Sk75sr-3e S5yt0023e02 Shop Manual - Part2

㨇24.
COMPONENTS SYSTEM㨉
(3) Outline of travel unit

Travel unit is composed of 3 main parts and each part has the following function respectively.
1. Hydraulic motor
1-1. Rotating function
1-2. Speed change function
1-3. Parking brake function
2. Brake valve
2-1. Counter balance valve function
2-2. Cross relief valve function
2-3. Automatic speed change function
3. Reduction gear
3-1. Reduction function
3-2. Final power output function

24-67
㨇24. COMPONENTS SYSTEM㨉
1. Hydraulic motor part
Hydraulic motor has the following 3 functions.
1-1. Rotating function

This motor generates the rotary action and the rotary torque by high pressured oil.
And this rotary action and torque are transmitted to reduction gear part.
1-2. 2 Speed change function

The speed of this motor is switched from low speed to high speed and from high speed to low
speed by changing displacement per 1 rotation of the motor.
1-3. Parking brake function

When high pressured oil does not enter into the motor, and the motor does not rotate, the parking
brake is actuated automatically.
When high pressured oil enters into the motor, and the motor rotates, the parking brake is released
automatically.
24-68
1-1. Rotation function

When high pressured oil is supplied to left port
of motor, oil passes through valve plate and
flows into cylinder barrel. The high pressured oil
pushes piston leftward. The piston shifted to the
left position and rotates cylinder barrel while
sliding on the cam surface.
The shaft is connected to barrel and sun gear
(A) is connected to the shaft. Consequently
the rotation is transmitted through the rotation of
sun gear (A) as shown in the figure.
When the high pressured oil is supplied to the

opposite port of motor, the rotating direction
reverses and the sun gear (A) rotates in the
opposite direction.
The rotation of sun gear (A) is transmitted to

the reduction gear.
The torque and rotation speed generated by

hydraulic motor depend on motor displacement
(motor displacement for one rotation).
And the motor displacement for one rotation
corresponds to cam angle ø.
1-2. Speed change (Transmission) function

The torque and rotation speed generated by
hydraulic motor depend on motor displacement
(motor displacement for one rotation).
And the motor displacement for one rotation
corresponds to cam angle ø.
The larger the cam angle ø is, the larger the

torque becomes.
The smaller the cam angle ø is, the smaller the

torque becomes.
The travel unit is equipped with 2-speed change

piston, and when high pressure is supplied to
this piston, the 2-speed change piston pushes
cam and makes the cam angle smaller. That is,
the motor is changed from low speed mode to
high speed mode by the action that the
2-speed change piston pushes cam.
24-69
1-3. Function of parking brake

The travel unit is equipped with parking brake.
When high pressured oil is not supplied to
motor and the motor is not rotated, the parking
brake actuates automatically. And when high
pressured oil is supplied to motor and the
motor is rotated, the parking brake is
automatically released.
The parking brake is released immediately

after high pressured oil is supplied to motor and
the motor is starts rotating. When high
pressured oil is stopped supplying to the
parking brake, the hydraulic oil motor stops
rotating and the brake piston is gradually
pushed leftward by spring force and
consequently the parking brake gradually
actuates, too.
The parking brake is gradually operated to

prevent damaging friction plate and separator
plate.
24-70
2. Brake valve part
The brake valve has the following 3 functions.

2-1. Functions of counterbalance valve
Function to prevent the shock due to travel stop, and the unintended overrun and cavitation on
downhill
Function to supply high pressured oil to parking brake release section immediately before the travel
unit starts rotating
2-2. Functions of shockless crossover relief valve

Function to reduce the shock during travel reduction or in stop operation
Function to prevent motor from overloading
Function to compensate the shortage of oil supply during speed reduction or in stop operation
Relief valve is of "Shockless type" which is available for shock reduction.
2-3. Auto 2-speed change function

The speed of motor is switched in the following 2 modes.
1) Constant low speed mode - Usually at low speed
2) Auto 2-speed change mode
a. In light travel load, high speed mode
b. In heavy travel load, low speed mode
24-71
2-1. Function of counterbalance valve

Traveling on flat ground
When high pressured oil is not supplied to
brake valve, counterbalance spool is set to the
center position by 2 springs installed on both
sides. In this condition, the oil passage from
motor is blocked.
After high pressured oil is led to port on the

right side of brake valve, counterbalance spool
is shifted to the left position by the pressure
at the right end. In this condition, the oil
passage from motor closes at the left of
counterbalance spool and accordingly oil flows
and the motor starts rotating. When the supply
oil rate to right port is reduced by the speed
reduction of the machine and the stop
operation, the pressure lowers at the right end
of counterbalance spool. As a result, the
counterbalance spool is moved rightward by
the force of spring on the spool left side.
Then, the opening of counterbalance spool
becomes narrow and finally when high
pressure supply to brake valve stops, the
opening completely closes. This action of
"completely closing" raises the pressure (back
pressure) in the motor outlet side.
Traveling on downhill
When counterbalance is not provided,

When the machine travels on downhill, the
speed is up unintentionally due to the specific
gravity. It is impossible to avoid this
"overrunning" by controlling the supply oil
quantity to motor. And then the high pressure
pump can not maintain the oil supply rate
resulting in cavitation inside of motor.
Function of counterbalance valve and mechanism

In traveling on downhill, the pressure to right port lowers due to the shortage of supply oil quantity to
motor. Accordingly the pressure on the right side of counterbalance valve also drops and the
counterbalance spool moves from the left side to the right. Then the opening of counterbalance spool
becomes narrow resulting in the pressure rise on the motor outlet. This back pressure prevents
overrunning and cavitation of motor.
Hydraulic pressure supply for parking brake release

To start rotating travel unit, when the oil delivered by pump is supplied to right port of brake valve,
counterbalance valve spool moves leftward and opens the oil passage for parking brake release.
The oil passage for parking brake release is closed with the travel unit stopped.
For details of parking brake functions, see Item "1-3. Function of parking brake".
24-72
2-2. Functions of crossover relief valve

The travel unit is equipped with 2 shockless
crossover relief valves. The purpose is as
shown below.
Relief valve is useful to ease the shock in
slow-down and stop operation.
Function to prevent overloading to motor
Function to make up the shortage of oil
supply during speed reduction or in stop
operation
Relief valve is of "Shockless type" which is
available for shock reduction.
When crossover relief valve is not provided,
(Two cases are taken as example.)
1)
In slow-down or stop operation, the pressure in
motor (back pressure) is raised with the function
of counterbalance valve. (See Item 2-1.) When
the machine is abruptly stopped, if crossover
relief valve is not provided, this back pressure
is abruptly produced and then operator feels
as a certain shock.
In the worst case, it might damage the machine.
2)
In travel start operation of the machine, high
pressured oil is supplied to motor. When being
abruptly started traveling, if crossover relief
valve is not provided, the pressure in motor is
abruptly raised causing shock.
The travel unit is equipped with crossover
relief valves to ease the harmful pressure
shock, to improve bad feeling of operator and
to protect machine from possible damage.
Function of shockless crossover relief valve and mechanism

See the figure in Item "2-1. Function of counterbalance valve" and Figure on the upper side in this
page.
The explanation for relief valve (right) is given here.
The relief valve is set to the above condition (1) first.
Case of Fig. (2).
The abrupt pressure rise on the motor outlet side in slow-down and stop operation pushes down
shockless piston in relief valve with the shock due to high pressured oil, and simultaneously poppet
moves and escapes high pressure.
In moving shockless piston downward, the pressure on the poppet back face is not very high
because oil flow used to move shockless piston exists, and as a result the relief pressure is lowered.
Case of Fig. (3).
And then, when shockless piston was pushed down to the stroke end completely, the relief pressure is
raised fully to the set pressure. Because oil flow used to move shockless piston is no longer exist and
the back pressure of poppet is high. After stopping motor, when the motor is rotated again the
shockless piston is reset and the shockless piston is pushed up by high pressure at motor inlet.
24-73
Oil filling
In relief operation, the relief valve has function to deliver the relieved oil from the motor outlet to inlet.
This function prevents the inside of motor from being in excessively negative pressure.
2-3. Auto 2-speed change function

The speed of motor is switched in the
following 2 modes.
1) Constant low speed mode - Usually at low
speed
2) Auto 2-speed change mode
a. In light travel load, high speed mode
b. In heavy travel load, low speed mode
The above functions are performed by the
following two parts.
Spool (For mode change and auto speed
change)
Auto speed change mode (When pressure PP
is supplied)
In case of negative pressure < In specified
pressure, high speed mode
In case of negative pressure > In specified
pressure, low speed mode
Constant low speed mode (When pressure PP
is not supplied)
High pressure select valve
The higher pressure at port is selected always,
and the high pressure is supplied to 2-speed
change spool regardless of motor rotation
direction.
Function
See Item 1).
When pilot pressure PP is not pressurized, the
spool is rested on the upper side by spring
force, and the mode is switched in constant low
speed mode.
See Item 2).
When being in low load pressure, the pilot
pressure exerts on the spool upper side, and
consequently the spool moves downward and
the mode is switched in high speed mode.
When load pressure rises, the load pressure
exerts on the spool differential area and
gradually pushes back the spool upward and
the mode is switched form high speed to low
speed at the specified load pressure.For
variation of cam angle, see Item "1. Hydraulic
motor part 1-2. Speed change (Transmission)
function".
24-74
3. Reduction gear
The reduction unit has the following two functions.
3-1. Slow-down function

The reduction unit is transmitted the rotation from hydraulic motor and changes the rotation as shown
below.
Rotation speed is reduced
Torque is increased
3-2. Final power output function

The final rotation power output (torque) is transmitted to the machine sprocket.

24-75
Planetary reduction gear

The rotation of hydraulic motor shaft is
transmitted to reduction unit.
The function is as follows.
The construction of general planetary reduction
gear is shown in right figure.
The reduction unit is mainly equipped with the
following 4 parts.
Name / Gear tooth number

Sun gear: Zs
Planetary gea: Zp
Carrier: --
Ring gear: Zr
(1) Planetary type

First, since the ring gear is fixed, the case where the rotation is transmitted by sun gear is
explained here. This is called "planetary type". When sun gear rotates in clockwise, planetary
gear rotates around the sun gear. The carrier is correspondingly rotated by the revolution.
And the rotation in counterclockwise is transmitted from carrier by rotating sun gear in clockwise.
The rotation speed of carrier (output) differs from rotation speed of sun gear (input) and the ratio
(input)/(output) is called "reduction gear ratio (i)", and the equation is as follows.
Reduction gear ratio (i) = (Input) / (Output) = Zr / Zs + 1
(2) Star type
And the case where carrier is fixed, the case where the rotation is transmitted by ring gear is
explained here. This is called "star type". When sun gear rotates in clockwise, planetary gear
rotates at the position and then ring gear rotates in counterclockwise.
And the rotation in counterclockwise is delivered from ring gear by rotating sun gear in clockwise.
The rotation speed of ring gear (output) differs from rotation speed of sun gear (input) and the
reduction gear ratio is as follows.
Reduction gear ratio (i) = (Input) / (Output) = Zr / Z
(3) In case of travel unit,
Travel unit is equipped with two-stage planetary reduction gear mechanism and both the planetary
type and the star type exist together. The input is transmitted to sun gear on the 1st stage and
the output is transmitted from ring gear. The ring gear is shared by 1st stage and 2nd stage.
Reduction gear ratio (i) = (Input)/(Output)
= (Zr / Zs1 + 1) X (Zr / Zs2 + 1) - 1
Where,
Zs1 : Tooth number of sun gear on 1st stage
Zs2 : Tooth number of sun gear on 2nd stage
Zr : Tooth number of ring gear
Final output
The ring gear is equipped with flange used to install sprocket for travel. The final rotation and torque
are taken out of the flange of ring gear.
24-76
24.1.7 SWIVEL JOINT

24.1.7.1 GENERAL VIEW
General view of swivel joint
24.1.7.2 SPECIFICATIONS
ITEM SPECIFICATION
PARTS No. YT55V00012F1
Working pressure
29.4 MPa (4263 psi)
High pressure port Max. impact pressure (pressure
44.1 MPa (6395 psi)
A, B, C, D proof)
66 L/min (17.4 gal/min)
Rated flow
Low pressure port Working pressure 0.5 MPa (73 psi)
E Rated flow 20 L/min (5.3 gal/min)
Working pressure
29.4 MPa (4263 psi)
High pressure port Max. impact pressure (pressure
44.1 MPa (6395 psi)
F, G proof)
49 L/min (12.9 gal/min)
Rated flow
Low pressure port Working pressure 3.5 MPa (508 psi)
H Rated flow 20 L/min (5.3 gal/min)
Revolution 15 min-1
A, B, C, D PF1/2
F, G PF3/8
Port size
E (stem) PF3/8
H PF1/4
Total length : L 403 mm (15.63")
Weight 34 kg (62 lbs)
24-77
24.1.7.3 CONSTRUCTION
Construction
No. NAME Q'TY No. NAME Q'TY

1 BODY 1 9 SOCKET BOLT (M8X20) 2
2 STEM 1 10 SOCKET BOLT (M8X30) 3
3 THRUST PLATE 1 11 PLUG : PT1/8 2
4 COVER 1 12 PLUG : PF1/4 2
5 SEAL 5 13 PLUG : PT3/8 4
6 SEAL 1 16 O-RING 2
7 O-RING (G95 1A) 1 17 O-RING 4
8 O-RING 2
24.1.7.4 OPERATION
The swivel joint consists mainly of mutually rotating body (1) and stem (2), thrust plate (3) that
prevents them from coming off, cover (4) that plugs up one part of body (1), seals (5), (6) that
partitioning circuits, and O rings (7), (8) that prevents oil from leaking out.
Four ports for the travel main circuits are provided on body (1) and stem (2). Further, four oil passing
grooves are arranged in the inner surface of body (1), with seal (5) fixed above and below the
circumferential groove.
The body (1) and the stem (2) rotate mutually. The oil flowing in from body (1) or stem (2) keeps on
flowing to stem (2) or body (1) past the circumferential groove between body (1) and stem (2) ; the oil
flow is never shut off because of rotation. Further, an oil groove for lubrication that connects with the
drain port is provided, in order to prevent the body (1) from binding with the stem (2). Such
construction of the swivel joint makes it possible to connect circuits between the swing body and the
lower travel body at all times.
24-78
24.1.8 CYLINDER
24.1.8.1 SPECIFICATIONS
(1) General View
General view of cylinder
(2) Specifications
Unit: mm(ft-in)
Center
Cushion
Part No. of Cylinder bore / distance of pins Dry weight
Use Stroke Extend side /
cylinder assy Rod Dia. Full extend B / kg (lbs)
Retract side
Full retract A
110 / 70 916 2,291 / 1,375 Including / 93
Boom YT01V00043F1
(4.33"/2.76") (30.1") (7'6" / 4'6") Without (205)
95 / 65 839 2,155 / 1,316 Including / 70
Arm YT01V00044F1
(3.74"/2.56) (33") (7'08" / 4'4") Including (154)
80 / 55 762 1,901 / 1,139 47
Bucket YT01V00045F1 Without
(3.15"/2.16") (30") (6'3" / 3'9") (104)
135 / 80 129 777 / 648 60
Dozer YT01V00046F1 Without
(5.32"/3.15") (5.08") (30.6" / 25.5") (132)

24-79
24.1.8.2 CONSTRUCTION AND FUNCTION

24.1.8.2.1 Construction
(1) Boom cylinder
Construction of boom cylinder
No. NAME Q'TY No. NAME Q'TY No. NAME Q'TY

1 CYLINDER TUBE ASSY 1 11 O-RING 1 21 SET SCREW 1
2 PISTON ROD ASSY 1 12 HOLDER 1 22 STEEL BALL 1
3 ROD COVER 1 13 CUSHION SEAL 2 23 PIN BUSHING 2
4 BUSHING 1 14 COLLAR 1 24 WIPER RING 2
5 SNAP RING 1 15 BACKUP RING 1 25 PIN BUSHING 2
6 BUFFER RING 1 16 CUSHION BEARING 1 26 WIPER RING 2
7 U-RING 1 17 PISTON 1
8 WIPER RING 1 18 SEAL RING ASSY 1
9 O-RING 2 19 SLIDE RING 2
10 BACKUP RING 1 20 NUT 1
24-80
(2) Arm cylinder
Construction of arm cylinder

1 CYLINDER TUBE ASSY 1 11 O-RING 1 21 CUSHION BEARING 1
2 PISTON ROD ASSY 1 12 HOLDER 1 22 CUSHION SEAL 1
3 ROD COVER 1 13 BACKUP RING 1 23 STOPPER 2
4 BUSHING 1 14 CUSHION BEARING 1 24 SNAP RING 1
5 SNAP RING 1 15 CUSHION SEAL 1 25 PIN BUSHING 4
6 BUFFER RING 1 16 PISTON 1 26 WIPER RING 4
7 U-RING 1 17 SEAL RING ASSY 1
8 WIPER RING 1 18 SLIDE RING 2
9 O-RING 2 19 SET SCREW 1
10 BACKUP RING 1 20 STEEL BALL 1

24-81
(3) Bucket cylinder
Construction of bucket cylinder

1 CYLINDER TUBE ASSY 1 8 WIPER RING 1 15 SET SCREW 1
2 PISTON ROD ASSY 1 9 O-RING 1 16 STEEL BALL 1
3 ROD COVER 1 10 BACKUP RING 1 17 WIPER RING 4
4 BUSHING 1 11 O-RING 1 18 FITTING 1
5 SNAP RING 1 12 PISTON 1 19 FITTING 1
6 BUFFER RING 1 13 SEAL RING ASSY 1
7 U-RING 1 14 SLIDE RING 2
24-82
(4) Dozer cylinder
Construction of dozer cylinder

1 CYLINDER TUBE ASSY 1 8 WIPER RING 1 15 BACKUP RING 1
2 PISTON ROD ASSY 1 9 BACKUP RING 1 16 O-RING 1
3 PISTON 1 10 U-RING 1 17 WIPER RING 4
4 ROD COVER 1 11 BUFFER RING 1 18 PIN BUSHING 2
5 NUT 1 12 BUSHING 1 19 FITTING 2
6 SEAL RING ASSY 1 13 SNAP RING 1
7 SLIDE RING 2 14 O-RING 1

24-83
HYDRAULIC CYLINDER CONSTRUCTION (See construction of arm cylinder Fig.)

The hydraulic cylinder is composed of three sections, cylinder tube assy (1), piston rod assy to
transmit the motion of piston (16) stroke in the tube, a rod cover (3) which serves as the cover and
guide. Also, the cylinder tube assy and piston rod assy (2) have piston mounting section (clevis) which
are used to connect the other device. And, in addition to these principal parts, seal ring assy (17),
slide ring (18) and piston rod assy (2), buffer ring (6), U-RING (7), and wiper ring (8) between piston
rod assy (2) and rod cover (3), and O ring and backup ring between cylinder tube assy (1) and rod
cover (3).
24.1.8.2.2 OPERATION
By feeding pressure oil through oil inlet and outlet on cylinder alternately, the oil pressure exerts on
the piston, and piston rod assy (2) starts moving the telescopic motion (stroke).
(1) Operation of cylinder with cushion

The hydraulic cylinder contains a shock absorber to shock generated when the moving piston rod
assy (2) strikes rod cover (3) without speed reduction.
(Cushion on rod side)

When pressurizing the rod cover side, the oil
in (A) chamber returns to the tank in constant
speed through passage (B) in the midway of
stroke. (See the right Fig.) Cushion on the rod side
As the end of the stroke approaches, the

cylinder bearing enters into passage (B), and
the passage (B) is throttle reducing oil
quantity. As a result, the speed of piston rod
is also lowered. (See the right Fig.)
Cushion on the rod side
(Cushion on head side)

Like the cushion on the rod side, the piston
end of the piston rod enters into the cushion
bearing, and passage (B) is throttled. As a
result, as the return oil level for (A) chamber
Cushion on the head side
lowers, the speed of piston rod lowers,
obtaining the effect of cushion. (See the right
Fig.)
Cushion on the head side
24-84
24.1.9 PILOT VALVE (DOZER)

24.1.9.1 OUTLINE
(1) General view
(2) Specifications
Part No. YY30V00061F2
Model AFAB
Primary pressure 5 Mpa
Secondary pressure 0.54 to 2.35 MPa
Operating torque Refer to the curve be low
Weight Approx, 1.7kg (3.75 lbs)
(3) Performance characteristics

24-85
Tightening Tightening
torque No. NAME Q'TY torque No. NAME Q'TY
N-m(lbf-ft) N-m(lbf-ft)
1 SHIM : t=0.1 2 16 BODY 1
2 SHIM : t=0.2 2 18 PLUG 1
3 SEAT 1 39.2 (2.9) 19 SOCKET BOLT : M12X25 1
4 SLEEVE 2 4.9 (3.6) 20 BOLT : M4X8 2
5 COVER 1 14.7 (10.8) 21 SET SCREW : M8X8 2
6 PUSHER 2 22 WASHER 2
7 SPRING 2 23 WASHER 2
8 SPRING 2 24 RIVET 2
9 NAME PLATE 1 25 PARALLEL PIN 2
10 SHIM : t=0.2 2 26 BALL 1
11 SHIM : t=0.1 2 27 BALL 3
12 CAM 1 28 O-RING : 1A P10 2
13 BOOTS 1 29 O-RING : 1B P11 1
14 PIN 1 30 O-RING 2
15 SPOOL 2 32 PUSHER ASSEMBLY 2
24-86
24.2 ELECTRICAL EQUIPMENT
24.2.1 ELECTRICAL EQUIPMENT LIST
Group Code Part Name Part No.

C - 1 MECHATRO CONTROLLER YN22E00425F1
C - 2 GAUGE CLUSTER YT59S00008F1
(C) Controller
C - 4 AIR CONDITIONER CONTROLLER YY20M01228P1
C - 8 ENGINE CONTROLLER VI5JX1748380
D - 4 DIODE YN02D01001P1
D - 5 DIODE Fuse & relay box accessory
D - 6 DIODE
D - 9 DIODE
D - 10 DIODE
D - 12 DIODE
D - 13 DIODE
D - 14 DIODE
D - 15 DIODE
(D) DIODE
D - 16 DIODE
D - 17 DIODE
D - 18 DIODE YN02D01001P1
D - 20 DIODE
D - 21 DIODE
D - 22 DIODE
D - 23 DIODE
D - 32 DIODE
D - 44 DIODE
E - 1 FUSE & RELAY BOX YY24E00021F1
E - 2 ALTERNATOR Engine accessory
E - 3 HOUR METER LQ58S00002P1
E - 6 HORN LOW LC53S00001D2
E - 7 TUNER AM / FM YN54S00046P2
E - 8 SPEAKER LEFT LQ54S00003S002
(E) ELECTRIC E - 9 SPEAKER RIGHT

FITTINGS E - 10 RECEIVER DRYER LQ54S00005P1
E - 11 AIR COMPRESSOR YX91V00001F1
E - 12 BATTERY PW72S00004P1

E - 22 DC-DC CONVERTER YT77S00001P1
E - 23 12V SOCKET YN81S01002P1
E - 35 GLOW Engine accessory
E - 49 DC-DC CONVERTER (PROPORTIONAL) YN77S00069P1
24-87

L - 1 BOOM WORKING LIGHT LEFT YN80S00012F1
L - 2 DECK WORKING LIGHT RIGHT YT80S00002F2
L - 5 ROOM LIGHT YT80S00001P1
(L) LIGHT
L - 6 BOOM WORKING LIGHT RIGHT YN80S00012F1
L - 7 CAB WORKING LIGHT FRONT 1 YT80S00002F2
L - 8 CAB WORKING LIGHT FRONT 2 YT80S00002F2
M - 1 STARTER MOTOR Engine accessory
M - 3 WIPER MOTOR LQ53C00003S001
(M) MOTOR M - 4 WASHER MOTOR YT54C00003F1
M - 11 FUEL SUPPLY PUMP Engine accessory
M - 12 FUEL PUMP VI8980093971
R - 1 BATTERY RELAY YN24S00008F1
R - 2 STARTER RELAY VI8980056310
R - 3 GLOW RELAY VI8944607061
R - 5 HORN RELAY YN24S00010P1
R - 6 WORKING LIGHT RELAY
R - 8 (TRAVEL ALARM RELAY)
R - 12 (REVOLUTION RIGHT RELAY)
R - 13 (REVOLUTION LEFT RELAY)
R - 15 (NIBBLER OPEN RELAY)
R - 16 (NIBBLER CLOSE RELAY)
R - 23 (AUTO IDLE STOP RELAY 1)
R - 24 (AUTO IDLE STOP RELAY 2)
(R) RELAY
R - 25 ENGINE EMERGENCY STOP RELAY
R - 26 LEVER LOCK RELAY
R - 28 ALTERNATOR RELAY
R - 29 WIPER MOTOR RELAY YN24S00012P2
R - 30 WIPER MOTOR REVERSING RELAY
R - 31 PREVENT SPARK RELAY
R - 32 WINDOW WASHER MOTOR RELAY
R - 94 NEUTRAL STOP RELAY YN24S00010P1
R - 106 STARTER CUT RELAY Engine accessory
R - 107 MAIN RELAY VI8980137900
R - 109 RESTART PREVENTION RELAY YN24S00010P1
R - 110 AIR CONDITIONER BLOWER RELAY
SE - 3 PRESS. SENSOR : BOOM UP LC52S00019P1
SE - 7 PRESS. SENSOR : ARM IN
SE - 8 PRESS. SENSOR : ARM OUT
(SE) SENSOR
SE - 9 PRESS. SENSOR : TRAVEL RIGHT
SE - 10 PRESS. SENSOR : TRAVEL LEFT
SE - 13 ENGINE REVOLUTION SENSOR Engine accessory
24-88

SE - 15 FUEL SENSOR YN52S00045F1
SE - 16 ACCEL POTENTIO. LQ52S00025P1
SE - 21 HYD. FLUID TEMP. SENSOR YN52S00040P1
SE - 32 PRESS. SENSOR : DOZER LC52S00019P1
SE - 40 PRESS. SENSOR : SWING RIGHT
SE - 41 PRESS. SENSOR : SWING LEFT
(SE) SENSOR SE - 60 HYD. FLUID FILTER RESTRICTION SENSOR EE52S00017P1
SE - 74 FUEL DISCRIMINANT SENSOR -
SE - 80 PRESS. SENSOR : PUMP P3 LS52S00015P1
SE - 81 PRESS. SENSOR : AUTO ACCEL SENSOR LC52S00019P1
SE - 82 FUEL FILTER PRESSURE SENSOR Engine accessory
SE - 83 BARO SENSOR
SE - 84 INTAKE AIR TEMP. SENSOR
SV - 1 SWING PARKING BRAKE SOL. YN35V00051F1
(YY35V00019F1)
(SV) SOLENOID SV - 3 TWO-SPEED SELECT SOL. YN35V00050F1
SOLENOID VALVE ASSY
SV - 4 LEVER LOCK SOL.
PSV - P1 P1 PUMP PROPO. VALVE YT35V00032F1
TRAVEL STRAIGHT
PSV - C YN35V00048F2
(P) PROPO. VALVE
PROPORTIONAL P1 BY-PASS CUT PROPO. (YT35V00019F1)
PSV-18(D)
SOLENOID VALVE VALVE SOLENOID VALVE ASSY
ARM IN 2 SPEED PROPO.
PSV-20(A) YN35V00049F1
VALVE
SW - 1 KEY SWITCH YN50S00026F1
SW - 4 SWING PARKING BRAKE RELEASE SWITCH YN50S00047P1
SW - 5 HORN SWITCH RIGHT YN50E00017P1
SW - 8 AIR FILTER RESTRICTION SWITCH YR11P00008S005
SW - 10 HORN SWITCH LEFT YN50E00017P1
SW - 11 LEVER LOCK SWITCH YN50S00055F1
SW - 12 OVERLOAD ALARM SELECT SWITCH YN50S00040D6
(SW) SWITCH
SW - 19 WIPER INTERLOCK SWITCH YT50S00004P1
SW - 26 CAB WORK LIGHT SWITCH YN50S00040D4
SW - 29 (NIBBLER OPEN SWITCH) YN03M01231P1
SW - 30 (NIBBLER CLOSE SWITCH)
SW - 55 BOOM-DECK WORKING LIGHT SWITCH YN50S00040D1
SW - 56 (FUEL SUPPLY AUTO STOP SWITCH) YF52F00004P1

SW - 111 (ATTACHMENT MODE SELECT SWITCH) PY50S00003P2
24-89
24.2.2 SPECIFICATIONS ELECTRICAL EQUIPMENT
24-90

24-91
24-92

24-93
24-94

24-95
24-96

24-97
24-98

24-99
24-100

24-101
24-102

24-103
24-104

24-105
24-106

24-107
24-108
㨇25. AIR-CONDITIONER SYSTEM㨉

25. AIR-CONDITIONER SYSTEM

TABLE OF CONTENTS
25.1 BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR CONDITIONER) ääääääääääää25-3

25.1.1 AIR CYCLE äääääääääääääääääääääääääääääääääääää25-3
25.1.2 AUTO AIR CONDITIONER SYSTEM OUTLINE ääääääääääääääääääää25-4
25.2 COMPONENT AND CONSTRUCTION äääääääääääääääääääääääääää25-5
25.2.1 COMPONENT ääääääääääääääääääääääääääääääääääää25-5
25.2.2 CONSTRUCTION ääääääääääääääääääääääääääääääääää25-6
25.3 PIPING äääääääääääääääääääääääääääääääääääääääää25-8
25.3.1 AIR CONDITIONER äääääääääääääääääääääääääääääääää25-8
25.3.2 AIR DRYER ASSY äääääääääääääääääääääääääääääääää25-14
25.4 FUNCTION äääääääääääääääääääääääääääääääääääääää25-15
25.4.1 MECHANISM OF COOLING CIRCUIT äääääääääääääääääääääääää25-15
25.4.2 COOLING CIRCUIT äääääääääääääääääääääääääääääääää25-17
25.4.3 COMPONENT PARTS ääääääääääääääääääääääääääääääää25-18
25.5 DISASSEMBLY AND ASSEMBLYäääääääääääääääääääääääääääää25-22
25.5.1 PRECAUTIONS TO BE EXERCISED IN OPERATION äääääääääääääääää25-22
25.5.2 DISASSEMBLY AND ASSEMBLY OF UNIT ääääääääääääääääääääää25-24
25.6 CHARGING REFRIGERANT äääääääääääääääääääääääääääääää25-28
25.6.1 PRECAUTIONS TO BE EXERCISED IN OPERATION äääääääääääääääää25-28
25.6.2 OPERATING PROCEDURE äääääääääääääääääääääääääääää25-30
25.6.3 CHARGING PROCEDURE ääääääääääääääääääääääääääääää25-31
25.7 ELECTRIC CIRCUIT äääääääääääääääääääääääääääääääääää25-36
25.7.1 WIRING DIAGRAM AND CONNECTORS äääääääääääääääääääääää25-36
25.7.2 STRUCTURE AND OPERATION OF EACH PARTS ääääääääääääääääää25-38
25.8 TROUBLESHOOTING ääääääääääääääääääääääääääääääääää25-42
25.9 SELF-DIAGNOSIS ääääääääääääääääääääääääääääääääääää25-49
Book Code No. S5Y725E01
25-1
Issue Date of Issue Applicable Machines Remarks

S5YT2523E01
First Edition October, 2013 SK75SR-3E : YT08-30001~
(EUR)
25-2
25.1 BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR

CONDITIONER)

Air-conditioner is the unit which places evaporator and heater core parallel, and unifies a blower fan
and an inside / outside air switching unit. And this unit changes hot air to cool air.
25.1.1 AIR CYCLE

࡮ Heater
Inside air or outside air is taken in through intake port and the air is passing through filter and
heat exchange is performed with hot air (heating) at the heater core of air-con unit, and then the
heated air blows off from grille through duct.
࡮ Cooler
Inside air or outside air is taken in through intake port and the air is passing through filter and
heat exchange is performed with cold air (dehumidifying and cooling) at the evaporator of air-con
unit, and then the cooled air blows off from grille through duct.
࡮ Heater system
The heater recycles (circulates) the cooling water in the engine, and the hot water delivered by
the engine flows in the heater core of air-con unit and then heat exchange is performed.
The intake air is heated and the heated air blows off from the grille provided on the inside of cab.
The blow off air temperature is controlled by the temperature control switch on the control panel,
and the operation is controlled by air mixing damper on the air-con unit.
25-3
25.1.2 AUTO AIR CONDITIONER SYSTEM OUTLINE
25-4
25.2 COMPONENT AND CONSTRUCTION

25.2.1 COMPONENT
Air-conditioner group
A/C ASSY: YT20M00026F1 (05)

No. Parts Q'ty No. Parts Q'ty No. Parts Q'ty
27 Air-conditioner assy 1 34 Condenser 1 35-9 S tube: 16 dia. 1
27-1 Air-conditioner unit 1 35 Air dryer assy 1 35-10 L tube: 8.5 dia. 1
27-2 Hose 2 35-1 Receiver dryer 1 35-11 D tube: 12 dia. 1
27-3 Clamp 2 35-2 Bracket 1 35-12 L tube: 8.5 dia. 1
27-4 Filter 1 35-5 S hose: 24 dia. 1 39 Filter 1
30 Panel assy 1 35-6 D hose: 19 dia. 1 40 Solar radiation sensor 1
32 Compressor 1 35-7 L hose: 15 dia. 1
33 Pulley 1 35-8 L hose: 15 dia. 1
25-5
25.2.2 CONSTRUCTION
(1) Air conditioner unit
Air conditioner unit
25-6
Air conditioner unit: YY20M00027F2 (02)

No. Parts Q'ty No. Parts Q'ty No. Parts Q'ty
1 SCREW, TAPPING 19 18 ROD 1 63 O-RING 1
2 HARNESS 1 19 RELAY 2 77 PACKING 1
3 MOTOR, ELEC 2 20 EVAPORATOR 1 82 TUBE 1
4 RESISTOR 1 21 VALVE ASSY 1 83 BRACKET 1
6 DUMPER 1 22 O-RING 1 84 CASE 1
7 LEVER 1 23 O-RING 2 85 THERMOMETER 1
9 DUMPER 1 24 CAPSCREW 2 93 CASE 1
10 LEVER 1 26 HOLDER 1 94 THERMOMETER 1
12 LEVER 1 27 CORE 1 110 CONDITIONER, AIR 1
13 DUMPER 1 28 HOLDER 1 111 BLOWER ASSY 1
14 LEVER 1 31 SCREW, TAPPING 6 112 TUBE 1
15 LEVER 1 51 PLATE 1 113 TUBE 1
16 ROD 1 54 CAPSCREW 1 114 PACKING 1
17 ROD 1 60 PACKING 1 115 PACKING 1
(2) Receiver dryer
Receiver dryer
25-7
25.3 PIPING
25.3.1 AIR CONDITIONER
Air conditioner piping (1/5)
25-8

25-9
25-10

25-11
25-12
Air conditioner: YT20M00026F1 (05)

Tightening Tightening
torque No. Parts Q'ty torque No. Parts Q'ty
N-m (lbf-ft) N-m (lbf-ft)
1 Hose : L = 1750 1 46.5 (34.3) 33 Pulley assy 1
2 Hose : L = 1850 1 34 Condenser 1
3 Bracket 1 35 Air dryer assy 1
4 V-belt 1 39 Filter 1
3.92~4.9 (2.9~3.6) 5 Clip 4 40 Solar radiation sensor 1
46.5 (34.3) 6 Capscrew : M10X25 2 41 Washer 4
4.9 (3.6) 7 Sems bolt : M6X20 2 44 Bracket 1
23.0 (16.9) 8 Sems bolt : M8X20 13 49 Clip 8
23.0 (16.9) 9 Capscrew : M8X100 4 46.6 (34.4) 50 Connector 2
10 Washer 4 46.6 (34.4) 51 Connector 1
46.5(34.3) 11 Sems bolt : M10X20 3 55 (41) 52 Connector 1
12 Tube for heater : L = 1400 2 53 Clip 1
20~25 (14.7~18.4) 14 Tube for D hose : L = 1500 1 54 Grommet 1
30~35 (22.1~25.8) 15 Tube for S hose : L = 1700 1 55 Grommet 1
16 Bracket 1 56 Bracket 1
12~15 (8.5~11.7) 17 Tube for L hose : L = 1600 1 57 Bracket 1
12~15 (8.5~11.7) 19 Tube for L hose : L = 1300 1 61 Clip 1
21 Clip 1 9.7 (7.21) 62 Sems bolt : M6X16 1
11 (8) 22 Capscrew : M8X30 4 69 Bracket assy 1
24 Clip 1 70 Bracket assy 1
25 Clip 21
26 Clip 18
27 Air conditioner assy 1
30 Panel 1
32 Compressor assy 1
25-13
25.3.2 AIR DRYER ASSY
Air dryer assy: YT96V00008F1 (01)

Tightening torque Tightening torque
No. Parts Q'ty No. Parts Q'ty
1 Receiver dryer 1 7 L hose 1
2 Bracket 1 8 L hose 1
3 Capscrew: M8X25 2 9 S tube 1
4 Capscrew: M6X25 4 10 L tube 1
5 S hose 1 11 D tube 1
6 D hose 1 12 L tube 1
25-14
25.4 FUNCTION

25.4.1 MECHANISM OF COOLING CIRCUIT
(1) Mechanism of Cooling
In the cooling process, the refrigerant that
flows through the cooling circuit changes its
phases from liquid to gas and vice versa during
which process heat is transferred from the low
temperature part (compartment) to the high
temperature part (outside of the vehicle).
1. Kind of Refrigerant
Many kinds of refrigerants that change in that
way are available, but the following equirements
are needed for use in such applications:
࡮ Latent heat of vaporization (heat of vaporization) is large.

࡮ It is easy to liquefy (condense). (It dose not require very high pressure for condensation.)
࡮ It is easy to gasify (evaporate). (It evaporates sufficiently at not too low pressure, i.e. cools down
an object.)
࡮ It has small specific heat. (Since the refrigerant itself is cooled by the expansion valve, the loss
resulting from it must be held down to a minimum.)
࡮ It has a high critical temperature and a low solidification point.
࡮ It is stable chemically and does not corrode and permeate into the circuit parts.
࡮ It is free from toxicity, objectionable odor, flammability and explosiveness and excels in thermal
conductivity and electric insulation.
࡮ It has small specific volume.
࡮ It is easy to find out leakage.
Out of refrigerants meeting the above-mentioned requirements, ones having characteristics that
suit the intended cooling unit are chosen and used. If a refrigerant other that those designated is
used, sufficient refrigeration will not be performed or the equipment in which the refrigerant is used
may be broken. Therefore, always use a designated refrigerant for the cooling unit.
Table shows the principal characteristics of the R134a refrigerant that is used in this machine.
25-15
(2) Characteristics of Refrigerant (Right Fig.)

In general, the fluid (general term of gas and
liquid) has the following qualities:
1.
As a gas under certain pressure is cooled
down, it begins to condensate at a certain
temperature to take a liquid state. The
temperature at which condensation begins is
unique to each substance (fluid) at a given
pressure. The temperature determined by a
given pressure is called saturation temperature.
Pressure-temperature characteristics of R134a
2.
Inversely to 1) above, the pressure at which a gas condenses for a temperature is determined. This
pressure is called saturation pressure.
above Fig. illustrates the relationships between the saturation temperature and the saturation pressure
in the case of refrigerant R134a used in the air-conditioner. At the temperature and the pressure on
the lower righthand side of the curve in above Fig. the refrigerant take a gaseous state, while at the
temperature and the pressure on the upper lefthand side of the curve, the refrigerant takes a liquid
state.
Let us think of a case where an air-conditioner is operated in the midst of summer. As the refrigerant
evaporates, it absorbs evaporation heat from the air of the compartment. In order to cool the inside of
the compartment down to 25C degrees (77F degrees), the refrigerant must transform (evaporate) from
a liquid to a gaseous state at a lower temperature. It can be seen from above Fig. that R134a under
a pressure above the atmospheric pressure is capable of cooling the inside of the compartment
sufficiently. (If a refrigerant that requires a pressure below the atmospheric pressure to cool it to a
required temperature is used, air is mixed into the circuits, thereby deteriorating the performance of the
cooling unit.) In the process in which gaseous refrigerant is brought back to a liquid state, the
refrigerant is cooled and condensed by the outer air exceeding 35C degrees (95F degrees).
Accordingly the refrigerant is capable of condensing at a pressure exceeding 1 MPa (145psi), as seen
from above Fig.
25-16
25.4.2 COOLING CIRCUIT

Right Fig. illustrates the cooling circuit of the

car air-conditioner.
In this circuit diagram, the portion that cools the
air of the compartment is the evaporator. The
object air is cooled off by utilizing the fact that
the refrigerant takes heat off the surrounding
area as evaporation heat as it evaporates in
the cooling circuit. Since the part at which
vaporization of the refrigerant takes place is
the evaporator, cooled air is constantly delivered
to the circumference of the evaporator by the
blower fan. In the meantime, liquid refrigerant
(slightly wet vaporized refrigerant) is fed into the
evaporator, when "cooling" effect is attained.
For instance, in order to cool the air to 15C
degrees (59F degrees), the refrigerant can not
Construction of cooling circuit
absorb evaporation heat from the air unless it
evaporates at a temperature lower that 15C
degrees (59F degrees). For that purpose, it
can be seen from right Fig. that the pressure of
the refrigerant in the evaporator must be less
than 0.51 MPa (74psi).
Furthermore, the cooling effect deteriorates
unless the feed rate of the refrigerant is
controlled so that all of the refrigerant supplied
to the evaporator vaporizes and turns into dry
vapor.
Consequently, the cooling circuit is so
constructed that the evaporator can cool down
an object (air in this case) sufficiently (i.e. so
as to decrease the pressure in the evaporator)
and that an adequate amount of refrigerant
can be fed to the evaporator.
The feed rate of the refrigerant is controlled by
the expansion valve, but the pressure in the
evaporator is held low by the throttling action of
the expansion valve and the suction action of
the compressor. The compressor acts as a
pump that allows the refrigerant to circulate.
The compressive action of the compressor and
the heat exchange (heat radiation) action of
the condenser transform the refrigerant in a
dry vapor state back to a liquid state.
25-17
25.4.3 COMPONENT PARTS

(1) Evaporator (See right Fig.)
The evaporator is an important heat exchanger
that absorbs the heat of the compartment air
(object) by the utilization of the latent
vaporization heat of the low-temperature,
low-pressure liquid-state refrigerant. Therefore,
it is necessary that satisfactory heat transfer
between the object and the refrigerant take
place in the evaporator.
To that end, the evaporator is equipped with
fins on the air side in order to increase the
heat transfer area of the air side and thereby
perform excellent thermal transfer between the
refrigerant and the air.
The humidity in the air condenses as the air
cools down and adheres to the outside of the
evaporator as water drops. The cooling effect
deteriorates if the water drops freeze. Therefore,
how to discharge water is an important point.
The amount of refrigerant supplied to the
evaporator is controlled by the expansion valve
which is described in the following. In order to
attain proper control, it is necessary to reduce
the pressure drop of the refrigerant of the
evaporator. Accordingly, reducing the pressure
drop is one element that makes the evaporator
attain its full performances.
(2) Expansion Valve

In order for the evaporator to fulfill its performances, a proper amount of low-pressure low-temperature
liquid refrigerant must be fed to the evaporator.
If the feed rate is too low, the refrigerant completes vaporization early in the evaporator which results
in deterioration of the cooling effect. If the feed rate is too high, unvaporized liquid refrigerant returns
to the compressor (liquid back). This not only deteriorates the cooling effect, but also damages the
compressor valves.
The expansion valve feeds the flowing high-pressure high-temperature liquid refrigerant to the
evaporator as low-pressure low-temperature liquid refrigerant (damp vapor of low dryness). The
expansion valve controls the feed rate of the refrigerant at the same time.
25-18
Right Fig. shows how the block type

expansion valve is constructed. The temperature
sensing part is provided in the shaft of the

expansion valve to directly detect the
refrigerant temperature at the outlet of the
evaporator.
The diaphragm contains R134a in saturated
state. The pressure in the diaphragm changes
according to the temperature detected by the
sensor. The change in the pressure causes
the force acting upon the diaphragm to vary
accordingly.
The high-pressure high-temperature liquid
refrigerant that is fed from the receiver side
reduces the pressure abruptly as it passes
through the valve (throttling action). On that Block type expansion valve
occasion, part of the refrigerant evaporates by
the very heat of the refrigerant and cooled off.
The result is that low-pressure low-temperature
damp refrigerant vapor is fed to the evaporator.
The opening of the valve is determined by the
equilibrium between the pressure (low) of the
evaporator side, the action of the adjust spring
and the pressing force of the diaphragm (the
temperature of the refrigerant at the outlet of
the evaporator to be sensed by the thermowell).
The feed rate is controlled automatically so
that under the pressure in the evaporator, the
refrigerant is properly overheated (3 to 8C
degrees ) and goes out of the evaporator. This
action is carried out by sensing the refrigerant
temperature at the outlet of the evaporator as
against the inlet pressure of the evaporator
and consequently controlling the feed rate of
the refrigerant.
This means that if the refrigerant pressure

drop in the evaporator is excessive, it is difficult
to control the overheating or the feed rate of
the refrigerant. For this reason, the smaller the
pressure drop of the evaporator, the better.
The expansion valve senses the pressure and
the temperature at the outlet of the evaporator
and controls the overheating of the refrigerant
Expansion valve outside view
and the refrigerant supply to the evaporator
more securely. The air-conditioner of this
machine adopts a block type expansion valve.
25-19
(3) Compressor (See right Fig.)

The compressor performs the following three
functions in the cooling circuit:
1) Suction action
2) Pumping action
3) Compressive action
1. The suction action, as combined with the throttling action, works to decrease the refrigerant
pressure in the evaporator. This permits the refrigerant to vaporize at low temperature in order to
perform cooling effect.
2. The pumping action serves to cause all the refrigerant to circulate in the cooling circuit. This
enables enables continuous cooling.
3. The compressive action, as combined with the action of the condenser which is mentioned
hereunder, transforms vaporized refrigerant back to a liquid state again.
The saturation temperature gets higher as the pressure increases. For instance, it becomes
possible to cool down the refrigerant by the use of an outer air of 35C degrees (77F degrees)
and liquefy it. The compressive action of the compressor works to turn low pressure vaporized
refrigerant to high pressure vapor refrigerant. The condenser then serves to cool down the
refrigerant. However, since the compressive action takes place only for a short period, the
refrigerant hardly exchanges heat with outer air. That is to say, it takes a near form of thermally
insulated compression, so that the refrigerant discharged by the compressor turns into
high-temperature high-pressure vapor and is delivered to the condenser.
(4) Condenser (See right Fig.)

This is a heat exchanger that cools the
vaporized refrigerant at high temperature and
high pressure by the use of outer air and
condenses the refrigerant. The direction in
which heat moves is from the refrigerant to air,
the opposite to the case of the evaporator. Fins
are equipped on the outer air side to improve
thermal transfer. If the refrigerant is not cooled
well by the condenser, the air in the
compartment can not be cooled sufficiently by
the evaporator. For that purpose, it is necessary
to secure ventilation required for the cooling of
the refrigerant. Condenser
25-20
(5) Receiver dryer (See right Fig.)

1. Receiver Tank
On the air-conditioner, the revolution of the

compressor varies greatly which causes
the proper flow of refrigerant in the cooling
circuit to vary. It is the receiver tank that
receives the variations. When the cooling
circuit does not need much refrigerant, the
receiver tank stores extra refrigerant
temporarily and supplies it when the cooling
circuit needs much refrigerant. The
receiver tank also stores an extra amount
of refrigerant to be used for filling balance
and supplement small amounts of leakage
of the refrigerant through penetration into
rubber hoses.
2. Dryer
If water is mixed in the cooling circuit, it
deteriorates the compressor valves and oil,
corrodes the metallic parts of the circuit or
clogs the circuit as the water freezes in the
expansion valve. It is desirable that the
amount of water mixed in the refrigerant
should be held below a concentration of
30ppm. The air-conditioner uses a
molecular sieve as desiccant suited for the
circuit, in order to absorb water content that
intrudes into the circuit when the dryer is
installed or when refrigerant is charged.
3. Sight Glass
This is a inspection window with which the
refrigerant level in the circuit is
determined, the only means of confirming
the inside of the circuit visually.
4. Filter
5. Pressure Switch
This machine employs pressure switches
of high/low pressure type.
The pressure switch protects the circuit by
cutting off the power supply to the
compressor when high pressure increases
abnormally high [more than 3.14MPa
(460psi) ].
The pressure switch also detects the
leakage of refrigerant by cutting the power
supply to the compressor when the
pressure of the circuit falls below 0.2MPa
(28psi).
25-21
25.5 DISASSEMBLY AND ASSEMBLY
25.5.1 PRECAUTIONS TO BE EXERCISED IN OPERATION

(1) Special Refrigerator Oil
This air-conditioner uses special refrigerator oil
SP20 for use with new refrigerant R134a. Oils
other than SP20 may not be used. Since
SP20 tends to absorb moisture and may
corrode paint and resin, the following points
must be noted:
1.
Do not keep open all pipe connections on a
new compressor and the component parts of
the installed refrigeration circuit
(Remove valves and caps at the pipe openings
of the compressor, just before connecting pipes.
If you have removed a pipe joint for repair,
put a cap to both ports immediately.)
2.
Use care so SP20 does not adhere to the
painted surface and resin parts. In case SP20
has adhered to such surfaces, wipe it off
immediately.
(2)
The receiver dryer is filled with desiccant to
absorb moisture in the circuit. Therefore,
remove the valve at the pipe port immediately
before connecting pipes.
(3)
Tightening Torque
1. Pipe Joints
When connecting pipe joints, coat the O-ring
with special oil (SP20) and fasten to the
tightening torque indicated in the table, using a
double spanner.
2. Screws and Bolts
Fasten to the tightening torque indicated in the
table
25-22
(4)
Amount of Oil for Compressor
The compressor SD7H (HD type) is filled with

135cc (8.2cuoin) of oil. If the oil volume is
small, seizure at high revolution and shortening
of service life will occur. If the oil volume is
large, the cooling ability will be deteriorated.
Once the air-conditioner is operated, part of
the oil is dispersed in the refrigeration circuit.
Therefore, when replacing the parts in right
Table, adjust the oil level to that of table.
(5)
Before performing operation, stop the engine
and turn off all power supplies to the equipment
related to the air-conditioner.
(6)
After the operation is over, confirm that all
faults have been repaired completely, by
operating the air-conditioner.
25-23
25.5.2 DISASSEMBLY AND ASSEMBLY OF UNIT

(1) Removing inner air filter
Slide the inner air filter leftward and remove it
from the unit.
(2) Removing selector box

Remove 6 plus screws, remove connector
connected to the mode actuator on mode
selector box, and separate the mode selector
box from the unit.
(3) Removing main harness

Pull out 3 harness clamps from the unit, and
disconnect all connected connectors and remove
harness on the body from the unit.
(4) Removing upper unit case

1.
Remove air MIX rod and air MIX rod sub from
air MIX lever.
2.
Remove 12 plus screws which are used to
install the upper and lower unit casings.
Pull out the upper unit casing upward giving
attention to the thermistor harness so as not
to be caught by the casing.
25-24
(5) Replacing blower controller

1.
Remove 2 plus screws and remove the blower

controller from the upper unit casing.
2.
Install new blower controller by the reverse
procedure of removal.
* Do not disassemble the blower controller.
(6) Removing heater core

1.
After draining the coolant, remove heater hose
from the heater core.
2.
Remove 1 plus screw, and remove pipe clamp
which is used to secure the heater core and
then remove the heater core from the lower unit
casing.
3.
Install it by the reverse procedure of removal.
(7) Replacing blower motor

1.
Disconnect connector which is connected to
the blower motor and remove the blower motor
from the lower unit casing.
* Do not remove the fan from the blower motor.
2.
Install it by the reverse procedure of removal.
(8) Replacing evaporator and expansion valve

1.
Take the evaporator with expansion valve off
from the lower casing.
2.
Remove evaporator sensor with sensor holder
from the removed evaporator.
3.
Insert the sensor holder into the new evaporator
at the position shown in right Fig. and install
the evaporator sensor again.
25-25
4.
Remove 2 socket bolts M5X40 with Allen
wrench (4mm) and remove the expansion
valve from the evaporator.
5.
Fit O-ring (NF O-ring 5/8 and 1/2 one each) to
new evaporator.
* When assembling again, fit O-ring paying
attention so as not to be caught with others.
(Socket bolt M5X40 (2 pcs.) Tightening torque
: 6.9Nom (5.1lbfoft)
* Do not apply undue force to pipe of
evaporator outlet. This undue stress causes
the leak of refrigerant from "A" part of
evaporator.
Moreover, when tube (78), (79) (see Structual
chart of air conditioner unit) connected with
expansion valve is disconnected from
expansion valve, similar careful work is
necessary.
(9) Replacing motor actuator

1. Replacing mode actuator
a.
Remove connector connected to the motor
actuator.
b.
Remove FACE rod and VENT rod which is
used to connect MA mode lever and mode cam
from the holder.
c.
Remove 3 plus screws and remove the motor
actuator with lever MA mode from the unit.
d.
Remove the lever MA mode from the removed
motor actuator, and install it on new motor
actuator by the reverse procedure of removal.
25-26
2. Replacing air mixing actuator

a.
Remove connector connected to the motor

actuator.
b.
Remove rod air MIX which is used to connect
the motor actuator and the lever MA air MIX.
c.
actuator with MA lever air MIX from the unit.
d.
Remove the MA lever air MIX from the
removed motor actuator, and install it on new
motor actuator by the reverse procedure of
removal.
3. Replacing inner and outer air switching

actuator
a.
Disconnect connector connected to the motor
actuator.
b.
Remove intake rod from MA intake lever.
c.
actuator with MA intake lever from the unit.
d.
Remove the MA intake lever from the removed
motor actuator, and install it on new motor
actuator by the reverse procedure of removal.
25-27
25.6 CHARGING REFRIGERANT
25.6.1 PRECAUTIONS TO BE EXERCISED IN OPERATION

(1) Always assign a person in charge of handling refrigerant.
Refrigerant charge operation involves dangers as it handles high pressure gas. Always assign a person
familiar with how work is done for handling refrigerant.
- Wear protective goggles. (You may lose your sight if the refrigerant gets in your eyes.)
- The refrigerant in liquid state is at very low temperature [approx. -26C degrees (-15F degrees)].
Therefore, handle it with care. (You may get a frostbite if the refrigerant is sprayed over your skin.)
(2) Storage and Transportation

1. Keep the service can (hereinafter called can) less than 40C degrees (104F degrees). Since high
pressure gas of R134a is filled in the can in a saturated liguefied state, the pressure in the can
increases sharply as temperature rises. The can may blast as the result.
It is for this reason why the can temperature must be kept below 40C degrees (104F degrees).
2. For storage, choose a cold dark place not exposed to direct sunlight.
3. If the can is placed near a fire source, it is subject to radiation heat and gets hot. This causes
the inside pressure to rise and may cause the can to blow out. Do not bring the can close to a
fire.
4. The inside of the closed compartment gets very hot as the radiation heat of the sunlight enters
the compartment. The areas of the compartment which are exposed to direct sunlight may rise to
a dangerous temperature level. Do not bring the can into the compartment. Also, the inside of
the trunk room may rise to a dangerous temperature level even in the summer time. Use sufficient
care, therefore, taking the above into account.
5. Note that if the can has scratches, dents and distortion, the strength of the can will deteriorate.
a. Do not drop or knock on the can.
b. When transporting, loading or unloading cans and packages containing cans, do not throw or
drop them.
6. Store cans beyond the reach of children.
(3) Charging
1. When warming the can in which refrigerant is charged, do not fail to open the service can valve
and the low pressure valve of the gauge manifold and warm the can in warm water of 40C
degrees (104F degrees or below (to an extent that you do not feel hot when you put your hand
in the water.) If the can is put in hot water or heated by a direct fire, the pressure of the can
may rise sharply, thereby blowing off the can.
2. When charging refrigerant while running the engine, do not open the high pressure valve (HI) of
the gauge manifold in any case.
25-28
(4) Others
Reuse of service cans is prohibited by law; never use them again. Do not allow foreign matter to
enter the air-conditioner circuit. Air, water and dust are detrimental to the refrigeration cycle. Install the

components of the air-conditioner correctly and speedily. Pay full attention to the entry of water and
dust.
- Be careful about overcharge of gas.

- Fasten pipes to the specified torque.
25-29
25.6.2 OPERATING PROCEDURE

(1)
Refrigerant charge into the air-conditioner consists mainly of "vacuum making operation", and "gas
charge operation".
1. The "vacuum making operation" consists of removing water in the air-conditioner circuit. If only a
little water remains in the circuit, the small holes of the expansion valve are frozen during
operation. This causes the circuit to clog up or rust, resulting in a variety of malfunctions.
Therefore, before filling refrigerant in the circuit, make vacuum and allow the water in the circuit
to boil and vaporize. Water in the circuit is thus eliminated.
2. The "gas charging operation" consists of filling refrigerant in the circuit after forming vacuum. Filling
gas not only depends upon the cooling performances of the air-conditioner, but also affects the
service life of the component parts of the circuit. Extreme overcharge will make the circuit pressure
extremely high and causes the cooling performance to deteriorate. On the contrary, undercharge
causes poor circulation of the lubricating oil of the compressor and causes seizure of the moving
parts of the compressor.
The gas filling operation involves handling of high pressure gas; filling gas according to incorrect
operation procedure is dangerous. Fill refrigerant correctly following the operation procedures and
cautions stated in this manual.
(2) Operation Chart
(3) Tools
25-30
25.6.3 CHARGING PROCEDURE

25.6.3.1 VACUUM MAKING OPERATION
(1) Connecting gauge manifold (See right Fig.)
1.
Close the high pressure valve (HI) and the low
pressure valve (LO) of the gauge manifold.
2.
Connect the charging hoses (red and blue)
with the service valves of the compressor.
Red hose :
High pressure side (HI) of the gauge manifold
--> high pressure side (DIS) of compressor
Blue hose :
Low pressure side (LO) of gauge manifold -->
low pressure side (SUC) of compressor
Do not mistake the high pressure hose for the low pressure hose in any circumstances when
connecting them. Put the hose in firmly till a clicking sound is heard.
3.
Connect the center valve of the gauge
manifold with the charging hose of the vacuum
pump.
Connecting gauge manifold
Some kinds of gauge manifolds are not equipped with an open/close valve in the center.
25-31
(2) Vacuum making (See right Fig.)

1.
Open the high pressure valve (HI) and the low
pressure valve (LO) of the gauge manifold.
2.
Turn on the switch of the vacuum pump and
make vacuum for more than 30 minutes.
3.
When vacuum making for a specified duration
is over (degree of vacuum : less than - 750
mmHg), close the high pressure valve and the
low pressure valve of the gauge manifold.
4.
Then turn off the vacuum pump.
Vacuum making operation
(3) Air-tightness Check

Close the high pressure valve and the low pressure valve of the gauge manifold, leave it as it is for
more than five minutes and make sure that the gauge indication does not return toward 0.
If the gauge indication goes toward 0, there is somewhere that is leaking. Retighten pipe joints,
make vacuum again and make sure of no leakage.
25-32
25.6.3.2 GAS CHARGING OPERATION

(1) Charging from high pressure side (See right Fig.)
1.

After making vacuum repeatedly, change the
charging hose (yellow) of the gauge manifold
from the vacuum pump to the service can.
2.
Air purge
Open the service can valve. (However, close
the high and low pressure valves of the gauge
manifold.) Then push the gas valve of the side
Gas charging operation
service port on the low pressure side of the
gauge manifold, using a screw driver, in order
to let out the air in the charging hose by the
pressure of the refrigerant. (See right Fig.)
(The operation ends when a hissing sound is
heard.)
3.
Open the high pressure valve of the gauge
manifold and charge in refrigerant. [Charge in
gaseous refrigerant to a gauge pressure of
0.1MPa (14psi).]
After charging, close the high pressure valve
of the gauge manifold and the service and
valve. (See right Fig.)
Gas charging operation (High pressure side)
Do not run the compressor during this work, (Otherwise the refrigerant flow in reverse direction which
causes the service can and the hoses to rupture. This is very dangerous.)
(2) Checking for gas leak

Check for gas leak in the cycle, using a gas leak detector (electric type). Retighten and correct leaking
points.
Always use the leak tester for R134a. (Do not use one for flon gas service as it provides poor
sensitivity.)
25-33
(3) Charging from low pressure side (See right Fig.)

1.
Make sure that the high-pressure and
low-pressure valves of the gauge manifold and
the service can valve are closed.
2.
Start the engine and run the revolution to
1500 to 100rpm and fully close the cab door
and the windows.
3.
Turn on the air-conditioner switch, set the fan
switch to Max and the temperature control
switch to cool Max.
4.
When charging gas, set the discharge pressure
Gas charging operation (Low pressure side)
of the compressor to 1.4 to 1.6 MPa (200 to
230psi).
5.
Open the low pressure valve of the gauge
manifold and the service can valve and fill in
refrigerant till air bubbles of the sight glass of
the receiver go away. (See Fig. "Gas charging
operation")
[Total amount of gas to be charged:
780g to 880g (1.72 to 1.94 lbs)]
6.
When refrigerant charge is over, close the low
pressure valve of the gauge manifold and the
service can valve. Receiver dryer
- Do not open the high pressure valve of the gauge manifold in any circumstances.
- Never place the service can upside down. (The compressor valve may be scored because the
refrigerant is sucked in a liquid state.)
25-34
(4) Criterion for checking the amount of refrigerant filled in

- If the air-conditioner is run with poor refrigerant R134a, it has adverse effect on the compressor.
- If the refrigerant is charged too much (overcharged), the cooling performance is deteriorated.
Moreover, the circuit pressure gets abnormally high: Always keep a proper level.
(5) Removing Gauge Manifold

When the refrigerant level has been checked, disconnect the charging hoses from the compressor in
the following manner:
1. Press the "L" shape metal fitting of the charging hose (blue) on the low pressure side against the
service valve of the compressor so the refrigerant does not leak out and loosen the nut. As soon
as the nut has been removed, disconnect the charging hose from the service valve.
2. Leave the high pressure side as it is till the high pressure gauge reading falls. [below 1MPa
(140psi)].
3. Disconnect the charge hose (red) on the high pressure side the same way as on the low pressure
side.
25-35
25.7 ELECTRIC CIRCUIT
25.7.1 WIRING DIAGRAM AND CONNECTORS
Electric diagram (1/2)
25-36

Electric diagram (2/2)
25-37
25.7.2 STRUCTURE AND OPERATION OF EACH PARTS

(1) Control panel
The control unit is integrated into control
panel, and processes the signal input by
each sensor, etc. and the signal input by Control panel
each switch through control panel with the
function of the built-in micro computer, and
comprehensively controls each actuator
(Air inlet / outlet mode select, air mix),
blower motor and compressor on the output
side.
And the self-diagnosis performance is
provided to facilitate the trouble shooting.
(2) Fan driver

The power transistor shifts the blower motor
into variable speed with base current from
the control unit.
<Check for fan driver>

Check over the continuities between
terminals of fan driver.
Blower controller
25-38
(3) Relay
Four-electrode relay is used for the blower OFF relay and compressor relay.

1. Blower OFF relay
The blower OFF relay turns on after
receiving the signal from the control
amplifier.
When the blower OFF relay turns on, the
source voltage is supplied to the blower
motor and the blower motor starts running.
2. Compressor relay
The relay ON-OFF is switched by the
control amplifier and electronic thermostat
control.
3. Relay specification and inspection
a. Coil resistance: 320 ohms
b. Specified voltage: DC20V to 30 V
c. Be careful about the coil polarity of relay.
d. Inspection:
Inspect the continuity between terminals 3
and 4 as follows.
20 to 30 V applied between terminals 1-2:
Continued
20 to 30 V not applied between terminals
1-2: Not continued
(4) Motor actuator

Air mix actuator is located in at the center
of air-con unit, and opens and closes air
mix damper through the link motion.
The air mix actuator incorporates
potentiometer which is switched by linked
shaft with actuator.
When the target air mix door position is
determined through the temperature control
switch, the control unit reads the level of Both motor actuators
potentiometer of the actuator. And it
determines the rotating direction of motor in
either normal rotation or reverse rotation.
And the motor rotates, the contact point is
moved, and when the contact point is
detached or the output signal of control unit
turns OFF, the motor stops.
25-39
(5) Mode actuator

Mode actuator is located in outlet of air
conditioner unit. And it opens or closes
mode door through link motion.
The mode actuator incorporates
potentiometer which is switched by linked
shaft with actuator.
When the target air mix door position is
determined through the temperature control
switch, the control unit reads the level of
potentiometer of the actuator. And it
determines the rotating direction of motor in
either normal or reverse rotation. And the
motor rotates, the contact point is
detached or the output signal of control unit
turns OFF, the motor stops.
(6) The actuator for air inlet / outlet (12V)

The actuator for inlet and outlet air mode
select is installed on the blower intake
unit, and opens and closes inlet or outlet
air damper through the link motion. The
actuator for inlet and outlet air mode
select incorporates position detection
switch which is switched with the movement
of shaft of the actuator. When the inlet or
outlet damper position is set by the inlet
and outlet switch on the control panel, the
control unit reads the signal of the position
detection switch in the actuator and
determines the rotation direction of motor in
either normal rotation or reverse rotation.
And the motor rotates, the position
detection switch also rotates and makes it
stop at the set position of the inlet or outlet
air damper.
25-40
(7) Evaporator sensor - air inlet sensor

This sensor is used to control the
evaporator outlet temperature with the

compressor ON-OFF to protect the
evaporator from freezing, and this
evaporator sensor functions as a sensor of
this control.
- Evaporator sensor and air inlet sensor
Evaporator sensor - air inlet sensor
specifications
Terminal resistance:
at 0 degree C: 7.2 kilo-ohms
at 25 degree C: 2.2 kilo-ohms
(8) Solar sensor

This solar sensor, which is used to correct
the solar radiation to the auto air
conditioner detects the strength and solar
orientation of sunbeam after transforming Solar sensor
them into current by means of photo diode.
<Check for solar sensor>
Disconnect solar sensor connecter from
harness. Using voltmeter measure the
voltage between connector terminals.
The measured voltage should be varied by
intensity of sunshine. (When there is no
sunshine, measured voltage is almost 0
volt.)
- Measure the voltage in the voltage measurement mode (V mode).

- Measurement in resistance mode (Ohm mode) causes the damage of devices.
(9) Dual pressure switch

This dual pressure switch is attached on L-hose and is used to turn OFF the compressor, and
employs dual type (for high and low pressure control) to protect the cooler cycle from possible
failure at the time when abnormal pressure was generated on the high pressure side.
Dual pressure switch
25-41
25.8 TROUBLESHOOTING
25-42

25-43
25-44

25-45
25-46

25-47
25-48
25.9 SELF-DIAGNOSIS

1. When error occurs in input circuit of motor actuator drive line, the error can be displayed on
the monitor of LCD display.
2. When error occurs in evaporator sensor and intake air sensor, the error can be displayed on
the monitor of LCD display.
3. Detection of each sensor error by monitor mode function (Detection of failure control of
control panel)
࡮ When the air conditioner is in operating condition, press the internal and external air selector
switch (6) and main power switch (1) for one second or more simultaneously. And the display of
monitor mode begins. To return the display to previous display, operate 2 switches according to
above mentioned same operation.
࡮ Normal condition, disconnection and short circuit of intake air sensor, evaporator sensor and solar
sensor are indicated in segment of display.
࡮ Normal condition and short circuit of solar sensor is indicated in segment of display.
(* Detection of disconnection is not indicated.)
25-49
25-50
㨇26. CAB INTERFERENCE PREVENTION SYSTEM㨉
26. CAB INTERFERENCE

PREVENTION SYSTEM
TABLE OF CONTENTS
26.1 OUTLINE AND FUNCTIONS äääääääääääääääääääääääääääääää26-3

26.1.1 OUTLINE ääääääääääääääääääääääääääääääääääääää26-3
26.1.2 CAB INTERFERENCE PREVENTION EQUIPMENTS ääääääääääääääääää26-4
26.1.3 HEIGHT/DEPTH LIMITATION DEVICE
ääääääääääääääääääääääää26-6
26.2 CONSTRUCTIONS ääääääääääääääääääääääääääääääääääää26-9
26.2.1 BOOM ANGLE SENSOR POSITION äääääääääääääääääääääääää26-9
26.2.2 ARM ANGLE SENSOR POSITION ääääääääääääääääääääääääää26-10
26.2.3 OFFSET ANGLE SENSOR POSITION ääääääääääääääääääääääää26-11
26.2.4 CONSTRUCTION OF ANGLE SENSOR ääääääääääääääääääääääää26-12
26.3 ADJUSTMENT PROCEDURE äääääääääääääääääääääääääääääää26-13
26.3.1 INTERFERENCE PREVENTION EQUIPMENT äääääääääääääääääääää26-13
26.3.2 SET PROCEDURES OF HEIGHT AND DEPTH INDICATIONS äääääääääääää26-14
26.3.3 RESET OF HEIGHT AND DEPTH INDICATIONS SETTING ääääääääääääää26-14
26.3.4 SETTING THE HEIGHT LIMITATION äääääääääääääääääääääääää26-15
26.3.5 SETTING THE DEPTH LIMITATION äääääääääääääääääääääääää26-16
26.3.6 SETTING THE OFFSET LIMITATION äääääääääääääääääääääääää26-17
26.3.7 RELEASING THE LIMITATION ääääääääääääääääääääääääääää26-18
26.3.8 RELEASING THE ALL LIMITATIONS äääääääääääääääääääääääää26-18
26.3.9 CHECKING ON CAB INTERFERENCE PREVENTION SYSTEMäääääääääääää26-19
26.4 INTERFERENCE PREVENTION RELEASE CONNECTOR ääääääääääääääääää26-21
26.5 INSPECTION OF ELECTRIC PARTS äääääääääääääääääääääääääää26-22
Book Code No. S5YT261E01
26-1

S5YT2619E01
First Edition September, 2012 SK75SR-3 : YT07-25001~
(SE Asia & Oceania)
75SR-3 : YT08-30001~
(NA)
December, 2012 E75CSR : YT08-30001~

(NHK-EUR)
August, 2013 SK75SR-3E : YT08-30001~

(NA)
October, 2013 SK75SR-3E : YT08-30001~

(EUR)
26-2
26.1 OUTLINE AND FUNCTIONS
26.1.1 OUTLINE
(1) When the bucket is closing to the
interference area, the display of interference
prevention appears. And the motion of
bucket stops automatically.
This cab interference prevention system has
following 5 functions.
1. Cab interference prevention function.
2. Height/depth display function.
3. Height limitation function.
4. Depth limitation function. Sensors position
5. Off-set L/H limitation function.
26-3
26.1.2 CAB INTERFERENCE PREVENTION EQUIPMENTS

(1) Operation
When the bucket is in the cab interference area
and the starter switch key is turned ON or
START, the right display appears. This display
means that the cab interference prevention
system is working properly.
Even if the switch is not pressed, this function
is normally on. Example of display
1. Movement of "B" area

When attachment is closing to cab, and
bucket teeth enter warning area "B",
operator will be noted by intermitted
warning buzzer and machine speed will be
reduce.
2. When bucket teeth is closing to stop area
"A", operator will be alerted by continuous
warning buzzer, and machine is
automatically stopped. Warning buzzer will
be stopped after 5 seconds.
-Travel/swing / dozer blade / offset (R/H) / boom lower / arm out are not automatically stopped.
Offset (L/H) will be automatically stopped when bucket is closing to 245 mm. And arm in and boom
up will be automatically stopped too.
-Stopping position of attachment is based on arm top pin position. The nearest distance between
bucket teeth and cab is shown In right figure.
26-4
(2) Release of automatic stop function

For the safety this machine has two release switches. To release the interference prevention function,
operate the following procedures.
1. While the machine is in automatically

stopped status, if the operator wants to
move an attachment close to cab more,
a. Press the release switch (1) on the
switch panel.
b. Press the interference release switch
(2) on the right control lever within 10
seconds after pressing above-mentioned
switch. At this time the buzzer sounds
intermittently.
While the release switch (2) is pressed, the
display "NO INTERFE. PREV. SYSTEM" is
indicated and automatic stop function is
released.
2. When move the attachment toward safety
area, it is not necessary to push the
release switch (R). In case of returning
the attachment to safety area, shift the
control lever and move the desired
attachment until the warning buzzer sounds
intermittently.
26-5
26.1.3 HEIGHT/DEPTH LIMITATION DEVICE

(1) Outline
The LCD multidisplay of the gauge cluster on the right front of the operator's seat indicates the
depth, height and left offset distance, and the depth, height and off-set left limit functions and those
conditions.
Read the depth, height and offset left limit setting and releasing procedure carefully.
(2) Switches and operations

The following switches are located on the
multi-display of the gauge cluster. And the
conditions of machine are displayed on this
LCD.
a. Multi display (LCD)
b. Indications switching switch
c. Select switch (Standard setting switch)
d. Buzzer stop switch (Limitation reset switch)
e. Height, depth and offset left limitation adjust
switch
f. Depth limitation value variable setting switch
(DOWN/UP)
g. Limitation reset switch
1. Multi-display (LCD)
Refer to the above (1) Outline.
2. Screen change switch
When the height, depth, and offset left are
set, press this switch (g) to change the
display to the setting display.
3. Select switch (Standard setting switch)

Press this switch to set the height, depth
and offset left setting.
4. Buzzer stop switch (Limitation reset switch)

Press this switch to release the set depth
or selected limitation function.
26-6
5. Height, depth and offset left limitation adjust

switch
Press this switch to increase and decrease
the values of the height, depth and offset
left setting.
6. Depth limitation value variable setting switch
(DOWN/UP)
Press the UP to increase setting value.
Press the DOWN to decrease setting value.
(3) Boom offset pedal
Use this pedal to operate the boom offset.
Boom offset pedal
Make sure to set the pedal lock to "LOCKED" position while the boom offset is not used.
Unexpected contact with "UNLOCKED" position of pedal may cause severe injury or death.
A : RH offset (Depress right side of pedal)

B : LH offset (Depress left side of pedal)
Move the pin leftward to lock the pedal, and move the pin rightward to unlock the pedal.
26-7
(4) Matchmark on the attachment

Match matchmarks, and the cab interference
prevention does not function and the attachment
can be operated in the minimum swing radius.
Boom matchmark
-When being offset on the right side of the matchmark point, the slewing in the minimum radius is
possible.
-When being offset on the left side of the matchmark point, the slewing in the minimum radius is
impossible because the cab interference prevention equipment is functioned.
26-8
26.2 CONSTRUCTIONS
26.2.1 BOOM ANGLE SENSOR POSITION

Boom angle sensor
1. Item 1 to be installed as the harness positions in "LA" range.

2. Item 3 to be installed as the marking of item 1 positions in "LB" range.
26-9
26.2.2 ARM ANGLE SENSOR POSITION
Arm angle sensor

2. Item3 to be indtalled as the marking of item 1 positions in "LB" range.
3. Non-specified tightening torque for M-treads
Threads size: M10, Tightening torque: 65.7N-m (48.5 lbf-ft)
26-10
26.2.3 OFFSET ANGLE SENSOR POSITION

Offset angle sensor

2. Non-specified tightening torque for M-treads
Threads size: M6, Tightening torque: 13.7N-m (10.1 lbf-ft)
26-11
26.2.4 CONSTRUCTION OF ANGLE SENSOR
Construction of angle sensor
(1) Manufacture Model : JCC-065-9

(2) Specification
1. Effective electric angle : 180degrees ~ 185degrees
2. Mechanical rotation angle : 360degrees continuous
3. Insulation resistance : MIN 500V DC 1000M㱅 or more

1 HOUSING 1 8 WIPER TIP 1 15 SNAP RING 1
2 ROTAR 1 9 WIPER 2 16 BEARING 1
3 SHAFT 1 10 CP RING 1 17 BEARING 1
4 PLATE 1 11 RESISTER 1 18 OIL SEAL 1
5 CORRECTOR 1 12 RUBBER BUSHING 1 19 O-RING 3
6 TERMINAL 2 13 NUT 1 20 ADHESIVE (EPOXY TYPE) -
7 WIPER HOLDER 1 14 WASHER 1
26-12
26.3 ADJUSTMENT PROCEDURE
26.3.1 INTERFERENCE PREVENTION EQUIPMENT

When the following components are replaced, adjust the indicator.
1. Attachment
2. Angle sensor
3. Mechatro controller
26-13
26.3.2 SET PROCEDURES OF HEIGHT AND DEPTH INDICATIONS

The standard basic level can be selected depending on operator's desire.
(1) When new machine is delivered and after

the reset of standard height, the ground
level is standard level.
(2) While usual screen is displayed, press the
"SCREEN CHANGE SWITCH" to display
the height standard setting display.
(3) Move the bucket teeth to required digging
depth
(0 m). This time; the bucket should be
facing vertically downward.
(4) Press the "SELECT SWITCH". The
standard of height and depth are indicated
as shown in the right figure. When you
need to change the standard position, move
the attachment to desired position, and
press the "SELECT SWITCH" again.
(5) To select the usual display, press the
"SCREEN CHANGE SWITCH" several times.
26.3.3 RESET OF HEIGHT AND DEPTH INDICATIONS SETTING

(1) Press the "SCREEN CHANGE SWITCH" during usual display. The height standard setting is
displayed.
(2) To return to the usual display, press the "BUZZER STOP SWITCH", and the standard of the
height and depth change to the ground level.
The preset standard level is not released even if the starter switch key is "OFF".
26-14
26.3.4 SETTING THE HEIGHT LIMITATION

When the highest position of the attachment is detected and the height reaches to the preset height,
the operation stops. Only two top positions of offset and arm are the height detection points.

"SELECT SWITCH" to display the set/reset
select display.
(2) Press the "SELECT SWITCH", and the
limitation select screen is displayed. In this
time, the each value indicates the preset
values. When the limitations were not
preset, the present value of attachment
height is indicated.
(3) Using the "UP " or "DOWN" switches,
select the "HEIGHT" and press the
"SELECT SWITCH". The screen of height
limitation setting is displayed. This time,
the indicated value is based on the
ground level always.
(4) Move the highest position of the attachment
to the desired position where you intend
to limit.
height limitation is set. The "HEIGHT" is
highlighted and the screen returns to usual
display.
(6) This time, the attachment is in the height
limitation area. Therefore, boom up and arm
out operations cannot be operated. But the
movement of the attachment to safety area
is possible, lower the attachment to the
safety area.
(7) During the operation, the highest position of
attachment reaches the area within 0.8 m
from set position, and the warning buzzer
sounds intermittently. And the movement of
the attachment slows down.
(8) Additionally, if the attachment moves to
0.3 m from set position, the warning buzzer
sounds for 5 seconds continuously, and
the movement of the attachment stops.
Lower the attachment to the safety area.
26-15
26.3.5 SETTING THE DEPTH LIMITATION

When the tip of the bucket teeth is detected and the teeth reach to the preset depth, the operation
stops.

select display.
preset, the present value of bucket teeth
position is indicated.
(3) Using the "UP" or "DOWN" switches,
select the "HEIGHT" and press the
"SELECT SWITCH". The screen of depth
limitation setting is displayed. This time,
the indicated value is based on the
ground level always.
(4) Move the deepest position of the bucket
to the desired position where you intend to
limit.
depth limitation is set.
(6) Using the "UP" or "DOWN" switches, and
adjust the value of depth limitation. For
each pressing the "UP" switch, the value
increases by 0.2 m from present depth.
Conversely, for each pressing the "DOWN"
switch, the value decreases by 0.2 m from
present depth. When you find the required
depth, press the "SELECT SWITCH". The
depth limitation is set, and the screen
returns to usual display.
(7) This time, the attachment may stop the
motion, because the depth limitation
function is actuated. But the movement of
the attachment to safety area is possible,
move the attachment to the safety area.
(8) During the operation, the bucket teeth
reach the area within 0.5 m from set
position, and the warning buzzer sounds
intermittently. And the movement of the
attachment slows down.
set position, the warning buzzer sounds
for 5 seconds continuously, and the
movement of the attachment stops. Raise
the attachment to the safety area.
26-16
26.3.6 SETTING THE OFFSET LIMITATION

When the offset distance of the attachment is detected and the distance reaches to the preset value,
the operation stops.

select display.
preset, the present distance of offset is
indicated.
select the "OFFSET LEFT" and press the
"SELECT SWITCH". The screen of offset
left limitation setting is displayed. This
time, the present distance of offset left
distance is indicated.
(4) Move the attachment to the desired position
where you intend to limit the offset distance.
offset left limitation is set. And the screen
returns to usual display.
(6) This time, the attachment is in the offset
left limitation area. Therefore, the offset left
operations cannot be operated. But the
movement of the attachment to safety area
is possible, move the attachment to the
safety area.
(7) During the operation, the offset distance of
attachment reaches the area within 0.3 m
from set position, and the warning buzzer
sounds intermittently. And the movement of
the attachment slows down.
set position, the warning buzzer sounds
for 5 seconds continuously, and the
movement of the attachment stops. Move
the attachment to the safety area.
26-17
26.3.7 RELEASING THE LIMITATION

select display.
height limitation select screen is displayed.
select the function, which you need to
release, and press the "SELECT
SWITCH". The screen of height limitation
setting is displayed.
(4) Press the "BUZZER STOP SWITCH", the
selected limitation is released, and the
screen returns to the usual display.
26.3.8 RELEASING THE ALL LIMITATIONS

The limitation settings of height, depth indications and the limitation settings of height, depth, and offset
left functions are released collectively.
(1) While usual screen is displayed, press the "SELECT SWITCH" to display the set/reset select
display.
(2) Press the "BUZZER STOP SWITCH", the all limitation settings are reset, and the screen returns to
the usual display.
26-18
26.3.9 CHECKING ON CAB INTERFERENCE PREVENTION SYSTEM

Next, check the cab interference prevention system.
When buzzer sounds continuously and "ELEC. CUSHION ERROR" is indicated on the gauge cluster,
the cab interference prevention and electronic cushioning might not be functioned normally.
Stop the operation immediately and contact our dealer/distributor.
Cab interference prevention system

-In case where there is a possibility of interference when bucket comes closer to the cab, the
warning buzzer sounds and the emergency stop of attachment is actuated automatically. Make sure to
check that this function works normally before starting operation. If the attachment stops to avoid the
accident, move the lever in the opposite direction and get the safety side.
Height, depth, left offset limitation functions
-If the height, depth, and left offset functions are set, the attachment stops operating automatically
when they reach to respective limit point.
Cab interference prevention release switch
-When abnormality of cab interference prevention system is detected and operation of attachment
must be unavoidably stopped, take the following actions as a measure.
After pressing the release switch (1) on the control panel, and then press the release switch (2) (R
mark) on the right grip within 10 seconds. And the attachment can be moved to the cab side.
In this case, since the height, depth, and left offset limit functions are released simultaneously with cab
interference prevention system, pay particular attention to the lever operation.
Except the machine is required to move urgently to the safety place, do not use cab interference
prevention release function.
26-19
Interference prevention area
࡮ Position attachment as shown Fig. "Interference prevention area", move the boom up and make
sure that warning buzzer normally sounds and attachment speed is slow down when the arm top
pin or bucket tooth tip comes in the front interference prevention area.
࡮ Make sure that the operation stops automatically and buzzer sounds continuously when the
attachment comes closer to operator's seat further.
But the buzzer is kept continuously sounding for only 5 seconds and then stops sounding.
࡮ The auto stop is released by pressing interference prevention release switch (2) (R mark) on the
right control lever grip within 10 seconds after the release switch (1) on the right control panel is
pressed.
࡮ And operate offset control pedal and attachment and make sure that the interference prevention
system functions normally in the side area of cab.
26-20
26.4 INTERFERENCE PREVENTION RELEASE CONNECTOR
In checking the equipment at the time of abnormality occurred on interference prevention and so on,
interference prevention release connector is provided as a measure for interference prevention so as
not to have intermittent function including fail treatment.
The function can be switched by replacing the insertion of connectors in the rear cover.
<In normal operation>
Connect the "NORMAL" tagged connector with the black connector of the harness.
<In case of releasing the interference prevention function>
Connect the "RELEASE" tagged connector with the black connector of the harness.
Interference prevention release connector
Make sure to connect the "NORMAL" tagged connector with the black connector of the harness when
shipping for clients.
If you neglect the connection, it is danger because interference prevention electronic cushion does not
work.
Make sure that the function was switched correctly with the following manners.
In normal condition, "HEIGHT DEPTH" is indicated on the display.
When interference prevention function is released, "NO INTERFE. PREV. SYSTEM" is indicated on the
display.
26-21
26.5 INSPECTION OF ELECTRIC PARTS
(1) Inspection of angle sensor of depth display

You can confirm the input signal of each angle sensor if you operate each attachment and check the
display
1. No display changed even though arm top pin height is moved over 0.1 m when operating boom
raise and boom down.
Or display is changed over 0.2 m even though actual movement is approx. 0.1 m.
2. No display changed even though arm top pin height is moved over 0.1 m when operating arm in
or arm out operation.
3. No display changed even though arm top pin height is moved over 0.1 m when operating offset
left and offset right operation.
(2) Inspection of angle sensor voltage signal

Check with SERVICE DIAGNOSIS.
(The value is as a guide, there is a difference according to machine.)
(3) Inspection of proportional solenoid valve (PSV) for stop

Check it with SERVICE DIAGNOSIS.
26-22
1. In the stop area, command feed back current is 750 mA.
2. No command
3. Command is OK but no feed back
4. Both command and feed back are OK.
(4) Display with failure code No.

1. Input signal failure from angle sensor
When disconnected wiring or short circuit, it will cause of input signal failure from angle sensor.
In this case following code will be displayed.
Also stop signals will be output and caution buzzer continuously sound.
ERROR CODE
BOOM ANGLE SENSOR FAIL : DISCONNECTION H023
: POWER SOURCE SHORT H024
CIRCUIT
ARM ANGLE SENSOR FAIL : DISCONNECTION H033
CIRCUIT
OFFSET ANGLE SENSOR FAIL : DISCONNECTION H043
CIRCUIT
In the case of plural number of sensor failure, all items will be displays alternately.
REMEDY : Check harness and angle sensors.
When above-mentioned error codes are displayed, boom, arm, and offset left operations are stopped.
When you need the operation of the troubled machine by necessity, you can operate the machine by
shifting the release switch which is located under the seat to the release side.
26-23
2. Proportional valve failure

Regarding the identification of proportional valve failure, confirm the cause by service diagnosis or
failure history screen.
Each error code of proportional valves is described below.
ERROR CODES
OUTPUT TRANSISTOR ON
DISCONNECTION
FAILURE
Boom raise inverse proportional valve D043 D042
Boom lower inverse proportional valve D053 D052
Arm out inverse proportional valve D073 D072
Arm in inverse proportional valve D083 D082
Offset left inverse proportional valve D103 D102
In case that all proportional valves are failed except boom lowering, there is a possibility that the
cylinder electric cushion and interference prevention do not function. Therefore, "ELEC. CUSHION
ERROR" and "NO INTERFE. PREV. SYSTEM" is displayed alternately (regardless of releasing of
interference prevention).
3. Inadequate data at adjustment

When adjusting, the angle sensor input data at respective stroke end of the boom up, arm out
and in, and offset right and left is stored in the controller. When respective input data differs 20
degree or more from the theoretical value, the data does not input in the adjustment or the angle
input sensor input value may be failed.
ERROR
CODES
Boom raise data failure : A045
Arm in data failure : A055
Arm out data failure : A065
Offset right data failure : A075
Offset left data failure : A085
26-24
㨇31. DISASSEMBLING AND ASSEMBLING㨉
31. DISASSEMBLING AND ASSEMBLING

TABLE OF CONTENTS
31.1 EXPLAINING CHAPTER OF WHOLE DISASSEMBLY & ASSEMBLY ääääääääääää31-3

31.1.1 FORM FOR CHAPTER OF DISASSEMBLY & ASSEMBLY äääääääääääääää31-3
31.1.2 INDICATION OF TIGHTENING TORQUE äääääääääääääääääääääää31-3

Book Code No. S5YN3129E01
31-1

SK200-8 : YN12-56001~ S5YN3129E01
First Edition December, 2008
SK210LC-8 : YQ12-08001~ (SE Asia & Oceania)
September, 2012 75SR-3 : YT08-30001~

(NA)
SK75SR-3 : YT07-25001~
(SE Asia & Oceania)
SK85MSR-3 : LF07-05001~
(OCE)
October, 2012 E85CMSR : LF08-05501~

(NHK-EUR)
85CS-3 : LF08-05501~
(NA)
November, 2012 SK75-8 : LG01-H5001~

(SE Asia)
E160CBR : LH02-01501~
(NHK-EUR)
ED160BR : LH02-01501~
(NA)
December, 2012 SK850LC-2 : LY03-

(NA)
May, 2013 SK500LC-9 : YS12-03001~

(OCE)
June, 2013 SK210LC-9 : YQ13-10001~

(NA)
SK260LC-9 : LL14-08001~
(NA)
SK330-9 : LC12-15001~
SK350LC-9 : YC12-10001~ (NA)
July, 2013 SK500LC-9 : YS12-03501~

(NA)
August, 2013 ED160-3 : LH02-01501~

(EUR)
ED160-3 : LH02-01501~
(NA)
SK75SR-3E : YT08-30001~
(NA)
SK85CS-3E : LF08-05501~
(NA)
SK130HDL-8B : LX08-T0101~
(TKCM)
SK140SRLC-3 : YH07-09001~
(NA)
September, 2013 SK230SRLC : LA07-03001~

(NA)
SK260SRLC : YU07-04028~
(NA)
October, 2013 SK75SR-3E : YT08-30001~

(EUR)
31-2
31.1 EXPLAINING CHAPTER OF WHOLE DISASSEMBLY &

ASSEMBLY
31.1.1 FORM FOR CHAPTER OF DISASSEMBLY & ASSEMBLY

This chapter is consist of 3-Section as follows.
(1) ATTACHMENTS : Chapter 32

1) Removing and Installing
2) Disassembling and Assembling
a. Cylinder
(2) UPPER STRUCTURE : Chapter 33
a. Hydraulic pump
b. Control Valve
c. Pilot Valve (ATT)
d. Pilot Valve (Travel)
e. Slewing Motor
f. Swivel Joint
(3) TRAVEL SYSTEM : Chapter 34
a. Travel Motor
31.1.2 INDICATION OF TIGHTENING TORQUE

Tightening torque is indicated as follows, for example ;
T=98N-m(72 lbf-ft)
Tolerance is to 10% unless otherwise specified.
࡮ Refer to "Chapter 11 TOOLS" for standard tightening torque.

31-3
㨇32. ATTACHMENTS㨉
32. ATTACHMENTS
TABLE OF CONTENTS
32.1 REMOVING AND INSTALLING ääääääääääääääääääääääääääääää32-3

32.1.1 ATTACHMENT ASSY ääääääääääääääääääääääääääääääää32-3
32.1.2 BUCKET ääääääääääääääääääääääääääääääääääääää32-3
32.1.3 ARM ääääääääääääääääääääääääääääääääääääääää32-6
32.1.4 BOOM äääääääääääääääääääääääääääääääääääääää32-9
32.1.5 DOZER äääääääääääääääääääääääääääääääääääääää32-14
32.2 DISASSEMBLING AND ASSEMBLING ääääääääääääääääääääääääää32-15
32.2.1 CYLINDER äääääääääääääääääääääääääääääääääääää32-15

32-1

S5YT3217E01
First Edition September, 2012 E75CSR : YT08-30001~
(NHK-EUR)
October, 2013 SK75SR-3E : YT08-30001~

(EUR)
PREFACE
(1) This Manual describes all the procedures from removing to attaching, arranging them by item.
(2) This Manual consists of 2 sections. "Removing and Installing", and "Disassembling and
Assembling".
(3) The removing and installing can be performed in the procedure specified in Table of Contents,
but in view of actual repairing or time saving some process can be omitted.
(4) The removing and installing procedure does not completely cover all possible situations because of
differences of field condition and defective section.
(5) Please be aware that the procedure to be followed must be determined according to the above
conditions.
When disassembly and assembly are required, select the necessary section, itemize the work
contents with good understanding, then starts working.
32-2
32.1 REMOVING AND INSTALLING
32.1.1 ATTACHMENT ASSY
Front attachment and position
32.1.2 BUCKET
32.1.2.1 REMOVING BUCKET
(1) Put the machine in position to remove
bucket.
Position to remove bucket
(2) Removing pin (2)

Expand slit of ring (1) with screwdriver, and
remove it. Push out the pin (2) with
flat-blade screwdriver .

Removing pin (2)
32-3
(3) Removing bucket attaching pin (K)

Lift up bucket, position it so that bucket
attaching pin (K) is not loaded, adjust
bucket link, and pull out bucket attaching
pin (K).
Removing bucket attaching pin
(4) Removing bucket drive pin (J)

Put bucket on the ground, position it so
that the bucket drive pin (J) is not loaded,
adjust bucket link, and pull out pin (J).
Store the removed pin (J) in original
position again.
Removing bucket drive pin
32.1.2.2 ATTACHING BUCKET

(1) Attaching bucket drive pin (J)
Attach bucket drive pin (J) first, then
continue in the reverse procedure of
removing.
Attaching bucket
-When aligning the pin holes, do not put your finger in the pin holes, but align them visually.
-Check the seals for damaged and replace as necessary.
-When inserting the pin, coat the shaft with grease.
32-4
32.1.2.3 PROCEDURE FOR ADJUSTING CLEARANCE

Adjustment of clearance between bucket and arm
(1) Shift O-ring (3) toward the bucket boss,

using a spatula. (a-->b)
(2) When adjusting clearance (B), bring the
non-adjusting side of the bucket in contact
with the arm.
(3) Measure clearance (B) and check that it is
within 1.0 mm (0.04 in).
(4) Adjust clearance (B) where it is more than
1.0 mm (0.04 in).
(5) An average of 5 shims (8) of 1mm
(0.04in) thickness are set in the plate (6)
fixed by the three capscrews (10). The
clearance can be decreased by 1mm Adjusting clearance between bucket and arm
(0.04in) if one shim is removed.
Tools: Socket: 19 mm,
Tightening torque : 279 N-m (206 lbf-ft)
(6) After adjustment, tighten the capscrews
evenly.
-The gap exceeding the specified dimension
causes early wear.
(7) Operate the bucket and confirm that the
total sum of both clearance is within 1.0
mm (0.04 in).
(8) Replace O-ring (3) on its original position.
-When shifting O-ring (3) by means of a spatula, use care so as not to damage O-ring (3).
-Remove shims (8), push out bushing (7) rightwards by means of three capscrews (10) and adjust
clearance (B) so it settles within the standard value evenly all round.
-Check the clearance at 120 hours' intervals in normal operation. Shorten these intervals in special
hard operation. Adjust the intervals as necessary.

32-5
32.1.3 ARM
32.1.3.1 REMOVING ARM
(1) Put the machine in position to remove arm.
Extend the arm cylinder, retract the bucket
cylinder and bring the arm down on the
ground.
Position to remove arm
(2) Disconnecting piping of bucket cylinder

Release pressure of hydraulic tank, place
oil pan to prepare for oil leaking, and
disconnect pipes.
When the removal of bucket cylinder is
not required, skip to procedure (6).
Disconnecting piping of bucket cylinder
Plug both end of disconnected pipes.

Plug : Tools section 11.5.2-(4, 5)
(3) Removing bucket cylinder rod pin (H)

1. Loosen nut (7), remove capscrew M12X100 (6), and push out pin (H).
Tools: Spanner: 19mm
2. Retract cylinder rod.
Detail of bucket cylinder rod pin (H)
32-6
(4) Removing cylinder head pin (G)

Loosen nut (3), remove capscrew
M12X100 (2), and push out pin (G).
Detail of bucket cylinder head pin (G)
(5) Removing bucket cylinder

Sling tube of bucket cylinder with nylon
sling, and remove it.
Bucket cylinder weight: 48 kg (106 lbs)
Slinging bucket cylinder
(6) Removing arm cylinder rod pin (E)

Loosen nut (3), remove capscrew (2) M14X115, and push out arm cylinder rod pin (E).
Retract arm cylinder rod, and return pin (E) to the original position (hole).
Detail of arm cylinder rod pin (E)

32-7
(7) Removing boom top pin (F)

Loosen remove capscrew (2) M10X25, and
pull out boom, top pin (F).
Put block between arm cylinder and boom.
Insert pin (F) into the original hole.
Detail of boom top pin (F)
(8) Slinging arm assy

Sling arm with nylon sling and remove it.
Arm weight:
230 kg (507 lbs) (with bucket cylinder)
180 kg (397 lbs) (without bucket cylinder)
Slinging arm assy
32.1.3.2 ATTACHING ARM

Instal the arm in the reverse order of removing, paying attention to the following:
1. When aligning the pin holes, do not put your finger in the pin holes, but align them visually.
2. Check the seals for damage and replace as necessary.
3. When inserting the pin, coat the shaft with grease.
4. Pin lock nut handling procedure

5. When installing the arm and the cylinder,
inspect the clearance in the thrust
direction of the pins and decide the
thickness of shims by referring to the
Maintenance Standard.
6. Tightening torque
32-8
32.1.4 BOOM
32.1.4.1 PREPARATION FOR REMOVING AND ATTACHING BOOM
When removing and attaching boom in the position shown in below Fig. to remove and attach boom
foot pin (A), removing and attaching of cab and guard are required.
32.1.4.2 REMOVING BOOM

(1) Put the machine in position to remove
boom.
Place top end of boom down on block, etc.
giving attention for arm cylinder rod not to
be extended.
Position to remove boom
(2) Lifting up boom cylinder temporarily

Lift up boom cylinder temporarily to
prevent it from dropping.
Lifting up boom cylinder temporarily
(3) Removing boom cylinder rod pin (C)

Loosen nut (7), remove capscrew (3)
M12X125, and push out pin (C).
(4) Preparing for separating cylinder pipes
Retract boom cylinder rod side, and place
one side of cylinder on block (See Fig.
"Lifting up boom cylinder temporarily")
Detail of boom cylinder rod pin (C)
32-9
(5) Separating piping of arm cylinder and bucket cylinder

Release pressure in hydraulic tank, and separate pipe at section E-E.
After separation of pipe, plug every pipe.

Plug : Tools section 11.5.2-(4)
Boom piping disconnection
(6) Lifting up boom assy temporarily

Lift up boom cylinder with nylon sling so that boom foot pin (A) is not loaded.
Weight of boom assy : 643 kg (1418 lbs)
Boom assy temporarily lift up procedure
32-10
(7) Removing boom foot pin (A)

1.
Remove snap pin (3) and pull out pin (2).
2.
Tools to Thread M16 X 54 for pin (1) :
Screw slide hammer in
Refer to Tool 10. Tools for boom attaching
pin.
3.
Force slide hammer in until the pin is out.
Details of boom foot pin (A) section
(8) Slinging boom assy

Sling and remove boom assy.
Weight of boom assy : 643 kg (1418 lbs)
Boom assy slinging procedure

32-11
(9) Completion of removal of front attachments

When the removing and attaching of
cylinder are not required, the work is
finished.
(10) Removing arm cylinder
Disconnect hose at A section, and plug
both ends.
Plug: TOOLS
11.5.2-(4) Plugs for ORS fitting
(11) Removing arm cylinder head pin (D)
Loosen nut (3), remove capscrew (2) and
pull out pin (D).
Removing arm cylinder (2).
Weight of arm cylinder: 68 kg (150 lbs) Removing arm cylinder
(12) Removing boom cylinder

Disconnect hose at B section. Plug both
ends.
plug : Tools section 11.5.2-(4)
(13) Removing boom cylinder foot pin (B)
Loosen capscrew (4) and pull out pin (B).
Removing boom cylinder
32-12
32.1.4.3 ATTACHING BOOM

(1) Attaching boom foot pin (A)
Screw tool 10. slide hammer M16 into boom foot pin (A) first, and fit boom assy.
Attach it in the reverse procedure of removing paying attention to the following points.
1. When aligning the pin holes, do not put

your finger in the pin holes, but align them
visually.
2. Check that the dust seals is not damaged
and replace as necessary.
3. When inserting the pin, coat the shaft with
grease.
4. M12 Tightening torque : 115 N-m (85 lbf-ft)
Boom cylinder head pin (B)
5. Pin lock nut handling procedure
6. To attach shim, fit resin shim on operating

side and iron shim on the outside, and
reduce the space.
Attaching boom cylinder head pin

32-13
32.1.5 DOZER
32.1.5.1 REMOVAL
(1) Put a support of appropriate height under
the mounting side of dozer body, and make
the dozer at a stable condition not to
exert any load to the pin (P).
(2) Disconnect the hydraulic hoses and apply a
plug to the connecting portions.
Tools : Spanner : 22mm
(3) Apply a nylon sling to the dozer cylinder
(C1), and lift it up slightly not to exert any
load to the pin (Q) of rod side. Removing / Installing Dozer
(4) Remove the capscrew (C2) and nuts (C3)
those are preventing the pin (Q) from
coming out. Remove the pin (Q), and
support the cylinder (C1) with wood block,
etc.
(5) Remove the capscrew (B2) and nuts (B3)
that are preventing the dozer body fixing
pin (Q) from coming out, and remove the
two pins (P).
(6) Gradually move the machine to backward
to remove the dozer.
Weight of dozer assy : 326kg (719 lbs)
(7) If necessary, remove the dozer cylinder by
means of removing the pin (R) of head
side.
Weight of dozer cylinder : 51kg (112 lbs)
32.1.5.2 INSTALLATION
The installation is carried out with the reverse order of the removal paying attention for the following.
(1) Referring to the Section "ATTACHMENT

DIMENSIONS" of Specifications, replace the
worn-out bushings and dust seals to new
ones.
(2) Before installing pin (P), (Q) and (R),
apply grease to their shaft area.
(3) Referring to right Fig., install the nuts for
capscrew to prevent the pin from coming
out.
Tools : Spanner : 19mm Tightening Procedures for Nuts
32-14
32.2 DISASSEMBLING AND ASSEMBLING
32.2.1 CYLINDER
32.2.1.1 PREPARATION BEFORE DISASSEMBLY
Before disassembly, secure a dustfree workshop and necessary equipment and facilities.
32.2.1.1.1 WORK AREA

The following working area is required for disassembly:
(1) Ample space
For the disassembly of the hydraulic cylinder, the cylinder tube and the piston rod must be drawn
out. For this reason, the first condition is that the working area is long enough for the work. In
terms of width, it is also necessary to keep sufficient space to disassembly, cleaning and
measuring equipment are placed and the work can be performed.
(2) Suitable working environment
The hydraulic cylinder is a precision-machined product that uses seals and packings made of
rubber and plastic materials. For this reason full care should be exercised so the hydraulic cylinder
is free from dust, dirt, and in particular, such hard particles as sand, metal chips, and weld slag
(spatter). If the hydraulic cylinder is assembled with hard particles adhered on such components
as the cylinder tube and the piston rod, the tube inner surface and the rod surface are scratched
as the cylinder operates, consequently disabling it in worst cases. Damage to the piston seals
and the rod seals will result in oil leaks. For this reason, grinding and welding operation should
not be performed in the neighborhood of the working area to keep it clean.
32.2.1.1.2 APPARATUS
The following equipment are required for disassembly:
(1) Hoist or crane
The hoist or crane must be capable of carrying the cylinder in an assembled condition. It must
also be capable of making level and liner movement under load for retracting and extending the
piston rod and the tube.
(2) Work bench
The work bench must have strength and rigi-dity capable of accommodating the total length of
the cylinder in its most retracted condition and of withstanding the repulsive force of the
tightening torques of the cylinder head and the piston nut. Since a vise is attached to the bench,
the width of the work bench must be sufficiently large.
(3) Support stand
If the piston rod is fully extended in a free condition, the bushing and the seals may be
damaged as the rod bushing and the piston are twisted due to the weight of the rod. A stand is
required to support the rod to prevent damage of seals.
(4) Hydraulic source
A Hydraulic source is required for disassembly and assembly of the cylinder head and piston nut
and for oil leak tests after completion of assembly.
(5) Jet air source
It is used for drying after oil draining and cleaning of the cylinder.
(6) Cleaning bath, cleaning oil and detergent
(7) Oil pan and oil reservoir
An oil pan is necessary to contain oil drained from the cylinder and oil spilt during work.
(8) Others
Oil extracting hoses, wooden blocks, clean cloths and sawdust in which oil soaked are also
necessary.
32-15
32.2.1.1.3 NECESSARY TOOLS

List of Tools and Jigs
Tool/Jig Remarks Tool/Jig Remarks
Hammer 1. Steel hammer Spatula Metallic one with smooth corners.
2. Wooden or plastic hammer
Screwdriver A few types of large and small sizes Gimlet A sharp-point tool may be used in
place of a gimlet.
Chisel Flat chisel Special jig 1. For fitting seal ring
2. For pushing seal ring
3. For inserting bushing
4. For press-fitting wiper ring
Vise One having an operation wide enough to Rust
hold cylinder head O.D. and tube remover
mounting pins (clevis)
Wrench 1. Eye wrench Measuring 1. Slide caliper
2. Allen wrench instruments 2. Micrometer
3. Extension pipe for wrenches 3. Cylinder gauge (Fig. "Cylinder gauge")
4. V-block
࡮ For the details of special tools and jigs, refer to the back pages of this manual.
32.2.1.1.4 EXTERNAL CLEANING

The cylinder taken off the excavator has dust
and foreign matter, and grease is usually
adhered to the clevis part. For this reason,
Cylinder gauge
remove external soil and contamination from the
cylinder with water and steam before bringing
it into the workshop.
-The following describes the construction of
arm cylinder (with cushions on both sides).
When disassembling and servicing the cylinder,
confirm the construction of cylinder referring to
Parts Manual.
32.2.1.1.5 DISCHARGING OIL

Place a wooden-block on the work bench and
place the cylinder on it to prevent it from
rotating. Charge air into ports A and B
alternately to actuate the piston rod till the
hydraulic oil in the cylinder is drained out. At
this time, connect a suitable hose to each port
so that the hydraulic oil may not gush out.
Preparation
32-16
32.2.1.2 CONSTRUCTION OF CYLINDER (AN EXAMPLE OF ARM CYLINDER)
Construction of cylinder (An example of arm cylinder)
No. NAME Q'ty No. NAME Q'ty No. NAME Q'ty

1 CYLINDER TUBE ASSY 1 11 O-RING 1 21 CUSHION BEARING 1
2 PISTON ROD ASSY 1 12 HOLDER 1 22 CUSHION SEAL 1
3 ROD COVER 1 13 BACKUP RING 1 23 STOPPER 2
4 BUSHING 1 14 CUSHION BEARING 1 24 SNAP RING 1
5 SNAP RING 1 15 CUSHION SEAL 1 25 PIN BUSHING 4
6 BUFFER RING 1 16 PISTON 1 26 WIPER RING 4
7 U-RING 1 17 SEAL RING ASSY 1
8 WIPER RING 1 18 SLIDE RING 2
9 O-RING 2 19 SET SCREW 1

10 BACKUP RING 1 20 STEEL BALL 1
32-17
32.2.1.3 DISASSEMBLY
࡮ Before starting disassembling and servicing, confirm the construction and supply parts referring to
Parts Manual in the separate volume, and also required tools and jig.
࡮ Figures noted just after the "Part name" correspond to the number stated in Fig. "Construction of
cylinder (An example of arm cylinder)". Other cylinders may have some different parts.
32.2.1.3.1 REMOVING ROD COVER AND PISTON ROD

(1) Fix the tube installing pin side using a vise. (Refer to 32.2.1.1.5 "Preparation".)
Take care not to damage the cylinder tube and machined surface.
Never use external pipe to stop turning.
(2) Pull piston rod (2) out about 200 mm (8

in).
Use air to push piston rod (2) out after
draining the oil because of the weight of
piston rod (2).
(3) Flatten the lock on slit section installed
between rod cover (3) and cylinder tube (1) Removing piston rod
with chisel and hammer.
(4) Lift up cylinder rod section with nylon sling
temporarily.
(5) Then, Hook a hook wrench to rod cover
(3), turn it counterclockwise and remove it.
Special tool : Refer to 32.2.1.8(7).
(6) After putting threads out of mesh, remove
the end of rod cover (3) using plastic
hammer.
Flatten the slit lock
Removing rod cover
Pulling piston rod out
In this case, apply the hoisting force equivalent to the weight of piston rod, because the weight of
piston rod weights upon the rod cover.
32-18
(7) Place pulled out piston rod assy (2) on

the wooden V-block horizontally.
Placing piston rod assy
(8) Remove slide ring (18).
Removing slide ring
32.2.1.3.2 REMOVING PISTON ASSY

(1) Fix piston rod (2) grasping the installing pin
portions with vise. Then fix it in strength so
that it can withstand the tightening torque
for piston rod (2) because the piston rod
(2) is secured with large tightening torque.
Fixing piston rod assy
(2) Shave off the caulked section on set

screw (20) with hand drill, loosen set screw
and take out steel ball (21).
Removing setscrew
(3) Remove nut section of piston with a

closed wrench.
Special tool : See 32.2.1.8 (8)
-Since the piston section (16) is tightened
by high torque, use the closed wrench
closely fitted to the width across flat.
-Approx. 1.5 times or higher of torque is
required to loosen piston nut. So prepare
Removing piston nut
power wrench equipped with hydraulic jack
or hydraulic cylinder, if possible.
32-19
(4) Removing cushion bearing on the retraction

side.
1.
Remove snap ring (24). Strike it lightly
being careful not to damage cushion
bearing and piston rod.
2.
Move cushion bearing (21) to threaded
side, and remove stopper (23) (two pieces
type).
3. Disassembling cushioning bearing
Pull out cushion bearing (21).
4.
Expand slit (1 place) of cushion seal (22)
and remove it.
(5) Removing cushion bearing on extension

side.
1.
Pull out cushion bearing (14).
2.
Expand slit (1 place) on cushion seal (15)
and remove it.
Disassembling cushioning bearing
32.2.1.3.3 DISASSEMBLING PISTON ASSY

Removing piston seal
(1) Remove slide ring (18) by hand.

(2) Cut seal ring (17) with driver (-) and
hammer as shown in the right figure.
(3) Pull out O-ring with spatula.
(4) Strictly prohibited to use pulled out seal
parts.
Disassembling piston assy
32-20
32.2.1.3.4 REMOVING ROD COVER ASSY

Remove rod cover assy from piston rod (2). If it
is too difficult to remove, strike flange section of
rod cover (3) with plastic hammer.
Hang the rod cover assy with crane and
remove it straight horizontally.
Removing rod cover assy
Care should be taken not to damage the bushing (4) lip section of link and seal with screw of piston
rod (2) when pulling out rod cover (3).
32.2.1.3.5 DISASSEMBLING ROD COVER ASSY

(1) Removing buffer ring
1. Buffer ring (6) (Teflon made seal) is fitted
on the inside of rod cover (3). Pierce with
pointed tool on the seal, raise it, insert
spatula and take it out.
-Strictly prohibited to use the removed seal.
Construction of rod cover assy
(2) Removing U-ring (7) and wiper ring (8)

1. Remove U-ring (7) with driver, etc.
2. The wiper ring (8) is press-fitted.
Pierce with driver, etc. on rubber and
strike and remove it with driver.
-Strictly prohibited to use removed seal.

Direction of buffer ring
32-21
(3) Removing bushing (4)

Raise snap ring (5) with hooked bar and take it
out from cylinder rod cover. And press out
bushing (4) with jig. If it is too difficult to take it
out with jig, use lathe to remove it.
Removing bushing
(4) Removing pin bushing

1. Remove wiper ring (26).
2. The pin bushing (25) of piston rod (2) is
pressfitted, so press it out with a press
applying a plate to the section.
Drawing out pin bushing (rod & tube)
Where it is impossible to press it out, cut it with gas burner.
(5) Cleaning
1. After completion of cylinder disassembly, clean all the parts with detergent.
Apply hydraulic oil on them and cover them to store.
Leaving them in the as-disassembled condition causes rust, adherence of dust, etc., which may
cause malfunction after assembling.
2. Replace all of U-ring, wiper ring, O-ring and backup ring as a general rule.
Do not use volatile agents (gasoline and thinner) as they deteriorate rubber.
32-22
32.2.1.4 INSTALL
࡮ Cylinder tube assy
࡮ Piston rod assy
࡮ Rod cover assy
࡮ Piston assy
32.2.1.4.1 ASSEMBLING CYLINDER TUBE ASSY, PISTON ROD ASSY

(1) Apply hydraulic oil on the head in which
pin bushing is inserted and on the pin
bushing hole of rod.
(2) Press pin bushing (26) into cylinder tube
(1) and piston rod (2), using a press.
(3) Insert wiper ring (27) in both sides.
Pressing in pin bushing (rod & tube)
32.2.1.4.2 ASSEMBLING ROD COVER ASSY

(1) Press fit bushing (4) in rod cover (3)
applying plate on the section. After
press-fitting, check that the bushing is not
projected from the end surface (A). (See
right Fig.)
Pressing in bushing

32-23
(2) Fit snap ring (5).

(3) Apply hydraulic oil on U-ring (7) and fit it
on the U-ring groove.
Fitting U-ring
-The U-ring is harder than other seals, so fit it in the groove by hand first, then press in with pushing
bar until it is fitted with a click.
-Fitting U-ring paying attention to the direction.
-After fitting U-ring (7), check that they are free from the permanent set.
(4) Installing buffer ring assy

Buffer ring assy (6) is equipped with square
ring and slide ring.
1. Fit square ring on the groove.
2. Depress slide ring in U shape by hand
to house it in groove, and fit it pushing
out to periphery.
Installing buffer ring assy (6)
-Depress it R 6 mm (0.24 in) or more, because if the depressed R is too small, it may remain
wrinkled.
-After fitting, check that it is free from wrinkles.
-Fit it giving attention to the seal fitting direction. Reverse fitting produces high pressure between U-ring
and seal and may cause the deformation of rod cover.
-Fit slide ring so that the groove matches to the root section of square ring.
32-24
(5) Press fit wiper ring (8) by means of Jig

32.2.1.8(4).
Pressing in wiper ring
(6) Fit backup ring (10) and O-rings (9), (12).

(Attention should be paid to the fitting
order.)
Fixing back-up ring and O-ring
32.2.1.4.3 ASSEMBLING PISTON ASSY

(1) Installing seal ring assy
1. Fit O-ring so as not to be distorted.
2. Press in seal ring (17) referring to Jig
32.2.1.8(1), (2).
Installing the seal ring (17)
3. Since the seal ring (17) is extended when

fitting, press it referring to Correction jig
32.2.1.8(5).

Correcting the seal ring (17)
32-25
4. Fitting slide ring (18)

Fit it from rod side expanding slit by both
hands.
-Expand slit in minimum.
If expansion is exceeded, the ring cannot
be fitted.
-Slit is mutually shifted 90 degree.
Installing the slide ring (18)
32.2.1.4.4 INSTALLING ROD COVER ASSY ON ROD

(1) Fix piston rod assy on work bench.
(2) Apply grease (or hydraulic oil) on outside of
piston rod (2), inner surface of buffer ring
(6), U-ring (7), wiper ring (8) and bushing
(4), and slide rod cover assy on piston
rod (2) taking care not to damage the lip
of wiper ring (8). Installing rod cover assy
It may not slide smoothly due to frictional
resistance of U-ring. In this case, sling rod
cover assy horizontally with crane, and
push it striking flange of rod cover with
mallet.
Pressing rod cover
While pushing, be careful that the rod cover assy is not rotated to piston rod (2).
32-26
32.2.1.4.5 INSTALLING PISTON ASSY ON ROD

(1) Fitting cushion bearing (14) on the extension side
Before attaching piston (nut ) (16), fit cushion bearing (14). If the piston nut is attached, the bearing
can not be fitted.
1. Expand slit of cushion seal (15) and insert

it into groove piston rod (2).
2. Fit cushion bearing (14).
Fitting cushion bearing (14) on the extension

side
-Insert cushion seal (15) directing the cut out toward the thread side of rod as shown in Figure.
-Fit cushion bearing (14) directing the flat section toward as shown in Figure.
(2) Fitting cushion bearing (21) on retraction side

1. Fit cushion seal (22) in groove directing the
cutout toward the thread side.
2. Assemble cushion bearing (21) directing the
flat section toward as shown in Figure.
3. Fit stopper (23) in groove.
4. Push cushion bearing (21) to stopper (23)
fully, and strike and fit snap ring (24).
Fitting cushion bearing (21) on retraction side
Strike snap ring with plastic hammer being careful not to damage rod (2) and cushion bearing (21).

32-27
(3) Tightening piston nut

1. Insert piston (nut) (16) into rod, and
tighten piston (nut) (16) to the specified
torque.
Special tool : See Table 32-12
Tightening torque : Refer to 32.2.1.7(1).
Tightening piston nut (16)
2. Put steel ball (20) in and tighten setscrew

(19).
Tools: Allen wrench,
Tightening torque : Refer to 32.2.1.7(2).
3. Caulk 2 places on outer surface with punch.
Caulking set screw of piston nut
32-28
32.2.1.4.6 OVERALL INSTALL

(1) Place a V-block on a rigid work bench (A
wooden V block is preferable.) Mount the
cylinder tube assy (1) on it and fix the
assy by barring a bar through the
attaching pin hole to lock the assy. (See
right Fig.)
(2) Insert piston rod (2) into cylinder tube (1)
while hanging and moving it with crane.
Then, apply hydraulic oil on tube lip inner
side and piston outer surface and insert
horizontally aligning the center of piston rod
and center of cylinder tube.
-Also, the use of fork lift makes inserting Installing piston rod
easier.
-Insert piston into tube being careful that
seal ring and slide ring are not caught in
the stepped section of tube.
(3) Apply Three Bond #1901 on thread

section of rod cover and hydraulic oil on
O-ring (12), rotate rod cover assy (3) by
hand. Screw in 2 or 3 threads first, then
tighten it to the specified torque with hook
spanner wrench.
(4) Bend slit of cylinder tube toward cutout of
rod cover (3) to lock. Bending lock of slit

32-29
32.2.1.5 MAINTENANCE STANDARDS

(1) Inspection after disassembly
1. Inspection
Parts Name Inspecting Portion Inspection Item Remedy

1. Neck of rod pin Presence of crack Replace
2. Stepped part to which
Presence of crack Replace
piston is attached
3. Threads Presence of seizure Recondition or replace
4. Bend Measure degree of bend Refer to rod bend
5. Plated surface Check that:
Piston rod 1) Plating is not worn off to 1) Replace or replate
base metal
2) Rust is not present on 2) Replace or replate
plating.
3) Scratches are not present 3) Recondition or replace
6. Rod Wear of O. D. Recondition or replace
7. Bushing at mounting part Wear of I. D. Replace
1. Weld on bottom Presence of crack Replace
2. Tube at mounting part Presence of crack Replace
Cylinder tube
3. Tube interior Scratches are not present Replace if oil leak is seen
4. Bushing at mounting part Wear of I.D. Replace
1.Bushing 1) Wear on inner surface
Rod cover Replace
2) Flaw on inner surface
(2) Maintenance standards

Replace sliding parts and seal parts according to the following.
1. Bushing: Where 1/4 of circumference is worn in red copper color.
2. Seals and slide ring: Replace them when cylinder is disassembled.
3. Pin bushing: Where severe scuffing is produced.
4. Piston rod: Where the bent 0.5 mm/m (0.02 in / 3.37 in) or more is produced.
(3) Inspection after assembling

No-load performance When operating 5 time or more in full stroke at no-load, it operates smoothly with no
inspection abnormality.
Dimensional inspection Check the fully retracted length and stroke specified in drawing.
After applying test pressure specified in drawing to each stroke end for 3 minutes or
Pressure inspection
more, it is free from loosening, permanent set and oil leaking.
No-load performance Check rod section for oil leaking.
inspection (Refer to Criterion of oil leak quantity on rod section in proceeding page.)
Oil leak quantity unit mL (cc) / 10min
Oil leak Oil leak Oil leak
I. D. mm (in) I. D. mm (in) I. D. mm (in)
quantity quantity quantity
Internal leakage 32 (1.26) 0.4 100 (3.94) 4.0 160 (6.30) 10.0
inspection 40 (1.57) 0.6 125 (4.92) 5.6 180 (7.09) 12.6
50 (1.97) 1.0 140 (5.51) 6.0 200 (7.87) 15.6
63 (2.48) 1.6 220 (8.66) 20.0
80 (3.15) 2.3 250 (9.84) 22.0
32-30
(4) Criterion of oil leak quantity on rod section

Determine according to the oil ring condition produced on rod after 20 strokes in oil temperature 20
degC (68 degF) to 40 degC (104 degF). When oil ring is changed to A condition, it is in abnormality.
Refer to 32.2.1.9 "Troubleshooting", and take a measure.
Oil ring condition on rod section
32.2.1.6 GENERAL TOOL

32-31
32.2.1.7 TIGHTENING TORQUE

(1) Piston nut
(2) Setscrew
(3) Rod cover
(4) For piping
32-32
32.2.1.8 TOOL AND JIGS LIST

(1) Seal ring fitting jig ( I )
Material : Mild steel
Unit: mm(in)
Applicable
D0 D1 (D2) D3 L0 (L1) L2
cylinder
Boom 111 (4.3701) 110 (4.3307) 86 (3.39) 96 (3.78) 100 (3.94) 72 (2.83) 24 (0.9449)
Arm 96 (3.7795) 95 (3.7401) 71 (2.80) 81 (3.19) 100 (3.94) 72 (2.83) 23 (0.9055)
Bucket 81 (3.1890) 80 (3.1496) 56 (2.20) 66 (2.60) 100 (3.94) 72 (2.83) 20 (0.7874)
Dozer 121 (4.7638) 120 (4.7244) 96 (3.78) 106 (4.17) 100 (3.94) 72 (2.83) 24 (0.9449)
(2) Seal ring fitting jig ( II )

Material : Nylon or acrylic resin
Unit: mm(in)
Applicable
D0 D1 L
cylinder
Boom 112 (4.41) 104 (4.09) 100 (3.9370)
Arm 97 (3.82) 89 (3.51) 100 (3.9370)
Bucket 82 (3.23) 74 (2.91) 100 (3.9370)
Dozer 122 (4.80) 114 (4.49) 100 (3.9370)
32-33
(3) Bushing press-fit jig

Unit: mm(in)
Applicable
D0 D1 (D2) D3 L0 (L1)
cylinder
Boom 85 (3.3465) 79.5 (3.13) 78 (3.07) 105 (4.13) 65.5 (2.58) 59.5 (2.3425)
Arm 75 (2.9528) 69.5 (2.74) 68 (2.68) 95 (3.74) 65.3 (2.57) 53.3 (2.0984)
Bucket 60 (2.3622) 54.5 (2.15) 53 (2.09) 80 (3.15) 20.5 (0.807) 8.5 (0.3346)
Dozer 85 (3.3465) 79.5 (3.13) 78 (3.07) 105 (4.13) 25.5 (1.00) 13.5 (0.5315)
(4) Wiper ring (rod cover) press-fit jig

Unit: mm(in)
Applicable cylinder D0 D1 D3
Boom, Dozer 70 (2.7559) 78.5 (3.0905) 95 (3.74)
Bucket 55 (2.1654) 63.5 (2.5000) 80 (3.15)
Arm 65 (2.5591) 73.5 (2.8937) 90 (3.54)
32-34
(5) Seal ring straightening jig

Unit: mm(in)
Applicable
D0 (D1) L0 (L1)
cylinder
Boom 110 (4.3307) 130 (5.12) 120 (4.72) 40 (1.57)
Arm 95 (3.7401) 115 (4.53) 120 (4.72) 40 (1.57)
Bucket 80 (3.1496) 100 (3.94) 120 (4.72) 40 (1.57)
Dozer 120 (4.72) 140 (5.51) 120 (4.72) 40 (1.57)
(6) Piston insert jig

Unit: mm(in)
Applicable
øA øB øC D E
cylinder
Boom 122 (4.80) 110 (4.3307) 113 (4.4488) 67 (2.64) 42 (1.65)
Arm 107 (4.21) 95 (3.7401) 98 (3.8583) 67 (2.64) 42 (1.65)
Bucket 92 (3.62) 80 (3.1496) 83 (3.2677) 62 (2.44) 37 (1.46)
Dozer 132 (5.20) 120 (4.7244) 123 (4.8425) 62 (2.44) 37 (1.46)
32-35
(7) Hook wrench
Unit: mm (in)
Applicable
A B C t D r f L
cylinder
138
Boom 12 (0.4724) 5 (0.1969) 15 (0.591) 2 (0.0787) 86 (3.39) 12 (0.472) 380 (15.0)
(5.433)
120
Arm 12 (0.4724) 4.5 (0.1772) 15 (0.591) 2 (0.0787) 80 (3.15) 12 (0.472) 380 (15.0)
(4.7244)
104
Bucket 10 (0.3937) 4.5 (0.1772) 15 (0.591) 2 (0.0787) 68 (2.68) 9 (0.354) 320 (12.6)
(4.094)
140
Dozer 12 (0.4724) 5 (0.1969) 15 (0.591) 2 (0.0787) 93 (3.66) 12 (0.472) 460 (18.1)
(5.5118)
(8) Eye wrench
Unit: mm (in)
Applicable L=300 (11.8) L=500 (19.7)

Size A
cylinder B1 B2 t B1 B2 B3 t
Boom 80 (3.1496) 110 (4.33) 78 (3.07) 28 (1.10) 122 (4.80) 107 (4.21) 87 (3.43) 28 (1.10)
Arm 75 (2.9528) 95 (3.74) 67 (2.64) 25 (0.984) 104 (4.09) 90 (3.54) 78 (3.07) 25 (0.984)
Bucket 60 (2.3622) 95 (3.74) 67 (2.64) 16 (0.630) 104 (4.09) 90 (3.54) 78 (3.07) 16 (0.630)
Dozer 80 (3.1496) 110 (4.33) 78 (3.07) 28 (1.10) 122 (4.80) 107 (4.21) 87 (3.43) 28 (1.10)
32-36
32.2.1.9 TROUBLESHOOTING
Failure on hydraulic cylinder and corrective action
It is very difficult to find defective section. The following table explains general phenomenon, estimated
causes and corrective actions.
For repair, refer to the estimated causes and corrective actions.
However, Most machine problems are not caused by the failure of only one part, but involve relations
with other parts.
Therefore corrective action other than those described in Table is often required. Please contact us to
pursue the problems and causes further and to take appropriate corrective action.
Items Phenomenon
Oil leakage from piston rod sliding section
1
(For criterion, refer to 32.2.1.5(3).)
2 Oil leakage from rod cover set section
3 Oil leakage from pipe and cylinder tube weld zone
4 Malfunction

32-37
32-38

32-39
32-40
㨇33. UPPER SLEWING STRUCTURE㨉

33. UPPER SLEWING STRUCTURE

TABLE OF CONTENTS

33.1.1 OPERATOR SEATääääääääääääääääääääääääääääääääää33-3
33.1.2 CAB ääääääääääääääääääääääääääääääääääääääää33-5
33.1.3 BATTERY ääääääääääääääääääääääääääääääääääääää33-8
33.1.4 GUARD äääääääääääääääääääääääääääääääääääääää33-10
33.1.5 UNDER COVER äääääääääääääääääääääääääääääääääää33-15
33.1.6 FUEL TANKäääääääääääääääääääääääääääääääääääää33-16
33.1.7 HYDRAULIC TANK äääääääääääääääääääääääääääääääää33-18
33.1.8 HYDRAULIC PUMP äääääääääääääääääääääääääääääääää33-22
33.1.9 AIR CLEANER äääääääääääääääääääääääääääääääääää33-25
33.1.10 MUFFLER äääääääääääääääääääääääääääääääääääää33-27
33.1.11 COUNTERWEIGHT äääääääääääääääääääääääääääääääää33-29
33.1.12 RADIATOR & OIL COOLERäääääääääääääääääääääääääääää33-30
33.1.13 ENGINE ääääääääääääääääääääääääääääääääääääää33-37
33.1.14 CONSOLE COVER äääääääääääääääääääääääääääääääää33-40
33.1.15 CONTROL VALVE äääääääääääääääääääääääääääääääää33-42
33.1.16 PILOT VALVE (FOR ATT) äääääääääääääääääääääääääääää33-45
33.1.17 PILOT VALVE (FOR TRAVEL) äääääääääääääääääääääääääää33-47
33.1.18 SWING MOTOR UNIT äääääääääääääääääääääääääääääää33-49
33.1.19 SWIVEL JOINTäääääääääääääääääääääääääääääääääää33-52
33.1.20 UPPER FRAME ääääääääääääääääääääääääääääääääää33-55
33.2.1 HYDRAULIC PUMP - REGULATORääääääääääääääääääääääääää33-58
33.2.2 CONTROL VALVE ääääääääääääääääääääääääääääääääää33-73
33.2.3 PILOT VALVE (FOR ATT) ääääääääääääääääääääääääääääää33-89
33.2.4 PILOT VALVE (FOR TRAVEL) ääääääääääääääääääääääääääää33-102
33.2.5 SWING MOTOR UNIT ääääääääääääääääääääääääääääääää33-112
33.2.6 SWIVEL JOINT äääääääääääääääääääääääääääääääääää33-128
Book Code No. S5<733E01
33-1

S5YT3323E01
(EUR)
PREFACE
(1) This Manual describes all the procedures from removing to installing, arranging them by item.
(2) This Manual consists [Removing and installing], and [Disassembling and assembling].
(3) The removing and installing can be performed in the procedure specified in Table of Contents,
but in view of actual repairing or time saving some process can be omitted.
(4) The removing and installing procedure does not completely cover all possible situations because of
(5) Recognize well that the service man must decide a work procedure before proceeding to repair.
When deciding the work procedure, choose an item that is needed, familiarize yourself with the
contents of the work and itemize the work procedure, before starting work.
(6) Disconnect the negative terminal of battery first, when the removing and the installing of the
electric component and wiring are performed.
(7) The explanatory note and figure of this manual may differ from the actual machine by the
difference in specification.
33-2

33.1.1 OPERATOR SEAT
33.1.1.1 REMOVAL
(1) Preparation for removal
1. Remove the head rest (A1-1) of the operator's seat (A1) to ease handling.
2. Move the whole control stand to its foremost position.
3. Move the operator's seat to its forward end.
4. Incline the reclining seat as forward as possible.
(2) Remove operator's seat. (Include upper rail.)

1. With the above-mentioned condition, remove
two cap screws (B2) M8X20 from the upper
rail. Then move the control stand to its
rearmost end and remove two capscrews
(B2) M8X20.
Tools: Allen wrench: 6 mm
2. Remove the operator's seat. [about 44 kg
(97 lbs).]
Carry out the following operations as
required.
3. Remove seat belt (C1), bracket (C2).
4. Remove armrest (A3)(A4).
5. Remove bracket assy (1), rail (7).
Disassembling and Assembling seat
33-3
Install it in reverse procedure of removing according to the tightening torque table.
Disassembling and Assembling armrest
Reference : Movement on rail

Upper rail.....Fixed on lower surface of seat
[Forward 80mm (0.26in), backward 80mm (0.26in)]
Lower rail.....Fixed on seat stand.
[Forward 60mm (0.19in), backward 60mm (0.19in)]
Amount of adjustment of seat height
[Up; 23mm (0.07in), down; 37mm (0.16in)]
Suspension stroke
[Up; 37.5mm (1.48in), down; 37.5mm (1.48in)]
33-4
33.1.2 CAB
33.1.2.1 REMOVAL
(1) Remove floor mat.
(2) Remove cover assy (A8).
1.
Remove 3 caps (A15) and loosen 4 sems
bolts (A38) M6X20.
Tools: Phillips screwdrive
2.
Disconnect harness connector of power
socket and remove cover assy (A8).
(3) Removal of cover assy (A10).
1.
Loosen 2 sems bolts (A38) M6X20.
Tools: Phillips screwdriver
2.
Remove cover assy (A10).
(4) Removal of harness connector.
(See Chapter 23 "Electric System")
1.
Disconnect connectors of cab harness at
rear right of cab.
2.
Disconnect antenna cable for tuner located
at rear left of cab.
3.
Disconnect harness for cab light located at
rear left of cab.
(5) Removal of cover assy (A1).
1.
Disassembly and assembly of right panels
Loosen 2 sems bolts (A38) M6X20.
(A1), (A8) and (A10)
Tools: Phillips screwdriver
2.
Disconnect harness connector of hour-meter
and remove cover assy (A1).
(6) Remove plastic tube for window washer
located at right front of cab.
33-5
(7) Removal of mechatro-controller

1.
Loosen 4 sems bolts (B9) M6X25.
2.
With harnesses are connected condition,
remove mechatro-controller, and place it in
front of it temporally.
Removal of mechatro-controller
(8) Removal of cab attaching bolts

1.
Loosen 4 capscrews (C1) M12X35.
2.
Loosen 4 nut (D4) M16.
Removing and installing cab mounting bolts
Removing and installing cab mounting bolts
33-6
(9) Slinging cab

1.
Remove 2 plastic plugs at the front of the

ceiling of the cab, and attach 2 eyebolts.
Then hook slinging wires to eyebolts as
shown in figure.
2.
Then lift up cab slowly avoiding interference
with surroundings.
Wire with hook;
Length 1.5m (4ft 11in) X Dia. 10mm
(0.4in) X 4pcs.
Weight of cab; Approx. 386kg (851lbs)
Slinging cab
33.1.2.2 Installation
Install it in reverse order of removing according to the Tightening Torque Table.
33-7
33.1.3 BATTERY
33.1.3.1 REMOVING
(1) Open left hand cover (1).
1.
Open it with starter key.
2.
Open left hand cover (1).
3.
Fix it with stay.
(2) Remove battery cover (A1)
1.
Loosen 3 clips (A5) and remove plate (A6).
2.
Remove battery cover (A1).
Tools: Flat-head screwdriver, Pliers
(3) Remove battery cable
1.
Remove cable (5) [between the earth and
battery (-)].
Grounding cable for main body
(Always remove (-) terminal first and install
it at last.)
2.
Remove cable (3) [between battery (+) and
(-)]
3.
Remove cable (4) [between battery (+)
and battery relay]
Follow the battery removal order.

Start removing battery from grounding side, and finish attaching to grounding side. If this order is
missed, short-circuits may occur.
33-8
(4) Remove battery (B1)

1.
Loosen 2 capscrews (A3) M10X225.

Tools: Socket: 17mm
2.
Remove plate (A2).
3.
Remove battery (B1).
Removing and installing battery cable
33.1.3.2 INSTALL
(1) Install the battery in the reverse order of removing.
Hold down plate (A2) against battery (B1), and tighten capscrew (A3).
Tools: Socket: 17mm
Tightening torque : 10.8N-m (8.0 lbf-ft)
(2) Installing grounding cable
Install grounding cable (5) last. Especially care must be taken that the grounding face is free
from painting, rust, etc.
33-9
33.1.4 GUARD
33.1.4.1 PREPARATION FOR REMOVAL
(1) Remove guard in the following procedure.
Remove these equipments according tothe
order of items (2), (4), (3), (5), and (1).
(2) All the locked equipment, open them
usingstarter key.
Guard assy
33.1.4.2 REMOVE GUARD

(1) Remove panel assy (4-3)
1.
Unlock panel assy (4-3) and open it.
2.
Remove 2 sems-bolts M12X25.
3.
Remove panel assy (4-3).
Tools: Socket: 19mm
Weight : 14kg (31 lbs)
(2) Removing cover assy (4-1)
1.
Remove 2 sems-bolts (4-16) M10X25 and 3
sems-bolts (4-17) M10X20.
2.
Removing cover assy (4-1).
Tools: Socket: 17mm
Removing panel assy (4-3) and cover assy

(4-1)
33-10

1.
Remove 3 sems-bolts (4-17) M10X20.

2.
Tools: Socket: 17mm
1.
Remove a sems-bolt (4-17) M10X20.
2.
3.
4.
5.
Tools: Socket: 17mm
Removing panel assy (4-4) and (4-5)
(5) Remove cover assy (5-5)

1.
2.
3.
Remove cover assy (5-5).
Tools: Socket: 17mm
Weight : 1 kg (2 lbs)
1.
2.
Tools: Socket: 17mm
Weight : 3 kg (7 lbs) Removing cover assy (5-1), (5-2), (5-3), (5-4)
(7) Remove cover assy (5-3) and (5-5)
1.
2.
Tools: Socket: 17mm
33-11

1.
2.
Tools: Socket: 17mm
1.
2.
Tools: Socket: 17mm
(10) Remove bonnet assy (1-1)

1.
Unlock bonnet assy (1-1) and open it.
2.
3.
Remove bonnet assy (1-1).
Tools: Socket: 19mm
Removing bonnet assy (1-1)
(11) Remove bonnet assy (1-2)

1.
2.
Remove bonnet assy (1-2).
Tools: Socket: 17mm
(12) Remove cover assy (1-3),(1-4)
1.
2.
Remove cover (1-3).
3.
4.
Remove cover (1-4).
Tools: Socket: 17mm
Weight : 6 kg, 4 kg (13 lbs, 9 lbs)
Removing bonnet assy (1-2), cover assy (1-3)
and (1-4)
33-12

1.

2.
Tools: Socket: 17mm
(14) Remove cover assy (1-6) and (1-7)
1.
2.
Remove cover assy (1-6) and (1-7).
Tools: Socket: 17mm
1.
2.
Remove cover assy (1-5). Removing cover (1-5),(1-6),(1-7) and (1-20),
Tools: Socket: 17mm bracket assy (1-8)
(16) Remove bracket assy (1-8)

1.
2.
Remove bracket assy (1-8).
Tools: Socket: 17mm
(17) Remove left hand cover (2-1)

Remove 2 sems-bolts (2-4) M12X25
andremove left hand cover (2-1).
Tools: Socket: 19mm
(18) Remove right hand cover (2-2)
Remove 2 sems-bolts (2-4) M12X25
andremove right hand cover (2-2).
Tools: Socket: 19mm
Removing left/right hand covers (2-1) and (2-2)
33-13
(19) Remove guard assy (3-1)

1.
2.
Remove guard assy (3-1).
Tools: Socket: 17mm
(20) Remove pillar (3-2)
1.
2.
Remove pillar (3-2).
Tools: Socket: 17mm
Removing guard assy (3-1) and pillar (3-2)
(21) Remove duct (6-1) and filter (6-2)

1.
2.
3.
Remove duct (6-1) and filter (6-2).
Tools: Socket: 13, 17mm
Weight : 12 kg (27 lbs), 2 kg (4 lbs)
Removing duct (6-1) and filter (6-2)
(1) Installing is done in the reverse order of removing.
(2) Tightening torque
Tools: Socket: 13mm, M8 23 N-m (17 lbf-ft)
Tools: Socket: 17mm, M10 46.5 N-m (34.3 lbf-ft)
Tools: Socket: 19mm, M12 79.4 N-m (58.6 lbf-ft)
33-14
33.1.5 UNDER COVER

33.1.5.1 REMOVAL
(1) Remove under cover (1,2,3,4,6)
1. Remove sems bolts (7) M10X30.
2. Remove covers.
Tools: Socket: 17mm
Removing under cover assy
(1) Install under cover (1,2,3,4,6)
Tools: Socket: 17mm
Tightening torque : 46.5 N-m (34 lbf-ft)
33-15
33.1.6 FUEL TANK

(1) Draining fuel (See Fig. "Removing fuel
tank")
1.
Unlock cap (B1) with a starter key and
open it.
2.
Loosen valve (A10) under the tank.
3.
Draining fuel
Capacity of tank : 120L (32gal)
(2) Remove panel assy (4-3),(4-4).
(See 33.1.4 GUARD)
(3) Remove the connector for fuel level sensor
(A4).
(See Fig. "Removing fuel tank")
(4) Remove fuel hose
1.
Loosen clip (27) and draw out hoses (11)
and (12). Removing fuel hose (11),(12)
2.
Put in plugs that match the hose bore.
33.1.6.2 REMOVAL
(1) Remove 2 capscrews (A1) M16X40 and
remove 2 capscrews (A17) M16X60.
Tools: Socket: 24mm
(2) Hook the wire to the lifting eye on the
fuel tank assy (B6) and remove the fuel
tank.
(3) Remove shim (A3).
Removing fuel tank
Record the shim locations.
33-16
Tank attaching 2 bolts (A1) M16X40, and 2 bolts (A17) M16X60

Tools: Socket: 24 mm, Apply Loctite #262
Tightening torque: 191N-m (140 lbf-ft)
If the gap (looseness) between tank mount and frame exceeds 1 mm (0.04 inch), adjust the gap with
shim (A3) and tighten capscrew (A1),(A17) to install the tank.
33-17
33.1.7 HYDRAULIC TANK

(1) Swinging upper structure 45 degrees.
Swing upper structure to make the
removal of suction hose for pump installed
under tank easier.
(2) Necessary to remove the hydraulic oil tank.
Swinging upper structure 45 degrees
(3) Bleeding internal air of tank

Press cap by finger to bleed internal air.
Bleeding internal air of tank
Keep pressing until the hissing sound stops.
(4) Remove cover (B2)

1. Remove 6 sems bolts (B9) M8X16.
Tools: Socket: 13mm
2. Remove cover (B2).
3. Remove suction strainer (B4).
(5) Remove cover (B3)
1. Remove 6 sems bolts (B9) M8X16.
Tools: Socket: 13mm
2. Remove cover (B3).
3. Remove filter element (B7).
(6) Turn the handle of element assy (B7), and
disassemble the removed filter element (B7).
(7) Draining hydraulic oil
Place pump in tank and draw up hydraulic
oil.
Capacity of tank : 58 L (15.3gal)
Remove cover (B2),(B3)
33-18
33.1.7.2 REMOVAL
(1) Draw out the suction hose (A3)
Remove 4 clips (A23) of the tank side

and pull out hose (A3).
Tools: Flat-blade screwdriver
Removing the suction hose (A3)
(2) Remove drain hose (B1) of pump

(3) Remove hose (B2) of oil cooler (out)
(4) Remove drain hose (B4) of swing motor
(5) Remove hose (B5)
Removing hose (B1),(B2),(B4) and (B5)
(6) Remove drain hose of control valve
1. Remove hose (C2).

Remove hose (C2),(C6) and (C7)
33-19
(7) Remove pilot return hose (D3)

(8) Remove return hose (D8) of swivel joint
Removing hose (D3),(D8)
(9) Remove hydraulic tank attaching bolt

Remove 2 capscrews (E1) M16X40 and 2
capscrews (E2) M16X60.
Tools: Socket: 24mm
(10) Slinging hydraulic oil tank
Place a wire sling, using the lifting plate on
top of the tank.
Tank weight: Approx : 61kg (135 lbs)
(11) Remove shim (A3).
Removing hydraulic tank
Record the shim locations.
33-20
(1) Cleaning hydraulic oil tank
(2) Cleaning suction hose

(3) Cleaning mount of tank.
Installing is done in the reverse order of removing.
(4) Install 4 mounting capscrews (E1) M16X50 and 2 capscrews (E2) M16X60 with Loctite #262.
(See Fig. "Removing hydraulic tank".)
Tools: Socket: 24mm, Apply Loctite # 262
If the gap (looseness) between tank mount and frame exceeds 1mm (0.04 inch), adjust the gap with
shim (A3) and tighten capscrew (E1),(E2) to install the tank.
(5) Connection of suction hose

(See 33.1.8.2)
1.
Apply PERMATEX on pipe side of hose
connection and insert it.
2.
Put the hose with clip (A19).
Tightening torque: 5.39N-m (4.0 lbf-ft)
(6) Assembling return element
Assemble filter element by the use of
element kit. (See right Fig.)
(7) Install return element. (See Fig. "Remove
cover (B2), (B3)")
(8) Installing suction strainer (B4)
(9) Tighten sems bolts (B10) M8X16 that
attach tank covers (B2), (B3). Return element & suction strainer
M8 Tightening torque : 23 N-m (17 lbf-ft)
Two elements (B7-1) are used as one set.
Replace O-ring fitted on the back side of tank cover with new one.
33-21
33.1.8 HYDRAULIC PUMP

(1) Remove bonnet assy (3-1),(3-2).
(See 33.1.4 GUARD (7),(8))
(2) Remove cover assy (3-3),(3-4).
(See 33.1.4 GUARD (9))
(3) Remove counterweight.
(4) Release pressure in hydraulic oil tank.
(See 33.1.7 HYDRAULIC TANK)
(5) Remove 6 capscrews (B9) M8.
(6) Remove cover (B2).
Tools: Socket: 13mm
(7) Take out suction strainer.
(8) Install suction stopper.
For suction stopper, see Chapter "Tools".
Hydraulic oil tank
Pump can be removed even when counterweight is not removed. But removal of counterweight
facilitates working, and the working time is also reduced.
(9) Disconnect drain down pipe installed under engine muffler.
33-22
33.1.8.2 REMOVAL
(1) Disconnect 5 hoses (A1),(A2),(F1),(G1) and
(G2) from the delivery side. (See right

Fig., and Fig. "Pump port")
Tools: Spanner: 19mm, 22mm, 27mm,
36mm
(2) Remove hose (H3)
(3) Remove suction flange
1.
Remove 4 capscrews (14) M12.
2.
Loosen clip (F13).
Tools: Flat-head screwdriver
3.
Remove elbow (14) of suction hose (A3)
from pump.
Tools: Allen wrench: 10mm
Pump port
(4) Removing main pump

1.
Attach eye bolt (M8) on upper surface of
pump.
2.
Lift it with wire lightly.
3.
Remove 2 socket bolts (4) M18.
4.
Pull pump horizontally and remove it.
Weight of pump : Approx. 60 kg (132 lbs)
Removing pump
33-23
Installing pump in the reverse procedure of removal following the specification for tightening torque and
sealant.
(1) Apply grease on spline of input shaft.

Grease ; Shell Retinax AM
(General-purpose extreme-pressure
molybdenum disulfide grease)
(2) Hook wire to eye bolts (M8) on upper
surface of pump and lift it.
(3) Insert pump spline section.
Installing pump
(4) Remove suction stopper

(5) Mounting suction strainer
(6) To bleed air by loosen the air vent port.
(7) Check hydraulic oil level.
(8) Start engine and check it for oil leakage
and noise.
(9) Install guards
See 33.1.4 GUARD
Release air in pump
After replacing pump, be sure to fill hydraulic oil of 1L (0.26 gal) or more.
33-24
33.1.9 AIR CLEANER

(1) Opening bonnet assy (2)
1.
Unlock it with starter key.
2.
Open bonnet (2).
(2) Unplug terminals on indicator lines (2-5)
(See Fig. "Pulling out hose (4)")
Preparation for removal
33.1.9.2 REMOVAL
(1) Pulling out hose (3).
1.
Loosen clips (10) on air cleaner side.
2.
Pulling out hose (3)
Tools: Flat-blade screw driver
(2) Pulling out hose (4)

1.
Loosen clip (10) on air cleaner side.
2.
Pulling out hose (4).
Tools: Flat-blade screw driver
(3) Remove air cleaner assy (2)
1.
Remove 2 sems-bolts (12) M10X25.
2.
Remove air cleaner assy (2) together with
bracket (7).
Tools: Socket: 13mm
33-25
(1) Installing is done in the reverse order of
removing.
(2) Spare parts for deteriorated elements
33-26
33.1.10 MUFFLER
(1) Remove 4 sems-bolts (5) M10×20.
(2) Remove exhaust tube (2).
(3) (3) Remove 4 sems-bolts (A17).
(4) Remove cover assy (A3).
(5) Open right hand cover (B2).
Preparation for removal
33.1.10.2 REMOVAL
(1) Remove exhaust tube (3)
1.
Remove 4 sems-bolts (4) M8×25.
Tools: Socket: 13mm
2.
Remove exhaust tube (3).
(2) Remove cover (C2)
1.
Remove 5 bolts (C3).
Tools: Socket:
2.
Remove cover (C2)
Removing exhaust tube (3)
33-27
(3) Remove harness connector of sensor (C4)

(4) Remove 2 bolts (C7) and remove 2
clips(C5)
Tools: Socket:
Removing harness connector of sensor (4),

removing clips (C5)
(5) Loosen a clip (12) and pull out hose(11)

(6) Remove 4 bolts (C6)
(7) Remove 4 capscrews (7) M10×35
Tools: Socket: 17mm
(8) Remove muffler
(9) Remove 4 bolts (8)
Tools: Socket:
(10) Remove bracket
Removing and installing the muffler
Installing is the reverse order of removing with attention paid to the following items:
33-28
33.1.11 COUNTERWEIGHT
(1) Removing bonnet assy (3-2).
Remove bonnet on engine.
(See 33.1.4 GUARD)
(2) Removing bonnet assy (3-1).
(See 33.1.4 GUARD)
(3) Preparing slinging jig
Remove plug (A6), and attach weight
slinging jig (See Chapter Tools.) to
counterweight.
Lifting up counterweight
33.1.11.2 REMOVAL
(1) Lifting up counterweight temporarily
Hook wire rope to slinging jig, and lift it
and stretch wire rope to the degree where
it is providing no slack temporarily.
Weight of counterweight : Approx. 800 kg
(1760 lbs)
Wire more than ø10 (0.394") : 1.5 m (4 ft
11 in) X 2 pcs.
(2) Removing counterweight
1.
Remove 3 capscrews (A1) M20X135.
Tools: Socket: 30mm
2.
Remove shim.
Removing counterweight
(1) Install counterweight in the reverse
procedure of removing.
(2) Install shim as it was
(3) Slinging counterweight
Check that 3 attaching bolts can be
screwed in by hand.
(4) Apply Loctite #262 on capscrews (A1),
and tighten them with washers (A2).
Tools: Socket: 30mm
(5) Remove slinging tools, and attach plugs
Attaching bolts counterweight
(A6).
33-29
33.1.12 RADIATOR & OIL COOLER

(1) Remove counterweight.
(2) Bleed air from the hydraulic tank and install the suction stopper. (See 33.1.12 RADIATOR & OIL
COOLER)
(3) Remove cover of suction strainer, and adjust oil quantity so that oil level becomes lower than the
return tube level.
(4) Remove air cleaner hose
Refer to 33.1.9 AIR CLEANER
(5) Removing under cover installed on lower

side of radiator.
1.
2.
Remove cover (3).
Tools: Socket: 17mm
Removing under cover (3)
(6) Drain down of radiator

Put container 18L (4.8gal) under drain valve
hose for draining water.
[Water capacity of radiator : 4.6L (1.2gal)]
(7) Remove hose from radiator sub tank (11).
1.
Remove clip of radiator cap side and
disconnect hose (10).
2.
3.
Remove radiator sub tank (6) and guard (2).
Tools: Socket: 13mm
Removing hose of sub tank (11)
33-30

Do not loosen the joints of the hoses related to the air-conditioner. Otherwise the refrigerant leaks.
(8) Move air-conditioner condenser and receiver

tank
1.
Loosen 4 sems-bolts (22) M8X30 and
Loosen 2 sems bolts (8) M8X20.
Tools: Socket: 13mm
2.
Move a set of air-conditioner condenser and
receiver tank.
Moving condensers and receiver tank
33.1.12.2 REMOVAL
(1) Remove radiator stay (A1).
1.
Remove 2 sems-bolts (A2) M12X30.
2.
Remove 2 stays (A1).
(2) Remove water hose (3), (4).
1.
Loosen the hose bands (17), (18) for
water hose (3).
2.
Remove hose (3).
3.
Loosen hose bands (17), (18) on water
hose (4). Removing radiator assy
4.
Remove hose (4).
33-31
(3) Remove hoses (5), (7) for inter-cooler.

1.
Loosen hose band (18) and remove hose
(5).
2.
Loosen hose bands (18), (22) and remove
hose (7).
3.
Remove 2 fixing sems-bolts (19) M8X20
from tube (8).
Tools: Socket: 13mm
4.
Loosen hose bands (22), (17) and remove Removing and installing radiator stay and
hose (6) and tube (8). hose
(4) Remove box (1)

1. Remove 4 sems-bolts (20) M8X16.
2. Remove box (1).
(5) Remove duct (C1)
1. Remove 6 sems-bolts (C2) M8X20.
2. Remove duct (C1).
Removing and installing box (1) snd duct (C1)
33-32
(6) Disconnecting hydraulic oil hose (D2), (D7)

1.
Loosen 2 capscrews (D24) M10X55 for

attaching clamp (D9), (D25).
2.
Loosen 2 sems-bolts (D23) M10X25 for
attaching support (D8).
3.
Place an oil pan under the hose joint.
4.
Remove connector (D10) and disconnect
"IN" side hose (D7).
5.
Remove elbow (D13) and disconnect "OUT"
side hose (D2).
(7) Remove radiator assy.
(See Fig. "Removing radiator assy")
1.
Remove 4 sems bolts (A2) M12X30.
Tools: Socket: 19mm Removing hydraulic oil hose (D2), (D3)
2.
When lifting the engine fan, shift the
radiator so it does not interfere with the
engine fan.
3.
Plug up pipe ends with clean cloth, etc.
4.
Removing radiator
Place a wire sling in the lifting eyes of the
radiator assy and remove the assy by
crane.
33-33
removing. And removed clips of hose
should be clamped at original position.
(2) Install radiator assy
Place a wire sling in the lifting eyes of the
radiator and move it to original position
temporally. And install hydraulic hose,
radiator hose and hose of inter-cooler.
Regarding Inserting width of hose. (See
right Fig.)
(3) Radiator attaching bolt
Apply Loctite #262 on 4 semsbolts (A2)
M12X30.
Tools: Socket: 19mm
(4) Adjust the clearance between the fan and
the radiator shroud all around the
circumference, as below :
Full circumference:
20±5mm (0.8in±0.2in)
(5) Clean the plastering area of the insulation
thoroughly before plastering it.
Inserting width of hose (1/2)
33-34
(6) Making up hydraulic oil and LLC (Long Life

Coolant)
After completion of other installation, make

up hydraulic oil and water.
Coolant volume of engine body : 4.1 L
(1.1gal)
Coolant capacity of radiator : 4.0 L (1.1gal)
Hydraulic oil capacity of oil cooler : 4.2 L
(1.1gal)
33-35
33.1.12.4 PROCEDURE OF DISASSEMBLING AND ASSEMBLING THE RADIATOR/INTER COOLER

CORE
(1) Preparation for disassembly and assembly
1. Remove one under cover at the bottom of
the radiator.
2. Wait till the engine coolant cools down so
you do not get burned. Then remove the
cap of the radiator, discharge the coolant
by opening the drain valve located at the
back bottom and receive it in a container.
* In case of removing inter cooler only,
the above mentioned work is not necessary.
Removing radiator and inter-cooler
(2) Disassembly
1. Loosen 6 sems bolts (A21) M8X20 attaching shroud assy (A5), remove shroud assy (A5).
2. Loosen 2 bolts (A17) attaching radiator core.
3. After confirming that the coolant has been drained out completely, loosen and remove only the
radiator side of hose bands (18) at the top and bottom of the radiator. (See 33.1.12.2 Fig.
"Removing radiator assy")
4. Lift and remove radiator core using lifting eyes and hoist on the radiator core.
Weight : approx. 4.8 kg (11 lbs)
Confirm the missing of rubber bushing (A16) under the radiator core.
5. Loosen a bolt (A17) attaching the top of the inter-cooler core.
6. Loosen and remove only the inter-cooler side of hose bands (18) at the top and bottom of the
inter-cooler. (See 33.1.12.2 Fig. "Removing radiator assy")
7. Lift and remove inter-cooler using lifting eyes and hoist on the inter-cooler.
Confirm the missing of rubber bushing (A16) under the inter-cooler.
8. Disconnection of oil cooler hose
Disconnect hose (D2), (D7) from upper and lower of cooler, and drain hydraulic oil. (See
33.1.12.2 Fig. "Removing hydraulic oil hose (D2), (D7)")
9. Lift cooler temporally using cooler head flange for slinging.
10. Loosen 4 sems-bolts (A22) M10X25 attaching oil cooler.
11. Lift the oil cooler.
There is no predetermined sequential order in removing radiator core, inter-cooler core and oil cooler.
Removing these components can be done as necessary.
(3) Installing
33-36
33.1.13 ENGINE
33.1.13.1 PREPARATION FOR REMOVING
(1) Remove battery ground (See 33.1.3 BATTERY)
(2) Remove bonnet and guard (See 33.1.4 GUARD ) Remove under cover (See 33.1.5 UNDER
COVER)
(3) Remove air cleaner hose (See 33.1.9 AIR CLEANER)
(4) Remove counterweight (See 33.1.11 COUNTERWEIGHT)
(5) Remove radiator hose and inter-cooler hose (See 33.1.12 RADIATOR & OIL COOLER)
(6) Remove fuel hose and heater hose, and if necessary disconnect air-con hose.
(7) If necessary, remove pump, muffler and radiator.
(8) Remove harness connector (Refer to ELECTRIC SYSTEM)
1. Remove E/G ground cable
2. Starter cable-Starter B terminal
3. Upper harness
Prepare a stand, which withstands the weight of the engine assy and can place the removed engine
firmly. (Refer to Tools)
Outside view of engine
33-37
33.1.13.2 REMOVAL
Dismantling and mounting engine
(1) Remove hose of engine oil filter

Place oil pan under the connection of filter (1), and disconnect 2 hoses (4).
(2) Plug connector of filter side and hose
(3) Loosen engine mounting bolt of frame
1. Loosen 2 nuts (16) M12.

Tools: Socket: 19mm
2. Loosen 4 capscrews (12) M12X110.
3. Remove 4 plates (6).
4. Remove upper rubber mounts (5) 4 each.
(4) Slinging engine body
Prepare a stand, which withstands the weight of the engine assy and can place the removed engine
firmly. (Refer to "Tool".)
1. Sling engine hooking wire to lifting lugs on the front and rear sides.
Weight: Approx. 232kg (512lbs)
Wire: 6 dia. (0.236 in) X 1 m (3 ft 3 in) - 2 pcs.
(5) Position engine on the stand stably.
33-38

33-39
33.1.14 CONSOLE COVER

33.1.14.1 REMOVAL
(1) Removing right-hand console cover
1. Press into the "A" part of rubber boot
which is tucked into console, and remove
right rubber boot (3-4) from console.
2. Loosen 2 sems bolts (7-9) M6X16.
Tools: Plus screw driver
3. During lifting right upper console cover
(7-1B) up; disconnect connector of tuner
and antenna. Move boot (3-4) upwards
and remove console cover (7-1B).
-Removing of boot and lever is
unnecessary.
4. Loosen 3 sems bolts (1-16) M6X16 and
Removing boot (3-4)
remove lower console (1-3A).
(2) Removing left-hand console cover

1. Remove left boot (3-4) same way as right
console cover. (See above Fig.)
2. Loosen 2 sems bolts (1-16) M6X16.
3. Remove the left upper console cover (1-4D)
in the same way as right-hand console
cover.
4. Loosen 2 sems bolts (1-16) M6X16 while
lifting left under console cover (1-5E) up,
and remove left lower console cover.
Removing console covers
33-40
Install it in reverse order of removing according to the tightening torque table.

Removing left armrest
33-41
33.1.15 CONTROL VALVE

(1) Remove panel assy (4-3) (See 33.1.4.2 Fig. "Removing cover assy (4-3)")
(2) Remove cover assy (4-1) (See 33.1.4.2 Fig. "Removing panel assy (4-1)")
(3) Release air in hydraulic oil tank, open cover of suction element of hydraulic oil, and lower the
level. (See 33.1.8.1 Fig. "Hydraulic oil tank")
Mark each hose with a port name before removing it.
33.1.15.2 REMOVAL
(1) Removing hoses for each piping
Attach tag on hose, and write port name on it, then remove hoses.
33-42

33-43
(2) Remove control valve

Remove 2 sems bolts (2) M12x35, remove
sems bolt (7) M12x30 and remove control valve
(1) by hoist.
Removing main control valve
(1) Installing is done in the reverse order of remove.
Tools: Socket: 19mm
Weight of seat stand :
121 N-m (89 lbf-ft) (Bracket to upper frame)
100 N-m (74 lbf-ft) (Bracket to control valve)
(2) Make certain that attachment moves normally in operation.
(3) Check oil level and that it is free from oil leakage.
33-44
33.1.16 PILOT VALVE (FOR ATT)

The removing procedure for right and left is the same, so the preparation for left side is described
here.
(1) Put attachment on ground, stop engine

and release pressure in tank.
(2) Remove left console cover (1-4D), (1-5E)
assy referring to Section 33.1.14CONSOLE
COVER.
(3) Disconnect harness connector for horn at *
position.
(4) Attach a tag to the hose to make assembly
work easier.
Installing and removing boot and lever part
33.1.16.2 REMOVAL
(1) Remove hoses from your side to far side in
order.
Tools: Spanner: 19mm, 22mm
(2) Move the boot (3-4) up and loosen nut
(3-3).
(See above Fig.)
(3) Turn and loosen lever (3-1B) tightened in
pilot valve, and remove lever assy in a set.
(See above Fig.)
(4) Remove 4 capscrews (A14) M6X25. (See
right Fig.)
(5) Remove pilot valve.
(6) Plug hose ends.
Plug PF1/4, PF3/8 Pilot valve connector
33-45
Install it in the reverse order of removal and
tighten it.
T = 11.8 N-m (11 lbf-ft) capscrew (A14)
Pilot valve port position (from upper side)
Make sure the tightening torque for capscrews, because pilot valve is made of aluminum.
33-46
33.1.17 PILOT VALVE (FOR TRAVEL)

(1) Release pressure in hydraulic oil tank
(See 33.1.7 HYDRAULIC TANK)
(2) Remove under cover (3) (See 33.1.5
UNDER COVER)
(3) Remove floor mat (B1).
Removing floor mat, pedal and and lever
33.1.17.2 REMOVAL
(1) Separate the two pressure sensors SE-9
(A11) and SE-10 (A11) at the connector.
(2) Attach tag, and discount connectors and
hoses (A2), (A3), (A6), (A7)
Tools: Spanner: 19mm (P port)
Tools: Spanner: 19mm, 22mm (T port, 1
to 4 port)
(3) Plug hose ends
Plug PF1/4, PF3/8
(4) Remove 4 sems bolts (A8) M8X25, and
remove right and left pedals (A5), (A6).
(5) Remove 4 sems bolts (A7) M10X20 and
remove right and left lever (A1), (A2).
Tools: Socket: 17mm
(6) Remove 4 sems bolts (A13) M10X30.
(7) Remove pilot valve lifting it upward.
(8) Stop up holes with plugs PF1/4.
Installing and Removing pilot valve
33-47
Install it in the reverse order of removal and tighten it.
Sems bolt (A13)
Tools: Spanner: 17mm T = 37 N-m (27.3 lbf-ft)
Sems bolt (A7)
Tools: Spanner: 17mm T = 35 N-m (25.8 lbf-ft)
Sems bolt (A8)
Tools: Socket: 13mm T = 23.5 N-m (17.3 lbf-ft)
Pressure sensor
Tools: Spanner: 24mm T = 16.7 N-m (12.3 lbf-ft)
33-48
33.1.18 SWING MOTOR UNIT

(1) Park machine on flat and solid ground and
put attachment and dozer on ground.
(2) Operate the switch on gauge cluster and
select the pressure release mode, and
then release the inner pressure in circuit by
operating control lever. (See HYDRAULIC
SYSTEM)
(3) Release internal pressure through bleeder
of hydraulic oil tank.
(4) Remove boom as necessary to make work
easier. (Refer to chapter of Attachment.)
(5) Remove cab if necessary to make work
easier. (Refer to Chapter of Upper
structure.)
(6) Remove cover under engine.
Swing unit piping
(7) Attach tag to hose.
33-49
33.1.18.2 REMOVAL
(1) Remove hose.
1.
Remove hose (3), (5) from the connector in the makeup port MU.
Tools: Spanner: 36 mm
2.
Remove 2 hoses (4), (6) from the Tee in the drain port Dr.
3.
Remove hose (A4) from the elbow of the PG port. (For swing parking brake)
4.
Remove 2 hoses (B1), (B2) from the connectors of the A, B port.
Put in plugs PF3/8, PF3/4, PF1/2, and PF1/4 into the removed ports.
(2) Removing the swing unit
1.
Remove a sems bolt (6) M10X16 and remove connector (11).
2. Remove 8 capscrews (1) M16X50.
Tools: Socket: 24mm
3.
Remove tee of MU port and install eye bolts.
4.
Put a wire sling in the eye bolts and remove the swing motor unit.
Weight of swing motor unit ;
Approx. 70kg (154 lbs) (Include reduction assy)
Installing swing motor unit
33-50
33.1.18.3 PREPARATION FOR INSTALL

(1) Clean mating surfaces of swing motor unit and upper frame.
Tools : spatula, wash oil

(2) Apply Loctite #515 on entire mounting surface of swing motor unit.
Install the swing motor unit in the reverse order of disassembly, confirming the orientation of the
swing motor unit.
(1) Tighten 8 capscrews (1) M16X50.

Tools: Socket: 24mm
Tightening torque: 279N-m (206 lbf-ft) Apply Loctite #262
(2) Fill inside from motor drain port to casing with hydraulic oil before piping for drain
33.1.18.5 PREPARATION FOR DRIVE

(1) Before starting operation, check that gear oil #90 (API grade GL-4) level of swing reduction is
sufficient.
Amount of oil : 3L (0.8gal)
(2) When starting operation, operate motor in low idling and at low speed for several minutes, and
check it for possible oil leak and noise.
33-51
33.1.19 SWIVEL JOINT

(1) Remove attachment assy (Refer to 3. ATTACHMENT DIMENSIONS)
(2) Remove cab (See 33.1.2 CAB)
(3) Remove guard (See 33.1.4 GUARD)
(4) Removing hoses on undercarriage (See Chapter : Undercarriage)
(5) Remove swing reduction unit if necessary. (See 33.2.5 SWING MOTOR UNIT)
33.1.19.2 REMOVAL
(1) Remove travel motor hose and tube
1. Remove 2 hoses (2). (B,C port : PF1/2)
Tools: Spanner: 32mm, Tightening torque : 147N-m (108 lbf-ft)
2. Remove 2 hoses (A1). (D port : PF1/2)
3. Remove 2 hoses (3). (E port : PF3/8)
Tools: Spanner: 22mm, Tightening torque : 73.5N-m (54 lbf-ft)
4. Remove hoses (4). (H port : PF1/4)
Tools: Spanner: 19mm, Tightening torque : 36.3N-m (27 lbf-ft)
5. Remove tubes (5),(6). (F, G port : PF3/8)
Removing piping (lower side)
33-52
(2) Disconnecting the hoses on the top part of swivel joint

1. Remove a drain hose (6). (E port : PF3/8)

Tightening torque: 73.5N-m (54 lbf-ft)
2. Remove hoses (7),(8).
(A, D port : 18 dia.)
3. Remove hose (9),(10).
(B, C port : 18 dia.)
4. Remove hoses (1).
(F, G port : PF3/8)
Disconnecting the hoses on the top part of

swivel joint
(3) Remove whirl-stop of swivel joint.

1. Loosen the nut (3) M20.
2. Remove a capscrew (4) M20X85.
Removing whirl-stop nut & the capscrew
33-53
(4) Remove capscrew for installation

Attach eye bolt, lift it up temporarily, and
remove 3 capscrews (C2) M12X30.
Tools: Socket: 19mm
(See 11.7 SPECIAL TOOLS No.9 Plug)
Removing sems bolts for installation
(5) Slinging the swivel joint

Weight: Approx. 34kg (75 lbs)
removing.
Piping tightening torque
(2) Check for oil leak and the hydraulic oil
level.
(3) Check for operating.
33-54
33.1.20 UPPER FRAME

(1) Remove attachment (See chapter 32)
(2) Remove cab (See 33.1.2 CAB)
(3) Remove guard (See 33.1.4 GUARD)
(4) Remove counterweight (See 33.1.11 COUNTERWEIGHT)
(5) Remove swivel joint (See 33.1.19 SWIVEL JOINT)
33.1.20.2 REMOVAL
(1) Lifting up upper frame temporarily
Attach an upper-frame hoisting jig to
attaching holes of counterweight. Attach 2
chain blocks to holes of boom foot pin
and use these four points and hoist
upper-frame.
Wire ropes ;
16 dia. X 2.5m, 1pc.
16 dia. X 1.5m, 2pcs.
Chain blocks ; For 1 ton, 2pcs.
Lifting up upper frame temporarily
(2) Marking match marks on swing bearing

Put match marks on upper frame and
swing bearing.
Matching mark on swing bearing and upper

frame
(3) Removing upper frame attaching bolts

Remove 23 capscrews (B2) M16X80 and
a reamer bolt (B1) used to install swing
bearing and upper frame.
Tools: Socket: 24mm
(4) Slinging upper frame
Sling according to Fig "Lifting up upper
frame temporarily", and remove upper frame
and put it on a stand.
Weight: Approx. 5ton (11,000 lbs)
Removing upper frame attaching bolts
33-55
(2) Cleaning mating surfaces of upper frame and swing bearing.
(3) Apply Loctite #515 to the inside of the capscrews on the contact surface.
(4) Slinging upper frame
Match marks and install it with three reamer bolts temporarily.
Tools: Socket: 24mm Apply Loctite #262
Tightening torque : 157N-m (120 lbf-ft)
(5) Install swing bearing
Install 23 capscrews (B2) M16X80.
Tools: Socket: 24mm Apply Loctite #262
Install a reamer bolt (B1).
Tools: Socket: 24mm,
Bearing mount
Reamer bolt position (*) Apply Loctite to

shaded area
Confirm the reamer bolt positions referring to above Fig.
33-56

This page is blank for editing convenience.
33-57
33.2 DISASSEMBLING AND ASSEMBLING
33.2.1 HYDRAULIC PUMP - REGULATOR

33.2.1.1 STRUCTURAL EXPLODED VIEW
Structural exploded view of hydraulic pump
33-58

111 DRIVE SHAFT 1 622 PISTON CASE 1
114 SPLINE COUPLING 1 624 SPRING SEAT (G) 1
115 COLLAR 1 626 OUTER SPRING 1
123 BALL BEARING 1 627 ADJUST STEM (C) 1
124 NEEDLE BEARING 1 628 ADJUST SCREW (C) 1
127 BEARING SPACER 2 630 LOCK NUT (C) 1
141 CYLINDER BLOCK 1 641 SPRING COVER 1
151 PISTON 10 651 SLEEVE 1
152 SHOE 10 652 SPOOL 1
153 RETAINER PLATE 1 653 PIN 1
156 SPHERICAL BUSHING 1 654 PIN 1
157 CYLINDER SPRING 10 655 PF PISTON 1
212 SWASH PLATE 1 656 PIN 1
214 TILTING BUSHING 1 657 PF PISTON CASE 1
261 SEAL COVER (F) 1 701 O-RING; G 85 1
271 PUMP CASING (F) 1 702 O-RING; P11 5
273 TOP COVER 1 703 O-RING; P18 3
312 VALVE COVER D 1 704 O-RING; AS568-015 1
313 VALVE PLATE 1 705 O-RING; P9 1
363 SEAL PIPE 1 706 O-RING; P8 11
364 SPACER 1 707 O-RING; P7 2
401 SOCKET BOLT; M12X70 2 708 O-RING 1
402 SOCKET BOLT; M12X40 3 709 O-RING; P26 1
404 SOCKET BOLT; M12X25 8 711 O-RING; G35 1
407 FLANGE SOCKET 2 713 O-RING; AS868-036 1
418 SOCKET BOLT; M5X12 2 751 SHEAT PACKING T 1
467 ROH PLUG; G 1/2 3 752 SHEAT PACKING F 1
468 ROH PLUG; G 1/4 3 774 OIL SEAL 1
469 ROH PLUG; G 1/8 1 788 BACK UP RING; T2-P7 2
490 PLUG 2 789 BACK UP RING; T2-P26 1
497 MH PLUG; M7X0.75 13 802 NUT; M10 1
531 TILTING PIN 1 824 SNAP RING; SR-35 2
532 SERVO PISTON 1 885 SPRING PIN 1
535 STOPPER (L) 1 901 EYE BOLT; EB-M8 1
536 PLUG 1 981 NAME PLATE 1
541 SEAT 2 983 PIN 2
543 STOPPER 1 2 04 GEAR PUMP 1
545 STEAL BALL 2 041 CHECK VALVE ASSY 2
548 FEED BACK PIN 1 078 RELIEF VALVE 1
611 FEED BACK LEVER 1 SOLENOID PROPORTIONAL
079 1
621 COMPENSATOR PISTON 1 REDUCING VALVE
33-59
33.2.1.2 Tools
The below list shows the tools required for
remove and install.
*REQUIRED
TOOL
TOOLS AND SIZE PARTS
PUMP
MODEL
PLUG ROH/VP PLUG SOCKET SET

TOOLS ᲼ K7SP36 SOCKET BOLT
(TAPER THREAD) (PARALLEL THREAD) SCREW
ALLEN WRENCH 2 - - - M4
2.5 - - - M5
3 - - - M6
4 * M5 Rc 1/16 - M8
5 * M6 Rc 1/8 G 1/8 M10
6 * M8 Rc 1/4 G 1/4 M12, M14
8 * M10 Rc 3/8 G 3/8 M16, M18
10 * M12 Rc 1/2 G 1/2 M20
12 * M14 - G 3/4 -
14 M16, M18 Rc 3/4 - -
17 M20, M22 Rc 1 G 1 -
19 M24, M27 - - -
21 - - - -
22 M30 - - -
OFFSET WRENCH 17 * - - - M10

SOCKET WRENCH
19 M12 - G 1/4 -
SPANNER
22 - - G 3/8 -
22.2
* PLUG ASSY
(7/8in)
ADJUST
24 * M16 - -
SCREW (C)
27 M18 - G 1/2 -
30 M20 - - -
32 * - - - PLUG ASSY
LOCK NUT
36 * - - G 3/4
(C)
41 - - G 1 -
50 - - G 1 1/4 -
55 - - G 1 1/2 -
ADJUSTABLE
- * MIDIUM 1pc. SMALL 1pc.
WRENCH
SCREW DRIVER - * FLAT BLADE DRIVER MIDIUM 2pcs.
HAMMER - * PLASTIC HAMMER 1pc.
FOR STOP RING TSR-160

PLIER - *
FOR LOCKING RING TRR-160
STEEL BAR - * STEEL ROD FOR THE MACHINE KEY 10X8X200 EQUIVALENT
TORQUE WRENCH - * WRENCH THAT CAN TIGHTEN AT THE PRESCRIBED TORQUE
33-60
33.2.1.3 DISASSEMBLING PROCEDURES

Read this "Disassembling procedures" section carefully to the end before disassembling the pump.
The number in parenthesis after the parts name indicates the parts number in the cross section

drawing of pump assembly.
Disassemble the pump in accordance with the following procedures.
(1) Select a place for disassembly.
Choose a clean place.

Spread rubber sheet or cloth on the work bench to protect parts from damaging.
(2) Remove dust and rust on the pump surface with wash oil.
(3) Drain out the oil in the pump casing (F)(271) and valve cover (312) by removing the drain port
plug (467).
(4) (1) Take out the spline coupling (114) and

collar (115) after removing the flange socket
(407) and gear pump (04). Remove the hex
S.H.C. screws (418) and then remove the
solenoid proportional reducing valve (079).
(5) Take out the feedback lever assy (610)

from the inside of the pump casing (F)(271)
after removing the hex S.H.C. screws (404),
top cover assy (034) and seat packing T
(751).
33-61
(6) Remove the hex S.H.C. screws (405) and

then remove the spring cover assy (033)
from the valve cover (312).
Do not loosen the lock nut (C)(630) and hex nut (802) of the spring cover. It will change the control
characteristics.
(7) Loosen the hex S.H.C. screws (401, 402

and 403) and separate the pump casing
(F)(271) and valve cover (312).
Pay attention not to score the rolling surface of the needle bearing for the drive shaft (111) when
removing the valve cover.
33-62
(8) Take out the spool assy (650) from the

pump casing (F)(271).

Paying enough attention is needed when disassembling or assembling the regulator components
because they consist of precision small parts.
(9) Remove the valve plate (313) from the

valve cover (312).
The valve plate may come off when performing the procedure (8).
(10) Draw out the cylinder block (141) in parallel

to the drive shaft (111) and draw out the
piston sub (151 and 152), retainer plate
(153), spherical bushing (156) and cylinder
spring (157) at the same time.
Pay attention not to score the sliding surface of the cylinder block, spherical bushing, shoe and swash
plate.
33-63
(11) Take out the Pf piston case (657), Pf

piston (655), piston case (622) and
compensator piston (621) after removing the
ROH plugs (467).
(12) Loosen the hex S.H.C. screws (405) and

then remove the seal cover (F)(261).
1. The oil seal is fitted to the seal cover (F). Therefore, pay attention not to score the oil seal when
removing the seal cover.
2. The seal cover (F) may be drawn out with ease if insert the bolts into the through holes (2
places) on the seal cover (F) at even intervals.
(13) Tap lightly the drive shaft (111) end with

a plastic hammer and draw out the drive
shaft (111) and ball bearing (123) from the
33-64
(14) Remove the swash plate (212) from the

tilting pin (531) and then draw out the
swash plate from the pump casing (F)(271).

Pay attention not to score the portions of swash plate such as the sliding surface of the shoe and
contacting surface with the arc surface of the pump casing (F), which working as a support of the
swash plate.
(15) Remove the stopper (L)(535), servo piston (532), tilting pin(531) and plug (536) from the pump
casing (F)(271) if necessary.
1. When removing the tilting pin, use a jig aiming not to score the head of the tilting pin.
2. Adhesive agent is applied on the mating part between the tilting pin and servo piston. Pay
attention not to score the servo piston when removing it.
3. Pay attention not to score the both end surfaces of the stopper (L).
(16) Remove the needle bearing (124) *1 from the valve cover (312) if necessary.
Remove the relieve valve (78).
*1
Do not remove the needle bearing except when their service life has ended.
(17) Remove the seat packing F (752), spacer (364), seal pipe (363) and check valve 1 assies (041)
from the pump casing (F)(271) and then all disassembling procedures are finished.
33-65
33.2.1.4 ASSEMBLING PROCEDURES

Assembling procedures are basically performed in a reverse order of disassembling procedures. Pay
attention to the following items when assembling the components.
࡮ Repair the parts damaged at disassembling and be sure to prepare a replacement part beforehand.
࡮ Wash parts sufficiently by cleaning oil and dry them with air blow.
࡮ Be sure to apply clean hydraulic oil to the sliding areas and bearings.
࡮ Replace sealing parts such as an O-ring, oil seal and seat packing in principle.
࡮ Tighten installation bolts and plugs by a torque wrench to specified torque described in
"Maintenance Standards" in this manual,
(1) Install the swash plate (212) to the pump

casing (F)(271) properly while inserting the
tilting bushing (214) of the swash plate
(212) into the tilting pin (531).
1. Install the check valve 1 assies (041) and spacer (364) to the pump casing (F) after confirming the
installation direction and no drop parts.
2. When the stopper (L)(535), servo piston (532), tilting pin and plug have been removed, install them
to the pump casing beforehand.
3. When tightening the servo piston and tilting pin, use a jig which can tighten the tilting pin with
turning force using couple of forces. Apply Three Bond No.1305N to the screwed portions and tighten
it with the tightening torque 240 (N-m). After that, confirm the smooth movement of the servo piston.
4. When installing the swash plate, apply grease to the sliding surfaces of the swash plate and pump
casing to enhance the workability of drive shaft (111) installation.
5. Confirm the smooth movement of the swash plate by using fingers of both hands.
33-66
(2) Install the drive shaft (111) which already

provided with the ball bearing (123), bearing
spacers (127) and stop rings (824) to the

1. Do not tap the drive shaft with a hammer when installing it.
2. Install the ball bearing by lightly tapping the outer race of it with a plastic hammer and fit it
securely to the end by using a steel rod.
(3) Install the seal cover (F) (261) to the pump

casing (F)(271) and fix it with the hex
H.S.C. screws (405).
1. Attach the oil seal (774) properly to the seal cover (F) before installation.
2. Pay enough attention not to score the oil seal when installing the seal cover (F) to the pump
casing (F).
33-67
(4) Install the ROH plugs (467) after installing

the compensator piston (621), piston case
(622), Pf piston (655) and Pf piston case
(657) to the pump casing (F).
Pay attention not to cut the O-ring and take appropriate care such as applying grease slightly to the
outer circumference of O-ring, when installing the Pf piston case to the pump casing.
(5) Assemble the cylinder block (141), piston

sub (151 and 152), retainer plate (153),
spherical bushing (156) and cylinder spring
(157) and align the spherical bushing with
the cylinder block spline and then insert
them into the drive shaft (111).
Pay attention not to score the sliding surfaces of the cylinder block, spherical bushing, shoe and
swash plate.
(6) Install the valve plate (313) to the pump

casing (F)(271) side of the valve cover
(312) by aligning the valve plate with the
spring pin (885).
1. Apply grease to the installation surfaces of the valve cover and valve plate to avoid dropping.
2. Pay attention not to mistake the suction and delivery sides of the valve plate.
33-68
(7) Install the spool assy (650) to the pump

casing (F)(271).

Install the spool assy with its oval hole for the pin (653) facing upward.
(8) Combine the pump casing (F) and valve

cover (312) by tightening the hex S.H.C.
screws (401, 402 and 403) after attaching
the seat packing F (752) to the mating
surface of valve cover (312) properly.
1. Install the seal pipe (363) to the valve cover beforehand.

2. Pay attention not to score the rolling surface of the needle bearing for the drive shaft and the seat
packing F when installing the valve cover.
33-69
(9) Install the spring cover assy (033) to the

valve cover and tighten the hex S.H.C
screws (405).
(10) Install the feedback lever assy (610) to

the pump casing (F)(271). After attaching
the seat packing T (751) to the mating
surface properly, install the top cover assy
(034) onto it and tighten the hex S.H.C.
screws (404).
Confirm that the pin (653) of the feedback lever is inserted into the sleeve (651) properly and the
feedback lever is caught by the feedback pin (548) of the tilting pin (531).
(11) Install the spline coupling (114), collar (115)

and gear pump (04) and tighten the flange
sockets(407).
And also install the solenoid proportional
reducing valve (079) and tighten the hex
S.H.C. screws (418).
(12) Install the drain port plug and then all assembling procedures are finished.
33-70
33.2.1.5 PUMP BODY MAINTENANCE

33.2.1.5.1 REPLACEMENT STANDARDS FOR ABRASIVE PARTS
Replace or readjust the parts when their values of following items exceed the following standards wear

values.
However, always replace the parts that show excessive damage on appearance.
Unit㧦mm (in)
Standard value / Recommended
value for replacement
Part name and inspection item Remedy
Pump type
K7SP36
Clearance between piston and 0.032 / 0.056
Replace piston assy or cylinder.
cylinder bore (D-d) (0.001 / 0.002)
Gap between piston and caulked 0~0.1 / 0.3
Replace piston assy.
part of shoe (㱐) (0~0.004 / 0.01)
3.9 / 3.7
Thickness of shoe (t) Replace piston assy.
(0.15 / 0.15)
41.1 / 40.3
Free height of cylinder spring (L) Replace cylinder spring.
(1.62 / 1.59)
Combined height of retainer plate 17.2 / 15.6 Replace spherical bushing or
and spherical bushing (H-h) (0.68 / 0.61) retainer plate.
33.2.1.5.2 REPAIR STANDARDS FOR CYLINDER, VALVE PLATE AND SWASH PLATE (SLIDING
SURFACE OF SHOE)
Valve plate (sliding surface) Surface roughness requiring
3-Z
Swash plate (shoe sliding surface) correction
Cylinder (sliding surface) Standard surface roughness
0.4Z (lapping) or less
Roughness of each surface (correction value)
33-71
33.2.1.5.3 TIGHTENING TORQUE
TIGHTENING TOOL
PARTS NAME SIZE TORQUE NAME
N-m (lbf-ft) (mm)
Hex S.H.C. screw M5 6.9 (5.1) B=4
(Material : SCM435) M6 12 (8.9) 5
M8 29 (21.4) 6
M10 57 (42.0) 8
M12 98 (72.3) 10 Hex wrench
M14 160 (118.0) 12
M16 240 (177.0) 14
M18 330 (243.4) 14
M20 430 (317.1) 17
Flange socket
M8 17 (12.5) 6 Same as above
(For gear pump installation)
PT plug Rc1/16 6.9 (5.1) 4
(Material: S45C) Rc1/8 10 (7.4) 5
Wind the seal tape 1.5-2 times
Rc1/4 17 (12.5) 6 Same as above
around it.
Rc3/8 34 (25.1) 8
Rc1/2 49 (36.1) 10
ROH plug G1/8 17 (12.5) 5
(Material:G3/8 or less: S45C) G1/4 36 (26.6) 6
(Material:G1/2 or more: SCM435)
G3/8 74 (54.6) 8 Same as above
G1/2 110 (81.1) 10
G3/4 170 (125.4) 12
Refer this tightening torque table when disassembling/assembling the components or piping.
33-72
33.2.2 CONTROL VALVE

33.2.2.1.1 PRECAUTIONS FOR DISASSEMBLY
(1) Release the trapped inner pressure of the actuator. Then stop the engine.
Replacement of the valve assembly or disassembly of the valve with the pressure inside can cause
dangerous situations such as a spurting out of the high pressure oil or sudden coming off of the parts.
Before disassembly, place the bucket on the ground, and thoroughly release the pressure.
(2) Release the air pressure in the tank.

(3) Clean around the component to be disassembled to protect the valve from entry of foreign
materials.
(4) The removed parts should be kept with tags to identify the position when reassembling.
(5) Be sure to replace the all removed seals (O-ring, backup ring) with new ones.
(6) Do not replace the spool because it is engaged with the housing by selective fit.
33.2.2.1.2 DISASSEMBLING PROCEDURES

࡮ The parts numbers described in this section show the reference numbers in the internal structural
drawing list. (See 24.1.2 CONTROL VALVE.)
࡮ Assembly component parts reference numbers in this section are shown in order of (main part
reference number - component parts reference number).
࡮ The emergency lowering valve (this valve is only installed to the machines for the specific areas)
is indicated by the reference number in the service diagram. (See 24.2.2.2.2 INDEPENDENT
OPERATION 4 Emergency lowering function)
(1) Disassembling the spool

1. Loosen the socket head bolt (64) (width across flats: 5), and disassemble the long cap (16).
2. Pull out the spools (2) to (7), (9) to (13), and (15) from the valve housing as a subassembly.
Remove the O-ring (23) from the valve housing groove.
Be sure to pull the spools straight out to protect it from denting or scratching. The dent or scratch
may damage the bore of body when pulling out and make insertion of spool difficult when
reassembling.
Even if the spool was inserted in, it may cause malfunction. Tag the every spool for identification to
prevent the wrong assembly when reassembling. The wrongly assembled spool may cause malfunction
of actuator and result in a significant danger.
33-73
3. Loosen the socket head bolt (64), and remove the short caps (17), (18), and plate (71).
Remove the O-ring (23) from the valve housing.
4. Pull out the dummy spool (8).
5. Loosen the spool end (21) of spools (2) to (7), (9) to (13), and (15) (width-across flats: 5), and
remove the spring seat (22) and springs (19), (20) and (74).
6. Loosen the set screw (80) for hollow spool (12) (width-across flats: 6), and remove the spacer
(79).
Remove the O-ring (77) and backup ring (78).
When disassembling the spool assembly, clamp the spool using the tightening wood to protect the
outer periphery of the spool from scratching, and secure it with a vise before proceeding.
At this time, clamp the spool as close as possible to its end to avoid the spool from bending.
Heat the outer periphery of the threaded sections of spool with an industrial dryer or etc. until the
spool end becomes easily loosened. (reference heating temperature: 200 to 250 degrees C) because
the adhesive is applied to the threaded section and the set threaded section on the spool end.
If the spool end should be overheated, deterioration in performance due to thermal deformation of
spring and in durability may occur. At this time, replace the spring with a new one.
After heating the spool, it becomes very hot. Therefore, use extreme caution not to touch the spool
with bare hands because it may result in severe burns.
Use the screw stock to remove the spacer because the M3X0.5 female screw process is made on
the head section.
7. Draw out the spring (76) and poppet (75).
(2) Disassembling the arm, boom anti-drift valve and emergency lowering valve
Steps 1 to 6 only refer to the emergency lowering valve. Concerning steps 7 and later, explanation is
common for the anti-drift valve and emergency lowering valve.
1. Loosen the nut (18-3) (width-across flats: 13), and remove the set screw (18-4) (Width-across flats:
4).
2. Loosen the plug (18-1) (width-across flats: 19), and remove the O-ring (18-5).
3. Remove the poppet (18-2), and remove the O-ring (18-6).
4. Loosen the plug (17) (width-across flats: 19), and remove the O-rings (17-2), (17-3).
5. Loosen the plug assembly (19) (Width-across flats: 5), and remove the O-ring (19-2).
6. Remove the orifice plug (20) (width-across flats: 2).
7. Loosen the plug assembly (38-14) (width-across flats: 38) and remove the O-ring (38-14-2).
8. Remove the piston (38-4), spool (38-5), and spring (38-7).
9. Loosen the plug (38-3) (width-across flats: 38), and remove the O-ring (38-13).
33-74

When disassembling this component with the control valve attached to the machine body, the internal
parts may pop out by the trapped pressure. To prevent this, slowly loosen the plug (38-3) and let the
trapped pressure out and then confirm that no resistance from the trapped pressure remains before
disassembly.
10. Remove the sleeve (38-6) and poppet (38-2).

Remove the O-rings (38-9, 10) and backup rings (38-11, 12) on the periphery of the sleeve.
11. Remove the spring seat (38-16) and spring (38-8) from inside of the hole.
12. Loosen the socket head bolt (65) (width-across flats: 5), and take out the body (38-1) from the
valve housing, and then remove the O-ring (38-15) on the mating surface.
13. Using the M4X0.7 screw of the end face, draw out the spacer (41) from the valve housing.
Remove the O-ring (42) and backup ring (43).
14. Remove the spring (40) and poppet (39).
(3) Disassembling the arm 1, 2 load check section

1. Loosen the plug (34) (width-across flats: 27) for the load check section, and remove the O-ring
(36) from the plug.
3. Remove the sleeves (30), (37), spring (32), and poppet (31).
At this time, be careful not to drop the spring onto the passage. If dropping it onto the passage by
mistake, the broken pieces of spring may be caught in the sliding portion of the main spool, and it
may result in a spool sticking, uncontrollability of the actuator, and/or inability of safety stop.
(4) Disassembling the travel straight throttle section (left drive section)
1. Loosen the plug (34) (width-across flats: 27) for the travel straight throttle section, and remove
the O-ring (36) from the plug.
2. Remove the sleeve (30), spring (32), and poppet (31).
(5) Disassembling the boom 1, 2, swing, bucket, dozer, N&B, extra, offset load check section
1. Loosen the plug (27) (width-across flats: 24), and remove the O-ring (28) from the plug.
(6) Disassembling the pressure reduction passage section (right drive section)
1. Loosen the plug (49) (width-across flats: 24), and remove the O-ring (28) from the plug.
(7) Disassembling the arm regeneration section

1. Loosen the plug assembly (59) (width-across flats: 8), and remove the O-ring (59-2).
(8) Disassembling the common check section

1. Loosen the plug assembly (60) (width-across flats: 10), and remove the O-ring (60-2).
2. Remove the spacer (53), spring (52), and poppet (51).
33-75
(9) Disassembling the relief valve

1. Remove the overload relief valves (61), (84) (width-across flats: 24) from the body valve.
2. Remove the main relief valves (24), (83) (width-across flats: 24) from the body valve.
* For details of disassembly/assembly of the relief valve, see 33.2.2.4.
(10) Disassembling the shutoff valve

1. Loosen the nut (29-5) (width-across flats: 14), and then remove the set screw (29-6) (width-across
flats:5).
2. Loosen the plug (29-4) (width-across flats: 17), remove the shutoff valve from the body, and then
remove the O-ring (29-3).
3. Remove the poppet (29-1) from the plug (29-4), and remove the O-ring (29-2).
(11) Disassembling the other plugs

1. Disassemble the plug assembly (50) on PP port section (width-across flats: 19), and remove the
O-rings (50-2), (50-3), (50-4).
2. Loosen the plug (54) on PA port section (width-across flats: 27), and remove the O-ring (28).
3. Disassemble the PF3/8-size plug (59) [width-across flats: 8 (9 points)], and remove the O-ring
(59-2).
4. Disassemble the PF1/2-size plug (60) [width-across flats: 10 (9 points)], and remove the O-ring
(60-2).
33.2.2.2 CLEANING
Thoroughly wash all removed parts with clean mineral oil.
Dry them with pressurized air, and place each part on a clean paper or vinyl sheet for inspection.
33.2.2.3 INSPECTION
Check the whole surface of each part for burrs, scratches, or other defects.
1. Check the load check seat surface of the valve housing for scratches, scores, dirt, dent, or rust.
If a minor scuff is found, remove it using an oilstone.
2. Check the spool periphery for scratches or dents. If a minor scuff is found, remove it using an
oilstone.
3. All sliding parts shall be operated smoothly. And all grooves and passages shall be free from
foreign materials.
4. If the spring is broken, extremely deformed, or worn, replace it with a new one.
5. If the relief valve malfunctions, perform inspection following the 33.2.2.4 RELIEF VALVE SERVICE
PROCEDURE.
6. Replace the removed O-rings and backup rings with new ones.
7. After removing the cap or plug, check that the paint chip is not remaining around the body hole or
the plug seat surface.
(If the paint chip enters the valve housing, it can cause seizing foreign materials or clogging and
result in malfunction or oil leakage.)
33-76
33.2.2.4 ASSEMBLY

Before assembly, check the quantity for each part, installation position, and necessary tools.
33.2.2.4.1 SUBASSEMBLY
࡮ Before assembling the parts to the valve housing body, assemble the necessary parts as a
subassembly in advance.
(1) Spool
1. Attach the O-ring (77) and backup ring (78) to the spacer (79) used for hollow spool (12), and
insert it into the hollow spool with the spring (76) and poppet (76) placed on the spacer tip.
2. Apply adhesive to the thread of the set screw (LOCTITE #638 or equivalent), and tighten it.
Tightening torque: 9.8 to 11.8 N-m (7.2 to 8.7 lbf-ft)
3. Apply the adhesive (LOCTITE #638 or equivalent) to the thread of spools (2) to (7), (9) to (13),
(15) and assemble the spring seat (22), springs (19), (20), (74) and spool end (21). Clamp the
spool with tightening wood and secure it with a vise, then tighten the spool end.
Tightening torque: 19 to 22 N-m (14.0 to 16.2 lbf-ft)
After tightening the spool end, leave it for the following cure periods to secure hardening of the
adhesive.
(The cure periods specified below apply to LOCTITE #638.)
-8 hours or more at ambient temperature of 22 degrees C or around
* Application method of the adhesive

a. Cleaning (Degrease)
Perform vapor degreasing with acetate or ether, or clean with alkaline detergent.
Do not use gasoline or kerosene.
b. Drying
Blow the adhesive surface with clean air or let it dry naturally.
Insufficient drying reduces the adhesive property.
c. Application of the adhesive
Apply small amount of adhesive (LOCTITE #638 or equivalent) to 2 or 3 threads at the beginning
portion of the screw of the spool. Rotate the spool so that the adhesive enters into circumference
of 2 or 3 threads of the screw.
During installation, be careful not to allow the application area stick to the spring seat.
Do not use "LOCTITE Primer T" hardening accelerator because insufficient strength status may
occur.
Clamp the spool as close as possible to its end to avoid the spool being bent due to tightening torque.
Springs differ according to the section. If springs are assembled to the wrong section, they can cause
actuator malfunction.
33-77
(2) Arm, boom anti-drift valve and emergency lowering valve
Steps 1 to 7 are explanations common for the anti-drift valve and emergency lowering valve. Steps 8
and later only refer to the emergency lowering valve.
1. Attach the O-rings (38-9, 10) and backup rings (38-11, 12) to the periphery groove of the sleeve
(38-6).
Pay attention to the assembly position of the O-rings and backup rings.
If assembly is reversed, the O-rings will be cut and it may lead to a larger natural lowering of the
actuator.
2. Insert the poppet (38-2) and spool (38-5) into the sleeve hole.
3. Install the spring seat (38-16) to the small diameter area of the poppet tip, place the spring
(38-8) on it, and insert them into the body (38-1) hole along with the sleeve.
Apply the grease to the poppet seat beforehand so that the spring and spring seat are securely placed
onto it.
4. Install the spring (38-7) and piston (38-4) to the plug (38-3).
5. Tighten the plug assembly (38-14) equipped with the O-ring (38-14-2) to the plug (38-3).
6. Tighten the plug assembly (38-3) equipped with the O-ring (38-13) to the body (38-1).
7. Attach the O-ring (38-15) to the mating surface groove between the valve housing and plug
assembly.
8. Tighten the orifice plug (20) to the body (1).
9. Tighten the plug assembly (19) equipped with the O-ring (19-2) to the body (1).
10. Attach the O-rings (17-2), (17-3) to the plug (17), and then tighten it to the body (1).
11. Attach the O-ring (18-6) to the periphery groove of the poppet (18-2).
12. Install the poppet to the plug assembly (18-1) equipped with the O-ring (18-5) to insert.
13. Tighten the set screw.
14. Tighten the nut.
33-78
(3) Shutoff valve

1. Attach the O-ring (29-2) to the poppet (29-1), and install it to the plug (29-4) equipped with the
O-ring (29-3).

2. Assemble the hexagon nut (29-5) to the set screw (29-6), and lightly screw the set screw (29-6)
into the plug (29-4).
33-79
33.2.2.4.2 ASSEMBLY FOR CONTROL VALVE BODY

(1) Assembling the arm 1, 2 load check section
1. Install the spring (32) and poppet (31) to the periphery of the sleeves (30), (37). Then, insert the
sleeve containing the poppet (33) and spring (35) into the valve housing.
2. Screw in the plug (34) equipped with the O-ring (36) and fasten it.
(2) Assembling the travel drawing section (left driving section)

1. Install the spring (32) and poppet (31) to the periphery of the sleeve (30). Then, insert it into the
valve housing.
2. Screw in the plug equipped with the O-ring (36), and fasten it.
The sleeve (37) for arm 2 and the sleeve (30) of straight travel throttle for arm 1 are similar in their
shapes. Therefore, be careful of wrong assembly. Wrongly assembled sleeve can cause malfunction.
(3) Assembling the boom 1, 2, swing, bucket, dozer, N&B, extra and offset load check section
1. Insert the poppet (25) and spring (26) into the valve housing.
(4) Assembling the check section (right driving section) of the pressure loss reduction passage
(5) Assembling the arm regeneration section

2. Screw in the plug assembly (59) equipped with the O-ring (59-2) and fasten it.
(6) Assembling common check section

1. Insert the poppet (51), spring (52), and spacer (53) into the valve housing.
Place the spring on the spacer seat properly with care.

Otherwise, the spring can be broken by the poppet and the broken pieces may enter and circulate in
the passage, resulting in operation failure at each movable portion.
2. Screw in the plug assembly (60) equipped with the O-ring (60-2) and fasten it.
33-80
(7) Assembling the boom, arm anti-drift valve and emergency lowering valve section
1. Insert the poppet (39) into the valve housing.
2. Push the spacer (41) equipped with the O-ring (42) and backup ring (43) into the valve housing

along with the spring (40).
Place the spring on the spacer seat properly with care.

Otherwise, the spring can be broken by the poppet and the broken pieces may enter and circulate in
the passage, resulting in operation failure at each movable portion.
3. Install the assembled anti-drift valve (38) or the anti-drift valve (1) with the emergency lowering
function, to the valve housing and tighten the socket head bolt (65).
Tightening torque: 8.8 to 11 N-m (6.5 to 8.1 lbf-ft)
(8) Assembling the other plugs

1. Screw in the plug assembly (50) on PP port section equipped with the O-rings (50-2), (50-3),
(50-4) and fasten it.
2. Screw in the plug (54) on PA port section equipped with the O-ring (28) and fasten it.
3. Screw in the PF3/8 size plug assembly (59) equipped with the O-ring (59-2) and fasten it.
4. Screw in the PF1/2 size plug assembly (60) equipped with the O-ring (60-2) and fasten it.
(9) Assembling the relief valve

1. Screw in the overload relief valves (61), (84) to the body valve and fasten it.
2. Screw in the main relief valves (24), (83) to the body valve and fasten it.
(10) Assembling the shutoff valve

1. Screw in the assembled shutoff valve (29) and fasten it.
2. Screw in the set screw (29-6), securely seat the poppet (29-1), and tighten the hexagon nut (29-5)
to fix them.
33-81
(11) Assembling the spool section

1. Attach the O-ring (23) to the groove on the cap mating surface of the valve housing.
2. Install the assembled spools (2) to (7), (9) to (13), (15) and dummy spool (8) to the same position
as before disassembly.
Always install the spools to the same position as before. Wrongly assembled spools can cause
actuator failure.
Insert the spools slowly and straight against the hole.

After inserting the spool, check the spools by sliding them manually for stiffness or harshness in sliding
motion.
If the inserted spool has stiffness or harshness in sliding motion, the spool malfunction may occur.
3. Install the long cap (16), short cap (17), and plate (71), and tighten the socket head bolt (64).
Tightening torque: 8.8 to 11 N-m (6.5 to 8.1 lbf-ft)
After completion of assembly, recheck if all the disassembled parts have already been installed and
tightened or not. If they have not been tightened after reassembly, oil leakage due to looseness of
parts may occur.
All indicated values for the tightening torque are in wet status (adhesion of hydraulic oil).
33-82
33.2.2.5 DISASSEMBLING AND ASSEMBLING PROCEDURES FOR MAIN RELIEF VALVE

(1) Disassembling
This part is replaced as an assembly unit.
Replace the plug (1: width-across flats 24). When oil leakage is found, loosen the adjuster and replace
the O-ring (4).
Disassembly of the main relief valve is not recommended because it may change the set pressure.
(2) Assembly
Thoroughly check for dirt or paint chip on the threaded section perimeter of the plug (1), and then
install a new O-ring (2).
Thoroughly clean the area around the relief valve mounting section of the valve housing, then install
the relief valve and tighten the plug (1: width-across flats 24) with the tightening torque 59 to 69 N-m
(43.5 to 50.9 lbf-ft).
When the adjuster kit is disassembled, thoroughly clean the threaded section and adjust the pressure
referring to 33.2.2.7.
All values for the tightening torque described above are in wet status (adhesion of hydraulic oil).
33-83
33.2.2.6 DISASSEMBLING AND ASSEMBLING PROCEDURES FOR OVERLOAD RELIEF VALVE
(1) Disassembling
This part is replaced as an assembly unit.
When performing replacement, loosen the cap (1: width-across flats 24) using a wrench or etc., and
remove the O-ring (2).
When oil leaks from the adjuster kit (3), loosen the adjuster kit and replace the O-ring (4).
When disassembling the adjuster kit, be careful of the parts popping out of the component due to the
spring or missing the poppet.
(2) Assembly
Thoroughly check for dirt or paint chip on the threaded section perimeter of the cap (1) and then
install a new O-ring (2).
Clean the area around the relief valve mounting section of the valve housing, then install the relief
valve and tighten the cap (1) (width-across flats: 24) with the tightening torque 59 to 69 N-m (43.5 to
50.9 lbf-ft).
When the adjuster kit is disassembled, thoroughly clean the area around the threaded section and
adjust the pressure referring to 33.2.2.7.
All values for the tightening torque described above are in wet status (adhesion of hydraulic oil).
33-84
33.2.2.7 ADJUSTMENT OF RELIEF VALVE

(1) Main relief valve
1. Attach an accurate pressure gauge to the inlet circuit.

2. Operate the pump at the rated speed.
3. Change the spool of the control valve, and read the pressure gauge at the cylinder stroke end.
Change the spool of the actuator when the set pressure of the overload relief valve is higher than that
of the main relief valve.
4. Rotate the adjuster clockwise until the necessary pressure is obtained.

The pressure increases by 17.7 MPa per one adjuster rotation.
5. When the pressure reaches to the specified pressure value, hold down the adjuster to stop the
rotation and tighten the lock nut.
6. Increase the pressure again, and check that the pressure is at the specified pressure value.
(2) Overload relief valve
When the set pressure is higher than the main relief valve, do not adjust the overload relief valve but
replace it with the already set relief valve as an assembly unit.
1. Change the spool of the control valve, and read the pressure gauge at the cylinder stroke end.
2. Rotate the adjuster clockwise until the necessary pressure is obtained.
The pressure increases by 21.2 MPa per one adjuster rotation.
3. When the pressure reaches to the specified pressure value, hold down the adjuster to stop the
rotation and tighten the lock nut.
4. Increase the pressure again, and check that the pressure is at the specified pressure value.
(1) Be careful not to apply an excessive force to the valve by the piping.
(2) Tighten all mounting bolts evenly.
(3) When carrying out welding work near the valve, excessive heat or spatter may damage the seals.
(4) In order to prevent entry of dirt, do not remove the tape for each port until the ports are
connected to the pipes.
33-85
33.2.2.9 OPERATION
1. After checking that the hydraulic circuit and hydraulic oil are clean, gradually increase the
pressure (Operate the machine by inching operation at low-idle.), and check that external leakage
is not found.
2. Use the hydraulic oil with the aniline point of 82 to 113degrees C.
3. Do not increase the set pressure of the relief valve to the specified set pressure or higher.
4. Difference of the set pressure between the main relief valve and overload relief valve shall be 2.0
Mpa or more.
5. After sufficiently warming up the machine, proceed to actual operations.
Particularly, when starting the machine in the condition that a hydraulic oil temperature and valve
temperature are low, be careful of the following points to prevent possible sticking due to heat
shock of the spool.
1.
Do not operate the main relief valve or overload relief valve continuously before operating the
valves to make the hydraulic oil filled in each actuator circulate through components to evenly
raise the temperature of each part.
2.
Because minute operations or multiple operations can be the cause of heat generation in each
throttle, avoid such operations when the machine is cold, before sufficient warming up.
33-86
33.2.2.10 TROUBLES AND COUNTERMEASURES

(1) Control valve in general
Failure Possible causes Countermeasures
Spool does not stroke. 1. Oil temperature abnormally increases Remove the portion resisting the oil
flow in the piping.
2. Contaminated hydraulic oil Replace the hydraulic oil and clean
the circuit.
3. Over-tightening of the piping port Check the torque.
joint
4. Distorted valve housing caused by Loosen the mounting bolt and check it.
improper installation
5. Pressure is too high Connect the pressure gauge to the
pump port and cylinder port, and
check the pressure.
6. Bent spool Replace the spool as a valve
assembly.
7. Damaged return spring Replace the damaged part.
8. Dislocated spring or cap Loosen to center the cap, and tighten
it.
9.Uneventemperature distribution Warm up the entire circuit.
inside the valve
10. Valve clogged with dirt Remove the dirt (flushing).
11. Insufficient pilot pressure Check the pilot valve and pilot relief
pressure.
Load cannot be maintained. 1. Oil leakage from cylinder Check the cylinder seal.
2. Oil bypassing from spool Check the spool for scratches.
3. Oil leakage from overload relief Clean the valve housing seat and
valve relief valve seat.
4. Oil leakage from the anti-drift valve Disassemble the anti-drift valve, and
clean the seat for each part. If the
seat is scratched, replace the poppet
or lap the poppet and seat section. If
defect is found in the spool of the drift
valve, replace the spool and sleeve
simultaneously, because they are
engaged parts.
Load drops when the spool is 1. Dirt is caught in the load check Disassemble the check valve to clean
changed from neutral to valve it.
raised position. 2. Scratched poppet or seat of the Replace the poppet, or lap the
check valve poppet and seat section.
33-87
(2) Relief valve

Pressure does not increase 1. Main poppet, sleeve or pilot Replace the relief valve.
at all poppet is stuck and left opened, or
dirt is caught by the valve seat section
Relief pressure is unstable 1. Pilot poppet seat is scratched Replace the relief valve.
2. Piston or main poppet is stuck
Relief pressure is a wrong 1. Worn seat section due to dirt
value 2. Lock nut or adjuster is loosened Set the pressure again and tighten the
lock nut with the specified torque.
Oil leakage 1. Damaged seat section of the relief Replace the relief valve.
valve
2. Each part is stuck due to dirt
3. Worn O-ring Replace the adjuster or O-ring in the
installation section.
(3) Hydraulic system in general

Hydraulic system is out of 1. Pump failure Check the pressure or replace the
order or does not work at all. pump.
2. Relief valve failure Replace the relief valve
3. Cylinder failure Repair or replace the cylinder.
4. Pump load pressure is higher than Check the circuit pressure.
usual
5. Valve is cracked Replace the valve as a valve
assembly.
6. Spool does not stroke. Check the spool movement.
7. Oil surface of the tank is too low Supply the hydraulic oil.
8. Clogged filter in the circuit Clean the filter or replace it.
9. Piping circuit is closed Check the piping.
33-88
33.2.3 PILOT VALVE (FOR ATT)

33.2.3.1 CROSS-SECTIONAL VIEW
Pilot valve (For ATT)
Apply loctite #277 to areas marked ‫ڏ‬

Tightening torque Tightening torque
101 Casing 1 218 Seat 2
151 Plate 1 221 Spring 4
201-1 Spool 2 241-1 Spring 2
201-2 Spool 2 241-2 Spring 2
211 Plug 4 246-1 Spring 2
212 Push rod 4 246-2 Spring 2
213 Seal 4 47.1 (35) 301 Joint: M14 1
214 O-ring; 1B P20 4 302 Circular plate 1
216-1 Spring seat 2 68.6 (51)ŭ 312 Adjust nut: M14 1
216-2 Spring seat 2 501 Boots 1
217 Washer 2 (Shim) 4
33-89
(1) Plug each port of pilot valve, and clean it
with kerosine.
P port: PF1/4
1 to 4 and T port: PF3/8
(2) Fix pilot valve with vise via a protective
plate (Alminum plate etc.), and remove
boots (501).
Removing boot (501)
(3) Remove adjusting nut (312) applying

spanners to adjusting nut (312) and
circular plate (302).
Tools: Spanner: 22mm, 32mm
Removing adjusting nut (312)
33-90
(4) Remove circular plate (302)


Removing circular plate (302)
Circular plate is removed
Installing Jig A
(5) Turn joint (301) in counterclockwise with Jig

A to remove.
Jig A: See page 33.2.3.7(1).
Removing joint (301)
When the force of return springs (221) is strong, never loosen joint (301). If loosened, it might result in
jumping out of plate (151), plug (211) and push rod (212).
Remove joint (301) pressing plate (151) downward with two fingers.
33-91
(6) Remove plate (151)

-When the force of return springs (221)
are strong, press plate to let it come up
slowly.
Removing plate (151)
-When the force of return springs (221) are

weak, plug is left in casing (101) due to
sliding resistance of O-ring (214).
Tools: Pull plug (211) out with a driver.
Removing plug (211)
To prevent personal injury, plug (211) must be removed slowly and evenly until the return spring
(221) force is completely released.
(7) Remove push rod (212), plug (211),

pressure reducing valve assy (spool),
return springs (221) from casing (101).
Removing push rod, plug, pressure reducing

valve and spring
Record combination of port holes on casing and the pulled out parts. The stroke differs according to
direction.
33-92
(8) Push springs (241-1), (241-2) in the range

of 7mm (0.276in) that the movement of
spring seats (216-1), (216-2) and shift the

seats (216) in a side direction, and
remove spools (201-1), (201-2) through the
larger hole of seat.
Removing spool (201)
Never push down spring seat (216-1) in 7 mm (0.276 in) or more. (For port 1,3)
Never push down spring seat (216-2) in 9.4 mm (0.370 in) or more. (For port 2,4)
(9) Remove spool (201-1), (201-2), spring seats

(216-1), (216-2), spring (241-1), (241-2)
and washer (217).
Disassembling pressure reducing valve
(10) Remove spring (246-1),(246-2), spring seat

(218) from push rod (212).
Disassembling push rod
33-93
(11) Pull out push rod (212) from plug (211).

(12) Remove O-ring (214) from plug (211).
Removing push rod (212)
(13) Remove inside seal (213) from plug (211)

with small driver.
Removing seal (213)
33.2.3.3 CLEANING PARTS

(1) Clean parts with wash oil roughly.
(2) Clean parts with wash oil completely.
(3) Dry parts by swabbing clean rag.
(4) Apply rust preventives on parts.
33.2.3.4 ASSEMBLING
(1) Fit washer 2 (217), springs (241-1), (241-2),
spring seats (216-1), (216-2) to spool
(201-1), (201-2).
Assembling pressure reducing valve
33-94
(2) Push spring (241-1), (241-2) in the range of

that the movement of spring seats (216-1),
(216-2) in a side direction, and install

spools (201-1) through the larger hole of
spring seat.
Installing spools (201-1), (201-2)
Never push down spring seat (216-1) in 7mm (0.276in) or more. (For port 1,3)
Never push down spring seat (216-2) in 9.4mm (0.370in) or more. (For port 2,4)
(3) Place spring (221) into ports 1,3 of casing

(101), and then install pressure reducing
valve assy in it.
Place springs (221) into ports 2,4 and
install it.
Installing pressure reducing valve assy
Install the removed respective assy into respective holes.
33-95
(4) Fit O-ring (214) and seal (213) into plug (211).
-Apply hydraulic oil on surface of push rod.
Installing O-ring (214) and seal (213)
(5) Insert push rod (212) in plug (211) and

install spring (246-1) and spring seat (218)
to push rod (212) on port 1,3 side.
Insert push rod (212) in plug (211) and
install spring (246-2) and spring seat (218)
to push rod (212) on port 2,4 side
Assembling push rod, spring (246-1),(246-2)

and seat (218)
(6) Fit plug (211) assy to casing (101).
1. When the force of spring (211) is weak, it

stops at the position where it is pushed in
by the sliding resistance of O-ring (214).
Installing plug assy
33-96
2. When the force of spring (221) is strong,

attach plate (151) and press 4 push rods
by hand at the same time, and tighten joint

(301) temporarily.
-Install spool (201) straight and evenly into
the hole of casing (101).
-Take care so that plug (211) and plate
(151) do not jump out of casing (101).
Installing plug assy and plate (151)
(7) Install joint (301) on casing (101) with jig A

securely.
Jig A : See 33.2.3.7 JIG.
Tightening torque : 47.1N-m (32.8 to 37.2
lbf-ft)
Installing joint (301)
(8) Install circular plate (302) to joint (301)

(9) Screw adjusting nut (312) in until it touches
circular plate (302), and tighten it applying
spanner to stop circular plate returning.
Tools: Socket: 22mm
-Apply Loctite #277 to threads of joint.
Tightening torque: 68.6N-m (51 lbf-ft)
Installing circular plate (302)
-Screw it in until it comes in contact with 4 push rods (212) equally.

-The exceeding of screw in may cause malfunction of machine.
33-97
(10) Apply heat-resisting grease to joint (301)

rotating section and the top of push rod
(212).
(11) Cover it with boots.
(12) Spray rust preventives through each port
and attach plug respectively.
Applying grease to joint section and push rod
33-98

Check item Standard Remarks
When leakage quantity reaches to 1000 cc/
min. or more where handle is set in neutral
Conditions
position, or to 2000 cc/min. or more in
Leakage Primary pressure 2.94 MPa (426 psi)
operation, replace spool with new one.
Hydraulic oil viscosity 23 cSt
If leaked, even if the spool is replaced,
replace pilot valve assy with new one.
When the wear of sliding section is 10 㱘m
This condition may be the same as the
Spool more than the that of non sliding section,
above.
replace it with new one.
Push rod When the wear of top is 1 mm (0.04 in) or more, replace it with new one.
When looseness of 2 mm (0.08 in) or more
Looseness of control on circular plate (302) on control section and In case of the looseness due to the
section joint section (301) due to wear is produced, loosening on tightening section, adjust it.
replace them with new ones.
When trouble such as noise, hunting, drop of
primary pressure, etc. has occurred in op-
eration, and it does not restore after taking
Stability of operation
corrective action according to below 33.2.3.6
(TROUBLESHOOTING), replace pilot valve
assy with new one.
-O-ring, etc. should be replaced with new one at every disassembling.

-If socket bolt (125) was loosened, seal washer (121) should be replaced.
33-99
33.2.3.6 TROUBLESHOOTING
It is very difficult to find defective section. The following table explains the several estimated causes.
For repair, refer to the estimated causes and corrective actions.
The following table explains general phenomenon, estimated causes and corrective actions. However,
most machine problems are not caused by the failure of only one part, but involve relations with
other parts. Therefore corrective action other than those described in this table is often required. The
following table does not cover causes and corrective actions for all the troubles. So it may be
necessary to perform further investigation of troubles and causes.
Phenomenon Possible Cause Corrective action

1. 1.
Primary pressure is insufficient. Secure primary pressure.
2. 2.
Secondary pressure springs (241) are Replace with new ones.
broken or fatigued.
Secondary pressure
3. 3.
does not rise.
Clearance between spool (201) and cas-ing Replace spool (201).
(101) is abnormally large.
4. 4.
Handle has a looseness. Disassembly and reassembly or replace
handle section.
1. 1.
Sliding parts are caught. Repair the unsmoothed section.
Secondary pressure 2. 2.
is unstable. Tank line pressure varies. Bring pressure directly to oil tank.
3. 3.
Air has mixed into pipeline. Bleed air by operating it several times.
1. 1.
Secondary pressure Tank line pressure is high. Bring pressure directly to oil tank.
is high. 2. 2.
Sliding parts are caught. Correct.
33-100
33.2.3.7 JIG
(1) Jig for removing and installing joint (301)

33-101
33.2.4 PILOT VALVE (FOR TRAVEL)

Exploded view of pilot valve

5 Rubber boots 2 12-x Seal Ø14X20X3 6
6 Foot pedal (Switch plate) (2) 12-y Wiper ring 6
6-d Switch plate 2 13 Damper spring 4
6-f Regulation screw M8X28 4 14 Check valve kit (2)
6-g Set screw M5X8 4 14-q Plug M8 2
7 Retaining plate kit (1) 14-r Ball M6, 35 2
7-h Plate 1 15 Orifice (4)
7-i Capscrew M10X20 2 15-u Plug M6 4
7-j Shaft 2 15-t Orifice M6, Ø0.6 4
7-k Set screw M4X10 2 17 Shuttle valve kit (2)
8 Flange kit 4 17-w' Shuttle valve & orifice 2
10 Control spool 4 17-r Ball M6, 35 2
11 Return spring 4 17-z Orifice M5, Ø0.8 2
12 Damper flange kit (4) 21 Plug 4
12-o Damper plunger Ø14 4
33-102
33.2.4.2 DISASSEMBLY AND ASSEMBLY

(1) Boot replacement

The pilot control unit does not need to be removed from the machine to perform this operation.
1. Remove both faulty boots.

(using a flat screw driver if necessary)
2. Replace both boots with a new one.
* Reassembly :
- First fit the lower part of the rubber boot
on the retaining plate between the 2 switch
plates
- Then put the lower part in the external
groove of the retaining plate
- Finish by fitting the upper part of the
rubber boot on the switch plate.
(2) Switch plate removal

1. Remove :
- The pilot control unit from the machine.
- Both rubber boots (See 33.2.4.2 (1))
2. Remove the screw locking the axis using
a 2mm socket wrench. (See right Fig. No.1)
* Reassembly :
- Apply a droplet of Loctite #262 on the
locking screw thread.
- Torque :1.2 N-m (0.89 lbf-ft)
3. Fit a M3 screw on the switch plate axis in
order to remove it
(Using pliers if necessary). (See right Fig.
No.2)
* Reassembly :
- Position the axis so that the hole is
aligned with the locking screw as shown on
the picture (See Fig. right No.3)
4. Mark out the position of the switch plate
before removing it.
5. Repeat the operation for the second switch
plate.
6. Reassemble parts in reverse order.
33-103
(3) Switch plate adjustment
If the switch plate is replaced, it is necessary to adjust the regulation screws.
1. Unscrew the 2 locking screws using a

2,5mm socket wrench (See right Fig.)
* Reassembly :
locking screw thread.
- Torque :3 N-m 2.2 (lbf-ft)
2. Set the switch plate horizontally.
3. Screw on simultaneously both regulation
screws using a flat screw driver (5,5X150)
until feeling some resistance.
Do not misadjust the two damping screws. (See below Fig.)
4. Tighten the locking screws to hold the

regulation screws in position.
5. Repeat the operation for the second
switch plate making sure both switch
plates are parallel. (See above Fig.)
33-104
(4) Retaining plate removal

1. Remove

- Both switch plates (See 33.2.4.2 (2))
2. Unscrew simultaneously both screws holding
the retaining plate using a 8mm socket
wrench.
(See right Fig.)
* Reassembly :
screw thread.
- Torque :30 N-m (22 lbf-ft)
3. Lift the retaining plate to remove it.

(See right Fig.)
* Reassembly :
- Use the retaining plate to insert the 4
guides into the body simultaneously and
perpendicularly.
(See right Fig.left side)
5. Drain the pilot control unit (See 33.2.4.3).
(5) Damping plunger seals replacement

1. Remove
- Both rubber boots. (See 33.2.4.2 (1))
- The retaining plate (See 33.2.4.2 (4))
2. Remove the wiper ring of the damping

plunger (1).
(See above Fig. No.1)
* Reassembly :
- Replace with a new wiper ring.
3. Remove the damping plunger (2).
(Above Fig. No.2)
33-105
Always place the damping plunger prior to the wiper ring, and make sure the wiper ring is correctly
positionned.
4. Using a needle, remove the seal placed

inside the body (See right Fig. No.3, 4)
* Reassembly :
- Replace with a new seal and grease it.
࡮ Squeeze the seal between your fingers to

obtain a 8-shape.
(See right Fig. No.5)
࡮ Insert the seal within the groove with your
fingers (lip in bottom position).
(See right Fig. No.6, 7)
࡮ Push the seal against the side using the
round head of a small socket wrench.
(Right Fig. No.8)
5. Repeat the operation for the other 3 assemblies.

6. Extract the damping springs from the body (using flat nose pliers).
7. Inspect the damping springs. If defects are detected, replace the 4 springs.
During the reassembly, make sure the seal is correctly positionned, and pay attention not to damage
nor twist it.
33-106
(6) Guide/plunger and regulation unit replacement

1. Remove

2. Guide/plunger replacement :
- Insert the end of a thin screwdriver
between the guide and the body, carefully
lift the guide to remove it from the body.
3. Remove the guide / plunger assembly.
4. Repeat the operation for the other 3
sub-assemblies.
5. Visually check that the guides / plungers
are in good condition. If defects are
present, replace the 4 sub-assemblies.
Hold the guides with the other hand during the extraction operation to limit the effect of the return
spring.
6. Guide/plunger and relulation unit

replacement
- Extract the regulation units from the
body (using flat nose pliers).
- Inspect the regulation units. If defects
are detected on the parts, replace the 4
units.
7. Return spring replacement :
- Extract the return springs from the body
(using flat nose pliers).
33-107
- Inspect the return springs. If defects are detected, replace the 4 springs.
(7) Throttle kit replacement

1. Remove
- The pilot control unit from the machine
- The damping plungers and springs (See
33.2.4.2 (5))
2. Unscrew the screw using a 3mm socket

wrench.
(See right Fig.)
* Reassembly :
screw thread
- Screw on until it sets just above the body.
(See righi Fig.)
3. Unscrew the throttle using a 3mm socket
wrench.
* Reassembly :
4. Repeat the operation for the other 3
assemblies.
5. Replace with new screws and new throttles.
33-108
(8) Shuttle valve kit removal

1. Remove the pilot control unit from the
machine

The pilot control unit does not need to be disassembled to perform this operation.
2. Unscrew the shuttle valve using a 4mm

socket wrench. (See right Fig.)
* Reassembly :
- Thoroughly clean the body to remove
any trace of loctite.
shuttle valve thread.
Wait for 8 hours before using the machine to let the Loctite #242 dry completely.
3. Put the body up-side-down to remove the

shuttle valve and the ball. (See 33.2.4.2(8)7)
4. Unscrew the throttle using a 2,5mm socket
wrench.
* Reassembly:
- Hand tighten.
5. Repeat the operation for the other
subassemblies.
6. Inspect the shuttle valves, balls and
throttles. If defects are detected, replace
all the assemblies.
33-109
(9) Check valve kit removal

1. Remove the pilot control unit from the machine
The pilot control unit does not need to be disassembled to perform this operation.
2. Unscrew the check valve plug using a 4mm

socket wrench.
(See right Fig.)
* Reassembly :
- Drain the pilot control unit
(See 33.2.4.3)
- Torque :5 N-m (3.7lbf-ft)
3. Put the body up-side-down to remove the
ball.
4. Repeat the operation for the second check
valve kit.
5. Inspect the check valve plugs, O-rings and

balls. If defects are detected, replace all
the assemblies. (See right Fig.)
33-110
33.2.4.3 DRAIN OF HYDRAULIC PILOT CONTROL UNIT

(1) When removing the retaining plate, the
throttle kit or the shuttle valve kit, it is

necessary to drain the pilot unit.
(2) Reassemble the pilot unit control completely.
(3) Install the pilot unit control in the machine.
(4) Slightly unscrew the check valve plug
using a 4mm socket wrench. (See right
Fig.)
(5) Switch on the machine.
(6) Operate gently the pedal until the bubbles
disappear.
(7) Tighten the check valve plug.
- Torque : 5 N-m (3.7 lbf-ft)
(8) Repeat the operation for the other check
valve plug.
33-111
33.2.5 SWING MOTOR UNIT

(1) Swing motor Composition
Swing motor
33-112
Torque Torque
M-1 TAPERED ROLLER 1 M-21 PISTON ASSY 7
BEARING M-22 RETURN PLATE 1
M-3 FRICTION PLATE 1 M-23 CAM PLATE 1
M-4 SEPARATOR PALATE 2 M-26 HOUSING 1
M-5 SNAP SING 2 M-27 COLLAR 1
M-6 NEEDLE BEARING 1 M-28 OIL SEAL 1
M-7 O-RING 1 M-30 BACK UP RING 2
M-8 O-RING 1 M-31 O-RING : 1B P21 2
M-9 O-RING 1 M-33 BACK UP RING 2
M-10 BALANCE PLATE 1 M-34 O-RING : 1B P26 2
M-11 PISTON 2 M-35 PARALLEL PIN 2
M-12 TEFLON RING 2 M-36 PLUG : PF3/8 1
M-13 PLUG ; PT 1/4 2 M-37 O-RING : 1B P14 1
M-14 BUSHING 4 M-38 SOCKET BOLT : M12X30 4
M-15 SCROLL WAVE 4 M-39 COVER 1
M-16 TEFLON RING 4 70 RELIEF VALVE ASSY 2
M-17 SPRING 13 100 BY-BASS VALVE ASSY 2
M-18 PISTON 1
M-19 CYLINDER 1
M-20 RETAINING SPRING 1
1. Relief and check valve assy (70)
2. By-pass valve assy (100)
33-113
(2) Swing reduction unit
Swing reduction unit
Torque Torque
R-1 PINION SHAFT 1 R-15 HOLDER 2 ASSY 1
R-2 COLLAR 1 R-16 NEEDLE BEARING 6
R-3 PLATE 1 R-17 SHAFT 2 3
R-4 TAPER ROLLER BEARING 1 R-18 SPUR GEAR 5 3
R-5 GEAR CASE 1 R-19 THRUST PLATE 2 6
R-6 GREASE NIPPLE 1 R-20 SPRING PIN : 8X5 3
R-7 OIL SEAL 1 R-21 HOLDER 2 1
R-8 TAPER ROLLER BEARING 1 R-22 COLLAR 2
R-9 PIN 2 R-23 RELIEF NIPPLE 1
R-10 RING GEAR 1
R-11 SPUR GEAR 4 1
R-12 SUN GEAR 1
R-13 HOLDER 1 ASSY 1
R-14 SOCKET BOLT : M12X95 6
33-114
33.2.5.2 DISASSEMBLY AND ASSEMBLY OF SWING MOTOR

(1) Disassembly
1. Remove the relief assy (70).

Tools: Socket: 27 mm
2. Remove the by-pass valve (100).
Removing relief valve assy and by-pass valve
Install it in the original position.
3. Apply match mark on cover (39) and

housing (26).
Maching marks on cover and housing
4. Remove socket bolt (38).

Removing cover mounting bolts
33-115
5. Lift up and remove cover (39).
Removing cover
6. Remove snap ring (5) with plier.

7. Remove inner race of needle bearing (6).
Removing bearing (6) inner race
8. Remove the O-ring (9).
Removing O-ring (9)
9. Remove the balance plate (10).
Removing balance plate
33-116
10. Remove the bushing (14) with a teflon

ring (16) on it, and the scroll wave (15).

Removing bushing (14) and scrollwave (15)
11. Remove spring (17) from brake piston (18).
Removing spring (17)
Fit spring in the original position.
12. Remove brake piston (18).
Removing brake piston (18)
The O-ring (7) (8) make it difficult to slide the piston (18) easily from the housing (26). For this
reason, use tapped hole (M6) provided in the piston (18) to remove it, as shown in the above Fig.
33-117
13. Remove the separator plate (4) and friction

plate (3).
Removing separator plate (4) and friction

plate (3)
14. Remove cylinder assy (19) from housing

(26).
Removing cylinder assy (19)
-Oil seal (28) and outer race of taper roller bearing (1) are left in housing.
-Take care not to damage the sliding surface on upper section of cylinder housing.
-Assemble piston bore of cylinder (19) and piston assy (21) in the same original combination.
15. Remove the outer race of tapered roller

bearing (1) from the housing.
Removing outer race of tapered roller bearing

(1)
33-118
16. Remove oil seal (28) from housing (26)

with driver and hammer.

-The reuse of the removed oil seal is not
allowed.
Removing oil seal (28)
17. Removing the cylinder assy.
a. Attach an gear puller to two positions of

the inner race of the tapered roller bearing
(1) and to the splined end of the cylinder
(19), and pull out the inner race along
with the collar (27).
Pulling inner race of tapered roller bearing (1)
b. Remove the cam plate (23), piston assy

(21) and return plate (22) together from
the cylinder (19).
Removing cam plate (23), piston assy (21)

and return plate (22)
33-119
c. Remove cam plate (23) from the piston

assy (21) as is by sliding it on sliding
surface of piston assy (21).
Removing cam plate (23)
Handle cam plate with care so as not to damage its sliding surface.
d. Remove retaining spring (20) from cylinder

(19).
Removing retaining spring (20)
33-120
(2) Installation
Install swing motor unit in the reverse procedure of disassembling.

1. Jigs
Jig used for installing is not provided with part number.
2. Assembling relief assy

Fit relief assy (70) to cover (39).
Assembling relief assy (70)
3. Confirming correct assembly

Open the brake release port, apply a pilot
pressure of 1.96 MPa (280 psi) to the P
port and confirm that the output shaft
rotates more than 1 turn smoothly by
19.6~29.4 N-m (14~22 lbf-ft) torque. In case
the output shaft does not rotate,
disassemble it again and readjust.
Confirming correct assembly
33-121
33.2.5.3 DISASSEMBLY AND ASSEMBLY OF SWING REDUCTION UNIT

(1) Removal
1. Remove the sun gear (12) and then
remove the holder 1 assy (13).
-Because the shafts in the holder 1 assy

(13) are press-fit in the holder (1), and
caulked at the end, further removal of the
assy is impossible.
Removing spring pin (20)
2. Remove spur gear 4 (11) and then

remove the holder 2 assy (15).
3. Removing the holder 2 assy (15).
a.
Drive the spring pin (20) through the holder
2 assy (15).
-The spring pin (20) cannot be reused.
b.
Holding spur gear 5 (18) with your hand,
remove the shaft 2 (17) from holder 2 (15). Removing shaft (17)
4. Remove the ring gear (10).
-The mating surface between the ring gear

(10) and the gear case (5) is coated with
liquid packing (Three Bond #1215, gray) to
prevent oil leakage. Use the notch in the
gear case (5) to remove the ring gear (10).
5. Removing the collar (16).
Remove the collar (16) from the shaft (1)
by tapping the collar with a screwdriver and Removing ring gear (10)
hammer.
6. Removing the shaft (1) assy.

Place blocks about 300 mm high under
the flange of the gear case (5) to allow
removal of the shaft (1) and push the end
of the shaft with a hydraulic press to
remove the shaft (1), collar (2), plate (3)
and taper roller bearing (4) as an assy.
7. Remove the oil seals (7) from the gear
case (5).
Removing shaft (1) assy
33-122

-Do not remove any further, unless the bearings etc. are abnormal.
-Do not reuse the oil seals.
(2) Installation
The jigs to be used for installation are shown below.
1. Apply grease to the rollers of the taper

roller bearing (4).
-Grade : SHELL ALVANA EP2 or equivalent
(grease for extreme pressure duty)
-Quantity : About 150cc (9.15 cu-in)
Applying grease to taper roller bearing (4)
2. Press-fitting the oil seal (7)

Degrease the oil seal position on the gear
case (5) and the oil seal (7). Apply liquid
packing (Three Bond #1211, white) to the
outside of the oil seal. Using the seal
press-fitting jig and a hand press, install the
oil seal (7) on the gear case (5).
Press-fitting oil seal (7)
-After press-fitting, apply grease to the oil
seal lips.
33-123
3. Place the gear case (5) with the output

shaft side facing upward, and install the
pinion shaft (1) assy into the gear case (5).
-Use the seal protector to prevent the

spline of the pinion shaft (1) from damaging
the lips of the oil seal (7).
Installing pinion shaft (1) assy
4. Installing the taper roller bearing (8)

Place gear case (5) directing pinion shaft
downward, warm collar (22) of taper roller
bearing to temperature adding +50 degC
(122 degF) to the room temperature and fit
it.
Installing taper roller bearing (8)
5. Installing the collar (22)

The nominal thickness of the collar (22) is
7.0 mm (0.2756 in). Adjust this thickness
so that the clearance between the collar
(22) and the groove in the shaft (1) is 0.06
mm (0.0024 in).
Adjusting clearance between collar (22) and

shaft (1)
33-124
6. Installing the ring gear (10).
࡮ Degrease the mating surface between the

gear case (5) and the ring gear (10) and
the pin (9).
࡮ Apply liquid packing (Three Bond #1215,
gray) to the area of the gear case (5)
inside the bolt circle, and install the ring
gear (10) on the gear case (5).
࡮ Apply sealant equally so that the thickness
projecting from nozzle is about 1.5 mm
Applying liquid packing to gear case (5)
(0.06 in) in diameter.
Installing ring gear (10)
7. Installing the holder 2 assy (15)
a. Install the needle bearing (16) in spur

gear 5 (18). Install this assy together with
the thrust plate 2 (19) into holder 2 (21),
and insert the shaft 2 (17) into the spur
gear.
-Apply hydraulic oil to the inside diameter

of spur gear 5 (18), needle bearing (16)
and the outside diameter of the shaft 2
(17).
Installing holder assy 2 (15)
33-125
b. Drive the spring pin (20)
Drive spring pin facing the split to gear side.
Driving spring pin (20)
8. Carefully mesh the holder 2 assy (15) in

the internal teeth of the ring gear (10),
and the spline of the pinion shaft (1) with
its mating part. In this condition, insert the
holder 2 assy (15) while turning it.
9. Carefully mesh spur gear 4 (11) in the spur
gear 5 (18).
Inserting holder 2 assy (15)
10. Installing the holder 1 assy (13)

a.
Carefully mesh the holder 1 assy (13) in
the internal teeth of the ring gear (10),
and holder 1 (13) in the teeth of sun gear
(12). In this condition, insert the holder 1
assy (13) while turning it slowly.
b.
Place sun gear (12) in while engaging
with planet gear of holder 1 assy (13)
slowly.
Inserting holder 1 assy (13)
11. Turn the holder 1 assy (13) with your
hand to confirm that the pinion shaft rotates
smoothly.
33-126

Parts Maintenance
Gear, Pinion Replace if harmful wear, pitting, peeling, scratch, etc. are found on the tooth face.
Replace if harmful wear, indentation, etc. are found on the spline portion, there is a
Holder 1, 2 assy backlash on the pin portion (For holder 1 assy, loosening of caulking, for holder 2
assy, wear of pin bore), or the needle bearing is worn making a backlash.
Even if the bearing works normally, when the "Hour meter" arrives to the time in
3000 hours, replace them with new ones.
Taper roller bearing, Even through the "Hour meter" is within 3000 hours, when the rolling contact
Needle bearing surface of needle bearing is flawed while removing, replace them with new ones.
And if possible we will recommend that you replace bearings with new ones
because they will often be damaged during removing.
When the lip is damaged, replace it with a new one.
Oil seal And even if there is no leak, replace seal every 3000 hours.
Also, replace it with new ones without fail while installation.
Other parts Replace parts worn or damaged with new ones.
33-127
33.2.6 SWIVEL JOINT

33.2.6.1 CONSTRUCTION VIEW
Construction of swivel joint

1 BODY 1 9 SOCKET BOLT (M8X20) 2
2 STEM 1 10 SOCKET BOLT (M8X30) 3
3 THRUST PLATE 1 11 PLUG : PT1/8 2
4 COVER 1 12 PLUG : PF1/4 2
5 SEAL 5 13 PLUG : PT3/8 4
6 SEAL 1 16 O-RING 2
7 O-RING (G95 1A) 1 17 O-RING 4
8 O-RING 2
33-128
33.2.6.2 DISASSEMBLY AND ASSEMBLY

33.2.6.2.1 Tools

33.2.6.2.2 Apparatus
(1) Hoist or crane
The lifting device should be capable of lifting the swivel joint assy.
(2) Work bench
The work bench should have an area of 1.2mX1.5m (4ftX5ft).
(3) Others
Also prepare cloth, wooden block and oil pan.
33.2.6.2.3 Cleaning outside

Clean the swivel joint to be free from dirt and dust, using steam and cleaning oil.
࡮ Keep all ports plugged up while cleaning.
33-129
33.2.6.2.4 Disassembly
The part numbers used in this disassembly procedure correspond to those of a construction drawing in
Fig."Construction of swivel joint".
(1) Removing cover

1. Mark cover (4) and body (1) with matching
marks for convenient reassembly.
2. Place a V-block on a work bench, place a
swivel joint set on the side, fix it and
loosen socket bolt (10) by means of a
pipe and wrench. Alternately, the swivel
joint may be fixed by holding stem (2) in a
vise.
Removing cover (4)
3. Remove cover (4) from body (1) and draw

out O-ring (7) from cover (4).
Removing O-ring (7)
(2) Removing thrust plate

Loosen socket bolt (9) fastening thrust plate (3),
in the same manner as the removing of the
above-mentioned cover.
Removing thrust plate (3)
When removing thrust plate (3) by fixing body (1), support stem (2) so it may not fall down.
33-130
(3) Removing stem

Place body (1) on a V-block. Put a wooden
block against stem (2) via the body so about

half of the stem is covered by the wooden
block and knock it out using a mallet.
By hitting out the stem over about 1/2 from
the body, it can be easily pulled out by hand.
Stem weight: 13kg (29 lbs)
Drawing out stem (2)
(4) Removing sealing parts

1. Remove rings (8) of seal assemblies (6)
and (5) with spatula (f).
Removing O-ring (8)
Pay attention to the body (1) not to be damaged by the top edge of spatula (f).
2. Pierce slipper ring of seal assemblies (6)

and (5) with pin (e) and remove them
from the seal groove. Right Fig. shows only
one pin, but use two pins to remove it
securely.
Removing out seal assy (5)(6)
33-131
33.2.6.2.5 Assembly
Prior to assembly, clean each parts (excluding the O-ring and seal), and arrange in the sequence of
assembly.
Apply grease on the groove of seal to be installed on seal assembly (6) and O-ring (8).
(1) Assembling seals to body

1. Apply hydraulic oil to O-ring (8) thinly and insert it in O-ring groove.
Check the twist of O-ring
2. Slipper ring is assembled, after first

inserting the backup ring, by
slightly-distorting the shape as shown in
Right Fig. Also after inserting all of the
seals, be certain that these are installed in
the seal groove by use of the spatula.
3. Assemble seal (5) by the same procedure
above mentioned.
Inserting slipper ring (6)
Remove grease, hydraulic oil and vaseline from the groove of seal.
And insert seal (5).
Seals (5) have no back-up ring.
(2) Assembling stem

Lightly coat the outer circumference of stem
(2) and the inner surface of body (1) with
grease or vaseline and slowly insert stem (2)
into body (1).
Inserting stem (2)
-If stem (2) is pressed in too fast, the seal may be damaged. Do it slowly.
-The clearance between body (1) and stem (2) is about 0.1mm (0.004in). Push stem straight along
the shaft center.
33-132
(3) Assembling thrust plate

1. While holding stem (2) and body (1), match
the hole of thrust plate (3) and the stem

(2) hole.
2. Next, after removing any oil from the thread
of socket bolt (9), coat it with Loctite #242
and tighten to stem (2).
Tools: Allen wrench: 6mm,
Tightening torque: 30.4N-m (22lbf-ft)
Tightening socket bolt (9)
(4) Assembling cover

After installing O-ring (7) to cover (4) and
aligning the matching marks of the cover (4)
and body (1), coat socket bolt (10) with Loctite
#242 and tighten it which will then complete
assembly.
Tools: Allen wrench: 6mm,
Tightening torque : 30.4N-m (22lbf-ft)
Tightening socket bolt (10)
33-133

33.2.6.3.1 USABLE LIMIT OF PARTS
33-134
33.2.6.3.2 INSPECTION AFTER ASSEMBLY

After completion of assembly, inspection for oil leakage, pressure resistance, etc., using a device as
shown in Right Fig.

(1) High pressure port
Install a directional valve and pressure
gauge to the stem side port and body
side port respectively, and while watching
the pressure gauge (for high pressure)
installed on the body side and also by
regulating high pressure relief valve (7),
gradually increase the pressure and when
the pressure has reached 1.5 times the
maximum working pressure, close stop
valve (3) and lock in the hydraulic oil in
the swivel. Keep stop valve (6) on the low
pressure relief valve side closed at this
time.
Check that it is free from looseness,
deformation, breakage, etc. under three
minutes pressurizing.
And, the oil leakage must be checked for
the first 1 minute, and if there be a
pressure drop for any reason, the pressure
drop should be in 10% of the trapped Hydraulic circuit for inspection equipment
pressure.
This checking must be carried out for every
circuit.
(2) Low pressure port (Drain port, return port,

etc.)
Similar to the high pressure port, install a
directional valve and pressure gauge on
each port of the stem side and body side.
Open stop valve (6) on the side of low
pressure relief valve (5) and while
watching the pressure gauge (for low
pressure) connected to the body side and
also by regulating low pressure relief valve
(5), gradually increase the pressure and
check for outside leakage with a color
check at a pressure of 0.49 MPa (71 psi).
࡮ The maximum working pressure stands for pressure of hydraulic excavator equipped with swivel
joint.
33-135
33.2.6.3.3 TROUBLESHOOTING
Trouble Cause Remedy
1.
External leakage of hydraulic oil Defective O-ring & seal Replace all seals.
2. 1) 1)
Internal leakage of hydraulic oil Defective slipper seal Replace all seals.
2) 2)
Sliding face worn excessively Replace assy.
3. 1) 1)
Swivel stem seized Stem and body seized Grind and hone.
Replace assy, if stem and body are too
loose and causing oil leakage.
2) 2)
Inappropriate swivel stopper Reinstall
bracket Secure 2 to 3 mm (0.08 to 0.12 in)
allowance for bolt stopper.
4.
Loose swivel stem and cover Socket bolt tightened Retighten to specified torque.
insufficiently.
33-136
㨇34. TRAVEL SYSTEM㨉

34. TRAVEL SYSTEM
TABLE OF CONTENTS

34.1.1 TRAVEL SYSTEM ääääääääääääääääääääääääääääääääää34-3
34.1.2 CRAWLER äääääääääääääääääääääääääääääääääääää34-3
34.1.3 UPPER ROLLER ääääääääääääääääääääääääääääääääää34-8
34.1.4 LOWER ROLLER (TRACK ROLLER) äääääääääääääääääääääääää34-14
34.1.5 FRONT IDLER (IDLER ADJUSTER ASSY) ääääääääääääääääääääää34-21
34.1.6 SPROCKET äääääääääääääääääääääääääääääääääääää34-31
34.1.7 TRAVEL MOTOR ääääääääääääääääääääääääääääääääää34-34
34.1.8 SWING BEARING ääääääääääääääääääääääääääääääääää34-37
34.2.1 TRAVEL MOTOR ääääääääääääääääääääääääääääääääää34-41
34-1

S5YT3423E01
(EUR)
PREFACE
(1) This Manual describes all the procedures from removing to attaching, arranging them by item.
(2) This Manual consists of first part. Removing and attaching, and sequel. Disassembling and
assembling.
(3) The removing and attaching can be performed in the procedure specified in Table of Contents, but
in view of actual repairing or time saving some process can be omitted.
(4) The removing and attaching procedure does not completely cover all possible situations because of
(5) Please be aware that the procedure to be followed must be determined according to the above
conditions.
When disassembly and assembly are required, select the necessary section, itemize the work
contents with good understanding, then starts working.
34-2
34.1.1 TRAVEL SYSTEM

Designation and location of undercarriage
34.1.2 CRAWLER
34.1.2.1 REMOVING CRAWLER
(1) Position the machine to remove crawler.
(2) Pushing out master pin.
1.
Find the master pin and place it in its
removing/fixing position in right Fig..
2.
Loosen the grease nipple and slacken crawler.
Crawler removing position
-When loosening the grease nipple of the adjuster, do not loosen it more than one turn.
-Where grease does not come out well, move the machine back and forth. The over loosening of
grease nipple may cause it to jump out incurring danger of injury. So be careful not to over loosen
the grease nipple.
34-3
3.
Pushing out master pin
Apply jig on master pin and strike it out with a
mallet.
(Refer to 34.1.2.2(4) Fig. "Press fitting of master
pin")
Removing/fixing position of master pin
When using a big hammer, wear protective goggles and a long-sleeved uniform so you do not injure
yourself by flying objects.
(3) Removing crawler

Put attachment on ground so that weight is
not loaded to the lower frame, and remove
track link assy rotating sprocket.
Removing crawler
Crawler end section may fall on the ground just before extending it on the ground incurring danger of
injury.
Please keep well away from the equipment.
34-4
34.1.2.2 INSTALLING
(1) Checking crawler installation direction.

Place the track links on the ground so they
converge, facing the front idler, as shown
in the figure on the right.

Installing direction of crawler
(2) Installing crawler

1. Preparation for installation
Treat paint flaking protection with care not
to damage lower flame.
2. Winding crawler
Insert bar into master pin hole, lift lower
frame up 1 or 2 cm (0.4 in~0.8 in) using
attachment and hold it, then turn sprocket
in rearward positioning the machine so
that the weight is not loaded to shoe.
(3) Preparation for press fitting master pin Winding crawler
1. Preparing for installation
Put square wood under the shoe plate.
2. Aligning master pin holes
Aligning master pin holes through fine
adjustment turning sprocket.
Preparation for press fitting master pin
-When using a big hammer, exercise care so you are not injured by flying objects the same way as
when pushing out the master pin.
-Coat the master pin with molybdenum disulfide grease, before pressing it in.
34-5

Sk75sr-3e S5yt0023e02 Shop Manual - Part2

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Sk75sr-3e S5yt0023e02 Shop Manual - Part2

Uploaded by

Copyright:

Available Formats

㨇24.

(3) Outline of travel unit

1. Hydraulic motor part

Hydraulic motor has the following 3 functions.

1-1. Rotating function

1-2. 2 Speed change function

1-3. Parking brake function

1-1. Rotation function

When the high pressured oil is supplied to the

The rotation of sun gear (A) is transmitted to

The torque and rotation speed generated by

1-2. Speed change (Transmission) function

The larger the cam angle ø is, the larger the

The smaller the cam angle ø is, the smaller the

The travel unit is equipped with 2-speed change

1-3. Function of parking brake

The parking brake is released immediately

The parking brake is gradually operated to

2. Brake valve part

The brake valve has the following 3 functions.

2-2. Functions of shockless crossover relief valve

2-3. Auto 2-speed change function

2-1. Function of counterbalance valve

After high pressured oil is led to port on the

When counterbalance is not provided,

Function of counterbalance valve and mechanism

Hydraulic pressure supply for parking brake release

2-2. Functions of crossover relief valve

Function of shockless crossover relief valve and mechanism

2-3. Auto 2-speed change function

The reduction unit has the following two functions.

3-1. Slow-down function

3-2. Final power output function

Planetary reduction gear

Name / Gear tooth number

(1) Planetary type

24.1.7 SWIVEL JOINT

General view of swivel joint

No. NAME Q'TY No. NAME Q'TY

General view of cylinder

24.1.8.2 CONSTRUCTION AND FUNCTION

Construction of boom cylinder

No. NAME Q'TY No. NAME Q'TY No. NAME Q'TY

(2) Arm cylinder

Construction of arm cylinder

No. NAME Q'TY No. NAME Q'TY No. NAME Q'TY

(3) Bucket cylinder

Construction of bucket cylinder

No. NAME Q'TY No. NAME Q'TY No. NAME Q'TY

(4) Dozer cylinder

Construction of dozer cylinder

No. NAME Q'TY No. NAME Q'TY No. NAME Q'TY

HYDRAULIC CYLINDER CONSTRUCTION (See construction of arm cylinder Fig.)

(1) Operation of cylinder with cushion

(Cushion on rod side)

As the end of the stroke approaches, the

(Cushion on head side)

Cushion on the head side

24.1.9 PILOT VALVE (DOZER)

(3) Performance characteristics

24.2 ELECTRICAL EQUIPMENT

24.2.1 ELECTRICAL EQUIPMENT LIST

Group Code Part Name Part No.

Book Code No. S5Y725E01