SHOP MANUAL

E215
CRAWLER EXCAVATOR

87360601
Issued January 2006
CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machine Remarks
First Edition 01-2006 E215 87360601 NA

Issued January 2006

Book/Form Number 87360601 NA
Copyright © 2006. CNH America, LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. S5PJ0010E01-KO01
 SHOP MANUAL
E215
CRAWLER EXCAVATOR
TABLE OF CONTENTS
SECTION 1
STANDARD SPECIFICATIONS AND MAINTENANCE
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
(Book/Form Number: 5-1540 NA)
CHAPTER 1
GENERAL INFORMATION AND SAFETY
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
(Book/Form Number: 5-1550 NA)
CHAPTER 2
TRANSPORTATION
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
(Book/Form Number: 5-1560 NA)
CHAPTER 3
SPECIFICATIONS
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
(Book/Form Number: 5-1570 NA)
CHAPTER 4
ATTACHMENT DIMENSIONS
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
(Book/Form Number: 5-1580 NA)
CHAPTER 11
TOOLS
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1
(Book/Form Number: 5-11590 NA)
CHAPTER 12
STANDARD MAINTENANCE TIME TABLE
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-1
(Book/Form Number: 5-1600 NA)
CHAPTER 13
MAINTENANCE STANDARDS AND TEST PROCEDURES
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-1
(Book/Form Number: 5-1610 NA)

SECTION 2
HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
(Book/Form Number: 5-1620 NA)
CHAPTER 21
MECHATRO CONTROL SYSTEM
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-I
(Book/Form Number: 5-1630 NA)
CHAPTER 22
HYDRAULIC SYSTEM
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22-1
(Book/Form Number: 5-1640 NA)
CHAPTER 23
ELECTRICAL SYSTEM
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23-1
(Book/Form Number: 5-1650 NA)

87360601 NA Issued 01-06 Bur I

 CHAPTER 24
COMPONENTS SYSTEM
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-1
(Book/Form Number: 5-1660 NA)
CHAPTER 25
AIR CONDITIONING SYSTEM
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-1
(Book/Form Number: 5-1670 NA)

SECTION 3
GENERAL DISASSEMBLY AND ASSEMBLY
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
(Book/Form Number: 5-1680 NA)
CHAPTER 31
GENERAL DISASSEMBLY AND ASSEMBLY
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-1
(Book/Form Number: 5-1690 NA)
CHAPTER 32
ATTACHMENTS
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-1
(Book/Form Number: 5-1700 NA)
CHAPTER 33
UPPER SLEWING STRUCTURE
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-I
(Book/Form Number: 5-1710 NA)
CHAPTER 34
TRAVEL SYSTEM
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-1
(Book/Form Number: 5-1720 NA)

SECTION 4
TROUBLESHOOTING
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
(Book/Form Number: 5-1730 NA)
CHAPTER 41
MECHTRO CONTROL
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41-1
(Book/Form Number: 5-1740 NA)
CHAPTER 42
TROUBLESHOOTING (HYDRAULIC SYSTEM)
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-1
(Book/Form Number: 5-1750 NA)
CHAPTER 43
TROUBLESHOOTING (ELECTRICAL SYSTEM)
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43-1
(Book/Form Number: 5-1760 NA)
CHAPTER 44
TROUBLESHOOTING (ENGINE)
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-1
(Book/Form Number: 5-1770 NA)

SECTION 5
ENGINE
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
(Book/Form Number: 5-1780 NA)
CHAPTER 51
................................................................................. 1
(Book/Form Number: 5-1790 NA)
II Issued 01-06 Bur 87360601 NA
SHOP MANUAL - SECTION 1

E215
CRAWLER EXCAVATORS

STANDARD SPECIFICATIONS
AND MAINTENANCE

Issued January 2006

Book/Form Number
5-1540 NA
Copyright © 2006. CNH America, LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. S5PJ0010E01-KO01
 SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE

CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Remarks
First Edition 01-2006 E215 5-1540 NA
 SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE

SECTION 1
STANDARD SPECIFICATIONS AND MAINTENANCE
TABLE OF CONTENTS
CHAPTER 1
GENERAL INFORMATION AND SAFETY
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
CHAPTER 2
SPECIFICATIONS
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
CHAPTER 3
ATTACHMENT DIMENSIONS
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
1. Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
2. Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3. Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
4. Dozer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
5. Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
CHAPTER 11
TOOLS
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
CHAPTER 12
STANDARD MAINTENANCE TIME TABLE
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
CHAPTER 13
MAINTENANCE STANDARDS AND TEST PROCEDURES
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

5-1540 NA Issued 01-2006 Bur 0-I

 SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE

0-II Issued 01-2006 Bur 5-1540 NA

 SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE

CHAPTER 1

E215
CRAWLER EXCAVATORS

GENERAL INFORMATION AND

SAFETY

Issued January 2006

Book/Form Number 5-1550 NA
Copyright © 2006. CNH America, LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. S5PJ0010E01-KO01
 SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE
CHAPTER 1 - GENERAL INFORMATION AND SAFETY

CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Remarks
First Edition 01-2006 E215 5-1550 NA

1-II Issued 01-06 Bur 5-1550 NA

 SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE

CHAPTER 1
GENERAL INFORMATION AND SAFETY
TABLE OF CONTENTS

1.1 GENERAL SAFETY INFORMATION

1.2 SAFETY PRECAUTIONS
1.3 GENERAL PRECAUTIONS FOR REPAIRS
1.3.1 Preparation Before Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.3.2 Safety In Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.3.3 Disassembling and Assembling Hydraulic Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.3.4 Electrical Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.3.5 Hydraulic Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.3.6 Welding Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.3.7 Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.4 INTERNATIONAL UNIT CONVERSION SYSTEM
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

5-1550 NA Issued 01-06 Bur 1-1

 SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE
CHAPTER 1 - GENERAL INFORMATION AND SAFETY

NOTES

1-2 Issued 01-06 Bur 5-1550 NA

 SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE
CHAPTER 1 - GENERAL INFORMATION AND SAFETY

1.1 GENERAL SAFETY INFORMATION

3. Messages of safety appear in the manual and on
WARNING: Do not operate or perform any the machine:
maintenance on this machine until all
All messages of safety are identified by either
instructions in the OPERATOR’S MANUAL
word of DANGER, WARNING, and CAUTION.
and this MANUAL have been thoroughly
read and understood. DANGER: Shows an imminently hazardous
situation which, if not avoided, will result in
death or serious injury.
WARNING: Improper operation or
maintenance of this machine may cause
accidents and could result in serious injury or WARNING: Shows a potentially hazardous
death. situation which, if not avoided, could result in
death or serious injury.
WARNING: Always keep the manual in
storage. CAUTION: Shows a potentially hazardous
If it is missing or damaged, place an order situation which, if not avoided, may result in
with an authorized Distributor for a minor or moderate injury. It may also be used
replacement. to alert against possible damage to the
If you have any questions, please consult machine and its components.
your dealer.
4. It is very difficult to foresee every danger that
1. Most accidents, which occur during operation, may occur during operation. However, safety can
are due to neglect of precautionary measures be ensured by fully understanding proper
and safety rules. Sufficient care should be taken operating procedures for this machine according
to avoid these accidents. Erroneous operation, to methods recommended.
lubrication or maintenance services are very
dangerous and may cause injury or death of 5. While operating the machine, be sure to perform
p e r s o n n e l . T h e r e fo r e a l l p r e c a u t i o n a r y work with great care, so no damage to the
measures, NOTES, DANGERS, WARNINGS and machine or accidents will occur.
CAUTIONS contained in the manual and on the 6. Continue studying the manual until all Safety,
machine should be read and understood by all Operation and Maintenance procedures are
personnel before starting any work with or on the completely understood by all persons working
machine. with the machine.
2. Operation, inspection, and maintenance should
be carefully carried out, safety must be given the
first priority. The safety information contained in
the manual is intended only to supplement safety
codes, insurance requirements, local laws, rules
and regulations.

5-1550 NA Issued 01-06 Bur 1-3

 SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE
CHAPTER 1 - GENERAL INFORMATION AND SAFETY

1.2 SAFETY PRECAUTIONS

WARNING: The proper lubrication and WARNING: Do not operate this machine
maintenance for this machine are outlined in unless you have read and understand the
the OPERATOR’S MANUAL. instructions in the OPERATOR’S MANUAL.
Improper machine operation is dangerous
and could result in injury or death.
WARNING: Improper lubrication and
maintenance procedures are dangerous and 6. Relieve all pressure in air, oil or water systems
could result in injury or death. Read and before any lines, fittings or related items are
understand the MANUAL before performing disconnected or removed. Always make sure all
maintenance or adding/changing lubricants. raised components are blocked correctly and be
alert for possible pressure when disconnecting
The technician may be unfamiliar with many of the any device from a system that utilizes pressure.
systems on this machine. This makes it important to
7. Lower the bucket, dozer, or other attachments to
use caution when perfor ming ser vice work. A
the ground before performing any work on the
knowledge of the system an/or components is
machine. If this cannot be done, make sure the
important before the removal or disassembly of any
bucket, dozer, ripper or other attachment is
component.
blocked correctly to prevent it from dropping
Because of the size of som e of the machine unexpectedly.
components, the technician should check the weights
8. Use steps and grab handles when mounting or
noted in this manual. Use proper lifting procedures
dismounting a machine. Clean any mud or debris
w h e n r e m o v i n g a n y c o m p o n e n t . We i g h t o f
from steps, walkways or work platforms before
components table is shown in the SPECIFICATIONS
using. Always face the machine when using
section.
steps, ladders and walkways. When it is not
The following is a list of basic precautions that must possible to use the designed access system,
always be observed. provide ladders, scaffolds, or work platforms to
1. Read and understand all warning plates and perform safe repair operations.
de c al s on t he m a c h i ne b e fo re o pe ra ti n g , 9. To avoid back injury, use a hoist when lifting
maintaining or repairing machine. components which weigh 20kg (45lbs) or more.
2. Always wear protective glasses and protective Make sure all chains, hooks, slings, etc., are in
shoes when working around machines. Wear good condition and are the correct capacity. Be
prote ctive glasses when u sing h amm ers, sure hooks are positioned correctly. Lifting eyes
punches or drifts on any part of the machine or are n ot to be side load ed du r ing a lifting
attachments. Use welders gloves, hood/goggles, operation.
apron and the protective clothing appropriate to 10. To avoid burns, be alert for hot parts on
any welding job being performed. Do not wear machines which have just been stopped and hot
loose fitting or torn clothing. Remove all rings fluids in lines, tubes and compartments.
from fingers, loose jewelry. Confine long hair and
11. Be careful when removing cover plates.
loose clothing before working on machinery.
Gradually back off the last two capscrews or nuts
3. Disconnect the battery and hang a “Do Not located at opposite ends of the cover or device
Operate” tag in the Operator’s Compartment. and carefully pry cover loose to relieve any
Remove ignition keys. spring or other pressure before removing the last
4. If possible, make all repairs with the machine two capscrews or nuts completely.
parked on a level, hard surface. Block the 12. Be careful when removing filler caps, breathers
machine so it does not roll while working on or and plugs on the machine. Hold a rag over the
under the machine. Hang a “Do Not Operate” tag cap or plug to prevent from being sprayed by
in the Operator’s Compartment. liquids under pressure. The danger is even
5. Do not work on any machine that is supported greater if the machine has just been stopped
only by jacks or a hoist. Always use blocks or because fluids can be hot.
jack stands capable of supporting the machine.

1-4 Issued 01-06 Bur 5-1550 NA

 SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE
CHAPTER 1 - GENERAL INFORMATION AND SAFETY

13. Always use the proper tools that are in good 19. Loose or damaged fuel, lubricant and hydraulic
condition and that are suited for the job. Be sure lines, tubes and hoses can cause fires. Do not
yo u u n d e r s t a n d h ow t o u s e t h e m b e fo r e bend or strike high pressure lines or install ones
performing any service work. which have been bent or damaged.
14. Reinstall all fasteners with the same part 20. Inspect lines, tubes and hoses carefully. Do not
number. Do not use a lesser quality fastener if check for leaks with your hands. Very small
replacements are necessary. (pinhole) leaks can result in a high velocity oil
15. Repairs which require welding should be stream that will be invisible close to the hose.
performed by personnel adequately trained and This oil can penetrate the skin and cause
knowledgeable in welding procedures. personal injury. Use card-board or paper to
Determine type of metal being welded and select locate pinhole leaks.
correct welding procedure and electrodes, rods 21. Tighten connections to the correct torque. Make
or wire to provide a weld strength equivalent at sure that all heat shields, clamps and guards are
least to that of the parent metal. Make sure to installed correctly to avoid excessive heat,
d i s c o n n e c t b a t t e r y b e fo r e a n y w e l d i n g vibration, or rubbing other parts during operation.
procedures are attempted. Shields that protect against oil spray onto hot
16. Do not damage wiring during removal exhaust components in event of a line, tube or
operations. Reinstall the wiring so it will not be seal failure must be installed correctly.
damaged during operation of the machine by 22. Do not operate a machine if any rotating part is
contacting sharp corners, or by rubbing against damaged or contacts any other par t during
some object or hot surface. operation. Any high speed rotating component
17. Be sure all protective devices including guards that has been damaged or altered should be
and shields are properly installed correctly before checked for balance before reusing.
starting machine. If a guard or shield must be 23. Be careful when servicing or separating the
removed to perform the repair work, replace the tracks. Chips can fly when removing or installing
guard or shield after repair is completed. a track pin. Wear safety glasses and long sleeve
18. Performing maintenance or repair work with the protective clothing. Tracks can unroll very quickly
bucket raised is dangerous due to the possibility when separated. Keep away from front and rear
of it falling. Lower the attachment and place the of machine. The machine can move
bucket on the ground before starting the work. unexpectedly when both tracks are disengaged
from the sprockets. Block the machine to prevent
it from moving.

5-1550 NA Issued 01-06 Bur 1-5

 SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE
CHAPTER 1 - GENERAL INFORMATION AND SAFETY

1.3 GENERAL PRECAUTIONS FOR REPAIRS

1.3.1 PREPARATION BEFORE DISASSEMBLING 4. Identify the location of a first-aid kit and a fire
extinguisher, also who to contact in case of an
emergency.
5. Choose a hard, level and safe place, and place
1. Understand operating procedure the attachment on the ground securely.
Read OPERATOR’S MANUAL and this MANUAL 6. Use a hoist to remove heavy parts (20 kg [45 lbs]
carefully prior to operating the machine. or more) from the machine.
2. Cleaning machines 7. Use proper tools, and replace or repair defective
tools.
Remove soil, mud, and dust from the machine
before service. This will increase work efficiency 8. Support the machine and attachment with
and prevent damaging parts, and aid in rust supports or blocks if the work is performed in the
p r ev e n t i o n a n d d u s t p r o t e c t i o n w h i l e lifted condition.
reassembling.
1.3.3 DISASSEMBLING AND ASSEMBLING
3. Inspecting machines HYDRAULIC EQUIPMENT
Identify the parts to be disassembled before
star ting work, determine the disassembling
procedure taking into consideration working
conditions etc. Request necessary par ts in
1. Removing hydraulic equipment
advance.
A. Before disconnecting pipes, release the
4. Record the following items
hydraulic pressure in the system.
A. Inspection date and place
B. Carefully drain oil from the removed pipes into
B. Model name, applicable machine number, and a containers without spilling on the floor.
hour meter reading
C. Install plugs or caps on the pipe ends to avoid
C. Problem conditions, place and cause. oil spillage and contamination.
D. Visible oil leakage, water leakage and D. Clean off the external surface of the
damage. equipment before disassembling, drain
E. Clogged filters, oil level, oil quality, oil hy d r a u l i c a n d g e a r o i l b e fo r e p l a c i n g
contamination and loose connections. component on the workbench.
F. Is it a recurring fault at approximately the 2. Disassembling hydraulic equipment
same amount of operating hours? A. Do not modify the hydraulic equipment without
5. Arrangement and cleaning in service shop t h e p e r m i s s i o n o f t h e m a n u fa c t u r e r.
Manufacturer will not be responsible for the
A. Tools required for repair work.
performance and function of the product after
B. Prepare space to place the disassembled modification.
parts.
B. When disassembling and reassembling for
C. Prepare oil containers for draining oil etc. repair, refer the work to qualified personnel
who have the knowledge or have completed
1.3.2 SAFETY IN DISASSEMBLING AND the service training.
ASSEMBLING
C. Provide aligning markings to facilitate
reassembly.
D. Before starting the work, read the manual for
disassembly procedures and decide whether
1. Wear appropriate clothes with safety shoes, the work can be performed by yourself or if
safety helmet, and protective safety glasses. assistance is required.
2. Suspend warning tag DO NOT OPERATE from E. Use the special jig or tools if they are
the doorknob or the operating lever. specified.
3. Stop the engine before starting inspection and
maintenance.

1-6 Issued 01-06 Bur 5-1550 NA

 SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE
CHAPTER 1 - GENERAL INFORMATION AND SAFETY

F. If it is hard to remove a part according to the C. Perform air bleeding of the hydraulic pump
procedure, do not force it, investigate the and slewing motor after loosening the upper
cause. drain plug, start and run the engine at low idle.
G. Place the removed parts in order and attach Air bleeding is completed when clear hydraulic
tags to facilitate the reassembly. oil is visible, tighten plug.
H. Note the location and quantity of parts D. Perform air bleeding of the travel motor and
commonly applied to multiple locations. the hydraulic cylinders by running the engine
3. Inspecting parts for more than 5 minutes at low speed without
load.
A. Ensure that the disassembled parts are free
from seizure, interference and uneven contact. NOTE: Do not allow hydraulic cylinders to bottom
out on the stroke end just after maintenance.
B. Measure and record wear condition of parts
and clearance. E. Perform air bleeding of pilot line by performing
a ser ies of digg ing, slewing and travel
C. If the problem is found in a part, repair or
operations.
replace it.
F. Check hydraulic oil level after placing the
4. Reassembling hydraulic equipment
attachment to the oil check position, and
A. Turn ON the ventilation fan or open windows replenish oil if necessary.
to maintain good ventilation prior to cleaning
parts.
B. Perform rough and finish cleaning before
assembling.
C. Remove solvent by air and apply clean
hydraulic or gear oil for assembling.
D. Always replace the removed O-rings, backup
rings and oil seals with new ones. Apply SPW01000004E01 Figure 1
grease in to aid installation.
1.3.4 ELECTRICAL EQUIPMENT
E. Remove dirt and moisture from and perform
degreasing on the surface where liquid gasket
is to be applied.
F. Remove rust preventive agent from the new
parts before use. 1. Turn the key OFF prior to connecting and
disconnecting connectors.
G. Fit bearings, bushings and oil seals using
proper tools. 2. Disconnect the connector by holding it and
pressing the lock. Do not pull on the wires to
H. Assemble the parts utilizing matching marks. separate connectors.
I. Ensure all the parts are completely assembled 3. Connect the connector and ensure it is
after the work. completely locked.
5. Installing hydraulic equipment 4. Turn the key OFF prior to touching the terminal of
A. Ensure hydraulic oil and lubricants are at starter or generator.
proper levels. 5. Remove the ground terminal of battery when
B. Perform air bleeding when: handling tools around the battery or its relay.
• Hydraulic oil is changed 6. Do not splash water on the electrical equipment
• Parts of suction piping is replaced and connectors during machine washing.
• Hydraulic pump is installed
• Slewing motor is installed 7. Check for moisture inside the waterproof
• Travel motor is installed connector after disconnection. If moisture is
• Hydraulic cylinders installed found, dry it completely before reconnecting.

WARNING: Operation of the hydraulic

equipment without filling hydraulic oil or
lubricant or without performing air bleeding
will result in damage to the equipment.

5-1550 NA Issued 01-06 Bur 1-7

 SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE
CHAPTER 1 - GENERAL INFORMATION AND SAFETY

2. Flexible hose
WARNING: Battery electrolyte is • Use approved parts.
hazardous. • Tighten the fitting at the specified torque.
Battery electrolyte is diluted sulfuric acid. • Ensure there are no kinks, tension, interference
Exposure of skin or eyes will cause burning nor oil leakage present.
or loss of eyesight.
If the exposure occurs, take the following 1.3.6 WELDING REPAIR
emergency measures and seek the advice of 1. Refer welding repair to qualified personnel.
a medical specialist.
2. Disconnect the ground cable of the battery
• When skin is exposed:
before starting the repair. Failure to do so will
Wash with water and soap immediately.
cause damage to the electrical equipment.
• When eyes are exposed:
Immediately wash away with water 3. Move away any objects that may cause fire if
continuously for more than 10 minutes. exposed to sparks.
• If a large spill occurs: 4. Before starting the repair of the attachment,
Neutralize with sodium bicarbonate or cover the plated surface of the piston rod with a
wash away with water. flameproof sheet to prevent it from being
• When swallowed: exposed to sparks.
Drink a large amount of milk or water.
1.3.7 ENVIRONMENTAL PROTECTION
• When clothing is exposed:
Immediately undress and wash. 1. Run the engine in a place that has sufficient
ventilation.
1.3.5 HYDRAULIC PARTS 2. Industrial waste disposal
Dispose of the following parts according to the
relevant regulations:
• Waste oil and waste container
1. O-ring • Battery
• Make sure O-rings have elasticity and are not 3. Precautions for handling hydraulic oil
damaged before use. Exposure of eyes to hydraulic oil will cause
• Use the appropriate O-rings. O-rings are made inflammation. Wear protective glasses before
of various kinds of materials having different handling to avoid an accident. If eyes are
hardness or materials to apply to a variety of exposed to the oil, take the following emergency
parts. Though sizes may be the same, physical measures:
materials may differ. Use only correct
When eyes are exposed:
replacement parts.
• Immediately wash away with water until
• Install the O-rings without distortion.
burning vanishes.
• Replace floating seals as a pair.
When swallowed:
• Do not induce vomiting, seek medical
treatment immediately.
When skin exposed:
• Wash thoroughly with water and soap.
4. Others
Use genuine replacement parts and lubricants
authorized by the manufacturer.

1-8 Issued 01-06 Bur 5-1550 NA

 SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE
CHAPTER 1 - GENERAL INFORMATION AND SAFETY

1.4 INTERNATIONAL UNIT CONVERSION SYSTEM

INTRODUCTION 3. Supplementary units
NOTE: Information based on MARKS’ STANDARD QUANTITY UNIT SYMBOL
HANDBOOK FOR MECHANICAL ENGINEERS
Plane angle radian rad
Although this manual includes International System Solid angle steradian sr
of Unit and Foot-Pound System of Units, if you need
SI unit, refer to the following international system of 4. Derived Units bearing Peculiar Designations
units.
SYMB
Given is an excerpt of the units that are related to this QUANTITY UNIT FORMULA
OL
manual. Frequency hertz Hz 1/s
1. Etymology of SI Unites Force newton N kg · m/s2
French: Le Systeme International d’ Unites Pressure and Stress pascal Pa N/m2
English: International System of Units Energy, Work and
joule J N·m
2. Construction of SI Unit System Quantity of heat
Power watt W J/s
coulom
Quantity of electricity C A·s
b
Electric potential
difference, Voltage,
volt V W/A
and Electromotive
force
Quantity of static
electricity and farad F C/V
Electric capacitance
Electric resistance ohm Ω V/A
Celsius
degree (t+273.15
SPW01000007E01 Figure 2 Celsius temperature
or
°C )K
1. Base units degree

QUANTITY UNIT SYMBOL

Illuminance lux lx l m/m2
Length meter m
5. Prefixes of SI
Mass kilogram kg
Time second s MULTIPLICATION
PREFIX SYMBOL
Electric current ampere A FACTORS

Thermodynamic temperature kelvin K giga G 109

Amount of substance mol mol mega M 106
Luminous intensity candela cd kilo k 103

2. Derived Units hecto h 102

deca da 10
QUANTITY UNIT SYMBOL
deci d 10–1
Area square meter m2 centi c 10–2
Volume cubic meter m3 milli m 10–3
Velocity meter per second m/s
micro m 10–6
Acceleration meter per second squared m/s2
nano n 10–9
Density kilogram per cubic meter kg/m3
pico p 10–12

5-1550 NA Issued 01-06 Bur 1-9

 SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE
CHAPTER 1 - GENERAL INFORMATION AND SAFETY

6. Unit Conversion

QUANTITY GRAVITATIONAL SI CONVERSION FACTOR

Mass kg kg
Force kgf N 1 kgf=9.807 N
Torque kgf·m Nm kgf m=9.807 Nm
Pressure kgf/cm2 MPa 1 kgf/cm2=0.09807 MPa
Motive Power PS kW 1 PS=0.7355 kW
Revolution rpm min–1 r/min *1
*1 Units that are allowed to use.

1-10 Issued 01-06 Bur 5-1550 NA

 SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE

CHAPTER 2

E215
CRAWLER EXCAVATORS

TRANSPORTATION

Issued January 2006

Book/Form Number 5-1560 NA
Copyright © 2006. CNH America, LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. S5PJ0010E01-KO02
 SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE
CHAPTER 2 - SPECIFICATIONS

CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Remarks
First Edition 01-2006 E215 5-1560 NA

2-II Issued 01-2006 Bur 5-1560 NA

 SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE

CHAPTER 2
GENERAL INFORMATION AND SAFETY
TABLE OF CONTENTS

A. GROUND TRANSPORTATION
1. Machine Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
2. Loading the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
3. Securing Machine to Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
B. LIFTING MACHINE
1. Lifting Machine with Attachment Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2. Lifting Machine without Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
C. SHIPPING DIMENSIONS
1. Figure 5-10A and 5-10B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
a. Machine with Standard Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
b. Boom With Arm Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
c. Arm with Bucket Cylinder and Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
e. Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2. Figure 12A and 5-12B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
a. Machine with Standard Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
b. Boom with Arm Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
c. Arm with Bucket Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
d. Arm with Bucket Cylinder and Bucket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
e. Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

5-1560 NA Issued 01-06 Bur 1-1

 SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE
CHAPTER 2 - GENERAL INFORMATION AND SAFETY

NOTES

1-2 Issued 01-06 Bur 5-1560 NA

A. GROUND TRANSPORTATION c. Obtain any permits required from proper
1. Machine Preparation gover nment agencies f or machine
transportation.
a. Know the total weight, length, width and
height of the machine being transported. d. Use only a trailer with a rated capacity
See Figures 5.2A and 5.2B. sufficient to transport the machine.

b. Know route to be traveled. Investigate e. Make certain trailer has ramps or a ramp is
bridges, overpasses, height of road signs on available for loading and unloading the
route. machine.

2,290 mm (7'-6")
9,440 mm (31'-0") [2,440 mm (8'-0")]

700 mm 3,070 mm (10'-1")

(2'-4") 3,770 mm (12'-4")
150 mm (5.9")

530
(1'9")

FIGURE 5.2A

Dimensions and weights are with 2.94 m (9’-8”) arm, SHOES 600 mm 700 mm 800 mm 900 mm
MODEL (23.6") (27.6") (31.5") (35.4")
0.81 m3(1.06 yard)
3
bucket and 5.65 m (18’-6”) boom.
20,000
(44,090)
-- -- --
Note: This illustration is for demonstration purposes
only. Always, make sure to check actual dimensions 20,500 21,000 21,300 21,500
E215 (45,200) (46,300) (47,000) (47,400)
after machine is loaded on trailer.

10,100 mm (33'-2") 2,360 mm (7'-9")

660 mm 3,140 mm (10'-4")

50 mm (2")

(2'-2") 3,800 mm (12'-6")

100 mm (3.9")

FIGURE 5.2B

Dimensions and weights are with 2.98 m (9’-9”) arm, SHOES 600 mm 800 mm 900 mm
MODEL (23.6") (31.5") (35.4")
1.04 m3 (1.36 yard3) Bucket and 6.02 m (19’-9”) Boom.
23,600
Note: This illustration is for demonstration purposes (52,000)
-- --
only. Always, make sure to check actual dimensions
24,200 24,800 25,100
after machine is loaded on trailer. E215 (53,350) (54,700) (55,300)

2
 Never attempt to load or unload machine without
ramps.

2. Loading the Machine

a. Apply parking brakes on tractor and trailer
and chock trailer wheels before attempting
to load or unload machine.
b. Lower ramps of trailer.
c. Place travel speed select switch on travel
lever in 1st (SLOW) speed position and move
throttle control to the LO idle position. See
Figure 5.3A.
d. Slowly drive machine up trailer ramps and
over rear axles of trailer.
e. Slowly drive machine completely onto trailer
until in proper transport position.
FIGURE 5.3A
f. Slowly swing machine 180° until attachment
is toward rear of trailer.
g. Slowly lower boom until attachment rests on
trailer bed.
h. Place safety lock lever in the up “LOCKED”
position. See Figure 5.3C.
i. Turn machine “OFF”, remove key and lock all
doors, filler caps and access panels.
Place a cover over the exhaust pipe of the machine
and secure to avoid water entering the engine, and
possible turbo damage.

To prevent the arm and bucket cylinder (s) from any

damage, you are advised to follow the following
instructions. Do not have the arm and/or bucket Do not try to load Machine without attachment in
cylinder fully extended to a “ramp over center” this type of trailer. machine could tip over. This
situation. This allows sudden and abrupt contact of illustration is for demonstration only.
the arm or bucket to a trailer deck, ramp or the FIGURE 5.3B
ground. This can result in internal mechanical
contact, which can stretch the cylinder rod(s).
SAFETY LOCK
LEVER IN
LOCKED
(UP) POSITION
Put a cover over the exhaust pipe of the machine to
keep water from entering the engine and possible
turbo damage.

SK32004152

FIGURE 5.3C

3
3. Securing Machine to Trailer B. LIFTING MACHINE
a. Use cable or wire rope with sufficient The following procedures are for lifting the machine,
capacity to secure front and rear of the as built by the manufacturer. These procedures do not
machine to trailer. See Figure 5.4A. Chock take into account modifications made to the machine
the tracks, use the lower frame front and rear
brackets to secure machine to trailer. Also, that affect machine weight or center of gravity.
make sure to secure front and rear of each 1. Lifting Machine With Attachment Installed
track.
a. Locate lifting locations at the front and rear of
b. Securely fasten all loose parts, as well as each crawler frame. See Figure 5.4B.
removed parts to trailer or transporting
platform. b. Attach cables or wire rope with a capacity
rating sufficient to lift the machine, at lifting
locations..

SECURE
FRONT and REAR
OF EACH TRACK

A B
Between 1st and 2nd Between last two rollers
front rollers

802 mm (31.6") 267 mm (10.5")

E215 843 mm (33.2") 307 mm (12.1")

SECURE
ATTACHMENT
FIGURE 5.4B

Place a hardwood or steel block between cables

FIGURE 5.4A SK32004153 and crawler frame to prevent damage to the tracks
from cables during lifting. See Figure 5.4C

Block
FIGURE 5.4C

4
 c. Bring loose ends of cables together at
machine center of gravity and attach to an
overhead lifting device with a rated lifting
capacity sufficient to lift the machine. See Always use proper lifting equipment and devices.
Figure 5.5A to 5.7A. Use of improper lifting equipment could allow the
load to shift or fall causing severe damage, serious
NOTE: It may be necessary to place reinforced injury or death.
spreader bars between lifting cables to prevent
damage to the machine during lifting. See Figures
5.5A to 5.7A.
IMPORTANT: Lifting machine with wider track
Do not use the counterweight lifting eyes to lift
shoes will tend to shift the Center of Gravity slightly
machine.
forward, toward the center of the slewing ring.

WEIGHT : 20,000 kg (44,100 lbs)

ARM : 2.94 M (9'-8") C
A

2,000 mm (6'-7")
SHOE : 600 mm (23.6") B

(45 )
(13 ) (45 )
) (11
4,000 mm (13'-1")
CENTER OF GRAVITY

3,400 mm (11'-2")
75 mm
670 mm (3") 645 mm
(26.4") (25.4")

PLACE BLOCK BETWEEN EACH CABLE AND FRAME

FIGURE 5.5A
A. One 33.5 x 15.0 m Cable B. One 33.5 x 14.9 m Cable C. Two 4.0 m Spreader Bars

WEIGHT : 20,500 kg (45,200 lbs)

ARM : 2.94 M (9'-8") C
2,000 mm (6'-7")

SHOE : 600 mm (23.6") B

A
MODEL : E215
(45 )
(45 )
(13 )
) (12 4,000 mm (13'-1")

CENTER OF GRAVITY
3,400 mm (11'-2")

75 mm
(3")
695 mm 635 mm
(27.4") (25")
PLACE BLOCK BETWEEN EACH CABLE AND FRAME
FIGURE 5.5B
A. One 33.5 x 15.2 m Cable B. One 33.5 x 15.1 m Cable C. Two 4.0 m Spreader Bars

5
 Always use proper lifting equipment and devices. Do not use the counterweight lifting eyes to lift
Use of improper lifting equipment could allow the machine.
load to shift or fall causing severe damage, serious
injury or death. IMPORTANT: Lifting machine with wider track
shoes will tend to shift the Center of Gravity slightly
forward, toward the center of the slewing ring.

2,000 mm (6'-7")
WEIGHT : 23,600 kg (52000lbs) A B
ARM : 2.98M (9'- 9")
SHOE : 600mm (23.6") (45 )
(13 (45 )
) (1 0)
4,000 mm (13'-1")
CENTER OF GRAVITY

3,400 mm (11'-2")
140mm
(5.5")
680 mm 645 mm
(26.8") (25.4")
PLACE BLOCK BETWEEN EACH CABLE AND FRAME
FIGURE 5.6A
A. One 37.5 x 15.2 m Cable B. One 37.5 x 15.1 m Cable C. Two 4.0 m Spreader Bars

WEIGHT : 24,200 kg (53,350lbs)

ARM : 2.98M (9'-9")
C
2,000 mm (6'-7")

SHOE :600 mm (23.6") A B

MODEL : E215
(45 )
(4 5 )
(15 ) 4,000 mm (13'-1")
) (12
CENTER OF GRAVITY
3,400 mm (11'-2")

710 mm 135 mm 675 mm

(5.3")
(28") (26.6")

PLACE BLOCK BETWEEN EACH CABLE AND FRAME

FIGURE 5.6B
A. One 37.5 x 15.5 m Cable B. One 37.5 x 15.3 m Cable C. Two 4.0 m Spreader Bars

6
 Always use proper lifting equipment and devices. Do not use the counterweight lifting eyes to lift
Use of improper lifting equipment could allow the machine.
load to shift or fall causing severe damage, serious
IMPORTANT: Lifting machine with wider track
injury or death.
shoes will tend to shift the Center of Gravity slightly
forward, toward the center of the slewing ring.

WEIGHT : 24,100 kg (53,130 lbs)

ARM : 2.98 M (9'-9") C

2,000 mm (6'-7")
A B
SHOE : 600 mm (23.6")
MODEL : E215
(45 )
(45 )
(14 ) 4,000 mm (13'-1")
) (13
CENTER OF GRAVITY

3,400 mm (11'-2")
710 mm 135 mm 675 mm
(5.3")
(28") (26.6")
PLACE BLOCK BETWEEN EACH CABLE AND FRAME

FIGURE 5.7A
A. One 37.5 x 15.5 m Cable B. One 37.5 x 15.3 m Cable C. Two 4.0 m Spreader Bars

7
2. Lifting Machine Without Attachment
Pass the cables through the lifting points on the
crawlers as indicated in page 4 and bring loose Always use proper lifting equipment and devices.
ends of cables together at machine center of Use of improper lifting equipment could allow the
gravity. Attach to an overhead lifting device with a load to shift or fall causing severe damage, serious
rated lifting capacity sufficient to lift the machine. injury or death.

See Figures 5.7B to 5.9B for better reference.

IMPORTANT: Lifting machine with wider track

shoes will tend to shift the Center of Gravity slightly Do not use the counterweight lifting eyes to lift
forward, toward the center of the slewing ring. machine.

2,000 mm (6'-7")
WEIGHT : 16,400 kg (36,160 lbs)
SHOE : 600 mm (23.6") A B
(45 )
(45 )
(2
0)

(5 ) 4,000 mm (13'-1")
CENTER OF GRAVITY

3,400 mm (11'-2")

765 mm
670 mm (30.1") 645 mm
(26.4") (25.4")
PLACE BLOCK BETWEEN EACH CABLE AND FRAME
FIGURE 5.7B
A. One 33.5 x 15.4 m Cable B. One 33.5 x 14.7 m Cable C. Two 4.0 m Spreader Bars

8
 Always use proper lifting equipment and devices. Do not use the counterweight lifting eyes to lift
Use of improper lifting equipment could allow the machine.
load to shift or fall causing severe damage, serious
IMPORTANT: Lifting machine with wider track
injury or death.
shoes will tend to shift the Center of Gravity slightly
forward, toward the center of the slewing ring.

WEIGHT : 16,900 kg (37,260 lbs)

SHOE : 600 mm (23.6")

2,000 mm (6'-7")
C
MODEL : E215 A
B (45 )
(45 )
(2
0
)

(5 ) 4,000 mm (13'-1")
CENTER OF GRAVITY

3,400 mm (11'-2")

750 mm
695 mm (29.5") 635 mm
(27.4") (25")
PLACE BLOCK BETWEEN EACH CABLE AND FRAME
FIGURE 5.8A
A. One 33.5 x 15.6 m Cable B. One 33.5 x 14.9 m Cable C. Two 4.0 m Spreader Bars

WEIGHT : 19,700 kg (43,430 lbs)

SHOE : 600 mm (23.6")
2,000 mm (6'-7")

C
A B
(45 )
(45 )
(2
0

(2 )
)

4,000 mm (13'-1")
CENTER OF GRAVITY
3,400 mm (11'-2")

865 mm
680 mm (34.1") 645 mm
(26.8") (25.4")
PLACE BLOCK BETWEEN EACH CABLE AND FRAME
FIGURE 5.8B
A. One 37.5 x 15.7 m Cable B. One 37.5 x 14.9 m Cable C. Two 4.0 m Spreader Bars

9
 Always use proper lifting equipment and devices. Do not use the counterweight lifting eyes to lift
Use of improper lifting equipment could allow the machine.
load to shift or fall causing severe damage, serious
IMPORTANT: Lifting machine with wider track
injury or death.
shoes will tend to shift the Center of Gravity slightly
forward, toward the center of the slewing ring.

WEIGHT : 20,300 kg (44,750 lbs)

2,000 mm (6'-7")
SHOE : 600 mm (23.6") C
MODEL : E215 A
B
(45 )
(45 )
(2

4,000 mm (13'-1")
2 )

CENTER OF GRAVITY (4 )

3,400 mm (11'-2")

845 mm
710 mm (33.3") 675 mm
(28") (26.6")
PLACE BLOCK BETWEEN EACH CABLE AND FRAME

FIGURE 5.9A
A. One 37.5 x 16.0 m Cable B. One 37.5 x 15.1 m Cable C. Two 4.0 m Spreader Bars

WEIGHT : 20,200 kg (44,530 lbs)

SHOE : 600 mm (23.6") A B C
2,000 mm (6'-7")

MODEL : E215

(45¡)
(2
2¡ (45¡)
) )
CENTER OF GRAVITY (1¡ 4,000 mm (13'-1")
3,400 mm (11'-2")

710 mm 845 mm 675 mm

(28") (33.3") (26.6")

PLACE BLOCK BETWEEN EACH CABLE AND FRAME

FIGURE 5.9B
A. One 37.5 x 16.0 m Cable B. One 37.5 x 15.1 m Cable C. Two 4.0 m Spreader Bars

10
C. SHIPPING DIMENSIONS a.1- Standard Boom - 5.65 m (18’-6”)
1. E215 - Figure 5-10A & 5-10B a.2- Standard Arm - 2.94 m (9’-8”)
a.3- Bucket - 0.80 m3 (1.05 yard)
3
a. Machine With Standard Attachments
Refer to Figure 5.10A & 5.10B for reference in
regards to the machine basic dimensions,
as manufactured with standard
attachments:

9,410mm (30'-10")
2,750mm (9'-0")
2,910mm (9'-7'')

2,930mm (9'-7")
1,060mm
(3'-6")
4,170mm (13'-8"), 4,450mm 14'-7'' -LC (23.6") 600mm 450mm(17.7")

4,960mm (16'-3'')-LC 2,990mm (9'-10'')-LC

4,820mm (15'-10'')
Marked dimensions do not include height of grouser.
FIGURE 5.10A

9,410mm (30'-10")
2,750mm (9'-0")
2,910mm (9'-7'')

2,930mm (9'-7")
1,060mm
(3'-6")

4,170mm (13'-8"), 4,450mm 14'-7'' -LC (31.5") 800mm 450mm (17.7")

4,960mm (16'-3'')-LC 3,190mm (10'-6'')
4,820mm (15'-10'')
Marked dimensions do not include height of grouser.
FIGURE 5.10B

b. Boom with Arm Cylinder

Height

Length
FIGURE 5.10C

Boom ....................................................5650 (18' 6")

Boom Length ..................................5850 mm (19' 2")
Boom Height .....................................1390 mm (4' 7")
Boom Width .........................................678 mm (2'3")
Boom Weight( with Arm Cylinder) 1570 Kg (3454 lbs)

11
c. Arm with Bucket Cylinder

Height

Length

FIGURE 5.11A

Arm 2400 mm (7' 10") Arm 2940 mm (9' 8") Arm 3330 mm (10' 10")

3380 x 828 x 348 3901 x 821 x 348 4310 x 821 x 348

L x W x H - mm (ft-in) (11' 1" x 2' 7" x 1' 2") (12' 10" x 2' 8" x 1' 2") (14' 2" x 2' 8" x 1' 2")
Weight- Kg (lbs)
880 (1936) 980 (2156) 1650 (3640)
with Bucket Cylinder

d. Arm with Bucket Cylinder and Bucket

FIGURE 5.11B
Arm 2.4 m (7' 10") Arm 2.94 m (9' 8") Arm 3.3 m (10' 10")
Bucket 0.93 m3 (1.22 yrd3) Bucket 0.81 m3 (1.06 yrd3) Bucket 0.70 m3 (0.92 yrd3)
4733 x 890 x 1330 5254 x 890 x 1160 5663 x 890 x 1080
L x W x H - mm (ft-in) (15' 7" x 2' 11" x 4' 4") (17' 3" x 2' 11" x 3' 10") (18' 6" x 2' 11" x 3' 7")

Weight - Kg (lbs) 1520 (3344) 1620 (3570) 1650 (3640)

e. Bucket - Standard bucket is 0.81 m3 (1.06 yard3)

A
C
D

FIGURE 5.11C
A - Length ........................................1,370 mm (4’-6”) D - Width with side cutters ..............1,160 mm (3’-10”)
B - Height ........................................ 1,260 mm (4’-2”) E - Bucket weight ...........................650 kg (1,430 lbs)
C - Width without side cutters ........... 1,050 mm (3’-5”)

12
C. SHIPPING DIMENSIONS a.1- Standard Boom - 5.65 m (18’-6”)
1. E215 - Figure 5-10A & 5-10B a.2- Standard Arm - 2.94 m (9’-8”)
a.3- Bucket - 0.80 m3 (1.05 yard)
3
a. Machine With Standard Attachments
Refer to Figure 5.10A & 5.10B for reference in
regards to the machine basic dimensions ,
as manufactured with standard
attachments:

9,410mm (30'-10")
2,750mm (9'-0")
2,910mm (9'-7'')

2,930mm (9'-7")
1,060mm
(3'-6")
4,170mm (13'-8"), 4,450mm 14'-7'' -LC (23.6") 600mm 450mm(17.7")

4,960mm (16'-3'')-LC 2,990mm (9'-10'')-LC

4,820mm (15'-10'')
Marked dimensions do not include height of grouser.
FIGURE 5.10A

9,410mm (30'-10")
2,750mm (9'-0")
2,910mm (9'-7'')

2,930mm (9'-7")
1,060mm
(3'-6")

4,170mm (13'-8"), 4,450mm 14'-7'' -LC (31.5") 800mm 450mm (17.7")

4,960mm (16'-3'')-LC 3,190mm (10'-6'')
4,820mm (15'-10'')
Marked dimensions do not include height of grouser.
FIGURE 5.10B

b. Boom with Arm Cylinder

Height

Length
FIGURE 5.10C

Boom ....................................................5650 (18' 6")

Boom Length ..................................5850 mm (19' 2")
Boom Height .....................................1390 mm (4' 7")
Boom Width .........................................678 mm (2'3")
Boom Weight( with Arm Cylinder) 1570 Kg (3454 lbs)

11
c. Arm with Bucket Cylinder

Height

Length

FIGURE 5.13A

Arm 2500 mm (8' 2") Arm 2980 mm (9' 9") Arm 3660 mm (12' 0")

3590 x 901 x 352 4048 x 896 x 352 4800 x 896 x 352

L x W x H - mm (ft-in) (11' 9" x 3' 0" x 1' 2") (13' 3" x 2' 11" x 1' 2") (15' 9" x 2' 11" x 1' 2")
Weight- Kg (lbs)
1060 (2340) 1110 (2450) 1270 (2800)
with Bucket Cylinder

d. Arm with Bucket Cylinder and Bucket

FIGURE 5.13B
Arm 2.50 m (8' 2") Arm 2.98 m (9' 9") Arm 3.66 m (12' 0")
Bucket 1.20 m3 (1.57 yrd3) Bucket 1.00 m3 (1.31 yrd3) Bucket 0.81 m3 (1.06 yrd3)
4733 x 890 x 1440 5254 x 890 x 1160 5663 x 890 x 1060
L x W x H - mm (ft-in) (15' 7" x 2' 11" x 4' 9") (17' 3" x 2' 11" x 3' 10") (18' 6" x 2' 11" x 3' 6")

Weight - Kg (lbs) 1940 (4280) 1940 (4280) 2010 (4400)

e. Bucket - Standard bucket is 1.04 m3 (1.36 yard3)

A
C
D

FIGURE 5.13C
A - Length ......................................1,470 mm (4’-10”) D - Width with side cutters ................1,280 mm (4’-2”)
B - Height ........................................ 1,340 mm (4’-5”) E - Bucket weight ...........................780 kg (1,720 lbs)
C - Width without side cutters ......... 1,180 mm (3’-10”)

14
 SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE
CHAPTER 2 - GENERAL INFORMATION AND SAFETY

NOTES

1-2 Issued 01-06 Bur 5-1290 NA

 SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE

CHAPTER 3

E215
CRAWLER EXCAVATORS

SPECIFICATIONS

Issued January 2006

Book/Form Number 5-1570 NA
Copyright © 2006. CNH America, LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. S5PJ0010E01-KO03
 SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE
CHAPTER 3 - SPECIFICATIONS

CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Remarks
First Edition 01-2006 E215 5-1570 NA

3-II Issued 01-2006 Bur 5-1570 NA

 SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE

CHAPTER 3
SPECIFICATIONS
TABLE OF CONTENTS

1 GENERAL SPECIFICATIONS
3.1.A. Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
3.1.B. Working Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
3.1.C. Standard Attachment Working Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.1.D. Digging Forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.1.E. Bucket Selection Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.1.F. Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3.1.G. Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3.1.H. Bucket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3.1.I. Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3.1.J. Performance Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1. Travel Speed, Swing Speed, and Grade Ability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2. Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3. Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4. Operating Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.1.K. Machine and Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.1.L. Lifting Capacities for European Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
3.1.M. Lifting Capacities (KAI Specifications) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
2. LONG REACH SPECIFICATIONS
3.2.A. Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
3.2.B. Working Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
3.2.C. Working Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
3.2.D. Digging Forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
3.2.E. Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
3.2.F. Long Reach Lifting Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
3. TORQUE SPECIFICATIONS
3.3.A. Cap Screws and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
3.3.B. ORS Joint (O-ring sealing type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
3.3.C. Nuts and Sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
3.3.D. Flare Type Fitting Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
3.3.E. Nylon (N2) Tube Fitting Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
3.3.F. Torque Values for Most Common Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
4. MISCELLANEOUS INFORMATION
Temperatures Tables, Plugs, Weights, etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

5. CONVERSION TABLES
3.4.1 Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

5-1570 NA Issued 01-2006 Bur 3-1

 SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE
CHAPTER 3 - SPECIFICATIONS

NOTES

3-2 Issued 01-2006 Bur 5-1570 NA

1. GENERAL SPECIFICATIONS
The specifications found in this section are given on the Standard E215 Hydraulic Excavator as
manufactured. No modifications or options are taken in to consideration in regard to these specifications.
1-A. MACHINE DIMENSIONS

600 mm Track Shoes: Machine dimensions with Standard Boom {5.65 m (18’ 6”)}, Standard Arm {2.94 m (9’ 8”)},
Bucket {0.81 m3(1.06 cu.Yd.)}, Track Shoes {600 mm (23.6”)}.
9,410mm (30'-10")
2,750mm (9'-0")

2,930mm (9'-7")
- )"
2,910 mm (9'7

1,060mm
(3'-6")
4,170mm (13'-8"), 4,450mm 14'-7'' -LC (23.6") 600mm 450mm(17.7")

4,960mm (16'-3'')-LC 2,990mm (9'-10'')-LC

4,820mm (15'-10'')
Marked dimensions do not include height of grouser.

800 mm Track Shoes: Machine dimensions with Standard Boom {5.65 m (18’ 6”)}, Standard Arm {2.94 m (9’ 8”)},
Bucket {0.81 m3 (1.06 cu.Yd.)}, Track Shoes {800 mm (23.6”)}.
9,410mm (30'-10")
2,750mm (9'-0")

2,930mm (9'-7")
- ")
2,910 mm (9'7

1,060mm
(3'-6")

4,170mm (13'-8"), 4,450mm 14'-7'' -LC (31.5") 800mm 450mm (17.7")

4,960mm (16'-3'')-LC 3,190mm (10'-6'')
4,820mm (15'-10'')
Marked dimensions do not include height of grouser.

1-B. WORKING WEIGHTS

TRIPLE GROUSER SHOES

Track Shoe Width mm (in) 600 (23.6) 700 (27.6) 800 (31.5) 900 (35.4)

Overall Width m (ft-in) 2.99 (9-10) 3.09 (10-2) 3.19 (10-6) 3.29 (10-10)

Ground Pressure kg/cm2 (psi) 0.43 (6.11) 0.37 (5.40) 0.33 (4.83) 0.30 (4.27)

Working Weight kg (lbs) 20,500 (45,200) 21,000 (46,300) 21,300 (47,000) 21,500 (47,000)

Bucket Weight: 650 kg (1,430 lbs)

2
1-C. STANDARD ATTACHMENT WORKING RANGES
A
A'
G
40 12.2

35 10.7

30 9.14

25 7.62

20 6.10

C
15 4.57

H
D
10 3.05

5 1.52
E

5 1.52

F 10 3.05
B

15 4.57

20 6.10

25 7.62

30 9.14
45 40 35 30 25 20 15 10 5 0 Feet Meters

13.7 12.2 10.7 9.14 7.62 6.10 4.57 3.05 1.52 Meters

WORKING RANGE ARM 2.40 M (7' 10") 2.94 M (9' 8") 3.30 M (10' 11")

A Maximum digging reach 9.420 (30' 11") 9.900 (32' 6") 10.260 (33' 8")

A' Maximum digging reach at ground level 9.250 (30' 4") 9.750 (32' 0") 10.100 (33' 2")

B Maximum digging depth 6.160 (20' 3") 6.700 (22' 0") 7.090 (23' 3")

C Maximum digging height 9.380 (30' 9") 9.600 (31' 6") 9.760 (32' 0")

D Maximum dumping clearance 6.560 (21' 6") 6.790 (22' 3") 6.950 (22' 10")

E Minimum dumping clearance 2.870 (9' 5") 2.330 (7' 8") 1.940 (6' 4")

F Minimum vertical wall digging depth 5.550 (18' 1") 6.040 (19' 10") 6.440 (21' 2")

G Minimum front swing radius 3.550 (11' 8") 3.560 (11' 8") 3.560 (11' 8")

H Height at minimum swing radius 7.600 (24' 11") 7.540 (24' 9") 7.650 (25' 1")

3
1-D. DIGGING FORCES
Arm Length 2.40 M (7'-10") 2.94 M (9'-8") 3.33 M (10'-11")
Bucket digging force *13,664 Kgf (30,000 lbf) *13,664 Kgf (30,000 lbf) 12,339 Kgf (27,300 lbf)
Arm crowding force *12,440 Kgf (27,500 lbf) *10,503 Kgf (23,200 lbf) 9,167 Kgf (20,200 lbf)
*Power Boost engaged

1-E. BUCKET SELECTION CHART

Capacity Width Weight Arm

Application 2.40 M 2.94 M 3.33 M
m3 (ydr3) cm (inches) Kg (lbs)
(7'-10") (9'-8") (10'-10")
0.67 (0.88) 61 (24) 530 (1165) H H H
0.70 (0.91) 76 (30) 602 (1325) H H H
General Purpose 0.87 (1.14) 91 (36) 659 (1450) H H M
1.05 (1.37) 107 (42) 750 (1651) H M L
1.22 (1.60) 122 (48) 809 (1780) M L X
0.52 (0.68) 61 (24) 568 (1250) H H H
0.70 (0.91) 76 (30) 645 (1420) H H M
Heavy Duty 0.87 (1.14) 91 (36) 709 (1560) H M L
1.04 (1.37) 107 (42) 786 (1730) M L X
1.22 (1.60) 122 (48) 866 (1905) L X X
0.48 (0.63) 66 (26) 661 (1455) H H H
0.57 (0.75) 79 (31) 723 (1590) H H H
Severe Duty
0.67 (0.88) 94 (37) 814 (1790) H M M
0.87 (1.13) 109 (43) 909 (2000) M L X

H- Used with material weight up to 1,780 kg/m3 (3,000 lb/yrd3).

M- Used with material weight up to 1483 kg/m3 (2,500 lb/yrd3).
L- Used with material weight up to 1186 kg/m3 (2,000 lb/yrd3).
X- Not recommended.

4
1-F. BOOM 1-H. BUCKET

B
ARM CYLINDER
BOSS

B
GROUND LEVEL
A
C
A D

1.Standard boom is 5.65 M (18’-6”) 1.Standard bucket is 0.81 M3 (1.06 cu yd)

A–Length is 5.65 M (18’-6”) A–Length is 1.37 M (4’-6”)
Center line to center line of pins. B–Height is 1.26 M (4’-2”)
B– Height is 1,182 mm (46.5”) C–Width without side cutters is 1.05 M (3’-5”)
From centerline of boom end to centerline of arm D–Width with side cutters is 1.16 M (3’-10”)
cylinder boss. E–Bucket weight is 650 kg (1,430 lbs)
C– Width is 674 mm (26.5”)
From edge to edge of boom foot.
WEIGHT– Approximately 1,240 kg (2,730 lbs)

1-G. ARM 1-I. SHOES

1.Standard arm is 2.94 M (9’-8”) 1.Standard shoes for the E215 are:
A–Length is 2.94 M (9’-8”) 800 mm (31.5”) Triple Grouser
Center line to center line of pins
. Height of grouser: 25 mm (0.98”)
B–Width is 325 mm (12.8”) 2.Quantity of shoes: E215 (49 per track)
From edge to edge of ar m tip.
C–Width is 348 mm (1’7”)
From edge to edge of ar m-boom pin connection.
WEIGHT– Approximately 610 kg (1,340 lbs)

5
1-J. PERFORMANCE SPECIFICATIONS
The following performance specifications are based on the standard machine with standard attachment.

1.Travel Speed, Swing Speed, and Gradeability

DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATION
Travel Speed (Fast mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 km per hr (3.7 mph) in fast mode
Travel Speed (Slow mode). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 km per hr (2.5 mph) in slow mode
Swing Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 RPM IN M-Mode / “HI” Idle
Gradeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70% (35 degrees) {Limited by engine lubrication}
Drawbar Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20,190 Kgf (44,512 lbf)

2. Engine
Engine Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mitsubishi
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D34-TEB
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-Cycle, Water Cooled, Direct Injection with Turbocharger, Diesel
Number of Cylinders– Bore x Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–104 mm x 115 mm (4.09" x 4.53")
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,861 liter (358 cu in.)
Compression Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.5 : 1
Output Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 kW (144 Hp) / 2,000 rpm
Maximum Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519 N•m (383 lb-ft)/ 1,600 rpm
Ignition Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5–3–6–2–4 Clockwise Rotation
Injection Timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 degrees Before Top Dead Point
Intake Valve Clearance Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 mm (0.0157")
Exhaust Valve Clearance Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 mm (0.0157")
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.C. 24 V
Starting Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 V–5.0 KW
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 V–35 A
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2– 12 V- (136 Ah)
Engine Dry Weight (Less flywheel and electrics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470 kg (1,040 lbs)
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Begin to open at 76.5°C (170°F). Full open at 90°C (194°F)
Cooling Fan Drive Method . . . . . . . . . . . . . . . . . . . . . . Ø600 (Ø24") Suction Type Belt Drive Pulley Ratio: 1.00
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dry Type with Safety Elements

3. Hydraulic Components
COMPONENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TYPE
Hydraulic Pumps . 2x210 L/m (55.5 Gal/Min)Tandem, Variable Displacement, Axial Piston w/Pilot Gear Pump
Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axial Piston
Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axial Piston
Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Spool Multiple Control
Cylinders (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Double Acting
Return Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Valve containing Filter Type
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cooled

4. Operating Pressures
Pilot System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Kgf (710 cm2)
Implement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350 Kgf (4 980 cm2)
Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285 Kgf (4 050 cm2)
Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350 Kgf (4 980 cm2)
Power Boost/Heavy Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385 Kgf (5 470 cm2)

6
1-L. LIFTING CAPACITIES FOR EUROPEAN SPEC’S

RATED OBJECT HANDLING CAPACITIES TABLE

600 mm Shoe Width

LIFT POINT (axis)

Axis
9
ARM (See the following table)
8
7
BOOM (See the following table)
6 Z2
LD 5
COUNTERWEIGHT 4,500kg (9900 lb)
4
WORKING CONDITIONS:
3
! With no tool (bucket, clamshell, etc.). If
object handling is performed with tool 2
installed, the weight of the tool shall be
deducted from the values of this table. 1
! With extended bucket cylinder.
! On a compact or horizontal, level ground. 0 Z1
! In complete swing of the upper structure.
1
WORKING CIRCUIT 2
PRESSURE 34,300 kPa (4975 psi)
3
HOLDING CIRCUIT
PRESSURE 34,300 kPa (4975 psi) 4
Z3
5
AXIS OF ROTATION
6
OUTREACH (m) 0 1 2 3 4 5 6 7 8 9

These loads are valid for the height of the considered Zone (Z1, Z2, Z3) for the intended outreach.
BOOM LENGTH 5.65 m Outreach
Maximum Reach
Arm Length LD* Zone 3m 4.5 m 6m 7.5 m 9m (Boom Foot Height)
Z2 -- 4220 kg 2840 kg -- --
2.40 m 2.80 m Z1 6 310 kg 5420 kg 3520 kg 2550 kg -- 2330 kg (8.10 m)
Z3 10 010 kg 3570 kg -- -- --
Z2 -- 4290 kg 2890 kg -- --
2.94 m 3.33 m Z1 6 650 kg 5380 kg 3480 kg 2490 kg -- 2100 kg (8.59 m)
Z3 10 630 kg 3490 kg -- -- --
Z2 -- 4350 kg 2920 kg -- --
3.33 m 3.72 m Z1 7 430 kg 5300 kg 3440 kg 2440 kg -- 1940 kg (8.95 m)
Z3 10 420 kg 3420 kg 2450 kg -- --
* LD = Distance from Boom point to Hook point

8
RATED OBJECT HANDLING CAPACITIES TABLE (Heavy Lift)
600 mm Shoe Width

LIFT POINT (axis)

Axis
9
ARM (See the following table)
8
7
BOOM (See the following table)
6 Z2
LD 5
COUNTERWEIGHT 4,500kg (9900 lb)
4
WORKING CONDITIONS:
3
! With no tool (bucket, clamshell, etc.). If
object handling is performed with tool 2
installed, the weight of the tool shall be
deducted from the values of this table. 1
! With extended bucket cylinder.
! On a compact or horizontal, level ground. 0 Z1
! In complete swing of the upper structure.
1
WORKING CIRCUIT 2
PRESSURE 37,300 kPa (5410 psi)
3
HOLDING CIRCUIT
PRESSURE 37,300 kPa (5410 psi) 4
Z3
5
AXIS OF ROTATION
6
OUTREACH (m) 0 1 2 3 4 5 6 7 8 9

These loads are valid for the height of the considered Zone (Z1, Z2, Z3) for the intended outreach.
BOOM LENGTH 5.65 m Outreach
Maximum Reach
Arm Length LD* Zone 3m 4.5 m 6m 7.5 m 9m (Boom Foot Height)
Z2 -- 4220 kg 2840 kg -- --
2.40 m 2.80 m Z1 7 020 kg 5420 kg 3520 kg 2550 kg -- 2330 kg (8.10 m)
Z3 10 810 kg 3570 kg -- -- --
Z2 -- 4290 kg 2890 kg -- --
2.94 m 3.33 m Z1 7 390 kg 5380 kg 3480 kg 2490 kg -- 2100 kg (8.59 m)
Z3 10 630 kg 3490 kg -- -- --
Z2 -- 4350 kg 2920 kg -- --
3.33 m 3.72 m Z1 8 250 kg 5300 kg 3440 kg 2440 kg -- 1940 kg (8.95 m)
Z3 10 420 kg 3420 kg 2450 kg -- --
* LD = Distance from Boom point to Hook point

9
RATED OBJECT HANDLING CAPACITIES TABLE
700 mm Shoe Width

LIFT POINT (axis)

Axis
9
ARM (See the following table)
8
7
BOOM (See the following table)
6 Z2
LD 5
COUNTERWEIGHT 4,500kg (9900 lb)
4
WORKING CONDITIONS:
3
! With no tool (bucket, clamshell, etc.). If
object handling is performed with tool 2
installed, the weight of the tool shall be
deducted from the values of this table. 1
! With extended bucket cylinder.
! On a compact or horizontal, level ground. 0 Z1
! In complete swing of the upper structure.
1
WORKING CIRCUIT 2
PRESSURE 34,300 kPa (4975 psi)
3
HOLDING CIRCUIT
PRESSURE 34,300 kPa (4975 psi) 4
Z3
5
AXIS OF ROTATION
6
OUTREACH (m) 0 1 2 3 4 5 6 7 8 9

These loads are valid for the height of the considered Zone (Z1, Z2, Z3) for the intended outreach.
BOOM LENGTH 5.65 m Outreach
Maximum Reach
Arm Length LD* Zone 3m 4.5 m 6m 7.5 m 9m (Boom Foot Height)
Z2 -- 4290 kg 2900 kg -- --
2.40 m 2.80 m Z1 6 310 kg 5530 kg 3600 kg 2610 kg -- 2380 kg (8.10 m)
Z3 10 810 kg 3640 kg -- -- --
Z2 -- 4370 kg 2950 kg -- --
2.94 m 3.33 m Z1 6 650 kg 5490 kg 3560 kg 2540 kg -- 2150 kg (8.59 m)
Z3 10 830 kg 3560 kg -- -- --
Z2 -- 4420 kg 2980 kg -- --
3.33 m 3.72 m Z1 7 430 kg 5410 kg 3510 kg 2500 kg -- 1980 kg (8.95 m)
Z3 10 610 kg 3490 kg 2510 kg -- --
* LD = Distance from Boom point to Hook point

10
RATED OBJECT HANDLING CAPACITIES TABLE (Heavy Lift)
700 mm Shoe Width

LIFT POINT (axis)

Axis
9
ARM (See the following table)
8
7
BOOM (See the following table)
6 Z2
LD 5
COUNTERWEIGHT 4,500kg (9900 lb)
4
WORKING CONDITIONS:
3
! With no tool (bucket, clamshell, etc.). If
object handling is performed with tool 2
installed, the weight of the tool shall be
deducted from the values of this table. 1
! With extended bucket cylinder.
! On a compact or horizontal, level ground. 0 Z1
! In complete swing of the upper structure.
1
WORKING CIRCUIT 2
PRESSURE 37,730 kPa (5410 psi)
3
HOLDING CIRCUIT
PRESSURE 37,730 kPa (5410 psi) 4
Z3
5
AXIS OF ROTATION
6
OUTREACH (m) 0 1 2 3 4 5 6 7 8 9

These loads are valid for the height of the considered Zone (Z1, Z2, Z3) for the intended outreach.
BOOM LENGTH 5.65 m Outreach
Maximum Reach
Arm Length LD* Zone 3m 4.5 m 6m 7.5 m 9m (Boom Foot Height)
Z2 -- 4290 kg 2900 kg -- --
2.40 m 2.80 m Z1 7 020 kg 5530 kg 3600 kg 2610 kg -- 2380 kg (8.10 m)
Z3 11 010 kg 3640 kg -- -- --
Z2 -- 4370 kg 2950 kg -- --
2.94 m 3.33 m Z1 7 390 kg 5490 kg 3560 kg 2540 kg -- 2150 kg (8.59 m)
Z3 10 830 kg 3560 kg -- -- --
Z2 -- 4420 kg 2980 kg -- --
3.33 m 3.72 m Z1 8 250 kg 5410 kg 3510 kg 2500 kg -- 1980 kg (8.95 m)
Z3 10 610 kg 3490 kg 2510 kg -- --
* LD = Distance from Boom point to Hook point

11
RATED OBJECT HANDLING CAPACITIES TABLE
800 mm Shoe Width

LIFT POINT (axis)

Axis
9
ARM (See the following table)
8
7
BOOM (See the following table)
6 Z2
LD 5
COUNTERWEIGHT 4,500kg (9900 lb)
4
WORKING CONDITIONS:
3
! With no tool (bucket, clamshell, etc.). If
object handling is performed with tool 2
installed, the weight of the tool shall be
deducted from the values of this table. 1
! With extended bucket cylinder.
! On a compact or horizontal, level ground. 0 Z1
! In complete swing of the upper structure.
1
WORKING CIRCUIT 2
PRESSURE 34,300 kPa (4975 psi)
3
HOLDING CIRCUIT
PRESSURE 34,300 kPa (4975 psi) 4
Z3
5
AXIS OF ROTATION
6
OUTREACH (m) 0 1 2 3 4 5 6 7 8 9

These loads are valid for the height of the considered Zone (Z1, Z2, Z3) for the intended outreach.
BOOM LENGTH 5.65 m Outreach
Maximum Reach
Arm Length LD* Zone 3m 4.5 m 6m 7.5 m 9m (Boom Foot Height)
Z2 -- 4340 kg 2940 kg -- --
2.40 m 2.80 m Z1 6 310 kg 5600 kg 3640 kg 2650 kg -- 2410 kg (8.10 m)
Z3 11 010 kg 3690 kg -- -- --
Z2 -- 4410 kg 2980 kg -- --
2.94 m 3.33 m Z1 6 650 kg 5560 kg 3610 kg 2580 kg -- 2180 kg (8.59 m)
Z3 10 960 kg 3610 kg -- -- --
Z2 -- 4470 kg 3010 kg -- --
3.33 m 3.72 m Z1 7 430 kg 5480 kg 3560 kg 2540 kg -- 2010 kg (8.95 m)
Z3 10 750 kg 3540 kg 2550 kg -- --
* LD = Distance from Boom point to Hook point

12
RATED OBJECT HANDLING CAPACITIES TABLE (Heavy Lift)
800 mm Shoe Width

LIFT POINT (axis)

Axis
9
ARM (See the following table)
8
7
BOOM (See the following table)
6 Z2
LD 5
COUNTERWEIGHT 4,500kg (9900 lb)
4
WORKING CONDITIONS:
3
! With no tool (bucket, clamshell, etc.). If
object handling is performed with tool 2
installed, the weight of the tool shall be
deducted from the values of this table. 1
! With extended bucket cylinder.
! On a compact or horizontal, level ground. 0 Z1
! In complete swing of the upper structure.
1
WORKING CIRCUIT 2
PRESSURE 37,730 kPa (5410 psi)
3
HOLDING CIRCUIT
PRESSURE 37,730 kPa (5410 psi) 4
Z3
5
AXIS OF ROTATION
6
OUTREACH (m) 0 1 2 3 4 5 6 7 8 9

These loads are valid for the height of the considered Zone (Z1, Z2, Z3) for the intended outreach.
BOOM LENGTH 5.65 m Outreach
Maximum Reach
Arm Length LD* Zone 3m 4.5 m 6m 7.5 m 9m (Boom Foot Height)
Z2 -- 4340 kg 2940 kg -- --
2.40 m 2.80 m Z1 7 020 kg 5600 kg 3640 kg 2650 kg -- 2410 kg (8.10 m)
Z3 11 140 kg 3690 kg -- -- --
Z2 -- 4410 kg 2980 kg -- --
2.94 m 3.33 m Z1 7 390 kg 5560 kg 3610 kg 2580 kg -- 2180 kg (8.59 m)
Z3 10 960 kg 3610 kg -- -- --
Z2 -- 4470 kg 3010 kg -- --
3.33 m 3.72 m Z1 8 250 kg 5480 kg 3560 kg 2540 kg -- 2010 kg (8.95 m)
Z3 10 750 kg 3540 kg 2550 kg -- --
* LD = Distance from Boom point to Hook point

13
E215 RATED OBJECT HANDLING CAPACITIES TABLE
600 mm Shoe Width

Axis LIFT POINT (axis)

9
ARM (See the following table)
8
7
BOOM (See the following table)
6 Z2
LD 5
COUNTERWEIGHT 4,500kg (9900 lb)
4
WORKING CONDITIONS: 3
! With no tool (bucket, clamshell, etc.). If
object handling is performed with tool 2
installed, the weight of the tool shall be
deducted from the values of this table. 1
! With extended bucket cylinder.
! On a compact or horizontal, level ground. 0 Z1
! In complete swing of the upper structure.
1
WORKING CIRCUIT 2
PRESSURE 34,300 kPa (4975 psi)
3
HOLDING CIRCUIT
PRESSURE 34,300 kPa (4975 psi) 4
Z3
5
AXIS OF ROTATION
6
OUTREACH (m) 0 1 2 3 4 5 6 7 8 9

These loads are valid for the height of the considered Zone (Z1, Z2, Z3) for the intended outreach.
BOOM LENGTH 5.65 m Outreach
Maximum Reach
Arm Length LD* Zone 3m 4.5 m 6m 7.5 m 9m (Boom Foot Height)
Z2 -- 4700 kg 3190 kg -- --
2.40 m 2.80 m Z1 6 310 kg 6170 kg 3990 kg 2890 kg -- 2630 kg (8.10 m)
Z3 10 010 kg 4040 kg -- -- --
Z2 -- 4780 kg 3240 kg -- --
2.94 m 3.33 m Z1 6 650 kg 6130 kg 3960 kg 2830 kg -- 2380 kg (8.59 m)
Z3 11 580 kg 3960 kg -- -- --
Z2 -- 4530 kg 3270 kg -- --
3.33 m 3.72 m Z1 7 430 kg 6050 kg 3910 kg 2780 kg -- 2210 kg (8.95 m)
Z3 12 100 kg 3890 kg 2800 kg -- --
* LD = Distance from Boom point to Hook point

14
E215 RATED OBJECT HANDLING CAPACITIES TABLE (Heavy Lift)
800 mm Shoe Width

Axis LIFT POINT (axis)

9
ARM (See the following table)
8
7
BOOM (See the following table)
6 Z2
LD 5
COUNTERWEIGHT 4,500kg (9900 lb)
4
WORKING CONDITIONS: 3
! With no tool (bucket, clamshell, etc.). If
object handling is performed with tool 2
installed, the weight of the tool shall be
deducted from the values of this table. 1
! With extended bucket cylinder.
! On a compact or horizontal, level ground. 0 Z1
! In complete swing of the upper structure.
1
WORKING CIRCUIT 2
PRESSURE 37,730 kPa (5410 psi)
3
HOLDING CIRCUIT
PRESSURE 37,730 kPa (5410 psi) 4
Z3
5
AXIS OF ROTATION
6
OUTREACH (m) 0 1 2 3 4 5 6 7 8 9

These loads are valid for the height of the considered Zone (Z1, Z2, Z3) for the intended outreach.
BOOM LENGTH 5.65 m Outreach
Maximum Reach
Arm Length LD* Zone 3m 4.5 m 6m 7.5 m 9m (Boom Foot Height)
Z2 -- 4700 kg 3190 kg -- --
2.40 m 2.80 m Z1 7 020 kg 6170 kg 3990 kg 2890 kg -- 2630 kg (8.10 m)
Z3 11 330 kg 4040 kg -- -- --
Z2 -- 4780 kg 3240 kg -- --
2.94 m 3.33 m Z1 7 390 kg 6130 kg 3960 kg 2830 kg -- 2380 kg (8.59 m)
Z3 12 320 kg 3960 kg -- -- --
Z2 -- 4840 kg 3270 kg -- --
3.33 m 3.72 m Z1 8 250 kg 6050 kg 3910 kg 2780 kg -- 2210 kg (8.95 m)
Z3 12 100 kg 3890 kg 2800 kg -- --
* LD = Distance from Boom point to Hook point

15
E215 RATED OBJECT HANDLING CAPACITIES TABLE
700 mm Shoe Width

Axis LIFT POINT (axis)

9
ARM (See the following table)
8
7
BOOM (See the following table)
6 Z2
LD 5
COUNTERWEIGHT 4,500kg (9900 lb)
4
WORKING CONDITIONS: 3
! With no tool (bucket, clamshell, etc.). If
object handling is performed with tool 2
installed, the weight of the tool shall be
deducted from the values of this table. 1
! With extended bucket cylinder.
! On a compact or horizontal, level ground. 0 Z1
! In complete swing of the upper structure.
1
WORKING CIRCUIT 2
PRESSURE 34,300 kPa (4975 psi)
3
HOLDING CIRCUIT
PRESSURE 34,300 kPa (4975 psi) 4
Z3
5
AXIS OF ROTATION
6
OUTREACH (m) 0 1 2 3 4 5 6 7 8 9

These loads are valid for the height of the considered Zone (Z1, Z2, Z3) for the intended outreach.
BOOM LENGTH 5.65 m Outreach
Maximum Reach
Arm Length LD* Zone 3m 4.5 m 6m 7.5 m 9m (Boom Foot Height)
Z2 -- 4790 kg 3260 kg -- --
2.40 m 2.80 m Z1 6 300 kg 6300 kg 4080 kg 2960 kg -- 2690 kg (8.10 m)
Z3 10 010 kg 4130 kg -- -- --
Z2 -- 4870 kg 3300 kg -- --
2.94 m 3.33 m Z1 6 650 kg 6260 kg 4040 kg 2890 kg -- 2440 kg (8.59 m)
Z3 11 580 kg 4050 kg -- -- --
Z2 -- 4530 kg 3320 kg -- --
3.33 m 3.72 m Z1 7 430 kg 6180 kg 4000 kg 2850 kg -- 2260 kg (8.95 m)
Z3 12 340 kg 3970 kg 2860 kg -- --
* LD = Distance from Boom point to Hook point

16
E215 RATED OBJECT HANDLING CAPACITIES TABLE (Heavy Lift)
700 mm Shoe Width

Axis LIFT POINT (axis)

9
ARM (See the following table)
8
7
BOOM (See the following table)
6 Z2
LD 5
COUNTERWEIGHT 4,500kg (9900 lb)
4
WORKING CONDITIONS: 3
! With no tool (bucket, clamshell, etc.). If
object handling is performed with tool 2
installed, the weight of the tool shall be
deducted from the values of this table. 1
! With extended bucket cylinder.
! On a compact or horizontal, level ground. 0 Z1
! In complete swing of the upper structure.
1
WORKING CIRCUIT 2
PRESSURE 37,730 kPa (5410 psi)
3
HOLDING CIRCUIT
PRESSURE 37,730 kPa (5410 psi) 4
Z3
5
AXIS OF ROTATION
6
OUTREACH (m) 0 1 2 3 4 5 6 7 8 9

These loads are valid for the height of the considered Zone (Z1, Z2, Z3) for the intended outreach.
BOOM LENGTH 5.65 m Outreach
Maximum Reach
Arm Length LD* Zone 3m 4.5 m 6m 7.5 m 9m (Boom Foot Height)
Z2 -- 4790 kg 3260 kg -- --
2.40 m 2.80 m Z1 7 020 kg 6300 kg 4080 kg 2960 kg -- 2690 kg (8.10 m)
Z3 11 330 kg 4130 kg -- -- --
Z2 -- 4870 kg 3300 kg -- --
2.94 m 3.33 m Z1 7 390 kg 6260 kg 4040 kg 2890 kg -- 2440 kg (8.59 m)
Z3 12 560 kg 4050 kg -- -- --
Z2 -- 4920 kg 3330 kg -- --
3.33 m 3.72 m Z1 8 250 kg 6180 kg 4000 kg 2850 kg -- 2260 kg (8.95 m)
Z3 12 340 kg 3970 kg 2860 kg -- --
* LD = Distance from Boom point to Hook point

17
E215 RATED OBJECT HANDLING CAPACITIES TABLE
800 mm Shoe Width

Axis LIFT POINT (axis)

9
ARM (See the following table)
8
7
BOOM (See the following table)
6 Z2
LD 5
COUNTERWEIGHT 4,500kg (9900 lb)
4
WORKING CONDITIONS: 3
! With no tool (bucket, clamshell, etc.). If
object handling is performed with tool 2
installed, the weight of the tool shall be
deducted from the values of this table. 1
! With extended bucket cylinder.
! On a compact or horizontal, level ground. 0 Z1
! In complete swing of the upper structure.
1
WORKING CIRCUIT 2
PRESSURE 34,300 kPa (4975 psi)
3
HOLDING CIRCUIT
PRESSURE 34,300 kPa (4975 psi) 4
Z3
5
AXIS OF ROTATION
6
OUTREACH (m) 0 1 2 3 4 5 6 7 8 9

These loads are valid for the height of the considered Zone (Z1, Z2, Z3) for the intended outreach.
BOOM LENGTH 5.65 m Outreach
Maximum Reach
Arm Length LD* Zone 3m 4.5 m 6m 7.5 m 9m (Boom Foot Height)
Z2 -- 4850 kg 3300 kg -- --
2.40 m 2.80 m Z1 6 310 kg 6380 kg 4140 kg 3010 kg -- 2740 kg (8.10 m)
Z3 10 010 kg 4190 kg -- -- --
Z2 -- 4900 kg 3350 kg -- --
2.94 m 3.33 m Z1 6 650 kg 6340 kg 4100 kg 2940 kg -- 2480 kg (8.59 m)
Z3 11 580 kg 4110 kg -- -- --
Z2 -- 4530 kg 3320 kg -- --
3.33 m 3.72 m Z1 7 430 kg 6260 kg 4050 kg 2890 kg -- 2300 kg (8.95 m)
Z3 12 370 kg 4030 kg 2910 kg -- --
* LD = Distance from Boom point to Hook point

18
E215 RATED OBJECT HANDLING CAPACITIES TABLE (Heavy Lift)
800 mm Shoe Width

Axis LIFT POINT (axis)

9
ARM (See the following table)
8
7
BOOM (See the following table)
6 Z2
LD 5
COUNTERWEIGHT 4,500kg (9900 lb)
4
WORKING CONDITIONS: 3
! With no tool (bucket, clamshell, etc.). If
object handling is performed with tool 2
installed, the weight of the tool shall be
deducted from the values of this table. 1
! With extended bucket cylinder.
! On a compact or horizontal, level ground. 0 Z1
! In complete swing of the upper structure.
1
WORKING CIRCUIT 2
PRESSURE 37,730 kPa (5410 psi)
3
HOLDING CIRCUIT
PRESSURE 37,730 kPa (5410 psi) 4
Z3
5
AXIS OF ROTATION
6
OUTREACH (m) 0 1 2 3 4 5 6 7 8 9

These loads are valid for the height of the considered Zone (Z1, Z2, Z3) for the intended outreach.
BOOM LENGTH 5.65 m Outreach
Maximum Reach
Arm Length LD* Zone 3m 4.5 m 6m 7.5 m 9m (Boom Foot Height)
Z2 -- 4850 kg 3300 kg -- --
2.40 m 2.80 m Z1 7 020 kg 6380 kg 4140 kg 3010 kg -- 2740 kg (8.10 m)
Z3 11 330 kg 4190 kg -- -- --
Z2 -- 4920 kg 3350 kg -- --
2.94 m 3.33 m Z1 7 390 kg 6340 kg 4100 kg 2940 kg -- 2480 kg (8.59 m)
Z3 12 720 kg 4110 kg -- -- --
Z2 -- 4980 kg 3380 kg -- --
3.33 m 3.72 m Z1 8 250 kg 6260 kg 4050 kg 2890 kg -- 2300 kg (8.95 m)
Z3 12 500 kg 4030 kg 2910 kg -- --
* LD = Distance from Boom point to Hook point

19
E215 RATED OBJECT HANDLING CAPACITIES TABLE
900 mm Shoe Width

Axis LIFT POINT (axis)

9
ARM (See the following table)
8
7
BOOM (See the following table)
6 Z2
LD 5
COUNTERWEIGHT 4,500kg (9900 lb)
4
WORKING CONDITIONS: 3
! With no tool (bucket, clamshell, etc.). If
object handling is performed with tool 2
installed, the weight of the tool shall be
deducted from the values of this table. 1
! With extended bucket cylinder.
! On a compact or horizontal, level ground. 0 Z1
! In complete swing of the upper structure.
1
WORKING CIRCUIT 2
PRESSURE 34,300 kPa (4975 psi)
3
HOLDING CIRCUIT
PRESSURE 34,300 kPa (4975 psi) 4
Z3
5
AXIS OF ROTATION
6
OUTREACH (m) 0 1 2 3 4 5 6 7 8 9

These loads are valid for the height of the considered Zone (Z1, Z2, Z3) for the intended outreach.
BOOM LENGTH 5.65 m Outreach
Maximum Reach
Arm Length LD* Zone 3m 4.5 m 6m 7.5 m 9m (Boom Foot Height)
Z2 -- 4900 kg 3340 kg -- --
2.40 m 2.80 m Z1 6 310 kg 6460 kg 4190 kg 3050 kg -- 2770 kg (8.10 m)
Z3 10 010 kg 4240 kg -- -- --
Z2 -- 4900 kg 3390 kg -- --
2.94 m 3.33 m Z1 6 650 kg 6420 kg 4160 kg 2980 kg -- 2510 kg (8.59 m)
Z3 11 580 kg 4160 kg -- -- --
Z2 -- 4530 kg 3320 kg -- --
3.33 m 3.72 m Z1 7 430 kg 6340 kg 4110 kg 2940 kg -- 2330 kg (8.95 m)
Z3 12 470 kg 4090 kg 2950 kg -- --
* LD = Distance from Boom point to Hook point

20
E215 RATED OBJECT HANDLING CAPACITIES TABLE (Heavy Lift)
900 mm Shoe Width

Axis LIFT POINT (axis)

9
ARM (See the following table)
8
7
BOOM (See the following table)
6 Z2
LD 5
COUNTERWEIGHT 4,500kg (9900 lb)
4
WORKING CONDITIONS: 3
! With no tool (bucket, clamshell, etc.). If
object handling is performed with tool 2
installed, the weight of the tool shall be
deducted from the values of this table. 1
! With extended bucket cylinder.
! On a compact or horizontal, level ground. 0 Z1
! In complete swing of the upper structure.
1
WORKING CIRCUIT 2
PRESSURE 37,730 kPa (5410 psi)
3
HOLDING CIRCUIT
PRESSURE 37,730 kPa (5410 psi) 4
Z3
5
AXIS OF ROTATION
6
OUTREACH (m) 0 1 2 3 4 5 6 7 8 9

These loads are valid for the height of the considered Zone (Z1, Z2, Z3) for the intended outreach.
BOOM LENGTH 5.65 m Outreach
Maximum Reach
Arm Length LD* Zone 3m 4.5 m 6m 7.5 m 9m (Boom Foot Height)
Z2 -- 4900 kg 3340 kg -- --
2.40 m 2.80 m Z1 7 020 kg 6460 kg 4190 kg 3050 kg -- 2770 kg (8.10 m)
Z3 11 330 kg 4240 kg -- -- --
Z2 -- 4980 kg 3390 kg -- --
2.94 m 3.33 m Z1 7 390 kg 6420 kg 4160 kg 2980 kg -- 2510 kg (8.59 m)
Z3 12 870 kg 4160 kg -- -- --
Z2 -- 4540 kg 3420 kg -- --
3.33 m 3.72 m Z1 8 250 kg 6340 kg 4110 kg 2940 kg -- 2330 kg (8.95 m)
Z3 12 650 kg 4090 kg 2950 kg -- --
* LD = Distance from Boom point to Hook point

21
1-M. LIFTING CAPACITIES (KAI SPEC’S)
1. Do not attempt to lift any load that exceeds these rated values at their specified load radii and heights.
2. Lifting capacities assume a machine standing on a level, firm, and uniform supporting surface. Operator must
make allowance for job conditions such as soft or uneven ground, out of level conditions, side loads, sudden
stopping of loads, hazardous conditions, inexperienced personnel, weight of various other buckets, lifting slings,
attachments, etc.
3. Ratings at bucket lift hook.
4. The previous rated loads are in compliance with SAE Hydraulic Excavator Lift Capacity Standard J 1097. They
do not exceed 87% of hydraulic lifting capacity or 75% of tipping load. Rated loads marked with and asterisk (*) are
limited by hydraulic capacity rather than tipping load.
5. Operator should be fully acquainted with the operator’s manual before operating this machine. Rules for safe
operation of equipment should be followed at all times.
6. Capacities apply to the machine as originally manufactured and normally equipped by the manufacturer.

22
E215 LIFTING CAPACITIES - Arm 2.40 m (7' 10")
A
Rated loads mar ked with and Based on a machine equipped with theollowing:
f
asterisk (*) are limited by hydraulic Boom: 5.65 m (18' 6")
capacity rather than tipping load. Arm: 2.40 m (7' 10")
See P age 22 f or additional Bucket: 0.93 m3(1.22 yd)3SAE/PCSA 660Kg (1,460 lbs)
B information. Shoes: 800 mm (31.5")
C

A 1.5 m (5'-0") 3.0 m (10'-0") 4.6 m (15'-0") 6.1 m (20'-0") 7.6 m (25'-0")

C
B
7.6 m lb
(25' 0" ) kg

6.1 m lb *10800 10790

(20' 0" ) kg *4900 4890

4.6 m lb *11730 10470

(15' 0" ) kg *5320 4750

3.0 m lb *26030 *26030 *17310 15630 *13400 9970 11050 6910

(10' 0" ) kg *11800 *11800 *7850 7090 *6070 4520 5010 3130

1.5 m lb *20820 14540 *15130 9450 10790 6680

(5' 0" ) kg *9440 6590 *6860 4280 4890 3030

lb *14520 *14520 *22570 13950 14980 9100 10600 6510

Gr o u n d L ev el
kg *6580 *6580 *10290 6320 6790 4120 4810 2950

-1.5 m lb *15480 *15480 *24530 *24530 *22410 13800 14830 8960

(-5' 0" ) kg *7020 *7020 *11120 *11120 *10160 6260 6720 4060

-3.0 m lb *25470 *25470 *28810 27780 *20350 13970 *14750 9080

(-10' 0" ) kg *11550 *11550 *13060 12600 *9230 6330 *6690 4110

-4.6 m lb *21380 *21380 *15140 14520

(-15' 0" ) kg *9700 *9700 *6860 6580

E215 LIFTING CAPACITIES (Heavy Lift) - Arm 2.40 m (7' 10")

A
Rated loads mar ked with and Based on a machine equipped with the following:
asterisk (*) are limited by hydraulic Boom: 5.65 m (18' 6")
capacity rather than tipping load. Arm: 2.40 m (7' 10")
See P age 22 f or additional Bucket: 0.93 m3(1.22 yd)3SAE/PCSA 660Kg (1,460 lbs)
B information. Shoes: 800 mm (31.5")
C Heavy Lift
A 1.5 m (5'-0") 3.0 m (10'-0") 4.6 m (15'-0") 6.1 m (20'-0") 7.6 m (25'-0")

C
B
7.6 m lb
(25' 0" ) kg

6.1 m lb *12200 10790

(20' 0" ) kg *5530 4890

4.6 m lb *13250 10470

(15' 0" ) kg *6010 4750

3.0 m lb *28760 *28760 *19480 15630 *15130 9970 11050 6910

(10' 0" ) kg *13040 *13040 *8830 7090 *6860 4520 5010 3130

1.5 m lb *23430 14540 15390 9450 10790 6680

(5' 0" ) kg *10620 6590 6980 4280 4890 3030

lb *16140 *16140 24070 13950 14980 9100 10600 6510

Gr o u n d L ev el
kg *7320 *7320 10910 6320 6790 4120 4810 2950

-1.5 m lb *17210 *17210 *27140 *27140 23890 13800 14830 8960

(-5' 0" ) kg *7800 *7800 *12300 *12300 10830 6260 6720 4060

-3.0 m lb *28180 *28180 *32440 27780 *22970 13970 14960 9080

(-10' 0" ) kg *12780 *12780 *14710 12600 *10410 6330 6780 4110

-4.6 m lb *24210 *24210 *17180 14520

(-15' 0" ) kg *10980 *10980 *7790 6580

23
E215 LIFTING CAPACITIES - Arm 2.94 m (9' 8")
A
Rated loads mar ked with and Based on a machine equipped with the following:
asterisk (*) are limited by hydraulic Boom: 5.65 m (18' 6")
capacity rather than tipping load. Arm: 2.94 m (9' 8")
See P age 22 f or additional Bucket: 0.80 m3(1.05 yd)3SAE/PCSA 620Kg (1,370 lbs)
B information. Shoes: 800 mm (31.5")
C

A 1.5 m (5'-0") 3.0 m (10'-0") 4.6 m (15'-0") 6.1 m (20'-0") 7.6 m (25'-0")

C
B
7.6 m lb *6540 *6540
(25' 0" ) kg *2960 *2960

6.1 m lb
(20' 0" ) kg

4.6 m lb *10690 10630 *8540 7210

(15' 0" ) kg *4840 4820 *3870 3270

3.0 m lb *24210 *24210 *15730 *15730 *12470 10090 *10860 6970

(10' 0" ) kg *10970 *10970 *7130 *7130 *5650 4570 *4920 3160

1.5 m lb *15790 *15790 *19630 14760 *14400 9520 10810 6690

(5' 0" ) kg *7160 *7160 *8900 6690 *6530 4320 4900 3030

lb *16380 *16380 *22040 14000 14990 9090 10560 6460

Gr o u n d L ev el
kg *7430 *7430 *9990 6350 6800 4120 4790 2930

-1.5 m lb *13900 *13900 *22760 *22760 *22560 13710 14740 8870 10450 6360
(-5' 0" ) kg *6300 *6300 *10320 *10320 *10230 6210 6680 4020 4740 2880

-3.0 m lb *21370 *21370 *31030 27360 *21240 13760 14770 8890

(-10' 0" ) kg *9690 *9690 *14070 12410 *9630 6240 6690 4030

-4.6 m lb *24850 *24850 *17410 14150

(-15' 0" ) kg *11270 *11270 *7890 6420

E215 LIFTING CAPACITIES (Heavy Lift) - Arm 2.94 m (9' 8")

A
Rated loads mar ked with and Based on a machine equipped with the following:
asterisk (*) are limited by hydraulic Boom: 5.65 m (18' 6")
capacity rather than tipping load. Arm: 2.94 m (9' 8")
See P age 22 f or additional Bucket: 0.80 m3(1.05 yd)3SAE/PCSA 620Kg (1,370 lbs)
B information. Shoes: 800 mm (31.5")
C Heavy Lift
A 1.5 m (5'-0") 3.0 m (10'-0") 4.6 m (15'-0") 6.1 m (20'-0") 7.6 m (25'-0")

C
B
7.6 m lb *7370 *7370
(25' 0" ) kg *3340 *3340

6.1 m lb
(20' 0" ) kg

4.6 m lb *12090 10630 *9580 7210

(15' 0" ) kg *5480 4820 *4340 3270

3.0 m lb *27130 *27130 *17710 15960 *14100 10090 11110 6970

(10' 0" ) kg *12300 *12300 *8030 7240 *6390 4570 5040 3160

1.5 m lb *17530 *17530 *22100 14760 15480 9520 10810 6690

(5' 0" ) kg *7950 *7950 *10020 6690 7020 4320 4900 3030

lb *18180 *18180 24140 14000 14990 9090 10560 6460

Gr o u n d L ev el
kg *8240 *8240 10950 6350 6800 4120 4790 2930

-1.5 m lb *15470 *15470 *25200 *25200 23800 13710 14740 8870 10450 6360
(-5' 0" ) kg *7010 *7010 *11420 *11420 10790 6210 6680 4020 4740 2880

-3.0 m lb *23680 *23680 *34920 27360 23860 13760 14770 8890

(-10' 0" ) kg *10740 *10740 *15830 12410 10820 6240 6690 4030

-4.6 m lb *28080 *28080 *19720 14150

(-15' 0" ) kg *12730 *12730 *8940 6420

24
E215 LIFTING CAPACITIES - Arm 3.33 m (10' 10")
A
Rated loads mar ked with and Based on a machine equipped with the following:
asterisk (*) are limited by hydraulic Boom: 5.65 m (18' 6")
capacity rather than tipping load. Arm: 3.33 m (10' 10")
See P age 22 f or additional Bucket: 0.68 m3(0.89 yd)3SAE/PCSA 590Kg (1,300 lbs)
B information. Shoes: 800 mm (31.5")
C

A 1.5 m (5'-0") 3.0 m (10'-0") 4.6 m (15'-0") 6.1 m (20'-0") 7.6 m (25'-0")

C
B
7.6 m lb
(25' 0" ) kg

6.1 m lb *6600 *6600

(20' 0" ) kg *2990 *2990

4.6 m lb *9890 *9890 *9340 7280

(15' 0" ) kg *4480 *4480 *4230 3300

3.0 m lb *14470 *14470 *11730 10180 *10320 7000

(10' 0" ) kg *6560 *6560 *5320 4610 *4680 3170

1.5 m lb *20540 *20540 *18580 14880 *13770 9550 10810 6680

(5' 0" ) kg *9310 *9310 *8420 6740 *6240 4330 4900 3030

lb *17010 *17010 *21410 13970 14960 9060 10520 6420

Gr o u n d L ev el
kg *7710 *7710 *9710 6330 6780 4100 4770 2910

-1.5 m lb *12620 *12620 *21890 *21890 *22410 13560 14650 8780 10360 6270
(-5' 0" ) kg *5720 *5720 *9920 *9920 *10160 6150 6640 3980 4700 2840

-3.0 m lb *19500 *19500 *30370 *30370 *21600 13540 14600 8730

(-10' 0" ) kg *8840 *8840 *13770 *13770 *9790 6140 6620 3960

-4.6 m lb *28180 *28180 *26830 *26830 *18550 13850 *13070 8990

(-15' 0" ) kg *12780 *12780 *12170 *12170 *8410 6280 *5920 4070

E215 LIFTING CAPACITIES (Heavy Lift) - Arm 3.33 m (10' 10")

A
Rated loads mar ked with and Based on a machine equipped with the following:
asterisk (*) are limited by hydraulic Boom: 5.65 m (18' 6")
capacity rather than tipping load. Arm: 3.33 m (10' 10")
See P age 22 f or additional Bucket: 0.68 m3(0.89 yd)3SAE/PCSA 590Kg (1,300 lbs)
B information. Shoes: 800 mm (31.5")
C Heavy Lift
A 1.5 m (5'-0") 3.0 m (10'-0") 4.6 m (15'-0") 6.1 m (20'-0") 7.6 m (25'-0")

C
B
7.6 m lb
(25' 0" ) kg

6.1 m lb *7440 7430

(20' 0" ) kg *3370 3360

4.6 m lb *11200 10760 *10470 7280

(15' 0" ) kg *5080 4880 *4740 3300

3.0 m lb *16310 16200 *13270 10180 11160 7000

(10' 0" ) kg *7390 7340 *6020 4610 5060 3170

1.5 m lb *22740 *22740 *20940 14880 15530 9550 10810 6680

(5' 0" ) kg *10310 *10310 *9490 6740 7040 4330 4900 3030

lb *18880 *18880 24130 13970 14960 9060 10520 6420

Gr o u n d L ev el
kg *8560 *8560 10940 6330 6780 4100 4770 2910

-1.5 m lb *14060 *14060 *24240 *24240 23650 13560 14650 8780 10360 6270
(-5' 0" ) kg *6370 *6370 *10990 *10990 10720 6150 6640 3980 4700 2840

-3.0 m lb *21630 *21630 *33570 26890 23620 13540 14600 8730

(-10' 0" ) kg *9810 *9810 *15220 12190 10710 6140 6620 3960

-4.6 m lb *31160 *31160 *30290 27560 *21000 13850 *14860 8990

(-15' 0" ) kg *14130 *14130 *13740 12500 *9520 6280 *6740 4070

25
E215 LONG REACH SPECIFICATIONS
The specifications found in this section are given on the SK210 LC -VI Long Reach (50 Feet) Hydraulic Excavator
as manufactured. No modifications or options are taken in to consideration in regard to these specifications.
2-A. MACHINE DIMENSIONS
A
E
G

C F

H L
O
M
I B
J
D

E215 LONG REACH MACHINE DIMENSIONS

A Overall length 12.54 m (41' 2")
Overall width with 800 mm shoes 3.19 m (10' 6")
B
Overall width with 900 mm shoes 3.29 m (10' 10")
C Overall height 3.05 m (10' 0")
D Basic machine length 4.96 m (16' 3")
E Width of revolving upper frame 2.69 m (8' 10")
F Height of cab top 2.93 m (9' 7")
G Radius of rear end 2.75 m (9' 0")
H Ground clearance of rear end 1.06 m (3' 6")
I Center distance of tumblers 3.66 m (12' 0")
J Overall length of crawler 4.45 m (14' 7")
L Crawler height at tumbler center 935 mm (36.8")
M Tire gauge 2.39 m (7' 10")
O Ground clearance undercarriage 450 mm (17.7")

Machine dimensions with: 8.75 m (28’ 8”) Boom, 6.35 m (20’ 10”) Arm, Bucket 0.45 m3(0.59 cu. Yd.)

2-B.WORKING WEIGHTS - E215 - 50 Ft. Long Reach

TRIPLE GROUSER SHOES

Track shoe width mm (In) 800 (31.5) 900 (35.4)

Overall width m (ft-In) 3.19 (10-6) 3.29 (10-10)

Ground pressure Kg/cm2 (psi) 0.37 (5.22) 0.33 (4.64)

Working weight Kg (lbs) 23,000 (50,700) 23,300 (51,400)

Bucket weight: 370 Kg (815 lbs)

26
2-C. WORKING RANGES - E215 Long Reach
A
A'
50 15.2
G

45 13.7

40 12.2

35 10.7

30 9.14

25 7.62

C
20 6.10
H
D
15 4.57

10 3.05

5 1.52
E

0
Meters

-5 1.52

-10 3.05

-15 4.57

F
B -20 6.10

-25 7.62

-30 9.14

-35 10.7

-40 12.2
50 45 40 35 30 25 20 15 10 5 0 Feet

15.2 13.7 12.2 10.7 9.14 7.62 6.10 4.57 3.05 1.52 0 Meters

WORKING RANGE ARM 6.35 M (20' 10")

A Maximum digging reach 15.820 (51' 11")

A' Maximum digging reach at ground level 15.720 (51' 7")

B Maximum digging depth 12.010 (39' 5")

C Maximum digging height 13.660 (44' 10")

D Maximum dumping clearance 11.300 (37' 1")

E Minimum dumping clearance 1.930 (6' 4")

F Minimum vertical wall digging depth 11.030 (36' 2")

G Minimum front swing radius 4.840 (15' 11")

H Height at minimum swing radius 10.370 (34' 0")

27
2-D. DIGGING FORCES
Arm Length 6.35 M (20'-10")
Bucket digging force 8,120 Kgf (17,900 lbf)
Arm crowding force 5,410 Kgf (11,930 lbf)

2-E. BUCKET SELECTION CHART

Capacity Width Weight

Application
m3 (ydr3) cm (inches) Kg (lbs)

0.34 (0.44) 61 (24) 379 (835)

General Purpose 0.44 (0.58) 76 (30) 438 (966)
0.56 (0.73) 91 (36) 474 (1045)
0.38 (0.50) 122 (48) 441 (972)
Ditch Cleaning 0.48 (0.63) 152 (60) 529 (1166)
0.57 (0.75) 183 (72) 637 (1404)

28
2-F. E215 LONG REACH LIFTING CAPACITIES
1. Do not attempt to lift any load that exceeds these rated values at their specified load radii and heights.
2. Lifting capacities assume a machine standing on a level, firm, and uniform supporting surface. Operator must
make allowance for job conditions such as soft or uneven ground, out of level conditions, side loads, sudden
stopping of loads, hazardous conditions, inexperienced personnel, weight of various other buckets, lifting slings,
attachments, etc.
3. Ratings at bucket lift hook.
4. The previous rated loads are in compliance with SAE Hydraulic Excavator Lift Capacity Standard J 1097. They
do not exceed 87% of hydraulic lifting capacity or 75% of tipping load. Rated loads marked with and asterisk (*) are
limited by hydraulic capacity rather than tipping load.
5. Operator should be fully acquainted with the operator’s manual before operating this machine. Rules for safe
operation of equipment should be followed at all times.
6. Capacities apply to the machine as originally manufactured and normally equipped by the manufacturer.

29
E215 (Long Reach) LIFTING CAPACITIES
A
Rated loads mar ked with and Based on a machine equipped with the following:
asterisk (*) are limited by hydraulic Boom: 8.75 m (28' 8")
capacity rather than tipping load. Arm: 6.35 m (20' 10")
See P age 22 f or additional Bucket: 0.45 m3(0.59 yd)3SAE/PCSA 370Kg (815 lbs)
B information. Shoes: 800 mm (31.5")
C

A 1.5 m (5'-0") 3.0 m (10'-0") 4.6 m (15'-0") 6.1 m (20'-0") 7.6 m (25'-0") 9.1 m (30'-0") 10.7 m (35'-0") 12.2 m (40'-0") 13.7 m (45'-0")

C
B
9.1 m lb *2400 *2400
(30' 0" ) kg *1080 *1080

7.6 m lb *4390 *4390 *3510 *3510

(25' 0" ) kg *1990 *1990 *1590 *1590

6.1 m lb *4670 *4670 *4270 3860 *2140 *2140

(20' 0" ) kg *2120 *2120 *1930 1750 *970 *970

4.6 m lb *5520 *5520 *5070 4860 *4750 3690 *3040 2780

(15' 0" ) kg *2500 *2500 *2300 2200 *2150 1670 *1380 1260

3.0 m lb *19430 *19430 *8930 *8930 *7270 *7270 *6240 6000 *5540 4550 *5050 3480 *3680 2660
(10' 0" ) kg *8810 *8810 *4050 *4050 *3290 *3290 *2830 2720 *2510 2060 *2290 1580 *1660 1200

1.5 m lb *5530 *5530 *15460 15230 *10810 10190 *8410 7350 *6980 5510 *6040 4220 *5380 3270 *4130 2530
(5' 0" ) kg *2510 *2510 *7010 6900 *4900 4620 *3810 3330 *3160 2500 *2730 1910 *2440 1480 *1870 1140

lb *5070 *5070 *12890 *12890 *12330 9120 *9410 6670 *7650 5060 *6490 3920 5350 3070 *4320 2410
Gr o u n d L ev el
kg *2300 *2300 *5840 *5840 *5590 4130 *4270 3020 *3470 2290 *2940 1780 2420 1390 *1960 1090

-1.5 m lb *4390 *4390 *6390 *6390 *11780 *11780 *13320 8420 *10150 6170 8060 4710 6390 3680 5170 2900 *4020 2310
(-5' 0" ) kg *1990 *1990 *2900 *2900 *5340 *5340 *6040 3820 *4600 2790 3650 2130 2890 1660 2340 1310 *1820 1040

-3.0 m lb *6290 *6290 *8190 *8190 *12770 12250 *13760 8040 10190 5850 7800 4470 6200 3500 5060 2790 *2820 2260
(-10' 0" ) kg *2850 *2850 *3710 *3710 *5790 5550 *6240 3650 4620 2650 3540 2020 2810 1590 2290 1260 *1280 1020

-4.6 m lb *8250 *8250 *10290 *10290 *14730 12240 *13720 7910 10030 5700 7670 4340 6110 3420 5010 2750
(-15' 0" ) kg *3740 *3740 *4660 *4660 *6680 5550 *6220 3580 4520 2580 3470 1970 2770 1550 2270 1240

-6.1 m lb *10350 *10350 *12700 *12700 *17480 124440 *13190 7960 10020 5700 7660 4330 6120 3420 *4290 2810
(-20' 0" ) kg *4690 *4690 *5750 *5750 *7920 5640 *5980 3610 4540 2580 3470 1960 2770 1550 *1940 1270

-7.6 m lb *12670 *12670 *15520 *15520 *15880 12830 *12120 8180 *9590 5840 *7710 4450 *6140 3560
(-25' 0" ) kg *5740 *5740 *7040 *7040 *7200 5810 *5490 3710 *4340 2640 *3490 2010 *2780 1610

-9.1 m lb *18260 *18260 *13310 *13310 *10310 8570 *8140 6140 *6310 4730
(-30' 0" ) kg *8280 *8280 *6030 *6030 *4670 3890 *3690 2780 *2860 2140

-10.7 m lb *9390 *9390 *7290 *7290

(-35' 0" ) kg *4260 *4260 *3300 *3300

E215 (Long Reach) LIFTING CAPACITIES (Heavy Lift)

A
Rated loads mar ked with and Based on a machine equipped with theollowing:
f
asterisk (*) are limited by hydraulic Boom: 8.75 m (28' 8")
capacity rather than tipping load. Arm: 6.35 m (20' 10")
See P age 22 f or additional Bucket: 0.45 m3(0.59 yd)3SAE/PCSA 370Kg (815 lbs)
B information. Shoes: 800 mm (31.5")
C

A 1.5 m (5'-0") 3.0 m (10'-0") 4.6 m (15'-0") 6.1 m (20'-0") 7.6 m (25'-0") 9.1 m (30'-0") 10.7 m (35'-0") 12.2 m (40'-0") 13.7 m (45'-0")

C
B
9.1 m lb *2400 *2400
(30' 0" ) kg *1080 *1080

7.6 m lb *4390 *4390 *3510 *3510

(25' 0" ) kg *1990 *1990 *1590 *1590

6.1 m lb *4670 *4670 *4270 3860 *2140 *2140

(20' 0" ) kg *2120 *2120 *1930 1750 *970 *970

4.6 m lb *5520 *5520 *5070 4860 *4750 3690 *3040 2780

(15' 0" ) kg *2500 *2500 *2300 2200 *2150 1670 *1380 1260

3.0 m lb *19430 *19430 *8930 *8930 *7270 *7270 *6240 6000 *5540 4550 *5050 3480 *3680 2660
(10' 0" ) kg *8810 *8810 *4050 *4050 *3290 *3290 *2830 2720 *2510 2060 *2290 1580 *1660 1200

1.5 m lb *5530 *5530 *15460 15230 *10810 10190 *8410 7350 *6980 5510 *6040 4220 *5380 3270 *4130 2530
(5' 0" ) kg *2510 *2510 *7010 6900 *4900 4620 *3810 3330 *3160 2500 *2730 1910 *2440 1480 *1870 1140

lb *5070 *5070 *12890 *12890 *12330 9120 *9410 6670 *7650 5060 *6490 3920 5350 3070 *4320 2410
Gr o u n d L ev el
kg *2300 *2300 *5840 *5840 *5590 4130 *4270 3020 *3470 2290 *2940 1780 2420 1390 *1960 1090

-1.5 m lb *4390 *4390 *6390 *6390 *11780 *11780 *13320 8420 *10150 6170 8060 4710 6390 3680 5170 2900 *4020 2310
(-5' 0" ) kg *1990 *1990 *2900 *2900 *5340 *5340 *6040 3820 *4600 2790 3650 2130 2890 1660 2340 1310 *1820 1040

-3.0 m lb *6290 *6290 *8190 *8190 *12770 12250 *13760 8040 10190 5850 7800 4470 6200 3500 5060 2790 *2820 2260
(-10' 0" ) kg *2850 *2850 *3710 *3710 *5790 5550 *6240 3650 4620 2650 3540 2020 2810 1590 2290 1260 *1280 1020

-4.6 m lb *8250 *8250 *10290 *10290 *14730 12240 *13720 7910 10030 5700 7670 4340 6110 3420 5010 2750
(-15' 0" ) kg *3740 *3740 *4660 *4660 *6680 5550 *6220 3580 4520 2580 3470 1970 2770 1550 2270 1240

-6.1 m lb *10350 *10350 *12700 *12700 *17480 124440 *13190 7960 10020 5700 7660 4330 6120 3420 *4290 2810
(-20' 0" ) kg *4690 *4690 *5750 *5750 *7920 5640 *5980 3610 4540 2580 3470 1960 2770 1550 *1940 1270

-7.6 m lb *12670 *12670 *15520 *15520 *15880 12830 *12120 8180 *9590 5840 *7710 4450 *6140 3560
(-25' 0" ) kg *5740 *5740 *7040 *7040 *7200 5810 *5490 3710 *4340 2640 *3490 2010 *2780 1610

-9.1 m lb *18260 *18260 *13310 *13310 *10310 8570 *8140 6140 *6310 4730
(-30' 0" ) kg *8280 *8280 *6030 *6030 *4670 3890 *3690 2780 *2860 2140

-10.7 m lb *9390 *9390 *7290 *7290

(-35' 0" ) kg *4260 *4260 *3300 *3300

30
E215 (Long Reach) LIFTING CAPACITIES
A
Rated loads mar ked with and Based on a machine equipped with the following:
asterisk (*) are limited by hydraulic Boom: 8.75 m (28' 8")
capacity rather than tipping load. Arm: 6.35 m (20' 10")
See P age 22 f or additional Bucket: 0.45 m3(0.59 yd)3SAE/PCSA 370Kg (815 lbs)
B information. Shoes: 900 mm (35.4")
C

A 1.5 m (5'-0") 3.0 m (10'-0") 4.6 m (15'-0") 6.1 m (20'-0") 7.6 m (25'-0") 9.1 m (30'-0") 10.7 m (35'-0") 12.2 m (40'-0") 13.7 m (45'-0")

C
B
9.1 m lb *2400 *2400
(30' 0" ) kg *1080 *1080

7.6 m lb *4390 *4390 *3510 *3510

(25' 0" ) kg *1990 *1990 *1590 *1590

6.1 m lb *4670 *4670 *4270 3910 *2140 *2140

(20' 0" ) kg *2120 *2120 *1930 1770 *970 *970

4.6 m lb *5520 *5520 *5070 4920 *4750 3740 *3040 2830

(15' 0" ) kg *2500 *2500 *2300 2230 *2150 1690 *1380 1280

3.0 m lb *19430 *19430 *8930 *8930 *7270 *7270 *6240 6080 *5540 4610 *5050 3530 *3680 2710
(10' 0" ) kg *8810 *8810 *4050 *4050 *3290 *3290 *2830 2750 *2510 2090 *2290 1600 *1660 1230

1.5 m lb *5530 *5530 *15460 15400 *10810 10310 *8410 7440 *6980 5580 *6040 4280 *5380 3320 *4130 2570
(5' 0" ) kg *2510 *2510 *7010 6980 *4900 4670 *3810 3370 *3160 2530 *2730 1940 *2440 1500 *1870 1160

lb *5070 *5070 *12890 *12890 *12330 9240 *9410 6760 *7650 5140 *6490 3980 5430 3120 *4320 2450
Gr o u n d L ev el
kg *2300 *2300 *5840 *5840 *5590 4190 *4270 3060 *3470 2330 *2940 1800 2460 1410 *1960 1110

-1.5 m lb *4390 *4390 *6390 *6390 *11780 *11780 *13320 8540 *10150 6260 8180 4780 6480 3740 5260 2950 *4020 2350
(-5' 0" ) kg *1990 *1990 *2900 *2900 *5340 *5340 *6040 3870 *4600 2830 3710 2170 2940 1690 2380 1340 *1820 1070

-3.0 m lb *6290 *6290 *8190 *8190 *12770 12420 *13760 8160 10330 5940 7920 4540 6300 3560 5140 2840 *2820 2310
(-10' 0" ) kg *2850 *2850 *3710 *3710 *5790 5630 *6240 3700 4680 2690 3590 2060 2850 1610 2330 1290 *1280 1040

-4.6 m lb *8250 *8250 *10290 *10290 *14730 12410 *13720 8030 10170 5790 7780 4410 6200 3480 5100 2800
(-15' 0" ) kg *3740 *3740 *4660 *4660 *6680 5620 *6220 3640 4610 2620 3530 2000 2810 1570 2310 1270

-6.1 m lb *10350 *10350 *12700 *12700 *17480 12610 *13190 8080 10170 5790 7770 4400 6210 3480 *4290 2860
(-20' 0" ) kg *4690 *4690 *5750 *5750 *7920 5710 *5980 3660 4610 2620 3520 1990 2820 1580 *1940 1290

-7.6 m lb *12670 *12670 *15520 *15520 *15880 13000 *12120 8300 *9590 5930 *7710 4520 *6140 3620
(-25' 0" ) kg *5740 *5740 *7040 *7040 *7200 5890 *5490 3760 *4340 2680 *3490 2050 *2780 1640

-9.1 m lb *18260 *18260 *13310 *13310 *10310 8690 *8140 6230 *6310 4810
(-30' 0" ) kg *8280 *8280 *6030 *6030 *4670 3940 *3690 2820 *2860 2180

-10.7 m lb *9390 *9390 *7290 *7290

(-35' 0" ) kg *4260 *4260 *3300 *3300

E215 (Long Reach) LIFTING CAPACITIES (Heavy Lift)

A
Rated loads mar ked with and Based on a machine equipped with the following:
asterisk (*) are limited by hydraulic Boom: 8.75 m (28' 8")
capacity rather than tipping load. Arm: 6.35 m (20' 10")
See P age 22 f or additional Bucket: 0.45 m3(0.59 yd)3SAE/PCSA 370Kg (815 lbs)
B information. Shoes: 900 mm (35.4")
C

A 1.5 m (5'-0") 3.0 m (10'-0") 4.6 m (15'-0") 6.1 m (20'-0") 7.6 m (25'-0") 9.1 m (30'-0") 10.7 m (35'-0") 12.2 m (40'-0") 13.7 m (45'-0")

C
B
9.1 m lb *2790 *2790
(30' 0" ) kg *1260 *1260

7.6 m lb *5120 *5120 *4010 *4010

(25' 0" ) kg *2320 *2320 *1820 *1820

6.1 m lb *5450 5200 *4860 3910 *2510 *2510

(20' 0" ) kg *2470 2350 *2200 1770 *1130 *1130

4.6 m lb *6400 *6400 *5920 4920 *5570 3740 *3500 2830

(15' 0" ) kg *2900 *2900 *2680 2230 *2520 1690 *1580 1280

3.0 m lb *22020 *22020 *10230 *10230 *8390 8220 *7240 6080 *6470 4610 5860 3530 *4200 2710
(10' 0" ) kg *9980 *9980 *4640 *4640 *3800 3720 *3280 2750 *2930 2090 2660 1600 *1900 1230

1.5 m lb *6230 *6230 *1770 15400 *12430 10310 *9720 7440 *8100 5580 *7050 4280 5640 3320 4560 2570
(5' 0" ) kg *2820 *2820 *8030 6980 *5630 4670 *4400 3370 *3670 2530 *3190 1940 2550 1500 2070 1160

lb *5720 *5720 *14310 13630 *14200 9240 *10890 6760 8560 5140 6740 3980 5430 3120 4430 2450
Gr o u n d L ev el
kg *2590 *2590 *6490 6180 *6440 4190 *4930 3060 3880 2330 3060 1800 2460 1410 2010 1110

-1.5 m lb *4990 *4990 *7180 *7180 *13100 12750 14840 8540 10680 6260 8180 4780 6480 3740 5260 2950 4330 2350
(-5' 0" ) kg *2260 *2260 *3250 *3250 *5940 5780 6730 3870 4840 2830 3710 2170 2940 1690 2380 1340 1960 1070

-3.0 m lb *7070 *7070 *9160 *9160 *14190 12420 14410 8160 10330 5940 7920 4540 6300 3560 5140 2840 *3260 2310
(-10' 0" ) kg *3200 *3200 *4150 *4150 *6430 5630 6530 3700 4680 2690 3590 2060 2850 1610 2330 1290 *1480 1040

-4.6 m lb *9220 *9220 *11460 *11460 *16350 12410 14260 8030 10170 5790 7780 4410 6200 3480 5100 2800
(-15' 0" ) kg *4180 *4180 *5200 *5200 *7410 5620 6470 3640 4610 2620 3530 2000 2810 1570 2310 1270

-6.1 m lb *11530 *11530 *14110 *14110 *19360 12610 14320. 8080 10170 5790 7770 4400 6210 3480 *4890 2860
(-20' 0" ) kg *5230 *5230 *6400 *6400 *8780 5710 6490 3660 4610 2620 3520 1990 2820 1580 *2210 1290

-7.6 m lb *14080 *14080 *17220 *17220 *18370 13000 *14060 8300 10320 5930 7890 4520 6360 3620
(-25' 0" ) kg *6380 *6380 *7810 *7810 *8330 5890 *6370 3760
31 4680 2680 3580 2050 2880 1640

-9.1 m lb *21020 *21020 *15500 13600 *12040 8690 *9540 6230 *7450 4810
(-30' 0" ) kg *9530 *9530 *7020 6170 *5460 3940 *4320 2820 *3380 2180

-10.7 m lb *11100 *11100 *8640 *8640

(-35' 0" ) kg *5030 *5030 *3920 *3920

31
 3 TORQUE SPECIFICATIONS
The following Torque Specifications are provided for use when actual torque value of a fastener is not known.
3-A. CAPSCREWS and NUTS
1. Metric Coarse Thread Standard Tightening Torque Values. Make certain to tighten all Capscrews and Nuts to
proper torque values.

Nominal 4.8 T 7T 10.9 T

SIZE NO LUBRICATION OIL LUBRICATION NO LUBRICATION OIL LUBRICATION NO LUBRICATION OIL LUBRICATION
M6 P=1 0.45±0.05 (3.2±0.4) 0.38±0.04(2.7±0.3) 0.98±0.1 (7.1±0.7) 0.83±0.08 (6.0±0.6) 1.77±0.18 (12.8±1.3) 1.5±0.15 (10.8±1.1)
M8 P=1.25 1.09±0.11 (7.9±0.8) 0.92±0.09 (6.6±0.7) 2.4±0.2 (17.3±1.4) 2.0±0.2 (14.4±1.4) 4.3±0.4 (31.0±2.9) 3.6±0.4 (26.0±2.9)
M10 P=1.5 2.2±0.2 (15.9±1.4) 1.83±0.18 (13.2±1.3) 4.7±0.5 (33.9±3.6) 4.0±0.4 (28.9±2.9) 8.5±0.9 (61.3±6.5) 7.2±0.7 (52.0±5.1)
M12 P=1.75 3.7±0.4 (26.7±2.9) 3.2±0.3 (23.1±2.2) 8.1±0.8 (58.5±5.8) 6.8±0.7 (49.1±5.1) 14.6±1.5 (105±10.8) 12.3±1.2 (88.8±8.7)
M14 P=2 5.9±0.6 (42.6±4.3) 5.0±0.5 (36.1±3.6) 12.8±1.3 (92.5±9.4) 10.8±1.1 (78.0±7.9) 23±2 (166±14) 19.5±1.9 (140±14)
M16 P=2 9.0±.09 (64.9±6.5) 7.6±0.7 (54.8±5.1) 19.5±2.0 (140±14.4) 16.4±1.6 (118±11.5) 35±4 (252±28.9) 29±3 (209±21.6)
M18 P=2.5 12.4±1.2 (89.6±8.7) 10.5±1.0 (75.8±7.2) 27±3 (195±22) 23±2 (166±14) 49±5 (354±36) 41±4 (296±29)
M20 P=2.5 17.5±1.7 (126±12.3) 14.7±1.4 (106±10.1) 38±4 (274±29) 32±3 (231±22) 68±7 (491±51) 57±6 (412±43)
M22 P=2.5 23±2 (166±14) 19.6±2.0 (142±14) 51±5 (368±36) 43±4 (310±29) 92±9 (663±65) 77±7 (555±58)
M24 P=3 30±3 (217±22) 24±3 (173±22) 65±7 (469±51) 53±5 (383±36) 118±12 (852±87) 96±10 (693±72)
M27 P=3 44±4 (318±29) 36±3 (260±22) 96±10 (693±72) 78±8 (563±58) 173±17 (1250±120) 140±14 (1010±100)
M30 P=3.5 60±6 (433±43) 50±5 (361±36) 131±13 (946±94) 110±11 (794±79) 235±24 (1700±170) 198±20 (1430±140)
M33 P=3.5 81±8 (585±58) 68±7 (491±51) 176±18 (1270±130) 48±15 (1070±110) 1317±32 (2290±200) 266±27 (1920±200)
M36 P=4 105±10 (758±72) 88±9 (636±65) 227±23 (1640±170) 190±19 (1370±140) 409±41 (2960±300) 343±34 (2480±250)
Torque Value Units = kgf-m (ft-lbs)

2.Metric Fine Thread Standard Tightening Torque Values. Make certain to tighten all Capscrews and Nuts to proper
torque values.
Nominal 4.8 T 7T 10.9 T
SIZE NO LUBRICATION OIL LUBRICATION NO LUBRICATION OIL LUBRICATION NO LUBRICATION OIL LUBRICATION
M8 P=1.0 1.15±0.11 (8.3±0.8) 0.97±0.1(7.0±0.7) 2.5±0.2 (18.0±1.4) 2.1±0.2 (15.2±1.4) 4.5±0.4 (32.5±2.9) 3.8±0.4 (27.4±2.9)
M10 P=1.25 2.3±0.2 (16.6±1.4) 1.91±0.19 (13.8±1.4) 4.9±0.5 (35.4±3.6) 4.2±0.4 (30.3±2.9) 8.9±0.9 (64.2±6.5) 7.5±0.7 (54.2±5.1)
M12 P=1.25 4.0±0.4 (28.9±2.9) 3.4±0.3 (24.5±2.2) 8.7±0.9 (62.8±6.5) 7.3±0.7 (52.7±5.1) 15.7±1.6 (113±13) 13.2±1.3 (95.3±9.4)
M16 P=1.50 9.4±0.9 (67.9±6.5) 7.9±0.8 (57.0±5.8) 20±2 (144±14) 7.2±1.7 (124±12) 37±4 (267±29) 31±3 (224±22)
M20 P=1.50 19±9 (137±14) 15.8±1.6 (114±14) 41±4 (296±29) 34±3 (246±22) 74±7 (535±51) 62±6 (448±43)
M24 P=2.0 32±3 (231±22) 27±3 (195±22) 70±7 (506±51) 58±6 (419±43) 126±12 (910±87) 105±10 (758±72)
M30 P=2.0 65±6 (469±43) 54±5 (390±36) 142±14 (1030±100) 118±12 (852±87) 255±26 (1840±190) 212±21 (1530±150)
M36 P=3.0 109±11 (787±79) 91±9 (657±65) 238±23 (1720±170) 198±20 (1430±140) 428±43 (3090±310) 357±36 (2580±260)
Torque Value Units = kgf-m (ft-lbs)

32
3-B. ORS JOINT (O-RING SEALING TYPE)

NOMINAL CONNECTOR O-RING NIPPLE

OPPOSING FLATS TORQUE VALUE WORKING PRESSURE
SIZE mm kgf•m (ft. lbs.) kgf/cm2 (psi)
1 - 14 UNS 30 • 32 14 ± 1.4 (101 ± 10)
350 (4980)
1 - 3/16 12 UN 36 • 41 18 ± 1.8 (130 ± 13) 385 (5475)
(Power Boost)
1 - 7/16 12 UN 41 • 46 21 ± 2.1 (152 ± 15)
Hose mouth ring and Coupling NUT

3-C. NUTS and SLEEVES

WORKING PRESSURE TUBE SIZE TORQUE VALUE
MANUFACTURER’S O.D. X THICKNESS OPPOSING FLATS
NAME kgf/cm2 (psi) mm Dimension B kgf•m (ft. lbs.)
mm (in)
10 x 1.5 (0.394 x 0.059) 19 4.5±0.5 (33±4)
15 x 2.0 (0.591 x 0.079) 27 15±2 (108±14)
350 (4980)
NIPPON A.M.C. Travel line only 18 x 2.5 (0.709 x 0.098) 32 18±2 (130±14)
22 x 3.0 (0.866 x 0.118) 36 22±2 (159±14)
28 x 4.0 (1.10 x 0.157) 41 128±3 (203±22)
350 (4980)
IHARA KOATSU Travel line only 35 x 5.0 (1.38 x 0.20) 55 35±4.5 (253±29)
B
SLEEVE NUT

O.D. (fl) O.D. (fl)

3-D. FLARE TYPE FITTING JOINTS 3-E. NYLON ( N2) TUBE FITTING JOINTS
Over tightening of flare type (Union Nut Type) metal 1.Clean tube and make certain tube end is trimmed
joints may cause damage to nuts, seat surfaces, and smooth.
prevent optimum sealing resulting in oil leaks. 2.Insert tube into fitting until tube end is securely
PIPE THREADS seated in fitting body.

NOMINAL SIZE TORQUE VALUE kg-m (ft. lbs.) 3.Tighten the nut by hand.
2.5±0.3 (18.1±1.8) 4.Use a spanner wrench, security tighten nut by
1/4"
turning 1-1/4 turns.
3/8" 5±0.5 (36.2±3.6)
6±0.6 (43.4±4.3) PLASTIC SLEEVE
1/2"
3/4" 12±1.2 (86.8±8.7)

1" 14±1.4 (101±10)

1-1/4" 17±1.7 (123±12)

1-1/2" 21±2.1 (152±15)

2" 42±4.2 (304±30) BODY NUT NYLON

TUBE

33
3-F. TORQUE VALUES FOR COMMON BOLTS - E215

Qty LOCATION.........................................................................................Bolt Size......................kgf-m (ft-lbs)

5 Fuel tank sending unit mounting...............................................................................M5...............0.2 ±0.02 (1.4 ±0.1)

6 Air Conditioning condenser mounting ..............................................................M6 x 50...............................0.45 (3.3)
1 Hydraulic oil tank sending unit mounting ............................................................................................15 ±2 (108 ±14)
6 Air Conditioning pulley mounting on damper ...................................................M8 x 16.....................................4 (29)
4 Coolant reservoir mounting ...............................................................................................................1.1 ±0.1 (8 ±0.7)
4 Air conditioning compressor mounting ...........................................................M8 x 100..................1.1 ±0.1 (8 ±0.72)
1 Air conditioning idler pulley nut ..............................................................................M10...........4~5.5 ±0.4 (29~40 ±3)
2 Pilot pump mount bolts (Apply Locktite #262).........................................................M10........................4 ±0.4 (29 ±3)
8 Hydraulic oil tank cover mounting ..........................................................................M10.....................4.7 ±0.5 (34 ±4)
2 Swing grease bath inspection cover mounting ......................................................M10........................3 ±0.5 (22 ±4)
8 Swivel joint dust cover mounting ............................................................................M10......................1.5 ±0.2 (11 ±2)
6 Muffler support bracket mounting ...........................................................................M10........................4 ±0.4 (30 ±3)
16 Engine mounting (Engine body side) (Apply Locktite #262) ..................................M10..........................6.6 ± (48 ±3)
4 Travel lever mounting .............................................................................................M10.....................2.4 ±0.2 (17 ±2)
3 Stepping motor mounting (Apply Locktite #262) ....................................................M10.....................................2 (14)
12 Hydraulic pump housing to engine block mounting (Apply Locktite #262) .............M10.....................6.6 ±0.6 (48 ±4)
35 Lower cover mounting (all) .....................................................................................M10.....................5.3 ±0.5 (38 ±4)
2 Air Conditioning compressor bracket..............................................................M10 x 45..................................6.6 (45)
10 Travel motor cover mounting (Apply Locktite #262)...........................................................................8.5 ±0.8 (61 ±6)
16 Cab support mounting bolts ............................................................................................................................4.7 (34)
3 Swivel joint mounting (Apply Locktite #262) ..........................................................................................11 ±1 (79 ±7)
4 Nuts for cab mounts .......................................................................................................................................19 (137)
4 Idler and idler adjuster connection (Apply Locktite #262)......................................M16..................28.5 ±3 (206 ±22)
4 Hydraulic oil and fuel tank mounting (Apply Locktite #262)...................................M16.....................22 ±2 (159 ±14)
4 Radiator bottom support mounting .........................................................................M16...................12.3 ±1.2 (89 ±9)
1 Swivel joint locking nut ...........................................................................................M16......................16 ±2 (115 ±14)
8 Hydraulic pump coupling mount (Apply Locktite #262) ..........................................M16.......................22 ±1 (159 ±7)
8 Track guide mounting (Apply Locktite #262) ..........................................................M18..................40.5 ±4 (292 ±29)
4 Engine mounting (upper frame side) (Apply Locktite #262) ...................................M18.....................23 ±2 (166 ±14)
44 Sprocket mounting (Apply Locktite #262)...............................................................M18..................40.5 ±4 (292 ±29)
56 Lower roller caps (Apply Locktite #262)..................................................................M18..................40.5 ±4 (292 ±29)
64 Lower roller caps (Apply Locktite #262)..................................................................M18..................40.5 ±4 (292 ±29)
4 Hydraulic pump mounting (Apply Locktite #262) ...................................................M20.....................44 ±4 (318 ±29)
12 Swing reduction unit mounting (Apply Locktite #262) ............................................M20.....................55 ±6 (397 ±43)
36 Swing bearing inner race mounting (Apply Locktite #262) .....................................M20...............57.5 ±5.8 (415 ±42)
33 Swing bearing outer race mounting (Apply Locktite #262) ....................................M20.....................40 ±4 (289 ±29)
184 Shoe bolt mounting ................................................................................................M20.....................87 ±5 (628 ±36)
196 Shoe bolt mounting ................................................................................................M20.....................87 ±5 (628 ±36)
4 Upper roller mounting (Apply Locktite #262) ..........................................................M20..................55 ±5.5 (397 ±40)
34 Travel motor mounting (Apply Locktite #262) ........................................................M20..................55 ±5.5 (397 ±40)
4 Counterweight mounting (Apply Locktite #262) .....................................................M24.................130 ±13 (939 ±94)
8 Side cutter mounting ..............................................................................................M24..................95~105 (686~758
2 Idler adjuster grease fitting mounting ........................................................5/8-18 UNF)...........................6 ±1 (43 ±7)
2 Connector for heater hoses (Apply three bond #1110B)..................................................................................2.5 (18)
1 Nut on breather valve ..........................................................................................................................1.0~1.4 (7 ±10)
4 Breather mounting bolts ...............................................................................................................................0.45 (3.5)
1 Hydraulic tank plug (Apply Teflon tape) ........................................................................................................16.5 (119)
4 Top nuts for U-bolt muffler mounting ....................................................................................................1.1 ±0.1 (8 ±1)
4 Bottom nuts for U-bolt muffler mounting ...........................................................................................0.9 ±0.1 (6.5 ±1)
1 Engine temperature sensor (Apply three bond #1110B) ...................................................................2.5 ±0.5 (18 ±4)
2 Air conditioning hose connection on compressor ...........................................................................2.3 ±0.2 (17 ±1.4)
2 Air conditioning hose connection on condenser ..........................................................................1.0 ±0.1 (7.2 ±0.72)
4 Cover mounting on swing motor ............................................................................M20..............................43.8 (317)
1 Swing reduction unit oil plug (Apply Teflon tape) ............................................................................................5.6 (41)
2 Oil plugs on travel reduction unit cover (Apply Teflon tape) ............................................................................5.6 (41)

34
4. MISCELLANEOUS INFORMATION 4-E. WEIGHT OF MATERIALS TABLE
3
4-A. TEMPERATURE TABLE Lb/yrd3 Kg/m Material (Loose weight)
°C °F °C °F °C °F °C °F °C °F °C °F 700 420 Wood chips
-10 14 55 131 120 248 185 365 250 482 315 599 750 440 Peat, dry
-5 23 60 140 125 257 190 374 255 491 320 608 950 560 Cinders
0 32 65 149 130 266 195 383 260 500 325 617 1170 690 Peat, wet
5 41 70 158 135 275 200 392 265 509 330 626 1600 950 Top Soil
10 50 75 167 140 284 205 401 270 518 335 635 1780 1050 Coal
15 59 80 176 145 293 210 410 275 527 340 644 2100 1250 Caliche
20 68 85 185 150 302 215 419 280 536 345 653 2100 1250 Earth, loam
25 77 90 194 155 311 220 428 285 545 350 662 2250 1330 Shale
30 86 95 203 160 320 225 437 290 554 355 671 2400 1420 Sand, dry
35 95 100 212 165 329 230 446 295 563 360 680 2500 1480 Clay, dry
40 104 105 221 170 338 235 456 300 572 365 689 2550 1510 Earth, dry
45 113 110 230 175 347 240 464 305 581 370 698 2600 1540 Limestone, broken or crushed
50 122 115 239 180 356 245 473 310 590 475 707 2700 1600 Earth, wet
2800 1660 Clay, wet
4-B. SPECIAL PIPE WRENCHES 2800 1660 Rock, granite, blasted and broken
2850 1690 Sand, moist
Tube Part
A B C D E F G 2900 1720 Sand and gravel, dry
Dia. Number
15 27 70 22 12.7 8 40 16 3100 1840 Sand, wet
(0.59) 2421T160 (1.06) (2.76) (0.87) (0.50) (0.32) (1.57) (0.43) 3400 2020 Sand and gravel, wet
18 32 70 22 12.7 11 42 19
(0.71) 2421T138 (1.26) (2.76) (0.87) (0.50) (0.43) (1.65) (0.75)
22 36 70 22 12.7 11.5 48 23
4-F. FEMALE PF CAPS
(0.87) 2421T130 (1.42) (2.76) (0.87) (0.50) (0.45) (1.89) (0.91)
SIZE PART NUMBER
28 41 109 22 12.7 14.5 60 29 PF 1/4 2444Z2729D1
(1.10) 2421T115 (1.61) (4.29) (0.87) (0.50) (0.57) (2.36) (1.14)
PF 3/8 2444Z2729D2
35 55 90 45 20 20.5 81 41
2421T314 PF 1/2 2444Z2729D3
(1.38) (2.17) (3.54) (1.77) (0.79) (0.81) (3.19) (1.61)
PF 3/4 2444Z2729D4
Unit: mm (inches)
A PF I 2444Z2729D5
B
Unit: mm
G C

4-G. MALE PF PLUGS

D
F E
PART A B C D
SIZE O.D. (ø) Length Length Flats
NUMBER
PF 1/4 2444Z2728D1 13.5 16.5 24.5 14
4-C. MALE PLUGS FOR ORFS FITTINGS
PF 3/8 2444Z2728D2 16.6 17.5 25.5 17
PLUG O-RING
PART PF 1/2 2444Z2728D3 20.6 20.0 31.0 22
SIZE PART
(A) NUMBER NUMBER PF 3/4 2444Z2728D4 26.2 21.5 34.0 27
5/8 IN YN01H01001P1 ZD12A01600 PF I 2444Z2728D5 33.3 23.5 36.0 36
A
2/4 IN YN01H01002P1 ZD12A01800 Unit: mm
1 IN YN01H01003P1 ZD12A02100 D
C
B

4-D. FEMALE CAPS FOR ORFS FITTINGS

A
PLUG
SIZE PART NUMBER
(A) 60 Degrees
5/8 IN YN01H01004P1
A
2/4 IN YN01H01005P1
1 IN YN01H01006P1

35
4-H. 4 BOLT FLANGE CAPS

ITEM 1 - Nominal Size ITEM 2 ITEM 3 ITEM 4 ITEM 5 ITEM 6 Dimension A Dimension B
12.7 mm 18.24 mm 40.49 mm
ZE13Q08000 (1/2") 2445Z831D1 ZS18C08030 ZW26X08000 ZS23C08030 ZW26K08000 (0.72") (1.59")
19.1 mm 23.80 mm 50.80 mm
ZE13Q12000 (3/4") ZD12P02600 ZS18C10035 ZW26X10000 ZS23C10035 ZW26K10000 (0.94") (2.00")
25.4 mm 27.76 mm 57.15 mm
ZE13Q16000 (1.0") ZD12P03400 ZS18C12040 ZW26X12000 ZS23C12040 ZW26K12000 (1.09") (2.25")
31.8 mm 31.75 mm 66.68 mm
ZE13Q20000 (1.25") ZD12P03800 ZS18C14045 ZW26X14000 ZS23C14045 ZW26K14000 (1.25") (2.26")
38.1 mm 36.50 mm 79.38 mm
ZE13Q24000 (1.50") ZD12P04800 ZS18C16050 ZW26X16000 ZS23C16050 ZW26K16000 (1.44") (3.12")
50.8 mm 44.45 mm 96.82 mm
ZE13Q32000 (2.0") 2445Z831D2 ZS18C20065 ZW26X20000 ZS23C20065 ZW26K20000 (1.75") (3.81")

3
B 4

5
2 6

4-I. TUBE AND HOSE PLUGS 4-J. TUBE AND HOSE PLUGS
TUBE A Internal B Nut C External BOLT THREAD TYPE PART NUMBER
DIAMETER (For hose end) (Use with A) (For tube end)
10 mm M10 ZS91C01000
10 mm ZF83P10000 ZF93N10000 ZF83H10000
12 mm M12 ZS91C01200
15 mm ZF83P15000 ZF93N15000 ZF83H15000
16 mm M16 ZS91C01600
18 mm ZF83P18000 ZF93N18000 ZF83H18000
20 mm M20 ZS91C02000
22 mm 2444T1338D4 ZF93N22000 2444T1329D4
30 mm M30 ZS91C03000
28 mm ZF83P28000 ZF93N28000 2444T1329D5
36 mm M36 ZS91C03600
35 mm ZF83P35000 ZF93N35000 ZF83H35000
48 mm M48 ZS91C04800

C
A

36
5. CONVERSION TABLES
5-A. UNITS OF WEIGHT
FROM INTO MULTIPLY BY
5-G. UNITS OFVOLUME
Kg FROM INTO MULTIPLY BY
lb 2.2
Gal (US liquid) 0.264
Lb Kg 0.454
in3 61.02
3
yard 0.00131
5-B. UNITS OF LENGTH quarts 1.0567
FROM INTO MULTIPLY BY DIVIDE BY ounces (US) 33.81
meters feet 3.28 m3 0.765
3
mm inches 25.4 in 46656
inches mm 25.4 ft3 27
cm3 764554.9
liters 764.555
5-C. UNITS OF POWER
FROM INTO MULTIPLY BY
Hp KW 0.7457
KW Hp 1.341

5-D. UNITS OF FLOW

FROM INTO MULTIPLY BY
Lit/min 3.79
Gal/min Lit/sec 0.0631
(US liquid) cm3/min 3785.4
ft3/min 0.1337
3
ft /min 0.0353
Gal/min 0.264
Lit/min
Gal/sec 0.004403
yard3/min 0.001308

5-E. UNITS OF TORQUE

FROM INTO MULTIPLY BY
Lbf-ft 0.738
Kgf-m 0.1019716
N-m
Lbf-ft 0.737561
Lbf-in 8.85075
Kgf-m 0.1382552
Lbf-ft N-m 1.35582
Lbf-in 12

5-F. UNITS OF PRESSURE

FROM INTO MULTIPLY BY
psi 14.223
Kg/cm3
Pa (Pascal) 9.807
Atm 0.06805
Bars 0.06895
Lit/min 3
Kg/cm 0.0703
Pa (Pascal) 6894.76
MPa (MegaPascal) psi 145.04

37
 SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE

CHAPTER 4

E215
CRAWLER EXCAVATORS

ATTACHMENT DIMENSIONS

Issued January 2006

Book/Form Number 5-1580 NA
Copyright © 2006. CNH America, LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. S5PJ0010E01-KO03
 SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE
CHAPTER 4 - ATTACHMENT DIMENSIONS

CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Remarks
First Edition 01-2006 E215 5-1580 NA

3-II Issued 01-2006 Bur 5-1580 NA

 SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE

CHAPTER 4
ATTACHMENT SPECIFICATIONS
TABLE OF CONTENTS

1 BOOM
4.1.1 Boom Dimensional Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
4.1.2 Boom Maintenance Standard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Clearance in Pin and Bushing on Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Clearance in Thrust Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2. ARM
4.2.1 Arm Dimensional Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
4.2.2 Arm Maintenance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3. BUCKET
4.3.1 Bucket Dimensional Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
4.3.2 Bucket Dimensional Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
4.3.3 Bucket Dimensional Drawing -Lug Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
4.3.4 Bucket Dimensional Drawing- Boss Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

5-1580 NA Issued 01-2006 Bur 4-1

Any use of editorial or pictorial content is strictly prohibited without express written permission from
CNH America LLC. Carol Stream, IL 60188 U.S.A.
Copyright © 2004 CNH America LLC. All Rights Reserved.
Issued January, 2004 - Form Number 6-75780NA-NH04
Source Code No. S5YQ/LL0412E-00
1.1 BOOM DIMENSIONAL DRAWING 1. BOOM

SECTION B-B

Fig. 1-1 Boom Dimension Drawing

Table 1-1 Unit: mm (Ft-in)

5.65M (18ft-6in) Boom YN02B00083F3 Unit:mm (ft-in)
A Boom Length 5,650mm (18’ 6")
B Boom foot width 674mm (26.5")
C Boom end inner width 347mm (13.7")
D Boom end outer width 482mm (19")
E Heigth of boom cylinder rod pin 985mm (38.8")
F Heigth of arm cylinder (head side) pin 1,182mm (3’ 10")
G Distance between pins and boss R2,425mm (7’ 11")
H Distance between pins and barcket R2,750mm (9’ 03")
I Arm cylinder (head side) inner width 122mm (4.8")
J Outer width of bracket on the arm cylinder (rod side) mounting 470mm (18.5")
d1 Boom foot pin diameter 90mm (3.54")
d2 Boom cylinder (rod side) pin diameter 85 (3.35")
d3 Pin diameter of arm end 90 (3.54")
d4 Arm cylinder (head side) pin diameter 85mm (3.35")
1
1.2 BOOM MAINTANCE STANDARD 1. BOOM
(1) Clearance of pin and bushing on
boom section

#D D

Fig. 1-2 Clearance of pin and bushing on boom section

Table 1-2 Unit: mm (Ft-in)

Repair-
Sym- Pin dia. Bushing I.D. Standard Service
bol Item Pin part No. Pin dia. able Remedy
Tolerance Tolerance value Limit
level

+.204mm +.224mm
(+0.0080") (+0.0088")
A Boom 2419T4651
+0.20mm -0.073mm +0.053mm
φ 90mm (+0.0008") (-0.0029") (+0.0021")

Boom (3.5433") -0.020mm +.230mm

cylinder (-0.0008") (+0.0091")
B YN02B01185P1
(head -0.150mm +.250mm
side) (-0.0059") (+0.0098")
+0.130mm More
Boom (+0.0051") Replace
than 2.5mm
C cylinder YN02B01186P1 bushing
+0.30mm 2.0mm (0.1")
(rod side) or pin
(+0.0012") (0.8")
-0.030mm +.260mm
+.230mm
(-0.0012") (+0.0102")
D YN02B01187P1 φ 85mm (+0.0091")
Arm +.120mm
(3.3464") +0.150mm
cylinder (+0.0047")
(+0.0059")
(Head +0.20mm +.250mm
side) (+0.0008") (+0.0098")
#D YN02B01272P1
-0.020mm +0.130mm
(-0.0008") (+0.0051")
# Mark Shows Ground Pin (EU spec.)
2
(2) Clearance in thrust direction on the 1. BOOM
boom cylinder installation section

l 2 l 2
l 1
X1 L

SECTION A-A X2 L2 L2 X2
SECTION B-B

l 4
X4 L4

L3 L3' X3
l 3
SECTION C_C
SECTION D-D

Fig. 1-3 Clearance in thrust direction on the boom clinder installation section.

3
(2) Clearance in thrust direction on the 1. BOOM
boom cylinder installation section

Fig. 1-3 Clearance in thrust direction on the boom cylinder installation section.

Table 1-3 Unit: mm (Ft-in)

Shim adjusting clearence Length under
Section Item Basic size
Total of both sides) pin neck
Remedy
Standard Repairable Service
Symbol Size No. Length
Value Level Limit

674mm
Boom 0.6mm
Boom (26.5") 809mm
A-A L1 (0.02") or l1
foot 676mm (31.9")
Upper frame less
(26.6") 2.0mm 2.5mm
110mm (0.08") (0.10")
Boom cylinder
Boom cylinder (4.33") 0.6~1.0mm 250mm
B-B L2 l2
(Head side) 110mm (0.02~0.04") (9.84")
Upper frame Shim
(4.33")
Adjust-
105mm ment
Boom cylinder L3
Boom cylinder (4.13") 0.6~2.0mm 3.0mm 4.0mm 734mm
C-C l3
(rod Side) 470mm (0.02~0.08") (0.12") (0.16") (28.9")
Boom L3’
(18.5")

120mm
Boom cylinder
Arm cylinder (4.72") 0.6~1.0mm 2.0mm 2.5mm 256mm
D-D L4 l4
(Head side) 122mm (0.02~0.04") (0.08") (0.10") (10.1")
Boom
(4.80")

4
 2. ARM
2.1 ARM DIMENSIONAL DRAWING

D1 D2
K

L
d1 d2

SECTION A-A d3

N
VIEW I

O
d5
D4

d4

SECTION B-B

5
 2. ARM
2.1 ARM DIMENSIONAL DRAWING

Fig. 2-1 Arm dimensional drawing

Table 2-1 Unit: mm (Ft-in)

DIMENSION DIMENSION
Code NAME No. NAME
2.9M (9ft-8in) Arm 2.94M (9ft-8in) ARM

2,940mm 346mm
C Arm length M Boss width
(9’ 8") (13.6")

Distance between pins of boss and R834mm Bracket inner 122mm

D N
bracket (32.8") width (4.8")

φ95mm Bracket inner 102mm

D1 I.D. of boss O
(3.74") width (4.02")

φ85mm Idler link 630mm

D2 I.D. of boss P
(3.35") dimension (24.8")

φ105mm Bucket link 610mm

D4 I.D. of boss Q
(4.13") dimension (24")

height between
Distance between pins of boss and R2,171 23mm
E R pins of boss and
bracket (7’1.5") (0.906")
center

Distance between pins of boss and R420 φ80mm

F d1 Pin diameter
boss (16.5") (3.15")

Height between pins of boss and 615.5mm φ70mm

G d2 Pin diameter
bracket (24.2") (2.76")

Height between pins of boss and 298mm φ85mm

H d4 Pin diameter
bracket (11.7") (3.35")

325mm φ90mm
K Arm top end boss width d4 Pin diameter
(12.8") (3.54")

320mm φ80mm
L Link section boss width d5 Pin diameter
(12.6") (3.15")

6
 2 ARM
2.2 ARM MAINTENANCE STANDARD
(1) Clearance of pin and bushing

Fig. 2-2 Clearance of pin and bushing on arm section

7
 2 ARM
2.2 ARM MAINTENANCE STANDARD
(1) Clearance of pin and bushing

Table 2-2 Unit: mm (Ft-in)

Standard value Clearance

No. Item Pin part No. Pin Remedy

Pin Bushing I.D. Standard Repairable Service
I.D.diamater
Diameter tolerance value level limit
tolerance

+0.226mm +0.286mm
(+0.0089") (+0.0113")
A Arm point
-0.020mm +0.153mm +0.173mm
φ80mm (+0.0008") (+0.0060") (+0.0068")
YN12B01073P1
(3.149") -0.060mm +0.231mm +0.291mm
Bucket link (-0.0024") (+0.0091") (+0.0115")
B (bucket
+0.161mm +0.181mm
connection)
(+0.0063") (+0.0071")

+0.240mm +0.300mm
Idler link φ70mm (+0.0095") (+0.0118")
C YN12B01307P1
(Arm connection) (2.755") +0.174mm +0.174mm
(+0.0069") (+0.0069")

+0.000mm +0.227mm +0.287mm

Bucket link
(+0.000") (+0.0089") (+0.0113")
D (Idler link
-0.060mm +0.155mm +0.155mm
connection)
(-0.0024") (+0.0061") (+0.0061")
LQ12B01089P1
+0.290mm
Bucket cylinder (+0.0114")
D’
(Rod side) +0.150mm
(+0.0059") Replace
φ80mm 2.0mm 2.5mm
bushing
(3.149") +0.030mm +0.260mm (0.08") (0.01")
or pin
(+0.0012") (+0.0102")
E YN12B01218P1
-0.030mm +0.120mm
Bucket cylinder (-0.00012") (+0.0047")
(head side) +0.020mm +0.230mm +0.250mm
# (+0.0008") (+0.0091") (+0.0100")
YN12B01348P1
E -0.020mm +0.150mm +0.130mm
(-0.0008") (+0.0059") (+0.0050")

+0.030mm +0.260mm
(+0.0012") (+0.0102")
F YN12B01243P1
-0.030mm +0.130mm
Arm Cylinder φ85mm (0.0012") (+0.0050")
(Rod side) (3.346") +0.250mm
# (+0.0100")
YN12B01247P1
F +0.020mm +0.130mm
(+0.0008") (+0.0050")
-0.020mm +0.231mm +0.251mm
φ90mm (0.0008") (+0.0091") (+0.0099")
G Arm foot YN12B01042P1
(3.346") +0.153mm +0.133mm
(+0.0060") (+0.0052")

Note ; The mark # shows ground pin. (EU spec.)

8
 2. ARM
(2) Clearance of arm and cylinder installing
sections in thrust direction

X1 L1
X2 L2
X3 L3

l2
l1
SECTION A-A SECTION B-B (standard) l3
SECTION C-C

l5
X4 L4
X6 L6

X7 L4
l4 X5 L5 l6
SECTION D-D, D'-D' SECTION E-E SECTION F-F

X7
L7
l7
SECTION G-G

9
 2. ARM
(2) Clearance of arm and cylinder installing
sections in thrust direction

Table 2-3 Unit: mm (Ft-in)

Shim adjusting clearance Length under

Basic size
(Total of both sides) pin neck
Section Item
Repairable Service
No. Size Standard vlaue No. Length Remedy
level limit

325mm
Arm
A-A Arm point (12.79")
L1 l 1
326mm
Bucket
(12.83") 0.6~1.0mm 2.0mm 481mm
Link 325mm (0.02~0.04") (0.08") (18.9")
side (12.79")
B-B Bucket link L2 l 2
327mm
Bucket
(12.87")

320mm
Idler link Arm
(12.60") 0.6mm 1.0mm 2.5mm
C-C (Arm L3 l 3
Link (0.02") (0.04") (0.10")
connection) ----
side

Rod
----
Bucket link side L4 419mm
D-D (Idler link Link 320mm (16.5")
connection) side (12.60") 0.6~1.0mm 2.0mm l 4 Shim
Rod 100mm (0.02~0.04") (0.08") Adjustment
Bucket link
(Rod side) side (3.94")
D’-D’ L4’
Link 102mm
side (4.02")

Head 100mm
Bucket side (3.94")
E-E cylinder L5 l 5 229mm
102mm (9.02")
(Head side) Arm
(4.02") 0.6~2.0mm 3.0mm 4.0
Rod 120mm (0.02~0.08") (0.12") (0.16")
Arm side (9.72")
F-F l 6 272mm
cylinder L6
122mm (10.7")
(Rod side) Arm
(4.80")

346mm
Arm
(13.62") 0.6mm 1.0mm 2.5mm
G-G Arm foot l 7 503mm
L7 347mm (0.02") (0.04") (0.10") (19.8")
Boom
(13.66")

10
 3. BUCKET
Dynamic Acera
3.1 BUCKET DIMENSIONAL DRAWING KAI SPECIFICATIONS

d2

E
d1
D

F *r2

A
α

B
*r1

I
Io
t1 t6

t2 t3

t5
t4
* Individual bucket designs could effect this clearance.

11
Attachment Specifications Unit mm (ft-in.)
Dynamic Acera
3.2 BUCKET DIMENSIONAL TABLE KAI SPECIFICATIONS

E215
A 442mm (17.401’’) 514mm (20.236’’)
B R 1,450mm (R 57.086’’) R 1,515mm (R 59.645’’)
D 399mm (15.708") 399mm (15.708")
d1 Ø 80mm (3.149") Ø 90mm (3.543")
d2 Ø 80mm (3.149") Ø 90mm (3.453")
E 327mm (12.873") 327mm (12.873")
F 837mm (32.952") 1060mm (41.732")
r1 150mm (5.905") 145mm (5.708")
r2 130mm (5.118") 133mm (5.236")
o o
α 96.75 102.86

I 542mm (21.338") 532mm (20.944")

I0 480mm (18.897") 470mm (18.503")
t1 30mm (1.181") 30mm (1.181")
+.0019 +.070 +.002
t2 Ø 80mm -+.05
.110 (3.149" - .004 ) Ø 90mm - .130 (2.559" - .005 )
∅ 70 (∅ 2.7") ∅ 65 (∅ 2.5") ∅ 65 (∅ 2.5") ∅ 65 (∅ 2.5")
t3 Ø 85mm (3.346") Ø 95mm (3.740")
t4 15mm (.590") 15mm (.590")
t5 17mm (.669") 17mm (.669")
t6 27mm (.669") 27mm (1.062")

LEGEND BUCKET and BUCKET PIN

BUCKET BUCKET PIN

A: Distance between pins of l: Overall length of pin

bracket I 0: Length under head to center
B: Distance from bucket pin to line of retainer hole
tooth tip t 1: Length of taper
D: Bracket inside width
d1: Diameter of pin t 2: Diameter of pin
d2: Diameter of pin t 3: Diameter of head
E: Bracket inside width
F: Side cutter outside width t 4: Center line of alignment hole
r 1: Clearance radious of arm t 5: Diameter of retainer and
(*for reference only) alignment hole (2 Places)
r2: Clearance fo linkage
t6: Lenght of pin head
(*for reference only)

α: Alpha angle

12
 3.2. BUCKET DIMENSIONAL TABLE REFERENCE

Table 3-1
Table 3-1

No. Name No. Name

Distance between pin and bracket

A G Outer width of bracket bottom

Distance between bucket pin and tooth end

B H Bucket outer width of front side

C Inner width of bucket top end I Pitch between teeth

D Inne width of lug I0 Pitch between teeth

E Inner width of bracket d1 Outer dia. of bushing

F Outer width of bracket d2 Pin dia.

Table 3-2 Unit: mm (Ft-in)

DD Bucket
HD Bucket
Type GD Bucket (General Duty) (Demolition
(Heavy Duty
Duty)

Capacit- [STD] 0.80m3 0.51m3 0.70m3 0.93m3 1.05m3 0.80m3 0.80m3

y (1.05cu-yd) (0.67cu-yd) (0.92cu-yd) (1.21cu-yd) (1.37cu-yd) (1.05cu-yd) (10.5cu-yd)
Part No. YN61B00064F2 YN61B00076F2 YN61B00094F2 YN61B00080F2 YN61B00082F2 YN61BOOO86F1 YN61B00075F1

A 445(17.5") 445(17.5") 445(17.5") 445(17.5") 445(17.5") 445(17.5") 445(17.5")

B R1,440(4’9”) R1,440(4’9”) R1,440(4’9”) R1,440(4’9”) R1,440(4’9”) R1,446 (4’ 9”) R1,440 (4’ 9”)

C 1,100(3’ 7”) 711(28") 921(36.3") 1,173(3’ 10”) 1,303(4’3”) 1000(3’ 3”) 1,000(3’3”)
D 399(15.7") 399(15.7") 399(15.7") 399(15.7") 399(15.7") 399(15.7") 399(15.7")

E 327(12.9") 327(12.9") 327(12.9") 327(12.9") 327(12.9") 327(12.9") 327(12.9")

F 1,159(3’10”) 868(34.2") 1,080(3’6”) 1,332(4’4”) 1,462(4’9”) 1,150(3’9”) 1,177(3’10”)

G 863(34") 572(22.5") 784(30.9") 1,036(3’5”) 1,166(3’10”) 863(34") 863(34")

H 1,057(3’6”) 766(30.2") 979(38.5") 1,230(4’) 1.360(4’6”) 1064(3’6”) 1,057(3’6”)

I 223(8.87") 300(11.8") 203(7.99") 266(10.5 ) 238(9.37") 291(11.5") 223(8.78")

I0 223(11") 300(11.8") 203(7.99") 266(10.5 ) 240(9.45") 291(11.5") 223(8.78")

d1 95(3.75") 95(3.75") 95(3.75") 95(3.75") 95(3.75") 95(3.75") 95(3.75")

d2 80(3.15") 80(3.15") 80(3.15") 80(3.15") 80(3.15") 80(3.15") 80(3.15")

13
 3. BUCKET
3.4 DETAIL DIMENSIONAL DRAWING OF BOSS SECTION

H 5
∅∅ G

I
∅∅∅ C
∅∅∅ D
∅∅∅ A

∅∅∅ B
∅

15

DETAIL I

Fig. 3-3 Dimension of boss section

Table 3-4 Unit: mm (Ft-in)

Type Capacity
Part No. of Part No.
of of bucket φA φB φC φD E F φG H I
bucket m3(cu-yd) bucket of boss

[STD]
0.80(1.05) YN61B00064F2
GD 0.51(0.67) YN61B00076F2 114.3mm 84mm 105.5mm 111.5mm 27mm 42mm 17mm 13mm 3.0mm
2418P26833 (4.50") (3.31") (4.15") (4.39") (1.06") (1.65") (0.669") (0.512") (0.118")
bucket 0.70(0.92) YN61B00094F2
.093(1.21) YN61B00080F2
1.05(1.37) YN61B00082F2

HD
bucket
0.80(1.05) YN61B00086F1

15
 3. BUCKET
3.4 DETAIL DIMENSIONAL DRAWING OF BOSS SECTION

H 5
∅G

I
∅C
∅D
∅A

∅B

15

DETAIL I

Fig. 3-3 Dimension of boss section

Table 3-4 Unit: mm (Ft-in)

Asian Market
Type Capacity
Part No. of Part No.
of of bucket φA φB φC φD E F φG H I
bucket m3(cu-yd) bucket of boss

[STD]
0.80(1.05) YN61B00064F2
GD 0.51(0.67) YN61B00076F2 114.3mm 84mm 105.5mm 111.5mm 27mm 42mm 17mm 13mm 3.0mm
2418P26833 (4.50") (3.31") (4.15") (4.39") (1.06") (1.65") (0.669") (0.512") (0.118")
bucket 0.70(0.92) YN61B00094F2
.093(1.21) YN61B00080F2
1.05(1.37) YN61B00082F2

HD
bucket
0.80(1.05) YN61B00086F1

15
NOTES

16
 SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE

CHAPTER 11

E215
CRAWLER EXCAVATOR

TOOLS

Issued January 2006

Book/Form Number 5-1590 NA
Copyright © 2006. CNH America, LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. S5PJ0010E01-KO11
 SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE
CHAPTER 11 - TOOLS

CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Remarks
First edition 01-2006 E215 5-1590 NA

11-II Issued 01-2006 Bur 5-1590 NA

 SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE

CHAPTER 11
TOOLS
TABLE OF CONTENTS

11.1 TORQUE SPECIFICATIONS FOR CAPSCREWS AND NUTS

11.1.1 Metric Coarse Thread Standard Tightening Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
11.1.2 Metric Fine Thread Standard Tightening Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
11.2 Screw and Tool Sizes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
111.3 TORQUE SPECIFICATIONS FOR NUTS AND SLEEVES
11.3.1 Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
11.3.2 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
11.5 PLUGS
11.5.1 Plug for Hydraulic Pipe Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
11.5.1.1 Plug for Flare Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
111.5.2.4 Plug for ORS Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
11.6 SPECIAL SPANNERS FOR TUBES
11.7 SPECIAL TOOLS
11.8 APPLICATION OF SCREW LOCKING AND SEALING COMPOUNDS
11.8.0.1 General Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
11.8.0.2 Specific Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
11.9 SUCTION STOPPER
11.9.1 Components, Dimensions, Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
11.10 COUNTERWEIGHT LIFTING JIG
Standard Eye Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Upper Frame Lifting Jig. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
11.13 ENGINE MOUNTING PEDESTAL

5-1590 NA Issued 01-2006 Bur 11-1

 SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE
CHAPTER 11 - TOOLS

NOTES

11-2 Issued 01-2006 Bur 5-1590 NA

 1.•TIGHTENING TORQUES FOR CAPSCREWS AND NUTS

Tables 1-1 and 1-2 indicate tightening torques Insufficient tightening may lead to a loosening or
applicable to cases where no special note is given. loss of bolts. Always tighten bolts to proper
Overtightening of bolts may result in a twist-off torques.
and a fracture under load.

Table 1-1•Tightening torque for metric coarse threads (not plated) unit : kgfŸm (ftŸlbs)
Strength
grade 4.8 T 7 T 10.9 T
Size Use No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication
•0.45±0.05 0.38±0.04 0.98±0.1 0.83±0.08 1.77±0.18 1.5±0.15
M 6 P=1 (3.3±0.4 ) (2.7±0.3) (7.1±0.7) (6.0±0.6) (13±1) (11±1)
1.09±0.11 0.92±0.09 2.4±0.2 2.0±0.2 4.3±0.4 3.6±0.4
M 8 P=1.25 (7.9±0.8) (6.7±0.7) (17±1) (14±1) (32±3) (26±3)
2.2±0.2 1.83±0.18 4.7±0.5 4.0±0.4 8.5±0.9 7.2±0.7
M10 P=1.5 (16±1) (13±1) (34±4) (29±3) (61±7) (52±5)
3.7±0.4 3.2±0.3 8.1±0.8 6.8±0.7 14.6±1.5 12.3±1.2
M12•P=1.75 (27±3) (23±2) (59±6) (49±5) (110±11) (89±9)
5.9±0.6 5.0±0.5 12.8±1.3 10.8±1.1 23±2 19.5±1.9
M14•P=2 (43±4) (36±4) (93±9) (78±8) (170±14) (140±14)
9.0±0.9 7.6±0.7 19.5±2.0 16.4±1.6 35±4 29±3
M16•P=2 (65±7) (55±5) (140±14) (120±12) (250±29) (210±22)
12.4±1.2 10.5±1.0 27±3 23±2 49±5 41±4
M18•P=2.5 (90±9) (76±7) (200±22) (170±14) (350±36) (300±29)
17.5±1.7 14.7±1.4 38±4 32±3 68±7 57±6
M20•P=2.5 (130±12) (110±10) (270±29) (230±22) (490±51) (410±43)
23±2 19.6±2.0 51±5 43±4 92±9 77±8
M22•P=2.5 (170±14) (140±14) (370±36) (310±29) (670±65) (560±58)
30±3 24±3 65±7 53±5 118±12 96±10
M24•P=3 (220±22) (170±22) (470±51) (380±36) (850±87) (690±72)
44±4 36±4 96±10 78±8 173±17 140±14
M27•P=3 (320±29) (260±29) (690±72) (560±58) (1300±120) (1000±100)
60±6 50±5 131±13 110±11 235±24 198±20
M30•P=3.5 (430±43) (360±36) (950±94) (800±80) (1700±170) (1400±140)
81±8 68±7 176±18 148±15 317±32 266±27
M33•P=3.5 (590±58) (490±51) (1300±130) (1100±110) (2300±230) (1900±200)
105±10 88±9 227±23 190±19 409±41 343±34
M36•P=4 (760±72) (640±65) (1600±170) (1400±140) (3000±300) (2500±250)

Table 1-2•Tightening torques for metric fine threads (not plated) unit : kgfŸm (ftŸlbs)
Strength
grade 4.8 T 7 T 10.9 T
Size Use No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication
1.15±0.11 0.97±0.1 2.5±0.2 2.1±0.2 4.5±0.4 3.8±0.4
M 8 P=1 (8.3±0.8) (7.0±0.7) (18±1) (15±1) (33±3) (27±3)
2.3±0.2 1.91±0.19 4.9±0.5 4.2±0.4 8.9±0.9 7.5±0.7
M10•P=1.25 (17±1) (14±1) (35±4) (30±3) (64±7) (54±5)
4.0±0.4 3.4±0.3 8.7±0.9 7.3±0.7 15.7±1.6 13.2±1.3
M12•P=1.25 (29±3) (25±2) (63±7) (53±5) (110±12) (95±9)
9.4±0.9 7.9±0.8 20±2 17.2±1.7 37±4 31±3
M16•P=1.5 (68±7) (57±6) (140±14) (120±12) (270±29) (220±22)
19±1.9 15.8±1.6 41±4 34±3 74±7 62±6
M20•P=1.5 (140±14) (110±12) (300±29) (250±22) (540±51) (450±43)
32±3 27±3 70±7 58±6 126±12 105±10
M24•P=2 (230±22) (200±22) (510±51) (420±43) (910±87) (760±72)
65±6 54±5 142±14 118±12 255±26 212±21
M30•P=2 (470±43) (390±36) (1000±100) (850±87) (1800±190) (1500±150)
87±9 72±7 190±19 158±16 341±34 284±28
M33•P=2 (630±65) (520±51) (1400±140) (1100±120) (2500±250) (2100±200)
109±11 91±9 238±23 198±20 428±43 357±36
M36•P=3 (790±80) (660±65) (1700±170) (1400±140) (3100±310) (2600±260)

1
 2.•SCREW SIZE

(1) Capscrew (2) Socket bolt

d
d

Table 2-1 Table 2-2 Table 2-3

Nominal B mm Nominal B mm Nominal B mm
screw size screw size screw size
Tool Unified Tool Tool
(d) size (d) size (d) size
M6 10 1/4-20UNC 11 (M3) 2.5
M8 13 5/16-18UNC 13 (M4) 3
M10 17 3/8-16UNC 14 (M5) 4
M12 19 7/16-14UNC 16 M6 5
(M14) (22) 1/2-13UNC 19 M8 6
M16 24 5/8-11UNC 24 M10 8
(M18) (27) 3/4-10UNC 29 M12 10
M20 30 7/8-9UNC 33 M14 12
(M22) 32 1-8UNC 38 M16 14
M24 36 1 1/8-7UNC 43 (M18) 14
(M27) (41) 1 1/4-7UNC 48 M20 17
M30 46 1 1/2-6UNC 57 (M22) 17
M36 55 M24 19
M42 65 (M27) 19
M45 70 M30 22
M48 75 M36 27
M56 85 M42 32
(M60) 90 (M45) 32
M64 95 M48 36
(M68) 100 M52 36
M72 105 Table 2-4
M76 110 (3) Set screw Nominal B mm
M80 115 screw size
(d) Tool
size
d M2.5 1.27
M3 1.5
M4 2
M5 2.5
M6 3
M8 4
B
M10 5
M12 6
M16 8
M20 10
2
 3. TIGHTENING TORQUES FOR NUTS AND SLEEVES

Table 3 indicates standard tightening torques sleeves in FLARELESS JOINT may develop oil
applicable to cases where no particular note is leaks through pipe connections.
given. Always tighten nuts and sleeves to proper
Overtightening or understanding of nuts and torques.

Table 3-1
Working pressure Tube size Opposing Tightening torque
Manufacturer´s name OD×thickness
kgf / cm (psi)
2
mm (in) flats (HEX) kgfŸm (ftŸlbs)
10×1.5 19 5.0±1.0
(0.394×0.059) (36±7.2)
15×2.0 27 12±1.2
(0.591×0.079) (87±8.7)
Nippon A.M.C. 300 18×2.5 32 15±1.5
(4270) (0.709×0.098) (110±11)
22×3.0 36 22±2.0
(0.866×0.118) (160±16)
28×4.0 41 28±2.8
(1.10×0.157) (200±20)
Ihara Koatu 300 35×5.0 55 45±4.5
(4270) (1.38×0.197) (330±33)

Table 3-2
SLEEVE NUT
B

∅d ∅d

Tube size Parts No. Tube size Opposing Parts No.

flats (HEX)
∅d Ihara Koatu Nippon A.M.C. ∅d B Ihara Koatu Nippon A.M.C.
6 ZF93S06000 • 6 14 ZF93N06000 •
8 ZF93S08000 • 8 17 ZF93N08000 •
10 ZF93S10000 ZA93S10000 10 19 ZF93N10000 ZA93N10000
12 ZF93S12000 • 12 22 ZF93N12000 •
15 ZF93S15000 ZA93S15000 15 27 ZF93N15000 ZA93N15000
18 ZF93S18000 ZA93S18000 18 32 ZF93N18000 ZA93N18000
22 ZF93S22000 ZA93S22000 22 36 ZF93N22000 ZA93N22000
28 ZF93S28000 ZA93S28000 28 41 ZF93N28000 ZA93N28000
32 ZF93S32000 • 32 50 ZF93N32000 •
35 ZF93S35000 ZA93S35000 35 55 ZF93N35000 ZA93N35000
38 ZF93S38000 • 38 60 ZF93N38000 •
3
 4. PLUG

(1) Plug for hydraulic pipe joint

Table 4-1
1) Cap nut (Joint plug)
Applicable Opposing flat
pipe Cap nut parts No. T screw
O. D : A H1 H
6 ZF83H06000 M12×1.5 14 14
8 ZF83H08000 M14×1.5 17 17
10 ZF83H10000 M16×1.5 17 19
12 ZF83H12000 M18×1.5 19 22
15 ZF83H15000 M22×1.5 24 27
18 ZF83H18000 M26×1.5 27 32
H1 T screw H
22 ZF83H22000 M30×1.5 32 36
28 ZF83H28000 M36×1.5 38 41

Table 4-2
2) Plug (Tube plug)
Applicable
pipe Plug parts No.
O. D : A
6 ZF83P06000
8 ZF83P08000
10 ZF83P10000
12 ZF83P12000
15 ZF83P15000

Flareless 18 ZF83P18000
joint body Nut 22 ZF83P22000
28 ZF83P28000

3) Nut Table 4-3

Applicable Opposing
pipe Nut parts No. D screw flat
O. D : A
D screw 6 ZF93N06000 M12×1.5 14
8 ZF93N08000 M14×1.5 17
10 ZF93N10000 M16×1.5 19
12 ZF93N12000 M18×1.5 22
15 ZF93N15000 M22×1.5 27
18 ZF93N18000 M26×1.5 32
22 ZF93N22000 M30×1.5 36
28 ZF93N28000 M36×1.5 41
32 ZF93N32000 M42×1.5 50
35 ZF93N35000 M45×1.5 55
38 ZF93N38000 M48×1.5 60

4
(2) Plug for hydraulic equipment
1) PF screw
B Table 4-4
O ring PF O ring parts Nominal
screw Plug parts No. B mm No. O ring
PF 1/4 ZE72X04000 19 ZD12P01100 1B•P11
PF 3/8 ZE72X06000 22 ZD12P01400 1B•P14
PF 1/2 ZE72X08000 27 ZD12P01800 1B•P18
PF 3/4 ZE72X12000 36 ZD12P02400 1B•P24
PF screw
PF 1 ZE72X16000 41 ZD12P02900 1B•P29

2) PT screw Table 4-5

PT Plug parts No. B mm
B screw
PT screw
PT 1/8 ZE82T02000 5
PT 1/4 ZE82T04000 6
PT 3/8 ZE82T06000 8
PT 1/2 ZE82T08000 10
PT 3/4 ZE82T12000 14
PT 1 ZE82T16000 17
PT 1 1/4 ZE82T20000 22
PT 1 1/2 ZE82T24000 22

(3) Plug for (F) flare hose

Table 4-6
PF screw
PF Plug parts No. B mm
screw
PF 1/4 2444Z2728D1 14
PF 3/8 2444Z2728D2 17
PF 1/2 2444Z2728D3 22
Opposing
flat B PF 3/4 2444Z2728D4 27
PF 1 2444Z2728D5 36

Table 4-7
PF Plug parts No. E mm F mm
screw
PF 1/4 2444Z2729D1 14 19
PF PF 3/8 2444Z2729D2 17 22
screw
PF 1/2 2444Z2729D3 23 27
Opposing Opposing PF 3/4 2444Z2729D4 27 36
flat F flat E PF 1 2444Z2729D5 36 41
PF 1 1/4 2444Z2729D6 40 50

5
(4) Plug for ORS joints
Male

O RING HEX
Table 4-8
Applicable
Opposing O ring parts Nominal
Screw size A hose Plug parts No.
O.D flats(HEX) No. O ring
A
A 1-14UNS ∅21.7 YN01H01001P1 27 ZD12A01600 1B•A16
A
1 3/16-12UN ∅27.2 YN01H01002P1 36 ZD12A01800 1B•A18
1 7/16-12UN ∅34.0 YN01H01003P1 41 ZD12A02100 1B•A21

HEX
Female Table 4-9
Applicable
Opposing
Screw size A tube Plug parts No.
O.D flats(HEX)

A 1-14UNS ∅21.7 YN01H01004P1 32

1 3/16-12UN ∅27.2 YN01H01005P1 36
1 7/16-12UN ∅34.0 YN01H01006P1 41

6
 5. SPECIAL SPANNER FOR TUBE
Table 5-1
Applicable tube diameter HEX
mm•(in) Part No. Drawing of a special spanner•mm (in)
mm
70 (2.76)
8(0.315)

15 16
8 PART-No. 22(0.866)
2421T160 27 (0.630)
(0.591)
HEX27 40(1.57)
• 12.7 •0.1
•0.3
( 0.500 •0.012
•0.004 )
70 (2.76)
42(1.65)

18 19
PART-No. 22(0.866)
2421T138 32 (0.748)
(0.709)
22(0.866)
HEX32 • 12.7 •0.3
•0.1 ( 0.500 •0.012
•0.004 )
70 (2.76)
40(1.57)

22 19
PART-No. 22(0.866)
2421T129 30 (0.748)
(0.866)
22(0.866)
HEX30 • 12.7 •0.3
•0.1 ( 0.500 •0.012
•0.004 )
48 (1.89) 70 (2.76)
11.5 (0.453)

22 23
2421T130 36 (0.906) PART-No. 22(0.866)
(0.866)

HEX36 • 12.7 •0.3

•0.1 ( 0.500 •0.012
•0.004 )
60 (2.36) 109 (4.29)
14.5 (0.571)

28 29 PART-No.
2421T115 41 (1.14)
22(0.866)
(1.10)
HEX41 • 12.7•0.1
•0.3
( 0.500 •0.012
•0.004 )
80 (3.15) 109 (4.29)

28 31
PART-No. 35(1.38)
2421T231 46 (1.22)
(1.10)

HEX46 • 19.05 •0.1

•0.5
( 0.750 •0.020
•0.004 )
80 (3.15) 109 (4.29)

32 33 PART-No. 35(1.38)
2421T232 50 (1.30)
(1.26)

HEX50
• 19.05 •0.5
•0.1 ( 0.750 •0.020
•0.004 )
7
 6. SPECIAL TOOLS

Table 6-1

No. Tools name Tools No. Shape Applicable

Allen wrench
ZT22A10000 Pump
1 Nominal B : 10
suction
C : 11.3

Commercial tool length (L1) • cut length = Required length

40(1.57½ )•••10(0.39½ )•=•30(1.18½ )
General tools

Spanner or
Pump
2 socket
install
Nominal B : 17

Cut

Swing
Spanner ZT12A36000
3 motor
Nominal S : 36
A,B port

Commercial tool outer width (D) • cut length = Required length

81(3.19½ )•••16(0.63½ )•=•65(2.56½ )

Additional M10×22 For

Plug ZE72X12000 threading slinging
4 for M10 eye bolt
PF3/4 the swing
motor
PF3/4 O ring

M10 Eye bolt

For
slinging
Eye bolt ZS91C01000 the swing
5
M10×18 or motor
commercial &
equivalent M10 Flare hose

8
 Table 6-2
No. Tools name Tools No. Shape Applicable
M8 Eye bolt

Plug ZF83P22000

( Nominal
tube dia. 22
)
Reference nut Flare hose
6 Reference
Eye bolt ZS91C00800
Nut ZF93N22000 M8×18
Additional
threading for
M8 Eye bolt
M8 Eye bolt
M8×18
Additional
threading
Plug YN01H01001P1
Nominal
7 Flare hose
1-14UNS

Eye bolt ZS91C00800

M8 Eye bolt
M8×18
Additional
threading
Plug YN01H01002P1
Nominal
8 Flare hose
1 3/16-12UN

Eye bolt ZS91C00800

M8 Eye bolt
For slinging the
Eye bolt ZS91C00800 swing motor
9 or
M8×15 &
commercial
Flare hose
equivalent

M8

M12 Eye nut

Plug ZE25F08000 For slinging the

10 Weld
PF1/2 Coupling half swivel joint

PF 1/2

9
 7. APPLICATION OF SCREW LOCKING •
COMPOUND AND SEALING COMPOUND
(1) For general use
Table 7-1

Manufacturer
Service Features
Locktite Three-Bond

#242 1360K Low strength

Screw locking
compound #262 1374 Middle strength

#271 1305 High strength

Sealing
compound #515 1215 Sealing

(2) For specific location

Table 7-2

No. Use Manufacturer Name Equivalent Applicable

(Manufacturer ; Locktite)

#1901 Anti-seizure Cylinder

#1215 gray #5699 Swing motor

Three-Bond
#1211 white #5301J Swing motor

#1303B #211 Main pump

Sealing compound & adhesive

(Manufacturer ; Three-Bond)

#222 #1344N Main pump

Locktite
#277 #1307N Pilot valve

(Manufacturer ; Three-Bond)

Locktite Parmatex 98D #1121 Hydraulic oil tank : Hose

Sumitomo
Chemical Cyano Bond P0•1 For swing bearing : Seal
Co., Ltd.
Showa-Shell Shell Alvania EP2 New Molyknock Grease 2 Swing bearing grease
petroleum bath

10
 8. SUCTION STOPPER
8.1 COMPONENTS

No. NAME PARTS No. Q’TY

SUCTION STOPPER ASSY 24100P978F2 1 Rod
1 ROD 2420T4660D1 1
2 NUT ZN16C08007 1
3 COVER 2414T2123D2 1
4 O RING 45Z91D6 1
2 Nut
3 Cover

4 O ring
8.2 DIMENSION
50
(1.97•)
Fig. 8-1 Components of suction stopper

∅113 (4.45•)
2
M8 NUT
∅8(1.315•)

M8 ∅100 +0.5
0

(3.94 +0.0197
0 )
•

∅108
(4.25 )
•

ROD COVER

fig. 8-2 Dimension of suction stopper

8.3 APPLICABLE MODEL

Applicable
SK115SR

SK135SR

SK235SR
SK100-2

SK120-2

SK100-3

SK120-3

SK200-6

model
SK100

SK120

Part No.

24100P978F2 • • • • • • • • • •

11
 9. COUNTER WEIGHT LIFTING JIG

(1) Standard eye bolt

Size Vertical
Part No. lifting load
d L
kg (lbs)
M8 15 ZS91C00800 80 (176)
M10 18 ZS91C01000 150 (331)
M12 22 ZS91C01200 220 (485)
M16 27 ZS91C01600 450 (992)
M20 30 ZS91C02000 630 (1390)
M24 38 ZS91C02400 950 (2090)
d
L

M30 45 ZS91C03000 1500 (3310)

M36 55 ZS91C03600 2300 (5070)
Fig. 9-1•Eye bolt M42 65 ZS91C04200 3400 (7490)
M48 70 ZS91C04800 4500 (9920)

12
10. UPPER FRAME LIFTING JIG

Q'ty : 2set
Material : POK400(SS41)
13
 11. ENGINE MOUNTING PEDESTAL
350(13.8˝ ) Note) Hold the oil pan
250(9.84˝ ) 16 325(12.8˝ ) 16 section of engine.

(0.63˝ )
(0.63˝ ) (0.63˝ )

16
(3.35˝ )
85
16 245(9.65˝ ) 16
(0.63˝ ) 40 40 (0.63˝ )
(1.57˝ ) (1.57˝ )

540(21.3˝)

(28˝ )
710
(3.35˝ )
85
16
(0.63˝ )

Material : Plywood or wooden plate

Fig. 11-1_Engine stand

12. TRACK SPRING SET JIG

M30
Retainer nut

Retainer plate

Stand

Hydraulic jack

Base
14
 SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE

CHAPTER 12

E215
CRAWLER EXCAVATORS

STANDARD MAINTENANCE TIME

TABLE

Issued January 2006

Book/Form Number 5-1600 NA
Copyright © 2006. CNH America, LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. S5PJ0010E01-KO12
 SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE
CHAPTER 12 - STANDARD MAINTENANCE TIME TABLE

CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Remarks
First Edition 01-2006 E130 5-1600 NA

12-II Issued 01-2006 Bur 5-1600 NA

 SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE

CHAPTER 12
STANDARD MAINTENANCE TIME TABLE
TABLE OF CONTENTS

1. STANDARD WORKING MAINTENANCE TIME TABLE

01 Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
02 Cab and Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
03 Swing Frame Excluded Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
04 Travel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
06 Electrical Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
2. STANDARD WORKING MAINTENANCE TIME TABLE2.1 COOLING SYSTEM2-1
2.2 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.4 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

5-1600 NA Issued 01-2006 Bur 12-1

 SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE
CHAPTER 12 - STANDARD MAINTENANCE TIME TABLE

NOTES

12-2 Issued 01-2006 Bur 5-1600 NA

 1. STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR
(1) Standard maintenance time table (2) Classification of working code
1) Unitsof working time : 6 minutes=0.1 hour
No. Group Remarks
2) Calculating method of standard maintenance
01 Attachment Indicates installing,
time : 02 Cab & Guard
03 Swing frame removing, replacement
Maintenance time=Working time×
04 Travel system and overhaul.
Number of workers
06 Electric Indicates the installing,
(Working time=Maintenance time÷ equipments removing and
Number of workers) replacement of single
3) When more than one operation is going on : items.
Add each standard service time. 09 E/G relation Indicates overhaul of the
single engine.
A pure time (readily started) is given except (Materials prepared by
covers easily removed by hand. Assy works manufacturer )
include the following works marked with
black dot • . (3) Conditions for standard service time of the
4)O/H : The removing and attaching time is not engine
included. 1) Tools designated by E/G maker are used
5) Abbreviations in the table. 2) Genuine parts are changed
A/C ; Air conditioner F hose ; Flexible hose 3) Correct working procedures are observed.
ASSY ; Assembly O/H ; Over haul • The time required for works specified
ATT ; Attachment SOL ; Solenoid in this Chapter shows the total time
BRG ; Bearing SW ; Switch for maintenance.
C/V ; Control valve V ; Valve
Cyl ; Cylinder
E/G ; Engine
Unit : Hour
Work to be
Group Location Unit Remark E215
done
00 Bucket relation 2. Reference for bucket
01 Bucket ASSY Detach/attach 1 pc. Include adjustment. 0.6
02 • Bucket attaching and detaching position Preparation 1 pc. 0.1
03 • Bucket attaching pin Detach/attach 1 Include stopper pin. 0.1
04 • Bucket drive pin Detach/attach 1 0.1
05 • Bucket sling and movement Preparation 1 pc. 0.2
06 Bucket (single) O/H 1 pc. Not include attaching and detaching. 2.4
07 • Tooth Replace 1 pc. 0.6
08 • Side cutter Replace 1 pc. 1.2
01 Attachment

09 • Bushing Replace 1 pc. 0.6

10 Arm relation 3. Reference for arm
11 Arm ASSY Detach/attach 1 pc. 1.2
• Bucket cylinder attaching and detaching
12 position and piping Preparation 1 pc. 0.4
13 • Bucket cylinder rod pin Detach/attach 1 pc. Include stopper pin. 0.1
14 • Bucket cylinder head pin Detach/attach 1 pc. Include stopper pin. 0.1
15 • Bucket cylinder assy Detach/attach 1 pc. 0.1
16 • Arm cylinder rod pin Detach/attach 1 pc. Include stopper pin. 0.1
17 • Boom top pin Detach/attach 1 pc. Include wire stop pin. 0.1
18 • Arm sling and movement Detach/attach 1 pc. 0.2
30 Boom relation 4. Reference for boom
31 Boom ASSY Detach/attach 1 pc. 1.4
32 • Boom attaching and detaching position Preparation 1 pc. 0.1
33 • Boom cylinder temporary slinging Preparation 2 pcs. 0.2
34 • Boom cylinder rod pin Detach/attach 2 Include two stopper pins. 0.2

-
1
 Unit : Hour
Work to be E215
Group Location Unit Remark
done
35 • Boom cylinder piping Detach/attach 2 pc. 0.2
36 • Arm & bucket piping Detach/attach 1 pc. 0.2
37 • Boom assy temporary slinging Detach/attach 1 pc. 0.1
38 • Boom foot pin Detach/attach 1 Include stopper pin. 0.2
39 • Boom assy slinging Detach/attach 1 pc. 0.2
40 Arm cylinder attaching and detaching Detach/attach 1 pc. 0.4
41 • Arm cylinder piping Detach/attach 1 pc. 0.2
01 Attachment

42 • Arm cylinder head pin Detach/attach 1 Include stopper pin. 0.1

43 • Arm cylinder slinging Detach/attach 1 pc. 0.1
50 Boom cylinder attaching and detaching Detach/attach 2 pcs. 0.7
51 • Boom cylinder piping Detach/attach 2 0.3
52 • Boom cylinder head pin Detach/attach 2 pcs. 0.2
53 • Boom cylinder slinging Detach/attach 2 0.2
60 Bucket cylinder O/H 1 3.6
61 • Pin bushing Replace 1 Include seal. 1.2
70 Arm cylinder O/H 1 3.6
71 • Pin bushing Replace 1 set Include seal. 1.2
80 Boom cylinder O/H 2 7.0
81 • Pin bushing Replace 1 set Include seal. 1.2
10 Cab relation 2. Reference for cab
11 Cab ASSY Detach/attach 1 pc. 1.2
12 • Front lower glass, floor mat Detach/attach 1 pc. each 0.1
13 • Rear cover mounting bolts, lock Detach/attach 9 places 0.2
14 • Seat rear cover top, bottom Detach/attach 1 pc. each 0.2
15 • Air-con duct Detach/attach 2 0.2
16 • Cable and harness (electric) Detach/attach 3 0.1
17 • Cab slinging Detach/attach 3 places 0.4
20 Guard relation 4. Reference for guard
21 Bonnet assy(1) Detach/attach 1 pc. 0.2
22 Guard (13) Detach/attach 1 pc. 0.2
23 Guard (12) Detach/attach 1 pc. 0.2
24 Stay (29) Detach/attach 1 pc. 0.2
25 Guard (8) Detach/attach 1 pc. 0.2
26 Panel assy (3) Detach/attach 1 pc. 0.2
02 Cab & Guard

27 Panel assy (5) Detach/attach 1 pc. 0.2

28 Panel assy (4) Detach/attach 1 pc. 0.2
29 Panel (6) Detach/attach 1 pc. 0.2
30 Guard assy (24) Detach/attach 1 pc. 0.2
31 Guard assy (22) Detach/attach 1 pc. 0.2
32 Bracket (16) Detach/attach 1 pc. 0.2
33 Bracket (23) Detach/attach 1 pc. 0.2
34 Guard (10) Detach/attach 1 pc. 0.2
35 Bracket (67) Detach/attach 1 pc. 0.2
36 Bracket (17) Detach/attach 1 pc. 0.2
37 Bracket (14) Detach/attach 1 pc. 0.2
38 Bracket (15) Detach/attach 1 pc. 0.2
39 Guard (19) Detach/attach 1 pc. 0.2
40 Guard (9) Detach/attach 1 pc. 0.2
41 Guard (18) Detach/attach 1 pc. 0.2
42 Guard (20) Detach/attach 1 pc. 0.2
43 Guard (21) Detach/attach 1 pc. 0.2
44 Cover assy (7) Detach/attach 1 pc. 0.2

1-2
 Unit : Hour
Work to be Remark E215
Group Location done Unit

50 Cover relation 5. Reference for under cover

51 Cover (2) Detach/attach 1 pc. 0.1
52 Cover (4) Detach/attach 1 pc. 0.1
53 Cover (5) Detach/attach 1 pc. 0.1
02 Cab & Guard

54 Cover (6) Detach/attach 1 pc. 0.1

55 Cover (10) Detach/attach 1 pc. 0.1
56 Cover (11) Detach/attach 1 pc. 0.1
57 Cover (12) Detach/attach 1 pc. 0.1
58 Cover (13) Detach/attach 1 pc. 0.1
60 Counter weight relation 11. Reference for counter weight
61 Counter weight ASSY Detach/attach 1 pc. 0.6
62 • Counter weight lifting eye bolt Detach/attach 1 set 0.1
63 • Counter weight temporary slinging Preparation 1 pc. 0.2
64 • Counter weight mounting bolt Detach/attach 1 pc. 0.2
65 • Counter weight slinging Detach/attach 1 pc. 0.1
00 Control relation
01 E/G control ASSY Detach/attach 1 pc. Include adjustment. 0.4
02 • Emergency stop knob (control) cable Replace 1 pc. 0.2
• Accel control cable Replace 1 pc. 0.2
10 Intake relation 9. Reference for Air cleaner
11 Air cleaner ASSY Detach/attach 1 pc. 0.4
12 • Hose (2) Detach/attach 1 0.1
13 • Hose (3) Detach/attach 1 0.1
14 • Element Replace 1 0.1
20 Exhaust relation 10. Reference for muffler
21 Muffler ASSY Detach/attach 1 pc. 0.5
22 • U bolt Detach/attach 1 pc. 0.1
23 • Clamp ASSY Detach/attach 1 pc. 0.1
24 • Gasket Replace 1 pc. 0.1
30 Radiator relation 12. Reference for Radiator
31 Radiator ASSY Detach/attach 1 pc. 4.0
32 • Coolant (LLC) Replace 1 pc. 0.3
03 Swing frame

33 •• Concentration of coolant Measuring 1 pc. 0.2

34 • A/C condenser Detach/attach 1 pc. 0.3
35 • Stay Detach/attach 1 pc. 0.1
36 • Bracket Detach/attach 1 0.3
37 • Sub tank Detach/attach 1 pc. 0.1
38 • Fan guard Detach/attach 1 pc. 0.3
39 • Water hose (radiator  E/G) Detach/attach 1 0.3
40 • Radiator mounting bolts removing Detach/attach 1 pc. 0.2
41 • Under cover Detach/attach 1 pc. 0.1
42 • Hydraulic oil tanksuction stopper Attach/detach 1 pc. 0.2
43 • Hydraulic oil piping coupling Detach/attach 1 pc. 1.0
44 • Hydraulic oil piping Detach/attach 1 pc. 0.2
45 • Water hose (E/G  radiator) Detach/attach 1 0.2
46 • Radiator lifting or hoisting Detach/attach 1 pc. 0.2
47 • Radiator core Cleaning 1 pc. 1.0
50 Fuel relation 6. Reference for fuel tank
51 Fuel tank ASSY Detach/attach 1 pc 1.8
52 • Fuel Replace 1 pc. 0.3
53 • Hose (water separator side) Detach/attach 2 0.1
54 • Water separator Detach/attach 1 pc. 0.1
55 • Tube (tank side) Detach/attach 1 0.1
57 • Fuel tank installing bolts Detach/attach 1 pc. 0.3
58 • Tank slinging Detach/attach 1 pc. 0.3
Other necessary works Detach/attach 1 pc. Removing and installing guard 0.4
Removing and installing battery 0.2

Note : The numbers in the parentheses like cover(1)

match the guard numbers on the upper structure.

1-3
 Unit : Hour
Work to be E215
Group Location done Unit Remark

60 Hydraulic oil tank relation 7. Reference for hydraulic oil tank

61 Hydraulic oil tank ASSY Detach/attach 1 pc. 3.0
65 • Cover Detach/attach 1 pc. 0.2
66 • Hydraulic oil Replace 1 pc. 0.5
68 • Pilot drain hose Detach/attach 1 pc. 0.2
69 • Pump suction hose Detach/attach 1 0.5
70 • Mounting bolt Detach/attach 1 pc. 0.2
71 • Hydraulic oil tank slinging Detach/attach 1 pc. 0.3
72 • Return filter Replace 1 0.2
73 • Suction filter Cleaning 1 0.2
80 Pump relation After removing counter weight
81 Pump ASSY Detach/attach 1 pc. 2.8
82 • Hydraulic oil tank cover Detach/attach 1 pc. 0.3
83 • Strainer & stopper Detach/attach 1 pc. 0.3
84 • Piping Detach/attach 1 set 1.0
85 • Guard Detach/attach 2 pcs 0.4
86 • Pump slinging Detach/attach 1 pc. 0.5
87 • Cleaning Cleaning 1 pc. 0.1
88 • Vent air Adjust 1 pc. 0.1
89 Pump ASSY O/H 1 pc. 4.0
Other necessary works Detach/attach 1 set Counter weight 0.5
90 Swing motor unit relation
91 Swing motor ASSY Detach/attach 1 pc. 2.7
03 Swing frame

92 • Piping Detach/attach 1 set 1.0

93 • Drain hose clamp Detach/attach 1 0.3
94 • Mounting bolt Detach/attach 1 pc. 0.7
95 • Unit slinging Detach/attach 1 pc. 0.5
96 • Cleaning and sealant Cleaning 1 set 0.2
97 • Swing motor O/H 1 pc. 3.6
98 • Swing reduction gear O/H 1 pc. 4.2
100 Swivel joint relation 20. Reference for swivel joint
101 Swivel joint ASSY Detach/attach 1 2.6
102 • Piping (Top part only) Detach/attach 1 set 0.5
103 • Whirl stop bolt Detach/attach 1 0.2
104 • Cover Detach/attach 1 0.4
105 • Joint & elbow Detach/attach 1 set 0.4
106 • Mounting bolt Detach/attach 1 set 0.4
107 • Swivel joint slinging Detach/attach 1 0.4
108 • Cleaning Cleaning 1 set 0.3
109 Swivel joint O/H 1 set Removing and installing guard 3.6
Other necessary works Detach/attach 1 set Lower piping 0.6
110 Multi control valve 15. Reference for multi C/V
111 • Multi C/V ASSY Detach/attach 1 After removing guard 1.7
112 Write hose name on multi C/V connecting hose Detach/attach 1 set 0.3
113 • Piping Detach/attach 1 set 0.5
114 • Mounting bolt Detach/attach 1 set 0.3
115 • Cleaning Cleaning 1 set 0.2
Other necessary works Detach/attach 1 set Guard 0.4
120 Main control valve 16. Reference for control valve
121 Main control valve ASSY Detach/attach 1 pc. 2.2
122 • Attach tag to port name of pipe Preparation 1 pc. 0.6
123 • Piping Detach/attach 1 set 1.0

1-4
 Unit : Hour
Work to be E215
Group Location done Unit Remark

124 • Bracket mounting bolt Detach/attach 1 pc. 0.1

125 • Valve slinging Detach/attach 1 pc. 0.1
126 Main control valve ASSY O/H 1 set 6.0
Other necessary works Detach/attach 1 set Guard 0.4
130 Valve relation
131 Solenoid valve ASSY Detach/attach 1 1.0
132 • Attach tag to port name of pipe Preparation 1 0.2
133 • Piping Detach/attach 1 set 0.5
134 • Mounting bolt Detach/attach 1 0.3
140 Engine (E/G) mounting relation 13. Reference for engine
141 Engine ASSY Detach/attach 1 pc. After removing pump & radiator 1.8
142 • Harness connector & grounding & cable connection Detach/attach 1 pc. 0.3
143 • Fuel hose Detach/attach 1 pc. 0.1
144 • Others Detach/attach 1 set 0.5
03 Swing frame

145 • Mounting bolt Detach/attach 1 pc. 0.5

146 • Engine slinging Detach/attach 1 set 0.2
147 • Cleaning Cleaning 1 pc. 0.3
148 Engine O/H 1 set Reference for engine
Other necessary works Detach/attach 1 set Removing and installing guard 0.6
Detach/attach 1 set Removing and installing counter weight 0.6
Detach/attach 1 set Removing and installing pump 2.8
Detach/attach 1 set Removing and installing air cleaner 0.4
Detach/attach 1 set Removing and installing muffler 0.5
Detach/attach 1 set Removing and installing radiator 2.0
150 Upper frame 21. Reference for upper frame
151 Upper frame ASSY Detach/attach 1 pc. After removing swivel joint 1.3
152 • Mounting bolt Detach/attach 1 set 0.4
153 • Upper frame slinging Detach/attach 1 pc. 0.4
154 • Cleaning Cleaning 1 pc. 0.3
155 • Sealant Apply 1 pc. 0.2
Other necessary works Detach/attach 1 set Cab 1.2
Detach/attach 1 set Guard 0.4
Detach/attach 1 set Counter weight 0.5
Detach/attach 1 set Boom 1.4
00 Travel relation 2. Reference for crawler
One
01 Track link ASSY Detach/attach side Include adjustment of tension. 1.5
One
02 • Track link attaching and detaching position Preparation side 0.1
One
03 • Master pin Detach/attach side 0.5
One
04 • Track link extending and winding Detach/attach side 0.5
05 Shoe plate Replace 1 pc. 0.4
10 Upper roller relation 3. Reference for upper roller
04 Travel system

11 Upper roller ASSY Detach/attach 1 After removing track link 0.2

12 Upper roller O/H 1 1.0
20 Lower roller relation 4. Reference for lower roller
21 Lower roller ASSY Detach/attach 1 0.2
22 Lower roller O/H 1 1.5
30 Front idler relation 5. Reference for front idler
One
31 Front idler ASSY Detach/attach side After removing track link 0.6
One
32 Front idler ASSY slinging Detach/attach side 0.3
One
33 Front idler ASSY Detaching side 0.3
One
34 Idler ASSY O/H side 1.0
One
35 Idler adjuster ASSY O/H side Replace spring 2.4
One
36 • Grease cylinder O/H side 0.6

1-5
 Unit : Hour
Work to be
Group Location done Unit Remark E215

40 Sprocket 6. Reference for sprocket

One
41 Sprocket Replace side After removing track link 0.6
50 Travel motor relation 7. Reference for travel motor
One
51 Travel motor ASSY Detach/attach side After removing track link 1.7
One
52 • Motor cover Detach/attach side 0.1
One
53 • Hydraulic piping Detach/attach side 0.9
04 Travel system

One
54 • Motor mounting bolt Detach/attach side 0.5
One
55 • Motor slinging Detach/attach side 0.1
One
56 Motor cleaning Cleaning side 0.1
One
57 Travel motor O/H side 3.6
One
58 Travel reduction gear O/H side 3.6
60 Swivel joint relation
Include bonnet assy removing and
61 Pipe on swivel joint travel side Detach/attach 1 pc. installing. 0.6
62 Swivel joint O/H 1 pc. Refer to YN33 Upper structure 20. 3.6
8. Refer to YN34. Swing bearing
70 Swing bearing removing and installing.

71 Swing bearing ASSY Detach/attach 1 pc. After removing upper flame 0.7
72 Swing bearing mounting bolt Detach/attach 1 pc. 0.5
73 Swing bearing slinging Detach/attach 1 pc. 0.3
Controller
C-1 Controller (KPSS) Replace 1 0.5
C-2 Gauge cluster Replace 1 1.0
C-3 Switch Replace 1 0.3
C-4 Air conditioner Amplifier Replace 1 2.0
C-6 Auto grease controller (OPT) Replace 1 0.3
Diode
D-1 Diode Replace 1 0.3
D-2 Diode Replace 1 0.3
D-3 Diode Replace 1 0.3
D-4 Diode Replace 1 0.3
06 Electric equipments

D-5 Diode Replace 1 0.3

D-6 Diode Replace 1 0.3
D-9 Diode Replace 1 0.3
Electric equipments
Include C1 controller removing and
E-1 Fuse box Replace 1 installing. 0.3
E-2 Alternator Replace 1 1.0
E-3 Hour meter Replace 1 0.3
E-4 Resistor Replace 1 0.3
E-5 Horn (High) Replace 1 0.3
E-6 Horn (Low) Replace 1 0.3
E-7 Tuner AM & FM(OPT) Replace 1 0.3
E-7 Tuner AM(OPT) Replace 1 0.3
E-8 Speaker left Replace 1 0.3
E-9 Speaker right Replace 1 0.3
E-10 Receiver dryer Replace 1 Include gas sealing. 1.0
Include counter weight removing and
E-11 Air compressor Replace 1 installing. 1.0
E-13 Travel alarm (OPT) Replace 1 0.3
E-14 Cigarette lighter Replace 1 0.3

1-6
 Unit : Hour
Work to be E215
Group Location done Unit Remark

Light
L-1 Boom work light left Replace 1 Bulb 0.2
L-2 Work light right Replace 1 0.2
L-3 Swing flusher & work light (left) Replace 1 0.2
L-4 Swing flusher & work light (right) Replace 1 0.2
L-5 Room light Replace 1 0.2
L-7 Cab work light (OPT) Replace 1 0.2
L-8 Cab work light (OPT) Replace 1 0.2
L-9 Boom cylinder work light (OPT) Replace 1 0.2
Motor
Include counter weight removing and
M-1 Starter motor Replace 1 installing. 1.0
Include counter weight removing and
M-2 Governor motor Replace 1 installing. 0.5
M-3 Wiper motor (Non rise up) Replace 1 0.5
M-4 Washer motor Replace 1 0.5
M-5 Cable assy (P/W motor OPT) Replace 1 0.5
M-6 Power window lock motor left (OPT) Replace 1 0.5
M-7 Power window lock motor right (OPT) Replace 1 0.5
M-8 Grease motor Replace 1 0.5
M-9 Skylight wiper motor (OPT) Replace 1 0.5
Proportional valve
PSV-A Arm recirculation conflux proportional valve Replace 1 0.5
Include proportional valve block
PSV-B P2 bypass cut proportional valve Replace 1 removing and installing. 0.5
PSV-C Travel straight proportional valve Replace 1 0.5
06 Electric equipments

PSV-D P1 bypass cut proportional valve Replace 1 0.5

PSV-P1 P1 pump proportional valve Replace 1 0.5
PSV-P2 P2 pump proportional valve Replace 1 0.5
Relay
R-1 Battery relay Replace 1 0.5
R-2 Starter relay Replace 1 0.5
R-3 Glow relay Replace 1 0.5
R-4 Safety relay Replace 1 Include guard removing and installing. 0.5
R-5 Horn relay Replace 1 0.5
R-6 Work light relay Replace 1 0.5
Include C1 controller removing and
R-7 Wiper motor relay Replace 1 installing 0.5
R-8 Travel alarm relay Replace 1 0.5
Sensor
SE-1 Pressure sensorBucket digging Replace 1 0.5
SE-2 Pressure sensorBucket dump Replace 1 0.5
SE-3 Pressure sensorBoom up Replace 1 0.5
SE-4 Pressure sensorBoom down Replace 1 0.5
SE-5 Pressure sensorSwingleft Replace 1 0.5
SE-6 Pressure sensorSwingright Replace 1 0.5
SE-7 Pressure sensorArm in Replace 1 0.5
SE-8 Pressure sensorArm out Replace 1 0.5
SE-9 Pressure sensorTravelright Replace 1 0.5
SE-10 Pressure sensorTravelleft Replace 1 0.5
SE-11 Pressure sensorP2 side OPT. Replace 1 0.5
SE-13 Engine speed sensor Replace 1 Include guard removing and installing. 0.5
SE-14 Engine water temperature sensor Replace 1 0.5
SE-15 Fuel sensor Replace 1 Include guard removing and installing. 0.5
SE-16 Accel potentio Replace 1 0.5
SE-22 Pressure sensorP1 pump Replace 1 0.5
SE-23 Pressure sensorP2 pump Replace 1 0.5

1-7
 Unit : Hour
Work to be
Group Location done Unit Remark E215

SE-26 Pressure sensorP1 negative control Replace 1 0.5

SE-27 Pressure sensorP2 negative control Replace 1 0.5
SE-28 Pressure sensorBack pressure Replace 1 0.5
Solenoid
Include proportional valve block
SV-1 Swing parking SOL Replace 1 removing and installing. 0.5
Include proportional valve block
SV-2 Attachment boost pressure SOL Replace 1 removing and installing. 0.5
Include proportional valve block
SV-3 2-speed travel SOL Replace 1 removing and installing. 0.5
Include proportional valve block
SV-4 Level lock SOL Replace 1 removing and installing. 0.5
Switch
06 Electric equipments

SW-1 Key switch Replace 1 0.3

SW-2 Switch assy (Mode, buzzer stop) Replace 1 0.3
SW-3 2-speed travel switch Replace 1 0.3
SW-4 Swing parking release switch Replace 1 0.3
SW-5 KPSS release switch Replace 1 0.3
SW-6 Engine water temperature switch Replace 1 0.3
SW-7 Engine oil pressure switch Replace 1 0.3
SW-8 Clogged air filter switch Replace 1 0.3
SW-10 Horn switch Replace 1 0.3
SW-11 Lever lock switch Replace 1 0.3
SW-13 Air conditioner switch Replace 1 0.3
SW-19 Wiper interlock switch Replace 1 0.3
SW-20 Switch assy (Wiper, washer, work light) Replace 1 0.3
SW-21 Attachment boost pressure switch Replace 1 0.3
SW-23 Engine oil level switch Replace 1 0.3
SW-24 Engine cooling coolant level switch Replace 1 0.3
SW-25 Hydraulic level switch Replace 1 0.3

1-8
2. STANDARD WORKING TIME TABLE ENGINE MAINTENANCE
Introduction
This standard working time table provides time
required for maintenance (if the work is
carefully carried out) under the following
condition :
 Special designated tools are used.
 Genuine parts are used.
 Correct working procedures are observed.
 The engine is mounted correctly to the
machine.
1. The working hours given in this table can not
be applied to special machine
construction.
2. Special equipment not listed in this table
has not been time calculated.
If this type of work is performed, list reasons on
the Claim Application Sheet in detail and
submit .
(Note 1) Unit of working time
The working time is given in 6
minutes=0.1 hour in the decimal system.
(Note 2) Applicable models : E215

2-1
2.1 COOLING SYSTEM Unit : Hour

NAME OF WORK PROBLEM

Cooling fan
Attaching and detaching or replacing fan. Cooling fan is broken.
Cooling fan makes an abnormal sound. 0.6
Cooling fan parts are defective.
Replacing belts (2 pcs.) Fan belt is damaged.
Note : Where two or more belts are used, Fan belt squeaks.
0.3
increase 0.4hr. for each belt
increased.
Adjusting belts. 0.2
Idler pulley overhaul
Incl. :detaching and attaching it. 

Detaching and attaching or replacing fan

0.7
coupling.
Thermostat
Inspecting or replacing thermostat. (1 pc.) Thermostat functions incorrectly.
Thermostat remains open.
0.6
Thermostat remains closed.
Thermostat system in general is out of order.
Inspecting or replacing thermostat. (RH one) Thermostat functions improperly.
Thermostat remains open.

Thermostat remains closed.
Thermostat system in general is out of order.
Inspecting or replacing thermostat. (LH one) Thermostat functions improperly.
Thermostat remains open.

Thermostat remains closed.
Thermostat system in general is out of order.
Water pump
Replacing water pump (that is mounted to Water pump squeaks.
this machine). Water leaks from water pump.
Incl. : (1) Detaching and attaching V-belt. Pump bearing is broken.
2.0
(2) Detaching and attaching idler Pump shaft is damaged.
pulley assy. Water pump parts are faulty.
Water pump in general are out of order.
Water pump overhaul, Water pump squeaks.
Excl. : detaching and attaching. Water leaks from water pump.
Pump bearings are damaged.
0.8
Pump shaft is damaged.
Water pump parts are faulty.
Water pump in general is out of order.

2-2
2.2 ELECTRICAL SYSTEM Unit : Hour

NAME OF WORK PROBLEM

Alternator
Replacing alternator assy Alternator functions improperly.
Alternator makes an abnormal sound.
Alternator is burnt.
1.0
Alternator bearing parts are faulty.
Alternator pulley is broken.
Alternator mounting bracket is broken.
Overhaul of alternator Alternator functions improperly.
Incl. : Detaching and attaching . Alternator makes an abonormal sound.
Alternator burnt out.

Alternator bearing parts are faulty.
Alternator pulley are broken.
Alternator mounting bracket is broken.
Overhaul of alternator. (single) Alternator functions improperly.
Alternator makes an unusual sound.
Alternator burnt out.

Alternator bearing parts are defective.
Alternator pulley is broken.
Alternator mounting bracket is broken.
Starter motor
Replacing starter. Starter motor malfunctions.
Starter motor rusts from inside.
Pinion is broken.
Overrunning clutsh slips. 0.8
Overrunning clutch parts are defective.
Pinion engagement is no good.
Starter motor system in general is out of order
Overhaul of starter, Starter motor malfunctions.
Incl. : detaching and attaching starter Starter motor rusts from inside.
Pinion is broken.
Overrunning clutch slips. 
Overrunning clutch parts are faulty.
Pinion meshing is no good.
Starter motor system in general is out of order.
Overhaul of starter Starter motor malfunctions.
Starter motor rusts from inside.
Pinion is broken.
Overrunning clutch slips. 
Overrunning clutch parts are faulty.
Pinion meshing is no good.
Starter motor system in general is out of order.
Replacing starter switch assy. Magnetic switch contacts are no good.
Magnetic switch burnt out.
1.0
Starter motor system in general is out of order.

2-3
 Unit : Hour

NAME OF WORK PROBLEM

Safety (starter) relay

Detaching/attaching or replacing starter relay. Relay malfunctions.
0.4
Relay system as a whole is out of order.
Voltage regulator
Replacing relay (safety relay) assy. Safety relay malfunctions.
0.5
Safety relay system as a whole is out of order.
Glow plug
Inspecting and replacing glow plugs. (all) Glow plug parts are faulty.
1.0
Glow plug system as a whole is out of order.
Intake air heater
Detaching/attaching or replacing intake air Intake heater parts are faulty.
heater assy. (one side) Intake heater system as a whole is out of order. 

Replacing resistor. Resistor parts are faulty. 

Detaching/attaching or replacing magnet valve. Magnet valve parts are faulty. 
Switch (units)
Replacing starter switch Starter switch does not return well.
0.4
Starter switch is broken or developed other fault.
Replacing starter switch. (in switch box) Starter switch does not return well.

Starter switch is broken or developed other fault.
Replacing water temperature gauge unit. Water temperature gauge unit malfunctions. 0.3
Detaching/attaching or replacing fuel tank Fuel gauge unit malfunctions.

gauge unit.
Replacing oil bypass alarm. Oil leaks from oil bypass alarm.
Oil bypass alarm is broken or developed other 0.3
fault.

2-4
2.3 ENGINE Unit : Hour

NAME OF WORK PROBLEM

Engine
Overhaul of engine assy. Refer to fault code table.
Incl. : (1) Detaching/attaching engine.
(2) Running-in of engine.
(3) Conditioning engine. (B)
Excl. : (1) Overhauling starter, dynamo
68.0
and injection pump.
(2) Grinding crankshaft.
(3) Boring and honing of cylinder
liners.

Semi overhaul of engine.

Incl. : (1) Semi overhaul of cylinder head.
(2) Replacing piston and piston ring. For each set of piston liners decreased 1.3hr.
28.0
(3) Replacing cylinder liners. Each time one line decreases 0.8hr.
(4) Adjusting engine. (A) Each time one piston decreases 0.5hr.
(5) Adjusting nozzle.
Adjusting engine. (A)
Incl. : (1) Adjusting valve clearance.
(2) Inspecting nozzle.
(3) Adjusting injection timing.
(4) Cleaning air cleaner element. 3.0
(5) Cleaning fuel filter element.
(6) Inspecting cooling water hose.
(7) Adjusting fan belt.
(8) Retightening all parts.
Adjusting engine (On-machine). (B)
(1) Retightening cylinder head.
(2) Cleaning air cleaner.
(3) Measuring compressive pressure.
(4) Inspecting cooling water hose.
(5) Inspecting fan belt for slackening
and adjusting it.
(6) Checking the max. and min
6.5
revolutions.
(7) Inspecting glow plug.
(8) Inspecting and adjusting nozzle.
(9) Adjusting injection timing.
(10) Cleaning oil and fuel filter
elements.
(11) Adjusting valve clearance.
(12) Retightening other parts.

2-5
 Unit : Hour

NAME OF WORK PROBLEM

Measuring compressive pressure. 2.0

Adjusting injection timing. Climbing power of vehicle is deficient.
Max. speed of vehicle is deficient.
Accelerating power of vehicle is deficient.
0.8
Engine starting is faulty.
Engine output is deficient.
Engine fuel is no good.
Adjusting valve clearance. 1.0
Measuring black exhaust. 0.6
Cylinder head
Replacing cylinder head assy. (1 unit) Cylinder head cracked.
Incl. : (1) Adjusting engine (A). Cylinder head is distorted.
(2) Adjusting nozzle. Cylinder head is corroded.
Cylinder head is blowholed.
8.0
Area between cylinder head and valve is cracked.
Cylinder head system in general is out of order.

Overhauling cylinder head assy. (1 set.) Cylinder head is cracked.

Incl. : (1) Detaching/attaching cylinder head. Cylinder head is distorted.
(2) Replacing combustion chamber. Cylinder head is corroded.
(3) Correcting valve seat ring. Cylinder head is blowholed.
10.5
(4) Replacing valve guide. Area between cylinder head and valve is cracked.
(5) Lapping valve. Cylinder head system in general is out of order.
(6) Adjusting engine (A).
(7) Adjusting nozzle.
Replacing cylinder head assy. (one side.) Cylinder head is cracked.
Incl. : (1) Adjusting engine (A). Cylinder head is distorted.
(2) Adjusting nozzle. Cylinder head is corroded.
Cylinder head is blowholed. 
Area between cylinder head and valve is cracked.
Cylinder head system in general is out of order.

Overhauling cylinder head assy. (1 set.) Cylinder head is cracked.

Incl. : (1) Detaching/attaching cylinder head. Cylinder head is distorted.
(2) Correcting seat face. Cylinder head is corroded.
(3) Replacing valve guide. Cylinder head is blowholed.

(4) Replacing combustion chamber. Area between cylinder head and valve is cracked.
(5) Lapping valve. Cylinder head system in general is out of order.
(6) Adjusting engine (A).
(9) Adjusting nozzle.
Hydrostatic test of cylinder head. (1 set) Cylinder head is cracked.
(single) Cylinder head is blowholed.
1.5
Cylinder head system in general is out of order.

2-6
 Unit : Hour

NAME OF WORK PROBLEM

Replacing cylinder head gasket (1 pc.) Water leaks from cylinder head.
(On-machine) Oil leaks from cylinder head.
Incl. : Adjusting engine (A). Gas leaks from cylinder head. 6.5
Cylinder head system in general is out of order.

Replacing cylinder head gasket. Water leaks from cylinder head gasket.
(one side) (On-machine) Oil leaks from cylinder head gasket. 
Incl. : Adjusting engine (A). Gas leaks from cylinder head gasket.
Retightening cylinder head bolts.
(1 unit) (On-machine) 2.0
Incl. : Adjusting valve clearance.
Replacing pre-combustion chamber. (1 pc.) Pre-combustion chamber is broken.
Excl.: Detaching/attaching head. Water leaks from pre-combustion chamber
Incl. : (1) Detaching/attaching and gasket.
cleaning glow plug (1 pc.).
1.0
(2) Adjusting nozzle (1 pc.) for each
nozzle increased :
Medium size 0.4hr.
Large size 0.5hr.
Rocker cover
Replacing rocker cover packing. (1 pc.) Rocker cover packing is cracked.
Increase 0.1hr. as one direct injection Oil leaks from rocker cover packing. 0.6
increases.
Replacing rocker casing packing. (1 unit) Oil leaks from rocker casing packing.
Incl. : (1) Adjusting valve clearance.

(2) Detaching/attaching rocker
casing.
Cylinder block
Replacing cylinder block
Incl. : (1) Detaching and attaching engine.
(2) Conditioning engine (B) and
50.0
travel test.
Excl. : Replacing associated parts.

Replacing cylinder liners.

(all Q’y on present vehicle)
25.0
Incl. : (1) Conditioning engine (A).
(2) Adjusting nozzle.
Replacing side cover packing. (front side) Oil leaks from side cover gasket. 
Replacing side cover packing. (left) Oil leaks from side cover gasket.


Replacing side cover packing. (right) Oil leaks from side cover gasket.

Increase 2.0hr. where injection pump is tilted.
Replacing side cover packing. (rear side) Oil leaks from side cover gasket. 
Detaching/attaching or replacing rear plate. Rear plate is cracked. 

2-7
 Unit : Hour

NAME OF WORK PROBLEM

Cam
 shaft 03 31
Detaching/attaching or replacing cam shaft. Cam shaft is worn.
Incl. : (1) Detaching and attaching engine. Cam shaft is broken.
(2) Conditioning engine. Cam shaft bushing is worn. 18.0
(3) Travel test. Cam shaft bushing seized.
Cam shaft system in general is out of order.
Replacing cam shaft bushing. Cam shaft bushing worn.
Incl. : (1) Detaching/attaching engine. Cam shaft bushing seized. 19.0
(2) Conditioning engine.
Push rod
Detaching/attaching or replacing push rod. Push rod is broken.
(all) (On-machine) Push rod is bent. 2.5
Incl. : Adjusting valve clearance. Push rod system in general is out of order.
Detaching/attaching or replacing push rod. Push rod is broken.
(16,18) (On-machine) Push rod is bent. 
Incl. : Adjusting valve clearance. Push rod system in general is out of order.
Rocker arm
Detaching/attaching or replacing valve rocker Rocker arm is worn.
assy. (all) Rocker arm is broken.
Incl. : Adjusting valve clearance. Bushing is worn. 2.5
Rocker arm system in general is out of order.
Rocker arm ball makes an unusual sound.
Detaching, attaching and disassembling Rocker arm is worn.
rocker arm and shaft. (1 unit) Rocker arm is broken.
Incl. : Adjusting valve clearance. Bushing is worn. 
Rocker arm system in general is out of order.
Rocker arm ball makes an unusual sound.
Detaching, attaching and disassembling Rocker arm is worn.
rocker assy. (one side) Rocker arm is broken.
Incl. : Adjusting valve clearance. Bushing is worn.

Rocker arm system in general is out of order.
Rocker arm ball makes an unusual sound.

Detaching, attaching and disassembling valve Rocker arm is worn.

rocker and shaft. (one shaft) Rocker arm is broken.

Incl. : Adjusting valve clearance. Bushing is worn.
Rocker arm system in general is out of order.
Replacing valve rocker adjusting screws. (all) Rocker arm system in general is out order.
Incl. : Adjusting valve clearance. 2.0

Replacing valve rocker adjusting screws. Rocker arm system in general is out of order.
(one side)

Incl. : Adjusting valve clearance.

2-8
 Unit : Hour

NAME OF WORK NAME OF TROUBLE

Tappet
Replacing tappet. (all) Tappet is worn.
(1) Detaching and attaching engine Tappet is broken.
(6DS). Tappet system in general is out of order. 18.5
(2) Conditioning engine.
Increase 10.0hr for old type tappets (DC).

Valve
Replacing valves. (all) (On-machine) Inlet valve is broken.
(1) Detaching and attaching cylinder Exhaust valve is broken.
head. 10.0
(2) Correcting and lapping valve seat.
(3) Conditioning engine (A).
Lapping valve seat surface. (all) Valve seat is worn.
(1) Detaching and attaching cylinder Contact of valve seat with valve is no good.

head. Valve seat fell off.
(2) Conditioning engine (A).
Replacing valves. (6 or 8 pcs.) Inlet valve is broken.
(1) Detaching and attaching cylinder Exhaust valve is broken.
head. 
(2) Correcting and lapping valve seat.
(3) Conditioning engine (A).
Replacing valve guides. (all) Valve guide is worn.
(1) Detaching and attaching cylinder Valve is seized.
head. Engine oil goes into combustion chamber. 10.8
(2) Conditioning engine (A). Valve guide fell off.
(3) Correcting and lapping valve seat.
Replacing valve guides. (one side) Valve guide is worn.
(1) Detaching and attaching cylinder Valve guide is sized.
head. Engine oil goes into combustion chamber. 
(2) Conditioning engine (A). Valve guide fell off.
(3) Correcting and lapping valve seat.
Replacing valve springs. (all) Valve spring is broken.
Incl. : Adjusting valve clearance. Valve spring is set parmanently.
Excl. : Detaching and attaching cylinder 3.4
head.

Replacing valve spring. (1 cylinder) Valve spring is broken.

(On-machine) Valve spring is set permanently.
Incl. : Adjusting valve clearance.
Excl. : Detaching and attaching cylinder head

Add 0.3hr. for medium size and
0.6hr. for large size as one cylinder increases.

2-9
 Unit : Hour

NAME OF WORK PROBLEM

Timing gear (chain) casing

Detaching/attaching or replacing timing gear Timing gear (chain) casing makes an unusual
casing. sound.
Timing gear (chain) casing parts are faulty.
4.5
Oil leaks from gasket.
Timing gear casing system in general is out of
order.
Replacing timing gear casing packing. Oil leaks from gasket. 4.5
Detaching, attaching and replacing timing Timing gear casing in general is out of order.

gear casing cover.
Replacing cam shaft gear and idle gear. Idle gear parts are defective.
Cam shaft gear is installed incorrectly. 5.3
Cam shaft gear parts are defective.
Replacing idle gear bushing Timing gear casing in general is out of order.

Note : Flywheel housing is dismantled.
Crank shaft
Detaching/attaching or replacing crank shaft.
Incl. : (1) Detaching/attaching engine. 24.0
(2) Adjusting idling.
Replacing crank shaft rear oil seal. Oil leaks from rear oil seal.
(On-machine)
7.0
Incl. : Detaching and attaching
transmission and flywheel.
Detaching/attaching or replacing crank pulley. Crank shaft pulley parts are faulty.
(On-machine) Crank shaft pulley nuts are loosened.
3.0
Incl. : Detaching and attaching radiator
shroud and fan.
Detaching/attaching or replacing crank pulley. Flywheel mounting bolts are broken.
Incl. : Detaching and attaching (incl. loosening) 6.5
transmission.
Detaching/attaching or replacing flywheel Flywheel ring gear is worn.
0.5
ring gear. (single body) Flywheel ring gear is broken.
Replacing flywheel pilot bearing. (single) Flywheel pilot bearing parts are faulty. 0.2
Replacing flywheel front oil seal. Oil leaks from front oil seal.
(On-machine)
5.0
Incl. : (1) Detaching and attaching fan and
front cover.
Replacing crank shaft gear. (On-machine) Crank shaft gear is worn.
Crank shaft gear is broken.


2-10
 Unit : Hour

NAME OF WORK PROBLEM

Connecting rod
Correcting bend of connecting rod. Connecting rod is bent.

(1 pc. single)
Replacing connecting rod bearings. (all) Bearings are worn.
4.8
Bearings are seized.
Replacing connecting rod bearings. (1 set) Bearing is worn.

Add 0.4hr. as one rod increases. Bearing is seized.
Replacing connecting rod bushing. (set by set) Small end bushing is worn.

Small end bushing is seized.
Piston
Detaching/attaching or replacing pistons. (all) Piston is broken.
(On-machine) Piston is seized.
Incl. : (1) Conditioning engine (A). Oil consumption of engine is large. 17.0
(2) Adjust nozzle. Piston system in general is out of order.
Add 0.5hr. each time one piston decreases. Piston and piston pin make abnormal sound.
Detaching/attaching or replacing piston rings. Engine consumes much oil.
(all) (On-machine) Piston rings are worn off.
Incl. : (1) Detaching/attaching cylinder Piston rings is broken.
head oil pan. Engine oil goes into combustion chamber.
16.0
(2) Checking and correcting rod. Piston system in general is out of order.
(3) Scraping off carbon.
(4) Conditioning engine (A).
(5) Adjusting nozzle.
Intake manifold
Detaching/attaching or replacing inlet manifold. Intake manifold is broken.
(1 pc) Intake manifold is blowholed.
Incl. : Replacing gasket. Gas leaks from intake manifold gasket. 1.5
Intake manifold system in general is out of
order.
Detaching/attaching or replacing inlet manifold. Intake manifold is broken.
(one side) Intake manifold is blowholed.
Incl. : Replacing gasket. Gas leaks from intake manifold gasket. 
Intake manifold system in general is out of
order.
Exhaust manifold
Detaching/attaching or replacing exhaust Exhaust manifold is broken.
manifold. Gas leaks from exhaust manifold gasket.
Incl. : Replacing gasket. Exhaust manifold system in general is out of 1.2
order.

Detaching/attaching or replacing exhaust Exhaust manifold is broken.

manifold. (one side) Gas leaks from exhaust manifold gasket.

Incl. : Replacing gasket. Exhaust manifold system in general is out of
order.

2-11
 Unit : Hour

NAME OF WORK PROBLEM

Oil
Replacing engine oil. 0.5
Oil filter
Replacing oil filter assy. Oil leaks from oil filter.
Oil filter casing is damaged.
1.0
Oil filter head is scored.
Oil filter system in general is out of order.
Cleaning or replacing oil filter assy. (1 set)
0.5

Inspecting or replacing relief valve. Relief valve parts are faulty.

Excl. : Detaching and attaching oil filter 0.4
assy.
Turbocharger
Detaching/attaching or replacing

turbocharger assy.
Overhauling turbocharger. (single)

Incl. : Cleaning (1 pc.).
Detaching/attaching or replacing 2-stack oil Oil leaks from oil filter.
filter assy. Oil filter casing is damaged.

Oil filter head is damaged.
Oil filter system in general is out of order.
Oil pan
Detaching and attaching oil pan and Oil leaks from oil pan gasket.
replacing gasket. Oil pan parts are faulty. 2.5
Oil pan system in general is out of order.
Retightening oil pan attaching bolts. 0.5
Replacing oil level gauge guide or packing. Oil level gauge parts are defective. 
Oil piping
Replacing oil piping. (between filter and Oil leaks from oil piping.
cooler) Oil piping system in general is out of order.
0.3

Replacing breather pipes. (2 pcs.) Oil piping system in general is out of order.
0.3

2-12
 Unit : Hour

NAME OF WORK PROBLEM

Oil pump
Detaching/attaching or replacing oil pump. 1.0
Overhauling oil pump assy.

Incl. : Detaching/attaching oil pump.
Overhauling oil pump.
1.0
Excl. : Detaching and attaching oil pump.
Detaching/attaching or replacing oil strainer. Oil screen is installed incorrectly.
Oil screen is broken.
Oil screen is clogged. 3.3
Oil screen stay is broken.
Oil pump system in general is out of order.
Engine support
Replacing front cushion rubber. (one side) Front mount bracket rubber is broken.
0.7
Engine support in general is out of order.
Replacing rear cushion rubber. (one side) Rear mount bracket rubber is broken.
0.9
Engine support in general is out of order.

2.4 FUEL SYSTEM

NAME OF WORK NAME OF TROUBLE

Engine control
Replacing decomp ression lever assy. Engine control system in general is out of order. 
Detaching/attaching or replacing decomp Engine control system in general is out of order.

ression shaft.
Replacing return spring. Engine control system in general is out of order. 
Fuel injection pump 05
Detaching and attaching or replacing Fuel injection pump malfunctions.
injection pump. Fuel injection pump develops leakage.
4.0
Incl. : (1) Adjusting injection timing. Fuel injection pump system in general is out
(2) Adjusting idling. of order.
Overhauling injection pump. (single) Fuel injection pump malfunctions. 
Incl. : Disassembling fuel feed pump. Leakage occurs from fuel injection pump.
Excl. : Disassembling auto timer. Fuel injection system in general is out of order.

Injection pump test. 

Overhauling auto timer assy. (single) 
Replacing injection pump coupling. Pump coupling parts are faulty.

Incl. : Detaching/attaching injection pump
Detaching/attaching or replacing injection Fuel injection pump malfunctions.

pump.
Replacing delivery valve gaskets. (all) Oil leaks from fuel injection pump. 

2-13
 Unit : Hour

NAME OF WORK PROBLEM

Fuel injection pipe

Replacing injection pipe. (1 pc.) Injection pipe is cracked.
Add 0.2hr. each time 1 pipe increases. Injection pipe system in general is out of 0.5
order.
Nozzle holder
Detaching/attaching or replacing nozzle Nozzle malfunctions.
holders. (all) Nozzle holder system in general is out of order. 1.8
Incl. : Nozzle test.
Detaching/attaching or replacing nozzle Nozzle malfunctions.
holder. Nozzle holder system in general is out of order.
(1 pc.)
0.8
0.2hr. for medium and 0.3hr. for large size
each time 1 nozzle increases.
Incl. : Nozzle test.
Detaching/attaching or replacing nozzles. (all) Nozzle malfunctions.

Incl. : Nozzle test. Nozzle holder system in general is out of order.
Replacing nozzle. (1 pc.) Nozzle malfunctions.
Add 0.3hr. and 0.4hr. for large size each time Nozzle holder system in general is out of order.

1 nozzle increases.
Incl. : Nozzle test.
Detaching/attaching or replacing nozzle tube. Nozzle tube is damaged.
Excl. : Detaching and attaching head. Water leaks from nozzle tube.

Incl. : Detaching and attaching nozzle. Nozzle holder system in general is out of order.
Add 0.2hr. for an increase of 1 nozzle.
Fuel pump
Replacing fuel feed pump. Fuel pump makes an unusual sound.
Incl. : Venting air. Fuel leaks from fuel pump.
Oil leaks from fuel pump. 0.8
Fuel pump parts are faulty.
Fuel pump system in general is out of order.
Overhauling fuel feed pump. (single) Fuel pump makes an unusual sound.
Fuel leaks from fuel pump.
Oil leaks from fuel pump. 1.0
Fuel pump parts are faulty.
Fuel pump system in general is out of order.
Cleaning feed pump gauze filter. 0.4
Fuel filter
Replacing fuel filter assy. Fuel filter is broken.
Fuel filter is clogged. 0.6
Fuel filter system in general is out of order.
Replacing or cleaning fuel filter element. Fuel filter is broken.
Fuel filter is clogged. 0.5
Fuel filter system in general is out of order.
Fuel piping
Replacing engine fuel pipe. (1 pc.) Sections related to engine fuel pipe (incl. hose)
are damaged.
Leakage occurs on sections related to engine
0.5
fuel pipe (incl. hose).
General trouble with fuel pump related to
engine (incl. hose).

-
2-14
 SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE

CHAPTER 13

E215
CRAWLER EXCAVATORS

MAINTENANCE STANDARDS
AND TEST PROCEDURES

Issued January 2006

Book/Form Number 5-1610 NA
Copyright © 2006. CNH America, LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. S5PJ0010E01-KO13
 SECTION 1 - STANDARD SPECIFICATIONS AND MAINTENANCE
CHAPTER 13 - MAINTENANCE STANDARDS AND TEST PROCEDURES

CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Remarks
First Edition 01-2006 E215 5-1610 NA

13-II Issued 01-06 Bur 5-1610 NA

 CHAPTER 13
Maintenance Standards and Test Procedures
TABLE OF CONTENTS
Performance inspection specification charts....................................................................................3-4
1. Verification of engine RPM..............................................................................................................5
A. Machine preparation procedures.............................................................................................5
2. Engine speed measured with service diagnostics (28 item check) ................................................5
3. Hydraulic oil cautions..................................................................................................................... 6
A. Checking the main relief setting using service diagnostics (28 item check) ...........................6
B. Tools & equipment required for checking and adjusting of pilot and main relief valves ...........6
4. Pilot circuit ......................................................................................................................................7
A. Machine preparation procedures ............................................................................................7
B. Pilot relief valve pressure measurement procedures ..............................................................7
C. Pilot relief valve adjustment procedures .................................................................................7
5. Main relief pressure adjustment .....................................................................................................8
A. Machine preparation procedures ............................................................................................8
B. Measurement of attachment main relief valve "Heavy Lift Switch On" ...................................8
6. Adjustment 2nd stage main relief with "Heavy Lift Switch On"........................................................9
A. Machine preparation procedures ............................................................................................9
B. 2nd stage main relief valve adjustment ...................................................................................9
7. Adjustment main relief with "heavy lift switch off"..........................................................................10
A. Machine preparation procedures ..........................................................................................10
B. Main relief valve adjustment ..................................................................................................10
8. Swing circuit .................................................................................................................................11
A. Machine preparation procedures ..........................................................................................11
B. Swing overload relief valve pressure measurement .............................................................11
C. Swing overload relief valve pressure adjustment...................................................................12
9. Over load relief valves ..................................................................................................................13
A. Machine preparation procedures...........................................................................................13
B. Tools and equipment required for checking and adjusting of over load relief valves .............13
C. Over load relief pressure measurement.................................................................................13
D. OR3 boom up over load relief ...............................................................................................14
E. OR4 boom down over load relief............................................................................................14
F. OR1 bucket in (DIG) over load relief......................................................................................14
G. OR2 bucket out over load relief ..............................................................................................16
H. OR7 arm in (DIG) over load relief .........................................................................................15
I. OR8 arm out over load relief ..................................................................................................15
J. Travel motor port reliefs .........................................................................................................15
10. Measurement of additional circuit pressure ports......................................................................17
Cylinder cycle time test.....................................................................................................................18
A. Tools & equipment..................................................................................................................18
B. Machine settings & site condition...........................................................................................18
C. Boom cylinder cycle time test................................................................................................18
D. Arm cylinder cycle time test ...................................................................................................19
E. Bucket cylinder cycle time test ...............................................................................................20
Cylinder drift .....................................................................................................................................21
A. Tools & equipment..................................................................................................................21
B. Machine settings & site condition...........................................................................................21
C. Cylinder drift test....................................................................................................................21
Swing speed .....................................................................................................................................21
A. Tools & equipment..................................................................................................................21
B. Machine settings and site condition.......................................................................................21

1
 C. Swing speed test....................................................................................................................22
Swing stopping..................................................................................................................................23
A. Tools and equipment ..............................................................................................................23
B. Machine settings & site condition...........................................................................................23
C. Swing stopping test................................................................................................................23
Swing drift .........................................................................................................................................24
A. Tools and equipment ..............................................................................................................24
B. Machine settings and site condition .......................................................................................24
C. Swing drift test .......................................................................................................................24
Swing bearing up-down (vertical) movement ....................................................................................25
A. Tools & equipment..................................................................................................................25
B. Machine settings and site condition .......................................................................................25
C. Swing bearing up-down (vertical) movement test ..................................................................25
Swing bearing side to side (horizontal) movement ...........................................................................26
A. Tools & equipment..................................................................................................................26
B. Machine settings and site condition .......................................................................................26
C. Swing bearing side to side (horizontal) movement test .........................................................26
Swing motor oil case drain ................................................................................................................27
A. Tools & equipment..................................................................................................................27
B. Machine settings and site condition .......................................................................................27
C. Swing motor oil case drain test ........................................................................................27, 28
Travel motor oil case drain ................................................................................................................29
A. Tools & equipment..................................................................................................................29
B. Machine settings and site condition .......................................................................................29
C. Travel motor oil case drain test.........................................................................................29, 30
Travel performance............................................................................................................................31
A. Tools & equipment..................................................................................................................31
B. Machine settings and site condition .......................................................................................31
C. Travel speed test ....................................................................................................................31
Travel speed specification chart ........................................................................................................31
Travel deviation .................................................................................................................................33
A. Tools & equipment..................................................................................................................33
B. Machine settings and site condition .......................................................................................33
C. Travel deviation test................................................................................................................33
Pre-checks prior to preforming adjustment "A" .................................................................................34
A. Emergency stop control and manual throttle cable................................................................34
B. Verify engine RPM .................................................................................................................34
C. RPM sensor test ....................................................................................................................34
Adjustment "A" procedure service.....................................................................................................35
A. Conditions to use adjustment "A"...........................................................................................35
B. Tools and equipment required for checking and adjusting of pilot & main relief valve ..........35
C. Verification of auto accel RPM ..............................................................................................35
D. Verification of engine low RPM .............................................................................................36
E. Machine settings and sight conditions ...................................................................................36
F. Removal of CPU access panel ..............................................................................................37
G. Removal of rod linkage and lever from stepping motor..........................................................37
Adjustment "A" procedure ................................................................................................................38
After completion of "A" adjustment ...................................................................................................41
Service diagnostic 28 item check......................................................................................................41
Diagnostic 28 item check chart ...................................................................................................42, 48

2
 PERFORMANCE INSPECTION SPECIFICATION CHART
YQU7U100~
INSPECTION ITEM PRESSURE MEASURING
Adjustment CONDITION,
Point
READING FROM SPECIFICATION FUNCTION
Cleanliness of Hydraulic Oil Hydraulic Oil Tank Class: NAS 7–9 N/A Take Sample
Temperature of Hydraulic Oil Hydraulic Oil Tank Surface °C- 45~55 °F-113~131 N/A Ambient Temperature
-10°C ~ 50°C
Engine Coolant Temperature Radiator Surface °C- 60~90 °F-140~194 N/A (14°F ~ 122°F)
STANDARDS Low Idle 950~1025 RPM Throttle @ "LO"- Idle
ENGINE RPM

Connector
Display change switch on

Installed
FOR

Service
M- Mode 2195~2245 RPM Throttle @ "HI"- Idle
TESTING gauge cluster
A- Mode 1925~1975 Throttle @ "HI"- Idle
B- Mode 2195~2245 Throttle @ "HI"- Idle

SYSTEM COMPONENT GAUGE @ SIZE PORT Kgf/cm 2

PSI Adj point
PSI Measuring Condition
PILOT CIRCUIT PRIMARY PRESSURE Gear Pump a7 50~55 710~780 P3 Engine - Hi Idle

POWER BOOST F a1
Main Pump 380~395 5400~5616 MR1 Boom Raising
MAIN R a2
RELIEF RH a1
ATTACHMENT Main Pump 350~355 4977~5048 MR1 Boom Raising
a2
LH
Port relief valves are set at a precise flow rate and cannot be adjusted on the machine. Port relief valves can be checked
NOTE: for excessive leakage by increasing the value of main relief valve. (turn main relief clockwise one complete turn). Check
at low idle, heavy lift on (if Applicable). Refer to chart below for port relief valve.
BOOM ROD a1 350~385 4977~5474 OR4 Boom Down
Main Pump
(DO NOT ADJUST) HEAD a2 350~405 4977~5760 OR3 Boom Up
ARM ROD a1 350~405 4977~5760 OR8 Arm Out (Cylinder In)
Main Pump
(DO NOT ADJUST) HEAD a2 350~385 4977~5474 OR7 Arm In (Cylinder Out)
BUCKET ROD a1 350~385 4977~5474 OR1 Bucket Out
Main Pump
PF1/4

PORT (DO NOT ADJUST) HEAD a2 350~405 4977~5760 OR2 Bucket In

RELIEFS Left Main Pump a2 327~355 4653~5050 OR5 Bucket Lock, Stall Swing
SWING
Right a2 327~355 4653~5050 OR6 Bucket Lock, Stall Swing
AUXILIARY */ All Main Pump a1a2 350~365 4977~5190 Auxiliary Attachment Stalled
**
Forward a1 350~365 4977~5190 "M"-Mode, Engine at Hi Idle.
Simultaneous LH/RH Travel
TRAVEL Reverse a2 350~365 4977~5190
Main Pump Engaged
(DO NOT ADJUST)
Forward a1 350~365 4977~5190 "M"-Mode, Engine at Hi Idle.
Simultaneous LH/RH Travel
Reverse a2 350~365 4977~5190 Engaged
SYSTEM COMPONENT GAUGE @ PORT Kgf/cm 2 mA Adj point Measuring Condition
P1 by-pass 5.5~ 6.5 330~360 Neutral
D No.20 Arm out
cut valve 634~660 activated
23~26
Multi display on C2 Gauge cluster

Display on service diagnostics

P2 by-pass 5.5~6.5 330~360 Neutral

B No.21 Boom up or Bucket dig
cut valve 23~26 634~660 activated
PROPORTIONAL
Travel 5.5~6.5 330~360 Neutral
VALVE C No.22 Arm in or Bucket dig
Straight valve 24~28 345~680 activated
BLOCK
Arm variable 23~25 633~650 Neutral
A No.23 Arm in
recirculation 24~0 450~200 activated

P1 pump 28~30 730~760 Neutral Power Shift

a8 No.24
proportional valve 10~24 350~680 activated *** / ** / *
Pump Regulation
P2 pump 28~30 730~760 Neutral Power Shift
a9 No.25
proportional valve 10~24 350~680 activated *** / ** / *

a7 a2 a1 Power Shift:
*** ...All controls in neutral 0~10 mA NOTE :
** ....Front attachment stalled 0~10 mA Take Measurements
* .....Both travel motors stalled 10~30 mA M-Mode Engine at "HI" Idle.
Levers in neutral for neutral
Auxiliary */** reading,
Auxilary port relief are as follows: then activate circuit to take
Swing priority, Breaker, Nibler Breaker activated readings

3
 PERFORMANCE INSPECTION SPECIFICATION CHART
LLO8U0101~
INSPECTION ITEM PRESSURE MEASURING
Adjustment CONDITION,
Point
READING FROM SPECIFICATION FUNCTION
Cleanliness of Hydraulic Oil Hydraulic Oil Tank Class: NAS 7–9 N/A Take Sample
Temperature of Hydraulic Oil Hydraulic Oil Tank Surface °C- 45~55 °F-113~131 N/A Ambient Temperature
-10°C ~ 50°C
Engine Coolant Temperature Radiator Surface °C- 60~90 °F-140~194 N/A (14°F ~ 122°F)
STANDARDS Low Idle 950~1025 RPM Throttle @ "LO"- Idle
ENGINE RPM

Connector
Installed
FOR Display change switch on

Service
M- Mode 2290~2345 RPM Throttle @ "HI"- Idle
TESTING gauge cluster
A- Mode 1925~1975 Throttle @ "HI"- Idle
B- Mode 2290~2345 Throttle @ "HI"- Idle

SYSTEM COMPONENT GAUGE @ SIZE PORT Kgf/cm 2

PSI Adj point
PSI Measuring Condition
PILOT CIRCUIT PRIMARY PRESSURE Gear Pump a7 50~55 710~780 P3 Engine - Hi Idle

POWER BOOST F a1
Main Pump 380~395 5400~5616 MR1 Boom Raising
MAIN R a2
RELIEF a1
RH Main Pump 350~355 4977~5048 MR1 Boom Raising
ATTACHMENT a2
LH
Port relief valves are set at a precise flow rate and cannot be adjusted on the machine. Port relief valves can be checked
NOTE: for excessive leakage by increasing the value of main relief valve. (turn main relief clockwise one complete turn). Check
at low idle, heavy lift on (if Applicable). Refer to chart below for port relief valve.
BOOM ROD a1 350~385 4977~5474 OR4 Boom Down
Main Pump
(DO NOT ADJUST) HEAD a2 350~405 4977~5760 OR3 Boom Up
ARM ROD a1 350~405 4977~5760 OR8 Arm Out (Cylinder In)
Main Pump
(DO NOT ADJUST) HEAD a2 350~385 4977~5474 OR7 Arm In (Cylinder Out)
BUCKET ROD a1 350~385 4977~5474 OR1 Bucket Out
Main Pump
PF1/4

PORT (DO NOT ADJUST) HEAD a2 350~405 4977~5760 OR2 Bucket In

RELIEFS Left Main Pump a2 327~335 4653~5050 OR5 Bucket Lock, Stall Swing
SWING
Right a2 327~335 4653~5050 OR6 Bucket Lock, Stall Swing
AUXILIARY */ All Main Pump a1a2 350~365 4977~5190 Auxiliary Attachment Stalled
**
Forward a1 350~365 4977~5190 "M"-Mode, Engine at Hi Idle.
Simultaneous LH/RH Travel
TRAVEL Reverse a2 350~365 4977~5190
Main Pump Engaged
(DO NOT ADJUST)
Forward a1 350~365 4977~5190 "M"-Mode, Engine at Hi Idle.
Simultaneous LH/RH Travel
Reverse a2 350~365 4977~5190 Engaged
SYSTEM COMPONENT GAUGE @ PORT Kgf/cm 2 mA Adj point Measuring Condition
P1 by-pass 5.5~ 6.5 330~360 Neutral
D No.20 Arm out
cut valve 634~660 activated
23~26
Multi display on C2 Gauge cluster

Display on service diagnostics

P2 by-pass 5.5~6.5 330~360 Neutral

B No.21 Boom up or Bucket dig
cut valve 23~26 634~660 activated
PROPORTIONAL
Travel 5.5~6.5 330~360 Neutral
VALVE C No.22 Arm in or Bucket dig
Straight valve 24~28 345~680 activated
BLOCK
Arm variable 23~25 633~650 Neutral
recirculation
A No.23 Arm in
24~0 450~200 activated

P1 pump 28~30 730~760 Neutral Power Shift

a8 No.24
proportional valve 10~24 350~680 activated *** / ** / *
Pump Regulation
P2 pump 28~30 730~760 Neutral Power Shift
a9 No.25
proportional valve 10~24 350~680 activated *** / ** / *

a7 a2 a1 Power Shift:
*** ...All controls in neutral 0~10 mA NOTE :
** ....Front attachment stalled 0~10 mA Take Measurements
* .....Both travel motors stalled 10~30 mA M-Mode Engine at "HI" Idle.
Levers in neutral for neutral
Auxiliary */** reading,
Auxilary port relief are as follows: then activate circuit to take
Swing priority, Breaker, Nibler Breaker activated readings

4
 VERIFICATION OF ENGINE RPM
1. VERIFICATION OF ENGINE RPM
ENGINE EMERGENCY
A. Machine Preparation Procedures STOP CONTROL
1. With safety lock in the lock (up)
position. See Figure 5.1. SAFETY LOCK
LEVER IN LOCK
2. Place the maintenance connector in
POSITION
the release position.See Figure 5.2
3. Place throttle potentiometer to low
idle position ; start engine, allow
engine to achieve normal operating
temperatureOC 45~55 (OF113~145)
4. Check the gauge cluster and confirm FIGURE 5.1
that the machine is in the default “M”
mode. See Figure 5.3. MAINTANCE CONNECTOR
FACTORY DEFAULT
5. Locate the screen change switch,
depress the switch once to select RELEASE
RPM. Check that engine low and hi
RPM are at the proper adjustment.
See Figure 5.3. MANUAL
THROTTLE
Refer to chart by model and serial CONTROL
number for specifications.
6. Return Throttle potentiometer to low
idle position. Press screen change
switch two times to return screen to
Monitor System OK.
7. Place front attachment to hydraulic
oil check position. See Figure 5.4.
8. Allow engine to idle for two minutes
and shut off engine. FIGURE 5.2
2.ENGINE SPEED MEASURED WITH
SERVICE DIAGNOSTICS (28 ITEM CHECK) MODE SELECT
1. With gauge cluster blank press and
SCREEN CHANGE
hold buzzer stop switch.
SWITCH
2. Turn key switch to on position.
3. Screen Change Switch advances the
display each time the screen change RPM 1008
switch is pushed.
4. Press the Screen change switch
once, diagnostic check of computer
will be at screen No. 2. Below.
2 No. 2 FIGURE 5.3
E/G SET 2200 No load set rpm
MEAS 2201 Actual rpm
E/G PRS. LIVE LIVE/DEAD indication
KPSS SW M A/M/B indication
5. Buzzer Stop Switch returns display to
previous screen each time switch is
pushed.
6. Screen will stay in diagnostic mode until
FIGURE 5.4
key switch is turned off.
5
 HYDRAULIC OIL CAUTIONS
3. HYDRAULIC OIL CAUTIONS
Excavators are set to ISO pilot controls •
at the factory. It is up to you to read and
understand the Operators & Maintenance Manual
before attempting any service or maintenance
procedures.

WARNING PILOT
CONTROL
• BE EXTREMELY CAUTIOUS WHILE RELEASING
FOR BUCKET
HYDRAULIC TANK PRESSURE OR REMOVING AND BOOM
LINES AND FITTINGS, VAPORS AND OIL MAY BE
EXTREMELY HOT.
• WEAR APPROVED SAFETY CLOTHES, SHOES, FIGURE 6.1
GLOVES AND HARD HAT WHEN PERFORMING
ANY MAINTENANCE OR TEST PROCEDURES.

A. Checking the Main Relief Setting Using

Service Diagnostics (28 ITEM CHECK)
1. With key in OFF position, gauge
cluster blank, press and hold buzzer SCREEN CHANGE
stop switch. SWITCH
2. Turn key switch to ON position. See
No.1
Figure 6.1. Main Cont. P/No.
Program Version
3. With key switch in on position release Ver.

buzzer stop switch. See Figure 6.1. 28 ITEM CHECK

4. By pressing the screen change switch
the service diagnostics is advanced
forward. See Figure 6.2.
5. By pressing the buzzer stop switch the FIGURE6.2
screen is returned to the last screen.
6. Advance the service diagnostics to
screen No.14. See Figure 6.3.
7. Screen No.14 will display the voltage
of high pressure sensor, and the
computer generated oil pressure at P1
and P2 pump. Use this for checking
pump and machine performance. See
Figure 6.3.
B. Tools & Equipment Required for Check-
ing and Adjusting of Pilot and Main Relief Valves No. 14 PRESSURE SENSOR
P-1 PUMP
1. Two 700kg/cm (10,000psi) Gauges.
2
07.V 0K
2. One 70kg/cm2 (1,000 psi) Gauges. P-2 PUMP
3. 32 mm spaner wrench 07.V 0K
22 mm spaner wrench
19 mm spaner wrench
6 mm allen wrench SCREEN CHANGE SCREEN
4. General hand or power tools to re-
Note: Pressure will be in Kg/cm2
move and replace hydraulic fittings and
0k = o kg/cm2
components.
5. Thermometer to read hydraulic oil tem-
perature. FIGURE 6.3
6
 PILOT CIRCUIT

4. PILOT CIRCUIT

A. Machine Preparation Procedures

1. Note: Refer to Verification of Engine RPM
before proceeding.
2. Confirm that the machine front attachment
is in the oil check position. See Figure 7.1.
3. Release hydraulic tank pressure by
depressing relief valve stem item (1) on
the pressure relief valve. See Figure 7.2.
4. Open Main Pump Access Door and
remove the PF1/4 test Port Plug (A&) from
Output Port on Pilot system Gear Pump
and install 105 kg/cm2 (1,000 psi)
Pressure Gauge. See Figure 7.3.
B . P i l o t R e l i e f Va l v e P r e s s u r e
Measurement Procedures
1. Perform machine preparation procedures
as described in MACHINE PREPARATION
PROCEDURES.
2. Start engine and place throttle control in Hi
Idle position.
3. Place KPSS mode Switch in “M” Mode.
4. Confirm the hydraulic oil is approximately
45-55° C (113-145° F). Engine water
temperature should be approximately 40-
100°C (104-212° F).
5. Place all pilot controls in neutral, read and
record the 70 kg/cm2 (1000 psi) pressure
gauge at the P3 pump, a7 pressure test
port. See Figure 7.3. Compare to chart for
specific model being tested.
Pilot Relief Valve Adjustment Procedures
1. Locate the Pilot Relief Valve mounted on
the bottom of the P3 Pilot Pump Assembly.
See Figure 7.4.
2. Loosen the adjusting screw locknut with a
24mm spanner. See Figure 7.4.
3. Adjust using a 6mm Allen wrench until
specified pressure according to proper
chart for specific machine being adjusted
is achieved.
4. After correct pressure is obtained, tighten
adjusting screw locknut, tightening torque
3.0 kg/cm2 (22 ft. lb.). See figure 7.4.
5. Verify pressure after tightening locknut.

7
 MAIN RELIEF PRESSURE ADJUSTMENT

5. MAIN RELIEF PRESSURE

ADJUSTMENT
A. MACHINE PREPARATION PROCEDURES
1. Note: Refer to Verification of Engine RPM
before proceeding.
2. Confirm that the machine front attachment
is in the oil check position. See Figure 8.1.
3. Release hydraulic tank pressure by
depressing relief valve stem item (1) on
the pressure relief valve. See Figure 8.2.
4. Open Main Pump Access Door and
remove two (2) PF1/4 test Port Plugs (a1)
P1 pump and (a2) Pump. Install 700
kg/cm 2 (10,000 psi) Pressure Gauges.
See Figure 8.3
B. MEASUREMENT OF ATTACHMENT MAIN
RELIEF VALVE “HEAVY LIFT SWITCH ON”
1. Perform machine preparation procedures
as described in MACHINE PREPARATION
PROCEDURES.
2. Place “Heavy Lift” Switch in the “ON”
position. See Figure 8.4.
3. Place KPSS Mode Switch in “M” Mode.
4. Start engine and place throttle control in
Low Idle position.
5. Confirm that the hydraulic oil is
approximately 45-55°C (113-145° F).
Engine water temperature is
approximately 40-100° C (104-212° F).
6. Move throttle control to “HI-IDLE”.
7. Operate Boom Raise control until boom is
completely up, then hold over relief.
8. Record readings from 700 kg/cm2 (10,000
psi) Pressure gauges at a1 port on P1
Main Pump and a2 port at P2 pump.
9. If pressure gauge readings are within
specifications for the particular machine
being tested, it is not necessary to adjust
relief valve pressure. Refer to chart for
machine and model being tested.

8
 ADJUSTMENT 2ND STAGE MAIN RELIEF WITH “HEAVY LIFT SWITCH ON”

Figure 1
6 . A D J U S T M E N T 2 N D S TAG E M A I N
RELIEF WITH “HEAVY LIFT SWITCH ON”
A. Machine Preparation Procedures
1. Confirm that the following is proper before
proceeding to Step 2.
a. KPSS is in “M” mode. See Figure 9.1.
b. Heavy lift switch on. See Figure 9.2.
c. Hydraulic oil is approximately 45-55° C
(113-145° F).
d. Engine water temperature is
approximately 40-100° C (104-212° F).
e. Maintenance connector is in the release
position.
f. High idle RPM is proper per machine
being tested.

B. 2nd Stage Main Relief Valve Adjustment

1. Locate main relief valve (MR1) on the main
control valve. See Figure 9.3.
2. Loosen second stage locknut with 32 mm
wrench. See Figure 9.4.
3. With engine at full RPM, raise boom up and
over relief. Adjust heavy lift, power boost
screw with 19 mm wrench, until proper
pressure is achieved at pump P1 at 1 test
port, and pump P2 (a2) test port with 700
kg/cm2 (10,000 psi) pressure gauges.
4. After correct pressure is obtained, tighten
adjusting screw locknut to 2.8-3.2 kg/cm2 (20-
30 ft. lb.). Verify pressure after tightening
locknut.
NOTE: Turning Heavy Lift Power Boost
Adjusting Screw clockwise one turn. This
increases pressure approximately 108 kg/cm2
180 (2560 psi).

9
 ADJUSTMENT 2ND STAGE MAIN RELIEF WITH “HEAVY LIFT SWITCH OFF”

Figure 1
6. “HEAVY LIFT SWITCH OFF”
A. Machine Preparation Procedures
1. Confirm that the following is proper before
proceeding to Step 2.
a. KPSS is in “M” mode. See Figure 10.1.
b. Heavy lift switch off. See Figure 10.2.
c. Hydraulic oil is approximately 45-55° C
(113-145° F).
d. Engine water temperature is
approximately 40-100° C (104-212° F).
e. Maintenance connector is in the release
position.
f. High idle RPM is proper per machine
being tested.

B. Main Relief Valve Adjustment

1. Locate main relief valve (MR1) on the main
control valve. See Figure 10.3.
2. Loosen second stage locknut with 22 mm
wrench. See Figure 10.4.
3. With engine at full RPM, raise boom up and
over relief. Adjust screw with 6 mm Allen
wrench, until proper pressure is achieved at
pump P1 at 1 test port, and pump P2 (a2) test
port with 700 kg/cm 2 (10,000 psi) pressure
gauges.
4. After correct pressure is obtained, tighten
adjusting screw locknut to 2.8-3.2 kg/cm2 (20-
30 ft. lb.). Verify pressure after tightening
locknut.
NOTE: Turning Heavy Lift Power Boost
Adjusting Screw clockwise one turn. This
increases pressure approximately 108 kg/cm2
180 (2560 psi).

10
Figure 1
8. SWING CIRCUIT
NOTE: The following procedures are provided
for reference only. Attachment Port Relief
Valves are factory preset and should not be
field adjusted.
A. Machine Preparation Procedures
1. Refer to Verification of Engine RPM before
proceeding.
2. Confirm that the machine front attachment
is in the oil check position. See Figure 11.1.
3. Relea se hy drau lic tan k pressure by
depressing relief valve stem, item (1) on the
pressure relief valve.
4. Open Main Pump Access Door and remove
the PF1/4 test Port Plug (A7) from output port
on pilot system gear pump and install 105 kg/
cm2 (1,000 psi) pressure gauge. See Figure
11.2.

B. Swing Over Load Relief Valve Pressure

Measurement
1. Perform machine preparation procedures
as described in MACHINE PREPARATION
PROCEDURES.
2. Move throttle control to “HI-IDLE,” place
KPSS mode switch in “M” mode.
3. Operate boom down control until bucket
teeth penetrate soil approximately 305 mm
(12"). See Figure 11.3.
4. Operate swing control to the left and hold,
stalling swing. Record reading from 700 kg/
cm2 (10,000 psi) pressure gauge installed to
test port a2 on P2 main pump. See Figure
11.2. Or, compare reading in Diagnostic
Check No. 14. See Figure 11.2.
5. Operate swing control to the right and hold,
stalling swing. Record reading from 700 kg/
cm2 (10,000 psi) pressure gauge installed to
test port a2 on P2 main pump. Or, compare
reading in Diagnostic Check No. 14. See
Figure 11.4.

11
 SWING CIRCUIT

Figure 1
C . L OA D R E L I E F VA LV E P R E S S U R E
ADJUSTMENT
Machine Preparation Procedures
1. Confirm that the following is proper before
proceeding to Step 2.
a. KPSS is in “M” mode.
b. Heavy lift switch off.
c. Hydraulic oil is approximately 45-55° C
(113-145° F).
d. Engine water temperature is
approximately 40-100° C (104-212° F).
e. Maintenance connector is in the release
position.
f. High idle RPM is proper.
g. Bucket teeth penetrate soil approximately
305 mm (12"). Figure 12.1.
2. Locate swing left overload relief OR5, loosen
24 mm locknut. See Figure 12.2.
3. Operate swing control to the left and hold,
stalling swing. Adjust pressure to specific
m a c h i n e us i n g 7 0 0 k g/ c m 2 (1 0 ,0 0 0 p s i )
pressure gauge installed to test port a2 on P2
main pump. See Figure 12.3.
4. After correct pressure is obtained, tighten
adjusting screw locknut to 2.8 - 3.2 kgfm2 (20-30
ft. lb.) Verify pressure after tightening locknut.
5. Locate swing right overload relief OR6,
loosen 24 mm locknut. Operate swing control to
the right and hold, stalling machine swing.
Adjust pressure to specific machine using 700
kg/cm2 (10,000 psi) pressure gauge installed to
test port a2 on P2 Main Pump.
6. After correct pressure is obtained, tighten
adjusting screw locknut to 2.8 - 3.2 kgfm2 (20-30
ft. lb.) Verify pressure after tightening locknut.
12
 OVERLOAD RELIEF VALVES

9. OVERLOAD RELIEF VALVES

A. Machine Preparation Procedures
a. Machine in the oil check position. KPSS
is in “A” mode.
b. Heavy lift switch on. See Figure 13.2.
c. Hydraulic oil is approximately 45-55° C
(113-145° F).
d. Engine water temperature is
approximately 40-100° C (104-212° F).
e. Maintenance connector is in the release
position.
f. Low idle RPM is proper per machine
being tested.
B . To o l s R e q u i r e d f o r C h e c k i n g &
Adjusting Overload Relief Valves
32 mm spanner wrench
22 mm spanner wrench
19 mm spanner wrench
6 mm Allen Wrench
B. Overload Relief Pressure Measurement
1. Move throttle control to “LO-IDLE,” place
KPSS mode switch in “A” mode.
2 . P la c e “ H E AV Y L I F T ” sw itc h in “ O N ”
position. See Figure 13.2.
3. Locate MR1 on main control valve and
adjust main relief valve 14 kg/cm 2 (200 psi)
above port relief valve pressure. See Figure
13.3.
4. Record reading from 700 kg/cm2 (10,000
psi) pressure gauge at a1 or a2 test port on
P1 or P2 main hydraulic pump. See Figure
13.4.
5. Compare readings to chart for specific
model being tested.

13
 OVER LOAD RELIEF VALVES
D. OR3 Boom Up Over load Relief
1. Operate Boom Up Control until boom WARNING
is completely up and hold. • PRECISE ADJUSTMENT OF THE MACHINE'S
2. Record reading from Pressure Gauge OVER LOAD RELIEF VALVES IS
at a1 or a2 test port on P1 or P2 Main NOT POSSIBLE ON THE MACHINE.
Pump. Compare reading to proper • SHOULD A PROBLEM BE FOUND WITH THE
chart for specific machin being tested. OVER LOAD RELIEF VALVES, IT IS
3. Locate OR3 on Main Control Valve, RECOMMENDED TO REPLACE FAULTY
loosen locknut and adjust OR3 to test OVER LOAD RELIEF VALVES.
SUCH ADJUSTMENT COULD VOID WARRANTY.
bench pressure. See Figure 14.27.
4. Secure locknut TO 2.8 ~3.2 kgfm2
(20~30 ft.lb).
E. OR4 Boom Down over Load Relief
1. Operate Boom Down Control until
boom is completely down and hold.
Nega-Con
2. Record reading from Pressure Gauge
back press.
at a test port on P1 Main Pump. Com- circuit
pare reading to proper chart for spe- Tn1
cific machine being tested.
3. Locate OR4 on Main Control Valve,
loosen locknut and adjust OR4 to test
bench pressure. See Figure 14.27.
4. Secure locknut, 2.8 ~3.2 kgfm2 (20~30
ft.lb).
F. OR1 Bucket In (DIG) Over Load Relief Nega-Con
1. Operate bucket in control until bucket circuit
is completely in, then hold. Pn1
2. Record reading from Pressure Gauge
at a1 test port on P1 Main Pump. Com-
pare reading to proper chart for spe- Figure 14.27 *
cific machine being tested.
3. Locate OR1 on Main Control Valve,
loosen locknut and adjust OR1 to test
bench pressure. See Figure 14.27.
4. Secure locknut, 2.8 ~3.2 kgfm2 (20~30 Nega-Con
circuit
ft.lb). Pn2

NOTE
Turning Over Load Adjusting Screw
Clockwise One turn
Increases Pressure Approximately
108 kgf/cm2 180 (2560 psi)

Figure 14.28 *
* Note: Swing Priority not shown
14
 OVER LOAD RELIEF VALVES

WARNING
• PRECISE ADJUSTMENT OF THE MACHINE'S Nega-Con
back press.
OVER LOAD RELIEF VALVES IS
circuit
NOT POSSIBLE ON THE MACHINE. Tn1
• SHOULD A PROBLEM BE FOUND WITH THE
OVER LOAD RELIEF VALVES, IT IS
RECOMMENDED TO REPLACE FAULTY
OVER LOAD RELIEF VALVES.
SUCH ADJUSTMENT COULD VOID WARRANTY.

G. OR2 Bucket Out Over Load Relief

1. Operate Bucket Out Control until Nega-Con
circuit
bucket is completely out and hold. Pn1
2. Record reading from Pressure Gauge
at a1 test port on P1 Main Pump. Com-
pare reading to proper chart for spe- Figure 15.27 *
cific machine being tested.
3. Locate OR2 on Main Control Valve,
loosen locknut and adjust OR1 to test
bench pressure. See Figure 15.27.
4. Secure locknut 2.8 ~3.2 kgfm2 (20~30
ft.lb).
Nega-Con
H. OR7 Arm In (DIG) Over Load Relief circuit
1. Operate arm in control until arm is com Pn2
pletely in and hold.
2. Record reading from Pressure Gauge
at a2 test port on P2 Main Pump.
Compare reading to proper chart for
specific machine being tested.
3. Locate OR7 on Main Control Valve,
loosen locknut and adjust OR7 to test
bench pressure. See Figure 15.28.
4. Secure locknut, 2.8 ~3.2 kgfm2 (20~30
ft.lb). Figure 15.28 *
I. OR8 Arm Out Over Load Relief
1. Operate arm out control until arm is * Note: Swing Priority not shown
completely out, then hold.
2. Record reading from Pressure Gauge
at a2 test port on P2 Main Pump.
Compare reading to proper chart for
NOTE
specific machine being tested.
Turning Over Load Adjusting Screw
3. Locate OR8 on Main Control Valve,
Clockwise One turn
loosen locknut and adjust OR8 to test
Increases Pressure Approximately
bench pressure. See Figure 15.28.
108 kgf/cm2 180 (2560 psi)
4. Secure locknut, 2.8 ~3.2 kgfm2 (20~30
ft.lb).
5. Adjust MR - 1 back to specified set-
tings. Verify pressures and that ma-
chine operation is correct.
15
 OVERLOAD RELIEF VALVES

J. Travel Motor Port Relief

1. Perform machine preparation procedures
prior to continuing to next step.
2. Move throttle control to “LO-IDLE” and
place KPSS mode switch in “M” mode. See
Figure 16.22.
3. Install special tool pin size 101 mm (4.0
inches) into sprocket on each side of machine
for stalling travel. See Figure 16.23.
4. Place travel speed select switch in 2nd
speed position. See Figure 16.24.
5 . P la c e “ H E AV Y L I F T ” sw itc h in “ O N ”
position. See Figure 16.24.
6. Operate both travel controls together to full
forward and hold. See Figure 16.25.
7. Locate MR1 on main control valve and
adjust main relief valve 14 kg/cm2 (200 psi)
above travel motor port relief value.
8. Record reading from 700 kg/cm2 (10,000
psi) pressure gauge at a1 or a2 test port on
P1 or P2 main hydraulic pump. Or compare
reading in diagnostic check item # 14.
9. Compare readings to chart for specific
model being tested.

Travel motor por t reliefs are set by the

m a nufa ct ur e r p r i or t o s h ip m en t . W h en
adjustment is required, loosen 19 mm nut and
adjust the pressure with 6 mm adjusting screw
to specification.

16
 MEASUREMENT OF ADDITIONAL CIRCUIT PRESSURE PORTS
10. MEASUREMENT OF ADDITIONAL CIRCUIT PRESSURE PORTS
1. High pressure sensor circuit 3. Pilot piston circuit
Remove a5, a6 port plugs PF 1/4 of main Remove a3, a4 port plugs PF 1/4 of main
pump and attach pressure gauge of 700 pump and attach pressure gauge of 70
kgf/cm² (10,000 psi). kgf/cm² (1000 psi).
2. Pump proportional valve secondary
pressure circuit Remove a8, a9 port plugs 4. Negative control pressure
PF 1/4 of main pump and attach pressure When operating in backup mode.
gauge of 70 kgf/cm² (1000 psi). Remove a3, a4 port plugs PF 1/4 of main
pump and attach pressure gauge of 70
kgf/cm² (1000 psi).

P1 BACK-UP MODE SCREW

P2 BACK-UP MODE SCREW

a7

17
 HYDRAULIC CYLINDERS

CYLINDER CYCLE TIME TEST

NOTE: The measuring time of the cylinder

cycle does not include the cushion stroke
times. Only measure time up to the beginning
of the cushion stroke.
A. Tools and Equipment
The following tools and equipment will be
required to perform the cylinder cycle time
test.
1. Stop Watch
2. Thermometer to read hydraulic oil
temperature.
B. Machine Settings & Site Conditions
1. Machine throttle in “High” idle position.
2. Confirm the hydraulic oil is approximately
45-55° C (113-131° F). CH13-19-01 Figure 1

3. Firm, level testing site.

4. Verify that engine RPM’s are correct to
specifications.
C. Boom Cylinder Cycle Time Test
1. Move the machine to a firm, level testing
area.
2. Place the machine throttle control to “High”
idle and the KPSS work mode switch to
“M” mode. See Figure 3.1.
3. Fully extend the bucket cylinder. See
Figure 3.2.
4. Fully retract arm cylinder. See Figure 3.2.
5. Lower boom until bucket rests on ground.
6. Raise boom (extending the cylinders) at
full stroke of the control and measure time
for the boom cylinder to reach the cushion
stroke. Record the time. See Figure 3.3.
7. Lower the boom (retracting cylinders) at CH13-18-01
full stroke and measure the time for the BOOM CYLINDER CYCLE TIME SPECIFICATIONS
bucket to reach ground level. Record the
CYLINDER POSITION M-MODE (UNIT SECONDS)
time. See Figure 3.3.
EXTENSION 2.9 - 3.5
8. Repeat steps 5 and 6 two more times. RETRACTION 2.5 - 3.1
Record the stop watch readings. Average
readings and compare average to boom
cylinder cycle time specification chart.

18
 HYDRAULIC CYLINDERS

CYLINDER CYCLE TIME TEST

NOTE: This test is designed for standard

boom, arm, and bucket. If the machine being
tested has any optional equipment check to
make certain there will be no interference with
the cab prior to performing the test.
D. Arm Cylinder Cycle Time Test
NOTE: The measuring time of the cylinder
cycle does not include the cushion stroke
times. Only measure time up to the beginning
of the cushion stroke.
1. Move the machine to a firm, level testing
area.
2. Place the machine throttle control to “High”
idle and the KPSS work mode switch to
“M” mode. See Figure 3.4.
3. Fully extend the boom cylinder. See Figure
3.5.
4. Fully retract the bucket cylinder. See
Figure 3.5.
5. Fully extend the arm (retracting cylinder).
6. At full stroke of the control, bring the arm
all the way in (extending cylinder) and
measure the time it takes for the arm
cylinder to reach the cushion stroke.
Record the time. See Figure 3.6.
7. At full stroke of the control, fully extend the
arm (retracting cylinder and measure the
time it takes until the cylinder reaches the
cushion stroke. Record the time. See
Figure 3.6.
8. Repeat steps 6 and 7 two more times.
Take the average of the recorded times
and compare to the average of the Arm
Cylinder Cycle time Specification Chart.
CH13-18-01

ARM CYLINDER CYCLE TIME SPECIFICATIONS

CYLINDER POSITION M-MODE (UNIT SECONDS)
EXTENSION 3.1 - 3.7
RETRACTION 2.4 - 3.0

19
 HYDRAULIC CYLINDERS

E. Bucket Cylinder Cycle Time Test

NOTE: The measuring time of the cylinder
cycle does not include the cushion stroke
times. Only measure time up to the beginning
of the cushion stroke.
1. Move the machine to a firm, level testing
area.
2. Place the machine throttle control to
“HIGH” idle and the KPSS work mode
switch to “M” mode. See Figure 3.7.
3. Raise boom to full height using “Boom Up”
control.
4. Adjust the arm until the arm is at 90° to
arm cylinder. See Figure 3.8
5. Lower boom until the arm tip is parallel
with the boom foot. See Figure 3.8.
6. Bring bucket all the way in.
7. Operate bucket out (retracting cylinder) at
full stroke of control and measure the time
it takes for the bucket cylinder to reach the
cushion stroke (if equipped). Record the
time. See Figure 3.9.
8. Operate the bucket in (extending cylinder)
at full stroke of control and measure the
time it takes for the bucket cylinder to
reach the cushion stroke (if equipped).
Record the time. See Figure 3.9.
9. Repeat steps 7 and 8 two more times.
Average the readings and compare to the
bucket cylinder cycle time specification
chart.

BUCKET CYLINDER CYCLE TIME

CYLINDER POSITION M-MODE (UNIT SECONDS)
EXTENSION 2.3 - 2.9
RETRACTION 1.7 - 2.3

CH13-20-01

20
 HYDRAULIC CYLINDERS
CYLINDER DRIFT 10. Adjust the boom until the tip of the bucket
teeth are 1.5 m (4’ 11") from ground level.
A. TOOLS AND EQUIPMENT
See figure 3.11.
The following tools and equipment will be
11. Turn engine “OFF” and allow machine to
required to perform the cylinder drift test.
set for 3 minutes.
1. Measuring tape
12. Measure the distance from the tip of the
2. Stop watch bucket teeth to ground level and record the
3. Device for marking starting points. reading.
4. Thermometer for hydraulic oil temperature. 13. Repeat steps 8 through 12 two more times
and record the readings.
B. MACHINE SETTINGS & SITE CONDITIONS
14. Average the readings and compare to the
1. Machine engine “OFF”. cylinder drift specification chart (Bucket
2. Confirm that the hydraulic oil is fall-top end).
approximately 45-55°C (113-131° F).
3. Firm, level testing site.

C. CYLINDER DRIFT TEST

1. Move the machine to a firm, level test site
and allow the hydraulic oil temperature to
reach 45-55°C (113-131° F)
2. Operate the arm out control until arm is
completely out (retracting cylinder).
3. Operate the bucket out control until bucket
is completely out (retracting cylinder).
4. Adjust the boom up or down with the
control until bucket is 1.5 m (4’-11”) from
ground level to tip of teeth. See Figure
3.10.
5. Turn engine “OFF” and allow machine to
sit for three minutes.
6. After three minutes, measure the
distances the boom, arm, and bucket
c y l i n d e r s h ave m o ve d . R e c o r d t h e
distances.
CH13-18-01
7. Repeat steps 4 through 6 two more times
and average the measurements. Compare
the average to the cylinder dr ift CYLINDER DRIFT SPECIFICATIONS
specification chart. BOOM DOWN ARM DOWN BUCKET IN BUCKET FALL
(RETRACT) (EXTEND) (EXTEND) (TOP END)
8. Start the engine. MAXIMUM
MAXIMUM 10 MM MAXIMUM 40 MM MAXIMUM 15 MM
(TEN MINUTES)
9. Operate the bucket in control until bucket (0.4") (1.6") (0.6")
300 MM (12")
is completely in (cylinder extended).
Unit: mm (inches)

21
 SWING SPEED
SWING STOPPING 7. Repeat steps 3-5 two more times and
A. TOOLS AND EQUIPMENT average the readings. Compare the
average to the swing speed specification
1. Stop watch chart.
2. Device for marking starting point. 8. Repeat steps 2-7 swinging counter
3. Measuring tape clockwise.
B. MACHINE SETTINGS & SITE CONDITIONS
1. Machine throttle in “HIGH” idle position.
2. Confirm that the hydraulic oil is
approximately 45-55°C (113-131° F).
3. Firm, level testing site.
4. Verify that engine RPM’s are correct.

C. SWING SPEED TEST

1. Move the machine to a firm, level testing
area.

CH13-22 -01
2. Move throttle to High Idle and place KPSS
switch in “M” mode.
3. Operate the arm out control until arm is
completely out (retracting cylinder). See
Figure 4.2.
4. Operate the bucket out control until bucket
is completely out (extending cylinder). See
Figure 4.1.
5. Adjust boom up or down until bucket teeth
are 1.5 mm (4’11”) from ground level. See
Figure 4.2.
NOTE: Turn on Swing Flasher and sound horn
BEFORE starting swing motion.
See Figure 4.3.
CH13-22-02
6. After sounding horn and with swing
flashers on, operate swing control at full SWING SPEED SPECIFICATIONS
s t r o k e fo r t w o c o m p l e t e r o t a t i o n s CLOCKWISE / COUNTERCLOCKWISE
clockwise. Time the last rotation and Unit: Seconds per Revolution
record the reading. Bring swing to a 4.9 - 5.3
complete stop.

22
 SWING STOPPING
A. TOOLS AND EQUIPMENT
1. Device for marking starting point.

B. MACHINE SETTINGS & SITE CONDITIONS

1. Machine throttle in “HIGH” idle position.
2. Confirm that the hydraulic oil is
approximately 45-55°C (113-131° F).
3. Firm, level testing site.

C. SWING STOPPING TEST

1. Move the machine to a firm, level testing
area.

2. Move throttle to High Idle and place KPSS

switch in “M” mode.
3. Operate the arm out control until arm is
completely out (retracting cylinder). See
Figure 4.4.
4. Operate the bucket in control until bucket
is completely in (extending cylinder). See
Figure 4.4.
CH13-23-02
5. Adjust boom up or down until bucket teeth FIGURE 4.6
are 1.5 mm (4’11”) from ground level. See
Figure 4.5.
NOTE: Turn on Swing Flasher and sound horn
BEFORE starting swing motion.
See Figure 4.6.
6. After sounding horn and with swing
flashers on, operate swing control at full
stroke for one complete rotation clockwise.
When bucket reaches star ting point,
release the swing control and allow
rotation to stop completely.
7. Measure the degree of angle from the
starting point to the stopping point of the
bucket. Record the angle degree. Repeat SWING STOPPING SPECIFICATIONS
test two more times and average the CLOCKWISE / COUNTERCLOCKWISE
r e a d i n g s . C o m p a r e t o sw i n g s t o p Unit: Degree of angle
specification chart. See Figure 4.7. 70° - 100°
8. Repeat steps 2-7 swing counter clockwise.

23
 SWING DRIFT
A. TOOLS AND EQUIPMENT
1. Device for marking starting point.
2. Stop watch

B. MACHINE SETTINGS & SITE CONDITIONS

1. Confirm that the hydraulic oil is
approximately 45-55°C (113-131° F).
2. Firm, level testing site with a 10° slope.

C. SWING DRIFT TEST

1. Move the machine to a firm, level testing
area with a 10° as shown in Figure 4.8.
2. Operate the bucket in Control until bucket
is completely in (extending cylinder). See
Figure 4.9.
3. 3. Operate the arm out control until the
arm is completely out (retracting cylinder).
See Figure 4.9.
4. Adjust the boom up or down until bucket
teeth are 1.5 m (4’11”) from ground level.
See Figure 4.10.
5. Stop engine and allow the machine to sit
for 20 seconds.
6. Measure the distance the swing drifted,
down grade, while sitting. Record the
distance. See Figure 4.11.
7. Repeat steps 2 through 6 two more times.
Average the distances and compare
averages to the Swing Drift Specification
Chart.
8. Start engine and swing machine 180°.
Repeat steps 2 through 7.

SWING DRIFT SPECIFICATIONS

SPECIFICATION
0 mm (0 inches) / 20 Seconds

CH13-24-01

24
 SWING BEARING VERTICAL MOVEMENT
UP-DOWN VERTICAL MOVEMENT 9. Record reading from dial indicator and
repeat steps 3 through 9 two more times.
A. TOOLS AND EQUIPMENT
Compare reading to Up-Down Movement
1. Dial indicator Chart.
2. Magnetic Base Assembly 10. Swing machine 180° and repeat steps 2
through 9.
B. MACHINE SETTINGS & SITE CONDITIONS
1. Confirm that the hydraulic oil is
approximately 45-55°C (113-131° F).
2. Firm, level testing site.

C. SWING STOPPING TEST

1. Move the machine to a firm, level area.

2. Attach dial indicator to the mounting area

of swing bearing at the location of a swing
bearing mounting bolt. See Figure 4.12.
3. Operate the arm control until the arm is
approximately at 90° with boom. See
Figure 4.13.
4. Operate the bucket control until bottom of
bucket is even with ground level. See
Figure 4.13.
5. Adjust boom up or down until bucket is
resting on the ground. With boom control,
raise the machine until tracts are 450 mm
(17.75") off the ground. See Figure 4.13.
6. Set Dial indicator to “0”.
7. Operate boom up and arm out controls
until arm is completely out. See Figure CH13-25-01
4.14.
8. Operate bucket control until bucket is SWING STOPPING SPECIFICATIONS
completely out and operate boom until STANDARD MAX. MOVEMENT
bucket teeth are 450 mm (17.75") from the 0.5-1.5 (0.020-0.060) 2.0 (0.080)
ground. See Figure 4.14.
Unit: mm (inches)

25
 SWING BEARING HORIZONTAL MOVEMENT
SWING BEARING SIDE TO SIDE
(HORIZONTAL MOVEMENT)

A. TOOLS AND EQUIPMENT

1. Dial indicator
2. Magnetic Base Assembly

B. MACHINE SETTINGS & SITE CONDITIONS

1. Confirm that the hydraulic oil is
approximately 45-55°C (113-131° F).
2. Firm, level testing site.

C. HORIZONTAL MOVEMENT TEST

1. Move the machine to a firm testing area.

2. Operate the bucket control until bucket is
completely out (retracting cylinder). See
Figure 4.15.
3. Operate arm control until arm is completely
out (retracting cylinder). See Figure 4.15.
4. Operate boom up or down until bucket teeth
are 10 mm (0.04") from ground level. See
Figure 4.16.
5. Mark center of bucket with marking device.
6. Make a mark on ground in line with mark on CH13-26-01 Figure 2
bucket. See Figure 4.17.
7. Manually move bucket to the left and record SWING STOPPING SPECIFICATIONS
distance of the center of bucket moved to the
STANDARD MAX. MOVEMENT
left of the mark on ground. See Figure 4.17. 20-44 (0.8-1.7) 90 (3.5)
8. Move bucket to r ight and record the
distance the center of the bucket moved to the Unit: mm (inches)
right of mark on ground. Figure 1

9. Repeat steps 7 and 8 two more times.

10. Average the readings and compare to the
side to side (hor izontal) movement
specification chart.
11. Swing machine 180°. Repeat steps 1 - 10.

26
 SWING MOTORS
SWING MOTOR OIL CASE DRAIN
A. Tools & Equipment
1. 38 Liter (10 U.S. Gal.) graduated bucket.
2. Hydraulic line wrenches
3. Hydraulic line plugs
4. Hydraulic fitting caps
5. Stopwatch
6. Thermometer
ARM OUT BUCKET OUT
B. Machine Settings & Site Condition (COMPLETELY OUT) (COMPLETELY OUT)
1. Machine throttle in "High" idle position.
2. Hydraulic oil temperature at 45°C to 55°C FIGURE 5.1
(113°F to 131°F)
3. Firm, level testing area.
4. Verify that engine RPM's are at correct
specification

C. Swing Motor Oil Case Drain Test

1. Move machine to a firm, level testing
area.
BOOM DOWN BUCKET
2. Allow the hydraulic oil to reach a tempera- (BUCKET TEETH
ture of 45°C to 55°C (113°F to 131°F). IN GROUND)
FIGURE 5.2

3. Operate the Arm Out Control until the arm

is completely out. See Figure 5.1. CAREFULLY
DEPRESS STEM
4. Operate the Bucket Out Control until
bucket teeth are positioned to go into
ground See Figure 5.1.

5. Lower the boom until bucket teeth are in

ground. See Figure 5.2.

6. Operate Swing Control in both directions

to make certain bucket teeth are in the
ground deep enough to stall swing. It
May be necessary to set bucket teeth
deeper to stall swing.

7. Turn engine "OFF" . FIGURE 5.3

8. Release hydraulic tank pressure by re- WARNING

moving cap from pressure relief valve and
depressing relief valve stem. See Figure • BE EXTREMELY CAUTIOUS WHILE RELEASING
5.3. HYDRAULIC TANK PRESSURE.
VAPORS MAY BE EXTREMELY HOT.
9. After cleaning away all dirt and debris, • WEAR APPROVED SAFETY CLOTHES, SHOES,
remove hydraulic line routed from "Tee" GLOVES AND HARD HAT WHEN PERFORMING
on top of swing motor to center port on ANY MAINTENANCE OR TEST PROCEDURES.
Swivel Joint at swing motor "Tee". See
Figure 5.4.
27
 SWING MOTOR

SWING MOTOR TEST CONTINUED

NOTE: Throughly clean all hydraluic lines and

NOTE: Fill hydraulic tank to proper level using
fittings before removal. Do not allow any dirt or
only approved new hydraulic oil as listed in the
debris to enter open lines or fittings.
List of Oils, Greases, Filters and Element
Thoroughly clean the bucket the oil is to be
Chart in this manual.
drained into.
10. Install one hydraulic line plug into line and
one hydraulic fitting cap onto “Tee”. See
Figure 5.4. Torque to proper value.
11. Remove line routed between “Tee” on top
of swing motor to hydraulic tank at the
hydraulic tank. See Figure 5.5.
12. Install one hydraulic fitting cap onto fitting
at hydraulic tank and torque. See Figure 5.5.
13. Place loose end of line into a clean 38 liter
(10 gallon) capacity bucket.
14. Start engine and place throttle control in
the “high” idle position.
Do not operate travel.
15. Operate the swing control to the left,
stalling swing for one minute. Record amount
of oil in bucket.
16. Operate swing control to the right, stalling
swing for one minute. Record the amount of
oil in bucket.

NOTE: If it seems the flow of oil will be high,

perform the test for 15 seconds and multiply
amount of oil by 4 to compare to the chart.
Example: 19 liters (5 U.S. Gallons) X 4 = 76
liters (20 Gallons)
CH13-28-01
17. Compare readings to swing motor oil case
drain specification chart.
18. If readings are greater than values in the BOOM CYLINDER CYCLE TIME SPECIFICATIONS
chart, refer to Shop Manual for additional LEFT RIGHT SWING
instructions. STANDARD 7 (1.8)
MAXIMUM 20 (5.3)
19. Remove hydraulic fitting caps and plugs.
Install hydraulic lines back to their original
fittings and torque to the proper value.
2 0 . C h e ck hy d ra u l i c o i l l evel . R e fe r t o
Operator’s Manual for hydraulic oil level check
procedures.

28
 TRAVEL MOTORS
TRAVEL MOTOR OIL CASE DRAIN
A. Tools & Equipment
1. 38 Liter (10 U.S. Gallon) graduated bucket
2. Hydraulic line wrenches
3. Hydraulic fitting cap
4. Stop watch
5. Thermometer
6. Special tool to lock sprockets (Two
required)
B. Machine Settings and Site Condition
1. Machine throttle in “High” idle position.
2. Confirm that the hydraulic oil is
approximately 45-55°C (113-131° F).
3. Firm, level testing site.
C. Travel Motor Oil Case Drain Test
1. Move machine to a firm, level testing area.
2. Allow the hydraulic oil to reach a
temperature of 45-55°C (113-131° F).
3. Install special tool into each sprocket. See
Figure 5.6.
NOTE: When placing special tool into
sprockets, have machine in “LOW IDLE” and
operate travel controls cautiously until tool is
in position.
4. Operate travel controls in forward until
machine tracks stall.
NOTE: Use the sprocket special tool that fits
the sprocket of the particular machine being
tested. See Figure 5.7.
5. Operate the arm in control until the arm is
completely in. See figure 5.8.
6. Operate the bucket in control until bucket
is completely in. See Figure 5.8.
7. Operate the boom down control until boom
is completely down. See Figure 5.8.
8. Turn engine “OFF”.
9. Release hydraulic tank pressure by
removing cap from pressure relief valve
and depressing relief valve stem. See A (LENGTH) B (DIAMETER)
Figure 5.9. 120 mm (4.72 inches) 60 mm (2.36 inches)
10. Clean away all dirt and debris. Remove
hydraulic line routed from “Tee” on top of
swing motor to center port on swivel joint
at swing motor “Tee”. See Figure 5.10.

29
 TRAVEL MOTORS

NOTE: Thoroughly clean all hydraulic lines

and fittings before removal. Do not allow any
dirt or debris to enter the open lines or fittings.
Thoroughly clean the bucket that the oil is to
be drained into.

11. Install one hydraulic fitting cap onto “Tee”.

See Figure 5.10. Torque to proper value.
12. Place loose end of line into a clean 38 liter
(10 gallon) capacity bucket.
13. Start engine, raise boom a little and place
throttle control in the “high” idle position.
14. With special tool installed in each travel
motor sprocket, operate the left travel
control at full stroke forward for one
minute. Measure the amount of oil in
bucket and record.
NOTE: If flow of oil will be high, perform the
test for 15 seconds and multiply the amount of
oil by 4 to compare chart.
EXAMPLE: 19 liters (5 U.S. Gallons) X 4 = 76
liters (20 Gallons)
15. Repeat step 14 with right control at full
stroke forward for one minute. Record
amount of oil in bucket.
16. Remove special tool and place into
sprocket to stall reverse movement. See CH13-20-01
Figure 5.11.
17. Repeat steps 14 and 15 with control to BUCKET CYLINDER CYCLE TIME
reverse movement. FORWARD/REVERSE TRAVEL
18. Compare readings for each travel motor to STANDARD 6 (1.6)
MAXIMUM 15 (4.0)
Travel Motor Oil Case Drain Chart.
19. If readings are greater than values in Unit: Liters Per Minute (Gallons Per Minute)
chart, refer to shop manual for additional
instructions.
20. Remove hydraulic fitting cap. Install NOTE: Fill hydraulic tank to proper level using
hydraulic lines back to the original fitting only approved new hydraulic oil as listed in the
and torque to the proper value. list of oils, greases, filters, and elements chart
21. Check hydraulic oil level. Refer to
in the Operator’s Manual.
Operator’s Manual for hydraulic oil level
check procedures.

30
 TRAVEL PERFORMANCE

TRAVEL SPEED 6. Place throttle control in “HI-IDLE” position

and KPSS switch in “M” mode. See Figure
A. Tools & Equipment 7.5.
1. Stop watch 7. Place travel speed select switch in 1(low)
2. Device to mark starting point of tracks. speed. See Figure 7.6.
B. Machine Settings and Site Condition 8. Operate the right travel control full forward
1. Machine throttle in “High” idle position. and measure the time it takes for track to
make three complete revolutions. Record
2. Test will be performed with KPSS mode the time.
switch in “M”.
9. Repeat step 7 and 8 two more times.
3. Confirm that the hydraulic oil is Average the readings and compare to
approximately 45-55°C (113-131° F).
travel speed specification chart.
4. Firm, level testing site.
10. Place travel speed select switch in 2
5. Verify that engine RPM’s are correct (higher) speed and repeat steps 8 and 9.
specification.
11. Repeat steps 4 through 13 with left track.
C. Travel Speed Test
1. Move machine to a firm, level testing area.
2. Allow the hydraulic oil to reach a
temperature of 45-55°C (113-131° F).
3. Operate swing right control until machine
is sitting across (perpendicular) tracks.
4. Operate the boom, arm, and bucket
controls until bucket is on ground. See
Figure 7.4.
5. Operate the boom control until bottom of
right track is approximately 300 mm (12")
off ground. See Figure 7.4. Make
reference mark on track.

31
 TRAVEL PERFORMANCE

TRAVEL SPEED SPECIFICATION CHART

MODE DIRECTION SPEED STANDARD/3 REV

M FORWARD * 23.5 - 25.9
M FORWARD ** 15.8 - 17.4
M REVERSE ** 17.2 - 19.0

Speed selection:
*1
**2

32
 TRAVEL PERFORMANCE
TRAVEL DEVIATION
A. Tools & Equipment
1. Measuring Tape 30 M (100-foot) capacity
2. Line parallel to machine in soil
B. Machine Settings and Site Condition
1. Machine throttle in “High” idle position.
2. KPSS mode switch in “M” mode position.
3. Confirm that the hydraulic oil is
approximately 45-55°C (113-131° F).
4. Firm, level testing site.
5. Verify engine RPM’s are at correct
specification.
C. Travel Deviation Test
1. Move machine to a firm, level testing area.
2. Allow the hydraulic oil to reach a
CH13-33-01
temperature of 45-55°C (113-131° F).
3. Operate the boom, arm, and bucket
controls until attachment is in a transport
position. See Figure 7.1.
4. Draw a line parallel to machine in the soil
for a distance of 20 M (65’ 7"). See Figure
7.2l.
5. Move throttle control to “HI-IDLE” position
and place KPSS switch in “M” mode. See
Figure 7.3.
6. Operate both travel controls together at full
fo r wa r d s p e e d fo r t h e 2 0 M ( 6 5 ’ 7 " )
distance. See Figure 7.2.
7. Measure and record dimension “A” See
Figure 7.2.
8. Repeat steps 6 and 7 two more times.
Average the readings and compare to
Travel Deviation Specification Chart.
9. Repeat steps 1 through 8 with
undercarriage turned 180°.
A (LENGTH) STANDARD A
0 mm to 1200 mm
20 M (65’ 7")
(0"-0” to 3-11”)

33
 PRE-CHECKS PRIOR TO PREFORMING ADJUSTMENT “A”

NOTE
With key in the “ON” position and engine not
running, Gauge cluster display must read
“MONITOR SYSTEM OK”. If any warning Icons
are visible in gauge cluster display, preform the Screen Change
proper maintenance or repairs to correct the Switch
problem. Then proceed to Adjustment “A”. See Monitor
Figure 10.29 A. System Ok

A. Emergency Stop Control, and Manual

Throttle Cable
1. Check the operation of Emergency
Stop control, confirm that cable moves
freely both in and out, and does not FIGURE 10.29 A
bind.
2. Emergency stop cable must be pushed Water
in to obtain proper engine Temperature
performance. Gauge
3. Confirm that the manual Throttle
Control Cable is pressed in (Release
Screen Change
position). RPM 2300
Switch
B. Verify engine RPM ( Push Switch
Once )
1. If possible start engine, run excavator
hydraulic system until water temperature
is at normal operating range.
2. Verify engine RPM in “M” mode, “A”
mode, and in “B”mode by pushing
screen change switch once. Record
engine RPM readings for later
verification. See Figure 10.29 B. FIGURE 10.29 B

C. RPM Sensor Test Resistance value

Proper adjustment of the RPM sensor is 2.3k 8 $0.2 k 8
critical to a successful Adjustment “A”
Procedure. With engine running press
screen change switch one time, RPM will
appear on screen.
1. If screen shows 0 RPM check the
following:
a. With engine OFF (not running)
disconnect the RPM sensor from the
machine electrical harness. Check the
Voltage must be
resistance value of RPM sensor. Value
4 V or more.
must be 2.3k 8$ 0.2k 8.
b. Connect the speed sensor, to a multi
meter. With engine running at low idle,
measure the voltage AC. voltage must
be 4 V or more. See Figure 10.29 C. FIGURE 10.29 C

34
 ADJUSTMENT “A” PROCEDURE
MECHATRONIC CONTROLLER

A. CONDITIONS TO USE ADJUSTMENT “A:

Adjustment “A” procedure must be performed
w h e n o n e o r m o r e o f t h e fo l l o w i n g
components have been removed, repaired,
adjusted or replaced.
1. Mechatronic controller (CPU)
2. Stepping motor assembly
3. Linkage between stepping motor and
engine fuel pump assembly
4. Engine fuel pump assembly
5. Engine
6. When the ROM DATA FAILURE is displayed
on the multi display.
7. When the ROM DATA FAILURE and/or
MECHATRO SET ERROR are displayed
alternately on the multi display.

B. TOOLS & EQUIPMENT REQUIRED FOR

CHECKING AND ADJUSTING OF PILOT AND
MAIN RELIEF VALVES
14 mm spanner wrench
13 mm spanner wrench
10 mm spanner wrench
6 mm Allen wrench
1 mm feeler gauge
1. General hand or power tools to remove and
replace hydraulic fittings and components.
2 . T h e r m o m e t e r t o r e a d hy d r a u l i c o i l
temperature.

C. VERIFICATION OF AUTO ACCEL RPM

1. With safety lock in the lock (up) position,
See Figure 10.30 B.
2. Maintenance connector in the factor y
default position. See Figure 10.30 C.
a. Turn key switch to start position and start
engine. See Figure 10.30 D.
b. Place throttle potentiometer to high idle
position. See Figure 10.30 D.
c. Locate the screen change switch, depress
the switch once to select RPM. See Figure
10.31 B.
d,. Place safety lock lever in the unlock (down)
position. See Figure 10.31 C.
e. Fully activate pilot control for bucket dig,
then release pilot control, wait three seconds
and check engine RPM. See Figure 10.30 D.
35
 ADJUSTMENT “A” PROCEDURE
D. Verification of Engine Low RPM
1. With safety lock in the lock (up)
position, See Figure 10.30 B.
a. Place the maintenance connector in
the release position. See Figure
10.30 C.
b. Turn key switch to start position and
start engine. See Figure 10.31 A. Pilot control
c. Place throttle potentiometer to low idle for Bucket
position. See Figure 10.31 A. and Boom

d. Locate the screen change switch,

depress the switch once to select
RPM. See Figure 10.31 B. FIGURE 10.31 A
e. Press screen change switch two times
to retun screen to Monitor System Ok.

E. Machine Settings and Site Conditions

1. Attachment in the Hydraulic Oil Check
Position. See Figure 10.30 A.
2. Engine Emergency Stop Knob pushed Screen Change
completely “IN”. See Figure 10.30 B. Switch
RPM 0
3. Maintenance Connector placed in the
“Release Condition”. See Figure 10.30
C.
4. Manual Throttle Control pressed “IN” all
the way. See Figure 10.30 C.
5. Firm level site.

FIGURE 10.31 B

SAFETY LOCK
LEVER IN UNLOCK
POSITION

FIGURE 10.31 C

36
 ADJUSTMENT “A” PROCEDURE
F. Removal of CPU Access Panel OPERATOR
CONTROL
STAND SEAT
1. Pull up on the top bail for seat adjustment
and move seat fully forward. See Figure
10.32 A.

2. Pull reclining adjustment lever up and

move seat back forward. See Figure
10.32 B.

3. Release the 4 top screws from rear

panel top cover (behind the operator’s
seat) by turning 90 degrees.
See Figure 10.32 C. FIGURE 10.32 A

4. Press the panel locks to release panel,

tilt the cover towards the operators seat
to obtain access to the speaker wires,
remove wires. See Figure 10.32 C.

5. With speaker wires removed carefully

remove CPU access panel from cab and
LEVER FOR SEAT
place in safe area. See Figure 10.32 D.
RECLINING

Remove Wires FIGURE 10.32 B

from Both TOP SCREWS
Speaker’s

CPU PANEL

PANEL LOCKS
FIGURE 10.32 D
LOWER PANEL

G. Removal of Rod linkage and Lever from ENGINE SPEED CONTROL

Stepping Motor.
FIGURE 10.32 C
1. Move to the engine compartment and
locate the injection pump and stepping Dimension B
Splined Lever
motor. See Figure 10.32 E.

2. With a 13 and 14 mm spanner wrench

remove the rod linkage from arm of
stepping motor and fuel injection pump.

FIGURE 10.32 E
37
 ADJUSTMENT “A” PROCEDURE

3. Using a 5 mm Allen wrench and a 10 mm

spanner wrench, remove the splined lever
from stepping motor. See Figure 10.33 A.
4. Loosen the left and right hand thread jam
nuts on rod, and inspect the heads of linkage
for excessive wear.
5. Set the rod length to the specific dimension
per machine model number listed below. see
figure 10.33 A.
NOTE: Dimension B is the starting dimension
of fuel injection rod assembly. Final dimension
of rod will be determined when rod and lever
is installed to the engine and the engine stop
gap is set.
Dimension B: See Figure 10.33
288 Mm (11.34")
NOTE: Make certain electrical power is “OFF”
before moving the controller “TEST-RUN”
toggle switch. This will avoid possible damage
to the Mechatronic controller and prevent loss
of computer memory.

ADJUSTMENT “A” PROCEDURE

1. Remove the key from key switch. See
Figure 10.33 B.
2. Locate the CPU behind operator’s seat.
Remove grommet located on the top of CPU.
Carefully move the test run switch to test
position. See Figure 10.33 C.
3. Insert key in key switch, turn key to the
“ON” position. Do not start engine. Gauge
cluster must display “Monitor System OK.” If
not, perform maintenance or repairs to correct
problem.
4. Turn accel dial to the low idle position. See
Figure 10.33 B.

38
 ADJUSTMENT “A” PROCEDURE
5. Press the buzzer stop switch for 5 to 10
seconds and release. Step 1 will not apear
until buzzer stop switch is released. See
Figure 10.34 D.

STEP 2
CPU GAP
(STOP)

FIGURE 10-34 D
6. STEP 1 is displayed in the gauge cluster,
wait until STEP 2 is displayed in gauge FIGURE 10.34 A
cluster. See Figure 10.34 A.

7. After verification that CPU STEP 2 GAP Rod and Linkage

STOP is displayed in the gauge cluster,
you will notice that the controller has
moved the stepping motor to the STOP
position.
See Figure 10.34 A.

8. Install the linkage (dimension B) and rod

assembly between the stepping motor and
injection pump. See Figure 10.34 B.

9. Confirm that the spline on the stepping

motor is protruding approximately 3mm FIGURE 10.34 B
(.125”) past the lever assembly. Secure
the lever to stepping motor with the 5mm
allen wrench and 10mm wrench.
Fuel Stop Bolt
Feeler Gauge
Note
Dimension “B”is only a starting point, NOT THE
FINAL DIMENSION. The final length or the rod
will be determened in the next step.

10. With a feeler gauge inserted between the

fuel shut off stop bolt and the fuel injection
pump lever adjust the clearance to 0.1mm
(.004 “). See Figure 10.34 C.

11. Once clearance has been reached with

only slight resistance on the feeler gauge
tighten all the rod linkage jam nuts with FIGURE 10.34 C
proper 13 and 14 mm wrenches. See
Figure 10.34 B.
39
 ADJUSTMENT “A” PROCEDURE
11. Press buzz start switch once and CPU
STEP 3 Start E/G will appear in gauge
Cluster. You will notice that the controller
will move the stepping motor to a position
higher than the normal RPM starting
range. See Figure 10.35 A.
CPU STEP
12. Start engine and wait until engine reaches 3
Start E/G
normal operating temperature range.

13. With engine running, press the buzzer stop

switch once, the gauge cluster will read
CPU STEP 4 MEMORY. The controller
FIGURE 10.35 A
will take control of the stepping motor and
bring the engine from:
a. Mid range.
b. Below Low Idle.
c. High Idle.
d. Low Idle.
See Figure 10.35 B.
CPU Step 4
Memory
NOTE
Required time for engine to memorise steps is
about 3 minutes.

14. CPU STEP 4 MEMORY will take

approximately three minutes to cycle the
FIGURE 10.35 B
stepping motor and record the data in the
controller.

15. After completion of the above, the gauge Note

cluster display will read the following: “Finished CPU
CPU FINISHED **** RPM (****) will (****)RPM”
represent the highest RPM which was represents the
read by the controller during Step 4. highestRPM
See Figure 10.35 C. whichwas recorded
by the controller FINISH
Please refer to the Measuring & Adjusting during Step 4. CPU **** RPM
Pressures on the following pages for the RPM
reading for your machine by Model and Serial
Number.

Note
The finished RPM in step 4 may show higher
than Actual High Idle RPM. FIGURE 10.35 C

40
 SERVICE DIAGNOSTIC 28 ITEM CHECK

E. AFTER COMPLETION OF “A”

ADJUSTMENT

1. Turn key switch to Off position, stop engine

and allow the battery relay to shut off
(approximately 4 seconds).
2. Return the CPU controller adjustment
switch from the TEST to RUN position.
Rein stall protective grom met in the
controller cover.
3. Change the maintenance connector from
t h e fact o r y d e fa u l t t o a cc e l r e le a se
position. Start the engine, raise the engine
speed to the high idle RPM. See Figure
10.36A.
4. Press the screen change switch once to
br i n g u p R P M . Ver i f y e ng i ne s pe ed
c h a n g e s o n t h e m u l t i - d i s p l ay i n
accordance with the set values which are
listed on the following pages by machine
model and serial number.
5. If all engine RPM’s are correct, reinstall
the CPU access cover and retur n
operator’s seat to the original position.

CH13-28-01
CH13-28-01

41
SHOP MANUAL - SECTION 2

E215
CRAWLER EXCAVATORS

HYDRAULIC, ELECTRICAL, AND

COMPONENT SYSTEMS

Issued January 2006

Book/Form Number 5-1620 NA
Copyright © 2006. CNH America, LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. S5PJ0010E01-KO22
 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS

CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Remarks
First Edition 01-2006 E215 5-1620 NA
 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS

SECTION 2
HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
TABLE OF CONTENTS
CHAPTER 21
MECHATRO SYSTEM
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-1
CHAPTER 22
HYDRAULIC SYSTEM
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-1
CHAPTER 23
ELECTRICAL SYSTEM
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-1
CHAPTER 24
COMPONENTS SYSTEM
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-1
CHAPTER 25
AIR CONDITIONING SYSTEM
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-1

5-1620 NA Issued 01-2006 Bur 0-I

NOTES
 SECTION 2 -HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS

CHAPTER 21

CRAWLER EXCAVATORS

MECHATRO
CONTROL SYSTEM

Issued January 2006

Book/Form Number 5-1630 NA
Copyright © 2006. CNH America, LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. S5PJ0010E01-KO13
 SECTION 2 -HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 21 - MECHATRO CONTROL SYSTEMS

CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Remarks
First Edition 01-2006 E215 5-1630 NA

21-II Issued 01-06 Bur 5-1630 NA

 SECTION 2 -HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS

CHAPTER 21
MECHATRO CONTROL SYSTEM
TABLE OF CONTENTS

1. SUMMARY OF MECHATRO CONTROL SYSTEM

1.1 Mechatro Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Pump Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.3 Boom Raise Conflux Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.4 Arm In Conflux Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.5 Variable Recycle Control for Light Load (Arm In) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.6 Arm In Anti-cavitation Controlt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.7 Arm Out Conflux Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.8 Travel Straight Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.9.1 Swing Priority Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2. MECHATRO CONTROLLER
2.1 Summary of Mechatro Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.2 Self Diagnosis Display Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
2.3 Service Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
2.4 Trouble History Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
2.5 Correcting Engine Oil Supply Cumulative Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
2.6 Mechatro Control Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

5-1630 NA Issued 01-06 Bur 21-1

 SECTION 2 -HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 21 - MECHATRO CONTROL SYSTEM

NOTES

21-2 Issued 01-06 Bur 5-1630 NA


:


High pressure sensor (P1, P2 : 2pcs)
1. SUMMARY OF MECHATRO CONTROL SYSTEM  : Low pressure sensor

1.1 MECHATRO CONTROL SYSTEM IN GENERAL (ATT : 8pcs, Travel : 2pcs, Back pressure : 1pc)
:Negative control pressure sensor (P1, P2 :


ATTACHMENT TRAVEL 2pcs)

OPERATION LEVER OPERATION LEVER
: Potentio meter
 : Engine speed sensor
LEFT RIGHT
 : Governor motor

Electric : Controller IN/OUT signal

P2 NEGATIVE
CONTROL
Hydraulic : Pilot secondary pressure
PRESSURE Solenoid proportional valve

RECIRCULATION

TRAVEL STRAIGHT VALVE

SENSOR

ARM VARIABLE
P2 NEGATIVE CONTROL

P1 BYPASS

P1 NEGATIVE CONTROL
CUT VALVE
secondary pressure

CONFLUX
Pilot primary pressure

TRAVEL RIGHT
MULTI CONTROL

TRAVEL LEFT
VALVE
BOOM

OPT 1 (1)
VALVE
Negative control pressure

BUCKET
SWING

BOOM
ARM
BACK
PRESS. BOOM CYLINDER
PRESSURE BOOM RAISE

P2 BYPASS
CUT VALVE
VALVE

SENSOR CONFLUX

CONFLUX
Pilot secondary pressure signal

VALVE
Travel 1 Reverse right

ARM
GAUGE BOOM LOWER 2 Forward right
RECIRCULATION
CLUSTER 3 Reverse left
A/M/B 4 Forward left
ARM CYLINDER
DISPLAY ATT  Bucket digging
ARM OUT
P1 NEGATIVE CONFLUX  Bucket dump
CONTROL ARM IN
PRESSURE RECIRCULATION Boom raising
MODE SENSOR
SELECT
BUCKET CYLINDER Boom lowering
SWITCH Swing left
Swing right
A/M/B Arm in
SWING PARKING
SELECT BRAKE  Arm out
VOLTAGE SWING PRIORITY
SERIAL NETWORK

PROPORTIONAL SOL.
Note, EU ;
1In use
ACCEL POTENTIO
TRAVEL SPEED

PROPORTIONAL
VOLTAGE PSV-H

SPEED SENSOR Furtures Purpose

P1 pump is controlled by A) The power curve shall
1 solenoid proportional be an ideal curve.
MECHATRO CONTROLLER

TRAVEL 1-2 SPEED

TRAVEL STRAIGHT
valve.
(C-1)

RECIRCULATION
ENGINE P2 pump is controlled by B) Supply an optimum

P1 BYPASS CUT

P2 BYPASS CUT

POWER BOOST
ARM VARIABLE
PUMP 2 solenoid proportional flow for each

LOCK LEVER
valve. operation.

SWING P/B

Mechatro controller
The travel straight valve
GOVERNOR MOTOR z Make the changeover
3 is controlled by solenoid soft.
(M-2) proportional valve.
PROPORTIONAL
The bypass cut valve is
COMMAND CURRENT P1 PUMP SOLENOID z Make the changeover
PROPORTIONAL VALVE 4 controlled by solenoid soft.
proportional valve.
PROPORTIONAL (PSV-P1)
COMMAND CURRENT P2 PUMP SOLENOID The arm variable
PROPORTIONAL VALVE recirculation valve is z Control the arm speed
5 controlled by solenoid as you desire.
(PSV-P2) LIMIT SW. proportional valve.

24V VOLTAGE The power boost is

6 controlled by solenoid
PROPORTIONAL changeover valve
COMMAND CURRENT
The open and close actions of the swing P/B are
7 controlled by solenoid changeover valve.
1-1
NOTES NOTES
1.2 PUMP CONTROL

RECIRCULATION VALVE

BOOM CONFLUX
P2 NEGATIVE

P1 BYPASS
CUT VALVE
CONTROL

ARM VARIABLE
PRESSURE
P1 NEGATIVE

P1 NEGATIVE CONTROL
P2 NEGATIVE CONTROL
SENSOR
CONTROL

VALVE

TRAVEL RIGHT
PRESSURE

TRAVEL STRAIGHT
TRAVEL LEFT
SENSOR

BUCKET
SWING

BOOM
ARM
BACK PRESS.

VALVE

ARM CONFLUX
PRESSURE
SENSOR

P2 BYPASS
CUT VALVE

VALVE
HIGH
PRESSURE SENSOR

PILOT SIGNAL PROCESS

COMMAND P1 PUMP
CURRENT SOLENOID
PROPORTIONAL
P1 NEGATIVE CONTROL VALVE
DIFFERENTIAL PRESSURE PSV-P1

PI
P2 COMMAND P2 PUMP

2
PUMP PRESSURE CURRENT SOLENOID
PROPORTIONAL
VALVE
PSV-P2

P2 NEGATIVE CONTROL MECHATRO

DIFFERENTIAL PRESSURE
CONTROLLER

Where
q : Delivery rate of pump /min
i : Secondary press. of
2
solenoid proportional valves kgf/cm

1
PUMP CONTROL

Negative control  Determining the delivery rate of pump
1) If ATT or travel action is performed, the 1) The lower of the pump delivery rate
secondary pilot pressure changes each spool. computed in the negative control and the
2) When the spool is changed, the negative pump delivery rate computed in the P-Q
control pressure changes according to the control is selected and put out as a current
spool stroke. The negative control pressure is command to the solenoid proportional valve
then put into the negative control pressure according to the delivery rate.
sensor. The back pressure in the control valve 2) The solenoid proportional valve of each pump
(the return pressure to tank) is put into the puts out the secondary pilot pressure
back pressure sensor. according to the current command from the
3) Voltage outputs from the negative control mechatro controller. It changes the tilting
pressure sensor and the back pressure sensor angle of the pump and controls the delivery
are put into the mechatro controller that rate of the pump.
computes the delivery rate of the pump 3) As the result, a delivery rate according to the
according to the voltage inputs. negative control pressure is supplied to the
actuator via the control valve. If load to the
 P-Q control actuator increases, the voltage from the high
The voltage output of the high pressure pressure sensor is put into the mechatro
sensor that is attached to the pump is put controller. This insures that the machine is
into the mechatro controller. The controller operated without engine failure even if load
then performs pilot signal processing and to the pump is increased.
computes the delivery rate of the pump
according to the voltage input (=load
pressure).

2
1.3 BOOM RAISE CONFLUX CONTROL

BOOM CONFLUX
RECIRCULATION VALVE
P2 NEGATIVE

P1 BYPASS
CUT VALVE
CONTROL
PRESSURE

ARM VARIABLE

P1 NEGATIVE CONTROL
SENSOR

P2 NEGATIVE CONTROL
PILOT P1 NEGATIVE

VALVE
VALVE

TRAVEL RIGHT
CONTROL

TRAVEL STRAIGHT
TRAVEL LEFT
PRESSURE

BUCKET
SENSOR

SWING

BOOM
ARM
BACK PRESS.

VALVE
PRESSURE

ARM CONFLUX
SENSOR

P2 BYPASS
CUT VALVE

VALVE
PILOT SIGNAL PROCESS

COMMAND P2 BYPASS CUT

SOLENOID
CURRENT PROPORTIONAL
VALVE
PSV-B

SECONDARY PILOT PRESS. OF BOOM RAISE

COMMAND P1 PUMP
SOLENOID
CURRENT PROPORTIONAL
VALVE
PSV-P1

P1 NEGATIVE CONTROL
DIFFERENTIAL PRESSURE

COMMAND P2 PUMP
CURRENT SOLENOID
PROPORTIONAL
VALVE
PSV-P2

P2 NEGATIVE CONTROL MECHATRO

DIFFERENTIAL PRESSURE CONTROLLER

(1) Boom raise conflux

1) Start boom raise operation, and the boom raise 5) The voltage output of the negative control
operation pilot pressure switches boom spool pressure sensor is put into the mechatro
and boom conflux spool, and inputs into low controller. The controller processes the
pressure sensor. negative control signal and puts out a current
2) The voltage output of the low pressure sensor command to the P1 and P2 pump solenoid
for the boom is put into the mechatro controller. proportional valves according to the voltage
The controller processes the pilot signal and input.
puts out a current command to the P2 cut 6) The P1 and P2 pump solenoid proportional
solenoid proportional valve according to the valves put out the secondary pilot pressure
voltage input. according to the current command from the
3) The P2 cut solenoid proportional valve puts out mechatro controller and changes the delivery
the secondary pilot pressure according to the rates of the P1 and P2 pumps.
current command from the mechatro controller 7) A pure hydraulic command changes over the
and changes the P2 cut valve. boom main spool and the boom conflux valve.
4) The moment the boom spool and the P2 When the mechatro controller command shifts
bypass cut valve are shifted, it is put into the the P2 bypass cut valve, the oil delivered by the
negative control pressure sensor. P1 pump is combined with that by the P2 pump
when the boom hoist operation is performed.

3
1.4 ARM IN SEQUENCE CONFLUX CONTROL

RECIRCULATION VALVE

BOOM CONFLUX
P2 NEGATIVE
CONTROL

P1 BYPASS
CUT VALVE
PRESSURE

ARM VARIABLE
SENSOR

P2 NEGATIVE CONTROL

P1 NEGATIVE CONTROL
PILOT P1 NEGATIVE
VALVE

VALVE
CONTROL

TRAVEL RIGHT
TRAVEL STRAIGHT
TRAVEL LEFT
PRESSURE
SENSOR

BUCKET
SWING

BOOM
ARM
BACK PRESS.
PRESSURE

VALVE
SENSOR

ARM CONFLUX
P2 BYPASS
CUT VALVE

VALVE
PILOT SIGNAL PROCESS

COMMAND P2 BYPASS CUT

CURRENT SOLENOID
PROPORTIONAL
VALVE
PSV-D

P2 PUMP PRESSURE

COMMAND TRAVEL STRAIGHT

CURRENT SOLENOID
PROPORTIONAL
VALVE
PSV-C

P2 PUMP PRESSURE

COMMAND P1 PUMP
CURRENT SOLENOID
PROPORTIONAL
VALVE
PSV-P1

P1 NEGATIVE CONTROL
DIFFERENTIAL PRESSURE

COMMAND P2 PUMP
CURRENT SOLENOID
PROPORTIONAL
VALVE
PSV-P2

P2 NEGATIVE CONTROL
MECHATRO
DIFFERENTIAL PRESSURE CONTROLLER

Sequence conflux control:

1) If the P2 pump pressure rises above a certain 3) When the travel straight valve is shifted, the
level during the arm in operation, the mechatro parallel passages on the P1 and P2 sides get
controller sensing the voltage output of the high through. Since the P1 bypass cut valve is
pressure sensor processes the pilot signal and shifted, the oil discharged by the P1 pump is
puts out a current command to the travel combined with that delivered by the P2 pump.
straight solenoid proportional valve and the P1
bypass cut solenoid proportional valve.
2) The travel straight solenoid proportional valve
and the P1 bypass cut solenoid proportional
valve put out the secondary pilot pressure
according to the command value of the
mechatro controller and shifts the travel straight
valve and the P1 bypass cut valve.

4
1.5 VARIABLE RECYCLE CONTROL FOR LIGHT LOAD ARM IN

BOOM CONFLUX
RECIRCULATION VALVE
P2 NEGATIVE
CONTROL

P1 BYPASS
CUT VALVE
PRESSURE

ARM VARIABLE
P2 NEGATIVE CONTROL
SENSOR P1 NEGATIVE

P1 NEGATIVE CONTROL
PILOT
VALVE CONTROL

VALVE

TRAVEL STRAIGHT

TRAVEL RIGHT
PRESSURE

TRAVEL LEFT
SENSOR

BUCKET
SWING

BOOM
ARM
BACK PRESS.
PRESSURE

VALVE
SENSOR

ARM CONFLUX
P2 BYPASS
CUT VALVE

VALVE
PILOT SIGNAL PROCESS

COMMAND ARM VARIABLE

RECIRCULATION
CURRENT SOLENOID
PROPORTIONAL
VALVE
PSV-A

SECONDARY Pi PRESS. OF ARM IN

P2 PUMP PRESSURE

COMMAND P1 PUMP
CURRENT SOLENOID
PROPORTIONAL
VALVE
PSV-P1

P1 NEGATIVE CONTROL
DIFFERENTIAL PRESSURE

COMMAND P2 PUMP
CURRENT SOLENOID
PROPORTIONAL
VALVE
PSV-P2
MECHATRO
P2 NEGATIVE CONTROL
DIFFERENTIAL PRESSURE CONTROLLER

Variable recirculation control for light load arm in:

Recirculation control 6) The arm variable recirculation solenoid
1) If the arm in operation is performed, the proportional valve puts out the secondary pilot
secondary pilot pressure for the arm operation pressure according to the current command of
shifts the arm spool and is put into the low the mechatro controller and shifts the arm
pressure sensor. variable recirculation solenoid proportional valve.
2) When the arm spool is shifted, the negative 7) The pure hydraulic command shifts the arm
control pressure changes and is put into the main spool. Then a command from the
negative control pressure sensor. mechatro controller changes over the variable
3) The voltage output of the negative control recirculation solenoid proportional valves for the
pressure sensor is put into the mechatro P2 pump and the arm. This allows the oil
controller, processes the negative control signal returned from the arm cylinder rod to be
and puts out a current command to the P2 recirculated to the oil delivered by the pump.
pump solenoid proportional valve according to
the voltage input.  Recirculation cut control
4) The P2 pump solenoid proportional valve puts 1) If the P2 pump pressure rises above a certain
out the secondary pilot pressure according to level during arm in operation, the mechatro
the current command from the mechatro controller sensing the voltage output of the high
controller and changes the delivery rate of the pressure sensor processes the pilot signal and
P2 pump. puts out a reduced current command to the arm
5) The voltage output of the arm in low pressure variable recirculation solenoid proportional valve.
sensor is put into the mechatro controller, 2) The arm variable recirculation solenoid
processes the pilot signal, and puts out a proportional valve is shifted to the recirculation
current command to the variable recirculation cut position as the secondary pilot pressure
solenoid proportional valve according to the falls according to the current command level of
voltage input. the mechatro controller.

5
1.6 ARM IN ANTI-CAVITATION CONTROL

RECIRCULATION VALVE

BOOM CONFLUX
P2 NEGATIVE

P1 BYPASS
CUT VALVE
CONTROL
PRESSURE

ARM VARIABLE
P2 NEGATIVE CONTROL
SENSOR

P1 NEGATIVE CONTROL
PILOT P1 NEGATIVE
VALVE CONTROL

VALVE

TRAVEL RIGHT
TRAVEL STRAIGHT
TRAVEL LEFT
PRESSURE
SENSOR

BUCKET
SWING

BOOM
ARM
BACK PRESS.
PRESSURE

VALVE
SENSOR

ARM CONFLUX
P2 BYPASS
CUT VALVE

VALVE
ACCEL POTENTIO

PILOT SIGNAL PROCESS

COMMAND ARM VARIABLE

RECIRCULATION
CURRENT SOLENOID
PROPORTIONAL
VALVE
PSV-A

E/G SPEED

ARM IN PILOT

COMMAND P2 PUMP
CURRENT SOLENOID
PROPORTIONAL
VALVE
PSV-P2

NEGATIVE CONTROL MECHATRO

DIFFERENTIAL PRESSURE
CONTROLLER

Arm in anti- cavitation control

1) If the arm in is operated, the secondary pilot 4) The mechatro controller processes the pilot
pressure for arm operation switches the arm signal according to the output of the negative
spool and arm in is put into the low pressure control pressure sensor and puts out a
sensor. command to the P2 pump solenoid proportional
2) An engine speed command put out from the valve.
acceleration potentiometer is put into the 5) Cavitation may be prevented even if the engine
mechatro controller. revolution is low.
3) The mechatro controller processes pilot signals
from the engine revolution command and the
voltage output of the low pressure sensor and
puts out a current command to the variable
recirculation proportional valve accordingly.

6
1.7 ARM OUT CONFLUX CONTROL

BOOM CONFLUX
RECIRCULATION VALVE
P2 NEGATIVE

P1 BYPASS
CUT VALVE
CONTROL

ARM VARIABLE
PRESSURE

P2 NEGATIVE CONTROL
SENSOR

P1 NEGATIVE CONTROL
PILOT P1 NEGATIVE

VALVE
VALVE CONTROL

TRAVEL RIGHT
TRAVEL STRAIGHT
TRAVEL LEFT
PRESSURE
SENSOR

BUCKET
SWING

BOOM
ARM
BACK PRESS.
PRESSURE

VALVE
SENSOR

ARM CONFLUX
P2 BYPASS
CUT VALVE

VALVE
LOW
PRESSURE
SENSOR PILOT SIGNAL PROCESS

COMMAND P1 BYPASS CUT

CURRENT SOLENOID
PROPORTIONAL
VALVE
PSV-D

SECONDARY PILOT PRESS. OF ARM OUT

COMMAND P1 PUMP
CURRENT SOLENOID
PROPORTIONAL
VALVE
PSV-P1

P1 NEGATIVE CONTROL
DIFFERENTIAL PRESSURE

COMMAND P2 PUMP
CURRENT SOLENOID
PROPORTIONAL
VALVE
PSV-P2

P2 NEGATIVE CONTROL MECHATRO

DIFFERENTIAL PRESSURE
CONTROLLER

Arm out conflux

1) Start arm out operation simultaneously, and 3) The P1 bypass cut solenoid proportional valve
arm operation pilot pressure switches arm puts out the secondary pilot pressure according
spool, arm conflux spool and is input into low to the current command from the mechatro
pressure sensor. controller and changes over the P1 bypass cut
2) The voltage output of the low pressure sensor valve of the control valve.
enters the mechatro controller. The controller 4) If the P1 bypass cut valve is changed over, the
processes the pilot signal and puts out a oil delivered by the P1 pump is combined with
current command to the proportional valve for the arm line during arm operation.
the P1 bypass cut valve according to the
voltage input.

7
1.8 TRAVEL STRAIGHT CONTROL

P2

BOOM CONFLUX
RECIRCULATION VALVE
NEGATIVE
CONTROL

P1 BYPASS
CUT VALVE
P2 SIDE P1 SIDE PRESSURE

ARM VARIABLE
(LEFT) (RIGHT) SENSOR

P2 NEGATIVE CONTROL

P1 NEGATIVE CONTROL
P1
PILOT NEGATIVE

VALVE
VALVE CONTROL

TRAVEL STRAIGHT

TRAVEL RIGHT
PRESSURE

TRAVEL LEFT
SENSOR

BUCKET
SWING

BOOM
ARM
PILOT VALVE BACK
FOR TRAVEL PRESS.
STRAIGHT PRESSURE

VALVE
SENSOR
(LEFT) (RIGHT)

ARM CONFLUX
P2 BYPASS
CUT VALVE

VALVE
PILOT SIGNAL PROCESS

COMMAND TRAVEL STRAIGHT

CURRENT SOLENOID
PROPORTIONAL
VALVE
PSV-C

SECONDARY PRESS. OF PILOT

COMMAND P2 BYPASS CUT

CURRENT SOLENOID
PROPORTIONAL
VALVE
PSV-D

SECONDARY PILOT PRESS.

OF P2 SIDE ATT & TRAVEL LEFT

COMMAND P2 BYPASS CUT

CURRENT SOLENOID
PROPORTIONAL
VALVE
PSV-B

SECONDARY PILOT PRESS. MECHATRO

OF P1 SIDE ATT & TRAVEL RIGHT
CONTROLLER

TRAVEL STRAIGHT Command to travel straight solenoid proportional

1) Start ATTs work operations (boom, arm, valve:
bucket, swing) in travel operation (right and The secondary pressure of the solenoid
left), and the pilot pressure switches respective proportional valve is put out according to the
spools, and is input into respective low higher of the pilot pressure during ATT
pressure sensors. operation and the travel pilot pressure.
2) If mechatro controller receives the input P1 cut solenoid proportional valve command:
satisfying the following combination shown in The higher of the pilot pressure during the P2
Table, the controller determines it as travel section ATT operation (arm and swing) and the
straight, and the travel straight signal turns on. left travel pilot pressure is put out as the select
3) After the travel straight signal has turned on, pressure.
the signal is input to respective proportional P2 cut solenoid proportional valve command:
valve corresponding to the following The higher of the pilot pressure during the P1
commands. section ATT operation (boom and bucket) and
4) In the travel straight operation, the P1 pump the right travel pilot pressure is put out as the
actuates ATT, while the P2 pump actuates the select pressure.
travel system. Boom Bucket Arm Swing
Right travel ○ ○ ― ―
Left travel ― ― ○ ○
Both travel ○ ○ ○ ○

8
1.9 −1 SWING PRIORITY CONTROL
OCEANIA, ASIA

P2 NEGATIVE

BOOM CONFLUX
RECIRCULATION VALVE
CONTROL

P1 BYPASS
CUT VALVE
PRESSURE
SENSOR

ARM VARIABLE
P2 NEGATIVE CONTROL

P1 NEGATIVE CONTROL
PILOT P1 NEGATIVE

VALVE
VALVE CONTROL

TRAVEL RIGHT
TRAVEL LEFT

TRAVEL STRAIGHT
PRESSURE
SENSOR

BUCKET
SWING

BOOM
BACK

ARM
PRESS.
PRESSURE

VALVE
SENSOR

ARM CONFLUX
P2 BYPASS
CUT VALVE

VALVE
PILOT SIGNAL PROCESS
LOW
PRESSURE
SENSOR

ARM IN PILOT PRESSURE

COMMAND ARM VARIABLE

RECIRCULATION
CURRENT SOLENOID
PROPORTIONAL
VALVE
PSV-A

SWING PILOT PRESSURE

COMMAND P2 PUMP
CURRENT SOLENOID
PROPORTIONAL
VALVE
PSV-P2

NEGATIVE CONTROL MECHATRO

DIFFERENTIAL PRESSURE
CONTROLLER

Swing priority
1) If swing operation is performed during arm in 3) The arm variable recirculation solenoid
(or arm in is performed during swing), the proportional valve puts out the secondary pilot
secondary pilot pressure for arm operation pressure according to the current command
switches the arm spool. The pressure is also from the mechatro controller and changes over
put into the low pressure sensor. The the arm variable recirculation valve.
secondary pilot pressure for swing operation 4) If the arm variable recirculation valve is
switches the swing spool and is put into the low changed over, the recirculation circuit from the
pressure sensor. rod (R) side to the head (H) side of the arm
2) If the voltage output of the low pressure sensor cylinder is restricted.
is put into the mechatro controller. 5) This action increases the pressure of the arm
The controller processes the pilot signal and rod (R) as well as the operating pressure on the
puts out a current command to the variable head (H) side. Since the arm and the swing
proportional valve according to the voltage system circuits are connected in parallel to
input. each other, the delivery rate of the P2 pump is
used preferentially to operate the swing system,
while the arm system is operated by
recirculated oil.

9
1.9-2 SWING PRIORITY CONTROL
EU

P2 NEGATIVE

BOOM CONFLUX
RECIRCULATION VALVE
CONTROL

P1 BYPASS
CUT VALVE
PRESSURE
SENSOR

ARM VARIABLE
P2 NEGATIVE CONTROL

P1 NEGATIVE CONTROL
PILOT

VALVE
VALVE

TRAVEL RIGHT
TRAVEL LEFT

TRAVEL STRAIGHT

BUCKET
SWING

BOOM
BACK

ARM
PRESS.
PRESSURE

VALVE
SENSOR

ARM CONFLUX
P2 BYPASS
CUT VALVE

P1 OPT.
VALVE
P1 NEGATIVE
CONTROL
PILOT SIGNAL PROCESS PRESSURE
LOW
PRESSURE SENSOR
SENSOR P1 BYPASS CUT
SOLENOID
PROPORTIONAL
VALVE
PSV-D

ARM IN PILOT PRESSURE

COMMAND ARM VARIABLE

RECIRCULATION
CURRENT SOLENOID
PROPORTIONAL
VALVE
PSV-A

SWING PILOT PRESSURE

COMMAND P2 PUMP
CURRENT SOLENOID
PROPORTIONAL
VALVE
PSV-P2

NEGATIVE CONTROL
DIFFERENTIAL PRESSURE

COMMAND SWING
CURRENT PRIORITY
PROPORTIONAL
SOLENOID
PSV-H
MECHATRO
CONTROLLER

Swing priority
1) If swing operation is performed during arm in 3) The swing priority solenoid proportional valve
(or arm in is performed during swing), the outputs pilot secondary pressure corresponding
secondary pilot pressure for arm operation to command current and switches the option
switches the arm spool. The pressure is also valve on P1 side which is swing conflux valve.
put into the low pressure sensor. The 4) Concurrently, P1 bypass cut solenoid
secondary pilot pressure for swing operation proportional valve outputs pilot secondary
switches the swing spool and is put into the low pressure corresponding to command current
pressure sensor. output by mechatro controller, and switches P1
2) The low pressure sensor output voltage for arm bypass cut valve.
in and swing operations is input into mechatro 5) With this operation, the pressure oil from P1
controller, and the mechatro controller executes pump flows into SG port on the upper stream of
pilot signal processing. After judging the arm in swing spool, and raises the flow rate for swing
and swing operations are concurrently carried operation resulting in the speeding up of swing
out, the mechatro controller outputs command operation. Consequently the swing operating
current corresponding to the input voltage of speed with the arm in operating speed is
swing low pressure sensor to swing priority relatively raised, that is, become in swing
solenoid proportional valve PSV-H and P1 priority condition.
bypass cut solenoid proportional valve.
10
 2. MECHATRO CONTROLLER
2.1 SUMMARY OF MECHATRO CONTROLLER
Electro-hydraulic conversion information is displayed on the multi display of the gauge cluster.
However, the mechatro display and the cumulative engine oil lubrication time may be changed over if
the screen change switch is pressed.

SAFETY LOCK GAUGE CLUSTER

RIGHT HAND OPERATOR

CONTROL LEVER
(WITH POWER BOOST SW.)

SWITCH PANEL
(WORK MODE SELECT

BUZZER STOP)

ACCEL DIAL

STARTER SWITCH

AT BACKUP
E/G CONTROL CABLE

SWING PARKING BRAKE RELEASE SWITCH

KPSS WORK MODE RELEASE SWITCH

GAUGE CLUSTER

WORK MODE DISPLAY SWITCH PANEL

Work mode select switch functions

Work mode select MAB
 Display item roll forwarded in trouble
history indication
 Cumulative hours from engine oil change
display up
 Flow rate display up in the B
LCD DISPLAY (breaker) mode

AIR CLEANER Buzzer stop switch functions

Stops the warning sounding
 Service diagnosis display item down
 Display item rollbacked in trouble history
indication
 Cumulative hours from engine oil change
display down
 Flow rate display down in the B
SCREEN CHANGE SWITCH
 SERVICE DIAGNOSIS DISPLAY ITEM UP
(breaker) mode

11
(1) Display on LCD by the work mode switch

Work mode Pattern System summary

A (Assist) mode ① The system recognizes the operator’s action, automatically
Digging adjusts the machine into four patterns shown on the left
Ditch digging and causes the mode to flash.
Trench box digging
② The below controls are performed as the result of
Leveling judgment.
Slope finishing • Engine revolution control
• Pump control
③ • Arm variable recirculation control
Spreading • Boom conflux control

④
Tamping

⑤ • In all modes(standby and travel)

OK Others

M (manual) mode Display lamp The mode is suited for heavy load work in which operating
MON lever actions are recognized sensitively and the machine is
operated at high speed with its priority laid on the rate of
operation.
B (breaker) mode Display lamp Where the breaker and other require a limit to the max..
BON flow rate
• Operation in flow adjust mode
1) After the engine stops, turn the starter switch to
ON
and the mode switch to “B” and turn the screen change
switch to
ON for 3-10 sec. Then the adjust mode is
available.
2) When the engine starts, 210/min. is indicated in the
primary stage. After that, the previous value is
indicated. The value increases by 10/min. each time
the mode switch is pushed one time and decreases by
30/min. each time the buzzer stop switch is pressed.
3) To release the adjust mode, turn the screen select
switch to
ON again.

(2) Display on LCD by the screen change switch

The engine revolution and the cumulative hours from the engine oil change are indicated.

LCD display Operating procedure Buzzer sound

MONITOR
SYSTEM OK 1515 RPM

Normal
None
display
256Hr. AFT E/G OIL CH

Supplementary explanation :
If the screen change switch is pressed, the above three
screen may be changed over.

12
The functions displayed on the multidisplay are classified roughly into the following 8 types.
※ 1. CPU error display.............................................Display the error of the mechatro controller, etc.
※ 2. Self-diagnosis display ......................................Displays the failure of the I/O system of the mechatro
controller such as the low pressure sensor, governor
motor, proportional valve, solenoid valve, etc. (33 items)
3. Service diagnosis display.................................Displays the information output by the mechatro controller
such as the pressure sensor detection, proportional valve,
solenoid valve, etc. (25 items)
4. Trouble history display ....................................Stores and displays the contents of the troubles
detected through the mechatro self diagnosis.
5. Mechatro A adjustment display........................Displays it by procedure during the mechatro A
adjustment.
6. E/G oil supply cumulative (integrated) time ....Displays the E/G oil supply cumulative time and E/G
speed (rpm) list.
7. Warning displays .............................................In case the self diagnosis (※) is normal but the machine
is faulty, or if the machine condition must be notified to
the operator, the below items are indicated each time it
is necessary.
8. Auto warming function .....................................If the key is turned ON with the WARM switch on, Auto
Warming of E/G and hydraulic oil are displayed.
Warning displays item

1 MECHATRO 12 LOW ! The buzzer sounds on display # 2, #3,

CPU CONT. FAIL FUEL LEVEL #5, #6, #7 and #28 .
Supplementary explanation

2 SWING PARKING 13 LOW HYD In the case of #5 and #6, the buzzer is
DISENGAGED OIL LEVEL not stopped even if the buzzer stop
switch is pushed.
3 KPSS 14 LOW E/G In the case of #7, the buzzer is stopped if
DISENGAGED COOL LEVEL the buzzer stop switch is pressed.
In the case of #2, #3, and #28, the
4 E/G 15 LOW E/G buzzer stops five seconds later
PREHEAT OIL LEVEL automatically.
FINISH 19 POWER
PREHEAT BOOST ON
6 LOW E/G 21 WARM
OIL PRESS WARMING UP
7 HIGH E/G 28
WARM FINISH
COOL TEMP
9 REST’D AIR 29 CHANGE
CLEANER E/G OIL
11 CHARGING
PROBLEM

13
2.2 SELF DIAGNOSIS DISPLAY FUNCTION
(1) Summary
It performs self diagnosis of control inputs and outputs of pressure sensors and proportional valves
while the machine is in operation. Errors coming out of the self diagnosis are displayed on the multi
display of the gauge cluster. Regarding the connector numbers and the pin numbers, refer to the C-1
Mechatro Controller which appears later. Wire numbers and colors may be confirmed on the electric
circuit diagram or on the harnesses diagram.
(2) I/O configuration
INPUT
SERIAL COMMUNICATION
Pressure sensor
Gauge cluster
Proportional valve

Control
(Buzzer alarm)
Selector valve (SOL)
Governor motor
Battery relay

(3) Self diagnosis display item

No. Contents Display of monitor No. Contents B-15 Display of monitor

Mechatro controller 1. MECHATRO Back pressure sensor BACK
1
fail CPU CONT. FAIL 18 fail SE PRESS
Gauge cluster→Mechatro I-1 RECEIVE P1 pump pressure C-1 PUMP P1
2 controller communication 19 sensor fail
failure ERROR PSV SENSOR
I-2 BAT. P2 pump pressure C-2 PUMP P2
3 Battery relay fail 20 PSV SENSOR
RELAY sensor fail
A-1 ROM DATA P1 bypass cut D-1 P1 BYPASS
4 ROM data CPU FAILURE
21
propo-valve fail PSV PROPO－VALVE
A-2 MECHATRO P2 bypass cut D-2 P2 BYPASS
5 Mechatro set error B-1 CPU SET ERROR
22
propo-valve fail PSV PROPO－VALVE
Boom raising pressue BOOM RAISE Travel priority D-3 TRAVEL
6
sensor fail B-2 SE SENSOR
23
propo-valve fail PSV PROPO－VALVE
Arm variable
7
Boom lowering pressue B-3 SE BOOM LOWER
24 recirculation
D-6 RECIRCULAT
sensor fail SENSOR PSV PROPO－VALVE
propo-valve fail
Arm in pressure B-4 ARM IN P1 pump pressure E-1 PUMP P1
8
sensor fail SE SENSOR
25
sensor fail PSV PROPO－VALVE
Arm out pressure B-5 ARM OUT P2 pump pressure E-2 PUMP P2
9
sensor fail SE SENSOR
26
sensor fail PSV PROPO－VALVE
Bucket digging pressure B-6 BUCKET DIG Power up solenoid valve F-1 POWER BOOST
10 sensor fail SE SENSOR
27
fail SV SOLENOID
B-7 BUCKET
DUNPSE
Bucket dump pressure F-3 TWO-SPEED
11 28 Travel 2-speed solenoid SV SOLENOID
sensor fail valve fail
B-8 SENSER
Swing right pressure SWING (R) Swing parking solenoid F-2 SWING BRAKE
12
sensor fail B-9
SE SENSOR
29
valve fail SV SOLENOID
Swing left pressure SWING (L) Governor motor current G-1 STEP MOTOR
13
sensor fail B-10 SE SENSOR
30
fail M CURRENT-NG
Travel right pressure TRAVEL (R) Governor motor starting G-2 STEP MOTOR
14
sensor fail B-11 SE SENSOR
31
point indexing fail M S/PT. ERROR
Travel left pressure TRAVEL (L) G-3 E/G REV.
15
sensor fail B-12 SE SENSOR
32 E/G speed sensor fail
RPM SENSOR
P1 negative control P1 NEGA-CON Accel potentio meter H-1 POT ACCELERATR
16
pressure sensor fail SE SENSOR 33
fail POTENTIO
P2 negative control P2 NEGA-CON
17
pressure sensor fail SE SENSOR

14
2.3 SERVICE DIAGNOSIS
The present service diagnosis in 25 items is displayed on the multidisplay according to the data received
from the mechatro controller.
How to display
1) Keep the buzzer stop switch pressing, turn the starter switch “ON” and starts the engine.
2) The 1st item Parts No. of Mechatro controller and the program version are displayed.
(Example)
EU OCEANIA ASIA
No.1 No.1 No.1
MAIN CONTROLLER P/No. MAIN CONTROLLER P/No. MAIN CONTROLLER P/No.
YN22E00069F2 YN22E00037F2 YN22E00037F2
PROGRAM VERSION PROGRAM VERSION PROGRAM VERSION
VER 5.00 VER 9.00 VER 9.00

3) Each time the screen change switch on the gauge cluster

Multidisplay
is pressed, the number runs like No.2, No.3 ... in order.
4) Each time the buzzer stop switch on the switch panel is
pressed, the number returns like No.25, No.24 ... in order.
Buzzer stop SW.

5) After service diagnosis No.2, release the auto accel function.

6) The display disappears only when the starter switch is turned OFF. Screen change SW.

Note : The scrolling of service diagnosis to see the variation by the work mode with
the work mode selector switch may cause the change of the mode, so use
the screen change switch on the gauge cluster for scrolling.
7) After completion of service diagnosis, restore the auto accel function.

Service diagnosis indication

No. DISPLAY REMARKS No. DISPLAY REMARKS
No.1 No.6
MAIN CONT.P/No. SOL. VALVE
YN22E000△△△△ P/No. indication F－ 3 1/2-TRAVEL
1 PROGRAM VER
VER △ .△ △
Version indication 6 COMP.
MEAS.
SWITCH
OFF
OFF
OFF
ON/OFF indication
ON/OFF indication
ON/OFF indication

No.2 No.7
E/G SET 2200 No load set rpm SOL. VALVE
MEAS 2050 Actual rpm F－ 1 POWEU RP
2 E/G PRS. LIVE LIVE/DEAD indication 7 COMP. OFF ON/OFF indication
KPSS SW M A / M / B indication MEAS. OFF ON/OFF indication
SWITCH OFF ON/OFF indication

No.3 No.8
H－ 1 RELAY
ACCEL VOLT. 4.9V Potentio voltage I－ 2 BATR
. ELAY Sensor voltage /
3 POS. 100% Voltage position 8 COMP. ON Pressure converted value
MOTOR STEP 420 No of motor steps MEAS. ON Sensor voltage /
POS. 100% Step position KEY SWITCH ON Pressure converted value

No.4 No.9
GOVERNOR MOTOR PRESS. SENSOR
G－ 1 COIL A 1.0A A phase current B－ 1 BOOM RAISE Sensor voltage /
4 G－ 1 COIL B 1.0A B phase current 9 4.5V 30k Pressure converted value
G－ 2 LIMIT OFF ON/OFF indication B－ 2 BOOM LOWER Sensor voltage /
4.5V 30k Pressure converted value

No.5 No.10
SOL. VALVE PRESS. SENSOR
F－ 2 SWING-BRAKE B－ 3 ARM OUT Sensor voltage /
5 COMP. ON ON/OFF indication 10 4.5V 30k Pressure converted value
MEAS. ON ON/OFF indication B－ 4 ARM IN Sensor voltage /
RELEASE SW OFF ON/OFF indication 4.5V 30k Pressure converted value

Note : The examples of displays are in the M mode with the engine at Hi and with the operating lever to full stroke.

15
No. DISPLAY REMARKS No. DISPLAY REMARKS
No.11 No.21
PRESS. SENSOR PROPO-VALVE
B－5 BUCKET DIG Sensor voltage / D－2 P2 CUT Command current /
11 4.5V 30k Pressure converted value
19 COMP. 647mA 25k Pressure converted value
B－6 BUCKET DUNP Sensor voltage / MEAS. 642mA 25k Feedback current /
45V 30k Pressure converted value Pressure converted value
No.12 No.22
PRESS. SENSOR PROPO-VALVE
B－7 SWING (R) Sensor voltage / D－3 S-TRAVEL Command current /
12 4.5V 30k Pressure converted value 20 COMP. 647mA 25k Pressure converted value
B－8 SWING (L) Sensor voltage / MEAS. 642mA 25k Feedback current /
4.5V 30k Pressure converted value Pressure converted value

No.13 No.23
PRESS. SENSOR PROPO-VALVE
B－9 TRAVEL (R) Sensor voltage / D－6 A-RECIRCULAT Command current /
13 4.5V 30k Pressure converted value 21 COMP. 409mA 10k Pressure converted value
B－10 TRAVEL (L) Sensor voltage / MEAS. 404mA 10k Feedback current /
4.5V 30k Pressure converted value Pressure converted value

No.14 No.24
PRESS. SENSOR PROPO-VALVE
C－1 PUMP P1 Sensor voltage / E－1 P1 PUMP Command current /
14 3.3V 350k Pressure converted value 22 COMP. 600mA 45k Pressure converted value
C－2 PUMP P2 Sensor voltage / MEAS. 600mA 45k Feedback current /
3.3V 350k Pressure converted value POWER SHIFT 0mA Pressure converted value

No.15 No.25
PRESS. SENSOR PROPO-VALVE
B－16 P1 OPT. Sensor voltage / E－2 P2 PUMP Command current /
15 4.5V 30k Pressure converted value 23 COMP. 600mA 45k Pressure converted value
B－17 P2 OPT. Sensor voltage / MEAS. 600mA 45k Feedback current /
4.5V 30k Pressure converted value POWER SHIFT 0mA Pressure converted value

No.16 No.39
PRESS. SENSOR MECHATRO ADJT.
B－16 P1 NEGATIVE Sensor voltage / CONT. SW TEST RUN/TEST indication
CONTROL Pressure converted value CONT. VOL 50% Inner trimmer
16 2.0V 19k 24 PROG. SW OFF ON/OFF indication
B－17 P2 NEGATIVE Sensor voltage /
CONTROL Pressure converted value
2.0V 19k
No.19 No.40
PROPO-VALVE RELEASE SW
B－15 BACK PRESS. Sensor voltage / KPSS OFF ON/OFF indication
17 0.7V 2k Pressure converted value 25 SWING BRAKE OFF ON/OFF indication
(Arm out, No load)

No.20
PROPO-VALVE
D－3 P1 CUT Command current /
18 COMP. 647mA 25k Pressure converted value
MEAS. 642mA 25k Feedback current /
Pressure converted value

16
2.4 TROUBLE HISTORY DIAGNOSIS (2) How to cancel the contents of the trouble
The error item detected by the self-diagnosis is history
stored in the mechatro controller as a history and 1) Display the trouble history mode.
is displayed on the multidisplay. 2) Press the work mode select switch and the
buzzer stop switch for 10 seconds or more
(1) How to display concurrently.
1) Turn the starter switch
ON. 3) When the erasing is completed, the “NO
2) Press the buzzer stop switch 5 times in ERROR” is displayed.
sequence for 10 seconds. 4) Turn the starter switchOFF.
(Example)
Note :
CONTENTS DISPLAY
All the stored items are erased.
No errors NO ERROR It is impossible to erase data partially.
00025H
Error detected in B-10 TRAVEL LEFT (3) Contents of the trouble history
the past D-2 P2 BYPASS CUT Symbol Display
F-3 TRAVEL 1.2-SPEED Controller A1 ROM DATA FAILURE
A relation
A2 MECHATRO SET ERROR
3) Transmits the error data (one or many) and B1 BOOM RAISE SENSOR
hour meter to the gauge cluster. B2 BOOM LOWER SENSOR
z Hour meter and 3 error data are displayed
B3 ARM OUT SENSOR
B4 ARM IN SENSOR
on the screen. B5 BUCKET DIG SENSOR
z If three error data or more exist, display the
B6 BUCKET DUMP SENSOR
data three by three in order for every 5 Low pressure
B sensor B7 SWING (R) SENSOR
seconds. B8 SWING (L) SENSOR
4) Scrolling pages (Item number) B9 TRAVEL (R) SENSOR
z The item number increases each time the
B10 TRAVEL (L) SENSOR
B11 P1 NEGA-CON SENSOR
work mode select switch is pushed. B12 P2 NEGA-CON SENSOR
z The item number decreases each time the
B15 BACK PRESS SENSOR
buzzer stop switch is pushed. High pressure
C1 PUMP P1 SENSOR
C sensor
(Hydraulic pump)
C2 PUMP P2 SENSOR
Note :
D1 P1 BYPASS PROPO-VALV
The system stores all error items at each hour meter
D2 P2 BYPASS PROPO-
reading. To check error items at different hour meter Proportional VALV
readings, push the work mode change switch or the D valve D3 TRAVEL PROPO-VALV
buzzer stop switch. (Control valve) D6 RECIRCULAT PROPO-VALV
D8 ARM IN PROPO-VALV
D10 OFFSET (L) PROPO-VALV
5) To erase the display, turn the starter switch
Portional valve E1 PUMP P1 PORPO-VALV
toOFF. E
(Hydraulic pump) E2 PUMP P2 PORPO-VALV
F1 POWER BOOST SOLENOID
F Solenoid valve F2 SWING BRAKE SOLENOID
F3 TWO-SPEED SOLENOID
G1 STEP MOTOR CURRENT-NG
G E/G Accessory G2 STEP MOTOR S/PT. ERROR
G3 E/G REV. SENSOR
Potentio
H relation H1 ACCELERATR POTENTIO

I1 RECEIVE ERROR

I
I2 BAT. RELAY
MONITOR SYSTEM OK

17
2.5 HOW TO CORRECT THE ENGINE OIL SUPPLY CUMULATIVE TIME :
(1) Displaying the engine revolution and the cumulative time. (Refer to “the display on LCD by the
screen change switch.”)

(2) How to correct

Proce-
dure Operating procedure Display on multidisplay

MONITOR
A Turn the starter switch “ON”. is displayed.
SYSTEM OK

Press the gauge cluster screen change MONITOR Press once E/G SPEED IS
B switch once, and the E/G speed (rpm) is SYSTEM OK DISPLAYED

displayed.

Press once more, and the engine oil supply E/G SPEED IS 100Hr AFT
C DISPLAYED E/G OIL CH
cumulative time screen is displayed.

Press the screen change switch and release

100Hr AFT MONITOR 100Hr AFT
D in the range of 5 to 10 seconds, it returns to
E/G OIL CH SYSTEM OK E/G OIL CH
the correction mode.

Press the work mode selector switch, and the 100Hr AFT Cumulative time 101Hr AFT
E E/G OIL CH increases E/G OIL CH
cumulative time increases. (once 1Hr)

Press the buzzer stop switch and the 100Hr AFT The cumulative 99Hr AFT
F time decreases
cumulative time decreases. (once 1Hr) E/G OIL CH E/G OIL CH

Press the gauge cluster screen change

switch once the correcting time is stored, 99Hr AFT Complete the MONITOR
E/G OIL CH correction SYSTEM OK
G and exits from the correction mode and OK
symbol is displayed to complete the
correction.
Note :
Press the screen change switch once after the procedure D, and the condition is stored and the correction is
completed.

18
NOTES

19
2.6 MECHATRO CONTROL EQUIPMENT
(1) C－1 Mechatro controller 10 2 1 6 2 1 4 2 18 2 1
1) Outside view 16
26
34
27 22 18 16 12 28 22
WINDOW CN11 CN12 CN13 CN14
FOR
ADJUST 13 2 18 2 1 11 2 1 CN18
ROM REWRITE COUPLER

26 14 16 9 22 12
CN15 CN16 CN17 ADJUSTMENT SWITCH

Connec- Pin Port In/out

tor No. No. name Specification put Signal level
1 G
2 A12 P1 pump pressure sensor IN 0.5～4.5V
3 +5V
Connec- Pin Port In/out 4 +5V
tor No. No. name Specification put Signal level
5 A13 P2 pump pressure sensor IN 0.5～4.5V
1 G 6 G
2 A1 Boom raise pressure sensor IN 0.5～4.5V 7 G
3 +5V P1 negative control
8 A14 pressure sensor IN 0.5～4.5V
4 +5V 9 +5V
Boom lower pressure
5 A2 sensor IN 0.5～4.5V 10 +5V
6 G P2 negative control
11 A15 pressure sensor IN 0.5～4.5V
7 G CN12 12 G
8 A3 Arm in pressure senor IN 0.5～4.5V 13 A16 Alternator voltage IN 0～36V
9 +5V Signal for maintenance (Released
14 A17 when the continuity is released) IN GND / OPEN
10 +5V
15 B2 Key switch(ON) ON/OFF IN +24V / OPEN
11 A4 Arm out pressure sensor IN 0.5～4.5V
16 B3 Key switch(GLOW) ON/OFF IN +24V / OPEN
12 G
17 B4 Travel 1.2 speed switch ON/OFF IN GND / OPEN
13 G Swing parking release switch
Bucket digging pressure 18 B5 IN 17Ω/ OPEN
14 A5 sensor IN 0.5～4.5V Release/Normal
KPSS rerease switch
15 +5V 19 B6 Release/Normal IN ～12V / 12V～
16 +5V 20 E1 IN 3.0～20Vp-p
Bucket dump pressure Engine revolution sensor
17 A6 sensor IN 0.5～4.5V 21 E1´
CN11 18 G 22 SHG Shield grounding
19 G 1 G
Swing right pressure
20 A7 sensor IN 0.5～4.5V 2 A18 Opt. P2 Pressure sensor IN 0.5～4.5V
21 +5V 3 +5V
22 +5V 4 +5V
23 A8 Swing left pressure sensor IN 0.5～4.5V 5 A19 Opt. P1 Pressure sensor IN 0.5～4.5V
24 G 6 G
25 G 7 G
Travel right pressure 〔Boom (R) pressure
26 A9 sensor IN 0.5～4.5V 8 A20 IN 0.5～4.5V
27 +5V CN13 sensor〕
9 +5V
28 +5V 10 +5V
29 A10 Travel left pressure sensor IN 0.5～4.5V 〔Boom (H) pressure
11 A21 IN 0.5～4.5V
30 G sensor〕
12 G
31 G 13 G
32 A11 Accel potentio IN 0～5.0V 14 A22 Back press. pressure sensor IN 0.5～4.5V
33 +5V 15 +5V
Accel motor starting point detection IN GND / OPEN
34 B1 LS starting Point/Reguler 16 B7 (High reach crane SW) ON/OFF IN GND / OPEN

20
Connec- Pin Port In/out Connec- Pin Port In/out
tor No. No. name Specification put Signal level tor No. No. name Specification put Signal level
Engine coolant high temp. LS 1 D7
1 B8 High/Normal IN GND / OPEN
Engine oil pressure low LS 2 D7´
2 B9 Without/With IN GND / OPEN
3 D8
Air filter clogged LS
3 B10 Clogged/Normal IN GND / OPEN 4 D8´
4 B11 5 D9
5 B12 E/G oil level SW. IN GND / OPEN 6 D9´
6 B13 E/G cool level SW. IN GND / OPEN 7 D10
7 B14 Hydraulic oil level SW. IN GND / OPEN 8 D10´
Fuel level thermistor CN16
8 B15 Low/Normal IN 670Ω/1140Ω 9 D11
9 B16 Wiper motor rise up(stop) IN GND / OPEN 10 D11´
10 Wiper motor rise 11 D12
B17 up(reverse) IN GND / OPEN
12 D12´
11 B18 Power boost SW. ON/OFF IN GND / OPEN
13 H1
12 C1 Wiper prevent spark relay OUT GND / OPEN
14 H1´
13 C2 Wiper motor relay(forward) OUT GND / OPEN
CN14 15 B26
14 C3 Wiper motor relay(reverse) OUT GND / OPEN
16 C22
15 C4 Washer motor relay Out/Stop OUT GND / OPEN
1 C15
16 C5 Front working light relay ON/OFF OUT GND / OPEN
2 C16 (Nibbler open relay) OUT GND / OPEN
17 C6 (Swing flasher & working light unit) OUT GND / OPEN (Swing flasher &
18 +5V 3 C17 working light unit) OUT GND / OPEN
(Swing flasher &
19 B19 IN GND / OPEN 4 C18 working light unit) OUT GND / OPEN
20 C7 OUT GND / OPEN 5 C19 (Nibbler close relay) OUT GND / OPEN
Switch assy mode
21 C8 OUT GND / OPEN 6 C20 (Travel alarm relay) OUT GND / OPEN
buzzer stop
22 C9 OUT GND / OPEN 7 C21 (Wiper/washer operation signal) OUT GND / OPEN
23 C10 OUT GND / OPEN 8 B20 Hydraulic oil temp SW. IN GND / OPEN
24 G 9 B21 (Travel alarm SW.) IN GND / OPEN
25 TXD1 IN/OUT 10 B22 (Swing flasher select switch) IN GND / OPEN
26 RXD1 Gauge cluster IN/OUT 11 B23 Lever lock SW. IN +24V / OPEN
CN17
27 G 12 B24 OUT GND / OPEN
28 SHG Shield earth 13 B25 IN GND / OPEN
1 F1 14 TXD2 IN/OUT
Accel motor A phase
2 F1´ 15 RXD2 IN/OUT

3 SHG Shield earth 16 G

4 D1 P1 bypass cut OUT 0～800mA 17 SHG
5 D1´ proportional valve D OUT 0～800mA 18 +5V (Boom potentio/Arm potentio)
6 D2 P2 bypass cut OUT 0～800mA 19 A23 (Boom potentio)
7 D2´ proportional valve B OUT 0～800mA 20 A24
8 D3 Travel straight OUT 0～800mA 21 A25 (Arm potentio)
9 D3´ proportional valve C OUT 0～800mA 22 G (Boom potentio/Arm potentio)

10 D4 Arm variable recirculation OUT 0～800mA 1 DL IN/OUT

proportional valve A
11 D4´ OUT 0～800mA 2 TXD3 IN/OUT
CN18 Handy checker
12 +24V 3 RXD3 IN/OUT
Power supply + 24V
13 +24V 4 G
CN15 14 +24V Battery back up
15 F2 OUT
Accel motor B phase Function in ( ) are optional specifications.
16 F2´ OUT
17 D5 P1 pump proportional OUT 0～800mA
18 D5´ valve OUT 0～800mA
19 D6 P2 pump proportional OUT 0～800mA
20 D6´ valve OUT 0～800mA
Travel 1,2-speed selector valve
21 C11 2 speed/1 speed OUT +24V / OPEN
Swing parking selector valve
22 C12 P /Release
◯ OUT +24V / OPEN
Power boost change valve
23 C13 ON/OFF OUT +24V / OPEN
24 C14 Battery relay Operation/Stop OUT +24V / OPEN
25 G
Power supply (GND)
26 G

21
19
 (2) Gauge cluster (symbol C-2)
1) General view

GAUGE AND
DISPLAY LAMP

Multi-Lock Connector (NIPPON Amp)

HOUSING 174931-1
MULTI DISPLAY LCD Terminal 173645-3 (Gold Plating)
(LIQUID CRYSTAL
DISPLAY) CN21

SCREEN CHANGE
SWITCH

DRAIN HOLE

2) Connector CN21

No. Name Wire No. Name Wire

color color
1 Fuel sensor 5 GND
2 Engine coolant temp. sensor 6 Power supply (+24V)
3 RXD 2 (Serial communication) 7 GND
4 TXD 1 (Serial communication) 8 SHIELD

3) Function
① It processes signals by communication between the gauge cluster and the mechatro controller, displays
them in lamps, displays them in LCDs and actuates the buzzer.
② It puts out coolant temperature signals, fuel level signals and panel switch signals to the mechatro
controller through the communication port.

4) Display and summary of actuate item

No. Item name Type

1 Monitor display LCD dot 128×55
2 Gauge display (Coolant temp., Fuel level) Tolerance coil
3 Mode display (A・M・B) Lamp display (1.4W)
4 Warning buzzer Piezoelectric type
5 Screen change switch
For gauge Lamp (2W)
6 Back light
For SW, For LCD LED

22
(3) Switch assy (SW-2)

WORK MODE
SELECT SW.
BUZZER STOP SW.

GND

LIGHT (＋)

LIGHT (－)

CIRCUIT DIAGRAM

WORK MODE
SELECT SW. LIGHT (＋)

NO USE LIGHT (－)

BUZZER STOP SW. GND

(4) Governor motor(Symbol M－2)

NAME PLATE

CONNECTION DIAGRAM MOTOR CONNECTOR

LIMIT SWITCH CONNETOR
BROWN RED
(A) (B) LIMIT SWITCH MOTION RANGE

ORANGE YELLOW
(A) (B)
LIMIT SWITCH CONNECTOR WIRE TABLE MOTOR CONNECTOR WIRE TABLE

5 6 No. Lead color Connection 1 2 No. Lead color Connection

5 White COM 1 Brown A
6 Red NO 2 Orange A
7 Yellow NC 3 Red B
7 4 Yellow B
3 4
23
NOTES

24
 SECTION 3 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS

CHAPTER 22

E215
CRAWLER EXCAVATORS

HYDRAULIC SYSTEM

Issued January 2006

Book/Form Number 5-1640 NA
Copyright © 2006. CNH America, LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. S5PJ0010E01-KO22
 SECTION 3 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 22 - HYDRAULIC SYSTEM

CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring
any obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Remarks
First Edition 01-2006 E215 5-1640NA

22-II Issued 01-2006 Bur 5-1640 NA

 SECTION 3 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS

CHAPTER 22
HYDRAULIC SYSTEM
TABLE OF CONTENTS

A. Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
B. Hydraulic Circuits and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
C. Color Coding Standard for Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
D. Neurtral Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
1. Travel Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
2. Bucket Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
3. Boom Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
4. Boom Lower (Lower Attachment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13
5. Swing Circuit (Single Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15
6. Arm Digging Circuit (Light Load). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-17)
6. Arm Digging Circuit (Heavy Load) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-19
6. Arm Extension (Arm Out Circuit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21
7. Combined Circuit (Boom Raise and Travel Circuit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-23
8. Combined Arm In and Swing Circuit (Swing Priority) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-25
11. Option Hydraulic Circuit and Componenets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26-27
12. Pilot Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28-32
13. Main Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36-42

5-1640 NA Issued 01-2006 Bur 22-1

NOTES
 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 22 - HYDRAULIC SYSTEM

22.1 SUMMARY
22.1.1 FUNCTION AND FEATURES OF HYDRAULIC CIRCUIT
The hydraulic circuits are built with the following functions and features in order to achieve easy operation, safety
and high working efficiency.
Performance Device Function Features
• Travel Straight • Travel straight at combined operation
• Travel 2-speed change & auto first • 1-2 travel speed change and low
(low) speed return speed/high torque at heavy duty
• Auto parking brake • Automatic braking when parking
Travel
• Motor over run protection • Prevents over running of travel motor
on down hill slope
• Travel pilot operation • Prevents hunting by the built in travel
shockless mechanism
• Reverse rotation protective function • Easy positioning to protect from swing
back when swinging stops’
• Swing priority circuit (simultaneous • Stable swing speed, arm slanted
Easy Operability and Safety

Swing operation of arm - digging and swing leveling, swing press digging
motions)
• Automatic swing parking brake • Swing parking when operating on a
slope
• Hydraulic pilot control system • Light action with operating lever
• Timer operated pilot lock type • Shut off of pilot circuit one second after
safety lock lever is operated
Attachment
• Lock valve (boom/arm) • Protect boom and arm from
unexpected drop (natural fall)
• Multi-control valve (optional) • For operating patterns with single lever
• Pressurized hydraulic oil tank • Prevents dust from entering hydraulic
oil and promotes self suction ability of
pump
• Suction strainer • Removes dust on suction side
• Line filter; pilot circuit • Prevents pilot operating circuit from
Other
malfunctioning
• Return circuit • Prevents hydraulic oil from
contamination
• Cooling hydraulic oil by oil cooler • Prevents hydraulic oil from
deterioration
• Electric flow controlled variable • Pump delivery rate controlled by
displacement pump current command to solenoid
Mass handling capabilities

proportional valve of the variable

displacement pump
Pump • Negative flow rate control • Flow control by negative control
pressure and negative control back
pressure
• Back-up control • Backup control when solenoid
proportional valve of pump fails
• Boom raise conflux circuit • Speed up of boom raise operation
• Arm conflux circuit • Speed up of arm operation
Attachment
• Optimum operation by work mode • Efficient operation in all work modes
select (A,M,B)
• Auto acceleration • Reduce fuel consumption and noise by
Consumption

lowering engine speed when control

Micro-computer lever is in neutral position
Fuel

5-1640 NA Issued 01-2006 Bur 22-3

 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 22 - HYDRAULIC SYSTEM

Hydraulic Schematic Legend

Item Number Description
1 Main Hydraulic Pump
2 Main Control Valve
3 Swing Motor
4 Travel Motor Assembly
5 Boom Cylinders
6 Boom Cylinders
7 Arm Cylinder
8 Bucket Cylinder
9 Swivel Joint
Left hand pilot valve
10
Right hand pilot valve
11 Travel pilot valve
12 Oil Cooler
13 Pilot filter manifold
14 Accumulator
15 Suction strainer
16 8 Solenoid block
17 Return filter
18 Bypass check valve
19 Tank breather
20 Return check valve
21 Return check valve
22 One way check assembly
23 Independent travel bypass valve
24 Independent travel solenoid valve
25 Swing priority solenoid
30 Swing priority/Breaker option valve

22-4 Issued 01-2006 Bur 5-1640 NA

 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 22 - HYDRAULIC SYSTEM

22.1.2 FOLD OUTS (28)

5-1640 NA Issued 01-2006 Bur 22-5

 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 22 - HYDRAULIC SYSTEM

FOLD OUTS

22-6 Issued 01-2006 Bur 5-1640 NA

 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS

CHAPTER 23

E215
CRAWLER EXCAVATORS

ELECTRICAL SYSTEM

Issued January 2006

Book/Form Number 5-1650 NA
Copyright © 2006. CNH America, LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. S5PJ0010E01-KO22
 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 23 - HYDRAULIC SYSTEM

CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Remarks
First Edition 01-2006 E215 5-1650 NA

23-II Issued 01-2006 Bur 5-1650 NA

 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS

CHAPTER 23
ELECTRICAL SYSTEM
TABLE OF CONTENTS

1.0 Electric Circuit Diagram (A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-1

1.0 Electric Circuit Diagram (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-2
1.0 Electric Circuit Diagram (C). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-3
2.0 Electrical Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-4.1
2.1 Electrical Equipment List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-4.1
2.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E1-5
3.0 Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.1 Harness List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.2 Harness Connection Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.3 Controller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3.4 Instrument Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A
3.5 Upper Electrical Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
3.6 Upper Harness Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3.7 Engine Harness Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3.8 Upper Harness Assembly (Floor Plate). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
3.9 Cab Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
3.10 Cab Harness Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

5-1650 NA Issued 01-2006 Bur 23-1

 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 23 - ELECTRICAL SYSTEM

NOTES

23-2 Issued 01-2006 Bur 5-1650 NA

 SPECIFICATIONS FOR ELECTRICAL EQUIPMENT
HARNESS ASSEMBLY YQ07U0101~

ITEM PART NUMBER DESCRIPTION QTY ITEM PART NUMBER DESCRIPTION QTY
HARNESS ASSY C3 YN13E01097P1 CABLE 1
C4 LB13E01020D1 CABLE 1
C5 YN13E01098P1 CABLE 1
YN13E00034F1 UPPER HARNESS ASSY C6 LE13E01006P1 HARNESS 1
(Floor Plate)
C7 ZW26X08000 LOCK WASHER 5
A1 YN13E01167P2 HARNESS 1 C8 ZN18C08007 NUT 4
A2 YN13E01156P1 HARNESS 1 C9 ZS18C08016 CAPSCREW 1
A3 YN13E01166P1 HARNESS 1 C10 LC13E01002D1 GROMMET 1
A4 ZW26X08000 LOCK WASHER 1 C11 PY01P01043D3 CLIP 2
A5 ZW16X08000 WASHER 1 C12 2432R233D2 CLIP 2
A6 ZN18C08007 NUT 1 C13 2420Z1330 GROMMET 1
A7 YN03E01001D5 CLIP 8 C14 2427Z1594D015 TRIM 1
A8 YN13E01190P1 GROMMET 1 C15 ZW16X08000 WASHER 1
A9 PY01P01043D3 CLIP 2 C16 2420R372D19 GROMMET 2
A10 LE13E01005P1 CABLE 1 C17 YN03E01001D5 CLIP 3
A11 YN13E01196P1 GROMMET 2
YN16E00009F1 ENGINE HARNESS ASSY
LB14E00003F1 CAB HARNESS ASSY
D1 YN16E01016P2 HARNESS 1
B1 LB14E01004P1 HARNESS 1 D2 YN16E01014P1 BRACKET 1
B2 YN03E01001D5 CLIP 6 D3 2432R233D2 CLIP 2
B3 ZS18C06016 CAPSCREW 1 D4 2432R233D1 CLIP 1
B4 2432R233D2 CLIP 1 D5 PY01P01043D3 CLIP 5
B5 ZW26X06000 LOCK WASHER 1 D6 2432R233D3 CLIP 7
B6 ZW16X06000 WASHER 1 D7 ZN18C10008 NUT 1
D8 ZN18C06005 NUT 2
D9 ZW26X10000 LOCK WASHER 1
YN13E00032F1 UPPER HARNESS ASSY D10 2420R608D1 SEMS-BOLT 1
D11 ZM66C06016 SEMS-BOLT 2
C1 YN13E01155P1 HARNESS 1 D12 ZM11C08016 SEMS-BOLT 3
C2 YN13E01053D2 CABLE 1 D13 ZM22C10020 SEMS-BOLT 1
D14 ZW26X06000 LOCK WASHER 3
D15 ZW16X10000 WASHER 2
D17 ZW26X08000 LOCK WASHER 1
D18 YN16E01012P1 BRACKET 1
D19 ZM22C10040 SEMS-BOLT 2
D20 2418T26637D1 SPACER 2
D21 ZS18C08016 CAPSCREW 1
D22 ZS18C06010 CAPSCREW 1
D23 ZW16X06000 WASHER 1

E1-4.7
NOTES
2.3 SPECIFICATION OF ELECTRIC EQIUPMENT
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

B 1 Type 115F51-N120

Voltage 12V
Battery
Capacity 5HR 96Ah
(Ah)
20HR 120Ah
2484U173
Weight 32kg (71 lbs)

Power

2484U174 Type 145F51 N150

Voltage 12V
Power
Capacity 5HR 112Ah
(Ah)
20HR 140Ah

Weight 35kg (77 lbs)

2484U175 Type 170F51 N250-12

Voltage 12V
Power
Capacity 5HR 120Ah
(Ah)
20HR 150Ah 502L 180W 255H
Weight 37kg (82 lbs)

C 1 Maker

Rated voltage DC24V

Controller
For details, refer to
Mechatro System. CN-18
YN22E00037F1
WINDOW FOR ADJUST 4-∅ 7 ATTACHING HOLE
Mechatro controller

E215
YN22E00069F2(EU)
YN22E00037F2(Asia, Oce)

LQ22E00029F2(EU)
LQ22E00018F3(Asia, Oce)

E1 5
 File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

C
2 Maker

Rated voltage DC24V

Controller More than 3M
at
Insulation resistance 500Vmegger
LCD

YN59E00001F2(EU)
YN59E00002F2(Asia, Oce)
YN59E00002F3(Thailand)
YN59E00002F4(Indonesia)

Gauge cluster

C
3 ○ Fitted to the controller group in

the cover that is located at the
back of the operator's seat. C-3 :
Controller SWITCH BOX ASSY

○ Function
YN50E00004F1 • Warm-up
• Conflux / Single select
Switch box assy • Mode / Buzzer stop
• Wiper / Washer / Light

C
4 Maker’s part No. TKSC215AO

Rated voltage DC 2030V CONTROLLER

Controller

YT20M00004S036
Air conditioner
controller
YT00101,YV00101
YY00101,YF00101
YN07-30001
YQ07-03501
LQ08-04501
LL08-03001
LC06-05501
YC06-02501

E1
6
 File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

D
1,2,510 Maker’s part No. 7321-9822

Diode Peak reverse voltage 400V

Mean output current 3A

YN02D01001P1
Surge current 200A
Key switch relay
YX01001
, YV00101

YH00101
, YY00101

YF01-00101
, YU01-00101

YN07-30001
, YQ07-
03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

D
3,4 Part No. 7321-9332-60

Rated current 2.5A

Diode

2475R132
Starter relay
Glow relay
YX01001
, YV00101

YH00101
, YY00101

YF01-00101
, YU01-00101

YN07-30001
, YQ07-
03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

E
1
Fuse capacity and circuit name
Fuse box No. Capacity Name of circuit

20A Mechatro controller
YN73E00007F1
 5A Wiper / washer relay
(EU) 18PAF-HD
 10A Cigarette lighter SUMITOMO
HOUSING : 6098-0257
Fuse  10A Converter TERMINAL : 8240-4422
 10A Horn
  
 5A Controller back-up, Hour meter back-up

20A Fuel suply pump 11 1

18PAF-HD 2
5A Room lamp, Controller back-up
12
20A Key switch 3
13
  4
14
 20A Flasher, Work light, Alarm 7PAF-HD 5
15
6
 5A Gauge cluster, (Power window) 16 7
17
 20A Wiper, Washer 8
18
 10A Solenoid valve, Lever lock 19 9
 20A Work light (front) 10
20
 20A Cab
Air conditioner, Heater 7PAF-HD
 20A
(option) SUMITOMO
HOUSING : 6950-1030
 5A Air conditioner
TERMINAL : 8230-4050
 20A Spare 8232-4238

E1
7
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

E
1 Fuse capacity and circuit name

No. Capacity Name of circuit
Fuse box  20A Mechatro controller
 5A Wiper / washer relay
YN73E00005F2
 10A Cigarette lighter 18PAF-HD
(Asia, Oceania) SUMITOMO
 5A Tuner HOUSING : 6098-0257
Fuse  10A Horn TERMINAL : 8240-4422


LQ08-04501  5A Controller back-up 11 1
LL08-03001
15A Power window back-up 18PAF-HD
2
LC06-05501 12
5A Tuner (back-up), Room lamp
YC06-02501 13
3
20A Key switch
7PAM-HD 14 4
10A Auto greaster
15 5
20A Flasher, Work light (rear),Alarm 6
16
 5A Gauge cluster, Power window 7
17
Wiper, Washer 8
 20A 18
 10A Solenoid valve, Lever lock 19 9
 20A Work light (front) 10
20
 20A Work light (OPT)
Air conditioner 7PAF-HD
 20A
SUMITOMO
 5A Air conditioner HOUSING : 6950-1030
TERMINAL : 8230-4050
 20A Spare
8232-4238

E
2 Type 3-phase AC method

TERMINAL : P
YAZAKI 7322-2129

Voltage 24V
CONNECTOR
Alternator YAZAKI 7322-6223-40
Output 35A(900W)

Drive A-Belt drive by pulley

ME088887

TERMINAL : E M6
1
Generator
TERMINAL : B
YN23301
, YQ02801
M8
1.25
YN07-30001

YQ07-03501

E
2 Rated output 24V35A

CONNECTOR
TERMINAL : P YAZAKI 7322-6223-40
Alternator CONNECTOR
YAZAKI 7322-2215
ME150693

Generator
YF01-00101 TERMINAL :
YU01-00101 B
LQ08-04501
LL08-03001

E1
8
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

E
3 Model 28000-MW1000

Movement Quartz Vss

YAZAKI 7122-2129
Hour meter
Rated voltage DC24V GND
M5 0.8
YN58S00004P1

Service meter
YN23301
, YQ02801

YT00101
, YR04001

YX01001
, YV00101

YX00101
, YF00101

YN07-30001
, YQ07-03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

∅3
E
4 Resistance Coupler (collar)
YAZAKI
E-4 D8 48 7122-2228 (white)
Resistor

LC22E01001D1

Resistance
YN07-30001
YQ07-03501
LQ08-04501
LL08-03001
LC06-05501
YC06-02501 ∅4.2

E
5,6 Type

Rated voltage


Horn Operating voltage
range

2479U1009F1(HIGH)
2479U1009F2(LOW) Sound level  

Basic frequency 415 20 Hz high sound

Warning sound 370 20 Hz low sound
Insulation resistance More than

YW06501

LP11001
, YP02301

YN18001
, YQ02301
STAMP
LQ03301
, LL02301
H HIGH SOUND
YT00101
, YR04001

YX01001
, YV00101
L LOW SOUND
YX00101
, YF00101
Drain 2-Hole
YN07-30001
, YQ07-03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

E1
9
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

E
7 1 OPEN
2 SPEAKER()
3 ACC(B)
Tuner 4 OPEN
LC54S00001P1 5 OPEN
(Asia) 6 SPEAKER()
YN54S00013P1 7 GND()
(Oceania) 8 BACK UP()
9 OPEN
Radio (AM&FM)

YT00101
,YR04001

YX01001
,YV00101

YY00101
,YF00101

YN07-30001

YQ07-03501
Mated side YAZAKI 7318-3090
LQ08-04501

LL08-03001

LC06-05501
Rated voltage DC24V
YC06-02501

1 L SPEAKER()
2 R SPEAKER()
3 ACC(B)
4 OPEN
5 L SPEAKER()
6 R SPEAKER()
7 GND()
8 BACK UP()
9 OPEN

E
8,9 Model SX-M1028K

Rated input 8W
Speaker
Impedance 8
YN54S00006P1
Frequency 33.3Hz

Radio
YW07901
,LP13601

YN23301
,YQ02801

LQ03701
,YT00101

YR04001
,YX01001

YV00101
, YY00101

YN07-30001

YQ07-03501

E
10 Refrigerant in use R134a

Maker’s part No. 56640-A0450

Receiver drier

YT54S00002P1

Air conditioner

YT00101
YN07-30001
YQ07-03501

E1
10
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

E
11 Makers part No. 73516000

Rated voltage DC 24V

Air compressor
Max. revolution 4000rpm
CP3.96MA
LC91V00001F1 YAZAKI 7120-8019 V belt Type B

Refregerant R134a
Air conditioner
Oil SP20 : 135cc

YF00101
YN07-30001
YQ07-03501
LQ08-04501 AVX1.25(BLACK)
AVX1.25(GREEN)
LL08-03001
LC06-05501 4-∅9
YC06-02501

E
13 Rated voltage DC12
36V

Rated current 0.2A / 24V

Travel alarm
Sound level 1074dB / 1.2m

2479U1710 Frequency 2200100 Hz

Travel warning
SUMITOMO 090
WATERPROOF 2PM
LC03801
, YC01001

LS00701
, YS00601
CONNECTOR 6187
2311
YF00101
TERMINAL 1500
0105
YN07-30001
, YQ07-03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

E
14 Model 409112-0000

Rated voltage DC 24V

Cigar lighter PLUG COMPLETE
KNOB
Max. current 5A
2421R180F1
Return time Less than 18sec

Cigar lighter Insulation resistance More than 3M /

500V megger
YW06501
Fusing temp.180
250
JIS CA104
LP11001
, YP02301
Temperature fuse CASE
YN18001
, YQ02301

(356
F
482
F)
LQ03301
, LL02301
SOCKET COMPLETE
YT00101
, YV00101

YX00101
, YF00101

YN07-30001
, YQ07-03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

E1
11
 File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

E
14 Input voltage DC 24V

Converter Output voltage DC 12V

YT77S00001P1 Output current 2.5A Max

(EU, KAI)
Ground Negative
YV
DC24VDC12V WG YB
OL
YY00101
Fix the wire B
YH00101
with tape
YT00101

YF01-00101

YU01-00101

YN07-30001
HOUSING YAZAKI 7122-2262
YQ07-03501
TERMINAL YAZAKI 7114-2020
LQ08-04501

LL08-03001

LC06-05501
VIEWA
YC06-02501
A

E
15 Power supply For 12V

Socket
YN81S00001P1
(KAI, EU)

Power socket
YY00101
, YH00101

YF01-00101
, YU01-00101

YN07-30001
,YQ07-03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

E
A Electrostatic capacity 80
7pF

More than 100M
Insulation resistance
Antenna (DC 500V megger)

YT54S00001P1

Radio
YT00101

YV00101

YY00101

YF01-00101

YU01-00101

YN07-30001

YQ07-03501

LQ08-04501

LL08-03001

LC06-05501

YC06-02501
ANTENNA JUMPER 30pF/m
Oceania : PART NO. 2486R99

ANTENNA JUMPER 30pF/m

KAI, EU : PART NO. YN54S00012D1

E1
12
 File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

L
1 Type BL84-130

Bulb 24V,70W
Light
CA104

YW80S00001F1

Boom work light

M141.5
(left)
YN23301
, YQ02801

YX01001
, YV00101

YY00101
, YF00101

YN07-30001
, YQ07-
03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

L
2,7,8,9 Type BL84
200

Bulb DC 24V,70W
Light
Effective area of lens 71cm2

YN80S00010F2

Deck work light (Right)

BRACKET
OPT:Cab work light (L&R) DRAIN HOLE
OPT:Boom cylinder work light
M121.2525
YW07901
, LP13601

YN23301
, YQ02801
CA104 CB104
LQ03701
, YF00101
(POWER SUPPLY) (EARTH)
YN07-30001
, YQ07-
03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

L
5 Bulb 24V,5W

BODY
Note) Equivalent to 2456Z322F1 LENS A
Light

YT80S00001P1

Room light
Bulb
YW06501

LP11001
,YP02301

YN18001
,YQ02301

LQ03301
,LL02301
OFF ON
YN07-30001
, YQ07-03501
A
LQ08-04501
, LL08-03001
SectionA
A Switch
LC06-05501
, YC06-02501
Door

M
1 Rated output DC24V, 5.0kW B-TERMINAL M81.25

MITSUBISHI part ME049303

Motor
No.
L- TERMINAL
ME049303

Starter motor
YF00101
SW- TERMINAL CONNECTOR
YN07-30001
, YQ07- MITSUBISHI PART
03501
NO.
LQ08-04501
, LL08-03001
VEIW D PH801-02021 D
LC06-05501
, YC06-02501

E1
13
 File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

M
2 Drive voltage DC 24V REDUCTION GEAR SECTION

OUTPUT OIL SEAL
Rated voltage DC 8.5V MOTOR SECTION
SHAFT
Motor Rated current 1.5A/ phase (INVOLUTE)

Number of phases 2 phase Z

YT20S00002F2 Excitation method 2 Excitation
Step angle 1.8 CAM

Governor motor Insulation resistance More than 100M

LIMIT
(500V megger)
SWITCH
YT00101 Reduction ratio 1/20.3
YR04001
YX01001 Brown(A) Red(B) Excitation sequence

YV00101


STEP
1 2 3 4
Lead
YY00101 Orange(A) Yellow(B)
A
 

YF00101 B

 
MOTOR LIMIT SWITCH
CONNECTOR CONNECTOR
YN07-30001 A 


YQ07-03501 B  


LQ08-04501 Limit switch connector No. color
Lead Connec-
tion
1 2
LL08-03001 6 No.
Lead
color
Connec-
tion 1 Brown A
LC06-05501 5 White COM 2 Orange A
5 6 Red NO 3 Red B
YC06-02501 4
7 7 Yellow NC 3 4 Yellow B LIMIT
HOUSING : 6181-0072(SUMITOMO DENSO) HOUSING : 6181-0073(SUMITOMO DENSO) SWITCH
TERMINAL : 1500-0134(SUMITOMO DENSO) TERMINAL : 1500-0105(SUMITOMO DENSO) MOTION
RETAINER : 6918-0327(SUMITOMO DENSO) RETAINER : 6918-0329(SUMITOMO DENSO) RANGE
WATER PROOF : 7165-0118 WATER PROOF : 7165-0118
(SUMITOMO DENSO) (SUMITOMO DENSO) VIEWZ

M
3 Drive voltage DC24V

Motor

YT53C00004P1

Wiper motor
YN07-30001

YQ07-03501

LQ08-04501
, LL08-03001
CIRCUIT DIAGRAM
LC06-05501
, YC06-02501

M
4 Type

Rated voltage 24V

WASHER TANK
Motor
Injection pressure More than 1.2kgf/cm2 (17psi)

Injection flow More than 1320cc/min

2427U900
Tank capacity More than 2.2 (0.58gal) 

TERMINAL

Washer pump
YW06501

LP11001
, YP02301

YN18001
, YQ02301
PUMP
LQ03301
, LL02301

 -TERMINAL
YN07-30001
, YQ07-
03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

E1
14
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

M
11 Flow rate 35L/min (Head 3m)

Pump Voltage 24V

Current 7A (Head 3m)

YT22P00001F5 (EU)
Fuse 10A
Fuel pump
YT00101
YF01-00101
YU01-00101
YN07-30001 Torque :
YQ07-03501 0.51kgfym
LQ08-04501
LL08-03001
LC06-05501
YC06-02501

RED CA104

BLACK CB104

250µ Mesh

At start 24V2000A
R
1 Rated voltage / (0.1sec.)
current At charge 28V120A
(continuous)
Relay Exciting current Less than 0.4A / 24V A-TERMINAL
FLW2.0
More than B-TERMINAL
FLW2.0
Contact force 3.5kgf (7.7 lbs)
YT24S00001F1
F HOUSING :
Closed circuit voltage Less than 16V SUMITOMO
7123-4220-30

Battery relay Open circuit voltage Less than 7V

F TERMINAL :
SUMITOMO
7116-3251
More than 3M
/ REAR HOLDER :
YT00101 Insulation resistance 500V megger SUMITOMO
7157-6801-30
YR04001 MODEL WATER
PROOF :
YX01001 NUMBER STAMPING SUMITOMO
POSITION IN A 7157-3580-60
YV00101
L-TERMINAL
FLOWING DIRECTION OF B-TERMINAL
PRODUCTION PROCESS
Z
YY00101 MAIN CURRENT
AVS1.25L
YF00101 A-TERMINAL B-TERMINAL AVS1.25B AVS1.25G
YN07-30001 A1→ ←B1 EARTH
TERMINAL HOUSING SUMITOMO
YQ07-03501 6181-0072
LQ08-04501 A1-TERMINAL LOCK SECTION
L-TERMINAL
RETAINER SUMITOMO
LL08-03001 6918-0327
TERMINAL SUMITOMO
LC06-05501 1500-0105
YC06-02501 WIRE SEAL SUMITOMO
7165-0119

B1-TERMINAL B-TERMINAL EARTH TERMINAL

VIEW Ⅰ VIEW Z
CIRCUIT DIAGRAM BRACKET
EARTH

E1
15
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
ENGINE
R
2
STARTER MOTOR
Relay
STARTER RELAY

ME701597 B-TERMINAL M8

STARTER (5kW)
Starter relay ME049303 ALTERNATOR
B-CONNECTOR (M6) (M8)
YF00101 MH057641
YN07-30001
YQ07-03501
TO STARTER SW
LQ08-04501
LL08-03001
LC06-05501
YC06-02501

TO STARTER SW
TO TO HEATER RELAY
TO BATTERY RELAY STARTER SW
TO SAFETY RELAY
ME077148

R
3 MITSUBISHI part ME072890

No.
Relay
Rated voltage DC24V

Exciting current 2.3A

ME072890
Fuse 127A

Glow relay
FUSE ATTACHING BOLT
M6
1.0
YF00101
FUSE
YN07-30001
CONTROL TERMINAL
YQ07-03501 COUPLER SIDE CONNECTOR
LQ08-04501 JISD5403 CB104
LL08-03001
M4
0.7
LC06-05501
YC06-02501

CONTACT TERMINAL : M6
1.0

E1
16
 File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

R
4 MITSUBISHI part ME077148

No.
Relay Rated voltage DC 24V
Operating alternator
revolution 1200
100rpm
ME077148
Rated time 30SEC ∅6.5
MMC PARTS NO. MH056359
Safety relay
(W yL)S
YN23301
, YQ02801

LQ03701
, YF00101
Y(L) E(B)
YN07-30001
, YQ07-
03501
(W yG)S P(W yY)
LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

R
7 Rated voltage DC 24V

More than 100M
Insulation resistance (500V megger)
Relay

YT24E00001F1

For wiper
YT00101
, YV00101

YY00101
, YF00101

YN07-30001
, YQ07-
03501

LQ08-04501
, LL08-03001

VIEWZ
CONNECTION DIAGRAM
LC06-05501
, YC06-02501

R
8 Maker’s part No. 488 368 8010

Rated voltage DC 24V / 10A

Relay More than 1M / 500V
Insulation resistance megger

YN24S00001P1

Travel alarm
Z
LC03801
, YC01101

LS00701
, YS00601

YN07-30001
, YQ07-
03501
VIEWZ
LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

R
5,6,9,11,12,13,15,16 Rated voltage DC 24V

Coil resistance 360
10%

Relay
Insulation resistance 20M(500V megger)

YR24S00002P1
Horn relay
Work light relay Applicable connector
Cab work light VCF4－1003(P&B)
YN07-30001
, YQ07-
03501

LQ08-04501
, LL08-03001

CONNECTION DIAGRAM
LC06-05501
, YC06-02501

E1
17
 File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

R
19
UPPER

Relay

YY24S00001P1

Flasher relay
YY00101

YH00101

YN07-30001
, YQ07- TERMINAL NUMBER
03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

R
20 Rated voltage DC24V A NOT USED
Consumption current 0.1A max.
Relay

YN25S00001P1 NO USED D

Timer CONNECTOR YAZAKI No.7122-2262 E NOT USED

EQUIVALENT
YN07-30001

YQ07-03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

CIRCUIT DIAGRAM
CONNECTOR MODEL
0
30kgf/cm2
SE
111,20,28 Pressure range (0
430psi)
HW090 3-P (T TYPE)
(SUMITOMO DENSO)
Max. allowable 3
Pressure sensor pressure 250kgf/cm2(3560psi) 2
(Low pressure) Operating source
voltage 50.5V DC
CONNECTOR
LC52S00001P2 Load resistance 10M MIN
TERMINAL
ARRANGEMENT
Bucket, Boom, Swing Insulation resistance
TERMINAL NO.
100M 1 1POWER
Arm,Travel,
SUPPLY(+)
P1,P2 Option, 2OUTPUT(+)
Back pressure 3COMMON
HEX 19
YT00101
, YR04001

YX01001
, YV00101

YY00101
, YF00101
O RING(P111B)
YN07-30001
, YQ07-
03501
PF1/4
LQ08-04501
, LL08-03001
TIGHTENING TORQUE 3.7kgfym (27ftylbs)
LC06-05501
, YC06-02501

SE
13 E/G RING GEAR

Speed sensor

MC849577 M161.5 F(GND)-B

HEX 22
E(OUTPUT)-Y
HEX 19
Speed sensor LOAD CIRCUIT

YF00101

YN07-30001
, YQ07-
CONNECTOR MITSUBISHI PART No. MH056401
03501

LQ08-04501
, LL08-03001
CONNECTOR YAZAKI PART No. 7322-1424-30
LC06-05501
, YC06-02501

E1
18
 File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
Z
SE
14 Makers part No. 71400KW0300

Resistance characteristics
Water temp. sensor
50
C 80 M16×1.5
YT52S00001P1 TORQUE
60
C 56.3 2.5 kgfym
E/G coolant (18ftylbs)
80
C 29.5
temp. sensor
YT00101
, YR04001
100
C 16.5
YX01001
, YV00101

YY00101
, YF00101
106
C 14.3 VIEW Z
YN07-30001
, YQ07-
03501
120
C 10
LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

FLOAT
SE
15 Float Resistance value  
+0.1
FULL 10 -0.5
Fuel sending unit
3/4 (19)
2489U267F1 1/2 323 
A
1/4 (49.5)
Fuel sensor
EMPTY 80 +12
+2
YW06501

FUEL LEVEL
LP11001
,YP02301

WARNING LAMP POSITION
YN18001
, YQ02301

LQ03301
, LL02301

YN07-30001
SENSOR SWITCH
YQ07-03501

LQ08-04501

FUEL METER
LL08-03001

LC06-05501

YC06-02501

24V3W FLU

DC
24V FLOAT SUMITOMO CONNECTOR
PART 6187－3231

VIEW A

SE
16 Total resistance value 2K

Effective electric angle 90 NOTCH PART BRACKET POTENTIO

Potentiometer
DIAL
Number of notches 10
YN52S00009P1
Source voltage 5V
3PAM-090
Accel dial
YN23301
, YQ02801
SUMITOMO
YT00101
, YR04001
6187-3231
YX01001
, YV00101

TERMINAL
YY00101
, YF00101

YN07-30001
, YQ07- 1500-0105
03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

E1
19
 File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
CONNECTOR MODEL
SE
22,23,24,25 0500kgf/cm2 HW090 3－P (T－TYPE)
Pressure range (07110psi) 3 (SUMITOMO DENSO)

Pressure sensor Max. allowable press. 270kgf/cm2(3840psi) 2

(low pressure)
Operating source voltage 5
0.5V DC
LC52S00001P1
Load resistance 10K MIN
1
P1 pump, P2 pump Insulation resistance More than 100M
CONNECTOR TERMINAL
ARRANGEMENT
YX01001
HEX TERMINAL No.
YN07-30001
O RING 1 ─ POWER SUPPLY (+)
YQ07-03501

(P11 1B) 2 ─ OUTPUT (+)
LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501
PF3/8 3 ─ COMMON
TIGHTENING TORQUE 7.5kgf!m (54ft!lbs)
CONNECTOR MODEL
SE
26,27 50kgf/cm2 HW090 3－P (T－TYPE)
Pressure range (710psi) 3 (SUMITOMO DENSO)
2
Max. allowable press. 525kgf/cm2(7470psi)
Pressure sensor
Operating source voltage 5
0.5V DC
YN52S00016P1 Load resistance 10K MIN
1
P1 negative control Insulation resistance More than 100M CONNECTOR TERMINAL
P2 negative control HEX 22 ARRANGEMENT
YN07-30001
TERMINAL No.
O RING 1 ─ POWER SUPPLY (+)
YQ07-03501

(P11 1B) 2 ─ OUTPUT (+)
LQ08-04501
, LL08-03001

PF3/8 3 ─ COMMON
LC06-05501
, YC06-02501
TIGHTENING TORQUE 3.7kgf!m (27ft!lbs)

SV
11 Rated voltage DC 24V

Working pressure 50kgf / cm2

Solenoid valve
Max. flowrate 16 /min

YN35V00010F1

Extra breaker

YN07-30001
YQ07-03501
LQ08-04501
LL08-03001
LC06-05501
YC06-02501
VIEW

E1
20
 File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

SV
1,2,3,4 Rated voltage 90kgf/cm2 (1280psi)

Solenoid selector
Solenoid valve (8 solenoid) valve Rated voltage DC 24V P1,T,A1 port PF3/8
Selector valve assy Dither current 100Hz,300mA P-P A2A8 port PF1/4
Solenoid
Refer to hydraulic proportional valve
Coil resistance 17.5
1(at20)
symbol A1,A2,A7,A8
SUMITOMO DENSO HW :
090 connector M(2P)
YN35V00022F1 Connector HOUSING part No. :
specification Equivalent 6181-0070
YN07-30001
TERMINAL part No. :
Equivalent 1500-0105
YQ07-03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

PSV
A,B,C,D YN35V00021F1 YN35V00020F1 YN35V00019F1 YN35V00020F1

Proportional
solenoid valve
Refer to hydraulic T=0.7kgfym

symbol A3A6 (5.1ftylbs)

YN07-30001
YQ07-03501 PLUG PT1/8

PLUG
SWING TRAVEL ARM P1 TRAVEL P2 ATTACH LOCK PT1/16
PARKING 2-SPEED VARIABLE BYPASS STRAIGHT BYPASS POWER LEVER
RECIRCU- CUT CUT BOOST
LATION PRESSURE

Hydraulic symbol
VIEW

E1
21
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

PSV
H Type IKWE5G
30

Max. press (P port) 90kgf/cm2 (1280psi)

Proportional valve
Rated press 050kgf/cm2 (0710psi)
YM35V00001F1
Allowable back press 10kgf/cm2 (140psi)

Swing priority Max. flow 10 /min (2.6gal/min)

M50.5
YF01-00101 Torque 0.7kgfym (5.1ftylbs)
YU01-00101
YN07-30001
YQ07-03501
LQ08-04501
LL08-03001
LC06-05501
YC06-02501

HYDRAULIC SYMBOL

PSV
P1,P2 Type KDRDE
5K

Proportional valve Max. feed press 140kgf/cm2 (1990psi)

Rated feed press 50kgf/cm2 (710psi)

YN35V00018F2
Allowable back press 10kgf/cm2 (140psi)
Proportional valve
for pump Control pressure range 030kgf/cm2 (0430psi)

YF01-00101 Rated voltage DC24V

YU01-00101 SUMITOMO DENSO CONNECTOR HW090M(2P)
YN07-30001 HOUSING 6181-0070

YQ07-03501 TERMINAL 1500-0105

LQ08-04501
LL08-03001 HEX32
LC06-05501
YC06-02501

O RING HEX 10
1B P20 T=0.75 kgfym (5.4ftylbs)

E1
22
 File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
AUTO RETURN
SW
1 T
P
B G1 G2 ACC M ST

Switch H


AUTO RETURN
OFF
YN50S00002F1
ACC

VIEW A
Starter switch
ON


“K250”STAMPED
YW06501

LP11001
, YP02301

YN18001
, YQ02301

LQ03301
, LL02301

START



A
YT00101
, YR04001

YX00101
, YV00101

YY00101
, YF00101

YN07-30001
, YQ07-03501

LQ08-04501
, LL08-03001
TERMINAL
LC06-05501
, YC06-02501
ARRANGEMENT

SW
2 Type Sheet type, with back light

Switch

YN50E00002F1

Mode, buzzer stop

YN07-30001

YQ07-03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

SW
3 Type Buried in right travel lever

MARKS ON SWITCH PORTION

Switch
YN03M01039P1
(Right travel grip)

Travel 1,2-spead
YW06501

LP11001
, YP02301

YN18001
, YQ02301

LQ03301
, LL02301

YN07-30001
, YQ07-
03501
CA103
LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

Single-pole single-throw
SW
3 Type momentary

Rated voltage DC 24V

Switch CONNECTOR (WITH LOCK) (R)
More than 1M
/
Insulation resistance DC500V megger
EQUIVALENT YAZAKI 7122-2228 RED

2479U1224F4
TERMINAL CONNECTOR
Travel 1,2-spead Terminal
Position R RW RED /
YN07-30001
WHITE
YQ07-03501
OFF
LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501
ON

E1
23
 File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
Single-pole double-throw
SW
4 Type (alternate) INSULATION TAPE
R B W
Rated DC 30V,10A
Switch
Insulation resistance

YX50E00002F1 VINYL TUBE

YAZAKI
Contact T No.
Swing parking construction : position
1 2 3 RED(2) 7122-2237
release 7114-2020
YN07-30001
Swing parking release ON
YQ07-03501
Normal ON
LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501
WHITE(3) BLUE(1)

M12P1
SW
5 Type 

CIRCUIT DIAGRAM
Switch

YN50S01003P1 KEY WAY

KPSS release
YW06501

LP11001
, YP02301

YN18001
, YQ02301

LQ03301
, LL02301

YV00101
, YY00101

YF00101
12PAM-HD
YN07-30001
, YQ07- SUMITOMO 6098-0252
03501

LQ08-04501
, LL08-03001
TERMINAL 8230-4282
LC06-05501
, YC06-02501

SW
6 MITSUBISHI Part No. ME039860
Closed circuit 1052
E/G water temperature (22135.6
F) M161.5 M40.7
temperature switch Temperature difference
in open/close action 7 (44.6
F) MAX
ME039860
Rated voltage DC24V
YN23301
, YQ02801
DATE OF MANUFACTURE
Current capacity 3A
YF00101

YN07-30001

Mounting position Mounting E/G
YQ07-03501

LQ08-04501

Contact type Nomally open
LL08-03001

LC06-05501

YC06-02501

SW
7 MITSUBISHI part MC840219

No.
E/G oil pressure
switch Rated voltage DC24V
Open circuit oil
MC840219 pressure
0.5kgf/cm2 (7.1psi)
MIN
Oil pressure ∅2 PT1/8
indication Contact type Nomally closed
YN18001
, YQ02301

LQ03301
, LL02301

YF00101

YN07-30001

YQ07-03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

E1
24
 File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

SW
8 Makers part No. REX801001

CA104 CB104

Switch

YR11P00008S005

Dust indicator
YR02001
, YN23301

YQ02801
, YF00101

YN07-30001
, YQ07-
03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

Single-pole single-throw
SW
9 Type momentary

Rated voltage DC 24V

Switch
More than 1M / CONNECTOR (WITH LOCK) (R)
Insulation resistance DC500V megger EQUIVALENT YAZAKI 7122-2228 RED

2479U1190F9
TERMINAL CONNECTOR
Swing flasher Terminal R RW
Position
RED /
YN07-30001

YQ07-03501
OFF WHITE
LQ08-04501
, LL08-03001

ON
LC06-05501
, YC06-02501

SW
10 Type Buried in left grip

Insulation resistance More than 100M /

DC500Vmegger
Horn switch
Grip assy YN03M01369F1

YN50E00007P1
SUMITOMO DENSO HOUSING ITEM : 60901031(2P male)
SUMITOMO DENSO TERMINAL ITEM : 82304282
Horn JYUNKOSYASEI LEAD ITEM : 861006(0.5sq)

YN07-30001

YQ07-03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

SW
11
    HEX17

Switch
CONNECTION TABLE
YN50S01001P1 2PAM




Safety lock lever 
YN23301
, YQ02801
  YAZAKI HOUSING 7122-2228
YT00101
, YR04001

YX01001
, YV00101
 TERMINAL 7114-2020
YY00101
, YF00101


YN07-30001
, YQ07-
03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

E1
25
 File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
Single-pole single-throw
SW
12 Type momentary

Rated voltage DC 24V

Switch CONNECTOR (WITH LOCK) (R)
More than 1M /
Insulation resistance DC500V megger
EQUIVALENT YAZAKI 7122-2228 RED

2479U1190F33
TERMINAL CONNECTOR
Overload alarm
Terminal
select switch Position R RW
RED /
YN07-30001
WHITE
YQ07-03501
OFF
LQ08-04501
, LL08-03001

ON
LC06-05501
, YC06-02501

SW
13
 SANDEN

Air conditioner Connector 21749551

switch panel Type With 
C↔
F converter

YN20M01299P1

Air conditioner panel

YN07-30001

YQ07-03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

SW
13 Maker’s part No. TKS-P215BO

Air conditioner NIPPON AMP
Connector 2-174955-1
switch panel 4-∅6
LC20M01013P1

Air conditioner
panel
YF01-00101

YU01-00101

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

OFF 40°ON
SW
16 Toggle switch
M12
Single-pole single-throw
Type alternate
Switch
Rated voltage DC 24V M3
LA103
YT50S00005P1 WIRE COLOR : BLACK
WIRE COLOR : RED
E/G room light
switch
YN07-30001

YQ07-03501
CB104 CB104
LQ08-04501
, LL08-03001
TERMINAL : YAZAKI TERMINAL : YAZAKI
LC06-05501
, YC06-02501
: 7113-1020-02 : 7115-1050-02
CAP : YAZAKI CAP : YAZAKI
: 7120-8012 : 7120-1010

E1
26
 File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

SW
19 Maker’s type DS430

Single-pole single-throw
Contact arrangement ON-(OFF)momentary
Switch Normally closed 8.7
More than 100M
14
Insulation resistance (500V megger)
YN50E00006P1 BLACK CB104

Wiper inter lock

YN07-30001
RED CA104
YQ07-03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

SW
20 Type Sheet type, with back light

Switch

YN50E00003F1

Wiper, washer, work light

YN07-30001

YQ07-03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

SW
21 Type Buried in right grip

More than 100M
/
Insulation resistance
DC500V megger
Switch
Grip assy YN03M01369F2

YN50E00007P1
SUMITOMO DENSOHOUSING ITEM : 60901031(2P male)

ATT power boost SUMITOMO DENSOTERMINAL ITEM : 82304282

JYUNKOSYALEAD WIRE ITEM : 861006(0.5sq)
YN07-30001

YQ07-03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

E1
27
 File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

SW
23 MITSUBISHI part No. MC867765

Type Normally closed

E/G oil level
Switch voltage Less than 0.3A

MC867765

SWITCH
E/G oil level OFF LEVEL
RELAY
LC04201
,YC01301

LS00801
,YS00701

YF00101
24V
YN07-30001
3W
YQ07-03501
24V
BULB SWITCH
LQ08-04501

LL08-03001
CLIP MODEL : MH056347
LC06-05501

YC06-02501
CONNECTION DIAGRAM

CONNECTOR PART No. : MH056304

CONNECTOR ON MATED SIDE : MH056354

SW
24 3.4 (0.90gal)

All water volume
Sub tank FULL 1.5 (0.40gal)
LOW level 0.43 (0.11gal)
E/G coolant OPEN-TO-
Remaining liquid level
temperature SW. Switch function 0.43
0.1 (0.11
0.023gal) ATOMOSPHERE
SIDE

2427U203S6 Contact type Normally closed

E/G coolant level

RADIATOR-
YAZAKI
LC03201
, YC00901
CONNECTED
PART No.
LS00501
, YS00501
7121
YF00101
LOW SIDE AV0.5FB
YN07-30001
, YQ07-
03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501
HOUSING YAZAKI : 7122-2228
SW
25 Max. contact rating 10W TERMINAL YAZAKI : 7114-2020
Between terminals 100M

Insulation or more (100V)
Between terminal-grounding
Switch resistance 100M
or more (500V)
CORRUGATE
TUBE AEX WIRE 0.85 (BLACK)
YN52E00023P1
Hydraulic oil level M27×1.5
switch
YF00101 Operating point
FLOAT OUTER
YN07-30001
Liquid type Specific gravity ON (Amm) OFF (Bmm)
DIAMETER ∅23
Less than More than
YQ07-03501
OIL 0.88 10.5mm 2.0mm
LQ08-04501
, LL08-03001
When the level of remaining liquid is low, it is
LC06-05501
, YC06-02501
turned off automatically by the function of float.

E1
28
 File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

SW
26 Single-pole single-throw

Type (Alternate)

Rated voltage DC 24V

Switch
CONNECTOR (WITH LOCK)
More than 1M
/ (R)
Insulation resistance DC500V megger EQUIVALENT YAZAKI 7122-2228 RED
2479U1190F1

Work light (OPT) TERMINAL CONNECTOR

Terminal L RW
YT00101
Position RED /
YF01-00101
WHITE
YU01-00101
OFF
YN07-30001
, YQ07-
ON
03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

SW
35 Type
Single-pole single-throw
(Alternate)

Switch Rated voltage DC 24V

More than 1M
/ CONNECTOR (WITH LOCK) (R)
Insulation resistance DC500V megger EQUIVALENT YAZAKI 7122-2228 RED
2479U1190F13

Heavy lift switch TERMINAL CONNECTOR

LQ08-04501 Position
Terminal L RW RED /
LL08-03001 WHITE
LC06-05501 OFF
YC06-02501 ON

SW
37 Operation
ON : at 3 (37.4F)
OFF : at 10 (50
F)

Switch

2479R2348 PT3/8 CA104 21

LOT No.

Hyd. Oil temp. BLUE PAINT

switch
LQ08-04501
LL08-03001
LC06-05501
YC06-02501

SW
38 Single-pole single-throw

Type (Alternate)

Rated voltage DC 24V

Switch CONNECTOR (WITH LOCK) (R)
More than 1M
/
Insulation resistance DC500V megger
EQUIVALENT YAZAKI 7122-2228 RED
2479U1190F31

Warm up switch TERMINAL CONNECTOR

Terminal
LQ08-04501 Position L RW RED /
LL08-03001 OFF
WHITE

LC06-05501
YC06-02501 ON

E1
29
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

SW
42 Rated voltage DC12 & 24V

Relief valve set
Switch pressure 1.40.2kgf/cm2
Fitted to an oil cooler
ME084614 More than 1M
/
Insulation resistance DC500V megger
E/G oil filter
bypass alarm
LQ08-04501
LL08-03001 ∅2 hole
LC06-05501
YC06-02501

SW
47 Type
Single-pole single-throw
(Alternate)

Switch Rated voltage DC 24V

More than 1M
/ CONNECTOR (WITH LOCK) (R)
Insulation resistance DC500V megger EQUIVALENT YAZAKI 7122-2228 RED
2479U1190F21
Extra & Breaker
switch TERMINAL CONNECTOR
LQ08-04501 Terminal L RW RED /
Position
LL08-03001 WHITE
LC06-05501 OFF
YC06-02501 ON

E1
30
NOTES NOTES
 3. HARNESS
3.1 HARNESS LIST
Table 2
INDEX No. DWG. No. HARNESS
ASSY No. Part No. REMARKS
DEVICE ITEM NAME ITEM NAME
EU OCEANIA ASIA EU OCEANIA ASIA
YN22E00057F2 3.3.23 Cab harness assy YN14E00013F4
― ― ― ―
Controller assy YN22E00060F1 3.3.23
11 Instrument panel harness YN14E01023P1
3.3
Controller instal YN22E00047F2 ← 3.3.9 Cab harness assy YN14E00013F1 ←
― ―
YN22E00046F3 ← 3.3.9
1 Instrument panel harness YN14E01013P5 ←
YN17M000113 ― ― 3.4.23 YN17M01072P1 ― ―
For tuner
― YN17M00010FK ― 3.4.23 ― YN17M01072P1 ―
― ― YN17M00010FD ― ― ― With swing flasher, Radioless
3.4 Instrument panel Cable
― ― YN17M00010FJ 3.4.23 ― ― YN17M01072P1 With swing flasher, With radio (China)
― ― YN17M00010FN ― ― ― Thailand
― ― YN17M00010FP ― ― ― Indonesia
LQ03E00004F2 ― ―
3.5 Electric assy
― LQ03E00004F1 ←
3.6.1 Upper harness ― YN13E01137P2 ← Upper
UPPER 3.6.2 Cable YN13E01053D2 ← ← Battery
FRAME 3.6.3 Cable 2486R89D5 ← ← Battery relay
3.6.4 Cable YN13E01118P1 ← ← Ground
3.6 Upper harness assy YN13E00030F3 YN13E00030F2 ←
3.6.5 Cable YN13E01098P1 ← ← Starter
3.6.6 Cable LE13E01006P1 ← ← Floor ground
3.6.18 Upper harness YN13E01205P1 ― ― Upper
3.6.19 Harness YN13E01209D1 ― ― E/G room light
3.7 Engine harness assy YN16E00009F1 ← ← 3.7.1 E/G sub harness YN16E01016P2 ← ←
3.8.1 Harness ― YN13E01139P1 ← Under floor
3.8.2 Harness ― YN13E01132P1 ← Inst panel (R)
3.8.3 Harness ― YN13E01133P1 ← Inst panel (L)
Upper harness assy
3.8 YN13E00029F2 YN13E00029F1 ← 3.8.10 Cable LE13E01005P1 ← ← Floor ground
(Floor plate)
3.8.12 Harness YN13E01167P2 ― ― Under floor
3.8.13 Harness YN13E01203P1 ― ― Inst panel (R)
3.8.14 Harness YN13E01204P1 ― ― Inst panel (L)
3.9 Cab assy YN02C00018F1 ← ← 3.9.62 Harness YN02C01761P1 ← ← Room light
CAB YN14E00012F2 ― ― 3.10.7 Harness YN14E01022P1 ― ―
3.10 Cab harness assy Cab front right
― YN14E00012F1 ← 3.10.1 Harness ― YN14E01014P2 ←
2484U175 ― ― 12V 120Ah
3.11 Battery
BATTERY ― 2484U173 ← 12V 96Ah
3.12 Battery instal YN72E00005F1 ← ←
UPPER YN80E00012F1 ← ― 3.13.1
3.13 Deck light instal
FRAME ― ― YN80E00012F2 3.13.2
3.14.2 Harness YN15E01012P1 ― ―
YN15E00008F2 ― ―
3.14 Boom harness assy 3.14.3 Harness YN15E01015D1 ― ―
― YN15E00003F1 ← 3.14.1 Harness ― YN15E01013D1 ←
BOOM
LC80E00004F1 ― ―
3.15 Boom light instal ― YN80E00011F1 ―
― ― YN80E00011F2
3.16.13 Harness YN02C01928P1 ― ― RH
YN80E00018F7 ― ―
3.16 3.1615 Harness YN02C01973P1 ― ― LH
CAB Cab light instal
― ― YN80E00018F9 3.16.6 Harness ― ― YN02C01760P1 Thailand
― ― YN80E00018FA 3.16.6 Harness ― ― YN02C01760P1 Indonesia
3.17 Flasher lamp instal YN80E00030F1 ← ←
UPPER
FRAME 3.18 Fuel pump assy instal YN22P00001F1 ― ―
3.19 Travel alarm assy ― LQ53E00001F1 ― Oceania

3
3.2 HARNESS CONNECTION DRAWING

3.6.3 BATTERY RELAY CABLE TRAVEL ALARM (OCEANIA, ASIA) FLASHER LANP (RIGHT)

CN-105 UPPER HARNESS GROUND

FUEL SENSOR
WORK LIGHT BATTERY RELAY
HORN (HIGHT) 3.6.2 CABLE
HORN (LOW) CN-111 UPPER HARNESS GROUND
BATTERY RELAY LEVER LOCK SOL. DECK LIGHT
TRAVEL ALARM ATT POWER BOOST PRESSURE
HYD. OIL FLUID LEVEL SW. 2-SPEED TRAVEL SOL.
BOOM CYL. WORK LIGHT SWING PARKING SOL.
HYDRAULIC PUMP
E/G ROOM LIGHT PRESSURE SENSOR SOL.
AIR FILTER CLOGGING SW. FUEL PUMP STARTER MOTOR
FUEL PUMP WASHER MOTOR MOTOR BATTERY
GROUND
OVER LOAD DETECT SW. E/G COOLANT LEVEL SW.
GROUND

GOVERNOR MOTOR E/G GROUND

E/G OIL PRESSURE LEVEL SW. 3.6.5 STARTER CABLE
3.14.3 3.6.4 GROUND CABLE
SWING FLASHER & BOOM HARNESS
REAR WORK LIGHT (LEFT)
HYD. OIL FLUID TEMP SW. OVER LOAD
GOVERNOR MOTOR
DETECT SW.

3.14.1 BOOM HARNESS

GLOW
HORN RELAY
CB-104 3.6.18 UPPER HARNESS

CAB GROUND
GAUGE CLUSTER
HOUR METER
GROUND
BOOM WORK LIGHT SWING FLASHER SW. 3.10.7 CAB FRONT RIGHT HARNESS ROOM LANP
CIGARETTE LIGHTER GAUGE CLUSTER
SW. ASSY
WIPER MOTOR ALTERNATOR

SOL. BLOCK
SW-ASSY GROUND E/G
TO A/C P29 ROOM
(WIPER, WASHER, WORK LIGHT) INPANE RIGHT LIGHT
FLASHER RELAY 3.8.13
INSTRUMENT PANEL LIGHT HARNESS 3.9.62 3.7.1
ROOM LIGHT HARNESS E/G SUB
HARNESS
3.6.6
FLOOR UNDER HARNESS 3.3.9-1
CN-28 UPPER FRAME>CONTROLLER BOX GROUND 3.3.23-1 INPANE HARNESS
GROUND
WIPER INTERLOCK SW. MECHATRO CONTROLER
ATT POWER BOOST SW.
MECHATRO CONTROLLER
HORN SW.
INSTRUMENT PANEL
SW-ASSY
HARNESS RIGHT
(MODE, BUZZER STOP)
INSTRUMENT PANEL
TUNER
HARNESS LEFT
CONNECTOR FOR 3.6.19 ALTERNATOR
SAFETY RELAY E/G ROOM
MAINTENANCE
KPSS. MODE RELEASE SW. LIGHT HARNESS
WIPER RELAY ASSY OPT WORK LIGHT SW. 3.8.10 GROUND CABLE
AIR CONDITIONER AMPLIFIER HORN SW.
CAB WORK LIGHT PRESSURE SENSOR BLOCK
ATT POWER BOOST SW. 3.6.6 FLOOR GROUND CABLE
24V RESERVE
P-2 INPANE LEFT
SAFETY RELAY
CAB>CONTROLLER GROUND 3.8.3 INSTRUMENT PANEL LIGHT HARNESS SWITCH BOX ASSY

FLASHER LANP (LEFT)

4
 3.3 CONTROLLER ASSY

YN22E00057F2 EU
CONTROLLER ASSY
YN22E00047F2 ASIA, OCEANIA
II
ITEM NAME PART No. Q’TY REMARKS
3 SWITCH BOX ASSY YN50E00004F1 1 1
4 STARTER SAFETY RELAY ME077148 1 1
5 CONTROLLER YN22E00037F1 - 1 KPSS
6 RESISTOR LC22E01001D1 1 1 22, 25

8 RELAY YR24S00002P1 4 2
9 CAB HARNESS ASSY YN14E00013F1 - 1
9-1 INSTRUMENT PANEL HARNESS YN14E01013P5 - 1
10 SWITCH YN50S01003P1 1 1 KPSS. mode release
11 SWITCH YX50E00002F1 1 1 Swing brake release
17 RELAY YT24E00001F1 1 1 Wiper / Washer 5, 24
22 FUSE ASSY YN73E00005F2 - 1
23 CAB HARNESS ASSY YN14E00013F4 1 -
3
23-11 INSTRUMENT PANEL HARNESS YN14E01023P1 1 -
24 CONTROLLER YN22E00069F1 1 - KPSS
25 FUSE ASSY YN73E00007F1 1 -

CONTROLLER INSTAL

YN22E00060F1 EU
CONTROLLER INSTAL
YN22E00046F3 ASIA, OCEANIA VIEW II 4
ITEM NAME PART No. Q’TY REMARKS
3 RELAY ASSY YN24E00005F1 1 - 8 8
R-5 : R-8 :
3-3 CONVERTER YN77S00005F1 1 - DC/DC HORN RELAY 8 TRAVEL ALARM RELAY
8 R-9 : E-8 : SPEAKER LEFT
3-4 FLASHER RELAY YY24S00001P1 1 1 R-6 :
WORK LIGHT
CAB WORK
LIGHT RELAY
RELAY C-3 :
5 TIMER YN25S00001P1 1 1 SWITCH BOX ASSY

8 RELAY ASSY YN24E00003F2 - 1

6
E-4 : RESISTOR

3-3 3-4
GND

3, 8 TO CAB WORK LIGHT LEFT

OPT.
TO ROOF WIPER MOTOR
TO MECHATRO C-6 : AUTO GREASTER
CONTROLER
CONTROLLER
TO INST-PANEL LEFT
(CN-32M)

9•1 17
23•1 11 10

VIEW I

Fig.3 Controller assy

5
3.3.9-1 INSTRUMENT PANEL HARNESS ; YN14E01013P5 (1/2) ASIA, OCEANIA

Fig. 4A(1/2)
Instrument panel harness

6A
 3.3.9-1 INSTRUMENT PANEL HARNESS ; YN14E01013P5 (2/2) ASIA, OCEANIA

Fig. 4A(2/2) Instrument panel harness

7A
ASIA, OCEANIA

8A
 ASIA, OCEANIA

9A
3.3.23-11 INSTRUMENT PANEL HARNESS ; YN14E01023P1 (1/2) EU

Fig. 4E(1/2)
Instrument panel harness

6E
 3.3.23-11 INSTRUMENT PANEL HARNESS ; YN14E01023P1 (2/2) EU

Fig. 4E(2/2) Instrument panel harness

7E
EU

8E
 EU

9E
3.4 INSTRUMENT PANEL ASSY ASIA, OCEANIA
With swing flasher 
YN17M00010FD
Radioless 17 44
INSTRUMENT With swing flasher and radio YN17M00010FJ 
PANEL ASSY
OCEANIA YN17M00010FK 2 23 22

THAILAND YN17M00010FN
INDONESIA YN17M00010FP B
8, 48
ITEM NAME PART No. Q’TY REMARKS
1 COVER ASSY YN17M01051F1 1 1 1 1 1
1-2 SWITCH ASSY YN50E00003F1 1 1 1 1 1 Wiper, washer, work light switch 36 B
2 COVER ASSY YN17M01052F1 1 1 1 1 1
41
2-2 POTENTIOMETER YN52S00009P1 1 1 1 1 1
SECTION
BB
2-3 KEY SWITCH YN52S00002F1 1 1 1 1 1
23
7 SPEAKER YN54S00006P1 ― 2 2 ― ― 24V
8 TUNER LC54S00001P1 ― 1 ― ― ― AM / FM VIEW

17 CIGARETTE LIGHTER 2421R180F1 1 1 1 1 1
20 HOUR METER YN58S00004P1 1 1 1 1 1
23 CABLE YN17M01072P1 ― 1 1 ― ― For tuner

36 SWITCH ASSY YN50E00003F1 1 1 1 1 1 

41 SWITCH ASSY YN50E00002F1 1 1 1 1 1 Buzzer stop, work mode switch

43 SWITCH 2479U1190F31 1 1 1 1 1 Warm up sw.

44 SWITCH 2479U1190F9 1 1 1 1 1 Swing flasher
45 GAUGE CLUSTER ASSY YN59E00002F2 1 1 1 ――
Machine front
48 TUNER YN54S00013P1 ―― 1 ――
51 GAUGE CLUSTER ASSY YN59E00002F3 ― ― ― 1 ― Thailand 52 
51
52 GAUGE CLUSTER ASSY YN59E00002F4 ― ― ― ― 1 Indonesia 45 20 1 12

43
3.4.23¸CABLE (FOR ANTENNA)¸YN17M01072P1

CLICK TYPE

HOUSED CONDENSER 150PF

VIEW 

Fig.5A Instrument panel assy

10A
 3.4 INSTRUMENT PANEL ASSY EU


INSTRUMENT PANEL ASSY YN17M00011F3 17
ITEM NAME PART No. Q’TY REMARKS

2 23 22
1 COVER ASSY YN17M01051F1 1
1-2 SWITCH ASSY YN50E00003F1 1 Wiper, washer, work light switch
B
2 COVER ASSY YN17M01052F1 1
2-2 POTENTIOMETER YN52S00009P1 1
2-3 KEY SWITCH YN52S00002F1 1
7 SPEAKER YN54S00006P1 2 24V B
17 CIGARETTE LIGHTER 2421R180F1 1 39
23 CABLE YN17M01072P1 1 For tuner
SECTION
BB
29 SWITCH 2479U1190F13 1 Heavy lift 23
31 SWITCH 2479U1224F4 1 2 speed travel
VIEW

33 SWITCH 2479U1190F9 1 Swing flasher
35 SWITCH ASSY YN50E00003F1 1
37 SWITCH 2479U1190F31 1 Warm up sw.
39 SWITCH ASSY YN50E00002F1 1 Buzzer stop, work mode switch


42 SWITCH 2479U1190F20 1 Rotary light
43 SWITCH 2479U1190F1 1 OPT work light
44 SWITCH 2479U1190F33 1 Over load cut
45 GAUGE CLUSTER ASSY YN59E00004F2 1
29 31 44 43 42
45-1 GAUGE CLUSTER LC59S00001F3 1
Machine front
47 HOUR METER YN58S00004P1 1

45 47 1 12
3.4.23¸CABLE (FOR ANTENNA)¸YN17M01072P1
37

CLICK TYPE

HOUSED CONDENSER 150PF

VIEW 

Fig.5E Instrument panel assy

10E
3.5 UPPER ELECTRIC ASSY (BLACK)
B
UPPER ELECTRIC ASSY LQ03E00004F2 GO
TIGHTEN FROM THE FRONT (GREEN / ORANGE)
ITEM NAME PART No. Q’TY REMARKS
1 BATTERY RELAY YT24S00001F1 1
CONNECT AS SHOWN SO
2 HORN 2479U1009F1 1 High AS TO AVOID SHORT CIRCUIT
ON POWER SOURCE LINE
3 HORN 2479U1009F2 1 Low
8 LIGHT ASSY YN80E00031F1 1 E/G room (EU only)

1
INSTALLING OF HORN DETAIL OF HORN

LOCATION OF E/G ROOM LIGHT VIEW A
A

A
TERMINAL

CONNECT THIS TERMINAL WITH STARTER CABLE A
TERMINAL LOCK SECTION

B
TERMINAL
CONNECT THIS TERMINAL WITH BATTERY CABLE
CN
103

CLIP CONNECTOR TO THE BRACKET B
TERMINAL

VIEW 

CN
10
TO BATTERY
CN
103
BRACKET L
TERMINAL
L
TERMINAL
CN
101 CN
102 B
TERMINAL 
1
TO STARTER MOTOR TO HARNESS (UPPER) AVS1.25L
EARTH TERMINAL
AVS1.25B AVS1.25G B
TERMINAL
DETAIL OF BATTERY RELAY EARTH TERMINAL

Fig.6 Upper harness assy

11
 3.6 UPPER HARNESS ASSY

WHITE TAPING
YN13E00030F3 EU
UPPER HARNESS ASSY
YN13E00030F2 ASIA, OCEANIA
ITEM NAME PART No. Q’TY REMARKS
1 HARNESS YN13E01137P2 - 1 UPPER
5
2 CABLE YN13E01053D2 1 1 BATTERY
M•1 :
3 CABLE 2486R89D5 1 1 BATTERY RELAY STARTER MOTOR

4 CABLE YN13E01118P1 1 1 GROUND

L-4 :
5 CABLE YN13E01098P1 1 1 STARTER L-2 :
SV-11 : SWING FLASHER &
R•1 : BATTERY RELAY DECK WORK SE-15 : SW-25 : E-12 : REAR WORKING LIGHT RIGHT
EXTRA SOL.
6 CABLE LE13E01006P1 1 1 FLOOR GROUND LIGHT FUEL SENSOR HYD. OIL LEVEL SW. TRAVEL ALARM

PSV-P2 : P2 PUMP SOL.

18 HARNESS YN13E01205P1 1 - UPPER I SE-23 : PRESS SENSOR : P2 PUMP

19 HARNESS YN13E01209D1 1 - E/G ROOM LIGHT M•8 : SE-22 : PRESS SENSOR : P1 PUMP
GREASE MOTOR (OPT)
PSV-P1 : P1 PUMP SOL.

1, 18
TO OVER LOAD DETECT SW. SE•13 :
CONNECT TO BE PRESS. SW. FIT CORNERS E/G SPEED SENSOR
3 ON THE TIP OF BOOM CYLINDER THEN INSTALL
WHITE TAPING
HARNESS ON
TIGHTEN AFTER THE FRAME
CHECKING NO PAINT HERE M•1 : STARTER MOTOR
GND TIGHTENING TORQUE L•9 :
2 0.35kgfŸm (2.5ftŸlbs) BOOM CYLINDER SE•28 :
M•2 : GOVERNOR MOTOR
WORK LIGHT (OPT) PRESS. SENSOR:
BACK PRESS. TO HARNESS•E/G SUB•

4 FIT CORNERS THEN INSTALL

HARNESS ON THE FRAME
SW-23 :
E/G OIL LEVEL SW.
HARNESS (ATT)

TO HARNESS
WHITE TAPING (INST-PANEL)

GND 6 CONNECT WITH • VI

TIGHTEN AFTER GROUND OF A
CHECKING NO PAINT HERE FLOOR PLATE

L-3 :
DETAIL OF BATTERY
• B SWING FLASHER &
REAR WORKING LIGHT LEFT
THIS HARNESS TO BE PASS
BEHIND WASHER TANK.

M-4 : TO E/G ROOM LIGHT

SW-24 :
WASHER MOTOR SW-8 : E/G COOLANT E - 10 :
GND
TIGHTEN AFTER CHECKING NO PAINT HERE AIR FILTER CLOGGING SW. LEVEL SW. RECEIVER DRIER

TO HARNESS (ATT)
FIX HARNESS WITH
FIX HARNESS WITH CLIP
CLIP ON GUARD
OF
RECEIVER DRIER

VIEW V Fig.9(1/2) Upper harness assy

12
 ENGINE ROOM LIGHT FOR EU

BY USING CAPSCREW, TIGHTEN SENSOR L
3 :

BLOCK AND CLIP TOGETHER. SWING FLASHER L
4 :
LEFT & REAR SWING FLASHER RIGHT
CLIP WORK LIGHT TO E/G & REAR WORK LIGHT
ROOM LIGHT CLIP

CLIP HARNESS TO
SV
1 : SWING PARKING SOL.
PRESS. SENSOR
SV
3 : 2-SPEED SELECT SOL.

CLIP CONNECT TO
2P CONNECTOR
ON PART OF
RECEIVER DRIER
PSV
A : ARM VARIABLE RECIRCULATION
SE
1 : UPPER HARNESS
PROPORTIONAL SOL.
PRESS. SENSOR : BUCKET DIGGING
PSV
D : P1 BYPASS CUT PROPORTIONAL SOL.
SE
2 :
PSV
C : TRAVEL PRIORITY PROPORTIONAL SOL. PRESS. SENSOR : BUCKET DUMP
SE
3 :
PSV
B : P2 BYPASS CUT PROPORTIONAL SOL. PRESS. SENSOR : BOOM RAISING
SE
4 :
SV
2 : ATT POWER BOOST SOL. PRESS. SENSOR : BOOM LOWERING
SE
5 :
SV
4 : LEVER LOCK SOL. PRESS. SENSOR : SWING LEFT SE
8 :
SE
6 : PRESS. SENSOR : ARM OUT VIEW

PRESS. SENSOR : SWING RIGHT
SE
7 :
PRESS. SENSOR : ARM IN

DETAIL OF A (PSV BLOCK)

DETAIL OF B (PRESS. SENSOR)

L
11 :
CONNECT RING TERMINAL TO ROOM LIGHT
ATTACHING BOLT & NUT (M5)
19

TO HARNESS
(UPPER)

L
2 :
DECK WORK LIGHT
(RIGHT) SE
15 :
FUEL SENSOR

CONNECT HARNESS IN THE CAP

FASTEN TO PRESSURE
SENSOR
TIGHTENING PASS HARNESS THROUGH THE HOLE CLIP
TORQUE
0.7kgf!m (5.1ft!lbs) SE
28 :
TIGHTEN CABLES PRESS. SENSOR :
IN THE CAPS BACK PRESS.
DETAIL OF BONNET

NOTE : Location of E/G room light is shown in page 11.

HARNESS (UPPER)
HARNESS (UPPER)
CABLE (STARTER)

VEIW
 VIEW


Fig.9(2/2) Upper harness assy

13
 3.6.1 UPPER HARNESS ; YN13E01137P2 ASIA, OCEANIA

Fig. 8A(1/2) Upper harness

14A
Fig. 8A(2/2)
Upper harness
15A
16A
3.6.18 UPPER HARNESS ; YN13E01205P1 EU

Fig. 8E(1/2)
Upper harness

14E
 Fig. 8E(2/2) Upper harness
15E
16E
 3.6.2 BATTERY CABLE ; YN13E01053D2 3.6.5 STARTER CABLE ; YN13E01098P1

3400 (11´2 )
430 (16.9 )

20 TERMINAL
TERMINAL 70 AV60sq INSTALL (0.787 ) 70 BA710
60-8 (2.76 ) CORRUGATE TUBE (2.76 )

CAP 130 (5.12 ) 550 CAP

YAZAKI 7034-1283 (21.7 ) YAZAKI 7034-1283
WHITE TAPING
AV60B A
CAP TERMINAL TERMINAL CAP TERMINAL
LA208
Fig.9 DOUBLE AVSS 0.75sq TAPING
SPLICE DOUBLE-WOUND TAPING
FROM TERMINAL TO CONNECTOR

3.6.3 BATTERY CABLE RELAY ; 2486R89D5

20
(0.787 )
470 (18.5 )
WIND TWO CONNECTORS BACK
TO BACK WITH VINYL TAPE AND
PUT A CAP

DETAIL OF A
Fig.12

3.6.6 FLOOR GROUND CABLE (UPPER FRAME SIDE) : LE13E01006P1

TERMINAL TERMINAL
60-8 BC818 100 (3.94 )
CAP AV60B LA308 5B 5B
CAP
YAZAKI 7034-1283
BTC-135-R (RED)
1PAM
Fig.10 YAZAKI 7123-3010
Fig.13

3.6.4 BATTERY GROUND CABLE ; YN13E01118P1 3.6.19 ENGINE ROOM LIGHT HARNESS ; YN13E01209D1 EU
SW-16 : E/G ROOM LIGHT SW.
CB104
350 (13.8 )

40
(1.57 ) 2PAM-HW
TO HARNESS (UPP) 1300 (4´3 )

LA105
L-11 : E/G ROOM LIGHT

TERMINAL
AV60B
TERMINAL 60-8
BC816 DOUBLE-WOUND
TAPING
Fig.11
Fig.14
17
3.7 ENGINE HARNESS ASSY 
SE
23 :
PRESS SENSOR : P2 PUMP
ENGINE HARNESS ASSY YN16E00009F1
ITEM NAME PART No. Q’TY REMARKS PSV
P1 : PSV
P2 :
P1 PUMP PROPORTIONAL P2 PUMP
1 HARNESS YN16E01016P2 1 E/G SUB HARNESS SOL. PROPORTIONAL SOL.
SE
13 : SE
22 :
M
1 : STARTER MOTOR
E/G SPEED SENSOR PRESS SENSOR :
NOTE : P1 PUMP
TIGHTENING TORQUE : M10 6.5kgf!m (47ft!lbs) HARNESS (UPPER)
HARNESS (UPPER)
M8 3.6kgf!m (26ft!lbs)
 M
2 : NUT
GOVERNOR MOTOR GND

CLIP
GND CABLE
(STARTER MOTOR)
1
SW
7 : SW
23 :
E/G OIL PRESS SW. E/G OIL LEVEL
FIX CONNECTOR TO BRACKET. SW.
E
2 : ALTERNATOR
R
3 :
CLIP GLOW RELAY
THROUGH THE OUTSIDE OF BLOWBY HARNESS (UPPER)
HOSE AND FASTEN HARNESS GLOW PLUG
TIGHTENING TORQUE E
11 :
CLIP SE
14 :
DIRECT CLIP 1.5kgf!m (6ft!lbs) AIR COMPRESSOR
E
2 : E/G WATER TEMP SENSOR
AS SHOWN CLUTCH
ALTERNATOR
CLIP
UPPER

LOWER

S
6 : TIGHTENING TORQUE

E/G WATER TEMP SW. 1.5kgf!m (11ft!lbs)

DETAIL OF GOVERNOR MOTOR VIEW


CLIP FASTEN HARNESS TO HOLE
AT SIDE OF COUNTER WEIGHT SE
26 :
FIX THIS POINT TO CLIP
CLIP PRESS SENSOR : P1 NEGA-CON
OF CONNECTOR
SE
23 :
PSV
P1 : PRESS SENSOR :
P1 PROPORTIONAL SOL. VALVE P2 PUMP
E/G ACCESSORY PART
STARTER SW.
BRACKET
GLOW RELAY
STARTER RELAY

INSTALL CAP AFTER

CONNECTING CABLE DETAIL OF ENGINE SPEED DETAIL OF AIR-CON COMPRESSOR
SENSOR CONNECTOR

CONNECT HARNESS FOR HARNESS

B-TERMINAL NOT TO (UPPER)
INTERFERE WITH ALTERNATOR
P-TERMINAL
CLIP
BY USING EXISTING CAPSCREW
FIX THE CONNECTOR STARTER MOTOR B-TERMINAL TIGHTEN LUG FOR E/G AND CLIP SE
22 :
FIX THE CONNECTOR GND TOGETHER. PRESS SENSOR :
OF STARTER RELAY L, R-TERMINAL
OF E/G OIL LEVEL SW. TO THIS BRACKET. AT THIS TIME APPLY LOCKTITE P1 PUMP
FIX THE #262 TO THE CAPSCREW. PSV
P2 : SE
27 :
WHITE TAPING CONNECTOR TIGHTNING TORQUE P2 PROPORTIONAL SOL. VALVE PRESS SENSOR :
TO THIS BRACKET. 2.0kgf!m (14ft!lbs) P2 NEGA-CON
CAPSCREW (GND)
DETAIL OF GLOW RELAY AND STARTER MOTOR CLIP HARNESS AT WHITE TAPING
E-TERMINAL

DETAIL OF ALTERNATOR VIEW
 DATAIL OF PUMP SECTION

DETAIL OF LIFTING LUG FOR
ENGINE
Fig.15
E/G harness assy

18
 3.7.1 ENGINE SUB HARNESS ; YN16E01016P2

Fig. 16 Engine sub harness

19
 SW
21 : ATT POWER BOOST SW. (YELLOW TAPING)
3.8 UPPER HARNESS ASSY (FLOOR PLATE) SE
20 : PRESS SENSOR : P1 OPT. CLIP HARNESS AT WHITE SW
10 : HORN SW. (BLUE TAPING)
TAPING POSITION
10 SE
16 : SW
2 : SW. ASSY
GND 1, 12(UNDER FLOOR) ACCEL POTENTIO (MODE , BUZZER STOP)
YN13E00029F2 EU
UPPER HARNESS ASSY CONNECT WITH
YN13E00029F1 ASIA, OCEANIA FRAME GND
SW
1 : KEY SW.

ITEM NAME PART No. Q’TY REMARKS SE
10 :

E
7 : TUNER
PRESS SENSOR :
1 HARNESS YN13E01139P1 1 ― Under floor TRAVEL LEFT
2 HARNESS YN13E01132P1 1 ― Inst panel RH
CLIP HARNESS AT
3 HARNESS YN13E01133P1 1 ― Inst panel LH SW
3 :
WHITE TAPING
2, 13
POSITION
2 SPEED SELECT SW.
10 CABLE LE13E01005P1 1 1 Floor ground
12 HARNESS YN13E01167P2 ― 1 Under floor SE
9 :
2
PRESS SENSOR :
13 HARNESS YN13E01203P1 ― 1 Inst panel RH TRAVEL RIGHT CLIP HARNESS
AT TAPING POSITION
1
14 HARNESS YN13E01204P1 ― 1 Inst panel LH
TO THE FACE SIDE VIEW

SE
11 : PRESS SENSOR : P2 CLIP HARNESS AT WHITE SW
3 :
OF FLOOR PLATE.
OPT TAPING POSITION 2-SPEED SELECT SW. SW
12 : OVER LOAD ALARM SW.
SW
35 : HEAVY LIFT SW. SW
16 : CAB WORK LIGHT SW.
VIEW FROM THE BACK SIDE OF FLOOR PLATE
SW
40 :
 ROTARY LIGHT SW.
2, 13
SW
47 :
EXTRA & BREAKER SW.
SW
38 : WARM UP SW.
1 SW
15 : CONFLUENCE / SINGLE SELECT SW. SW
13 :
AIR CONDITIONER SW.
2
VIEW
(Case F2)

SW
26 : SW
22 :
SW
17 : ROOF WIPER SW. OPT WORK LIGHT SW. TRAVEL ALARM SW.

VIEW




4 3
SW
38 : WARM UP SW.

SW
15 : CONFLUENCE / SINGLE SELECT SW.
 3, 14 SW
13 : AIR CONDITIONER SW.
SW
18 : LMN / BH SELECT SW.
FLOOR PLATE SIDE
CONNECT WITH INST
CAB PANEL HARNESS 4 VIEW
(Case F1)
DETAIL OF GROMMET
5 UPP HARNESS
SW
10 : HORN SW. (BLUE TAPING)
TO CAB HARNESS BACK-UP MODE SW
21 : ATT POWER BOOST SW. (YELLOW TAPING)
CABLE
TO AIR 5
CONDITIONER AMP. Machine front
UPP

CONNECT WITH INST

UNDER FLOOR HARNESS
PANEL HARNESS
INST PANEL RH
UNDER FLOOR 3, 14

TO FLOOR PLATE

3
3
1
2
SW
11 :
R
20 : TIMER CLIP HARNESS AT
SAFETY LOCK LEVER SW.
VIEW
WHITE TAPING
VIEW

 
POSITION

Fig.17
Upper harness assy (floor plate) VIEW


20
 3.8.1 UNDER FLOOR HARNESS : YN13E01139P1, ASIA, OCEANIA

Fig.18A Under floor harness

21A
3.8.12 UNDER FLOOR HARNESS : YN13E01167P2, EU

Fig.18E Under floor harness

21E
 3.8.13 INSTRUMENT PANEL RH HARNESS : YN13E01203P1, EU

Fig.19E Instrument panel right harness

22E
3.8.2 INSTRUMENT PANEL RH HARNESS : YN13E01132P1, ASIA, OCEANIA

Fig.19A
Instrument panel right harness

22A
 3.8.3 INSTRUMENT PANEL LH HARNESS : YN13E01133P1, ASIA, OCEANIA 3.8.10 GROUND CABLE (FLOOR PLATE SIDE) : LE13E01005P1

100
LA308 5B 5B
1PAM
YAZAKI 7123-3010
Fig.20 Ground cable

Fig.20A Instrument panel left harness

23A
3.8.14 INSTRUMENT PANEL LH HARNESS : YN13E01204P1, EU

Fig.20E
Instrument panel left harness

23E
 3.9 CAB ASSY 3.9.62 ROOM LAMP HARNESS : YN02C01761P1

CAB ASSY YN02C00018F1

ITEM NAME PART No. Q’TY REMARKS
25 SWITCH YT50S00004P1 1 DOOR SW.
42 WINDOW WASHER ASSY YT54C00001P1 1
55 STOPPER ASSY YT02C01330F2 1 WIPER INTERLOCK
62 HARNESS YN02C01761P1 1 ROOM LIGHT HARNESS
68 ROOM LIGHT YT80S00001P1 1
78 WIPER ASSY YN53C00004P1 1

Attach the windshield wiper switch harness,

branching off from the room light to the switch.
Connected point to be pushed into the hole in
the interior material.
Also the grommet is set up and attached in the
interior material.
Stopper adjustment is made when the front 55
window is raised and locked by turning the
stopper to the CCW and, after the gum cover
contacts the glass side, tightening it one full turn
to fix it in place.

25
68

42

62

78

CONNECT TO
MAIN HARNESS

Fig.21 Cab assy Fig.22 Room light harness

24
3.10 CAB HARNESS ASSY
E－14 : SW－20 :
YN14E00012F1 ASIA, OCEANIA CIGARETTE LIGHTER SW. ASSY（WIPER, WASHER, WORK LIGHT）
CAB HARNESS ASSY
YN14E00012F2 EU
ITEM NAME PART No. Q’TY REMARKS
1 HARNESS YN14E01014P2 － 1 Cab front RH
7 HARNESS YN14E01022P1 1 － Cab front RH

SW－14 :
WINDOW WIPER SW. SW－9 :
SWING FLASHER SW.
C－2 :
GAUGE CLUSTER

TO INST-PANEL HARNESS

GND

CAPSCREW
（GND）

1, 7 E－22 :
DC-DC
CONVERTER

R－19 :
FLASHER RELAY

M－3 :
WIPER MOTOR
DETAIL OF A

E－3 :
HOUR METER

Fig.23 Cab harness assy

25
 3.10.1 CAB FRONT RH HARNESS : YN14E01014P2, ASIA, OCEANIA

Fig.24A Cab front right harness

26A
3.10.7 CAB FRONT RH HARNESS : YN14E01022P1, EU

Fig.24E Cab front right harness

26E
 3.11 BATTERY ; 2484U175 : 12V120Ah / 5HR, EU 3.13 DECK LIGHT INSTAL
; 2484U173 : 12V96Ah / 5HR, ASIA, OCEANIA
YN80E00012F1 EU, ASIA, OCEANIA
DECK LIGHT INSTAL
YN80E00012F2 THAILAND, CHINA
ITEM NAME PART No. Q’TY REMARKS
1 LIGHT YN80S00010F2 1 -

179
2 LIGHT YN80S00002F2 - 1

1, 2
502
NEGATIVE POSITIVE
(•)POLE (•)POLE

255 TIGHTENING TORQUE

1.1kgfŸm (8ftŸlbs)
3
500 2

Fig.25 Battery

3.12 BATTERY INSTAL

BATTERY INSTAL YN72E00005F1 1

ITEM NAME PART No. Q’T REMARKS
Y MAIN HARNESS
1 BRACKET YN72E01004P1 1
2 ROD YJ72E01002P1 2
3 NUT ZN18C08007 4

NUT (SUPPLIED WITH LIGHT)

TIGHTENING TORQUE•
1.9kgfŸm (14ftŸlbs)

HOW TO INSTAL DECK LIGHT

Fig.27 Deck light instal

Fig.26 Battery instal

27
3.14 BOOM HARNESS ASSY 3.14.1 BOOM HARNESS ; YN15E01013D1, ASIA, OCEANIA

YN15E00003F1 ASIA, OCEANIA 4000 (13´1˝ )

BOOM HARNESS ASSY
YN15E00008F2 EU
730 (28.7˝ )
ITEM NAME PART No. Q’TY REMARKS
1 HARNESS YN15E01013D1
1 One light
2 HARNESS YN15E01012P1 1
Two light
3 HARNESS YN15E01015D1 1
Over load detect CB104
CAP : 7120-1010 T-AV0. 85sq WHITE TAPING 1PAM
TERMINAL : 7115-1050-02 YAZAKI 7122-2810
TERMINAL : 7114-2020
Only EU

Fig.29A Boom harness

CLAMP TAPING 3.14.2 BOOM HARNESS ; YN15E01012P1, EU

L－5 :
BOOM WORKING LIGHT RIGHT
1, 2 CB104

CLAMP TO THE
TUBE FOR GREASE

A
DOUBLE
SPLICE
LIGHT HARNESS TO BE
TO UPPER HARNESS
BUNDLED AND FIXED WHITE TAPING 1PAM TO UPPER
WITH EXISTING CLIP CN－110M HARNESS

DETAIL OF A
CB104
L－1 :
BOOM WORKING LIGHT LEFT

Fig.29E Boom harness

3

BOOM CYL. LH
3.14.3 HARNESS ; YN15E01015D1, EU

3000 (9´10˝ )
SUPPLY WITH

CONNECT WITH
UPPER HARNESS
2PAM－HW 2PAF－HW 2PAM－HW
SEALING PLUG TO BE OVERLOAD TO UPPER
INSERTED INTO ALL DETECTION SW . HARNESS
BOOM CYL. RH TERMINAL

Fig.30Overload detection harness

CLIP

DETAIL OF BOOM FOOT

Fig.28Boom harness assy

28
 3.15 BOOM LIGHT INSTAL

YN80E00011F1 ASIA, OCEANIA

BOOM LIGHT INSTAL YN80E00011F2 THAILAND, INDONESIA
LC80E00004F1 EU
ITEM NAME PART No. Q’TY REMARKS
1 LIGHT YN80S00001F1 2 - 1
6 LIGHT YN80S00012F1 - 1 -

1, 6 (ASIA, OCEANIA)

1 (EU)

TO BUCKET BOTTOM CENTER

DIRECT THE LIGHT BEAM TO THE BOTTOM OF BUCKET, WHEN
ARM IS COMPLETELY EXTENDED (ARM OUT) AND BUCKET IS
FULLY CLOSED.

1, 6

SECTION A-A

Fig.31 Boom light install

29
3.16 CAB LIGHT INSTAL 3.16.6 HARNESS ; YN02C01760P1, ASIA

YN80E00018F7 EU
CAB LIGHT INSTAL YN80E00018F9 THAILAND
YN80E00018FA INDONESIA
ITEM NAME PART No. Q’TY REMARKS
6 HARNESS YN02C01760P1 － 2 2
7 SWITCH 2479U1190F1 － 1 － Travel 1-2 speed
100 (3.94˝ )
11 RELAY YR24S00002P1 － 1 －
13 HARNESS YN02C01928P1 1 － － RH
Fig.33A Harness
15 HARNESS YN02C01973P1 1 － － LH
16 LIGHT YT80S00002F2 － 1 －
3.16.13 CAB LIGHT HARNESS (RH) ; YN02C01928P1, EU

A
16

100 (3.94˝ )

Fig.33E Cab light harness (RH)

3.16.15 CAB LIGHT HARNESS (LH) ; YN02C01973P1, EU

6, 13, 15

CONNECT WITH
7 MAIN HARNESS.
R-9:
CLIP OPT WORK CONNECT TO
LIGHT RELAY INST-PANEL HARNESS
11

100 (3.94˝ )
13 (RH)
15 (LH)


Machine Front
DETAIL OF A DETAIL OF LOWER STAGE OF CONTROLLER ASSY
Fig.34E Cab light harness (LH)
Fig.32
Cab light instal

30
 3.17 FLASHER LAMP INSTAL 3.18 FUEL PUMP ASSY INSTAL EU

FLASHER LAMP INSTAL YN80E00030F1 FUEL PUMP ASSY INSTAL YN22P00001F1

ITEM NAME PART No. Q’T REMARKS ITEM NAME PART No. Q’T REMARKS
Y Y

1 FLASHER LAMP YN80S00015F3 1 For RH 1 FUEL PUMP ASSY YN22P00001F5 1

2 FLASHER LAMP YN80S00015F4 1 For LH
TO TANK

COUNTERWEIGHT

VIEW I

2 1

Fig.37 Fuel pump assy instal

VIEWED FROM BACK OF MACHINE
3.18.1 FUEL PUMP ASSY EU
Fig.35 Flasher lamp instal
FUEL PUMP ASSY YT22P00001F5
ITEM NAME PART No. Q’T REMARKS
3.17.1,2 FLASHER LAMP ; YN80S00015F3, F4 Y

10 ELECTRIC MOTOR YT22P00001S010 1

22 FUSE YT22P00001S022 1

10

SWING LIGHT SWING LIGHT

22 CA-104

RED (•)

BLACK (•)
REAR WORK LIGHT REAR WORK LIGHT CABLE LENGTH
APPROX 180mm CB-104

Fig.36 Flasher lamp (For LH) Fig.38 Fuel pump assy

31
3.19 TRAVEL ALARM ASSY, OCEANIA

ALARM ASSY LQ53E00001F1

ITEM NAME PART No. Q’TY REMARKS
1 ALARM 2479U1710 1 Travel
3 SWITCH 2479U1190F16 1
4 RELAY YN24S00001P1 1

E
13 :
TRAVEL ALARM

COUNTERWEIGHT

VIEW 

R
8 : CONNECT TO
TRAVEL ALARM 4 INST-PANEL HARNESS
RELAY

ATTACH THIS SWITCH DIRECTING

ONE PAWL SIDE TO MACHINE FRONT
DETAIL OF LOWER STAGE OF CONNTROLLER ASSY

CONNECT WITH HARNESS

3
FOR TRAVEL ALARM
A

DETAIL OF A

DETAIL OF LEFT INST. PANEL

Fig.35
Travel alarm assy

32
NOTES NOTES
 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS

CHAPTER 24

E215
CRAWLER EXCAVATORS

COMPONENTS SYSTEM

Issued January 2006

Book/Form Number 5-1660 NA
Copyright © 2006. CNH America, LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. S5PJ0010E01-KO24
 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 24 - COMPONENTS SYSTEM

CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Remarks
First Edition 01-2006 E215 5-1660 NA

24-II Issued 01-2006 Bur 5-1660 NA

 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS

CHAPTER 24
COMPONENTS SYSTEM
TABLE OF CONTENTS

1. HYDRAULIC COMPONENTS
1.0 Hydraulic Pump - Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-1
1.1 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-1
1.2 Hydraulic Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-1
1.3 Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-3
2.1 Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-7
2.1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-1
2.2 Pilot Valve Construction, Function, And Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-1
2.2. Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-2
2.3 Pilot Valve (Travel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-2
3.1 Outline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-1
3.2 Construction and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-2
3.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-3
4.0 Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-1
4.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-1
4.2 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-2
4.3 Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-8
4.4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4-9
5.0 Swing Motor Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-1
5.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-1
5.2 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-2
5.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-6
6.0 Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6-1
6.1Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6-1
6.2 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6-2
6.3 Make up of Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6-4
6.4 Functions of Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6-6
6.5 Reduction Valve Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6-13
7.0 Swivel Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7-1
7.1 Outside View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7-1
7.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7-1
7.3 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7-2
8.0 Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8-1
8.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8-1
8.2 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8-2
2. ELECTRICAL EQUIPMENT
2.1 List of Electrical Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E1-1-E
2.2 Summary of Main Electrical Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E1-2
2.3 Specifications of Electrical Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E1-5

5-1660 NA Issued 01-2006 Bur 24-1

SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 24 - COMPONENTS SYSTEM

NOTES
 1. HYDRAULIC PUMP ・ REGULATOR
1.1 SUMMARY
(1) Outside view and hydraulic port

a3 Dr Pn1 EYE BOLT (M10) PH2 a6 2 A3



A1 A2

B3 VIEW
MAX. FLOW RATE
a5 PH1 ADJUSTING SCREW Pn2 A4 4
MIN. FLOW RATE
a8 PSV PSV2 a9 ADJUSTING SCREW
Pn1 4
Pn2 a5
a3 a9 PH2
a4
a5 2 a6

Pn2
Pn1
3

B3

A3
B3
Dr

B1 1 Dr3,a7 Dr3 a2 a7
Dr a1 a2

Fig. 1-1Hydraulic pump y regulator

Table 1-1Hydraulic ports
Code Ports name Size
A1,2 Delivery port
B1 Suction port

No. NAME Dr Drain port PF3/4

1 MAIN PUMP ASSY PSV1,2 Servo assist port PF1/4
2 REGULATOR ASSY
Pn1,2 Servo assist port PF1/4
3 GEAR PUMP ASSY(FOR PILOT)
PH1,2 Pressure sensor port PF3/8
4 SOLENOID PROPORTIONAL REDUCING VALVE
a1
9 Gauge port PF1/4
A3 Delivery port of gear pump PF3/8
B3 Suction port of gear pump PF3/4
Dr3 Drain port of gear pump PF3/8

11
NOTES
 1.2 HYDRAULIC PUMP
1.2.1 CONSTRUCTION
(1) Main pump Apply adhesive
(Three Bond No.13038)

806 535 789 732 532 214 548 531 724 702 792 534 808 901 954 717 151 152 211 113
953
886
717
261
406 04 546
Apply oil seal
With adhesive
(Locktite No.222) 725
774
111
724

325

407
127

824
710 VIEW_A
Tightning torque
123 Frange socket(4-M8_1.25)
1.7kgfŸm(12ftŸlbs)
312
251
212 490 153 156 468 157 981 313 124 114 466 885 314 141 271 401
728 983 Valve plate for 725 Valve plate for
P1 pump P2 pump
Table 1-3
Tightening torque Tightening torque Tightening torque Q’T
kgfŸm (ftŸlbs) No. NAME Q’TY kgfŸm (ftŸlbs) No. NAME Q’TY kgfŸm (ftŸlbs) No. NAME
Y
111 DRIVE SHAFT (F) 1 313 VALVEPLATE(R) 1 725 O RING_1B P11 7
113 DRIVE SHAFT (R) 1 314 VALVEPLATE(L) 1 728 O RING_1B P24 4
114 SPLINE JOINT 1 325 COVER 1 732 O RING_1B P18 2
123 ROLLER BEARING 2 44 (320) 401 SOCKET BOLT_M20_210 8 774 OIL SEAL 1
124 NEEDLE BEARING 2 3.0 (22) 406 SOCKET BOLT_M8_20 4 789 BACK UP RING 2
127 BEARING SPACER 4 1.2 (8.7) 407 SOCKET BOLT_M6_30 3 792 BACK UP RING 2
141 CYLINDER BLOCK 2 3.7 (27) 466 VP PLUG_PF1/4 2 13 (94) 806 NUT_M16 2
151 PISTON 18 17 (120) 468 VP PLUG_PF3/4 4 24 (170) 808 NUT_M20 2
152 SHOE 18 0.9 (6.5) 490 PLUG_NPTF1/16 20 824 SNAP RING 2
153 RETAINER PLATE 2 24 (170) 531 TILTING PIN_M24_2 2 885 VALVE PLATE PIN 2
156 SPHERICAL BUSHING 2 24 (170) 532 SERVO PISTON_M24_2 2 886 SPRING PIN 4
157 CYLINDER SPRING 18 534 STOPPER(L) 2 901 EYE BOLT_M10 2
211 SHOE PLATE 2 535 STOPPER(S) 2 953 SOCKET SCREW_M16_30 2
212 SWASH PLATE 2 546 SPACER 2 954 SET SCREW_M20 2
214 TILTING BUSHING 2 548 FEED BACK PIN 2 04 GEAR PUMP 1
251 SWASH PLATE SUPPORT 2 702 O RING_1B G35 2
261 SEAL COVER(F) 1 710 O RING_1B G95 1
271 PUMP CASING 2 717 O RING_1B G145 4
312 VALVE BLOCK 1 724 O RING_1B P8 16
The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
Fig. 1-3_Construction of hydraulic pump 1-1-3
 (2) Gear pump (For pilot)

700 354 351 433

Suction port : PF3/4
Tightening torque : 7.5kgfŸm (54ftŸlbs)

728

434

Delivery port : PF3/8

Tightening torque :
3.5kgfŸm (25ftŸlbs)
311
312

732
850 467
309
355
310 434 466
Drain port : PF3/8 307 308 725
710 435 361 353 Tightening torque : 3.5kgfŸm
(25ftŸlbs)

Fig.1-4 Gear pump (for pilot) construction

Table 1-4

No. NAME Q’TY No. NAME Q’TY

307 POPPET 1 433 FRANGE SOCKET; M8× 40 2
308 SEAT 1 434 FRANGE SOCKET; M8× 55 2
309 SPRING SEAT 1 435 FRANGE SOCKET; M8× 20 4
310 SPRING 1 466 VP PLUG ; PF1/4 1
311 ADJUST SCREW 1 467 ADAPTER ; PF1/2-PF3/8 1
312 LOCK NUT ; M14×1.5 1 700 RING 1
351 GEAR CASE 1 710 O RING ; 1B G95 1
353 DRIVE GEAR 1 725 O RING ; 1B P11 1
354 DRIVEN GEAR 1 728 O RING ; 1B P18 1
355 FILTER 1 732 O RING ; 1B P16 1
361 FRONT CASE 1 850 LOCKING RING 1

1 -1- 4
1.2.2 OPERATION
The pump system has two pumps linked with a
spline joint (114). Two pumps may be operated at 114
the same time as the engine rotation is 312
transmitted to the drive shaft (F) (111) of the Delivery port
front side. The oil suction and delivery flows are
converged into the joint of the two pumps i.e. the Rear pump
valve block (312). The suction port is common for (No.2 pump)
the front and rear pumps.
The pump system consists largely of the rotary Suction port
group that is the main part of the pumps making
111 Front pump
rotary action, the swash plate group that varies (No.1 pump)
the delivery rate, and the valve cover group that
changes the suction and delivery of the oil. Fig. 1-5
Construction of hydraulic pump

(1) Rotary group
(See Fig. 1-6)

The rotary group consists of drive shaft
(F)(111), cylinder block (141), piston (151),
111
shoe (152), retainer plate (153), spherical
bushing (156) and cylinder spring (157). 123
The drive shaft is supported by bearings
(123) and (124) at its both ends. The shoe, 313
141 124
which is caulked to the piston, forms a 157
spherical joint and relieves it of thrust force 153156
that is generated by load pressure. 151152
211
Further, the piston is provided with a pocket
so it moves lightly on shoe plate(211), taking
hydraulic balance.
The cylinder block is pressed against valve
plate (313)
by the action of cylinder spring.
Fig. 1-6
Rotary group
(2) Swash plate group
(See Fig. 1-7)
531
The swash plate group is composed of swash
plate (212), shoe plate(211), swash plate
support (251), tilting bushing (214), tilting
pin(531) and servo piston (532). The swash
plate is a cylindrical part that is formed on
the opposite side of the shoe sliding surface
and is supported by the swash plate support. 251
The hydraulic pressure controlled by the
regulator is induced into the hydraulic
211
chamber that is provided on both sides of the 214
servo piston and moves the servo piston to
the right and the left. The swash plate swings 212
over the swash plate support via the
spherical part of the tilting pin that is linked
to the servo piston and changes its tilting
angle. Fig. 1-7
Swash plate group

15
(3) Valve cover group
The valve cover group consists of valve block
(312), valve plate (313), and valve plate pin
(885). The valve plate having two crescent-
shaped ports is installed to the valve block to
supply oil to the cylinder block and deliver oil Delivery port
from it.
Now, if the drive shaft is driven by the
313
engine, the cylinder block rotates at the same
time via the spline.
Now, let us keep an eye on a single piston
arranged in the cylinder block: While the
cylinder block makes one turn, the piston Suction port
885 312
moves away from the valve plate (oil suction
process) in the first 180° and moves close to Fig.1-8 Valve cover group
the valve plate in the remaining 180°(oil
discharge process). When the tilting angle of
the swash plate is zero, the piston makes no
stroke i.e. no oil deliver.

1 - 1- 6
1.3 REGULATOR
1.3.1 CONSTRUCTION Table 1-5
No. NAME Q'TY No. NAME Q'TY No. NAME Q'TY
412 SOCKET BOLT ; M8_50 2 625 OUTER SPRING 1 725 O RING ; 1B_P10 1
545 755 413 SOCKET BOLT ; M8_70 2 626 INNER SPRING 1 727 O RING ; 1B_P14 1
418 SOCKET BOLT ; M5_12 2 627 ADJUSTING STEM 1 728 O RING ; 1B_P18 1
541
436 SOCKET BOLT ; M6_50 5 628 ADJUSTING SCREW 1 730 O RING ; 1B_P22 1
543
438 SOCKET BOLT ; M6_20 4 629 COVER (C) 1 732 O RING ; 1B_P16 2
801 439 SOCKET BOLT ; M6_40 4 630 LOCK NUT 1 733 O RING ; 1B_P20 2
642 753 467,727 466 VP PLUG ; PF1/4 3 631 SLEEVE 1 734 O RING ; 1B_P25 1
SECTION_E_E 467 PLUG 1 641 PILOT COVER 1 753 O RING ; 1B_P9 1
SECTION_D_D
496 PLUG 18 642 ROD 1 755 O RING ; 1B_P11 6
541 SEAT 2 643 PILOT PISTON 1 756 O RING ; 1B_P26 2
418 543 STOPPER 1 2 644 SPRING 1 763 O RING ; 1B_G35 1
496
545 BALL 2 645 ADJUSTING STEM 1 801 NUT ; M8 3
079
601 CASING 1 646 PILOT SPRING 1 814 SNAP RING 1
439 656 755 413 466,755 611 FEED BACK LEVER 1 651 SLEEVE 1 836 SNAP RING 1
612 LEVER (1) 1 652 SPOOL 1 858 LOCKING RING 2
646 438 613 LEVER (2) 1 653 SPRING 1 874 PIN 1
436
614 FULCRUM PLUG 1 654 RETURN SPRING 1 875 PIN 4
466
755 615 ADJUSTING PLUG 1 655 SET SPRING 1 887 PIN 1
621 COMPENSATING PISTON 1 656 PORT PLATE 1 897 PIN 1
924
622 PISTON CASE 1 708 O RING ; 1B_G75 1 898 PIN 1
801 623 COMPENSATING ROD 1 722 O RING ; 1B_P6 2 924 SOCKET SCREW ; M8_20 1
624 SPRING SEAT 1 724 O RING ; 1B_P8 12 925 ADJUSTING SCREW 1
730 643 708 644 645 728 The codes in a rectangle represent adjust screws.
722 724 733 725 466,755
Do not tamper with the adjust screws as much as possible.
SECTION_B_B
VIEW_C

875 874 755 858

897
734 654 836 651 652 601 624 629 630 628
612 653
614 655
412
641
615 801
814
613
925
631

611 898 627

732
732
756

733 622 621 623 625 626 887 763

SECTION_A_A

Fig. 1-9_Construction of regulator

1-1-7
 1.3.2 OPERATION The output power of the pumps is controlled flat section (D section) of feed back lever, feed This regulator is of the simultaneous total
(1) Control function to a constant level by the pressure supplied back lever rotates putting fulcrum on D point horse power control system, the tilt angles
Control function ......... Electric flow control. by PSV1 and PSV2. with the movement of pin (897). (displacement) of two pumps are controlled to
Negative flow control. Feed back lever is linked to spool (652) with the same value as calculated by the following
Total horsepower control. (3) Electric flow control and negative flow control pin (874), and the spool (652) moves formula.
Back-up control. As shown in Fig.1-10, the delivery rate of the rightward. With the movement of spool, the Tin=P1×q/2 +P2× q/2 =(P1+P2)q/2
Hydraulic negative control. pumps is controlled by the input current I delivery pressure P1 flows into CL port (q : Displacement)
Hydraulic total horsepower control. (pilot pressure Pi). through spool and is led into the servo piston The horse power controlling function is the
large bore section. The delivery pressure P1 same as the flow rate control, and explains
(2) Summary is regularly led into the servo piston small below briefly. (For details of movement of

Delivery flow rate Q

The regulator KR3G-9TIL for the in-line type bore section, but servo piston moves parts, refer to Article “Flow control”.)
axial piston pump K3V series is composed of rightward due to the difference of area and
the control mechanism as mentioned below: makes the tilt angle smaller.

Delivery flow rate Q

1) Electric flow control and negative flow control With the movement of servo piston
The tilting angle of the pump (delivery rate) is rightward, the D section also moves
controlled freely by controlling the current rightward. Since spool is equipped with
command value of the solenoid proportional return spring (654) and the spool is regularly
reducing valve attached to the regulator. The pulled leftward, pin (897) is pushed against
regulator makes negative flow control (negative the large bore section (C section) of lever 2.
control) that decreases the delivery rate as the Input current (Pilot pressure Pi) Therefore, feed back lever rotates putting
secondary pressure of the solenoid proportional Fig.1-10 fulcrum on the C point with the movement of
reducing valve rises. Since this function D section, and spool moves leftward. With
permits the output power of the pump to be 1) Flow rate decrease the movement, sleeve (651) and spool (652) Delivery pressure (P1+P2)
varied, it is possible to attain optimum power As the input current I rises, the secondary opening section are gradually closed, and Fig.1-12
according to the operating condition. Also, since pressure of the solenoid proportional servo piston (532) rests at the position where
the pump delivers only the necessary oil flow, it is completely closed. 1) Prevention of overload
reducing valve (pilot pressure Pi) rises.
the machine does not consume unwanted 2) Flow rate increase When the self pump delivery pressure P1 or
If the pilot pressure Pi rises, the pilot piston
power. If the input current I (pilot pressure Pi) opposite pump delivery pressure P2 is raised,
2) Back-up full power control moves to the right and stops where the action decreases, the pilot piston (643) moves to the P1 and P2 act on the step section of
In case the solenoid proportional reducing of pilot spring (646) balances the hydraulic left by the action of pilot spring (646). compensating piston (621), compensating rod
valve is disabled, the electric control may be power. Since pin (875) fixed on lever 2 (613) The lever 2 (613) turns on point B of it as the (623) is pushed rightward, and moves to the
switched over to the hydraulic control (Back- is fitted on the groove section of pilot piston, fulcrum. Pin (897) is pushed against the large position where the spring force of outer
up mode) if the back-up select rods (642) of the lever 2 (613) rotates putting the fulcrum bore section (C section) with return spring spring (625) and inner spring (626) are
the front and rear regulators are loosened on the B points [fixed with fulcrum plug (654) through spool (652), pin (874) and feed balanced with the oil pressure. The
completely. back lever (611), and feed back lever rotates movement of compensating rod is
(614), pin (875)]. Since pin (897) fixed on feed
In that case, the tilting angle of the pump putting fulcrum on the D point with the transmitted to lever 1 through pin (875), and
back lever (611) is protruded from the large
(delivery rate) is reduced automatically as rotation of lever 2 and spool moves leftward. lever 1 (612) rotates centered on pin (875) (E
the self pump's delivery pressure P1 and the hole section (C section) of lever 2 (613), piston With the movement of spool (652), the section) fixed on casing (601). Since pin (897)
opposite pump's delivery pressure P2 rise so (897) moves rightward with the rotation of pressure flows into the tank port through C fixed on feed back lever 1 is protruded from
as to restrict the input torque below a certain lever 2. port, consequently the pressure in the servo the large hole section (F section) of lever 1,
level. (The input power is made constant Since pin (548) fixed on tilt pin (531) to shake piston large bore chamber is released, and feed back lever (611) rotates putting fulcrum
when the revolution is constant.) swash plate (212) is fixed on the width across servo piston (532) is moved leftward by the on the D section with the rotation of lever 1.
This is the simultaneous total power control delivery pressure P1 in the small bore section With the movement of spool, the delivery
642 612
that operates on the sum of the load and raises the flow rate. pressure P1 is led into the servo piston large
pressures of two pumps of the tandem double With the movement of servo piston the D bore section through C port, servo piston
625
pump system. When power control is section also moves leftward, feed back lever moves rightward, the pump delivery flow rate
626
underway, the regulator of each pump is rotates putting fulcrum on the C point, and is reduced, and consequently the overload of
controlled at the same tilting angle (delivery 651 spool moves rightward. The spool engine is prevented. The movement of servo
rate). This system automatically prevents the continuously moves until the sleeve opening piston is transmitted to feed back lever (611)
652
engine from being overloaded regardless of closes completely and rests at the closed through the D section, feed back lever (611)
the size of loads acting on the two pumps. 898 (Pin) position. rotates putting fulcrum on the F point, and
3) Back-up power shift control 654 spool moves leftward. Spool continuously
In the back-up operation, the power shift 621 (4) Simultaneous back-up total power control moves until the opening section to sleeve
C port
control (reduced power) is achieved by the
(Compensating When the load pressure rises, as shown in the (651) is closed, and rests at the position
piston)
figure, the overload of engine is prevented by where it is completely closed.
primary pressure that is supplied from PSV1 623 643 613 646 532 reducing the tilt angle of pump.
and PSV2. (Pilot piston)

Fig. 1-11 Regulator hydraulic circuit

1-1-8
 626
625

623
621
(Lever 1)
612
611
874
[B]
875 897 (Lever 2)
898 613
875 646
652
644
651

[E]
654 [F] [C]
[D] 643
875
[A]
[B] 614

875 615
[C]
[A]
[D]

548

531
532

Fig.1-13
Functional explanation of regulator

19
2) Flow return The primary pressure PSV of the solenoid
When the self pump delivery pressure P1 or proportional reducing valve is admitted to pin
opposite pump delivery pressure P2 is (898) and controlled at a constant power level
lowered, compensating rod (623) is pushed in a power shifted (reduced power) condition.
back by the spring force of outer spring (625) The pressure of the Pn1 port is admitted to
and inner spring (626) and lever 1 rotates the pilot piston and performs flow control as
centered on the E section. Feed back lever 1 the pressure goes up and down.
(611) rotates putting fulcrum on the D point
Note
and spool moves leftward. Consequently the Do not use the back-up select rod(642) when the
pressure flows into the tank port through C front and rear regulators are fully closed or fully
port, the pressure of the large bore section of loosened. The pump can not be controlled if the
the servo piston is released, servo piston position of the front regulator differs from that of
moves leftward, and the pump delivery flow the rear regulator.
rate is raised.
The movement of servo piston is transmitted
to spool with the feed back mechanism, and
continues the action until the openings of
spool and sleeve are closed.
At electric flow control

(5) Low tilt angle (low flow rate) command

priority mechanism
As described above, the tilt angle command
for the flow rate control and horse power
642
control is transmitted to feed back lever and
spool through lever 1 and large bore sections
(C,F sections) of lever 2, but the C and F 801
sections are constructed so that pin ∅4
(0.157in) is protruded from large hole ∅8 (642)
(0.315in), and the pin (897) comes in contact
with the large hole ∅8 (0.315in) of lever
898
which makes the tilt angle smaller, and other
large hole ∅8 (0.315in) of the lever in the
condition of tilt angle in large radius is free At back-up control
without contact with pin (897). This way, the
command for smaller tilt rotation side of flow
control and horse power control has a priority
according to the mechanical selecting system. Fig.1-14Switching to back-up function

(6) Back-up function

As shown in Fig.1-14, loosen nut (801) and
Delivery flow rate Q

change the position of rod (642). This causes

the electric flow control to be switched to the
hydraulic control.
In the electric flow control, the secondary
pressure Pi of the solenoid proportional
reducing valve is admitted to the pilot piston
to perform flow control of the pump.
In case the solenoid proportional reducing
valve is disabled, the control mode is Delivery pressure (P1
P2)
switched over to the hydraulic control if rod
(642) is switched over. Fig.1-14Power shift control

110
1.3.3 ADJUSTING THE REGULATOR
The regulator may be adjusted in terms of max-
imum flow, minimum flow, horsepower (at back-
up control) control characteristics, flow control
characteristics using the adjust screw.

(1) Adjusting the maximum flow (See Fig.1-3)

Adjust the maximum flow by loosening nut
(808) and by tightening set screw (954) (or

Delivery flow rate Q

loosening it). Tightening set screw (954)
decreases the delivery rate, as indicated in
Fig.1-16.
Only the maximum flow varies, but other
control characteristics remain unchanged.

Adjust screw No. 954

No. of turns for tightening 1/4
Pilot pressure Pi Input current
Pilot pressure Pi
(Input current) No change
Fig.1-16
Adjusting the max. delivery flow
Min. increase in delivery flow
/min (gal/min) 5.8 (1.5)

(2) Adjusting the minimum flow (See Fig.1-3)

Adjust the minimum flow by loosening nut
(806) and by tightening socket screw (953) (or
loosening it). Tightening socket screw increases
the delivery rate, as indicated in Fig.1-17.
Other control characteristics remain
unchanged in the same way as maximum
flow adjustment care should be used of the
fact that overtightening may increase a
required power at the maximum delivery
pressure (at relieving action).

Adjust screw No. 953

No. of turns for tightening 1/4
Pilot pressure Pi
(Input current) No change
Min. increase in delivery flow
Delivery flow rate Q

/min (gal/min) 4.6 (1.2)

(3) Adjusting the input horsepower
(at back-up control)
Since the regulator is of total horsepower
control type, turn the adjust screws of both
the front (No.1) and rear (No.2) pumps when
changing horsepower set values. Adjust the
horsepower settings of both pumps to a same
Input current
Pilot pressure Pi
level. The pressure change values by
adjustment are based on two pumps
Fig.1-17
Adjusting the min. delivery flow
pressurized at the same time, and the values
will by halved when only one pump is loaded.

111
1) Adjusting the Outer Spring (See Fig. 1-9)
(At back-up control)
Adjust it by loosening lock nut (630) and by
tightening adjust screw C (628) (or loosening
it). Tightening the adjust screw shifts the
control chart to the right and increases the
input horsepower, as indicated in Fig.1-18.
Since turning the adjust screw C by N turns
changes the setting of the inner spring,
return the adjust screw (925) by 2.2N turns

Delivery flow rate Q

at first.

Adjust screw No. 628

No. of turns for tightening 1/4
Increase in delivery pressure kgf/cm2 (psi) 17.8 (250)
Increase in input torque
kgf!m (ft!lbs) 4.7 (34)

Delivery pressure (P1+P2)

2) Adjusting the Inner Spring (See Fig. 1-9) Fig.1-18
Adjusting the input horsepower (1)
(At back-up control)
Adjust it by loosening nut (801) and by adjust
screw (925) (or loosening it). Tightening the
adjust screw increases the flow and then the
Delivery flow rate Q

input horsepower, as indicated in Fig.1-19.

And the input torque raises.

Adjust screw No. 925

No. of turns for tightening 1/4
Increase in flow
/min (gal/min) 18.4 (4.9)
Increase in input torque
kgf!m (ft!lbs) 3.2 (23)
Delivery pressure (P1+P2)
Fig.1-19
Adjusting the input horsepower (2)
(4) Adjusting the flow control characteristics
(See Fig. 1-9)
Adjust them by loosening nut (801) and
socket screw (924) (or loosening it). Socket
screw causes the control chart to move to the
right as shown in Fig.1-20. Socket screw
raises the flow control start pilot pressure.
Delivery flow rate Q

And the delivery rate increases.

Adjust screw No. 924

No. of turns for tightening 1/4
Increase Pilot pressure Pi
kgf/cm2 (psi) 1.3 (18)
Increase input current I
mA 21mA
Increase in delivery flow 13.0 Input current I
Pilot pressure Pi
/min (gal/min) (3.4) Fig.1-20
Adjusting the flow control

112
1.3.4 CAUSES OF FAULT RESULTING FROM
REGULATOR
When trouble due to this regulator occurs,
Disassemble and inspect it referring to “Chapter
YN33”.

(1) When the engine is overloaded,

Load every unit of pump, and check on
pumps on the right and left sides for possible
damages. When pumps on both sides are
failed, check on them for the following
failures 1), 2). When pump on the one side is
failed, start checking from par. 3).
1) Check that the power shift command current
I is normal.
2) The power shift pressure is low.
! Check the dither of amp.

! Replace solenoid proportional reducing valve.

3) Stick of compensating piston and

compensating rod
! Disassemble and clean it.

4) Stick of pin (898)

! Disassemble and clean it.

(2) The max. flow rate is not delivered.

1) Check that pilot differential pressure Pi is
normal.
2) Stick of pilot piston
! Disassemble and clean it.

3) Stick of spool
! Disassemble and clean it.

Note : When the damage of part is severe, replace

the part with new one.

113
 2. PILOT VALVE (ATT)
2.1 OUTLINE
(1) Outside view (2) Specification
SINGLE SINGLE
Table 2-1
OPERATION OPERATION
ANGLE ANGLE Item Specification
(PORT 2,4) (PORT 1,3)
The adjust nut Part No. YT30V00008F2
(opposing flats : 22) :
Model PV48K1008
Fix adjust nut
(opposing flats : 22) Operating torque Refer to the curve below
when the lever is installed by
means of spanner or the like.
Max. primary pressure 50kgf/cm2 (710psi)
Then tighten the mating lock Primary pressure 50kgf/cm2 (710psi)
nut to 4.2±0.3kgfym
(30±2.2ftylbs). Rated flow 20 /min (5.3gal/min)
Weight Approx. 2kg (4 lbs)

(3) Performance characteristics

5-PF3/8
T=5±0.5

PF1/4
T=3±0.2

T=Tightening torque : kgfym (ftylbs)

Hydraulic symbol
Fig. 2-1

21
 2.2 CONSTRUCTION,FUNCTION
AND
OPERATION
(1) Cross section view

312
501
302
Rotating sliding
part, apply
grease.
213 301 Beware of the
assembly
direction
151 212

Apply grease
246 to top
218
2
211

214
218
1

216
2 216
1

241
1
241
2

201
2 201
1

011
2 011
1

131
217 122
Secondary
pressure 101
adjusting shim 121 Not to
Designed value 126 be reused
t=0.4 (0.016˝ ), PORT 2,4 PORT 1,3 125
1 pc. 111
Fig. 2-2Pilot valve (ATT)
Apply Locktite #277 to areas marked .
Tightening torque Tightening torque

yy No. NAME Q
TY
yy No. NAME Q
TY
101 CASING 1 216
1 SPRING SEAT 1 2
111 PORT PLATE 1 216
2 SPRING SEAT 1 2
121 SEAL WASHER 2 217 WASHER 2 (SHIM) 4
122 O RING 1 218
1 SPRING SEAT 2 2
2.1 (15) 125 SOCKET BOLT ; M8
35 2 218
2 SPRING SEAT 2 2
126 SPRING PIN 1 011
1 SPRING 2
131 BUSHING 1 011
2 SPRING 2
151 PLATE 1 241
1 SPRING 2
201
1 SPOOL 2 241
2 SPRING 2
201
2 SPOOL 2 246 SPRING 4
211 PLUG 4 4.8 (35) 301 JOINT ;M14 1
212 PUSH ROD 4 302 CIRCULAR PLATE 1
213 SEAL 4 7 (51)  312 ADJUST NUT ; M14 1
214 O RING ; 1BP20 4 501 BOOTS 1


2
2
(2) Construction
The pilot valve is constructed as shown in the
cross-sectional view (Fig.2-2). The casing has
a vertical shaft hole in which a reducing
valve is assembled.
The reducing valve consists of spool (201),
spring (241) (for secondary pressure setting),
spring (011) (for return), spring seat (216),
and washer (217). The spring (241) (for
secondary pressure setting) is so set as to
achieve the secondary pressure conversion
5~10kgf/cm2 (71~140psi) (varies with the
model.). The spool (201) is pressed against
push rod (212) by spring (011) (for return).
If push rod (212) is pushed down by tilting
the control part of the handle, the spring seat
(216) falls at the same time and changes a set
pressure of spring (241) (for secondary
pressure setting).
The casing (101) and the port plate (111) are
provided with an oil inlet (primary pressure)
port P and an outlet (tank) port T. They are
further provided with ports 1, 2, 3, 4 from
which secondary pressure is discharged.

(3) Function
1) Basic functions 2) Main functions
The pilot valve controls the stroke and the The function of spool (201) is to receive the
direction of the control valve spool. This is supply pressure of the hydraulic pump by
achieved by applying the output pressure of port P and admit the hydraulic pressure at
the pilot valve to the end of the control valve port P to output ports (1, 2, 3, 4) or admit the
spool. hydraulic pressure at the output ports to port
In order to satisfy the functions, the pilot T. Spring (241) (for secondary pressure
valve is constructed with the following setting) acts upon spool (201) and determines
elements : the output pressure.

Inlet port (P) to which the oil of the Push rod (212) that changes the deflection of
hydraulic pump is supplied. spring (241) (for secondary pressure setting)
 Multiple output ports (1, 2, 3, 4) that is inserted in plug (211) so as to enable
exert the supply pressure from the input smooth movement.
port upon the end of the spool of the Spring (011) (for return) acts upon casing
control valve. (101) and spring seat (216) and brings push
 Tank port (T) to control the above rod (212) toward zero displacement
mentioned output pressure. regardless of output pressure, in order to
 Spool that connects the output port with positively bring spool (201) back to neutral.
the inlet port or the tank port. The spring also acts as a reactive force that
 The mechanical means including springs gives the operator a proper operating feeling.
that act upon the above- mentioned
spool, in order to control the output
pressure.

23
(4) Function
Now, let us explain the function of the pilot
valve, using the hydraulic diagram (the
figure on the right) and the functional
explanation drawing (Fig.2-3 to 2-5).

1 3
P T

Pilot valvePilot pump

Lever in neutral

1) Lever in neutral (See Fig.2-3.)

The action of spring (241) (for secondary
pressure setting) that determines the output
pressure of the pilot valve does not act upon
spool (201). Therefore, spool (201) (for return)
is pushed up by spring (011) [spring seat 1
(216)]. The output ports (2,4) connect with
the T port. The result is that the output
pressure is equal to the tank pressure.

216

241

011

201

PORT(2,4)

Fig. 2-3Lever in neutral

24
2) When the pilot lever is tilted (See Fig. 2-4 )
When the lever is tilted and the push rod
(212) strokes, the spool (201) spring seat
(216) moves down-ward to make the port P to
connect with the port 2, 4, with the result
that the oil of the pilot pump flows to the port 212
2 ,4 to produce a pressure.

216

201

PORT(2,4)
3) Lever held (See Fig.2-5.) Fig. 2-4
When the lever is tilted
When the pressure at ports (2,4) rises to a
level equivalent to the action of spring (241)
that is set by tilting the lever, the hydraulic
pressure balances the spring action. When
the pressure of ports (2,4) rises above a set
value, ports (2,4) and the P port close while
ports (2,4) and the T port open. When the
pressure at ports (2,4) falls below a set value,
ports (2,4) and the P port open while ports
(2,4) and the T port close. Thus the secondary
pressure is kept constant.
241

T PORT

P PORT

PORT (2,4)
Fig. 2-5
When the lever is held
(When the secondary pressure is higher than a set value)

4) Operation in the area where the tilting angle the bottom of the bore of the push rod
of the lever is large. (varies with the model) contacts the spring if the lever is turned
If the lever is inclined beyond a certain angle beyond a certain angle. This causes the
on certain models, the top end of the spool secondary pressure gradient to change by the
contacts the bottom of the bore of the push spring action. Thereafter, the bottom of the
rod. This keeps the output pressure bore of the push rod contacts the top end of
connected with the P port pressure. the spring seat, keeping the output pressure
Furthermore, on a model in which a spring connected with the P port.
seat and a spring are built in the push rod,

25
3.1 OUTLINE 3. PILOT VALVE (TRAVEL)
(1) Outside view

VIEW FROM MACHINE FRONT SIDE

Tightening
Port torque Port 4-∅11
size
yy name Function
Through
1 LH travel forward port
2 LH travel reverse port
7.50.5
PF3/8 3 RH travel forward port
(543.6)
4 RH travel reverse port
T Tank port
5 Travel pressure sensor
6 port
3.70.2
PF1/4 P Travel pressure sensor
(271.4) Fig. 3-1
Outside view of travel pilot valve
port
(2) Specification Pilot primary pressure port
(3) Performance characteristics
Item Specification
Parts No. YX30V00004F1
Type 07291-00000
Primary pressure 50kgf/cm2 (710psi)
Secondary pressure 5.524kgf/cm2 (78340psi)
Rated flow 10 /min (2.6gal/min)
Weight Approx. 11kg (24 lbs)

Hydraulic symbol Control diagram

31
3.2 CONSTRUCTION AND OPERATION
Z
33 2 36 33
13 12 28 5
36 14
PORT

42
19
37 26 25
1,3 30
20
34 25
22 15
20 21 42
20
39

PORT 6
32 17
44,16 33 36 33
40
6 7 SECTION AA
18 8
24 25,42
41
27
4 10,11 35
9 31 5 29

T=TIGHTENING TORQUE : kgfym(ftylbs)

38
4-M10
T=4.3
0.4(31
29)

SECTION BB
24,41 VIEW Z Fig. 3-2Construction of travel pilot valve
Apply Locktite #262 to areas marked .
Tightening Q
T Tightening Q
T
torque No. NAME torque No. NAME
kgfym (ftylbs) Y kgfym (ftylbs) Y
1 ORIFICE(SHIM) 4 22 SPRING 4
1.5(11) 2 SEAT 2 1.0(7.2) 24 PLUG : PF1/8 3
3 ORIFICE(SHIM) 4 2.5(18) 25 PLUG : PF1/4 3
4 SPOOL 4 6.0(43) 26 SOCKET BOLT : M1060 2
5 BODY 1 0.5(3.6) 27 FLANGE BOLT 4
6 STOPPER 4 1.5(11) 28 SETSCREW : M8 4
7 SPRING 4 29 WASHER 4
8 SPRING 4 30 WASHER 2
9 NAME PLATE 1 31 RIVET 2
10 SHIMt=0.2 4 32 PIN : ∅5 4
11 SHIMt=0.1 4 33 BALL 6
12 CAM 2 34 BALL 4
13 BOOTS 2 35 BALL 4
14 PIN 2 36 BALL 6
15 COVER 2 37 U PACKING 4
16 PISTON 4 38 O RING : 1AP5 4
17 GUIDE 4 39 O RING : 1AP24 4
18 SLEEVE 4 40 O RING : 1AP26 4
19 HOLDER 4 41 O RING : 1BP8 3
20 RING 12 42 O RING : 1BP11 3
21 ORIFICE(SHIM) 4 44 PISTON ASSY 4

32
3.3 OPERATION
(1) Construction z If the cam operates during travel operation,
The valve consists of the following parts in the oil in the damper chamber is kept from
terms of hydraulic function : flowing back by the check valve. Thus the oil
flows to part
E only from the orifice. Damper
A : Damper section
action operates by the resistance that is built
B : Reducing valve section
up as the oil passes through the orifice.
C : Shuttle section Let us explain the profile of the piston (See
(2) Operation Fig. 3-4.)
1) Damper section The upper part of the piston has a diameter
z If the primary pressure is supplied by P, it is of 12mm(0.472in), while the lower part of it
flowed to the damper chamber by way of has a diameter of 11mm(0.433in). This
circuits

D and
E . results in an areal difference, with the result
The pressure is then filled up in the damper that the piston is constantly subject to a
vertical force.
chamber via the orifice and the check valve.
For this reason, the orifice rises by the pressure
In that case, the air present in the damper
caused by the areal difference between the
chamber is pushed out to the T port from operating part of the cam and the piston on the
circuits
F and
G , in order to prevent opposite side i.e. the piston follows the cam.
thedamper characteristics from That is to say, constant damper action
fluctuating by air mixture. operates wherever the cam is located.
Since the larger diameter of the piston, the
cover, the 11mm diameter part of the piston
CAM
and the guide are manufactured with
minimal clearance, only a little leakage
occurs. Consequently, the damper
performance is not affected at all.

F


PISTON G

COVER
E

CHECK
VALVE

GUIDE

ORIFICE

DAMPER
SPRING FOR CHAMBER
T
SECONDARY
PRESSURE
D

I

SPOOL P P

H


SECONDARY PRESSURE PORT
BODY
Fig. 3-3
33
2) Reducing valve section If the pressure at the secondary pressure port
z At neutral rises above the action of the secondary
The primary pressure supplied by P is shut off pressure spring, the spool is pushed up by
by the seal between the circumference of the the
pressure. The result is that the notch  J
spool and the body hole. enters the hole of the body, shuts off the
The secondary pressure port is connected circuit from the primary pressure port to
with the T port through the vertical hole  H the
secondary pressure port, and causes the
and the horizontal hole  I in the center of the horizontal hole I to connect with the T port
spool. This causes the pressure to be reduced to let the pressure of the secondary pressure
to zero. port out to the T port.
z At operation If the above-mentioned action is repeated, the
If the cam tilts toward the operating pressure at the secondary pressure port
direction, the piston goes down. The spool sub becomes a level that balances the
assy moves down. compressive
load of the secondary pressure
If the notch  J on the circumference of the spring proportional to the cam stroke.
spool connects with the secondary pressure The return spring provides proper reactive
port, the primary pressure supplied by P force and positively brings the spool of the
enters the secondary pressure port. reducing valve back to its neutral position.
In that case, the horizontal hole I enters the
hole of the body and seals it. As the result,
the circuit from the secondary pressure
port
to the T port is shut off.

∅12
(0.472˝)

∅11
(0.433˝ )
RETURN
SPRING

T T
I


J

P P

J


H

SECONDARY Fig. 3-4
PRESSURE PORT

34
3) Shuttle section
z If pressure is built up at port 1 or 3, the ball
is pressed against the seat by the pressure.
The pressure goes through from port 1 to port
5(or from port 3 to port 6).
Only a little leakage occurs from port 2 or 4
as the ball is metallical sealed by the seat.
If pressure occurs at port 2 or 4, the ball is
pressed against the body by the pressure. The
result is that the pressure connects with port
5 from port 2(with port 6 from port 4).
Only a little leakage occurs at port 1 or 3 as
the ball is metallical sealed against the body.



PORT 2 PORT 1

SEAT BALL

BODY

PORT 4 PORT 3

PORT 6

Fig. 3-5 Shuttle section

35
 4.2 CONSTRUCTION
273 273 154 164 101
P1,P2 T2 T T T2

TRAVEL TRAVEL
STRAIGHT PBL PAL
978 LEFT

TRAVEL
SWING
RIGHT PBs PAs

977
BOOM
BUCKET CONFLUX PB1

BOOM ARM
PBa PAa

CUT ARM
(ARM CONFLUX) RECIRCULATION
(CUT) PCa Pis

NEGATIVE NEGATIVE CONTROL

CONTROL RELIEF
RELIEF

162(4pc)
OPTION 1 212
274
SECTION_A_A

974 154 164 102 974

102 274 272
P2 P1
974 101 167
162 562 (Tn1)
T2
515 157
552 (Pn2) PTb
562 CT1 CT2
522 156
P1 166 973 973
552
512 Pn2’
PBr PAr
522 Pn1’
P2
161 212 (Pn1)
T 215 PBc PAc
974 156
166 Tn2 973 973
PBb PAb

SECTION_H_H 274 272 973 973

SECTION_I_I
PA1 Pcb

162(4pc)
215

PB01 PA01

213 271
SECTION_B_B

Fig. 4-2 (1/3)_Construction of control valve

1-4-2
 203
334
332 166 156 203
203
338
334
334 PAs 201
328 332 PAr
PAL 332 333
325 338 331
332 338
327 336
601 327 322
325
262 325 332 321
332 262 331
161 262 261
Dra
PLL
512
Ar As
AL 511 511
522 511 521
521
CMR1 521 551
552 CP2 CP1
562 551 551
562 CMR2
164 164
164
552 163 Br Bs
BL
522 306 ; TRAVEL SPOOL
512
264 Drb
303_SWING SPOOL
205
161 TRAVEL SPOOL_306
TRAVEL STRAIGHT
SPOOL ; 307 264 264 PBs 264
PBr
205 205
PTb PBL 205
SECTION_C_C SECTION_D_D

PLc1 Drc Pcb Pis

201 201
(PLc2) (Drd)
333 333
331 PAb PAa
336 331 204 204
322 334 332 334
321 336 332 332
331 337
261 337
323 603 326
211
SECTION_K_K 326 325
163 321 332
325
162 602 262 262
331 CUT SPOOL_309
310_ARM RECIRCULATION
164 261 CAr 562 SPOOL
161 Ab
CRb 302 ; ARM SPOOL 552
556 Aa
511 163 522
521 162 512
524 551 168
514 164
LCb LCa 158 X1
551 514 164
524 Ba
164 556 551 CCa
521 Bb CRa 164 521 309_P2 BYPASS CUT
167 511
511 157
ARM CONFLUX SPOOL ; 308 603
211
BOOM SPOOL ; 301 162 262
602 262 332
326 332 325
PBb PBa 337 326
325 337
205 264 163 205 264 332 332
334 334
204 PCa 204
SECTION_F_F PA1

SECTION_G_G
Fig. 4-2 (2/3)_Construction of control valve

1-4-3
 Table 4-3 Apply Locktite #262 to areas marked _.
201 Tightening Q’TY Tightening Q’TY
333 PB1
555 torque No. NAME torque No. NAME
331 PAc 166 kgfŸm (ftŸlbs) STD OPT2 kgfŸm (ftŸlbs) STD OPT2
336 201
322 333 101 CASING A 1 _ 309 CUT SPOOL 2 _
321 331 102 CASING B 1 _ 310 ARM RECIRCULATION SPOOL 1 _
339 38_42
602 153 PLUG ; PF1 1 _ 311 ROD SPOOL 1 _
331 324 (270_300)
261 321 22_26 SPRING (ARM,BOOM,BUCKET,SWING,
(160_190) 154 PLUG ; PF3/4 3 _ 321 BOOM CONFLUX OUTER) 5 _
331 7_8
161 156 PLUG ; PF3/8 4 _ 322 SPRING (BOOM,BUCKET,SWING INNER) 3 _
261 (51_58)
161 3.5_4.0
511 (25_29) 157 PLUG ; PF1/4 2 _ 323 SPRING(ARM INNER) 1 _
Ac 521 1.3_1.7
CCb 551 (9.4_12) 158 PLUG ; PF1/8 1 _ 324 SPRING (BOOM CONFLUX INNER) 1 _
511 164
521 SPRING (ARM CONFLUX,CUT, TRAVEL,
305 ; BOOM CONFLUX 161 O RING ; 1B_G38 7 _ 325 ARM RECIRCULATION,TRAVEL STRAIGHT OUTER) 7 _
551
LAc 551 SPRING (CUT, ARM RECIRCUL ATION,
_______SPOOL 162 O RING ; 1B_G30 12 _ 326 ARM CONFLUX INNER) 4 _
164 164
165 163 O RING ; 1B_P15 4 _ 327 SPRING (TRAVEL, TRAVEL INNER) 2 _
Bc 153
311_ROD SPOOL 164 O RING ; 1B_P24 14 _ 328 SPRING (TRAVEL STRAIGHT INNER) 1 _
161 164
165 O RING ; 1B_P29 1 _ 331 SPRING SEAT 10 _
154
(T3) 166 O RING ; 1B_P14 5 _ 332 SPRING SEAT 14 _
BUCKET SPOOL_304 264 1.6_1.8 SPACER BOLT (ARM,BOOM,BUCKET, SWING,
167 O RING ; 1B_P11 2 _ _ 333 5 _
PBc 205 (12_13) BOOM CONFLUX)
603 1.6_1.8 _ SPACER BOLT (TRAVEL,ARM CONFLUX,CUT,
166 168 O RING ; 1B_P8 1 _ (12_13) 334 ARM RE CIRCULATION,TRAVEL STRAIGHT) 7 _
264 205
156 201 SPRING COVER 336 STOPPER (ARM,BOOM,BUCKET,SWING)
5 _ 4 _
SECTION_E_E STOPPER(ARM CONFLUX,CUT,
203 SPRING COVER 3 _ 337 ARM RECIRCULATION) 4 _
204 SPRING COVER 4 _ 338 STOPPER (TRAVEL, TRAVEL STRAIGHT) 3 _
205 SPRING COVER 8 _ 339 STOPPER (BOOM CONFLUX) 1 _
LOCK VALVE SELECTOR
211 SUB ASSY 2 _ 511 LOAD CHECK VALVE (POPPET) (D=25) 8 _
NEGATIVE CONTROL
PA02 212 RELIEF VALVE BLOCK 2 1 512 LOAD CHECK VALVE (POPPET) (D=20) 4 _
CONTROL VALVE FOR
214 OPTION 0 1 514 LOAD CHECK VALVE (POPPET) (LOCK VALVE) 2 _
NEGATIVE CONTROL
215 RELIEF VALVE BLOCK 0 1 515 LOAD CHECK VALVE (POPPET) (D14-D13) 1 _
261 O RING ; S50 5 _ 521 SPRING 8 _
212 214 262 O RING ; S39 7 _ 522 SPRING 5 _
264 O RING ; 1B_G40 8 _ 524 SPRING 2 _
272
274 10_12 22_26
(72_87) 272 CAPSCREW ; M12_120 0 4 (160_190) 551 ROMH PLUG ; M27 9 _
A02
2.5_3.5 12_16
(18_25) 273 CAPSCREW ; M8_25 40 _ (87_120) 552 ROMH PLUG ; M22 5 _
(P4)
10_12 7_8
(72_87) 274 CAPSCREW ; M12_50 8 4 (51_58) 555 PLUG 1 _
22_26
301 BOOM SPOOL ASSY 1 _ (160_190) 556 PLUG (LOCK VALVE) 2 _
B02
302 ARM SPOOL ASSY 1 _ 562 O RING ; 1B P20 5 _
274 272 7_8
303 SWING SPOOL 1 _ (51_58) 601 RELIEF VALVE (MAIN) 1 _
7_8
304 BUCKET SPOOL 1 _ (51_58) 602 RELIEF VALVE (OVER LOAD) 3 _
7_8
305 BOOM CONFLUX SPOOL 1 _ (51_58) 603 RELIEF VALVE (OVER LOAD) 3 _
PB02
14_18
306 TRAVEL SPOOL 2 _ (100_130) 973 CAPSCREW ; M14_140 6 _
SECTION_J_J 14_18
307 TRAVEL STRAIGHT SPOOL 1 _ (100_130) 974 CAPSCREW ; M14_100 2 _

Fig. 4-2 (3/3)_Construction of control valve 308 ARM CONFLUX SPOOL 1 _

1-4-4
(2) Main relief valve (Two step relief) (601) (3) Over load relief valve (602,603)
564 563 161 123 124 125 101 162 621 661 612
123 124 125 561 562 611 104 103 614 661 613

512 541 521 121 122 621 663 163 664 673 652 671 301 541 511 522 521 561 562 611 102 651 671

Fig. 4-3 Fig. 4-4

Tightening Tightening Tightening Tightening

torque No. NAME Q'TY torque No. NAME Q'TY torque No. NAME Q'TY torque No. NAME Q'TY
kgfŸm (ftŸlbs) kgfŸm (ftŸlbs) kgfŸm (ftŸlbs) kgfŸm (ftŸlbs)
7_8 (51_58) 103 PLUG_M27 1 562 BACK UP RING 1 7_8 (51_58) 101 BODY ; M27 1 541 SEAT 1
104 ADJUST SCREW 1 611 POPPET 1 7_8 (51_58) 102 PLUG ; M27 1 561 O RING 1
121 C RING 1 613 STOPPER 1 123 C RING 1 562 BACKUP RING 1
122 SPACER 1 614 PISTON 1 124 FILTER STOPPER 1 563 O RING 1
123 C RING 1 621 SPRING 1 125 FILTER 1 564 BACKUP RING 1
124 FILTER STOPPER 1 652 ADJUST SCREW 1 161 O RING 1 611 POPPET 1
125 FILTER 1 661 O RING 1 162 O RING 1 612 SPRING SEAT 1
163 O RING 1 663 O RING 1 301 PISTON 1 621 SPRING 1
512 PLUNGER 1 664 O RING 1 511 PLUNGER 1 651 ADJUST SCREW 1
521 SPRING 1 2.8_3.2 (20_23) 671 LOCK NUT ; M14 1 521 SPRING 1 661 O RING 1
541 SEAT 1 2.8_3.2 (20_23) 673 LOCK NUT ; M24 1 522 SPRING 1 2.8_3.2 (20_23) 671 LOCK NUT ; M14 1
561 O RING 1

(4) Boom spool (301)

B352 B340 B317 B303 B316 B330 B315 B320 B353

Fig. 4-5

Tightening Tightening
torque No. NAME Q'TY torque No. NAME Q'TY
kgfŸm (ftŸlbs) kgfŸm (ftŸlbs)
B301 SPOOL 1 B330 SPRING B2 1
B315 PLUNGER 1 1 B340 SPRING B3 1
B316 PLUNGER 2 1 B352 PLUG 1
B317 PLUNGER 3 1 B353 PLUG 2 1
B320 SPRING B1 1

1-4-5
 (5) Control valve for option 1 VBY-148 (214) (6) Lock valve selector sub assy (211)

S101
P202 S541
P334 PA02 P552 P562 PLC1(PLC2)
S162
P337 (P0’)
P323 S163
P324
602
P333
P271 S171 Drc(Drd)
P337 P0
S511
P261 P603
SECTION_B_B
P101 P512 S512
A02
28E P522 S161
P561
P551 S201
(P0’)

Fig. 4-7
B02

P262 Tightening Tightening

torque No. NAME Q’TY torque No. NAME Q’TY
PB02 602 kgfŸm (ftŸlbs) kgfŸm (ftŸlbs)
SECTION_A_A P204 S101 CASING 1 7_8 (51_58) S201 PLUG ; M27 1
S161 O RING ; 1B P22A 1 S511 SPOOL 1
Fig. 4-6 S162 O RING ; AS568-017 3 S512 SPRING 1
S163 O RING ; 1B P8 2 S541 BUSHING 1
1_1.4 (7.2_10) S171 CAPSCREW ; M6_45 4

Apply Locktite #262 to areas marked _.

Tightening Tightening
torque No. NAME Q’TY torque No. NAME Q’TY
kgfŸm (ftŸlbs) kgfŸm (ftŸlbs)
P101 CASING 1 P337 SPRING SEAT 2
P202 SPRING COVER 1 P512 POPPET 1
P204 SPOOL COVER 1 P522 SPRING 1
P261 O RING ; S50 1 12_14 (87_100) P551 ROMH PLUG ; M30 1
P262 O RING ; 1B G40 1 11_13 (80_94) P552 ROH PLUG ; PF1/2 1
2.5_3.5 (18_25) P271 SOCKET BOLT ; M8_25 4 P561 O RING ; 1B P28 1
28E SPOOL 1 P562 O RING ; 1B P18 1
P323 SPRING (INNER) 1 7_8 (51_58) 602 REL IEF VALVE (OVE R LOAD) 2
P324 SPRING (OUTER) 1 P991 NAME PLATE 1
P333 STOPPER 1 P992 RIVET 2
1.6_1.8 (12_13)__ P334 SPACER BOLT 1

1-4-6
(7) Negative control relief valve block VBY-145 (212) (8) Negative control relief valve block VBY-146 (215)
(without optional valve) (with optional valve)

N101 N162

N153
N153 (The plug head should be sunk
(The plug head should be sunk lower Pn lower than the casing surface.
Pn
than the casing surface. 2 places) 2 places)

N162 Pn’ N153

Pn’
N152
N101
N611
N611
N561
N561
N551
N551

N151 N151

(Tn) (Tn)
N161 N161
N977 N977
N978 N978

Fig. 4-9
N153

SECTION A－
A Tightening Tightening
torque No. NAME Q'TY torque No. NAME Q'TY
kgf!m (ft!lbs) kgf!m (ft!lbs)

Fig. 4-8 N101 CASING 1 23
27 (170
200) N551 ROMH PLUG ; M27 1
3.5
4.0 (25
29) N151 ROH PLUG ; PF1/2 1 N561 O RING ; 1B P27 1
NEGATIVE CONTROL RELIEF
2.0
2.4 (14
17 N153 SUNK PLUG ; PF1/4 MECK 2 N611 VALVE SUB 1
N161 O RING ; 1 P11 1 N977 NAME PLATE 1
N162 O RING ; 1 P30 3 N978 RIVET 2

Tightening Tightening
torque No. NAME Q'TY torque No. NAME Q'TY
kgf!m (ft!lbs) kgf!m (ft!lbs)
N101 CASING 1 23
27 (170
200) N551 ROMH PLUG ; M27 1
3.5
4.0 (25
29) N151 ROH PLUG ; PF1/4 1 N561 O RING ; 1B P24 1
NEGATIVE CONTROL RELIEF
10
12 (72
84) N152 ROH PLUG ; PF1/2 1 N611 VALVE SUB 1
2.0
2.4 (14
17) N153 SUNK PLUG ; PF1/4 MECK 2 N977 NAME PLATE 1
N161 O RING ; 1B P11 1 N978 RIVET 2
47
N162 O RING ; 1B P18 1
 4.3 HYDRAULIC CIRCUIT

Table 4
No. NAME
601 512 307 54 306
51 Main passage (P1 side)
52 Bypass circuit (P1 side)
53 Parallel circuit (P1 side)
TRAVEL 511 TRAVEL LEFT
54 Main passage (P2 side)
STRAIGHT
51 55 Bypass circuit (P2 side)
303
306
56 Parallel circuit (P2 side)
56 60 Arm recirculation passage
TRAVEL RIGHT 515 SWING
61 Arm recirculation low pressure passage
53 55
52 305 211 Lock valve selector spool
304
511
212 Negative control relief valve block
BOOM CONFLUX
BUCKET 511 215 Negative control relief valve block
301 Boom spool
603
602 302 Arm spool
302
303 Swing spool
511 512 ARM
BOOM
304 Bucket spool
603
301 305 Boom conflux spool
602
603 602 306 Travel spool
(CUT) 307 Travel straight spool
CUT ARM RECIRCULATION
(ARM CONFLUX) 60 308 Arm conflux spool

514 309 P1,P2 bypass cut spool

NEGATIVE CONTROL
61 NEGATIVE CONTROL RELIEF 310 Arm recirculation spool
RELIEF
511 215 511 Poppet (D=25)
212
310 512 Poppet (D=20)
514 Lock valve poppet
211 309 514 N611 308
OPTION 2 515 Poppet (with restrictor)
211
601 Main relief valve
602 Port relief valve
603 Port relief valve
309 602 512 N611 28E 602
28E Spool for option valve
N611 Negative control relief valve

Fig. 4-10Hydraulic circuit

48
4.4 OPERATION
(1) Control valve in neutral The poppet section of negative control relief
Purpose : valve (N611) has many small holes, and the
To reduce the pump flow rate by means of the oil delivered passes these holes and returns
negative control signal. into the tank port. Consequently the rise of
Principle : flow rate causes the rise of Pn1 pressure and
The negative control signal pressure is output the negative control signal is output through
when the flow rate at the extreme down Pn1 port or Pn1' port. When the pressure of
stream is raised. the negative control valve rises higher than
Operation : the specified pressure, the poppet opens and
The oil delivered from the hydraulic pump P1 the oil is led into the tank port (T).
flows into P1 port of the control valve, passes The oil delivered from the hydraulic pump P2
through the travel spool (307) and main also passes through main passage (54) and is
passage (51), is led into bypass circuit which led into bypass circuit (55) which passes
passes through the travel right, bucket and through the travel left, boom conflux and arm
boom control sections and P1 bypass cut spool control sections and P2 bypass cut spool (309)
(309). like the oil delivered from the hydraulic
The oil delivered passes through P1 bypass pump P1. The oil delivered flows into
cut spool (309) and flows into negative control negative control relief valve (N611) like P1
relief valve (N611) located in negative control side, causes the rise of Pn2 pressure, and the
relief valve block (212) because P1 bypass cut negative control signal is output through Pn2
spool (309) is not switched. port or Pn2' port.

309 307 309

T2

(54) (55) 212 (51) (52) 215

(NEGATIVE CONTROL (NEGATIVE CONTROL
RELIEF VALVE BLOCK) RELIEF VALVE BLOCK)

P2 pump side P1 pump side

Fig. 4-11Functions at neutral

49
(2) Functions for travel action
1) At independent travel
In the meantime, the pressurized oil
C/V Port name
Operation Pilot secondary Main pressure delivered by pump (P2) passes between the
pressure side oil supply side outer circumference of the left travel straight
Forward PAr Ar spool (306) and the casing, runs to port AL
Right
Reverse PBr Br and is supplied to the left travel motor P2
Forward PAL AL side, the same way as the pressure oil by
Left
Reverse PBL BL pump (P1).
Meanwhile, the oil which has returned from
If travel operation (forward) is performed, the the right travel P1 side and the left travel P2
secondary pilot pressure from ports
1 and side passes between the outer circumference

3 of the travel pilot valve acts upon ports of the left travel spool (306) and the casing
PAr and PAL of the control valve and moves and returns to the hydraulic tank via the
the right and left travel spools (306). tank port (T) of the low pressure circuit (D).
The pressurized oil delivered by pump (P1) At backward travel action (when the
flows to the main passage (51) past the travel secondary pilot pressure acts upon ports PBr
straight spool (307), passes between the outer and PBL of the control valve), the pressurized
circumference of the right travel spool (306) oil works the same way as in the forward
and the casing and is supplied to the right travel action.
travel motor B by way of port Ar.

RIGHT TRAVEL MOTOR

P1 P2

306
Br Ar

PILOT PORT
PBr PAr

51 52 51

Fig. 4-12At right travel forward (when PAr is pressurized)

410
2) Travel straight valve switching at
Travel/ATT combined operation
Purpose : The result is that the pressurized oil
While travelling, it is possible to travel delivered by pump P1 flows from A to B in
straight even if the attachment is operated. most amount of oil and becomes the pressure
Principle : for the actuators except one for travel action.
The travel and attachment operation can be The pressure oil delivered by pump P2 flows,
performed by separate pump. in most amount of oil, in the C
D direction
Operation : and the main passage (54), becomes the oil
When the actuator other than that for pressure for the right travel and the left
travelling and travelling are simultaneously travel motions and realizes simultaneous
operated, the pilot secondary pressure acts on operation of the actuator and travel action.
PTb port of the control valve, moves travel (travel straight function)
straight spool (307) upward to the position
[II].

307 307

PL1 P1 PL1

B B
P1

A
A
CMR1 CMR1
D
CMR2 D CMR2
C

P2 P2

PTb
PTb

Position [] Position []

D C P2
B A P1 D C P2
B A P1

PTb
PTb

At travel straight action

Fig. 4-13Functions at travel straight spool

411
(3) Bucket
1) When the bucket is digging the check valve open, enters the parallel
circuit (53), pushes the load check valve LCC
C/V Port name
(511) open, goes between the outer
Operation Pilot secondary Main pressure
pressure side oil supply side circumference of the bucket spool (304) and
Bucket digging PBc Bc the casing by way of the U-shaped passage
and is supplied to the bucket cylinder head
When the bucket is digging, secondary pilot (H) via port (Bc).
pressure coming from port
 of the pilot In the meantime, the oil which has returned
valve enters port PBc of the control valve and from the bucket cylinder rod side goes
moves the bucket spool (304) to the right. between the outer circumference of the
The pressure oil delivered by pump (P1) flows bucket spool (304) and the casing through the
to the bypass circuit (52) past the main port (Ac) and returns to the hydraulic oil
passage (51), but since it is blocked by the tank by way of the low pressure circuit (D)
bucket spool (304) that has shifted, it and the tank port (T).
pushes

D (52) (53) 304

PILOT PORT
PBc
PAc

U-SHAPED PASSAGE Ac Bc

511
R H

BUCKET CYLINDER

Fig. 4-14When bucket is digging

412
2) When the bucket is dumped
valve open, enters the parallel circuit (53) the
C/V Port name load check valve LCc (511) open, goes
Operation Pilot secondary Main pressure
pressure side oil supply side between the outer circumference of the
Bucket dump PAc Ac bucket spool (304) and the casing via the U-
shaped passage and supplied to the bucket
When the bucket is dumped, secondary pilot cylinder rod (R) via port (Ac).
pressure from port
of the pilot valve enters In the meantime, the oil which has returned
port PAc of the control valve and moves the from the bucket cylinder head goes between the
bucket spool (304) to the right. outer circumference of the bucket spool (304)
The pressure oil delivered by the pump P1 and the casing through the port (Bc) and is
flows to the bypass circuit (52) through the supplied to the hydraulic oil tank by way of the
main passage (51), but since it is blocked by low pressure circuit (D) and the tank port (T).
the bucket spool (304), it pushes the
check

(52) (53) D 304

PAc
PBc

U-SHAPED PASSAGE
Ac Bc

511
R H

BUCKET CYLINDER

Fig. 4-15When bucket is dumped

413
(4) Boom
1) When the boom is up The pressure oil delivered by pump P1 flows
into bypass circuit (52) through main circuit
C/V Port name (51), but since the circuit is cut with boom
Operation Pilot secondary Main pressure
pressure side oil supply side spool (301), the pressure oil opens check valve
Pab CP1 and enters in parallel circuit (53), and
Boom up PB1 Ab opens load check valve LCb (511) and flows in
PCa the chamber BH through U-shaped passage
and between the outer surface of boom spool
When the boom is up, secondary pilot (301) and the casing, then opens lock valve
pressure from port
of the pilot valve enters poppet CRb (514) and finally is led in the
port PAb of the control valve and moves the boom cylinder head (H) side through port
boom spool (301) to the right. It also acts (Ab). Meanwhile, the oil port (Bb) which
upon port PB1 (Refer to next page) and returns from the boom cylinder rod (R) goes
change over the boom conflux spool (305). between the outer circumference of the boom
And at the same time, the pilot secondary spool (301) and the casing, flows into the tank
pressure acts on PCa port of the control valve port (T) via the low pressure circuit (D) and
and switches P2 bypass cut spool (309). returns to the hydraulic tank.

INSIDE CONFLUX PASSAGE (53) 301 D

CHAMBER E

PAb
PBb

BOOM CYLINDER CHAMBER BH (Ab) Bb

514

R R 511 U-SHAPED PASSAGE

 

Fig. 4-16When boom is up (Boom spool)

414
2) Conflux for boom up
Purpose : Speed up of boom raise operation The oil then pushes the load check valve CCb
Principle : Confluxing 2-pump delivery flows (511) open, passes between the outer
The oil delivered by the pump P2 flows into circumference of the boom conflux spool (305)
the main passage (54), but since the bypass and the casing via the A side of the U-shaped
circuit (55) and the parallel circuit (56) are passage, enters port Ab through the conflux
closed by the P2 bypass cut spool (309) which passage in the casing and combines with the
has shifted as explained in 1) above (Refer to pressure on the pump P1 side.
Fig. 4-17), the oil enters the parallel circuit
(56) from travel spool. (Refer to Fig. 4-18)

P2 BYPASS CUT SPOOL

(55) 309
TANK PASSAGE
Ba

Pca

Fig. 4-17P2 bypass cut valve

CONFLUX CHECK VALVE CCb

(511) (56)

U-SHAPED PASSAGE

PB1

305
To port Ab through the conflux passage in casing
BOOM CONFLUX SPOOL

Fig. 4-18When boom is up (Boom conflux spool)

415
3) When the boom is down
If the boom down action is performed, the Drc, the valve opens. And the return oil
secondary pilot pressure from port
of the enters in the chamber BH, and flows in the
pilot valve acts upon port PBb of the control chamber E inside of boom spool (301) through
valve and lock valve selector port PLc and the circular notch of boom spool (301). Since
shifts the boom spool (301) to the left, it also the returned oil has sufficient pressure by the
change over the lock valve. weight of the boom, arm, etc. , it pushes the
The pressure oil delivered by the pump (P1) poppet on the right of the illustration through
flows into the bypass circuit (52) through the in the spool, passes through its outer
main passage (51), but since it is blocked by circumference and is supplied to the boom
the boom spool (301), it pushes the check cylinder R side as the hydraulic oil for boom
valve (CP1) open, enters the parallel circuit down motion.
(53), pushes the load check valve LCb (512) (Boom fixed recirculation function).
open, enters the U-shaped passage, goes Some of the return oil from the head end of the
between the outer circumference of the boom boom cylinders forces open the boost check
spool (301) and the casing and is supplied to valve, and flows through the low pressure
the boom cylinder rod side via port (Bb). circuit D to the tank port T, and back to the
On the other hand, the return oil from the hydraulic oil tank. The purpose is to allow
boom cylinder (H) side flows in the control excess return oil to escape to the tank. This
valve through port (Ab). The lock vale poppet excess oil is caused by the fact that the area of
CRb (514) is located just before boom the piston at the head end is larger than the
spool(301), but since the pilot secondary area of the piston at the rod end.
pressure acts on PLc1 port and the lock valve The boost check valve acts on oil flowing to
selector spool is switched and the back the tank to secure an adequate amount of
pressure of lock valve poppet CRb (514) is recirculating oil.
connected to

D 301 CHAMBER E
CONFLUX
PASSAGE
BOOST CHECK IN CASING (52) (53)
LOCK VALVE
SELECTOR SPOOL

PBb
PLc1

LOCK VALVE
SELECTOR

Bb
BOOM CYLINDER
CHAMBER 514 (Ab) 511 U-SHAPED PASSAGE
BH

R R

H H

Fig. 4-19When boom is down (in M or A mode)

416
(5) Arm
1) Arm out operation The pressure oil delivered by pump P2 flows
into the bypass circuit (55) by way of the main
C/V Port name
passage (54), but since it is blocked by the arm
Operation Pilot secondary Main pressure
pressure side oil supply side spool (302), it pushes the check valve CP2
PBa open, flows into the parallel circuit (56),
Arm out PA1 Ba pushes the load check valve LCa (511) open,
PCb goes between the outer circumference of the
arm spool and the casing by way of the U-
If arm out operation is performed, the shaped passage, runs into chamber AR,
secondary pilot pressure from port
of the pushes the lock valve poppet Cra (514) open
pilot valve acts upon ports PBa and PA1,PCb and is supplied to the arm cylinder rod R side
of the control valve. (refer to next page) via port (Ba).
The pressure oil which enters port PBa shifts In the meantime, the oil which returns from
the arm spool (302) leftwards. The pressure the arm cylinder H side passes between the
oil which enters port PA1 changes over the outer circumference of the arm spool (302)
arm conflux valve. and the casing by way of the port (Aa), flows
And, the arm out secondary pressure after into the tank port (T) from the low pressure
high pressure selection in the proportional circuit (D) and returns to the hydraulic oil
valve block acts on PCb port of the control tank.
valve and switches P1 bypass cut valve (309).

ARM CYLINDER

H R

302 511 514 CHAMBER AR

(Ba)

Aa

PBa
PAa

U-SHAPED
D PASSAGE (55) (56)
INSIDE
CONFLUX PASSAGE

Fig. 4-20At arm out operation (Arm spool)

417
2) Arm out conflux
In operation 1), the oil delivered by pump P1 Part of the delivered oil passes through the
flows into the bypass circuit (52) through the parallel circuit (53) and the restrictor,
main passage (51), but since the bypass combines with the pressure oil of the bypass
circuit (52) and the low pressure circuit (D) circuit (52), pushes the conflux check poppet
are blocked by the bypass cut spool (309), it (511) open, enters port Ba by way of the
does not run into the low pressure circuit (D). conflux circuit in the casing and finally
Meanwhile, since the arm conflux spool (308) combines with the pressure oil on the pump
has now been changed over, the pressure oil P2 side.
of the bypass circuit (52) goes between the
outer circumference of the arm conflux spool
(308) and the casing.

To port Ba through the conflux

P1 CUT passage in the casing
309 (52) 308

PCb D
PA1

(53) 511

Fig. 4-21At arm out operation (Bypass cut spool and arm conflux spool)

418
3) When the arm is in (under light load)
C/V Port name Meanwhile, the oil which has returned from
Pilot Solenoid the arm cylinder (R) enters the control valve
Operation proportional Main
secondary secondary pressure oil through the port (Ba).
pressure side pressure side supply side The lock valve poppet CRa (514) is located
Arm in PAa ― just before arm spool (302), but since the pilot
(under light PLC2 ― Ab
load) secondary pressure acts on PLc2 port and the
― Pis
lock valve selector spool is switched, lock
Purpose : valve poppet (514) opens and the pressure is
Speed up of in operation and prevention of led into chamber AR. In addition, the return
cavitation when operating the arm at light oil has sufficient pressure because of the
load. weight of the arm, etc., consequently the
Principle : secondary pressure is led in the arm spool.
The return oil from the arm cylinder (R) side Consequently, the return oil from the arm
is recirculated into the cylinder (H) side in cylinder (R) side passes through the inside of
the C/V. arm spool and notches on the arm spool, and
If the arm in operation is performed, the flows through recirculation circuit and led in
secondary pilot pressure coming out of arm recirculation spool (310).
port
 of the pilot valve acts upon the PAa In that case, the secondary pressure of the
port of the control valve and the PLc2 port of solenoid proportional valve (Pis) is acting on
the lock valve selector. This causes the arm the Pis port of the control valve and the arm
spool
(302) to move to the right and changes recirculation spool is in position (II).
the lock valve selector spool (211). Therefore, the oil pressure enters the passage
The pressure oil delivered by the pump P2 (61) through the inside of the arm
flows into the bypass circuit (55) past the recirculation spool (310), pushes open the
main passage (54), but since the bypass arm recirculation check valve poppet (512)
circuit (55) is blocked by the arm spool (302), and is supplied once again to the arm
the oil pressure pushes the check valve (CP2) cylinder (H) as the operating oil for arm
open, flows into the parallel circuit (56), digging operation.
pushes the load check valve LCa (511) open, Part of the hydraulic oil admitted to arm
goes between the outer circumference of the recirculation spool (310) flows into tank port
arm spool (302) and the casing through the (T) from low pressure circuit (D) and returns
U-shaped passage and is supplied to the arm to the hydraulic oil tank.
cylinder (H) side via port (Aa).

420
 PLc2
Drd

ARM CYLINDER

LOCK VALVE SELECTOR LOCK VALVE

H R SELECTOR
CHAMBER AR SPOOL
514
Aa

PAa

(60) (56) (55) Pisc CHAMBER F

310 512 (61)

Ba

Pis

D (60)
D

(61)

Position [Ⅱ]

Fig. 4-22When arm is in (under light load)

421
4) When the arm is in (under heavy load)
C/V Port name that is, when no recirculation occurs, the oil
Pilot Solenoid supply passage to the arm cylinder is the same
Operation proportional Main
secondary secondary pressure oil as during recirculation described above, but
pressure side pressure side supply side the return oil passage is different.
Arm in PAa In a heavy duty condition
The pump
Pis Ab
(under heavy load) PLC2
pressure=Arm cylinder (H) pressure is more
The arm oil recirculation function is effective than 200kgf/cm2 (2840psi)., the secondary
when operating the arm cylinder quickly pressure of the solenoid proportional valve
under a light load, but under a heavy load (Pis) is reduced and the arm recirclation
(when heavy duty is required), this function spool (310) is switched to position (I).
wastes power. As the result, the passage (61) connects with
The control valve switches automatically the low pressure circuit (D). Then the oil
between oil recirculation under light load returning from the arm cylinder (R) runs
conditions and no recirculation under heavy from the low pressure circuit (D) to the tank
load conditions by detecting pump pressure. port (T) and returns to the hydraulic oil tank.
This is called the variable recirculation The result is that no oil is supplied to the arm
function. When the arm is under a heavy cylinder (H). (recirculation cut)
load,

422
 PLc2
Drd

ARM CYLINDER

LOCK VALVE SELECTOR

H LOCK VALVE
R SELECTOR
CHAMBER AR
SPOOL
514
Aa

PAa

(60) (56) (55)

310 512 (61) Ba

Pis

(60)
D
D

Pis

(61)

Position [Ⅰ]

Fig. 4-23When arm is in (under heavy load)

423
5) Simultaneous operation of swing and arm in
C/V Port name
Operation Pilot secondary Main pressure In order to improve such a condition, the load
pressure side oil supply side on the arm in side is increased intentionally
PAa so the simultaneous operation of swing and
Swing left As
Pis
arm in motions is performed easily.
PBs
Swing right Bs (swing priority)
Pis
PAa In the above condition, the system detects the
Arm in Aa
PLc2 pilot pressure that actuates the swing spool.
The secondary pressure of the solenoid
Purpose : proportional valve (Pis) acts upon the Pis port
Improvement of simultaneous operation of the control valve and changes the arm
when starting swing operation for swing / recirculation spool (310) to position [
].
arm in operation The result is that the hydraulic oil flowed
Principle : into arm recirculation spool (310) is higher on
The arm in side circuit pressure is raised the arm cylinder (R) because the passage to
intentionally because they are used with the arm cylinder (H) and the passage to the
parallel circuit. low pressure circuit (D) are restricted. The
If the swing and arm in actions are result is that the pressure on the arm
performed at the same time, the hydraulic oil cylinder (H) side rises which in turn
from pump P2 passes through the parallel increases the operating pressure for the arm
circuit (56) and flows into the swing motor in operation.
and the arm cylinder at the same time.
However, since the swing system is more
heavily loaded than the arm system at the
start of swing action and during arm in (at
light load), most of the hydraulic oil flow to
the arm cylinder that is lighter loaded.
This causes the simultaneous operation to
deteriorate.

424
 PLc2
Drd

ARM CYLINDER

LOCK VALVE SELECTOR

LOCK VALVE
H R SELECTOR
CHAMBER AR
514 SPOOL
Aa

PAa

(60) (56) (55)

310 512 (61) Ba

Pis

D
D (60)

Pis
(61)

Position [Ⅲ]

Fig. 4-24 Simultaneous operation of swing and arm in

425
(6) Swing action
C/V Port name check valve CP2 (511) open, enters the
Pilot parallel circuit (56) and pushes the swing
Operation secondary Main pressure
load check valve LCs (511) open. The
pressure side oil supply side
pressure, which enters the U-shaped passage
Swing left PAs As
in the swing spool (303), passes between the
Swing right PBs Bs
outer surface of the swing spool (303) and the
If swing action is performed, the secondary casing and is supplied to A or B of the swing
pilot pressure from port
or  of the pilot motor from the As port or the Bs port.
valve acts upon port PAs or PBs of the control In the meantime, the oil which has returned
valve and shifts the swing spool (303) from the B or A side of the swing motor
rightward or leftward. passes between the outer circumference of
The oil delivered by pump (P2) enters the the swing spool (303) and the casing through
bypass circuit (55) past the main passage the port (Bs) or (As), flows from the low
(54), but since the circuit is shut off as the pressure circuit (D) to the tank port (T) and
swing spool (303) is shifted, the pressure returns to the hydraulic oil tank.
pushes the check valve CP2 (511) open,
enters the parallel circuit (56) and pushes the
swing load

A B
SWING MOTOR
511
As BS
U-SHAPED PASSAGE
FOR SWING MOTION

303

PBs
PAs

D (55)

Fig. 4-25Swing left action

426
(7) Action of option valve (for P2 pump)
into bypass circuit (55) through the main
C/V Port name passage (54), but since it is cut off by P2
Operation Pilot secondary Main pressure
pressure side oil supply side bypass cut spool (309) that has shifted, the oil
PA02 A02 pushes the check valve CP2 open, flows into
Option parallel circuit (56), pushes the load check
PB02 B02
valve open, passes through the clearance
With the operation of attachment which between the outer circumference of the option
requires the option valve like nibbler & spool and the casing and is supplied to each
breaker, etc. to operate, the pilot secondary attachment from port (Ao2) or (Bo2).
pressure discharged by the pilot valve acts on In the meantime, the oil returned from the
PAo2 or PBo2 of the control valve, and moves attachment enters the control valve from port
the option spool rightward or leftward, and (Bo2) or (Ao2), passes through the clearance
concurrently the pilot secondary pressure between the outer circumference of the option
acts on PCa port of the control valve and spool and the casing and returns to the
switches P2 bypass cut spool (309). hydraulic oil tank from the low pressure
The hydraulic oil delivered by pump P2 circuit (D) and the tank port (T).
runs

Ao2 Bo2
LOAD CHECK VALVE

PBo2

(56)
D

BYPASS CUT SPOOL

(55) 309
TANK PASSAGE
Ba

PCa

Fig. 4-26Action of option valve

427
(8) Functions of lock valve
After connection of the arm cylinder (R) side That is to say, lock valve selector sub spool
and the boom cylinder (H) side, lock valve (S511) is pressed against bushing (S541) by
(514) housed between Ba port and Ab port of the action of spring (S512).
the control valve and between arm spool In this position, the holding pressure from
(302) and boom spool(301) reduces the boom cylinder (H) side passes through
amount of leak due to the hold pressure passage Sa, passage (a) of bushing (S541) and
received from the respective cylinder. around spool (S511), and connects to (b), then
1) To prevent natural fall when the main spool flows through passage Sb, consequently
is at neutral ; poppet (514) of the lock valve is pressed down
The boom spool (301) will be explained maintaining the seated condition, and the
hereinunder. The arm spool (302) will be leakage results in minimal quantity.
explained also.
When boom spool (301) is in neutral position,
it is held in the position shown in Fig. 4-27.

DETAIL OF LOCK VALVE SELECTOR SPOOL (211)

PLc1 Drc
CHAMBER RH 514 S511 S512
BOOM CYLINDER
HEAD (H) SIDE

Sb
Sa

(a) (b) S541

301

Fig. 4-27Functions of lock valve (when the main spool is neutral)

1 - 4 - 28
2) At boom lower action : (S541) to the drain port (Drc) through the
inside of the bushing (S541).
C/V Port name This causes the orifice (b) of the bushing
Operation Pilot secondary Main pressure
pressure side oil supply side (S541) to connect with the passage Sb, the
PBb spring chamber of the lock valve poppet (514)
Boom lower Bb
PLc1 and the low pressure circuit. The lock valve
Arm in PBa Ab
PLc2 poppet (514) is received by the ring-shaped
pressure bearing area that consists of the
The secondary pilot pressure from port
of guide diameter and the seat diameter of the
the pilot valve acts upon the PBb port of the lock valve poppet (514), so that the lock valve
control valve and the PLc1 port of the lock poppet is pushed open upwards to release the
valve selector and shifts the boom spool (301) lock function.
to the right. At the same time, the pressure
shifts the spool (S511) of the lock valve The operation described above is performed
selector to the right. before the opening (meter out opening) which
As the spool (S511) is shifted, the orifice (a) in is used to return the return oil from the boom
the bushing (S541) closes. This shuts off the cylinder (H) side of boom spool (301) to the
continuity from passage Sa to passage Sb in tank while performing the boom lower
the lock valve selector (211) and the hold operation. Therefore, the action does not
pressure received from the boom cylinder (H) affect the controllability of the boom lower
side ceases to act upon the spring chamber motion.
(RH) of the lock valve poppet (514). The operation is the same as the arm in
As the spool (S511) moves, continuity is operation.
established from the orifice (b) of the
bushing

DETAIL OF LOCK VALVE SELECTOR SPOOL (211)

S511 S512
BOOM CYLINDER
HEAD (H) SIDE
514 PLc1 Drc
CHAMBER RH

Sb
Sa
Pressurized
part of poppet (a) (b) S541
(514)

PAb

301

Fig. 4-28Functions of lock valve (at boom lower)

429
(9) Operation of main relief valve
The main relief valve is built in casing and
operates as follows :

1) The pressure oil is filled up in chamber A

through the orifice (B) of the plunger (512) B A
and seats the plunger (512) securely against
the body (541). R

PL
541 512 YN-B74
Fig. 4-29
2) When the hydraulic pressure of (P) reaches a
set pressure of the spring (621), it pushes B D
open the poppet (611) through the orifice (B)
and flows through the hole (D) to (R). R

611 PL 621
YN-B74

Fig. 4-30

3) When the poppet (611) opens, the pressure in

chamber A falls, which causes the plunger
(512) to open and the pressure oil of port (P) A
to flow directly to (R).
R

611 PL
512
YN-B74
Fig. 4-31

4) Press the boost

Press the boost button, and the pilot pressure
enters in PL port. The pilot pressure pushes
piston (614) leftward, the spring (621) force is
R
raised, and finally the relief pressure is
raised.
P

z The numbers of the parts of the PL

main relief valve in this section 621 614 YN-B74

correspond to those in Fig.4-3. Fig. 4-32

430
(10) Operation of over load relief valve
The over load relief valve is located between
the cylinder port and the low pressure
passage, functions as both a relief valve and
an anti cavitation check valve, as mentioned
below :
301 A B
1) Operation as a relief valve
1. The pressurized oil enters the hole A through
the clearance between piston (301) and
plunger (511) and fills up chamber B. Thus
P
plunger (511) is seated tightly against seat
(541).
R

511 541 YN-B74

2. When the hydraulic pressure of the port (P) Fig. 4-33

arrives at a set pressure of the spring (621), it C
pushes the poppet (611) open, flows on the
circumference of the poppet (611) and passes
through the hole (C) to (R).

611 621
3. When the poppet (611) opens, the hydraulic Fig. 4-34 YN-B74
pressure in chamber B falls which causes the
plunger (511) to open and allows the 511 B
hydraulic pressure of port (P) to flow directly
to (R).

R
2) Operation of anti cavitation check valve
The check valve supplies oil from port (R) 611 YN-B74

when a negative pressure is built up at port Fig. 4-34

(P). When the pressure at (R) gets higher
than that of port (P), the push-up force of
circuit (R) gets stronger than the pressing
force of chamber B.
This causes seat (541) to move to the right. P
Then the oil passes through the clearance of
seat (541) and enters port (P) in sufficient
quantity to fill up the vacancy. R
YN-B74
541
z The numbers of the parts of the over
Fig. 4-36
load relief valve in this section
correspond to those in Fig.4-4.

431
 5. SWING MOTOR UNIT

5.1 SPECIFICATION

 
(1) Outside view

 
Tightening
Port torque
THREAD FOR EYE
Symbol Port name size kgfym (ftylbs) BOLT 2-M12
M L
PB DEPTH 24
AB Main port PF3/4 17 (120)
B RELIEF VALVE
DB Drain port PF3/8 7.5 (54) (B PORT SIDE)

M Make-up port PF3/4 17 (120) (SH)

PA,PB Pressure measuring port PT1/4 3.7 (27)
PG Parking brake release port PF1/4 3.7 (27)
IP
L Gear oil level Gauge PT1/2 6.6 (48) PG
IP Gear oil filling port PF3/4 10 (72) RELIEF VALVE
(A PORT SIDE)
A
DB
PA

PB PA SWING SHOCKLESS
VALVE BLOCK
M DB
A,(B)

IP
PG FILLING PORT
PT3/4
DB

PA PB

A B

Hydraulic diagram

Fig. 5 -1Outside view of swing motor

51
(2) Specification

Swing motor unit part No. YN15V00010F1

Type M2X120B
CHB
10A
37/285

Part No. YN15V00002F4

Displacement cm3 (in3) 121.6 (7.54)

Hydraulic motor

Working pressure kgf/cm2 (psi) 350 (4980)

Max. flow /min (gal/min) 207 (55)

Braking torque kgfym (ftylbs) 63.5 (460)

Release pressure
(Stroke end) kgf/cm2 (psi) 29 (410)

Relief set pressure kgf/cm2 (psi) 285 (4050)

Weight kg (lbs) 54 (119)

Swing Type 2KAR6P72/240-712

shockless
valve block Weight kg (lbs) 2.5 (5.5)

Hydraulic motor assy weight kg (lbs) 56.5 (125)

Type M2X120B

Part No. YN32W00004F1

Speed reduction type Planetary 2-stage

Reduction ratio 15.38

Reduction unit

Lubicate oil Gear oil SAE90 (API class GL
4 grade)

Lubicate oil volume (gal) 7.5 (1.98)

Grease Extreme pressure multipurpose grease

Grease volume A small amount

Weight kg (lbs) 158.5 (349)

Total weight kg (lbs) 215 (474)


5
2
5.2 CONSTRUCTION
(1) Swing motor

488 469 992

355 401
ANTI CAVITATION
PLUNGER
351 051 RELIEF VALVE

051-1

VALVE CASING SECTION

SWING SHOCKLESS
VALVE BLOCK 161,
052 171 151 162 163
391 390
303 981 111 984 131 451

444
981 485

438 464
472 706
712 743
707 742
121 (400-1)

980 113 (400-2)

052
122
702 123 400
114
118 SECTION_A_A

116
117

301 443 491 305 101 437 124 994

Fig. 5-2 Swing motor Pg. 3

53
 Tightning Tightning
torque No. NAME Q’TY torque No. NAME Q’TY
kgfym (ftylbs) kgfym (ftylbs)
18 (130) 051 RELIEF VALVE ; M33-P1.5 2 391 RIVET 2
SWING SHOCKLESS VALVE ;
051-1 O RING ; 1B
G30 2 7.0 (51) 400 M22-P1.5 2
SWING SHOCKLESS VALVE
052 SUB 1 400-1 O RING ; 1B
P20 2
CASING FOR SWING
100 SHOCKLESS VALVE 1 400-2 BACK UP RING 2
101 DRIVE SHAFT 1 44 (320) 401 SOCKET BOLT ; M20
45 4
111 CYLINDER 1 437 SNAP RING 1
113 SPHERICAL BUSHING 1 438 SNAP RING 1
114 CYLINDER SPRING 1 443 ROLLER BEARING 1
116 PUSH ROD 12 444 ROLLER BEARING 1
117 SPACER F 1 451 PIN 2
118 SPACER 2 3.7 (27) 464 VP PLUG ; PF1/4 1
121 PISTON 9 34 (250) 469 ROMH PLUG ; M30-P1.5 2
122 SHOE 9 472 O RING 1
123 SET PLATE 1 485 O RING ; 1B
P11 1
124 SHOE PLATE 1 488 O RING ; 1B
P28 2
131 VALVE PLATE 1 491 OIL SEAL 1
151 PLUG 2 702 BRAKE PISTON 1
161 O RING ; 1B
P11 2 706 O RING 1
162 O RING ; 1B
P12 2 707 O RING 1
163 O RING ; 1B
P6 2 712 BRAKE SPRING 24
3.0 (22) 171 SOCKET BOLT ; M855 4 742 FRICTION PLATE 3
301 CASING 1 743 SEPARATOR PLATE 4
303 VALVE CASING 1 0.09 (0.65) 980 PLUG ; PF1/4 1
305 SEAL COVER 1 0.45 (3.3) 981 PLUG ; PF3/4 3
351 PLUNGER 2 0.17 (1.2) 984 PLUG ; PF3/8 1
355 SPRING 2 6.6 (48) 992 PLUG ; PT1/2 1
390 NAME PLATE 1 10 (72) 994 PLUG ; PT3/4 1

54
(2) Swing reduction unit

33 29 28 27 26
19 25
18 22
17 23
16 24
14 22
20
15
21
13 10
12
11
34

31
30

32 9
8
7
5

6
2 1

Fig. 5-3Cross-sectional view of swing reduction unit

Tightening
torque No. NAME Q’TY No. NAME Q’TY
kgfym (ftylbs)
1 PINION SHAFT 1 19 #.1 SUN GEAR 1
2 SLEEVE 1 20 SPRING PIN 4
4 PLUG 1 21 SHAFT 4
5 O RING 1 22 THRUST WASHER 8
6 OIL SEAL 1 23 #.2 PINION 4
7 RETAINER 1 24 NEEDLE BEARING 4
3.4 (25) 8 SOCKET BOLT ; M8
25 12 25 THRUST WASHER 3
9 BEARING 1 26 #.1 PINION 3
10 HOUSING 1 27 ROLLER 102
11 SPACER 1 28 THRUST WASHER 3
12 BEARING 1 29 SNAP RING 3
13 SNAP RING 1 30 PIPE ; L=180 1
14 #.2 SPIDER 1 31 ELBOW 1
15 #.2 SUN GEAR 1 32 PLUG ; PT3/4 2
16 RING GEAR 1 33 SNAP RING 1
17 #.1 SPIDER ASSY 1 34 SET SCREW ; M20
20 2
18.5 (130) 18 SOCKET BOLT ; M14
130 10
z
Apply Three-Bond #1360K

55
5.3 OPERATION
CYLINDER BLOCK(111)
5.3.1 OPERATION OF HYDRAULIC MOTOR
If the high pressure oil flows into the cilynder F2
through the inlet port (a) of valve plate (131), as F1

shown on the figure on the right, the hydraulic

F
pressure acts upon piston (121) and creates force
F in the axial direction.
The force F may be divided into force F1 vertical
DRIVE SHAFT(101)
to shoe plate (124) via shoe (122) and force F2 at
right angles with the shaft.
The force F2 is transmitted to cylinder block (111)
via pistons (121) and causes drive shaft to turn so
as to produce a rotating moment.
VALVE
The cylinder block (111) has nine pistons equally
PLATE
arranged. Rotating torque is transmitted to drive (131)
shaft by turns by pistons connected to inlet port of SHOE SHOE PISTON
PLATE (122) (121)
high pressure oil.
(124)
If the oil supply and discharge directions are
reversed, the drive shaft rotates in the opposite (LOW PRESSURE OIL) (HIGH PRESSURE OIL)
direction.

Theoretical output torque T can be given by the

OUTLET INLET (a)
following equation.

pq
T=
2π
p : Effective differential pressure kgf/cm2
q : Displacement per revolution c.c. /rev

Fig. 5-4
Operation of hydraulic motor

5.3.2 VALVE CASING SECTION 351

(1) Operation of anti-cavitation check plunger
Since the system using this type of motor is
not equipped with a valve having a
counterbalance function, the motor is rotated
beyond the oil feed rate in some cases.
The system has check plunger(351) and sucks
in dificient oil, in order to prevent cavitation
from occurring due to oil deficiency.

Fig. 5-5
Operation of anti-cavitation check plunger

56
(2) Operation of relief valve CHAMBER h
1) Consider where the P port is pressurized ORIFICE m SPRING(321) PISTON 1(302)
from the tank pressure.
The pressure at the P, R ports is equal to the
tank pressure at the beginning, as shown in
Fig.5-6-(1).
The relief valve begins to operates when the
hydraulic pressure that
is determined by
the product of the pressure-receiving area A1
of plunger(301) and the pressure P balances PRESSURE-
CHAMBER g
A3 A2 ORIFICE n A4
the hydraulic pressure that is determined by RECEIVING
PLUNGER (301)

the product of the pressure-receiving area A2 AREA A1

of the plunger(301) and the pressure Pg of Fig. 5-6-(1)
chamber g.
Thereafter, the pressure of chamber g rises CHAMBER h
and the piston 1 (302) begins to stroke. The ORIFICE m SPRING(321)
PIN(303)
load to spring (321) increases by this PISTON 1(302)

movement of the piston.

As the result, the relief pressure P is raised
and controlled in the pressure boost time t1
from P1 till Ps.

This process is explained in the following in
the relationships between the movements of
the components shown in (2) to (4) of Fig. 5- 
6 and the relief pressure : PLUNGER (301)
ORIFICE n
CHAMBER g
 Condition shown in Fig. 5-6. (2)
If the P port of the relief valve is pressurized, Fig. 5-6-(2)
pressure is built up in chamber g via the
restrictor m of plunger (301). CHAMBER h
The hydraulic pressure acting on plunger ORIFICE m SPRING(321) PIN(303) PISTON 1(302)
(301) increases and when it balances the load
Fsp of spring (321), the relief valve performs
relieving action by the pressure P1.
This relationship is expressed as :
P1A1FSP1Pg1A2

where Fsp1:
primary set load value of spring (321) 
2. Condition shown in Fig.5-6. (3)
The pressure of chamber g acts upon the PLUNGER (301)
ORIFICE n
CHAMBER g
pressure-receiving area A3-A4 of piston 1
(302). When the hydraulic pressure rises Fig. 5-6-(3)
above the load of spring (321), the piston 1
begins to move to the left.
On that occasion, since the machine turns to ORIFICE m SPRING(321) PIN(303) PISTON 1(302)
the left while discharging the oil of chamber
h arranged between piston 1 and adjust plug
(401) into chamber g via restrictor n provided
in piston 1 (302), chamber h serves as a
dumping chamber.

The load of the spring increases slowly till
piston 1 reaches the end of the adjust plug.
The relief pressure P rises smoothly. 
3. Condition shown in Fig.5-6. (4) ORIFICE n
The machine does not travel to the left PLUNGER (301) CHAMBER g

further when piston 1 (302) arrives at the end Fig. 5-6-(4)

of adjust plug (401). Therefore, the relief Fig. 5-6
Functional explanation of relief valve
valve keeps its normal relieving action
whereby the relief pressure is held at P2.
In the processes 1 to 3 above, the relief
pressure changes as shown in Fig.5-7.
2) Function when the relief valve pressure is
reduced
Let us consider the pressure of the P port is
reduced.
When the pressure at port P is reduced to
zero, the pressure of chamber g falls to the
tank pressure level. The result is that the
plunger (301) which is now open moves to the
left and is seated on seat (341). At the same
time, the piston 1 (302) moves to the right by
the action of spring (321) and returns to the Fig. 5-7
Pressure boost characteristics
condition of Fig.5-6 (1).

57
(3) Operation of swing shockless valve

Fig. 5-8 Hydraulic circuit diagram for

1) Neutral condition : swing shockless valve.
Fig.5-8 illustrates the relationship between
the neutral condition of the swing shockless
valve and the hydraulic circuits. Now,
let us
consider a braking condition in which brake
pressure generates on the AM port side.
2) When brake pressure occurs :
If pressure (P) generates at the AM port, it k
passes through the passage l,
the hole on 322 313 321 311
the shaft of seat (313) and the passage m of
plunger (311) and is admitted to the n Fig. 5-9(1) Neutral condition
chamber. m n
When the pressure P rises above a value (Ps)
set by spring (321), plunger (311) compresses
P=PS
spring (321) and shifts it to the left.
Seat (313) compresses weak spring (322) as
pushed by plunger (311) and moves to the
left.
3) At swing shockless action 322 313 321 311
When inertia load stops moving (point Y, Fig. 5-9(2) When brake pressure occurs
Fig.5-10), brake pressure (P) tries to fall. p t
When P<PS, plunger (311) moves toward the
right return side by the action of spring (321).
Seat (313) tries to move to the right by the P<PS
action of spring (322), but since chamber p
provides damping action by orifice g, the
return of the seat makes a time delay with
regard to the return of the plunger. k
322 313 g r 321 311
Consequently, seat t opens. This makes a
passage connecting the AM
port and BM Fig. 5-9(3) At swing shockless action
ports or both ports of the hydraulic motor by Fig. 5-9 Operation of swing shockless valve
way of

trk. The result is that the pressures at
the AM and BM ports become equal (PB),
falling into the condition at point Z in Fig.5-
10. This prevents the hydraulic motor from
swing shock by the closing
pressure of the
AM port.
Fig. 5-10 Pressure change diagram of swing
shockless operation

58
5.3.3 OPERATION OF BRAKE SECTION
The cylinder (111) is jointed by drive shaft (101)
and a spline. Separator plate (743) is fixed in its
111
circumferential direction by circular grooves
712
provided in casing (301).
Now, if the friction plate (742) splined to the outer
circumference of the cylinder is pressed against
casing (301) via separator plate (743) and brake 702
piston (702) by the action of brake spring (712), 712 743
frictional force is created between friction plate
(742) and casing (301) and between separator 742
plate (743) and brake piston (702). The frictional
force bounds the drive shaft to brake the motor. 702
301
In the meantime, when brake release pressure
applied to the oil chamber formed between brake 743 742 301 101
piston (702) and casing (301) overcomes the Fig. 5-11
Operation of swing brake
spring force, the brake is released as brake piston
(702) moves till friction plate (742) is detached
from casing (301).

59
5.3.4 SWING REDUCTION UNIT
The swing reduction unit is used to reduce the
rotating speed, which is transmitted by the
hydraulic motor, and to convert it to the strong
turning effort (torque).
This swing speed reduction unit is equipped with
planetary speed reducing mechanism.
The planetary mechanism is made up of sun gear, RING GEAR (FIXED) PLANETARY SHAFT
planetary pinion, planetary shaft, and spider and
ring gear, as shown in Fig. 5-12.
For the operation of the 1st stage planetary, the
hydraulic motor rotates #1 sun gear (19). Sun
SPIDER
gear (19) is engaged with planetary pinion (26)
and rotates, but since ring gear (16) is fixed,
planetary pinion (26) revolves about sun gear (19) SUN
GEAR
with the planetary shaft and spider (17).

The role of spider is to hold the planetary pinion

and planetary shaft and transmits the power from
the planetary pinion to the spider through the
planetary shaft.
The #1 spider (17) is linked with #2 sun gear (15) PLANETARY PINION
by the inverted spline, and transmits the power to Fig. 5-12
Planetary mechanism
the 2nd stage planetary mechanism.
For the operation of the 2nd stage planetary, the
power is transmitted to sun gear (15)planetary
pinion (23)spider(14) similarly to the 1st stage.
SWING MOTOR
The #2 spider (14) is linked with pinion shaft (1)
by the involute spline, and pinion shaft(1) is 26
engaged with the swing gear fixed on the 19
undercarriage (lower frame) and rotates. 16

17

15

14

10
23
12

9 1

Fig. 5-13
Function of reduction unit

510
 (2) Specification
6._TRAVEL MOTOR Travel motor unit YN15V00011F1 M4V150/100-RG3.5B

6.1 SPECIFICATION • Motor Parts No. Type YN15V00017F1 M4V150/100Z

(1) Appearance • Reduction YN53D00008F1 _
SPROCKET CENTER Reduction ratio 41.46
T=Tightening torque : kgfŸm (ftŸlbs)
Number of reduction stages 2
Reduction unit
22-M19 Lube oil capacity (gal) 5.5 (1.5)
OVERLOAD RELIEF VALVE
M27 Lube oil capacity specification Engine oil SAE#30 (CD class)
T=11 (80) P T=5.5 (40)
T=5.5 (40) Max. displacement cc/rev (cuŸin/rev) 154.4 (41)
Min. displacement cc/rev (cuŸin/rev) 103.7 (27)
8-M12 2
T=10 (72) Relief valve set pressure kgf/cm (psi) 350 (4,980)
2 speed changeover
Travel motor pilot pressure kgf/cm2 (psi) 50 (710)
Parking brake torque kgfŸm (ftŸlbs) More than 45_70 (330_510)
Y Parking brake release
pressure kgf/cm2 (psi) Less than 16 (230)
MB MA Working 2.0 (28)
Allowable drain pressure kgf/cm2 (psi)
Surge 10.0 (140)
VA,VB Unit Weight (With oil) kg (lbs) Motor 82 (181)_Reduction 156 (344)=238 (525)

Dr
PT3/4 17-M20
FILLING PORT 8-M16
OIL LEVEL CHECK PORT T=23.5 (170)
T=10 (72)

GEAR OIL LEVEL

FILL
LEVEL
15-M10
T=8 (58)
LOCKTITE#242

DRAIN
PT3/4
DRAIN PORT
VIEW Y T=10 (72)
Fig. 6-1_Travel motor

Rotation direction
Oil inlet Oil outlet Rotation direction Tightening
port port (Viewed from shaft side) Port name Port size torque Function
kgfŸm(ftŸlbs)
VA VB Right (Clockwise)
P PF1/4 5.5 (40) Pilot (2 speed changeover) port
VB VA Left (Counterclockwise)
Dr PF1/2 11.0 (80) Drain port
VA,VB PF1 26.0 (190) Motor drive port
MA,MB PF1/4 3.0 (22) Pressure measurement

1-6-1
 6.2 CONSTRUCTION No. NAME Q’TY No. NAME Q’TY No. NAME Q’TY
6.2.1 TRAVEL MOTOR 1 CASING 1 21 BALL 1 41 O RING_1B_P11 4
35 37 12 13 3 7 5 6 40 24 28 36
2 REAR COVER 1 22 PIVOT 2 42 O RING_1B_P14 2
20 33 3 CYLINDER BLOCK 1 23 PISTON SEAL 1 43 O RING_190.17_2.62 1
21 4 SHOE RETAINER 1 24 M6 RESTRICTOR (∅0.6) 2 44 OVERLOAD RELIFE VALVE 2
23 5 FRICTION PLATE 3 25 OIL SEAL 1 45 SPOOL 1
29 32 6 BRAKE PISTON 1 26 SPRING 3 46 PLUG_PF3/8 1
17 7 SEPARATOR PLATE 4 27 SPRING (CYLINDER) 9 47 SPRING RETAINER 1
18 26
8 VALVE PLATE 1 28 SPRING (BRAKE) 2 48 PIN 1
38
9 SHAFT 1 29 BEARING 1 49 SPRING 1
9 40
Z 10 COUPLING 1 30 BEARING 1 50 CONNECTOR 1
39
41 11 SHOE PLATE 1 31 SOCKET BOLT_M16_45 8 51 SPOOL ASSY 1
10 12 BALL JOINT 1 32 SHIM 1_2 52 COVER 2
13 SPRING RETAINER 1 33 PARALLEL PIN_∅6_12 1 53 SPRING 2
19 2 14 PISTON ASSY 9 _ ___ _ 54 SPRING RETAINER 2
15 D RING (SMALL) 1 35 PLUG_NPT1/16 1 55 RESTRICTOR VALVE 2
30
16 D RING (LARGE) 1 36 PLUG_NPT1/16(Meck : TB) 10 56 SPRING 2
8 17 CHECK VALVE 3 37 PLUG 1 57 PLUG 2
25
18 SNAP RING 1 38 PLUG_PF1/8 3 58 O RING_42.52_2.62 2
22 1 11 4 27 15 16 43 14
19 SNAP RING 1 39 PLUG_PF1/4 2 59 O RING_1B_P9 2
44 50 42 45 48 47 49 42 46
20 TILTING PISTON 1 40 O RING_1B_P8 5 60 SOCKET BOLT_M12_35 8

58
54

60

53

52

57

41

31 51 59 55 56

VIEW Z (Sectional view is shown partially)

Fig. 6-2_Travel motor

1-6-2
6.2.2 REDUCTION UNIT

24 15 16 14 13 12 18 25

5
20
10
Clearance :
6 0.08 to0.02mm
(0.0031 to0.0008in)
Adjust it with one shim.
9

8 Store it so the shaft center is

1 level with regard to the ground.

11

26

17 21 22 19 23

Fig6-3Reduction unit

No. NAME Q’TY No. NAME Q’TY No. NAME Q’TY

1 COVER 1 10 SUN GEAR 2 1 19 BEARING 2
2 CARRIER 1 1 11 CARRIER 2 1 20 SHIM 1
3 CARRIER PIN 1 3 12 CARRIER PIN 2 3 21 LOCK WASHER 2
4 NEEDLE BEARING 3 13 NEEDLE BEARING 3 22 SUPPORT RING 1
5 THRUST WASHER 1 6 14 PLANETARY GEAR 2 3 23 FLOATING SEAL 1
6 PLANETARY GEAR 1 3 15 SPRING PIN
∅636 3 24 SOCKET BOLT
M1025 15
7 SPRING PIN
∅422 3 16 THRUST WASHER 2 6 25 SOCKET BOLT
M1680 19
8 THRUST PLATE 1 17 RING GEAR 1 26 SOCKET PLUG
PT3/4 2
9 SUN GEAR 1 1 18 HOUSING 1

63
6.3 MAKEUP OF TRAVEL MOTOR (3) Variable displacement mechanism
The travel motor consists mainly of the rotary The variable displacement mechanism
group that generates rotating power, the negative consists of pivot (22) supporting shoe plate
brake that prevents the machine from moving by (11) that is put in two semispherical concave
itself while it is parked, the variable displacement provided in shoe plate tilting piston (20) that
mechanism that switches over the motor capacity tilts shoe plate on pivot (22) tilting stopper
to the large or small mode, the overload relief (1-1) supporting the piston at a certain
valve that is built in the rear cover, and the brake position; the pilot valve that admits the
valve (counterbalance valve) that controls the pressurised oil to the tilting piston (20) by an
hydraulic circuits. external command; and three check valves
(17) that take out the highest of the external
(1) Rotary group command activated pilot pressure, the motor
Cylinder block (3) is inserted in the gear inlet pressure and the motor outlet pressure
tooth grooves of the spline of shaft (9) that is and that sends it to the pilot valve.
supported by bearings (29, 30) at it both ends.
The cylinder block (3) is pressed against rear (4) Overload relief valve
cover (2) with valve plate (8) by the action of The overload relief valve consists of socket
spring (27). (44-1) that has valve seat (44-3) metallically
9 piston assy (14) slide over shoe plate (11), seating rear cover (2) of the motor and
while stroking in cylinder block (3). screwed up in rear cover (2) valve (44-2)
A bearing retainer is arranged at the end face engaged with socket (44-1) that is tangential
of piston assy (14) to reduce the sliding in contact with valve seat (44-3) by the action
resistance. The action of spring (27) is of adjust spring (44-9) connecting piston (44-
transmitted to spring retainer (13), ball joint 4) that is inserted in valve (44-2) and serves
(12), and shoe retainer (4) and presses the also as an oil path to pilot body (44-6) piston
end face of piston assy (14) against shoe plate (44-7) that is put in pilot body (44-6) and
(11) so the piston assy moves close to the pressed against plug (44-6) and shim (44-8).
surface of shoe plate (27).

44-2 44-9 44-12 44-9 44-12 44-11 44-7

(2) Negative brake 44-3 44-1 44-13 44-8 44-10 44-6 44-5
Four separator plates (7) and three friction
plates (5) are inserted by turns in the spline
grooves in the outer surface of cylinder block
(3) and are pressed against casing (1) by the
action of 12 springs (28) via brake piston (6).

Fig. 6-4Construction of overload relief valve

No. NAME No. NAME

44-1 SOCKET 44-8 SHIM
44-2 VALVE 44-9 SPRING
44-3 VALVE SEAT 44-10 O RING
1BP7
44-4 CONNECTING PISTON 44-11 BACKUP RING
44-5 PLUG 44-12 O RING
1BG25
44-6 PILOT BODY 44-13 BACKUP RING
44-7 PISTON

64
(5) Brake valve
1) Spool 2) Check valve (built in the spool)
If the spool (51) is shifted, the oil discharged It is the oil feeding passage to the hydraulic
from the hydraulic motor is shut off and motor and locks the exhaust oil. Therefore,
throttled automatically. The hydraulic motor the check valve serves as the suction valve
performs holding, acceleration, stop and and the holding valve for the hydraulic
counterbalance actions. motor.

Spool select pressure 6.110.2kgf/cm2 (87150psi)

Check valve cracking pressure 0.1kgf/cm2 (1.4psi)

53 54 58 60 52

57 41 56 55 59 51

Fig. 6-5Brake valve

65
6.4 FUNCTIONS OF TRAVEL MOTOR
(1) Functions of motor
The high pressure hydraulic oil delivered by
the hydraulic pump enters from the inlets
(VA, VB), passes through the brake valve,
rear cover (2) and valve plate (8), and is
admitted into cylinder block (3).
The high pressure oil acts upon each of the
pistons arranged in 180bordering on the
line Y-Y that connects the upper dead point
with the lower dead point of the piston, as
shown in Fig.6-6 (a).
And the high pressure oil creates ;
Force F1=PA (P; Pressure, A; Sectional
area of piston).
This force F1 becomes thrust component F2
and radial components F31-F34 (or F35) by
Fig. 6-6
(a) Fig. 6-6
(b)
shoe plate (11) having a tilting angle
. [See
Fig.6-6 (b).] These radial components act
upon the Y-Y axis as rotating force, and
T=r1yF31+r2yF32+r3yF33+r4yF34
(If high pressure acts upon five pistons, add
r5yF35.) is produced.
This torque is transmitted to the spline via
cylinder block (3) and then to shaft (9).

(2) Functions of negative brake

The negative brake is released when
preferentially selected high pressure from the
counterbalance built in rear cover (2) acts
upon brake piston (6) and is generating
braking torque when there is no pressure.
The braking torque is produced by frictional
force that is created by separator plate (7)
linked to casing (1) with the spline and 7 5 28 2
friction plate (5) linked to cylinder block with
the spline.
When pressure is not acting upon the brake
piston, brake piston (6) is pushed by the
action of spring (28). Friction plate (5) and
separator plate (7) are sandwiched between
brake piston (6) and casing (1).
This sandwiching force generates frictional 9
force between friction plate (5) and separator
plate (7) and acts as braking torque that
binds cylinder block (3) or shaft (9). 1 3 6

Fig. 6-7
Negative brake

66
(3) Functions of variable displacement mechanism The point on which the sum of the forces act is nearly
Fig.6-8 shows a modeled variable displacement the center of shoe plate (11) as shown in Fig. 6-8.
mechanism. Since pivot (22) is located away from the center by
When pressure overcoming spring (49) enters the distance S, the rotating force resulting from S mul-
high speed travel command line PA, spring (49) is tiplied by the pressing force of the piston is gener-
compressed. Then spool (45) moves to the right ated. The pistons return to their original position
which connects port P with port C. The highest of and the motor changes to the low speed.
motor pressures A, B and the high speed travel com- In case the engine power lacks in climbing up a steep
mand line pressure is selected in check valve (17) slope at high speed or during steering, the motor
and presses tilting piston (20). For that reason, shoe speed is changed to low speed automatically to pre-
plate (11) tilts along the broken line with the line L vent engine stop.
connecting two pivots (22) as the axis center, stops The mechanism is as below :
tilting when it hits tilting stopper (H), and keeps The hydraulic pump pressure is admitted to the PB
that condition. port as in Fig.6-8.
This decreases the stroke of piston (14) and makes This pressure acts upon pin (48). When the pres-
the motor displacement smaller. The motor is capa- sure exceeds a specified level, spool (45) is brought
ble of rotating at high speed without increasing the back to the left by the reaction of pin (48). Then the
oil flow from the main pump. The speed is approx. pressure which has been pressing tilting piston (20)
1.5 times on this machine. is released to the tank. Shoe plate (11) tilts which
Inversely, if the high speed travel command line makes a larger displacement motor to take up low
pressure PA disappears, spool (45) is brought back speed.
to the left by the action of spring (49). The result is When the pressure falls below a specified level, spool
that the hydraulic pressure pressing tilting piston (45) moves to the right and the motor changes to
(20) is released to the tank and makes the pressing high speed.
force zero.
The motor has nine pistons that are arranged evenly
over shoe plate (11) and presses shoe plate (11).

TO CONTROL VALVE
A B
HIGH SPEED TRAVEL COMMAND LINE
17 17 17
21 20 H 14

S
L

22 22 11
45 PB P C 48 49

Fig. 6-8 Function of variable displacement mechanism

I-6-7
(4) Function of overload relief valve If the A port pressure of the overload relief
Two overload relief valves are arranged in valve rises at the start of the hydraulic
the crossover and operate as below : motor, it acts upon the effective
1) To stop the hydraulic motor, the system circumference on which valve seat (44-3) of
keeps the braking pressure generating on the valve (44-2) is seated and upon connecting
motor discharge side at a certain level to stop piston (44-4) in the valve (44-2) through the
inertia load. small holes of it. The valve (44-2) causes the
2) At start, the hydraulic motor is driven at a pressure to rise to a set pressure by standing
specified set pressure to make sharp against adjust spring (44-9) by the areal
acceleration. At stop, generated pressure is difference between the effective
held low for a short time to dampen shocks by circumference of the valve seat and the
braking the motor. circumference of the connecting piston.
Further, the circuit pressure is held at a set When the hydraulic motor is braked, piston
pressure so the reduction and travel crawler (44-7) at the back of the valve is on its left by
sprockets are engaged smoothly. the drive pressure. As the A port pressure
In short, boost pressure cushioning action is rises, it acts upon piston (44-7) through the
performed. small hole in the valve. The piston moves to
the right till the piston hits plug (44-5).
During this period, valve (44-2) holds the A
port pressure relatively low, counteracting
adjust spring (44-9) and discharges the oil to
the B port side.
After piston (44-7) strikes plug (44-5), the
valve operates the same way as at the start of
the motor.

PLUG
CONNECTING PISTON (44-5)
B port (44-4)

VALVE SEAT
(44-3)

A port

Small hole VALVE ADJUST SPRING PISTON

(44-2) (44-9) (44-7)

Fig. 6-9Function of overload relief valve

68
5) Function of brake valve If an external force acts upon the hydraulic motor,
1) Hold condition (See Fig. 6-10) the motor is kept normally from turning by the nega-
When the selector valve is at neutral, the VA and tive brake. Suppose the negative brake is released,
VB ports are connected with the tank. Spool (51) is pressure is built up at the MA or MB port. Since the
held in its center position by the action of springs hydraulic motor turns a little as the high pressure
located at its both ends. Since the VA → MA pas- of the closed circuit escapes due to internal leaks of
sage and the VB → MB passage are closed, the MA the hydraulic motor, cavitation is about to be built
and MB ports that are connected with both sides of up on the low pressure side of the closed circuit.
the hydraulic motor are closed. The check valve built in the spool operates to pre-
Furthermore, since the parking brake passage is vent cavitation it allows the VA →MA or VB →MB
connected with the tank, the feed pressure for the passage to be formed and makes up an amount of
brake cylinder of the negative brake mechanism is oil equal to the leakage to the closed circuit from
equal to the tank pressure. This makes the brake in the tank.
operating condition and prevents the hydraulic
motor from turning mechanically.

Fig. 6 - 10 Hold condition

I- 6-9
2) At acceleration (See Fig. 6-11)
If the inertia load of the hydraulic motor is large, the pres-
If the selector valve is shifted, the VA port is connected
sure required for acceleration reaches a set pressure of the
with the main pump and the VB port with the tank, the hy-
relief valve. Then the hydraulic motor increases revolution,
draulic oil from the hydraulic pump pushes up the check
while relieving the pressurized oil. As the hydraulic motor
valve in the spool via the VA port. Then hydraulic oil is fed
increases speed, the amount of relieving oil falls and the
to the hydraulic motor from the MA port to turn it.
motor arrives at a constant speed.
The result is that the oil delivered by the pump rises and
releases the brake in the negative brake mechanism. Mean-
while, since the pressure in the pilot chamber rises, the spool
overcomes the spring action in the pilot chamber of the VB
port side and moves to the left. Then the return passage
MB¨VB is formed which makes the hydraulic motor to
rotate.

Fig. 6 - 11 At acceleration

I - 6 - 10
3) At stop operation (See Fig. 6-12) The release pressure for the negative brake falls
If the selector valve is brought back to neutral while slowly by the restrictor. The brake falls into an op-
erating condition which causes the hydraulic motor
the hydraulic motor is rotating to cut off the oil sup-
to stop mechanically
ply and the VA and VB ports are connected with the
tank, the pressures of the pilot chamber at both ends
of the spool are equalized. Then the spool returns to
neutral position by the spring action. This closes the
MB¨VB passage. However, since the hydraulic
motor tries to rotate by inertia load, the hydraulic
motor makes pumping action to discharge the hy-
draulic oil to the MB port. Since the passage is shut
off, the pressure rises, the relief valve operates and
the hydraulic motor is decelerated gradually to a
complete stop.

Fig. 6-12 At stop operation

I - 6 - 11
4) Counterbalance function (See Fig. 6-13) Then the pressure in the pilot chamber on the VB port
If the hydraulic motor is decelerated which is rotat- side rises. The result is that the spool moves to the
ing by inertia force, counterbalance action is re- right which makes the MA¨VA passage area
quired. Now if the hydraulic oil supplied to the VB larger and decreases the braking action. The revo-
port of the hydraulic pump decreases gradually, the lution of the hydraulic motor is at last controlled to
hydraulic motor tries to rotate by inertia beyond the a level equal to the oil feed rate.
oil feed rate. A restrictor that gives damping effect to the spool is
Then the pressure in the pilot chamber of the VB built in the pilot chambers at its both ends to make
side falls. The spool is pushed to the left by spring the counterbalance action stable.
action and moves toward neutral position. Then the The negative brake is released while the spool is
area of the MA¨VA passage decreases and the regulating the pressure.
passage resistance increases. The pressure on the
MA side rises. The hydraulic motor is braked and
decelerated below a revolution equal to the oil feed
rate.

Fig. 6-13@At counterbalance action

I - 6 - 12
6.5 FUNCTIONAL PRINCIPLE OF REDUCTION
GEAR
The reduction gear reduces the revolution
transmitted from the hydraulic motor and
converts it to powerful rotating power.
The reduction gear employs a planetary 2- FIXED RING GEAR
stage reduction method.
The planetary mechanism consists of a sun PLANETARY CARRIER (k)
gear, a planetary gear, a (planetary) carrier, PINION
and a ring gear. (b)
If the sun gear (s) on the input side is rotated,
INPUT OUTPUT
the planetary gear (b) revolves meshed with
the fixed ring gear (a) while rotating by itself. SUN GEAR (s)
This revolution is transmitted to the carrier
(k) to convey torque.
This is the planetary gear mechanism.
RING GEAR (a)
CARRIER (k)

SUN GEAR (s)

PLANETARY PINION
(b)

Fig. 6-14
Planetary gear mechanism

In Fig.6-15, if the sun gear S1 on the input

side rotates, planetary motion occurs between a
gear S1, a and b. The revolution of gear b
conveys the input of carrier K1 to the No.2 b d
sun gear S2 to cause planetary motion to
occur between gear S2, a and d.
S1 S2
On that occasion, since carrier K2 is fixed to
the frame body, gear d transmits the power to
the ring gear and makes ring gear a rotate. K1 K2

Fig. 6-15
2-stage reduction mechanism

613
NOTES
 7. SWIVEL JOINT
7.1 OUTSIDE VIEW
C D E

E
D
A
F

C
B

A
VIEW Z

E
Z

Fig. 7-1General view of swivel joint

7.2 SPECIFICATION

Table 7-1

Item Spec.
Assy parts No. 24100J15939F1
Working pressure 350kgf/cm2(4980psi)
High pressure ports
Max. impact pressure 525kgf/cm2(7470psi)
A,B,C,D
Rated flow 255 /min(67gal/min)
Low pressure ports Working pressure 5kgf/cm2(71psi)
E Rated flow 50 /min(13gal/min)
Low pressure ports Working pressure 50kgf/cm2(710psi)
F Rated flow 30 /min(8gal/min)
Revolution 15rpm
A,B,C,D PF1
Ports size E PF1/2
F PF1/4
Length (height) 320mm(12.6
)
Weight 27kg(60 lbs)

71
7.3 CONSTRUCTION

D
2
C E B

6
X

1
X
A

D
VIEW
Y

C 10
F

B F

5 SECTION
XX

7
9
3
E 8
4 Fig. 7-2
Construction

No. NAME Q’TY No. NAME Q’TY

1 BODY 1 6 O RING 2
2 STEM 1 7 O RING ; 1A
G95 1
3 THRUST PLATE 1 8 CAPSCREW ; M820 2
4 COVER 1 9 CAPSCREW; M830 4
5 SEAL ASSY 5 10 PLUG 1

7.2.4 OPERATION
The swivel joint consists mainly of body(1) and The body (1) and the stem (2) rotate mutually.
stem(2) that rotate mutually, thrust plate(3) The oil flowing in from body (1) or stem (2) keeps
preventing both components from falling off, on flowing to stem (2) or body (1) past the
cover(4) closing one side of body(1), seal(5) that circumferential groove between body (1) and stem
partitions off the circuits and O rings(6) and (7) (2); the oil flow is never shut off because of
that prevent external leaks. rotation. Further, an oil groove for lubrication
Four ports for the travel main circuits are that connects with the drain port is provided, in
provided on body (1) and stem (2). Further, four order to prevent the body (1) from seizure with
oil passing grooves are arranged in the inner the stem (2).
surface of body (1), with seal (5) fixed above and This construction keeps on connecting the circuits
below the circumferential groove. between the swing bodies by means of a swivel joint.

72
 8. CYLINDER
8.1 SPECIFICATION
(1) Outside view

Part No. and Manufacturing No.

Stamp position

Fig. 8-1Outside view of cylinder

(2) Specification

Table 8-1 Unit : mm (ft-in)

Center distance Dry
Cylinder bore / of mounting pins
Use Part No. of cylinder assy Rod Dia. Stroke Full extend B / Cushion weight
Full retract A kg (lbs)
RH YN01V00037F1 ∅125 / ∅85
1,240 3,000 / 1,760 With cushion
Boom (4.92
/ 3.35
168 (370)
LH YN01V00038F1 (41
) (910
/ 59
) on rod side
)
∅135 / ∅95 1,490
3,520 / 2,030 With cushion
Arm YN01V00039F1 (5.31
/ 3.74
(411

(116
/ 68
) on both sides 233 (514)
) )
∅115 / ∅80 1,080 2,680 / 1,600 With cushion
Bucket YN01V00068F1 135 (298)
(4.53
/ 3.15
) (36
) (89
/ 53
) on rod side

81
8.2 CONSTRUCTION
(1) Boom cylinder T=Tightening torque ; kgfym (ftylbs)
M121.75 (Through)
27
3
B 6

T=1.8
2.2(13
16)

26
29
28
DETAIL 22 DETAIL B DETAIL C
VIEW Z

T=1.5(11) T=190(1370) T=100(720)

2 14 13 9 8 10 11 12 7 15 4 1 19 20 21 16 18 17 22 23 24 5

PT1/4

∅1.0
PT1/8 (0.0394) 25 T=35
37(250
270)
Fig. 8-2
Construction of boom cylinder
YN01V00037F1 (The figure shows the right-hand cylinder.)
P/No.
YN01V00038F1
No. NAME Q’TY No. NAME Q’TY No. NAME Q’TY
1 CYLINDER TUBE 1 11 WEAR RING 2 21 O RING ; 1B
G125 1
2 BUSHING 1 12 DUST RING 1 22 BUFFER SEAL 1
3 DUST SEAL 2 13 PISTON NUT 1 23 ROD PACKING 1
4 PISTON ROD 1 14 SET SCREW ; M8 1 24 DUST SEAL 1
5 PIN BUSHING 1 15 CUSHION RING 1 25 SOCKET BOLT ; M16140 10
6 DUST SEAL 2 16 ROD COVER 1 26 BAND 1
7 PISTON 1 17 BUSHING 1 27 BAND 1
8 O RING ; 1B
G65 1 18 SURCLIP 1 28 CAPSCREW ; M1030 2
9 BACKUP RING 2 19 O RING ; 1B
G120 1 29 LOCK WASHER 2
10 PISTON SEAL 1 20 BACKUP RING 1

82
(2) Arm cylinder T=Tightening torque ; kgfym (ftylbs)

31 32 30
29

T=1.8
2.2
(13
16)

DETAIL 20 DETAIL B DETAIL C

VIEW Z

T=1.5 (11) T=190 (1370) T=100 (720)

2,3 12 11 7 6 8 9 10 5 13 4 1 17 18 19 14 16 15 20 21 22 2,3

C PT1/8
PT1/4

A ∅1.3 23 T=35
37
24 (0.0512) (250
410)
25
26
27 T=5 (36)
28
DETAIL A Fig. 8-3Construction of arm cylinder
P/No. YN01V00039F1
No. NAME Q’TY No. NAME Q’TY No. NAME Q’TY
1 CYLINDER TUBE 1 12 SET SCREW ; M8 1 23 SOCKET BOLT ; M16
80 14
2 BUSHING 2 13 CUSHION RING 1 24 RESTRICTOR 1
3 DUST SEAL 4 14 ROD COVER 1 25 SPRING 1
4 PISTON ROD 1 15 BUSHING 1 26 SPRING SEAT 1
5 PISTON 1 16 SURCLIP 1 27 PLUG ; PF3/8 1
6 O RING ; 1BG75 1 17 O RING ; 1BG130 1 28 O RING ; 1BP14 1
7 BACKUP RING 2 18 BACK UP RING 1 29 BAND 1
8 PISTON SEAL 1 19 O RING ; 1BG135 1 30 BAND 1
9 WEAR RING 2 20 BUFFER SEAL 1 31 CAPSCREW ; M10
30 2
10 DUST RING 2 21 ROD PACKING 1 32 LOCK WASHER 2
11 PISTON NUT 1 22 DUST SEAL 1
83
(3) Bucket cylinder
T=Tightening torque ; kgfym (ftylbs)

PT1/8
PT1/8

25 26,27 T=1.8
2.2(13
16)

DETAIL 20 DETAIL B DETAIL C

24
VIEW Z

T=1.5 (11)

T=190(1370) T=100(720)

2 3 12 11 7 6 8 9 10 5 13 4 1 17 18 19 14 16 15 20 21 22 2,3




∅1.5(0.0591) 23 T=35
37
(250
270)

Fig. 8-4Construction of bucket cylinder

P/No. YN01V00068F1
No. NAME Q’TY No. NAME Q’TY No. NAME Q’TY
1 CYLINDER TUBE 1 11 PISTON NUT 1 21 ROD PACKING 1
2 BUSHING 2 12 SET SCREW ; M8 1 22 DUST SEAL 1
3 DUST SEAL 4 13 CUSHION RING 1 23 SOCKET BOLT ; M16
70 12
4 PISTON ROD 1 14 ROD COVER 1 24 BAND 1
5 PISTON 1 15 BUSHING 1 25 BAND 1
6 O RING ; 1BWG8 1 16 SURCLIP 1 26 CAPSCREW ; M10
30 2
7 BACK UP RING 2 17 O RING ; 1BG110 1 27 LOCK WASHER 2
8 PISTON SEAL 1 18 BACK UP RING 1
9 WEAR RING 2 19 O RING ; 1BG115 1
10 DUST RING 2 20 BUFFER SEAL 1

84
Hydraulic cylinder construction
(See Fig. 8-2, 8-3, 8-4)
By construction the hydraulic cylinder consists
mainly of cylinder tube assy (1), piston rod assy
(4) that takes out the motion of pistons
reciprocating in the cylinder tube assy, and rod
cover (14) that serves as both a lid and a guide.
Cylinder tube assy (1) is equipped with a piston
mount (clevis) that connects piston rod assy (4)
with other parts.
In addition to these main components, piston seal
(8) and wear ring (9) are located between cylinder
tube assy (1) and piston rod assy (4); buffer seal
(20), rod packing (21) and dust seal (22) are
located between piston rod assy (4) and rod cover
(14); and an O ring and a backup ring are placed
between cylinder tube assy (1) and rod cover (14). CUSHION RING(13) CHAMBER “A”
TANK PATH “B”
8.2.2 OPERATION PISTON(5)
If pressurized oil is fed alternatively to the oil ROD(4)
inlet and outlet provided in the cylinder, force
acts on the piston which in turn causes the piston ROD SIDE
HEAD
rod (4) to extend and retract. SIDE

(1) Operation of cylinder with cushion (14)

CUSHION STROKE
(Cushion on rod side) ROD COVER
The cushion mechanism is provided to Fig. 8-5
Cushion mechanism on the rod side
prevent the generation of shock when the
moving speed of piston (5) is not reduced and
strikes rod cover(14).
RESTRICTED PATH “C”
An oil in chamber “A” returns to the tank by
TANK
passing through paths “B” and “C” at a fixed CLEARANCE “D”
flow rate in a intermediate stroke state (Fig. 8-5)
of pressing bottom side. Next, in a state of
just before stroke end (Fig. 8-6), cushion ring
(13) plunges into path “B”.
At this time, an oil in chamber “A” passes
clearance “D” and restricted path “C”, an oil
flow volume returning to tank suddenly drops
and the piston part movement slows down. Fig. 8-6
Cushioning action on the rod side

CUSHION RING RESTRICTED PATH

Fig. 8-7
Cushioning action on the rod side

85
(Cushion on head side) PLUNGER
This construction is similar to the one of cushion TANK CHAMBER “A”
on rod side. In a state of intermediate stroke
pressing rod side, an oil in chamber “A” returns
to tank by passing through paths “B” and “C” at
a fixed flow rate.
Next, in a state of just before stroke end,
plunger plunges into path “B”. At this time,
an oil in chamber “A” path clearance “D” and
restricted path “C”, an oil flow volume PATH “B” E CLEARANCE “D”
returning to tank suddenly drops and the RESTRICTED PATH “C”
piston part movement slows down.
RESTRICTOR VALVE

SPRING

SPRING SEAT

PLUG

O RING
DETAIL E
Fig. 8-8
Cushioning action on the head side

86
2.2 SUMMARY OF MAIN ELECTRICAL EQUIPMENT

CONTROLLER GROUP

E1 - 2
E1 - 3
 C-4
AIR-CONTROLLER

MACHINE
FRONT

E-A
ANTENNA L-5
HARNESS
ROOM LIGHT

SW-19
WIPER INTERLOCK
SWITCH

L-5
ROOM LIGHT SWITCH

M-3 M-4
WIPER MOTOR WASHER MOTOR

E1-4
NOTES NOTES
2.3 SPECIFICATION OF ELECTRIC EQIUPMENT
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

B 1 Type 115F51-N120

Voltage 12V
Battery
Capacity 5HR 96Ah
(Ah)
20HR 120Ah
2484U173
Weight 32kg (71 lbs)

Power

2484U174 Type 145F51 N150

Voltage 12V
Power
Capacity 5HR 112Ah
(Ah)
20HR 140Ah

Weight 35kg (77 lbs)

2484U175 Type 170F51 N250-12

Voltage 12V
Power
Capacity 5HR 120Ah
(Ah)
20HR 150Ah 502L 180W 255H
Weight 37kg (82 lbs)

C 1 Maker

Rated voltage DC24V

Controller
For details, refer to
Mechatro System. CN-18
YN22E00037F1
WINDOW FOR ADJUST 4-∅ 7 ATTACHING HOLE
Mechatro controller

E215
YN22E00069F2(EU)
YN22E00037F2(Asia, Oce)

LQ22E00029F2(EU)
LQ22E00018F3(Asia, Oce)

E1 5
 File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

C
2 Maker

Rated voltage DC24V

Controller More than 3M
at
Insulation resistance 500Vmegger
LCD

YN59E00001F2(EU)
YN59E00002F2(Asia, Oce)
YN59E00002F3(Thailand)
YN59E00002F4(Indonesia)

Gauge cluster

C
3 ○ Fitted to the controller group in

the cover that is located at the
back of the operator's seat. C-3 :
Controller SWITCH BOX ASSY

○ Function
YN50E00004F1 • Warm-up
• Conflux / Single select
Switch box assy • Mode / Buzzer stop
• Wiper / Washer / Light

C
4 Maker’s part No. TKSC215AO

Rated voltage DC 2030V CONTROLLER

Controller

YT20M00004S036
Air conditioner
controller
YT00101,YV00101
YY00101,YF00101
YN07-30001
YQ07-03501
LQ08-04501
LL08-03001
LC06-05501
YC06-02501

E1
6
 File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

D
1,2,510 Maker’s part No. 7321-9822

Diode Peak reverse voltage 400V

Mean output current 3A

YN02D01001P1
Surge current 200A
Key switch relay
YX01001
, YV00101

YH00101
, YY00101

YF01-00101
, YU01-00101

YN07-30001
, YQ07-
03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

D
3,4 Part No. 7321-9332-60

Rated current 2.5A

Diode

2475R132
Starter relay
Glow relay
YX01001
, YV00101

YH00101
, YY00101

YF01-00101
, YU01-00101

YN07-30001
, YQ07-
03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

E
1
Fuse capacity and circuit name
Fuse box No. Capacity Name of circuit

20A Mechatro controller
YN73E00007F1
 5A Wiper / washer relay
(EU) 18PAF-HD
 10A Cigarette lighter SUMITOMO
HOUSING : 6098-0257
Fuse  10A Converter TERMINAL : 8240-4422
 10A Horn
  
 5A Controller back-up, Hour meter back-up

20A Fuel suply pump 11 1

18PAF-HD 2
5A Room lamp, Controller back-up
12
20A Key switch 3
13
  4
14
 20A Flasher, Work light, Alarm 7PAF-HD 5
15
6
 5A Gauge cluster, (Power window) 16 7
17
 20A Wiper, Washer 8
18
 10A Solenoid valve, Lever lock 19 9
 20A Work light (front) 10
20
 20A Cab
Air conditioner, Heater 7PAF-HD
 20A
(option) SUMITOMO
HOUSING : 6950-1030
 5A Air conditioner
TERMINAL : 8230-4050
 20A Spare 8232-4238

E1
7
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

E
1 Fuse capacity and circuit name

No. Capacity Name of circuit
Fuse box  20A Mechatro controller
 5A Wiper / washer relay
YN73E00005F2
 10A Cigarette lighter 18PAF-HD
(Asia, Oceania) SUMITOMO
 5A Tuner HOUSING : 6098-0257
Fuse  10A Horn TERMINAL : 8240-4422


LQ08-04501  5A Controller back-up 11 1
LL08-03001
15A Power window back-up 18PAF-HD
2
LC06-05501 12
5A Tuner (back-up), Room lamp
YC06-02501 13
3
20A Key switch
7PAM-HD 14 4
10A Auto greaster
15 5
20A Flasher, Work light (rear),Alarm 6
16
 5A Gauge cluster, Power window 7
17
Wiper, Washer 8
 20A 18
 10A Solenoid valve, Lever lock 19 9
 20A Work light (front) 10
20
 20A Work light (OPT)
Air conditioner 7PAF-HD
 20A
SUMITOMO
 5A Air conditioner HOUSING : 6950-1030
TERMINAL : 8230-4050
 20A Spare
8232-4238

E
2 Type 3-phase AC method

TERMINAL : P
YAZAKI 7322-2129

Voltage 24V
CONNECTOR
Alternator YAZAKI 7322-6223-40
Output 35A(900W)

Drive A-Belt drive by pulley

ME088887

TERMINAL : E M6
1
Generator
TERMINAL : B
YN23301
, YQ02801
M8
1.25
YN07-30001

YQ07-03501

E
2 Rated output 24V35A

CONNECTOR
TERMINAL : P YAZAKI 7322-6223-40
Alternator CONNECTOR
YAZAKI 7322-2215
ME150693

Generator
YF01-00101 TERMINAL :
YU01-00101 B
LQ08-04501
LL08-03001

E1
8
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

E
3 Model 28000-MW1000

Movement Quartz Vss

YAZAKI 7122-2129
Hour meter
Rated voltage DC24V GND
M5 0.8
YN58S00004P1

Service meter
YN23301
, YQ02801

YT00101
, YR04001

YX01001
, YV00101

YX00101
, YF00101

YN07-30001
, YQ07-03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

∅3
E
4 Resistance Coupler (collar)
YAZAKI
E-4 D8 48 7122-2228 (white)
Resistor

LC22E01001D1

Resistance
YN07-30001
YQ07-03501
LQ08-04501
LL08-03001
LC06-05501
YC06-02501 ∅4.2

E
5,6 Type

Rated voltage


Horn Operating voltage
range

2479U1009F1(HIGH)
2479U1009F2(LOW) Sound level  

Basic frequency 415 20 Hz high sound

Warning sound 370 20 Hz low sound
Insulation resistance More than

YW06501

LP11001
, YP02301

YN18001
, YQ02301
STAMP
LQ03301
, LL02301
H HIGH SOUND
YT00101
, YR04001

YX01001
, YV00101
L LOW SOUND
YX00101
, YF00101
Drain 2-Hole
YN07-30001
, YQ07-03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

E1
9
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

E
7 1 OPEN
2 SPEAKER()
3 ACC(B)
Tuner 4 OPEN
LC54S00001P1 5 OPEN
(Asia) 6 SPEAKER()
YN54S00013P1 7 GND()
(Oceania) 8 BACK UP()
9 OPEN
Radio (AM&FM)

YT00101
,YR04001

YX01001
,YV00101

YY00101
,YF00101

YN07-30001

YQ07-03501
Mated side YAZAKI 7318-3090
LQ08-04501

LL08-03001

LC06-05501
Rated voltage DC24V
YC06-02501

1 L SPEAKER()
2 R SPEAKER()
3 ACC(B)
4 OPEN
5 L SPEAKER()
6 R SPEAKER()
7 GND()
8 BACK UP()
9 OPEN

E
8,9 Model SX-M1028K

Rated input 8W
Speaker
Impedance 8
YN54S00006P1
Frequency 33.3Hz

Radio
YW07901
,LP13601

YN23301
,YQ02801

LQ03701
,YT00101

YR04001
,YX01001

YV00101
, YY00101

YN07-30001

YQ07-03501

E
10 Refrigerant in use R134a

Maker’s part No. 56640-A0450

Receiver drier

YT54S00002P1

Air conditioner

YT00101
YN07-30001
YQ07-03501

E1
10
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

E
11 Makers part No. 73516000

Rated voltage DC 24V

Air compressor
Max. revolution 4000rpm
CP3.96MA
LC91V00001F1 YAZAKI 7120-8019 V belt Type B

Refregerant R134a
Air conditioner
Oil SP20 : 135cc

YF00101
YN07-30001
YQ07-03501
LQ08-04501 AVX1.25(BLACK)
AVX1.25(GREEN)
LL08-03001
LC06-05501 4-∅9
YC06-02501

E
13 Rated voltage DC12
36V

Rated current 0.2A / 24V

Travel alarm
Sound level 1074dB / 1.2m

2479U1710 Frequency 2200100 Hz

Travel warning
SUMITOMO 090
WATERPROOF 2PM
LC03801
, YC01001

LS00701
, YS00601
CONNECTOR 6187
2311
YF00101
TERMINAL 1500
0105
YN07-30001
, YQ07-03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

E
14 Model 409112-0000

Rated voltage DC 24V

Cigar lighter PLUG COMPLETE
KNOB
Max. current 5A
2421R180F1
Return time Less than 18sec

Cigar lighter Insulation resistance More than 3M /

500V megger
YW06501
Fusing temp.180
250
JIS CA104
LP11001
, YP02301
Temperature fuse CASE
YN18001
, YQ02301

(356
F
482
F)
LQ03301
, LL02301
SOCKET COMPLETE
YT00101
, YV00101

YX00101
, YF00101

YN07-30001
, YQ07-03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

E1
11
 File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

E
14 Input voltage DC 24V

Converter Output voltage DC 12V

YT77S00001P1 Output current 2.5A Max

(EU, KAI)
Ground Negative
YV
DC24VDC12V WG YB
OL
YY00101
Fix the wire B
YH00101
with tape
YT00101

YF01-00101

YU01-00101

YN07-30001
HOUSING YAZAKI 7122-2262
YQ07-03501
TERMINAL YAZAKI 7114-2020
LQ08-04501

LL08-03001

LC06-05501
VIEWA
YC06-02501
A

E
15 Power supply For 12V

Socket
YN81S00001P1
(KAI, EU)

Power socket
YY00101
, YH00101

YF01-00101
, YU01-00101

YN07-30001
,YQ07-03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

E
A Electrostatic capacity 80
7pF

More than 100M
Insulation resistance
Antenna (DC 500V megger)

YT54S00001P1

Radio
YT00101

YV00101

YY00101

YF01-00101

YU01-00101

YN07-30001

YQ07-03501

LQ08-04501

LL08-03001

LC06-05501

YC06-02501
ANTENNA JUMPER 30pF/m
Oceania : PART NO. 2486R99

ANTENNA JUMPER 30pF/m

KAI, EU : PART NO. YN54S00012D1

E1
12
 File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

L
1 Type BL84-130

Bulb 24V,70W
Light
CA104

YW80S00001F1

Boom work light

M141.5
(left)
YN23301
, YQ02801

YX01001
, YV00101

YY00101
, YF00101

YN07-30001
, YQ07-
03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

L
2,7,8,9 Type BL84
200

Bulb DC 24V,70W
Light
Effective area of lens 71cm2

YN80S00010F2

Deck work light (Right)

BRACKET
OPT:Cab work light (L&R) DRAIN HOLE
OPT:Boom cylinder work light
M121.2525
YW07901
, LP13601

YN23301
, YQ02801
CA104 CB104
LQ03701
, YF00101
(POWER SUPPLY) (EARTH)
YN07-30001
, YQ07-
03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

L
5 Bulb 24V,5W

BODY
Note) Equivalent to 2456Z322F1 LENS A
Light

YT80S00001P1

Room light
Bulb
YW06501

LP11001
,YP02301

YN18001
,YQ02301

LQ03301
,LL02301
OFF ON
YN07-30001
, YQ07-03501
A
LQ08-04501
, LL08-03001
SectionA
A Switch
LC06-05501
, YC06-02501
Door

M
1 Rated output DC24V, 5.0kW B-TERMINAL M81.25

MITSUBISHI part ME049303

Motor
No.
L- TERMINAL
ME049303

Starter motor
YF00101
SW- TERMINAL CONNECTOR
YN07-30001
, YQ07- MITSUBISHI PART
03501
NO.
LQ08-04501
, LL08-03001
VEIW D PH801-02021 D
LC06-05501
, YC06-02501

E1
13
 File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

M
2 Drive voltage DC 24V REDUCTION GEAR SECTION

OUTPUT OIL SEAL
Rated voltage DC 8.5V MOTOR SECTION
SHAFT
Motor Rated current 1.5A/ phase (INVOLUTE)

Number of phases 2 phase Z

YT20S00002F2 Excitation method 2 Excitation
Step angle 1.8 CAM

Governor motor Insulation resistance More than 100M

LIMIT
(500V megger)
SWITCH
YT00101 Reduction ratio 1/20.3
YR04001
YX01001 Brown(A) Red(B) Excitation sequence

YV00101


STEP
1 2 3 4
Lead
YY00101 Orange(A) Yellow(B)
A
 

YF00101 B

 
MOTOR LIMIT SWITCH
CONNECTOR CONNECTOR
YN07-30001 A 


YQ07-03501 B  


LQ08-04501 Limit switch connector No. color
Lead Connec-
tion
1 2
LL08-03001 6 No.
Lead
color
Connec-
tion 1 Brown A
LC06-05501 5 White COM 2 Orange A
5 6 Red NO 3 Red B
YC06-02501 4
7 7 Yellow NC 3 4 Yellow B LIMIT
HOUSING : 6181-0072(SUMITOMO DENSO) HOUSING : 6181-0073(SUMITOMO DENSO) SWITCH
TERMINAL : 1500-0134(SUMITOMO DENSO) TERMINAL : 1500-0105(SUMITOMO DENSO) MOTION
RETAINER : 6918-0327(SUMITOMO DENSO) RETAINER : 6918-0329(SUMITOMO DENSO) RANGE
WATER PROOF : 7165-0118 WATER PROOF : 7165-0118
(SUMITOMO DENSO) (SUMITOMO DENSO) VIEWZ

M
3 Drive voltage DC24V

Motor

YT53C00004P1

Wiper motor
YN07-30001

YQ07-03501

LQ08-04501
, LL08-03001
CIRCUIT DIAGRAM
LC06-05501
, YC06-02501

M
4 Type

Rated voltage 24V

WASHER TANK
Motor
Injection pressure More than 1.2kgf/cm2 (17psi)

Injection flow More than 1320cc/min

2427U900
Tank capacity More than 2.2 (0.58gal) 

TERMINAL

Washer pump
YW06501

LP11001
, YP02301

YN18001
, YQ02301
PUMP
LQ03301
, LL02301

 -TERMINAL
YN07-30001
, YQ07-
03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

E1
14
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

M
11 Flow rate 35L/min (Head 3m)

Pump Voltage 24V

Current 7A (Head 3m)

YT22P00001F5 (EU)
Fuse 10A
Fuel pump
YT00101
YF01-00101
YU01-00101
YN07-30001 Torque :
YQ07-03501 0.51kgfym
LQ08-04501
LL08-03001
LC06-05501
YC06-02501

RED CA104

BLACK CB104

250µ Mesh

At start 24V2000A
R
1 Rated voltage / (0.1sec.)
current At charge 28V120A
(continuous)
Relay Exciting current Less than 0.4A / 24V A-TERMINAL
FLW2.0
More than B-TERMINAL
FLW2.0
Contact force 3.5kgf (7.7 lbs)
YT24S00001F1
F HOUSING :
Closed circuit voltage Less than 16V SUMITOMO
7123-4220-30

Battery relay Open circuit voltage Less than 7V

F TERMINAL :
SUMITOMO
7116-3251
More than 3M
/ REAR HOLDER :
YT00101 Insulation resistance 500V megger SUMITOMO
7157-6801-30
YR04001 MODEL WATER
PROOF :
YX01001 NUMBER STAMPING SUMITOMO
POSITION IN A 7157-3580-60
YV00101
L-TERMINAL
FLOWING DIRECTION OF B-TERMINAL
PRODUCTION PROCESS
Z
YY00101 MAIN CURRENT
AVS1.25L
YF00101 A-TERMINAL B-TERMINAL AVS1.25B AVS1.25G
YN07-30001 A1→ ←B1 EARTH
TERMINAL HOUSING SUMITOMO
YQ07-03501 6181-0072
LQ08-04501 A1-TERMINAL LOCK SECTION
L-TERMINAL
RETAINER SUMITOMO
LL08-03001 6918-0327
TERMINAL SUMITOMO
LC06-05501 1500-0105
YC06-02501 WIRE SEAL SUMITOMO
7165-0119

B1-TERMINAL B-TERMINAL EARTH TERMINAL

VIEW Ⅰ VIEW Z
CIRCUIT DIAGRAM BRACKET
EARTH

E1
15
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
ENGINE
R
2
STARTER MOTOR
Relay
STARTER RELAY

ME701597 B-TERMINAL M8

STARTER (5kW)
Starter relay ME049303 ALTERNATOR
B-CONNECTOR (M6) (M8)
YF00101 MH057641
YN07-30001
YQ07-03501
TO STARTER SW
LQ08-04501
LL08-03001
LC06-05501
YC06-02501

TO STARTER SW
TO TO HEATER RELAY
TO BATTERY RELAY STARTER SW
TO SAFETY RELAY
ME077148

R
3 MITSUBISHI part ME072890

No.
Relay
Rated voltage DC24V

Exciting current 2.3A

ME072890
Fuse 127A

Glow relay
FUSE ATTACHING BOLT
M6
1.0
YF00101
FUSE
YN07-30001
CONTROL TERMINAL
YQ07-03501 COUPLER SIDE CONNECTOR
LQ08-04501 JISD5403 CB104
LL08-03001
M4
0.7
LC06-05501
YC06-02501

CONTACT TERMINAL : M6
1.0

E1
16
 File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

R
4 MITSUBISHI part ME077148

No.
Relay Rated voltage DC 24V
Operating alternator
revolution 1200
100rpm
ME077148
Rated time 30SEC ∅6.5
MMC PARTS NO. MH056359
Safety relay
(W yL)S
YN23301
, YQ02801

LQ03701
, YF00101
Y(L) E(B)
YN07-30001
, YQ07-
03501
(W yG)S P(W yY)
LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

R
7 Rated voltage DC 24V

More than 100M
Insulation resistance (500V megger)
Relay

YT24E00001F1

For wiper
YT00101
, YV00101

YY00101
, YF00101

YN07-30001
, YQ07-
03501

LQ08-04501
, LL08-03001

VIEWZ
CONNECTION DIAGRAM
LC06-05501
, YC06-02501

R
8 Maker’s part No. 488 368 8010

Rated voltage DC 24V / 10A

Relay More than 1M / 500V
Insulation resistance megger

YN24S00001P1

Travel alarm
Z
LC03801
, YC01101

LS00701
, YS00601

YN07-30001
, YQ07-
03501
VIEWZ
LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

R
5,6,9,11,12,13,15,16 Rated voltage DC 24V

Coil resistance 360
10%

Relay
Insulation resistance 20M(500V megger)

YR24S00002P1
Horn relay
Work light relay Applicable connector
Cab work light VCF4－1003(P&B)
YN07-30001
, YQ07-
03501

LQ08-04501
, LL08-03001

CONNECTION DIAGRAM
LC06-05501
, YC06-02501

E1
17
 File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

R
19
UPPER

Relay

YY24S00001P1

Flasher relay
YY00101

YH00101

YN07-30001
, YQ07- TERMINAL NUMBER
03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

R
20 Rated voltage DC24V A NOT USED
Consumption current 0.1A max.
Relay

YN25S00001P1 NO USED D

Timer CONNECTOR YAZAKI No.7122-2262 E NOT USED

EQUIVALENT
YN07-30001

YQ07-03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

CIRCUIT DIAGRAM
CONNECTOR MODEL
0
30kgf/cm2
SE
111,20,28 Pressure range (0
430psi)
HW090 3-P (T TYPE)
(SUMITOMO DENSO)
Max. allowable 3
Pressure sensor pressure 250kgf/cm2(3560psi) 2
(Low pressure) Operating source
voltage 50.5V DC
CONNECTOR
LC52S00001P2 Load resistance 10M MIN
TERMINAL
ARRANGEMENT
Bucket, Boom, Swing Insulation resistance
TERMINAL NO.
100M 1 1POWER
Arm,Travel,
SUPPLY(+)
P1,P2 Option, 2OUTPUT(+)
Back pressure 3COMMON
HEX 19
YT00101
, YR04001

YX01001
, YV00101

YY00101
, YF00101
O RING(P111B)
YN07-30001
, YQ07-
03501
PF1/4
LQ08-04501
, LL08-03001
TIGHTENING TORQUE 3.7kgfym (27ftylbs)
LC06-05501
, YC06-02501

SE
13 E/G RING GEAR

Speed sensor

MC849577 M161.5 F(GND)-B

HEX 22
E(OUTPUT)-Y
HEX 19
Speed sensor LOAD CIRCUIT

YF00101

YN07-30001
, YQ07-
CONNECTOR MITSUBISHI PART No. MH056401
03501

LQ08-04501
, LL08-03001
CONNECTOR YAZAKI PART No. 7322-1424-30
LC06-05501
, YC06-02501

E1
18
 File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
Z
SE
14 Makers part No. 71400KW0300

Resistance characteristics
Water temp. sensor
50
C 80 M16×1.5
YT52S00001P1 TORQUE
60
C 56.3 2.5 kgfym
E/G coolant (18ftylbs)
80
C 29.5
temp. sensor
YT00101
, YR04001
100
C 16.5
YX01001
, YV00101

YY00101
, YF00101
106
C 14.3 VIEW Z
YN07-30001
, YQ07-
03501
120
C 10
LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

FLOAT
SE
15 Float Resistance value  
+0.1
FULL 10 -0.5
Fuel sending unit
3/4 (19)
2489U267F1 1/2 323 
A
1/4 (49.5)
Fuel sensor
EMPTY 80 +12
+2
YW06501

FUEL LEVEL
LP11001
,YP02301

WARNING LAMP POSITION
YN18001
, YQ02301

LQ03301
, LL02301

YN07-30001
SENSOR SWITCH
YQ07-03501

LQ08-04501

FUEL METER
LL08-03001

LC06-05501

YC06-02501

24V3W FLU

DC
24V FLOAT SUMITOMO CONNECTOR
PART 6187－3231

VIEW A

SE
16 Total resistance value 2K

Effective electric angle 90 NOTCH PART BRACKET POTENTIO

Potentiometer
DIAL
Number of notches 10
YN52S00009P1
Source voltage 5V
3PAM-090
Accel dial
YN23301
, YQ02801
SUMITOMO
YT00101
, YR04001
6187-3231
YX01001
, YV00101

TERMINAL
YY00101
, YF00101

YN07-30001
, YQ07- 1500-0105
03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

E1
19
 File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
CONNECTOR MODEL
SE
22,23,24,25 0500kgf/cm2 HW090 3－P (T－TYPE)
Pressure range (07110psi) 3 (SUMITOMO DENSO)

Pressure sensor Max. allowable press. 270kgf/cm2(3840psi) 2

(low pressure)
Operating source voltage 5
0.5V DC
LC52S00001P1
Load resistance 10K MIN
1
P1 pump, P2 pump Insulation resistance More than 100M
CONNECTOR TERMINAL
ARRANGEMENT
YX01001
HEX TERMINAL No.
YN07-30001
O RING 1 ─ POWER SUPPLY (+)
YQ07-03501

(P11 1B) 2 ─ OUTPUT (+)
LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501
PF3/8 3 ─ COMMON
TIGHTENING TORQUE 7.5kgf!m (54ft!lbs)
CONNECTOR MODEL
SE
26,27 50kgf/cm2 HW090 3－P (T－TYPE)
Pressure range (710psi) 3 (SUMITOMO DENSO)
2
Max. allowable press. 525kgf/cm2(7470psi)
Pressure sensor
Operating source voltage 5
0.5V DC
YN52S00016P1 Load resistance 10K MIN
1
P1 negative control Insulation resistance More than 100M CONNECTOR TERMINAL
P2 negative control HEX 22 ARRANGEMENT
YN07-30001
TERMINAL No.
O RING 1 ─ POWER SUPPLY (+)
YQ07-03501

(P11 1B) 2 ─ OUTPUT (+)
LQ08-04501
, LL08-03001

PF3/8 3 ─ COMMON
LC06-05501
, YC06-02501
TIGHTENING TORQUE 3.7kgf!m (27ft!lbs)

SV
11 Rated voltage DC 24V

Working pressure 50kgf / cm2

Solenoid valve
Max. flowrate 16 /min

YN35V00010F1

Extra breaker

YN07-30001
YQ07-03501
LQ08-04501
LL08-03001
LC06-05501
YC06-02501
VIEW

E1
20
 File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

SV
1,2,3,4 Rated voltage 90kgf/cm2 (1280psi)

Solenoid selector
Solenoid valve (8 solenoid) valve Rated voltage DC 24V P1,T,A1 port PF3/8
Selector valve assy Dither current 100Hz,300mA P-P A2A8 port PF1/4
Solenoid
Refer to hydraulic proportional valve
Coil resistance 17.5
1(at20)
symbol A1,A2,A7,A8
SUMITOMO DENSO HW :
090 connector M(2P)
YN35V00022F1 Connector HOUSING part No. :
specification Equivalent 6181-0070
YN07-30001
TERMINAL part No. :
Equivalent 1500-0105
YQ07-03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

PSV
A,B,C,D YN35V00021F1 YN35V00020F1 YN35V00019F1 YN35V00020F1

Proportional
solenoid valve
Refer to hydraulic T=0.7kgfym

symbol A3A6 (5.1ftylbs)

YN07-30001
YQ07-03501 PLUG PT1/8

PLUG
SWING TRAVEL ARM P1 TRAVEL P2 ATTACH LOCK PT1/16
PARKING 2-SPEED VARIABLE BYPASS STRAIGHT BYPASS POWER LEVER
RECIRCU- CUT CUT BOOST
LATION PRESSURE

Hydraulic symbol
VIEW

E1
21
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

PSV
H Type IKWE5G
30

Max. press (P port) 90kgf/cm2 (1280psi)

Proportional valve
Rated press 050kgf/cm2 (0710psi)
YM35V00001F1
Allowable back press 10kgf/cm2 (140psi)

Swing priority Max. flow 10 /min (2.6gal/min)

M50.5
YF01-00101 Torque 0.7kgfym (5.1ftylbs)
YU01-00101
YN07-30001
YQ07-03501
LQ08-04501
LL08-03001
LC06-05501
YC06-02501

HYDRAULIC SYMBOL

PSV
P1,P2 Type KDRDE
5K

Proportional valve Max. feed press 140kgf/cm2 (1990psi)

Rated feed press 50kgf/cm2 (710psi)

YN35V00018F2
Allowable back press 10kgf/cm2 (140psi)
Proportional valve
for pump Control pressure range 030kgf/cm2 (0430psi)

YF01-00101 Rated voltage DC24V

YU01-00101 SUMITOMO DENSO CONNECTOR HW090M(2P)
YN07-30001 HOUSING 6181-0070

YQ07-03501 TERMINAL 1500-0105

LQ08-04501
LL08-03001 HEX32
LC06-05501
YC06-02501

O RING HEX 10
1B P20 T=0.75 kgfym (5.4ftylbs)

E1
22
 File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
AUTO RETURN
SW
1 T
P
B G1 G2 ACC M ST

Switch H


AUTO RETURN
OFF
YN50S00002F1
ACC

VIEW A
Starter switch
ON


“K250”STAMPED
YW06501

LP11001
, YP02301

YN18001
, YQ02301

LQ03301
, LL02301

START



A
YT00101
, YR04001

YX00101
, YV00101

YY00101
, YF00101

YN07-30001
, YQ07-03501

LQ08-04501
, LL08-03001
TERMINAL
LC06-05501
, YC06-02501
ARRANGEMENT

SW
2 Type Sheet type, with back light

Switch

YN50E00002F1

Mode, buzzer stop

YN07-30001

YQ07-03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

SW
3 Type Buried in right travel lever

MARKS ON SWITCH PORTION

Switch
YN03M01039P1
(Right travel grip)

Travel 1,2-spead
YW06501

LP11001
, YP02301

YN18001
, YQ02301

LQ03301
, LL02301

YN07-30001
, YQ07-
03501
CA103
LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

Single-pole single-throw
SW
3 Type momentary

Rated voltage DC 24V

Switch CONNECTOR (WITH LOCK) (R)
More than 1M
/
Insulation resistance DC500V megger
EQUIVALENT YAZAKI 7122-2228 RED

2479U1224F4
TERMINAL CONNECTOR
Travel 1,2-spead Terminal
Position R RW RED /
YN07-30001
WHITE
YQ07-03501
OFF
LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501
ON

E1
23
 File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
Single-pole double-throw
SW
4 Type (alternate) INSULATION TAPE
R B W
Rated DC 30V,10A
Switch
Insulation resistance

YX50E00002F1 VINYL TUBE

YAZAKI
Contact T No.
Swing parking construction : position
1 2 3 RED(2) 7122-2237
release 7114-2020
YN07-30001
Swing parking release ON
YQ07-03501
Normal ON
LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501
WHITE(3) BLUE(1)

M12P1
SW
5 Type 

CIRCUIT DIAGRAM
Switch

YN50S01003P1 KEY WAY

KPSS release
YW06501

LP11001
, YP02301

YN18001
, YQ02301

LQ03301
, LL02301

YV00101
, YY00101

YF00101
12PAM-HD
YN07-30001
, YQ07- SUMITOMO 6098-0252
03501

LQ08-04501
, LL08-03001
TERMINAL 8230-4282
LC06-05501
, YC06-02501

SW
6 MITSUBISHI Part No. ME039860
Closed circuit 1052
E/G water temperature (22135.6
F) M161.5 M40.7
temperature switch Temperature difference
in open/close action 7 (44.6
F) MAX
ME039860
Rated voltage DC24V
YN23301
, YQ02801
DATE OF MANUFACTURE
Current capacity 3A
YF00101

YN07-30001

Mounting position Mounting E/G
YQ07-03501

LQ08-04501

Contact type Nomally open
LL08-03001

LC06-05501

YC06-02501

SW
7 MITSUBISHI part MC840219

No.
E/G oil pressure
switch Rated voltage DC24V
Open circuit oil
MC840219 pressure
0.5kgf/cm2 (7.1psi)
MIN
Oil pressure ∅2 PT1/8
indication Contact type Nomally closed
YN18001
, YQ02301

LQ03301
, LL02301

YF00101

YN07-30001

YQ07-03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

E1
24
 File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

SW
8 Makers part No. REX801001

CA104 CB104

Switch

YR11P00008S005

Dust indicator
YR02001
, YN23301

YQ02801
, YF00101

YN07-30001
, YQ07-
03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

Single-pole single-throw
SW
9 Type momentary

Rated voltage DC 24V

Switch
More than 1M / CONNECTOR (WITH LOCK) (R)
Insulation resistance DC500V megger EQUIVALENT YAZAKI 7122-2228 RED

2479U1190F9
TERMINAL CONNECTOR
Swing flasher Terminal R RW
Position
RED /
YN07-30001

YQ07-03501
OFF WHITE
LQ08-04501
, LL08-03001

ON
LC06-05501
, YC06-02501

SW
10 Type Buried in left grip

Insulation resistance More than 100M /

DC500Vmegger
Horn switch
Grip assy YN03M01369F1

YN50E00007P1
SUMITOMO DENSO HOUSING ITEM : 60901031(2P male)
SUMITOMO DENSO TERMINAL ITEM : 82304282
Horn JYUNKOSYASEI LEAD ITEM : 861006(0.5sq)

YN07-30001

YQ07-03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

SW
11
    HEX17

Switch
CONNECTION TABLE
YN50S01001P1 2PAM




Safety lock lever 
YN23301
, YQ02801
  YAZAKI HOUSING 7122-2228
YT00101
, YR04001

YX01001
, YV00101
 TERMINAL 7114-2020
YY00101
, YF00101


YN07-30001
, YQ07-
03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

E1
25
 File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
Single-pole single-throw
SW
12 Type momentary

Rated voltage DC 24V

Switch CONNECTOR (WITH LOCK) (R)
More than 1M /
Insulation resistance DC500V megger
EQUIVALENT YAZAKI 7122-2228 RED

2479U1190F33
TERMINAL CONNECTOR
Overload alarm
Terminal
select switch Position R RW
RED /
YN07-30001
WHITE
YQ07-03501
OFF
LQ08-04501
, LL08-03001

ON
LC06-05501
, YC06-02501

SW
13
 SANDEN

Air conditioner Connector 21749551

switch panel Type With 
C↔
F converter

YN20M01299P1

Air conditioner panel

YN07-30001

YQ07-03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

SW
13 Maker’s part No. TKS-P215BO

Air conditioner NIPPON AMP
Connector 2-174955-1
switch panel 4-∅6
LC20M01013P1

Air conditioner
panel
YF01-00101

YU01-00101

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

OFF 40°ON
SW
16 Toggle switch
M12
Single-pole single-throw
Type alternate
Switch
Rated voltage DC 24V M3
LA103
YT50S00005P1 WIRE COLOR : BLACK
WIRE COLOR : RED
E/G room light
switch
YN07-30001

YQ07-03501
CB104 CB104
LQ08-04501
, LL08-03001
TERMINAL : YAZAKI TERMINAL : YAZAKI
LC06-05501
, YC06-02501
: 7113-1020-02 : 7115-1050-02
CAP : YAZAKI CAP : YAZAKI
: 7120-8012 : 7120-1010

E1
26
 File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

SW
19 Maker’s type DS430

Single-pole single-throw
Contact arrangement ON-(OFF)momentary
Switch Normally closed 8.7
More than 100M
14
Insulation resistance (500V megger)
YN50E00006P1 BLACK CB104

Wiper inter lock

YN07-30001
RED CA104
YQ07-03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

SW
20 Type Sheet type, with back light

Switch

YN50E00003F1

Wiper, washer, work light

YN07-30001

YQ07-03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

SW
21 Type Buried in right grip

More than 100M
/
Insulation resistance
DC500V megger
Switch
Grip assy YN03M01369F2

YN50E00007P1
SUMITOMO DENSOHOUSING ITEM : 60901031(2P male)

ATT power boost SUMITOMO DENSOTERMINAL ITEM : 82304282

JYUNKOSYALEAD WIRE ITEM : 861006(0.5sq)
YN07-30001

YQ07-03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

E1
27
 File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

SW
23 MITSUBISHI part No. MC867765

Type Normally closed

E/G oil level
Switch voltage Less than 0.3A

MC867765

SWITCH
E/G oil level OFF LEVEL
RELAY
LC04201
,YC01301

LS00801
,YS00701

YF00101
24V
YN07-30001
3W
YQ07-03501
24V
BULB SWITCH
LQ08-04501

LL08-03001
CLIP MODEL : MH056347
LC06-05501

YC06-02501
CONNECTION DIAGRAM

CONNECTOR PART No. : MH056304

CONNECTOR ON MATED SIDE : MH056354

SW
24 3.4 (0.90gal)

All water volume
Sub tank FULL 1.5 (0.40gal)
LOW level 0.43 (0.11gal)
E/G coolant OPEN-TO-
Remaining liquid level
temperature SW. Switch function 0.43
0.1 (0.11
0.023gal) ATOMOSPHERE
SIDE

2427U203S6 Contact type Normally closed

E/G coolant level

RADIATOR-
YAZAKI
LC03201
, YC00901
CONNECTED
PART No.
LS00501
, YS00501
7121
YF00101
LOW SIDE AV0.5FB
YN07-30001
, YQ07-
03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501
HOUSING YAZAKI : 7122-2228
SW
25 Max. contact rating 10W TERMINAL YAZAKI : 7114-2020
Between terminals 100M

Insulation or more (100V)
Between terminal-grounding
Switch resistance 100M
or more (500V)
CORRUGATE
TUBE AEX WIRE 0.85 (BLACK)
YN52E00023P1
Hydraulic oil level M27×1.5
switch
YF00101 Operating point
FLOAT OUTER
YN07-30001
Liquid type Specific gravity ON (Amm) OFF (Bmm)
DIAMETER ∅23
Less than More than
YQ07-03501
OIL 0.88 10.5mm 2.0mm
LQ08-04501
, LL08-03001
When the level of remaining liquid is low, it is
LC06-05501
, YC06-02501
turned off automatically by the function of float.

E1
28
 File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

SW
26 Single-pole single-throw

Type (Alternate)

Rated voltage DC 24V

Switch
CONNECTOR (WITH LOCK)
More than 1M
/ (R)
Insulation resistance DC500V megger EQUIVALENT YAZAKI 7122-2228 RED
2479U1190F1

Work light (OPT) TERMINAL CONNECTOR

Terminal L RW
YT00101
Position RED /
YF01-00101
WHITE
YU01-00101
OFF
YN07-30001
, YQ07-
ON
03501

LQ08-04501
, LL08-03001

LC06-05501
, YC06-02501

SW
35 Type
Single-pole single-throw
(Alternate)

Switch Rated voltage DC 24V

More than 1M
/ CONNECTOR (WITH LOCK) (R)
Insulation resistance DC500V megger EQUIVALENT YAZAKI 7122-2228 RED
2479U1190F13

Heavy lift switch TERMINAL CONNECTOR

LQ08-04501 Position
Terminal L RW RED /
LL08-03001 WHITE
LC06-05501 OFF
YC06-02501 ON

SW
37 Operation
ON : at 3 (37.4F)
OFF : at 10 (50
F)

Switch

2479R2348 PT3/8 CA104 21

LOT No.

Hyd. Oil temp. BLUE PAINT

switch
LQ08-04501
LL08-03001
LC06-05501
YC06-02501

SW
38 Single-pole single-throw

Type (Alternate)

Rated voltage DC 24V

Switch CONNECTOR (WITH LOCK) (R)
More than 1M
/
Insulation resistance DC500V megger
EQUIVALENT YAZAKI 7122-2228 RED
2479U1190F31

Warm up switch TERMINAL CONNECTOR

Terminal
LQ08-04501 Position L RW RED /
LL08-03001 OFF
WHITE

LC06-05501
YC06-02501 ON

E1
29
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine

SW
42 Rated voltage DC12 & 24V

Relief valve set
Switch pressure 1.40.2kgf/cm2
Fitted to an oil cooler
ME084614 More than 1M
/
Insulation resistance DC500V megger
E/G oil filter
bypass alarm
LQ08-04501
LL08-03001 ∅2 hole
LC06-05501
YC06-02501

SW
47 Type
Single-pole single-throw
(Alternate)

Switch Rated voltage DC 24V

More than 1M
/ CONNECTOR (WITH LOCK) (R)
Insulation resistance DC500V megger EQUIVALENT YAZAKI 7122-2228 RED
2479U1190F21
Extra & Breaker
switch TERMINAL CONNECTOR
LQ08-04501 Terminal L RW RED /
Position
LL08-03001 WHITE
LC06-05501 OFF
YC06-02501 ON

E1
30
 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS

CHAPTER 25

E215
CRAWLER EXCAVATOR

AIR CONDITIONING SYSTEM

Issued January 2006

Book/Form Number 5-1670 NA
Copyright © 2006. CNH America, LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. S5PJ0010E01-KO22
 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONING SYSTEM

CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring
any obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Remarks
First Edition 01-2006 E215 5-1670 NA

25-2 Issued 01-2006 Bur 5-1670 NA

 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS

CHAPTER 25
AIR CONDITIONING SYSTEM
TABLE OF CONTENTS

25.1 CONSTRUCTION AND PIPING

25.1.0.1 Intake Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-3
25.1.0.2 Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-4
25.1.0.3 Heater Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-5
25.2 MAIN COMPONENT CONSTRUCTION
25.2.1 Intake Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-6
25.2.1.1 aIR cONDITIONER uNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-7
25.2.2 Component Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-8
25.2.2.1 Intake Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-8
25.2.2.2 Unit Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-9
25.2.3 Air Conditioner Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-11
25.2.3.1 Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-11
25.2.3.2 Component Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-13
25.2.3.2.1 Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-13
25.2.3.2.2 Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-13
25.2.3.2.3 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-15
25.2.3.2.4 Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-15
25.3 DISASSEMBLY AND ASSEMBLY
25.3.1 Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-18
25.3.1.0.1 Removing the blower unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-18
25.3.1.0.3 Replacing the blower controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-18
25.4 CHARGING REFRIGERANT
25.4.1 Precautions during charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-22
25.4.2 Operating Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-23
25.4.3 Charging Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-24
25.4.3.0.1 Creating Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-24
25.4.4 Air tightness check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-25
25.4.4.1 Gas Charging Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-25
25.4.5 Checking amount of refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-27
25.4.6 Detaching the gauge manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-27
25.4.7 Electrical Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-28
25.4.8 Functional Parts Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-29
25.4.8.0.1 Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-29
25.4.8.0.2 inner air sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-29
25.4.8.0.3 blower controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-29
25.4.8.0.4 motor actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-29
25.4.8.0.5 pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-30
25.5 TROUBLESHOOTING

5-1670 NA Issued 01-2006 Bur 25-1

 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONING SYSTEM

NOTES

25-2 Issued 01-2006 Bur 5-1670 NA

 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONING SYSTEM

25.1 CONSTRUCTION AND PIPING

25.1.0.1 INTAKE UNIT

CH25-03-01 Figure 1

5-1670 NA Issued 01-2006 Bur 25-3

 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONING SYSTEM

25.1.0.2 PIPING
t

CH25-04-01 Figure 2

25-4 Issued 01-2006 Bur 5-1670 NA

 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONING SYSTEM

25.1.0.3 HEATER CIRCUIT

t

CH25-05-01N Figure 3

5-1670 NA Issued 01-2006 Bur 25-5

 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONING SYSTEM

25.2 MAIN COMPONENT CONSTRUCTION

25.2.1 INTAKE UNIT

CH25-06-01N Figure 4

25-6 Issued 01-2006 Bur 5-1670 NA

 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONING SYSTEM

25.2.1.1 AIR CONDITIONER UNIT

t

CH25-07-01N Figure 5

5-1670 NA Issued 01-2006 Bur 25-7

 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONING SYSTEM

25.2.2 COMPONENT CONSTRUCTION

25.2.2.1 INTAKE UNIT

CH25-06-01 Figure 6

25-8 Issued 01-2006 Bur 5-1670 NA

 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONING SYSTEM

25.2.2.2 UNIT CONSTRUCTION

CH25-07-01 Figure 7

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 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONING SYSTEM

CH25-08-01 Figure 8

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 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONING SYSTEM

25.2.3 AIR CONDITIONER FUNCTION

25.2.3.1 MECHANISM
1. Mechanism of Cooling
In the cooling process, the refrigerant that flows
through the cooling circuit changes its characteristics
from liquid to gas then from gas back to liquid as heat
is transferred from the low temperature compartment
to outside the machine.
A. Types of refrigerant
Different types of refrigerants are available and
are subject to regulation. The EPA issues strict
guide lines for re fr igerants. The following
requirements are necessary for use in machine
applications.
Latent heat of vaporization should be high.
Refrigerant will liquefy or condense easily
and does not require high pressure for
condensation.
The refrigerant must evaporate in order to
cool. It must not evaporate at too low a
pressure.
Refrigerant is cooled by the expansion valve,
and loss resulting from this must be held to a
minimum. It must be stable chemically and
not corrode or permeate into circuit parts.
Refrigerant should be free from objectionable
odor, flammability, and/or combustion.
Always use an approved refrigerant. Table 1
shows the principal characteristics of R134a.
2. Characteristics of Refrigerant (See Fig. 6)
A. Refrigerant as a gas under certain
pressure as it cools begins to condensate
and become liquid. The temperature at
which condensation occurs is unique at
g i ve n p r e s s u r e s . T h e t e m p e r a t u r e
determined by a given pressure is the
saturation temperature. The pressure at
which gas condenses at a determined
temperature is saturation pressure. Fig. 7
illustrates the relationship between
saturation temperature and saturation
pressure for R134a.

CH25-09-01 Figure 9

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 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONING SYSTEM

B. Refrigerant absorbs evaporated heat from

the air inside of the machine cab as it
ev a p o r a t e s . I n o r d e r t o c o o l , t h e
refrigerant must evaporate from a liquid to
a gaseous state at a lower temperature.
As it is brought back to a liquid state, the
refrigerant is cooled and condensed.
R 1 3 4 a w i l l c on d e n s e a t a p r es s u re
exceeding 102.kgf/cm2 (145 psi).
3. Cooling Circuit
A. Fig. 8 illustrates a typical cooling circuit.
A i r i s c o o l e d b y t h e e v a p o r a t o r.
Refrigerant removes heat from the cab by
absorbing heat in the surrounding area,
and this heat is evaporated in the cooling
circuit. Cooled air is delivered to the
circumference of the evaporator by the
b l o w e r fa n . S i m u l t a n e o u s l y, l i q u i d
refrigerant is fed into the evaporator when
the cooling effect is attained.
In order to cool air to 15°C (59°F), the CH25-10-01 Figure 10
refrigerant cannot absorb evaporation
heat from the air unless it evaporates at a
temperature lower than 15°C (59°F). The
pressure of the refrigerant in the
evaporator must be less than 5.2 kgf/cm2
( 7 4 p s i ) . T h e eva p o r a t o r i s a h e a t
absor ption component. Its primar y
function is to remove heat from the inside
of the cab, while a second benefit is
dehumidification. As warm air travels
through the fins of the cooler or
evaporator coil, moisture contained in the
air condenses on its surface. Refrigerant
enters the bottom of the evaporator as a
low pressure liquid. Warm air passing
through the evaporator fins causes the
refrigerant to boil (refrigerants have an
extremely low boiling point). As the
refrigerant begins to boil, it can absorb
large amounts of heat. This heat is then
dispensed to the outside of the cab.
B. 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
compressor action and the heat exchange
action transform the refrigerant in a dry
vapor state back to a liquid state.

25-12 Issued 01-2006 Bur 5-1670 NA

 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONING SYSTEM

25.2.3.2 COMPONENT PARTS

CH25-11-01 Figure 11

CH25-12-01 Figure 12
25.2.3.2.1 EVAPORATOR 25.2.3.2.2 EXPANSION VALVE
The evaporator (Fig. 9) is an important heat A proper amount of low pressure, low-
exchanger that absorbs the heat of the cab temperature liquid refrigerant must be fed to the
compartment air by latent vaporization heat. It is evaporator. If feed rate is too low, the refrigerant
necessary that heat transfer between the air in completes vaporization too soon and gives poor
the cab and the refrigerant take place in the cooling. If the feed rate is too high, unvaporized
evaporator. liquid refrigerant returns to the compressor. This
The evaporator is equipped with fins on the air will give poor cooling and may damage the
side in order to increase the heat transfer area compressor valves.
and perfor m ther mal transfer between the The expansion valve feeds the flowing high
refrigerant and the air. The humidity in the air pressure, high temperature liquid refrigerant to
condenses as the air cools down and adheres to t h e ev a p o r a t o r a s a l o w p r e s s u r e , l o w
the outside of the evaporator. The water droplets temperature liquid refrigerant (damp vapor/low
that for m outside the evaporator must be dryness). The expansion valve controls the rate
discharged in order to keep the cooling effect of the refrigerant.
from deteriorating.
Fig. 10 illustrates the construction of a block type
The amount of refr igerant supplied to the expan sion valve. Te mperature sensin g is
evaporator is controlled by the expansion valve. 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 a saturated state. As the pressure of
t h e d i a p h ra g m c h a n g e s a c c o r d i n g to t h e
temperature detected by the sensor, the force
acting upon the diaphragm will vary accordingly.
The high pressure, high temperature liquid
refrigerant that is fed from the receiver side
reduces the pressure abruptly as it passes
throug h the valve. Par t o f the refr igera nt
evaporates by the very heat of the refrigerant and
is cooled off. This results in a low pressure, low
temperature damp refrigerant vapor to be fed to
the evaporator.

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 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONING SYSTEM

The opening of the valve is determined by the

balance between the pressure (low) of the
evaporator side, the action of the spring, and the
pressing force of the diaphragm (the temperature
of the refrigerant at the outlet of the evaporator).
The feed rate is controlled automatically so that
under pressure in the evaporator, the refrigerant
is properly overheated (3-8°) and leaves the
evaporator. If the refrigerant pressure drops
excessively, it is difficult to control the feed rate or
the over heating of the refrigerant. The pressure
drop rate of the evaporator should be minimal.
The expansion valve senses the pressure and
the temperature at the outlet of the evaporator. It
controls the overheating of the refrigerant and
the refrigerant supply to the evaporator. The air
conditioner utilizes a block type expansion valve.
CH25-12-02 Figure 13
EXPANSION VALVE OUTSIDE VIEW

25-14 Issued 01-2006 Bur 5-1670 NA

 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONING SYSTEM

CH25-13-01 Figure 14 CH25-13-02 Figure 15

25.2.3.2.3 COMPRESSOR 25.2.3.2.4 CONDENSER
In the cooling circuit, the compressor performs the This is a heat exchanger that cools the vaporized
following functions: suction action, pumping action, refrigerant at high temperature and high pressure by
and compressive action. the use of outer air and condenses the refrigerant.
The suction action, as combined with the throttling The direction in which heat moves is from the
action works to decrease the refrigerant pressure in refrigerant to air, the opposite of the evaporator. Fins
the evaporator. This allows the refrigerant to vaporize on the outer air side improve thermal transfer. If the
at low temperatures in order to cool. refrigerant is not cooled well by the condenser, the air
in the cab compartment cannot be cooled sufficiently
The pumping action causes all the refrigerant to by the evaporator. It is necessary to secure proper
circulate in the cooling circuit, providing continuous ventilation for optimum refrigerant cooling.
cooling.
The compressive action combined with the action of
the condenser transforms vaporized refrigerant back
to a liquid state.
The saturation temperature gets higher as the
pressure increases. It becomes possible to cool the
refrigerant by the use of outside air of 35°C (95°F)
and liquefy it. The compressive action of the
compressor works to turn low pressure vaporized
refrigerant to high pressure vapor refrigerant. The
condenser then ser ves to cool the refrigerant.
Compressive action takes place only for a short
period and the refrigerant exchanges heat with outer
a i r. I t t a ke s t h e fo r m o f t h e r m a l l y i n s u l a t e d
compression, so that the refrigerant discharged by
the compressor turns into high temperature, high
pressure vapor and is delivered to the condenser.

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 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONING SYSTEM

25.2.3.2.5 RECEIVER DRYER

Receiver Tank
The revolution of the compressor varies greatly in an
air conditioning system. This causes the flow of
refrigerant in the cooling circuit to vary. The receiver
tank receives these variations. When the cooling
circuit does not need much refrigerant, the receiver
tank stores the extra refrigerant temporarily and then
supplies it as the cooling circuit needs it. The receiver
tank also stores an extra amount of refrigerant to be
used for filling balance and to supplement any small
amounts of leakage of refrigerant.
Dryer
If water is mixed in the cooling circuit, it deteriorates
the compressor valves and oil, corrodes the metallic
parts of the circuit, or it can clog the circuit as the
water freezes in the expansion valve. Water mixed in
the refrigerant should be held below a concentration
of 30 ppm. 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.
Sight Glass
This is a visual window gauge to allow determination
of the refrigerant level and is the only means of
confirming the inside of the circuit visually.
Pressure Switch
The air conditioning system uses high/low pressure
switches. The pressure switch protects the circuit by
cutting off the power supply to the compressor when
high pressure increases abnormally {more than 32
kgf/cm2 (460 psi)}. 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 2 kgf/cm2 (28 psi).

CH25-14-01 Figure 16

25-16 Issued 01-2006 Bur 5-1670 NA

 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONING SYSTEM

25.3 DISASSEMBLY AND ASSEMBLY

NOTE: The following conditions should be observed prior and during air conditioning repair operations:
1. Special refrigerant oil: The air conditioner uses
special refrigerant oil, SP20 designed for use
with the new refrigerant R134a. SP20 tends to
absorb moisture and may corrode paint and resin
and the following points should be noted.
• Keep all pipe connections open on a new
compressor and the component parts of the
installed refrigeration circuit.
• Use care so SP20 does not adhere to painted
surfaces and/or resin parts. If SP20 comes in
contact with these surfaces, wipe it off
immediately.
2. Pipe joints (See Table 2). 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.
3. When tightening screws and bolts refer to Table 3
for tightening torque.
4. For the amount of oil for compressor, see Table
4. The compressor SD7H (HD type) is filled with
135 cc (8 cu. in.) of oil. If the oil volume drops,
seizure at high revolution and/or shortening of
service life may occur. If the oil volume is too
high, cooling ability will deteriorate. Once the air
conditio ner is operated, par t of the oil is
dispersed in the refrigeration circuit. When
replacing the parts in Table 4, adjust the oil level
to that of Table 4.
5. Prior to performing any repairs, stop the engine
and turn off all power supplies related to air
conditioner equipment.
6. Run the air conditioner to confirm all problems or
faults have been repaired.

CH25-15-01 Figure 17

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 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONING SYSTEM

25.3.1 REMOVAL AND INSTALLATION 25.3.1.0.2 REPLACING THE BLOWER MOTOR

25.3.1.0.1 REMOVING THE BLOWER UNIT

CH25-16-01 Figure 18
Remove the connectors fastening the inner/outer air CH25-16-03 Figure 20
select motor actuator, the blower motor and the To replace the blower motor, disconnect the cooling
blower controller. Remove the electrical harness from hose connecting the blower motor and the blower
the blower casing. casing. Remove the 3 Phillips screws N5 X16 (W)
from the bottom of the blower unit casing. Remove
the blower motor.
NOTE: Do not separate the fan from the blower
motor.
Assembly is the reverse order of disassembly.

25.3.1.0.3 REPLACING THE BLOWER

CONTROLLER
Remove the 2 Phillips screw T4X14 (T1) from the
bottom of the blower unit casing and draw out the
blower controller. Install a new blower controller in the
reverse order of removal.
NOTE: Do not disassemble the blower controller
under any circumstances. Replace it as a complete
unit.
CH25-16-021 Figure 19
Remove the inner air filter from the intake casing.
Remove the 4 Phillips screws T5 X 14 (T1) from the
top of the intake casing. Then remove the intake
casing. Remove the 3 screws T5 X14 (T1) fastening
the blower casing to the unit casing. Separate the
blower unit from the air conditioner unit.

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 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONING SYSTEM

25.3.1.0.4 REMOVING THE HEATER CORE 25.3.1.0.5 REMOVING THE UPPER AND LOWER
UNIT CASING

CH25-17-01 Figure 21 CH25-17-02 Figure 22

After discharging the cooling water, disconnect the Remove the connectors from the mode motor
heater hose from the heater core. Remove the actuator and the evaporator sensor. Separate the rod
Phillips screw N5X16 (T2) for the AHC bracket that 120 from the rod holder that is affixed to lever MAL1
fastens the heat core to the unit. Remove the on the mode motor actuator. Remove the 3 Phillips
mounting screw fastening the pipe clamp. Draw the screws N4X22 (T2) fastening the mode motor
heater core straight out from the unit. actuator that holds the bottom of the casing unit to
Assembly is the reverse order of disassembly. the back of the casing unit.

CH25-17-03 Figure 23
Separate the mode motor actuator. Remove the 11
Phillips screws N5X16 (T2) that install the bottom of
the unit casing to the top of the unit casing. Lift the
unit casing up, using care so the evaporator sensor
cord does not catch on the casing.

5-1670 NA Issued 01-2006 Bur 25-19

 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONING SYSTEM

25.3.1.0.6 REPLACING THE EVAPORATOR AND 25.3.1.0.7 REPLACING THE MOTOR ACTUATOR
EXPANSION VALVE

CH25-18-01 Figure 24
Remove the evaporator assembly from the bottom of
CH25-18-03 Figure 26
the casing together with the casing insulator and the
expansion valve. Remove the upper and lower casing Remove the connector fixed to the motor actuator.
insulators, and pull the evaporator sensor and the Remove the Rod 120 linking the motor actuator with
sensor holder out. Remove the 2 socket head cap the mode cam from the rod holder. Remove the 3
screws M5X40 from the evaporator in order to Phillips screws T4X14 (T1) holding the motor
remove the expansion valve from the evaporator. actuator. Separate the motor actuator from the unit
together with the rod holder and the lever MAL1.
Remove the rod holder and the lever MAL1 from the
motor actuator and install to the new motor actuator.
Assembly is the reverse order of disassembly.

CH25-18-02 Figure 25
Attach o-rings (NFO ring 5/8 and 1/2) to a new
evaporator. Be careful to keep o-rings straight and do
not bend. Reinstall expansion valve. Install the
evaporator sensor as per the measurements
illustrated being careful to not catch or damage the
sensor with the casing.

Tightening torque 0.7 kgfm (5.1 lb ft)

25-20 Issued 01-2006 Bur 5-1670 NA

 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONING SYSTEM

25.3.1.0.8 REPLACING THE AIR MIX MOTOR 25.3.1.0.9 REPLACING THE AIR SELECT MOTOR
ACTUATOR ACTUATOR

CH25-19-01 Figure 27
Remove the connector holding the motor actuator. CH25-19-02 Figure 28
Separate the Rod 67 linking the motor actuator with To replace the inner/outer air select motor actuator,
the lever AM from the rod holder. Remove the 3 remove the connector holding the motor actuator.
Phillips screws T4X14 (T1) fastening the motor Separate the motor actuator with lever MAL2 from
actuator. Remove the motor actuator with the rod the unit. Remove the lever MAL2 from the motor
holder and the lever MAL1 from the unit. Remove the actuator and reinstall it to a new motor actuator.
rod holder and the lever MAL1 from the motor Assembly is the reverse order of disassembly.
actuator. Reinstall the rod holder and the lever MAL
to a new motor actuator. Assembly is the reverse
order of disassembly.

5-1670 NA Issued 01-2006 Bur 25-21

 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONING SYSTEM

25.4 CHARGING REFRIGERANT

25.4.1 PRECAUTIONS DURING CHARGING 4. Charging
1. Assign a person to be in charge of handling A. When warming the can in which refrigerant is
refrigerant. Refrigerant is under high pressure. charged, do not fail to open the service can
valve and the low pressure valve of the gauge
manifold. Warm the can in warm water 40°C
WARNING
(104°F) or less. Do not place the can in water
Always wear protective goggles. Refrigerant can temperatures higher than 40°C (104°F), as
damage eye sight and/or cause blindness. this may cause the can to burst.
Refr igerant in its liquid state has a ver y low B. When charging refrigerant while running the
temperature {approximately -26°C (-15°F)} and can engine, do not open the high pressure valve
cause frostbite to exposed skin. (HI) of the gauge manifold.
SAFETY_ID_1C02 C. Reuse of service cans is prohibited by law.
2. Storage and Transportation Do not allow foreign matter to enter the air
A. Store the service can where temperatures conditioner circuit. Air, water, and dust are
are less than 40°C (104°F). R134a is stored detrimental to the refrigeration cycle. Install
in the can under high pressure and extreme t he c o m p o n e n ts o f th e a i r c o n d i t i o n e r
temperatures may cause the can to burst. correctly and pay close attention to avoid the
entry of water and dust.
B. Store in a cool, dark area not exposed to
sunlight.
C. Do not place the can near a heat source (fire,
WARNING
registers, etc.). Radiated heat can cause the Do not overcharge, as refrigerant is under high
can to burst. pressure.
D. Do not store inside machine cab, inside truck Make certain all pipes are tightened to the correct
or car, or trunk. This can cause the can torque.
pressure to rise to a dangerous level. SAFETY_ID_1C02

E. Store cans beyond the reach of children.

3. Cans that have scratches, marks, or dents may
have metal deterioration. Do not drop or strike
t h e c a n . D o n o t d r o p o r t h r ow p a ck a g e s
containing cans.

25-22 Issued 01-2006 Bur 5-1670 NA

 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONING SYSTEM

25.4.2 OPERATING PROCEDURE 2. The gas charging operation consists of filling the
1. Refrigerant charge into the air conditioner circuit with refrigerant. Filling the circuit not only
consists mainly into creating a vacuum and the effects the cooling performances of the air
gas charge operation. conditioner, but also effects the service life of the
component par ts of the circuit. An extreme
The “vacuum making operation” causes the overcharge will make the circuit pressure high
water in the air conditioner circuit to be removed. and cause cooling performance to deteriorate.
If only a small amount of water remains in the Undercharge causes poor circulation of the
circuit, the small holes of the expansion valve lubricating oil of the compressor and causes
can be frozen during operation. This will cause seizure of the moving parts of the compressor.
the system to clog or rust, resulting in any Be certain when filling the circuit to handle the
number of malfunctions. Prior to filling refrigerant high pressure refrigerant carefully and follow all
in the circuit, allow the water in the circuit to boil operational and safety cautions.
and vaporize.

CH25-21-01 Figure 29
5-1670 NA Issued 01-2006 Bur 25-23
 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONING SYSTEM

25.4.3 CHARGING PROCEDURE

25.4.3.0.1 CREATING VACUUM

CH25-22-02 Figure 31

CH25-22-01 Figure 30
Connect the middle valve of the gauge manifold with
the charging hose of the vacuum pump. Some types
To connect the gauge manifold, close the high
of gauge manifolds are not equipped with an open/
pressure valve (HI) and the low pressure valve (LO)
close valve in the center.
of the gauge manifold. Connect the charging hoses
(red and blue) with the ser vice 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.

WARNING
Do not confuse the high pressure side with the low
pressure side.
Connect the “L” like end of the charging hose with
the service valve of the compressor. If the charging
hose is connected the opposite way, the mini core
valve of the compressor will not open.
SAFETY_ID_1C02

CH25-22-03 Figure 32
Open the high pressure valve (HI) and the low
pressure valve (LO) of the gauge manifold. Turn on
the switch of the vacuum pump and allow it to run for
more than 30 minutes. Check the degree of vacuum
(less than 750 mm Hg). Close the high pressure
valve and the low pressure valve of the gauge
manifold. Turn off the vacuum pump.

25-24 Issued 01-2006 Bur 5-1670 NA

 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONING SYSTEM

25.4.4 AIR TIGHTNESS CHECK

Close the high pressure valve and the low pressure
valve of the gauge manifold. Wait for 5 minutes or
more, then recheck to be certain the gauge indication
does not return to “0”.
IMPORTANT: If the gauge indicator swings
towards “0”, there is a leak. Retighten pipe joints
and repeat the vacuum steps.
25.4.4.1 GAS CHARGING OPERATION

CH25-23-02 Figure 34
Open the high pressure valve of the gauge manifold
and charge with refrigerant. Charge in gaseous
refrigerant to a gauge pressure of 1 kgf/cm2 (14 psi).
After charging, close the high pressure valve of the
gauge manifold and the service valve.

WARNING
CH25-23-01 Figure 33 Do not run the compressor. The refrigerant can flow
To charge from the high pressure side, create in a reverse direction and cause the service can and
vacuum, then change the charging hose (yellow) of the hoses to rupture causing personal injury or
the gauge manifold from the vacuum pump to the damage to the machine.
service can. Be certain to purge air. Close the high SAFETY_ID_1C02
and low pressure valves of the gauge manifold. Open
the service can valve. Push the mini core valve of the
Check for Gas leakage using an electric gas leak
side service port on the low pressure side of the
detector. Retighten and correct any leaking points.
gauge manifold, using a screwdriver in order to purge
Always use R134a for the leak test.
the air in the charging hose. A hissing sound will be
heard.

5-1670 NA Issued 01-2006 Bur 25-25

 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONING SYSTEM

CH25-24-02 Figure 36
CH25-24-01 Figure 35
Open the low pressure valve of the gauge manifold
To charge from the low pressure side, make sure that
and the service can valve. Fill with refrigerant until no
the high pressure and low pressure valves of the
air bubbles can be seen in the sight glass. The total
gauge manifold and the service can valve are closed.
amount of gas to be charged should be 800 g (1.8
Start the engine and run to approximately 1500 rpm.
lbs).
Open the cab door and windows fully. Turn on the air
conditioner switch, set the fan switch to maximum When the charge is complete, close the low pressure
and the temperature control switch to maximum valve of the gauge manifold and the service can
cooling. valve.

NOTE: When charging gas, set the discharge

pressure of the compressor to 14-16 kgf/cm2 WARNING
(200-230 psi).
Do not open the high pressure valve of the gauge
manifold under any circumstance.
Do not place the service can upside down, as the
compressor valve may be scored if the refrigerant
enters in a liquid state.
SAFETY_ID_1C02

25-26 Issued 01-2006 Bur 5-1670 NA

 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONING SYSTEM

25.4.5 CHECKING AMOUNT OF REFRIGERANT 25.4.6 DETACHING THE GAUGE MANIFOLD

CH25-25-01 Figure 37
Proper charge level
After the air conditioning unit is turned on, a few
small bubbles will be present, thereafter a milky white
tone will be seen in the sight gauge.

CH25-22-01 Figure 40

CH25-25-02 Figure 38
After the refrigerant level has been checked and is
determined to be correct, disconnect the charging
Overcharge
hoses from the compressor. Press the “L” shaped
After air conditioning unit is turned on, no air bubbles metal fitting of the charging hose (blue) on the low
are visible in the sight gauge. pressure side against the ser vice valve of the
compressor so the refrigerant does not leak out.
Loosen the nut and remove it. Disconnect the
charging hose from the service valve. Leave the high
pressure side as is until the high pressure gauge
reading falls below 10 kg/cm2 (140 psi). Disconnect
the charge hose (red) on the high pressure side in
the same manner as the low pressure side.
CH25-25-02 Figure 39
Undercharge
After air conditioning unit is turned on, continuous air
bubbles are visible in the sight gauge.
IMPORTANT: Always maintain a proper level of
refrigerant charge. If the air conditioner operates
in an under charged condition, the compressor
may be damaged.
If the system is over charged, the cooling
performance will be poor and the circuit pressure
will be abnormally high.

5-1670 NA Issued 01-2006 Bur 25-27

 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONING SYSTEM

25.4.7 ELECTRICAL CIRCUIT

25-28 Issued 01-2006 Bur 5-1670 NA

 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONING SYSTEM

25.4.8 FUNCTIONAL PARTS INSPECTION 25.4.8.0.3 BLOWER CONTROLLER

25.4.8.0.1 RELAY

CH25-29-03 Figure 44

CH25-29-01 Figure 41
The blower controller changes the output voltages for
the motor according to signals emitted by the
When inspecting relay, the coil resistance should be
controller.
320 ohms (across 1 and 2)
• Operating voltage: DC20-30V 25.4.8.0.4 MOTOR ACTUATOR

• Relay coil has polarity

• Turn the power to blower motor on and off. Check
continuity across 3 and 4 for the following
• Apply 20-30 volts across terminals 1 and 2: Shows
continuity
• No voltage applied across terminals 1 and 2:
Shows no continuity
Figure 42
25.4.8.0.2 INNER AIR SENSOR

CH25-29-04 Figure 45
The motor actuator should have an operating voltage
of: DC20-30V. The operating temperature range is
-30°C (-22°F) to +75°C (167°F). The motor is
controlled by signal (pulses) generated by the
controller.

CH25-29-02 Figure 43
Over charge
When inspecting inner air sensor, the resistance
across terminals should be:
• At 0°C (32°F): 7.2K ohms
• At 25°C (77°F): 2.2K ohms
The inner air sensor is installed to the sensor bracket
under the operator seat. The temperature in the cab
is sens ed by the th er mistor. Changes in the
resistance according to temperature variations are
transmitted to the controller.
5-1670 NA Issued 01-2006 Bur 25-29
 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONING SYSTEM

25.4.8.0.5 PRESSURE SWITCH 25.4.8.0.6 THERMISTOR

CH25-30-01 Figure 46 CH25-30-01 Figure 47

The pressure switch is attached to the receiver dryer. When inspecting thermistor the resistance across the
• Low pressure side OFF pressure: terminals is:

2.0 ±0.2 kgf/cm2 (28 ±3 psi) • at 0°C (32°F): 7.2k ohms

• Low pressure side return pressure: • at 25°C (77°F): 2.2k ohms

OFF pressure +0.3 kgf/cm2 (4.3 psi) or below 2.0 ±0.2 kgf/cm2 (28 ±3 psi)

• High pressure side OFF pressure: In order to prevent freezing of the evaporator, the
blowoff air temperature of the evaporator is controlled
32.0 ±0.2 kgf/cm2 (455 ±28 psi) by turning the compressor clutch ON and Off. The
• High pressure side return pressure: thermistor operators as the sensor of the control.
OFF pressure -6 ±2 kgf/cm2 (-85 ± 28 psi)

CH25-30-02 Figure 48
Low Pressure side: To prevent actuation of the
compressor clutch when refrigerant is low.
High Pressure Side: To prevent actuation of the
compressor clutch when pressure rises too high
because of refrigeration circuit clogging, etc.

25-30 Issued 01-2006 Bur 5-1670 NA

 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONING SYSTEM

25.5 TROUBLESHOOTING

CH25-31-01ID Figure 49

5-1670 NA Issued 01-2006 Bur 25-31

 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONING SYSTEM

CH25-32-01ID Figure 50

25-32 Issued 01-2006 Bur 5-1670 NA

 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONING SYSTEM

CH25-33-01ID Figure 51

5-1670 NA Issued 01-2006 Bur 25-33

 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONING SYSTEM

CH25-34-01ID Figure 52

25-34 Issued 01-2006 Bur 5-1670 NA

 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONING SYSTEM

CH25-35-01ID Figure 53

5-1670 NA Issued 01-2006 Bur 25-35

 SECTION 2 - HYDRAULIC, ELECTRICAL, AND COMPONENT SYSTEMS
CHAPTER 25 - AIR CONDITIONING SYSTEM

CH25-36-01 Figure 54

25-36 Issued 01-2006 Bur 5-1670 NA

SHOP MANUAL - SECTION 3

E215
CRAWLER EXCAVATORS

GENERAL DISASSEMBLY AND

ASSEMBLY

Issued January 2006

Book/Form Number 5-1680 NA
Copyright © 2006. CNH America, LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. S5PJ0010E01-KO22
 SECTION 3 - GENERAL DISASSEMBLY AND ASSEMBLY

CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Remarks
First Edition 01-2006 E215 5-1680 NA
 SECTION 3 - GENERAL DISASSEMBLY AND ASSEMBLY

SECTION 3
GENERAL DISASSEMBLY AND ASSEMBLY
TABLE OF CONTENTS
CHAPTER 31
GENERAL DISASSEMBLY AND ASSEMBLY
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-1
CHAPTER 32
ATTACHMENTS
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-1
CHAPTER 33
UPPER SLEWING STRUCTURE
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-1
CHAPTER 34
TRAVEL SYSTEM
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-1

5-1680 NA Issued 01-2006 Bur 0-I

NOTES
 SECTION 3 - DISASSEMBLY AND ASSEMBLY

CHAPTER 31

E215
CRAWLER EXCAVATORS

GENERAL DISASSEMBLY AND

ASSEMBLY

Issued January 2006

Book/Form Number 5-1690 NA
Copyright © 2006. CNH America, LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. S5PJ0010E01-KO31
 SECTION 3 - DISASSEMBLY AND ASSEMBLY
CHAPTER 31 - GENERAL DISASSEMBLY AND ASSEMBLY

CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Remarks
First Edition 01-2006 E215 5-1690 NA

31-II Issued 01-2006 Bur 5-1690 NA

 SECTION 3 - DISASSEMBLY AND ASSEMBLY

CHAPTER 31
GENERAL DISASSEMBLY AND ASSEMBLY
TABLE OF CONTENTS

1. DISASSEMBLY AND ASSEMBLY

31.1 Contents of General Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

5-1690 NA Issued 01-2006 Bur 31-1

 SECTION 3 - DISASSEMBLY AND ASSEMBLY
CHAPTER 31 - GENERAL DISASSEMBLY AND ASSEMBLY

NOTES

31-2 Issued 01-2006 Bur 5-1690 NA

ASSEMBLY AND DISASSEMBLY INFORMATION

See the following chapters for the assembly and disassembly information.
SEE CHAPTER 11, TOOLS, FOR TORQUE SPECIFICATIONS AND HARDWARE INFORMATION.
Some of the items in this Chapter are: Torque Specifications, Special Tools, and Jigs.
See the Table of Contents for a complete listing.
SEE CHAPTER 32, ATTACHMENTS, FOR ASSEMBLY AND DISASSEMBLY INFORMATION.
Some of the items in this Chapter are: Arm, Boom, and Cylinders.
See the Table of Contents for a complete listing.
SEE CHAPTER 33, UPPER STRUCTURE, FOR ASSEMBLY AND DISASSEMBLY INFORMATION.
Some of the items in this Chapter are: Cab, Battery, Fuel Tank, Hydraulic Tank, and Pumps.
See the Table of Contents for a complete listing.
SEE CHAPTER 34, TRAVEL SYSTEM, FOR ASSEMBLY AND DISASSEMBLY INFORMATION.
Some of the items in this Chapter are: Crawler, Upper Roller, Lower Roller, Idler, Sprocket, and Swing
Bearing.
See the Table of Contents for a complete listing.

1
NOTES

2
 SECTION 3 - DISASSEMBLY AND ASSEMBLY

CHAPTER 32

E215
CRAWLER EXCAVATORS

ATTACHMENTS

Issued January 2006

Book/Form Number 5-1700NA
Copyright © 2006. CNH America, LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. S5PJ0010E01-KO32
 SECTION 3 - DISASSEMBLY AND ASSEMBLY
CHAPTER 32 - ATTACHMENTS

CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Remarks
First Edition 01-2006 E215 5-1700 NA

32-2 Issued 01-2006 Bur 5-1700 NA

 SECTION 3 - DISASSEMBLY AND ASSEMBLY

CHAPTER 32
ATTACHMENTS
TABLE OF CONTENTS

1. REMOVING AND INSTALLING

1.1 Attachment Assembly and Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2.1 Removal of Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2.2 Installation of Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
32.1.2.3 Adjusting Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.3 Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
3.1 Removal of Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
3.2 Attaching Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.4 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
4.1 Preparation for Removal of Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
4.2 Removing Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
4.3 Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
2. DISASSEMBLY AND ASSEMBLY
2.1 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-1
2.1.1 Disassembly Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-1
2.1.2 Cylinder Construction (Boom Cylinder). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-3
2.1.3 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-4
2.1.4 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-9
2.1.5 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-9
2.1.6 Inspection after Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-14
2.1.7 Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-15
2.1.8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-17
2.1.9 Tool Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-18

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NOTES

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32.1 REMOVING AND INSTALLING

32.1.1 ATTACHMENT ASSEMBLY AND NAME

CH32-03-01-215N Figure 1
FIG. 32-1 ATTACHMENT NAME AND POSITION

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CHAPTER 32 - ATTACHMENTS

32.1.2 BUCKET
32.1.2.1 REMOVAL OF BUCKET
32.1.2.2 INSTALLATION OF BUCKET
Installation is performed in the reverse order of
removal.

CAUTION: When aligning the pin position,

do not put your finger in the pin holes in any
circumstances. Align them visually.

CH32-03-02N Figure 2

CH32-04-03 Figure 4
1. Clean the welded part of the structures, and
check that there are no cracks or other damage
to the parts.
2. Check that the dust seal is not damaged, replace
as needed.
CH32-03-03N Figure 3
3. Inspect pins and bushings according to the
1. Expand slit of ring (1) with driver and remove. Section “ATTACHMENT DIMENSIONS” and
Push pin out with driver. “SPECIFICATIONS”.
2. Lift the bucket up, adjust so the attaching pin is 4. When inserting the pin, coat the shaft with
not loaded, adjust bucket pin, adjust bucket link, grease.
and pull out bucket attaching pin. Put bucket on
the ground, position so drive pin is not loaded, NOTE: The bucket can be mounted easily if the
adjust bucket link, and drive or pull out pin. bucket link is installed first.
Remove bucket assembly.

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32.1.2.3 ADJUSTING CLEARANCE 32.1.3 ARM

32.1.3.1 REMOVAL OF ARM

CH32-06-01

1. Retract the bucket and arm cylinders, lower the

boom to the ground.
2. Shut off the engine and operate the control
CH32-05-01 Figure 5
levers several times to release the pressure in
circuits.
1. Shift O-ring (3) toward the bucket boss, using a
putty knife or flat blade scraper (a-b). Be careful 3. Put the safety lock lever in the “Locked” position,
not to score O-ring. depress the air breather on the hydraulic oil tank
to release the pressure in the tank.
2. When adjusting clearance (B), bring the non-
adjusting side of the bucket in contact with the
arm.
3. Measure clearance (B) to be certain it is within
1.2 mm (0.05 inch). Adjust where necessary.
4. An average of 10 shims (12) of 1 mm (0.04 inch)
thickness are used with the plate (6) attached by
3 cap screws M16X50 (10). Clearance can be
de creased by 1 mm (0.0 4) if one shim is
removed.
5. After adjustment, tighten socket bolts evenly.
Operate th e bucket an d confir m the total
clearance is within 1.2 mm (0.05 inch). CH32-06-02 Figure 6
4. Disconnect the hoses connected to the bucket
6. Replace O-ring (3) to its original position.
cylinder. Plug the openings.
7. Install pin (13) until the top of pin is even with
5. Lift up the arm cylinder with an appropriate lifting
surface of bushing.
device in order to release any load to the pin.
NOTE: Any gap exceeding the specified
dimension may cause excessive or rapid wear.
Recheck clearance at approximately 120 hour
intervals under normal operating conditions.
Shorten these intervals for heavy operation.

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CH32-07-01 Figure 10
CH32-04020N Figure 7
6. To remove the bucket cylinder rod pin (H), loosen 8. To remove bucket cylinder, sling tube of bucket
nut (9), remove cap screw M16X140 (8) and cylinder with appropriate lifting device and
push out pin (H). remove it.
Bucket cylinder weight: 135 kg (298 pounds)
Nibbler - HD weight: 144 kg (317 pounds)

CH32-06-03 Figure 8 CH32-05-01NA Figure 11

9. To remove arm cylinder rod pin (E), loosen nut
(6), remove capscew M16 X 150 (4), and push
out arm cylinder rod pin (E). Retract the arm
cylinder rod and return the pin (E) to its original
position in the hole. To remove the top boom pin
(F), loosen and remove capscews (3) and pull
out pin. Place a block between the arm cylinder
and boom. Insert pin (F) into its original hole.

CH32-06-03 Figure 9
7. After adjustment of shim, the total gap should be
within 0.6-2.0 mm (0.02-0.08 inches)

CH32-05-03NA Figure 12

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CH32-006-01N Figure 14
CH32-08-01 Figure 13
6. When installing the arm and cylinder, inspect the
10. Sling the arm and remove it. clearance in the thrust direction of the mounts to
Arm weight 600 kg (1320 pounds) determine thickness of shims.
Nibbler - HD weight 650 kg (1430 pounds) 7. For clearance adjustment, insert plastic shims
first, then adjust clearance with metal shims.
32.1.3.2 ATTACHING ARM
8. Tighten to torque indicated by table.
Installation is performed in the reverse order of
removal, including the following.

CAUTION: When aligning the pin position,

do not put your finger in the pin holes in any
circumstances, align them visually.

1. Clean the welded part of the structures, and

check that there are no cracks or damage to the
CH32-06-02N Figure 15
parts.
2. Check the dust seal for damage, replace as
needed.
3. Inspect pins and bushings according to the
Section “ATTACHMENT DIMENSIONS” and
“SPECIFICATIONS”.
4. Before installing the pin, apply grease to the
shaft area.
5. Apply Loctite #242 to pin securing cap screws
and nuts and install them.

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32.1.4 BOOM
32.1.4.1 REMOVAL OF BOOM

CH32-07-02N3 Figure 18
CH32-07-01N Figure 16
5. After adjustment of shim, the total gap should be
1. Lower the boom and support the boom end with within 0.6-2 mm (0.02-0.08 inches).
a suitable stand.
CH32-10-01 Figure 19
2. Disconnect all hoses from the bucket cylinder, 6. To disconnect cylinder pipes, retract boom
arm cylinder and boom cylinder, install plugs in cylinder rod and place one side of cylinder on
all the openings. block.
3. Disconnect the wiring for working light at the
connector.

CH32-09-02 Figure 17
4. To remove boom cylinder, lift up boom with an
appropriate lifting device to prevent the boom
cylinder from falling. Remove the cap screw and
nuts that secure pin (C), then remove pin (C).

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7. To disconnect arm cylinder piping, release the

pressure in the hydraulic tank and disconnect
pipe at section (A1). (A2), (a3), AND (A4). After
disconnection, plug pipes to prevent dust, debris
contamination.

CH32-08-01N Figure 20

CH32-10-03 Figure 21
8. Lift boom cylinder with appropriate lifting device
so weight is removed from boom foot pin (A).

Weight of single boom:

STD:1240 kg (2730 pounds)
Nibbler - HD: 1380 kg (3040 pounds)
9. To remove boom foot pin (A), remove capscrews
M14 (30) (3). Remove pin (3) and plate (4).
10. Remove pin with slide hammer. Force slide
hammer in until pin is pushed out. Thread
M24X35 (screw thread length) for pin 1.

CH32-10-04 Figure 22

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32.1.4.2 SLINGING BOOM ASSEMBLY

CH32-11-01 Figure 23
1. Sling and remove boom assembly Weight of single boom
Weight of single boom: 720 kg (1600 pounds) STD: 1240 kg (2730 pounds)
2. Lift the boom assembly in order to relieve any Nibbler- HD: 1380 kg (3040 pounds)
load on the boom foot pin (A).

32.1.4.3 FRONT ATTACHMENT REMOVAL

32.1.4.3.1 REMOVING ARM CYLINDER
32.1.4.3.2 REMOVING BOOM CYLINDER

CH32-09-01N Figure 24
1. Disconnect hose at A section and plug both ends
to prevent contamination.
2. Remove arm cylinder head pin (D). Loosen nut
(3) remove cap screw M16 X 50 (2) and pull out
pin D.
CH32-11-03 Figure 26
1. Disconnect hose at B section. Plug both ends to
prevent contamination.
2. Remove boom cylinder foot pin (B) section. then
loosen cap screw M16 X 150 and pull out pin (B).
3. Remove boom cylinder.

CH32-09-01N Figure 25

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32.1.4.3.3 ATTACHING BOOM

CH32-12-02 Figure 29
5. For the adjustment of clearance, insert plastic
CH32-12-01 Figure 27 shim first, then adjust the clearance with steel
Installation is performed in the reverse order of shims.
removal, including the following.

CAUTION: When aligning the pin position,

do not put your finger in the pin holes in any
circumstances, align them visually.

1. Clean the welded part of the structures, and

check that there are no cracks on the parts.
2. Check the dust seals for damage, replace as
needed.
3. Inspect pins and bushings according to the
Section “ATTACHMENT DIMENSIONS” and
“SPECIFICATIONS”.
4. Before inserting the pin, apply grease to the
shaft.
M16 Tightening torque:
28.5 kgf m (210 pound-foot)

CH32-12-03 Figure 28
PIN LOCK:

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32.1.5 CYLINDER NECESSARY TOOLS

32.1.5.1 GENERAL PRECAUTIONS Though the required tools and jigs differ for different
• During disassembly and assembly keep work types of cylinders, as a guideline, tools and jigs to be
area clean, and always keep disassembled prepared are shown in Table 32-1.
parts clean. Table 32-1 List of Tools and Jigs
• Prior to disassembly, thoroughly clean the
cylinder externally. Tool/Jig Remarks
• Use caution to prevent damage to parts during 1.Steel hammer
Hammer
disassembly/assembly. 2.Wooden or plastic hammer
• Apply a thin layer of grease or hydraulic oil to Screwdriver Several kinds of small and large sizes
seals prior to installation. Chisel Flat chisel
• After the installation of o-rings, make sure they
Capable to hold outer dia. of cylinder
are not twisted. Vise
head and tube installing pin portion.
• Apply clean hydraulic oil to each sliding portion
of the cylinder before installation. 1.Special wrench
Wrench
• Make sure each sliding part is free of burrs and 2.Extension pipe for wrench
defects and operates smoothly. A sharp-point tool may be used in place of
Gimlet
gimlet
This manual describes the boom cylinder as a typical 1.For installing seal ring
example. Before assembly, secure a dust free work 2.For pushing seal ring into groove
area, necessary equipment, and facilities. Jig
3.For reforming seal ring
4.For pressing bushing
WORK AREA
1.Slide calipers
The work area should have ample space for the 2.Micrometer
Measuring
disassembly of the hydraulic cylinder, as the cylinder
Device 3.Cylinder gauge
tube and piston rod must be drawn out.
4.V-block
APPARATUS/EQUIPMENT
The following equipment is required for disassembly: 32.1.5.2 EXTERNAL CLEANING
1. A hoist or crane capable of lifting the cylinder Usually when a cylinder is removed from the
in an assembled condition. It should also be machine, it will have dust, grease, and other foreign
capable of marking level and linear. matter adhered to the clevis. Remove the external
2. A suitable working environment should be soil and contamination prior to bringing it into the
available, as the hydraulic cylinder is a workshop.
precision machined product that uses seals
and packing. Care should be taken to keep
the area free from dust, dir t, and hard
particles such as sand, metal chips, weld
slag. If the hydraulic cylinder is assembled
with any hard par ticles adhering to the
components such as the tube or piston rod,
the tube inner surface and rod surface can be
scratched or etched, possibly disabling the
machine during operation. Damage to the
piston seals can also occur.
3. The work bench or stand must have strength
and length to accommodate the total length of CH32-16-03 Figure 30
the cylinder in its retracted position. A support Place a wooden block on the work bench and mount
stand should be available if the clevis of the the cylinder on it to prevent it from rolling. Charge air
piston rod is fully extended so as not to into ports A and B alternately to actuate the piston
damage the bushing and seals. Use a stand rod and drain the hydraulic oil.
to support the rod.

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CH32-12-01N Figure 31
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32.1.6 CYLINDER DISASSEMBLY

32.1.6.1 ROD COVER AND PISTON ROD
DISASSEMBLY OF CYLINDER

SPW32000026J01 Figure 34

5. Pull the piston rod assembly from the tube.

• Pull the piston rod straight out to prevent
damage to the sliding surface.
SPW32000024J01 Figure 32 6. Disassembly of piston rod assembly
1. Secure the clevis portion of tube in a vice, • Clamp the piston rod end in a vise. Support
support the other end with a wooden stand to the piston end with a wooden block to hold
hold the cylinder level. the rod level.
2. Drain the hydraulic oil from the cylinder.
• Slowly move the piston rod in and out.
3. Straighten the locking fin for the cylinder head.
• Use caution bending or straightening the
locking fin, the locking fin and cylinder tube
are one piece.

CH32-19-02 Figure 35
7. Do not use wire to hold the center of the piston
rod, as it may score the surface.

SPW32000025J01 Figure 33
4. Loosen the cylinder head.
• Prior to loosening the cylinder head, pull out
the piston rod by 100 to 200 mm (4 to 8
inches).

CH32-19-041 Figure 36
8. Remove wear ring (11) and dust ring (12) from
piston.

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SPW32000027J01 Figure 37
1. Secure clevis section in a vice, as the piston nut CH32-20-04 Figure 40
is tightened to a high torque. Protect the rod from 4. Loosen piston, utilizing the two holes in the side
scoring by wrapping or covering it with a cloth. of the piston. If the O-ring comes off, the piston
may be easily turned by hand. Be careful not to
drop the piston, as it may damage the threads.

CH32-20-02 Figure 38 CH32-21-01 Figure 41

2. Scrape off any caulking on set screw (14) of 5. Remove the rod cover (16) from the piston rod
piston nut (13) using a a hand drill, if necessary. (4). If it is to heavy to move, strike the flange on
Loosen and remove set screw. the rod cover (16) with a plastic or soft mallet.
Pull it straight out so it may be lifted with a crane
or other lifting device. Use care not to damage
the rod bushing (17) and the lip of the piston (22),
(23) and (24).

CH32-20-03 Figure 39
3. The piston nut (13) is tightened to a high torque.
Use a spanner wrench on the outside diameter
of the piston nut.
CH32-21-02 Figure 42
6. Separate O-ring (8) and backup ring (9) from
piston. After removing the two backup rings (9),
remove the O-ring (8). The backup ring can be
extended using a flat blade knife for easier
removal.

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32.1.6.2 DISASSEMBLING PISTON ASSEMBLY

CH32-22-03 Figure 46
3. Place rod cover (16) in a vise, and remove the
dust seal (24).
CH32-21-03 Figure 43
1. To remove the piston seal (10), cut the seal by
tapping it with a screwdriver or chisel. Do not
strike too hard in order not to damage the
groove.
32.1.6.3 DISASSEMBLING ROD COVER
ASSEMBLY

CH32-22-04 Figure 47
4. Remove snap ring (18) and rod bushing (17).
The rod bushing (17) has been pressed on to the
rod cover, and it is necessary to machine the
bushing on a lathe in order to remove it. Once it
has been machined thin, insert a flat blade knife
into the gap at the chamfered edge and pry up.

CH32-22-01 Figure 44
1. Remove the back-up ring (20) and then the O-
ring (21). The back up ring may be widened for
easier removal.

CH32-22-02 Figure 45
2. Remove buffer seal (22) and rod packing (23).
Seals are fixed in the groove on the bore and will
usually be damaged on removal.

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32.1.6.4 REMOVING PIN BUSHINGS 32.1.6.4.2 ASSEMBLING PISTON ASSEMBLY

CH32-23-01 Figure 48
1. The cylinder tube is pressed into the pin bushing
(2) of the piston rod. When disassembling, use a
jig (A) and push the rod out.
CH32-24-01 Figure 50
2. When all cylinder parts have been disassembled, 2. Coat O-ring (8) with hydraulic oil and set in place
wash all parts with a suitable solution. Do not use using inserting jig. Push slipper seal (10-1) in
volatile agents such as gasoline or thinner, as place. Slipper seal will soften if heated, but do
they deteriorate rubber. Do not reuse the oil not heat the seal above 100° C (212° F).
seals, o-rings, or back-up rings. Dry all parts with
jet air and protect them from damage.

32.1.6.4.1 CYLINDER TUBE AND

PISTON ROD ASSEMBLY

CH32-24-02 Figure 51

3. Hold the heated seal in place, using a holding jig

(G). Wind vinyl tape around seal and leave in
place before piston (7) is set into cylinder tube.
Attach wear ring and dust ring when inserting
CH32-23-02 Figure 49 piston (7) into cylinder tube.
1. Press fit pin bushing (2) into cylinder tube (12)
and piston rod (4).

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32.1.6.4.3 ASSEMBLING CYLINDER HEAD 32.1.6.4.4 INSERTING ROD COVER ASSY TO

PISTON ROD

CH32-24-03 Figure 52
1. Press rod bushing (17) into rod cover (16) using
a metal ring. Fit circlip (18) into groove. Prior to
pressing in, coat the inner face of rod cover (16)
with hydraulic oil. The circlip can be pushed in by
hand, but cannot be set in place unless rod CH32-25-02 Figure 55
bushing (17) is press fit full into stop surface.
1. Rod packing (23) is difficult to form. Put rod
packing in the groove by hand as deep as
possible, and use a push bar until it goes in place
with a click. Be sure to check that rod packing
and buffer seal (22) are in their correct positions.
Attach back up ring (20) on the open air side of
the O-ring.
2. Place the piston rod assembly into the rod cover
(16). Hold the rod assembly with a vise, if
necessary.

CH32-24-04 Figure 53
2. Apply grease to dust seal (24) or the hole of rod
cover (16) and fit the dust seal (24) to the bottom
of hole. Press the metal ring of dust seal (24) in
with jig E.

CH32-26-01 Figure 56
3. Apply hydraulic oil or grease to the outside
diameter of the piston rod (4), the bore of
packings (22,23,24) and the rod bushing (17).
CH32-25-01 Figure 54
Hold the rod cover assembly carefully and slide it
over the piston rod (4) being careful not to
3. Coat buffer seal and rod packing with hydraulic
damage the lip of the dust seal (24). It may be
oil and fit into their grooves. When attaching
difficult to slide the rod cover assembly over the
seals, pinch into shape as illustrated.
piston rod because of the resistance of the rod
packing and buffer seal. It can be forced in by
using a suitable plate and piston nut (13).
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4. After lifting the rod cover (16) to the level where it

is pressed by piston nut (13), remove the piston
nut and plate. Press the rod cover in
approximately 300 mm (12 inches) further. Do
not allow the rod cover assembly to turn.
32.1.6.4.5 INSERTING ROD COVER ASSY TO
PISTON ROD

CH32-27-02 Figure 59
3. Insert the set screw (14) and tighten. Caulk the
set screw threads.
Tightening torque 1.5 kgf m (11 pound-foot)

CH32-26-02 Figure 57
1. To install the piston assembly to the piston rod
(4), apply hydraulic oil or grease to the inside of
the piston assembly and to the piston mounting.
Install the piston assembly, be careful not to
damage the O-r ing (8) and the seal. Tur n
clockwise and tighten the piston to specified
torque.

CH32-27-03 Figure 60
4. Attach the two wear rings (11) and dust rings
(12). Remove vinyl tape previously wound
around perimeter of piston (7). Apply high quality
grease to wear ring (11) and dust ring (12).
Attach wear rings at about 90 degrees apart from
one another so that the 45 degree slits do not
point the same direction.

CH32-27-01 Figure 58
2. Turn the piston nut (13) until it gets tight. Tighten
the piston nut (13) to the specified torque.
Correct the threads of the tapped hole in the
piston nut before tightening the piston nut. Use a
tap if necessary.

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32.1.6.4.6 OVERALL ASSEMBLY 32.1.6.4.7 INSPECTION AFTER ASSEMBLY

CH32-27-04 Figure 61
1. Place a v-block on a sturdy work bench (a
wooden v-block is preferable). Place the cylinder
tube assembly on the block and fasten the CH32-28-02 Figure 63
assembly to the v-block by passing a bar through
the clevis pin hole to hold the assembly in place.
1. Perform a no-load function test by placing the
2. Insert the piston rod assembly into the cylinder cylinder level at no load and operate the piston
tube assembly while lifting and moving the piston rod 5 to 6 strokes by the directional valve to
assembly with a crane. Apply hydraulic oil to the make certain it operates correctly.
i n n e r s u r fa c e o f t h e t u b e m o u t h a n d t h e
circumference of the piston. Align the center of NOTE: Do not raise the hydraulic pressure above
the piston rod assembly with the center of the the maximum pressure of 380 kg/cm2 (5400 psi)
cylinder tube assembly and inser t it. Make for the cylinder of the machines. If the grease
certain the wear ring (11) and the dust ring (12) from the o-rings and seals of the cylinder head
on the perimeter of the piston are in place and in oozes out, wipe it off and retest the cylinder.
the groove. 32.1.6.4.8 INSERTING ROD COVER ASSY TO
PISTON ROD

CH32-28-01 Figure 62
3. Turn socket bolt (25) up. Match the bolt holes of
the rod cover flange to the tapped holes in the CH32-20-01N Figure 64
cylinder assembly and screw in socket bolts (25). 1. To perform a leak test apply a test pressure to
Tighten the bolts to the specified torque, the retracting and extending sides of the cylinder
tightening them evenly. Protect the rod surface for three minutes. Check the rod section and the
from damage by covering it so it is not damaged welds for external leaks and/or per manent
by the wrench slipping. damage. For an inter nal test, connect the
Tightening torque: cylinder with a test unit.

35-37 kgf m (250-270 pound-foot)

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32.1.7 MAINTENANCE STANDARDS

32.1.7.1 INSPECTION AFTER DISASSEMBLY
Visually inspect all parts after cleaning to check for
excessive wear, cracks, or other faults.
32.1.7.1.1 REPAIR METHOD
1. Check all seals and parts to make sure they
do not have excessive damage or wear.
2. Correct fine scratches with an oilstone.
Replace the piston rod if the scratch is deep.
3. In case of a smooth indentation of the piston
CH32-28-04 Figure 65
rod, remove the shar p area around the
2. After completing the test, apply a plug to each indenta tion. If th e flaw or indention is
port. For storage, place the cylinder on wooden excessive, replace or replate the part.
v-blocks and bring the cylinder to the most
retracted condition. 4. Always regrind after replating. The thickness
of the plating should be a maximum of 0.2
mm (0.004 inch)
5. If plating is removed to the base metal during
any reconditioning with an oilstone, replate
the surface.

CH32-29-01 Figure 66
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32.1.7.2 LIMIT OF SERVICEABILITY

Serviceability limits represent the limits of wear on
the sliding surfaces of the cylinder tube and rod that
have no damage that may effect sealing.
1. Clearance between the piston rod and the rod
bushing should not exceed 0.25 mm (0.000984
inch), if so replace the bushing.

CH32-30-02 Figure 67
2. Bend of piston rod: the allowable bend of the
piston rod is 1 m m/ 1m (0.04:/3’ 3"0). To
measure, suppor t both ends of the parallel
section of the piston rod with v-blocks, set a dial
indicator in the center of the piston rod and read
the difference between the maximum and
minimum oscillations on the dial indicator.
NOTE: Even if the bend is within the above limit, the
cylinder may not operate smoothly because of the
localized bend. Replace the rod if the cylinder makes
a squeaking noise or does not operate smoothly.

CH32-22-01N Figure 68

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32.1.8 TROUBLESHOOTING

CH32-31-01 Figure 69

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 SECTION 3 - DISASSEMBLY AND ASSEMBLY
CHAPTER 32 - ATTACHMENTS

32.1.8.1 TOOL REQUIREMENTS 2. The pin section of pin wrenches (symbol “PS”)
The tools and jig list provides dimensions and and pin hook wrenches (symbol “PF”) must have
necessary materials to build required specialty tools. a large shear ing force. A used drill shank
provides ideal material.
1. For the rod cover, piston nut, etc. that require a
high tightening torque, use eye wrenches
(symbol “FS”) if possible. Tools and jigs are
designed to withstand maximum tightening
torque even if SS400 (JIS) material is used.
However, the hook of the tool (symbol “PS”) may
be distorted if struck with a hammer. If distortion
occurs, apply a reinforcement weld and finish by
grinding.

CH32-32-01 Figure 70
32.1.8.1.1 ALLEN WRENCH (AW)
(FOR CYLINDER HEAD SOCKET BOLT)

CH32-32-02 Figure 71

32-24 Issued 01-2006 Bur 5-1700 NA

 SECTION 3 - DISASSEMBLY AND ASSEMBLY
CHAPTER 32 - ATTACHMENTS

32.1.8.1.2 EYE WRENCH (SYMBOL FS)

CH32-33-01 Figure 72

5-1700 NA Issued 01-2006 Bur 32-25

 SECTION 3 - DISASSEMBLY AND ASSEMBLY
CHAPTER 32 - ATTACHMENTS

32.1.8.2 BUSHING EXTRACTION JIG (SYMBOL A)

CH32-34-01 Figure 73

32-26 Issued 01-2006 Bur 5-1700 NA

 SECTION 3 - DISASSEMBLY AND ASSEMBLY
CHAPTER 32 - ATTACHMENTS

32.1.8.3 SLIPPER SEAL - HOLD DOWN JIG

CH32-35-01 Figure 74
5-1700 NA Issued 01-2006 Bur 32-27
 SECTION 3 - DISASSEMBLY AND ASSEMBLY
CHAPTER 32 - ATTACHMENTS

32-28 Issued 01-2006 Bur 5-1700 NA

 SECTION 3 - DISASSEMBLY AND ASSEMBLY

CHAPTER 33

E215
CRAWLER EXCAVATOR

UPPER SLEWING STRUCTURE

Issued January 2006

Book/Form Number 5-1710 NA
Copyright © 2006. CNH America, LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. S5PJ0010E01-KO33
 SECTION 3 - DISASSEMBLY AND ASSEMBLY
CHAPTER 33 - UPPER SLEWING STRUCTURE

CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Remarks
First Edition 01-2006 E215 5-1710 NA

33-II Issued 01-2006 Bur 5-1710 NA

 SECTION 3 - DISASSEMBLY AND ASSEMBLY

CHAPTER 33
UPPER SLEWING STRUCTURE
TABLE OF CONTENTS

1. Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-5

1. Operator’s Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2. Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
3. Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
4.Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
5. Under Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
6. Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
7. Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
8. Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
9. Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
10. Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
11. Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
12. Radiator and Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
13. Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
14. Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
15. Multi Control Valve (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
16. Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
17. Pilot Valve (For Attachment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
18. Pilot Valve (For Travel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
19. Swing Motor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
20. Swivel Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37
21. Upper Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40
2. Disassembly and Assembly
1. Hydraulic Pump - Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2. Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
3. Pilot Valve (For Attachment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
4. Pilot Valve (For Travel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
5. Swing Motor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
6. Swivel Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

5-1710 NA Issued 01-2006 Bur 33-1

 SECTION 3 - DISASSEMBLY AND ASSEMBLY
CHAPTER 33 - UPPER SLEWING STRUCTURE

NOTES

33-2 Issued 01-2006 Bur 5-1710 NA

 1. OPERATOR SEAT HEAD REST

1.1 REMOVAL 2
(1) Remove seat belt.
1) Remove the head rest of the operator’s seat to
1
ease handling.
SNAP HOOK
2) Move the whole control stand to its foremost
position. EYE BOLT
2
3) Move the operator's seat to its forward end.
4) Incline the reclining seat as forward as
possible.
5) Remove the snap hook of the seat belt (1)
from the eye bolts (2 places)
1
SNAP HOOK
(2) Remove operator’s seat. (Include upper rail.)
EYE BOLT
1) With the above-mentioned seat belt removed,
remove two cap screws (A8) M820 from the
upper rail. Then move the control stand to its
rearmost end and remove two cap screws (A8)
SEAT ASSY
M820.
: 6mm
2) Remove the operator’s seat. [about 22kg (48
lbs).]
Before removing the cab, remove the A/C
A8
mounting cover assembly in this condition.
This eases removal and fixing of harness
connectors.
Carry out the following operations as
UPPER RAIL
required. A1
3) Remove cover (A3).
4) Remove support (A1).
5) Remove seat stand (A2).
LOWER RAIL

1.2 INSTALLATION
Install it in reverse procedure of removing
A3
according to the tightening torque table.
A8
Allen Tightening torque
Tightening position wrench
kgfym (ftylbs) A2
HEX
Sems bolt (A7) 17 4.7 (34) A7
Capscrew (A8) 6 4.3 (31)

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 Fig. 1-1
Disassembling and Assembling seat
[Up; 23mm (0.07in), down; 37mm (0.16in)]

1
 2. CAB Rotate 90 degrees to remove
4-3
BOLT (4-3)
GROMMET COVER
2.1 REMOVAL 18,19
(1) Remove floor mat
(2) Remove air conditioner cover (4).
Turn four cover mounting machine sc CATCH (3)
BRACKET

rews
(4-3) 90°, remove them from catch (3) and 4
push up black locks (4-1F). Then the air-
4-1F
conditioner cover (4) comes off.
(3) Remove cover assy (5).
5-3
If the black locks on the right and left and at
5
the top and bottom of cover assy (5) is pushed
up, the locks come off. Then cover assy (5) FLOOR MAT
comes off. Fig. 2-1 Detaching and attaching air conditioner cover
(4) Remove the harness connector from the back
right of the cab. WINDOW 62
WASHER ROOM LAMP
1) Pull out the room lamp harness
connectors (1PAM & 2PAM).
2) Remove the cab earth (LA306) of the ANTENNA
instrument panel harness.
3) Remove the antenna cable at the back of
the tuner from the back right of it.
1PAM
(5) Remove the plastic tube for the window 2PAM
washer from the back left of the cab.
(6) Remove the control cable (19) from the 19
CONTROL
bracket of the cab side. DOOR SW. CABLE
(7) Remove cab attaching bolt
WASHER
1) Eight capscrews (A1) M12×65 (Mark △) TANK
WINDOW WASHER
2) Four nuts M16 (Mark ○) CABLE
A1
(8) Slinging cab (M12×65) 8pcs.
1) Remove two plastic plugs at the front of the
ceiling of the cab. Then place a wire sling
with eye rings and a hook around the cab, as
NUT
shown in Fig.2-3. M16×4 pcs.
2) Then lift up slowly avoiding interference with
surroundings.
Wire with hook ; Fig. 2-2 Removing and attaching harness
connector and cab attaching bolts
Length 1.5m (4ft 11in) × Dia. 8mm (0.315in)
× 3pcs.
Weight of cab ; Approx. 260kg (570 lbs) M10 EYE BOLT

1.2 INSTALLATION
Install it in reverse procedure of Removing
according to the Tightening Torque Table. A1
Tightening torque
Tightening position Tool kgfym (ftylbs)
Nut M16 24 19 (140)
Capscrew (A1) 19 11 (80)

Fig. 2-3 Slinging cab

Ⅰ－2
 3. BATTERY
3.1 REMOVING 7
(1) Open right cover assy.
1) Open it with starter key.
2) Open cover assy (7). (Refer to 4. GUARD)
3) Fix it with stay.

(2) Remove battery cable

1) Remove cable (C4) [between the earth and Fig. 3-1 Preparation for removing battery
battery Θ]. (Always remove Θ terminal first
and install it at last.)
2) Cable (C2) [between battery + and Θ]
3) Cable (C3) [between battery + and battery relay] C3
: 13mm C2

Follow the battery removal order.

C4
Start removing battery from grounding
side, and finish attaching to grounding
side. If this order is missed, short-
circuits may occur.

(3) Remove battery (B1)

1) Remove four nuts (A3) M8. Fig. 3-2 Remove battery cable
: 13mm
2) Remove bracket (A1). A1
3) Remove battery (B1).
A3

3.2 INSTALL B1
(1) Install the battery in the reverse procedure of
removing.
Battery attaching rod bolt (A2)
: 8mm,
Tightening torque: 1.1kgfym (8.0ftylbs)
A2
(2) Installing grounding cable
Install grounding cable last. Especially care
must be taken that the grounding face is free
from painting, rust, etc.
: 13mm

Fig. 3-3 Removing battery

Ⅰ－3
 4. GUARD
4.1 PREPARATION FOR REMOVAL 29
(1) Remove guard in the following procedure. 7
8 12
Remove the guards in the order of (1), (13),
6
(12), (29), (8), (3), (5), (4), (6) and (7). 4
13
(2) All the locked cover, open them using starter
key. 8

5
3 1
Fig. 4-1 Arrangement of guard assy

4.2 REMOVE GUARD

52
(1) Remove bonnet assy (1) 53
1) Unlock catches (52) and (53) and open bonnet 1
(1).
2) Remove four nuts (43) M12.
3) Remove bonnet (1).
: 19mm
Weight : 25kg (55 lbs)

43
Fig. 4-2 Removing bonnet assy (1)

(2) Remove guard (13)

1) Remove four sems bolts (36) M12×30. 36
13
2) Remove guard (13).
: 19mm 3
Weight : 15kg (33 lbs)

Fig. 4-3 Removing guard (13)

(3) Remove guard (12)

1) Remove four sems bolts (36) M12×30.
2) Remove guard (12). 12
: 19mm 36
Weight : 8kg (17 lbs)

Fig. 4-4 Removing guard (12)

Ⅰ－4
(4) Remove stay (29)
29
1) Remove two sems bolts (35) M12×25.
2) Remove two sems bolts (37) M12×35.
3) Remove stay (29).
: 19mm 35
Weight : 11kg (24 lbs)

37

Fig. 4-5 Removeing stay (29)

(5) Remove guard (8)
1) Remove two sems bolts (35) M12×25.
2) Remove connector for right side deck light.
35 8 DECK LIGHT POSITION
3) Remove guard (8).
: 19mm

Fig. 4-6 Removing guard (8)

(6) Remove panel assy (3)
1) Unlock panel assy (3).
2) Remove four nuts (41) M10.
3) Remove panel assy (3).
: 17mm
Weight : 17kg (37 lbs)

41

Fig. 4-7 Removing panel assy (3)

(7) Remove panel assy (5)
1) Remove four nuts (41) M10.
2) Remove panel assy (5). 41
5
: 17mm
Weight : 14kg (30 lbs)

Fig. 4-8 Removing panel assy (5)

Ⅰ－5
(8) Remove panel assy (4)
1) Unlock and open panel assembly (4).
2) Remove four nuts (41) M10. 4
3) Remove panel assy (4).
: 17mm
Weight : 14kg (30 lbs)

41
Fig. 4-9 Removing panel assy (4)
(9) Remove panel (6) 35
1) Remove three sems bolts (35) M12×25 and
panel (6).
6 35
: 19mm

Fig. 4-10 Removing panel (6)

(10) Remove guard assy (24), (22) and guard (62)
1) Remove two sems bolts (35) M12×25 and 36
three capscrews (63) M12×25 and guard 22
(24). 63
2) Remove two sems bolts (36) M12×30 and 62
35
guard assy (22).
3) Remove three sems bolts (35) M12×25 and
guard (62).
: 19mm 35
Weight : guard assy (22)：13kg (28 lbs)
guard (24)：2kg (4 lbs) 16
guard (62)：5kg (11 lbs) BRACKET
24
35
Fig. 4-11 Removing guard assy (24),(22)
and guard (62)
35
(11) Remove bracket (16), (23) (See Fig. 4-11,12)
1) Remove two sems bolts (35) M12×25 and
bracket (16).
2) Remove two sems bolts (36) M12×30.
3) Remove bracket (23).
: 19mm
23
Weight : 9kg (19 lbs)

36
Fig. 4-12 Removing bracket (23)

Ⅰ－6
(12) Remove guard (10)
1) Remove four sems bolts (36) M12×30.
36
2) Remove guard (10).
: 19mm
36

10
Fig. 4-13 Removing guard (10)
(13) Remove bracket (67)
1) Remove one sems bolt (35) M12×25,
Remove one sems bolt (36) M12×30,
Remove three sems bolts (37) M12×35.
: 19mm
2) Remove bracket (67). 37

35
67

36

Fig. 4-14 Removing bracket (67)

(14) Remove brackets (17), (14), (15) 35
1) Remove two sems bolts (35) M12×25.
2) Remove two sems bolts (36) M12×30.
: 19mm 17
3) Remove brackets (17), (14), (15). 35
36
35

15

14

36

Fig. 4-15 Removing bracket (17), (14), (15)

Ⅰ－7
(15) Remove guard (19)
35
1) Remove five sems bolts (35) M12×25 and 9
35
guard (19).
: 19mm

(16) Remove four guards (9), (18), (20), (21) as an

assy.
1) Loosen the hose clamp of the E/G intake and
separate the hose. 18
2) Remove four sems bolts (37) M12×25. 35 35
3) Remove four sems bolts (36) M12×30.
: 19mm
4) Remove four guards as an assy. 35 35
23kg ＋ 23kg ＋ 1kg ＋ 26kg ＝ 73kg 20
(50 lbs)＋(50 lbs)＋(2 lbs)＋(57 lbs)＝(161 lbs)

37
19
21

36
Fig. 4-16 Guard
(17) Remove cover assy (7)
1) Unlock the locks and open cover (7-2).
2) Remove four sems bolts (37) M12×35. 37 7-2 7
3) Disconnect the connections of three
connectors of the battery relays.
4) Remove cover assy (7).
: 19mm
6
Weight : 29kg (63 lbs)

BATTERY RELAY
POSITION

(18) Remove other brackets, as required. Fig. 4-17 Remove cover assy (7)

Ⅰ－8
4.3 INSTALLATION
(1) Installing is done in the reverse order of
removing.

(2) Tightening torque

Table 1
Tightening torque Unit：kgfym (ftylbs)
Size Capscrew Sems bolt
M8 3.6 (26) ─
M10 7.2 (52) 5.0 (36)
M12 11 (80) 8.5 (61)

Ⅰ－9
 5. UNDER COVER
5.1 REMOVAL
(1) Remove under cover (2,4,5,6,10,11,12,13)
1) Remove attaching sems bolts (7) M12×30.
2) Remove covers.
: 19mm

7
13
10

7 12
5
7
7
7 4

7 2 11 7

Fig. 5-1 Under cover assy

5.2 INSTALLATION
(1) Install under cover (2,4,5,6,10,11,12,13)
: 19mm
Tightening torque : 8.5kgfym (61ftylbs)

Ⅰ－10
 6. FUEL TANK
6.1PREPARATION FOR REMOVAL
(1)Draining fuel.
1)Unlock cap (A2) with a starter key and open it. A2
2)Loosen cock (B8) under the tank.
(See Fig.6-2.)
3) Draining fuel
Capacity of tank : 336 (89gal) 8
2

(2) Remove stay (29), panel (6) and guard (8).

8
(Refer to 4. GUARD)

(3) Remove the connector for level sensor (B4). 5

(See Fig. 6-2)

(4) Remove fuel hose

1) Loosen clip (8) and draw out hoses (2) and (5). Fig. 6-1 Removing fuel hose (2), (5)
2) Put in plugs that match the hose bore.

6.2 REMOVAL
A2
1) Remove four capscrews (B1) M16×40 and
three shims (B3).
: 24mm
2) Hook the wire to the lifting eye on the fuel
tank assy and remove the fuel tank.
B4
Weight : 91kg (201 lbs) FUEL TANK

6.3 INSTALLATION
(1) Installing is done in the reverse order of
removing. Coil seal tape
around
Tank attaching bolt (B1) M16×40 A4
: 24mm, Apply Locktite #262
Tightening torque : 22.0kgfym (160ftylbs)

(2) Tightening torque B3

Tightening torque B1
No. NAME Q’TY kgfym (ftylbs)
B8
A4 PLUG 1 5.0 (36)
Fig. 6-2 Removing fuel tank
B1 CAPSCREW 4 22 (160)
B6 MACHINE SCREW 5 0.2 (1.4)
B8 COCK 1 4.0 (29)

Ⅰ－11
 7. HYDRAULIC TANK
7.1 PREPARATION FOR REMOVAL 12 6
(1) Remove panel assy (6), guard (12) and other
guards necessary to remove the hydraulic oil
tank. (Refer to 4. GUARDS.)

Fig. 7-1 Remove guard

(2) Bleeding internal air of tank (A9)
Push
Press the rubber cap by your finger tip to
bleed off the inside air.
A9 ELEMENT NO.
Keep pressing until the hissing stops. YN57V00002S010

Fig. 7-2 Bleeding internal air of tank

(3) Remove cover (A7).

1) Remove six capscrews (A13) M10×20. A13
2) Remove cover (A7). A13
: 17mm
A7
3) Remove suction strainer (A2). A8

A2
A9
A3
(4) Remove cover (A8).
1) Remove six capscrews (A13) M10×20.
: 17mm
2) Remove cover (A8).

3) Remove filter element (A3).

Fig. 7-3 Remove cover (A7), (A8)

Ⅰ－12
 PUMP PLATE
(6) Draining hydraulic oil
FOR
Place pump in tank and draw up hydraulic
LIFTING
oil.
Capacity of tank : 155 (41gal)

7.2 REMOVAL
(1) Draw out the suction hose (3)
1) Remove two clips (13) of the tank side.
2) Pulling out hose (3).
PILOT
: Flat-blade screwdriver RETURN
HOSE
POSITION

13
B3
3

B1
Fig. 7-4 Draining hydraulic oil and
drawing out the suction hose
(2) Disconnecting the main pipe return hose
1) Remove coupling (9) and separate tube (40).
2) Remove hose (5), (6). HYDRAULIC TANK

(3) Remove radiator return tube (3)

1) Remove coupling (9) M8 nut. 9
: 13mm 40
2) Separate tube (3).

Fig. 7-5 Removing main piping return hose

(4) Disconnecting pilot return hose
1) Remove pilot hose (A7).
: 19,22mm
2) Remove pilot hose (D16).
: 19,22mm D16
3) Remove pilot hose (D18).
: 19,22mm

D18

A7

Fig. 7-6 Remove pilot drain hose

Ⅰ－13
(5) Remove manihold assy and pump drain
piping
1) Remove two capscrews (A17)M10×30 and
manihold assy (A20). A6
: 17mm
2) Remove pump drain hose (A6).
: 19, 22mm A20
(6) Remove hydraulic tank attaching bolt
(Sse Fig. 7-4)
Remove four capscrews (B1) M16×40, and a
shim (B3).
: 24mm

Record the shim locations. A17

Fig. 7-7 Removing manifold assy and
(7) Slinging hydraulic oil tank pump drain hose
Place a wire sling, using the lifting plate on
top of the tank.
Tank weight : Approx : 145kg (320 lbs)

HYDRAULIC OIL TANK

7.3 INSTALLATION
(1) Cleaning hydraulic oil tank
(2) Cleaning suction hose
(3) Cleaning mount of tank.
Installing is done in the reverse order of
removing. 13
(4) Install four mounting capscrews (B1) 3
M16×40 with Locktite #262. (See Fig. 7-4) 13
: 24mm
Tightening torque: 22kgfym (160ftylbs) Fig. 7-8

If the clearance (gap) between the tank

mount and the frame is more than O RING
1mm (0.04in), adjust it with a 1mm
(0.04in) shim (B3) and fasten them
together.

(5) Connection of suction hose (3)

1) Apply PERMATEX on pipe side of hose
connection and insert it.
2) Put the hose with clip (13).
Tightening torque : 0.55kgfym (4.0ftylbs)
(6) Installing return element (A3) A2
SUCTION
(7) Installing suction strainer (A2) STRAINER
(8) Tighten capscrews (A13) M10×20 that attach YW50V00004F3
tank covers (A7), (A8).
: 17mm
Tightening torque : 4.7kgfym (34ftylbs) A3
RETURN FILTER
YN50V00001P1
Fig. 7-9 Element & filter

Ⅰ－14
 8. HYDRAULIC PUMP A13
8.1 PREPARATION FOR REMOVAL
(1) Release pressure in hydraulic oil tank.
(Refer to 7. Hydraulic Tank.) A7
SUCTION
(2) Remove six capscrews (A13) M10×20. STOPPER

(3) Remove cover (A7) SUCTION

: 17mm STRAINER

(4) Take out suction strainer.

(5) Install suction stopper.

For suction stopper, see chapter “YN11 Tools”.

Fig. 8-1 Suction stopper installing

(6) Remove guards
1) Remove bonnet assy (1), guard (13), panel 13
assy (4), guards (24), (62) and bracket (16).
1
4
2) Remove those parts that are required to
remove the hydraulic pump such as the fuel 16
filter assy.

3) Remove drain hose at the bottom of the

FILTER
muffler.
ASSY

24 62

8.2 REMOVAL Fig. 8-2 Removing guards

(1) Loosen half clamp (8) on hoses (1), (2) and
capscrews (16) M10×35 and disconnect two
hoses on the delivery side.
: 17mm
6 1 2 8,16
(2) Remove suction tube
1) Remove four capscrews (17) M12×30.
: 19mm

2) Remove elbow (5) of suction hose (3) from

pump.
3
3) Remove drain hose (6) (Dr1).
: 30, 36mm

5 17

Fig. 8-3 Removing hose (1), (2), (3) and (6)

Ⅰ－15
(3) Removing other hoses
1) Disconnect hoses of the following ports.
(See Fig. 8-4.)

Port Remarks
Tool
Pn1 19 P1 pump negative control pressure
Pn2 19 P2 pump negative control pressure
Dr3 19,22 Drain
Psv1 19 Pilot primary pressure P1 side
Psv2 19 Pilot primary pressure P2 side
A3 19,22 Pilot pump delivery
B3 36 Pilot pump suction

2) Attach tags to hoses to identify.

3) Put a plug in the hoses and the pump.
Fig. 8-4 Hydraulic pump port
(4) Remove connector
Remove six connectors of all pressure sensors
and proportional valves.

SE-26 :
Pressure sensor：P1 nega-con

SE-23 :
Pressure sensor：P2 pump

PSV-P2 :
P2 pump proportional valve

SE-27 :
Pressure sensor：P2 nega-con

PSV-P1 : P1 pump proportional valve

SE-22 :Pressure sensor：P1 pump

Fig. 8-5 Removing connector

Ⅰ－16
(5) Remove main pump 0
1) Put a wire sling on the hydraulic pump and 3
tension the wire sling a little. Loosen eleven
cap screws (8) M10×30 and one cap screw (5)
M10×25.
: 17mm
2) Draw out the power take-off assy from the 8
flywheel housing slowly, adjusting the
tension of the wire rope.
On that occasion, the assembly is drawn out
with the insert NA (2-2) remaining on the 4
flywheel side.
3) Remove element (2-1) from the tip of the 5
6
spline shaft.
4) Remove four capscrews (4) M16×50 that fasten 2-4
insert R (2-3) and remove insert R (2-3). 2-3
4
: 14mm 2-2 1
5) Remove hub (2-4) 7 2-1
If you loosen two set screws (6) M16×25, hub 7
2
comes off from the spline shaft of the pump.
: 14mm Fig. 8-6 Removing pump
6) Remove eight capscrews (4) M16×50 that
fasten the insert NA (2-2) with the engine
side flywheel, as necessary. Then remove
insert R (2-3) and spring pin (7) from hub (2-
4).
: 14mm
7) Bracket (1) is an accessory to the pump. For
disassembly, refer to Disassembly and
Assembly of Pump.

8.3 INSTALLATION
Installing is done in the reverse order of
removing.
(1) Installing hub (2-4)
Put hub (2-4) into the pump spline till it
enters 5mm (0.197in) from the end face of the
spline (Refer to Detail a.). Then install two
set screws (6) coated with Locktite #262 and
fix them together.
: 8mm (4) Installing element (2-1)
Tightening torque : 12kgfym (87ftylbs) Put element (2-1) into hub (2-4) and insert R
(2-3).
(2) Installing spring pin (7)
Install spring pin (7) in hub (2-4). (5) Installing insert NA (2-2)
Put spring pin (7) into insert NA (2-2) and
(3) Installing insert R (2-3) install it to the engine flywheel by means of
Install insert R (2-3) into hub (2-4) by means capscrews (4) coated with Locktite #262.
of capscrews (4) coated with Locktite #262. : 14mm,
: 14mm, Tightening torque : 22kgfym (160ftylbs)
Tightening torque : 22kgfym (160ftylbs)

Ⅰ－17
(6) Installing the pump T=Tightening torque
Apply Locktite #262
Lift the pump with bracket (1). Place T=22kgfym (160ftylbs)
coupling (2) in the groove of element (2-1) so 4
7
as to receive insert NA (2-2).
(7) Coat eleven capscrews (8) M10×30 and one Dr
capscrew (5) M10×25 with Locktite #262 and 2
put them in place.
: 17mm,
a
Tightening torque : 6.6kgfym (48ftylbs) Apply
Locktite #262
(8) Fasten hoses (1), (2) on the discharge side T＝12kgfym
with half clamp (8) and capscrews (16) (87ftylbs)
6
M10×35. (Refer to Fig.8-3.)
: 17mm 7
(9) Install suction hose (3) with four capscrews
(17) M12×30. (See Fig. 8-3.) 4
Apply Locktite 1
: 19mm, #262 Apply Locktite #262
Tightening torque : 6.8kgfym (49ftylbs) T=22kgfym 8,5 T=6.6kgfym(48ftylbs)
(160ftylbs)
(10) Install the hydraulic piping by referring to
2-4
“HYDRAULIC SYSTEM”. STARTER MOTOR (11 pcs.)
(11) Installing the hose 8

Tightening torque
Port kgfym (ftylbs)
Tool
Cap nut Pn1,2 19 3.0 (22) 5
(1 pc.)
Cap nut Dr3 19,22 5.0 (36)
Cap nut Psv1,2 19 3.0 (22) 5 (0.2″) 4 VIEWⅡ
Cap nut A3 19,22 3.0 (22) DETAIL a
Cap nut B3 36 12 (87) Fig. 8-7 Installing hydraulic pump

(12) Installing pressure sensor connector and

proportional valve connector.
(13) Remove suction stopper
(14) Install suction strainer

When the pump is replaced, replenish

more than 1 (0.26gal) of hydraulic oil
from the drain port (Dr). Dr 0 Dr

(15) Bleed air in pump

Bleed air by loosening the oil filling port F.
(16) Check hydraulic oil level.
(17) Start engine and check it for oil leakage and
noise.
(18) Attach drain down pipe under engine muffler.
(19) Install guards
(See Fig. 8-2) (See Fig. 4-11)
Fig. 8-8 Bleed air port (Dr) in pump
Tightening torque
Tightening position kgfym (ftylbs)
Tool
Sems bolt (35), (36) 19 8.5 (61)

Ⅰ－18
 9. AIR CLEANER 1

9.1 PREPARATION FOR REMOVAL

(1) Opening bonnet assy (1)

(2) Opening panel assy (3)

(3) Unplug terminals on indicator (1-5) wiring.

(See Fig. 9-2)
5
9.2 REMOVAL
(1) Pulling out hose (2). 3
1) Loosen clips (4), (5) on both sides of hose (2).
2) Pulling out hose (2) Fig. 9-1 Preparation for removal
: Flat-blade screw driver 2
1-5 4
5
(2) Pulling out hose (3).
1) Loosen clips (5), (6) on both sides of hose (3).
2) Pulling out hose (3)
: Flat-blade screw driver 1
1-1
1-6
(3) Remove air cleaner assy (1) 1-2
1) Remove four sems bolts (7) M10×30
1-3
: 17mm 1-4
2) Remove air cleaner assy (1) from guard assy 7
(9). 9

9.3 INSTALLATION 6
(1) Installing is the reverse order of removing 5 3
with attention paid to the following items:
1) Put in air hoses (2), (3) to the deepest end.

2) Tightening torque :
Tightening Torque
No. NAME kgfym (ftylbs)
1-5 INDICATOR 0.4 (2.9)
7 SEMS BOLT 4.0 (29) Apply Locktite #262

(2) Replacing parts

Fig. 9-2 Removing air cleaner

FILTER ELEMENT (1-2) O RING (1-6)

(YN11P00001S002) (YN11P00001S006)

Ⅰ－19
 10. MUFFLER 1
13
10.1 PREPARATION FOR REMOVAL
4
(1) Remove bonnet assy (1) and guard (13).
(2) Remove panel assy (4).
(3) Remove guard (24), (62) and bracket (16).
(See Fig.8-2)

10.2 REMOVAL
(1) Remove bracket (7), (8).
(2) Remove U bolt (10).
1) Remove four nuts (21) M8.
: 13mm Fig. 10-1 Preparation for removal
2) Remove two U bolts (10). 13
(2) Remove clamp assy (9) 16 14 15
1
1) Remove two capscrews (20) M10×35
8 10
: 17mm
2) Separate clamp assy (9) from muffler (1). 7 20
(3) Removing other parts 14 6 9
Remove exhaust tube (2) and brackets (3), (4), 2
as necessary.
13 12
: 13mm, 17mm 17 18
5
18 21
10.3 INSTALLATION 11
Installing is the reverse order of removing with
attention paid to the following items: 19 4
21
(1) Procedure of fastening U bolt (10)
(See Fig. 10-2)
1) Tighten four nuts (A) till there is no space
and make sure that the dimension C is even 3
28 18
all around.
2) Tighten nuts (A) to specified torque and
confirm the C dimensions on the right and 5mm (0.20in) from the
SPACE tip of muffler slit
left once again.
9
3) Tighten nuts (B) to specified torque and make
sure that U bolts are not inclined.
4) Tightening torque
B
Nut A : 0.9kgfym(6.5ftylbs)
Nut B : 1.1kgfym(8.0ftylbs) C
A
(2) Installing clamp assy (9) PROCEDURE OF
1) Place the end of clamp (9) 5mm (0.20in) away FASTENING U BOLT
The joint of seal clamp does
from the tip of the muffler slit so the joint of not extend over the slit.
clamp does not extend over the slit in the
Installing clamp (9)
muffler. (See Fig. 10-2.)
2) Install the clamp assy (9) in the illustrated Fig. 10-2 Removing and installing the muffler
direction.
(3) Tightening torque : (4) Replacing parts

Tightening torque NAME PART No.

No. NAME kgfym (ftylbs)
13 CAPSCREW 2.0 (14.5) MUFLLER(1) YN12P00013P1
18,19 CAPSCREW 4.0 (28.9) GASKET(12) ME088841(MMC PART No.)

Ⅰ－20
 11. COUNTERWEIGHT
11.1 PREPARATION FOR REMOVAL
Remove plug (C6) on the counterweight and
attach two M36 eye bolts (Refer to chapter “YN11
Tools”) to the counterweight.
: 55mm

Fig. 11-1 Lifting up counterweight

11.2 REMOVAL
(1) Lifting up counterweight temporarily
Hook wire rope to slinging jig, and lift it and
C6
stretch wire rope to the degree where it is
providing no slack temporarily.
Weight of counterweight ;
Approx. 3900kg (8600 lbs)
Wire more than ∅16 (0.63″) ;
1.5m (5ft)×2 pcs.

(2) Removing counterweight A1

1) Remove four capscrews (C1) M27×300.
C3,C4,C5
: 41mm

2) Remove shim (C3), (C4), (C5). (Select)

3) Remove counterweight (A1).
C2

C1

Fig. 11-2 Removing counterweight

11.3 INSTALLATION
(1) Install counterweight in the reverse
procedure of removing. C6

(2) Install shim (C3), (C4), (C5) as it was. (select)

(3) Slinging counterweight

Check that the attaching bolts can be
C3,C4,C5
screwed in by hand.

(4) Apply Locktite #242 on capscrews (C1), and

tighten them with washers (C2).
: 41mm
Tightening torque : 130kgfym (940ftylbs)

(5) Remove slinging tools, and attach plugs (C6). C1,C2

Fig. 11-3 Fastening the counterweight
attaching capscrew

Ⅰ－21
 12. RADIATOR & OIL COOLER
12.1 PREPARATION FOR REMOVAL
(1) Bleed air from the hydraulic tank and install
the suction stopper.

(2) Remove bonnet assy (1)

Refer to
(3) Remove guard (10) (Fig. 4-13) 4. GUARD

(4) Remove panel assy (3)

7 4
(5) Removing under cover installed on lower side
7 2
of radiator.
1) Remove eight sems bolts (7) M12×30. Fig. 12-1 Removing under cover (2), (4)
2) Remove cover (2), (4).
: 19mm

B16 B7
(6) Drain down of radiator
Put container 18 (4.8gal) under drain cock
hose for draining water.
[Water capacity of radiator : 9.5 (1.8gal)] B1

(7) Remove washer tank (B1) B6

1) Remove coolant level switch (B1-3).
B1-3
2) Pulling out hose (B6), (B7).
3) Remove four capscrews (B16) M8×25 and
separate sub tank (B1) from bracket assy.
: 13mm
Fig. 12-2 Removing sub tank (B1)
Do not loosen the joints of the hoses
related to the air-conditioner. Otherwise
the refrigerant leaks.

(8) Move air-conditioner condensers. CONNECTOR

1) Remove six capscrews (12) M6×50.
2) Move A/C condenser
: 10mm
12
11
(9) Move receiver tank
1) Remove the connector for receiver tank
2) Remove two capscrews (11) M8×16 which
are used to install receiver tank with bracket. A/C CONDENSOR
3) Move receiver tank.
: 13mm 12
RECEIVER TANK
(10) Remove counter weight Fig. 12-3 Moving condensers and receiver tank
(Refer to 11. COUNTER WEIGHT)

Ⅰ－22
(11) Assembling travel straight spool 3) Fit O ring (264) to the spool cover (205) in
1) Put a protective plate (aluminum plate, etc.) par. 1) to the assy and tighten socket bolts
in the vise and hold the center of travel (273) to the specified torque.
straight spool (307) in it. Set spring seat : 6mm,
(332), springs (325), (328) and stopper (337) Tightening torque :
and tighten bolts (334) to the specified 2.5
3.5kgfym (18
25ftylbs)
torque.
: 10mm,
Tightening torque :
1.6
1.8kgfym (12
13ftylbs)

z When tightening bolts (334), coat

them with Locktite #262.
z Be careful so as not to distort travel
straight spool (307) by over-
tightening it in the vise.

2) Assemble the travel straight spool assy in

par. 1) into casing B (102).

When assembling the travel straight

spool assy into casings B (102), do it
slowly and carefully, never force it in.

3) Fit O ring (262) to the spring side of the

travel straight spool assy. Then attach spring
cover (203) to the assy and tighten socket
bolts (273) to the specified torque.
: 6mm,
Tightening torque :
2.5
3.5kgfym (18
25ftylbs)

(12) Assembling rod spool

1) Fix spool cover (205) in a vise, put O ring
(166) in plug (156) and fasten it to a specified
torque.
: 8mm,
Tightening torque :
7
8kgfym (51
58ftylbs)

2) Assemble the rod spool (311) into casing B

(102).

When assembling the rod spool (311)

into casing B (102), do it slowly and
carefully ; never force it in.

223
12.3 INSTALLATION C1
(1) Installing is done in the reverse order of
RADIATOR SHROUD
removing.

(2) Install radiator assy

Place a wire sling in the lifting metals of the
radiator, match the openings of the hydraulic
pipes, match the mounting positions of the
radiator and assemble it temporarily.
Water hose insert allowance 40mm (1.6in)

(3) Radiator attaching bolt A3

Apply Locktite #262 on four capscrews (A3) Tightening torque
M12, and tighten it with washer respectively. 12.3kgfym
: 19mm (89ftylbs)
Apply Locktite
Tightening torque ; 12.3kgfym (89ftylbs)
#262

Fig. 12-7 Installing radiator

(4) Adjust the clearance between the fan and the
radiator shroud all around the circumference, Adjust the engine fan so its rear end sticks
out 24.5mm (0.965in) from the radiator
as below : h d
Circumferential direction:
15±5mm (0.591in±0.197in)
Longitudinal direction :
24.5±5mm (0.965in±0.197in)

(5) Clean the plastering area of the insulation

thoroughly before plastering it.

(6) Making up hydraulic oil and LLC (Long Life

Coolant)
After completion of other installation, make
up hydraulic oil and water.

Cooling water volume of engine body

：9.5 (2.5gal) Fig. 12-8 Back-and-forth
Water capacity of radiator ：9.5 (2.5gal) adjusting position of radiator

Ⅰ－24
12.4 PROCEDURE OF DISASSEMBLING AND
ASSEMBLING THE RADIATOR CORE
(1) Preparation for disassembly and assembly
1) Remove one under cover at the bottom of the
radiator.

2) Wait till the engine cooling water cools down

so you do not suffer a burn. Then remove the
cap of the radiator, discharge the cooling
water by opening the drain cock located at 4 RADIATOR CORE 2 OIL COOLER

the back bottom and receive it in a container.

(2) Disassembly
1) Loosen two wing bolts (1) at the top of the 1
radiator and pull up the insect proof net (2).
4
2) Remove four cap screws (3) M8×20 fastening
the right and left pads (4) on the shoulder of 3
7
the radiator. Then remove pads (4).

3) Remove four cap screws (5) M10×25

fastening the top of the radiator core. 5

4) Remove two cap screws (6) M8×20 fastening

the lowermost part of the radiator core.
6
5) After confirming that the cooling water has
been drained out completely, loosen and PULL UP
remove only the radiator side of hose bands 7
(7) at the top and bottom of the radiator.
Pull toward the oil cooler

6) Put two eye bolts into the holes of the bolts

fastening the top of the radiator core. Place a
wire sling on it, pull it toward the oil cooler
and list it up.

7) Clean the radiator core with tap water and

assemble it in the reverse order of
disassembly. Fig. 12-9 Procedure of disassembling and
assembling the radiator core

Ⅰ－25
 13. ENGINE
13.1 PREPARATION FOR REMOVING
(1) Remove battery ground (8) Remove harness connector
(Refer to 3. BATTERY) (Refer to ELECTRIC SYSTEM)
1) Remove E/G ground cable
(2) Remove bonnet and cover 2) Starter cable ─ Starter B terminal
(Refer to 4. GUARD) 3) Remove the connector that connects the
Remove under cover upper harness with the engine.
(Refer to 5. UNDER COVER) 4) Upper harness
－CN-206－E/G sub harness
(3) Remove air cleaner hose －CN-134, CN135－Governor motor
(Refer to 9. AIR CLEANER) －CN-136－E/G speed sensor
－CN-143－E/G oil level SW.
(4) Remove counterweight －CN-141, CN142－ Pump proportional
(Refer to 11. COUNTERWEIGHT) valve
－CN-113, CN-115－P1,P2 negative control
(5) Remove radiator hose pressure sensor
(Refer to 12. RADIATOR) －CN-139, CN-140－P1,P2 pump pressure
sensor
(6) Remove fuel hose and heater hose, and if
necessary disconnect air-con hose. Prepare a stand, which withstands the
weight of the engine assy and can place
(7) If necessary, remove pump, muffler and the removed engine firmly.
radiator. (Refer to Tools on Page 14.)
OIL PRESSURE SWITCH

SPEED SENSOR

FUEL FILTER
BYPASS VALVE OIL FILTER GASKET ELEMENT
ELEMENT

STARTER ASSY

THERMOSTAT
KIT

HEATER RELAY
THERMO SENSOR

ALTERNATOR
THERMO SWITCH
ASSY

OIL LEVEL SENSOR

Fig. 13-1 Outside view of engine

Ⅰ－26
13.2 REMOVAL 11
T=Tightening torque
13
Locktite #262 5
T=6.6kgfym (48ftylbs) 10 14 7

7
11 5 3
13 13
Three Bond
5 #1110B 12
T=2.5kgfym
6 (18ftylbs)
Locktite #271
11 T=23kgf m (170ft lbs)
y y

1 13
10 8
14 5
11 7
6 13 3
5 5
14
6
13 10
12 7
2 5
14 10
15 6
5 13
12
13

12

Fig. 13-2 Dismantling and mounting engine

(1) Removing attaching bolt to frame 1) Sling engine hooking wire to lifting lugs on
1) Remove four nuts (12) M18. the front and rear sides.
: 27mm Weight : Approx. 500kg (1,100 lbs)
2) Remove cover (5) and rubber mount (6). Wire : ∅6 (0.236″)×1m (3ft 3in)－2pcs.
3) Remove four capscrews (11) M18×130. (3) Position engine on the stand stably.
4) Remove four washers (13).
5) Remove four covers (5). 13.3 INSTALLATION
6) Remove four rubber mounts (6). Installing is done in the reverse order of
removing.
(2) Slinging engine body 1) Tightening torque Tightenig
No. NAME torque REMARKS
kgfym (ftylbs)
Prepare a stand, which withstands the
Apply Three
weight of the engine assy and can place 7 TEMPERATURE SENSOR 2.5 (18) Bond #1110B
the removed engine firmly. (Refer to Apply
9 CAPSCREW 6.6 (48) Locktite #262
“Tool” on page 14.) Apply
10 CAPSCREW 23 (170) Locktite #271

Ⅰ－27
 14. INSTRUMENT PANEL
14.1 PREPARATION FOR REMOVAL
Remove terminal (－) from battery.

14.2 REMOVAL 12 12
(1) Removing the right-hand instrument panel
1) Remove caps (25), (28) and take off four sems
bolts (12) M6×20.
: Flat-blade screwdriver
2) Hold up the right-hand instrument panel
cover (2).
3) Take off four connectors below that are
located at the back of right-hand instrument 12
12
panel cover (2).
9P for tuner, 3P for accel potentiometer, Fig. 14-1 Around of instrument panel
6P for key switch and 6P switch assy 25
28 12
(2) Removing the left-hand instrument panel
12
1) Remove cap (25) and take off four sems bolts 12
(2) M6×20.
2
2) Draw out the connectors at the back face of
left-hand instrument panel cover (6).
8P for air-conditioner switch, 2P for warming
up switch, and OPT connector
25
12
(3) Removing the right-hand side face cover (1) of
12
the cab
1) Remove the cap of capscrew (27). Take off one 6
machine screw M6×11 and two sems bolts
(14) M6×16. Then remove cover (1).
2) Draw out the harness connector at the back
of cover (1).
Remove the connector 6P for the switch assy.
Fig. 14-2 Removing instrument panel
(4) Removing cover (3) on the right side face of 3
cab.
1) Remove four caps (26), take off seven sems
14 27
bolts (14) M6×16 and separate cover (3). 26 HOUR CIGAR
2) Draw out the harness connector at the back METER LIGHTER
1
of cover (3).
1P for cigar lighter, 8P for gauge cluster, 2P
for hour meter and 6P for wiper motor.

14.3 INSTALLATION 14
Install it in reverse procedure of removing 14
according to the tightening torque table. 26

Tightening Tightening torque 14

Tool
position kgfym (ftylbs) 26 14
cross recessed Fig. 14-3 Installing cab instrument panel
Sems bolt (12) 0.27 (2.0)
screw driver
Ⅰ－28
 15. MULTI CONTROL VALVE (IF EQUIPPED)
15.1 PREPARATION FOR REMOVAL
(1) Bleed pressure air in hydraulic oil tank FLOOR PLATE
(Refer to 7. HYDRAULIC TANK.)

Fig. 15-1 Removing multi control valve

15.2 REMOVAL
(1) Attach tag on which hose name is entered to
the remote control hoses between multi
control valve and main control valve, and
write numbers C1 to C8 on it.
Remove the hose on the multi valve side and
put a plug in each opening.
Refer to 4. Tool of Plug (3).
(2) Attach tag on which hose name is entered to
the remote control hoses between multi
control valve and pilot V, and write numbers
P1 to P8 on it.
(3) Remove hoses P1 to P8 on multi control valve
side and plug connection.
Refer to 4. Tool of Plug (3).

Fig. 15-2 Connection between

15.3 INSTALLATION multi control valve and C/V
(1) Installing is done in the reverse order of
removing
(2) Relations between pilot valve and multi
control valve hose

P/V Hose ISO multi mark

port Size Color operation pattern port -ing
1 1/4 Red Bucket digging P1 BK
2 1/4 Blue Bucket dump P2 BA
Right 3 1/4 Green Boom up P3 BR
side 4 1/4 Gray Boom down P4 B
P 1/4 Black Pilot primary － －
T 3/8 Black Drain － －
5 1/4 Gray Swing left P5 SL
6 1/4 Red Swing right P6 SR
Left 7 1/4 Blue Arm in P7 AK
side 8 1/4 Green Arm out P8 AR
P 1/4 Black Pilot primary － －
T 3/8 Black Drain － －
Fig. 15-3 Connection between
P/V and multi control valve

Ⅰ－29
15.4 OPTIONAL MULTI CONTROL VALVE Specification of multiless control valve
(1) Changing from “multiless valve” to “with 271 355 356 354
multi valve”
1) Be certain that the engine stops.
Y
2) Set multi control valve to other than ISO (Y) O RING (161)
position.
S SENSOR
BLOCK
3) Remove six socket bolts (271).
: 6mm

4) Remove repair kit “multiless valve” and Fig. 15-4

attach repair kit “with multi valve”. Multiless control block assy 2436U1244F4
No. NAME Part No.
Q’T
5) Then check that the inside O ring (161) is Y
free from distortion. S SENSOR BLOCK ── 1S
Y MULTILESS REPAIR KIT 2436U1244R200 1S
6) Check that O ring (461) and backup ring 161 z O RING ZD12G08000 1
(462) are fitted on cover of valve “with multi 271 z SOCKET BOLT ZS23C08035 6
control”, and install it on sensor block (S). 354 z COVER ── 1
355 z PIN ── 1
356 z SPRING PIN ZP26D05010 1
7) Fit socket bolt (271) and (273) and tighten it
to the specified torque. Optional multi control valve
: 6mm 352 353 271 472 471 401 261 201 273 274
Tightening torque ; 4.3kgfym (31ftylbs)

(2) Changing from “with multi valve” to

“multiless valve”
M
1) Stop engine, and remove repair kit for “with
multi valve” in the reverse procedure of the 275 O RING
said procedure, and attach repair kit for 462 (161)
“multiless valve”. S SENSOR
461 BLOCK

Fig. 15-5
C/V assy with multi 2436U1244F3
No. NAME Part No. Q’TY
S SENSOR BLOCK 1S
M REPAIR KIT WITH MULTI 2436U1244R400 1S
161 z O RING ZD12G08000 1
201 z COVER FOR MULTI 2436U1244S201 1
261 z DUST SEAL 2436U1244S261 1
271 z SOCKET BOLT ZS23C08035 4
273 z SOCKET BOLT ZS23C08055 2
274 z SPACER 2436U1244S274 2
275 z SLEEVE 4
352 z KNOB 2436U1244S352 1
353 z LEVER 2436U1244S353 1
401 z PIN 2436U1244S401 1
461 z O RING ZD12P02800 1
462 z BACK UP RING ZD85P02800 1
471 z SPRING PIN ZP26D06025 1
472 z WING BOLT 2436U1244S50 1

Ⅰ－30
 16. CONTROL VALVE
16.1 PREPARATION FOR REMOVAL
(1) Remove guard (12) (Refer to 4. GUARD)
(2) Install the suction stopper to the hydraulic oil
tank. 4
(3) Remove the hoses located at the below ports :

Mark each hose with a port name

before removing it.

16.2 REMOVAL
(1) Remove four capscrews (3) M12×35. 1 3
: 19mm
(2) Remove the control valve with brackets (1), (2)
3
Weight : Approx. 162kg (357 lbs)

2
16.3 INSTALLATION
(1) Installing is done in the reverse order of
remove. Fig. 16-1 Removing the standard
: 19mm, Apply locktite #262 main control valve
Tightening torque :
This figure shows the control valve
12.3kgfym(89ftylbs)
with option 1 valve.
(2) Check for oil leakage and operation.

Functions Ports Ports on upper sides (on machine) Ports Functions

LEFT SIDE← →RIGHT SIDE PA01 Drain port
－ A01 relief valve
PA01
PCb P1 bypass cut
Arm variable recirculation PiS
PiS PCb － P1 negative control relief valve
Arm in PAa
PAb Boom up
Arm (H) rilief valve － PAa PAb Drc

Drc Boom lock drain

Boom conflux PB1 PB1 PAC
PLC1
PLC1 Boom down lock release
Swing left PAS
PAS PAr PAC Bucket dump
Travel left forward PAL
PAL
－ Bucket (R) rilief valve
PAr
－ Main rilief valve
Ports on rear sides (on machine)
REAR SIDE← →FRONT SIDE

Swing motor boost circuit T2 P1 P1 pump

T2
P1

Tank return T P2 P2 pump

P2
T

Ⅰ－31
 Functions Ports Ports on right sides (on machine) Ports Functions
UPPER SIDE← →LOWER SIDE

B01
B01 Swing priority
Boom up Ab Pn1’ P1 negative control
Pn1’

Ab
Bucket dump Ac Bb Boom down
Bb

AC BC Bc Bucket digging

Travel right forward Ar Ar Br

Br Travel right reverse

Ports on left sides (on machine)

LOWER SIDE← →UPPER SIDE

Pn2’
P2 tank circuit Tn2 Tn2
Pn2’ P2 negative control

Ba

Arm out Ba Aa Arm in

Aa

Swing right Bs As Swing left

Bs As

Travel left reverse BL AL Travel left forward

AL
BL

Ports on lower sides (on machine)

LEFT SIDE← →RIGHT SIDE
PTb Travel straight
Travel left reverse PBL PTb
PBr Travel right reverse
Swing right PBs PBL

－ Bucket (Ｈ) relief valve

Arm in PAa
PBs
PBr

PBc Bucket digging

Arm in lock release PLC2 PAa PBc
PLC2
－ Boom (Ｒ) relief valve
Arm out PBa PBa PBb

Drd
PBb Boom (R) relief valve
Arm lock valve drain Drd PCa

PA1 Arm conflux

P2 negative control relief valve － PA1

－ B01 relief valve

P2 bypass cut Pca
PB01 Swing priority
PB01

Ⅰ－32
 17. PILOT VALVE (FOR ATT)
17.1 PREPARATION FOR REMOVING
The removing procedure for right and left is the
same, so the preparation for left side is described
here. 16
(1) Put attachment on ground, stop engine and
release pressure in tank. LEFT PANEL ASSY
5
6
(2) Remove panel assy referring to Section 14.
Instrument Panel.

(3) Remove two sems bolts (16) M6×20 from

lower side of control box. 16
16
: cross recessed screw driver
Fig. 17-1 Removing instrument panel
(4) Remove cover (6) on outer surface.
BOOTS

(5) Remove sems bolt (16) securing cover (5) and

control box on inside surface. A1
: cross recessed screw driver

(6) Remove cover on inside surface.

PILOT VALVE
: cross recessed screw driver

(7) Remove harness connector for horn.

PF3/8
VALVE SIDE PF1/4
Opposing Opposing
(8) Attach a tag to the hose to make assembly Flats 22 Flats 19
work easier.

MARK “F”
17.2 REMOVAL
(1) Remove hoses from your side to far side in PF3/8
PF1/4
order. P PORT CONNECTOR
: 19mm,22mm HOSE SIDE (WITH FILTER)
1～4,5～6,T PORT CONNECTOR
(2) Shift boots. Fig. 17-2 Pilot valve connector

(3) Remove four socket bolts (A1) M6×25. FRONT OF THE MACHINE
: 5mm
T ⑧ ARM(R) ④ ②
(GREEN) T BUCKET
BOOM(R)
(4) Remove pilot valve. (R)
⑥ (BLUE)
SWING
(5) Plug hose ends. (R.H)
⑤ (RED)
Plug PF1/4, PF3/8 SWING(L.H)
(GRAY)
①
17.3 INSTALLATION P
P BUCKET(H)
Install it in the reverse order of removal and ⑦ ARM(H) (RED)
tighten it. (BLUE) ③ BOOM(H)
(GREEN)
: 5mm T=1.5kgfym (11ftylbs)
LEFT SIDE RIGHT SIDE
: 19mm T=3.0kgfym (22ftylbs)
: 22mm T=5.0kgfym (36ftylbs) Fig. 17-3 Pilot valve port position (from upper side)

Ⅰ－33
 18. PILOT VALVE (FOR TRAVEL)
18.1 PREPARATION FOR REMOVING
(1) Release pressure in hydraulic oil tank

(2) Remove under cover (6)

(Refer to 5. UNDER COVER)

(3) Remove floor mat 2

CB103
18.2 REMOVAL 17
(1) Separate the two pressure sensors SE-9 (B8)
and SE-10 (B19) at the connector.
: 19mm 18
B8
(SE-9) 9
(2) Separate lead wire CB103 for the travel two-
B19
speed switch at two positions of the body (SE-10)
harness.

(3) Attach tag, and disconnect connectors and B6

hoses (B9), (B10), (B11), (B12)． B8
: 19mm (P port)
: 22mm (T port, 1～4 port) PILOT VALVE

(4) Plug hose ends

Plug PF1/4, PF3/8 B8 B10

(5) Remove four sems bolts (17) M10×20. B12

B9
(6) Remove right and left levers (2).

(7) Remove four socket bolts (B6) M10×30.

B12 B11
: 8mm
B11

(8) Remove four sems bolts (18) M10×25 and

remove plate (9).
: 17mm Opposing
PF3/8 flats 22
PF3/8
(9) Remove pilot valve lifting it upward.

(10) Stop up holes with plugs PF1/4, PF3/8. VALVE HOSE

SIDE SIDE
VALVE SIDE ◯
T port connector
18.3 INSTALLATION
PF3/8
Install it in the reverse order of removal and Opposing
MARK “F”
Opposing flats 19
tighten it. flats 22 PF1/4
PF1/4
Hose PF3/8
: 19mm T=3.0kgfym (22ftylbs)
: 22mm T=5.0kgfym (36ftylbs) HOSE SIDE
: 8mm T=4.7kgfym (34ftylbs) ①～④ port connector ◯
P port connector
: 17mm T=4.7kgfym (34ftylbs)
Pressure sensor Fig. 18-1 Installing and Removing pilot V
: 19mm T=3.5kgfym (25ftylbs)
Ⅰ－34
 19. SWING MOTOR UNIT
19.1 PREPARATION FOR REMOVING
(1) Park machine on flat and solid ground and
put attachment on ground.
5 5
(2) Remove the guard (3). (Refer to 4. GUARD)

(3) Stop engine and release pressure in circuit

operating swing control lever.

(4) Bleed air from the hydraulic oil tank and 7

attach to each hose a tag showing port name
and other information.

A7

A8

Fig. 19-1 Removing swing unit piping

19.2 REMOVAL
(1) Remove hose.
B2
1) Remove hose (7) from the Tee in the makeup
port M.
: 36mm

2) Remove two hoses (5) from the Tee in the

drain port Dr.
11
: 27mm
B1
3) Remove one hose (11) from the elbow of the
PG port (See Fig. 19-2).
: 19mm

4) Remove two hoses (A7), (A8) from the elbows

of the A, B port.
: 36mm

Put in plugs PF3/4, PF1/2, and PF1/4 into the

removed ports.

Fig. 19-2 Removing swing unit

Ⅰ－35
(2) Removing the swing unit
Remove twelve capscrews (B1) M20×55.
: 30mm

1) Remove two plastic caps (B2) M12 at the top

of the swing motor and install eye bolts.
: Flat-blade screw driver

2) Put a wire sling in the eye bolts and remove

the swing motor unit.
Weight of swing motor unit ; Approx. 60kg
(132 lbs)

19.3 PREPARATION FOR INSTALL

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

(2) Apply Locktite #515 on entire mounting

surface of swing motor unit.

19.4 INSTALLATION
Install the swing motor unit in the reverse order
Coat all the mounting surface
of disassembly, confirming the orientation of the
of the swing motor with
swing motor unit.
Locktite #515 equivalent.
1) Tighten capscrews (1).
: 30mm
Tightening torque : 55.0kgfym (400ftylbs)
Apply Locktite #262

Detail of swing motor unit assy mount

19.5 PREPARATION FOR DRIVE
(1) Before starting operation, check that gear oil
#90 (API grade GL-4) level of swing reduction
is sufficient.
Amount of charge : 7.5 (2gal)

Apply Locktite #262 equivalent.

(2) Confirm no oil leaks.
Tightening torque 55kgfym (400ftylbs) 1

(3) Confirm proper operations.

Fig. 19-3 Installing swing motor unit

Ⅰ－36
 20. SWIVEL JOINT
20.1 PREPARATION FOR REMOVE 20.2 REMOVAL
1) Remove boom piping hose (1) Remove travel motor hose and tube
[Refer to Travel section under HYDRAULIC
SYSTEM YN22 (8)]
1) Remove tube (A5), (A6). (E port : PF1/2)
: 32mm
Tightening torque :
15.0kgfym (108ftylbs)
2) Remove tubes (A1), (A2). (A, B port : PF1)
: 41mm
Tightening torque :
26.0kgfym (190ftylbs)
3) Remove tubes (A3), (A4). (C, D port : PF1)
: 41mm
Tightening torque :
26.0kgfym (190ftylbs)
4) Remove two hoses (A13). (F port : PF1/4)
: 19mm
Tightening torque : 3.7kgfym (27ftylbs)

◯
C

A2
A4

B2 A13
A13
A3
A1

A6

A5

Fig. 20-1 Removing piping (lower side)

Ⅰ－37
(2) Disconnecting the hoses on the top part of
A5
swivel joint
[Refer to Swivel Joint under, HYDRAULIC
SYSTEM YN22 (4), (5).]
1) Remove drain hose (5). (E port : PF1/2) 5
: 27mm
Tightening torque : 8.0kgfym (58ftylbs) A9
2) Remove hoses (A9), (A5).
(A, C port : 1-3/16-12UN)
: 36mm
Tightening torque :
18.0kgfym (130ftylbs)
3) Remove hoses (A9), (A5).
(B, D port : 1-3/16-12UN) A5
: 36mm A9
Tightening torque :
18.0kgfym (130ftylbs) 10
4) Remove hose (10).
(2-speed change over port : PF1/4)
: 19mm
Tightening torque : 3.0kgfym (22ftylbs) Fig. 20-2 Disconnecting the hoses
on the top part of swivel joint

(3) Remove whirl-stop of swivel joint. C5 C3 T=16kgfym

1) Loosen the nut (C5) M16. (120ftylbs)
2) Remove a capscrew (C3)M16×110.
: 24mm

Fig. 20-3 Removing whirl-stop nut & the

capscrew

(4) Remove joint for piping (Refer to Fig.20-1,

20-2)
1) Remove two connectors (B2). (F port) TIGHTENING TORQUE
2) Remove connector (B2) for travel 2-speed 0.69kgfym (5ftylbs) B9
change over. (PF1/4) TIGHTENING TORQUE
: 19mm 1.5kgfym (11ftylbs) B8
Tightening torque : 3.7kgfym (27ftylbs)

(5) Remove seal (B4)

1) Remove six capscrews (B8) M10×20.
PLATE
: 17mm

2) Remove clip (B9).

Before mounting the seal B4
: Flat-blade screw driver (B4), apply adhesive to
3) Remove seal (B4). the adhering surface of
S/J and the upper frame.

Ⅰ－38
(6) Remove capscrew for installation
Attach eye bolt, lift it up temporarily, and
remove three capscrews (2) M12×25.
: 19mm
(See “YN11 Tools” No.6－11)

EYE BOLT

LOWER FRAME

CAPSCREW
M12×25
Locktite #262
T=11kgfym(80ftylbs)
SWIVEL JOINT

Fig. 20-5 Removing capscrew for installation

(7) Slinging the swivel joint
Weight : Approx.26kg (57 lbs)

20.3 INSTALLATION
(1) Installing is done in the reverse order of
removing.
Piping tightening torque

Tool Tightening torque kgfym(ftylbs)

Size
HEX O ring type Hydraulic hose
PF1/4 19 3.7(27) 3.0(22)

PF3/8 22 7.5(54) 5.0(36)

PF1/2 27 11.0(80) 8.0(58)

PF3/4 36 16.5(120) 12.0(87)

PF1 41 26.0(180) 14.0(100)

1-3/16-12UN 36 ─ 18.0(130)

(2) Check for oil leakage and the hydraulic oil

level.

(3) Check for operating.

Ⅰ－39
 21. UPPER FRAME
21.1 PREPARATION FOR REMOVAL
(1) Remove attachment
(Refer to YN32 : ATTACHMENT)

(2) Remove cab (Refer to 2. CAB.)

(3) Remove guard (Refer to 4. GUARD)

WIRE ROPE
(4) Remove counterweight
(Refer to 11. COUNTERWEIGHT) CHAIN BLOCK

(5) Remove swivel joint LIFTING

(Perform the steps (1) thru (7) of 20. SWIVEL JIG
JOINT)

21.2 REMOVAL
(1) Lifting up upper frame temporarily
Insert two upper swing body lifting jigs and C1
two counterweight fastening cap screws (C1) Fig. 21-1 Temporarily lift upper frame
M27×300 into the counterweight mounting
holes from above. Attach two chain blocks to
the boom foot side and lift the upper frame at MATCH
MARK
four points.
Wire rope ; ∅16 (0.630″)×2.5m(8ft-2in), 2pcs.
∅16 (0.630″)×1.5m(4ft-11in), 2pcs.
Chain block ; For 2,000kg (4,410 lbs) 2pcs.

(2) Marking match marks on swing bearing

Mark match marks on upper frame and
swing bearing.
Fig. 21-2 Matching mark on swing bearing
(3) Removing upper frame attaching bolts and upper frame
Remove thirty capscrews M20×105 and
three reamer bolts used to install swing
bearing and upper frame.
: 30mm

(4) Slinging upper frame

Sling according to Fig.21-1, and remove
upper frame and put it on a stand.
Weight : Approx. 5ton (11,000lbs)

Fig. 21-3 Removing upper frame attaching bolts

Ⅰ－40
21.3 INSTALLATION
Apply Locktite #515 to the race surface over the whole
(1) Installing is done in the reverse order of circumference (hatched) on the inside of capscrew.
removing.

(2) Cleaning mating surfaces of upper frame and

swing bearing.

(3) Apply Locktite #515 to the inside of the

capscrews on the contact surface.
10,11
(4) Slinging upper frame Apply Locktite #262
equivalent.
Match marks and install it with three reamer T=40kgfym (290ftylbs)
bolts (11) temporarily.
Fig. 21-4 Bearing mount
Confirm the reamer bolt positions
referring to Fig. 21-5.

OUTER (S) ZONE POSITION

: 30mm, Tightening torque :
40kgfym (290ftylbs)
Apply Locktite #262

(5) Install swing bearing

Install thirty capscrews (10) M20×105.
: 30mm, Tightening torque :
40kgfym (290ftylbs)
Apply Locktite #262

Fig. 21-5 Reamer bolt position (※)

Apply Locktite on section specified
by slanting lines

Ⅰ－41
 NOTES

Ⅰ－42
 Table 1-1
1. HYDRAULIC PUMP・REGULATOR TIGHTENING
1.1 HYDRAULIC PUMP
REGULATOR
TORQUE No. NAME Q’TY
REGULATOR kgfym (ftylbs)
1.1.1 STRUCTURAL EXPLODED VIEW
(1) Main pump 153 RETAINER 2
156 SPHERICAL BUSHING 2
157 CYLINDER SPRING 18
211 SHOE PLATE 2
212 SWASH PLATE 2
214 TILTING BUSHING 2
534
792 251 SWASH PLATE SUPPORT 2
531,548 702 261 SEAL COVER (F) 1
732 532 271 PUMP CASING 2
789 808 312 VALVE BLOCK 1
535 954
953 886 901 313 VALVE PLATE (R) 1
724
314 VALVE PLATE (L) 1
806 325 COVER 1
717
44 (320) 401 SOCKET BOLT: M20×210 8
728 954 314
808 3.0 (22) 406 SOCKET BOLT: M8×20 4
824 1.2 (8.7) 407 SOCKET BOLT: M6×30 3
124
127
3.7 (27) 466 VP PLUG: PF1/4 2
123 468 17 (120) 468 V PLUG: PF3/4 4
127
546 0.9 (6.5) 490 PLUG: NPTF1/16 20
113 24 (170) 531 TILTING PIN: M24×2 2
111 271 24 (170) 532 SERVO PISTON: M24×2 2
717 885 534 STOPPER (L) 2
774 717 886 535 STOPPER (S) 2
710 490 546 SPACER 2
114
261 251 548 FEED BACK PIN 2
401 407
406 124 312 702 O RING: 1B G35 2
157 313 325 710 O RING: 1B G95 1
156 141 717 O RING: 1B G1455 4
151 886 724 O RING: 1B P8 16
153
885 725 O RING: 1B P11 7
152 728 O RING: 1B P24 4
211 732 O RING: 1B P18 2
TIGHTENING
Q’T 774 OIL SEAL 1
TORQUE No. NAME
214 Y
ENGINE SIDE kgfym (ftylbs) 789 BACK UP RING 2
212
111 SHAFT (F) 1 792 BACK UP RING 2
113 SHAFT (R) 1 13 (94) 806 NUT: M16 2
114 SPLINE JOINT 1 24 (170) 808 NUT: M20 2
123 ROLLER BEARING 2 824 SNAP RING 2
124 NEEDLE BEARING 2 885 VALVE PLATE PIN 2
127 BEARING SPACER 4 886 SPRING PIN 4
141 CYLINDER BLOCK 2 901 EYE BOLT: M10 2
151 PISTON 18 953 SOCKET SET SCREW: M16×30 2
152 SHOE 18 954 SET SCREW: M20 2

The codes in a rectangle represent adjust screws.

Do not tamper with the adjust screws as much as possible.
Fig. 1-1 Structural exploded view of main pump II-1-1
NOTES NOTES
(2) Gear pump (for pilot)

DELIVERY PORT：PF3/4
TIGHTENING TORQUE：
3.5kgfym (25ftylbs) 467 728
A3
850
433
355
308 351
434

435
354

B3 SUCTION PORT：PF3/4
TIGHTENING TORQUE：
7.5kgfym (54ftylbs)

725 307
710
310
353
466 309
a3
Dr4 732
700 311
DRAIN PORT：PF3/4
TIGHTENING TORQUE： 312
361 3.5kgfym (25ftylbs)

Fig. 1-2 Structure of gear pump (for pilot)

Table 1-2
TIGHTENING TIGHTENING
TORQUE No. NAME Q’TY TORQUE No. NAME Q’TY
kgfym (ftylbs) kgfym (ftylbs)
307 POPPET 1 1.7 (12) 433 FLANGE SOCKET ; M8×40 2
308 SEAT 1 1.7 (12) 434 FLANGE SOCKET ; M8×55 2
309 SPRING SEAT 1 1.7 (12) 435 FLANGE SOCKET ; M8×20 4
310 SPRING 1 1.6 (12) 466 VP PLUG ; PF1/4 1
311 ADJUSTING SCREW 1 467 ADAPTER ; PF1/2-PF3/8 1
3.0 (22) 312 LOCK NUT ; M14×P1.5 1 700 RING 1
351 GEAR CASE 1 709 O RING ; 1B G95 1
353 DRIVE GEAR 1 725 O RING ; 1B P11 1
354 DRIVEN GEAR 1 728 O RING ; 1B P18 1
355 FILTER 1 732 O RING ; 1B P16 1
361 FRONT CASE 1 850 SNAP RING 1

Ⅱ－1－3
1.1.2 DISASSEMBLY AND ASSEMBLY OF MAIN
PUMP
(1) Preparation before disassembly
1) Tools
Prepare the following tools to disassembly or
assembly.

Table 3 Unit : mm
Size
No. Nomenclature Application Shape
B
a Allen key wrench Socket bolt (407) 5 M6
(406)
b Socket bolt (412) 6 M8
(413)
c Socket bolt (953) 14 M16

d B Socket bolt (401) 17 M20

e Eye wrench VP plug (466) 19 PF1/4

Socket wrench double
f heads (single end) VP plug (468) 36 PF3/4
B
g Nut (806) 24 M16

h Nut (808)
30 M20
i Set screw (954)
Flat blade screwdriver medium
j Screw driver size 2 pcs
k Hammer Plastic hammer 1pc

l Pliers Snap ring (824) For snap rings

m Stopper drawing bolt Stopper (534・535) M8

n Locktite #242

2) Cleaning
Put a plug in each port and clean the pump to
remove dust and dirt from the outer surface.

Fig. 1-3 Cleaning pump

Ⅱ－1－4
(2) Disassembling procedure 808
1) Selecting a place for disassembly.
806 806
z Choose a clean place.
z Spread rubber sheet or cloth on work
bench to protect parts from
damaging.
z Do not loosen nuts (808) of valve
block (312) and nuts (806) of swash
plate support (251). The set flow
value changes.
z The figures in the parentheses after 251 312 251
part names in the instructions Fig. 1-4 Put it on a work bench on
correspond to those in Fig. 1-1. which a rubber sheet is laid

2) Drain oil 468

Drain out the oil in the pump casing by
removing drain port plug (468).
：36mm

Fig. 1-5 Draining oil from pump

3) Remove regulator and gear pump
Remove socket bolt (412,413,435) and take off
the regulator (gear pump).
435
: 6mm

z Regarding the disassembly of the

412
regulator, refer to the regulator
manual.
413

412 413
412 413
Fig. 1-6 Removing regulator
4) Disassembling valve block and pump casing
Separate valve block (312) from pump casing 312
(271) by socket bolt (401). 271
: 17mm

z Execute this operation after

removing the gear pump.
401

Fig. 1-7 Removing valve block (312)

Ⅱ－1－5
5) Drawing out the cylinder 141
Draw out cylinder (141) out of pump casing 156
151
(271) in shaft (111). At the same time draw 152
out piston (151), shoe (152), retainer (153),
271 212
spherical bushing (156) and cylinder spring
(157).
157
153
z Use care so as not to score the
sliding surface of the cylinder (141),
211
spherical bushing (156), shoe (152)
and the swash plate (212) .
111Fig. 1-8 Disassembling in pump casing
6) Remove seal cover
Loosen socket bolts (406) fastening seal cover
(F) and take off seal cover (F) (261).
: 6mm
710
774
z The seal cover (F) (261) may be
drawn out with ease if it is taken out 261
by capscrew in the tapped holes (M6 406
tapped) of the seal cover (F) (261).
z An oil seal (774) and O ring (710) are
fitted to seal cover (F) (261).
Therefore, use care so as not to score
the oil seal. Fig. 1-9 Removing seal cover (261)

7) Remove swash plate support

Separate pump casing (271) by knocking on
717
the mounting flange of swash plate support 251
(251) from pump casing (271) by means of a
plastic mallet.

z O ring (717) is fitted to swash plate

support (251). Take care so the O
ring is not scored when removed.

271

Fig. 1-10 Removing swash plate support (251)

8) Remove shoe plate and swash plate
Draw out shoe plate (211) and swash plate
(212) from pump casing (271).
211

212

271

Fig. 1-11 Removing swash plate (212)

Ⅱ－1－6
9) Drawing out the shaft 251
Draw out shaft (111) fixed in swash plate
support (251) by lightly tapping it with a
hammer.

111

Fig. 1-12 Drawing out the shaft (111)

10) Disassembling the shaft
Remove stop ring (824) from shaft (111) and 127 824
123
take off bearing spacer (127) and bearing
(123). 127

111

Fig. 1-13 Disassembling the shaft (111)

11) Remove valve plate
Remove valve plate (313, 314) from valve
block (312).

z The valve plate may come off during

the operation under 4). 313
314

312

Fig. 1-14 Removing valve plates (313), (314)

12) Remove tilting pin and servo piston
Draw out stopper (L) (534) and stopper (S) 531
(535) from pump casing (271), using a jig.
Then separate tilting pin (531) and servo
piston (532). 534
z When removing tilting pin (531), use
535 532
full care so as not to score the tilting
pin head.
z The jointing screws fastening the
tilting pin (531) with servo piston 271
(532) are coated with Locktite
(strong adhesive). Therefore do not
disassemble the servo piston and the
tilting pin as much as possible,
except when they are damaged. Fig. 1-15 Removing servo piston (532)

Ⅱ－1－7
12) Remove spline joint ※808
Separate needle bearing (124) and spline
joint (114) from valve block (312).
z Do not draw out needle bearings
(124) except when their service life
has ended. 114
124
z Do not loosen nuts (808) (marked ※)
124
of valve block (312) and swash plate
support (251) : A set flow rate
changes.
312

Fig. 1-16 Removing spline joint

(3) Installing procedure
1) Precautions to be exercised in installation
Assembly is a reverse order of disassembly,
but notice the following.
1. Repair scored parts at disassembly. Get
replacements ready beforehand.
2. Wash parts sufficiently in cleaning oil and
dry them with jet air.
3. Do not forget to coat the sliding areas and
bearings with clean hydraulic oil.
4. In principle, replace sealing parts such as O
rings and oil seals.
5. Tighten socket bolts and plugs to specified
torques in this manual, using a torque
wrench.
6. Do not mix up front pump parts with rear
pump parts. 531
271
2) Installing servo piston, etc.
Fit servo piston (532), tilting pin (531), 534
stopper (L) (534) and stopper (S) (535) to 535
532
pump casing (312).
z When tightening servo piston (532)
and tilting pin (531), use a jig so as
not to damage the head of the tilting
pin and feedback pin (548). Fig. 1-17 Installing servo piston (532), etc.
z Coat the screwed part with Locktite
#242. 271

3) Installing swash plate support

Attach swash plate support (251) to pump 251
casing (271) by tapping the swash plate
support lightly with a plastic hammer (K).

Fig. 1-18 Attaching swash plate support (251)

Ⅱ－1－8
4) Installing swash plate 214
531
Place the pump casing (271) with its 271
mounting surface of the regulator facing
down, insert the tilting bushing (214) of the
swash plate into tilting pin (531), and fit 251
swash plate (212) to swash plate support
(251) properly.
212

z Confirm by the fingers of your both

hands that swash plate (212) moves
smoothly.
z The shaft be installed easily if grease Fig. 1-19 Installing swash plate (212)
is applied to the moving parts of 824
127
swash plate (212) and swash plate 123
127
support (251).

111
5) Assembling shaft
Fit bearing (123), bearing spacer (127) and
snap ring (824) to shaft (111).

z Assembling the outer race of the

bearing by lightly tapping it with a
hammer (K). Fig. 1-20 Assembling shaft (111)

6) Assembling shaft
Assemble shaft (111) into pump casing (271)
with sufficient care. 111

z Do not knock on the shaft (111) with

a hammer or something.

7) Assembling seal cover 271

Assemble O ring (710) and oil seal (774) into Fig. 1-21 Assembling shaft assy
seal cover (F) (261). 710 774
261
z Coat oil seal (710) in seal cover (F)
(261) with a thin film of grease.
z Fix seal cover (F) (261), taking full
care so oil seal (710) is not scored.

8) Assembling seal cover Fig. 1-22 Assembling seal cover (261)

Assemble seal cover (F) (261) to pump casing
271
(271) and fasten it with socket bolts (406) to a
fastening torque of 3kgfym (22ftylbs).
: 6mm
261
406

Fig. 1-23 Assembling seal cover (261)

Ⅱ－1－9
9) Assembling piston cylinder sub assy
Assemble the piston cylinder sub assy [piston
(151), shoe (152), cylinder block (141),
retainer (153), spherical bushing (156), and
cylinder spring (157)].

141
157
156
151・152 153
Fig. 1-24 Assembling piston cylinder sub assy
10) Inserting piston cylinder sub assy
271
Align the phase of spherical bushing (156) 156
with the phase of the spline of cylinder block
(141). Then align them to the spline of shaft
(111) and insert the piston cylinder sub into
pump casing (271).
141
SPLINE

Fig. 1-25 Inserting piston cylinder sub assy

11) Installing valve plate
Attach valve plate (R) (313) and valve plate
(L) (314) to valve block (312) by aligning
them with valve plate pin (885).

Do not mistake the suction and 313

314
discharge ports of the valve plate.

312

885
Fig. 1-26 Installing valve plate (313,314)
12) Assembling valve block
Attach pump casing (271) to valve block (312) 312
by aligning them with spring pin (886). Then
271
fasten them together with socket bolts (401)
to a tightening torque of 44kgfym (320ftylbs).
: 17mm
z The work is facilitated if the pump
on the rear side is assembled first.

Take care so as not to mistake the

orientation of the valve block. (Install it 886
so the regulator faces upward and the 401
delivery flange is on the left as seen
from the front.)

Fig. 1-27 Assembling valve block (312)

Ⅱ－1－10
13) Installing regulator 412 413
Hold feedback pin (548) of tilting pin (531) in
the feedback lever of the regulator and install FEEDBACK
the regulator and fasten it with socket bolts LEVER
(412, 413) to a torque of 3.0kgfym (22ftylbs).
: 6mm

TILTING PIN (531)

FEEDBACK PIN
(548)

531・548

Fig. 1-28 Installing regulator

14) Installing cover
Attach cover (325) to valve block (312) and
fasten them together with socket bolts (407)
to a fastening torque of 1.2kgfym (8.7ftylbs).
: 5mm

407

312 325

Fig. 1-29 Installing cover

15) Fitting drain plug
Attach drain plug (468) to pump casing (271)
and fasten it to a torque of 17kgfym (120ftylbs).
: 36mm

468
271
Fig. 1-30 Fitting drain plug (468)

Ⅱ－1－11
1.1.3 MAINTENANCE STANDARDS
(1) Replacement standards for worn parts However, always replace such parts that
Replace or readjust parts that exceed the show excessive damage on appearance.
following standards of wear.
Unit: mm (in)

Standard Recommended
Inspection item value for Remedy
dimension replacement
Clearance between piston and 0.039 0.067
Replace piston or cylinder.
cylinder bore (D－d) (0.0015˝ ) (0.0026˝ )

Gap between piston and caulked part 0～0.1 0.3

Replace piston shoe assy.
of shoe (δ) (0.004˝ ) (0.012˝ )

4.9 4.7
Thickness of shoe (t) Replace piston shoe assy.
(0.193˝ ) (0.185˝ )

41.1 40.3
Free height of cylinder spring (L) Replace cylinder spring .
(1.62˝ ) (1.59˝ )

Combined height of retainer plate and 12.0 11.0 Replace a set of spherical
spherical bushing (H－h) (0.472˝ ) (0.433˝ ) bushing or retainer plate.

H
h

Combination of retainer plate and spherical

Clearance between piston and bushing Height=H-h
cylinder bore: D－d

t δ

L
Gap between piston and shoe : δ
Thickness of shoe: t Free height of cylinder spring: L

(2) Repair standards for cylinder, valve plate and swash plate (shoe plate face)
Valve plate (sliding section) Surface roughness requiring correction 3－Z
Swash plate (shoe plate face)
Cylinder (sliding section) Standard surface roughness
(correction value) Less than 0.4Z (lapping)
Roughness of each surface

Ⅱ－1－12
(3) Cautions to be exercised in repairing the
internally broken pump 3) Flush the system for more than 30 minutes
1) Replace all operating oil and clean the and replace the return filter element once
hydraulic oil tank. again. Observe the above-mentioned three
2) Clean the suction filter, replace the drain items without fail.
filter and replace the return filter element.

1.1.4 TROUBLESHOOTING
(1) Locating causes of troubles
The pump is usually fitted with a regulator, 3) When two pumps are used
auxiliary valves and auxiliary pumps, and In case two single pumps or motors are used
this makes fault location extremely difficult. or when a double pump is used. Change
However faults would be found out easily if pump pipelines. This will make clear that the
the following check items were attended to. pumps are faulty or the circuit after the
pumps is faulty.
1) Inspecting the filter and drain oil
Inspect the filter element to check for 4) Pressure measurements
abnormal contaminations. Some metallic If the problem is related to control functions,
particles will be deposited on it as the shoe avoid disassembling the pumps carelessly,
and the cylinder wear off. In case metallic but look for causes by measuring pressures.
particles are found in large quantity, the
elements may be damaged. In that case check
the drain oil in the pump casing as well.

2) Checking for abnormal vibration and sound

Check that the pump does not vibrate and
make an abnormal sound.
Check that the hunting of the regulator and
the attached valve’s relief valve are of regular
frequency. In case vibration and sound are
abnormal, the pump may be making a
cavitation or internally broken.

(2) Troubleshooting
1) Overloading to engine

Cause Remedy Remarks

1. Revolution and pressure are 1) Set pressure to specified
higher than set values. value.
2. Regulator torque is set higher 2) Readjust regulator. 2) Refer to Regulator Manual.
than normal.
3. Pump’s internal parts are 3) Replace damaged parts. 3) Check filter and drain oil to see if
seized or broken. abnormal wear particles are
present.
4. Regulator is piped incorrectly. 4) Pipe regulator correctly.

Ⅱ－1－13
(2) Pump’s oil flow rate is extremely low and delivery pressure is not available.

Cause Remedy Remark

1. Regulator is out of order 1) Repair regulator. 1) Refer to Regulator Manual.

2. Pump’s internal parts are 2) Replace damaged parts. 2) Check filter and drain oil.
seized or broken.
3. Attached pump is out of order. 3) Replace damaged parts. 3) Remove attached pump and check
shaft joint.
4. Attached valve is out of order. 4) Check attached valve. 4) Refer to Manual for Attached
Particularly poppet, Valve.
seat and spring.
5. Regulator is piped incorrectly. 5) Pipe correctly.

(3) Abnormal Sound and Vibration

Cause Remedy Remark

1. Cavitation 1) Prevent cavitation. 1-1) The boost pressure is low.
Check that hydraulic oil 1-2) The attached pump is in trouble.
is not clouded. 1-3) The suction pipe is inhaling air.
1-4) The suction resistance is high.
2. Caulked part of shoe is broken. 2) Replace piston shoe and 2) Check filter and drain oil.
shoe plate.
3. Cylinder is cracked 3) Replace cylinder.

4. Pump is installed improperly. 4) Correct installation.

5. Regulator is hunting. 5) Repair regulator, 5) See Regulator Manual.

6. Relief valve in attached valve 6) Repair attached valve. 6) See the Manual for Attached
is hunting. Valve.

Ⅱ－1－14
1.2 REGULATOR Table 1-4
626 627 732
1.2.1 STRUCTURAL EXPLODED VIEW COMPENSATING TIGHTENING TIGHTENING
PISTON SECTION TORQUE No. NAME Q’TY TORQUE No. NAME Q’TY
625
kgfym (ftylbs) kgfym (ftylbs)
624
3.0 (22) 412 SOCKET BOLT: M8×50 2 614 FULCRUM PLUG 1
3.0 (22) 413 SOCKET BOLT: M8×70 2 615 ADJUST PLUG 1
418 SOCKET BOLT: M5×12 2 621 COMPENSATING PISTON 1
436 SOCKET BOLT: M6×50 5 622 PISTON CASE 1
1.2 (8.7) 438 SOCKET BOLT: M6×20 4 623 COMPENSATING ROD 1
623
612 1.2 (8.7) 439 SOCKET BOLT: M6×40 4 624 SPRING SEAT 1
621 611 728 3.7 (27) 466 VP PLUG: PF1/4 3 625 OUTER SPRING 1
874 645
897 PILOT PISTON 7.5 (54) 467 PLUG ; PF3/8×M8 1 626 INNER SPRING 1
622 613 SECTION 0.9 (6.5) 496 PLUG 18 627 ADJUST STEM C 1
733 875
875 646 541 SEAT 2 628 ADJUST SCREW C 1
732
631 644 543 STOPPER 1 2 629 COVER (C) 1
898 652
545 STEEL BALL 2 16 (120) 630 LOCK NUT: M30 1
651 601 CASING 1 631 SLEEVE 1
836 611 FEEDBACK LEVER 1 641 PILOT COVER 1
655 612 LEVER (1) 1 642 ROD 1
654
653 613 LEVER (2) 1 643 PILOT PISTON 1
814 643 644 SPRING 1
438 645 ADJUST STEM 1
630
629 646 PILOT SPRING 1
924 651 SLEEVE 1
801 652 SPOOL 1
763 653 SPRING 1
801
466 925 654 RETURN SPRING 1
656
755 655 SET SPRING 1
628
439 656 PORT PLATE 1
756
708 O RING : 1B G75 1
722 O RING : 1B P6 2
413 412 724 O RING : 1B P8 12
722
496 725 O RING : 1B P10 1
755
727 O RING : 1B P14 1
722
079 728 O RING : 1B P18 1
418 496 730 O RING : 1B P22 1
732 O RING : 1B P16 2
733 O RING : 1B P20 2
755 601
541 734 O RING : 1B P25 1
496 875
545 734 753 O RING : 1B G9 1
543 755 O RING : 1B P11 6
496 756 O RING : 1B P26 2
614
755 755 763 O RING : 1B G35 1
543 858 1.6 (12) 801 HEX NUT : M8 3
466 545 814 SNAP RING 1
541
755 496 875 836 SNAP RING 1
724 735
496 725 887 466 615 858 LOCKING RING 2
730 755
733 724 708 858 874 PIN 1
875 PIN 4
496 887 PIN 1
897 PIN 1
436 641 898 PIN 1
924 SOCKET BOLT: M8×20 1
925 ADJUST SCREW 1
642 079 SOLENOID PROPORTIONAL 2
REDUCING VALVE
753
727 The codes in a rectangle represent adjust screws.
467 801
Fig. 1-31 Structural exploded view of regulator Do not tamper with the adjust screws as much as possible.
Ⅱ－1－15,16
NOTES NOTES
1.2.2 DISASSEMBLY AND ASSEMBLY
(1) Tools Table 1-4
The right list shows the tools required for
Tool name Dimension
remove and install.
Allen wrench Opposing flats 4,5,6mm
Socket wrench,
Wrench with double
heads (single head)

Adjust wrench Small size (MAX. 36mm)

Screw driver

Plastic hammer

Torque wrench

Plier For snap ring 2pcs.

Dia. less than 4mm
Steel bar ＝100mm (4˝ )
(2) Disassembling procedure
1) Selecting a place for disassembly. Pincers

z Choose a clean place. Bolt M4 About ＝50mm (2˝ )

z Spread rubber sheet or cloth on work SOLENOID
bench to protect parts from PORT PLATE PROPORTIONAL
damaging. (656) VALVE (079)
413
412
2) Cleaning COVER
Remove dust and rust, etc. on regulator (629)
surface with wash oil.
439 438
3) Remove regulator (See Fig.1-32)
Remove socket bolts (412, 413) and separate
the regulator from the pump body.
: 6mm PILOT COVER CASING (601)
(641)
4) Remove port plate (See Fig.1-32) Fig. 1-32 Removing regulator
Remove socket bolt (439) and separate the
port plate (656).
: 6mm

5) Remove cover
Remove socket bolts (438) and remove cover
(629).
624,625,626
: 5mm
627
z The cover is equipped with adjust 801
screws (628, 925), adjust stem (627), 629(628,925)
lock nut (630), hex nut (801) and set
screw (924). Do not loosen those
screws and nuts. If they are 630 924
loosened, preadjusted set pressure Fig. 1-33 Removing cover (629)
and flow values change.

Ⅱ－1－17
6) Remove compensating parts 645
Ⅴ section)
(Fig. 1-31 ◯ 644,646
After removing the cover (629) sub assy, take
out outer spring (625), inner spring (626) and
spring seat (624) from the compensating part. 629
Then take out adjust stem (645), pilot spring
(646) and spring seat (644) from the pilot
part.

z Adjust stem (645) comes out easily if

an M4 bolt is used.
Fig. 1-34 Removing compensating parts

7) Remove pilot cover and the set spring 641

Remove capscrew (436) and pilot cover (641). 655
Once the pilot cover comes off, separate set
spring (655) from the pilot section.
Ⅰ section)
(Fig. 1-31 ◯

: 5mm

436
Fig. 1-35 Removing pilot cover (641)
and set spring (655)

8) Remove spring seat, return spring and sleeve

Ⅰ section)
(Fig. 1-31 ◯ 814(653)
Remove snap ring (814). Then remove spring
seat (653), return spring (654) and sleeve
(651). 654,
651(836)
z Sleeve (651) is equipped with snap
ring (836).
z When removing snap ring (814),
return spring (654) comes out : Use
care so as not to lose it. Fig. 1-36 Removing spring seat (653),
return spring (654) and sleeve (651)

858
9) Remove adjust plug (Fig. 1-31 ◯G ,◯
B section)
Remove snap ring (858) and take out fulcrum
plug (614) and adjust plug (615).
615

z Fulcrum plug (614) and adjust plug 614

(615) come off easily if an M6 bolt is
used.

Fig. 1-37 Removing adjust plug (615) [1]

Ⅱ－1－18
 614

Fig. 1-38 Removing adjust plug (614) [2]

10) Remove lever
Remove lever (613).
Do not draw out pin (875).

z The work is eased if pincers are

used.

613(875)

Fig. 1-39 Removing lever (613)

11) Remove feedback lever

Draw out pin (874) and remove feedback
874
lever (611).

z Push out pin (874) [pin dia : ∅4mm

(0.157in)] from above with a slender
steel rod so as not to interfere with 611
lever (612).

Fig. 1-40 Removing feedback lever (611) [1]

611
Fig. 1-41 Removing feedback lever (611) [2]

Ⅱ－1－19
12) Remove lever (Fig. 1-31 ◯
B section)
Remove lever (612).
Do not draw out pin (875).

13) Remove pilot piston and spool

Ⅲ ,◯
(Fig. 1-31 ◯ Ⅰ section)
Draw out pilot piston (643) and spool (652).

14) Remove piston casing, compensating piston

Ⅱ section)
and compensating rod (Fig. 1-31 ◯
Draw out piston casing (622), compensating
piston (621) and compensating rod (623). This
completes disassembly of the regulator.

z Piston casing (622) comes out from

the opposite side of the piston casing if
compensating rod (623) is pushed out.

(3) Installing procedure :

Assembly is the reverse order of disassembly.
Do the work paying attention to the following
:
1. Repair those parts that were damaged during
disassembly and prepare replacement parts
beforehand.
2. If foreign matter enters, it causes
malfunction; clean parts thoroughly in
cleaning oil, blow them with jet air and
assemble parts in a clean place.
3. Always tighten bolts and plugs to specified
torque.
4. Do not fail to coat the moving parts with
clean hydraulic oil, before assembly.
5. In principle, replace seals such as O ring.

1) Installing compensating rod

Ⅱ section)
(Fig. 1-31 ◯
Assemble compensating rod (623) into the
compensating hole of casing (601).

2) Assembling lever
Put the pin pressed in lever (612) into the
groove of the compensating rod. Then
assemble the lever to the pin that is pressed
in the casing.

Ⅱ－1－20
3) Assembling spool and sleeve
(Fig. 1-31 ◯
Ⅰ section)
Assemble spool (652) and sleeve (651) into the
spool hole of the casing.

z Make sure that the spool and the

sleeve move smoothly in the casing.
SPOOL (652) FEEDBACK LEVER (611)
z Beware of the direction of the spool.
Fig. 1-42 Direction of spool (652)
4) Assembling feedback lever
Assemble feedback lever (611). Then put pin
(874) into the pin hole of the feedback lever.
LEVER 1 LEVER 2 (613) SIDE
z The work is eased if the pin is put in (612) SIDE (FULCRUM PLUG AND
the feedback lever a little, ADJUST PLUG SIDES)
beforehand.
z Take care so as not to mistake the
direction of the feedback lever.
Fig. 1-43 Assembling feedback lever (611)
5) Assembling pilot piston (Fig. 1-31 ◯ Ⅲ
section)
Assemble pilot piston (643) into the negative
control hole of the casing.

z Make sure that the pilot piston

moves smoothly.

6) Assembling lever
Place pin (875) pressed in lever 2 (613) into
the groove of the pilot piston and assemble
lever 2 (613).

613 (875)

Fig. 1-44 Assembling lever 2 (613)

7) Installing fulcrum plug (Fig. 1-31 ◯ B

section)
Assemble fulcrum plug (614) so pin (875)
pressed in the fulcrum comes in the pin hole 614 (875,858)
of lever 2 (613). Then fit snap ring (858).

Fig. 1-45 Installing fulcrum plug (614)

Ⅱ－1－21
8) Installing adjust plug (Fig. 1-31 ◯
G section) 652
Insert adjust plug (615) and fit a snap ring
814
(858).
653
z Use care so as not to mistake the
654
holes into which the fulcrum and
adjust plug are inserted.
z At this point, operate the feedback
lever and make sure that the gap is
not large and that the lever moves
smoothly.
Fig. 1-46 Installing return spring (654)
and spring seat (653)
9) Installing return spring and the spring seat
(Fig. 1-31 ◯Ⅰ section)
Assemble return spring (654) and spring seat
(653) into the spool hole and fit snap ring
(814).

10) Assembling compensating parts

(Fig. 1-31 ◯Ⅰ, ◯Ⅱ section)
Assemble set spring (655) into the spool hole.
Place compensating piston (621) and piston 622(621)
casing (622) into the compensating hole and Fig. 1-47 Assembling compensating parts
attach pilot cover (641). Then fasten them
together with socket bolts (436). 644,645,646
626
: 5mm,
Tightening torque : 1.2kgfym (8.7 lbfyft)
625
11) Assembling into the pilot hole and the
compensating hole (Fig. 1-31 ◯Ⅴ, ◯ Ⅳ section)
Put spring seat (644), pilot spring (646) and
adjust stem (645) into the pilot hole. Then
assemble spring seat (624), inner spring (626)
and outer spring (625) into the compensating Fig. 1-48 Assembling into the pilot hole
hole. and compensating hole

z Do not mistake the direction of the

spring seat.

12) Installing cover

Attach cover (C) (629) fitted with adjust
624,625,626
screws (628), (925), adjust stem (627), lock
nut (630), nut (801) and socket bolt (924). 627
Then fasten them with socket bolts (438). 801
: 5mm, 629 (628,925)
Tightening torque : 1.2kgfym (8.7 lbfyft)

This completes assembly. 630 924

Fig. 1-49 Installing cover (629)

Ⅱ－1－22
(6) Assembling boom spool (7) Assembling boom conflux spool
(See YN24,Ⅰ－4－5, Fig.4-5) 1) Fix spring cover (201) in a vise, put O ring
1) Assemble plunger 1 (B315), plunger 2 (B316), (166) in plug (555) and fasten it to the
plunger 3 (B317), spring B1 (B320), spring B2 specified torque.
(B330) and spring B3 (B340) in boom spool : 27mm,
(301). Then tighten plugs (B352), (B353) to Tightening torque :
the specified torque. 7～8kgfym (51～58ftylbs)
: 24mm,
Tightening torque : 2) Put a protective plate (aluminum plate, etc.)
6～7kgfym (43～51ftylbs) and hold the middle of boom conflux spool
(305) in the vise. Set spring seat (331),
Use care so parts are assembled in springs (321), (325) and stopper (339) and
correct positions and make sure that tighten bolts (333) to the specified torque.
each plunger slides lightly in boom : 10mm,
spool (301). Tightening torque :
1.6～1.8kgfym (12～13ftylbs)
2) Put a protective plate (aluminum plate, etc.)
in a vise and hold the middle of boom spool z When tightening bolts (333), coat
(301) in the vise. Set spring seat (331), them with Locktite #262.
springs (321), (322) and stopper (336) and z Use care so as not to distort boom
tighten bolts (333) to the specified torque. conflux spool (305) by overtightening
: 10mm, it in the vise.
Tightening torque :
1.6～1.8kgfym (12～13ftylbs) 3) Fix the boom conflux spool assy in par. 2) into
casing A (101).
z When tightening bolts (333), coat
them with Locktite #262. When assembling the boom conflux
z Be careful so as not to distort boom spool assy into casing A (101), do it
spool (301) by overtightening it in slowly and carefully, never force it in.
the vise.
z Note that bolts (333) differ from 4) Fit O ring (261) to the spring side of the boom
other bolt (334). conflux spool assy and attach spring cover
(201) to the assy. Then tighten socket bolts
3) Install the boom spool assembly reassembled (273) to the specified torque.
in par. 2) above in casing B (102). : 6mm,
Tightening torque :
When assembling the boom spool assy 2.5～3.5kgfym (18～25ftylbs)
into casing B (102), do it slowly and
carefully, never force it in.

4) Attach O rings (261) to the spring side of the

boom spool assy. Then fit spring cover (201)
to the assy and tighten socket bolts (273) to
the specified torque.
: 6mm,
Tightening torque :
2.5～3.5kgfym (18～25ftylbs)

Ⅱ－2－21
(8) Assembling bucket spool 2) Assemble the swing spool assy in par. 1) into
1) Put a protective plate (aluminum plate, etc.) casing A (101).
to the vise and hold the middle of bucket
spool (304) in it. Set spring seat (331), spring When assembling the swing spool assy
(321), (322) and stopper (336) and tighten into casing A (101), do it slowly and
bolts (333) to the specified torque. carefully, never force it in.
: 10mm,
Tightening torque : 3) Put O ring (261) to the spring side of the
1.6～1.8kgfym (12～13ftylbs) swing spool assy and attach spring cover
(201) to the assy. Then tighten socket bolts
z When tightening bolts (333), coat (273) to the specified torque.
them with Locktite #262. : 6mm,
z Be careful so as not to distort bucket Tightening torque :
spool (304) by overtightening it in 2.5～3.5kgfym (18～25ftylbs)
the vise.
(10) Assembling travel spool
2) Assemble the bucket spool assy in par. 1) into 1) Put a protective plate (aluminum plate, etc.)
casing B (102). in the vise and hold the middle of travel spool
(306) in it. Set spring seat (332), springs
When assembling the bucket spool assy (325), (327) and stopper (338) and tighten
into casing B (102), do it carefully and bolts (334) to the specified torque.
slowly, never force it in. : 10mm,
Tightening torque :
3) Fit O ring (261) to the spring side of the 1.6～1.8kgfym (12～13ftylbs)
bucket spool assy and attach spring cover
(201) to the assy. Then tighten socket bolts z When tightening bolts (334), coat
(273) to the specified torque. them with Locktite #262.
: 6mm, z Be careful so as not to distort travel
Tightening torque : spool (306) by overtightening it in
2.5～3.5kgfym (18～25ftylbs) the vise.

(9) Assembling swing spool 2) Assemble the travel spool assy in par. 1) into
1) Put a protective plate (aluminum plate, etc.) casing A (101), B (102).
to the vise and hold the middle of swing spool
(303). Set spring seat (331), springs (321), When assembling the travel spool assy
(322) and stopper (336) and tighten bolts into casings A (101), B (102), do it
(333) to the specified torque. slowly and carefully, never force it in.
: 10mm,
Tightening torque : 3) Fit O ring (262) to the spring side of the
1.6～1.8kgfym (12～13ftylbs) travel spool assy. Then attach spring cover
(203) to the assy and tighten socket bolts
z When tightening bolts (333), coat (273) to the specified torque.
them with Locktite #262. : 6mm,
z Be careful so as not to distort swing Tightening torque :
spool (303) by overtightening it in 2.5～3.5kgfym (18～25ftylbs)
the vise.

Ⅱ－2－22
(11) Assembling travel straight spool 3) Fit O ring (264) to the spool cover (205) in
1) Put a protective plate (aluminum plate, etc.) par. 1) to the assy and tighten socket bolts
in the vise and hold the center of travel (273) to the specified torque.
straight spool (307) in it. Set spring seat : 6mm,
(332), springs (325), (328) and stopper (337) Tightening torque :
and tighten bolts (334) to the specified 2.5
3.5kgfym (18
25ftylbs)
torque.
: 10mm,
Tightening torque :
1.6
1.8kgfym (12
13ftylbs)

z When tightening bolts (334), coat

them with Locktite #262.
z Be careful so as not to distort travel
straight spool (307) by over-
tightening it in the vise.

2) Assemble the travel straight spool assy in

par. 1) into casing B (102).

When assembling the travel straight

spool assy into casings B (102), do it
slowly and carefully, never force it in.

3) Fit O ring (262) to the spring side of the

travel straight spool assy. Then attach spring
cover (203) to the assy and tighten socket
bolts (273) to the specified torque.
: 6mm,
Tightening torque :
2.5
3.5kgfym (18
25ftylbs)

(12) Assembling rod spool

1) Fix spool cover (205) in a vise, put O ring
(166) in plug (156) and fasten it to a specified
torque.
: 8mm,
Tightening torque :
7
8kgfym (51
58ftylbs)

2) Assemble the rod spool (311) into casing B

(102).

When assembling the rod spool (311)

into casing B (102), do it slowly and
carefully ; never force it in.

223
(13) Assembling spool covers (15) Assembling overload relief valve
1) Arm, boom, bucket, swing, travel (right, left) (See YN24,Ⅰ－4－5, Fig.4-4)
and travel straight 1) Assemble spring seat (612) with poppet (611),
Fit O ring (264) to spool cover (205) and spring (621) and O ring (661), into plug (102)
tighten socket bolts (273) to the specified that is fitted with O rings (162), (561) and
torque. backup ring (562). Then temporarily
: 6mm, assemble adjust screw (651) and locknut
Tightening torque : (671).
2.5～3.5kgfym (18～25ftylbs)
Make certain that poppet (611) is
(14) Assembling main relief valve snugly fitted in the seat of plug (102).
(See YN24,Ⅰ－4－5, Fig.4-3)
1) Fit spacer (122), C ring (121), O rings (163), 2) Fit O ring (563) and backup ring (564) to seat
(561) and backup ring (562). (541) and attach the seat to plunger (511) and
2) Fit piston (614) and O ring (661) to adjust assemble piston (301) and springs (521),
screw (104). Then fix stopper (613) to the (522).
adjust screw and temporarily assemble it
with adjust screw (652) and locknut (671). 3) Assemble the seat (541) assy in par. 2) into
3) Fix poppet (611) and spring (621) to plug body (101) and tighten the plug (102) assy in
(103) in par. 1) above. Then fix O rings (663), par. 1) to the specified torque.
(664) in par. 2) fitted with adjust screw (104). : 30mm,
Tightening torque :
Make sure that poppet (611) is snugly 7～8kgfym (51～58ftylbs)
placed in the seat of plug (103).
Confirm that springs (521), (522) are
4) Assemble plunger (512) and spring (521) into guided properly.
seat (541).
4) Pressure adjustment is performed in
5) Assemble the seat in par. 4) to the plug (103) accordance with “Maintenance Standard and
assy under par. 3) and fix it with C ring Test Procedure” and adjust screw (651) is left
(121). temporarily assembled.

6) Pressure adjustment is performed in

accordance with “Maintenance Standard and
Test Procedure”. Leave adjust screws (104),
(652) temporarily assembled.

Ⅱ－2－24
(16) Assembling option valve VBY-147 (OPT1) 7) Install overload relief valve (P603) to casing
and VBY-148 (OPT2). (P101) and fasten it to the specified torque.
(See See YN24,Ⅰ－4－6, Fig.4-6) : 32mm,
1) Tighten plug (P552) with O ring (P562) to Tightening torque :
casing (P101) and fasten it to the specified 7～8kgfym (51～58ftylbs)
torque.
: 10mm, Note that the tightening torque differs
Tightening torque : for VBY-147 and VBY-148.
11～13kgfym (80～94ftylbs)
(17) Assembling negative control relief valve VBY-
2) Assemble poppet (P512) and spring (P522) to 145, 146
casing (P101) and fasten plug (P551) with O (See See YN24,Ⅰ－4－7, Fig. 4-8, 4-9)
ring (P561) to the specified torque. 1) Assemble negative control relief valve sub
: 12mm, into casing (N101).
Tightening torque :
32～36kgfym (230～260ftylbs) 2) Fit O ring (N561) to plug (N551) and tighten
the plug against casing (N101) to the
3) Put a protective plate (aluminum plate, etc.) specified torque.
in the vise and hold the middle of option spool : 6mm,
(P301) in it. Set spring seat (P337), springs Tightening torque :
(P323), (P324) and stopper (P333) and tighten 2.3～2.7kgfym (17～20ftylbs)
bolts (P334) to the specified torque.
: 10mm,
Tightening torque :
1.6～1.8kgfym (12～13ftylbs)

z When tightening bolts (P334), coat

them with Locktite #262.
z Be careful so as not to distort option
spool (P301) by overtightening it in
the vise.

4) Assemble the option spool assy in par. 3) into

casing (P101).

5) Put O ring (P261) to the spring side of the

option spool assy, attach spring cover (P202)
to the assy and tighten socket bolts (P271) to
the specified torque.
: 6mm,
Tightening torque :
2.5～3.5kgfym (18～325ftylbs)

6) Install spool cover (P204) with O ring (P262)

and fasten socket bolt (P271) to the specified
torque.

Ⅱ－2－25
2.4 MAINTENANCE STANDARDS
(1) Inspection of components

Part name Inspection item Criterion and remedy

Casing 1) Look for scratches, rusting and 1) If any of the following parts are
corrosion. damaged, replace the casing.
z Sliding part of casing hole and spool,
particularly the land, to which holding
pressure is applied.
z Part of sealing pocket through which
spool is inserted.
z Area of sealing part that is in contact
with O ring.
z Sealing and seating part of main or
overload relief valve.
z Defects of other parts that seem to
prevent normal function.
Spool 1) Look for scratches, galling, rusting 1) If a defect detectable with your
and corrosion. fingernail is found on the sliding part of
the outer circumference, replace the
spool.
2) Inspect ends that are sealed with an 2) If the sliding part is damaged, replace
O ring. the spool.
3) Insert the spool in the casing bore, 3) If the spool damages the O ring or does
and move it while turning it. not move smoothly, repair or replace
the spool.
Poppet 1) Look for damage on the poppet and 1) If sealing is incomplete, correct or
the spring. replace the seal.
2) Insert the poppet in the casing, and 2) If the poppet moves lightly without
move it. catching, it is normal.
Spring and 1) Look for rust, corrosion, deformation, 1) If damaged heavily, replace.
related parts and breakage of the spring, spring
seat, plug and cover.
Spool seal and 1) Look for external oil leak. 1) Repair or replace.
related parts 2) Look for rust, corrosion and deformation 2) Repair or replace.
of sealing plate.
Main relief valve 1) Look for rust and damage on outer 1) Replace.
Port relief valve surface.
2) Inspect the contact face of the valve 2) If damaged, replace.
seat.
3) Inspect the contact face of the poppet. 3) If damaged, replace.
4) Look for spring abnormality. 4) Replace.
5) Inspect the O ring, backup ring, and 5) As a general rule, replace all parts with
seal. new ones.
Lock valve 1) Spool, bushing and spring are not 1) If damaged, replace.
(selector portion) damaged.
2) Spool seat shows even contact marks. 2) If damaged, replace.

Ⅱ－2－26
2.5 TROUBLESHOOTING
1) If an abnormal condition is noticed, check to 3) Moving parts must be handled with care. If
see if the problem is with the control valve they are damaged, smooth the damage using
itself, one of the main pumps, the gear pump, an oil stone or the like.
or a circuit. To this end, you will need to 4) Take care not to damage the contact face of
measure pilot pressure, pump delivery O rings. A damaged contact face will
pressure, load pressure, etc. If any part of the certainly cause oil leaks.
system is to be disassembled for inspection,
follow the disassembly and reassembly
procedures in this manual.
2) Dust is the enemy of hydraulic components.
Pay strict attention to protection from dust.
If any part of the system is to be
disassembled, take dust protection measures
beforehand.

(1) Control valve

Trouble Cause Remedy

1. Travel does not 1) Malfunctioning main relief valve. 1) Measure travel relief valve pressure
occur. z Foreign matter between main z Disassemble and clean. If damaged
Slow to start up poppet and seat. heavily, replace the assy as a unit.
(or poor power). z Foreign matter between poppet z Same as above.
Slow response. and seat.
z Sticking main poppet. z Smooth sticking part with oil stone.
z Broken or deformed spring. z Replace spring.
z Clogged main poppet throttle. z Remove foreign matter.
z Loosened adjusting screw. z Readjust, and tighten lock nut to
specified torque.
2. Machine does not 1) Malfunctioning travel straight 1) Measure pilot pressure.
move straight valve.
during simultane- z Sticking spool. z Smooth sticking part with oil stone.
ous travel and z Broken or deformed spring. z Replace spring.
operate z Clogged small hole in spool. z Remove foreign matter.
attachment. 2) Malfunctioning right or left 2) Measure pilot pressure.
neutral cut valve.
z Sticking spool. z Smooth sticking part with oil stone.
z Broken or deformed spring. z Replace spring.
z Excessive clearance between right z Replace spool.
or left casing and spool.
z Clogged small hole in spool. z Remove foreign matter.

3) Malfunctioning main relief valve. 3) Replace main relief valve.

See item 1. 1) above.

Ⅱ－2－27
 Trouble Cause Remedy
3. Excessive natural 1) Excessive clearance between 1) Replace spool.
falls of attachment casing and spool.
under its own
2) Spool is not completely in 2) Measure secondary pilot pressure.
weight when spool
neutral position.
is in neutral.
z Foreign matter between casing z Disassemble, clean and smooth sticking
and spool, or sticking spool. part with oil stone.
z Broken or deformed spring. z Replace spring.
z Clogged pilot circuit. z Remove foreign matter.

3) Malfunctioning overload relief 3) Measure overload relief valve pressure.

valve. Refer to item 1. 1) above. Refer to item 1. 1) above.
4) Malfunctioning anti-cavitation 4) Checking the overload relief valve
check valve.
z Foreign matter between poppet z Disassemble and clean.
and casing.
z Broken or deformed spring. z Replace spring.

5) Lock valve function is faulty. 5)

z Foreign matter between poppet z Disassemble and clean. In case
and casing. scratches are excessive, replace casing.
z Poppet is stuck. z Correct stuck part with oil stone.
z Broken or deformed spring. z Replace spring.
z Selector spool is stuck. z Replace lock valve selector sub assy.
z Dirt is included between selector z Replace lock valve selector sub assy.
spool and bushing.
z O ring in bushing is worn out. z Replace lock valve selector sub assy.
4. When raising 1) Malfunctioning load check valve. 1)
attachment, at z Foreign matter between poppet z Disassemble and clean. If heavily
first it drops. and casing. damaged, replace control valve.
z Sticking poppet. z Smooth sticking part with oil stone.
z Broken or deformed spring. z Replace spring.

5. Bucket, boom, arm 1) Malfunctioning main spool. 1) Measure secondary pilot pressure.
or swing does not z Excessive clearance between z Replace spool.
operate. casing and spool.
z Foreign matter between casing z Disassemble and clean.
Slow to start up
and spool.
(or poor power).
z Sticking spool. z Smooth stuck part with oil stone.
Slow response. z Broken or deformed return z Replace spring.
spring.
z Clogged pilot circuit. z Remove foreign matter.

2) Malfunctioning main relief 2) Measure main relief valve pressure.

valve. Refer to item 1. 1) above. Refer to item 1. 1) above.
3) Malfunctioning overload relief 3) Measure overload relief valve pressure.
valve. Refer to item 1. 1) above. Refer to item 1. 1) above.
4) Malfunctioning pilot valve. 4) Refer to Pilot valve section.
Refer to Pilot valve section.

Ⅱ－2－28
 Trouble Cause Remedy
6. Swing priority 1) Operating fault of arm recirculation 1) The same way as 5-1).
function does not spool [the same way as 5-1) below].
operate.

7. Boom or arm 1) Malfunctioning conflux valve. 1) Measure pilot pressure.

conflux does not Refer to item 5.1) above. Refer to item 5.1) above.
operate.

(2) Relief valve

Trouble Cause Remedy

1. No pressure rise. Main or pilot poppet of relief valve is z Check for foreign matter on each
sticking and valve is open, or there is poppet.
foreign matter on valve seat. z Confirm that each component slides
smoothly.
z Clean all components thoroughly.
2. Unstable relief Damaged pilot poppet seat of relief z Replace damaged component.
pressure. valve. Pilot piston sticks against main z Clean all components thoroughly.
poppet. z Smooth surface damage.

3. Irregular relief 1) Wear due to foreign matter. 1) Disassemble and clean.

pressure.
2) Loosened locknut or adjusting 2) Adjust pressure.
screw.
4. Oil leak. 1) Damaged seat. 1) Replace damaged or worn
Damaged O ring. component. Confirm that each
component operates smoothly before
reassembling.
2) Sticking component due to foreign 2) Confirm that there are no scratches,
matter. scores, or foreign matter present
before reassembling.

Ⅱ－2－29
NOTES
 3. PILOT VALVE (FOR ATT)
3.1 INSTALLATION VIEW
(1) Cross-sectional view

312
501
302
Apply grease
on rotating and
sliding sections.
213 301 Be careful the
assembling
direction.
151 212

Apply
246 grease on
218－2 top section.
211

214
218－1

216－2 216－1

241－1
241－2

201－2 201－1

011－1
011－2
131
217 122
Secondary
pressure 101
adjusting shim 121 Not to be
target value at 126
PORT 2,4 PORT 1,3 125 reused.
center
t=0.4 (0.016˝ ), 111
1 piece Fig. 3-1 Pilot valve (for ATT)

☆ Apply Locktite #277

TIGHTENING TIGHTENING
TORQUE TORQUE
No. NAME Q’TY No. NAME Q’TY
kgfym (ftylbs) kgfym (ftylbs)
101 CASING 1 216－1 SPRING SEAT 1 2
111 PORT PLATE 1 216－2 SPRING SEAT 1 2
121 SEAL WASHER 2 217 WASHER 2(SHIM) 4
122 O RING 1 218－1 SPRING SEAT 2 2
2.1 (15) 125 SOCKET BOLT ; M8×35 2 218－2 SPRING SEAT 2 2
126 SPRING PIN 1 011－1 SPRING 2
131 BUSHING 1 011－2 SPRING 2
151 PLATE 1 241－1 SPRING 2
201－1 SPOOL 2 241－2 SPRING 2
201－2 SPOOL 2 246 SPRING 4
211 PLUG 4 4.8 (35) 301 JOINT ;M14 1
212 PUSH ROD 4 302 CIRCULAR PLATE 1
213 SEAL 4 7 (51)☆ 312 ADJUSTING NUT ; M14 1
214 O RING ; 1B P20 4 501 BOOTS 1

Ⅱ－3－1
(2) Explosion view

011－1
011－2
312

241－1
241－2
217
501 217

201－1
302 201－2

301 101

151

213

213 211 122

131
211
214
126
214
212
212
246 111
246 218－1
218－2
216－1 121
216－2 121
125
125

Fig. 3-2 Pilot valve (for ATT)

Ⅱ－3－2
3.2 DISASSEMBLY
(1) Plug each port of pilot valve, and clean it.
P port : PF1/4
1～4 and T port : PF3/8

(2) Fix pilot valve with vise, and remove boots

(501).

(3) Remove adjusting nut (312) applying

spanners to adjusting nut (312) and circular 312
plate (302).
: 22mm,32mm
302

(4) Remove circular plate (302)

: 32mm

Fig. 3-3 Removing adjusting nut (312)

(5) Turn joint (301) in counterclockwise with Jig A

to remove.
JIG
Jig A : Refer to 3.7 Detail of jig on page
Ⅱ－3－10. 301
: 24mm

When the force of return springs (011-1),

(011-2) is high, 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.

Fig. 3-4 Removing joint (301)

151
(6) Remove plate (151)

z
When the force of return s
pring
(011-1), (011-2) is high, press plate to
let it come up slowly.

Fig. 3-5 Removing plate (151)

Ⅱ－3－3
 z When the force of return springs
(011-1), (011-2) is low, plug is left in
casing (101) due to sliding resistance
of O ring (214).
211

101

Fig. 3-6 Removing plate (151)

Pull plug (211) out with a driver (－).

211
Fig. 3-7 Removing plug (211)
(7) Remove push rod (212), plug (211), pressure
reducing valve assy (spool), return springs 212
(011-1), (011-2) from casing (101).

Record combination of port holes on casing 211

and the pulled out parts. The stroke differs
according to direction. 011－1
or 011－2
101

Fig. 3-8 Removing push rod, plug, pressure

reducing valve and spring
(8) Reverse it to direct port plate (111) upward,
and fix it with vise.

(9) Remove socket bolt (125).

111
: 6mm

125

Fig. 3-9 Removing socket bolt (125)

Ⅱ－3－4
(10) Remove port plate (111), O ring (122) from 126 SPRING
casing (101).
111
(11) Remove bushing (131) from casing (101).
131

122

101

Fig. 3-10 Removing port plate, bushing

(12) Push springs (241-1), (241-2) in the range of
216－1
that the movement of spring seats (216-1), or 216－2
(216-2) is 7mm (0.276in) or less, and remove
spools (201-1), (201-2) through the large hole
of seat.

Never push spring seat (216-1) in 7mm

(0.276in) or more. (For ports 1,3)
Never push spring seat (216-2) in 9.4mm 201－1
or 201－2
(0.370in) or more. (For ports 2,4)
Fig. 3-11 Removing spool (201)

(13) Remove spool (201-1), (201-2), spring seats

216－1
(216-1), (216-2), spring (241-1), (241-2) and or 216－2
washer (217).
201－1 241－1
or 217 or
201－2 241－2

Fig. 3-12 Disassembling pressure reducing valve

218－1
(14) Remove spring (246), spring seat (218-1), or 218－2 214
(218-2) from push rod (212).
246
(15) Pull out push rod (212) from plug (211).

(16) Remove O ring (214) from plug (211).

211 212

Fig. 3-13 Disassembling push rod

Ⅱ－3－5
(17) Remove inside seal (213) from plug (211) with
small driver.

213
Fig. 3-14 Removing seal (213)
3.3 CLEANING PARTS
(1) Clean parts with wash oil roughly.

(2) Clean parts with wash oil completely.

(3) Dry parts by swabbing clean waste cloth.

(4) Apply rust preventives on parts.

3.4 ASSEMBLING
(1) Fit bushing (131) and O ring (122) to casing
(101). (See Fig.3-10.)

Meet the position of spring pin (126).

(2) Install port plate (111) on casing with socket

bolt (125) and seal washer (121).
: 6mm,
Tightening torque ; 2.1kgfym
(15ftylbs) 111
125
Replace seal washer (121) with new one.

121

Fig. 3-15 Installing port plate (111)

(3) Fit washer 2 (217), springs (241-1), (241-2), 201－1
spring seats (216-1), (216-2) to spool (201-1), or 201－2
(201-2). 241－1 216－1
or or
241－2 216－2
(4) Push spring seat (216-1) in the range of that
the movement is 7mm (0.276in) or less, and
install spools (201-1) through the large hole
of spring seat. (See Fig.3-11.)
For spring seat (216-2), push spring seat
(216-2) in 9.4mm (0.370in) or less and install
spool (201-2).
217
Fig. 3-16 Assembling pressure reducing valve

Ⅱ－3－6
(5) Place spring (011-1) into ports 1,3 of casing
(101), and then install pressure reducing PRESSURE REDUCING
valve assy in it. VALVE ASSY
Place spring (011-2) into ports 2,4 and install 011－1
it.
101
Install the removed respective assy into
respective holes.

Fig. 3-17 Installing pressure reducing valve assy

(6) Fit O ring (214) and seal (213) into plug 214 211 213
(211).

z Apply hydraulic oil on surface of

push rod. PLUG (211)
SEAL (213)

O RING (214)

PUSH ROD (212) Apply

hydraulic oil

For the assembling Fig. 3-17 Installing O ring (214) and seal (213)
direction of seal (213).

(7) Insert push rod (212) in plug (211) and install

spring seat (218-1) to push rod (212) on port
1,3 side.
And install spring seat (218-2) to push rod on
port 2,4 side.

212 211 246 218－1

Fig. 3-19 Assembling push rod, spring (246) and
seat (218)

(8) Fit plug (211) assy to casing (101).

1) When the force of spring (011) is low, it stops

at the position where it is pushed in by the
sliding resistance of O ring (214).

101 211
Fig. 3-20 Installing plug assy

Ⅱ－3－7
2) When the force of spring (011-1), (011-2) is
high, attach plate (151) and press 4 push rods
by hand at the same time, and tighten joint 301
(301) temporarily.

151

Fig. 3-21 Installing plug assy and plate (151)

(9) Install joint (301) on casing (101) with jig A
securely.
Jig A : Refer to 3.7 JIG on page Ⅱ－3－10.
Tightening torque : 4.8±0.3kgfym
(35±2.2ftylbs)
101 JIG A

Fig. 3-22 Installing joint (301)

(10) Install circular plate (302) to joint (301)

Screw it in until it comes in contact

with 312
4 push rods (212) equally.
The exceeding of screw in may cause 302
malfunction of machine.

(11) Screw adjusting nut (312) in until it touches

circular plate (302), and tighten it applying
spanner to stop circular plate returning.
: 32mm Fig. 3-23 Installing circular plate (302)
: 22mm
z Apply Locktite #277 to threads of
joint. GREASE
Tightening torque : 7±0.5kgfym
(51±3.6ftylbs)

(12) Apply heat-resisting grease to joint (301)

rotating section and the top of push rod (212). 301

(13) Cover it with boots.

212
(14) Spray rust preventives through each port and
attach plug respectively. Fig. 3-24 Applying grease to joint section and
push rod

Ⅱ－3－8
3.5 MAINTENANCE STANDARDS
Check items Standard Remarks
When leakage quantity reaches to Conditions
1000cc/min. or more where handle is set in Primary pressure 3.0kgf/cm2
neutral position, or to 2000cc/min. or more in (43psi)
Leakage
operation, replace spool with new one. Hydraulic oil viscosity 2.3 cSt
If leaked, even if the spool is replaced,
replace pilot valve assy with new one.
When the wear of sliding section is 10μ more This condition may be the same as the
Spool than the that of non sliding section, replace it above.
with new one.
Push rod When the wear of top is 1mm (0.04in) or more, replace it with new one.
When looseness of 2mm (0.08in) or more on In case of the looseness due to the
circular plate (302) on control section and loosening on tightening section, adjust
Looseness of
joint section (301) due to wear is produced, it.
control section
replace them with new ones.

When trouble such as noise, hunting, drop of

primary pressure, etc. has occurred in
Stability of operation, and it does not restore after taking
operation corrective action according to below
Troubleshooting, replace pilot valve assy with
new
Note 1) one.
O ring, etc. should be replaced with every disassembling.
Note 2) When socket bolt (125) has been loosened, don't fail to replace seal washer (121).

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.

Trouble Cause Remedy

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

Ⅱ－3－9
3.7 JIG
(1) Jig for removing and installing joint (301)

SECTION AA

BUSHING

①
Material ;
SCM415 ◯ N
Carburizing
and Quenching
②
Material ; S45C
A A

※① and ② are tight fitted.

Installing condition on joint

Sectional drawing of jig

Detail of bushing

Material ;
SCM415◯ N
Carburizing and Quenching
Q’ty ; 2

Ⅱ－3－10
 4. PILOT
↓ZVALVE (FOR TRAVEL) 33 2 36 33
4.1 CONSTRUCTION 13 12 28
(1) Sectional view 36 42
14
19
37 25
26
1,3 30
20
34 25
22 15
21 42
20
39 20
32 17
33 36 33
44,16 40
6 7 SECTION AA
18 8
24
25,42
41
27
4 10,11 35
9 31 5 29

4-M10
T=4.3±0.4 38
(31±2.9)

T=Tightening torque : kgfym (ftylbs)

24,41
VIEW Z SECTION BB
Fig.4-1 Sectional view of pilot valve (for travel)
☆Apply Locktite #262
TIGHTENING TIGHTENING
TORQUE NO. NAME Q’TY TORQUE NO. NAME Q’TY
kgfym (ftylbs) kgfym (ftylbs)
1 ORIFICE (SHIM) 4 22 SPRING 4
☆1.5 (11) 2 SEAT 2 1.0 (7.2) 24 PLUG ; PF1/8 3
3 ORIFICE (SHIM) 4 2.5 (18) 25 PLUG ; PF1/4 3
4 SPOOL 4 6.0 (43) 26 SOCKET BOLT ; M10×60 2
5 BODY 1 0.5 (3.6) 27 FLANGE BOLT 4
6 STOPPER 4 1.5 (11) 28 SET SCREW ; M8 4
7 SPRING 4 29 WASHER 4
8 SPRING 4 30 WASHER 2
9 NAME PLATE 1 31 RIVET 2
10 SHIM t=0.2 4 32 PIN ; ∅5 4
11 SHIM t=0.1 4 33 BALL 6
12 CAM 2 34 BALL 4
13 BOOTS 2 35 BALL 4
14 PIN 2 36 BALL 6
15 COVER 2 37 U PACKING 4
16 PISTON 4 38 O RING ; 1A P5 4
17 GUIDE 4 39 O RING ; 1A P24 4
18 SLEEVE 4 40 O RING ; 1A P26 4
19 HOLDER 4 41 O RING ; 1B P8 3
20 RING 12 42 O RING ; 1B P11 3
21 ORIFICE (SHIM) 4 44 PISTON ASSY 4

Ⅱ－4－1
(2) Explosion view

13

26
30

28

12 LIP DETAIL

37 14

15

6
27

18
36
DAMPER SECTION

19
8
1,3

10,11,29
REDUCING VALVE SECTION

16,44

20 21
4
34
22
20 7
20
39 40
17 32

38

24

41 5

Fig. 4-2 Explosion view of travel pilot valve

Ⅱ－4－2
1. Tools used 3. Disassembling the damper (See Fig.4-3.)
Tool name Use (1) Draw out piston assy (44) and guide (17) from
For fixing the valve cover (15).
Vise
body z The damper is drawn out easily if it is pushed
Small vise from the ball (36) side.
For disassembling the
(Place a copper plate on
reducing valve spool (2) Draw out four balls (36), holders (19) and
the mouthpiece.)
orifices (1), (3) from piston assy (44).
Allen wrench 3, 4, 5, 6, 8mm
z On that occasion, align the hole in the cover,
Scriber the piston assy and the guide as a set as each
For disassembling the
(or a sharp point rod of
U-packing part is shop fitted. Therefore, if parts for
the same shape)
Allen wrench for torque different locations are assembled, functional
3, 4, 5, 6, 8mm
wrench faults may occur in some cases.
Torque wrench z Ring (20), orifice (21), spring (22) and ball
For picking up ball (36) (34) can not be separated from the piston
Magnet bar assy as they are assembled with ring (20)
and holder (19)
press fitted.
z Disassembly and assembly procedures
It is usual that disassembly and assembly are
executed at the maker’s factory, but in
unusual cases, do the work at a service shop
where skilled technicians are available.
Hydraulic parts are precision products of 37
small clearance. Therefore, disassembly and 15
assembly work shall be performed in a clean
place where there is little dust in the
following manner:
Never knock on precision parts in case they
do not operate smoothly.
Replace seal parts such as O rings and U 36
packings with new ones. 19
1,3
2. Disassembly 44,16
(1) Put a plug into each port (P,T,1,2,3,4,5,6) of 20
the valve and clean the outside. 21
(2) Fix the valve after cleaning it in a vise. 34
(3) Remove two boots (13). 22
(4) Loosen 2×2 places of socket head set screws 20
20
(28) and remove them from cam (12). 39
: 4mm 17

(5) Draw out two pins (14) from cover (15). On

that occasion, the pins may be drawn out Fig. 4-3 Disassembling the damper
with ease if the pins are pushed out of the
inside by the use of an allen wrench 4mm.
(6) Remove two cams (12).
(7) Loosen socket bolts (26) and remove two of
them with washers (30).
: 8mm

(8) Remove two dampers from the reducing

valve.

Ⅱ－4－3
(3) Separate four O rings (39) from guide (17). (3) Draw out two balls (36) from body (5) by
(4) Remove four U packings (37) from cover (15), attracting the balls to a magnet.
using a scriber. z Balls (33), (35) are for circuit plugs and press
fitted to body (5). Therefore, they are not
4. Disassembling the reducing valve section separable.
(See Fig.4-4.)
(1) Separate three socket plugs (24) from body

REDUCING VALVE SPOOL ASSY

(5).
: 5mm 6

(2) Separate O ring (41) from socket plug (24).

(3) Remove four reducing valve spool assemblies
from body (5).
(4) Remove stopper (6) from the reducing valve
spool assy.
7
(5) Remove four springs (7), parallel pins (32), O
rings (38), (40) from body (5). 40

32
5. Disassembling the reducing valve spool assy
(See Fig.4-5.) 38
z The outer diameter of reducing valve spool (4) 24
is finished with a small clearance against the
hole of body (5). Therefore, put a copper plate 5
41
on the mouthpiece of the vise at disassembly
so as not to score the outer diameter.
Note that the spool is deformed if the vise is Fig. 4-4 Disassembling the reducing valve
tightened too much.
(1) Fix spool (4) in a vise (Put a copper plate
against the mouthpiece.) and loosen four 27
socket flange bolts (27). 18
: 3mm

8
(2) Draw out socket flange bolt (27), sleeve (18),
spring (8), shims (10), (11) and washer (29) 10,11,29
from spool (4), in that order.
z On that occasion, mate the disassembled
parts with mating parts as sets. 4

6. Disassembling the shuttle (See Fig.4-6.) Fig. 4-5 Disassembling the reducing spool assy
z The shuttle is unseparable basically as seat
(2) is fixed with adhesive agent (Locktite 33 33
#262.). 36 36
(1) Remove two socket plugs (25) from body (5). 2 2
: 6mm
33 33
(2) Remove two seats (2) from body (5).
: 5mm

z On that occasion, the Locktite comes off. 42 42

Remove it including that adhered to the 25 25
neighboring area of the screw. Fig. 4-6 Disassembling the shuttle

Ⅱ－4－4
7. Assembly 11. Assembling the damper (See Fig.4-3.)
z Clean and degrease parts before assembly. In (1) Fit four U packings (37) to cover (15).
particular, clean the body with a nylon brush. z On that occasion, place the cover so the lip of
Foreign matter intruded into the valve causes the U packing faces down (damper chamber
functional faults to occur. side).
z Prepare new seals (O rings and U packings) (2) Insert four piston assemblies (44) into cover
and coat the surface with hydraulic oil or a (15).
thin film of grease. z In that case, make sure that each piston is
set in the same hole where it was before
8. Assembling the shuttle. (See Fig.4-7.) disassembly.
(1) Put two balls (36) into body (5). The performances of the piston are not
(2) Coat the screwed part of seat (2) with affected at all if it is placed in any direction
Locktite#262 and fit two of them to body (5). on the circumference.
: 5mm, Tightening torque : (3) Fit O ring (39) to guide (17). Install four
1.5±0.1kgfym(11±0.7ftylbs) guides to cover (15).
z Fix the guide in the same hole where it was
(3) Set O rings (42) to socket plugs (25) and set before disassembly.
fasten two plugs to body (5).
: 6mm, Tightening torque :
2.5±0.2kgfym (18±1.4ftylbs)
33 33
36 36
9. Assembling the reducing valve spool assy
2 2
(See Fig. 4-5.)
(1) Fix spool (4) in a vise. (Put copper plates 33 33
against the mouth.) Set washer (29), shims
(10), (11), spring (8) and sleeve (18), in that
order, and tighten them with four socket
flange bolts (27).
: 3mm, Tightening torque : 42 42
0.5±0.1 kgfym (3.6±0.7ftylbs) 25 25
Fig. 4-7 Assembling the shuttle
z On that occasion, pair parts with the
disassembled parts as sets, before performing 6 REDUCING VALVE
assembly work. Incorrect pairing may change SPOOL ASSY
the secondary pressure.

10. Assembling the reducing valve (See Fig.4-8.)

(1) Fit four O rings (38), (40), parallel pins (32)
and springs (7) to body (5).
7
(2) Fit four reducing valve spool assemblies and
40
stoppers (6). On that occasion, use care as
stopper (6) has a direction in which it should 32
be installed; Place it so the concave surface of
38
it faces down (reducing valve spool side).
(3) Set O rings (41) to socket plugs (24). Fasten 24
three plugs to body (5).
: 5mm, Tightening torque : 5
41
1±0.1 kgfym (7.2±0.7ftylbs)

Fig. 4-8 Assembling the reducing valve

Ⅱ－4－5
(4) Set orifices (1), (3) to piston assy (44) that is In case such scratches and burrs can not be
set in the cover. corrected with ease, replace the parts with
z The orifices absorbs rattles that are made new ones in pairs.
when cam (12) is in neutral: either orifice (3) If you feel the moving parts of the reducing
may be at the top or at the bottom. valve, body (5) and spool (4) unsmooth,
z In case the cam rattles very much because correct them to be free from scratches and
the cam and the pin are worn out after long burrs, using #1000 emery paper. If it is
hours of use, increase the number of orifices. difficult to correct, replace the parts with new
However, if many orifices are set when there ones in pairs.
is no gap, the reducing valve spool is actuated (4) If you feel the moving parts of the cam
at neutral and pressure is built up in the assembly such as, cam (12), pin (14) and
secondary pressure port. When there is no cover (15), correct them to be free from
gap on the cam at neutral, do not increase the scratch and burr, using #1000 emery paper. If
orifices. it is hard to correct, replace the parts with
(5) Set four holders (19) and balls (36) to piston new ones.
13
assembly (44). 28
36 12
(6) Install two dampers on the reducing valve 14
19
and fasten them with socket bolts (26) with 37 15 35
washers (30). 16,44
In that case, parallel pin (32) set in body (5) 20
34 26
is placed in the hole of cover (15) to position 22
20
the reducing valve and the damper in place. 17
39 30
32
: 8mm, Tightening torque : 40 6 1,3
6±0.5kgfym (43±3.6ftylbs) 18 27 21 38
(7) Set cam (12) to cover (15) and insert pin (14). 24
41 20
On that occasion, check the gap of the cam 8
7 25,42
and if the gap is large, increase orifices (1),
4 10,11,29
(3) according to item (4) above.
z Ball (36) and holder (19) can be drawn out 5

easily by magnet bar. If a magnet bar is not

available, place the valve on its side and give 13 Fig. 4-9
vibration to it.
(8) When the gap adjustment of the cam has
been finished, apply grease to the moving 28
parts of cam (12), pin (14), cover (15) and ball
12
(36).
(9) Attach 2×2 pcs. set screws to cam (12) and 26
30
tighten them.
: 4mm, Tightening torque :
1.5±0.1kgfym (11±0.7ftylbs) 14
(10) Fit two boots (13).
DAMPER

12. Standard for the judgement of serviceability

of parts
(1) Replace seals with new ones at disassembly
and reassembly.
REDUCING

(2) If you feel the moving parts of the damper,

cover (15), piston assy (44) and guide (17)
VALVE

unsmooth, correct the moving surfaces and

corners to be free from scratches and burrs,
using #1000 emery paper.

Ⅱ－4－6
 5. SWING MOTOR UNIT

5.1 SPECIFICATION
5.1 仕 様
(1) Outside view
(1) 外 観
Tightening
Port torque
THREAD FOR EYE
Symbol Port name size kgfym (ftylbs) BOLT 2-M12
M L
PB DEPTH 24
AB Main port PF3/4 17 (120)
B RELIEF VALVE
DB Drain port PF3/8 7.5 (54) (B PORT SIDE)

M Make-up port PF3/4 17 (120) (SH)

PA,PB Pressure measuring port PT1/4 3.7 (27)
PG Parking brake release port PF1/4 3.7 (27)
IP
L Gear oil level Gauge PT1/2 6.6 (48) PG
IP Gear oil filling port PF3/4 10 (72) RELIEF VALVE
(A PORT SIDE)
A
DB
PA

PB PA SWING SHOCKLESS
VALVE BLOCK
M DB
A,(B)

IP
PG FILLING PORT
PT3/4
DB

PA PB

A B

Hydraulic diagram

Fig. 5 -1 Outside view of swing motor

Ⅰ－5－1
(2) Specification

Swing motor unit part No. YN15V00010F1

Type M2X120B－CHB－10A－37/285

Part No. YN15V00002F4

Displacement cm3 (in3) 121.6 (7.54)

Hydraulic motor

Working pressure kgf/cm2 (psi) 350 (4980)

Max. flow /min (gal/min) 207 (55)

Braking torque kgfym (ftylbs) 63.5 (460)

Release pressure
(Stroke end) kgf/cm2 (psi) 29 (410)

Relief set pressure kgf/cm2 (psi) 285 (4050)

Weight kg (lbs) 54 (119)

Swing Type 2KAR6P72/240-712

shockless
valve block Weight kg (lbs) 2.5 (5.5)

Hydraulic motor assy weight kg (lbs) 56.5 (125)

Type M2X120B

Part No. YN32W00004F1

Speed reduction type Planetary 2-stage

Reduction ratio 15.38

Reduction unit

Lubicate oil Gear oil SAE90 (API class GL－4 grade)

Lubicate oil volume (gal) 7.5 (1.98)

Grease Extreme pressure multipurpose grease

Grease volume A small amount

Weight kg (lbs) 158.5 (349)

Total weight kg (lbs) 215 (474)

Ⅰ－5－2
(2) Swing reduction unit

33 29 28 27 26
19 25
18
18 22
17 23
16
16 24
14 22
20
15
21
13 10
12
11
34

31
30

32 9
8
7
5

6
2 1

Fig. 5-2 Sectional view of swing reduction unit

TIGHTENING
TORQUE No. NAME Q’TY No. NAME Q’TY
kgfym (ftylbs)

1 PINION SHAFT 1 19 #1 SUN GEAR 1

2 SLEEVE 1 20 SPRING PIN 4
4 PLUG (NOT SHOWN) ; PT1/2 1 21 SHAFT 4
5 O RING 1 22 THRUST WASHER 8
6 OIL SEAL 1 23 #2 PINION 4
7 RETAINER 1 24 NEEDLE BEARING 4
※3.4 (25) 8 SOCKET BOLT ; M8×25 12 25 THRUST WASHER 3
9 BEARING 1 26 #1 PINION 3
10 HOUSING 1 27 ROLLER 102
11 SPACER 1 28 THRUST WASHER 3
12 BEARING 1 29 SNAP RING 3
13 SNAP RING 1 30 PIPE ; L=180 1
14 #2 SPIDER 1 31 ELBOW 1
15 #2 SUN GEAR 1 32 PLUG PT3/4 2
16 RING GEAR 1 33 SNAP RING 1
17 #1 SPIDER ASSY 1 34 SET SCREW; M20×20 2
※18.5 (130) 18 SOCKET BOLT ; M14×130 10
Coat the parts marked ※ with Three-Bond #1360K.

Ⅱ－5－3
5.2 DISASSEMBLY AND ASSEMBLY OF SWING MOTOR
5.2.1 TOOL

Tools Remarks
Socket
VP plug PF1/4 19mm
wrench
Allen
M8,M14,M20,M20(Set screw) 6,10,12,17mm
wrench
Plier For bearing fixing locking rings Snap ring for hole ∅60, ∅52
Screwdriver Flat-bladed type, medium size 2 pcs.
10×8×200 (0.39˝×0.31˝×7.87˝ )
Steel bar
(key material) 1 pc.
Hammer Plastic hammer 1 pc.
1.0～4.5 (7.2～33)
Torque wrench kgfym(ftylbs) 4.0～18 (29～130)
12～48 (87～350)
Slide hammer bearing puller

(1.57˝)
40
∅40 (1.57˝)
100(4˝)
250(10˝)

Brake piston drawing tool (0.433˝ )

(Bolt M8×75 2pcs.) BORE DIA.∅11

M8
10 (0.4˝)

M10
(0.2˝)
150(5.91˝)
5

175.5(6.91˝) Place this

200(7.87˝) claw in the
groove of
brake piston.

Ⅱ－5－4
5.2.2 DISASSEMBLY
(1) General cautions
1) Hydraulic components are precision products
and have small clearance. Therefore,
assemble and disassemble in a less dusty
clean place. Use clean tools and cleaning oil
and handle components with full care.
2) If a component is removed from the main
body, clean the area around the ports
thoroughly and plug them up so no dust and
water do not enter. When fitting them back to
the body, do not remove the plugs till piping
is completed.
3) Study the structural drawing before the work
begins and prepare necessary parts according
to your purpose and the scope of work. Seals
and O rings once removed can not be used
again.
Some parts can not be supplied as single
parts and available only in sub assy. Prepare
such parts according to the parts manual.
4) The piston and the cylinder block are shop
fitted when new. If you intend to reuse them,
put a matching mark on the piston and the
cylinder block.
(2) Disassembly procedure
The figures in parentheses after part names
in this manual represent those item numbers
in Fig. 5-1 and Fig. 5-2.

1) Draining oil
Remove the drain plug and drain hydraulic
oil from casing (301).
2) Preparation for removing the valve casing
Fix the motor on a work bench so the drive
shaft (101) end comes down. On that
occasion, put a matching mark on the mating 052
parts of casing (301) and valve casing (303). 051
303
z Choose a clean place, and lay with a
rubber sheet or a cloth on a work 712
bench. Handle the valve casing with 702
care so parts do not have dents.

301

101

Fig.5-3 Removing valve casing (303)

Ⅱ－5－5
3) Loosen relief valve (051) and separate it from 052 351 355
valve casing (303).
: 41mm

4) Loosen swing shockless valve sub assy (052) 303

and valve casing (303).
: 6mm 469

5) Separate RO plug (469) from valve casing

(303) and draw out spring (355) and plunger
(351).
: 14mm
401
6) Loosen socket bolt (401) and separate valve 051
casing (303) from casing (301). If the socket Fig. 5-4 Removing relief valve (651), swing
bolt (401) are loosened, the valve casing floats shockless valve (052), anti-cavitation
off casing (301) by the force of brake spring plunger (351) and valve casing (303)
(712).
BRAKE PISTON
Then separate valve plate (131) from valve DRAWING JIG
casing (303).
: 17mm 131

7) Draw out brake spring (712) from brake

piston (702).

8) Put the claw of the brake piston removing jig

in the concaved part of brake piston (702).
Hold the cylindrical part of the jig and pull it
702
straight up at once by reaction.
Draw out the brake piston with the jig, from 301
the casing. Fig. 5-5 Removing brake piston (702)

9) Lay the motor on its side again and draw out 117
cylinder block (111) from drive shaft (101).
Then draw out piston (121), retainer plate
(123), spherical bushing (113), spacer F (117)
and shoe plate (124).

Handle the parts with care so as not to

score the sliding surfaces of cylinder
block (111), spherical bushing (113)
and shoe (122).
101

124

122 121 743

301 123 113 742 111
Fig. 5-6 Drawing cylider block (111), piston sub
assy, friction plate (742) and separator plate

Ⅱ－5－6
10) Draw out friction plate (742) and separator
plate (743) from casing (301).
301

11) Draw out drive shaft (101) from casing (301),

while lightly tapping the side face of valve
casing (303) in drive shaft (101), using a
plastic mallet.

PLASTIC
MALLET

101 443

Fig. 5-7 Removing drive shaft (101)

z Do the following work as required.

PRESS
1. Drawing the inner race of roller bearing (443)
101
from drive shaft (101), using a press.

z Do not reuse the removed bearing.

443
2. Remove snap ring (437) with pliers. Then
draw out seal cover (305) from casing (301).
Put a bolt in the screwed hole (M4×0.7) of oil
seal (491). Then draw out oil seal (491) from
casing (301). Put the inner race
on the press bench.

3. Drawing out the outer race of roller bearing Fig. 5-8 Removing inner race of roller
(443) from casing (301), by lightly tapping the bearing (443)
steel rod from the oil seal (491) housing side.
(Do not reuse the bearing.)

4. Separate the outer race of roller bearing (444)

from valve casing (303), using a slide
hammer bearing puller.

Ⅱ－5－7
5.2.3 ASSEMBLY
(1) General cautions
1) Repair those parts damaged after
disassembly and prepare replacement parts
beforehands.

2) Clean all parts thoroughly in cleaning oil and

dry them with jet air.

3) Always coat the moving parts with clean

hydraulic oil, before assembly.

4) Replace such seals as O ring and oil seal in OUTPUT SHAFT SIDE
principle. 101

5) Tighten socket bolts and plugs to specified

torques, using a torque wrench.
443

(2) Assembly procedure

The figures in parentheses after part names
in this manual represent those item numbers
in the Fig. 5-1 and Fig. 5-2.

1) Preparation for assembly

Place casing (301) on a proper bench so its
valve casing (303) faces upward.

z This operation is necessary only 444

when the roller bearing is removed. Fig.5.9 Assembling the inner race of
bearings (443), (444)
2) Shrinkage fit the inner race of roller bearing
(443) into drive shaft (101).

3) Shrinkage fit the inner race of roller bearing

(444) to drive shaft (101).

z This operation is necessary only

when the oil seal is removed.
Fit snap ring (437) to casing (301),
put in seal cover (305) and fix oil seal
(491) by the use of the jig. On that
occasion, coat the lip of the oil seal
with grease and check the direction
of it, before fixing it.

4) Assemble the outer race of roller bearing

(443) into casing (301), by lightly tapping the 301
steel rod. 443 437 305 101 491
Fig.5.10 Fitting snap ring (437), seal cover (305),
5) Attach drive shaft (101) to casing (301). oil seal (491), outer race of roller
bearing (443), and drive shaft (101)

Ⅱ－5－8
6) Place casing (301) as shown in Fig. 5-11 and
insert shoe plate (124).
On that occasion, the shoe plate does not
come off if it is coated with grease.

The larger
chamfer side 124

301
443

Fig. 5-11 Inserting shoe plate (124)

7) Fix spacer (118) and spring to cylinder (111),
fit snap ring (438) to it and insert push rod
(116) into cylinder (111).
Then mount the spherical bushing (113) with
spacer F (117) on the cylinder.

8) Place piston sub assy (121, 122) on retainer

plate (123). 117
123 116
9) Assemble piston sub assy (121, 122) fixed in 118
122
retainer plate (123) into cylinder (111). Match
it to the spline of drive shaft (101) and insert 113
it in place. 114
On that occasion, drive shaft (101) is easy to 121
be inserted if the phase of spherical bushing
(113) is aligned with that of the spline of
cylinder (111).

111

101
438

Fig. 5.12 Inserting cylinder assy

10) Replace casing (301) with seal cover facing
downward and assemble separator plate
(743) and friction plate (742) into casing
(301), in that order.
Assemble four separator plates and three
friction plates.

Assemble the same phases of four slits

in the gears of friction plate (742).
Assemble four slits in the four claws of
separator plate (743) in the position of
Fig.5-13.

PG PORT

Fig. 5-13 Mounting position of separator plate

Ⅱ－5－9
11) Fit O rings (706), (707) to casing (301). In 702
that case, if the O rings are coated with
grease, they are hard to tear off when brake
piston (702) is inserted.

12) Assemble brake piston (702) into casing

(301).

13) Assemble brake spring (712) into brake

piston (702). In that case, make sure that a
SLIT (OPPOSITE SIDE)
spring is placed positively in the spot faced
part of the brake piston. PG PORT

z This operation is necessary only Fig. 5-14 Assembling brake piston

where roller bearing (444) is
removed.

14) Insert the outer race of roller bearing (444)

into valve casing (303), while lightly tapping
the steel rod placed on the outer race, using a
hammer.

15) Assemble valve plate (131) into valve casing

(303) and fit O ring (472) in it.

16) Install valve casing (303) to casing (301) and

fasten them with socket bolts (401).
: 17mm,
Tightening torque : 44kgfym (320ftylbs)

17) Fit plunger (351) and spring (355) to valve

casing (303). Then tighten RO plug (469)
fitted with O ring (488) against valve casing
(303).
: 14mm,
Tightening torque : 34kgfym (250ftylbs)

18) Fit relief valve (051) to valve casing (303).

: 41mm,
Tightening torque : 18kgfym (130ftylbs)

19) Fit reverse turn preventing sub (052) to valve

casing (303).
: 6mm,
Tightening torque : 3kgfym (22ftylbs)

20) Fit O ring (485) to plug (464) and fasten the

plug against casing (301).
: 19mm,
Tightening torque : 3.7kgfym (27ftylbs)

Ⅱ－5－10
5.3 DISASSEMBLY AND ASSEMBLY OF SWING REDUCTION UNIT
5.3.1 TOOLS

Code Tool name Remarks

Material : SS41

10mm
(0.394˝)
50mm
(1.97˝)
Jig
a
(for press fitting bearing )
∅910.5mm
(3.583˝
0.020˝)

∅1400.5mm
(5.512˝
0.020˝)

b Snap ring plier For shaft

Material : SS41 ∅140mm

(5.51˝)
(0.591˝)
c Oil seal fitting jig 15mm
0
mm
∅208 0.5
0
(8.189˝ )
0.020˝

d Torque wrench Class 14kgfym (100ftylbs)

e Plastic hammer (Wooden hammer)

f Press Class 10ton (22000 lbs )

h Flat screwdriver
∅20mm
(0.787˝)

i Metal bar 3 pcs. 155mm

(6.10˝)

j General tools Allen key wrench and steel rod

Screw lock compound Three-Bond 1360K

k
Sealing compound Locktite #515

5.3.2 DISASSEMBLY
The numbers in parentheses correspond to the
ones in construction drawings (Fig. 5-2).
3) Disconnect the drain hose.
(1) Preparation
1) Before disassembly, clean the outside of the 4) Matching Mark
reduction unit thoroughly and check for no To facilitate the reassembly of the unit, put
damage and scoring. matching mark on the joining parts of the
2) Drain gear oil from the reduction unit. housing before disassembly.

511
(2) Separating swing motor from reduction unit
1) Preparation for disassembly SWING MOTOR
Place the reduction unit assy on a stable
work bench as shown in Fig.5-15, remove
plug (32), drain out oil put a matching mark 18
on the matching surface of the figure on the 32
right.
h
2) Removing swing motor assy MATCHING
MARK
Loosen all socket bolt (18) (M14). Attach eye
bolts (M12
1.75) in the lifting bolt holes in
the top surface of the swing motor and lift the 160 290
assy by crane. (6˝) (12˝)
If it is hard to remove the swing motor assy Fig. 5-15Removing swing motor assy
from the reduction unit, float it by inserting a 17
flat-blade screwdriver (h) in the groove of the 19
flange.
: 12mm
16
(3) Disassembling reduction unit
1) Remove #1 sun gear (19).

2) Removing #1 spider assy (17).

The spider assy (17) [consisting of thrust 10
washer (28), #1 pinion (26), needle bearing
(27) and snap ring (29)] can be removed from Fig. 5-16Removing #1 sun gear and
the spline easily if it is lifted up in that #1 spider assy
condition.

3) Removing ring gear (16) #2 SPIDER ASSY

Attach eye bolts (M14) to the top surface of
ring gear (16) and lift the ring gear lightly by
a wire sling. 16
Put a flat-blade screwdriver (h) into the h
matching surface of ring gear (16) and
housing (10) and remove ring gear (16) by
lightly tapping the outer circumference of the 10
ring gear with a plastic mallet.

4) Remove #2 sun gear and separate the #2 Fig. 5-17Removing ring gear (16)
spider assy. #2 SPIDER ASSY
Draw out #2 sun gear (15) and separate the
15
#2 spider assy.
Regarding the disassembly of the #2 assy,
refer to par. (4) which will come up later.

Fig. 5-18Removing #2 spider assy

512
5) Turn over the housing so gear side of pinion
1
shaft faces up, as shown in Fig. 5-19.

180 (7˝ )
35010(14˝0.4˝)

Fig. 5-19
Turning over housing

6) Remove all socket bolts (8).
: 6mm

8
Fig. 5-20
Removing socket bolts (8)
7) Remove retainer (7) with oil seal (6).

Fig. 5-21
Removing retainer (7)

513
8) Removing pinion shaft assy M10
Attach an M10 eye bolt to the end of the
pinion and lift it upright : The pinion shaft 1
assy (1,2,5,9,11,12,13) can be lifted up easily. 5
2
9

11

12

13

Fig.5-22
Removing the pinion shaft assy

(4) Disassembling spider assy
1) Disassembling #1 spider assy
1. Remove snap ring (29) with a plier (b).
2. Remove thrust washers (25,28), pinion (26) 17 26 29 27 28
and roller (27).

z The shaft attached to spider assy 25

(17) is caulked. When replacing
parts, replace the spider assy as a Fig.5-23
Disassembling #1 spider assy
whole.
z The pinion can not be replaced as a
piece. For replacement, do it in a set
of three.

2) Disassembling #2 spider assy

1. Draw out spring pin (20).
2. Draw out shaft (21) from spider (14) and
remove thrust washer (22), pinion (23) and 21 22
needle bearing (24).

24
z Pinions (23) can not be replaced
singly. Replace them in a set of four. 23

22
14 20
Fig.5-24
Disassembling #2 spider assy

514
(5) Disassembling pinion shaft assy
1) Remove snap ring (13), using pliers (b).

13

Fig. 5-25Removing snap ring

2) Removing pinion shaft (1)
Erect three supporting metal bars (i) at equal
intervals in the grooves in the teeth of pinion
shaft (1), place sleeve (2) on them and draw
down the pinion shaft by press in Fig. 5-26.
Pressing force : about 10
11 tons
(22000
24000 lbs)

Bind the supporting metal bars (i)

around their outside with a steel wire
when performing press operation.

Fig. 5-26Removing pinion shaft (1)

3)
Drawoutthepinionshaft(1)and
7
remove
O ring (5) from sleeve (2). Then the pinion
shaft is disassemlbed into the parts in Fig. 5- 12 5
27.
2
11

9 1

Fig. 5-27Disassembling pinion shaft assy

515
5.3.3 ASSEMBLY
(1) Preparation
1) Clean parts thoroughly in cleaning oil and
dry them with jet air.

2) Check that parts are not faulty.

(2) Assembling pinion shaft assy

1) Apply grease 5
Apply a thin film of grease over O ring (5)
and the O ring seat of pinion shaft (1).
2

2) Insert sleeve 1
Heat sleeve (2) to 100
120 (212
248 F),
fit O ring (5) and fix it into pinion shaft (1).
Fig. 5-28Inserting sleeve to pinion shaft
3) Coat the outer surface of the sleeve with a
thin film of grease.

4) Coat the gear oil

a
Coat the outer circumference of pinion shaft
(1) with a thin film of gear oil to prevent
13
seizure.
12
5) Assembling bearing
Heat bearings (9,12) to 100
120
19
(212
248 F), fit the bearings with spacer (19)
into pinion shaft (1). Push them in, using jig 9
(a) and fix snap ring (13).
Pressing force : 11
12ton
(24000
26500 lbs) 1
OIL SEAL

Fig. 5-29Assembling pinion shaft assy

516
(3) Assembling spider assy
1) Assembling #1 Spider Assy
1. Coat the bore surface of pinion (26) with
grease. Put pinion (26) on thrust washer (25) 17 26 29 27 28
and assemble roller (27) into the bore surface.

2. Fit thrust washers (25,28) and pinion (26) as

in Fig. 5-30, 5-31 and fit snap ring (29) by 25
means of pliers (b).
Fig. 5-30Assembling #1 spider assy
Fix the snap ring with the sharp edge
on the motor side (top side in the
position of Fig.5-31 ).

b
MOTOR SIDE

SNAP RING (29)

25, 28

17

29 26

Fig. 5-31Fixing snap ring

2) Assembling #2 Spider Assy
GEAR SIDE
1. Coat the bore surface of pinion (23) with
grease. Put pinion (23) on thrust washer (22) CAULK TWO
POINTS WITH
and fit needle bearing (24) to the bore
A PUNCH.
surface.

2. Fit thrust washer (22) and pinion (23) as in

Fig. 5-32, insert shaft (21) into spider (14)
and fix spring pin (20).
67mm 67mm
(0.24
0.28in) (0.24
0.28in)
z Make sure that the oil hole (
A in
Fig. 5-32) in shaft (21) faces the VIEW
outside as shown in the figure.
z Insert shaft (21) into spider (14) so
“A” 21 22
spring pin hole (20) is aligned.

24
23

22
14 20

Fig. 5-32Assembling #2 spider assy

517
(4) Assembling reduction unit assy
1) Mounting pinion assy 1
Place housing (10) on a work bench. Lift the
pinion assy and lower it slowly into the
housing till it is set in place.

9
z Take care on this step so that outer
race of bearing (9) is installed
straight along the inner face of
housing (10).
z Outer races of bearings (9,12) can
normally be installed in the housing
(10) easily as enough clearance is 12
provided between the two parts. If
10
they cannot be inserted easily, check
to see whether or not the outer race
of bearings (9,12) are positioned Fig. 5-33
Installing pinion assy
correctly and if there is any damage
to housing (10). Pressing them in
with undue force may damage these
parts.

2) Attaching retainer
1. Fill grease in the groove of the oil seal lip in
contact with the oil seal till about 1/3 of the
groove is filled with grease.
M825
2. Fit the oil seal to retainer (7), making sure of 8
its direction and set it in place by using oil 10 7
seal fixing jig (c). Fig. 5-34
Assembling retainer (7)
3. Apply sealing compound (Locktite #515) to
the retainer (7) with oil seal and the #2 SPIDER ASSY
matching surface of housing (10). Then fit it
to sleeve (2).

Use care when assembling so as not to

score the oil seal by the gear teeth of
pinion (1)

4. Tighten socket bolt (8)

: 6mm, Fig. 5-35
Installing #2 spider assy
tightening torque 3.4kgfym (25ftylbs)
19
3) Turning over housing (10)
Place pinion shaft (1) on a stable work bench,
with its spline facing up.
4) Attaching #2 spider Assy
Insert the #2 spider assy into the spline shaft
of pinion shaft (1).
5) Attaching #2 sun gear (19)
Install #2 sun gear (19) with its spline facing
up. Fig. 5-36
Installing #2 sun gear (19)

518
6) Installing ring gear (16)
Apply a thin film of sealing compound
(Locktite #515) to the matching surface of #2 SPIDER ASSY
housing (10) and ring gear (16) and assemble
16
them, aligning the gear teeth and according ALIGN
MATCHING MARKS.
to the matching marks given.

10

Fig. 5-37Installing ring gear (16)

7) Installing #1 spider assy
1. Mesh the #1 spider assy with ring gear (16)
and set them in place.
2. Mesh #1 sun gear (19) with #1 pinion (26)
and set them in place. 19
#1 SPIDER ASSY

8) Fit drain hose (36) and plug (37). 16

: 12mm
26
9) Filling Lube Oil
Fill in 7.5 (2.0gal) of Extreme pressure gear
oil SAE90 (API Service Grade GL
4).
10

Fig.5-38Installing #1 spider assy

10) Installing swing motor assy
Attach eye bolts (M121.75) in the tapped
holes of the swing motor and put a wire sling
in them.
SWING MOTOR
Coat the matching surface of ring gear (16)
with sealing compound (Locktite #515), insert
M14130
the spline joint of the swing motor and match
18
the matching marks.
Coat socket bolts (18) with screw lock
compound (Three-Bond 1360K) and fasten
them.
: 12mm, MATCHING
MARKS
Tightening torque 18.5kgfym (130ftylbs)

160 290
(6˝) (12˝)
Fig. 5-39Installing swing motor assy


5
19
5.4 MAINTENANCE STANDARDS
5.4.1 SWING MOTOR
(1) Replacement standards for parts
The following are the standards to determine disassembly, it is most important to
whether or not parts may be reused from determine how many parts should be
values taken at disassembly. These are only replaced, depending upon the purpose of
general standards and in case the motor disassembly and the remaining service life of
displays poor performance or parts shows the motor that the user expects.
extreme
damage
and
discoloration
befo
re
Standard Recommended
Item Dimension Value for Remedy
mm (in) Replacement
mm (in)
Clearance between piston and
cylinder bore (D-d)

0.027 0.052
Replace piston or cylinder.
d D (0.00160) (0.00205)

Gap between piston and caulked

part of shoe ()

0.3
0 Replace piston and shoe assy.
(0.0112)

Thickness of shoe (t)

5.5 5.3
Replace piston and shoe assy.
t (0.217) (0.209)

Assembled height of retainer plate

and retainer (H-h)

5.5 5.0 Replace a spherical bushing and a

(0.217) (0.197) retainer plate as a pair.
H
h

Thickness of friction plate

1.8 1.6
 Replace.
(0.0709) (0.0630)

520
(2) Standard for correcting sliding surfaces
If the surface roughness of the sliding surface
of parts exceeds the following standard,
correct it or replace the parts.

Standard for correcting sliding surfaces

Standard surface Surface roughness
Name of parts roughness requiring correction
0.8
Z(Ra=0.2)
Shoe 3
Z(Ra=0.8)
(lapping)
0.4
Z(Ra=0.1)
Shoe plate 3
Z(Ra=0.8)
(lapping)
1.6
Z(Ra=0.4)
Cylinder 12.5
Z(Ra=3.2)
(lapping)
0.8
Z(Ra=0.2)
Valve plate 6.3
Z(Ra=1.6)
(lapping)

z Lap each sliding surface to a z If the sliding surface of the cylinder

standard roughness level or finer. block, valve plate, retaining plate or
spherical bushing is roughened,
replace parts in pairs.


5
21
5.4.2 SWING REDUCTION GEAR
(1) Inspection at disassembly (2) Inspection after assembly
1) Spacer and thrust washer 1) Function
1. Inspect that the parts are not seized or worn Check to see that #1 sun gear (19) is not
abnormally or unevenly. faulty when turned by hand.
2. Inspect and measure the parts to see that the
wear does not exceed the allowable values. 2) Checking for oil leakage and oil quality
Check for oil leakage.
2) Gears Check the oil level by level gauge and confirm
1. Inspect that the gear teeth do not show that the oil is not dirty. If the oil is short,
pitching and seizure. replenish engine oil SAE90 (API Service
2. Inspect by dye penetrant examination that Grade GL-4).
the bottom of the teeth does not show cracks.

3) Bearing
Turn the bearing and check that it does not
develop abnormal sound, binding and other
faults.

4) O rings and oil seals

Do not reuse O rings and oil seals; always
replace them with new ones at reassembly.

522

    

(H) A

LUBE OIL LEVEL

D

APPLY LOCKTITE #515.

G
APPLY LOCKTITE #515.

Unit : mm (in)
Serviceability
Code Item Standard Value Remedy
Limit

0.021
∅39.45
0.032 Replace entire
A Wear in #1 planetary shaft
0.00083˝
(1.55315˝
0.00126˝ ) spider assy.
0
No flaking
∅29
0.009 Replace four
B Wear in #2 planetary shaft 0
(1.14173˝
0.00035˝ ) shafts as a set.
There should be no pitching
Condition of tooth face exceeding 1.6mm (0.0630in) dia, Replace
abnormal wear or seizure. (Planetary pinion
C Gears
should be replaced
Condition of tooth flank There should be no cracks. in a set of four.)

2.00.1
D Thickness of thrust washer 1.8 (0.0709˝ ) Replace
(0.079˝0.004˝)
0
Wear in sleeve (Diameter of part coming ∅160
0.063 ∅159.5
F 0 Replace
in contact with oil seal ) (6.29920˝
0.00248˝ ) (6.28˝ )
Apply Three-Bond
G M83.4 kgfym(25ftylbs)
Capscrew tightening torque 1360K and tighten
(H) M1418.5 kgfym(130ftylbs)
to specified torque.
Extreme pressure engine oil
Lube Replenish or
I SAE90(API Service Grade 7.5(2.0gal)
oil replace.
GL4)
523
5.5 TROUBLESHOOTING
5.5.1 SWING MOTOR
(1) Hydraulic motor does not rotate.

Trouble Cause Remedy

Pressure does not 1. Relief valve pressure in circuit is not 1. Set to correct value.
rise. adjusted correctly.
2. Malfunction of relief valve. 2.
2-1. Sticking plunger. 2-1. Correct the stuck areas or
replace the plunger.
2-2. Orifice on plunger is clogged. 2-2. Disassemble and clean.
3. Plunger seat is faulty. 3. Check the seat surface and
replace the plunger if scored.
4. Swing shockless valve seat is faulty. 4. Replace the swing shockless
valve cartridge or block.
Pressure rises. 1. Overload. 1. Eliminate overload.
2. Moving parts are seized. 2. Inspect and repair piston, shoe
and cylinder valve plate.
3. Brake release pressure is not 3. Check circuit and correct it.
working on the motor
4 Brake piston is stuck. 4. Disassemble and check.
5. Friction plate is seized. 5. Disassemble, check and repair.
Replace one that is seized.

(2) Rotating direction is opposite.

Trouble Cause Remedy

Rotating direction 1. Motor’s assembling direction is reversed. 1. Assemble correctly.
is opposite. 2. Piping inlets and outlets are reversed. 2. Pipe correctly.

524
(3) Revolution does not rise to set value.

Trouble Cause Remedy

Revolution does not 1. Oil inflow is deficient. 1. Check pump’s delivery rate and
rise to set value circuits to motor.
2. Oil leaks are excessive due to high 2. Lower oil temperature.
temperature.
3. Sliding surfaces are worn or broken. 3. Replace.

(4) Brake torque is insufficient.

Trouble Cause Remedy

Brake torque is 1. Friction plate is worn. 1. Disassemble and check. Replace if
insufficient. wear is beyond standard value.
2. Brake piston is stuck. 2. Disassemble and check.
3. Brake release pressure is not 3. Check and correct circuit.
released. 4. Disassemble and check.
4. Spline of friction plate is broken. Replace broken part.

(5) The swing motor drifts much.

Check the drain rate of the hydraulic motor.
If it is less than 200cc/min(12cuyin/min), you
should think that the motor is not faulty.

Trouble Cause Remedy

The swing motor 1. Relief valve malfunctions. 1.
drifts much when it is Same as (1). Same as (1).
actuated by external 2. Plunger seat is faulty. 2. Replace.
torques. (e.g. Machine 3. Seat of the swing shockless valve is 3. Replace the swing shockless valve
is on a slope.) no good. cartridge or block.

525
(6) Oil leaks
1) Oil leak from oil seal

Trouble Cause Remedy

Oil leaks from oil 1. Lip of seal contains dirt and 1. Replace oil seal.
seal damaged. 2. Shift the lip and shaft positions or
2. Shaft is damaged or worn. replace oil seal.
3. Repair drain piping if clogged up.
3. Casing inner pressure has risen
abnormally high, with the result that
lip of oil seal has turned up. 4. Disassemble and correct.
4. Shaft is rusted.

2) Oil leak from matching surface

Trouble Cause Remedy

Oil leak from 1. O ring is missing. 1. Set O ring correctly and assemble
matching surface it.
2. O ring has a scratch. 2. Replace.
3. Seal surface has a scratch. 3. Disassemble and correct.
4. Bolt is loose or broken. 4. Tighten to specified torque or
replace.

526
 6. SWIVEL JOINT
6.1 CONSTRUCTION VIEW

D
2

C B
E
6
G
1
G
A

10
B
F

A
F

7
9 SECTION GG
3
E 8
4

Tble 6-1
No. NAME Q’TY No. NAME Q’TY
1 BODY 1 6 O RING 2
2 STEM 1 7 O RING(1A G95) 1
3 THRUST PLATE 1 8 SOCKET BOLT (M8×20) 2
4 COVER 1 9 SOCKET BOLT (M8×30) 4
5 SEAL ASSY 5 10 PLUG 1

Fig.6-1 Construction of swivel joint

Ⅱ－6－1
6.2 DISASSEMBLY AND ASSEMBLY
6.2.1 TOOLS Table 6-2
Code Tool Name Used for Remarks

1. Steel hammer
a Hammer
2. Wooden or plastic mallet

b Rubber mat 750mm (30in) square or more

1. Allen wrench
c Wrench 2. Double-ended and single-ended wrench
3. Extension pipe

d Torque wrench Assembly 10kgfym (72ftylbs)

Grind the tip of“a nail”to shape
as a screwdriver.
e Pin Disassembly

Made from a hack-saw blade

Disassembly Approx. 120mm (4.72 in)

f Spatula
Assembly

Vinyl tape Remove the edge completely

and make corner round smooth.

Disassembly
g Vise Vise movable over 150mm (6in)
Assembly

h Locktite #242

i Lubricating oil Hydraulic oil or vaseline

j Cleaning oil

6.2.2 APPARATUS 6.2.3 CLEANING OUTSIDE

(1) Hoist or crane Clean the swivel joint to be free from dirt and
The lifting device should be capable of lifting dust, using steam and cleaning oil.
the swivel joint assy.
(2) Work bench z Keep all ports plugged up while
The work bench should have an area of cleaning.
1.2m×1.5m (4ft×5ft).
(3) Others
Also prepare waste cloth, wooden block and
oil pan.

Ⅱ－6－2
6.2.4 DISASSEMBLY 2
1
The part numbers used in this disassembly 4
procedure correspond to those of a construction 9
drawing in Fig.6-1.

(1) Removing cover

1) Mark cover (4) and body (1) with matching
marks for convenient reassembly.
ALLEN
WRENCH
2) Place a V-block on a work bench, place a V-BLOCK PIPE
swivel joint set on the side, fix it and loosen
socket bolt (9) by means of a pipe and
wrench. Alternately, the swivel joint may be Fig. 6-2 Removing cover (4)
fixed by holding stem (2) in a vise.
: 6mm

3) Remove cover (4) from body (1) and draw out

7 4
O ring (7) from cover (4).
Fig. 6-3 Removing O ring (7)
1 BODY
(2) Removing thrust plate 3 THRUST PLATE
Loosen socket bolt (8) fastening thrust plate 8 SOCKET BOLT
(3), in the same manner as the removing of
the above-mentioned cover.

z When removing thrust plate (3) by

fixing body (1), support stem (2) so it PIPE
may not fall down.
: 6mm

(3) Removing stem

2
Place body (1) on a V－block. Put a wooden STEM
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 Fig. 6-4 Removing thrust plate (3)
the body, it can be easily pulled out by hand. WOODEN BLOCK Secure
FOR PROTECTOR with hands. 1
Stem weight ; 12kg(26 lbs) 2

WORK BENCH V-BLOCK

Fig. 6-5 Drawing out stem (2)

Ⅱ－6－3
(4) Removing seals SPATULA(f)
1) Remove O ring (6) from the O ring groove
with the aid of a spatula.
6
Use the tip of the spatula taking not to score
the body. Also do not strike the spatula.

2) Stick pin (e) to seal (5) and extract slipper

ring (5). Fig.6-7 shows the use of one pin, but
by using two pins, this can be extracted with Fig. 6-6 Removing O ring (6)
more sureness.
As the backup ring is made of rubber, remove
this in the same procedure as O ring (6).
SLIPPER RING

BUCK-UP RING
DETAIL(5)

GROOVES
FOR O RING
GROOVES
FOR
HYDRAULIC PIN(e)

GROOVES
FOR 5
SLIPPER SEAL
SEAL ASSY
6.2.5 ASSEMBLY
Prior to assembly, clean each parts (excluding the Fig. 6-7 Removing out seal assy (5)
O ring and slipper ring), and arrange in the
sequence of assembly.

BACK-UP RING
(1) Assembling seals to body
1) Coat O ring (6) lightly with hydraulic oil and
install in the O ring groove. Also make sure
that the O ring is not distorted after
installation.
2) Make sure that oiliness, such as hydraulic oil
and grease, has been completely removed.
3) Slipper ring is assembled, after first inserting
the backup ring, by slightly-distorting the
shape as shown in Fig.6-8. Also after
inserting all of the seals, be certain that these
are installed in the seal groove by use of the
spatula. Fig. 6-8 Inserting slipper ring into backup ring

Ⅱ－6－4
(2) Assembling stem
Lightly coat the outer circumference of stem Press in by applying your weight
(2) and the inner surface of body (1) with by your both hands.
grease or vaseline and slowly insert stem (2)
into body (1).
2 STEM
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). O RING 6
Push stem straight along the shaft
1 BODY
center.

5
SEAL ASSY
WORK BENCH

Fig. 6-9 Inserting stem (2)

(3) Assembling thrust plate

1) While holding stem (2) and body (1), match 8 3 2
the hole of thrust plate (3) and the stem (2)
hole.
2) Next, after removing any oil from the thread
of socket bolt (8), coat it with Locktite #242
and tighten to stem (2).
: 6mm,
Tightening torque : 3.1±0.3kgfym
(22±2ftylbs)
Fig. 6-10 Tightening socket bolt (8)

1
(4) Assembling cover
MATCHING MARK
After installing O ring (7) to cover (4) and
aligning the matching marks of the cover (4)
and body (1), coat socket bolt (9) with 9
Locktite #242 and tighten it which will then 4
complete assembly.
: 6mm,
Tightening torque : 3.1±0.3kgfym
(22±2ftylbs) ALLEN
WRENCH

PIPE

Fig. 6-11 Tightening socket bolt (9)

Ⅱ－6－5
6.3 MAINTENANCE STANDARDS
6.3.1 INSPECTION PROCEDURE AND REMEDY
Table 6-3

Interval Check Item Checking Procedure Remedy

2,000Hrs. Seal for oil Check oil leakage outside Replace O ring, if any oil leakage can be
leakage outside found.
4,000Hrs. All sealing Replace all sealing parts such as slipper
In principle, parts seal with back-up ring and O ring.
disassemble
and check re- All sliding parts Check abnormal wear, scoring Repair or replace referring to their limit
gardless of oil or corrosion caused by foreign of service.
leakage or not. matters or seizure.

When All parts Check them for seizure, foreign Repair or replace referring to their limit
disassembled matters, abnormal wear, and of service.
for repair defect of seals. O rings should be replaced.

6.3.2 SERVICE LIMIT OF THE PARTS

Table 6-4

Parts Maintenance Standards Remedy

Sliding surface with

Plating worn or peeled due to seizure or contamination. Replace
sealing sections
Sliding surface 1) Worn abnormality or damaged more than 0.1mm Replace
between body and (0.004in) in depth due to seizure or contamination.
stem other than
Body, Smooth with
sealing sections 2) Damaged less than 0.1mm (0.004in) in depth.
Stem oilstone.

1) Worn more than 0.5mm (0.02in) or abnormality. Replace

Sliding surface 2) Worn less than 0.5mm (0.02in). Smooth

with thrust plate 3) Damage due to seizure or contamination repairable Smooth
within wear limit 0.5mm (0.02in).

1) Worn more than 0.5mm (0.02in) or abnormality. Replace

Sliding surface 2) Worn less than 0.5mm (0.02in). Smooth

Cover
with thrust plate 3) Damage due to seizure or contamination repairable Smooth
within wear limit 0.5mm (0.02in).

Ⅱ－6－6
 Parts Maintenance Standards Remedy

1) Protruded excessively from seal groove.

Replace
PROTRUSION (With back-
up ring)

BACK-UP RING

2) Slipper ring 1.5mm (0.06in) narrower than seal

groove, or narrower than back-up ring. Replace
(With back-
Slipper ring
up ring)

1.5mm (max.)
(0.06in)

BACK-UP RING

3) Worn unevenly more than 0.5mm (0.02in)

0.5mm (max.) Replace
(0.02in) (With back-
up ring)

Ⅱ－6－7
6.6.3 INSPECTION AFTER ASSEMBLY
After completion of assembly, inspection for oil 1
leakage, pressure resistance, etc., using a device
as shown in the figure right.
9
(1) High pressure port (A,B,C,D port) Connect to
Install a directional valve and pressure gauge body side
to the stem side port and body side port
2
respectively, and while watching the pressure
Connect to
gauge (for high pressure) installed on the stem side
body side and also by regulating high
pressure relief valve (7), gradually increase
3
the pressure and when the pressure has
reached 1.5 times the maximum working 8
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 7
at this time.

(2) Low pressure port

(Drain port, return port : E,F port.)
Similar to the high pressure port, install a
directional valve and pressure gauge on each
port of the stem side and body side.
Hy draulic 6 5
Open stop valve (6) on the side of low pres- source
sure relief valve (5) and while watching the
pressure gauge (for low pressure) conne cted Fig. 6-12 Hydraulic circuit for inspection equipment
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 5 kgf/cm2
(71psi).

Table 6-5
Item Description Remarks
High and Low Pressures
1 Pressure Gauge
are required.
2 Swivel Joint

3 Stop Valve
Relief Valve for Setting Pressure :
5
low pressure 5kgf/cm2 (71psi)
6 Stop Valve
Relief Valve for Setting Pressure
7
high pressure (Working pressure×1.5times)

8 Directional Valve

9 Piping, etc.

Ⅱ－6－8
6.4 TROUBLESHOOTING
Table 6-6

Trouble Cause Remedy

1.External leakage of Defective O ring Replace all seals.
hydraulic oil
2.Internal leakage of 1) Defective slipper seal 1) Replace all seals.
hydraulic oil 2) Sliding face worn 2) Replace assy.
excessively
1) Stem and body 1) Grind and hone.
seized Replace assy, if stem and body
are too loose and causing oil
3.Swivel joint seized leakage.
2) Inappropriate swivel 2) Reinstall
stopper bracket Secure 2～3mm (0.08～0.12in)
allowance for bolt stopper.
4.Loose swivel stem and Socket bolt tightened Retighten.
cover insufficie ntly.

Ⅱ－6－9
 NOTES

Ⅱ－6－
 SECTION 3 - DISASSEMBLY AND ASSEMBLY

CHAPTER 34

E215
CRAWLER EXCAVATORS

TRAVEL SYSTEM

Issued January 2006

Book/Form Number 5-1720 NA
Copyright © 2006. CNH America, LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. S5PJ0010E01-KO34
 SECTION 3 - DISASSEMBLY AND ASSEMBLY
CHAPTER 34 - TRAVEL SYSTEM

CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Remarks
First edition 01-2006 E215 5-1720 NA

PREFACE
1. This manual covers all the procedures required for the disassembly and assembly of the travel system.
2. This manual consists of 34.1;REMOVING AND INSTALLING, and 34.2;DISASSEMBLING AND
ASSEMBLING.
3. General disassembly and assembly procedures are in the Table of Contents, some items may be
omitted because of the circumstances at the time of printing.
4. Please understand that it is impossible to account for all cases of the actual process for the removal/
installation of the assembled components, because of difference in the field conditions or defects.
5. Please be aware the importance to establish the working order.
Prior to beginning the removal/installation and the disassembly/assembly, select the sections required,
fully understand the description, and itemize the working procedures, then start the work.

34-II Issued 01-2006 Bur 5-1720 NA

 SECTION 3 - DISASSEMBLY AND ASSEMBLY

CHAPTER 34
TRAVEL SYSTEM
TABLE OF CONTENTS

1. Re moval And Installation

1. Travel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2. Crawler
2.1 Removing Crawler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
2.3 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
2.4 Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
2.5 Tools and Jigs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
3. Upper Roller
3.1 Upper roller Assembly 1-5
3.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
3.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
3.4 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
3.5 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
3.6 Maintenance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
3.7 tools and Jigs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
4. Lower Roller (Track Roller)
4.1 Lower Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
4.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
4.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
4.4 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
4.5 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
4.6 Maintenance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
4.7 Tools and Jigs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
5. Front Idler
5.1 Front Idler (Idler Adjustment Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
5.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
5.3 Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
5.4 Idler Adjustment Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
6. Sprocket
6.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
6.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
6.3 Maintenance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
6.4 Tools and Jigs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
7. Travel Motor
7. 1 Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
7.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
7.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
8. Swing Bearing
8.1 Swing Bearing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
8.2 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
8.3 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
8.4 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
8.5 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
8.6 Maintenance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34

5-1720 NA Issued 01-2006 Bur 34-1

 SECTION 3 - DISASSEMBLY AND ASSEMBLY
CHAPTER 34 - TRAVEL SYSTEM

2. Disassembly and Assembly

1. Travel Motor
1.1 Construction of Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
1.2 Construction of Reduction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
1.3 Travel Motor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
1.4 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-9
1.5 Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
1.6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15
1.7 Reduction Unit Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18

34-2 Issued 01-2006 Bur 5-1720 NA

[Part I; Removing and Installing]
1. TRAVEL SYSTEM

8. SWING BEARING

2. CRAWLER
7. TRAVEL MOTOR
5. FRONT IDLER 6. SPROCKET
GUARD LOWER FRAME
GREASE NIPPLE OF THE 3. UPPER ROLLER
TRACK SPRING ADJUSTER
4. LOWER ROLLER
Fig. 1-1 Designation and location of undercarriage

2. CRAWLER

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 Fig.2.2.
2) Loosen the grease nipple and slacken crawler.
: 19mm

z When loosening the grease nipple of

the adjuster, do not loosen it more
than one turn. Fig. 2-1 Crawler removing position
z 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.
3) Pushing out master pin
Apply jig on master pin and strike it out with
a mallet.
(Refer to Fig.2-6 Fixing the master pin.)
z When using a big hammer, wear
protective goggles and a long-sleeved Removing/fixing
position of master pin
uniform so you do not injure yourself
by flying objects. Fig. 2-2 Removing/fixing position of master pin

I-1
(3) Removing crawler
Removing
Put attachment on ground so that weight is
master pin
not loaded to the lower frame, and remove
track link assy rotating sprocket.

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.
Fig. 2-3 Removing crawler
2.2 INSTALLING
Installing is done in the reverse order of
removing.
(1) Checking crawler installation direction. Front
idler side
Place the track links on the ground so they
converge, facing the front idler, as shown in
the figure on the right.

(2) Installing crawler

1) Preparation for installation
Treat paint flaking protection with care not
to damage lower flame. Fig. 2-4 Installing direction of crawler

2) Winding crawler
Insert a crowbar into the master pin hole, lift
the lower frame 1 to 2cm above the ground
level by holding it by hand so the machine
body weight is not exerted on the shoe.
Retract the sprocket to help push the back
winding of the crawler.

(3) Preparation for press fitting master pin

1) Preparing for installation
Put square wood under the shoe plate.

2) Aligning master pin holes Fig. 2-5 Winding crawler

Aligning master pin holes through fine
adjustment turning sprocket.

z 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.
z Coat the master pin with
molybdenum disulfide grease, before
pressing it in.
Press fitting jig
on master pin
(4) Press fitting of master pin
Apply press fitting jig on master pin, and Fig. 2-6 Press fitting of master pin
strike it with a mallet to press fit.

I-2
(5) Adjusting crawler tension(See Fig. 2-8)
After installing, adjust tension of crawler.
: 19mm

Standard dimension A
Dimension of iron crawler in a 320~350mm
max. slackened condition (12.6~13.8in)

2.3 CONSTRUCTION Fig. 2-8Adjusting crawler tension

1-1 1-6 Triple shoe Flat shoe
2 2
1-8
1-4
1-3
1-8
Triangle shoe 3 Rubber pad shoe
1-7 2 2 3

1-1
4
1-5
1-7 3
1-2 1-2 3
Fig. 2-9 Track link assy
Fig.2-10 Shoe plate
E215
YN60D00010F1 YN60D00011F2
Shoe assy

YN60D00010F2 YN60D00011F3
Shoe assy

YN60D00010F3 YN60D00011F4
YN60D00010F4 YN60D00011F5
YN60D00010F5 YN60D00011F6
YN60D00010F6 YN60D00011F1
No. NAME Q TY No. NAME Q TY
1 稀 LINK ASSY YN62D00007F1 1 1 1 1 1 1 1 稀 LINK ASSY YN62D00007F2 1 1 1 1 1 1
1-1 稀稀 TRACK LINK (R.H) 46 46 46 46 46 46 1-1 稀稀 TRACK LINK (R.H) 49 49 49 49 49 49
1-2 稀稀 TRACK LINK (L.H) 46 46 46 46 46 46 1-2 稀稀 TRACK LINK (L.H) 49 49 49 49 49 49
1-3 稀稀 BUSHING 45 45 45 45 45 45 1-3 稀稀 BUSHING 48 48 48 48 48 48
1-4 稀稀 PIN 45 45 45 45 45 45 1-4 稀稀 PIN 48 48 48 48 48 48
1-5 稀稀 MASTER BUSHING 1 1 1 1 1 1 1-5 稀稀 MASTER BUSHING 1 1 1 1 1 1
1-6 稀稀 MASTER PIN 1 1 1 1 1 1 1-6 稀稀 MASTER PIN 1 1 1 1 1 1
1-7 稀稀 COLLAR 2 2 2 2 2 2 1-7 稀稀 COLLAR 2 2 2 2 2 2
1-8 稀稀 SEAL 90 90 90 90 90 90 1-8 稀稀 SEAL 96 96 96 96 96 96
2 稀 SHOE 600mm (24in) 46 - - - - - 2 稀 SHOE 700mm (28in) 49 - - - - -
稀 SHOE 700mm (28in) - 46 - - - - 稀 SHOE 800mm (32in) - 49 - - - -
稀 SHOE 800mm (32in) - - 46 - - - 稀 SHOE 900mm - - 49 - - -
稀 SHOE 900mm - - - 46 - - (36in)TRIANGLE
(36in)TRIANGLE 稀 SHOE 600mm (24in) FLAT - - - 49 - -
稀 SHOE 600mm (24in) FLAT - - - - 46 - 稀 SHOE 600mm (24in) - - - - 49 -
Rubber pad

稀 SHOE 600mm (24in) - - - - - 46

Rubber pad 稀 SHOE 600mm (24in) Rubber pad - - - - - 49
3 稀 BOLT 2420Z1292 184 184184 - - 184 3 稀 BOLT 2420Z1292 196 196 - - 196196
稀 BOLT 2420T7262D1 - - - 184 - - 稀 BOLT 2420T7262D1 - - 196 - - -
稀 BOLT 2420T7262D2 - - - - 184 - 稀 BOLT 2420T7262D2 - - - 196 - -
4 稀 NUT 2420Z1293 184 184184184184184 4 稀 NUT 2420Z1293 196 196196196196196
I-3
2.4 MAINTENANCE STANDARD

Fig. 2-10
Table 1-1 Unit: mm(in)
REPAIRABLE
No. ITEM STANDARD VALUE
LEVEL
SERVICE LIMIT REMEDY

A Link pitch 190
0.1 (7.4803
0.0039) 194 (7.64) 198 (7.80) Replace the link
assy if the
B O.D. of bushing ∅58.78
0.05 (2.3142
0.0020) 55 (2.17) 54 (2.13)
service limit is
C Height of link 106
0.3 (4.1732
0.0118) 100 (3.94) 98 (3.86) exceeded
Basic
Interference dimension Tolerance Fit Fit
D between bushing ∅58.78
and link
0.05 Interference Interference
(2.3142) Shaft (
0.0020) 0.05 (0.0020) 0 Replace
Interference ∅36.63
0.05 Interference Interference
E between track pin (1.4421) Shaft
(
0.0020) 0.05 (0.0020) 0
and link

0.03
Interference ∅36.50
0.088 Interference Interference Replace
F between master (1.43701) Shaft
0.00118 0.05 (0.0020) 0 Link
pin and link

0.00315
Clearance between 1.5 (0.06) 8 (0.32) 10 (0.39)
G links (both side) (both side) (both side) Replace
Tightening torque
H of shoe bolt 87kgfym (630ftylbs) Reassembly

2.5 TOOLS AND JIGS

(1) Tightening tools (2) Jig
Unit : mm (in)

NAME OPPOSING FLATS NAME SHAPE

Socket 30
Master pin
fixing jig
for iron
crawler

I-4
 3. UPPER ROLLER
3.1 UPPER ROLLER ASSY

UPPER ROLLER ASSY No. YN64D00014F1

ITEM NAME Q
T REMARKS
Y

1 ROLLER ASSY 4 YN64D01022F1

2 CAPSCREW 4 M20×P2.5×120
3 NUT 4 3 4
4 WASHER 8
4
2
3.2 REMOVING
(1) Preparation for removal 1
Remove crawler (Above mentioned).

(2) Removing upper roller (1)

1) Remove nuts on support tightening section,
and also remove capscrew (2) M20×120.
: 30mm

Fig. 3-1 Removing upper roller

3.3 INSTALLING
Installing is done in the reverse order of
removing.
(1) Inspection
Before reassembling, check it that it rotates
smooth manually and for leakage.
Countersinking
(2) Installing upper roller (1)
1) To install the upper roller, turn up socket
bolts (2) toward the center of machine.

2) Insert it until collar comes in contact with

support.

3) Fit it directing the countersinking mark of Bolt Nut

shaft end upward.

4) Apply Locktite #262 on capscrew M20×120,

Center of machine

and tighten it to the specified torque.

: 30mm,
Tightening torque : 55kgfym (400ftylbs)

2,4 1 3,4
Fig. 3-2 Installing upper roller

I-5
3.4 CONSTRUCTION 2 3 7 6 4 8 11

ROLLER ASSY PART NO. YN64D01022F1

No NAME Q
T No. NAME Q
T
Y Y

1 ROLLER 1 7 FLOATING SEAL 1

2 SHAFT 1 8 O RING : 1A
P65 1
3 COLLAR 1 9 SOCKET BOLT 2
4 PLATE 1 10 PLUG 1
5 COVER 1 11 SNAP RING 1 10
6 BUSHING 1
1 9 5
Fig. 3-3 Construction of upper roller
3.5 DISASSEMBLY AND ASSEMBLY 9 11
(1) Disassembly 4
10
1) Draining out oil
Remove plug (10) and drain out oil. 8
: 6mm 5

1
2) Removing snap ring (11)
Mount the end face inside upper roller (1) on
stand jig (f) and separate snap ring (11),
using snap ring pliers. f

3) Removing cover (5)

Take off cover (5) upwards, utilizing the
screwed hole for the plug.

Fig. 3-4 Preparation for disassembly

4) Removing O ring (8)
Separate O ring (8) from cover (5). Push with press

5) Removing plate (4)

h
Loosen two socket bolts (9) and draw out
plate (4) from roller (1).
: 8mm 2

7
6) Removing shaft (2)
3
Put the extrusion jig (h) against the end face
of shaft (2) and push shaft (2) with collar (3)
for floating seal (7), using a press or hammer.
f

Fig. 3-5 Extruding shaft

I-6
7) Removing floating seal (7). 7
Take out floating seal (7) from roller (1).

8) Removing floating seal (7). Fig. 3-6 Taking out floating seal
Remove from collar (3), floating seal (7) that
is located on the side from which shaft (2) g
was disparted.
2 6
Collar (3) is press fitted into shaft (2).
Therefore do not disassemble it. 7 1

3
9) Removing bushing (6)
Since the bushing is thin, machine it on a
f
lathe or scrape it off, exercise care so as not
to damage the bore of roller (1).
Fig. 3-7 Removing
If the bushing is not worn much, mount floating seal
upper roller (1) on jig (f), insert jig (g) into the
end face of bushing (6) and push it out with a
Fig. 3-8 Extruding bushing
press.
Push with press (e)
(2) Assembly
Assembly of the upper roller is done in the i
reverse order of disassembly.
6
1) Place upper roller (1) on the top end face of
jig ( f ) , with its floating seal setting side
1
facing down.
2) Confirm that the outer surface of bushing (6)
is not seized and coat the outer surface of the
inserting side of the bushing, with f
molybdenum disulfide grease.
3) Put jig (i) into bushing (6) and press it in,
using the bore of the bushing and the bore of
the roller as guides.
Fig. 3-9 Pushing in bushing
If you fail in this operation by pressing
2
the bushing unevenly, the bushing is
distorted and gets unserviceable. In 7
that case, do not re-use the bushing as
7
it may develop malfunctioning after 1
assembly.
3

Fig. 3-10
Fixing floating seal

I-7
4) Installing floating seals (7). Push with press
Two floating seals (7) make a pair. Attach one
floating seal to retainer fixed in shaft (2), and
another to the inside of upper roller (1). 2

z Prior to placing floating seal (7) in,

apply engine oil lightly to seal
surface.
1

5) Inserting shaft (2).

Coat shaft (2) with a thin film of oil and
insert it into upper roller (1).
Fig. 3-11 Inserting shaft
6) Installing plate (4). 11
Mount upper roller (1) on the stand jig ( f ) 9
8
and attach plate (4) to the end face of the
5
shaft with bolt (9).
4
: 8mm,
1
Tightening torque : 11.7kgfym (85ftylbs)

7) Installing O ring (8).

Fit O ring (8) to the groove of cover (5).
z Apply grease to O ring.

8) Installing cover (5).

Attach cover (5) to upper roller (1). Use a f
press in this operation as a press fit is used.

9) Installing snap ring (11).

Fix snap ring (11) into upper roller (1), using
snap ring pliers.

Fig. 3-12 Installing cover

10) Filling oil
Fill in 50cc (3.05cuyin) of engine oil API grade
5
CD#30 through the plug hole in cover (4).

11) Installing plug (10).

Wind seal tape around plug (10) and screw it 1
into the plug hole of cover (4).
: 6mm,
Tightening torque : 2.3kgfym
(17ftylbs)

z After assembling the upper roller, f

confirm that oil is not leaking from it
and that it rotates smoothly by hand.

Fig. 3-13 Filling oil

I-8
3.6 MAINTENANCE STANDARD

∅E
∅F

∅C

∅A
D D

Table 3-1 Unit : mm (in)

REPAIRABLE
No. ITEM STANDARD VALUE LEVEL SERVICE LIMIT REMEDY

A Dia. ∅160 (6.30) - -

B Width 150 (5.91) - -
Replace
C Tread dia. ∅140 (5.51) ∅130 (5.12) ∅128 (5.04)
D Tread width 33 (1.30) - -
Basic
dimension Tolerance Fit Fit
Clearance +/- 0.025
E between shaft and ∅50 Clearance Clearance
+/- 0.050
bushing Shaft
(1.96850) +/- 0.00098 0.7 (0.028) 1.0 (0.039)
+/- 0.00197 Replace bushing.
+/- 0.030
Interference ∅55 0 Interference Clearance
F between roller Hole
and bushing (2.16535) +/- 0.00118 0 0.01 (0.0004)
0
Tightening torque
G of socket bolt 11.7kgfym(85ftylbs)
Oil Engine oil API grade CD #30, 50cc (3.05cuyin) Refill
Roller rotation Roller rotates smoothly by hand. Reassembly

I-9
3.7 TOOLS AND JIGS
(1) Tightening tools
Unit : mm (in)

NAME OPPOSING FLATS

Socket 30
Allen wrench 6, 8

(2) Jigs Unit : mm (in)

No. NAME SHAPE

∅140 (5.51˝ )
∅100 (3.94˝ )

160 (6.30˝ )

f Stand jig

∅52.5 (2.07˝ )

For
(0.709˝ )

g extruding
18

bushing

∅49 (1.93˝ )

For
(1.18˝ )

h extruding
30

shaft
(1.953˝ +0.004 )
+0.
0
(2.36˝ )

∅49.6 1

0
∅60

Bushing
i
fixing jig
20 50
(0.787˝ ) (1.97˝ )
70
(2.76˝ )

I - 10
 4. LOWER ROLLER (TRACK ROLLER)
4.1 LOWER ROLLER ASSY
4 Apply Locktite #262
YN64D00010F1 T=40.5kgf礀m (290ft礀lbs)
ROLLER E215
ASSY YN64D00010F2
ITEM NAME Q TY REMARKS
1 LOW ROLLER 14 16 YN64D00013F1
2 CAPSCREW 56 64 M18×80(P=1.5)
3 TRACK GUIDE 2 2 YN01F01039P1
2 3
4 CAPSCREW 8 8 M18×40(P=1.5) Apply Locktite #262
T=40.5kgf礀m (290ft礀lbs) 1
Fig. 4-1 Lower roller assy and track guide
4.2 REMOVAL
(1) Preparation for removal
1) Loosen the tension of the crawler, lift up the
lower frame by the front attachment and stop
the engine in that condition.
2) Place a safety block (wooden) at the front and
back of the lower frame.

SAFETY BLOCK
(2) Removing track guide
(Square
Remove capscrews (4) and remove track guide.
: 27mm
Weight of track guide : Approx.24kg (52 lbs) Fig. 4-2 Preparation for removal

(3) Remove lower roller

Remove capscrews (2) and remove lower roller
(1).
: 27mm
Weight of lower roller : Approx.35kg (77 lbs)

4.3 INSTALLATION
(1) Installation of lower roller
Coat mounting capscrews (2) with Locktite #262
and fasten all four capscrews temporarily. Then
tighten them to a specified torque.
: 27mm
Tightening torque : 40.5kgfym(290ftylbs) Fig. 4-3 Installing lower roller

(2) Installation of track guide

Capscrews (4) with Locktite #262 and fasten all GREASE NIPPLE
four capscrews temporarily. Then tighten them
to a specified torque.
: 27mm
Tightening torque : 40.5kgfym(290ftylbs)

(3) Adjusting tension of crawler.

Tighten grease nipple and fill it with grease.
: 19mm,
Tightening torque : 6kgf ym(43ftylbs)
Fig. 4-4 Adjusting tension of crawler

I - 11
4.4 CONSTRUCTION

LOWER ROLLER YN64D00013F1 4 1 6 2 7 5

8
No. NAME Q
T REMARKS
Y
1 ROLLER 1
2 COLLAR 2
3 SHAFT 1
4 BUSHING 2
5 PIN 2 3
FLOATING
6 SEAL
2
Fig. 4-5 Construction of lower roller
7 O RING 2 1A,G60
8 PLUG 2 PT1/4

4.5 DISASSEMBLY AND ASSEMBLY

(1) Disassembly
1) Drain oil
Remove plug (8) and drain out oil.
: 6mm

2
2) Removing pin (5)
Put both ends of lower roller assy on the V-
shaped blocks (K), apply push-out bar ( ) on 5
upper end face of pin (5), and push pin (5) out
striking with mallet.

3) Removing collar (2), O ring (7) Fig. 4-6 Pushing out collar fixing pin (5)
Put lower roller on jig (m) for repair stand so
that the shaft (3) is perpendicularly located,
apply push-out jig (P) on shaft end on upper
side, and push shaft (3) until the O ring (7) JIG P
separate from collar (2) with press or mallet,
and take out collar (2) and O ring (7). 7 2

4) Removing shaft (3) 1

In addition, push out and remove shaft (3)
together with the lower collar (2) and O ring 3
(7).
JIG m
The shaft (3) extrusion operation may
cause the remaining lube oil to flow
out. Prepare an oil container
beforehand.

Fig. 4-7 Removing shaft (3), collar (2), O ring (7)

I -12
5) Removing collar (2), O ring (7)
Remove O ring (7) from shaft (3) that was
drawn out in the previous paragraph.
6
6) Removing floating seal (6)
Remove floating seal (6) from collar (2).

2
7) Removing floating seal (6)
Remove floating seal (6) from roller (1).

Fig. 4-8 Removing floating seal (6)

8) Removing bushing (4)

Since thickness of bushing (4) is thin 1
[thickness is 2.0mm (0.079in)], remove it
through lathe or strip it with care not
damage inner hole of roller. When the wear of
bushing is not large, place upper roller (1) on
jig (m) for repair stand and apply the end of
push-out jig on the end face of bushing (4) Fig. 4-9 Removing floating seal (6)
end, and push it out striking it with mallet.

Hammer the inside surface of roller

lightly so as not to damage the surface.
Put the extrusion jig (n) uniformly over n
the circumference of bushing (4) and
extrude it perpendicularly little by 1
little.

JIG m

Fig. 4-10 Extruding bushing (4)

I - 13
(2) Installing
7 3
1) Attach O ring (7) to one side
Install O ring (7) to groove on shaft.
z Grease O ring.
z Replace O ring with new one without
fail at reassembling.
Fig. 4-11 Attach O ring (7) to one side
2) Press fitting bushing (4)
Align inner hole of roller (1) and bushing (4)
and press fit it vertically in capacity of press
JIG
Q
fit load, 5ton (11000 lbs), in the condition that
bushing push-in jig (Q) is inserted into
bushing (4). 4

z Apply molybdenum disulfide grease

on press-fit section of bushing, and
press fit it in ordinary temperature.

z Bushing which fails to press-fit

because of the one-side pressing Fig. 4-12 Press fitting bushing (4)
should not be fitted.

3) Press fitting collar (2)

Fit O ring (7) to the one side of shaft (3)
6
mating pin hole of collar (2) on which floating 5
seal (6) is fit with pin hole of shaft (3) in
advance. Use the press of capacity 17 ton
(37500 lbs) or more. 3

z Care should be taken not to damage

O ring (7) while press-fitting collar
(2) to shaft (3). 2
7
Fig. 4-13 Inserting pin (5)

4) Inserting pin (5)

Press-fit pin (5) to pin hole on aligning pin
holes of shaft (3) and collar (2).

5) Attach floating seal (6) to roller side

Fit floating seal (6) to inner holes on both
ends of roller (1).
z Check that the seal surface is free
from flaws, rusts, etc. before reusing 6
the floating seal.

6) Inserting roller (1) 3

Insert roller (1) from the side where collar (2),
2
O ring (7) is not press-fitted to the shaft (3). 7

Fig. 4-14 Inserting roller (1)

I - 14
7) Installing O ring (7) Press
Install O ring (7) to groove on shaft.

z Grease O ring. Pin hole

z Replace O ring with new one without 2
fail at reassembling.

8) Press fitting collar (2) 7

Press-fit collar (2) to shaft (3).

z Press-fit collar (7) on aligning pin (5)

3
hole.

9) Inserting pin (5)

Press-fit pin (5) in to the pin hole mating pin
hole of collar (2) with pin hole on the end side
of shaft (3).

Fig. 4-15 Installing O ring (7), collar (2)

10) Filling oil
Remove plug (8) and fill in 160cc (9.8cuyin) of
engine oil API grade CD#30.

11) Check it for leakage

Before tightening plug (8), check it for
leakage in the condition of air pressure
2.0kgf/cm2 (28psi). 8
Tightening
torque
12) Installing plug (8) 2.4kgfym
Apply oil resistant sealant on plug (8), and (17ftylbs)
tighten it in the plug hole on the collar (2)
end face. 2
: 6mm,
Tightening torque : 2.4kgfym (17ftylbs)

After assembling the lower roller, Fig. 4-16 Installing filling oil plug (8)
confirm that oil is not leaking and that
the roller rotates smoothly by hand.

I - 15
4.6 MAINTENANCE STANDARD

C C

G
∅A

∅B
∅D
∅E

Fig. 4-17 Lower roller (Track roller)

Table 4-1 Unit : mm (in)

No. ITEM STANDARD VALUE REPAIRABLE LEVEL SERVICE LIMIT REMEDY

A O.D. of flange ∅185 (7.28)

Reinforcement

B Tread dia. ∅150 (5.91) ∅134 (5.28) ∅128 (5.04) weld, repair or
replace
C Flange width 23.5 (0.925) 18 (0.709) 16.5 (0.65)
Basic
Tolerance Fit Fit
dimension
Clearance between
- 0.060
D shaft and bushing
∅65 - 0.090 Clearance Clearance
(Wrapped bushing) Shaft
(2.55905) - 0.00236 0.7 (0.276) 1.0 (0.394) Replace
- 0.00354 bushing.
- 0.030
Interference
∅69 - 0.020 Interference Clearance
E between roller and Hole
(2.71653) 0.00118 0 0.01 (0.0004)
bushing
0.00079
F Oil Engine oil API grade CD #30, 150cc (9.8cuyin) Refill
Clearance between
G Keep 2.50.5 (0.09840.0917).
roller and collar
H Plug (8) Execute air leak test at 2.0kgf/cm2 (28psi) before tightening the plug.

Roller rotation Rotates smoothly by hand. Reassembly

I - 16
4.7 TOOLS AND JIGS
(1) Tightening tools
Unit : mm (in)
NAME OPPOSING FLATS
Socket 19,27
Allen wrench 6

(2) Jig

Unit : mm (in)
No. NAME SHAPE

k V-block

∅100 (3.94˝ )
Pin (5)
extrusion ∅14 (0.551˝ )
rod

200 (7.87˝
Bushing
n extrusion ∅16 (0.630˝
)
rod

290 (11.4˝

m Stand jig
(4.92˝ )

(6.30˝ )
∅125

∅160

Shaft 270 (10.6˝

p extrusion
∅64 (2.52˝ )
jig

∅86 (3.39˝
30 (1.18˝ )
(3.72˝ )
94.5
(2.54˝ )

Bushing
64.5

q
fixing jig

+0.
∅64.6 1
(2.543˝+0.004
0
)

17
 5. FRONT IDLER (IDLER ADJUSTER ASSY)
5.1 FRONT IDLER ASSY
Apply Locktite#262 or equivalent
FRONT IDLER ASSY YN52D00012F1 T=28.5kgfym (210ftylbs)
1 4 2
No. NAME Q
T REMARKS
Y
1 IDLER ASSY 2 YN52D00009F1
2 IDLER
ADJUSTER 2 YN54D00003F1
ASSY
3 GREASE NIPPLE 2
4 CAPSCREW 4 M16×45

Fig. 5-1 Front idler assy

5.2 REMOVING
(1) Preparation for removal
Remove crawler. (Above mentioned)
BAR
(2) Removing idler assy
Sling idler assy, and push it forward with
bar.
Weight of crawler/idler assy : 420kg (926 lbs)

Keep away from the front side of front

idler.

(3) Installing
Installing is done in the reverse order of
removing.
Fig. 5−2 Removingand
installationthefrontidler

1
(4) Where idling assy (1) has to be separated
Loosen capscrew (4), and separate idler assy
(1) from idler adjuster assy (2).
: 24mm (0.945in)
Weight of idler assy : 107kg (236 lbs)
Weight of idler adjuster assy : 103kg (227 lbs) 2

z The separated idler assy should be

placed on square timbers.

4 3

Fig. 5-3 Separating idler assy (1)

from idler adjuster

I - 18
5.3 IDLER ASSY
5.3.1 CONSTRUCTION

IDLER ASSY YN52D00009F1 1

No. NAME Q
T REMARKS 2
3
Y 7
1 IDLER 1 YN52D01006P1
8
2 BUSHING 2
6
3 COLLAR 2 YN52D01011P1 5
4 FLOATING SEAL 2 4
5 PIN 2
6 SHAFT 1
Fig. 5-4 Idler assy
7 O RING 2 1AG70
5
8 PLUG 2 PT1/8 R
5.3.2 REMOVING AND INSTALLING
(1) Removing
1) Drain oil
Remove plug (8) on the side of collar (3) to
drain.
: 5mm

2) Removing pin (5) Fig. 5-5 Removing pin (5)

Apply pin push bar (jig R) to the top of pin,
Push with press
and push out striking bar (jig R) lightly by
hammer.
S
6
3) Removing collar (3)
3
Put idler (1) on repair stand (U), apply push- 1
out jig (S) on shaft (6), push out shaft (6) with
collar (3), then remove collar (3).

U
3

Fig. 5-6 Removing collar (3)

Push with press
4) Removing collar (3) from shaft (6)
If removal of collar (3) on the opposite side is S
required, turn over front idler and proceed
6 3
with the procedure described in Par. 3).

Fig. 5-7 Removing collar (3)

I - 19
5) Removing bushing (2)
With idler (1) mounted on the stand, tap
bushing (2) lightly by hammer, while placing
the bushing drawing rod (T) against the end
face of bushing (2) evenly all round, till it
comes out.
T 2
1
6) Removing floating seals (4)
Take out floating seals (4) from idler (1),
collar (3). If you intend to re-use floating
seals (4), confirm that there is no scoring and
rusting on the contact surface and store the
floating seals in pairs by placing card board
between the sealing faces.
U
7) Removing O ring (7)
Separate O ring (7) from shaft (6).
Fig. 5-8 Removing bushing (2)
(2) Assembly
1) Pressing in bushing (2)
Align inner hole of idler (1) and bushing (2) 2 Push with press V
and press fit it vertically with press so that 1
jig (V) for bushing press-fitting is inserted
into bushing (2).

2) Installing O ring (7)

Fit O ring (7) to O ring groove on shaft (6).

z Apply grease to O ring Fig. 5-9 Pressing in bushing (2)

3) Installing collar (3) (See Fig. 5-10) Pressing

Press fit the O ring (7) installed side of shaft
(6) into collar (3), and drive pin (5). 6

4) Installing floating seal (4)

Fit the half of floating seal (4) on each side of 3
5
collar (3) and idler (1).

5) Inserting idler (1)

Insert floating seal (4) fitted side of idler (1) Fig. 5-10 Installing collar (3), shaft (6)
into shaft (6).
6
4
6) Installing floating seal (4)
Fit floating seal (4) on the other side of idler
1
(1).

Fig. 5-11 Inserting idler (1) and installing

floating seal (4)

I - 20
7) Installing collar (3)
Fit the half of floating seal (4) on the other
collar (3), press fit it in shaft (6), and drive 8
pin (5) in with hummer. 3
5
8) Filling oil・Inspection
Fill in 200cc (12.2cuyin) of engine oil API 1
grade CD #30 through the plug hole of collar
(3), wind seal tape and tighten plug (8).

: 5mm
Fig. 5-12 Installing collar (3) and filling oil
z After installing the idler assy to the
idler adjuster assy, make certain 160
that no oil leaks from floating seal C
and plug (8) and that idler (1)
rotates smoothly.

5.3.3 MAINTENANCE STANDARD F

A
B

Fig. 5-13 Front idler

Table 5-1 Unit : mm (in)

No. ITEM STANDARD VALUE REPAIRABLE LEVEL SERVICE LIMIT REMEDY
Dia. of idler
A projection ∅535 (21.1) - -
B Tread dia. ∅497 (19.6) ∅490 (19.3) ∅487 (19.2) Replace
C Flange width 84
0.5 (3.307
0.020) 78 (3.07) 76 (2.99)
Basic
dimension
Tolerance Fit Fit
Clearance - 0.030
D between shaft ∅75 - 0.060
and bushing Shaft
Clearance Clearance
(2.95275) - 0.00118 1.5 (0.059) 2.0 (0.079) Replace
- 0.00236
bushing.
+0.036
Interference ∅83 0 Interference Clearance
E between idler Hole
(3.26771) +0.00142 0 0.01 (0.0004)
and bushing
0
F Oil Engine oil API grade CD#30, 200cc (12.2cuyin) Refill
Idler rotation Rotates smoothly by hand. Reassemble

I - 21
5.3.4 TOOLS AND JIGS
(1) Tightening tools

Unit : mm(in)
NAME OPPOSING FLATS
Socket 24
Allen wrench 5

(2) Jigs
Unit : mm(in)

No. NAME SHAPE

(1.18˝ )
∅15
∅30
(0.591˝ )
Pin
R
striking jig
105 15
(4.13˝ ) (0.591˝ )

340 (13.4˝ )
Shaft
S push out
jig ∅74 (2.91˝ )

300 (11.8˝ )
Bushing
T drawing ∅16 (0.630˝ )
rod

About. 150 (5.91˝ )

About. 600
(23.6˝ )

U Stand
About.
400
(15.7˝ )
2 pcs.

∅105 (4.13˝ )
(2.76˝ ) (0.787˝ )
20

Bushing
(3.54˝ )
90

V Press
70

fitting jig

+0.
∅74.61
+0.004
(2.937˝0 )

∅103 (4.06˝ )
Collar
W Press
30 (1.18˝ )
fitting jig

I - 22
5.4 IDLER ADJUSTER ASSY
5.4.1 CONSTRUCTION
2 4 3 7 1 5 9 8 6
IDLER ADJUSTER ASSY YN54D00003F1
Q
T
No. NAME REMARKS
Y
1 GREASE CYLINDER 1
2 BRACKET 1
3 NUT 1
4 SPRING PIN 1 ∅880
5 SPRING 1 11 10
6 PISTON 1
7 COLLAR 1
Fig. 5-14 Idler adjuster assy
8 O RING 1 1B G80
9 OIL SEAL 1
10 PIN 2
11 DISASSEMBLY
5.4.2 COVER 1
AND ASSEMBLY
(1) Disassembly
1) Spring set special jig M30
Holding-down nut
Before disassembling and assembling the
idler adjuster assy, prepare spring setting jig Retainer plate
(V).

Capacity of hydraulic jack : more than 20

tons (44000 lbs) V
: 46mm
Hydraulic jack

Large power is needed to set the

spring. Prepare a special jig before
disassembly and assembly. BASE
Fig. 5-15 Spring set special jig (V)
2) Preparation for working
Place a hydraulic jack between the jig base
and the stand.
Loosen the holding-down nuts of the jig and
draw out the retainer plate upward.
: 46mm
3) Draw out grease cylinder (See Fig. 5-14)
Draw out piston (6) from grease cylinder (1)
of the idler adjuster assy.
4) Removing oil seal (9), O ring (8)
(See Fig. 5-14)
Taken out oil seal (9) and O ring (8) from
5
grease cylinder (1).

5) Slinging work idler adjuster

Set the idler adjuster assy on the stand of
the jig, with its bracket side facing up. V
Fig. 5-16 Slinging work idler adjuster

23
6) Fixing idler adjuster assy
Fit retainer plate to bracket (2), tighten 4
holding-down nuts alternately, and secure
idler adjuster assy.

Holding-down nut
: 46mm

3 Retainer plate
Fig. 5-17 Fixing idler adjuster assy
7) Compression of spring (5)
Remove spring pin (4), press spring (5) lifting
it with jack so that nut (3) can be turned 5
freely, and remove nut (3).

: 46mm
: 75mm

Fig. 5-18 Compression of spring (5)

8) Removing bracket (2)
Allow the hydraulic jack to retract slowly till
the spring is extended to its free length.
Retainer plate
Remove the retainer plate and take off
bracket (2), cover (11).
The free length of the spring :
About 531.1mm(20.9in)
2

: 46mm 11

Fig. 5-19 Removing retainer plate, bracket (2)

9) Removing spring (5), grease cylinder (1)
Hook lifting eye nut (W) to screw M48×P2 on W
grease cylinder (1) top end and hoist it. Then, 1
remove the set of grease cylinder (1) and
spring (5) using crane from the jig.
Remove spring (5), collar (7), grease cylinder 5
(1), in that order.

Fig. 5-20 Removing spring (5), grease cylinder (1)

I - 24
(2) Assembly W
Assembly is done in the reverse order of
disassembly.
1
1) Installing spring (5), grease cylinder (1)
Insert grease cylinder (1), collar (7) into
spring (5) and attach lifting eye nut (W) to
5
screw M48×P2 at the tip of the grease
cylinder. Lift the grease cylinder by crane
and erect it in the center of the jig stand
upright.

2) Fixing idler adjuster assy Fig. 5-21 Attach spring (5) and grease
Install bracket (2), cover (11) on top of spring cylinder (1) to the jig
(5). Center the rod of grease cylinder (1) and
Holding-down nut
the holes in bracket (2). Attach the retainer
plate and four holding-down nuts. Fasten the Retainer plate
nuts evenly all round and fix the idler
adjuster assy to the jig body.

: 46mm 2
4
3) Compressing spring (5) and removing nut (3) 3
Extend the hydraulic jack, compress spring 7
11
(5) to a set length and screw in nut (3) to the
screwed part at the tip of grease cylinder (1). 1

5
Set length of the spring : 429mm (16.9in)

4) Installing spring pin (4) Fig. 5-22 Compression of spring (5), and
Tighten nut (3) till the holes for locking attaching nut (3) and spring pin (4)
spring pins (4) are aligned. Then fit spring
pin (4).

: 46mm
: 75mm

5) Removing idler adjuster assy

Remove idler adjuster assy from jig.

Fig. 5-23 Removing idler adjuster assy

I - 25
6) Installing oil seal (9), O ring (8)
Fit oil seal (9) and O ring (8) to grease
cylinder (1).

z Grease oil seal (9) and O ring (8). 1 9 8 6

7) Filling grease cylinder(1) with grease.

Fill up grease in cylinder (1), remove the
grease nipple from piston (6) to discharge the
inside air, and press in the piston by hand.

z Direct grease nipple hole downward

to make air discharge easier. Grease Nipple
Fig. 5-24 Grease cylinder (1)
8) Installing grease nipple
Tighten grease nipple to piston (6).

: 19mm,
Tightening torque : 6kgfym (43ftylbs)

5.4.3 MAINTENANCE STANDARD

STANDARD
No. ITEM
VALUE
A Installed length of spring 429mm (16.9in)
About. 531.1mm
B Free length of spring (20.9in)
C Stroke 50mm (1.97in)

D Set length 630mm (24.8in)

Nor scoring
E Outside view of piston and rusting
Tightening torque of 6kgfym
F grease nipple (43ftylbs)

F
A, B
D

I - 26
 6. SPROCKET
6.1 REMOVING
(1) Preparation for removal
Remove crawler referring to Section 2.
"Crawler", lift up crawler frame with
attachment, and put it on square timbers to
float and stabilize.

Fig. 6-1 Preparation for removal

(2) Removing sprocket
Loosen twenty two capscrews (2) M18×50,
for the attaching of the sprocket by means of
a socket and remove the sprocket (1).
Weight of sprocket : 57kg (126 lbs)

: 27mm

1
Fig. 6-2 Removing sprocket
6.2 INSTALLING
(1) Check before installing
Check the mating portion of the travel
reduction unit and the sprocket, eliminate
burrs and contamination thoroughly and
install the sprocket.

(2) Securing sprocket temporarily

Coat the sprocket attaching capscrews with
Locktite #262 and fasten the sprocket
temporarily.

(3) Securing sprocket completely

Remove the wooden blocks under the truck
frame, bring the machine down on the ground
and tighten the sprocket.

: 27mm,
Tightening torque : 40.5kgfym (290ftylbs)

Fig. 6-3 Securing sprocket completely

I - 27
6.3 MAINTENANCE STANDARD (2404N262)
Table 6-1
96.07mm NUMBER
PITCH 21
(3.78in) OF TEETH
SPECIFICATION
ROLLER ∅58.72 PITCH 644.602
DIA. (2.31in) DIA. (25.333in)

A C

Fig. 6-4 Sprocket

Table 6-2 Unit:mm(in)

No. NAME STANDARD VALUE REPAIRABLE LEVEL SERVICE LIMIT REMEDY

∅664 ∅656 ∅654 Reinforcement weld,

A O.D. of sprocket (26.1) (25.8) (25.7) repair or replace.

B Width of 0 0
70
(2.751

4
)

0.157 64 (2.52) 62 (2.44) Replace.
sprocket teeth

C O.D. of sprocket Reinforcement weld,

∅586 (23.1) ∅578 (22.8) ∅576 (22.7)
bottom repair or replace.

6.4 TOOLS AND JIGS

(1) Tightening tools
Unit : mm (in)
NAME OPPOSING FLATS
Socket 27

I - 28
(2) Sprocket tooth profile gauge : W

Unit : mm (in)

Fig. 6-5 Tooth profile gauge (Full scale)

I - 29
 7. TRAVEL MOTOR Apply Locktite #262
7.1 TRAVEL MOTOR or equivalent
T=40.5kgfym (290ftylbs)
TRAVEL MOTOR YN53D00005F1 2
No. NAME Q
TY REMARKS
0 TRAVEL MOTOR ASSY 2 LQ15V00011F1
1 SPROCKET 2 2404N262 3
2 CAPSCREW 44 M18×50 Apply Locktite #262
or equivalent
3 CAPSCREW 34 M20×60 T=55kgfym (400ftylbs)
1
0

Fig. 7-1 Installing travel motor

7.2 REMOVING
(1) Preparation for removal
Remove crawler, lift up crawler frame using
attachment, and put it on square timbers to
float and stabilize.

7
(2) Removing cover (1),(2)
Remove sems bolt (7) M12×25 and also 1,2
remove covers (1),(2).

: 19mm Fig. 7-2 Removing and installing cover (1), (2)

(3) Preparation of oil pan

(4) Removing hydraulic pipe

Bleed air in hydraulic oil tank, remove all
pipes connecting to travel motor. Then plug
up all pipes and joint section to protect them
from entry of dust.

: 19mm, 27mm, 32mm, 41mm

Refer to tool 4.plug (1).
Hydraulic pipe plug 4-1
ORS plug 4-1 YN11 See tools Fig. 7-3Removing and installing hydraulic pipe

I - 30
(5) Removing sprocket
Removing forty four (both side) capscrews (2)
M18×50.

: 27mm

Fig. 7-4 Removing and installing sprocket

(6) Loosening travel motor attaching bolts (3)
Apply match marks on travel motor and Remove pipes.(Disconnect)
crawler frame, and remove thirty four (both
side) capscrews (3) M20×60.

: 30mm

Fig. 7-5 Removing and installing travel motor

(7) Slinging travel motor assy attaching bolts
Sling travel motor with nylon sling applied on
the side close to sprocket installing section
and remove the motor.

Weight of motor : About. 240kg (529 lbs)

Fig. 7-6 Slinging travel motor

7.3 INSTALLING
Tightening
Installing of the travel motor piping is performed Tools
Torque
RE-
NAME SIZE HEX No. MARKS
in the reverse order of removal. kgfym(fty lbs)
1) Cleaning Sems bolt M12 19 7 8.5 (61)
Apply
Check that contact surface of travel motor M18 27 2 40.5 (290) Locktite
Capscrew
and crawler frame is free from burr and M20 30 3 55 (400) #262
stain. Flareless ∅10
1.5 19 - 5 (36)
nut for ∅18
2.5 32 - 15 (110)
pipes,
2) Tightening torque ∅28 41 - 28 (200)
sleeve
Tighten capscrew and hydraulic pipes to the PF1/4 19 - 3.7 (27)
Connector PF1/2 27 - 11 (80)
torque specified in "Tightening Torque". PF1 41 - 26 (190)

I - 31
 8. SWING BEARING
8.1 SWING BEARING ASSY

SWING BEARING ASSY YN40F00012F1

No. NAME Q
T REMARKS
Y

1 SWING BEARING 1 YN40F00004F1

FRONT
2 CAPSCREW 36 M20×P1.5×65

2 Locktite #262 or equivalent Inner S zone position of

to be applied swing bearing
SECTION A-A T=57.4kgfym (420ftylbs)
Fig. 8-1 Swing bearing assy
NOTE: Fill grease bath with 8.3kg (18.3 lbs) of
grease NLGI-2 (containing molybdenum
disulfide) or equivalent.

8.2 REMOVING
(1) Matchmarks
Remove upper structure, apply matchmarks Swing bearing
on inner race of swing bearing and lower
Outer race
frame.

(2) Remove thirty six capscrews (2) M20×65 for Inner race
installation inner race.
: 30mm
Matchmarks

(3) Drawing out grease

Remove grease in grease bath.
Fig. 8-2 Matchmarks
(4) Removing swing bearing
Attach eyebolt on swing bearing and sling it.

Weight of swing bearing : 232kg (511 lbs)

Swing bearing
Eye bolt

Grease bath
Fig. 8-3 Removing and installing swing

I - 32
8.3 INSTALLING
(1) Cleaning
Clean it completely so that installing surfaces
of swing bearing and lower frame are free
from dust and stain.
FRONT
(2) Installing
Install swing bearing on lower frame meeting
the matchmarks and positioning the S mark
on inner race as shown in the figure.

(3) Temporary fastening of inner race

Coat the threads of the capscrews (2) with Inner S zone position of
Locktite #262 and tighten all the capscrews swing bearing
(2) temporarily. Fig. 8-4 Location of S mark on swing bearing
: 30mm

(4) Regular tightening of inner race

Tighten the capscrews (2) at 180 degrees
intervals alternately to a specified torque.
:30mm, 1
Tightening torque :
57.4kgfym (420ftylbs)
2Locktite #262 or equivalent
to be applied
(5) Filling grease. T=57.4kgfym (420ftylbs)
SECTION A-A
Fill grease bath with 8.3kg (18 lbs) of grease
NLGI-2 (containing molybdenum disulfide) or Fig. 8-5 Removing and installing capscrew (2)
equivalent.

8.4 CONSTRUCTION
ASSY PART NO. YN40F00004F1 6
No. NAME Q
T No. NAME Q
T 1 8
Y Y 9
1 OUTER RACE 1 6 SEAL 1 7
2 INNER RACE 1 7 TAPER PIN 1 3,4
3 BALL 104 8 PLUG 1
5
4 RETAINER 104 9 GREASE NIPPLE 1
5 SEAL 1 (PT1/8)
2
8.5 DISASSEMBLY AND ASSEMBLY Fig. 8-6 Cross-sectional view of swing bearing
(1) Disassembly
1) Take out seal (5) fitted in the groove in the EYE BOLT
6 2
outer circumference under inner race (2) and
7
seal (6) fitted in the groove in the inner
circumference on top of outer race (1) and 1
place them level on a square wooden block or Square wooden
something. block
2) Draw out taper pin (7), using a hammer and
an extrusion rod.
8
3) Draw out plug (8), utilizing an pull bolt
inserted in the screwed hole (M10) in the 5
center of the plug and using a puller. Fig. 8-7 Removing swing bearing

I - 33
4) While rotating outer race (1) little by little, 1
take out ball (3) and retainer (4) through plug
hole, in that order.

2
4
3
Fig. 8-8 Removing balls (3) and retainers (4)
(2) Installing
1) Thoroughly degrease the groove for seal (6)
located on the inner surface of outer race (1)
and the groove for seal (5) located on the
outer surface of inner race (2). Coat the
grooves with adhesive Cyano Bond PX-3000
equivalent, fit seal (5) and place it on a 1
surface plate. Push rod 6
2) Lower outer race (1) to the position where
2
upper surface of inner race (2) and lower
portion of seal groove is mated, put adjusting 3
5
washer under outer race (1) so that outer Square
wooden block
raceway surface of ball (3) aligns with inner
raceway, and support it. Fig. 8-9 Fitting balls (3)
3) Insert ball (3) and retainer (4), on which
grease is applied, through plug (8) hole on Eye bolt
outer race (1), alternately.

To insert ball (3) and retainer (4), use a

push rod, etc., to protect persons from Hooked rod
injury from inserting fingers into plug
hole.

4) Fit plug (8) to outer race (1) while checking it 4

for direction and position of taper pin hole.
5) Coat seal (6) with adhesive Cyano Bond PX- Square
wooden block
3000 equivalent and fit it in the groove of
outer race (1). Fig. 8-10 Fitting retainer (4)
6) Check that grease nipple (7) is properly
fitted, and fill it with grease. Then, check
bearing for smooth rotation and flaws on seal
lip portion.
z Shell Alvania EP#2 ; 270cc (16.48cuyin)

8.6 MAINTENANCE STANDARD

Maintenance standard concerning wear of swing
bearing is described in the section “Maintenance
Standard and Test Procedure” in the separate
volume.

I - 34
 ☆：Apply Locktite #242
1. REMOVAL AND INSTALLATION OF TRAVEL MOTOR UNIT
1.1 CONSTRUCTION OF TRAVEL MOTOR Tightening Opposing Tightening Opposing
Q
T Q
T
torque flats No. NAME torque flats No. NAME
35 37 12 13 3 7 5 6 39 24 28 36 kgfym( ftylbs) mm Y kgfym( ftylbs) mm Y
1 CASING 1 23.5 (170) 14 31 SOCKET BOLT；M16×45 8
2 REAR COVER 1 32 SHIM 1~2
20 33 3 CYLINDER BLOCK 1 33 PARALLEL PIN；∅6×12 1
21 4 SHOE RETAINER 1 ― ─── ―
5 FRICTION PLATE 3 35 PLUG；NPT1/16 1
23 6 BRAKE PISTON 1 36 PLUG；NPT1/16(Meck : TB) 10
29 32 7 SEPARATOR PLATE 4 1.4 (10)☆ 37 PLUG 1
8 VALVE PLATE 1 1.5 (11) 5 38 PLUG；PF1/8 3
17 9 SHAFT 1 3.0 (22) 6 39 PLUG；PF1/4 2
9 26 10 COUPLING 1 40 ORING；1B P8 5
38 11 SHOE PLATE 1 41 ORING；1B P11 4
18 12 BALL JOINT 1 42 ORING；1B P14 2
40 13 SPRING RETAINER 1 43 ORING；190.17×2.62 1
39 View Z 14 PISTON ASSY 9 11 (80) 32 44 OVER LOAD RELIEF VALVE；M27 2
41 15 D RING (SMALL) 1 45 SPOOL 1
16 D RING (LARGE) 1 5.5 (40) 22 46 PLUG；PF3/8 1
10 17 CHECK VALVE 3 47 SPRING RETAINER 1
18 SNAP RING 1 48 PIN 1
2 19 SNAP RING 1 49 SPRING 1
19
20 TILTING PISTON 1 5.5 (40) 50 CONNECTOR 1
21 BALL 1 51 SPOOL ASSY 1
30 22 PIVOT 2 52 COVER 2
23 PISTON SEAL 1 53 SPRING 2
8 24 M6 ORIFICE；∅0.6 2 54 SPRING RETAINER 2
25 25 OIL SEAL 1 55 RESTRICTOR VALVE 2
26 SPRING 3 56 SPRING 2
22 1 11 4 27 15 16 43 14 27 SPRING(CYLINDER) 9 2.8 (20) 57 PLUG 2
44 50 42 45 48 47 49 42 28 SPRING(BRAKE) 2 58 ORING；42.52×2.62 2
46
29 BEARING 1 59 ORING；1B P9 2
30 BEARING 1 10 (72) 10 60 SOCKET BOLT；M12×35 8
58
54 44-3 44-2 44-1 44-4 44-12 44-13 44-9 44-8 44-12 44-10 44-11 44-6 44-7 44-5

60

53

52

57

Note) Quantities are worth one overload relief valve.

41 Tightening Tightening Opposing
Opposing
torque flats No. NAME Q
TY torque flats No. NAME Q
TY
kgfym( ftylbs) mm kgfym( ftylbs) mm
11 (80) 32 44-1 SOCKET 1 44-8 SHIM 1
44-2 VALVE 1 44-9 ADJUSTMENT SPRING 1
31 51 59 55 56 44-3 VALVE SEAT 1 44-10 O RING；1B P7 1
44-4 CONNECTING PISTON 1 44-11 BACK UP RING 2
VIEW Z (Shows part of the cross-sectional view) 16 (120) 35 44-5 PLUG 1 44-12 O RING；1B G25 2
Fig.1-1 Construction of travel motor 44-6 PILOT BODY 1 44-13 BACK UP RING 1
44-7 PISTON 1
II-1
 1.2 CONSTRUCTION OF REDUCTION UNIT

24 15 16 14 13 12 18 25 20

5
10 Clearance:-0.08 to+0.02mm (-0.0031 to+0.0008in)
Adjust it with only one shim.
6

9
(0.043˝ )

(0.016˝ ～0.094˝ )
8 Storage this unit in condition
that the axis is horizon.
1

11

26

17 21 22 19 23

Fig.1-2 Construction of reduction unit

Apply Locktite #242

Tightening Opposing Q
T

Tightening Opposing Q
T
torque flats No. NAME torque flats No. NAME
kgfym( ftylbs) mm Y kgfym( ftylbs) mm Y

1 COVER 1 14 PLANETARY GEAR 2 3

2 CARRIER 1 1 15 SPRING PIN；∅6×36 3
3 CARRIER PIN 1 3 16 THRUST WASHER 2 6
4 NEEDLE BEARING 3 17 RING GEAR 1
5 THRUST WASHER 1 6 18 HOUSING 1
6 PLANETARY GEAR 1 3 19 BEARING 2
7 SPRING PIN；∅4×22 3 20 SHIM 1
8 THRUST PLATE 1 21 LOCK WASHER 2
9 SUN GEAR 1 1 22 SUPPORT RING 1
10 SUN GEAR 2 1 23 FLOATING SEAL 1
11 CARRIER 2 1 8.0 (58)☆ 8 24 SOCKET BOLT；M10×25 15
12 CARRIER PIN 2 3 28.0 (200)☆ 14 25 SOCKET BOLT；M16×80 19
13 NEEDLE BEARING 3 1.0 (7.2) SEAL
TAPE 14 26 SOCKET PLUG；PT3/4 2

Ⅱ－2
1.3 TRAVEL MOTOR DISASSEMBLY
1.3.1 TOOLS

Table 1-1
TOOL NAME SPECIFICATION
Alen wrench Opposing flats 5, 6, 10, 14
Spanner Opposing flats 19, 27, 32, 35
Plier for snapring For shaft ∅45 (1.77˝ )
Plier for snapring For hole ∅32～∅80 (1.26˝ ～3.15˝ )
Plastic hammer
Screw driver Flat-bladed (－), Medium size 2pc.
Torque wrench 23.5kgfym (170ftylbs) max.
Gear (Bearing) puller Effective opening dimension: diameter 75
width 45

Holding-down metal fitting Ex. L160×W70×H37, 20×100 oval hole:

2 tools are needed.

W
(0.787˝ )
20
100
(3.94˝ )

H
Oil seal fitting jig ∅90
(3.54˝ ) (0.394˝
10

)))))
(0.394˝ )
10

∅52
(2.05˝ )

Brake piston fitting jig

(0.866˝ )

PCD220
(0.394˝ )

(8.66˝ )
22

DRILL THROUGH 2-18

10

Others
Seal tape
Cleaning oil (Kerosene) ∅170
Grease (6.69˝ )
∅190
Hydraulic oil (7.48˝ )
Rag ∅250
(9.84˝ )
Compressed air

II - 3
1.3.2 DISASSEMBLY
(1) General cautions C Separate spring (53), spring retainer (54) and
1) In general, the hydraulic components are spool assembly (51).
made to precision and have very little
clearance. For this reason, disassemble and Put a matching mark on spool
assemble them in a less dusty clean place. assembly (51) and rear cover (2) so
Use clean tools and cleaning oil and handle they are reassembled in correct
them with care. directions. (Right and left directions)
Since the screw threads of spool
2) When the motor has been separated from the assembly (51) is coated with
machine , clean the ports and the neighboring adhesive, further disassembly is not
areas thoroughly and put plugs into ports so possible.
no dirt, water and other foreign matter enter
the motor. D Draw out plug (57), O ring (41), spring (56)
and restrictor valve (55).
3) Study the assembly drawing before starting
the work and prepare necessary parts E Remove overload relief valve (44).
according to the purpose and the scope of
disassembly. Seals and O rings once : 32mm
disassembled can not be used again. Some
parts cannot be supplied singly, but must be F Remove coupling (10).
supplied as sub-assemblies. Prepare such
parts beforehand according to the parts
manual.

4) Pistons and cylinders do not have specific

combinations when new. If you expect to use
disassembled pistons again, put a matching
mark on each piston and cylinder so they are
reassembled where they were.

5) Use care so you do not pinch your finger

between parts and drop parts on your foot.

(2) Disassembly procedure

1) Removing the attached valves.
Remove the attached valves before
disassembling the motor.
44
Do not remove such valves that are
2
not supposed to be taken off because 58
of the purpose of disassembly. 60
10
However, you can not disassemble
the motor without removing the
52
brake valve. 53
54
B Loosen socket bolts (60) and take off O rings 57
41
(58), (59). 5655
59
51
: 10mm

II - 4
2) Disassembling the motor
B Place the motor shaft level and remove all
bolts (31) except two vertically diagonal ones. AIR SUPPLY 28
2
: 14mm

C Loosen two remaining bolts slowly at the

same time.

D Remove rear cover (2) and spring (28), taking

care so cylinder block (3) does not come off
with rear cover (2).

3 8 30 43 31
In that case, do not drop valve plate
(8), brake spring (28) or O ring (43).
Fig.1-4 Removing the rear cover
E Remove valve plate (8) so cylinder block (3)
does come off together.

Put a matching mark on valve plate

(8) and rear cover (2) so they are
reassembled correctly. (so the face
and the back are not reversed.)

F Push in cylinder block (3), using removed bolt

(31) in the holding-down metal so the
cylinder block is not damaged, till the inner
race of rear bearing (30) sticks out.

G Remove the inner race of rear bearing (30) by

putting the gear (bearing) puller in the inner
race.

30

Fig.1-5 Removing the rear bearing

II - 5
7) Hold down brake piston (6) by hand and press
it out by blowing air through the brake AIR SUPPLY
releasing oil hole.
7 5 13

Use care as the brake piston pops up

3
by air pressure.

8) Put such a bar (marked) that does not score

cylinder block (3) (such as a coiled paper
shaped like a pipe) into the hole of piston (14) 14
and give a matching mark on the outer
surface of cylinder block (3).
9) Remove cylinder block (3), spring retainer (13)
and spring (27). MARK
10) Remove separator plate (7) and friction plate MATCHING MARK
(5).
11) Take off nine piston assy (14), shoe retainer 12 4 27 6
(4) and ball joint(12) at the same time.

With piston assy (14) and shoe

retainer (4) removed, match the Fig.1-6 Removing the cylinder block
mark with the matching mark and
put them into the cylinder block.
This operation is to insure that the
pistons are reassembled where they
were.

Take care so as not to score the

moving surfaces. Scored ones can not
be used again.

The piston and the shoe are caulked

together and can not be separated.

(Reference)
The above-mentioned explanations are associated
with a single motor, but the motor with a
reduction gear may be separated the same way.
The motor with a reduction gear may be
disassembled more easily in some cases as the
shaft does not swing too much.

II - 6
12) Remove shoe plate (11).

13) Do not remove tilting piston (20). In case it

must be removed for unavoidable reason, AIR SUPPLY
hold down tilting piston (20) by hand and
push it out by blowing air through the hole in 19 25 29 1 20 11
the figure.

14) Shaft (9) comes off.

15) Take off snap ring (19) and oil seal (25).

16) When replacing the bearing, remove the

inner race and the outer race with a bearing 9
puller and replace them as an assembly.

Shim (32) is placed under the outer

22
race of bearing (20). Put it in as it is
at reassembly.

When replacing such parts that are Fig.1-7 Removing the shoe plate
related with the fastening allowance
of the bearing such as bearings (29,
30), shaft (9), casing (1) and rear
cover (2), the thickness of shim (32)
needs adjustment.
Measure the shim clearance
correctly when the shim is placed
lightly, replace it with a proper one
and adjust the clearance of the
bearing to 0 to 0.1mm.
A special jig is required to determine
the shim thickness.

Do not take off pivot (22). In case it

must be taken off for indispensable
reason, put a matching mark on shoe
plate (11).

Do not take off oil seal (25). Replace

it with a new one in case it was
taken off.

II - 7
17) Determining the shim thickness for taper
roller bearing
This operation is necessary when
any of casing (1), rear cover (2), shaft 2
(9) and bearings (29), (30) has been
replaced.

1. Measure the dimension E in the as-

assembled condition in Fig.1-8.

9
Make sure that shaft (9) is
30
perpendicularly positioned.

F
S
(Not tilted).

E
2. Measure the dimension F on the rear cover
side.

Measure four diagonal points on the

circumference and make a mean
value.
1
3. Suppose the thickness of shim (32) to be used Fig.1-8 Determining the shim thickness
is "S", the clearance "Y" is as below:
Y=F-(E+S)

4. Choose one or two shims that make the

clearance "Y" 0~0.1mm (0~0.004˝ ).

3) Disassembling the overload valve

B Remove the overload valve as an assembly,
utilizing the opposing faces of the hexagon of
socket (44-1).
C In principle, the overload valve is handled as
an assembly, but in case it must be
disassembled for unavoidable reason, remove
plug (44-5) from socket (44-1) and pull out the
internal parts.

44-3 44-2 44-1 44-4 44-12 44-13 44-9 44-8 44-12 44-10 44-11 44-6 44-7 44-5

Fig.1-9 Disassembling the overload relief

II - 8
1.4 ASSEMBLING THE TRAVEL MOTOR
1.4.1 GENERAL PRECAUTIONS TO BE EXERCISED
(1) Clean the parts in cleaning oil and blow them
with jet air.
(2) Coat the moving parts with clean hydraulic
oil before proceeding to assembly.
(3) Take care so you do not pinch your hand
between parts and you do not drop parts on
your foot.

1.4.2 ASSEMBLY PROCEDURE

(1) Coat the outer surface of oil seal (25) and the
inner surface of casing(1) with grease. Insert
oil seal (25) into casing (1) by lightly tapping 25
it so it does not tilt, using the fixing jig.
(2) Fix oil seal (25) with snap ring (19).
(3) Put the outer race of bearing (29) into casing
(1) (clearance fit) and press the inner race
1
into shaft (9). (interference fit).

The inner race is set more easily if it Fixing jig of oil seal
is heated below 1000C.

(4) Put shaft (9) in casing (1). In that case, coat

the contact surface of oil seal with grease. Fig.1-10 Oil seal fixing
(5) Put in tilting piston (20).
(6) Fit pivot (22).

z In that case, put it on the side on

which the matching marks of the
shoe plate are aligned. If the motor
is run for a long time, put the shoe
plate where the traces on the
spherical part match the contact
marks of shoe plate (11). 19 25 29 1 20 11

22

Fig.1-11 Installing the shoe plate

Ⅱ－9
(7) Coat the three spherical areas of shoe plate
(11) with a thick film of grease.

(8) Assemble piston assy (14), shoe retainer (4),

ball joint (12), spring retainer (13) and
cylinder spring (27) into cylinder block (3), as
shown in the figure. Then put the whole
assembly into shaft (9). 4 14 13 3

Do not fail to bring back each piston

assy (14) into the hole in which the
assy was set.

(9) Install the inner race of bearing (30) to the

end of shaft (9) by lightly tapping it with a
mallet.

(10) Assemble separator plate (7) and friction 9 1 12 27

plate (5) by turns till all of them are put
together. The first and the last are separator
plates (7).
Fig.1-12 Assembling the piston assy

(11) Fit brake piston (6) with D rings (15, 16) to

casing (1), using a fixing jig.

The brake piston is equipped with

two D rings (15, 16), large and small. 1 14 7 5 15 16 31
The larger D ring (16) enters the
hole first and the small D ring (15)
enter the hole later.
You can not check visually that the
smaller D ring (15) is entering.
In some cases, the D ring is scraped
off by the hole of casing (1). 30

BRAKE
PISTON
6 FIXING JIG

Fig.1-13 Assembling the brake piston

II - 10
(12)Put valve plate (8) into rear cover (2)
according to the matching marks left at
disassembly. Fit brake spring (28) and O ring
(43) to the rear cover, insert rear cover (2)
into casing (1), and fasten them together with
socket bolts (31).
: 14mm,
Tightening torque: 23.5kgfym (170ftylbs)

In case the outer race of bearing (30)

was removed, do not forget to fit 1 15 16
shim (32). 6
18 10 28
(13) Attach coupling (10). 8

(14) Install overload relief valve (44).

30 32
(15) Put restrictor valve (55) and spring (55) in
cover (52). Then fix the cover with plug (57)
that is fitted with O ring (41). 42 2 31
: 22mm,
Tightening torque: 2.8kgfym Fig.1-14 Assembling the rear cover
(20ftylbs)

(16) Fit O rings (58), (59) to cover (52).

(17) Put spool assy (51) into rear cover (2)

according to the matching marks left at
disassembly. Then assemble spring retainer
(54) and spring (53).

Exercise care of the orientation of

spool assy (51).
44
(18) Install cover (52) with socket bolts (60).
: 10mm, 52 60 58 54 54 60 52
Tightening torque: 10kgfym (72ftylbs)

51 53
57 41 56 55 59 53
Fig.1-15 Assembling the brake valve

II - 11
1.5 TRAVEL MOTOR
1.5.1 PARTS MAINTENANCE STANDARDS
The following are reference values by which
serviceability of the disassembled parts are
determined. These are general values and the
extent of disassembly should be determined
depending upon the performances, extreme
external damage and discoloration, the purpose of
disassembly and the expected service life.

Table 1-2
Inspection Item / Method Criterion and Remedy
Standard Surface Allowable surface
(1) Sliding surface of cylinder Inspection item Remedy
roughness roughness
block, valve plate and swash
plate Cylinder block
Replace
valve plate
Measure the surface roughness 0.4-Z max. 3.0Z max. or
surface roughness
of the sliding surface of the correct.
of shoe plate
cylinder, valve plate and
swash plate, using a surface
roughness meter. To correct the surface roughness of the cylinder block and the
valve plate,lap them together. (lapping powder # 1200 )

Allowable hardness
Inspection item Standard hardness requiring Remedy
Measure the hardness of the replacement

sliding surface of the valve

plate and swash plate, using a Shoe plate HS78 min. HS74 Replace.
hardness meter.

(2) Piston and cylinder block Inspection item Standard Allowable value Remedy
clearance
Piston O.D. d
d1 0.01mm(0.0004˝ ) 0.05(0.0020˝ ) Replace
Measure the outside diameter
piston or
of pistons and the bore of the Cylinder bore D－D1 0.01mm(0.0004˝ ) 0.022(0.00087˝ )
cylinders at least three Clearance D－d 0.035
0.045mm 0.065(0.0026˝ ) cylinder
(0.0014
0.0018˝ ) block.
locations longitudinally by
means of a micrometer, and let
the maximum O.D. value be d, When any piston is to be replaced, replace nine pistons
the minimum O.D. value be d1, altogether.
the maximun bore value be D,
and the minimum bore value
be D1.

II - 12
 Inspection Item/Method Criterion and Remedy

(3) Gap of piston shoe Part name and Standard Allowable

Remedy
inspection item dimension value
Gap of caulked part
Hold down the shoe to the
between piston and
surface plate by means of jig,
shoe
draw out the piston upward 0~0.1mm 0.3mm
Replace piston
and measure the gap δ between (0~0.004˝ ) (0.012˝ )

the piston and the shoe.

DIAL INDICATOR

PISTON

JIG
MAGNET SHOE
SURFACE
PLATE

∅40
(1.57˝
Fig.1-16 Measure ∅27+0.2
+0.1

(1.06˝ +0.0079˝
+0.0039˝ )

(2.76˝ )
70

Fig.1-17 Gap of caulked part Fig.1-18 Jig

(4) Negative brake force Standard Allowable

Inspection item Remedy
value value
After the end of assembly, place
a torque wrench in the end of Replace all of
the output shaft, apply torque 50kgfym 41kgfym separator
to it and measure the torque Brake torque plate, friction
(360ftylbs) (300ftylbs)
reading when the motor begins plate and
to turn. spring.

II - 13
 Inspection Item/Method Criterion and Remedy
(5) Shaft Allowable stepped wear is up to 0.5mm (0.002in).

Measure the wear of the shaft

When the shaft is to be replaced. replace the oil seal (25)
seal by means of a roughness
at the same time.
meter.
When replacing the shaft, the thickness of shims (32)
must be adjusted.

(6) Bearing Replace bearing (29) and bearing (30) within 10,000
hours on the hour meter.
Replace bearing

When replacing the bearings, replace the inner race and

the outer race at the same time.
When the bearings have been replaced, the thickness of
shims (32) must be adjusted.

(7) Spline Serviceable stepped wear is up to 0.3mm (0.012in) on the

contact surface.
Replace spline if it is worn
beyond its allowable limit.

(8) Overload relief valve section Replace the sub assembly every 10,000 hours on the
hour meter.
This is the overload relief
valve section. Pressure can
not be checked and regulated
without a special test bench.

II - 14
1.6 TRAVEL MOTOR TROUBLESHOOTING
Troubleshooting cause and remedy
The following are corrective actions to be taken in
case the motor is in trouble.

1.6.1 GENERAL PRECAUTIONS

(1) Cautions to be exercised before work
(3) Handling parts
Before proceeding to work, determine the
Handle parts with due care, particularly the
nature of abnormality and think if a similar
moving portions, so as not to damage the
symptom occurred before.
moving parts.
Think once again if the fault really comes
from the motor.
(4) Handle O rings so as not to score the seat
surfaces.
(2) Beware of dust.
At removal, replacing O rings with new ones
Many faults are caused by dust. Therefore,
is recommended.
take dustproofing measures at disassembly.

1.6.2 TROUBLESHOOTING CAUSE AND

REMEDY
(1) Motor does not start.

Symptom Cause Remedy

Pressure does not
Built-in relief valve is out of order. Repair or replace relief valve.
rise.
Pressure rises. 1. Negative brake is not released. 1. Check if orifice is not clogged.
(Orifice in release pressure path is Clean or replace orifice.
clogged.)
2. Negative brake is not released. 2. Assemble the spool in correct
(The spool is assembled the other orientation.
way in terms of right and left.)
3. Friction plate or separator plate in 3. Replace friction plate and separator
Negative brake is stuck. plate.
4. Negative brake piston in mechanical 4. Recondition O. D. of brake piston of
brake section is stuck. replace brake piston.
5. Sliding area is seized. 5. Repair or replace piston, shoe, shoe
plate, cylinder block and valve plate.
6. Spool malfunctions 6. Correct or replace
(Spool is stuck.)
(The hole in the restrictor valve is
clogged.)

(2) Motor does not start powerfully.

Symptom Cause Remedy

A set pressure is Spool malfunctions Correct or replace
normal, but brake (Spool is stuck.)
release lags behind.

II - 15
 Symptom Cause Remedy
Negative brake is The viscosity of hydraulic oil is too high. Raise the oil temperature.
released but the
motor is late to
start.
Negative brake is 1. Negative brake is not released 1. Investigate to see if orifice is not
released but the completely. clogged.
motor starts feebly. (The orifice in the release pressure
path is clogged with dirt.)
2. Dirt is included in relief valve. 2. Clean relief valve.
Inspect seat surface or replace relief
valve.
3. Sliding surfaces are seized. 3. Inspect and repair sliding surface or
replace relief valve.

(3) Revolution does not reach a set value.

Symptom Cause Remedy

Pressure does not 1. Oil flow is insufficient. 1. Inspect pump, delivery rate and the
reach a set value. oil path to motor.
2. Shoe, cylinder block and valve plate 2. Inspect and repair faulty parts or
are worn off or scratched much. replace faulty parts.

(4) Brake does not work.

Symptom Cause Remedy

Brake does not Negative brake malfunctions. Inspect and repair or replace brake
work. piston, friction plate and spring.

1. Friction plate is worn off.

2. Spring is broken.

Reverse brake Spool malfunctions Correct or replace

works. 1. Spool and the body are stuck
together.
2. Check valve is stuck or includes dirt.
3. The hole in the restrictor valve is
clogged.

(5) Oil leaks.

Symptom Cause Remedy

Oil leaks. 1. Bolts and plugs are loosen. 1. Tighten bolts or plugs to a specified
torque.
2. O rings are galled. 2. Replace O ring.
3. Oil is leaking into gear casing. 3. Replace oil seal.

II - 16
(6) The motor speed does not change from high to low.

Trouble Cause Remedy

Motor does not Spool of pilot valve is stuck. Check and repair pilot valve.
change from high to
low speed.

(7) Abnormal sound occurs.

Trouble Cause Remedy

Intense vibration Spool malfunctions. Bleed air.
and sound occur Air remains in circuit and valve.
when brake is
operated slowly or Spool is stuck. Correct or replace.
with other circuits.

(8) Hunting occurs when machine goes down a slope.

Trouble Cause Remedy

Hunting is intense Spool malfunctions. Correct or replace.
during inching. • Spool and body are stuck.
• Seat of restrictor valve is poor.

Interference with negative brake Correct or replace.

• Spring at end of spool is fatigued
or broken.

II - 17
1.7 REDUCTION UNIT DISASSEMBLY
1.7.1 TOOLS
Before removal and installation, prepare tools,
jigs and measuring instruments.

No. Tools Application

1 Torque wrench 0~50kgfym (360ftylbs)
2 Allen wrench Opposing flats 8mm (0.315in), 14mm(0.551in)
3 Stand ∅420 min.
(16.5˝ )

(7.09˝ )
∅340

180
(13.4˝ )

t=16 (0.63˝ )
4 Micro depth meter 0~15mm (0～0.591in)
5 Caliper 0~150mm (0～5.91in)
6 Eye bolt M10, M18 3pcs. each
7 Pin Spring pin ∅3.5×75 (0.138˝×2.95˝ ), ∅5×55 (0.197˝×2.17˝ )

8 Press machine It is used to insert the angular bearing and fix the lock
washer.
Capacity 3 tons (6610 lbs)
9 Others Cleaning oil, Detergent, Gear oil, Grease,
Locktite#242, #515, Seal tape, rag and others

1.7.2 DISASSEMBLY
(1) Preparation before removal
1) The travel unit removed from the machine
has dust and mud. Wash them with cleaning
oil.

2) Loosen drain or oil filling plug (26) and drain

the oil out of the reduction unit.

When oil is hot, pressure is built up

inside. Take care as the oil gushes
out in some cases.

3) Leaving matching marks

Put a matching mark on the outside of each
matching surface so it may be installed where
it was.

z The numbers in the parentheses after

part names correspond to those in the
assembly drawing on page II-2.

II - 18
(2) Mounting the travel unit to the mount. COVER MATCHING MARK
1) Remove three M10 socket bolts (24) in cover
(1) at equal spacings. Put eye bolts and lift it.
Then install the travel unit so the cover
comes up and the motor faces down.
: 8mm

Take care so you do not pinch your

hand between parts and drop parts.

(3) Removing the cover Fig.1-19

1) Take off the remaining M10 socket bolts (24).
: 8mm

2) The contact surfaces of cover (1) and ring

gear (17) are coated with sealing compound.
Therefore, remove cover (1) by placing a 24
wooden piece on the area of the cover
1
protruded from ring gear (17) and knocking it
with a hammer.

Fig.1-20

17

Fig.1-21

II - 19
(4) Removing Carrier 1 Assy
1) Remove thrust plate (8).

2) Remove sun gear 1 (9). 2

3) Place three M10 eye bolt in carrier 1 (2) and 6

remove carrier 1 assy (2, 3, 4, 5, 6, 7). (3,4,5,7)

Fig.1-22
(5) Removing carrier 2 assy
1) Remove sun gear 2 (10).

11
2) Place three M10 eye bolt in carrier 2 (11) and
remove carrier 2 assy (11, 12, 13, 14, 15, 16).

14
(12,13,15,16)

Fig.1-23
(6) Removing housing assy
1) Remove support ring (22).

2) Remove lock washer (21) by hammering on

22
something like a screwdriver that is placed in
the split surface.

3) Place an eye bolt in each of the three M10

threaded holes in ring gear (17). Then remove
housing assy [ring gear (17), housing (18),
bearing (19), and floating seal (23)].

Fig.1-24

21

Fig.1-25

II - 20
(7) Removing housing assy
1) Place the housing assy with ring gear (17)
facing downward and housing (18) upward.
Leave a matching mark on the outer surface
19 25 18
of the housing and the ring gear.
2) Separate floating seal (23) from housing (18).
3) Take off all M16 socket bolts (25), except two
in diagonal directions.
: 14mm
4) With the remaining two loosened, knock the
17
head of them with a hammer. Then ring gear
(17) comes off from housing (18) easily.

Use care so as not to score the

moving surface of the floating seal
(23) and the O ring. Fig.1-26 Three stands of same height

The outer circumference of the

bearing (19) is engaged with the bore
diameter of the housing (18) by a
very close fit. Do not remove them
except when necessary.
When the bearing has been
separated from the housing, do not
use it again, but replace it with a
new one.

(8) Removing the floating seal

1) Remove the floating seal (23) on the motor
side.
23

(9) Removing carrier 1 assy

When reusing a carrier pin 1 (3),

store it by putting a mark in the
carrier 1 (2) hole and the carrier pin
1 (3) so they are assembled the same Fig.1-27 Removing floating seal (23)
way before they were removed.

Fig.1-28 Carrier 1 assy

II - 21
1) Drive in spring pin (7) into carrier pin 1 (3).
2) Remove carrier pin 1 (3) from carrier 1 (2).
3) Separate thrust washer 1 (5), planetary gear
1 (6), and needle bearing (4). 7
4) Draw spring pin (7) from carrier pin 1 (3).
3
When replacing the carrier pin 1 (3)
or the planetary gear 1 (6), always 2
replace a set of three at one time.

2
Fig.1-29 Removing carrier 1 assy

5
(10) Removing carrier 2 assy

6 4
When reusing a carrier pin 2 (12),
store it by putting a mark in the 6
carrier 2 (14) hole and the carrier Fig.1-30 Removing carrier 1 assy
pin 2 (12) so they are assembled the
same way before they were removed.

1) Drive in spring pin (15) into carrier pin 2

(12).
2) Remove carrier pin 2 (12) from carrier 2 (11).
3) Separate thrust washer 2 (16), planetary gear 15
2 (14), and needle bearing (13). 12
4) Draw spring pin (15) from carrier pin 2 (12).
11 11

When replacing the carrier pin 2 (12)

or the planetary gear 2 (14), always
replace a set of three at one time.
Fig.1-31 Removing carrier 2 assy

11 14

16

13
Fig.1-32 Removing carrier 2 assy

II - 22
1.8 INSTALLATION
(1) General precautions
1) Clean parts thoroughly in cleaning oil and
dry it up by jet air. Degrease areas to coated
with Locktite, using thinner or something. 11
2) Check that parts are free from fault.
3) Coat socket bolt with Locktite #242, before
tightening them. 14(13,16)
4) Coat the parts with a thin film of gear oil,
before proceeding to assembly operation.
5) Use care so you do not pinch your hand
between parts and you do not drop parts.

(2) Installing carrier 2 assy Fig.1-33 Installing carrier assy

1) Install planetary gear 2 (14), needle bearing
(13), and thrust washer 2 (16) into carrier 2
(11).
2) Insert carrier pin 2 (12) into carrier 2 (11),
14(13,16)
matching the carrier pin in the direction of
the spring pin hole.
3) Drive spring pin(15) into carrier 2 (11) and
carrier pin 2 (12).
15
[Drive in the spring pin 1 to 2mm
(0.04~0.08in) below the surface into which it 11
is placed.]
4) Caulk two places 180°diagonally located.
Fig.1-34 Install spring pin
(3) Installing carrier 1 assy
(See carrier 2 in the figure.)
1) Install planetary gear 1 (6), needle bearing
(4), and thrust washer 1 (5) into carrier 1 (2).
2) Insert carrier pin 1 (3) into carrier 1 (2),
matching the carrier pin in the direction of
the spring pin hole.
3) Drive spring pin (7) into carrier 1 (2) and
carrier pin 1 (3).
[Drive in the spring pin 1 to 2mm
CAULKING
(0.04～0.08in) below the surface into which it
POSITION
is placed.]
4) Caulk two places 180°diagonally located.
15
Fig.1-35 Caulking the spring pin

II - 23
(4) Installing floating seal
1) Install floating seal (23) on the motor side. 23

(5) Installing housing assy

1) Apply Locktite #515 to the matching surface
of housing (18) and ring gear (17). Fig.1-36 Installing floating seal (23)

2) Attach three eye bolt M18 in housing (18), lift

it with a wire sling, align the matching
marks, and install the housing to ring gear
(17). 18

3) Apply Locktite #242 to nineteen socket bolts

M16×80 (25) and tighten them up.
: 14mm,
Tightening torque : 28kgfym (200ftylbs)
LOCKTITE #515

4) Install floating seal (23) to the housing side.

Clean the floating seal to be free

from oil, dirt, paint and other foreign
matter.
Fig.1-37 Installing housing assy
Coat the moving part of the floating
seal (23) with a thin film of gear oil. HOUSING SIDE 23 25 18

Fix the O ring so it is not twisted.

Confirm that the floating seal (23) is

17
fixed parallel to the housing (18) and
the motor, as illustrated.

GOOD

BAD

BAD
Fig.1-38 Install floating seal (23)

II - 24
SHOP MANUAL - SECTION 4

E215
CRAWLER EXCAVATORS

TROUBLESHOOTING

Issued January 2006

Book/Form Number 5-1730 NA
Copyright © 2006. CNH America, LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. S5PJ0010E01-KO31
 SECTION 4 - TROUBLESHOOTING

CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Remarks
First Edition 01-2006 E215 5-1730 NA
 SECTION 4 - TROUBLESHOOTING
GENERAL DISASSEMBLY AND ASSEMBLY

SECTION 4
TROUBLESHOOTING
TABLE OF CONTENTS
CHAPTER 41
MECHTRO CONTROL
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41-1
CHAPTER 42
TROUBLESHOOTING (HYDRAULIC SYSTEM)
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-1
CHAPTER 43
TROUBLESHOOTING (ELECTRICAL SYSTEM)
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43-1
CHAPTER 44
TROUBLESHOOTING (ENGINE)
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-1

5-1730 NA Issued 01-2006 Bur 0-I

NOTES
 SECTION 4 - TOUBLESHOOTING

CHAPTER 41

E215
CRAWLER EXCAVATOR

MECHATRO CONTROL
(TROUBLESHOOTING)

Issued January 2006

Book/Form Number 5-1740 NA
Copyright © 2006. CNH America, LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. S5PJ0010E01-KO01
 SECTION 4 - STANDARD TROUBLESHOOTING
CHAPTER 41 - MECHTRO CONTROL

CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Remarks
First Edition 01-2006 E215 5-1740 NA

1-II Issued 01-06 Bur 5-1740 NA

 SECTION 4- STANDARD TROUBLESHOOTING
CHAPTER 41 - MECHTRO CONTROL

CHAPTER 41
MECHTRO CONTROL
TABLE OF CONTENTS

1. OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 Confirm Actual Problem Conditions at Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3. OUTLINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
4. MECHATRO CHECKPOINTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
4.1 Attaching Position of Sensor and Electrical Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
4.2 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4.3 Swing Priority Proportional Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

5-1740 NA Issued 01-06 Bur 41-1

 SECTION 4 - STANDARD TROUBLESHOOTING
CHAPTER 41 - MECHTRO CONTROL

41-2 Issued 01-06 Bur 5-1740 NA

 SECTION 4- TROUBLESHOOTING
CHAPTER 41 - MECHATRO CONTROL (TROUBLESHOOTIN)

41.1 OUTLINE
Troubleshooting provides a process to investigate the cause of problems. This manual describes how to solve a
specific problem systematically and as quickly as possible. For problems concerning a specific component, refer to
the troubleshooting section for that component.

41.1.1 CONFIRM ACTUAL PROBLEM 41.1.2 DIAGNOSING PROBLEMS

CONDITIONS AT SITE
3. How to diagnose
1. Verify the machine model, serial number,
A. Verify defective part.
problem, and notify the owner/user of possible
arrival time of service crew. B. Reproduce the conditions.
2. Verify background of trouble. C. Where the defective part can not be
verified, surmise the possible causes
A. Model name and serial number.
systematically.
B. Kind of attachment.
D. Verify the surmised cause.
Check that the combination of attachments
E. Report estimated repairing method/
was proper and that the operating manner
procedures to the user.
was not unreasonable.
C. Operating time on the hour-meter.
4. Explanation of the cause
D. Record of problems.
A. Explain the cause to the user.
First occurrence or repeated problems.
For example, explain the oil leakage
E. History of the problem and additional
through the piston is caused by defect on
modifications.
the piston rod. The proper operating
Reoccurrence of the same problem in the manner of the machine should be
past or due to additional modification. ex p l a i n e d t o t h e u s e r t o p r ev e n t
reoccurrence of the same kind of problem.
B. Handling of damaged parts
NOTE: The damaged parts to be claimed and
returned are the evidence of problems, so they
should be handled with care. For example, protect
them from contamination of water, soil, etc., from
getting into ports on a hydraulic system. Also be
careful not to damage or break removed
components.

41-1
 SECTION 4 - TROUBLESHOOTING
CHAPTER 41 - MECHATRO CONTROL (TROUBLESHOOTING)

NOTES

41-2
 Independent operation

operation

(1st. speed)

(2nd speed)
Bucket dump
Bucket digging

Swing operation
Actuator

Boom lowering operation

Arm in inching operation

Travel LH / RH operation
Travel LH / RH operation
Arm out inching operation

Arm in full lever operation

Operating condition

Arm out full lever operation

Heavy duty arm in full lever

Boom raising inching operation

Boom raising full lever operation

S
E
 Hi pressure sensor (P1)
22

Hi pressure sensor (P2)
S
E

Low pressure sensor
S
E
 

Arm variable recirculation

S
P

A
V
23 1-10 

solenoid proportional valve

P2 bypass cut
S
P

B
V


solenoid proportional valve

Travel straight
S
P

C
V
2. TROUBLESHOOTING ; MECHATRO CONTROL

solenoid proportional valve
Electric

P1 bypass cut
S
P
V

D


solenoid proportional valve
Swing P/B
1
S
V


solenoid valve
Attachment power
2
S
V


boost
Travel 1-2spead
3
S
V


solenoid valve
Safety look lever
4
S
V


solenoid valve
P1 pump solenoid
S
P

V

P1

proportional valve
P2 Pump solenoid
S
P

V


P2

proportional valve

Boom

Arm

Bucket

Swing

Travel right

Travel left

P1 bypass cut valve

Control valve

P2 bypass cut valve

Travel straight valve

Boom conflux valve

Hydraulic

Arm conflux valve

Arm variable recirculation

valve
Right travel motor

Left travel motor

Motor

Swing motor

Boom

Arm










Cylinder

Bucket

Boom lock valve

Other

Arm lock valve

3
 3. OUTLINE ; MECHATRO
OPERATING Pilot secondary pressure Pressur sensor Pump proportional valve
Lever
ATT position
TRAVEL High pressure Low pressure P1 Negative P1 Pump P2 Travel P1 Arm variable
ATT Travel Back pressure
(Pump) (Pilot) P2 controller P2 Bypass cut straight Bypass cut recirculation

ATT

Bucket digging
MAX MAX
Control Negative
Bucket dump Approx Approx controller
Back
lever at full More than More than MIN MAX MAX MAX MIN
35kgf/cm2 24kgf/cm2 pressure pressure
stroke 4.5V 4.5V 350mA 647mA 647mA 647mA 200mA
Boom raise (500psi) or (340psi) or
more more
Boom lower

Swing left
Swing right

Arm in

Arm out MAX MAX

Lever at Approx Approx More than More than MAX
TRAVEL neutral Approx 0.5V Approx 0.5V 350mA 350mA 350mA 647mA
6.0kgf/cm2 6.0kgf/cm2 2.0V 0.7V 750mA
(85psi) or less (85psi) or less
Forward

Reverse

Operating condition : Engine speed is High idling.

4
 4. CHECK POINTS FOR MECHATRO SYSTEM (FOR TROUBLESHOOTING)
4.1 ATTACHING POSITION OF SENSOR (3) Solenoid proportional valve block
(1) Pump relation SE
26 :
Pressure sensor :
P1 Negative control sensor
SE
23 :
PSV
P1 : Pressure sensor :
P1 Pump P2 Pump
proportional valve

SV
1 : Swing parking SOL

SV
3 : Travel 1-2 speed SOL

PSV
A : Arm Variable recirculation valve

PSV
D : P1 Bypass cut proportional valve

Harness PSV
C : Travel straight proportional valve

(Upper)
PSV
B : P2 Bypass cut proportional valve

SE
22 : SV
2 : Attachment power boost pressure SOL

Pressure sensor :
P1 Pump SV
4 : Safety lock lever SOL
PSV
P2 : SE
27 :
P2 Pump Pressure sensor :
proportional valve P2 Negative control
sennsor

Pump high pressure sensor SE22, SE23 ; LC52S00002P1 PROPORTIONAL BLOCK SECTION
Pump assy ; YN10V00007F1 Pump proportional valve PSVP1, PSVP2 ; YN35V00018F2 (PSV-A
PSV-D ; YN35V00022F1)
Negative control sensor SE26, SE27 ; YN52S00016P1

(2) Low pressure sensor for pilot operation

(4) Back pressure sensor

Tighten capscrew for attaching block

sensor with clip.
Clip

Fix the harness to pressure

sensor with clip.
Clip
Fix the sensor to pressure
sensor with clip.
SE
1 : Clip
Pressure sensor : Bucket digging
SE
2 : SE
28 :
Pressure sensor : Bucket dump Pressure sensor : Back pressure
SE
3 :
Pressure sensor : Boom raise
SE
4 :
Pressure sensor : Boom lower
SE
5 :
Pressure sensor : Swing left
SE
8 : HarnessUpper
SE
6 : Pressure sensor : Arm out
Pressure sensor : Swing right
SE
7 :
Pressure sensor : Arm in

LOW PRESSURE SENSOR BACK PRESSURE SENSOR SECTION

(SE1
SE8 ; LC52S00001P2) (SE28 ; LC52S00001P2)
5
4.2 COMPONENTS (2) Back pressure sensor: LCS52S00001P2 (3) High Pressure sensor; LC52200002P1

(1) Solenoid proportional valve block; YN35V000022F1

Solenoid proportional valve block

No. NAME PARTS No. Q’TY
CONNECTOR MODE
601 Solenoid proportional reducing valve YN35V00019F1 4
HW090 (T-TYPE)
701 Solenoid directional valve YN35V00020F1 3 (SUMITOMO DENSON)
702 Solenoid directional valve YN35V00021F1 1
CONNECTOR TERMINAL
ARRANGEMENT
TERMINAL No.
1 POWER SUPPLY (+)
2 OUTPUT (-)
Arm variable recalculation 3 COMMON
Attachment power boost
Safety lock lever

Travel 2- speed
Travel straight
P2 bypass cut

P1 bypass cut

Swing P/B

(4) Negative control sensor: LCS52S00001P2

HYDRAULIC SYMBOL CONNECTOR MODE

701 701 601 601 601 601 701 701
HW090 (T-TYPE)
(SUMITOMO DENSON)

CONNECTOR TERMINAL
ARRANGEMENT
TERMINAL No.
1 POWER SUPPLY (+)
2 OUTPUT (-)
3 COMMON
CONNECTOR; SUMITOMO DENSO HW090 CONNECTOR (2PM)
HOUSING – 6181 01070
(Directional valve) Emergency manual screw
TERMINAL – 1500 0105
Tighten torque; 75± 5kgf.·cm Max,. tightening torque 20kgf·cm (1.4 ft.lbs) and below DETAIL OF SENSOR CONNECTOR
(5.4 ± 0.36 ft.lb Slit width 1.0 (0.04”) X depth 1.3 (0.05 in)
Tighten torque; 75± 5kgf.·cm
(5.4 ±0.36 ft.lb

DIRECTIONAL VALVE CONNECTOR

(+) SIDE (-) SIDE
LEAD WIRE LEAD WIRE

DETAIL OF DIRECTIONAL VALVE CONNECTOR

6
4.3 SWING PRIORITY PROPORTIONAL VALVE ; Eu
(1) Control valve piping ; YN64H00070F1

YM35V00001F1 ; PSV-H

Solenoid valve assy YM35V00001F1

No. NAME PART No. Q’TY
Solenoid proportional
601 reducing valve YN35V00019F1 1

CONNECTOR ; SUMITOMO DENSO

HW090 CONNECTOR (2PM)
601 HOUSING 6181-0070
TERMINAL 1500-0105

Tightening torque ; 70±7kgfŸcm

(5.1±0.5ftŸlbs)

HYDRAULIC SYMBOL

7
NOTES

8
 SECTION 4 - TROUBLESHOOTING

CHAPTER 42

E215
CRAWLER EXCAVATORS

TROUBLE SHOOTING
(HYDRAULIC SYSTEM)

Issued January 2006

Book/Form Number 5-1750 NA
Copyright © 2006. CNH America, LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. S5PJ0010E01-KO31
 SECTION 4 - TROUBLESHOOTING
CHAPTER 42 - TROUBLESHOOTING (HYDRAULIC SYSTEM)

CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Remarks
First Edition 01-2006 E215 5-1750 NA

42-II Issued 01-2006 Bur 5-1750 NA

 SECTION 4 - TROUBLESHOOTING

CHAPTER 42
TROUBLESHOOTING (HYDRAULIC SYSTEM)
TABLE OF CONTENTS

1. DIAGNOSIS
1.1 Hydraulic System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Hydraulic Pressure Measurement (Diagnosis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2. TROUBLESHOOTING
2.1 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

5-1750 NA Issued 01-2006 Bur 42-1

 SECTION 4 - TROUBLESHOOTING
CHAPTER 42 - TROUBLESHOOTING (HYDRAULIC SYSTEM)

NOTES

42-2 Issued 01-2006 Bur 5-1750 NA

 1. TROUBLE DIAGNOSIS
1.1 TROUBLE DIAGNOSIS ; HYDRAULIC SYSTEM

Oil pressure
Component Pump Control valve Swing motor Travel motor Cylinder Other valve Proportional valve block Relief valve
SV1 SV2 SV3 SV4 A B C D Main control valve Travel Swing

Arm variable recirculation valve

Counterbalance check valve

Pilot valve (1-2speed select)

Travel 1
2 speed SOL valve

Travel straight roportional valve

P2 bypass cut proportional valve

P1 bypass cut proportional valve

Arm variable recirculation valve
Swing parking SOL valve
Boom conflux spool valve
Arm conflux spool valve

Power boost SOL valve

Counterbalance valve

Lever lock SOL valve

Check valve for relief
Travel straight spool

P2 bypass cut valve

P1 bypass cut valve

Pilot valve (travel)

Pilot valve (ATT)
Load check valve

Main relief valve

Pilot relief valve

Reduction parts

Bucket cylinder

Right shockless

Right shockless
Bucket digging

Boom lowering
E/G revolution

Parking brake

Parking brake

Boom cylinder

Left shockless

Left shockless
Bucket dump
Boom raising
Arm cylinder
Bypass valve
Bucket spool
Travel spool
Swing spool

Swivel joint
Boom spool
Classification

Pilot pump

Lock valve
Arm spool
P1 pump
P2 pump

Arm out
Group No.

Trouble

Arm in
Motor
Device No. 1 2 3 4 6 7 8 9 10 11 16
No operation is possible.       
(1) Machine operates freely even
though lever is in neutral.                 
All actions      
Speed is low.

Bucket digging and dump             

Lower            
(2) Boom
Raise               
Attachment operation

Arm in conflux                
Arm out conflux              
All motions       
Power lacks.

Bucket digging              
(3) Lower             
Boom
Hydraulic systems

Raise                
Arm in and out                 
Bucket digging and dump           
Fine operation
impossible.

Lower            
(4) Boom
Raise               
Arm in and out               
Travel 1, 2 speed change
(5)    
Swing operation Travel operation

impossible

(6) Travel speed is low.                  

(7) Travel power is low.                  
Machine cannot travel straight
(8) or deviates in one direction or
zigzags.
                
(9) Machine
slope.
does not stop still on a
       
(10) Swing motion does not work.     
(11) Swing speed is low.                 
Swing power is low.                 
(12)
Swing drifts very large.        
(13) Fine operation impossible.   

1
 1.2 HYDRAULIC PRESSURE MEASUREMENT BY SERVICE DIAGNOSIS
(1) Main circuit pressure. (2) Secondary pilot pressure (3) Solenoid primary pressure (4) Solenoid proportional valve secondary
(Att. operation No. Travel operation 1 4 ) pressure

E/G Hi, E/G Hi, E/G Hi, E/G Hi, E/G Hi, E/G Hi,
Operation is not working In operation
Full lever, at relief No load, at neutral Full lever, at relief No load, at neutral Full lever operation No load, at neutral
No.14 No.9 No.5 No.20
PRESS. SENSOR Main pump P1,P2 PRESS. SENSOR 3 4 SOL. VALVE Swing P/B PROPO-VALVE P1 bypass cut
C 1 PUMP P1 B 1 BOOM RAISE F 2 SWING-BRAKE Swing & arm digging D 1 P1 BYPASS
50k
3.3V 350k 0. 7V 20k 4.5V 30k 0. 5V 0k COMP. ON OFF indication COMP. 647mA 25k 350mA 6k
C 1 PUMP P2 B 2 BOOM LOWER MEAS. ON OFF indication MEAS. 642mA 25k 345mA 6k
3.3V 350k 0. 7V 20k 4.5V 30k 0. 5V 0k RELEASE SW OFF ON/OFF indication
No.21
No.15 No.10 No.6
PROPO-VALVE P2 bypass cut
PRESS. SENSOR OPT PRESS. SENSOR 7 8 SOL. VALVE Travel 2-speed select
D 2 P2 BYPASS
B 16 P1 OPT. B 3 ARM OUT F 3 1/2-TRAVEL
50k COMP. 647mA 25k 350mA 6k
4.5V 30k 0. 5V 0k 4.5V 30k 0. 5V 0k COMP. OFF ON indication
MEAS. 642mA 25k 345mA 6k
B 17 P2 OPT. B 4 ARM IN MEAS. OFF ON indication
4.5V 30k 0. 5V 0k 4.5V 30k 0. 5V 0k SWITCH OFF ON/OFF indication
No.22
No.16 No.11 No.7 PROPO-VALVE Travel straight
PRESS. SENSOR Negative control P1,P2 PRESS. SENSOR 1 2 SOL. VALVE Boost pressure select D 3 TRAVEL STRAIGHT
B 16 P1 NEGA-CON B 5 BUCKET DIG F 1 POWER UP COMP. 647mA 25k 350mA 6k
50k
0.5V 0k 3. 0V 31k 4.5V 30k 0. 5V 0k COMP. OFF ON indication MEAS. 642mA 25k 345mA 6k
B 17 P2 NEGA-CON B 6 BUCKET DUMP MEAS. OFF ON indication
0.5V 0k 3. 0V 31k 4.5V 30k 0. 5V 0k SWITCH OFF ON/OFF indication No.23
No.19 No.12 PROPO-VALVE Arm variable
PRESS. SENSOR PRESS. SENSOR 6 5 D 6 A-RECIRCULAT recirculation
Back pressure
B 15 BACK PRESS. B 7 SWING (R) COMP. 409mA 10k 647mA 25k
(Nega-con pressure)
0. 9V 3k 4.5V 30k 0. 5V 0k MEAS. 404mA 10k 642mA 25k
B 8 SWING (L)
4.5V 30k 0. 5V 0k No.24
PROPO-VALVE P1 pump
No.13
E 1 P1 PUMP
PRESS. SENSOR 1,2 3,4 COMP. 400mA 9k 750mA 30k
B 9 TRAVEL (R)
MEAS. 395mA 9k 745mA 30k
4.5V 30k 0. 5V 0k
POWER SHIFT 0mA
B 10 TRAVEL (L)
4.5V 30k 0. 5V 0k
No.25
PROPO-VALVE P2 pump
E 2 P2 PUMP
LH. control lever RH. control lever
COMP. 400mA 9k 750mA 30k
Swing left Bucket digging MEAS. 395mA 9k 745mA 30k
Swing right Bucket dump POWER SHIFT 0mA

Arm in Boom raise

Arm out Boom lower
NOTE OPERATION
No.20 ARM OUT or ARM IN RELIEF OPERATION
No.21 BOOM RAISE RELIEF OPERATION
LH. travel lever RH. travel lever No.22 ARM IN RELIEF OPERATION
3 Travel left reverse 1 Travel right reverse No.23 ARM IN OPERATION LEVER TURNED TO FULL
(At 200mA ARM IN RELIEF)
4 Travel left forward 2 Travel right forward
No.24 DURING BUCKET DIGGING OPERATION
No.25 DURING ARM IN OPERATION

2
(1)-1 2. TROUBLESHOOTING
No operation is possible

24V is alive between white/orange

NO
and black terminals of connector To electric troubleshooting
(2PAF) of lever lock solenoid (SV-4).
YES (Service diagnosis No.22)
Moves when connector for travel
Travel straight valve port PTb NO straight proportional valve YES Refer to electric
pressure is about 6.9kgf/cm2 (98psi) (PSV-C) is disconnected. troubleshooting.
YES NO
Replace travel straight
proportional valve block.
NG
Replace porportional valve
block.

The primary pressure of pilot pump NO Adjust or replace pilot pump

is about 50kgf/cm2 (710psi). and pilot relief valve.

YES
The pilot valve P port inlet pressure Inspect or replace lever lock
NO
is approx. 50kgf/cm2 (710psi). solenoid valve.

YES
The secondary pressure of pilot valve for NO Inspect or replace pilot valve.
ATT ; approx. 50kgf/cm2 (710psi)
Travel; approx. 24kgf/cm2 (340psi)

YES

The pressure of main relief valve is; NO NO Replace main relief valve.
P1, P2; 350kgf/cm2 (4980psi) Adjustable with relief valve. (Main C/V, OPT C/V)

YES

Inspect or replace pump and

replace pump coupling.

3
(1)-2

Machine moves freely with levers in neutral.

Machine stops moving freely if the

connector (2PAF,2PAF) for YES
proportional valve P1,P2 bypass To electric troubleshooting.
cut is disconnected.

NO

(Service diagnosis No.16)

Negative control pressure of P1, P2 The secondary pilot pressure of the
is more than 30kgf/cm2 (430psi).
NO system that is moving freely is YES Inspect or replace
pilot valve.
generated when the lever is in neutral.
YES
NO
The spool returning spring of the circuit YES Inspect or replace spool assy
that is moving freely is broken. and pilot cover.
NO
The spool of the system that is The outer
NO circumference of YES
operating freely moves smoothly Replace spool assy.
by hand. (Remove pilot cover.) spool is scratched.
NG
YES NO
Replace control valve.
(Diagnosis No.20,No.21)
Pilot pressure at ports PCa, PCb
(P1, P2 bypass cut valve) is
NO Inspect or replace the proportional valve
for bypass cut valve that is defective.
approx. 6.9kgf/cm2 (98psi).
NG
YES
Inspect or replace
proportional valve block.

Return spring of bypass cut valve YES Inspect or replace bypass

spool is broken. cut valve spool assy and
pilot cover.
NO
Bypass cut valve spool moves NO Spool is scored YES Replace bypass cut
smoothly by hand. (together with on inspection. valve spool assy.
P1 and P2 bypass cut valves)
NO NG
YES
Replace control valve.

Replace control valve.

When the lock valve, body seat and Replace lock valve and
YES selector parts were inspected, faults YES correct body seat or replace
Boom or arm?
such as scratch were discovered. body or replace selector.
NO NO
Faults such as scratch are discovered in
load check valve and seats in conflux YES Replace check valve, correct
passage and recirculation passage. body seat or replace body.
(CCb,CCa, CAr)

NO

Spool of the circuit that operates YES

freely is scored on inspection. Replace spool assy.

NO
Inspect or replace Inspect the cylinder of the circuit that Inspect or replace control
overload relief valve. operates freely and replace if faulty. valve.
(Inside leak)

4
(2)-1

All attachment motions are slow.

(Mechatro controller Service diagnosis No.19,No.16)

With key ON and engine at stop :
Back pressure sensor : 0.4
0.5V
P1 negative control sensor : 0.4
0.5V NO
P2 negative control sensor : 0.4
0.5V Replace faulty sensor.

Diagnosis
YES (Diagnosis No.24,No.25) Difference(Pn1=Pn1-Pt,
Current values of proportional Pn2=Pn2-Pt) between Inspect or replace negative
NO negative control pressure NO
valves of pumps (right, P1; left, controll poppet.
P2) are approx. 350mA sensor values(Pn1, Pn2) and
during travel idling. back pressure sensor value(Pt) NG
in travel idling is : Inspect negative control
YES less than 2kgf/cm2 (28psi). block.
YES
Refer to electric
troubleshooting.

Primary pilot pressure is NO Inspect or replace pilot

50kgf/cm2 (710psi). pump and pilot relief valve.

YES (Diagnosis No.14)

Main relief valve pressure is ; P1, NO Inspect or replace main
P2 : 350kgf/cm2 (4980psi). relief valve.
YES NG
Replace control valve or
pump.
Is the action slow even if connector
for travel straight proportional NO Refer to electric
valve is disconnected.
troubleshooting.
YES (Diagnosis No.22)
Pilot pressure at PTb port (travel
straight) is NO Inspect or replace travel
approx. 6.9kgf/cm2 (98psi). straight proportional valve.

YES NG
Inspect or replace
Proportional valve block.

Return spring of travel straight NO Inspect or replace travel

spool is broken. (Remove pilot cover) straight spool assy.

YES

Travel straight spool moves NO Outer circumference of travel YES Replace Travel straight
smoothly by hand. straight spool is scored. spool assy.
(Remove the pilot cover.)
NO NG
YES
Replace control valve.

NG Inspect or replace pump

Replace pump proportional valve. regulator.

NG
Replace pump.

5
(2)-2
Only the bucket motion is slow.
(Service diagnosis No.19,No.16)
With key ON and engine at stop :
Back pressure sensor : 0.4 0.5V NO
P1 negative control sensor : 0.4 0.5V Replace faulty sensor.

YES
Is the motion normal if connector (2PAF)
YES
for P2 bypass cut proportional valve is To electric troubleshooting.
disconnected.
NO
Secondary pilot pressure at PBc, PAc
ports (bucket digging and dump ports) is
NO Inspect or Replace pilot
50kgf/cm2 (710psi). valve.

YES (Diagnosis No.24)

(Diagnosis No.16,No.19)
The difference( Pn1=Pn1-Pt)
Command current values of pump proportional
valve during operation are as below :
NO between P1 negative control NO Inspect or Replace P1
pressure sensor value and back negative control poppet.
Bucket dump P1 ; approx. 483mA, P2 ; approx.705mA
Bucket digging P1 ; approx. 400mA, P2 ; approx.705mA
pressure sensor value(Pt) during NG
operation is less than 2kgf/cm2
Inspect negative controll
YES (28psi).
YES valve.

To electric troubleshooting.
(Diagnosis No.14)
NO Relief pressures for both digging and NO Inspect overload relief valve
The relief pressure during bucket
dump operations are abnormal. on the faulty pressure side
operation is 350kgf/cm2 (4980psi) for both
and replace valve if
digging and dump.
YES defective.
YES Confirm the check valve before
NG
relief valve for control valve. Check Replace control valve.
the seat of it as well. CMR 1,CMR2)

Return spring for bucket spool is broken.

YES
Replace bucket spool assy.

NO
Bucket spool moves smoothly by hand.
NO Outer circumference of bucket YES
(Remove pilot cover.) Replace bucket spool assy.
spool is scored.
YES NG
NO
Replace control valve.
Is the motion slow if coupler for travel
straight proportional valve is NO To electric troubleshooting.
disconnected. (to“All motions are slow.”)
YES
Pilot pressure at port PTb (travel
NO Inspect or replace travel
straight) is approx. 6.9kgf/cm2 (98psi). straight proportional valve.
YES NG
Inspect or replace
proportional valve block.

YES Inspect travel straight spool assy and

Return spring for travel straight spool is broken. pilot cover and replace them if faulty.

NO
Travel straight spool moves smoothly by NO Outer circumference of travel YES Replace travel straight
hand. straight spool is scored. spool assy.
YES NO NG
Replace control valve.
Is the motion slow if pump delivery ports NO
P1 and P2 are exchanged. Inspect or replace pump.

YES Replace control valve.

Inspect bucket cylinder for oil

tightness and replace if defective.

6
(2)-3

Only the boom raise motion is slow.

(Service diagnosis No.19,No.16)

With key ON and engine at stop :
Back pressure sensor : 0.4
0.5V
P1 negative control sensor : 0.4
0.5V NO
P2 negative control sensor : 0.4
0.5V Replace faulty sensor.

YES (Diagnosis No.21)

The control current value of P2
bypass cut proportional valve NO
during boom hoist full lever To electric trouble shooting.
operation is approx. 647mA.
YES
Pilot pressure at port PCa (P2 NO Inspect or replace P2 bypass cut NG Inspect or replace
bypass cut valve) is approx. proportional valve. proportional valve block.
25kgf/cm2 (360psi).
YES
The secondary pilot pressure for
PAb and PB1 ports(boom hoist and NO Orifice of slow return valve for YES Inspect or replace orifice of
boom conflux) is 50kgf/cm2 (710psi). pilot piping is clogged with dirt. slow return valve block.
(near control valve)
NO
YES Inspect or replace pilot valve.
(Service diagnosis No.16,No.19)
(Diagnosis No.24,No.25)
The difference(Pn1=Pn1-Pt,
Command current values of pump NO Pn2=Pn2-Pt) between negative control NO Inspect or replace P1
proportional valve during operation pressure sensor values(Pn1, Pn2) and negative control poppet.
are : P1, P2 ; approx. 490
520mA. back pressure sensor value(Pt) during NG
YES operation is less than 2kgf/cm2 (28psi).
Inspect negative controll bolck.
YES
YES If a heavy ATT is installed, the boom
Weight varies with ATT type, etc.
hoist operating speed gets low.
NO To electric trouble shooting.
Relief pressure during boom hoist
NO Inspect or replace overload
operation is 350kgf/cm2 (4980psi) as
relief valve at port Ab (boom
standard.
head side).
YES (Diagnosis No.14)
Relief pressure during service diagnosis is
350kgf/cm2 (4980psi) as standard.
NO To electric troubleshooting.
YES
Inspect or replace P2 bypass
Return spring for P2 bypass cut YES
valve spool is broken. cut spool assy and pilot
cover.
NO
P2 bypass cut valve spool moves
NO Outer circumference of P2 YES Replace P2 bypass cut spool
smoothly by hand. (Remove pilot
bypass cut valve spool is scored. assy.
cover.)
YES NO NG
Replace control valve.
Return spring of boom spool is
broken. (Remove pilot cover.)
YES Inspect or replace boom
spool assy and pilot cover.
NO
Boom spool moves smoothly by
hand. (Remove pilot cover.)
NO Outer circumference of boom YES Replace boom spool assy.
spool is scored.
YES NO NG
Replace control valve.
Return spring for boom conflux YES Inspect or replace boom
spool is broken. spool assy and Pilot cover.
NO
Boom conflux spool moves smoothly NO Outer circumference of boom YES Replace boom conflux spool assy.
by hand. conflux spool is scored.
NG
YES NO Replace control valve.

Replace control valve.

7
(2)-4

With out boom raise, arm in and arm out are slow.

(Service diagnosis No.22)

Control current for travel straight proportional
valve is approx. 350mA. NO
(Are the motions slow if coupler (PSV-C) for travel To electric troubleshooting
straight proportional valve is disconnected?)
YES (Diagnosis No.22)
Pilot pressure at port PTb (travel YES Inspect or replace travel straight NG Inspect or replace
straight) is approx. 6.9kgf/cm2 (98psi).
proportional valve. proportional valve block.
NO
Return spring for travel straight spool Inspect or replace travel
YES
is broken. straight spool assy and pilot
cover.
NO
Travel straight spool moves smoothly NO Outer circumference of travel YES Replace travel straight
by hand. (Remove pilot cover.) straight spool is scored. spool assy.
YES NO NG
Replace control valve.

Replace control valve.

8
(2)-5

Only arm in action is slow.

(Service diagnosis No.19,No.16)

With key ON and engine at stop :
Back pressure sensor : 0.40.5V NO
P2 negative control sensor : 0.40.5V Replace faulty sensor.

YES (Service diagnosis No.23)

Control current value of arm variable
recirculation proportional valve during
NO
To electric troubleshooting
full lever arm in is approx. 409mA.
YES
Pilot pressure at arm variable
recirculation is port Pis
NO Inspect or replace arm variable
recirculation proportional valve.
approx. 10.5kgf/cm2 (150psi).

YES NG
Inspect or replace
(Service diagnosis No.16,No.19) proportional valve block.
(Service diagnosis No.25)
The difference(
Pn2=Pn2-Pt)
Command current value of pump between P2 negative control pressure
NO NO Inspect or replace
proportional valve during operation sensor value and back pressure sensor P2 negative control poppet.
P1 ; approx. 705mA or less, value(Pt) during operation is less than
P2 ; approx. 400mA 2kgf/cm2 (28psi). NG
YES Inspect negative control
YES block.

To electric troubleshooting.

Is the motion slow if pump delivery ports NO Inspect or replace

P1 and P2 are exchanged. P2 pump proportional valve.
YES
Service diagnosis NG
Is the secondary pilot pressure at PAa Inspect or replace pump.
and PLc2 ports(arm in and lock valve
release) normal. NO
50kgf/cm2 (710psi) Inspect or replace pilot valve.
YES
Service diagnosis
Inspect or replace
Relief pressure during arm in operation NO overload relief valve on the
is 350kgf/m2 (4980psi) Aa port of arm head side.
YES

Arm spool return spring is broken.

NO Inspect or replace arm spool
assy.
(Remove pilot cover.)
YES

Arm spool moves smoothly by hand. NO Outer circumference of arm YES

(Remove pilot cover.) spool is scored. Replace arm spool assy.

YES NO NG
Replace control valve.

Arm variable recirculation spool return YES Inspect or replace arm

spring is broken. variable recirculation spool
assy.
NO
Arm variable recirculation spool moves NO Outer circumference of YES Replace recirculation spool
smoothly by hand. recirculation spool is scored.
assy.
YES NO NG
Replace control valve.

Replace control valve.

9
(2)-6

Only arm out operation is slow.

(Service diagnosis No.20)

Command current for P1 bypass cut
NO
proportional control valve is approx. 647mA To electric troubleshooting
when arm out lever is shifted to the full.
YES
Pilot pressure at port PCb NO Inspect or replace P1 bypass
(P1 bypass cut) is approx. 25kgf/cm2 cut proportional valve.
(360psi).
NG
YES Inspect or replace
proportional valve block.
Secondary pilot pressure at port PBa NO Orifice of slow return valve for NO Inspect or replace
(arm out) is approx. 50kgf/cm2 (710psi). pilot piping is clogged with dirt. slow return valve.
YES YES
Inspect or replace
(Diagnosis No.24, No.25) (Diagnosis No.16, pilot valve.
Command current values of pump Difference( Pn1=Pn1-Pt, Pn2=Pn2-
proportional valve during relief NO Pt) between negative control pressure NO Inspect or replace
operation are ; sensor values(Pn1, Pn2) and back P1 negative control poppet.
P1, P2 : approx. 520 550mA. pressure sensor value(Pt) in travel NG
idling is: less than 2kgf/cm2 (28psi).
YES Inspect negative control
YES block.

Weight varies with ATT type, NO If a heavy ATT is installed, the boom
raise operating speed gets low.
YES
To electric troubleshooting.
(Diagnosis No.14)
Relief pressure lies within standard Inspect or replace overload
level (below) in arm out NO
relief valve at port Ba (arm
operation. 350kgf/cm2 (4980psi) rod side).
350kgf/cm (4980psi)
YES (Service diagnosis No.25)
Relief pressure on service diagnosis is NO
approx. 350kgf/cm2 (4980psi) To electric troubleshooting.

YES
YES Inspect or replace arm spool
Arm spool return spring is broken.
assy and pilot cover.
NO

Arm spool moves smoothly by hand. NO Outer circumference of arm spool YES
(Remove pilot cover.) is scored. Replace arm spool assy.

YES NO NG
Replace control valve.

Inspect or replace P1 bypass

Return spring of P1 bypass cut valve NO cut valve spool assy and
spool is broken.
pilot cover.
YES
P1 bypass cut valve spool moves NO Outer circumference of P1 YES Replace P1 bypass cut valve
smoothly by hand. bypass cut valve spool is scored. spool assy.
(Remove pilot cover.)
NO NG
YES
Replace control valve.

Inspect or replace arm conflux

Arm conflux spool return spring is YES spool assy and pilot cover.
broken.

NO
Replace arm conflux spool
Arm conflux spool moves smoothly by NO Outer circumference of arm YES
hand. (Remove pilot cover.) conflux spool is scored. assy.

YES NG
NO
Replace control valve.

10
(3)-1
All ATT operating power is poor.

Each independent operating speed is NO Refer to
All motions are

within a standard value. slow..
YES
(Diagnosis No.14) (Service diagnosis No.14)
Relief pressure lies within standard NO Confirm by service diagnosis NO
level. P1, P2 ; 350kgf/cm2 (4980psi) during relief action. 

YES YES
Adjust main relief pressure of NG Replace the relief valve of
control valve. main control valve.

Primary pilot pressure is NO Adjust pilot relief pressure. Replace pilot pump and
approx. 50kgf/cm2 (710psi). relief valve.
YES
Travel straight spool return spring is YES Inspect or replace travel
broken. straight spool assy and pilot
cover.
NO
Travel straight spool moves smoothly NO Outer circumference of travel YES Replace travel straight
by hand. (Remove pilot cover.) straight spool is scored. spool assy.
NO NG
YES
Replace control valve.

Inspect or replace control

(3)-2 valve or pump.

Bucket digging power is poor.

No-load independent operating speed NO Refer to
Only bucket

is within a standard value. motion is slow.
YES
(Service diagnosis No.14)
Relief pressure lies within standard Replace overload relief
level (below) when bucket digging NO Adjust overload relief valve on NG
valve at port BC (bucket
lever is turned to the full. bucket digging side.
head side).
350kgf/cm2 (4980psi)

YES
Secondary pilot pressure at port PBC
(bucket digging) is approx. 50kgf/cm2 NO
Inspect or replace pilot valve.
(710psi).
YES
Inspect or replace bucket
Bucket spool return spring is broken. YES
spool assy and pilot cover
NO

Bucket spool moves smoothly by NO Outer circumference of bucket YES

hand. (Remove pilot cover.) spool is scored. Replace bucket spool assy.

YES NO NG
Replace control valve.

Replace control valve or

pump.

11
(3)-3
Boom raise operating power is poor.

Is the no load single operation speed normal. NO Refer to“Only boom

raise motion is slow.”
YES
(Service diagnosis No.14)
Relief pressure lies within NO Adjust or replace overloa
standard level (below) at boom up d relief valve at port A
operation. b (boom head side).
P1,P2 ; 350kgf/cm (4980psi)
YES

(Diagnosis No.19)
Current value of P2 bypass cut valve
NO
during boom raise relief action is To electric troubleshooting.
647mA.
YES

Secondary pressure of P2 bypass cut NO Inspect or replace proportional NG Inspect or replace

valve during boom raise relief action is valve for P2 bypass cut valve proportional valve block.
25kgf/cm2 (360psi).

YES
Secondary pilot pressure at port PAb,
PB1 (boom raise, boom conflux) is NO Orifice of slow return valve for NO
pilot piping is clogged with dirt. Inspect or replace pilot valve.
30kgf/cm2 (430psi) or more.
YES
YES
Inspect or replace pilot v

YES Inspect or replace

Boom spool return spring is broken.
boom spool assy and pilot
NO cover.

NO Outer circumference of YES Replace boom spool assy.

Boom spool moves smoothly by hand. boom spool is scored.
NG
YES NO
Replace control valve.

Inspect or replace
Boom conflux spool return spring is YES boom conflux spool assy and
broken. pilot cover.
NO
Boom conflux NO Outer circumference of boom YES Replace boom conflux spool
spool moves smoothly by hand. conflux spool is scored. assy.
YES NO NG
Replace control valve.

Replace control valve or

pump.

12
(3)-4
Arm in power is poor.

No-load independent operating speed is NO Refer to
Only arm in is

within a standard value. slow..
YES (Servicediagnosis No.14)
Relief pressure during arm in for both P1 and Adjust or replace overload
P2 pumps lies within standard levels.
NO Relief pressure are low in both of YES relief valve at port Aa
P1,P2. (on arm head side).
P1,P2 ; 350kgf/cm2 (4980psi)
NO
YES (Diagnosis No.23)
Control current readings for arm recirculation NO
proportional valve are about 409mA when arm To electric troubleshooting
in lever is turned to the full.
YES (Diagnosis No.23)
Control current of arm recirculation NO
proportional valve during arm in relief normal.
(approx. 200mA)
YES
Pilot pressure of port Pis (arm recirculation)
during arm in operation is approx. 10.5kgf/cm2
NO Inspect or replace arm variable
(150psi) lever is turned to the full. recirculation proportional

YES NG
Pilot pressure of port Pis (arm recirculation) Inspect or replace
NO
during arm in relief is approx. 5kgf/m2 (71psi) proportional valve block.
or less.

YES (Diagnosis No.22)

Current of travel straight proportional valve
during arm in relief is approx. 647mA.
NO
To electric troubleshooting.
YES
Secondary pressure of travel straight proportional valve
during arm in relief is approx. 25kgf/cm2 (360psi).
NO Inspect or replace proportional NG Inspect or replace
valve for travel straight proportional valve block.
YES (Diagnosis No.20)
Current of P1 bypass cut during arm in relief is
approx. 647mA
NO
To electric troubleshooting.
YES
Secondary pressure of P1 bypass cut valve during
arm in relief is approx. 25kgf/cm2 (360psi)
NO Inspect or replace proportional NG Inspect or replace
valve for P1 cut valve proportional valve block.
YES
Secondary pilot pressure at arm in port
PAa and arm lock valve release PLc2 port
NO Inspect or replace
is approx. 30kgf/cm2 (430psi) or more. pilot valve.

YES
YES Inspect or replace arm spool
Arm spool return spring is broken. assy and pilot cover.

NO
Arm spool moves smoothly by hand. NO Outer circumference of arm spool YES
(Remove pilot cover.) is scored. Replace arm spool assy.

YES NO NG
Replace control valve.

Arm variable recirculation spool return YES Inspect or replace arm

spring is broken. variable recirculation spool
assy and pilot cover.
NO
Outer circumference of arm
  recirculation   NO variable recirculation spool is YES Replace arm variable
  hand    recirculation spool assy.
scored.
YES NG
NO
Replace control valve.

Replace control valve or

pump.
13
(4)-1

Machine can not perform fine operation of bucket digging and dump.

(Diagnosis No.24)
(Service diagnosis No.16)
Current value of P1 pump Is the action okay if the
Negative control pressure when
YES proportional valve when NO proportional valve for P1 is YES Replace pump
lever is neutral is 30
40kgf/cm2
lever is neutral is less than exchanged by the one for P2.
(430
570psi). (engine high idle) proportional valve.
705mA. (engine high idle)
NO NO
YES Inspect or replace negative
(Diagnosis No.19,No.16) control poppet, negative
With key ON and engine at stop : control block.
Back pressure sensor ; 0.4
0.5V NO
P1 negative control sensor ; 0.4
0.5V Replace faulty sensor.

YES
Is the action normal if the connector for P1 YES
bypass cut proportional valve is pulled out. To electric trouble shooting.

NO (Diagnosis No.14)
(Diagnosis No.20)
Unload pressure of P1 pump when Inspect or replace P1 bypass
lever is neutral is equal to the P1 NO Pilot pressure at port PCb (P1 bypass NO
cut proportional valve.
pump pressure ; approx. 5kgf/cm2 cut valve) is approx. 6.9kgf/cm2
(71psi) or less. YES NG
Inspect or replace
YES proportional valve block.

P1 bypass cut spool return YES Inspect or replace P1 bypass

spring is broken. cut spool assy and pilot cover.
NO
P1 bypass cut spool moves
smoothly by hand. NO Outer circumference YES Replace P1 bypass cut
of P1 bypass cut spool spool assy.
(Remove pilot cover.)
is scored.
YES NG
NO
Replace control valve.

(Diagnosis No.11) Replace control valve.

Secondary pressure of pilot valve is
approx. 5.5kgf/cm2 (78psi) when bucket NO Inspect or replace control
close lever is just shifted a little. valve.
YES

Pilot spool return spring is broken. YES Inspect or replace bucket

spool assy and pilot cover.
NO

Bucket spool moves smoothly by NO Outer circumference of backet YES Replace bucket spool assy.
hand. (Remove pilot cover.) spool is scored.
YES NO NG
Replace control valve.

Replace control valve.

14
(4)-2

Machine can not perform fine operation of boom raise and lower motions.

(Service diagnosis No.16) (Diagnosis No.24)

Negative control pressure when Current value of P1 pump
Is the action okay if the
lever is neutral is YES proportional valve when NO proportional valve for P1 is YES Replace pump
3040kgf/cm2 (430470psi) lever is neutral is less
exchanged by the one for P2. proportional
(engine high idle) than 705mA. (engine high
YES NO Inspect or replace Negative control
NO
poppet, negative control block.
(Diagnosis No.19,No.16)
With key ON and engine at stop :
Back pressure sensor ; 0.40.5V
NO
Replace faulty sensor.
P1 negative control sensor ; 0.40.5V

YES
Is the action normal if the connector for P1 YES
bypass cut proportional valve is pulled out. To electric

NO (Diagnosis No.14)
(Diagnosis No.20)
Unload pressure of P1 pump
when lever is neutral is equal
NO Pilot pressure at port PCb (P1 bypass NO Inspect or replace NG Inspect or replace
to the P1 pump pressure; cut valve) is approx. 6.9kgf/cm2 P1bypass cut proportional valve
approx. 35kgf/cm2 (500psi) or less. (98psi). poroportional valve block.
YES
YES
P1 bypass cut spool return YES Inspect or replace P1
spring is broken. bypass cut spool assy and
pilot cover.
NO
P1 bypass cut spool moves
smoothly by hand. NO Outer circumference of YES Replace P1 bypass
(Remove pilot cover.) P1 bypass cut spool is
cut spool assy.
scored.
YES NO NG
Replace control valve.

Replace control valve.

(Diagnosis No.9)
Secondary pressure of boom pilot is
approx. 5.5kgf/cm2 (78psi) when bucket
NO
Inspect or replace pilot valve.
close lever is just shifted a little.
YES
YES Inspect or replace boom
Boom spool return spring is
spool assy and pilot cover.
NO
Boom spool moves smoothly by NO Outer circumference of boom YES Replace boom spool assy.
hand. spool is scored.

YES NO NG
Replace control valve.

Does boom lock valve move

smoothly by hand. Inspect or replace lock valve.

YES
Replace control valve.

15
(4)-3

Machine can not perform fine swing operation.

(Service diagnosis No.16) (Diagnosis No.25)

Negative control pressure when Current value of P1 pump Is the action okay if
YES proportional valve when NO the proportional valve YES
 
lever is neutral is 3040kgf/cm2
(430470psi). (engine high idle) lever is neutral is less than for P1 is exchanged by    
705mA. (engine high idle) the one for P2.
NO YES NO Inspect or replace Negative
(Diagnosis No.19,No.16) control poppet, negative
control block.
With key ON and engine at stop :
Back pressure sensor ; 0.40.5V NO

faulty 
P2 negative control sensor ; 0.40.5V
YES
Action is normal if the connector
for P2 bypass cut proportional YES
valve is pulled out. To electric trouble shooting.

NO
Action is normal if the connector
YES
for swing parking brake solenoid is To electric trouble shooting.
pulled out.

NO
Unload pressure of P2 pump
when lever is neutral is equal or
NO Pilot pressure at port PCa (P2 NO Inspect or replace NG Inspect or replace
bypass cut valve) is P2 bypass cut valve proportional
low to the P2 pump pressure ; approx. 6.9kgf/cm2 (81psi). proportional valve. valve block.
approx. 35kgf/cm2 (498psi) or less.
YES
YES Inspect or Replace P2
P2 bypass cut spool return spring YES
bypass cut spool assy and
is broken.
pilot cover.
NO
P2 bypass cut spool moves
smoothly by hand. (remove NO Outer circumference YES Replace P2 bypass
of P2 bypass cut cut spool assy.
pilot cover.) spool is scored.
NG
YES NO
Replace control valve.

(Diagnosis No. 5) Replace control valve.

Secondary pressure when lever is
neutral during swing parking SOL. NO Inspect or replace swing parking NG Inspect or replace
is ON is 0kgf/cm2 (0psi) solenoid valve. proportional valve block.
(engine high idle)
NG
YES Inspect or replace
(Diagnosis No.12)
proportional valve block.
Secondary pressure of pilot valve is
NO Inspect or replace pilot
approx. 5.5kgf/cm2 (78psi) just
shifted a little. valve.

YES
Swing spool return spring is YES
Replace swing spool assy.
broken.
NO
Swing spool moves smoothly by NO Outer circumference of swing YES
Replace swing spool.
hand. spool is scored.

YES NO NG
Replace control valve.

Replace control valve.

16
(4)-4
Machine can not perform fine operation of arm in and out.
(Service diagnosis (Diagnosis No.25)
No.16)
Current value of P2 pump Is the action okay if
Negative control pressure when
YES proportional valve when NO the proportional valve YES Replace pump
lever is neutral is 30
40kgf/cm2.
lever is neutral is less than for P1 is exchanged by proportional valve.
(430
570psi) (engine high idle)
705mA. (engine high idle) the one for P2.
NO NO
YES Inspect or replace negative
control poppet, negative
(Diagnosis No.19,No.16)
control block.
With key on and engine at stop :
NO
Back pressure sensor ; 0.4
0.5V Replace faulty sensor.
P2 negative control sensor ; 0.4
0.5V
YES
Action is normal if the connector
for P2 bypass cut proportional YES
valve is pulled out. To electric trouble shooting.
NO (Diagnosis No.14)
Unload pressure of P2 pump Inspect or replace
when lever is neutral is equal or
NO Pilot pressure at port PCa (P2 bypass NO P2 bypass cut NG Inspect or replace
cut valve) is approx. 6.9kgf/cm2 (81psi). proportional valve. proportional valve
low to the P2 pump pressure;
block.
approx. 35kgf/cm2 (500psi) or less. YES
YES Inspect or replace P2 bypass
P2 bypass cut spool return spring YES cut spool assy and pilot
is broken.
cover.
NO
P2 bypass cut spool Outer circumference Replace P2 bypass cut
moves smoothly by NO of P2 bypass cut YES spool assy.
hand. spool is scored.
(remove pilot cover.) NG
NO
YES Replace control valve.

(Diagnosis No.10)
Secondary pressure is approx. Replace control valve.
5.5kgf/cm2 (78psi) when arm lever
is just shifted a little. NO
Inspect or replace pilot valve.
YES

YES Replace arm spool assy.

Arm spool return spring is broken.

NO
NO Outer circumference of arm spool YES
Arm spool moves smoothly by hand. Replace arm spool assy.
is scored.
YES NO NG
Replace control valve.
Arm lock valve moves smoothly by NO
hand. Inspect or replace lock

YES
Replace control valve.

17
(5)

Travel 1st and 2nd speeds can not be changed over.

24V is alive between light

green/black and black of connector NO
To electric
troubleshooting
(2PAF) for travel 1-2 speed solenoid
(SV-3).
YES
(Diagnosis No.6)
Travel 1-2 speed select solenoid NO Inspect or replace travel 1-2 NG Inspect or replace
(SV-3) is excited. speed select solenoid valve. proportional valve block.

YES
Travel 1-2 speed select can not be Inspect travel motor (throttle in passage
NO
done in heavy duty condition on a to 1-2 speed select valve, inclusion of
steep slope or on a muddy land. foreign matter in shuttle valve, etc.) or
YES
Since the delivery rate of pump is small at
heavy duty, the difference between 1st
and 2nd speeds gets smaller. This makes
you feel sometimes that speed is not
changed. But this is normal.

18
(6)

Travel independent speed is low.

Both the right and left travel idling speeds

are low. (M mode, Hi idle 1st-speed, NO Refer to
Travel
sprocket rotation ; approx. 33 rpm) independent deviates..
YES
Since the pump delievery
Machine is slow on steep slopes and in YES rate is decreased at high
muddy fields. (Is that on heavy duty.) load, travel speed is
decreased, but it is normal.
NO (Service diagnosis No.19,No.16)
With key ON and engine at stop :
Back pressure sensor ; 0.40.5V NO
P1 negative control sensor ; 0.40.5V Replace faulty sensor.
P2 negative control sensor ; 0.40.5V
YES (Diagnosis No.14)
(Diagnosis No.16, No.19)
When travel is idling, the difference
Current readings of pump
proportional valve lie within (Pn1=Pn1-Pt, Pn2=Pn2-Pt)
standard levels during both NO between negative control pressure NO Inspect or NG Inspect or
sensor values (Pn1, Pn2) and back replace P1,P2 replace negative
travel speeds.
P1,P2 ;approx. 350mA pressure sensor value(PT) is less than negative control control block.
2kgf/cm2 (28psi).
YES
YES
Secondary pressure for travel NO Inspect or replace pilot
pilot valve is valve for travel.
approx. 24kgf/cm2 (340psi).
YES
Control current of travel straight To electric troubleshooting.
proportional valve is approx. 350mA.
Is the machine slow even if connector NO
for travel straight proportional valve is To electric troubleshooting.
disconnected.

YES
Secondary pilot pressure at Inspect or replace Inspect or replace
Is the pivot turn possible. NO port PTb (travel straight valve) YES travel straight NG proportional valve
(in both directions)
is approx. 6.9kgf/cm2 (98psi). proportional valve. block.
YES
NO
Return spring of travel straight YES Inspect or replace travel
spool is broken. straight spool assy and pilot
cover.
NO
Travel straight spool moves NO Outer circumference of travel YES Replace travel
smoothly by hand. straight spool is scored. straight spool assy.
YES NO NG
Replace control valve.

Replace control valve.

Return spring of travel spool is YES Inspect or replace travel

broken. spool assy and pilot cover.

NO
NO Outer circumference of travel YES
Travel spool moves smoothly. spool is scored. Replace travel spool assy.
YES NO NG
Replace control valve.

Relief pressure during both travel

speeds lies within standard value. NO Inspect or replace travel
; 350kgf/cm2 (4980psi) motor relief valve.

YES
Inspect or replace travel
motor.
19
(7)
Travel power is poor.

Both travel speeds are slow during idle

traveling.(M-mode, Hi idle, 1st-speed, NO Refer to
Travel
sprocket revolution ; approx. 33rpm) independent is slow..
YES

(Service diagnosis
Command current for travel straight NO
proportional valve is approx. 350mA. To electric troubleshooting.

YES
Since the delivery rate of pump is
Power lack is felt on a steep slope small and travel speed is low in
YES
or in muddy fields. heavy duty condition, power lack is
felt in some cases, but it is normal.
NO

Is the secondary pilot pressure for NO Inspect or replace travel

travel approx. 24kgf/cm2 (340psi). pilot valve.
YES Inspect or replace
Pilot pressure at port PTb travel straight
Is a pivot turn possible. NO (travel straight valve) is NO proportional NG Inspect or replace
(in both directions) proportional valve block.
approx. 6.9kgf/cm2 (98psi). valve.
YES YES
Return spring of travel straight YES Inspect or replace travel
spool is broken. straight spool assy and pilot
cover.
NO
Travel straight NO Outer circumference YES Replace travel straight
spool moves spool assy.
of travel straight
smoothly by hand. spool is scored. NG
YES NO Replace control valve.

Replace control valve.

Inspect or replace travel

Return spring of travel spool is YES
straight spool and pilot
broken.
cover.
NO
Travel spool moves smoothly by NO Outer circumference of travel YES
spool is scored. Replace travel spool assy.
hand.

YES NO NG
Replace control valve.
Relief pressure lie within standard
value in both travel speeds. NO Inspect or replace travel
350kgf/cm2 (4980psi) motor relief valve.
YES
Inspect or replace travel
motor.

20
(8)-1
Machine deviates in one direction or zigzags.

There is no speed difference Since the delivery rate of

between right and left rotations YES Machine deviates on a slope and YES pumps decreases at high
during travel idling motion. in muddy ground. load, the flow rate differs
(Is the idling speed within a between P1 and P2 pumps.
standard value.) NO This is normal.
Relief pressure when travel is
NO
350kgf/cm2 (4980psi).

YES (Diagnosis No.14)

YES Is the P1,P2 pressure of service diagnosis normal NO
during travel relief. 350kgf/cm2 (4980psi) To electric
troubleshooting

(Diagnosis No.24, No.25) (Diagnosis No.16, No.19)

When travel is idling, Inspect or replace
Machine travel deviates in YES Current values of NO NO P1,P2 negative
proportional valves for the difference(Pn1=Pn1-Pt,
opposite direction if the delivery control poppet
both P1 and P2 pumps Pn2=Pn2-Pt) between
ports of pumps are changed.
are approx. 350mA. negative control pressure NG
NO sensor values(Pn1, Pn2) and
Inspect negative
YES back pressure sensor value(Pt)
control block
is less than 2kgf/cm2 (28psi).
YES
To electric
troubleshooting.
Machine deviates in opposite
direction if proportional valves of YES Replace pump proportional
pumps are exchanged. valve.
NO
Machine deviates in opposite YES
direction if regulators are Replace regulator.
exchanged.
NO
Inspect or replace pump.

Secondary pressure of travel pilot NO Inspect or replace travel

valve is approx. 24kgf/cm2 (340psi). pilot valve.
YES (Diagnosis No.14)
Machine travel motion deviates in NO Relief pressure in each travel NO Inspect or replace travel
opposite direction if the right and action is 350kgf/cm
(4980psi). motor relief valve.
left pipes between control valve
YES
and motor are exchanged.
Inspect or replace travel
YES motor.

Return spring of travel straight YES Inspect or replace travel

spool is broken. straight spool assy and pilot
cover.
NO
Travel straight spool moves NO Outer circumference of travel YES Replace travel straight
smoothly by hand. straight spool is scored. spool assy.
YES NO NG
Replace control valve.

Replace control valve.

21
(8)-2
Machine does not travel straight when travel and
ATT actions are combined.
(Service diagnosis No.22)
Control current for travel straight NO Secondary pressure of travel NO Inspect or replace travel
proportional valve is approx.647mA pilot valve is 24kgf/cm2 (340psi). pilot valve.
YES YES
To electric troubleshooting.

(Diagnosis No.22)
Secondary pilot pressure at port PTb NO Inspect or replace travel
(travel straight) is approx. 25kgf/cm2 straight proportional valve.
(340psi)
NG
YES Inspect or replace
proportional valve block

Return spring of travel straight YES Inspect or replace travel

spool is broken. straight spool assy and pilot
cover.
NO
Travel straight spool moves NO Outer circumference of travel YES Inspect or replace travel
smoothly by hand. straight spool is scored. straight spool assy.
YES NO NG
Replace control valve.

Replace control valve.

(9)
Machine drifts on a slope. (Machine can not be held on a slope.)

Machine can not be held on a slope YES Inspect or replace travel

when engine is OFF. Inspect travel motor. motor counterbalance.

NO NG
Inspect or replace travel
motor relief valve.

NG
Inspect or replace travel
spool assy.
NG
Inspect or replace travel
reduction unit assy.

(Diagnosis No.13)
Secondary pilot pressure for travel NO Inspect or replace remote
is 0kgf/cm2 (0psi). control valve.

YES
Return spring of travel straight YES Inspect or replace travel
spool is broken. spool assy and pilot cover.
NO
Travel straight spool moves NO Outer circumference of travel YES
smoothly by hand. spool is scored. Replace travel spool assy.
YES NO NG
Replace control valve.

Replace control valve.

22
(10)

Swing motion dose not work.

Does the machine work if the

connector for swing parking brake YES
release solenoid valve is To electric troubleshooting.
disconnected.
NO (Diagnosis No.5)
Secondary solenoid pressure is
0kgf/cm2 (0psi) when the engine is NO Is the swing pilot pressure YES Inspect or replace swing
at high speed, the lever is at sensor normal. parking solenoid.
neutral and the swing parking
solenoid is excited. NO NG
Inspect or replace
YES To electrical troubleshooting
proportional valve block.

In case of a machine with a multi control

valve, check if the condition returns normal by
changing swing lever back & forth operation.
Secondary pressure of swing pilot
valve is 30kgf/cm2 (430psi) or more
NO Dirt or something is stuck in the YES
orifice. Inspect or replace orifice.
for both ways.
YES NO
Inspect or replace pilot valve.

Return spring of swing spool is YES Inspect or replace swing

broken. spool assy and pilot cover.
NO
Swing spool moves smoothly by
hand. (Remove pilot cover.)
NO Outer circumference of swing YES
spool is scored. Replace swing spool assy.

YES NO NG
Replace control valve.

Swing relief pressure lies within

standard level. NO Inspect or replace swing
285kgf/cm2 (4050psi). motor relief.

NG
YES
Machine can be held on a slope NO Inspect or replace swing
during swing motion. reduction unit and swing
motor.
YES
Machine drifts very much when
swing parking is released (arm in YES Inspect or replace swing
action) on a slope. motor.

NO
Inspect or replace swing
reduction unit.

23
(11)
Swing speed is slow.

(Service diagnosis No.19,No.16)

With key ON and engine at stop :
Back pressure sensor : 0.4~ 0.5V
NO
Replace faulty sensor.
P2 negative control sensor : 0.4~ 0.5V
YES (Diagnosis No.16)
Current readings of pump proportional
NO Negative control pressure of P2 NO Inspect or replace P2
valve lie within standard levels during negative control poppet
during operation is 5kgf/cm2
both swing speeds.
(71psi) or less.
P1 ; approx.735mA. or less. NG
P2 ; approx.483mA YES Replace negative control
block.
YES
To electric troubleshooting
In case of a machine with a multi control
valve, check if the condition returns normal
by changing swing lever back & forth
Secondary pilot pressure for swing operation.
motion is approx. 30kgf/cm2 (430psi)
NO Orifice in remote control YES Inspect or NG Inspect or replace pilot
pipe is clogged with dirt. replace orifice. valve.
or more in both right and left.
YES NO
To electric troubleshooting.

Pilot pressure at PCa port (P2 bypass NO Inspect or replace P2 bypass

cut) during swing action is approx.
cut proportional valve.
25kgf/cm2 (360psi). (M mode Hi idle)

YES NG
Inspect or replace
proportional valve block.
Swing relief pressure lies ; NO Inspect or replace swing
300kgf/cm2 (4270psi) motor relief.
YES NG

Machine drifts very much when swing

parking is released (arm in action) on a YES Inspect or replace swing
slope. motor.
NO
Return spring of swing spool is broken.
YES Inspect or replace swing
spool assy and pilot cover.
NO
NO Outer circumference of swing YES
Swing spool moves smoothly. Replace swing spool assy.
spool is scored.
YES NO NG
Replace control valve.

Is the motion slow if pump delivery ports NO Inspect or replace P2 pump

P1 and P2 are exchanged. proportional valve.
NG
Inspect or replace pump
regulator.

NG
Inspect or replace pump.

24
(12)-1

Swing power is poor.

Swing speed lies within standard

NO Refer to “Swing speed is
slow.” .
YES
In case of a machine with a multi control
valve, check if the condition returns normal by
changing swing lever back & forth operation.
Secondary pilot pressure of swing
motion is approx.30kgf/cm2 (430psi)
NO Dirt or something is stuck in the YES
in either direction when lever is orifice. Inspect or replace orifice.
turned to the full.
YES NO
Inspect or replace Pilot
valve.
Swing relief pressure lies within
standard level. NO Inspect or replace swing
; 300kgf/cm 2 (4270psi) motor relief.

YES NG

Machine drifts largely when swing

parking is released (arm in action)
YES Inspect or replace swing
on a slope. motor.

NO
The pressure at the P(PG) port of
swing motor is 30kgf/cm2 (430psi) or NO Inspect or replace NG Inspect or replace
more when swing lever is turned to Swing parking SOL valve. Proportional block.
the full or during arm in action.
YES
Return spring of swing spool is YES Inspect or replace swing
spool assy and pilot cover.
NO

Swing spool moves smoothly by NO Outer circumference of swing YES

hand. (Remove pilot cover) spool is scored. Replace swing spool assy.

YES NO NG
Replace control valve.

Replace control valve.

25
(12)-2
Swing motion drifts very large.

Swing relief pressure lies within

NO Inspect or replace swing
standard level. motor relief valve.
; 300kgf/cm2 (4270psi)

YES

Swing can be held on a slope. NO Inspect or replace shockless

valve.
YES NG
Inspect or replace swing
reduction unit or swing motor.

Machine drifts largely when swing

parking is released (arm in action) YES Inspect or replace swing
on a slope. motor.

NO In case of a machine with a multi control

valve, check if the condition returns normal by
changing swing lever back & forth operation.
Secondary pilot pressure in swing
motion decreases within 0.2 second NO Dirt or something is stuck in the YES
Inspect or replace orifice.
when swing lever is brought to orifice.
neutral.
NO
YES Inspect or replace pilot valve.

YES Inspect or replace swing

Return spring swing spool is broken. spool assy and pilot cover.

NO

Swing spool moves smoothly. NO Outer circumference of swing YES

(Remove pilot cover) spool is scored. Replace swing spool assy.

YES NO NG
Replace control valve.

Replace control valve.

26
(13)-1
Swing parking brake is not held on a slope.
(Service diagnosis No.5)
Command voltage of swing parking YES
To electric troubleshooting.
brake solenoid is OFF.

NO Replace swing motor parking NG Inspect or replace swing

brake lining. motor and reduction unit.

(13)-2
Abnormal sound is heard during swing motion.

Abnormal sound occurs during YES Inspect or replace swing

swing relief action. motor relief valve.
NO
Abnormal sound occurs when swing YES Inspect or replace swing
motion stops. motor shockless valve.

NO
(Diagnosis No.14)
Relief pressure on the P2 side of
Swing relief pressure lies within NO NO Inspect or replace main
main control valve is 350kgf/cm2
standard level. 300kgf/cm2 (4270psi) control valve and relief valve.
(4980psi) during arm in or out
YES action.
YES
Inspect or replace swing
motor relief valve.

NG
Inspect or replace swing
motor.

Return spring of swing spool is YES Inspect or replace swing

broken.
spool assy and pilot cover.
NO

Swing spool moves smoothly by NO Outer circumference of swing YES

hand. (Remove pilot cover) spool is scored. Replace swing spool assy.

YES NO NG
Replace control valve.

Swing can be held on a slop. NO Inspect or replace swing

motor and reduction unit.
YES Inspect or replace swing motor
pinion gear, swing bearing race
and swing bearing.

27
NOTES

24
 SECTION 4 - TROUBLESHOOTING

CHAPTER 43

E215
CRAWLER EXCAVATORS

TROUBLE SHOOTING
(ELECTRICAL SYSTEM)

Issued January 2006

Book/Form Number 5-1760 NA
Copyright © 2006. CNH America, LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. S5PJ0010E01-KO31
 SECTION 4 - TROUBLESHOOTING
CHAPTER 43 - TROUBLESHOOTING (ELECTRICAL SYSTEM)

CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Remarks
First Edition 01-2006 E215 5-1760 NA

43-II Issued 01-2006 Bur 5-1760 NA

 SECTION 4 - TROUBLESHOOTING

CHAPTER 43
TROUBLESHOOTING (ELECTRICAL SYSTEM)
TABLE OF CONTENTS

1. TROUBLE DIAGNOSIS: ELECTRICAL SYSTEM

1.1 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Hydraulic Pressure Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2. TROUBLESHOOTING
1.1 No Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.2 Movement When Lever is at Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.1 All movement (motion) slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2.2 Bucket Motion Slow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.3 Boom Raise Speed Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.4 Machine Motion Slow Except Boom Raise or Arm Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.5 Arm in Motion Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2.6 Arm Out Operation Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3.1 Attachment Operation Power Poor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
3.2 Bucket Operation Power Poor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
3.3 Boom Raise Operation Power Poor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
3.4 Arm in Operation Power Poor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
4.1 Fine Operation of Bucket Digging Cannot be Performed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
4.2 Fine Operation of Boom Raise Cannot be Performed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
4.3 Fine Operation of Arm In and Out are Not Possible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
5.0 Travel 1-2 Speeds cannot be Changed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
6.0 Travel Independent is Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
8.1 Machine Does Not Travel Straight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
8.2 Deviation of Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
9.0 Machine Drifts on a Slope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
10.0 Swing Operation Inoperable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
12.0 Swing Speed Slow (When 2P Connector is Disconnected) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
13.1 Swing Cannot be Held on Slope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

5-1760 NA Issued 01-2006 Bur 43-1

 SECTION 4 - TROUBLESHOOTING
CHAPTER 43 - TROUBLESHOOTING (ELECTRICAL SYSTEM)

NOTES

43-2 Issued 01-2006 Bur 5-1760 NA

 1. TROUBLE DIAGNOSIS; ELECTRIC

C1 mechatro controller
Low pressure sensor Power supply & other signal Switch & relay

Engine coolant temp. high LS

Bucket dump pressure sensor
Boom raising pressure sensor

P2 side OPT pressure sensor

P1 side OPT pressure sensor
Travel right pressure sensor

Fuel level sensor thermister

Accel motor start point indexing
Swing right pressure sensor

Wiper motor prevent spark

Engine oil pressure low LS
Travel left pressure sensor
Swing left pressure sensor

Swing parking release SW

Component

Wiper motor reverse relay

Front working light relay

P1 pump pressure sensor
P2 pump pressure sensor

C/V back pressure sensor

P1 negative control pressure

P2 negative control pressure

Arm out pressure sensor

Bucket digging pressure

Boom lowering pressure

SW for High reach machine

Engine coolant level LS

Arm in pressure sensor

Signal for maintenance

Key switch
ON/OFF

Hydraulic oil level LS

Air filter clogging LS

ATT power boost SW

Travel 1-2 speed SW

Engine speed sensor

Wiper motor reverse

Key switch
GLOW

Washer motor relay

Engine oil level LS

Swing flasher relay

Alternator voltage

Wiper motor relay

KPSS release SW

Sealed grounding

Sealed grounding
Wiper motor stop
Accel potentio

Gauge cluster
Switch assy
ON/OFF
sensor

sensor

sensor

sensor

relay
LS
Group No.

Connector No. CN-11 CN-12 CN-13 CN-14

System

1 4 7 10 13 16 19 22 25 28 31 34 1 4 7 10 13 14 15 16 17 18 19 20 22 1 4 7 10 13 16 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16 17 18 25 28
                     19 
Trouble
20 26
2 5 8 11 14 17 20 23 26 29 32 2 5 8 11 21 2 5 8 11 14
                    21 
Pin No. 22
3 6 9 12 15 18 21 24 27 30 33 3 6 9 12 3 6 9 12 15 24
27

No motions operate. 
(1) Machine moves unexpectedly when
lever is at neutral.            
All operate                
Only bucket speed is slow.              
Speed is slow

Only boom raise speed is slow.      

Attachment opration

(2) Motions are slow except boom raise

or arm out.            
Only arm in motion is slow.   
Only arm out motion is slow.      

All operate                  
Power is poor

Bucket digging              
(3)
Boom raising      
Arm in   
Fine operation

Bucket digging              
Electric systems

impossible

(4) Boom raising, lowering              

Arm in, out  
(5) Travel 1-2 speeds can not be changed 
Travel operation

(6) Travel independent speed is low.               

(7) Travel power is poor               
ATT travel combined and travel
straight are impossible.            
(8)
Travel deviates, zigzags.  
Machine drifts on a downhill and does
(9) not stop still on a slope
(10) Swing motion does not work   
Swing operation

(11) Swing speed is slow     

(12) Swing power is poor       
Swing P/B is not held on a slope     
(13)
Swing fine operation impossible              
Option

1
 C1 mechatro system
B
Governor motor & proportional valve & SOL Option C D

Flasher switch & working light relay

Flasher switch & working light relay

Travel straight proportional valve C
P1 bypass cut proportional valve D

P2 bypass cut proportional valve B

Swing priority proportional valve

Component

P1 pump proportional valve

P2 pump proportional valve
Accelerator motor B phase

Hydraulic oil temp. switch

Accelerator motor A phase

Power supply grounding

Safety lock lever switch

Arm variable recirculation

ATT power boost SOL

Travel 1-2 speed SOL

Air conditioner amplifier

Flasher select switch

Rotary N & B switch

Battery back up 24V
Power supply
24V

Travel alarm switch

Swing parking SOL

Travel alarm relay

Nibbler close relay

Auto grease controller

Nibbler open relay
proportional valve A
Sealed grounding

Mechatro contoller
P/W controller

P/W controller
Battery relay

Switch box assy

P/W controller
Gauge cluster
Battery

Diode
Group No.
System

Connector No. CN-15 CN-16 CN-17 CN-18

1 3 4 6 8 10 12 14 15 17 19 21 22 23 24 25 7 2 3 4 5 6 7 8 9 10 11 12 13 14 18 18 1 B C C C C C C D D D D D D D D D
Trouble
              2 1 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9
2 5 7 9 11 13 16 18 20 26 8 15 19 21 3
Pin No.    4
16 22 22

No motions operate.  
(1) Machine moves unexpectedly when
lever is at neutral.  
All operate   
Only bucket speed is slow.   
Speed is slow

Only boom raise speed is slow.   

Attachment opration

(2) Motions are slow except boom raise

or arm out. 
Only arm in motion is slow.  
Only arm out motion is slow.   
All operate   
Power is poor

Bucket digging   
(3)
Boom raising   
Arm in    
Fine operation
Electric systems

Bucket digging  
impossible

(4) Boom raising, lowering  

Arm in, out  
(5) Travel 1-2 speeds can not be changed 
Travel operation

(6) Travel independent speed is low.   

(7) Travel power is poor   
ATT travel combined and travel
straight are impossible. 
(8)
Travel deviates, zigzags.  
Machine drifts on a downhill and does
(9) not stop still on a slope
(10) Swing motion does not work 
Swing operation

(11) Swing speed is slow  

(12) Swing power is poor  
Swing P/B is not held on a slope 
(13)
Swing fine operation impossible  
Option

2
 Electrical equipments

   
S/M P/W

Travel straight proportional valve

Swing priority proportional valve

Arm variable rcirculation proportional valve

P2 bypass cut proportional valve

P1 bypass cut proportional valve

Flasher & working light unit (right)
Component

Flasher & working light unit (left)

CAB working light left
right

Boom cylinder working light

P1 pump proportional valve

P2 pump proportional valve

OPT
working light relay

High reach rotary light

Right revolution relay

Power window motor

Left revolution relay

working light relay

Nibbler close relay

Travel alarm relay

Nibbler open relay

Lock motor (right)

Roof wiper motor

Tuner AM & FM

Cigarette lighter

Wiper relay assy

Lock motor (left)
Boom work light
Deck work light

Governor motor
Air compressor
Receiver dryer

Washer motor
Starter motor

Grease motor

Battery relay
Travel alarm

Starter relay
Wiper motor

Safety relay
Hourmeter

Room light

Horn relay
Glow relay
Alternator
Fuse box

Resistor

Speaker


Timer
Group No.

Horn
System











                                     
Trouble 1 2 3 4 5 7 8 10 11 13 14 1 2 3 4 5 7 9 10 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 12 13 15 16 20
  
Pin No.


6 9 8   P1 P2

No motions operate. 
(1) Machine moves unexpectedly when
lever is at neutral.  
All operate   
Only bucket speed is slow.   
Speed is slow

Only boom raise speed is slow.   

Attachment opration

(2) Motions are slow except boom raise

or arm out. 
Only arm in motion is slow.  
Only arm out motion is slow.   
All operate   
Power is poor

Bucket digging   
(3)
Boom raising   
Arm in    
Fine operation

Bucket digging  
Electric systems

impossible

(4) Boom raising, lowering  

Arm in, out  
(5) Travel 1-2 speeds can not be changed
Travel operation

(6) Travel independent speed is low.   

(7) Travel power is poor   
ATT travel combined and travel
straight are impossible. 
(8)
Travel deviates, zigzags.  
Machine drifts on a downhill and does
(9) not stop still on a slope
(10) Swing motion does not work
Swing operation

(11) Swing speed is slow 

(12) Swing power is poor 
Swing P/B is not held on a slope
(13)
Swing fine operation impossible  
Option

3
 Electrical equipments




Swing motor parking release SW

Component

Single/Conflux select switch

OPT
Working light switch

Switch assy (mode/buzzer)

Hydraulic oil temp. switch

Hydralulic oil level switch
E/G coolant temp. switch

Air filter clogging switch

ATT power boost switch

Safety lock lever switch
E/G oil pressure switch

Wiper, washer, light SW

ATT power boost SOL

Travel 2-speed switch

Safety lock lever SOL

E/G coolant level SW

Swing flasher switch
KPSS release switch

Nibbler close switch

Travel alarm switch

Nibbler open switch

Swing parking SOL

Travel 2-speed SOL

Wiper interlock SW

Nibbler stop switch

Nibbler close SOL
Nibbler open SOL

Roof wiper switch

Warm-up switch
E/G oil level SW
Air-con switch
Horn switch
Key switch

Group No.
System

Trouble                                         
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 13 14 15 17 19 20 21 22 23 24 25 26 29 30 31 33 34 37 38 41
Pin No.

No motions operate.  
(1) Machine moves freely when lever is at
neutral.
All operate
Only bucket speed is slow.
Speed is slow

Only boom raise speed is slow.

Attachment opration

(2) Motions are slow except boom

raiseor arm out.
Only arm in motion is slow.
Only arm out motion is slow.

All operate
Power is poor

Bucket digging
(3)
Boom raising
Arm in
Electric systems

Bucket digging
Fine operation
impossible

(4) Boom raising, lowering

Arm in, out

(5) Travel 1-2 speeds can not be changed  

Travel operation

(6) Travel independent speed is low.

(7) Travel power is poor
ATT travel combined and travel
straight are impossible.
(8)
Travel deviates, zigzags.
Machine drifts on a downhill and does
(9) not stop still on a slope
(10) Swing motion does not work 
Swing operation

(11) Swing speed is slow (fast) 

(12) Swing power is poor 
Swing P/B is not held on a slope 
(13)
Swing fine operation impossible
Option


 Electrical equipments



P1 negative control pressure sensor

P2 negative control pressure sensor

Bucket digging pressure sensor
Boom lowering pressure sensor

Bucket dump pressure sensor

Boom raising pressure sensor

P2 Side OPT pressure sensor

P1 Side OPT pressure sensor

Travel right pressure sensor
Component

Swing right pressure sensor

Travel left pressure sensor

Swing left pressure sensor

P1 pump pressure sensor

P2 pump pressure sensor
Arm out pressure sensor

Arm in pressure sensor

Back pressure sensor

Engine speed sensor
Accel potentio
Group No.


System

S S S S S S S S S S S S S S S S S S S
Trouble E E E E E E E E E E E E E E E E E E E
3 4 8 7 1 2 6 5 9 10 16 22 23 26 27 13 11 20 28
Pin No.

No motions operate.
(1) Machine moves freely when lever is at
neutral.












All operate
















Only bucket speed is slow.














Speed is slow

Only boom raise speed is slow.

Attachment opration

(2) Motions are slow except boom

raiseor arm out.












Only arm in motion is slow.



Only arm out motion is slow.

All operate


















Power is poor

Bucket digging














(3)
Boom raising






Arm in



Electric systems

Bucket digging














Fine operation
impossible

(4) Boom raising, lowering

Arm in, out


(5) Travel 1-2 speeds can not be changed
Travel operation

(6) Travel independent speed is low.

(7) Travel power is poor













ATT travel combined and travel
straight are impossible.












(8)
Travel deviates, zigzags.


Machine drifts on a downhill and does
(9) not stop still on a slope
(10) Swing motion does not work


Swing operation

(11) Swing speed is slow (fast)

(12) Swing power is poor






Swing P/B is not held on a slope





(13)
Swing fine operation impossible














Option


NOTES

6
 2. TROUBLESHOOTING


No motions operate.
More than 1 sec. after lever stand is lowered.
24V is alive between OW and B of
YES To hydraulic troubleshooting
connector for lever lock solenoid
(SV-1).
NO
Harness between lever lock
24V is alive on OW of connector for YES
timer relay (R-20). solenoid (SV-1) and timer rlay Inspect harness.
(R-20) is disconnected.
NO
24V is alive on YV of connector for YES B of connector for timer relay YES
timer relay (R-20). (R-20) is at grounding level. Replace timer relay (R-20).

NO 
Harness between timer relay (R-
20) and ground is disconnected. Inspect harness.

Harness between timer relay

24V is alive on YV of connector for YES (R-20) and lever lock switch Inspect harness.
lever lock switch (SW-11). (SW-11) is disconnected.
NO
Lever lock switch (SW-11) is
faulty. Replace switch.
24V is alive on WB of connector for YES
lever lock switch (SW-11).
Lever lock switch (SW-11) is
NO attached improperly. Adjust and replace.

YES Harness between lever lock

24V is alive on WB of connector on
switch (SW-11) and fuse box Inspect harness.
fuse box (E-1).
(E-1) is disconnected.
NO
YES Inspect the shorted point of
Fuse No.15 is blown. Harness shorted to frame.
harness.

NO
Inspect if there is no
disconnection in fuse box (E-1).



Machine moves freely when lever is at neutral.

The machine operates freely if the connector

for the P1 bypass cut proportional valve and
YES
To hydraulic troubleshooting
P2 bypass cut proportional valve is removed.
NO (Service diagnosis No.9,10,11,12,13)
Are all low pressure sensor readings
(boom, arm, bucket, swing, travel
NO Replace faulty sensor.
and OPT) 0.4 to 0.5V at neutral?
NG
YES Inspect electric wiring of faulty
sensor or pilot valve.

Is the electric wiring to P1 bypass

NO Correct electric wiring.
cut proportional valve and P2 bypass
cut proportional valve all right?

YES
Replace proportional valve.

NG

Replace mechatro controller.

7
(2) -1

All motions are slow.

(Service diagnosis No.2)

Actual engine revolution reading is 0 YES
Adjust speed sensor gap.
or a false value by service diagnosis.
NG
NO
Replace speed sensor.
(Diagnosis No.2)
Service diagnosis at neutral
indicates that a set engine
YES
Adjust engine.
revolution differs more than 50 rpm
from an actual value.
NO
(Diagnosis No.19, No.16)
Service diagnosis with the key ON indicates
: NO
Back pressure sensor voltage: 0.4
0.5V Replace faulty sensor.
P1 negative control sensor: 0.4
0.5V NG
YES Check electric wiring.

(Diagnosis No.24,25) (Diagnosis No.16,

Current values of pump proportional The difference (Pn1-Pt, Pn2-Pt) between
valves during travel idling are NO negative control pressure sensor value NO
approx. 350mA for both the right To hydraulic troubleshooting
(Pn1, Pn2) and back pressure sensor
(P1) and the left (P2). value (Pt) is less than 2kgf/cm2 (28psi).
YES YES
Is the electric wiring to each sensor NO Correct electric wiring.
all right?
YES
Replace proportional valve.

NG
(Diagnosis No.22) Replace mechatro controller.
Motions are slow even if connector of
travel straight proportional valve is
pulled out. (Is the current value of
YES
To hydraulic troubleshooting
travel straight proportional valve
approx. 350mA?)
NO (Diagnosis No.9,10,11,12,13)

Are all low pressure sensor readings

(boom, arm, bucket, swing, travel
NO
Replace faulty sensor.
and OPT) 0.4 to 0.5V at neutral?
NG
YES Inspect electric wiring of faulty
sensor or pilot valve.

Is the electric wiring to travel NO

Correct electric wiring.
straight proportional valve all right?
YES
Replace proportional valve.

NG
Replace mechatro controller.

8
(2)-2
Only bucket motion is slow.
(Service diagnosis No.11)
Is the voltage level of low pressure sensor NO
for bucket action normal?
(0.4 to 0.5V at Replace low pressur sensor.
neutral)(more than 4.5V at full lever)
NG
YES Inspect electric wiring of faulty
(Diagnosis No.19, No.16) sensor or pilot valve.
Service diagnosis with the key ON indicates
: NO
Replace faulty sensor.
Back pressure sensor voltage: 0.40.5V

YES NG
Check electric wiring.
(Diagnosis No.24) (Diagnosis No.16, No.19)
Is the current value of pump The difference (Pn1-Pt) between P1
proportional valve during NO negative control pressure sensor value NO
operation normal? (Pn1) and back pressure sensor value (Pt) To hydraulic troubleshooting
Dump : during operation is less than 2kgf/cm2
P1 ; approx. 483mA or over, and (28psi).
P2 ; approx. 705mA or over.
YES
Digging : NO
P1 ; approx. 400mA or over, and Is the electric wiring to abovementioned Correct electric wiring.
P2 ; approx. 705mA or over. sensor and proportional valve all right?

YES YES Replace P1 pump proportional

valve.
NG
Replace mechatro controller.
(Diagnosis No.22)
Motions are slow even if connector of
travel straight proportional valve is YES Motions are slow even if connector of YES
P2 bypass cut proportional valve is To hydraulic troubleshooting
pulled out. (Is the current value of
pulled out.
travel straight proportional valve
approx. 350mA?) NO (Diagnosis No.9,10,12,13)
NO Are all low pressure sensor readings NO
(boom, arm, bucket, swing, travel Replace faulty sensor.
and OPT) 0.4 to 0.5V at neutral?
NG
YES Inspect electric wiring of faulty
sensor or pilot valve.

Is the electric wiring to P2 bypass NO

cut proportional valve all right? Correct electric wiring.

YES
Replace proportional valve.

NG
(Diagnosis No.9,10,12,13) Replace mechatro controller.
Are all low pressure sensor readings NO
(boom, arm, bucket, swing, travel Replace faulty sensor.
and OPT) 0.4 to 0.5V at neutral?
NG
YES Inspect electric wiring of faulty
sensor or pilot valve.

Is the electric wiring to travel NO

Correct electric wiring.
straight proportional valve all right?
YES
Replace proportional valve.

NG
Replace mechatro controller.

9
(2)-3
Only boom raise speed motion is slow.

(Service diagnosis No.9)

Is the voltage level of low pressure
sensor for boom raise action normal?
NO
(0.4 to 0.5V at neutral)(more than Replace low pressur sensor.
4.5V at full lever)
NG

(Diagnosis No.19, No.16) Check electric wiring.

Service diagnosis with the key ON indicates

: NO
Replace faulty sensor.
Back pressure sensor voltage: 0.4
0.5V
P1 negative control sensor: 0.4
0.5V NG
Inspect electric wiring of faulty
YES
(Diagnosis No.21) sensor or pilot valve..
Are the current values of P2 bypass
cut proportional valve during boom NO Is the electric wiring to NO Correct electric wiring.
raise full lever operation normal or proportional valve all right?
approx. 647mA.
YES
YES Replace proportional valve.

NG
Replace mechatro controller.

(Diagnosis No.24, No.25) (Diagnosis No.16, No.19)

Are the command current value of The difference (Pn1-Pt, Pn2-Pt)
pump proportional valve during NO between negative control pressure NO
sensor value (Pn1,Pn2) and back To hydraulic troubleshooting
operation normal?
P1, P2 : approx. 490mA
520mA. pressure sensor value (Pt) during
operation is less than
( )
YES YES
Is the electric wiring to
NO Correct electric wiring.
abovementioned sensor and
proportional valve all right?

YES
Replace pump proportional valve.

NG
Replace mechatro controller.
(Diagnosis No.14)
Is the relief pressure by service
diagnosis normal or approx. YES To hydraulic troubleshooting
350kgf/cm2 (4980psi)?
NO
Replace high pressure sensor
for pump pressure.
NG
Check electric wiring.

10
(2)-4
Machine motions are slow except boom raise or arm out.
(Service diagnosis No.22)
Motions are slow even if connector of
travel straight proportional valve is YES
pulled out. (Is the current value of travel To hydraulic troubleshooting
straight proportional valve approx.
NO
(Diagnosis No.9,10,11,12,13)
Are all low pressure sensor readings
NO
(boom, arm, bucket, swing, travel Replace faulty sensor.
and OPT) 0.4 to 0.5V at neutral?
NG
YES Inspect electric wiring of faulty
sensor or pilot valve.

Is the electric wiring to travel NO

Correct electric wiring.
straight proportional valve all right?
YES
Replace proportional valve.

NG
Replace mechatro controller.

11
(2)-5
Only arm in motion is slow.

(Service diagnosis No.10)

Is the voltage level of low pressure
sensor for arm in action normal?
NO
(0.4 to 0.5V at neutral) (more than Replace low pressur sensor.
4.5V at full lever)
NG
 Inspect electric wiring of faulty
sensor or pilot valve.
(Diagnosis No.19, No.16)
Service diagnosis with the key ON indicates NO
: Replace faulty sensor.
Back pressure sensor voltage: 0.4
0.5V
NG
YES
Check electric wiring.
(Diagnosis No.23)
Is the current value of arm variable
recirculation proportional valve NO Is the electric wiring to NO Correct electric wiring.
during arm in full lever operation proportional valve all right?
normal or approx. 409mA?
YES
YES Replace proportional valve.

NG
Replace mechatro controller.

(Diagnosis No.24, No.25) (Diagnosis No.16, No.19)

Are the command current value of The difference (Pn2-Pt) between P2
negative control pressure sensor NO
pump proportional valve during NO
value (Pn2) and back pressure To hydraulic troubleshooting
operation normal?
P1 : 705mA or over sensor value (Pt) during operation is
P2 : approx. 400mA less than 2 kgf/cm2 (28psi).

YES YES
Is the electric wiring to
NO Correct electric wiring.
abovementioned sensor and
proportional valve all right?

YES Replace P2 pump proportional

valve.
NG
Replace mechatro controller.

To hydraulic troubleshooting

12
 SECTION 4 - TROUBLESHOOTING

CHAPTER 44

E215
CRAWLER EXCAVATORS

TROUBLE SHOOTING
(ENGINE)

Issued January 2006

Book/Form Number 5-1770 NA
Copyright © 2006. CNH America, LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. S5PJ0010E01-KO31
 SECTION 4 - TROUBLESHOOTING
CHAPTER 44 - TROUBLESHOOTING (ENGINE)

CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Remarks
First Edition 01-2006 E215 5-1770 NA

44-II Issued 01-2006 Bur 5-1770 NA

 SECTION 4 - TROUBLESHOOTING

CHAPTER 44
TROUBLESHOOTING (ENGINE)
TABLE OF CONTENTS

1. PROBLEM DIAGNOSIS: ENGINE

1.1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2. TROUBLESHOOTING
1.0 Starter Does Not run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2.0 Starter Turns - Engine is Difficult to Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.0 Engine Revolution is Faulty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
6.0 Engine Output Insufficient. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
7.0 Engine Knocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
8.0 Exhaust Abnormal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
9.0 Excessive Oil Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
10. Excessive Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
11.0 Engine Does Not Stop When Turned Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

5-1770 NA Issued 01-2006 Bur 44-1

 SECTION 4 - TROUBLESHOOTING
CHAPTER 44 - TROUBLESHOOTING (ENGINE)

NOTES

44-2 Issued 01-2006 Bur 5-1770 NA

 Engine
Rotation trouble System
Other trouble Drop in output Starting trouble

Group No.

(7)
(6)
(5)
(4)
(2)
start.
1.

not stop.
Over heat
revolution.
Idling unsmooth

warming-up E/G

(8) Exhaust gas is white

(11) key is turned off.

Trouble

not work properly.

Does not reach max
Component

Exhaust gas is black

(1) Starter does not run.

not disappear after idling.)

(3) High speed unsmooth

Knocking occurs after

Medium speed hunting

E/G deficiency in output

modes are changed. (A
M/B)

Accel potentiometer does

(12) turned to OFF, but engine does

Starter runs but does not

(In cold state, white smoke does

(9) Excessive oil consumption.

Engine does not stop when

Max. revolution is too high.

(10) Excessive fuel consumption.

Power is off the moment the key is

Revolution does not change if work


Fuel not filled up or leaking.

Oil cooler element clogged.
Fuel system trouble(Air or water entered.)

OiL filter clogged.

Air cleaner clogged.
Filters

Gauze filter clogged.

Fuel filter clogged.

V-belt slips.
Inspection

Breather hose bent.
Cooling water level
TROUBLE DIAGNOSIS TABLE ; ENGINE

Fuel is of poor quality or leaking.

Specific gravity of battery fluid


Fluid

Viscosity of engine oil is not suited, engine oil is

leaking, or the engine oil level not proper.

Poor quality fuel is used or heavy oil is used.

Blowby gas is much.

Gas leaks from valve and gasket.

Engine oil is too much.
Gas / fluid
Visual check

Battery fluid level

Fuse

Starter key

Battery relay

Mechatoronic controller
Mechatoro “A” adjust.
Shovel side

Stepping motor
Accel potentiometer

Connector and electric wiring

Safety relay
Electrical fittings

Glow relay

Glow
Starter motor
Engine side

Starter relay
Alternator
Feed pump function

Check injection timing

Fuel

Inspect nozzle.
system

Stop

Injection pump
position

Valve clearance

Valve spring is fatigued.

system
Intake /
exhaust

Air cleaner & muffler

Check if engine oil goes into combustion chamber.

Check relief valve.

Oil strainer clogged.
system
Lubrication

Fuel is mixed.

Check thermostat.

Oil cooler eleent damaged.

Cooling

Compression pressure low.

Control rack movement unsmooth.

Governor spring fatigued.

Crank shaft oil seal no good.
Piston liner worn.

Piston ring worn.

Valve spring fatigued.

Main structure

Internal parts stuck.

Check fuel feed.

Head gasket faulty.

Flywheel gear damaged.

1
 NOTES NOTES

2
 2. TROUBLESHOOTING
(1) ; (1) matches the group No. on page 1. The same is true on the following pages.
Note

Starter does not run.

NO Check battery fluid level

Check battery voltage. Charge or replace battery.
and specific gravity.
OK
(See Fig.1)
Check on A terminal on A side is 24V, but A1 YES
battery relay OUT side. Replace fusible link 60A.
side is no 24V.
Check on A1 terminal on
battery relay OUT side.

OK
The voltage at outlet
NO
side of 20A fuse for key- Replace fuse.
Check fuse box voltage.
switch is 24V.
OK OK The voltage at pin connecting
The voltage at inlet side YES line No. 10 white / purple NO Check electric wiring and
of keyswitch is no 24V. line on connector CN-9M
connectors.
connected to fuse box for
instrument panel harness.
(See Fig.2)
Measure the voltage at
L terminal of battery NO Check electric wiring
relay instead of M
and connector.
terminal of keyswitch to
check the voltage of the
Check key switch M terminal. Check or replace key
voltage. switch.
Check that ST terminal
OUT side is 24V with
No. 63 white / yellow NO Check electric wiring
line on E/G sub harness and connector.
starter relay when Key
SW. is turned to start
position.
OK

The voltage at L YES

Check voltage of battery
terminal of battery relay Replace battery relay.
relay coil. (See Fig.1)
is 24V or more.
OK

Check on starter motor 24V is alive on terminal

battery terminal. B of starter motor.
OK OK
Replace starter motor.

Check on starter motor 24V is alive on terminal

relay side terminal S. S of starter motor.

OK
The voltage of No. 64 white /
When starting engine,
check on safety realy IN
blue line on instrument panel YES
safety relay connector CN-12F
side.
S terminal side is 24V.
OK Replace safety relay.
The voltage of No. 59 white line
When starting engine,
on instrument panel safety
check on safety realy IN
relay connector CN-12F R YES
side terminal R.
terminal side is 24V.

Condition ; Check keyswitch in START position.

Emergency stop knob (engine stop) is back in position

3
(2)

Starter turns but engine is hard to start.

OK
Check E/G oil of viscosity if it is
NO
Check viscosity of E/G oil. suited to atmospheric Replace engine oil.
temperature.
OK

Check starter power is strong or WEAK Check battery fluid level and
Charge or replace
battery.
weak. specific gravity.
STRONG
Check compression
Check engine itself. pressure and valve
clearance. Check that
valve spring is not
Check that air filter clogged
Check air intake system. fatigued, that piston
lamp lights.
liner is not worn, that
OK OK piston ring is not worn,
Check that air cleaner clogged that head gasket is not
sensor. faulty and that flywheel
gear is not damaged.
Also check radiator and
thermostat

E/G side Check gauze filter. Check feed pump

OK performance, injection
Check fuel feed system. pump, injection nozzle
Check fuel gauge and water and injection timing
Machine
separator. Check that poor
side
quality fuel is not used.

YES
Check electric system. E/G side 24V is alive on glow plug. Glow plug is faulty.

NO
Harness between glow
24V is alive on wire No. 34 (5W) YES relay and glow plug is
of P-25 on glow plug. faulty.
Machine NO (See Fig.3)
side Voltage of No. 33 line (20B) of NO Harness between glow
P-23 of glow relay (R-3) is 24V. relay and battery relay
is faulty.
OK
Voltage between No.58 pink line YES
of F21 of glow relay to grounding Replace glow relay.
is 24V.
NO Harness between key
NO
Ground connection is poor. switch and glow relay is
faulty.

Check the function of governor NG

Governor motor is out of tune. motor limit switch. Replace governor motor.

OK
Adjust mechatro “A”.

Checking condition ; E/G starter key is in START position.

4
(3)
E/G revolution is faulty.

Check high pressure pipe

and injection nozzle. Check
that compression
Idling not smooth.
pressures in cylinder are
equal. Check injection
pump and thermostat.
Idling is faulty.

1
Idling revolution is too
high. Adjust mechatroA.

Medium revolution is Hunting occurs at medium Check control rack.

faulty. revolution. Change over governor
spring.

Check that air is not mixed YES

in fuel. Bleed air.
OK
Check that air cleaner is
Check air intake system. not clogged.
OK
Check fuel gauge, water
separator and gauze filter.
Check fuel feed system.
Check also that poor
OK quality fuel is not used.
High idling is faulty.

Check injection nozzle,

injection pump and
injection timing.

E/G does not reach max.

revolution.
1

Adjust mechatroA.
Max revolution is too high.

Checking condition ; E/G water temperature is more than 50
5 (122
12

F).

1 ; Refer to Electric Troubleshooting.

5
(6)

E/G output is insufficient.

Check that E/G water OK
temperature lamp is on and Check the contents of
Overheat
that buzzer sounds. excavating.

NO
Check E/G water
temperature switch, gauge
Inspect electric system.
cluster, electric wiring and
OK connectors.

Check cooling water level.

Check that fan belt does
Check cooling system.
not slip.
OK Check thermostat.
Also check that radiator.
Oil cooler is not clogged.

Check that poor quality

Check fuel system.
fuel is not used.
OK
Check E/G oil system. Check E/G oil filter.

Check air intake Check that air filter clogged OK Check that air cleaner is
system. display of warning not clogged.
OK
Check fuel feed Check that air is not mixed in
system fuel. Bleed air.

OK OK
Check water separator and Check feed pump
gauze filter. Check also that performance, injection
poor quality fuel is not used. pump, injection nozzle and
injection timing.

Check viscosity of E/G oil if it

Check E/G oil. is suited to atmospheric Replace engine
oil.
temperature.
OK
Check compression
Check that blowby gas is not pressure and valve
much, that gas does not leak clearance. Check that
Check engine
from gasket, and that engine valve spring is not
itself.
oil goes into combustion fatigued. Check that
chamber. control rack moves
smoothly. Check that
Checking condition ; High idling piston ring is not worn.
Check also that head
gasket is not faulty
(7)

Knocking occurs after warming-up E/G.

Check that poor quality fuel is

Check fuel
system. not used. Replace fuel.

Check that engine oil does not Judge it if oil is there on

Check E/G itself. rise. exhaust port.
OK
Check that blowby gas is not Check compression
much and that gas does not pressure, injection timing
leak from gasket. and injection nozzle.

Checking condition ; E/G water temperature is more than 50
5(122
12

F).

6
(8)

Exhaust is abnormal.

Check that air cleaner is not

Exhaust gas is black. clogged. Replace air element.

OK
Check engine oil viscosity.
Check that engine oil is not too
much.
Check injection nozzle,
OK injection timing, injection
Check that gas is not leaking pump and valve clearance.
from head gasket. Check that valve spring is not
fatigued and that piston ring is
not faulty.

Check that water is not mixed

Exhaust gas is white. in fuel. Check water separator.

OK
Check that engine oil goes
into combustion chamber. Check compression pressure
Blowby gas is much. A lot of and injection timing.
gas leaks from gasket.

Checking condition ; Engine water temperature is more than 50
5 (122
12

F).

(9)

Excessive oil consumption.

Check that engine oil is not Check leakage by checking the Retighten.
leaking. ground under E/G or an oil Replace packing and seal.
(Check that engine oil is not OK
filled up too much.) Check that breather hose is not
bent or clogged. Replace breather hose.

OK
Check that poor quality fuel is
Advise to replace fuel.
not used.
OK
Check viscosity of engine oil. Advise to replace engine oil.

OK Check that; CR shaft oil seal is

Check that engine oil goes into not faulty, piston liner is not
Checking condition ; No engine oil leaks. combustion chamber. worn, or piston ring is not
worn.
(10)

Excessive fuel consumption.

Check that poor quality fuel is

Check fuel leakage. not used. Advise to replace fuel.

OK
Blowby gas is much.
Check that gas does not leak Check nozzle function.
from gasket.
OK
Check injection timing.

Check compression pressure.

Checking condition ; Use proper fuel.

7
(11)
E/G does not stop Confirm governor Check if governor Check that governor
when starter key is lever stop bolt motor is not faulty motor link
turned off. position. mechanically. connecting bolts are
not loose.
OK (See Fig.3) Wire No. 60 blue /
Check resistance (See Fig.3)
white line C1
Check that terminal NG between terminals Replace starter key
controller connector
M of starter key M and B of starter if resistance across
of instrument panel
switch shows 0V. key M and B is 0
.
harness 22PAF
shows 0V. YES
Check harness
between starter key
(12) and C1 controller.
Check that battery Wire No.700 white
When starter key is Check harness
relay terminal B2 /green of upper NG between C1
turned ON, power is OK
measures 0V four harness battery Check C1 controller.
not cut off but controller and
seconds after key is relay connector
engine stops. battery relay.
turned off. 3PAF measures 0V.
OK (See Fig.2.)
Does battery YES
Check that battery Replace battery
terminals between A
relay operates. relay.
and B measure 0
.

Checking condition ; Starter key is ON.

CN-152F
TERMINAL A1 LOCK
Flowing direction of
main current

TERMINAL A1,A B,B1 TERMINAL

A A
FLW
TERMINAL B1
FLW
2.0sq 2.0sq TERMINAL A VIEW 
FLW2.0sq
TERMINAL B
G B2 FLW2.0sq
W L P COIL

H COIL

BRACKET EARTH
TERMINAL B2
Circuit diagram

L TERMINAL  L TERMINAL

AVS1,25L GROUNDING
AVS1,25G
EARTH CABLE B2 TERMINAL TERMINAL
AVS1,25B
CN-150M
Fig. 1
Battery relay

Fig. 2
Key SW. terminal Fig. 3
Glow relay terminal and

connection diagram
8
SHOP MANUAL - SECTION 5

E215
CRAWLER EXCAVATORS

ENGINE

Issued January 2006

Book/Form Number 5-1780 NA
Copyright © 2006. CNH America, LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. S5PJ0010E01-KO51
 SECTION 5 - ENGINE

CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Remarks
First Edition 01-2006 E215 5-1780 NA
 SECTION 5 - ENGINE
CHAPTER 0 - GENERAL DISASSEMBLY AND ASSEMBLY

SECTION 5
ENGINE
TABLE OF CONTENTS

CHAPTER 51 - ENGINE

5-1780 NA Issued 01-2006 Bur 0-I

NOTES
 SECTION 5 - ENGINE

CHAPTER 51

E215
CRAWLER EXCAVATORS

ENGINE

Issued January 2006

Book/Form Number 5-1790 NA
Copyright © 2006. CNH America, LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. S5PJ0010E01-KO51
 SECTION 5 - ENGINE
CHAPTER 51 - ENGINE

CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Remarks
First Edition 01-2006 E215 5-1790 NA

51-II Issued 01-2006 Bur 5-1790 NA

 SECTION 5 - ENGINE

CHAPTER 51

1 PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00
2. ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
3. LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
4. FUEL AND ENGINE CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
5. COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
6. INTAKE AND EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
7. ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Note: This engine chapter is a reproduction of a Mitsubishi Motors Corporation Service Manual. The original
information has been modified by removing selected information not related to the engine in this machine.

5-1790 NA Issued 01-2006 Bur 51-1

 SECTION 5 - ENGINE
CHAPTER 51 - ENGINE

NOTES

51-2 Issued 01-2006 Bur 5-1790 NA

1
 NOTES

2
3
4
5
6
7
8
9
10
00-1
00-2
00-3
00-4
00-5
00-6
00-7
00-8
00-9
 NOTES

00-10
11-1
11-2
11-3
11-4
11-5
11-6
11-7
11-8
11-9
11-10
11-11
11-12
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11-53
11-54
11-55
11-56
11-57
11-58
11-59
11-60
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 NOTES

11-62
12-1
12-2
12-3
12-4
12-5
12-6
12-7
12-8
12-9
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12-13
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12-15
12-16
12-17
12-18
12-19
12-20
12-21
 NOTES

12-22
13-1
13-2
13-3
13-4
13-5
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 NOTES

13-28
14-1
14-2
14-3
14-4
14-5
14-6
14-7
14-8
14-9
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14-17
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 15-1
15-1
15-2
15-3
15-4
15-5
15-6
15-7
15-8
15-9
15-10
54-1
54-2
54-3
54-4
54-5
54-6
54-7
54-8
54-9
54-10
54-11
54-12
54-13
54-14
54-15
54-16
54-17
54-18
54-19
54-20
54-21
54-22
54-23
54-24
54-25
54-26
54-27
54-28
54-29
54-30
54-31
54-32
54-33
54-34
54-35
 NOTES

54-36