CX350C Excavator PDF

CX350C
Tier 4
Crawler Excavator
SERVICE MANUAL
Printed in U.S.A. Part number 84402832

1st edition English
Copyright © 2011 CNH America LLC. All Rights Reserved.
Case is a registered trademark of CNH America LLC. August 2011
Racine Wisconsin 53404 U.S.A.
Section
1001
Safety, general information and standard torque data
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ROPS Judgment Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Standard Torque Data For Cap Screws And Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
84402832 NA - May 2011 Copyright © 2011 CNH FRANCE S.A.

1001-1 PRINTED IN FRANCE
GENERAL INFORMATION
CLEANING
Clean all metal parts except bearings, in a suitable cleaning solvent or by steam cleaning.
Do not use caustic soda for steam cleaning.
After cleaning, dry and put oil on all parts.
Clean oil passages with compressed air.
Clean bearings in a suitable cleaning solvent,
dry the bearings completely and put oil on the bearings.
INSPECTION
Check all parts when the parts are disassembled.
Replace all parts that have wear or damage.
Small scoring or grooves can be removed with a hone or crocus cloth.
Complete a visual inspection for indications of wear, pitting and the replacement of parts necessary to prevent early
failures.
BEARINGS
Check bearings for easy action.
If bearings have a loose fit or rough action replace the bearing.
Wash bearings with a suitable cleaning solvent and permit to air dry.
DO NOT DRY BEARINGS WITH COMPRESSED AIR.
NEEDLE BEARINGS
Before you press needle bearings in a bore always remove any metal protrusions in the bore or edge of the bore.
Before you press bearings into position put petroleum jelly on the inside and outside diameter of the bearings.
GEARS
Check all gears for wear and damage.
Replace gears that have wear or damage.
Oil seals, O-rings and gaskets.
Always install new oil seals, O-rings and gaskets.
Put petroleum jelly on seals and O-rings.
SHAFTS
Check all shafts that have wear or damage.
Check the bearing and oil seal surfaces of the shafts for damage.
SERVICE PARTS
Always install genuine Case service parts.
When ordering refer to the
Parts Catalogue for the correct part number of the genuine Case replacement items.
Failures due to the use of other than genuine Case replacement parts are not covered by warranty.
LUBRICATION
Only use the oils and lubricants specified in the Operator’s or Service Manuals.
Failures due to the use of non-specified oils and lubricants are not covered by warranty.
84402832 NA - May 2011

1001-3
Safety
This symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED.

The message that follows the symbol contains important information about safety.
Carefully read the message.
Make sure you fully understand the causes of possible injury or death.
To prevent injury always follow the Warning, Caution and Danger notes in this section and throughout the manual.
Put the warning tag shown below on the key for the key switch when servicing or repairing the machine.
One warning tag is supplied with each machine.
Additional tags are available from your service parts supplier.
WARNING
Read the operator's manual to familiarize yourself with the correct control functions.
WARNING
Operate the machine and equipment controls from the seat position only.
Any other method could result in serious injury.
WARNING
This is a one man machine, no riders allowed.
WARNING
Before starting engine, study Operator’s Manual safety messages.
Read all safety signs on machine.
Clear the area of other persons.
Learn and practice safe use of controls before operating.
It is your responsibility to understand and follow manufacturers instructions on machine operation, ser-
vice and to observe pertinent laws and regulations.
Operator's and Service Manuals may be obtained from your CASE dealer.
WARNING
If you wear clothing that is too loose or do not use the correct safety equipment for your job, you can
be injured.
Always wear clothing that will not catch on objects.
Extra safety equipment that can be required includes hard hat, safety shoes, ear protection, eye or face
protection, heavy gloves and reflector clothing.
WARNING
When working in the area of the fan belt with the engine running, avoid loose clothing if possible, and
use extreme caution.
WARNING
When doing checks and tests on the equipment hydraulics, follow the procedures as they are written.
DO NOT change the procedure.
WARNING
When putting the hydraulic cylinders on this machine through the necessary cycles to check operation
or to remove air from a circuit, make sure all people are out of the way.
WARNING
Use insulated gloves or mittens when working with hot parts.
84402832 NA - May 2011

1001-4
WARNING
Lower all attachments to the ground or use stands to safely support the attachments before you do any
maintenance or service.
WARNING
Pin sized and smaller streams of hydraulic oil under pressure can penetrate the skin and result in serious
infection.
If hydraulic oil under pressure does penetrate the skin, seek medical treatment immediately.
Maintain all hoses and tubes in good condition.
Make sure all connections are tight.
Make a replacement of any tube or hose that is damaged or thought to be damaged.
DO NOT use your hand to check for leaks, use a piece of cardboard or wood.
WARNING
When removing hardened pins such as a pivot pin, or a hardened shaft, use a soft head (brass or bronze)
hammer or use a driver made from brass or bronze and a steel head hammer.
WARNING
When using a hammer to remove and install pivot pins or separate parts using compressed air or using
a grinder, wear eye protection that completely encloses the eyes (approved goggles or other approved
eye protectors).
WARNING
Use suitable floor (service) jacks or chain hoist to raise wheels or tracks off the floor.
Always block machine in place with suitable safety stands.
WARNING
When servicing or repairing the machine, keep the shop floor and operator's compartment and steps
free of oil, water, grease, tools, etc.
Use an oil absorbing material and/or shop cloths as required.
Use safe practices at all times.
WARNING
Some components of this machine are very heavy.
Use suitable lifting equipment or additional help as instructed in this Service Manual.
WARNING
Engine exhaust fumes can cause death.
If it is necessary to start the engine in a closed place, remove the exhaust fumes from the area with an
exhaust pipe extension.
Open the doors and get outside air into the area.
WARNING
When the battery electrolyte is frozen, the battery can explode if (1), you try to charge the battery, or (2),
you try to jump start and run the engine.
To prevent the battery electrolyte from freezing, try to keep the battery at full charge.
If you do not follow these instructions, you or others in the area can be injured.
84402832 NA - May 2011

1001-5
ROPS Judgment Method

1. Purpose
Check against the ROPS judgment criteria to judge whether the machine satisfies the ROPS criteria or not.
The weight and boom of the machine greatly effects whether the ROPS judgment criteria is satisfied or not.
The ROPS test assumes that the weight being used is the weight of the machine when the maximum number of
selectable options are mounted (as of 2009).
However, depending on the derivative machinery or the order details, the weight and boom position may differ
from the assumed weight or position.
2. Criteria for judging whether a machine satisfies the ROPS criteria
1) Weight
The weight must not be over the weight shown below for each class.
If the weight is exceeded, there is a danger that the cab could be damaged and the operator could die or
sustain a serious injury when the machine falls over.
If the weight exceeds the stipulated weight, the machine will not satisfy the ROPS criteria.
• Weight (C series model)
To satisfy the ROPS criteria, the weight must not be over the indicated weight. (The below weights are
the weights indicated on the nameplate within the ROPS cab)
Machine body total

Class
weight
CX250C
31000 kg or less CX250CLR
CX300C
40000 kg or less CX370C
50000 kg or less CX470C
* The ROPS test assumes that the CX470C has a cage guard (alone).
• Weight (B series model)
To satisfy the ROPS criteria, the weight must not be over the indicated weight. (The below weights are
the weights indicated on the nameplate within the ROPS cab)
Machine body total

Class
weight
CX130B
CX160B
25000 kg or less CX180B
CX210B
CX230B
84402832 NA - May 2011

1001-6
2) Boom position
WARNING
• If the machine has been modified so that the boom position has been lowered, the machine
will not satisfy the ROPS criteria.
• It is necessary to consult with our company if it is possible that the boom's position has been
lowered by modification.
• The extent to which a boom position has moved cannot be determined in the same way for
all machines.
a Ground point
With the tip of the bucket in contact with the ground surface at maximum work radius, if the position (* in the
diagram) that overlaps with the cab when viewed from the side is markedly lower than that of a standard
machine (standard arm), the machine will not satisfy the ROPS criteria.
Also, with a machine body with a cab mounted that can withstand up to 31 tons, the effect of mounting a
24 ton machine, which is near the restriction weight, and a 21 ton machine to the same cab will not be the
same.
84402832 NA - May 2011

1001-7
3. Prohibited items
• Modifications that reduce the strength of a platform that has a cab with a ROPS mounted to it. (Actions or
modifications that reduce the functionality of the anchoring part at the left-rear of the cab)
• Modifications that effect the strength of the ROPS of a cab.
A forbidden all
All modifications (grinding, welding, drilling holes, removing, etc.) are prohib-
modifications
ited.
(red part)
Allow under spec-
Removal of parts is prohibited.
ified conditions
Bar welding and making holes (up to diameter 20 mm) by drilling are possible.
(gray part)
[C series Cab]
84402832 NA - May 2011

1001-8
[B series Cab]
• In general, high cabs do not satisfy the ROPS criteria. (It is necessary to consult with our company to check if
the high cab model satisfies the ROPS criteria.)
84402832 NA - May 2011

1001-9
Standard Torque Data For Cap Screws And Nuts

BOLT AND NUT TIGHTENING
• Tighten alternating between left and right and top and bottom so that uniform tightening force is applied.
• If Loctite was used on a removed bolt (there is something white sticking to the bolt when it is removed), clean the
old Loctite off with cleaning fluid, dry the bolt, then apply 2 - 3 drops of Loctite to the thread section of the bolt.
Torque table
Bolt nominal diameter (size) M6 M8 M10 M12 M14 M16 M18 M20
Wrench [mm] 10 13 17 19 22 24 27 30
Hexagon bolt Tightening
[N･m] 6.9 19.6 39.2 58.8 98.1 156.9 196.1 294.2
torque
Wrench [mm] 5 6 8 10 12 14 14 17
Hexagon socket
head bolt Tightening
[N･m] 8.8 21.6 42.1 78.5 117.7 176.5 245.2 343.2
torque
84402832 NA - May 2011

1001-10
Section
1002A
Specifications
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Overall (CX350C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Main Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Main Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Upper Side Work System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operating Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Swing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Travel Lower Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Control Valve and Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Capacities, Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Coolant and Oil Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1002A-1 PRINTED IN FRANCE
Specifications
Overall (CX350C)
Main Data
Operating weight 34700 kg
Engine output 198 kW/1900 min-1
Performance
Standard weight 18.0 kN
Swing speed 9.7 min-1
Low speed 3.2 km/h
Travel speed
High speed 5.4 km/h
Maximum pulling force 264 kN
Grade ability 70 ％ (35°)
65 kPa (600 mm grouser shoe)
Ground pressure 50 kPa (800 mm grouser shoe)
Standard weight 18.0 kN

Swing speed 9.7 min-1
Low speed 3.2 km/h
Travel speed
High speed 5.4 km/h
Maximum pulling force 264 kN
Grade ability 70 ％ (35°)
Ground pressure 51 kPa (800 mm grouser shoe)
Main Unit Dimensions

Main unit length 6010 mm
Main unit width 3200 mm (600 G shoe)
Upper swing body width 3030 mm
Cab width 1000 mm
Main unit height 3160 mm
Swing radius (rear end) 3550 mm
Swing body rear end distance 3520 mm
Swing body rear section bottom
1210 mm (not including lug height of 36 mm)
height
Distance between tumblers 4040 mm
Overall track length 4980 mm
Overall track width 3200 mm (600 G shoe)
Distance between tracks 2600 mm
Track shoe width 600 mm (options 700 mm, 800 mm, 850 mm, 900 mm)
480 mm (to bottom of lower frame) (not including lug height of
Minimum ground clearance
36 mm)
Engine
Name Isuzu 6HK1X diesel engine
4-cycle, water-cooled, overhead camshaft type
Model Common rail system (electronic control), cooled EGR, with tur-
bocharger (variable displacement type), DPD system
Number of cylinders - bore x
6 - D115 mm x 125 mm
stroke
84402832 NA - May 2011
1002A-3
Specifications
Total stroke volume 7.790 L

Maximum torque 1043 N·m/1500 min-1
Starter 24 V 5.0 kW reduction type
Charging generator 24 V 50 A AC type
Battery 12 V 128 Ah/5 HR x 2
Cooling System
Fan type D850 mm, 6 blades, suction
Radiator
Fin type Wavy
Fin pitch 1.75 mm
Oil cooler
Fin type Wavy
Fin pitch 1.75 mm
Intercooler
Fin type Wavy
Fin pitch 2.5 mm
Fuel cooler
Fin type Wavy
Fin pitch 2.0 mm
Upper Side Work System

Model Backhoe Attachment
Components, dimensions, working di-
mensions
Bucket capacity (reference) Heaped 1.40 m3 (Leveled 1.04 m3)
Bucket width 1300 mm
Bucket width with side cutter 1440 mm
Bucket weight with side cutter 1150 kg
Boom length 6450 mm
Standard
Long Short Ultra-short
Arm type (STD/HD)
(4.04 m) (2.63 m) (2.21 m)
(3.25 m)
Arm length 3250 mm 4040 mm 2630 mm 2210 mm
Bucket radius 1680 mm
Bucket wrist angle 173°
Maximum digging radius 11170 mm 11900 mm 10670 mm 10200 mm
Maximum digging radius at ground
10980 mm 11720 mm 10470 mm 9990 mm
line
Maximum digging depth 7340 mm 8140 mm 6730 mm 6300 mm
Maximum vertical straight wall dig-
6350 mm 7150 mm 5970 mm 5080 mm
ging depth
Maximum digging height 10370 mm 10670 mm 10320 mm 9850 mm
Maximum dump height 7230 mm 7540 mm 7140 mm 6770 mm
Minimum swing radius at front 4500 mm 4560 mm 4630 mm 4660 mm
Height for minimum swing radius
8480 mm 8490 mm 8540 mm 8650 mm
at front
Operating Device
Operator's seat
Position Left side
Adjustable forward and back and up and down, reclining mech-
Structure
anism, with seat suspension
Cab Sealed steel type, all reinforced glass, ROPS, with sunroof
Levers and pedals
For travel use Lever and pedal type (hydraulic pilot type) x 2
84402832 NA - May 2011
1002A-4
Specifications
For operating machine use Lever type (hydraulic pilot type) x 2

Instruments and switches
Work mode switchover 3 modes (SP/H/A)
Travel mode switchover Low-speed/high-speed switch type
One-touch idle Knob switch type
Engine emergency stop Switch type
Monitor device
Machine status display (TFT color
liquid crystal)
Message display
Work mode select status SP/H/A
Instruments
Fuel gauge
Engine coolant temperature gauge
Hydraulic oil temperature gauge
Hour meter
Rear view camera monitor
Warning display and warning alarm * has warning alarm
Overheat (*) Battery charge (*) Electrical system abnormality (*) Refill fuel (*)
Engine oil pressure (*) Refill coolant (*) Engine pre-heat Auto Warm-up Air cleaner (*)
Anti-theft device triggered Engine system abnormality (*) Engine emergency stop (*)
Illumination equipment
Right front tool
Working light box front sur- 24 V 70 W x 1
face:
Cab top: 24 V 70 W x 2
Boom side: 24 V 70 W x 1
Interior light 4 V 10 W x 1
Horn Electric horn x 2
Wiper with intermittent function, window washer, air conditioner,
Other 4 rear view mirrors (2 on cab sides, 1 front right stay, 1 CTWT
rear right), 1 rear view mirror (on CTWT)
Swing Units
Swing circle Swing bearing type (with inner gear)
Swing hydraulic motor Fixed displacement piston motor x 1
Reduction gear Planetary gear 2-stage reduction gear
Swing parking brake Mechanical lock (operational lever linkage type)
Travel Lower Body

Travel hydraulic motor Variable displacement piston motor x 2
Reduction gear Planetary gear 2-stage reduction gear(Nabtesco Corporation)
Travel brake Hydraulic lock
Parking brake Mechanical lock (travel lever linkage type)
Track shoe
Model Assembly-type triple grouser shoe
Number of shoes (per side) 48
Shoe width 600 mm (options 700 mm, 800 mm, 850 mm, 900 mm)
Grouser height 36 mm
Link pitch 216 mm
Roller
No. of upper rollers (per
2
side)
No. of lower rollers (per
8
side)
Track belt tension adjuster Grease cylinder type (with cushion spring)
84402832 NA - May 2011
1002A-5
Specifications
Hydraulic Equipment
Hydraulic Device
Hydraulic pump drive type Direct engine link (no transmission)

Hydraulic pump
Double variable displacement piston pump x 1
Model
Gear pump x 1
Piston pump 2 x 285 L/min
Discharge volume
Gear pump 28.5 L/min
Pump control method Simultaneous output full-horsepower control
Set pressure of main relief valve 34.3 MPa (37.3 MPa for pressure boost)
27.4 MPa (boom down)
Set pressure of overload relief valve
39.2 MPa (boom up/arm/bucket)
Control Valve and Cylinder
Control valve
Model Quadruple spool + quintuple spool x 1
Operating method Hydraulic pilot type: travel, swing, and operating machine
Cylinder No. of cylinders x tube bore - rod diameter - stroke
Boom cylinder 2 x D145 mm - D100 mm - 1495 mm
Arm cylinder 1 x D170 mm - D120 mm - 1748 mm
Bucket cylinder 1 x D150 mm - D105 mm - 1210 mm
Capacities, Filters
Coolant and Oil Capacities
Coolant 35.4 L
Fuel 580 L
Engine lubricating oil (including remote oil filter) 49 L
Travel reduction gear lubricating oil (one side) 11 L
Swing reduction gear lubricating oil 5L
Hydraulic oil 350 L
Hydraulic oil tank regulation amount 175 L
Hydraulic Oil Filters
Suction filter (inside tank) 105 μm

Return filter (inside tank) 6 μm
Pilot line filter (inside pump chamber) 8 μm
Fuel Filter
Main filter 2 μm
Pre-filter 7 μm
84402832 NA - May 2011

1002A-6
Section
1002B
Main Equipment Table
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Main Equipment Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Lower Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Travel Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Take-up Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Recoil Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Shoe (CX350C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Upper Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Swing Unit (CX350C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine-related . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Air Cleaner (double element) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Control-related . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Solenoid Valve (4 stack) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Remote Control Valve (left/right, travel operations) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Remote Control Valve for Left/Right Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Remote Control Valve for Travel Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Remote Control Valve Characteristic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Operation Remote Control Valve Control Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Travel Remote Control Valve Control Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cushion Valve (heat circuit, with shuttle valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Center Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Backhoe Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1002B-1 PRINTED IN FRANCE

Lower Component
Travel Unit
Manufacturer Nabtesco Corporation
Motor type Variable displacement piston motor
Automatic 2-speed switchover with parking brake
Intake amount 290.7/170.1 cm3/rev
Operating pressure 34.3 MPa
Operating flow 285 L/min
Brake torque 47.39 kN·m min. (including reduction gear)
Relief valve set pressure 35.8 - 37.8 MPa
Automatic 2-speed switchover
26.5 MPa
pressure
Reduction gear
Reduction gear type Planetary gear 2-stage reduction gear
Reduction ratio 40.467
Dry weight 399 kg
Take-up Roller
Sumitomo part No. LH5146
Weight 164.6 kg
Upper Roller
Weight 43 kg
Lower Roller
Weight 61 kg
Recoil Spring
Item Weight (kg) Q'ty
Yoke 39.8 1
Sems B M16 x 50 0.5 4
Threaded rod 49.1 1
Groove height N M64 1.9 1
SP pin 10 x 100 0.1 1
Recoil spring 119.4 1
Grease cylinder assembly 41.1 1
Sems B M16 x 65 0.3 2
Assembly (Total) 252.2
Mounting length of spring 779 mm
84402832 NA - May 2011

1002B-3
Shoe (CX350C)
Weight or Q'ty
600 grouser 2217 kg
Link 1 set
Shoe 48
Bolt 192
Nut 192
700 grouser 2473 kg
Link 1 set
Shoe 48
Bolt 192
Nut 192
800 grouser 2618 kg
Link 1 set
Shoe 48
Bolt 192
Nut 192
850 grouser 2735 kg
Link 1 set
Shoe 48
Bolt 192
Nut 192
900 grouser 2817 kg
Link 1 set
Shoe 48
Bolt 192
Nut 192
84402832 NA - May 2011

1002B-4
Upper Component
Swing Unit (CX350C)
Swing motor assembly
Swing motor
Manufacturer Kawasaki Precision Machinery Ltd.
Motor type Fixed displacement piston motor
With parking brake
Intake amount 180.1 cm3/rev
Operating flow 285 L/min
Mechanical brake torque 1010.8 N・m min.
Brake off pressure 3.1 MPa max.
Relief valve set pressure 30.4 MPa
Swing reduction gear
Reduction gear type Planetary gear 2-stage reduction gear
Reduction ratio 27.143
Dry weight 437 kg
Turntable bearing
No. of teeth 92
Weight 540 kg
Counterweight
Weight 6400 kg
84402832 NA - May 2011

1002B-5
Engine-related
Engine
Sumitomo part No. KSH11600
Engine model name Isuzu 6HK1X diesel engine
4-cycle, water-cooled, overhead camshaft type, common rail system
Engine type (electronic control), cooled EGR, with turbocharger (variable displace-
ment type), DPD system
No. of cylinders - bore - stroke 6 - D115 mm - 125 mm
Total displacement 7.79 L
Compression ratio 17.5
Rated output 198 kW/1900 min-1
Maximum torque 1043 N·m/about 1500 min-1
Fuel consumption ratio 221 - 241 g/kW·h at 1900 min-1
Engine dry weight About 640 kg
Engine dimension L 1388 - W 1047 - H 1194 mm
Cooling fan D850 mm - suction type - 6 vanes, plastic and steel
With bell mouth-type fan guide
Pulley ratio 0.9 (reduction)
Charging generator 24 V 50 A AC type
Starter motor 24 V 5 kW reduction type
Coolant capacity 14.5 L
Oil pan capacity Max: 46 L Min: 36 L (not including oil filter)
Direction of rotation Right (viewed from fan side)
Compliant with JISD 0006-2000.
DPD
Manufacturer Isuzu Motors, Ltd.
Weight 38 kg
Air Cleaner (double element)

Manufacturer Nippon Donaldson, Ltd.
Element (outer)
Element (inner)
Weight 13 kg
Radiator
Manufacturer Tokyo Radiator MFG. Co.,Ltd.
Oil cooler Weight 39.0 kg
Oil volume 12.9 L
Radiator Weight 11.9 kg
Coolant capacity 9.4 L
Air cooler Weight 12.6 kg
Capacity -
Fuel cooler Weight 1.0 kg x 2
Capacity 0.3 L x 2
Total weight 159 kg
84402832 NA - May 2011

1002B-6
Hydraulic Device
Hydraulic Pump
Main pump
Pump type Double variable displacement piston pump
Displacement capacity 150 x 2 cm3/rev
Operating pressure Rated 34.3 MPa
Maximum 37.3 MPa
Input revolution speed 1900 min-1
Maximum discharge flow 289 x 2 L/min (at Pd = 3.0 MPa. 1900 min-1)
285 x 2 L/min (at Pd = 8.0 MPa. 1900 min-1)
Pilot pump
Pump type Gear pump
Displacement capacity 15 cm3/rev
Maximum discharge flow 28.5 L/min (at 1900 min-1)
Control method Hydraulic simultaneous constant output control
Maximum flow adjustment control through external com-
mands (negative control)
Maximum flow adjustment control through external com-
mand milli-amp (negative control, front side)
Setting horsepower adjustment control through external
command milli-amp
Dry weight 188 kg
84402832 NA - May 2011

1002B-7
Control-related
Control Valve
STD (with 2nd option add-on valve)
Manufacturer KYB Corporation
Maximum flow 285 L/min (at 1900 min-1)
Overload set pressure 27.4 MPa boom down
39.2 MPa boom up, arm, bucket
22.6 MPa attachment 2
Main relief set pressure 34.3 MPa
(at boosting) 37.3 MPa
Foot relief set pressure 2.55 MPa
Function Straight travel circuit
Boom-up/arm 2 pumps internal flow
Boom and arm load holding circuit
Boom-down regenerative circuit
Bucket-close regenerative circuit
Arm-in forced regenerative circuit
Swing priority variable orifice
2 pumps flow (external flow merging)
Weight 199 kg 215 kg
Solenoid Valve (4 stack)

Manufacturer Yuken Kogyo Co., Ltd.
Valve specifications
Maximum flow P → B 20 L/min Other 5 L/min
Rated pressure 4.5 MPa
Port size G3/8 P.T.B. port
G1/4 C1, C2, C3, C4, C5 ports
Solenoid specifications
Operating voltage DC 20 - 32 V
Power consumption 17 W max.
Weight 5 kg
84402832 NA - May 2011

1002B-8
Remote Control Valve (left/right, travel operations)

Remote Control Valve for Left/Right Operations
Secondary pressure 0.64 - 2.45 MPa primary short type
Operating 1, 3 port 19°
2, 4 port 25°
Weight 1.9 kg
Remote Control Valve for Travel Operations

Secondary pressure 0.64 - 2.45 MPa primary short type
Operating angle 12.4°
Weight 5.5 kg
Remote Control Valve Characteristic Diagram

Operation Remote Control Valve Control Diagram
Ports 1, 3
Secondary pressure [MPa]
Push rod stroke [mm]
Operating angle [deg.]
Secondary pressure
1
84402832 NA - May 2011

1002B-9
Ports 2, 4
Operating angle [deg.]
Secondary pressure
1
Travel Remote Control Valve Control Diagram
Pedal operating angle [deg.]
Secondary pressure
1
84402832 NA - May 2011
1002B-10
Cushion Valve (heat circuit, with shuttle valve)

Manufacturer Yanagisawa Seiki MFG. Co., Ltd.
Port size G 3/8 (A - P ports)
G 1/4 (Q - V ports)
Weight 12.5 kg
Center Joint
Operating pressure High-pressure passage (ABCD) 34.3 MPa
Drain port (T) 1.0 MPa
Pilot port (P) 3.9 MPa
Flow High-pressure passage (ABCD) 360 L/min
Drain port (T) 40 L/min
Pilot port (P) 31 L/min
Port A Forward right G1
Port B Forward left G1
Port C Backward right G1
Port D Backward left G1
Port T Drain port G1/2
Port P Pilot port G1/4
Weight 55.5 kg
Backhoe Attachment
Cylinder
Boom Cylinder
Cylinder bore D145 mm
Rod diameter D100 mm
Maximum retracted length 2090 mm
Stroke 1495 mm
Weight 279 kg
Arm Cylinder
Stroke 1748 mm
Weight 462 kg
Bucket cylinder
Stroke 1210 mm
Weight 276 kg
84402832 NA - May 2011

1002B-11
84402832 NA - May 2011

1002B-12
Section
1002C
Main Unit Weight
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Main Unit Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Divided Weight (standard specifications) CX350C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Stand Alone Part Weight (CX350C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Shoe Weight (per side) CX350C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Arm Weight (CX350C). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1002C-1 PRINTED IN FRANCE
Main Unit Weight
Main Unit Weight

Divided Weight (standard specifications) CX350C
Weight
Code Component name
(kg)
A Operating weight 34700
Upper component (including counterweight and turntable
B 15370
bearing)
C Counterweight 6420
D Lower component (with grouser shoe) 12290
E Main unit weight 27700
F Attachments 7000
G Boom (including cylinders) 3920
H Arm (including cylinders and linkage) 1800
84402832 NA - May 2011

1002C-3
Main Unit Weight
* The weights displayed are approximate weights.
Stand Alone Part Weight (CX350C)

Component name Weight (kg)
Nabtesco 505
1 Travel unit
KYB 500
2 Take-up roller 165
3 Upper roller 43
4 Lower roller 61
5 Swing unit 467
6 Turntable bearing 541
7 Engine 785
8 Radiator 187
9 Hydraulic pump 222
10 Fuel tank 244
11 Hydraulic oil tank 203
12 Control valve 211
13 Center joint 58
Standard 2427
14 Boom
HD 2720
Shoe Weight (per side) CX350C

1 600mm grouser shoe 2220
Arm Weight (CX350C)

1 Standard arm 1112
2 Ultra-short Arm 1102
3 Short Arm 1209
4 Long Arm 1447
84402832 NA - May 2011

1002C-4
Section
1002D
Maintenance Standards
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Drive Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Take-up Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Track Shoe (grouser shoe) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Attachment (backhoe) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1. Boom and Swing Frame Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2. Boom Cylinder and Swing Frame Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3. Boom and Boom Cylinder Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4. Boom and Arm Cylinder Installation Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5. Boom and Arm Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6. Arm and Arm Cylinder Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7. Arm and Bucket Cylinder Installation Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
8. Arm and Arm Link Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
9. Bucket and Bucket Link Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
10. Bucket Link and Bucket Cylinder Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
11. Bucket and Arm Installation Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Inspection Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
For Drive Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
For Take-up Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
For Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
For Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1002D-1 PRINTED IN FRANCE
Drive Sprocket
* See the gauge list for measurement gauges.
Measurement di- Standard Usage

Part name Code mensions value limit Judgment Solution
(mm) (mm) (mm)
a Acceptable/
83 73
Unacceptable
Acceptable/
b D D660.7 D650.7
Unacceptable
c Acceptable/
D D748 D738
Unacceptable Cladding by welding
Drive sprocket
Acceptable/ or replacement
d D D732.5 -
Unacceptable
e Acceptable/
40 45
Unacceptable
p - Acceptable/
215.9
Unacceptable
84402832 NA - May 2011

1002D-3
Take-up Roller

(mm) (mm) (mm)
a - Acceptable/
D D560
Unacceptable
Acceptable/ Cladding by welding
Take-up roller b 22.5 25.5
Unacceptable or replacement
c Acceptable/
102 100
Unacceptable
Acceptable/
Shaft d D D85 D84 Replacement
Unacceptable
Acceptable/
d D D85 D86
Unacceptable
Bushing Replacement
e Acceptable/
82 81
Unacceptable
Acceptable/
Hub f 24 23.6 Replacement
Unacceptable
84402832 NA - May 2011

1002D-4
Upper Roller

(mm) (mm) (mm)
a Acceptable/
D D150 D138
Unacceptable
- Acceptable/ Cladding by welding
Carrier roller b 15
c - Acceptable/
104
Unacceptable
Acceptable/
Shaft d D D65 D64 Replacement
Unacceptable
Acceptable/
Bushing d D D65 D66 Replacement
Unacceptable
e Acceptable/
Bushing 69 68 Replacement
Unacceptable
Acceptable/
Thrust plate f 9 8.5 Replacement
Unacceptable
g - Acceptable/
Cover 15 Replacement
Unacceptable
84402832 NA - May 2011

1002D-5
Lower Roller
Standard
Measurement di- Usage
Part name Code value Judgment Solution
mensions (mm) limit (mm)
(mm)
a Acceptable/
D D180 D168
Unacceptable
Track roller b 25 20
Acceptable/
d 216 224
Unacceptable
e Acceptable/
Shaft D D75 D74 Replacement
Unacceptable
e Acceptable/
D D75 D76
Unacceptable
Bushing Replacement
Acceptable/
f D82 D81
Unacceptable
g Acceptable/
Collar 17.5 17.0 Replacement
Unacceptable
84402832 NA - May 2011

1002D-6
Track Shoe (grouser shoe)

(mm) (mm) (mm)
a Acceptable/
Shoe plate 49 34 Replacement
Unacceptable
Link b 129 123
c Acceptable/
D D71.4 D67.4
Unacceptable
Master bushing Replacement
- Acceptable/
d D D47.9
Unacceptable
e - Acceptable/
Master pin D D47.3 Replacement
Unacceptable
Acceptable/
f 216.2 220.7
Link pitch Unacceptable
Replacement
4 linked sections Acceptable/
f' 864.6 882.6
Unacceptable
Acceptable/
c' D D71.4 D67.4
Unacceptable
Track bushing Replacement
- Acceptable/
d' D D48.4
Unacceptable
- Acceptable/
Track pin e' D D47.6 Replacement
Unacceptable
84402832 NA - May 2011

1002D-7
Attachment (backhoe)
84402832 NA - May 2011

1002D-8
1. Boom and Swing Frame Installation Section
Measurement di- Standard Usage lim-

Part name Code mensions value its Judgment Solution
(mm) (mm) (mm)
a Acceptable/ -
Swing frame 861.5 869.5
Unacceptable
Acceptable/
Boom b 857 855 Replacement
Unacceptable
c Shim ad- Acceptable/ Adjustment with
Clearance 1 mm max.
justment Unacceptable shims
Acceptable/
Pin d D D110 D109 Replacement
Unacceptable
e Acceptable/
Bushing (boom) D D110 D111.5 Replacement
Unacceptable
84402832 NA - May 2011

1002D-9
2. Boom Cylinder and Swing Frame Installation Section

(mm) (mm) (mm)
a Acceptable/ -
Swing frame 131 137
Unacceptable
Boom cylinder Acceptable/
b 130 128 Replacement
(foot section) Unacceptable
Clearance 1.0 - 2.5
Acceptable/
Unacceptable
Bushing e Acceptable/
D D90 D91.5 Replacement
(boom cylinder) Unacceptable
84402832 NA - May 2011

1002D-10
3. Boom and Boom Cylinder Installation Section

(mm) (mm) (mm)
Boom cylinder a Acceptable/
123 121 Replacement
(top section) Unacceptable
Acceptable/
Boom b 669 665 Replacement
Unacceptable
c 1.2 mm Shim ad- Acceptable/ Adjustment with
Clearance
max. justment Unacceptable shims
Acceptable/
Unacceptable
(boom cylinder) Unacceptable
84402832 NA - May 2011

1002D-11
4. Boom and Arm Cylinder Installation Section

(mm) (mm) (mm)
a Acceptable/
Boom 146 152 Replacement
Unacceptable
Arm cylinder Acceptable/
(foot section) Unacceptable
Clearance
Acceptable/
Unacceptable
(arm cylinder) Unacceptable
84402832 NA - May 2011

1002D-12
5. Boom and Arm Installation Section

(mm) (mm) (mm)
a Acceptable/
Boom 392 395 Replacement
Unacceptable
Acceptable/
Arm b 387.7 385.7 Replacement
Unacceptable
Clearance 1 mm max.
Acceptable/
Unacceptable
e Acceptable/
Bushing (arm) D D115 D116.5 Replacement
Unacceptable
Acceptable/
Boom f D D115 D116.5 Replacement
Unacceptable
g Acceptable/
Boom 89 87.5 Replacement
Unacceptable
84402832 NA - May 2011

1002D-13
6. Arm and Arm Cylinder Installation Section

(mm) (mm) (mm)
a Acceptable/
Arm 146 152 Replacement
Unacceptable
Arm cylinder Acceptable/
Clearance 0.5 - 3.0
Acceptable/
Unacceptable
(arm cylinder) Unacceptable
84402832 NA - May 2011

1002D-14
7. Arm and Bucket Cylinder Installation Section

(mm) (mm) (mm)
a Acceptable/
Arm 146 152 Replacement
Unacceptable
Bucket cylinder (foot Acceptable/
section) Unacceptable
Clearance
Acceptable/
Unacceptable
(bucket cylinder) Unacceptable
84402832 NA - May 2011

1002D-15
8. Arm and Arm Link Installation Section

(mm) (mm) (mm)
a Acceptable/
Arm link 50 48 Replacement
Unacceptable
Acceptable/
Arm b 375 373 Replacement
Unacceptable
Clearance
Acceptable/
Unacceptable
e Acceptable/
Bushing (arm) D D85 D86.5 Replacement
Unacceptable
84402832 NA - May 2011

1002D-16
9. Bucket and Bucket Link Installation Section

(mm) (mm) (mm)
a Acceptable/
Bucket 401 406 Replacement
Unacceptable
Acceptable/
Bucket link b 400 398 Replacement
Unacceptable
Clearance 1.0 - 3.5
Acceptable/
Unacceptable
(bucket link) Unacceptable
84402832 NA - May 2011

1002D-17
10. Bucket Link and Bucket Cylinder Installation Section

(mm) (mm) (mm)
a Acceptable/
Arm link 50 48 Replacement
Unacceptable
Acceptable/
Bucket link b 375 373 Replacement
Unacceptable
Clearance
Acceptable/
Bucket link d 121 123 Replacement
Unacceptable
Bucket cylinder e Acceptable/
120 118 Replacement
Shim ad- Acceptable/ Adjustment with
Clearance f 1.0 - 2.0
g Acceptable/
Pin D D105 D104 Replacement
Unacceptable
Bushing Acceptable/
h D D105 D106.5 Replacement
(bucket link) Unacceptable
Bushing Acceptable/
i D D105 D106.5 Replacement
(bucket cylinder) Unacceptable
84402832 NA - May 2011

1002D-18
11. Bucket and Arm Installation Section

(mm) (mm) (mm)
a Acceptable/
Bucket 401 406 Replacement
Unacceptable
Acceptable/
Arm b 400 398 Replacement
Unacceptable
Clearance
Acceptable/
Bushing (bucket) d 16 7 Replacement
Unacceptable
e Acceptable/
Pin D D90 D89 Replacement
Unacceptable
Acceptable/
Bushing (arm) f D D90 D91.5 Replacement
Unacceptable
g Acceptable/
Bushing (bucket) D D90 D91.5 Replacement
Unacceptable
84402832 NA - May 2011

1002D-19
Inspection Gauge
For Drive Sprocket
84402832 NA - May 2011

1002D-20
For Take-up Roller
84402832 NA - May 2011

1002D-21
For Upper Roller
84402832 NA - May 2011

1002D-22
For Lower Roller
84402832 NA - May 2011

1002D-23
84402832 NA - May 2011

1002D-24
Section
1002E
Bolt Size and Torque Table
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Special Torque Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1002E-1 PRINTED IN FRANCE
Special Torque Settings

Bolt nominal Tightening
Code Retightening location Wrench
diameter torque [N•m]
1* Travel motor M24 36 mm 900 - 1051
2* Drive sprocket M20 30 mm 521 - 608
3* Take-up roller M16 24 mm 267 - 312
4* Upper roller M20 30 mm 521 - 608
5* Lower roller M24 36 mm 902 - 1049
6* Track guard M24 36 mm 902 - 1049
7 Shoe M24 32 mm 1236 - 1510
8 Counterweight M33 50 mm 1862 - 2058
9* Turntable bearing M24 36 mm 900 - 1050
10* Swing unit M24 36 mm 900 - 1050
11* Mount M20 30 mm 289 - 337
12* Engine Front bracket M10 17 mm 64 - 73
13* Rear bracket M12 19 mm 109 - 127
14* Radiator M16 24 mm 147 - 176
15* Flange M10 17 mm 64 - 73
Hydraulic pump 17 mm
16* Pump M20 hexagon 367 - 496
socket head
17* Hydraulic oil tank M16 24 mm 233 - 276
18* Fuel tank M16 24 mm 233 - 276
19* Control valve M16 24 mm 267 - 312
20* Lock bar M16 24 mm 267 - 312
Center joint
21* Joint M12 19 mm 109 - 127
22 Cab M16 24 mm 149 - 173
23 Battery M10 17 mm 20 - 29
CAUTION
For items marked with *, always apply Loctite #262 or the equivalent and tighten to the specified torque.
The tightening torque in kgf•m is determined with N•m ÷ 9.8.
The tightening for bolts and nuts not otherwise specified in the table above is as follows.
Bolt nominal diameter (size) M6 M8 M10 M12 M14 M16 M18 M20
Wrench [mm] 10 13 17 19 22 24 27 30
Hexagon bolt Tightening
[N・m] 6.9 19.6 39.2 58.8 98.1 156.9 196.1 294.2
torque
Wrench [mm] 5 6 8 10 12 14 14 17
Hexagon socket head
bolt Tightening
[N・m] 8.8 21.6 42.1 78.5 117.7 176.5 245.2 343.2
torque
84402832 NA - May 2011

1002E-3
84402832 NA - May 2011

1002E-4
84402832 NA - May 2011

1002E-5
84402832 NA - May 2011

1002E-6
Section
1002F
Overall View
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
CX350C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Standard Arm (3.25 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Short Arm (2.63 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Long Arm (4.04 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Ultra-short Arm (2.21 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1002F-1 PRINTED IN FRANCE
Overall View
CX350C
Standard Arm (3.25 m)
Note: 1. Numbers are subject to change without notice due to design change or other reason.
Note: 2. The diagrams give values that include the shoe lug height (a) (36 mm).
84402832 NA - May 2011

1002F-3
Overall View
Short Arm (2.63 m)

84402832 NA - May 2011

1002F-4
Overall View
Long Arm (4.04 m)

84402832 NA - May 2011

1002F-5
Overall View
Ultra-short Arm (2.21 m)

84402832 NA - May 2011

1002F-6
Section
1003
List of special tools
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Tools to purchase or to make locally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Travel Motor Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CX350C/CX370C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Take-up Roller Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CX350C/CX370C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Upper Roller Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
CX350C/CX370C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Lower Roller Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CX350C/CX370C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Grease Cylinder Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Jig Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Center Joint Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CX350C/CX370C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Swing Motor Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CX350C/CX370C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Remote Control Valve Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CX350C/CX370C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Gas Filling Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CX250C/CX350C/CX370C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
CASE SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Isuzu Engine Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4HK1X-6HK1X Tier 4 Isuzu Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Attachment Special Tool (for Cylinder Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Special Jigs Part Number List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
CNH-EST DIAGNOSTIC TOOL (SCAN TOOL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Tools to purchase or to make locally

Note: Dimensions in the drawings are shown in mm
Travel Motor Special Tool
CX350C/CX370C
Code Order No. Jig name Remarks

1 Holder fitting
2 Rear cover guide pin
3 Brake piston removal jig
Shim thickness adjust-
4 No diagram
ment jig
5 Oil seal insertion jig
Rear bearing insertion
6
jig
84402832 NA - May 2011

1003-3

7 Brake piston insertion jig
Piston and shoe mea- When the rear cover bolts are used as is: D1: 2-20 drill, D2: 10 - Plain
8
surement jig flat washer with rounded finish 18 mm
84402832 NA - May 2011

1003-4

*1: Welding (8 loca-
9 Motor assembly pedestal
tions)
Snap ring removal and installa-
10
tion (removal) jig
Ball bearing removal and instal-
11
lation jig
84402832 NA - May 2011

1003-5

Holder A subassembly
12
lifting jig
Holder B subassembly
13
lifting jig
84402832 NA - May 2011

1003-6

*1: Socket head bolt (1)
Holder C subassembly lift- *2: M10 nut (1)
14
ing jig *3: JIS B1354 Type A equiv-
alent (2)
Motor assembly disassem-
15
bly and assembly rod
16 Angular bearing press-fit jig
84402832 NA - May 2011

1003-7
84402832 NA - May 2011

1003-8

*1: 4 - M6 x 1.0
equipartition
*2: 4 - 7 mm
17 Floating seal press-fit jig 1
equipartition
*3: 4 - 11 mm
equipartition
*1: 4 - M6 x 1.0
equipartition
*2: 4 - 11 mm
equipartition
*3: 4 - 7 mm
equipartition

20 Oil seal press-fit jig
84402832 NA - May 2011
1003-9

21 Bearing press-fit jig
M12 x 1.75 x L45 socket head
22
bolt
84402832 NA - May 2011

1003-10
Take-up Roller Special Tool

CX350C/CX370C

1 Bushing removal jig
2 Bushing press-fit jig
3 Floating seal installation jig
84402832 NA - May 2011

1003-11
Upper Roller Special Tool

CX350C/CX370C

2 Bushing press-fit jig 1
3 Bushing press-fit jig 2
84402832 NA - May 2011

1003-12
Lower Roller Special Tool

CX350C/CX370C

2 Bushing press-fit jig
84402832 NA - May 2011

1003-13
Grease Cylinder Special Tool

Jig Dimension Diagram
A Dust seal press-fit jig

B Removal jig
84402832 NA - May 2011

1003-14
Center Joint Special Tool

CX350C/CX370C
Axle removal jig
a Axle removal jig Hexagon socket head bolt (7)

*4
M10 x 25
M16 - M20 full threaded bolt Backing plate
*1 Axle (1) outer diameter - about
L = 370 - 420 mm *5
*2 M16 - M20 female thread 5 mm
t = about 5 mm
Cover (9) installation dimen-
*3
sions
Removal jig (for O-ring and

b
V-ring)
84402832 NA - May 2011

1003-15
Swing Motor Special Tool

CX350C/CX370C

1 Oil seal assembly jig
2 Pinion shaft assembly jig
84402832 NA - May 2011

1003-16

84402832 NA - May 2011

1003-17
Remote Control Valve Special Tool

CX350C/CX370C
a Detailed diagram of jig main

unit
b Joint installation state
c Detailed diagram of bushing
*1 SCM415N carburized *4 Hole *7 Bushing

*2 S45C *5 Shaft *8 2
*1 and *2 are inserted by tight-
*3 Bolt width *6
ening.

Joint disassembly
1
jig
84402832 NA - May 2011
1003-18
Center hole possible (φ 2 or

*1
less)

Special jig 1 (for bushing
2
removal)
84402832 NA - May 2011

1003-19
Gas Filling Special Tool

CX250C/CX350C/CX370C
Code Jig name Remarks

1 Gauge manifold
2 Charging hose
3 Quick joint 27.5
4 Quick joint 23.5
5 T joint
6 Service can valve
7 Vacuum pump adapter
84402832 NA - May 2011

1003-20
Hydraulic Circuit
Vacuum pump and power sup-

Wrenches (17, 19, 24, 27 x 2,
1 ply 5 9 Recording sheet
32, 36 x 2)
(for vacuum pump)
2 Pressure gauge (10 MPa-1) 6 Rag 10 Pen
3 Pressure gauge (60 MPa-2) 7 Extension cable 11 Cleaning fluid
Hexagon wrench (8 mm, 6 Hydraulic oil tank lid
4 8
mm) (for vacuum pump)
84402832 NA - May 2011

1003-21
CASE SPECIAL TOOLS

Isuzu Engine Special Tools
4HK1X-6HK1X Tier 4 Isuzu Engine
Illustration Isuzu Reference CASE Tool Number Description
8-9439-6856-0 380001712 Oil seal setting tool kit
5-8840-2627-0 380001719 Oil seal Installer
5-8840-2623-0 380001720 Remover; Nozzle sleeve
5-8840-2624-0 380001721 Installer; Nozzle sleeve
5-8840-2626-0 380001722 Installer; Bridge guide
5-8840-2360-0 380002574 Slinger puller
5-8840-2826-0 380002601 Fuel Injector Remover
5-8840-0019-0 380002602 Sliding Hammer
84402832 NA - May 2011

1003-22
5-8840-2222-0 380002604 Sealing cup Installer
5-8840-9061-0 380002611 Oil seal installer kit
5-8840-2675-0 (5-8531-
380002626 Compression Gauge (adapter)
7002-0)
8980131700 380002630 Main filter wrench
5-8840-0266-0 380300009 Angle gauge
5-8840-2625-0 380300013 Installer; Valve guide oil seal
5-8840-2628-00 380300014 Remover/Installer; Valve guide
5-8840-2815-0 380300015 Compression Gauge Adaptor
8–9439–6818–0 Common tool Crankshaft gear puller
84402832 NA - May 2011

1003-23
8–9439–6819–0 380002613 Crankshaft gear installer
5-8840–9018–0 380300022 Piston setting tool
1-8522–1029–0 380300005 Piston ring setting tool
5-8840-2835-0 Common Probes Connector test adapter kit
5-8840-2621-0 Common Tool Remover; Valve spring
Digital multimeter with an input

Not Illustrated 5-8840-2691-0 Common Tool
impedance of 10MΩ
5-8840-2674-1 Not needed Scissors gear spring wrench
8-9439-6862-0 Not needed Pivot ASM
84402832 NA - May 2011

1003-24
Attachment Special Tool (for Cylinder

Assembly)
Special Jigs Part Number List
• Select jigs for the cylinder head according to the rod diameter.
• Select jigs for the piston according to the cylinder bore.
CASE Tool
Description (applicable rod diameter in mm) Illustration
Number
KHV0511 Cylinder head assembly and disassembly jig (65)
CASE Tool
Description (applicable cylinder bore diameter in mm) Illustration
Number
KHV0526 Seal ring insertion and calibration jig (100)
84402832 NA - May 2011

1003-25
CNH-EST DIAGNOSTIC TOOL (SCAN

TOOL)
The EST (Electronic Service Tool) system allows diag-
noses on machines and engines by detecting the oper-
ating parameters of electronic control components (con-
trol units, sensors etc.). It is also capable of reading fault
codes.
To use this tool, please refer to the book provided during
the CXC series training sessions.
Y-Cable 380060269 is required to connect the EST to the
controllers.
84402832 NA - May 2011

1003-26
Section
1004
FLUIDS AND LUBRICANTS
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
HYDRAULIC FLUID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Conditions applicable to diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
RECOMMENDED CONDITIONS THAT CAN BE APPLIED TO DIESEL FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Lubricants must have the correct properties for each application.

IMPORTANT:
The conditions of use for individual fluids and lubricants must be respected.
HYDRAULIC FLUID
CASE/AKCELA hydraulic fluid is specially designed for high pressure applications and for the CASE hydraulic system.
The type of fluid to be used depends on the ambient temperature.
ENGINE OIL
The "CASE Tutela LE ENGINE OIL" is recommended for
your engine. This oil ensures correct lubrication of your
engine in all working conditions.
If the "CASE Tutela LE ENGINE OIL" cannot be obtained,
use the oil corresponding to one of the following cate-
gories:
API CJ-4.
ACEA E6.
FUEL
IMPORTANT:
The fuel must conform to Interim Tier 4/Stage 3B Ex- EPA regulation ultra low sulfur fuel only.
haust Gas Control Regulations.
Use grade number 2-D (S15) fuel. IMPORTANT:
Using other types of fuel may lead to stalled engine out- If a serious problem occurs when other fuels are used,
put or deterioration in fuel economy. the warranty is invalidated.
During cold weather (lower than -7℃), it is temporarily
acceptable to use a mixture of No. 1-D (S15) and No. Using a non-recommended fuel may lead to damage of
2-D (S15). the fuel injection pump, injector, DPD, and other fuel
Consult the fuel supplier or the CASE dealer. supply systems or to the engine.
If the temperature drops below the fuel cloud point, out- CASE assumes no responsibility for these damages.
put deficiency or engine start problems may occur due Note that the warranty will not be applied for these dam-
to wax crystals. ages.
It is recommended that the following safety information
Conditions applicable to diesel fuel be considered in order to prevent damage to the engine
fuel supply system.
The diesel fuel used must:
- Some fuel suppliers mix old engine oil and diesel fuel.
- be free from dust particles, even minute ones,
- have the proper viscosity, Makers of larger engine permit the use of this kind of
- have a high cetane number, fuel.
- present great fluidity at low temperatures, However, do not use diesel fuel contaminated with en-
- have low sulphur content, gine oil in customer's engines.
- have very little residual carbon. Not only will this fuel damage the engine, it may also
have a negative impact on the exhaust gas purification
RECOMMENDED CONDITIONS function.
Before using diesel fuel, confirm with the supplier
THAT CAN BE APPLIED TO whether the fuel complies with the above specifications.
DIESEL FUEL IMPORTANT:
Consult the supplier or the CASE dealer regarding ap-
- JIS (Japanese Industrial Standards): No. 2 propriate use of fuel additives.
- DIN (Deutsche Industrie Normen): DIN 51601 Do not use fuel oil or gasoline as these may damage the
- SAE-J-313C: SAE (Society of Automotive Engineers) engine.
based on No. 2-D (S15)
- BS (British Standards) based on BS/2869-1970: Class IMPORTANT:
A-1 In order to prevent condensation during cold weather, fill
- EN 590 (less than 10 ppm sulfur) the fuel tank to full after the completing the day's work.
- Or fuel specified by the country using these standards
and this machine
84402832 NA - May 2011

1004-3
84402832 NA - May 2011

1004-4
Section
1005
Conversion Table
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Metric to U.S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
U.S to Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Conversion Table
Metric to U.S
MULTIPLY BY TO OBTAIN
square meter 10.763 91 square foot
AREA:
hectare 2.471 05 acre
newton 3.596 942 ounce force
FORCE:
newton 2.224 809 pound force
millimeter 0.039 370 inch
LENGTH: meter 3.280 840 foot
kilometer 0.621 371 mile
MASS: kilogram 2.204 622 pound
MASS/AREA: kilogram/hectare 0.000 466 ton/acre
MASS/ENERGY: gr/kW/hr. 0.001 644 lbs/hp/hr.
MASS/VOLUME: kg/cubic meter 1.685 555 lb/cubic yd.
POWER: kilowatt 1.341 02 horsepower
kilopascal 0.145 038 lb/sq. inch
PRESSURE: bar 14.50385 lb/sq. inch
megapascal (MPA) 145.0385 psi
TEMPERATURE: degree C 1.8 x C +32 degree F
newton meter 8.850 748 lb/inch
TORQUE:
newton meter 0.737 562 lb/foot
VELOCITY: kilometer/hr 0.621 371 miles/hr.
cubic centimeter 0.061 024 cubic inch
cubic meter 35.314 66 cubic foot
cubic meter 1.307 950 cubic yd.
milliliter 0.033 814 ounce (US fluid)
VOLUME: quart (US liquid)
litre 1.056 814
litre 0.879 877 quart (Imperial)
litre 0.264 172 gallon (US liquid)
litre 0.219 969 gallon (Imperial)
litre/min. 0.264 172 gallon/min. (US liquid)
VOLUME/TIME:
litre/min 0.219 969 gallon/min. (Imperial)
84402832 NA - May 2011

1005-3
Conversion Table
U.S to Metric
MULTIPLY BY TO OBTAIN
square foot 0.092 903 square meter
AREA:
acre 0.404 686 hectare
ounce force 0.278 014 newton
FORCE:
pound force 4.448 222 newton
inch 25.4 millimeter
LENGTH: foot 0.304 8 meter
mile 1.609 344 kilometer
pound 0.453 592 kilogram
MASS: gram
ounce 28.35
MASS/AREA: ton/acre 2241 702 kilogram/hectare
MASS/ENERGY: lbs/hp/hr. 608.277 4 gr/kW/hr.
MASS/VOLUME: lb/cubic yd. 0.593 276 kg/cubic meter
POWER: horsepower 0.745 700 kilowatt
lb/sq. inch 6.894 757 kilopascal
PRESSURE: lb/sq. inch 0.069 bar
psi lb/sq. inch 0.070 303 kg/sq. cm
psi 0.006 895 megapascal (Mpa)
TEMPERATURE: degree F 1.8 F - 32 degree C
lb/inch 0.112 985 newton meter
TORQUE:
lb/foot 1.355 818 newton meter
VELOCITY: miles/hr. 1.609 344 kilometer/hr
cubic inch 16.387 06 cubic centimeter
cubic foot 0.028 317 cubic meter
cubic yd. 0.764.555 cubic meter
ounce (US fluid) 29.573 53 milliliter
VOLUME: quart (US liquid) 0.946 353 litre
quart (Imperial) 1.136 523 litre
gallon (US) 3.785 412 litre
gallon (Imperial) 4.546 092 litre
VOLUME/TIME: gallon/min. 3.785 412 litre/min.
84402832 NA - May 2011

1005-4
Section
1900
Abbreviations
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Abbreviations
Abbreviations
Abbreviation description
AC air conditioner
A/D analog/digital
ABDC after bottom dead center
AC alternating current
ACC accessory
ACG alternating current generator
ACT actuator
API american petroleum industry
ASM assembly
ATDC after top dead center
ATF automatic transmission fluid
drilled head B drilled head bolt
eye B eye bolt
full threaded B full threaded bolt
hexagon socket head B hexagon socket head bolt
high-strength B high-strength bolt
reamer B reamer bolt
B+ battery + terminal
BAT battery
BBDC before bottom dead center
BKT bracket
BRG bearing
BTDC before the top dead center
C/B circuit breaker
C/U control unit
CAL calibration
CAN a control unit communication method (control area network)
CFG config
CHK check
CKP crankshaft position
CMP camshaft position
CO carbon monoxide
CPU central processing unit
DC direct current
DI direct injection type
DIAG diagnosis
DLC data link connector
DMM digital multi–meter
DPD diesel particulate diffuser
DTC self-diagnosis code
ECM engine control module
ECT engine coolant temperature
ECU electronic control unit
EEPROM electrically erasable/programmable ROM
EGR exhaust gas recirculation
EMI electromagnetic interference
EMPS engine module programing system
ENG engine
EPF engine protection feature
EVRV electric vacuum regulating valve
EXH exhaust
F/B feedback
F/C fuel cut
F/L fusible link
FLW fusible link wire
FRT front
84402832 NA - May 2011
1900-3
Abbreviations
FT fuel temperature
FWD front
GEN generator
GND ground
HBCV hose burst check valves
HC hydrocarbon
HO2S superheat O2 sensor
HR hour
HRD high reach
IAC idle air control
IAT intake air temperature
IC integrated circuit
ID Plate ID plate (Name plate)
IMT intake manifold temperature
INL intake
INJ injection
ISO international organization for standardization
ISP intake shutter position
ITP intake throttle position
J/C joint connector
JIS japan Industrial Standard
KW a communication method (Keyword)
LED light emitting diode
LH left
LLC long life coolant
LM lifting magnet
M/V electromagnetic valve
MAF mass air flow
MAP manifold air pressure
Max maximum
MIL warning light (diagnostic)
milli-amp milli-amperage
Min minimum
MPU micro processing unit
high-strength N high-strength nut
NC normally closed
NO normally open
NOx nitrogen oxide
N-TDC top dead center revolution speed
PM particle material
O2S O2 sensor
OBD on-board diagnosis
OEM original equipment manufacturer
OPT option
OT oil temperature
P/L pilot light
PCV pump control valve/positive crankcase ventilation
P-I proportion-integration
PM particle material
PTO power take-off
PWM pulse width modulation wave
QOS quick on start system
QWS quick warming up system
R/L relay
RAM RAM (random access memory)
REF reference
RH right
ROM ROM (read only memory)
84402832 NA - May 2011

1900-4
Abbreviations
RP rail pressure
Rr rear
RWD rear
flush head S flush head screw
phillips pan head S phillips pan head screw
truss head S truss head screw
subassembly sub assembly
SAE society of atomotive engineers
SBF slow blow fuse
SCV suction control valve
SIG signal
SLD shield
SP pin special pin
ST starter/start
STD standards
SW switch
TDC top dead center
TEMP temperature
TP throttle position
TEMP temperature
UART universal asynchronous receiver transmitter
VB battery voltage
VGS Turbo variable geometry system turbo
high-strength W high-strength washer
toothed W toothed washer
W/H wire/harness
W/L warning light
W/S weld splice
WOT wide open throttle
84402832 NA - May 2011

1900-5
Abbreviations
84402832 NA - May 2011

1900-6
Section
2000
Removal and Installation of Engine Assembly
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

WARNING Removal of Engine Assembly

• Keep away from fire. 1. Drain the engine oil.(For details, see "Engine Oil
• Be sure to release hydraulic pressure before Replacing".)
beginning work. 2. Drain the coolant from the radiator.(For details, see
• The air conditioner circuit is filled with high- "Removal and Installation of Radiator".)
pressure gas, so there is the danger of gas 3. Remove the engine hood.(For details, see "Re-
spraying out when loosening lines. moval and Installation of Engine Hood".)
• Do not use open flames and do not allow 4. Remove the hydraulic pump.(For details, see "Re-
sparks near the battery. moval and Installation of Hydraulic Pump".)
5. Use a wrench (13 mm) to remove the 3 bolts (1).
CAUTION
• Be sure to stop the engine before beginning
work.
• Be sure to inspect the wire rope and other
lifting equipment before beginning work.
• Do not stand or pass under the suspended
load.
Items to prepare
• Wrenches (7 mm, 8 mm, 13 mm, 17 mm, 19 mm, 36
mm)
• Box wrench (30 mm)
• Shackle (with the required lifting capacity) x 2
• Wire ropes (with the required breaking load)
• Liftcrane (with the required lifting capacity)
• Marking pen
• Cap
• Plug
• Waste oil can
• Rag
• Cleaning fluid
• Wood planks, etc.
84402832 NA - May 2011

2000-3
6. Use a wrench (13 mm) to remove the 3 bolts (1), 8. Use a wrench (8 mm) to loosen the hose band (1)
and then remove the bracket (2). on the radiator, and then remove the upper hose (2).
9. Remove the cushion seal on the side of the radiator,

use a wrench (8 mm) to loosen the hose band (1) of
the radiator, and then remove the lower hose (2).
• Use caps to cover the radiator and hoses to pre-
vent the entry of water, dust or dirt.
• Before removing the radiator hoses, completely
drain the coolant.
7. Remove the fan guard (1).
10. Use a wrench (13 mm) to loosen the line bolts (1) in
2 locations, and then remove the 2 lines (2) and (3)
from the compressor.
• Always remove the low-pressure (suction side)
line (2) first.
• Attach caps or plugs to the compressor and lines
to prevent any entry of water, dust or dirt.
Tightening torque for bolt installation: 19.6 - 24.5
N•m
84402832 NA - May 2011

2000-4
12. Use a wrench (17 mm) to remove the 5 bolts (1),

and then remove the under cover (2).
• Use caution when removing as the parts are
heavy.
N•m
13. Prepare the waste oil can (1).

• Drain the engine oil before removing the engine
oil hose.
11. Use a wrench (8 mm) to loosen the hose band (1)

on the inter cooler, and then remove the hose (2).
• Use caps to cover the lines and hoses to prevent
the entry of water, dust or dirt.
14. Use a wrench (36 mm) to remove the 2 engine oil

remote hoses (1).
• Mark the engine and hoses so that the connectors
match at the time of assembly.
• Attach caps or plugs to the engine and hoses to
prevent any entry of water, dust or dirt.
84402832 NA - May 2011

2000-5
• Clean the engine and hoses by spraying them 16. Use a wrench (17 mm) to remove the 5 bolts (1),
with a parts cleaner to prevent scratches and pre- and then remove the under cover (2).
vent dirt from accumulating on the connectors. Tightening torque for bolt installation: 63.7 - 73.5
N•m
17. Use a wrench (8 mm) to remove the 2 nuts (1), and

then remove the wiring (2) from the starter motor.
15. Use a wrench (17 mm) to remove the bolt (1), and
then remove the battery cable (2) on the negative 18. Remove the hose band (1), and then remove the
side. fuel hose (2).
• When removing the terminal and harness, secure • Attach caps or plugs to the engine and hoses to
them so that they do not interfere with the frame. prevent any entry of water, dust or dirt.
• Also, cover with a rubber cap to protect against
sparks.
84402832 NA - May 2011

2000-6
19. Remove the hose band (1), and then remove the 22. Use a wrench (8 mm) to loosen the hose band (1),
fuel hose (2). and then remove the heater hose (2).
Attach caps or plugs to the engine and hoses to
• Attach caps or plugs to the engine and hoses to prevent any entry of water, dust or dirt.
23. Use a wrench (8 mm) to loosen the hose band (1),

20. Use a wrench (13 mm) to remove the 4 bolts (1), and then remove the heater hose (2).
and then remove the box cover (2).
• Attach caps or plugs to the engine and hoses to
21. Remove the connectors (1) in the box.

• Wrap the removed connectors in plastic after tying 24. Use a wrench (8 mm) to loosen the hose band (1),
them together to prevent any entry of water, dust
and then remove the radiator hose (2).
or dirt.
any entry of water, dust or dirt.
84402832 NA - May 2011

2000-7
25. Use a wrench (8 mm) to loosen the hose band (1), 27. Remove the connectors (1) from the alternator.
and then remove the air hose (2).
28. Remove the cap (1), use the wrench (10 mm) to
remove the nut (2), and then remove the alternator
wiring (3).

and then remove the air hose (2).
Tightening torque for bolt installation: 8.8 - 9.8 N•m
29. Install the 2 shackles (1), and then use the wire rope
(2) and liftcrane to secure the engine main unit.
84402832 NA - May 2011

2000-8
30. Use a box wrench (30 mm) to remove the 4 bolts 31. Use the wire rope (1) and liftcrane to lift the engine
(1) from the mount. main unit.
Tightening torque for bolt installation: 289 - 337 N•m Thoroughly check that the location is safe before
lowering the engine on wood planks, etc.
84402832 NA - May 2011

2000-9
Installation of Engine Assembly 2. Run the engine at no-load idling and check for any
water or oil leaks.
1. To install the engine, perform the reverse of the re- 3. Attach the hydraulic pump, covers, and counter-
moval procedure. weight.
Tighten bolts being installed to the specified torque. For details, see the individual explanations for each
For bolts for which the torque is not specified, see procedure.
"Standard Torque Data for Cap Screws and Nuts".
After installing the engine, resupply coolant and en-
gine oil, perform fuel line air bleeding, and perform
filling for the air conditioner gas.
For details, see the individual explanations for each
procedure.
84402832 NA - May 2011

2000-10
Section
2001
Removal and installation of the fuel cooler engine

inter-cooler radiator and oil cooler
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal and Installation of Fuel Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Removal of Fuel Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Fuel Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal and Installation of Engine Inter Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal of Inter Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation of Inter Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal and Installation of Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal of Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation of radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal and Installation of Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal of oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation of oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
Removal and Installation of Fuel Removal of Fuel Cooler
Cooler 1. Mark the fuel cooler and hoses (1) and (2) so that
the connectors match at the time of assembly.
CAUTION Use pliers to loosen the hose bands (3) and (4), and
then remove the hoses.
• Be sure to stop the engine before beginning Fuel will spill out, so place a drip pan directly below
work. the area.
• As the fuel hose will be removed, strictly pro- Attach caps or plugs to the fuel cooler and hoses to
hibit open flames. prevent any entry of water, dust or dirt.
Items to prepare
• Wrench (13 mm)
• Screwdriver
• Pliers
• Marking pen
• Cap
• Plug
• Rag
• Cleaning fluid
• Drip pan

and then remove the fuel cooler (2).
Installation of Fuel Cooler

To installation, perform the reverse of the removal pro-
cedure.
After connecting the hoses, carefully check for any fuel
leaks.
Tighten bolts being installed to the specified torque.
For bolts for which the torque is not specified, see "Stan-
dard Torque Data for Cap Screws and Nuts".
84402832 NA - May 2011

2001-3
Removal and Installation of Engine Removal of Inter Cooler
Inter Cooler 1. Remove the fuel cooler.(For details, see "Removal
and Installation of Fuel Cooler".)
CAUTION Use a wrench (13 mm) to remove the 4 bolts (1), and
then remove the bracket (2) from the fuel cooler.
work.
• As the fuel hose will be removed, strictly pro-
hibit open flames.
Items to prepare
• Wrenches (8 mm, 13 mm)
• Flathead screwdriver
• Wire cutters
• Cap
• Rag
• Cleaning fluid
2. Use a wrench (8 mm) or flathead screwdriver to

loosen the hose bands (1) in the 2 locations, and
then remove the 2 hoses (2) and (3).
Use caps to cover the inter cooler and hoses to pre-

and then remove the inter cooler (2).
84402832 NA - May 2011

2001-4
Installation of Inter Cooler Removal and Installation of
To install, perform the reverse of the removal procedure. Radiator
Check for any air leaks.
Tighten bolts being installed to the specified torque. WARNING
dard Torque Data for Cap Screws and Nuts". • Do not remove the radiator cap when the ra-
diator coolant temperature is high.
Hot liquid could spray out.
CAUTION
• Be sure to release hydraulic pressure before
beginning work.
work.
load.
Items to prepare
• Wrenches (8 mm, 14 mm, 19 mm)
• Box wrenches (8 mm, 10 mm)
• Pliers
• Wire ropes (with the required breaking load)
• Caps
• Plugs
• Drain tank
• Drain hose
• Rag
• Cleaning fluid
84402832 NA - May 2011

2001-5
Removal of Radiator 4. Loosen the drain plug (1), and then drain the
coolant.

and then remove the hose (2).
2. Install the drain hose (1), and then prepare the drain
tank (2). • Use caps to cover the lines and hoses to prevent
3. To make it easier to drain the coolant, remove the

radiator cap (1). 6. Use a box wrench (13 mm) to remove the 1 nut (1)
and the 3 bolts (2) of the radiator cover.
84402832 NA - May 2011

2001-6
7. Use a wrench (8 mm) to loosen the hose band (1) 10. Loosen the hose band (2), and then remove the
on the radiator, and then remove the upper hose (2). hose (1) from the radiator cap.
• Attach caps or plugs to the hoses to prevent any
entry of water, dust or dirt.
8. Remove the cushion seal on the side of the radiator,

use a wrench (8 mm) to loosen the hose band (1) of
the radiator, and then remove the lower hose (2).
• Use caps to cover the radiator and hoses to pre-
• Before removing the radiator hoses, completely
drain the coolant.
9. Remove the drain plug (1), loosen the hose band

(2), and then remove the hose (3).
84402832 NA - May 2011

2001-7
12. Use a wrench (13 mm) to remove the 3 bolts (1), 14. Remove the 2 butterfly bolts (1), and then remove
and then remove the bracket (2) the front anti-insect net (2).
15. Install the 2 shackles (1) to the top of the radiator,

and then use the wire rope (2) and liftcrane to lift the
radiator.
13. Remove the fan guard (1).
84402832 NA - May 2011

2001-8
16. Lift the radiator together with the radiator cover (2) Installation of radiator
until the fixtures (1) at the bottom of the radiator
become disconnected. To install, perform the reverse of the removal procedure.
For details on the method for coolant filling, see the (Ser-
vice Text Procedures for Replacing Consumable Parts •
Radiator Coolant Replacement).
Coolant capacity is 30 L.
Finally, check that the level of coolant is correct.
17. Thoroughly check that the location is safe before

lowering the radiator on square wooden pieces.
When laying down the radiator, be careful not to
bend or crush the bottom fixtures (1).
84402832 NA - May 2011

2001-9
Removal and Installation of Oil Removal of oil cooler
Cooler 1. Drain the hydraulic oil from the hydraulic oil tank.
See "Draining Oil from Hydraulic Oil Tank" for de-
WARNING tails of the procedure.
• Keep away from fire. and then remove the under cover (2).
CAUTION
work.
load.
Items to prepare
• Hexagon wrench (10 mm)
• Pliers
• Screwdriver 3. Prepare the waste oil can (1).
• Eyebolts (M12 x 2)
• Wire rope (with the required breaking load)
• Caps
• Waste oil can
• Rag
• Cleaning fluid
4. Remove the 4 butterfly bolts (1), and then remove

the anti-insect net (2).
84402832 NA - May 2011

2001-10
5. Use a wrench (19 mm) to remove the 7 bolts (1) and 6. Use a hexagon wrench (10 mm) to remove the 2
bracket (2), and then remove the seal cushion. upper hexagon socket head bolts (6) and 2 lower
bolts (6), and then remove the lines (7) and (8).
• Use caps to cover the oil cooler and lines to pre-
84402832 NA - May 2011

2001-11
8. Install the 2 eyebolts (M12) (10) on the top of the oil 10. Thoroughly check that the location is safe before
cooler. lowering the oil cooler on wood planks, etc.
• Fully tighten the eyebolts, and then loosen them
by a half turn.
9. Install the 2 shackles (11) to the eyebolts, and then

use the wire rope (12) and liftcrane to lift the oil
cooler main unit.
Installation of oil cooler

To install, perform the reverse of the removal procedure.
84402832 NA - May 2011

2001-12
Section
2004
Removal and Installation of Turbo Charger
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Turbo Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Turbo Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

WARNING Removal of Turbo Charger

The engine is extremely hot just after stopping. 1. Battery ground cable Disconnect
Wait for them to sufficiently cool before begin- 1) Disengage the battery ground cable from the
ning work. battery.
2. Coolant Drain
CAUTION
1) Drain the coolant from the radiator.
work. CAUTION
Items to prepare • After the coolant is discharged,

make sure to tighten the drain plug.
• Wrenches (8 mm, 10 mm, 13 mm, 17 mm)
• Cap 3. Turbocharger assembly Removal
• Plug
• Rag 1) Remove the air cleaner duct from the air
• Cleaning fluid cleaner assembly and the turbocharger as-
sembly.
2) Remove the air intake hose from the tur-
bocharger assembly and the intercooler.
3) Remove the exhaust pipe from the tur-
bocharger.
4) Disengage the oil feed pipe from the tur-
bocharger assembly.
ANNOTATION:
• Remove the clip.
5) Disengage the oil return pipe from the tur-
bocharger assembly.
6) Disengage the water return pipe from the tur-
bocharger assembly.
7) Disengage the water feed pipe from the tur-
bocharger assembly.
ANNOTATION:
8) Disengage the harness connector from the
turbocharger assembly.
9) Remove the turbocharger assembly from the
exhaust manifold.
1 Oil feed pipe

2 Clip
3 Oil return pipe
4 Water feed pipe
5 Water return pipe
84402832 NA - May 2011

2004-3
Installation of Turbo Charger 7) Connect the oil feed pipe to the turbocharger
assembly.
1. Turbocharger assembly Installation Tightening torque： 34 N・m { 3.5 kgf・m /
1) Replenish the engine oil with the turbocharger 25 lb・ft }
assembly. Tightening torque： 24 N・m { 2.4 kgf・m /
2) Align the gasket to the turbocharger assem- 17 lb・ft } Clip
bly. CAUTION
3) Install the turbocharger assembly to the ex-
haust manifold. • Use a new gasket.
Tightening torque： 52 N・m { 5.3 kgf・m /
38 lb・ft }
4) Connect the water feed pipe to the tur-
bocharger assembly.
30 lb・ft }
CAUTION
• Use a new gasket.
5) Connect the water return pipe to the tur-

bocharger assembly.
30 lb・ft }
CAUTION
1 Oil feed pipe
2 Clip
6) Connect the oil return pipe to the turbocharger 3 Oil return pipe
assembly. 4 Water feed pipe
Tightening torque： 24 N・m { 2.4 kgf・m / 5 Water return pipe
17 lb・ft }
8) Install the exhaust pipe to the turbocharger
CAUTION assembly.
9) Install the air intake hose to the turbocharger
• Use a new gasket. assembly and the intercooler.
10) Install the air cleaner duct to the air cleaner
assembly and the turbocharger assembly.
2. Coolant Filling
1) Loosen the valve using a wrench.
2) Replenish the coolant with the radiator.
CAUTION
• Be careful not to let coolant over-
flow splash on the exhaust system
parts.
Coolant overflow should be wiped off.

3) Tighten the valve using a wrench.
CAUTION
• Use new gaskets.

16 lb・ft }
84402832 NA - May 2011

2004-4
4) Replenish the coolant with the radiator. 5) Battery ground cable Connect
1) Connect the battery ground cable to the
battery.
1 Valve
2 Gasket
84402832 NA - May 2011

2004-5
84402832 NA - May 2011

2004-6
Section
2005
Removal and Installation of EGR Cooler and EGR Valve
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
EGR valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

EGR valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

EGR valve Removal 3) Remove the EGR cooler C from the EGR
bracket C.
1. Battery ground cable Disconnect 4) Remove the EGR bracket C from the EGR
1) Disengage the battery ground cable from the cooler B.
battery. 5) Remove the EGR cooler B from the EGR
cooler bracket A.
2. Coolant Drain 6) Remove the EGR cooler bracket A from the
EGR cooler A.
CAUTION
• After the coolant is discharged,
3. EGR cooler Removal

1) Disengage the water rubber hose from the
EGR cooler.
1 EGR cooler C
2 EGR bracket C
3 EGR cooler B
4 EGR cooler bracket A
7) Remove the EGR heat protector from the

EGR pipe A.
1 Water rubber hose
2) Remove the EGR pipe B from the EGR valve

and the EGR cooler C.
1 EGR heat protector
1 EGR valve
2 EGR pipe B 8) Remove the EGR cooler A from the EGR pipe
3 EGR cooler C A.
84402832 NA - May 2011

2005-3
9) Remove the EGR pipe A from the exhaust EGR valve Installation
manifold.
1. EGR valve Installation
1) Install the EGR valve to the inlet pipe.
Tightening torque： 46 N・m ｛4.7 kgf・m /
33.9 lb・ft｝
1 EGR cooler A
2 EGR pipe A
3 Exhaust manifold
4. EGR valve Removal 1 EGR valve

2) Connect the harness connector to the EGR
EGR valve.
valve.
2) Remove the EGR valve from the inlet pipe.
2. EGR cooler Installation
1) Temporarily tighten the EGR pipe A to the ex-
haust manifold.
2) Temporarily tighten the EGR cooler A to the
EGR pipe A.
1 EGR valve
1 EGR cooler A
2 EGR pipe A
3 Exhaust manifold
3) Temporarily tighten the EGR cooler bracket A

to the EGR cooler A.
4) Temporarily tighten the EGR cooler B to the
EGR cooler A.
5) Temporarily tighten the EGR bracket C to the
EGR cooler B.
84402832 NA - May 2011

2005-4
6) Temporarily tighten the EGR cooler C to the 13) Securely tighten the EGR pipe B to the EGR
EGR bracket C. cooler C.
18 lb・ft｝
14) Securely tighten the EGR pipe B to the EGR
valve.
34 lb・ft｝
15) Securely tighten the EGR cooler bracket A to
the EGR cooler bracket C.
17 lb・ft｝
16) Securely tighten the EGR cooler bracket C to
the EGR cooler bracket B.
34 lb・ft｝
17) Securely tighten the EGR pipe B to the rear
engine hanger bracket.
1 EGR cooler C Tightening torque： 46 N・m ｛4.7 kgf・m /
2 EGR cooler bracket C 34 lb・ft｝
3 EGR cooler B 18) Install the EGR heat protector to the EGR
4 EGR cooler bracket A pipe.
7) Temporarily tighten the EGR pipe B to the 23 lb・ft｝
EGR cooler C and the EGR valve.

1 EGR valve
2 EGR pipe B 19) Connect the water rubber hose to the EGR
3 EGR cooler C cooler.
8) Securely tighten the EGR pipe A to the ex-

haust manifold.
Tightening torque： 67 N・m {6.8 kgf・m / 49
lb・ft}
9) Securely tighten the EGR cooler A to the EGR
pipe A.
lb・ft}
10) Securely tighten the EGR cooler B to the EGR
cooler A.
lb・ft}
the EGR cooler B.
lb・ft} 1 Water rubber hose
12) Securely tighten the EGR cooler C to the EGR
cooler bracket C.
3. Coolant Filling
lb・ft} 1) Loosen the valve using a wrench.
84402832 NA - May 2011
2005-5
2) Replenish the coolant with the radiator. 4) Replenish the coolant with the radiator.
CAUTION
parts.
• Coolant overflow should be wiped
off.
CAUTION

16 lb・ft｝
1 Valve
2 Gasket
4. Battery ground cable Connect

1) Connect the battery ground cable to the bat-
tery
84402832 NA - May 2011

2005-6
Section
2006
Removal and Installation of Engine Hood
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Engine Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Engine Hood. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CAUTION Removal of Engine Hood

• Be sure to stop the engine before beginning 1. Open the engine hood until the lock is engaged.
work. Wrap the nylon sling around the engine hood, and
• Do not perform this operation in strong wind. then gently lift with the liftcrane until there is no force
• Be sure to inspect the nylon sling and other on the open lock stay (1).
lifting equipment before beginning work. Remove the pin (2) and washer (3) that are on the
• Do not stand or pass under the suspended engine hood side of the open lock stay (1), and then
load. remove the open rock stay (1) from the guide.
Items to prepare
• Wrench (19 mm)
• Nylon sling (with the required breaking load)
84402832 NA - May 2011

2006-3
2. After closing the engine hood (1), use a wrench (19 3. Wrap the nylon sling (1) around the engine hood (2),
mm) to remove the 9 bolts (2) from the engine hood. and then use the liftcrane to lift the engine hood (2).
Installation of Engine Hood

84402832 NA - May 2011

2006-4
Section
2007
Removal and Installation of Muffler
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

WARNING 2. Use a wrench (19 mm) to remove the 4 bolts (1),

and then remove the muffler (2).
• The engine is extremely hot just after stop-
ping. Wait for it to sufficiently cool before be-
ginning work.
CAUTION
work.
Items to prepare
• Wrench (14 mm)
• Cap
• Rag
• Cleaning fluid
Removal of Muffler Installation of Muffler

1. Use a wrench (13 mm) to loosen the 4 nuts (1), and To Installation perform the reverse of the removal proce-
then remove the 4 bolts (2). dure.
After installation, check for any leaks or vibration.
• Use caps to cover the lines to prevent any entry Tighten bolts being installed to the specified torque.
of water, dust or dirt.
84402832 NA - May 2011

2007-3
84402832 NA - May 2011

2007-4
Section
2401
Primary specifications
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Primary specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1. Primary specifications
Engine main specifications
Item Engine model 6HK1X

Type Diesel/ 4-cycle /water cooling, inline 6 cylinder OHC
Shape of combustion chamber Direct injection type
Cylinder liner type Dry type
Cylinder bore x stroke 115 mm ｛4.53 in｝ x 125 mm ｛4.92 in｝
Displacement 7.790 L {475.35 cu・in}
Compression ratio 17.5
Compression pressure ： 3.04 MPa {31.0 kgf/cm2 / 441 psi} 200 min-1 {200 rpm}
Idling rotation speed 900 min-1 {900 rpm}
Intake ： 0.4 mm {0.016 in} While cool
Valve clearance
Exhaust ： 0.4 mm {0.016 in} While cool
Ignition method Compression ignition
Injection order 1,5,3,6,2,4
Lubricant system
Lubricating type Pressure type
Oil pump type Gear type
Lubrication oil amount ： 36.0 - 46.0 L {9.5 - 12.2 US gal}
Oil filter type Full-flow filter (cartridge type)
Oil cooling type Built-in type, water cooled
Cooling system
Cooling type Water cooling
Radiator type Corrugated fin (pressure type)
Water pump type Centrifugal, belt type
Thermostat type 2 wax type unit
Open valve temperature of the thermostat ： 82 °C {180 °F} Without jiggle valve
valve ： 85 °C {185 °F} With jiggle valve
Coolant container ： 16.0 L {4.2 US gal}
Fuel system
Injection pump type Electronic control common rail type
Governor type Electronic type
Timer type Electronic type
Multi-hole type 7 holes
Injection nozzle type
Inner diameter D0.14 mm {0.0055 in}
Charging system
Generator type AC type
Output 24 - 90 V/50 A
Regulator type IC
Starting system
Starter type Reduction type
Output 24 V/5.0 kW
Preheat system type Glow plug
Glow plug standard voltage/current 23 V/3.5 A
Cleaning system main specifications
Item Specifications
Water pump Centrifugal impeller method
Pulley ratio 0.950
Thermostat Wax pellet type
： 82 °C{180 °F} Without jiggle valve
Open valve temperature
： 85 °C {185 °F} With jiggle valve
： 95 °C {203 °F} Without jiggle valve
Full-open temperature
： 100 °C {212 °F} With jiggle valve
84402832 NA - May 2011
2401-3
Electrical system main specifications
Generator
Item Specifications
Manufacturer name Mitsubishi Electric Corporation
Isuzu parts number 1-81200-633-0 1-81200-603-2
Manufacturer type A009TU3782 A004TU6285
Nominal voltage 24V
Output current 90 A 50 A
Rated rotation count 500 min-1 {5000 rpm}
Output current/voltage 114 A/27 V/5000 min-1 {5000 rpm} 50 A/27 V/5000 min-1 {5000 rpm}
No-load voltage 24 V/900 min-1 {900 rpm}
Rotational direction Clockwise direction
Polarity (－)
Pulley diameter (P.C.D) ： 90.0 mm {3.54 in} ： 80.0 mm {3.15 in}
Starter
Item Specifications
Manufacturer Mitsubishi Electric Corporation
Isuzu parts number 181100-4140
Manufacturer code number M008T60971
Output 24 V/5.0 kW
Rating 30 sec
York outer diameter : 85.0 mm {3.35 in}
Rotational direction Right
Protection type Dust proof, drip proof
Low speed mechanism Inner contact gear
Weight ： 7.2 kg {15.9 lb}
Module 3
Pressure angle 14.5
Pinion Number of teeth 11
Gear ratio
12.8 {129/11}
{ring gear/pinion gear}
Voltage 23 V
No load Current 85 A or less
Rotational speed 3,300 min-1 {3,300 rpm} or more
Voltage 9V
Restraint Current 1,400 or less
Torque 88 N・m {9kgf・m} or more
Pinion/engaged voltage 16.0 V or less
Glow plug
Item Type
Preheat device model Glow plug
Glow plug rated voltage/current 23 V/3.5 A
84402832 NA - May 2011

2401-4
Section
2415
Removal and Installation of Cylinder Head
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Cylinder head cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Cylinder head cover Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal and Installation of Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cylinder head assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cylinder head assembly Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Cylinder head assembly Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Cylinder head assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Cylinder head assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Cylinder head cover Removal 4) Remove the head cover gasket from the cylin-
der head cover.
1. Cylinder head cover Removal
1) Disengage the water pipe bracket from the
cylinder head cover.
2) Disengage the ventilation hose from the air
breather.
1 Cylinder head cover

2 Head cover gasket
3 Lower cover
1 Ventilation hose
2 Water pipe bracket
3 Clip
3) Remove the cylinder head cover from the

lower cover.
84402832 NA - May 2011

2415-3
Cylinder head cover Installation 1 Cylinder head cover

2 Head cover gasket
1. Cylinder head cover Installation 3 Lower cover
1) Align the head cover gasket to the cylinder
head cover. 3) Connect the ventilation hose to the air
2) Install the cylinder head cover to the lower breather.
cover. 4) Connect the water pipe bracket to the cylinder
Tightening torque： 13 N・m ｛1.3 kgf・m / head cover.
115.1 lb・in｝ Tightening torque： 20 N・m ｛2.0 kgf・m /
14.75 lb・ft｝
ANNOTATION:
• Referring to the tightening order in the dia-
gram, temporarily tighten all bolts and then
completely tighten them.
1 Ventilation hose
3 Clip
84402832 NA - May 2011

2415-4
Removal and Installation of 11) Remove the water feed pipe from the cylinder
block.
Cylinder Head
ANNOTATION:
Cylinder head assembly Removal • Remove the clip.
1. Battery ground cable Disconnect 12) Disengage the harness connector from the
1) Disengage the battery ground cable from the turbocharger assembly.
battery. 13) Remove the turbocharger assembly from the
exhaust manifold.
2. Coolant Drain
CAUTION
3. Engine harness Disconnect

1) Disengage the engine harness from the en-
gine assembly.
ANNOTATION:
• Disconnect each connector.
4. Turbocharger assembly Removal
1 Oil feed pipe
1) Remove the air cleaner duct from the air 2 Clip
cleaner assembly and the turbocharger as- 3 Oil return pipe
sembly. 4 Water feed pipe
2) Remove the air intake hose from the tur- 5 Water return pipe
bocharger. 5. EGR cooler Removal
4) Disengage the oil feed pipe from the tur- 1) Disengage the water rubber hose from the
bocharger assembly. EGR cooler.
ANNOTATION:
5) Remove the oil feed pipe from the pipe
bracket.
ANNOTATION:
bocharger assembly.
7) Remove the oil return pipe from the cylinder
block.
bocharger assembly.
9) Remove the water return pipe from the cylin-
der head assembly. 1 Water rubber hose
bocharger assembly.
ANNOTATION:
84402832 NA - May 2011

2415-5
2) Remove the EGR pipe B from the EGR valve 7) Remove the EGR heat protector from the
and the EGR cooler C. EGR pipe A.
1 EGR valve
2 EGR pipe B 1 EGR heat protector
3 EGR cooler C
8) Remove the EGR cooler A from the EGR pipe
3) Remove the EGR cooler C from the EGR A.
bracket C. 9) Remove the EGR pipe A from the exhaust
4) Remove the EGR bracket C from the EGR manifold.
cooler B.
5) Remove the EGR cooler B from the EGR
cooler bracket A.
6) Remove the EGR cooler bracket A from the
EGR cooler A.
1 EGR cooler A
2 EGR pipe A
3 Exhaust manifold
1 EGR cooler C
2 EGR bracket C 6. EGR valve Removal
3 EGR cooler B 1) Disengage the harness connector from the
4 EGR cooler bracket A EGR valve.
84402832 NA - May 2011

2415-6
2) Remove the EGR valve from the inlet pipe. 2) Remove the ventilation hose from the air
breather.
3) Remove the oil separator bracket from the
cylinder head assembly.
1 EGR valve
7. Oil separator bracket Removal 1 Oil separator bracket

1) Remove the clip from the cylinder block. 2 Clip
84402832 NA - May 2011

2415-7
8. EGR cooler water pipe Removal
84402832 NA - May 2011

2415-8
1) Remove the fan guide stay from the fan guide 2) Disengage the oil level gauge guide tube from
and the fan guide bracket. the front engine hanger bracket.
3) Remove the oil level gauge guide tube from
the cylinder block.
1 Fan guide
2 Fan guide stay
3 Fan guide bracket 1 Oil level gauge guide tube
10. Intake throttle valve Removal

2) Disengage the radiator upper hose from the
water outlet pipe. 1) Remove the air duct from the intake throttle
3) Remove the EGR cooler water pipe from the valve.
engine assembly. 2) Disengage the harness connector from the in-
4) Remove the water bypass hose from the wa- take throttle valve.
ter pump assembly and the water duct. ANNOTATION:
• Pull the lock operation portion to release the
lock.
1 Water bypass hose
9. Oil level gauge guide tube Removal 1 Lock operation section

1) Remove the oil level gauge from the oil level 2 Lock release
gauge guide tube. 3 Lock
84402832 NA - May 2011

2415-9
3) Remove the intake throttle valve from the inlet 5) Remove the inlet pipe from the inlet cover.
pipe.
1 Inlet pipe
1 Intake throttle valve
2 Gasket 12. Glow plug Removal
3 Inlet pipe 1) Remove the glow plug connector from the
glow plug.
11. Inlet pipe Removal
boost sensor.
2) Disconnect the harness connector from the
boost temperature sensor.
IMT sensor.
4) Remove the harness clip from the inlet pipe.
2) Remove the glow plug from the cylinder head

assembly.
1 Boost sensor
2 Harness clip
3 Boost temperature sensor
4 IMT sensor
13. Injection pipe Removal

1) Remove the clip from the inlet pipe.
2) Remove the injection pipe from the injector
and the common rail assembly.
84402832 NA - May 2011

2415-10
CAUTION 3) Disengage the fuel leak-off pipe from the com-

mon rail assembly.
• Do not reuse the removed injection 4) Remove the fuel leak-off pipe from the inlet
pipe. pipe.
• Seal the common rail and injector to ANNOTATION:
prevent foreign material from enter-
ing. • Remove the clip.
1 No.1 injection pipe 1 Fuel leak-off pipe

2 No.2 injection pipe
3 No.3 injection pipe 16. Common rail assembly Removal
4 No.4 injection pipe 1) Disengage the harness connector from the
5 No.5 injection pipe fuel pressure sensor.
6 No.6 injection pipe 2) Remove the common rail assembly from the
7 Fuel pipe inlet cover.
14. Fuel pipe Removal

1) Remove the fuel pipe from the fuel supply
pump and the common rail assembly.
ANNOTATION:
CAUTION
• Do not reuse the removed fuel pipe.
15. Fuel leak off pipe assembly Removal

1) Disengage the fuel leak-off pipe from the cylin-
der head.
2) Remove the fuel leak-off pipe from the fuel 1 Common rail assembly
supply pump.
ANNOTATION: 17. Cylinder head cover Removal
• Remove the eyebolt tightened together with 1) Disengage the ventilation hose from the air
the fuel feed pipe. breather.
84402832 NA - May 2011

2415-11
2) Remove the cylinder head cover from the 2) Disengage the injector harness from the injec-
lower cover. tor.
3) Remove the head cover gasket from the cylin-
der head cover. CAUTION
• Be careful not to damage the injec-
tor side stud bolts.

2 Head cover gasket
3 Lower cover
1 Injector
18. Injector harness Removal 2 Injector harness
3 Terminal nut
1) Remove the connector from the lower cover.
CAUTION 3) Remove the injector harness from the cylinder

head assembly.
• Do not pull the wire, or pry the con-
nector with a screwdriver. ANNOTATION:
• Remove the bracket tightening bolts and
then remove the injector harness together
with the bracket.
1 Injector harness terminal

2 Injector harness bracket
19. Lower cover Removal

1) Remove the lower cover from the cylinder
head assembly.
2) Remove the rubber plug from the cylinder
head assembly.
20. Injector Removal
1) Remove the injector leak-off pipe from the in-
jector.
2) Remove the injector from the cylinder head
assembly.
84402832 NA - May 2011
2415-12
ANNOTATION: CAUTION
• When it is difficult to remove the injector, use
a special tool. • Confirm that the sleeve is not pulled
out together when pulling out the
injector using a special tool.
• Store each ID code plate on the in-
jector head with the cylinder num-
ber tag attached to avoid a mix-up.
• Be extremely careful not to damage
the injector nozzle.
Special tool: fuel injector remover (refer

to section 1003)
21. Rocker arm shaft Removal

1) Loosen the adjust screw using the wrench.
ANNOTATION:
• Loosen all valve clearance adjustment
screws.
Special tool: sliding hammer (refer to

section 1003)
2) Remove the rocker arm shaft from the cylinder

head assembly.
ANNOTATION:
• Evenly loosen the rocker arm shaft bracket
and the rocker arm assembly bracket tight-
1 Sliding hammer ening bolts from both ends and remove
2 Fuel injector remover them.
3 Injector CAUTION
• Be careful not to remove the bolt
shown in the diagram.
84402832 NA - May 2011

2415-13
23. Bridge Removal

1) Remove the bridge cap from the bridge.
CAUTION
• Be careful not to drop the bridge
cap into the engine.
2) Remove the bridge from the bridge guide.

ANNOTATION:
• After removing, organize to avoid a mix-up
with other installation locations.
22. Camshaft Removal

1) Remove the camshaft bearing cap from the
2) Remove the camshaft bearing from the
camshaft bearing cap.
3) Remove the camshaft from the cylinder head.
4) Remove the camshaft bearing from the cylin-
der head assembly.
ANNOTATION:
• Temporarily assemble the removed caps
and bearings in the original position to avoid
a mix-up after the bearings have been in-
spected.
1 Bridge cap
2 Bridge
24. Cylinder head assembly Removal

1) Remove the cylinder head assembly from the
cylinder block.
ANNOTATION:
• Loosening order of the head bolts
84402832 NA - May 2011

2415-14
CAUTION 1 Idle gear C
• Since the idle gear C protrudes 2) Remove the cylinder head gasket from the
from the bottom surface of the cylinder block.
cylinder head, be careful not to
damage the gear. CAUTION
• Do not reuse the cylinder head gas-
ket.
84402832 NA - May 2011

2415-15
Cylinder head assembly Disassembly 2. Inlet cover Removal

1. Engine hanger bracket Removal 1) Remove the inlet cover from the cylinder head
assembly.
1) Remove the front engine hanger bracket from
the cylinder head assembly.
2) Remove the rear engine hanger bracket from
1 Gasket
2 Inlet cover
3. Exhaust manifold Removal

1) Remove the exhaust manifold cover from the
exhaust manifold.
2) Remove the heat protector from the exhaust
manifold.
1 Front engine hanger

2 Front engine hanger bracket
3 Rear engine hanger
4 Rear engine hanger bracket
1 Heat protector
2 Exhaust manifold cover
84402832 NA - May 2011

2415-16
3) Remove the exhaust manifold from the cylin- 5. Thermostat Removal

der head assembly.
1) Remove the water outlet pipe from the cylin-
der head assembly.
1 Exhaust manifold
2 Distance nut 1 Fan guide bracket
2 Water outlet pipe
4) Disassemble the exhaust manifold.
2) Remove the thermostat from the cylinder
head assembly.
3) Remove the gasket from the thermostat.
6. Overheat switch Removal
1) Remove the overheat switch from the cylinder
head assembly.
1 Rear side exhaust manifold

2 Seal ring
3 Front side exhaust manifold
4. Bracket Removal
1) Remove the EGR cooler bracket B from the 1 Overheat switch
1 EGR cooler bracket B

84402832 NA - May 2011
2415-17
7. Engine coolant temperature sensor Removal 2) Remove the idle gear C cover from the cylin-
der head assembly using the pliers.
1) Remove the engine coolant temperature sen-
sor from the cylinder head assembly.
3) Remove the idle gear C from the cylinder head

assembly.
1 Overheat switch
2 Water temperature sensor
8. CMP sensor Removal

CMP sensor.
2) Remove the CMP sensor from the cylinder
head assembly.
1 Idle gear C
2 Idle gear shaft
10. Valve spring Removal

1) Press the valve spring using the special tool.
CAUTION
• Be careful not to subject the sensor
to shock.
9. Idle gear C Removal

1) Press the idle gear C cover using the driver.
ANNOTATION:
• Lightly tap the outer perimeter of the cover Special tool: remover, valve spring (refer
using a screwdriver and tilt the cover. to section 1003)
84402832 NA - May 2011

2415-18
1) Remove the exhaust valve from the cylinder

head assembly.
ANNOTATION:
• Organize the removed valve according to
the cylinders.
Special tool: pivot ASM (refer to section

1003)
13. Valve stem oil seal Removal

1) Remove the valve stem oil seal from the valve
guide using the pliers.
CAUTION
• Do not reuse the valve stem oil seal.
2) Remove the valve spring seat from the cylin-

der head assembly.
2) Remove the split collar from the spring seat.
3) Remove the special tool from the cylinder 14. Valve guide Removal
head assembly.
1) Remove the valve guide from the cylinder
4) Remove the valve spring seat from the valve
head assembly using the special tool.
spring.
5) Remove the valve spring from the cylinder
head assembly.
ANNOTATION:
• Store the removed valve springs according
to the cylinders.
11. Inlet valve Removal
1) Remove the inlet valve from the cylinder head
assembly.
ANNOTATION:
• Organize the removed valve according to
the cylinders.
12. Exhaust valve Removal Special tool: remover/installer valve guide
(refer to section 1003)
ANNOTATION:
• Tap the valve guides out from the bottom
surface of the cylinder head.
84402832 NA - May 2011

2415-19
• Tap the injector sleeve out from the bottom

surface of the cylinder head.
15. Valve seat insert Removal

1) Heat the valve seat insert with the gas burner.
Heating temperature ： 700.0 - 800.0 °C
｛1292 - 1472 °F｝: 2 sections inner surface 1 Injector sleeve
of the insert
ANNOTATION: CAUTION
• Cool the valve seat insert naturally after • Be careful not to damage the bot-
heating. tom surface of the cylinder head.
• Do not reuse the removed injector
Specified time： 5 min Natural cooling sleeve.
2) Remove the valve seat insert from the cylinder
head assembly using the driver. 17. Bridge guide Removal
CAUTION 1) Install the nut to the bridge guide.
• Be careful not to damage the cylin- ANNOTATION:
der head.
• Electrically weld the nut to the top of the
bridge guide.
16. Injector sleeve Removal
2) Remove the bridge guide from the cylinder
1) Remove the injector sleeve from the cylinder head assembly using the sliding hammer.
Special tool: remover, nozzle sleeve (refer 1 Nut

to section 1003)
ANNOTATION: 18. Oil seal Removal
84402832 NA - May 2011

2415-20
1) Remove the oil seal from the cylinder head Cylinder head assembly Reassembly
assembly.
1. Oil seal Installation
ANNOTATION:
1) Install the oil seal to the cylinder head assem-
• Attach a rod from the inner surface of the bly.
cylinder head, and tap it to remove it to the
outer side.
Special tool: oil seal installer (refer to

section 1003)
CAUTION
• Be careful not to damage the lip
section of the oil seal.
1 Cylinder head
2 Oil seal installer
2. Bridge guide Installation

1) Apply the engine oil to the bridge guide.
84402832 NA - May 2011
2415-21
2) Install the bridge guide to the cylinder head 4) Apply the engine oil to the cylinder head as-
assembly using the special tool. sembly.
ANNOTATION:
• Apply engine oil to the injector sleeve con-
tact surface.
Special tool: bridge guide setting tool

Specified length： 122.0 - 123.0 mm {4.8031

to 4.8425 in} 1 in the diagram
Specified length： 37.5 mm {1.4764 in} 2 in
the diagram
3. Injector sleeve Installation
1) Install the O-ring to the injector sleeve. 1 O-ring with white paint
2) Apply the engine oil to the O-ring. 2 O-ring
3) Apply the cement to the injector sleeve. 3 Loctite 620 application
4 Engine oil application
ANNOTATION:
• Apply Loctite 620 to the tapered section of
the injector sleeve. 5) Install the injector sleeve to the cylinder head
assembly using the special tool.
Special tool: nozzle sleeve setting tool

84402832 NA - May 2011
2415-22
4) Install the valve seat insert to the cylinder

head assembly using the press.
1 Dolly block
2 Valve seat insert
3 Press
5. Valve guide Installation

1) Apply the engine oil to the valve guide.
2) Install the valve guide to the cylinder head
assembly using the special tool.
1 Punch bar
2 Ball
3 Guide sleeve
4 Injector sleeve
5 Clamp
6 Bolt
CAUTION
• Allow the cylinder head to float so
that the ball comes out from the bot- Special tool: remover/installer valve guide
tom surface. (refer to section 1003)
ANNOTATION:
4. Valve seat insert Installation
• Tap the valve guides from the upper side of
1) Prepare the dolly block. the cylinder head.
ANNOTATION:
• Prepare the one which has smaller outer
diameter than the valve seat insert.
2) Align the valve seat insert to the cylinder head.
3) Align the dolly block to the valve seat insert.
Specified length ： 17.1 - 17.9 mm {0.6732

- 0.7047 in} From the upper surface of the
84402832 NA - May 2011
2415-23
cylinder head to the edge surface of the valve Special tool: installer valve guide oil seal
guide (refer to section 1003)
CAUTION CAUTION
• When replacing the valve guide, re- • Inspect the valve stem oil seal for
place it with the valve. deformation or cracks.
• Confirm that the garter spring has
6. Valve stem oil seal Installation not come loose.
1) Install the valve spring seat to the cylinder 7. Exhaust valve Installation
head assembly.
2) Apply the engine oil to the valve guide. 1) Apply the engine oil to the exhaust valve.
2) Install the exhaust valve to the cylinder head
ANNOTATION:
assembly.
• Apply engine oil to the outer circumference ANNOTATION:
of the valve guide.
• Confirm that there is an E-mark on the valve.
CAUTION
• Use a new valve stem oil seal.
3) Install the valve stem oil seal to the valve

guide using the special tool.
8. Inlet valve Installation

1) Apply the engine oil to the inlet valve.
84402832 NA - May 2011

2415-24
2) Install the inlet valve to the cylinder head as-

sembly.
ANNOTATION:
• Confirm that there is an I-mark on the valve.
Special tool: remover, valve spring (refer

to section 1003)
9. Valve spring Installation

1) Check the identification paint of the valve
spring.
Valve spring identification paint

Inlet Blue
Exhaust White
Special tool: pivot ASM (refer to section

1003)
1 Spring pitch (small)

2 Identification paint
2) Install the valve spring to the cylinder head 5) Install the split collar to the spring seat.
assembly. ANNOTATION:
ANNOTATION: • Lightly tap the valve stem head to stabilize
• Turn the valve spring to face the identifica- the split collar.
tion paint application area towards the cylin-
der head assembly. CAUTION
3) Install the spring seat to the valve spring. • Confirm that the split collar is in the
4) Press the valve spring using the special tool. valve stem groove.
10. Idle gear C Installation

1) Apply the engine oil to the idle gear C.
ANNOTATION:
• Apply to the sliding surface of the gear.
84402832 NA - May 2011

2415-25
2) Apply the engine oil to the idle gear shaft. Special tool: sealing cup installer (refer to
section 1003)
ANNOTATION:
• Apply engine oil to the outer circumference
of the idle gear shaft.
3) Temporarily tighten the idle gear C to the cylin-
der head assembly.
CAUTION
• Confirm that the spigot of the idle
gear shaft is firmly installed to the
Between the idle gear C cover

1 end surface and cylinder head
chamfered edge section
Specified length： 1.5 - 2.5 mm ｛0.0591 -

0.0984 in｝
11. CMP sensor Installation
1) Apply the engine oil to the O-ring.
2) Install the CMP sensor to the cylinder head
1 Idle gear C assembly.
2 Idle gear shaft CAUTION
4) Securely tighten the idle gear C to the cylinder • Be careful not to subject the sensor
head assembly. to shock.
70 lb・ft｝ ANNOTATION:
5) Apply the cement to the idle gear C cover.
• Tighten together with the clip.
ANNOTATION:
• Apply Loctite 962T to the outer circumfer- 69 lb・in｝
ence of the idle gear C cover. 3) Connect the harness connector to the CMP
6) Install the idle gear C cover to the cylinder sensor.
12. Engine coolant temperature sensor Installation
84402832 NA - May 2011

2415-26
1) Install the engine coolant temperature sensor 14. Thermostat Installation

to the cylinder head assembly.
1) Install the gasket to the thermostat.
ANNOTATION:
CAUTION
• Apply Loctite 572 to the threaded portion.
18.4 lb・ft｝
2) Install the thermostat to the cylinder head as-
sembly.
1 Overheat switch
2 Water temperature sensor 1 Jiggle valve position
13. Overheat switch Installation CAUTION
1) Install the overheat switch to the cylinder head • Be careful not to mistake the as-
assembly. sembly position and direction.
ANNOTATION: 3) Install the water outlet pipe to the cylinder
• Apply Loctite 572 to the threaded portion. head assembly.
Tightening torque： 29 N・m ｛3.0 kgf・m / 18.4 lb・ft｝
21.4 lb・ft｝
1 Fan guide bracket

1 Overheat switch 2 Water outlet pipe
84402832 NA - May 2011

2415-27
15. Bracket Installation • It will ride on the casted surface of the cylin-
der head as shown in the diagram when in-
1) Install the EGR cooler bracket B to the cylin- stalled incorrectly.
der head assembly.
17 lb・ft｝
1 Casted surface
2 Gasket
1 EGR cooler bracket B
2) Assemble the exhaust manifold.
16. Exhaust manifold Installation
ANNOTATION:
1) Install the gasket to the cylinder head assem-
bly. • Assemble the seal ring onto the rear side
exhaust manifold and adjust each seal ring
ANNOTATION: joint to be 120 degrees apart.
• Install the gasket by turning the protruding
section downward.

2 Seal ring
CAUTION 3 Front side exhaust manifold
• Confirm that the gasket is firmly in-

3) Install the exhaust manifold to the cylinder
stalled to the cylinder head.
head assembly.
ANNOTATION: ANNOTATION:
84402832 NA - May 2011

2415-28
• Assemble the distance tube and washer re- 5) Install the exhaust manifold cover to the ex-
ferring to the diagram. haust manifold.
23 lb・ft｝
1 Exhaust manifold
2 Distance nut
1 Heat protector
17. Inlet cover Installation

1) Install the gasket to the inlet cover.
2) Install the inlet cover to the cylinder head as-
sembly.
18 lb・ft｝
ANNOTATION:
• Refer to the diagram for the tightening order.
• 1 and 7 in the diagram indicate reamer bolts.
1 Distance tube
2 Nut
3 Washer
4 Distance nut

41 lb・ft｝ Nut
25 lb・ft｝ Distance nut
4) Install the heat protector to the exhaust mani-
fold.
14 lb・ft｝ Bolt
Tightening torque： 41 N・m ｛4.2 kgf・m / 1 Gasket
30 lb・ft｝ Nut 2 Inlet cover
84402832 NA - May 2011

2415-29
2) Temporarily tighten the rear engine hanger

bracket to the cylinder head assembly.
CAUTION
• Completely tighten the rear engine
hanger bracket after installing the
EGR cooler.

69 lb・ft｝ Rear engine hanger bracket
35 lb・ft｝ Rear engine hanger
18. Engine hanger bracket Installation

1) Install the front engine hanger bracket to the
35 lb・ft｝ Front engine hanger bracket
69 lb・ft｝ Front engine hanger
1 Front engine hanger

2 Front engine hanger bracket
3 Rear engine hanger
4 Rear engine hanger bracket
84402832 NA - May 2011

2415-30
Cylinder head assembly Installation 2) Install the cylinder head gasket to the cylinder
block.
1. Cylinder head assembly Installation
CAUTION
CAUTION
• Use a new cylinder head gasket.
• Clean the aligning surface of the cylinder
head and cylinder block before installing 3) Install the cylinder head assembly to the cylin-
the cylinder head assembly. der block.
• Be careful not to damage the cylinder
head and cylinder block while cleaning. CAUTION
1) Apply the liquid gasket to the cylinder block. • Be careful not to damage the cylin-
der head gasket.
ANNOTATION:
• Use ThreeBond 1207B.
Bead width： 3.0 mm {0.1181 in}
Bead height： 2.0 mm {0.0787 in}
ANNOTATION:
• Tightening order of the head bolts
CAUTION
• After applying liquid gasket, install
the cylinder head within 5 minutes.
ANNOTATION: • Apply engine oil to the seat surface and

threaded portion of the M10 head bolts.
• 1 to 26 in the diagram indicate the M14 bolts.
• 27 and 28 in the diagram indicate the M10 5) Tighten the head bolt using the torque wrench.
bolts. Tightening torque： 98 N・m {10.0 kgf・m /
72 lb・ft} M14 bolt
4) Prepare the head bolt.
6) Tighten the head bolt using the torque wrench.
ANNOTATION: Tightening torque： 147 N・m {15.0 kgf・m
/ 108 lb・ft} M14 bolt
• Apply molybdenum disulfide grease to the
seat surface and threaded portion of the
M14 head bolts.
84402832 NA - May 2011

2415-31
7) Tighten the head bolt using the special tool. 1) Align 1st cylinder to the compression top dead
center.
Special tool: angle gauge (refer to section

1003) 2) Apply the engine oil to the camshaft bearing.
Tightening angle： 30 - 60 ° M14 bolt ANNOTATION:
Tightening torque： 38 N・m {3.9 kgf・m / 28 • Apply engine oil to the sliding surface of the
lb・ft} M10 bolt bearing.
CAUTION
Tightening torque：142 N・m {14.5 kgf・m /
105 lb・ft} Check the tightening M14 bolt • Apply engine oil after cleaning the
2. Bridge Installation bearing installation sections of
the camshaft bearing and cylinder
1) Apply the engine oil to the bridge. head.
2) Install the bridge to the bridge guide.
3) Install the camshaft bearing to the cylinder
CAUTION head assembly.
• Confirm that the bridge moves ANNOTATION:
smoothly.
• To prevent the effect of spring force on the
3) Apply the engine oil to the bridge cap. sub gear, use a scissors gear spring wrench
4) Install the bridge cap to the bridge. to rotate the sub gear before installing the
camshaft on the cylinder head.
4) Align the sub gear to the camshaft gear using
the special tool.
ANNOTATION:
• Install the alignment pin from the sub gear
side if the holes of the sub gear and the
camshaft main gear are aligned.
CAUTION
3. Camshaft Installation
Special tool: scissors gear spring wrench

84402832 NA - May 2011

2415-32
7) Apply the engine oil to the camshaft bearing.

ANNOTATION:
• Apply engine oil to the sliding surface of the
bearing.
CAUTION
• Apply engine oil after cleaning the
bearing installation sections of the
camshaft bearing and camshaft
bearing cap.
8) Install the camshaft bearing to the camshaft

bearing cap.
9) Install the camshaft bearing cap to the cylinder
1 Alignment pin head assembly.
5) Install the camshaft to the cylinder head as- ANNOTATION:

sembly. • Turn the camshaft bearing cap so that the
ANNOTATION: arrow mark on the top surface faces the en-
gine front side, and assemble in numerical
• Mesh together the idle gear C and the order.
camshaft gear so that the alignment mark
on the camshaft gear matches the top sur- Tightening torque：28 N・m {2.8 kgf・m / 20
face of the cylinder head, and gently install lb・ft} Engine oil application
the camshaft.
CAUTION
• Align the alignment marks of the
sub gear side.
4. Rocker arm shaft Installation

1) Apply the engine oil to the bracket.
ANNOTATION:
• Apply to each sliding surface.
6) Check alignment mark of the camshaft gear.
CAUTION
• Confirm that the alignment mark is
not misaligned before installing the
• If the alignment mark is not at
the correct position, reinstall the
camshaft.
84402832 NA - May 2011

2415-33
2) Apply the engine oil to the rocker arm. 5. Rocker arm shaft Adjustment
• Confirm that the adjust screw is fully loos- • Valve clearance adjustment
ened.
CAUTION
• Adjust the valve clearance while cool.
• Loosen all adjust screws before adjust-
ment.
1 Front side camshaft bracket

2 Rocker arm
3 Rear side camshaft bracket
3) Install the rocker arm shaft to the cylinder 1) Align 1st cylinder to the compression top dead
head assembly. center.
ANNOTATION:
• On the camshaft bearing assembly section
only, apply oil to the threaded portion of
the stud bolts and the seat surface/threaded
portion of the nuts, then tighten them.
• Tightening order
2) Prepare the feeler gauge.

Thickness： 0.4 mm {0.0157 in} 2 pieces
ANNOTATION:
• Insert the thickness gauge between the
rocker arm and bridge cap.
bridge and valve.
Rocker arm shaft tightening torque
Parts Tightening torque
Front side camshaft
bearing cap : 28 N・m {2.8 kgf・m /
Rear side camshaft 20 lb・ft}
bearing cap
: 56 N・m {5.7 kgf・m /
Rocker arm bracket
41 lb・ft}
84402832 NA - May 2011

2415-34
3) Turn the adjust screw. • Check if the valve shaft end on the opposite
side is floating or touching at an angle.
ANNOTATION:
• If it is floating or touching at an angle, slightly
• When the movement of the thickness gauge loosen the bridge adjust screw and adjust
becomes stiff, secure the adjust screw nut the valve shaft ends on both sides to touch
of the rocker arm. properly.
Tightening torque： 22 N・m {2.2 kgf・m / 16 Valve bridge clearance ： less than 0.1 mm
lb・ft} {less than 0.0039 in}
ANNOTATION:
• To prevent turning, fix the bridge adjust
screw with a flathead screwdriver, and
tighten the adjust screw nut.
Tightening torque： 22 N・m {2.2 kgf・m /
16.lb・ft}
4) Turn the adjust screw.

ANNOTATION:
• With the thickness gauge inserted, lightly
tighten the adjust screw of the bridge.
• Confirm that the leading end of the adjust
screw and valve shaft end have made con-
tact and the movement of the thickness
gauge has become stiff.
Cylinder No. 1 2 3 4 5 6
Condision Arrangement of valves IN EXH IN EXH IN EXH IN EXH IN EXH IN EXH
When the #1 cylinder is
set at the compression ○ ○ ○ ○ ○ ○
Valve to be top dead center
adjusted When the #6 cylinder is
top dead center
6. Lower cover Installation 1 Rubber plug

2 Liquid gasket
1) Apply the liquid gasket to the rubber plug.
ANNOTATION:
CAUTION
• Apply ThreeBond 1207B.
• After applying the liquid gasket, in-
stall the lower cover within 5 min-
utes.
2) Install the rubber plug to the cylinder head

assembly.
3) Install the gasket to the lower cover.
84402832 NA - May 2011

2415-35
4) Install the lower cover to the cylinder head 8. Fuel leak off pipe assembly Installation
assembly.
1) Temporarily tighten the fuel leak-off pipe to the
112 lb・in}
ANNOTATION: CAUTION
• Tightening order • Use new gaskets.

common rail assembly.
CAUTION

fuel supply pump.
ANNOTATION:
• Tighten the fuel feed pipe together.
CAUTION
7. Common rail assembly Installation • Use new gaskets.
1) Align the common rail assembly to the inlet 4) Securely tighten the fuel leak-off pipe to the
cover. cylinder head assembly.
2) Temporarily tighten the bolt to the common rail Tightening torque： 14 N・m {1.4 kgf・m /
assembly. 123.9 lb・in}
3) Temporarily tighten the nut to the common rail 5) Securely tighten the fuel leak-off pipe to the
assembly. common rail assembly.
4) Securely tighten the bolt to the common rail Tightening torque： 20 N・m {2.1 kgf・m /
assembly. 14.8 lb・ft}
Tightening torque： 25 N・m {2.5 kgf・m / 6) Securely tighten the fuel leak-off pipe to the
18.4 lb・ft} fuel supply pump.
5) Securely tighten the nut to the common rail Tightening torque： 10 N・m {1.0 kgf・m /
assembly. 88.5 lb・in}
Tightening torque： 25 N・m {2.5 kgf・m / 7) Install the clip to the fuel leak-off pipe.
18.4 lb・ft} Tightening torque： 9 N・m {0.9 kgf・m / 79.7
lb・in}
1 Common rail assembly

1 Fuel leak-off pipe
6) Connect the harness connector to the fuel
pressure sensor. 9. Fuel pipe Installation
84402832 NA - May 2011

2415-36
1) Install the fuel pipe to the fuel supply pump 4) Temporarily tighten the injection pipe to the
and the common rail assembly. common rail assembly.
5) Securely tighten the injector to the cylinder
CAUTION head assembly.
• Use new fuel pipes. lb・ft}
6) Install the injector leak-off pipe to the injector.
32.5 lb・ft} CAUTION
2) Install the clip to the bracket.
Tightening torque： 9 N・m {0.9 kgf・m / 79.7 • Use new gaskets.
lb・in}
10. Injector Installation 126 lb・in}
CAUTION 11. Injection pipe Installation
• When reusing an injector, do not change 1) Securely tighten the injection pipe to the injec-
the installation position. tor.
1) Apply the engine oil to the bolt. 32.5 lb・ft}
2) Temporarily tighten the injector to the cylinder 2) Securely tighten the injection pipe to the com-
head assembly. mon rail assembly.
CAUTION 32.5 lb・ft}
3) Install the clip to the inlet cover.
• Be extremely careful not to damage Tightening torque： 6 N・m {0.6 kgf・m / 53.1
lb・ft}
1 Injector 1 No.1 injection pipe

2 Installation bolt 2 No.2 injection pipe
3) Temporarily tighten the injection pipe to the 4 No.4 injection pipe
injector. 5 No.5 injection pipe
CAUTION 7 Fuel pipe
• Use new injection pipes.
12. Glow plug Installation
84402832 NA - May 2011

2415-37
1) Install the glow plug to the cylinder head as- 1) Install the injector harness to the cylinder head
sembly. assembly.
ANNOTATION:
14.8 lb・ft}
• Tighten the bolts on the bracket and in-
CAUTION stall the injector harness together with the
bracket.
• Be careful not to exceed the speci-
fied torque when tightening. Tightening torque： 22 N・m {2.2 kgf・m / 16
lb・ft}
2) Install the glow plug connector to the glow

plug.
Tightening torque： 1 N・m {0.1 kgf・m / 8.9 1 Injector harness terminal
lb・in} 2 Injector harness bracket
CAUTION
2) Connect the injector harness to the injector.
• Confirm that the glow plug connec-
tor does not interfere with the sur- CAUTION
rounding parts.
13. Injector harness Installation
1 Injector
2 Injector harness
3 Terminal nut
3) Install the connector to the lower cover.

lb・in}
14. Cylinder head cover Installation
head cover.
2) Install the cylinder head cover to the lower
cover.
84402832 NA - May 2011
2415-38
Tightening torque： 13 N・m {1.3 kgf・m / 1) Install the inlet pipe to the inlet cover.
115 lb・in} Tightening torque： 25 N・m {2.5 kgf・m / 18
lb・ft}
ANNOTATION:
1 Inlet pipe
2) Connect the harness connector to the boost

sensor.
temperature sensor.
4) Connect the harness connector to the IMT
sensor.
5) Install the harness clip to the inlet pipe.
lb・ft}

2 Head cover gasket
3 Lower cover
3) Connect the ventilation hose to the air

breather.
15. Inlet pipe Installation
1 Boost sensor
2 Harness clip
4 IMT sensor
84402832 NA - May 2011

2415-39
16. Intake throttle valve Installation 3) Connect the harness connector to the intake
throttle valve.
1) Install the intake throttle valve to the inlet pipe.
Tightening torque： 24 N・m {2.4 kgf・m / 17 ANNOTATION:
lb・ft}
• After connecting the harness connector,
press in the lock operation portion to lock.

2 Gasket
3 Inlet pipe 1 Lock operation section
2 Lock release
2) Install the air duct to the intake throttle valve. 3 Lock
84402832 NA - May 2011

2415-40
17. EGR cooler water pipe Installation
84402832 NA - May 2011

2415-41
1) Install the water bypass hose to the water 5) Install the fan guide stay to the fan guide.
pump assembly and the water duct. Tightening torque： 30 N・m {3.1 kgf・m / 22
lb・ft}
1 Water bypass hose
2) Install the EGR cooler water pipe to the engine 1 Fan guide
assembly. 2 Fan guide stay
Clamp tightening torque： 20 N・m {2.0 kgf・ 3 Fan guide bracket
m / 14 lb・ft}
ANNOTATION:
18. Oil separator bracket Installation
• Tightening torque of bolt 1 in the diagram is
different from others. 1) Temporarily tighten the oil separator bracket
lb・ft} ANNOTATION:
2) Install the ventilation hose to the air breather.
3) Securely tighten the oil separator bracket to
lb・ft}
CAUTION
• Pay attention to the installation an-
gle of the hose.
4) Install the clip to the cylinder block.

lb・ft}
1 Installation bolt
3) Connect the radiator upper hose to the water

outlet pipe.
4) Install the fan guide stay to the fan guide
bracket.
lb・ft}
1 Oil separator bracket

2 Clip
84402832 NA - May 2011
2415-42
19. EGR valve Installation 6) Temporarily tighten the EGR cooler C to the
EGR bracket C.
33.9 lb・ft}
1 EGR cooler C
2 EGR cooler bracket C
3 EGR cooler B
1 EGR valve
7) Temporarily tighten the EGR pipe B to the
1) Temporarily tighten the EGR pipe A to the ex- EGR cooler C and the EGR valve.
haust manifold.
EGR pipe A.
1 EGR valve
2 EGR pipe B
3 EGR cooler C
1 EGR cooler A
2 EGR pipe A 8) Securely tighten the EGR pipe A to the ex-
3 Exhaust manifold haust manifold.
3) Temporarily tighten the EGR cooler bracket A lb・ft}
to the EGR cooler A. 9) Securely tighten the EGR cooler A to the EGR
4) Temporarily tighten the EGR cooler B to the pipe A.
EGR cooler A. Tightening torque： 31 N・m {3.2 kgf・m / 23
5) Temporarily tighten the EGR bracket C to the lb・ft}
EGR cooler B. 10) Securely tighten the EGR cooler B to the EGR
cooler A.
lb・ft}
the EGR cooler B.
lb・ft}
cooler bracket C.
lb・ft}
84402832 NA - May 2011
2415-43
13) Securely tighten the EGR pipe B to the EGR 21. Oil level gauge guide tube Installation
cooler C.
1) Install the oil level gauge guide tube to the
cylinder block.
lb・ft}
lb・ft}
valve.
Tightening torque： 46 N・m {4.7 kgf・m / 34 2) Connect the oil level gauge guide tube to the
lb・ft}
15) Securely tighten the EGR cooler bracket A to Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft}
Tightening torque： 24 N・m {2.4 kgf・m / 17 3) Install the oil level gauge to the oil level gauge
guide tube.
lb・ft}
lb・ft}
lb・ft}
18) Install the EGR heat protector to the EGR
pipe.
lb・ft}
1 Oil level gauge guide tube
22. Turbocharger assembly Installation

1) Replenish the engine oil with the turbocharger
assembly.
2) Align the gasket to the turbocharger assem-
bly.
haust manifold.
lb・ft}
4) Install the water feed pipe to the cylinder
1 EGR heat protector block.
19) Connect the water rubber hose to the EGR lb・ft}
cooler. Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft} Clip
CAUTION

bocharger assembly.
lb・ft}
CAUTION
1 Water rubber hose
84402832 NA - May 2011

2415-44
6) Install the water return pipe to the cylinder 11) Connect the oil feed pipe to the turbocharger
block. assembly.
Tightening torque： 41 N・m {4.2 kgf・m / 30 Tightening torque： 34 N・m {3.5 kgf・m / 25
lb・ft} lb・ft}
lb・ft} Clip lb・ft} Clip
CAUTION CAUTION
• Use a new gasket. • Use a new gasket.

bocharger assembly.
lb・ft}
CAUTION
8) Install the oil return pipe to the cylinder block.

lb・ft}
CAUTION
1 Oil feed pipe
9) Connect the oil return pipe to the turbocharger 2 Clip
assembly.
3 Oil return pipe
lb・ft} 4 Water feed pipe
5 Water return pipe
CAUTION
• Use a new gasket. assembly.
10) Install the oil feed pipe to the pipe bracket. assembly and the intercooler.
Tightening torque： 34 N・m {3.5 kgf・m / 25 14) Install the air cleaner duct to the air cleaner
lb・ft} assembly and the turbocharger assembly.
lb・ft} Clip 23. Engine harness Connect
1) Connect the engine harness to the engine as-
CAUTION sembly.
• Use a new gasket. ANNOTATION:
• Connect each connector.
24. Coolant Filling
CAUTION
parts.
off.
84402832 NA - May 2011

2415-45
3) Tighten the valve using a wrench. 2) Turn ON the starter switch.
CAUTION ANNOTATION:
• Use new gaskets. • This is for the models with an electromag-

netic pump.
Tightening torque： 22 N・m {2.2 kgf・m / 16 3) Loosen the plug using the wrench.
lb・ft} 4) Operate the priming pump.
4) Replenish the coolant with the radiator. Number of times： 20 count(s) or more
ANNOTATION:
• Confirm that fuel comes out from around the
plug.
5) Tighten the plug using the wrench.
6) Operate the priming pump.
Number of times： 10 count(s) or more
ANNOTATION:
• Wait for the specified time after operating
the priming pump.
Specified time： 1 min
7) Loosen the plug using the wrench.
ANNOTATION:
1 Valve • Remove the air in the fuel filter.
2 Gasket
25. Battery ground cable Connect Number of times： 10 count(s) or more
1) Connect the battery ground cable to the bat- ANNOTATION:

tery. • Wait for the specified time after operating
26. Fuel Air bleed the priming pump.
CAUTION 10) Loosen the plug using the wrench.
• To prevent engine failure, be sure to per- ANNOTATION:
form air removal after the installation or
removal of fuel system parts. • Remove the air in the fuel filter.
ANNOTATION:
the priming pump.
ANNOTATION:
• Remove the air in the fuel filter.
88.5 lb・in}
1 Priming pump
CAUTION
2 Plug
3 Drain plug • Remove the fuel around the plug
4 Case thoroughly after tightening.
5 Fuel filter element
Number of times： 10 count(s)
1) Prepare the pan. 16) Start the engine.
84402832 NA - May 2011

2415-46
ANNOTATION: Specified time： 3 min

• Do not accelerate the engine revolution right ANNOTATION:
after staring.
• Accelerate the engine revolution to maxi-
Specified time： 5 s mum.
• Lower the rotation.
ANNOTATION:
• Accelerate the engine revolution gradually.
84402832 NA - May 2011

2415-47
Cylinder head assembly Inspection 3. Idle gear C Inspection

1. Bridge cap Inspection 1) Measure the clearance using the feeler
gauge.
1) Measure the bridge cap using the dial gauge.
ANNOTATION:
ANNOTATION:
• Measure the clearance in the axis direction
• Measure the contact surface of the bridge between the cylinder head and idle gear C.
cap and rocker arm.
Specified value： 0.090 - 0.145 mm {0.0035 -
Limit： 0.1 mm {0.0039 in} Amount of wear on 0.0057 in}
the bridge cap Limit： 0.20 mm {0.0079 in}
CAUTION
• Replace the bridge cap if the mea-
sured value exceeds the limit value.
• Replace the bridge cap if it
has an abnormal wear such as
band-shaped wear.
1 Idle gear C
2) Measure the idle gear shaft using the vernier

caliper.
ANNOTATION:
• Outer diameter of the idle gear shaft
2. Bridge Inspection
Specified value： 30.00 mm {1.1811 in}
1) Inspect the bridge. Limit： 29.85 mm {1.1752 in}
ANNOTATION: 4. Inlet valve Inspection
• Confirm that the bridge moves smoothly. 1) Measure the inlet valve using the micrometer.
2) Check the clearance of the bridge cap. ANNOTATION:
Standard value： 0.020 - 0.057 mm {0.0008 -
0.0022 in} Between the bridge and bridge cap • Outer diameter of the valve stem
Specified value ： 0.1 mm {0.0039 in} Be- Measurement part： 3 section(s)
tween the bridge and bridge cap Specified value： 8.0 mm {0.3150 in} Diame-
ter
Limit： 7.88 mm {0.3102 in} Diameter
CAUTION
• Replace the inlet valve and valve
guide if the measured value is un-
der the limit value.
1 Bridge
2 Bridge guide
84402832 NA - May 2011

2415-48
2) Install the inlet valve to the valve guide.

3) Measure the valve guide clearance using the CAUTION
dial gauge.
ANNOTATION: guide if the measured value ex-
ceeds the limit value.
• Valve guide clearance
Specified value： 0.039 - 0.071 mm {0.0015 - 5) Inspect the inlet valve using the red lead
0.0028 in} primer.
Limit： 0.2 mm {0.0079 in}
ANNOTATION:
• Inspect the contact surface of the inlet valve
and valve seat.
Specified value： 2.7 mm {0.1063 in} Contact
width
Limit： 3.0 mm {0.1181 in} Contact width
CAUTION
• If the measured value exceeds the
limit value, fix the contact surface
of the valve seat using a sheet cut-
ter.
• If the contact position is not in the
center of the valve seat, fix the con-
tact surface of the valve seat using
a sheet cutter.
1 Valve
• If the contact surface is not smooth,
The position 10 mm under the fix the contact surface of the valve
2
valve guide head seat using a sheet cutter.
3 Valve guide
CAUTION
guide if the measured value ex-
ceeds the limit value.
4) Measure the inlet valve using the micrometer.

ANNOTATION:
• Valve thickness
Limit： 1.30 mm {0.0512 in}
84402832 NA - May 2011

2415-49
6) Adjust the valve seat to standard value using 10) Check the sinking amount of the inlet valve.
the valve seat cutter. Specified value： 0.80 - 1.03 mm {0.0315 -
0.0406 in}
CAUTION Limit： 2.3 mm {0.0906 in}
• Use a seat cutter suitable for the
valve seat angle and valve stem di-
ameter.
Valve seat angle： 30 °

External diameter of the valve stem： 8.0 mm
{0.3150 in} Diameter
5. Exhaust valve Inspection

1) Measure the exhaust valve using the microm-
eter.
ANNOTATION:
• Outer diameter of the valve stem
7) Apply the compound to the valve seat. Measurement part： 3 section(s)
8) Install the inlet valve to the valve guide. Specified value： 8.00 mm {0.3150 in} Diam-
9) Adjust contact surface to standard value using eter
the valve lapper. Limit： 7.88 mm {0.3102 in} Diameter
ANNOTATION:
CAUTION
• Lightly tap the inlet valve on the valve seat
while turning it. • Replace the exhaust valve and
valve guide if the measured value
is under the limit value.
CAUTION
2) Install the exhaust valve to the valve guide.
• After fixing the valve, remove all 3) Measure the valve guide clearance using the
compounds. dial gauge.
ANNOTATION:
• Valve guide clearance
0.0038 in}
Limit： 0.25 mm {0.0098 in}
84402832 NA - May 2011

2415-50
Limit： 3.0 mm {0.1181 in} Contact width
CAUTION
• If the measured value exceeds the
limit value, fix the contact surface
of the valve seat using a sheet cut-
ter.
• If the contact position is not in the
center of the valve seat, fix the con-
tact surface of the valve seat using
a sheet cutter.
• If the contact surface is not smooth,
fix the contact surface of the valve
seat using a sheet cutter.
1 Valve
The position 10 mm under the
2
valve guide head
3 Valve guide
CAUTION
• Replace the exhaust valve and
exceeds the limit value.
4) Measure the exhaust valve using the microm-

eter.
6) Adjust the valve seat to standard value using
ANNOTATION:
the valve seat cutter.
• Valve thickness
CAUTION
Limit： 1.30 mm {0.0512 in} • Use a seat cutter suitable for the
valve seat angle and valve stem di-
ameter.
Valve seat angle： 45 °

External diameter of the valve stem： 8.0 mm
{0.3150 in} Diameter
CAUTION
• Replace the exhaust valve and
7) Apply the compound to the valve seat.
5) Inspect the exhaust valve using the red lead 8) Install the exhaust valve to the valve guide.
primer. 9) Adjust contact surface to standard value using
ANNOTATION: the valve lapper.
• Inspect the contact surface of the exhaust ANNOTATION:
valve and valve seat.
• Tap the exhaust valve on the valve seat
Specified value： 2.5 mm {0.0984 in} Contact while turning it.
width
84402832 NA - May 2011
2415-51
ANNOTATION:
• Fix it if it is possible.
CAUTION
• After fixing the valve, remove all
compounds. 2) Perform dye penetrant check.
ANNOTATION:
10) Check the sinking amount of the exhaust
valve. • Check if there is a problem which cannot be
Specified value： 1.24 - 1.47 mm {0.0488 - detected by visual inspection.
0.0579 in} 3) Align the simple straight ruler to the cylinder
Limit： 2.8 mm {0.1102 in} head assembly.
4) Measure the clearance using the feeler
gauge.
ANNOTATION:
• Flatness of the bottom of the cylinder head
6. Cylinder head assembly Inspection
CAUTION
• Clean the each part of the cylinder head
assembly before inspecting.
Measurement part： 6 section(s)
head while cleaning the cylinder head as- Limit： 0.2 mm {0.0079 in}
sembly. 5) Inspect the water leak using the water pres-
sure tester.
Specified pressure： 490.0 kPa {5.00 kgf/cm2
1) Inspect the cylinder head assembly.
/ 71 psi}
ANNOTATION: Specified time： 3 min
• Installation surface of the cylinder head gas- ANNOTATION:
ket
• Perform a hydraulic test with the injector
• Combustion chamber holder installed.
• Exhaust port
• Valve seat
• Glow plug hole
CAUTION
• Replace the cylinder head if dam-
age such as a crack has been found
in the inspection.
84402832 NA - May 2011

2415-52
Section
2425
Removal and Installation of Cylinder Block
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Cylinder block Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Cylinder block Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Cylinder block Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Cylinder block Removal 1) Remove the fan guide from the fan guide
bracket.
1. Battery ground cable Disconnect
1) Disengage the battery ground cable from the
battery.
2. Coolant Drain
CAUTION
3. Engine oil Drain

1) Remove the drain plug from the oil pan.
2) Drain the engine oil from the oil pan.
3) Install the drain plug to the oil pan. 1 Bolt
Tightening torque： 70 N・m {7.1 kgf・m / 52 2 Washer
lb・ft} 3 Rubber mount
4. Engine harness Disconnect 4 Rubber mount
5 Guide tube
6 Fan guide
gine assembly.
ANNOTATION: 2) Remove the fan guide bracket from the engine
assembly.
7. Drive belt Removal
5. Cooling fan Removal
1) Remove the drive belt from the engine assem-
1) Remove the cooling fan from the adapter. bly.
1 Cooling fan 1 Adjust bolt

2 Adapter 2 Fixing bolt
3 Fixing bolt
6. Fan guide Removal
8. Crankshaft pulley Removal
1) Remove the crankshaft pulley from the crank-
shaft.
2) Remove the crankshaft damper from the
crankshaft pulley.
9. Crankshaft front oil seal Removal
84402832 NA - May 2011

2425-3
1) Remove the crankshaft front oil seal from the

timing gear case.
CAUTION
• Be careful not to damage the oil
seal press-fitting surface of the tim-
ing gear case.
10. Water pump assembly Removal

1) Remove the fan pulley from the water pump
assembly.
1 Felt
2 Slinger
3 Crankshaft front oil seal
2) Remove the slinger from the crankshaft using

the special tool.
2) Remove the water bypass hose from the wa-

ter pump assembly and the water duct.
Special tool: rear oil seal remover (refer

to section 1003)
CAUTION
• When replacing the oil seal, replace
the slinger. 1 Water bypass hose
3) Remove the water hose from the EGR cooler

water pipe and the water pump assembly.
4) Remove the water pump assembly from the
gear case cover cover.
11. Cover of gear case cover Removal
1) Remove the adjust plate from the gear case
cover cover.
2) Remove the gear case cover cover from the
cylinder block.
84402832 NA - May 2011
2425-4
1) Remove the air cleaner duct from the air 1) Disengage the water rubber hose from the
cleaner assembly and the turbocharger as- EGR cooler.
sembly.
bocharger.
bocharger assembly.
ANNOTATION:
5) Remove the oil feed pipe from the pipe
bracket.
ANNOTATION:
1 Water rubber hose
bocharger assembly.
7) Remove the oil return pipe from the cylinder 2) Remove the EGR pipe B from the EGR valve
block. and the EGR cooler C.
bocharger assembly.
der head assembly.
bocharger assembly.
ANNOTATION:
11) Remove the water feed pipe from the cylinder
block.
ANNOTATION:
12) Disengage the harness connector from the 1 EGR valve
turbocharger assembly. 2 EGR pipe B
3 EGR cooler C
exhaust manifold.
3) Remove the EGR cooler C from the EGR
bracket C.
4) Remove the EGR bracket C from the EGR
cooler B.
5) Remove the EGR cooler B from the EGR
cooler bracket A.
1 Oil feed pipe

2 Clip
3 Oil return pipe
4 Water feed pipe
5 Water return pipe

84402832 NA - May 2011
2425-5
6) Remove the EGR cooler bracket A from the 9) Remove the EGR pipe A from the exhaust
EGR cooler A. manifold.
1 EGR cooler C 1 EGR cooler A

2 EGR bracket C 2 EGR pipe A
3 EGR cooler B 3 Exhaust manifold
14. EGR valve Removal
7) Remove the EGR heat protector from the EGR valve.
EGR pipe A. 2) Remove the EGR valve from the inlet pipe.
1 EGR heat protector 1 EGR valve
15. Oil separator bracket Removal

A. 1) Remove the clip from the cylinder block.
84402832 NA - May 2011

2425-6
2) Remove the ventilation hose from the air 3) Remove the oil separator bracket from the
breather. cylinder head assembly.

2 Clip
84402832 NA - May 2011

2425-7
1) Disengage the radiator upper hose from the 2) Remove the EGR cooler water pipe from the
water outlet pipe. engine assembly.
84402832 NA - May 2011

2425-8
3) Remove the water bypass hose from the wa- 2) Disengage the harness connector from the in-
ter pump assembly and the water duct. take throttle valve.
ANNOTATION:
lock.
1 Water bypass hose
17. Oil level gauge guide tube Removal

1 Lock operation section
2) Disengage the oil level gauge guide tube from
the front engine hanger bracket. 3) Remove the intake throttle valve from the inlet
3) Remove the oil level gauge guide tube from pipe.
the cylinder block.

1 Oil level gauge guide tube 2 Gasket
3 Inlet pipe
18. Intake throttle valve Removal 19. Inlet pipe Removal

1) Remove the air duct from the intake throttle 1) Disengage the harness connector from the
valve. boost sensor.
84402832 NA - May 2011

2425-9
2) Disconnect the harness connector from the 2) Remove the glow plug from the cylinder head
boost temperature sensor. assembly.
IMT sensor.

1 Boost sensor and the common rail assembly.
2 Harness clip CAUTION
4 IMT sensor • Do not reuse the removed injection
pipe.
• Seal the common rail and injector to
5) Remove the inlet pipe from the inlet cover. prevent foreign material from enter-
ing.
1 Inlet pipe
20. Glow plug Removal 2 No.2 injection pipe
1) Remove the glow plug connector from the
glow plug.
7 Fuel pipe

ANNOTATION:
CAUTION
84402832 NA - May 2011
2425-10
23. Fuel leak off pipe assembly Removal 25. Cylinder head cover Removal
1) Disengage the fuel leak-off pipe from the cylin- 1) Disengage the ventilation hose from the air
der head. breather.
2) Remove the fuel leak-off pipe from the fuel 2) Remove the cylinder head cover from the
supply pump. lower cover.
ANNOTATION:
der head cover.
• Remove the eyebolt tightened together with
the fuel feed pipe.
3) Disengage the fuel leak-off pipe from the com-
mon rail assembly.
4) Remove the fuel leak-off pipe from the inlet
pipe.
ANNOTATION:

2 Head cover gasket
3 Lower cover
26. Injector harness Removal

1) Remove the connector from the lower cover.
CAUTION
1 Fuel leak-off pipe nector with a screwdriver.
24. Common rail assembly Removal
fuel pressure sensor.
2) Remove the common rail assembly from the
inlet cover.
84402832 NA - May 2011

2425-11
2) Disengage the injector harness from the injec-

tor.
CAUTION
Special tool: injector remover (refer to

section 1003)
1 Injector
2 Injector harness
3 Terminal nut
3) Remove the injector harness from the cylinder

head assembly.
ANNOTATION:
• Remove the bracket tightening bolts and section 1003)
with the bracket.
1 Sliding hammer
2 Fuel injector remover
1 Injector harness terminal 3 Injector
CAUTION
1) Remove the injector leak-off pipe from the in- • Confirm that the sleeve is not pulled
jector. out together when pulling out the
2) Remove the injector from the cylinder head injector using a special tool.
assembly. • Store each ID code plate on the in-
jector head with the cylinder num-
ANNOTATION: ber tag attached to avoid a mix-up.
• When it is difficult to remove the injector, use the injector nozzle.
a special tool.
84402832 NA - May 2011
2425-12
28. Lower cover Removal 30. Camshaft Removal

1) Remove the lower cover from the cylinder 1) Remove the camshaft bearing cap from the
head assembly. cylinder head assembly.
2) Remove the rubber plug from the cylinder 2) Remove the camshaft bearing from the
head assembly. camshaft bearing cap.
3) Remove the camshaft from the cylinder head.
4) Remove the camshaft bearing from the cylin-
1) Loosen the adjust screw using the wrench. der head assembly.
• Loosen all valve clearance adjustment • Temporarily assemble the removed caps
screws. and bearings in the original position to avoid
spected.

head assembly.
ANNOTATION: 31. Bridge Removal
• Evenly loosen the rocker arm shaft bracket 1) Remove the bridge cap from the bridge.
ening bolts from both ends and remove CAUTION
them.
CAUTION cap into the engine.

84402832 NA - May 2011

2425-13
2) Remove the bridge from the bridge guide. 32. Cylinder head assembly Removal
ANNOTATION: 1) Remove the cylinder head assembly from the
cylinder block.
with other installation locations. ANNOTATION:
1 Bridge cap
2 Bridge
CAUTION 1 Idle gear C
• Since the idle gear C protrudes 2) Remove the cylinder head gasket from the
from the bottom surface of the cylinder block.
damage the gear. CAUTION
• Do not reuse the cylinder head gas-
ket.
33. Fuel supply pump Removal

fuel supply pump.
84402832 NA - May 2011

2425-14
2) Remove the fuel supply pump from the cylin- 2) Remove the CKP sensor from the flywheel
der block. housing.
ANNOTATION: CAUTION
• Remove together with the bracket. • Be careful not to subject the sensor
to shock.
1 Fuel supply pump

2 Bracket 1 Oil pressure switch
3 Gear 2 Oil port cover
4 Nut 3 Flywheel housing
5 Bolt 4 CKP sensor
6 O-ring
7 O-ring 36. Flywheel Removal
8 Nut 1) Remove the flywheel from the crankshaft.
9 Bolt
10 Nut ANNOTATION:
• Gradually loosen the flywheel installation
bolts in the order shown in the diagram.
34. Starter assembly Removal
1) Disengage the earth cable from the starter as-
sembly.
2) Remove the starter assembly from the fly-
wheel housing.
CAUTION
• Fix the flywheel firmly so that it will
not rotate.
35. CKP sensor Removal 37. Crankshaft rear oil seal Removal
1) Disengage the harness connector from the 1) Remove the crankshaft rear oil seal from the
CKP sensor. crankshaft using the special tool.
84402832 NA - May 2011

2425-15
3) Remove the gasket from the oil pan.

39. Oil strainer Removal
1) Remove the oil strainer from the crankcase.
2) Remove the O-ring from the oil strainer.

to section 1003)
40. Flywheel housing Removal

1) Remove the PTO oil pipe from the flywheel
housing and the cylinder block.
2) Remove the oil pipe from the pipe bracket and
the oil port cover.
1 Felt
2 Slinger
3 Crankshaft rear oil seal
1 Oil pipe
2 Pipe bracket
3 PTO oil pipe
3) Remove the cover from the flywheel housing.
CAUTION
seal press-fitting surface.
ANNOTATION:
• Remove the slinger and oil seal together.
38. Oil pan Removal
1) Disengage the harness connector from the oil
level switch. 1 O-ring
2) Remove the oil pan from the crankcase. 2 Cover
84402832 NA - May 2011
2425-16
4) Remove the PTO idle gear from the cylinder

block.
5) Remove the flywheel housing from the cylin-
der block and the crankcase.
CAUTION
• Do not forget to remove the bolt

gauge.
ANNOTATION:
• Measure the clearance between the idle
gear and the thrust collar.
CAUTION
• Measure the play of the idle gear in
the axis direction before removing
the idle gear B.
1 Bolt
41. Idle gear Measurement 0.0061 in}
Limit： 0.20 mm {0.0079 in}
1) Align the dial gauge to the idle gear.
CAUTION
ANNOTATION:
• Attach the dial gauge to the idle gear tooth • Replace the idle gear if the mea-
to be measured. sured value exceeds the limit value.
2) Inspect the backlash.

ANNOTATION:
• Gently move the gear right and left to read
the inconsistency on the dial gauge.
CAUTION
• Measure the idle gear backlash be-
fore removing the idle gear A.

0.0067 in}
Limit： 0.30 mm {0.0118 in}
CAUTION
42. Idle gear A Removal
• Replace the idle gear if the mea-
sured value exceeds the limit value. 1) Remove the idle gear A from the idle gear A
shaft.
84402832 NA - May 2011

2425-17
2) Remove the idle gear A shaft from the cylinder 1) Clean the cylinder liner using the scraper.
block.
ANNOTATION:
• Remove carbon from the top of the cylinder
liner using a scraper.
43. Oil pump assembly Removal

1) Remove the oil pump assembly from the cylin-
der block. 2) Remove the connecting rod bearing cap from
the connecting rod.
ANNOTATION:
• Set the piston of the cylinder to be removed
to the bottom dead center.
44. Idle gear B Removal

1) Remove the idle gear B from the idle gear B
shaft.
2) Remove the idle gear B shaft from the cylinder
block.
3) Remove the connecting rod bearing from the
connecting rod bearing cap.
ANNOTATION:
• Organize the removed bearings by the cylin-
ders using tags, etc.
4) Remove the piston from the cylinder block.
ANNOTATION:
• Pull out the piston and connecting rod to-
gether to the cylinder head side.
CAUTION
• Be careful not to damage the oil jet.
45. Piston Removal
5) Remove the connecting rod bearing from the
connecting rod.
ANNOTATION:
• Organize the removed bearings by the cylin-
ders using tags, etc.
46. Crankshaft Removal
84402832 NA - May 2011
2425-18

gauge.
ANNOTATION:
• Measure the crankshaft clearance in the
axis direction at the bearing section No.7.
0.0081 in}
1 Replacer hole
: 4 section(s)
3) Remove the thrust bearing from the
crankcase.
4) Remove the crankshaft bearing from the
crankcase.
CAUTION
• Replace the thrust bearing if the
measured value is not within the
range of the standard value.
2) Remove the crankcase from the cylinder

block.
5) Remove the crankshaft from the cylinder

block.
6) Remove the thrust bearing from the cylinder
block.
7) Remove the crankshaft bearing from the cylin-
der block.
47. Piston oil jet Removal
ANNOTATION: 1) Remove the piston oil jet from the cylinder
• Remove the crankcase using the replacer block.
holes.
48. Cylinder liner Removal

84402832 NA - May 2011
2425-19
1) Remove the cylinder liner from the cylinder Cylinder block Installation
block.
1. Cylinder liner Preparation
CAUTION
• When replacing the cylinder liner, select
the cylinder liner following the procedure
below.
1) Check marking of the cylinder block.

ANNOTATION:
• A marking on a cylinder block indicates the
cylinder block bore grade.
CAUTION
• Do not tilt the cylinder liner when
storing.
1 Grade marking location
2) Check the grade of the cylinder liner.
1 Grade confirmation location
3) Select the cylinder liner.
Matching grades for cylinder block and liner

outer diameter
Marking on the block 1 2 3
Liner outer diameter 1X 3X
84402832 NA - May 2011
2425-20
Cylinder block inner diameter, liner outer diam- CAUTION

eter grade
Grade 1・1X 2・1X 3・3X • After replacing the cylinder liner,
: 118.001 : 118.011 : 118.021 be sure to measure the protrusion
- 118.010 - 118.020 - 118.030 amount of the cylinder liner.
Block inner
mm mm mm
diameter 4) Measure the cylinder liner using the dial
{4.6457 - {4.6461 - {4.6465 -
4.6461 in} 4.6464 in} 4.6468 in} gauge.
: 118.001 Specified value： 0.05 - 0.10 mm {0.0020 -
- 118.010 0.0039 in} Protrusion amount of cylinder liner
Liner outer : 117.991 - 118.000 mm Limit： under 0.03 mm {0.0012 in}
mm
diameter {4.6453 - 4.6457 in}
{4.6457 - ANNOTATION:
4.6461 in}
• The limit value indicates the difference in the
2. Cylinder liner Installation protrusion amounts with the adjacent cylin-
der liner.
CAUTION
• Since the cylinder liner is thin, handle it
carefully.
• Do not tilt the cylinder liner when storing.
3. Piston oil jet Installation

1) Install the piston oil jet to the cylinder block.
CAUTION
1) Clean the cylinder block using the air. • Be careful not to deform or damage
2) Clean the cylinder liner using the air. the nozzle part of the piston oil jet.
3) Install the cylinder liner to the cylinder block.
ANNOTATION: lb・ft}
• Install the cylinder liner on the cylinder block
vertically.
CAUTION
• Do not tap or apply excessive force
when inserting the liner.
84402832 NA - May 2011

2425-21
4. Crankshaft bearing Preparation ANNOTATION:
CAUTION • Check the marking on the crankshaft.

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

ANNOTATION:
• Refer to the bearing selection table.
Bearing selection table

Grade combination Oil clearance
Cylinder block Crank journal Bearing identifi-
No.1, 2, 3, 5, 6, 7 No.4
grade grade cation color
: 0.065 - 0.092 mm : 0.095 - 0.122 mm
1 1 Black
{0.0026 - 0.0036 in} {0.0037 - 0.0048 in}
: 0.063 - 0.089 mm : 0.093 - 0.119 mm
1 2 Brown
{0.0025 - 0.0035 in} {0.0037 - 0.0047 in}
: 0.067 - 0.094 mm : 0.097 - 0.124 mm
2 1 Blue
{0.0026 - 0.0037 in} {0.0038 - 0.0049 in}
: 0.065 - 0.091 mm : 0.095 - 0.121 mm
2 2 Black
{0.0026 - 0.0036 in} {0.0037 - 0.0048 in}
CAUTION
• Be careful not to mistake the bear-
ing shape when installing the
crankshaft bearing.
84402832 NA - May 2011

2425-22
5) Apply the engine oil to the crankshaft.

6) Put the crankshaft on the cylinder block.
7) Install the thrust bearing to the cylinder block.
ANNOTATION:
• Install the thrust bearing on the No.7 journal
so that the oil groove faces the engine rear.
1 Upper bearing
2 Oil hole
3 Grade identification color
4 Oil groove
5 Lower bearing
6 Grade identification color
8) Install the crankshaft bearing to the
crankcase.
5. Crankshaft Installation
CAUTION
1) Install the crankshaft bearing to the cylinder
block. • Make sure there is no grime or oil on
the crankcase contact surface for
ANNOTATION: the crankshaft bearing.
• Install a bearing with an oil hole on the cylin-
der block. 9) Apply the grease to the thrust bearing.
CAUTION ANNOTATION:
• Make sure there is no grime or oil on • Apply a small amount of grease to the thrust
the cylinder block contact surface bearing to prevent falling.
for the crankshaft bearing. 10) Install the thrust bearing to the crankcase.
2) Apply the grease to the thrust bearing. ANNOTATION:
ANNOTATION: • Install the thrust bearing on the No.7 journal

so that the oil groove faces the engine rear.
• Apply a small amount of grease to the thrust
bearing to prevent falling.
3) Install the thrust bearing to the cylinder block.
ANNOTATION:
• Install the thrust bearing on the No.7 journal
so that the oil groove faces the engine front.
11) Apply the engine oil to the crankshaft bearing.

12) Apply the liquid gasket to the crankcase.
ANNOTATION:
• Apply ThreeBond 1207B to the crankcase
thoroughly so that there is no break in appli-
cation of the bead.
4) Apply the engine oil to the crankshaft bearing. Bead width： 3 - 4 mm {0.118 - 0.157 in}
84402832 NA - May 2011
2425-23
Bead hight： 3 - 4 mm {0.118 - 0.157 in}
15) Tighten the bolt using the torque wrench.

CAUTION 72 lb・ft} M14 bolt
• After applying the liquid gasket, in- Tightening torque： 132 N・m {13.5 kgf・m
stall the crankcase within 5 min- / 97 lb・ft} M14 bolt
utes. 17) Tighten the bolt using the special tool.
13) Put the crankcase on the cylinder block.
CAUTION
• Be careful not to let the thrust bear-
ing fall.

1003)
Tightening angle： 30 ° M14 Bolt
lb・ft} M10 bolt
14) Apply the disulfide molybdenum grease to the Tightening torque：142 N・m {14.5 kgf・m /
bolt. 105 lb・ft} Check the tightening M14 bolt
ANNOTATION:
CAUTION
• Apply to the threaded portion and seat sur-
face on the M14 bolt for crankcase installa- • Confirm that the crankshaft turns
tion. smoothly after tightening the bolts.
CAUTION 6. Piston Installation
• Do not apply grease to the M10 bolt. 1) Install the connecting rod bearing to the con-
necting rod.
ANNOTATION: 2) Apply the engine oil to the connecting rod
bearing.
CAUTION
• Apply engine oil only to the inter-
nal diameter of the connecting rod
bearing.
3) Apply the engine oil to the piston ring.
84402832 NA - May 2011

2425-24
4) Apply the engine oil to the piston. 8) Align the piston to the cylinder block.
• Thoroughly apply engine oil to the ring • Turn the piston so that the front mark faces
grooves and piston side surface. the engine front.
5) Adjust the piston ring. 9) Press the piston.
ANNOTATION: CAUTION
• Shift each piston ring joint by the specified • To avoid damaging the oil jet, place
angle. the crank pin on the cylinder on
Specified angle： 90 ° which the piston will be installed at
6) Apply the engine oil to the cylinder liner. top dead center.
• To avoid damaging the piston ring,
firmly attach the piston installer to
the cylinder block and push it.
• Be careful not to damage the crank
pin and cylinder liner.
• Attach a stopper so that the liner
does not protrude.
1 Engine oil application
7) Install the piston installer to the piston.
1 No.1 compression ring joint

2 No.2 compression ring joint
3 Oil ring joint
4 Front mark
10) Install the connecting rod bearing to the con-

necting rod bearing cap.
11) Apply the engine oil to the connecting rod
bearing.
CAUTION
• Apply engine oil only to the inter-
nal diameter of the connecting rod
Special tool: piston setting tool (refer to
bearing.
section 1003)
84402832 NA - May 2011

2425-25
12) Align the connecting rod bearing cap to the 14) Apply the disulfide molybdenum grease to the
connecting rod. bolt.
• Confirm that the numbers on the connecting • Apply to the threaded portion and seat sur-
rod bearing cap and the connecting rod are face of the bolts for the connecting rod in-
the same. stallation.
lb・ft}
16) Tighten the bolt using the special tool.
Front and back side discrimina-

1
tion boss
Grade mark of the large end
2 Special tool: angle gauge (refer to section
hole diameter
1003)
3 Cylinder number
Tightening angle： 60 °
13) Install the connecting rod bearing cap to the 18) Tighten the bolt using the torque wrench.
connecting rod. Tightening torque： 98 N・m {10.0 kgf・m /
ANNOTATION: 72 lb・ft} Check the tightening
• Precautions when tightening the connecting

rod bolt
CAUTION
• Set each cylinder to the bottom
dead center while working.
7. Idle gear B Installation

1) Install the idle gear B shaft to the cylinder
block.
lb・ft}
2) Apply the engine oil to the idle gear B shaft.
3) Apply the engine oil to the idle gear B.
CAUTION
• Do not allow tightening tools to
touch the oil jet.
• Confirm that the crankshaft turns
smoothly after tightening the con-
necting rod bolt.
84402832 NA - May 2011

2425-26
4) Install the idle gear B to the cylinder block. CAUTION

lb・ft} • Do not allow the liquid gasket to ad-
here to the locations indicated by
CAUTION arrows in the diagram.
• Confirm that the idle gear B turns
stall the oil pump within 5 minutes.
smoothly after installing.
4) Install the oil pump to the cylinder block.
8. Oil pump assembly Installation
1) Clean the cylinder block using the scraper. lb・ft}
ANNOTATION:
• Remove grime and oil from the oil pump in-
stallation area.
2) Apply the engine oil to the cylinder block.
9. Idle gear A Installation

1) Align 1st cylinder to the compression top dead
center.
2) Apply the engine oil to the idle gear A shaft.
3) Apply the engine oil to the idle gear A.
CAUTION 4) Install the idle gear A shaft to the idle gear A.
5) Align the idle gear A to alignment mark.
• Do not allow engine oil to adhere on ANNOTATION:
the oil pump installation surface.
• Align the L mark on the crank gear with the
3) Apply the liquid gasket to the oil pump. O mark on the idle gear A.
ANNOTATION:
• Refer to the diagram and apply the Three-
Bond 1207C to the oil pump.
1 L mark
2 O mark
84402832 NA - May 2011

2425-27
6) Install the idle gear A to the cylinder block. 10. Flywheel housing Installation
Tightening torque： 133 N・m {13.6 kgf・m
1) Clean the cylinder block using the scraper.
/ 98 lb・ft}
ANNOTATION:
• Remove dust and oil from the flywheel hous-
ing installation area.
2) Apply the liquid gasket to the cylinder block.
ANNOTATION:
Bond 1201 to the cylinder block.
Liquid gasket application pro-

1
hibited area
CAUTION
• Do not apply liquid gasket to the lo-
cation indicated in 1 in the diagram.
1 Camshaft gear
2 Aligning position stall the flywheel housing within 5
3 Idle gear B minutes.
4 Aligning position
5 PTO gear
6 PTO idle gear
7 Crank gear
8 Oil pump gear
9 Supply pump gear
10 Idle gear A
11 Idle gear C
84402832 NA - May 2011

2425-28
3) Install the flywheel housing to the cylinder 6) Install the PTO idle gear to the cylinder block.
block. Tightening torque： 119 N・m {12.1 kgf・m /
88 lb・ft}
ANNOTATION:
• Install the flywheel housing after aligning
with the knock pin position of the cylinder
block.
Tightening torque
No.1 bolt : 96 N・m {9.8 kgf・m / 71 lb・ft}
7) Install the O-ring to the cover.

8) Install the cover to the flywheel housing.
1 O-ring
2 Cover
9) Install the oil pipe to the pipe bracket and the

oil port cover.
lb・ft} Pipe bracket side
4) Apply engine oil to the PTO gear shaft. lb・ft} Oil port cover side
5) Install the PTO idle gear shaft to the PTO idle Tightening torque： 24 N・m {2.4 kgf・m / 17
gear. lb・ft} Clip
84402832 NA - May 2011

2425-29
10) Install the PTO oil pipe to the flywheel housing • Apply ThreeBond 1207B to each joint of the
and the cylinder block. crankcase, flywheel housing and gear case.
lb・ft} Flywheel housing side Bead width： 3.0 mm {0.1181 in}
Tightening torque： 15 N・m {1.5 kgf・m / 11 Bead height： 2.0 mm {0.079 in}
lb・ft} PTO side
lb・ft} Cylinder block side
lb・ft} Clip
1 Crankcase
2 Timing gear case
3 Flywheel housing
1 Oil pipe CAUTION

2 Pipe bracket
3 PTO oil pipe stall the oil pan within 5 minutes.
2) Install the gasket to the oil pan.

11. Oil strainer Installation 3) Install the oil pan to the crankcase.
1) Install the O-ring to the oil strainer.
lb・in} 4 stud bolts
2) Install the oil strainer to the crankcase.
Tightening torque：24 N・m {2.4 kgf・m / 17
lb・ft}
lb・ft} M8 bolt
Tightening torque： 48 N・m {4.9 kgf・m / 35 CAUTION
lb・ft} M10 bolt
• Note that one of the bolts has a dif-
ferent length from others.
1 M10 bolt
2 M8 bolt
1 Short bolt installation area
2 Stud bolt installation area
12. Oil pan Installation
4) Connect the harness connector to the oil level
ANNOTATION: switch.
84402832 NA - May 2011
2425-30
13. Crankshaft rear oil seal Installation 4) Install the adapter to the crankshaft.
1) Prepare the special tool.
Special tool: oil seal installer (refer to 1 Collar

section 1003) 2 Adapter tightening bolts
3 Adapter
ANNOTATION:
• In order to install the crankshaft rear oil seal,
5) Install the adapter ring to the sleeve.
use the one(s) in the following table from
6) Install the sleeve to the adapter.
among the parts included in the kit.
Legend Parts number

1：Adapter 5–8840–2709–0
2：Adapter tightening bolts 5–8840–2714–0
3：Center bolt 5–8840–2713–0 1 Sleeve
4：Sleeve 5–8840–9063–0 2 Adapter ring
5：Collar 5–8840–2710–0
6：Adapter ring 5–8840–2711–0
7) Install the center bolt to the sleeve.
7：Crankshaft rear oil seal -
8) Tighten the center bolt using the wrench.
2) Apply the engine oil to the crankshaft rear oil ANNOTATION:

seal. • Tighten the center bolt until the sleeve
touches the adapter.
CAUTION
• Apply only to the lip section of the
oil seal.
3) Install the crankshaft rear oil seal to the

adapter.
84402832 NA - May 2011

2425-31
9) Inspect the crankshaft rear oil seal. 4) Tighten the bolt using the special tool.
ANNOTATION:
• Measure the distance between the crank-
shaft head and the crankshaft rear oil seal.
Specified value： 7.2 - 7.8 mm {0.283 - 0.307
in}

1003)
1 Flywheel housing / 202 lb・ft} Check the tightening
2 Crankshaft rear oil seal 15. CKP sensor Installation
Oil seal press-fitting measure-
3 1) Install the CKP sensor to the flywheel housing.
ment
4 Crankshaft CAUTION
14. Flywheel Installation • Be careful not to subject the sensor

to shock.
1) Apply the disulfide molybdenum grease to the
bolt. ANNOTATION:
ANNOTATION: • Tighten together with the clip.
• Apply to the seat surface and threaded por- Tightening torque： 6 N・m {0.6 kgf・m / 52
tion on the flywheel installation bolts. lb・in}
2) Connect the harness connector to the CKP
2) Install the flywheel to the crankshaft.
sensor.
CAUTION
• Pay attention to the knock pin posi-
tion of the crankshaft.
ANNOTATION:
1 Oil pressure sensor

2 Oil port cover
3 Flywheel housing
4 CKP sensor
16. Starter assembly Installation

lb・ft}
84402832 NA - May 2011
2425-32
1) Install the starter assembly to the flywheel 3) Align the fuel supply pump to the cylinder
housing. block.
60.5 lb・ft}
2) Connect the earth cable to the starter assem-
bly.
14.0 lb・ft}
1 Confirmation hole
2 Supply pump gear
17. Fuel supply pump Installation 4) Install the fuel supply pump to the cylinder
1) Align 1st cylinder to the compression top dead block.
center. Tightening torque： 75 N・m {7.6 kgf・m / 55
2) Align alignment mark to the bracket. lb・ft} No.5 in the diagram
lb・ft} No.8 in the diagram
1 Supply pump bracket side slit

Supply pump gear side align-
2
ment mark
1 Fuel supply pump

2 Bracket
3 Gear
4 Nut
5 Bolt
6 O-ring
7 O-ring
8 Nut
9 Bolt
10 Nut

supply pump.
18. Cylinder head assembly Installation
84402832 NA - May 2011
2425-33
CAUTION 2) Install the cylinder head gasket to the cylinder

block.
head and cylinder block before installing CAUTION
head and cylinder block while cleaning.
3) Install the cylinder head assembly to the cylin-
der block.
ANNOTATION: CAUTION
• Use ThreeBond 1207B. • Be careful not to damage the cylin-

der head gasket.
Bead width： 3.0 mm {0.1181 in}
Bead height： 2.0 mm {0.0787 in}
ANNOTATION:
CAUTION • Tightening order of the head bolts
• After applying liquid gasket, install
ANNOTATION: • Apply engine oil to the seat surface and

• 1 to 26 in the diagram indicate the M14 bolts.
• 27 and 28 in the diagram indicate the M10 5) Tighten the head bolt using the torque wrench.
bolts. Tightening torque： 98 N・m {10.0 kgf・m /
ANNOTATION: Tightening torque： 147 N・m {15.0 kgf・m
/ 108 lb・ft} M14 bolt
M14 head bolts.
84402832 NA - May 2011

2425-34
7) Tighten the head bolt using the special tool. 4) Install the gear case cover cover to the cylin-
der block.
CAUTION
tion of the cylinder block.

lb・ft}
112 lb・in} Stud bolt

1003)
Tightening angle： 30 - 60 ° M14 Bolt
lb・ft} M10 bolt
Tightening torque：142 N・m {14.5 kgf・m /
105 lb・ft} Check the tightening M14 boltg
19. Cover of gear case cover Installation
2) Apply the liquid gasket to the gear case cover Location for tightening together
1
cover. with the adjust plate
2 Stud bolt
ANNOTATION:
• Use ThreeBond 1207B. 20. Water pump assembly Installation
Bead width： 1.5 - 5.0 mm {0.0591 - 0.1969 1) Install the water pump assembly to the gear
in} case cover cover.
Bead height： 0.3 - 1.5 mm {0.0118 - 0.0591
in} CAUTION
3) Install the O-ring to the gear case cover cover.

28.8 lb・ft} Nut in the diagram
14.8 lb・ft}
1 O-ring
CAUTION
• After applying the liquid gasket,
install the gear case cover cover
within 5 minutes. 1 Nut
84402832 NA - May 2011

2425-35
2) Install the water hose to the EGR cooler water 1) Prepare the special tool.
pipe and the water pump assembly.
3) Install the water bypass hose to the water
pump assembly and the water duct.
Special tool: oil seal setting tool kit (refer

to section 1003)
ANNOTATION:
1 Water bypass hose • In order to install the front slinger, use the
one(s) in the following table from among the
4) Install the fan pulley to the water pump assem- parts included in the kit.
bly.
38.4 lb・ft}
Legend Parts number

1：Slinger -
21. Crankshaft front oil seal Installation 2：Adapter 8–9439–6857–0
3：Adapter tightening bolt 8–9702–0656–0
4：Sleeve 8–9702–0623–0
5：Center bolt 8–9702–0655–0
2) Install the slinger to the adapter.

ANNOTATION:
• There is a left handed quadruple-start screw
cut at the front slinger.
CAUTION
• Be careful not to allow the assem-
bly direction of the slinger to be in-
correct.
84402832 NA - May 2011

2425-36
3) Install the adapter to the crankshaft. 7) Inspect the slinger.

ANNOTATION:
shaft head and the slinger.
0.7205 in}
1 Adapter
4) Install the sleeve to the adapter.

ANNOTATION:
Slinger press-fitting measure-
• Tighten the center bolt until the sleeve 1
ment
touches the adapter. 2 Slinger
3 Crankshaft
8) Prepare the special tool.

ANNOTATION:
• In order to install the crankshaft front oil
seal, use the one(s) in the following table
from among the parts included in the kit.
Legend Parts number

1：Adapter 8–9439–6857–0
2：Oil seal -
3：Adapter tightening bolt 8–9702–0656–0
4：Sleeve 8–9702–0625–1
5：Center bolt 8–9702–0655–0
9) Apply the engine oil to the crankshaft front oil

seal.
CAUTION
oil seal.
84402832 NA - May 2011

2425-37
10) Install the crankshaft front oil seal to the 1) Install the crankshaft damper to the crankshaft
adapter. pulley.
11) Install the sleeve to the adapter. Tightening torque： 48 N・m {4.9 kgf・m / 35
12) Install the center bolt to the sleeve. lb・ft}
ANNOTATION:
ANNOTATION:
• Tighten the bolts in a diagonal line order.
• Tighten the center bolt until the sleeve
touches the adapter.
2) Install the crankshaft pulley to the crankshaft.
14) Inspect the crankshaft front oil seal. CAUTION

ANNOTATION: • Pay attention to the knock pin posi-
shaft head and the crankshaft front oil seal.
Specified value： 8.35 - 8.65 mm {0.3287 - / 148 lb・ft} Apply engine oil on the threaded
0.3406 in} area of bolt
ANNOTATION:
Oil seal press-fitting measure-

1
ment
2 Timing gear case
3 Crankshaft front oil seal 23. Bridge Installation
4 Crankshaft 1) Apply the engine oil to the bridge.
2) Install the bridge to the bridge guide.
22. Crankshaft pulley Installation
CAUTION
• Confirm that the bridge moves
smoothly.
3) Apply the engine oil to the bridge cap.
84402832 NA - May 2011

2425-38
4) Install the bridge cap to the bridge. 4) Align the sub gear to the camshaft gear using
the special tool.
ANNOTATION:
CAUTION

Special tool: scissors gear spring wrench
center.

1 Alignment pin
ANNOTATION:
• Apply engine oil to the sliding surface of the 5) Install the camshaft to the cylinder head as-
bearing. sembly.
CAUTION ANNOTATION:
• Apply engine oil after cleaning the • Mesh together the idle gear C and the
bearing installation sections of camshaft gear so that the alignment mark
the camshaft bearing and cylinder on the camshaft gear matches the top sur-
head. face of the cylinder head, and gently install
the camshaft.
CAUTION
head assembly.
ANNOTATION: • Align the alignment marks of the
sub gear side.
• To prevent the effect of spring force on the
sub gear, use a scissors gear spring wrench
to rotate the sub gear before installing the
84402832 NA - May 2011

2425-39
25. Rocker arm shaft Installation

ANNOTATION:
• Apply to each sliding surface.
2) Apply the engine oil to the rocker arm.
ANNOTATION:
• Confirm that the adjust screw is fully loos-
ened.
CAUTION
camshaft.

ANNOTATION:
• Apply engine oil to the sliding surface of the 2 Rocker arm
bearing. 3 Rear side camshaft bracket
CAUTION
3) Install the rocker arm shaft to the cylinder
• Apply engine oil after cleaning the head assembly.
ANNOTATION:
bearing cap. • On the camshaft bearing assembly section
only, apply oil to the threaded portion of
8) Install the camshaft bearing to the camshaft the stud bolts and the seat surface/threaded
bearing cap. portion of the nuts, then tighten them.
9) Install the camshaft bearing cap to the cylinder • Tightening order
head assembly.
ANNOTATION:
• Turn the camshaft bearing cap so that the
arrow mark on the top surface faces the en-
order.
Tightening torque：28 N・m {2.8 kgf・m / 20
lb・ft} Engine oil application

Front side camshaft
bearing cap : 28 N・m {2.8 kgf・m / 20
Rear side camshaft lb・ft}
bearing cap
: 56 N・m {5.7 kgf・m / 41
Rocker arm bracket
lb・ft}
84402832 NA - May 2011
2425-40
26. Rocker arm shaft Adjustment 3) Turn the adjust screw.

• Valve clearance adjustment • When the movement of the thickness gauge
becomes stiff, secure the adjust screw nut
CAUTION of the rocker arm.
• Adjust the valve clearance while cool. Tightening torque： 22 N・m {2.2 kgf・m / 16
• Loosen all adjust screws before adjust- lb・ft}
ment.

ANNOTATION:
center. • With the thickness gauge inserted, lightly
• Check if the valve shaft end on the opposite
loosen the bridge adjust screw and adjust
the valve shaft ends on both sides to touch
properly.
Valve bridge clearance ： less than 0.1 mm
{less than 0.0039 in}
ANNOTATION:
2) Prepare the feeler gauge.
Thickness： 0.4 mm {0.0157 in} 2 pieces • To prevent turning, fix the bridge adjust
screw with a flathead screwdriver, and
ANNOTATION:
rocker arm and bridge cap.
lb・ft}
bridge and valve.
84402832 NA - May 2011

2425-41
top dead center
27. Lower cover Installation 28. Common rail assembly Installation

1) Apply the liquid gasket to the rubber plug. 1) Align the common rail assembly to the inlet
cover.
ANNOTATION: 2) Temporarily tighten the bolt to the common rail
• Apply ThreeBond 1207B. assembly.
3) Temporarily tighten the nut to the common rail
assembly.
4) Securely tighten the bolt to the common rail
assembly.
18.4 lb・ft}
5) Securely tighten the nut to the common rail
assembly.
18.4 lb・ft}
1 Rubber plug
2 Liquid gasket
CAUTION
utes.

assembly.
3) Install the gasket to the lower cover.
4) Install the lower cover to the cylinder head 6) Connect the harness connector to the fuel
assembly. pressure sensor.
Tightening torque： 13 N・m {1.3 kgf・m / 29. Fuel leak off pipe assembly Installation
112 lb・in}
ANNOTATION: cylinder head assembly.
CAUTION

CAUTION

fuel supply pump.
ANNOTATION:
84402832 NA - May 2011
2425-42
CAUTION 1) Apply the engine oil to the bolt.

2) Temporarily tighten the injector to the cylinder
• Use new gaskets. head assembly.
4) Securely tighten the fuel leak-off pipe to the CAUTION

cylinder head assembly. • Be extremely careful not to damage
Tightening torque： 14 N・m {1.4 kgf・m / the injector nozzle.
123.9 lb・in}
5) Securely tighten the fuel leak-off pipe to the
14.8 lb・ft}
fuel supply pump.
88.5 lb・in}
7) Install the clip to the fuel leak-off pipe.
Tightening torque： 9 N・m {0.9 kgf・m / 79.7
lb・in}
1 Injector
2 Installation bolt
3) Temporarily tighten the injection pipe to the

injector.
CAUTION

head assembly.
30. Fuel pipe Installation Tightening torque： 30 N・m {3.1 kgf・m / 22
lb・ft}
1) Install the fuel pipe to the fuel supply pump
CAUTION
CAUTION
• Use new fuel pipes.
126 lb・in}
32.5 lb・ft}
2) Install the clip to the bracket. 32. Injection pipe Installation
lb・in} 1) Securely tighten the injection pipe to the injec-
tor.
31. Injector Installation Tightening torque： 44 N・m {4.5 kgf・m /
32.5 lb・ft}
CAUTION 2) Securely tighten the injection pipe to the com-
mon rail assembly.
• When reusing an injector, do not change
the installation position.
32.5 lb・ft}
84402832 NA - May 2011

2425-43
3) Install the clip to the inlet cover. 2) Install the glow plug connector to the glow
Tightening torque： 6 N・m {0.6 kgf・m / 53.1 plug.
lb・in} Tightening torque： 1 N・m {0.1 kgf・m / 8.9
lb・in}
CAUTION
tor does not interfere with the sur-
rounding parts.

6 No.6 injection pipe 34. Injector harness Installation
7 Fuel pipe
1) Install the injector harness to the cylinder head
assembly.
33. Glow plug Installation ANNOTATION:
1) Install the glow plug to the cylinder head as- • Tighten the bolts on the bracket and in-
sembly. stall the injector harness together with the
Tightening torque： 20 N・m {2.0 kgf・m / bracket.
14.8 lb・ft}
CAUTION lb・ft}

fied torque when tightening.

84402832 NA - May 2011

2425-44
CAUTION

2 Head cover gasket
3 Lower cover

breather.
1 Injector 4) Connect the water pipe bracket to the cylinder
2 Injector harness head cover.
3 Terminal nut Tightening torque： 20 N・m {2.0 kgf・m / 14
lb・ft}
lb・in}
head cover.
cover.
115 lb・in}
ANNOTATION:
1 Ventilation hose
3 Clip
84402832 NA - May 2011

2425-45
1) Install the inlet pipe to the inlet cover. 37. Intake throttle valve Installation
1) Install the intake throttle valve to the inlet pipe.
lb・ft}
lb・ft}
1 Inlet pipe
2) Connect the harness connector to the boost 2 Gasket
sensor. 3 Inlet pipe
temperature sensor. 2) Install the air duct to the intake throttle valve.
4) Connect the harness connector to the IMT 3) Connect the harness connector to the intake
sensor. throttle valve.
ANNOTATION:
lb・ft} • After connecting the harness connector,
1 Boost sensor
2 Harness clip 1 Lock operation section
3 Boost temperature sensor 2 Lock release
4 IMT sensor 3 Lock
84402832 NA - May 2011

2425-46
84402832 NA - May 2011

2425-47
pump assembly and the water duct. Tightening torque： 30 N・m {3.1 kgf・m / 22
lb・ft}
1 Water bypass hose
Clamp tightening torque： 20 N・m {2.0 kgf・ 3 Fan guide bracket
m / 14 lb・ft}
ANNOTATION:
lb・ft}
CAUTION
gle of the hose.

lb・ft}
1 Installation bolt

outlet pipe.
bracket.
lb・ft}

2 Clip
84402832 NA - May 2011
2425-48
EGR bracket C.
33.9 lb・ft}
1 EGR cooler C
3 EGR cooler B
1 EGR valve
haust manifold.
EGR pipe A.
1 EGR valve
2 EGR pipe B
3 EGR cooler C
1 EGR cooler A
EGR cooler A. Tightening torque： 31 N・m {3.2 kgf・m / 23
cooler A.
lb・ft}
the EGR cooler B.
lb・ft}
cooler bracket C.
lb・ft}
84402832 NA - May 2011
2425-49
cooler C.
cylinder block.
lb・ft}
lb・ft}
valve.
Tightening torque： 46 N・m {4.7 kgf・m / 34 2) Connect the oil level gauge guide tube to the
lb・ft}
15) Securely tighten the EGR cooler bracket A to Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft}
Tightening torque： 24 N・m {2.4 kgf・m / 17 3) Install the oil level gauge to the oil level gauge
guide tube.
lb・ft}
lb・ft}
lb・ft}
pipe.
lb・ft}

assembly.
bly.
haust manifold.
lb・ft}
cooler. Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft} Clip
CAUTION

bocharger assembly.
lb・ft}
CAUTION
1 Water rubber hose
84402832 NA - May 2011

2425-50
block. assembly.
lb・ft} lb・ft}
CAUTION CAUTION

bocharger assembly.
lb・ft}
CAUTION

lb・ft}
CAUTION
9) Connect the oil return pipe to the turbocharger 1 Oil feed pipe
assembly. 2 Clip
Tightening torque： 24 N・m {2.4 kgf・m / 17 3 Oil return pipe
5 Water return pipe
CAUTION
• Use a new gasket. 12) Install the exhaust pipe to the turbocharger
assembly.
10) Install the oil feed pipe to the pipe bracket. 13) Install the air intake hose to the turbocharger
Tightening torque： 34 N・m {3.5 kgf・m / 25 assembly and the intercooler.
lb・ft} 14) Install the air cleaner duct to the air cleaner
Tightening torque： 24 N・m {2.4 kgf・m / 17 assembly and the turbocharger assembly.
lb・ft} Clip
44. Drive belt Installation
CAUTION
1) Install the drive belt to the engine assembly.
45. Drive belt Adjustment
84402832 NA - May 2011

2425-51
1) Press the drive belt. 2) Install the fan guide to the fan guide bracket.
ANNOTATION: 22.1 lb・ft}
• Measure the amount of drive belt flex by
pressing on the point indicated by the arrow
in the diagram with the specified pressure.
Standard： 98.0 N {10.0 kg / 22 lb}
Specified value ： 5.5 - 7.5 mm {0.2165 -
0.2953 in} Amount of flex
1 Bolt
2 Washer
3 Rubber mount
4 Rubber mount
5 Guide tube
6 Fan guide
1 Crankshaft pulley
2 Generator
3 Fan pulley 47. Cooling fan Installation
1) Install the cooling fan to the adapter.
2) Adjust the drive belt to standard value using
the adjust bolt.
55.3 lb・ft} Nut of the adjust plate
/ 92.9 lb・ft} Bolt of the bracket side
1 Cooling fan
2 Adapter

1 Adjust bolt 38.4 lb・ft}
2 Adjust plate side nut 48. Engine harness Connect
3 Bracket side bolt
46. Fan guide Installation sembly.
1) Install the fan guide bracket to the engine as- ANNOTATION:
sembly.
29.5 lb・ft} 49. Engine oil Filling
84402832 NA - May 2011

2425-52
1) Replenish the engine oil with the engine as-

sembly.
CAUTION
• Check the tightening of the drain
plug before adding engine oil.
50. Coolant Filling

CAUTION
parts.
1 Priming pump
off. 2 Plug
3 Drain plug
3) Tighten the valve using a wrench. 4 Case
CAUTION
1) Prepare the pan.
2) Turn ON the starter switch.
• This is for the models with an electromag-
netic pump.
ANNOTATION:
plug.
ANNOTATION:
1 Valve the priming pump.
2 Gasket Specified time： 1 min
ANNOTATION:
tery. • Remove the air in the fuel filter.
52. Fuel Air bleed 8) Tighten the plug using the wrench.
CAUTION Number of times： 10 count(s) or more
• To prevent engine failure, be sure to per- ANNOTATION:

form air removal after the installation or • Wait for the specified time after operating
removal of fuel system parts. the priming pump.
ANNOTATION:
84402832 NA - May 2011
2425-53
12) Operate the priming pump. CAUTION

ANNOTATION: • Replace the cylinder block if dam-
• Wait for the specified time after operating in the inspection.
the priming pump.
4) Measure the cylinder liner using the cylinder
gauge.
Measurement position ： 15.0 - 20.0 mm
ANNOTATION: ｛ 0.5906 - 0.7874 in ｝ From the cylinder
block top surface
• Remove the air in the fuel filter. Specified value ： 115.021 - 115.050 mm
14) Tighten the plug using the wrench. ｛4.5284 - 4.5295 in｝ Diameter
Tightening torque： 10 N・m {1.0 kgf・m / Limit： 115.20 mm ｛4.5354 in｝ Diameter
88.5 lb・in}
CAUTION
CAUTION
• Replace the cylinder block if the
• Remove the fuel around the plug measured value exceeds the limit
thoroughly after tightening. value.
15) Operate the priming pump. 5) Remove the cylinder liner from the cylinder
Number of times： 10 count(s) block.
6) Align the simple straight ruler to the cylinder
Cylinder block Inspection 7)
block.
Measure the clearance using the feeler
1. Cylinder block Inspection gauge.
CAUTION ANNOTATION:
• Clean the each part of the cylinder block • Flatness of the cylinder block top surface
before inspecting. Measurement part： 6 section(s)
• Be careful not to damage the cylinder Limit： 0.2 mm ｛0.0079 in｝
block while cleaning.
CAUTION
1) Inspect the cylinder block.
• Replace the cylinder block if the
CAUTION measured value exceeds the limit
value.
• Replace the cylinder block if dam-
in the inspection.
2) Perform dye penetrant check.

ANNOTATION:
• Check if there is a problem which cannot be
detected by visual inspection.
CAUTION
• Replace the cylinder block if dam-
in the inspection.
3) Inspect the water leak using the water pres-

sure tester. 1 Thickness gauge
ANNOTATION:
8) Inspect the oil jet.
• Check if there is a problem which cannot be
detected by visual inspection. ANNOTATION:
Specified pressure： 490 kPa {5 kgf/cm2 / 71 • Oil hole clogging

psi} • The fuel pipe deformation
Specified time： 3 min • Check valve operation
160.0 kPa {2 kgf/cm2 / 23 psi} Open valve
pressure of check valve
84402832 NA - May 2011
2425-54
84402832 NA - May 2011

2425-55
84402832 NA - May 2011

2425-56
Section
2445
Lubrication System
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal and Installation of Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Oil pan Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Oil pan Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal and Installation of Oil Level Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Oil level switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Oil level switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal and Installation of Oil Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Oil pump assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Oil pump assembly Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Oil pump assembly Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Oil pump assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Oil pump assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Engine oil Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Removal and Installation of Oil Port Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Oil port cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Oil port cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Lubrication System
Removal and Installation of Oil Oil pan Installation

Pan 1. Oil pan Installation
Oil pan Removal
ANNOTATION:
• Apply ThreeBond 1207B to each joint of the
1) Disengage the battery ground cable from the crankcase, flywheel housing and gear case.
battery.
Bead width： 3 mm {0.118 in}
2. Engine oil Drain Bead height： 2 mm {0.079 in}
3) Install the drain plug to the oil pan.
51.6 lb・ft｝
3. Oil pan Removal
level switch.
2) Remove the oil pan from the crankcase.
1 Crankcase
2 Timing gear case
3 Flywheel housing
CAUTION
stall the oil pan within 5 minutes.

3) Install the oil pan to the crankcase.
lb・ft}
CAUTION

84402832 NA - May 2011
2445-3
Lubrication System
4) Connect the harness connector to the oil level Removal and Installation of Oil
switch.
Level Switch
2. Engine oil Filling
1) Replenish the engine oil with the engine as- Oil level switch Removal
sembly. 1. Engine oil Drain
CAUTION 1) Remove the drain plug from the oil pan.
• Check the tightening of the drain 3) Install the drain plug to the oil pan.
51.6 lb・ft｝
2. Oil level switch Removal
tery. 1) Disengage the harness connector from the oil
level switch.
2) Remove the oil level switch from the oil pan.
1 O-ring
2 Oil level switch
3 Spacer
84402832 NA - May 2011

2445-4
Lubrication System
Oil level switch Installation Removal and Installation of Oil

1. Oil level switch Installation Pump Assembly
1) Install the O-ring to the oil pan.
Oil pump assembly Removal
CAUTION 1. Battery ground cable Disconnect
• Use new O-rings. 1) Disengage the battery ground cable from the
battery.
2) Install the oil level switch to the oil pan.
2. Coolant Drain
CAUTION
• Confirm that the O-ring is not mis-
aligned or bent. CAUTION
Tightening torque： 10 N・m ｛1.0 kgf・m / make sure to tighten the drain plug.
88.5 lb・in｝
3) Connect the harness connector to the oil level 3. Engine oil Drain
switch.
3) Install the drain plug to the oil pan.
lb・ft}
gine assembly.
ANNOTATION:
1) Remove the air cleaner duct from the air
cleaner assembly and the turbocharger as-
1 O-ring sembly.
2 Oil level switch 2) Remove the air intake hose from the tur-
3 Spacer bocharger assembly and the intercooler.
2. Engine oil Filling bocharger.
1) Replenish the engine oil with the engine as- bocharger assembly.
sembly.
ANNOTATION:
CAUTION
• Check the tightening of the drain 5) Remove the oil feed pipe from the pipe
bracket.
ANNOTATION:
bocharger assembly.
7) Remove the oil return pipe from the cylinder
block.
bocharger assembly.
der head assembly.
bocharger assembly.
ANNOTATION:
84402832 NA - May 2011
2445-5
Lubrication System
11) Remove the water feed pipe from the cylinder 2) Remove the EGR pipe B from the EGR valve
block. and the EGR cooler C.
ANNOTATION:
exhaust manifold.
1 EGR valve
2 EGR pipe B
3 EGR cooler C
3) Remove the EGR cooler C from the EGR

bracket C.
1 Oil feed pipe 4) Remove the EGR bracket C from the EGR
2 Clip cooler B.
3 Oil return pipe 5) Remove the EGR cooler B from the EGR
4 Water feed pipe cooler bracket A.
5 Water return pipe 6) Remove the EGR cooler bracket A from the
EGR cooler A.
1) Disengage the water rubber hose from the
EGR cooler.
1 EGR cooler C
2 EGR bracket C
3 EGR cooler B
1 Water rubber hose 4 EGR cooler bracket A
84402832 NA - May 2011

2445-6
Lubrication System
7) Remove the EGR heat protector from the 1) Disengage the harness connector from the
EGR pipe A. EGR valve.

1 EGR valve
A. 8. Oil separator bracket Removal
9) Remove the EGR pipe A from the exhaust 1) Remove the clip from the cylinder block.
manifold. 2) Remove the ventilation hose from the air
breather.
1 EGR cooler A
2 EGR pipe A
3 Exhaust manifold
7. EGR valve Removal 2 Clip
84402832 NA - May 2011

2445-7
Lubrication System
84402832 NA - May 2011

2445-8
Lubrication System
1) Remove the fan guide stay from the fan guide 2) Disengage the oil level gauge guide tube from
and the fan guide bracket. the front engine hanger bracket.
3) Remove the oil level gauge guide tube from
the cylinder block.
1 Fan guide
2 Fan guide stay
3 Fan guide bracket 1 Oil level gauge guide tube

water outlet pipe. 1) Remove the air duct from the intake throttle
3) Remove the EGR cooler water pipe from the valve.
engine assembly. 2) Disengage the harness connector from the in-
4) Remove the water bypass hose from the wa- take throttle valve.
ter pump assembly and the water duct. ANNOTATION:
lock.
1 Water bypass hose
10. Oil level gauge guide tube Removal 1 Lock operation section
84402832 NA - May 2011

2445-9
Lubrication System
3) Remove the intake throttle valve from the inlet 5) Remove the inlet pipe from the inlet cover.
pipe.
1 Inlet pipe
2 Gasket 13. Glow plug Removal
3 Inlet pipe 1) Remove the glow plug connector from the
glow plug.
12. Inlet pipe Removal
boost sensor.
IMT sensor.

assembly.
1 Boost sensor
2 Harness clip
4 IMT sensor

84402832 NA - May 2011

2445-10
Lubrication System
CAUTION 3) Disengage the fuel leak-off pipe from the com-

mon rail assembly.
• Do not reuse the removed injection 4) Remove the fuel leak-off pipe from the inlet
pipe. pipe.
• Seal the common rail and injector to ANNOTATION:
ing. • Remove the clip.
1 No.1 injection pipe 1 Fuel leak-off pipe

3 No.3 injection pipe 17. Common rail assembly Removal
4 No.4 injection pipe 1) Disengage the harness connector from the
5 No.5 injection pipe fuel pressure sensor.
6 No.6 injection pipe 2) Remove the common rail assembly from the
7 Fuel pipe inlet cover.

ANNOTATION:
CAUTION

der head.
2) Remove the fuel leak-off pipe from the fuel 1 Common rail assembly
supply pump.
ANNOTATION: 18. Cylinder head cover Removal
• Remove the eyebolt tightened together with 1) Disengage the ventilation hose from the air
the fuel feed pipe. breather.
84402832 NA - May 2011

2445-11
Lubrication System
2) Remove the cylinder head cover from the 2) Disengage the injector harness from the injec-
lower cover. tor.
der head cover. CAUTION

2 Head cover gasket
3 Lower cover
1 Injector
19. Injector harness Removal 2 Injector harness
1) Remove the connector from the lower cover. 3 Terminal nut
CAUTION
3) Remove the injector harness from the cylinder
• Do not pull the wire, or pry the con- head assembly.
nector with a screwdriver.
ANNOTATION:
with the bracket.


jector.
assembly.
ANNOTATION:
a special tool.
84402832 NA - May 2011
2445-12
Lubrication System
Special tool: injector remover (refer to 21. Lower cover Removal

section 1003)
head assembly.
head assembly.
1) Loosen the adjust screw using the wrench.
ANNOTATION:
• Loosen all valve clearance adjustment
screws.

section 1003)

head assembly.
ANNOTATION:
• Evenly loosen the rocker arm shaft bracket
ening bolts from both ends and remove
1 Sliding hammer them.
2 Fuel injector remover CAUTION
3 Injector
CAUTION
23. Camshaft Removal
• Confirm that the sleeve is not pulled
out together when pulling out the 1) Remove the camshaft bearing cap from the
injector using a special tool. cylinder head assembly.
• Store each ID code plate on the in- 2) Remove the camshaft bearing from the
jector head with the cylinder num- camshaft bearing cap.
ber tag attached to avoid a mix-up. 3) Remove the camshaft from the cylinder head.
84402832 NA - May 2011

2445-13
Lubrication System
4) Remove the camshaft bearing from the cylin- 2) Remove the bridge from the bridge guide.
der head assembly.
ANNOTATION:
ANNOTATION:
• Temporarily assemble the removed caps with other installation locations.
and bearings in the original position to avoid
spected.
1 Bridge cap
2 Bridge
24. Bridge Removal
25. Cylinder head assembly Removal
1) Remove the bridge cap from the bridge.
1) Remove the cylinder head assembly from the
CAUTION cylinder block.
• Be careful not to drop the bridge ANNOTATION:
CAUTION
• Since the idle gear C protrudes
from the bottom surface of the
damage the gear.
1 Idle gear C
84402832 NA - May 2011

2445-14
Lubrication System
2) Remove the cylinder head gasket from the 28. CKP sensor Removal
cylinder block.
CAUTION CKP sensor.
2) Remove the CKP sensor from the flywheel
• Do not reuse the cylinder head gas- housing.
ket.
CAUTION
1) Disengage the harness connector from the to shock.
fuel supply pump.
2) Remove the fuel supply pump from the cylin-
der block.
ANNOTATION:
• Remove together with the bracket.
1 Oil pressure switch

2 Oil port cover
3 Flywheel housing
4 CKP sensor
1 Fuel supply pump
2 Bracket 29. Flywheel Removal
3 Gear
4 Nut 1) Remove the flywheel from the crankshaft.
5 Bolt ANNOTATION:
6 O-ring
• Gradually loosen the flywheel installation
7 O-ring bolts in the order shown in the diagram.
8 Nut
9 Bolt
10 O-ring
27. Starter assembly Removal

1) Disengage the earth cable from the starter as-
sembly.
2) Remove the starter assembly from the fly-
wheel housing.
CAUTION
• Fix the flywheel firmly so that it will
not rotate.
30. Crankshaft rear oil seal Removal

1) Remove the crankshaft rear oil seal from the
crankshaft using the special tool.
84402832 NA - May 2011

2445-15
Lubrication System
ANNOTATION:
• Remove the slinger and oil seal together.
31. Oil pan Removal
level switch.
2) Remove the oil pan from the crankcase.
32. Flywheel housing Removal
1) Remove the PTO oil pipe from the flywheel
housing and the cylinder block.
2) Remove the oil pipe from the pipe bracket and
the oil port cover.
to section 1003)
1 Oil pipe
2 Pipe bracket
1 Felt 3 PTO oil pipe
2 Slinger
3 Crankshaft rear oil seal 3) Remove the cover from the flywheel housing.
1 O-ring
CAUTION 2 Cover
4) Remove the PTO idle gear from the cylinder
seal press-fitting surface.
block.
84402832 NA - May 2011

2445-16
Lubrication System
5) Remove the flywheel housing from the cylin-

der block and the crankcase.
CAUTION
• Do not forget to remove the bolt

gauge.
ANNOTATION:
• Measure the clearance between the idle
gear and the thrust collar.
CAUTION
1 Bolt • Measure the play of the idle gear in
the axis direction before removing
33. Idle gear Measurement the idle gear B.
1) Align the dial gauge to the idle gear. Specified value： 0.080 - 0.155 mm {0.0031 -
ANNOTATION: 0.0061 in}
Limit： 0.20 mm {0.0079 in}
• Attach the dial gauge to the idle gear tooth
to be measured. CAUTION
2) Inspect the backlash. • Replace the idle gear if the mea-
ANNOTATION:
• Gently move the gear right and left to read
the inconsistency on the dial gauge.
CAUTION
• Measure the idle gear backlash be-
fore removing the idle gear A.

0.0067 in}
Limit： 0.30 mm {0.0118 in}
CAUTION
• Replace the idle gear if the mea-
34. Idle gear A Removal
1) Remove the idle gear A from the idle gear A
shaft.
84402832 NA - May 2011

2445-17
Lubrication System
2) Remove the idle gear A shaft from the cylinder Oil pump assembly Disassembly
block.
1. Oil pump assembly Disassembly
1) Remove the driven gear from the body.
35. Oil pump assembly Removal

1) Remove the oil pump assembly from the cylin- 2) Remove the cotter pin from the body.
der block. 3) Remove the spring from the body.
4) Remove the ball from the body.
1 Split pin
84402832 NA - May 2011

2445-18
Lubrication System
Oil pump assembly Reassembly Oil pump assembly Installation

1. Oil pump assembly Reassembly 1. Oil pump assembly Installation
1) Install the ball to the body. 1) Clean the cylinder block using the scraper.
2) Install the spring to the body.
3) Install the cotter pin to the body. ANNOTATION:
• Remove grime and oil from the oil pump in-
stallation area.
2) Apply the engine oil to the cylinder block.
1 Split pin
4) Apply the engine oil to the driven gear.

5) Install the driven gear to the body. CAUTION
• Do not allow engine oil to adhere on
the oil pump installation surface.
3) Apply the liquid gasket to the oil pump.

ANNOTATION:
Bond 1207C to the oil pump.
CAUTION
• Do not allow the liquid gasket to ad-
here to the locations indicated by
arrows in the diagram.
stall the oil pump within 5 minutes.
84402832 NA - May 2011

2445-19
Lubrication System
4) Install the oil pump to the cylinder block. 6) Install the idle gear A to the cylinder block.
Tightening torque: 24 N・m {2.4 kgf・m / 18 Tightening torque: 133 N・m {13.6 kgf・m /
lb・ft} 98 lb・ft}
2. Idle gear A Installation

center.
2) Apply the engine oil to the idle gear A shaft.
3) Apply the engine oil to the idle gear A.
4) Install the idle gear A shaft to the idle gear A.
5) Align the idle gear A to alignment mark.
ANNOTATION:
• Align the L mark on the crank gear with the
O mark on the idle gear A.
1 Camshaft gear
2 Aligning position
3 Idle gear B
4 Aligning position
5 PTO gear
6 PTO idle gear
7 Crank gear
8 Oil pump gear
9 Supply pump gear
10 Idle gear A
1 L mark 11 Idle gear C
2 O mark
3. Flywheel housing Installation
ANNOTATION:
• Remove dust and oil from the flywheel hous-
ing installation area.
ANNOTATION:
Bond 1201 to the cylinder block.
84402832 NA - May 2011

2445-20
Lubrication System
3) Install the flywheel housing to the cylinder

block.
ANNOTATION:
• Install the flywheel housing after aligning
with the knock pin position of the cylinder
block.
Tightening torque
No.1 bolt 96 N・m {9.8 kgf・m / 71 lb・ft}
Liquid gasket application pro-

1
hibited area
CAUTION
• Do not apply liquid gasket to the lo-
cation indicated in 1 in the diagram.
stall the flywheel housing within 5
minutes.
4) Apply engine oil to the PTO gear shaft.

5) Install the PTO idle gear shaft to the PTO idle
gear.
84402832 NA - May 2011

2445-21
Lubrication System
6) Install the PTO idle gear to the cylinder block. 10) Install the PTO oil pipe to the flywheel housing
Tightening torque: 119 N・m {12.1 kgf・m / and the cylinder block.
88 lb・ft} Tightening torque: 34 N・m {3.5 kgf・m / 25
lb・ft} Flywheel housing side
Tightening torque: 15 N・m {1.5 kgf・m / 11
lb・ft} PTO side
lb・ft} Cylinder block side
lb・ft} Clip
7) Install the O-ring to the cover.

8) Install the cover to the flywheel housing.
1 Oil pipe
2 Pipe bracket
3 PTO oil pipe
4. Oil pan Installation

ANNOTATION:
• Apply ThreeBond 1207B to each joint of the
1 O-ring crankcase, flywheel housing and gear case.
2 Cover
Bead width: 3.0 mm {0.118 in}
Bead height: 2.0 mm {0.079 in}
9) Install the oil pipe to the pipe bracket and the
oil port cover.
lb・ft} Pipe bracket side
lb・ft} Oil port cover side
lb・ft} Clip
1 Crankcase
2 Timing gear case
3 Flywheel housing
CAUTION
stall the oil pan within 5 minutes.

84402832 NA - May 2011
2445-22
Lubrication System
3) Install the oil pan to the crankcase. 1) Prepare the special tool.
lb・ft}
CAUTION
Special tool: oil seal installer (refer to

section 1003)
ANNOTATION:
• In order to install the crankshaft rear oil seal,
use the one(s) in the following table from
among the parts included in the kit.

4) Connect the harness connector to the oil level

switch.
5. Crankshaft rear oil seal Installation
Legend Parts number

1: Adapter 5–8840–2709–0
2: Adapter tightening bolts 5–8840–2714–0
3: Center bolt 5–8840–2713–0
4: Sleeve 5–8840–9063–0
5: Collar 5–8840–2710–0
6: Adapter ring 5–8840–2711–0
7: Crankshaft rear oil seal -
2) Apply the engine oil to the crankshaft rear oil

seal.
CAUTION
oil seal.
3) Install the crankshaft rear oil seal to the

adapter.
4) Install the adapter to the crankshaft.
5) Install the adapter ring to the sleeve.
84402832 NA - May 2011

2445-23
Lubrication System
6) Install the sleeve to the adapter. 9) Inspect the crankshaft rear oil seal.
ANNOTATION:
shaft head and the crankshaft rear oil seal.
Specified value: 7.2 - 7.8 mm {0.283 - 0.307
in}
1 Sleeve
2 Adapter ring

ANNOTATION:
1 Flywheel housing
• Tighten the center bolt until the sleeve 2 Crankshaft rear oil seal
touches the adapter. Oil seal press-fitting measure-
3
ment
4 Crankshaft
6. Flywheel Installation
1) Apply the disulfide molybdenum grease to the
bolt.
ANNOTATION:
• Apply to the seat surface and threaded por-
tion on the flywheel installation bolts.
2) Install the flywheel to the crankshaft.
CAUTION
ANNOTATION:
lb・ft}
84402832 NA - May 2011

2445-24
Lubrication System
4) Tighten the bolt using the special tool. 8. Starter assembly Installation
1) Install the starter assembly to the flywheel
housing.
Tightening torque: 82 N・m {8.4 kgf・m / 60.5
lb・ft}
2) Connect the earth cable to the starter assem-
bly.
lb・ft}

1003)
Tightening angle: 60 °
Tightening angle: 60 °
Tightening torque: 274 N・m {27.9 kgf・m /
202 lb・ft} Check the tightening
7. CKP sensor Installation 9. Fuel supply pump Installation
1) Install the CKP sensor to the flywheel housing. 1) Align 1st cylinder to the compression top dead
center.
CAUTION 2) Align alignment mark to the bracket.
to shock.
ANNOTATION:
lb・in}
sensor.

2
ment mark

2 Oil port cover
3 Flywheel housing
4 CKP sensor
84402832 NA - May 2011

2445-25
Lubrication System
3) Align the fuel supply pump to the cylinder 10. Cylinder head assembly Installation
block.
CAUTION
ANNOTATION:
• Confirm that the white paint can be seen head and cylinder block before installing
through the timing confirmation hole on the the cylinder head assembly.
top surface of the flywheel housing.
head and cylinder block while cleaning.

ANNOTATION:
• Use ThreeBond 1207B.
Bead width: 3.0 mm {0.1181 in}
Bead height: 2.0 mm {0.0787 in}
1 Confirmation hole
2 Supply pump gear
4) Install the fuel supply pump to the cylinder

block.
lb・ft} No.8 in the diagram CAUTION
lb・ft} No.10 in the diagram • After applying liquid gasket, install
2) Install the cylinder head gasket to the cylinder

block.
CAUTION
3) Install the cylinder head assembly to the cylin-

der block.
CAUTION
• Be careful not to damage the cylin-
der head gasket.
1 Fuel supply pump

2 Bracket
3 Gear
4 Nut
5 Bolt
6 O-ring
7 O-ring
8 Nut
9 Bolt
10 Nut

supply pump.
84402832 NA - May 2011
2445-26
Lubrication System
ANNOTATION: • Tightening order of the head bolts
ANNOTATION: 2) Install the bridge to the bridge guide.

• 1 to 26 in the diagram indicate the M14 bolts. CAUTION
• 27 and 28 in the diagram indicate the M10
bolts. • Confirm that the bridge moves
smoothly.
ANNOTATION: 3) Apply the engine oil to the bridge cap.
4) Install the bridge cap to the bridge.
M14 head bolts.
• Apply engine oil to the seat surface and
lb・ft} M14 bolt
7) Tighten the head bolt using the special tool.
CAUTION

center.

1003)
Tightening angle: 30 - 60 ° M14 Bolt
lb・ft} M10 bolt
105 lb・ft} Check the tightening M14 bolt
11. Bridge Installation
1) Apply the engine oil to the bridge. 2) Apply the engine oil to the camshaft bearing.
84402832 NA - May 2011

2445-27
Lubrication System
ANNOTATION: 1 Alignment pin

bearing. 5) Install the camshaft to the cylinder head as-
sembly.
CAUTION ANNOTATION:
• Apply engine oil after cleaning the • Mesh together the idle gear C and the
bearing installation sections of camshaft gear so that the alignment mark
the camshaft bearing and cylinder on the camshaft gear matches the top sur-
head. face of the cylinder head, and gently install
the camshaft.
head assembly. CAUTION
ANNOTATION: • Align the alignment marks of the
• To prevent the effect of spring force on the sub gear side.
sub gear, use a scissors gear spring wrench
to rotate the sub gear before installing the
4) Align the sub gear to the camshaft gear using
the special tool.
ANNOTATION:
CAUTION
camshaft.
Special tool: scissors gear spring wrench 7) Apply the engine oil to the camshaft bearing.
(refer to section 1003) ANNOTATION:
bearing.
CAUTION
• Apply engine oil after cleaning the
bearing cap.
8) Install the camshaft bearing to the camshaft

bearing cap.
84402832 NA - May 2011

2445-28
Lubrication System
9) Install the camshaft bearing cap to the cylinder ANNOTATION:

head assembly.
• On the camshaft bearing assembly section
ANNOTATION: only, apply oil to the threaded portion of
the stud bolts and the seat surface/threaded
• Turn the camshaft bearing cap so that the portion of the nuts, then tighten them.
arrow mark on the top surface faces the en-
order.
lb・ft} Engine oil application

13. Rocker arm shaft Installation Front side camshaft
bearing cap : 28 N・m {2.8 kgf・m / 20
Rear side camshaft lb・ft}
ANNOTATION: bearing cap
: 56 N・m {5.7 kgf・m / 41
• Apply to each sliding surface. Rocker arm bracket
lb・ft}
2) Apply the engine oil to the rocker arm.
ANNOTATION:
14. Rocker arm shaft Adjustment
• Confirm that the adjust screw is fully loos-
ened. ANNOTATION:
• Valve clearance adjustment
CAUTION
• Adjust the valve clearance while cool.
• Loosen all adjust screws before adjust-
ment.

2 Rocker arm
3 Rear side camshaft bracket
3) Install the rocker arm shaft to the cylinder

head assembly.
84402832 NA - May 2011

2445-29
Lubrication System
1) Align 1st cylinder to the compression top dead ANNOTATION:

center.
• With the thickness gauge inserted, lightly
• Check if the valve shaft end on the opposite
loosen the bridge adjust screw and adjust
the valve shaft ends on both sides to touch
properly.
Valve bridge clearance: less than 0.1 mm
{less than 0.0039 in}
2) Prepare the feeler gauge. ANNOTATION:
Thickness: 0.4 mm {0.0157 in} 2 pieces
• To prevent turning, fix the bridge adjust
ANNOTATION: screw with a flathead screwdriver, and
rocker arm and bridge cap. Tightening torque: 22 N・m {2.2 kgf・m / 16
• Insert the thickness gauge between the lb・ft}
bridge and valve.
ANNOTATION:
• When the movement of the thickness gauge
becomes stiff, secure the adjust screw nut
of the rocker arm.
lb・ft}
top dead center
15. Lower cover Installation ANNOTATION:

1) Apply the liquid gasket to the rubber plug. • Apply ThreeBond 1207B.
84402832 NA - May 2011
2445-30
Lubrication System
5) Securely tighten the nut to the common rail

assembly.
lb・ft}
1 Rubber plug
2 Liquid gasket
CAUTION
• After applying the liquid gasket, in- 1 Common rail assembly
utes. 6) Connect the harness connector to the fuel
pressure sensor.
assembly. 17. Fuel leak off pipe assembly Installation
3) Install the gasket to the lower cover. 1) Temporarily tighten the fuel leak-off pipe to the
4) Install the lower cover to the cylinder head cylinder head assembly.
assembly.
Tightening torque: 13 N・m {1.3 kgf・m / 112 CAUTION
lb・in}
ANNOTATION:
• Tightening order 2) Temporarily tighten the fuel leak-off pipe to the
CAUTION

fuel supply pump.
ANNOTATION:
CAUTION

16. Common rail assembly Installation
1) Align the common rail assembly to the inlet Tightening torque: 14 N ・ m {1.4 kgf ・ m /
cover. 123.9 lb・in}
2) Temporarily tighten the bolt to the common rail 5) Securely tighten the fuel leak-off pipe to the
assembly. common rail assembly.
3) Temporarily tighten the nut to the common rail Tightening torque: 20 N・m {2.0 kgf・m / 14.8
assembly. lb・ft}
4) Securely tighten the bolt to the common rail 6) Securely tighten the fuel leak-off pipe to the
assembly. fuel supply pump.
Tightening torque: 25 N・m {2.5 kgf・m / 18.4 Tightening torque: 10 N・m {1.0 kgf・m / 88.5
lb・ft} lb・in}
84402832 NA - May 2011

2445-31
Lubrication System
7) Install the clip to the fuel leak-off pipe. 2) Temporarily tighten the injector to the cylinder
Tightening torque: 9 N・m {0.9 kgf・m / 79.7 head assembly.
lb・in}
CAUTION
18. Fuel pipe Installation

1) Install the fuel pipe to the fuel supply pump 1 Injector
and the common rail assembly. 2 Installation bolt
CAUTION 3) Temporarily tighten the injection pipe to the
• Use new fuel pipes. injector.
Tightening torque: 44 N・m {4.5 kgf・m / 32.5 CAUTION

lb・ft} • Use new injection pipes.
Tightening torque: 9 N・m {0.9 kgf・m / 79.7 4) Temporarily tighten the injection pipe to the
lb・in} common rail assembly.
19. Injector Installation 5) Securely tighten the injector to the cylinder
head assembly.
CAUTION Tightening torque: 30 N・m {3.1 kgf・m / 22
lb・ft}
• When reusing an injector, do not change 6) Install the injector leak-off pipe to the injector.
the installation position.
CAUTION
1) Apply the engine oil to the bolt.

lb・in}
20. Injection pipe Installation
1) Securely tighten the injection pipe to the injec-
tor.
lb・ft}
2) Securely tighten the injection pipe to the com-
mon rail assembly.
lb・ft}
84402832 NA - May 2011

2445-32
Lubrication System
3) Install the clip to the inlet cover. 2) Install the glow plug connector to the glow
Tightening torque: 6 N・m {0.6 kgf・m / 53.1 plug.
lb・in} Tightening torque: 1 N・m {0.1 kgf・m / 8.9
lb・in}
CAUTION
rounding parts.

7 Fuel pipe
1) Install the injector harness to the cylinder head
assembly.
21. Glow plug Installation ANNOTATION:
1) Install the glow plug to the cylinder head as- • Tighten the bolts on the bracket and in-
sembly. stall the injector harness together with the
Tightening torque: 20 N・m {2.0 kgf・m / 14.8 bracket.
lb・ft}
CAUTION lb・ft}


84402832 NA - May 2011

2445-33
Lubrication System
CAUTION

2 Head cover gasket
3 Lower cover

breather.
3 Terminal nut Tightening torque: 20 N・m {2.0 kgf・m / 14
lb・ft}
lb・in}
head cover.
cover.
lb・in}
ANNOTATION:
completely tighten them. 1 Ventilation hose
3 Clip

1) Install the inlet pipe to the inlet cover.
lb・ft}
84402832 NA - May 2011

2445-34
Lubrication System
2) Connect the harness connector to the boost 1) Install the intake throttle valve to the inlet pipe.
sensor. Tightening torque: 24 N・m {2.4 kgf・m / 17
3) Connect the harness connector to the boost lb・ft}
temperature sensor.
sensor.
lb・ft}

2 Gasket
3 Inlet pipe
2) Install the air duct to the intake throttle valve.

3) Connect the harness connector to the intake
1 Boost sensor throttle valve.
2 Harness clip
ANNOTATION:
4 IMT sensor • After connecting the harness connector,
25. Intake throttle valve Installation

2 Lock release
3 Lock
84402832 NA - May 2011

2445-35
Lubrication System
84402832 NA - May 2011

2445-36
Lubrication System
pump assembly and the water duct. Tightening torque: 30 N・m {3.1 kgf・m / 22
lb・ft}
1 Water bypass hose
Clamp tightening torque: 20 N・m {2.0 kgf・ 3 Fan guide bracket
m / 14 lb・ft}
ANNOTATION:
lb・ft}
CAUTION
gle of the hose.

lb・ft}
1 Installation bolt

outlet pipe.
bracket.
lb・ft}

2 Clip
84402832 NA - May 2011
2445-37
Lubrication System
EGR bracket C.
lb・ft}
1 EGR cooler C
3 EGR cooler B
1 EGR valve
haust manifold.
EGR pipe A.
1 EGR valve
2 EGR pipe B
3 EGR cooler C
1 EGR cooler A
EGR cooler A. Tightening torque: 31 N・m {3.2 kgf・m / 23
cooler A.
lb・ft}
the EGR cooler B.
lb・ft}
cooler bracket C.
lb・ft}
84402832 NA - May 2011
2445-38
Lubrication System
cooler C.
cylinder block.
lb・ft}
lb・ft}
valve.
Tightening torque: 46 N・m {4.7 kgf・m / 34 2) Connect the oil level gauge guide tube to the
lb・ft}
15) Securely tighten the EGR cooler bracket A to Tightening torque: 24 N・m {2.4 kgf・m / 17
lb・ft}
Tightening torque: 24 N・m {2.4 kgf・m / 17 3) Install the oil level gauge to the oil level gauge
guide tube.
lb・ft}
lb・ft}
lb・ft}
pipe.
lb・ft}

assembly.
bly.
haust manifold.
lb・ft}
cooler. Tightening torque: 24 N・m {2.4 kgf・m / 17
lb・ft} Clip
CAUTION

bocharger assembly.
lb・ft}
CAUTION
1 Water rubber hose
84402832 NA - May 2011

2445-39
Lubrication System
block. assembly.
Tightening torque: 41 N・m {4.2 kgf・m / 30 Tightening torque: 34 N・m {3.5 kgf・m / 25
lb・ft} lb・ft}
Tightening torque: 24 N・m {2.4 kgf・m / 17 Tightening torque: 24 N・m {2.4 kgf・m / 17
CAUTION CAUTION

bocharger assembly.
lb・ft}
CAUTION

lb・ft}
CAUTION
1 Oil feed pipe
9) Connect the oil return pipe to the turbocharger 2 Clip
assembly.
3 Oil return pipe
5 Water return pipe
CAUTION
• Use a new gasket. assembly.
10) Install the oil feed pipe to the pipe bracket. assembly and the intercooler.
Tightening torque: 34 N・m {3.5 kgf・m / 25 14) Install the air cleaner duct to the air cleaner
lb・ft} assembly and the turbocharger assembly.
lb・ft} Clip 32. Engine oil Filling
1) Replenish the engine oil with the engine as-
CAUTION sembly.
CAUTION
• Check the tightening of the drain
33. Engine harness Connect

sembly.
ANNOTATION:
34. Coolant Filling
84402832 NA - May 2011

2445-40
Lubrication System
2) Replenish the coolant with the radiator. 1 Priming pump

2 Plug
CAUTION 3 Drain plug
• Be careful not to let coolant over- 4 Case
flow splash on the exhaust system 3 Drain plug
parts.
• Coolant overflow should be wiped 1) Prepare the pan.
off. 2) Turn ON the starter switch.
3) Tighten the valve using a wrench. ANNOTATION:
CAUTION • This is for the models with an electromag-

netic pump.
• Use new gaskets. 3) Loosen the plug using the wrench.
Tightening torque: 22 N・m {2.2 kgf・m / 16 Number of times: 20 count(s) or more
lb・ft}
4) Replenish the coolant with the radiator. ANNOTATION:
plug.
Number of times: 10 count(s) or more
ANNOTATION:
the priming pump.
Specified time: 1 min
ANNOTATION:
1 Valve 9) Operate the priming pump.
2 Gasket Number of times: 10 count(s) or more
ANNOTATION:
35. Battery ground cable Connect • Wait for the specified time after operating
the priming pump.
tery. Specified time: 1 min
36. Fuel Air bleed
ANNOTATION:
CAUTION
• To prevent engine failure, be sure to per- 11) Tighten the plug using the wrench.
removal of fuel system parts.
Number of times: 10 count(s) or more
ANNOTATION:
the priming pump.
ANNOTATION:
84402832 NA - May 2011

2445-41
Lubrication System
14) Tighten the plug using the wrench. Oil pump assembly Inspection
lb・in} 1. Oil pump assembly Inspection
CAUTION gauge.
• Remove the fuel around the plug ANNOTATION:
thoroughly after tightening.
• The clearance between the inner wall of the
15) Operate the priming pump. body and each gear tooth tip.
Number of times: 10 count(s) Specified value： 0.125 - 0.220 mm ｛0.0049
16) Start the engine. - 0.0087 in｝
ANNOTATION: Limit： 0.30 mm ｛0.0118 in｝
• Do not accelerate the engine revolution right

after staring.
Specified time: 5 s
ANNOTATION:
ANNOTATION:
mum.
CAUTION
• Replace the gear if the measured
value exceeds the limit value.
2) Measure the shaft using the micrometer.

ANNOTATION:
• Driven gear shaft outer diameter
Specified value ： 15.989 - 16.000 mm
｛0.6295 - 0.6299 in｝
Limit： 15.900 mm ｛0.6260 in｝
3) Measure the body using the gauge.
ANNOTATION:
• Measure the bush inner diameter of the
body.
84402832 NA - May 2011

2445-42
Lubrication System
4) Measure the cylinder block using the gauge. Engine oil Inspection
ANNOTATION: 1. Engine oil Inspection
• Measure the bush inner diameter of the
cylinder block. CAUTION
• The engine should be in a horizontal po-
sition.
• Wait at least 5 minutes before starting the
engine and after stopping the engine.
1) Remove the oil level gauge from the oil level

gauge guide tube.
ANNOTATION:
• Wipe off the engine oil remaining on the oil
level gauge.
2) Install the oil level gauge to the oil level gauge
guide tube.
3) Remove the oil level gauge from the oil level
5) Calculate the clearance from the measured gauge guide tube.
value. 4) Inspect the engine oil.
• The difference between the shaft outer di- • Check the engine oil remaining on the oil
ameter and the bush inner diameter is the level gauge to inspect the engine oil level.
clearance.
Specified value： 0.04 - 0.07 mm ｛0.0016 -
0.0028 in｝
Limit： 0.20 mm ｛0.0079 in｝
CAUTION
• Replace the gear if the clearance
6) Inspect the ball.

7) Inspect the spring.
1 Upper limit
2 Lower limit
ANNOTATION:
• If the oil level is under the lower limit, add
engine oil.
• Replace the engine oil if engine oil is dirty.
1 Ball
2 Spring
84402832 NA - May 2011

2445-43
Lubrication System
Removal and Installation of Oil Oil port cover Installation

Port Cover 1. Oil port cover Installation
1) Install the O-ring to the oil port cover.
Oil port cover Removal
1. Oil pressure sensor Removal
1) Disconnect the harness connector from the oil
pressure sensor.
2) Remove the oil pressure sensor from the oil
port cover.
1 O-ring
2 O-ring
2) Install the oil port cover to the cylinder block.

1 Oil pressure sensor lb・ft}
2 Oil port cover
3 Flywheel housing
4 CKP sensor
2. Oil port cover Removal

1) Disengage the oil feed pipe from the oil port
cover.
2) Remove the oil port cover from the cylinder
block.
3) Remove the O-ring from the oil port cover.
1 Bolt - short
2 Bolt - long
3) Connect the oil feed pipe to the oil port cover.

lb・ft} eyebolt
CAUTION
1 O-ring
2 O-ring 2. Oil pressure sensor Installation
1) Install the oil pressure sensor to the oil port
cover.
lb・ft}
CAUTION
84402832 NA - May 2011
2445-44
Lubrication System
2) Connect the harness connector to the oil pres-

sure sensor.

2 Oil port cover
3 Flywheel housing
4 CKP sensor
84402832 NA - May 2011

2445-45
Lubrication System
84402832 NA - May 2011

2445-46
Section
2455
Cooling System
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal and Installation of Water Pump Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Water pump assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Water pump assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Water pump assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal and Installation of Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Thermostat Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Thermostat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Thermostat Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Coolant Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Drive belt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal and Installation of Overheat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Overheat switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Overheat switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Cooling System
Removal and Installation of Water 2) Remove the fan guide bracket from the engine
assembly.
Pump Assembly
5. Drive belt Removal
Water pump assembly Removal 1) Remove the drive belt from the engine assem-
1. Battery ground cable Disconnect bly.

battery.
2. Coolant Drain
CAUTION
• After the coolant is discharged, make
sure to tighten the drain plug.
3. Cooling fan Removal

1) Remove the cooling fan from the adapter.
1 Adjust bolt
2 Fixing bolt
3 Fixing bolt
6. Water pump assembly Removal

1) Remove the fan pulley from the water pump
assembly.
1 Cooling fan
2 Adapter
4. Fan guide Removal

1) Remove the fan guide from the fan guide
bracket.
2) Remove the water bypass hose from the wa-

ter pump assembly and the water duct.
1 Bolt
2 Washer
3 Rubber mount
4 Rubber mount
5 Guide tube
6 Fan guide 1 Water bypass hose
84402832 NA - May 2011
2455-3
Cooling System
3) Remove the water hose from the EGR cooler Water pump assembly Installation
water pipe and the water pump assembly.
4) Remove the water pump assembly from the 1. Water pump assembly Installation
gear case cover cover. 1) Install the water pump assembly to the gear
case cover cover.
CAUTION

28.8 lb・ft} Nut in the diagram
14.8 lb・ft}
1 Nut
2) Install the water hose to the EGR cooler water

pipe and the water pump assembly.
3) Install the water bypass hose to the water
pump assembly and the water duct.
1 Water bypass hose
84402832 NA - May 2011

2455-4
Cooling System
4) Install the fan pulley to the water pump assem- 2) Adjust the drive belt to standard value using
bly. the adjust bolt.
Tightening torque： 52 N・m {5.3 kgf・m / Tightening torque： 75 N・m {7.6 kgf・m /
38.4 lb・ft} 55.3 lb・ft} Nut of the adjust plate
/ 92.9 lb・ft} Bolt of the bracket side
2. Drive belt Installation

1) Install the drive belt to the engine assembly.
3. Drive belt Adjustment 1 Adjust bolt
2 Adjust plate side nut
1) Press the drive belt. 3 Bracket side bolt
ANNOTATION:
4. Fan guide Installation
pressing on the point indicated by the arrow 1) Install the fan guide bracket to the engine as-
in the diagram with the specified pressure. sembly.
Standard value： 98.0 N {10.0 kg / 22 lb} 29.5 lb・ft}
Specified value ： 5.5 - 7.5 mm {0.2165 - 2) Install the fan guide to the fan guide bracket.
0.2953 in} Amount of flex Tightening torque： 30 N・m {3.1 kgf・m /
22.1 lb・ft}
1 Crankshaft pulley
2 Generator 1 Bolt
3 Fan pulley 2 Washer
3 Rubber mount
4 Rubber mount
5 Guide tube
6 Fan guide
84402832 NA - May 2011

2455-5
Cooling System
5. Cooling fan Installation 3) Tighten the valve using a wrench.

1) Install the cooling fan to the adapter. CAUTION

lb・ft}
1 Cooling fan
2 Adapter

38.4 lb・ft}
6. Coolant Filling 1 Valve
1) Loosen the valve using a wrench. 2 Gasket
CAUTION
• Be careful not to let coolant over- tery.
parts.
off.
84402832 NA - May 2011

2455-6
Cooling System
Water pump assembly Inspection Removal and Installation of

1. Water pump assembly Inspection Thermostat
1) Inspect the water pump assembly.
Thermostat Removal
ANNOTATION:
• Cracks and damage on the water pump
body 1) Disengage the battery ground cable from the
• Cracks and corrosion on the impeller battery.
• Water leak from the seal unit 2. Coolant Drain
CAUTION 1) Drain the coolant from the radiator.
• If any abnormality is found in the CAUTION
inspection, replace the water pump
assembly. • After the coolant is discharged,
2) Inspect the bearing unit.
3. Thermostat Removal
ANNOTATION:
1) Remove the fan guide stay from the fan guide
• Rotate the fan while pushing the fan center and the fan guide bracket.
to the radius direction and inspect for any
significant looseness or abnormal sounds.
CAUTION
• If any abnormality is found in the
inspection, replace the water pump
assembly.
1 Fan guide
2 Fan guide stay
3 Fan guide bracket

water outlet pipe.
3) Remove the water outlet pipe from the cylin-
der head assembly.
1 Fan guide bracket

2 Water outlet pipe
84402832 NA - May 2011
2455-7
Cooling System
4) Remove the thermostat from the cylinder Thermostat Installation

head assembly.
5) Remove the gasket from the thermostat. 1. Thermostat Installation
1) Install the gasket to the thermostat.
CAUTION
2) Install the thermostat to the cylinder head as-

sembly.
1 Jiggle valve position
CAUTION
• Be careful not to mistake the as-
sembly position and direction.
3) Install the water outlet pipe to the cylinder

head assembly.
18.4 lb・ft}
1 Fan guide bracket

2 Water outlet pipe

outlet pipe.
bracket.
29.5 lb・ft}
84402832 NA - May 2011
2455-8
Cooling System
6) Install the fan guide stay to the fan guide. 3) Tighten the valve using a wrench.
22.1 lb・ft} CAUTION

lb・ft}
1 Fan guide
2 Fan guide stay
3 Fan guide bracket
2. Coolant Filling
1) Loosen the valve using a wrench. 1 Valve
2) Replenish the coolant with the radiator. 2 Gasket
CAUTION 3. Battery ground cable Connect

• Be careful not to let coolant over- 1) Connect the battery ground cable to the bat-
flow splash on the exhaust system tery.
parts.
off.
84402832 NA - May 2011

2455-9
Cooling System
Thermostat Inspection CAUTION

1. Thermostat Inspection
• Do not heat the thermostat directly.
1) Inspect the thermostat.
4) Measure the water temperature using the
ANNOTATION: thermometer.
• Inspect the pellet, spring, shaft, jiggle valve,
and crimped sections for damage. ANNOTATION:
• Measure open valve temperature of the
thermostat.
Valve opening temperature： 80 - 84 ℃ ｛176
- 183 °F｝
Temperature when fully open： 90.0 ℃ ｛194
°F｝
Lift amount： 8.0 mm ｛0.3150 in｝
1 Jiggle valve
2) Prepare the container.

ANNOTATION:
• Put water and the thermostat into a heatable
container.
3) Raise the water temperature. 1 Piece of wood
2 Stirring rod
ANNOTATION:
• In order to equalize the water temperature
in the container, stir well.
84402832 NA - May 2011

2455-10
Cooling System
Coolant Inspection 3) Measure the specific gravity using the hy-

drometer.
1. Coolant Inspection Engine coolant temperature： 0 - 50 °C{32 -
122 °F} For inspection
WARNING
ANNOTATION:
• If the coolant temperature is high, do not
perform the inspection. • Use a container that is deeper than the
• When removing the cap, be careful as the length of the hydrometer.
coolant will burst out if the coolant tem-
perature is high.
CAUTION
• Be sure to use long life coolant which is
specified or recommended by Isuzu.
• Using at an unspecified concentration
may result in freezing due to decreased
anti-freezing performance.
• Use a coolant concentration appropriate
for the usage environment.
ANNOTATION:
• Before using, dilute the specified long life coolant
to the specified concentration with soft tap water.
1 Radiator
2 Hydrometer
Area where the equipment is LLC concen-
used tration 4) Measure the temperature using the ther-
General area; Area where the mometer.
lowest temperature is higher than ： 30 ％ Engine coolant temperature： 0 - 50 °C {32 -
(-12) degrees. 122 °F} For inspection
Cold area; Area where the lowest 5) Calculate the concentration from the mea-
： 50 ％ sured value.
temperature is (-30) degrees.
Area where temperature drop to
： 55 ％
(-30) degrees.
1) Inspect the radiator reverse tank.

ANNOTATION:
• If coolant level is MIN or less, add it until it
reaches MAX.
CAUTION
SPECIFIC
• When adding coolant, use coolant GRAVITY
appropriate for the usage environ-
ment.
Volume of coolant： 16.0 L {4.2 US gal}

2) Inspect the water leak using the radiator cap
tester.
Inspection pressure ： 200.0 kPa {2.04 kgf/
cm2 / 29 psi}
ANNOTATION:
TEMPERATURE (°C)
• Inspection locations
• Radiator assembly
ANNOTATION:
• Water pump assembly
• Radiator hose • Measuring the coolant concentration using
• Heater hose a coolant scope is also possible.
84402832 NA - May 2011

2455-11
Cooling System
Drive belt Inspection Removal and Installation of

1. Drive belt Inspection Overheat Switch
1) Inspect the drive belt.
Overheat switch Removal
ANNOTATION:
1. Overheat switch Removal
• Inspect for wear or damage.
2. Drive belt Adjustment overheat switch.
1) Press the drive belt. 2) Remove the overheat switch from the cylinder
head assembly.
ANNOTATION:
pressing on the point indicated by the arrow
in the diagram with the specified pressure.
Standard value： 98.0 N ｛10.0 kg / 22 lb｝
Specified value ： 5.5 - 7.5 mm ｛ 0.2165 -
0.2953 in｝ Amount of flex
1 Overheat switch
1 Crankshaft pulley
2 Generator
3 Fan pulley
2) Adjust the drive belt to standard value using

the adjust bolt.
55.3 lb・ft｝ Nut of the adjust plate
Tightening torque： 126 N・m ｛12.8 kgf・
m / 92.9 lb・ft｝ Bolt of the bracket side
1 Adjust bolt
2 Adjust plate side nut
3 Bracket side bolt
84402832 NA - May 2011
2455-12
Cooling System
Overheat switch Installation

1. Overheat switch Installation
1) Install the overheat switch to the cylinder head
assembly.
ANNOTATION:
• Apply Loctite 572 to the threaded portion.
21.4 lb・ft｝
1 Overheat switch
ANNOTATION:
• Connect the harness connector to the over-
heat switch.
84402832 NA - May 2011

2455-13
Cooling System
84402832 NA - May 2011

2455-14
Section
2465
Removal and Installation of Exhaust Manifold
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Exhaust manifold Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Exhaust manifold Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Exhaust manifold Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Exhaust manifold Removal 13) Remove the turbocharger assembly from the
exhaust manifold.
battery.
1) Remove the air cleaner duct from the air
cleaner assembly and the turbocharger as-
sembly.
bocharger.
bocharger assembly.
ANNOTATION:
1 Oil feed pipe
• Remove the clip. 2 Clip
5) Remove the oil feed pipe from the pipe 3 Oil return pipe
bracket. 4 Water feed pipe
5 Water return pipe
ANNOTATION:
• Remove the clip. 3. Oil level gauge guide tube Removal
6) Disengage the oil return pipe from the tur- 1) Remove the oil level gauge from the oil level
bocharger assembly. gauge guide tube.
7) Remove the oil return pipe from the cylinder 2) Disengage the oil level gauge guide tube from
block. the front engine hanger bracket.
8) Disengage the water return pipe from the tur- 3) Remove the oil level gauge guide tube from
bocharger assembly. the cylinder block.
der head assembly.
bocharger assembly.
ANNOTATION:
11) Remove the water feed pipe from the cylinder
block.
ANNOTATION:
4. Exhaust manifold Removal

EGR pipe A.
84402832 NA - May 2011

2465-3
4) Remove the exhaust manifold from the cylin-

der head assembly.
CAUTION 1 Exhaust manifold

2 Distance nut
• Remove the EGR pipe A from the
EGR cooler A and exhaust mani-
fold. 5) Disassemble the exhaust manifold.

1 EGR cooler A 2 Seal ring
2 EGR pipe A 3 Front side exhaust manifold
3 Exhaust manifold
2) Remove the exhaust manifold cover from the

exhaust manifold.
3) Remove the heat protector from the exhaust
manifold.
1 Heat protector
84402832 NA - May 2011
2465-4
Exhaust manifold Installation 2) Assemble the exhaust manifold.
1. Exhaust manifold Installation ANNOTATION:
1) Install the gasket to the cylinder head assem- • Assemble the seal ring onto the rear side
bly. exhaust manifold and adjust each seal ring
joint to be 120 degrees apart.
ANNOTATION:
• Install the gasket by turning the protruding
section downward.

2 Seal ring
CAUTION 3 Front side exhaust manifold
• Confirm that the gasket is firmly in-

stalled to the cylinder head. 3) Install the exhaust manifold to the cylinder
head assembly.
ANNOTATION:
ANNOTATION:
• It will ride on the casted surface of the cylin-
der head as shown in the diagram when in- • Assemble the distance tube and washer re-
ferring to the diagram.
stalled incorrectly.
1 Casted surface 1 Exhaust manifold

2 Gasket 2 Distance nut
84402832 NA - May 2011

2465-5
6) Install the EGR pipe A to the EGR cooler A

and the exhaust manifold.
lb・ft} Bolt
lb・ft} Nut
1 Distance tube
2 Nut
3 Washer
4 Distance nut

lb・ft} Nut 1 EGR cooler A
Tightening torque： 34 N・m {3.5 kgf・m / 25 2 EGR pipe A
lb・ft} Distance nut 3 Exhaust manifold
4) Install the heat protector to the exhaust mani-
fold. 7) Install the EGR heat protector to the EGR pipe
Tightening torque： 20 N・m {2.0 kgf・m / 14 A.
lb・ft} Bolt Tightening torque： 31 N・m {3.2 kgf・m / 23
Tightening torque： 41 N・m {4.2 kgf・m / 30 lb・ft}
lb・ft} Nut
5) Install the exhaust manifold cover to the ex-
haust manifold.
lb・ft}
2. Oil level gauge guide tube Installation

cylinder block.
1 Heat protector Tightening torque： 24 N・m {2.4 kgf・m / 17
2 Exhaust manifold cover lb・ft}
2) Connect the oil level gauge guide tube to the
lb・ft}
84402832 NA - May 2011

2465-6
3) Install the oil level gauge to the oil level gauge 6) Install the water return pipe to the cylinder
guide tube. block.
lb・ft}
lb・ft} Clip
CAUTION

bocharger assembly.
lb・ft}
CAUTION
3. Turbocharger assembly Installation Tightening torque： 24 N・m {2.4 kgf・m / 17
1) Replenish the engine oil with the turbocharger lb・ft}
assembly.
2) Align the gasket to the turbocharger assem- CAUTION
bly. • Use a new gasket.
haust manifold. 9) Connect the oil return pipe to the turbocharger
Tightening torque： 52 N・m {5.3 kgf・m / 38 assembly.
lb・ft} Tightening torque： 24 N・m {2.4 kgf・m / 17
4) Install the water feed pipe to the cylinder lb・ft}
block.
Tightening torque： 41 N・m {4.2 kgf・m / 30 CAUTION
lb・ft}
Tightening torque： 24 N・m {2.4 kgf・m / 17 • Use a new gasket.
lb・ft} Clip
10) Install the oil feed pipe to the pipe bracket.
CAUTION Tightening torque： 34 N・m {3.5 kgf・m / 25
lb・ft}
• Use a new gasket. Tightening torque： 24 N・m {2.4 kgf・m / 17
lb・ft} Clip
bocharger assembly. CAUTION
lb・ft} • Use a new gasket.
CAUTION
84402832 NA - May 2011

2465-7
11) Connect the oil feed pipe to the turbocharger Exhaust manifold Inspection
assembly.
Tightening torque： 34 N・m {3.5 kgf・m / 25 1. Exhaust manifold Inspection
lb・ft} 1) Inspect the exhaust manifold.
lb・ft} clip ANNOTATION:
CAUTION • Inspect the exhaust manifold for cracks.

2) Align the simple straight ruler to the cylinder
• Use a new gasket. head assembly.
gauge.
ANNOTATION:
• Flatness of the exhaust manifold
Limit： 0.5 mm ｛0.0197 in｝
Specified value： 0.3 mm ｛0.0118 in｝
1 Oil feed pipe

2 Clip
3 Oil return pipe
4 Water feed pipe
5 Water return pipe

assembly. CAUTION
13) Install the air intake hose to the turbocharger • Replace the exhaust manifold if flat-
assembly and the intercooler. ness is above the limit value.
14) Install the air cleaner duct to the air cleaner
assembly and the turbocharger assembly.
tery.
84402832 NA - May 2011

2465-8
Section
2470
Disassembly, Removal and Installation of DPD Assembly
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
DPD assembly Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

DPD assembly Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DPD assembly Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

DPD assembly Disassembly 2) Disengage the harness connector from the

exhaust differential pressure sensor.
1. Exhaust differential pressure sensor Safety Infor- 3) Remove the exhaust differential pressure sen-
mation sor from the DPD assembly.
CAUTION CAUTION
• Do not use a tool which causes vibra- • Remove the DPD differential pres-
tions such as an impact wrench when in- sure sensor with the attached
stalling and removing the DPD differen- bracket.
tial pressure sensor.
• Do not reuse a DPD differential pressure
sensor which has been subjected to
shock such as being dropped.
• Install or remove the DPD differen-
tial pressure sensor together with the
bracket.
• Be sure not to loosen the 4 screws in-
stalled on the DPD differential pressure
sensor.
• Replace the DPD differential pressure
sensor if the 4 screws installed on the
DPD differential pressure sensor have
been loosened.
DPD differential pressure sen-

1
sor
3. Exhaust gas temperature sensor Safety Information
CAUTION
• Before removing, be sure to check the
DPD pressure difference, status, and in-
spection/maintenance contents using a
scan tool.
• Do not reuse an exhaust gas tempera-
1 Screw ture sensor which has been subjected to
2. Exhaust differential pressure sensor Removal
4. Exhaust gas temperature sensor Removal
CAUTION
• Before performing work, be sure to exhaust gas temperature sensor.
check the DPD differential pressure sen-
ANNOTATION:
sor precautions.
• To prevent incorrect assembling, make an
1) Disengage the differential pressure hose from alignment mark on the connector before dis-
the exhaust differential pressure sensor. connecting.
84402832 NA - May 2011

2470-3
2) Remove the exhaust gas temperature sensor 4) Remove the differential pressure pipe from
from the DPD assembly. the DPD assembly.
Exhaust gas temperature sen- 1 Bracket

1
sor 1 2 Differential pressure pipe
Exhaust gas temperature sen-
2
sor 2 5) Remove the oxidation catalyst assembly from
the filter assembly.
5. DPD assembly Disassembly 6) Remove the filter assembly from the exhaust
silencer assembly.
1) Remove the bracket from the DPD assembly.
2) Loosen the differential pressure pipe using the
wrench.
3) Remove the clip from the differential pressure
pipe.
1 Oxidation catalyst assembly

2 Filter assembly
3 Exhaust silencer assembly
84402832 NA - May 2011

2470-4
DPD assembly Reassembly 6) Temporarily tighten the clip to the differential

pressure pipe.
1. DPD assembly Reassembly 7) Securely tighten the clip to the differential
pressure pipe.
CAUTION Tightening torque： 10 N・m ｛1.0 kgf・m /
• Do not reuse gaskets, bolts, and nuts. 88.5 lb・in｝
8) Securely tighten the differential pressure pipe
1) Temporarily tighten the filter assembly to the to the DPD assembly.
exhaust silencer assembly. Tightening torque： 35 N・m ｛3.6 kgf・m /
25.8 lb・ft｝ pipe sleeve nut
ANNOTATION: 9) Install the bracket to the DPD assembly.
• Tighten together with the bracket. 18.4 lb・ft｝
2) Temporarily tighten the oxidation catalyst as-
sembly to the filter assembly.
ANNOTATION:
• Tighten together with the bracket.
• Place the DPD assembly tightened tem-
porarily on a flat surface to determine the
position so that the bracket installation area
is horizontal.
3) Securely tighten the filter assembly to the ex-
haust silencer assembly.
21.4 lb・ft｝
4) Securely tighten the oxidation catalyst assem-
bly to the filter assembly.
Tightening torque： 29 N・m ｛3.0 kgf・m / 1 Bracket
21.4 lb・ft｝
2 Differential pressure pipe
2. Exhaust gas temperature sensor Installation
CAUTION
• Do not subject the tip of the exhaust gas
temperature sensor to shock when in-
stalling.
• Remove the old anti-seize lubricant on
the sleeve nut.
• Apply the anti-seize lubricant on the
threaded portion of the sleeve nut.
• Apply Never-Seez High Tempera-
ture Stainless Grade ： 5-87411-039-0
anti-seize lubricant, manufactured by
Bostik in the United states.
1 Oxidation catalyst assembly
• Replace the oxidation catalyst assembly
2 Filter assembly if damage has been found in the sensor
3 Exhaust silencer assembly installation section of the oxidation cata-
lyst assembly.
5) Temporarily tighten the differential pressure
pipe to the DPD assembly. 1) Temporarily tighten the exhaust gas tempera-
ture sensor to the DPD assembly.
CAUTION
CAUTION
• Remove the old anti-seize lubricant
on the sleeve nut. • To avoid damaging the sensor in-
• Apply the anti-seize lubricant on the stallation sections due to sensor
threaded portion of the sleeve nut. incorrect assembly, tighten it by
• Apply Never-Seez High Tem- hand.
perature Stainless Grade ：
5-87411-039-0 anti-seize lubricant, ANNOTATION:
manufactured by Bostik in the
United states. • Exhaust gas temperature sensor identifica-
tion
84402832 NA - May 2011
2470-5
Connector
Sensor type Screw size
color
Exhaust gas tempera-
M12 x 1.75 Dark gray
ture sensor 1
M12 x 1.25 Light gray
ture sensor 2
2) Securely tighten the exhaust gas temperature

sensor to the DPD assembly.
22.1 lb・ft｝
3) Connect the harness connector to the exhaust
gas temperature sensor.
CAUTION
• Be careful not to twist the harness. 1 Screw
4. Exhaust differential pressure sensor Installation
CAUTION
• Before performing work, be sure to
sor precautions.
1) Install the exhaust differential pressure sensor

to the DPD assembly.
differential pressure sensor.
3) Connect the differential pressure hose to the
CAUTION
1 • Be careful not to mistake the con-
sor 1
Exhaust gas temperature sen- necting position of the differential
2 pressure hose.
sor 2
• Since the differential pressure sen-
ANNOTATION: sor may malfunction if exhaust gas
leaks from the joint sections, con-
• Start the engine after assembling each part, firm that there is no exhaust gas
and check for gas leaks from each joint and leakage after the engine starts.
for vibration.
3. Exhaust differential pressure sensor Safety Infor-
mation
CAUTION
• Do not use a tool which causes vibra-
tions such as an impact wrench when in-
stalling and removing the DPD differen-
bracket.
stalled on the DPD differential pressure DPD differential pressure sen-
1
sensor. sor
been loosened.
84402832 NA - May 2011

2470-6
DPD assembly Inspection ANNOTATION:
1. Filter assembly Inspection • Attach the filter on the DPD ash removal device.
1) Inspect the filter assembly.
ANNOTATION:
• Inspect the filter for erosion, crack, damage,
or clogging.
• Replace the filter assembly if light passes
through when shining light from the other
side of the filter.
ANNOTATION:
• Add air pressure of the specified pressure to the
air tank until it increases to the specified pressure,
and then stop adding.
Specified pressure： 0.4 MPa ｛58.0 psi｝
CAUTION
• Confirm that there is no air leakage on
1 Filter the pipe connections by checking the
2 Filter case pressure gauge attached to the pressure
reducing valve to avoid supplying air
2. Oxidation catalyst assembly Inspection pressure to the air tank over the limit
value.
1) Inspect the oxidation catalyst assembly.
ANNOTATION: Limit： 0.5 MPa ｛72.5 psi｝
• Inspect the catalyst section for erosion, ANNOTATION:
damage, or clogging.
• Operate the mechanical valve for 3 seconds to
3. Filter assembly Cleaning clean the filter by backwashing.
• Repeat the 2 operations above 3 times or more.
CAUTION
CAUTION
• Clean the filter when clogged because
gradual accumulation or firm, sticky cal- • While cleaning, ashes may gush from
cination occurs on the filter since ashes the air removal filter with backwashing
are nonflammable unlike particle materi- noise, so be sure to wear protective
als (PM). equipments such as a protective mask,
• When cleaning, use a DPD ash removal protective glasses, earplugs, etc. and
device which blows compressed air in- keep your face and hands away.
stantaneously.
• For further details on the cleaning proce-
dure, check the DPD ash removal device
handling manual.
84402832 NA - May 2011

2470-7
84402832 NA - May 2011

2470-8
Section
3001
Removal and Installation of Fuel Tank
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of fuel tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

WARNING 3. Use a wrench (19 mm) to remove the 2 bolts (1),

and then remove the stay (2).
• Keep away from fire.
CAUTION
work.
load.
Items to prepare
• Shackle (with the required lifting capacity) x 4 4. Use a wrench (19 mm) to remove the 6 bolts (1),
• Wire ropes (with the required breaking load) and then remove the top cover (2).
• Caps
• Plugs
• Drum can (for draining fuel)
• Rag
• Cleaning fluid
Removal of Fuel Tank

1. Remove the cap (1) and filter (2).
5. Use a wrench (19 mm) to remove the 2 bolts (1)

from the fuel tank front cover (tank) (2), and then
remove the cover (tank).
2. Drain out all the fuel from the fuel tank into a drum
can.
84402832 NA - May 2011

3001-3
6. Use a wrench (19 mm) to remove the 6 bolts (1) and 8. Use a wrench (19 mm) to remove the 5 bolts (1),
clamps (2), and then remove the handle (3). and then remove the under cover (2).
N•m
9. Loosen the hose band (1), and then remove the

hose (2).
• Mark the fuel tank and hose so that the connec-
tors match at the time of assembly.
• Attach caps or plugs to the fuel tank and hoses to

from the fuel tank side cover (2), and then remove
the side cover.
10. Remove the connector (1).
11. Use a wrench (24 mm) to remove the 6 bolts (1) and
6 spacers (2) from the bottom of the fuel tank.
• Depending on the machine, there may be height
adjustment shims between the tank and the
frame. Do not lose them.
• Also, mark or write down the locations where they
are and how many.
84402832 NA - May 2011

3001-4
• Tightening torque for bolt installation: 233.0 - 14. Connect the 4 shackles (1) to the eyebolts, then use
276.0 N•m the wire ropes (2) and liftcrane to lift.
Thoroughly check that the location is safe before
lowering the fuel tank (3) on wood planks.

and then remove the side covers (tank) (2).
13. Install the 4 eyebolts (M12) (1) on top of the fuel

tank.
by a half turn.
84402832 NA - May 2011

3001-5
Installation of fuel tank For bolts for which the torque is not specified, see "Stan-
To install, perform the reverse of the removal procedure. Finally, carefully check for any fuel leaks.
84402832 NA - May 2011

3001-6
Section
3004A
Removal and Installation of Fuel Supply Pump
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Fuel supply pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Fuel supply pump Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Fuel supply pump Removal 2) Remove the fuel supply pump from the cylin-
der block.
ANNOTATION:
battery. • Remove together with the bracket.
gine assembly.
ANNOTATION:
ANNOTATION:
CAUTION
1 Fuel supply pump
• Do not reuse the removed fuel pipe. 2 Bract
3 Gear
4. Fuel leak off pipe assembly Removal 4 Nut
1) Disengage the fuel leak-off pipe from the cylin- 5 Bolt
der head. 6 O-ring
2) Remove the fuel leak-off pipe from the fuel 7 O-ring
supply pump. 8 Nut
ANNOTATION: 9 Bolt
10 Nut
the fuel feed pipe.
mon rail assembly.
pipe.
ANNOTATION:

fuel supply pump.
84402832 NA - May 2011
3004A-3
Fuel supply pump Installation 4) Install the fuel supply pump to the cylinder
block.
1. Fuel supply pump Installation Tightening torque： 75 N・m {7.6 kgf・m / 55
1) Align 1st cylinder to the compression top dead lb・ft} No.5 in the diagram
center. Tightening torque： 75 N・m {7.6 kgf・m / 55
2) Align alignment mark to the bracket. lb・ft} No.8 in the diagram

2 1 Fuel supply pump
ment mark
2 Bracket
3 Gear
3) Align the fuel supply pump to the cylinder 4 Nut
block.
5 Bolt
ANNOTATION: 6 O-ring
• Confirm that the white paint can be seen 7 O-ring
through the timing confirmation hole on the 8 Nut
top surface of the flywheel housing. 9 Bolt
10 Nut

supply pump.
2. Fuel leak off pipe assembly Installation
CAUTION

CAUTION
1 Confirmation hole
2 Supply pump gear • Use new gaskets.

fuel supply pump.
ANNOTATION:
CAUTION
84402832 NA - May 2011

3004A-4

123.9 lb・in}
14.8 lb・ft}
fuel supply pump.
88.5 lb・in}
7) Install the clip to the fuel leak-off pipe.
lb・in}
1 Priming pump
2 Plug
3 Drain plug
4 Case
1) Prepare the pan.

ANNOTATION:
netic pump.
1 Fuel leak-off pipe 4) Operate the priming pump.
3. Fuel pipe Installation ANNOTATION:
1) Install the fuel pipe to the fuel supply pump • Confirm that fuel comes out from around the
and the common rail assembly. plug.
CAUTION 5) Tighten the plug using the wrench.
• Use new fuel pipes. Number of times： 10 count(s) or more
Tightening torque： 44 N・m {4.5 kgf・m / ANNOTATION:
32.5 lb・ft}
2) Install the clip to the bracket. the priming pump.
lb・in} Specified time： 1 min
ANNOTATION:
sembly. • Remove the air in the fuel filter.
ANNOTATION: 8) Tighten the plug using the wrench.
• Connect each connector. Number of times： 10 count(s) or more
5. Battery ground cable Connect ANNOTATION:
tery. the priming pump.
6. Fuel Air bleed Specified time： 1 min
CAUTION
ANNOTATION:
• To prevent engine failure, be sure to per-
form air removal after the installation or • Remove the air in the fuel filter.
84402832 NA - May 2011
3004A-5
12) Operate the priming pump. 15) Operate the priming pump.
Number of times： 10 count(s) or more Number of times： 10 count(s)
16) Start the engine.
ANNOTATION:
ANNOTATION:
the priming pump. • Do not accelerate the engine revolution right
after staring.
13) Loosen the plug using the wrench. Specified time： 5 s
• Remove the air in the fuel filter. • Accelerate the engine revolution gradually.
14) Tighten the plug using the wrench. Specified time： 3 min
88.5 lb・in} ANNOTATION:
CAUTION mum.
• Remove the fuel around the plug • Lower the rotation.
84402832 NA - May 2011

3004A-6
Section
3004B
Removal and Installation of Common Rail Assembly
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Common rail assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Common rail assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Common rail assembly Removal 2) Disengage the harness connector from the in-
take throttle valve.
ANNOTATION:
battery. • Pull the lock operation portion to release the
lock.
2. Coolant Drain
CAUTION

gine assembly.
ANNOTATION:
4. Oil separator bracket Removal
1) Remove the clip from the cylinder block.
2 Lock release
2) Remove the ventilation hose from the air
breather. 3 Lock
cylinder head assembly. 3) Remove the intake throttle valve from the inlet
pipe.

2 Clip 1 Intake throttle valve
2 Gasket
5. Intake throttle valve Removal 3 Inlet pipe
1) Remove the air duct from the intake throttle
valve. 6. EGR cooler Removal
84402832 NA - May 2011

3004B-3
1) Disengage the water rubber hose from the 5) Remove the EGR cooler B from the EGR
EGR cooler. cooler bracket A.
6) Remove the EGR cooler bracket A from the
EGR cooler A.
1 Water rubber hose
1 EGR cooler C
2) Remove the EGR pipe B from the EGR valve
2 EGR bracket C
and the EGR cooler C.
3 EGR cooler B

EGR pipe A.
1 EGR valve
2 EGR pipe B
3 EGR cooler C
3) Remove the EGR cooler C from the EGR 1 EGR heat protector
bracket C.
4) Remove the EGR bracket C from the EGR 8) Remove the EGR cooler A from the EGR pipe
cooler B. A.
84402832 NA - May 2011

3004B-4
9) Remove the EGR pipe A from the exhaust 4) Remove the harness clip from the inlet pipe.
manifold.
1 Boost sensor
1 EGR cooler A 2 Harness clip
2 EGR pipe A 3 Boost temperature sensor
3 Exhaust manifold 4 IMT sensor
5) Remove the inlet pipe from the inlet cover.

7. EGR valve Removal
EGR valve.
1 Inlet pipe

1 EGR valve 2) Remove the injection pipe from the injector
8. Inlet pipe Removal CAUTION
• Do not reuse the removed injection
boost sensor.
pipe.
ing.
IMT sensor.
84402832 NA - May 2011

3004B-5

pipe.
ANNOTATION:

7 Fuel pipe 1 Fuel leak-off pipe
10. Fuel pipe Removal 12. Common rail assembly Removal

1) Remove the fuel pipe from the fuel supply 1) Disengage the harness connector from the
pump and the common rail assembly. fuel pressure sensor.
ANNOTATION: 2) Remove the common rail assembly from the
inlet cover.
CAUTION

der head.
2) Remove the fuel leak-off pipe from the fuel
supply pump.
ANNOTATION:
the fuel feed pipe.
mon rail assembly. 1 Common rail assembly
84402832 NA - May 2011

3004B-6
Common rail assembly Installation 4) Securely tighten the fuel leak-off pipe to the
1. Common rail assembly Installation Tightening torque： 14 N・m {1.4 kgf・m /
1) Align the common rail assembly to the inlet 123.9 lb・in}
cover. 5) Securely tighten the fuel leak-off pipe to the
2) Temporarily tighten the bolt to the common rail common rail assembly.
assembly. Tightening torque： 20 N・m {2.1 kgf・m /
3) Temporarily tighten the nut to the common rail 14.8 lb・ft}
assembly. 6) Securely tighten the fuel leak-off pipe to the
4) Securely tighten the bolt to the common rail fuel supply pump.
assembly. Tightening torque： 10 N・m {1.0 kgf・m /
Tightening torque： 25 N・m {2.5 kgf・m / 88.5 lb・in}
18.4 lb・ft} 7) Install the clip to the fuel leak-off pipe.
5) Securely tighten the nut to the common rail Tightening torque： 9 N・m {0.9 kgf・m / 79.7
assembly. lb・in}
18.4 lb・ft}
1 Common rail assembly 3. Fuel pipe Installation

1) Install the fuel pipe to the fuel supply pump
pressure sensor.
2. Fuel leak off pipe assembly Installation CAUTION
1) Temporarily tighten the fuel leak-off pipe to the • Use new fuel pipes.
CAUTION 32.5 lb・ft}
• Use new gaskets. Tightening torque： 9 N・m {0.9 kgf・m / 79.7
lb・in}
common rail assembly. 4. Injection pipe Installation
CAUTION 1) Temporarily tighten the injection pipe to the

injector.
CAUTION
fuel supply pump.
ANNOTATION: 2) Temporarily tighten the injection pipe to the
• Tighten the fuel feed pipe together. 3) Securely tighten the injection pipe to the injec-
tor.
CAUTION
• Use new gaskets. 32.5 lb・ft}
4) Securely tighten the injection pipe to the com-
mon rail assembly.
32.5 lb・ft}
84402832 NA - May 2011
3004B-7
5) Install the clip to the inlet cover. 4) Connect the harness connector to the IMT
Tightening torque： 6 N・m {0.6 kgf・m / 53.1 sensor.
lb・in} 5) Install the harness clip to the inlet pipe.
lb・ft}

3 No.3 injection pipe 1 Boost sensor
4 No.4 injection pipe 2 Harness clip
5 No.5 injection pipe 3 Boost temperature sensor
6 No.6 injection pipe 4 IMT sensor
7 Fuel pipe
6. EGR valve Installation
5. Inlet pipe Installation 1) Install the EGR valve to the inlet pipe.
1) Install the inlet pipe to the inlet cover. 33.9 lb・ft}
lb・ft}
1 EGR valve
1 Inlet pipe 2) Connect the harness connector to the EGR
valve.
2) Connect the harness connector to the boost 7. EGR cooler Installation
sensor.
3) Connect the harness connector to the boost 1) Temporarily tighten the EGR pipe A to the ex-
temperature sensor. haust manifold.
84402832 NA - May 2011

3004B-8
2) Temporarily tighten the EGR cooler A to the 7) Temporarily tighten the EGR pipe B to the
EGR pipe A. EGR cooler C and the EGR valve.
1 EGR cooler A 1 EGR valve

2 EGR pipe A 2 EGR pipe B
3 Exhaust manifold 3 EGR cooler C
8) Securely tighten the EGR pipe A to the ex-

3) Temporarily tighten the EGR cooler bracket A
haust manifold.
to the EGR cooler A.
4) Temporarily tighten the EGR cooler B to the
lb・ft}
EGR cooler A.
9) Securely tighten the EGR cooler A to the EGR
5) Temporarily tighten the EGR bracket C to the
pipe A.
EGR cooler B.
6) Temporarily tighten the EGR cooler C to the
lb・ft}
EGR bracket C.
10) Securely tighten the EGR cooler B to the EGR
cooler A.
lb・ft}
the EGR cooler B.
lb・ft}
cooler bracket C.
lb・ft}
cooler C.
lb・ft}
1 EGR cooler C 14) Securely tighten the EGR pipe B to the EGR
2 EGR cooler bracket C valve.
3 EGR cooler B
lb・ft}
4 EGR cooler bracket A 15) Securely tighten the EGR cooler bracket A to
lb・ft}
lb・ft}
lb・ft}
84402832 NA - May 2011

3004B-9
18) Install the EGR heat protector to the EGR 1) Install the intake throttle valve to the inlet pipe.
pipe. Tightening torque： 24 N・m {2.4 kgf・m / 17
Tightening torque： 31 N・m {3.2 kgf・m / 23 lb・ft}
lb・ft}

1 EGR heat protector 2 Gasket
3 Inlet pipe
19) Connect the water rubber hose to the EGR
cooler. 2) Install the air duct to the intake throttle valve.
throttle valve.
ANNOTATION:
• After connecting the harness connector,
1 Water rubber hose
8. Intake throttle valve Installation

2 Lock release
3 Lock

1) Temporarily tighten the oil separator bracket
ANNOTATION:
84402832 NA - May 2011

3004B-10
3) Securely tighten the oil separator bracket to 4) Replenish the coolant with the radiator.
lb・ft}
CAUTION
gle of the hose.

lb・ft}
1 Valve
2 Gasket

tery.
13. Fuel Air bleed
CAUTION
1 Oil separator bracket form air removal after the installation or
2 Clip

sembly.
ANNOTATION:
11. Coolant Filling
CAUTION
flow splash on the exhaust system 1 Priming pump
parts. 2 Plug
• Coolant overflow should be wiped 3 Drain plug
off. 4 Case
CAUTION 1) Prepare the pan.

ANNOTATION:
Tightening torque： 22 N・m {2.2 kgf・m / 16 • This is for the models with an electromag-
lb・ft} netic pump.
84402832 NA - May 2011

3004B-11
3) Loosen the plug using the wrench. 12) Operate the priming pump.
4) Operate the priming pump. Number of times： 10 count(s) or more
ANNOTATION:
ANNOTATION:
• Confirm that fuel comes out from around the the priming pump.
plug.
5) Tighten the plug using the wrench. 13) Loosen the plug using the wrench.
Number of times： 10 count(s) or more ANNOTATION:
ANNOTATION: • Remove the air in the fuel filter.

the priming pump. Tightening torque： 10 N・m {1.0 kgf・m /
88.5 lb・in}
7) Loosen the plug using the wrench. CAUTION
ANNOTATION: • Remove the fuel around the plug
8) Tighten the plug using the wrench. 15) Operate the priming pump.
9) Operate the priming pump. Number of times： 10 count(s)
Number of times： 10 count(s) or more 16) Start the engine.
• Wait for the specified time after operating • Do not accelerate the engine revolution right
the priming pump. after staring.
Specified time： 1 min Specified time： 5 s
ANNOTATION:
ANNOTATION:
• Remove the air in the fuel filter. Specified time： 3 min
ANNOTATION:
mum.
84402832 NA - May 2011

3004B-12
Section
3005
Removal and Installation of Injector
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Injector Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Injector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Injector Removal 4. Injector harness Removal
1. Battery ground cable Disconnect 1) Remove the connector from the lower cover.
1) Disengage the battery ground cable from the CAUTION

battery.
2. Engine harness Disconnect nector with a screwdriver.
gine assembly.
ANNOTATION:
3. Cylinder head cover Removal
1) Disengage the water pipe bracket from the
cylinder head cover.
2) Disengage the ventilation hose from the air
breather.
2) Disengage the injector harness from the injec-

tor.
CAUTION
1 Ventilation hose
3 Clip
3) Remove the cylinder head cover from the

lower cover.
der head cover.
1 Injector
2 Injector harness
3 Terminal nut

2 Head cover gasket
3 Lower cover
84402832 NA - May 2011
3005-3
3) Remove the injector harness from the cylinder 4 No.4 injection pipe
head assembly. 5 No.5 injection pipe
ANNOTATION: 6 No.6 injection pipe
7 Fuel pipe
with the bracket.
7. Injector Removal
jector.
assembly.
ANNOTATION:
a special tool.

5. Lower cover Removal

head assembly.
head assembly. Special tool: injector remover (refer to
section 1003)
CAUTION
• Do not reuse the removed injection
pipe.
ing.

section 1003)

84402832 NA - May 2011
3005-4
1 Sliding hammer Injector Installation

2 Fuel injector remover
3 Injector 1. Injector Installation
CAUTION
CAUTION
• When reusing an injector, do not change
• Confirm that the sleeve is not pulled the installation position.
out together when pulling out the
injector using a special tool. 1) Apply the engine oil to the bolt.
• Store each ID code plate on the in- 2) Temporarily tighten the injector to the cylinder
jector head with the cylinder num- head assembly.
ber tag attached to avoid a mix-up.
• Be extremely careful not to damage CAUTION
1 Injector
2 Installation bolt

injector.
CAUTION

head assembly.
lb・ft}
CAUTION

126 lb・in}
2. Injection pipe Installation
1) Securely tighten the injection pipe to the injec-
tor.
32.5 lb・ft}
84402832 NA - May 2011

3005-5
2) Securely tighten the injection pipe to the com- 2) Install the rubber plug to the cylinder head
mon rail assembly. assembly.
Tightening torque： 44 N・m {4.5 kgf・m / 3) Install the gasket to the lower cover.
32.5 lb・ft} 4) Install the lower cover to the cylinder head
3) Install the clip to the inlet cover. assembly.
Tightening torque： 6 N・m {0.6 kgf・m / 53.1 Tightening torque： 13 N・m {1.3 kgf・m /
lb・in} 112 lb・in}
ANNOTATION:

4 No.4 injection pipe 1) Install the injector harness to the cylinder head
5 No.5 injection pipe assembly.
7 Fuel pipe ANNOTATION:
• Tighten the bolts on the bracket and in-
stall the injector harness together with the
3. Lower cover Installation bracket.
1) Apply the liquid gasket to the rubber plug. Tightening torque： 22 N・m {2.2 kgf・m / 16
lb・ft}
ANNOTATION:
• Apply ThreeBond 1207B.

1 Rubber plug
2 Liquid gasket
CAUTION
utes.
84402832 NA - May 2011

3005-6
CAUTION

2 Head cover gasket
3 Lower cover

breather.
3 Terminal nut Tightening torque： 20 N・m {2.0 kgf・m / 14
lb・ft}
lb・in}
head cover.
cover.
115 lb・in}
ANNOTATION:
1 Ventilation hose
3 Clip

sembly.
ANNOTATION:
tery.
8. Fuel Air bleed
CAUTION
84402832 NA - May 2011

3005-7

ANNOTATION:
the priming pump.
ANNOTATION:
ANNOTATION:
1 Priming pump
2 Plug • Wait for the specified time after operating
3 Drain plug the priming pump.
4 Case Specified time： 1 min
5 Fuel filter element 13) Loosen the plug using the wrench.
ANNOTATION:
1) Prepare the pan. • Remove the air in the fuel filter.
ANNOTATION: Tightening torque： 10 N・m {1.0 kgf・m /
88.5 lb・in}
netic pump. CAUTION
• Remove the fuel around the plug
ANNOTATION: 15) Operate the priming pump.
• Confirm that fuel comes out from around the 16) Start the engine.
plug.
ANNOTATION:
6) Operate the priming pump. • Do not accelerate the engine revolution right
Number of times： 10 count(s) or more after staring.
ANNOTATION: Specified time： 5 s
• Wait for the specified time after operating ANNOTATION:
the priming pump.
7) Loosen the plug using the wrench. Specified time： 3 min
• Remove the air in the fuel filter. • Accelerate the engine revolution to maxi-
mum.
8) Tighten the plug using the wrench. • Lower the rotation.
84402832 NA - May 2011

3005-8
Section
4001A
Electrical and Engine Basic Functions
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Monitor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Coolant Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Oil Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Monitor Display Dimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Eco Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DPD Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Diagnostic Trouble Code Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fuel Economy Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Neutral Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine Start/Stop Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Idling Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Auto Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
One-touch Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Auto Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Quick Warm-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Idling Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Idle up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Travel Speed Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Swing Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Static Horsepower Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Working Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Radio Mute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Engine Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Travel Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Back/Side View Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Swing Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Overload Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Operability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Swing Speed Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Pressure Boost Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Free Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Energy saving / Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Swing Relief Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Stroke Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Boom Down Energy Save. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Auto Energy Save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Overload Reduction Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
End Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Breaker Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Crusher Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Anti-theft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Enabling the anti-theft function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Immobilizer Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Feed Pump Automatic Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Coolant Level Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Hydraulic Oil Filter Clog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Air Filter Clog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Fuel Filter Clog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
DPD Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Automatic Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Manual Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Forced Manual Regeneration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Hydraulic Assist Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Monitor Control
Fuel Gauge
Summary
The fuel level is displayed as one of 9 levels, 0-8.
When the fuel level reaches Level 1, a warning is is-
sued.
If the sensor breaks down, the level becomes 0.
(When the sensor is normal, the Levels 1-8 are dis-
played.)
Configuration
• The table below shows the correspondence be-

tween the fuel sensor % and the bar graph level.
Lever angle [%] Bar graph level

100 8
83 7
67 6
50 5
33 4
17 3
1 2
0 1
* Currently, the above settings are common to all

models.
*1 Monitor
*2 Computer B
*3 Computer A
• Refueling warning: When the gauge falls to Level
*4 Overhead 1, the "LOW FUEL" message is displayed on the
*5 Fuel sensor monitor and the buzzer sounds for 5 sec..
*6 Reserve (1 hour of work) • Monitor display: The following processing is used to
*7 Fuel tank prevent the monitor gauge from fluctuating due to
fluctuation of the fuel surface.
Sensor angle measurement period = 1 sec.
Operation explanation Gauge update period = 5 sec.
Gauge update judgment = Average of sensor angle
• Computer A reads out the resistance of the fuel level for past 20 sec. (20 times)
sensor installed in the fuel tank and communicates • Gauge display: For the work screen, an arc is dis-
it to the monitor. played at the center of the screen.
On the camera screen, displayed vertically on the
right edge of the screen.
Resistance [Ω] Fuel sensor [%]
• Trouble mode: If trouble occurs in the fuel level sen-
10 100 sor, the fuel gauge itself is not displayed.
38 50 If an abnormality occurs in monitor communication,
80 0 the display will not update.
84402832 NA - May 2011
4001A-3
Coolant Temperature Gauge

Purpose
Displays the coolant temperature using a meter and bar graph.(Coolant temperature check)
1 Coolant temperature gauge 3 Computer A 5 Coolant temperature sensor

2 Monitor 4 ECM 6 Engine
a Bar graph display

b Meter display
Operation explanation
1. When the key is turned ON, the coolant temperature meter indicates the current coolant temperature range.
2. When the camera screen select switch is pressed to switch to the camera screen, the coolant temperature bar
graph is displayed on the left side.
3. The meter and bar graph are not displayed if coolant temperature sensor trouble is detected.
Remarks
The coolant temperature ranges are shown in the table below.
Meter indicator angle

Temperature [°C]
[deg.]
Lower than 50 0 - 15
50 15
77 58
82 66
97 90
100 118
102 137
105 165
84402832 NA - May 2011
4001A-4
Oil Temperature Gauge

Purpose
Displays the oil temperature on a meter.(Oil temperature check)
1 Oil temperature gauge 3 Computer A 5 Oil temperature sensor

2 Monitor 4 Hydraulic oil tank 6 Hydraulic pump
a Meter display
1. When the key is turned ON, the oil temperature meter indicates the current oil temperature range.
2. When the camera screen select switch is pressed to switch to the camera screen, the oil temperature meter is
not displayed.
3. The meter is not displayed if oil temperature sensor trouble is detected.
Remarks
The oil temperature ranges are shown in the table below.
Meter indicator angle

Temperature [°C]
[deg.]
Lower than 25 0 - 15
25 15
45 42
60 63
80 90
88 123
92 140
95 153
97 161
98 165
84402832 NA - May 2011
4001A-5
Monitor Display Dimming

Purpose
Adjusts the brightness of the backlight through operation that is linked to the working light and solar radiation sensor.
1 Monitor 3 Solar radiation sensor 5 Working light relay

2 Computer A 4 Working light switch
a Dimming level automatic adjustment using the solar radiation

sensor
b Working light-linked dimming using the working light relay
1. When the operator turns the key ON, the monitor screen brightness is set to "brightness (day)".
2. When the operator turns the working light ON, the monitor screen brightness is set to "brightness (night)" (=
working light-linked dimming).
• When working light-linked dimming is set to OFF on the rear screen, instead of using "brightness (night)" to
adjust the monitor screen brightness when the working light is ON, the brightness is judged using the solar
radiation sensor (= dimming level automatic adjustment).
• The brightness when the working light is OFF is set to "brightness (day)" regardless of whether working light-
linked dimming is set to ON or OFF.
3. The operator can set "brightness (day)" or "brightness (night)" in the menu screen.
• The screen brightness setting is stored inside the monitor, so the setting is saved even if a computer is re-
placed.
84402832 NA - May 2011

4001A-6
Eco Gauge
Purpose
Displays on the monitor whether energy-saving operation is being performed.(Eco function)
1 Eco gauge
2 Monitor
3 Computer A
1. The eco gauge is displayed on the monitor.
2. The eco-saving performance is judged in levels from 0 to 9.(The higher the number, the better the eco perfor-
mance.)
In SP mode, the maximum is 4.
In H mode, the maximum is 6.
In A mode, the maximum is 8.
In low idle, the maximum is 9.
84402832 NA - May 2011

4001A-7
DPD Gauge
Purpose
Displays an icon and bar graph on the monitor during DPD regeneration.
1 DPD gauge
2 Monitor
3 Computer A
1. DPD bar graph display conditions
1) The DPD clogging level is displayed on the DPD bar graph during normal operation.(5-level display)
When 5 white lamps are displayed, it indicates that the tank is full.
2) The regeneration progress is displayed on the DPD bar graph during DPD regeneration (5-level display).
The white lamps go off one by one, and when all have gone off, regeneration is complete.
2. DPD amber lamp display condition
1) The amber lamp turns on and flashes during manual DPD regeneration.
3. DPD green lamp display condition
1) The green lamp turns on and flashes during automatic DPD regeneration.
84402832 NA - May 2011

4001A-8
Diagnostic Trouble Code Indicator

Purpose
Displays a diagnostic trouble code (DTC) on the monitor when trouble occurs. (Makes troubleshooting easier)
1 Diagnostic trouble code

2 Monitor
3 Computer A
1. If trouble occurs, the "!" symbol and the diagnostic trouble code (DTC) are displayed in the top right of the
monitor.
• When multiple cases of trouble occur, they are displayed in turn at 5-second intervals.
• At the same time, "ELEC. PROBLEM" and "CHECK ENGINE" are displayed.
• Up to 8 items can be displayed.
2. When the trouble is repaired, the diagnostic trouble code (DTC) goes off.
84402832 NA - May 2011

4001A-9
Clock
Purpose
Displays the time on the monitor.
• The time is always displayed on the monitor.
• The clock continues to operate, without display, when the key is turned OFF. (Because it uses power from the
battery)
Fuel Economy Gauge

Purpose
Displays the fuel economy on the monitor.
1 Fuel economy gauge

2 Monitor
3 Computer A
1. The fuel economy gauge is displayed on the monitor after the key is turned ON.
2. When trouble occurs, the fuel economy gauge goes off and the diagnostic trouble code is displayed.
3. When the trouble is recovered from, the diagnostic trouble code goes off and the fuel economy gauge is dis-
played again.
84402832 NA - May 2011

4001A-10
Basic Operation
Neutral Start
Purpose
The engine will not start with the gate lever lifted.(It will not crank.)
This prevents accidental operation if the operation lever is touched when the engine is started.
Configuration
1 Key switch 4 Starter cut relay 7 Starter relay

2 Gate lock limit switch 5 Lever lock solenoid 8 Neutral start relay
3 Starter motor 6 Battery relay 9 ECM
1. Lower the gate lever.
2. The starter cut relay is excited and the excitation to the safety relay is cut off.
3. Engine cranking is prohibited.
4. If the gate lever is then raised, cranking is enabled.
84402832 NA - May 2011

4001A-11
Engine Start/Stop Control

Purpose
Engine starting and stopping
1 Computer A 3 Crank sensor 5 Speed

2 Cam sensor 4 ECM 6 Engine
1. Start the engine.
2. When the engine speed rises to 500 min-1 or higher, engine start is judged.
3. Stop the engine.
4. When the engine speed drops to less than 200 min-1, engine stop is judged.
a Start c 200 min-1

b 500 min-1 d Stop
84402832 NA - May 2011

4001A-12
Preheating
Purpose
Before cranking, the insides of the engine cylinders are automatically heated to improve starting.(Warm-up opera-
tion)
1 Key switch 3 ECM 5 Coolant temperature sensor

2 Computer A 4 Engine
1. Turn the key ON.
2. When the key is turned ON, the pre-glow time is calculated based on the current coolant temperature. At the
same time, the glow relay is excited and the glow lamp is turned on.
3. After pre-glow is completed, the glow lamp goes off and the operator is prompted to begin cranking.
4. Perform cranking to start the engine.
5. When engine start and cranking stop are recognized, the after-glow time is calculated from the current coolant
temperature.
84402832 NA - May 2011

4001A-13
Throttle
Purpose
Indicates the target engine speed.
1 Monitor 3 Throttle volume 5 Engine

2 Computer A 4 ECM
a Icon
1. Turn the key ON.
2. The target engine speed is calculated based on the throttle VOL voltage signal.
3. An icon that indicates the work mode is displayed on the monitor.
84402832 NA - May 2011

4001A-14
Idling Start
Purpose
When the engine starts, the engine speed starts in low idle regardless of the throttle volume position.(Warm-up
operation, engine protection)
1 Throttle volume 4 Pressure sensor (upper) 7 Pressure sensor (option 1)

2 Computer A 5 Pressure sensor (swing) 8 Pressure sensor (option 2)
3 One-touch idle switch 6 Pressure sensor (travel)
1. Idling start operation condition
Because idling start is a warm-up operation, it operates when the engine is started.
2. Idling start end conditions
The operation ends under the following conditions.
1) When an operation lever is operated.(When one of the following pressure sensors is turned ON: upper,
swing, travel, option 1, or option 2)
2) When the throttle volume is operated.
3) When the one-touch idle switch is pressed.
84402832 NA - May 2011

4001A-15
Auto Idle
Purpose
Automatically put the engine into an idling state (1200 min-1) when the machine is not being operated. (Energy
saving)
1 Monitor display 5 One-touch idle switch 9 Pressure sensor (upper)

2 Computer A 6 Throttle volume 10 Pressure sensor (swing)
3 Engine 7 Pressure sensor (option 1) 11 Pressure sensor (travel)
4 ECM 8 Pressure sensor (option 2)
1. Operation conditions for auto idle
Operation starts when all the conditions below are satisfied.
1) The auto idle mode switch is pressed, turning the auto idle mode ON.
2) An operating lever is not operated for a continuous period of 5 sec. (The upper, swing, travel, option 1,
and option 2 pressure sensor are OFF for a continuous period of 5 sec.)
2. End conditions for auto idle
Operation ends under the following conditions.
1) An operation lever is operated during auto idle. (The upper, swing, travel, option 1, or option 2 pressure
sensor is ON.)
2) The throttle volume is operated.
3) The one-touch idle switch is pressed.
84402832 NA - May 2011

4001A-16
One-touch Idle
Purpose
Reduces the engine speed when the one-touch idle switch is pressed. (Energy saving)
1 Monitor display 5 One-touch idle switch 9 Pressure sensor (upper)

2 Computer A 6 Throttle volume 10 Pressure sensor (swing)
3 Engine 7 Pressure sensor (option 1) 11 Pressure sensor (travel)
4 ECM 8 Pressure sensor (option 2)
1. Operation conditions for one-touch idle
When the one-touch idle switch is pressed.
2. End conditions for one-touch idle
When the one-touch idle switch is pressed once more after the one-touch idle switch is pressed and the engine
has gone into low idle.
84402832 NA - May 2011

4001A-17
Auto Warm Up
Purpose
Incrementally raises the engine speed if the coolant temperature is low when the engine starts.
1. Operation conditions for auto warm up
Auto warm up operates if the coolant temperature is less than 50°C when the engine starts.
2. Summary
The engine speed increases incrementally as shown in the diagram.
1) Low idle; 5 min.
2) 1200 min-1; 3 min.
3) 1500 min-1; 3 min.
4) SP mode; 3 min.
a 5 min. d 3 min. g 1200 min-1

b 3 min. e SP mode h Low idle
c 3 min. f 1500 min-1
3. End conditions for auto warm up

Auto warm up is ended and operation shifts to idling start under the following conditions.
1) Coolant temperature is 50°C or more.
2) The one-touch idle switch is pressed.
3) The entire auto warm up process has ended (after 14 min.).
4) An operation lever is operated (upper, swing, travel, option 1, option 2 pressure sensor is ON).
84402832 NA - May 2011

4001A-18
Quick Warm-up
Summary
When the engine starts up, if the outside air temperature is low, a hydraulic load is put on to warm up the engine.
Configuration
*1 Key switch *6 Computer A *11 Option pressure switch

Pump flow proportional valve
*2 *7 ECM *12 2nd option pressure switch
(on hydraulic pump)
*3 Boom 2 proportional valve *8 Upper pressure sensor *13 Coolant temperature sensor
*4 Color monitor *9 Swing pressure sensor *14 Suction air temperature sensor
*5 Computer B *10 Travel pressure sensor
1. When the following conditions are all detected, quick warm-up starts.
• The engine must be starting up.
• The engine must not be warming up (Step 1: low idle 5 minutes).
• The machine must not be operating (upper, swing, travel, option 1, or option 2).
• The outside air temperature must be -15°C.
• The coolant temperature must be between 0 and 80°C.
• There must not be any sensor abnormality (P1, upper, swing, travel, option (1 or 2), coolant temperature,
outside air temperature.
• DPD regeneration must not be underway.
2. This control can be disabled with the Setup/Parameters screen.
3. When the engine starts, the speed incrementally increases according to the diagram below if the coolant tem-
perature is < 50°C. (If the coolant temperature is 50°C, a normal idling start occurs.)
4. When the quick warm-up starts, the system sets the pump flow proportional valve to the minimum flow (Current
740 mA).
5. After 1 sec., the system sets the boom 2 proportional valve current to 540 mA.
An icon that indicates the start of quick warm-up is displayed on the monitor for 2 sec..
84402832 NA - May 2011
4001A-19
6. After 1 sec., if the system detects event (a) below for 20 sec. or longer, it raises the boom 2 proportional valve
target current at a pace of 2 mA/20 sec..
When event (b) is detected, the system sets the boom 2 proportional valve target current to 540 mA.
Also, if no event is detected, the system holds the boom 2 proportional valve target current in its current state.
(a) P1 pressure < 10 MPa
(b) P1 pressure > 15 MPa
7. If the system does not detect either of the above two conditions, it ends or stops quick warm-up.
84402832 NA - May 2011

4001A-20
Idling Stop
Purpose
Automatically stops the engine after a certain time has passed. (Energy saving)
1 Monitor 3 Engine 5 One-touch idle switch

2 Computer A 4 Idle stop relay 6 Throttle volume
1. Operation conditions for idle stop mode
Idle stop operates after performance of 1 through 3.
1) The auto idle stop switch is pressed, switching on the idle stop mode.
2) If the gate lever is raised, the engine speed is less than 1200 min-1, and the throttle volume, auto idle
switch and one-touch idle switch are not operated for a continuous period of 15 sec., an alarm displays
on the monitor screen and a buzzer sounds.
3) After another 3 min., the idle stop relay turns ON and the engine stops.
* To restart, the key is switched OFF, and cranking is performed to start the engine.
* If a restart is not performed, the key is to be switched OFF.
2. Operations conditions for idle stop and auto idle mode
Idling stop operates after performance of 1 through 4.
1) The auto idle stop switch is pressed, switching on the idle stop mode.
2) If the operation lever is not operated for a continuous period of 5 sec., the engine speed is reduced to
1200 min-1. (The upper, swing, travel, option 1, and option 2 pressure sensor are OFF for a continuous
period of 5 sec.)
3) If the throttle volume, auto idle switch and one-touch idle switch are not operated for a continuous period
of 3 min., an alarm displays on the monitor screen and a buzzer sounds.
4) After another 3 min., the idle stop relay turns ON and the engine stops.
* To restart, the key is switched OFF, and cranking is performed to start the engine.
* If a restart is not performed, the key is to be switched OFF.
84402832 NA - May 2011

4001A-21
Idle up
Purpose
Raises the engine speed and maintains mechanical speed.
1 Throttle volume 3 Pressure sensor (travel) 5 Engine

2 Computer A 4 ECM
a Engine speed
1. Operation conditions for idle up

Operation starts when all the conditions below are satisfied.
1) Travel operation is performed. (Travel pressure sensor ON)
2. End conditions for idle up
1) The work mode is a mode other than SP mode.
2) A travel operation is not performed.
84402832 NA - May 2011

4001A-22
Travel Speed Selection

Purpose
The travel motor tilting angle is changed by switching the travel speed between low speed and high speed with the
switch. (Travel speed switchover)
Travel 2-speed switchover so-

1 Computer A 3 Travel motor 5
lenoid
Travel 2-speed switchover so-
2 4 Monitor
lenoid
1. When the key is turned ON, the travel 2-speed switchover solenoid turns OFF, and the travel mode icon on the
monitor goes to low speed.
2. When the travel speed switchover switch is pressed, the travel 2-switchover solenoid turns ON, and the travel
mode icon on the monitor goes to high speed.
3. When the travel speed switchover switch is pressed again, the travel 2-speed switchover solenoid turns OFF,
and the travel mode icon on the monitor goes to low speed.
* Even when the travel 2-speed switchover solenoid is ON, the tilting angle will automatically switch over to low
speed due to a travel motor function if the travel motor drive pressure becomes high.
However, the travel 2-speed switchover solenoid is ON.
84402832 NA - May 2011

4001A-23
Swing Brake
Purpose
The swing brake is turned OFF when either the upper or swing is operating. (Operational ability is increased)
1 Computer A 3 Pressure sensor (swing) 5 Swing brake

2 Pressure sensor (upper) 4 Swing brake solenoid valve
1. Operation conditions for swing brake

Operation starts under the following conditions.
1) An upper operation is not being performed. (Upper pressure sensor OFF)
* The swing brake is applied 1 sec. after the upper pressure sensor turns OFF.
2) A swing operation is not being performed. (Swing pressure sensor OFF)
* The swing brake is applied 5 sec. after the swing pressure sensor turns OFF.
2. End conditions for swing brake
1) An upper operation is performed. (Upper pressure sensor ON)
2) A swing operation is performed. (Swing pressure sensor ON)
84402832 NA - May 2011

4001A-24
Static Horsepower Control

Purpose
Monitor the engine actual speed and the engine target speed and set the appropriate amount of horsepower. (En-
gine stop prevention, energy saving)
1 Hydraulic pump 4 ECM 7 Pressure sensor (travel)

Horsepower control propor-
2 5 Engine
tional valve
3 Computer A 6 Engine speed sensor
a Engine target speed

b Discharge volume fluctuation
Operation Explanation
1. The minimum milli-amp and maximum milli-amp is selected from the milli-amp set for each engine speed.
2. When the engine actual speed falls 30/min or more below the target engine speed, the milli-amp is gradually
lowered to the minimum.
3. When the engine actual speed is not 30/min or more below the target engine speed, the milli-amp is gradually
raised to the maximum.
4. When the engine speed is at a low speed, the milli-amp decreases.
5. When the engine speed is increasing after being at a low speed, the milli-amp increases.
84402832 NA - May 2011

4001A-25
Accessories
Working Light
Purpose
Press the working light switch to turn the working light on.(To improve visibility during night work.)
1 Monitor 3 Working light relay

2 Computer A 4 Working light switch
1. When the key is turned ON, the working light is OFF.
2. When the working light switch is pressed, the working light relay turns ON, and the working light icon on the
monitor turns ON.
The boom light and cab light turn on.
3. When the working light switch is pressed again, the working light relay turns OFF, and the working light icon on
the monitor turns OFF.
The boom light and cab light turn off.
84402832 NA - May 2011

4001A-26
Radio Mute
Purpose
Enables the radio volume to be turned ON or OFF with a one-touch operation.
1. Each time the radio mute switch (1) is pressed, the radio volume is switched between ON Û OFF.
2. When the key is switched ON, the radio always starts with mute off (normal radio volume).
84402832 NA - May 2011

4001A-27
Safety
Engine Emergency Stop
Purpose
Stops the engine in an emergency.
1 Computer A 3 Engine emergency stop switch

2 Engine 4 ECM
1. If an emergency occurs while the engine is running, press the emergency stop switch.
2. When the ECM and computer A detect that the emergency stop switch is ON, the engine is stopped.
* To restart, make sure that the emergency stop switch is OFF, and then start cranking the engine.
84402832 NA - May 2011

4001A-28
Travel Alarm
Purpose
The travel alarm sounds when a travel operation is performed.(Safety function)
1 Computer A
2 Travel pressure sensor
3 Travel alarm
84402832 NA - May 2011

4001A-29
1. Operation conditions for travel alarm

The operation starts under the following conditions.
1) When a travel operation is being performed.(Travel pressure sensor ON)
2. End conditions for travel alarm
1) When the travel operation is stopped.
2) When 10 sec. or longer elapses while a travel operation is being performed.
a Travel alarm
b Pressure sensor (travel)
c 10 sec.
84402832 NA - May 2011

4001A-30
Back/Side View Monitor

Purpose
Displays an image on the monitor from the camera that is installed on the shovel.(Improves rear visibility. Improves
safety)
1 Monitor 3 Camera select switch 5 Side camera

2 Camera screen switch 4 Rear camera
a Options
1. When the key is turned ON, the camera screen can be viewed by pressing the camera screen switch.
• Each time the camera screen switch is pressed, the screen alternates between the work screen and the
camera screen.
• In the camera screen, only the minimum required icons and gauges are displayed.
2. When the camera select switch is pressed in the camera screen, the screen display can be selected in the
order of rear → side → rear + side → rear.
• To perform camera selection, camera ON must be set in the camera setting screen.
• The camera select switch is enabled when multiple cameras are set.
The switch does not respond if there is only 1 rear camera.
3. If image interruption due to camera trouble (disconnection, etc.) is detected, the camera screen turns black
and ERROR is displayed.
* When the camera select switch is pressed in the work screen, the trip meter select switch function is activated.
* The camera screen switch is disabled if no cameras are mounted.
84402832 NA - May 2011

4001A-31
Swing Lock
Purpose
Turns the swing brake ON.
1 Monitor 4 Travel speed select switch 7 Swing brake

2 Working light switch 5 Computer A
3 Auto idle switch 6 Swing brake solenoid
1. Operation conditions for swing lock
1) Hold down the travel speed select switch, working light switch and auto idle switch at the same time for
3 sec.
* When the swing lock is ON and the key is OFF.Then, when the key is turned ON again, the swing lock stays
ON.
* When the swing lock and free swing are both ON, the swing lock is prioritized.
* When the swing lock is ON, the swing lock icon is displayed on the monitor.
* Even when an attachment operation or swing operation is performed while swing is ON, swing lock ON is
prioritized.(Be careful because if the swing operation is performed in this condition, the swing brake plate will
be dragged.)
2. End conditions for swing lock
1) While the swing lock is ON, hold down the travel speed select switch, working light switch and auto idle
switch at the same time for 3 sec.
84402832 NA - May 2011

4001A-32
Overload Warning
Summary
Overload warning device for lifting work with shovel
If the bottom pressure of the boom cylinder exceeds the stipulated pressure, it is judged that there is a danger of
the machine falling over and the monitor buzzer sounds (overload warning).
Configuration
*1 Overload switch *3 Computer B *5 Overload pressure sensor

*2 Color monitor *4 Computer A
1. When the overload switch is turned ON, the buzzer sound starts and stops according to the conditions below.
When the overload switch is OFF, the buzzer does not sound.
1) Overload warning start: The boom bottom pressure is greater than or equal to the set pressure continu-
ously for 1 sec.
2) Overload warning stop: The boom bottom pressure is less than or equal to the set pressure -2 MPa
continuously for 1 sec.
2. The alarm pattern is a 1-second cycle - ON for 0.5 sec. and OFF for 0.5 sec.
*1 Overload switch *3 Monitor buzzer

*2 Boom bottom pressure *4 Set pressure
3. Display: The warning is only given with the monitor buzzer.

The lamps etc. do not illuminate.
84402832 NA - May 2011
4001A-33
Operability
Swing Speed Limit
Purpose
When the pump flow rises during a swing operation, the swing speed increases.
To prevent this, control of the pump flow is performed.(Swing speed control)
1 Computer A 5 Pressure sensor (N1) 9 Regulator

P1 flow control proportional
2 Throttle volume 6 Pressure sensor (N2) 10
valve
3 Pressure sensor (travel) 7 Pressure sensor (P1)
4 Pressure switch (option 1) 8 Pressure sensor (P2)
a Arm (1) d Option 1 g Boom (1)

b Boom (2) e Travel (left) h Bucket
c Swing f Arm (2) i Travel (right)
1. Operation conditions for swing speed limit control
Control is executed when all the conditions below are satisfied.
1) Independent swing operation (swing pressure sensor ON)
2) When travel or option operations are not being performed (travel and option pressure sensors OFF)
3) Work mode is SP or H mode(except CX350C/CX370C/350X3)
2. Swing speed limit end conditions
1) Ends immediately after a travel or option operation is performed (travel or option pressure sensor ON).
2) Ends gradually after an attachment operation is performed (upper pressure sensor ON).
84402832 NA - May 2011

4001A-34
Pressure Boost Control

Purpose
Raises the relief pressure.(Increases the digging force)
1 Computer A 6 Pressure sensor (option 2) 11 P2 pressure sensor

2 Engine 7 Control valve 12 Pump
3 Pressure sensor (upper) 8 Main relief valve 13 Monitor
4 Pressure sensor (travel) 9 Pressure boost solenoid 14 Regulator
5 Pressure sensor (option 1) 10 P1 pressure sensor 15 ECM
a Pressure boost icon

b Engine load ratio
84402832 NA - May 2011

4001A-35
1. Operation conditions for pressure boost control (SP or H mode)
The operation starts when all the following conditions are satisfied.
1) When high-load work is being performed (P1 or P2 is high pressure, upper pressure sensor ON, swing
pressure sensor OFF)
2) When the work mode is SP or H mode.
2. End conditions for pressure boost control (SP or H mode)
1) When 8 sec. or longer elapses after starting the pressure boost (pressure boost time expires)
* When the pressure boost time expires, pressure boost is not performed again unless the operation lever
is returned one time to neutral.
2) When an attachment operation is not performed (upper pressure sensor OFF)
3) When a travel or option operation is performed (travel or option pressure sensor ON)
* Pressure boost is not performed to protect the travel and option circuits.
3. Operation conditions for pressure boost control (A mode)
When the work mode is A mode, pressure boost is performed for the lifting work.
* When a travel or option operation is performed in A mode, the pressure boost is continued.
4. Time chart (when work mode = SP or H)
a Pressure boost solenoid valve d Icon g Less than 8 sec.

e Pressure sensor (travel) and/or
b High-load work
pressure sensor (option)
c Pressure sensor (upper) f 8 sec.
84402832 NA - May 2011

4001A-36
Free Swing
Purpose
Prevents swinging of the suspended load while swinging is stopped during lifting work.
1 Free swing（Locker switch） 3 Monitor 5 Swing motor

2 Computer A 4 Free swing solenoid valve 6 Control valve
a Free swing icon
1. Operation conditions for free swing
1) When the free swing switch is pressed.
* The free swing is disabled during a swing lock.
* The free swing icon is displayed on the monitor.
2. End conditions for free swing
1) When the free swing switch is pressed during free swing.
84402832 NA - May 2011

4001A-37
Energy saving / Noise

Swing Relief Cut
Purpose
When independent swing operation is running, the pump flow is reduced, and the excess oil ejected from the swing
motor relief valve is eliminated.
1 Computer A 4 Pressure sensor (option 1) 7 Pressure sensor (P2)

2 Oil temperature sensor 5 Pressure sensor (N2) 8 Regulator
3 Pressure sensor (travel) 6 Pressure sensor (P1) 9
valve
a Arm (1) d Option 1 g Boom (1)

b Boom (2) e Travel (left) h Bucket
c Swing f Arm (2) i Travel (right)
1. Operation conditions for swing relief cut
The operation starts when all the conditions below are satisfied.
Oil temperature is 30°C or higher
1) When a swing operation is performed. (Swing pressure sensor ON)
2) Within 1 sec. after start of swing
3) When travel or option operations are not being performed.(Travel and option pressure sensors OFF)
2. Swing relief cut end conditions
1) When a swing operation is not being performed.(Swing pressure sensor OFF)
2) When a travel or option operation is performed.(Travel or option pressure sensor ON)
84402832 NA - May 2011

4001A-38
Stroke Control
Summary
In order to improve fuel efficiency, the pump pressure is lowered by reducing the orifice loss.
A 3-stack proportional valve is used for control.
Arm 2 control
1. In normal operations, flow volume loss is reduced by suppressing the spool opening for Arm 2.
2. In the second half of leveling work, the spool opening is opened to reduce P2-arm bottom pressure loss and to
give priority to the arm for flow volume, thus suppressing flow volume loss.
Configuration
• The larger the proportional valve output current, the more the secondary pressure output is suppressed.
*1 P2 pressure sensor *4 Computer B *7 Arm-in pressure sensor

Arm-in reverse proportional
*2 Travel pressure sensor *5 *8 Bucket-close pressure sensor
valve
*3 Computer A *6 Boom-up pressure sensor
1. The operator operates the shovel.
2. When the system detects the events below, it judges that this is the start of leveling.
• When any of the following conditions is established the instant that arm-in operation becomes full
• Boom-up lever operation is at half lever.
• The boom-up and bucket-close levers are operated at the same time.
3. When the system judges leveling to be starting, it releases the restriction on Arm 2.
4. If the events below occur when the system does not judge leveling to be starting, it releases the restriction
on Arm 2. When that is not the case, it restricts Arm 2.
• Boom-up lever operation is at half lever.
5. The operator stops arm-in full operation or travels.
6. The system restricts Arm 2.
* When Arm 2 is released from the restricted state, it is released gradually as a measure against shock from
the restriction release.
Boom 2 control
In leveling work, the boom spool is pressed back to reduce P1-arm bottom pressure loss and to allow more flow to
the arm and bucket.
Configuration
• When the output current is raised, the force pushing back the spool is increased.
84402832 NA - May 2011

4001A-39
*1 Boom-up proportional valve *4 Computer B *7 Bucket-close pressure sensor

*2 Travel pressure sensor *5 Boom-up pressure sensor
*3 Computer A *6 Arm-in pressure sensor
Operation
2. When the system detects the events below, it judges that this is the start of leveling.
• When any of the following conditions is established the instant that arm-in operation becomes full
• The boom-up lever operation is at half lever.
• The boom-up and bucket-close levers are operated at the same time.
3. If the system detects any of the events below when the system judges leveling to be starting, it issues the
Boom-2-down proportional valve instruction.
• The boom-up lever operation is at half lever.
• During bucket-close operation
4. When the system does not judge leveling to be starting, it does not issue the Boom-2-down proportional valve
instruction.
5. The operator stops arm-in full operation or travels.
6. The system stops the Boom-2-down proportional valve instruction.
* When the Boom-2-down proportional valve instruction changes, as a measure against vibration, the Boom-
2-down proportional valve command current value is lowered gradually (for both ON→OFF and OFF→ON).
Bucket control
Mostly in the second half of leveling and when collecting dirt and sand during digging, the spool opening is opened
so that a larger volume can flow.
Configuration
The larger the output current, the more the secondary pressure output is suppressed.
Bucket-close reverse propor-

*1 Travel pressure sensor *4 *7 Bucket-close pressure sensor
tional valve
*2 Computer A *5 Boom-up pressure sensor
*3 Computer B *6 Arm-in pressure sensor
84402832 NA - May 2011
4001A-40
2. If any of the events below occurs, the system outputs current restricting the bucket secondary pressure.
• Not arm-in full operation
• The boom-up operation is not at half lever.
• During travel
84402832 NA - May 2011

4001A-41
Boom Down Energy Save

Purpose
Reduces the engine speed during swinging (except during lift swinging).
1 Computer A 4 Pressure sensor (P1) 7 Pressure sensor (swing)

2 ECM 5 Pressure sensor (P2) 8 Pressure sensor (upper)
3 Engine 6 Pressure sensor (N2) 9 Throttle volume
a Engine speed control
1. Operation conditions for boom down energy save
The operation starts when all the conditions below are satisfied.
1) When the work mode is H mode or lower.
2) When the boom down and swing operation is performed.Or when the swing operation is performed.
2. End conditions for boom down energy save
The operation ends when all the conditions below are satisfied.
1) When the work mode is SP mode.
2) When an operation other than boom down and swing is performed.Or when an operation other than swing
is performed.
* When control is established at the same time as auto energy save, the control that reduces the engine speed the
most is prioritized.
84402832 NA - May 2011

4001A-42
Auto Energy Save

Purpose
Reduces the engine speed when machine operations are not being performed.(Energy saving)
1 Computer A 4 Pressure sensor (P1) 7 Pressure sensor (swing)

2 ECM 5 Pressure sensor (P2) 8 Pressure sensor (upper)
3 Engine 6 Pressure sensor (N2)
a Engine speed control
1. Operation conditions for auto energy save.
1) When a machine operation is not being performed.
2. End conditions for auto energy save.
1) When a machine operation is performed.
* When control is established at the same time as boom down energy save, the control that reduces the engine
speed the most is prioritized.
84402832 NA - May 2011

4001A-43
Overload Reduction Control

Purpose
Prevents reductions in the engine speed by detecting sharp attachment operations and sharp loads during opera-
tion. (Lowers the pump milli-amp and prevents reductions in the engine speed.)
1. Operation conditions for transient load reduction control
The milli-amp of the pump horsepower proportional valve is temporarily reduced under the following conditions.
1) When a sharp attachment operation is performed. (Judged from the upper pressure sensor pressure
boost state.)
2) When there is a sharp load during operation. (Judged from the main pressure boost state of the P1 or
P2 pressure sensor.)
2. End conditions for transient load reduction control
The milli-amp of the pump horsepower proportional valve is restored under the following conditions.
1) When a sharp attachment operation is not being performed. (Judged from the upper pressure sensor
pressure boost state.)
2) When there is no sharp load during operation. (Judged from the main pressure boost state of the P1 or
P2 pressure sensor.)
84402832 NA - May 2011

4001A-44
End Attachment
Breaker Mode
Purpose
Maximum flow and maximum pressure settings can be set for each breaker used for up to 5 breakers.(Available for
models with an electromagnetic proportional relief valve only.)
1. The mode is switched from one mode to the next in the sequence normal mode → breaker mode → crusher
mode → normal mode each time the attachment select switch is pressed.
The maximum flow for the mode that has been switched to will display on the indicator for 2 sec.
* In the default state, there is only 1 breaker mode, but more can be added in the flow setting screen.
2. The breaker can be used when breaker mode is selected.
* Set the maximum flow and maximum pressure in the flow setting screen first.
* If 2 pumps flow is necessary at the set flow volume, 2 pumps flow will be used.
3. The suitability of the flow volume to the breaker will be judged.
If the acceptable flow volume has been exceeded, the message “CHECK FLOW RATE” will display.
* This message only displays during breaker operation. The display ends if operation is stopped.
4. The next time the key is switched OFF and then ON again, the machine will be set to the last attachment mode
that was selected.
Crusher Mode
Purpose
Maximum flow and maximum pressure settings can be set for each crusher used for up to 5 crushers.(Available for
models with an electromagnetic proportional relief valve only.)
1. The mode is switched from one mode to the next in the sequence normal mode → breaker mode → crusher
mode → normal mode each time the attachment select switch is pressed.
The maximum flow for the mode that has been switched to will display on the indicator for 2 sec.
* In the default state, there is only 1 crusher mode, but more can be added in the flow setting screen.
2. The crusher can be used when crusher mode is selected.
* Set the maximum flow and maximum pressure in the flow setting screen first.
* If 2 pumps flow is necessary at the set flow volume, 2 pumps flow will be used.
3. When an arm in + crusher operation is performed, milli-amp control will be performed so that the arm-in oper-
ation will not be performed with 2 pumps flow.
* This is to prevent crusher operation from being stopped.
4. The next time the key is switched OFF and then ON again, the machine will be set to the last attachment mode
that was selected.
84402832 NA - May 2011

4001A-45
Maintenance
Anti-theft
Enabling the anti-theft function
With the key OFF, connect the anti-theft knob terminal.
When the male and female knob terminals are connected on the cab main harness in the rear cover, the anti-theft
function is enabled.
The factory setting is for these knob terminals to be disconnected.
Anti-theft setting knob Connect VG (purple / green) and BG (black / green)
Password
Purpose
Locks the machine if is operated without authorization. (Anti-theft)
1. When the anti-theft function is ON, turn the key ON.
2. Enter the correct password at the password input screen.
* If an incorrect password is input, "ERROR" is displayed and the buzzer buzzes.
If the correct password is then input, the lock is released.
3. The machine lock is released and the normal screen is displayed.
* If the “ERROR” message is ignored and the engine is started, the machine will lock.
Machine lock conditions
• The engine speed is fixed at low idle.
• The swing brake cannot be released.
• The travel alarm buzzes continuously.
* In addition, if the operator tries to operate the machine in the machine lock state, the engine will be stopped.
Machine operation judgment conditions
• The P1 or P2 pressure rises to 5 MPa or higher.
• The engine load ratio is 50 % or higher for 2 sec. cumulative.
• The upper, travel, P1, or P2 pressure sensor is removed.
84402832 NA - May 2011

4001A-46
Immobilizer Key
Purpose
Prevents starting of the engine with keys other than the designated key. (Anti-theft)
• When the key is switched ON, the immobilizer computer performs verification of the key.
• If the key is verified as the designated key, cranking is performed.
• If the key is not verified as the designated key, cranking is not performed.
* At this time, cranking will not be performed even if the key is turned up to ST.
84402832 NA - May 2011

4001A-47
Feed Pump Automatic Stop

Summary
The feed pump power supply is controlled and when the fuel tank is full (Level 8), the fuel feed is automatically
stopped.
Configuration
*1 Monitor *3 FUEL PUMP STOP RL *5 BUZZER

*2 FUEL PUMP RL *4 FUEL PUMP
The fuel pump rocker switch has three positions: Manual, OFF, and Auto.
• Auto mode
The switch is the toggle type. When it comes ON, the fuel feed starts.
When the fuel tank angle sensor reaches the full level (Level 8), the monitor relay is driven and the feed pump
power is switched OFF.
In place of that, the relay buzzes the buzzer to announce that the automatic feed has ended.
To silence the buzzer, the rocker switch must be switched to OFF or Manual.
• Manual mode
The switch is the momentary type. The feed pump only drives fuel feed while the switch is pressed.
84402832 NA - May 2011

4001A-48
Coolant Level Drop

Summary
If the engine coolant level drops, the low coolant level warning is issued.
Configuration
*1 Reserve tank *3 Computer A *5 Monitor

*2 Coolant level switch *4 Computer B *6 Buzzer
Operation
1. The radiator reserve tank level switch is detected and an warning is issued.
• SW ON: 0.33 - 0.53 L
2. When the monitor receives the level drop signal, it carries out the following operation.
• Message: "LOW COOLANT" is displayed.
Even after the coolant level is restored to normal, the "LOW COOLANT" message remains displayed while
the key is ON.
• Diagnostic Trouble Code: "7423" is displayed.
the key is ON.
• Monitor buzzer: The buzzer sounds at the same time that the message is displayed and the buzzer automat-
ically stops after 5 sec.
3. When 3 sec. have passed after the coolant level switch was detected going OFF, the low coolant level alarm
stops, the "LOW COOLANT" message goes off, and the buzzer stops.
84402832 NA - May 2011

4001A-49
Hydraulic Oil Filter Clog

Summary
If the hydraulic oil filter clogs, a warning is issued.
Configuration
*1 Monitor *4 Breaker mode switch *7 Hydraulic oil tank

Breaker/crusher (1st option)
*2 Computer B *5 *8 1st option pressure switch
pedal
*3 Computer A *6 Hydraulic oil filter clog switch
If clogging occurs in the return filter inside the hydraulic tank, a message is displayed on the monitor giving the
diagnostic trouble code and the warning buzzer sounds. (For breaker, multi-purpose machines only)
1. Configuration: When the clog detection pressure switch goes open, Computer A detects the clog and sends a
command to the monitor.
2. Clog detection: Starts 10 sec. after the engine starts.
When the clog switch contact opens, Computer A detects this.
If the contact point is ON continuously for 1 sec., the return filter is judged to be clogged.
However, detection does not occur in the following cases.
• During breaker operation: Because pulsation is severe (In other words, no warning is issued while the breaker
is operating.)
• When the oil temperature is less than 30°C: Because the hydraulic oil viscosity is high and accurate detection
is not possible.
• When the clog detection switch is broken: For details, see the sections below.
3. Warning: When the monitor receives the filter clog command, it carries out the following operation.
• Message: "RETURN FILTER" is displayed.
the key is ON.
the key is ON.
84402832 NA - May 2011
4001A-50
4. Clog switch trouble detection: Before engine starting, the contact point of the clog detection switch should be
closed (B contact point).
However, if the circuit is open (continuously for 1 sec.), it is judged that the clog detection switch is disconnected,
the "Electrical system abnormality" message and diagnostic trouble code "7063" are displayed, and the buzzer
sounds for 5 sec..
5. Time chart:
*1 1st option pressure switch *3 Message trouble card

*2 Hydraulic oil filter clog switch *4 Monitor buzzer
84402832 NA - May 2011

4001A-51
Air Filter Clog

Summary
If clogging occurs in the air cleaner filter, a message is displayed on the monitor giving the diagnostic trouble code
and the warning buzzer sounds.
Configuration
*1 Color monitor *3 Computer A *5 Barometric pressure

*2 Computer B *4 Clog sensor *6 Air cleaner
1. When the clog detection pressure switch comes ON, Computer A detects the clog and sends a command to
the monitor via Computer B
2. Clog detection starts 10 sec. after the engine starts.
3. When the clog switch comes ON, Computer A detects this.
If the contact point is ON continuously for 1 sec., the return filter is judged to be clogged.
4. When the monitor receives the filter clog command, it carries out the following operations.
• Message: "AIR FILTER" is displayed.
the key is ON.
the key is ON.
84402832 NA - May 2011

4001A-52
Fuel Filter Clog

Summary
If the fuel filter clogs, a warning is issued.
There are 2 types of clogs: Stage 1 and Stage 2.
Configuration
*1 Color monitor *3 Computer B *5 ECM

*2 Buzzer *4 Computer A *6 Fuel filter clog sensor
1. Turn the key ON.
• Control is performed by Computer A and is displayed on the monitor via Computer B.
2. When the system detects the following, it issues the fuel filter clog warning.
• The fuel filter clog signal from the ECM is ON continuously for 5 sec. or longer.
• The clog is judged by the ECM and only the results are sent to the computer via the CAN.
• The signal is sent with values of 0-2.
Signal numeric value Meaning Sensor pressure Error code

0 No clog
1 Clog stage 1 -30 kPa max. 7426
2 Clog stage 2 -40 kPa max. 7427
3. A message is displayed and the buzzer sounds.

• The "FUEL FILTER CLOG" warning message is displayed on the monitor.
• The buzzer sounds.
4. Engine protection
When a 2nd stage clog (40 kPa max.) occurs, the engine speed is fixed to 1700 min-1.
84402832 NA - May 2011

4001A-53
DPD Regeneration
Purpose
The DPD (Diesel Particle Diffuser) is a device that purifies particulate matter (PM) from exhaust gases.
Particulate matter is collected in the DPD filter, and when a certain amount has accumulated, that particulate matter
is automatically combusted to regenerate the filter.
During normal work, the amount of PM accumulated is displayed on the DPD gauge.
Configuration
*1 ECM *5 DPD SW *9 DPD Prerss sensor

*2 CONT_A *6 Water Temp. sensor *10 Pump Flow P-S/V
*3 CONT_B *7 DPD(CT) Temp. sensor *11 Boom2 P-S/V
*4 MONITOR *8 DPD(FT) Temp. sensor *12 Lever lock S/V
There are the following 4 regeneration methods.
• Automatic regeneration: The filter is automatically regenerated during machine operation.
The machine can work normally.
• Manual regeneration: If automatic regeneration is incomplete or the amount of accumulated PM is large, the filter
is regenerated with a switch.
The machine cannot operate.
• Forced manual regeneration: During automatic regeneration, it is possible to interrupt automatic regeneration and
switch to manual regeneration.
• Slow regeneration: When manual regeneration is interrupted for a prolonged period, it is necessary to combust
the PM slower than normal.
The diagnostic trouble code is displayed and service engineer operation is required. The machine cannot operate.
1. Switch the key ON and operate.
The system displays the current amount of PM accumulated on the DPD bar graph.
The PM accumulated on the filter continually self-combusts due to high-temperature exhaust gases during
engine operation.
84402832 NA - May 2011

4001A-54
2. When the work was at low load, because the exhaust gas temperature is low, the PM does not self combust
but accumulates.
When the DPD differential pressure is high or every 8 hours, the ECM forces up the exhaust gas temperature
to combust the accumulated PM. (See Automatic Regeneration.)
3. Normally, the above continuous regeneration and automatic regeneration keep the accumulated amount of PM
from going above a certain amount, but if the operating conditions are such that the accumulated amount of
PM becomes excessive, in order to avoid the risk of damage to the DPD assembly due to excessive tempera-
ture rise during regeneration, the ECM prohibits automatic regeneration and requests the operator to perform
manual regeneration.
The operator receives this request and starts regeneration. (See Manual Regeneration.)
4. While automatic regeneration is stopped, the operator can execute manual regeneration at any time with switch
operation. (See Forced Manual Regeneration.)
5. If the operator ignores the manual regeneration request and continues to work, this causes (excess PM collec-
tion) and the ECM issues the diagnostic trouble code.
When this point is reached, regeneration by the operator is no longer possible and special regeneration using
service tools has become necessary. (See Slow Regeneration.)
6. If any of the following troubles occurs during regeneration, the hydraulic pressure load is stopped.
Excess PM collection
When the accumulated amount of PM exceeds the limit and the excess PM collected state is reached, the system
behaves as follows.
• Ends the hydraulic pressure assist load.
• Lights the red lamp.
• Lights up the DPD gauge all red.
• Displays the "CHECK ENGINE" message.
Slow regeneration
Regeneration through a process that raises the temperature slower than for normal regeneration.
84402832 NA - May 2011

4001A-55
Automatic Regeneration
Summary
The filter is automatically regenerated during machine operation. The machine can work normally.
The ECM determines the amount of PM accumulated from the difference in pressure before and after the DPD filter.
When a certain amount has accumulated, the ECM regenerates the filter automatically.
Also, if the operating time since the last regeneration reaches a certain level, the ECM automatically regenerates
the filter.
Configuration

1. Conditions for the start of automatic regeneration: When the automatic regeneration request comes from the
ECM, if the following conditions are met, automatic regeneration is started.
• Engine is starting
• The engine coolant temperature is at least 70°C but less than 100°C.
• The difference in pressure before and after the DPD filter has been stable for a certain period of time.
• The gate bar limit switch is ON (hydraulic operation is enabled).
• There is no sensor or DPD related abnormality.
2. Start of automatic regeneration: If the conditions above are met, the computer starts the following control.
• Lights the DPD green lamp.
• Sets off the buzzer for 2 sec..
• Switches the DPD gauge from accumulated amount display to regeneration progress display.
• Displays the "AUTO DPD RE-GEN" and "CAUTION! HOT EXHAUST" messages alternating.
• Computer A drives the DPD relay and sends the DPD regeneration signal to the ECM.
• Stops the auto idle/idle stop control.
3. Stopping automatic regeneration: When the operations below are performed, the ECM regeneration prohibition
signal is sent and automatic regeneration is stopped.
84402832 NA - May 2011
4001A-56
While automatic regeneration is stopped, the DPD green lamp goes out.
Displays the "PUSH DPD SWITCH TO ACTIVATE" message.
Switches the DPD gauge from regeneration progress display to accumulated amount display.
Starts the auto idle/idle stop control.
To restart regeneration, after the cause of the stoppage has been eliminated, press the DPD switch.
• If the gate bar limit switch comes OFF (hydraulic operation is disabled), regeneration is stopped.
• During automatic regeneration, if the monitor's DPD switch is pressed, regeneration is stopped.
• If the exhaust gas temperature reaches 400°C or higher, regeneration is stopped.
4. Ending automatic regeneration: The computer receives the automatic regeneration end signal from the ECM
and ends the control.
• Puts out the DPD green lamp.
• Switches the DPD gauge from regeneration progress display to accumulated amount display.
• Puts out the "AUTO DPD RE-GEN" and "CAUTION! HOT EXHAUST" messages.
• Starts the auto idle/idle stop control.
84402832 NA - May 2011

4001A-57
Manual Regeneration
Summary
If automatic regeneration is incomplete or the amount of accumulated PM is large, the ECM requests manual re-
generation.
The machine cannot be operated during manual regeneration.
The computer controls the regeneration assist load.
Configuration

1. Requesting manual regeneration: When the manual regeneration request comes from the ECM to the com-
puter, it displays the following items on the monitor.
• Flashes the DPD amber lamp (2-second cycle at first, high-speed 0.6-second cycle afterward)
• Displays the "PUSH DPD SWITCH TO ACTIVATE" message.
2. Manual regeneration start conditions: When the following conditions are all met and the DPD switch is pressed,
the computer sets the engine speed to 1000 min-1 and starts manual regeneration.
• The gate bar limit switch is OFF (hydraulic operation is disabled).
• The engine coolant temperature is at least 70°C but less than 100°C.
• There is no sensor or DPD related abnormality.
• When released, automatically goes to 1000 min-1.
3. Start of manual regeneration: If the conditions above are met, Computer A starts the following control.
• Lights the DPD amber lamp.
84402832 NA - May 2011
4001A-58

• Starts the hydraulic pressure assist load control (in order to raise the exhaust gas temperature).
4. Stopping manual regeneration: When the operations below are performed, the ECM regeneration prohibition
signal is sent and manual regeneration is stopped.
While regeneration is stopped, the DPD amber lamp flashes.
• If the gate bar limit switch comes ON (hydraulic operation enabled), regeneration is stopped.
• If the hydraulic pressure assist proportional valve breaks down during regeneration
• If the throttle is operated
5. Ending manual regeneration: The computer receives the manual regeneration end signal from the ECM and
ends the control.
• Puts out the DPD amber lamp.
6. Regeneration hydraulic pressure load assist: During manual regeneration, puts a load on the pump in order to
raise the exhaust gas temperature.
• Computer A set the pump flow proportional valve to the minimum flow at 740 mA.
• After 1 sec., Computer A sets the boom 2 proportional valve to 600 mA for the maximum load.
• After 1 sec., Computer A sets the pump flow proportional valve to 600 mA.
• After 30 sec., Computer A controls the pump flow proportional valve so that the DPD exhaust gas temperature
(before DOC) is constant at 270°C. (Lowers it gradually 50 mA/second. update period 15 sec., update width
5 mA)
84402832 NA - May 2011

4001A-59
Forced Manual Regeneration

Summary
During automatic regeneration, it is possible to interrupt automatic regeneration and switch to manual regeneration.
This can only be executed while automatic regeneration is stopped.
Configuration

1. With automatic regeneration stopped and with the gate bar open, if the DPD switch is held down for 3 sec.,
Computer A sends the forced manual regeneration start request signal to the ECM via the DPD relay.
2. When the ECM receives the forced manual regeneration start request signal, the following is displayed on the
monitor.
• Lights up the amber lamp for 3 sec..
3. If the system meets the following conditions, the ECM judges that manual regeneration is necessary, puts out
the amber lamp, and returns to the automatic regeneration stopped state.
• If the state of it being impossible to complete automatic regeneration has continued or longer than 8 hours
• If the ECM judges that manual regeneration is not necessary
4. If the ECM judges that manual regeneration is necessary, the system receives the manual regeneration request
signal from the ECM, and waits for the manual regeneration switch to be pressed.
• After 10 sec., it flashes the amber lamp (2-second cycle).
Displays the "PUSH DPD SWITCH TO ACTIVATE" message on the monitor.
• The operator presses the DPD switch during this time.
• If the operator does not press the DPD switch at least 10 sec., the ECM puts out the amber lamp and returns
to the automatic regeneration stopped state.
(From here on is the same process as from 2 in manual regeneration.)
5. Lowers the engine speed to 1000 min-1 and starts manual regeneration.
84402832 NA - May 2011
4001A-60
6. Start of manual regeneration: If the conditions above are met, the computer starts the following control.
• Lights the DPD amber lamp.
• Starts the hydraulic pressure assist load control (in order to raise the exhaust gas temperature).
7. Stopping manual regeneration: When the operations below are performed, the ECM regeneration prohibition
signal is sent and manual regeneration is stopped.
While regeneration is stopped, the DPD amber lamp flashes.
• If the gate bar limit switch comes ON (hydraulic operation enabled), regeneration is stopped.
• If the hydraulic pressure assist proportional valve breaks down during regeneration
• If the throttle is operated
8. Ending manual regeneration: The computer receives the manual regeneration end signal from the ECM and
ends the control.
• Puts out the DPD amber lamp.
9. Regeneration hydraulic pressure load assist: During manual regeneration, puts a load on the pump in order to
raise the exhaust gas temperature.
• The computer set the pump flow proportional valve to the minimum flow at 740 mA.
• After 1 sec., the computer sets the boom 2 proportional valve to 600 mA for the maximum load.
• After 1 sec., the computer sets the pump flow proportional valve to 600 mA.
• After 30 sec., the computer controls the pump flow proportional valve so that the DPD exhaust gas temper-
ature (before DOC) is constant at 270°C. (Lowers it gradually 50 mA/second. update period 15 sec., update
width 5 mA)
84402832 NA - May 2011

4001A-61
Hydraulic Assist Load

Summary
During DPD manual regeneration, hydraulic load is added to raise the exhaust gas temperature.
1. When regeneration starts, the system sets the pump flow proportional value to the minimum flow (Current 740
mA).
2. After 1 sec., the system sets the boom 2 proportional valve to the maximum load (Current 600 mA).
3. After 1 sec., the system sets the current for pump flow proportional valve to 600 mA. (*1)
4. After 30 sec., the system controls the pump flow proportional valve so that the DPD exhaust gas temperature
(before DOC) is constant at 270°C. (*2) (*3)
• Lowers it gradually 50 mA/sec..
• Current update width: 5 mA, update period 15 sec.
• If the DPD exhaust gas temperature (before DOC) exceeds 400°C, addition of the hydraulic load is stopped.
When the temperature falls below 250°C, the addition of the hydraulic load resumes after 1 sec..
84402832 NA - May 2011

4001A-62
Section
4001B
Service Support
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Service Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Screen Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Screen Display List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHECK Screen List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MACHINE STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FAULT HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
WORK HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ENGINE HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
HYDRAULIC HISTORY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
PART NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SETUP Screen List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
MACHINE SELECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Model Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Throttle Volume Default Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Password Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Adjusting the Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Option Flow Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Screen Brightness Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Service Support
Service Support
Screen Operations
Screen Display List
1 Travel speed select switch 3 Menu screen display switch 5 Wiper switch
2 Attachment select switch 4 Working light switch 6 Auto idling switch
84402832 NA - May 2011

4001B-3
Service Support
CHECK Screen List check sensor and switch input/output states, as well as
the angle, load ratio and work radius, etc. at the applied
In CHECK mode, in addition to the machine status (milli- machine (liftcrane specifications machine, lifting magnet
amp, oil pressures, temperatures, etc.), it is possible to machine).
1 Section MACHINE STATUS

1. Engine and pump
For the CHECK mode section types and their contents,
see the separate sheet.
By pressing and on the monitor,

MACHINE STATUS, FAULT HISTORY, etc. can be
selected.
Detailed data for the selected item can be seen by press-
ing .
ENGINE SPEED min-1 Engine speed

ENGINE LOAD
% Engine load ratio
RATIO
Pump 1; Discharge
P1 PRESS. MPa
pressure
Pump 2; Discharge
P2 PRESS. MPa
pressure
Pump 1; Negative
N1 PRESS. MPa
control pressure
Pump 2; Negative
N2 PRESS. MPa
control pressure
Horsepower control
P.SOL;PUMP-
mA proportional valve;
POWER
Actual milli-amp
Flow milli-amp pro-
P.SOL;PUMP-
mA portional valve; Ac-
FLOW
tual milli-amp
SOL;POWER-
on/off Power save solenoid
SAVE
84402832 NA - May 2011

4001B-4
Service Support
2. Temperature and pressure 4. Pressure and solenoid
BOOST PRESS. kPa Boost pressure BOOM-UP PILOT Boom-up pilot pres-
MPa
BAROMETRIC PRESS. sure
kPa Barometric pressure ARM-CLOSE PI-
PRESS. MPa Arm-in pilot pressure
BOOST TEMP. °C Boost temperature LOT PRESS.
Suction air tempera- BUCKET-CLOSE Bucket-close pilot
AIR INLET TEMP. °C MPa
ture PILOT PRESS. pressure
FUEL TEMP. °C Fuel temperature P.SOL;BOOM-
mA Boom-down solenoid
MANIFOLD IN- DOWN
°C Manifold temperature P.SOL;BOOM-UP mA Boom-up solenoid
NER TEMP.
COOLANT TEMP. °C Coolant temperature P.SOL;ARM-
mA Arm-in solenoid
HYD.OIL TEMP. °C Oil temperature CLOSE
P.SOL;BUCKET- Bucket-close sole-
mA
3. Pressure and solenoid CLOSE noid
P.SOL;OFFSET-
mA Offset left solenoid
LEFT
SOL;BUCKET Bucket-open sole-
on/off
OPEN noid
UPPER PILOT
MPa Upper pilot pressure
PRESS.
SWING PILOT
MPa Swing pilot pressure
PRESS.
TRAVEL PILOT
MPa Travel pilot pressure
PRESS.
OPT.LINE
on/off 1st option operation
PRESS SW.
2ND OPT.LINE
on/off 2nd option operation
PRESS SW.
TRAVEL ALARM
on/off Travel alarm
OUT.
POWER SAVE
on/off Power save solenoid
SOL.
SWING BRAKE
on/off Swing brake solenoid
SOL.
FREE SWING
on/off Free swing solenoid
SOL.
84402832 NA - May 2011
4001B-5
Service Support
5. Pressure and solenoid 6. Engine
PILOT SW. on/off Pilot switch

Pump 1; Discharge ENGINE OIL
P1 PRESS. MPa kPa Engine oil pressure
pressure PRESS
Pump 2; Discharge COOLANT LLC reserve tank
P2 PRESS. MPa on/off
pressure LEVEL SW. level switch
Pump 1; Negative Air cleaner clog
N1 PRESS. MPa AIR FILTER SW. on/off
control pressure switch
Pump 2; Negative BATTERY VOLT-
N2 PRESS. MPa V Battery voltage
control pressure AGE
P.SOL;OPT.LINE BATTERY Alternator power
mA Option line solenoid on/off
RELIEF CHARGE generation
SOL;OPTION 2 pumps flow sole- IDLE SHUT Idling stop relay out-
on/off on/off
2SPEED noid DOWN OUT put
SOL;OPTION SE- Option selection so- 2SPEED TRAVEL Travel 2nd speed so-
on/off
LECT lenoid SOL lenoid output
SOL;POWER FAN REVERS- Option switchover
on/off Power boost solenoid
BOOST ING SOL solenoid output
84402832 NA - May 2011

4001B-6
Service Support
7. Fuel 8. Engine
FUEL DENSITY ENGINE SPEED min-1 Engine speed

g/cm3 Fuel density
(RAW) ENGINE LOAD
FUEL DENSITY % Engine load ratio
g/cm3 Fuel density RATIO
(15℃) DPD DPD exhaust gas dif-
FUEL TEMP. (IN- kPa
℃ Fuel temperature DIFF.PRESS. ferential pressure
NER TANK) EXHAUST TEMP. Exhaust gas temper-
FUEL SENSOR ℃
% Fuel sensor (DOC) ature (DOC)
POSITION EXHAUST TEMP. Exhaust gas temper-
REFUEL AUTO- Fuel supply auto- ℃
on/off (DPD) ature (DPD)
STOP OUT matic stop P.SOL;RE-
HYD.OIL FILTER Hydraulic oil filter mA
on/off GEN.ASSIST
SW. switch Flow milli-amp pro-
LOCK STATUS1 - - P.SOL;PUMP-
mA portional valve; Ac-
LOCK STATUS2 - - FLOW
tual milli-amp
Pump 1; Discharge
P1 PRESS. MPa
pressure
Pump 1; Negative
N1 PRESS. MPa
control pressure
84402832 NA - May 2011

4001B-7
Service Support
9. Engine 11. Safety distances
ENGINE TAR- BOOM ANGLE deg Boom angle

min-1 Engine target speed
GET SPEED OFFSET ANGLE deg Offset angle
ENGINE SPEED min-1 Engine speed ARM ANGLE deg Arm angle
ENGINE LOAD P.SOL;BOOM-UP % Boom-up solenoid
% Engine load ratio
RATIO P.SOL;OFFSET-
% Offset solenoid
FUEL INJEC- LEFT
% Fuel injection ratio
TION LIMIT P.SOL;ARM-
mA Arm-in solenoid
COMMON RAIL Common rail pres- CLOSE
MPa
PRESS. sure SAFETY DIS- Safety distance
m
C.RAIL Common rail differ- TANCE(TOP) (side)
MPa
DIFF.PRESS. ential pressure SAFETY DIS- Safety distance
m
SUPPLY- TANCE(SIDE) (front)
Supply pump pres-
PUMP(IN) kPa
sure (IN)
PRESS 12. Hanging load
TARGET FUEL Target fuel injection
mm3/st
INJECTION quantity
FUEL FLOW L/h
10. Work radius and height
BOOM BOTTOM Boom bottom pres-

MPa
PRESS. sure
BOOM ROD
MPa Boom rod pressure
PRESS.
WORKING RA- m Work radius
BOOM ANGLE deg Boom angle DIUS
OFFSET ANGLE deg Offset angle LIFTING LOAD kg Hanging load
ARM ANGLE deg Arm angle RATED LOAD kg Rated load
WORKING RA- TOTAL MOMENT kg.m Total moment
m Work radius Attachment indepen-
DIUS ATT.MOMENT kg.m
LIFTING HEIGHT m Work height dent moment
HEIGHT LIMIT m Hanging limit height
LIFTING LOAD kg Hanging load
RATED LOAD kg Rated load
WARNING
on/off Liftcrane buzzer
BUZZER OUT
84402832 NA - May 2011
4001B-8
Service Support
13. GPS information FAULT HISTORY

1. With FAULT HISTORY, the contents for the trouble
currently occurring and a log of trouble that has oc-
curred in the past can be checked.
To switch to a page from 1 to 15, press the monitor
switch while the MACHINE STATUS screen

is displayed and select the desired page.
1 Displayed/Not displayed
2 Occurrence count
3 Initial occurrence time
4 Final occurrence time
• Diagnostic trouble codes that occur display in

"DTC-1" - "DTC-4".
•
The cursor is moved with the and
switches. (The cursor moves between "DTC-1"
and "DTC-4".)
• The information for the diagnostic trouble code for
the location under the cursor is displayed with the
items from "STATUS" to "LAST HOUR".
• Up to 30 diagnostic trouble codes can be dis-
played.
To switch to a page from 1 to 6, press the monitor
switch while the FAULT HISTORY screen

is displayed and select the desired page.
84402832 NA - May 2011

4001B-9
Service Support
WORK HISTORY
Operation times for mechanical parts, electrical parts,
etc., and operation counts for switches can be displayed.
1. Machine main unit 2. Work mode
KEY-ON TIME hour Key ON time SP-MODE OPERA- SP mode operation

hour
Engine operation TION TIME time
ENGINE-RUN TIME hour
time H-MODE OPERA- H mode operation
hour
OPERATION TIME hour Operation time TION TIME time
UPPER OPERA- A-MODE OPERA- A mode operation
hour Upper operation time hour
TION TIME TION TIME time
SWING OPERATION - - -
hour Swing operation time POWER-BOOST Boosted pressure
TIME hour
TRAVEL OPERA- TIME time
hour Travel operation time AUTO IDLE TIME hour Auto idle time
TION TIME
INDEPENDENT Independent travel ONE-TOUCH-IDLE
hour hour One-touch idle time
TRAVEL TIME operation time TIME
Lo-SPEED TRAVEL 1st speed travel oper-
hour
TIME ation time
Hi-SPEED TRAVEL 2nd speed travel op-
hour
TIME eration time
84402832 NA - May 2011

4001B-10
Service Support
3. End attachment 5. Electrical part
WIPER-INT. OPER-
BREAKER OPERATION Breaker operation hour Wiper (INT) time
hour ATION TIME
TIME time
WIPER-CNT. OPER-
CRUSHER OPERA- Crusher operation hour Wiper (CNT) time
hour ATION TIME
TION TIME time
WASHER OPERA- Washer operation
OPT.1 PUMP OPERA- 1st option opera- hour
hour TION TIME time
TION TIME tion time
WORKING LAMP Working light ON
OPT.2 PUMP OPERA- 2nd option opera- hour
hour ON TIME time
TION TIME tion time
RADIO MUTE TIME hour Radio mute time
2ND OPT. OPERATION 2 pumps flow op-
hour DISPLAY-MODE1 No camera screen
TIME eration time hour
TIME selection time
CRANE OPERATION Liftcrane opera-
hour DISPLAY-MODE2 Camera screen dis-
TIME tion time hour
TIME play 1 selection time
MAGNET OPERATION Lifting magnet op-
hour DISPLAY-MODE3 Camera screen dis-
TIME eration time hour
TIME play 2 selection time
4. Electrical part
KEY-ON COUNT hour Key ON count

ENGINE-START
hour Engine ON count
COUNT
IDLE SHUT Front window open
hour
DOWN COUNT count
WINDOW OPEN
hour Door open count
TIME
WINDOW OPEN
10 times Idle stop time
COUNT
DOOR OPEN Front window open
hour
TIME time
DOOR OPEN
10 times Door open time
COUNT
84402832 NA - May 2011
4001B-11
Service Support
6. Air conditioner 7. Air conditioner
A/C OPERATION AC power supply Maximum cooling op-

hour COOL-MAX TIME hour
TIME ON time eration time
A/C BLOWER-Lo AC blower Lo set- T1 TARGET TEMP T1 Target tempera-
hour hour
TIME ting time ＜ T2 TIME ture T ＜ T2 time
A/C BLOWER-M1 AC blower M1 set- T2 TARGET TEMP T2 Target tempera-
hour hour
A/C BLOWER-M2 AC blower M2 set- T3 TARGET TEMP T3 Target tempera-
hour hour
A/C BLOWER-M3 AC blower M3 set- Maximum heating
hour HOT-MAX TIME hour
TIME ting time operation time
A/C BLOWER-M4 AC blower M4 set- RECIRC.AIR MAX- Maximum inside air
hour ℃
TIME ting time TEMP. temperature
A/C BLOWER-Hi AC blower Hi set- RECIRC.AIR MIN- Minimum inside air
hour ℃
TIME ting time TEMP. temperature
MAG.CLUTCH RE- Electromagnetic INTAKE AIR MAX- Maximum outside air
hour ℃
LAY ON TIME clutch ON time TEMP. temperature
CLUTCH RELAY ON Electromagnetic INTAKE AIR MIN- Minimum outside air
10 times ℃
COUNT clutch ON count TEMP. temperature
To switch to a page from 1 to 7, press the monitor switch
while the WORK HISTORY screen is displayed

and select the desired page.
84402832 NA - May 2011

4001B-12
Service Support
ENGINE HISTORY
The engine speed, coolant temperature, fuel tempera-
ture, and suction air temperature distributions, etc. can
be displayed.
1. Actual speed distribution 2. Water temperature distribution
ROTATION ＜ R1 hour S 1025 TEMP. ＜ T1 hour T ＜ 77

R1 REV. SPEED ＜ T1 TEMP. ＜ T2 hour 77 T ＜ 82
hour 1025 S ＜ 1225
R2 T2 TEMP. ＜ T3 hour 82 T ＜ 97
hour 1225 S ＜ 1425
R3 T4 TEMP. ＜ T5 hour 100 T ＜ 103
hour 1425 S ＜ 1625
R4 T6 TEMP. hour 105 T
R4 REV. SPEED ＜ - - -
hour 1625 S ＜ 1825
R5 Maximum temper-
R5 REV. SPEED ＜ TEMP. MAX ℃
hour 1825 S ＜ 2025 ature
R6
R6 REV. SPEED hour 2025 S
84402832 NA - May 2011

4001B-13
Service Support
3. Fuel temperature distribution 5. Boost temperature distribution
TEMP. ＜ T1 hour T ＜ 40 TEMP. ＜ T1 hour T＜0

T1 TEMP. ＜ T2 hour 40 T ＜ 50 T1 TEMP. ＜ T2 hour 0 T ＜ 20
T6 TEMP. hour 90 T T6 TEMP. hour 100 T
- - - - - -
Maximum temper- Maximum temper-
TEMP. MAX ℃ TEMP. MAX ℃
ature ature
6. Suction air temperature distribution

4. Suction air temperature distribution
PRESS. ＜ P1 hour P ＜ 100

TEMP. ＜ T1 hour T ＜ -20 P1 PRESS. ＜ P2 hour 100 P ＜ 140
T1 TEMP. ＜ T2 hour -20 T ＜ 0 P2 PRESS. ＜ P3 hour 140 P ＜ 180
T2 TEMP. ＜ T3 hour 0 T ＜ 15 P3 PRESS. ＜ P4 hour 180 P ＜ 220
T5 TEMP. ＜ T6 hour 45 T ＜ 60 P6 PRESS. hour 300 P
T6 TEMP. hour 60 T Maximum pres-
PRESS. MAX kPa
- - - sure
Maximum temper- Minimum pres-
TEMP. MAX ℃ PRESS. MIN kPa
ature sure
84402832 NA - May 2011

4001B-14
Service Support
7. Oil pressure distribution 9. Load ratio distribution
PRESS. ＜ P1 hour P＜0 RATIO ＜ R1 hour R＜ 30

P1 PRESS. ＜ P2 hour 0 P ＜ 150 R1 RATIO ＜ R2 hour 30 R ＜ 40
P6 PRESS. hour 750 P R6 RATIO hour 80 R
Maximum pres-
PRESS. MAX kPa
sure 10. SP mode load ratio distribution
Minimum pres-
PRESS. MIN kPa
sure
8. Boost pressure distribution
RATIO ＜ R1 hour R ＜ 30
R1 RATIO ＜ R2 hour 30 R ＜ 40
R2 RATIO ＜ R3 hour 40 R ＜ 50
R3 RATIO ＜ R4 hour 50 R＜60
PRESS. ＜ P1 hour P＜0 R4 RATIO ＜ R5 hour 60 R ＜ 70
P2 PRESS. ＜ P3 hour 150 P ＜ 300 R6 RATIO hour 80 R
P3 PRESS. ＜ P4 hour 300 P＜450
P4 PRESS. ＜ P5 hour 450 P ＜ 600
P5 PRESS. ＜ P6 hour 600 P ＜ 750
P6 PRESS. hour 750 P
Maximum pres-
PRESS. MAX kPa
sure
Minimum pres-
PRESS. MIN kPa
sure
84402832 NA - May 2011

4001B-15
Service Support
11. H mode load ratio distribution 13. DOC temperature distribution
RATIO ＜ R1 hour R ＜ 30 TEMP. ＜ T1 hour T ＜ 200

R1 RATIO ＜ R2 hour 30 R ＜ 40 T1 TEMP. ＜ T2 hour 200 T ＜ 300
R6 RATIO hour 80 R T6 TEMP. hour 700 T
- - -
12. Fuel density distribution Maximum temper-
TEMP. MAX ℃
ature
14. DPD temperature distribution
DENSITY ＜ D1 hour D＜ D1
D1 DENSITY ＜ D2 hour D1 D ＜ D2
TEMP. ＜ T1 hour T ＜ 200
T1 TEMP. ＜ T2 hour 200 T ＜ 300
T2 TEMP. ＜ T3 hour 300 T ＜ 400
T3 TEMP. ＜ T4 hour 400 T ＜ 500
D6 DENSITY hour D6 D
T4 TEMP. ＜ T5 hour 500 T ＜ 600
T5 TEMP. ＜ T6 hour 600 T ＜ 700
T6 TEMP. hour 700 T
- - -
Maximum temper-
TEMP. MAX ℃
ature
84402832 NA - May 2011

4001B-16
Service Support
15. Supply pump inlet pressure distribution 17. DPD differential pressure distribution
PRESS. ＜ P1 hour P ＜ -40

PRESS. ＜ P1 hour P＜0
P1 PRESS. ＜ P2 hour -40 P ＜ -30
P1 PRESS. ＜ P2 hour 0 P＜5
P2 PRESS. ＜ P3 hour -30 P ＜ -20
P2 PRESS. ＜ P3 hour 5 P ＜ 10
P3 PRESS. ＜ P4 hour -20 P ＜ -10
P4 PRESS. ＜ P5 hour -10 P ＜ 0
P6 PRESS. hour 10 P
P6 PRESS. hour 25 P
Maximum pres-
PRESS. MAX kPa Maximum pres-
sure PRESS. MAX kPa
sure
Minimum pres-
PRESS. MIN kPa Minimum pres-
sure PRESS. MIN kPa
sure
16. Hot shutdown

18. DPD regeneration count
ITEM-1 - -
ITEM-2 - -
ITEM-1 - -
ITEM-3 - -
ITEM-2 - -
ITEM-4 - -
ITEM-3 - -
ITEM-5 - -
ITEM-4 - -
ITEM-6 - -
ITEM-5 - -
ITEM-7 - -
ITEM-6 - -
ITEM-8 - -
ITEM-7 - -
ITEM-9 - -
ITEM-8 - -
ITEM-9 - -
while the ENGINE HISTORY screen is displayed

and select the desired page.
84402832 NA - May 2011
4001B-17
Service Support
HYDRAULIC HISTORY
The P1 and P2 pilot pressure can be displayed.
1. P1 pressure 2. P2 pressure
PRESS. ＜ P1 hour P＜ 10 PRESS. ＜ P1 hour P ＜ 10

P1 PRESS. ＜ P2 hour 10 P＜ 15 P1 PRESS. ＜ P2 hour 10 P ＜ 15
P6 PRESS. hour 35 P P6 PRESS. hour 35 P
84402832 NA - May 2011

4001B-18
Service Support
3. N1 pressure 5. P1 + P2 pressure
PRESS. ＜ P1 hour P＜ 1.0

P1 PRESS. ＜ P2 hour 1.0 P＜ 1.5 PRESS. ＜ P1 hour P＜ 20
P2 PRESS. ＜ P3 hour 1.5 P＜ 2.0 P1 PRESS. ＜ P2 hour 20 P＜ 30
P6 PRESS. hour 3.5 P P5 PRESS. ＜ P6 hour 60 P＜ 70
P6 PRESS. hour 70 P
4. N2 pressure
6. Operation count
PRESS. ＜ P1 hour P＜ 1.0

P1 PRESS. ＜ P2 hour 1.0 P＜ 1.5
P2 PRESS. ＜ P3 hour 1.5 P＜ 2.0
P3 PRESS. ＜ P4 hour 2.0 P＜ 2.5 UPPER PILOT Upper operation
P4 PRESS. ＜ P5 hour 2.5 P＜ 3.0 1000 times
PRESS count
P5 PRESS. ＜ P6 hour 3.0 P＜ 3.5 SWING PILOT Swing operation
1000 times
P6 PRESS. hour 3.5 P PRESS count
TRAVEL PILOT Travel operation
1000 times
PRESS count
ARM-CLOSE PI- Arm-in operation
1000 times
LOT PRESS. count
OPT.LINE 1st option opera-
1000 times
PRESS SW. tion count
2ND OPT.LINE 2nd option opera-
1000 times
PRESS SW. tion count
POWER BOOST Pressure boost
1000 times
SOL. operation count
SWING BRAKE Swing operation
1000 times
SOL. count
POWER-SAVE Power save oper-
1000 times
TIME ation count
84402832 NA - May 2011
4001B-19
Service Support
7. Oil temperature distribution PART NUMBER

The software version for computers A, B, C can be dis-
played.
TEMP. ＜ T1 hour T ＜ 45
T1 TEMP. ＜ T2 hour 45 T ＜ 60
T2 TEMP. ＜ T3 hour 60 T ＜ 80
T3 TEMP. ＜ T4 hour 80 T ＜ 88
T4 TEMP. ＜ T5 hour 88 T ＜ 95
T5 TEMP. ＜ T6 hour 95 T ＜ 98
T6 TEMP. hour 98 T
- - -
Maximum tempera-
TEMP. MAX ℃
ture
while the HYDRAULIC HISTORY screen is dis-

played and select the desired page.
SETUP Screen List

The model selection, work mode speed, etc. can be
changed.
84402832 NA - May 2011

4001B-20
Service Support
By pressing "Wiper switch" (5) and "Auto idling switch" MACHINE SELECT
(6) on the monitor, MACHINE SELECT, PARAMETERS,
etc. can be selected. Machine data information, etc. are registered.
Detailed data for the selected item can be seen by press-
ing "Working light switch" (4).
MACHINE 0 Japanese
Fix the selection. 1 English
TERRITORY 2 Thai
3 Chinese
0 JAPAN 4 German
1 NA 5 French
2 - 6 Italian
3 EU 7 Spanish
4 IHI 8 Portuguese
5 TURK 9 Dutch
6 CHINA 10 Danish
11 Norwegian
12 Swedish
BRAND
13 Finnish
14 Turkish
0 SUMITOMO 15 Arabic
1 LBX 16 Malay
2 CASE 17 Indonesian
3 IHI 18 Russian
19 Canadian French
LANGUAGE 20 Pictographs only
84402832 NA - May 2011

4001B-21
Service Support
PARAMETERS 3. Work mode engine speed

The work mode speed and pump milli-amps can be set.
1. Engine
ITEM-1 min-1 SP mode speed

ITEM-2 min-1 H mode speed
ITEM-3 min-1 A mode speed
ITEM-1 min-1 Auto idling speed ITEM-4 min-1 Idling speed
ITEM-2 ms*100 Auto idle time
Transient load minimum milli- 4. Energy save
ITEM-3 mA
amp (normally 50 mA)
Semi-transient load minimum
ITEM-4 mA
milli-amp
Eco gauge update period (nor-
ITEM-5 ms*100
mally 1000 ms)
2. Work mode milli-amp
Speed change amount during

ITEM-1 min-1
boom-down swing operation
ITEM-2 - -
Semi-auto idling speed change
ITEM-3 min-1
amount
ITEM-4 - -
ITEM-5 - -
ITEM-1 mA SP mode milli-amp (Hi) - -
ITEM-6
ITEM-2 mA SP mode milli-amp (Low)
ITEM-7 mA Speed limit milli-amp
ITEM-3 mA H mode milli-amp (Hi)
ITEM-4 mA H mode milli-amp (Low)
ITEM-5 mA A mode milli-amp (Hi)
ITEM-6 mA A mode milli-amp (Low)
ITEM-7 mA Minimum milli-amp
84402832 NA - May 2011

4001B-22
Service Support
5.
ITEM-1 - -
ITEM-2 - -
ITEM-3 - -
ITEM-4 - -
ITEM-5 - -
ITEM-6 - -
ITEM-7 - -
ITEM-8 - -
ITEM-9 - -
84402832 NA - May 2011

4001B-23
Service Support
Setting
Model Select
Summary
The model information is input to set the control parameters specific to the model.
Configuration
• Screen
Move up and down to move the cursor, left and right to select a model, set the throttle to H mode, and decide with
the menu switch.
• · Reset by holding down the left and right. (The display changes to "?" for all items.)
* From Ver. 1.8.6
Without a reset, only the LANGUAGE and UNIT can be changed.
Other changes always require a complete reset.
Setting items, values and details
Select "SET UP" on the service screen and input the following items.
The setting item values and setting details are given below.
Explanation of item
Page Item name Explanation Remarks

MACHINE Model
TERRITORY Destination
BRAND Brand
LANGUAGE Language
1 UNIT Unit 0: {MPa, °C}, 1: {psi, °F}, 2: {kgf/cm2, °C}
-
-
-
-
-
-
OVERLOAD WARNING Load warning
Interference preven-
ANTI INTERFERENCE Not currently supported
tion
ATT. TYPE Attachment type Used for interference prevention·crane·overload warning
2
OPTION LINE Option Line
GENERATOR Lifting magnet Not currently supported
-
-
-
84402832 NA - May 2011

4001B-24
Service Support
Page Item name Explanation Remarks

-
Currently not supported; used for Computer ST trouble
REMOTE SUPPORT Remote Support
diagnosis
Fuel abnormality Currently not supported; used for density sensor trouble
FMS
warning diagnosis
3 RESERVE 1 Free Swing
RESERVE 2 Reserve 2 Not currently supported
RESERVE 3 Reserve 3 Not currently supported
-
-
-
Explanation of number
1. Model (Machine)
Omitted
2. Destination (Territory)
Value Details Remarks

0 JAPAN
Travel alarm continuous buzzing function ON (Cannot be set
1 NA
OFF)
2 - (Skipped number)
3 EU
4 IHI
5 TURK
6 CHINA
3. Brand

Background color = blue, Sumitomo logo displayed after model
0 SUMITOMO
selection completed
Background color = black, LBX logo displayed after model se-
1 LBX
lection completed
Background color = black, CASE logo displayed after model se-
2 CASE
lection completed
3 IHI Not currently supported, background color = ?
84402832 NA - May 2011

4001B-25
Service Support
4. Language
• Can be changed with "LANGUAGE" on the menu screen.

0 Japanese
1 English
2 Thai Not currently supported
3 Chinese
4 German
5 French
6 Italian
7 Spanish
8 Portuguese
9 Dutch
10 Danish
11 Norwegian
12 Swedish
13 Finnish
14 Turkish
15 Arabic
16 Malay Not currently supported
17 Indonesian Not currently supported
18 Russian
19 Canadian French
20 Pictographs only
5. Unit

0 Domestic, Europe (SI units) (MPa, °C)
1 North America (psi, °F)
2 Weight unit system (kgf/cm2, °C)
6. Load warning (OVERLOAD WARNING)

0 None
1 Liftcrane Not currently supported
2 Overload warning
3 Overload warning (rod pressure correction) Not currently supported
7. Interference prevention (ANTI INTERFERENCE)

0 None Not currently supported
1 Yes Not currently supported
8. Attachment type (ATT. TYPE)

0 STD
1 HD
2 Ultra-long
84402832 NA - May 2011
4001B-26
Service Support
9. Option line

None (Option adjustment screen cannot be
0
displayed)
1 Breaker
2 Double-acting no 2nd speed
3 Double-acting with 2nd speed
4 W/O multi-purpose pressure adjustment
5 W/ Multi-purpose pressure adjustment
10. Lifting magnet (Generator)

11. Remote Support

12. Fuel abnormality warning (FMS)

13. Free swing (Reserve 1)

0 None
1 Yes
84402832 NA - May 2011

4001B-27
Service Support
Throttle Volume Default Setting

Summary
Corrects the throttle volume installation error.
Configuration
*1 Throttle volume *3 Computer B *5 ECM

*2 Color monitor *4 Computer A *6 ENG
1. Switch the key ON and select (Select Model). (See Select Model.)
2. Set all the model selection items and set the throttle volume to H mode, then finalize the selections.
3. The system performs the initial adjustment of the throttle volume. (*1)
• The adjustment results are retained in memory even after the key is switched OFF.
84402832 NA - May 2011

4001B-28
Service Support
Password Setting
Summary
Set the anti-theft password.
Configuration
• Monitor: Connected to Computer B
• Anti-theft setting knob: On the cab main harness
1. With the key OFF, connect the anti-theft setting knob.
2. After connecting the knob, when you switch ON the key, the system displays the password setting screen.
3. After setting the 4-digit password, if you switch the key ON→OFF→ON→OFF, the system switches ON the
anti-theft function.
• All the key switching operations should be done within 2 sec.
4. When the anti-theft function comes ON, the monitor sets off the buzzer and the key icon is displayed.
* See Anti-theft (password type).
84402832 NA - May 2011

4001B-29
Service Support
Adjusting the Clock *1 Color monitor

Summary
This adjusts the clock displayed on the monitor. Operation explanation
• For details on the clock, see the clock section. 1. When the key is turned ON, --:-- is displayed on
the monitor.
Configuration 2. The operator can set the time with "CLOCK AD-
JUST" on the menu screen.
Move left and right to move the cursor, up and
down to change the time, and decide with the
menu switch.
3. The system displays the time on the monitor.
• Since the clock data is stored in the monitor, the
time is retained even if Computer B is replaced.
When the monitor is replaced, it is necessary to
set the clock again.
84402832 NA - May 2011

4001B-30
Service Support
Parameter Settings
* The following covers software Version 1.8.7.
Summary
Control parameters can be changed using the monitor.
For example, the time until auto idle is started or the current and speed for work mode can be set.
The items up to the 3rd page of the setting screen can overwrite the parameters changed with the key OFF.
Configuration
The diagram below shows the items that can be checked with each page of the setting screen.
Page Item name Unit Explanation Remarks

Lo-IDLE ENGINE SPEED min-1 Low idle engine speed
AUTO IDLE TIME sec Auto idle time
AUTO IDLE ENGINE
min-1 Auto idling speed
SPEED
IDLE SHUT DOWN TIME min Idle shut-down time 10 minutes max.
AUTO POWER BOOST Y/N Auto pressure boost function
Milli-amp for pump horsepower control
1 PUMP POWER AT START mA proportional valve (mA); when ATT op-
erations start
PUMP POWER DOWN mA proportional valve (mA); negative offset
amount
Flow control (breaker mode) with en-
REV. LIMIT AT BREAKER Y/N Not currently supported
gine speed
Can only be changed for 20
ENABLE POWER SAVE Y/N Power save function
tons - 29 tons.
Cannot be switched OFF on
ENABLE TRAVEL ALARM Y/N Travel alarm function
North American models
TRV. ALARM-ON TIME sec Travel alarm sounding time Range = 1..30, Step = 1
Previous travel speed data hold func-
MEMORIZE TRV. SPEED Y/N
tion
ENABLE EPF Y/N EPF Yes/No
2 OVERLOAD PRESS. MPa Overload set pressure
MAINTENANCE MES-
Y/N Service due message
SAGE
FORCED DIM. BY W.LAMP Y/N working light linked dimming
AUTO CLOCK ADJUST Y/N For automatic adjustment Not currently supported
TIME DIFFERENCE WITH -
hour Not currently supported
UTC
ITEM-1 Y/N Eco gauge display
ITEM-2 - -
ITEM-3 - -
ITEM-4 - -
3 ITEM-5 - -
ITEM-6 - -
ITEM-7 - -
ITEM-8 - -
ITEM-9 - -
84402832 NA - May 2011

4001B-31
Service Support
Page Item name Unit Explanation Remarks

ITEM-1 mA
proportional valve (SP_Hi)
ITEM-2 mA
proportional valve (SP_Low)
ITEM-3 mA
proportional valve (H_Hi)
ITEM-4 mA
proportional valve (H_Low)
4
ITEM-5 mA
proportional valve (A_Hi)
ITEM-6 mA
proportional valve (A_Low)
ITEM-7 mA
proportional valve (Min)
ITEM-8 - -
ITEM-9 - -
ITEM-1 Y/N Quick warm-up control ON/OFF
ITEM-2 - Development parameter
5 ITEM-5 - Development parameter
ITEM-1 min-1 Engine speed (SP)
ITEM-2 min-1 Engine speed (H)
ITEM-3 min-1 Engine speed (A)
ITEM-4 - -
6 ITEM-5 - -
ITEM-6 - -
ITEM-7 - -
ITEM-8 - -
ITEM-9 - -
1. Select an item with the cursor, then input the number with ←→.
2. Decide the selection with the menu switch, then press the menu switch again to leave the screen.
84402832 NA - May 2011

4001B-32
Service Support
Option Flow Pressure Setting 4. Maximum pressure setting

5. Pressure adjustment
Summary
Sets the option line flow / pressure. For Item 1), when a multi-purpose circuit is set with
Sets the breaker/crusher maximum flow and maxi- model selection, the maximum pressure settings
mum pressure. and pressure adjustment items in 4) and 5) are only
After making the setting, follow the procedure and cor- displayed when pressure adjustment is set with the
rect so that the pressure becomes the set pressure. model selection.
Configuration • Message displayed on the option line setting screen:
There is one message display area at the top of the
• The 1st option, 2nd option pressure switch: Con- screen and one at the bottom of the screen.
nected to Computer A "PRESSURE ADJUSTING INCOMPLETE" or "AD-
Used during pressure adjustment to judge whether JUST PRESSURE" is displayed in the top message
or not operation is independent breaker (crusher) display area.
operation. "BREAKER OPERATION REQUIRED/CRUSHER
• Bucket-close, arm-in, boom-up pressure sensor: OPERATION REQUIRED", "SET IN SP-MODE",
Connected to Computer B and sent to Computer A "INCREASE ENGINE RPM", "INCREASE OIL
via the CAN. TEMP.", "ADJUSTING PRESSURE", "PRESSURE
Used during pressure adjustment to judge whether ADJUSTING. COMPLETE", PRESSURE ADJUST-
or not operation is independent breaker (crusher) ING INCOMPLETE", or "CHECK FLOW RATE" is
operation. displayed in the bottom message display area.
• Oil temperature sensor: Connected to Computer A
Used to judge whether or not the temperature per-
mits pressure adjustment.
• Engine speed sensor: Connected to the ECM and
recognized by Computer A via the CAN.
Used to judge whether or not the speed permits
pressure adjustment.
• P1 pressure sensor: Connected to Computer A
Used to judge whether pressure is being relieved
according to the set pressure.
• Option line switching solenoid: Connected to and
controlled by Computer A.
When this solenoid is ON, it switches to the breaker
circuit and at the same time that the relief pressure
reaches the breaker setting, the return hydraulic oil
falls directly into the tank through the filter.
• Pump flow proportional valve: Connected to and Operation explanation
controlled by Computer A. 1. The operator enters the option line setting screen
So that the preset maximum flow is not exceeded in from the menu.
breaker/crusher mode. The system cuts away option line switching sole-
• Option relief pressure proportional valve: Con- noid, pump flow
nected to Computer B proportional valve, option relief pressure propor-
The target command current value is sent from Com- tional valve, 2 pumps flow from normal controls
puter A via CAN communication. and sets to setting mode.
• 2 pumps flow solenoid: Connected to and controlled
by Computer A. • There are two ways to enter the option line set-
When this solenoid is ON, if a backup operation is ting screen.
carried out, 2 pumps flow. One is from the menu screen.
2 pumps will not flow if a backup operation is not The other is by holding down the ATT select
carried out even if this solenoid is ON. switch for one second.
• With the X2, the 2 pumps flow switch was installed When the former method is used, the ATT
on the console as a rocker switch, but with X3, this when one enters the option line setting screen
was eliminated. is Breaker 1. (However, if a double-acting cir-
Instead, this is decided beforehand with the option cuit is selected with the model selection, it is
line setting screen. Crusher 1.)
• Option line setting screen items: consists of follow- When the latter method is used, the display
ing five items moves to the currently selected ATT and a
switch guide is displayed on the monitor. (Nor-
1. Attachment selection, mally, this is from Breaker 1. (However, if
2. Breaker No. (or Crusher No.) double-acting circuit is selected with the model
3. Maximum flow setting selection, it is from Crusher 1).)
84402832 NA - May 2011

4001B-33
Service Support
2. The operator selects the breaker or the crusher the settings are made in increments of 0.5 MPa.
from the "Attachment selection". (When (See (Number table) pressure adjustment range
multi-purpose circuit is selected with model se- below.)
lection: For a breaker or crusher, "Attachment • No maximum pressure can be set that exceeds
selection" is not displayed and the selection can- the relief valve pressure setting range.
not be changed.) • When an item that had been set is reset, four
For a breaker, the system sets the item immedi- hyphens (---) are displayed for either the "SET
ately below to "Breaker No." and for a crusher, MAX FLOW" or the "SET MAX PRESSURE"
"Crusher No.". and when you exit the options adjustment
At the same time, the system switches the option screen, the information that had been set is
line switching solenoid to ON for a breaker or OFF reset.
for a crusher. • If the pressure adjustment is not selected with
3. The operator selects a number from 1 to 5 with the model selection, the option flow setting ends
the "Breaker No. (or Crusher No.)" item. after just setting the maximum flow.
The system displays the maximum flow and max- • When multi-purpose circuit is selected with
imum pressure corresponding to that number model selection, when the flow volume for 2
in the two items immediately below "SET MAX pumps flow is set with breaker mode, "CHECK
FLOW" and "SET MAX PRESSURE". FLOW RATE" is displayed on the monitor.
Once that flow volume is decided, the "CHECK
• The factory setting is that the maximum flow and FLOW RATE" display goes out.
maximum pressure setting are only for Breaker
1 and Crusher 1. 5. When the operator has changed the maximum
(* The pressure is not adjusted, so for pressure flow or maximum pressure, the system redoes the
adjustment model setting, the icon does not ap- option relief pressure proportional valve adjust-
pear even if the ATT select switch is pressed. ment again.
The icon appears for the model setting only with The system displays "ADJUST PRESSURE" on
flow setting.) the monitor.
Other breakers, 2-5, and crushers, 2-5, are not 6. The operator checks that the work mode is SP
set. and that the oil temperature is 30°C minimum and
When an breaker or crusher is selected that has operates the breaker (crusher).
not been set, four hyphens (---) are displayed for The system displays "ADJUSTING PRESSURE"
the "SET MAX FLOW" and "SET MAX PRES- on the monitor.
SURE". At the same time, the "PRESSURE SETTING"
• If the maximum flow and maximum pressure and "CURRENT PRESSURE" items are dis-
have not yet been set, that breaker or crusher played.
cannot be selected with a work screen.
To put it the other way, everything set here can • When the operator stops the operation, the dis-
play returns to "BREAKER OPERATION RE-
be selected with a work screen.
QUIRED".
Since the X3 has only one ATT selection switch,
when the flow volume is set here for all the • When the work mode is not SP, "SET IN
SP-MODE" is displayed instead of "ADJUST-
breakers or crushers, care is required because
ING PRESSURE".
selecting the target ATT requires pressing the
switch a number of times. • During one-touch idle or while the engine is
stopped, "INCREASE ENGINE RPM" is dis-
* When items that had been set are reset, the played instead of "ADJUSTING PRESSURE".
reset items can no longer be selected. • When the operator operates in SP mode, if the
oil temperature is less than 30°C, "INCREASE
4. The operator sets the maximum flow from the OIL TEMP." is displayed instead of "ADJUST-
"SET MAX FLOW" item and sets the maximum ING PRESSURE".
pressure from the "SET MAX PRESSURE" item. At the same time, the "TARGET OIL TEMP." and
• As selection options for the maximum flow, the "CURRENT OIL TEMP." items are displayed.
system has available 20 levels for the flow vol- • During adjustment, if any operation other than
ume, 10 for without 2 pumps flow and 10 for with breaker (crusher) operation is done, the sys-
2 pumps flow. tem stops the adjustment, displays "BREAKER
• However, the maximum flow depends on the OPERATING REQUIRED" on the monitor, and
model. Even though 20 levels are displayed waits for operation of the breaker (crusher) in-
for all models, the flow volumes for the levels dependently.
depend on the model. (See (Number table) flow 7. The operator continues operating the breaker
adjustment levels below.) (crusher).
• When the flow volume is set, if a stand-alone The system waits for the pressure to stabilize for
option operation is executed, the flow propor- 2 sec., then starts the adjustment.
tional valve command current value is output The system continues to compare the actual P1
to achieve that flow volume. (Breaker mode or pressure and the target set pressure and when
crusher mode processing is executed.) the difference between them is no more than 0.5
• The range in which the maximum pressure can
be set depends on the model, but for all models,
84402832 NA - May 2011
4001B-34
Service Support
MPa (*) continuously for at least 5 sec., it judges Screen Brightness Setting
the adjustment to be complete.
The system displays "PRESSURE ADJUSTING. <Summary>
COMPLETE" on the monitor and puts out the Decides the brightness of the backlight through oper-
"PRESSURE ADJUSTING INCOMPLETE" dis- ation that is linked to the working light and solar radi-
play. ation sensor.
<Operation explanation>
• During adjustment, the system updates the op- The screen brightness can be selected on the menu
tion relief pressure proportional valve current screen.
every 500 ms in increments of 5 mA. Dimming setting can be changed on the service
• If the pedal continues to be held down even after screen.
the setting value is finalized, the setting value is
updated every 5 sec.. 1. Working Light OFF: Normal (with key ON),
• If the pressure adjustment does not end within "Brightness (day)" setting
30 sec., "PRESSURE ADJUSTING INCOM- 2. Working Light ON: The monitor brightness is re-
PLETE" is displayed on the monitor. duced and the display changes automatically to
the "Brightness (night)" setting.
8. When the operator presses the menu switch to 3. Brightness settings: "Brightness (day)" and
exit the option line setting screen, the system "Brightness (night)" can be set on the menu
stores the settings into memory. screen.
4. Dimming by solar radiation sensor: When the
• If the setting screen was entered from the menu
screen, the display returns to the menu screen. working light-linked dimming is set OFF on the
If the setting screen was entered from the menu screen, the dimming level is adjusted au-
main screen by holding down the ATT select tomatically to the ambient brightness by the solar
switch for 1 sec., the display returns to the main radiation sensor.
screen.
84402832 NA - May 2011

4001B-35
Service Support
84402832 NA - May 2011

4001B-36
Section
4001C
Function, Structure, Operation
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Function, Structure, Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3


1. Engine number
1 Engine number stamping
84402832 NA - May 2011

4001C-3
2. Function, Structure, Operation

1) Engine structural diagram
84402832 NA - May 2011

4001C-4
2) Description of functions and operations

Engine electronic control
The control provided by the control unit applies to the range from injection to air intake and exhaust in-
cluding fuel injection amount, injection timing, air intake restriction, EGR and idling speed.
Cylinder block
The cylinder block is made of cast iron, and it has the equal center distance for each bore and a high
rigidity, and the center of the crankshaft matches the center of the block.
The bearing cap has the ladder frame structure, and is tightened using the plastic region rotational angle
tightening method.
Cylinder liner
The cylinder liner is selected in accordance with the inner diameter of the cylinder block bore, and its
identification number is stamped on the left side of the cylinder.
Piston
The piston is a strut cast autothermatic piston made of aluminum alloy, and the combustion chamber is
the round re-entrant type.
Cylinder head
The cylinder head is made of cast iron, and has four valves per each cylinder.
The angle tightening method has been adopted to the cylinder head bolt to further improve its reliability
and durability.
Crankshaft
The tufftrided steel is being used, and the grade of each journal diameter is engraved on the No. 1 balance
weight.
EGR system
The EGR system is controlled by the engine control module (ECM) according to various data including
the water temperature, engine RPM, and engine load to recirculate the exhaust gas for purification.
The primary components are the EGR valve, EGR cooler, and various sensors.
Connecting rod cap bolt
The angle tightening method has been adopted to the connecting rod cap bolt to further improve its reli-
ability and durability.
Common rail type electronic control injection system
The common rail type electronic control injection system consists of the supply pump that sets the target
pressure of high-pressure fuel to supply the fuel, the common rail that measures the high-pressure fuel
and the fuel injector that injects the fuel in the form of a fine mist.
84402832 NA - May 2011

4001C-5
Each of these are controlled by the ECM based on various signals to control the injection timing and
injection amount in accordance with the working condition.
Fuel injector
The fuel injector has adopted the 7-hole nozzle, and adjusts the fuel injection amount and injection timing
by opening or closing the electromagnetic valve on the injector head portion.
The ECM corrects variation in the fuel injection amount from fuel injector to fuel injector in accordance
with the ID code data in the memory.
When adjusting the fuel injector, the ID code date must be recorded in the ECM.
Fuel filter with sedimenter
The fuel filter with sedimenter removes the water by using the difference in the relative density between
diesel oil and water, and notifies the operator through the indicator when it becomes full of water.
Preheat system
The preheat system consists of the ECM, glow relay, glow plug and glow indicator light.
The preheat system is activated when the engine coolant temperature is low to help engine start.
Lubricating system
It uses and oil filter with a full-flow bypass, and cools down the pistons using the water-cooled oil cooler
and the oil jet.
DPD
An integrated DPD oxidation catalyst is installed for reducing exhaust gas.
84402832 NA - May 2011

4001C-6
3) Fuel system
Fuel system diagram
Unless specifically instructed in the diagnostic pro-

cedure, do not use a test light when diagnosing the
1 powertrain electronic system. 4 Fuel injector 7 Supply pump
When a probe connector is required in the diagnos-
tic procedure, use the connector test adapter kit.
2 Fuel filter 5 Fuel return pipe 8 Pre-fuel filter
3 Common rail 6 Fuel tank
CAUTION
• Since the high-precision fuel system has been adopted, take care to prevent any foreign
matter from entering the fuel system.
84402832 NA - May 2011

4001C-7
Common rail
1 Flow damper 3 Fuel inlet

2 Pressure limiter 4 Pressure sensor
84402832 NA - May 2011

4001C-8
Fuel supply pump
Fuel temperature High pressure

1 3 5 Union
sensor pipe
Suction control
2 4 Camshaft nut 6 Joint bolt
valve
CAUTION
• There is a gauze filter assembled inside the union of the fuel supply pump, but the union
should not be removed to prevent any foreign matter from entering.
84402832 NA - May 2011

4001C-9
1 Union
2 Gauze filter
3 Supply pump
4 Strainer
5 Joint bolt
Injector
1 ID plate
2 Terminal stud
3 Injector drive section
4 Injector assembly
5 Gasket
6 O-ring
Leak-off pipe installation sec-
7
tion
84402832 NA - May 2011
4001C-10
Fuel filter
1 Priming pump
2 Air bleed
3 Case
4 Drain plug
84402832 NA - May 2011

4001C-11
4) Cooling system
The coolant system is the forced-circulation system, and its main components are the water pump, thermo-
stat and radiator.
1 Water jacket 6 Radiator 11 Thermostat, 2 units

2 Drain plug 7 Cooling fan 12 Water temperature sensor
3 Oil cooler 8 Radiator cap 13 Bypass route
4 Water pump 9 Radiator reserve tank 14 EGR cooler
5 Drain cock 10 Water outlet pipe
84402832 NA - May 2011

4001C-12
Water pump
The water pump is a centrifugal impeller type pump and is driven by the engine fan belt.
1 Fan guide 3 Impeller

2 Bearing 4 Seal unit
84402832 NA - May 2011

4001C-13
Thermostat
The thermostat is the wax pellet type, and consists of 2 units.
One unit is the bottom bypass type and its initial open valve temperature is 82 °C (180°F), and the other
unit is the inline type and its initial open valve temperature is 85 °C (185 °F).
The structure allows the water temperature to be fine adjusted, and it is assembled inside the thermostat
housing unit.
1 Jiggle valve 3 Valve 5 Piston

Stamp mark (initial open valve
2 4 Gasket
temperature)
84402832 NA - May 2011

4001C-14
5) Lubrication system
A full-flow bypass integrated filter element, water　cooling oil cooler, and piston coolant oil jet are adopted
　for the lubrication system.
*1 Delivery Valve *9 Oil Cooler *17 Conn-rod Bearing

*2 Oil Port *10 Thermo Valve *18 Oiling jet
*3 Full Flow Oil Filter *11 Oil gallery *19 Oil pump
*4 Oil pressure switch *12 Valve Mechanism *20 Strainer
*5 Oil Pressure Indicator Lamp *13 Crankshaft Bearing *21 Flywheel P.T.O
*6 Fuse *14 Crank Valve *22 Turbochager
*7 Starter Switch *15 Relief Valve *23 Engine Oil Pan
*8 Battery *16 Gear Train
84402832 NA - May 2011

4001C-15
Oil pump structural diagram
1 Driven gear assembly 4 Oil pump drive gear 7 Driven gear assembly
2 Oil pump body 5 Oil pump body 8 Oil pump drive gear
3 Drive gear assembly 6 Drive gear assembly
84402832 NA - May 2011

4001C-16
6) Induction system
Turbocharger structural diagram
1 Turbine housing 5 Compressor housing 9 Seal ring

2 Heat protector 6 Seal plate 10 Turbine shaft
3 Floating metal 7 Compressor impeller
4 Oil thrower 8 Seal ring
84402832 NA - May 2011

4001C-17
7) Exhaust system
1 DPD assembly 3 Exhaust temperature sensor 2

2 Exhaust temperature sensor 1 4
sor
84402832 NA - May 2011

4001C-18
8) Emission control device

EGR
The EGR system recirculates a part of the exhaust gas to the intake manifold, and the generation of NOx
is suppressed.
By controlling the EGR system, high operability and exhaust gas reduction are both achieved.
The control current from the ECM activate the solenoid to control the EGR valve lift amount.
The EGR position sensor detects the actual valve lift amount and the data is used for precise control of
the EGR amount.
The EGR operates when the engine RPM, engine coolant temperature, intake temperature, and atmo-
spheric pressure satisfy certain criteria.
Thereafter, the valve opening angle is calculated according to the engine RPM and the desired fuel injec-
tion amount.
The calculated valve opening angle is used to determine the motor drive duty and the valve is driven
accordingly.
The intake throttle valve closes when the EGR operates to ensure an appropriate internal pressure of the
intake manifold.
84402832 NA - May 2011

4001C-19
*1 Intake throttle position sensor *7 Engine speed *13 Exhaust

*2 EGR valve *8 Engine load *14 Intake throttle valve
*3 EGR position sensor *9 Outlet port coolant *15 Boost temperature sensor
*4 ECM *10 Inlet port coolant *16 Boost sensor
*5 ITA/MAF sensor *11 EGR cooler
*6 Intake air *12 IMT sensor
84402832 NA - May 2011

4001C-20
9) Electrical system
Charging system
The main components of the charging system are the battery, generator, and battery discharge indicator
light circuit.
Generator is a self-rectifier type with a regulator built in.
Generator
The generator is the brushless type.
The main components are the rotor, stator, rectifier assembly, front bracket, rear bracket, IC regulator,
bearing, pulley, etc.
The moving parts are the rotor and pulley.
The field coil is fixed to the rear bracket.
6 main diodes and 2 additional diodes are used to change the three-phase alternating current generated
in the stator coil to a direct current.
3 out of the 6 main diodes are referred to as positive diode, and the rest is referred to as negative diode.
In addition, 3 small diodes that are referred to as triodiode are used to supply the field current.
This generator has 3 terminals of B terminal (direct current output terminal), L terminal and R terminal.
Since the L terminal is connected to the field coil, it works as an input terminal together with the R terminal
until the generator starts generating power.
Also, it functions as an output terminal. (current capacity is 1 A)
When the L terminal voltage reaches the battery voltage, the charge light turns off.
Since the both bearings are sealed, periodic lubrications are not required.
The IC regulator cannot be disassembled, so it should be handled as an assembly.
Starter system
The starter is 5 kW and uses a reduction type.
Gear housing and armature end bearing housing are made of aluminum.
Brush assembly is an replaceable type.
Commutator bar is insulated with mica and undercut.
Starter circuit is started using a battery.
The battery cable is connected to a large terminal on the starter.
The wiring is connected from the terminal to the engine control switch and the starter relay.
Starter
The starter is an outer gearing mesh method reduction starter adopting the magnetic shift type.
When the starter switch is turned ON, the plunger is drawn in, the contact point of the magnetic switch
closes and the armature rotates.
84402832 NA - May 2011
4001C-21
At the same time, the pinion is pushed to the front via the shift lever to mesh with the ring gear.
When the ring gear rotates, the crankshaft is turned to start the engine.
After the engine is started, the plunger returns, the pinion separates from the ring gear, and the armature
stops rotating when the starter switch is turned OFF.
When the engine rotation becomes faster than the pinion, the pinion is caused to turn in reverse, but the
pinion just idles due to the one-way clutch function, so the armature is not driven.
1 Brush holder 4 Pinion 7 Armature

2 Magnetic switch assembly 5 Clutch 8 Yoke
3 Lever assembly 6 Internal gear
Preheat system
The preheat system has adopted the QOS system glow plug type.
Also, the energization control is performed by the ECM.
84402832 NA - May 2011

4001C-22
10) Engine control system

Engine control system overview and implementation
The engine control system is an electronic control system that controls the engine to be always in the
optimal combustion state according to the driving condition, and consists of the electronic control fuel
injection system, EGR, and idling control.
Also, besides controlling the engine, the engine control system has the QOS system, engine RPM sig-
nal output, self-diagnosing function, and CAN communication SAE J1939/21 and SAE J1939/11 system
control functions.
System control schematic
The specifications vary depending on the actual unit, so refer to the manual of the actual unit.
84402832 NA - May 2011

4001C-23
Correction
Engine coolant temperature correction
Barometic Pressure
a Fuel temperture boost pressure correction
Correction between sylinder
Q-key correction
QR correction
84402832 NA - May 2011

4001C-24
Accelerator position sensor in- SCV opening time determina-

*1 *8 *15 SCV
put tion
Injector coil energizing time
*2 Boost sensor input *9 *16 Supply pump
Timing determination
*3 CKP sensor input *10 CAN communication *17 Fuel tank
*4 CMP sensor input *11 Machine control unit *18 Injector coil
*5 Engine control module (ECM) *12 Water temperture sensor input *19 Injector
*6 Basic fule injection amount *13 Common rail pressure sensor
*7 Correction *14 Common rail
Fuel injection correction

The ECM calculates the basic injection amount based on the signals from the accelerator position sensor,
boost sensor, crankshaft position sensor, camshaft position sensor, etc.
At this time, the open or close timing of the SCV and the energizing time of the injector are controlled
based on the conditions such as the common rail pressure and engine coolant temperature to make
optimal corrections to the injection timing and injection amount.
84402832 NA - May 2011

4001C-25
About initial Q correction

ECM implements the initial Q correction when the initial Q correction is under the specified engine rotation
during engine start.
Also, ECM cannot implement the initial about initial Q correction and cannot start the engine because it
does not recognize the engine rotation when it is under the engine rpm the system can recognize.
Engine speed (r/min)
*1 Idle speed
*2 Starting Q specified engine
*3 Minimum firing engine speed
Systme realization engine
*4
speed
84402832 NA - May 2011

4001C-26
About high altitude correction

ECM calculates the current altitude using signals from the atmospheric pressure sensor.
According to the conditions such as the current altitude, the fuel amount is corrected properly.
Fuel flow limit (mm3/st)
Barometric pressure kPa (psi)
*1 High/and
84402832 NA - May 2011

4001C-27
Control during overheat

To protect the engine, restriction on fuel flow is started when the engine coolant temperature exceeds 100
°C (212 °F).
When the engine coolant temperature increases further, the fuel flow is also restricted further.
When the temperature reaches 110 °C (230 °F), a failure is recorded in the ECM.
When the temperature is near 120 °C (248 °F), the fuel flow is restricted to a certain level.
The setting varies depending on the actual unit manufacturer.
The actual unit is designed to issue an alarm from 105 °C (221 °F).
By reducing the load applied to the actual unit upon alarm issuance, it is possible to avoid the operation
condition with fuel flow restriction.
Fuel flow
Water temperature
*1 Warning indication DTC set
If the ECM is equipped with an emergency stop function by a high engine coolant temperature, it stops
the engine when the temperature has reached 105 °C (221 °F).
Fuel flow
Water temperature
*1 Engine emergency stop
84402832 NA - May 2011

4001C-28
Engine emergency stop function

The ECM is designed to make an emergency engine stop when an input from the engine stop switch,
decrease in the engine oil pressure, increase in the engine coolant temperature or overrun occurs.
As for emergency stop made due to decrease in the engine oil pressure, increase in the engine coolant
temperature or overrun, the control is performed when the corresponding function is added to the calibra-
tion of the ECM.
Input from engine stop switch
The engine stops when the battery voltage is applied to the ECM terminal No. 121.
*1 Engine stop switch

*2 Starter switch (ON)
Decrease in engine oil pressure

When the engine oil pressure drops to 100 kPa (100 °C) or lower, an alarm for engine oil pressure de-
crease is issued and the engine is stopped.
Increase in engine coolant temperature When the engine coolant temperature increases to 105 °C (221
°F) or higher, an alarm for engine coolant temperature increase is issued and the engine is stopped.
Overrun
When the engine RPM reaches to the specified value, an alarm for overrun is issued and the engine is
stopped.
It varies depending on the actual unit manufacturer.
84402832 NA - May 2011

4001C-29
I/O Table
Sensor input Injection control output

• CKP sensor • Suction control valve
• CMP sensor • TWV (injector)
• Water temperature sensor
• Fuel temperature sensor
Actuator control output
• IAT sensor
• IMT sensor • EGR DC motor
• Fuel pressure sensor • Intake throttle motor
• Boost temperature sensor
• Barometric pressure sensor
Relay, lamp control output
• Accelerator position senser
• EGR position sensor • Glow relay
• Intake throttle position sensor • Starter cut relay
• DPD differential pressure sensor • ECM main relay
(1: in front of filter, 2: in front of oxidation cata- • Hour meter relay
lyst) • Fiagnosis lamp
• Boost sensor • Glow lamp
• Oil pressure sensor ECM • Engine hydraulic lamp
• MAF sensor • Boost temperature sensor pilot
• Fuel sensor lamp
• Overhead lamp
• Engine overrun lamp
Switch input
• DPD regenerate lamp
• Starter switch (ON/start) • Fuel temperature lamp
• Diagmostic swich • Fuel filter pressure lamp
• Idling control selector switch • DPD lamp
• Idling control switch (UP/Down)
• Mode map switch 0
• Mode map switch 1
• Mode map switch 2 Commumication
• Reguration mode switch
• Load advance switch • Speed signal
• SCV switch • Diagnostic scan tool
• Memory clear switch • CAN (ECU on machine side)
• Engine stop switch
• DPD switch
84402832 NA - May 2011

4001C-30
Electronic control fuel injection system

This is the system in which the ECM obtains information such as the engine RPM and engine load and
sends the electrical signals based on the information to the supply pump, injectors, etc. to properly control
the fuel injection amount and injection timing for each cylinder.
Injection amount control
To make the injection amount optimal, the fuel injection amount is controlled by regulating the injector
based on mainly the signals from the engine RPM and accelerator opening angle or the instructed rotation
from the control unit in the actual unit.
• Boost Press.
a • Coolant Temp,
• Barometiric Press.
Maximum Fuel Injection Quan-

*1 Accelerator Pedal Position *4 *7 Fuel Injection Quantity Correction
tity
*2 Engine Speed *5 Recuction Rate *8 Injector ON Time Determination
*3 Basic Fuel Injection Quantity *6 Final Fuel Injection Quantity *9 Cylinder Dry Cylinder Crrection
84402832 NA - May 2011

4001C-31
Injection pressure control

The injection pressure is controlled by regulating the fuel pressure inside the common rail.
The proper pressure inside the common rail is controlled by calculating from the engine RPM, fuel injection
amount, etc., and the appropriate amount of the fuel is discharged by regulating the supply pump to be
force-fed to the common rail.
Injection timing control
This control is performed by calculating the proper fuel injection timing mainly from the engine RPM or
injection amount in substitution for the timer function to regulate the injector.
Injection rate control
To improve combustion inside the cylinder, only a small amount of the fuel is injected first to be ignited,
and then the second injection is performed when ignition is made.
This control for injection timing and injection amount is performed through regulating the injector.
Maximum fuel injection amount
The maximum fuel injection amount is the amount of fuel injection calculated by adjustment of initial in-
jection amount under certain water temperature, limitation of maximum injection amount for the boost
pressure, and control of injection amount for the high altitude due to the atmospheric pressure.
Inter-cylinder correction
It is not used for this engine.
84402832 NA - May 2011

4001C-32
System schematic
Each sensor
a Accelerator, Boost pressure,
Water tempe rature, etc.
*1 Electromagnetic pump *5 Fuel pressure sensor *9 Injctor

*2 Fuel filter *6 Common rail *10 CMP sensor
*3 Pre filter *7 Pressure limiter *11 CKP sensor
*4 Supply pump *8 Flow damper *12 ECM
84402832 NA - May 2011

4001C-33
Fuel system
The fuel is supplied to the supply pump from the fuel tank, and then it is boosted by the pump before
supplied to the common rail.
At this time, the fuel amount to be supplied to the common rail is controlled by regulating the suction
control valve based on the signal from the ECM.
1 Electromagnetic pump 4 Fuel injector 7 Supply pump

2 Fuel filter 5 Fuel return pipe 8 Pre-fuel filter
3 Common rail 6 Fuel tank
Fuel filter clog warning function and engine RPM restriction function
When the clogged fuel filter is kept used, the ECM detects DTC P0093, and the output restriction is im-
plemented.
The first stage
In order to notify a filter clogging before DTC P0093 is detected, the first stage alarm is issued when the
output value from the fuel filter pressure sensor falls below the specified threshold value.
The alarm stops when the output value exceeds the threshold value.
The second stage
The second stage alarm is issued when the output value from the fuel filter pressure sensor falls below
the threshold value even after the first stage alarm occurs.
The second stage alarm remains as issued until the starter switch is turned OFF.
At the same time as the second stage alarm is issued, the target engine RPM is reduced gradually at a
constant rate.
When the output value from the sensor exceeds the specified threshold value, reduction of the restricted
engine RPM is stopped, and the regulation is continued maintaining the restricted engine RPM at that
time.
When the output value from the sensor falls below the threshold value again, the restricted engine RPM
is reduced further.
When the starter switch is turned OFF and then turned back ON, the restriction is once cancelled.
84402832 NA - May 2011

4001C-34
1 Supply pump 4 Monitor, CAN communication 7 Electromagnetic pump

2 Warning light 5 Fuel tank 8 Fuel filter pressure sensor
3 Monitor 6 Pre-filter 9 Main filter
84402832 NA - May 2011

4001C-35
1 First stage
2 Second stage
*1 Lamp
*2 Starter SW
*3 Engine Speed (r/min)
84402832 NA - May 2011

4001C-36
Removing air from fuel system

Place an appropriate pan under the air removal plug.
Turn the starter switch ON, and activate the electromagnetic pump.
Loose the air removal plug of the fuel filter sufficiently, and operate the priming pump 20 times or more
until the fuel comes out from near the plug.
Tighten the plug, and operate the priming pump 10 times or more until the fuel permeates.
Wait for approx. 1 minute, and then loosen the plug to remove the air in the fuel filter.
This should be repeated at least 3 times until no air comes out from the plug.
Securely tighten each plug, and wipe off the fuel spilled around.
Operate the priming pump 10 - 15 times until the fuel permeates and then is fed to the engine.
a On the machine with electro-

magnetic pump
*1 Pre fuel filter

*2 Electromagnetic pump
*3 Fuel filter
*4 Supply pump
84402832 NA - May 2011

4001C-37
EGR
The EGR system recirculates a part of the exhaust gas to the intake manifold, and by mixing in inert gas
to the intake air, the combustion temperature is lowered and the generation of NOx is suppressed.
The EGR amount is controlled by opening and closing the EGR valve provided between the exhaust
manifold and intake manifold.
The EGR amount is determined from the engine RPM and engine load ratio and the EGR valve is operated
to control the EGR amount.
By installing the EGR cooler on the path of the EGR gas, high-temperature gas is cooled by the EGR
cooler and then mixed with fresh air to further lower the burning temperature in order to reduce NOx
amount.
Further, the EGR system is also equipped with a check valve to prevent the EGR from flowing in the
opposite direction to increase the EGR amount.
EGR control
The ECM controls the EGR valve lift amount by operating the motor according to the engine status such
as the engine RPM and engine load.
The valve lift amount is detected by the EGR position sensor.
Darker portions in the diagram represent large valve lift amounts and the darkest portion represents the
lift
amount of nearly 100 %.
Accelerator position
Engine speed
*1 No idle EGR
84402832 NA - May 2011

4001C-38
EGR system schematic diagram
*1 Intake thottle position sensor *7 Engine speed *13 Exhaust

*2 EGR valve *8 Engine load *14 Intake throttle valve
*3 EGR position sensor *9 Outlet port of coolant *15 Boost temperature sensor
*4 ECM *10 Inlet port of coolant *16 Boost sensor
*5 IAT/MAF sensor *11 EGR cooler
*6 Intake air *12 IMT sensor
84402832 NA - May 2011

4001C-39
EGR and turbine noise

Some engines may generate high frequency noise due to the turbine rotation.
This high frequency noise can be muted using an appropriate silencer.
For some OEMs which use in residential areas is not assumed, the silencer for muting the high frequency
noise may be omitted from the specifications, leaving the noise.
The high frequency noise tends to become lower while controlling the EGR and louder when EGR control
is not provided.
*1 Without EGR
*2 Wiht EGR
Turbocharger control
The turbocharger is a system that provides efficient supercharge to archive the turbo effect by overcoming
the turbo's weakness of low exhaust energy during low engine revolution.
The turbocharger optimizes the turbine revolution by varying the nozzle opening angle within the turbine
housing to adjust the turbo inlet area according to the revolution and load of the engine and control the
supercharging pressure.
The ECM sends the target nozzle opening angle based on the information from each sensor to the tur-
bocharger through CAN communication to control the boost pressure properly in accordance with the
engine load requirements.
The turbocharger drives the actuator based on the information received from the ECM and controls the
nozzle opening angle through the control rod.
*1 ECM *4 Actuator with built-in ECU *7 Exhaust gas outlet

*2 CAN communication *5 Nozzle closing direction *8 Turbine wheel
*3 Control rod *6 Exhaust gas inlet *9 Nozzle
84402832 NA - May 2011

4001C-40
Engine operation control

There are the following 4 types of operation control instructions, and the selection varies depending on
each specification.
Voltage input by APS, 1 - 4 V
Accelerator opening angle instruction given through CAN communication control, 0 - 100 %, RPM instruc-
tion RPM instruction given through mode map switch control, RPM instruction and change instruction
given by APS Increase and decrease instruction for each rotation given by the idle switc
Mode map switch
The mode map switch has 6 rotation control mode types of H, S, L, B, I and LM.
The rotation settings are H > S > L > B, I > LM.
For H, S, L and B, the rotation speed can be decreased by the APS
However, any change cannot be made from the APS for I and LM.
When the regulation mode switch input is present in addition to the mode map switch, the following 2
types of control methods are available.
*1 Directed speed
*1 Directed speed
84402832 NA - May 2011

4001C-41
H, S, L and B of the mode map switch change as follows depending on the APS input.
Meaning of mode map switch and each mode In the APS, a change toward the engine RPM decrease
direction can be made from each mode point.
The specified engine RPM for H, S, L and B are determined depending on the calibration of the ECM.
CAN communication
When CAN controller does not exist on the actual unit side
*1 Diagnostic scan tool

*2 MCX
*3 ECM
*4 LCD
*5 TCM
*6 Shift Control
84402832 NA - May 2011

4001C-42
When CAN controller exists on the actual unit side
*1 Diagnostic scan tool

*2 MCX
*3 ECM
*4 TCM
*5 Shift Control
Mode map switch control
*1 Accelerator position sensor *5 Idle down switch *9 Reguration mode switch

*2 Engine stop switch *6 Mode map switch 0 *10 Load advance switch
*3 Idling selector switch *7 Mode map switch 1
*4 Idle up switch *8 Mode map switch 2
84402832 NA - May 2011

4001C-43
Outer switch Control

Operation mode
MAP0 MAP1 MAP2
H OFF OFF OFF Basic operations
OFF ON ON
ON ON ON
S ON OFF OFF Maximum rotation count control #1
L OFF ON OFF Maximum rotation count control #2
I OFF OFF ON Constant rotation operation #1
B ON ON OFF Maximum rotation count control #3
LM ON OFF ON Constant rotation operation #2
I, LM and H modes
*1 Regulation mode switch

*2 Idle speed
*3 Max. speed
H, S, L, and B modes
*1 Idle speed
*2 Max. speed
84402832 NA - May 2011

4001C-44
H, S, L, and B modes (irrigation pump)
*1 Idle speed
*2 Max. speed
Accelerator position switch

By operating the accelerator position switch, the output voltage changes between 1 V and 4 V.
Voltages between 0.2 V and 1.05 V are recognized as 1 V.
When the voltage is lowered below 0.2 V or raised above 1.05 V, an error is detected.
In addition, if the ECM terminals 85 and 86 are not at the same potential, DTC P2138 is detected.
Accelerator pedal position sen-

*1
sor
84402832 NA - May 2011

4001C-45
Accelerator position switch, with APS learning control If the APS learning control is available, for example,
when the ignition cycle ends with the accelerator position as 2 V (1), the accelerator position learning
causes the 2 V status to be recognized as the opening angle 0 % and the control range is set to 2 V to 4
V (2).
Regulation mode switch

When an input from the regulation mode switch is present, the engine RPM changes as follows.
*1 Regulation mode switch
84402832 NA - May 2011

4001C-46
Idling control
By operating the idling control change switch during the warm-up operation, the minimum idling RPM can
be adjusted.
In addition, by operating the idling control change switch, the minimum idling RPM can be automatically
set to the optimum value in accordance with the engine coolant temperature.
ANNOTATION:
• The specifications vary depending on the actual unit, so availability of functions also differ.
Idling control change switch
By operating the idling control change switch, the idling control functions can be switched.
The idling control switch
By operating idling control switch, the idling RPM can be adjusted.
ANNOTATION:
• As for the installation positions of the idling control change switch and idling control switch, refer to the
manual of the actual unit.
The engine RPM upper limit varies depending on the engine model, actual unit specifications and engine
warming-up condition.
Up
While the Up side of the switch is pressed, the engine RPM is increased and the idling RPM can be raised.
Down
While the Down side of the switches is pressed, the engine RPM is decreased and the idling RPM can
be lowered.
However, the engine RPM cannot be decreased below the minimum idling RPM.
Control during starter switch OFF state
There are 2 types of controls provided when the starter switch is turned OFF after the idling control switch
is operated, and either one of them is performed depending on the specification.
The engine RPM adjusted by the idling control switch is recorded in the ECM, and the next operation is
performed with the engine RPM at the time when the starter switch is turned OFF.
The engine RPM adjusted by the idling control switch is not recorded in the ECM, and the next operation
is performed with the default engine RPM.
As for confirmation and questions regarding the specifications, contact an Isuzu service related person.
Idle manual control
*1 Starter switch *3 Idle down switch

*2 Idle up switch *4 Engine speed
84402832 NA - May 2011

4001C-47
Engine RPM output to tachometer

The ECM outputs the engine rpm pulse to the tachometer as a tachometer output.
The tachometer displays the engine RPM based on the engine RPM pulse sent from the ECM.
a Output from machine control

unit by machine
*1 CKP sensor *4 CAN communication *7 Tachometer

*2 Engine speed *5 Control unit on machine side
*3 Engine control module (ECM) *6 Tachometor output
Preheat control
QOS system
The ECM determines the glow time according to the engine coolant temperature, and activates the glow
relay and the QOC indicator light.
The QOS system is a system to facilitate engine start in a low temperature as well as reducing the amount
of white smoke and noise generated immediately after engine start.
When the starter switch is turned ON, the ECM detects the temperature of the engine coolant based on
the signal sent from the water temperature sensor to change the glow time, so the engine can be always
started under the optimum conditions.
Also, the after-glow function can stabilize the idling immediately after engine start.
a LCD or Lamp
*1 Starter switch (ON) *4 QOS indicator lamp *7 Glow plug

*2 Battery *5 (ECM)
*3 Glow relay *6 Water temperature sensor
84402832 NA - May 2011

4001C-48
DPD
DPD uses the oxidation catalyst to clean NOx and HC, and uses a dedicated filter to collect PM emitted
from the engine.
When PM has accumulated on the filter, the filter regeneration is performed.The ECM detects the accu-
mulation status of PM from the DPD differential pressure sensor or mileage.
When the accumulated amount of PM or mileage has reached a certain value, automatic regeneration of
the filter is performed.
During regeneration, the filter is heated up to burn the accumulated PM.
To adjust the burning temperature to the optimum value, the ECM detects the exhaust temperature using
the the exhaust temperature sensor and control fuel injection to raise the temperature to burn the accu-
mulated PM.
When regeneration has started, it must complete within a certain period of time.
After regeneration has completed, the purification status of the filter can be determined by checking the
exhaust differential pressure.
When excessive amount of accumulated PM has been detected, regeneration is not performed because
burning cannot be controlled, but the check engine warning light is turned ON instead.
84402832 NA - May 2011

4001C-49
1 Engine 5 ECM 9 Oxidation catalyst

2 MAF sensor 6 DPD switch 10 Exhaust gas temperature sensor
3 Air cleaner 7 Silencer 11 DPD differential pressure sensor
4 Various sensors 8 Filter
84402832 NA - May 2011

4001C-50
ECM
About ECM function
The ECM constantly monitors the information sent from various sensors, and controls the each system
of the powertrain.
The ECM performs the diagnostic functions of the system, detects operational problems of the system,
warns the operator via the monitor, and records the DTC.
The DTC identifies the area where the problem has occurred to assist the repair operation performed by
the technician.
The ECM outputs voltages (e.g., 5 V) to supply power to various sensors and switches.
The ECM controls the output circuit by controlling the ground or power supply circuit via one of the devices.
ANNOTATION:
• As for the ECM installation position, refer to the manual of the actual unit.
ECM and components

The ECM is designed to maintain regulation levels of exhaust gases while obtaining excellent fuel effi-
ciency.
The ECM monitors various engine functions via the sensors such as the crankshaft position sensor.
ECM voltage
The ECM applies the standard voltage to various switches and sensors.
The ECM is able to apply voltage in such a way because the ECM resistance value is very high.
The voltage that is actually applied to the circuit is low.
Therefore, the test light may not illuminate even if it is connected to the circuit.
The voltmeter that is normally used at maintenance factories may not display a correct reading because
its input impedance is too low.
An accurate voltage reading can be obtained by using a digital multimeter with an input impedance of
10MΩ (for example, 5-8840-2691-0).
Electrically Erasable Programmable Read Only Memory, EEPROM
EEPROM contains various programs and calibration information necessary for the ECM to control the
power train operations.
If abnormalities are found with the EEPROM, replace the ECM.
The program and calibration information for the ECM power train control includes the engine type, engine
number, ECM part number, DTC, inter-cylinder correction learning value, QR, Q tune, and EGR correction
learning value.
Notes on ECM maintenance
The ECM has been designed to withstand the regular current consumption associated with the actual unit
operation.
Make sure that the circuit does not overload.
When performing tests for an open circuit or short circuit, do not ground or apply voltage to the circuit of
the ECM, unless otherwise instructed.
When performing these circuit tests, make sure to use the digital multimeter 5-8840-2691-0.
ANNOTATION:
• Use the ECM which has the part No. corresponding to the actual unit.
When performing welding work on the actual unit, start the work after disconnecting the negative ter-
minal of the battery.
Turning OFF of the ECM power supply
In approximately 10 seconds after turning the starter switch to OFF, the internal power supply of the ECM
is not turned to OFF.
84402832 NA - May 2011

4001C-51
When it is necessary to turn OFF the ECM power supply, e.g., when clearing the memory, it is required
to wait for 10 seconds or longer after turning the starter switch OFF.
*1 Starter switch ON
*2 Starter switch OFF
84402832 NA - May 2011

4001C-52
Engine components location diagram

Locations, shapes and existence or nonexistence of components vary depending on the specifications of
the actual unit.
1 Overheat switch 6 Boost temperature sensor 11 Oil pressure sensor

2 Water temperature sensor 7 IMT sensor 12 Oil level switch
3 Glow plug 8 Fuel temperature sensor 13 Fuel pressure sensor
4 Injector 9 Suction control valve 14 EGR valve
5 Boost sensor 10 CKP sensor 15 CMP sensor
84402832 NA - May 2011

4001C-53
Supply pump
The supply pump highly pressurizes the fuel using the engine torque, and force-feeds the fuel to the
common rail.
Also, the suction control valve, fuel temperature sensor, feed pump, etc, are installed on the supply pump.
1 Fuel temperature sensor

2 Suction control valve
3 Feed pump
84402832 NA - May 2011

4001C-54
Suction control valve

The suction control valve is installed on the supply pump portion, and controls the fuel force-feed to the
common rail.
The ECM controls the fuel discharge amount by regulating the energizing time to the suction control valve.
84402832 NA - May 2011

4001C-55
Fuel temperature sensor

The fuel temperature sensor is installed on the supply pump, and the thermistor changes the resistance
value according to the temperature change.
The resistance value becomes lower when the fuel temperature is high, and it becomes higher when the
fuel temperature is low.
The ECM applies 5 V to the fuel temperature sensor through the pull-up resistor, and it calculates the fuel
temperature from changes in the voltage and uses it for controlling the supply pump, etc.
The voltage becomes lower when the resistance is lower, and it becomes higher when the resistance is
higher.
ANNOTATION:
• Do not replace the fuel temperature sensor.
When an abnormality is found, replace the supply pump assembly.
84402832 NA - May 2011

4001C-56
Common rail
The common rail receives the fuel from the supply pump, retains the fuel pressure and distributes the fuel
to each cylinder.
The fuel pressure sensor, flow damper and pressure limiter are installed on the common rail.
1 Flow damper
2 Pressure limiter
3 Fuel pressure sensor
4 Common rail
Flow damper
The flow damper is installed to the discharge port on the common rail leading to each injector, and regu-
lates the pressure pulsation in the common rail and prevents excess fuel injection from the injector.
When the flow damper is activated, fuel supply to the injector is stopped.
1 Flow damper
Pressure limiter
The pressure limiter is activated when the pressure in the common rail becomes abnormally high to re-
lease the pressure inside the common rail.
84402832 NA - May 2011

4001C-57
1 Pressure limiter
84402832 NA - May 2011

4001C-58
Fuel pressure sensor

The fuel pressure sensor is installed on the common rail, and detects the fuel pressure inside the common
rail to convert into the voltage signal and sends it to the ECM.
The voltage becomes higher when the pressure is higher, and it becomes lower when the pressure is
lower.
The ECM calculates the actual fuel pressure from the voltage signal sent from the sensor, and uses it to
control the fuel injection, etc.
1 Fuel pressure sensor
Injector
The injector is installed on the cylinder head portion, and is controlled by the ECM to perform fuel injection.
The ECM internally boosts the voltage for driving the injector to apply it to the injector, and uses it for fuel
injection amount control and injection timing control by regulating the energizing time of the injector.
84402832 NA - May 2011

4001C-59
Water temperature sensor

Water temperature sensor is installed on the engine block, and the thermistor changes the resistance
value according to the temperature change.
The resistance value becomes smaller when the engine coolant temperature is high, and the value be-
comes larger when the engine coolant temperature is low.
The ECM applies 5 V to the water temperature sensor through the pull-up resistor, and calculates the
engine coolant temperature from changes in the voltage.
This value is used in various control mechanisms, such as for fuel injection control.
The voltage becomes higher when the resistance is higher, and it becomes lower when the resistance is
lower.
Overheat switch
The overheat switch is installed on the water outlet pipe, and is turned ON when the engine coolant
temperature exceeds 105 °C (221 °F).
Crankshaft position sensor

The crankshaft position sensor is installed on the flywheel housing and the CKP signal is generated every
time when the protruding section of the flywheel passes the sensor.
The ECM determines the cylinder and specifies the crank angle using the CMP signal input from the
camshaft position sensor, and uses the information for the fuel injection control and calculation of the
engine RPM.
While this control is usually performed using the CKP signal, the CMP signal is used instead when the
crankshaft position sensor is faulty.
84402832 NA - May 2011

4001C-60
Camshaft position sensor

The camshaft position sensor is installed behind the cylinder head, and generates a CMP signal when
the camshaft cam passes by it.
The ECM determines the cylinder and specifies the crank angle using the CMP signal input from the
camshaft position sensor, and uses the information for the fuel injection control and calculation of the
engine RPM.
While this control is usually performed using the CKP signal, the CMP signal is used instead when the
crankshaft position sensor is faulty.
1 Camshaft gear
2 Rotational direction
3 CMP sensor
Oil pressure sensor

The oil pressure sensor is installed near the starter motor of the cylinder block, and it detects the pressure
of the engine oil to convert into the voltage signal and send it to the ECM.
lower.
Accelerator position sensor

The accelerator position sensor is installed on the console panel of the actual unit to supply the voltage
signal which varies in accordance with the accelerator volume angle to the ECM.
The ECM calculates the trottle accelerator switch position from the voltage signal, and uses it for fuel
injection control and many other controls.
ANNOTATION:
• As for the installation position of the accelerator position sensor, refer to the manual of the actual unit.
84402832 NA - May 2011

4001C-61
Atmospheric pressure sensor

The atmospheric pressure sensor is installed on the actual unit side, and it replaces the atmospheric
pressure with the voltage signal.
The ECM calculates the atmospheric pressure from the voltage signal, and uses the atmospheric pres-
sure to correct the fuel injection amount.
ANNOTATION:
• As for the installation position of the atmospheric pressure sensor, refer to the manual of the actual unit.
EGR position sensor

This sensor is installed inside the EGR valve to detect the EGR valve lift amount.
ANNOTATION:
• Do not disassemble the EGR position sensor.
When an abnormality is found, replace the EGR valve assembly.
Boost sensor
The boost sensor detects the boost using the pressure hose between the boost sensor and intake pipe
to convert into the voltage signal and sends it to the ECM.
lower.
The ECM calculates the boost from the voltage signal sent from the sensor, and uses it to control the fuel
injection, etc.
84402832 NA - May 2011

4001C-62
84402832 NA - May 2011

4001C-63
The boost temperature sensor

The boost temperature sensor is installed to the EGR valve upstream side of the intake manifold.
The sensor is the thermistor type, and the resistance value inside the sensor changes in accordance with
the change in the temperature.
Fuel filter pressure sensor

The fuel filter pressure sensor is installed on the fuel filter, and converts the negative pressure in the fuel
filter into the voltage signal.
The ECM calculates the negative pressure in the fuel filter based on the voltage signal to determine clog-
ging in the fuel filter.
84402832 NA - May 2011

4001C-64
Intake air temparture and mass air flow sensors

Intake air temperature sensor
The intake air temperature sensor is installed on the duct between the air cleaner and turbocharger.
The intake air temperature sensor is variable resistance inside the mass air flow sensor to measure the
temperature of air taken into the engine.
When the intake air temparture sensor is cold, the resistance of the sensor is high.
When the air temperature rises, the resistance of the sensor becomes low.
For high sensor resistance, the ECM detects a high voltage of the signal circuit.
For low sensor resistance, the ECM detects a low voltage of the signal circuit.
Mass air flow sensor
The mass air flow sensor measures the amount of air taken into the engine, and it is installed on the duct
between the air cleaner and turbocharger.
The mass air flow sensor consists of the mass air flow sensor and intake air temperature sensor to mea-
sure some of air flowing in the duct.
A small amount of air taken into the engine indicates deceleration or idle RPM.
A large amount of air indicates acceleration or high load.
Intake throttle valve
The intake throttle valve is installed on the inlet of the inlet manifold.
The ECM controls the opening angle of the intake throttle valve according to the condition of engine
operation.
The motor inside the intake throttle valve is controlled based on the duty ratio signals sent from the ECM.
The opening angle of the intake throttle valve is adjusted when the duty ratio is changing from 0 % to the
appropriate ratio.
The valve closes when the duty signal increases, and the valve opens when the duty signal decreases.
The opening angle of the intake throttle valve is detected by the position sensor.
The position sensor outputs the signal representing the intake throttle valve opening angle.
The ECM detects a low signal voltage when the opening angle is small or the valve is at the closed
position.
Also, the ECM detects a high signal voltage when the opening angle is large.
84402832 NA - May 2011

4001C-65
DPD differential pressure sensor

The DPD differential pressure sensor is installed near DPD.
DPD differential pressure sensor varies the signal voltage according to changes of the exhaust gas dif-
ferential pressure between in front and rear of DPD filter.
he ECM detects a lower signal voltage when the differential pressure is small due to a small amount of
accumulated PM.
The ECM detects a higher signal voltage when the differential pressure is large due to a large amount of
accumulated PM.
The ECM uses this voltage signal for controlling DPD regeneration and determining purification after re-
generation.
It also uses the signal voltage to detect filter failures such as a too low differential pressure.
Exhaust gas temperature sensor

The exhaust gas temperature sensors are the variable resistors that are installed at 2 locations on the
DPD housing, and one is installed in front of the DPD oxidation catalyst, and the other is installed in front
of the filter.
The exhaust gas temperature sensor 1 that is located in front of the filter measures the temperature of the
exhaust gas before entering the DPD filter, and the exhaust gas temperature sensor 2 that is located in
front of the oxidation catalyst measures the temperature of the exhaust gas before entering the oxidation
catalyst.
When the exhaust gas temperature sensor is cold, the resistance of the sensor is high.
When the exhaust temperature rises, the resistance of the sensor decreases.
The ECM detects a high voltage in the signal circuit when the sensor resistance is high.
Also, the ECM detects a low voltage in the signal circuit when the sensor resistance is low.
The ECM uses this voltage signal for temperature control during the DPD regeneration.
84402832 NA - May 2011

4001C-66
IMT sensor
The IMT sensor is a variable resistance installed on the intake manifold to measure the intake temperature
of the intake manifold.
When the sensor is cold, the sensor resistance is high.
When the intake temperature rises, the sensor resistance decreases.
For low sensor resistance, the ECM detects a low voltage of the signal circuit.
Turbocharger
The turbocharger has an actuator with built-in control unit installed.
The opening angle of the turbocharger variable nozzle is driven by the actuator.
The built-in control unit performs CAN communication, and the ECM performs control that changes the
boost pressure by adjusting the nozzle opening angle in accordance with the load requirement for the
engine.
*1 Turbo actuator
84402832 NA - May 2011

4001C-67
Monitor
By turning ON the diagnostic switch, the DTC is indicated by blinking.
ANNOTATION:
• As for the installation position of the monitor, refer to the manual of the actual unit.
DLC
DLC is the connector for communication and connection between the trouble diagnosis scanning tool and
various controllers.
ANNOTATION:
• As for the DLC installation position, refer to the manual of the actual unit.
84402832 NA - May 2011

4001C-68
Diagnostic switch
The diagnostic switch shorts the DLC terminal No. 1 and No.4 or No.5 and flashes the monitor to indicate
the DTC.
ANNOTATION:
• As for the installation position and shape of the diagnostic switch, refer to the manual of the actual unit.
Memory clear switch
This is used when clearing the recorded DTCs in the ECM by operating the diagnostic switch and the
memory clear switch.
ANNOTATION:
• As for the installation position of the memory clear switch, refer to the manual of the actual unit.
Mode change switch (0, 1, 2)
The operation can be performed at the engine RPM specified for each mode by switching the mode
change switch.
ANNOTATION:
• As for the installation position of the mode change switch, refer to the manual of the actual unit.
1 Starter switch
2 Engine stop switch
3 Fuel meter
4 Memory clear switch
5 Mode switch
6 Water temperature gauge
7 Oil temperature gauge
8 Hour meter
84402832 NA - May 2011

4001C-69
ECM power distribution diagram Some sensors may not be connected to the ECM depending on the
specifications of the actual unit.
Since some sensors may perform input/output with the ECM depending on the CAN communication, con-
firm the specifications of the actual unit.
84402832 NA - May 2011

4001C-70
84402832 NA - May 2011

4001C-71
Accelerator pedal position sen-

*1 *18 Memory clear switch *35 Power ground
sor
*2 BARO sensor *19 diagnosis switch *36 Power ground
*3 *20 MAF sensor *37 Power ground
sor
*4 fuel filter pressure sensor *21 IAT sensor *38 Power ground
Exhaust temperature sensor 1
*5 *22 CKP sensor *39 diagnosis lamp
(in front of filter)
*6 Exhaust temperature sensor 2 *23 Fuel pressure sensor *40 Oil pressure lamp
*7 Engine stop switch *24 Starter switch (ON) *41 Glow plug lamp
*8 Idling selector switch *25 Starter switch (START) *42 Boost temperature lamp
*9 Idle up switch *26 Main relay *43 Over heat lamp
*10 Idle down switch *27 Starter switch *44 Engine over run lamp
*11 Mode map switch 0 *28 Battery *45 DPD regemerate lamp
*12 Mode map switch 1 *29 Dropping resistor *46 Fuel temperature lamp
*13 Mode map switch 2 *30 Case ground *47 Fuel filter pressure lamp
*14 Reguration mode switch *31 Signal ground *48 DPD lamp
*15 Load advance switch *32 Signal ground *49 Glow relay
*16 DPD regeneration switch *33 Power ground *50 Glow plug
*17 SCV switch *34 Power ground *51 ECM
84402832 NA - May 2011

4001C-72
84402832 NA - May 2011

4001C-73
*1 Boost sensor *10 Starter cut relay *19 Intake thrttle motor
*2 EGR position sensor *11 Hour meter relay *20 Fuel injector 1 (Cylinder #1)
*3 Intake throttle position sensor *12 Starter *21 Fuel injector 1 (Cylinder #3)
*4 Fuel temperature sensor *13 Tacho meter *22 Fuel injector 1 (Cylinder #2)
*5 CMP sensor *14 TOOL *23 Fuel injector 1 (Cylinder #5)
*6 Boost temperature sensor *15 OEM unit *24 Fuel injector 1 (Cylinder #6)
*7 Oil pressure sensor *16 Terminator *25 Fuel injector 1 (Cylinder #4)
*8 Water temperature sensor *17 Turbo unit *26 Suction control valve
*9 IMT sensor *18 EGR DC motor *27 ECM
84402832 NA - May 2011

4001C-74
ECM pin assignment
60 pin connector
Pin No. Pin name Connection

1 OP-COM1A Injector power supply 1, First cylinder
2 OP-COM1B Injector power supply 1, Third cylinder
3 OP-COM1C Injector power supply 1, Second cylinder
4 - -
OM-EBM3
5 valve DC servomotor power input W
EGR
6 SP-5V4 Boost sensor power supply
7 SP-5V8 -
8 IA-MAT IMT sensor signal
9 IA-THL Fuel temperature sensor signal
10 IA-THBST Boost temperature sensor signal
11 IA-PFUEL Fuel pressure sensor signal
12 IA-OILPRESS Oil pressure sensor signal
84402832 NA - May 2011
4001C-75

13 IA-MAP Boost sensor signal
14 IA-IDMPOS Intake throttle position sensor signal
15 OP-SCVHI SCV-HI drive
16 OP-COM2A Injector power supply 2, Fifth cylinder
17 OP-COM2B Injector power supply 2, Sixth cylinder
18 OP-COM2C Injector power supply 2, Fourth cylinder
19 - -
20 OM-EBM2 EGR valve DC servomotor power input V
21 SP-5V5 Crankshaft position sensor, fuel pressure sensor power supply
22 SP-5V6 Camshaft position sensor power supply
23 SP-5V7 Oil pressure sensor power supply
24 - -
25 IA-THW Water temperature sensor signal
Boost sensor, EGR position sensor, intake throttle position sensor, fuel temperature sensor
26 SG-5VRT4
GND
27 - -
28 SG-SLD5 Crankshaft position sensor shield
29 IA-OPLO -
30 OP-SCVHI SCV-HI drive
31 OS-INJ1 Injector 1, First cylinder
32 OS-INJ5 Injector 5, Second cylinder
33 OS-INJ4 Injector 4, Sixth cylinder
34 - -
35 OM-EBM1 EGR valve DC servomotor power input U
36 - -
37 - -
38 - -
39 - -
40 SG-5VRT7 Oil pressure sensor, water temperature sensor GND
41 SG-5VRT5 Intake air temperature sensor, crankshaft position sensor, fuel pressure sensor GND
42 SG-5VRT6 Camshaft position sensor, boost temperature sensor GND
43 SG-SLD6 Camshaft position sensor GND
44 - -
45 IA-SCVLO SCV-LO drive
46 OS-INJ3 Injector 3, Third cylinder
47 OS-INJ6 Injector 6, Fourth cylinder
48 OS-INJ2 Injector 2, Fifth cylinder
49 OM-IDM1 Intake throttle motor, +
50 OM-IDM2 Intake throttle motor, -
51 - -
52 IS-EBMPOS1 EGR position sensor signal U
53 IS-EBMPOS2 EGR position sensor signal V
54 IS-EBMPOS3 EGR position sensor signal W
55 SG-5VRT8 IMT sensor GND
56 IF-CAM Camshaft position sensor signal
57 IF-CRANK Crankshaft position sensor signal
58 SG-SLD8 Fuel pressure sensor shield
59 - -
60 IA-SCVLO SCV-LO drive
94 pin connector

61 PG-POWER GND
62 PG-POWER GND
63 PG-POWER GND
64 PG-POWER GND
65 PG-POWER GND
84402832 NA - May 2011
4001C-76

66 PG-POWER GND
67 PS-+B Power supply
68 SP-5V1 Accelerator position sensor power supply
69 SP-5V2 Atmospheric pressure sensor power supply
70 SP-5V3 DPD differential pressure sensor, fuel filter pressure sensor power supply
71 - -
72 CC-KW2000 Data link connector
(CC- -
73
BOOTRX)
74 - -
75 - -
76 - -
77 - -
78 - -
79 IA-THE1 Exhaust gas temperature sensor 1 signal
80 IA-THE2 Exhaust gas temperature sensor 2 signal
81 IA-IAT Intake air temperature sensor signal
82 IA-MAF Mass air flow sensor signal
83 IA-FIPRESS Fuel filter pressure sensor signal
84 IA-EXHP DPD differential pressure sensor signal
85 IA-ACCEL1 Accelerator pedal position sensor 1 signal
86 IA-ACCEL2 Accelerator pedal position sensor 2 signal
87 IA-BARO Atmospheric pressure sensor signal
88 CC-ISOCAN-L ISO CAN-Low
90 SG-5VRT1 Accelerator position sensor GND
91 - -
92 - -
93 - -
94 - -
(CC- -
95
BOOTTX)
96 (MOD1) -
97 PG-SIGN GND
98 - -
99 IS-SCVSW SCV switch signal
100 IS-START Starter switch start signal
101 IS-LOAD Load advance switch signal
102 IS-REG Regulation mode switch signal
103 IS-SWLO1 -
104 IS-IDLMNL Idling control change selector switch signal
105 IS-MDMAP0 Mode map switch 0 signal
106 IS-IDLUP Idling control switch Up signal
109 IS-IDLDWN Idling control switch Down signal
CC-ISO-
110 ISO CAN-High
CAN-H
DPD differential pressure sensor, fuel filter pressure sensor, exhaust gas temperature sen-
112 SG-5VRT3
sor 1, exhaust gas temperature sensor 2 GND
113 SG-12VRT Mass air flow sensor GND
114 OS-MAINR ECM main relay
115 SG-SLD1 Accelerator position sensor shield
116 - -
117 SP-12V Mass air flow sensor power supply
118 - -
119 PG-SIGN GND
84402832 NA - May 2011

4001C-77

120 - -
121 IS-ENGSTP Engine stop switch signal
122 IS-DPDREG DPD switch
123 OS-OVRL Engine overrun light
124 OS-OILPL Engine oil pressure light
125 OS-BOOSTL Boost temperature sensor pilot light
126 OS-OVHL Overheat light
127 OS-OPL1 -
128 OF-TACHO Tachometer
129 OS-DPDREG DPD regeneration light
130 OS-DIAGL Moniter
131 OS-EGRTL -
132 CC-CAN-L CAN-Low
134 IS-IGKEY Starter switch ON signal
135 SG-5VRT2 Atmospheric pressure sensor GND
136 OS-MAINR ECM main relay signal
137 PG-CASE GND
138 - -
139 PS-MAFBAT dropping resistor
140 IS-SWHI1 -
141 IS-DIAG Diagnostic switch signal
142 IS-MEMCL Memory clear switch signal
143 IS-DGSEL Diagnostic switch signal
144 IS-SWHI2 -
145 OS-GLOWL Glow light
146 OS-OPL2 -
OS-FI-
147 Fuel filter clogging light
PRESSL
148 OS-THLL Fuel temperature light
149 OS-DPDSL DPD light
150 OS-HOUR Hour meter relay
151 - -
152 OS-STARTR Starter cut relay
153 OS-GLOWR glow relay
154 CC-CAN-H CAN-High
84402832 NA - May 2011

4001C-78
Section
4001E
Symptom
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Frequent DPD regeneration by manual regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Long DPD regeneration time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine start failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine stalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine hunting, rough idling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Excessive white smoke in the exhaust gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Excessive black smoke in the exhaust gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Abnormal noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Large fuel consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Large oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Insufficient engine output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Symptom
Frequent DPD regeneration by Inspect the hose and pipe of the DPD differential
pressure sensor for clogging, collapsing, or twist-
manual regeneration ing.
Inspect the DPD differential pressure sensor for
1. DPD system manual regeneration frequently De-
incorrect installation.
scription of Symptom
The manual regeneration is frequently requested by
damage.
blinking the DPD manual regeneration lamp or indi-
cating Press DPD switch.
contamination and foreign materials which inter-
Or, it is requested more frequently than before.
fere with its inlet.
{Automatic regeneration cannot be performed fre-
Check the DPD differential pressure sensor for
quently}
abnormalities and operation delay with the scan
ANNOTATION: tool data display exhaust differential pressure.
Check the exhaust temperature sensor at vari-
• Depending on the manufacturer of the actual unit, ous temperatures, and inspect for the possibility
the indication may not be shown. of sensor abnormalities.
2. DPD system manual regeneration frequently Diag- Check the mass air flow sensor for abnormalities
nostics and operation delay with the scan tool data dis-
play MAF.
• Preliminary inspection Check the boost pressure and atmospheric pres-
Inspect the fuel quality. sure when the starter switch is ON and the engine
Inspect the engine oil level and quality. is not started.
Inspect whether the hourmeter operates correctly. It is normal if both data displays are within 7.0 kPa
If excessive amount of black smoke is observed, {0.07 kgf/cm2 / 1.0 psi}.
inspect the black smoke. • Inspection of the air intake system
Inspect the inside of the DPD filter for excessive Inspect the air cleaner and air intake duct for clog-
ash deposits. ging, holes, and leakage.
Check the scan tool data list. Inspect whether a condition exists where the flow
Check the service technical report. in the turbocharger inlet duct is restricted.
Confirm the ECM carry part number. Inspect the intake throttle valve for anchoring.
Check the operator's operating habits and condi- Inspect the inside of the intake manifold for clog-
tions. ging or air leaks.
Recommend the owner to voluntarily carry out re- Inspect the air intake system for modification.
generation as necessary. Inspect the mass air flow sensor for contamination
Check whether the idling time is too long under and damage.
the normal operation conditions. Inspect the turbocharger turbine wheel, shaft, or
Check whether operation is frequently performed compressor wheel for wear and damage.
at low speed under the normal operation condi- • Inspection of the exhaust system
tions. Inspect for any condition that restricts the flow of
Check whether long downhill working is per- the exhaust system.
formed under the normal operation conditions. Inspect for absence or damage of the exhaust
Check whether the idling time is too long in DPD system gasket.
regeneration. Inspect for exhaust gas leakage from the exhaust
Check whether operation is frequently performed pipe, gasket, DPD, exhaust temperature sensor,
at low speed in DPD regeneration. and DPD differential pressure sensor's hose and
Check whether PTO is activated frequently and pipe.
for long period of time in DPD regeneration. Inspect the exhaust system for modification.
Check whether the engine operating time is short Inspect the inside of the DPD filter for excessive
in DPD regeneration. ash deposits.
Check whether accelerator is switched frequently Inspect the DPD filter for damages, cracks, melt
between ON and OFF in DPD regeneration. and excessive deposits.
• Inspection of the sensor Inspect the oxidation catalyst for damages,
Inspect the hose and pipe of the DPD differen- cracks, melt and excessive deposits.
tial pressure sensor for incorrect piping or if they If any excessive white smoke is observed in the
came off. regeneration process, the oxidation catalyst may
{The hose of the DPD differential pressure sensor be deteriorated or damaged.
has a specified installation direction}
84402832 NA - May 2011

4001E-3
Symptom
Long DPD regeneration time • Inspection of the cooling system

Inspect the engine coolant level.
1. DPD system regeneration long time Description of Inspect the engine coolant leakage.
Symptom Inspect the cooling fan belt slip.
The regeneration requires more time than ex- Inspect the operation of the cooling fan clutch.
pected. Inspect the operation of the thermostat.
Or, it takes longer than before. Inspect the operation of the water pump.
2. DPD system regeneration long time Diagnostics Inspect the radiator for clogging.
Inspect whether the cooling amount of the cooling
• Preliminary inspection
Inspect the fuel quality. system is not low due to modification.
Check the scan tool data list. • Inspection of the air intake system
Check the service technical report. Inspect the air cleaner, air intake duct, and inter-
Check whether DPD regeneration and engine cooler for clogging, holes, or leakage.
warm up control are mixed up. Inspect whether a condition exists where the flow
Check the operator's operating habits and condi- in the turbocharger inlet duct is restricted.
tions. Inspect the intake throttle valve for anchoring.
Check whether the manual regeneration is started Inspect the inside of the intake manifold for clog-
when the engine is cold in DPD regeneration. ging or air leaks.
Check whether the idling time is too long in DPD Inspect the air intake system for modification.
regeneration. Inspect the mass air flow sensor for contamination
Check whether operation is frequently performed and damage.
at low speed in DPD regeneration. Inspect the turbocharger turbine wheel, shaft, or
Check whether the engine operating time is short compressor wheel for wear and damage.
in DPD regeneration. • Inspection of the exhaust system
Check whether accelerator is switched frequently Inspect for any condition that restricts the flow of
between ON and OFF in DPD regeneration. the exhaust system.
Check whether the temperature in the work envi- Inspect for absence or damage of the exhaust
ronment is excessively high in DPD regeneration. system gasket.
Inspect for exhaust gas leakage from the exhaust
• Inspection of the sensor
Inspect the hose and pipe of the DPD differen- pipe, gasket, DPD, exhaust gas temperature sen-
tial pressure sensor for incorrect piping or if they sor, and DPD differential pressure sensor's hose
came off. and pipe.
{The hose of the DPD differential pressure sensor Inspect the exhaust system for modification.
has a specified installation direction} Inspect the Inspect the inside of the DPD filter for excessive
hose and pipe of the DPD differential pressure ash deposits.
sensor for clogging, collapsing, or twisting. Inspect the DPD filter for damages, cracks, melt
Inspect the DPD differential pressure sensor for and excessive deposits.
incorrect installation. Inspect the oxidation catalyst for damages,
Inspect the DPD differential cracks, melt and excessive deposits.
pressure sensor for damage. If any excessive white smoke is observed in the
Inspect the DPD differential pressure sensor for regeneration process, the oxidation catalyst may
contamination and foreign materials which inter- be deteriorated or damaged.
fere with its inlet. • Other inspections Inspect for possible factors of
Check the DPD differential pressure sensor for overheat.
abnormalities and operation delay with the scan
tool data display exhaust differential pressure.
Check the exhaust gas temperature sensor at var-
ious temperatures, and inspect for the possibility
of sensor abnormalities.
84402832 NA - May 2011

4001E-4
Symptom
Engine start failure

1. Engine start failure Description of Symptom
The cranking revolution is low.
The cranking revolution is normal, but the engine
does not start.
The engine starts but cannot maintain its revolution
stably or does not reach normal revolution speeds.
2. Engine start failure Diagnostics
Before using this section, perform the functional
inspection and OBD system check to check all of
the following.
Check whether the actual unit has a significant
load.
The ECM and monitor are operating correctly.
DTC check.
The scan tool data is within the normal operating
range.
Check the condition of the actual unit, and locate
the appropriate symptom.
Check with the customers whether they are using
the specified engine oil and fuel.
• Visual inspection
Careful visual inspection is required for several
symptom procedures.
This can lead to fixing a problem without further
inspections, and can save valuable time.
The inspection includes the following.
Whether there is grime or clogging of the fuel filter.
Whether there is an improper connection of con-
nectors. *1 Pre fuel filter
Particularly for the crankshaft position sensor and
*2 Electromagnetic pump
camshaft position sensor.
Whether the battery terminal voltage has *3 Fuel filter
dropped.
Proper wiring connections, tightening, and dis- • Diagnostic aids
connection Fuel system abnormalities such as fuel running
Whether the power of any commercial acces- out, fuel freezing, mixture of air into the fuel pip-
sories is being taken divergingly from the ECM ing, filter abnormalities, piping abnormalities, fuel
power. quality, fuel tank, etc.
Whether the ECM ground is free of dirt, etc. and Air intake system abnormalities such as filter clog-
securely installed in the correct location Proper ging, air intake piping abnormalities, etc.
connections, cracks, and twists in the pipes and Use of low-viscosity fuel such as kerosene causes
hoses related to fuel, air, and oil. wear on the supply pump plunger and may re-
Extensively check for any leaks or blockage. sult in the discharge abnormalities and cause start
Whether the layout of the fuel filter, pre-filter, and failure.
electromagnetic pump has a structure in which air In such cases, replacement of the supply pump is
accumulates easily. required.
Check whether they are arranged to prevent air When a start failure has occurred, check with the
accumulation as Isuzu genuine pre-filters do not customer about the fuel used.
have any plugs for air removal. If low-viscosity fuel such as kerosene has been
Also check whether the inlet and outlet of the elec- used, instruct the customer not to use low-viscos-
tromagnetic pump have an appropriate layout. ity fuel because the malfunction recurs even after
Fix layouts which have the electromagnetic pump replacing the supply pump.
inlet on the upper side or have an outlet toward A mixed oil biofuel containing long-term storage
the motion direction of the actual unit. fuel and organic substances is easily oxidizable.
Whether there are any fuel leaks, pipe damage, An oxidized fuel causes wear on the camshaft re-
or dents in the fuel system. lated parts in the supply pump and may result in
Abnormalities of the air intake system parts start failure due to discharge abnormalities.
Abnormalities of the exhaust system parts In such cases, replacement of the supply pump is
required.
Since the replacement of the supply pump due
to the use of mixed oil biofuel containing long-
term storage fuel and organic substances is at the
84402832 NA - May 2011
4001E-5
Symptom
customer’s expense, instruct the customer not to

use mixed oil biofuel containing long-term storage
fuel and organic substances.
When using fuel with a high water content, add the
larger sedimenter to the pre-fuel filter to prevent
water from entering into the fuel system.
Abnormalities of the supply pump, non-pressure Abso-
fuel supply lute
The ECM determination of the supply pump non- pres-
pressure fuel supply DTC will not be detected un- sure
less a condition continues for 3 seconds or more
in which the engine revolution speed is 900 min-1
{900 r/min} and the absolute pressure is below 15
MPa {153 kgf/cm2 / 2175 psi}.
Therefore, the DTC will not be detected when the
engine does not start with non-pressure fuel sup-
ply due to the supply pump abnormalities.
Engine speed (min-1 {r/min})
ANNOTATION:
• Since the crankshaft position sensor abnormali- *1 Non-criteria range
ties will not be diagnosed unless cranking is per- *2 P0093 Criteria range
formed 14 revolutions or more, crank for more *3 Range in P0093 is established
than 14 seconds at 60 min-1 {60 r/min} or more.
For crankshaft position sensor errors at low en- Abnormalities of the common rail such as the flow
gine revolution speed, the crankshaft position damper, operation of the pressure limiter, or in-
sensor DTC may not be detected. side sealing degradation
For intermittent failure, increase the engine rev- Abnormalities of the injector, no fuel injection
olution speed to No Load Max and check if the System down due to failure
crankshaft position sensor related DTC is de- Engine body abnormalities such as seizure, insuf-
tected. ficient compression pressure, and other mechan-
ical failures, etc.
ACG failure
Failure related to the actual unit equipment such
as the oil pressure pump, etc.
Effect of the post-installed accessories such as
wireless devices and lights, etc.
ECM failure
Inspect the connector for connection failures
and the harness for abnormalities such as abra-
Engine speed sions, bending, etc.
(min-1 {r/min}) Inspect to see if the wires inside the harness
are separate and have not caused a short circuit
with other circuits.
Perform inspections for functional diagnosis,
and confirm the operation, control of each part,
etc.
Repair if abnormalities are found.
Engine stalling
P0093 Judgment required en- 1. Engine stalling Description of Symptom
*1 Engine cranks but takes a long time to start.
gine speed
The engine ultimately operates, or starts but stops
*2 Minimum fining engine speed
soon.
System realization engine 2. Engine stalling Diagnostics
*3
speed
the following.
Check whether the actual unit has a significant
load.
Since the crankshaft position sensor abnormali-
ties will not be diagnosed with cranking less than
84402832 NA - May 2011
4001E-6
Symptom
14 revolutions, crank for more than 14 seconds at

60 r/min or more.
DTC check.
For crankshaft position sensor errors at low en-
gine revolution speed, the crankshaft position
sensor DTC may not be detected.
For intermittent failure, increase the engine rev-
olution speed to No Load Max and check if the
crankshaft position sensor related DTC is de-
tected.
range.
Check whether fuel is contained.
symptom procedures.
nectors.
Particularly for the crankshaft position sensor and
Proper wiring connections, tightening, and dis-
connection
Whether the power of any commercial acces-
sories is being taken divergingly from the ECM
power.
Whether the ECM ground is free of dirt, etc. and *1 Pre fuel filter
securely installed in the correct location. *2 Electromagnetic pump
Proper connections, cracks, and twists in the *3 Fuel filter
pipes and hoses related to fuel, air, and oil.
Extensively check for any leaks or blockage. • Diagnostic aids
Whether there are any fuel leaks, pipe damage, Fuel system abnormalities such as fuel running
or dents in the fuel system. out, fuel freezing, mixture of air into the fuel pip-
Whether the layout of the fuel filter, pre-filter, and ing, filter abnormalities, piping abnormalities, fuel
electromagnetic pump has a structure in which air quality, fuel tank, etc.
accumulates easily. Air intake system abnormalities such as filter clog-
Check whether they are arranged to prevent air ging and air intake piping abnormalities, etc.
accumulation as Isuzu genuine pre-filters do not Abnormalities of the supply pump, non-pressure
have any plugs for air removal. fuel supply
Also check whether the inlet and outlet of the elec- The ECM determination of the supply pump non-
tromagnetic pump have an appropriate layout. pressure fuel supply DTC will not be detected un-
Fix layouts which have the electromagnetic pump less a condition continues for 3 seconds or more
inlet on the upper side or have an outlet toward in which the engine revolution speed is 900 r/min
the motion direction of the actual unit. and the absolute pressure is below 15 MPa (2176
Abnormalities of the air intake system parts psi).
Abnormalities of the exhaust system parts Therefore, the DTC will not be detected when the
engine does not start with non-pressure fuel sup-
ply due to supply pump abnormalities.
84402832 NA - May 2011

4001E-7
Symptom
*1 Non-criteria range
*2 P0093 Criteria range
*3 Range in P0093 is established
Abnormalities of the common rail such as the flow

damper, operation of the pressure limiter, or in-
side sealing degradation
Abnormalities of the injector, no fuel injection
Engine speed System down due to failure
(r/min) Engine body abnormalities such as seizure, insuf-
ficient compression pressure, and other mechan-
ical failures, etc.
ACG failure
Failure related to the actual unit equipment such
Effect of the post-installed accessories such as
wireless devices and lights, etc.
ECM failure
Inspect the connector for connection failures
P0093 Judgment required en- and the harness for abnormalities such as abra-
*1
gine speed sions, bending, etc.
*2 Minimum fining engine speed Inspect to see if the wires inside the harness
System realization engine are separate and have not caused a short circuit
*3 with other circuits.
speed
Perform inspections for functional diagnosis,
and confirm the operation, control of each part,
etc.
Repair if abnormalities are found.
Abso-
lute
pres-
sure
Engine speed (r/min)
84402832 NA - May 2011

4001E-8
Symptom
Engine hunting, rough idling Check whether they are arranged to prevent air
accumulation as Isuzu genuine pre-filters do not
1. Engine hunching, rough idling Description of Symp- have any plugs for air removal.
tom Also check whether the inlet and outlet of the elec-
The engine has variable engine idling, or has tromagnetic pump have an appropriate layout.
change in idling revolution speed. Fix layouts which have the electromagnetic pump
In a severe case, the engine or the actual unit may inlet on the upper side or have an outlet toward
vibrate. the motion direction of the actual unit.
In either case, the engine stall may occur if the Whether there are any fuel leaks, pipe damage,
symptom gets worse. or dents in the fuel system.
2. Engine hunching, rough idling Diagnostics Abnormalities of the air intake system parts
Abnormalities of the exhaust system parts
the following.
DTC check.
range.
symptom procedures.
nectors.
Whether the battery terminal voltage has
dropped.
connection
power.
Whether the ECM ground is free of dirt, etc. and
securely installed in the correct location.
Proper connections, cracks, and twists in the
Extensively check for any leaks or blockage.
Whether there are any fuel leaks, pipe damage,
or dents in the fuel system.
Whether the layout of the fuel filter, pre-filter, and *1 Pre fuel filter
electromagnetic pump has a structure in which air *2 Electromagnetic pump
accumulates easily. *3 Fuel filter
84402832 NA - May 2011

4001E-9
Symptom
• Diagnostic aids Failure related to the actual unit equipment such

Fuel system abnormalities such as fuel running as the oil pressure pump, etc.
out, fuel freezing, mixture of air into the fuel pip- Effect of the post-installed accessories such as
ing, filter abnormalities, piping abnormalities, fuel wireless devices and lights, etc.
quality, fuel tank, etc. Inspect the connector for connection failures and
Air intake system abnormalities such as filter clog- the harness for abnormalities such as abrasions,
ging, air intake piping abnormalities, etc. bending, etc.
Abnormalities of the supply pump, non-pressure Inspect that the wires inside the harness are sepa-
fuel supply rate and have not caused a short circuit with other
Switch input circuit system abnormalities Abnor- circuits.
malities of the sensor input circuit system such as Perform inspections for functional diagnosis, and
the accelerator position sensor, harness, and wa- confirm the operation, control of each part, etc.
ter temperature sensor Repair if abnormalities are found.
Accelerator position sensor system abnormalities
Engine body abnormalities such as seizure, insuf-
ficient compression pressure, and other mechan-
ical failures, etc.
84402832 NA - May 2011

4001E-10
Symptom
Excessive white smoke in the Whether the ECM ground is free of dirt, etc. and
exhaust gas Proper connections, cracks, and twists in the
1. Excessive white smoke in the exhaust gas Descrip-
tion of Symptom
Excessive white smoke when driving.
2. Excessive white smoke in the exhaust gas Diagnos-
Abnormalities of the air intake system parts
tics
• Preliminary inspection • Diagnostic aids
Before using this section, perform the functional Fuel quality when using a product with a low
inspection and OBD system check to check all of cetane number or a product other than those
the following. specified
The ECM and monitor are operating correctly. Use of low-viscosity fuel such as kerosene may
DTC check. result in abnormal wear on the seat area of the
The scan tool data is within the normal operating injector and cause abnormal spray and white
range. smoke.
Check the condition of the actual unit, and locate In such cases, replacement of the injector is re-
the appropriate symptom. quired.
Check with the customers whether they are using Since the replacement of the injector due to the
the specified engine oil and fuel. use of low-viscosity fuel such as kerosene is at
• Visual inspection the customer's expense, instruct the customer not
Careful visual inspection is required for several to use low-viscosity fuel such as kerosene.
symptom procedures. Idling for a long time
This can lead to fixing a problem without further Failure of the water temperature sensor, fuel tem-
inspections, and can save valuable time. perature sensor, intake air temperature sensor,
The inspection includes the following. boost sensor failure, or air pressure sensor
Whether there is an improper connection of injec- Engine body failure such as insufficient compres-
tor connectors. sion pressure, piston related failure, turbocharger
Proper wiring connections, tightening, and dis- failure, and raised oil or sucked down oil, etc.
connection ECM failure
power.
84402832 NA - May 2011

4001E-11
Symptom
Excessive black smoke in the Whether there is grime or clogging in the air
cleaner element Proper wiring connections, tight-
exhaust gas ening, and disconnection
1. Excessive black smoke in the exhaust gas Descrip-
tion of Symptom
power Whether the ECM ground is free of dirt,
Excessive black smoke when driving.
etc. and securely installed in the correct location
2. Excessive black smoke in the exhaust gas Diagnos-
tics
• Preliminary inspection Extensively check for any leaks or blockage.
Before using this section, perform the functional Whether there are any fuel leaks, pipe damage,
inspection and OBD system check to check all of or dents in the fuel system.
the following. Abnormalities of the air intake system parts
The ECM and monitor are operating correctly. Abnormalities of the exhaust system parts
DTC check. • Diagnostic aids
The scan tool data is within the normal operating Fuel quality when using a product other than
range. those specified, etc.
Check the condition of the actual unit, and locate Air intake system abnormalities such as filter clog-
the appropriate symptom. ging, air intake piping abnormalities, etc.
Check with the customers whether they are using Abnormalities of the EGR control system
the specified engine oil and fuel. Abnormalities of the exhaust system such as ex-
• Visual inspection haust pipe abnormalities, etc.
Careful visual inspection is required for several Water temperature sensor malfunction
symptom procedures. Boost sensor failure
This can lead to fixing a problem without further Engine body failure such as insufficient compres-
inspections, and can save valuable time. sion pressure, piston related failure, turbocharger
The inspection includes the following. failure, and raised oil, etc.
84402832 NA - May 2011

4001E-12
Symptom
Abnormal noise Proper connections, cracks, and twists in the

1. Abnormal noise Description of Symptom Extensively check for any leaks or blockage.
Engine combustion noise is abnormal. Whether there are any fuel leaks, pipe damage,
2. Abnormal noise Diagnostics or dents in the fuel system.
Abnormalities of the air intake system parts
Before using this section, perform the functional Abnormalities of the exhaust system parts
inspection and OBD system check to check all of • Diagnostic aids
the following. Fuel system abnormalities such as fuel running
Refer to the actual unit manual and inspect the out, fuel freezing, mixture of air into the fuel pip-
abnormal noise. ing, filter abnormalities, piping abnormalities, fuel
The ECM and monitor are operating correctly. quality, fuel tank, etc.
DTC check. Air intake system abnormalities such as EGR
The scan tool data is within the normal operating valve abnormalities, etc.
range. Abnormalities of the injector, no fuel injection
Check the condition of the actual unit, and locate Engine body abnormalities such as seizure, insuf-
the appropriate symptom. ficient compression pressure, and other mechan-
Check with the customers whether they are using ical failures, etc.
the specified engine oil and fuel. Failure related to the actual unit equipment such
Careful visual inspection is required for several ECM failure Inspect the connector for connection
symptom procedures. failures and the harness for abnormalities such as
This can lead to fixing a problem without further abrasions, bending, etc.
inspections, and can save valuable time. Inspect that the wires inside the harness are sepa-
The inspection includes the following. rate and have not caused a short circuit with other
Proper wiring connections, tightening, and dis- circuits.
connection Perform inspections for functional diagnosis, and
Whether the ECM ground is free of dirt, etc. and confirm the operation, control of each part, etc.
securely installed in the correct location. Repair if abnormalities are found.
84402832 NA - May 2011

4001E-13
Symptom
Large fuel consumption Proper wiring connections, tightening, and dis-

connection
1. Large fuel consumption Description of Symptom Whether the ECM ground is free of dirt, etc. and
Fuel consumption is significantly larger than indi- securely installed in the correct location.
cated in the actual unit manual. Proper connections, cracks, and twists in the
2. Large fuel consumption Diagnostics pipes and hoses related to fuel, air, and oil.
Before using this section, perform the functional Whether there are any fuel leaks, pipe damage,
inspection and OBD system check to check all of or dents in the fuel system.
the following. Abnormalities of the air intake system parts
Since the fuel consumption varies widely depend- Abnormalities of the exhaust system parts
ing on the handling of the actual unit, check the • Diagnostic aids
reference fuel consumption (A) of the actual unit Fuel system abnormalities such as fuel running
manufacturer. out, fuel freezing, mixture of air into the fuel pip-
Reference fuel consumption (L {qts}/hour) ing, filter abnormalities, piping abnormalities, fuel
Check the actual fuel consumption (B). quality, fuel tank, etc.
Actual fuel consumption (L {qts}/hour) Air intake system abnormalities such as EGR
If B is greater than A, refer to the actual unit man- valve abnormalities, etc.
ual and check the setting of the unit. Abnormalities of the injector such as excessive
Check whether the actual unit does not have a fuel injection
significant load. Engine body abnormalities such as seizure, insuf-
Refer to the inspections and maintenance list in ficient compression pressure, and other mechan-
the operation manual and perform the inspection ical failures, etc.
based on the operation time of the actual unit. Failure related to the actual unit equipment such
Refer to the actual unit manual to inspect an as the oil pressure pump, etc.
actual unit whose operation time exceeds 3,000 ECM failure
hours. Inspect the connector for connection failures and
The ECM and monitor are operating correctly. the harness for abnormalities such as abrasions,
DTC check. bending, etc.
Check the condition of the actual unit, and locate Inspect that the wires inside the harness are sepa-
the appropriate symptom. rate and have not caused a short circuit with other
Check with the customers whether they are using circuits.
the specified engine oil and fuel. Perform inspections for functional diagnosis, and
Check whether engine oil change or periodical confirm the operation, control of each part, etc.
maintenance for the air cleaner filter or fuel filter, Repair if abnormalities are found.
etc. has been performed. For the inspection locations of the engine air
intake and exhaust system Inspect the air intake
Careful visual inspection is required for several and exhaust system for abnormalities such as
symptom procedures. clogging, collapsing and damage.
This can lead to fixing a problem without further Other than the inspection locations of the engine
inspections, and can save valuable time. body, inspect the air cleaner, intercooler, and muf-
The inspection includes the following. fler.
84402832 NA - May 2011

4001E-14
Symptom
1 Primary EGR cooler 4 From the intercooler 7 Exhaust pipe

2 EGR duct 5 From the air cleaner 8 Secondary EGR cooler
3 EGR valve 6 To the intercooler
84402832 NA - May 2011

4001E-15
Symptom
Large oil consumption Check with the customers whether they are using
1. Large oil consumption Description of Symptom • Visual inspection
The oil consumption amount described in the man- Careful visual inspection is required for several
ual of the actual unit is significantly exceeded. symptom procedures.
2. Large oil consumption Diagnostics This can lead to fixing a problem without further
Before using this section, perform the functional The inspection includes the following.
inspection and OBD system check to check all of Whether bluish white smoke continuously comes
the following. out.
Since the oil consumption varies widely by han- Whether blow-by gas comes out excessively.
dling of the actual unit, check the reference oil Whether oil is mixed into the coolant.
consumption (A) of the actual unit manufacturer. Proper connections, cracks, and twists in the
Reference oil consumption/hour pipes and hoses related to oil.
Reference oil consumption per engine: 4 L {4.2 Extensively check for any leaks or blockage.
qts}/100 hours Whether there is any fuel leak, pipe damage, or
Check the actual oil consumption (B). Actual oil dents in the lubricant system.
consumption/hour Abnormalities of the air intake system parts such
Refer to the inspections and maintenance list in as the turbocharger inspection
the operation manual and perform the inspection • Diagnostic aids
based on the operation time of the actual unit. Air intake system abnormalities such as sucked
Refer to the actual unit manual to inspect an down oil or raised oil and excessive blow-by gas
actual unit whose operation time exceeds 3,000 Engine body abnormalities such as oil combustion
hours. and excessive blow-by gas
The ECM and monitor are operating correctly. Perform inspections for functional diagnosis, and
DTC check. confirm the operation, control of each part, etc.
Check the condition of the actual unit, and locate Repair if abnormalities are found.
84402832 NA - May 2011

4001E-16
Symptom
Insufficient engine output Exhaust system abnormalities such as exhaust

pipe abnormality
1. Insufficient engine output Description of Symptom Abnormalities of the sensor input circuit system
The engine output is lower than expected, the out- including the accelerator position sensor and the
put does not change when the accelerator lever harness
(throttle lever) is lifted up, the operation is not ef- Abnormalities of the switch input circuit system
fective. Engine unit abnormalities including other me-
2. Insufficient engine output Diagnostics chanical failures such as compression pressure,
valve clearance, turbocharger, supply pump, in-
Before using this section, perform the functional jector, and common rail Failures related to actual
inspection, OBD system check to confirm the fol- unit side equipment such as hydraulic pump
lowing all items. Influence of the post-mounted electrical compo-
The ECM and the monitor are operating properly. nents such as wireless devices and lights
DTC check. Inspect for connector improper connections, har-
The scan tool data is within the normal operating ness abnormalities such as abrasions and bends,
range. and short circuits with other circuits due to wire
Check the actual unit condition, and locate the split inside harness.
corresponding symptom. Also, perform inspections for functional diagnosis,
Check with the customer if the customer is using and check the operation and control of each part.
the specified engine oil and fuel. Make repairs if any abnormality is found.
For insufficient output, various causes can be sus- Output reduction due to fuel flow restriction im-
pected, so thoroughly investigate the relationship posed upon overheat
between the engine and the actual unit side. Insufficient output due to fuel flow restriction dur-
Check what kind of operations cause insufficient ing operation at high altitude
output. • Control when overheating
If hesitation or lug-down is included in the symp- To protect the engine, restriction on fuel flow is
toms of insufficient output, it is related to the con- started when the engine coolant temperature ex-
trol on the actual unit side, so contact the manu- ceeds 100 °C (212 °F).
facturer of the actual unit. When the engine coolant temperature increases
Itrouble diagnosis scan tool is available, the en- further, the fuel flow is also restricted further.
gine output at the rated point can be easily veri- When the temperature is near 120 °C (248 °F),
fied by checking the boost at the rated point. the fuel flow is restricted to a certain level.
The setting varies depending on the actual unit
Careful visual inspection is required for several manufacturer.
symptom procedures. The actual unit is designed to issue an alarm from
This can lead to fixing a problem without further 105 °C (221 °F).
inspections, and can save valuable time. By reducing the load applied to the actual unit
The inspection includes the following. upon alarm issuance, it is possible to avoid the
Whether there is grime or clogging in the air operation condition with fuel flow restriction.
cleaner element.
connection
power.
Whether the ECM ground is free of dirt, etc. and
Fuel
flow
Increased resistance due to grime, clogging, or
air intake piping collapsing particularly in the air
cleaner element among the air intake system
parts
• Diagnostic aids Engine coolant temperature
Fuel system abnormalities such as running out of
fuel, fuel freezing, air intrusion in the fuel pipe, fil-
ter abnormality, pipe abnormality, fuel quality, and *1 Warning indication
fuel tank *2 DTC set
Air intake system abnormalities such as filter clog-
ging and air intake pipe abnormality • High altitude correction
84402832 NA - May 2011

4001E-17
Symptom
The ECM calculates the current altitude in accor-

dance with the signal from the atmospheric pres-
sure sensor.
Depending on the conditions of altitude, etc. at
this time, the SCV opening and closing timing and
injector energizing time are controlled and the fuel
flow is corrected to be optimum.
Fue-
l flow
limit (
mm3/
st)
Barometric pressure kPa (psi)
*1 Highland
84402832 NA - May 2011

4001E-18
Section
4001F
Functional Inspection
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Inspection of the monitor warning light blinking circuit system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Inspection of the scan tool power circuit system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection of the starter circuit system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Compression pressure inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspection of the starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspection of the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection of the air intake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspection of the EGR control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspection of the glow control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Functional inspection of the DPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
OBD system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Inspection of the monitor warning light illumination circuit system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Inspection of the monitor warning Inspection of the scan tool power

light blinking circuit system circuit system
1. Inspection of the monitor warning light blinking cir- 1. Inspection of the scan tool power circuit system De-
cuit system Description of Function scription of Function
The monitor is supplied with power supply voltage The ECM and other ECU communicate with the
via the starter switch and shows an abnormality dis- trouble diagnosis scan tool via the DLC.
play due to a signal from the ECM. The power voltage of the trouble diagnosis scan tool
The ECM makes the monitor show an abnormality is supplied by the battery or AC power.
display during a lamp check when the starter switch
is ON and when the DTC is set. CAUTION
It also blinks the monitor depending on the detected
DTC when the body ground terminal and diagnostic • Draw power for the trouble diagnosis
scan tool from the battery or AC power.
switch terminal of the DLC are shorted.
A monitor circuit is incorporated inside the ECM and • The power supply voltage is the same as
the battery voltage of the actual unit.
monitors operation of the light.
2. Inspection of the monitor warning light blinking cir-
cuit system Inspection 2. Inspection of the scan tool power circuit system In-
Inspection if the monitor continues showing an ab- spection
normality display and does not flash when the diag- Inspection when the trouble diagnosis scan tool
nostic switch is switched ON does not power on
1) Perform the OBD system check. 1) Inspect the battery voltage of the actual unit
2) Turn OFF the starter switch. using the DMM.
3) Connect the DMM between the DLC diagnos- Standard value：18V
tic switch terminal and GND. 2) Charge or replace the battery if it is below the
4) Turn ON the starter switch. standard value.
5) Confirm that the voltage displayed on the 3) Check that the battery cable of the trouble di-
DMM exceeds the standard value. agnosis scan tool does not have a defective
Standard value: 18 V connection.
6) Inspect the diagnostic switch circuit between 4) Repair the connection if a problem is discov-
the ECM and DLC using the DMM if it is under ered.
the standard value. 5) Check that the battery cable of the trouble di-
agnosis scan tool does not have an open or
• No open circuit or high resistance should be short circuit.
found. 6) Request repair of the battery cable if a prob-
Standard value: 100 Ω or less lem is discovered.
• No short circuit with GND should be found.
Standard value: 10 MΩ or more
7) Repair if a problem is discovered.
8) Turn OFF the starter switch.
9) Confirm that there is continuity between the
DLC body ground and GND.
11) Short the DTC.
ANNOTATION:
• Short the No.4 terminal and No.12 terminal.
12) Check if the monitor is blinking.
ANNOTATION:
• If it does not blink, inspect the monitor blink-
ing circuit system.
13) Replace the ECM.
Removal of ECM
Installation of ECM
14) After replacing the ECM, perform EGR learn-
ing.
16) Short the body ground terminal and diagnostic
switch terminal of the DLC.
17) Check if the monitor is blinking.
18) Perform the OBD system check
84402832 NA - May 2011

4001F-3
Inspection of the starter circuit 8) Inspect the starter relay.

system • Connect the battery between the coil side
terminals and check the continuity between
1. Inspection of the starter circuit system Description the switch side terminals.
of Function Standard value: 100 Ω or less
The starter relay on the ECM is turned to ON when
the starter switch moves to the START position. 9) Replace the relay if a problem is discovered.
When the starter relay is turned to ON, the starter 10) Inspect the starter switch start signal circuit.
operates to start the engine. • No open circuits or high resistance should
2. Inspection of the starter circuit system Inspection be found between the starter switch and
Inspection when the starter does not operate ECM.
1) Turn the emergency stop switch to OFF. Standard value: 100 Ω or less
• No short circuits with the GND should be
ANNOTATION: found between the starter switch and ECM.
Standard value: 10 MΩ or more
• If the actual unit does not have an emer-
gency stop switch setting, do not perform 11) Repair the circuit if a problem is discovered.
this operation. 12) Inspect the starter circuit.
2) Check the DTC. • No open circuit should be found between
the starter switch and starter cut relay.
ANNOTATION:
• No open circuit should be found between
• If the DTC P0117, P0340, P0341, P0615, the starter cut relay and starter relay.
P0651, or P1625 is detected, inspect the • No open circuit should be found between
corresponding DTC. the starter relay and GND.
• No open circuit should be found between
3) Turn OFF the starter switch. the starter relay and starter.
4) Remove the starter cut relay.
5) Inspect the starter cut relay. 13) Repair the circuit if a problem is discovered.
14) Inspect the starter.
• Check the continuity between the switch Inspection of the starter
side terminals. 15) Replace the starter if a problem is discovered.
Standard value: 100 Ω or less 16) Replace the ECM.
6) Replace the relay if a problem is discovered. Removal of ECM
7) Remove the starter relay. Installation of ECM
17) After replacing the ECM, perform EGR learn-
ing.
84402832 NA - May 2011

4001F-4
Compression pressure inspection

1. Engine compression pressure inspection Inspection
ANNOTATION:
• Warm-up the engine.
assembly.
ANNOTATION:
• Remove all glow plugs.
2) Remove the injector harness connector from
the lower cover.
Special tool: compression gauge (adapter)
3) Install the special tool to the cylinder head as-

sembly.
ANNOTATION:
• Insert the compression gauge adapter into
the installation hole of the glow plug to install
the compression gauge.
1 Compression gauge
2 Compression gauge adapter
Special tool: compression gauge adapter
4) Measure the compression pressure.
ANNOTATION:
• Rotate the starter, and read the indication
of the compression pressure when the com-
pression gauge needle stabilizes at approx-
imately 200 rpm.
• Measure the compression pressure of all
cylinders.
Specified value: 3240.0 kPa {33.04 kgf/cm2 /
470 psi}
Limit: 2260.0 kPa {23.05 kgf/cm2 / 328 psi}
84402832 NA - May 2011
4001F-5
Difference between each cylinder: 294.0 kPa 1) Turn the emergency stop switch to OFF.
{3.00 kgf/cm2 / 43 psi}
ANNOTATION:
CAUTION • If the actual unit does not have an emer-
gency stop switch setting, do not perform
• Note that air will burst out through
the glow plug hole during rotation. this operation.
2) Inspect the overheat switch circuit.
ANNOTATION:
ANNOTATION:
• When the starter switch is turned to ON with • If the actual unit does not have a overheat
the injector harness connector removed, the switch setting, do not perform this operation.
ECM determines a malfunction and records
a DTC, so make sure the DTC has been 3) Repair the circuit if a problem is discovered.
cleared after the inspection is completed. 4) Check the DTC.
ANNOTATION:
Inspection of the starting system
• If the DTC is detected, inspect the corre-
1. Starting system check Description of Function sponding DTC.
This diagnosis chart is an organized approach to
identifying a condition that causes the status for 5) Check the SCV F/B display using a trouble
when an engine does not start. diagnosis scan tool while cranking the engine.
The appropriate system diagnosis can be per- Standard value: 900 mA
formed with this diagnostic chart. 6) Repair the SCVLO drive circuit if it is below
the standard value.
• The battery should be fully charged when per- 7) Remove the harness connector from the SCV.
forming this diagnosis. 8) Crank the engine.
• The battery cable should be securely connected
when performing this diagnosis. ANNOTATION:
• The rotation speed during cranking should be nor- • If the engine starts, diagnose the DTC
mal when performing this diagnosis. P0090.
• The appropriate fuel should be sufficiently sup-
plied when performing this diagnosis. 9) Inspect the fuel system if the engine does not
• No fuel leaks should be found when performing start.
this diagnosis. 10) Inspect the engine coolant temperature sen-
• No air should be mixed into the fuel when perform- sor.
ing this diagnosis. 11) Inspect the fuel pressure sensor.
• The air cleaner element should be clean when 12) Inspect the EGR position sensor.
performing this diagnosis. 13) Inspect the injector.
• The fuel filter should be clean when performing 14) Inspect the engine mechanical timing.
this diagnosis. 15) Inspect the installation status of the flywheel.
16) Inspect the air intake system.
2. Starting system check Inspection 17) Inspect the exhaust piping for collapsing,
Inspection when the starter operates and cranks but damage, and exhaust leakage.
the engine does not start 18) Repair or replace the part found to have a
problem.
84402832 NA - May 2011

4001F-6
Inspection of the fuel system Inspection of the air intake system

1. Fuel system check Description of Function 1. Air intake system check Description of Function
The fuel system is composed of the fuel filter, supply
pump, common rail, and injector, and each of them CAUTION
connects with the fuel pipe.
2. Fuel system check Inspection • If the air intake system part is installed by
the actual unit manufacturer, refer to the
Inspection when there is a possibility that there is
manual of the actual unit.
an abnormality in the fuel system
1) Inspect the quality of fuel. The air intake system is comprised of the air
Appropriate fuel should be used. cleaner, air intake piping, turbocharger, etc.
2) Check the amount of fuel. The intake air is supplied to the engine through the
Sufficient amount should be supplied. air cleaner and intake manifold.
3) Perform the fuel discharge inspection for the 2. Air intake system check Inspection
supply pump. Inspection when there is a possibility that there is
Fuel discharge inspection an abnormality in the air intake system
The fuel discharge should be normal and no
air should be mixed. 1) Inspect the air cleaner.
4) Confirm that the genuine fuel filter, pre filter, • No excessive contamination or clogging
and filters other than for the electromagnetic should be found.
pump are added to the fuel piping of the actual
unit. 2) Clean or replace if a problem is discovered.
3) Inspect the air intake piping.
ANNOTATION:
• No collapsing, damage, or air leakage
• A problem such as the detection of the DTC should be found.
P0093 may occur as the resistance of fuel • There are no distorted or improper piping ar-
increases due to the added filter. rangements which may lead to an increase
5) Remove it if the filter is added. in the air intake resistance.
6) Inspect the main fuel filter, pre-fuel filter, and • The lead valve should have no damage.
electromagnetic pump filter. 4) Repair or replace if a problem is discovered.
5) Inspect the turbocharger.
• No excessive contamination or clogging
should be found. • The turbine axis should have no abnormal
• No air should be mixed in. looseness.
7) Clean or replace if a problem is discovered. • There are no oil leaks.
8) Inspect the fuel pipe. 6) Repair or replace if a problem is discovered.
• No damage, clogging, or improper connec-
tions should be found.
9) Repair or replace if a problem is discovered.
10) Inspect the fuel tank.
• No dust should be mixed in.
• The fuel supply pipe should have no mis-
alignment or damage.
• The tank should have no collapsing or dam-
age.
• The fuel pipe should not be arranged incor-
rectly.
• The fuel filler should have no clogging.
• No water should be mixed into the tank.
11) Repair or replace the fuel tank if a problem is
discovered.
12) Remove air.
84402832 NA - May 2011

4001F-7
Inspection of the exhaust system Inspection of the EGR control

1. Exhaust system check Description of Function system
The exhaust system is comprised of the exhaust
pipe, tail pipe, etc. 1. EGR control system check Description of Function
2. Exhaust system check Inspection The ECM controls the EGR valve based on the en-
Inspection when there is a possibility that there is gine revolution speed, engine coolant temperature,
an abnormality in the exhaust system intake air temperature, fuel injection amount, and
atmospheric pressure.
1) Inspect the exhaust pipe and tail pipe. The EGR valve is driven by the EGR motor, and the
EGR valve opening is detected by the EGR position
• No collapsing, damage, or exhaust leakage sensor.
should be found.
2. EGR control system check Inspection
2) Repair or replace if a problem is discovered. Inspection when there is a possibility that there is
3) Repair the actual unit. an abnormality in the locations relating to the EGR.
1) Check the DTC.
ANNOTATION:
• If the DTC is detected, inspect the corre-
sponding DTC.
2) Start the engine and warm it up until the
coolant temperature exceeds the standard
value.
Specified value: 70 °C ｛158 °F｝
3) Check the EGR position display using a trou-
ble diagnosis scan tool.
Standard value: (-3) - 3 ％
4) Perform the actuator test EGR control using a
trouble diagnosis scan tool if the EGR position
display is outside the standard value.
5) Execute an Up and Down command to the
EGR valve and check the EGR position dis-
play.
6) Inspect the EGR piping if the EGR position
No damage or gas leaks should be found.
7) Repair or replace if a problem is discovered.
8) Start the engine and warm it up until the
coolant temperature exceeds the standard
value.
Specified value: 70 °C ｛158 °F｝
9) Check the EGR position display using a trou-
10) Replace the EGR valve if the EGR position
EGR valve Removal
EGR valve Installation
11) When replacing the EGR valve, perform EGR
learning to the ECM.
84402832 NA - May 2011

4001F-8
Inspection of the glow control 8) Replace the relay if a problem is discovered.

9) Remove all glow plugs.
system 10) Measure the resistance between the glow
plug terminal and GND using the DMM.
1. Glow control system check Description of Function
Standard value: 6 Ω at room temperature
CAUTION ANNOTATION:
• The starter ECM control specification • If it is outside the standard value, inspect the
and safety relay specification are the corresponding glow plug.
same for the QOS circuit.
11) Replace the glow plug if a problem is discov-
The QOS system is comprised of the ECM, glow ered.
relay, glow plug, and QOS indicator light. 12) Connect the DMM to the glow plug connector
When the starter switch is turned to ON under low and GND.
engine coolant temperature, the ECM determines 13) Turn ON the starter switch.
the glow time according to the engine coolant tem- 14) Perform the actuator test glow plug relay using
perature, and starts the glow relay and QOS indica- a trouble diagnosis scan tool.
tor light. ANNOTATION:
The ECM will turn to OFF the glow relay and QOS
indicator light after a certain period of time. • Turn the command to OFF and check the
2. Glow control system check Inspection voltage value of the DMM.
Inspection when there is a possibility that there is Standard value: 0 V
an abnormality in the locations relating to the QOS 15) Inspect the circuit if it is outside the standard
system control value.
1) Perform the OBD system check. ANNOTATION:
2) Check the DTC.
• No short circuit to battery or ignition power
ANNOTATION: supply should be found between the glow
• If the DTC P0117, P0118, P0380, or P0381 relay and glow plug.
is detected, inspect the corresponding DTC. 16) Repair or replace the circuit if a problem is
3) Turn ON the starter switch. discovered.
4) Check the operation of the QOS indicator 17) Perform the actuator test glow plug relay using
light. a trouble diagnosis scan tool.
• If the QOS does not operate, the QOS in- • Turn the command to ON and check the
dicator light will illuminate when the starter voltage value of the DMM.
switch is turned to ON by the light check Standard value: 18 V
function. 18) Inspect the circuit if it is below the standard
• The QOS indicator light turns off within 10 value.
seconds.
• No fuse should be blown.
5) Inspect the circuit if the QOS indicator light • No open circuit should be found between
does not illuminate or turn off. the fuse and glow relay.
• No fuse should be blown. • No open circuit should be found between
• No open circuit should be found between the glow relay and glow plug.
the fuse and QOS indicator light. • No open circuit should be found between
• No open circuit or short circuit should be the glow relay and ECM.
found between the the QOS indicator light 19) Repair or replace the circuit if a problem is
and ECM. discovered.
• The QOS indicator light should not have a 20) Replace the ECM.
burned-out bulb. Removal of ECM
6) Repair or replace the circuit if a problem is Installation of ECM
discovered. 21) After replacing the ECM, perform EGR learn-
7) Inspect the glow relay. ing.
84402832 NA - May 2011

4001F-9
Functional inspection of the DPD • Damage on the DPD differential pressure

sensor
1. DPD control system check Description of Function • Foreign matter or contamination which inter-
The ECM detects the condition of PM accumula- feres with the DPD differential pressure sen-
tions from the DPD differential pressure sensor. sor inlet
The DPD differential pressure sensor changes the • Wrong detection or slow response for the
signal voltage in accordance with changes in the DPD differential pressure sensor
exhaust gas pressure difference between the front
and the rear of the DPD filter. 12) Inspect the exhaust system.
When the DPD differential pressure sensor reaches 13) Inspect the air intake system.
to a certain amount of PM accumulation, or a certain 14) Start the engine and maintain idling for 30 sec-
period of operating hours, DPD automatic regener- onds.
ation starts. 15) Confirm that the DPD manual regeneration in-
If the automatic regeneration cannot be completed dicator light blinks.
due to working, the DPD manual regeneration indi- ANNOTATION:
cator light in the monitor panel blinks to prompt the
driver to perform manual regeneration. • If it is not blinking, use the trouble diagno-
When regeneration has once started, it must be sis scan tool to confirm DPD accumulation
completed within a certain period of time. status and DPD time status and applicable
After completion of DPD regeneration, purification area based on the DPD status table.
status of the filter is determined based on the ex- • Compare DPD accumulation status and
haust differential pressure. DPD time status and use the DPD status ta-
When the ECM detects excessive amount of PM ac- ble to determine DPD regeneration process
cumulation, it becomes so hot that it is eroded dur- status.
ing regeneration process and cannot control com- • To use the DPD status table, confirm the
bustion; therefore, DPD regeneration is not allowed data display values on the trouble diagnosis
to start. scan tool and readings in the DPD status
2. DPD control system check Inspection table.
Inspection for determining the failure location in the
DPD system
1) Perform the inspection of the engine control
system.
2) Turn the starter switch ON for 30 seconds.
3) Check that the monitor panel functions nor-
mally.
• DPD automatic regeneration indicator light
illuminates in green DPD Ac-
• DPD manual regeneration indicator light il- cumula-
luminates orange tion Sta-
tus
ANNOTATION:
• If it does not illuminate, inspect the circuit of
the DPD indicator light.
4) Turn the starter switch OFF for 30 seconds.
5) Inspect the amount of engine oil.
6) Connect the trouble diagnosis scan tool to the
DTC. DPD Distance Status
8) Display the scan tool data DPD regeneration
switch using a trouble diagnosis scan tool. Range
9) Check if the data displayed on the DPD regen- A Normal range
eration switch of the trouble diagnosis scan DPD amber lamp binks but
tool is turned to ON or OFF when changing B manual regeneration is possi-
each switch. ble.
Exhaust differential pressure is
ANNOTATION:
C excessive high range and man-
• If the ON or OFF operation does not link, ual regeneration is inhibited.
inspect the DPD switch and harness. Time status is abnormal range
D and manual regeneration is in-
10) Inspect the installation condition of the DPD
hibited.
11) Inspect the exhaust differential pressure sen-
sor. ANNOTATION:
84402832 NA - May 2011

4001F-10
• The area where 2 status values meets will • If no error message has been displayed, in-
point to either A, B, C, or D. spect for a problem in the fuel system.
16) Operate the trouble diagnosis scan tool. 19) Confirm that the data display of exhaust tem-
perature 1 is below the standard value using a
ANNOTATION:
trouble diagnosis scan tool if the regeneration
• Use a trouble diagnosis scan tool to reset completed.
the DPD status. Specified value: 130 °C {266 °F}
• If it is range A or B, perform the DPD forced ANNOTATION:
regeneration test with the trouble diagnosis
• If it is the standard value or greater, idle the
scan tool.
engine until it reaches the standard value or
• If it is range C or D, perform the DPD forced lower.
slow regeneration test with the trouble diag-
nosis scan tool. 20) Accelerate the engine revolution to maximum
revolution speed without load.
ANNOTATION:
21) Check the data display of the exhaust differen-
• After the DPD forced slow regeneration is tial pressure when the data display of exhaust
completed, replace the engine oil. temperature 1 reaches the standard value.
Specified value: 150 °C {302 °F}
17) Check the DTC detection with the trouble di- 22) Check the exhaust differential pressure data
agnosis scan tool if the regeneration does not display using a trouble diagnosis scan tool.
start. Specified pressure: 0.5 - 1.8 kPa {0.01 - 0.02
ANNOTATION: kgf/cm2 / 0.1 - 0.3 psi}
• If no DTC is detected, confirm data display ANNOTATION:
related to DPD regeneration control. • If it is the standard value or lower, perform
18) Inspect the corresponding DTC if the regener- ash removal.
ation is not completed and the scan tool dis- • If it is the standard value or greater, inspect
plays an error message. for the abnormalities in the DPD differential
pressure sensor system.
ANNOTATION:
23) Replace the ECM if any problem can be seen
• If no error message has been displayed, in- through the inspections above.
spect the DPD filter for damage, cracks, or ECM Removal
melting. ECM Installation
• If no error message has been displayed, in- 24) Set the injector ID code on the ECM.
spect the oxidation catalyst for degradation, 25) Perform the unit difference learning of the fuel
damage, cracks, melting, or excessive sed- supply pump to the ECM.
iment.
• If no error message has been displayed, in-
spect for the cause of overheating.
84402832 NA - May 2011

4001F-11
OBD system check 4) Check if the monitor is blinking.
1. OBD system check Description of Function ANNOTATION:

The OBD system check is a systematic method for • If the actual unit does not have a monitor
checking problems caused by functional failures in setting, do not perform this operation.
the engine control system, and is also the starting • If the monitor is not blinking, inspect the
point for all diagnoses for driveability complaints. monitor blinking circuit system.
By correctly using this diagnostic step, it is possible
to reduce the time for diagnosis and prevent the 5) Use the trouble diagnosis scan tool and con-
replacement of parts that are not defective. firm the DTCs of the ECU that has communi-
cation established.
ANNOTATION: Loss of communication with the trouble diag-
• Points to remember regarding the OBD system nosis scan tool occurs due to the abnormali-
check ties in the communication circuit of each ECU
and trouble diagnosis scan tool.
• If there are no complaints on driveability, do not 6) Start the engine.
perform these diagnostic steps unless otherwise
instructed in other sections. ANNOTATION:
• Check the service technical report before starting • If the starter does not operate, inspect the
the diagnosis. starter circuit system.
• Do not delete the DTCs unless it is instructed in a • If the engine does not start, check the DTC.
diagnostic step. • If the DTC is detected, inspect the corre-
• If a malfunction is found in the engine starting sys- sponding DTC.
tem, inspect the starting system. • If no DTC has been detected, inspect the
• The battery should be fully charged. starting system.
• The battery cable should be normal and securely
connected. 7) Check the engine stalling for problems.
• The GND of the ECM should be securely con- 8) Check the engine hunching and rough idling
nected in the correct position. for problems.
• The harness connector of the ECM should be 9) Check if there are problems with insufficient
clean and correctly connected. engine output, blowup failure, or engine hesi-
tation.
2. OBD system check Inspection 10) Check for problems with sudden stopping.
Inspection for determining the failure location in the 11) Check for problems with sudden change.
OBD system 12) Check for problems with insufficient output or
1) Turn ON the starter switch. blowup failure.
2) Check the abnormality display of the monitor. 13) Check for problems with engine hesitation or
acceleration failure.
ANNOTATION: 14) Check for problems with dark smoke.
15) Check for problems with white smoke.
• If the actual unit does not have a monitor
setting, do not perform this operation. 16) Check for problems with the idling revolution
speed maladjustment.
• If the monitor is off, an abnormality display is
performed for the monitor illumination circuit 17) Check for problems with the idling revolution
system. speed not decreasing.
18) Check for problems with frequent DPD regen-
3) Short the DTC. eration by the manual regeneration.
19) Check for problems with long DPD regenera-
ANNOTATION:
tion time.
• Short the No.4 terminal and No.12 terminal.
• If the actual unit does not have a monitor
setting, do not perform this operation.
84402832 NA - May 2011

4001F-12
Inspection of the monitor warning Inspection if the monitor does not show an abnor-
mality display when the starter switch is switched
light illumination circuit system ON
1. Inspection of the monitor warning light illumination 1) Perform the OBD system check.
circuit system Description of Function 2) Inspect the monitor bulb.
The monitor is supplied with power supply voltage 3) Replace the valve if a problem is discovered.
via the starter switch and shows an abnormality dis- 4) Inspect the monitor circuit.
play due to a signal from the ECM.
The ECM makes the monitor show an abnormality • No open circuit or high resistance should be
display during a lamp check when the starter switch found between the fuse and monitor.
is ON and when the DTC is set. • No open circuit or high resistance should be
It also blinks the monitor depending on the detected found between the monitor and ECM.
DTC when the body ground terminal and diagnostic 5) Repair the circuit if a problem is discovered.
switch terminal of the DLC are shorted. 6) Replace the ECM.
A monitor circuit is incorporated inside the ECM and Removal of ECM
monitors operation of the light. Installation of ECM
2. Inspection of the monitor warning light illumination 7) After replacing the ECM, perform EGR learn-
circuit system Inspection ing.
84402832 NA - May 2011

4001F-13
84402832 NA - May 2011

4001F-14
Section
4001G
Maintenance precautions
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS

4001G-1 PRINTED IN FRANCE
1. Maintenance precautions aged due to foreign matter accidentally in-

truded.
1) Precautions on maintenance For this reason, extreme care must be taken
To prevent the engine from being damaged to prevent any foreign matter from entering.
and to ensure the reliability of engine perfor- When performing maintenance on the fuel
mance, be careful of the following points when system, take extreme care to prevent any
performing maintenance works. foreign matter from entering the system.
When placing the engine on the ground, make
sure that the bearing surface of the oil pan • Before starting maintenance, clean the fuel
does not directly contact the ground. line and its surroundings.
Use an appropriate wood frame, etc. to sup- • Be sure to wash your hands before starting
port the engine at the engine foot portion and maintenance.
the flywheel housing portion. Do not put on cotton work gloves.
There is only a small gap between the oil pan • When the fuel hose or fuel pipe is removed,
and oil pump strainer, so be careful not to cover the opening with a plastic bag and fix
damage the oil pan and oil strainer. it with a piece of tape.
• While the air duct or air cleaner is removed, WARNING
cover the open section of the intake to pre-
vent foreign matters from entering the cylin- When the high-pressure piping of
der. the fuel system is removed, be sure
If a foreign matter enters the cylinder, it may to replace it with a new one.
seriously damage the cylinder when the en- If it is reused, the sealing surface
gine starts. may be damaged to cause fuel leak-
• When maintaining the engine, be sure to age.
disconnect the negative battery cable.
Failure to do this may cause the harness or • When replacing the fuel hose and/or fuel
electrical components to be damaged. pipe, do not unpack new components be-
If energizing is required for inspection, be fore starting installation.
careful not to cause a short. • When the fuel pipe, injection pipe, fuel injec-
• Before assembly, apply the engine oil to the tor, fuel supply pump, and/or common rail
slide contact surface of the engine. are removed, seal each opening immedi-
This work ensures appropriate lubrication ately.
when first starting the engine. • Store the eyebolt and gasket in a clean parts
• When the valve train component, piston, box with a cover so that foreign matter does
piston ring, connecting rod, connecting rod not attach to them.
bearing, and/or crankshaft journal bearing • Fuel leakage may cause a fire.
are removed, line them up in the correct or- Therefore, be sure to wipe spilled fuel af-
der so that their original positions are clear. ter completing the maintenance work and
• When installing, install it in the same posi- confirm that there is no fuel leakage before
tion as when it was removed. starting the engine.
• When assembling the engine, replace the
gasket, oil seal, and O-ring with new ones. 2) Cautions on electronic system
• For a component with the liquid gasket ap- Using circuit test tools
plied, carefully remove the old liquid gasket Unless specifically instructed in the diag-
and clean the component so that no oil, wa- nostic procedure, do not use a test light
ter, and/or dust remain. when diagnosing the powertrain electronic
Thereafter, apply the specified liquid gasket system.
to each component before assembly. When a probe connector is required in the
• Assemble components with the liquid gas- diagnostic procedure, use the connector
ket applied within 5 minutes of applying the test adapter kit.
liquid gasket.
If 5 minutes have passed, remove the old
liquid gasket and apply liquid gasket again.
• When assembling or installing a compo-
nent, make sure to tighten them at the
specified torque to ensure secure installa-
tion.
Important precautions for handling this engine
The holes and gaps in the fuel system includ-
ing inside the injector where the fuel passes
through are manufactured with high precision.
Therefore, these are extremely sensitive to
any foreign matter, and may be severely dam-
84402832 NA - May 2011

4001G-3
Special tool: connector test adapter kit he/she slides across the seat of the ma-
(refer to section 1003) chine.
Commercial electronic equipment A person wearing insulated shoes can
Commercial electronic equipment refers build an electrostatic charge by induction
to commercially available electronic equip- if he/she momentarily touches the ground
ment attached to the unit after it has been while standing near a highly charged object.
shipped from the factory. A charge of the same polarity flows out, and
Be careful, as such accessories are not with a highly opposing polarity, that person
taken into particular consideration at the becomes charged.
machine design stage. As static electricity causes damage, be
Commercial electronic equipment may cautious when handling or testing electronic
cause malfunctions in the electronic control components.
system, even if the equipment is properly
attached. CAUTION
This includes equipment not connected to
the electronic system of the machine, such • To prevent damage due to electro-
static discharge, do not touch the
as mobile telephones and radios.
connector pins of the ECM or the
Therefore, when diagnosing power train
electronic components soldered
problems, confirm whether such commer-
onto the circuit board of the ECM.
cial electronic equipment is attached first
and then remove them from the machine if • To prevent damage due to elec-
trostatic discharge, do not open
such equipment is attached.
the packaging of a replacement
If the problem has not been resolved after
part until installation preparation
removing the equipment, perform the diag-
for the replacement part is com-
nosis using the regular procedure.
pleted.
CAUTION • To prevent damage due to electro-
static discharge, connect the part
• Make sure that commercial elec- packaging to a properly working
tronic equipment is connected to ground connection of the actual
a circuit that is not involved with unit before removing the part
the circuits of the electronic con- from its packaging.
trol system for both power and • To prevent damage due to electro-
ground. static discharge, when handling a
part while sliding across the seat,
Welding operation for the actual unit sitting down from a standing po-
When performing welding to the actual unit, sition, or walking a certain dis-
make sure to disconnect the battery in prior tance, touch a properly working
to the operation. ground connection before attach-
Current that occurred during welding may ing the part.
lead to failure and/or damage to the elec-
tronic control system. Fuel injection system
Damage caused by electrostatic discharge
As the electronic components used in the Fuel piping
electronic control system are designed to WARNING
operate at extremely low voltages, they
can be easily damaged by electrostatic The high pressure pipe and injec-
discharge, and some types of electronic tor pipe in the fuel system should
components can be damaged by static not be reused.
electricity of 100 V or less, which cannot be When it is once removed, make
felt by a person. sure to replace it with new one.
Note that a voltage of 4000 V is required for
a person to be able to detect electrostatic The pressure limiter or fuel pressure sen-
discharge. sor should not be replaced individually.
There are various ways a person can build When a failure is found, the common rail
up an electrostatic charge. assembly and all fuel pipes should be re-
The most common way to build up an elec- placed.
trostatic charge is through methods based
on friction or induction.
An example of when a person builds an
electrostatic charge by friction is when
84402832 NA - May 2011

4001G-4
injector data into the ECM - it can either

be done with the Isuzu EIDSS or the en-
gine service monitor on the machine. Doug
Reinhardt wrote up the procedure in his
service training document, XC Engine Ser-
vice Monitor. Need clarification from Isuzu
on use of the EIDSS.
As for the programming method, refer to the
instruction manual of the trouble diagnosis
scan tool.
Prior confirmation item for programming
When performing programming, check the
ECM part No. as necessary.
engine type as necessary.
1 Injector pipe engine No. as necessary.
2 Flow damper When performing programming, check the
3 Pressure limiter injector ID code as necessary.
4 Fuel pressure sensor Items require programming
5 Common rail When the ECM has been replaced, perform
programming.
3) Programming When the engine has been replaced, per-
Programming guideline form programming.
When the ECM or injector has been re- When the injector has been replaced, per-
placed, the EST cannot be used to write form programming.
84402832 NA - May 2011

4001G-5
84402832 NA - May 2011

4001G-6
Section
4004
Removal and Installation of Starter Motor
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Job code 55201AE50 Removal of Starter Motor

WARNING then remove the battery cable (2) on the negative
side.
• Do not use open flames and do not allow
sparks near the battery. • When removing the terminal and harness, secure
them so that they do not interfere with the frame.
CAUTION Also, cover with a rubber cap to protect against
sparks.
work.
Items to prepare
• Rag
• Cleaning fluid

N·m
3. Use a wrench (8 mm) to remove the nut (5), then

remove the wiring (6).
84402832 NA - May 2011

4004-3
4. Use a wrench (8 mm) to remove the bolt (7), and Installation of Starter Motor
then remove the wiring (8).
Tighten bolts and nuts to the specified torque.

then remove the wiring on the ground side (9).
6. Use a wrench (17 mm) to remove the 2 nuts (11),

then remove the starter motor (12).
Tightening torque for nut installation: 82.4 N·m
84402832 NA - May 2011

4004-4
Section
4005
Removal and Installation of Alternator
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

WARNING Removal of Alternator

• Do not use open flames and do not allow 1. Remove the fan belt.(For details, see "Removal and
sparks near the battery. Installation of Fan Belt".)
then remove the battery cable (2) on the negative
CAUTION side.
• Be sure to stop the engine before beginning • When removing the terminal and harness, secure
work. them so that they do not interfere with the frame.
• Also, cover with a rubber cap to protect against
Items to prepare sparks.
• Rag
• Cleaning fluid
4. Remove the cap (1), use the wrench (10 mm) to

remove the nut (2), and then remove the wiring (3).
84402832 NA - May 2011

4005-3
5. Use a wrench (20 mm) to remove the bolt (1), and Installation of Alternator
then remove the alternator (2).
Tightening torque for bolt installation：40 N•m To install, perform the reverse of the removal procedure.
84402832 NA - May 2011

4005-4
Section
4008
Preheating System
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal and Installation of Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Glow plug Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Glow plug Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Glow plug Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Preheating System
Removal and Installation of Glow 3) Remove the intake throttle valve from the inlet
pipe.
Plug
Glow plug Removal
battery.
1) Remove the air duct from the intake throttle
valve.
2) Disengage the harness connector from the in-
ANNOTATION:
lock. 1 Intake throttle valve
2 Gasket
3 Inlet pipe
3. Glow plug Removal

1) Remove the glow plug connector from the
glow plug.

2 Lock release
3 Lock

assembly.
84402832 NA - May 2011

4008-3
Preheating System
Glow plug Installation 1) Install the intake throttle valve to the inlet pipe.
1. Glow plug Installation 17.7 lb・ft｝
1) Install the glow plug to the cylinder head as-
sembly.
14.8 lb・ft｝
CAUTION

2 Gasket
3 Inlet pipe
2) Install the air duct to the intake throttle valve.

throttle valve.
2) Install the glow plug connector to the glow ANNOTATION:

plug. • After connecting the harness connector,
Tightening torque： 1 N・m ｛0.1 kgf・m / press in the lock operation portion to lock.
8.9 lb・in｝
CAUTION
rounding parts.

2 Lock release
3 Lock
2. Intake throttle valve Installation 1) Connect the battery ground cable to the bat-
tery.
84402832 NA - May 2011

4008-4
Preheating System
Glow plug Inspection

1. Glow plug Inspection
1) Measure the resistance using the circuit
tester.
Standard resistance： 5.00 Ω less than
CAUTION
• Replace the glow plug if the mea-
sured value is not within the range
of standard value.
• Use a set of 6 glow plugs from the
same manufacturer.
84402832 NA - May 2011

4008-5
Preheating System
84402832 NA - May 2011

4008-6
Section
4020A
Electrical Equipment Layout Diagram
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Electrical Equipment Layout Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Main Unit Left Side Layout Diagram (radiator chamber) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine Section Layout Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Main Unit Right Side Layout Diagram (pump chamber) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Main Unit Center Section Layout Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cab Layout Diagram 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cab Layout Diagram 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Layout Around Operator Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Stand Alone Parts Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17


Overall View
84402832 NA - May 2011

4020A-3
Main unit left side (radiator Main unit right side (pump
1 3 5 In Cab
chamber) chamber)
2 Engine 4 Main unit center section
84402832 NA - May 2011

4020A-4
Main Unit Left Side Layout Diagram (radiator chamber)
1 Air cleaner sensor 5 Fuse 15A：controller 9 Battery relay

2 Fusible link 65A (F1):fuse box 6 Relay compressor 10 Receiver dryer sensor
3 Fusible link 60A：safety relay 7 Swing pilot pressure sensor 11 Battery
4 Fusible link 50A：Back up 8 Starter relay
84402832 NA - May 2011

4020A-5
Engine Section Layout Diagram
84402832 NA - May 2011

4020A-6
Engine coolant temperature

1 5 EGR valve 9 Suction control valve
sensor
2 Boost pressure sensor 6 Boost temperature sensor 10 Fuel temperature sensor
3 Overheat switch 7 Starter motor 11 Cam position sensor
Engine hydraulic pressure sen-
4 Common rail pressure sensor 8 Crank position sensor 12
sor
84402832 NA - May 2011

4020A-7
Main Unit Right Side Layout Diagram (pump chamber)
84402832 NA - May 2011

4020A-8
Horsepower control propor-

1 Charge fuel pump 6 Lever lock 11
tional valve
2 P1 pressure sensor 7 Travel high speed 12 N2 pressure sensor
3 P2 pressure sensor 8 Boosted pressure 13 Oil temperature sensor
4 4 Stack Solenoid Valve 9 N1 pressure sensor
5 Swing lock 10
valve
84402832 NA - May 2011

4020A-9
Main Unit Center Section Layout Diagram
1 Upper pressure sensor

2 Travel pressure sensor
84402832 NA - May 2011

4020A-10
Cab Layout Diagram 1
84402832 NA - May 2011

4020A-11
1 Air conditioner sunlight sensor 6 Rocker switch 11 Air conditioner control panel
2 Monitor display 7 Wiper motor 12 Engine emergency stop switch
3 Knob 8 Radio 13 Rocker switch
4 Cigar lighter 9 Throttle volume 14 Gate lock limit switch
5 Wiper controller 10 Key cylinder
84402832 NA - May 2011

4020A-12
Cab Layout Diagram 2
84402832 NA - May 2011

4020A-13
1 Computer B 3 ECM (engine control module) 5 Relay

2 Computer A 4 Fuse box
No. Name No. Name No. Name

CN. A9 ECM relay CN. A14 Neutral start relay CN. A19 Beacon relay
CN. A10 DPF relay CN. A15 Key ON relay CN. A20 Room lamp relay
CN.A11 Battery relay CN. A16 Horn relay CN. A21 Right speaker relay
CN. A12 Idle stop relay CN. A17 Boom, house light relay CN. A22 Left speaker relay
CN. A13 Starter cut relay CN.A18 Cab top light relay
No. Name No. Name

F1 Key switch 15 A F11 Wiper, washer 15 A
F2 ECM (engine control module) 20 A F12 Travel alarm, signal lamp 10 A
F3 GPS computer 15 A F13 Cigar lighter, seat suspension 10 A
F4 Backup (radio, room lamp) 10 A F14 DC converter 10 A
F5 Gate lock lever 10 A F15 Air conditioner unit 5A
F6 Solenoid 10 A F16 Air conditioner blower motor 15 A
F7 Horn 10 A F17 Air conditioner compressor 5A
F8 Cab top light 15 A F18 Option power supply 10 A
F9 Boom, house light 15 A F19 Feed pump 15 A
F10 Option power supply 15 A F20 Option line solenoid 10 A
84402832 NA - May 2011

4020A-14
Layout Around Operator Seat
84402832 NA - May 2011

4020A-15
Air conditioner
1 Cup holder 5 Throttle volume 9
control panel
Engine emer-
2 Starter switch 6 Tilt lever right 10
gency stop switch
Rocker switch
3 7 Tilt lever left 11 Gate lever
space
4 Radio 8 Ashtray
84402832 NA - May 2011

4020A-16
Stand Alone Parts Diagram

Name Shape Circuit Remarks
Model ； DC24
V Specifica-
tions
Starter relay
Sumitomo
part No. ；
KHH13250
Model ； For
+24 V DC
Battery relay Sumitomo
part No. ；
KHR1241
Model ； 5.0
kW-24 V
Starter motor Isuzu part
No. ； 898001-
9150
Model ； 50
A-24 V
Alternator Isuzu part
No. ； 897375-
0171
84402832 NA - May 2011

4020A-17
Model ；
180G51
Battery Sumitomo
part No. ；
KHR4197
Sumitomo
part No. ；
Washer motor
KHR2261
(Tank + Motor)
Model；65 A
Fusible link Sumitomo
(fuse box) part No. ；
KHR1592
Model；60 A
Fusible link Sumitomo
(safety relay) part No. ；
KHR3850
84402832 NA - May 2011

4020A-18
Fusible link
Model；50 A
（back up）
Fuse
Model；15 A
(computer)
Sumitomo
Relay con-
part No. ；
denser
KHR3802
Model ；
RA30Y2
Throttle vol- 30SKB1KΩK
ume Sumitomo
part No. ；
KHR2751
84402832 NA - May 2011

4020A-19
Model ； DC24
V
Starter switch Sumitomo
part No. ；
KHR20050
Sumitomo
Fuel level sen-
part No. ；
sor
KHR1935
Model ； DC24
V
Charge fuel
Sumitomo
pump
part No. ；
KHH11880
Sumitomo
Reserve tank
part No. ；
limit switch
KHH10850
84402832 NA - May 2011

4020A-20
Sumitomo
Vacuum sen-
part No. ；
sor
KHH10330
Isuzu part
Glow plug No. ； 894390-
7775
EGR valve ac-

cessory
EGR motor
EGR valve
EGR position
Isuzu part
sensor
No. ； 898001-
1910
Common rail
accessory
Common rail
Common rail
pressure sen-
Isuzu part
sor
No. ； 897306-
0632
84402832 NA - May 2011

4020A-21
Isuzu part
Cam angle
No. ； 898014-
sensor
8310
Isuzu part
Crank angle
No. ； 897306-
sensor
1131
Isuzu part
Oil pressure
No. ； 897600-
sensor
4340
Isuzu part
Boost pressure
No. ； 180220-
sensor
0140
Isuzu part
Boost temper-
No. ； 81246-
ature sensor
8300
84402832 NA - May 2011

4020A-22
Supply pump
accessory
Fuel tempera- Supply pump
ture sensor Isuzu part
No. ； 897306-
0448
Supply pump
accessory
Suction control Supply pump
valve Isuzu part
No. ； 897306-
0448
Isuzu part
Injector No. ； 897329-
7032
Suction Air Sumitomo

Temperature part No. ；
Sensor KHH13270
Engine coolant Isuzu part

temperature No. ； 897170-
sensor 3270
84402832 NA - May 2011

4020A-23
Barometric Sumitomo
pressure sen- part No. ；
sor KHH0536
Sumitomo
Computer A part No. ；
KHR29000
Sumitomo par-
Computer B t No.;KHR2905
0
Model ； DC24
V
Relay Sumitomo
part No. ；
KHR3802
Sumitomo
DC-DC con-
part No. ；
verter
KHR2447
84402832 NA - May 2011

4020A-24
Sumitomo
Alarm
part No. ；
(feed pump)
KHR4024
Sumitomo
Feed pump part No. ；
KHR12840
Sumitomo
Feed pump
part No. ；
switch
KHR12900
Model ； 24 V
Lamp 70 W
(front right Sumitomo
housing) part No. ；
KHR2475
Model ； 24 V
70 W
Lamp
Sumitomo
(boom)
part No. ；
KHR0957
84402832 NA - May 2011

4020A-25
Model ； 24 V
70 W
Lamp
Sumitomo
(cab top)
part No. ；
KHR16240
Sumitomo
Speaker
part No. ；
(right) (left)
CAP2284
Model ；
SD107023
Monitor display Sumitomo
part No. ；
KHR23591
Model ； 50.0
Pressure sen- MPa
sor Sumitomo
(P1) (P2) part No. ；
KHR10290
84402832 NA - May 2011

4020A-26
Pressure sen- Model ； 5.0

sor MPa
(N1) (N2) Sumitomo
(swing) (upper) part No. ；
(travel) (arm in) KHR26940
Model ； 0.49
Pressure
MPa
switch
Sumitomo
(option) (2nd
part No. ；
option)
KHR21490
Pressure Sumitomo
switch part No. ；
(filter) KHR14470
Sumitomo
4 stack sole-
part No. ；
noid valve
KHJ15450
84402832 NA - May 2011

4020A-27
2 stack sole-
Sumitomo
noid valve
part No. ；
(knob switch
KHJ14780
type)
2 stack sole- Sumitomo

noid valve part No. ；
(pedal type) KHJ14000
P1 flow control Sumitomo

proportional part No. ；
valve LJ016060
Horsepower
Sumitomo part
control propor-
No.；LJ00684
tional valve
84402832 NA - May 2011

4020A-28
Sumitomo
Free swing
part No. ；
switch
KHR16140
Model ； KAB
555
KAB seat Sumitomo
part No. ；
KHN13560
Free swing so- Sumitomo part

lenoid No.；KHJ0659
Hydraulic oil Sumitomo

temperature part No. ；
sensor KHR2433
84402832 NA - May 2011

4020A-29
Model；With 4
Knob; Right switches
(with one- Sumitomo
touch switch) part No. ；
KHJ24640
Model；With 4
Knob; Left
switches
(with horn
Sumitomo
switch and ra-
part No. ；
dio mute)
KHJ24630
Sumitomo
part No. ；
KHR3852
Travel alarm
Basic fre-
quency ； 2560
Hz
Sumitomo
part No. ；
KHR11440
Horn (low)
Basic fre-
quency ； 303
Hz
Sumitomo
part No. ；
KHR11450
Horn (high)
Basic fre-
quency ； 333
Hz
84402832 NA - May 2011

4020A-30

Sumitomo
Wiring Sys-
tems par ；
6098-0017
Diode
6098-0061
Sumitomo
part No. ；
KHP1796
Sumitomo
Lever lock limit
part No. ；
switch
KHR14930
Model ；
AM/FM ST
（12/24 V）
Radio
Sumitomo
part No. ；
KHR27980
Model ； 24
V,10 W
Lamp
Sumitomo
(room lamp)
part No. ；
KHN2714
84402832 NA - May 2011

4020A-31
Model ； DC12
V
Accessory
Sumitomo
socket
part No. ；
KHR2501
Model ； DC24
V
Cigar lighter 24
Sumitomo
V
part No. ；
KHR11210
Sumitomo
Air conditioner
part No. ；
unit
KHR27160
Limit switch Sumitomo

(front window) part No. ；
(door) KHN26000
84402832 NA - May 2011

4020A-32
Sumitomo
Wiper con-
part No. ；
troller
KHN3392
Sumitomo
Wiper motor part No. ；
KHN25780
Sumitomo
Solar radiation
part No. ；
sensor
KHR10540
Sumitomo
Receiver dryer
part No. ；
(switch)
KHR13590
84402832 NA - May 2011

4020A-33
Air conditioner
Sumitomo
compressor
part No. ；
(magnetic
KHR3197
clutch)
Motor actuator
(air mix)
(mode) (inside/
outside air)
EVA sensor
Interior tem-
perature sen-
sor
84402832 NA - May 2011

4020A-34
Relay
(compressor)
(blower OFF)
Blower motor
Blower amp
Sumitomo
Air conditioner
part No. ；
switch panel
KHR27250
84402832 NA - May 2011

4020A-35
Sumitomo
Travel alarm
part No. ；
switch
KHR15850
Sumitomo
Horn volume
part No. ；
switch
KHR28540
Engine emer- Sumitomo

gency stop part No. ；
switch KHR28530
3 stack propor-
tional valve Sumitomo
(boom up, part No.;
arm in, bucket KHJ23870
close)
84402832 NA - May 2011

4020A-36
Fuel filter sen- Sumitomo

sor part No.;
(Isuzu) KHH13230
DPF exhaust
Isuzu part No.;
gas pressure
897360-3682
differential
Sumitomo
pressure sen-
part No.;
sor
KHH13330
(Isuzu)
Isuzu part No.;

DPF tempera-
898004-3300
ture sensor
Sumitomo
(Isuzu) (cen-
part No.;
ter)
KHH13360
Isuzu part No.;

DPF tempera-
898004-3290
ture sensor
Sumitomo
(Isuzu)
part No.;
(front)
KHH13350
Isuzu part No.;

Turbo com- 898077-1181
puter Sumitomo
(Isuzu) part No.;
KBH13650
84402832 NA - May 2011

4020A-37
EGR manifold Isuzu part No.;

temperature -
sensor Sumitomo part
(Isuzu) No.; -
Sumitomo part
VGS TURBO
No.; -
84402832 NA - May 2011

4020A-38
Section
4020B
Connection Connector Pin Layout
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Computer A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Computer A
84402832 NA - May 2011

4020B-3
Monitor
84402832 NA - May 2011

4020B-4
Section
4020C
Sequence Circuit Diagram
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Code table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Computer A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Computer B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Lever Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Working lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electrical Symbol List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Code table
FUSE 10A ; DC/DC CONVER-

A1 COMPUTER F14 R7 RESISTOR (MAF)
TOR
FUSE 5A ; AIR CONDITIONER
A2 ENGINE CONTROLLER F15 S1 KEY SWITCH
HEATER UNIT
FUSE 15A ; AIR CONDI- ENGINE EMERGENCY STOP
A4 WIPER CONTROLLER F16 S9
TIONER BLOWER SWITCH
FUSE 5A; AIR CONDITIONER
A6 BLOWER CONTROLLER F17 S13 OVERLOAD SWITCH (EU)
COMPRESSOR
FREE SWING (NA) ; OP-
A13 CONTROLLER B F18 FUSE 10A ; SPARE S22
TIONAL (EU)
HYDRAULIC FUNCTION
COOLANT TEMPERATURE FUSE 15A; FUEL FILLER
B1 F19 S51 CANCELLATION LEVER
SENSOR PUMP
SWITCH
HYDRAULIC OIL TEMPERA- AIR CONDITIONING COM-
B2 F20 FUSE 10A ; OPTION LINE S52
TURE SENSOR PRESSOR CLUTCH SWITCH
FUEL TEMPERATURE SEN-
B3 F41 FUSIBLE 50A ; LINK BACK UP S53 DOOR LIMIT SWITCH
SOR
FRONT WINDOW LIMIT
B5 EVAPORATOR SENSOR F42 FUSE 15A ; CONT S54
SWITCH
ENGINE OIL PRESSURE FUSIBLE 65A ; LINK FUSE RESERVE TANK LOW
B21 F43 S55
SWITCH BOX SWITCH
SWING PILOT PRESSURE FUSIBLE 60A ; LINK SAFETY
B22 F45 S61 REFUEL PUMP SWITCH
SWITCH RL
UPPER PILOT PRESSURE
B26 G1 BATTERY S62 AIR CLEANER SENSOR
SENSOR
TRAVEL PILOT PRESSURE
B27 G2 ALTERNATOR S70 HORN VOLUME SWITCH
SENSOR
PRESSURE SWITCH FILTER
SECOND OPTION PILOT CIR-
B28 H2 TRAVEL ALARM S71 INDICATOR (BREAKER OP-
CUIT 1 PRESSURE SWITCH
TION)
PUMP PRESSURE SENSOR
B40 H4 SPEAKER RIGHT S85 BEACON (EU)
(NEGA-CONT. P2)
PUMP PRESSURE SENSOR DC-DC (24V-12V) CON-
B42 H5 SPEAKER LEFT U1
(P1) VERTER
PUMP PRESSURE SENSOR ROTARY LIGHT CONNEC-
B43 K2 RELAY-GLOW PLUG X2
(NEGA-CONT. P1) TOR
PUMP PRESSURE SENSOR OPTIONAL POWER CON-
B44 K3 RELAY-HORN X3
(P2) (BLUE BAND) NECTOR
OVERLOAD INDICATOR ENGINE TEST POINT CON-
B45 K5 RELAY-ROTARY LIGHT X4
PRESSURE SWITCH NECTOR
RELAY-AIR CONDITIONER CONTROLLER TEST POINT
B47 BOOST PRESSURE SENSOR K6 X5
CONDENSER FAN CONNECTOR
AMBIENT AIR (BAROMET- CAB SEAT COMPRESSOR
B48 K7 RELAY BATTERY X6
RIC) PRESSURE SENSOR MOTOR CONNECTOR
RELAY-WORKING LIGHT
CRANKSHAFT POSITION ANTI-THEFT SYSTEM CON-
B49 K10 (UPPERSTRUCTURE / AT- X9
SENSOR NECTOR
TACHMENT)
BOOST TEMPERATURE RELAY-WORKING LIGHT
B51 K11 X15 ACCESSORY SOCKET
SENSOR (CAB)
COMMON RAIL PRESSURE
B52 K17 BLOWER OFF RELAY X23 CLEAR MEMORY 1
SENSOR
B61 SUNLOAD SENSOR K30 REFUEL PUMP RELAY X24 CLEAR MEMORY 2
B82 REFUEL PUMP STOP ALARM K31 REFUEL PUMP STOP RELAY X25 TO CONTROLLER C
PRESS. SENSOR (PILOT
B83 K34 RELAY STARTER CUT X26 EST CONECTOR B
ARM CLOSE)
B84 K35 RELAY ROOM LAMP X27 TO GPS UNIT
BUCKET CLOSE)
B85 K36 RELAY SPEAKER LEFT X32 TO DRM
BOOM UP)
84402832 NA - May 2011
4020C-3
B86 EGR INTAKE TEMP. SENSOR K37 RELAY SPEAKER RIGHT X33 FOR CRANE
B87 CAM ANG(MRE) SENSOR K51 RELAY CONDENSER X34 FOR FAN REVERSE
12V OUTPUT(FOR RADIO
B88 FUEL FILTER SENSOR K63 RELAY ECM X36
EU)
PILOT PRESSURE SOLE-
B89 EXSHAUST PRESS. SENSOR K64 RELAY KEY ON Y2
NOID VALVE (BLUE BAND)
EXSHAUST TEMP. SEN- SWING BRAKE SOLENOID
B90 K65 RELAY BATTERY RL Y3
SOR(CNT) VALVE (WHITE BAND)
EXSHAUST TEMP. SEN- 2 STAGE TRAVEL SOLENOID
B91 K66 RELAY IDLE STOP Y4
SOR(FNT) VALVE (RED BAND)
POWER-UP SOLENOID
B92 HORN LOW (LEFT) K67 RELAY DPF Y5
VALVE (YELLOW BAND)
MAIN PUMP POWER PRO-
B93 HORN HIGH (RIGHT) K68 RELAY NEUTRAL START Y7
PORTIONAL SOLENOID
PRESS. SWITCH (1ST OP- AIR CONDITIONER MAGNET
B94 K69 RELAY STARTER Y8
TION) CLUTCH
AIR INTAKE SENSOR MASS OPTION 2 SPEED SOLENOID
B95 M1 STARTER MOTOR Y9
& TEMP VALVE (BLUE TAPE)
WORKING LIGHT (UPPER- MAIN PUMP FLOW PROPOR-
E1 M3 WIPER MOTOR Y11
STRUCTURE) TIONAL SOLENOID
WORKING LIGHT (ATTACH- FREE SWING SOLENOID
E2 M4 WASHER MOTOR Y18
MENT) VALVE (NA)
OPT.1 KNOB (R) -R SOLE-
E3 WORKING LIGHT (CAB) M5 MOTOR (AIR CHANGING) Y23
NOID VALVE (BLUE TAPE)
AIR VENT DIRECTION CON- OPT.1 KNOB (R) -L SOLE-
E4 CAB LIGHT M6 Y24
TROL MOTOR NOID VALVE (RED TAPE)
MOTOR ACTUATOR (AIR OPT.2 KNOB (L) -R SOLE-
E51 CIGAR LIGHTER M7 Y25
MIX) NOID VALVE (BLUE TAPE)
OPT.2 KNOB (L) -L SOLENOID
E52 AIR CONDITIONER M8 BLOWER MOTOR Y26
VALVE (RED TAPE)
OPTION SELECT SOLENOID
E68 CONDENSER M14 FUEL FEED PUMP MOTOR Y27
VALVE (RED TAPE)
SUCTION CONTROL VALVE
F1 FUSE 15A ; KEY SWITCH M20 ELECTRIC FUEL PUMP Y35
(SCV)
FUSE 20A ; ENGINE CON- BOOM UP PROPORTIONAL
F2 M23 VGS TURBO Y59
TROLLER SOLENOID VALVE (NO TAPE)
ARM CLOSE PROPOTIONAL
FUSE 10A ; GPS CON- INTAKE THROTTLE DC-MO-
F3 M24 Y60 SOLENOID VALVE (RED
TROLLER TOR
TAPE)
BUCKET CLOSE PROPO-
EXHAUST GAS RECIRCULA-
F4 FUSE 10A ; BACK UP M25 Y61 TIONAL SOLENOID VALVE
TION VALVE
(BLUE TAPE)
FUSE 10A ; LEVER LOCK OPTION PRESS. PROPOR-
F5 P1 INSTRUMENT PANEL Y62
(GATE) TIONAL SOLENOID VALVE
SWITCH PANEL (LEFT-
F6 FUSE 10A ; SOLENOID P2 Y63 INJ1 (#1)
HAND)
SWITCH PANEL (RIGHT-
F7 FUSE 10A ; HORN P3 Y64 INJ2 (#3)
HAND)
AIR CONDITIONER SWITCH
F8 FUSE 15A ; LAMP (CAB) P6 Y65 INJ3 (#4)
PANEL
FUSE 15A ; LAMP (BOOM,
F9 P15 RADIO SET (NA) Y66 INJ4 (#2)
HOUSE)
OPTION SELECT SOLENOID
F10 FUSE 15A ; SPARE R1 GLOW PLUG Y67
VALVE (BLUE TAPE)
OPTION 2SPEED SOLENOID
F11 FUSE 15A ; WIPER/WASHER R3 THROTTLE VOLUME Y68
VALVE (RED TAPE)
FUSE 10A ; TRAVEL ARALM ; THERMISTOR INNER TEM-
F12 R4 Y69 INJ5 (#2)
BEACON PERATURE
FUSE 10A ; CIGAR LIGHTER ;
F13 R5 FUEL SENSOR Y70 INJ6 (#4)
SEAT SUS
84402832 NA - May 2011

4020C-4
Overall
84402832 NA - May 2011

4020C-5
84402832 NA - May 2011

4020C-6
Block diagram
Computer A
84402832 NA - May 2011

4020C-7
Computer B
84402832 NA - May 2011

4020C-8
ECM
84402832 NA - May 2011

4020C-9
Monitor
84402832 NA - May 2011

4020C-10
Air Conditioner
84402832 NA - May 2011

4020C-11
Lever Lock
Horn
Working lights
84402832 NA - May 2011

4020C-12
Option
84402832 NA - May 2011

4020C-13
Other
84402832 NA - May 2011

4020C-14
Electrical Symbol List

Symbol Name Symbol Name
Fuse Variable solenoid valve
Diode Resistor
LED Variable resistor
Toggle switch "a" contact Variable resistor
Push switch "a" contact Alarm
Limit switch "a" contact Buzzer
Limit switch "b" contact Horn
Relay coil Motor
Relay contact "a" contact Solar radiation sensor
84402832 NA - May 2011

4020C-15
Symbol Name Symbol Name
Relay contact "b" contact Speaker
Solenoid valve Lamp
84402832 NA - May 2011

4020C-16
Section
4021
Engine-side DTC List
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Engine-side DTC List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3


DTC code Description
P0016 Abnormally correlation between crankshaft position and camshaft position
P0045 Turbocharger boost pressure control system abnormality
P0087 Fuel rail system pressure low pressure error
P0088 Fuel rail system pressure high pressure error
P0089 Fuel rail pressure regulator characteristics error
P0091 Fuel rail pressure regulator control system low input
P0092 Fuel rail pressure regulator control system high input
P0093 Fuel system leak detection
P0102 Mass air flow sensor system law input
P0103 Mass air flow sensor system high input
P0112 Intake temperature sensor system low input
P0113 Intake temperature sensor system high input
P0117 Engine coolant temperature sensor system low input
P0118 Engine coolant temperature sensor system high input
P0122 Throttle sensor system low input
P0123 Throttle sensor system high input
P0182 Fuel temperature sensor system low input
P0183 Fuel temperature sensor system high input
P0192 Fuel rail pressure sensor system low input
P0193 Fuel rail pressure sensor system high input
P0201 Injector first cylinder system error
P0202 Injector second cylinder system error
P0203 Injector third cylinder system error
P0204 Injector fourth cylinder system error
P0205 Injector fifth cylinder system error
P0206 Injector sixth cylinder system error
P0217 Engine coolant high temperature error
P0219 Engine high rpm error
P0234 Turbocharger high boost pressure state
P0299 Turbocharger low boost pressure state
P0237 Boost sensor circuit low input
P0238 Boost sensor circuit high input
P0335 Crankshaft position sensor system error
P0336 Crankshaft position sensor system characteristics error
P0340 Camshaft position sensor system error
P0341 Camshaft position sensor characteristics error
P0404 EGR1 control system error
P0409 EGR1 position sensor system error
P041C IMT sensor system high input
P041D IMT sensor system low input
P0426 Pre-filtered exhaust gas high temperature error
P0427 Exhaust temperature sensor 1 system low input
P0428 Exhaust temperature sensor 1 system high input
P042B Exhaust gas high temperature error before oxidation catalyst
P042C Exhaust temperature sensor 2 system low input
P042D Exhaust temperature sensor 2 system high input
P0522 Oil pressure sensor system low input
P0523 Oil pressure sensor system high input
P0560 System voltage error
P0563 System voltage high input
P0601 Control module memory checksum error
P0602 Control module program error
P0604 Control module RAM error
P0606 Control module processing device error
P060B Control module A/D converter processing system characteristics error
P0638 Throttle actuator control system characteristics error
84402832 NA - May 2011
4021-3
DTC code Description

P0641 Sensor voltage system error
P0650 MIL control system error
P0685 ECM main relay control system low input
P0687 ECM main relay control system high input
P1093 Fuel rail pressure low pressure error
P1112 Boost temperature sensor system low input
P1113 Boost temperature sensor system high input
P1261 Injector group 1 voltage control system error
P1262 Injector group 2 voltage control system error
P1293 Fuel filter pressure sensor system low input
P1294 Fuel filter pressure sensor system high input
P1404 EGR close position characteristics error
P1455 DPD restriction 2
P1471 DPD regeneration error
P1621 Control module EEPROM error
P1669 DPD light control system error
P2122 Pedal position sensor 1 system low input
P2123 Pedal position sensor 1 system high input
P2127 Pedal position sensor 2 system low input
P2128 Pedal position sensor 2 system high input
P2146 Injector group 1 supplied voltage system error
P2149 Injector group 2 supplied voltage system error
P2228 Atmospheric pressure sensor system low input
P2229 Atmospheric pressure sensor system high input
P242F DPD restriction
P2452 DPD differential pressure sensor system error
P2453 DPD differential pressure sensor system characteristics error
P2454 DPD differential pressure sensor system low input
P2455 DPD differential pressure sensor system high input
P2456 DPD differential pressure sensor learning position error
P2458 DPD regeneration time error
U0001 CAN bus communication error
U0073 Control module communication error
U0101 TCM communication error
U0110 Turbocharger control module communication error
U0411 Turbocharger control module signal error
84402832 NA - May 2011

4021-4
Section
4022
Main Unit-side DTC List
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Main Unit-side DTC List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

DTC Trouble mode

7000 P1 Pressure Sensor Signal Abnormality
7001 P2 Pressure Sensor Signal Abnormality
7002 N1 Pressure Sensor Signal Abnormality
7003 N2 Pressure Sensor Signal Abnormality
7004 Overload Pressure Sensor Signal Abnormality
7005 Bottom Pressure Sensor Signal Abnormality
7006 Rod Pressure Sensor Signal Abnormality
7020 Upper Pressure Sensor Signal Abnormality
7021 Swing Pressure Sensor Signal Abnormality
7022 Travel Pressure Sensor Signal Abnormality
7023 Arm-in Pressure Sensor Signal Abnormality
7040 Fuel Level Sensor Signal Abnormality
7041 Oil Temperature Sensor Signal Abnormality
7045 Monitor Thermistor Signal Abnormality
7060 Boom Angle Sensor Signal Abnormality
7061 Arm Angle Sensor Signal Abnormality
7063 Return Filter Clogging Pressure Switch Signal Abnormality
7065 Boom-up Pilot Pressure Sensor Signal Abnormality
7066 Bucket-close Pilot Pressure Sensor Signal Abnormality
7200 Swing Brake Solenoid Signal Abnormality
7201 Travel High-speed Solenoid Signal Abnormality
7202 Pressure Boost Solenoid Signal Abnormality
7203 Travel Alarm Buzzer Signal Abnormality
7204 Power Save Solenoid Signal Abnormality
7205 Feed Pump Relay Signal Abnormality　
7206 Option Line Switchover Solenoid Signal Abnormality
7207 Free Swing Solenoid Signal Abnormality
7210 Liftcrane Buzzer Signal Abnormality
7211 Rotating Light Relay and Bucket Lock Signal Abnormality
7240 Pump Horsepower Proportional Valve Signal Abnormality
7241 P1 Flow Control Proportional Valve Signal Abnormality
7242 Fan Proportional Valve Signal Abnormality
7246 2 Pumps Flow Solenoid Signal Abnormality
7247 Boom-down Proportional Valve Signal Abnormality
7248 Arm-in Proportional Valve Signal Abnormality
7250 Option Relief Pressure Proportional Valve Signal Abnormality
7251 Battery Control Relay Signal Abnormality
7252 Idle Stop Relay Signal Abnormality
7253 DPD Regeneration Request Output Signal Abnormality
7400 Abnormally High Coolant Temperature (105℃ or higher)
7404 Abnormally High Oil Temperature (95℃ or higher)
7405 Boost temperature is abnormally high ( 80 ℃ or more )
7406 Boost temperature is abnormally high ( 90 ℃ or more)
7420 Abnormally Low Alternator Voltage
7421 Coolant Level Reduction
7422 Abnormally Low Engine Oil Pressure
7423 Air Cleaner Clogging
7424 Return Filter Clogging (breaker specifications)
7425 Fuel Density Error Signal Abnormality
7600 CAN Bus Abnormality
7601 Monitor Communication Abnormality
7602 ECM Communication Abnormality
7603 Computer B Communication Abnormality
84402832 NA - May 2011
4022-3
DTC Trouble mode

7605 ECM Mismatch
7606 EEPROM Data Abnormality
7607 Computer C Communication Abnormality
84402832 NA - May 2011

4022-4
Section
4023B
Introduction to the trouble diagnosis
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Introduction to the trouble diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3


1. Introduction to the trouble diagnosis
1) About trouble diagnosis
The following trouble diagnosis procedure is extremely important to resolve problems of all electric/elec-
tronic systems.
Neglecting to implement these steps may result in requiring unnecessary repairs.
Read and understand the procedure carefully and proceed with the trouble diagnosis.
Also, use available functions and the trouble diagnosis scan tool to perform the trouble diagnosis and sys-
tem check.
2) Trouble diagnosis procedure
Checking complaints from customer
• Use the check sheet to organize the trouble situation.
Performing preliminary inspection
• Perform overall visual inspection.
• Check the past maintenance history.
• Detect any abnormality such as abnormal noise, smell, etc.
• Collect the failure trouble DTC information to provide effective repair.
• Inspect for an abnormality by comparing to the standard value.
Inspect the service information
• Check the market service bulletin.
Perform inspection for the displayed code.
• Inspect the item shown by DTC.
Perform an inspection for problems according to symptoms
• Check the item that is not displayed in the DTC.
NOTE
System trouble diagnosis type
The system diagnosis method is a standardized method applied for repairing all electric/electronic systems.
Failures in electric/electronic systems often occur in the following steps unlike common actual unit failures.
Initial stage of failure
The failure occurs sporadically and for a short time, often times the driver does not notice it.
At this stage, the customer's complaint is unclear, and the malfunction cannot be reproduced.
However, the ECM may have recorded the failure.
Past malfunction, past failures
Middle stage of failure
The failure occurs sporadically and for a short time, but may occur repeatedly at intervals, and occurs under
specific conditions.
The customer complaint is clear, but the failure conditions are unclear.
Therefore, the person performing the diagnosis can reproduce the failure by understanding its conditions.
Intermittent failures, intermittent
Stage where failure is realistic
The occurrence of the failure is set, and the customer complaint is real and clear.
Therefore, the person performing the diagnosis can reproduce the failure.
However, there may sometimes be more than 2 causes for the failure.
Current malfunction, Current failures
3) Diagnosis
Fully understand the description given by the customer using the Engine Control System Check Sheet.
ANNOTATION:
• When questioning, do not ask randomly but focus on the system that is inferred to be defective based on
the malfunction phenomenon.
Determine failure information accurately.
Have concrete understanding based on 5W1H.
Low air temperature, at start or on a steady basis, near the engine parts, metallic sound, etc.
Check points
• Failure symptoms
• Month and Date, Time, Frequency of occurrence
• Road conditions
84402832 NA - May 2011
4023B-3
• Working conditions, Operation conditions, Weather

• Feeling of symptom
Engine control system check sheet
When receiving the actual unit from the customer at the service factory, the failure symptoms and the data
on occurrence of failure must be confirmed with the customer based on the engine control check sheet.
• Failure symptoms may not be able to be reproduced at the service factory.
• The customer's complaint may not always be a malfunction.
• Notification of incorrect malfunction conditions to the person in charge of repairs may result in unneces-
sary man-hours for repairs.
• The check sheet assists in actual unit diagnosis, repair, and repair confirmation at the vehicle servicing
factory.
1 Failure symptoms
Failure frequency・failure con-
2
ditions
84402832 NA - May 2011

4023B-4
4) Preparatory check
Visual inspection of engine room
When implementing the diagnostic procedures, carefully make a visual inspection of the engine room.
84402832 NA - May 2011
4023B-5
This inspection can often lead to solving a problem without taking extra steps.
• Visually inspect all air hoses for punched holes, cuts, disconnections, and appropriate piping.
• Visually inspect the hoses that are difficult to see behind other components.
• For every harness in the engine room, visually inspect that all harnesses are properly connected.
Inspect that there are no burned or worn areas, that the harnesses are properly fastened and that they
are not in contact with sharp edges or the hot exhaust manifold or pipes.
Checking the actual unit maintenance status
If the maintenance of the actual machine is not performed correctly, the monitor may illuminate.
Restricted oil filters, fuel filters, and crankcase deposits due to lack of oil changes or improper oil viscosity
can trigger actual unit faults that were not previously monitored prior to OBD.
Poor vehicle maintenance cannot be classified as a non-machine failure, but since the sensitivity of OBD
system checks is high, actual unit maintenance schedules must be further closely followed.
Non-OEM parts
All the OBD system checks are adjusted to operate with the genuine parts.
Therefore, when a commercially sold sensor or switch, etc. is installed, a wrong diagnosis is made, and
the monitor comes on.
Accordingly, if general commercially-available sensors or switches are installed, this will cause mistakes in
diagnosis and the monitor to show an abnormality display.
If a commercially-available electronic device such as a mobile phone, stereo or anti-theft device is inappro-
priately installed, an EMI may be emitted to the control system.
As a result, incorrect sensor information will be generated and the monitor will show an abnormality display.
When conducting a trouble diagnoses, either turn OFF the power for all commercially sold parts or remove
them, and then check the failure again.
NOTE
Related system failure
Many OBD system checks go into the backup operation mode based on the instruction from the ECM which
is given when the ECM detects a failure in the related systems or components.
When the backup operation mode is activated, the output is reduced to protect the actual unit.
5) Trouble diagnosis
Basic knowledge of tools required
ANNOTATION:
• When performing the diagnostic procedure, lack of basic knowledge regarding this powertrain could result
in an incorrect diagnosis or damage to the powertrain components.
Do not attempt to diagnose a problem related to the powertrain without having the basic knowledge.
A basic understanding of hand tools, such as the trouble diagnosis scan tools, is required to utilize the
service manual effectively.
About the diagnostic test performed on the actual unit
Past failures
• The diagnostic tests of the previous ignition cycle have been completed.
• The diagnostic tests of the current ignition cycle have passed.
• Problems identified in the diagnostic tests currently do not exist.
Current failures
• The diagnostic tests of the previous ignition cycle have been completed.
• Problems identified in the diagnostic tests currently exist.
• Problems exist in the current ignition cycle.
Glossary
DTC
Every time the starter switch is turned ON, the ECM performs the self-test on most of the wiring and com-
ponents, records any detected system failure in the memory of the ECM, and performs the backup control,
depending on the DTC.
Also, abnormalities that affect travel will cause the monitor to show an abnormality display to inform the
operator.
Ignition cycle
Because the actual unit activates with a method to satisfy a predetermined diagnosis standard, an ignition
cycle is defined as turning the starter switch ON, running, then turning the starter switch OFF.
Monitor
In general, the monitor shows an abnormality display when a malfunction occurs in electronic control such
as the ECM and a DTC is detected.
DLC
The equipment for communicating with the control unit is the Data Link Connector (DLC).
84402832 NA - May 2011
4023B-6
The DLC is also provided to establish a connection with the scan tool.
Identification of recorded
DTC Reading the serial data
ANNOTATION:
• The installation position of the DLC and existence or nonexistence of the DLC vary depending on the
actual unit, so refer to the manual of the actual unit.
ECM OFF
Turn the ECM off starter switch off and the ECM power supply completely tops in approximately 10 seconds
to disable the ECM.
General diagnostic operations of the components monitor
To run the engine normally, a general diagnosis of the components is required.
Input components
Inspect the input components to see whether an open in the circuit or outside range value exists.
Crankshaft position sensor
Camshaft position sensor
Water temperature sensor
Boost sensor
Fuel pressure sensor
Accelerator position sensor
Output components
The output components are inspected to diagnose whether responses to commands from the control unit
are appropriate.
Inspect whether the circuits have disconnections and whether their values are within the range.
Suction control valve
Light, Relay control
Magnetic valve
Monitor
6) DTC reading procedure
Reading DTC with monitor
Current and past DTCs recorded in the ECM can be displayed by connecting the diagnostic switch and
blinking the monitor.
• Switch the starter switch ON and check that the monitor shows an abnormality display.
• Turn the starter switch ON, but the engine off.
• Connect the diagnostic switch.
For an actual unit with no diagnostic switch, short the DLC No. 1 and No. 4 or No. 5.
• Read the blinking count of the monitor.
• The DTC determines the failure contents from the diagnostic trouble code list.
If the trouble diagnostic scan tool is connected, the diagnostic codes can be read by operating the trouble
diagnostic scan tool.
ANNOTATION:
• As for the installation position of the monitor, refer to the manual of the actual unit.
Display code when no DTC is recorded
Code 1 (indicating the start of code display) continues to be displayed.
Display when a DTC is recorded
The recorded trouble codes are displayed 3 times.
If more than 2 or more trouble codes have been recorded, the DTCs will be output in ascending order with
each DTC being displayed three times.
After displaying all codes, the codes will be displayed again starting with the smallest code number.
This display continues while the diagnosis connector is connected.
84402832 NA - May 2011

4023B-7
a At code "23"
b At code "413"
*1 ON *3 Tens digit *5 Hundreds digit

*2 Goes off *4 Units digit
t1 Approx. 0.3 sec t3 Approx. 1.2 sec

t2 Approx. 0.6 sec t4 Approx. 2.4 sec
DTC indicated by monitor blinking display

The current and past DTCs are both displayed while the engine is being stopped.
While the engine is in operation, the light is turned on only when a current DTC exists.
Using the trouble display monitor to read the DTC
When a DTC occurs, the DTC can be displayed on the trouble display monitor of the actual unit.
Using the scan tool to read the DTC
The DTC can be read using the trouble diagnosis scan tool.
ANNOTATION:
• For the work procedure, refer to the manual of the trouble diagnosis scan tool.
When the DTC is recorded
Perform repairs accurately according to the specified DTC chart.
If no DTC is available
Select the symptom from "Diagnosis By Symptom".
Complete the repair according to the diagnostic procedure.
It is also possible to perform the inspection by referring to the functional diagnosis.
When the appropriate symptom is not found;
Investigate the complaint in detail.
Create a diagnosis plan.
Utilize the schematics and operation principles.
When repair history for similar cases are available, request technical assistance.
Combine technical knowledge and effective utilization of available service information.
Intermittent
84402832 NA - May 2011
4023B-8
A failure condition that does not necessarily always appear is referred to as intermittent.
Check the DTC information and the data display.
Verify the symptoms and conditions reported by the customer.
Use a check sheet or other method to check the circuit or electronic system components.
When no trouble is detected
This status indicates that the actual unit is determined as operating properly.
The condition reported by the customer may be normal.
Check the customer complaint by comparing to other actual unit that is operating properly.
However, depending on the condition, it may be an intermittent.
Before returning the actual unit, check the complaint under the conditions given by the customer.
Investigate the complaint again.
If the complaint cannot be adequately detected or confirmed , it is necessary to perform the diagnosis again
to verify the complaint.
As stated above in "Intermittent", the complaint may be an intermittent or normal condition.
Repair and confirm.
Perform the repair when the cause has been confirmed.
Confirm that the operation is performed properly, and that the symptom has been corrected.
This includes the confirmation test performed on the actual unit or other methods to confirm that the com-
plaint has been resolved.
Confirm by testing under the conditions given by the customer.
When a DTC is diagnosed, confirm that the failure has been repaired by reproducing the condition that
appeared when the DTC was set while checking the scan tool data.
7) Check after repair
Check repair on actual unit
When an repair has been performed for the electronic control system, it is necessary to check that the repair
is accurate after repairing the actual unit.
If this confirmation is not done thoroughly, the monitor may show an abnormality display again or operability
problems may occur when the actual machine is handed over to the customer.
It is especially necessary to recreate customer complaint conditions and confirm repair for intermittent prob-
lems.
Especially for an intermittent failure, it is necessary to perform the check by reproducing the conditions of
the customer complaint.
About confirmation of the actual unit repairs
It is effective to use the OBD system check for confirming actual unit repairs.
After the repair is completed, the person who have performed the actual unit diagnosis shall review either
the DTC that was diagnosed or scan tool data, or both, and record it.
Clear the DTC.
Run the actual unit based on the scan tool data.
Check the DTC status information of the specified DTC that was diagnosed until the diagnosis test related
to that DTC is implemented by the control unit.
The implementation of these steps is extremely important when checking the repair status with the OBD
system check.
Neglecting to implement these steps may result in unnecessary repairs.
8) Final check item list
Item Item Objective Method

Clear the previous DTCs.
Keep the engine idling to warm up, then perform
1 DTC check Confirm the DTC display after the repair.
a racing run to increase the engine rpm to No
Load Max to secure the test conditions.
Check whether the idling rotation speed is con-
Idling speed stant under the no load condition after engine is
To check whether the idling control is op-
2 check after warm- warmed up.
erating normally.
ing up the engine If a problem is detected, refer to Idling Unstable
in Diagnosis by Symptom.
Monitor the scan tool data list, and check the
Check the engine control, communica-
Confirm the scan values using a typical value sheet.
3 tion status error and abnormality under
tool data list Confirm the typical values of the scan tool data
the standard condition.
list.
84402832 NA - May 2011

4023B-9
Item Item Objective Method

After warming up the engine, confirm that the
Re-startability To check whether the starting control is cranking time is 5 seconds or less when restart-
4
check normal. ing the vehicle, and that the engine revolution is
stable after starting.
Check whether turning the electromagnetic
When electromagnetic transmitters such transmitter such as a transceiver ON and OFF
Check powerful
as a transceiver have been added to the causes the idling engine rpm to change.
5 electromagnetic
vehicle, confirm that no interfering waves If a problem is found, let the customer know that
transmitters
are being emitted. the installation position and output of the elec-
tromagnetic transmitter need to be changed.
Supplementary information regarding the check for powerful electromagnetic transmitters

If you discover a problem in this item, convey it to the customer as necessary.
• Install the antenna to the a place distant from the electronic control system of the actual unit such as the
control units and sensors.
• Install the antenna cord at least 20 cm away from the electronic systems of the actual unit, such as the
control units and sensors.
• Do not wire other cables together with antenna.
Also, locate the antenna cord as far away from other wiring as possible.
• Make sure to attach retrofitted equipment in accordance with their respective installation manuals.
• Do not install high-output mobile communication devices.
CAUTION
• Follow the steps when performing the OBD system checks to confirm the repair.
Failure to follow these steps may result in performing unnecessary repair works.
• Review the scan tool data relating to the DTC that was diagnosed and make a record.
• Clear the DTC.
• Operate the actual unit while checking the related scan tool data.
9) DTC clearing method

Clearing DTC
If an error occurs in the system and the DTC is recorded in the ECU, that DTC is not deleted from the
memory even when the malfunctioning part is repaired, so use the following measures to execute a forced
deletion.
Using the scan tool to delete the DTC
If the trouble diagnosis scan tool is connected, you can delete codes by performing turning off of the trouble
diagnosis scan tool.
Erasure by ECM
A DTC recorded in the ECM is erased if the same DTC has not been satisfied for 40 consecutive ignition
cycles.
About trouble diagnosis scan tool
This tool is effective for diagnosing electrical failures in engine control units and performing system checks.
If you connect the SAE 16/19 adapter to the DLC installed in the unit, it performs communication with the
control units of the machine, and enables various diagnoses and tests to be performed.
Functions of the trouble diagnosis scan tool.
Data display
Snapshot
Programming
Actuator test
CAUTION
• When conditions such as the running state of the actual unit or the engine, water tempera-
ture, switches and gear position are not met, or when a DTC has been detected, each test
may possibly not operate.
ECM reflash
The ECM can be updated by overwriting its control program using the most recent control data issued every
3 months.
Normal reflash
The ECM is reflashed by automatically searching for the ECM part number compatible with the part number
currently reflashed.
Forced reflash
84402832 NA - May 2011
4023B-10
The ECM is reflashed by specifying an arbitrary ECM part number.

In this case, a password dedicated for forced reflash is necessary.
Campaign reflash The ECM is reflashed by selecting the part number during a campaign carried out by the
manufacturer.
Rewriting injector QR code
The injector QR code that is required when replacing the injector can be rewritten.
This allows fuel compensation to be performed on each injector to optimize the engine condition.
Engine replacement mode
This should be used when changing back to the old ECM part number which requires hardware changes
such as addition of actual unit wiring is performed along with engine replacement, etc.
ECM replacement
When replacing the ECM within the same model, the data can be updated from the current ECM to a trouble
diagnosis scan tool and then downloaded it from the trouble diagnosis scan tool to the new ECM after
replacement.
Factory shipment settings
Based on the engine serial number, data such as ECM injector QR code can be downloaded to ECM.
Actuator test
The injector test, fuel injection test, rail pressure test, glow plug test, and EGR control test are performed
to inspect the operation and function of each target component.
CAUTION
• When conditions such as the running state of the actual unit or the engine, water tempera-
ture, switches and gear position are not met, or when a DTC has been detected, each test
may possibly not operate.
Links with the HTML manual display

DTC to display the manual along with the failure diagnosis procedure.
Reading saved data
Read in the saved snapshot data to display reproduction.
CAUTION
• When using the trouble diagnosis scan tool, refer to the separate instruction manual for the
trouble diagnosis scan tool.
10) Reference data value
84402832 NA - May 2011

4023B-11
84402832 NA - May 2011

4023B-12
Section
4023D
Engine Control System
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal and Installation of Suction Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Suction control valve Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Suction control valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal and Installation of Fuel filter pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel filter pressure sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel filter pressure sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal and Installation of Engine coolant temperature sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine coolant temperature sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine coolant temperature sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine coolant temperature sensor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal and Installation of CKP sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CKP sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CKP sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CKP sensor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal and Installation of CMP sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CMP sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CMP sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CMP sensor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal and Installation of Oil pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Oil pressure sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Oil pressure sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Oil pressure sensor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal and Installation of Boost sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Boost sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Boost sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal and Installation of Boost temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Boost temperature sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Boost temperature sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Removal and Installation of IMT sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
IMT sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
IMT sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal and Installation of Exhaust differential pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Exhaust differential pressure sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Exhaust differential pressure sensor Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Exhaust differential pressure sensor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Removal and Installation of Exhaust gas temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Exhaust gas temperature sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Exhaust gas temperature sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Exhaust gas temperature sensor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Removal and Installation of 2) Remove the suction control valve from the fuel
supply pump.
Suction Control Valve
Suction control valve Removal
battery.
2. Suction control valve Removal
CAUTION
• Before removing the suction control
valve, clean the surrounding area.
1 Relief valve
2 Union
3 Fuel temperature sensor
3) Remove the O-ring from the fuel supply pump.

suction control valve.
1 O-ring
84402832 NA - May 2011

4023D-3
Suction control valve Installation 2. Battery ground cable Connect

1. Suction control valve Installation 1) Connect the battery ground cable to the bat-
tery.
1) Install the O-ring to the fuel supply pump.
3. Fuel Air bleed
CAUTION
1 O-ring

3) Temporarily tighten the suction control valve
to the fuel supply pump.
ANNOTATION:
1 Priming pump
• Temporarily tighten by hand until it adheres 2 Plug
the supply pump. 3 Drain plug
CAUTION 4 Case
• Be careful not to allow the O-ring to
caught in. 1) Prepare the pan.
4) Securely tighten the suction control valve to
ANNOTATION:
the fuel supply pump.
Tightening torque： 9 N・m {0.9 kgf・m / 79.7 • This is for the models with an electromag-
lb・in} netic pump.
5) Connect the harness connector to the suction
control valve. 3) Loosen the plug using the wrench.
ANNOTATION:
plug.
ANNOTATION:
the priming pump.
1 Relief valve ANNOTATION:
2 Union
3 Fuel temperature sensor • Remove the air in the fuel filter.
4 Suction control valve 8) Tighten the plug using the wrench.
84402832 NA - May 2011

4023D-4
9) Operate the priming pump. Removal and Installation of Fuel

filter pressure
ANNOTATION:
• Wait for the specified time after operating Fuel filter pressure sensor Removal
the priming pump. 1. Fuel filter pressure sensor Removal
Specified time： 1 min 1) Disengage the harness connector from the
10) Loosen the plug using the wrench. fuel filter pressure sensor.
ANNOTATION: 2) Remove the fuel filter pressure sensor from
the fuel filter.
ANNOTATION:
the priming pump.
ANNOTATION:
Tightening torque： 10 N・m {1.0 kgf・m / 1 Fuel filter pressure sensor
88.5 lb・in}
CAUTION
• Remove the fuel around the plug

ANNOTATION:
• Do not accelerate the engine revolution right
after staring.
Specified time： 5 s
ANNOTATION:
ANNOTATION:
mum.
84402832 NA - May 2011

4023D-5
Fuel filter pressure sensor Installation Removal and Installation of Engine

1. Fuel filter pressure sensor Installation coolant temperature sensor
1) Install the fuel filter pressure sensor to the fuel
filter. Engine coolant temperature sensor
Removal
CAUTION
1. Engine coolant temperature sensor Removal
• After cleaning the threaded portion
of the fuel filter body, install it. 1) Disengage the harness connector from the
engine coolant temperature sensor.
Tightening torque： 12 N・m {1.2 kgf・m / 2) Remove the engine coolant temperature sen-
106.2 lb・in} sor from the cylinder head assembly.
2) Connect the harness connector to the fuel fil-
ter pressure sensor.
1 Overheat switch
1 Fuel filter pressure sensor

ANNOTATION:
• Check that there is no fuel leaks.
• Confirm that DTC has not yet been de-
tected.
84402832 NA - May 2011

4023D-6
Engine coolant temperature sensor Engine coolant temperature sensor

Installation Inspection
1. Engine coolant temperature sensor Installation 1. Engine coolant temperature sensor Inspection
1) Install the engine coolant temperature sensor 1) Inspect the engine coolant temperature sen-
to the cylinder head assembly. sor using the circuit tester.
• Apply Loctite 572 to the threaded portion. • Confirm that the resistance value according
to water temperature matches the thermis-
tor characteristics.
18.4 lb・ft｝
1 Overheat switch GND terminal for engine con-

1
trol
Signal terminal for engine con-
2
trol
2) Connect the harness connector to the engine 3 Signal terminal for meters
coolant temperature sensor.
Re-
sis-
tance
(kΩ)
Temperature°C (°F)
84402832 NA - May 2011

4023D-7
Removal and Installation of CKP CKP sensor Installation

sensor 1. CKP sensor Installation
1) Install the CKP sensor to the flywheel housing.
CKP sensor Removal
1. Battery ground cable Disconnect CAUTION
1) Disengage the battery ground cable from the • Be careful not to subject the sensor
battery. to shock.
2. CKP sensor Removal ANNOTATION:

1) Disengage the harness connector from the • Tighten together with the clip.
CKP sensor.
2) Remove the CKP sensor from the flywheel Tightening torque： 6 N・m {0.6 kgf・m / 52
housing. lb・in}
CAUTION sensor.

to shock.

2 Oil port cover
3 Flywheel housing
1 Oil pressure switch 4 CKP sensor
2 Oil port cover
3 Flywheel housing
4 CKP sensor 1) Connect the battery ground cable to the bat-
tery.
CKP sensor Inspection

1. CKP sensor Inspection
1) Inspect the CKP sensor.
ANNOTATION:
• Condition of the sensor installation
• Grime on the sensor and connector
84402832 NA - May 2011

4023D-8
Removal and Installation of CMP CMP sensor Installation

sensor 1. CMP sensor Installation
CMP sensor Removal 2) Install the CMP sensor to the cylinder head
1. Battery ground cable Disconnect assembly.
1) Disengage the battery ground cable from the CAUTION

battery.
2. CMP sensor Removal to shock.
CMP sensor. ANNOTATION:
2) Remove the CMP sensor from the cylinder • Tighten together with the clip.
head assembly.
lb・in}
3) Connect the harness connector to the CMP
sensor.
CAUTION
to shock.
tery.
CMP sensor Inspection

1. CMP sensor Inspection
1) Inspect the CMP sensor.
ANNOTATION:
• Condition of the sensor installation
• Grime on the sensor and connector
84402832 NA - May 2011

4023D-9
Removal and Installation of Oil Oil pressure sensor Installation

pressure sensor 1. Oil pressure sensor Installation
1) Install the oil pressure sensor to the oil port
Oil pressure sensor Removal cover.
1. Oil pressure sensor Removal Tightening torque： 41 N・m ｛4.2 kgf・m /
30.2 lb・ft｝
pressure sensor. CAUTION
2) Remove the oil pressure sensor from the oil
port cover. • Use new gaskets.
2) Connect the harness connector to the oil pres-

sure sensor.

2 Oil port cover
3 Flywheel housing 1 Oil pressure sensor
4 CKP sensor 2 Oil port cover
3 Flywheel housing
4 CKP sensor
84402832 NA - May 2011

4023D-10
Oil pressure sensor Inspection Removal and Installation of Boost

1. Oil pressure sensor Inspection sensor
2) Disconnect the harness connector from the oil Boost sensor Removal
pressure sensor. 1. Battery ground cable Disconnect
3) Inspect the continuity using the circuit tester. Disengage the battery ground cable from the bat-
tery.
2. Boost sensor Removal
boost sensor.
2) Remove the boost sensor from the inlet pipe.
CAUTION
• Replace the oil pressure sensor if
there is no continuity.

5) Inspect the circuit using the jumper wire.
1 Boost sensor
2 Inlet pipe
6) Check lighting of the warning light.

ANNOTATION:
• If the warning light does not illuminate, in-
spect the circuit between the meter and the
oil pressure.
84402832 NA - May 2011

4023D-11
Boost sensor Installation Removal and Installation of Boost

1. Boost sensor Installation temperature sensor
1) Install the boost sensor to the inlet pipe.
Tightening torque： 2 N・m {0.2 kgf・m / 17.7 Boost temperature sensor Removal
lb・in} 1. Boost temperature sensor Removal
2) Remove the boost temperature sensor from
the inlet pipe.
1 Boost sensor
2 Inlet pipe

sensor.
1 Boost sensor
2. Battery ground cable Connect 2 Harness clip
1) Connect the battery ground cable to the bat- 3 Boost temperature sensor
tery. 4 IMT sensor
84402832 NA - May 2011

4023D-12
Boost temperature sensor Installation Removal and Installation of IMT

1. Boost temperature sensor Installation sensor
1) Install the boost temperature sensor to the in-
let pipe. IMT sensor Removal
Tightening torque： 13 N・m {1.3 kgf・m / 1. IMT sensor Removal
115.1 lb・in}
2) Connect the harness connector to the boost 1) Disconnect the harness connector from the
temperature sensor. IMT sensor.
2) Remove the IMT sensor from the inlet pipe.
1 Boost sensor 1 Boost sensor

2 Harness clip 2 Harness clip
3 Boost temperature sensor 3 Boost temperature sensor
4 IMT sensor 4 IMT sensor
84402832 NA - May 2011

4023D-13
IMT sensor Installation Removal and Installation of

1. IMT sensor Installation Exhaust differential pressure
1) Install the IMT sensor to the inlet pipe. sensor
14.8 lb・ft｝ Exhaust differential pressure sensor
sensor. Removal
1. Exhaust differential pressure sensor Safety Infor-
mation
CAUTION
bracket.
1 Boost sensor stalled on the DPD differential pressure
2 Harness clip sensor.
3 Boost temperature sensor • Replace the DPD differential pressure
4 IMT sensor sensor if the 4 screws installed on the
been loosened.
1 Screw
2. Exhaust differential pressure sensor Removal
CAUTION
sor precautions.
1) Disengage the differential pressure hose from

the exhaust differential pressure sensor.
84402832 NA - May 2011

4023D-14
3) Remove the exhaust differential pressure sen- Exhaust differential pressure sensor
sor from the DPD assembly. Installation
CAUTION 1. Exhaust differential pressure sensor Safety Infor-
mation
• Remove the DPD differential pres-
sure sensor with the attached CAUTION
bracket.
bracket.
stalled on the DPD differential pressure
sensor.
been loosened.
1
sor
1 Screw
2. Exhaust differential pressure sensor Installation
CAUTION
sor precautions.
1) Install the exhaust differential pressure sensor

to the DPD assembly.
3) Connect the differential pressure hose to the
84402832 NA - May 2011

4023D-15
CAUTION Exhaust differential pressure sensor

Inspection
• Be careful not to mistake the con-
necting position of the differential 1. Exhaust differential pressure sensor Inspection
pressure hose.
• Since the differential pressure sen- CAUTION
sor may malfunction if exhaust gas
leaks from the joint sections, con- • Perform 0-point correction when replac-
ing the DPD differential pressure sensor.
firm that there is no exhaust gas
leakage after the engine starts. • Perform 0-point correction when the DPD
differential pressure sensor is at room
temperature.
• Do not perform 0-point correction within
two hours after regenerating DPD.
ANNOTATION:
• 0-point correction
CAUTION
• Do not start the engine.
Starter switch ON time： 40 s or more

DPD differential pressure sen- Starter switch OFF time： 15 s or more
1
sor
84402832 NA - May 2011

4023D-16
Removal and Installation of Exhaust gas temperature sensor

Exhaust gas temperature sensor Installation
1. Exhaust gas temperature sensor Installation
Removal CAUTION
1. Exhaust gas temperature sensor Safety Information • Do not subject the tip of the exhaust gas
temperature sensor to shock when in-
CAUTION stalling.
• Remove the old anti-seize lubricant on
• Before removing, be sure to check the the sleeve nut.
DPD pressure difference, status, and in- • Apply the anti-seize lubricant on the
spection/maintenance contents using a threaded portion of the sleeve nut.
scan tool. • Apply Never-Seez High Tempera-
• Do not reuse an exhaust gas temperature Stainless Grade ： 5-87411-039-0
ture sensor which has been subjected to anti-seize lubricant, manufactured by
shock such as being dropped. Bostik in the United states.
• Replace the oxidation catalyst assembly
2. Exhaust gas temperature sensor Removal if damage has been found in the sensor
installation section of the oxidation cata-
lyst assembly.
exhaust gas temperature sensor.
ANNOTATION: 1) Temporarily tighten the exhaust gas tempera-
ture sensor to the DPD assembly.
• To prevent incorrect assembling, make an
alignment mark on the connector before dis- CAUTION
connecting.
• To avoid damaging the sensor in-
2) Remove the exhaust gas temperature sensor stallation sections due to sensor
from the DPD assembly. incorrect assembly, tighten it by
hand.
ANNOTATION:
• Exhaust gas temperature sensor identifica-
tion
Connector
Sensor type Screw size
color
M12 x 1.75 Dark gray
ture sensor 1
M12 x 1.25 Light gray
ture sensor 2
2) Securely tighten the exhaust gas temperature

sensor to the DPD assembly.
1 Tightening torque： 30 N・m ｛3.1 kgf・m /
sor 1
22.1 lb・ft｝
Exhaust gas temperature sen- 3) Connect the harness connector to the exhaust
2
sor 2 gas temperature sensor.
CAUTION
• Be careful not to twist the harness.
84402832 NA - May 2011

4023D-17

Inspection
1. Exhaust gas temperature sensor Inspection
1) Measure the resistance using the circuit
tester.
ANNOTATION:
• The reference values for the sensor charac-
teristics are indicated in the diagram.
Temperature Resistance value

1000.0°C ｛1832°F｝ 115 - 127 Ω
950.0°C ｛1742°F｝ 130 - 143 Ω
Exhaust gas temperature sen- 900.0°C ｛1652°F｝ 147 - 163 Ω
1 850.0°C ｛1562°F｝ 167 - 187 Ω
sor 1
Exhaust gas temperature sen- 800.0°C ｛1472°F｝ 192 - 219 Ω
2 750.0°C ｛1382°F｝ 226 - 258 Ω
sor 2
700.0°C ｛1292°F｝ 267 - 309 Ω
ANNOTATION: 650.0°C ｛1202°F｝ 333 - 360 Ω
600.0°C ｛1112°F｝ 406 - 442 Ω
• Start the engine after assembling each part, 550.0°C ｛1022°F｝ 504 - 552 Ω
and check for gas leaks from each joint and
for vibration. 500.0°C ｛932°F｝ 640 - 709 Ω
450.0°C ｛842°F｝ 835 - 937 Ω
400.0°C ｛752°F｝ 1130 - 1280 Ω
350.0°C ｛662°F｝ 1590 - 1850 Ω
300.0°C ｛572°F｝ 2360 - 2830 Ω
200.0°C ｛392°F｝ 6230 - 7830 Ω
150.0°C ｛302°F｝ 11900 - 16300 Ω
100.0°C ｛212°F｝ 27600 - 41200 Ω
50.0°C ｛122°F｝ 82000 - 137000 Ω
84402832 NA - May 2011

4023D-18
Section
4023G
Engine-side Trouble
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Engine-side Trouble. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DTC U0001 (Flash Code 84) CAN-Bus Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DTC P0016 (Flash Code 16) Crankshaft Position - Camshaft Position Correlation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DTC P0045 (Flash Code 33) Turbocharger Boost Control Solenoid Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DTC U0073 (Flash Code 84) Control Module Communication Bus Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DTC P0087 (Flash Code 225) Fuel Rail/System Pressure - Too Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DTC P0088 (Flash Code 118) Fuel Rail/System Pressure - Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DTC P0089 (Flash Code 151) Fuel Pressure Regulator Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DTC P0091 (Flash Code 247) Fuel Pressure Regulator Control Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DTC P0092 (Flash Code 247) Fuel Pressure Regulator Control Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DTC P0093 (Flash Code 227) Fuel System Leak Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DTC U0101 (Flash Code 85) Lost Communication with TCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DTC P0102 (Flash Code 91) Mass Air Flow Circuit Low Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DTC P0103 (Flash Code 91) Mass Air Flow Circuit High Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DTC P0237 (Flash Code 32) Turbo Charger Boost Sensor Circuit Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DTC P0238 (Flash Code 32) Turbo Charger Boost Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DTC U0110 (Flash Code 87) Lost Communication with VNT System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DTC P0112 (Flash Code 22) Intake Air Temperature Sensor Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DTC P0113 (Flash Code 22) Intake Air Temperature Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DTC P0117 (Flash Code 23) Engine Coolant Temperature Sensor Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DTC P0118 (Flash Code 23) Engine Coolant Temperature Sensor Circuit High. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
DTC P0122 (Flash Code 43) Throttle Position Sensor Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DTC P0123 (Flash Code 43) Throttle Position Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
DTC P0182 (Flash Code 211) Fuel Temperature Sensor Circuit Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DTC P0183 (Flash Code 211) Fuel Temperature Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DTC P0192 (Flash Code 245) Fuel Rail Pressure Sensor Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
DTC P0193 (Flash Code 245) Fuel Rail Pressure Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DTC P0201 (Flash Code 271) Injector Circuit - Cylinder 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
DTC P0336 (Flash Code 15) Crankshaft Position Sensor Circuit Range/Performance. . . . . . . . . . . . . . . . . . . . . . . 34
DTC P0340 (Flash Code 14) Camshaft Position Sensor Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
DTC P0404 (Flash Code 45) Exhaust Gas Recirculation Control Circuit Range/Performance . . . . . . . . . . . . . . . . 36
DTC P0409 (Flash Code 44) Exhaust Gas Recirculation Sensor Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
DTC P0426 (Flash Code 143) Catalyst Temperature Sensor Circuit Range/Performance Sensor 1 . . . . . . . . . . . 38
DTC P0427 (Flash Code 48) Catalyst Temperature Sensor Circuit Low Sensor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . 38
DTC P0428 (Flash Code 48) Catalyst Temperature Sensor Circuit High Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 39
DTC P0522 (Flash Code 294) Oil Pressure Sensor Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
DTC P0523 (Flash Code 294) Oil Pressure Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
DTC P0560 (Flash Code 155) System Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
DTC P0563 (Flash Code 35) System Voltage High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
DTC P0601 (Flash Code 53) Internal Control Module Memory Check Sum Error . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
DTC P0602 (Flash Code 154) Control Module Programming Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

DTC P0604 (Flash Code 153) Internal Control Module Random Access Memory (RAM) Error . . . . . . . . . . . . . . . 44
DTC P0606 (Flash Code 51) ECM/PCM Processor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
DTC P0638 (Flash Code 61) Throttle Actuator Control Range/Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
DTC P0641 (Flash Code 55) Sensor Reference Voltage 1 Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
DTC P0685 (Flash Code 416) ECM/PCM Power Relay Control Circuit/Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
DTC P0687 (Flash Code 416) ECM/PCM Power Relay Control Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
DTC P1093 (Flash Code 227) Fuel Rail Pressure (FRP) Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
DTC P1112 (Flash Code 295) Boost Temperature Sensor Circuit Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
DTC P1113 (Flash Code 295) Boost Temperature Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
DTC P1261 (Flash Code 34) Injector Positive Voltage Control Circuit Group 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
DTC P1262 (Flash Code 34) Injector Positive Voltage Control Circuit Group 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
DTC P1293 (Flash Code 211) Fuel Pressure Sensor Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
DTC P1294 (Flash Code 211) Fuel Pressure Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
DTC P1404 (Flash Code 45) Exhaust Gas Recirculation (EGR) Closed Position Performance . . . . . . . . . . . . . . . 57
DTC P1455 (Flash Code 132) PM Over Accumulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
DTC P1471 (Flash Code 149) DPD Insufficient Regeneration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
DTC P1621 (Flash Code 54) Control Module Long Term Memory Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
DTC P1655 (Flash Code 57) Sensor Reference Voltage Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
DTC P1669 (Flash Code 75) DPD Lamp Control Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
DTC P2146 (Flash Code 158) Fuel Injector Group 1 Supply Voltage Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
DTC P2149 (Flash Code 159) Fuel Injector Group 2 Supply Voltage Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
DTC P2228 (Flash Code 71) Barometric Pressure Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
DTC P2229 (Flash Code 71) Barometric Pressure Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
DTC P2452 (Flash Code 142) DPD Differential Pressure Sensor Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
DTC P2453 (Flash Code 141) DPD Differential Pressure Sensor Circuit Range/Performance . . . . . . . . . . . . . . . . 68
DTC P2454 (Flash Code 47) DPD Differential Pressure Sensor Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
DTC P2455 (Flash Code 47) DPD Differential Pressure Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
DTC P2458 (Flash Code 139) DPD Regeneration Duration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
DTC P042B (Flash Code 145) Catalyst Temperature Sensor Circuit Range/Performance Sensor 2 . . . . . . . . . . . 72
DTC P042C (Flash Code 49) Catalyst Temperature Sensor Circuit Low Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 72
DTC P042D (Flash Code 49) Catalyst Temperature Sensor Circuit High Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 73
DTC P060B (Flash Code 36) Internal Control Module A/D Processing Performance . . . . . . . . . . . . . . . . . . . . . . . . 74
DTC P242F (Flash Code 131) DPD Restriction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Engine-side Trouble
Engine-side Trouble
DTC U0001 (Flash Code 84) 5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.
CAN-Bus Malfunction
1. DTC U0001 Diagnostics DTC P0016 (Flash Code 16)
1) Turn OFF the starter switch. Crankshaft Position - Camshaft
ECM.
Position Correlation
3) Measure the resistance between the CAN- 1. DTC P0016 Priority DTC
High side terminal and CAN-Low side termi- DTC P0335
nal. DTC P0336
ANNOTATION: DTC P0340
2. DTC P0016 Diagnostics
• Measure the resistance between the termi-
nals of the ECM harness connector. 1) Inspect the CKP sensor.
Refer to "1.Engine 1B.Mechanical(6HK1X)
Resistance： about 120.0 Ω CKP sensor Inspection".
4) If it is outside the standard range, inspect 2) If a problem is discovered, replace the crank-
the CAN-Low circuit and CAN-High circuit be- shaft position sensor.
tween the ECM and the control unit of the ac- Refer to "1.Engine 1B.Mechanical(6HK1X)
tual unit. CKP sensor Removal".
• There should be no short to the battery or
ignition power supply. CKP sensor Installation".
3) Inspect the CMP sensor.
• There should be no open circuit or high re-
sistance. Refer to "1.Engine 1B.Mechanical(6HK1X)
CMP sensor Inspection".
• There should be no short to GND.
4) If a problem is discovered, replace the
5) If a problem is discovered, repair the CAN camshaft position sensor.
circuit. Refer to "1.Engine 1B.Mechanical(6HK1X)
6) If the CAN circuit is normal, replace the control CMP sensor Removal".
unit of the actual unit. Refer to "1.Engine 1B.Mechanical(6HK1X)
7) Connect the harness connector to the ECM. CMP sensor Installation".
8) Disconnect the harness connector from the 5) Inspect the flywheel.
control unit of the actual unit.
9) Measure the resistance between the CAN- • The sensor rotor should not be damaged.
High side terminal and CAN-Low side termi- • The ring gear should be installed correctly.
nal. 6) If a problem is discovered, repair the flywheel.
ANNOTATION: 7) Inspect the camshaft gear.
• Measure the resistance between the termi- • The camshaft gear should not be damaged
nals of the ECM harness connector. • The camshaft gear should be installed cor-
rectly.
Resistance： about 120.0 Ω
10) If it is outside the standard range, replace the 8) If a problem is discovered, repair the camshaft
ECM. gear.
Refer to "1.Engine 1J.Electrical(6HK1X) ECM 3. DTC P0016 Confirm Resolution
Removal".
Refer to "1.Engine 1J.Electrical(6HK1X) ECM 1) Clear the DTC using the trouble diagnosis
Installation". scan tool.
11) Set the injector ID code on the ECM. 2) Turn the starter switch OFF for 30 seconds or
12) Perform the unit difference learning of the fuel longer.
supply pump to the ECM. 3) Start the engine.
2. DTC U0001 Confirm Resolution ANNOTATION:
1) Clear the DTC using the trouble diagnosis • When the engine does not start, crank the
scan tool. engine for 10 seconds.
2) Turn the starter switch OFF for 30 seconds or 4) Perform a test-run.
longer. 5) Use the trouble diagnosis scan tool to confirm
3) Start the engine. that a DTC has not been detected.
4) Perform a test-run.
84402832 NA - May 2011

4023G-3
Engine-side Trouble
DTC P0045 (Flash Code 33) DTC U0073 (Flash Code 84)
Turbocharger Boost Control Control Module Communication
Solenoid Circuit Bus Off
1. DTC P0045 Priority DTC 1. DTC U0073 Diagnostics
DTC U0073
2) Measure the resistance between the termi-
1) Inspect the turbocharger assembly. nals of the termination resistor harness con-
Refer to "1.Engine 1F.Induction(6HK1X) Tur- nector.
bocharger assembly Inspection".
2) If a problem is discovered, repair the tur- ANNOTATION:
bocharger assembly. • Make a measurement from the back with the
3) Turn OFF the starter switch. harness connector connected.
4) Disconnect the turbocharger harness connec- • Confirm that the parallel resistance of the
tor. 120 Ω resistor in the termination resistor and
5) Remove the fuse. that of the 120 Ω resistor in the ECM are
6) Inspect the fuse for meltdown. both 60Ω.
7) If a problem is discovered, replace the fuse.
8) Inspect to see if there is an open circuit or Resistance： 50.0 - 70.0 Ω
high resistance between the fuse and the 3) Disconnect the harness connector from termi-
power supply circuit of the turbocharger inter- nation resistor if the resistance value is out-
nal ECU. side the standard range.
9) If a problem is discovered, repair the power 4) Measure the resistance of the termination re-
supply circuit. sistor.
10) Inspect to see if there is an open circuit or high Resistance： 110.0 - 130.0 Ω
resistance between the turbocharger GND cir- 5) If the resistance value is outside the standard
cuit and GND. range, replace the termination resistor.
11) If a problem is discovered, repair the GND 6) Connect the harness connector to the termi-
circuit. nation resistor .
12) Inspect the turbocharger harness connector 7) Disconnect the harness connector from the
for an contact failure. control unit of the actual unit.
13) If a problem is discovered, repair the harness 8) Measure the resistance between the termi-
connector. nals of the termination resistor harness con-
14) If the harness connector is normal, replace the nector.
turbocharger assembly. ANNOTATION:
Refer to "1.Engine 1F.Induction(6HK1X) Tur-
bocharger assembly Removal". • Make a measurement from the back with the
Refer to "1.Engine 1F.Induction(6HK1X) Tur- harness connector connected.
bocharger assembly Installation". Resistance： 50.0 - 70.0 Ω
3. DTC P0045 Confirm Resolution 9) If the resistance value is within the standard
range, replace the control unit of the actual
1) Clear the DTC using the trouble diagnosis unit.
scan tool. 10) Disconnect the harness connector from the
2) Turn the starter switch OFF for 30 seconds or ECM.
longer. 11) Measure the resistance between the termi-
3) Start the engine. nals of the termination resistor harness con-
4) Perform a test-run. nector.
5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected. ANNOTATION:
• Make a measurement from the back with the
harness connector connected.
Resistance： 110.0 - 130.0 Ω
12) Replace the ECM if the resistance value is
within the range of standard value.
Refer to "1.Engine 1J.Electrical(6HK1X) ECM
Removal".
Installation".
13) Set the injector ID code on the ECM.
14) Perform the unit difference learning of the fuel
supply pump to the ECM.
84402832 NA - May 2011

4023G-4
Engine-side Trouble
16) Connect the harness connector to the ECM. DTC P0087 (Flash Code 225) Fuel
18) Measure the voltage between the CAN-High Rail/System Pressure - Too Low
terminal and GND of the termination resistor
1. DTC P0087 Priority DTC
harness connector.
DTC P0088
19) Measure the voltage between the CAN-Low
DTC P0089
terminal and GND of the termination resistor
DTC P0091
harness connector.
DTC P0092
Voltage： 1.5 - 3.5 V
DTC P0192
20) If the voltage is outside the standard range,
DTC P0193
replace the ECM.
DTC P0201
DTC P0202
Removal".
DTC P0203
DTC P0204
Installation".
DTC P0205
DTC P0206
DTC P2146
DTC P2149
24) Connect the harness connector to the control
unit of the actual unit. 1) Start the engine.
25) Turn ON the starter switch. 2) Rev the engine a few times in neutral while
26) Measure the voltage between the CAN-High checking for a DTC with the trouble diagnosis
terminal and GND of the termination resistor scan tool.
harness connector. 3) Check to see if the DTC P0087 is detected.
27) Measure the voltage between the CAN-Low 4) If the DTC P0087 is not detected, replace the
terminal and GND of the termination resistor fuel filter element.
harness connector.
Voltage： 1.5 - 3.5 V ANNOTATION:
28) If the voltage is outside the standard range, • An intermittent problem due to foreign mat-
replace the control unit of the actual unit. ter in the fuel is suspected.
29) If the voltage is within the standard range, re-
place the termination resistor. Refer to "1.Engine 1C.Fuel System(6HK1X)
Fuel filter element Removal".
2. DTC U0073 Confirm Resolution Refer to "1.Engine 1C.Fuel System(6HK1X)
1) Use the trouble diagnosis scan tool to clear Fuel filter element Installation".
the DTC. 5) Turn OFF the starter switch.
2) Turn the starter switch OFF for 30 seconds. 6) Wait for the specified period of time until the
3) Start the engine. fuel pressure is released from the common
4) Perform a test-run. rail.
5) Use the trouble diagnosis scan tool to check Specified time: 2 min
if a DTC has been detected. 7) Turn ON the starter switch.
8) Check the fuel rail pressure sensor display
with the trouble diagnosis scan tool.
Voltage: 0.9 - 1.0 V
9) If the fuel rail pressure sensor display is out-
side the standard range, inspect the fuel pres-
sure sensor harness connector for a contact
failure.
10) If a problem is discovered, repair the harness
connector.
11) Inspect the ECM harness connector for a con-
tact failure.
connector.
13) Inspect each circuit for high resistance.
14) Repair the circuit if a problem is discovered.
84402832 NA - May 2011

4023G-5
Engine-side Trouble
15) If the harness connector and each circuit are ANNOTATION:

normal, replace the fuel pressure sensor.
Refer to "1.Engine 1C.Fuel System(6HK1X) • The fuel may leak to the bottom section of
the cylinder head cover from the high pres-
Common rail assembly Removal".
sure hose inlet.
Refer to "1.Engine 1C.Fuel System(6HK1X)
Common rail assembly Installation". • The engine oil level increases when the fuel
leaks to the bottom portion of the cylinder
ANNOTATION: head cover.
• Inspect for fuel leaks into the engine oil.
• Do not replace the fuel pressure sensor sep-
arately. 30) If fuel leak if found, fix the problem.
When a problem is found, replace the com- 31) Turn OFF the starter switch.
mon rail assembly. 32) Remove the fuel hose on the fuel supply pump
side from the fuel filter.
16) If the fuel rail pressure sensor display is within
the standard range, start the engine. ANNOTATION:
17) Perform the injector stop test with the trouble
diagnosis scan tool. • Use a pan to catch the fuel from the re-
moved fuel hose.
18) Command each injector OFF, and confirm that
the engine RPM changes on each injector. • Clean the pressure gauge and connection
hose before connecting to the fuel pipe.
19) If any injector does not change the engine
RPM when OFF is instructed, replace the rel- • The fuel supply pump may be damaged due
to foreign matter that has entered in the con-
evant injector.
nection hose.
Injector Removal". 33) Connect the pressure gauge between the fuel
Refer to "1.Engine 1C.Fuel System(6HK1X) filter and the removed fuel hose.
Injector Installation".
20) When the injector has been replaced, set the ANNOTATION:
injector ID code on the ECM. • Confirm that the fuel system is connected
21) Inspect to see if there is clogging with the fuel securely.
system between the fuel tank and the fuel sup-
ply pump. 34) Remove the air using the priming pump, and
22) If a problem is discovered, repair the clogging crank the engine for the specified period of
of the fuel system. time or shorter.
23) Inspect the fuel hose between the fuel tank Specified time: 5 s
and the fuel supply pump for a cut and crack. ANNOTATION:
24) If a problem is discovered, replace the fuel
hose. • Repeat this until the engine starts.
ANNOTATION: 35) Leave the engine idling for the specified pe-
riod of time or longer.
• The fuel hose between the fuel tank and the Specified time: 1 min
fuel supply pump becomes negative pres- 36) While keeping the engine rotating at the spec-
sure state when the engine is running. ified engine RPM for the specified period of
• When the fuel hose is not connected se- time, check the pressure gauge.
curely, the air can enter. Specified time: 1 min
• When the engine RPM or the engine load Rotational speed: 2500 min-1 {2500 r/min}
increases while the air has intruded in the 37) Check if the pressure gauge shows a negative
fuel system, fluctuation in the common rail pressure value at or above the standard value
pressure is caused, and DTC P0087 may during inspection.
be detected. Specified value: 17.0 kPa {128 mmHg / 5
25) Check that an appropriate clamp is used be- inHg}
tween the fuel tank and the fuel supply pump. ANNOTATION:
26) If a problem is discovered, replace the clamp.
27) Operate the priming pump until the handle be- • Fuel clogging is checked with the negative
comes heavy. pressure amount in the fuel system.
ANNOTATION: 38) If the negative pressure is at or above the
standard value, inspect to see if there is dam-
• When a leak exists in the fuel system be- age or twisting with the fuel system between
tween the priming pump and the fuel sup- the fuel supply pump and the fuel tank.
ply pump, the pressing weight of the priming 39) If a problem is discovered, repair the fuel sys-
pump does not become heavy. tem.
28) Start the engine. 40) Inspect the fuel tank bent hose.
29) Inspect the high-pressure side of the fuel sys- 41) If a problem is discovered, repair the bent
tem and check for fuel leak between the fuel hose.
supply pump and common rail.
84402832 NA - May 2011
4023G-6
Engine-side Trouble
42) Check to see if there is any foreign matter in 53) Inspect the suction control valve harness con-
the fuel tank or any foreign matter which can nector for a contact failure.
cause fuel clogging. 54) If a problem is discovered, repair the harness
43) If a problem is discovered, repair it. connector.
44) Replace the fuel filter element. 55) Inspect the ECM harness connector for a con-
Refer to "1.Engine 1C.Fuel System(6HK1X) tact failure.
Fuel filter element Removal". 56) If a problem is discovered, repair the harness
Refer to "1.Engine 1C.Fuel System(6HK1X) connector.
Fuel filter element Installation". 57) Inspect each circuit for high resistance.
45) If the negative pressure is at or below the stan- 58) Repair the circuit if a problem is discovered.
dard value, pinch the fuel hose at a position as 59) If the suction control valve harness connector
close as possible to the fuel tank, so that the and the ECM harness connector are normal
fuel does not flow. and there is no high resistance in each circuit,
replace the fuel supply pump and the fuel filter
ANNOTATION: element.
• The fuel pipe can be disconnected and Refer to "1.Engine 1C.Fuel System(6HK1X)
clogged with a plug. Fuel supply pump Removal".
46) Start the engine and use the idling control Fuel supply pump Installation".
switch to increase the RPM to the highest Refer to "1.Engine 1C.Fuel System(6HK1X)
level. Fuel filter element Removal".
47) Check the pressure gauge. Refer to "1.Engine 1C.Fuel System(6HK1X)
Specified value: 27.0 kPa {203 mmHg / 8 Fuel filter element Installation".
inHg}
ANNOTATION:
ANNOTATION:
• When replacing the fuel supply pump, it is
• When the pressure gauge is likely to indi- required to also replace the fuel filter ele-
cate a value exceeding the standard value ment at the same time.
during inspection, release the fuel being
blocked. 60) Perform the unit difference learning of the fuel
• Air mixture is checked with the negative supply pump to the ECM.
pressure amount while the fuel flow is being 3. DTC P0087 Confirm Resolution
blocked.
1) Clear the DTC using the trouble diagnosis
48) If the standard negative pressure cannot be scan tool.
generated, inspect to see if there is a cut or 2) Turn the starter switch OFF for 30 seconds or
crack with the fuel hose. longer.
49) If a problem is discovered, replace the fuel 3) Start the engine.
hose. 4) Perform a test-run.
50) Inspect to see if appropriate clamp is used. 5) Use the trouble diagnosis scan tool to confirm
51) If a problem is discovered, replace the clamp that a DTC has not been detected.
with an appropriate one.
84402832 NA - May 2011

4023G-7
Engine-side Trouble
DTC P0088 (Flash Code 118) Fuel 15) If the harness connector and each circuit are
Rail/System Pressure - Too High Refer to "1.Engine 1C.Fuel System(6HK1X)
DTC P0089
Common rail assembly Installation".
DTC P0091
DTC P0092 ANNOTATION:
DTC P0192
DTC P0193 • Do not replace the fuel pressure sensor sep-
DTC P0201 arately.
DTC P0202 When a problem is found, replace the com-
DTC P0203 mon rail assembly.
DTC P0204 16) Start the engine.
DTC P0205 17) Perform the injector stop test with the trouble
DTC P0206 diagnosis scan tool.
DTC P2146 18) Command each injector OFF, and confirm that
DTC P2149 the engine RPM changes on each injector.
2. DTC P0088 Diagnostics 19) If any injector does not change the engine
1) Start the engine. RPM when OFF is instructed, replace the rel-
2) Rev the engine a few times in neutral while evant injector.
checking the actual fuel rail pressure display Refer to "1.Engine 1C.Fuel System(6HK1X)
with the trouble diagnosis scan tool. Injector Removal".
3) Check the actual fuel rail pressure display with Refer to "1.Engine 1C.Fuel System(6HK1X)
the trouble diagnosis scan tool. Injector Installation".
Standard value: (-5) - 5 MPa 20) When the injector has been replaced, set the
4) If it is at or below the standard value, replace injector ID code on the ECM.
the fuel filter element. 21) Inspect to see if there is clogging with the fuel
ANNOTATION: ply pump.
22) If a problem is discovered, repair the clogging
• An intermittent problem due to foreign mat- of the fuel system.
ter in the fuel is suspected.
23) Inspect the fuel hose between the fuel tank
Refer to "1.Engine 1C.Fuel System(6HK1X) and the fuel supply pump for a cut and crack.
Fuel filter element Removal". 24) If a problem is discovered, replace the fuel
Refer to "1.Engine 1C.Fuel System(6HK1X) hose.
Fuel filter element Installation".
ANNOTATION:
6) Wait for the specified period of time until the • The fuel hose between the fuel tank and the
fuel pressure is released from the common fuel supply pump becomes negative pres-
rail. sure state when the engine is running.
Specified time: 2 min • When the fuel hose is not connected se-
7) Turn ON the starter switch. curely, the air can enter.
8) Check the fuel rail pressure sensor display • When the engine RPM or the engine load
with the trouble diagnosis scan tool. increases while the air has intruded in the
Voltage: 0.9 - 1.0 V fuel system, fluctuation in the common rail
9) If the fuel rail pressure sensor display is out- pressure is caused, and DTC P0088 may
side the standard range, inspect the fuel pres- be detected.
sure sensor harness connector for a contact
failure. 25) Check that an appropriate clamp is used be-
10) If a problem is discovered, repair the harness tween the fuel tank and the fuel supply pump.
connector. 26) If a problem is discovered, replace the clamp.
11) Inspect the ECM harness connector for a con- 27) Operate the priming pump until the handle be-
tact failure. comes heavy.
12) If a problem is discovered, repair the harness ANNOTATION:
connector.
13) Inspect each circuit for high resistance. • When a leak exists in the fuel system be-
14) If a problem is discovered, repair the circuit. tween the priming pump and the fuel sup-
ply pump, the pressing weight of the priming
pump does not become heavy.
29) Inspect the high-pressure side of the fuel sys-
tem and check for fuel leak between the fuel
supply pump and common rail.
84402832 NA - May 2011

4023G-8
Engine-side Trouble
ANNOTATION: 39) If a problem is discovered, repair the fuel sys-

tem.
• The fuel may leak to the bottom section of 40) Inspect the fuel tank bent hose.
the cylinder head cover from the high pres- 41) If a problem is discovered, repair the bent
sure hose inlet. hose.
• The engine oil level increases when the fuel 42) Check to see if there is any foreign matter in
leaks to the bottom portion of the cylinder the fuel tank or any foreign matter which can
head cover. cause fuel clogging.
• Inspect for fuel leaks into the engine oil. 43) If a problem is discovered, repair it.
30) If fuel leak if found, fix the problem. 44) Replace the fuel filter element.
31) Turn OFF the starter switch. Refer to "1.Engine 1C.Fuel System(6HK1X)
32) Remove the fuel hose on the fuel supply pump Fuel filter element Removal".
side from the fuel filter. Refer to "1.Engine 1C.Fuel System(6HK1X)
ANNOTATION: 45) If the negative pressure is at or below the stan-
• Use a pan to catch the fuel from the re- dard value, pinch the fuel hose at a position as
moved fuel hose. close as possible to the fuel tank, so that the
• Clean the pressure gauge and connection fuel does not flow.
hose before connecting to the fuel pipe. ANNOTATION:
• The fuel supply pump may be damaged due
to foreign matter that has entered in the con- • The fuel pipe can be disconnected and
nection hose. clogged with a plug.
33) Connect the pressure gauge between the fuel 46) Start the engine and use the idling control
filter and the removed fuel hose. switch to increase the RPM to the highest
level.
ANNOTATION: 47) Check the pressure gauge.
• Confirm that the fuel system is connected Specified value: 27.0 kPa {203 mmHg / 8
securely. inHg}
34) Remove the air using the priming pump, and ANNOTATION:
crank the engine for the specified period of • When the pressure gauge is likely to indi-
time or shorter. cate a value exceeding the standard value
Specified time: 5 s during inspection, release the fuel being
ANNOTATION: blocked.
• Air mixture is checked with the negative
• Repeat this until the engine starts. pressure amount while the fuel flow is being
35) Leave the engine idling for the specified pe- blocked.
riod of time or longer. 48) If the standard negative pressure cannot be
Specified time: 1 min generated, inspect to see if there is a cut or
36) While keeping the engine rotating at the spec- crack with the fuel hose.
ified engine RPM for the specified period of 49) If a problem is discovered, replace the fuel
time, check the pressure gauge. hose.
Specified time: 1 min 50) Inspect to see if appropriate clamp is used.
Rotational speed: 2500 min-1 {2500 r/min} 51) If a problem is discovered, replace the clamp
37) Check if the pressure gauge shows a negative with an appropriate one.
pressure value at or above the standard value 52) Turn OFF the starter switch.
during inspection. 53) Inspect the suction control valve harness con-
Specified value: 17.0 kPa {128 mmHg / 5 nector for a contact failure.
inHg} 54) If a problem is discovered, repair the harness
ANNOTATION: connector.
• Fuel clogging is checked with the negative tact failure.
pressure amount in the fuel system. 56) If a problem is discovered, repair the harness
38) If the negative pressure is at or above the connector.
standard value, inspect to see if there is dam- 57) Inspect each circuit for high resistance.
age or twisting with the fuel system between 58) Repair the circuit if a problem is discovered.
the fuel supply pump and the fuel tank.
84402832 NA - May 2011

4023G-9
Engine-side Trouble
59) If the suction control valve harness connector DTC P0089 (Flash Code 151) Fuel
and the ECM harness connector are normal
and there is no high resistance in each circuit, Pressure Regulator Performance
replace the fuel supply pump and the fuel filter
element.
DTC P0091
DTC P0092
Fuel supply pump Removal".
DTC P0192
DTC P0193
Fuel supply pump Installation".
DTC P0201
DTC P0202
Fuel filter element Removal".
DTC P0203
DTC P0204
DTC P0205
ANNOTATION: DTC P0206
DTC P2146
• When replacing the fuel supply pump, it is DTC P2149
required to also replace the fuel filter ele- 2. DTC P0089 Diagnostics
ment at the same time.
1) Wait for the specified period of time until the
60) Perform the unit difference learning of the fuel fuel pressure is released from the common
supply pump to the ECM. rail.
3. DTC P0088 Confirm Resolution Specified time： 2 min
1) Clear the DTC using the trouble diagnosis with the trouble diagnosis scan tool.
scan tool. Voltage： 0.9 - 1.0 V
2) Turn the starter switch OFF for 30 seconds or 3) If the fuel rail pressure sensor display is out-
longer. side the standard range, inspect the fuel pres-
3) Start the engine. sure sensor harness connector for a contact
4) Perform a test-run. failure.
5) Use the trouble diagnosis scan tool to confirm 4) If a problem is discovered, repair the harness
that a DTC has not been detected. connector.
tact failure.
connector.
9) If the harness connector and each circuit are
ANNOTATION:
arately. When a problem is found, replace
the common rail assembly.
10) Inspect the suction control valve harness con-
nector for a contact failure.
connector.
tact failure.
connector.
16) Turn the starter switch OFF for 30 seconds or
longer.
18) Rev the engine a few times in neutral while
checking the actual fuel rail pressure display
84402832 NA - May 2011

4023G-10
Engine-side Trouble
19) Use the trouble diagnosis scan tool to check DTC P0091 (Flash Code 247) Fuel
if the actual fuel rail pressure display shows a
value within the standard range at a sufficient Pressure Regulator Control Circuit
rate.
Standard values: (-5) - 5 MPa
Low
ANNOTATION:
1) Check the rail pressure regulator feedback
• If possible, compare with other actual unit
current display with the trouble diagnosis scan
equipped with the same model engine.
tool.
20) If it is within the standard range, replace the Current： 300 - 900 mA
fuel filter element. 2) If it is at or above the standard value, inspect
Refer to "1.Engine 1C.Fuel System(6HK1X) to see if there is a short circuit to the battery
Fuel filter element Removal". or ignition power supply with the High side cir-
Refer to "1.Engine 1C.Fuel System(6HK1X) cuit between the ECM and the suction control
Fuel filter element Installation". valve.
21) If it is outside the standard range, replace the
ANNOTATION:
fuel supply pump and the fuel filter element.
Refer to "1.Engine 1C.Fuel System(6HK1X) • When the High side circuit is shorted to the
Fuel supply pump Removal". voltage, the engine stalls and does not start.
Fuel supply pump Installation". 3) If a problem is discovered, repair the High side
Refer to "1.Engine 1C.Fuel System(6HK1X) circuit.
Fuel filter element Removal". 4) If it is within the standard range, inspect to
Refer to "1.Engine 1C.Fuel System(6HK1X) see if there is a short circuit to the GND with
Fuel filter element Installation". the Low side circuit between the ECM and the
ANNOTATION:
ANNOTATION:
required to also replace the fuel filter ele- • When the Low side circuit is shorted to
ment at the same time. GND, DTC P0091 may not be detected.
• When the Low side circuit is shorted to
22) Perform the unit difference learning of the fuel GND, the engine stalls and does not start.
5) If a problem is discovered, repair the Low side
3. DTC P0089 Confirm Resolution circuit.
longer.
scan tool.
longer.
8) Connect the test light between the suction
control valve High side circuit and a normal
GND.
10) Check if the test light comes on and then goes
off.
11) If it does not turn off, inspect the High side cir-
cuit between the ECM and the suction control
valve.
sistance.
• There should be no short to the LOW side
circuit.
12) If a problem is discovered, repair the High side
circuit.
longer.
control valve Low side circuit and battery
power supply.
off.
84402832 NA - May 2011

4023G-11
Engine-side Trouble
17) If it does not turn off, inspect the Low side DTC P0092 (Flash Code 247) Fuel
circuit between the ECM and suction control
valve. Pressure Regulator Control Circuit
• There should be no open circuit or high re- High
sistance.
ignition power supply. 1) Check the rail pressure regulator feedback
current display with the trouble diagnosis scan
tool.
circuit.
Current： 300 - 900 mA
19) Inspect the suction control valve harness con-
2) If it is at or above the standard value, inspect
to see if there is a short circuit to the battery
or ignition power supply with the High side cir-
connector.
21) If the harness connector is normal, replace the
valve.
Refer to "1.Engine 1C.Fuel System(6HK1X) ANNOTATION:
Suction control valve Removal".
Refer to "1.Engine 1C.Fuel System(6HK1X) • When the High side circuit is shorted to the
Suction control valve Installation". voltage, the engine stalls and does not start.
22) Inspect the ECM harness connector for a con- 3) If a problem is discovered, repair the High side
tact failure. circuit.
23) If a problem is discovered, repair the harness 4) If it is within the standard range, inspect to
connector. see if there is a short circuit to the GND with
24) If the harness connector is normal, replace the the Low side circuit between the ECM and the
ECM. suction control valve.
Removal". ANNOTATION:
Refer to "1.Engine 1J.Electrical(6HK1X) ECM • When the Low side circuit is shorted to
Installation". GND, DTC P0092 may not be detected.
25) Set the injector ID code on the ECM. • When the Low side circuit is shorted to
26) Perform the unit difference learning of the fuel GND, the engine stalls and does not start.
2. DTC P0091 Confirm Resolution circuit.
1) Clear the DTC using the trouble diagnosis 6) Turn the starter switch OFF for 30 seconds or
scan tool. longer.
2) Turn the starter switch OFF for 30 seconds or 7) Disconnect the harness connector from the
longer. suction control valve.
3) Start the engine. 8) Connect the test light between the suction
4) Perform a test-run. control valve High side circuit and a normal
5) Use the trouble diagnosis scan tool to confirm GND.
that a DTC has not been detected. 9) Turn ON the starter switch.
off.
11) If it does not turn off, inspect the High side cir-
valve.
sistance.
• There should be no short to the LOW side
circuit.
12) If a problem is discovered, repair the High side
circuit.
longer.
control valve Low side circuit and battery
power supply.
off.
84402832 NA - May 2011

4023G-12
Engine-side Trouble
17) If it does not turn off, inspect the Low side DTC P0093 (Flash Code 227) Fuel
circuit between the ECM and suction control
valve. System Leak Detected
• There should be no open circuit or high re- 1. DTC P0093 Priority DTC
sistance. DTC P0087
• There should be no short to the battery or DTC P0091
ignition power supply. DTC P0092
DTC P0192
18) If a problem is discovered, repair the Low side DTC P0193
circuit. DTC P0201
19) Inspect the suction control valve harness con- DTC P0202
nector for a contact failure. DTC P0203
20) If a problem is discovered, repair the harness DTC P0204
connector. DTC P0205
21) If the harness connector is normal, replace the DTC P0206
suction control valve. DTC P2146
Refer to "1.Engine 1C.Fuel System(6HK1X) DTC P2149
Suction control valve Removal". 2. DTC P0093 Diagnostics
Suction control valve Installation". 1) Inspect for fuel leaks on the high-pressure
22) Inspect the ECM harness connector for a con- side between the fuel supply pump and injec-
tact failure. tor.
connector. • There should be no fuel leakage from the
fuel supply pump.
ECM. • There should be no fuel leakage from the
common rail.
Removal". • There should be no fuel leakage from the
pressure limiter valve.
Installation". • There should be no fuel leakage from the
26) Perform the unit difference learning of the fuel • There should be no fuel leakage from the
fuel pipe between the fuel supply pump and
common rail.
2. DTC P0092 Confirm Resolution • There should be no fuel leakage from the
fuel pipe between the common rail and in-
1) Clear the DTC using the trouble diagnosis jector.
scan tool.
• There should be no fuel leakage from the
2) Turn the starter switch OFF for 30 seconds or sleeve nut of the fuel pipe.
longer.
3) Start the engine. 2) If fuel leak if found, fix the problem.
ANNOTATION:
that a DTC has not been detected. • The fuel may leak to the bottom section of
the cylinder head cover from the high pres-
sure pipe inlet.
• The engine oil level increases when the fuel
leaks to the bottom portion of the cylinder
head cover.
• Inspect for fuel leaks into the engine oil.
• Remove and inspect the high pressure pipe
joint connected to the injector for a fuel leak-
age from the sleeve nut.
• When foreign matter has been attached,
replace the injector and the high pressure
pipe.
3) Remove each glow plug from the cylinder
head assembly.
Cylinder head assembly Removal".
4) Inspect for fuel leaks into the combustion
chamber
5) Inspect to see if there is a cylinder from which
fuel leaks into the combustion chamber.
84402832 NA - May 2011

4023G-13
Engine-side Trouble
6) If fuel leak is found, replace the corresponding 27) If a problem is discovered, replace the fuel
injector. hose.
ANNOTATION:
Injector Removal".
Refer to "1.Engine 1C.Fuel System(6HK1X) • The fuel hose between the fuel tank and
Injector Installation". the supply pump becomes negative pres-
7) When the injector has been replaced, set the sure state when the engine is running.
injector ID code on the ECM. • When the fuel hose is not connected se-
8) Turn OFF the starter switch. curely, the air can enter.
9) Wait for the specified period of time until the • When the engine RPM or the engine load
fuel pressure is released from the common increases while the air has intruded in the
rail. fuel system, fluctuation in the common rail
Specified time: 2 min pressure is caused, and DTC P0093 may
10) Turn ON the starter switch. be detected.
with the trouble diagnosis scan tool. 28) Check that an appropriate clamp is used be-
Voltage: 0.9 - 1.0 V tween the fuel tank and the fuel supply pump.
12) If the fuel rail pressure sensor display is out- 29) If a problem is discovered, replace the clamp
side the standard range, inspect the fuel pres- with an appropriate one.
sure sensor harness connector for a contact 30) Operate the priming pump until the handle be-
failure. comes heavy.
13) If a problem is discovered, repair the harness ANNOTATION:
connector.
14) Inspect the ECM harness connector for a con- • When a leak exists in the fuel system be-
tact failure. tween the priming pump and the fuel sup-
15) If a problem is discovered, repair the harness ply pump, the pressing weight of the priming
connector. pump does not become heavy.
16) Inspect each circuit for high resistance. 31) Start the engine.
17) Repair the circuit if a problem is discovered. 32) Inspect the high-pressure side of the fuel sys-
18) If the harness connector and each circuit are tem and check for fuel leak between the fuel
normal, replace the fuel pressure sensor. supply pump and common rail.
Common rail assembly Removal". ANNOTATION:
Refer to "1.Engine 1C.Fuel System(6HK1X) • The fuel may leak to the bottom section of
Common rail assembly Installation". the cylinder head cover from the high pres-
ANNOTATION: sure hose inlet.
• The engine oil level increases when the fuel
• Do not replace the fuel pressure sensor sep- leaks to the bottom portion of the cylinder
arately. head cover.
When a problem is found, replace the com- • Inspect for fuel leaks into the engine oil.
mon rail assembly.
33) If fuel leak if found, fix the problem.
19) If the fuel rail pressure sensor display is within 34) Turn OFF the starter switch.
the standard range, start the engine. 35) Remove the fuel hose on the fuel supply pump
20) Perform the injector stop test with the trouble side from the fuel filter.
diagnosis scan tool.
21) Command each injector OFF, and confirm that ANNOTATION:
the engine RPM changes on each injector. • Use a pan to catch the fuel from the re-
22) If any injector does not change the engine moved fuel hose.
RPM when OFF is instructed, replace the rel- • Clean the pressure gauge and connection
evant injector. hose before connecting to the fuel pipe.
Refer to "1.Engine 1C.Fuel System(6HK1X) • The fuel supply pump may be damaged due
Injector Removal". to foreign matter that has entered in the con-
Refer to "1.Engine 1C.Fuel System(6HK1X) nection hose.
23) When the injector has been replaced, set the 36) Connect the pressure gauge between the fuel
injector ID code on the ECM. filter and the removed fuel hose.
24) Inspect to see if there is clogging with the fuel ANNOTATION:
ply pump. • Confirm that the fuel system is connected
25) If a problem is discovered, repair clogging. securely.
26) Inspect to see if there is cut or crack with the
fuel hose in the fuel system between the fuel
tank and the fuel supply pump.
84402832 NA - May 2011

4023G-14
Engine-side Trouble
37) Remove the air using the priming pump, and • When the pressure gauge is likely to indi-
crank the engine for the specified period of cate a value exceeding the standard value
time or shorter. during inspection, release the fuel being
Specified time: 5 s blocked.
• Air mixture is checked with the negative
ANNOTATION: pressure amount while the fuel flow is being
• Repeat this until the engine starts. blocked.
38) Leave the engine idling for the specified pe- 51) If the standard negative pressure cannot be
riod of time or longer. generated, inspect to see if there is a cut or
Specified time: 1 min crack with the fuel hose.
39) While keeping the engine rotating at the spec- 52) If a problem is discovered, replace the fuel
ified engine RPM for the specified period of hose.
time, check the pressure gauge. 53) Inspect to see if appropriate clamp is used.
Specified time: 1 min 54) If a problem is discovered, replace the clamp
Rotational speed: 2500 min-1 {2500 r/min} with an appropriate one.
40) Check if the pressure gauge shows a negative 55) Turn OFF the starter switch.
pressure value at or above the standard value 56) Inspect the suction control valve harness con-
during inspection. nector for a contact failure.
Specified value: 17.0 kPa {128 mmHg / 5 57) If a problem is discovered, repair the harness
inHg} connector.
ANNOTATION: tact failure.
• Fuel clogging is checked with the negative 59) If a problem is discovered, repair the harness
pressure amount in the fuel system. connector.
41) If the negative pressure is at or above the 61) Repair the circuit if a problem is discovered.
standard value, inspect to see if there is dam- 62) If the suction control valve harness connector
age or twisting with the fuel system between and the ECM harness connector are normal
the fuel supply pump and the fuel tank. and there is no high resistance in each circuit,
42) If a problem is discovered, repair the fuel sys- replace the fuel supply pump and the fuel filter
tem. element.
43) Inspect the fuel tank bent hose. Refer to "1.Engine 1C.Fuel System(6HK1X)
44) If a problem is discovered, repair the bent Fuel supply pump Removal".
hose. Refer to "1.Engine 1C.Fuel System(6HK1X)
45) Check to see if there is any foreign matter in Fuel supply pump Installation".
the fuel tank or any foreign matter which can Refer to "1.Engine 1C.Fuel System(6HK1X)
cause fuel clogging. Fuel filter element Removal".
46) If a problem is discovered, repair it. Refer to "1.Engine 1C.Fuel System(6HK1X)
47) Replace the fuel filter element. Fuel filter element Installation".
Fuel filter element Removal". ANNOTATION:
Refer to "1.Engine 1C.Fuel System(6HK1X) • When replacing the fuel supply pump, it is
Fuel filter element Installation". required to also replace the fuel filter ele-
48) If the negative pressure is at or below the stan- ment at the same time.
dard value, pinch the fuel hose at a position as
close as possible to the fuel tank, so that the 63) Perform the unit difference learning of the fuel
fuel does not flow. supply pump to the ECM.
ANNOTATION: 3. DTC P0093 Confirm Resolution
• The fuel pipe can be disconnected and 1) Clear the DTC using the trouble diagnosis
clogged with a plug. scan tool.
49) Start the engine and use the idling control longer.
switch to increase the RPM to the highest 3) Start the engine.
level. 4) Perform a test-run.
50) Check the pressure gauge. 5) Use the trouble diagnosis scan tool to confirm
Specified value: 27.0 kPa {203 mmHg / 8 that a DTC has not been detected.
inHg}
ANNOTATION:
84402832 NA - May 2011

4023G-15
Engine-side Trouble
DTC U0101 (Flash Code 85) Lost DTC P0102 (Flash Code 91) Mass
Communication with TCM Air Flow Circuit Low Input
1. DTC U0101 Diagnostics 1. DTC P0102 Priority DTC
DTC P0560
1) Inspect the CAN-Low circuit and CAN-High 2. DTC P0102 Diagnostics
circuit between the ECM and the control unit
of the actual unit. 1) Turn OFF the starter switch.
• There should be no short to the battery or mass air flow sensor.
ignition power supply. 3) Inspect to see if there is an open circuit or high
• There should be no open circuit or high re- resistance in the 12 V power supply circuit be-
sistance. tween the ECM and the mass air flow sensor.
• There should be no short to GND. 4) If a problem is discovered, repair the 12 V
2) If a problem is discovered, repair the CAN power supply circuit.
circuit. 5) Connect the test cable with fuse between the
3) If the CAN circuit is normal, connect all har- 12 V power supply circuit and the signal circuit
nesses. of the mass air flow sensor harness connector.
4) Clear the DTC using the trouble diagnosis 6) Check the mass air flow sensor display with
scan tool. the trouble diagnosis scan tool.
5) Turn the starter switch OFF for 30 seconds or Voltage： 4.9 V
longer. 7) If it is at or above the standard value, inspect
6) Perform a test-run. to see if there is a contact failure with the mass
7) Check the DTC. air flow sensor harness connector.
8) If a DTC has been detected, replace the con- 8) If a problem is discovered, repair the harness
trol unit of the actual unit. connector.
9) Connect all harnesses. 9) If the harness connector is normal, replace the
10) Clear the DTC using the trouble diagnosis mass air flow sensor.
scan tool. 10) Inspect the signal circuit between the ECM
11) Turn the starter switch OFF for 30 seconds or and the mass air flow sensor.
longer.
sistance.
13) Check the DTC.
14) If a DTC has been detected, replace the ECM.
Refer to "1.Engine 1J.Electrical(6HK1X) ECM 11) If a problem is discovered, repair the signal
Removal". circuit.
Refer to "1.Engine 1J.Electrical(6HK1X) ECM 12) Inspect the ECM harness connector for a con-
Installation". tact failure.
15) Set the injector ID code on the ECM. 13) If a problem is discovered, repair the harness
16) Perform the unit difference learning of the fuel connector.
supply pump to the ECM. 14) If the harness connector is normal, replace the
ECM.
2. DTC U0101 Confirm Resolution
1) Clear the DTC using the trouble diagnosis Removal".
scan tool. Refer to "1.Engine 1J.Electrical(6HK1X) ECM
2) Turn the starter switch OFF for 30 seconds or Installation".
longer. 15) Set the injector ID code on the ECM.
3) Start the engine. 16) Perform the unit difference learning of the fuel
4) Perform a test-run. supply pump to the ECM.
3. DTC P0102 Confirm Resolution
scan tool.
longer.
84402832 NA - May 2011

4023G-16
Engine-side Trouble
DTC P0103 (Flash Code 91) Mass DTC P0237 (Flash Code 32) Turbo
Air Flow Circuit High Input Charger Boost Sensor Circuit Low
1. DTC P0103 Priority DTC 1. DTC P0237 Priority DTC
DTC P0560 DTC P1655
2. DTC P0103 Diagnostics 2. DTC P0237 Diagnostics
1) Turn OFF the starter switch. 1) Turn OFF the starter switch.
2) Disconnect the harness connector from the 2) Disconnect the harness connector from the
mass air flow sensor. boost sensor.
3) Check the mass air flow sensor display with 3) Turn ON the starter switch.
the trouble diagnosis scan tool. 4) Measure the voltage between the 5 V power
Voltage： 0.1 V supply circuit of the boost sensor harness con-
4) If it is at or above the standard value, inspect nector and a normal GND.
the signal circuit between the ECM and the Voltage： 4.5 V
mass air flow sensor. 5) If it is at or below the standard value, inspect
to see if there is an open circuit or high re-
• There should be no short to the battery or sistance with the 5 V power supply circuit be-
ignition power supply. tween the ECM and the boost sensor.
• There should be no short to the 12 V or 5 V
power supply. ANNOTATION:
5) If a problem is discovered, repair the signal • The boost sensor shares the 5 V power sup-
circuit. ply circuit with other sensors.
6) Inspect to see if there is an open circuit or • The DTC set on a sensor which shares this
high resistance in the GND circuit between the circuit may be detected.
ECM and the mass air flow sensor.
7) If a problem is discovered, repair the GND 6) If a problem is discovered, repair the 5 V
circuit. power supply circuit.
8) Inspect the mass air flow sensor harness con- 7) Connect the test cable with fuse between the
nector for a contact failure. 5 V power supply circuit and the signal circuit
9) If a problem is discovered, repair the harness of the boost sensor harness connector.
connector. 8) Check the boost pressure sensor display with
10) If the harness connector is normal, replace the the trouble diagnosis scan tool.
mass air flow sensor. Voltage： 4.5 V
11) Inspect the ECM harness connector for a con- 9) If it is at or above the standard value, inspect
tact failure. to see if there is a contact failure with the boost
12) If a problem is discovered, repair the harness sensor harness connector.
connector. 10) If a problem is discovered, repair the harness
13) If the harness connector is normal, replace the connector.
ECM. 11) If the harness connector is normal, replace the
Refer to "1.Engine 1J.Electrical(6HK1X) ECM boost sensor.
Removal". Refer to "1.Engine 1F.Induction(6HK1X)
Refer to "1.Engine 1J.Electrical(6HK1X) ECM Boost sensor Removal".
Installation". Refer to "1.Engine 1F.Induction(6HK1X)
14) Set the injector ID code on the ECM. Boost sensor Installation".
15) Perform the unit difference learning of the fuel 12) Inspect the signal circuit between the ECM
supply pump to the ECM. and the boost sensor.
3. DTC P0103 Confirm Resolution • There should be no open circuit or high re-
sistance.
1) Clear the DTC using the trouble diagnosis • There should be no short to GND.
scan tool.
2) Turn the starter switch OFF for 30 seconds or 13) If a problem is discovered, repair the signal
longer. circuit.
3) Start the engine. 14) Inspect the ECM harness connector for a con-
4) Perform a test-run. tact failure.
5) Use the trouble diagnosis scan tool to confirm 15) If a problem is discovered, repair the harness
that a DTC has not been detected. connector.
ECM.
Removal".
Installation".
84402832 NA - May 2011

4023G-17
Engine-side Trouble
18) Perform the unit difference learning of the fuel DTC P0238 (Flash Code 32) Turbo
Charger Boost Sensor Circuit High
1) Clear the DTC using the trouble diagnosis DTC P1655
scan tool. 2. DTC P0238 Diagnostics
longer. 1) Turn OFF the starter switch.
3) Start the engine. 2) Disconnect the harness connector from the
4) Perform a test-run. boost
5) Use the trouble diagnosis scan tool to confirm 3) Check the boost pressure sensor display with
that a DTC has not been detected. the trouble diagnosis scan tool.
Voltage： 0.1 V
the signal circuit between the ECM and the
boost sensor.
ignition power supply.
• There should be no short to the 5 V power
supply.
5) If a problem is discovered, repair the signal
circuit.
6) Inspect to see if there is an open circuit or
high resistance in the GND circuit between the
ECM and the boost sensor.
ANNOTATION:
• The boost sensor shares the GND circuit
with other sensors.
• The DTC set on a sensor which shares this
circuit may be detected.
7) If a problem is discovered, repair the GND
circuit.
8) Inspect the boost sensor harness connector
for a contact failure.
connector.
boost sensor.
Refer to "1.Engine 1F.Induction(6HK1X)
Boost sensor Removal".
Boost sensor Installation".
tact failure.
connector.
ECM.
Removal".
Installation".
3. DTC P0238 Confirm Resolution sensor.
scan tool.
longer.
84402832 NA - May 2011

4023G-18
Engine-side Trouble
4) Perform a test-run. DTC U0110 (Flash Code 87) Lost

that a DTC has not been detected. Communication with VNT System
1. DTC U0110 Priority DTC
DTC P0045
DTC U0001
2. DTC U0110 Diagnostics
2) Remove the harness connector from the turbo
control unit.
3) Measure the voltage between the ISO CAN-
Low circuit and GND of the turbo control unit
harness connector.
4) Measure the voltage between the ISO CAN-
High circuit and GND of the turbo control unit
harness connector.
Voltage： 1.5 - 3.5 V
5) If it is outside the standard range, inspect to
see if there is an open circuit or high resis-
tance with the ISO CAN-High circuit between
the turbo control unit and the ECM.
6) If a problem is discovered, repair the ISO
CAN-High circuit.
high resistance with the ISO CAN-Low circuit
between the turbo control unit and the ECM.
8) If a problem is discovered, repair the ISO
CAN-Low circuit.
9) Inspect the turbo control unit harness connec-
tor for a contact failure.
connector.
11) Replace the turbocharger assembly.
bocharger assembly Removal".
bocharger assembly Installation".
3. DTC U0110 Confirm Resolution
scan tool.
longer.
84402832 NA - May 2011

4023G-19
Engine-side Trouble
DTC P0112 (Flash Code 22) DTC P0113 (Flash Code 22)
Intake Air Temperature Sensor Intake Air Temperature Sensor
Circuit Low Circuit High
DTC P0641 DTC P0641
intake air temperature sensor. intake air temperature sensor.
3) Check the intake air temperature sensor dis- 3) Turn ON the starter switch.
play with the trouble diagnosis scan tool. 4) Measure the voltage between the intake air
Voltage： 4.5 V temperature sensor signal circuit and a nor-
4) If it is at or above the standard value, replace mal GND.
the intake air temperature sensor. Voltage： 5.5 V
5) Inspect to see if there is a short circuit to the 5) If it is at or above the standard value, inspect
GND with the signal circuit between the ECM the signal circuit between the ECM and the
and the intake air temperature sensor. intake air temperature sensor.
circuit. • There should be no short to the battery or
ignition power supply
8) Disconnect the harness connector from the • There should be no short to the 12 V power
ECM. supply.
9) Inspect the ECM harness connector for a con- 6) If a problem is discovered, repair the signal
tact failure. circuit.
10) If a problem is discovered, repair the harness 7) Connect the test cable with fuse between the
connector. intake air temperature sensor signal circuit
11) If the harness connector is normal, replace the and the GND circuit.
ECM. 8) Check the intake air temperature sensor dis-
Refer to "1.Engine 1J.Electrical(6HK1X) ECM play with the trouble diagnosis scan tool.
Removal". Voltage： 0.1 V
Refer to "1.Engine 1J.Electrical(6HK1X) ECM 9) If it is at or below the standard value, inspect to
Installation". see if there is a short circuit to the 5 V power
12) Set the injector ID code on the ECM. supply circuit with the signal circuit between
13) Perform the unit difference learning of the fuel the ECM and the intake air temperature sen-
supply pump to the ECM. sor.
3. DTC P0112 Confirm Resolution 10) If a problem is discovered, repair the signal
circuit.
1) Clear the DTC using the trouble diagnosis 11) Inspect the intake air temperature sensor har-
scan tool. ness connector for a contact failure.
2) Turn the starter switch OFF for 30 seconds or 12) If a problem is discovered, repair the harness
longer. connector.
3) Start the engine. 13) If the harness connector is normal, replace the
4) Perform a test-run. intake air temperature sensor.
5) Use the trouble diagnosis scan tool to confirm 14) Connect the test cable with fuse between the
that a DTC has not been detected. intake air temperature sensor signal circuit
and a normal GND.
15) Check the intake air temperature sensor dis-
play with the trouble diagnosis scan tool.
Voltage： 0.1 V
16) If it is at or below the standard value, inspect
to see if there is an open circuit or high resis-
tance with the GND circuit between the ECM
and the intake air temperature sensor.
ANNOTATION:
• The intake air temperature sensor shares
the GND circuit with other sensors.
circuit.
84402832 NA - May 2011

4023G-20
Engine-side Trouble
18) Inspect to see if there is an open circuit or DTC P0117 (Flash Code 23)
high resistance in the signal circuit between
the ECM and the intake air temperature sen- Engine Coolant Temperature
19)
sor.
If a problem is discovered, repair the signal
Sensor Circuit Low
circuit. 1. DTC P0117 Priority DTC
20) Inspect the ECM harness connector for a con- DTC P0697
tact failure. 2. DTC P0117 Diagnostics
connector. 1) Turn OFF the starter switch.
22) If the harness connector is normal, replace the 2) Disconnect the harness connector from the
ECM. water temperature sensor.
Refer to "1.Engine 1J.Electrical(6HK1X) ECM 3) Check the coolant temperature sensor display
Removal". with the trouble diagnosis scan tool.
Refer to "1.Engine 1J.Electrical(6HK1X) ECM Voltage： 4.5 V
Installation". 4) If it is at or above the standard value, replace
23) Set the injector ID code on the ECM. the water temperature sensor.
24) Perform the unit difference learning of the fuel Refer to "1.Engine 1D.Cooling(6HK1X) En-
supply pump to the ECM. gine coolant temperature sensor Removal".
Refer to "1.Engine 1D.Cooling(6HK1X) En-
3. DTC P0113 Confirm Resolution gine coolant temperature sensor Installation".
5) Inspect to see if there is a short circuit to the
GND with the signal circuit between the ECM
scan tool.
and water temperature sensor.
longer.
circuit.
tact failure.
connector.
ECM.
Removal".
Installation".
scan tool.
longer.
84402832 NA - May 2011

4023G-21
Engine-side Trouble
DTC P0118 (Flash Code 23) 14) Connect the test cable with fuse between the
water temperature sensor signal circuit and
Engine Coolant Temperature normal GND.
Sensor Circuit High 15) Check the coolant temperature sensor display
1. DTC P0118 Priority DTC Voltage： 0.1 V
DTC P0697 16) If it is at or below the standard value, inspect
2. DTC P0118 Diagnostics to see if there is an open circuit or high resis-
tance with the water temperature sensor GND
1) Turn OFF the starter switch. circuit.
water temperature sensor. ANNOTATION:
• The water temperature sensor shares the
4) Measure the voltage between the water tem-
GND circuit with other sensors.
perature sensor signal circuit and normal
GND.
Voltage： 5.5 V
5) If it is at or above the standard value, inspect 17) If a problem is discovered, repair the GND
to see if there is a short circuit to the battery circuit.
or ignition power supply with the signal circuit 18) Inspect to see if there is a breakage or high re-
between the ECM and the water temperature sistance in the signal circuit of the water tem-
sensor. perature sensor.
6) If a problem is discovered, repair the signal 19) If a problem is discovered, repair the signal
circuit. circuit.
7) Connect the test cable with fuse between the 20) Inspect the ECM harness connector for a con-
water temperature sensor signal circuit and tact failure.
GND circuit. 21) If a problem is discovered, repair the harness
8) Check the coolant temperature sensor display connector.
with the trouble diagnosis scan tool. 22) If the harness connector is normal, replace the
Voltage： 0.1 V ECM.
9) If it is at or below the standard value, inspect to Refer to "1.Engine 1J.Electrical(6HK1X) ECM
see if there is a short circuit to the 5 V power Removal".
supply circuit with the signal circuit between Refer to "1.Engine 1J.Electrical(6HK1X) ECM
the ECM and the water temperature sensor. Installation".
10) If a problem is discovered, repair the signal 23) Set the injector ID code on the ECM.
circuit. 24) Perform the unit difference learning of the fuel
11) Inspect to see if there is a contact failure with supply pump to the ECM.
the water temperature sensor harness con-
nector. 3. DTC P0118 Confirm Resolution
12) If a problem is discovered, repair the harness 1) Clear the DTC using the trouble diagnosis
connector. scan tool.
13) If the harness connector is normal, replace the 2) Turn the starter switch OFF for 30 seconds or
water temperature sensor. longer.
Refer to "1.Engine 1D.Cooling(6HK1X) En- 3) Start the engine.
gine coolant temperature sensor Removal". 4) Perform a test-run.
Refer to "1.Engine 1D.Cooling(6HK1X) En- 5) Use the trouble diagnosis scan tool to confirm
gine coolant temperature sensor Installation". that a DTC has not been detected.
84402832 NA - May 2011

4023G-22
Engine-side Trouble
DTC P0122 (Flash Code 43) 10) If a problem is discovered, repair the harness
connector.
Throttle Position Sensor Circuit 11) If the harness connector is normal, replace the
Low intake throttle valve.
Refer to "1.Engine 1B.Mechanical(6HK1X) In-
1. DTC P0122 Priority DTC take throttle valve Removal".
DTC P1655 Refer to "1.Engine 1B.Mechanical(6HK1X) In-
2. DTC P0122 Diagnostics take throttle valve Installation".
12) Inspect the signal circuit between the ECM
1) Turn OFF the starter switch. and intake throttle position sensor.
intake throttle valve. • There should be no open circuit or high re-
3) Turn ON the starter switch. sistance.
4) Measure the voltage between the intake throt- • There should be no short to GND.
tle position sensor 5 V power supply circuit
and a normal GND.
circuit.
Voltage： 4.9 V
tact failure.
to see if there is an open circuit or high re-
sistance with the 5 V power supply circuit be-
connector.
tween the ECM and the intake throttle position
sensor.
ECM.
ANNOTATION: Refer to "1.Engine 1J.Electrical(6HK1X) ECM
Removal".
• The intake throttle position sensor shares Refer to "1.Engine 1J.Electrical(6HK1X) ECM
the 5 V power supply circuit with other sen- Installation".
sors. 17) Set the injector ID code on the ECM.
• The DTC set on a sensor which shares this 18) Perform the unit difference learning of the fuel
circuit may be detected. supply pump to the ECM.
6) If a problem is discovered, repair the 5 V 3. DTC P0122 Confirm Resolution
power supply circuit.
7) Connect the test cable with fuse between the 1) Clear the DTC using the trouble diagnosis
intake throttle position sensor 5 V power sup- scan tool.
ply circuit and the signal circuit. 2) Turn the starter switch OFF for 30 seconds or
8) Check the intake throttle position sensor dis- longer.
play with the trouble diagnosis scan tool. 3) Start the engine.
Voltage： 4.9 V 4) Perform a test-run.
9) If it is at or above the standard value, inspect 5) Use the trouble diagnosis scan tool to confirm
to see if there is a contact failure with the in- that a DTC has not been detected.
take throttle valve harness connector.
84402832 NA - May 2011

4023G-23
Engine-side Trouble
DTC P0123 (Flash Code 43) 9) Inspect to see if there is an open circuit or
Throttle Position Sensor Circuit ECM and the intake throttle position sensor.
High ANNOTATION:
1. DTC P0123 Priority DTC • The intake throttle position sensor shares
DTC P1655 the GND circuit with other sensors.
2. DTC P0123 Diagnostics • The DTC set on a sensor which shares this
2) Disconnect the harness connector from the 10) If a problem is discovered, repair the GND
intake throttle valve. circuit.
3) Check the intake throttle position sensor dis- 11) Check the ECM harness connector for a con-
play with the trouble diagnosis scan tool. tact failure.
Voltage： 0.1 V 12) If a problem is discovered, repair the harness
4) If it is at or above the standard value, inspect connector.
the signal circuit between the ECM and the 13) If the harness connector is normal, replace the
intake throttle position sensor. ECM.
• There should be no short to the battery or Removal".
• There should be no short to the 5 V power Installation".
supply.
5) If a problem is discovered, repair the signal 15) Perform the unit difference learning of the fuel
circuit. supply pump to the ECM.
6) Inspect the intake throttle valve harness con-
7) If a problem is discovered, repair the harness 1) Clear the DTC using the trouble diagnosis
connector. scan tool.
8) If the harness connector is normal, replace the 2) Turn the starter switch OFF for 30 seconds or
intake throttle valve. longer.
Refer to "1.Engine 1B.Mechanical(6HK1X) In- 3) Start the engine.
take throttle valve Removal". 4) Perform a test-run.
Refer to "1.Engine 1B.Mechanical(6HK1X) In- 5) Use the trouble diagnosis scan tool to confirm
take throttle valve Installation". that a DTC has not been detected.
84402832 NA - May 2011

4023G-24
Engine-side Trouble
DTC P0182 (Flash Code 211) Fuel DTC P0183 (Flash Code 211) Fuel
Temperature Sensor Circuit Low Temperature Sensor Circuit High
DTC P1655 DTC P1655
fuel temperature sensor. fuel temperature sensor.
3) Check the fuel temperature sensor display 3) Turn ON the starter switch.
with the trouble diagnosis scan tool. 4) Measure the voltage between the fuel temper-
voltage： 4.5 V ature sensor signal circuit and normal GND.
4) If it is at or above the standard value, replace Voltage： 5.5 V
the fuel temperature sensor. 5) If it is at or above the standard value, inspect
Refer to "1.Engine 1C.Fuel System(6HK1X) to see if there is a short circuit to the battery
Fuel supply pump Removal". or ignition power supply with the signal circuit
Refer to "1.Engine 1C.Fuel System(6HK1X) between the ECM and the fuel temperature
Fuel supply pump Installation". sensor.
ANNOTATION: circuit.
• Do not replace the fuel temperature sensor 7) Connect the test cable with fuse between
separately. If a problem is found, replace the fuel temperature sensor signal circuit and
the fuel supply pump. GND circuit.
8) Check the fuel temperature sensor display
5) Inspect to see if there is a short circuit to the with the trouble diagnosis scan tool.
GND with the signal circuit between the ECM Voltage： 0.1 V
and fuel temperature sensor. 9) If it is at or below the standard value, inspect to
6) If a problem is discovered, repair the signal see if there is a short circuit to the 5 V power
circuit. supply circuit with the signal circuit between
7) Inspect the ECM harness connector for a con- the ECM and the fuel temperature sensor.
tact failure. 10) If a problem is discovered, repair the signal
8) If a problem is discovered, repair the harness circuit.
connector. 11) Inspect to see if there is a contact failure with
9) If the harness connector is normal, replace the the fuel temperature sensor harness connec-
ECM. tor.
Refer to "1.Engine 1J.Electrical(6HK1X) ECM 12) If a problem is discovered, repair the harness
Removal". connector.
Refer to "1.Engine 1J.Electrical(6HK1X) ECM 13) If the harness connector is normal, replace the
Installation". fuel temperature sensor.
10) Set the injector ID code on the ECM. Refer to "1.Engine 1C.Fuel System(6HK1X)
11) Perform the unit difference learning of the fuel Fuel supply pump Removal".
supply pump to the ECM. Refer to "1.Engine 1C.Fuel System(6HK1X)
3. DTC P0182 Confirm Resolution Fuel supply pump Installation".
1) Clear the DTC using the trouble diagnosis ANNOTATION:
scan tool. • Do not replace the fuel temperature sensor
2) Turn the starter switch OFF for 30 seconds or separately. If a problem is found, replace
longer. the fuel supply pump.
4) Perform a test-run. 14) Connect the test cable with fuse between the
5) Use the trouble diagnosis scan tool to confirm fuel temperature sensor signal circuit and nor-
that a DTC has not been detected. mal GND.
15) Check the fuel temperature sensor display
Voltage： 0.1 V
and fuel temperature sensor.
ANNOTATION:
• The fuel temperature sensor shares the
84402832 NA - May 2011

4023G-25
Engine-side Trouble
• The DTC set on a sensor which shares this DTC P0192 (Flash Code 245) Fuel
Rail Pressure Sensor Circuit Low
circuit. 1. DTC P0192 Priority DTC
18) Inspect to see if there is an open circuit or DTC P0641
high resistance in the signal circuit between 2. DTC P0192 Diagnostics
the ECM and the fuel temperature sensor.
circuit.
tact failure.
Voltage： 4.5 V
connector.
4) If it is at or below the standard value, inspect to
see if there is a short circuit to the GND with
ECM.
Removal".
circuit.
Installation".
6) Measure the voltage between the fuel pres-
sure sensor 5 V power supply circuit and nor-
mal GND.
Voltage： 4.5 V
3. DTC P0183 Confirm Resolution 7) If it is at or above the standard value, inspect
to see if there is a contact failure with the fuel
1) Clear the DTC using the trouble diagnosis pressure sensor harness connector.
scan tool. 8) If a problem is discovered, repair the harness
2) Turn the starter switch OFF for 30 seconds or connector.
longer. 9) If the harness connector is normal, replace the
3) Start the engine. fuel pressure sensor.
4) Perform a test-run. Refer to "1.Engine 1C.Fuel System(6HK1X)
ANNOTATION: Common rail assembly Removal".
• Run the engine for 3 minutes or longer. Common rail assembly Installation".
5) Use the trouble diagnosis scan tool to confirm ANNOTATION:
10) Inspect to see if there is an open circuit or high
resistance with the 5 V power supply circuit
between the ECM and fuel pressure sensor.
ANNOTATION:
• The fuel pressure sensor shares the 5 V
power supply circuit with other sensors.
11) If a problem is discovered, repair the 5 V
tact failure.
connector.
ECM.
Removal".
Installation".
84402832 NA - May 2011

4023G-26
Engine-side Trouble
3. DTC P0192 Confirm Resolution DTC P0193 (Flash Code 245) Fuel
1) Clear the DTC using the trouble diagnosis Rail Pressure Sensor Circuit High
scan tool.
2) Turn the starter switch OFF for 30 seconds or 1. DTC P0193 Priority DTC
longer. DTC P0641
3) Start the engine. 2. DTC P0193 Diagnostics
sure sensor signal circuit and normal GND.
Voltage： 5.5 V
to see if there is a short circuit to the battery
or ignition power supply with the signal circuit
between the ECM and the fuel pressure sen-
sor.
circuit.
sure sensor signal circuit and normal GND.
Voltage： 4.5 V
to see if there is a short circuit to the 5 V power
supply circuit with the signal circuit between
the ECM and the fuel pressure sensor.
circuit.
10) Connect the test cable with fuse between the
fuel pressure sensor signal circuit and GND
circuit.
Voltage： 0.1 V
pressure sensor harness connector.
connector.
ANNOTATION:
ECM and the fuel pressure sensor.
ANNOTATION:
• The fuel pressure sensor shares the GND
circuit with other sensors.
circuit.
84402832 NA - May 2011

4023G-27
Engine-side Trouble
the ECM and the fuel pressure sensor. Injector Circuit - Cylinder 1
circuit.
19) Inspect the ECM harness connector for a con- 1) Turn OFF the starter switch.
tact failure. 2) Disconnect the injector harness intermediate
20) If a problem is discovered, repair the harness connector from the cylinder head cover case.
connector. 3) Measure the resistance between the first
21) If the harness connector is normal, replace the cylinder injector power supply terminal and
ECM. the first cylinder injector drive signal terminal
Refer to "1.Engine 1J.Electrical(6HK1X) ECM of the injector harness intermediate connec-
Removal". tor.
Refer to "1.Engine 1J.Electrical(6HK1X) ECM Resistance： 2.0 Ω
Installation". 4) If it is at or below the standard value, inspect
22) Set the injector ID code on the ECM. to see if there is an open circuit or high resis-
23) Perform the unit difference learning of the fuel tance with the circuit between the ECM and
supply pump to the ECM. injector harness intermediate connector.
6) Remove the cylinder head cover.
1) Clear the DTC using the trouble diagnosis 7) Inspect to see if the first cylinder injector har-
scan tool. ness tightening nut is loose.
2) Turn the starter switch OFF for 30 seconds or 8) If the first cylinder injector harness tightening
longer. nut is loose, tighten it.
3) Start the engine. 9) Inspect to see if a foreign matter is attached
4) Perform a test-run. to the first cylinder injector terminal.
5) Use the trouble diagnosis scan tool to confirm 10) If a foreign matter is attached to the first cylin-
that a DTC has not been detected. der injector terminal, remove it.
11) Inspect the injector harness intermediate con-
12) If a problem is discovered, repair the connec-
tor.
13) Inspect the circuit between the first cylinder
injector and intermediate connector.
sistance.
• There should be no short between the injec-
tor circuits.
15) If the circuit is normal, replace the first cylinder
injector.
Injector Removal".
16) When the injector has been replaced, set the
injector ID code on the ECM.
tact failure.
connector.
ECM.
Removal".
Installation".
scan tool.
84402832 NA - May 2011
4023G-28
Engine-side Trouble
2) Turn the starter switch OFF for 30 seconds or DTC P0202 (Flash Code 272)
longer.
3) Start the engine. Injector Circuit - Cylinder 2
that a DTC has not been detected. 1) Turn OFF the starter switch.
2) Disconnect the injector harness intermediate
connector from the cylinder head cover case.
3) Measure the resistance between the second
cylinder injector power supply terminal and
the second cylinder injector drive signal termi-
nal of the injector harness intermediate con-
nector.
Resistance： 2.0 Ω
tance with the circuit between the ECM and
injector harness intermediate connector.
7) Inspect to see if the second cylinder injector
harness tightening nut is loose.
8) If the second cylinder injector harness tighten-
ing nut is loose, tighten it.
9) Inspect to see if a foreign matter is attached
to the second cylinder injector terminal.
10) If a foreign matter is attached to the second
cylinder injector terminal, remove it.
tor.
13) Inspect the circuit between the second cylin-
der injector and intermediate connector.
sistance.
tor circuits.
15) If the circuit is normal, replace the second
cylinder injector.
Injector Removal".
tact failure.
connector.
ECM.
Removal".
Installation".
scan tool.
84402832 NA - May 2011
4023G-29
Engine-side Trouble
longer.
3) Measure the resistance between the third
the third cylinder injector drive signal terminal
of the injector harness intermediate connec-
tor.
7) Inspect to see if the third cylinder injector har-
ness tightening nut is loose.
8) If the third cylinder injector harness tightening
nut is loose, tighten it.
to the third cylinder injector terminal.
10) If a foreign matter is attached to the third cylin-
der injector terminal, remove it.
tor.
13) Inspect the circuit between the third cylinder
sistance.
tor circuits.
15) If the circuit is normal, replace the third cylin-
der injector.
Injector Removal".
tact failure.
connector.
ECM.
Removal".
Installation".
scan tool.
84402832 NA - May 2011
4023G-30
Engine-side Trouble
longer.
3) Measure the resistance between the fourth
the fourth cylinder injector drive signal termi-
nal of the injector harness intermediate con-
nector.
7) Inspect to see if the fourth cylinder injector
harness tightening nut is loose.
8) If the fourth cylinder injector harness tighten-
ing nut is loose, tighten it.
to the fourth cylinder injector terminal.
10) If a foreign matter is attached to the fourth
cylinder injector terminal, remove it.
tor.
13) Inspect the circuit between the fourth cylinder
sistance.
tor circuits.
15) If the circuit is normal, replace the fourth cylin-
der injector.
Injector Removal".
tact failure.
connector.
ECM.
Removal".
Installation".
scan tool.
84402832 NA - May 2011
4023G-31
Engine-side Trouble
longer.
3) Measure the resistance between the fifth
the fifth cylinder injector drive signal terminal
tor.
7) Inspect to see if the fifth cylinder injector har-
8) If the fifth cylinder injector harness tightening
to the fifth cylinder injector terminal.
10) If a foreign matter is attached to the fifth cylin-
tor.
13) Inspect the circuit between the fifth cylinder
sistance.
tor circuits.
15) If the circuit is normal, replace the fifth cylinder
injector.
Injector Removal".
tact failure.
connector.
ECM.
Removal".
Installation".
scan tool.
84402832 NA - May 2011
4023G-32
Engine-side Trouble
longer.
3) Measure the resistance between the sixth
the sixth cylinder injector drive signal terminal
tor.
7) Inspect to see if the sixth cylinder injector har-
8) If the sixth cylinder injector harness tightening
to the sixth cylinder injector terminal.
10) If a foreign matter is attached to the sixth cylin-
tor.
13) Inspect the circuit between the sixth cylinder
sistance.
tor circuits.
15) If the circuit is normal, replace the sixth cylin-
der injector.
Injector Removal".
tact failure.
connector.
ECM.
Removal".
Installation".
scan tool.
84402832 NA - May 2011
4023G-33
Engine-side Trouble
longer.
3) Start the engine. Crankshaft Position Sensor Circuit
4)
5)
Perform a test-run.
Use the trouble diagnosis scan tool to confirm
Range/Performance
that a DTC has not been detected. 1. DTC P0336 Priority DTC
DTC P0335
DTC P0340
DTC P0641
1) Inspect the crankshaft position sensor circuit.
ANNOTATION:
• It should not be too close to the wiring or
components of the fuel injection device.
• It should not be too close to any electronic
device additionally installed.
• It should not be too close to the solenoid and
relay
2) If a problem is discovered, repair the crank-
shaft position sensor circuit.
ECM.
tact failure.
connector.
crankshaft position sensor.
8) Inspect the crankshaft position sensor har-
ness connector for a contact failure.
connector.
10) Inspect the CKP sensor.
CKP sensor Inspection".
11) If a problem is discovered, replace the crank-
shaft position sensor.
CKP sensor Removal".
CKP sensor Installation".
scan tool.
longer.
84402832 NA - May 2011

4023G-34
Engine-side Trouble
DTC P0340 (Flash Code 14) 18) If it is at or above the standard value, inspect
to see if there is a contact failure with the
Camshaft Position Sensor Circuit camshaft position sensor harness connector.
connector.
DTC P0601
20) If the harness connector is normal, inspect the
DTC P0651
1) Turn OFF the starter switch. CMP sensor Inspection".
2) Disconnect the harness connector from the 21) If a problem is discovered, replace the
camshaft position sensor. camshaft position sensor.
3) Turn ON the starter switch. Refer to "1.Engine 1B.Mechanical(6HK1X)
4) Measure the voltage between the 5 V CMP sensor Removal".
power supply circuit and normal GND of the Refer to "1.Engine 1B.Mechanical(6HK1X)
camshaft position sensor harness connector. CMP sensor Installation".
Voltage： 4.5 V 22) Inspect the camshaft gear.
to see if there is an open circuit or high re- • The camshaft gear should not be damaged
sistance with the 5 V power supply circuit be- • The camshaft gear should be installed cor-
rectly.
tween the ECM and the camshaft position
sensor. 23) If a problem is discovered, repair the camshaft
6) If a problem is discovered, repair the 5 V gear.
power supply circuit. 24) Inspect the GND circuit between the ECM and
7) Measure the voltage between the signal cir- the camshaft position sensor for an open cir-
cuit and normal GND of the camshaft position cuit and high resistance.
sensor harness connector.
Voltage： 5.5 V ANNOTATION:
8) If it is at or above the standard value, inspect • The camshaft position sensor shares the
to see if there is a short circuit to the battery GND circuit with other sensors.
or ignition power supply with the signal circuit • The DTC set on a sensor which shares this
between the ECM and the camshaft position circuit may be detected.
sensor.
9) If a problem is discovered, repair the signal 25) If a problem is discovered, repair the GND
circuit. circuit.
10) Measure the voltage between the signal cir- 26) Inspect the ECM harness connector for a con-
cuit of the camshaft position sensor harness tact failure.
connector and a normal GND again. 27) If a problem is discovered, repair the harness
Voltage： 4.5 V connector.
11) If it is at or below the standard value, inspect 28) If the harness connector is normal, replace the
the signal circuit between the ECM and the ECM.
camshaft position sensor. Refer to "1.Engine 1J.Electrical(6HK1X) ECM
Removal".
• There should be no open circuit or high re- Refer to "1.Engine 1J.Electrical(6HK1X) ECM
sistance. Installation".
• There should be no short to GND. 29) Set the injector ID code on the ECM.
13) Connect the test light between the signal cir- 3. DTC P0340 Confirm Resolution
cuit and normal GND of the camshaft position
sensor harness connector. 1) Clear the DTC using the trouble diagnosis
14) Measure the voltage between the probe of the scan tool.
test light and a normal GND. 2) Turn the starter switch OFF for 30 seconds or
Voltage： 4.5 V longer.
15) If it is at or above the standard value, inspect 3) Start the engine.
to see if there is a short circuit to the 5 V power 4) Perform a test-run.
supply circuit with the signal circuit between 5) Use the trouble diagnosis scan tool to confirm
the ECM and the camshaft position sensor. that a DTC has not been detected.
circuit.
17) Measure the voltage between the 5 V power
supply circuit and GND circuit of the camshaft
position sensor harness connector.
Voltage： 4.5 V
84402832 NA - May 2011

4023G-35
Engine-side Trouble
DTC P0404 (Flash Code 45) • There should be no short to EGR position
sensor circuit.
Exhaust Gas Recirculation Control
13) If a problem is discovered, repair the EGR
Circuit Range/Performance solenoid circuit.
14) If the EGR solenoid circuit is normal, replace
the EGR valve.
DTC P0409
Refer to "1.Engine 1H.Aux. Emission Control
Devices(6HK1X) EGR valve Removal".
1) Remove the EGR valve assembly from the Refer to "1.Engine 1H.Aux. Emission Control
engine. Devices(6HK1X) EGR valve Installation".
2) Inspect the EGR valve. 15) Restore the actual unit.
• There should be nothing to limit flow inside 17) Clear the DTC using the trouble diagnosis
the EGR valve. scan tool.
• There should be no excessive accumulates 18) Turn the starter switch OFF for 30 seconds or
inside the EGR valve. longer.
• There should be no bending with the valve 19) Start the engine.
shaft or valve itself inside the EGR valve. 20) Perform a test-run. valve.
3) Turn OFF the starter switch. 21) Check the DTC using the trouble diagnosis
4) Disconnect the harness connector from the scan tool.
EGR valve. 22) If the DTC P0404 has been detected, replace
5) Inspect the EGR valve harness connector for the ECM.
a contact failure. Refer to "1.Engine 1H.Aux. Emission Control
6) If a problem is discovered, repair the harness Devices(6HK1X) EGR valve Removal".
connector. Refer to "1.Engine 1J.Electrical(6HK1X) ECM
7) Disconnect the harness connector from the Removal".
ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM
8) Inspect the ECM harness connector for a con- Installation".
tact failure. 23) Set the injector ID code on the ECM.
9) If a problem is discovered, repair the harness 24) Perform the unit difference learning of the fuel
connector. supply pump to the ECM.
10) Inspect to see if there is an open circuit or high 3. DTC P0404 Confirm Resolution
resistance in the EGR control circuit.
11) If a problem is discovered, repair the EGR 1) Clear the DTC using the trouble diagnosis
control circuit. scan tool.
12) Inspect the EGR solenoid circuit between the 2) Turn the starter switch OFF for 30 seconds or
ECM and EGR valve. longer.
• There should be no short to GND. 4) Perform a test-run.
• There should be no short to the battery or 5) Use the trouble diagnosis scan tool to confirm
ignition power supply circuit. that a DTC has not been detected.
• There should be no short between the cir-
cuits.
84402832 NA - May 2011

4023G-36
Engine-side Trouble
DTC P0409 (Flash Code 44) 14) While momentarily disconnecting the test ca-
ble with fuse from the EGR position sensor
Exhaust Gas Recirculation Sensor 2 signal circuit and 5 V power supply circuit,
Circuit check the EGR position 2 display with the
1. DTC P0409 Priority DTC 15) While momentarily disconnecting the test ca-
DTC P1655 ble with fuse from the EGR position sensor
2. DTC P0409 Diagnostics 3 signal circuit and 5 V power supply circuit,
check the EGR position 3 display with the
1) Turn OFF the starter switch. trouble diagnosis scan tool.
2) Disconnect the harness connector from the 16) Check to see if there is a data display which
EGR valve. does not display ON when the EGR position
3) Turn ON the starter switch. sensor signal circuit and 5 V power supply
4) Use the trouble diagnosis scan tool to check circuit are shorted.
if any of the EGR position 1, EGR position 2, 17) If there is a data display which does not dis-
and EGR position 3 shows ON. play ON, inspect the EGR position sensor cir-
5) If there is a data display showing ON, inspect cuit which does not display ON.
the signal circuit between the ECM and EGR
valve of the EGR showing ON. • There should be no open circuit or high re-
sistance between ECM and EGR position
• There should be no short to the battery or sensor.
ignition power supply. • There should be no short to GND between
• There should be no short to the 5 V power ECM and EGR position sensor.
supply.
6) If a problem is discovered, repair the signal position sensor circuit.
circuit. 19) Inspect the EGR valve harness connector for
7) Measure the voltage between the EGR posi- a contact failure.
tion sensor 5 V power supply circuit and a nor- 20) If a problem is discovered, repair the harness
mal GND. connector.
voltage： 4.5 V 21) In the EGR solenoid circuit between the ECM
8) If it is at or below the standard value, inspect and EGR valve, inspect to see if there is a
to see if there is an open circuit or high re- short circuit with the EGR position sensor.
sistance with the 5 V power supply circuit be- 22) If a problem is discovered, repair the EGR
tween the ECM and the EGR position sensor. solenoid circuit.
ANNOTATION: 23) If the EGR solenoid circuit is normal, replace
the EGR valve.
• The EGR position sensor shares the 5 V Refer to "1.Engine 1H.Aux. Emission Control
power supply circuit with other sensors. Devices(6HK1X) EGR valve Removal".
• The DTC set on a sensor which shares this Refer to "1.Engine 1H.Aux. Emission Control
circuit may be detected. Devices(6HK1X) EGR valve Installation".
9) If a problem is discovered, repair the 5 V 24) Inspect the ECM harness connector for a con-
power supply circuit. tact failure.
10) Measure the voltage between the EGR posi- 25) If a problem is discovered, repair the harness
tion sensor 5 V power supply circuit and the connector.
GND circuit. 26) If the harness connector is normal, replace the
voltage： 4.5 V ECM.
11) If it is at or below the standard value, inspect Refer to "1.Engine 1J.Electrical(6HK1X) ECM
to see if there is an open circuit or high resis- Removal".
tance with the GND circuit between the ECM Refer to "1.Engine 1J.Electrical(6HK1X) ECM
and EGR position sensor. Installation".
ANNOTATION: 28) Perform the unit difference learning of the fuel
• The EGR position sensor shares the GND supply pump to the ECM.
circuit with other sensors. 3. DTC P0409 Confirm Resolution
circuit may be detected. 1) Clear the DTC using the trouble diagnosis
scan tool.
12) If a problem is discovered, repair the GND 2) Turn the starter switch OFF for 30 seconds or
circuit. longer.
13) While momentarily disconnecting the test ca- 3) Start the engine.
ble with fuse from the EGR position sensor 4) Perform a test-run.
1 signal circuit and 5 V power supply circuit, 5) Use the trouble diagnosis scan tool to confirm
check the EGR position 1 display with the that a DTC has not been detected.
84402832 NA - May 2011

4023G-37
Engine-side Trouble
Catalyst Temperature Sensor Catalyst Temperature Sensor
Circuit Range/Performance Circuit Low Sensor 1
Sensor 1 1. DTC P0427 Priority DTC
DTC P0697
1. DTC P0426 Priority DTC 2. DTC P0427 Diagnostics
DTC P0093
DTC P0427 1) Turn OFF the starter switch.
DTC P1093 2) Disconnect the harness connector from the
2. DTC P0426 Diagnostics exhaust gas temperature sensor 1.
3) Check the exhaust temperature sensor (be-
1) Inspect the exhaust gas temperature sensor fore the filter) display with the trouble diagno-
1. sis scan tool.
Refer to "1.Engine 1G.Exhaust(6HK1X) Ex- Voltage： 4.5 V
haust gas temperature sensor Inspection". 4) If it is at or above the standard value, replace
2) If a problem is discovered, replace the ex- the exhaust gas temperature sensor 1.
haust gas temperature sensor 1. Refer to "1.Engine 1G.Exhaust(6HK1X) Ex-
Refer to "1.Engine 1G.Exhaust(6HK1X) Ex- haust gas temperature sensor Removal".
haust gas temperature sensor Removal". Refer to "1.Engine 1G.Exhaust(6HK1X) Ex-
Refer to "1.Engine 1G.Exhaust(6HK1X) Ex- haust gas temperature sensor Installation".
haust gas temperature sensor Installation". 5) Inspect to see if there is a short circuit to the
3) Inspect the DPD filter for a damage. GND with the signal circuit between the ECM
Refer to "1.Engine 1G.Exhaust(6HK1X) DPD and the exhaust gas temperature sensor 1.
assembly Inspection". 6) If a problem is discovered, repair the signal
4) If a problem is discovered, replace the DPD circuit.
filter. 7) Inspect the ECM harness connector for a con-
Refer to "1.Engine 1G.Exhaust(6HK1X) DPD tact failure.
assembly Disassembly". 8) If a problem is discovered, repair the harness
Refer to "1.Engine 1G.Exhaust(6HK1X) DPD connector.
assembly Reassembly". 9) If the harness connector is normal, replace the
5) Perform the DPD regeneration data reset with ECM.
the trouble diagnosis scan tool. Refer to "1.Engine 1J.Electrical(6HK1X) ECM
3. DTC P0426 Confirm Resolution Removal".
1) Clear the DTC using the trouble diagnosis Installation".
scan tool. 10) Set the injector ID code on the ECM.
2) Turn the starter switch OFF for 30 seconds or 11) Perform the unit difference learning of the fuel
longer. supply pump to the ECM.
4) Perform a test-run. 3. DTC P0427 Confirm Resolution
5) Use the trouble diagnosis scan tool to confirm 1) Clear the DTC using the trouble diagnosis
that a DTC has not been detected. scan tool.
longer.
84402832 NA - May 2011

4023G-38
Engine-side Trouble
DTC P0428 (Flash Code 48) 16) If it is at or above the standard value, inspect
Catalyst Temperature Sensor tance with the signal circuit between the ECM
Circuit High Sensor 1 17)
and the exhaust gas temperature sensor 1.
1. DTC P0428 Priority DTC circuit.
DTC P0697 18) Inspect to see if there is an open circuit or
2. DTC P0428 Diagnostics high resistance in the GND circuit between the
ECM and the exhaust gas temperature sensor
1) Turn OFF the starter switch. 1.
exhaust gas temperature sensor 1. ANNOTATION:
• The exhaust gas temperature sensor 1
4) Measure the voltage between the exhaust gas
shares the GND circuit with other sensors.
temperature sensor 1 signal circuit and nor-
• The DTC may be detected on a sensor
mal GND.
which shares this circuit.
Voltage： 5.5 V
or ignition power supply with the signal circuit 20) Inspect the ECM harness connector for a con-
between the ECM and the exhaust gas tem- tact failure.
perature sensor 1. 21) If a problem is discovered, repair the harness
6) If a problem is discovered, repair the signal connector.
circuit. 22) If the harness connector is normal, replace the
7) Connect the test cable with fuse between the ECM.
exhaust gas temperature sensor 1 signal cir- Refer to "1.Engine 1J.Electrical(6HK1X) ECM
cuit and GND circuit. Removal".
8) Check the exhaust temperature sensor (be- Refer to "1.Engine 1J.Electrical(6HK1X) ECM
fore the filter) display with the trouble diagno- Installation".
sis scan tool. 23) Set the injector ID code on the ECM.
Voltage： 0.1 V 24) Perform the unit difference learning of the fuel
9) If it is at or below the standard value, inspect to supply pump to the ECM.
see if there is a short circuit to the 5 V power
supply circuit with the signal circuit between 3. DTC P0428 Confirm Resolution
the ECM and the exhaust gas temperature 1) Clear the DTC using the trouble diagnosis
sensor 1. scan tool.
10) If a problem is discovered, repair the signal 2) Turn the starter switch OFF for 30 seconds or
circuit. longer.
11) Inspect to see if there is a contact failure with 3) Start the engine and warm it up until the
the exhaust gas temperature sensor 1 har- coolant temperature exceeds the standard
ness connector. value.
12) If a problem is discovered, repair the harness Specified value： 70 °C {158 °F}
connector. 4) Repeatedly rev the engine in neutral to in-
13) If the harness connector is normal, replace the crease the engine rpm while checking the ex-
exhaust gas temperature sensor 1. haust temperature sensor (in front of the filter)
Refer to "1.Engine 1G.Exhaust(6HK1X) Ex- display with the trouble diagnosis scan tool.
haust gas temperature sensor Removal". 5) Use the trouble diagnosis scan tool to confirm
Refer to "1.Engine 1G.Exhaust(6HK1X) Ex- that the exhaust temperature sensor (before
haust gas temperature sensor Installation". the filter) display does not exceed the stan-
14) Connect the test cable with fuse between the dard value.
exhaust gas temperature sensor 1 signal cir- Voltage： 4.8 V
cuit and normal GND. 6) Use the trouble diagnosis scan tool to confirm
15) Check the exhaust temperature sensor (be- that a DTC has not been detected.
fore the filter) display with the trouble diagno-
sis scan tool.
Voltage： 0.1 V
84402832 NA - May 2011

4023G-39
Engine-side Trouble
DTC P0522 (Flash Code 294) Oil 12) Inspect the signal circuit between the ECM
and the oil pressure sensor.
Pressure Sensor Circuit Low
1. DTC P0522 Priority DTC sistance.
DTC P0697 • There should be no short to GND.
1) Turn OFF the starter switch. circuit.
2) Disconnect the harness connector from the oil 14) Inspect the ECM harness connector for a con-
pressure sensor. tact failure.
3) Turn ON the starter switch. 15) If a problem is discovered, repair the harness
4) Measure the voltage between the 5 V power connector.
supply circuit and normal GND of the oil pres- 16) If the harness connector is normal, replace the
sure sensor harness connector. ECM.
Voltage： 4.5 V Refer to "1.Engine 1J.Electrical(6HK1X) ECM
5) If it is at or below the standard value, inspect Removal".
to see if there is an open circuit or high re- Refer to "1.Engine 1J.Electrical(6HK1X) ECM
sistance with the 5 V power supply circuit be- Installation".
tween the ECM and the oil pressure sensor. 17) Set the injector ID code on the ECM.
6) If a problem is discovered, repair the 5 V 18) Perform the unit difference learning of the fuel
power supply circuit. supply pump to the ECM.
5 V power supply circuit and signal circuit of 3. DTC P0522 Confirm Resolution
the oil pressure sensor harness connector. 1) Clear the DTC using the trouble diagnosis
8) Check the oil pressure sensor display with the scan tool.
trouble diagnosis scan tool. 2) Turn the starter switch OFF for 30 seconds or
Voltage： 4.5 V longer.
9) If it is at or above the standard value, inspect 3) Start the engine.
to see if there is a contact failure with the oil 4) Perform a test-run.
pressure sensor harness connector. 5) Use the trouble diagnosis scan tool to confirm
10) If a problem is discovered, repair the harness that a DTC has not been detected.
connector.
oil pressure sensor.
Refer to "1.Engine 1E.Lubrication(6HK1X) Oil
pressure sensor Removal".
pressure sensor Installation".
84402832 NA - May 2011

4023G-40
Engine-side Trouble
DTC P0523 (Flash Code 294) Oil 8) Inspect the oil pressure sensor harness con-
Pressure Sensor Circuit High 9) If a problem is discovered, repair the harness
connector.
DTC P0697
oil pressure sensor.
1) Turn OFF the starter switch. pressure sensor Removal".
2) Disconnect the harness connector from the oil Refer to "1.Engine 1E.Lubrication(6HK1X) Oil
pressure sensor. pressure sensor Installation".
3) Check the oil pressure sensor display with the 11) Inspect the ECM harness connector for a con-
trouble diagnosis scan tool. tact failure.
voltage： 0.1 V 12) If a problem is discovered, repair the harness
4) If it is at or above the standard value, inspect connector.
the signal circuit between the ECM and the oil 13) If the harness connector is normal, replace the
pressure sensor. ECM.
• There should be no short to the battery or Removal".
ignition power supply. Refer to "1.Engine 1J.Electrical(6HK1X) ECM
• There should be no short to the 5 V power Installation".
supply. 14) Set the injector ID code on the ECM.
6) Inspect to see if there is an open circuit or 3. DTC P0523 Confirm Resolution
ECM and the oil pressure sensor. 1) Clear the DTC using the trouble diagnosis
scan tool.
ANNOTATION: 2) Turn the starter switch OFF for 30 seconds or
• The oil pressure sensor shares the GND cir- longer.
cuit with other sensors. 3) Start the engine.
• The DTC set on a sensor which shares this 4) Perform a test-run.
circuit may be detected. 5) Use the trouble diagnosis scan tool to confirm
circuit.
84402832 NA - May 2011

4023G-41
Engine-side Trouble
DTC P0560 (Flash Code 155) 18) Measure the voltage between the ignition
power supply circuit of the dropping register
System Voltage and a normal GND.
Voltage： 18.0 V
1) Turn OFF the starter switch. the fuse.
2) Disconnect the harness connector from the 20) If the fuse is faulty, replace the fuse.
mass air flow sensor. 21) If it is at or below the standard value, repair
3) Use the trouble diagnosis scan tool to check an open circuit or high resistance in the igni-
if a DTC is detected. tion power supply circuit between the fuse and
4) If a DTC has not been detected, inspect the dropping register.
mass air flow sensor harness connector for a 22) Measure the voltage between the voltage sup-
contact failure. ply circuit of the dropping register and a nor-
5) If a problem is discovered, repair the harness mal GND.
connector. Voltage： 13.0 V
6) If the harness connector is normal, replace the 23) If it is at or above the standard value, inspect
mass air flow sensor. to see if there is a contact failure with the drop-
7) Turn OFF the starter switch. ping register harness connector.
8) Leave the mass air flow sensor harness con- 24) If a problem is discovered, repair the harness
nector disconnected. connector.
9) Disconnect the harness connector from the 25) Inspect to see if there is an open circuit or
dropping register. high resistance in the voltage supply circuit
10) Use the trouble diagnosis scan tool to check between the ECM and the dropping register.
if a DTC is detected. 26) If a problem is discovered, repair the voltage
11) If a DTC has been detected, inspect the volt- supply circuit.
age supply circuit between the ECM and drop- 27) Inspect the ECM harness connector for a con-
ping register. tact failure.
• There should be no short to GND. connector.
• There should be no short to the battery or 29) If the harness connector is normal, replace the
ignition power supply. ECM.
12) If a problem is discovered, repair the voltage Refer to "1.Engine 1J.Electrical(6HK1X) ECM
supply circuit. Removal".
13) If the voltage supply circuit is normal, inspect Refer to "1.Engine 1J.Electrical(6HK1X) ECM
the 12 V power supply circuit between the Installation".
ECM and the mass air flow sensor. 30) Set the injector ID code on the ECM.
• There should be no short to GND. supply pump to the ECM.
ignition power supply. 2. DTC P0560 Confirm Resolution
14) If a problem is discovered, repair the 12 V 1) Clear the DTC using the trouble diagnosis
power supply circuit. scan tool.
15) Check the resistance value of the dropping 2) Turn the starter switch OFF for 30 seconds or
register. longer.
Resistance： 45.0 - 55.0 Ω 3) Start the engine.
16) If the resistance value is outside the standard 4) Perform a test-run.
range, replace the dropping register. 5) Use the trouble diagnosis scan tool to confirm
17) Turn ON the starter switch. that a DTC has not been detected.
84402832 NA - May 2011

4023G-42
Engine-side Trouble
System Voltage High Internal Control Module Memory
1. DTC P0563 Diagnostics Check Sum Error
1) Check if the battery charger has been recently 1. DTC P0601 Diagnostics
connected to the battery.
2) Start the engine, and idle it. 1) Replace the ECM.
3) Check the ignition voltage display with the Refer to "1.Engine 1J.Electrical(6HK1X) ECM
trouble diagnosis scan tool. Removal".
Voltage： 32.0 V Refer to "1.Engine 1J.Electrical(6HK1X) ECM
4) If it is at or above the standard value, inspect Installation".
the charging system. 2) Set the injector ID code on the ECM.
Refer to "1.Engine 1J.Electrical(6HK1X) Gen- 3) Perform the unit difference learning of the fuel
erator Reassembly". supply pump to the ECM.
5) If a problem is discovered, repair the charging 2. DTC P0601 Confirm Resolution
system.
6) If the charging system is normal, replace the 1) Clear the DTC using the trouble diagnosis
ECM. scan tool.
Refer to "1.Engine 1J.Electrical(6HK1X) ECM 2) Turn the starter switch OFF for 30 seconds or
Removal". longer.
Refer to "1.Engine 1J.Electrical(6HK1X) ECM 3) Start the engine.
Installation". 4) Perform a test-run.
7) Set the injector ID code on the ECM. 5) Use the trouble diagnosis scan tool to confirm
8) Perform the unit difference learning of the fuel that a DTC has not been detected.
scan tool.
longer.
3) Start the engine, and idle it.
4) Check the ignition voltage display with the
trouble diagnosis scan tool, and confirm that
the value does not exceed the standard value.
Voltage： 32.0 V
84402832 NA - May 2011

4023G-43
Engine-side Trouble
Control Module Programming Internal Control Module Random
Error Access Memory (RAM) Error
1) Confirm that the connecting sections of all 1) Replace the ECM.
tools are securely connected. Refer to "1.Engine 1J.Electrical(6HK1X) ECM
2) Confirm that the programming device is oper- Removal".
ating normally. Refer to "1.Engine 1J.Electrical(6HK1X) ECM
3) Use the trouble diagnosis scan tool to confirm Installation".
that the correct injector ID code has been en- 2) Set the injector ID code on the ECM.
tered to the ECM. 3) Perform the unit difference learning of the fuel
ANNOTATION:
• When the injector ID code has been cor-
rectly input, clear the DTC using the trouble 1) Clear the DTC using the trouble diagnosis
diagnosis scan tool. scan tool.
longer.
longer. 3) Start the engine.
6) Use the trouble diagnosis scan tool to check 5) Use the trouble diagnosis scan tool to confirm
if a DTC has been detected. that a DTC has not been detected.
7) If a DTC has been detected, replace the ECM.
Removal".
Installation".
scan tool.
longer.
84402832 NA - May 2011

4023G-44
Engine-side Trouble
DTC P0606 (Flash Code 51) DTC P0638 (Flash Code

ECM/PCM Processor 61) Throttle Actuator Control
1. DTC P0606 Diagnostics Range/Performance
1) Replace the ECM. 1. DTC P0638 Priority DTC
Refer to "1.Engine 1J.Electrical(6HK1X) ECM DTC P0122
Removal". DTC P0123
Refer to "1.Engine 1J.Electrical(6HK1X) ECM 2. DTC P0638 Diagnostics
Installation".
2) Set the injector ID code on the ECM. 1) Remove the air intake hose from the intake
3) Perform the unit difference learning of the fuel throttle valve.
supply pump to the ECM. Refer to "1.Engine 1B.Mechanical(6HK1X) In-
take throttle valve Removal".
2. DTC P0606 Confirm Resolution 2) Inspect the intake throttle valve.
1) Clear the DTC using the trouble diagnosis • The intake throttle valve flow should not be
scan tool. limited.
2) Turn the starter switch OFF for 30 seconds or • There should be no excessive deposit inside
longer. the throttle bore of the intake throttle valve.
3) Start the engine. • There should be no bending with the butter-
4) Perform a test-run. fly valve of the intake throttle valve.
5) Use the trouble diagnosis scan tool to confirm • The intake throttle valve should not be
that a DTC has not been detected. locked
3) If a problem is discovered, replace the intake
throttle valve.
take throttle valve Installation".
intake throttle valve.
6) Inspect the intake throttle valve harness con-
connector.
ECM.
tact failure.
connector.
11) Inspect the intake throttle valve circuit for high
resistance.
13) Inspect the solenoid circuit between the ECM
and the intake throttle valve.
• There should be no short between the sole-
noid circuits.
• There should be no short to the intake throt-
tle position sensor circuit.
14) If a problem is discovered, repair the solenoid
circuit.
15) If the solenoid circuit is normal, replace the
intake throttle valve.
16) Restore the actual unit.
84402832 NA - May 2011

4023G-45
Engine-side Trouble
17) Turn ON the starter switch. DTC P0641 (Flash Code 55)
18) Turn the starter switch OFF for 30 seconds.
Sensor Reference Voltage 1
ANNOTATION:
Circuit
• The starter switch must be once turned ON
and then turned OFF before clearing the 1. DTC P0641 Diagnostics
DTC.
19) Clear the DTC using the trouble diagnosis 2) Disconnect the harness connector from the
scan tool. accelerator position sensor.
20) Turn the starter switch OFF for 30 seconds or 3) Turn ON the starter switch.
longer. 4) Measure the voltage between the 5 V power
21) Start the engine. supply terminal and GND of the accelerator
22) Use the trouble diagnosis scan tool to check position sensor harness connector.
if a DTC has been detected. Voltage： 5.5 V
23) If a DTC has been detected, replace the ECM. 5) If it is at or above the standard value, inspect
Refer to "1.Engine 1J.Electrical(6HK1X) ECM to see if there is a short circuit to the battery or
Removal". ignition power supply with the accelerator po-
Refer to "1.Engine 1J.Electrical(6HK1X) ECM sition sensor 5 V power supply circuit between
Installation". the ECM and the accelerator position sensor.
24) Set the injector ID code on the ECM. 6) If a problem is discovered, repair the acceler-
25) Perform the unit difference learning of the fuel ator position sensor 5 V power supply circuit.
supply pump to the ECM. 7) Inspect to see if there is a short circuit to the
battery or ignition power supply with the crank-
3. DTC P0638 Confirm Resolution shaft position sensor 5 V power supply circuit
1) Turn ON the starter switch. between the ECM and the crankshaft position
2) Turn the starter switch OFF for 30 seconds or sensor.
longer. 8) If a problem is discovered, repair the crank-
shaft position sensor 5 V power supply circuit
ANNOTATION: between the ECM and the crankshaft position
• The starter switch must be once turned ON sensor.
and then turned OFF before clearing the 9) Inspect to see if there is a short circuit to the
DTC. battery or ignition power supply with the fuel
pressure sensor 5 V power supply circuit be-
3) Clear the DTC using the trouble diagnosis tween the ECM and the fuel pressure sensor.
scan tool. 10) If a problem is discovered, repair the fuel pres-
4) Turn the starter switch OFF for 30 seconds or sure sensor 5 V power supply circuit.
longer. 11) If it is at or below the standard value, measure
5) Start the engine. the voltage between the 5 V power supply cir-
6) Perform a test-run with the intake throttle so- cuit and GND of the accelerator position sen-
lenoid drive duty of 20% or above. sor harness connector.
7) Use the trouble diagnosis scan tool to confirm Voltage： 4.5 V
that a DTC has not been detected. 12) If it is at or above the standard value, replace
the accelerator position sensor.
13) If it is at or below the standard value, turn the
starter switch OFF.
crankshaft position sensor.
16) Measure the voltage between the accelerator
position sensor 5 V power supply circuit and
GND of the accelerator position sensor har-
ness connector.
Voltage： 4.5 V
17) If it is at or above the standard value, replace
the crankshaft position sensor. Refer to "1.En-
gine 1B.Mechanical(6HK1X) CKP sensor Re-
moval".
CKP sensor Installation".
starter switch OFF.
84402832 NA - May 2011

4023G-46
Engine-side Trouble
21) Measure the voltage between the accelerator DTC P0651 (Flash Code 56)
position sensor 5 V power supply circuit and
GND of the accelerator position sensor har- Sensor Reference Voltage 2
ness connector.
Voltage： 4.5 V
Circuit
22) If it is at or above the standard value, replace 1. DTC P0651 Diagnostics
the fuel pressure sensor.
Refer to "1.Engine 1C.Fuel System(6HK1X) 1) Turn OFF the starter switch.
Common rail assembly Removal". 2) Disconnect the harness connector from the
Refer to "1.Engine 1C.Fuel System(6HK1X) camshaft position sensor.
Common rail assembly Installation". 3) Turn ON the starter switch.
4) Measure the voltage between the camshaft
ANNOTATION: position sensor 5 V power supply circuit and
GND of the camshaft position sensor harness
connector.
Voltage： 5.5 V
23) If it is at or below the standard value, inspect to see if there is a short circuit to the battery or
to see if there is a short circuit to the GND with ignition power supply with the camshaft posi-
the accelerator position sensor 5 V power sup- tion sensor 5 V power supply circuit between
ply circuit between the ECM and the acceler- the ECM and the camshaft position sensor.
ator position sensor. 6) If a problem is discovered, repair the camshaft
24) If a problem is discovered, repair the acceler- position sensor 5 V power supply circuit.
ator position sensor 5 V power supply circuit. 7) Inspect to see if there is a short circuit to the
25) Inspect to see if there is a short circuit to the battery or ignition power supply with the atmo-
GND with the crankshaft position sensor 5 V spheric pressure sensor 5 V power supply cir-
power supply circuit between the ECM and the cuit between the ECM and atmospheric pres-
crankshaft position sensor. sure sensor.
26) If a problem is discovered, repair the crank- 8) If a problem is discovered, repair the atmo-
shaft position sensor 5 V power supply circuit. spheric pressure sensor 5 V power supply cir-
27) Inspect to see if there is a short circuit to the cuit.
GND with the fuel pressure sensor 5 V power 9) If it is at or below the standard value, mea-
supply circuit between the ECM and the fuel sure the voltage between the camshaft posi-
pressure sensor. tion sensor 5 V power supply circuit and GND
28) If a problem is discovered, repair the fuel pres- of the camshaft position sensor harness con-
sure sensor 5 V power supply circuit. nector.
29) Replace the ECM. Voltage： 4.5 V
Refer to "1.Engine 1J.Electrical(6HK1X) ECM 10) If it is at or above the standard value, replace
Removal". the camshaft position sensor.
Refer to "1.Engine 1J.Electrical(6HK1X) ECM Refer to "1.Engine 1B.Mechanical(6HK1X)
Installation". CMP sensor Removal".
30) Set the injector ID code on the ECM. Refer to "1.Engine 1B.Mechanical(6HK1X)
31) Perform the unit difference learning of the fuel CMP sensor Installation".
supply pump to the ECM. 11) If it is at or below the standard value, turn the
starter switch OFF.
2. DTC P0641 Confirm Resolution 12) Disconnect the harness connector from the
1) Clear the DTC using the trouble diagnosis atmospheric pressure sensor.
scan tool. 13) Turn ON the starter switch.
2) Turn the starter switch OFF for 30 seconds or 14) Measure the voltage between the camshaft
longer. position sensor 5 V power supply circuit and
3) Start the engine. GND of the camshaft position sensor harness
4) Perform a test-run. connector.
5) Use the trouble diagnosis scan tool to confirm Voltage： 4.5 V
that a DTC has not been detected. 15) If it is at or above the standard value, replace
the atmospheric pressure sensor.
to see if there is a short circuit to the GND with
the camshaft position sensor 5 V power sup-
ply circuit between the ECM and the camshaft
position sensor.
17) If a problem is discovered, repair the camshaft
position sensor 5 V power supply circuit.
84402832 NA - May 2011

4023G-47
Engine-side Trouble
18) Inspect to see if there is a short circuit to the DTC P0685 (Flash Code 416)
GND with the atmospheric pressure sensor 5
V power supply circuit between the ECM and ECM/PCM Power Relay Control
19)
the atmospheric pressure sensor.
If a problem is discovered, repair the atmo-
Circuit/Open
spheric pressure sensor 5 V power supply cir- 1. DTC P0685 Diagnostics
cuit.
20) Replace the ECM. 1) Turn the starter switch OFF for 30 seconds or
Refer to "1.Engine 1J.Electrical(6HK1X) ECM longer.
Removal". 2) Replace the main relay with a glow relay or
Refer to "1.Engine 1J.Electrical(6HK1X) ECM normal relay.
Installation". 3) Turn ON the starter switch.
21) Set the injector ID code on the ECM. 4) Use the trouble diagnosis scan tool to check
22) Perform the unit difference learning of the fuel if a DTC is detected.
supply pump to the ECM. 5) If a DTC has not been detected, replace the
main relay.
2. DTC P0651 Confirm Resolution 6) Inspect the body grounding terminal for a con-
tact failure.
7) If a problem is discovered, repair the terminal.
scan tool.
8) Inspect the slow blow fuse.
9) If a problem is discovered, replace the slow
longer.
blow fuse.
4) Perform a test-run. ANNOTATION:
that a DTC has not been detected. • When the fuse is blown again, repair the
cause of slow-blow fuse meltdown.
ECM.
tact failure.
connector.
ECM.
Removal".
Installation".
scan tool.
longer.
84402832 NA - May 2011

4023G-48
Engine-side Trouble
ECM/PCM Power Relay Control Sensor Reference Voltage 3
Circuit High Circuit
2) Remove the main relay. 2) Disconnect the harness connector from the
3) Turn ON the starter switch. DPD differential pressure sensor.
4) Use the trouble diagnosis scan tool to see if 3) Turn ON the starter switch.
DTC P0685 is detected. 4) Measure the voltage between the DPD differ-
5) If the DTC P0685 is not detected, repair the ential pressure sensor 5 V power supply cir-
short circuit to the battery power supply of the cuit and GND of the DPD differential pressure
power supply circuit between the ECM and sensor harness connector.
main relay. Voltage： 5.5 V
6) Turn the starter switch OFF for 30 seconds or 5) If it is at or above the standard value, inspect
longer. to see if there is a short circuit to the battery or
7) Replace the main relay with a glow relay or ignition power supply with the DPD differential
normal relay. pressure sensor 5 V power supply circuit be-
8) Turn ON the starter switch. tween the ECM and the DPD differential pres-
9) Use the trouble diagnosis scan tool to check sure sensor.
if DTC P0687 has been detected. 6) If a problem is discovered, repair the DPD
10) If the DTC P0687 is not detected, replace the differential pressure sensor 5 V power supply
main relay. circuit.
2. DTC P0687 Confirm Resolution battery or ignition power supply with the oil
1) Clear the DTC using the trouble diagnosis pressure sensor 5 V power supply circuit be-
scan tool. tween the ECM and oil pressure sensor.
2) Turn the starter switch OFF for 30 seconds or 8) If a problem is discovered, repair the oil pres-
longer. sure sensor 5 V power supply circuit.
3) Turn ON the starter switch. 9) Inspect to see if there is a short circuit to the
4) Use the trouble diagnosis scan tool to confirm battery or ignition power supply with the fuel
that a DTC has not been detected. filter pressure sensor 5 V power supply circuit
between the ECM and the fuel filter pressure
sensor.
10) If a problem is discovered, repair the fuel filter
pressure sensor 5 V power supply circuit.
11) If it is at or below the standard value, mea-
sure the voltage between the DPD differential
pressure sensor 5 V power supply circuit and
GND of the DPD differential pressure sensor
harness connector.
Voltage： 4.5 V
the DPD differential pressure sensor.
Refer to "1.Engine 1G.Exhaust(6HK1X) Ex-
haust differential pressure sensor Removal".
haust differential pressure sensor Installa-
tion".
starter switch OFF.
pressure sensor.
16) Measure the voltage between the DPD differ-
ential pressure sensor 5 V power supply cir-
cuit and GND of the DPD differential pressure
Voltage： 4.5 V
84402832 NA - May 2011

4023G-49
Engine-side Trouble
17) If it is at or above the standard value, replace DTC P1093 (Flash Code 227) Fuel
the oil pressure sensor.
Refer to "1.Engine 1E.Lubrication(6HK1X) Oil Rail Pressure (FRP) Too Low
pressure sensor Removal".
DTC P0087
pressure sensor Installation".
DTC P0091
DTC P0092
starter switch OFF.
DTC P0192
DTC P0193
fuel filter pressure sensor.
DTC P0201
DTC P0202
21) Measure the voltage between the DPD differ-
DTC P0203
ential pressure sensor 5 V power supply cir-
DTC P0204
cuit and GND of the DPD differential pressure
DTC P0205
DTC P0206
Voltage： 4.5 V
DTC P2146
DTC P2149
the fuel filter pressure sensor.
Fuel filter pressure sensor Removal". 1) Turn OFF the starter switch.
Refer to "1.Engine 1C.Fuel System(6HK1X) 2) Wait for the specified period of time until the
Fuel filter pressure sensor Installation". fuel pressure is released from the common
23) If it is at or below the standard value, inspect rail.
to see if there is a short circuit to the GND Specified time: 2 min
with the DPD differential pressure sensor 5 V 3) Turn ON the starter switch.
power supply circuit between the ECM and the 4) Use the trouble diagnosis scan tool to check
DPD differential pressure sensor. if the fuel rail pressure sensor display is within
24) If a problem is discovered, repair the DPD the standard range.
differential pressure sensor 5 V power supply Voltage: 0.9 - 1.0 V
circuit. 5) If the fuel rail pressure sensor display is out-
25) Inspect to see if there is a short circuit to the side the standard range, inspect the fuel pres-
GND with the oil pressure sensor 5 V power sure sensor harness connector for a contact
supply circuit between the ECM and oil pres- failure.
sure sensor. 6) If a problem is discovered, repair the harness
26) If a problem is discovered, repair the oil pres- connector.
sure sensor 5 V power supply circuit. 7) Inspect the ECM harness connector for a con-
27) Inspect to see if there is a short circuit to the tact failure.
GND with the fuel filter pressure sensor 5 V 8) If a problem is discovered, repair the harness
power supply circuit between the ECM and connector.
fuel filter pressure sensor. 9) Inspect each circuit for high resistance.
28) If a problem is discovered, repair the fuel filter 10) Repair the circuit if a problem is discovered.
pressure sensor 5 V power supply circuit. 11) If the harness connector and each circuit are
29) Replace the ECM. normal, replace the fuel pressure sensor.
Refer to "1.Engine 1J.Electrical(6HK1X) ECM Refer to "1.Engine 1C.Fuel System(6HK1X)
Removal". Common rail assembly Removal".
Refer to "1.Engine 1J.Electrical(6HK1X) ECM Refer to "1.Engine 1C.Fuel System(6HK1X)
Installation". Common rail assembly Installation".
31) Perform the unit difference learning of the fuel ANNOTATION:
supply pump to the ECM. • Do not replace the fuel pressure sensor sep-
2. DTC P0697 Confirm Resolution arately.
When a problem is found, replace the com-
1) Clear the DTC using the trouble diagnosis mon rail assembly.
scan tool.
2) Turn the starter switch OFF for 30 seconds or 12) Inspect to see if there is clogging with the fuel
longer. system between the fuel tank and the fuel sup-
3) Start the engine. ply pump.
4) Perform a test-run. 13) If a problem is discovered, repair the clogging
5) Use the trouble diagnosis scan tool to confirm of the fuel system.
that a DTC has not been detected. 14) Inspect the fuel hose between the fuel tank
and the fuel supply pump for a cut and crack.
hose.
ANNOTATION:
84402832 NA - May 2011

4023G-50
Engine-side Trouble
• The fuel hose between the fuel tank and the 26) Leave the engine idling for the specified pe-
fuel supply pump becomes negative pres- riod of time or longer.
sure state when the engine is running. specified time: 1 min
• When the fuel hose is not connected se- 27) While keeping the engine rotating at the spec-
curely, the air can enter. ified engine RPM for the specified period of
• When the engine RPM or the engine load time, check the pressure gauge.
increases while the air has intruded in the Specified time: 1 min
fuel system, fluctuation in the common rail Rotational speed: 2500 min-1 {2500 r/min}
pressure is caused, and DTC P1093 may 28) Check if the pressure gauge shows a negative
be detected. pressure value at or above the standard value
during inspection.
16) Check that an appropriate clamp is used be- Specified value: 17.0 kPa {128 mmHg / 5
tween the fuel tank and the fuel supply pump. inHg}
17) If a problem is discovered, replace the clamp.
18) Operate the priming pump until the handle be- ANNOTATION:
comes heavy.
• Fuel clogging is checked with the negative
ANNOTATION: pressure amount in the fuel system.
• When a leak exists in the fuel system be- 29) If the negative pressure is at or above the
tween the priming pump and the fuel sup- standard value, inspect to see if there is dam-
ply pump, the pressing weight of the priming age or twisting with the fuel system between
pump does not become heavy. the fuel supply pump and the fuel tank.
30) If a problem is discovered, repair the fuel sys-
19) Start the engine. tem.
20) Inspect the high-pressure side of the fuel sys- 31) Inspect the fuel tank bent hose.
tem and check for fuel leak between the fuel 32) If a problem is discovered, repair the bent
supply pump and common rail. hose.
ANNOTATION: 33) Check to see if there is any foreign matter in
the fuel tank or any foreign matter which can
• The fuel may leak to the bottom section of cause fuel clogging.
the cylinder head cover from the high pres- 34) If a problem is discovered, repair it.
sure hose inlet. 35) Replace the fuel filter element.
• The engine oil level increases when the fuel Refer to "1.Engine 1C.Fuel System(6HK1X)
leaks to the bottom portion of the cylinder Fuel filter element Removal".
head cover. Refer to "1.Engine 1C.Fuel System(6HK1X)
• Inspect for fuel leaks into the engine oil. Fuel filter element Installation".
21) If fuel leak if found, fix the problem. 36) If the negative pressure is at or below the stan-
22) Turn OFF the starter switch. dard value, pinch the fuel hose at a position as
23) Remove the fuel hose on the fuel supply pump close as possible to the fuel tank, so that the
side from the fuel filter. fuel does not flow.
• Use a pan to catch the fuel from the re- • The fuel pipe can be disconnected and
moved fuel hose. clogged with a plug.
• Clean the pressure gauge and connection 37) Start the engine and use the idling control
hose before connecting to the fuel pipe. switch to increase the RPM to the highest
• The fuel supply pump may be damaged due level.
to foreign matter that has entered in the con- 38) Check the pressure gauge.
nection hose. Specified value: 27.0 kPa {203 mmHg / 8
24) Connect the pressure gauge between the fuel inHg}
filter and the removed fuel hose. ANNOTATION:
ANNOTATION: • When the pressure gauge is likely to indi-
• Confirm that the fuel system is connected cate a value exceeding the standard value
securely. during inspection, release the fuel being
blocked.
25) Remove the air using the priming pump, and • Air mixture is checked with the negative
crank the engine for the specified period of pressure amount while the fuel flow is being
time or shorter. blocked.
Specified time: 5 s
39) If the standard negative pressure cannot be
ANNOTATION: generated, inspect to see if there is a cut or
• Repeat this until the engine starts. crack with the fuel hose.
hose.
84402832 NA - May 2011
4023G-51
Engine-side Trouble
41) Inspect to see if appropriate clamp is used. 55) Perform the injector stop test with the trouble
42) If a problem is discovered, replace the clamp diagnosis scan tool.
with an appropriate one. 56) Check to see if any injector does not change
43) Turn OFF the starter switch. the engine RPM when OFF is instructed.
44) Inspect the suction control valve harness con- 57) If any injector does not change the engine
nector for a contact failure. RPM when OFF is instructed, replace the rel-
45) If a problem is discovered, repair the harness evant injector.
connector. Refer to "1.Engine 1C.Fuel System(6HK1X)
46) Inspect the ECM harness connector for a con- Injector Removal".
tact failure. Refer to "1.Engine 1C.Fuel System(6HK1X)
47) If a problem is discovered, repair the harness Injector Installation".
connector. 58) When the injector has been replaced, set the
48) Inspect each circuit for high resistance. injector ID code on the ECM.
49) Repair the circuit if a problem is discovered. 59) If the engine RPM changes when OFF is in-
50) If the suction control valve harness connector structed to all injectors, replace the pressure
and the ECM harness connector are normal limiter valve.
and there is no high resistance in each circuit, Refer to "1.Engine 1C.Fuel System(6HK1X)
replace the fuel supply pump and the fuel filter Common rail assembly Removal".
element. Refer to "1.Engine 1C.Fuel System(6HK1X)
Refer to "1.Engine 1C.Fuel System(6HK1X) Common rail assembly Installation".
Fuel supply pump Removal".
ANNOTATION:
Fuel supply pump Installation". • The pressure limiter valve may be fixed
Refer to "1.Engine 1C.Fuel System(6HK1X) open, or the operation pressure may de-
Fuel filter element Removal". crease.
Refer to "1.Engine 1C.Fuel System(6HK1X) • Do not replace the pressure limiter valve
Fuel filter element Installation". separately. When a problem is found, re-
place the common rail assembly.
ANNOTATION:
required to also replace the fuel filter ele- 1) Clear the DTC using the trouble diagnosis
ment at the same time. scan tool.
longer.
52) If the negative pressure is normal, turn OFF
the starter switch.
53) Restore the fuel system.
84402832 NA - May 2011

4023G-52
Engine-side Trouble
Boost Temperature Sensor Circuit Boost Temperature Sensor Circuit
Low High
DTC P0651 DTC P0651
2) Remove the harness connector from the 2) Remove the harness connector from the
boost temperature sensor. boost temperature sensor.
3) Check the boost temperature sensor display 3) Turn ON the starter switch.
with the trouble diagnosis scan tool. 4) Measure the voltage between the boost tem-
Voltage： 4.5 V perature sensor signal circuit and a normal
4) If it is at or above the standard value, replace GND.
the boost temperature sensor. Voltage： 5.5 V
Refer to "1.Engine 1F.Induction(6HK1X) 5) If it is at or above the standard value, inspect
Boost temperature sensor Removal". to see if there is a short circuit to the battery
Refer to "1.Engine 1F.Induction(6HK1X) or ignition power supply with the signal circuit
Boost temperature sensor Installation". between the ECM and the boost temperature
5) Inspect to see if there is a short circuit to the sensor.
GND with the signal circuit between the ECM 6) If a problem is discovered, repair the signal
and boost temperature sensor. circuit.
6) If a problem is discovered, repair the signal 7) Connect the test cable with fuse between the
circuit. boost temperature sensor signal circuit and
7) Inspect the ECM harness connector for a con- GND circuit.
tact failure. 8) Check the boost temperature sensor display
8) If a problem is discovered, repair the harness with the trouble diagnosis scan tool.
connector. Voltage： 0.1 V
9) If the harness connector is normal, replace the 9) If it is at or below the standard value, inspect to
ECM. see if there is a short circuit to the 5 V power
Refer to "1.Engine 1J.Electrical(6HK1X) ECM supply circuit with the signal circuit between
Removal". the ECM and the boost temperature sensor.
Refer to "1.Engine 1J.Electrical(6HK1X) ECM 10) If a problem is discovered, repair the signal
Installation". circuit.
10) Set the injector ID code on the ECM. 11) Inspect boost temperature sensor harness
11) Perform the unit difference learning of the fuel connector for a contact failure.
supply pump to the ECM. 12) If a problem is discovered, repair the harness
connector.
3. DTC P1112 Confirm Resolution 13) If the harness connector is normal, replace the
1) Clear the DTC using the trouble diagnosis boost temperature sensor.
scan tool. Refer to "1.Engine 1F.Induction(6HK1X)
2) Turn the starter switch OFF for 30 seconds or Boost temperature sensor Removal".
longer. Refer to "1.Engine 1F.Induction(6HK1X)
3) Start the engine. Boost temperature sensor Installation".
4) Perform a test-run. 14) Connect the test cable with fuse between the
5) Use the trouble diagnosis scan tool to confirm boost temperature sensor signal circuit and a
that a DTC has not been detected. normal GND.
15) Check the boost temperature sensor display
Voltage： 0.1 V
tance with the
GND circuit between the ECM and the boost
temperature sensor.
ANNOTATION:
• The boost temperature sensor shares the
circuit.
84402832 NA - May 2011
4023G-53
Engine-side Trouble
the ECM and the boost temperature sensor. Injector Positive Voltage Control
circuit.
Circuit Group 1
20) Inspect the ECM harness connector for a con- 1. DTC P1261 Diagnostics
tact failure.
21) If a problem is discovered, repair the harness 1) Replace the ECM. Refer to "1.Engine 1J.Elec-
connector. trical(6HK1X) ECM Removal".
22) If the harness connector is normal, replace the Refer to "1.Engine 1J.Electrical(6HK1X) ECM
ECM. Installation".
Refer to "1.Engine 1J.Electrical(6HK1X) ECM 2) Set the injector ID code on the ECM.
Removal". 3) Perform the unit difference learning of the fuel
Refer to "1.Engine 1J.Electrical(6HK1X) ECM supply pump to the ECM.
Installation". 2. DTC P1261 Confirm Resolution
24) Perform the unit difference learning of the fuel 1) Clear the DTC using the trouble diagnosis
supply pump to the ECM. scan tool.
3. DTC P1113 Confirm Resolution longer.
1) Clear the DTC using the trouble diagnosis 3) Start the engine.
scan tool. 4) Perform a test-run.
2) Turn the starter switch OFF for 30 seconds or 5) Use the trouble diagnosis scan tool to confirm
longer. that a DTC has not been detected.
ANNOTATION:
• Run the engine for 3 minutes or longer.
84402832 NA - May 2011

4023G-54
Engine-side Trouble
DTC P1262 (Flash Code 34) DTC P1293 (Flash Code 211) Fuel
Injector Positive Voltage Control Pressure Sensor Circuit Low
Circuit Group 2 1. DTC P1293 Priority DTC
DTC P0697
1) Replace the ECM. Refer to "1.Engine 1J.Elec- 1) Turn OFF the starter switch.
trical(6HK1X) ECM Removal". 2) Disconnect the harness connector from the
Refer to "1.Engine 1J.Electrical(6HK1X) ECM fuel filter pressure sensor.
Installation". 3) Turn ON the starter switch.
2) Set the injector ID code on the ECM. 4) Measure the voltage between the 5 V power
3) Perform the unit difference learning of the fuel supply circuit of the fuel filter pressure sensor
supply pump to the ECM. harness connector and normal GND.
2. DTC P1262 Confirm Resolution Voltage： 4.5 V
1) Clear the DTC using the trouble diagnosis to see if there is an open circuit or high re-
scan tool. sistance with the 5 V power supply circuit be-
2) Turn the starter switch OFF for 30 seconds or tween the ECM and the fuel filter pressure
longer. sensor.
4) Perform a test-run. ANNOTATION:
• The fuel filter pressure sensor shares the 5
that a DTC has not been detected. V power supply circuit with other sensors.
6) If a problem is discovered, repair the 5 V
5 V power supply circuit and signal circuit of
the fuel filter pressure sensor harness con-
nector.
8) Check the fuel filter pressure sensor display
Voltage： 4.5 V
filter pressure sensor harness connector.
connector.
Fuel filter pressure sensor Removal".
Fuel filter pressure sensor Installation".
12) Inspect the signal circuit between the ECM
and the fuel filter pressure sensor.
sistance.
circuit.
tact failure.
connector.
ECM.
Removal".
Installation".
84402832 NA - May 2011

4023G-55
Engine-side Trouble
17) Set the injector ID code on the ECM. DTC P1294 (Flash Code 211) Fuel
supply pump to the ECM. Pressure Sensor Circuit High
3. DTC P1293 Confirm Resolution 1. DTC P1294 Priority DTC
DTC P0697
1) Clear the DTC using the trouble diagnosis 2. DTC P1294 Diagnostics
scan tool.
2) Turn the starter switch OFF for 30 seconds or 1) Turn OFF the starter switch.
longer. 2) Disconnect the harness connector from the
3) Start the engine. fuel filter pressure sensor.
4) Perform a test-run. 3) Check the fuel filter pressure sensor display
5) Use the trouble diagnosis scan tool to confirm with the trouble diagnosis scan tool.
that a DTC has not been detected. Voltage： 0.1 V
supply.
circuit.
ECM and the fuel filter pressure sensor.
ANNOTATION:
• The fuel filter pressure sensor shares the
circuit.
8) Inspect to see if there is a contact failure with
the fuel filter pressure sensor harness con-
nector.
connector.
Fuel filter pressure sensor Removal".
Fuel filter pressure sensor Installation". 11.In-
spect the ECM harness connector for a con-
tact failure.
connector.
ECM.
Removal".
Installation".
scan tool.
longer.
84402832 NA - May 2011

4023G-56
Engine-side Trouble
3) Start the engine. DTC P1404 (Flash Code 45)

5) Use the trouble diagnosis scan tool to confirm Exhaust Gas Recirculation (EGR)
that a DTC has not been detected. Closed Position Performance
DTC P0404
DTC P0409
1) Remove the EGR valve assembly from the
engine.
2) Inspect the EGR valve.
• There should be nothing to limit flow inside
the EGR valve.
• There should be no excessive accumulates
inside the EGR valve.
• There should be no bending with the valve
shaft or valve itself inside the EGR valve.
3) If a problem is discovered, repair or replace
the EGR valve.
Devices(6HK1X) EGR valve Installation".
EGR valve.
6) Inspect the EGR valve harness connector for
a contact failure.
connector.
ECM.
tact failure.
connector.
11) Inspect the EGR valve circuit between the
ECM and the EGR valve for an open circuit
and high resistance.
valve circuit.
13) Inspect the solenoid circuit between the ECM
and EGR valve.
ignition power supply circuit.
• There should be no short between the cir-
cuits.
• There should be no short to EGR position
sensor circuit.
14) If a problem is discovered, repair the solenoid
circuit.
15) If the circuit is normal, replace the EGR valve.
Devices(6HK1X) EGR valve Installation".
84402832 NA - May 2011

4023G-57
Engine-side Trouble
1) Clear the DTC using the trouble diagnosis DTC P1455 (Flash Code 132) PM
scan tool.
2) Turn the starter switch OFF for 30 seconds or Over Accumulation
longer.
4) Perform a test-run. 1) Check with the operator if the DPD light has
5) Use the trouble diagnosis scan tool to confirm blinked before.
that a DTC has not been detected. 2) If necessary, explain DPD regeneration.
• Check with the operator if the engine oper-
ating time was short.
• Ckeck with the operator if the idling time was
too long.
3) Inspect the DPD differential pressure sensor
hose.
• There should be no incorrect piping or dis-
connection.
4) If a problem is discovered, repair the hose.
5) Inspect the DPD differential pressure sensor.
• DPD differential pressure sensor unit should
not be damaged.
• There should be no dirt or foreign matter
blocking the DPD differential pressure sen-
sor entrance.
• There should be no detection error or slow
response from the DPD differential pressure
sensor.
6) If a problem is discovered, replace the DPD
tion".
7) When the DPD differential pressure sensor
has been replaced, perform the 0-point cor-
rection.
haust differential pressure sensor Inspection".
8) Inspect the exhaust system.
• There should be no absence or damage of
the exhaust pipe gasket.
• There should be no exhaust gas leak from
the exhaust system.
• The exhaust system should not be modified.
• There should be no damage or excessive
deposits on the oxidation catalyst.
the exhaust system.
10) Inspect the DPD assembly.
Refer to "1.Engine 1G.Exhaust(6HK1X) DPD
assembly Inspection".
assembly.
12) If the DPD assembly has been replaced, use
the trouble diagnosis scan tool to perform
DPD regeneration data reset.
13) Inspect the mass air flow sensor with the trou-
14) If a problem is discovered, replace the mass
air flow sensor.
84402832 NA - May 2011

4023G-58
Engine-side Trouble
15) Use the trouble diagnosis scan tool to check if 34) Use the trouble diagnosis scan tool to check if
the boost pressure and atmospheric pressure the exhaust differential pressure data display
are operating properly. is at or below the standard value.
16) Inspect the air cleaner element. Specified value: 7.5 kPa {0.08 kgf/cm2 / 1.1
Refer to "1.Engine 1F.Induction(6HK1X) Air psi}
cleaner element Inspection". 35) If it is at or above the standard value, replace
17) If a problem is discovered, replace the air the DPD filter.
cleaner element. Refer to "1.Engine 1G.Exhaust(6HK1X) DPD
18) Check the intake duct for a clogging, hole, and assembly Disassembly".
leakage. Refer to "1.Engine 1G.Exhaust(6HK1X) DPD
19) If a problem is discovered, replace the intake assembly Reassembly".
duct. 36) If the DPD filter has been replaced, use the
20) Inspect the intake throttle valve for fixing. trouble diagnosis scan tool to perform DPD
21) If a problem is discovered, replace the intake regeneration data reset.
throttle valve. 37) When a DTC has been detected, clear it using
Refer to "1.Engine 1B.Mechanical(6HK1X) In- the trouble diagnosis scan tool.
take throttle valve Removal". 38) Turn the starter switch OFF for 30 seconds or
Refer to "1.Engine 1B.Mechanical(6HK1X) In- longer.
take throttle valve Installation". 39) Perform the DPD forced slow regeneration
22) Inspect the turbocharger assembly. with the trouble diagnosis scan tool.
ANNOTATION:
23) If a problem is discovered, replace the tur- • After the DPD forced slow regeneration is
bocharger assembly. completed, replace the engine oil.
bocharger assembly Removal". 40) Check the exhaust temperature (before the
Refer to "1.Engine 1F.Induction(6HK1X) Tur- filter) display with the trouble diagnosis scan
bocharger assembly Installation". tool.
24) Inspect the quality of fuel. 41) Confirm that the exhaust temperature is at or
below the standard value.
ANNOTATION: Specified value: 130 °C {266 °F}
42) If it is at or above the standard value, idle the
• An appropriate fuel is used.
engine until it falls to or below the standard
25) Turn the starter switch ON for 30 seconds. value.
43) Check the exhaust differential pressure dis-
ANNOTATION: play when the exhaust temperature (in front
• Do not start the engine. of the filter) display has reached the standard
• This is for the DPD differential pressure sen- value with the engine revolution increased to
sor to relearn. the maximum revolution speed without load.
26) Clear the DTC using the trouble diagnosis 44) Use the trouble diagnosis scan tool to check if
scan tool. the exhaust differential pressure display is at
27) Perform the DPD regeneration data reset with or below the standard value.
the trouble diagnosis scan tool. Specified value: 1.8 kPa {0.02 kgf/cm2 / 0.3
28) Turn the starter switch OFF for 30 seconds or psi}
longer. 45) If it is at or above the standard value, perform
29) Start the engine. ash removal.
30) Check the exhaust temperature (before the Refer to "1.Engine 1G.Exhaust(6HK1X) DPD
filter) display with the trouble diagnosis scan assembly Inspection".
tool.
31) Confirm that the exhaust temperature is at or 2. DTC P1455 Confirm Resolution
below the standard value. 1) Turn ON the starter switch.
Specified value: 130 °C {266 °F} 2) Use the trouble diagnosis scan tool to confirm
32) If it is at or above the standard value, idle the that a DTC has not been detected.
engine until it falls to or below the standard
value.
play when the exhaust temperature (in front
of the filter) display has reached the standard
value with the engine revolution increased to
the maximum revolution speed without load.
84402832 NA - May 2011

4023G-59
Engine-side Trouble
DTC P1471 (Flash Code 149) 13) If a problem is discovered, repair the intake
system.
DPD Insufficient Regeneration 14) Use the trouble diagnosis scan tool to inspect
the mass air flow sensor.
1) Inspect the DPD differential pressure sensor air flow sensor.
hose. 16) Turn the starter switch ON for 30 seconds.
• There should be no incorrect piping or dis- ANNOTATION:
connection.
2) If a problem is discovered, repair the hose. • This is for the DPD differential pressure sen-
3) Inspect the DPD differential pressure sensor. sor to relearn.
• DPD differential pressure sensor unit should 17) Start the engine.
not be damaged. 18) Use the trouble diagnosis scan tool to check
• There should be no dirt or foreign matter the DPD accumulation status and the DPD
blocking the DPD differential pressure sen- time status, and confirm the corresponding
sor entrance. area from the DPD status table.
• There should be no detection error or slow 19) If the situation falls in the area A or B, use
response from the DPD differential pressure the trouble diagnosis scan tool to perform the
sensor. DPD forced regeneration.
4) If a problem is discovered, replace the DPD ANNOTATION:
Refer to "1.Engine 1G.Exhaust(6HK1X) Ex- • When a DTC has been detected, clear it
using the trouble diagnosis scan tool.
Refer to "1.Engine 1G.Exhaust(6HK1X) Ex- 20) If the situation falls in the area C or D, use
haust differential pressure sensor Installa- the trouble diagnosis scan tool to perform the
tion". DPD forced slow regeneration.
has been replaced, perform the 0-point cor- ANNOTATION:
rection. • When a DTC has been detected, clear it
Refer to "1.Engine 1G.Exhaust(6HK1X) Ex- using the trouble diagnosis scan tool.
haust differential pressure sensor Inspection". • After the DPD forced slow regeneration is
6) Inspect the exhaust system. completed, replace the engine oil.
• There should be no absence or damage of 21) Check the exhaust temperature (before the
the exhaust pipe gasket. filter) display with the trouble diagnosis scan
• There should be no exhaust gas leak from tool.
the exhaust system. 22) Confirm that the exhaust temperature is at or
• The exhaust system should not be modified. below the standard value.
7) If a problem is discovered, repair or replace Specified value: 130 °C {266 °F}
the exhaust system. 23) If it is at or above the standard value, idle the
8) Inspect the exhaust gas temperature sensor. engine until it falls to or below the standard
Refer to "1.Engine 1G.Exhaust(6HK1X) Ex- value.
haust gas temperature sensor Inspection". 24) Check the exhaust differential pressure dis-
9) If a problem is discovered, replace the ex- play when the exhaust temperature (in front
haust gas temperature sensor. of the filter) display has reached the standard
Refer to "1.Engine 1G.Exhaust(6HK1X) Ex- value with the engine revolution increased to
haust gas temperature sensor Removal". the maximum revolution speed without load.
Refer to "1.Engine 1G.Exhaust(6HK1X) Ex- Specified value: 150 °C {302 °F}
haust gas temperature sensor Installation". 25) Use the trouble diagnosis scan tool to check if
10) Inspect the air cleaner element. the exhaust differential pressure display is at
Refer to "1.Engine 1F.Induction(6HK1X) Air or below the standard value.
cleaner element Inspection". Specified value: 1.8 kPa {0.02 kgf/cm2 / 0.3
11) If a problem is discovered, replace the air psi}
cleaner element. 26) If it is at or above the standard value, perform
12) Inspect the air intake system. ash removal.
• There should be no crush, limited flow, or assembly Inspection".
damage of the duct between the air cleaner
and intake manifold. 2. DTC P1471 Confirm Resolution
• The intake system should not be modified. 1) Turn ON the starter switch.
• There should be no air leak with the intake 2) Use the trouble diagnosis scan tool to confirm
system. that a DTC has not been detected.
84402832 NA - May 2011

4023G-60
Engine-side Trouble
Control Module Long Term Sensor Reference Voltage Circuit
Memory Performance 1. DTC P1655 Diagnostics
1. DTC P1621 Diagnostics 1) Turn OFF the starter switch.
1) Confirm that the connecting sections of all boost sensor.
tools are securely connected. 3) Turn ON the starter switch.
2) Confirm that the programming device is oper- 4) Measure the voltage between the boost sen-
ating normally. sor 5 V power supply terminal and GND of the
3) Turn the starter switch OFF, and wait for 30 boost sensor harness connector.
seconds. Voltage： 5.5 V
4) Turn ON the starter switch. 5) If it is at or above the standard value, inspect
5) Use the trouble diagnosis scan tool to check to see if there is a short circuit to the battery or
if a DTC has been detected. ignition power supply with the boost sensor 5
6) If a DTC has been detected, replace the ECM. V power supply circuit between the ECM and
Refer to "1.Engine 1J.Electrical(6HK1X) ECM the boost sensor.
Removal". 6) If a problem is discovered, repair the boost
Refer to "1.Engine 1J.Electrical(6HK1X) ECM sensor 5 V power supply circuit.
Installation". 7) Inspect to see if there is a short circuit to the
7) Set the injector ID code on the ECM. battery or ignition power supply with the intake
8) Perform the unit difference learning of the fuel throttle position sensor 5 V power supply cir-
supply pump to the ECM. cuit between the ECM and the intake throttle
2. DTC P1621 Confirm Resolution valve.
8) If a problem is discovered, repair the intake
1) Clear the DTC using the trouble diagnosis throttle position sensor 5 V power supply cir-
scan tool. cuit.
2) Turn the starter switch OFF for 30 seconds or 9) Inspect to see if there is a short circuit to the
longer. battery or ignition power supply with the EGR
3) Start the engine. valve position sensor 5 V power supply circuit
4) Use the trouble diagnosis scan tool to confirm between the ECM and EGR valve.
that a DTC has not been detected. 10) If a problem is discovered, repair the EGR
valve position sensor 5 V power supply circuit.
11) If it is at or below the standard value, mea-
sure the voltage between the boost sensor 5
V power supply terminal and GND of the boost
Voltage： 4.5 V
the boost sensor.
Boost sensor Removal".
Boost sensor Installation".
starter switch OFF.
14) Remove the harness connector from the in-
16) Measure the voltage between the boost sen-
sor 5 V power supply terminal and GND of the
boost sensor harness connector.
Voltage： 4.5 V
the intake throttle valve.
starter switch OFF.
EGR valve.
84402832 NA - May 2011
4023G-61
Engine-side Trouble
21) Measure the voltage between the boost sen- DTC P1669 (Flash Code 75) DPD
sor 5 V power supply terminal and GND of the
boost sensor harness connector. Lamp Control Circuit
Voltage： 4.5 V
the EGR valve. 1) Confirm that the monitor panel operates prop-
Refer to "1.Engine 1H.Aux. Emission Control erly.
Devices(6HK1X) EGR valve Removal". 2) Turn OFF the starter switch.
Refer to "1.Engine 1H.Aux. Emission Control 3) Inspect the fuse.
Devices(6HK1X) EGR valve Installation". 4) If a problem is discovered, replace the fuse.
to see if there is a short circuit to the GND ANNOTATION:
with the boost sensor 5 V power supply circuit • When the fuse is blown again, repair the
between the ECM and the boost sensor. cause of fuse meltdown.
24) If a problem is discovered, repair the boost
sensor 5 V power supply circuit.
ECM.
GND with the intake throttle position sensor 5
V power supply circuit between the ECM and
8) Check to see if the DPD light is off.
the intake throttle valve.
9) If the DPD light is not turned off, repair the
26) If a problem is discovered, repair the intake
short circuit to GND in the DPD light con-
throttle position sensor 5 V power supply cir-
trol circuit between the ECM and the monitor
cuit.
panel.
GND with the EGR valve position sensor 5
11) Remove the fuse.
V power supply circuit between the ECM and
EGR valve.
13) Measure the voltage between the DPD light
control circuit and GND of the ECM harness
valve position sensor 5 V power supply circuit.
connector.
29) Replace the ECM.
Voltage： 1.0 V
14) If it is at or above the standard value, repair
Removal".
the short circuit to the battery or ignition power
supply circuit in the DPD light control circuit
Installation".
between the ECM and the monitor panel.
16) Install the fuse.
2. DTC P1655 Confirm Resolution DPD light control circuit and GND of the ECM
harness connector.
1) Clear the DTC using the trouble diagnosis 18) Turn ON the starter switch.
scan tool. 19) If the DPD light turns on, inspect the ECM
2) Turn the starter switch OFF for 30 seconds or harness connector for a contact failure.
longer. 20) If a problem is discovered, repair the harness
3) Start the engine. connector.
4) Perform a test-run. 21) If the harness connector is normal, replace the
5) Use the trouble diagnosis scan tool to confirm ECM.
that a DTC has not been detected. Refer to "1.Engine 1J.Electrical(6HK1X) ECM
Removal".
Installation".
24) If the DPD light does not turn on, remove the
DPD light bulb from the monitor panel.
25) Inspect the DPD light bulb.
26) Replace the valve if a problem is discovered.
27) Inspect to see if there is an open circuit or high
resistance in the ignition power supply circuit
between the fuse and the monitor panel.
28) If a problem is discovered, repair the ignition
84402832 NA - May 2011

4023G-62
Engine-side Trouble
29) Inspect to see if there is an open circuit or DTC P2146 (Flash Code 158) Fuel
high resistance in the DPD light control circuit
between the ECM and the monitor panel. Injector Group 1 Supply Voltage
30) If a problem is discovered, repair the control
circuit.
Circuit
31) Inspect the monitor panel harness connector 1. DTC P2146 Diagnostics
32) If a problem is discovered, repair the harness 1) Turn the starter switch OFF.
connector. 2) Disconnect the harness connector from the
33) When the harness connector is normal, re- cylinder head injector harness intermediate
place the monitor panel. connector.
3) Turn the starter switch ON.
2. DTC P1669 Confirm Resolution 4) Measure the resistance between the solenoid
control circuit and a normal GND.
scan tool. ANNOTATION:
longer. • Solenoid control circuit - normal GND of the
3) Turn the starter switch ON, and wait for 40 first cylinder injector
seconds. • Solenoid control circuit - normal GND of the
4) Start the engine. second cylinder injector
5) Use the trouble diagnosis scan tool to confirm • Solenoid control circuit - normal GND of the
that a DTC has not been detected. third cylinder injector
Resistance： 10.0 MΩ
to see if there is a short circuit to the GND
with the control circuit between the ECM and
6) If a problem is discovered, repair the control
circuit.
7) Inspect the charge voltage circuit between the
ECM and the injector harness intermediate
connector.
8) If a problem is discovered, repair the charge
voltage circuit.
9) If the charge voltage circuit is normal, replace
the ECM.
Removal".
Installation".
13) If a problem is discovered, repair the injector
harness intermediate connector.
14) Disconnect the ECM harness connector.
tact failure.
connector.
17) ECM and components The ECM is designed
to maintain regulation levels of exhaust gases
while obtaining excellent fuel efficiency. The
ECM monitors various engine functions via
the sensors such as the crankshaft position
sensor.
voltage circuit.
84402832 NA - May 2011

4023G-63
Engine-side Trouble
19) Remove the cylinder head cover. DTC P2149 (Flash Code 159) Fuel
Cylinder head cover Removal". Injector Group 2 Supply Voltage
20) Inspect the injector harness tightening nut for
looseness.
Circuit
21) If the injector harness tightening nut is loose, 1. DTC P2149 Diagnostics
tighten it.
22) Inspect to see if any foreign matter is attached 1) Turn OFF the starter switch.
to the injector terminal. 2) Disconnect the harness connector from the
23) If any foreign matter is attached to the injector cylinder head injector harness intermediate
terminal, remove it. connector.
24) Inspect the injector harness intermediate har- 3) Turn the starter switch ON.
ness connector for a contact failure. 4) Measure the resistance between the solenoid
25) If a problem is discovered, repair the injector control circuit and a normal GND.
harness intermediate connector. ANNOTATION:
26) Check if insulation resistance of the first cylin-
der, second cylinder, and third cylinder injec- • Solenoid control circuit - normal GND of the
tor is at or above the standard value. fourth cylinder injector
Resistance： 1.0 MΩ • Solenoid control circuit - normal GND of the
27) If any injector is at or below the standard fifth cylinder injector
value, replace the relevant injector. • Solenoid control circuit - normal GND of the
Refer to "1.Engine 1C.Fuel System(6HK1X) sixth cylinder injector
Injector Removal". Resistance： 10.0 Ω
Refer to "1.Engine 1C.Fuel System(6HK1X) 5) If it is at or below the standard value, inspect
Injector Installation". to see if there is a short circuit to the GND
28) When the injector has been replaced, set the with the control circuit between the ECM and
injector ID code on the ECM. injector harness intermediate connector.
29) If all the resistance values are at or above the 6) If a problem is discovered, repair the control
standard value, repair or replace the injector circuit.
harness. 7) Inspect the charge voltage circuit between the
2. DTC P2146 Confirm Resolution ECM and the injector harness intermediate
connector.
scan tool. • There should be no short to the battery or
2) Turn the starter switch OFF for 30 seconds or ignition power supply.
longer. • There should be no short to GND.
3) Start the engine. 8) If a problem is discovered, repair the charge
4) Perform a test-run. voltage circuit.
5) Use the trouble diagnosis scan tool to confirm 9) If the charge voltage circuit is normal, replace
that a DTC has not been detected. the ECM.
Removal".
Installation".
13) If a problem is discovered, repair the injector
harness intermediate connector.
14) Disconnect the ECM harness connector.
tact failure.
connector.
high resistance with the charge voltage circuit
between the ECM and the injector harness
intermediate connector.
voltage circuit.
Cylinder head cover Removal".
84402832 NA - May 2011
4023G-64
Engine-side Trouble
20) Inspect the injector harness tightening nut for DTC P2228 (Flash Code 71)
looseness.
21) If the injector harness tightening nut is loose, Barometric Pressure Circuit Low
tighten it.
22) Inspect to see if any foreign matter is attached
DTC P0651
to the injector terminal.
23) If any foreign matter is attached to the injector
terminal, remove it. 1) Turn OFF the starter switch.
24) Inspect the injector harness intermediate har- 2) Disconnect the harness connector from the
ness connector for a contact failure. atmospheric pressure sensor.
25) If a problem is discovered, repair the injector 3) Turn ON the starter switch.
harness intermediate connector. 4) Measure the voltage between the atmo-
26) Check to see if insulation resistance of the spheric pressure sensor 5 V power supply
fourth cylinder, fifth cylinder, and sixth cylinder circuit and GND.
injector is at or above the standard value. Voltage： 4.5 V
Resistance： 1.0 MΩ 5) If it is at or below the standard value, inspect
27) If any injector is at or below the standard to see if there is an open circuit or high re-
value, replace the relevant injector. sistance with the 5 V power supply circuit be-
Refer to "1.Engine 1C.Fuel System(6HK1X) tween the ECM and the atmospheric pressure
Injector Removal". sensor.
Refer to "1.Engine 1C.Fuel System(6HK1X) 6) If a problem is discovered, repair the 5 V
Injector Installation". power supply circuit.
28) When the injector has been replaced, set the 7) Connect the test cable with fuse between the
injector ID code on the ECM. atmospheric pressure sensor 5 V power sup-
29) If all the resistance values are at or above the ply circuit and the signal circuit.
standard value, repair or replace the injector 8) Check the atmospheric pressure sensor dis-
harness. play with the trouble diagnosis scan tool.
Voltage： 4.5 V
1) Clear the DTC using the trouble diagnosis to see if there is a contact failure with the at-
scan tool. mospheric pressure sensor harness connec-
2) Turn the starter switch OFF for 30 seconds or tor.
longer. 10) If a problem is discovered, repair the harness
3) Start the engine. connector.
4) Perform a test-run. 11) If the harness connector is normal, replace the
Engine Control (6HK1X) 1A-103 atmospheric pressure sensor.
5) Use the trouble diagnosis scan tool to confirm 12) If it is at or below the standard value, inspect
that a DTC has not been detected. the signal circuit between the ECM and the
atmospheric pressure sensor.
sistance.
circuit.
tact failure.
connector.
ECM.
Removal".
Installation".
scan tool.
longer.
84402832 NA - May 2011
4023G-65
Engine-side Trouble
4) Perform a test-run. DTC P2229 (Flash Code 71)

that a DTC has not been detected. Barometric Pressure Circuit High
P0651
3) Check the atmospheric pressure sensor dis-
Voltage： 0.1 V
supply.
circuit.
6) Connect the test light between the atmo-
spheric pressure sensor GND circuit and
battery power supply.
7) If the test light comes on, inspect the atmo-
spheric pressure sensor harness connector
connector.
10) If the test light does not come on, inspect to
see if there is an open circuit or high resis-
and the atmospheric pressure sensor.
circuit.
tact failure.
connector.
ECM.
Removal".
Installation".
scan tool.
longer.
84402832 NA - May 2011

4023G-66
Engine-side Trouble
DTC P2452 (Flash Code 142) 17) If a problem is discovered, repair the harness
connector.
DPD Differential Pressure Sensor 18) Inspect the signal circuit between the ECM
Circuit and the DPD differential pressure sensor for
a high resistance.
1. DTC P2452 Priority DTC 19) If a problem is discovered, repair the signal
DTC P2456 circuit.
2. DTC P2452 Diagnostics 20) If the harness connector and circuit are nor-
mal, replace the DPD differential pressure
1) Inspect the DPD differential pressure sensor sensor.
hose. Refer to "1.Engine 1G.Exhaust(6HK1X) Ex-
• There should be no incorrect piping or dis- haust differential pressure sensor Removal".
connection. Refer to "1.Engine 1G.Exhaust(6HK1X) Ex-
2) If a problem is discovered, repair the hose. tion".
3) Inspect the DPD differential pressure sensor. 21) When the DPD differential pressure sensor
• DPD differential pressure sensor unit should has been replaced, perform the 0-point cor-
not be damaged. rection.
• There should be no dirt or foreign matter Refer to "1.Engine 1G.Exhaust(6HK1X) Ex-
blocking the DPD differential pressure sen- haust differential pressure sensor Inspection".
sor entrance. 22) Restore the actual unit.
• There should be no detection error or slow 23) Turn the starter switch ON for 30 seconds.
response from the DPD differential pressure ANNOTATION:
sensor.
4) If a problem is discovered, replace the DPD • This is for the DPD differential pressure sen-
differential pressure sensor. sor to relearn.
haust differential pressure sensor Removal". 24) Clear the DTC using the trouble diagnosis
Refer to "1.Engine 1G.Exhaust(6HK1X) Ex- scan tool.
haust differential pressure sensor Installa- 25) Perform the DPD regeneration data reset with
tion". the trouble diagnosis scan tool.
5) When the DPD differential pressure sensor 26) Turn the starter switch OFF for 30 seconds or
has been replaced, perform the 0-point cor- longer.
rection. 27) Perform the DPD forced regeneration with the
Refer to "1.Engine 1G.Exhaust(6HK1X) Ex- trouble diagnosis scan tool.
haust differential pressure sensor Inspection". ANNOTATION:
• When the DPD filter is replaced by a new
• There should be no absence or damage of one, do not perform the DPD forced regen-
the exhaust pipe gasket. eration.
the exhaust system. 28) Use the trouble diagnosis scan tool to confirm
• The exhaust system should not be modified. that the exhaust temperature (before the filter)
display is at or below the standard value.
7) If a problem is discovered, repair or replace Specified value: 130 °C {266 °F}
the exhaust system. 29) If it is at or above the standard value, idle the
8) Inspect the DPD assembly. engine until it falls to or below the standard
Refer to "1.Engine 1G.Exhaust(6HK1X) DPD value.
assembly Inspection". 30) Check the exhaust differential pressure dis-
9) If a problem is discovered, replace the DPD play when the exhaust temperature (in front
assembly. of the filter) display has reached the standard
10) If the DPD assembly has been replaced, use value with the engine revolution increased to
the trouble diagnosis scan tool to perform the maximum revolution speed without load.
DPD regeneration data reset. Specified value: 150 °C {302 °F}
11) Turn OFF the starter switch. 31) Use the trouble diagnosis scan tool to check if
12) Disconnect the harness connector from the the exhaust differential pressure display is at
DPD differential pressure sensor. or above the standard value.
13) Inspect the DPD differential pressure sensor Specified value: 0.5 kPa {0.01 kgf/cm2 / 0.1
harness connector for a contact failure. psi}
connector. 3. DTC P2452 Confirm Resolution
ECM.
tact failure.
84402832 NA - May 2011

4023G-67
Engine-side Trouble
DTC P2453 (Flash Code 141) 13) Inspect the ECM harness connector for a con-
tact failure.
DPD Differential Pressure Sensor 14) If a problem is discovered, repair the harness
Circuit Range/Performance 15)
connector.
Inspect the signal circuit between the ECM
1. DTC P2453 Priority DTC and the DPD differential pressure sensor for
DTC P2456 a high resistance.
2. DTC P2453 Diagnostics 16) If a problem is discovered, repair the signal
circuit.
1) Inspect the DPD differential pressure sensor 17) If the harness connector and signal circuit are
hose. normal, replace the DPD assembly.
• There should be no incorrect piping or dis- 18) If the DPD assembly has been replaced, use
connection. the trouble diagnosis scan tool to perform
2) If a problem is discovered, repair the hose. 19) Restore the actual unit.
3) Inspect the DPD differential pressure sensor. 20) Turn the starter switch ON for 30 seconds.
• DPD differential pressure sensor unit should ANNOTATION:
not be damaged.
• There should be no dirt or foreign matter • Do not start the engine.
blocking the DPD differential pressure sen- • This is for the DPD differential pressure sen-
sor entrance. sor to relearn.
• There should be no detection error or slow 21) Clear the DTC using the trouble diagnosis
response from the DPD differential pressure scan tool.
sensor. 22) Perform the DPD regeneration data reset with
4) If a problem is discovered, replace the DPD the trouble diagnosis scan tool.
differential pressure sensor. 23) Turn the starter switch OFF for 30 seconds or
Refer to "1.Engine 1G.Exhaust(6HK1X) Ex- longer.
haust differential pressure sensor Removal". 24) Perform the DPD forced regeneration with the
Refer to "1.Engine 1G.Exhaust(6HK1X) Ex- trouble diagnosis scan tool.
haust differential pressure sensor Installa- 25) Use the trouble diagnosis scan tool to confirm
tion". that the exhaust temperature (before the filter)
5) When the DPD differential pressure sensor display is at or below the standard value.
has been replaced, perform the 0-point cor- Specified value: 130 °C {266 °F}
rection. 26) If it is at or above the standard value, idle the
Refer to "1.Engine 1G.Exhaust(6HK1X) Ex- engine until it falls to or below the standard
haust differential pressure sensor Inspection". value.
6) Inspect the exhaust system. 27) Check the exhaust differential pressure dis-
play when the exhaust temperature (in front
• There should be no missing or damage with of the filter) display has reached the standard
the gasket of the exhaust pipe. value with the engine revolution increased to
• There should be no exhaust gas leak from the maximum revolution speed without load.
the exhaust system. Specified value: 150 °C {302 °F}
• The exhaust system should not be modified. 28) Use the trouble diagnosis scan tool to check if
• There should be no flow limitation or crush the exhaust differential pressure display is at
of the exhaust system. or below the standard value.
7) If a problem is discovered, repair or replace Specified value: 1.8 kPa {0.02 kgf/cm2 / 0.3
the exhaust system. psi}
8) Turn OFF the starter switch. 29) If it is at or above the standard value, perform
9) Disconnect the harness connector from the ash removal.
DPD differential pressure sensor. Refer to "1.Engine 1G.Exhaust(6HK1X) Ex-
10) Inspect the DPD differential pressure sensor haust differential pressure sensor Inspection".
harness connector for a contact failure. 3. DTC P2453 Confirm Resolution
connector. 1) Turn ON the starter switch.
12) Disconnect the harness connector from the 2) Use the trouble diagnosis scan tool to confirm
ECM. that a DTC has not been detected.
84402832 NA - May 2011

4023G-68
Engine-side Trouble
DTC P2454 (Flash Code 47) 11) If the harness connector is normal, replace the
DPD differential pressure sensor.
DPD Differential Pressure Sensor Refer to "1.Engine 1G.Exhaust(6HK1X) Ex-
Circuit Low haust differential pressure sensor Removal".
1. DTC P2454 Priority DTC haust differential pressure sensor Installa-
DTC P0697 tion".
2. DTC P2454 Diagnostics 12) When the DPD differential pressure sensor
1) Turn OFF the starter switch. rection.
2) Disconnect the harness connector from the Refer to "1.Engine 1G.Exhaust(6HK1X) Ex-
DPD differential pressure sensor. haust differential pressure sensor Inspection".
3) Turn ON the starter switch. 13) If it is at or below the standard value, inspect
4) Measure the voltage between the DPD differ- the signal circuit between the ECM and the
ential pressure sensor 5 V power supply cir- DPD differential pressure sensor.
cuit and GND.
Voltage： 4.5 V • There should be no open circuit or high re-
5) If it is at or below the standard value, inspect sistance.
to see if there is an open circuit or high re- • There should be no short to GND.
sistance with the 5 V power supply circuit be-
tween the ECM and the DPD differential pres-
circuit.
sure sensor.
ANNOTATION: tact failure.
• The DPD differential pressure sensor connector.
shares the 5 V power supply circuit with 17) If the harness connector is normal, replace the
other sensors. ECM.
• The DTC set on a sensor which shares this Refer to "1.Engine 1J.Electrical(6HK1X) ECM
circuit may be detected. Removal".
6) If a problem is discovered, repair the 5 V Refer to "1.Engine 1J.Electrical(6HK1X) ECM
power supply circuit. Installation".
7) Connect the test cable with fuse between the 18) Set the injector ID code on the ECM.
5 V power supply circuit and signal circuit of 19) Perform the unit difference learning of the fuel
the DPD differential pressure sensor. supply pump to the ECM.
8) Check the exhaust differential pressure dis- 3. DTC P2454 Confirm Resolution
Voltage： 4.5 V 1) Clear the DTC using the trouble diagnosis
9) If it is at or above the standard value, inspect scan tool.
to see if there is a contact failure with the DPD 2) Turn the starter switch OFF for 30 seconds or
differential pressure sensor harness connec- longer.
tor. 3) Start the engine.
10) If a problem is discovered, repair the harness 4) Perform a test-run.
connector. 5) Use the trouble diagnosis scan tool to confirm
84402832 NA - May 2011

4023G-69
Engine-side Trouble
DTC P2455 (Flash Code 47) 10) When the DPD differential pressure sensor
DPD Differential Pressure Sensor rection.
Circuit High Refer to "1.Engine 1G.Exhaust(6HK1X) Ex-
1. DTC P2455 Priority DTC 11) If the test light does not come on, inspect to
DTC P0697 see if there is an open circuit or high resis-
2. DTC P2455 Diagnostics tance with the GND circuit between the ECM
and the DPD differential pressure sensor.
2) Disconnect the harness connector from the ANNOTATION:
DPD differential pressure sensor.
• The DPD differential pressure sensor
Voltage： 0.1 V
the signal circuit between the ECM and the 12) If a problem is discovered, repair the GND
DPD differential pressure sensor. circuit.
• There should be no short to the battery or tact failure.
• There should be no short to the 5 V power connector.
supply.
5) If a problem is discovered, repair the signal ECM.
circuit. Refer to "1.Engine 1J.Electrical(6HK1X) ECM
6) Connect the test light between the GND circuit Removal".
and battery power supply of the DPD differen- Refer to "1.Engine 1J.Electrical(6HK1X) ECM
tial pressure sensor. Installation".
7) If the test light comes on, inspect DPD differ- 16) Set the injector ID code on the ECM.
ential pressure sensor harness connector for 17) Perform the unit difference learning of the fuel
a contact failure. supply pump to the ECM.
connector.
9) If the harness connector is normal, replace the 1) Clear the DTC using the trouble diagnosis
DPD differential pressure sensor. scan tool.
Refer to "1.Engine 1G.Exhaust(6HK1X) Ex- 2) Turn the starter switch OFF for 30 seconds or
haust differential pressure sensor Removal". longer.
Refer to "1.Engine 1G.Exhaust(6HK1X) Ex- 3) Start the engine.
haust differential pressure sensor Installa- 4) Perform a test-run.
tion". 5) Use the trouble diagnosis scan tool to confirm
84402832 NA - May 2011

4023G-70
Engine-side Trouble
DTC P2458 (Flash Code 139) 9) If a problem is discovered, repair the cooling
system.
DPD Regeneration Duration 10) Turn the starter switch ON for 30 seconds.
1. DTC P2458 Priority DTC ANNOTATION:
DTC P0426
DTC P0427 • Do not start the engine.
DTC P0428 • This is for the DPD differential pressure sen-
DTC P042B sor to relearn.
DTC P042C 11) Turn the starter switch OFF for 30 seconds.
DTC P042D 12) Start the engine.
2. DTC P2458 Diagnostics 13) Use the trouble diagnosis scan tool to check
1) Inspect the DPD differential pressure sensor the DPD accumulation status and the DPD
hose. time status, and confirm the corresponding
area from the DPD status table.
• There should be no incorrect piping or dis- 14) If the situation falls in the area A or B, use
connection. the trouble diagnosis scan tool to perform the
DPD forced regeneration.
3) Inspect the DPD differential pressure sensor. ANNOTATION:
• DPD differential pressure sensor unit should • When a DTC has been detected, clear it
not be damaged. using the trouble diagnosis scan tool.
• There should be no dirt or foreign matter
blocking the DPD differential pressure sen- 15) If the situation falls in the area C or D, use
sor entrance. the trouble diagnosis scan tool to perform the
DPD forced slow regeneration.
response from the DPD differential pressure ANNOTATION:
sensor.
• When a DTC has been detected, clear it
4) If a problem is discovered, replace the DPD using the trouble diagnosis scan tool.
differential pressure sensor. • After the DPD forced slow regeneration is
Refer to "1.Engine 1G.Exhaust(6HK1X) Ex- completed, replace the engine oil.
Refer to "1.Engine 1G.Exhaust(6HK1X) Ex- 16) Use the trouble diagnosis scan tool to confirm
haust differential pressure sensor Installa- that the exhaust temperature (before the filter)
tion". display is at or below the standard value.
5) When the DPD differential pressure sensor Specified value: 130 °C {266 °F}
has been replaced, perform the 0-point cor- 17) If it is at or above the standard value, idle the
rection. engine until it falls to or below the standard
Refer to "1.Engine 1G.Exhaust(6HK1X) Ex- value.
haust differential pressure sensor Inspection". 18) Check the exhaust differential pressure data
6) Inspect the exhaust system. display when the exhaust temperature (in
front of the filter) data display has reached
• There should be no absence or damage of the standard value with the engine revolution
the exhaust pipe gasket. increased to the maximum revolution speed
• There should be no exhaust gas leak from without load.
the exhaust system. Specified value: 150 °C {302 °F}
• The exhaust system should not be modified. 19) Confirm if the exhaust differential pressure
• There should be no incorrect detection or data display is at or below the standard value.
slow response from the exhaust tempera- Specified value: 1.8 kPa {0.02 kgf/cm2 / 0.3
ture sensor. psi}
7) If a problem is discovered, repair or replace 20) If it is at or above the standard value, perform
the exhaust system. ash removal.
8) Inspect the engine cooling system for a factor Refer to "1.Engine 1G.Exhaust(6HK1X) DPD
causing overheat. assembly Inspection".
Refer to "1.Engine 1D.Cooling(6HK1X) 3. DTC P2458 Confirm Resolution
Coolant Inspection".
Refer to "1.Engine 1D.Cooling(6HK1X) Drive 1) Turn ON the starter switch.
belt Inspection". 2) Use the trouble diagnosis scan tool to confirm
Refer to "1.Engine 1D.Cooling(6HK1X) Ther- that a DTC has not been detected.
mostat Inspection".
Refer to "1.Engine 1D.Cooling(6HK1X) Water
pump assembly Inspection".
Refer to "1.Engine 1D.Cooling(6HK1X) Radi-
ator Inspection".
84402832 NA - May 2011

4023G-71
Engine-side Trouble
DTC P042B (Flash Code 145) DTC P042C (Flash Code 49)
Catalyst Temperature Sensor Catalyst Temperature Sensor
Circuit Range/Performance Circuit Low Sensor 2
Sensor 2 1. DTC P042C Priority DTC
DTC P0697
1. DTC P042B Priority DTC 2. DTC P042C Diagnostics
DTC P0093
DTC P042C 1) Turn OFF the starter switch.
DTC P1093 2) Disconnect the harness connector from the
2. DTC P042B Diagnostics exhaust gas temperature sensor 2.
3) Check the exhaust temperature sensor (be-
1) Inspect the exhaust gas temperature sensor fore the oxidation catalyst) display with the
2. trouble diagnosis scan tool.
Refer to "1.Engine 1G.Exhaust(6HK1X) Ex- Voltage： 4.5 V
haust gas temperature sensor Inspection". 4) If it is at or above the standard value, replace
2) If a problem is discovered, replace the ex- the exhaust gas temperature sensor 2.
haust gas temperature sensor 2. Refer to "1.Engine 1G.Exhaust(6HK1X) Ex-
Refer to "1.Engine 1G.Exhaust(6HK1X) Ex- haust gas temperature sensor Removal".
haust gas temperature sensor Removal". Refer to "1.Engine 1G.Exhaust(6HK1X) Ex-
Refer to "1.Engine 1G.Exhaust(6HK1X) Ex- haust gas temperature sensor Installation".
haust gas temperature sensor Installation". 5) Inspect to see if there is a short circuit to the
3) Inspect the DPD filter for a damage. GND with the signal circuit between the ECM
Refer to "1.Engine 1G.Exhaust(6HK1X) DPD and the exhaust gas temperature sensor 2.
assembly Inspection". 6) If a problem is discovered, repair the signal
4) If a problem is discovered, replace the DPD circuit.
filter. 7) Inspect the ECM harness connector for a con-
Refer to "1.Engine 1G.Exhaust(6HK1X) DPD tact failure.
assembly Disassembly". 8) If a problem is discovered, repair the harness
Refer to "1.Engine 1G.Exhaust(6HK1X) DPD connector.
assembly Reassembly". 9) If the harness connector is normal, replace the
5) Perform the DPD regeneration data reset with ECM.
the trouble diagnosis scan tool. Refer to "1.Engine 1J.Electrical(6HK1X) ECM
3. DTC P042B Confirm Resolution Removal".
1) Clear the DTC using the trouble diagnosis Installation".
scan tool. 10) Set the injector ID code on the ECM.
2) Turn the starter switch OFF for 30 seconds or 11) Perform the unit difference learning of the fuel
longer. supply pump to the ECM.
4) Perform a test-run. 3. DTC P042C Confirm Resolution
5) Use the trouble diagnosis scan tool to confirm 1) Clear the DTC using the trouble diagnosis
that a DTC has not been detected. scan tool.
longer.
84402832 NA - May 2011

4023G-72
Engine-side Trouble
DTC P042D (Flash Code 49) 16) If it is at or above the standard value, inspect
Catalyst Temperature Sensor tance with the signal circuit between the ECM
Circuit High Sensor 2 17)
and the exhaust gas temperature sensor 2.
1. DTC P042D Priority DTC circuit.
DTC P0697 18) Inspect to see if there is an open circuit or
2. DTC P042D Diagnostics high resistance in the GND circuit between the
ECM and the exhaust gas temperature sensor
1) Turn OFF the starter switch. 2.
exhaust gas temperature sensor 2. ANNOTATION:
• The exhaust gas temperature sensor 2
4) Measure the voltage between the exhaust gas
temperature sensor 2 signal circuit and nor-
mal GND.
Voltage： 5.5 V
or ignition power supply with the signal circuit 20) Inspect the ECM harness connector for a con-
between the ECM and the exhaust gas tem- tact failure.
perature sensor 2. 21) If a problem is discovered, repair the harness
6) If a problem is discovered, repair the signal connector.
circuit. 22) If the harness connector is normal, replace the
7) Connect the test cable with fuse between the ECM.
exhaust gas temperature sensor 2 signal cir- Refer to "1.Engine 1J.Electrical(6HK1X) ECM
cuit and GND circuit. Removal".
8) Check the exhaust temperature sensor (be- Refer to "1.Engine 1J.Electrical(6HK1X) ECM
fore the oxidation catalyst) display with the Installation".
trouble diagnosis scan tool. 23) Set the injector ID code on the ECM.
Voltage： 0.1 V 24) Perform the unit difference learning of the fuel
9) If it is at or below the standard value, inspect to supply pump to the ECM.
see if there is a short circuit to the 5 V power
supply circuit with the signal circuit between 3. DTC P042D Confirm Resolution
the ECM and the exhaust gas temperature 1) Clear the DTC using the trouble diagnosis
sensor 2. scan tool.
10) If a problem is discovered, repair the signal 2) Turn the starter switch OFF for 30 seconds or
circuit. longer.
11) Inspect to see if there is a contact failure with 3) Start the engine, and warm it up until the
the exhaust gas temperature sensor 2 har- coolant temperature reaches the standard
ness connector. value.
12) If a problem is discovered, repair the harness Specified value： 70 °C {158 °F}
connector. 4) Repeatedly rev the engine in neutral to in-
13) If the harness connector is normal, replace the crease the engine rpm while checking the ex-
exhaust gas temperature sensor 2. haust temperature sensor (in front of the oxi-
Refer to "1.Engine 1G.Exhaust(6HK1X) Ex- dation catalyst) display with the trouble diag-
haust gas temperature sensor Removal". nosis scan tool.
Refer to "1.Engine 1G.Exhaust(6HK1X) Ex- 5) Use the trouble diagnosis scan tool to con-
haust gas temperature sensor Installation". firm that the exhaust temperature sensor (be-
14) Connect the test cable with fuse between the fore the oxidation catalyst) display does not
exhaust gas temperature sensor 2 signal cir- exceed the standard value.
cuit and normal GND. Voltage ： 4.8 V Engine Control (6HK1X)
15) Check the exhaust temperature sensor (be- 1A-57
fore the oxidation catalyst) display with the 6) Use the trouble diagnosis scan tool to confirm
trouble diagnosis scan tool. that a DTC has not been detected.
Voltage： 0.1 V
84402832 NA - May 2011

4023G-73
Engine-side Trouble
DTC P060B (Flash Code 36) DTC P242F (Flash Code 131)
Internal Control Module A/D DPD Restriction
Processing Performance 1. DTC P242F Diagnostics
1. DTC P060B Diagnostics 1) Check with the operator if the DPD light has
blinked before.
1) Replace the ECM. Refer to "1.Engine 1J.Elec- 2) If necessary, explain DPD regeneration.
trical(6HK1X) ECM Removal".
Refer to "1.Engine 1J.Electrical(6HK1X) ECM • Check with the operator if the engine oper-
Installation". ating time was short.
2) Set the injector ID code on the ECM. • Ckeck with the operator if the idling time was
3) Perform the unit difference learning of the fuel too long.
3) Inspect the DPD differential pressure sensor
2. DTC P060B Confirm Resolution hose.
1) Clear the DTC using the trouble diagnosis • There should be no incorrect piping or dis-
scan tool. connection.
longer.
5) Inspect the DPD differential pressure sensor.
4) Perform a test-run. • DPD differential pressure sensor unit should
5) Use the trouble diagnosis scan tool to confirm not be damaged.
that a DTC has not been detected. • There should be no dirt or foreign matter
blocking the DPD differential pressure sen-
sor entrance.
response from the DPD differential pressure
sensor.
tion".
rection.
• There should be no absence or damage of
the exhaust pipe gasket.
the exhaust system.
• The exhaust system should not be modified.
• There should be no damage or excessive
deposits on the oxidation catalyst.
the exhaust system.
10) Inspect the DPD assembly.
assembly Inspection".
assembly.
12) If the DPD assembly has been replaced, use
the trouble diagnosis scan tool to perform
13) Inspect the mass air flow sensor with the trou-
air flow sensor.
84402832 NA - May 2011

4023G-74
Engine-side Trouble
15) Use the trouble diagnosis scan tool to check if 35) Check the exhaust differential pressure dis-
the boost pressure and atmospheric pressure play when the exhaust temperature (before
are operating properly. the filter) display has reached the standard
16) Inspect the air cleaner element. value with the throttle accelerator switch fully
Refer to "1.Engine 1F.Induction(6HK1X) Air depressed.
cleaner element Inspection". Specified value: 150 °C {302 °F}
17) If a problem is discovered, replace the air 36) Use the trouble diagnosis scan tool to check if
cleaner element. the exhaust differential pressure display is at
18) Inspect the intercooler. or below the standard value.
Refer to "1.Engine 1F.Induction(6HK1X) Inter- Specified value: 7.5 kPa {0.08 kgf/cm2 / 1.1
cooler Inspection". psi}
19) If a problem is discovered, replace the inter- 37) If it is at or above the standard value, replace
cooler. the DPD filter.
20) Check the intake duct for a clogging, hole, and Refer to "1.Engine 1G.Exhaust(6HK1X) DPD
leakage. assembly Disassembly".
21) If a problem is discovered, replace the intake Refer to "1.Engine 1G.Exhaust(6HK1X) DPD
duct. assembly Reassembly".
22) Inspect the intake throttle valve for fixing. 38) If the DPD filter has been replaced, use the
23) If a problem is discovered, replace the intake trouble diagnosis scan tool to perform DPD
throttle valve. regeneration data reset.
Refer to "1.Engine 1B.Mechanical(6HK1X) In- 39) When a DTC has been detected, clear it using
take throttle valve Removal". the trouble diagnosis scan tool.
Refer to "1.Engine 1B.Mechanical(6HK1X) In- 40) Turn the starter switch OFF for 30 seconds or
take throttle valve Installation". longer.
24) Inspect the turbocharger assembly. 41) Perform the DPD forced slow regeneration
Refer to "1.Engine 1F.Induction(6HK1X) Tur- with the trouble diagnosis scan tool.
ANNOTATION:
25) If a problem is discovered, replace the tur-
bocharger assembly. • After the DPD forced slow regeneration is
Refer to "1.Engine 1F.Induction(6HK1X) Tur- completed, replace the engine oil.
bocharger assembly Removal".
Refer to "1.Engine 1F.Induction(6HK1X) Tur- 42) Check the exhaust temperature (before the
bocharger assembly Installation". filter) display with the trouble diagnosis scan
26) Inspect the quality of fuel. tool.
43) Confirm that the exhaust temperature is at or
ANNOTATION: below the standard value.
• An appropriate fuel is used.
44) If it is at or above the standard value, idle the
27) Turn the starter switch ON for 30 seconds. engine until it falls to or below the standard
value.
ANNOTATION: 45) Check the exhaust differential pressure dis-
• Do not start the engine. play when the exhaust temperature 1 (in front
• This is for the DPD differential pressure sen- of the filter) display has reached the standard
sor to relearn. value with the engine revolution increased to
the maximum revolution speed without load.
28) Clear the DTC using the trouble diagnosis Specified value: 150 °C {302 °F}
scan tool. 46) Use the trouble diagnosis scan tool to check if
29) Perform the DPD regeneration data reset with the exhaust differential pressure display is at
the trouble diagnosis scan tool. or below the standard value.
30) Turn the starter switch OFF for 30 seconds or Specified value: 1.8 kPa {0.02 kgf/cm2 / 0.3
longer. psi}
31) Start the engine. 47) If it is at or above the standard value, perform
32) Check the exhaust temperature (before the ash removal.
filter) display with the trouble diagnosis scan Refer to "1.Engine 1G.Exhaust(6HK1X) DPD
tool. assembly Inspection".
33) Confirm that the exhaust temperature is at or
below the standard value. 2. DTC P242F Confirm Resolution
Specified value: 130°C {266 °F} 1) Turn ON the starter switch.
34) If it is at or above the standard value, idle the 2) Use the trouble diagnosis scan tool to confirm
engine until it falls to or below the standard that a DTC has not been detected.
value.
84402832 NA - May 2011

4023G-75
Engine-side Trouble
84402832 NA - May 2011

4023G-76
Section
4023H
Main Unit-side Trouble
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Main Unit-side Trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Diagnostic Trouble Code: 7000 P1 Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Diagnostic Trouble Code: 7001 P2 Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Diagnostic Trouble Code: 7002 N1 Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Diagnostic Trouble Code: 7003 N2 Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Diagnostic Trouble Code: 7004 Overload Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Diagnostic Trouble Code: 7005 Bottom Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Diagnostic Trouble Code: 7006 Rod Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Diagnostic Trouble Code: 7020 Upper Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Diagnostic Trouble Code: 7021 Swing Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Diagnostic Trouble Code: 7022 Travel Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Diagnostic Trouble Code: 7023 Arm-in Pressure Sensor Signal Abnormality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Diagnostic Trouble Code: 7040 Fuel Level Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Diagnostic Trouble Code: 7041 Oil Temperature Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Diagnostic Trouble Code: 7045 Monitor Thermistor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Diagnostic Trouble Code: 7060 Boom Angle Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Diagnostic Trouble Code: 7061 Arm Angle Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Diagnostic Trouble Code: 7063 Return Filter Clogging Pressure Switch Signal Abnormality. . . . . . . . . . . . . . . . . . 34
(Breaker specifications). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
(Other than breaker specifications) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Diagnostic Trouble Code: 7065 Boom-up Pilot Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . 36
Diagnostic Trouble Code: 7066 Bucket-close Pilot Pressure Sensor Signal Abnormality. . . . . . . . . . . . . . . . . . . . . 38
Diagnostic Trouble Code: 7200 Swing Brake Solenoid Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Diagnostic Trouble Code: 7201 Travel High-speed Solenoid Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Diagnostic Trouble Code: 7202 Pressure Boost Solenoid Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Diagnostic Trouble Code: 7203 Travel Alarm Buzzer Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Diagnostic Trouble Code: 7204 Power Save Solenoid Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Diagnostic Trouble Code: 7205 Feed Pump Relay Signal Abnormality　 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Diagnostic Trouble Code: 7206 Option Line Switchover Solenoid Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . 54
Diagnostic Trouble Code: 7207 Free Swing Solenoid Signal Abnormality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Diagnostic Trouble Code: 7210 Liftcrane Buzzer Signal Abnormality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Diagnostic Trouble Code: 7211 Rotating Light Relay and Bucket Lock Signal Abnormality . . . . . . . . . . . . . . . . . . . 58
Diagnostic Trouble Code: 7240 Pump Horsepower Proportional Valve Signal Abnormality . . . . . . . . . . . . . . . . . . . 59
Diagnostic Trouble Code: 7241 P1 Flow Control Proportional Valve Signal Abnormality . . . . . . . . . . . . . . . . . . . . . 61
Diagnostic Trouble Code: 7242 Fan Proportional Valve Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Diagnostic Trouble Code: 7246 2 Pumps Flow Solenoid Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Diagnostic Trouble Code: 7247 Boom-down Proportional Valve Signal Abnormality. . . . . . . . . . . . . . . . . . . . . . . . . 66
Diagnostic Trouble Code: 7248 Arm-in Proportional Valve Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Diagnostic Trouble Code: 7250 Option Relief Pressure Proportional Valve Signal Abnormality . . . . . . . . . . . . . . . 70
Diagnostic Trouble Code: 7251 Battery Control Relay Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Diagnostic Trouble Code: 7252 Idle Stop Relay Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Diagnostic Trouble Code: 7253 DPD Regeneration Request Output Signal Abnormality. . . . . . . . . . . . . . . . . . . . . 75
Diagnostic Trouble Code: 7400 Abnormally High Coolant Temperature (105°C or higher) . . . . . . . . . . . . . . . . . . . 77
Diagnostic Trouble Code: 7401 Abnormally High Coolant Temperature (110°C or higher). . . . . . . . . . . . . . . . . . . . 77
Diagnostic Trouble Code: 7402 Abnormally High Coolant Temperature (120°C or higher) . . . . . . . . . . . . . . . . . . . 77
Diagnostic Trouble Code: 7404 Abnormally High Oil Temperature (95°C or higher) . . . . . . . . . . . . . . . . . . . . . . . . . 78

4023H-1 PRINTED IN FRANCE
Diagnostic Trouble Code: 7405 Abnormally High Boost Temperature (80°C or higher), 7406 Abnormally High Boost
Temperature (90°C or higher) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Diagnostic Trouble Code: 7420 Abnormally Low Alternator Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Diagnostic Trouble Code: 7421 Coolant Level Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Diagnostic Trouble Code: 7422 Abnormally Low Engine Oil Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Diagnostic Trouble Code: 7423 Air Cleaner Clogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Diagnostic Trouble Code: 7424 Return Filter Clogging (breaker specifications). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Diagnostic Trouble Code: 7425 Fuel Density Error Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Diagnostic Trouble Code: 7600 CAN Bus Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Diagnostic Trouble Code: 7601 Monitor Communication Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Diagnostic Trouble Code: 7602 ECM Communication Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Diagnostic Trouble Code: 7604 Computer B Communication Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Diagnostic Trouble Code: 7605 ECM Mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Diagnostic Trouble Code: 7606 EEPROM Data Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Diagnostic Trouble Code: 7607 Computer C Communication Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93


Diagnostic Trouble Code: 7000 P1 Pressure Sensor Signal Abnormality
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7000 is displayed. Go to Step 2
Is diagnostic trouble code: 7000 displayed?
1. Inspect the connection status of each
connector.
2 2. Check whether diagnostic trouble code: Go to Step 3
7000 is displayed.
1. Check the P1 pressure sensor voltage
on the service support screen. 4.75 V or When 0.25 V or
3 Go to Step 4
higher lower, go to Step 8
Is it 4.75 V or higher?
Inspect for shorts to the power supply
1. Turn the key switch OFF and disconnect
CN. D45.
2. Turn the key switch ON. W400 harness defect
4 About 5 V Go to Step 5
3. Measure the voltage between the (short). Replace
ground and terminal 1 of the CN. D45
harness side.
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. D45 4.75 V or Y410 harness defect
5 harness side. Go to Step 6
lower (short). Replace
Is it 4.75 V or lower?
ground and terminal 3 of the CN. D45 0.25 V or BW420 harness de-
lower fect (short). Replace
Judge as a computer A defect.
7
…Replace computer A
1. Inspect the P1 pressure sensor.
2. Turn the key switch OFF.
3. Disconnect CN. D45.
8 4. Measure the resistance between termi- About 10 Go to Step 9 P1 pressure sensor
nals 1 and 3 of the CN. D45 P1 pressure kΩ defect. Replace
sensor side.
Is it about 10 kΩ?
Inspect for shorts to ground and disconnec-
tions.
1. Inspect for continuity between the
ground and terminal 1 of the CN. D45 W400 or Y410 har-
9 harness side. ness defect (short). Go to Step 10
2. Inspect for continuity between the Replace
harness side.
Is there continuity?
ground and terminal 3 of the CN. D45 BW420 harness de-
10 harness side. Go to Step 11 fect (disconnection).
Repair or replace
84402832 NA - May 2011

4023H-3
Standard
Step Action Yes No
value
2. Measure the voltage between the W400 or W401 har-
ground and terminal 1 of the CN. D45 About 5 V ness defect (discon-
11 Go to Step 12
harness side. nection). Repair or
replace
Is it about 5 V?
ground and terminal 2 of the CN. D45 0.25 V or Computer A defect. Y410 harness defect
12 harness side. (disconnection). Re-
higher Replace
place
1 COMPUTER A
2 PRESS. SENSOR (P1)
84402832 NA - May 2011

4023H-4
Diagnostic Trouble Code: 7001 P2 Pressure Sensor Signal Abnormality

Standard
Step Action Yes No
value
connector.
7001 is displayed.
1. Check the P2 pressure sensor voltage
3 Go to Step 4
CN. D46.
W400 or W401 har-
4 About 5 V Go to Step 5 ness defect (short).
Replace
harness side.
Is it about 5 V?
ground and terminal 2 of the CN. D46 4.75 V or L411 harness defect
ground and terminal 3 of the CN. D46 0.25 V or Computer A defect. BW420 or BW421
6 harness side. harness defect
lower Replace
(short). Replace
7 4. Measure the resistance between termi- About 10 Go to Step 8 P2 pressure sensor
nals 1 and 3 of the CN. D46 P2 pressure kΩ defect. Replace
sensor side.
Is it about 10 kΩ?
tions.
ground and terminal 1 of the CN. D46 W400, W401, or
8 harness side. L411 harness defect Go to Step 9
2. Inspect for continuity between the (short). Replace
harness side.
1. Inspect for continuity between the BW420 or BW421
ground and terminal 3 of the CN. D46 harness defect (dis-
connection). Repair
Is there continuity? or replace
84402832 NA - May 2011

4023H-5
Standard
Step Action Yes No
value
10 Go to Step 11
replace
Is it about 5 V?
ground and terminal 2 of the CN. D46 0.25 V or Computer A defect. L411 harness defect
higher Replace
place
1 COMPUTER A
2 PRESS. SENSOR (P1)
84402832 NA - May 2011

4023H-6
Diagnostic Trouble Code: 7002 N1 Pressure Sensor Signal Abnormality

Standard
Step Action Yes No
value
connector.
7002 is displayed.
1. Check the N1 pressure sensor voltage
3 Go to Step 4
CN. D47.
W400 or W402 har-
Replace
harness side.
Is it about 5 V?
ground and terminal 2 of the CN. D47 4.75 V or Lg412 harness de-
lower Replace
(short). Replace
7 4. Measure the resistance between termi- About 10 Go to Step 8 N1 pressure sensor
nals 1 and 3 of the CN. D47 N1 pressure kΩ defect. Replace
sensor side.
Is it about 10 kΩ?
tions.
8 harness side. Lg412 harness de- Go to Step 9
2. Inspect for continuity between the fect (short). Replace
harness side.
connection). Repair
84402832 NA - May 2011

4023H-7
Standard
Step Action Yes No
value
10 Go to Step 11
replace
Is it about 5 V?
ground and terminal 2 of the CN. D47 0.25 V or Computer A defect. Lg412 harness de-
11 harness side. fect (disconnection).
higher Replace
Repair or replace
1 COMPUTER A
2 PRESS. SENSOR (N1)
84402832 NA - May 2011

4023H-8
Diagnostic Trouble Code: 7003 N2 Pressure Sensor Signal Abnormality

Standard
Step Action Yes No
value
connector.
7003 is displayed.
1. Check the N2 pressure sensor voltage
3 Go to Step 4
CN. D48.
W400 or W403 har-
Replace
harness side.
Is it about 5 V?
ground and terminal 2 of the CN. D48 4.75 V or G413 harness defect
lower Replace
(short). Replace
1. Inspect the N2 pressure sensor.
7 4. Measure the resistance between termi- About 10 Go to Step 8 N2 pressure sensor
nals 1 and 3 of the CN. D48 N2 pressure kΩ defect. Replace
sensor side.
Is it about 10 kΩ?
tions.
8 harness side. G413 harness defect Go to Step 9
harness side.
connection). Repair
84402832 NA - May 2011

4023H-9
Standard
Step Action Yes No
value
10 Go to Step 11
replace
Is it about 5 V?
ground and terminal 2 of the CN. D48 0.25 V or Computer A defect. G413 harness defect
higher Replace
pair or replace
1 COMPUTER A
2 PRESS. SENSOR (N2)
84402832 NA - May 2011

4023H-10
Diagnostic Trouble Code: 7004 Overload Pressure Sensor Signal

Abnormality
Standard
Step Action Yes No
value
connector.
7004 is displayed.
1. Check the overload pressure sensor
3 voltage on the service support screen. 4.75 V or Go to Step 4 When 0.25 V or
CN. D52-1.
W400 or W409 har-
Replace
ground and terminal 1 of the CN. D52-1
harness side.
Is it about 5 V?
ground and terminal 2 of the CN. D52-1 4.75 V or Gr419 harness de-
ground and terminal 3 of the CN. D52-1 0.25 V or Computer A defect. BW420 or BW429
lower Replace
(short). Replace
1. Inspect the overload pressure sensor.
3. Disconnect CN. D52-1. Overload pressure
7 4. Measure the resistance between termi- About 10 Go to Step 8 sensor defect. Re-
nals 1 and 3 of the CN. D52-1 overload kΩ place
pressure sensor side.
Is it about 10 kΩ?
tions.
ground and terminal 1 of the CN. D52-1 W400, W409, or
8 harness side. Gr419 harness de- Go to Step 9
harness side.
ground and terminal 3 of the CN. D52-1 harness defect (dis-
connection). Repair
84402832 NA - May 2011

4023H-11
Standard
Step Action Yes No
value
ground and terminal 1 of the CN. D52-1 About 5 V ness defect (discon-
10 Go to Step 11
replace
Is it about 5 V?
ground and terminal 2 of the CN. D52-1 0.25 V or Computer A defect. Gr419 harness de-
higher Replace
Repair or replace
1 COMPUTER A
2 PRESS. SENSOR (HBCV)
84402832 NA - May 2011

4023H-12
Diagnostic Trouble Code: 7005 Bottom Pressure Sensor Signal

Abnormality
Standard
Step Action Yes No
value
connector.
7005 is displayed.
1. Check the bottom pressure sensor volt-
age on the service support screen. 4.75 V or When 0.25 V or
3 Go to Step 4
CN. CR9.
2. Turn the key switch ON. W414 harness defect
4 About 5 V Go to Step 5
3. Measure the voltage between the (short). Replace
ground and terminal 1 of the CN. CR9
harness side.
Is it about 5 V?
ground and terminal 2 of the CN. CR9 4.75 V or Y434 harness defect
ground and terminal 3 of the CN. CR9 0.25 V or Computer B defect. BW454 harness de-
6 harness side. lower Replace fect (short). Replace
Inspect the bottom pressure sensor.
2. Disconnect CN. CR9.
About 10 Bottom pressure sen-
7 3. Measure the resistance between termi- Go to Step 8
kΩ sor defect. Replace
nals 1 and 3 of the CN. CR9 bottom sen-
sor.
Is it about 10 kΩ?
tions.
ground and terminal 1 of the CN. CR9 W414 or Y434 har-
8 harness side. ness defect (short). Go to Step 9
2. Inspect for continuity between the Replace
harness side.
ground and terminal 3 of the CN. CR9 BW454 harness de-
Repair or replace
84402832 NA - May 2011

4023H-13
Standard
Step Action Yes No
value
2. Measure the voltage between the W414 harness defect
10 ground and terminal 1 of the CN. CR9 About 5 V Go to Step 11 (disconnection). Re-
harness side. pair or replace
Is it about 5 V?
ground and terminal 2 of the CN. CR9 0.25 V or Computer B defect. Y434 harness defect
higher Replace
pair or replace
84402832 NA - May 2011

4023H-14
Diagnostic Trouble Code: 7006 Rod Pressure Sensor Signal Abnormality

Standard
Step Action Yes No
value
connector.
7006 is displayed.
1. Check the rod pressure sensor voltage
3 Go to Step 4
CN. CR10.
W414 or W415 har-
Replace
harness side.
Is it about 5 V?
ground and terminal 2 of the CN. CR10 4.75 V or L435 harness defect
ground and terminal 3 of the CN. CR10 0.25 V or Computer B defect. BW454 or BW455
lower Replace
(short). Replace
Inspect the rod pressure sensor.
About 10 Rod pressure sensor
kΩ defect. Replace
nals 1 and 3 of the CN. CR10 rod pres-
sure sensor side.
Is it about 10 kΩ?
tions.
ground and terminal 1 of the CN. CR10 W414, W415, or
8 harness side. L435 harness defect Go to Step 9
harness side.
ground and terminal 3 of the CN. CR10 harness defect (dis-
connection). Repair
84402832 NA - May 2011

4023H-15
Standard
Step Action Yes No
value
ground and terminal 1 of the CN. CR10 About 5 V ness defect (discon-
10 Go to Step 11
replace
Is it about 5 V?
ground and terminal 2 of the CN. CR10 0.25 V or Computer B defect. L435 harness defect
higher Replace
pair or replace
84402832 NA - May 2011

4023H-16
Diagnostic Trouble Code: 7020 Upper Pressure Sensor Signal

Abnormality
Standard
Step Action Yes No
value
connector.
7020 is displayed.
1. Check the upper pressure sensor volt-
3 Go to Step 4
CN. D50.
W400 or W405 har-
Replace
harness side.
Is it about 5 V?
ground and terminal 2 of the CN. D50 4.75 V or V415 harness defect
lower Replace
(short). Replace
1. Inspect the upper pressure sensor.
7 4. Measure the resistance between termi- About 10 Go to Step 8 Upper pressure sen-
nals 1 and 3 of the CN. D50 upper pres- kΩ sor defect. Replace
sure sensor side.
Is it about 10 kΩ?
tions.
8 harness side. V415 harness defect Go to Step 9
harness side.
connection). Repair
84402832 NA - May 2011

4023H-17
Standard
Step Action Yes No
value
10 Go to Step 11
replace
Is it about 5 V?
ground and terminal 2 of the CN. D50 0.25 V or Computer A defect. V415 harness defect
higher Replace
pair or replace
1 COMPUTER A
PRESS. SENSOR (PILOT UP-
2
PER)
84402832 NA - May 2011

4023H-18
Diagnostic Trouble Code: 7021 Swing Pressure Sensor Signal

Abnormality
Standard
Step Action Yes No
value
connector.
7021 is displayed.
1. Check the swing pressure sensor volt-
3 Go to Step 4
CN. D49.
W400 or W404 har-
Replace
harness side.
Is it about 5 V?
ground and terminal 2 of the CN. D49 4.75 V or GR414 harness de-
lower Replace
(short). Replace
1. Inspect the swing pressure sensor.
7 4. Measure the resistance between termi- About 10 Go to Step 8 Swing pressure sen-
nals 1 and 3 of the CN. D49 swing pres- kΩ sor defect. Replace
sure sensor side.
Is it about 10 kΩ?
tions.
8 harness side. GR414 harness de- Go to Step 9
harness side.
connection). Repair
84402832 NA - May 2011

4023H-19
Standard
Step Action Yes No
value
10 Go to Step 11
replace
Is it about 5 V?
ground and terminal 2 of the CN. D49 0.25 V or Computer A defect. GR414 harness de-
higher Replace
Repair or replace
1 COMPUTER A
2
SWING)
84402832 NA - May 2011

4023H-20
Diagnostic Trouble Code: 7022 Travel Pressure Sensor Signal

Abnormality
Standard
Step Action Yes No
value
connector.
7022 is displayed.
1. Check the travel pressure sensor volt-
3 Go to Step 4
CN. D51.
W400 or W406 har-
Replace
harness side.
Is it about 5 V?
ground and terminal 2 of the CN. D51 4.75 V or YG416 harness de-
lower Replace
(short). Replace
1. Inspect the travel pressure sensor.
7 4. Measure the resistance between termi- About 10 Go to Step 8 Travel pressure sen-
nals 1 and 3 of the CN. D51 travel pres- kΩ sor defect. Replace
sure sensor side.
Is it about 10 kΩ?
tions.
8 harness side. YG416 harness de- Go to Step 9
harness side.
connection). Repair
84402832 NA - May 2011

4023H-21
Standard
Step Action Yes No
value
10 Go to Step 11
replace
Is it about 5 V?
ground and terminal 2 of the CN. D51 0.25 V or Computer A defect. YG416 harness de-
higher Replace
Repair or replace
1 COMPUTER A
2
TRAVEL)
84402832 NA - May 2011

4023H-22
Diagnostic Trouble Code: 7023 Arm-in Pressure Sensor Signal

Abnormality
Standard
Step Action Yes No
value
connector.
7023 is displayed.
1. Check the arm-in pressure sensor volt-
3 Go to Step 4
CN. D54.
3. Measure the voltage between the About 5 V WL430 harness de-
4 Go to Step 5
ground and terminal 1 of the CN. D54 fect (short). Replace
harness side.
-
Is it about 5 V?
1. 1. Measure the voltage between the
harness side. 4.75 V or YG445 harness de-
5 Go to Step 6
-
1. 1. Measure the voltage between the
harness side. 0.25 V or Computer B defect. BL450 harness de-
6
lower Replace fect (short). Replace
-
1. Inspect the arm-in pressure sensor.
7 4. Measure the resistance between termi- About 10 Go to Step 8 Arm-in pressure sen-
nals 1 and 3 of the CN. D54 arm-in pres- kΩ sor defect. Replace
sure sensor side.
Is it about 10 kΩ?
tions.
ground and terminal 1 of the CN. D54 WL430 or YG445
8 harness side. harness defect Go to Step 9
harness side.
ground and terminal 3 of the CN. D54 BL450 harness de-
Repair or replace
84402832 NA - May 2011
4023H-23
Standard
Step Action Yes No
value
2. Measure the voltage between the WL430 harness de-
10 ground and terminal 1 of the CN. D54 About 5 V Go to Step 11 fect (disconnection).
harness side. Repair or replace
Is it about 5 V?
ground and terminal 2 of the CN. D54 0.25 V or Computer B defect. YG445 harness de-
higher Replace
Repair or replace
84402832 NA - May 2011

4023H-24
Diagnostic Trouble Code: 7040 Fuel Level Sensor Signal Abnormality

Standard
Step Action Yes No
value
connector and ground.
7040 is displayed.
1. Check the fuel level sensor resistance
on the service support screen. 100 Ω or When 2 Ω or lower,
3 Go to Step 4
higher go to Step 7
Is it 100 Ω or higher?
Inspect for disconnection.
CN. D57.
2. Measure the resistance between termi- Fuel level sensor de-
4 Go to Step 5
nals 1 and 2 of the CN. D57 fuel level fect. Replace
sensor side.(See the Float position and
resistance table.)
Is it the standard value?
1. Inspect for continuity between the BG660 or BG601
connection). Repair
2. Measure the voltage between the GL492 harness de-
ground and terminal 2 of the CN. D57 About 5 V Computer A defect.
6 fect (disconnection).
harness side. Replace
Repair or replace
Is it about 5 V?
Inspect for shorts.
2. Connect CN. D57.
GL492 harness de-
7 3. Inspect for continuity between the Go to Step 8
fect (short). Replace
harness side.
2. Measure the voltage between the BG660 or BG601
ground and terminal 1 of the CN. D57 0 V Computer A defect.
8 harness defect
(short). Replace
Is it 0 V?
84402832 NA - May 2011

4023H-25
1 COMPUTER A
2 FUEL LEVEL SENSOR
84402832 NA - May 2011

4023H-26
Diagnostic Trouble Code: 7041 Oil Temperature Sensor Signal

Abnormality
Standard
Step Action Yes No
value
connector.
7040 is displayed.
1. Check the oil temperature sensor resis-
tance (or voltage) on the service support 67200 Ω (or When 111 Ω (or 0.5
3 screen. 4.93 V) or Go to Step 4 V) or lower, go to
higher Step 7
Is it 67200 Ω (or 4.93 V) or higher?
CN. D56.
2. Measure the resistance between termi- Oil temperature sen-
4 Go to Step 5
nals 1 and 2 of the CN. D56 oil temper- sor defect. Replace
ature sensor side.(See the Oil tempera-
ture and resistance table.)
Is it the standard value?
connection). Repair
2. Measure the voltage between the YB490 harness de-
Repair or replace
Is it about 5 V?
Inspect for shorts.
2. Connect CN. D56.
YB490 harness de-
harness side.
2. Measure the voltage between the BW491 or BW420
8 harness defect
(short). Replace
Is it 0 V?
84402832 NA - May 2011

4023H-27
1 COMPUTER A
2 HYD. OIL TEMP SENSOR
84402832 NA - May 2011

4023H-28
Diagnostic Trouble Code: 7045 Monitor Thermistor Signal Abnormality

Standard
Step Action Yes No
value
Monitor defect. Replace
CAUTION
Contrast correction is
performed when the
1. Turn the key switch ON. monitor thermistor is
2. On the service support DIAG at an extremely high
screen, or low temperature.
check whether diagnostic trouble Even if the monitor
1
code: 7045 (●) is displayed. thermistor has a de-
fect, there is a correc-
Is diagnostic trouble code: 7045 (●) dis- tion function inside
played? the monitor, so the
monitor thermistor
does not need to be
replaced if the moni-
tor contrast is not sig-
nificantly affected.
84402832 NA - May 2011

4023H-29
Diagnostic Trouble Code: 7060 Boom Angle Sensor Signal Abnormality

Standard
Step Action Yes No
value
connector.
7060 is displayed.
1. Check the boom angle sensor voltage
on the service support screen. 4.8 V or When 0.2 V or lower,
3 Go to Step 4
higher go to Step 7
CN. CR11.
W414 or W416 har-
Replace
harness side.
Is it about 5 V?
ground and terminal 2 of the CN. CR11 4.8 V or Lg436 harness de-
ground and terminal 1 of the CN. CR11 0.2 V BW454 or BW456
or Computer B defect.
lower Replace
(short). Replace
Inspect the boom angle sensor.
About 10 Boom angle sensor
kΩ defect. Replace
nals 1 and 3 of the CN. CR11 boom an-
gle sensor side.
Is it about 10 kΩ?
tions.
ground and terminal 3 of the CN. CR11 W414, W416, or
8 harness side. Lg436 harness de- Go to Step 9
harness side.
ground and terminal 1 of the CN. CR11 harness defect (dis-
connection). Repair
84402832 NA - May 2011

4023H-30
Standard
Step Action Yes No
value
10 Go to Step 11
replace
Is it about 5 V?
ground and terminal 2 of the CN. CR11 0.2 V Lg436 harness de-
higher Replace
Repair or replace
84402832 NA - May 2011

4023H-31
Diagnostic Trouble Code: 7061 Arm Angle Sensor Signal Abnormality

Standard
Step Action Yes No
value
connector.
7061 is displayed.
1. Check the arm angle sensor voltage on
the service support screen. 4.8 V or When 0.2 V or lower,
3 Go to Step 4
higher go to Step 7
CN. CR12.
BW457 or W414 har-
Replace
harness side.
Is it about 5 V?
ground and terminal 2 of the CN. CR12 4.8 V or Br437 harness defect
ground and terminal 3 of the CN. CR12 0.2 V BW454 or W417 har-
6 harness side. ness defect (short).
lower Replace
Replace
Inspect the arm angle sensor.
About 10 Arm angle sensor de-
kΩ fect. Replace
nals 1 and 3 of the CN. CR12 arm angle
sensor side.
Is it about 10 kΩ?
tions.
ground and terminal 1 of the CN. CR12 BW457, W414, or
8 harness side. Br437 harness defect Go to Step 9
harness side.
1. Inspect for continuity between the BW454 or W417 har-
ground and terminal 3 of the CN. CR12 ness defect (discon-
nection). Repair or
Is there continuity? replace
84402832 NA - May 2011

4023H-32
Standard
Step Action Yes No
value
2. Measure the voltage between the BW457 or W414 har-
10 Go to Step 11
replace
Is it about 5 V?
ground and terminal 2 of the CN. CR12 0.2 V Br437 harness defect
higher Replace
pair or replace
84402832 NA - May 2011

4023H-33
Diagnostic Trouble Code: 7063

Return Filter Clogging Pressure
Switch Signal Abnormality
(Breaker specifications)
Standard
Step Action Yes No
value
7063 is displayed.
Inspect the return filter clog pressure switch.
CN. D81. Return filter clog
3 2. Inspect for continuity between terminals Go to Step 4 pressure switch de-
1 and 2 of the CN. D81 return filter clog fect. Replace
pressure switch side.
1. Inspect for continuity between the BG652 harness de-
4 ground and terminal 1 of the CN. D81 Go to Step 5 fect (disconnection).
harness side. Repair or replace
2. Measure the voltage between the YL538 harness de-
Repair or replace
Is it about 5 V?
1 COMPUTER A
PRESS. SWITCH (FILTER IN-
2
DICATOR)
84402832 NA - May 2011

4023H-34
(Other than breaker specifications)

Standard
Step Action Yes No
value
7063 is displayed.
CN. D81. Jump harness defect
3 2. Inspect for continuity between terminals Go to Step 4 (disconnection). Re-
1 and 2 of the CN. D81 jump harness pair or replace
side.
ground and terminal 1 of the CN. D81 BG652 harness de-
Repair or replace
2. Measure the voltage between the YL538 harness de-
Repair or replace
Is it about 5 V?
1 COMPUTER A
84402832 NA - May 2011

4023H-35
Diagnostic Trouble Code: 7065 Boom-up Pilot Pressure Sensor Signal

Abnormality
Standard
Step Action Yes No
value
connector.
7065 is displayed.
1. Check the boom-up pilot pressure sen-
sor voltage on the service support 4.75 V or When 0.25 V or
3 screen. Go to Step 4
CN. D53.
WL432 or WL430
4 About 5 V Go to Step 5 harness defect
(short). Replace
harness side.
Is it about 5 V?
ground and terminal 2 of the CN. D53 4.75 V or GW444 harness de-
ground and terminal 3 of the CN. D53 0.25 V or Computer B defect. BL452 or BL450 har-
lower Replace
Replace
1. Inspect the boom-up pilot pressure sen-
sor.
3. Disconnect CN. D53. Boom-up pilot pres-
About 10
7 4. Measure the resistance between termi- kΩ Go to Step 8 sure sensor defect.
nals 1 and 3 of the CN. D53 boom-up Replace
pilot pressure sensor side.
Is it about 10 kΩ?
tions.
ground and terminal 1 of the CN. D53 WL432, WL430, or
8 harness side. GW444 harness de- Go to Step 9
harness side.
1. Inspect for continuity between the BL452 or BL450 har-
ground and terminal 3 of the CN. D53 ness defect (discon-
nection). Repair or
84402832 NA - May 2011

4023H-36
Standard
Step Action Yes No
value
2. Measure the voltage between the WL432 or WL430
ground and terminal 1 of the CN. D53 About 5 V harness defect (dis-
10 Go to Step 11
harness side. connection). Repair
or replace
Is it about 5 V?
ground and terminal 2 of the CN. 120 0.25 V or Computer B defect. GW444 harness de-
higher Replace
Repair or replace
84402832 NA - May 2011

4023H-37
Diagnostic Trouble Code: 7066 Bucket-close Pilot Pressure Sensor

Signal Abnormality
Standard
Step Action Yes No
value
connector.
7067 is displayed.
1. Check the bucket-close pilot pressure
sensor voltage on the service support 4.75 V or When 0.25 V or
3 screen. Go to Step 4
CN. D55.
WL431 or WL430
4 About 5 V Go to Step 5 harness defect
(short). Replace
harness side.
Is it about 5 V?
ground and terminal 2 of the CN. D55 4.75 V or LR446 harness de-
ground and terminal 3 of the CN. D55 0.25 V or Computer B defect. BL451 or BL450 har-
lower Replace
Replace
Inspect the bucket-close pilot pressure sen-
sor.
Bucket-close pilot
2. Disconnect CN. D55. About 10
7 Go to Step 8 pressure sensor de-
3. Measure the resistance between termi- kΩ
fect. Replace
nals 1 and 3 of the CN. D55 bucket-
close pilot pressure sensor side.
Is it about 10 kΩ?
tions.
ground and terminal 1 of the CN. D55 WL431, WL430, or
8 harness side. LR446 harness de- Go to Step 9
harness side.
1. Inspect for continuity between the BL451 or BL450 har-
ground and terminal 3 of the CN. D55 ness defect (discon-
nection). Repair or
84402832 NA - May 2011

4023H-38
Standard
Step Action Yes No
value
2. Measure the voltage between the WL431 or WL430
ground and terminal 1 of the CN. D55 About 5 V harness defect (dis-
10 Go to Step 11
harness side. connection). Repair
or replace
Is it about 5 V?
ground and terminal 2 of the CN. D55 0.25 V or Computer B defect. LR446 harness de-
higher Replace
Repair or replace
84402832 NA - May 2011

4023H-39
Diagnostic Trouble Code: 7200 Swing Brake Solenoid Signal

Abnormality
Standard
Step Action Yes No
value
connector.
2. Inspect the fusible link F1 (65 A) fuse
and fuse box F13 (10 A) fuse to see if
2 either is blown. Go to Step 3
7200 is displayed.
Inspect the swing brake solenoid.
CN. D60.
Swing brake solenoid
3 2. Measure the resistance between termi- 34 Ω - 47 Ω Go to Step 4
defect. Replace
nals 1 and 2 of the CN. D60 swing brake
solenoid side.
Is it 34 Ω - 47 Ω?
Inspect for shorts.
2. Measure the voltage between the W800 harness defect
4 0V Go to Step 5
ground and terminal 2 of the CN. D60 (short). Replace
harness side.
Is it 0 V?
2. Inspect for continuity between the R181, GR180, R105,
5 ground and terminal 1 of the CN. D60 or R104 harness de- Go to Step 6
harness side. fect (short). Replace
W800 harness defect
Inspect for continuity between the ground
6 Go to Step 7 (disconnection). Re-
and terminal 2 of the CN. D60 harness side.
pair or replace
2. Measure the voltage between the R181, GR180, R105,
ground and terminal 1 of the CN. D60 24 V Computer A defect. or R104 harness de-
7
harness side. Replace fect (disconnection).
Repair or replace
Is it 24 V?
84402832 NA - May 2011

4023H-40
1 COMPUTER A 6 FUSE CONT 11 RELAY KEY ON

2 ENGINE COMPUTER 7 SWING BRAKE 12 FUSIBLE LINK FUSE BOX
3 8 RELAY BATTERY 13 KEY SWITCH
SWING)
4 9 BATTERY (24 V)
PER)
5 CRANK ANGLE SENSOR 10 FUSIBLE LINK BACK UP
a CAN COMMUNICATION
84402832 NA - May 2011

4023H-41
Diagnostic Trouble Code: 7201 Travel High-speed Solenoid Signal

Abnormality
Standard
Step Action Yes No
value
connector.
7201 is displayed.
Inspect the travel high-speed solenoid.
CN. D61. Travel high-speed
3 2. Measure the resistance between ter- 34 Ω - 47 Ω Go to Step 4 solenoid defect. Re-
minals 1 and 2 of the CN. D61 travel place
high-speed solenoid side.
Is it 34 Ω - 47 Ω?
Inspect for shorts.
2. Measure the voltage between the L801 harness defect
4 0V Go to Step 5
harness side.
Is it 0 V?
2. Inspect for continuity between the R183, GR180,
ground and terminal 1 of the CN. D61 R105a, R104, or
5 Go to Step 6
harness side. R105 harness defect
(short). Replace
L801 harness defect
pair or replace
1. Turn the key switch ON. R183, GR180,
2. Measure the voltage between the R105a, R104, or
7 R105 harness defect
(disconnection). Re-
Is it 24 V? pair or replace
84402832 NA - May 2011

4023H-42
1 COMPUTER A 5 FUSE CONT 9 FUSE KEY

2 ENGINE COMPUTER 6 2 STAGE TRAVEL 10 RELAY KEY ON
3 7 RELAY BATTERY 11 FUSIBLE LINK FUSE BOX
TRAVEL)
4 CRANK ANGLE SENSOR 8 BATTERY (24 V) 12 KEY SWITCH
a CAN COMMUNICATION
84402832 NA - May 2011

4023H-43
Diagnostic Trouble Code: 7202 Pressure Boost Solenoid Signal

Abnormality
Standard
Step Action Yes No
value
connector.
7202 is displayed.
Inspect the pressure boost solenoid.
CN. D62.
Pressure boost sole-
noid defect. Replace
nals 1 and 2 of the CN. D62 pressure
boost solenoid side.
Is it 34 Ω - 47 Ω?
Inspect for shorts.
2. Measure the voltage between the Y802 harness defect
4 0V Go to Step 5
harness side.
Is it 0 V?
Y802 harness defect
pair or replace
7
Repair or replace
Is it 24 V?
84402832 NA - May 2011

4023H-44
84402832 NA - May 2011

4023H-45

1 COMPUTER A 7 13 BATTERY (24 V)
TRAVEL)
PRESS. SWITCH (1ST OP-
2 ENGINE COMPUTER 8 14 BACK UP FUSIBLE LINK
TION)
PRESS. SWITCH (2ND OP-
3 THROTTLE VOL. 9 15 RELAY KEY ON
TION)
4 PRESS. SENSOR (P1) 10 FUSE CONT 16 MONITOR DISPLAY
5 PRESS. SENSOR (P2) 11 2 STAGE RELIEF 17 FUSIBLE LINK FUSE BOX
PER)
a CAN COMMUNICATION
84402832 NA - May 2011

4023H-46
Diagnostic Trouble Code: 7203 Travel Alarm Buzzer Signal Abnormality

Standard
Step Action Yes No
value
2. On the service support DIAG screen,
check whether diagnostic trouble code:
1 7203 (●) is displayed. Go to Step 2
Is diagnostic trouble code: 7203 (●) dis-
played?
connector.
2 and fuse box F21 (10 A) fuse to see if Go to Step 3
either is blown.
Are 1 and 2 above both OK?
Inspect the travel alarm.
CN. D69.
2. Connect terminal 1 of the CN. D69 travel
Travel alarm defect.
3 alarm side to the negative terminal of Go to Step 4
Replace
the battery and terminal 2 to the positive
terminal, and inspect the operation of
the travel alarm.
Does the travel alarm sound?
Inspect for shorts.
2. Measure the voltage between the WL807 harness de-
4 0V Go to Step 5
ground and terminal 1 of the CN. D69 fect (short). Replace
harness side.
Is it 0 V?
2. Inspect for continuity between the GW215, R105, or
5 ground and terminal 2 of the CN. D69 R104 harness defect Go to Step 6
harness side. (short). Replace
Inspect whether there is continuity between
WL807 harness de-
the ground and terminal 1 of the CN. D69
6 Go to Step 7 fect (disconnection).
harness side for 0.4 sec. after the key switch
Repair or replace
is turned ON.
2. Measure the voltage between the GW215, R105, or
ground and terminal 2 of the CN. D69 24 V Computer A defect. R104 harness defect
7
harness side. Replace (disconnection). Re-
pair or replace
Is it 24 V?
84402832 NA - May 2011

4023H-47
1 COMPUTER A 5 BACK UP FUSIBLE LINK 9 FUSIBLE LINK FUSE BOX

TRAVEL)
3 FUSE CONT 7 RELAY KEY ON
4 TRAVEL ALARM 24 V, 107 dB 8 BATTERY (24 V)
84402832 NA - May 2011

4023H-48
Diagnostic Trouble Code: 7204 Power Save Solenoid Signal Abnormality

Standard
Step Action Yes No
value
connector.
7204 is displayed.
Inspect the power save solenoid.
CN. D60.
Power save solenoid
defect. Replace
nals 1 and 2 of the CN. D60 power save
solenoid side.
Is it 34 Ω - 47 Ω?
Inspect for shorts.
2. Measure the voltage between the G812 harness defect
4 0V Go to Step 5
harness side.
Is it 0 V?
G812 harness defect
pair or replace
7
Repair or replace
Is it 24 V?
84402832 NA - May 2011

4023H-49
84402832 NA - May 2011

4023H-50
1 COMPUTER A 6 CRANK ANG (MRE) SENSOR 11 RELAY BATTERY

2 ENGINE COMPUTER 7 FUSE CONT 12 FUSIBLE LINK BACK UP
3 8 POWER SAVE 13 FUSIBLE LINK FUSE BOX
SWING)
PER)
5 10 BATTERY (24 V) 15 COMPUTER B
TRAVEL)
a CAN COMMUNICATION
84402832 NA - May 2011

4023H-51
Diagnostic Trouble Code: 7205 Feed Pump Relay Signal Abnormality　

Standard
Step Action Yes No
value
connector.
2. Inspect the fusible link F (65 A) fuse and
2 fuse box F19 (30 A) fuse to see if either Go to Step 3
is blown.
Inspect the feed pump relay.
CN. D83-1.
Feed pump relay de-
3 2. Inspect for continuity between terminals Go to Step 4
fect. Replace
1 and 2 of the CN. D83-1 feed pump
relay side.
Inspect for shorts.
VR845, W250,
1. Install CN. D83-1.
VR894, L846, or
4 R105 harness defect Go to Step 5
(short). Replace
harness side.
VR845, W250,
VR894, L846, or
2. Inspect for continuity between the Computer B defect.
5 R105 harness defect
ground and terminal 1 of the CN. D83-1 Replace
(disconnection). Re-
harness side.
pair or replace
84402832 NA - May 2011

4023H-52
1 RELAY BATTERY 4 RELAY STOP 7 REFUEL PUMP

2 FUSIBLE LINK FUSE BOX 5 MANUAL/AUTO 8 MONITOR DISPLAY
3 RELAY PUMP 6 ALARM 24V,107dB
84402832 NA - May 2011

4023H-53
Diagnostic Trouble Code: 7206 Option Line Switchover Solenoid Signal

Abnormality
Standard
Step Action Yes No
value
connector.
fuse box F20 (10 A) fuse to see if either
2 is blown. Go to Step 3
7206 is displayed.
Inspect the option line switchover solenoid.
CN. 162. Option line
3 2. Measure the resistance between termi- 34 Ω - 47 Ω Go to Step 4 switchover solenoid
nals 1 and 2 of the CN. 162 option line defect. Replace
switchover solenoid side.
Is it 34 Ω - 47 Ω?
Inspect for shorts.
2. Measure the voltage between the LY806 harness de-
4 0V Go to Step 5
ground and terminal 2 of the CN. 162 fect (short). Replace
harness side.
Is it 0 V?
2. Inspect for continuity between the WL260 or SR105
5 ground and terminal 1 of the CN. 162 harness defect Go to Step 6
LY806 harness de-
and terminal 2 of the CN. 162 harness side.
Repair or replace
2. Measure the voltage between the WL260 or SR105
ground and terminal 1 of the CN. 162 24 V Computer A defect. harness defect (dis-
7
harness side. Replace connection). Repair
or replace
Is it 24 V?
84402832 NA - May 2011

4023H-54
1 RELAY BATTERY 3 OPTION SELECT

2 FUSIBLE LINK FUSE BOX 4 CONTROLLER A
84402832 NA - May 2011

4023H-55
Diagnostic Trouble Code: 7207 Free Swing Solenoid Signal Abnormality

Standard
Step Action Yes No
value
connector.
7207 is displayed.
Inspect the free swing solenoid.
CN. D64.
Free swing solenoid
defect. Replace
nals 1 and 2 of the CN. D64 free swing
solenoid side.
Is it 34 Ω - 47 Ω?
Inspect for shorts.
2. Measure the voltage between the Br803 harness defect
4 0V Go to Step 5
harness side.
Is it 0 V?
2. Inspect for continuity between the R187, GR180, or
5 ground and terminal 1 of the CN. D64 SR105 harness de- Go to Step 6
Br803 harness defect
pair or replace
2. Measure the voltage between the R187, GR180, or
ground and terminal 1 of the CN. D64 24 V Computer A defect. SR105 harness de-
7
Repair or replace
Is it 24 V?
84402832 NA - May 2011

4023H-56
Diagnostic Trouble Code: 7210 Liftcrane Buzzer Signal Abnormality

Standard
Step Action Yes No
value
connector.
either is blown.
Inspect the liftcrane buzzer.
CN. CR5 and CN. CR6.
2. Connect the terminal of the CN. CR6
liftcrane buzzer side to the negative ter-
Liftcrane buzzer de-
3 minal of the battery and the terminal of Go to Step 4
fect. Replace
the CN. CR5 liftcrane buzzer side to the
positive terminal, and inspect the oper-
ation of the liftcrane buzzer.
Does the liftcrane buzzer sound?

Inspect for shorts.
2. Measure the voltage between the VG815 harness de-
4 0V Go to Step 5
ground and the terminal of the CN. CR6 fect (short). Replace
harness side.
Is it 0 V?
2. Inspect for continuity between the BrW237, BrW236,
ground and the terminal of the CN. CR5 R111, R106, or
5 Go to Step 6
harness side. R105 harness defect
(short). Replace
Inspect for disconnection. BrW237, BrW236,
Turn the key switch ON and measure the R111, R106, or R105
6 voltage between the ground and the terminal About 24 V Go to Step 7 harness defect (dis-
of the CN. CR5 harness side. connection). Repair
Is it about 24 V? or replace
CN. CR4.
2. Inspect whether there is continuity be- VG815 harness de-
tween the terminal of the CN. CR6 har- Computer B defect.
ness side and terminal 6 of the CN. CR4 Replace
Repair or replace
harness side.
84402832 NA - May 2011

4023H-57
Diagnostic Trouble Code: 7211 Rotating Light Relay and Bucket Lock
Signal Abnormality
Standard
Step Action Yes No
value
connector.
either is blown.
Inspect the rotating light relay.
CN. 19.
Rotating light relay
defect. Replace
1 and 2 of the CN. 19 rotating light relay
side.
Inspect for shorts.
1. Install CN. 19. VW858, GW226,
2. Inspect for continuity between the GW227, R106, or
4 Go to Step 5
ground and terminal 1 of the CN. 19 R105 harness defect
VW816, VW817,
1. Turn the key switch ON. GW227, GW226,
2. Inspect for continuity between the Computer B defect. GW225, R106, or
5
ground and terminal 1 of the CN. 19 Replace R105 harness defect
harness side. (disconnection). Re-
pair or replace
84402832 NA - May 2011

4023H-58
Diagnostic Trouble Code: 7240 Pump Horsepower Proportional Valve

Signal Abnormality
Standard
Step Action Yes No
value
connector.
7240 is displayed.
1. Reset the diagnostic trouble code on the
service support DIAG screen.
3 2. Check whether diagnostic trouble code: Go to Step 4 Go to Step 5
7240 is displayed.
Inspect for shorts.
CN. D39.
Y900 harness defect Computer A defect.
4 2. Inspect for continuity between the
(short). Replace Replace
harness side.
Inspect the pump horsepower proportional
valve.
Pump horsepower
5 Go to Step 6 proportional valve
3. Inspect for continuity between terminals
defect. Replace
1 and 2 of the CN. D39 pump horse-
power proportional valve side.
YR940 harness de-
1. Disconnect CN. A56.
fect (disconnection)
2. Inspect for continuity between terminal
6 Go to Step 7 between CN. D39
1 of the CN. D39 female side and termi-
and CN. A56. Repair
nal 1 of the CN. A56 male side.
or replace
BY901 harness de-
Inspect for continuity between terminal 2 of
the CN. D39 female side and terminal 9 of
the CN. A56 male side.
and CN. A56. Repair
or replace
1. Disconnect CN. A4. Y900 harness defect
2. Inspect for continuity between terminal (disconnection) be-
8 1 of the CN. A56 male side and terminal Go to Step 9 tween CN. A56 and
3 of the CN. A4 female side. CN. A4. Repair or re-
Is there continuity? place
1. Inspect for continuity between terminal BY901 harness de-
9 of the CN. A56 male side and terminal fect (disconnection)
Computer A defect.
9 6 of the CN. A4 female side. between CN. A56
Replace
and CN. A4. Repair
84402832 NA - May 2011

4023H-59

1 COMPUTER A 4 7 ENGINE COMPUTER
PER)
2 PRESS. SENSOR (P1) 5 CRANK ANGLE SENSOR
3 PRESS. SENSOR (P2) 6 PUMP POWER
a CAN COMMUNICATION
84402832 NA - May 2011

4023H-60
Diagnostic Trouble Code: 7241 P1 Flow Control Proportional Valve

Signal Abnormality
Standard
Step Action Yes No
value
connector.
7241 is displayed.
7241 is displayed.
Inspect for shorts.
CN. D40.
L904 harness defect Computer A defect.
harness side.
Inspect the P1 flow control proportional
valve.
P1 flow control pro-
5 Go to Step 6 portional valve de-
fect. Replace
1 and 2 of the CN. D40 flow control
proportional valve side.
Y904 harness defect
(disconnection) be-
6 Go to Step 7 tween CN. D40 and
1 of the CN. D40 male side and terminal
CN. A56. Repair or
3 of the CN. A56 female side.
replace
BL905 harness de-
the CN. D40 male side and terminal 11 of the
CN. A56 female side.
and CN. A56. Repair
or replace
1. Disconnect CN. A3. Y904 harness defect
BL905 harness de-
the CN. A56 male side and terminal 5 of the Computer A defect.
9 between CN. A56
CN. A3 female side. Replace
and CN. A3. Repair
or replace
84402832 NA - May 2011

4023H-61

1 COMPUTER A 4 7 ENGINE COMPUTER
TRAVEL)
2 5 CRANK ANGLE SENSOR
SWING)
3 6 P1 FLOW
PER)
a CAN COMMUNICATION
1 COMPUTER A 3 WATER TEMP. SENSOR

2 ENGINE COMPUTER
84402832 NA - May 2011

4023H-62
Diagnostic Trouble Code: 7242 Fan Proportional Valve Signal

Abnormality
Standard
Step Action Yes No
value
connector.
7242 is displayed.
7242 is displayed.
Inspect for shorts.
CN. H1.
YG944 harness de- Computer B defect.
fect (short). Replace Replace
ground and terminal 1 of the CN. H1
harness side.
Inspect the fan proportional valve.
2. Disconnect CN. H1. Fan proportional
5 3. Inspect for continuity between terminals Go to Step 6 valve defect. Re-
1 and 2 of the CN. H1 fan proportional place
valve side.
YG494 harness de-
6 Go to Step 7 between CN. H1 and
1 of the CN. H1 female side and terminal
CN. A54. Repair or
5 of the CN. A54 female side.
replace
BY495 harness de-
1. Inspect for continuity between terminal fect (disconnection)
2 of the CN. H1 female side and terminal between CN. H1 and
7 15 of the CN. A54 female side. Go to Step 8
CN. A54. Repair or
1. Disconnect CN. A7. W908 harness defect

1. Inspect for continuity between terminal WB909 harness de-
15 of the CN. A54 male side and termi- fect (disconnection)
Computer B defect.
9 nal 4 of the CN. A7 female side. between CN. A54
Replace
and CN. A7. Repair
84402832 NA - May 2011

4023H-63
Diagnostic Trouble Code: 7246 2 Pumps Flow Solenoid Signal

Abnormality
Standard
Step Action Yes No
value
connector.
7246 is displayed.
Inspect the 2 pumps flow solenoid.
CN. 163.
2 pumps flow sole-
noid defect. Replace
nals 1 and 2 of the CN. 163 2 pumps
flow solenoid side.
Is it 34 Ω - 47 Ω?
Inspect for shorts.
2. Measure the voltage between the YR805 harness de-
4 0V Go to Step 5
ground and terminal 3 of the CN. 163 fect (short). Replace
harness side.
Is it 0 V?
2. Inspect for continuity between the WL260, WL261, or
5 ground and terminal 1 of the CN. 163 SR105 harness de- Go to Step 6
YR805 harness de-
and terminal 3 of the CN. 163 harness side.
Repair or replace
2. Measure the voltage between the WL260, WL261, or
ground and terminal 1 of the CN. 163 24 V Computer A defect. SR105 harness de-
7
Repair or replace
Is it 24 V?
84402832 NA - May 2011

4023H-64
1 RELAY BATTERY 3 OPTION 2SPEED

2 FUSIBLE LINK FUSE BOX 4 CONTROLLER A
84402832 NA - May 2011

4023H-65
Diagnostic Trouble Code: 7247 Boom-down Proportional Valve Signal

Abnormality
Standard
Step Action Yes No
value
connector.
7247 is displayed.
7247 is displayed.
Inspect for shorts.
CN. D41.
O902 harness defect Computer A defect.
harness side.
Inspect the boom-down proportional valve.
2. Disconnect CN. D41. Boom-down propor-
5 3. Inspect for continuity between terminals Go to Step 6 tional valve defect.
1 and 2 of the CN. D41 boom-down pro- Replace
portional valve side.
O902 harness defect
(disconnection) be-
6 Go to Step 7 tween CN. A56 and
CN. D41. Repair or
nal 2 of the CN. A56 female side.
replace
O903 harness defect
(disconnection) be-
the CN. A56 female side.
CN. D41. Repair or
replace
1. Disconnect CN. A3. O902 harness defect
O903 harness defect
(disconnection) be-
the CN. A56 male side and terminal 4 of the Computer A defect.
9 tween CN. A56 and
CN. A3. Repair or re-
place
84402832 NA - May 2011

4023H-66
1 CONTROLLER A
2 BOOM DOWN
84402832 NA - May 2011

4023H-67
Diagnostic Trouble Code: 7248 Arm-in Proportional Valve Signal

Abnormality
Standard
Step Action Yes No
value
connector.
7248 is displayed.
3 2. Check whether diagnostic trouble code: Go to Step 4 Go to Step 5.
7248 is displayed.
Inspect for shorts.
CN. D42.
G906 harness defect Computer B defect.
harness side.
Inspect the arm-in proportional valve.
2. Disconnect CN. D42. Arm-in proportional
5 3. Inspect for continuity between terminals Go to Step 6 valve defect. Re-
1 and 2 of the CN. D42 arm-in propor- place
tional valve side.
G906 harness defect
(disconnection) be-
CN. D42. Repair or
nal 4 of the CN. A56 female side.
replace
GB907 harness de-
7 Go to Step 8 between CN. A56
the CN. A56 female side.
and CN. D42. Repair
or replace
1. Disconnect CN. A7. G906 harness defect
GB907 harness de-
the CN. A56 male side and terminal 6 of the Computer B defect.
9 between CN. A56
and CN. A7. Repair
or replace
84402832 NA - May 2011

4023H-68
1 CONTROLLER B
2 ARM CLOSE
84402832 NA - May 2011

4023H-69
Diagnostic Trouble Code: 7250 Option Relief Pressure Proportional

Valve Signal Abnormality
Standard
Step Action Yes No
value
connector.
7250 is displayed.
7250 is displayed.
Inspect for shorts.
CN. D44-1.
V910 harness defect Computer B defect.
harness side.
Inspect the option relief pressure propor-
tional valve.
Option relief pressure
2. Disconnect CN. D44-1.
5 Go to Step 6 proportional valve
defect. Replace
1 and 2 of the CN. D44-1 option relief
pressure proportional valve side.
V910 harness defect
(disconnection) be-
6 Go to Step 7 tween CN. D44-1 and
1 of the CN. D44-1 female side and ter-
CN. D44. Repair or
minal 1 of the CN. D44 male side.
replace
1. Inspect for continuity between terminal VG911 harness de-
2 of the CN. D44-1 female side and ter- fect (disconnection)
7 minal 2 of the CN. D44 male side. Go to Step 8 between CN. D44-1
and CN. D44. Repair
1. Disconnect CN. A7. V910 harness defect
1 of the CN. D44 female side and termi- tween CN. D44 and
8 Go to Step 9
nal 2 of the CN. A7 female side. CN. A7. Repair or re-
place
1. Inspect for continuity between terminal VG911 harness de-
2 of the CN. D44 female side and termi- fect (disconnection)
Computer B defect.
9 nal 5 of the CN. A7 female side. between CN. D44
Replace
and CN. A7. Repair
84402832 NA - May 2011

4023H-70
1 CONTROLLER B
2 PROPORTIONAL S/V
3 OPT PRESS
84402832 NA - May 2011

4023H-71
Diagnostic Trouble Code: 7251 Battery Control Relay Signal Abnormality

Standard
Step Action Yes No
value
connector.
2 Inspect the computer fuse (15 A) to see Go to Step 3
if it is blown.
Inspect the battery control relay.
CN. A11.
Battery control relay
defect. Replace
1 and 2 of the CN. A11 battery control
relay side.
Inspect for shorts.
1. Install CN. A11.
W113, W112, W107,
4 or W106 harness de- Go to Step 5
ground and terminal 1 of the CN. A11
harness side.
W113, W112, W107,
W106, or OG804 har-
2. Inspect for continuity between the Computer A defect.
5 ness defect (discon-
ground and terminal 1 of the CN. A11 Replace
nection). Repair or
harness side.
replace
1 RELAY BATTERY 3 RELAY BATTERY RL

2 FUSE CONT 4 CONTROLLER A
84402832 NA - May 2011

4023H-72
Diagnostic Trouble Code: 7252 Idle Stop Relay Signal Abnormality

Standard
Step Action Yes No
value
connector.
2 and computer (15 A) fuse to see if either Go to Step 3
is blown.
Inspect the idle stop relay.
CN. A12.
Idle stop relay defect.
Replace
1 and 2 of the CN. A12 idle stop relay
side.
Inspect for shorts.
1. Install CN. A12. W115, W114, W112,
2. Inspect for continuity between the W113, or W107 har-
4 Go to Step 5
ground and terminal 1 of the CN. A12 ness defect (short).
W106, W107, W112,
W113, W114, W115,
2. Inspect for continuity between the Computer B defect.
5 or LY824 harness de-
fect (disconnection).
harness side.
Repair or replace
84402832 NA - May 2011

4023H-73
1 RELAY BATTERY 3 RELAY IDLE STOP 5 KEY SWITCH

2 FUSE CONT 4 RELAY KEY ON 6 MONITOR DISPLAY
84402832 NA - May 2011

4023H-74
Diagnostic Trouble Code: 7253 DPD Regeneration Request Output

Signal Abnormality
Standard
Step Action Yes No
value
connector.
2 fuse box F4 (10 A) fuse to see if either Go to Step 3
is blown.
Inspect the DPF relay.
CN. A10. DPF relay defect.
3 Go to Step 4
2. Inspect for continuity between terminals Replace
1 and 2 of the CN. A10 DPF relay side.
Inspect for shorts.
1. Install CN. A10.
WR147, WR141, or
4 WR140 harness de- Go to Step 5
harness side.
WR147, WR141,
WR140, or YL806
2. Inspect for continuity between the Computer A defect.
5 harness defect (dis-
connection). Repair
harness side.
or replace
84402832 NA - May 2011

4023H-75
1 FUSIBLE LINK BACK UP 3 RELAY DPF 5 ENGINE CONTROLLER

2 RELAY ECM 4 CONTROLLER A 6 RELAY BATTERY
84402832 NA - May 2011

4023H-76
Diagnostic Trouble Code: 7400 Abnormally High Coolant Temperature

(105°C or higher)
Standard
Step Action Yes No
value
1. Start the engine and perform a warm-up
operation until the engine is fully
warmed up.
1 check whether diagnostic trouble code: Go to Step 2
7400 (●) is displayed.
played?
2 Inspect the engine unit.

(110°C or higher)
Standard
Step Action Yes No
value
warmed up.
played?

(120°C or higher)
Standard
Step Action Yes No
value
warmed up.
played?
84402832 NA - May 2011

4023H-77
Diagnostic Trouble Code: 7404 Abnormally High Oil Temperature (95°C

or higher)
Standard
Step Action Yes No
value
warmed up.
played?
2 Inspect the hydraulic oil temperature.
1 COMPUTER A
2 HYD. OIL TEMP SENSOR
84402832 NA - May 2011

4023H-78
Diagnostic Trouble Code: 7405 Abnormally High Boost Temperature

(80°C or higher), 7406 Abnormally High Boost Temperature (90°C or
higher)
Standard
Step Action Yes No
value
warmed up.
1 check whether diagnostic trouble code Go to Step 2.
7405 (●) or 7406 (●) is displayed.
Is diagnostic trouble code 7405 (●) or 7406
(●) displayed?
84402832 NA - May 2011

4023H-79
Diagnostic Trouble Code: 7420 Abnormally Low Alternator Voltage

Standard
Step Action Yes No
value
played?
2 connector. Go to Step 3
Is 1 above OK?
Inspect for shorts.
CN. D14.
Br515 harness defect
(short). Replace
harness side.
Inspect the alternator.
1. Start the engine.
2. Measure the voltage between the 10 V or Alternator defect.
4 Go to Step 5
ground and terminal 2 of the CN. D14 lower Replace
alternator side.
Is it 10 V or lower?
2. Connect CN. D14.
3. Disconnect CN. A1. Br515 harness defect
10 V or Computer A defect.
5 4. Start the engine. (disconnection). Re-
lower Replace
5. Measure the voltage between the pair or replace
harness side.
Is it 10 V or lower?
84402832 NA - May 2011

4023H-80
84402832 NA - May 2011

4023H-81
1 COMPUTER A 6 FUSIBLE LINK FUSE BOX 11 STARTER MOTOR

2 RELAY STARTER CUT 7 FUSIBLE LINK BACK UP 12 ALTERNATOR
3 BATTERY (24 V) 8 FUSIBLE LINK SAFETY RL 13 RELAY STARTER
4 RELAY BATTERY 9 RELAY KEY ON
5 FUSE CONT 10 KEY SWITCH
84402832 NA - May 2011

4023H-82
Diagnostic Trouble Code: 7421 Coolant Level Reduction

Standard
Step Action Yes No
value
1. Check that the "LOW COOLANT" dis-
play appears.
2. Fill with coolant.
1 4. On the service support DIAG screen, Go to Step 2
played?
connector.
played?
Inspect the coolant level switch.
CN. D79.
Coolant level switch Computer A defect.
3 2. Inspect for continuity between terminals
defect. Replace Replace
1 and 2 of the CN. D79 coolant level
switch side.
1 COMPUTER A
LEVEL SWITCH (RESERVE
2
TANK)
84402832 NA - May 2011

4023H-83
Diagnostic Trouble Code: 7422 Abnormally Low Engine Oil Pressure

Standard
Step Action Yes No
value
1. Start the engine and wait for 30 sec.
played?
1 COMPUTER A
2 ENGINE COMPUTER
3 OIL PRESS SENSOR
84402832 NA - May 2011

4023H-84
Diagnostic Trouble Code: 7423 Air Cleaner Clogging

Standard
Step Action Yes No
value
1. Check that the "AIR FILTER" display ap-
pears.
2. Clean or replace the air cleaner ele-
ment.
3. Start the engine and wait for 10 sec.
1 4. On the service support DIAG screen, Go to Step 2
played?
connector.
played?
Inspect the air cleaner clog pressure switch.
CN. D80. Air cleaner clog pres-
3 Inspect for continuity between terminals sure switch defect. Go to Step 4
1 and 2 of the CN. D80 air cleaner clog Replace
pressure switch side.
Inspect for shorts.
LW533 harness de- Computer A defect.
4 ground and terminal 2 of the CN. D80
fect (short). Replace Replace
harness side.
1 COMPUTER A
PRESS. SWITCH (AIR
2
CLEANER)
84402832 NA - May 2011

4023H-85
Diagnostic Trouble Code: 7424 Return Filter Clogging (breaker

specifications)
Standard
Step Action Yes No
value
1. Check that the "HYD. OIL FILTER" dis-
play appears.
2. Replace the return filter.
1 3. Turn the key switch ON. Go to Step 2
7424 is displayed.
7424 is displayed.
Inspect the return filter clog switch.
CN. D81. Return filter clog
Computer A defect.
3 2. Inspect for continuity between terminals pressure switch de-
Replace
1 and 2 of the CN. D81 return filter clog fect. Replace
switch side.
1 COMPUTER A
PRESS. SWITCH (FILTER IN-
2
DICATOR)
84402832 NA - May 2011

4023H-86
Diagnostic Trouble Code: 7425 Fuel Density Error Signal Abnormality

Standard
Step Action Yes No
value
1. View the fuel density data on the service
support CHK-MAIN-11 screen.
2. Turn the key switch OFF, but just before
doing so, record the fuel density data.
3. Turn the key switch OFF. The fuel is not appro-
4. Turn the key switch ON, and record the priate. Go to Step 4
2 fuel density data at this time. If the fuel density is a Go to Step 3
5. Compare the data from 2 and 4 above to borderline value, per-
check whether the difference between form fuel analysis.
the values has dropped by 0.01 g/cm3
or more.
Has the value dropped by 0.01 g/cm3 or
more?
1. While the diagnostic trouble code is dis-
played, turn the key switch OFF.
2. After checking that the display has
turned off, turn the key switch ON again.
3. When the diagnostic trouble code is dis- Check again from the
3 played, wait for at least 5 min. End
beginning of the step.
4. Turn the key switch OFF, turn the igni-
tion key ON again, and check whether
the error code is displayed.
Has the error code disappeared?
1. Check whether the customer has
changed gas station or fuel manufac- Have the customer If the fuel density is
turer. return to the previous clearly outside the
4
gas station or fuel standard, go to Step
Has the customer changed gas station or manufacturer. 5
fuel manufacturer?
1. Drain the fuel.
2. Check whether the fuel density sensor Check for fuel density
5 is dirty. Clean
sensor trouble.
Is the fuel density sensor dirty?
84402832 NA - May 2011

4023H-87
Diagnostic Trouble Code: 7600 CAN Bus Abnormality

Standard
Step Action Yes No
value
connector.
7600 is displayed.
Inspect for shorts.
P040, P042, P044,
CN. 50.
P046, P048, or
P050 harness defect
ground and terminal A of the CN. 50
(short). Replace
harness side.
1. Inspect for continuity between the PG041, PG043,
ground and terminal B of the CN. 50 PG045, PG047,
4 harness side. PG049, or P051 har- Go to Step 5
ness defect (short).
Is there continuity? Replace
P040, P042, P044,
P046, P048, P050,
1. Inspect for continuity between terminals PG041, PG043,
5 A and B of the CN. 50 harness side. PG045, PG047, Go to Step 6
Is there continuity? PG049, or P051 har-
ness defect (short).
Replace
Inspect the ECM, computer A, computer B,
and computer S units.
1. Connect CN. 50.
2. Disconnect CN. A0 and turn the key ECM defect. Re-
6 Go to Step 7
switch ON. place
7600 is displayed.
1. Turn the key switch OFF and connect
CN. A0.
2. Disconnect CN. C2 and turn the key
switch ON. Computer S defect. Computer A defect.
7
3. Check whether diagnostic trouble code: Replace Replace
7600 is displayed.
84402832 NA - May 2011

4023H-88
Diagnostic Trouble Code: 7601 Monitor Communication Abnormality

Standard
Step Action Yes No
value
connector.
7601 is displayed.
CN. A2 and CN. C1. WL061 harness de-
3 2. Inspect for continuity between terminal Go to Step 4 fect (disconnection).
10 of the CN. A2 harness side and ter- Repair or replace
minal 8 of the CN. C1 harness side.
3 of the CN. A2 harness side and termi- W060 harness defect
4 nal 9 of the CN. C1 harness side. Go to Step 5 (disconnection). Re-
pair or replace
2. Check whether diagnostic trouble code: Computer A defect. Monitor defect. Re-
5 7601 is displayed. Replace place
1 COMPUTER A
2 MONITOR
a CAN COMMUNICATION
84402832 NA - May 2011

4023H-89
Diagnostic Trouble Code: 7602 ECM Communication Abnormality

Standard
Step Action Yes No
value
connector.
7602 is displayed.
1. Check whether diagnostic trouble codes
7603 and 7604 are displayed at the
same time. Inspect the connec-
3 Go to Step 4
tion status of CN. C2.
Are diagnostic trouble codes 7603 and 7604
displayed at the same time?
P040 or P042 har-
CN. C2 and CN. A0.
ness defect (discon-
4 2. Inspect for continuity between terminal Go to Step 5
nection). Repair or
6 of the CN. C2 harness side and termi-
replace
nal 18 of the CN. A0 harness side.
1. Inspect for continuity between terminal PG041 or PG043
14 of the CN. C2 harness side and ter- ECM defect. Re- harness defect (dis-
5 minal 37 of the CN. A0 harness side. place connection). Repair
84402832 NA - May 2011

4023H-90
Diagnostic Trouble Code: 7604 Computer B Communication Abnormality

Standard
Step Action Yes No
value
connector.
7602 and 7603 are displayed at the Inspect the connec-
2 Go to Step 3
same time. tion status of CN. C2.
Are diagnostic trouble codes 7602 and 7603
displayed at the same time?
P040 or P048 har-
CN. C2 and CN. C7.
nection). Repair or
6 of the CN. C2 harness side and termi-
replace
nal 8 of the CN. C7 harness side.
1. Inspect for continuity between terminal PG041 or PG049
14 of the CN. C2 harness side and ter- Computer S defect. harness defect (dis-
4 minal 16 of the CN. C7 harness side. Replace connection). Repair
84402832 NA - May 2011

4023H-91
Diagnostic Trouble Code: 7605 ECM Mismatch

Standard
Step Action Yes No
value
1. Check for an error on the service sup-
port model selection screen. Correctly set the
2 Go to Step 3
model selection.
Is the model selection screen correct?
1. Check that the ECM which matches the Replace with an ECM
model is installed. ECM defect. Re-
3 that matches the
place
Does the ECM match the model? model.
1 COMPUTER A
2 ENGINE COMPUTER
a CAN COMMUNICATION
84402832 NA - May 2011

4023H-92
Diagnostic Trouble Code: 7606 EEPROM Data Abnormality

Standard
Step Action Yes No
value
played?
Rewriting of the com-
1. Check whether rewriting was performed puter changed the
on computer A before the diagnostic used space of the
trouble code was displayed. EEPROM. Computer A defect.
2
Was rewriting performed on computer A be- Turn the key switch Replace
fore the diagnostic trouble code was dis- OFF, and then turn
played? the key switch ON
again.
Diagnostic Trouble Code: 7607 Computer C Communication Abnormality

Standard
Step Action Yes No
value
connector.
7602, 7603, 7604 are displayed at the Inspect the connec-
2 Go to Step 3
same time. tion status of CN. A2.
Are diagnostic trouble codes 7602, 7603,
7604 displayed at the same time?
P040 or V050 har-
CN. A2 and CN. A23.
nection). Repair or
6 of the CN. A2 harness side and termi-
replace
nal 7 of the CN. A23 harness side.
1. Inspect for continuity between terminal PG041 or VG051
14 of the CN. A2 harness side and ter- Computer C defect. harness defect (dis-
4 minal 8 of the CN. A23 harness side. Replace connection). Repair
84402832 NA - May 2011

4023H-93
84402832 NA - May 2011

4023H-94
Section
4023K
Data Reference Values
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Non-operational P rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Two pump relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4023K-1 PRINTED IN FRANCE
4023K-2 PRINTED IN FRANCE
The purpose of data list is for checking the status of the This display menu is subject to change without notice.
machine and each equipment.
This data is used in trouble diagnosis by comparing the Non-operational P rotation
each machine data with standard values, and checking
whether the vehicle data is temporarily or always differ-
ent from the reference values.
Idling speed reference value This varies depend-

Data display items Unit
ing on the conditions of the machine.
Battery voltage V 22 - 30
Target engine rpm RPM 800
Engine rpm RPM 895 - 905
Throttle accelerator switch position sensor 1
V 0.0
(APP1)
Throttle accelerator switch position sensor 2
V 0.0
(APP2)
Throttle accelerator switch position (APP) ％ 0
Fuel rail pressure sensor V 1.8
Fuel rail pressurefeedback Feedback mode
Coolant temperature sensor V 0.5 - 0.8
Coolant temperature °C 65 - 78
Intake air temperature sensor V 0.9 - 4.1
Intake air temperature °C -10 - 40
Fuel temperature sensor V 2.3
Fuel temperature °C 20
Barometric pressure sensor V Approx. 2
Barometric pressure kPa Approx. 100
Boost temperature sensor voltage V 4.4
Boost pressure sensor kPa Approx. 100
1st cylinder fuel correction amount mm3/st (-3) - 3 or less
2nd cylinder fuel correction amount mm3/st (-3) - 3 or less
3rd cylinder fuel correction amount mm3/st (-3) - 3 or less
4th cylinder fuel correction amount mm3/st (-3) - 3 or less
Engine mode Fuel mode
EGR valve 1 drive duty ％ 0
ON/OF- Any one among 1, 2 and 3 is polarity-inverted (Exam-
EGR position 1
F ple: 1 = ON, 2 = ON, 3 = OFF)
EGR position 2
F ple: 1 = ON, 2 = ON, 3 = OFF)
EGR position 3
F ple: 1 = ON, 2 = ON, 3 = OFF)
ON/OF-
Ignition switch ON
F
ON/OF-
Starter switch OFF
F
ON/OF- OFF
Glow relay
F ON immediately after the starter switch is turned ON
Fuel delivery rate data 1 - Depending on the machine
84402832 NA - May 2011

4023K-3
Two pump relief

Two Pump Relief reference value
Data display items Units
It varies depending on the actual unit
Battery voltage V 22 - 30
Target engine rpm min-1 500
Engine rpm min-1 1,945 - 1,950
Throttle accelerator switch position sensor 1 (APP1) V 0.0
Throttle accelerator switch position sensor 2 (APP2) V 0.0
Throttle accelerator switch position (APP) ％ 0
Fuel rail pressure sensor V 1.5
Fuel rail pressure feedback Feedback mode
Coolant temperature sensor V 0.4 - 0.5
Coolant temperature °C 80 - 85
Intake temperature sensor V 2.2
Intake air temperature °C 29
Fuel temperature sensor V 1.0
Fuel temperature °C 53
barometric pressure sensor V Approx. 2
Atmospheric pressure kPa Approx. 100
Boost temperature sensor voltage V 4.3
Boost pressure sensor kPa Approx. 180 - 200
First cylinder fuel correction amount mm3/st (-3) - 3 or less
Second cylinder fuel correction amount mm3/st (-3) - 3 or less
Third cylinder fuel correction amount mm3/st (-3) - 3 or less
Fourth cylinder fuel correction amount mm3/st (-3) - 3 or less
Fifth cylinder fuel correction amount mm3/st (-3) - 3 or less
Sixth cylinder fuel correction amount mm3/st (-3) - 3 or less
Engine mode Fuel mode
EGR valve 1 drive duty ％ 0 - 97
ON/OF- Reverse the polarity of either 1, 2, or 3
EGR position 1
F (Example: 1=ON, 2=ON, 3=OFF, etc)
EGR position 2
EGR position 3
ON/OF-
Ignition switch ON
F
ON/OF-
starter switch OFF
F
ON/OF- OFF
glow relay
F ON immediately after the starter switch ON
Q adjustment compensation data 1 - This differs depending on the actual unit.
84402832 NA - May 2011

4023K-4
Section
4040
Electrical Wiring Diagram
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine and Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Cab Main Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Main Frame
84402832 NA - May 2011

4040-2
*1 Yellow adhesive tape *3 Red adhesive tape *5 Pink adhesive tape CN. D12 Starter motor: S CN. D57F Fuel level sensor
*2 Blue adhesive tape *4 White adhesive tape *6 Nameplate CN. D13 Alternator: B CN. D58F Solenoid valve joint connector
CN. D14F Alternator: L/R CN. D59F Lock lever SOL. V
CN. D15 Alternator: E CN. D60F Swing brake SOL. V
a The connector (CN. D52F) must e The connector (CN. D83F) must The connector (CN. D90F) must CN. D16 Alternator: GND CN. D61F 2-stage travel SOL. V
i
be fastened with red tape. be fastened with red tape. be fastened with red tape. CN. D17 Battery relay: B CN. D62F 2-stage relief SOL. V
The connector (CN. D82F) must The connector (CN. D38F) must The connector (CN. D68F) must CN. D18 Battery relay: IGN CN. D64F Free swing solenoid valve
b f j
be fastened with red tape. be fastened with red tape. be fastened with red tape.
CN. D19 Battery relay: IGN CN. D65F Housing lamp
c The connector (CN. D76F) must g The connector (CN. D58F) must The connector (CN. D69F) must
k CN. D20 Battery relay: Coil CN. D66F Boom lamp harness
be fastened with red tape. be fastened with red tape. be fastened with red tape.
CN. D21 Battery relay: Coil CN. D67F Washer motor
The connector (CN. D44F) must The connector (CN. D74F) must Detail of engine controller connec-
d h l CN. D22M Battery relay: GND CN. D68F Diode: Washer
be fastened with red tape. be fastened with red tape. tor
CN. D23M Fusible link: 50 A CN. D69F Travel alarm
CN. D24M Fusible link: 60 A CN. D70F Horn: L+
CN. A50F Cab main harness: A CN. D41F Reducing valve: Boom CN. D25 Fusible link: 65 A CN. D71F Horn: L-
CN. A51F Cab main harness: B CN. D42F Reducing valve: Arm CN. D26F Fusible link: 15 A CN. D72F Horn: H+
CN. A52F Cab main harness: C CN. D43F Reducing valve: Bucket CN. D27F Starter relay: B/C CN. D73F Horn: H-
CN. A53F Cab main harness: D CN. D44F Electromagnetic proportional valve CN. D28F Starter relay: S/E CN. D74F Beacon harness
CN. A54F Cab main harness: E CN. D45F P1 pressure sensor CN. D29F Glow relay: Coil *CN. D76F Feed pump harness
CN. A55F Cab main harness: F CN. D46F P2 pressure sensor CN. D30F Glow relay: 1 CN. D77F Receiver dryer
CN. A56F Cab main harness: G CN. D47F N1 pressure sensor CN. D31F Glow relay: 2 CN. D78F Air conditioner compressor
CN. D1F ECM: 1 CN. D48F N2 pressure sensor CN. D32M DPD pressure sensor CN. D79F Reserve tank switch
CN. D2F ECM: 2 CN. D49F Swing pressure sensor CN. D33M DPD temperature sensor: CSF CN. D80M Air cleaner sensor
CN. D5F Barometric pressure sensor CN. D50F Upper pressure sensor CN. D34M DPD temperature sensor: DOC CN. D81 Ground G2
CN. D6F DPD register CN. D51F Travel pressure sensor CN. D35F MAF sensor *CN. D82F Oil feeding device
CN. D7F Engine harness: A *CN. D52F HBCV pressure sensor CN. D36F Fuel filter sensor CN. D83F Pressure switch filter
CN. D8M Engine harness: B CN. D53F Boom-up pressure sensor CN. D37F Charge fuel pump CN. D84 Ground G1
CN. D9M Engine harness: C CN. D54F Arm-in pressure sensor CN. D38F Diode: Pump CN. D86F Condenser relay
CN. D10M Engine harness: D CN. D55F Bucket-close pressure sensor CN. D39F Hydraulic pump CN. D89F Condenser fan
CN. D11M Engine harness: H CN. D56F Oil temperature sensor CN. D40F Hydraulic pump: PTO CN. D90F Condenser fan diode
84402832 NA - May 2011

4040-3
Cab Main Harness
84402832 NA - May 2011

4040-4
*1 White adhesive tape *3 Blue ID tape CN. A10F DPD relay CN. A37F Memory clear
*2 Red ID tape *4 Fuse box CN. A11F Battery relay CN. A37M Memory clear: GND
CN. A12F Idle stop relay CN. A38F ECM joint connector
CN. A13F Starter cut relay CN. A39F Joint connector: CONT
a CN. A33M and A33F must be fas- e CN. A24 must be fastened with CN. A32F, 32M and 29F must be CN. A14F Neutral start relay CN. A40F Joint connector: GND
i
tened with red tape. red tape. fastened with red tape. CN. A15F Key ON CN. A41F Joint connector: A
CN. A31M and A31F must be con- CN. A16F Horn relay CN. A42F Joint connector: B
CN. A26F must be fastened with CN. A58 must be fastened with
b nected, then fastened with red f j
red tape. red tape. CN. A17F Lamp relay CN. A43 Ground: Cab
tape.
CN. A18F Lamp relay: CAB CN. A44F Cab harness: A
c CN. A30 and A38 must be fas- g CN. A34F and 35F must be fas- CN. A40F, 41F and 42F must be
k CN. A19F Beacon relay CN. A45F Cab harness: B
tened with red tape. tened with red tape. tied together with red tape.
CN. A23 must be fastened with CN. A25M and CN. A25F must be CN. A20F Room lamp relay CN. A46F Console harness: A
d h l Nameplate position CN. A21F Speaker relay: R CN. A47F Console harness: B
red tape. connected.
CN. A22F Speaker relay: L CN. A48F Console harness: C
CN. A23F Computer C harness CN. A49F Console harness: D
CN. A1F Computer A: 1 CN. A31M Hour meter: - CN. A24F Computer T harness CN. A50M Frame main harness: A
CN. A2F Computer A: 2 CN. A32F Option power supply CN. A25F EST-B connector CN. A51M Frame main harness: B
CN. A3F Computer A: 3 CN. A32M Option power supply: GND CN. A25M EST-B connector CN. A52M Frame main harness: C
CN. A4F Computer A: 4 CN. A33F Immobilizer CN. A26F EST-A harness CN. A53M Frame main harness: D
CN. A5F Computer B: 1 CN. A33M Immobilizer: GND CN. A27F Diagnostic connector CN. A54M Frame main harness: E
CN. A6F Computer B: 2 CN. A34F CAN CN. A28F DC/DC converter CN. A55M Frame main harness: F
CN. A7F Computer B: 3 CN. A35F CAN CN. A29F FMS harness CN. A56M Frame main harness: G
CN. A8F Computer B: 4 CN. A36F Diagnostic switch CN. A30F Diode CN. A57M Option line harness
CN. A9F ECM relay CN. A36M Diagnostic switch: GND CN. A31F Hour meter: + CN. A58F Horn jumper
84402832 NA - May 2011

4040-5
Frame
84402832 NA - May 2011

4040-6
a Marking position; Align white tape g CN. A52 Cab main harness: C (8-pin) CN. D54 Pressure sensor: Arm (3-pin) ID tape: Red
d ID: H detail of cab
of harness. CN. A53 Cab main harness: D (14-pin) CN. D55 Pressure sensor: Bucket (3-pin) ID tape: Blue
Tighten together with the starter e Tighten together with the washer CN. A54 Cab main harness: E (22-pin) CN. D64 Free swing harness (2-pin)
b
cable motor tube CN. A55 Cab main harness: F (20-pin) CN. D65 Lamp: Housing (2-pin)
c ID: L f Applying the adhesive CN. A56 Cab main harness: G (18-pin) CN. D66 Boom lamp harness (2-pin)
CN. D1 ECM: 1 (60-pin) CN. D67 Washer motor (2-pin)
Wire harness; Light (frame main) Travel alarm (2-pin) (secured to harness with
*1 Round terminal M8 *3 *5 Register (engine accessory) CN. D2 ECM: 2 (94-pin) CN. D69
(KHR14280) red tape)
Barometric pressure sensor (en- CN. D6 Register (2-pin) CN. D70, 71 Horn (left)
*2 Starter cable *4 Floor *6
gine accessory) CN. D35 Suction air sensor (5-pin) CN. D72, 73 Horn (right)
Grease-up pump harness (3-pin) (secured to
CN. D41 Proportional valve: Boom (2-pin) ID tape: None CN. D76
Code Part name Q'ty Code Part name Q'ty harness with red tape)
1 Wire; Ground (floor) 1 5 Light; Working 24 V × 70 W 1 CN. D42 Proportional valve: Arm (2-pin) ID tape: Red CN. D77 Receiver dryer (2-pin)
2 Harness; Wire (frame main) 1 6 Bracket lamp 1 CN. D43 Proportional valve: Bucket (2-pin) ID tape: Blue CN. D80 Pressure switch; Air cleaner (2-pin)
3 Sensor; Pressure (5 MPa) G1/4 7 7 Alarm; Travel 1 Option proportional valve harness (2-pin) (se-
CN. D44 CN. D81 Ground G2
4 Horn; Electric (Assembly) 1 cured to harness with red tape)
Grease-up pump (2-pin) (secured to harness
CN. D47 Pressure sensor: Swing (3-pin) CN. D82
with red tape)
HBCV harness (3-pin) (secured to harness with
CN. A50 Cab main harness: A (2-pin) CN. D52 CN. D50 Pressure sensor: Upper (3-pin) CN. D84 Floor ground; Ground G1
red tape)
CN. D51 Pressure sensor: Travel (3-pin) ID tape: Red CN. D89 Condenser fan: 2-pin
CN. A51 Cab main harness: B (8-pin) CN. D53 Pressure sensor: Boom (3-pin)
84402832 NA - May 2011

4040-7
Engine and Pump
84402832 NA - May 2011

4040-8
ANNOTATION: *CN. D9 Engine harness; C (14-pin) CN. D48 Pressure sensor N2 (3-pin)
CN. D12 Starter motor: S CN. D56 Sensor; Oil temperature (2-pin)
1. When assembling the ground terminals marked with a ※, it should be confirmed that the frame seating surface is not
coated. Joint connector (8-pin) (secured to red tape har-
CN. D15 Alternator: E Electrical wiring color: Black CN. D58
If the surface is coated, assembly should be performed after removing the coating. ness)
2. Clean the terminal of the connectors marked with a * using cleaning agent (37) before mating, and then coat with an CN. D16 Alternator ground CN. D59 SV; Lever lock (2-pin)
anti-rust agent (38). CN. D32 Pressure sensor; Exhaust gas (3-pin) CN. D60 SV; Swing brake (2-pin) ID tape: Blue
3. The clamp positions of the electrical wiring that comes out from connectors should be adjusted so that the wiring does Temperature sensor DPD (FRONT) (2-pin)
CN. D33 CN. D61 SV; 2-stage travel (2-pin) ID tape: Red
not form sharp rounded shapes. (R = 10 mm or more) Connector color: Dark gray
Temperature sensor DPD (CENTER) (2-pin)
CN. D34 CN. D62 SV; 2-stage relief (2-pin)
a Be careful to assemble the battery cable in the correct direction. Connector color: Light gray
CN. D36 Fuel filter (3-pin) CN. D78 Compressor (1-pin)
Engine harness (attached to en- CN. D37 Charge fuel pump (2-pin)
*1 *4 Frame; Housing (center front) *7 KHR28790 (battery starter cable)
gine main unit)
Starter motor (attached to engine
*2 Round terminal M8 *5
main unit)
Engine ground (attached to en-
*3 Round terminal M5 *6
gine main unit)
Code Part name Q'ty

1 Sensor; Pressure (50 MPa) M18 × 1.5 2
2 Sensor; Thermo 1
3 Sensor; Pressure (50 MPa) G1/4 1
*CN. 10 Engine harness; D (20-pin) CN. D39 Proportional valve; Horsepower control (2-pin)
*CN. 11 Engine harness; H (1-pin) CN. D40 Proportional valve: Flow control (2-pin)
*CN. D7 Engine harness; A (32-pin) CN. D45 Pressure sensor P1 (3-pin) ID tape: Red
*CN. D8 Engine harness; B (16-pin) CN. D46 Pressure sensor P2 (3-pin) ID tape: Blue
84402832 NA - May 2011

4040-9
Attachments
84402832 NA - May 2011

4040-10
a Tighten together with the attachment line
b Tighten together with the arm line
Code Part name Q'ty

1 Wire harness; Light (frame main) 1
2 Light; Working 1
CN. D73 Connect to the frame main harness
84402832 NA - May 2011

4040-11
Battery
84402832 NA - May 2011

4040-12
ANNOTATION: Round terminal M8 (battery relay IGN) Wire
CN. D19 CN. D28 Starter relay S/E (2-pin)
color: white
1. When assembling the ground terminals marked with a *, it should be confirmed that the frame seating surface is not
Round terminal M4 (battery relay coil 1) Wire
coated. CN. D20 CN. D29 Glow relay coil (2-pin)
color: green
If the surface is coated, assembly should be performed after removing the coating.
2. The clamp positions of the electrical wiring that comes out from connectors should be adjusted so that the wiring does Round terminal M4 (battery relay coil 2) Wire
CN. D21 CN. D30 Glow relay 1 (1-pin)
not form sharp rounded shapes. (R = 10 mm or more) color: red stripe on white background
CN. D22 Battery relay GND (1-pin) CN. D31 Glow relay 2 (1-pin)
a Marking position: Align white tape of harness c Detail of battery CN. D23 Fuse 50 A +B (2-pin) CN. D68 Switch; LLC tank (2-pin)
Install the battery indicator in such a way that it is com- CN. D24 Fuse 60 A ST (2-pin) CN. D80 Harness; Beacon (2-pin)
b d Detail of battery box CN. D25 Fuse 65 A IGN (2-pin) CN. D86 Relay; Condenser (5-pin)
pletely visible
KSR13401 (harness; wire (frame

*1 *3 M8 (battery accessory) *5 Starter relay (engine accessory)
main))
*2 M10 (battery accessory) *4 Glow relay (engine accessory)
Code Part name Q'ty Code Part name Q'ty

1 Holder; Battery 1 6 Battery 180G51 (with terminal) 2
2 Cable; Battery relay (starter) 1 7 Cable; Battery bridge 1
3 Bracket; Battery relay 1 8 Cable; Battery B+ relay 1
4 Relay; Changeover (24 V) 1 9 Cable; Battery ground 1
5 Relay; Battery 1 10 Harness; Wire (diode) 1
CN. D17 Round terminal M8 (battery relay B) red ID tape CN. D26 Fuse 15 A CONT (2-pin)
Round terminal M8 (battery relay IGN) Wire
CN. D18 CN. D27 Starter relay B/C (2-pin)
color: red
84402832 NA - May 2011

4040-13
Cab
84402832 NA - May 2011

4040-14
Remove only CN. A31 F from the CN. A4 Computer A: 4: 22-pin CN. A47 Console harness: B: 8-pin
a Marking position (align white tape red tape and fasten it again with g For HBCV specifications ma- CN. A5 Computer B: 1: 26-pin CN. A48 Console harness: C: 14-pin
d
of harness) the red tape after connecting it chines CN. A6 Computer B: 2: 16-pin CN. A49 Console harness: D: 18-pin
with the joint harness (45). CN. A7 Computer B: 3: 12-pin CN. A50 Frame main harness: A: 2-pin
Connect with the supplied cab an- e Tighten the harness and the an- CN. A8 Computer B: 4: 22-pin CN. A51 Frame main harness: B: 8-pin
b
tenna line. tenna together. CN. A9 ECM CN. A52 Frame main harness: C: 8-pin
Fasten the harness with the clip. CN. A10 DPF; White marking CN. A53 Frame main harness: D: 14-pin
c Connect the (45) CN. A32 M and
f The clip (KHN17050) is a console
the cab main harness CN. A32F. Frame main harness: F: 20-pin Connect with
accessory. CN. A11 Battery relay CN. A55
joint harness (45)
CN. A12 Idling start; White marking CN. A55 Cab main harness: F
*1 Monitor; System *5 Cover; Top (console right) *9 Air conditioner panel CN. A13 Starter cut CN. A56 Frame main harness: G: 18-pin
*2 Trim; Side (upper) *6 Cover; Top (console left) *10 Radio external input terminal CN. A14 Neutral start; White marking CN. A57 Option line harness: 10-pin
Engine controller (engine acces- Switch rocker; Overload warning CN. A15 Key ON CN. B1 Starter switch: 6-pin
*3 *7 Register (engine accessory) *11
sory) (KHR15490) CN. A16 Horn; White marking CN. B2 Throttle volume: 3-pin
Barometric pressure sensor (en- Box; Fuse (cab main harness ac- CN. A17 Relay lamp: Upper CN. B3 Limit switch: 2-pin
*4 *8
gine accessory) cessory) CN. A18 CAB lamp; White marking CN. B4 Knob right switch: 8-pin
CN. A19 Relay beacon CN. B5 Knob left switch: 8-pin
Code Part name Q'ty Code Part name Q'ty CN. A20 Room lamp; White marking CN. B7 Engine stop SW: 10-pin ID: None
1 Switch; Rocker (horn switchover) 1 8 Switch; Starter assembly (CASE) 1 CN. A21 Speaker: R CN. B8 Fan reverse SW: 10-pin ID: Red tape
2 Plastic plug (25) 2 9 Switch; Rocker (E. STOP) 1 CN. A22 Speaker: L; White marking CN. B9 Free swing SW: 10-pin ID: Blue tape
3 Harness; Wire (console) 3 10 Radio; Car (12/24 V) (with AUX; NA) 1 CN. A23 Computer C: 14-pin (fastened with red tape) CN. B10 SW beacon: 10-pin ID: Red tape
4 Harness; Wire (cab; main) 4 11 Switch; Rocker (warning switchover) 1 CN. A24 Computer T: 8-pin (fastened with red tape) CN. B11 SW alarm switchover: 10-pin ID: Blue tape
5 Changeover relay; 24V 5 12 Switch; Rocker (beacon) 1 CN. A25 EST-B: 12-pin CN. B12 SW liftcrane: 10-pin ID: None
CN. A27 Diagnostic: 16-pin CN. B12 Radio: 9-pin
6 Harness; Wire (EST-A) 1 13 Harness; Wire (joint) 1
CN. A28 DC converter: 7-pin CN. B17 Seat suspension: 2-pin (fastened with red tape)
7 Code; Antenna 1
Air conditioner unit A: 8-pin Connect with sup-
CN. A34 CAN H CN. B19
plied air conditioner harness
CN. 52 EST: A: 9-pin CN. A41 Joint: A: 20-pin Air conditioner unit B: 22-pin Connect with sup-
CN. A35 CAN L CN. B20
CN. 54 Frame main harness: E: 22-pin CN. A42 Joint: B: 20-pin plied air conditioner harness
Cab; Harness: A: 14-pin Connect with supplied CN. A36 Diagnostic SW CN. B21 Air conditioner panel: A: 20-pin
CN. A1 Computer A: 1: 26-pin CN. A44
cab harness CN. A37 Memory clear SW CN. B22 Air conditioner panel: B: 16-pin
Cab; Harness: B: 18-pin Connect with supplied CN. B23.
CN. A2 Computer A: 2: 16-pin CN. A45 CN. A39 Joint: Controller: 6-pin Controller DRM (fastened with red tape)
cab harness B24. B25
CN. A3 Computer A: 3: 12-pin CN. A46 Console harness: A: 10-pin CN. A40 Joint: GND: 6-pin
84402832 NA - May 2011

4040-15
84402832 NA - May 2011

4040-16
Section
5001A
Removal and Installation of Shoe Assembly
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Shoe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Shoe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Job code 48100AD07 2. Use a box wrench (19 mm) to loosen the check
valve (1) to release grease, and then loosen the
track shoe tension.
WARNING Do not loosen the check valve all at once.
Loosen it slowly while monitoring the grease output
• When loosening the grease cylinder check
valve, loosen it a little at a time. and shoe loosening.
Use a rag to catch grease that trickles out of the
• The pressure inside the cylinder is very high,
so there is the danger of grease being ex- check valve.
pelled and the plug flying off. If the check valve is loosened too much at this time,
The check valve adjustment procedure it may fly off. Be careful not to work in front of the
should not be done in front of the check check valve.
valve.
• Do not get under the main unit when it is
jacked up.
Make sure to place the main unit on crossties
to prevent falling.
CAUTION
• Make sure to stop the engine for loosening
shoes and when removing master pins.
Items to prepare
• Wrench (19 mm)
• Hammer
• Striking jig
• Crowbar
• Rag
• Lifting equipment (with the required breaking load)
Removal of Shoe Assembly

1. Rotate the shoe and align it so that the master pin
(1) is next to the idler.

then remove the check valve (2) and stopper (3).
• If the check valve (2) is removed, it is easier to
loosen the track shoe tension.
4. Straighten out the S-pin (2) attached to the master

pin (1) by striking one side of it with a hammer, and
use a crowbar, etc. to remove it.
84402832 NA - May 2011

5001A-3
6. Remove the track shoe (1).

At this time, place a wood plank (2) under the bot-
tom track shoe (1) so that it does not fall.
7. Start the engine, raise the lower side frame of the

track shoe removal side about 20 cm, slowly set the
travel lever to backwards, and move the track shoe
(1) to remove it from the lower frame.
5. Use a hammer (2) and striking rod (3) to push the

master pin (1) out.
84402832 NA - May 2011

5001A-4
Installation of Shoe Assembly 3. Wrap the edge of the track shoe (1) onto the take-up
roller (2).
1. Raise the lower side frame about 20 cm. Place a wood plank (3) on the ground and lift the
Lift the track shoe (1) and align it with the sprocket bottom-side link to align the position where the mas-
(2). ter pin is inserted.
Pay attention to the backwards and forward direc-
tion of the track shoe.
4. Insert the master pin (1).

Insert the S-pin (2) and bend it so that it cannot slip
out.
2. Slowly set the travel lever to forward and feed the 5. Tighten the check valve (1).
track shoe to the take-up roller side as shown in the While monitoring the track shoe tension, inject
diagram. grease into the grease cylinder.
In the middle of this procedure when the track shoe
passes the upper roller, use a crowbar, etc. to lift
the track shoe while it is being fed.
Lower the lower side frame after the shoe has
reached position A shown in the diagram.
84402832 NA - May 2011

5001A-5
6. To adjust the track shoe tension, raise the lower 7. Adjust the tension so that the distance indicated
side frame with a wood plank (1) or other device as with A between the frame bottom (1) of the center
shown in the diagram. area of the lower side frame and the lowest hanging
part of the top of the shoe plate (2) is 340 - 360 mm.
84402832 NA - May 2011

5001A-6
Section
5001B
Removal and Installation of Shoe Plate
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Shoe Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Shoe Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Job code 48100AB14 Installation of Shoe Plate

1. Install the shoe plate (1).
CAUTION
work.
Items to prepare
• Grease
• Rag
• Cleaning fluid
Removal of Shoe Plate

1. Use a box wrench (32 mm) to remove the 4 shoe
bolts (1).
2. Use a box wrench (32 mm) to install the 4 shoe bolts
(1).
Bolt (1) tightening torque: 1236 - 1510 N・m
2. Remove the shoe plate (1).
84402832 NA - May 2011

5001B-3
84402832 NA - May 2011

5001B-4
Section
5003A
Removal and Installation of Upper Roller
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Upper Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Job code 48138AB21 2. Use a jack (3) to lift the top of the shoe, and then
insert wood planks (4) to separate the shoe (2) and
upper roller (1) by about 10 mm.
WARNING
• When loosening the check valve, loosen it a
little at a time and stop when any grease ap-
pears.
The pressure inside the cylinder is very high,
so there is the danger of grease being ex-
pelled and the plug flying off if the check
valve is loosened too much.
The check valve adjustment procedure
should not be done in front of the check
valve.
CAUTION
• Be sure to stop the engine before beginning 3. Use a box wrench (30 mm) to remove the 4 bolts
work. (2), and then remove the upper roller (1).
Items to prepare
• Jack (That meets the lifting weight.)
• Rag
• Cleaning fluid
Removal of Upper Roller

1. Use a box wrench (19 mm) to loosen the grease
cylinder check valve (1), then loosen the shoe ten-
sion.
• Grease drains out, so provide rag (2) close to the
drain port.
Do not loosen the check valve all at once.
Loosen it slowly while monitoring the grease out-
put and shoe loosening.
84402832 NA - May 2011

5003A-3
Installation of Upper Roller 4. To adjust the track shoe tension, raise the lower side
frame as shown in the diagram.
1. Use a jack (2) to lift the top of the shoe (1), and then Place a wood plank (1) under the lower frame to
insert wood planks (3). prevent falling.
2. Use a box wrench (30 mm) to install the 2 bolts (4), 5. Adjust the tension so that the distance indicated
and then install the upper roller (1). with A between the frame bottom (1) of the center
area of the lower side frame and the lowest hanging
• Apply Loctite.
part of the top of the shoe plate (2) is 340 - 360 mm.
• Bolt (2) tightening torque: 521 - 608 N・m
3. Tighten the check valve (1).

While monitoring the track shoe tension, inject
grease into the grease cylinder.
84402832 NA - May 2011

5003A-4
Section
5003B
Assembly and Disassembly of Upper Roller
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Configuration Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Jig Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Job code 48138AC30
CAUTION
• To ensure safe operations, wear protective
devices before beginning work and follow all
precautions.
• When removing devices or positioning de-
vices at the time of installation, use a removal
jig and a hammer or steel rod.
• Follow the precautions below when suspend-
ing the load.
• The liftcrane must be operated by a qualified
operator.
load.
• Check the weight of the roller to determine
whether it can be carried by hand or whether
a liftcrane must be used.
• Fix the roller to a level surface so it does not
roll.
• Be sure to repair any parts damaged during
disassembly, and prepare replacement parts
in advance.
• If any parts are significantly rusted or dirty,
clean them before disassembling.
• Any foreign matter entering the equipment
during assembly can create a malfunction.
Therefore, after thoroughly cleaning the
equipment with cleaning oil, air blow the
equipment, and assemble in a clean location.
• When assembling touching parts, be sure to
coat them with new hydraulic oil.
• As a rule, replace all O-rings and other seal
parts with new parts.
<General cautions>
• Be careful not to drop precision parts or let
bump them with other parts during work.
• Do not forcefully open or hit parts in an effort
to speed up operations. Pay careful attention
and proceed slowly so as not to damage any
parts, create any oil leaks, or compromise the
efficiency of the equipment, etc.
• Disassembled parts can easily rust or collect
dust. Therefore, immediately after disassem-
bling parts, take precautions to prevent the
parts from rusting or collecting dust.
Items to prepare
• Hammer
• Wrenches (17 mm)
• Screwdriver
• Engine oil (Shell Rimula Oil #30)
• Specialty jigs
• Pressing machine
• Loctite 262
• Special fiber cloth (Kimwipe)
• Marking pen
• Micrometer caliper
• Caliper
84402832 NA - May 2011

5003B-3
Configuration Diagram
Code Part name Code Part name

1 Cover 7 Bushing
2 O-ring 8 Shaft
3 Plug 9 Bushing
4 Hexagon bolt 10 Roller
5 Loctite 11 Floating seal
6 Thrust plate 12 Bracket
84402832 NA - May 2011

5003B-4
Dimension Diagram
*1 Press fit length
84402832 NA - May 2011

5003B-5
A Bushing removal jig B2 For bushing press-fit jig (9)

B1 For bushing press-fit jig (7) C Floating seal installation jig
84402832 NA - May 2011

5003B-6
Disassembly Procedures 4. Use a box wrench (17 mm) to remove the 3 bolts (1)
inside the roller, and then remove the thrust plate
1. Stand the roller vertically and use a hexagon (2).
wrench (6 mm) (1) to remove the plug (2).
• The plug is coated with seal nylon, which comes
off when the plug is removed. To reuse the plug,
using seal tape is necessary.
5. Lift the roller (1) and remove the shaft (2).
2. Face down the part of the roller from which the

plug was removed and empty the oil from within the
roller.
• It may take a few hours to completely empty the
oil.
• Place an oil pan (1) under the roller to catch the
oil.
6. Remove the floating seal (2) on the roller (1).

Check whether the sliding surface has rusted or is
damaged.

from the cover (1), and then remove the cover.
84402832 NA - May 2011

5003B-7
7. Remove the floating seal (2) on the shaft (1). 9. Use a caliper (4), micrometer caliper (5), and cylin-
der gauge (6) to measure the roller (with bushing)
(1), bracket (2), and shaft (3) for wear and deforma-
tion. Replace with new parts as necessary.
8. Remove the O-ring (2) on the cover (1) side.

• Check whether the O-ring is twisted.
If it is twisted, replace it with a new one.
10. When replacing bushings (1) (2), use jig A (4) to

restrain it from the side where the shaft (3) was re-
moved and press it out with a pressing machine (5).
84402832 NA - May 2011

5003B-8
Assembly Procedures 4. Invert the roller (1) and insert the bushing (2).
Restraining from above using jig B1 (3), push in with
1. Clean all parts. the pressing machine (4).
Push in all the way to the position where jig B1
• Find a clean location.
stops.
• Place a rubber plate or cloth on the work platform
so as not to damage the parts.
5. Insert the floating seal (3) into the roller (1) and
bracket (2).
Use jig C (4) to press it into position.
1 Cleaning fluid
2. After cleaning the parts, air blow them to remove

any remaining cleaning fluid or debris.
6. Use a special fiber cloth to wipe the surfaces of the

floating seals so as to increase adhesion and pre-
vent dust from entering.
3. If the bushing (1) was removed during disassembly,

put it into the roller (2).
Face up the thrust plate installation side, restrain
from above using jig B2 (3), and push in with the
pressing machine (4).
84402832 NA - May 2011

5003B-9
7. Apply hydraulic oil to the roller (1). 10. Install the thrust plate (1) with 3 bolts (2). Degrease
the bolts well, apply Loctite (3) to the bolt open-
ings, and tighten the bolts. After tightening the bolts,
mark them (4).
Bolt (2) tightening torque: 62.8 - 72.6 N・m
8. Install the shaft (1) to the roller (2).
11. Install the cover (1) with 3 bolts (2).

Degrease the bolts, apply Loctite (3) to the bolt
openings, and tighten the bolts.
After tightening the bolts, mark them (4).
Bolt (2) tightening torque: 62.8 - 72.6 N・m
9. Use a special fiber cloth to thoroughly wipe the sur-

face of the thrust plate (1) to prevent any dust or
scratches.
12. Rotate the roller in the direction of the arrow and

check that it rotates smoothly.
84402832 NA - May 2011

5003B-10
13. Inject compressed air (0.2 MPa) from the oil fill port 14. Fill engine oil (about 160 cc) into the roller.
and immerse in water to check that there are no After filling the engine oil, use a hexagon wrench (1)
leaks. to tighten the plug (2) (coated with seal nylon).
After tightening the bolts, mark them (3).
• To reuse a plug, wrap it with seal tape.
Plug (2) tightening torque: 24.5 N・m
This completes the assembly.
84402832 NA - May 2011

5003B-11
84402832 NA - May 2011

5003B-12
Section
5003C
Removal and Installation of Lower Roller
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Lower Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Job code 48138AD50 2. Jack up the side frame on the side where the roller
is being replaced, as shown in the diagram.
Jack up so that the shoe is floating about 5 cm,
WARNING and insert wood plank (1) under the lower frame to
prevent falling.
• Do not get under the main unit when it is
jacked up.
Make sure to place the main unit on wood
planks to prevent falling.
• When loosening the grease cylinder check
valve, loosen it a little at a time and stop when
any grease appears. The pressure inside the
cylinder is very high, so there is the danger
of grease being expelled and the plug flying
off if the check valve is loosened too much.
CAUTION
work.
3. If it is impossible to insert wood planks (3) under
Items to prepare the lower frame, insert wood planks (3) between the
• Box wrenches (19 mm, 36 mm) side frame and the link shoe (2) to separate the link
• Rag shoe and lower roller (1) by about 15 mm.
• Cleaning fluid
Removal of Lower Roller

1. Use a box wrench (19 mm) to loosen the check
valve (1), and then loosen the shoe tension.
Do not loosen the check valve all at once.
Loosen it slowly while monitoring the grease output
and shoe loosening.
• Grease drains out, so provide rag (2) close to the
drain port.
4. Use a box wrench (36 mm) to remove the 4 bolts

(2), then remove the lower roller (1).
84402832 NA - May 2011

5003C-3
Installation of Lower Roller 3. When adjusting the track shoe tension, raise the
lower side frame as shown in the diagram.
1. Insert wood planks (4) between the side frame and Place a wood plank (1) under the lower frame to
the link shoe (3), use a box wrench (36 mm) to install prevent falling.
4 bolts (2) and then install the lower roller (1).
• Bolt (2) tightening torque: 902 - 1049 N・m
4. Adjust the tension so that the distance indicated

with A between the lower frame (1) of the center
area of the lower side frame and the lowest hang-
2. Tighten the check valve (1). ing part of the shoe plate (2) is 340 - 360 mm.
While monitoring the track shoe tension, inject
grease into the grease cylinder.
84402832 NA - May 2011

5003C-4
Section
5003D
Assembly and Disassembly of Lower Roller
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS

CAUTION
precautions.
ing the load.
• The liftcrane must be operated by a qualified
operator.
load.
• Check the weight of the roller to determine
whether it can be carried by hand or whether
a liftcrane must be used.
roll.
in advance.
• When assembling sliding parts, be sure to
<General cautions>
to speed up operations.
Pay careful attention and proceed slowly so
as not to damage any parts, create any oil
leaks, or compromise the efficiency of the
equipment, etc.
dust.
Therefore, immediately after disassembling
parts, take precautions to prevent the parts
from rusting or collecting dust.
Items to prepare
• Hammer
• Wire clip
• Pliers
• Gear puller
• Screwdriver
• Gear oil (Mobile Gear Oil SHC320)
• Specialty jigs
• Loctite
• Caliper
• Cylinder gauge
84402832 NA - May 2011

5003D-3
Part name Part name

1 Roller 6 Collar (with plug)
2 Shaft 7 Wire clip
3 Bushing 8 Plug
4 Floating seal 9 Collar (without plug)
5 O-ring
84402832 NA - May 2011

5003D-4
Dimension Diagram
84402832 NA - May 2011

5003D-5
A Bushing removal jig Disassembly Procedures

B Bushing press-fit jig
C Floating seal installation jig 1. Stand the roller vertically and use a hexagon
wrench (6 mm) (1) to remove the plug (2).
off when the plug is removed.
To reuse the plug, using seal tape is necessary.

roller.
oil.
• Place an oil pan (1) underneath to catch the oil.
• Securely fasten so that the roller does not fall
over.
3. Remove the wire clip (1).

Tap another wire (2) with the hammer (3) from the
outside to push out the wire clip that is already in
the roller.
• Place the roller horizontally and secure it so it
does not roll before doing this work.
• The wire in the roller is very securely fixed, so
prepare several wire clips.
Also be sure to coat with lubricant.
84402832 NA - May 2011

5003D-6
6. Check whether the surface of the floating seal (2)

sliding against the removed collar (1) has rusted or
is damaged.
Also make sure the O-ring (3) on the seal ring (4) is
not twisted.
• The O-ring cannot be reused.
Replace it with new part.
4. Use pliers (2) to remove the pushed out wire clip (1).
7. Remove the floating seal (1) on the roller.

As described in step 6, check whether the sliding
surface has rusted or is damaged.
Also make sure the O-ring is not twisted.
5. Use a gear puller (2) to remove the collar (1).

If the collar is difficult to remove, hook the collar on
the bolt and catch the puller on that part.
• If the collar has rusted or is difficult to remove due
to an accumulation of debris, subject it to a shock,
for example by hitting it with a hammer, to make
it easier to move.
• When hitting it with a hammer, be careful not to
dent it.
8. Remove the O-ring (2) on the shaft (1).

84402832 NA - May 2011

5003D-7
9. Remove the shaft (1). 12. Use a caliper (6), micrometer caliper (5), and cylin-
der gauge (7) to measure the roller (with bushing)
(1), collars (2) (3), and shaft (4) for wear and defor-
mation.
Replace with new parts as necessary.
10. Check whether the surface of the floating seal (2)

sliding against the removed collar (1) on the oppo-
site side has rusted or is damaged.
Also make sure the O-ring (3) on the seal ring (4) is
not twisted.
13. When replacing a bushing, insert jig A (3) into the

bushing (1), and use a cylindrical object (such as a
11. As described in step 6,7, remove the floating seal shaft) (2) to push from the top.
(1) on the opposite side. The bushing comes off.
84402832 NA - May 2011

5003D-8
Assembly Procedures 4. Use jig C (5) to push the floating seal (4) into the
collars (2) (3) and roller (1) by hand.
1. Clean all parts by immersing them in cleaning fluid
(1).
• Select a clean location.
5. Use a special fiber cloth to wipe the surfaces of the

floating seals so as to increase adhesion and pre-
vent dust from entering.

6. Apply gear oil to the floating seals (3) on the collars

(1) (2).

Restraining from above using jig B (3), push in with
the pressing machine (4).
Invert the roller and insert the bushing on the oppo-
site side in the same manner.
84402832 NA - May 2011

5003D-9
7. Attach O-rings (3) to the shaft (2) and mount into the 10. Turn the main unit and check that the roller rotates
roller (1). properly.
8. Install the collars (1) (2) on both sides. 11. Inject compressed air (0.2 MPa) from the oil fill port
and immerse in water to check that there are no
leaks.
9. Attach the wire clip (1).

• When attaching the wire clip, secure the roller 12. Fill gear oil (about 280 cc) into the roller.
main unit so that it does not roll. Use a hexagon wrench (6 mm) (2) to tighten the
plug (1) with the nylon seal applied.
• Mobile Gear Oil SHC320 is recommended for
use.
Plug (1) tightening torque: 24.5 N・m
84402832 NA - May 2011

5003D-10
Section
5004
Removal and Installation of Sprocket
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

WARNING 2. Slowly rotate the shoe so that the shoe joint section
(1) is aligned as in the diagram on the right.
• When loosening the check valve, loosen it a Place wood plank (2) under the shoe and return the
little at a time and stop when any grease ap- bucket to its original position.
pears. Perform air bleeding for the hydraulic line.
The pressure inside the cylinder is very high, For details, see Air Bleed Procedures.
CAUTION
• Before removing the shoes, be sure to bleed
off any air in the hydraulic circuits.
load.
Items to prepare
• Box wrenches (19 mm)
• Hammer (to remove the master pin)
• Striking jig (to remove the master pin)
• Loctite #262
• Rag
• Cleaning fluid
Removal of Sprocket
1. Allow the bucket (1) to touch the ground so as to
elevate the shoe (2) of the side to be removed as in
the diagram on the right.
84402832 NA - May 2011

5004-3
3. Use a box wrench (19 mm) to rotate the grease 5. Place a striking jig (2) against the master pin (1) and
cylinder check valve (1) and loosen the shoe ten- hit it with a hammer (3) to push the master pin out.
sion.
• Grease will flow out, so have rag ready.
If the check valve is loosened too much at this
time, it may fly off.
Be careful not to work in front of the check valve.
6. Open the shoe (1) to the rear.
4. Pull out the S-pin (1) from the rear of the joint sec-
tion.
8. Use a wire rope (1) to lift the drive sprocket (2) and
remove it from the travel motor (3).
84402832 NA - May 2011

5004-4
Installation of Sprocket • Tightening torque M16: 267 - 312 N・m

84402832 NA - May 2011

5004-5
84402832 NA - May 2011

5004-6
Section
5005A
Removal and Installation of Take-up Roller
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Take-up Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Take-up Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

WARNING 3. Install the lifting equipment (4) on the take-up roller

(1) and recoil spring assembly (3) and hang them
• When loosening the grease cylinder check from the side frame (2) with the liftcrane.
valve, loosen it a little at a time.
• The pressure inside the cylinder is very high,
so there is a danger of grease being expelled
and the plug flying off.
valve.
• Do not get under the machine when the main
unit is jacked up.
• Make sure to place the main unit on wood
planks or the like to prevent falling.
• Align the shoe assembly feed location and
stop the engine except when working.
Items to prepare
4. Place the take-up roller (1) and recoil spring assem-
• Wrench (24 mm) bly (2) onto wood planks (4) as in the diagram.
• Hammer Use a wrench (24 mm) to remove the take-up roller
• Lifting equipment bolt (3) and separate the roller and the recoil spring
• Loctite #262 assembly.
• Striking jig
• Liftcrane
• Crowbar
• Rag
Removal of Take-up Roller

1. Remove the shoe assembly.
See the "Removal and Installation of Shoe Assem-
bly".
2. Use a crowbar (3) to pull off the take-up roller (1)
and recoil spring assembly from the side frame (2).
84402832 NA - May 2011

5005A-3
Installation of Take-up Roller 2. Install the lifting equipment (4) on the take-up roller
(1) and recoil spring assembly (3) as in the diagram,
1. Place the take-up roller (1) and recoil spring assem- lift them up with the liftcrane, and insert them into
bly (2) onto wood planks (4) as in the diagram. Use the side frame (2).
a wrench (24 mm) to fasten the take-up roller (1) Push in with the crowbar until the recoil spring as-
and recoil spring assembly (2) with the bolt (3). sembly contacts the grease cylinder.
At this time, be sure to coat the bolt with Loctite
#262.
Installation bolt tightening torque: 267 - 312 N·m
3. Install the shoe assembly.

For details on installation, see the "Removal and
Installation of Shoe Assembly" procedure.
84402832 NA - May 2011

5005A-4
Section
5005B
Assembly and Disassembly of Take-up Roller
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS

CAUTION • Seal tape

• Oil pan (drip pan)
• To ensure safe operations, wear protective • Water container for inspection
precautions.
ing the load.
• The liftcrane must be operated by a quali-
fied operator.
load.
• Check the weight of the roller to deter-
mine whether it can be carried by hand or
whether a liftcrane must be used.
roll.
in advance.
• When assembling sliding (5) parts, be sure to
• The take-up roller is a heavy object and re-
quires at least 2 workers to handle.
<General cautions>
to speed up operations. Pay careful attention
and proceed slowly so as not to damage any
parts, create any oil leaks, or compromise the
efficiency of the equipment, etc.
dust. Therefore, immediately after disassem-
bling parts, take precautions to prevent the
parts from rusting or collecting dust.
Items to prepare
• Hammer
• Pliers
• Gear puller
• Screwdriver
• Engine oil (Shell Rimula Oil #30)
• Specialty jigs
• Loctite
• Caliper
• Cylinder gauge
84402832 NA - May 2011

5005B-3
Code Part name Code Part name

1 Take-up roller 6 Pin hub
2 Wrapping bearing 7 Hub (with plug)
3 Floating seal 8 Plug
4 O-ring 9 Hub (without plug)
5 Roller shaft
84402832 NA - May 2011

5005B-4
Dimension Diagram
84402832 NA - May 2011

5005B-5
A Bushing removal jig Disassembly Procedures

B Bushing press-fit jig
C Floating seal installation jig 1. After cleaning the roller with kerosene, use the
hexagon wrench (1) to remove the plug (2) from
the hub (3).
off when the plug is removed.
Seal tape is necessary for reusing.

roller.
oil.
• Place an oil pan (1) underneath to catch the oil.
3. Remove the pin hub (2) from the hub (1), and re-
move the hub (1) from the shaft (3).
• Only remove on one side.
84402832 NA - May 2011

5005B-6
4. After removing the O-ring (2) on the shaft (1), pull 7. Remove the floating seals (2) from the roller (1).
the shaft (1) out from the roller (3).
• The O-ring cannot be reused. Replace it with new
part.
8. Use a micrometer caliper (4), cylinder gauge (5),

and caliper (6) to measure the roller (with bushing)
(1), hub (2), and shaft (3) for wear and deformation.
Replace with new parts as necessary.
5. Remove the pin hub (2) from the hub (1).
Next, after removing the hub (1) from the shaft (3),
remove the O-ring (4) from the shaft (3).
6. Remove the floating seals (2) from the hub (1).
9. When replacing the bushing (1), remove it by plac-

ing a striking rod (2) against the end surface and
striking that with a hammer (3) uniformly left and
right as in the diagram.
• Do not disassemble the bushing (1) unless it has
become unusable due to wear, etc.
• Be careful not to scratch the inside of the roller
when striking the end of the bushing.
84402832 NA - May 2011

5005B-7
Assembly Procedures
1. Clean all parts.
• Find a clean location.
• In order to clean off adhered matter that forms
sharp points and causes scratches, immerse
parts in cleaning fluid (1) until dirt and grease
float to the top.
10. Invert the roller (1), use jig A (2) to push up against
the bushing (3), and press with a rod-shaped object
(4) (such as a shaft). The bushing comes off.

• If the parts are to be left as is for a long time after
drying them, apply engine oil.

Use a pressing machine (3) to press in both the left
and right sides.
84402832 NA - May 2011

5005B-8
4. Use the jigs (1) (2) attached to the pressing machine 7. Use a special fiber cloth to thoroughly wipe the slid-
to install the bushing (3). ing surface of the floating seal to prevent any dust
Use the pressing machine to press from the oppo- or scratches.
site side.
Next, use a special fiber cloth to remove all dust and
debris.
8. Apply engine oil to the floating seals (1) on the hubs

(2) (3).
5. Install the floating seal (2) to the hub (1).

Use jig C (3) to press it into position.
9. After installing the O-ring (2) to the shaft (1), attach

the shaft to the hub (3) and fasten it with the pin hub
(4).
6. Use jig C (3) to install the floating seal (2) to the
roller (1) side.
84402832 NA - May 2011

5005B-9
10. Install the shaft (2) and O-ring (3) to the roller (1). 13. Fill engine oil (190 cc) into the roller main unit.
• The roller main unit can be very unstable, so be
careful in securing it.
11. After attaching the O-ring (4) to the shaft (1), attach
the hub (2) and fasten it with the pin hub (3).
14. After filling the oil, use a hexagon wrench (6 mm) (2)
to tighten the plug (1) with the nylon seal applied.
12. Inject compressed air (0.2 MPa) from the oil fill port
and immerse in water to check that there are no
leaks.
84402832 NA - May 2011

5005B-10
Section
5005C
Removal and Installation of Grease Cylinder
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of grease cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of grease cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

WARNING 3. Jack up the side frame on the side where the grease
cylinder is being removed as shown in the diagram.
• When loosening the grease cylinder check Jack up so that the shoe is floating about 5 cm,
valve, loosen it a little at a timec and insert wood plank (1) under the lower frame to
• The pressure inside the cylinder is very high, prevent falling.
so there is a danger of grease being expelled
and the plug flying off.
valve.
• Do not get under the machine when the main
unit is jacked up.
• Make sure to place the main unit on wood
planks or the like to prevent falling.
• Align the shoe assembly feed location and
stop the engine except when working.
Items to prepare
• Hammer 4. Use a wrench (36 mm) to remove the bolts (1) and
• Lifting equipment washers (2), and then remove the track guard (3).
• Loctite #262 Tightening torque for bolt installation: 902 - 1049
• Striking jig N・m
• Liftcrane
• Crowbar
• Wood plank
• Rag
Removal of grease cylinder

1. Remove the shoe assembly.
See the "Removal and Installation of Shoe Assem-
bly" procedure.
2. Use a crowbar (3) to pull off the take-up roller (1)
and recoil spring assembly about 100 mm from the
side frame (2).
When removing the grease cylinder, use a wood
plank or the like (4) to prevent the take-up roller (1)
and recoil spring assembly from coming out. 5. Install the wire (2) on the grease cylinder assem-
bly (1), and then lift it with the liftcrane so that it is
slightly tensed.
84402832 NA - May 2011

5005C-3
6. Use a wrench or box wrench (24 mm) to remove the Installation of grease cylinder
bolt (1) and washer (2), and then remove the grease
cylinder (3). To install, perform the reverse of the removal procedure.
Lower the liftcrane as is to lower to under the frame, Grease cylinder installation bolt tightening torque: 267 -
and then take out from between the lower rollers. 312 N・m
When installing bolts, coat the threaded sections with
Loctite #262.
84402832 NA - May 2011

5005C-4
Section
5005D
Assembly and Disassembly of Grease Cylinder
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS

CAUTION
gear before beginning work and follow all
precautions.
ing the load.
• The liftcrane must be operated by a quali-
fied operator.
load.
• Check the weight of the grease cylinder to
determine whether it can be carried by hand
or whether a liftcrane must be used.
in advance.
• When assembling sliding parts, be sure to
<General cautions>
• Do not forcefully open or hit parts in an
effort to speed up operations. Pay care-
ful attention and proceed slowly so as not
to deform any parts, create any oil leaks,
or compromise the efficiency of the equip-
ment, etc.
• Disassembled parts can easily rust or col-
lect dust. Therefore, immediately after dis-
assembling parts, take precautions to pre-
vent the parts from rusting or collecting
dust.
Items to prepare
• Hammer
• Wrench (19 mm)
• Screwdriver
• Specialty jigs
• Marking pen
84402832 NA - May 2011

5005D-3

1 Dust seal 1 7 Spring washer 2
2 Piston rod 1 8 Bracket 1
3 U-packing 1 9 Check valve assembly 1
4 Retaining ring 1
5 Grease cylinder 1
6 High-strength bolt 2 Dimension Diagram
84402832 NA - May 2011

5005D-4
A Dust seal press-fit jig Disassembly Procedures

B Removal jig
1. Clean the grease cylinder with kerosene, remove
the bolt (1) and washer (2), and remove the bracket
(3).
Remove the check valve (5) from the grease cylin-
der (4).
84402832 NA - May 2011

5005D-5
2. Pull out the piston rod (2) from the grease cylinder Assembly Procedures
(1).
1. Place parts in a rough cleaning container filled with
kerosene to clean off any adhered matter that can
form sharp points and cause scratches.
• Immerse in kerosene until dust, grease, and other
adhered matter comes off and floats to the sur-
face.
2. Place parts in a finish cleaning container filled with
kerosene and clean while gently moving the parts.
After cleaning, wipe away the kerosene with a clean
rag.
• Place the parts in a location free of dust and mois-
ture and use compressed air to dry the parts. After
drying, coat parts with engine oil.
3. Use the removal jig (B) to remove the dust seal (2) 3. Install the U-packing (1) coated with grease onto the
from the grease cylinder (1). piston rod (2), and then install the snap ring (3).
• Use a new U-packing (1).
• Be careful that the U-packing (1) faces correctly.
4. Remove the snap ring (2) from the piston rod (1),
and then use the removal jig (B) to remove the
U-packing (3).
84402832 NA - May 2011

5005D-6
4. Use the jig (A) and hammer (C) to install the dust 5. Coat the surface of the piston rod (1) with grease
seal (2) on the grease cylinder (1). and insert into the grease cylinder (2).
Apply grease to the lip section of the dust seal (2).
Use a new dust seal (2).
6. Tighten the check valve (1) to the grease cylinder

(2) to the specified tightening torque.
Install the bracket (3) and secure it with the spring
washer (4) and the bolt (5).
Check valve tightening torque: 48.99 - 68.61 N・m
Bracket installation bolt tightening torque: 58.8 N・
m
84402832 NA - May 2011

5005D-7
84402832 NA - May 2011

5005D-8
Section
6001
Removal and Installation of Travel Motor
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Travel Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

WARNING 4. Perform air bleeding for the hydraulic line.

For details, see "Air Bleed Procedures" under Main-
• When loosening the check valve, loosen it a tenance in the Service Text.
little at a time and stop when any grease ap-
pears.
The pressure inside the cylinder is very high,
CAUTION
• Before removing the shoes, be sure to bleed
off any air in the hydraulic circuits.
load.
Items to prepare
• Hammer (to remove the master pin)
• Striking jig (to remove the master pin)
• Loctite #262
• Rag
• Cleaning fluid
Removal of Travel Motor

1. Allow the bucket (1) to touch the ground so as to 5. Use a box wrench (19 mm) to rotate the grease
elevate the shoe (2) of the side to be removed as in cylinder check valve (5) and loosen the shoe ten-
the diagram on the right. sion.
• Grease will flow out, so have rag ready.
If the check valve is loosened too much at this
time, it may fly off.
Be careful not to work in front of the check valve.
2. Slowly rotate the shoe so that the shoe joint section

(3) is aligned as in the diagram on the right.
3. Place wood planks (4) under the shoe and return
the bucket to its original position.
84402832 NA - May 2011

6001-3
6. Pull out the S-pin (6) from the rear of the joint sec- 9. Use a wrench (19 mm) to remove the 4 bolts (10),
tion. then remove the cover (11).
7. Place a striking jig (9) against the master pin (7) and 10. Use wrenches (27 mm for drain hose, 41 mm for
hit it with a hammer (8) to push the master pin out. high-pressure hose) to remove the drain hose (13)
and 3 high-pressure hoses (12).
• Be sure to use plugs on the removed drain and
high-pressure hoses.
8. Open the shoe (2) to the rear.
11. Use a wrench (19 mm) to remove the pilot hose (15)
and a wrench (27 mm) to remove the elbow (14).
84402832 NA - May 2011

6001-4
12. Attach the wire rope (17) to the travel motor (16) as Installation of Travel Motor
in the diagram.
Adjust the wire rope so that it is located at the center 1. Attach the travel motor to the lower frame as in the
of mass and lift it with the liftcrane so that it is slightly diagram.
tensed.
• Be careful of the installation angles.
13. Use a box wrench (36 mm) to remove all 18 bolts

(18). 2. Apply Loctite #262 to the installation bolt (2)
threaded sections and temporarily tighten them.
Tighten top and bottom alternately to the specified
torque so that an even tightening force acts on op-
posing corners as shown in the diagram below.
Installation bolt tightening torque: 900 - 1051 N・m
14. Remove the travel motor (16).
84402832 NA - May 2011

6001-5
3. Use a wrench (27 mm) to remove the elbow (3) and 6. Wrap the shoe (9).
a wrench (19 mm) to install the pilot hose (4).
7. Insert the master pin (11).

4. Use wrenches (27 mm for drain hose, 36 mm for Insert the S-pin (10) and bend it so that it cannot slip
high-pressure hose) to install the drain hose (6) and out.
high-pressure hoses (5).
8. Tighten the check valve (12).

5. Use a wrench (19 mm) to install the cover (8) with While monitoring the track shoe tension, inject
the 4 bolts (7). grease into the grease cylinder.
Installation bolt tightening torque: 63.7 - 73.5 N・m
9. When adjusting the track shoe tension, raise the

lower side frame as shown in the diagram.
Place a wood plank (13) under the lower frame to
prevent falling.
Adjust the tension so that the distance indicated
with A between the frame bottom (14) of the center
area of the lower side frame and the lowest hang-
ing part of the top of the shoe plate (15) is 340 - 360
mm.
84402832 NA - May 2011

6001-6
84402832 NA - May 2011

6001-7
84402832 NA - May 2011

6001-8
Section
6002
Assembly and Disassembly of Travel Motor
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Tools for Assembly and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Standard tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Secondary materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special Tool (jig) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Measurement device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Motor Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Precautions before motor disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassembly procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal of supplied valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disassembly of motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Disassembly of overload relief valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Reduction gear disassembly procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Disassembly preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Disassembly procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation to receiving platform of reduction gear (unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Removal of reduction gear cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Removal of carrier 1 assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Removal of carrier 2 assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Removal of housing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Disassembly of housing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Removal of floating seal from motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Disassembly of carrier 1 assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Disassembly of carrier 2 assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Maintenance standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Motor parts maintenance standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Reduction gear parts maintenance standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Inspection prior to reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Thrust washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Floating seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Parts maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Assembly of motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Precautions before Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Assembly procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Motor Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Motor assembly procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Assembly of the carrier 2 assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Assembly of the carrier 1 assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Installation of bearing and floating seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Assembly of the housing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Determining the thickness of the angular bearing shim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Installation of housing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Installation of carrier 2 assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Installation of carrier 1 assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Cover attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Gear oil filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Initial pre-conditioning operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Drain charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Performing initial operation (pre-conditioning operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
General cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Causes of troubles and countermeasures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Structural diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Travel motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Reduction gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Tools for Assembly and Disassembly

Use the tools indicated below for assembly and disassembly of the motor.
Standard tools
Secondary materials
Standardized
Secondary materials No. Type and dimen-
No. Part used with
name Manufacturer sions
name
1 Seal tape
242 4, 25
2 Adhesive Loctite
515 24
GL-4#90 equiva-
3 Gear oil
lent
ISO VG46 equiva-
4 Hydraulic oil
lent
5 Grease Lithium series
No.2 equivalent
6 White kerosene
oil
7 Liquid packing ThreeBond 1211
For sliding sur-
8 Lapping plate
face repair
For sliding sur-
9 Lapping agent #1000
face repair
10 Copper plate
11 Tube brush For cleaning
12 Bamboo brush For cleaning
13 Oil pan For receiving oil
14 Plastic container For filling grease
15 Rag
16 Color check 9, 10, 11, 15, 16, 17, 18, 22, 23
84402832 NA - May 2011

6002-3
Special Tool (jig)

Usage target
No. Tool name Type and dimensions
part
1 Gear (bearing) puller 10, 51
2 Holder fittings (2) 13, 51
3 Rear cover guide pins (2) 1, 24
4 Brake piston removal jig (2) 21
5 Shim thickness adjustment jig 52
6 Oil seal insertion jig 3
7 Rear bearing insertion jig 51
84402832 NA - May 2011

6002-4
Usage target
No. Tool name Type and dimensions
part
8 Brake piston insertion jig 21
Piston and shoe measurement

9 12, 18
jig
84402832 NA - May 2011

6002-5
Hexagon socket head bolt M6 x

d
100
t 10 mm or longer
When the rear cover bolts are
*1
used as is
D1 2-20 notch
10 - Plain flat washer with
D2
rounded finish 18 mm
84402832 NA - May 2011

6002-6
Measurement device
No. Tool name Specifications Part used with
1 Dial gauge
2 Micrometer caliper
3 Micro depth gauge 0 - 15 mm (JIS B7544)
4 Caliper 0 - 150 mm (JIS B7507: 1997)
84402832 NA - May 2011

6002-7
Motor Disassembly Procedures 5. When removing lines connected to the motor, hy-
draulic oil from inside the lines will spray out.
Precautions before motor disassembly For this reason, remove these lines only after re-
moving pressure from inside the lines and prepar-
Begin motor disassembly only after thoroughly reading ing an oil pan.
the precautions below. To prevent injuries due to the motor falling when
1. When performing disassembly, always wear protec- transporting it by lifting the motor with a liftcrane,
tive devices such as a helmet, goggles and safety lift the machine with the eyebolts (a) mounted in the
shoes. positions indicated in the diagram below.
2. Use the specified tools when performing disassem- 6. The motor is filled with hydraulic oil.
bly. Before disassembling the motor, prepare an oil pan
3. Remove all lines connected to the motor and re- and drain the hydraulic oil from the motor.
move the motor from the mother machine only after 7. To prevent injuries during disassembly, prepare a
making sure that the machine is on a level surface waist-high, stable work platform to perform work on.
and there are no external forces acting on rotating 8. The motor comprises high-precision parts.
parts so that the mother machine does not operate For this reason, foreign matter adhering to parts can
uncontrollably when the motor is removed. be damaging.
4. To prevent foreign matter from entering the lines Motor disassembly should be done in an inside
and motor when removing the motor from the space without dust, and mud and dirt should be
mother machine, sufficiently clean off mud and dirt prevented from adhering to parts.
adhered around the motor before removing lines 9. The motor comprises high-precision parts.
connected to the motor. For this reason, dents and scratches on part sur-
faces can be damaging.
Be very careful when handling parts during disas-
sembly and do not create any dents or scratching.
10. To prevent personal injury and damage to parts dur-
ing disassembly, do not force disassembly of parts
which are especially tight to disassemble.
Motor lifting positions

Tightening torque
Dimen-
Code Part name Tightening torque (N•m)
sions
415.8 - 340.2 N・m
(4) Hexagon socket head bolt M18 x 110
(Loctite #242 coating)
75.5 - 61.7 N・m
(25) Hexagon socket head bolt M10 x 30
(Loctite #242 coating)
(26) Hexagon socket head plug G3/4 161.7 - 132.3 N・m
(29) Plug M42 441 - 461
(35) Pilot valve plug G3/8 49.0 - 58.8
(38) Plug G1/4 26.46 - 32.34
(42) Plug G1/8 16.17 - 13.23
(56) Hexagon socket head bolt M18 356.4 - 291.6
(57) Overload relief valve M27 98.1 - 118
(60) Plug G1/2 107.91 - 88.29
84402832 NA - May 2011

6002-8
Disassembly procedure However, the motor cannot be disassembled if the over-

load relief valve (57) is not removed first.
Removal of supplied valves
CAUTION
Remove the supplied valves before disassembling the
motor parts. Perform the disassembly procedure after the
• It is recommended not to remove any supplied valves motor has reached its normal temperature, oth-
other than those required for disassembly. erwise burns can occur.
Removal of supplied valves • Adhesive is applied to the thread sections to fix

the spool assembly (26), so no further disassem-
1. Remove the M42 plug (29) and O-ring (30). bly is possible.
2. Remove the spring (28), spring receiver (27), and
spool assembly (26). 3. Remove the plug (42), O-ring (43), orifice spring
(41), and orifice (40).
• Make reference marks on the spool assembly (26)
and rear cover (24), and when reassembling the
parts, make sure that the assembly direction does
not go in the opposite left-right direction.
84402832 NA - May 2011
6002-9
4. Remove the overload relief valve (57). 6. Remove the coupling (58).
• When removing the overload relief valve (57), the CAUTION
valve seat (57-3) can easily come off, so be care-
ful not to let it fall inside the rear cover (24), and Be very careful not to get hands stuck between
check that it is not lost. parts or drop the carried parts on feet.
5. Loosen the pilot valve plug (35), and remove the
O-ring (36), spring (34), spring receiver (33), pilot
valve spool (31), and pin (32).
84402832 NA - May 2011

6002-10
Disassembly of motor 5. Remove the valve plate (54) while making sure that
the cylinder block (13) does not come off.
1. Place the motor shaft horizontally and pull it out
while leaving the 2 vertically-opposite hexagon • Make reference marks on the valve plate (54) and
socket head bolts M18 x 50 (56) in place. rear cover (24), and when reassembling the parts,
2. Install guide pins (a) at the 2 vertically-opposite lo- be sure not to reverse the front and rear.
cations. (Purpose: This prevents the rear cover
from falling when removed and acts as a guide dur-
ing assembly.)
3. Slowly loosen the remaining 2 hexagon socket head
bolts M18 x 50 (56) at the same time.
4. Remove the rear cover (24) and brake spring (55)
while making sure that the cylinder block (13) does
not come out together with the rear cover (24).
CAUTION
Be very careful not to get hands stuck be-
tween parts or drop the carried parts on
feet.
• Be careful not to drop the valve plate (54), brake

spring (55), rear bearing (51) outer race, shim
(52), or O-rings (50) (47) (49).
• There is a shim (52) under the rear bearing (51)
outer race.
Be very careful not to lose this during disassem-
bly.
Removal of rear cover
b Air feed source (left side hole)
6. Using the removed hexagon socket head bolt M18 x

50 (56), press the holder fitting so as not to scratch
the sliding surface of the cylinder block (13), and let
the rear bearing (51) inner race come out.
• Insert a rubber plate between the sliding surface
and the holder fitting so as not to scratch the slid-
ing surface of the cylinder block (13).
84402832 NA - May 2011

6002-11
7. Attach the gear (bearing) puller to the rear bearing • The piston and shoe are caulked and cannot be
(51) inner race and remove it. disassembled.
Removal of rear bearing Casing matching surface enlargement

8. While holding the brake piston (21) with the hand,
fill compressed air from the brake release oil hole
(c) and push out.
CAUTION
Be very careful as the air pressure can
cause the brake piston (21) to fly off.
• When using a removal jig, install the removal jig to

the M6 taps (2 locations) on the end of the brake
piston (21), and pull out the brake piston (21).
9. Insert a rod that will not scratch the cylinder block
(13) (such as rolled-up cylindrical paper) into the
piston (18) hole, and make a reference mark on
the outer circumference of the cylinder block (13)
for reference.
10. Remove the rotary group (cylinder block (13), piston
assembly (18), shoe retainer (17), spherical joint
(16), spring receiver (15), and cylinder spring (14)).
CAUTION
feet.
11. Remove the separator plate (19) and friction plate

(20).
12. Remove the 9 piston assemblies (18), shoe retainer
(17), and spherical joint (16) from the rotary group
at the same time. Removal of cylinder block
13. Remove the spring receiver (15) and cylinder spring
(14) from the cylinder block (13). [Tip]
The preceding described how to disassemble the
• With the piston assembly (18) and shoe retainer motor unit, but the disassembly is also the same
(17) removed, align the alignment mark (e) and if it comes with a reduction gear.
the reference mark (d) and insert them into the Disassembling a motor with a reduction gear may
cylinder block (13). be easier because the shaft does not swing as
The purpose is to house the pistons into the same much.
holes before disassembly when reassembling.
• Be careful not to scratch each of the sliding sur- 14. Remove the shoe plate (12).
faces.
If the sliding surface is scratched, the part cannot
be reused.
84402832 NA - May 2011

6002-12
15. Do not remove the tilting piston set (6), (7).

If these parts must be removed, hold the tilting pis-
ton (6) with the hand and fill air from the tilting path
hole (f) and push out the parts.
CAUTION
Be very careful as the air pressure can
cause the tilting piston (6) to fly off.
16. The shaft (9) can be pulled out.

17. When replacing the front bearing (10), remove the
inner race from the shaft (9) with the bearing puller,
and replace with a new bearing.
• When replacing parts related to the tightening
margin of the bearing, such as the bearings (10)
(51), shaft (9), casing (1), and rear cover (24), the
thickness of the shim (52) needs to be adjusted.
Correctly measure the shim gap when the shim
is lightly positioned, replace with a shim (52) that
matches the gap, and adjust the bearing gap to 0
- 0.1 mm.
A separate jig or other tool is needed to determine
the jig thickness.
Contact us for details.
• Do not remove the pivot (11).
If removing the part, make a reference mark on
the area aligned with the shoe plate (12).
• Do not remove the oil seal (3).
If the part is removed, always replace with a new
part. Removal of shoe plate
If removing the oil seal, remove the retaining ring 18. Determining the thickness of the taper roller bearing
(4), and then remove the oil seal (3). shim (52)
Casing matching surface enlargement
84402832 NA - May 2011

6002-13
Determining the shim thickness Disassembly of overload relief valve

• This needs to be performed when replacing the • The overload relief valve (57) is an important part in
motor casing (1), rear cover (24), shaft (9), or terms of performance and safety.
bearings (10) (51). Because resetting the pressure of this part is ex-
tremely difficult, the overload relief valve assembly
1) Measure dimension E in the assembled con-
should be replaced without disassembling if a problem
dition indicated in the above diagram.
occurs.
• Be careful not to allow the shaft (9) to fall.
2) Measure dimension F on the rear cover side.
• Use the average of the measurements of
the 4 orthogonally intersecting points on the
circumference.
3) When the thickness of the used shim (52) is
"S," gap "Y" is as follows.
Y = F - (E + S)
4) In the case of this motor, select 1 or 2 shims
(52) so that gap Y is 0 - 0.1 mm.
• The valve seat (57-3) fits into the socket (57-1) internal
hole by a clearance fit and can easily come off, so
when removing the overload relief valve (57) from the
rear cover (24), be careful not to drop or lose the valve
seat (57-3).When installing the overload relief valve
(57) to the rear cover, apply grease (g) to the fitting
section and install in a way that the valve seat (57-3)
does not come off.
Valve seat fitting section
84402832 NA - May 2011

6002-14
Reduction gear disassembly Disassembly procedure

procedures Installation to receiving platform of reduction
gear (unit)
Disassembly preparations
1. Remove 3 hexagon socket head bolts M10 x 30
1. The unit removed from the actual machine is dirty (25) screwed into the cover (24) at approximately
with dirt and debris. the same distance apart, and instead, install and
Clean the exterior of the unit and let it dry. suspend the M10 eyebolts, and install the receiving
platform with the cover in the raised position and the
CAUTION
CAUTION
Perform the disassembly procedure after
the reduction gear has sufficiently cooled • Be very careful not to get hands stuck be-
down, otherwise burns can occur. tween parts or drop the suspended parts
on feet.
2. Loosen the drain and the feed plug G3/4 (26) to • Lift the part in a horizontal position.
drain the gear oil inside the reduction gear.
CAUTION
When the gear oil is still hot, the pressure
inside can cause the oil to spray out.
3. Make reference marks (h) to the outside of each

alignment surface so that the part can be assem-
bled in its original form.
84402832 NA - May 2011

6002-15
Removal of reduction gear cover 2. The contact surfaces of the cover (24) and ring gear
(3) are coated with sealant, so place a metal pin
1. Remove the remaining hexagon socket head bolts
against the projected part of the cover and use a
M10 × 30 (25).
hammer to strike it obliquely upward to remove the
cover.
CAUTION
tween parts or drop the suspended parts
on feet.
Removal of carrier 1 assembly 3. Remove the sun gear 1 (22).

1. Remove the thrust plate (23). CAUTION
2. Install 3 M10 eyebolts on the carrier 1 (16), then
remove the carrier 1 assemblies (16, 17, 18, 19, 20, Be very careful not to get hands stuck be-
21). tween gears.
CAUTION
• Be very careful not to get hands stuck be-
on feet.
• Lift the part in a horizontal position.
84402832 NA - May 2011

6002-16
Removal of carrier 2 assembly 2. Install 3 M10 eyebolts on carrier 2 (9), then remove
the carrier 2 assemblies (9, 10, 11, 12, 13, 14).
1. Remove the sun gear 2 (15).
CAUTION
CAUTION
Be very careful not to get hands stuck between parts or drop the suspended parts
tween gears. on feet.
Removal of housing assembly CAUTION

1. Remove the support ring (8). • Be very careful not to get hands stuck be-
on feet.
2. Place a screwdriver or other tool on the divided sur-

face of the lock washer (7) and strike the tool with a
hammer to remove the lock washer (7).
3. Install 3 M10 eyebolts into the M10 threaded holes

on the ring gear (3) at approximately the same dis-
tance apart, and remove the housing assembly (ring
gear (3), housing (1), bearing (2), floating seal (5), Removal of housing assembly
hexagon socket head bolt M18 x 110 (4)) while lift-
ing it in a horizontal position.
84402832 NA - May 2011
6002-17
Disassembly of housing assembly Disassembly of housing assembly

2. Remove the floating seal (5) from the housing (1).
1. Install 3 M20 eyebolts into the M20 threaded holes
3. Remove the hexagon socket head bolts M18 x 110
on the housing (1) at approximately the same dis-
(4) while leaving 2 diagonally opposite bolts.
tance apart, and place it on the receiving platform
4. With the remaining 2 hexagon socket head bolts
with the ring gear (3) in the lowered position and the
M18 x 110 (4) loosened, tap the heads of the bolts
housing (1) in the raised position. with a hammer to easily remove the ring gear (3)
Make reference marks to the outer circumference of
from the housing (1).
the housing and ring gear.
CAUTION
CAUTION
tween parts or drop the suspended parts tween parts or drop the suspended parts
on feet. on feet.
• Make the receiving platform 300 mm high
or more.
Removal of floating seal

• Be careful not to scratch the sliding surface of the
floating seal (5) and its O-ring.
• The bearing (2) outer race and housing (1) inner
diameter form a very tight fit.
Do not disassemble this unless it is necessary to
replace the bearing (2).
When removing the bearing (2) from the housing
(1), replace with a new part instead of reusing the
part.
84402832 NA - May 2011

6002-18
Removal of floating seal from motor 3. Remove the thrust washer 1 (18), planetary gear 1
(17), and needle bearing (19) from the carrier 1 (16).
1. Remove the floating seal (5) on the motor.
Disassembly of carrier 1 assembly CAUTION
• When reusing the carrier pin 1 (20), place codes on Be very careful not to get hands stuck be-
the carrier 1 (16) hole and carrier pin 1 (20) so that the tween the gear and carrier.
parts can be reassembled in the same combination as
before disassembly, and store the parts. 4. Pull out the spring pin 6 x 36 (21) from the carrier
pin 1 (20).
1. Push the spring pin 6 x 36 (21) into the carrier pin 1
(20). • When replacing the carrier pin 1 (20) or planetary
gear 1 (17), be sure to replace with 1 set of 3 parts.
2. Remove the carrier pin 1 (20) from the carrier 1 (16).
84402832 NA - May 2011

6002-19
Disassembly of carrier 2 assembly 3. Remove the thrust washer 2 (11), planetary gear 2
(10), and needle bearing (12) from the carrier 2 (9).
• When reusing the carrier pin 2 (13), place codes on
the carrier 2 (9) hole and carrier pin 2 (13) so that the CAUTION
parts can be reassembled in the same combination as
before disassembly, and store the parts. Be very careful not to get hands stuck be-
tween the gear and carrier.
1. Push the spring pin 10 x 50 (14) into the carrier pin
2 (13).
4. Pull out the spring pin 10 x 50 (14) from the carrier
pin 2 (13).
• When replacing the carrier pin 2 (13) or planetary
gear 2 (10), be sure to replace with a set of 3 parts.
2. Remove the carrier pin 2 (13) from the carrier 2 (9).
84402832 NA - May 2011

6002-20
Maintenance standards
Motor parts maintenance standards
The reference values indicating whether or not a part can be reused are indicated using the measurement values at
the time a part is disassembled.
However, this is a general reference, and when determining whether a part should be replaced, priority is given to
performance prior to disassembly, the purpose of disassembly and the expected remaining life of the part if there is
any damage or discoloration that significantly affects the part appearance.
Measurement item and measurement method
1. Sliding surfaces: cylinder block, valve plate, and shoe plate
Judgment criteria and solution
• Use a surface roughness gauge to measure the roughness of the sliding surfaces of these parts.
Part name and inspection Permissible

Standard value Solution
item limit value
Surface roughness
• Cylinder block 0.4 Zμ or lower 3.0 Zμ or lower Repair or replace.
• Valve plate
• Shoe plate
(Perform common lapping to correct the surface roughness of the cylinder block and valve plate. (Lapping
material #1200))
• Use a hardness gauge to measure the hardness of the shoe plate sliding surface.

item limit value
Shoe plate
HS78 or higher HS74 Replace
• Sliding surface hardness
84402832 NA - May 2011

6002-21
2. Clearance of piston and cylinder block

• Use a micrometer caliper to measure the piston outer diameter and cylinder bore inner diameter at least 3
locations in the longitudinal direction.
Maximum outer diameter value (piston) = d maximum
Minimum outer diameter value (piston) = d minimum
Minimum inner diameter value (cylinder bore) = D minimum
Maximum inner diameter value (cylinder bore) = D maximum
Measurement locations

item limit value
Piston outer diameter d
0.01 mm 0.05 mm
maximum - d minimum
Cylinder bore inner diame-
Replace the piston or cylinder block.
ter D maximum - D mini- 0.01 mm 0.022 mm
mum
Clearance D - d 0.037 - 0.047 mm 0.065 mm
(Piston replacement should be performed 9 pistons at a time.)

3. Piston and shoe backlash
• Use a jig (d) (See "Measurement jig") to press the shoe (e) on the surface plate, slide the pistons (c) in an
upward direction, and measure the piston and shoe backlash δ. (See "Caulking section backlash" and "Mea-
suring backlash".)

item limit value
Piston and shoe backlash 0 - 0.1 mm 0.3 mm Replace piston.
Caulking section backlash Measuring backlash

84402832 NA - May 2011
6002-22
a Magnet
b Dial gauge
f Surface plate
4. Parking brake force

• After completing assembly, tighten the torque of the output shaft end with a torque wrench, and measure the
torque when starting rotation.

item limit value
• Separator plate
Parking brake torque 1171 N・m 1055 N・m • Friction plate
• Spring Replace all.
Guidelines for replacing the friction plates and partner plates

To measure the brake torque, the motor must be separated to a single unit.
It is extremely difficult to separate the motor by removing it from the mother machine or disassembling the
reduction gear.
Use the following method to determine whether to replace these parts when inspecting the parts during main-
tenance.
(Replacement guidelines)
Measure the pack length of the 6 friction plates and 7 separator plates, and if the value is less than the permis-
sible value indicated below, replace all friction plates, separator plates, and springs.
Reference value: 33.04 mm (nominal dimensions in the diagram)
Permissible value: 31.5 mm
5. Shaft
• Use a roughness gauge to measure the wear on the oil seal contact areas of the shaft.
The parts can be reused with a stepped wear of up to 0.05 mm.
(When replacing the shaft (9), replace the oil seal (3) at the same time.)
6. Bearing
• Replace the bearings.
Replace the bearings (10) (51) before the hour meter on the mother machine reaches 10000 hr.
(When replacing the bearings (10) (51), replace the inner race and outer race at the same time.
Also, when replacing the shaft (9) or bearings (10) (51), the shim (52) thickness must be adjusted.)
7. Spline
• Replace the spline when the spline wear exceeds the permissible limit value.
The parts can be reused with a stepped wear of up to 0.3 mm on the contact surface.
8. Overload relief valve
• Pressure inspection and adjustments cannot be performed without a specialty test bench.
Replace as a valve assembly every time the hour meter on the mother machine reaches 10000 hr.
84402832 NA - May 2011

6002-23
Reduction gear parts maintenance standards

Inspection prior to reassembly
Thrust washer
1. Inspect for seizing, abnormal wear, and uneven wear.
2. Inspect for wear that exceeds the permissible value.
Gears
1. Inspect for pitching or seizing on the tooth surfaces.
2. Perform a color check for cracks in the tooth base.
Bearing
Rotate by hand and inspect for abnormal noise or catching.
Floating seal
Perform a color check for cracks in the tooth base.
84402832 NA - May 2011

6002-24
Parts maintenance
The reference values indicating whether or not a part can be reused are indicated below using the measurement
values at the time a part is disassembled.
However, this is a general reference, and when determining whether a part should be replaced, priority is given to
performance prior to disassembly, the purpose of disassembly and the expected remaining life of the part if there is
any damage or discoloration that significantly affects the part appearance.
Parts with specified maintenance standards
Permissible limit
Code Item Standard value Solution
value
Smooth with no ab-
Replace using a set of 3
A Planetary shaft wear normal wear or seiz- ←
parts.
ing
No pitching of D 1.6
Smooth with no ab- Replace
Tooth surface and tooth base con- mm or more, or no
B normal wear or seiz- (Replace using a set of 3
dition cracks in the tooth
ing planetary gears.)
base.
84402832 NA - May 2011
6002-25
Permissible limit
Code Item Standard value Solution
value
Angular bearing (2) Inner race - 0.08 mm or more ←
C Shim adjustment
thrust gap 0.02 mm or less
D Thrust washer 1 (18) thickness 3.3 - 3.7 mm Wear of 0.1 mm Replace
E Thrust washer 2 (11) thickness 5.3 - 5.7 mm Wear of 0.1 mm Replace
F Thrust plate (23) thickness 4.34 - 4.66 mm Wear of 0.15 mm Replace
Initial 250 hr.
G Gear oil Replace
2000 operating hr. (hour meter)
84402832 NA - May 2011

6002-26
Assembly of motor Motor Assembly Procedure

1. Apply grease to the oil seal (3) outer circumference
Precautions before Motor Assembly and casing (1) inner circumference, then use an in-
Begin motor assembly only after thoroughly reading the sertion jig (h) to tap the oil seal (3) into the casing
precautions below. (1) evenly so that it does not fall down.
2. Use a retaining ring (4) to fasten the oil seal (3).
1. When performing assembly, always wear protec- 3. Insert the front bearing (10) outer race into the cas-
tive devices such as a helmet, goggles and safety ing (1). (Clearance fit)
shoes. Press fit the inner race into the shaft (9). (Tight fit)
2. Use the specified tools when performing assembly.
3. To prevent injuries during disassembly, prepare a • Heating the inner race to 100°C or lower provides
waist-high, stable work platform to perform work on. for easier press fitting.
4. The motor comprises high-precision parts.
For this reason, foreign matter adhering to parts can CAUTION
be damaging. Use caution to prevent burns.
Motor assembly should be done in an inside space
without dust, and mud and dirt should be prevented 4. Install the shaft (9) into the casing (1).
from adhering to parts. Apply grease to the surface contacting the oil seal
5. The motor comprises high-precision parts. (3).
For this reason, dents and scratching on part sur- 5. Install the tilting piston sets (tilting piston (6), tilting
faces can be damaging. piston seal (7), steel ball (8)).
Be very careful when handling parts during assem-
bly and do not create any dents or scratching. • Insert the tilting piston (6) so that it is not tilted.
6. Be sure to repair any damage discovered during • When installing the tilting piston (6), apply grease
disassembly and prepare replacement parts before to the seal parts and insert the piston carefully so
beginning assembly. as not to cut anything.
7. Remove metal fragments and foreign matters from
6. Install the pivot (11).
all parts and check that there are no burrs or dents
Install it to the side matching the reference mark on
on parts before beginning assembly.
the shoe plate (12).
If there are burrs or dents, use a whetstone to re-
When operated for a long period of time, install it
move them.
in the direction in which the slide imprints of the
8. When performing assembly, apply clean hydraulic
spherical section match the contact imprints of the
oil to each sliding and rotating sections before as-
shoe plate (12).
sembly.
7. Thoroughly grease the 3 spherical sections of the
9. Thoroughly degrease areas where Loctite and liquid
shoe plate (12) before installation.
packing is used and remove oil and water before
assembly.
10. Replace all seal parts such as O-rings and backup
rings with new parts.
11. Be careful not to damage O-rings and backup rings
during assembly.
When assembling O-rings and backup rings, apply
a small amount of grease for assembly.
12. It is recommended that petroleum jelly or grease be
used to prevent parts from falling during assembly.
13. Tighten the bolts and other fastening sections to the
tightening torque.
Tightening torque should be controlled with a torque
wrench.
14. After assembly is complete, plug all ports leading
into the motor to prevent dirt from entering.
Assembly procedure
Perform assembly by observing the precautions listed in
"Precautions before motor disassembly" and following
the procedure indicated below.
84402832 NA - May 2011

6002-27
8. After subassembling the piston assembly (18), shoe

retainer (17), spherical joint (16), spring receiver
(15), cylinder spring (14), and cylinder block (13),
insert the entire subassembly into the shaft (9).
CAUTION
feet.
• The piston assembly (18) must be inserted into

the same holes of the cylinder block (13) used
before disassembly.
Installation of oil seal
Installation of piston assembly

9. Use specialty rear bearing insertion jigs (A1, A2) to
insert the rear bearing (51) inner race into the shaft
(9).
10. Alternately install all of the separator plates (19) and
friction plates (20) in turn.
The separator plate (19) should be the first and last
parts.
11. Use the brake piston insertion jig (B) to insert the
brake piston (21) installed with D-rings (22) (23) in
the casing (1).
• Apply grease to the D-rings (22) (23).
• Use the insertion jig to make sure the brake piston
(21) is inserted evenly.
The brake piston is equipped with 2 large and
small D-rings (22) (23).
First, the large-diameter D-ring (23) is inserted
Installation of shoe plate into the hole, then the small-diameter D-ring (22)
is inserted.
84402832 NA - May 2011

6002-28
The insertion condition of the small-diameter 14. Insert the rear cover (24) into the casing (1) ac-
D-ring (22) cannot be visually checked, so do not cording to the guide pins, and tighten with hexagon
forcefully insert this D-ring. socket head bolts M18 x 50 (56) at 2 vertically-op-
This can cause chipping by the casing (1) hole. posite locations so that the rear cover is installed in
• The shim must be adjusted when replacing parts a parallel orientation.
related to the shim adjustment. After tightening the bolts, tighten with hexagon
Perform the assembly after determining the shim socket head bolts M18 x 50 (56) at the locations
thickness in advance by using the procedure excluding the 2 locations with installed guide pins.
in "Determining the thickness of the taper roller After tightening the bolts, remove the guide pins
bearing shim (52)" page 25 in the disassembly and tighten the remaining 2 locations with hexagon
procedure. socket head bolts M18 x 50 (56).
CAUTION
feet.
Installation of brake piston
i Hammer
10 - Plain flat washer with
k
rounded finish 18 mm
Installation of rear cover
When the rear cover bolts are
*1 • If the outer race of the rear bearing (51) is re-
used
moved, do not forget to install the shim (52).
12. Install guide pins (j) at 2 vertically-opposite locations Check whether the O-rings (47) (49) (50) are in-
on the casing (1). stalled in the rear cover (24).
13. Install the valve plate (54) in the rear cover (24) • The tightening torque for the hexagon socket
according to the reference mark made at the time of head bolts M18 x 50 (56) is 291.6 - 356.4 N・m.
disassembly, then mount the shim (52), rear bearing 15. Install the coupling (58).
(51) outer race, brake spring (55), and O-rings (50)
(47) (49).
84402832 NA - May 2011

6002-29
16. Install the spring (34), spring receiver (33), pilot 17. Install the overload relief valve (57).
valve spool (31), and pin (32) in the rear cover (24),
then tighten with the pilot valve plug (35) with the • The valve seat (57-3) is fit with a clearance fit,
O-ring (36) installed. so during installation, install the valve seat after
making sure that it will not come off by applying
grease to the fitting sections so that the valve seat
does not fall off or become lost.
• The tightening torque for the overload relief valve
(57) is 98.1 - 118 N·m.
18. Install the orifice (40) and orifice spring (41) in the
rear cover (24), then tighten with the plug (42) with
the O-ring (43) installed.
• The tightening torque for the plug (42) is 14.7 N·m.
• When using a new orifice (40), adjust the seat
section. (With a hammer, tap the orifice installed
to the rear cover.)
19. Insert the spool assembly (26) into the rear cover
(24) according to the reference mark made at the
time of disassembly, then install the spring receiver
(27) and spring (28) in that order.
• The spool assembly (26) is directional, so insert it
in the correct direction.
20. Tighten the M42 plug (29) with the O-ring (30) in-
stalled.
• The tightening torque for M42 plug (29) is 441 -
446 N·m.
Installation of supplied valve

• The tightening torque for the pilot valve plug (35)
is 49.0 - 588 N·m.
84402832 NA - May 2011

6002-30
Motor assembly procedure

Assembly of the carrier 2 assembly
1. Insert the planetary gear 2 (10), needle bearing
(12), and thrust washer 2 (11) into the carrier 2 (9).
CAUTION
tween the gear and carrier.
2. Align the carrier pin 2 (13) with the spring pin hole
and insert it into the carrier 2 (9).
Spring pin and caulking details
The spring pin opening section

*1
must be as in the diagram.
2 locations opposing each
*2 other at 180° must be caulked
as in the diagram.
The 0.5 mm spring pin must be
*3
hidden by the "caulking".
Sink the spring pin tip 1.0 to 2.0
*4
mm.
3. Insert the spring pin 10 x 50 (14) into the carrier pin c Pinion side
2 (9) and carrier pin 2 (13). (Hammer it 1 - 2 mm
deeper than the striking surface.)
4. Caulk at 2 opposing 180° locations.

• For the direction of inserting the spring pin and
the caulking method, see "Spring pin and caulking
details".
84402832 NA - May 2011

6002-31
Assembly of the carrier 1 assembly Installation of bearing and floating seal

1. Insert the planetary gear 1 (17), needle bearing 1. Install the bearings (2) in the inner diameter of the
(19), and thrust washer 1 (18) into the carrier 1 (16). housing (1).
2. Install the floating seals (5) on the motor and hous-
CAUTION ing (1).
Be very careful not to get hands stuck be- • Clean the floating seal installation section of any
tween the gear and carrier. oil, dirt, paint, or other foreign matter.
• Lightly apply gear oil to the sliding sections of the
2. Align the carrier pin 1 (20) with the spring pin hole floating seals (5). (Do not coat the O-rings with
and insert it into the carrier 1 (16). gear oil.)
3. Insert the spring pin 6 x 36 (21) into the carrier pin • Install in such a way that the O-rings do not be-
1 (16) and carrier pin 1 (20). (Hammer it 1 - 2 mm come twisted.
deeper than the striking surface.) Check that the floating seal (5) is correctly in-
stalled between the housing (1) and motor in a
parallel direction, as shown in the diagram.(Use
of an insertion jig is recommended.)
4. Caulk at 2 opposing 180° locations.

• For the direction of inserting the spring pin and
the caulking method, see "Spring pin and caulking
details". Installation of floating seal
84402832 NA - May 2011

6002-32
Assembly of the housing assembly

1. Thoroughly coat the housing (1) surface that
matches with the ring gear (3) with Loctite #515 (a).
2. Install 3 housing (1) M20 eyebolts and lift with a
wire, and install onto the ring gear (3) while aligning
the reference marks.
Applying Loctite to the housing end surface
CAUTION
on feet.
3. Coat the 25 hexagon socket head bolts M18 x 110

(4) with Loctite #242, and tighten the bolts to the Assembly of the housing assembly
tightening torque of 340 - 416 N・m.
• Soak 20 mm from the bolt tip in Loctite #242. (*1)
Method of applying Loctite #242
84402832 NA - May 2011

6002-33
Determining the thickness of the angular 4. Measure the lock washer groove width (C) of the
bearing shim motor casing.
5. Measure the lock washer (7) thickness (D).
• This needs to be performed when replacing the motor
(casing), housing (1), (angular) bearing (2), or lock • Use the average of the measurements of the 4
washer (7). orthogonally intersecting points on the circumfer-
Otherwise use the previous shim (6) as is. ence.
Measure the dimensions with a precision of 0.01
1. Press the outer races of the 2 bearings (2) into the mm.
housing (1).
2. Press the inner races of the 2 bearings (2) evenly 6. When the thickness of the used shim (6) is S, gap
and measure the inner race installation width (A). X is as follows.
X=(B+C)-(A+D+S)
• Before measuring the inner race installation width, 7. In the case of this unit, select 1 shim so that gap
rotate the bearings at least 5 times to stabilize X is -0.08 - 0.02 mm. ((+) indicates a gap and (-)
them. indicates pressing.)
3. Measure the bearing installation width (B) of the mo-
tor casing.
Determining the angular bearing shim Installation of housing assembly

thickness
1. Place the motor shaft upwards on the work platform,
and then place the shim (6) selected by (determin-
ing the thickness of the angular bearing shim) on
the end surface of the bearing insertion part of the
motor casing.
CAUTION
on feet.
2. Install and suspend 3 M10 eyebolts to the ring gear

(3), slowly lower it vertically while aligning it with the
motor core, and insert the bearings (2) installed in
the inner diameter of the housing (1) into the motor.
Use a pressing machine (b) to press the inner race
parts of the bearings (2), and insert them completely
to the bottom.
CAUTION
on feet.
84402832 NA - May 2011

6002-34
3. Insert the lock washer (7) into the groove while

pressing the flange part of the housing (1).
4. Insert the support ring (8) into the outside of the lock
washer (7).
Press fitting of the housing assembly
84402832 NA - May 2011

6002-35
Installation of carrier 2 assembly 2. Insert the sun gear 2 (15).

1. Insert the carrier 2 assembly into the ring gear (3) CAUTION
so that the 3 planetary gears 2 (10) are at the posi-
tion indicated in "carrier 2 installation direction," and Be very careful not to get hands stuck be-
have the gears mesh with the spline of the motor tween gears.
casing.
• The carrier 2 assembly is assembled at the posi-
tion indicated in "carrier 2 (c) installation direction"
to improve oil lubrication, so be sure to observe
this procedure.
Lift the part in a horizontal position.
CAUTION
on feet.
Carrier 2 installation direction
d Motor port
*1 Notching V into carrier 2
84402832 NA - May 2011

6002-36
Installation of carrier 1 assembly

1. Install and suspend 3 M10 eyebolts to the carrier 1
assembly, insert it into the ring gear (3), rotate the
planetary gear 1 (17) by hand to align it, and then
have the gear mesh with the sun gear 2 (15).
CAUTION
on feet.
2. After making sure that the coupling (See the motor

parts Operator's Manual.) is at the end of the motor
shaft, insert the sun gear 1 (22).
CAUTION
tween gears.
Installation of carrier 1 assembly

3. Install the thrust plate (23) on the carrier 1 (16).
• Face the sharp edge toward the cover (24) side.
Thrust plate installation direction
e Reduction gear cover

f Sharp edge
84402832 NA - May 2011

6002-37
Cover attachment 2. Coat the 18 hexagon socket head bolts M10 x 30

(25) with Loctite #242 sealant, and tighten the bolts
• The gear oil can be filled before installing the cover to the tightening torque of 61.7 - 75.5 N•m.
(24).
• For details on applying Loctite #242 to the bolts,
1. Coat the cover (24) surface that matches with the see "Method of applying Loctite #242".
ring gear (3) with Loctite #515 (g), and install the
cover (24) on the ring gear (3).
CAUTION
on feet.
Applying Loctite to the cover end surface

Gear oil filling
1. Fill the gear oil (SAE90, API GL-4 or GL-5, 9.5 L)
into the filling port G3/4.
2. Install the hexagon socket head plug G3/4 (26) to
the cover (24) at a tightening torque of 132.4 - 161.8
N•m.
84402832 NA - May 2011

6002-38
Initial pre-conditioning operation

Drain charge
After disassembly and assembly, completely fill the case of the motor casing with hydraulic oil.
This motor has 2 drain ports (G1/2). Perform air bleeding from the port on the side without a line (top side).
Performing initial operation (pre-conditioning operation)
Perform a pre-conditioning operation for about 5 min. at the motor tilting 1st speed and engine low idle, and check
for abnormalities, such as abnormal noise or external leaks.
Troubleshooting
See the troubleshooting section below to perform checking, countermeasures and to solve problems when any kind
of problem occurs in the motor during operation.
General cautions
Think before attempting to fix a problem.
Determine the nature of the abnormality before beginning work, and think whether this same kind of problem has
occurred before.
Also, reconfirm whether the motor is the source of the problem.
Be careful about dust and dirt.
The cause of wear is very often dust and dirt. So take measures to prevent dust or dirt from entering the parts during
disassembly.
Parts handling
Handle parts carefully, be especially careful with the drive section, and do not scratch the sliding sections.
Seals handling
Do not damage the seat surfaces of O-rings while performing work.
Also, it is recommended that O-rings be replaced with new ones during disassembly.
Causes of troubles and countermeasures

Hydraulic motor does not operate.
Symptom Cause Countermeasure

Pressure does not rise. Operation problem with internal relief valve Repair or replace the relief valve.
1. The parking brake cannot be released.
1. Check the orifice clog, and
(Orifice of release pressure path is
then clean or replace the part.
clogged.)
2. The parking brake cannot be released. 2. Install the spool in the correct
(The spool assembly is inverted.) direction.
3. The friction plate or separator plate of 3. Replace the friction plate or
the parking brake section is sticking. separator plate.
Pressure rises.
4. The brake piston of the parking brake 4. Repair or replace the brake
section is sticking. piston outer diameter.
5. Inspect and then repair or
replace the sliding parts (piston,
5. Seizing of sliding section
shoe, shoe plate, cylinder block,
valve plate, etc.)
6. Spool operation defect 6. Repair or replace.
Weak startup of the hydraulic motor

The set pressure is normal, but
Spool operation defect
there is a delay in the release of Repair or replace.
(Spool sticking)
the parking brake.
The parking brake is released,
The hydraulic oil viscosity is too high. Raise the oil temperature.
but startup is delayed.
84402832 NA - May 2011

6002-39

1. The parking brake is not fully released.
(Orifice of release pressure path is 1. Check the orifice clog.
clogged.)
The parking brake is released, 2. Clean the relief valve, and
but startup is weak. 2. Debris is caught in the relief valve. then inspect or replace the seat
surface.
3. Inspect and repair or replace
3. Seizing of sliding section
the sliding parts.
Rotation speed does not reach the setting value.

1. Check the pump discharge
1. Insufficient oil flow amount volume and the oil pressure path
Rotation speed does not reach
up to the motor.
the setting value.
2. The shoe, cylinder block, or valve plate 2. Inspect and repair or replace
shows signs of wear or serious damage. the part (s).
The brake does not operate.

Parking brake operation problem Inspect and repair or replace the
The brake does not operate. a) Wear on the friction plate brake piston, friction plate, and
b) Broken spring spring(s).
a) Sticking of the spool and main unit
The reverse brake works. b) Sticking of the check valve or debris is Repair or replace.
caught in the check valve
c) Orifice hole is clogged.
Oil leak

1. Retighten to the specified
1. Bolt and plug loosening
torque.
Oil leak
2. Gouging of O-ring(s) 2. Replace the O-ring.
3. Leak inside gear casing 3. Replace the oil seal(s).
84402832 NA - May 2011

6002-40
Cannot shift from high speed to low speed.

Cannot shift from high speed to Inspect and repair or replace the
The pilot valve spool is sticking.
low speed. pilot valve spool.
Abnormal noise emitted

When braking slowly or braking Spool operation defect
Air bleeding implementation
at the same time as operating a Air is remaining in the circuit or valve section.
circuit other than the motor cir-
cuit, a noise is emitted along with Spool sticking Repair or replace.
a strong vibration.
Hunting occurs when going down an incline

a) Sticking of the spool and main unit Repair or replace.
Strong hunting occurs during b) Orifice seating problem
inching operation. Interference with parking brake
The springs in the spool end section are Repair or replace.
worn or broken.
84402832 NA - May 2011

6002-41
Structural diagram
Travel motor
Diagram 1 Travel motor structural diagram
Code Part name Code Part name Code Part name

1 Casing 22 D-ring (small diameter) 43 O-ring 1B P8
2 NPT 1/16 plug 23 D-ring (large diameter) 44 Check valve
3 Oil seal 24 Rear cover 45 Check valve spring
4 Circle R retaining ring IRTW68 25 NPT 1/16 plug (mec) 46 M6 orifice (D0.6)
5 Expansion plug 26 Spool assembly 47 O-ring 1B P12.5
6 Tilting piston 27 Spring receiver 48 M6 orifice (D0.8)
7 Tilting piston seal 28 Spring 49 O-ring 1B P15
8 Steel ball 29 M42 plug 50 O-ring 215.57 x 2.62
9 Shaft 30 O-ring 1B G40 51 Bearing HR32207C
10 Bearing HR32209J 31 Pilot spool 52 Shim
84402832 NA - May 2011
6002-42

11 Pivot 32 Pin 53 Parallel pin
12 Shoe plate 33 Spring receiver 54 Valve plate
13 Cylinder block 34 Spring 55 Brake spring
Hexagon socket head bolt
14 Cylinder spring 35 Pilot valve plug G3/8 56
M18 x 50
15 Spring receiver 36 O-ring 1B P14 57 Overload valve
16 Spherical joint 37 Joint 58 Coupling
17 Shoe retainer 38 G1/4 plug 59 C retainer ring 40 for hole
18 Piston assembly 39 O-ring 1B P11 60 G1/2 plug
19 Separator plate 40 Orifice (brake valve) 61 O-ring 1B P18
20 Friction plate 41 Orifice spring (brake valve)
21 Brake piston 42 G1/8 plug
84402832 NA - May 2011

6002-43
Reduction gear
Diagram 2 Reduction gear structural diagram

1 Housing 10 Planetary 2 19 Needle bearing
2 Bearing 11 Thrust washer 2 20 Carrier pin 1
3 Ring gear 12 Needle bearing 21 Spring pin
4 Hexagon socket head bolt 13 Carrier pin 2 22 Sun gear 1
5 Floating seal 14 Spring pin 10 x 50 23 Thrust plate
6 Shim 15 Sun gear 2 24 Cover
7 Lock washer 16 Carrier 1 25 Hexagon socket head bolt
8 Support ring 17 Planetary 1 26 Plug G 3/4
9 Carrier 2 18 Thrust washer 1 27 O-ring
84402832 NA - May 2011

6002-44
Section
6003
Removal and Installation of Swing Unit
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Swing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Swing Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Job code 35352AL08 Removal of Swing Unit

1. Use a hexagon wrench (5 mm) to remove the 4 bolts
WARNING (1), and then remove the air breather (2) on the
hydraulic oil tank.
• Be sure to release hydraulic pressure before Tightening torque for bolt installation: 2.94 - 4.90
beginning work.
N•m
CAUTION
work.
load.
• When removing this product from the equip-
ment it is mounted on, stop that equipment
system and wait for the surface temperature
of this product to fall to about 40 °C or below
before removing it.
Working on this product while it is still hot
can cause burns. 2. Attach the specialty adapter (1) to the area where
Additionally, always bleed out the pressure the air breather was removed, and set the vacuum
before removing any line from this product. pump.
Removing a pressurized line can result in oil Create negative pressure in the hydraulic oil tank
spraying out and causing injury or oil leak. using the vacuum pump (2).
Items to prepare
• Wrenches (14 mm, 19 mm, 27 mm, 36 mm, 41 mm)
• Hexagon wrenches (5 mm, 8 mm, 17 mm)
• Pliers
• Hammer
• Grease
• Specialty adapter for vacuum pump connection
• Vacuum pump (vacuum pump power supply)
• Extension cable
• Marking pen
• Caps
• Plugs 3. Use a wrench (19 mm) to remove the 6 bolts (1),
• Liftcrane (with the required lifting capacity) and then remove the center cover (2).
• Rag
• Cleaning fluid
4. Use a hexagon wrench (8 mm) to remove the 8

hexagon bolts, and then remove the hoses (1) and
(2).
Next, use a wrench (41 mm) to remove the hose (3),
use a wrench (36 mm) to remove the hoses (4) and
(5).
84402832 NA - May 2011

6003-3
• Mark the swing motor and hoses so that the con- 7. Use a box wrench (36 mm) to remove the 12 bolts
nectors can be matched during assembly. (1) from the swing unit.
• Attach caps or plugs to the swing motor and hoses Tightening torque for bolt installation: 900 - 1050
to prevent any entry of water, dust or dirt. N•m
• Clean the swing motor and hoses by spraying
them with a parts cleaner to prevent scratching
and prevent dirt from accumulating on the con-
nectors.
8. Wrap the wire rope (1) around the swing motor and
lift it with a liftcrane.
• A knock pin (2) is driven into the installation sec-
tion of the swing unit.
5. Use a wrench (19 mm) to remove the 4 bolts (1), Apply lubricating oil to the knock pin and pull it
and then remove the under cover (2). out together with the main unit of the swing motor
while hitting with a hammer.
6. Use a wrench (13 mm) to remove the bolt (3) on the

clamp (2) for the hose (1).
lowering the swing unit on wood planks (1).
• Thoroughly secure the swing unit so that it does
not fall over.
84402832 NA - May 2011

6003-4
Installation of Swing Unit 2. Before driving, be sure to fill the inside of the motor
casing with hydraulic oil from the drain port (1).
1. To install, perform the reverse of the removal pro- Thoroughly perform air bleeding from the air bleed
cedure. port (2).
When installing the swing unit, be careful with the Use the level gauge (3) to check that gear oil for the
position of the knock pin. reduction gear is filled to the stipulated volume.
Tighten bolts being installed to the specified torque
For bolts for which the torque is not specified, check
"Standard Torque Data for Cap Screws and Nuts" in
the explanation in the materials.
84402832 NA - May 2011

6003-5
84402832 NA - May 2011

6003-6
Section
6004
Assembly and Disassembly of Swing Unit
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Job code 35352AF10 Disassembly

1. Making a reference mark on the unit matching sur-
CAUTION face
It is useful to place a reference mark (*1) on the
1. Read and understand the contents of this matching surface of the housing (1) and ring gear
Maintenance Manual before performing (2) with paint, etc.
disassembly, reassembly, inspection, re-
pair, or other such work of this product.
2. Handle this product according to the sep-
arate "Usage Precautions".
3. When removing this product from the
equipment it is mounted on, stop that
equipment system and wait for the surface
temperature of this product to fall to about
40 °C or below before removing it.
can cause burns.
Additionally, always bleed out the pressure
before removing any line from this prod-
uct.
Removing a pressurized line can result in
oil spraying out and causing injury or oil 2. Removal of level gauge assembly
leak. Remove the level gauge assembly (3) and cap (4)
4. Use the specialty tools and measurement (27 mm hexagon diameter).
instruments for disassembly, reassembly,
inspection, and repair, etc. of this product.
Using an inappropriate tool may result in
injury or product damage.
5. Be careful of parts falling when performing
disassembly, reassembly, inspection or re-
pair, etc. of this product.
This may result in injury or parts damage.
6. Do not directly touch with bare hands the
machined edges or threaded sections of
parts during disassembly, reassembly, in-
spection, or repair etc. of this product.
This may result in injury.
7. Check performance after reassembly.
Do not resume use unless performance is
fully recovered.
Use may result in damage to product.
8. The cautions (mark !) listed in this Main-
tenance Manual do not cover all possible
dangers.
Always think of safety first during disas-
sembly, inspection, reassembly, repair, or
other such work.
84402832 NA - May 2011

6004-3
3. Gear oil draining 5. Removal of motor

Loosen the drain hose (*2) end plug, and then drain Use the hexagon wrench (17 mm) to loosen and
the gear oil. remove the 12 hexagon socket head bolts (6).
Use the make-up port (G1) to raise the motor and
• Gear oil cannot be reused. remove it.
• Liquid packing has been applied to the matching
surfaces of the housing (7) and ring gear (8), so
use the notch sections (*3) in the diagram to re-
move the motor.
5 Reduction gear
4. Removal of hose
Remove the drain hose (*2).
5 Reduction gear
This completes the disassembly.
84402832 NA - May 2011

6004-4
Assembly Install a plug in the female side of the hose, and

install a hose (*3) in the drain port on the side of the
1. Application of liquid packing gear case (5).
After cleaning and degreasing the reduction gear Fill with gear oil (6 L) from the housing (3) gear oil
ring gear (1) and the motor housing matching sur- fill port.
faces, apply liquid packing (ThreeBond Co.,Ltd.
"1215" gray or the equivalent) as shown in the
diagram on the right (*1).
2. Motor installation
Lift the motor and gently install it in the reduction
gear, and use the hexagon wrench (17 mm) to
tighten the hexagon socket head bolts (2) to the
tightening torque of 568 - 649 N・m.
• Align the housing (3) and ring gear (4) according
to the reference mark (*2) made before disassem-
bly.
4. Installation of level gauge assembly

Install the cap (6) (27 mm hexagon diameter) into
the housing by tightening it to a torque of 98 N・m,
and insert the level gauge assembly (7).
3. Gear oil filling
84402832 NA - May 2011

6004-5
5. Grease-up
Remove the plug (8) (5 mm hexagon socket diam-
eter) from the gear case (5) and inject grease (1 L)
from the grease fill port (9).
• When injecting grease, there is the possibility of
the reduction gear oil seal being damaged by in-
ternal pressure, so remove the air bleed port plug
before injecting grease.
Tighten the plug to the gear case to a tightening
torque of 20 N・m.
After injecting grease, install the grease hose in
the grease fill port.
84402832 NA - May 2011

6004-6
Section
8001A
Overall view
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Overall view. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PUMP CHAMBER HYDRAULIC EQUIPMENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SWING BODY CENTER SECTION HYDRAULIC EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
HOUSING LEFT SIDE HYDRAULIC EQUIPMENT LAYOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
LAYOUT OF HYDRAULIC EQUIPMENT IN CAB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Overall view
Overall view
84402832 NA - May 2011

8001A-3
Overall view
1 Housing left side 3 Pomp chamber 5 Fuel tank

2 Swing body center section 4 Hydrauric oil tank
84402832 NA - May 2011

8001A-4
Overall view
PUMP CHAMBER HYDRAULIC EQUIPMENT LAYOUT
84402832 NA - May 2011

8001A-5
Overall view
1 Hydraulic pump 5 N1 sensor 9 N2 sensor

Horsepower control electro-
2 Accumulator 6 P2 pressure sensor 10
magnetic proportional
Hydraulic oil temperature sen-
3 Pilot filter 7 P1 pressure sensor 11
sor
4 5 stack solenid valve 8 Pilot pump
84402832 NA - May 2011

8001A-6
Overall view
SWING BODY CENTER SECTION HYDRAULIC EQUIPMENT
84402832 NA - May 2011

8001A-7
Overall view
1 Swing motor
2 Center joint
3 Control valve
84402832 NA - May 2011

8001A-8
Overall view
HOUSING LEFT SIDE HYDRAULIC EQUIPMENT LAYOUT
84402832 NA - May 2011

8001A-9
Overall view
Cushion valve (with heat cir-

1
cuit)
2 Swing pilot pressure sensor
3 Oil cooler
84402832 NA - May 2011

8001A-10
Overall view
LAYOUT OF HYDRAULIC EQUIPMENT IN CAB
1 Travel remote control valve

Upper operation remote control
2
valve
84402832 NA - May 2011

8001A-11
Overall view
84402832 NA - May 2011

8001A-12
Section
8001B
Port Diagram
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Hydraulic Pump (standard model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 Stack Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 Stack Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Remote Control Valves (upper, travel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Remote Control Valves (left-right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Remote Control Valve (travel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Cushion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Direction Valve/Relief Valve (electromagnetic proportional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Direction Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Relief Valve (electromagnetic proportional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Manifold Under Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Manifold (accumulator section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Manifold (hydraulic oil tank section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Center Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Port Diagram
Hydraulic Pump (standard model)
*1 Discharge port
Port Port name Port size

SAE
A1, A2 Discharge port
6000psi 1
SAE
B1 Suction port
2000psi 3
Dr1 Drain port G3/4-23
Proportional valve primary
P1 G1/4-13
pressure port
Psv Servo assist port G1/4-15
Pi1, Pi2 Negative control port G1/4-13
a1, a2, a4, a5,
Gauge port G1/4-15
a6
84402832 NA - May 2011
8001B-3
Port Diagram

A3 Gear pump discharge port G1/2-19
B3 Gear pump suction port G3/4-20.5
a3 Gauge port G1/4-14
Dr3 Drain port (gear pump) G3/8-15
A4 Gear pump discharge port G1/2-16
B4 Gear pump suction pump G1-21
84402832 NA - May 2011

8001B-4
Port Diagram
Control Valve
Relief Valve
Detailed diagram of main relief valve adjustment
1 Boom up 5 Arm out 9 Standard lock nut

2 Arm in 6 Bucket open 10 Pressure boost lock nut
3 Boom down 7 Main a (normal use) 11 Pressure boost adjusting screw
Standard pressure adjusting
4 Bucket close 8 Main b (pressure boost) 12
screw
84402832 NA - May 2011

8001B-5
Port Diagram
Port Port size Port name Port Port size Port name
SAE
P1 Pressure line pb1 G1/4 Left travel backward pilot line
6000psi 1
SAE
A1 Left travel (forward) line pb6 G1/4 Right travel backward pilot line
5000psi 1
SAE
B1 Left travel (backward) line pb3 G1/4 Left swing pilot line
5000psi 1
SAE
A2 Option line pb5 G1/4 Arm-in pilot line
5000psi 1
SAE
B2 Option line pb7 G1/4 Bucket-close pilot line
5000psi 1
SAE
A3 Swing right line pb8 G1/4 Boom-down pilot line
5000psi 1
SAE
B3 Swing left line PH G1/4 Pressure boost signal port
5000psi 1
SAE
A5 Arm-out line Ps1 G1/4 Negative control line
5000psi 1
84402832 NA - May 2011
8001B-6
Port Diagram
SAE
B5 Arm-in line T8 G1/4 Heat circuit line
5000psi 1
T1 Return line Pb2 G1/4 Option line
SAE
P2 Pressure line pa3 G1/4 Right swing pilot line
6000psi 1
SAE
A6 Right travel (forward) line pa8 G1/4 Boom-up pilot line
5000psi 1
SAE
B6 Right travel (backward) line pa5 G1/4 Arm-out pilot line
5000psi 1
SAE
A7 Bucket-open line PA G1/4 Upper signal
5000psi 1
SAE
B7 Bucket-close line PT G1/4 Travel signal
5000psi 1
84402832 NA - May 2011
8001B-7
Port Diagram
SAE
A8 Boom-up line Ps2 G1/4 Negative control line
5000psi 1
SAE Swing priority variable orifice switch sig-
B8 Boom-down line Pbu G1/4
5000psi 1 nal
T2 Return line Pa2 G1/4 Option line
pa1 G1/4 Left travel forward pilot line DR2 G1/4 Drain
pa6 G1/4 Right travel forward pilot line DR4 G1/4 Drain
DR3 G1/4 Straight travel drain line P3 G1/4 Backup confluence line
pa7 G1/4 Bucket-open pilot line
DR4 G1/4 Drain
P3 G1/4 Backup confluence line
84402832 NA - May 2011

8001B-8
Port Diagram
4 Stack Solenoid Valve
Port Port size

C3 G1/4
C1 G1/4
View from bottom Port Port size

B G3/8
T G3/8
Port Port size

C2 G1/4
P G3/8
84402832 NA - May 2011

8001B-9
Port Diagram
1 Swing lock 3 Pressure boost

2 Lever lock 4 Travel high speed
84402832 NA - May 2011

8001B-10
Port Diagram
2 Stack Solenoid Valve
B port side A port side
Port Port size

A1 G1/4
B1 G1/4
A2 G1/4
B2 G1/4
T G1/4
84402832 NA - May 2011

8001B-11
Port Diagram
Remote Control Valves (upper, travel)

Remote Control Valves (left-right)
Right side Left side
Right
Port name Left side
side
1 Bucket close 1
2 Boom down 2
3 Bucket open 3
4 Boom up 4
P Pressure P
T Return T
84402832 NA - May 2011

8001B-12
Port Diagram
Remote Control Valve (travel)

1 Backward left G1/4
2 Forward left G1/4
3 Backward right G1/4
4 Forward right G1/4
P Pressure G1/4
T Return G1/4
84402832 NA - May 2011

8001B-13
Port Diagram
Cushion Valve
Port Port name Port size Port Port name Port size
E, F Boom up G3/8 I, J Swing right G3/8
G, H Boom down G3/8 Q Swing pressure sensor signal G1/4
O, P Bucket open G3/8 U - G1/4
M, N Bucket close G3/8 S Swing priority orifice switch G1/4
C, D Arm out G3/8 V - G1/4
A, B Arm in G3/8 T Return (drain line) G1/4
K, L Swing left G3/8 R Heat circuit G1/4
84402832 NA - May 2011

8001B-14
Port Diagram
Direction Valve/Relief Valve (electromagnetic proportional)

Direction Valve
Port Port size Port Port size Port Port size

A G1 T1 G1 PP G1/4
B G1 T2 G3/4 DR G1/4
84402832 NA - May 2011

8001B-15
Port Diagram
Relief Valve (electromagnetic proportional)
Port Port size Port Port size

A G1 C G3/4
B G1 T G3/4
84402832 NA - May 2011

8001B-16
Port Diagram
HBCV
B port opening side
Port Port size Remarks

SAE 6000psi 1 Arm HBCV
A
SAE J6000psi 1 Boom HBCV
SAE 6000psi 1 Arm HBCV
B
SAE J6000psi 1 Boom HBCV
C G1/4
DR G3/8
PL G1/4
84402832 NA - May 2011

8001B-17
Port Diagram
Manifold Under Cab
Port Port size Port Port size Port Port size

P1 G3/8 P5 G1/4 T4 G1/4
P2 G3/8 T1 G3/8 T5 G1/4
P3 G3/8 T2 G3/8
P4 G1/4 T3 G3/8
84402832 NA - May 2011

8001B-18
Port Diagram
Manifold (accumulator section)
Port Port size

P G1/2
P1 G1/4
P2 G1/4
P3 G1/2
P0 G3/8
84402832 NA - May 2011

8001B-19
Port Diagram
Manifold (hydraulic oil tank section)
Port Port size

D1 G3/8
D2 G1/4
D3 G1/4
D6 G1/4
T G1/2
T1 G3/8
D7 G3/8
84402832 NA - May 2011

8001B-20
Port Diagram
Swing Motor
Air bleed port (when applying

*1
grease)

M Make up G1
DB Drain G1/2
PG Brake release G1/4
A Right swing -
B Left swing -
PA, PB Pressure measurement G1/4
Dr Gear oil drain port PT3/8
SGr Grease-up port PT1/8
84402832 NA - May 2011

8001B-21
Port Diagram
Travel Motor

D1,
Drain port G1/2
D2
P Pilot port G1/4
MA,
Pressure detection port G1/4
MB
VA,
Main port G1
VB
84402832 NA - May 2011

8001B-22
Port Diagram
Center Joint

A' Forward right (connected to travel motor) G1
B' Forward left (connected to travel motor) G1
C' Backward right (connected to travel motor) G1
D' Backward left (connected to travel motor) G1
P' Pilot port (connected to travel motor) G1/4
T Drain port G1/2
A Forward right (connected to control valve) 500psi 1
B Forward left (connected to control valve) 500psi 1
C Backward right (connected to control valve) 500psi 1
D Backward left (connected to control valve) 500psi 1
P Pilot port (connected to control valve) G1/4
84402832 NA - May 2011

8001B-23
Port Diagram
84402832 NA - May 2011

8001B-24
Section
8001D
Pressure Measurement and Adjustment Procedures
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Procedures for Pressure Measurement from the Monitor Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Monitor and switch panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pressure Measurement Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operating Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PROCEDURES FOR MEASURING HYDRAULIC OIL TEMPERATURE FROM THE MONITOR DISPLAY . . . . . . 4
Hydraulic Oil Temperature Measurement Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operating Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Procedures for Pressure Measurement by Installing Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Items to Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pressure Measuring Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Structure and Operation Explanation of Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Location of Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pressure Measurement Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pressure Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Main Pressure Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
A.Attachment pressure measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Boom-down pressure measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
B.Travel pressure measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
C.Swing pressure measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
D.Option line pressure measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Pilot Pressure Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pressure gauge installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Negative Control Pressure Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Pressure gauge installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Main Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Main relief pressure adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Pressure measurement and adjustment preparation work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Overload relief pressure adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Swing relief pressure adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Pilot Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Procedures for Pressure

Measurement from the Monitor
Display
Monitor and switch panel
1 Liquid crystal monitor 3 Design panel

2 Switch panel 4 Diffuser
Pressure Measurement Method

The P1, P2, N1, and N2 pressure can be measured from the monitor display. (The pilot pressure cannot be mea-
sured.)
Operating Method
1. If both the travel speed select switch and the attachement select switch on the switch panel are held down, the
display switches to the service support screen.
2. CHECK the select service support screen.
3. MACHINE STATUS the select service support screen.
4. The respective pressures are displayed "P1" (P1 pump main pressure), "P2" (P2 pump main pressure), "N1" (N1
negative control pressure), and "N2" (N2 negative control pressure) columns.
* MENU switch is held down the display returns to the normal screen.
a Normal screen
b Service support screen
84402832 NA - May 2011

8001D-3
PROCEDURES FOR MEASURING HYDRAULIC OIL TEMPERATURE

FROM THE MONITOR DISPLAY
Hydraulic Oil Temperature Measurement Method
The hydraulic oil temperature can be measured from the monitor display.
Operating Method
1. If both the travel speed select switch and the attachement select switch on the switch panel are held down, the
display switches to the service support screen.
2. CHECK the select service support screen.。
3. MACHINE STATUS the select service support screen.
4. The hydraulic oil temperature is displayed in the "Hyd.OIL TEMP" column.
84402832 NA - May 2011

8001D-4
Procedures for Pressure Measurement by Installing Pressure Gauge

Preparations
Role (worker 1: work supervisor, pressure
Workers 2
adjustment)
Role (worker 2: operator)
Items to Prepare
Vacuum pump and power supply Wrenches (17, 19, 24, 27 x 2, 32,
1 5 9 Recording sheet
(for vacuum pump) 36 x 2)
2 Pressure gauge (10 MPa-1) 6 Rag 10 Pen
3 Pressure gauge (60 MPa-2) 7 Extension cable 11 Cleaning fluid
Hydraulic oil tank lid
4 Hexagon wrench (8 mm, 6 mm) 8
(for vacuum pump)
84402832 NA - May 2011

8001D-5
Pressure Measuring Ports

There are the following 3 ports for pressure measurement.
• Main pressure: pressure ports (P1, P2)
(Remove the Main pressure sensor, then Install the pressure gauge.)
• Negative control pressure: pressure ports (N1, N2)
(Remove the negative control pressure sensor, then Install the pressure gauge.)
• Pilot pressure: pressure port (P3)
84402832 NA - May 2011

8001D-6
84402832 NA - May 2011

8001D-7
1 Pump 3 Pressure port: P1 5 Pressure port: N2

2 Pressure port: P2 4 Pressure port: N1 6 Pressure port: P3
84402832 NA - May 2011

8001D-8
Structure and Operation Explanation of Control Valve

Location of Relief Valves
Tool Pressure per
Set pressure rotation of Measuring
Position Adjusting
Lock nut (MPa) adjusting port
screw screw (MPa)
a Main Hexagon diam- Hexagon diam-
34.3 21.3 Monitor P1
(normal use) eter 27 mm eter 27 mm
1 Main
Hexagon diam- Hexagon diam-
b (boosted pres- 37.3 28.4 Monitor P1
eter 32 mm eter 27 mm
sure)
2 Boom up 39.2 21.2 Monitor P2
3 Boom down 27.4 21.2 Monitor P2
4 Arm in Hexagon diam- 39.2 21.2 Monitor P1
5 Arm out eter 17 mm Hexagon diam- 39.2 21.2 Monitor P1
6 Bucket close eter 6 mm 39.2 21.2 Monitor P2
7 Bucket open 39.2 21.2 Monitor P2
Hexagon diam-
8 Pilot 3.92 2.0
eter 24 mm
Detailed diagram of main relief valve adjust-

ment
*1 Pressure boost lock nut

*2 Pressure boost adjusting screw
*3 Standard lock nut
Standard pressure adjusting
*4
screw
84402832 NA - May 2011

8001D-9
Pressure Measurement 3. Main unit installation

Put the main unit on solid, level ground, put the
Preparations bucket cylinder at its open stroke end, the arm cylin-
der at its out stroke end, lower the boom, and touch
1. Items to prepare
the arm top to the ground.
For 10 MPa (for pilot and negative
1 ） Pres- control pressure measurement)
sure gauge For 60 MPa (for main pressure mea-
surement)
Wrench (closed wrench) 17 mm
2）Tool
Hexagon wrench 6 mm
Rag
3）Others
Cleaning fluid
4. Ignition key
Switch OFF the ignition key (1), check that the en-
gine has stopped, then switch the ignition key ON
again. (Do not start the engine.)
2. Monitor check
Use the service check to check the no-load engine
maximum speed and the SP mode pump input milli-
amp.
Engine max. SP mode milli-amp

2000 min-1 600 mA (during operation)
5. Oil temperature check

Use the service check to check the hydraulic oil tem-
perature.
Oil temperature 45 - 55 °C
If the oil temperature is low, raise the oil temperature

according to the warm-up operation procedure in
the operator's manual.
6. Bleeding pressure from inside circuits

84402832 NA - May 2011
8001D-10
Flip the gate lock lever (1) forward, then turn the 7. Bleeding pressure from inside the hydraulic oil tank
upper operation lever (2) about 10 times to bleed Press the air breather button (1) on top of the hy-
out the pressure. draulic oil tank to release the pressure inside the
tank.
3 Gate lever 8. Side door opening and closing

Open the side door (1).
Move the travel lever (1) back and forth about 5 At this time, be sure to use the lock (2).
times to bleed out the pressure.
This completes the preparations.
84402832 NA - May 2011

8001D-11
Pressure Measurement
Main Pressure Measurement
1. Pressure gauge installation
Remove the pressure sensor (a1) (a2) installed
on the hydraulic pump (1) and install the pressure
gauge.
a1: Can be measured a2: Can be measured

Travel left Travel right
Option Bucket
Swing
Arm 1 pump flow Arm 2 pumps flow
Install the pressure gauge (2) on the adapter (1) and
Boom 2 pumps flow Boom 1 pump flow
fasten it.
Pressure gauge
for 60 MPa G1/4
Port size
Install the adapter (2) on the gauge port (1).
84402832 NA - May 2011

8001D-12
A.Attachment pressure measurement

Example: Arm-out pressure measurement
Measure with the following operations.
Engine speed 1900 min-1

Work mode SP mode
Lever operation Arm-out relief
1 pump: P1 port
Measuring port
2 pumps: P2 port
Boosted pressure: 37.3 MPa
Set pressure
Standard: 34.3 MPa
a Arm-out relief
When the attachment operates, since the pressure boost operates automatically, the pressure resulting from the pres-
sure boost setting can be checked for about 8 sec.
After 8 sec.or more, the standard set pressure can be checked.
Measure relieving each cylinder with the arm out/in, the bucket open/close, and the boom up.
Bucket Bucket Boom

Lever operation Arm out Arm in Boom up
open close down
Work mode SP mode
1 pump flow measuring port P1 P1 P2 P2 P2 P2
2 pumps flow measuring port P2 P2 No No P1 P1
Pressure boost 37.3 MPa 27.4 MPa
Standard pressure 34.3 MPa 27.4 MPa
84402832 NA - May 2011

8001D-13
Boom-down pressure measurement the bucket tip on the ground, carry out the boom-down
operation, and measure.
For pressure measurement with the boom down, put the
arm cylinder at its out stroke end, open the bucket, put
a Boom-down relief B.Travel pressure measurement

1. Install the stopper (1) on the crawler sprocket sec-
tion (2) and lock the travel motor.
2. Measure with the following operations.

Work mode SP mode (1st speed)
Lever operation Travel relief
Left travel: P1 port
Measuring port
Right travel: P2 port
Set pressure 34.3 MPa
84402832 NA - May 2011

8001D-14
C.Swing pressure measurement D.Option line pressure measurement

1. Do not let the bucket move even if swing pressure 1. Close the option line stop valve (1).
is relieved with a swing operation such as digging a
hole.

Work mode SP mode
Lever operation Swing relief
Measuring port P1 port
2. Switch the attachment select switch of the monitor

to the option line to be measured (breaker, crusher).

Work mode SP mode
Pedal operation Option relief
1 pump: P2 port
Measuring port
2 pumps: P1 port
* Adjust the set pressure to match the specifications of

the attachment used.
84402832 NA - May 2011

8001D-15
Pilot Pressure Measurement

Pressure gauge installation
Remove the plug with the wrench (1) to install a pressure
gauge at the pump pressure measuring port (P3).
Install the adapter (1).
Install the pressure gauge (1) and measure the pres- Pressure gauge
for 10 MPa G1/4
sure. Port size

Work mode SP mode
84402832 NA - May 2011

8001D-16
Negative Control Pressure

Measurement
Pressure gauge installation
Remove the pump N1 pressure sensor (1) or N2 pres-
sure sensor (2) connector (3), and then remove the pres-
sure sensor.(N1, N2: pressure port) (The pressure sen-
sor location becomes the measuring port.)
Install the adapter (1) of the pressure gauge at the port Measure the negative control pressure for each opera-
where the N1 or N2 pressure sensor was removed and tion.
install the pressure gauge (2).
84402832 NA - May 2011

8001D-17
Pressure Engine speed 1900 min-1

gauge for 10 MPa G1/4 Work mode SP mode
Port size Oil temperature 45 - 55°C
P1 pump side: N1 port
Measuring port
P2 pump side: N2 port
Set pressure 3.92 MPa max.
84402832 NA - May 2011

8001D-18
Pressure Adjustment Boosted pressure:37.3

Measurement pressure MPa
Main Pressure Adjustment Standard:34.3 MPa
Boosted pressure:28.4
Main relief pressure adjustment Pressure per rotation of MPa/rotation
adjusting screw Standard:21.3 MPa/ro-
tation
Before adjusting, remove the pilot hose for the pressure
Work mode SP mode
boost signal (2) connected to the main relief valve (1),
Lever operation Arm-in relief then insert the plug (3) into the hose side.
Oil temperature 45 - 55 °C The procedures for boosted pressure and standard
Measuring port P1 port pressure are different.
4 Control valve
5 Wrench (19 mm)
84402832 NA - May 2011

8001D-19
Pressure measurement and adjustment For boosted pressure

preparation work 1. Loosen the standard lock nut (27 mm) (1) and
Pressure is adjusted with control valves. tighten the adjusting screw (27 mm) (2).
The following preparations are required for adjusting Fasten with a wrench (27 mm) so that the pres-
with control valves. sure boost adjusting screw does not turn.
1. Engine hood opening and closing
Unfasten the 2 latches (2) on the engine hood (1)
and open the engine hood (1).Pull the latches (2) to
release the locks.
2. After tightening until the adjusting screw stops

turning, tighten the pressure boost lock nut (1).
2. Cover removal
Remove the 5 bolts (1), then remove the cover (2).
3. Start the engine and run it at maximum rotation.

4. Move the arm lever to the in side, set the relief
state, and hold.
5. Loosen the pressure boost lock nut (32 mm) (1)
and adjust the set pressure with the adjusting
screw (27 mm) (2).
• When lower than the set pressure, tighten.
• When higher than the set pressure, first lower

below the set pressure, then adjust on the tight-
ening side.
6. After adjustment, fasten the adjusting screw with
a wrench (27 mm), then tighten the lock nut.
84402832 NA - May 2011

8001D-20
7. After locking, check the pressure on the boosted For standard pressure
pressure side.
1. Loosen the standard lock nut (27 mm) (1).
Repeat [1] - [7] until the set pressure is correctly ad-
justed.
2. Loosen the adjusting screw (1), lower below the

set pressure, then adjust on the tightening side.
3. After adjustment, tighten the lock nut while fasten-

ing the adjusting screw (1) with a wrench (2).
4. After locking, check the pressure.

Repeat [1], [2], and [3] until the set pressure is cor-
rectly adjusted.
Stop the engine.
84402832 NA - May 2011

8001D-21
Overload relief pressure adjustment Since the overload relief pressure is set higher than the
main relief pressure, it is necessary to provisionally set
Engine speed 1900 min-1 the main relief pressure higher than the overload relief
Work mode SP mode pressure. (Except for boom down)
Measuring port P1/P2 port
Boom down: 27.4
Measurement pressure MPa
Others: 39.2 MPa
Pressure per rotation of adjust-
21.2 MPa/rotation
ing screw
1 Control valve 5 Arm-out

2 Boom down 6 Bucket open
3 Bucket close
4 Boom up Main relief pressure provisional setting
84402832 NA - May 2011
8001D-22
• Using the main pressure adjustment procedure for

reference, temporarily set the boosted pressure and
standard pressure to at least 39.2 MPa.
* For boom down (1), since the overload set pres-
sure is lower than the main relief set pressure,
there is no need to temporarily set the main relief
pressure.
Pressure adjustment
Example: Arm-out (1) overload relief adjustment
2. After adjustment, lock the lock nut (1).
1. Loosen the lock nut (1) with the wrench (2) and
adjust by turning the adjusting screw (3) with the
hexagon wrench (4).
• When higher than the set pressure, first loosen
to a pressure lower than the set pressure, then
adjust on the tightening side. 3. After adjusting the overload relief pressure, adjust
the boosted pressure and standard pressure to
their normal values referencing the main pressure
adjustment procedure.
* For the position of each overload relief, see the
"Control Valve Relief Locations".
84402832 NA - May 2011

8001D-23
Swing relief pressure adjustment 3. After adjustment, lock the lock nut (1).

Work mode SP mode
Measurement pressure 30.4 MPa
Pressure per rotation of adjust-
11.6 MPa/rotation
ing screw
1. Using the swing pressure measurement procedure

for reference, lock the swing, and check the swing
pressure.
2. Use a wrench (1) to loosen the lock nut (2) and
adjust by turning the adjusting screw (3).
• When higher than the set pressure, first loosen
to a pressure lower than the set pressure, then
adjust on the tightening side.
84402832 NA - May 2011

8001D-24
Pilot Pressure Adjustment

1. Install the pressure gauge (1).
While holding the plug with a wrench (24 mm) (2),
adjust with a hexagon wrench (6 mm) (3).

Lever operation Neutral
Measuring port P3
84402832 NA - May 2011

8001D-25
84402832 NA - May 2011

8001D-26
Section
8001E
Hydraulic Pump Flow Measurement Procedures
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Hydraulic Pump Flow Measurement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Items to Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Work Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Flow Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7


Preparations
Role (worker 1: work supervisor, pressure ad-
Workers 3
justment)
Role (worker 2: operator)
Role (worker 3: flow, pressure measurement,
recording)
Items to Prepare
1 Vacuum pump and power supply 6 Extension cable 11 Pen

Hydraulic oil tank lid (for vacuum
2 Flow meter 7 12 Cleaning fluid
pump)
3 Pressure gauge (60 MPa x 2) 8 Adapter (flange type) 13 Rag
84402832 NA - May 2011
8001E-3
Hydraulic hose (for flow mea-

4 Hexagon wrench (6 mm, 10 mm) 9
surement)
Wrenches (17, 19, 24, 27 x 2, 32,
5 10 Recording sheet
36 x 2)
84402832 NA - May 2011

8001E-4
Work Preparations 5. Install the vacuum pump (1) on the hydraulic oil tank
lid.
1. Check that the main unit is in its work posture (arm-
vertical).
2. Bleed out the pressure. (See the details on Bleed-
ing Pressure in the Pressure Measurement and Ad-
justment Procedures.)
* Perform a swing prevention check.
6. After setting the vacuum pump (1) as in the diagram

on the right, switch on the power.(If the cable is too
short, use an extension cable.)
3. Use a wrench (17 mm) to remove the feed port

cover (1).
7. Use a hexagon wrench (1) (10 mm) to remove the

split flanges (2) and hydraulic hose (3). (This sec-
tion explains flow measurement at the P2 pump.)
4. Use the bolts removed in 3. to install the hydraulic

oil tank lid (for vacuum pump) (1).
4 Bolt
84402832 NA - May 2011

8001E-5
8. Use the split flange (2) to install the adaptor (flange * When connecting, always check the connection
type (3)) on the tip of the hydraulic hose (1) removed positions.
in 7.. * Always have the metering valve (7) fully open.
Remove the vavuum pump and re-install the hy-
draulic oil tank the same way it was.
Install pressure gauges on P1 and P2.(See "Main
Pressure Measurement".)
Open the engine hood.(See "Main Pressure Adjust-
ment".)
4 Hydraulic hose
9. Install the adaptor (1) at the position from which the

hydraulic hose was removed.
If necessary, install an "elbow adaptor" (3) on the
(prepared) hydraulic hose (2) connected to the flow
meter IN side.
10. Install the hydraulic hose (3) on the flow meter (1) 11. Remove the cover.
IN side(2), then fasten with the spanner. 12. Remove the pilot hose for the boosted pressure sig-
Install the (prepared) hydraulic hose (5) on the flow nal, then plug the hose side. (See "Main Relief
meter (1) OUT side (4), then fasten with the span- Pressure Adjustment".)
ner.
Installs the adapter (6) to have instralled in opposite This completes the preparation for flow measurement.
in 8..
84402832 NA - May 2011

8001E-6
Flow Measurement 5. Worker 2 lowers the arm-out port relief. (Min: 24

MPa P1+P2)
1. Measure the flow. 6. Start of flow measurement
When measuring the flow, position the workers as 7. The arm-out relief operation is carried out.
in the diagram on the right. 8. Data measured in units of 2.0 MPa (P1+P2)
(Worker 1 (1): Work supervisor, pressure adjust-
ment) * The measurement is carried out from 24.0 - 76.0
(Worker 2 (2): Operator) MPa and ends when the maximum pressure is
(Worker 3 (3): Flow, pressure measurement, reached.
recording) 9. Remove the flow meter.
* Because the maximum limit of the flow meter
pressure gauge is exceeded starting from 40
MPa.
10. Reset the arm-in port relief valve to normal pres-
sure.(For details on this adjustment, see "Pressure
Adjustment".)
11. Remove the pressure gauges etc. and put every-
thing back to normal.
This completes the work.
2. At the signal from the work supervisor, the operator

starts the engine.
3. Check the hydraulic oil temperature on the monitor.
(50 °C)
Check that the engine rotation and pump milli-amp
is normal.
4. The operator signals the arm-out relief operation to
worker 1.
1 Lock nut 17 mm
2 Hexagon wrench 6 mm
1 Ignition key
84402832 NA - May 2011

8001E-7
84402832 NA - May 2011

8001E-8
Section
8001F
Drain Volume Measurement Procedures
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Travel Motor Drain Volume Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Swing Motor Drain Volume Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Preparations 4. Use a wrench to remove the drain hose (5). (Always

install a cap on the removed drain hose (5).)
Measuring conditions

Mode SP mode
Oil temperature About 50°C
* Be careful.
The drain volume varies greatly with the oil tempera-
ture.
Travel Motor Drain Volume

Measurement
1. Allow the bucket (2) to touch the ground so as to 5. Install the extension hose for measurement (1) on
elevate one shoe crawler (1) as in the diagram on the side of the motor from which the drain hose was
the right. removed.
2. Remove the bolts (2), then remove the cover (1). 6. Prepare a waste oil can (1) and measuring con-
tainer (2) and set them as in the diagram on the
right.
3. Always lay a rag (2) underneath before removing

the drain hose (1).
84402832 NA - May 2011

8001F-3
7. Catch the stopper (1) between the sprocket section Forward Backward
and the frame and lock the travel motor. 1st 2nd 1st 2nd
speed speed speed speed
Right
Left
* Measure at least 3 times each for left, right, for-

ward, and backward.
8. In SP mode at medium speed, relieve the travel op-

eration, and move the extension hose to the mea-
suring container (1) at the same time the motor
starts. (At starting, start measurement with a stop
watch (3).)
9. After 30 sec., move the extension hose to the waste
oil can (1).
10. Measure the volume of oil in the measuring con-
tainer (2) as the drain volume for 30 sec. a 30 seconds
84402832 NA - May 2011

8001F-4
Swing Motor Drain Volume 5. After 60 sec., move the extension hose (3) to the
waste oil can (4).
Measurement 6. Measure the volume of oil in the measuring con-
tainer (1) as the drain volume for 60 sec.
1. Remove the 2 drain hoses (1) and put plugs in the
Measure at least 3 times each for left and right.
hose side of each. (wrench size: 27 mm, clamp 22
mm (hose side))
Right Left
2. Install the extension hose (1) for measuring the

drain volume on one side of the T nipple.
Install the hose facing in a direction that makes
measurement easy and install a plug (2) on the
other side.
3. Prepare a waste oil receiver and measuring con-

tainer (1) and set them as in the diagram on the
right.
For details on the method for locking the swing mo- a 60 seconds
tor, see "Swing relief pressure adjustment".
4. In SP mode, relieve the swing operation and move
the extension hose to the measuring container (1)
at the same time the motor starts.(At starting, start
measurement with a stop watch (2).)
84402832 NA - May 2011

8001F-5
84402832 NA - May 2011

8001F-6
Section
8001G
Air Bleed Procedure
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Boom Cylinder HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Arm Cylinder HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Air Bleed Procedure
CAUTION
Always bleed off any air in the hydraulic cir-
cuits after replacing the hydraulic oil, repairing
or replacing hydraulic equipment, or removing
hydraulic pipes.
Air bleed procedure mode (when bleeding, follow the procedure be-
low.)
Hydraulic
Cylinder air Swing motor Travel motor
pump air Check
bleeding air bleeding air bleeding
bleeding
Hydraulic oil or hydraulic pump re-
placement
Cylinder replacement
Swing motor replacement
Travel motor replacement
* Failure to completely bleed off all the air can reduce

the service life of hydraulic equipment and lead to
damage.
84402832 NA - May 2011

8001G-3
Air Bleed Procedure
Hydraulic Pump
1. Loosen the air bleed plug (1) and check that oil
oozes from the air bleed port (2)s.
If oil does not ooze out, remove the air bleed plug
(1), and fill hydraulic oil(3) from the air bleed port (2)
into the pump (4) case.
Temporarily tighten the air bleed plug (1).
Run the engine at low idle, slightly loosen the air
bleed port, and run until oil oozes from the air bleed
port (2) section.
Completely tighten the air bleed plug (1).
84402832 NA - May 2011

8001G-4
Air Bleed Procedure
Travel Motor 5. Start the engine and execute a slow travel opera-
tion.
1. Remove the bolts (2), then remove the cover (1). 6. Repeatedly travelling forward and backward bleeds
off the air.
2. Remove the hose (1) of drain port and elbow (2).
3. Pour in of hydraulic oil (1) from the air bleed port.

4. When inside the motor is filled with hydraulic oil,
tighten the elbow and hose.
84402832 NA - May 2011

8001G-5
Air Bleed Procedure
Swing Motor 3. Temporarily tighten the tee (1) of drain hose (3).
Run the engine at low idle, slightly loosen the tee
1. Run the engine at low idle, loosen the tee (1) of drain (1) of drain hose, and run until oil oozes from the
hose (3), and check that oil oozes from the air bleed port section (2).
port section (2). Completely tighten the tee (1) of drain hose.
* Do not execute a swing operation.
4. With the engine at low idle, slowly swing evenly left

and right at least 2 rotations.
2. If oil does not ooze out, stop the engine for now,
remove the tee (1) and fill hydraulic oil (2) into the Check
motor case.
After the air bleeding is complete, stop the engine for at
least 5 minutes to allow any air bubbles in the hydraulic
oil tank to dissipate.
84402832 NA - May 2011

8001G-6
Air Bleed Procedure
HBCV Arm Cylinder HBCV

For arm-in operations, bleed the air from the arm cylin-
CAUTION
der HBCV (1) using the same procedure as for boom
The HBCV air bleeding work requires 2 work- cylinder HBCV air bleeding.
ers: an operator and an air bleed worker.
Decide the signals beforehand and work safely.
Set the main unit so that the arm HBCV is at the
highest position.
Boom Cylinder HBCV

1. Start the engine and lower the boom without jacking
up the main unit.
2. In the above state, loosen the hose mouthpiece (1)
at the position in the figure.
Foaming hydraulic oil comes out from the hose
mouthpiece section.
When foaming hydraulic oil stops coming out,
tighten the hose mouthpiece (1).
2 HBCV
3. Execute steps 2. for the opposite side boom cylin-

der too.
4. Check boom operations.
If there is a delay in the operation response, bleed
the air again with the same procedure.
84402832 NA - May 2011

8001G-7
Air Bleed Procedure
2 Hose mouthpiece
84402832 NA - May 2011

8001G-8
Section
8002
Removal and Installation of Hydraulic Oil Tank
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

WARNING Removal of Hydraulic Oil Tank

• Keep away from fire. 1. Drain the oil from the hydraulic oil tank. (For details,
• Bleed off the pressure in the hydraulic oil see "Draining Oil from Hydraulic Oil Tank".)
tank before beginning work. 2. Use a wrench (19 mm) to remove the 6 bolts (1),
• The temperature of the hydraulic oil is high and then remove the under cover (2).
immediately after stopping the engine. Tightening torque for bolt installation: 63.7 - 73.5
Wait until the hydraulic oil temperature has N•m
decreased (to 40°C or less) before beginning
work.
CAUTION
work.
load.
Items to prepare
mm, 40 mm) 3. Prepare a waste oil can (1) under the hydraulic oil
• Eyebolts (M12 x 2) tank.
• Marking pen
• Caps
• Plugs
• Waste oil can
• Rag
• Cleaning fluid

then remove the seal washer (2).
• Cover the seal washer to prevent the entry of wa-
ter, dust or dirt.
• Tightening torque for bolt installation: 233.0 -
276.0 N•m
84402832 NA - May 2011

8002-3
5. After closing the engine hood (1), use a wrench (19 • Attach caps or plugs to the hydraulic oil tank and
mm) to remove the 10 bolts (2), and then remove hoses to prevent any entry of water, dust or dirt.
the top covers (3) and (4). • Clean the hydraulic oil tank and hoses by spray-
ing them with a parts cleaner to prevent scratches
nectors.


and then remove the drain hoses (2) and (3).
Use caps to cover the lines to prevent any entry of
water, dust or dirt.
9. Use a wrench (19 mm) to remove the 7 bolts (1), and
then remove the top cover (2) from the hydraulic oil
tank.
7. Use wrenches (19 mm, 22 mm, 27 mm, 36 mm, 40

mm) to remove the drain hoses (1).
• Mark the hydraulic oil tank and hoses so that the
connectors match at the time of assembly.
84402832 NA - May 2011

8002-4

and 6 spacers (2) from the bottom of the hydraulic
oil tank.
• Depending on the machine, there may be height
adjustment shims between the tank and the
frame. Do not lose them.
Also, mark or write down the locations where they
are and how many.

from the fuel tank front cover (tank) (2), and then
remove the cover (tank).

and then remove the side covers (tank) (2).

from the fuel tank side cover, and then remove the
side cover (2).
14. Connect the 2 eyebolts (M12) (1) to the top of the

hydraulic oil tank, and then use the shackles (2),
wire rope (3) and liftcrane to lift the hydraulic oil tank
(4).
• When lifting, be careful that the level gauge (5)
does not interfere with the frame at the side of the
hydraulic oil tank.
by a half turn.
84402832 NA - May 2011

8002-5

lowering the hydraulic oil tank on wood planks (1).
Thoroughly secure the hydraulic oil tank so that it
does not fall down.
Installation of Hydraulic Oil Tank

dard Torque Data for Cap Screws and Nuts"
84402832 NA - May 2011

8002-6
Section
8003
Removal and Installation of Hydraulic Pump
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of hydraulic pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

WARNING 3. Tighten the cock (3).

beginning work.
CAUTION
work.
load.
Items to prepare
• Wrenches (10 mm, 13 mm, 17 mm, 19 mm, 27 mm, 4. Prepare the waste oil can (1).
36 mm, 41 mm) Use a wrench (10 mm) to loosen the air bleed plug
• Hexagon wrenches (10 mm, 14 mm) (2).
• Nylon sling (with the required breaking load)
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid
Removal of hydraulic pump

2. Remove the engine hood. For the procedure, see

"Removal and Installation of Engine Hood".
84402832 NA - May 2011

8003-3
5. Remove the drain plug (1). 7. Loosen the hose bands (1), and then remove the 2
hoses (2).
Use a wrench (13 mm) to remove the 3 bolts (3),
and then remove the fuel filter (4).
6. Drain the fuel.
8. Remove the charge fuel pump filter.

For the procedure, see "Charge Fuel Pump Filter in
Procedures for Replacing Consumable Parts".
84402832 NA - May 2011

8003-4
9. Use a wrench (10 mm) to loosen the air bleed plug 10. Loosen the hose clip (1), and then remove the 2
(1) of the fuel pre-filter (2). hoses (2). Use a wrench (13 mm) to remove the 2
Loosen the cap (3) at the bottom and drain out any bolts (3), and then remove the fuel pre-filter (4).
remaining fuel.
* Put a waste oil case (4) underneath.
11. Remove the engine oil filter hose (1).

and then remove the engine oil filter (3).
84402832 NA - May 2011

8003-5
12. Remove the 3 pilot filter (1) hoses (2). 14. Use a wrench (19 mm) to remove the 2 bolts (1),
Use a wrench (17 mm) to remove the 2 bolts (3), and then remove the bracket (2).
and then remove the pilot filter (1). Use a wrench (19 mm) to remove the 8 bolts (3),
and then remove the cover (4).

15. Use a wrench (19 mm) to remove the 4 bolts (1) and
the 4 washers (2), and then remove the bracket (3).
84402832 NA - May 2011

8003-6
16. Use a wrench (17 mm) to remove the 4 bolts (1). • Clean the pump and hoses by spraying with a
Use a wrench (19 mm) to remove the 4 bolts (2), parts cleaner to prevent scratches and prevent
and then remove the brackets (3) (4). dirt from accumulating on the connectors.
18. Secure the pump with a liftcrane and nylon sling (1)
so that it does not fall during removal and installation
operations.
17. Remove the hoses and connectors that are con-

nected to the pump.
• Use a hexagon wrench (10 mm) to remove the
8 hose bolts (1), and remove the pressure hoses
(2).
• Use a wrench (41 mm) to remove the drain hose
(3).
• Use a wrench (27 mm) to remove the pilot hose
(4).
• Use a wrench (36 mm) to remove the suction hose
(5).
• Remove the connectors (6).
• Use a wrench (19 mm) to remove the hydraulic
pilot hoses (7).
• Use a hexagon wrench (14 mm) to remove the
suction line 4 bolt and remove the suction line (8).
• Mark the pump and hoses so that the connectors
• Attach caps or plugs to the pump and hoses to
84402832 NA - May 2011

8003-7
19. Use a wrench (17 mm) to remove the 8 bolts (1) 20. Use a liftcrane and the nylon sling (1) to pull the
from the pump. pump out from the shaft and lift the pump.
Tightening torque for bolt installation:63.8 - 73.6
N•m

lowering the pump on wood planks (1).
• Thoroughly secure the pump so that it does not
fall over.
84402832 NA - May 2011

8003-8
Installation of hydraulic pump Fill the pump case with hydraulic oil from the drain port
so that no air remains in the pump case.
To install, perform the reverse of the removal procedure. Additionally, when there is a 2nd option gear pump,
Tighten bolts being installed to the specified torque. bleed off air from the air bleed port on the top surface
For bolts for which the torque is not specified, see "Stan- of the power take-off case.
84402832 NA - May 2011

8003-9
84402832 NA - May 2011

8003-10
Section
8004
Removal and Installation of Control Valve
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

WARNING 3. After opening the engine hood (1), use a wrench (19
mm) to remove the 10 bolts (2), and then remove
• Keep away from fire. the top covers (3) (4).
beginning work.
CAUTION
work.
load.
Items to prepare
mm)
• Hexagon wrenches (8 mm, 10 mm)
• Wire cutters
• Wire ropes (with the required lifting capacity)
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid
Removal of Control Valve

1. Extend the attachment and bring in contact with the
ground.
N•m
2. Drain the oil from the hydraulic oil tank.(For details,

see "Draining Oil from Hydraulic Oil Tank")
84402832 NA - May 2011

8004-3

and then remove the housing frame (2).
6. Remove the connectors (1) and (2) from the pres-

sure sensor.
7. Use a wrench (7 mm) to remove the hose band (1),

and then remove the low-pressure hose (2).
8. Use wrenches (19 mm, 22 mm, 25 mm) and

hexagon wrenches (8 mm, 10 mm) to remove the
control valve lines and hoses.
• Mark the lines and hoses so that the connectors
• Use caps or plugs to cover the lines and hoses to
• Clean the lines by spraying with a parts cleaner to
prevent scratches and prevent dirt from accumu-
lating on the connectors.
84402832 NA - May 2011

8004-4
9. Use a wrench (24 mm) to remove the 4 bolts (1) 11. Install the shackles (1) on the eyebolts, then use the
from the control valve. liftcrane and wire ropes (2) to lift the control valve
Tightening torque for bolt installation: 267 - 312 N•m (3).
10. Install the 2 eyebolts (1) (M10) on the control valve.
12. Place the control valve (1) on wood planks (2).
Installation of Control Valve

Tighten bolts to the specified torque.
84402832 NA - May 2011

8004-5
84402832 NA - May 2011

8004-6
Section
8005A
Removal and Installation of Bucket Cylinder
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Bucket Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Bucket Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Job code 35738AA10 Removal of Bucket Cylinder

• Remove the bucket. (For details, see "Removal and
CAUTION Installation of Bucket".)
• Remove the bucket link. (For details, see "Removal
• Stop the machine on a level location with and Installation of Bucket Link".)
good footing.
• Be sure to stop the engine before beginning 1. Bring the arm (1) top in contact with the ground.
work. Retract the bucket cylinder rod.
• When working together with others, always
be sure to exchange signals and pay ade-
quate attention to safety.
• Always wear protective devices (protective
eyewear and safety shoes, etc.) when work-
ing with a hammer.
• Be sure to inspect the nylon sling and other
load.
Items to prepare
• Hammer 2. Tie the cylinder rod with wire (1) so that it cannot
• Striking rod come out.
• Nylon sling (with the required lifting capacity)
• Grease
• Rag
• Cleaning fluid
• Crosstie
• Wire
3. Turn the key switch (1) OFF and stop the engine.
84402832 NA - May 2011

8005A-3
4. Switch the key switch ON again, and then turn the Remove the hose (1) in the same way.
control lever (1) about 10 times to bleed out any
pressure. • Use caps or plugs to cover the hoses and lines to
NOTE: • Clean the hoses and lines by spraying them with
Do not operate the bucket at this time. a parts cleaner to prevent scratches and prevent
dirt from accumulating on the connectors.
5. Move the travel lever (1) back and forth about 5

times to bleed off the pressure.
Return the key switch to OFF.
6. Press the air breather button (1) on top of the hy- 8. Use a liftcrane and nylon sling (2) to secure the
draulic oil tank to release the pressure inside the bucket cylinder (1).
tank. • Wrap the nylon sling to the inside of the line so
that it is not crushed.

hexagon socket head bolts (3) of the hose (2), and
then remove the 2 split flanges (4) and O-ring (5).
84402832 NA - May 2011

8005A-4
9. Use a wrench (30 mm) to remove the bolt (1) and

spacer (2).
pin (1) out.
• When removing the pin, be careful not to damage
the installed O-rings or dust seals.
11. Lift the bucket cylinder (1) and then place it on the
crosstie.
84402832 NA - May 2011

8005A-5
Installation of Bucket Cylinder 4. Align the bucket cylinder (1) with the arm and use a
hammer (3) to push in the pin (2).
• Tighten lines and bolts being installed to the specified
torque. • If a pin is hard to insert, the cylinder is tilted.
• When the torque is not specified, check the "Bolt Size • When inserting the pin, be careful not to damage
and Torque Table". the installed O-rings or dust seals.
1. Clean each pin and pin hole.
5. Use a wrench (30 mm) to install the bolt (1) and

spacer (2).
2. Tie the cylinder rod with wire (1) so that it cannot
come out.
6. After setting the O-ring (5) on the line side, install

3. Use a liftcrane and nylon sling (2) to lift the bucket the hose (2) with the 2 split flanges (4) and the 4
cylinder (1). hexagon socket head bolts (3).
• Wrap the nylon sling to the inside of the line so • Install the hose (1) with the same procedure.
that it is not crushed. • The O-rings cannot be reused.
Replace them with new parts.
• Install the bucket link. (For details, see "Removal
and Installation of Bucket Link".)
• Install the bucket. (For details, see "Removal and
Installation of Bucket".)
84402832 NA - May 2011

8005A-6
84402832 NA - May 2011

8005A-7
84402832 NA - May 2011

8005A-8
Section
8005B
Removal and Installation of Arm Cylinder
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Arm Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Arm Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Job code 35737AA10 Removal of Arm Cylinder

1. Use a liftcrane and nylon sling (1) to secure the arm
CAUTION cylinder (2).
• Stop the machine on a level location with
good footing.
work.
ing with a hammer.
load.
Items to prepare spacer (2).
• Cap
• Plug
• Hammer
• Striking rod
• Grease
• Rag
• Cleaning fluid
• Crosstie
• Wire
3. Use a hammer (2) and striking rod (3) to remove the

pin (1).
Be careful. The arm and arm cylinder rod may come
out of place at this time.
84402832 NA - May 2011

8005B-3
4. Start the engine, move the arm out at idle, and re-
tract the arm cylinder (1) rod.

times to bleed off the pressure.
come out.
8. Switch the key switch OFF.

9. Press the air breather button (1) on top of the hy-
6. Switch the key switch (1) OFF to stop the engine. draulic oil tank to release the pressure inside the
Switch the key switch ON again, then turn the con- tank.
trol lever (2) about 10 times to bleed off any pres-
sure.
Switch the key switch OFF.

then remove the 2 split flanges (5) and O-ring (4).
• Remove the hose (3) with the same procedure.
• Use caps or plugs to cover the hoses and lines to
• Clean the hoses and lines by spraying them with
a parts cleaner to prevent scratches and prevent
84402832 NA - May 2011

8005B-4
• If a pin is hard to remove, there is a load on the

pin.
11. Use a wrench (19 mm) to remove the grease hose

(1).
• Use caps or plugs to prevent any entry of water,
dust or dirt.
14. Lift the arm cylinder (1), and then place it on the
crosstie.
spacer (2).
pin (1) out.
84402832 NA - May 2011

8005B-5
Installation of Arm Cylinder • If a pin is hard to insert, there is a load on the pin.
• When inserting the pin, be careful not to damage
• Tighten lines and bolts being installed to the specified the installed dust seals.
torque.
• When the torque is not specified, check the "Bolt Size
and Torque Table".
5. Use a wrench (30 mm) to install the bolt (1) and

spacer (2).

come out.
6. Use a wrench (19 mm) to attach the grease hose

(1).
3. Use a liftcrane and nylon sling (2) to lift the arm

cylinder (1).
• Wrap the nylon sling to the inside of the line so
that it is not crushed.
7. After setting the O-ring (4) on the line side, install

the hose (2) with the 2 split flanges (5) and the 4
hexagon socket head bolts (1).
• Install the hose (3) with the same procedure.
• The O-rings cannot be reused.
4. Align the arm cylinder with the boom and use a ham- Tightening torque for installation: 85.2 - 101.2 N·m
mer (2) to push in the pin (1).
84402832 NA - May 2011

8005B-6
9. Align the arm cylinder (1) with the arm pin hole and
use a hammer (3) to insert the pin (2).
Be careful. The arm and arm cylinder rod may come
out of place at this time.
8. Start the engine, move the arm in at idle, and extend

the arm cylinder (1) rod.
10. Use a wrench (30 mm) to tighten the bolt (1) and
spacer (2).
• Grease up.
84402832 NA - May 2011

8005B-7
84402832 NA - May 2011

8005B-8
Section
8005C
Removal and Installation of Boom Cylinder
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Boom Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Boom Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Job code 35736AA10 Removal of Boom Cylinder

• When removing only the boom cylinder, put the attach-
CAUTION ments in the temporary decommissioning posture.
• When removing as far as the boom, first remove the
• Stop the machine on a level location with bucket, bucket link, bucket cylinder, arm, arm cylinder
good footing.
according to their respective removal and installation
• Be sure to stop the engine before beginning procedures.
work.
Bring the boom top in contact with the ground.
be sure to exchange signals and pay ade- 1. Use a liftcrane and nylon sling (1) to secure the
quate attention to safety. boom cylinders (right) (left) (2) (3).
ing with a hammer.
load.
Items to prepare
• Crowbar
• Wire rope (with the required lifting capacity)
• Nylon sling 2. Use a wrench (19 mm) to remove the grease hoses
• Marking pen on the left and right sides (1).
• Cap
• Plug • Use caps or plugs to prevent any entry of water,
• Hammer dust or dirt.
• Striking rod
• Grease
• Rag
• Cleaning fluid
• Crosstie
• Wire
3. Use 2 wrenches (36 mm) to remove the 2 double

nuts (1) and bolt (2), and then remove the fastening
ring (3).
Also, remove the cab side in the same way.
84402832 NA - May 2011

8005C-3
4. Use a hammer (2) and striking rod (3) to push the 7. Switch the key switch ON again, and then turn the
pin (1) out. control lever (1) about 10 times to bleed out any
Start the engine, lower the boom at idle, and retract pressure.
the boom cylinder (right) (left) rods.

5. Tie the cylinder rods on the left and right sides with times to bleed off the pressure.
wire (1) so that they cannot come out.
• Switch the key switch OFF.
6. Turn the key switch (1) OFF and stop the engine.
9. Press the air breather button (1) on top of the hy-
draulic oil tank to release the pressure inside the
tank.

then remove the 4 split flanges (3) and 2 O-rings (4).
• Mark the lines and hoses so that the connectors
• Use caps or plugs to cover the hoses and lines to
84402832 NA - May 2011

8005C-4
• Clean the hoses and lines by spraying them with 12. Use a crowbar to remove the pin (1).
a parts cleaner to prevent scratches and prevent Also, remove the cab side in the same way.
13. Use a liftcrane and nylon slings (1) to lift the boom
11. Use a wrench (30 mm) to remove the bolt (1) and cylinders (right) (left) (2) (3) and remove.
spacer (2). • Place the boom cylinders (right) (left) (2) (3) on
Also, remove the cab side in the same way. crossties.
84402832 NA - May 2011

8005C-5
Installation of Boom Cylinder 4. Align the boom cylinders (right) (left) with the swing
frame pin holes and use a hammer (2) to push in
• Tighten bolts being installed to the specified torque. the pin (1).
and Torque Table". • When inserting the pin, be careful not to damage
the installed dust seals.

2. Tie the cylinder rods on the left and right sides with spacer (2).
wire (1) so that they cannot come out. Also, attach the cab side in the same way.
3. Use a liftcrane and nylon slings (1) to lift the boom 6. After setting the 2 O-rings (4) on the line side, install
cylinders (right) (left) (2) (3). the hose (1) with the 4 split flanges (3) and the 8
hexagon bolts (2).
• The O-rings cannot be reused.
84402832 NA - May 2011

8005C-6
7. Start the engine, raise the boom at idle, and extend 9. Use a wrench (19 mm) to attach the grease hoses
the boom cylinder (right) (left) (1) (2) rods. on the right and left sides (1).
Align the boom cylinder (right) (left) (1) (2) with the
boom pin holes and use a hammer (4) to push in • Grease up.
the pin (3). • When installing as far as the boom, first install
the bucket, bucket link, bucket cylinder, arm, arm
• If the insertion of a shim is possible according to cylinder according to their respective removal and
the tolerance adjust the shim. installation procedures.
8. Use 2 wrenches (36 mm) to attach the 2 double nuts

(1) and bolt (2), and install the fastening ring (3).
Also, install the cab side in the same way.
84402832 NA - May 2011

8005C-7
84402832 NA - May 2011

8005C-8
Section
8006
Removal and Installation of Center Joint
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Center Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Center Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

CAUTION Removal of Center Joint

• Be sure to stop the engine before beginning 1. Use a hexagon wrench (5 mm) to remove the 4 bolts
work. (1), and then remove the air breather (2) on the
• Be sure to inspect the wire rope and other hydraulic oil tank.
lifting equipment before beginning work. Tightening torque for bolt installation: 2.94 - 4.90
• Do not stand or pass under the suspended N•m
load.
Items to prepare
• Hexagon wrenches (5 mm, 8 mm)
• Specialty adapter for vacuum pump connection
• Vacuum pump (vacuum pump power supply)
• Extension cable
• Marking pen
• Cap
• Plug
• Wood planks, etc. 2. Attach the specialty adapter (1) to the area where
• Rag the air breather is removed, and set the vacuum
• Cleaning fluid pump (2).
Create negative pressure in the hydraulic oil tank
using the vacuum pump.

(1), and then remove the lower under covers (2).
84402832 NA - May 2011

8006-3
4. Prepare a waste oil can (1) to receive the oil that 7. Use a wrench (24 mm) to remove the 3 bolts (1),
spills out under the center joint. and then remove the center joint lock bar (2).
Tightening torque for installation: 267 - 312 N•m
5. Use a wrench (41 mm) to remove the 4 travel hoses

(1) and a wrench (27 mm) to remove the 2 drain 8. Use a hexagon wrench (8 mm) to remove each
hoses (2). group of 4 hexagon bolts (1), and then remove the
4 travel hoses (2).
• Mark the center joint and hoses so that the con-
nectors match at the time of assembly. • Mark the hoses so that the connectors can be
• Attach caps or plugs to the center joint and hoses matched during assembly.
to prevent any entry of water, dust or dirt. • Attach caps or plugs to the hoses to prevent any
• Clean the center joint and hoses by spraying them entry of water, dust or dirt.
with a parts cleaner to prevent scratches and pre- • Clean the hoses by spraying them with a parts
vent dirt from accumulating on the connectors. cleaner to prevent scratches and prevent dirt from
accumulating on the connectors.
N•m
6. Use a wrench (27 mm) to remove the drain hose (1).

• Attach caps or plugs to the center joint and hoses
9. Wrap wire ropes (1) around the center joint and sus-
• Clean the center joint and hoses by spraying them
pend it with a liftcrane so that the center joint does
with a parts cleaner to prevent scratches and pre-
not fall during removal and installation operations.
vent dirt from accumulating on the connectors.
84402832 NA - May 2011

8006-4
10. Use a wrench (19 mm) to remove the 3 bolts (1) Installation of Center Joint
from the center joint.
Tightening torque for installation: 109 - 127 N•m To install, perform the reverse of the removal procedure.
11. Use the wire ropes (1) and liftcrane to lift the center
joint (2).

lowering the center joint on wood planks.
84402832 NA - May 2011

8006-5
84402832 NA - May 2011

8006-6
Section
8007A
Removal and Installation of Travel Remote Control Valve
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Travel Remote Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Travel Remote Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Job code 35356AK19 3. Use a hexagon wrench (8 mm) to remove the 2 bolts
(2) on both the left and right sides of the lever, and
then remove the levers (1).
WARNING
beginning work.
CAUTION
work.
Items to prepare
• Wrench (19 mm)
• Phillips screwdriver
• Marking pen
• Cap 4. Use a wrench (19 mm) to remove the 6 bolts (2),
• Plug and then remove the under cover (1).
• Rag
• Cleaning fluid
Removal of Travel Remote Control

Valve
1. Remove the floor mat (1).
5. Use a wrench (19 mm) to remove the 6 hoses (1).

• Mark the valve and hoses so that the connectors
• Install caps or plugs to the valve and hoses to
• Clean the valve and hoses by spraying with a
parts cleaner to prevent scratches and prevent
2. Use a hexagon wrench (8 mm) to remove the 2 bolts dirt from accumulating on the connectors.
(2) on both the left and right sides, and then remove
the left and right travel pedals (1).
84402832 NA - May 2011

8007A-3
6. Use a wrench (19 mm) to remove the 2 hose Installation of Travel Remote
adapters (1).
Control Valve
Be careful not to connect the hydraulic hoses in incorrect
locations.
Before installing the hoses, check that the hose adapters
are not loose and retighten them to the specified torque.
When the torque is not specified, check the "Bolt Size
and Torque Table".
1. Pull down the travel remote control valve (1) into the
cab, then install the travel remote control valve.
7. Use a hexagon wrench (8 mm) to remove the 2 bolts

(1) on both the left and right sides of the travel lever.
2. Use a hexagon wrench (8 mm) to install the 2 bolts

(1) on both the left and right sides of the travel lever.
8. Pull up the travel remote control valve (1) into the

cab, and then remove the travel remote control
valve.
3. Use a wrench (19 mm) to install the 2 hose adapters

(1).
84402832 NA - May 2011

8007A-4
4. Use a wrench (19 mm) to install the 6 hoses (1). 7. Use a hexagon wrench (8 mm) to install the 2 bolts
Tightening torque: 25.4 - 31.4 N・m/44.0 - 54.0 N・ (2) on both the left and right sides, then install the
m left and right travel pedals (1).
5. Use a wrench (19 mm) to install the 6 bolts (2) and 8. Install the floor mat (1).
install the under cover (1).
6. Use a hexagon wrench (8 mm) to install the 2 bolts

(2) on both the left and right sides of the lever, then
install the levers (1).
84402832 NA - May 2011

8007A-5
84402832 NA - May 2011

8007A-6
Section
8007B
Removal and Installation of Operation Remote Control Valve
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Operation Remote Control Valve (left side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Operation Remote Control Valve (left side). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal of Operation Remote Control Valve (right side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation of Operation Remote Control Valve (right side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Job code 35355AA12 3. Use a hexagon wrench (5 mm) to remove the 2 bolts
(2), and remove the grip (1) of the gate lock lever.
WARNING
beginning work.
CAUTION
work.
Items to prepare
• Phillips screwdriver 4. Use the Phillips screwdriver to remove the 2 screws
• Marking pen (1) of the console top cover.
• Cap
• Plug
• Rag
• Cleaning fluid
Removal of Operation Remote

Control Valve (left side)
1. Roll up the boot (1) of the control lever and use
the Phillips screwdriver or box wrench (10 mm) to
remove the 2 bolts (2) of the console top cover.
5. Remove the 3 connectors (2) and remove the con-

sole top cover (1).
2. Use the Phillips screwdriver to remove the 2 screws

(2), and then remove the handle of the tilt lever (1).
84402832 NA - May 2011

8007B-3
6. Use the Phillips screwdriver or box wrench (10 mm) 9. Roll back the hose cover (1).
to remove the 5 bolts (2), then remove the cover (1).
10. Use a wrench (22 mm) to remove the 6 hoses (1).

7. Roll up the boot (1) of the control lever, remove the
connector (2) of the horn switch, and cut the wire • Mark the joystick remote control valve and hoses
so that the connectors match at the time of as-
band (3).
sembly.
• Use caps and plugs to cover the joystick remote
control valve and hoses to prevent any entry of
• Clean the joystick remote control valve and hoses
by spraying them with a parts cleaner to prevent
scratches and prevent dirt from accumulating on
the connectors.
8. While securing the nut (2) with a wrench (22 mm),

use a wrench (19 mm) to remove the lock nut (3)
and remove the control lever (1).
11. Use the hexagon wrench (5 mm) to remove the 3

bolts (1) and 3 washers (2).
84402832 NA - May 2011

8007B-4
12. Remove the joystick remote control valve (1). Installation of Operation Remote
Control Valve (left side)
1. Clean all the parts with a rag.
2. Install the joystick remote control valve (1).
3. Use the hexagon wrench (5 mm) to install the 3 bolts

(1) and 3 washers (2).
4. Use a wrench (22 mm) to install the 6 hoses (1).

• P port
Hose adapter tightening torque: 25.4 - 31.4 N·m
Hydraulic hose tightening torque: 44 - 54 N·m
• T port, 1 - 4 ports
Hose adapter, hydraulic hose tightening torque:
44 - 54 N·m
84402832 NA - May 2011

8007B-5
8. Use the Phillips screwdriver or box wrench (10 mm)

to install the 5 bolts (2), then install the cover (1).
5. Put the hose cover (1) in place.
9. Install the 3 connectors (2) and install the console

top cover (1).

use a wrench (19 mm) to install the lock nut (3) and
install the control lever (1).
10. Use the Phillips screwdriver to install the 2 screws
(1) of the console top cover.
7. Install the horn switch connector (2), bundle with the

wire band (3), then cover the control lever boot (1).
84402832 NA - May 2011

8007B-6
11. Use a hexagon wrench (5 mm) to install the 2 bolts Removal of Operation Remote
(2), and install the grip (1) of the gate lock lever.
Control Valve (right side)
1. Roll up the boot (1) of the control lever and use
the Phillips screwdriver or box wrench (10 mm) to
remove the 2 bolts (2) of the console top cover.

(2), then install the handle of the tilt lever (1).

(2), and then remove the handle of the tilt lever (1).

to install the 2 bolts (2) for the console top cover and
cover the control lever boot (1).

84402832 NA - May 2011

8007B-7
4. Remove the 3 connectors (2) and remove the con- 7. While securing the nut (2) with a wrench (22 mm),
sole top cover (1). use a wrench (19 mm) to remove the lock nut (3)
and remove the control lever (1).

to remove the 5 bolts (2), then remove the cover (1). 8. Roll back the hose cover (1).
6. Roll up the boot (1) of the control lever, remove the 9. Use a wrench (22 mm) to remove the 6 hoses (1).
connector (2) of the horn switch, and cut the wire
band (3). • Mark the joystick remote control valve and hoses
so that the connectors match at the time of as-
sembly.
• Use caps and plugs to cover the joystick remote
control valve and hoses to prevent any entry of
• Clean the joystick remote control valve and hoses
by spraying them with a parts cleaner to prevent
the connectors.
84402832 NA - May 2011

8007B-8
10. Use the hexagon wrench (5 mm) to remove the 3 Installation of Operation Remote
bolts (1) and 3 washers (2).
Control Valve (right side)
1. Clean all the parts with a rag.
11. Remove the joystick remote control valve (1).
2. Install the joystick remote control valve (1).
3. Use the hexagon wrench (5 mm) to install the 3 bolts

(1) and 3 washers (2).
4. Use a wrench (22 mm) to install the 6 hoses (1).

• P port
Hose adapter tightening torque: 25.4 - 31.4 N·m
Hydraulic hose tightening torque: 44 - 54 N·m
• T port, 1 - 4 ports
Hose adapter, hydraulic hose tightening torque:
41 - 54 N·m
84402832 NA - May 2011

8007B-9

to install the 5 bolts (2), then install the cover (1).
5. Put the hose cover (1) in place.
9. Install the 3 connectors (2) and install the console

top cover (1).

use a wrench (19 mm) to install the lock nut (3) and
install the control lever (1).
7. Install the horn switch connector (2), bundle with the

wire band (3), then cover the control lever boot (1).
84402832 NA - May 2011

8007B-10
11. Use the Phillips screwdriver to install the 2 screws 12. Use the Phillips screwdriver or box wrench (10 mm)
(2), then install the handle of the tilt lever (1). to install the 2 bolts (2) for the console top cover and
cover the control lever boot (1).
84402832 NA - May 2011

8007B-11
84402832 NA - May 2011

8007B-12
Section
8007C
Removal and Installation of 4 Stack Solenoid
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of 4 Stack Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of 4 Stack Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Job code 35350AL06 3. Remove the 4 connectors (1).
WARNING
beginning work.
CAUTION
work.
Items to prepare
• Marking pen
• Cap 4. Use a wrench (19 mm) to remove the hoses (1) (2).
• Plug • Mark the solenoid valve and hose so that the con-
• Rag nector matches at the time of assembly.
• Cleaning fluid • Use a cap or a plug to cover the solenoid valve
and hose to prevent any entry of water, dust or
Removal of 4 Stack Solenoid Valve dirt.
• Clean the solenoid valve and hose by spraying
1. Attach the specialty adapter (1) to the area where them with a parts cleaner to prevent scratches
the air breather is removed, and set the vacuum and prevent dirt from accumulating on the con-
pump (2). nector.
5. Use a wrench (22 mm) to remove the hoses (1) (2).

2. Use a wrench (13 mm) to remove the bolts (1) on • Mark the solenoid valve and hose so that the con-
the clamp. nector matches at the time of assembly.
Remove the 2 bolts (2) on the cover and remove the • Use a cap or a plug to cover the solenoid valve
cover (3). and hose to prevent any entry of water, dust or
dirt.
them with a parts cleaner to prevent scratches
nector.
84402832 NA - May 2011

8007C-3
Installation of 4 Stack Solenoid

Valve
1. Use a wrench (17 mm) to install the 4 stack solenoid
valve (1) with the 2 bolts (2).
6. Use a wrench (22 mm) to remove the hoses (1) (2).

• Mark the solenoid valve and hose so that the con-
nector matches at the time of assembly.
• Use a cap or a plug to cover the solenoid valve
and hose to prevent any entry of water, dust or
dirt. 2. Use a wrench (22 mm) to install the hoses (1) (2).
them with a parts cleaner to prevent scratches
nector.
• The hose connections are as follows.

and then remove the 4 stack solenoid valve (1).
84402832 NA - May 2011

8007C-4
3. Use a wrench (22 mm) to install the hoses (1) (2).
4. Use a wrench (19 mm) to install the hoses (1) (2).
5. Install the 4 connectors (1).

Connect the connectors with the matching color ID
tape.
1 Assembly hose
2 Solenoid valve
*1 Code
Solenoid valve (left side) de-
*2
tails
Solenoid valve (right side) de-
*3
tails
84402832 NA - May 2011

8007C-5
6. Use a wrench (13 mm) to install the cover (3) with 7. Use a hexagon wrench (5 mm) to tighten the 4 bolts
the 2 bolts (2). (1), then remove the air breather (2) on the hydraulic
Fasten the clamp with the bolt (1). oil tank.
• Bolt (1) tightening torque: 2.94 - 4.9 N·m
84402832 NA - May 2011

8007C-6
Section
8007D
Removal and Installation of Cushion Valve
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Cushion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Cushion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Job code 35350AF50 2. Use a wrench (19 mm) to remove the 5 bolts (2),
WARNING
beginning work.
CAUTION
work.
Items to prepare
• Marking pen
• Cap 3. Prepare the waste oil can (1).
• Plug
• Waste oil can
• Rag
• Cleaning fluid
Removal of Cushion Valve

1. Attach the specialty adapter (1) to the area where
the air breather is removed, and set the vacuum
pump (2).
4. Remove the sensor (1).

Use wrenches (19 mm, 22 mm) to remove the hoses
connected to the ports.
• Mark the cushion valve, hoses and lines so that
the connectors match at the time of assembly.
• Use caps or plugs to cover the cushion valve,
hoses and lines to prevent any entry of water, dust
or dirt.
• Clean the cushion valve, hoses and lines by
spraying them with a parts cleaner to prevent
the connectors.
84402832 NA - May 2011

8007D-3

on the cushion valve bottom, and then remove the
cushion valve.
*2 Use 22 mm wrench
*3 Use 19 mm wrench
84402832 NA - May 2011

8007D-4
Installation of Cushion Valve

1. Use a wrench (17 mm) to tighten the 4 bolts (1)
on the cushion valve bottom, and then install the
cushion valve.
2. Install the sensor (1).

Use wrenches (19 mm, 22 mm) to connect the
hoses to the nipples and elbows on the ports.
2 Use 22 mm wrench
3 Use 19 mm wrench
• The hose connections are as follows.
84402832 NA - May 2011

8007D-5
3 Swing right
4 Bucket close
5 Heat circuit line
6 Arm out
7 Boom down
8 Swing left
9 Bucket open
10 Pressure sensor (swing)
Swing priority switching pilot
11
line
12 Drain line
3. Use a wrench (19 mm) to tighten the 5 bolts (2) and

install the under cover (1).
4. Use a hexagon wrench (5 mm) to tighten the 4 bolts

(1) and install the air breather (2) on the hydraulic
oil tank.
1 Arm in
2 Boom up
84402832 NA - May 2011

8007D-6
Section
8008
Procedures for Assembly and Disassembly of Hydraulic

Pump Main Unit
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Procedures for Assembly and Disassembly of Hydraulic Pump
Main Unit
Tools 4. Remove the hexagon socket head bolts (412, 413),
and remove the regulator.
The table below shows the tools required for assembly
and disassembly of the K3V/K5V pump.The bolts and • See "Procedures for Assembly and Disassembly
plugs may vary by pump type. of Regulator" in the manual for the regulator for
how to disassemble the regulator.
Tool name Tool dimensions

4, 5, 6, 8, 14, 17 (B dimen-
Hexagon wrench
sion, mm)
Socket wrench, dou-
ble-head (single- 19, 27 mm
head) wrench
Monkey wrench Medium-sized
Flathead screwdriver
Screwdriver
(medium size) x 2
Plastic hammer
With adjustable specified
Torque wrench
torque tightening
Snap ring pliers For stop ring, TSR-160
Key material steel rod, 10 x 5. Loosen the hexagon socket head bolts (401) that
Steel rod fasten together the swash plate support boards
8 x 200
(251), pump casings (271), and valve block (312).
Tweezers
Bolt M8, L = about 50 • When a gear pump, etc. is attached to the pump
rear surface, remove the gear pump, etc. first
before performing work.
6. Face down the pump regulator installation surface
Disassembly Procedures horizontally on the work platform, and separate the
When disassembling the pump, read the disassembly pump casing (271) and valve block (312).
procedures all the way to the end before disassembling • When placing the regulator installation surface
according to the sequence below. facedown, be sure to place a rubber plate or
The numbers in the parentheses after the part names similar material on the work platform so as not to
indicate part numbers in the pump structural diagram. damage the regulator installation surface.
This manual lists the disassembly procedures for the • When separating the pump casings and valve
tandem pump. Perform disassembly using the type col- block, remove the 1st gear at the same time.
umn as reference.
Also, be careful that parts from the front pump and rear
pump do not get mixed together.
1. Select a location for disassembly.
• Select a clean location.
2. Use cleaning oil to remove any dirt or rust from the
surface of the pump.
3. Remove the drain port plug (468) and drain the oil
from the pump casing.
• Remove the plugs from both the front and rear
pumps and drain the oil.
84402832 NA - May 2011

8008-3
Main Unit
7. Remove the cylinder blocks (141) out from the 9. Tap the installation flange section of the swash plate
pump casings (271) in a straight line in relation support board (251) on the pump casing side, and
to the drive shafts (111), and remove the pistons separate the swash plate support board and the
(151), holder plates (153), spherical bushings pump casing.
(156), and cylinder springs (157) at the same time.
• Be careful not to damage the sliding surfaces
of the cylinders, spherical bushings, shoes, and
swash plates.
10. Remove the shoe plate (211) and the swash plate
(212) from the pump casing (271).
8. Remove the hexagon socket head bolts (406) and

remove the seal cover (F) (261).
• Removal can be performed easily by inserting a
bolt into the hole on the seal cover (F) and then
pulling the bolt out.
• The seal cover (F) has an oil seal, so be careful
not to damage the oil seal when removing the seal
cover.
11. Lightly strike the shaft end sections of the drive

shafts (111) (113) with a plastic hammer, etc. to re-
move the drive shafts from the swash plate support
board.
84402832 NA - May 2011

8008-4
Main Unit
12. Remove the valve plates (313) (314) from the valve Assembly Procedures
block (312).
The assembly procedure is the reverse of the disassem-
• These can also be removed in Step 6. bly procedure. However, follow the precautions below.
1. Be sure to repair any parts damaged during disas-
sembly, and prepare replacement parts in advance.
2. Thoroughly clean all parts with cleaning oil and air
blow them before assembly.
3. Be sure to apply clean hydraulic oil to sliding parts
and bearings before assembly.
4. As a rule, replace all O-rings, oil seals, and other
seal parts with new parts.
5. Use a torque wrench to tighten all installation bolts
and plugs to the torque specified in "Maintenance
Standards."
6. Be careful not to mix up the pump parts for the front
and rear.
7. Install the swash plate support board (251) on the
13. If necessary, remove the stopper (L) (534), stopper pump casing (271) by lightly striking it with a ham-
(S) (535), servo piston (532), and tilting pin (531) mer.
from the pump casing (271), and remove the nee-
• If the servo pistons, tilting pin, stoppers (L), and
dle bearing (124) and 1st gear (116) from the valve stoppers (S) have been removed, install these
block (312). parts on the pump casings in advance.
• To avoid damaging the head of the tilting pin, use • To avoid damaging the heads of the tilting pins
a jig when removing it. and the feedback pins, use a jig when tightening
• Loctite has been applied to the section where the the servo pistons and tilting pins. Also be sure to
tilting pin and the servo piston are bonded, so be apply Loctite (moderate strength) to the threaded
careful not to damage the servo piston. sections.
• Try to avoid removing the needle bearings unless
they are at the end of their service life.
• Do not loosen the hexagon nuts of the valve block
or swash plate support board. This changes the
flow setting.
8. Face down the regulator installation surface of the

pump casing, insert the tilting bushing of the swash
plate onto the tilting pin (531), and correctly mount
the swash plate (212) and swash plate support
board (251).
• Use the fingertips of both hands to check that the
swash plate moves smoothly.
• Coat the swash plates, swash plate support
boards, and all sliding sections with grease for
easier installation of the drive shaft.
84402832 NA - May 2011

8008-5
Main Unit
11. Assemble the piston cylinder subassembly [cylin-
ders (141), pistons (151, 152), holder plates (153),
spherical bushings (156), spacers (158), cylinder
springs (157)], and then insert it into the pump cas-
ing in alignment with the phase of the splines of the
spherical bushings and cylinder blocks.
9. Install the drive shaft (111) with a bearing (123),

bearing spacers (127), and stop ring (824) attached
to the swash plate support board (251).
• Do not strike the drive shaft with a hammer, etc.
• Lightly strike the outside ring of the bearing with
a plastic hammer to install it, and use a steel rod,
etc. to tightly insert it all the way in. 12. Install into the valve block (312) while aligning the
valve plate (313) with the pin (885).
• Be careful not to mistake the suction and dis-
charge directions of the valve plates.
10. Attach the seal cover (F) (261) to the pump casing
(271), and secure with the hexagon socket head
bolts (406).
• Apply a thin layer of grease to the oil seal inside 13. Install the valve block (312) into the pump casing
the seal cover (F). (271) and tighten it with the hexagon socket head
• Be careful not to damage the oil seal when attach- bolts (401).
ing it. • Assembly is easier when starting with the rear
side pump.
• Install the valve block in the correct direction. (In-
stall the valve block so that the regulator faces up
and the suction flange faces right when looking at
the valve block from the front.)
• Insert the 1st gear into the valve block before-
hand and couple it with the drive shaft joint section
spline.
84402832 NA - May 2011

8008-6
Main Unit
14. Insert the feedback pins of the tilting pins into the
feedback lever of the regulators, install the regu-
lators, and tighten the hexagon socket head bolts
(412, 413).
• Install the regulator, making sure not to mistake
the front and the rear of the regulator.
15. Install the drain port plug (468) to finish assembly.
84402832 NA - May 2011

8008-7
Main Unit
84402832 NA - May 2011

8008-8
Section
8010
Pump Main Unit Maintenance Standards
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Replacement standards for worn parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Standards for repairing cylinders, valve plates, and swash plates (shoe plates) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overall View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Attached diagram 1. pump assembly cross-section diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Drive Shaft Front Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Drive Shaft Rear Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Part Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Procedures for Assembly and Disassembly of Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disassembly preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disassembly procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Replacement standards for worn parts

If wear on any part exceeds the standard values below, replace or readjust that part.
If, however, the appearance of the part shows significant damage, replace that part.
Recom-
Reference mended
Part name and inspection item dimen- replace- Solution
sions ment
value
Piston and cylinder bore clearance (D - d) 0.038 mm 0.065 mm Replace piston or cylinder.
Piston and shoe caulking section backlash (δ) 0 - 0.1 mm 0.3 mm Replace piston and shoe assembly.
Shoe thickness (t) 5.4 mm 5.0 mm Replace piston and shoe assembly.
Free height of cylinder spring (L) 40.9 mm 40.1 mm Replace cylinder spring.
Assembled height of holder plate and spherical Replace holder plate or spherical
23.8 mm 22.8 mm
bushing (H - h) bushing.
Cylinder opening diameter(spline in cylinder) Replace cylinder and spherical bush-
35.17 mm 35.57 mm
Spherical bushing spline ing.
Clearance between the piston and cylinder bore : D-d Free height of cylinder spring : L
Loseness of piston, shoe, and caulking : δ Combined height of pressure plate and spherical bush :
Thickness of shoe : t H-h
Standards for repairing cylinders, valve plates, and swash plates (shoe
plates)
Valve plate (sliding section)
Surface roughness re-
Swash plate (shoe plate 3-Z
quiring repair
section)
Cylinder Standard surface rough-
0.4 Z or lower (lapping)
Surface roughness ness (repair value)
84402832 NA - May 2011

8010-3
Tightening torque
Tighten-
Part name Size ing torque Tool name (mm)
(N•m)
M5 6.9 B=4
M6 11.8 5
M8 29.4 6
M10 56.9 8
Hexagon socket head bolt M12 98.1 10
M14 156.9 12
M16 235.4 14
M18 333.4 14
M20 431.5 17
R 1/16 6.9 4
Rc plug R 1/8 10.3 5
NOTE: R 1/4 17.2 6
Wrap seal tape around the plug 1.5 - 2 times R 3/8 34.3 8
R 1/2 49.0 10 Hexagon
G1/4 29.4 6 wrench
G1/2 98.1 10
G3/4 147.1 14
PO plug
G1 186.3 17
G1 1/4 264.8 17
G1 1/2 274.6 17
Overall View
Attached diagram 1. pump assembly cross-section diagram
Drive shaft front side Drive shaft rear side
84402832 NA - May 2011

8010-4
Drive Shaft Front Side
84402832 NA - May 2011

8010-5
Drive Shaft Rear Side
84402832 NA - May 2011

8010-6
Part Table
Adhesion agent (ThreeBond
a Co., Ltd. No. 130SN) applica- d Left rotation valve plate
tion
Oil seal outer circumference Tightening torque
b Lubricant (Sealub L101) coat- e Flange socket (4-M10 x 1.5):
ing 33 N·m
Tightening torque
c Right rotation valve plate f Hexagon bolt (3-M6 x 1.0): 12
N·m
Component part no. (q'ty)

Code Part name Q'ty
or type
04 Gear pump 1 set ZX15LHRZ2-07A-V
011 Piston subassembly 2 set 151 (9PC), 152 (9PC)
013 Cylinder subassembly (R) 1 set 141 (1PC), 313 (1PC)
014 Cylinder subassembly (L) 1 set 141 (1PC), 314 (1PC)
030 Swash plate subassembly 2 sets 212 (1PC), 214 (1PC)
541 (1PC), 543 (1PC), 545
041 Check valve 1 subassembly 2 sets
(1PC)
541 (1PC), 544 (1PC), 545
042 Check valve 2 subassembly 2 set
(1PC)
Electromagnetic proportional
079 pressure reducing valve, cas- 1 set KDRDE5KR-V3-V
ing subassembly
530 Tilting pin subassembly 2 sets 531 (1PC), 548 (1PC)

111 Drive shaft (F) 1 531 Tilting pin 531
113 Drive shaft (R) 1 532 Servo piston 532
114 1st gear 1 534 Stopper (L) 534
123 Cylinder roller bearing 2 535 Stopper (S) 535
124 Needle roller bearing 2 541 Seat 541
127 Bearing spacer 4 543 Stopper 1 543
141 Cylinder block 2 544 Stopper 2 544
151 Piston 18 545 Steel ball 545
152 Shoe 18 548 Feedback pin 548
153 Holder plate 2 702 O-ring 702
156 Spherical bushing 2 710 O-ring 710
157 Cylinder spring 18 714 O-ring 714
211 Shoe plate 2 717 O-ring 717
212 Swash plate 2 724 O-ring 724
214 Tilting bushing 2 725 O-ring 725
251 Swash plate support board 2 728 O-ring 728
261 Seal cover (F) 1 732 O-ring 732
271 Pump casing 2 774 Oil seal 774
312 Valve block 1 789 Backup ring 789
313 Valve plate (R) 1 792 Backup ring 792
314 Valve plate (L) 1 808 Hexagon nut 808
326 Cover 1 824 Stop ring 824
401 Hexagon socket head bolt 8 885 Valve plate pin 885
406 Hexagon socket head bolt 4 886 Spring pin 886
414 Hexagon socket head bolt 4 901 Eyebolt 901
Hexagon socket head stop
466 VP plug 2 953 953
screw
467 VP plug 2 954 Stop screw 954
468 VP plug 4 981 Nameplate 981
490 Insert plug 27 983 Driving tack 983
492 Insert plug 12
84402832 NA - May 2011
8010-7
Bolt, plug, nut, servo piston tightening torque

Tightening
Part
Screw size torque
No.
N·m
401 M20 430
406 M8 29
414 M12 98
466 G1/4 36
468 G3/4 170
490 NPTF 1/16 8.8
492 Rc 1/8 9.8
531,
M30 430
532
808 M20 240
84402832 NA - May 2011

8010-8
Procedures for Assembly and Disassembly of Regulator

Tools
Tool name Tools dimensions
Hexagon wrench 4, 5, 6 (B dimension, mm)
Socket wrench, double-head (single-head) wrench
Monkey wrench Small-sized (maximum 36 mm)
Screwdriver
Plastic hammer
Torque wrench
Pliers For stop ring, x 2
Steel rod Diameter D4 or less, L = 100
Tweezers
Bolt M4, L = about 50
Disassembly preparations
1. These regulators comprise small precision parts, so assembly and disassembly operations are somewhat com-
plex.
2. The pressure-flow settings of the front side regulator and the rear side regulator differ, so mark the regulators
when disassembling to differentiate between the drive side and the driven side.
3. When disassembling the regulators, read this disassembly procedure thoroughly before following the sequence
below.
The numbers in parentheses after the part names are the codes indicated in "Diagram 1.
Front-side regulator assembly cross-section diagram" "Diagram 2.
Rear-side regulator assembly cross-section diagram".
84402832 NA - May 2011

8010-9
Disassembly procedures 5. After removing the cover (C) (629) subassembly,

remove the outer spring (625), inner spring (626),
1. Select a location for disassembly. and spring seat (C) (624) from the compensation
• Select a clean location. section, and pull out the adjusting ring (Q) (645),
• Place a rubber plate or cloth on the work platform pilot spring (646), and spring seat (644) from the
so as not to damage the parts. pilot section.
2. Use cleaning oil to remove any dirt or rust from the • The adjusting ring (Q) (645) can be easily re-
surface of the regulator. moved by pulling it out with an M4 bolt.
3. Remove the hexagon socket head bolts (412, 413),
and remove the regulator from the pump main unit.
• Be careful not to lose the O-rings.
6. Remove the hexagon socket head bolts (436, 438),

and remove the pilot cover (641).
When the pilot cover is removed, remove the set
spring (655) from the pilot section.
4. Remove the hexagon socket head bolts (438), and
remove the cover (C) (629).
• The cover (C) is assembled with an adjusting
screw (C) (628), adjusting ring (C) (627), lock nut
(630), hexagon nuts (801, 802), and hexagon
socket head locking screw (924).
Do not loosen these screws and nuts.
Loosening causes the adjusted pressure and flow
setting to change.
7. Remove the stop ring (814), and remove the spring

seating (653), return spring (654), and sleeve (651).
• The sleeve (651) is assembled with a retaining
ring (836).
• When removing the stop ring (814), the return
spring (654) will fly out, so be careful not to lose it.
84402832 NA - May 2011

8010-10
8. Remove the locking rings (858), and remove the 10. Pull out the pin (874), and remove the feedback
fulcrum plug (614) and adjusting plug (615). lever (611).
• The fulcrum plug (614) and adjusting plug (615) • Use a fine steel rod to push out the pin (874) (pin
can be easily removed by pulling them out with diameter D4) from above without touching lever 1
an M6 bolt. (612).
9. Remove lever 2 (613). 11. Remove lever 1 (612).

Do not pull out the pin (875). Do not pull out the pin (875).
• It can be easily removed by using a pair of tweez- 12. Pull out the pilot piston (643) and spool (652).
ers. 13. Pull out the piston case (622), compensation piston
(621), and compensation rod (623) to complete dis-
assembly of the regulator.
• The piston case (622) can be removed by pushing
out the compensation rod (623) from the opposite
side of the piston case.
* The component parts are small, so be very careful not
to lose them.
84402832 NA - May 2011

8010-11
Assembly procedures
The assembly procedure is the reverse of the disas-
sembly procedure. However, follow the precautions
below.
1. Be sure to repair any parts damaged during dis-
assembly, and prepare replacement parts in ad-
vance.
2. Any foreign matter entering the equipment can
create a malfunction. Therefore, after thoroughly
cleaning the equipment with cleaning oil, air blow
the equipment, and perform assembly in a clean
location.
3. Make sure to tighten bolts and plugs of each sec-
tion to the specified torque.
4. Be sure to apply clean hydraulic oil to sliding sec-
a Lever (1) side
tions before assembly.
5. As a rule, replace all seals such as O-rings with Lever (2) side (Fulcrum plug,
b
new parts. adjusting plug side)
1. Install the compensation rod (623) into the compen-

sation hole on the casing (601). 5. Install the pilot piston (643) into the flow control hole
2. Insert the pin press fit in lever 1 (612) into the groove on the casing.
on the compensation rod, and install lever 1 on the • Check that the pilot piston slides smoothly without
pin press fit in the casing. catching.
3. Install the spool (652) and sleeve (651) in the casing
spool hole. 6. Insert the pin press fit in lever 2 (613) into the groove
on the pilot piston, and assemble lever 2.
• Check that the spool and sleeve slide smoothly in
the casing without catching.
• Be careful to assemble the spool in the correct
direction.
7. Assemble the fulcrum plug (614) and install the

locking ring (858) so that the pins press fit in the
fulcrum plug are inserted into the pin holes on lever
2.
*1 Spool
*2 Feedback lever
4. Install the feedback lever (611), and insert the pin

(874) in alignment with the pin hole on the feedback
lever.
• This is easier to assemble by inserting the pin into
the feedback lever to a small degree in advance.
• Be careful to assemble the feedback levers in the
correct direction.
8. Insert the adjusting plug (615), and install the lock-

ing ring.
• Be careful to insert the fulcrum plug and adjusting
plug into the correct openings.
84402832 NA - May 2011
8010-12
• At this time, check that the backlash from the 11. Install the spring seating (644), pilot spring (646),
movement of the feedback lever is not too great and adjusting ring (645) into the pilot hole, and in-
and that the feedback lever does not catch on stall the spring seating (624), inner spring (626), and
anything. outer spring (625) into the compensation hole.
9. Install the return spring (654) and spring seating • Be careful to install the spring seating in the cor-
(653) into the spool hole, and install the stop ring rect direction.
(814).
12. Assemble the cover (C) (629) set with the adjusting
10. Assemble the set spring (655) into the spool hole, screw (628), adjusting ring (C) (627), lock nut (630),
assemble the compensation piston (621) and piston hexagon nuts (801, 802), and the hexagon socket
case (622) into the compensation hole, install the head locking screw (924), and tighten the hexagon
pilot cover (641), and tighten the hexagon socket socket head bolts (438).
head bolts (436, 438).
84402832 NA - May 2011

8010-13
84402832 NA - May 2011

8010-14
Section
8011
Procedures for Assembly and Disassembly of Control Valve
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cautions for disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal of long cap and pull out of main spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly of arm 1 parallel-tandem spool, neutral cut spool section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly of arm regeneration release valve section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly of load check valve section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly of antidrift valve section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly of relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly of option section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly of straight travel signal control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly of other plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly of add-on section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly of valve housing union bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cautions for assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cautions for O-Ring handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cautions for spool handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Adhesive application method (for male thread section and female thread section of parts requiring adhesion)8
Procedure for assembly of sub-assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assembly of spool assembly (main spool) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assembly of arm 1 parallel-tandem spool assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assembly of neutral cut spool assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assembly of antidrift valve assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Procedure for assembly of control valve main unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly of relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly of load check valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly of antidrift valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assembly of option section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assembly of arm regeneration release valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assembly of arm 1 parallel-tandem spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assembly of neutral cut spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembly of main spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembly of straight travel signal control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembly of add-on section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembly of other plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Internal structure diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Part list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Procedures for assembly and disassembly of main relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Procedures for assembly and disassembly of overload relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Procedures for assembly and disassembly of low-pressure relief valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Procedures for assembly and disassembly of add-on main relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Relief valve adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Troubles and countermeasures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Disassembly
Cautions for disassembly
1. On level ground, bring all the operating machines into contact with the ground.
When doing this, have the main machine in a horizontal position.
Check that the machine is in such a state that it will not travel or swing on its own.
Then stop the engine and bleed out the pressure from each actuator.
CAUTION
Do not replace a valve assembly or disassemble a valve with pressure remaining in the system.
This would be dangerous.
High-pressure oil might spray out or parts might suddenly come out.
For disassembly, bring the bucket to the ground and adequately bleed out any pressure in the cir-
cuits.
2. Bleed the air pressure from the tank.

3. Clean well around the location to be disassembled and keep foreign matter from getting into the valve during
disassembly.
4. Identify disassembled parts with shipping tags to show their position for re-assembly.
5. Do not reuse any disassembled seals (O-rings, backup rings).
Replace them with new ones.
6. The spool was selected to fit with the valve housing and sleeve, so do not replace the spool.
Disassembly procedure
Removal of long cap and pull out of main spool
1. Loosen the hexagon socket head bolts (74) (8 mm hexagon socket diameter) for the 9 caps (8) and the 1 cap
(9), and remove them.
When pulling out the spool only, do not loosen the M6 screws on the plate except for the 4 hexagon socket head
bolts (75) and the 1 hexagon socket head bolt (94) fastening the plate assemblies.
2. Loosen and remove the plugs (91) (19 mm hexagon diameter) attached to the ports as necessary.
3. Remove the O-rings (7) (1 in each section) from the plate assemblies (10) and (11).
4. Pull out each spool from the valve housing still in the sub-assembly state.
CAUTION
1) When pulling out the spool, be careful not to cause any dents or scratches.
2) 2Identify each spool with a shipping tag so that there will be no mistake about their positions
when they are re-assembled.
5. Loosen and remove the hexagon socket head bolts (75) (8 mm hexagon socket diameter) and hexagon socket
head bolts (94) (5 mm hexagon socket diameter) those fastens the plate assemblies (10), (11), (28) and (29) to
the housing.
Remove the plate assemblies still in the assembly state.
Do not disassemble them.
6. Loosen and remove the plugs (91) (19 mm hexagon socket diameter) as necessary.
7. Remove the O-rings (7) and (41) from the valve housings (1) and (13).
8. Disassembly of spool assembly
84402832 NA - May 2011

8011-3
CAUTION
1) In order to avoid damaging the outer edge of the spool, sandwich the spool with wooden blocks
(as in the diagram on the right) and fasten with a vise before starting the work.
2) Since adhesive is applied to the spool end thread section, heat up the outer edge of the spool
thread section to break down the adhesive.
3) Heat so that the spool heating temperature is 200 - 250℃ ℃.
Heat until the spool end loosens easily immediately after the heating.
4) If overheating occurs, replace the spring with a new one. (Wooden blocks for spool assembly/
disassembly)
(Wooden blocks for spool assembly/disassembly)
1) Loosen the spool assembly (2) - (6) and (14) - (17) spool ends (8 mm hexagon socket diameter) and dis-
assemble the spring seat and spring.
2) The spools in spool assemblies (3), (4), (6) and (14) have poppets, springs, plugs, and filters in the spools,
but do not disassemble them unless necessary.
When disassembly is required, heat up the outer edge of the spool to break down the adhesive on the
thread section, then remove the plug.
When assembling, always replace O-rings and backup rings with new ones.
Disassembly of arm 1 parallel-tandem spool, neutral cut spool section

1. Loosen and remove the hexagon socket head bolts (78) (5 mm hexagon socket diameter) for the caps (18) and
(86).
2. Remove the O-ring (23) from the cap (18).
Remove the O-rings (65) from the housing (1).
3. Pull out the spools (19) and (84) from the valve housing still in the sub-assembly state.
4. Disassembly of spool assembly
CAUTION
1) In order to avoid damaging the outer edge of the spool, sandwich the spool with wooden blocks
for assemble (as in the diagram) and fasten with a vise before starting the work.
2) Since adhesive is applied to the spool end thread section, heat up the outer edge of the spool
thread section to break down the adhesive.
3) Heat so that the spool heating temperature is 200 - 250℃ ℃.
Heat until the spool end loosens easily immediately after the heating.
4) If overheating occurs, replace the spring with a new one.
1) Loosen the spool (19) spool end (22) (5 mm hexagon socket diameter) and disassemble the spring seat
(20) and spring (21).
Disassembly of arm regeneration release valve section

Sub-parts in the assembly are expressed as [main number - sub-number].
84402832 NA - May 2011

8011-4
CAUTION
1. When removing the plug, pressure left within can make parts fly out dangerously.
2. Slowly loosen the plug to check that there is no resistance due to residual pressure, then disassem-
ble.
1. Loosen and remove the plug (24) (32 mm hexagon diameter) and remove the O-ring (25).
2. Remove the spring (26) and spool (27-1) from the sleeve (27-2).
3. Pull out the sleeve (27-2) from the valve housing.
4. Remove the piston (27-3), O-ring (30), and backup ring (31) from the sleeve (27-2).
Disassembly of load check valve section

CAUTION
1. When removing the plug, pressure left within can make parts fly out dangerously.
2. Slowly loosen the plug to check that there is no resistance due to residual pressure, then disassem-
ble.
1. Loosen and remove the hexagon socket head bolts (75) (4 in each section, 8 mm hexagon socket diameter) for
the flanges (37) (6 locations) and (61) (1 location).
Only (61) has a different shape from the others, so keep it separate from (37).
2. Remove the spring (35), poppets (34) and (51) and O-ring (36) from the valve housing.
Remove the arm 2 (E-E cross section) poppet (59), spring (60), and sleeve (58).
3. Loosen and remove the hexagon socket head bolts (75) (8 mm hexagon socket diameter) for the flanges (52) (2
locations) .
4. Remove the spacer (53) from the valve housing and remove the O-ring (54) and backup ring (55) from the spacer
(53).
5. Remove the spring (35) and poppet (34) from the valve housing.
6. Loosen and remove the plug (72) (8 mm hexagon socket diameter). (D-D cross section)
8. Loosen and remove the plug (72) (8 mm hexagon socket diameter). (D-D cross section)
9. Remove the spacer (57), spring (33), and poppet (32) from the valve housing.
10. Loosen and remove the plug assembly (92) (36 mm hexagon diameter). (P4 section, cross section H-H )
11. Loosen and remove the hexagon socket head bolts (74) (4 locations, 8 mm hexagon socket diameter) for the
flange (43) .
12. Remove the spring (45), poppet (44), and O-ring (36) from the valve housing.
13. Loosen and remove the plug (46) (27 mm hexagon diameter) and remove the O-ring (47). (H-H cross section)
Disassembly of antidrift valve section

Sub-parts in the assembly are expressed as [main number - sub-number].
CAUTION
1. When removing the antidrift valve assembly, pressure left within can make seals and other parts fly
out dangerously.
2. Slowly loosen the hexagon socket head bolt to check that there is no resistance due to residual
pressure, then disassemble.
1. Loosen and remove the hexagon socket head bolts (74) (4 in each section, 8 mm hexagon socket diameter) for
the 2 antidrift valve assemblies (67).
2. Remove the O-rings (36) and (41) from the valve housing.
4. Disassembly of antidrift valve assembly
CAUTION
1) If parts inside the antidrift valve are disassembled with the antidrift valve installed in the valve
housing, pressure left within can make parts fly out dangerously.
2) Slowly loosen the plug assembly (67-12) to check that there is no resistance due to residual
pressure, then disassemble.
1) Loosen and remove the plug assembly (67-14) (38 mm hexagon diameter) and remove the O-ring.
2) Remove the piston (67-3), spool (67-4), and spring (67-6).
84402832 NA - May 2011
8011-5
3) Loosen and remove the plug (67-14) (12 mm hexagon diameter).

4) Remove the sleeve (67-5) and poppet (67-2) from the body and remove the O-rings (67-8) and (67-9),
backup rings (67-10) and (67-11) from the outer edge of the sleeve.
5) Remove the spring seat (67-13) and spring (67-7) from deep in the hole.
84402832 NA - May 2011

8011-6
Disassembly of relief valve

CAUTION
1. When removing the relief valve, loosen and remove the main unit installation section plug.
2. Do not loosen the set pressure adjustment plug or lock nut.
3. Doing so would be dangerous because the set pressure changes if the set pressure adjustment plug
turns.
1. Loosen and remove the overload relief valve (69) (32 mm hexagon diameter).
2. Loosen and remove the main relief valve (68) (32 mm hexagon diameter).
3. Loosen and remove the 2 relief valve assemblies (70) (32 mm hexagon diameter).
Remove the O-rings (70-5) and (70-8).
Disassembly of option section

1. Loosen and remove the hexagon socket head bolts (75) (8 mm hexagon socket diameter) for the 2 caps (88),
and remove the O-rings (89).
2. Loosen and remove the 2 plug assemblies (93) (24 mm hexagon diameter), and remove the O-rings and backup
rings.
Disassembly of straight travel signal control valve

1. Remove the hexagon socket head bolts (83) (5 mm hexagon socket diameter) and remove the body assembly
(42).
2. Loosen and remove the plug assembly (42-5) (5 mm hexagon socket diameter) and remove the O-ring.
3. Pull out the spools (42-2) and (42-3) and spring (42-4).
4. Loosen the orifice plug (42-7) (36 mm hexagon diameter) and remove it from the body (42-1).
Disassembly of other plugs

1. Loosen and remove the plug assembly (71) (10 mm hexagon socket diameter) and remove the O-ring.
3. Loosen and remove the orifice plug (40) (5 mm hexagon socket diameter). (D-D cross section)
4. Loosen and remove the plug assembly (92) (36 mm hexagon diameter) and remove the O-ring.
Disassembly of add-on section

1. Loosen and remove the 4 hexagon nuts (97) (22 mm hexagon diameter).
2. Remove the outlet housing (95).
Execute Steps [3] - [5] below as necessary.
3. Remove the spool section assembly (98) and remove the matching surface O-rings (98-10) and (98-11).
4. Remove the inlet section assembly (99) and remove the matching surface O-rings (99-3) and (99-4).
5. Remove the spool section assembly (111) and remove the matching surface O-rings (110-10) and (110-11).
6. Remove the main unit body matching surface O-rings (56) and (64).
7. Loosen the tie rod (96) and remove it from the main unit valve housing (1).
(Use a pipe wrench.)
CAUTION
When removing the add-on section, be careful not to cause any dents, scratches, or the like on
matching surfaces.
Any dents, scratches, or the like on matching surfaces have a danger of allowing oil to leak from
those surfaces and causing malfunction.
Also, be careful not to let any foreign matter enter the oil path.
Such foreign matter has a danger of the spool sticking due to biting of the spool sliding section or
a load check seat defect making the actuator run wild or stop disabled.
Disassembly of valve housing union bolt

CAUTION
1. Do not disassemble the union bolt (77) unless necessary.
2. If such disassembly is necessary, place the main unit on a flat table to do the work.
3. Prepare the replacement O-rings (65) and (66).
84402832 NA - May 2011

8011-7
1. Loosen and remove the 8 hexagon socket head bolts (77) (14 mm hexagon socket diameter).
Tightening torque: 166 - 177 N•m
2. Remove the valve housing matching surface O-rings (65) and (66).
Cleaning
Completely clean all the disassembled parts with clean mineral oil.
Dry with compressed air and place each part on clean paper or vinyl for inspection.
Inspection
Inspect all surfaces of each part for burrs, scratches, gouges, and other defects.
1. Inspect the valve housing load check seat surface for scratches, gouges, and also for debris, dents, rust.
Repair any minor scratches with an oilstone.
2. Check that there are no scratches, dents, etc. on the outer edge of the spool.
Repair any small scratches with an oilstone.
3. Sliding parts must all move easily.
Also, all grooves and paths must be free of foreign matter.
4. If a spring is broken or extremely deformed or worn, replace it.
5. If relief valve operation is poor, inspect according to "Troubles and countermeasures Relief valve".
6. Replace all O-rings and backup rings from disassembled parts.
7. After removing caps or plugs, check for any paint fragments around the body opening or plug seating surface. (If
paint fragments were to get inside the valve, they could jam up or clog up the valve, resulting in operation defects
and oil leaks.)
Cautions for assembly

Cautions for O-Ring handling
1. Do not use any O-ring with a molding defect or damage caused by handling.
2. Apply enough grease or hydraulic oil to the O-ring and the section where it is mounted so that it can be mounted
smoothly.
3. Do not stretch an O-ring so far that this causes permanent deformation.
4. When assembling an O-ring, be careful not to roll the O-ring into place.(If an O-ring is mounted twisted, it is
difficult for it to naturally recover to its normal state and that twist causes oil leaks.)
Cautions for spool handling
1. Excessive torque on thread sections causes spool operation defects, so always tighten to just the specified torque.
2. Be careful to assemble all spools, springs, and spool ends in the same combinations as before disassembly.
Adhesive application method (for male thread section and female thread section of parts
requiring adhesion)
1. Cleaning (degreasing)
Either use vapor degreasing with acetate, ether or clean with an alkali cleaning agent.
2. Drying
Dry the surface to be glued, either by blowing clean air on it or letting it dry naturally.
Inadequate drying reduces the effectiveness of the adhesive.
3. Applying the adhesive
Apply a small amount of adhesive (equivalent to Loctite #638) to the first 2 - 3 threads at the entrance of the spool
female threads.
At this time, install being careful that the application section does not touch the spring seat.
CAUTION
Do not use "Loctite Primer T" hardening accelerator.
It causes insufficient adhesion strength.
4. Adhesive hardening time

In order to ensure the hardening of the adhesive, after fastening the spool end, leave the part out in the air for
the following period of time.
- Ambient temperature around 22℃: 8 hr. or longer
84402832 NA - May 2011

8011-8
CAUTION
If the parts are not left out in the air for the above period, adequate adhesive strength may not be
achieved.
Procedure for assembly of sub-assembly

CAUTION
Before starting the assembling, check the quantity of each part, the installation location, the required
tools, etc.
Assembly of spool assembly (main spool)

1. Apply adhesive to the thread sections of the spools (2) - (6), (14) - (17) and assemble the spring seat, spring,
and spool end.
2. Sandwich the spool with the wooden blocks (the same ones used for disassembly), fasten in place with a vise,
then tighten the spool ends to the specified torque.
3. For spools (3), (4), and (14), insert the poppets and springs from the end opposite from the spool end, then apply
adhesive to the thread sections of the plugs with the O-rings and backup rings mounted, and tighten.
Also, for spool (5), the plug with filter is mounted at this location.
CAUTION
1) Be careful not to apply so much adhesive that it drips into the spool.
2) Be careful not to tighten any spool end with excessive torque.
Excessive torque there would deteriorate spool operation.
3) There are 2 types of spring.
Be careful to assemble each in its correct location. (only boom 2 different)
Assembly of arm 1 parallel-tandem spool assembly

1. Apply adhesive to the thread sections of the spool (19) and assemble the spring seat (20), spring (21), and spool
end (22).
CAUTION
Excessive torque there would deteriorate spool operation.
Assembly of neutral cut spool assembly

1. Apply adhesive to the thread sections of the spool (84-1) and assemble the spring seat (84-2), spring (84-3), and
spring end (84-4).
CAUTION
84402832 NA - May 2011

8011-9
Assembly of antidrift valve assembly

1. Assemble the O-rings (67-8) and (67-9) and backup rings (67-10) and (67-11) into the grooves on the outer edge
of the sleeve (67-5).
CAUTION
1) Be careful to assemble O-rings and backup rings in the correct locations.
2) If they are assembled backwards, there is a danger of an O-ring being damaged and the drop
of the actuator from its own weight increasing.
2. Insert the poppet (67-2) and spool (67-4) in the sleeve hole.
Be careful to assemble the spool in the correct direction.
3. Install the spring seat (67-13) at the small-diameter section at the tip of the poppet, mount on the spring (67-7),
and insert into the body (67-1) together with the sleeve.
CAUTION
Apply grease to the poppet seat so that the spring and spring seat can be installed correctly on the
poppet seat.
4. Screw the plug (67-14) into the body (67-1) and tighten it.
5. Assemble the spring (67-6) and piston (67-3) on the plug (67-14).
6. Tighten the plug assembly (67-12) with O-ring mounted to the body (67-1).
Procedure for assembly of control valve main unit

Assembly of relief valve
CAUTION
1. When installing the relief valve, be sure to tighten the main unit installation section plug.
2. Do not tighten the set pressure adjustment plug or lock nut.
3. Doing so would be dangerous because the set pressure changes if the set pressure adjustment plug
turns.
1. Screw in and tighten the main relief valve (68).

2. Screw in and tighten the 6 overload relief valves (69) at each section.
3. Screw in and tighten the 2 relief valve assemblies with O-rings mounted (70).
Assembly of load check valve

1. Mount the O-rings (36) in the arm 1 section (E-E cross section), Boom 1 and 2 sections (F-F cross sections),
swing section, and bucket section (G-G cross sections) and assemble the poppets (34) and springs (35).
Mount the flanges (37) and tighten with the hexagon socket head bolts (75).
For the arm 2 section (E-E cross section), assemble the sleeve (58), poppet (59) and spring (60), mount the
flange (61), and tighten with the hexagon socket head bolts (75).
2. Mount the O-ring (36) in the travel section (I-I cross section) and assemble the poppet (51) and spring (35).
Tighten the flange (37) with the hexagon socket head bolt (75).
3. Assemble the poppet (34) and spring (35) on the common check section (J-J cross section), then insert the
spacers (53) with the O-ring (54) and backup ring (55) mounted.
84402832 NA - May 2011
8011-10
Tighten the flange (52) with the hexagon socket head bolt (75).
CAUTION
1) Be careful to assemble O-rings and backup rings in the correct locations.
2) If they are assembled backwards, there is a danger of an O-ring being damaged and causing
external leaks.
4. Mount the O-ring (36) in the option section (H-H cross section) and assemble the poppet (44) and spring (45).
Mount the flange (43) and tighten with the hexagon socket head bolts (74).
5. Assemble the poppet (49) and spring (48) in the travel section (H-H cross section).
Screw in and tighten the plug (46) with O-ring (47) mounted.
6. Assemble the poppet (32) and spring (33) in the arm 1 parallel-tandem section (D-D cross section).
Screw in and tighten the plug assembly (72) with O-ring mounted.
7. Assemble the poppet (32), spring (33), and spacer (57) in the arm 2 parallel-tandem section (D-D cross section).
Screw in and tighten the plug assembly (72) with O-ring mounted.
Assembly of antidrift valve

1. Mount the O-rings (36) and (41) on the antidrift valve installation surfaces in the arm 1 section (E-E cross section)
and boom 1 section (F-F cross section).
2. Assemble the poppet (38) and spring (39).
3. Install the 2 antidrift valve assemblies (67) and tighten with the hexagon socket head bolts (74).
Assembly of option section

1. Install the 2 caps (88) with O-rings (89) mounted and tighten with the hexagon socket head bolts (75).
2. Screw in and tighten the 2 plug assemblies (93) with O-rings and backup rings mounted.
Assembly of arm regeneration release valve

1. Mount the O-ring (30) and 2 backup rings (31) in the sleeve (27-2).
2. Assemble the piston (27-3) and spool (27-1) in the sleeve and insert into the valve housing.
3. Put the spring (26) into the plug (24) with O-ring (25) mounted, then screw into the valve housing and tighten.
Assembly of arm 1 parallel-tandem spool

1. Assemble the spool (19) in the sub-assembly state into the valve housing.
CAUTION
After inserting the spool, slide it to check for any sticky or rough feeling.
2. Mount the cap (18) with O-ring mounted (23) and tighten with the hexagon socket head bolt (78).
Tightening torque: 8.8 - 10.8 N•m
84402832 NA - May 2011

8011-11
Assembly of neutral cut spool

1. Assemble the spool assembly (84) into the valve housing.
CAUTION
After inserting the spool, slide it to check for any sticky or rough feeling.
2. Mount the O-ring (65) into the housing and tighten the cap (86) with the hexagon socket head bolt (78).
Tightening torque: 8.8 - 10.8 N•m
Assembly of main spool

1. Mount the O-rings (7) and (41) on the valve housing cap matching surface.
2. Assemble the spool assemblies (2) - (6), (14) - (17) in the sub-assembly state into the same location as before
disassembly.
CAUTION
1) Line up the spool straight with the opening and insert it slowly.
2) After inserting the spool, slide it to check for any sticky or rough feeling.
3) If a spool is left inserted that feels sticky or rough, there is a danger of a spool operation defect.
3. Install the plate assemblies (28) and (29) and tighten the hexagon socket head bolts in the order (75), (94).
Be careful not to apply excessive tightening torque to (94).
Tightening torque:
(75) 39 - 44 N•m
(94) 8.8 - 10.8 N•m
4. Install the plate assemblies (10) and (11), and tighten with the hexagon socket head bolts (75).
5. Install the caps (8) and (9), and tighten with the hexagon socket head bolts (74).
6. Screw in the plug assembly (110) with O-ring mounted into the option section (H-H cross section) short cap and
tighten it.
7. Screw in the plugs (91) with O-rings (90) mounted into the option section (H-H cross section) and straight travel
section (I-I cross section) long caps and tighten them.
CAUTION
1) Be careful not to apply excessive torque when tightening a plug to a cap.
2) Applying excessive torque could crush the cap threads.
Assembly of straight travel signal control valve

1. Screw the orifice plug (42-7) (36 mm hexagon diameter) into the body (42-1) and tighten it.
Tightening torque: 3.0 - 3.8 N・m
2. Being careful about the insertion orientation, assemble the spools (42-2) and (42-3) and spring (42-4).
3. Tighten the plug assembly (42-5) (5 mm hexagon socket diameter) with O-ring mounted to the body.
4. Install the body assembly (42) with the hexagon socket head bolts (83) (5 mm hexagon socket diameter).
Assembly of add-on section

1. Screw the tie rod (96) into the main unit valve housing (1).
2. Install the main unit body matching surface O-rings (56) and (64).
Execute Steps [1] - [3] below as necessary.
84402832 NA - May 2011
8011-12
1) Remove the spool section assembly (111) and remove the matching surface O-rings (110-10) and (110-11).
2) Remove the inlet section assembly (99) and remove the matching surface O-rings (99-3) and (99-4).
3) Remove the spool section assembly (98) and remove the matching surface O-rings (98-10) and (98-11).
4) Install the outlet housing (95).
5) Tighten the 4 hexagon nuts (97) (22 mm hexagon diameter).
84402832 NA - May 2011

8011-13
Assembly of other plugs

1. Screw in and tighten the plug assembly (71) with O-ring mounted.
Tightening torque: 116 - 128 N・m
3. Screw in and tighten the orifice plug (40).
ightening torque: 14 - 18 N・m
84402832 NA - May 2011

8011-14
Internal structure diagram
84402832 NA - May 2011

8011-15
a [FOR HOOK BOLT] 2-M10 x 1.5 c

M10 x 1.5,THREAD DEPTH 12 e 4-M16 x 2 THREAD DEPTH 27
THREAD DEPTH 14
[FOR HOOK BOLT] 5-M10 x 1.5 RETIGHTEN AFTER NO.75
b d
THREAD DEPTH 17 LOCKED
*1 ARM 1 *3 SWING *5 TRAVEL

*2 BOOM 2 *4 OPTION
84402832 NA - May 2011

8011-16
84402832 NA - May 2011

8011-17
a RETIGHTEN AFTER NO.75 LOCKED

6.6 - 7.2 N・m
b M10 x 1.5 THREAD DEPTH 17
*1 ARM 2 *3 BUCKET *5 STRAIGHT TRAVEL

*2 BOOM 1 *4 TRAVEL
84402832 NA - May 2011

8011-18
84402832 NA - May 2011

8011-19
*1 PARALLEL LINE *5 CYLINDER PORT *9 BUCKET CLOSE Û OPEN

*2 TANK *6 ATTACHMENT 1 *10 TRAVEL
*3 DRAIN *7 ARM 2 IN Û OUT *11 STRAIGHT TRAVEL
*4 PILOT *8 BOOM 1 DOWN Û UP
84402832 NA - May 2011

8011-20
84402832 NA - May 2011

8011-21
*1 ARM 1 OUT Û IN *7 CYLINDER LINE *13 CYLINDER

*2 BOOM 2 UP Û DOWN *8 PILOT *14 STRAIGHT TRAVEL LINE
*3 SWING *9 (SUB VALVE) *15 COMMON CHECK LINE
*4 OPTION *10 (CAP) *16 PARALLEL
*5 TRAVEL *11 TANK
*6 DRAIN *12 BRIDGE LINE
84402832 NA - May 2011

8011-22
84402832 NA - May 2011

8011-23
*1 TANK *4 BOOM 1 *7 OPTION

*2 BOOM 2 *5 TRAVEL
*3 UP Û DOWN *6 STRAIGHT TRAVEL
84402832 NA - May 2011

8011-24
84402832 NA - May 2011

8011-25
*1 SWING *3 BUCKET *5 OUT Û IN

*2 OPEN Û CLOSE *4 ARM 1 *6 ARM 2
Part list
1 Valve housing 1 48 Spring 1
2 Spool assembly 1 49 Poppet 1
3 Spool assembly 1 51 Poppet 1
4 Spool assembly 1 52 Flange 2
5 Spool assembly 2 53 Spacer 2
6 Spool assembly 1 54 O-ring 2
7 O-ring 20 55 Backup ring 2
8 Cap 9 56 O-ring 1
9 Cap 1 57 Spacer 1
10 Plate assembly 1 58 Sleeve 1
11 Plate assembly 1 59 Poppet 1
13 Valve housing 1 60 Spring 1
14 Spool assembly 1 61 Flange 1
18 Cap 1 67 Antidrift valve assembly 2
19 Spool 1 68 Relief valve kit 1
20 Spring seat 2 69-1 Relief valve kit 5
21 Spring 1 69-2 Relief valve kit 1
22 Spool end 1 70 Relief valve assembly 2
23 O-ring 1 71 Plug assembly 3
24 Plug 1 72 Plug assembly 10
26 Spring 1 74 Socket head bolt 32
27 Spool assembly 1 75 Socket head bolt 66
28 Plate assembly 1 77 Socket head bolt 8
29 Plate assembly 1 78 Socket head bolt 4
30 O-ring 1 79 Name plate 1
31 Backup ring 2 80 Drive screw 2
32 Poppet 2 82 Metal plug 5
33 Spring 2 83 Socket head bolt 4
34 Poppet 7 84 Spool assembly 1
35 Spring 8 86 Cap 1
36 O-ring 10 88 Cap 2
37 Flange 6 89 O-ring 2
38 Poppet 2 90 O-ring 2
39 Spring 2 91 Plug 2
40 Orifice plug 1 92 Plug assembly 2
42 Body assembly 1 94 Socket head bolt 2
43 Flange 1 95 Outlet housing 1
44 Poppet 1 96 Tie rod 4
45 Spring 1 97 Nut 4
46 Plug 1 110 Plug assembly 1
47 O-ring 1
84402832 NA - May 2011

8011-26
Relief valve
Procedures for assembly and disassembly of main relief valve
1 Plug (32 mm hexagon diameter) 5 O-ring 9 1-1/16-12UN-2A

2 O-ring 6 Plug (27 mm hexagon diameter) 10 Piston
Hexagon nut
3 O-ring 7 11 PF1/4 JIS O-ring type
(30 mm hexagon diameter)
Hexagon nut
4 8 Plug (27 mm hexagon diameter)
(36 mm hexagon diameter)
1. Disassembly
This part is replaced as an assembly.
When replacing, loosen the plug (1) (32 mm diameter) with a wrench and remove the O-ring (2).
If oil leaks from the nut (4) (36 mm hexagon diameter), loosen the nut (4) (36 mm hexagon diameter) and the
plug (1) (32 mm hexagon diameter), and replace the O-ring (3).
If oil leaks from the nut (7) (30 mm hexagon diameter), loosen the nut (7) (30 mm hexagon diameter) and the
plug (8) (27 mm hexagon diameter), and replace the O-ring (5).
2. Assembly
Carefully check to make sure there is no debris, paint fragments around the thread sections of the plugs (1) (32
mm hexagon diameter), (6) (27 mm hexagon diameter), (8) (27 mm hexagon diameter) and nuts (4) (36 mm
hexagon diameter), (7) (30 mm hexagon diameter) and assemble the new O-rings.
Also clean the valve housing relief valve installation section well, install the relief valve, and tighten the plug (1)
(32 mm hexagon diameter).
When the plug has been disassembled, adjust the pressure according to the Main relief valve item in 5).
Procedures for assembly and disassembly of overload relief valve
Lock nut (17 mm hexagon diam-

1 Cap 5 Poppet 9
eter)
Adjuster (6 mm hexagon diame-
2 O-ring 6 Spring 10
ter)
84402832 NA - May 2011
8011-27
3 Adjuster kit section 7 1-1/16-12UN-2A

Cap (31.75 mm hexagon diame-
4 O-ring 8
ter)
1. Disassembly
When replacing, loosen the cap (1) (31.75 mm hexagon diameter) with a wrench and remove the O-ring (2).
Also, if oil leaks from the adjuster kit section, loosen the adjuster kit and replace the O-ring (4).
CAUTION
Be careful disassembling the adjuster kit.
The spring may make parts fly out and the poppet could be lost.
2. Assembly
Check carefully that there is no debris, paint fragments around the thread section of the cap and assemble a new
O-ring (2).
Also clean the valve housing relief valve installation section well, install the relief valve, and tighten the cap (1)
(31.75 mm hexagon diameter).
When the adjuster kit has been disassembled, clean around the thread sections well and adjust the pressure
according to the Overload relief valve item in 5).
Procedures for assembly and disassembly of low-pressure relief valve
1 Plug 5 O-ring 9 PF1/4

2 Poppet 6 Piston 10 PF3/4
3 Plug 7 Plug 11 1 3/16-12UN-2A
4 Spring 8 O-ring
1. Disassembly
Fasten the assembly with a vise, loosen the plug, and remove the piston (6), spring (4), and poppet (2).
Then loosen the plug and take out the O-rings (5) and (8) from each part.
2. Assembly
Check carefully that there is no debris, paint fragments around the thread section of the plug and assemble a
new O-ring.
Install new O-rings (5) and (8) on the plug and install the plug.
Assemble the poppet (2), spring (4), and piston (6) and screw in and tighten the plug.
Also clean the valve housing relief valve installation section well and tighten the relief assembly plug (1) (36 mm
hexagon diameter).
84402832 NA - May 2011

8011-28
Procedures for assembly and disassembly of add-on main relief valve
Lock nut (17 mm hexagon diam-

1 Plug (32 mm hexagon diameter) 5 Poppet 9
eter)
Adjuster (6 mm hexagon diame-
2 O-ring 6 Spring 10
ter)
3 Adjuster kit section 7 1-5/16-12UN-2A
4 O-ring 8 Plug (24 mm hexagon diameter)
1. Disassembly
When replacing, loosen the plug (1) (32 mm hexagon diameter) with a wrench and remove the O-ring (2).
Also, if oil leaks from the adjuster kit section, loosen the adjuster kit and replace the O-ring (4).
CAUTION
Be careful disassembling the adjuster kit.
The spring may make parts fly out and the poppet could be lost.
2. Assembly
Check carefully that there is no debris, paint fragments around the thread section of the plug and assemble a
new O-ring (2).
Also clean the valve housing relief installation section well, install the relief valve, and tighten the plug.
When the adjuster kit has been disassembled, clean around the thread sections well and adjust the pressure
according to the Add-on main relief valve item in 5).
Relief valve adjustment
CAUTION
This part is neither disassembled nor adjusted. (It is replaced as an assembly.)
Therefore, be aware that proper operation is not guaranteed if pressure is adjusted.
Installation
1. Be careful that the line does not apply excessive force to the valve.
2. Tighten all the bolts the same.
3. Be careful.
Welding close to a valve can damage its seal due to excess heat and sputter.
4. In order to keep out debris, do not remove the cap for a port until it is time to work on the line.
Operation
1. Check that the hydraulic circuits and hydraulic oil are clean, then gradually raise the pressure (inch the operating
machine in low idle) and check that no oil leaks to the outside.
2. For the oil, use hydraulic oil with an aniline point of 82 - 113°C.
3. Do not raise the relief valve above the specified set pressure.
4. Set a difference of at least 2.0 MPa between the set pressure for the main relief valve and for the overload relief
valve.
84402832 NA - May 2011
8011-29
5. Warm up the machine adequately before starting the actual work.

Pay attention to the following points in order to avoid sticking due to spool heat shock particularly when starting
up with the hydraulic oil temperature or valve temperature low.
• Do not operate the main relief valve and overload relief valve right too suddenly after each other.
Raise the temperature of each section uniformly and operate in such a way that the hydraulic oil circulates
within each actuator.
• Fine operations and compound operations generate heat locally due to throttling of individual sections, so do
not suddenly perform these operations with the machine still at low temperature.
Troubles and countermeasures
Control valves overall
Trouble content Conceivable cause Countermeasure

Eliminate the section that is providing re-
1.The oil temperature is abnormally high.
sistance to the oil flow in the line.
Replace the hydraulic oil and at the same
2.Dirty hydraulic oil
time, clean the circuits.
3.Line port joint tightened too much Check the torque.
4.The valve housing was warped during
Loosen the installation bolts and check.
installation.
Attach a pressure gauge to the pump and
The spool does not move 5.The pressure is too high. the cylinder port and check the pressure.
through its stroke.
6.The spool is bent. Replace the spool as an assembly.
7.Return spring damage Replace the damaged part.
8.The spring or cap is out of place. Loosen the cap, center it, then tighten it.
9.The temperature distribution within the
Warm up the circuits as a whole.
valve is not uniform.
10.Debris is clogging inside the valve. Remove (flush out) the debris.
Inspect for the pilot valve and pilot relief
11.Pilot pressure insufficient
pressure.
1.Oil leak from cylinder Check the cylinder seal section.
2.Oil from the spool is bypassing. Check for spool damage.
Clean the valve housing seat section and
3.Oil leak from overload relief valve
relief valve seat section.
Disassemble the antidrift valve and clean
the seat section for each part.
The load cannot be held. If a seat section is damaged, replace the
poppet or lap the poppet and seat sec-
4.Oil leak from antidrift valve tion.
If the antidrift valve spool is abnormal,
since the spool and the sleeve are mat-
ing parts, replace them both at the same
time.
1.There is debris jammed in the load
When the spool is switched check valve. Disassemble and clean the check valve.
from the neutral to the raise
2.The check valve poppet or seat section Replace the poppet or lap the poppet and
position, the load falls.
is damaged. seat section.
Relief valve

1.Either the main poppet, sleeve, or
pilot poppet is stuck open or there is
Pressure does not rise at all.
debris jammed in the valve seat sec-
tion.
1.The pilot poppet seat section is Replace the relief valve.
The relief pressure is unstable. damaged.
2.The piston or main poppet is stuck.
1.Seat section worn by debris
The relief pressure is wrong. Set the pressure again, then tighten
2.The lock nut and adjuster are loose.
the lock nut to the specified torque.
84402832 NA - May 2011
8011-30

1.Relief valve seat section damage
Replace the relief valve.
2.Each part is stuck due to debris.
Oil leak
Replace the adjuster or installation
3.An O-ring is worn.
section O-ring.
Hydraulic system overall

Check the pressure or replace the
1.Pump trouble
pump.
2.Relief valve trouble Replace the relief valve.
3.Cylinder trouble Repair or replace.
4.Pump load pressure is high. Check the circuit pressure.
The hydraulic system is not working
5.There is a crack in the valve. Replace the valve as an assembly.
properly or is not working at all.
6.The spool does not move through its
Check the spool movement.
full stroke.
7.The tank oil level is too low. Fill the hydraulic oil.
8.The filter in the circuit is clogged. Clean or replace the filter.
9.The circuit line is throttled. Check the line.
84402832 NA - May 2011

8011-31
84402832 NA - May 2011

8011-32
Section
8012
Procedures for Operation/Assembly and Disassembly of

Hydraulic Cylinder
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Specifications and structure diagram (including the assembly diagram and parts table) . . . . . . . . . . . . . . . . . . . . . . 3
Basic functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Function of Each Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cylinder Head Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pipe assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Precautions for Installing the Cylinder on the Machine Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Usage Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Maintenance and Inspection Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Maintenance Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Trouble Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Storage Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Storing Parts Individually (In principle, store indoors.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
When Mounted on Vehicle Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Recommended Anti-rust Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Assembly and Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
General Work Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Inspection after Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Required Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
General Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Wrench assembly (U1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Piston Ring Expander . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Bushing Tool Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Piston Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Disassembly of piston assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Disassembly of Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Assembly of Piston Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Assembly of Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Piston Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Structural Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Boom Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Arm Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Bucket Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Hydraulic Cylinder
Specifications and structure diagram (including the assembly diagram
and parts table)
In this manual, explanation is done using a product with a representative structure for a construction machine hydraulic
cylinder.
Basic functions
Hydraulic cylinders are a type of hydraulic actuator.
A hydraulic cylinder converts the energy of pressure supplied from the hydraulic pump into a large force of linear
motion. By operating the hydraulic pressure direction switchover valve, one can switch the direction of operation
between extension and retraction.
This linear motion with large force and the switchover of the operation direction are the basic functions.
Function of Each Location
This manual explains the functions of each section of the cylinder using a product with a typical structure.
There may be some slight differences with the product being used, but the functions are the same.
Cylinder Head Assembly
The cylinder head assembly has the function of bearing the piston rod (2) by the bushing (4) press fit into the inner
diameter of the cylinder head (3).
The seal system of the inner diameter of the cylinder head prevents oil from leaking to the outside and prevents foreign
matter from getting into the cylinder.
The cylinder head assembly also has the function of supplying and discharging high-pressure oil from inside the
cylinder tube to the retraction side port.
1 Cylinder tube 5 Snap ring 9 Snap ring

2 Piston rod 6 Buffer ring 10 Collar
3 Cylinder head 7 Rod packing
4 Bushing 8 Dust seal
• Bushing
The bushing is press fit to the inside surface of the cylinder head (3) and touches the piston rod (2).
Together with the slide rings (18) (19) on the outer circumference of the piston, the bushing divides the lateral load
applied to the cylinder and moves linearly relative to the piston rod.
Furthermore, it supports one end of the piston rod and has the function of minimizing eccentricity which has a
negative impact on the sealing.
• Buffer ring/Rod packing
The buffer ring (6), together with the rod packing (7), prevents cylinder oil leakage from the rod section to the outside.
• Dust seal
The dust seal (9) is positioned in the opening where the piston rod (2) comes out from and goes into the cylinder
and prevents dust and water from getting into the cylinder from the outside.
It also has the function of wiping off any mud sticking to the surface of the piston rod as the piston rod moves.
84402832 NA - May 2011

8012-3
Hydraulic Cylinder
Piston Assembly
The piston assembly has the function of transmitting the propulsion of the cylinder. A piston ring (14) is mounted on
the center of the piston (13) to prevent the flow of pressurized oil from either the left or right chamber to the other
chamber.
There are wear rings (15) mounted at each end of the piston ring. They have the function of a bearing to receive the
cylinder lateral load.
Cut off the oil on the extension side and retraction side and move the rod.
1. Piston ring (14)
Cut off the oil on the extension side and retraction side.
2. Wear ring (15)
Prevent metal contact of the cylinder tube and piston.
3. Ring (16)
Prevent damage to the piston ring due to diesel ignition or foreign matter.
4. Screw (19)
Retain the piston.
5. Plunger (11)
Narrow the flow path of the oil by plunging to the collar near the extension stroke end and establish the contain-
ment pressure. (To alleviate the shock on the extension stroke end)
6. Plunger (12)
Narrow the flow path of the oil by plunging to the bottom near the retraction stroke end and establish the contain-
ment pressure. (To alleviate the shock on the retraction stroke end)
7. Ball (18)
Holds in the plunger. Also support plunger eccentricity.
8. Cap (17)
Holds in the ball.
1 Cylinder tube 13 Piston 17 Cap

2 Piston rod 14 Piston ring 18 Ball
Cushion ring (plunger exten-
11 15 Wear ring 19 Screw
sion side)
Cushion seal (plunger retrac-
12 16 Ring
tion side)
84402832 NA - May 2011
8012-4
Hydraulic Cylinder
• Piston ring
The piston ring (14) is positioned at the center of the piston (13) and seals the ring-shaped gap between the piston
and the cylinder tube (1) and forms chambers with a high-pressure side and a low-pressure side with the piston as
the boundary.
• Wear ring
Wear rings are positioned at both ends of the piston ring (14) and contact the inside surface of the cylinder tube
(1). Together with the bushing (4) positioned on the inside surface of the cylinder head (3), the wear ring divides
the lateral load applied to the cylinder and moves linearly relative to the inside surface of the cylinder tube.
Furthermore, it supports one end of the piston rod (2) and has the functions of minimizing eccentricity, which has a
negative impact on the sealing, and buries and captures any impurities trapped between the cylinder tube and the
wear rings (15).
• Plunger
When the cylinder is fully extended, the cylinder head (3) and the plunger (11) fit together. When it is fully retracted,
the cylinder bottom and the plunger (12) fit together. In both cases, this forms a ring-shaped gap and squeezes the
oil to reduce the cylinder collision speed at full extension or full retraction and thus soften the impact.
Pipe assembly
The pipe assembly is mounted on the extension side and retraction side ports of the cylinder tube assembly. It has the
function of supplying and discharging high-pressure oil by connecting with the hydraulic circuits of the machine body.
20 Pipe assembly
21 Pipe assembly
84402832 NA - May 2011

8012-5
Hydraulic Cylinder
Handling Precautions
Precautions for Installing the Cylinder on the Machine Body
• When installing the cylinder on the machine body or removing it from the machine body, secure the piston rod at
the fully retracted position, check safety, and suspend.
CAUTION
Never suspend the cylinder from the line section. This would not only pose the danger of falling but
could also damage the cylinder.
Use a band to secure the piston rod in the fully retracted state.
If the piston rod is not in the fully retracted state, it could be easily damaged. This could create the
need for repair or make the piston rod unusable.
Also, not securing the piston rod is dangerous because the piston rod might fly out unexpectedly.
• Do not weld after the cylinder has been mounted on the machine body.
CAUTION
Electric welding on the cylinder or even at a position separated from the cylinder can generate a spark
within the cylinder and damage parts.
This could cause extensive damage, making it necessary to replace parts or replace the cylinder.
• When painting the machine body, mask the piston rod and wiper ring.
CAUTION
If the cylinder is operated with paint sticking to the piston rod surface and the wiper ring, the wiper
ring does not function adequately, greatly interfering with cylinder functions. For example, dirt and
paint from the outside may get into the cylinder easily and damage seal parts and cause an oil leak.
• Clean the cylinder before installing it.
84402832 NA - May 2011

8012-6
Hydraulic Cylinder
Usage Cautions
• Use under the determined conditions.
CAUTION
Use of hydraulic oil other than that specified can cause rapid deterioration of and damage to seal parts.
If the relief valve is set to a value higher than that on the assembly diagram, there is a danger of this
leading to cylinder damage.
General sealing materials cannot handle high ambient temperature (about 100℃ ℃ or higher) or low am-
bient temperature (-20℃ ℃ or lower), so the cylinder would be damaged if used at such temperatures.
Such temperatures require special seal materials, so check if the cylinder being used complies with
this requirement.
The number one cause of cylinder trouble is oil leaks due to piston rod scratches.
Operate very carefully to avoid scratching.
If the piston rod is scratched, handle this according to "Trouble Diagnostics".
• Warm up the equipment adequately before work.

CAUTION
After the cylinder has been stopped for a long time, the seal parts inside the cylinder are stuck to the
metal of sliding surfaces, so do not suddenly pressurize or operate such a cylinder.
A new cylinder or one that has been left unused for a long time has much air built up inside, so it does
not operate smoothly.
Also, if the cylinder is suddenly operated or pressurized without bleeding out the air, the adiabatic
compression of the air generates high temperatures, which may burn and carbonize seal parts, leading
to a drastically reduced functionality.
Before starting work, always warm up the cylinder by moving slowly through a few full strokes under
no load to bleed off any air in the cylinder.
• For stopping the machine temporarily or storing it, always have the machine in a safely secure posture.
CAUTION
When extended, the cylinder cannot hold a load for a long time in a fixed position.
This is because the cylinder is extended and retracted by very minor oil leaks from hydraulic circuits
and from inside the cylinder and changes in the volume of the hydraulic oil due to oil temperature
variation.
This results in the danger of machine moving unexpectedly, which can lead to serious accidents.
For stopping the machine temporarily or storing it, always have the machine in a safely secure posi-
tion.
84402832 NA - May 2011

8012-7
Hydraulic Cylinder
Maintenance and Inspection Cautions
• Always carry out daily maintenance inspections.
CAUTION
The most important point for realizing the cylinder functions for a longer time is "daily maintenance
inspections".
In order to ensure adequate functioning, execute "Maintenance Inspection and Service".
Constantly clean off any mud, water, dust, oil or grease stuck to the piston rod and keep the piston
rod in a clean state.
However, do not use water or the like to clean the wiper ring section and seal section. Wipe with a rag.
When leaving the machine unused for a week or longer, apply anti-rust oil to the surface of the piston
rod in order to prevent rusting.
• Use genuine parts for replacement parts.

CAUTION
If replacement parts are used that are not genuine parts, adequate functioning cannot be attained.
Always use genuine parts.
Specialty jigs have been produced so that assembly work and disassembly work can be done safely
and quickly, so order them.
• Be careful about assembly and disassembly too.

CAUTION
Disassembling a cylinder still installed on the machine body is extremely dangerous because it can
cause unexpected movement of the machine body.
Always remove the cylinder from the machine body before disassembling it.
Assembling with dirty hands can get dirt inside the cylinder and not only reduce the cylinder service
life but also damage other hydraulic equipment.
Assemble under clean conditions.
Use the thread part tightening torque indicated in the diagram.
If the torque is either too low or too high, this can cause thread damage.
• Strictly observe the cylinder storage standards.

CAUTION
Execute according to "Assembly and Disassembly Procedures".
84402832 NA - May 2011

8012-8
Hydraulic Cylinder
Maintenance Inspection and Service
In order to ensure that hydraulic cylinders function properly for a long time, periodically carry out maintenance in-
spection and service based on the "Autonomous inspection table". Repair any trouble locations quickly based on the
Trouble Diagnostics.
CAUTION
For periodic inspection and service, first work to prevent any hazard to operators. Strive to prevent
hazards by working with an attitude based on good sense.
Inspection and ser- Mont-

Inspection and service detail Daily Yearly Remarks
vice location hly
Is the cylinder clean (especially rod sliding ○
sections)?
Appearance Is any oil leaking from line installation sec- ○
tions or other fixed sections?
Is there missing or peeling paint or rust? ○
Is operation smooth and free of abnormal ○
noise and any other abnormality?
Is the responsiveness good? ○
Is any oil leaking from sliding sections? ○
Operation
Are there internal leaks? ○
Is the operating pressure normal? ○
Is the overload relief valve set pressure nor- ○
mal?
Is hydraulic oil dirty or deteriorated? ○
Hydraulic oil Is hydraulic oil replaced periodically? ○
Are filters inspected periodically? ○
Is the supply of grease to pins adequate? ○
Do pin sections have any abnormal noises ○
or seizing?
Section for installa- Do pin sections have any backlash or wear? ○
tion with main unit Are pin seals normal? ○
Are any installation screws loose or fallen ○
out?
Retighten installation screws. ○
Are sliding sections worn? ○ When leaving pis-
Are sliding sections scratched or dented? ○ ton rod sliding
Is sliding section plating peeling off? ○ sections exposed
Piston rod section
Are sliding sections bent? ○ for long periods,
Are there any welding section cracks or apply anti-rust oil
○ to the piston rod.
damage?
Are there any loose bolts or nuts (screws)? ○
Retighten installation screws (bolts and nuts ○
Cylinder tube section (screws)).
(including line sec-
tions) Are there any welding section cracks or ○
damage?
Are there large dents on the tube? ○
84402832 NA - May 2011

8012-9
Hydraulic Cylinder
Trouble Diagnostics
Hydraulic cylinder trouble, countermeasure and solution
It is not easy to discover trouble locations.
The table below shows general symptoms, suggested causes and also solutions.
For repairs, see the suggested causes and solutions in the table.
The cause of machine problems are often not rooted in just a single part. Problems are often due to the relationship
of one part with another.
In some cases, solutions are required other than those given in the table.
In such a case, contact with our company to investigate the problem and its cause further and take appropriate mea-
sures.
Item Symptom
Piston rod sliding section oil leak
1
(For the judgment values, see "Inspection after Assembly".)
2 Cylinder head matching section oil leak
3 Pipe and cylinder tube welding section oil leak
4 Operation defect
84402832 NA - May 2011

8012-10
Hydraulic Cylinder
Item Symptom Related part Cause Countermeasure and solution
1. Remove the scratches with a
whetstone to make the sliding
surface smooth (1.5 s max.).
If the oil leak continues, the rod
scratches may have damaged
A sliding surface has rust and the U-ring or other seal, so dis-
scratches that catch on a fin- assemble and inspect.
gernail. 2. If the scratches or rust cover too
large an area to be repaired with
Piston rod a whetstone, replace the piston
rod and the U-ring, wiper ring,
or other seal and the piston rod
bearing part.
1. Replate or replace the piston rod.
2. At this time, inspect the seals and
Plating is peeling off. piston rod bearing part as well
and replace any that are dam-
aged.
There is foreign matter caught 1. Remove the foreign matter.
in the inner or outer diameter 2. If the packing is damaged, re-
section. place it.
There are scratches on the in-
Replace.
ner or outer diameter section.
1. This may be scorching due to adi-
abatic compression of air remain-
ing in the cylinder.
Piston rod sliding The lips and groove section are 2. When operating the cylinder for
1
section oil leak locally carbonized (scorched). the first time after replacing a
packing, run at low pressure and
low speed to adequately bleed off
the air.
The packing has lost its rubber 1. Replace.
elasticity and is in tatters. 2. This may be the end of the pack-
ing service life, deterioration of
Rod packing the hydraulic oil, or high temper-
(Buffer ring and ature of the hydraulic oil.
U-ring) 1) Replace with a new hy-
The lip section is defective all draulic oil.
the way around. 2) Check the temperature of
the hydraulic oil.(The oil
temperature should be no
higher than 80℃.)
3) Check for local high tem-
perature.
1. Replace.
2. Abnormally high pressure may
be operating on the packing.
There is major extrusion of the 1) Check the pressure during
packing heel section. operation.
2) There may be trouble with
the buffer ring section.
Inspect the buffer ring sec-
tion.
84402832 NA - May 2011

8012-11
Hydraulic Cylinder
1. As a rule, replace the rod packing
too at the same time.
2. Abnormally high pressure is often
Backup ring The part is greatly deformed. the cause.
The check items for this are the
same as those given above for
packing heel section extrusion.
There is foreign matter caught
Remove the foreign matter.
in the lip.
Wiper ring The lip is damaged.
There is other abnormal dam- Replace.
age.
Piston rod sliding
1 There is major wear of the
section oil leak
bushing and the gap with the
piston rod exceeds the limit on Replace.
Bearing part inner diameter wear in "Usage
(bushing) Limits".
1. Replace.
There are large scratches on a
2. Inspect the piston rod sliding sur-
sliding surface.
faces for scratches and rust.
1. Remove the scratches or rust
with a whetstone.
A seal mounting section has
Cylinder head 2. If the repair does not solve the
scratches and rust.
problem, replace the cylinder
head.
1. Remove the foreign matter.
2. If the O-ring is damaged, replace
it.
3. Tube interior surface inspection:
If there are any scratches or rust,
use a whetstone to make the sur-
There is foreign matter caught face smooth.
O-ring in the inner or outer diameter. 4. Cylinder head O-ring groove in-
There is damage to the O-ring. spection: Same as above
5. Backup ring inspection: If the
backup ring is deformed or ex-
truded, replace it.
Check the above and replace the
O-ring.
The part is deformed or ex-
Backup ring Replace together with the O-ring.
truded.
1. Disassemble the cylinder head
Cylinder head and inspect the O-ring and
2 matching section backup ring.
oil leak If there is damage, replace.
2. Check the tube and cylinder head
Cylinder
A part is loose. threads for damage and if there is
head
any damage, replace.
3. When the inspection is complete,
tighten to the specified torque.
See "Assembly Procedures".
4. Stop rotation.
There is looseness, stretching Replace all the bolts and tighten to the
Bolt
or breakage. specified torque.
1. Replace with a new one.
2. Oil leaks at matching sections
may be caused by abnormally
high pressure (including cush-
Cylinder tube There is abnormal swelling.
ion pressure), so if the tube is
swollen or deformed, replace it
with a new one.
Also inspect the circuit pressure.
84402832 NA - May 2011

8012-12
Hydraulic Cylinder
CAUTION
Replace with a new one.
Pipe and cylinder
Pipe and cylinder There are cracks on the weld- The crack progresses and ultimately
tube welding sec-
tube ing section. the part fractures.
tion oil leak
A fracture is extremely dangerous, so
if a crack is seen, quickly stop work
3 and replace that part.
Welding over a crack is ineffective.
Tighten to the specified torque ac-
Line fastening bolt is loose.
cording to the work procedure.
Oil leak from cylin- The line is bent. Replace with a new one.
der line connec- Pipe assembly 1. Use a whetstone to make the sur-
tion section There are scratches on a con- face smooth.
tact surface. 2. If the oil leak does not stop, re-
place.
The bending is large and ex-
2. There may also be damage to
ceeds the stipulated bend
Piston rod seals and sliding parts, so inspect
warp.
Cylinder tube them.
(Bend warp: See "Mainte-
If there is any abnormality, re-
nance Standards".)
place.
Operation defect Replace with a new one.
Movement is not Cylinder tube There are dents. Inspect the seal and sliding parts the
smooth. same as above.
Abnormal wear of sliding parts
Inspect the seal and sliding parts
Piston rod and damage
the same as above.
Cylinder tube Foreign matter caught at the
2. Remove the foreign matter.
Sliding part piston section or the cylinder
Inspect the seal and sliding parts
head sliding section
the same as above.
Replace with a new one.
There are scratches, wear, or
Piston seal Also inspect the cylinder tube interior
other damage.
4 surfaces.
1. Use honing or a whetstone to
eliminate the scratches and rust
and make the surface smooth.
Internal oil leak There are scratches and rust
Cylinder tube If the scratches cover too large an
The piston rod ex- on interior surface.
area to be repaired, replace the
tends and retracts cylinder tube with a new one.
on its own and 2. Replace with a new piston seal.
drops abnormally
1. Tighten to the specified torque.
during operation.
See "Assembly Procedures".
Also, the stipu-
2. The piston rod thread section
lated speed is not
could be stretched.
output. Piston nut Tightening is insufficient.
Measure the diameter where the
rod and piston fit together and if
this area is tapered, replace the
piston rod assembly.
Inspect the amount of valve leakage
Valves Leak from valve.
and perform maintenance.
84402832 NA - May 2011

8012-13
Hydraulic Cylinder
Bleed out the air.
1. Cylinder with no air bleeding
Bleed out the air by moving the
cylinder back and forth at few
times at low pressure and low
speed.
2. Cylinder with air bleeding (air
breather)
After securing the machine so
Operation is un- There is air remaining in the that the cylinder does not move,
Air
steady. cylinder. bleed the air from the air breather.
HINT
The cylinder may extend or retract
somewhat when the cylinder stops
suddenly.
This phenomenon occurs due to the
4 compressibility of the hydraulic oil.
This occurs particularly easily for
cylinders with long strokes.
The impact is high
when switching The gap between the installa- Measure the pin and pin bushing di-
Pin bushing
over between ex- tion section and the pin bushing mensions and replace any part that
Pin
tension and re- is enlarged. exceeds its specified dimension.
traction.
The oil or grease feed is inade-
Cylinder sliding Apply oil or grease.
Pin bushing quate.
operations make
Pin There is seizing at matching Replace with a new part and apply oil
sounds.
section. or grease.
CAUTION
The hydraulic oil expands and contracts with changes in temperature and pressure.
This causes the cylinder to extend and retract too, so it can be mistaken for an internal oil leak.
For internal oil leaks, always check the temperature and pressure under the same conditions.
84402832 NA - May 2011

8012-14
Hydraulic Cylinder
Storage Standards
When a hydraulic cylinder is shipped from the plant, every measure is taken, but in order to prevent trouble during
storage and to extend the product service life, pay attention to the following items.
Storing Parts Individually (In principle, store indoors.)
• Store parts off the floor and do not store in any location with high temperature and humidity, corrosive gas or liquids.
• Before shipment, we operate the cylinder with hydraulic oil to which a fixed quantity of vaporizing anti-rust agent
has been added (in order to prevent rust within the cylinder), carry out the pre-shipping inspection, retract the pis-
ton rod with ultra-dry air (condensation point -35℃ or lower) (in order to prevent condensation due to temperature
difference), and then put caps on the ports and line joints before shipping the cylinder.
• Any product that has been in storage in our product warehouse longer than the standard storage period is disas-
sembled and inspected before being shipped.
Therefore, do not store or leave a cylinder unused with a cap removed or with the remaining oil in the cylinder
drained.
Storage for 6 month or longer

Storage for 1 month or longer Storage for 1 year or longer
(3 months for cylinder alone)
Clean any dust from the cylinder, Operate the cylinder back and forth
Since there is a danger of packings
and then apply anti-rust oil to the with clear hydraulic oil, and then pour
deterioration, disassemble, inspect,
1 pin bushings, flange sections, pis- anti-rust oil into the cylinder and store
and replace packings.
ton rod, and other sections that in compliance with the items on the
Also, check for rust inside the cylinder.
rust easily. left for storage of 1 month.
If a cylinder that has been stored for
If the cylinder cannot be operated, a long time is used as is, oil may leak
2 -
seal in anti-rust oil. due to temporary running-in defects of
seals.
3 When storing, be extremely careful not to let parts drop, let them collide with anything, or let anything strike them.
When Mounted on Vehicle Body

1. Operate the cylinder at least once per month.
2. Retract the cylinder so that as much as possible outside air does not touch the piston rod and apply anti-rust oil
at least once per month to the exposed part of the piston rod.
3. Handle carefully to absolutely avoid scratching the piston rod.
4. When putting the cylinder into an environment where rust occurs particularly easily, for example due to exposure
to sea breezes during export, always apply anti-rust oil to the piston rod and as much as possible protect with
polyethylene sheets or VCI paper (vaporizing anti-rust paper).
5. Anti-rust oil and other solvents can have negative impacts on seals, so select anti-rust oil carefully and as much
as possible keep it off dust seals etc.(For details on anti-rust oil to select, see "Recommended Anti-rust Oil".)
Recommended Anti-rust Oil

Vaporizing anti-rust oil
a. Ferro Gard #1009 (from USC Limited)
b. Knuckle Oil #105S (from Parker Industries, Inc.)
For inside cylinder For both a. and b., add 3 - 5 % of the hydraulic oil.
By volume,
Ferro Gard: 5/100
Knuckle Oil: 3/100
For piston rod Anti-rust P-1300 (from the Nippon Oil Corporation)
For machine worked sur-
faces other than parts with Select from JIS K 2246 (anti-rust oil) NP-1 through NP-6.
oil sealed in
84402832 NA - May 2011

8012-15
Hydraulic Cylinder
Assembly and Disassembly Procedures
Preparations
Prepare the Following before Starting Disassembly:
1. Work platform preparation
Prepare a sufficiently spacious, solid and stable work surface so that parts will not fall or move during work.
2. Tool and materials preparation
Prepare the tools and materials shown on the following pages.
General Work Precautions

1. Thoroughly clean any dirt or mud from the outside walls of the cylinder before starting disassembly.
2. Each part has been manufactured with a high degree of precision, so be careful not to let parts bump each other
or fall when handling them.
3. If parts are struck or pried off with excessive force during work because they are tight, this may cause burrs or
damage which causing reduction in performance or oil leaking.
Perform work carefully and thoroughly.
4. If a cylinder is left disassembled, humidity and dirt can cause rust on parts.
If a pause in the work is unavoidable, be careful to prevent rust and keep off dust.
Replace sliding parts and seal parts as follows.
1. Bushing
When 1/4 of the circumference is worn brown over the entire length.
2. Seals and slide rings
Replace with new parts when the cylinder is disassembled.
3. Pin bushing
When there is severe seizing.
4. Piston rod
When the piston rod is bent 0.5 mm/1 m or more.
84402832 NA - May 2011

8012-16
Hydraulic Cylinder
Inspection after Assembly
Dimension inspec-
Check the maximum retracted length and stroke as instructed on the diagram.
tion
Pressure with- Check for looseness, permanent deformation, and external leaks when the test pressure in-
stand inspection structed on the diagram is applied to each stroke end for at least 3 min.
Check the amount of oil leak at the rod section.
• Judgment value for rod section oil leak amount
Move the piston rod back and forth 20 times with the oil at a temperature from 20℃ to 40℃,
then judge by the state of the oil ring formed on the rod surface. If the oil ring is in a broken
down A state, this is judged to be trouble. See "Trouble Diagnostics" for information on how
to solve this.
External leak in-

spection
Oil leak amount unit: ml/10 min.

Inner diameter Oil leak Inner diameter Oil leak Inner diameter Oil leak
mm amount mm amount mm amount
Internal leak in- 32 0.4 100 4.0 160 10.0
spection 40 0.6 125 5.6 180 12.6
50 1.0 140 6.0 200 15.6
63 1.6 220 20.0
80 2.3 250 22.0
1 Oil ring
a Acceptable
b Not acceptable
84402832 NA - May 2011

8012-17
Hydraulic Cylinder
Required Tool
General Tool
No. Tool name Q'ty
Screwdriver (flathead screw-

1 1
driver)
2 Hexagon wrench 1 set
3 Vise 1
4 Wrench (for piston nuts) 1 set
5 Punch 1
6 Torque wrench 1 set
84402832 NA - May 2011

8012-18
Hydraulic Cylinder
No. Tool name Q'ty
7 Hammer (plastic hammer) 1
8 Monkey wrench 1
9 Scoop 1 set
84402832 NA - May 2011

8012-19
Hydraulic Cylinder
Wrench assembly (U1)
Part number: KRV10620
Application: Use for removal and installation of screw-type piston.
Component parts
No. Part name Q'ty Remarks
1 Arm 1 Each drive 3/4"
2 Arm 1
3 Center pin 1
4 Pin 2 Diameter 1/4", 5/16"
5 Set screw 2
Adjustment
2" (50.8 mm) - 6" (152.4 mm)
Usage example
84402832 NA - May 2011

8012-20
Hydraulic Cylinder
a Piston
b Wrench
c Torque wrench
Piston Ring Expander
Component parts
Tools Part name Part No. Q'ty Remarks
U2 Expander KRV10570 1
KRV10600 1 Piston outer diameter D120 - D135
U3 Clamp
U4 Ring (rubber band)
Characteristics
A teflon ring is used on the piston of the hydraulic cylinder, but this cannot be installed as is.
By simply rotating the handle, the ring expander can be used to expand the ring smoothly and easily for mounting on
the piston without creating any damage.
With the use of a compression ring, the teflon ring to be installed on the piston can be mounted exactly at the specified
position.
Bushing Tool Kit
Part number: KRV10630
Application: Each bushing tool can be installed to the grip by bolts and be used as striking tool when press fitting the
wrapping bearing on the attachment cylinder.
84402832 NA - May 2011

8012-21
Hydraulic Cylinder
Disassembly Procedures
Piston Rod Assembly
1. Remove the line from the cylinder assembly.
2. Remove the installation bolts and separate the head
assembly (1).
3. Remove the piston rod assembly (2).
• Place a drip pan or other object under the cylinder
to receive the oil.
4. Disassemble the piston rod assembly with the pro-

cedure below.
1) Set the piston rod assembly (2) on the stand
(*1).
3) Use tool U1 to remove the piston assembly
(4).
• When not using tool U1, use the 2 notch
holes (D10) (*3) to loosen the piston assem-
bly.
2) Remove the piston assembly rotation stopper

screw (3).
• If the screw (3) caulking is so strong the
screw cannot be removed, screw the screw
all the way in and then insert the tap (*2) in
the threaded section and try to remove the 4) Remove the plunger (5).
screw.
• Boom cylinder
• Arm cylinder
• Bucket cylinder
5) Remove the collar (6).
• Boom cylinder
• Arm cylinder
• Bucket cylinder
84402832 NA - May 2011

8012-22
Hydraulic Cylinder
6) Remove the head assembly (7). Disassembly of piston assembly
1. Remove the rings (11).
2. Remove the wear rings (12).
3. Remove the piston ring (13).
4. Remove the O-ring and backup ring (14).
7) Remove the cap (8), remove the 12 balls (9),

and then remove the cushion plunger (10).
• Arm cylinder
84402832 NA - May 2011

8012-23
Hydraulic Cylinder
Disassembly of Cylinder Head Assembly 3. Remove the rod packing (18).
4. Remove the buffer ring (19).
1. Remove the O-ring and backup ring (15).
5. Remove the snap ring (21).
2. Remove the snap ring (16), and then remove the
6. Remove the bushing (20).
dust seal (17).
84402832 NA - May 2011

8012-24
Hydraulic Cylinder
Assembly Procedures Assembly of Piston Assembly
• Be careful not to scratch the packing, dust seal, or 1. Use tool U2 to widen the piston ring (13).
O-ring.
• Set the piston ring on tool U2 and widen the piston
• Insert the backup ring after heating with hot water at ring by rotating the handle 8 - 10 times.
about 50°C - 60°C without forcing it in.
2. Set tool U3 and retract the piston ring (13).
Assembly of Piston Rod Assembly
1. Use a tool to press fit the bushing (20) and install
the snap ring (21).
2. Install the buffer ring (19).
3. Install the rod packing (18).
4. Use a tool to install the dust seal (17) and secure
with the snap ring (16).
3. Install the backup ring and O-ring (14).

4. Install the wear rings (12).
5. Install the rings (11).
• Be careful not to widen the ring abutment section
too much.
Ring groove: grease (G2-L1)
5. Install the backup ring and O-ring (15).
84402832 NA - May 2011

8012-25
Hydraulic Cylinder
Piston Rod Assembly
1. Set the piston rod assembly (2) on the stand (*1).
1) Screw in the piston assembly (4) and use tool

U1 to tighten the piston assembly (4) until it
2. Install the head assembly (7). matches the position of the screw threaded
3. Attach the O-ring and backup ring to the collar (6) hole.
and install it. • Use a file to remove burrs and barbs on the
• Boom cylinder thread section.
• Arm cylinder 2) Tighten the screw (3).
• Bucket cylinder
Tightening torque: 58.85 - 73.55 N·m
4. Install the plunger (5).
• Boom cylinder
• Arm cylinder
• Bucket cylinder
• Check that the top of the plunger has slight back-
lash.
a 2-D10 notch hole
3) Use a punch (*3) to caulk the threaded section

at 4 locations.
5. Set the cushion plunger (10) on the piston rod, in- • When using new parts for the rod and/or
stall the 12 balls (9), and then secure with the cap piston assembly (4)
(8). Mark the cushion plug position on the end
surface of the rod with bottom cushion.
• Arm cylinder only • Arm cylinder only
6. Assemble the piston assembly (4) with the proce-
dure below.
• When reusing the rod and piston assembly (4)
Thoroughly clean and remove all shavings and
debris.
84402832 NA - May 2011

8012-26
Hydraulic Cylinder
4) Screw in the piston assembly (4) until it 6) After creating holes, thoroughly clean and re-
touches the end surface of the rod (*4), and move all shavings and debris.
use tool U1 to tighten the piston assembly. 7) Tighten the screw (3).
• After tightening the piston, check that the 8) Use a punch to caulk the threaded section at
plunger (5) has backlash.
4 locations.
• Boom cylinder
• Arm cylinder
• Bucket cylinder
7. Install the piston rod assembly (2).

Ring groove: grease (G2-L1)
• Set the ring abutment section (*5) at a horizontal
5) Create a threaded hole for mounting the screw position and insert the ring abutment section while
(3). aligning the cylinder tube and shaft.
• After inserting, check that the ring is not damaged
• Align the drill of the V groove on the or fallen out, and push it all the way in.
threaded section of the rod (2) with the
piston (4) and create a threaded hole hori-
zontally.
• Create a threaded hole on the cylinder with
bottom cushion (arm cylinder) while avoid-
ing the position of the cushion plug.
Threaded hole dimensions (mm)

Drill di-
ame- Bottom
Cylinder Used Depth
ter of hole
name tap of tap
bottom depth
hole
Book and
10.3 24 12×1.75 20
bucket
Arm 10.3 36 12×1.75 29 8. Tighten the head assembly (1) with installation
bolts.
Installation bolt tightening torque

Cylinder
Tightening torque
name
Boom 451.2 - 608.2 N·m
Arm 755 - 1029 N·m
Bucket 451.2 - 608.2 N·m
84402832 NA - May 2011

8012-27
Hydraulic Cylinder
9. Install the line.
84402832 NA - May 2011

8012-28
Hydraulic Cylinder
Structural Diagram
Boom Cylinder
* This diagram shows the parts for the left side.The parts for the right side are symmetrical.
Sumitomo Part No. + manufac-

*1
turing number stamping range
Sumitomo Part No. + manu-
facturing number stamping po-
sition (For the range on the cir-
*2 cumference, see the side dia-
gram.)
Sumitomo Part No. (KRV1925
right, KRV1926 left)
*3 Dimensions after press fitting
L1 Stroke 1495 mm
Maximum retracted length
L2
2090 mm
Code Part name Q'ty Code Part name Q'ty Code Part name Q'ty
01 Cylinder tube 1 16 Backup ring 2 31 Clip 2
02 Rod 1 17 O-ring 1 32 Nut 4
03 Cylinder head 1 18 Ring 2 33 Washer 4
04 Snap ring 1 19 Piston ring 1 34 Bolt 12
05 Dust seal 1 20 Wear ring 2 35 Washer 12
06 Rod packing 1 21 Screw 1 36 Bolt 4
07 Buffer ring 1 22 Snap ring 1 37 Washer 4
08 Backup ring 1 23 Line 1 38 Grease nipple 1
09 O-ring 1 24 Line 1 39 O-ring 2
10 Bushing 1 26 Band 1 40 Bushing 1
84402832 NA - May 2011
8012-29
Hydraulic Cylinder
11 Collar 1 25 Bracket 1 41 Dust seal 2
12 Backup ring 2 27 Bolt 4 42 Bushing 1
13 O-ring 1 28 Washer 4 43 Dust seal 2
14 Plunger 1 29 Bolt 4
15 Piston 1 30 Washer 4
84402832 NA - May 2011

8012-30
Hydraulic Cylinder
Arm Cylinder

*1
*2 sition (For the range on the cir-
cumference, see the side dia-
gram.)
L1 Stroke 1748 mm
L2
2445 mm
84402832 NA - May 2011

8012-31
Hydraulic Cylinder
01 Cylinder tube 1 21 Screw 1 41 Bracket 1
02 Rod 1 22 Plug 1 42 Band 1
03 Cylinder head 1 23 O-ring 1 43 Bolt 4
04 Snap ring 1 24 Spring 1 44 Washer 4
05 Dust seal 1 25 Valve 1 45 Clip 2
06 Rod packing 1 26 Plunger 1 46 Nut 4
07 Buffer ring 1 27 Ball 12 47 Washer 4
08 O-ring 1 28 Cap 1 48 Bolt 2
09 Backup ring 1 29 O-ring 1 49 Washer 2
10 Bushing 1 30 Grease nipple 1 50 Clamp 1
11 Collar 1 31 Snap ring 1 51 Band 1
12 O-ring 1 32 Bolt 12 52 Bracket 1
13 Backup ring 2 33 Washer 12 53 Bolt 2
14 Plunger 1 34 Line 1 54 Washer 2
15 Piston 1 35 O-ring 1 55 Bushing 1
16 O-ring 1 36 Bolt 4 56 Dust seal 2
17 Backup ring 2 37 Washer 4 57 Bushing 1
18 Ring 2 38 Line 1 58 Dust seal 2
19 Piston ring 1 39 Bolt 4
20 Wear ring 2 40 Washer 4
84402832 NA - May 2011

8012-32
Hydraulic Cylinder
Bucket Cylinder

*1
*2 sition (For the range on the cir-
cumference, see the side dia-
gram.)
*4 (Bottom center)
L1 Stroke 1210 mm
L2
1870 mm
84402832 NA - May 2011
8012-33
Hydraulic Cylinder
01 Cylinder tube 1 16 Backup ring 2 31 O-ring 2
02 Rod 1 17 O-ring 1 32 Bolt 12
03 Cylinder head 1 18 Ring 2 33 Washer 12
04 Snap ring 1 19 Piston ring 1 34 Bolt 4
05 Dust seal 1 20 Wear ring 2 35 Washer 4
06 Rod packing 1 21 Screw 1 36 Grease nipple 2
07 Buffer ring 1 22 Snap ring 1 37 Bushing 1
08 Backup ring 1 23 Line 1 38 Dust seal 2
09 O-ring 1 24 Line 1 39 Bushing 1
10 Bushing 1 25 Clamp 2 40 Dust seal 2
11 Collar 1 26 Bracket 2 41 Bolt 4
12 Backup ring 2 27 Bolt 4 42 Washer 4
13 O-ring 1 28 Washer 4 43 Band 2
14 Plunger 1 29 Bolt 4
15 Piston 1 30 Washer 4
84402832 NA - May 2011

8012-34
Section
8013
Procedures for Assembly and Disassembly of Operation

Remote Control Valve
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Procedures for Assembly and Disassembly of Operation Remote Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Required Tools and Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Causes of Trouble and Countermeasures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Procedures for Assembly and Disassembly of Operation Remote
Control Valve
Procedures for Assembly and Disassembly of Operation Remote Control
Valve
Job code 35355AA18
CAUTION
• To ensure safe operations, wear protective devices before beginning work and follow all precautions.
• Be sure to repair any parts damaged during disassembly, and prepare replacement parts in advance.
• If any parts are significantly rusted or dirty, clean them before disassembling.
• Any foreign matter entering the equipment during assembly can create a malfunction. Therefore, after
thoroughly cleaning the equipment with cleaning oil, air blow the equipment, and assemble in a clean
location.
• When assembling sliding parts, be sure to coat them with new hydraulic oil.
• As a rule, replace all O-rings and other seal parts with new parts.
General cautions
• Be careful not to drop precision parts or let bump them with other parts during work.
• Do not forcefully open or hit parts in an effort to speed up operations.
Pay careful attention and proceed slowly so as not to damage any parts, create any oil leaks, or com-
promise the efficiency of the equipment, etc.
• Disassembled parts can easily rust or collect dust. Therefore, immediately after disassembling parts,
take precautions to prevent the parts from rusting or collecting dust.
Items to prepare
Maintenance Procedures
Required Tools and Tightening Torque
Tightening
Dimension
Tools Part No. Part name Screw size torque
(mm)
(N·m)
Adjusting
22 312 M14 63.7 - 73.5
Wrench nut
32 302 Disk M14
Special jig 24 301 Joint M14 44.2 - 50.0
Other
• Vapor corrosion inhibitor
• White kerosene
• Heat-resistant grease
• Sandpaper (#1000, #2000)
• Whetstone
• Vise
• Screwdriver
• Torque wrench
84402832 NA - May 2011

8013-3
Control Valve
Maintenance in-
Standard Remarks
spection item
When handle is in neutral 1000 cc/min or more
Conditions
During operation 2000 cc/min or more
Leak amount Primary pressure 2.94 MPa
If either condition occurs, replace the remote
Oil viscosity 23 mm2/S
control valve as one unit.
When wear on the sliding sections exceeds
The same approximate conditions as those
wear on the non-sliding sections by 10 μm or
Spool listed above for leak amount are expected when
more, replace the remote control valve as one
the condition on the left occurs.
unit.
If the end section is worn by 1 mm or more, perform replacement.
Push rod
Replace the operation section disk (302) and

Operation section Make adjustments if the backlash is due to
joint section (301) if there is backlash of 2 mm
backlash looseness in the tightening sections.
or more due to wear.
If abnormal noise, hunting, or a drop in primary
pressure occurs and the problem cannot be re-
Operation stability solved with "Causes of Trouble and Counter-
measures", replace the remote control valve as
a unit.
NOTE:
It is desirable for seal materials such as O-rings to be replaced with each disassembly, but it is acceptable to reuse
these after it is confirmed that they are not damaged.
84402832 NA - May 2011

8013-4
Control Valve
Disassembly Procedures 4. If the return springs are strong, the plate (2), plugs,
and push rods (3) will rise at the same time the joint
1. Use copper plate (or lead plate) to secure the re- (1) is loosened, so be careful of parts flying off when
mote control valve in a vise, then remove the bel- removing the joint.
lows (1).
• Be careful not to tear the bellows.
5. Remove the plate (1).
2. Use a wrench on the bolt width of the adjusting nut

(1) and disk (2) to loosen them, then remove the
adjusting nut and disk.
6. If the return springs are weak, the plugs (1) will re-
main in the casing due to the sliding resistance of
the O-rings, so use a flathead screwdriver to re-
move it.
3. Use a jig (1) to remove the joint. • Use the groove in the outer circumference of the
plugs and remove them while making sure they
are not damaged by an unbalanced load.
• Use caution as plugs may fly off when they are
being removed due to the return springs.
84402832 NA - May 2011

8013-5
Control Valve
7. Remove the push rods (1), plugs (2), pressure re- 10. Remove push rods (2) from the plugs (1).
ducing valve assembly, and the return springs (3)
from the casing.
• Record the relation of parts to the casing hole po-
sitions through marking, etc.
11. Remove the O-rings (2) from the plugs (1).

8. For disassembly of pressure reducing valve, press

in the spring seating (1), move the spring seating
to the side while bending the secondary pressure
spring (2), and remove the spring from the spools
(3) by passing through the larger hole.
• Do not press in the spring seating by 6 mm or
more.
12. Remove the seal (1).

Use a small flathead screwdriver, etc. to remove
seals.
• The seal cannot be reused.
9. Separate the spool (1), spring seating (2), sec-

ondary pressure spring (3), and washer (4).
• Be careful not to scratch the surface of the spools.
• Handle as an assembly until assembly is per-
formed.
13. Cleaning parts

Clean all parts by placing them in a rough cleaning
container filled with white kerosene. (rough clean-
ing)
Clean each part by placing it in a finish cleaning
container filled with white kerosene, and thoroughly
clean each part, including the interior, while slowly
rotating the part. (finish cleaning)
Use a clean rag to thoroughly remove any white
kerosene stuck to parts.
84402832 NA - May 2011

8013-6
Control Valve
• Scratching can easily occur if cleaning of a part Assembly Procedures
is begun just after parts are immersed in white
kerosene, so let each part sit in white kerosene 1. Insert washer (4), secondary pressure spring (3)
until debris and grease sufficiently loosen from the and spring seating (2) onto each of the spool (1) in
surface of the part and float to the surface. that order.
• If the white kerosene is dirty, this will encourage
damage to parts and result in reduced perfor-
mance after reassembly. Thoroughly manage the
level of cleanliness of the white kerosene.
• Do not dry parts with compressed air, as this will
damage parts and cause rust to form due to de-
bris and moisture being dispersed into the atmos-
phere.
Preventing rust on parts
Apply an anti-rust agent to each part.
• Rust will form on parts if they are left as is af-
ter cleaning, and this will cause reduced perfor-
mance of functions after reassembly.
2. Press in the spring seating (1) and move it to the
side while bending the secondary pressure spring
(2) to pass the seating over the larger hole and in-
stall it on each of the spools.
• Do not press in the spring seating by 6 mm or
more.
3. Install the return springs (1) in the casing (2).

Install the pressure reducing valve assembly (3) in
the casing (2).
• Install them in the positions they were in before
disassembly.
84402832 NA - May 2011

8013-7
Control Valve
4. Install O-rings (2) on the plugs (1). 6. Install push rods (1) into the plugs (2).
• Apply hydraulic oil to surface of the push rod.
5. Install seal (1) on the plug (2).

• Install so that the seal lips are as shown in the 7. Install the plug assembly (1) in the casing (2).
diagram below. If the return spring is weak, it will be stopped by the
sliding resistance of the O-ring.
• Be careful not to scratch the casing hole by forcing
in the spool.
3 Push rod
8. If the return spring is strong, use the plate (1) to
install all 4 plug assemblies at the same time and
a Hydraulic oil application temporarily tighten them with the joint (2).
• Be careful of the plug assemblies and plate flying
off.
84402832 NA - May 2011

8013-8
Control Valve
9. Install the plate (1). • Tightening torque: 63.7 - 73.5 N·m
• During tightening, do not move the disk position.
10. Use a jig, and tighten the joint (1) to the casing (2)
to the specified torque. 13. Apply grease to the rotating section of the joint and
Tightening torque: 44.2 - 50.0 N·m to the top of the push rods (1).
11. Install the disk (1) onto the joint (2). 14. Install the bellows (1).
• Screw the disk in until it is equally touching each • Be careful not to tear the bellows.
of the 4 push rods (3). • Inject vapor corrosion inhibitor into each port, and
Secondary pressure will cause faulty operation of then place plugs in the ports.
the machine if the disk is screwed in too much,
so pay attention to adjustment of the tightening
position.
12. Install the adjusting nut, use a wrench on the bolt

width of the disk (1) to secure it, and tighten the
adjusting nut to the specified torque.
84402832 NA - May 2011

8013-9
Control Valve
Causes of Trouble and Countermeasures
A few problems that may sometimes occur are listed in the table below.
Repairs are difficult, so refer to the possible causes and solutions in the table.
The table below shows general symptoms, suggested causes, and also solutions.
However, the cause of machine problems are often not rooted in just a single part. Problems are often due to the
relationship of one part with another.
Also keep in mind that solutions other than those listed in the table may sometimes be necessary.
The numbers in parentheses after the part names are the codes indicated in "Attached diagram 1 Remote control
valve assembly cross-section diagram".
The table below does not include all possible causes and countermeasures.
Further investigation of problems and causes should be done by an experienced and qualified repair person, as nec-
essary.
Symptom Cause Solution

1. Insufficient primary pressure 1. Maintain primary pressure.
2. Secondary pressure spring (241) is bro- 2. Replace it with new part.
Secondary pressure is ken or worn. 3. Replace the remote control valve as one
not rising. 3. The gap between spool (201) and the unit.
casing (101) is abnormally large. 4. Assemble and disassemble and/or re-
4. There is backlash in the handle section. place the handle section.
1. Repair the sticking sections.
1. Sliding parts are sticking.
Secondary pressure is 2. Return directly to the oil tank.
2. Tank line pressure is variable.
unstable. 3. Perform operation several times and let
3. Air is getting into lines.
out air.
Secondary pressure is 1. Tank line pressure is high. 1. Return directly to the oil tank.
high. 2. Sliding parts are sticking. 2. Repair the sticking sections.
84402832 NA - May 2011

8013-10
Control Valve
Attached diagram 1. Remote control valve assembly cross-section diagram
a c Grease application to rotating sliding sections. Be

Grease application to top
careful with the installation direction.
Secondary pressure adjustment shim
b Design central value d Hydraulic symbol
t = 0.4 1 shim

101 Casing 1 217 Washer 4
151 Plate 1 221-1 Return spring (port 1) 1
201 Spool 4 221-2 Return spring (port 3) 1
211 Plug 4 221-3 Return spring (ports 2, 4) 2
212-1 Push rod (ports 1, 3) 2 241-1 Secondary pressure spring (ports 1, 3) 2
212-2 Push rod (ports 2, 4) 2 241-2 Secondary pressure spring (ports 2, 4) 2
213 Seal 4 301 Joint 1
214 O-ring 4 302 Disk 1
84402832 NA - May 2011
8013-11
Control Valve
216-1 Spring seating (ports 1, 3) 2 312 Adjusting nut 1
216-2 Spring seating (ports 2, 4) 2 501 Bellows 1
Tightening torque
Tightening
Code Screw size
torque
301 M14 44.2 - 50.0 N·m
302
M14 63.7 - 73.5 N·m
312
Detailed diagram of jig main unit (1) and (2) are inserted by tightening. Attached diagram 2. Jig main unit
*1 (1) Material: SCM415 (N) carburized *3 (Bolt width)

Hole H6 + 0.13
*2 (2) Material: S45C *4
Shaft n6 + 0.028
84402832 NA - May 2011
8013-12
Control Valve
Detailed diagram of bushing

Joint installation state Material: SCM415 (N) carburized
Quantity: 2
Attached diagram 3. Joint disassembly jig
c Bushing
84402832 NA - May 2011

8013-13
Control Valve
84402832 NA - May 2011

8013-14
Section
8014
Procedures for Assembly and Disassembly of Travel

Remote Control Valve
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Procedures for Assembly and Disassembly of Travel Remote Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Causes of Trouble and Countermeasures and Cross-section Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Procedures for Assembly and Disassembly of Travel Remote
Control Valve
Procedures for Assembly and Disassembly of Travel Remote Control
Valve
Job code 35356AK20
CAUTION
• To ensure safe operations, wear protective devices before beginning work and follow all precautions.
• When removing devices or positioning devices at the time of installation, use a removal jig and a ham-
mer or steel rod.
• Follow the precautions below when suspending the load.
• The liftcrane must be operated by a qualified operator.
• Do not stand or pass under the suspended load.
• Check the weight of the load to determine whether it can be carried by hand or whether a liftcrane
must be used.
• Be sure to repair any parts damaged during disassembly, and prepare replacement parts in advance.
• If any parts are significantly rusted or dirty, clean them before disassembling.
• Any foreign matter entering the equipment during assembly can create a malfunction.
Therefore, after thoroughly cleaning the equipment with cleaning oil, air blow the equipment, and as-
semble in a clean location.
• When assembling sliding parts, be sure to coat them with new hydraulic oil.
• As a rule, replace all O-rings and other seal parts with new parts.
General cautions
• Be careful not to drop precision parts or let bump them with other parts during work.
• Do not forcefully open or hit parts in an effort to speed up operations.
Pay careful attention and proceed slowly so as not to damage any parts, create any oil leaks, or
compromise the efficiency of the equipment, etc.
• Disassembled parts can easily rust or collect dust.
Therefore, immediately after disassembling parts, take precautions to prevent the parts from rusting
or collecting dust.
Items to prepare
• Wrench
• Screwdriver
• Specialty jigs
• Vise
• Loctite 262
• White kerosene
84402832 NA - May 2011

8014-3
Control Valve
Maintenance Procedures
Disassembly Procedures 4. Remove the cams (1) as an assembly with the lock-
ing screws and lock nuts left attached.
1. Use a shock plate to secure the remote control valve Record the positions of the cams in relation to the
in a vise, then remove the bellows (1) from the cover covers (2).
(2).
• Be careful when removing, as the push rods (3)
• Be careful not to tear the bellows. may fly off.
2. Use a hexagon wrench (1) on the hexagon socket 5. Use a hexagon wrench (1) on the hexagon socket
head locking screws to loosen them. head bolts to loosen and remove them.
Be careful, as application of Loctite #241 makes the
loosening torque high.
6. Remove the cover (1).
3. Place a round rod (D8 mm or less) against one end • Record the positions of the covers in relation to
of the cam shafts (1) and lightly strike it with a ham- the casings (4).
mer to remove the shafts. Be careful when removing, as the push rods (2) or
plugs (3) may fly off due to the damping springs.
(The plugs are only kept in the casing by the slid-
ing resistance of the O-rings.)
84402832 NA - May 2011

8014-4
Control Valve
7. Remove push rods (2) from the plugs (1). 10. Remove the damping springs (2) (3) from the casing
Record the positions of the plugs in relation to the (1).
push rods. Record the positions of the damping springs in re-
Be careful not to scratch the surface of the push lation to the casing holes.
rods.
Be careful when removing, as the plugs may fly off.
11. Remove the spring seating (2) from the casings (1).
8. Remove the plugs (1) with the grease caps and • Record the positions of the spring seating in rela-
NHU packings left attached. tion to the casing holes.
Record the positions of the plugs in relation to the
casing holes.
Be careful when removing parts, as the pistons (3)
may fly off due to the damping springs (2).
12. Use a magnet, etc. to remove steel balls (1).

Be careful not to lose the steel balls.
9. Remove the pistons (1).

Record the positions of the pistons in relation to the
casing holes.
84402832 NA - May 2011

8014-5
Control Valve
13. Use the hexagon wrench to remove the hexagon 16. Remove the return spring (1) from the casing (2).
socket head bolts (1).
17. Lay the covers (1) on their sides on a level surface,

14. Remove the damper casing (1) and remove the place special tool 1 against the bushings, and re-
O-rings (4) (3) from the casing. move the bushings by lightly striking them with a
hammer.
• Record the positions of the damper casing in re-
lation to the casing (2).
• Be careful when removing parts, as the pressure
reducing valve assembly may fly off due to the
return springs.
18. Secure each cam assembly (1) in a vise, use a

wrench to loosen the lock nuts (2), and remove the
lock nuts and locking screws (3).
• As neutral adjustment of locking screws is neces-
15. Remove the pressure reducing valve assembly (1) sary during assembly, handle them as part of the
cam assembly as long as replacement of locking
from the casing (2).
screws is not necessary.
• Record the positions of these parts in relation to
the casing holes.
84402832 NA - May 2011

8014-6
Control Valve
19. For disassembly of the pressure reducing valve as- 22. Remove the NHU packings (2) from the plugs (1).
semblies, place the bottom end of the spools (1) Use a small flathead screwdriver, etc. to remove.
perpendicular on a level work platform, lower the
spring seating (2), and use the end of a small flat- • Be careful not to scratch the inner surface of the
plugs.
head screwdriver to remove the 2 half-circle wash-
ers 1 (3).
Be careful not to scratch the surface of the spool.
Do not press in the spring seating by 4 mm or more.
23. Remove the O-rings (2) from the plugs (1).
20. Separate the spools (1), spring seating (2), sec-

ondary pressure springs (3), washers 2 (4), and
washers 3 (5).
Handle as an assembly until assembly is performed.
Washers 2 are used for pre-set adjustment of the
secondary pressure springs, so thickness is differ-
ent for each spool assembly. Additionally, these are
sometimes not used, so record the status for each
assembly.
24. Cleaning parts

• Clean all parts by placing them in a rough clean-
ing container filled with white kerosene. (rough
cleaning)
• Scratching can easily occur if cleaning of parts
is begun just after parts are immersed in white
kerosene, so let each part sit in white kerosene
until debris and grease sufficiently loosen off from
the surface of parts and float to the surface.
• If the white kerosene is dirty, this will encourage
damage to parts and result in reduced perfor-
21. Remove the grease cups (2) from the plugs (1). mance after reassembly. Thoroughly manage the
level of cleanliness of the white kerosene.
• Clean each part by placing it in a finish cleaning
container filled with white kerosene, and thor-
oughly clean each part, including the interior,
while slowly rotating it (finish cleaning).
Use a clean rag to thoroughly remove any white
kerosene stuck to parts.
• Do not dry parts with compressed air, as this will
damage parts and cause rust to form due to de-
bris and moisture being dispersed into the atmos-
phere.
• Preventing rust on parts
Apply an anti-rust agent to each part.
Rust will form on parts if they are left as is af-
ter cleaning, and this will cause reduced perfor-
mance of functions after reassembly.
84402832 NA - May 2011

8014-7
Control Valve
Assembly Procedures
1. Install the washers 3 (5), washers 2 (4), secondary
pressure springs (3), and the spring seating (2) onto
each of spools (1) in that order.
Washers 2 are used for pre-set adjustment of the
secondary pressure springs, so thickness is differ-
ent for each spool assembly. Additionally, these are
sometimes not used.
Check the status recorded during disassembly and
attach parts accordingly.
3. Install the return springs (1) in the casing (2).

disassembly.
2. Place the bottom end of the spools (1) perpendicu-

lar on a level work platform, push the spring seating
(2) down, and install the 2 half-circle washers 1 (3)
onto the spring seating in such a way that they are
not on top of each other.
4. Install the pressure reducing valve subassemblies

(1) assembled in steps 1) and 2) above into the cas-
ing (2).
disassembly.
• Install the washers 1 so that the sharp edge side

(a) faces up and the washer catches the head of
the spool.
Do not press in the spring seating by 4 mm or
more.
• When installing the pressure reducing valve sub-

assemblies, be careful not to strongly strike the
casing corners (b) with the bottom ends of the
spools.
84402832 NA - May 2011

8014-8
Control Valve
7. Install the steel balls (1) into the bushings.
5. Install O-rings (1) (2) on the casing (3).

8. Install the spring seating (1) into the bushings.
disassembly.
6. Tighten the damper casing (1) and casing (2) with

the hexagon socket head bolts (3) to the specified
torque.
disassembly. 9. Install the damping springs (2) (3) in the casing (1).
• Tighten the 2 hexagon socket head bolts (3) • Install them in the positions they were in before
evenly, and tighten the damper casing (1) in a disassembly.
parallel orientation.
• Hexagon socket head bolt (3) tightening torque:
7.8 - 9.8 N·m
84402832 NA - May 2011

8014-9
Control Valve
10. Install the pistons (1).
disassembly.
13. Install grease cups (2) into the plugs (1).
11. Install O-rings (2) on the plugs (1).
14. Install push rods (2) into the plugs (1).

• Before installing push rods, apply hydraulic oil to
the rod surfaces.
12. Install NHU packings into the plugs (1). Do not press the rods in strongly, as this may dam-
age the NHU packing lip sections.
• When installing the NHU packings (1), be careful

of the installation direction. (See the diagram.)
Before installing NHU packings, apply a thin layer
of grease.
84402832 NA - May 2011

8014-10
Control Valve
15. Install the push rod subassemblies assembled in 18. Tighten the hexagon socket head bolts to the spec-
steps 11), 12), 13), 14) above into the casing (1). ified torque.
• Be careful that the cover is horizontal.
• Hexagon socket head bolt tightening torque:
45.2 - 64.8 N·m
16. Use special tool 1 on the covers (1) to press down

the bushings, and lightly strike the bushings with a
hammer to press fit them.
• Be careful that the ends of the bushings do not
stick out from within the cover. 19. Temporarily install the locking screws (3) and lock
nuts (2) on the cams (1).
17. Install the covers (1) on the casing (2).

20. Install the cams (1) on the covers (2).
disassembly. • Install them in the positions they were in before
• Be careful of the cover rising up due to the damp- disassembly.
ing springs.
84402832 NA - May 2011

8014-11
Control Valve
21. While holding the cams (1), insert the cam shafts 24. Adjust the height of the locking screws so that the
(2) from the outside. top surface of the cams (1) and the bottom surface
of the covers (2) are parallel, and tighten the lock
nuts to the specified torque after rotating the cams
left and right to check if there is any neutral back-
lash.
Even if the push rods are pressed in too much by the
locking screws, backlash during neutral will occur.
Use caution as this may cause sudden movement
when starting the engine.
• Locking screw tightening torque: 29.9 - 36.7 N·m
22. Apply Loctite #241 or the equivalent to the surfaces

of the hexagon socket head locking screws (1).
25. Tilt the cams (1) and fill the grease cups of the plugs
with grease while coating the top of the push rods
with grease.
• For grease application and filling, use a flat object
made of soft material so as to not scratch the push
rod or plug surfaces.
23. Tighten the hexagon socket head locking screws to
the specified torque.
• Hexagon socket head locking screw tightening
torque: 5.9 - 7.9 N·m
26. After mounting the top end of the bellows (1) on the
cams, mount the bottom end into the grooves on the
covers (2).
• Before mounting the bottom end of the bellows
into the grooves of the covers, spray anti-rust oil
on the parts within the bellows.
• Be careful that the bellows are properly mounted
in the grooves and not twisted, as this may reduce
anti-rust and anti-moisture protection.
84402832 NA - May 2011

8014-12
Control Valve
84402832 NA - May 2011

8014-13
Control Valve
Causes of Trouble and Countermeasures and Cross-section Diagram
A few problems that may occur are listed in the table below.
Repairs are difficult, so refer to the possible causes and solutions in the table.
The table below shows general symptoms, suggested causes, and also solutions.
However, the cause of machine problems are often not rooted in just a single part. Problems are often due to the
relationship of one part with another.
Also keep in mind that solutions other than those listed in the table may sometimes be necessary.
The numbers in parentheses after the part names are the codes indicated in "Attached diagram 1 Remote control
valve assembly cross-section diagram".
Also, the table below does not include all possible causes and countermeasures.
Further investigation of problems and causes should be done by an experienced and qualified repair person, as nec-
essary.

1. Insufficient primary pressure 1. Maintain primary pressure.
2. Secondary pressure spring (324) is worn. 2. Replace it with new part.
Secondary pressure is
3. The gap between spool and the casing is 3. Replace spool and casing assembly.
not rising.
abnormally large. 4. Disassemble and assemble or re-
4. There is backlash in the operation section. place operation section parts.
Secondary pressure is 2. Return directly to the oil tank.
2. Tank line pressure is variable.
unstable. 3. Perform operation several times and
3. Air is getting into lines.
let out air.
Secondary pressure is 1. Tank line pressure is high. 1. Return directly to the oil tank.
high. 2. Sliding parts are sticking. 2. Repair the sticking sections.
1. Perform operation several times and
1. Air is gathering in the piston chamber.
let out air.
3. Damping springs (336) (337) are worn.
3. Replace it with new part.
4. The gap between piston (224) and the cas-
Damping is not working. 4. Replace piston and casing assem-
ing is abnormally large.
bly.
5. There are check valve operation problems.
5. Disassemble and adjust the check
6. The piston metering hole is abnormally
valve section.
large.
6. Replace piston.
1. Sliding parts are sticking. 1. Repair the sticking sections.
Damping torque is high.
2. Piston metering hole is clogged. 2. Repair or replace piston.
84402832 NA - May 2011

8014-14
Control Valve
Hydraulic symbols Cross section B-B
Attached diagram 1. Remote control valve assembly cross-section diagram
84402832 NA - May 2011

8014-15
Control Valve
ANNOTATION:
Since hydraulic equipment is crucial to safety, we cannot guarantee performance and functions if disassembly and
reassembly are performed.

101 Casing 1 271 Hexagon socket head bolt 2
102 Casing (damper) 1 301 Spool 4
201 Cover 2 311 Spring seating 4
202 Plug 4 313 Washer 3 4
203 Grease cup 4 324 Spring 4
210 NHU packing 4 335 Spring 4
211 O-ring 2 336 Spring 4
213 O-ring 4 412 Bushing 4
214 Push rod 4 413 Camshaft 2
245 Washer 1 8 420 Cam 2
Hexagon socket head locking
217 Washer 2 4 423 2
screw
218 Spring seating 4 471 Locking screw 4
220 Hexagon socket head bolt 2 472 Lock nut 4
224 Piston 2D085 4 501 Bellows 2
225 Steel ball 2
Tightening torque list

Code Screw size Tightening torque
220 M6 7.8 - 9.8 N·m
271 M12 45.2 - 64.8 N·m
423 M6 5.9 - 7.9 N·m (Loctite coating)
472 M10 29.9 - 36.7 N·m
a Grease application to top

Filling of grease cup with
b
grease
Attached diagram 2. Jig dimension diagram
c Center hole possible (D2 or

less)
84402832 NA - May 2011

8014-16
Section
8016
Assembly and Disassembly of Cushion Valve
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Reverse Operation Spool Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Check Plunger Section with Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Shuttle Valve Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Reverse Operation Spool Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Check Plunger Section with Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Shuttle Valve Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Written Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Disassembly Procedures
This valve has a structure that forms small gaps. It is precision processed and the parts are carefully selected and fit
together, so do not disassemble it as much as possible.
If assembly and disassembly is unavoidable, pay attention to the following. (The product warranty may be invalidated.)
• Only disassemble in a clean location with minimal dirt.
• Use only clean tools and cleaning oil and handle them with care.
• Use plugs, caps to cover ports to prevent any entry of dirt and clean the outside of the assembly.
• Check the internal structure before starting work, and carefully study the disassembly objective and scope.
Reverse Operation Spool Section Check Plunger Section with Throttle

1. Remove the plugs (1) and O-rings (2). 1. Remove the plugs (1) and O-rings (2).
• Remove the springs (3). • Remove the springs (3) and remove the check
• Remove the spools (4) with the cap screws and plungers (4).
O-rings assembled in them.
CAUTION
The check plungers have similar shapes,
so identify them in such a way that no
one will mix them up with each other.
Diagram 1
2. Fasten the spool (3) assemblies taken out in 1. in a
vise.
CAUTION
Diagram 3
Use a piece of wood (jig) (4) to prevent
scratches.
• Remove the cap screws (1) and O-rings (2).
Diagram 2
84402832 NA - May 2011

8016-3
Shuttle Valve Section

1. Remove the plugs (1) and O-ring (2), and then re-
move the seat (4) and O-ring (3).
• Remove the steel balls (5).
Diagram 4
84402832 NA - May 2011

8016-4
Assembly Procedures
This valve has a structure that forms small gaps.
It is precision processed and the parts are carefully selected and fit together, so do not disassemble it as much as
possible.
If assembly and disassembly is unavoidable, pay attention to the following. (The product warranty may be invalidated.)
• Only assemble in a clean location with minimal dirt.
• Use only clean tools and cleaning oil and handle them with care.
• Clean the disassembled parts and prepared parts.
• Study the internal structure before starting the work and prepare the parts required by the disassembly objective
and scope.
Reverse Operation Spool Section CAUTION

1. Assemble the cap screw (1) with O-ring (2) on the The spool assemblies are symmetrical left/
spool (3). right, so the insertion direction does not
matter.
• Tightening torque: 9.8 - 14.7 N·m
CAUTION • Insert the springs (2) and assemble the plugs (3)
with the O-rings (4) attached.
Use a piece of wood (jig) (4) to prevent • Tightening torque: 39.2 - 49.0 N·m
scratches.q
Diagram 6
Diagram 5
2. Insert the spool assemblies (1) assembled in 1. into
the body.
84402832 NA - May 2011

8016-5
Check Plunger Section with Throttle Shuttle Valve Section

1. Insert the check plungers (1). 1. Insert the steel balls (1).
CAUTION • Assemble the seat (2) with the O-ring (3) attached
and the plug (4) with the O-ring (5) attached.
The check plungers have similar shapes, • Tightening torque: 39.2 - 49.0 N・m
so be careful to insert each one in its cor-
rect position.
• Insert the springs (2) and assemble the plugs (4)

with the O-rings (3) attached.
• Tightening torque: 29.4 - 31.4 N・m
Diagram 8
Diagram 7
84402832 NA - May 2011

8016-6
Written Materials
1. Check plunger table
Metering orifice diame-

Part No. Name Remarks
ter (D)
65301-11705 Check plunger 0.5
2. Cushion valve assembly diagram
External shape diagram
84402832 NA - May 2011

8016-7
Cross section X - Cross section Y -
Cross section V -
Cross-section diagram

1 Body 9 Check plunger 17 Seat
2 Spool 10 Check plunger 18 O-ring
3 Spring 11 Check plunger 19 Plug
4 Plug 12 Check plunger 20 O-ring
5 O-ring 13 Spring 21 Name plate
6 Cap screw 14 Plug 22 Drive screw
7 O-ring 15 O-ring 23 Plug
8 Plug 16 Steel ball 24 Plug
84402832 NA - May 2011

8016-8
Section
8017A
Removal and Installation of Arm HBCV
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Arm HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Arm HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CAUTION 2. Use a hexagon wrench (10 mm) to remove the 4

hexagon socket head bolts (1), and then remove the
• Stop the machine in the temporary decom- line (2) and O-ring (3).
missioning posture on a level location with
good footing. • Use caps or plugs to cover the HBCV and line to
work. • Clean the HBCV and line by spraying them with
• When working together with others, always dirt from accumulating on the connectors.
beginning work.
Items to prepare
• Wrench (22 mm)
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid
Removal of Arm HBCV

1. Use a wrench (22 mm) to remove the line (1) and hexagon socket head bolts (1), and then remove the
(2). arm HBCV (2) and O-ring (3).
• Mark the HBCV and hoses so that the connectors
• Use caps or plugs to cover the line and HBCV to
• Clean the line and HBCV by spraying them with
84402832 NA - May 2011

8017A-3
Installation of Arm HBCV 2. Set the O-ring (3) on the line (2), and then install
with 4 hexagon socket head bolts (1).
1. Set the O-ring on the arm HBCV, and then install
with 4 hexagon socket head bolts (1). • The O-ring cannot be reused.
Replace with a new part.
Replace with a new part. Tightening torque: 74.9 - 109.9 N・m
3. Install the line assemblies (1) (2).

• Install at the position where the HBCV and hoses
are marked so that the connectors match at the
time of assembly.
84402832 NA - May 2011

8017A-4
Section
8017B
Removal and Installation of Boom HBCV
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Boom HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Boom HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CAUTION • Clean the HBCV and lines by spraying them with

• Stop the machine on a level location with dirt from accumulating on the connectors.
good footing.
work.
beginning work.
Items to prepare
• Marking pen
• Caps
• Plugs 3. Use a hexagon wrench (10 mm) to remove the 4
• Rag hexagon socket head bolts (1), and then remove the
• Cleaning fluid boom HBCV (2).
• Crossties
Removal of Boom HBCV

1. Use wrenches (19 mm, 22 mm) to remove the hoses
from the tool box side boom HBCV (1), (2), (3) and
(4).
• Use caps or plugs to cover the HBCV and lines to
• Clean the HBCV and lines by spraying them with
4. Use wrenches (19 mm, 22 mm) to remove the hoses
(1) (3) (4) (5) of the cab side boom HBCV in step
1, and use a wrench (27 mm) to remove the boom
bottom pressure sensor (6).
• Clean the HBCV and lines by spraying them with
1 Pilot hose (use 19 mm wrench)

Drain hose (use 22 mm
2
wrench)
3
wrench)

line (2).
84402832 NA - May 2011
8017B-3
1 Pilot hose (use 22 mm wrench) Installation of Boom HBCV

3 1. Set the O-ring (1) on the boom HBCV (2), and then
wrench)
4 Pilot hose (use 22 mm wrench) install with 4 hexagon socket head bolts (3).
5 Pilot hose (use 22 mm wrench) • The O-ring cannot be reused.
hexagon socket head bolts (3), and then remove the Tightening torque: 74.9 - 109.9 N・m
line (2) and O-ring (1).
• Use caps or plugs to cover the HBCV and line to
• Clean the HBCV and line by spraying them with
2. Set the O-ring (1) on the line (2), and then install
with 4 hexagon socket head bolts (3).

boom HBCV (2) and O-ring (1).
84402832 NA - May 2011

8017B-4
3. Use wrenches (19 mm, 22 mm) to install the hoses 5. Set the O-ring (1) on the line (2), and then install
(1) (3) (4) (5) of the boom HBCV, and use a wrench with 4 hexagon socket head bolts (3).
(27 mm) to install the boom bottom pressure sensor
(6). • The O-ring cannot be reused.
• Install at the position where the HBCV and hoses
time of assembly.
6. Use wrenches (19 mm, 22 mm) to install the hoses

from the tool box side boom HBCV (1) (2) (3) (4).
1 Pilot hose (use 22 mm wrench) • Install at the position where the HBCV and hoses
3 time of assembly.
wrench)
4. Set the O-ring (1) on the boom HBCV (2), and then
install with 4 hexagon socket head bolts (3).

2
wrench)
3
wrench)
84402832 NA - May 2011

8017B-5
84402832 NA - May 2011

8017B-6
Section
8018
Assembly and Disassembly of Center Joint
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS

Job code 35354AE28 CAUTION

General cautions
CAUTION
• The following cautions for hydraulic equip- bump them with other parts during work.
ment should be observed with these parts. • Do not forcefully open or hit parts in an effort
• To ensure safe operations, wear protective to speed up operations.
devices for the work and follow all precau- Pay careful attention and proceed slowly so
tions. as not to damage any parts, create any oil
• When removing devices or positioning de- leaks, or compromise the efficiency of the
vices at the time of installation, use a removal equipment, etc.
jig and a hammer or steel rod. • Disassembled parts can easily rust or collect
• Make sure that the jig is used for disassembly dust. Therefore, immediately after disassem-
of the axle and rotor. bling parts, take precautions to prevent the
• Follow the precautions below when suspend- parts from rusting or collecting dust.
ing the load. • Make sure that foreign matter such as debris
• The liftcrane must be operated by a quali- and moisture does not enter.
fied operator. • The work platform used should be solid, sta-
• Do not stand or pass under the suspended ble, and sufficiently spacious.
load. Also, items should be clean and free of debris
• Check the weight of the load to deter- and moisture.
mine whether it can be carried by hand or Remove debris and moisture before perform-
whether a liftcrane must be used. ing work.
• Inspect, remove debris and moisture, and
• Be sure to repair any parts damaged during clean tools and jigs before work.
disassembly, and prepare replacement parts • Jigs and tools that are appropriate to the con-
in advance. tents of work should be used.
clean them before disassembling. Items to prepare
during assembly can create a malfunction. • Hexagon wrenches (6 mm, 8 mm, 14 mm, or 17 mm)
Therefore, after thoroughly cleaning the • Torque wrench
equipment with cleaning oil, air blow the • Socket wrenches (6 mm, 8 mm, 14 mm, or 17 mm)
equipment, and assemble in a clean location. • Lights
• When assembling V-rings, O-rings, and other • Mirror
sliding parts, be sure to coat them with new • Brush (plastic)
grease. • Specialty jigs
84402832 NA - May 2011

8018-3

1 Axle 5 Packing ring 9 Cover
2 V-ring 6 Thrust plate 10 Hexagon socket head bolt
3 Rotor 7 Hexagon socket head bolt 11 Loctite #262
4 O-ring 8 O-ring
84402832 NA - May 2011

8018-4
Dimension Diagram
Maximum gap 10.0 3 - M16 screw depth 22 mm,

*1 *3
Minimum gap 8.5 bottom hole depth 27 mm
Maximum gap 0.7 4 x 4 - M10, screw depth 16
*2 *4
Minimum gap 0.3 mm, bottom hole depth 18 mm
84402832 NA - May 2011

8018-5

Axle removal jig
a Axle removal jig Hexagon socket head bolt (7)

*4
M10 x 25
M16 - M20 full threaded bolt Backing plate
*1 Axle (1) outer diameter - about
L = 370 - 420 mm *5
*2 M16 - M20 female thread 5 mm
t = about 5 mm
Cover (9) installation dimen-
*3
sions
Removal jig (for O-ring and

b
V-ring)
84402832 NA - May 2011
8018-6
Disassembly Procedures 3. Use a hexagon wrench (6 mm) to remove the 4

1. Use a hexagon wrench (8 mm) to remove the 4 thrust plate (6).
hexagon socket head bolts (10), and then remove
the cover (9).
4. Use the axle removal jig (a) to push out the axle (1)
from the rotor (3).
2. Remove the O-ring (8).
• Do not strike it with the hammer at this time.
84402832 NA - May 2011

8018-7
5. Use the removal jig (b) or the like to remove the Assembly Procedures
V-ring (2) from the axle (1).
1. Place parts in a rough cleaning container filled with
kerosene to clean off any adhered matter that can
form sharp points and cause scratches.
• Immerse in kerosene until dust, grease, and other
adhered matter comes off and floats to the sur-
face.
6. Use the removal jig (b) or the like to remove the

O-ring (4) and packing rings (5) from the rotor (3).
2. Place parts in a finish cleaning container filled with

kerosene and clean while gently moving the parts.
After cleaning, wipe away the kerosene with a clean
rag.
• Place the parts in a location free of dust and mois-
ture and use compressed air to dry the parts. After
drying, coat parts with engine oil.
• Polish away burrs, barbs, and scratches with a
whetstone.
84402832 NA - May 2011

8018-8
3. Use cleaning fluid or compressed air to clean the 5. After installing the O-ring and packing rings, use the
rotor (3). mirror to check for any parts that are sticking out or
After cleaning, check inside the rotor and in the are twisted. Also, check for installation mistakes.
groove sections for burrs, barbs and scratches and After checking, coat with grease. After coating with
for scratches caused by striking. grease, check again for any parts sticking out,etc.
4. Check the quantity of packing rings (5) and O-ring 6. Install the V-ring (2) on the axle (1) and coat suffi-
(4). Coat with grease and install in the sequence ciently with grease. Be careful that no water or dirt
below. gets into the grease.
• Set one packing ring (5) in each of the 7 grooves • Use a new V-ring (2).
from the 2nd groove on the axle insertion side to
the thrust plate side.
• Set the O-ring (4) in the front-most groove on the
axle insertion side.
• Use new packing rings (5) and a new O-ring (4).
7. Install the axle (1) on the rotor (3).

• Set in a way that the V-ring (2) will not be cut or
damaged.
84402832 NA - May 2011

8018-9
8. Using a hexagon wrench (6 mm), coat the hexagon 10. Using a hexagon wrench (8 mm), coat the hexagon
socket head bolts (7) with Loctite, install the thrust socket head bolts (10) with Loctite #262, install the
plate (6) on the axle (1), and tighten to the specified cover (9) on the rotor (3), and tighten to the specified
tightening torque. tightening torque.
Installation bolt tightening torque: 31.4 - 37.3 N•m Installation bolt tightening torque: 62.7 - 72.5 N•m
9. Install the O-ring (8) on the rotor (3). This completes the assembly.
• Use new O-ring (8).
84402832 NA - May 2011

8018-10
Section
8019
Assembly and Disassembly of Swing Motor
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Causes of Trouble and Solutions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Maintenance Standard Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Swing Motor Internal Structural Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Job code 35352AF10
CAUTION
1. Read and understand the contents of this
maintenance manual before performing
disassembly, reassembly, inspection, re-
pair, or other such work of this product.
2. Handle this product according to the sep-
arate "Usage Precautions".
3. When removing this product from the
equipment it is mounted on, stop that
equipment system and wait for the surface
temperature of this product to fall to about
40 °C or below before removing it.
can cause burns.
Additionally, always bleed out the pressure
before removing any line from this prod-
uct.
Removing a pressurized line can result in
oil spraying out and causing injury or oil
leak.
4. Use the specialty tools and measurement
instruments for disassembly, reassembly,
inspection, and repair, etc. of this product.
Using an inappropriate tool may result in
injury or product damage.
5. Be careful of parts falling when performing
disassembly, reassembly, inspection or re-
pair, etc. of this product.
This may result in injury or parts damage.
6. Do not directly touch with bare hands the
machined edges or threaded sections of
parts during disassembly, reassembly, in-
spection, or repair etc. of this product.
This may result in injury.
7. Check performance after reassembly.
Do not resume use unless performance is
fully recovered.
Using this product at a sub-par perfor-
mance level may result in product damage.
8. The cautions (mark !) listed in this main-
tenance manual do not cover all possible
dangers.
Always think of safety first during disas-
sembly, inspection, reassembly, repair, or
other such work.
84402832 NA - May 2011

8019-3
Causes of Trouble and Solutions

This list consists of actions to be taken when an abnormality is sensed or there are problems with functions during
use of the hydraulic motor. Additionally, details concerning disassembly inspection and reassembly are listed after
this, but sufficient caution should be exercised in handling during these actions so as to prevent scratching of sliding
parts of the motor.
1. General cautions
This list consists of actions to be taken when an abnormality is sensed during use of the hydraulic motor.
General cautions are listed below.
1) Think before attempting to fix a problem.
Determine the nature of the abnormality before beginning work and think whether this same kind of problem
has occurred before.
Also, reconfirm whether the motor is the source of the problem.
2) Be careful about dust and dirt.
The cause of wear is very often dust and dirt. So be careful that dust and dirt do not get into parts during
disassembly.
3) Parts handling
Parts are manufactured with a high degree of precision, so be careful not to scratch them during handling.
4) Do not damage O-rings or gasket surfaces while performing work. Also, it is recommended that O-rings
are replaced for new ones during disassembly.
2. Investigating abnormalities in the motor main unit
It is very difficult to search for the source of troubles in the hydraulic circuits. Inspect the following items and
thoroughly investigate whether the motor is the source of troubles.
1) Inspecting oil within the casing
Remove the drain plug and inspect the hydraulic oil within the casing. If a large amount of metal particles
come out at the same time as oil, it is very likely that there is damage with parts within the motor.
2) Existence of abnormal noise
Check whether abnormal noise is coming from the motor main unit.
3) Measure pressure for each part.
Do not perform disassembly inspection carelessly. Measure pressure for each part and look for abnormal-
ities in each area.
4) Measure the amount of oil drained from the motor.
1) Operation is normal if about 6 L/min or less of oil drains from the motor when pressure oil is applied
after the swing is locked.
2) 2 L/min or less of drained oil at constant swing is normal.
3. Trouble conditions and countermeasures
1) Hydraulic motor does not rotate.

1) Incorrect setting of the circuit safety 1) Reset safety valve correctly.
valve 2) Disassemble and inspect.
2) Operation problems with relief
valve 1) Repair or replace sticking
Pressure does not
section.
rise.
1) Plunger sticking 2) Disassemble and clean.
2) Clogged plunger orifice
3) Check seating sections and replace
3) Plunger seating problem scratched part.
1) Eliminate load.
1) Overload
2) Inspect and repair piston/shoe,
2) Seizing of driving part
cylinder/valve plate, etc.
3) No release pressure acting on the
3) Inspect and repair circuit.
Pressure rises. brake
4) Disassemble and inspect.
4) Piston sticking to the brake
5) Spool for brake release sticking
6) Disassemble and inspect. Replace
6) Friction plate seizing
seizing part.
84402832 NA - May 2011

8019-4
2) Rotation direction is reversed.

1) Check the rotation direction and as-
Reversed rotation di- 1) Motor rotation direction reversed.
semble correctly.
rection 2) Input and output for line reversed.
2) Correct line configurations.
3) Motor speed is not reaching the set value.

1) Insufficient oil flow amount
1) Check the pump discharge volume
Motor speed is not 2) High temperature and severe leak
and the circuit up to the motor.
reaching the set of oil
2) Lower the temperature of the oil.
value. 3) Wear or damage on each sliding
3) Replace.
section
4) Hydraulic motor does not rotate.

1) Wear on the friction plate
parts worn beyond the limit.
2) Brake piston sticking
Insufficient braking 3) Brake release pressure cannot be
3) Inspect and repair circuit.
torque released.
4) Spool for brake release sticking
5) Damaged friction plate spline
damaged part.
5) Severe hydraulic motor slipping

Investigate the amount of oil drained from the hydraulic motor. Motor operation is normal if the amount is
500 cc/min or less.

1) Operation problems with relief
Slipping is severe valve 1) Repair or replace sticking
when an external section.
1) Plunger sticking
driving torque acts on 2) Disassemble and clean.
2) Clogged plunger orifice
the hydraulic motor.
2) Check seating section and replace
2) Plunger seating problem
scratched part.
6) Oil leak
1) Oil leak from oil seal

1) Debris lodged in lip causing
scratching. 1) Replace oil seal.
2) Shaft scratched or worn 2) Stagger the position of the lip and
Oil leak from oil seal 3) Pressure within the casing becom- shaft or replace.
ing abnormally high caused oil seal 3) Repair any clogged drain line.
lip to turn up. 4) Disassemble and repair.
4) Shaft rusted.
2) Oil leak from matching surface

1) Insert O-ring and assemble cor-
1) O-ring has not been inserted. rectly.
Oil leak from match- 2) Scratched O-ring 2) Replace.
ing surface 3) Scratched seal surface 3) Disassemble and repair.
4) Loosened or damaged bolt 4) Tighten to the specified torque or
replace.
84402832 NA - May 2011
8019-5
Maintenance Standard Table

1. Replacement standards for worn parts
If wear on any part exceeds the standard values below, replace or readjust.
However, parts should be replaced regardless of these standards if they appear to be extremely damaged based
on appearance.
Recom-
Standard mended
dimen- replace-
Item Solution
sions ment
(mm) value
(mm)
Clearances between piston and cylinder
bore 0.028 0.058 Replace the piston or cylinder.
(D-d)
Piston and shoe caulking section back-
0 0.3 Replace the piston and shoe assembly.
lash (δ)
Shoe thickness (t) 5.5 5.3 Replace the piston and shoe assembly.
Friction plate thickness 2.0 1.6 Replace.
Clearance (D-d) Piston and shoe backlash (δ)
Shoe thickness (t)
84402832 NA - May 2011

8019-6
2. Sliding surface repair standards

If the roughness of the sliding surface in any section exceeds the standard values below, repair or replace.
Surface roughness
Part name Standard surface roughness
requiring repair
Shoe 0.8 - Z (Ra = 0.2) (lapping) 3 - Z (Ra = 0.8)
Shoe plate 0.4 - Z (Ra = 0.1) (lapping) 3 - Z (Ra = 0.8)
Cylinder 1.6 - Z (Ra = 0.4) (lapping) 12.5 - Z (Ra = 3.2)
Valve plate 0.8 - Z (Ra = 0.2) (lapping) 6.3 - Z (Ra = 1.6)
Note:
1) Using lapping, make the degree of surface roughness of each sliding surface equal to or lower than the
standard value.
2) If the plate spring and cylinder spherical surface sliding section are rough, these should be replaced as
a set.
84402832 NA - May 2011

8019-7
Disassembly 5. Remove the ROH plug (469) from valve casing H0

(303) and take out the springs and plungers.
1. Wrap the wire rope around the outer circumference Be careful not to scratch the plunger seating sec-
of the motor, lift the motor with a liftcrane, and clean tions.
with white kerosene. After cleaning, dry the motor
using compressed air.
• To prevent foreign matter from entering the motor,
mask each port with tape, etc. Also clean off ad-
hered dirt and dust.
2. From the drain plug, drain the oil inside the housing.
3. Point the shaft end of the drive shaft downwards and
place a reference mark (*1) on the matching surface
of valve casing H0 (303) and casing JA1 (301) with
paint, etc.
• Select a clean location. Place a rubber plate or
cloth on the work platform so as not to damage
the parts.
6. Loosen the hexagon socket head bolt (401) and re-
move valve casing H0 (303) from casing JA1 (301).
• The valve casing H0 (303) will rise up from the
casing JA1 (301) when the bolts are removed due
to the force of the brake springs (712).
7. Remove valve plate B (131) from valve casing H0
(303).
• Do this carefully so as not to let valve plate B (131)
fall from valve casing H0 (303). (Valve plate B
(131) may be attached to the cylinder side.)
• When prying open the matching surface with a
screwdriver, be careful not to scratch the surface.
4. Loosen the relief valves (051) and remove them

from valve casing H0 (303).
• Be sure to replace the O-ring (051-1). The O-ring
(051-1) is damaged when the relief valve is loos-
ened.
8. Take out the brake springs (712) from the brake pis-
ton (702).
84402832 NA - May 2011

8019-8
9. Use a jig and remove the brake piston (702) from

casing JA1 (301).
• Apply the tips of the jig to the grooves of the brake
piston, and pull straight up.
10. Reposition the motor on its side, and remove the

cylinder (111) from the drive shaft. Next, remove
the pistons (121), holder plate (123), plate spring
(114), and shoe plate (124).
• Be careful not to scratch the sliding surfaces of
the cylinder (111), shoe (122), etc.
13. Perform the following as necessary. Do not reuse a

removed bearing.
• Use a press to remove the inner race of the roller
bearing (443) from the drive shaft (101). When
using a steel rod to hit the inner race of the roller
bearing, hit the inner race evenly while being care-
ful not to damage the bearing.
• Using a steel rod, tap from the housing section
side of the oil seal, and pull out the outer race of
the roller bearing from the housing.
• Use a slide hammer bearing puller (*3) to remove
the roller bearing (404) from valve casing H0
11. Take out the friction plate (742) and separator plate (303).
(743) from casing JA1 (301).
12. Take out the drive shaft (101) and shoe plate (124).
• The spline will damage the oil seal (491) when the
drive shaft is removed, so wrap the spline section
of the drive shaft with vinyl tape, etc. (*2).
84402832 NA - May 2011

8019-9
Assembly
1) Check each part for scratches from use or from
disassembly. If there are any scratches, remove them
with a whetstone or sandpaper of the necessary grain,
clean with pure cleaning oil, then dry off with an air
blower.
2） Replace seal parts with new ones.
3） Thoroughly clean all parts with cleaning fluid and
dry with compressed air.
4 ） When assembling sliding sections, apply clean
hydraulic oil before assembling.
1. Place the housing on an appropriate platform with
the cover on top.
2. If the roller bearing (443) was removed, shrink fit
This completes the disassembly.
the inner race of the roller bearing to the drive shaft
(101).
• Be careful with the direction of the flange of the
roller bearing.
3. Use a jig to insert the oil seal (491) into casing JA1
(301).
• Be careful with the direction of the oil seal.
• Apply a thin layer of grease to the oil seal lip sec-
tion.
• Be careful to evenly hit it without scratching the
outer circumference.
84402832 NA - May 2011

8019-10
4. Use a steel rod to install the outer race of the roller 7. Set the plate spring (114) on the holder plate (123),
bearing (443) into casing JA1 (301). and then set the pistons (121).
5. Mount the drive shaft (101) in casing JA1 (301). 8. Install the piston subassembly (10) on the cylinder
(111).
• Carefully insert it so as not to scratch the lip sec-
tion of the oil seal (491).
• Wrap vinyl tape, etc. around the shaft spline sec-
tion to protect it.
9. Align the piston subassembly (10) and cylinder

(111) with the drive shaft spline and insert into the
housing.
6. Lay casing JA1 (301) horizontal and insert the shoe
plate (124).
• Install with the larger chamfered side of the shoe
plate (124) on the casing JA1 side.
• Apply a thin layer of grease to the matching sur-
face to prevent it from falling out.
10. Set the housing down with the oil seal side facing
downwards, and alternately install separator plates
(743) and friction plates (744) in that order to the
housing. Install the 4 separator plates and 3 friction
plates.
84402832 NA - May 2011

8019-11
13. Install the brake springs (712) into the brake piston
(702).
14. If the roller bearing (444) was removed, use a ham-

mer and steel rod to insert it into valve casing H0
(303).
11. Mount the O-rings (706) (707) on casing JA1 (301).

• If grease is applied to the O-ring, it will not break
easily when inserting the brake piston.
15. Install valve plate B (131) in valve casing H0 (303).

• Apply a thin layer of grease to the matching sur-
face (*1) of the valve plate.
12. Install the brake piston (702) into the housing.
84402832 NA - May 2011

8019-12
16. Mount the O-ring (472) to the cover. 19. Mount the relief valve (051) in valve casing H0
(303).
• Apply grease to the O-ring. Tightening torque: 177 N·m
17. Install valve casing H0 (303) on casing JA1 (301) 20. Assembly confirmation
and tighten with the bolt (401). Open the input/output ports, apply 3.2 - 4.9 MPa of
• Be careful with the installation direction of the pilot pressure to the brake release port to check if
valve. the output shaft rotates smoothly for at least 1 ro-
• Make sure that valve plate B (131) does not fall tation with about 30 - 40 N·m of torque. There is
over. an assembly problem if it does not rotate, so disas-
• Make sure that the brake springs (712) do not fall semble again and adjust it.
over. • At this time, have the drain port open.
Tightening torque: 430 N·m

18. Insert plungers H2 (351) and springs (355) into
valve casing H0 (303) and tighten the ROMH plugs • Check that the set pressure of the relief assembly is
(469) with the O-rings (488) mounted on them. at the correct pressure after the hydraulic motor is in-
stalled in the actual machine.
• Check that plunger H2 (351) moves smoothly.
Tightening torque: 539 N·m
84402832 NA - May 2011

8019-13
Relief internal structural diagram 6 Liner

7 Piston
1 Seat 8 Cap
2 Poppet 9 Backup ring
3 Spring 10 O-ring
4 Spring seat 11 Holder
5 Shim
84402832 NA - May 2011

8019-14
Jig
84402832 NA - May 2011

8019-15

2 Brake piston
3 Casing
84402832 NA - May 2011

8019-16
Swing Motor Internal Structural Diagram
84402832 NA - May 2011

8019-17
a Brake spring layout diagram
Code Part name Q'ty

052 Reverse prevention valve subassembly 1 set
100 Casing 1
151 ROH plug 2
161 O-ring 2
162 O-ring 2
163 O-ring 2
171 Hexagon socket head bolt 4
2
400 Reverse prevention valve
sets
400-1 O-ring 2
400-2 Backup ring 2
Code Part name Q'ty

2
051 Relief valve
sets
051-1 O-ring 2
10 Piston subassembly 1 set
101 Drive shaft 1
111 Cylinder 1
114 Plate spring 1
121 Piston 9
122 Shoe 9
123 Holder plate 1
124 Shoe plate 1
131 Valve plate B 1
20 Valve casing H0 subassembly 1 set
301 Casing JA1 1
303 Valve casing H0 1
351 Plunger H2 2
355 Spring H2 2
390 Nameplate 1
391 Driving tack 2
401 Hexagon socket head bolt 4
443 Cylinder roller bearing 1
444 Cylinder roller bearing 1
451 Pin 2
469 ROMH plug 2
472 O-ring 1
488 O-ring 2
491 Oil seal 1
702 Brake piston 1
706 O-ring 1
707 O-ring 1
712 Brake spring 14
742 Friction plate 3
743 Separator plate 4
2
983 Masking plug
sets
984 Masking plug 1 set
994 Insert plug 1 set
84402832 NA - May 2011

8019-18
Bolt and plug tightening torque

Part
Screw size ・m)
Tightening torque (N・ Width across flat (mm)
No.
051 M33 x 1.5 177 41
151 G1/4 36 6
171 M8 29 6
400 M22 x 1.5 69 24
401 M20 430 17
469 M36 x 1.5 539 17
984 G1/2 2.7 8
985 G1 5.6 14
986 G1/4 0.9 6
994 Rc3/4 98 14
84402832 NA - May 2011

8019-19
84402832 NA - May 2011

8019-20
Section
8020A
Explanation of Hydraulic Circuit and Operations (standard

model)
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS Boom-down tilting prevention circuit (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Boom-down load holding valve circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Boom-down load holding valve circuit (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Travel Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Arm Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Travel low-speed circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Arm-out circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Travel high-speed circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Arm-out circuit (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Straight travel circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Arm-in forced regenerative circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Straight travel circuit (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Arm-in forced regenerative circuit (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Swing Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Arm-in load holding valve circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Swing speed limit control circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Arm-in load holding valve circuit (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Swing relief cut-off control circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Bucket Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Bucket-open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Swing priority circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Bucket-close regenerative circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Swing priority circuit (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Negative Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Swing brake circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Negative Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Swing parking circuit (lever in neutral) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Horsepower Boost Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Swing parking circuit (brake release) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Arm-in Horsepower Boost Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Swing parking circuit (machine stop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Travel Horsepower Boost Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Boom Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Boom-up circuit (independent operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Other Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Cushion circuit (arm-out operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Boom-up circuit (independent operation) (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Cushion circuit (arm-out operation stopped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Boom-up circuit (compound boom-up + arm-in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Cushion circuit (arm-out → arm-in operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Boom-up circuit (compound boom-up + arm-in) (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Heat circuit (lever in neutral) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Boom-down regenerative circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Auto pressure boost circuit (bucket close) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Boom-down regenerative circuit (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Boom-down tilting prevention circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Explanation of Hydraulic Circuit and Operations (standard model)
Travel Circuit
Travel low-speed circuit
84402832 NA - May 2011

8020A-2
Pressure line Pilot tank line
Tank line Electric line
Pilot pressure line
1 Travel motor 7 Travel high speed 13 Check valve

2 Travel high-speed select switch 8 Lever lock 14 Oil cooler
3 Computer A 9 4 stack solenoid valve 15 Backward left
4 Control valve 10 Console lever lock switch 16 Forward left
5 Travel (left) 11 Hydraulic pump 17 Backward right
6 Travel (right) 12 Travel remote control valve 18 Forward right
As an example, this section explains the forward travel operation.

The travel motor 2-stage tilting angle is a large angle side.Even if the travel switchover is set to the high-speed side, switching
the key switch OFF and then ON again always returns the system to this state.
By operating the travel remote control valve to the forward side, the pilot pressure oil is fed to the control valve pa1 port and
switches the left travel spool to the forward side.
At the same time, the oil is also fed to the pa6 port to switch the right travel spool to the forward side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and the discharge oil from hydraulic pump A2 enters
the control valve P2 port.
Each flows to the respective travel motor and causes forward travel through the left and right travel spools being switched.
The return oil from the travel motor goes through the left and right travel spools and returns to the hydraulic oil tank.
The travel high-speed solenoid valve goes OFF, the travel motor Ps port oil connects with the tank line, and the travel motor
tilting angle moves to the large tilting side.
84402832 NA - May 2011

8020A-3
Travel high-speed circuit
84402832 NA - May 2011

8020A-4
Pilot pressure line
1 Travel motor 7 Travel high speed 13 Check valve

2 Travel high-speed select switch 8 Lever lock 14 Oil cooler
3 Computer A 9 4 stack solenoid valve 15 Backward left
4 Control valve 10 Console lever lock switch 16 Forward left
5 Travel (left) 11 Hydraulic pump 17 Backward right
6 Travel (right) 12 Travel remote control valve 18 Forward right
As an example, this section explains the forward travel operation.

Sets the travel motor 2-stage tilting angle to a small angle to set high speed.
The travel motor has an automatic switchover function that switches the speed to low speed according to the load pressure
on the travel motor only during high-speed travel conditions.
At the same time, the oil is also fed to the pa6 port to switch the right travel spool to the forward side.
The return oil from the travel motor goes through the left and right travel spools and returns to the hydraulic oil tank.
Electrical signals are sent to the computer A by operation of the travel high-speed select switch and the computer A sends
electrical signals to the travel high-speed solenoid valve.
Due to the switching of the travel high-speed solenoid valve, the pilot pressure (3.9 MPa) from the C1 port enters the left and
right travel motor Ps ports through the center joint and sets the travel motor tilting angle to a small angle to raise the speed.
84402832 NA - May 2011

8020A-5
Straight travel circuit
84402832 NA - May 2011

8020A-6
Pilot pressure line
1 Travel motor 10 Straight travel signal (left) 19 Boom cylinder

2 Boom (up) 11 Straight travel signal (right) 20 Travel remote control valve
3 Boom (down) 12 Travel high-speed select switch 21 Check valve
4 Cushion valve 13 Computer A 22 Oil cooler
Remote control valve
5 14 Travel high speed 23 Backward left
(boom, bucket)
6 Control valve 15 Lever lock 24 Forward left
7 Travel (left) 16 4 stack solenoid valve 25 Forward right
8 Travel (right) 17 Console lever lock switch 26 Backward right
9 Straight travel valve 18 Hydraulic pump
As an example, this section explains simultaneous forward travel and boom-up operations.
In the same way, oil is also fed to the pa6 port to switch the right travel spool to the forward side.
Furthermore, the right forward travel pilot pressure oil separated internally from the control valve pa6 port switches the straight
travel signal (right).
On the other hand, the travel pilot pressure oil separated internally from the pa1 port switches the straight travel signal (left)
via the straight travel signal (right).
If a boom-up operation is carried out during travel, the pilot pressure oil is fed via the cushion valve to the control valve pa4
port and switches the boom (1) and (2) spools to the up side.
The upper (boom, arm, bucket, swing, option) pilot pressure oil separated internally from the control valve pa4 port is fed to
the straight travel valve via the straight travel signal (left) and the straight travel spool is switched.
The amount of switching of the straight travel spool varies with the upper pilot pressure.
(Because the pilot pressure is low for slight upper operation, the amount of switching of the straight travel spool is slight to
prevent sharp reduction in the travel speed.)
Through the straight travel valve being switched, it is possible for the control valve P1 pressurized oil to drive the left and right
travel motors and for the control valve P2 pressurized oil to drive the boom.
Because the left and right motors are driven by 1 pump, the left and right motors have the same pressure and straight travel
is possible.
Furthermore, the P2 excess pressurized oil is fed to the travel side via the check valve with travel merge orifice to minimize
the drop in speed.
The same operations are carried out when travel and an upper actuator other than for the boom are operated simultaneously.
84402832 NA - May 2011

8020A-7
Straight travel circuit (with HBCV)
84402832 NA - May 2011

8020A-8
Pilot pressure line
1 Travel motor 10 Straight travel signal (left) 19 Boom cylinder

2 Boom (up) 11 Straight travel signal (right) 20 Travel remote control valve
3 Boom (down) 12 Travel high-speed select switch 21 Check valve
4 Cushion valve 13 Computer A 22 Oil cooler
Remote control valve
5 14 Travel high speed 23 Backward left
(boom, bucket)
6 Control valve 15 Lever lock 24 Forward left
7 Travel (left) 16 4 stack solenoid valve 25 Forward right
8 Travel (right) 17 Console lever lock switch 26 Backward right
9 Straight travel valve 18 Hydraulic pump
As an example, this section explains simultaneous forward travel and boom-up operations.
In the same way, oil is also fed to the pa6 port to switch the right travel spool to the forward side.
Furthermore, the right forward travel pilot pressure oil separated internally from the control valve pa6 port switches the straight
travel signal (right).
On the other hand, the travel pilot pressure oil separated internally from the pa1 port switches the straight travel signal (left)
via the straight travel signal (right).
If a boom-up operation is carried out during travel, the pilot pressure oil is fed via the cushion valve to the control valve pa4
port and switches the boom (1) and (2) spools to the up side.
The upper (boom, arm, bucket, swing, option) pilot pressure oil separated internally from the control valve pa4 port is fed to
the straight travel valve via the straight travel signal (left) and the straight travel spool is switched.
The amount of switching of the straight travel spool varies with the upper pilot pressure.
(Because the pilot pressure is low for slight upper operation, the amount of switching of the straight travel spool is slight to
prevent sharp reduction in the travel speed.)
Through the straight travel valve being switched, it is possible for the control valve P1 pressurized oil to drive the left and right
travel motors and for the control valve P2 pressurized oil to drive the boom.
Because the left and right motors are driven by 1 pump, the left and right motors have the same pressure and straight travel
is possible.
Furthermore, the P2 excess pressurized oil is fed to the travel side via the check valve with travel merge orifice to minimize
the drop in speed.
The same operations are carried out when travel and an upper actuator other than for the boom are operated simultaneously.
84402832 NA - May 2011

8020A-9
Swing Circuit
Swing speed limit control circuit
84402832 NA - May 2011

8020A-10
Pilot pressure line
1 Swing motor 9 Travel pilot pressure sensor 17 P1 flow control proportional valve
2 Swing 10 Upper pilot pressure sensor 18 Hydraulic pump
Horsepower control proportional
3 Cushion valve 11 Computer A 19
valve
4 Right swing 12 Lever lock 20 P2 pressure sensor
5 Left swing 13 Swing brake 21 Check valve
6 Swing pilot pressure sensor 14 4 stack solenoid valve 22 Oil coolere
7 Remote control valve (arm, swing) 15 Console lever lock switch
8 Control valve 16 P1 pressure sensor
This control is for suppressing increases in the swing speed accompanying increased pump flow. (Only in SP mode)
For independent swing operation, due to the swing pilot pressure sensor and P1 pressure sensor input electric signal, the
computer A outputs a signal to the P1 flow control proportional valve.
The discharge oil from the hydraulic pump A3 is fed to the P1 flow control proportional valve.
The hydraulic pump A1 side discharge flow is reduced to 280 L/min by the signal output from the computer A to the P1 flow
control proportional valve.
84402832 NA - May 2011

8020A-11
Swing relief cut-off control circuit
84402832 NA - May 2011

8020A-12
Pilot pressure line
1 Swing motor 9 Travel pilot pressure sensor 17 P1 flow control proportional valve
2 Swing 10 Upper pilot pressure sensor 18 Hydraulic pump
3 Cushion valve 11 Computer A 19
valve
4 Right swing 12 Lever lock 20 P2 pressure sensor
5 Left swing 13 Swing brake 21 Check valve
6 Swing pilot pressure sensor 14 4 stack solenoid valve 22 Oil cooler
8 Control valve 16 P1 pressure sensor
This control aims for an energy-saving effect by controlling the pump in such a way as to minimize the excess oil drained from
the swing motor relief valve for the starting pressure boost for a independent sharp swing operation.
When a swing operation starts, due to the swing pilot pressure sensor and P1 pressure sensor input electrical signals, com-
puter A outputs a signal to the hydraulic pump P1 flow control proportional valve.
The discharge oil from the hydraulic pump A3 is fed to the P1 flow control proportional valve.
The output signal from computer A to the P1 flow control proportional valve controls the pilot pressure to reduce the hydraulic
pump A1 side discharge flow.
Also, the input signal from hydraulic pump P1 pressure sensor controls the pilot pressure to gradually increase the discharge
flow.
84402832 NA - May 2011

8020A-13
Swing priority circuit
84402832 NA - May 2011

8020A-14
Pilot pressure line
1 Swing motor 10 Remote control valve (arm, swing) 19 Arm load holding valve check valve
2 Arm (in) 11 Lever lock 20 Regeneration release valve
3 Arm (out) 12 Swing brake 21 Control valve
4 Right swing 13 4 stack solenoid valve 22 Swing priority variable orifice
5 Left swing 14 Console lever lock switch 23 Arm (2)
6 Cushion valve 15 Arm cylinder 24 Upper pilot pressure sensor
7 Swing pilot pressure sensor 16 Arm (1) 25 Hydraulic pump
8 Shuttle valve 17 Swing 26 Check valve
9 Computer A 18 Arm load holding valve spool 27 Oil cooler
The swing pilot pressure is fed to the Pc3' port via the shuttle valve and holds the swing priority variable orifice to the right side.
By metering the parallel circuit, for arm and swing simultaneous operation, the swing pressure is boosted to secure the swing
force for pressing digging.
As an example, this section explains the right-swing and arm-in operation.
By moving the remote control valve to the right swing side, the pilot pressure oil is fed via the shuttle valve to the control valve
pa3 port and switches the spool to the right swing side.
At this time, by moving the remote control valve to the arm-in side, the pilot pressure oil is fed via the cushion valve to the
control valve pb5 port and switches the spool to the arm-in side.
At the same time, the pilot pressure oil from the shuttle valve S port is fed to the control valve Pc3' port to move the swing
priority variable orifice to the right side and hold it.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the parallel oil path to the swing
spool.
Switching the spool lets the oil flow into the swing motor B port and the right swing operation is carried out.
The discharge oil from hydraulic pump A2 enters the control valve P2 port, is fed from the parallel oil path to the arm (2) spool
and merges upstream of the arm (1) spool.
Switching the spool lets the oil flow into the arm cylinder bottom and the arm-in operation is carried out.
When the right swing and arm-in operations are carried out at the same time, the swing priority variable orifice on the control
valve P1 port parallel oil path moves and narrows, so the pressure is boosted to secure the swing force for pressing digging.
84402832 NA - May 2011

8020A-15
Swing priority circuit (with HBCV)
84402832 NA - May 2011

8020A-16
Pilot pressure line
1 Swing motor 10 Remote control valve (arm, swing) 19 Arm load holding valve check valve
2 Arm (in) 11 Lever lock 20 Regeneration release valve
3 Arm (out) 12 Swing brake 21 Control valve
4 Right swing 13 4 stack solenoid valve 22 Swing priority variable orifice
5 Left swing 14 Console lever lock switch 23 Arm (2)
6 Cushion valve 15 Arm cylinder 24 Upper pilot pressure sensor
7 Swing pilot pressure sensor 16 Arm (1) 25 Hydraulic pump
8 Shuttle valve 17 Swing 26 Check valve
9 Computer A 18 Arm load holding valve spool 27 Oil cooler
The swing pilot pressure is fed to the Pc3' port via the shuttle valve and holds the swing priority variable orifice to the right side.
By metering the parallel circuit, for arm and swing simultaneous operation, the swing pressure is boosted to secure the swing
force for pressing digging.
As an example, this section explains the right-swing and arm-in operation.
By moving the remote control valve to the right swing side, the pilot pressure oil is fed via the shuttle valve to the control valve
pa3 port and switches the spool to the right swing side.
At this time, by moving the remote control valve to the arm-in side, the pilot pressure oil is fed via the cushion valve to the
control valve pb5 port and switches the spool to the arm-in side.
At the same time, the pilot pressure oil from the shuttle valve S port is fed to the control valve Pc3' port to move the swing
priority variable orifice to the right side and hold it.
spool.
Switching the spool lets the oil flow into the swing motor B port and the right swing operation is carried out.
The discharge oil from hydraulic pump A2 enters the control valve P2 port, is fed from the parallel oil path to the arm (2) spool
and merges upstream of the arm (1) spool.
Switching the spool lets the oil flow into the arm cylinder bottom and the arm-in operation is carried out.
When the right swing and arm-in operations are carried out at the same time, the swing priority variable orifice on the control
valve P1 port parallel oil path moves and narrows, so the pressure is boosted to secure the swing force for pressing digging.
84402832 NA - May 2011

8020A-17
Swing brake circuit
84402832 NA - May 2011

8020A-18
Pilot pressure line
1 Swing motor 7 Hydraulic pump 13 Computer A

2 Cushion valve 8 Check valve 14 Control valve
3 Right swing 9 Lever lock 15 Oil cooler
4 Left swing 10 Swing brake 16 Upper pilot pressure sensor
5 Swing pilot pressure sensor 11 4 stack solenoid valve
As an example, this section explains the brake circuit operation after the end of a right swing operation.
When the remote control valve is returned to neutral from a right swing operation, the pilot pressure oil is cut off and the control
valve swing spool returns to neutral.
The pressurized oil fed to the swing motor A port from the control valve A3 port is cut.
At the same time, the destination location is eliminated for the pressurized oil flowing from the swing motor B port to the control
valve B3 port, so the pressure rises to the swing motor relief valve set pressure.
The pressure generated here becomes a brake force and stops the motor.
When the swing is stopped, the swing motor continues to rotate for a while due to inertial force.In order to make up the shortfall
in the oil volume, oil is supplied from the make-up line connected to the swing motor Mu port from the control valve T3 port to
open the make-up check valve and oil is suctioned in to prevent cavitation.
84402832 NA - May 2011

8020A-19
Swing parking circuit (lever in neutral)
84402832 NA - May 2011

8020A-20
Pilot pressure line
1 Swing motor 7 Check valve 13 Computer A

2 Cushion valve 8 Oil cooler 14 Control valve
3 Right swing 9 Lever lock 15 Upper pilot pressure sensor
4 Left swing 10 Swing brake 16 Hydraulic pump
When the key is switched ON, the swing brake solenoid valve is switched by the electrical signal from computer A.
The swing motor P port oil goes from the 4 stack solenoid valve C2 port through the swing brake solenoid, and returns to the
hydraulic oil tank to hold the swing parking brake.
84402832 NA - May 2011

8020A-21
Swing parking circuit (brake release)
84402832 NA - May 2011

8020A-22
Pilot pressure line
1 Swing motor 7 Swing 13 Control valve

2 Cushion valve 8 Lever lock 14 Upper pilot pressure sensor
3 Right swing 9 Swing brake 15 Hydraulic pump
4 Left swing 10 4 stack solenoid valve 16 Check valve
5 Swing pilot pressure sensor 11 Console lever lock switch 17 Oil cooler
6 Remote control valve (arm, swing) 12 Computer A
When the engine is started and the swing lever is in neutral, the swing brake solenoid valve comes ON (24 V input), the
pressure to the swing motor P port is cut, and the swing parking brake works.
When the lever operation raises the reading to 0.5 MPa or higher at the pressure sensor in the swing pilot line, the output from
computer A to the swing brake solenoid valve goes OFF, the swing motor PR port pressure rises, the swing parking brake is
released, and swing becomes possible.
As an example, this section explains the right swing operation.
By carrying out the right swing operation on the remote control valve, the pilot pressure oil is fed to the control valve pa3 port
via the shuttle valve and switches the swing spool to the right swing side.
At the same time, computer A detects the swing pilot pressure sensor signal, judges that there is a swing operation, the
electrical signal output from computer A goes OFF, and the swing brake solenoid valve is switched.The pilot pressure oil is
fed to the swing motor PR port from the swing brake solenoid valve C2 port to release the swing parking brake.
spool.
Switching the spool lets the oil flow into the swing motor A port and the right swing operation is carried out.
The pressurized oil from the swing motor B port goes through the swing spool and returns to the hydraulic oil tank.
When this is followed by an attachment operation, the pilot pressure is detected by the control valve PA port pressure sensor
and the swing parking brake continues to be released.
After the swing operation ends, if about 5 sec. pass with no upper operation, the swing brake solenoid valve output from
computer A comes ON and the swing parking brake works again.
After the swing ends, if this is followed by an upper operation or there is an upper operation within about 5 sec., when about
1 sec. passes after the end of the upper operation, the swing parking brake works again.
The swing parking brake is also released for independent upper operations and when about 1 sec. passes after the end of
the upper operation, the swing parking brake works again.
Swing pilot pressure Upper pilot pressure Swing brake solenoid Swing motor mechani-
Key switch
sensor sensor valve cal brake
OFF 0 MPa 0 MPa OFF ON
ON 0 MPa 0 MPa ON ON
ON 0.5 MPa min. 0 MPa OFF OFF
ON 0 MPa 0.5 MPa min. OFF OFF
ON 0.5 MPa min. 0.5 MPa min. OFF OFF
Pilot pressure sensor judgment standard

Operation is judged when at 0.5 MPa or above.
Non-operation is judged when at 0.3 MPa or below.
84402832 NA - May 2011

8020A-23
Swing parking circuit (machine stop)
84402832 NA - May 2011

8020A-24
Pilot pressure line
1 Swing motor 7 Check valve 13 Computer A

2 Cushion valve 8 Oil cooler 14 Control valve
3 Right swing 9 Lever lock 15 Upper pilot pressure sensor
4 Left swing 10 Swing brake 16 Hydraulic pump
When the machine is stopped (the key is switched OFF), the swing motor P port oil goes from the swing brake solenoid C2
port through the lever lock solenoid and returns to the hydraulic oil tank, holding the swing parking brake hold status.
84402832 NA - May 2011

8020A-25
Boom Circuit
Boom-up circuit (independent operation)
84402832 NA - May 2011

8020A-26
Pilot pressure line
1 Cushion valve 8 4 stack solenoid valve 15 Monitor display

2 Boom (up) 9 Control valve 16 Computer A
Boom load holding valve check
3 Boom (down) 10 17 P1 pressure sensor
valve
4 Boom (2) 11 Boom cylinder 18 P2 pressure sensor
Remote control valve (boom,
5 12 Travel pilot pressure sensor 19 Hydraulic pump
bucket)
6 Lever lock 13 Upper pilot pressure sensor 20 Check valve
7 Boost pressure relief 14 Console lever lock switch 21 Oil cooler
By operating the remote control valve to the boom-up side, the pilot pressure oil is fed via the cushion valve to the control
valve pa4 port and the boom (2) spool is switched.
At the same time, the pilot pressure oil from the pa4 port separated in the internal path is fed to the boom (1) pilot port and
switches the boom (1) spool to the up side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port, is fed from the parallel oil path to the boom (2)
spool and merges downstream of the boom (1) spool.
The discharge oil from hydraulic pump A2 is fed to the boom (1) spool via the parallel oil path, merges with the discharge
oil from boom (2), flows through the boom load holding valve check valve and into the boom cylinder bottom side and the
boom-up operation is carried out.
The boom cylinder rod side return oil goes through the boom (1) spool and returns into the hydraulic oil tank.
84402832 NA - May 2011

8020A-27
Boom-up circuit (independent operation) (with HBCV)
84402832 NA - May 2011

8020A-28
Pilot pressure line
1 Cushion valve 9 Control valve 17 P1 pressure sensor

2 Boom (up) 10 18 P2 pressure sensor
valve
3 Boom (down) 11 Boom cylinder 19 Hydraulic pump
4 Boom (2) 12 Travel pilot pressure sensor 20 Check valve
5 13 Upper pilot pressure sensor 21 Oil cooler
bucket)
6 Lever lock 14 Console lever lock switch 22 Boom HBCV check valve
7 Boost pressure relief 15 Monitor display
8 4 stack solenoid valve 16 Computer A
By operating the remote control valve to the boom-up side, the pilot pressure oil is fed via the cushion valve to the control
valve Pa4 port and the boom (2) spool is switched. At the same time, the pilot pressure oil from the Pa4 port separated in the
internal path is fed to the boom (1) pilot port and switches the boom (1) spool to the up side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port, is fed from the parallel oil path to the boom (2)
spool and merges downstream of the boom (1) spool. The discharge oil from hydraulic pump A2 is fed to the boom (1) spool
via the parallel oil path, merges with the discharge oil from boom (2), pushes open the boom load hold valve check valve,
flows through the boom cylinder HBCV check valve and into the bottom side, and the boom-up operation is carried out.
The boom cylinder rod side return oil goes through the boom (1) spool and returns into the hydraulic oil tank.
84402832 NA - May 2011

8020A-29
Boom-up circuit (compound boom-up + arm-in)
84402832 NA - May 2011

8020A-30
Pilot pressure line
1 Arm cylinder 12 Arm (1) 23 Upper pilot pressure sensor

2 Arm (in) 13 Boom (up) 24 Console lever lock switch
3 Arm (out) 14 Arm load holding valve spool 25 Monitor display
4 Boom (up) 15 Load holding valve check valve 26 Computer A
5 Boom (down) 16 Regeneration release valve 27 P1 pressure sensor
7 18 Swing priority variable orifice 29 Hydraulic pump
bucket)
8 Remote control valve (arm, swing) 19 Arm (2) 30 Check valve
9 Lever lock 20 31 Oil cooler
valve
10 Boost pressure relief 21 Boom cylinder
11 4 stack solenoid valve 22 Travel pilot pressure sensor
As an example, this section explains the boom-up + arm-in compound operation (leveling work).
For leveling work, the boom-up pilot pressure oil is fed to the pbu port, the swing priority variable orifice is moved to the left
side and the restriction on the flow to the arm is released to smooth the arm movement.
By operating the remote control valve to the boom-up side and arm-in side, the pilot pressure oil is fed via the cushion valve
to the control valve pa4 port and pb5 port and switches the boom (1) and arm (1) spools.
At the same time, pressurized oil separated from the boom (1) side pilot internal path is fed from the pa8 port to the pbu port
and the swing priority variable orifice spool is switched to the left side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the parallel oil path to the boom (2)
and arm (1) spools.
Because the swing priority variable orifice spool in the parallel oil path is moved, the restriction on flow to the arm is released
and the oil flows through the arm (1) spool and into the arm cylinder bottom side.
This makes arm-in operation movement smooth.
The arm cylinder rod side return oil goes through the load holding valve check valve and the arm (1) spool and returns to the
hydraulic oil tank.
spool.
Switching the spool lets the oil flow through the boom load holding valve check valve and into the boom cylinder bottom side
and the boom-up operation is carried out.
When the circuit has an HBCV, the discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the
parallel oil path to the boom (1) spool.
Switching the spool lets the oil flow through the boom load holding valve check valve and HBCV check valve and into the
boom cylinder bottom side and the boom-up operation is carried out.
The boom cylinder rod side return oil goes through the boom (1) spool and returns to the hydraulic oil tank.
84402832 NA - May 2011

8020A-31
Boom-up circuit (compound boom-up + arm-in) (with HBCV)
84402832 NA - May 2011

8020A-32
Pilot pressure line
1 Arm cylinder 12 Arm (1) 23 Upper pilot pressure sensor

2 Arm (in) 13 Boom (up) 24 Console lever lock switch
3 Arm (out) 14 Arm load holding valve spool 25 Monitor display
4 Boom (up) 15 Load holding valve check valve 26 Computer A
5 Boom (down) 16 Regeneration release valve 27 P1 pressure sensor
7 18 Swing priority variable orifice 29 Hydraulic pump
bucket)
8 Remote control valve (arm, swing) 19 Arm (2) 30 Check valve
9 Lever lock 20 31 Oil cooler
valve
10 Boost pressure relief 21 Boom cylinder 32 HBCV check valve
11 4 stack solenoid valve 22 Travel pilot pressure sensor
As an example, this section explains the boom-up + arm-in compound operation (leveling work).
For leveling work, the boom-up pilot pressure oil is fed to the pbu port, the swing priority variable orifice is moved to the left
side and the restriction on the flow to the arm is released to smooth the arm movement.
By operating the remote control valve to the boom-up side and arm-in side, the pilot pressure oil is fed via the cushion valve
to the control valve pa4 port and pb5 port and switches the boom (1) and arm (1) spools.
At the same time, pressurized oil separated from the boom (1) side pilot internal path is fed from the pa8 port to the pbu port
and the swing priority variable orifice spool is switched to the left side.
and arm (1) spools.
Because the swing priority variable orifice spool in the parallel oil path is moved, the restriction on flow to the arm is released
and the oil flows through the arm (1) spool and into the arm cylinder bottom side.
This makes arm-in operation movement smooth.
The arm cylinder rod side return oil goes through the load holding valve check valve and the arm (1) spool and returns to the
hydraulic oil tank.
spool.
Switching the spool lets the oil flow through the boom load holding valve check valve and into the boom cylinder bottom side
and the boom-up operation is carried out.
When the circuit has an HBCV, the discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the
parallel oil path to the boom (1) spool.
Switching the spool lets the oil flow through the boom load holding valve check valve and HBCV check valve and into the
boom cylinder bottom side and the boom-up operation is carried out.
The boom cylinder rod side return oil goes through the boom (1) spool and returns to the hydraulic oil tank.
84402832 NA - May 2011

8020A-33
Boom-down regenerative circuit
84402832 NA - May 2011

8020A-34
Pilot pressure line
1 Load holding valve check valve 9 Boom (down) 17 Boom cylinder

2 Check valve 10 18 Boom (1)
bucket)
3 Oil cooler 11 Lever lock 19 Travel pilot pressure sensor
4 P1 pressure sensor 12 Boost pressure relief 20 Upper pilot pressure sensor
5 Orifice 13 4 stack solenoid valve 21 Console lever lock switch
6 Bleed-off 14 Control valve 22 Monitor display
7 Cushion valve 15 P2 pressure sensor 23 Computer A
8 Boom (up) 16 Hydraulic pump
By moving the remote control valve to the boom-down side, the pilot pressure oil is fed via the cushion valve to the control
valve pb8 port and switches the boom (1) spool to the down side.
spool.
Switching the spool lets the oil flow into the boom cylinder rod side and the boom-down operation is carried out.
The pilot pressure oil from the pb8 port separated in the internal path is fed to the load holding valve spool and moves the
spool to the left.
In this way, the load holding valve check valve spring chamber oil is connected to the tank line through the load holding valve
spool, the spring chamber pressure drops, and the load holding valve check valve is opened.
When the circuit has an HBCV, the pilot pressure oil separated in the internal path operates on the HBCV PL port and switches
the spool.
This opens the HBCV check valve.
The boom cylinder bottom side pressurized oil goes through the load holding valve check valve (passes through the HBCV
check valve and goes through the load holding valve check valve when the circuit has an HBCV) and is metered by the boom
(1) spool regeneration orifice.
Through this, the return oil pushes open the check valve in the spool and is regenerated on the cylinder rod side.
The lower the cylinder rod side load pressure, the greater the volume of regeneration.
When the cylinder rod side load pressure becomes high, the check valve is closed and the cylinder bottom return oil goes
through the boom spool (1) without regeneration and returns to the hydraulic oil tank.
Because the circuit is configured in such a way that, even if the boom (1) spool is at full stroke, negative control pressure is
generated by the center bypass bleed-off oil path and the pump does not discharge full flow, the shortfall is made up for with
regeneration and engine output can be used effectively.
84402832 NA - May 2011

8020A-35
Boom-down regenerative circuit (with HBCV)
84402832 NA - May 2011

8020A-36
Pilot pressure line
1 Load holding valve check valve 9 Boom (down) 17 Boom cylinder

2 Check valve 10 18 Boom (1)
bucket)
3 Oil cooler 11 Lever lock 19 Travel pilot pressure sensor
4 P1 pressure sensor 12 Boost pressure relief 20 Upper pilot pressure sensor
5 Orifice 13 4 stack solenoid valve 21 Console lever lock switch
8 Boom (up) 16 Hydraulic pump 24 Boom HBCV check valve
valve pb8 port and switches the boom (1) spool to the down side.
spool.
Switching the spool lets the oil flow into the boom cylinder rod side and the boom-down operation is carried out.
spool to the left.
When the circuit has an HBCV, the pilot pressure oil separated in the internal path operates on the HBCV PL port and switches
the spool.
The boom cylinder bottom side pressurized oil goes through the load holding valve check valve (passes through the HBCV
check valve and goes through the load holding valve check valve when the circuit has an HBCV) and is metered by the boom
(1) spool regeneration orifice.
Through this, the return oil pushes open the check valve in the spool and is regenerated on the cylinder rod side.
The lower the cylinder rod side load pressure, the greater the volume of regeneration.
When the cylinder rod side load pressure becomes high, the check valve is closed and the cylinder bottom return oil goes
through the boom spool (1) without regeneration and returns to the hydraulic oil tank.
Because the circuit is configured in such a way that, even if the boom (1) spool is at full stroke, negative control pressure is
generated by the center bypass bleed-off oil path and the pump does not discharge full flow, the shortfall is made up for with
regeneration and engine output can be used effectively.
84402832 NA - May 2011

8020A-37
Boom-down tilting prevention circuit
84402832 NA - May 2011

8020A-38
Pilot pressure line
1 Load holding valve check valve 9 Lever lock 17 Travel pilot pressure sensor
2 Check valve 10 Boost pressure relief 18 Upper pilot pressure sensor
3 Oil cooler 11 4 stack solenoid valve 19 Console lever lock switch
6 Boom (up) 14 Hydraulic pump 22 P1 pressure sensor
7 Boom (down) 15 Boom cylinder
8 16 Boom (1)
bucket)
By operating the remote control valve all the way to the boom-down side at once, even if the boom spool goes its full stroke,
negative control pressure is generated by the center bypass bleed-off oil path and the circuit is such that the hydraulic pump
does not discharge full flow, so the generation of high pressure is restrained and main unit tilt is reduced.
Since the shortfall in the oil volume is compensated by the regenerative circuit, the engine output can be used effectively.
84402832 NA - May 2011

8020A-39
Boom-down tilting prevention circuit (with HBCV)
84402832 NA - May 2011

8020A-40
Pilot pressure line
1 Load holding valve check valve 9 Lever lock 17 Travel pilot pressure sensor
2 Check valve 10 Boost pressure relief 18 Upper pilot pressure sensor
3 Oil cooler 11 4 stack solenoid valve 19 Console lever lock switch
6 Boom (up) 14 Hydraulic pump 22 P1 pressure sensor
7 Boom (down) 15 Boom cylinder 23 Boom HBCV check valve
8 16 Boom (1)
bucket)
By operating the remote control valve all the way to the boom-down side at once, even if the boom spool goes its full stroke,
negative control pressure is generated by the center bypass bleed-off oil path and the circuit is such that the hydraulic pump
does not discharge full flow, so the generation of high pressure is restrained and main unit tilt is reduced.
Since the shortfall in the oil volume is compensated by the regenerative circuit, the engine output can be used effectively.
84402832 NA - May 2011

8020A-41
Boom-down load holding valve circuit
84402832 NA - May 2011

8020A-42
Pilot pressure line

1 9 4 stack solenoid valve 17 Console lever lock switch
valve
2 Load holding valve spool 10 Control valve 18 Monitor display
3 Cushion valve 11 Check valve 19 Computer A
4 Boom (up) 12 Oil cooler 20 P1 pressure sensor
5 Boom (down) 13 Boom cylinder 21 P2 pressure sensor
6 14 Boom (1) 22 Hydraulic pump
bucket)
7 Lever lock 15 Travel pilot pressure sensor
8 Boost pressure relief 16 Upper pilot pressure sensor
When the remote control valve boom operation lever is in neutral, the oil at the boom cylinder bottom side is sealed by the
load holding valve check valve, reducing internal leakage from the main spool and reducing the natural drop of the boom.
valve pb8 port and switches the boom spool to the down side.
The discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the parallel oil path to the boom (1).
Switching the spool lets the oil flow into the boom cylinder bottom side and the boom-down operation is carried out.
spool to the left.
The boom cylinder bottom side pressurized oil goes through the load holding valve check valve and the boom (1) spool and
returns to the hydraulic oil tank.
84402832 NA - May 2011

8020A-43
Boom-down load holding valve circuit (with HBCV)
84402832 NA - May 2011

8020A-44
Pilot pressure line

1 9 4 stack solenoid valve 17 Console lever lock switch
valve
2 Load holding valve spool 10 Control valve 18 Monitor display
3 Cushion valve 11 Check valve 19 Computer A
4 Boom (up) 12 Oil cooler 20 P1 pressure sensor
5 Boom (down) 13 Boom cylinder 21 P2 pressure sensor
6 14 Boom (1) 22 Hydraulic pump
bucket)
7 Lever lock 15 Travel pilot pressure sensor 23 Boom HBCV check valve
8 Boost pressure relief 16 Upper pilot pressure sensor
When the remote control valve boom operation lever is in neutral, the oil at the boom cylinder bottom side is sealed by the
load holding valve check valve, reducing internal leakage from the main spool and reducing the natural drop of the boom.
valve pb8 port and switches the boom spool to the down side.
The discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the parallel oil path to the boom (1).
Switching the spool lets the oil flow into the boom cylinder bottom side and the boom-down operation is carried out.
spool to the left.
The boom cylinder bottom side pressurized oil goes through the load holding valve check valve and the boom (1) spool and
returns to the hydraulic oil tank.
84402832 NA - May 2011

8020A-45
Arm Circuit
Arm-out circuit
84402832 NA - May 2011

8020A-46
Pilot pressure line
1 Arm cylinder 9 Control valve 17 Computer A

2 Arm (in) 10 Load holding valve check valve 18 P1 pressure sensor
3 Arm (out) 11 Arm (1) 19 P2 pressure sensor
4 Cushion valve 12 Arm (2) 20 Hydraulic pump
5 Remote control valve (arm, swing) 13 Travel pilot pressure sensor 21 Check valve
6 Lever lock 14 Upper pilot pressure sensor 22 Oil cooler
7 Boost pressure relief 15 Console lever lock switch
8 4 stack solenoid valve 16 Monitor display
By moving the remote control valve to the arm-out side, the pilot pressure oil is fed via the cushion valve to the control valve
pa5 port and pa9 port and switches the arm (1) and (2) spools to the out side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the center bypass oil path to the
arm (1) spool.
The discharge oil from hydraulic pump A2 enters the control valve P2 port, flows from the center bypass oil path and through
the arm (2) spool front arm merge oil path and merges upstream of the arm (1) spool.
Switching the arm spool lets the oil flow through the load holding valve check valve and into the arm cylinder rod side, carrying
out the arm-out operation.
When the circuit has an HBCV, switching the arm spool lets the oil flow through the load holding valve check valve to push
open the arm cylinder HBCV check valve and flow into the rod side, carrying out the arm-out operation.
The arm cylinder bottom side return oil goes through the arm (1) and (2) spools and returns to the hydraulic oil tank.
84402832 NA - May 2011

8020A-47
Arm-out circuit (with HBCV)
84402832 NA - May 2011

8020A-48
Pilot pressure line
1 Arm cylinder 9 Control valve 17 Computer A

2 Arm (in) 10 Load holding valve check valve 18 P1 pressure sensor
6 Lever lock 14 Upper pilot pressure sensor 22 Oil cooler
7 Boost pressure relief 15 Console lever lock switch 23 Arm HBCV check valve
8 4 stack solenoid valve 16 Monitor display 24 Arm HBCV
By moving the remote control valve to the arm-out side, the pilot pressure oil is fed via the cushion valve to the control valve
pa5 port and pa9 port and switches the arm (1) and (2) spools to the out side.
arm (1) spool.
Switching the arm spool lets the oil flow through the load holding valve check valve and into the arm cylinder rod side, carrying
out the arm-out operation.
When the circuit has an HBCV, switching the arm spool lets the oil flow through the load holding valve check valve to push
open the arm cylinder HBCV check valve and flow into the rod side, carrying out the arm-out operation.
The arm cylinder bottom side return oil goes through the arm (1) and (2) spools and returns to the hydraulic oil tank.
84402832 NA - May 2011

8020A-49
Arm-in forced regenerative circuit
84402832 NA - May 2011

8020A-50
Pilot pressure line
1 Load holding valve spool 10 Cushion valve 19 Travel pilot pressure sensor
2 Load holding valve check valve 11 Remote control valve (arm, swing) 20 Upper pilot pressure sensor
3 Oil cooler 12 Lever lock 21 Console lever lock switch
4 Regeneration check valve 13 Boost pressure relief 22 Monitor display
5 Metering large 14 4 stack solenoid valve 23 Computer A
6 Metering small 15 Control valve 24 P1 pressure sensor
7 Forced regeneration release valve 16 Arm cylinder 25 P2 pressure sensor
8 Arm (in) 17 Arm (1) 26 Hydraulic pump
9 Arm (out) 18 Arm (2) 27 Check valve
By moving the remote control valve to the arm-in side, the pilot pressure oil is fed via the cushion valve to the control valve
pb5 port and pb9 port and switches the arm (1) and (2) spools to the in side.
arm (1) spool.
Switching the arm spool lets the oil flow into the arm cylinder bottom side and the arm-in operation is carried out.
spool to the right.
The arm cylinder rod side pressurized oil goes through the load holding valve check valve and the arm (1) spool and is metered
by the forced regeneration release valve.Through this, the return oil pushes open the check valve in the arm (1) spool and is
forcibly regenerated on the cylinder bottom side, securing the arm speed for leveling work etc.
When the cylinder bottom load pressure becomes high, the forced regeneration release valve is switched to the large metering
side and the opening becomes larger.
Through this, the check valve in the spool is closed and the cylinder rod side return oil returns to the hydraulic oil tank via the
arm spool (1) and forced regeneration release valve without being regenerated.
84402832 NA - May 2011

8020A-51
Arm-in forced regenerative circuit (with HBCV)
84402832 NA - May 2011

8020A-52
Pilot pressure line
1 Load holding valve spool 11 Remote control valve (arm, swing) 21 Console lever lock switch
2 Load holding valve check valve 12 Lever lock 22 Monitor display
3 Oil cooler 13 Boost pressure relief 23 Computer A
4 Regeneration check valve 14 4 stack solenoid valve 24 P1 pressure sensor
5 Metering large 15 Control valve 25 P2 pressure sensor
6 Metering small 16 Arm cylinder 26 Hydraulic pump
7 Forced regeneration release valve 17 Arm (1) 27 Check valve
8 Arm (in) 18 Arm (2) 28 Arm HBCV check valve
9 Arm (out) 19 Travel pilot pressure sensor 29 Arm HBCV
10 Cushion valve 20 Upper pilot pressure sensor
arm (1) spool.
spool to the right.
The arm cylinder rod side pressurized oil goes through the load holding valve check valve and the arm (1) spool and is metered
by the forced regeneration release valve.Through this, the return oil pushes open the check valve in the arm (1) spool and is
forcibly regenerated on the cylinder bottom side, securing the arm speed for leveling work etc.
When the cylinder bottom load pressure becomes high, the forced regeneration release valve is switched to the large metering
side and the opening becomes larger.
Through this, the check valve in the spool is closed and the cylinder rod side return oil returns to the hydraulic oil tank via the
arm spool (1) and forced regeneration release valve without being regenerated.
84402832 NA - May 2011

8020A-53
Arm-in load holding valve circuit
84402832 NA - May 2011

8020A-54
Pilot pressure line
1 Load holding valve spool 9 Boost pressure relief 17 Console lever lock switch
2 Load holding valve check valve 10 4 stack solenoid valve 18 Monitor display
3 Oil cooler 11 Control valve 19 Computer A
4 Arm (in) 12 Arm cylinder 20 P1 pressure sensor
8 Lever lock 16 Upper pilot pressure sensor
When the remote control valve arm operation lever is in neutral, the oil at the arm cylinder rod side is sealed by the load
holding valve check valve, reducing internal leakage from the main spool and reducing the natural drop of the arm.
arm (1) spool.
spool to the right.
The arm cylinder rod side pressurized oil goes through the load holding valve check valve and the arm (1) spool and returns
to the hydraulic oil tank.
84402832 NA - May 2011

8020A-55
Arm-in load holding valve circuit (with HBCV)
84402832 NA - May 2011

8020A-56
Pilot pressure line
1 Load holding valve spool 10 4 stack solenoid valve 19 Computer A

2 Load holding valve check valve 11 Control valve 20 P1 pressure sensor
3 Oil cooler 12 Arm cylinder 21 P2 pressure sensor
4 Arm (in) 13 Arm (1) 22 Hydraulic pump
5 Arm (out) 14 Arm (2) 23 Check valve
6 Cushion valve 15 Travel pilot pressure sensor 24 Arm HBCV check valve
7 Remote control valve (arm, swing) 16 Upper pilot pressure sensor 25 Arm HBCV
8 Lever lock 17 Console lever lock switch
When the remote control valve arm operation lever is in neutral, the oil at the arm cylinder rod side is sealed by the load hold
valve check valve, reducing internal leakage from the main spool and reducing the natural drop of the arm.
Pb5 port and Pb9 port and switches the arm (1) and (2) spools to the in side.
arm (1) spool. The discharge oil from hydraulic pump A2 enters the control valve P2 port, flows from the center bypass oil
path and through the arm (2) spool front arm merge oil path and merges upstream of the arm (1) spool.
Switching the arm spool lets the oil flow into the arm cylinder bottom side and carries out the arm-in operation.
The pilot pressure oil from the Pb5 port separated in the internal path flows into the HBCV PL port and switches the spool.
The pilot pressure oil from the Pb5 port separated in the internal path is fed to the load hold valve spool and moves the spool
to the right. In this way, the load hold valve check valve spring chamber oil is connected to the tank line through the load hold
valve spool, the spring chamber pressure drops, and the load hold valve check valve is opened.
The arm cylinder rod side pressurized oil goes through the HBCV check valve, load hold valve check valve and the arm (1)
spool and returns to the hydraulic oil tank.
84402832 NA - May 2011

8020A-57
Bucket Circuit
Bucket-open circuit
84402832 NA - May 2011

8020A-58
Pilot pressure line
1 Cushion valve 8 Control valve 15 Computer A

2 Bucket (close) 9 Bucket 16 P1 pressure sensor
3 Bucket (open) 10 Bucket cylinder 17 P2 pressure sensor
4 11 Travel pilot pressure sensor 18 Hydraulic pump
bucket)
5 Lever lock 12 Upper pilot pressure sensor 19 Check valve
6 Boost pressure relief 13 Console lever lock switch 20 Oil cooler
7 4 stack solenoid valve 14 Monitor display
By moving the remote control valve to the bucket-open side, the pilot pressure oil is fed via the cushion valve to the control
valve pa7 port and switches the bucket spool to the open side.
The discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the parallel oil path to the bucket
spool.
Switching the spool lets the oil flow into the bucket cylinder rod side and the bucket-open operation is carried out.
The bucket cylinder bottom side pressurized oil goes through the bucket spool and returns to the hydraulic oil tank.
84402832 NA - May 2011

8020A-59
Bucket-close regenerative circuit
84402832 NA - May 2011

8020A-60
Pressure line Pilot tank line pressure, the greater the volume of regeneration. When the cylinder rod side load pressure becomes high, the check valve is
Tank line Electric line closed and the cylinder bottom side return oil goes through the bucket spool without regeneration and returns to the hydraulic
Pilot pressure line oil tank.
1 Regeneration check valve 9 Boost pressure relief 17 Monitor display

2 Oil cooler 10 4 stack solenoid valve 18 Computer A
3 Orifice 11 Control valve 19 P1 pressure sensor
4 Cushion valve 12 Bucket 20 P2 pressure sensor
5 Bucket (close) 13 Bucket cylinder 21 Hydraulic pump
6 Bucket (open) 14 Travel pilot pressure sensor 22 Check valve
7 15 Upper pilot pressure sensor
bucket)
8 Lever lock 16 Console lever lock switch
By moving the remote control valve to the bucket-close side, the pilot pressure oil is fed via the cushion valve to the control
valve pb7 port and switches the bucket spool to the close side.
The discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the parallel oil path to the bucket
spool. Switching the spool lets the oil flow into the bucket cylinder bottom and the bucket-close operation is carried out.
The bucket cylinder rod side pressurized oil is metered by the bucket spool regeneration orifice.Through this, the return oil
pushes open the check valve in the spool and is regenerated on the cylinder bottom side. The lower the cylinder rod side load
84402832 NA - May 2011

8020A-61
Negative Control Circuit

Negative Control Circuit
84402832 NA - May 2011

8020A-62
Pilot pressure line Negative control line

1 P1 negative control relief 7 Console lever lock switch 13
valve
2 P2 negative control relief 8 Lever lock 14 P1 flow control proportional valve
3 Control valve 9 4 stack solenoid valve 15 Hydraulic pump
4 Travel pilot pressure sensor 10 P1 pressure sensor 16 Check valve
5 Upper pilot pressure sensor 11 P2 pressure sensor 17 Oil cooler
N2 negative control pressure sen-
6 Computer A 12
sor
When the remote control valve operation lever is set to neutral, the discharge oil from hydraulic pumps A1 and A2 goes from
the control valve P1 and P2 ports through the center bypass oil path, and through the negative control relief valve, and returns
The negative control pressure oil separated from the center bypass oil path is fed from the Ps1 and Ps2 ports to the hydraulic
pump Pi1 and Pi2 ports, moves the pump tilting to the minimum flow side, and the pump discharge flow is reduced.
84402832 NA - May 2011

8020A-63
Horsepower Boost Circuits

Arm-in Horsepower Boost Circuit
84402832 NA - May 2011

8020A-64
Pilot pressure line
1 Arm (in) 9 Arm pilot pressure sensor 17 Computer A

2 Arm (out) 10 Control valve 18 P1 pressure sensor
3 Cushion valve 11 Arm (1) 19 P2 pressure sensor
4 Remote control valve (arm, swing) 12 Arm (2) 20
sor
5 Lever lock 13 Travel pilot pressure sensor 21 Hydraulic pump
6 Boost pressure relief 14 Upper pilot pressure sensor 22 Check valve
7 4 stack solenoid valve 15 Console lever lock switch 23 Oil cooler
8 Arm cylinder 16 Monitor display
For the arm-in operation, the horsepower boost signal is output to the hydraulic pump horsepower control proportional valve
from computer A by the arm pilot pressure sensor input signal and P1 pressure sensor and P2 pressure sensor input signals.
The hydraulic pump discharged volume is increased by the horsepower boost signal to the horsepower control proportional
valve from computer A.
Condition under which the arm-in horsepower boost control is entered
Arm-in pilot pressure 0.5 MPa {72.5 psi} or higher (arm-in operation)
P1＋P2 45 MPa {6527 psi}
Conditions under which the arm-in horsepower boost control is ended
Arm-in pilot pressure 0.3 MPa {43.5 psi} or lower (arm-in operation end)
P1＋P2 45 MPa {6527 psi}
When either occurs
84402832 NA - May 2011

8020A-65
Travel Horsepower Boost Circuit
84402832 NA - May 2011

8020A-66
Pilot pressure line
1 Travel motor 9 Control valve 17 Computer A

2 Travel remote control valve 10 Travel (left) 18 P1 pressure sensor
3 Travel high speed 11 Travel (right) 19 P2 pressure sensor
4 Lever lock 12 Travel pilot pressure sensor 20
sor
5 4 stack solenoid valve 13 P1 pressure sensor 21 Hydraulic pump
6 Console lever lock switch 14 P2 pressure sensor 22 Check valve
7 Travel high-speed select switch 15 Console lever lock switch 23 Oil cooler
8 Computer A 16 Monitor display
Travel Horsepower Boost Circuit

For travel single operation, the horsepower boost signal is output to the hydraulic pump horsepower control proportional valve
from computer A by the travel pilot pressure sensor input signal.
The hydraulic pump discharged volume is increased by the horsepower boost signal to the horsepower control proportional
valve from computer A.
Conditions under which the travel horsepower boost control is entered
Travel pilot pressure 0.5 MPa {72.5 psi} or higher.
SP mode
Conditions under which the travel horsepower boost control is ended
Travel pilot pressure 0.3 MPa {43.5 psi} or lower.
AUTO mode, H mode
84402832 NA - May 2011

8020A-67
Other Circuits
As examples, this section explains the cases when an arm-out operation is carried out, when an arm-out operation is stopped,
and when an arm-out operation is followed by an arm-in operation.
Cushion circuit (arm-out operation)
84402832 NA - May 2011

8020A-68
Pilot pressure line
1 Arm (in) 7 Remote control valve (arm, swing) 13 Console lever lock switch
2 Arm (out) 8 Lever lock 14 Hydraulic pump
3 Cushion spool 9 4 stack solenoid valve 15 Check valve
4 Orifice 10 Control valve 16 Oil cooler
5 Check valve 11 Arm (1)
6 Cushion valve 12 Arm (2)
When a remote control valve arm-out operation is carried out, the pilot pressure oil enters from the remote control valve 2 port
into the cushion valve, pushes up the internal check valve, and is fed to the control valve pa5 and pa9 ports.
At the same time, the cushion valve cushion spool is switched to the left.
The arm-in side oil pushed out from the control valve pb9 and pb5 ports passes from the cushion valve B port through the
cushion spool switched to the left and returns to the hydraulic oil tank.
At this time, the warmed oil from the return line enters the remote control valve through the cushion spool from the cushion
valve R port and returns to the hydraulic oil tank, so heat performance is improved.
84402832 NA - May 2011

8020A-69
Cushion circuit (arm-out operation stopped)
84402832 NA - May 2011

8020A-70
Pilot pressure line
1 Arm (in) 6 Remote control valve (arm, swing) 11 Arm (2)

2 Arm (out) 7 Lever lock 12 Console lever lock switch
3 Cushion spool 8 4 stack solenoid valve 13 Hydraulic pump
4 Orifice 9 Control valve 14 Check valve
5 Cushion valve 10 Arm (1) 15 Oil cooler
When the remote control valve arm-out operation is returned to neutral, the oil pushed out from the control valve pa5 and pa9
ports flows to the cushion valve D port through the cushion orifice and returns from the remote control valve to the hydraulic
oil tank.
Through this orifice, the arm spool moves to the neutral position without returning sharply, so the cushioning is improved.
84402832 NA - May 2011

8020A-71
Cushion circuit (arm-out → arm-in operation)
84402832 NA - May 2011

8020A-72
Pilot pressure line
1 Arm (in) 6 Remote control valve (arm, swing) 11 Arm (2)

2 Arm (out) 7 Lever lock 12 Console lever lock switch
3 Cushion spool 8 4 stack solenoid valve 13 Hydraulic pump
4 Orifice 9 Control valve 14 Check valve
5 Cushion valve 10 Arm (1) 15 Oil cooler
When the lever is operating all at once from an arm-out operation to an arm-in operation (arm rattling operation), the pilot
pressure oil is fed from the remote control valve 2 port into the cushion valve A port, pushes up the internal check valve, and
reaches the control valve pb5 port and pb9 port.
At the same time, the cushion valve cushion spool is switched to the right.
At this time, the oil pushed out from the pa5 and pa9 ports does not pass through the cushion orifice, but passes through the
cushion spool that has been switched to the right and returns to the hydraulic oil tank, so response is improved.
84402832 NA - May 2011

8020A-73
Heat circuit (lever in neutral)
84402832 NA - May 2011

8020A-74
Pilot pressure line
1 Arm (in) 5 Lever lock 9 Hydraulic pump

2 Arm (out) 6 4 stack solenoid valve 10 Check valve
3 Cushion valve 7 Control valve 11 Oil cooler
The pilot line is equipped with a heat circuit to prevent response delay at low temperatures.
When the remote control valve operation lever is set to neutral, the discharge oil from hydraulic pumps A1 and A2 goes from
the control valve P1 and P2 ports through the center bypass oil path, and returns to the hydraulic oil tank.
The pressurized oil from the control valve T8 port is fed to the cushion valve R port and returns through the cushion spool to
the hydraulic oil tank.
By circulating the oil inside the cushion spool, the temperature of the oil in the cushion valve is raised to improve heat perfor-
mance.
84402832 NA - May 2011

8020A-75
Auto pressure boost circuit (bucket close)
84402832 NA - May 2011

8020A-76
Pilot pressure line

2 Bucket (close) 9 Bucket 16 P2 pressure sensor
3 Bucket (open) 10 Bucket cylinder 17 Hydraulic pump
4 11 Upper pilot pressure sensor 18 Check valve
bucket)
5 Lever lock 12 Console lever lock switch 19 Oil cooler
7 4 stack solenoid valve 14 Computer A
When an attachment is operated, this circuit boosts the control valve main relief set pressure from 34.3 MPa to 36.8 MPa
according to the engine load ratio and hydraulic load pressure, then ends the pressure boost after 8 sec.
As an example, this section explains bucket-close operations.
By moving the remote control valve to the bucket-close side, the pilot pressure oil is fed via the cushion valve to the control
valve pb7 port and switches the bucket spool to the close side.
At the same time, the output signal from the upper pilot pressure sensor that detected the pressurized oil separated from the
pilot internal path is input to computer A, which judges that there is upper operation.
Furthermore, computer A judges that there is a boost in the main pump P1 and P2 pressure, outputs the ON (24 V) signal to
the pressure boost relief solenoid, switches the valve, and the pilot pressure oil is fed to the control valve main relief valve PH
port to hold the pressure boost relief set pressure for 8 sec.
There is no boost for the option circuit and during travel operation.
84402832 NA - May 2011

8020A-77
84402832 NA - May 2011

8020A-78
Section
8020B
Explanation of Hydraulic Circuit and Operations (option)
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS Double-acting circuit (hydraulic fork). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Multi-purpose circuit (breaker Q control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Multi-purpose circuit (2 pumps flow crusher) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Option Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2nd option circuit (hydraulic rotation fork) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Breaker circuit (independent operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Option Circuits
Breaker circuit (independent operation)
84402832 NA - May 2011

8020B-2
Pilot pressure line
1 Control valve 8 Monitor display 15 P1 pressure sensor

2 Manifold 9 Breaker switch 16 P2 pressure sensor
3 Relief valve 10 Option remote control valve 17
sor
4 Breaker 11 Option pilot pressure switch 18 P1 flow control proportional valve
5 Travel pilot pressure sensor 12 Console lever lock switch 19 Hydraulic pump
6 Upper pilot pressure sensor 13 Lever lock 20 Check valve
7 Computer A 14 4 stack solenoid valve 21 Oil cooler
By operating the option remote control valve to the breaker side, the pilot pressure oil is fed to the control valve pa2 port and
switches the option spool.
The discharge oil from hydraulic pump A1 is fed from the control valve P1 port through the parallel oil path and fed to the
option spool.
Switching the spool lets the oil flow from the relief valve A port through the B port and into the breaker.
The breaker set pressure is set by this relief valve.
At this time, the option pilot pressure switch signal is detected, the P1 flow control proportional valve is controlled by the output
signals from the computer A to adjust the discharge flow.
The return oil from the breaker goes through the manifold and returns to the hydraulic oil tank.
Because the breaker operating flow can be set to 5 levels on the service support screen of the monitor display with the ON
signal from the breaker switch in the cab, the optimum operating flow can be selected.
84402832 NA - May 2011

8020B-3
Double-acting circuit (hydraulic fork)
84402832 NA - May 2011

8020B-4
Pilot pressure line
1 Control valve 6 Computer A 11 Option remote control valve

2 Hydraulic fork 7 Lever Lock 12 Option pilot pressure switch
3 Travel pilot pressure sensor 8 4 stack solenoid valve 13 Check valve
4 Upper pilot pressure sensor 9 Console lever lock switch 14 Oil cooler
5 Monitor display 10 Hydraulic pump
As an example, this section explains the case in which the hydraulic fork attachment is used.
By operating the option remote control valve to the fork close side, the pilot pressure oil is fed to the control valve pa2 port
and switches the option spool to the close side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port, is fed from the parallel oil path to the option spool,
flows into the hydraulic fork because of the option spool switching and operates to the close side.
At this time, the option pilot pressure switch signal is detected and the auto idle function is released.
The return oil from the hydraulic fork goes through the option spool and returns to the hydraulic oil tank.
84402832 NA - May 2011

8020B-5
Multi-purpose circuit (breaker Q control)
84402832 NA - May 2011

8020B-6
Pilot pressure line
1 Control valve 8 Computer A 15 P1 pressure sensor

2 3-direction valve 9 Monitor display 16 P2 pressure sensor
3 Shut-off valve 10 Option switchover solenoid valve 17
sor
4 Breaker 11 Console lever lock switch 18 P1 flow control proportional valve
5 Option remote control valve 12 Lever lock 19 Hydraulic pump
6 Option pilot pressure switch 13 4 stack solenoid valve 20 Check valve
7 Multi-purpose circuit switch 14 21 Oil cooler
valve
When the switch in the cab is flipped to the breaker side, the ON signal (24 V) is output from the computer A to the option
switchover solenoid valve to switch the valve.
The pilot pressure oil flows from the option switchover solenoid valve B1 port to the A1 port and is fed to the 3-direction valve
PP port and shut-off valve PP port and each valve is switched.
Always switch the 2 pumps flow select switch to the 1 pump side.
By operating the option remote control valve to the breaker side, the pilot pressure oil is fed to the control valve pa2 port and
switches the option spool.
option spool.
Switching the spool lets the oil flow from the shut-off valve A port through the B port and into the breaker.
The breaker set pressure is set by the relief valve built into the shut-off valve.
The return oil from the breaker returns from the 3-direction valve A1 port through the T1 port and to the hydraulic oil tank.
Because the breaker operating flow can be set to 5 levels on the service support screen of the monitor display, the optimum
operating flow can be selected.
84402832 NA - May 2011

8020B-7
Multi-purpose circuit (2 pumps flow crusher)
84402832 NA - May 2011

8020B-8
Pilot pressure line
1 3-direction valve 10 Monitor display 19 4 stack solenoid valve

2 Shut-off valve 11 Computer A 20 Console lever lock switch
3 Crusher 12 Multi-purpose circuit switch 21
valve
4 Option switchover solenoid valve 13 2 pumps flow select switch 22 P1 pressure sensor
5 2 pumps flow solenoid valve 14 Control valve 23 P2 pressure sensor
6 Option remote control valve 15 Neutral cut valve 24
sor
7 Check valve 16 Travel pilot pressure sensor 25 P1 flow control proportional valve
8 Oil cooler 17 Upper pilot pressure sensor 26 Hydraulic pump
9 Option pilot pressure switch 18 Lever lock
When the 2 pumps flow select switch in the cab is flipped to the 2 pumps flow side, the ON signal (24 V) is output from the
computer A to the 2 pumps flow solenoid valve to switch the valve.
When the multi-purpose circuit switch is flipped to the crusher side, the crusher circuit is formed without outputting a signal
from the computer A to the option switchover solenoid valve and without switching the valve.
At this time, the pilot signal does not go to the 3-direction valve or to the shut-off valve and the 3-direction valve forms the A
⇔ B circuit.
By operating the option remote control valve to the crusher close side, the pilot pressure oil is fed to the control valve pa2 port
and switches the option spool.
At the same time, the pilot pressure oil flows from the solenoid valve for 2 pumps flow B2 port to the A2 port and is fed to the
control valve pcc port and the control valve neutral cut valve is switched.
The discharge oil from hydraulic pump A2 enters the control valve P2 port and goes through the center bypass oil path and
since the neutral cut valve has closed the port to the tank, the oil goes from the P3 port via the P4 port and merges on the
upstream side of the option spool.
option spool.
Switching the spool lets the oil flow from the shut-off valve A port through the B port and into the crusher.
The return oil from the crusher returns from the 3-direction valve A port through the B port and the option spool and returns
Because the crusher operating flow can be set to 5 levels on the service support screen of the monitor display, the optimum
operating flow can be selected.
84402832 NA - May 2011

8020B-9
2nd option circuit (hydraulic rotation fork)
84402832 NA - May 2011

8020B-10
Pilot pressure line
1 Control valve 6 Console lever lock switch 11 2nd option pilot pressure switch
2 Travel pilot pressure sensor 7 2nd option remote control valve 12 Monitor display
3 Upper pilot pressure sensor 8 Check valve 13 Computer A
4 Lever lock 9 Oil cooler 14 4th pump
5 4 stack solenoid valve 10 Hydraulic rotation fork 15 Hydraulic pump
As an example, this section explains the case in which the hydraulic rotation fork attachment is used.
By operating the 2nd option remote control valve to the right swing side, the pilot pressure oil is fed to the control valve par1
port.
The 4th hydraulic pump OUT discharge oil is fed to the control valve Pr port, goes through the 2nd option spool and flows to
the hydraulic rotation fork to operate to the right swing side.
At this time, the 2nd option pilot pressure switch signal is detected and the auto idle function is released.
The return oil from the hydraulic rotation fork goes through the 2nd option spool and returns to the hydraulic oil tank.
The oil in the 2nd option drain line returns to the hydraulic oil tank without going through the control valve.
84402832 NA - May 2011

8020B-11
This page is intentionally left blank
84402832 NA - May 2011

8020B-12
Section
8030A
Structure and Operation Explanation of Hydraulic Pump
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Structure and operation explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Hydraulic Pump Internal Structure Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overall view. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Drive shaft front side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Drive shaft rear side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Part table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Gear pump internal structure diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Structure and Operation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Structure and operation explanation

This pump has a structure in which 2 pumps are coupled by the 1st gear (116) and the 2 pumps can be driven at the
same time through the rotation of the power source being transmitted to the drive shaft F (111) on the front side. The
oil suction and discharge port are located in the connection section of the 2 pumps (specifically, the valve block (312)),
and the suction port is used in common by the front pump and rear pump. Pump structure and operation principles
are the same for the front and rear pumps. The front pump is explained below.
The pump can be roughly divided into the rotary group, which is the main part of the pump that performs rotation, the
swash plate group, which changes the discharge flow, and the valve cover group, which switches between oil suction
and discharge.
The rotary group is made up of the drive shaft F (111), cylinder block (141), piston shoes (151) (152), holder plate
(153), spherical bushing (156), and cylinder spring (157). The drive shaft is supported at both ends with bearings (123)
(124). Along with being caulked to the piston to form a spherical joint, the shoe has a pocket section for balancing
the hydraulic pressure in order to reduce the thrust force generated by the load pressure and allow the shoe to slide
lightly on the shoe plate (211).The piston shoe sub-group is pressed against the shoe plate by the cylinder spring
via the holder plate and spherical bushing so that it can slide smoothly on the shoe plate. Also, in the same way the
cylinder block is pressed against the valve plate (314) by the cylinder spring.
The swash plate group comprises the swash plate (212), shoe plate (211), swash plate support board (251), tilting
bushing (214), tilting pin (531), and servo piston (532). The swash plate is supported by the swash plate support board
at the cylindrically shaped section formed by the opposite side of the shoe sliding surface. By leading the hydraulic
pressure force controlled by the regulator into the hydraulic pressure chambers on both sides of the servo piston, the
servo piston moves left and right. This moves the swash plate on the swash plate support board via the tilting pin
spherical section and changes the tilting angle (α).
The valve cover group comprises the valve block (312), valve plates (313) (314), and valve plate pin (885). The valve
plate, which has 2 oval-shaped ports, is installed on the valve block. Its function is to feed oil to the cylinder block
and recover it from the cylinder block. The oil switched by the valve plate is connected through the valve block to the
outside lines.
Now when the drive shaft is driven by the power source (motor, engine, etc.), the cylinder block is also rotated at the
same time via the spline coupling. When the swash plate tilts, the piston located at the center of the cylinder block
moves reciprocally relative to the cylinder while turning with the cylinder block.
Therefore, if just one piston is looked at, during one cylinder block rotation the piston moves away from the valve plate
(oil intake stroke) for 180° and then moves toward the valve plate (oil discharge stroke) for the remaining 180°. When
the swash plate tilting angle is 0°, the piston does not move through a stroke and oil is not discharged.
84402832 NA - May 2011

8030A-3
Hydraulic Pump Internal Structure

Diagram
Overall view
Drive shaft front side Drive shaft rear side
Drive shaft front side
84402832 NA - May 2011

8030A-4
Drive shaft rear side
84402832 NA - May 2011

8030A-5
Part table
Adhesion agent (ThreeBond Tightening torque
a Co., Ltd. No. 130SN) applica- c Right rotation valve plate e Flange socket (4-M10 x 1.5):
tion 33 N•m
Oil seal outer circumference Tightening torque
b Lubricant (Sealub L101) coat- d Left rotation valve plate f Hexagon bolt (3-M6 x 1.0): 12
ing N•m
Component part no. (q'ty) or

Code Part name Q'ty
type
ZX15LHRZ2-07A-
04 Gear pump 1set
VZX15LHRZ2-07A-V
011 Piston subassembly 2set 151 (9PC), 152 (9PC)
013 Cylinder subassembly (R) 1set 141 (1PC), 313 (1PC)
014 Cylinder subassembly (L) 1set 141 (1PC), 314 (1PC)
030 Swash plate subassembly 2set 212 (1PC), 214 (1PC)
541 (1PC), 543 (1PC), 545
041 Check valve 1 subassembly 2set
(1PC)
541 (1PC), 544 (1PC), 545
042 Check valve 2 subassembly 2set
(1PC)
Electromagnetic proportional
079 pressure reducing valve, cas- 1set KDRDE5KR-V3-V
ing subassembly
530 Tilting pin subassembly 2set 531 (1PC), 548 (1PC)

111 Drive shaft (F) 1 492 Insert plug 12
113 Drive shaft (R) 1 531 Tilting pin 2
114 1st gear 1 532 Servo piston 2
123 Cylinder roller bearing 2 534 Stopper (L) 2
124 Needle roller bearing 2 535 Stopper (S) 2
127 Bearing spacer 4 541 Seat 4
141 Cylinder block 2 543 Stopper 1 2
151 Piston 18 544 Stopper 2 2
152 Shoe 18 545 Steel ball 4
153 Holder plate 2 548 Feedback pin 2
156 Spherical bushing 2 702 O-ring 2
157 Cylinder spring 18 710 O-ring 1
211 Shoe plate 2 714 O-ring 1
212 Swash plate 2 717 O-ring 2
214 Tilting bushing 2 724 O-ring 16
251 Swash plate support board 2 725 O-ring 6
261 Seal cover (F) 1 728 O-ring 4
271 Pump casing 2 732 O-ring 2
312 Valve block 1 774 Oil seal 1
313 Valve plate (R) 1 789 Backup ring 2
314 Valve plate (L) 1 792 Backup ring 2
326 Cover 1 808 Hexagon nut 2
401 Hexagon socket head bolt 8 824 Stop ring 2
406 Hexagon socket head bolt 4 885 Valve plate pin 2
414 Hexagon socket head bolt 4 886 Spring pin 4
466 VP plug 2 901 Eyebolt 2
Hexagon socket head stop
467 VP plug 2 953 2
screw
468 VP plug 4 954 Stop screw 2
490 Insert plug 27 981 Nameplate 1
492 Insert plug 12 983 Driving tack 2
84402832 NA - May 2011

8030A-6
Gear Pump
Gear pump internal structure diagram
Hydraulic circuit
a Front case side c To main pump

b Gear case side
*1 (2PLACES)
Component part No. (q'ty) or

Code Part name Q'ty
type
307 (1PC), 308 (1PC), 351
350 Gear case subassembly 1set (1PC), 353 (1PC), 354 (1PC),
361 (1PC), 887 (2PC)
84402832 NA - May 2011
8030A-7

307 Poppet 1 433 Flange socket 2
308 Seat 1 434 Flange socket 2
309 Ring 1 435 Flange socket 4
310 Spring 1 466 VP plug 1
311 Adjusting screw 1 700 Angle ring 1
312 Lock nut 1 710 O-ring 1
351 Gear case 1 725 O-ring 1
353 Drive gear 1 732 O-ring 1
354 Driven gear 1 850 Locking ring 1
355 Filter 1 887 Pin 2
361 Front case 1
Structure and Operation Explanation

Structure
The casing comprises the front case (361) and gear case (351). Inside the casing the drive gear (353), driven gear
(354) pair and the relief valve for setting the discharge pressure are installed.
The relief valve comprises the filter (355), poppet (307), seat (308), spring (310), ring (309), adjusting screw (311),
and lock nut (312).
In order to prevent oil leaking to the outside, an angle ring (700) and O-ring (710) are mounted on the front case (361).
Operation
Oil suctioned in from suction port B3 is discharged from discharge port A3 by the drive and driven gears.
The discharge oil is held at the set pressure of 3.9 MPa by the relief valve.
Unnecessary discharge oil is drained from the drain port via the relief valve.
84402832 NA - May 2011

8030A-8
Section
8030B
Structure and Operation Explanation of Travel Motor
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Travel motor operation explanation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Summary explanation of component parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Rotary group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Variable Capacity Mechanism Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overload Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Brake Valve Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Motor operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Parking Brake Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Operation of Variable Capacity Mechanism Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Overload Relief Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Brake Valve Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Travel motor operation explanation

Structure
Diagram 1 Travel motor structural diagram

1 Casing 22 D-ring (small diameter) 43 O-ring
2 NPT 1/16 plug 23 D-ring (large diameter) 44 Check valve
3 Oil seal 24 Rear cover 45 Check valve spring
4 Circle R retaining ring 25 NPT 1/16 plug (mec) 46 M6 orifice
5 Expansion plug 26 Spool assembly 47 O-ring
6 Tilting piston 27 Spring receiver 48 M6 orifice
7 Tilting piston seal 28 Spring 49 O-ring
8 Steel ball 29 M42 plug 50 O-ring
9 Shaft 30 O-ring 51 Bearing
10 Bearing 31 Pilot spool 52 Shim
84402832 NA - May 2011
8030B-3

11 Pivot 32 Pin 53 Parallel pin
12 Shoe plate 33 Spring receiver 54 Valve plate
13 Cylinder block 34 Spring 55 Brake spring
14 Cylinder spring 35 Pilot valve plug 56 Hexagon socket head bolt
15 Spring receiver 36 O-ring 57 Overload valve
16 Spherical joint 37 Joint 58 Coupling
C-shaped retaining ring for
17 Shoe retainer 38 G1/4 plug 59
hole
18 Piston assembly 39 O-ring 1B P11 60 G1/2 plug
19 Separator plate 40 Orifice (brake valve) 61 O-ring
20 Friction plate 41 Orifice spring (brake valve)
21 Brake piston 42 G1/8 plug
Summary explanation of component parts

The motor is made up of the following main components.
• Rotary group producing rotational force
• Parking brake that prevents self-travel when the machine is parked
• Variable mechanism section that switches the motor capacity between high and low
• Overload relief valve installed to the rear cover
• Brake valve section (counter balance valve) that plays a critical role in controlling the hydraulic circuits
Rotary group
The cylinder block (13) is fit into the teeth grooves on the spline of the shaft (9), which is supported at both ends by
the bearings (10), (51). This cylinder block (13) is pressed against the rear cover (24) together with the valve plate
(54) by the cylinder spring (14).
The nine piston assemblies (18) slide along the surface of the shoe plate (12) while moving in and out of the cylinder
block (13). There are static pressure bearings at the end surface of the piston assembly (18) shoe to reduce the sliding
resistance. The spring force of the cylinder spring (14) is transmitted through the spring receiver (15), spherical joint
(16), and shoe retainer (17) to press the end surface of the piston assembly (18) against the shoe plate (12) so that
the piston moves without separating from the surface of the shoe plate (12).
Parking Brake
A separator plate (19) and friction plate (20) are fit into the spline groove around the outer edge of the cylinder block
(13) in an alternating pattern and are pressed against the casing (1) by the 14 brake springs (55) via the brake piston
(21).
Variable Capacity Mechanism Section
This section comprises the pivot (11), which is fit into the 2 semispherical indentations on the shoe plate (12) and
support the shoe plate (12), the tilting piston (6), which revolves the shoe plate (12) around the pivot (11), the tilting
stopper (1-1), which supports this revolution at the determined position, the pilot valve section, which brings the pres-
sure oil to the tilting piston (6) according to the external command, and the 3 check valves (44), which take out and
send to the pilot valve section the highest of the 3 pressures among the external command pilot pressure, the motor
inlet pressure, and the motor outlet pressure.
84402832 NA - May 2011

8030B-4
Overload Relief Valve

This comprises the socket (57-1), which holds the valve seat (57-3) that seats metal to the motor rear cover (24)
internal hole section and which screws it into the rear cover (24) to secure it, the valve (57-2), which is contacted
to the valve seat (57-3) by the adjusting spring (57-9) and which is fit into the socket (57-1) internal hole, the linking
piston (57-4), which is inserted into the valve internal hole and serves as the oil path to the pilot section body (57-6),
the piston (57-7), which is inserted into the pilot section body (57-6) and is pressed against the lid (57-5), and the
spring adjusting shims (57-8).
Diagram 2 Overload relief valve structural diagram

57-1 Socket 57-6 Pilot section body 57-11 Backup ring T2 P7
57-2 Valve 57-7 Piston 57-12 O-ring 1B G25
57-3 Valve seat 57-8 Shim 57-13 Backup ring T2 G25
57-4 Linking piston 57-9 Adjusting spring
57-5 Lid 57-10 O-ring 1B P7
84402832 NA - May 2011

8030B-5
Brake Valve Section

Spool switchover pressure: 0.59 - 0.95 MPa
Check valve cracking pressure: 0.015 MPa
Diagram 3 Brake valve section
*1 Check valve
1. Spool
Shut-off of hydraulic motor discharge oil and orifice operation are automatically performed by switchover of this
spool (26), and holding, acceleration, stop, and counter balance operations affect the hydraulic motor.
2. Check valve (built into spool)
This is the oil feed path of the hydraulic motor and provides a discharge oil locking function.
Therefore, this is the hydraulic motor suction valve as well as the holding valve.
84402832 NA - May 2011

8030B-6
Function
Diagram 4 Port position
Dis-
Inflow
charge Direction of rotation (view from rear cover side)
port
port
VB VA Right (clockwise)
VA VB Left (counter-clockwise)
*1 VA port
*2 VB port
84402832 NA - May 2011

8030B-7
Motor operation
The high-pressurized hydraulic oil sent from the hydraulic pump flows from the inflow ports (VA and VB) passes the
brake valve section, rear cover (24), and valve plate (54), and is led into the cylinder block (13).
The table shows the inflow port, the discharge port, and the direction of rotation of the output shaft.
Diagram 5
As in Diagram 5 (a), this high-pressure oil operates on each piston during 180°, with the Y-Y line connecting the piston
top dead center and bottom dead center as the boundary, and generates force of .
F1 = P x A (P) (P: Pressure, A: Piston area)
This force F1 becomes a thrust force F2 and radial forces F31 - F34 (or F35) due to the shoe plate (12), which has
a tilting angle of α. (See Diagram 5 (b).)
These radial forces operate as the rotation force of the Y-Y shaft and generate a torque of .
T = r1・F31 + r2・F32 + r3・F33 + r4・F34
(When high pressure operates on 5 pistons, r5/F35 is added.)

This torque is transmitted to the shaft (9) spline via the cylinder block (13) and is transmitted to the shaft (9).
84402832 NA - May 2011

8030B-8
Parking Brake Operation

The parking brake is released when the high hydraulic pressure selected by the counter balance section installed in
the rear cover operates on the brake piston (21).
When this pressure does not operate on the piston, brake torque is always generated.
This brake torque is generated by the force of friction between the separator plate (19) coupled by the casing (1) and
spline and the friction plate (20) coupled with the cylinder block (13) by the spline.
When pressure is not operating on the brake piston section, the brake piston (21) is pressed by the brake spring (55)
and the brake piston (21) sandwiches the friction plate (20) and separator plate (19) against the casing (1).
This sandwiching force generates friction force between the friction plate (20) and the separator plate (19), serving
as brake torque that constrains the cylinder block (13) as well as the shaft (9).
Diagram 6 Parking brake section
84402832 NA - May 2011

8030B-9
Operation of Variable Capacity Mechanism Section
Diagram 7 Operation of variable capacity mechanism section
a To counter balance valve

(brake valve)
High-speed travel command
b
line (external pilot)
c Adhesion force point
Diagram 7 shows a model of the variable capacity mechanism section.

When pressure overcoming the spring (34) enters the high-speed travel command line PA, the spring (34) is com-
pressed, the spool (31) moves to the right, the P and C ports are connected, the highest of the 3 pressures (motor
pressure MA, motor pressure MB, and the high-speed travel command line pressure) is selected by the check valve
(44), and the tilting piston (6) is pressed.
Therefore, the shoe plate (12) tilts as shown by the broken line with line L connecting the 2 pivots (11) as the axis
center, and tilting stops and is held at the point where it contacts the tilting stopper (1-1).
As a result, the amount of the piston (18) coming in and out is reduced and the motor capacity becomes small, so the
motor rotates at high speed without increasing the amount of oil sent from the hydraulic pump.
For this machine, the capacity ratio is about 1.71 times.
On the other hand, when the high-speed travel command line PA pressure disappears, the spool (31) is returned to
the left by the spring (34), the oil that had been pressing against the tilting piston (6) is released to the tank via the
orifice (46), and the force pressing against the piston disappears.
There are 9 pistons (18) distributed uniformly on the shoe plate (12), and they press against the shoe plate (12).
The adhesion force point for the total force of these 9 pistons is positioned pretty much at the center of the shoe plate
(12) as in the diagram, and the pivots (11) are at a position S away from the center, so a rotational force that is the
product of S and the piston pressing force is generated, returning the motor to its original status and switching to
low-speed travel.
Also, when the engine power is exceeded, for example when steering or climbing a steep hill at high speed, in order
to prevent the engine stalling, the motor is automatically switched to low-speed when the engine load exceeds the
stipulated value.
When the hydraulic pump pressure (VA or VB) is led to the PB port of Diagram 7, this pressure operates on the pin
(32), and when the stipulated pressure is exceeded, the spool (31) is returned to the left by the reaction force of the
84402832 NA - May 2011
8030B-10
pin (32), the oil that had been pressing against the tilting piston (6) is released to the tank, and the shoe plate (12)
tilts to configure the high-capacity motor, resulting in low-speed travel.
When this pressure falls to the stipulated pressure, the spool (31) moves to the right, resulting in high-speed travel.
84402832 NA - May 2011

8030B-11
Overload Relief Valve Operation

There are 2 overload relief valves. They have a crossover configuration and operate as follows.
1. When the hydraulic motor is stopped, in order to prevent load inertia, the brake pressure generated on the motor
discharge side is held to no greater than a certain value.
2. In order to get sharp acceleration with driving at the stipulated set pressure when starting the hydraulic motor
and to attenuate the brake shock when stopping, what is called boost attenuation operation is carried out. The
pressure generated is held at low pressure for a short time and the reduction gear, travel crawler sprocket section,
etc. mesh smoothly, then the circuit pressure is held at the stipulated set pressure.
When the A port pressure for the overload relief valve rises at the time the hydraulic motor starts, this pressure is
applied to the effective diameter section seated to the valve seat (57-3) of the valve (57-2) and it is also applied to
the linking piston (57-4) of the valve interior through the small hole in the valve (57-2). The A port pressure rises and
the valve (57-2) resists the adjusting spring (57-9) with the surface area difference between the linking piston hole
diameter section and the valve seat effective diameter section and the stipulated set pressure is set.
When the hydraulic motor brakes, the piston (57-7) in the rear section is on the left side due to the drive pressure,
and when the A port pressure rises, it is also applied to the piston (57-7) through the small hole in the valve and the
small hole in the linking piston (57-4), moving the piston to the right until it contacts the lid (57-5).
During this time, the valve (57-2) resists the adjusting spring (57-9) and holds the A port pressure comparatively low
and releases oil to the B port.
After the piston (57-7) contacts the lid (57-5), operation is the same as when the motor starts.
Diagram 8 Operation of overload relief valve
a From the A port

b To the B port
c Small hole
84402832 NA - May 2011

8030B-12
Brake Valve Operation

1. Hold status (See Diagram 9.)
In the switchover valve neutral state, the VA and VB ports are connected to the tank and the spool (26) is held in
a central position by springs at both ends.
Because the paths from the VA port to the MA port and from the VB port to the MB port are closed, the MA and
MB ports connecting to both sides of the hydraulic motor are both blocked.
Also, because the parking brake release path is connected to the tank, the parking brake is operating and rotation
of the hydraulic motor is mechanically stopped by the brake spring force.
If an external force is acting on the hydraulic motor, normally the rotation of the motor is stopped by the parking
brake.
When a torque larger than the parking brake force is generated, the parking brake slips, but hold pressure is
generated on the MA port or MB port side, and the hold pressure holds the motor to minor rotation.
When the hydraulic motor has minor rotation, high-pressure oil escapes from the closed circuit and cavitation can
occur on the low-pressure side of the closed circuit.
The check valve built into the spool operates in order to prevent this cavitation, a VA → MA or VB → MB path is
formed, and an oil volume equal to the leaked volume is filled into the closed circuit from the tank.
Diagram 9 Hold status
1 Spring
84402832 NA - May 2011

8030B-13
2. When accelerating (See Diagram 10.)

When the VA port is connected to the hydraulic pump and the VB port is connected to the tank as a result of the
switchover of the switchover valve, pressure oil from the hydraulic pump pushes up the check valve inside the
spool from the VA port, is fed to the hydraulic motor via the MA port, aiming to rotate the hydraulic motor.
The pressure oil is fed to the pilot chamber on the VA port side, overcoming the spring pressure of the VB port
side and moving the spool (26) to the left.
When this happens, a return path from the MB port to the VB port is formed, pressure oil is fed to the parking
brake release line, and the parking brake is released.
This causes the hydraulic motor to rotate.
If the inertial load of the hydraulic motor is large, the pressure required for acceleration will reach the overload
relief valve set pressure, and the rotation speed will increase as the hydraulic motor relieves the pressure oil.
As the rotation of the hydraulic motor increases, the relief volume decreases and a constant speed is finally
reached.
Diagram 10 When accelerating
1 Spring
2 Pilot chamber
84402832 NA - May 2011

8030B-14
3. When stopping (See Diagram 11.)

When the switchover valve returns to the neutral position during hydraulic motor rotation, the feed oil is cut off,
and the VA and VB ports connect to the tank, the pressure in the pilot chamber of both ends of the spool becomes
equal and the spool (26) is returned to the neutral position by the spring force.
As a result the path from the MB port to the VB port is closed.
However, because the hydraulic motor tries to continue to rotate by the inertial force of the load, the hydraulic
motor causes pump operation and continually discharges hydraulic oil to the MB port. Because the path is cut off,
the pressure rises, the overload relief valve operates, and the hydraulic motor gradually decelerates and finally
comes to a stop.
Also, because the parking brake release pressure is narrowed, the pressure slowly decreases, the brake finally
operates, and rotation of the hydraulic motor is mechanically stopped.
Diagram 11 When stopping
1 Spring
2 Pilot chamber
84402832 NA - May 2011

8030B-15
4. When the counter balance is operating (Diagram 12)

When the rotating hydraulic motor decelerates by the load inertia, the counter balance must be operated.
As the hydraulic oil that is currently fed from the hydraulic pump to the VB port is gradually reduced, the hydraulic
motor tries to rotate in excess of the feed flow due to inertia. As a result, the pressure in the pilot chamber on the
VB port side is reduced and the spool (26) is pressed to the left side by the spring (28) and moved to the neutral
position.
Consequently, the area of the path from the MA port to the VA port decreases and path resistance increases,
causing a rise in the pressure on the MA port side and the brake to operate for the hydraulic motor.
When the rotation speed is decreased to or below the rotation speed equivalent to the oil feed volume, the pres-
sure in the pilot chamber on the VB port side rises, the spool (26) moves to the right, and the area of the path
from the MA port to the VA port increases, thereby decreasing the braking operation and controlling the rotation
speed of the hydraulic motor to the rotation speed equivalent to the oil feed volume.
To ensure stable counter balance operation, orifices (40) that provide a damping effect on the spool (26) are
installed in the pilot chambers on both ends.
The parking brake is released during pressure adjustment of the spool (26).
Diagram 12 When the counter balance is operating
84402832 NA - May 2011

8030B-16
1 Spring
2 Pilot chamber
3 Check valve with orifice
84402832 NA - May 2011

8030B-17
84402832 NA - May 2011

8030B-18
Section
8030C
Structure and Operation Explanation of Swing Motor
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Swing Motor Operation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Hydraulic Motor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Valve Casing Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Brake Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Relief Valve Operation Explanation (relief valve model: KRD22EK10). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Swing Motor Internal Structure Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Swing Motor Operation

Explanation
Hydraulic Motor Section
As the diagram below shows, when the high-pressure oil passes through the valve plate (1) inlet-side port (a) and flows
into the cylinder, the hydraulic pressure operates on the piston (5) and a force F is generated in the axial direction.
This force F is divided into 2 vectors, a force F1 perpendicular to the swash plate (3) via the shoe (2) and a force F2
perpendicular to the shaft.
This force F2 is transmitted to the cylinder block (4) via the piston (5), generating a rotational couple around the output
shaft.
9 pistons (5) are arrayed in the cylinder block. Rotation torque is transmitted sequentially to the output shaft (6) by
multiple pistons (5) linked with the high-pressure oil inlet-side port.
When the oil in and out directions are reversed, the rotation of the output shaft (6) also reverses.
The theoretical output torque T [N·m] is given by the following equation.
Diagram 1 Motor section operation explanation diagram
q Compartments per rotation

[cm3]
p Effective pressure difference
[MPa]
*1 Low-pressure oil *3 Outlet

*2 High-pressure oil *4 Inlet
84402832 NA - May 2011

8030C-3
Valve Casing Section

1. Anti-cavitation check section
Because the system using this type of motor does not have a valve with a counter-balance function, the motor
sometimes rotates more than the quantity of oil fed.
In order to prevent cavitation due to insufficient oil, there is a check valve to take in the oil shortfall.
Diagram 2 Hydraulic circuit diagram
1 M port
2 Control valve
Brake Section
The cylinder (111) is coupled with the drive shaft (101) by the gear. Also, the separator plate (743) is constrained for
circumferential rotation by the arc groove cut into the casing (301).
When the friction plate (742) that is gear coupled to the cylinder outer circumference section is pressed to the casing
(301) by the brake spring (712) via the separator plate (743) and the brake piston (702), friction force is generated
between the friction plate and casing and between the separator plate and the brake piston. The drive shaft is con-
strained and braked by this friction force.
On the other hand, when brake release pressure is applied to the oil chamber (1) formed between the brake piston
and the casing and the hydraulic pressure (3) wins out over the spring force (2), the brake piston moves, the force
pressing the friction plate against the casing disappears, and the brake is released.
84402832 NA - May 2011

8030C-4
Diagram 3 Brake operation diagram

Relief Valve Operation Explanation (relief valve model: KRD22EK10)
1. Operation explanation for when the relief valve is pressurized
In the case where the P port is pressurized with the tank pressure,the P and R ports are initially at the tank
pressure and the valve status is as shown in Diagram 4 (1).
At the pressure where there is balance between the hydraulic pressure determined by the product of the pressure
P and the pressurized area A1 of the plunger (301) on the one hand and the hydraulic pressure determined by
the product of the spring (321) load FSP and plunger (301) pressurized area A2 and the g chamber pressure Pg
on the other, the relief valve starts to operate.
After that, the g chamber pressure rises and the piston (302) starts its stroke.
Accompanying this movement, the load on the spring (321) increases.
Through the operation above, the relief pressure P is increased from P1 to Ps in the pressure boost time t1.
This process is explained below in terms of the relationship between the movement state of the parts in diagrams
4-(2) - (4) and the relief pressure.
1) State shown in Diagram 4-(2)
When the relief valve P port is pressurized, pressure is generated in the g chamber via the orifice m in the
plunger (301).
When the hydraulic pressure operating on the plunger (301) increases and reaches the pressure at which
it balances the spring (321) load FSP, the relief valve carries out the relief operation at pressure P1.
The relationship at this time is expressed by the following equation.
P1 x A1 = FSP1 + Pg1 x A2 FSP1: Initial set load for the spring (321)
The g chamber pressure operates on pressurized areas A3 and A4 of the piston (302).
When this hydraulic pressure becomes larger than the load on the spring (321), the piston starts to move
to the left.
At this time, the oil in the h chamber formed between the piston and the adjusting plug (401) is discharged
into the g chamber via the orifice n set up on the piston (302) while the piston moves to the left, so the h
chamber functions as a damping chamber.
Through this, the spring load gradually increases until the piston reaches the adjusting plug end section
and the relief pressure P rises smoothly.
84402832 NA - May 2011

8030C-5

When the piston (302) reaches the adjusting plug (401) end section, it does not move farther to the left, so
the constant relief state is reached and the relief pressure is held at P2.
Through the processes (1) - (4) above, the relief pressure varies as in Diagram 5.
2. Operation explanation for when the relief valve is depressurized
In the case where the P port pressure falls,the P port pressure and the g chamber pressure fall together to the
tank pressure when the pressurization of the P port ends.
Through this process, the plunger (301) which was open moves to the left and is placed in the seat (401).
At the same time, the piston (302) also is moved to the right by the spring (321) and returns to the state in Diagram
4-(1).
Diagram 4 Relief valve operation explanation diagram
a Orifice m c A1 pressurized area e g chamber

b h chamber d Orifice n
84402832 NA - May 2011

8030C-6
Diagram 5 Pressure boost characteristics
84402832 NA - May 2011

8030C-7
Swing Motor Internal Structure Diagram
84402832 NA - May 2011

8030C-8
Brake spring layout diagram
84402832 NA - May 2011

8030C-9
Reverse prevention
052 1 set 121 Piston 9 469 ROMH plug 2
valve subassembly
100 Casing 1 122 Shoe 9 472 O-ring 1
151 ROH plug 2 123 Holder plate 1 488 O-ring 2
161 O-ring 2 124 Shoe plate 1 491 Oil seal 1
162 O-ring 2 131 Valve plate B 1 702 Brake piston 1
Valve casing H2 sub-
163 O-ring 2 20 1 set 706 O-ring 1
assembly
Hexagon socket head
171 4 301 Casing JA1 1 707 O-ring 1
bolt
Reverse prevention
400 2 sets 303 Valve casing H2 1 712 Brake spring 18
valve
400-1 O-ring 2 351 Plunger H2 2 742 Friction plate 2
400-2 Backup ring 2 355 Spring H2 2 743 Separator plate 4
051 Relief valve 2 sets 390 Nameplate 1 984 Masking plug 1 set
051-1 O-ring 2 391 Driving tack 2 985 Masking plug 1 set
Hexagon socket head
10 Piston subassembly 1 set 401 4 986 Masking plug 1 set
bolt
101 Drive shaft 1 443 Cylinder roller bearing 1 994 Insert plug 1
111 Cylinder 1 444 Cylinder roller bearing 1
114 Plate spring 1 451 Pin 2
a ID mark
84402832 NA - May 2011

8030C-10
Section
8030D
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Structure and Operation Explanation of Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Basic configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3


Basic configuration
This valve is based on the main unit housing which combines the P1 side housing and P2 side housing with the rear
surfaces against each other and has a configuration that makes it possible to mount the inlet, add-on section, and
outlet on the P2 side housing top.
Operation
1. When all spools in neutral
1) Neutral path [Fig. 1, Fig. 2]
1) When Pn1 and Pn2 ports are pressurized
The oil fed from the P1 port enters the tank path (Ta) from the neutral path (L1) through the low-
pressure relief orifice (Lc1) and returns to ports T1 - T8.
The oil fed from the P2 port enters the tank path (Ta) from the neutral path (R1) through the low-
pressure relief orifice (Rc1) and returns to the T1 - T8 ports.
The pressure in the pressure chambers (L2) and (R2) upstream from the low-pressure relief valve is
led into the pump from the ps1 and ps2 ports and controls the P1 and P2 pump discharge volume.
Also, if excess oil flows into the neutral path (L1), the poppet opens to provide low-pressure relief.
This prevents the ps1 and ps2 port pressures from becoming abnormally high.
2) When Pn1 and Pn2 ports are not pressurized
In this case, the low-pressure relief poppets open at lower pressure than in (a).
Therefore, the oil fed from the P1 port enters the tank path (Ta) from the neutral path (L1) primarily
through the low-pressure relief valve discharge port (L3) and returns to the T1 - T8 ports.
Also, the oil fed from the P2 port enters the tank path (Ta) from the neutral path (R1) primarily through
the low-pressure relief valve discharge port (R3) and returns to the T1 - T8 ports.
84402832 NA - May 2011

8030D-3
84402832 NA - May 2011

8030D-4
84402832 NA - May 2011

8030D-5
1 Low-pressure relief valve (L) 6 Travel 11 Arm 2

2 Arm 1 7 Outlet 12 Boom 1
3 Boom 2 8 Attachment 2 13 Bucket
4 Swing 9 Inlet 14 Straight travel
5 Option 10 Attachment 1 15 Low-pressure relief valve (R)
a (Section 5) f P1 side k (Section 7)

b (Section 4) g (Section R2 ) l (Section 6)
c (Section 3) h (Section R1) m (Section ST)
d (Section 2) i (Section 9) n P2 side
e (Section 1) j (Section 8)
84402832 NA - May 2011

8030D-6
84402832 NA - May 2011

8030D-7
84402832 NA - May 2011

8030D-8
Variable arm regeneration ori-

1 6 Travel 11 Boom 1
fice
2 Arm 1 7 Attachment 2 12 Bucket
3 Boom 2 8 Attachment 1 13 Travel
4 Swing 9 Neutral cut 14 Straight travel
5 Option 10 Arm 2
a Open j (Section R2 ) s Down

b Close k (Cylinder extension) t Up
c (Section 5) l (Cylinder retraction) u (Section 8)
d Up m Down v Close
e Down n Up w Open
f (Section 4) o (Section R1) x (Section 7)
g (Section 3) p Close y (Section 6)
h (Section 2) q Open z (Section ST)
i (Section 1) r (Section 9)
84402832 NA - May 2011

8030D-9
2) Signal, straight travel signal control valve, plate assembly [Fig. 3]

There are 2 signals, (a) and (b) below. The pilot signal for each spool for which a lever is operated is used
to generate the pressure that is output.
The straight travel signal control valve integrates each signal pressure and controls straight travel spool
switchover. Also, the plate assembly has a function for picking up the pilot pressures with the built-in shuttle.
1) Travel signal (PT)
The highest of the pilot pressures applied to the travel section 1 (pa1, pb1) and travel section 6 (pa6,
pb6) is selected and output to the PT port.
Therefore, when the travel spool is in the neutral position (no-load pilot pressure), no pressure is
generated at the PT port.
2) Front signal (PA)
The highest of the pilot pressures (pa2 - 9 and pb2 - 9) applied to sections 2 - 9 that use the pressurized
oil from the P1 and P2 pumps, except for the travel sections, is selected and output to the PA port.
(Note 1)
Therefore, when all the spools are in the neutral position (no-load pilot pressure), no pressure is gen-
erated at the PA port.
<Note 1>
When an add-on (main pump add-on) is used through the feed from P2, the branches for the add-on pilot
signals par1 and pbr1 are connected to the respective main unit valves, prs1 and prs2 ports, and thus
incorporated in the front signal PA selection area.
Be careful. If the above line connection is not done, the PA pressure will not rise through add-on selection.
Also, when using 2 main pump add-ons, set the circuit so that the maximum of the add-on pilot pressures
(par1 and 2, pbr1 and 2) can be taken out as desired and connect to either prs1 or prs2.
84402832 NA - May 2011

8030D-10
Straight travel signal control

1 5 Boom 9 Option
valve
2 Travel 6 Arm 10 Add-on (main pump)
Main unit housing section (op-
3 7 Bucket
tion)
4 Plate assembly 8 Swing
a RCV Remote control valve c RCV Remote control valve e RCV Remote control valve
b MCV d MCV f MCV
84402832 NA - May 2011

8030D-11
2. Independent operation
1) Travel spool switchover [Fig. 4 and Fig. 5]
When a travel spool is switched by pressurizing from the travel (section 1) pilot port Pb1 (Pa1), the oil fed
from the P1 port flows from the neutral path (L1) through the spool neck section and into the B1 (A1) port.
The return oil returns to the tank path (Ta) from the A1 (B1) port through the spool neck section.
When a travel spool is switched by pressurizing from the travel (section 6) pilot port Pb6 (Pa6), the oil fed
from the P2 port flows from the neutral path (R1) through the spool neck section or path (S6-1) and into the
B6 (A6) port.
For independent travel operation, the parallel path (R3) and the path (S6-1) have the same pressure, so
the poppet (S6-2) does not open. The return oil returns to the tank path (Ta) from the A6 (B6) port through
the spool neck section.
1 Switching state 3 Option

2 Neutral state 4 Travel
a (Section 2)
b (Section 6)
84402832 NA - May 2011

8030D-12
1 Switching state 3 Travel

2 Neutral state 4 Straight travel
a (Section 1)
b (Section ST)
84402832 NA - May 2011

8030D-13
2) Option spool switchover [Fig. 4]

When the option spool is switched by pressurizing from the option (section 2) pilot port Pb2 (Pa2), the
neutral path (L1) is closed. The oil fed from the P1 port flows from the parallel path (L3) through the load
check valve (S2-2), path (S2-1), and the spool neck section, and into the B2 (A2) port.
The return oil returns to the tank path (Ta) from the A2 (B2) through the spool neck section.
Also, when oil is fed from the P4 port, it passes through the inside of the load check valve (S2-2) and merges
with path (S2-1).
1 Switching state 3 Option

2 Neutral state 4 Travel
a (Section 2)
b (Section 6)
84402832 NA - May 2011

8030D-14
1 Switching state 3 Travel

2 Neutral state 4 Straight travel
a (Section 1)
b (Section ST)
84402832 NA - May 2011

8030D-15
3) Swing spool switchover [Fig. 6]

When the swing spool is switched by pressurizing from the swing (section 3) pilot port Pb3 (Pa3), the neutral
path (L1) is closed. The oil fed from the P1 port flows from the parallel path (L3) through the load check
valve (S3-2), path (S3-1), and the spool neck section, and into the B3 (A3) port.
The return oil returns to the tank path (Ta) from the A3 (B3) through the spool neck section.
1 Switching state 3 Swing

2 Neutral state 4 Bucket
a (Section 3)
b (Section 7)
84402832 NA - May 2011

8030D-16
4) Bucket spool switchover [Fig. 7 and Fig. 8]

1) Close (regeneration) [Fig. 7]
When the bucket spool is switched by pressurizing from the bucket (section 7) pilot port Pb7, the
neutral path (R1) is closed. The oil fed from the P2 port flows through the parallel path (R3), the load
check valve (S7-2), path (S7-1), and the spool neck section, and into the B7 port.
At the same time, the return oil from the A7 port returns to the tank path (Ta).
After part of the return oil pushes open the poppet (S7-3) inside the bucket spool, it merges into the
B7 port to prevent cylinder head side cavitation.
Cylinder speed increase and P2 port pressure reduction effects also accompany depending on the
port pressure conditions.
Bucket close (regeneration)
1 Neutral state 3 Swing

2 Switching state 4 Bucket
a (Section 3)
b (Section 7)
84402832 NA - May 2011

8030D-17
2) Open [Fig. 8]
When the bucket spool is switched by pressurizing from the bucket (section 7) pilot port Pa7, the
neutral path (R1) is closed. The oil fed from the P2 port flows through the parallel path (R3),
the load check valve (S7-2), path (S7-1), and the spool neck section, and into the A7 port.
The return oil returns to the tank path (Ta) from the B7 port through the spool neck section.
Bucket open
1 Neutral state 3 Swing

2 Switching state 4 Bucket
a (Section 3)
b (Section 7)
84402832 NA - May 2011

8030D-18
5) Boom spool switchover [Fig. 9, Fig. 10, and Fig. 11]

1) Neutral [Fig. 9]
This valve mounts an anti-drift valve on the boom 1 cylinder head (A8) side.
In neutral, the poppet (AD1) is reliably seated by the pressure of the A8 port itself led through path
(AD2) and the spool (AD3) into the spring chamber (AD4) to cut off the return oil from the A8 port.
Neutral
1 Boom 2
2 Boom 1
a (Section 4)
b (Section 8)
84402832 NA - May 2011

8030D-19
2) Boom up (2 pumps flow) [Fig. 10]

When the boom 1 spool is switched by pressurizing from the boom 1 (section 8) pilot port Pa8, the
check valve (S8-2), and the spool neck section and into the A8 port.
When the boom 2 spool is switched by pressurizing from the boom 2 (section 4) pilot port Pa4, the
neutral path (L1) is closed. The oil fed from the P1 port flows through the parallel path (L3), the load
check valve (S4-2), the spool neck section, and path (4) and merges into the A8 port. The return oil
returns to the tank path (Ta) from the B8 port through the spool neck section.
Up (2 pumps flow)
1 Boom 2
2 Boom 1
a (Section 4)
b (Section 8)
84402832 NA - May 2011

8030D-20
3) Boom down (regeneration) [Fig. 11]

When the boom 1 spool is switched by pressurizing from the boom 1 (section 8) pilot port pb8, the
check valve (S8-2), and the spool neck section and into the B8 port.
The pilot pressure applied to pb8 at this time moves the anti-drift valve spool (AD3) through the path
built into the housing at the same time that the spool is switched and reduces the pressure of the
spring chamber (AD4) to open the poppet (AD1).
Through this movement, the cutoff of the A8 port is released before the spool is switched.
After that, the return oil from the A8 port returns to the tank path (Ta).
Part of the return oil pushes open the poppet (S8-3) inside the boom 1 spool, passes through path
(S8-1), and merges into the B8 port to prevent cylinder rod side cavitation.
Cylinder speed increase and P2 port pressure reduction effects also accompany depending on the
port pressure conditions.
Down (regeneration)
1 Boom 2
2 Boom 1
a (Section 4)
b (Section 8)
84402832 NA - May 2011

8030D-21
6) Arm spool switchover [Fig. 12 - 15]

1) Neutral [Fig.12]
This valve mounts an anti-drift valve on the arm 1 cylinder rod side.
In neutral, the poppet (AD1) is led through path (AD2) and the spool (AD3) into the spring chamber
(AD4). It is reliably seated by the pressure of the A5 port itself to cut off the return oil from the A5 port.
Neutral
1 Arm 1
2 Arm 2
a (Section 5)
b (Section 9)
84402832 NA - May 2011

8030D-22
2) Arm in (2 pumps flow) [Fig. 13]

When the arm 1 spool is switched by pressurizing from the arm 1 (section 5) pilot port Pb5, the oil fed
from the P1 port flows from the neutral path (L1) through the load check valve (S5-2), path (S5-1),
and the spool neck section and into the B5 port. When the arm 2 spool is switched by pressurizing
from the arm 2 (section 9) pilot port Pb9, the oil fed from the P2 port flows from the neutral path (R1)
through the load check valve (S9-2), path (S9-1), the spool neck section, and path (6) and merges
into the B5 port.
The pilot pressure applied to pb5 at this time moves the anti-drift valve spool (AD3) through the path
built into the housing at the same time that the spool is switched and reduces the pressure of the
spring chamber (AD4) to open the poppet (AD1). Through this movement, the cutoff of the A5 port is
released before the spool is switched.
After that, the return oil from the A5 port splits into the flow through the regeneration check in the spool
that is regenerated at the B5 port and the flow returning to the tank path (Ta) through the regeneration
control valve.
(For details on the regeneration function, see the regeneration valve operation explanation in next
section 3).)
Arm in (2 pumps flow)
1 Arm 1
2 Arm 2
a (Section 5)
b (Section 9)
84402832 NA - May 2011

8030D-23
3) Arm in (variable regeneration) [Fig. 14]

For an arm-in operation, after the return oil from the A5 port passes through the notch (a), it divides
into 2 paths:
1. The return oil returns to the tank path (Ta) through the fixed orifice (d) in the regeneration control
valve, path (e), and the variable orifice (f).
2. The return oil passes through the fixed orifice (b) in the arm 1 spool, the regeneration check (c),
and the fixed orifice (i), then merges into the bridge path (S5-1).
Here, when the bridge path (S5-1) pressure goes higher due to the port B5 load pressure, the regen-
eration control valve spool (h) is pressed through the regeneration control valve piston (g), and the
variable orifice (f) section opening surface area increases, so the quantity of oil returning to the tank
path (Ta) increases.
On the other hand, the quantity of oil regenerated in the B5 port decreases.
Though this variable mechanism, both the regeneration ratio for low loads is secured and reduction
in the return back pressure for high loads is established.
Arm in (variable regeneration)
Regeneration control valve

1
(variable)
2 Arm 1
a (Section 5)
84402832 NA - May 2011

8030D-24
4) Arm out (2 pumps flow) [Fig. 15]

When the arm 1 spool is switched by pressurizing from the arm 1 (section 5) pilot port Pa5, the oil fed
from the P1 port flows from the neutral path (L1) through the load check valve (S5-2), path (S5-1),
and the spool neck section and into the A5 port.
When the arm 2 spool is switched by pressurizing from the arm 2 (section 9) pilot port Pa9, the oil fed
from the P2 port flows from the neutral path (R1) through the load check valve (S9-2) and path (S9-1),
merges into the arm 1 section path (S5-1) and heads toward the A5 port through the arm 1 spool neck
section. The return oil from the B5 port returns to the tank path (Ta) through the spool neck section.
Arm out (2 pumps flow)
1 Arm 1
2 Arm 2
a (Section 5)
b (Section 9)
84402832 NA - May 2011

8030D-25
7) Arm parallel orifice [Fig. 16]

Metering by the spool is installed in the arm 1 parallel path of this valve to control the quantity of oil fed to
arm 1 for compound operations.
The oil fed from the arm 1 (Section 5) parallel path (L3) pushes open the poppet (S5-3) and passes through
the variable metering spool orifice (Lc8), then is connected to path (L5).
Here, the quantity metered by the orifice (Lc8) is adjusted by pressurizing the pilot port (Pbu).
For boom up (for Pbu pressur-

1 Low-pressure relief valve (L) 3
ization)
2 Pbu signal path 4 For neutral
84402832 NA - May 2011

8030D-26
8) Relief valve
1) Main relief valve [Fig. 17]
The oil fed from the P1 port passes through the poppet (LP) and the oil fed from the P2 port passes
through the poppet (RP) and path (3) and is led to the main relief valve. The maximum pressure of
the P1 and P2 side pumps is controlled by the operation of the main relief valve.
84402832 NA - May 2011

8030D-27
2) Overload relief valve [Fig. 18]

There is an overload relief valve at the boom 1, arm 1, bucket, and add-on cylinder ports to prevent
any abnormal rise in actuator pressure, for example due to an external force.
This relief valve is also equipped with a function for preventing cavitation (suction function) by taking
in oil from the tank when the cylinder port pressure becomes negative pressure.
a Suction function Operating
84402832 NA - May 2011

8030D-28
3. Compound operation
1) Travel compound operation [Fig. 19, Fig. 20]
Under the conditions below when the travel left/right and the front system are operated at the same time,
the straight travel spool is switched, and the straight travel characteristic is maintained.
1 When the front is operated during travel left/right simultaneous operation (forward, backward, or pivot
turn)
2 When the left/right are operated simultaneously during front system operation
Front system operation is not affected by the switchover section or quantity of switchovers.
1) Signal circuit [Fig. 19]
(A) When the [Travel 1] side lever is operated, the pressure branched off from the valve main unit
pilot port passes through the filter and the shuttle, then switches the switchover valve [V1].
(B) When the [Travel 2] side lever is operated, the pressure branched off from the valve main unit
pilot port passes through the filter and the shuttle, then if the switchover valve [V1] is switched, it
switches the switchover valve [V2] through the path. On the other hand, if the switchover valve [V1]
is in the neutral state, the path is cut off by the switchover valve [V1]. Therefore, if both (A) and (B)
are established at the same time, the straight travel spool internal path (Pst) is connected to PA.
Also, if either (A) or (B) are established, the travel signal (PT) pressure rises.
(C) If at least one of the front systems is switched, the highest pressure of all the pilot pressures
in the front system is selected and is connected to the front signal port (PA). Therefore, if (A), (B),
and (C) are established at the same time, the straight travel spool switchover quantity is determined
proportional to the front signal (PA) pressure through the internal straight travel signal path (Pst).
[Fig. 19] shows the example of a case of travel left/right forward + boom up.
84402832 NA - May 2011

8030D-29

1 5 Boom 9 Option
valve
2 Travel 1 6 Arm 10 Add-on (main pump)
3 Travel 2 7 Bucket 11
tion)
a Advance d Down g Right

b Reverse e Close h Left
c Up f Open
84402832 NA - May 2011

8030D-30
2) Main unit circuit [Fig. 20]

When the straight travel spool is switched, the oil fed from the P1 port flows from the neutral path (L1)
to travel (section 1) and at the same time passes through path (2), the straight travel spool neck sec-
tion, and the neutral path (R1) and into travel (section 6) and feeding to travel left and right becomes
possible.
On the other hand, when the oil fed from the P2 port flows to the parallel path (R3), at the same time
it passes through the straight travel spool neck section and path (1) and into the parallel path (L3), so
it becomes possible to feed oil to the entire front system.
When the front system is switched during travel and that pressure becomes higher than the load
pressure on travel (section 6), part of the oil fed from the P2 port pushes up the poppet (S6-2) from
the parallel path (R3) and the oil flows through the orifice at the poppet tip and merges into path (S6-1).
This softens the shock on the machine body of the sharp drop in speed caused by the switchover to
1 pump travel.
As described above, because travel (sections 1 and 6) operates with the oil fed from the P1 port and
operations other than travel are operated with oil fed from the P2 port, travel curving is prevented and
straight travel characteristics are maintained during compound operations.
84402832 NA - May 2011

8030D-31
1 Switching state 3 Straight travel

2 Travel 4 Travel
a (Section 1)
b (Section 6)
c (Section ST)
4. Anti-drift valve
The anti-drift valve is mounted on the arm rod (boom head) side cylinder port to prevent the arm (boom) cylinder
from dropping naturally.
Also, the release signal operates led by the internal path from the pilot signal.
(The arm side (A5) is shown as a typical example.)
1) Neutral (A5 port hold)
1) The A5 port hold pressure passes from path (a) through path (b), through path (c), and is connected
to the poppet (1) spring chamber (d).
2) Therefore, the A5 port pressurized oil is cut off by the seat section (S1) and the seat section (S2).
1 Main spool
84402832 NA - May 2011

8030D-32
2) Release signal application

1) When the pi port is pressurized, the piston (2) moves and the spool (3) operates.
2) Furthermore, the spool (3) operates the poppet (4).
3) Then, the operation of the poppet (4) cuts off the connection between the A5 port and the spring
chamber (d).
1 Main spool
3) Ending hold state

1) When the piston (2) operates further, the spring chamber (d) passes from path (c) through path (e)
and is connected to the drain chamber [DR] through the (T2) section.
2) The spring chamber (d) pressure becomes the drain pressure and the main poppet (1) operates.
1 Main spool
84402832 NA - May 2011

8030D-33
5. Relief valve
1) Main relief valve operation
1) This relief valve is incorporated between the neutral path "HP" and the low-pressure path "LP". The
oil passes through the metering hole of the main poppet (C) and charges the interior space (D). Also,
the sleeve (E) and the main poppet (C) seat securely operating on the different surface areas [A] and
[B].
2) When the neutral path "HP" pressure reaches the set pilot poppet spring force, the pilot poppet (F)
opens. The oil flows around the poppet, passes through the notch hole (G), and is led to the low-
pressure path "LP".
84402832 NA - May 2011

8030D-34
3) Because the pilot poppet has opened, the (D) pressure drops and the main poppet (C) opens, so the
oil flows directly into the path "LP".
"Boosted pressure operation"

When pressure is applied to the pilot port "PH", the piston (H) is moved to the set position by the plug (I).
Because of this, the pilot spring force rises and the "HP" pressure rises.
2) Overload relief valve operation

1) This relief valve is incorporated between the cylinder port "HP" and the low-pressure path "LP". The
oil passes through the metering hole of the piston (C) and charges the interior space (G). The sleeve
(K) and the main poppet (D) seat securely operating on the different surface areas [A] and [B].
84402832 NA - May 2011

8030D-35
2) When the cylinder port "HP" pressure reaches the set pilot poppet spring force, the pilot poppet (E)
opens. The oil flows around the poppet, passes through the notch hole (H), and is led to the low-
pressure path "LP".
3) Because the pilot poppet (E) has opened, oil flow is generated through the orifice (I) of the piston (C),
a pressure difference is generated between the path "HP" and the rear side of the piston (C), and the
piston (C) moves and seats with the poppet (E).
4) The flow of oil from the path "HP" to the rear side of the poppet (D) is only through the ring-shaped
gap between the poppet (D) and the piston (C) and through the orifice (F), so the pressure difference
increases.
Because of this, the poppet (D) opens and the oil flows directly into the path "LP".
84402832 NA - May 2011

8030D-36
3) Overload relief valve intake operation

1) This relief valve has a built-in anti-void unit that supplies oil if cavitation occurs at the cylinder port
"HP".
When the cylinder port "HP" pressure is lower than the low-pressure side "LP", the sleeve (K) is
opened by the surface area difference between (A) and (B). Oil enters the cylinder port "HP" from the
low-pressure side "LP" to prevent cavitation.
6. Neutral cut spool [Fig. 21]

This valve is equipped as standard with a neutral cut spool in the P2 side housing neutral path (R1) minimum
flow (low-pressure relief valve upstream).
When the pcc port is pressurized and the neutral cut spool is switched, the path through the orifice [Lc7] to
low-pressure relief is cut off and output to the outside from the P3 port becomes possible.
1 Low-pressure relief valve (R)
84402832 NA - May 2011

8030D-37
7. Plate assembly [Fig. 22]

This valve is equipped with a plate assembly hermetically sealed with a gasket piling a plate on the housing side
surface.
The shuttle is built into the inside and this valve has a function for selecting and controlling the spool pilot pressure.
Also, in order to protect the shuttle section from contamination from the outside, a filter is mounted between the
plates.
When removing, do not loosen the screws shown in the diagrams and be careful that internal parts are not dis-
persed.
[Short cap side] [Long cap side]
1 Subassembly screw
84402832 NA - May 2011

8030D-38
8. Straight travel signal control valve [Fig. 19, Fig. 23]

This valve integrates the pilot pressure for the spool of the front system and travel selected with each plate as-
sembly and is used to switch the straight travel spool.
When the Travel 1 pilot pressure is pressurized, the spool [V1] is switched.
When the Travel 2 pilot pressure is pressurized at the same time, the spool [V2] can be switched.
Here, when the front system pilot pressure [PA] is pressurized, the PA pressure flows into Pst and is led to the
straight travel spool pilot chamber and the spool is switched.
a Travel 2
b Travel 1
84402832 NA - May 2011

8030D-39

1 5 Boom 9 Option
valve
2 Travel 1 6 Arm 10 Add-on (main pump)
3 Travel 2 7 Bucket 11
tion)
a Advance d Close g Left

b Reverse e Open
c Up f Right
84402832 NA - May 2011

8030D-40
9. Add-on [Fig. 24, Fig. 25]

1) Add-on main relief valve
The oil fed from the Pr port is led to the main relief valve. The Pr pump maximum pressure is regulated by
the operation of the main relief valve.
a Advance d Close g Left

b Reverse e Open
c Up f Right
2) Spool section
When the spool is pressurized from the add-on (Section 10) pilot port par1 (pbr1) and switched, the neutral
path [Pg] is closed. The oil fed from the Pg port flows from the parallel path [Rg] through the load check
valve [S10-1], the path [S10-2], and the spool neck section, and into the AR1 (BR1) port.
The return oil returns to the tank path [Ta] from the BR1 (AR1) through the spool neck section.
84402832 NA - May 2011

8030D-41
3) Low-pressure relief valve operation [Fig. 26, Fig. 27]

1) Signal pressure generation (when pin1 (pin2) port pressurized)
The oil fed from the pump port (P1 (P2)) flows through the neutral path (L1 (R1)), then flows from the
low-pressure relief path (L2 (R2)) through the orifice (Lc1 (Rc1)) and out into the tank path (Ta).
At this time, the pressure generated in path (L2 (R2)) by the orifice (Lc1 (Rc1)) is led to the low-
pressure relief signal port (Ps1 (Ps2)).
When the (L2 (R2)) upstream main spool operates, the oil flowing through (L2 (R2)) is reduced, so
the (Ps1 (Ps2)) signal pressure becomes lower.
2) Relief operation
When excess oil flows in path (L2 (R2)), the poppet is operated by the pressure generated in path (L2
(R2)) by the orifice (Lc1 (Rc1)).
Through this poppet operation, the oil flows from the path, through the notch hole path, and out to the
tank path [Ta]. This prevents the generation of excess pressure at the low-pressure relief signal port.
4) Add-on main relief valve

1) Add-on main relief valve operation
This relief valve is incorporated between the neutral path "HP" and the tank path "LP". The oil passes
through the metering hole of the main poppet [1] and charges the interior space [C].
Also, the sleeve [2] and the main poppet [1] seat securely operating on the different surface areas "A"
and "B".
84402832 NA - May 2011

8030D-42
2) When the neutral path "HP" pressure reaches the set pilot spring force, the pilot poppet [3] opens.
The oil flows around the pilot poppet [3], passes from the notch hole [E] and through the ring-shaped
gap [D] and is led to the tank path "LP".
3) Because the pilot poppet [3] has opened, the interior space [C] pressure drops and the main poppet
[1] opens, so the "HP" oil flows directly into the path "LP".
84402832 NA - May 2011

8030D-43
84402832 NA - May 2011

8030D-44
Section
8030E
4 Stack Solenoid Valve Operation Explanation
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
External Shape Diagram and Component Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Operation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

External Shape Diagram and Component Parts

This valve is made up of the body and the electromagnetic switchover valve.
Normal closed type solenoid; SP, S1, S3 Normal open type solenoid; S2
1 Electromagnetic switchover valve

2 Body
84402832 NA - May 2011

8030E-3
Hydraulic circuit diagram

The pressure oil fed from the P port feeds pressure oil to the C1 - C3 ports according to the excitation or non-excitation
of electromagnetic switchover valves S3 - S4 resulting from exciting electromagnetic switchover valve SP.
Electromagnetic switchover valves S1, S3 → Oil passing through when valve excited
Electromagnetic switchover valve S2 → Oil passing through when valve not excited
84402832 NA - May 2011

8030E-4
Section
8030F
Structure and Operation Explanation of Upper Pilot Valve

(remote control valve)
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Structural Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Structure
The structure of the remote control valve is as shown in the Structural Diagram. There is a longitudinal axial hole in
the casing and the pressure reduction valve is installed in it.
The pressure reduction valve comprises the spool (201), secondary pressure setting spring (241), return spring (221),
spring seating (216), and washer 2 (217). The secondary pressure setting spring (241) is set so that the secondary
pressure calculation is 0.5 - 1 MPa (depending on the model). The spool (201) is pressed against the push rod (212)
by the return spring (221).
When the push rod (212) is pushed down by tilting the handle or another operation, the spring seating goes down at
the same time and the secondary pressure setting spring (241) setting is changed.
The casing (101) has the oil inlet (primary pressure) port P and the outlet (tank) port T and, furthermore, the secondary
pressure is taken out from the ports 1, 2, 3, 4.
Function
1. Basic functions
The remote control valve is for controlling the control valve spool stroke quantity, direction, etc. This is done by
operating the pilot valve output pressure on the control valve spool end section.
In order to satisfy this function, the remote control valve is made up of the following elements.
1) Inlet port (P) to which the oil is fed from the hydraulic pump
2) Multiple output ports (1, 2, 3, 4) for operating the feed pressure from the inlet port on the control valve spool
end
3) Tank port (T) required for controlling the above output pressure
4) Spool connecting the output port to the inlet port or tank port
5) Mechanical means including a spring operating on the above spool in order to control the output pressure
2. Main part functions
The function of the spool (201) is to switch the oil path either to have the hydraulic pressure fed from the hydraulic
pump received by the P port and lead the P port pressure oil to the output ports (1, 2, 3, 4) or to lead the output
port pressure oil to the T port. The output pressure operating on this spool (201) is determined by the secondary
pressure setting spring (241).
In order to change the deflection quantity of the secondary pressure setting spring (241), the push rod (212) is
inserted into the plug (211) in such a way that it can slide.
The return spring (221) operates on the casing (101) and spring seating (216) and operates to return the push
rod (212) in the displacement zero direction regardless of the output pressure and makes the spool (201) neutral
return reliable. It also has the effect of a counter-force spring for giving an operator an appropriate operation feel.
Operation
Operation of the remote control valve is explained based on the hydraulic circuit diagram (Diagram 1) and operation
explanation diagrams (Diagram 2 - Diagram 4).
Diagram 1 is a typical usage example for the remote control valve.
84402832 NA - May 2011

8030F-3
Diagram 1 Remote control valve usage example
1 Pilot valve 3 Main pump 5 Hydraulic motor

2 Pilot pump 4 Control valve 6 Hydraulic cylinder
84402832 NA - May 2011

8030F-4
1. When the handle is in neutral (See Diagram 2.)
The force of the secondary pressure setting spring (241) that determines the remote control valve output pressure
does not operate on the spool (201). Therefore, the spool (201) is pushed up by the return spring (221) (spring
seating (216)) and the output ports (2, 4) are connected with the T port. Therefore, the output pressure is the
same as the tank pressure.
Diagram 2 When the handle is in neutral
84402832 NA - May 2011

8030F-5
2. When the handle is tilted (See Diagram 3.)
When the handle is tiled and the push rod (212) is moved through a stroke, the (spring seating (216)) spool (201)
moves down and the oil fed from the pilot pump flows out to the ports (2, 4) through the P port and the ports (2,
4) and pressure is generated.
Diagram 3 When the handle is tilted
84402832 NA - May 2011

8030F-6
3. When the handle is held (See Diagram 4.)
When the handle is tilted and the pressure of the ports (2, 4) rises to a pressure equivalent to the set spring force
(241), the hydraulic pressure and the spring force are in balance. When the ports (2, 4) pressure becomes higher
than the set pressure, the ports (2, 4) and the P port close and the ports (2, 4) and the T port open. When the
ports (2, 4) pressure becomes lower than the set pressure, the ports (2, 4) and the P port open and the ports (2,
4) and the T port close, so the secondary pressure is held constant.
Diagram 4 When handle held (secondary pressure at or above set pressure)
1 T port
2 P port
4. Operation in area in which the handle tilt is large (depends on the model)
For certain models, when the handle is flipped down beyond a certain angle, the spool top end section touches
the push rod bore bottom section and the output pressure goes into the state of still being connected with the P
port pressure.
Furthermore, with the structure in which the spring seating and spring are installed inside the push rod, when
the handle is flipped down beyond a certain angle, the push rod bore bottom section and the spring touch. That
spring force changes the 2nd pressure gradient and after that the push rod bore bottom section and the spring
seating top end section touch, and the output pressure remains connected to the P port.
84402832 NA - May 2011

8030F-7
Structural Diagram
Code Part name Q'ty

101 Casing 1
151 Plate 1
201 Spool 4
211 Plug 4
212-1 Push rod 2
212-2 Push rod 2
213 Seal 4
214 O-ring 4
216-1 Spring seating 1 2
216-2 Spring seating 1 2
217 Washer 2 4
221-1 Spring (port 1) 1
221-2 Spring (port 3) 1
84402832 NA - May 2011
8030F-8
Code Part name Q'ty
221-3 Spring 2
241-1 Spring 2
241-2 Spring 2
301 Joint 1
302 Disk 1
312 Adjusting nut 1
501 Bellows 1
84402832 NA - May 2011

8030F-9
84402832 NA - May 2011

8030F-10
Section
8030G
Structure and Operation Explanation of Travel Pilot Valve

(remote control valve))
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pressure Reduction Valve Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operating Section Damping Mechanism Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Structural Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Operation
The remote control valve with built-in damper (hereinafter, remote control valve with damper) is a remote control valve
that incorporates into the remote control valve main unit a damping function for preventing the man-machine system
hunting (lever hunting) phenomenon.
Operation of the remote control valve with damper is divided into the Pressure Reduction Valve Section and the Op-
eration Section Damping Mechanism Section. The explanations in these 2 sections are based on the hydraulic circuit
diagram, assembly cross-section diagram, and damping operation explanation diagram below. The diagram below is
a typical usage example for the remote control valve.
Hydraulic circuit diagram
1 Remote control valve 4 Control valve

2 Pilot pump 5 Hydraulic motor
3 Main pump 6 Hydraulic cylinder
84402832 NA - May 2011

8030G-3
Pressure Reduction Valve Section
1. For the neutral state
The spool (301) is pushed up by the return spring (335) via the spring seating (311) and washer 1 (215) and is in
the neutral position shown in the assembly cross-section diagram.
Therefore, since the output port is connected only to port T by the spool switching function, the pressure at output
ports 1 and 2 is the same as the pressure at port T.
2. When the remote control valve operation section is tilted from the neutral state
In the assembly cross-section diagram, when the cam (420) is rotated clockwise, the port 1 side push rod (214)
is pushed down, the spool moves down via washer 1, the spring seating, the secondary pressure setting spring
(324), washer 2 (217), and washer 3 (313), the port P and port 1 are connected, and the oil fed from the pilot
pump flows to port 1 and generates pressure.
When the port 1 pressure rises to the pressure equivalent to the secondary pressure setting spring force that
has been set by tilting the operation section, the hydraulic pressure on the spool and the spring force come into
balance and the port 1 output pressure is held constant. The port 2 spool stays in the neutral state and the oil
from the control valve is discharged via port T.
Some specifications are of the type that near the maximum angle of the operation section, a push rod directly
touches the spool top section and forcibly pushes in the spool to connect port P and the output port so that they
have the same pressure.
Operating Section Damping Mechanism Section

1. For the neutral state
The push rod is pushed up by the damping springs (333, 337) via the piston (224) and is in the position shown
in the assembly cross-section diagram.
2. When the operation section is tilted from the neutral state (See Damping operation explanation diagram (1).)
In the assembly cross-section diagram, when the cam is rotated clockwise, the port 1-side push rod is pushed
down and the piston moves down (2-1).
At this time, the oil in the damping piston chamber is discharged from the piston metering hole and the pressure
generated at this time generates damping force.
On the other hand, the port 2-side push rod is moved up by the damping spring via the piston.
At this time, the tank chamber oil is suctioned in through the 3 ball check sections made up of bushings (223)
and steel balls (225) and into the damping piston chamber.
The oil outside the piston chamber drains out from the path that leads from the casing top end section to port T.
3. When the operation section is tilted back from a full tilt (See Damping operation explanation diagram (2).)
In the assembly cross-section diagram, after the cam is fully tilted clockwise then rotated counter-clockwise, the
port 2-side push rod is pushed down and the piston moves down.
At this time, as described above, the oil in the damping piston chamber is discharged from the piston metering
hole and the pressure generated at this time generates damping force (3-1).
On the other hand, the port 1-side push rod is moved up by the return spring (335) and the damping spring (3-2).
At the same time, the tank chamber oil is suctioned in through the 3 ball check sections made up of bushings
and steel balls and into the damping piston chamber (3-3).
Also, the oil outside the piston chamber drains out from the path that leads from the casing top end section to
the tank port (3-4).
In other words, the structure is such that damping force works for either tilt operation, from the neutral position to
the full tilt position or from the full tilt position to the neutral position.
84402832 NA - May 2011

8030G-4
Damping operation explanation diagram
1. Operation when lever is moved through its stroke from the neutral position
1 Push rod 3 Piston

2 Orifice 4 Piston chamber
84402832 NA - May 2011

8030G-5
2. Lever stroke state and operation when lever is moved back
*1 Neutral *3 (Þ during operation)

*2 Full stroke 12.5° *4 Oil drains to T.
84402832 NA - May 2011

8030G-6
Structural Diagram

101 Casing 1 271 Hexagon socket head bolt 271
151 Plug 2 301 Spool 301
201 Cover 2 311 Spring seating 311
202 Plug 4 313 Washer 3 313
203 Grease cup 4 324 Spring 324
210 NHU packing 4 335 Spring 335
214 Push rod 4 337 Spring 337
215 Washer 1 8 412 Bushing 412
217 Washer 2 4 413 Camshaft 413
218 Spring seating 4 420 Cam 420
221 Locking ring 4 423 Hexagon socket head locking screw 423
223 Bushing 4 471 Locking screw 471
84402832 NA - May 2011
8030G-7
224 Piston 2D085 4 472 Lock nut 472
225 Steel ball 12 501 Bellows 501
84402832 NA - May 2011

8030G-8
Section
8030H
Structure and Operation Explanation of Cushion Valve
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Structure
This valve is made up of a shuttle valve section and cushion valve section with heat circuit.
The cushion valve with a heat circuit is connected between the hydraulic shovel car control valve and the pilot oper-
ation valve to reduce body shaking (cushion function) caused by emergency stop operations by the operator.
This valve is also equipped with a circuit with which the operator can deliberately disable the cushion function for
reverse operations.
The shuttle valve selects the high-pressure signal pressure from 2 signal pressure systems.
This valve has 2 circuits.
*1 Arm
*2 Boom
84402832 NA - May 2011

8030H-3
1. Normal operation
The pressure oil fed from the pilot operation valve to the A port (or C, E, or G port) pushes up the check plunger
and is sent to the B port (or D, F, or H port).
The pressure oil that has passed through the B port operates on the control valve spool and operates the actuator.
The oil pushed out from the control valve spool passes through the D port (or B, F, or H port) and flows out to the
T port.
84402832 NA - May 2011

8030H-4
2. Cushion operation
When the pressure oil fed from the pilot operation valve to the A port (or C, E, or G port) is closed by the pilot
operation valve, the pressure oil that has operated on the control valve spool is pushed back to the B port (or the
D, F, or H port) by the return spring on the spool.
The returned oil passes through the check plunger metering orifice, is sent to the A port (or the C, E, or G port),
and is drained from the pilot operation valve.
At this time, by passing through the metering orifice, the pressurized oil holds down the control valve spool speed,
which prevents the sudden stopping of the actuator and reduces shaking of the body. (Cushion function)
84402832 NA - May 2011

8030H-5
3. Reverse operation
When the pressure oil fed from the pilot operation valve to the A port (or C, E, or G port) is switched to the C port
(or A, E, or G port), the pressure oil that has operated on the control valve spool is pushed back to the B port.
Because the pushed back oil flows out to the T port without passing through the check plunger metering orifice,
it does not hold down the control valve spool speed, so the cushion function does not work.
84402832 NA - May 2011

8030H-6
4. Heat circuit
When the pilot operation valve is in the neutral position, the oil fed to the R port passes through the inside of the
reverse operation spool and flows out to the T port, which heats up the inside of the valve.
When pressure oil is being fed from the pilot operation valve to the A port (or C, E, or G port), the oil fed to the
R port flows out to the C port (or A, E, or G port) and heats up the circuit to the pilot operation valve and inside
the valve.
5. Shuttle valve
The steel ball is pressed from the higher of the pressures between the I and J ports and the K and L ports to the
lower of these pressures. Through this process, high-pressure oil is fed to the S port or the Q port.
In the same way, oil of the higher pressure between the M and N ports and the O and P ports is fed to the U port.
84402832 NA - May 2011

8030H-7
84402832 NA - May 2011

8030H-8
Section
9002
Removal and Installation of Counterweight
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CAUTION 4. Use the wire ropes and liftcrane to lift and remove
the counterweight.
work. • Move the counterweight about 50 cm to the rear
while lifting it so that it does not interfere with the
• Be sure to inspect the wire rope and other housing, engine parts and pipes.
load.
• Thoroughly secure the removed counter-
weight with the wire ropes and liftcrane so
that it does not fall over.
Items to prepare
• Balance lifting device
• Shackles (with the required lifting capacity) x 4
• Wire rope (with the required breaking load) x 4
• Rag
• Cleaning fluid
Removal of Counterweight
1. Remove the following before beginning work.。
• Engine hood, gas damper and lock stay
• Rear view camera and electrical parts bracket
2. Install the shackles (1), and then use the wire ropes
(2) and liftcrane to secure the counterweight so that
it does not fall during removal and installation oper-
ations.

(1) at the bottom section of the counterweight.
84402832 NA - May 2011

9002-3
5. Thoroughly check that the location is safe before Installation of Counterweight

lowering the counterweight on wood planks (1).
1. Install the shackles (1), and then use the wire ropes
• Thoroughly secure the counterweight with the (2) and liftcrane to secure the counterweight so that
wire ropes and liftcrane so that it does not fall it does not fall during removal and installation oper-
over. ations.
2. Use the wire ropes and liftcrane to lift and install the
counterweight.
• Suspend the counterweight so that it does not in-
terfere with the housing, engine parts and pipes.
3. Coat the threaded section of the bolt (1) with Loctite,

and use a box wrench (50 mm) to fasten the coun-
terweight using the 4 bolts (1) and 4 high-strength
washers (2) at the bottom section of the counter-
weight.
Tightening torque: 1862 - 2058 N·m
4. Install the following after finishing work.

• Engine hood, gas damper and lock stay
• Rear view camera and electrical parts bracket
84402832 NA - May 2011

9002-4
Section
9003A
Removal and Installation of Bucket
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Job code 84100AB20 Installation of Bucket

CAUTION
good footing.
work.
• Always wear protective gear (protective eye-
wear and safety shoes, etc.) when working
with a hammer.
Items to prepare
• Hammer
Striking rod 2. Place the back of the bucket parallel to the ground.
•
Grease Use a hammer (4) to press in the bucket side pin (3)
•
Rag and arm side pin (2), and then install the bucket (1).
•
• Cleaning fluid • If a pin is hard to insert, there is a load on the pin.
• Wrench (36 mm) x 2 Do not force it in. Adjust the bucket installation
position.
Removal of Bucket • When inserting the pin, be careful not to damage
• Place the back of the bucket parallel to the ground.
1. Remove the bolts (1) and the nuts (2).
3. Install the bolts (1) and nuts (2) to the bucket and
arm side pins.
bucket side pin (3) and arm side pin (2) out, and • When installing the pin bolts, leave about 1 to 2
mm of gap between both nuts and the retaining
then remove the bucket (1).
ring.
• When removing the pin, be careful not to damage • Grease up.
84402832 NA - May 2011

9003A-3
84402832 NA - May 2011

9003A-4
Section
9003B
Removal and Installation of Bucket Link
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Bucket Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Bucket Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CAUTION 2. Use 2 wrenches (36 mm) to remove the double nuts

(1), and then pull out the bolts (2) (3).
good footing.
work.
• Always wear protective gear (protective eye-
wear and safety shoes, etc.) when working
with a hammer.
Items to prepare
• 2 wrenches (36 mm)
• Hammer
• Striking rod 3. Use a hammer (3) and striking rod (4) to push the
• Grease pin (2) out and remove the bucket link (1).
• Rag
• Cleaning fluid
Removal of Bucket Link

1. Place the bucket link (1) parallel to the ground.

pin (3) out and remove the arm links (1) (2).
84402832 NA - May 2011

9003B-3
Installation of Bucket Link 3. Place the bucket link (1) parallel to the ground.
Use a hammer (3) to push in the pin (2) and install
1. Clean each pin and pin hole. the bucket link (1).
2. Use a hammer (4) to push in the pin (1) and install 4. Use 2 wrenches (36 mm) to attach the double nuts
the arm links (2) (3). (1), and then install the bolts (2) (3).
• If a pin is hard to insert, there is a load on the pin. • When installing the pin bolts, leave about 1 to 2
• When inserting the pin, be careful not to damage mm of gap between both nuts and the retaining
the installed O-rings or dust seals. ring.
• Grease up.
84402832 NA - May 2011

9003B-4
Section
9003C
Removal and Installation of Arm
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Job code 39121AA10 2. Use a wrench (30 mm) to remove the bolt (1) and
spacer (2).
CAUTION
good footing.
work.
ing with a hammer.
• Do not stand or pass under the suspended 3. Use a hammer (3) and striking rod (4) to push the
load. pin (2) out and remove the arm (1).
Items to prepare • If a pin is hard to remove, there is a load on the
pin.
• Wrench (30 mm) • When removing the pin, be careful not to damage
• Hammer the installed dust seals.
• Striking rod • Be very careful. When the pin is removed, the
• Nylon sling (with the required lifting capacity) arm may fall slightly.
• Liftcrane (with the required lifting capacity) • Be very careful. The arm may fall over to the side.
• Grease
• Rag
• Cleaning fluid
• Crosstie
Removal of Arm
• Remove the bucket cylinder. (For details, see "Re-
moval and Installation of Bucket Cylinder".)
• Remove the arm cylinder. (For details, see "Removal
and Installation of Arm Cylinder".)
1. Bring the arm (1) top in contact with the ground and 4. Lift the arm and then place it on the crosstie.
use a liftcrane and nylon sling (2) to secure it.
At this time, insert the arm cylinder pin (3) and se-
cure with the nylon sling.
84402832 NA - May 2011

9003C-3
Installation of Arm • When inserting the pin, be careful not to damage

the installed dust seals.
• Tighten bolts being installed to the specified torque.
and Torque Table".

spacer (2).
• Install the arm cylinder. (For details, see "Re-
moval and Installation of Arm Cylinder".)
2. Bring the arm (1) top in contact with the ground and • Install the bucket cylinder. (For details, see "Re-
use a liftcrane and nylon sling (2) to secure it. moval and Installation of Bucket Cylinder".)
At this time, insert the arm cylinder pin (3) and se- • Install the bucket link. (For details, see "Removal
cure with the nylon sling. and Installation of Bucket Link".)
3. Align the arm (1) with the boom and use a hammer
(3) to push in the pin (2) and then install the arm (1).
• If a pin is hard to insert, there is a load on the pin.
84402832 NA - May 2011

9003C-4
Section
9003D
Removal and Installation of Boom
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Job code 39105AB10 1. Bring the boom (1) top in contact with the ground.
CAUTION
good footing.
work.
ing with a hammer.
lifting equipment before beginning work. 2. Use a wrench (19 mm) to remove the grease hoses
• Do not stand or pass under the suspended on the left and right sides (1).
load.
• Use caps or plugs to prevent any entry of water,
Items to prepare dust or dirt.
• Wrenches (10 mm、19 mm、22 mm、30 mm、36

mm、41 mm)
• Slide hammer (24 mm)
• Marking pen
• Cap
• Plug
• Rag
• Striking rod
• Cleaning fluid
• Wood piece
• Square wooden pieces
• Wire 3. Use a wrench (36 mm) to remove the double nuts
(1) and bolt (2), and then remove the fastening ring
Removal of Boom (3).
• Remove the bucket cylinder. (For details, see "Re-
• Remove the arm cylinder. (For details, see "Removal
and Installation of Arm Cylinder".)
• Remove the arm. (For details, see "Removal and In-
stallation of Arm".)
• This section explains the procedure for when attaching
the boom cylinder to the frame.
When removing the boom cylinder too, see "Removal
and Installation of Boom Cylinder".
84402832 NA - May 2011

9003D-3
4. Use a hammer (2) and striking rod (3) to push the 7. Secure the base of the boom cylinder with the wood
pin (1) out. piece (1).
Use a liftcrane and nylon slings (4) to hold the boom
cylinders (right) (left) so that they does not fall.
8. Lower the boom cylinders (right) (left) and let them

rest on the wood piece (1).
5. Start the engine, lower the boom at idle, and retract
the boom cylinder (1) (2) rod. • Remove the cab side boom cylinder from the
boom in the same way.
6. Tie the cylinder rods on the left and right sides with
wire (1) so that they cannot come out. 9. Install the pin (1) removed in Step 4.
Use a wrench (36 mm) to tighten the bolt (3) with
the 2 double nuts (2), and then install the fastening
ring (4).
10. Use wrenches (41 mm) to remove the hoses (1),

(2), (3).
Use a hexagon wrench (12 mm) to remove the
4 hexagon socket head bolts (5) and the 2 split
flanges (6), and then remove the hose (4).
• Mark the hoses and lines so that the connectors
84402832 NA - May 2011

9003D-4
• Use caps or plugs to cover the hoses and lines to 12. Use a wrench (30 mm) to remove the bolt (1) and
prevent any entry of water, dust or dirt. washer (2).
• Clean the hoses and lines by spraying them with
13. Use a slide hammer (1) (24 mm) to remove the pin
(2).
11. Wrap nylon slings (1) around the pins on the left and
right sides installed in Step 9 and secure with the
liftcrane.
14. Back up the machine and remove the boom (1).
84402832 NA - May 2011

9003D-5
Installation of Boom 4. Tie the cylinder rods on the left and right sides with
wire (1) so that they cannot come out.
• This section explains the procedure for when not in-
stalling the boom cylinder.
• Tighten bolts being installed to the specified torque.
and Torque Table".
5. Align the boom with the swing frame pin hole and
use a slide hammer (1) (24 mm) to tighten the pin
(2).
• When inserting pins, be careful not to damage the
dust seals.
• If the insertion of a shim is possible according to
2. Install the pin (1). the tolerance adjust the shim.
Use a wrench (36 mm) to tighten the bolt (3) with
the 2 double nuts (2), and then install the fastening
ring (4).

washer (2).
• Grease up.
3. Wrap the nylon slings (1) around pins on the left and
right sides installed in Step 2 and secure with the
liftcrane.
84402832 NA - May 2011

9003D-6
7. Use a wrench (41 mm) to install the hoses (1) (2) 10. Use a wrench (36 mm) to attach the double nuts (1)
(3). and bolt (2), and install the fastening ring (3).
After setting the O-ring (4) on the line side, install Also, install the cab side in the same way.
the hose (4) with the 2 split flanges (6) and the 4
hexagon socket head bolts (5).
11. Use a wrench (19 mm) to attach the grease hoses

on the right and left sides (1).
8. Start the engine, raise the boom at idle, and extend

the boom cylinder (1) (2) rod.
12. Bring the boom (1) top in contact with the ground.
• When installing the boom cylinder too, see "Re-
moval and Installation of Boom Cylinder".
• Install the arm. (For details, see "Removal and
9. Use a hammer (2) to push in the pin (1). Installation of Arm".)
Use a liftcrane and nylon slings (3) to hold the boom • Install the arm cylinder. (For details, see "Re-
cylinders (right) (left) so that they does not fall. moval and Installation of Arm Cylinder".)
• Install the bucket cylinder. (For details, see "Re-
• Install the bucket link. (For details, see "Removal
84402832 NA - May 2011

9003D-7
84402832 NA - May 2011

9003D-8
Section
9004
Removal and Installation of Operator's Seat
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Operator's Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Operator's Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Job code 90120AD17 3. Use a wrench (13 mm) to remove the 2 bolts (1)
from the rear of the seat.
Tightening torque for bolt (1) installation: 19.6 N·m
Items to prepare
• Wrench (13 mm)
Removal of Operator's Seat

1. Pull the slide lever (1) to slide the seat (2) to the
rear.
Use a wrench (13 mm) to remove the 2 bolts (3)
from the front of the seat.
Tightening torque for bolt (3) installation: 19.6 N·m
4. Remove the operator's seat (1).
2. Pull the slide lever (1) to slide the seat forward, and
then pull the reclining lever (2) to fold the seatback
forward.
Installation of Operator's Seat

84402832 NA - May 2011

9004-3
84402832 NA - May 2011

9004-4
Section
9005A
Removal and Installation of Cab Assembly
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Cab Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Cab Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Job code 90150AA08 2. Use a box wrench (10 mm) to remove the 3 bolts
(1), and then remove the air conditioner ducts on
both sides (2) (3).
CAUTION Tightening torque for bolt (1) installation: 2.9 - 3.9
N·m
work.
load.
Items to prepare
• Wrenches (10 mm, 12 mm, 13 mm, 19 mm, 41 mm)
• Box wrenches (10 mm, 13 mm, 19 mm)
• Longnose pliers
• Eyebolt (M24 x 4)
• Chains (wire ropes) (with the required breaking load)
3. Use a Phillips screwdriver or box wrench (10 mm)
• Lubricating oil
to remove the 2 bolts (1), and then remove the side
• Rag
front lower trim (2).
• Cleaning fluid
Tightening torque for bolt (1) installation: 5.9 - 7.8
N·m
Removal of Cab Assembly
• Remove the operator's seat. (For details, see "Re-
moval and Installation of Operator's Seat".)
(1), and then remove the trim rear assembly (2).
N·m
4. Use a flathead screwdriver or longnose pliers to re-

move the clip pins (1), and then remove the air con-
ditioner ducts (2) by pulling them forward.
84402832 NA - May 2011

9005A-3
5. Use a wrench (13 mm) to remove the 2 bolts (2), 8. Remove the connector (1) and wire band (2), and
and then remove the bracket (1) and air conditioner then use a wrench (13 mm) to remove the 2 bolts
duct (3). (3).
6. Remove the radio antenna (1). 9. Remove the washer fluid hose (
).
7. Use a wrench (13 mm) to remove the bolts (2) for

the ground wire (1) connecting the cab and frame. 10. Use a wrench (13 mm) to remove the 4 bolts (1), use
a wrench (12 mm) to remove the 3 bolts (4) and 2
nuts (2), and then remove the rear brackets (3) (5).
84402832 NA - May 2011

9005A-4
11. Use a wrench (13 mm) to remove the 3 bolts (1), 14. Remove the connector (1).
and then remove the bracket (2).
15. Remove the 4 connectors (1) and the 2 wire bands

12. Use a flathead screwdriver or longnose pliers to re- (2).
move the 2 clips (1), and then remove the suction
ducts (2) (3).
16. Remove the 4 caps (1) from the top of the cab.

and then remove the bracket (2).
84402832 NA - May 2011

9005A-5
17. Install the 4 eyebolts (M24) (1) in place of the re- 19. Use a wrench (19 mm) to remove the 8 cab bolts
moved caps. (1) and 4 nuts (2).
by a half turn.
18. Use chains (1) and liftcrane to secure the cab.
20. Use a wrench (41 mm) to remove the anchor bolt

(1).
84402832 NA - May 2011

9005A-6
21. Use chains (1) and liftcrane to remove the cab (2). 22. Thoroughly check that the location is safe before
lowering the cab on wood planks (1).
• Thoroughly secure the cab with the chains and
liftcrane so that it does not fall down.
84402832 NA - May 2011

9005A-7
Installation of Cab Assembly Tighten bolts being installed to the specified torque.
If the torque is not specified, see the "Tightening Torque"
To install, perform the reverse of the removal procedure. section.
84402832 NA - May 2011

9005A-8
Section
9005B
Removal and Installation of Wiper
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Wiper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Items to prepare Installation of Wiper

• Wrench (17 mm) To install, perform the reverse of the removal procedure.
• Phillips screwdriver Tighten bolts being installed to the specified torque.
Removal of Wiper
1. Use a wrench (17 mm) to remove the 1 nut (1), and
then remove the wiper arm (2).
Tightening torque for nut (1) installation: 12 - 16 N·m
2. Use the Phillips screwdriver to remove the 1 screw

(1), and then remove the wiper (2).
84402832 NA - May 2011

9005B-3
84402832 NA - May 2011

9005B-4
Section
9005C
Removal and Installation of Wiper Controller
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Wiper Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Wiper Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Job code 55518BH01 Installation of Wiper Controller

Items to prepare Tighten bolts being installed to the specified torque.
• Wrench (10 mm) If the torque is not specified, see the "Tightening Torque"
• Box wrench (10 mm) section.
Removal of Wiper Controller

rear B trim (2).
2. Remove the connector (2) from the wiper controller

(1).
3. Use a flathead screwdriver to slightly bend the 4 in-

stallation clips (1), and then remove the wiper con-
troller (2).
84402832 NA - May 2011

9005C-3
84402832 NA - May 2011

9005C-4
Section
9005D
Removal and Installation of Wiper Motor
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Job code 55518AZ46 3. Use a Phillips screwdriver or box wrench (10 mm)
to remove the 2 bolts (1), use a hexagon wrench (5
mm) to remove the 3 bolts (2) and 3 washers (3),
Items to prepare
and then remove the front upper trim assembly (4).
• Hexagon wrench (5 mm) Tightening torque for bolt (1) installation: 5.9 - 7.8
• Wrenches (10 mm, 17 mm) N·m
• Flathead screwdriver (longnose pliers)
Removal of Wiper Motor

N·m
4. Use a wrench (17 mm) to remove the 1 nut (1), and

then remove the wiper arm (2).
Tightening torque for installation: 12 - 16 N·m
2. Use a flathead screwdriver or longnose pliers to re-

move the clip pins (1), and then remove ducts B (2).
5. Use a wrench (17 mm) to remove the 1 nut (1).

Tightening torque for installation: 11 - 13 N·m
84402832 NA - May 2011

9005D-3
6. Use a box wrench (10 mm) to remove the 4 bolts Installation of Wiper Motor
(1), and then remove the wiper motor assembly (2).
• Be careful about the wiper link and wiper arm installa-
tion location.
• Check the wiper arm wipe location and stop location.
• When installing the bolts, tighten them to the specified
torque.
If the torque is not specified for an installation bolt, see
the "Tightening Torque" section.
84402832 NA - May 2011

9005D-4
Section
9005E
Removal and Installation of Monitor
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Job code 55640AO14 3. Remove the connector (1).
Items to prepare
• Wrench (10 mm)
Removal of Monitor

and then remove the monitor (1).

to remove the 2 bolts (1), use a hexagon wrench (5
mm) to remove the 3 bolts (2) and 3 washers (3),
and then remove the front upper trim assembly (4).
Installation of Monitor
For the tightening torques of the installation bolts, see
the "Tightening Torque" section.
84402832 NA - May 2011

9005E-3
84402832 NA - May 2011

9005E-4
Section
9005F
Removal and Installation of Cab Front Glass
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Cab Front Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Cab Front Glass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Job code 90156AL10 3. Use a wrench (10 mm) to remove the 3 bolts (1)
each, and then remove the brackets (2) (3).
Tightening torque for bolt (1) installation: 880 - 1270
CAUTION N·cm
Reinforced glass is used for the front win-
dow.
Be extremely careful not to damage it when
touching it during removal or installation.
Items to prepare
• Wrench (10 mm)
• Rag
• Cleaning fluid
Removal of Cab Front Glass

1. Use a Phillips screwdriver to remove the 8 clips (2),
4. Remove the covers (1) (2) for the bracket.

2. Use a Phillips screwdriver to remove the screw
and then remove the front glass left lower bracket
(1), and then install the removed screw (1) into the
(2).
screw hole (2).
Tightening torque for bolt (1) installation: 880 - 1270
• The assist spring is locked. N·cm
84402832 NA - May 2011

9005F-3
6. Use a wrench (10 mm) to remove the 3 bolts (1), Installation of Cab Front Glass
and then remove the front glass right lower bracket
(2). To install, perform the reverse of the removal procedure.
Tightening torque for bolt (1) installation: 880 - 1270 Tighten bolts being installed to the specified torque.
N·cm If the torque is not specified, see the "Tightening Torque"
section.
7. Remove the cab front glass (1).
84402832 NA - May 2011

9005F-4
Section
9005G
Window Lock Adjustment Procedures
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Window Lock (front side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Window Lock (rear side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Items to prepare 3. Set the cab front glass (1) in place.

• Wrench (10 mm)
• Rag
• Cleaning fluid
Window Lock (front side)

1. Release the lock with the lever (1), and then remove
the lock of the cab front glass.
4. Use a wrench (10 mm) to retighten the 2 bolts (1).
2. Use a wrench (10 mm) to loosen the 2 bolts (1).
84402832 NA - May 2011

9005G-3
Window Lock (rear side) 3. Set the cab front glass (1) in place.
1. Use a Phillips screwdriver to remove the 8 clips (2),

4. Use a wrench (10 mm) to retighten the 4 bolts (1).
2. Use a wrench (10 mm) to loosen the 4 bolts (1).
84402832 NA - May 2011

9005G-4
Section
9005H
Tightening torque
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Tightening torque
Tightening torque
When installing cab inner and outer parts, for bolts and screws for which the torque is not specified, tighten according
to the following.
Bolt nominal di-

ameter M3 x 0.5 M4 x 0.7 M5 x 0.8 M6 x 1.0 M8 x 1.25 M10 x 1.5
(size)
N•m 0.59 - 0.79 1.27 - 1.86 2.45 - 3.53 4.52 - 6.14 9.84 - 14.74 19.58 - 28.4
kgf•m 0.06 - 0.08 0.13 - 0.19 0.25 - 0.36 0.43 - 0.63 1.00 - 1.50 2.0 - 2.9
84402832 NA - May 2011

9005H-3
Tightening torque
84402832 NA - May 2011

9005H-4
Section
9006
Air Conditioner Overall Diagram
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Air Conditioner Overall Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Equipment Layout Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Air Conditioner Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Explanation of Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Explanation of Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Air Mix Motor Actuator Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Blow Mode Motor Actuator Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Refresh/Recirculate Switch Motor Actuator Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Blower Amp Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Compressor Clutch Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
COOLMAX Control and HOTMAX Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Abnormality Detection and Control after Abnormality Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Monitor Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Door Switch Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Inside Air Filter Clogging Detection Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Actuator Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Air Mix Motor Actuator Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Refresh/Recirculate Switch Motor Actuator Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Mode Motor Actuator Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Self-diagnosis Function with Panel Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Abnormality Display and Self-check Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Abnormality Display Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Explanation of Abnormality Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Motor Actuator Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Sensor Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Explanation of Monitor Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Monitor Mode Display Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Monitor Mode Display Operating Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Display Contents in Monitor Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Part Function and Good/Poor Judgment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Blower Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Air Mix Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Refresh/Recirculate Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Blow Mode Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Evaporator Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Dual Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Solar Radiation Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Inside Air Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54


Frame
84402832 NA - May 2011

9006-3
Compressor; Air con-
1 Cooler hose (Liquid 2) 1 5 1 9 Dryer receiver (D60.5) 1
ditioner
2 Cooler hose (Suction) 1 6 Slide shaft 1 10 Cooler hose (Liquid 1) 1
Rubber hose 16 x Tension pulley (With Bracket receiver
3 2 7 1 11 1
5600 cover) (D60.5)
Cooler hose (Dis-
4 1 8 Air condenser 1 12 V belt B-45.5 1
charge)
White marking
a Air conditioner unit e Heater (Engine output) i Must be connected with the air
conditioner unit.
b Engine f Heater (Unit outlet) j Clamp
c Heater (Engine return) g Heater (Unit inlet)
Must be connected with the air
d White marking h
conditioner unit.
84402832 NA - May 2011
9006-4
* in the diagram indicates a clamp position. Figures indicate hose lengths.
84402832 NA - May 2011

9006-5
Cab
84402832 NA - May 2011

9006-6
84402832 NA - May 2011

9006-7
1 Solar radiation sensor 1 8 Duct; H and C box 1 15 Duct; Intake-B (Fresh) 1
2 Duct; Face-A 1 9 Bracket; Box 1 16 Unit; Air conditioner 1
3 Duct; Def-A 1 10 Box; Hot and cool 1 17 Duct; Foot 1
4 Grille; Air vent 7 11 Duct; Vent (Left) 1 18 Duct; Def-B
5 Duct; Face-B 1 12 Duct; Vent (Right) 1 19 Control panel (AC) 1
6 Duct; Def-C 1 13 Air filter (Fresh) 1 20 Drain hose 2
7 Duct; Face-C 1 14 Duct; Intake-A (Fresh) 1 21 Flange plate 1
a e Should be connected with the

Monitor display Heater hose (Eng.Out) i
console harness.
b Trim side; Front (Right) f Cooler hose (Suction) j Wire harness (Console)
c Trim side; Front (Left) g Cooler hose (Liquid) k Floor
d Heater hose (Eng.Return) h Cover; Top (Console left)
84402832 NA - May 2011

9006-8
Equipment Layout Diagram
84402832 NA - May 2011

9006-9

Motor actuator (refresh/recir-
1 Motor actuator (mode) 4 7 Blower amp
culate switch)
2 Compressor relay 5 Interior temperature sensor 8 Motor actuator (air mix)
3 Blower OFF relay 6 Blower motor 9 Evaporator sensor
84402832 NA - May 2011

9006-10
Circuit Diagram
Air Conditioner Circuit Diagram
84402832 NA - May 2011

9006-11
84402832 NA - May 2011

9006-12
5 V system
5 V are always applied.
Analog Signal:0 - 5 V are applied
GND
P W B R Y G L Br Lg O Sb V
Light Sky
Pink White Black Red Yellow Green Blue Brown Orange Violet
green blue

1 Main key switch 7 Compressor 13 Inside air sensor
2 A/C main power supply 8 Blower OFF relay 14 Motor actuator (air mix)
Power supply for compres-
3 9 Blower motor 15 Motor actuator (mode)
sor clutch
Motor actuator (refresh/re-
4 Power supply for controller 10 Blower amp 16
circulate switch)
5 Sunlight sensor 11 Compressor relay 17 CAN signal
Pressure switch (receiver Control panel (TKS-
6 12 Evaporator sensor 18
dryer) CP208C0)
NOTE:
• Wire diameters that are not indicated are 0.5.
• Broken lines indicate wiring on the vehicle side.
• Codes displayed on the connectors indicate the code colors seen from the connection ports of the connectors.
84402832 NA - May 2011

9006-13
Explanation of Functions
Explanation of Control
Back-up function
Even when air conditioner operation is stopped (switched OFF) with the vehicle main key power supply or operation
panel ON/OFF switch, the set temperature and all the other setting states are stored in memory, so the next time air
conditioner operation starts, it goes into the same state as before it was stopped.
When the vehicle main key power supply is cut off, the data is backed up by storing it in the internal EEPROM.
However, if the main key power supply is cut off within 0.5 sec. of switch input, that switch input is not stored into
memory.
Also, the data read out from EEPROM when the power is switched ON is judged to see if it is within the valid range.
If data outside the valid range was written into memory, for example due to noise, then operation starts from the default
setting values to avoid abnormal operation.
Fahrenheit temperature display
To switch, hold down both the temperature setting UP and DOWN switches for 5 sec.
The display toggles between Celsius and Fahrenheit display each time the switches are both held down for 5 sec.
The Fahrenheit display is a 2-digit integer and below the decimal point is not used, so "F" is displayed.
However, in case of trouble, this display takes priority.
When this display is switched, the new status is backed up in memory, so even if the main key power supply is
switched OFF, the display status is retained.
Internal calculations are all done in Celsius.
Only the operation panel display is in Fahrenheit.
Therefore, the display may differ slightly from the exact Fahrenheit temperature.
Below is shown the Fahrenheit temperature and the corresponding Celsius temperature used in internal processing.
CAUTION
These specifications are written with Celsius as the standard.
Therefore, if the temperature is displayed in Fahrenheit, convert the temperature to centigrade by using
the table below.
Fahrenheit dis- Interior recognition set temper-

play [°F] ature (Celsius) [°C]
63 18.0
64 18.5
65 19.0
：：
77 25.0
：：
91 32.0
84402832 NA - May 2011

9006-14
Air Mix Motor Actuator Control

1. Summary explanation
The provisional target degree of opening is determined from the target blow temperature and the current blow
mode, various restrictions are applied, and the target degree of opening is calculated.
Then drive is output to move the motor actuator position to the target degree of opening.
Below are the details.
2. Heater unit hysteresis correction operation (motor actuator one-direction stop)
After the actuator moves to the target degree of opening, it returns to the specified position.
However, if the target degree of opening is less than 0°, the actuator is treated as having reached the target
degree of opening when it reaches 0°, then it moves to the specified position. (A stop in the fully-open direction
is used as the reference.)
3. Motor actuator operation priority order
The operation priority for this motor actuator is No. 1.
This means that if the target degree of opening for this motor actuator changes and operation becomes necessary,
even if some other motor actuator is operating, that other motor operation is paused, and this motor actuator
operates.
4. Motor actuator retry control
Even when there are no changes to the target values after the target is attained, if the difference between the
current value and the target value once every 5 min. is equal to or greater than the operation start angle, the
motor actuator is operated.
84402832 NA - May 2011

9006-15
Blow Mode Motor Actuator Control

The blow mode is switched by rotating the diffuser switching damper with the motor actuator.
There are 2 types of control: auto and manual.
2. Auto control
When AUTO blow mode is set, the blow mode changes to auto control.
During auto control, the diffuser is switched according to the target blow temperature
Auto control continues until operation of the blow mode select switch is recognized.
*1 Target blow temperature *3 MODE 2 VENT *5 MODE 4　FOOT

*2 Blow mode *4 MODE 3 B/L
3. Manual control
1) When operation of the blow mode select switch is recognized, the blow mode motor actuator is driven to
attain the output shaft angle below and the display is switched too.
Each time operation of the switch is recognized, the display switches MODE 1 → MODE 2 → MODE 3 →
MODE 4 → MODE 1 →...
However, if this switch is pressed during auto control, auto control is ended and the diffuser is fixed at its
current position.
2) MODE 5 in the table below only occurs when operation of the DEF select switch is recognized.
After that, when operation of the blow mode select switch is recognized, the blow mode becomes the one
that was in effect just before operation of the DEF select switch was recognized.
Also, even if the DEF switch is pressed again during this mode, the mode is not canceled.
MODE MODE MODE MODE MODE

Blow mode
1 2 3 4 5
Blow mode motor actuator degree of opening 90° 67° 48° 26° 0°
FACE VENT B/L FOOT DEF
Panel display
4. Blow mode control priority order

The priority order for auto control and manual control is as follows.
Priority order Control

1 Manual control
2 Auto control
84402832 NA - May 2011

9006-16
Refresh/Recirculate Switch Motor Actuator Control

1. Recirculate mode
In refresh mode, when it is recognized that the refresh/recirculate select switch on the operation panel has been
closed, the system goes into recirculate mode.At this time, the display switches to recirculate and the motor
actuator operates to the refresh angle (damper angle) of 0°.
2. Refresh mode
In recirculate mode, when it is recognized that the refresh/recirculate select switch on the operation panel has
been closed, the system goes into refresh mode. At this time, the display switches to refresh and the refresh/
recirculate switch motor actuator operates to the refresh angle.
1) Refresh mode I
When blow mode control is manual and is set to B/L or FOOT, the set temperature is set to 32 °C (HOTMAX),
and air flow control is manual and is set to Hi, the refresh angle (damper angle) operates to 67°.
2) Refresh mode II
When in a mode other than refresh mode I, the refresh angle (damper angle) operates to 30°.
3. Operation stop judgment
1) The operating motor actuator stops when the current position comes within the target position range.
2) The stopped motor actuator operates when the current position goes beyond the target position range.
Refresh/recirculate mode and refresh/recirculate display

Refresh/recirculate mode Recirculate Outside air
Panel display
84402832 NA - May 2011

9006-17
Blower Amp Control

The air flow is controlled by outputting to the blower amp connected in series with the blower motor.
The air flow is switched by varying the analog voltage output by changing the PWM output duty ratio and increas-
ing or decreasing the blower motor speed.
There are 2 types of air flow control: auto air flow control and manual air flow control.
Also, in auto air flow control, the air flow is restricted by the cold blast prevention control etc.
2. Manual air flow control
Each time it is recognized that the air flow UP switch has been closed, the air flow is fixed to the next higher level
of air flow from Lo → M1 → M2 → M3 → M4 → Hi.
When Hi is already displayed, the air flow is not changed.
In the same way, each time it is recognized that the air flow DOWN switch has been closed, the air flow is fixed
to the next lower level of air flow from Hi → M4 → M3 → M2 → M1 → Lo.
When Lo is already displayed, the air flow is not changed.
The same is true when air flow control is switched from auto to manual. For example, when AUTO M1 is dis-
played, if it is recognized that the air flow DOWN switch has been closed, the display becomes Lo and AUTO is
no longer displayed.
Also, the change speed for air flow output switchover is the same as discussed for auto below.
Relationship between air flow and display during manual operation

Lo Hi
Air flow (minimum air M1 M2 M3 M4 (maximum air
flow) flow)
Blower air
40 % 46 % 54 % 64 % 80 % 100 %
flow %
Display
3. Auto air flow control

When it is recognized that the AUTO switch has been closed, the air flow is controlled automatically and AUTO
is displayed.
1) During auto air flow control, the air flow is set according to the target blowing temperature as shown in the
diagram below.
2) Auto air flow control continues until closing of either the air flow UP or air flow DOWN switch is recognized.
3) The auto air flow amount calculation results are continuous, not divided into levels.
4) When it is recognized that the AUTO switch has been closed, the display becomes as in the table below
according to the results of the auto air flow amount calculation.
5) The normal auto air flow output change is roughly 5 V/sec.
6) Auto air flow control is restricted by the cold blast prevention control described in (4), which is the next item.
84402832 NA - May 2011

9006-18
*1 Target blow temperature *4 M4 *7 M1

*2 Auto air flow *5 M3 *8 Lo
*3 Hi *6 M2
Relationship between air flow and target blow temperature
Display refreshing and air flow output correspondence table

Current display Item Target % (about)
Lo display Output range changed to M1 When 44 % or higher
Output range changed to Lo When 40 % or lower
M1 display
Output range changed to M2 When 52 % or higher
Output range changed to M1 When 48 % or lower
M2 display
M3 display
M4 display
Output range changed to Hi When 88 % or higher
Hi display Output range changed to M4 When 84 % or lower
4. Cold blast prevention control

The air flow is restricted according to the value of the coolant temperature data and other parameters sent from
the vehicle side via CAN communication.
The air flow restriction has 2 levels - air flow 0 and air flow Lo. Whether or not to use the restriction is determined
from the judgment results.
1) Conditions under which cold blast prevention control is used
1) Auto air flow
2) When set temperature - inside air sensor temperature 11.
3) When the coolant temperature signal from vehicle is the less than 30 °C signal or the 30 °C or higher
but less than 45 °C signal
Under the condition above, the inside air sensor temperature is the value immediately after the vehicle main
key power supply is switched ON and AUTO and Tset are according to the current switch states.
Therefore, when the AUTO switch is pressed after the air flow has been set manually, if the coolant tem-
perature is within the cold blast prevention range, the air flow is restricted.
In the same way, even if the set temperature is changed, if the conditions are met, the air flow is restricted.
While cold blast prevention control is being executed, the display corresponds to the restricted air flow.
2) Air flow 0 control
When the coolant temperature signal from vehicle is the less than 30 °C, the air flow is set to 0.
This continues until a coolant temperature signal of 30°C or higher is received.
Once a coolant temperature signal of 30 °C or higher is received and these conditions are no longer met,
air flow 0 is ended.
3) Air flow Lo control
When the coolant temperature signal from vehicle is the 30 °C or higher but less than 45 °C signal, the air
flow is set to Lo.
This continues until a coolant temperature signal of 45 °C or higher is received.
Also, the same as for [2], this shift is irreversible.
Once a coolant temperature signal of 45 °C or higher is received, control is normal.
5. Blower air flow control when mode motor actuator angle switched
When the mode motor actuator is operated with the blower air flow at M1 or higher, the mode motor actuator is
operated with the blower air flow first set to Lo.
After the end of operation, the original blower air flow returns.
Changes to the blower output at this time are the same as normal auto air flow control.
However, the blower display is not changed during control.
84402832 NA - May 2011

9006-19
6. Air flow control priority order

The priority order for auto air flow control, manual air flow control, and cold blast prevention control is as follows.
Priority or-
Control
der
Blower air flow control when mode motor actuator angle
1
switched
2 Manual air flow control
3 COOLMAX control
4 Cold blast prevention control
5 HOTMAX control
6 Auto air flow control
84402832 NA - May 2011

9006-20
Compressor Clutch Control

The compressor clutch is controlled by the power to the clutch coil being switched ON/OFF by an external relay.
This control is executed by thermo operation and the fletching prevention function.
Thermo operation has control mode 1 and control mode 2. These modes are applied according to the blow mode
and other conditions.
However, for blower air flow 0, the compressor clutch is switched OFF.
The operation temperature does not include the thermistor variation.
2. Thermo operation (AC switch ON)
1) Control mode switchover
• When the blow mode is B/L and the target blow temperature is as in the diagram below, control mode 2
is used.
As the diagram shows, there is hysteresis between control modes 1 and 2.
• Other than the above is all control mode 1.
*1 Target blow temperature

*2 Control mode 1
*3 Control mode 2
3. Fletching prevention function

1) Operation conditions
After the end of initial operation, if 4 - 5 min. continue with the air flow M3 or higher and the compressor
clutch not coming ON even once, the compressor clutch is switched ON one time.
This control is cleared by the vehicle main key power supply being switched OFF and this control starts
again when this power supply is switched ON again.
2) This control takes priority over all other control.
4. AUTO switch link function
When operation of the AUTO switch is recognized, compressor clutch control comes ON and AUTO is displayed.
1) Compressor clutch control is the same control as for the AC switch being switched ON.
2) When it is recognized that the AC switch has been switched OFF, the AUTO display goes out.
Even when it is recognized that the AC switch has been switched ON again, AUTO is not displayed.
However, at this time, if the main key power supply is switched OFF, then ON again, since the AC ON, air flow
AUTO, and blow mode AUTO conditions are all met, AUTO is displayed.
84402832 NA - May 2011

9006-21
COOLMAX Control and HOTMAX Control

1. When the set temperature is 18.0 °C [COOLMAX] (or 18.E)
1) The air mix motor actuator is set to the 0° limiter position (fully closed).
2) For auto air flow control, the air flow is set to Hi.
3) For AUTO blow mode control, the blow mode is set to VENT.
2. When the set temperature is 32.0 °C [HOTMAX] (or 32.E)
1) The air mix motor actuator is set to the 90° limiter position (fully open).
2) For auto air flow control, the air flow is set to M4.
3) For AUTO blow mode control, the blow mode is set to FOOT.
Abnormality Detection and Control after Abnormality Detected
If there is an abnormality in a motor actuator drive line or sensor computer input circuit, the abnormality is detected
and control after detection is performed as described below.
In all cases, abnormality control does not end once abnormality has been detected and the location is returned
to normal.
Trouble control is only ended when the vehicle main key power supply is switched OFF or when air conditioner
operation is stopped with the ON/OFF switch on the operation panel.
However, motor actuator restriction is only ended by switching OFF the main key power supply.
2. Trouble in a motor actuator and its input/output circuits
1) Disconnection detection
After the main key power supply is switched ON, if a motor actuator potentio-meter line is disconnected or
shorted, the display in the table below for that motor actuator is carried out and that motor actuator is not
driven until the main key power supply is switched OFF, then ON again.
Abnormality location Abnormality display

HL. E is displayed on the set temperature display LCD.
Air mix motor actuator
See the diagram below.
Blow mode motor actuator The passenger icon display flashes.
Refresh/recirculate switch motor actuator The refresh/recirculate mark flashes.
84402832 NA - May 2011

9006-22
2) Motor lock detection

If the output shaft rotation angle of a motor actuator does not reach the target value within 15 sec., locking
is detected, output to that motor is stopped, and the abnormality is displayed on the computer according to
the abnormality location.
Abnormality location Abnormality display

HL. E is displayed on the set temperature display LCD.
Air mix motor actuator
See the diagram below.
Blow mode motor actuator The passenger icon display flashes.
Refresh/recirculate switch motor actuator The refresh/recirculate mark flashes.
3. Trouble in a sensor or its input/output circuits (disconnection or short)

1) Disconnection or short in the inside air sensor or its input/output circuits
1) Operator compartment temperature control end
• The operator compartment temperature control (all control related to target blow temperature) is
stopped and the air mix degree of opening is directly adjusted according to the temperature adjust-
ment switch input.
• Accompanying this, the operation panel set temperature display changes as in the diagram below.
* is a value between 0 - 9, and each time the DOWN switch is closed, this value decreases by 1; each
time the UP switch is closed, this value increases by 1.
* value Motor actuator degree of opening (°)

0 0°
1-8 * value × 10°
9 90°
2) Auto air flow control end

• The air flow is temporarily fixed at the setting that was in effect when the inside air sensor abnor-
mality was detected.
• The AUTO display is set flashing.
• After this, the air flow is switched by the manual air flow switch.
3) AUTO blow mode control end
• The blow mode is temporarily fixed at the setting that was in effect when the inside air sensor ab-
normality was detected.
• The AUTO display is set flashing.
• After this, the blow mode is switched by the manual blow mode switch.
4) Air mix damper degree of opening display priority
• Even if the trouble shown by one of the items below occurs during inside air sensor trouble, E is not
displayed in the * section below the decimal point and the air mix damper degree of opening display
is given priority.
• HL. E is only displayed for air mix motor actuator trouble.
84402832 NA - May 2011
9006-23
5) Thermo operation control mode fixed

• Switching of the control mode according to the blow mode and target blow temperature is stopped
and the control mode is fixed at control mode 1.
2) Disconnection or short in evaporator sensor or its input/output circuits
1) Compressor control is not executed and the compressor clutch is always OFF.
2) E is displayed in the first fraction position of the set temperature display LCD.
See the diagram below. (The temperature setting is in 1 °C steps.)
However, E is not displayed for inside air sensor trouble.
3) The AC mark flashes.
Disconnection or short in evaporator sensor or its input/output circuits
*1 The AC mark flashes

*2 E is not displayed
3) Disconnection or short in solar radiation sensor or its input/output circuits

1) The solar radiation compensation data is set to 0.
2) E is not displayed in the first fraction position of the set temperature display LCD as it is for other
sensors.
4) Coolant temperature signal trouble
Cold blast prevention control does not work and normal control is used.
4. CAN communication abnormality processing
1) Recovery from bus off
1) Initial retry processing: 5 msec.
2) Re-retry processing: every 1 sec.
Bus off retry processing is performed at the above rate.
2) Receiving data abnormality
1) Definition: The data field is outside the prescribed range regardless of whether the receiving data is
operating normally or abnormally.
2) Processing: In the case of the former, all data that time are discarded and the previous data are
retained.
In the case of the latter, data is discarded only for those items determined to be abnormal.
3) Communication interruption abnormality
1) Interruption judgment
Monitor Display: When normal reception is not possible 1 sec. or more since the previous normal
reception
Engine: When normal reception is not possible 10 sec. or more since the previous normal reception
2) Internal use data: Shift to alternate data (processing)
3) Sending process: Continue
4) Recover: As soon as valid data is received
4) Alternate data (processing)
＜Sending mode: ENGINE ECU＞
84402832 NA - May 2011
9006-24
1) Outside air data abnormality

Perform estimated outside air control.
* However, once there is a shift to estimated outside air, estimated outside air control continues until
the ignition is switched OFF.
2) Coolant temperature data abnormality
Control the internal coolant temperature data to 45 °C (the temperature at which to avoid cold air
prevention control).
＜Sending mode: MONITOR DISPLAY ECU＞
1) Open window signal data abnormality
Perform control with the internal open window data closed.
2) Open door signal data abnormality
Perform control with the internal open door data closed.
5) Alternate data (processing) up to initial normal reception
＜Send node: ENGINE ECU＞
1) Outside air data abnormality
Within 5 sec. after ignition is turned on: No data
After 5 sec. after ignition is turned on: Perform estimated outside air control.
2) Coolant temperature data abnormality
Within 5 sec. after ignition is turned on: Perform control at 30 °C (the temperature at which to control
cold air prevention)
After 5 sec. after ignition is turned on: Perform control at 45 °C (the temperature at which to avoid
cold air prevention control)
＜Send node: MONITOR DISPLAY ECU)＞
1) Open window signal data abnormality
Perform control with the internal open window data closed.
2) Open door signal data abnormality
Perform control with the internal open door data closed.
84402832 NA - May 2011

9006-25
Monitor Mode
Monitor mode is a mode for understanding abnormalities in the operation panel itself or in other control.
The system goes into monitor mode when there is the special switch input below on the operation panel.
2. Starting monitor mode
When the air conditioner is operating with basic control, if the operation panel ON/OFF switch closed path con-
tinues for 1 sec. while the refresh/recirculate select switch closed path is ongoing, monitor mode is started.
3. Monitor contents
1) LCD segment diagnosis
When monitor mode is entered, the target LCD lights up for 1 sec.
An LCD with trouble does not light up.
2) Sensor diagnosis
The detection value (AD value or °C) for each sensor is displayed.
3) Coolant temperature signal recognition value
This displays the reception status for the coolant temperature signal sent from the vehicle.
4. Display contents in monitor mode
In monitor mode, the data (detection value for each sensor, coolant temperature signal recognition, etc.) is dis-
played in the 3-digit of the 7-segment display for the temperature setting.
The data displayed is selected with the blower UP/DOWN switches and AUTO switch.
The blower UP/DOWN switches move the display on the dedicated monitor mode 7-segment display through 16
displays, 0 - F, and the corresponding data is displayed.(Table A)
Hexadecimal data display and decimal data display can be selected with the AUTO switch. Only for the coolant
temperature signal recognition value, the value detected immediately before entry into monitor mode is displayed.
The difference between hexadecimal data and decimal data is indicated by the 3rd-digit of the 7-segment display
for the temperature setting. For hexadecimal data, "H" is displayed there and for decimal data, numbers (0 - 9)
are displayed there.
1) Hexadecimal display
AD values 00H - FFH are displayed.
When the AD value corresponds to that in Table B (or Table C for the solar radiation sensor), this indicates
a disconnection or short.
In the hexadecimal display, when the value of a sensor changes in monitor mode, the hexadecimal display
changes with it.
If the display before entering monitor mode was , the error judgment value is displayed. (In
other words, the detected value before the abnormality was detected) In the same way, if the display be-
fore entering monitor mode was , the display becomes **.E and the error judgment value is
displayed.
2) Decimal display
Decimal display is used from -99.9 °C to 99.9 °C.
Also, the "-" minus display is displayed on the left side of the 3 digit segment.
5. Air conditioner operation in monitor mode
When the system enters monitor mode, all output (operation) through control is stopped and until monitor mode
is ended, operations and settings of basic control through all the switches are not possible.
6. Ending monitor mode
In monitor mode, if the operation panel ON/OFF switch closed path continues for 1 sec. while the refresh/recir-
culate select switch closed path is ongoing, monitor mode is ended and the system returns to the basic control
state.
The same also occurs if the vehicle main key power supply is switched OFF.
Exclusively for monitor

mode Display contents
7 seg
0 Inside air sensor temperature data
1 Evaporator sensor temperature data
2 Solar radiation compensation data
3 Outside air data
4 -
84402832 NA - May 2011

9006-26
Exclusively for monitor

mode Display contents
7 seg
Coolant temperature signal status data
30°C or higher
C Abnormal Lower than 30°C 45°C or higher
Lower than 45°C
4 1 2 3
5-F Data (sensor diagnosis etc.)
Sensor Discon-
Short
name nection
Inside air
F6H 0CH
sensor
Evaporator
F6H 0CH
sensor
Sensor
5 V short Ground short
name
Solar radia-
D5H 0CH
tion sensor
84402832 NA - May 2011

9006-27
Door Switch Control

This control adds a restriction to air conditioner operation with the door switch or front window switch. Its purpose
is to prevent overheating of the vehicle main unit.
Concretely, it suppresses condenser heating and controls in a way restricted in order to obtain a feeling of comfort.
2. Door switch/front window switch signal
Due to data sent from CAN communication.
Message ID: 0x18FF1028
Sending mode: Monitor Display
Send cycle: 10 ms
Data: Open door signal and open window signal data
Data judgment: Set with continuous 5 times of the same data for 20 ms cycle sampling
3. Control restricted by door switch/front window switch
1) Starting restricted control
When either the door or front window is open continuously for 1 sec. or longer, it is recognized that the
switch is open.
At the count of 60 sec., the buzzer buzzes the same way as for switch input to tell the operator that restricted
control is starting and that control starts.
2) Restricted control
1) For both auto and manual blow mode control
Regardless of being selected in either auto or manual blow mode, unless the blow mode is FACE, the
following air flow restriction is executed. (If the blow mode is FACE, the air flow is not restricted.)
Ⅰ. If the target blow temperature ＜ 20 °C, the air flow upper limit is set to M1.
Ⅱ. If the target blow temperature 25 °C, the air flow restriction in I is ended.
2) When the current blow mode control is AUTO
Auto control with the AUTO blow mode VENT changed to FACE is used.
3) When the current blow mode control is manual selection
Only if the blow mode is VENT immediately after the open switch is recognized, that mode is changed
to FACE.
After this, all the blow modes can be selected with manual operation.
3) Ending the restriction
When both the door and front window are closed continuously for 1 sec. or longer, it is recognized that the
switches are closed.
After a count of 1 sec., the buzzer buzzes the same way as for switch input to tell the operator that restricted
control has been ended.
When the restricted control is ended, the restriction on the air flow discussed in 1. above and the change
from VENT to FACE in 3. are ended and control returns to normal.
However, if the blow mode has been manually selected, even if the mode was changed from VENT to FACE
by the above restriction, it does not return to VENT when the restricted control is ended.
84402832 NA - May 2011

9006-28
Inside Air Filter Clogging Detection Control

This control recognizes the blower current with the dedicated shunt resistor voltage input, judges from that value
whether or not the A/C unit inside air filter is clogged and if it judges that that filter is clogged, it issues a warning
to encourage the operator to replace the filter.
2. Filter detection control
1) Starting detection control (detection timing)
5 sec. after the end of initial operation, if the air conditioner is operating and the cold blast prevention con-
ditions are not present, this control is started. Also, this control is executed every 50 hours of air conditioner
(blower) operation. However, during a temporary filter clog or filter clog, it is executed every time.
2) Detection method
Cooling / heating is judged from the operation mode and in this way the air mix motor actuator target position
is determined. Also, the mode motor actuator target value is set to FOOT, the blower air flow target value
is set to M1, and output is made to attain the target values. When all the target values are attained, the
blower current from the shunt resistor voltage is recognized, and the filter clog is judged by comparing this
current with the default current value.
(cooling / heating judgment)

When the operation mode is FACE or VENT, : Cooling (COOLMAX)
When FOOT or DEF : Heating (HOTMAX)
When B/L: Final inside air temperature If < 22 ºC, heating
When B/L: Final inside air temperature If ≥ 22 ºC, cooling
(detection current threshold)
Relative to the default current value For cooling : 0.35 - 0.39 A min.
For heating : 0.48 - 0.54 A min.
If the value is below this three times in a row, it is judged that there is a clog.
(default current value)
Current found in the initialization operation described below.
3) Clog warning
(buzzer)
The buzzer buzzes intermittently at 1 Hz for 10 sec.
(display)
"FIL" is displayed on the 7-segment display for the set temperature for 10 sec. Other marks go out.
However, if there is any switch input, the "FIL" display is ended immediately.
4) Alarm reset
If a reset detection value is recognized during the clog state, the clog state is reset.
The reset detection value is 50 % of the clog detection threshold.
5) ON/OFF switching
This function is switched ON/OFF by pressing the [Refresh / Recirculate], [MODE], and [DEF] switches
at the same time. The factory setting for this function is OFF. This function does not come ON until the
initialization operation discussed below is executed.
(buzzer)
When operation of this switch is recognized, there is the normal switch input sound.
(display)
ON or OFF is displayed on the set temperature 7-segment display, whichever is the state after switching.
Other marks go out.
6) Initialization operation
When the [Refresh / Recirculate] and [DEF] switches are pressed at the same time, the default current
value is detected and all the data for filter detection is initialized. Before executing this operation, make
sure that the air conditioner unit (with a new inside air filter installed), ducts, and grilles (with all grilles fully
open) are all installed in their normal states on the vehicle. If initialization is carried out in any other state,
there is a danger of the clog detection judgment control making an incorrect judgment. Immediately after
replacing the inside air filter with a new one, execute the initialization operation.
(buzzer)
When operation of the switch is recognized, the buzzer buzzes with the normal switch input sound. When
the detection ends, the buzzer buzzes for 3 sec.
7) Detection processing avoidance
84402832 NA - May 2011
9006-29
• When the inside / outside air damper is not at the recirculate position immediately before the current value
is read
• When the power supply voltage is not in the tolerance range for the voltage during the initialization oper-
ation
• Trouble in any of the motor actuators
84402832 NA - May 2011

9006-30
Actuator Inspection
Air Mix Motor Actuator Inspection
• Structural diagram
Air mix damper operation defect

↓
See the chart.
↓
Specifying the trouble location
1 Control panel 3 Connector 1

2 Air mix motor actuator 4 Connector 9
• Chart
Standard
Step Action Yes No
value
Press the temperature setting
switches and set to COOLMAX
1 (18.0 °C). Go to Step 2 Go to Step 3
Does the actuator operate at
all?
2 Is an error displayed? Go to Step 6 Damper lock or link defect
Press the temperature setting
switches and set to HOTMAX
3 (32.0 °C). Go to Step 2 Go to Step 4
Does the actuator operate at
all?
4 Is an error displayed? Go to Step 5 Control panel defect
Is there continuity in harness
Actuator defect or damper
5 between the actuator and con- Harness defect
lock or link defect
trol panel?
Remove the actuator connec-
tor (9).
About 4.7
6 Is the resistance between L/Y Go to Step 7 Actuator defect
KΩ
and B/L of the actuator about
4.7 KΩ?
Is there continuity between the
7 G/L and L/Y and between G/L Control panel defect Actuator defect
and B/L of the actuator?
Set temperature Air mix motor actuator position

COOLMAX (18 °C) 0°
HOTMAX (32 °C) 90°
84402832 NA - May 2011

9006-31
Refresh/Recirculate Switch Motor Actuator Inspection

Inside/outside air mix damper op-

eration defect
↓
See the chart.
↓

2 Refresh/recirculate motor actuator 4 Connector 11
• Chart
Standard
Step Action Yes No
value
Press the refresh/recirculate
1 switch. Does the actuator operate Go to Step 2 Go to Step 3
at all?
Is there continuity in harness be-
4 tween the actuator and control Harness defect
lock or link defect
panel?
Remove the actuator connector
(11). About 4.7
5 Go to Step 6 Actuator defect
Is the resistance between L/Y and KΩ
B/L of the actuator about 4.7 KΩ?
Is there continuity between the L/G
6 and L/Y and between L/G and B/L Control panel defect Actuator defect
of the actuator?
84402832 NA - May 2011

9006-32
Mode Motor Actuator Inspection

Mode damper operation defect

↓
See the chart.
↓

2 Mode motor actuator 4 Connector 10
• Chart
Standard
Step Action Yes No
value
Press the mode select switch.
1 Go to Step 4 Go to Step 2
Does the actuator operate at all?
Is there continuity in harness be-
3 tween the actuator and control Harness defect
lock or link defect
panel?
Remove the actuator connector
(10). About 4.7
5 Go to Step 6 Actuator defect
Is the resistance between L/Y and KΩ
B/L of the actuator about 4.7 KΩ?
Is there continuity between the Y/L
6 and L/Y and between Y/L and B/L Control panel defect Actuator defect
of the actuator?
Blow mode MODE 1 MODE 2 MODE 3 MODE 4 MODE 5

Blow mode motor actuator degree of open-
90° 67° 48° 26° 0°
ing
FACE VENT B/L FOOT DEF
Panel display
84402832 NA - May 2011

9006-33
Self-diagnosis Function with Panel Display

Abnormality Display and Self-check Procedures
Motor actuator and sensor abnormalities can be checked on the panel display.
Abnormality Display Position
a This segment is displayed only in the monitor mode

below.
b Error is displayed on the 3-digit 7-segment display.
84402832 NA - May 2011

9006-34
Explanation of Abnormality Display

Motor Actuator Abnormality
1. HL. E displayed on 3-digit 7-segment display.
Check the air mix damper motor actuator for a harness disconnection or disconnected
connector.
This is also displayed when locked due to air mix motor actuator abnormality and link
abnormality.
2.
flashes.
Check the blow mode damper motor actuator for a harness disconnection or discon-
nected connector.
3.
flashes.
Check the refresh/recirculate damper motor actuator for a harness disconnection or

disconnected connector.
CAUTION
The above display and flashing is displayed on the 3-digit 7-segment display when trouble occurs with
the panel ON/OFF switch ON status.
After trouble occurs, when the panel ON/OFF switch is switched ON, the function is displayed.
After trouble is resolved, the abnormality display and flashing are not ended until the main switch is
switched OFF → ON.
84402832 NA - May 2011

9006-35
Sensor Abnormality
1. HL. * displayed on 3-digit 7-segment display
Check the inside air sensor and check its harness for disconnection, short, or connector
connection defect.
a (* is any number 0 - 9.)
2.
**.E and the mark flashing are flashing on the 3-digit 7-segment display. (** displays the set temperature
value at that time still remaining.)
Check the evaporator sensor and check its harness for disconnections, shorts, or con-
nector connection defects.
CAUTION
The display in 1 and 2 above is displayed on the 3-digit 7-segment display when trouble occurs with the
panel ON/OFF switch ON status.
After the trouble section is repaired, end the abnormality display by switching the panel ON/OFF switch
OFF → ON.
84402832 NA - May 2011

9006-36
Explanation of Monitor Mode

2. When sensor abnormality is displayed, the sensor status (disconnection, short) can be checked in monitor mode.
Monitor Mode Display Position
a 3-digit 7-segment
b 7-segment dedicated to monitor display
84402832 NA - May 2011

9006-37
Monitor Mode Display Operating Method
1 Refresh/recirculate select switch

2 Blower switch UP/DOWN switch
3 ON/OFF switch
1. Hold down the refresh/recirculate select switch and the ON/OFF switch at the same time for 1 sec. or longer.
2. Press the AUTO switch.
(All the 7 segments light up for 1 sec., then the system enters monitor mode.)
3. Numbers 0 - 9 or letters A - F are displayed in the 2nd and 3rd digit of the 3-digit 7-segment display.
"H" is displayed in the 1st-digit.
4. The display of 0 - 2 on the dedicated 7-segment display is carried out with the blower UP/DOWN switches. The
necessary sensor is selected from the table below.
7-segment display table dedicated to monitor

0 Inside air sensor
1 Evaporator sensor
2 Solar radiation sensor
(Display other than the above (3 - 9, B - F) is not

used during service.)
5. To end the monitor display, either hold down the refresh/recirculate select switch and the ON/OFF switch at the
same time for 1 sec. again or longer or switch the vehicle main switch OFF.
CAUTION
1. During monitor mode, operations and settings of basic control through all the switches are not pos-
sible until the air conditioner control operation is stopped and monitor mode ended.
2. During monitor mode, even if a sensor is repaired, the abnormality display is recorded in memory,
and until the ON/OFF switch is switched OFF, then ON again, the abnormality display is not ended.
84402832 NA - May 2011

9006-38
Display Contents in Monitor Mode

See the dedicated monitor 7-segment display table and 3-digit 7-segment table.
1. Display example 1
The dedicated monitor 7-segment display is 0 (indicates the inside air sensor
state).
From the 3-digit 7-segment table 3F → The sensor is normal.
→ The inside air sensor is normal.
The dedicated monitor 7-segment display is 1 (indicates the evaporator sensor

state).
From the 3-digit 7-segment table 0C → The sensor is disconnected.
→ The evaporator sensor is disconnected.
The dedicated monitor 7-segment display is 2 (indicates the solar radiation sen-
sor state).
From the 3-digit 7-segment table D5 → The sensor is shorted on the 5 V side.
→ The solar radiation sensor is shorted.
3-digit 7-segment table
84402832 NA - May 2011

9006-39
a Solar radiation sensor short g Solar radiation sensor 5 V side

2nd-digit of 7-segment display d
OCH2 display short D5H2 display
Inside air sensor disconnection e Inside air sensor short F6H0
b 3rd-digit of 7-segment display h
OCH0 display display
c Evaporator sensor disconnec- Evaporator sensor short F6H1
f Sensors normal i
tion OCH1 display display
Air conditioner troubleshooting

The blow temperature does not go down.
* M/A means motor actuator.
Standard
Step Action Yes No
value
• The air mix motor actuator
connector is disconnected
or has a contact defect.
When the AUTO switch or AC • Air mix motor actuator de-
switch is pressed, HL. E is dis- fect
1 Go to Step 2
played in the panel set temper- • Main harness continuity
ature display section. defect
Inspect and repair or re-
place part.
HL. * is displayed on the panel
set temperature display sec-
tion.
* is No. 0 to 9.
84402832 NA - May 2011

9006-40
Standard
Step Action Yes No
value
• Inside air sensor or har-
ness disconnection or
• Inside air sensor and short
evaporator sensor simul-
The inside air sensor con-
taneous disconnection or •
nector is disconnected or
3 The panel snow mark flashes. short
has a contact defect.
• Computer breakdown
See the Monitor Mode sec-
tion too.
tion too.
place part.
• The evaporator sensor
or there is a contact de-
fect.
• Evaporator sensor simul-
4 The panel snow mark flashes. taneous disconnection or Go to Step 5
short
tion too.
place part.
When the set temperature is
18.0 and the blow mode is set
5 18.0 ﾟC Go to Step 6 Go to Step 7
to vent mode, the blow temper-
ature drops.
Inspect the duct or eliminate Computer breakdown or in-
Cool air is flowing into the in-
6 the cause of the cool air inside air sensor defect
side air sensor section.
filtration. Inspect and replace.
Switch compressor clutch
ON/OFF and inspect and
The air mix damper is at the repair the power supply cir-
7 Go to Step 8
COOLMAX position. cuit.
See the cooling cycle trou-
bleshooting.
If motor actuator operation
• Inspect, repair, or replace
stops midway, remove the
Motor actuator breakdown the motor actuator lever
cause or correct the problem, 1.5 kgf or link section.
8 or computer breakdown
and then measure the operat- less
Replacement • Clean the lever link sec-
ing force. tion, then apply grease.
Is it 1.5 kgf or less?
The blow temperature does not go up.
84402832 NA - May 2011

9006-41
Standard
Step Action Yes No
value
• The air mix motor actuator
or has a contact defect.
HL. E is displayed on the panel • Air mix motor actuator de-
1 set temperature display sec- fect Go to Step 2
tion. • Main harness continuity
defect
place part.
• Inside air sensor or har-
ness disconnection or
short
HL. * is displayed on the panel • The inside air sensor con-
set temperature display sec- nector is disconnected or
2 has a contact defect. Go to Step 3
tion.
* is No. 0 to 9. See the Monitor Mode sec-
tion too.
place part.
When the set temperature is
32.0 and the blow mode is set
3 32.0 ﾟC Go to Step 4 Go to Step 5
to foot mode, the blow temper-
ature rises.
Inspect the duct or eliminate Computer breakdown or in-
Warm air is flowing into the in-
4 the cause of the warm air side air sensor defect
side air sensor section.
infiltration. Inspect and replace.
The air mix damper is at the Inspect the warm coolant
5 Go to Step 6
HOTMAX position. lines.
If motor actuator operation
• Inspect motor actuator
stops midway, remove the
Motor actuator breakdown lever link section.
cause or correct the problem, 1.5 kgf or Repair or replace.
6 or controller breakdown
and then measure the operat- less
Replacement • Clean the lever link sec-
ing force. tion, then apply grease.
Is it 1.5 kgf or less?
The blower motor does not rotate.
Standard
Step Action Yes No
value
With the flow set to HI, battery
voltage is applied to the termi-
1 Replace the blower motor. Go to Step 2
nals (+ and -) of the blower mo-
tor. (Note: 1)
The battery voltage is applied
between the blower motor (+)
power supply red/blue and the
body.
Voltage of about 10 V is ap-
3 plied between the blower amp About 10 V Go to Step 4 Replace computer.
brown/yellow line and ground.
Remove the blower amp and
refer to the section on Blower
Eliminate the cause of the
Amp Inspection. Is there any Inspect and repair the wire
4 trouble, then replace the
abnormality? harness.
blower amp.
No abnormality → Yes
Abnormality → No
Inspect the blower motor relay.
When the blower motor relay
Inspect, repair, or replace
5 white/red and blue/red are di- Go to Step 6
the wire harness.
rectly connected, the blower
motor rotates. (Note: 2)
84402832 NA - May 2011
9006-42
Standard
Step Action Yes No
value
The battery voltage is applied
Inspect, repair, or replace
6 between the blower motor relay Go to Step 7
the wire harness.
white/red and the body.
When the blower motor re-
Inspect or repair the wire
lay purple/white is dropped to
7 harness or replace the com- Replace the relay.
ground, the blower motor ro-
puter.
tates.
NOTE:
1. Measure with the connector connected.
2. For the sake of safety, have the air conditioner, vehicle key, and light switches all OFF when working with direct
connections in place.
The blower motor speed does not change.
Part 1
Step Action Yes No

• Inside air sensor or harness
disconnection or short
• The inside air sensor connec-
HL. * is displayed on the panel set tor is disconnected or has a
contact defect. Replace the blower amp or
1 temperature display section.
computer.
* is No. 0 to 9. See the Monitor Mode section
too.
Inspect and repair or replace
part.
Part 2
Step Action Yes No

Does the blower motor fail to change
1 speed when the mode is other than Go to Step 2 See Part 1.
FACE?
While operating under restric-
2 Is the door or front window open? tive control by door switch or See Part 1.
front window switch.
The magnetic clutch does not engage.
Step Action Yes No

The snow mark flashes and E is
When the AUTO switch or AC switch
1 Go to Step 2 displayed on the panel display
is pressed, the snow mark lights up.
section.
Clutch defect. Replace the
2 Voltage is applied to the clutch. Go to Step 3
compressor.
Pressure switch defect or
coolant pressure abnormally
Voltage is applied between the har-
3 high or low Go to Step 4
ness and pressure switch.
See the cooling cycle trou-
bleshooting.
Voltage is applied between the vehicle
4 side harness connector blue/red and Go to Step 5 Inspect the clutch fuse.
ground (black).
Is there trouble in the air conditioner
5 Replace computer. Replace the harness.
harness?
Refresh/recirculate mode does not switch

84402832 NA - May 2011
9006-43
Step Action Yes No

The refresh/recirculate motor
actuator connector is discon-
The refresh/recirculate mode display
nected, there is a contact de-
1 on the operation panel LCD display Go to Step 2
fect, or there is trouble with the
section is flashing.
motor actuator or the main har-
ness.
There is foreign matter on the refresh/
recirculate motor actuator lever sec- Remove the foreign matter or
2 Replace the motor actuator.
tion or the motor actuator lever sec- replace the part.
tion is broken.
The mode is not switched.
Standard
Step Action Yes No
value
The refresh/recirculate mo-
tor actuator connector is dis-
The passenger icon display on connected, there is a con-
1 the operation panel LCD dis- tact defect, or there is trou- Go to Step 2
play section flashes. ble with the motor actuator
or the main harness.
Inspect or replace.
The motor actuator rod is cor-
2 Go to Step 3 Correction
rectly in place.
A damper lever is correctly in
3 Go to Step 4 Correction
place.
• Foreign matter or break-
age at cam section or
damper shaft section
• Operation defect due to
When the cam with the rod re- soiling with grease or the
2 kgf or like Replace the motor actuator
4 moved is moved by hand, it is
more or computer.
sluggish (2 kgf or more).
• Remove the foreign mat-
ter or replace the part.
• Clean the cam section,
then apply grease.
84402832 NA - May 2011

9006-44
Part Function and Good/Poor Judgment

Control Panel
Function of each switch
1 Main power switch 4 Air flow select switch 7 Diffuser select switch
Refresh/recirculate select
2 Auto control switch 5 Air conditioner ON/OFF switch 8
switch
3 Temperature control switch 6 Defrost switch
Through the operation of its internal microcomputer, the control panel compares, operates on, and processes the
sensor input signals and control panel switch input signals, switches the output side actuators (refresh/recirculate
switching, mode switching, air mix) and comprehensively controls the fan motor and compressor.
Also, it is equipped with self-diagnosis functions to make trouble diagnosis easier. (For details see the air conditioner
troubleshooting.)
84402832 NA - May 2011

9006-45
Blower Amp
The power transistor receives the base current from the control unit and changes the speed of the fan motor.
Blower amp inspection
The blower amp can be easily judged by removing the blower amp connector and checking for continuity across
the blower amp terminals.
Terminal No.
Continuity
1 2 3
+ --- - Yes (4.7 kΩ)
Tester - + --- No
+ - --- Yes (diode parallel forward direction)
a Temperature fuse: 132 - 138 °C
84402832 NA - May 2011

9006-46
Relay
4-pole relays are used for the blower OFF relay and compressor relay.
Blower OFF relay
This relay receives the signal from the control amp and switches the blower OFF relay ON.
When the blower OFF relay is switched ON, the power supply voltage is fed to the blower motor via the blower amp
and the blower motor is started.
Compressor relay
The compressor relay is switched ON/OFF by the control amp compressor control.
Relay inspection contents
1. Relay
2. Coil resistor: 320Ω
3. Specification voltage: DC 20 - 30 V
4. Be careful. The coil side of this relay must be installed with the poles facing correctly.
5. Inspection: Inspect for continuity between 3 and 4 under the conditions below.
20 - 30 V applied between term8inals 1 and 2 : Continuity

No voltage applied between terminals 1 and 2 : No continuity
84402832 NA - May 2011

9006-47
Air Mix Actuator

CAUTION
The air conditioning system voltage specifications are 24 V, but the motor actuator has 12 V specifica-
tions.
The air mix actuator is installed at the center of the air conditioner unit contained behind the link cover. It opens and
closes the air mix damper via the link.
Built into the air mix actuator is the potentio-meter which switches linked with the actuator shaft.
When the target air mix door position is determined by the temperature control switch, the control unit reads in the
potentio-meter position in the actuator and determines whether the motor turns forward or reverse.
The contacts move linked with the motor. When the contacts move open or the control unit output signal goes OFF,
the motor stops.
Control panel Motor actuator
1 M/A 1 3 GND 5 5 VDC

2 M/A 2 4 Potentio-meter
Terminal
Direction of rotation 1 2
Clockwise (forward) + -
Counter-clockwise (reverse) - +
84402832 NA - May 2011

9006-48
Refresh/Recirculate Actuator
CAUTION
tions.
The refresh/recirculate switch actuator is installed on the blower intake unit. It opens and closes the refresh/recirculate
door via the link.
Built into the refresh/recirculate switch actuator is the potentio-meter that switches linked with the actuator shaft.
When the refresh/recirculate door position is determined by the refresh/recirculate switch on the control panel, the
control unit reads in the signal of the potentio-meter in the actuator and determines whether the motor turns forward
or reverse.
The position detection switch also rotates linked with the motor and stops the refresh/recirculate door at the set po-
sition.
84402832 NA - May 2011

9006-49
Blow Mode Actuator
CAUTION
tions.
The blow mode actuator is installed at the center of the air conditioner unit contained behind the link cover. It opens
and closes the mode door via the link.
Built into the blow mode actuator is the potentio-meter which switches linked with the actuator shaft.
When blow mode is determined by the temperature control switch, the control unit reads in the potentio-meter position
in the actuator and determines whether the motor turns forward or in reverse.
The contacts move linked with the motor. When the contacts move open or the control unit output signal goes OFF,
the motor stops.
84402832 NA - May 2011

9006-50
Evaporator Sensor
In order to prevent the evaporator from freezing, the evaporator blow temperature is detected and the compressor
ON/OFF is controlled.
• Evaporator sensor inspection method (specifications value)

Disconnect the evaporator sensor from the main harness and measure the resistance between the sensor side
connector terminals using the tester.
Resistance between When the sensor section detection temperature is 0 °C : 7.2 kΩ

terminals When the sensor section detection temperature is 25 °C : 2.2 kΩ
84402832 NA - May 2011

9006-51
Dual Pressure Switch
• The dual pressure switch is installed on the receiver dryer.

When there is pressure trouble in the coolant high-pressure side line (abnormally high pressure or abnormally low
pressure), the dual pressure switch contacts open up to cut off the compressor power and protect the cooling cycle.
Dual pressure switch specifications
1 (Low-pressure side)
2 (High-pressure side)
• Simple inspection method for dual pressure switch

1. With the cooling cycle stopped, disconnect the connector from the switch and check the conductance between
the switch side connector terminals using the tester.
If there is conductance, the switch is normal. (When the outside air temperature is 0 °C or higher)
2. Connect the gauge manifold high-pressure side hose to the high-pressure side charge port.
With the cooling cycle operating, the condenser front surface is covered with a plate shaped object and the high
pressure rises.
If the compressor stops around 3.14 MPa, the switch is normal.
3. With the coolant removed, check the conductance between the switch side connector terminals using the tester.
If there is no conductance, the switch is normal.
84402832 NA - May 2011

9006-52
Solar Radiation Sensor

This is the air conditioner solar radiation correct sensor. It detects the strength of sunlight with a photodiode, converts
it into milli-amp and sends that to the controller.
• Solar radiation sensor inspection method

Disconnect the solar radiation sensor connector from the harness and measure the voltage between the sensor
side connector terminals using the tester's voltage measurement mode.
The voltage must be different when light is striking the photoreceiver section and when it is not. (The voltage is
about 0 V when absolutely no light is striking the photoreceiver.)
CAUTION
Always measure with the tester in voltage measurement mode (V mode).
Measuring in resistance mode (Ω mode) would destroy the sensor.
84402832 NA - May 2011

9006-53
Inside Air Sensor
The inside air sensor is installed in the inside air side intake port of the air conditioner unit and switches the tempera-
ture inside the cab to the resistance.
This resistance value is converted into a voltage value in the control panel and processed.
Inside air sensor inspection method
Remove the inside air sensor connector from the main harness and measure the resistance between the sensor
side connector terminals using the tester.
Inside air sensor inspection details (specifications)
Resistance between terminals
For 0 °C: 7.2 kΩ ± 3 %
For 25 °C: 2.2 kΩ ± 3 %
84402832 NA - May 2011

9006-54
Section
9007
Assembly and Disassembly of Air Conditioner Units
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Blower Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Replacement of Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Replacement of Blower Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal of Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal of Heat Case Right/Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Replacement of Evaporator and Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation of Evaporator Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Replacement of Motor Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

CAUTION 2. Remove the filter cover (1) and inside air filter (2).
• Remove the 4 Phillips screws (3) and remove the
• Be sure to stop the engine before beginning intake case (4).
work.
Screw size
Phillips screws (3): M5 x 16 (T1)
CAUTION
• When replacing the evaporator, re-supply
and check the compressor oil quantity.
Removal of Blower Unit

1. Remove the connectors connected to the refresh/
recirculate motor actuator connector (1), blower mo-
tor connector (2), inside air sensor connector (3),
evaporator sensor connector (4) and relay connec-
tor (5).
84402832 NA - May 2011

9007-3
Replacement of Blower Motor Replacement of Blower Amp

CAUTION CAUTION
Do not remove the fan from the blower motor. Never disassemble the blower amp.
Removing with the power on can suddenly in-
1. Remove the cooling hose (2) from the air condi- crease the blower amp temperature, damaging
tioner unit (1). the part.
Also, touching the surface could cause burns.
blower motor (4). 1. Remove the connector (1) from the blower amp (2).
Screw size
Phillips screws (3): M5 x 14 • Remove the 2 Phillips screws (3) and remove the
blower amp (2).
• The installation procedure is the reverse of the Screw size
removal procedure. Phillips screws (3): M4 x 16
• The installation procedure is the reverse of the
removal procedure.
Removal of Heater Core

CAUTION
Remove while being careful not to apply exces-
sive force to the pipe.
1. Drain the coolant.

link cover (2).
Screw size
Phillips screws (1): M5 x 16
• Remove the mode actuator connector (3), and re-
move the heater core (4).
• The installation procedure is the reverse of the
removal procedure.
84402832 NA - May 2011

9007-4
Removal of Heat Case Right/Left Replacement of Evaporator and

CAUTION Expansion Valve
At this time, perform work with the heater core CAUTION
removed from the heater case.
The evaporator sensor cord is sandwiched in Be careful of the O-rings getting caught, etc.
the groove of the HVAC unit, so carefully check when installing the expansion valve.
it and remove it while making sure not to dam- The evaporator sensor cord is sandwiched in
age it. the groove of the HVAC unit, so carefully check
it and remove it while making sure not to dam-
age it.
1. Remove the 10 Phillips screws (1) and remove the
heater case right (2) and heater case left (3).
Screw size 1. Turn the HVAC unit upside down and place it on a
Phillips screws (1): M4 x 16 stand.
drain case (2).
• Remove the 1 Phillips screw (1) and remove the
evaporator pipe stay (3).
• Remove the evaporator sensor connector (4), and
remove the evaporator (5).

expansion valve (2).
• Install O-rings (3) on the new evaporator (4) (1 NF
O-ring 5/8 and 1 NF O-ring 1/2).
Bolt (1) tightening torque: 6.9 N·m
84402832 NA - May 2011

9007-5
Installation of Evaporator Sensor Make sure to install the harness holder (1) and thermis-
tor holder (2) in the original position of the evaporator (4)
CAUTION as shown in the diagram.
Be careful that the sensor cord does not get • Install the evaporator sensor (3) end and thermistor
squeezed in the case when the case is assem- holder (2) as shown in the diagram.
bled.
a Thermistor holder position Replacement of Motor Actuator

b 20 mm
c 73 mm 1. Replacement of mode motor actuator
d 9th row Remove the link cover.
e 27th row Remove the connector (2) from the motor actuator
(1).
Remove the 3 Phillips screws (3) securing the mo-
tor actuator (1), remove the rod (4) attached to the
motor actuator (1) from the rod hole on the mode
cam, and then install the new motor actuator (1).
The installation procedure is the reverse of the re-
moval procedure.
Screw size
84402832 NA - May 2011

9007-6
2. Replacement of air mix motor actuator 3. Replacement of refresh/recirculate motor actuator

Remove the link cover. Remove the link cover.
Remove the connector (2) from the motor actuator Remove the connector (2) from the motor actuator
(1). (1).
Remove the 3 Phillips screws (3) securing the mo- Remove the 3 Phillips screws (3) securing the motor
tor actuator (1), remove the rod (4) attached to the actuator (1), remove the lever pin (4) attached to
motor actuator (1) from the rod hole on the damper the motor actuator (1) from the slot hole, and then
lever, and then install the new motor actuator (1). install the new motor actuator (1). The installation
The installation procedure is the reverse of the re- procedure is the reverse of the removal procedure.
moval procedure. Screw size
Screw size Phillips screws (3): M4 x 16 (T1)
84402832 NA - May 2011

9007-7
84402832 NA - May 2011

9007-8
Section
9009
Removal and Installation of Compressor
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Job code 50200AA26 • Always remove the low-pressure side line (2) first.
• Attach caps or plugs to the compressor and lines
WARNING Tightening torque for bolt installation: 19.6 - 24.5
N·m
• Be careful when loosening the lines. The air
conditioner circuit is filled with high-pressure
gas, so there is the danger of gas splaying
out.
CAUTION
work.
• When removing and installing the compres-
sor, check the compressor oil quantity.
Items to prepare
• Wrench (13 mm)
• Rag 3. Use a wrench (13 mm) to remove the 4 bolts (1),
• Cleaning fluid and then remove the compressor (2).
Removal of Compressor N·m
2. Use a box wrench (13 mm) to loosen the bolts (1)

on the lines in the 2 locations, and then remove the
2 lines (2) (3).
84402832 NA - May 2011

9009-3
Installation of Compressor 2. Check the compressor oil quantity.

The compressor contains 135 cc of oil.
1. To install, perform the reverse of the removal pro- The oil quantity being low will cause compressor
cedure. seizing and a reduction in durability. The oil quantity
When installing the bolts, tighten them to the spec- being high will cause a reduction in cooling capabil-
ified torque. ities.
Make sure to check the oil quantity and adjust if
needed.
Measure the oil quantity of the removed compres-
sor. Only this oil quantity is necessary, so subtract
this quantity from 135 cc to determine the amount by
which the oil quantity of the new compressor should
be reduced.
Example)
If the remaining oil quantity of the removed com-
pressor is 30 cc:
Remove 135 cc - 30 cc = 105 cc from the new com-
pressor to be installed.
Resupply oil: SP-10 or SP-20 (P.A.G. oil)
3. Perform air conditioner gas charging.
For details, see "Gas Filling Procedures".
84402832 NA - May 2011

9009-4
Section
9010
Removal and Installation of Condenser
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Job code 50200AK72 2. Use a wrench (19 mm) to remove the 2 bolts (1),
CAUTION and then remove the top cover.
out.
CAUTION
work.
CAUTION
• When removing and installing the condenser,
resupply and check the compressor oil quan-
tity. 3. Use a wrench (10 mm) to remove the bolt (1), and
then remove the line (2).
Items to prepare
• Attach caps or plugs to the condenser and line to
• Wrenches (10 mm, 13 mm, 19 mm) prevent any entry of water, dust or dirt.
• Cap • Clean the lines by spraying with a parts cleaner to
• Plug prevent scratches and prevent dirt from accumu-
• Rag lating on the connectors.
• Cleaning fluid
Tightening torque for line installation: 7.8 - 11.8 N·m
Removal of Condenser
1. Remove the wing nut (1), and then remove the pre-
cleaner (2).

then remove the line (2).
84402832 NA - May 2011

9010-3
5. Use a wrench (13 mm) to remove the bolt (1), and 6. Use a wrench (13 mm) to remove the 6 bolts (1),
then remove the clamp (2). and then remove the condenser (2).
84402832 NA - May 2011

9010-4
Installation of condenser 2. Make sure to resupply and check the compressor

oil quantity.
1. To install, perform the reverse of the removal pro- The compressor contains 135 cc of oil.
cedure. The oil quantity being low will cause compressor
Tighten lines and bolts to the specified torque. seizing and a reduction in durability. The oil quantity
For bolts for which the torque is not specified, check being high will cause a reduction in cooling capabil-
"Bolt Size and Torque Table" in the explanation in ities.
the materials. Make sure to check the oil quantity and adjust if
needed.
Resupply quantity: 40 cc
For details, see "Procedures for Gas Filling".
84402832 NA - May 2011

9010-5
84402832 NA - May 2011

9010-6
Section
9011
Removal and Installation of Receiver Dryer
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Removal of Receiver Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of receiver dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Job code 50200AN92 3. Remove the connector (1).
WARNING
out.
CAUTION
work.
CAUTION
• When replacing the receiver dryer, resupply from the line (1).
and check the compressor oil quantity.
• Install caps or plugs to the receiver dryer and line
Items to prepare to prevent any entry of water, dust or dirt.
• Clean the receiver dryer and line by spraying them
• Wrenches (10 mm, 19 mm) with a parts cleaner to prevent scratches and pre-
• Cap vent dirt from accumulating on the connectors.
• Plug Tightening torque for line installation: 7.8 - 11.8
• Rag N·m
• Cleaning fluid
Removal of Receiver Dryer

1. Remove the wing nut (1), and then remove the pre-
cleaner (2).
5. Use a wrench (10 mm) to remove the 2 bolt (1), and

then remove the receiver dryer (2).

and then remove the top cover (4).
84402832 NA - May 2011

9011-3
Installation of receiver dryer 2. Check the compressor oil quantity.

The compressor contains 135 cc of oil.
1. To install, perform the reverse of the removal pro- The oil quantity being low will cause compressor
cedure. seizing and a reduction in durability. The oil quantity
Tighten lines and bolts being installed to the speci- being high will cause a reduction in cooling capabil-
fied torque. ities.
For bolts for which the torque is not specified, check Make sure to check the oil quantity and adjust if
"Bolt Size and Torque Table" in the explanation in needed.
the materials. Resupply quantity: 20 cc
For details, see "Gas Filling Procedures".
84402832 NA - May 2011

9011-4
Section
9015
Work Precautions
84402832 NA - May 2011

84402832 NA - May 2011
CONTENTS
Work Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Work Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Air Conditioner Refrigerant "Vacuum Operation" and "Gas Filling Operation". . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operation Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Filling Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Charging Hose Connection Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Gauge Manifold Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Vacuuming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Gas Filling Operation, High-pressure Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Gas Filling Operation, Low-pressure Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Work Precautions
Work Precautions
WARNING
• Refrigerant gas filling involves handling dangerous high-pressure gas, so make sure that a experi-
enced and qualified worker with the procedure performs this operation.
• Always wear protective eyewear.
• Gas entering the eyes may cause blindness.
• Refrigerant in the liquid state is very cold (about -26 °C), so be very careful during handling.
• Refrigerant coming in contact with skin may cause frostbite.
Always use R134a refrigerant.

• Storage
Keep service cans (hereinafter, cans) with refrigerant in them at 40 °C or below.
The insides of the cans are highly pressurized and filled with refrigerant, so if the temperature rises there is the
danger of internal pressure rising sharply and an explosion occurring.
Never store in direct sunlight, in a closed vehicle, or near open flames.
Be careful not to drop cans or have them collide with other objects.
• Filling operation
When cans are heated in order to fill them with refrigerant, make sure that the service can valve and gauge manifold
low-pressure valve are open and heat with water at 40 °C or below.
Direct heating or heating to 40 °C or higher may cause explosions, so use caution.
If refrigerant filling is done after the engine is started, never open the gauge manifold high-pressure valve.
This is very dangerous, as the high-pressure gas will flow in the opposite direction and may cause a can or charging
hose explosion.
Be careful not to allow the entry of dust or dirt into the air conditioner circuit.
Air, moisture and dirt are very bad for the cooling cycle.
Perform work quickly and accurately, and be especially careful to prevent the entry of foreign matter.
Be careful not to overfill with gas.
84402832 NA - May 2011

9015-3
Work Precautions
Work Procedures
Air Conditioner Refrigerant "Vacuum Operation" and "Gas Filling Operation".
1. The "vacuum operation" consists of eliminating moisture in the air conditioner circuit.
If there is any moisture left inside the air conditioner circuit, various problems may occur during operation such
as freezing in the small hole of the expansion valve causing the circuit to clog and rust developing in the circuit.
For this reason, perform vacuuming before filling the circuit with refrigerant. This operation consists of eliminating
moisture inside the circuit through boiling and evaporation.
2. The "gas filling operation" consists of filling the circuit with refrigerant after the vacuum operation.
Gas filling does not only affect the cooling capabilities of the air conditioner, it also affects the life of the parts
which make up the circuit.
Severely overfilling the circuit will cause pressure inside the circuit to be abnormally high, and this will cause
reductions in the cooling ability of the air conditioner.
Additionally, if pressure is extremely low, the circulation of lubricating oil within the compressor will be poor and
this will cause seizing with sliding parts of the compressor.
Because the gas filling operation itself involves handling high-pressure gas, performing the operation using an
incorrect procedure is very dangerous.
Follow the operation and observe all precautions indicated in this text to correctly perform refrigerant filling.
Operation Chart
Vacuuming start 30 min. or longer (750 mmHg or less)
↓
Vacuuming stop Let sit for 5 min.
Vacuuming
↓
operation
Gauge display abnormality (connectors check and
Airtightness check
repair)
↓
Fill with refrigerant gas up to a gauge pressure of
Refrigerant filling
0.098 MPa.
Refrigerant fill- ↓
ing operation Gas leak check
↓
Refrigerant filling
84402832 NA - May 2011

9015-4
Work Precautions
Tools
No. Part name Q'ty Shape Application
1 Gauge manifold 1
Red: high-pressure
side
Blue: low-pressure
2 Charging hose 3
side
Yellow: vacuum
pump side
3 Quick joint 1
4 Quick joint 1 Low-pressure side
5 T joint 1 For service can valve
6 Service can valve 2 For service can
Vacuum pump
7 1 For vacuum pump
adapter
84402832 NA - May 2011

9015-5
Work Precautions
Filling Procedures
CAUTION
• Because gauge manifold specifications such as hose color are different depending on the manufac-
turer, read the operator's manual for the gauge manifold to be used for details.
Charging Hose Connection Positions
High-pressure side (DIS) ser-

1 3 Air conditioner compressor 5 Receiver dryer
vice valve
Low-pressure side (SUC) ser-
2 4 Condenser 6 Air conditioner unit
vice valve
Gauge Manifold Connection

1. Close the high-pressure valve (HI) (12) and low-pressure valve (LO) (11) of the gauge manifold (13).
2. Connect the charging hoses (red and blue) to the service valve.
Red hose (14): Gauge manifold high-pressure side (HI) → compressor high-pressure side (DIS) service valve (1)
Blue hose (15): Gauge manifold low-pressure side (LO) → compressor low-pressure side (SUC) service valve
(2)
Push in the connections for the high-pressure and low-pressure sides until a "click" is heard to make sure they
are secure and in the correct position.
3. Connect the charging hose (yellow) (7) to the vacuum pump (8).
84402832 NA - May 2011

9015-6
Work Precautions
9 Low-pressure gauge
10 High-pressure gauge
84402832 NA - May 2011

9015-7
Work Precautions
Vacuuming
1. Open the high-pressure valve (HI) (12) and low-pressure valve (LO) (11) of the gauge manifold (13).
2. Turn the vacuum pump (8) switch on and vacuum for at least 30 min.
3. After the prescribed vacuuming time has elapsed (degree of vacuuming achieved: -750 mmHg or less), close
the gauge manifold (13) high-pressure valve (12) and low-pressure valve (11).
4. Next, turn the vacuum pump (8) switch off.
5. Perform a check of air-tightness.
Let the gauge manifold (13) sit for at least 5 min. with the high-pressure valve (12) and low-pressure valve (11)
closed, and check that the gauge indicator does not go back to 0.
If the gauge indicator starts to swing back to 0, this indicates there is a leak. Tighten the line connections, perform
vacuuming again, and check to see if there is still a leak.
84402832 NA - May 2011

9015-8
Work Precautions
Gas Filling Operation, High-pressure Side

First, prepare the regulation amount of refrigerant, then start the filling operation from the high-pressure side.
1. After repeating vacuuming, switch the charging hose (yellow) (7) of the gauge manifold (13) from the vacuum
pump to the service can (16).
2. Air purging
Open the valve for the service can (17). (However, keep the gauge manifold high-pressure and low-pressure
valves closed.)
Next, press the air purge valve (18) of the side service port on the gauge manifold low-pressure side with a
screwdriver to discharge the air inside the charging hose using the refrigerant pressure. (Complete after the
swooshing sound stops.)
3. Open the high-pressure valve (12) of the gauge manifold (13), and fill with coolant. (Fill with refrigerant gas up
to a gauge pressure of 0.098 MPa.)
After filling, close the gauge manifold high-pressure valve and valve for the service can (17).
Never operate the compressor. (This is very dangerous, as the refrigerant will flow in the opposite direction and
may cause a service can or hose explosion.)
4. Gas leak check
Check for gas leaks in the cycle using the gas leak tester.
If there are leaks, eliminate them through tightening.
Always use the tester for R134a.
84402832 NA - May 2011

9015-9
Work Precautions
Gas Filling Operation, Low-pressure Side

CAUTION
• Never open the gauge manifold high-pressure valve.
• Never tip over the service can. This may cause damage to the compressor.
After finishing the high-pressure side filling operation, perform the operation for the low-pressure side.
1. Check that the high-pressure valve (12) and low-pressure valve (11) of the gauge manifold (13) and the valve for
the service can (17) are closed.
2. Start the engine, increase speed to 1400 - 1600 min-1, and completely open the cab door and window.
3. Turn the air conditioner switch on, move the fan switch to the maximum position, and move the temperature
adjustment switch to the maximum cooling position.
4. During filling, set the degree of discharge for the compressor at 1.37 - 1.57 MPa.
5. Open the low-pressure valve (11) of the gauge manifold (13) and valve for the service can (17), and fill with the
regulation amount of refrigerant until the air bubbles in the receiver sight glass (19) are gone.
• Judging the amount of refrigerant from the receiver dryer sight glass
After the AC is turned ON, a few air
When the amount is bubbles are visible. The glass then be-
correct comes transparent and turns to a pale,
milky-white color.
When overfilling oc- After the AC is turned ON, no air bubbles

curred at all are visible.
When filling was in- After the AC is turned ON, air bubbles are
sufficient seen continuously.
(Total gas filling amount: 950 - 1050 g)
6. After refrigerant filling is complete, close the low-pressure valve (11) of the gauge manifold (13) and the valve for
the service can (17), and stop the engine.
84402832 NA - May 2011
9015-10
Work Precautions
• If the air conditioner is operated with very little refrigerant (R134a), this will have a damaging effect on the
compressor.
• If the air conditioner is filled with too much refrigerant (overcharge), this will actually cause insufficient cooling
and there is the danger of pressure in the circuit becoming abnormally high.
Be sure to use an appropriate amount of refrigerant.
• Never open the gauge manifold high-pressure valve (12).
• Never invert the service can. (Gas is suctioned in liquid form, so this may cause damage to the compressor
valve.)
7. After refrigerant filling and inspection, remove the gauge manifold and hoses.
Quickly remove the low-pressure side charge hose (blue) (15) from the low-pressure side (SUC) service valve.
Do not do anything on the high-pressure side until the high-pressure gauge indicator falls to 0.98 MPa or below.
After confirming that the indicator has fallen below this point, quickly remove the high-pressure side charge hose
(red) (14) from the high-pressure side (DIS) service valve.
84402832 NA - May 2011

9015-11
BOX FUSE(ATTACHMENT FOR CAB MAIN HARNESS)
8R 105 8R 105 2 8R 105
F34
5RW 103 5RW 103 1 5RW 103
F41 F42 F43 F45
(F16) 3R 105d
3R 105b
(F19) 3R 105e
(F12) 3R 105c
3R 105a
180,215,242,250,260,267
400,410,411,412,413,414,415,416,419,420,430,444,445,446,450,490,492,532,534,535,538,559,660,800,801,802,803,805,0806,807,812,813,900,901,902,903,904,905,906,907,908,909,910,911
5RW 020
DIESEL ENGINE
(CN.A50
YAZAKI
(F20)
(F18)
(F17)
(F15)
(F14)
(F13)
(F10)
1
2
(F11)
FUSIBLE LINK FUSE FUSIBLE LINK FUSIBLE LINK
(F9)
(F8)
(F7)
(F6)
(F5)
(F4)
(F3)
(F2)
(F1)
58L
10 9 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 BACK UP CONT FUSE BOX SAFETY RL
20 19 18 17 16 15 14 13 12 11 20 19 18 17 16 15 14 13 12 11 ALTERNATOR
15A
15A
10A
10A
10A
10A
10A
20A
15A
10A 50A 15A 65A 60A
15A
10A
15A
10A
10A
10A
15A
15A
1 1 1 1 8B 797 E 24V 50A
5A
5A
SUMITOMO SUMITOMO 2
(CN.A41) (CN.A42) 2 2 2 YAZAKI M6
YAZAKI YAZAKI YAZAKI
BLOWER MOTOR
YAZAKI M8 (CN.D15)
WIPER/WASHER
CIGAR LIGHTER
TRAVEL ARALM
(BOOM,HOUSE)
1 2 3 1 2 3 1 2 3
COMPRESSOR
REFUEL PUMP
2
1
2
1
1
2
58L 58L 58L
CONTROLLER
CONTROLLER
1.25BG 600 8 2BG 600 CN-A
2
1
AIRCON UNIT
LEVER LOCK
CONVERTOR
KEY SWITCH
4 5 6 4 5 6 4 5 6 (CN.D23) (CN.D26) (CN.D25) (CN.D24) IC
SOLENOID
1.25B 700 2B 700 YAZAKI
SEAT SUS
7
BACK UP
REGULATOR
BEACON
10
12
13
14
15
16
17
18
19
20
10
12
13
14
15
16
17
18
19
20
11
11
AIRCON
AIRCON
OPTION
ENGINE
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
6
5
4
3
2
1
1
2
3
4
5
6
YAZAKI YAZAKI YAZAKI (CN.D16)
SPARE
SPARE
(GATE)
DC/DC
HORN
6
LAMP
LAMP
(CAB)
5RW 103
5RW 102
8R 105
8R 104
5R 002
5R 003
M M M
GPS
1.25W 107
1.25W 106
(CN.A38) (CN.A39) (CN.A40) 5
PG 41b
PG 41d
PG 41g
PG 41h
BG 630
BG 637
BG 640
PG 41a
PG 41c
PG 41e
P 40b
P 40d
P 40g
P 40h
P 40a
P 40c
P 40e
RL 160
RL 161
RL 162
RL 163
RL 164
PG 41f
PG 41i
PG 41j
P 40f
P 40i
P 40j
G2
1.25W 109
1.25W 108
1.25W 107
1.25Y 870 1.25Y 870
1.25WR 141
1.25WR 142
1.25WR 145
1.25WR 146
1.25WR 147
1.25WR 148
1.25W 112
1.25W 110
1.25G 510 0.75R R
1.25W 111
0.85G 502
0.85G 503
0.85G 504
0.85G 505
0.85G 506
1.25BG 600
1.25BG 601
1.25BG 602
0.85BG 603
1.25BG 609
1.25BG 610
0.85BG 620
1.25B 700
0.85B 701
0.85B 702
1.25B 703
0.85B 704
0.85B 720
4 1
WB 245
WL 260
2W 250
GR 180
LgW 190
VR 230
RL 160
0.85GW 215
WL 267
1.25WR 235
1.25RW 140
1.25W 205
0.85VW 170
1.25Br 515 0.75L L
0.85OR 225
1.25LW 200
0.85R 130
3 2
1.25RB 150
0.85YR 220
0.85LR 240
1.25GrR 195
0.85BrR 210
WL 266
WL 267
0.85GW 216
0.85GW 215 2 0.85GW 215
0.85YR 221
0.85LR 242
(CN.D14)
SWP
YAZAKI
B 749 2W 250 1 2W 250
1 2
0.85B 708
RL 166 0.85G 507 K7
(CN.D17)
(CN.D19)
(CN.D18)
1 2 3 4
5 6 7 8
YAZAKI
YAZAKI
YAZAKI
0.5μF
(CN.A51)
8R 030 B
YAZAKI
108,109,110 YAZAKI M6
58M
A1 601,602,603,701,702,703 G1 RELAY BATTERY
(CN.D13)
STARTER MOTOR
CONTROLLER A 503,504,505,515,520,521,530,536,537,539,558,804,808,809
K63 (CN.A09) K64 (CN.A13) K65 (CN.A11) K66 (CN.A12) K67 (CN.A10) (CN.A14) K68 (CN.A15) K34 60R 100 60R 101
M8 M8
YAZAKI
60R 001 B
M10
M
RELAY RELAY RELAY RELAY RELAY RELAY RELAY
M1
10 11 12 13 14 15 16 17 18 19 20
6 7 8 9
POWER 24V 1.25W 108 V 097 (CN.D21) 5Y 004 S
0.85BG 660
1 1
ECM KEY ON BATTERY RL IDLE STOP DPF NEUTRAL START STARTER CUT M10 M10 M10 M10
(CN.D11)
58Y
YAZAKI
12 1.25W 108a VG 098 2 M4
YAZAKI YAZAKI M5
7 8 9 10 11 12 13 14
4 5 6
- + - +
(CN.D12)
(CN.C21)
SDL
YAZAKI
POWER 24V 11 G 099 3 (CN.D20)
6 5 4 3
2
1
24V 5.0kw
P1 VR 595 M4
(CN.C3)
YAZAKI
22 4
60B 799
(CN.A44)
YAZAKI
SDL
GND_2 2 1.25BG 601 Br 596 5 5L 021 1 5BW
1.25WR 511
1.25G 501
1 2 3 4 5
1
GLOW PLUG
SDL
B
13 1.25BG 601a BG 612 6
1 2 3
1 4 2 1
GND_3 5 0.85B 701 MONITOR DISPLAY 5 12V 12V YAZAKI
R1
1
16 0.85B 701a 3 M8 CN-A
14 13 12 11
(CN.D9)
SWP
YAZAKI
7 6 5 4
BZ. (CN.D22)
10 9 8
GND BATT. 0.85RL 161 0.85RL 161 0.85RL 161 RL 161 SUMITOMO
3 2 1
9 1 1 1
VGS TURBO&C/UNIT
3
1
2
5
4
3
1
2
5
4
3
1
2
5
4
3
1
2
5
4
3
1
2
5
4
3
1
2
5
4
3
1
2
5
4
20 IGN 2 1.25W 111 2 1.25W 111 1.25W 111 2 1.25W 111 1.25W 107 1 1.25W 107 0.85B 751
GND_A 10 D-IN8 ALTERNATOR 4 0.85BrW 519 4 0.85BrW 519 0.85BrW 519 3 0.85BrW 519 0.85G 501 2 1.25G 501 1 U
P4 V
M
0.85GW 303
P 040b P 040b 0.85LR 881 LR 881 0.85WR 511 1.25WR 511 0.75B 786 0.75YR GND
1.25WR 141
1.25WR 146
1.25WR 147
1.25WR 145
1.25RW 140
0.85W 112
0.85W 113
0.85W 114
0.85W 115
0.85WR 511
CAN H
0.85G 501
0.85O 804
0.85GR 845
0.85B 704
0.85B 705
0.85B 706
21 5 5 4 3 2 2
0.85YR 370
0.85LR 890
0.85LR 891
0.85LR 890
0.85Y 011
0.85Y 011
0.85LR 373
0.85YL 808
0.85LgR 500
0.85LY 824
0.85GrR 012
0.85BrR 010
NPN_OUT1 SOL SWING BRAKE 6 W 800 H1 CAN L 6 PG 041b 6 PG 041b 0.85YR 882 5 YR 882 0.85Br 515 4 1.25Br 515 0.75WR 145 3 0.75LR 3 Vcc W
(CN.E1)
SUMITOMO
NPN_OUT2 SOL 2 STAGE TRAVEL 4 L 801 CAN GND 18 18 V 809 6 V 809 0.85GrR 012 5 0.85GrR 011 8
LCD DISPLAY
RELAY STARTER
NPN_OUT3 SOL 2 STAGE RELIEF 7 Y 802 TxD(RS232C) 8 WL 061b 8 WL 061b P 040b 7 P 040b 373 0.85RY 840 6 0.75RG 840
K69
5 U
M23
(CN.D30)
CN-A
YAZAKI
SENSOR
POSITION
CPU RELAY GLOW
K2
NPN_OUT4 FREE SWING 3 Br 803 RxD(RS232C) 9 W 060b 9 W 060b PG 041b 8 PG 041b 303 7 VG 051a 6 BrL 6 L V
TFT FULL COLOR
508
509
118
10 11 12 13 14 15 16 17 18 19 20
5 6 7 8 9
1
NPN_OUT5 RL BATTERY 8 0.85O 804 GND(RS232C) 19 BL 064b 19 BL 064b WL 061b 9 WL 061b 142 8 0.85B 779 1 5R 003 V 050a 7 L 7 H W
517
519
6
7
I/O
NPN_OUT6 SOL OPT 2 SPEED 14 YR 805 5V-OUT PGM_WRITE 3 V 097 3 V 097 W 060b 10 W 060b 140 370 2 5Y 004 9 VCC
(CN.D28)
SWP
YAZAKI
GND
2
3
NPN_OUT7 SOL OPT SELECT 15 LY 806 PGM_WRITE SW 12 VG 098 12 VG 098 BL 064b 11 BL 064b 804,808 301 5RW 020 1 1 5L 021 4 0.75BW
070MIULTI
1 2
NPN_OUT8 TRAVEL ALARM 18 WL 807 RESET 7 G 099 7 G 099 WB 949 12 WB 949 500 501 10
(CN.C1)
2 3
4 5 6 7 8
INTAKE THROTTLE
AMP
NPN_OUT9 RL DPF 17 0.85YL 808 8V-OUT CAMERA+ 10 R 960 10 R 960 BW 950 13 BW 950 112 511 0.75B 392 12 BL
(CN.A52)
(CN.D27)
P10
1 2
YAZAKI
DC-MOTOR
YAZAKI
1 2 3 4
NPN_OUT10 SIG WASHER 19 V 809 CAMERA GND 11 B 961 11 B 961 1.25BG 610 14 1.25BG 610 515 515 0.85G 509 1 0.85GrR 011 1 0.75GR 393 13 G
SDL
(CN.D31)
58
YAZAKI
A/D-IN THERMO SN 010 012 0.85L 372 0.85B 750 0.75P 326 VW BL
1
13 13 2 2 11 2
M
1
040/070HYBRID I/O
CN-A
SWITCH PANEL AGND 14 14 840 840 14 G 1
1 2 3 4 5
(CN.E2)
AMP
PWM_OUT1 PUMP POWER(OUT) 3 0.85Y 900 SCL(12C) 16 16 845 6
9 10 11 12 13 14 15 16 17 18
5 6 7 8
S11 M24
(CN.D29)
CN-A
YAZAKI
PWM_RTN1 PUMP POWER(RTN) 6 0.85BY 901 SDA(12C) 17 17 824 L 5 Vcc
WIPER
AMP
PWM_OUT2 BOOM DOWN(OUT) 0.85O 902 GND 1.25BG 611 1.25BG 611 VW OUT
2
1
1 15 15 3
S12
(CN.A45)
PWM_RTN2 BOOM DOWN(RTN) 4 0.85BO 903 GND 20 1.25BG 610 20 1.25BG 610 704 508,372 LW 4 GND
YAZAKI
16 15 14 13
12 11 10 9
(CN.D8)
SWP
YAZAKI
8 7 6 5
4 3 2 1
WASHER
K36 K35 K5 K3 K11
22 21 20 19 18 17 16 15 14 13 12
11 10 9 8 7 6 5 4 3 2 1
PWM_OUT3 P1 FLOW(OUT) 0.85L 904
SDL
2
S10
1 2 3 4
(CN.D38)
MT090
SUMITOMO
PWM_RTN3 P1 FLOW(RTN) 5 0.85BL 905 1.25RW 119 1
520
521
K37 EGR VALVE
BG 613
BG 614
W.LAMP RELAY RELAY RELAY RELAY RELAY RELAY RELAY
1 2
K10
SHLD GND 8 CAMERA1 SIG 1 Y 962 1 Y 962 1.25G 754 2
S2 SPEAKER:R SPEAKER:L ROOM LAMP BEACON HORN LAMP:CAB LAMP:UPPER
0.85WR 512
W 963 W 963 0.75WR 386 0.75WR
0.85Br 516
7 CAMERA1 GND 11 11 5 5
(CN.A4)
U
S-G BOOT_CNT 11 WR 062
TRAVEL MODE
CAMERA2 SIG 2 YB 967 2 YB 967 0.85BrR 210 1 0.85BrR 210 (CN.A21) (CN.A22) (CN.A20) (CN.A19) (CN.A16) (CN.A18) (CN.A17)
M20 0.75WB 387 6 0.75WB 6 M
FWE 12 WR 063 S4
IDLE MODE
CAMERA2 GND 12 WB 968 12 WB 968 0.85YR 220 2 0.85YR 220 M8 FUEL PUMP 0.75WL 388 7 0.75WL 7
V
W
SW_IN12 LM MAG SW 9 YR 541 CAMERA3 SIG 3 YR 972 3 YR 972 0.85WR 282 3 0.85WR 282 0.75RG 356 8 0.75LW 8 GND
S86 YAZAKI
M25
(CN.D37)
58W
YAZAKI
1
2
O 542 WR 973 WR 973 0.85WY 829 0.85WV 829 1.25W 118 2BY 0.75GB 353 0.75GB U
M
SW_IN13 LM MODE 10 CAMERA3 GND 13 13 4 (CN.D81) SOLENOID VALVE 1 1 1
(CN.E3)
DL090
SUMITOMO
DPF CLEAN
1 2
5 6 7 8
1 2 3 4
D-IN1 F-WINDOW SW 4 O 590 4 O 590 1.25GR 875 5 1.25GR 875 1.25G 753 2 2B 0.75GW 354 2 0.75GW 2 V
S87 1 4 2 24V
6 5 4 3 2 1
12 11 10 9 8 7
LEVER
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
(CN.D59)
SWP
YAZAKI
D-IN2 MUTE SW 5 YL 591 5 YL 591 VG 822 6 VG 822 5 0.75RG 840 1 0.75R 0.75GR 355 3 0.75GY 3 W
ATT SELECT (SP)
1 2
TXD 4 PW 055 D-IN3 CAMERA SW 6 V 592 6 V 592 WG 823 7 WG 823 3 0.75B 752 2 0.75B LAMP 0.75RW 352 4 0.75L 4 VCC
S88
(CN.A3)
LOCK
RXD 12 PL 056 D-IN4 DOOR SW 7 OL 593 7 OL 593 LY 824 8 0.85LY 824 SUMITOMO SUMITOMO (BOOM) 9
(PINK TAPE)
Y2
040MIULTI
3
1
2
5
4
3
1
2
5
4
3
1
2
5
4
3
1
2
5
4
3
1
2
5
4
3
1
2
5
4
3
1
2
5
4
MENU MT090
RS232C_TXD 3 W 060a D-IN5 ONE TIME WIPER 8 YG 594 8 YG 594 LG 825 9 LG 825 10
S89
(CN.C2)
(CN.A30) SWING CRANK ANG(MRE)
(CN.D60)
SWP
YAZAKI
AMP
RS232C_RXD 10 WL 061a D-IN6 SPARE1 9 VR 595 9 VR 595 OR 826 10 OR 826 0.75RW 181 1 0.75R 1.25Y 871 1 1.25Y 871 1 0.85R 11
24V
1 2
WG 831
WG 823
SENSOR
G 888
OR 826
LW 841
LgW 190
LgW 191
(S2)
LG 825
LG 832
LG 842
LR 880
2 1
RL 164
RL 165
DIAPLAY SEL
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
0.85GW 216
0.85GW 217
RS232C_GND BL 064a D-IN7 SPARE2 Br 596 Br 596 G 888 G 888 0.75WB 800 0.75B 1.25B 758 1.25B 758 0.85B
1.25GR 875
1.25LW 200
1.25LW 201
0.85R 885
2 10 10 11 2 2 2 12
0.85RB 292
0.85RB 293
0.85RB 290
S90
0.85Y 980
0.85YB 984
1.25Y 870
0.85L 981
0.85LB 985
BRAKE
1.25GrR 195
1.25GrR 196
D-OUT1 WIPER-INT GR 820 GR 820 YL 591 YL 591
70W Vcc
Y3
GND 5 14 14 12 (BLUE TAPE) 13 1
(CN.E4)
YAZAKI
TRIP/CAMERA
B49
(CN.A2)
1 2 3
GND 13 D-OUT2 WIPER-CNT 15 Lg 821 15 Lg 821 V 592 13 14 3 OUT(PULSE)
(CN.D66)
SWP
YAZAKI
(CN.G2)
CN-A
YAZAKI
LR 881
2 STAGE
(CN.D61)
SWP
YAZAKI
CAN_H 6 P 040c D-OUT3 RL FUEL PUMP 16 VG 822 16 VG 822 YG 594 14 YG 594 GR 180 1 0.75GR 180 0.75RW 182 1 0.75R 15 2 GND
1 2
(S1)
E2
2
1
1 2
CAN_L 14 PG 041c D-OUT4 RL LAMP 17 WG 823 17 WG 823 0.85YB 984 15 0.85YB 984 833 W 800 2 0.75WB 800 0.75L 801 2 0.75B TRAVEL 16
D-OUT5 RL IDLE STOP LY 824 LY 824 0.85LB 985 0.85LB 985 164,190,195,200,216 L 801 0.75L 801 LAMP
Y4
+5V_OUT 11 18 18 16 3 (RED TAPE)
D-OUT6 RL MUTE LG 825 LG 825 0.85BY 982 0.85BY 982 Y 802 0.75Y 802
(HOUSE) COMMON RAIL PRESS
FREQUENCY_IN 1 19 19 17 4
26 25 24 23 22 21 20 19 18 17 16 15 14
13 12 11 10 9 8 7 6 5 4 3 2 1
2 STAGE SENSOR
(CN.D62)
SWP
YAZAKI
FREQUENCY_GND 9 D-OUT7 RL ROOM LAMP 20 OR 826 20 OR 826 0.85BL 983 18 0.85BL 983 829,834850,851,852,853,880,882,885,943 Br 803 5 0.85Br 803 0.75RW 183 1 0.75R 1.25Y 870 1 0.85R
24V
1 2
AVcc 7 0.85Y 408 11 WB 949 G 812 6 0.75Y 802 2 0.75B RELIEF
(S3)
1.25B 757 2 0.85B
70W E1 1
(CN.E5)
AMP
B52
1 2 3
L 530 BW 950 Lg 813 0.75WB 310 VW
Y5
SW_1 IDLE SW 15 22 7 1 2
(CN.D65)
CN-A
YAZAKI
(YELLOW TAPE)
S1
SW_2 ANTI-THEFT 16 VG 531 WL 807 8 0.85WL 807 0.75R 311 6 GrB 3
(CN.A1)
2
1
R3 S51
12 13 14 15 16 17 18 19 20 21 22
SUNLOAD SENSOR
1 2 3 4 5 6 7 8 9 10 11
SW_3 COOLANT 8 GrR 532 VG 822 9 0.85VG 822 0.75G 312 15 WB

TRAVEL
7 8 9 10 11 12 13
4 5 6
1 WB 949 X28 0.85R 130

0.85RB 290
1
2
0.85R 130
0.85RB 290
KEY SWITCH LR 880
YR 882
10
11
0.85LR 880
0.85YR 882
SOLENOID VALVE 0.85WL 807
0.85GW 215
1
2
B
R ALARM
H2
0.75B 690b 11
12
0.75B
CONNECTION
B61 THROTTLE VOL. LIMIT SWITCH OFF ACC 24V,107dB BOOST PRESS
(CN.C6)
FREE
A4
(CN.D64)
SWP
YAZAKI
（CN.C4）
0.85YB 490 BW 950 0.85VW 170 0.85VW 170 0.85WV 829 0.85V 829 0.75RW 187 0.75R 0.75W 313 L
(CN.D69)
SWP
YAZAKI
SN_IN1 SN HYD.TEMP 2 2 3 12 1 5
B G1 G2 ACC M ST
AMP
(GATE)
Y18 SENSOR
YAZAKI
TO CAMERA 1
1 2
1 2 3
0.85GL 492 R 970 0.85LgR 500 0.85LgR 500 0.85R 885 0.85R 885 0.85Br 803 0.75B 0.75L 314 LW
ON
1 2
SN_IN2 SN FUEL LEVEL 15 1 4 13 2 10
1.0Ⅲ
SWING
POT_IN1 SN_P P1 21 0.85Y 410 WIPER B 971 2 (NO TAPE) 0.85BrR 010 5 0.85BrR 010 HEAT 0.85GW 943 14 0.85GW 943 (NO TAPE) 0.75G 315 17 Br 0.75RW 1
(CN.E6)
SUMITOMO
ST
OFF B47
1 2 3
POT_IN2 SN_P P2 9 0.85L 411 CONTROLER YR 972 3 0.85RY 840 6 0.85RY 840 0.85LR 242 15 0.85LR 242 2W 250 1 0.75BW 691b 14 0.75BW 0.75L 2
(CN.C5)
(CN.C18)
1 2
1 2
3 4
YAZAKI
POT_IN3 SN_P N1 0.85Lg 412 WR 973 0.85GR 845 0.85GR 845 0.85VG 822 0.75RL
22 4 7
ACC 16 3 16 3
AMP
REFUEL PUMP
SWP
040
(CN.D58)
SWP
YAZAKI
POT_IN4 SN_P N2 10 0.85G 413 WIPER SW.IN(INT) 11 GR 820 0.85G 507 8 0.85G 507 17 2B 764 0.75RW 319 0.75RW
5 6 7 8
1 2 3 4
2 29
ON (See page 2/2)
Br 834
0.85GR 414 WIPER SW.IN(CNT) Lg 821 0.85B 720 0.85B 720
K51 0.75GW 320 0.75L
(CN.D76)
58W
YAZAKI
POT_IN5 SN_P SWING 23 12 9 18 24
10 11 12 13 14 15 16 17 18 19 20
5 6 7 8 9
RELAY CONDENSER OIL PRESS
ST
0.85B
A/D
0.85Y
0.85L
0.85V 415 WASHER SW. IN V 809 0.85BG 620 0.85BG 620 0.75RG 321 0.75RL
1 2
POT_IN6 SN_P UPPER
X29
12 13 10 19 19
(CN.D86F)
3
0.85YG 416 POWER (24V) IN 0.85BrR 210
SENSOR
POT_IN7 SN_P TRAVEL 24 1 20 18
ROOM LAMP 3 2 1 1 2
5 6 7 8 9 10
1 2
(CN.D68)
MT090
SUMITOMO
WASHER CONT.(+) 0.85WY 829 0.75GR 180 0.85V 830 0.75WB 322 0.75WB 0.75WB
(CN.B6)
MT090
SUMITOMO
POT_IN8 13 2
E4 1 4 1 30 1
(CN.A46)
SDL
YAZAKI
(CN.E7)
SUMITOMO
YAZAKI
(CN.A55)
(CN.C8)
1
2
3
YAZAKI
1 2
1
2
YAZAKI
YAZAKI
1 2
TO CAMERA 2
B21
1 2 3
0.85LY 418 WASHER CONT.(-) 0.75RW 181 0.85GR 897 0.85B 756 0.75Y 323 0.75LY 0.75LY
1 2
POT_IN9 SN_ANG THROTTLE 25 3 24 R 965 1 SDL 1 2 3 2 5 2 25 2
090
SWP
SDL
4
2
5
3
6
1
POT_IN10 SN_P OVER LOAD 26 0.85Gr 419 WINDOW CONTROL 9 B 966 2 (RED TAPE) (CN.B2)
(CN.B3) 4 5 6 0.75RW 182 3 2 B 769 0.75BY 324 20 0.75BY 0.75BY 3
1 2 3 4
3 4
OFF
(CN.C22)
0.85G 503 REV. SIG. 0.85G 485 ，10W G 888 G 888 0.75RW 183 GW 953
0.85VW 170
COMP_IN1 KEY ON
0.85BO 428
7 7 2 1 YB 967 4 1 21
0.85Y 408
YAZAKI
0.85RY 840
3
0.85LY 418
YAZAKI
1
2
WASHER
(CN.C19)
CN-A
CN-A
1 2
3 4
0.85RY 520 STOP SIG. 0.85L 486 Y 843 Y 843 0.85RY 844 0.85LR 242 0.75YG 342 0.75YG
YAZAKI
COMP_IN2 SW GATE LEVER WB 968
0.85R 130
20 1 2 2 5 3 31
0.85RB 290
DOOR
0.85LgR 500
0.85BrR 010
4
(CN.B1)
SWP
COMP_IN3 BATTERY CHARGE 8 0.85Br 515 WINDOW LIMIT SW. 4 ON L 530 1 0.85L 530 0.85GR 845 1 0.75RW 185 6 22
0.85W 400 WIPER MOTOR(CW) 0.85LR 827 YG 594 0.85YG 594 0.85V 829 0.75B 344 0.75BR FUEL TEMP.SENSOR
SW_IN1 AVcc 11
0.85BO 428 WIPER MOTOR(CCW)
8
5
0.85LB 828 TO CAMERA 3 G 850
2
0.85G 850 0.75RW 187
7 1
M M4
9
t℃
SUMITOMO
SW_IN2 AGND 0.85B 755 0.75G 345 0.75RL 0.75YG
(CN.E8)
ECO-J
AMP
1 6 LIMIT SW R 960 1 3 8 2 13 1
(CN.C9)
B3
YAZAKI
1 2
3 4
1 4 2
(BLUE TAPE) 24V
1 2
SW_IN3 AGND 14 0.85BW 420 GND 10 1.25B 710 B 961 O 851 4 0.85O 851 23 0.75LW 2
(CN.D67)
CN-A
YAZAKI
（DOOR）
5
3
2
SW_IN4 SW AIR CLEANER 16 LW 533 Y 962 LW 841 5 0.85LW 841 0.75WR 365 7 0.75WR
S53 3
2
1
M3 RADIO AM/FM STEREO
(CN.C20)
VY 534 OL 593 OL 593
1 2
SW_IN5 P-SW OPT1 3 4 YL 591 0.85YL 591 0.75GW 366 0.75GY
YAZAKI
3 1 2 W 963 6 2
P15
4
KNOB(RIGHT) 24V,2A<NA> HORN LOW
SWP
1 2 3
4 5 6
SW_IN6 P-SW OPT2 17 GY 535 2 Y 843 4 Y 843 GL 852 7 0.85GL 852 0.85Y 900 1 0.75Y 900 0.85LR 880 26
(CN.C7)
YAZAKI
HYD.OIL TEMP BOOST TEMP.SENSOR

S16 P3 (LEFT)
CN-A
WIPER MOTOR
SW_IN7 SW FREE SWING GW 536 BG 613 BG 613 OL 853 0.85OL 853 0.85O 902 0.85O 902
B92 0.75RW 340 0.75RB
(CN.C23)
4 3 1 8 2 YAZAKI(CN.D70) 3
I/O
SENSOR
YAZAKI
24V,303Hz
BUCK UP
1
2
3
WG 537 0.85L 530 L IDLE SW 0.85L 904 0.75L 904 0.85B 760 0.75R 0.75BR t℃
CN-A
SW_IN8 SW HBCV/TRVL ALM
(CN.E9)
PACKARD
18 3 6 3 8 1
X30 115dB
B51
GND
4 5 6 7 8
1
ACC
(CN.A47)
SDL
YAZAKI
R(+)
1 2
L(+)
YL 538 0.85LR 0.85LR 827 0.85BG 625 L 0.85G 906 0.85G 906 0.75Y 490 t℃ 0.75RL
R(-)
L(-)
SW_IN9 SW FILTER IND 5 1 7 4 2 YAZAKI(CN.D71) 27 2
SW_IN10 SW ENG STOP 19 LB 539 M 0.85LB 3 0.85LB 828 DOOR OPEN:CLOSE 0.85YG 594 4 Y S11 0.85W 908 5 0.75BW 491 1 B2 4 0.75G
DOOR CLOSE:OPEN
U1 WIPER
4 5 6 7 8
1
2 3
0.85BG 626 Y 0.85V 910 0.85V 910 HORN HIGH
(CN.B4)
62C
YAZAKI
(CN.D56)
SWP
YAZAKI
SW_IN11 6 2 5 6 28
GrR
OW
(CN.C10)
GR
S31
1 2
3 4
0.85YR 882
Gr
YAZAKI
H4
G
R
B
0.85G 0.85G 485 0.85G 850 G (RIGHT)
B93
1 2
SW_IN12 4 3 7 32
SPEAKER(R) FUEL LEVEL EGR INTAKE TEMP.SENSOR
0.85L 0.85L 486 RL 167 0.85B 723 G 1ST.ACT X8 YAZAKI(CN.D72)
24V,333Hz
2 3
SW_IN13 6 8 8
DC/DC(24V/12V) SENSOR 0.85B 761
1
2
3
4
5
6
7
8
9
S/V(R)
R5 115dB
X2
(CN.E10)
YAZAKI
0.85B 5 1.25B 711 1 0.85BY 982 3 0.85BY 982 RL 162 1 RL 162 0.85O 851 1 O 0.85BY 901 9 0.75BY 901 0.75WR 1 t℃
CONVERTER
S32 YAZAKI(CN.D73) B86
(CN.C24)
BEACON
1 2
R
YAZAKI
2 0.85YB 984 1 0.85YB 984 0.85YR 221 2 0.85YR 221 0.85B 724 2 O 0.85BO 903 10 0.85BO 903 0.85GL 492 2 0.75Y 0.75GY 2
1
2
(CN.D7)
NMW
MITSUBISHI
32
27
22
17
14
10
5
CN-A
RL 162
24V 1 2 3 4
(CN.D74)
SWP
YAZAKI
0.85BL 983 24V IN (MAIN) 0.85OR 225 GW 536 0.85GW 536 1ST.ACT 0.85BL 905 0.75BL 905 0.85BG 660 0.75B 0.85R 885
1.25B 728
4 6 3 11 1 1
0.85RB 291
0.85Y 980
0.85BY 982
31 30 29 28
26 25 24 23
21 20 19 18
13 12 11
0.85L 981
0.85BL 983
9 8 7 6
4 3 2 1
5 6 7 8 9
S/V(L)
1 2
0.85LB 985 24V IN (BACKUP) RL 163 WG 537 0.85WG 537 0.85GB 907 0.85GB 907 0.85B 762
(CN.D57)
SWP
YAZAKI
2 2 4 12 2
YAZAKI
16 15
A13 GND 0.85B 708 YL 558 0.85YL 558 0.85YL 818 0.85YL 818
1 2
5 5 13
ACC PA PRESS. SENSOR WATER TEMP.SENSOR
(CN.D90F)
MT090
SUMITOMO
X15 SOCKET H5 SPEAKER(L)
12V OUT(BACKUP) 3 0.85RY 280 YB 570 6 0.85YB 570 (CN.B13) 14
B42 0.85GR 898 1
(CN.E11)
SUMITOMO
KNOB(LEFT) (P1) (NOT USED)
1 2
12V OUT(MAIN) 1 0.85WR 281 V 571 7 0.85V 571 0.85WB 909 15 0.85B 768 2 0.75RB 1 t℃
P2
1 2
S15 B1
3
0.85B 712 0.85WR 282 1 0.85BL 983 GND 4 0.85BW 709 Br 834 8 0.85Br 834 0.85VG 911 16 0.85VG 911 0.75WB 400 1 0.75BY 2
12V
(CN.D45)
ECO-J
AMP
M8 YAZAKI
(CN.C25)
L HORN
E68
YAZAKI
1 2 3
POWER 24V 1 1.25W 109 YAZAKI YAZAKI 2 0.85LB 985 SHUT OFF 7 LG 842 9 0.85LG 842 0.85LW 841 6 L 17 0.75Y 410 2 0.75R 3
1
2
(CN.B22) CONDENSER
CN-A
1.25W 109a (CN.C16) (CN.C15) 0.85Y 980 0.85Y 980 0.85B 725 L
S69 0.85RY 280 0.75BW 420
9 10 11 12 13 14 15 16 17 18
5 6 7 8
12 10 7 18 3
YAZAKI(CN.B14)
POWER 24V 0.85L 981 0.85L 981 0.85YL 591 Y 0.85WR 281
11 11 4
X36
(CN.D89)
AMP
RADIO YAZAKI(CN.B15) 0.85B 767 1.25 B
CIGAR LIGHTER 2
M
4 5 6 7 8
1
0.85BY 982 0.85BY 982 0.85BG 627 Y 0.85BW 709
(CN.B5)
62C
YAZAKI
22 12 5 MUTE OVER HEAT SW.
1 2
YAZAKI(CN.B16) PRESS. SENSOR 0.85GR 897 1.25 BL
S33
24V,5A 1
B44
4 5 6 7
2 3
(CN.A56)
X35
GND_2 2 1.25BG 602 0.85BL 983 13 0.85BL 983 0.85GL 852 3 G M4
YAZAKI
24V
(CN.A28)
E51 LIMIT SW 12V OUTPUT (P2) ISUZU(CN.A24)

YAZAKI
1.25BG 602a 0.85B 713 0.85YR 220 0.85RY 280 0.85RY 280 0.85B 726 G 2ND.ACT
2 3
SDL
13 14 8
（WINDOW） (FOR RADIO) CAM ANG(MRE)
1 2 3 4
PA
P-G S/V(R)
1
GND_3 5 0.85B 702 YAZAKI YAZAKI YAZAKI(CN.A30F) 0.85WR 281 15 0.85WR 281 0.85OL 853 1 O 0.75WB 401 1
X6
(CN.D46)
ECO-J
AMP
SENSOR
(CN.C14) (CN.C13)
S34 DUAL SWITCH
S52
1 2 3
16 0.85B 702a O 590 6 O 590 0.85BW 709 16 0.85BW 709 0.85B 727 2 O 0.75L 411 2
S54 (RECIVER DRYER)
(CN.B17)
SWP
YAZAKI
N-G GND 9 BG 614 3 BG 614 17 2ND.ACT 0.75BW 421 3 GW 953 1 Vcc
HORN VOL.SW
(CN.E12)
SUMITOMO
1 2
9 10 11 12 13 14 15 16 17 18
1 2 3 4
B87
(CN.D77)
090
SUMITOMO
S/V(L)
1 2 3
20 YAZAKI(CN.A31F) 2 18 AIR SUSPENSION 0.85GW 943 2 3 OUT(PULSE)
9 10
L-G
1 2
GND_A 10 6 3 5 1.25RW 944 1 2 GND
PRESS. SENSOR
B43
(CN.A49)
SDL
YAZAKI
5 2 WINDOW OPEN:CLOSE 1.25GR 875 0.85YR 221 1.25R 0.85W 400 0.75WB 400 0.75R 316 Y
21
WINDOW CLOSE:OPEN
1 1
M 1
(N1)
17
(CN.D78)
SWP
YAZAKI
A-G 4 1 1.25B 714 0.85B 720 1.25B 0.85BW 420 0.75BW 420 0.75L 317 T
NPN_OUT1 6 4 2 2 MAGNET CLUTCH 18
7 8
0.85Y 410 0.75Y 410 0.85W 402 0.75G 318 OB
1
NPN_OUT2 4 3 1 (COMPRESSOR) 19
5 6 7 8
(CN.D47)
ECO-J
AMP
E3
10
SUCTION CONT.VALVE
1
2
3
4
5
6
7
8
9
CARLING
Y8
(CN.B18)
MT090
SUMITOMO
1 2 3
NPN_OUT3 SOL POWER SAVE 7 G 812 YAZAKI(CN.A26F) 0.85YR 222 1 0.85L 411 4 0.75L 411 0.85Lg 412 2 0.75BL 692b 15 0.75BL
VC2 24V
1 2
(CN.E13)
MT090
SUMITOMO
NPN_OUT4 SOL FAN REVERSE 3 Lg 813 0.85R 1.25GR 875 0.85B 721 2 0.85Lg 412 5 0.85Lg 412 0.85BW 422 3 1.25RW 944 1 1.25G 0.75RG 394 20 0.75RB 2
(CN.C12)
24V Y35
1 2 3
4 5 6
(CN.C11)
YAZAKI
S70
1 2
NPN_OUT5 8 0.85LR 881 0.85W 1.25B 714 0.85G 413 6 0.75G 413 0.75RW 396 16 0.75RW 1
LAMP 70W
CN-A
I/O
NPN_OUT6 14 0.85YR 882 VR 230 1 VR 230 0.85GR 414 7 0.85GR 414 11

(CAB) YAZAKI(CN.A27F) PRESS. SENSOR
NPN_OUT7 15 1.25WR 235 2 1.25WR 235 0.85V 415 8 0.85V 415
(N2) B40 1.25R 374 5 1.25BW 5
NPN_OUT8
NPN_OUT9 BUCKET CLOSE(PWM)
18
17 0.85YL 818
0.85LR 240
1.25WR 148
3
4
0.85LR 240
0.85WR 148
S9 ENG STOP S85 BEACON<EU> 0.85YG 416
0.85Gr 419
9
10
0.85YG 416
0.85Gr 419 0.75WB 403 1
PUMP
1.25G 375
1.25Br 382
1
7
1.25L
1.25R
1
INJ1 (#1)
MEMORY CLEAR
E3
(CN.D48)
ECO-J
AMP
X23 PUMP
(CN.D39)
SWP
YAZAKI
(CN.E14)
MT090
SUMITOMO
1 2 3
YAZAKI(CN.A28F) BG 635 0.85LG 302 0.85LG 302 0.85WL 430 0.85WL 430 0.75G 413 0.75Y 900 1.25G 383 1.25G
Y7
NPN_OUT10 19 5 11 2 1 3 3 1
Y63
YAZAKI(CN.A37M)
1 2
1 2
0.85R 1.25GR 876 BrY 084 LB 539 6 0.85LB 539 0.85BL 450 12 0.85BL 450 0.75BW 423 3 0.75BY 901 2 1.25R 378 6 1.25R 2
IMMOBILIZER 24V POWER
040/070HYBRID I/O
YAZAKI(CN.A37F)
PWM_OUT1 ARM CLOSE(OUT) 3 0.85G 906

VG 531
BG 637
YAZAKI(CN.A33F) X9 LAMP 70W
0.85W 1.25B 715 0.85Y 408
0.85LY 418
7
8
0.85Y 408
0.85LY 418
9
6
10
3
9
6
10
3
0.85GW 444
0.85VG 445
13
14
0.85GW 444
0.85VG 445
1.25Br 379 2
12
1.25WB 6
2
(CAB) DIAG SW PRESS. SENSOR
10
10
YAZAKI(CN.A33M) YAZAKI(CN.A29F) INJ5 (#2)
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
PWM_RTN1 ARM CLOSE(RTN) 6 0.85GB 907 M8 M8
X24 YAZAKI(CN.A36M)
BG 634 0.85BO 428 9 0.85BO 428 5
4
2
1
5
4
2
1
0.85LR 446 15 0.85LR 446
(PILOT SWING) B22 P1
1.25R 384 14 1.25LR
(CN.D40)
ECO-J
AMP
(CN.E15)
MT090
SUMITOMO
AMP
PWM_OUT2 FAN SPEED(OUT) 1 0.85W 908 PB 083 P 040g 10 P 040g 0.85YB 490 16 0.75Y 490 0.75L 904 1 1.25RW 385 10 1.25P 1
TO CONTROLLER C YAZAKI(CN.A36F) 7 8 7 8
Y11 Y69
1 2
1 2
0.85WR 148
0.85WB 909 YAZAKI YAZAKI PG 041g PG 041g 0.85GL 492 0.85GL 492 0.85W 404 0.75BL 905 1.25R 376 1.25B
0.85BG 620
0.85LG 302
PWM_RTN2 FAN SPEED(RTN)
0.85LB 539
0.85B 722
4 11 17 1 2 8 2
0.85LG 842
FLOW
(CN.D49)
ECO-J
AMP
(CN.C17) (CN.C32) CARLING CARLING
(CN.E20)
YAZAKI
22 21 20 19 18 17 16 15 14 13 12
1 2 3
11 10 9 8 7 6 5 4 3 2 1
PWM_OUT3 OPT PRESS(OUT) 2 0.85V 910 1.25W 110 1 WB 949 12 WB 949 VC2 VC2 0.85BG 660 18 0.85BG 660 0.85GR 414 2 1.25RW 377 4 1.25WL
X25 A BG 631 1 BG 631
2 3
1 5 6
PWM_RTN3 OPT PRESS(RTN) 5 0.85VG 911 WL 266 2 BW 950 13 BW 950 (CN.B7) (CN.B10) GrR 532 19 0.85GrR 532 0.85BW 424 3 1.25R 380 13 1.25LR
SHLD GND 8 0.85G 505 3 B RL 166 2 RL 166 0.85GW 943 14 0.85GW 943 LW 533 20 0.85LW 533 1.25RW 381 9 1.25BR INJ3 (#3)
C P 040 3 P 040h
(CN.E16)
MT090
SUMITOMO
7 0.85RY 521 4 YL 538 21 0.85YL 538 1
EST CONNECTOR A
(CN.A8)
PRESS. SENSOR PROPORTIONAL S/V

D PG 041 4 PG 041h
B26 Y65
7 8 9 10 11 12 13 14
1 2 3
S-G
1 2
BOOT_CNT 11 YR 067 YB 570 5 LB 559 22 2
X5 (PILOT UPPER)
3 2 1
14 13 12 11 10 9 8 7
PL 081 PL 081
F A B
BOOM
(CN.52)
HD10
DEUTSCH
E 5
(CN.D41)
SWP
YAZAKI
(CN.D10)
D
SUMITOMO
YR 068 V 571 0.85O 902
Y59
G
20 19 18 17
16 15 14 13
12 11 10 9
(CN.A48)
SDL
YAZAKI
E
FWE 12 6 1
8 7 6 5
4 3 2 1
F 6 SOL3
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
1 2
H
SW_IN12 9 P 040e 7 0.85W 405 1 0.85BO 903 2 UP
(CN.D50)
ECO-J
AMP
C
(CN.A23)
G
YAZAKI
1 2 3
SW_IN13 10 PG 041e 8 OVER LOAD WARNING<EU> FREE SWING<NA> 0.85V 415 2
CAN
S13 S22
(NO TAPE)
INJ2 (#5)
4 5 6
SDL
H
YR 541 9
X31 P 040j 0.85BW 425 3
6 5 4
YAZAKI(CN.A34F) LED
(CN.A26)
SDL
YAZAKI
6 5 4 3 2 1
12 11 10 9 8 7
J ARM
3 4 5 6
1
(CN.D42)
SWP
YAZAKI
(CN.E17)
MT090
SUMITOMO
O 542 10 PG 041j 0.85G 906 1 8 1
Y60 Y64
(CN.A54)
YAZAKI(CN.A35F) SOL2
YAZAKI
1 2
1 2
TXD 4 PL 056 LG 833 11 0.85GB 907 2 4 2
(CN.A7)
PRESS. SENSOR CLOSE
SDL
RXD PW 055
B27
1 2 3 4 5
2
12 12 9 10 9 10 (RED TAPE)
(PILOT TRAVEL)
EST CONNECTOR B
7 8 9 10 11 12
6 5 4 3 2 1
RS232C_TXD 3 Y 065a 1.25B 703 13 6 3 6 3 10

OPT POWER A/C PANEL
10
10
INJ6 (#4)
DEUTSCH
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
X3
5 2 5 2 BUCKET
(CN.D43)
SWP
YAZAKI
X26
(CN.A25)
RS232C_RXD 10 YL 066a 1.25BG 603 14 1.25B 749 1 0.85W 406 1 0.75RW 185 1
& A/C UNIT
Y61
(CN.D51)
ECO-J
AMP
YAZAKI(CN.A32M) 4 1 4 1 SOL1
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
1 2
(CN.E18)
MT090
SUMITOMO
1 2 3
RS232C_GND 2 BY 069 1.25W 205 2 7 8 7 8 0.85YG 416 2 0.85YL 818 2 CLOSE 13 1
(See page 2/2)
S28 Y70
DT
YAZAKI(CN.A32F)
X4 TRAVEL ALARM<NA>
1 2
0.85WG 537
0.85GW 536
GND P 040i 0.85BW 426
0.85BG 623
0.85BG 622
5 3 3 9 2
0.85YR 223
(BLUE TAPE)
0.85Br 834
CARLING CARLING
(CN.A6)
GND 13 WB 245 1 4 BG 633 WL 260 1

TO GPS UNIT VC2 VC2
CAN_H 6 P 040d W 060a 7 Y 065b 2 5 BG 632 (CN.B11) (CN.B9) LY 806 2
X27 INJ4 (#6)
0.85BW 429
0.85Gr 419
PG 041d WL 061a YL 066b 1.25RB 150 V 050 YR 805
0.85W 409
CAN_L 14 12 3 1 6 3
PROPORTIONAL S/V
X32 Y62
16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
(CN.E19)
MT090
SUMITOMO
+5V_OUT WR 062 BG 636 4 0.85G 506 PL 080 RL 167 VY 534
(CN.E21)
YAZAKI
11 4 2 7 13 4 1
(See page 2/2)

OPTION LINE
Y66
CONNECTOR
DIAGNOSTIC
OPT
1 2
BL 064a 0.85Br 517 0.85G 507 GY 535 0.85VR 910 0.85VR 910
10 8 13
FREQUENCY_IN
(CN.A27)
DIAG
AMP
1 11 3 8 5 5 1 1 2
9 4
26 25 24 23 22 21 20 19 18 17 16 15 14
13 12 11 10 9 8 7 6 5 4 3 2 1
3 2 1
(CN.D36)
PACKARD
4 3 2 1
8 7 6 5 4
3
(CN.A24)
SDL
YAZAKI
FREQUENCY_GND 9 Y 065a 1 W 060b 4 9 2 P 040k G 850 6 YAZAKI 0.85VG 911 2 0.85VG 911 2
B45
PRESS
(CN.A29)
PRESS. SENSOR
YAZAKI
1 2
TO DRM
2
3
1
YL 066a WL 061b PG 041k O 851 SDL
3
X34
AVcc 7 3 5 10 8 7
X33
SDL
(CN.D52) (HBCV)
(CN.D44-1)
ECO-J
AMP
YR 067
2 1
P 040f PG 041i 0.85Y 085 GL 852
(CN.D44)
SWP
YAZAKI
SW_1 15 6 6 11 3 (FOR CRANE) 10 9 10 9 8
YAZAKI(CN.B24)
7 8 9 10 11 12 13
1 2 3
BY 069 BL 064b PG 041f PB 082 0.85BG 629 3 6 3 6 OL 853 1.25W 405 FUEL FILTER
1 2
1 2
SW_2 16 8 7 12 1 (NOT USED) 9 1
(CN.A5)
(CN.B23)
PA
YAZAKI
YAZAKI(CN.B25)
(CN.G6)
ECO-J
AMP
2 5 (FOR FAN REVERSE) 2 5 SENSOR
1 2 3
1.25B 740 BG 640 1.25Gr 425
60B 798
SW_3 8 9 8 13 4 10 2
1 4 1 4
5 14 VG 051 6 8 7 8 7 1.25BW 445 3
LEVEL SWITCH S55 0.75WB 334
10
10
4 5 6
2
4
5
6
1
2
3
7
8
9
1
2
3
4
5
6
7
8
9
5 6 7 8 9 10
3 4
10 15 9 M10
M8 (RESERVE TANK)
B88
CARLING CARLING 0.75GW 335 3
SN_IN1 2 BG 630 2 16 10
(CN.A57)
VC2 VC2 0.75BW 336
YAZAKI
1
(CN.D79)
SWP
YAZAKI
SN_IN2 (CN.B12) (CN.B8) 0.85GrR 532
0.85BG 624
0.85BG 621
15 11 2
0.85V 571
0.85YB 570
0.85YL 558
YAZAKI(CN.A43)
SDL
1 2
1 2
POT_IN1 21 12 0.85BG 651 1
POT_IN2 9 7 0.85BG 628
PRESS. SENSOR
(PILOT ARM CLOSE)
B83 EXSHAUST PRESS
POT_IN3 22 1.25WR 142 1 1.25WR 142 SENSOR
040a,041a
POT_IN4 10 0.85YR 370 2 0.85YR 370 0.85WL 430 1

CX350C Excavator PDF

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

CX350C Excavator PDF

Hochgeladen von

Copyright:

Verfügbare Formate

CX350C

Printed in U.S.A. Part number 84402832

Safety, general information and standard torque data

84402832 NA - May 2011

84402832 NA - May 2011 Copyright © 2011 CNH FRANCE S.A.

84402832 NA - May 2011

This symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED.

84402832 NA - May 2011

84402832 NA - May 2011

ROPS Judgment Method

Machine body total

Machine body total

84402832 NA - May 2011

84402832 NA - May 2011

84402832 NA - May 2011

84402832 NA - May 2011

Standard Torque Data For Cap Screws And Nuts

84402832 NA - May 2011

84402832 NA - May 2011

84402832 NA - May 2011 Copyright © 2011 CNH FRANCE S.A.

Standard weight 18.0 kN

Main Unit Dimensions

Total stroke volume 7.790 L

Upper Side Work System

For operating machine use Lever type (hydraulic pilot type) x 2

Travel Lower Body

Hydraulic pump drive type Direct engine link (no transmission)

Control Valve and Cylinder

Hydraulic Oil Filters

Suction filter (inside tank) 105 μm

84402832 NA - May 2011

Main Equipment Table

84402832 NA - May 2011

Main Equipment Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84402832 NA - May 2011 Copyright © 2011 CNH FRANCE S.A.

Main Equipment Table

84402832 NA - May 2011

84402832 NA - May 2011

84402832 NA - May 2011

Air Cleaner (double element)

84402832 NA - May 2011

84402832 NA - May 2011

Solenoid Valve (4 stack)

84402832 NA - May 2011

Remote Control Valve (left/right, travel operations)

Remote Control Valve for Travel Operations

Remote Control Valve Characteristic Diagram

Secondary pressure [MPa]

Push rod stroke [mm]

Operating angle [deg.]

84402832 NA - May 2011

Secondary pressure [MPa]

Push rod stroke [mm]

Operating angle [deg.]

Travel Remote Control Valve Control Diagram

Secondary pressure [MPa]

Push rod stroke [mm]

Pedal operating angle [deg.]

Cushion Valve (heat circuit, with shuttle valve)

84402832 NA - May 2011

84402832 NA - May 2011

Main Unit Weight

84402832 NA - May 2011