooden Block
6 W16J-04-02-001
W166-04-01-009
2 3
5
9
3 2
W166-04-01-007
W166-04-01-006
6 7 4
1- Link A 4 - Bucket Cylinder 6- Link B (2 Used) 8- Pin

2- Lock Nut (4 Used) 5 - Pin 7- Shim (2 Used) 9- Stopper
3- Bolt (2 Used)
W4-2-10
Removal
1. Insert a wooden block between the arm and 1. Remove the hydraulic hoses (2 used) from the
bucket cylinder (4). Remove the lubrication hose cylinder bottom side.
from the bottom side of bucket cylinder (4). : 10 mm
: 19 mm
2. Place the wooden block under link A (1). Secure
link A and link B by using a wire in order not to CAUTION: Metal fragments may fly off when
drop links B (6) (2 used) when removing pin (5). a hammer is used. Wear necessary
CAUTION: Bucket cylinder weight: 410 kg
(905 lb)
7. Remove lock nuts (2) (2 used) from the cylinder
Pin (5) weight: 46 kg (101 lb)
bottom side. Remove bolt (3). Remove pin (8).
CAUTION: Metal fragments may fly off when : 30 mm
protection, such as goggles, hard hats, etc in 8. Hoist and remove bucket cylinder (4).
3. Attach a wire rope onto bucket cylinder (4) and

hold bucket cylinder (4). Remove lock nuts (2) (2
used) from the cylinder rod side. Remove bolt (3).
Remove pin (5) and remove shims (7) (2 used).
: 30 mm

bucket cylinder (4).

in the hydraulic lines and oil tank.
(Refer to W4-1-1, W1-4-1.)
W4-2-11
W1J1-04-01-003
Hydraulic Hose
1 2 3 4
Lubrication Hose
8
5 Arm
Wooden Block
6 W16J-04-02-001
W166-04-01-009
2 3
5
9
3 2
W166-04-01-007
6 7 4
W166-04-01-006
1- Link A 4 - Bucket Cylinder 6- Link B (2 Used) 8- Pin

2- Lock Nut (4 Used) 5 - Pin 7- Shim (2 Used) 9- Stopper
3- Bolt (2 Used)
W4-2-12
Installation
CAUTION: Bucket cylinder weight: 410 kg CAUTION: Pin (5) weight: 46 kg (101 lb)
(905 lb)
1. Hoist bucket cylinder (4). Align the pin hole on
mounting part for cylinder bottom side with that on
arm side.
5. Hoist pin (5). While aligning, insert pin (5) into the
CAUTION: Pin (8) weight: 20 kg (44 lb) pin hole on cylinder rod side. Install bolt (3) and
lock nuts (2) (2 used). Insert shim (7) so that the
maximum clearance between link A (1) and link B
(6) is 1.5 mm or smaller.
: 30 mm
: 400 N⋅m (41 kgf⋅m, 295 lbf⋅ft)
2. Hoist and insert pin (8) into the cylinder bottom
6. Remove the wire to secure links B (6) (2 used) in
side. Install bolt (3) and lock nuts (2) (2 used) to
order not to drop. Start the engine. Remove the
stopper (9) in the arm. Insert a wooden block
wooden block set under link A (1).
between the arm and bucket cylinder (4).
: 30 mm
7. After completing the work, operate the bucket
: 400 N⋅m (41 kgf⋅m, 295 lbf⋅ft)
cylinder several times to the stroke end and
release the pressure in the circuit.
3. Install the hydraulic hoses (2 used) and the
lubrication hose to the bottom side in bucket
cylinder (4).
: 10 mm
: 90 N⋅m (9.2 kgf⋅m, 66 lbf⋅ft)
: 19 mm
: 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
4. Hoist the cylinder rod side. Remove the wire to

secure the cylinder rod. Start the engine. Extend
the cylinder rod. Align with the pin (5) holes on
link A (1) and link B (6).
W4-2-13
DISASSEMBLE CYLINDERS
Boom Cylinder
12
13
14
15
16
15
14
17
18
19
20
21 2
10
11
W1J1-04-02-020
1 - Cylinder Rod 7- Backup Ring 12 - Cushion Seal 17 - Piston

2 - Wiper Ring 8- U-Ring 13 - Cushion Bearing 18 - Nut
3 - Socket Bolt (8 Used) 9- Ring 14 - Slide Ring (2 Used) 19 - Steel Ball
4 - Cylinder Head 10 - Bush 15 - Slide Ring (2 Used) 20 - Set Screw
5 - Backup Ring 11 - Retaining Ring 16 - Seal Ring 21 - Cylinder Tube
6 - O-Ring
W4-2-14
Disassemble Boom Cylinder
• The disassembling procedure starts on the 5. Remove set screw (20) and ball (19) from nut
premise that the hydraulic lines and the bands (18).
securing lines have been removed. : 6 mm
NOTE: As set screw (20) was mushroomed by
CAUTION: Boom cylinder weight: 430 kg using a punch and hammer at two places
(950 lb) after set screw (20) had been screwed in,
cut away its mushroomed part by using a
1. Hoist the cylinder. Secure the cylinder on a drill first.
workbench horizontally. Drain hydraulic oil from
the cylinder. 6. Loosen nut (18) and remove piston (17) from
cylinder rod (1) by using special tool (ST 5908).
Special Tools when turning nut: 125 mm (ST
3268)
IMPORTANT: Do not re-use slide rings (14, 15).

When the cylinder disassembled,
replace slide rings (14, 15) with the
new ones.
7. Remove slide rings (14) (2 used), (15) (2 used)
and seal ring (16) from piston (17).
W102-04-02-027
8. Remove cylinder head (4) from cylinder rod (1).

2. Fully extend and support cylinder rod (1).
Remove socket bolts (3) (8 Used) from cylinder
9. Remove O-ring (6) and backup ring (5) from
head (4).
cylinder head (4). Remove dust seal (2), retaining
: 19 mm
ring (11), bush (10), ring (9), U-ring (8) and
backup ring (5).
IMPORTANT: Pull out cylinder rod (1) straightly in
Special tool when removing bushing: 115 mm (ST
order not to damage the sliding
2671)
surface.
3. Tap and remove cylinder head (4) with cylinder
rod (1) together from cylinder tube (21) by using
a plastic hammer.
4. Secure cylinder rod (1) on special tool (ST 5908).

Put the matching marks on cylinder rod (1) and
nut (18).
ST 5908
W158-04-02-022
W4-2-15
Arm Cylinder
15
16
17
18
19
20
19
18
14 1
22 13
23
2
3
6
7
8
9
10
11
12
W1J1-04-02-021
1- Cylinder Rod 8- Buffer Ring 13 - Set Screw 18 - Slide Ring (2 Used)

2- Wiper Ring 9- Bushing 14 - Steel Ball 19 - Slide Ring (2 Used)
3- Cylinder Head 10 - Retaining Ring 15 - Cushion Seal 20 - Seal Ring
4- Socket Bolt (8 Used) 11 - Backup Ring 16 - Cushion Bearing 22 - Nut
6- Backup Ring 12 - O-Ring 17 - Piston 23 - Cylinder Tube
7- U-Ring
W4-2-16
Bucket Cylinder
16
17
18
19 1
20
19
18
22
14
23 13
2
3
4
6
7
8
9
10
11
12
W1J1-04-02-022
1- Cylinder Rod 7- U-Ring 12 - O-Ring 18 - Slide Ring (2 Used)

2- Wiper Ring 8- Buffer Ring 13 - Set Screw 19 - Slide Ring (2 Used)
3- Cylinder Head 9- Bushing 14 - Steel Ball 20 - Seal Ring
4- Socket Bolt (8 Used) 10 - Retaining Ring 16 - Cushion Bearing 22 - Nut
6- Backup Ring 11 - Backup Ring 17 - Piston 23 - Cylinder Tube
W4-2-17
NOTE: The illustration shows arm cylinder.
15
16
17
18
19
20
19
14 1
22 13
23
2
3
6
7
8
9
10
11
12
W1J1-04-02-021
W4-2-18
Disassemble Arm Cylinder, Bucket Cylinder
• As the other hydraulic oil cylinders are very IMPORTANT: Pull out cylinder rod (1) straightly in
similar in construction, the procedures of arm order not to damage the sliding
cylinder are shown as an example. surface.
• The disassembling procedure starts on the 3. Tap and remove cylinder head (3) with cylinder
premise that the hydraulic lines and the bands rod (1) together from cylinder tube (23) by using
securing lines have been removed. a plastic hammer.
4. Secure cylinder rod (1) on special tool (ST 5908).

CAUTION: Cylinder weight:
Put the matching marks on cylinder rod (1) and
Arm cylinder: 660 kg (1455 lb)
nut (22).
Bucket cylinder: 410 kg (905 lb)
ST 5908
1. Hoist the cylinder. Secure the cylinder on a
workbench horizontally. Drain hydraulic oil from
the cylinder.
W158-04-02-022
5. Remove set screw (13) and ball (14) from nut

(22).
: 8 mm
W102-04-02-027
NOTE: As set screw (13) was mushroomed by
using a punch and hammer at two places
after set screw (13) had been screwed in,
CAUTION: Cylinder rod (1) weight: cut away its mushroomed part by using a
Arm cylinder: 275 kg (606 lb) drill first.
2. Fully extend cylinder rod (1) and hold cylinder rod

(1). Remove socket bolts (4) (8 used) from
cylinder head (3).
Bucket
: 19 mm
Arm
: 22 mm
W4-2-19
15
16
17
18
19
20
19
14 1
22 13
23
2
3
6
7
9
10
11
12
W1J1-04-02-021
W4-2-20
6. Loosen nut (21) and remove piston (17) by using 10. Remove retaining ring (10) and bushing (9) from
special tool (ST 5908). cylinder head (3).
Special Tool when turning nut:
Arm cylinder 11. Remove O-ring (12) and backup ring (11) from
ST 3283: 135 mm (5.3 in) cylinder head (3).
Bucket cylinder
ST 7213: 130 mm (5.1 in)
ST 5908
W158-04-02-022
IMPORTANT: Do not re-use slide rings (18, 19).

When the cylinder disassembled,
replace slide rings (18, 19) with the
new ones.
7. Remove slide rings (18) (2 used), (19) (2 used)
and seal ring (20) from piston (17).
8. Remove cushion bearing (16), cushion seal (15)

and cylinder head (4) from cylinder rod (1).
NOTE: Cushion seal (15) is not equipped for the
bucket cylinder.
IMPORTANT: Do not re-use slide ring (5). When

the cylinder disassembled, replace
slide ring (5) with the new one.
9. Remove wiper ring (2), backup ring (6), U-ring (7)
and buffer ring (8) from cylinder head (3).
W4-2-21
ASSEMBLE CYLINDERS
Boom Cylinder
4 2 7 8 9 10 11 14 15 16 15 14 17
3 5, 6 1 21 12 13 18 19, 20
W1J1-04-02-023
1 - Cylinder Rod 7- Backup Ring 12 - Cushion Seal 17 - Piston

2 - Wiper Ring 8- U-Ring 13 - Cushion Bearing 18 - Nut
3 - Socket Bolt (8 Used) 9- Ring 14 - Slide Ring (2 Used) 19 - Steel Ball
4 - Cylinder Head 10 - Bush 15 - Slide Ring (2 Used) 20 - Set Screw
5 - Backup Ring 11 - Retaining Ring 16 - Seal Ring 21 - Cylinder Tube
6 - O-Ring
W4-2-22
Assemble Boom Cylinder
1. Install bushing (10) and retaining ring (11) to 8. Align the matching marks before disassembling
cylinder head (4). and tighten nut (18) by using special tool (ST
Special tool when installing bushing: 5908).
ST 2671: 115 mm (4.5 in) Special Tool when turning nut:
ST 3268: 125 mm (4.9 in)
2. Install ring (9), backup ring(7) and U-ring (8) to : 14220±1420 N⋅m
cylinder head (4). (1450±145 kgf⋅m, 10490±1049 lbf⋅ft)
3. Install dust seal (2) to cylinder head (4) by using ST 5908

a plastic hammer and special tool (ST 2672).
Special tool when installing dust seal: ST 2672
4. Install O-ring (6) and backup ring (5) to cylinder

head (4).
5. Install slide rings (14) (2 used), (15) (2 used) and W158-04-02-022
seal ring (16) to piston (17).

9. Tighten nut (18). Install steel ball (19) to nut (18)
6. Install the cylinder head (4) assembly to cylinder and tighten set screw (20). Crimp by using a
rod (1). punch at two places.
: 6 mm
7. Install the piston (17) assembly to cylinder rod : 64±5.9 N⋅m
(1). (6.5±0.6 kgf⋅m, 47±4.4 lbf⋅ft)
IMPORTANT: Align with the center of cylinder

tube (21) and insert the cylinder rod
(1) assembly straightly in order not
to damage the rings.
10. Secure cylinder tube (21) horizontally on a
workbench. Insert the cylinder rod (1) assembly
into cylinder tube (21).
11. Tighten cylinder head (4) to cylinder tube (21)

: 19 mm
: 1230±123 N⋅m
(125±12.5 kgf⋅m, 907±91 lbf⋅ft)
W4-2-23
Arm Cylinder Bucket Cylinder
1 2 2
1
8 8
6 6
9 9
7
10 7
10
4 4
11, 12
11, 12
3 3
23 23
16 16
18
18
19
19 17
20
17 20
19
19
18
18 14 22
14 22
13
13
W1J1-04-02-024 W1J1-04-02-025
1- Cylinder Rod 7- U-Ring 12 - O-Ring 18 - Slide Ring (2 Used)

2- Wiper Ring 8- Buffer Ring 13 - Set Screw 19 - Slide Ring (2 Used)
3- Cylinder Head 9- Bushing 14 - Steel Ball 20 - Seal Ring
4- Socket Bolt (8 Used) 10 - Retaining Ring 16 - Cushion Bearing 22 - Nut
6- Backup Ring 11 - Backup Ring 17 - Piston 23 - Cylinder Tube
W4-2-24
Assemble Arm Cylinder, Bucket Cylinder
1. Install bushing (9) to cylinder head (3). Install 5. Install O-ring (12) and backup ring (11) to cylinder
retaining ring (10). head (3).
Special tool when installing bushing:
Arm cylinder 6. Install seal ring (20) to piston (17) using special
ST 8023: 135 mm (5.3 in) tool.
Bucket cylinder Special tool when installing seal ring:
ST 8036: 120 mm (4.7 in) Arm cylinder: ST 2971
Bucket cylinder: ST 2970
IMPORTANT: Install buffer ring (8) with the lip
facing to the cylinder bottom side. IMPORTANT: Install slide rings (18, 19) with their
2. Install buffer ring (8) to cylinder head (3). slits positioned 180 degrees each
facing the opposite of each other.
IMPORTANT: Install U-ring (7) with the lip facing 7. Install slide rings (18, 19) (2 used for each) to
to the cylinder bottom side. piston (17).
3. Install backup ring (6) to cylinder head (3). Install
U-ring (7). 8. Install special tool to piston (17). Retract seal ring
(20) and slide rings (18, 19).
IMPORTANT: Install wiper ring (2) with the lip Special tool:
facing to the outside. Arm cylinder: ST 2971
4. Install wiper ring (2) to cylinder head (3). Bucket cylinder: ST 2970
Arm cylinder
ST 8023: 135 mm (5.3 in)
CAUTION: Cylinder rod (1) weight:
Bucket cylinder
ST 8036: 120 mm (4.7 in)
9. Secure cylinder rod (1) to special tool (ST 5908).
ST 5908
W158-04-02-022
W4-2-25
Arm Cylinder Bucket Cylinder
1 2 2
1
8 8
6 6
9 9
7
10 7
10
4 4
11, 12
11, 12
3 3
23 23
16 16
18
18
19
19 17
20
17 20
19
19
18
18 14 22
14 22
13
13
W1J1-04-02-024 W1J1-04-02-025
W4-2-26
10. Install cylinder head (3) to cylinder rod (1) using 15. Install steel ball (14) to nut (22) and tighten set
special tool. screw (13).
Special tool when installing cylinder head: : 8 mm
Arm cylinder: ST 8023 : 100 N⋅m (10 kgf⋅m, 74 lbf⋅ft)
Bucket cylinder: ST 8022
16. Crimp set screw (13) at two places on the outer
IMPORTANT: Install cushion bearing (16) with the surface by using a punch in order not to loosen.
chamfered side facing to the
cylinder head (3) side.
CAUTION: Cylinder tube (23) weight:
11. Install cushion bearing (16) to cylinder rod (1).
12. Install piston (17) to cylinder rod (1).
17. Secure cylinder tube (23) horizontally on a
13. Install nut (22) to cylinder rod (1).
workbench.
14. Tighten nut (22) using special tool.
Special tool when turning nut: CAUTION: Cylinder rod (1) weight:
Arm cylinder Arm cylinder: 275 kg (606 lb)
ST 3283: 135 mm (5.3 in) Bucket cylinder: 170 kg (375 lb)
: 27300 N⋅m (2780 kgf⋅m, 20135 lbf⋅ft)
Bucket cylinder IMPORTANT: Align with the center of cylinder
ST 7213: 130 mm (5.1 in) tube (23) and insert the cylinder rod
: 20900 N⋅m (2130 kgf⋅m, 15415 lbf⋅ft) (1) assembly straightly in order not
to damage the rings.
18. Insert cylinder rod (1) into cylinder tube (23).
19. Install cylinder head (3) to cylinder tube (23) and

tighten with socket bolts (4) (8 used).
Arm cylinder
: 22 mm
: 1560 N⋅m (160 kgf⋅m, 1150 lbf⋅ft)
Bucket cylinder
: 19 mm
: 1140 N⋅m (116 kgf⋅m, 840 lbf⋅ft)
W4-2-27
Cylinder Tube
1. Tube Section (1) 1 2
• Check the inside and outside for any damage.
2. Pin, Bushing Section (2)

• Check whether the wear on surface of inner
diameter is 0.5 mm (0.02 in) more than specified A B
dimension (B).
• Check the inside for any damage.
IMPORTANT: Check the inner bore in tube W145-04-01-015

completely.
Cylinder Rod Piston

4 3
1. Rod Section (3)
• Place two V-blocks 1 m apart on level ground.
Lay the cylinder rod across the V-blocks. Rotate
the rod one turn and measure the rod deflection
by using a dial gauge. Measure the deflection in D C
three positions. If one measured deflection is 1
mm or more, replace the rod.
• Check the surface for any damage.
• Check the plated part for any rust. W166-04-02-023
• Check the cushion part for any damage.

Dial Gauge
2. Pin, Bushing Section (4) Cylinder Rod
• Check if the bushing bore (D) wear is 0.2 mm or
more than specification.
• Check the inside for any damage.
W166-04-02-022
1m
V Block
Standard Dimension List Unit: mm (1 mm=0.03937 in)

Boom Arm Bucket
+0.063 +0.072 +0.063
Cylinder Tube Inner Dia. (A) 170 0
190 0
170 0
+0.25 +0.25 +0.25

Cylinder Tube Pin, Bushing Bore Dia. (B) 110 +0.05 110 +0.05 100 +0.05
Rod Dia. (C) Recommended O.D size after -0.012 +0.031 +0.027
Re-plating 115 -0.027 130 -0.061 120 -0.057
+0.25 +0.25 +0.25

Piston Rod Pin, Bushing Bore Dia. (D) 120 +0.05 110 +0.05 110 +0.05
Adjusted Piston Rod Deflection 0.125/1000
W4-2-28
Pipe
5 6
5 6
1. Pipe (5)
• Check for any damage in depth more than 0.1
mm (0.004 in).
• Check for any deformation and damage
2. Socket bolt (6)

• Check for any heavy rust.
7
• Check the thread for any damage.
7
3. Ring (7)
• Replace O-ring when disassembling. T182-05-02-004
Piston, Cylinder Head

• Check the inside and outside for any damage.
• Check the groove for any damage.
• When the internal leakage is found, check the
seals for damage.
• Replace when the base metal of bushing slide
surface shows.
W4-2-29
(Blank)
W4-2-30
MEMO
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Fax: 81-29-831-1162
NAME OF COMPANY: MODEL:

PUBLICATION NO.:
YOUR NAME: (Located at the right top corner in the cover page)
DATE: PAGE NO.:

(Located at the bottom center in the page. If two or more re-
FAX: visions are requested, use the comment column)

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ZX450 470 500 520LC-3 Full Technical Manual

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ZX450 470 500 520LC-3 Full Technical Manual

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INTRODUCTION

• Please refer to the other materials (operator’s

• Each page has a number, located on the center

Consecutive Page Number for Each Group

Group 2 Component Layout

Group 3 Component Specifications

Model ZX450-3 ZX450LC-3 ZX500LC-3

ZAXIS470H-3, ZAXIS470LCH-3, ZAXIS520LCH-3

Model ZX470H-3 ZX470LCH-3 ZX520LCH-3

Category 7.0 m (22 ft 12 in) Boom 8.2 m (26 ft 11 in) Boom

Category 7.0 m ( 22 ft 12 in) Boom 8.2 m (26 ft 11 in) Boom

Backhoe Backhoe Backhoe Backhoe Backhoe

ZAXIS470H-3, ZAXIS470LCH-3, ZAXIS520LCH-3

Category 3.4 m (11 ft 2 in) H Arm

NOTE: Symbols in the above table have the following meaning.

ZX470H-3, ZX470LCH-3, ZX520LCH-3

ZX470R-3, ZX470LCR-3, ZX520LCR-3

NOTE: Symbols in the above table have the following meanings.

1 - Arm Cylinder 8- Control Valve 15 - Fan Pump 22 - Hydraulic Oil Tank

Above of Control Valve

1 - Inter Cooler 3 - Air Conditioner Condenser 5 - Oil Cooler 6 - Accumulator

Around Horn (Refer to T1-2-7)

Around Horn Around Radiator

1 - Horn 4 - Fresh Air Temperature 7- Starter Relay 10 - Auto-Lubrication Pump

Pressure Sensor Brock

Swing Device Side

Solenoid Valve Unit

Signal Control Valve

SWING DEVICE TRAVEL DEVICE

COMPONENTS IN CONTROL VALVE

Boom 1 Boom 2 Bucket Auxiliary

Cross Section I-I

Pilot Valve Side

Control Valve Side

Control Valve Side

Control Valve Side

ENGINE STOP SYSTEM

EXHAUST RECIRCULATION SYSTEM

PERFORMANCE (at New engine)

Radiator Oil Cooler

SWING PARKING BRAKE

TRAVEL BRAKE VALVE

TRAVEL PARKING BRAKE

Bucket Counterweight Removal (Optional)

FRONT ATTACHMENT PILOT VALVE

TRAVEL PILOT VALVE

AUXILIARY/ COUNTER WEIGHT REMOVAL PILOT VALVE (Optional)

SOLENOID VALVE UNIT

PILOT PRESSURE SIGNAL CONTROL VALVE

PILOT SHUT-OFF SOLENOID VALVE

BYPASS CHECK VALVE

OIL COOLER BYPASS CHECK VALVE

GLOW PLUG RELAY

Group 4 Hydraulic System

The controllers are provided for each control respec-

• ECM：Engine Control Module

Monitor Unit ICF

CAN Bus Line

CAN Bus Line

NOTE: CAN (CAN Bus Line)

The CAN bus line consists of two harnesses, CAN

Monitor Unit ICF

CAN Bus Line