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SM - CX130 Tier4 - EN

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SM - CX130 Tier4 - EN

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Copyright ©

SERVICE MANUAL
Lep 84592788 EN

CX130C Tier 4
Crawler Excavator

Issue date March 2012

CRAWLER EXCAVATOR
CX130C TIER 4
SERVICE MANUAL

TABLE OF CONTENTS
DIVISION/SECTION SECTION N°
1 GENERAL INFORMATION
Safety, general information and standard torque data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002A
Main Equipment Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002B
Main Unit Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002C
Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002D
Bolt Size and Torque Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002E
Overall View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002F
New Machine Performance Judgment Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002G
List of special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1003
Fluid and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1004
Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1005
Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1900
2 ENGINE
Removal and Installation of Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000
Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler . . . . . . . . . . . . . . . 2001
Removal and Installation of Turbo Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2004
Removal and Installation of EGR Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2005
Removal and Installation of Engine Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2006
Removal and Installation of Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2007
Primary specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2401
Removal and Installation of Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2415
Removal and Installation of Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2425
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2445
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2455
Removal and Installation of Exhaust Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2465
Disassembly, Removal and Installation of DPD Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2470
3 FUEL SYSTEM
Removal and Installation of Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3001
Removal and Installation of Fuel Supply Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3004A
Removal and Installation of Common Rail Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3004B
Removal and Installation of Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3005
4 ELECTRICAL SYSTEM
Electrical and Engine Basic Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001A
Service Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001B
Function, Structure, Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001C
Symptom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001E
Functional Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001F
Engine, Electronic and Programming Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001G
Removal and Installation of Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4004
Removal and Installation of Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4005
Preheating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4008
Electrical Equipment Layout Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4020A
Connection Connector Pin Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4020B
Sequence Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4020C
Engine-side DTC List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4021
Main Unit-side DTC List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4022
Introduction to the trouble diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4023B
Engine Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4023D
Engine-side Trouble. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4023G

Lep 84592788 EN Copyright © 2012 CNH France

March 2012 Printed in France
Copyright ©

TABLE OF CONTENTS
DIVISION/SECTION SECTION N°
Main Unit-side Trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4023H
Data Reference Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4023K
Electrical Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4040
5 UNDERCARRIAGE
Removal and Installation of Shoe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5001A
Removal and Installation of Shoe Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5001B
Removal and Installation of Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5003A
Assembly and Disassembly of Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5003B
Removal and Installation of Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5003C
Assembly and Disassembly of Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5003D
Removal and Installation of the Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5004
Removal and Installation of Take-up Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5005A
Assembly and Disassembly of Take-up Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5005B
Removal and Installation of Grease Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5005C
Assembly and Disassembly of Tension Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5005D
6 DRIVE TRAIN
Removal and Installation of Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6001
Assembly and Disassembly of Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6002
Removal and Installation of Swing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6003
Assembly and Disassembly of Swing Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6004
7 UNDERCARRIAGE HYDRAULICS
8 UPPERSTRUCTURE HYDRAULICS
Overall view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8001A
Port Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8001B
Pump P-Q Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8001C
Pressure Measurement and Adjustment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8001D
Hydraulic Pump Flow Measurement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8001E
Drain Volume Measurement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8001F
Air Bleed Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8001G
Removal and Installation of Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8002
Removal and Installation of Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8003
Removal and Installation of Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8004
Removal and Installation of Bucket Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8005A
Removal and Installation of Arm Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8005B
Removal and Installation of Boom Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8005C
Removal and Installation of Center Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8006
Removal and Installation of Travel Remote Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8007A
Removal and Installation of Operation Remote Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8007B
Removal and Installation of 5 Stack Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8007C
Removal and Installation of Cushion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8007D
Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit . . . . . . . . . . . . . . . . . . . . . . . . 8008
Pump Main Unit Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8010
Procedures for Assembly and Disassembly of Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8011
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder (made by KYB) . . . . . . . . . 8012
Procedures for Assembly and Disassembly of Operation Remote Control Valve . . . . . . . . . . . . . . . . . . . 8013
Procedures for Assembly and Disassembly of Travel Remote Control Valve . . . . . . . . . . . . . . . . . . . . . . 8014
Assembly and Disassembly of Cushion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8016
Removal and Installation of Arm HBCV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8017A
Removal and Installation of Boom HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8017B
Assembly and Disassembly of Center Joint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8018
Assembly and Disassembly of Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8019
Explanation of Hydraulic Circuit and Operations (standard model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8020A
Explanation of Hydraulic Circuit and Operations (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8020B

Lep 84592788 EN Issued 2012-03

TABLE OF CONTENTS
DIVISION/SECTION SECTION N°

Structure and Operation Explanation of Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8030A

Structure and Operation Explanation of Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8030B
Structure and Operation Explanation of Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8030C
Structure and Operation Explanation of Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8030D
5 Stack Solenoid Valve Operation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8030E
Structure and Operation Explanation of Upper Pilot Valve (remote control valve) . . . . . . . . . . . . . . . . . 8030F
Structure and Operation Explanation of Travel Pilot Valve (remote control valve). . . . . . . . . . . . . . . . . . 8030G
Structure and Operation Explanation of Cushion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8030H
9 UPPERSTRUCTURE
Removal and Installation of Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9002
Removal and Installation of Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9003A
Removal and Installation of Bucket Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9003B
Removal and Installation of Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9003C
Removal and Installation of Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9003D
Removal and Installation of Operator’s Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9004
Removal and Installation of Cab Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9005A
Removal and Installation of Wiper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9005B
Removal and Installation of Wiper Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9005C
Removal and Installation of Wiper Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9005D
Removal and Installation of Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9005E
Removal and Installation of Cab Front Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9005F
Window Lock Adjustment Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9005G
Cab Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9005H
Air Conditioner Overall Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9006
Assembly and Disassembly of Air Conditioner Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9007
Removal and Installation of Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9009
Removal and Installation of Condenser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9010
Removal and Installation of Receiver Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9011
Air Conditioning Gas Vacuum and Filling Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9015
10 LARGE SIZE SCHEMATICS
Large size hydraulic schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84596657EN
Large size electrical schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84596655EN

NOTE: CNH France Company reserves the right to make changes in the specification and design of the
machine without prior notice and without incurring any obligation to modify units previously sold.

The description of the models shown in this manual has been made in accordance with the technical speci-
fications known as of the date of design of this document.

All data given in this manual is subject to production variations. Dimensions and weights are provided with
approximate values and the machine fitting shown in the illustrations may not correspond with standard
models. For precise information on specific machine models and versions, please contact your CASE
dealer.
Reproduction or tranlation, even partial, is prohibited without written authorization from CNH France Com-
pany.

Lep 84592788 EN Copyright © 2012 CNH France

March 2012 Printed in France
Copyright ©

Lep 84592788 EN Issued 2012-03

Section

1001

Safety, general information and standard torque data

84592788 EN - March 2012

CONTENTS

GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ROPS Judgment Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bolt and Nut Tightening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

1001-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

1001-2 PRINTED IN FRANCE
Copyright ©
Safety, general information and standard torque data

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

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Safety, general information and standard torque data

Safety

This symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED.

The message that follows the symbol contains important information about safety.
Carefully read the message.
Make sure you fully understand the causes of possible injury or death.

To prevent injury always follow the Warning, Caution and Danger notes in this section and throughout the manual.
Put the warning tag shown below on the key for the key switch when servicing or repairing the machine.
One warning tag is supplied with each machine.
Additional tags are available from your service parts supplier.

WARNING
Read the operator's manual to familiarize yourself with the correct control functions.

WARNING
Operate the machine and equipment controls from the seat position only.
Any other method could result in serious injury.

WARNING
This is a one man machine, no riders allowed.

WARNING
Before starting engine, study Operator’s Manual safety messages.
Read all safety signs on machine.
Clear the area of other persons.
Learn and practice safe use of controls before operating.
It is your responsibility to understand and follow manufacturers instructions on machine operation, ser-
vice and to observe pertinent laws and regulations.
Operator's and Service Manuals may be obtained from your CASE dealer.

WARNING
If you wear clothing that is too loose or do not use the correct safety equipment for your job, you can
be injured.
Always wear clothing that will not catch on objects.
Extra safety equipment that can be required includes hard hat, safety shoes, ear protection, eye or face
protection, heavy gloves and reflector clothing.

WARNING
When working in the area of the fan belt with the engine running, avoid loose clothing if possible, and
use extreme caution.

WARNING
When doing checks and tests on the equipment hydraulics, follow the procedures as they are written.
DO NOT change the procedure.

WARNING
When putting the hydraulic cylinders on this machine through the necessary cycles to check operation
or to remove air from a circuit, make sure all people are out of the way.

WARNING
Use insulated gloves or mittens when working with hot parts.

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Safety, general information and standard torque data

WARNING
Lower all attachments to the ground or use stands to safely support the attachments before you do any
maintenance or service.

WARNING
Pin sized and smaller streams of hydraulic oil under pressure can penetrate the skin and result in serious
infection.
If hydraulic oil under pressure does penetrate the skin, seek medical treatment immediately.
Maintain all hoses and tubes in good condition.
Make sure all connections are tight.
Make a replacement of any tube or hose that is damaged or thought to be damaged.
DO NOT use your hand to check for leaks, use a piece of cardboard or wood.

WARNING
When removing hardened pins such as a pivot pin, or a hardened shaft, use a soft head (brass or bronze)
hammer or use a driver made from brass or bronze and a steel head hammer.

WARNING
When using a hammer to remove and install pivot pins or separate parts using compressed air or using
a grinder, wear eye protection that completely encloses the eyes (approved goggles or other approved
eye protectors).

WARNING
Use suitable floor (service) jacks or chain hoist to raise wheels or tracks off the floor.
Always block machine in place with suitable safety stands.

WARNING
When servicing or repairing the machine, keep the shop floor and operator's compartment and steps
free of oil, water, grease, tools, etc.
Use an oil absorbing material and/or shop cloths as required.
Use safe practices at all times.

WARNING
Some components of this machine are very heavy.
Use suitable lifting equipment or additional help as instructed in this Service Manual.

WARNING
Engine exhaust fumes can cause death.
If it is necessary to start the engine in a closed place, remove the exhaust fumes from the area with an
exhaust pipe extension.
Open the doors and get outside air into the area.

WARNING
When the battery electrolyte is frozen, the battery can explode if (1), you try to charge the battery, or (2),
you try to jump start and run the engine.
To prevent the battery electrolyte from freezing, try to keep the battery at full charge.
If you do not follow these instructions, you or others in the area can be injured.

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Safety, general information and standard torque data

ROPS Judgment Method

1. Purpose
Check against the ROPS judgment criteria to judge whether the machine satisfies the ROPS criteria or not.
The weight and boom of the machine greatly effects whether the ROPS judgment criteria is satisfied or not.
The ROPS test assumes that the weight being used is the weight of the machine when the maximum number of
selectable options are mounted (as of 2009).
However, depending on the derivative machinery or the order details, the weight and boom position may differ
from the assumed weight or position.
2. Criteria for judging whether a machine satisfies the ROPS criteria
1) Weight
The weight must not be over the weight shown below for each class.
If the weight is exceeded, there is a danger that the cab could be damaged and the operator could die or
sustain a serious injury when the machine falls over.
If the weight exceeds the stipulated weight, the machine will not satisfy the ROPS criteria.
• Weight (X3 model)
To satisfy the ROPS criteria, the weight must not be over the indicated weight. (The below weights are
the weights indicated on the nameplate within the ROPS cab)

Machine body total weight Class

CX75C
16000 kg (35274.146 lb) or less
CX145C
CX130C
20500 kg (45195.000 lb) or less CX160C
CX180C
28000 kg (61729.756 lb) or less CX235C
CX210C
CX250C
31000 kg (68343.658 lb) or less
CX250C LR
CX300C
40000 kg (88185.365 lb) or less CX370C
50000 kg (110231.707 lb) or less CX470C

* The ROPS test assumes that the CX470C has a cage guard (alone).

Machine body total weight Class

* The ROPS test assumes that the CX470C has a cage guard (alone).
• Weight (X2 model)
To satisfy the ROPS criteria, the weight must not be over the indicated weight. (The below weights are
the weights indicated on the nameplate within the ROPS cab)

Machine body total weight Class

CX130B
CX160B
26600 kg (58643.268 lb) or less CX180B
CX210B
CX240B
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Safety, general information and standard torque data

2) Boom position

WARNING
• If the machine has been modified so that the boom position has been lowered, the machine
will not satisfy the ROPS criteria.
• It is necessary to consult with our company if it is possible that the boom's position has been
lowered by modification.
• The extent to which a boom position has moved cannot be determined in the same way for
all machines.

a Ground point

With the tip of the bucket in contact with the ground surface at maximum work radius, if the position (* in the
diagram) that overlaps with the cab when viewed from the side is markedly lower than that of a standard
machine (standard arm), the machine will not satisfy the ROPS criteria.
Also, with a machine body with a cab mounted that can withstand up to 31 tons, the effect of mounting a
24 ton machine, which is near the restriction weight, and a 21 ton machine to the same cab will not be the
same.
3. Prohibited items
• Modifications that reduce the strength of a platform that has a cab with a ROPS mounted to it. (Actions or
modifications that reduce the functionality of the anchoring part at the left-rear of the cab)
• Modifications that effect the strength of the ROPS of a cab.

1001-10
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Section

1002A

Specifications

84592788 EN - March 2012

CONTENTS

CX130C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Main Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Main Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Upper Side Work System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operating Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Swing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Travel Lower Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Control Valve and Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Capacities, Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Coolant and Oil Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CX130C NLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Main Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Main Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Upper Side Work System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operating Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Swing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Travel Lower Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Hydraulic Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Hydraulic Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Control Valve and Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Capacities, Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Coolant and Oil Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hydraulic Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

1002A-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

1002A-2 PRINTED IN FRANCE
Copyright ©
Specifications

CX130C
Main Data
Operating weight 12800 kg (28219.317 lb)
Engine output 74.9 kW/2000 min-1 (100.443 HP/2000 rpm)
Heaped 0.480 m3
Bucket capacity
Leveled 0.361 m3

Operating weight 12700 kg (27998.900 lb)

Engine output 74.9 kW/2000 min-1 (100.443 HP/2000 rpm)
Heaped 0.480 m3
Bucket capacity
Leveled 0.361 m3

Performance
Standard weight 8.825 kN (1984.27853 lbf)
Swing speed 14.3 min-1 (14.3 rpm)
Low speed 3.4 km/h (2.1127 mile/h)
Travel speed
High speed 5.6 km/h (3.4797 mile/h)
Maximum pulling force 115 kN (25857.45 lbf)
Grade ability 70 ％ (35゜)
41 kPa (5.95 psi) [500 mm (19.685 in) grouser shoe]
Ground pressure 34 kPa (4.93 psi) [600 mm (23.622 in) grouser shoe]
30 kPa (4.35 psi) [700 mm (27.559 in) grouser shoe]

Standard weight 8.825 kN (1984.27853 lbf)

Swing speed 14.3 min-1 (14.3 rpm)
Low speed 3.4 km/h (2.1127 mile/h)
Travel speed
High speed 5.6 km/h (3.4797 mile/h)
Maximum pulling force 115 kN (25857.45 lbf)
Grade ability 70 ％ (35゜)
41 kPa (5.95 psi) [500 mm (19.685 in) grouser shoe]
Ground pressure 34 kPa (4.93 psi) [600 mm (23.622 in) grouser shoe]
29 kPa (4.21 psi) [700 mm (27.559 in) grouser shoe]

Main Unit Dimensions

Main unit length 3880 mm (152.756 in)
Main unit width 2590 mm (101.969 in)
Upper swing body width 2540 mm (100.000 in)
Cab width 1000 mm (39.370 in)
Main unit height 2820 mm (111.024 in)
Swing radius (rear end) 2130 mm (83.858 in)
Swing body rear end distance 2130 mm (83.858 in)
Swing body rear section bottom height 895 mm (35.236 in)
Distance between tumblers 2790 mm (109.843 in)
Overall track length 3500 mm (137.795 in)
Overall track width 2590 mm (101.969 in)
Distance between tracks 1990 mm (78.346 in)
Track shoe width 600 mm (23.622 in) [options 500 mm (19.685 in), 700 mm (27.559 in)]
Minimum ground clearance 440 mm (17.323 in) (to bottom of lower frame)

Main unit length 3880 mm (152.756 in)

Main unit width 2590 mm (101.969 in)
Upper swing body width 2540 mm (100.000 in)
Cab width 1000 mm (39.370 in)
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Specifications

Main unit height 2840 mm (111.811 in)

Swing radius (rear end) 2130 mm (83.858 in)
Swing body rear end distance 2130 mm (83.858 in)
Swing body rear section bottom height 895 mm (35.236 in)
Distance between tumblers 2790 mm (109.843 in)
Overall track length 3500 mm (137.795 in)
Overall track width 2590 mm (101.969 in)
Distance between tracks 1990 mm (78.346 in)
Track shoe width 600 mm (23.622 in) [options 500 mm (19.685 in), 700 mm (27.559 in)]
Minimum ground clearance 440 mm (17.323 in) (to bottom of lower frame)

Engine
Name Isuzu 4JJ1X diesel engine
4-cycle, water-cooled, overhead camshaft type, common rail system (elec-
Model tronic control), cooled EGR, with turbocharger (variable displacement type),
DPD system
No. of cylinders - bore x stroke 4 - D95.4 mm (3.7559 in) x 104.9 mm (4.1299 in)
Total stroke volume 2.999 L (0.79227 gal)
Maximum torque 359 N・m/1600 min-1 (264.83 lbf・ft/1600 rpm)
Starter 24 V 4.0 kW reduction type
Charging generator 24 V 50 A AC type
Battery 12 V 92 Ah/5 HR x 2

Cooling System
Fan type D550 mm (21.654 in) 8 blades, suction
Radiator
Fin type Wavy
Fin pitch 1.75 mm (0.06890 in)
Oil cooler
Fin type Wavy
Fin pitch 1.75 mm (0.06890 in)
Intercooler
Fin type Wavy
Fin pitch 2.0 mm (0.0787 in)
Fuel cooler
Fin type Wavy
Fin pitch 2.0 mm (0.0787 in)

Upper Side Work System

Model Backhoe attachment
Components, dimensions, working dimensions
Standard bucket capacity Heaped 0.480 m3 (Leveled 0.361 m3)
Bucket width 888 mm (34.961 in)
Bucket width with side cutter 962 mm (37.874 in)
Bucket weight with side cutter 371.3 kg (818.5807 lb)
Boom length 4630 mm (182.283 in)
Standard Long Short
Arm type ［ 2.50 m (8.2021 ［ 3.01 m (9.8753 ［ 2.11 m (6.9226
ft)］ ft)］ ft)］
3010 mm (118.504
Arm length 2500 mm (98.425 in) 2110 mm (83.071 in)
in)
Bucket radius 1200 mm (47.244 in)
Bucket wrist angle 178°
8310 mm (327.165 8770 mm (345.276 7960 mm (313.386
Maximum digging radius
in) in) in)
84592788 EN - March 2012
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Specifications

8170 mm (321.654 8640 mm (340.157 7810 mm (307.480

Maximum digging radius at ground line
in) in) in)
5540 mm (218.110 6050 mm (238.189 5150 mm (202.756
Maximum digging depth
in) in) in)
4950 mm (194.882 5350 mm (210.630 4600 mm (181.102
Maximum vertical straight wall digging depth
in) in) in)
8770 mm (345.276 9050 mm (356.299 8550 mm (336.614
Maximum digging height
in) in) in)
6390 mm (251.575 6680 mm (262.992 6170 mm (242.913
Maximum dump height
in) in) in)
2660 mm (104.724
Minimum swing radius at front 2340 mm (92.126 in) 2360 mm (92.913 in)
in)
6560 mm (258.268 6590 mm (259.449 6560 mm (258.268
Height for minimum swing radius at front
in) in) in)

Operating Device

Operator's seat
Position Left side
Adjustable forward and back and up and down, reclining mechanism,
Structure
with seat suspension
Cab Sealed steel type, all reinforced glass
Levers and pedals
For travel use Lever and pedal type (hydraulic pilot type) x 2
For operating machine use Lever type (hydraulic pilot type) x 2
Instruments and switches
Work mode switchover 3 modes (SP/H/A)
Travel mode switchover Low-speed/high-speed switch type
One-touch idle Knob switch type
Engine emergency stop Switch type
Monitor device
Machine status display (full color liquid
crystal)
Work mode select status SP/H/A
Instruments (full color liquid crystal)
Fuel gauge Bar graph and indicator
Engine coolant temperature gauge Bar graph and indicator
Hydraulic oil temperature gauge Bar graph and indicator
Hour meter Digital type
Machine status and warnings (full color liquid crystal and warning alarm) * has warning alarm
Overheat (*) Battery charge (*) Electrical system abnormality (*) Refill fuel (*) Engine oil pressure (*) Refill coolant
(*) Engine pre-heat Auto warm up Air cleaner (*) Anti-theft device triggered Engine system abnormality (*) Engine
emergency stop (*)
Illumination equipment
Tank front surface 24 V 70 W x 1
Working light Cab top 24 V 70 W x 2
Boom up 24 V 70 W x 1
Interior light 24 V 10 W x 1
Horn Electric horn x 2
Wiper with intermittent function, window washer, air conditioner, clock,
Other
rear view mirrors (left and right, total of 4)

Swing Units

Swing circle Swing bearing type (with inner gear)

Swing hydraulic motor Fixed displacement piston motor x 1
Reduction gear Planetary gear 2-stage reduction gear
Swing parking brake Mechanical lock (operational lever linkage type)
84592788 EN - March 2012
1002A-5
Copyright ©
Specifications

Travel Lower Body

Travel hydraulic motor Variable displacement piston motor x 2

Reduction gear Planetary gear 2-stage reduction gear
Travel brake Hydraulic lock
Parking brake Mechanical lock (travel lever linkage type)
Track shoe
Model Assembly-type triple grouser shoe
600G with seal, 500L with seal, 700G with seal: 46
No. of shoes (per side)
500G with seal: 43
Shoe width 600 mm (23.622 in) [options 500 mm (19.685 in), 700 mm (27.559 in)]
Grouser height 20 mm (0.787 in)
Link pitch 171.5 mm (6.7520 in)
Roller
No. of upper rollers (per side) 1
No. of lower rollers (per side) 7
Track belt tension adjuster Grease cylinder type (with cushion spring)

Hydraulic Equipment
Hydraulic Device

Hydraulic pump drive type Direct engine link (no transmission)

Hydraulic pump
Model Double variable displacement piston pump x 1
Gear pump x 1
Discharge volume Piston pump 2 x 129 L/min (34.079 gpm)
Gear pump 20 L/min (5.284 gpm)
Pump control method Simultaneous output full-horsepower control
Set pressure of main relief valve 34.3 MPa (4975.341 psi) [36.3 MPa (5265.45 psi) for pressure boost]
32.3 MPa (4685.234 psi) (boom down)
Set pressure of overload relief valve
38.2 MPa (5541.050 psi) (other)

Control Valve and Cylinder

Control valve
Quadruple spool
Model One-piece type x 1
Quintuple spool
Operating method Hydraulic pilot type: travel, swing, and operating machine
Cylinder No. of cylinders x tube bore - rod diameter - stroke
Boom cylinder 2 x D105 mm (D4.134 in) - D70 mm (D2.756 in) - 961 mm (37.835 in)
Arm cylinder 1 x D115 mm (D4.528 in) - D80 mm (D3.150 in) - 1108 mm (43.622 in)
Bucket cylinder 1 x D95 mm (D3.740 in) - D65 mm (D2.559 in) - 881 mm (34.685 in)

Capacities, Filters
Coolant and Oil Capacities

Coolant 16.2 L (4.280 gal)

Fuel 260 L (68.69 gal)
Engine lubricating oil 17 L (4.49 gal)
Travel reduction gear lubricating oil (one side) 2.1 L (0.555 gal)
Swing reduction gear lubricating oil 2.2 L (0.581 gal)
Hydraulic oil 157 L (41.48 gal)
Hydraulic oil tank regulation amount 82 L (21.66 gal)
84592788 EN - March 2012
1002A-6
Copyright ©
Specifications

Hydraulic Oil Filters

Suction filter (inside tank) 105 μm

Return filter (inside tank) 6 μm
Pilot line filter (inside housing) 8 μm

Fuel Filter

Main filter 2 μm
Pre-filter 5.5 μm

CX130C NLC
Main Data
Operating weight 13000 kg (28660.200 lb)
Engine output 74.9 kW/2000 min-1 (100.443 HP/2000 rpm)
Heaped 0.480 m3
Bucket capacity
Leveled 0.361 m3

Operating weight 12300 kg (27117.000 lb)

Engine output 74.9 kW/2000 min-1 (100.443 HP/2000 rpm)
Heaped 0.480 m3
Bucket capacity
Leveled 0.361 m3

Performance
Standard weight 8.825 kN (1984.27853 lbf)
Swing speed 14.3 min-1 (14.3 rpm)
Low speed 3.4 km/h (2.1127 mile/h)
Travel speed
High speed 5.6 km/h (3.4797 mile/h)
Maximum pulling force 115 kN (25857.45 lbf)
Grade ability 70 ％ (35゜)
39 kPa (5.66 psi) [500 mm (19.685 in) grouser shoe]
Ground pressure 33 kPa (4.79 psi) [600 mm (23.622 in) grouser shoe]
28 kPa (4.06 psi) [700 mm (27.559 in) grouser shoe]

Standard weight 8.825 kN (1984.27853 lbf)

Swing speed 14.3 min-1 (14.3 rpm)
Low speed 3.4 km/h (2.1127 mile/h)
Travel speed
High speed 5.6 km/h (3.4797 mile/h)
Maximum pulling force 115 kN (25857.45 lbf)
Grade ability 70 ％ (35゜)
39 kPa (5.66 psi) [500 mm (19.685 in) grouser shoe]
Ground pressure 32 kPa (4.64 psi) [600 mm (23.622 in) grouser shoe]
28 kPa (4.06 psi) [700 mm (27.559 in) grouser shoe]

Main Unit Dimensions

Main unit length 4010 mm (157.874 in)
Main unit width 2590 mm (101.969 in)
Upper swing body width 2540 mm (100.000 in)
Cab width 1000 mm (39.370 in)
Main unit height 2820 mm (111.024 in)
Swing radius (rear end) 2130 mm (83.858 in)
Swing body rear end distance 2130 mm (83.858 in)
Swing body rear section bottom height 895 mm (35.236 in)
Distance between tumblers 3040 mm (119.685 in)
84592788 EN - March 2012
1002A-7
Copyright ©
Specifications

Overall track length 3760 mm (148.031 in)

Overall track width 2590 mm (101.969 in)
Distance between tracks 1990 mm (78.346 in)
Track shoe width 600 mm (23.622 in) [options 500 mm (19.685 in), 700 mm (27.559 in)]
Minimum ground clearance 440 mm (17.323 in) (to bottom of lower frame)

Main unit length 4010 mm (157.874 in)

Main unit width 2590 mm (101.969 in)
Upper swing body width 2540 mm (100.000 in)
Cab width 1000 mm (39.370 in)
Main unit height 2840 mm (111.811 in)
Swing radius (rear end) 2130 mm (83.858 in)
Swing body rear end distance 2130 mm (83.858 in)
Swing body rear section bottom height 895 mm (35.236 in)
Distance between tumblers 3040 mm (119.685 in)
Overall track length 3760 mm (148.031 in)
Overall track width 2590 mm (101.969 in)
Distance between tracks 1990 mm (78.346 in)
Track shoe width 600 mm (23.622 in) [options 500 mm (19.685 in), 700 mm (27.559 in)]
Minimum ground clearance 440 mm (17.323 in) (to bottom of lower frame)

Upper Side Work System

Boom length 4630 mm (182.283 in)

Standard Long Short
Arm type ［ 2.50 m (8.2021 ［ 3.01 m (9.8753 ［ 2.11 m (6.9226
ft)］ ft)］ ft)］
3010 mm (118.504
Arm length 2500 mm (98.425 in) 2110 mm (83.071 in)
in)
Bucket radius 1200 mm (47.244 in)
Bucket wrist angle 178°
8310 mm (327.165 8770 mm (345.276 7960 mm (313.386
Maximum digging radius
in) in) in)
8170 mm (321.654 8640 mm (340.157 7810 mm (307.480
Maximum digging radius at ground line
in) in) in)
5540 mm (218.110 6050 mm (238.189 5150 mm (202.756
Maximum digging depth
in) in) in)
4950 mm (194.882 5350 mm (210.630 4600 mm (181.102
Maximum vertical straight wall digging depth
in) in) in)
8770 mm (345.276 9050 mm (356.299 8550 mm (336.614
Maximum digging height
in) in) in)
6390 mm (251.575 6680 mm (262.992 6170 mm (242.913
Maximum dump height
in) in) in)
2660 mm (104.724
Minimum swing radius at front 2340 mm (92.126 in) 2360 mm (92.913 in)
in)
6560 mm (258.268 6590 mm (259.449 6560 mm (258.268
Height for minimum swing radius at front
in) in) in)

Operating Device

Operator's seat
Position Left side
Adjustable forward and back and up and down, reclining mechanism,
Structure
with seat suspension
Cab Sealed steel type, all reinforced glass
Levers and pedals
For travel use Lever and pedal type (hydraulic pilot type) x 2
For operating machine use Lever type (hydraulic pilot type) x 2
Instruments and switches
Work mode switchover 3 modes (SP/H/A)
Travel mode switchover Low-speed/high-speed switch type
One-touch idle Knob switch type
Engine emergency stop Switch type
Monitor device
Machine status display (full color liquid
crystal)
Work mode select status SP/H/A
Instruments (full color liquid crystal)
Fuel gauge Bar graph and indicator
Engine coolant temperature gauge Bar graph and indicator
Hydraulic oil temperature gauge Bar graph and indicator
Hour meter Digital type
Machine status and warnings (full color liquid crystal and warning alarm) * has warning alarm
Overheat (*) Battery charge (*) Electrical system abnormality (*) Refill fuel (*) Engine oil pressure (*) Refill coolant
(*) Engine pre-heat Auto warm up Air cleaner (*) Anti-theft device triggered Engine system abnormality (*) Engine
emergency stop (*)
Illumination equipment
Tank front surface 24 V 70 W x 1
Working light Cab top 24 V 70 W x 2
Boom up 24 V 70 W x 1
Interior light 24 V 10 W x 1
84592788 EN - March 2012
1002A-9
Copyright ©
Specifications

Horn Electric horn x 2

Wiper with intermittent function, window washer, air conditioner, clock,
Other
rear view mirrors (left and right, total of 4)

Swing Units

Swing circle Swing bearing type (with inner gear)

Swing hydraulic
Fixed displacement piston motor × 1
motor
Reduction gear Planetary gear 2-stage reduction gear
Swing parking Mechanical lock (operational lever
brake linkage type)

Travel Lower Body

Travel hydraulic motor Variable displacement piston motor x 2

Reduction gear Planetary gear 2-stage reduction gear
Travel brake Hydraulic lock
Parking brake Mechanical lock (travel lever linkage type)
Track shoe
Model Assembly-type triple grouser shoe
No. of shoes (per side) 46
Shoe width 600 mm (23.622 in) [options 500 mm (19.685 in), 700 mm (27.559 in)]
Grouser height 20 mm (0.787 in)
Link pitch 171.5 mm (6.7520 in)
Roller
No. of upper rollers (per side) 2
No. of lower rollers (per side) 7
Track belt tension adjuster Grease cylinder type (with cushion spring)

Hydraulic Equipment
Hydraulic Device

Hydraulic pump drive type Direct engine link (no transmission)

Control Valve and Cylinder

Capacities, Filters
Coolant and Oil Capacities

Coolant 16.2 L (4.280 gal)

Hydraulic Oil Filters

Suction filter (inside tank) 105 μm

Return filter (inside tank) 6 μm
Pilot line filter (inside housing) 8 μm

Fuel Filter

Main filter 2 μm
Pre-filter 5.5 μm

84592788 EN - March 2012

1002A-11
Copyright ©
Specifications

84592788 EN - March 2012

1002A-12
Copyright ©

Section

1002B

Main Equipment Table

84592788 EN - March 2012

CONTENTS

Main Equipment Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

1002B-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

1002B-2 PRINTED IN FRANCE
Copyright ©
Main Equipment Table

Main Equipment Table

Lower Component
Travel Unit
Manufacturer Nabtesco Corporation
Motor type Variable displacement piston motor
Automatic 2-speed switchover with parking brake
Intake amount 44.9/75.5 cm3/rev
Operating pressure 34.3 MPa (4975.341 psi)
Operating flow 130.0 L/min (34.3431 gpm)
Brake torque 11.1 kN・m (8188.34 lbf・ft) min. (including reduction gear)
Relief valve set pressure 37.3 MPa (5410.502 psi)
Automatic 2-speed switchover pres-
25.0 - 27.0 MPa (3626.342 - 3916.449 psi) at 3.9 MPa (565.709 psi)
sure
Reduction gear
Reduction gear type Planetary gear 2-stage reduction gear
Reduction ratio 54
Dry weight 145 kg (319.672 lb)

Take-up Roller
Weight 65.2 kg (143.7421 lb)

Upper Roller
Weight 15.5 kg（34.1718 lb）

Lower Roller
Weight 21.4 kg（47.1792 lb）

Recoil Spring
Item Weight [kg (lb)] Q'ty
Yoke 15.1 (33.2900) 1
Sems B M16 x 50 0.8 (1.7637) 6
Threaded rod 13.0 (28.6602) 1
Groove height N M39 0.6 (1.3228) 1
SP pin 8 x 80 0.1 (0.2205) 1
Recoil spring 31.7 (69.8869) 1
Grease cylinder assembly 14.5 (31.9672) 1
Sems B M16 x 60 75.8 (167.1113)
Assembly(Total) 419 mm (16.496 in)

Shoe
Weight or Q'ty
500G with seal 715.2 kg (1576.75 lb)
Link 1 set
Shoe 43
Bolt 172
Nut 172
500L with seal 801.8 kg (1767.68 lb)
Link 1 set
Shoe 46
Bolt 184
84592788 EN - March 2012
1002B-3
Copyright ©
Main Equipment Table

Weight or Q'ty
Nut 184
500G with hole 760.4 kg (1676.40 lb)
Link 1 set
Shoe 46
Bolt 184
Nut 184
600G with seal 852.4 kg (1879.23 lb)
Link 1 set
Shoe 46
Bolt 184
Nut 184
700G with seal 1008.8 kg (2224.04 lb)
Link 1 set
Shoe 46
Bolt 184
Nut 184

Upper Component
Swing Unit
Swing motor assembly
Swing motor
Manufacturer Hyest Corporation Ltd.
Motor type Fixed displacement piston motor
With parking brake
Intake amount 65 cm3/rev
Operating pressure 27.9 MPa (4046.997 psi)
Operating flow 130 L/min (34.343 gpm)
Mechanical brake torque 336.1 N・m (247.937 lbf・ft)min.
Brake off pressure 2.9 MPa (420.656 psi)max.
27.9 MPa (4046.997 psi) at 108 L/min (28.531 gpm)
Relief valve set pressure
27.3 MPa (3959.965 psi) at 40 L/min (10.567 gpm)
Swing reduction gear
Reduction gear type Planetary gear 2-stage reduction gear
Reduction ratio 17.03
Dry weight 99 kg (218.259 lb)
Turntable bearing
Number of teeth 98
Weight 177.7 kg (391.7635 lb)
Counterweight
Weight 2200 kg (4850.195 lb)

Engine-related
Engine
Engine model name Isuzu 4JJ1X diesel engine
4-cycle, water-cooled, overhead camshaft type straight cylinder, direct fuel
Engine type
injection type (electronic control)
Number of cylinders-bore-stroke 4 - D95.4 mm (3.7559 in) - 104.9 mm (4.1299 in)
Total displacement 2.999 L (0.79227 gal)
Compression ratio 17.5
Rated output 74.9 kW / 2000 min-1 (100.443 HP / 2000 rpm)
Maximum torque 359 N・m / about 1600 min-1 (264.83 lbf・ft / about 1600 rpm)
Fuel consumption ratio 224 g/kW・h at 2000 min-1
Engine dry weight about 333 kg (about 734.143 lb)
84592788 EN - March 2012
1002B-4
Copyright ©
Main Equipment Table

Engine dimension L928 (36.535) - W823 (32.402) - H888 (34.961) mm (in)

Cooling fan D550 mm (21.654 in) - suction type - 8 vanes, plastic
With bell mouth-type fan guide
Pulley ratio 0.95 (reduction)
Charging generator 24 V 50 A AC type
Starter motor 24 V 4 kW reduction type
Coolant capacity 6.0 L (1.585 gal)
Oil pan capacity Max：15.0 L (3.963 gal) Min：11.0 L (2.906 gal) (not including oil filter)
Direction of rotation Right (viewed from fan side)
Compliant with JISD 0006-2000.

DPD

Weight 32.300 kg (71.209683 lb)

Air Cleaner (double element)

Manufacturer Nippon Donaldson, Ltd.

Element (outer)
Element (inner)
Weight 5.4 kg (11.9050 lb)

Radiator

Manufacturer T.RAD Co., Ltd.

Weight 17.5 kg (38.5811 lb)
Oil cooler
Oil volume 6.9 L (1.823 gal)
Weight 8.8 Kg (19.4008 lb)
Radiator
Coolant capacity 6.3 L (1.664 gal)
Weight 6.3 kg (13.8892 lb)
Air cooler
Capacity 4.4 L (1.162 gal)
Weight 0.7 kg (1.5432 lb)
Fuel cooler
Capacity 0.2 L (0.053 gal)
Total weight 75.9 kg (167.3317 lb)

Hydraulic Device
Hydraulic Pump

Manufacturer Kawasaki Heavy Industries, Ltd.

Main pump
Pump type Double variable displacement piston pump
Displacement capacity 65.2 x 2 cm3/rev
Rated 34.3 MPa (4975.341 psi)
Operating pressure
Maximum 36.3 MPa (5265.448 psi)
Input revolution speed 2000 min-1 (2000 rpm)
Maximum discharge flow 129 x 2 L/min (at 2000 min-1)［34.079 x 2 gpm (at 2000 rpm)］
Pilot pump
Pump type Gear pump
Displacement capacity 10 cm3/rev
Operating pressure 3.92 MPa (568.6104 psi)
Maximum discharge flow 20 L/min (at 2000 min-1)［5.284 gpm (at 2000 rpm)］
84592788 EN - March 2012
1002B-5
Copyright ©
Main Equipment Table

Hydraulic simultaneous constant output control

Maximum flow adjustment control through external commands (negative con-
trol)
Control method
Maximum flow adjustment control through external command milli-amp (neg-
ative control, front side)
Setting horsepower adjustment control through external command milli-amp
Dry weight 86 kg (189.599 lb)

Control-related
Control Valve
Manufacturer Hyest Corporation Ltd.
Maximum flow 130 L/min (at 2000 min-1)［34.343 gpm (at 2000 rpm)］
Overload set pressure 32.3 MPa (4685.234 psi)boom down
38.2 MPa (5541.050 psi)other
Main relief set pressure 34.3 MPa (4975.341 psi)
(at boosting) 36.8 MPa (5337.975 psi)
Foot relief set pressure 2.55 MPa (369.8869 psi)
Function Straight travel circuit
Boom-up/arm 2 pumps internal flow
Boom and arm load holding circuit
Boom-down regenerative circuit
Bucket-close regenerative circuit
Arm-in forced regenerative circuit
Swing priority variable orifice (for arm operation)
2 pumps flow
Weight 160 kg (352.742 lb)

Solenoid Valve (4 stack)

Manufacturer Yuken Kogyo Co., Ltd.
Valve specifications
Maximum flow P→B 20 L/min（5.284 gpm） Other 5 L/min（1.321 gpm）
Rated pressure 4.5 MPa（652.742 psi）
Port size P.T.B port G3/8
C1、C2、C3 ports G1/4
Solenoid specifications
Operating voltage DC 20 - 32 V
Power consumption 17 W max.
Weight 5.0 kg（11.0232 lb）

Valve for Left/Right Operations

Manufacturer Kawasaki Heavy Industries, Ltd.
Operating pressure 3.92 MPa (568.6104 psi)
Secondary pressure 0.64 - 2.45 MPa (92.8343 - 355.3815 psi) MPa primary short type
1,3 port 19°
Operating angle
2,4 port 25°
Weight 1.9 kg (4.1888 lb)

Valve for Travel Operation

Manufacturer Kawasaki Heavy Industries, Ltd.
Operating pressure 3.92 MPa (568.6104 psi)
Secondary pressure 0.64 - 2.45 MPa (92.8343 - 355.3815 psi) primary short type
Operating angle 12.4°
Weight 5.5 kg (12.1255 lb)
84592788 EN - March 2012
1002B-6
Copyright ©
Main Equipment Table

Remote Control Valve Characteristic Diagram

Operation Remote Control Valve Control Diagram

Ports 1, 3

Secondary pressure [MPa (psi)]

Push rod stroke [mm (in)]

Operating angle [deg.]

1 Secondary pressure

Ports 2, 4

Secondary pressure [MPa (psi)]

Push rod stroke [mm (in)]

Operating angle [deg.]

1 Secondary pressure

84592788 EN - March 2012

1002B-7
Copyright ©
Main Equipment Table

Travel Remote Control Valve Control Diagram

Secondary pressure [MPa (psi)]

Push rod stroke [mm (in)]

Pedal operating angle [deg.]

1 Secondary pressure

Cushion Valve (heat circuit, with shuttle valve)

Manufacturer Yanagisawa Seiki MFG. Co., Ltd.
Port size G 3/8 (A - P ports)
G 1/4 (Q - V ports)
Weight 12.5 kg (27.5579 lb)

Selector Valve (option)

2WAY
Manufacturer Nishina Industrial Co., Ltd.
Rated flow 25 L/min (6.604 gpm)
Operating method ISO, JOHN DEERE
Port size G3/8
Weight 4 kg (8.819 lb)

Center Joint
Operating pressure High-pressure passage (ABCD) 34.3 MPa (4975.341 psi)
Drain port (E) 0.5 MPa (72.527 psi)
Pilot port (F) 3.9 MPa (565.709 psi)
Flow High-pressure passage (ABCD) 234 L/min (61.818 gpm)
Drain port (E) 10 L/min (2.642 gpm)
Pilot port (F) 21 L/min (5.548 gpm)
Port A Forward right G3/4
Port B Forward left G3/4
Port C Backward right G3/4
Port D Backward left G3/4
Port E Drain port G1/2
Port F Pilot port G1/4
Weight 30 kg (66.139 lb)
84592788 EN - March 2012
1002B-8
Copyright ©
Main Equipment Table

Backhoe Attachment
Cylinder
Boom cylinder
Manufacturer Toyo Electric Corporation
Cylinder bore D105 mm (D4.134 in)
Rod diameter D70 mm (D2.756 in)
Maximum retracted length 1464 mm (57.638 in)
Stroke 961 mm (37.835 in)
Weight 102 kg (224.873 lb)

Arm cylinder
Manufacturer Toyo Electric Corporation
Cylinder bore D115 mm (D4.528 in)
Rod diameter D80 mm (D3.150 in)
Maximum retracted length 1619 mm (63.740 in)
Stroke 1108 mm (43.622 in)
Weight 150 kg (330.695 lb)

Bucket cylinder
Manufacturer Toyo Electric Corporation
Cylinder bore D95 mm (D3.740 in)
Rod diameter D65 mm (D2.559 in)
Maximum retracted length 1373 mm (54.055 in)
Stroke 1010 mm (39.764 in)
Weight 145 kg (319.672 lb)

84592788 EN - March 2012

1002B-9
Copyright ©
Main Equipment Table

84592788 EN - March 2012

1002B-10
Copyright ©

Section

1002C

Main Unit Weight

84592788 EN - March 2012

CONTENTS

Main Unit Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Divided Weight (standard specifications) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Stand Alone Part Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Shoe Weight (per side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Arm Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

1002C-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

1002C-2 PRINTED IN FRANCE
Copyright ©
Main Unit Weight

Main Unit Weight

Divided Weight (standard specifications)

Weight
Code Component name
kg lb
A Operating weight 12846 28320.73
B Upper component (including counterweight and turntable bearing) 6387 14080.998
C Counterweight 2218 4889.879
D Lower component (with grouser shoe) 4121 9085.297
E Main unit weight 10530 23214.798
F Attachments 2263 4989.087
G Boom (including cylinders) 1277 2815.318
H Arm (including cylinders and linkage) 584 1287.506

84592788 EN - March 2012

1002C-3
Copyright ©
Main Unit Weight

LC
Weight
Code Component name
kg lb
A Operating weight 13156 29004.167
B Upper component (including counterweight and turntable bearing) 6387 14080.998
C Counterweight 2218 4889.879
D Lower component (with grouser shoe) 4431 9768.734
E Main unit weight 10840 23898.234
F Attachments 2263 4989.087
G Boom (including cylinders) 1277 2815.318
H Arm (including cylinders and linkage) 584 1287.506

Weight
Code Component name
kg lb
A Operating weight 12667 27926.101
B Upper component (including counterweight and turntable bearing) 6268 13818.647
C Counterweight 2218 4889.879
D Lower component (with grouser shoe) 4121 9085.297
E Main unit weight 10411 22952.446
F Attachments 2204 4859.014
G Boom (including cylinders) 1241 2735.951
H Arm (including cylinders and linkage) 560 1234.595

LC
Weight
Code Component name
kg lb
A Operating weight 12977 28609.537
B Upper component (including counterweight and turntable bearing) 6268 13818.647
C Counterweight 2218 4889.879
D Lower component (with grouser shoe) 4431 9768.734
E Main unit weight 10721 23635.883
F Attachments 2204 4859.014
G Boom (including cylinders) 1241 2735.951
H Arm (including cylinders and linkage) 560 1234.595

* The weights displayed are approximate weights.

Stand Alone Part Weight

Component name Weight [kg (lb)]

1 Travel unit 145 (319.672)
2 Take-up roller 65.2 (143.7421)
3 Upper roller 15.5 (34.1718)
4 Lower roller 21.4 (47.1792)
5 Swing unit 99 (218.259)
6 Turntable bearing 177.7 (391.7635)
7 Engine 339.1 (747.5914)
8 Radiator 75.9 (167.3317)
9 Hydraulic pump 86 (189.599)
10 Fuel tank 84.1 (185.4097)
11 Hydraulic oil tank 95 (209.440)
12 Control valve 160 (352.741)
13 Center joint 29.5 (65.0367)
14 Boom 701 (1545.449)
84592788 EN - March 2012
1002C-4
Copyright ©
Main Unit Weight

Shoe Weight (per side)

Component name Weight [kg (lb)]
1 500G with seal 715.2 (1576.7543)
2 500L with seal 801.8 (1767.6757)
3 500G with hole 760.4 (1676.4038)
4 600G with seal 852.4 (1879.2301)
5 700G with seal 1008.8 (2224.0349)

Arm Weight
Component name Weight [kg (lb)]
1 Standard arm 342.6 (755.3077)
2 Short arm 365.8 (806.4552)
3 Long arm 440.4 (970.9209)

84592788 EN - March 2012

1002C-5
Copyright ©
Main Unit Weight

84592788 EN - March 2012

1002C-6
Copyright ©

Section

1002D

Maintenance Standards

84592788 EN - March 2012

CONTENTS

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

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

1002D-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

1002D-2 PRINTED IN FRANCE
Copyright ©
Maintenance Standards

Drive Sprocket

* See the gauge list for measurement gauges.

Measurement Standard value Usage limit

Part name Code dimension Judgment Solution
(mm））（ in）））
(mm））
（ in）
[mm (in)]
a Acceptable/
59 2.323 53 2.087
Unacceptable
D584.4 D22.77 Acceptable/
b D D23.011 D578.5
8 6 Unacceptable
Cladding by weld-
c D25.66 D25.43 Acceptable/
Drive sprocket D D652 D646 ing or replace-
9 3 Unacceptable
ment
D635.4 D25.01 - - Acceptable/
d D
8 9 Unacceptable
e - - Acceptable/
171.45 6.75
Unacceptable

84592788 EN - March 2012

1002D-3
Copyright ©
Maintenance Standards

Take-up Roller

* See the gauge list for measurement gauges.

Measurement Standard value Usage limit

Part name Code dimensions Judgment Solution
(mm））（ in）））
(mm））
（ in）
[mm (in)]
a D20.07 Acceptable/
D D510 506 19.921
9 Unacceptable
Cladding by weld-
- - Acceptable/
Take-up roller b 17.5 0.689 ing or replace-
Unacceptable
ment
c Acceptable/
68 2.677 64 2.52
Unacceptable
Acceptable/
Shaft d D D55 D2.165 D54.5 D2.146 Replacement
Unacceptable
Acceptable/
d D D55 D2.165 D55.8 D2.197
Unacceptable
Bushing Replacement
e Acceptable/
55 2.165 54.6 2.15
Unacceptable
Acceptable/
Hub f 19.9 0.783 20.4 0.803 Replacement
Unacceptable

84592788 EN - March 2012

1002D-4
Copyright ©
Maintenance Standards

Upper Roller

* See the gauge list for measurement gauges.

Measurement Standard value Usage limit

Part name Code dimension Judgment Solution
(mm））（ in）））
(mm））
（ in）
[mm (in)]
a Acceptable/
D D120 D4.724 112 4.409
Unacceptable
Cladding by weld-
- - Acceptable/
Carrier roller b 10 0.394 ing or replace-
Unacceptable
ment
c Acceptable/
68 2.677 62 2.441
Unacceptable
Acceptable/
Shaft d D D40 D1.575 D39.5 D1.555 Replacement
Unacceptable
Acceptable/
Bushing d D D40 D1.575 D40.8 D1.606 Replacement
Unacceptable
e Acceptable/
Bushing 63 2.48 62.6 2.465 Replacement
Unacceptable
Acceptable/
Thrust plate f 5.5 0.217 5 0.197 Replacement
Unacceptable
g Acceptable/
Cover 22.5 0.886 22 0.866 Replacement
Unacceptable

84592788 EN - March 2012

1002D-5
Copyright ©
Maintenance Standards

Lower Roller

* See the gauge list for measurement gauges.

Measurement Standard value Usage limit

Part name Code dimension Judgment Solution
(mm））（ in）））
(mm））
（ in）
[mm (in)]
a Acceptable/
D D130 D5.118 D122 D4.803
Unacceptable
Cladding by weld-
- - Acceptable/
Track roller b 15 0.591 ing or replace-
Unacceptable
ment
Acceptable/
d 142 5.591 148 5.827
Unacceptable
e Acceptable/
Shaft D D50 D1.969 D49.5 D1.949 Replacement
Unacceptable
e Acceptable/
D D50 D1.969 D50.8 D2
Unacceptable
Bushing Replacement
Acceptable/
f 53 2.087 52.6 2.071
Unacceptable
g Acceptable/
Collar 24.3 0.957 23.8 0.937 Replacement
Unacceptable

84592788 EN - March 2012

1002D-6
Copyright ©
Maintenance Standards

Track Shoe (grouser shoe)

Measurement Standard value Usage limit

Part name Code dimension Judgment Solution
(mm））（ in）））（ in）
（mm））
[mm (in)]
a Acceptable/
Shoe plate 28 1.102 18 0.709 Replacement
Unacceptable
Acceptable/
b 89 3.504 84 3.307
Unacceptable
Cladding by weld-
c Acceptable/
Link 17 0.669 15 0.591 ing or replace-
Unacceptable
ment
Acceptable/
d 10.7 0.421 9 0.354
Unacceptable
e Acceptable/
D D50.6 D1.992 D49.5 D1.949
Unacceptable
Master bushing Replacement
Acceptable/
f D D34.1 D1.343 D35.5 D1.398
Unacceptable
g Acceptable/
Master pin D D33.25 D1.309 D32.5 D1.28 Replacement
Unacceptable
Link pitch Acceptable/
h 171.45 6.75 175 6.89 Replacement
4 linked sections Unacceptable
Acceptable/
e' D D50.6 D1.992 D49.5 D1.949
Unacceptable
Track bushing Replacement
Acceptable/
f' D D34.1 D1.343 D35.5 D1.398
Unacceptable
Acceptable/
Track pin g' D D33.5 D1.319 D32.5 D1.28 Replacement
Unacceptable

84592788 EN - March 2012

1002D-7
Copyright ©
Maintenance Standards

Attachment (backhoe)

1. Boom and Swing Frame Installation Section

Measure-
ment di- Standard value Usage limits
Part name Code mensions Judgment Solution
(m-
(in) (mm) (in) (mm) (in)
m)
a Acceptable/ -
Swing frame 569.5 22.421 577.5 22.736
Unacceptable
Acceptable/ Replace-
Boom b 566 22.283 564 22.205
Unacceptable ment
c Shim ad- Shim ad- Acceptable/ Adjustment
Clearance 0.5-3.0 0.02-0.118
justment justment Unacceptable with shims
Acceptable/ Replace-
Pin d D D D75 D2.953 D74 D2.913
Unacceptable ment
Bushing e Acceptable/ Replace-
D D D75 D2.95 D76.5 D3.012
(boom) Unacceptable ment
84592788 EN - March 2012
1002D-8
Copyright ©
Maintenance Standards

2. Boom Cylinder and Swing Frame Installation Section

Measure-
ment di- Standard value Usage limits
Part name Code mensions Judgment Solution
(m-
(in) (mm) (in) (mm) (in)
m)
Swing a Acceptable/ -
83.5 3.287 89.5 3.524
frame Unacceptable
Boom
cylinder Acceptable/
b 82.5 3.248 80.5 3.169 Replacement
(foot sec- Unacceptable
tion)
c 0.039- Shim ad- Shim ad- Acceptable/ Adjustment
Clearance 1.0-2.5
0.098 justment justment Unacceptable with shims
Acceptable/
Pin d D D D70 D2.765 D69 D2.717 Replacement
Unacceptable
Bushing
e Acceptable/
(boom D D D70 D2.765 D71.5 D2.815 Replacement
Unacceptable
cylinder)

3. Boom and Boom Cylinder Installation Section

Measure-
ment di- Standard value Usage limits
Part name Code mensions Judgment Solution
(m-
(in) (mm) (in) (mm) (in)
m)
Boom
cylinder a Acceptable/
92 3.622 90 3.543 Replacement
(top sec- Unacceptable
tion)
Acceptable/
Boom b 437 17.205 433 17.047 Replacement
Unacceptable
84592788 EN - March 2012
1002D-9
Copyright ©
Maintenance Standards

Measure-
ment di- Standard value Usage limits
Part name Code mensions Judgment Solution
(m-
(in) (mm) (in) (mm) (in)
m)
c 0.039- Shim ad- Shim ad- Acceptable/ Adjustment
Clearance 1.0-2.5
0.098 justment justment Unacceptable with shims
Acceptable/
Pin d D D D70 D2.765 D69 D2.717 Replacement
Unacceptable
Bushing
e Acceptable/
(boom D D D70 D2.765 D71.5 D2.815 Replacement
Unacceptable
cylinder)

84592788 EN - March 2012

CONTENTS

Special Torque Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

1002E-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

1002E-2 PRINTED IN FRANCE
Copyright ©
Bolt Size and Torque Table

Special Torque Settings

Bolt nomi-
Tightening Tightening
Code Retightening location nal diame- Wrench
・m]
torque [N・・ft]
torque [lbf・
ter
1* Travel motor M16 24 mm 0.945 in 267 - 312 196.96 - 230.16
2* Drive sprocket M16 24 mm 0.945 in 267 - 312 196.96 - 230.16
3* Take-up roller M16 24 mm 0.945 in 267 - 312 196.96 - 230.16
4* Upper roller M16 24 mm 0.945 in 267 - 312 196.96 - 230.16
5* Lower roller M16 24 mm 0.945 in 267 - 312 196.96 - 230.16
6* Track guard M16 24 mm 0.945 in 267 - 312 196.96 - 230.16
7 Shoe M16 24 mm 0.945 in 373 - 451 275.16 - 332.69
8 Counterweight M27 41 mm 1.614 in 1078 - 1274 795.23 - 939.82
9 Turntable bearing M16 24 mm 0.945 in 280 - 312 206.55 - 230.16
10* Swing unit M16 24 mm 0.945 in 280 - 312 206.55 - 230.16
11* Mount M16 24 mm 0.945 in 264.9 - 313.9 195.414 - 231.560
Engine
13* Rear bracket M12 19 mm 0.748 in 109 - 127 80.41 - 93.69
14 Radiator M12 19 mm 0.748 in 63.8 - 73.6 47.06 - 54.29
Hy- 14 mm 0.551 in
15* draulic Pump M16 hexagon hexagon 223 - 247 164.50 - 182.21
pump socket head socket head
16* Hydraulic oil tank M16 24 mm 0.945 in 232.4 - 276 171.44 - 203.60
17* Fuel tank M16 24 mm 0.945 in 232.4 - 276 171.44 - 203.60
18* Control valve M16 24 mm 0.945 in 267 - 312 196.97 - 230.15
19* Center Lock bar M12 19 mm 0.748 in 88.3 - 107 65.14 - 78.93
20* joint Joint M12 19 mm 0.748 in 109 - 127 80.41 - 93.68
21 M16 24 mm 0.945 in 149 - 173 109.92 - 127.62
Cab
22 M10 17 mm 0.669 in 19.6 - 29.4 14.459 - 21.688

CAUTION
For items marked with *, always apply Loctite #262 or the equivalent and tighten to the specified torque.
The tightening torque in kgf•m is determined with N・・m ÷ 9.8 ( lbf・
・ft ÷ 7.2 ).

84592788 EN - March 2012

1002E-3
Copyright ©
Bolt Size and Torque Table

84592788 EN - March 2012

Short Arm [2.11 m (6.9226 ft)]

Note: 1. Numbers are subject to change without notice due to design change or other reason.
Note: 2. The diagrams give values that include the shoe lug height (a) [20 mm (0.787 in)].

b 895 (35.236) d 600 (23.622) f 1290 (50.787)

c 1990 (78.346) e 440 (17.323) g 1250 (49.213)

84592788 EN - March 2012

1002F-4
Copyright ©
Overall View

Long Arm [3.01 m (9.8753 ft)]

Note: 1. Numbers are subject to change without notice due to design change or other reason.
Note: 2. The diagrams give values that include the shoe lug height (a) [20 mm (0.787 in)].

b 895 (35.236) d 600（23.622） f 1290 (50.787)

c 1990 (78.346) e 440（17.323） g 1250 (49.213)

84592788 EN - March 2012

1002F-5
Copyright ©
Overall View

84592788 EN - March 2012

1002F-6
Copyright ©

Section

1002G

New Machine Performance Judgment Table

84592788 EN - March 2012

CONTENTS

Standard Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Measurement Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pressure in Each Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cylinder Falling Amount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Attachment Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Swing Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Swing (180°) Brake Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Travel Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Off Travel Amount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Travel Sprocket Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Shoe Tension Amount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Swing Ball Race Bearing Movement Amount and Bucket Tip Movement Amount . . . . . . . . . . . . . . . . . . . . . . . 11

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

1002G-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

1002G-2 PRINTED IN FRANCE
Copyright ©
New Machine Performance Judgment Table

Standard Table
CX130C
SP Mode (with standard bucket)

Item Unit Reference value

Idling 890 - 910 (890 - 910)
1490 - 1510 (1490 -
No load A mode
1510)
1 Engine speed min-1 (rpm) 1590 - 1610 (1590 -
No load H mode
1610)
1740 - 1760 (1740 -
No load SP mode
1760)
32.3 - 36.3 (4685.234 -
Standard
5265.448)
Main relief
35.1 - 39.1 (5091.384 -
Boosted pressure
5671.598)
36.2 - 42.2 (5250.943 -
Up
6121.264)
Boom relief
30.0 - 36.0 (4351.611 -
Down
5221.932)
37.0 - 43.0 (5366.986 -
Out
6237.307)
Arm relief
37.0 - 43.0 (5366.986 -
In
6237.307)
2 Pressure in each section MPa (psi) 37.0 - 43.0 (5366.986 -
Open
6237.307)
Bucket relief
38.0 - 44.0 (5512.040 -
Close
6382.361)
28.8 - 32.8 (4177.546 -
Swing relief Left and right
4757.760)
Left and right, front 32.3 - 36.3 (4685.234 -
Travel relief
and back 5265.448)
4th pump relief -
2.9 - 4.9 (420.656 -
Pilot pump
710.762)
For crusher -
Option relief
For breaker -
Natural fall distance (po- Boom cylinder retraction 5 (0.197) Max.
sition change) for each Arm cylinder extension 12 (0.472)Max.
3 mm (in)
cylinder with no load (in Bucket cylinder retraction 13 (0.512)Max.
10 min.) Overall bucket tip falling 250 (9.843)Max.
Up (Stroke 688 mm
2.5 - 3.7
{27.087 in})
Boom (bucket open)
Down (stroke 688
1.8 - 3.0
mm {27.087 in})
4 Attachment speed sec
Out 2.0 - 3.2
Arm
In 2.5 - 3.7
Open 1.5 - 2.7
Bucket
Close 1.9 - 3.1
sec/rev 4.5 - 5.7
5 Swing speed (one rotation) Left and right
min-1 (rpm) 10.6 - 13.0 (10.6 - 13.0)
6 Swing brake angle (180°) Left and right deg 50°Max.
L/min
7 Swing motor leakage amount 10 (2.642)
(gpm)

84592788 EN - March 2012

1002G-3
Copyright ©
New Machine Performance Judgment Table

1002G-9
Copyright ©
New Machine Performance Judgment Table

Travel Sprocket Speed Shoe Tension Amount

Measurement method Measurement method
1. Engine high idle 1. Raise the shoe and, at the central position of the
2. Oil temperature is 45 °C - 55 °C (113.0 °F - 131.0 track, measure the gap between the underside of
°F). lower side frame and the topside of the shoe plate.
3. Raise a shoe, and after achieving a constant 2. Measure for both the left and right sides.
speed, measure the time required for the sprocket
Main unit posture
to rotate 10 times both forwards and backwards.
4. Measure for both high-speed and low-speed trav-
eling.
Main unit posture: 90°swing, shoe raised.

a Topside of shoe plate

b Underside of lower side frame

84592788 EN - March 2012

1002G-10
Copyright ©
New Machine Performance Judgment Table

Swing Ball Race Bearing Movement Amount and Bucket Tip Movement Amount
Measurement method
1. Up and down direction measurement
1) Measure the up and down movement amount at two locations in front of and behind the ball race.
2) Move the arm cylinder out and close the bucket cylinder, and move the bottom surface of the bucket 30
cm (11.811 in) above the ground.
Attach a dial gauge to the lowering section as shown in the figure below and do zero point adjustment.
3) Jack up the main unit and measure the amount of movement with the dial gauge.
* Jack up the main body until the swinging of the dial gauge becomes constant.
Main unit posture

a Front
b Rear

*1 Lowering

84592788 EN - March 2012

1002G-11
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New Machine Performance Judgment Table

2. Left and right direction measurement

1) Measure the left to right movement amount at the front side of the ball race and the left to right movement
amount of the bucket tip.
2) The arm cylinder and bucket cylinder are in the open position, apply 30 - 40 kgf of force to one side, and
zero point adjustment is done for these conditions.
3) 30 - 40 kgf of force is applied to the opposite side and the left to right movement is measured.
Main unit posture

Attach a dial gauge to the ball

a race mounting bolt, and mea-
sure the amount of movement.

*1 Bearing

84592788 EN - March 2012

1002G-12
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Section

1003

1
V-ring)
84592788 EN - March 2012
1003-12
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List of special tools

Swing Motor Special Tool

CX130C

Code Order No. Jig name Remarks

Tapered roller bearing/inner race
1
assembly jig
2 Oil seal assembly jig 1
3 Cylinder assembly jig
4 Brake piston assembly jig

a 0.8 (0.0315)

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List of special tools

Code Order No. Jig name Remarks

5 Oil seal assembly jig 2
6 Pinion shaft assembly jig

a 0.8 (0.0315)

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1003-14
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List of special tools

Code Order No. Jig name Remarks

7 Brake piston removal jig

84592788 EN - March 2012

1003-15
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List of special tools

Remote Control Valve Special Tool

CX130C

Detailed diagram of jig main D27.016 - 27.020 (1.063623 -

a d D23.0 - 23.2 (0.9056 - 0.9133) g
unit 1.063779)
b Joint installation state e D31 (1.220) h 15.4 - 15.6 (0.6063 - 0.6141)
c D27.000 - 27.013 (1.062993 -
Detailed diagram of bushing f i 6.4 - 6.6 (0.2520 - 0.2598)
1.063503)

1 SCM415N carburized 4 Hole *7 Bushing

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

Code Order No. Jig name Remarks

Joint disassembly
1
jig
84592788 EN - March 2012
1003-16
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List of special tools

a 3.2 (0.1260)

Center hole possible [D2

*1
(0.079) or less]

Code Order No. Jig name Remarks

2 Special jig 1 (for bushing removal)
Special jig 2 (for locking ring instal-
3
lation)

84592788 EN - March 2012

1003-17
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List of special tools

Gas Filling Special Tool

CX130C

Code Order No. Jig name Remarks

1 Gauge manifold
2 Charging hose
Quick joint 27.5
3
(1.0827)
Quick joint 23.5
4
(0.9252)
5 T joint
6 Service can valve
Vacuum pump
7
adapter

84592788 EN - March 2012

1003-18
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List of special tools

Hydraulic Circuit

Vacuum pump and power sup-

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

84592788 EN - March 2012

1003-19
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List of special tools

CASE SPECIAL TOOLS

Isuzu Engine Special Tools
4JJ1X Tier 4 Isuzu Engine

Illustration Isuzu Reference CASE Tool Number Description

5-8840-2820-0 380300028 Oil seal Installer

5-8840-2360-0 380002574 Slinger puller

5-8840-2826-0 380002601 Fuel Injector Remover

5-8840-0019-0 380002602 Sliding Hammer

5-8840-9065-0 380300172 Crankshaft stopper

5-8840-2359-0 380300010 Oil seal installer kit

5-8840-2675-0 (5-8531-
380002626 Compression Gauge (adapter)
7002-0)

8980131700 380002630 Main filter wrench

84592788 EN - March 2012

1003-20
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List of special tools

Illustration Isuzu Reference CASE Tool Number Description

5-8840-0266-0 380300009 Angle gauge

5-8840-2815-0 380300015 Compression Gauge Adaptor

5-8840-2835-0 Common Probes Connector test adapter kit

5-8840-2843-0 380300171 Oil pressure gauge

8-9439-6818-0 380300021 Valve clearance adjust nut wrench

8-9439-6819-0 380300173 Oil seal installer

5-8840-2818-0 380300018 Valve spring compressor lever

5-8840-2819-0 380300019 Valve spring compressor pivot

5-8840-2816-0 380300016 Valve guide special tool

84592788 EN - March 2012

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List of special tools

Illustration Isuzu Reference CASE Tool Number Description

5-8840-2817-0 380300017 Valve stem seal installer

5-8840-9018-0 380300022 Piston setting tool

1-8522-1029-0 380300005 Piston ring setting tool

Section

1004

FLUIDS AND LUBRICANTS

84592788 EN - March 2012

CONTENTS

HYDRAULIC FLUID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OIL RANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Conditions applicable to diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
RECOMMENDED CONDITIONS THAT CAN BE APPLIED TO DIESEL FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

1004-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

1004-2 PRINTED IN FRANCE
Copyright ©
FLUIDS AND LUBRICANTS

Lubricants must have the correct properties for each application.

IMPORTANT:
The conditions of use for individual fluids and lubricants must be respected.

HYDRAULIC FLUID
CASE/AKCELA hydraulic fluid is specially designed for high pressure applications and for the CASE hydraulic system.
The type of fluid to be used depends on the ambient temperature.
ENGINE OIL
The "CASE Tutela LE ENGINE OIL" is recommended for
your engine. This oil ensures correct lubrication of your
engine in all working conditions.
If the "CASE Tutela LE ENGINE OIL" cannot be obtained,
use the oil corresponding to one of the following cate-
gories:
API CJ-4.
ACEA E6.
OIL RANGE

1 With mineral base

Abbreviations
Abbreviation description
AC air conditioner
A/D analog/digital
ABDC after bottom dead center
AC alternating current
ACC accessory
ACG alternating current generator
ACT actuator
API american petroleum industry
ASM assembly
ATDC after top dead center
ATF automatic transmission fluid
drilled head B drilled head bolt
eye B eye bolt
full threaded B full threaded bolt
hexagon socket head B hexagon socket head bolt
high-strength B high-strength bolt
reamer B reamer bolt
B+ battery + terminal
BAT battery
BBDC before bottom dead center
BKT bracket
BRG bearing
BTDC before the top dead center
C/B circuit breaker
C/U control unit
CAL calibration
CAN a control unit communication method (control area network)
CFG config
CHK check
CKP crankshaft position
CMP camshaft position
CO carbon monoxide
CPU central processing unit
DC direct current
DI direct injection type
DIAG diagnosis
DLC data link connector
DMM digital multi–meter
DPD diesel particulate diffuser
DTC self-diagnosis code
ECM engine control module
ECT engine coolant temperature
ECU electronic control unit
EEPROM electrically erasable/programmable ROM
EGR exhaust gas recirculation
EMI electromagnetic interference
EMPS engine module programing system
ENG engine
EPF engine protection feature
EVRV electric vacuum regulating valve
EXH exhaust
F/B feedback
F/C fuel cut
F/L fusible link
FLW fusible link wire
FRT front
84592788 EN - March 2012
1900-3
Copyright ©
Abbreviations

Abbreviation description
FT fuel temperature
FWD front
GEN generator
GND ground
HBCV hose burst check valves
HC hydrocarbon
HO2S superheat O2 sensor
HR hour
HRD high reach
IAC idle air control
IAT intake air temperature
IC integrated circuit
ID Plate ID plate (Name plate)
IMT intake manifold temperature
INL intake
INJ injection
ISO international organization for standardization
ISP intake shutter position
ITP intake throttle position
J/C joint connector
JIS japan Industrial Standard
KW a communication method (Keyword)
LED light emitting diode
LH left
LLC long life coolant
LM lifting magnet
M/V electromagnetic valve
MAF mass air flow
MAP manifold air pressure
Max maximum
MIL warning light (diagnostic)
milli-amp milli-amperage
Min minimum
MPU micro processing unit
high-strength N high-strength nut
NC normally closed
NO normally open
NOx nitrogen oxide
N-TDC top dead center revolution speed
PM particle material
O2S O2 sensor
OBD on-board diagnosis
OEM original equipment manufacturer
OPT option
OT oil temperature
P/L pilot light
PCV pump control valve/positive crankcase ventilation
P-I proportion-integration
PM particle material
PTO power take-off
PWM pulse width modulation wave
QOS quick on start system
QWS quick warming up system
R/L relay
RAM RAM (random access memory)
REF reference
RH right
ROM ROM (read only memory)

84592788 EN - March 2012

1900-4
Copyright ©
Abbreviations

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

84592788 EN - March 2012

1900-5
Copyright ©
Abbreviations

84592788 EN - March 2012

1900-6
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Section

2000

Removal and Installation of Engine Assembly

84592788 EN - March 2012

CONTENTS

Removal of Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

using a shackle, and lift the inter cooler to remove
it.

84592788 EN - March 2012

16. Lift until the fixtures (1) at the bottom of the radiator
become disconnected.

17. Thoroughly check that the location is safe before

lowering the radiator on square wooden piece.
When laying down the radiator, be careful not to
bend or crush the bottom fixtures (1).

84592788 EN - March 2012

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

2004-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

2004-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Turbo Charger

WARNING Turbocharger assembly Removal

The engine is extremely hot just after stopping. 1. Battery ground cable Disconnect
Wait for them to sufficiently cool before begin- 1) Disconnect the battery ground cable from the
ning work. battery.
2. Coolant Drain
CAUTION
1) Drain coolant from the radiator.
• Be sure to stop the engine before beginning
work. CAUTION

Items to prepare • Do not loosen or remove the radia-

tor cap when the coolant is hot.
• Wrenches [8 mm (0.315 in), 13 mm (0.512 in), 14 mm • Steam and boiling water can burst
(0.551 in), 17 mm (0.669 in)] out, possibly causing burns or heat
• Cap related injuries.
• Plug • When opening the radiator cap,
• Rag place a thick cloth over the cap
• Cleaning fluid when the coolant is cooled, and
turn it gradually to release the pres-
sure before opening it.

1 Water pipe

2) Remove the water feed pipe from the oil

cooler assembly.
3) Disconnect the oil feed pipe from the tur-
bocharger assembly.

84592788 EN - March 2012

2004-3
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Removal and Installation of Turbo Charger

4. Remove the oil feed pipe from the oil cooler assem- 7. Remove the turbocharger assembly from the ex-
bly. haust manifold.

1 Oil feed pipe 1 Turbocharger assembly

5. Disconnect the oil return pipe from the turbocharger ANNOTATION:

assembly.
6. Remove the oil return pipe from the crankcase. • Remove both the water feed hose and the water
drain hose.

CAUTION
• Do not hold the actuator rod.

ANNOTATION:
• Do not reuse the gasket.

1 Oil return pipe

84592788 EN - March 2012

2004-4
Copyright ©
Removal and Installation of Turbo Charger

Turbocharger assembly 6) Install the oil return pipe to the crankcase.

Tightening torque: 25 N・m {2.5 kgf・m / 18
Installation lb・ft}
7) Connect the oil return pipe to the turbocharger
1. Turbocharger assembly Installation
assembly.
1) Install the turbocharger assembly to the ex- Tightening torque: 10 N・m {1.0 kgf・m / 7.38
haust manifold. lbf・ft}
Tightening torque: 35 N・m {3.6 kgf・m / 26
lb・ft}

CAUTION
• Do not hold the actuator rod.

ANNOTATION:
• Fill with 0.5 cc of engine oil from the fuel
filler.

1 Oil return pipe

8) Connect the vacuum hose to the turbocharger

assembly.
2. Engine oil filling
1) Replenish the engine with engine oil.
ANNOTATION:
• Recheck the tightening of the oil pan drain
1 Turbocharger assembly plug.
2) Install the water feed pipe to the oil cooler. 3. Coolant filling
Tightening torque: 41 N・m {4.2 kgf・m / 30 1) Replenish the radiator assembly with coolant.
lb・ft}
3) Connect the water feed pipe to the tur- 4. Battery ground cable Connect
bocharger assembly.
1) Connect the battery ground cable to the bat-
Tightening torque: 35 N・m {3.6 kgf・m / 26
tery.
lb・ft}
4) Install the oil feed pipe to the oil cooler assem-
bly.
5) Connect the oil feed pipe to the turbocharger
assembly.
Tightening torque: 23 N・m {2.3 kgf・m / 17
lb・ft} Eyebolt

1 Oil feed pipe

84592788 EN - March 2012

2004-5
Copyright ©
Removal and Installation of Turbo Charger

84592788 EN - March 2012

2004-6
Copyright ©

Section

2005

Removal and Installation of EGR Valve

84592788 EN - March 2012

CONTENTS

Removal and Installation of EGR Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

EGR cooler Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
EGR cooler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal and Installation of EGR Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
EGR valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
EGR valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

2005-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

2005-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of EGR Valve

Removal and Installation of EGR ANNOTATION:

Cooler • Remove the IN side and OUT side of the
rubber hose for the water pipe and remove
EGR cooler Removal the EGR cooler and gasket.

1. Battery ground cable Disconnect CAUTION

1) Disconnect the battery ground cable from the • Do not hold the water pipe section
battery. when removing the EGR cooler.
2. Coolant Drain
1) Drain coolant from the radiator.

CAUTION
• Do not loosen or remove the radia-
tor cap when the coolant is hot.
• Steam and boiling water can burst
out, possibly causing burns or heat
related injuries.
• When opening the radiator cap,
place a thick cloth over the cap
when the coolant is cooled, and
turn it gradually to release the pres-
sure before opening it.
1 EGR cooler
ANNOTATION:
• Loosen the water drain plug on the rear right ANNOTATION:
side of the engine, as well as the radiator
drain plug. • Because the plastic pipe is easily damaged
• Completely drain the coolant. during hose removal, do not remove from
• After completely draining the coolant, se- the side of the plastic pipe if possible.
curely tighten the drain plug.
3. Water pipe removal
1) Remove the water pipe from the engine as-
sembly.

1 Water pipe

ANNOTATION:
• Because the plastic pipe is easily damaged
during hose removal, do not remove from
the side of the plastic pipe if possible.
4. EGR cooler Removal
1) Remove the EGR cooler from the exhaust
manifold and cylinder head assembly.
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Removal and Installation of EGR Valve

EGR cooler Installation 2. Water pipe installation

1. EGR cooler Installation 1) Install the water pipe to the engine assembly.
Tightening torque: 25 N・m {2.5 kgf・m / 18
1) Temporarily tighten the EGR cooler to the ex- lb・ft} M8 bolt
haust manifold and cylinder head assembly. Tightening torque: 10 N・m {1.0 kgf・m / 7.38
ANNOTATION: lbf・ft} M6

• Install the gasket and EGR cooler, and tem-

porarily tighten them in the order specified
in the diagram.

1 M8 bolt

ANNOTATION: 3. Coolant filling

• Do not hold the water pipe section when 1) Replenish the radiator assembly with coolant.
installing the EGR cooler.
4. Battery ground cable Connect
2) Securely tighten the EGR cooler to the ex-
haust manifold and cylinder head assembly. 1) Connect the battery ground cable to the bat-
tery.
ANNOTATION:
• Securely tighten them to the specified Removal and Installation of EGR
torque in the order of the numbers shown Valve
in the diagram.
Tightening torque: 27 N・m {2.8 kgf・m / 20 EGR valve Removal
lb・ft}
1. Battery ground cable Disconnect
1) Disconnect the battery ground cable from the
battery.
2. EGR valve Removal
1) Remove the harness connector from the EGR
valve.
2) Remove the EGR valve from the inlet mani-
fold.

1 EGR valve
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Removal and Installation of EGR Valve

EGR valve Installation 2) Connect the harness connector to the EGR

valve.
1. EGR valve Installation
2. Battery ground cable Connect
1) Install the EGR valve to the inlet manifold.
Tightening torque: 27 N・m {2.8 kgf・m / 20 1) Connect the battery ground cable to the bat-
lb・ft} tery.

1 EGR valve

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Removal and Installation of EGR Valve

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2005-6
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Section

2006

Removal and Installation of Engine Hood

84592788 EN - March 2012

CONTENTS

Removal of Engine Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

2006-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

2006-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Engine Hood

CAUTION Removal of Engine Hood

• Be sure to stop the engine before beginning 1. Open the engine hood (1) until the lock is engaged.
work. Wrap the nylon sling (2) around the engine hood (1),
• Do not perform this operation in strong wind. and then gently lift with the liftcrane until there is no
• Be sure to inspect the nylon sling and other force on the open lock stay (3).
lifting equipment before beginning work. Remove the pin (1) and washer (2) that are on the
• Do not stand or pass under the suspended engine hood side of the open lock stay, and then
load. remove the open rock stay (3) from the guide.
• When removing the gas damper, be sure to
do so while the lock is applied, because the
hood holding force may be reduced and the
hood may drop.
• Be careful not to let the hood fall and catch
fingers.
• The damper’s rod may fly out suddenly.
Completely extend the gas dumper when re-
moving it.
• Operate the liftcrane slowly and gently.
• The diagrams may show a different model,
but the procedures for removal and installa-
tion are the same.

2007-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

2007-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Muffler

WARNING Removal of Muffler

• Keep fire away. 1. Use a Wrench [13 mm (0.512 in)] to loosen the nut
• The machine is extremely hot just after the (1); remove the bolt (2), washers (3), and gasket
engine has been stopped. (4); and then remove the exhaust pipe (5).
Wait for it to sufficiently cool before begin-
ning work.

CAUTION
• Be sure to stop the engine before beginning
work.

Items to prepare
• Wrench [13 mm (0.512 in), 19 mm (0.748 in)]
• Cap
• Cutters
• Rag
• Cleaning fluid 2. Remove the connector (1), then remove the band
(2).

2007-5
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Removal and Installation of Muffler

84592788 EN - March 2012

2007-6
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Section

2401

Primary specifications

84592788 EN - March 2012

CONTENTS

Primary specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

2401-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

2401-2 PRINTED IN FRANCE
Copyright ©
Primary specifications

Primary specifications
1. 1. Primary specifications
Engine main specifications

Item Engine model 4JJ1

Type Diesel/4-cycle/Water cooled, Inline 4-cylinder DOHC
Shape of combustion chamber Direct injection type
Cylinder liner type No liner
Cylinder bore x stroke 95.4 mm {3.76 in} x 104.9 mm {4.13 in}
Displacement 2.999 L ｛183 cu・in｝
Compression ratio ： 17.5
Compression pressure ： 3 MPa {30.6 kgf/cm2 / 435 psi} 200 r/min
Idling rotation speed ： 800 r/min
Intake ： 0.15 mm {0.006 in} While cool
Valve clearance
Exhaust ： 0.15 mm {0.006 in} While cool
Ignition method Compression ignition
Injection order 1, 3, 4, 2
Lubricant system
Lubricating type Pressure type
Oil pump type Gear type
Lubrication oil amount ： 15 L {4 US gal / 3 Imp.gal}
Oil filter type Full-flow filter (cartridge type)
Oil cooling type Built-in type, water cooled
Cooling system
Cooling type Water cooling
Water pump type Centrifugal, belt type
Thermostat type Wax type unit
Open valve temperature of the thermostat valve ： 85.0 °C {185 °F}
Coolant container ： 6.0 L {1.6 US gal / 1.3 Imp.gal} Engine only
Fuel system
Injection pump type Electronic control common rail type
Governor type Electronic type
Timer type Electronic type
Multi-hole type
Injection nozzle type
8 holes
Charging system
Generator type AC type
Output ： 24 V / 50 A
Regulator type IC
Starting system
Starter type Reduction type
Output ： 24 V / 4.0 kw
Preheat system
Preheat system type Glow plug
Glow plug standard voltage/current ： 23 V / 3.8 A

Cleaning system main specifications

Item Specifications
Water pump Centrifugal impeller method
Pulley ratio 1.03
Thermostat Wax pellet type
Open valve temperature ： 85.0 °C {185 °F} With jiglu valve
Full-open temperature ： 100.0 °C {212 °F} With jiglu valve
Valve lift amount when fully opened ： 10 mm {0.394 in}

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Primary specifications

Electrical system main specifications

Generator
Item Specifications
Isuzu parts number 8980921122
Nominal output ： 24 V / 50 A
Rated rotation count ： 5000 r/min
Regulator type IC type
Regulated voltage ： 28 to 29 V
Weight ： 9.1 kg {20.1 lb}

Starter
Type (Manufacturer) Hitachi
Voltage ： 24 V
Rating Output ： 4 kW
Time ： 30 s
Number of pinion teeth 11
Rotational direction (facing the pinion) Right
Weight (Approx.) ： 6.3 kg {13.9 lb}
Current/voltage ： less than 120 A / 23 V
No-load characteristics
Revolution speed ： more than 3500 r/min
Current/voltage ： less than 250 A / 18.6 V
Load characteristics Torque ： more than 13.2 N・m {more than 1.3 kgf・m}
Revolution speed ： more than 1590 r/min
Current/voltage ： less than 1100 A / 10 V
Locking characteristics
Torque ： more than 47 N・m {more than 4.8 kgf・m}

Glow plug
Item Type
Preheat device model Glow plug
Glow plug rated voltage/current ： 23 V /3.5 A

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Section

2415

Removal and Installation of Cylinder Head

84592788 EN - March 2012

CONTENTS

Cylinder head cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Cylinder Head Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal and Installation of Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal of Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly of Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Assembly of Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation of Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

2415-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

2415-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Cylinder Head

Cylinder head cover Removal CAUTION

1. Battery ground cable Disconnect • Do not reuse the leak-off pipe clip.
1) Disconnect the battery ground cable from the
battery.
2. Fuel hose removal
1) Remove the cover from the cylinder head
cover.

1 Clip

3. Cylinder head cover Removal

1) Remove the cylinder head cover from the
cylinder head.
1 Cover
CAUTION

2) Remove the harness connector from the in- • Do not damage the lip section of the
jector. oil seal with the connector of the
3) Remove the nozzle leak off pipe from the in- injector.
jector.
ANNOTATION:
• Shift the head cover to the left side of the
engine and lift upwards to remove.

1 Nozzle leak off pipe

2 Injector harness connector

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Removal and Installation of Cylinder Head

4. Cam end gasket removal Installation of Cylinder Head Cover

1) Remove the cam end gasket from the cylinder 1. Oil seal installation
head.
1) Install the oil seal to the cylinder head cover.
ANNOTATION:
ANNOTATION:
• Clean any liquid gasket remaining on the
cylinder head. • Insert the oil seal from the bottom of the
cylinder head cover until it touches the end.
2. Cam end gasket installation
1) Install the cam end gasket to the cylinder
head.
ANNOTATION:
• Apply liquid gasket, ThreeBond 1207B to
the area 2 indicated in the diagram with a
width of 2.0 - 3.0 mm {0.0787 - 0.1181 in}
and install to the cylinder head.

1 Cam end gasket

5. Oil seal removal

1) Remove the oil seal from the cylinder head
cover.
ANNOTATION:
• When removing the oil seal from the cylinder
head cover, remove it from under the cylin-
der head cover.

1 Cam end gasket

2 Liquid gasket application area
3 Bead width

ANNOTATION:
• Apply liquid gasket, ThreeBond 1207B as
shown in the diagram.

3.0 - 5.0 mm {0.1181 - 0.1969

1
in}
3.0 - 5.0 mm {0.1181 - 0.1969
2
in}
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Removal and Installation of Cylinder Head

3. Cylinder head cover Installation 2) Connect the harness connector to the injector.
1) Install the cylinder head cover to the cylinder
head.
Tightening torque: 10 N・m {1.0 kgf・m / 7.38
lbf・ft}
2) Connect the PCV hose to the cylinder head
cover.
4. Fuel hose installation
1) Install the nozzle leak off pipe to the injector.
ANNOTATION:
• If the nozzle leak off hose has been re-
moved, install with the clip knob facing the
exhaust side as shown in the diagram.
1 Nozzle leak off pipe
2 Injector harness

3) Install the cover to the cylinder head cover.

1 Cover

5. Battery ground cable Connect

1) Connect the battery ground cable to the bat-
tery.

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Removal and Installation of Cylinder Head

Removal and Installation of 4. Fan shroud removal

Cylinder Head 1) Remove the fan shroud from the bracket.
ANNOTATION:
Removal of Cylinder Head
• Remove the fan shroud and fan guard as a
1. Battery ground cable Disconnect unit.
1) Disconnect the battery ground cable from the
battery.
2. Coolant Drain
1) Drain coolant from the radiator.

CAUTION
• Do not loosen or remove the radia-
tor cap when the coolant is hot.
• Steam and boiling water can burst
out, possibly causing burns or heat
related injuries.
• When opening the radiator cap,
place a thick cloth over the cap
when the coolant is cooled, and 5. Cooling fan Removal
turn it gradually to release the pres- 1) Remove the cooling fan from the fan pulley.
sure before opening it.
ANNOTATION:
ANNOTATION:
• Remove the spacer at the same time.
• Loosen the water drain plug on the rear right
side of the engine, as well as the radiator
drain plug.
• Completely drain the coolant.
• After completely draining the coolant, se-
curely tighten the drain plug.
3. Engine oil Drain
1) Drain the engine oil from the oil pan.
ANNOTATION:
• After draining the oil, tighten the drain plug
to the specified torque.
Tightening torque: 78 N・m {8.0 kgf・m / 58
lb・ft} Drain plug
Tightening torque: 70 N・m {7.1 kgf・m / 52 1 Cooling fan
lb・ft} Drain cock 2 Spacer
3 Fan pulley
CAUTION 4 Bolt
• Do not forget to tighten ｔhe drain
plug or drain cock.

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Removal and Installation of Cylinder Head

6. Cooling fan belt Removal 2) Remove the harness connector from the in-
jector.
1) Remove the cooling fan belt from the pulley.
3) Remove the nozzle leak off pipe from the in-
ANNOTATION: jector.
• Loosen the nuts fastening the bolts.
• Loosen the generator adjust bolt to remove
the belt.

1 Nozzle leak off pipe

2 Injector harness connector
1 Adjust bolt
2 Lock nut
3 Bolt CAUTION
4 Nut • Do not reuse the leak-off pipe clip.
7. PCV hose removal
1) Disconnect the PCV hose from the cylinder
head cover.
2) Remove the PCV hose from the engine as-
sembly.
ANNOTATION:
• Remove the clamp.
8. Fuel hose removal
1) Remove the cover from the cylinder head
cover.

1 Clip

9. Cylinder head cover Removal

1) Remove the cylinder head cover from the
cylinder head.

CAUTION
• Do not damage the lip section of the
oil seal with the connector of the
1 Cover injector.

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Removal and Installation of Cylinder Head

ANNOTATION: 1) Remove the water pipe from the engine as-

sembly.
• Shift the head cover to the left side of the
engine and lift upwards to remove.

1 Water pipe
10. Cam end gasket removal
ANNOTATION:
1) Remove the cam end gasket from the cylinder
head. • Because the plastic pipe is easily damaged
during hose removal, do not remove from
ANNOTATION: the side of the plastic pipe if possible.
• Clean any liquid gasket remaining on the 13. EGR cooler Removal
cylinder head.
1) Remove the EGR cooler from the exhaust
manifold and cylinder head assembly.
ANNOTATION:
• Remove the IN side and OUT side of the
rubber hose for the water pipe and remove
the EGR cooler and gasket.

CAUTION
• Do not hold the water pipe section
when removing the EGR cooler.

1 Cam end gasket

11. Generator Removal

1) Disconnect the harness from the generator.
ANNOTATION:
• Disconnect the harness connector and
B-terminal cable.
2) Remove the generator from the generator
bracket. 1 EGR cooler
ANNOTATION:
ANNOTATION:
• Remove the nuts at 2 locations, pull out the
bolts, and remove the generator. • Because the plastic pipe is easily damaged
during hose removal, do not remove from
12. Water pipe removal the side of the plastic pipe if possible.

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Removal and Installation of Cylinder Head

14. Turbocharger assembly Removal 7) Remove the turbocharger assembly from the
exhaust manifold.
1) Remove the return hose from the water pipe.

1 Turbocharger assembly
1 Water pipe

ANNOTATION:
2) Remove the water feed pipe from the oil
cooler assembly. • Remove both the water feed hose and the
3) Disconnect the oil feed pipe from the tur- water drain hose.
bocharger assembly.
4) Remove the oil feed pipe from the oil cooler CAUTION
assembly. • Do not hold the actuator rod.

ANNOTATION:
• Do not reuse the gasket.
15. Exhaust manifold Removal
1) Remove the exhaust manifold bracket from
the exhaust manifold and the oil cooler as-
sembly.
2) Remove the exhaust manifold from the cylin-
der head.

1 Oil feed pipe

5) Disconnect the oil return pipe from the tur-

bocharger assembly.
6) Remove the oil return pipe from the
crankcase.

1 Exhaust manifold
2 Exhaust manifold bracket

ANNOTATION:
• Do not reuse the gasket.
16. Turbocharger control solenoid removal
1) Disconnect the harness connector from the
turbocharger control solenoid.
2) Disconnect the vacuum hose from the tur-
1 Oil return pipe bocharger control solenoid.
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Removal and Installation of Cylinder Head

3) Remove the turbocharger control solenoid 20. Leak-off pipe removal

from the inlet manifold.
1) Remove the fuel leak-off pipe from the fuel
ANNOTATION: supply pump and common rail assembly.
• Remove together with the bracket. ANNOTATION:
• Do not reuse the gasket.

1 Turbocharger control solenoid

2 IMT sensor 1 Leak-off pipe, hose
3 Boost sensor
4 Boost temperature sensor
21. Injection pipe Removal
17. Intake throttle valve Removal 1) Remove the injection pipe from the injector
1) Disconnect the connector from the intake and the common rail assembly.
throttle valve.
CAUTION
ANNOTATION:
• Do not reuse the injection pipe.
• Pull the red claw to release the lock.
2) Remove the intake throttle valve from the inlet
manifold.
ANNOTATION:
• Remove with the adapter pipe as a unit.
18. Oil level gauge guide tube Removal
1) Remove the oil level gauge from the oil level
gauge guide tube.
2) Remove the oil level gauge guide tube from
the crankcase.
19. Injector safety information

CAUTION
1 Injection pipe
• Including the inside of the injector, the 2 Clip
holes and gaps that are to be used as
the fuel paths for the fuel system have an
extremely precise finish.
• Because there is the possibility of dam-
age due to foreign material contamina-
tion, cover the cap after removing parts,
etc., to prevent the intrusion of foreign
material.

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Removal and Installation of Cylinder Head

22. Timing chain lower cover removal 2) Remove the water intake pipe from the cylin-
der block.
1) Remove the timing chain lower cover from the
gear case cover.

1 Water intake pipe

1 Timing chain upper cover
2 CMP sensor
3 Timing chain lower cover 25. Injector Removal

23. Timing chain upper cover removal 1) Remove the injector from the cylinder head
assembly.
1) Remove the timing chain upper cover from the 2) Remove the injector gasket from the injector.
cylinder head. 3) Remove the O-ring from the injector.

CAUTION
• Do not reuse the clip, injector gas-
ket, or O-ring.

1 Timing chain upper cover

2 Fan shroud bracket
3 Fan shroud stay

24. Water intake pipe removal

1) Disconnect the water intake pipe from the oil 1 Injector
cooler.
2 Leak-off pipe
CAUTION 3 Clip
4 O-ring
• Do not reuse the gasket or O-ring. 5 Injector gasket

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Removal and Installation of Cylinder Head

CAUTION 1) Install the bolt to the camshaft gear.

ANNOTATION:
• The injector ID code identifies the injec-
tors. • Install the M5 bolt.
• Do not remove the injector ID codes from
the injectors.
• Absolutely never touch the injector
solenoids because that can hinder their
performance or cause damage.
• Store the removed injector with the cylin-
der number on it.
• When the injector has been replaced,
erase the ID code of the replaced cylin-
der number on the injector ID code label
using a black pen, etc.

2) Remove the baffle plate from the cylinder

head.

1 Injector ID code
2 Injector

26. Glow plug connector removal

1) Remove the glow plug connector from the 1 Baffle plate
glow plug.
29. Camshaft Removal
27. Glow plug Removal
1) Remove the camshaft bearing cap from the
1) Remove the glow plug from the cylinder head cylinder head.
assembly.
ANNOTATION:
• Confirm that the camshaft bearing cap is
marked.
• The marking indicates the installation posi-
tion.

28. Baffle plate removal

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Removal and Installation of Cylinder Head

CAUTION 1) Remove idle gear D from the gear case cover.

ANNOTATION:
• Take necessary measures in ad-
vance so that the inlet side and • Remove idle gear D together with the
exhaust side do not get mixed up. sprocket.

2) Remove the camshaft from the cylinder head.

30. Timing chain tensioner removal

1) Remove the timing chain tensioner from the
cylinder head.

1 Bolt
2 Washer
3 Idle gear D
4 Idle gear shaft

1 Timing chain tensioner

33. Timing chain removal
2 Gasket
3 Nut 1) Remove the timing chain from the sprocket.
ANNOTATION:
31. Timing chain lever pivot removal • Remove from the supply pump sprocket.
1) Remove the timing chain lever pivot from the 34. Timing chain guide removal
timing gear case.
1) Remove the timing chain guide from the cylin-
der head.

32. Idle gear D removal

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Removal and Installation of Cylinder Head

35. Rocker arm shaft assembly removal 3) Loosen the bolt using a wrench.
1) Remove the rocker arm shaft assembly from ANNOTATION:
the cylinder head.
• Loosen and remove the cylinder head bolts
ANNOTATION: in the order shown in the diagram.
• If reusing the rocker arm shaft assembly, CAUTION
install it to its original position.
• Do not reuse the bolt.

Exhaust rocker arm shaft as- 4) Remove the cylinder head from the cylinder
1
sembly block.
2 Bolt
ANNOTATION:
3 Bolt
4 Inlet rocker arm shaft assembly • Remove with the inlet manifold.
37. Cylinder head gasket removal
36. Cylinder head assembly Removal
1) Remove the cylinder head gasket from the
1) Remove the bolt from the timing gear case.
cylinder head.
2) Remove the nut from the timing gear case.
CAUTION
• Do not reuse the gasket.

1 Nut
2 Bolt

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Removal and Installation of Cylinder Head

Disassembly of Cylinder Head

1. Sprocket removal
1) Remove the sprocket from idle gear D.

Special tool: valve spring compressor

lever (refer to section 1003)

2. EGR valve Removal

1) Remove the EGR valve from the cylinder
head.

Special tool: valve spring compressor

pivot (refer to section 1003)

1 EGR valve

3. Inlet manifold removal

1) Remove the inlet manifold from the cylinder
head.
4. Water outlet pipe removal
1) Remove the water outlet pipe from the cylin-
der head.
7. Spring seat removal
5. Valve stem end cap removal
1) Remove the spring seat from the valve spring
1) Remove the valve stem end cap from the bulb. using special tool.
6. Split collar removal ANNOTATION:
1) Remove the split collar from the valve using • Remove the upper spring seat.
special tool.
8. Valve spring Removal
ANNOTATION:
1) Remove the valve spring from the cylinder
• Using a replacer, compress the valve spring head.
and remove the split collar.
ANNOTATION:
• Organize the removed valve springs in the
order of the cylinder number.
9. Inlet valve Removal

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Removal and Installation of Cylinder Head

1) Remove the inlet valve from the cylinder head. 12. Valve guide Removal

CAUTION 1) Remove the valve guide from the cylinder

head using special tool.
• Organize the removed valves ac-
cording to the cylinders using tags, ANNOTATION:
etc. • Using a valve guide remover, tap out the
valve guide from the lower surface side of
10. Exhaust valve Removal the cylinder head.
1) Remove the exhaust valve from the cylinder
head.
ANNOTATION:
• Organize the removed valves according to
the cylinders using tags, etc.

Special tool: valve guide remover and

installer (refer to section 1003)

11. Valve stem oil seal Removal

1) Remove the valve stem oil seal from the cylin-
der head using pliers.

13. Oil seal removal

1) Remove the oil seal from the cylinder head.

CAUTION
• Do not reuse the removed oil seal.

2) Remove the spring seat from the cylinder

head.
ANNOTATION:
• Remove the spring lower seat.

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Removal and Installation of Cylinder Head

Assembly of Cylinder Head 2. Valve guide Installation

1. Oil seal installation 1) Install the valve guide to the cylinder head
using special tool.
1) Install the oil seal to cylinder head using spe-
cial tool. ANNOTATION:
ANNOTATION: • Using a valve guide installer, tap in the valve
guide from the upper surface side of the
• Install to the injection pipe insertion surface cylinder head.
using an oil seal installer.
• Uniformly tap the seal so that it is not CAUTION
slanted.
• When replacing the valve guide, re-
CAUTION place with the valve as a set.
• Be careful not to damage the lip
section.

Special tool: valve guide remover and

installer (refer to section 1003)
Special tool: oil seal installer (refer to
section 1003)

valve stem height: 12.5 - 12.7 mm {0.4921 -

0.5000 in}

The height from the upper sur-

1 Cylinder head 1 face of the cylinder head to the
2 Oil seal installer end surface of the valve guide

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Removal and Installation of Cylinder Head

3. Valve stem oil seal Installation 2) Install the exhaust valve to the cylinder head.
1) Install the spring seat to the cylinder head. 5. Inlet valve Installation
ANNOTATION: 1) Apply the engine oil to the inlet valve.
• Install the spring lower seat. ANNOTATION:
2) Install the valve stem oil seal to the cylinder • Apply engine oil to the valve stem.
head using special tool.
2) Install the inlet valve to the cylinder head.
ANNOTATION:
• Apply engine oil to the outer periphery of the
valve guide and install the oil seal using a
valve stem seal installer.

6. Valve spring Installation

1) Install the valve spring to the cylinder head.
7. Spring seat installation
Special tool: valve stem seal installer 1) Install the spring seat to the valve spring.
(refer to section 1003)
ANNOTATION:
ANNOTATION:
• Install the spring upper seat.
• After installing the valve stem oil seal, con-
firm that it is securely inserted all the way in. 8. Split collar installation
1) Install the split collar to the valve using special
CAUTION
tool.
• Confirm that the valve stem oil seal ANNOTATION:
is not inclined.
• Confirm that the garter spring is • Using a replacer, compress the valve spring
placed correctly. and install the split collar.

Special tool: valve spring compressor

4. Exhaust valve Installation lever (refer to section 1003)
1) Apply the engine oil to the exhaust valve.
ANNOTATION:
• Apply engine oil to the valve stem.

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Removal and Installation of Cylinder Head

Special tool: valve spring compressor 12. EGR valve Installation

pivot (refer to section 1003) 1) Install the EGR valve to the cylinder head.
Tightening torque: 27 N・m {2.8 kgf・m / 20
lb・ft}

9. Valve stem end cap installation

1) Install the valve stem end cap to the bulb.
10. Water outlet pipe installation 1 EGR valve
1) Install the water outlet pipe to the cylinder 13. Sprocket installation
head assembly.
Tightening torque: 25 N・m {2.5 kgf・m / 18 1) Install the sprocket to idle gear D.
lb・ft} Tightening torque: 8 N・m {0.8 kgf・m / 5.90
lbf・ft}
11. Inlet manifold installation
ANNOTATION:
• Install the gasket and inlet manifold, and tem-
porarily tighten.
• Tighten to the specified torque in the order shown
in the diagram.
Tightening torque: 25 N・m {2.5 kgf・m / 18 lb・ft}

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Removal and Installation of Cylinder Head

Installation of Cylinder Head 3 Measurement location

4 Measurement location
1. Cylinder head gasket preparation
1) Select the cylinder head gasket.
ANNOTATION:
• Select the grade for the cylinder head gas-
ket by measuring the protrusion amount of
the piston head.
• Remove the water deposit on the top sur-
face of the cylinder block, and the carbon
from the piston head.
2) Measure the piston using a dial gauge.
ANNOTATION:
• Measure the protruding amount of piston
head.
1 Measurement location
2 Measurement location
3 Measurement location
4 Measurement location

3) Calculate the average value from the mea-

sured value.
ANNOTATION:
• Select the required grade of cylinder head
gasket using the average measured value.

Protrusion
Gasket Gasket thick-
amount of the
CAUTION grade ness
piston
• Make sure that the measuring point ： 0.087 to 0.117
： 0.95 mm
is as close to the cylinder block as A mm {0.0034 to
{0.0374 in}
possible. 0.0046 in}
• The difference in protrusion ： 0.117 to 0.167
： 1.00 mm
amounts between pistons should B mm {0.0046 to
{0.0394 in}
not exceed the specified value. 0.0066 in}
• Disassemble and reassemble if the ： 0.167 to 0.217
： 1.05 mm
protrusion amount of each piston C mm { 0.0066 to
{0.0413 in}
is outside of the specified value 0.0085 in}
range.

specified value: 0.05 mm {0.0020 in} or less

1 Gasket A
2 Gasket B
1 Measurement location 3 Gasket C
2 Measurement location 4 Grade identification location

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2. Cylinder head gasket installation • Tighten the head bolts in the order shown
in the diagram using a torque wrench and
1) Install the dowel pin to the cylinder block.
angle gauge.
ANNOTATION:
• Install only when the dowel pin has been
removed from the cylinder block.
2) Apply the liquid gasket to the cylinder block.
ANNOTATION:
• As shown in the diagram, apply ThreeBond
1207B to the aligning surface of the gear
case.
• Use the same grade for the gear case gas-
ket as the cylinder head gasket.
3) Install the cylinder head gasket to the cylinder
block.
Special tool: angle gauge (refer to section
CAUTION 1003)
Tightening torque: 70 N・m {7.1 kgf・m / 52
• Install the cylinder head gasket and lb・ft} 1st time
gear case gasket within five min- Tightening torque: 70 N・m {7.1 kgf・m / 52
utes of applying liquid gasket. lb・ft} 2nd time
specified angle: 60 - 75 ° 3rd time
specified angle: 60 - 75 ° 4th time

1 2 - 3 mm {0.0787 - 0.1181 in}

3) Install the bolt to the timing gear case.
2 3 - 4 mm {0.1181 - 0.1575 in} 4) Install the nut to the timing gear case.
ANNOTATION:
3. Cylinder head assembly Installation
• Tighten at the specified torque in the order
1) Install the cylinder head assembly to the cylin- of the numbers in the diagram.
der block.
ANNOTATION:
• Gently place the cylinder head while align-
ing with the cylinder block dowel.

CAUTION
• When installing, be careful not to
damage the cylinder head gasket.

2) Apply engine oil to the head bolt.

CAUTION
• Use a new head bolt.
4. Rocker arm shaft assembly installation
ANNOTATION:
1) Apply the engine oil to the bolt.
• Apply engine oil to the threaded portion of
the head bolt and seat surface.
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2) Install the rocker arm shaft assembly to the 1) Align No.1cylinder to the compression top
cylinder head. dead center.
ANNOTATION: ANNOTATION:
• Tighten to the specified torque in the order • Rotate the crankshaft in the forward direc-
shown in the diagram. tion to align the No.1 cylinder piston to com-
pression top dead center.
Tightening torque: 21 N・m {2.1 kgf・m / 15
lb・ft}

Compression top dead center

Exhaust rocker arm shaft as- 1
1 alignment position
sembly
2 Inlet rocker arm shaft assembly
2) Install the timing chain to the sprocket.
5. Timing chain guide installation 7. Idle gear D installation
1) Install the timing chain guide to the cylinder 1) Apply engine oil to the shaft.
head.
Tightening torque: 25 N・m {2.5 kgf・m / 18 ANNOTATION:
lb・ft}
• Apply to the front and inner surfaces of the
shaft, as well as to the threaded portion and
seat surface of the bolt.
2) Install idle gear D to the cylinder head.
Tightening torque: 59 N・m {6.0 kgf・m / 44
lb・ft}

ANNOTATION:
• Install the timing chain tension lever.
6. Timing chain installation

Shaft front surface and inner

1
surface
Threaded portion of the bolt
2
and seat surface.

ANNOTATION:
• Align the two timing alignment marks as in-
dicated in the diagram.
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Removal and Installation of Cylinder Head

1) Connect the hook to the pin.

ANNOTATION:
• Push down the latch of the timing chain
tensioner, insert the plunger, and hang the
hook to the pin.

1 Timing mark
2 Alignment mark
3 Plate, blue
4 Plate, yellow

8. Timing chain lever pivot installation

1) Install the timing chain lever pivot to the timing 1 Pin
chain tension lever. 2 Plunger
3 Latch
ANNOTATION: 4 Hook
• Check that the timing chain lever moves
smoothly.
2) Install the timing chain tensioner to the cylin-
Tightening torque: 25 N・m {2.5 kgf・m / 18 der head.
lb・ft}
ANNOTATION:
• Install the gasket, and tighten it to the spec-
ified torque.

CAUTION
• Do not reuse the gasket.

Tightening torque: 10 N・m {1.0 kgf・m / 7.38

lbf・ft}

9. Timing chain tensioner installation

1 Timing chain tensioner

2 Gasket
3 Nut

CAUTION
• Turn the protruding section of the
gasket downward to install.

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Removal and Installation of Cylinder Head

3) Disconnect the hook from the pin.

ANNOTATION:
• Lightly push the area indicated with an ar-
row in the diagram.
• The hook of the tensioner opens, the
plunger pushes the tension lever, and the
chain is pulled.

ANNOTATION:
• Confirm that the alignment marks of the
camshaft bearing cap and the camshaft are
aligned.

10. Camshaft Installation

1) Align the camshaft gear with the alignment
mark.
ANNOTATION:
• As indicated in the diagram, align the align-
ment marks of the inlet camshaft gear and
the exhaust camshaft gear, as well as the
alignment mark of idle gear D.
2) Install the camshaft to the cylinder head.

1 Alignment mark

4) Apply the engine oil to the bolt.

ANNOTATION:
• Apply engine oil to the threaded portion and
tighten the bearing cap.
• Tighten the bearing cap to the specified
torque in the order shown in the diagram.
Tightening torque: 18 N・m {1.8 kgf・m / 13
lb・ft}

1 Exhaust camshaft gear

2 Inlet camshaft gear
3 Idle gear D

3) Install the camshaft bearing cap to the cylinder

head.
ANNOTATION:
• Apply engine oil to the journal section of the
cylinder head.
• Face the bearing cap front mark to the en- 5) Remove the bolt from the camshaft gear.
gine front side, and assemble in numbered
order to the cylinder head. ANNOTATION:
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Removal and Installation of Cylinder Head

• Remove the M5 bolt of the camshaft gear.

1 Driver
ANNOTATION: 2 Ring spanner
• After rotating the crankshaft 720˚, the marks 3 Adjust nut wrench
on the collared end of the crankshaft and
that of the bearing cap should align. 2) Align 1st cylinder to the compression top dead
center.
ANNOTATION:
• Rotate the crankshaft in the forward direc-
tion to align the No.1 cylinder piston to com-
pression top dead center.

1 Exhaust camshaft gear

2 Inlet camshaft gear
3 Idle gear D

11. Rocker arm adjustment Compression top dead center

1
1) Loosen the adjust screw using special tool. alignment position

3) Adjust the valve clearance to specified value

using a feeler gauge.
ANNOTATION:
• Insert a feeler gauge between the rocker
arm roller and cam and tighten the rocker
arm adjust screw.
specified value: 0.15 mm {0.0059 in}
4) Align the No.4 cylinder to compression top
dead center.
ANNOTATION:

Special tool: valve clearance adjust nut • Rotate the crankshaft 360˚ from compres-
wrench (refer to section 1003) sion top dead center of the No.1 cylinder
and align the No.4 cylinder to compression
ANNOTATION: top dead center.
• Use the adjust nut wrench to loosen each 5) Adjust the valve clearance to specified value
adjust screw of the rocker arm. using a feeler gauge.
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Removal and Installation of Cylinder Head

ANNOTATION: cylinder is at the compression top dead

center, or when an X is marked on the
• Insert a feeler gauge between the rocker diagram when the No.4 cylinder is at the
arm roller and cam and tighten the rocker compression top dead center.
arm adjust screw.
• Adjust the valve clearance if a circle is
marked on the diagram when the No.1

Valve ar-
Inlet Exhaust Inlet Exhaust Inlet Exhaust Inlet Exhaust
rangement
No.1 cylinder
compression ○ ○ ○ ○
top dead cen-
ter
No.4 cylinder
compression × × × ×
top dead cen-
ter

specified value: 0.15 mm {0.0059 in} 12. Baffle plate installation

CAUTION 1) Install the baffle plate to the cylinder head.

Tightening torque: 10 N・m {1.0 kgf・m / 7.38
• Make sure to adjust while cool. lbf・ft}

6) Tighten the bolt using special tool.

ANNOTATION:
• When the movement of the thickness gauge
becomes stiff, secure the adjust screw nut
of the rocker arm.
Tightening torque: 18 N・m {1.8 kgf・m / 13
lb・ft}

1 Baffle plate

1 Cam: exhaust side

2 Cam: intake side
3 Roller: intake side
4 Roller: exhaust side

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13. Glow plug Installation 2) Install the O-ring to the injector.

1) Install the glow plug to the cylinder head as- ANNOTATION:
sembly.
Tightening torque: 18 N・m {1.8 kgf・m / 13 • When installing the O-ring, be careful not to
lb・ft} cause damage by applying engine oil to it.

CAUTION
• Do not exceed specifications when
tightening as over-tightening may
result in breakage.

1 Injector
2 Leak-off pipe
3 Clip
4 O-ring
5 Injector gasket
14. Glow plug connector installation
1) Install the glow plug connector to the glow 3) Install the clamp to the injector.
plug. ANNOTATION:
ANNOTATION: • Apply engine oil to the threaded portion and
• Install the glow plug connector to the glow seat surface of the injector clamp bolt.
plugs of the No.1, No.3 and No.4 cylinders.

CAUTION
• Install the glow plug connector so
that there is no interference with the
cylinder head.

Tightening torque: 1.8 N・m {0.2 kgf・m /

1.328 lbf・ft}
15. Injector Installation
1) Install the injector gasket to the injector.
ANNOTATION:
• Push in until your hand stops.
• Do not forcibly push the injector gasket in as 1 Injector
it will be pushed in to the end during clamp 2 Injector clamp bolt
tightening. 3 Injector clamp

CAUTION
• Do not reuse the clip, injector gas-
ket, or O-ring.

4) Temporarily tighten the injector to the cylinder

head.
ANNOTATION:
• Install and temporarily tighten the injector,
injector clamp, and clamp bolt to the cylinder
head.
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Removal and Installation of Cylinder Head

• When installing the injector to the cylinder 3) Securely tighten the injection pipe to the injec-
head, confirm that the injector gasket is in- tor.
stalled to the injector.
ANNOTATION:
CAUTION • Tighten the sleeve nut on the injector side
of the injection pipe to the specified torque.
• If the injector has been replaced,
record the injector ID code of the Tightening torque: 30 N・m {3.1 kgf・m / 22
new injector. lb・ft}
• Record the 24 figures of the injector 4) Securely tighten the injection pipe to the com-
ID plate. mon rail assembly.
ANNOTATION:
• Tighten the sleeve nut on the common rail
side of the injection pipe to the specified
torque.
Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft}
Tightening torque: 7.8 N・m {0.8 kgf・m /
5.754 lbf・ft} Clamp nut

1 Injector ID code
2 Injector

16. Injection pipe Installation

CAUTION
• If the high pressure pipe of the fuel sys- 1 Injection pipe
tem has been removed, make sure to re-
2 Clamp
place with a new part.
• Reuse may cause the seal surface to be 17. Timing chain upper cover installation
damaged and fuel to leak.
1) Apply liquid gasket to the timing chain upper
1) Temporarily tighten the injection pipe to the cover.
injector and common rail assembly. ANNOTATION:
ANNOTATION:
• Apply ThreeBond 1207B.
• Apply engine oil to the threaded portion of
the sleeve nut on the injector side of the CAUTION
injection pipe and the O-ring of the injector. • Install the cover within five minutes
• When installing, do not damage the injector of applying liquid gasket.
sleeve gasket.
• Using an open-end wrench, lightly tighten
the sleeve nut on the common rail side until
it is firmly attached.
• Tighten the sleeve nuts on the injector side
until they can no longer be turned by hand.
2) Securely tighten the injector to the cylinder
head.
ANNOTATION:
• Tighten the injector clamp bolt to the speci-
fied torque.
Tightening torque: 26 N・m {2.7 kgf・m / 19
lb・ft}

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Removal and Installation of Cylinder Head

1 Liquid gasket 2) Install the timing chain lower cover to the gear
2 2 - 2.5 mm {0.0787 - 0.0984 in} case cover.
3 2 - 2.5 mm {0.0787 - 0.0984 in} Tightening torque: 10 N・m {1.0 kgf・m / 7.38
lbf・ft}

2) Install the timing chain upper cover to the

cylinder head.
ANNOTATION:
• Apply Loctite 262 to the threaded portion on
the cylinder head side.
Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft}

1 Timing chain upper cover

2 CMP sensor
3 Timing chain lower cover

19. Leak-off pipe installation

1) Install the fuel leak-off pipe to the fuel supply
pump and common rail assembly.

1 Timing chain upper cover ANNOTATION:

2 Fan shroud bracket • Also install the hose at the same time.
3 Fan shroud stay
CAUTION

18. Timing chain lower cover installation • Do not reuse the gasket.

1) Apply liquid gasket to the timing chain lower

cover.
ANNOTATION:
• Apply ThreeBond 1207B.
CAUTION
• Install the cover within five minutes
of applying liquid gasket.

1 Leak-off pipe, hose

Tightening torque: 10.3 N・m {1.1 kgf・m /

7.598 lbf・ft} Eyebolt
20. Oil level gauge guide tube Installation
1) Apply the engine oil to the O-ring.
2) Install the oil level gauge guide tube to the
crankcase.
Tightening torque: 25 N・m {2.5 kgf・m / 18
1 Liquid gasket lb・ft} Oil cooler side
2 2 - 2.5 mm {0.0787 - 0.0984 in} Tightening torque: 51 N・m {5.2 kgf・m / 38
3 2 - 2.5 mm {0.0787 - 0.0984 in} lb・ft} Cylinder head side
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Removal and Installation of Cylinder Head

3) Install the oil level gauge to the oil level gauge 23. Water intake pipe installation
guide tube.
1) Install the O-ring to the water intake pipe.
21. Turbocharger control solenoid installation
ANNOTATION:
1) Install the turbocharger control solenoid to the
inlet manifold. • Apply soapy water to the O-ring.
2) Install the water intake pipe to the cylinder
ANNOTATION:
block.
• Install the bracket together with the tur-
bocharger assembly control solenoid. CAUTION
Tightening torque: 25 N・m {2.5 kgf・m / 18 • Be careful so as not to pinch the
lb・ft} Bolt O-ring during installation.
Tightening torque: 15 N・m {1.5 kgf・m / 11
lb・ft} Nut
2) Connect the vacuum hose to the turbocharger
control solenoid.

CAUTION
• Insert the hose until it stops.

3) Connect the harness connector to the tur-

bocharger control solenoid.

CAUTION
• Install the harness and hose clip to
their original locations.

1 Water intake pipe

Tightening torque: 25 N・m {2.5 kgf・m / 18

lb・ft}

CAUTION
• Assembling the oil cooler and water
inlet pipe with their installation sur-
faces tilted will cause the coolant to
leak.

1 Turbocharger control solenoid

2 IMT sensor
3 Boost sensor
4 Boost temperature sensor

22. Intake throttle valve Installation

1) Install the gasket to the inlet manifold.
2) Install the intake throttle valve to the inlet man-
ifold.
ANNOTATION:
1 Water bypass pipe
• Install with the adapter pipe as a unit. 2 Gasket
Tightening torque: 10 N・m {1.0 kgf・m / 7.38 3 Oil cooler
lbf・ft}
3) Connect the harness connector to the intake 24. Exhaust manifold Installation
throttle valve.
1) Install the exhaust manifold to the cylinder
ANNOTATION: head.
• Press the red claw to lock. ANNOTATION:
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Removal and Installation of Cylinder Head

• Assemble so that the gasket ear portion is 2) Install the exhaust manifold bracket to the ex-
on the engine rear side. haust manifold and the oil cooler assembly.
Tightening torque: 27 N・m {2.8 kgf・m / 20
lb・ft}

1 Gasket ear portion

1 Exhaust manifold
ANNOTATION: 2 Exhaust manifold bracket
• Assemble the washer and nut as indicated
in the diagram and temporarily tighten.
25. Turbocharger assembly Installation
1) Install the turbocharger assembly to the ex-
haust manifold.
Tightening torque: 35 N・m {3.6 kgf・m / 26
lb・ft}

CAUTION
• Do not hold the actuator rod.

ANNOTATION:
• Fill with 0.5 cc of engine oil from the fuel
filler.

1 Stud
2 Washer
3 Nut

ANNOTATION:
• Tighten to the specified torque in the order
shown in the diagram.
Tightening torque: 52 N・m {5.3 kgf・m / 38
lb・ft}

1 Turbocharger assembly

2) Install the water feed pipe to the oil cooler.

Tightening torque: 41 N・m {4.2 kgf・m / 30
lb・ft}
3) Connect the water feed pipe to the tur-
bocharger assembly.
Tightening torque: 35 N・m {3.6 kgf・m / 26
lb・ft}
4) Install the oil feed pipe to the oil cooler assem-
bly.
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5) Connect the oil feed pipe to the turbocharger 1) Temporarily tighten the EGR cooler to the ex-
assembly. haust manifold and cylinder head assembly.
Tightening torque: 23 N・m {2.3 kgf・m / 17
lb・ft} Eyebolt ANNOTATION:
• Install the gasket and EGR cooler, and tem-
porarily tighten them in the order specified
in the diagram.

1 Oil feed pipe

6) Install the oil return pipe to the crankcase. ANNOTATION:

Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft} • Do not hold the water pipe section when
7) Connect the oil return pipe to the turbocharger installing the EGR cooler.
assembly.
2) Securely tighten the EGR cooler to the ex-
Tightening torque: 10 N・m {1.0 kgf・m / 7.38
haust manifold and cylinder head assembly.
lbf・ft}
ANNOTATION:
• Securely tighten them to the specified
torque in the order of the numbers shown
in the diagram.
Tightening torque: 27 N・m {2.8 kgf・m / 20
lb・ft}

1 Oil return pipe

8) Connect the vacuum hose to the turbocharger

assembly.
26. EGR cooler Installation

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27. Water pipe installation width of 2.0 - 3.0 mm {0.0787 - 0.1181 in}
and install to the cylinder head.
1) Install the water pipe to the engine assembly.
Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft} M8 bolt
Tightening torque: 10 N・m {1.0 kgf・m / 7.38
lbf・ft} M6

1 Cam end gasket

2 Liquid gasket application area
3 Bead width

1 M8 bolt ANNOTATION:
• Apply liquid gasket, ThreeBond 1207B as
28. Generator Installation shown in the diagram.
1) Install the generator to the generator bracket.
ANNOTATION:
• Install the generator to the bracket and ad-
just plate, and temporarily tighten the instal-
lation nut.

CAUTION
• Tighten the generator after adjust-
ing the work belt.

2) Connect the harness to the generator.

ANNOTATION:
• Connect the harness connector and B-ter-
minal cable. 3.0 - 5.0 mm {0.1181 - 0.1969
1
in}
29. PCV hose installation 3.0 - 5.0 mm {0.1181 - 0.1969
2
1) Install the PCV hose to the engine assembly. in}
Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft} Clamp 31. Cylinder head cover Installation
30. Cam end gasket installation 1) Install the cylinder head cover to the cylinder
head.
1) Install the cam end gasket to the cylinder
Tightening torque: 10 N・m {1.0 kgf・m / 7.38
head.
lbf・ft}
ANNOTATION: 2) Connect the PCV hose to the cylinder head
cover.
• Apply liquid gasket, ThreeBond 1207B to
the area 2 indicated in the diagram with a 32. Fuel hose installation

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Removal and Installation of Cylinder Head

1) Install the nozzle leak off pipe to the injector. 1) Install the cooling fan belt to the fan pulley.
ANNOTATION: ANNOTATION:
• If the nozzle leak off hose has been re- • Install the spacer at the same time.
moved, install with the clip knob facing the
exhaust side as shown in the diagram. Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft}

2) Connect the harness connector to the injector.

1 Cooling fan
2 Spacer
3 Fan pulley
4 Bolt

35. Fan shroud installation

1) Install the fan shroud to the bracket.
ANNOTATION:
• Install the fan shroud and fan guard.
Tightening torque: 51 N・m {5.2 kgf・m / 38
lb・ft}
1 Nozzle leak off pipe
2 Injector harness

3) Install the cover to the cylinder head cover.

36. Cooling fan belt Adjustment

1) Adjust the cooling fan belt.
ANNOTATION:
• Loosen the adjust plate lock bolt and the
mounting bolt at the bottom side of the gen-
1 Cover erator.
• Turn the adjust bolt to adjust the belt.
33. Cooling fan belt Installation • Press the specified position on the belt with
the specified load to inspect the amount of
1) Install the cooling fan belt to the pulley. belt flex.
34. Cooling fan Installation load: 98 N {10 kg / 22 lb}
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Removal and Installation of Cylinder Head

Amount of deflection the pulley groove when installing a new belt

： 4.2 to 5.0 mm {0.1654 to or when readjusting the belt tension.
New
0.1969 in} • Follow the specified method to adjust the
When adjusting the ： 6.6 to 7.4 mm {0.2598 to belt tension.
tension 0.2913 in} • Start and idle the engine for 5 minutes or
more to settle the belt.
• Stop the engine and readjust the belt ten-
ANNOTATION: sion to the specified value.
• Verify whether precise tension has been set 37. Engine oil filling
using a sonic tension meter.
1) Replenish the engine with engine oil.
Frequency of vibrations ANNOTATION:
New ： 220 to 244 Hz • Recheck the tightening of the oil pan drain
When adjusting the plug.
： 182 to 206 Hz
tension
38. Coolant filling
1) Replenish the radiator assembly with coolant.
39. Fuel Air bleed
ANNOTATION:
• Before starting the engine
1) Prepare the pan.
ANNOTATION:
• Place an appropriate pan under the fuel fil-
ter.
2) Turn the plug.
ANNOTATION:
• Sufficiently loosen the air removal plug.
1 Crankshaft pulley
2 Installation bolt 3) Operate the priming pump.
3 Generator ANNOTATION:
4 Adjust bolt
5 Lock nut • Operate the priming pump 20 times or more
until fuel spills out around the plug.
6 Fan pulley
Inspection position for belt flex 4) Close the plug.
7 5) Operate the priming pump.
amount
ANNOTATION:
CAUTION • Operate the priming pump 10 times or more
until it is completely filled with fuel.
• Always take care to set the correct • Wait for approximately 1 minute after oper-
tension as belt service life may be ating the priming pump.
shortened or the belt squeaking
may occur if tension is inadequate. 6) Drain air from the fuel filter assembly.
ANNOTATION:
ANNOTATION:
• Sufficiently loosen the air removal plug.
• After adjustment, tighten the adjust plate
lock bolt and mounting bolt at the bottom 7) Close the plug.
side of the generator to the specified torque.
ANNOTATION:
Tightening torque: 51 N・m {5.2 kgf・m / 38
lb・ft} M10 bolt, M10 nut • Sufficiently tighten the air bleeding plug to
the fuel filter.
Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft} M8 bolt, M8 nut CAUTION
ANNOTATION:
• Tighten the air removal plug and
• When installing a new belt, initial elongation then completely wipe away any ex-
of the belt occurs. cess fuel in the vicinity.
• Adjust the belt according to the adjustment
method below in order to settle the belt in 8) Operate the priming pump.
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Removal and Installation of Cylinder Head

ANNOTATION: Inspection
• Push the priming pump 10 times to 15 times 1. Cylinder head assembly Inspection
to feed fuel into the supply pump.
• or less, after starting the engine 1) Measure the deformation using a feeler
gauge.
9) Start the engine and put it into an idling state.
ANNOTATION:
ANNOTATION:
• Use a feeler gauge and a simple straight
• Idle for 5 seconds. ruler to measure cylinder head deformation.
• As shown in the diagram, measure the four
CAUTION sides and the diagonal line.
• Do not rev the engine. • Replace if the limit is exceeded.

10) Adjust the engine speed.

ANNOTATION:
• Slowly increase the engine speed and main-
tain for 3 seconds.
• After completion of the above operation, op-
erate at maximum revolutions on the side
of the machine and repeat the operation
of revving to the maximum speed multiple
times.

CAUTION
• If air removal operations are insuf-
ficient, due to the possibility of en-
gine trouble, make sure to follow all
procedures.

40. Battery ground cable Connect

1) Connect the battery ground cable to the bat-
tery.

specified value: 0.05 mm {0.0020 in} or less

Limit: 0.20 mm {0.0079 in}

CAUTION
• Do not polish the cylinder head bot-
tom surface.

ANNOTATION:
• Measure the height of the cylinder head.
specified value: 143.4 mm {5.6457 in}

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Removal and Installation of Cylinder Head

ANNOTATION:
• Measure the diameter of the valve stem.
• If the diameter of the valve stem is smaller
than the limit, replace the valve and valve
guide as a set.
specified value: 6.947 - 6.962 mm {0.2735 -
0.2741 in}
Limit: 6.920 mm {0.2724 in}

1 Cylinder head height

2) Measure the deformation using a feeler

gauge.
ANNOTATION:
• Measure the flatness of the exhaust mani-
fold and inlet manifold installation surface.
• Use a feeler gauge and a simple straight 2) Measure the valve guide clearance using a
ruler to measure deformation of the instal- dial gauge.
lation surface.
• Measure the four sides and the diagonal ANNOTATION:
lines. • Measure the clearance between the valve
guide and valve stem within a range of 10
mm {0.3937 in} from the valve guide.
• Replace the valve and valve guide together
as an assembly if the measured value ex-
ceeds the limit.
specified value: 0.038 - 0.068 mm {0.0015 -
0.0027 in}
Limit: 0.25 mm {0.0098 in}

ANNOTATION:
• Replace if the limit is exceeded.
specified value: 0.05 mm {0.0020 in} or less
Limit: 0.20 mm {0.0079 in}
2. Valve guide inspection
1) Inspect the valve guide.
ANNOTATION: ANNOTATION:
• If there are scratches or abnormal worn on • Measure the thickness of the valve.
the inner diameter of the valve stem or valve • Replace the valve and valve guide together
guide, replace the valve guide as a set. as an assembly if the measured value ex-
ceeds the limit.
3. Exhaust valve measurement
specified value: 1.3 mm {0.0512 in}
1) Measure the exhaust valve using a microme-
Limit: 1.1 mm {0.0433 in}
ter.

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Removal and Installation of Cylinder Head

specified value: 2.12 mm {0.0835 in}

Limit: 2.5 mm {0.0984 in}

ANNOTATION:
• Remove carbon and water deposits, etc.,
from the bottom surface of the cylinder
1 45˚
head.
3) Install the exhaust valve to the cylinder head. ANNOTATION:
4) Measure the exhaust valve using a depth
gauge. • Measure the contact surface of the valve
seat.
ANNOTATION: • Repair the seat contact surface if it is defec-
• Use a depth gauge or simple straight ruler tive, or replace the valve, valve guide, and
to measure the sinking amount of the valve valve seat together as a set.
from the bottom surface of the cylinder
head.
• Replace the valve insert or cylinder head
assembly if the limit is exceeded.
specified value: 2.5 mm {0.0984 in}

1 45˚

4. Inlet valve measurement

1) Measure the inlet valve using a micrometer.
1 45˚ ANNOTATION:
• Measure the diameter of the valve stem.
ANNOTATION: • If the diameter of the valve stem is smaller
than the limit, replace the valve and valve
• Measure the contact width of the valve seat. guide as a set.
• Repair or replace if the seat contact is dam-
aged or rough, or when the friction of the specified value: 6.955 - 6.970 mm {0.2738 -
contact surface exceeds the limit. 0.2744 in}

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Removal and Installation of Cylinder Head

Limit: 6.935 mm {0.2730 in}

ANNOTATION:
2) Measure the valve guide clearance using a
dial gauge. • Remove carbon and water deposits, etc.,
from the bottom surface of the cylinder
ANNOTATION: head.
• Measure the clearance between the valve 3) Install the inlet valve to the cylinder head.
guide and valve stem within a range of 10 4) Measure the inlet valve using a depth gauge.
mm {0.3937 in} from the valve guide.
• Replace the valve and valve guide together ANNOTATION:
as an assembly if the measured value ex- • Use a depth gauge or simple straight ruler
ceeds the limit. to measure the sinking amount of the valve
specified value: 0.030 - 0.060 mm {0.0012 - from the bottom surface of the cylinder
0.0024 in} head.
clearance: 0.20 mm {0.0079 in} • Replace the valve insert or cylinder head
assembly if the limit is exceeded.
specified value: 2.5 mm {0.0984 in}

ANNOTATION:
• Measure the thickness of the valve.
• Replace the valve and valve guide together 1 45˚
as an assembly if the measured value ex-
ceeds the limit. ANNOTATION:
specified value: 1.3 mm {0.0512 in} • Measure the contact width of the valve seat.
Limit: 1.1 mm {0.0433 in} • Repair or replace if the seat contact is dam-
aged or rough, or when the friction of the
contact surface exceeds the limit.
specified value: 2.26 mm {0.0890 in}
Limit: 2.6 mm {0.1024 in}

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Removal and Installation of Cylinder Head

1 45˚
1 90˚
ANNOTATION: 2 50˚

• Measure the contact surface of the valve

seat.
• Repair the seat contact surface if it is defec- CAUTION
tive, or replace the valve, valve guide, and • Eliminate only scratched or uneven
valve seat together as a set. portions, while taking care not to
overcut.
• The valve cutter pilot should not
wobble inside the valve guide.
• Use an adjustable valve cutter pilot.

Removal and Installation of Cylinder Block

84592788 EN - March 2012

CONTENTS

Removal of Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

2425-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

2425-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Cylinder Block

Removal of Cylinder Block 1) Remove the fan shroud from the bracket.

1. Battery ground cable Disconnect ANNOTATION:

1) Disconnect the battery ground cable from the • Remove the fan shroud and fan guard as a
battery. unit.

2. Coolant Drain
1) Drain coolant from the radiator.

CAUTION
• Do not loosen or remove the radia-
tor cap when the coolant is hot.
• Steam and boiling water can burst
out, possibly causing burns or heat
related injuries.
• When opening the radiator cap,
place a thick cloth over the cap
when the coolant is cooled, and
turn it gradually to release the pres-
sure before opening it. 5. Cooling fan belt Removal
1) Remove the cooling fan belt from the pulley.
ANNOTATION:
ANNOTATION:
• Loosen the water drain plug on the rear right
side of the engine, as well as the radiator • Loosen the nuts fastening the bolts.
drain plug. • Loosen the generator adjust bolt to remove
• Completely drain the coolant. the belt.
• After completely draining the coolant, se-
curely tighten the drain plug.
3. Engine oil Drain
1) Drain the engine oil from the oil pan.
ANNOTATION:
• After draining the oil, tighten the drain plug
to the specified torque.
Tightening torque: 78 N・m {8.0 kgf・m / 58
lb・ft} Drain plug
Tightening torque: 70 N・m {7.1 kgf・m / 52
lb・ft} Drain cock

CAUTION
1 Adjust bolt
• Do not forget to tighten ｔhe drain 2 Lock nut
plug or drain cock. 3 Bolt
4 Nut
4. Fan shroud removal
6. Cooling fan Removal
1) Remove the cooling fan from the fan pulley.
ANNOTATION:
• Remove the spacer at the same time.

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Removal and Installation of Cylinder Block

2) Remove the fan pulley from the water pump 3) Remove the nozzle leak off pipe from the in-
assembly. jector.

1 Cooling fan 1 Nozzle leak off pipe

2 Spacer 2 Injector harness connector
3 Fan pulley
4 Bolt CAUTION

7. PCV hose removal • Do not reuse the leak-off pipe clip.

1) Disconnect the PCV hose from the cylinder

head cover.
2) Remove the PCV hose from the engine as-
sembly.
ANNOTATION:
• Remove the clamp.
8. Fuel hose removal
1) Remove the cover from the cylinder head
cover.

1 Clip

9. Cylinder head cover Removal

1) Remove the cylinder head cover from the
cylinder head.

CAUTION
• Do not damage the lip section of the
oil seal with the connector of the
injector.
1 Cover
ANNOTATION:
2) Remove the harness connector from the in- • Shift the head cover to the left side of the
jector. engine and lift upwards to remove.

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Removal and Installation of Cylinder Block

1) Remove the water pipe from the engine as-

sembly.

10. Cam end gasket removal

1) Remove the cam end gasket from the cylinder
head.
ANNOTATION: 1 Water pipe

• Clean any liquid gasket remaining on the

cylinder head. ANNOTATION:
• Because the plastic pipe is easily damaged
during hose removal, do not remove from
the side of the plastic pipe if possible.
13. EGR cooler Removal
1) Remove the EGR cooler from the exhaust
manifold and cylinder head assembly.
ANNOTATION:
• Remove the IN side and OUT side of the
rubber hose for the water pipe and remove
the EGR cooler and gasket.

CAUTION

1 Cam end gasket • Do not hold the water pipe section

when removing the EGR cooler.
11. Generator Removal
1) Disconnect the harness from the generator.
ANNOTATION:
• Disconnect the harness connector and
B-terminal cable.
2) Remove the generator from the generator
bracket.
ANNOTATION:
• Remove the nuts at 2 locations, pull out the
bolts, and remove the generator.
12. Water pipe removal

1 EGR cooler

ANNOTATION:
• Because the plastic pipe is easily damaged
during hose removal, do not remove from
the side of the plastic pipe if possible.
14. Turbocharger assembly Removal
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Removal and Installation of Cylinder Block

1) Remove the return hose from the water pipe. 7) Remove the turbocharger assembly from the
exhaust manifold.

1 Water pipe 1 Turbocharger assembly

2) Remove the water feed pipe from the oil ANNOTATION:

cooler assembly. • Remove both the water feed hose and the
3) Disconnect the oil feed pipe from the tur- water drain hose.
bocharger assembly.
4) Remove the oil feed pipe from the oil cooler CAUTION
assembly.
• Do not hold the actuator rod.

1 Oil feed pipe

5) Disconnect the oil return pipe from the tur-

bocharger assembly.
6) Remove the oil return pipe from the
crankcase.

1 Exhaust manifold
2 Exhaust manifold bracket

ANNOTATION:
• Do not reuse the gasket.
16. Intake throttle valve Removal
1) Disconnect the connector from the intake
throttle valve.
ANNOTATION:
1 Oil return pipe • Pull the red claw to release the lock.
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Removal and Installation of Cylinder Block

2) Remove the intake throttle valve from the inlet 1) Remove the fuel pipe from the fuel supply
manifold. pump and the common rail assembly.
ANNOTATION:
• Remove with the adapter pipe as a unit.
17. Turbocharger control solenoid removal
1) Disconnect the harness connector from the
turbocharger control solenoid.
2) Disconnect the vacuum hose from the tur-
bocharger control solenoid.
3) Remove the turbocharger control solenoid
from the inlet manifold.
ANNOTATION:
• Remove together with the bracket.

1 Fuel pipe

CAUTION
• Do not reuse the fuel pipe.

21. Leak-off pipe removal

1) Remove the fuel leak-off pipe from the fuel
supply pump and common rail assembly.
ANNOTATION:
• Do not reuse the gasket.

1 Turbocharger control solenoid

2 IMT sensor
3 Boost sensor
4 Boost temperature sensor

18. Oil level gauge guide tube Removal

1) Remove the oil level gauge from the oil level
gauge guide tube.
2) Remove the oil level gauge guide tube from
the crankcase.
19. Injector safety information

CAUTION
1 Leak-off pipe, hose
• Including the inside of the injector, the
holes and gaps that are to be used as
the fuel paths for the fuel system have an 22. Injection pipe Removal
extremely precise finish.
• Because there is the possibility of dam-
age due to foreign material contamina-
tion, cover the cap after removing parts,
etc., to prevent the intrusion of foreign
material.

20. Fuel pipe Removal

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Removal and Installation of Cylinder Block

1) Remove the injection pipe from the injector 24. Timing chain upper cover removal
and the common rail assembly.
1) Remove the timing chain upper cover from the
CAUTION cylinder head.

• Do not reuse the injection pipe.

1 Timing chain upper cover

2 Fan shroud bracket
1 Injection pipe
3 Fan shroud stay
2 Clip

23. Timing chain lower cover removal 25. Water intake pipe removal
1) Remove the timing chain lower cover from the 1) Disconnect the water intake pipe from the oil
gear case cover. cooler.

CAUTION
• Do not reuse the gasket or O-ring.

2) Remove the water intake pipe from the cylin-

der block.

1 Timing chain upper cover

2 CMP sensor
3 Timing chain lower cover

1 Water intake pipe

26. Injector Removal

1) Remove the injector from the cylinder head
assembly.
2) Remove the injector gasket from the injector.
3) Remove the O-ring from the injector.

CAUTION
• Do not reuse the clip, injector gas-
ket, or O-ring.

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Removal and Installation of Cylinder Block

28. Glow plug Removal

1) Remove the glow plug from the cylinder head
assembly.

1 Injector
2 Leak-off pipe
3 Clip 29. Baffle plate removal
4 O-ring
1) Install the bolt to the camshaft gear.
5 Injector gasket
ANNOTATION:
• Install the M5 bolt.
CAUTION
• The injector ID code identifies the
injectors.
• Do not remove the injector ID codes
from the injectors.
• Absolutely never touch the injector
solenoids because that can hinder
their performance or cause dam-
age.
• Store the removed injector with the
cylinder number on it.
• When the injector has been re-
placed, erase the ID code of the
replaced cylinder number on the
injector ID code label using a black 2) Remove the baffle plate from the cylinder
pen, etc. head.

1 Baffle plate

1 Injector ID code 30. Camshaft Removal

2 Injector
1) Remove the camshaft bearing cap from the
cylinder head.
27. Glow plug connector removal ANNOTATION:
1) Remove the glow plug connector from the • Confirm that the camshaft bearing cap is
glow plug. marked.
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Removal and Installation of Cylinder Block

• The marking indicates the installation posi- 32. Timing chain lever pivot removal
tion.
1) Remove the timing chain lever pivot from the
timing gear case.

CAUTION
33. Idle gear D removal
• Take necessary measures in ad-
vance so that the inlet side and 1) Remove idle gear D from the gear case cover.
exhaust side do not get mixed up.
ANNOTATION:
2) Remove the camshaft from the cylinder head. • Remove idle gear D together with the
sprocket.

31. Timing chain tensioner removal

1) Remove the timing chain tensioner from the
cylinder head.

1 Bolt
2 Washer
3 Idle gear D
1 Timing chain tensioner 4 Idle gear shaft
2 Gasket
3 Nut 34. Timing chain removal

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Removal and Installation of Cylinder Block

1) Remove the timing chain from the sprocket. 2) Remove the nut from the timing gear case.
ANNOTATION:
• Remove from the supply pump sprocket.
35. Timing chain guide removal
1) Remove the timing chain guide from the cylin-
der head.

1 Nut
2 Bolt

3) Loosen the bolt using a wrench.

ANNOTATION:
36. Rocker arm shaft assembly removal • Loosen and remove the cylinder head bolts
in the order shown in the diagram.
1) Remove the rocker arm shaft assembly from
the cylinder head. CAUTION
ANNOTATION: • Do not reuse the bolt.
• If reusing the rocker arm shaft assembly,
install it to its original position.

4) Remove the cylinder head from the cylinder

block.
ANNOTATION:
Exhaust rocker arm shaft as-
1
sembly • Remove with the inlet manifold.
2 Bolt 38. Cylinder head gasket removal
3 Bolt 1) Remove the cylinder head gasket from the
4 Inlet rocker arm shaft assembly cylinder head.

CAUTION
37. Cylinder head assembly Removal
• Do not reuse the gasket.
1) Remove the bolt from the timing gear case.

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Removal and Installation of Cylinder Block

39. EGR water pipe removal 42. Water pump assembly removal
1) Remove the EGR water pipe from the oil 1) Remove the water pump from the timing gear
cooler. case.
ANNOTATION: ANNOTATION:
• Remove the pipe clip installation bolt. • Remove the water pump installation nut and
bolt.
• Remove the water pump assembly and gas-
ket.

1 EGR water pipe

40. Oil cooler assembly removal 43. Supply pump gear nut removal
1) Remove the oil cooler from the cylinder block. 1) Fasten special tool to flywheel housing.
ANNOTATION:
• Install the crankshaft stopper to the flywheel
housing starter installation section and en-
sure the crankshaft does not rotate.

41. Starter motor removal

1) Disconnect the earth cable from the starter
motor.
2) Disconnect the S-terminal from the starter mo-
tor.
Special tool: crankshaft stopper (refer to
3) Disconnect the B-terminal from the starter mo-
section 1003)
tor.
4) Remove the starter motor from the flywheel CAUTION
housing.
• Verify that the stopper is installed
and securely bites into the ring
gear.

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Removal and Installation of Cylinder Block

2) Turn the nut. 1) Check alignment mark of the supply pump

gear.
ANNOTATION:
• Loosen the nut of the supply pump gear.

2) Remove the supply pump gear from the fuel

supply pump.
ANNOTATION:
1 Supply pump gear nut
• Remove the supply pump gear using a gear
44. Sprocket removal puller.

1) Remove the nut from the sprocket.

2) Remove the sprocket from the supply pump
gear.

46. Fuel supply pump removal

1) Disconnect the harness connector from the
fuel supply pump.

1 Timing chain tension lever pivot ANNOTATION:

2 Sprocket • Disconnect the harness connector of the
3 Nut suction control valve and fuel temperature
sensor.
ANNOTATION:
• After removing the sprocket, move the tim-
ing chain upward.

Fuel temperature sensor con-

1
nector
45. Supply pump gear removal 2 Suction control valve connector
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Removal and Installation of Cylinder Block

2) Remove the supply pump bracket from the 1) Remove the common rail assembly from the
cylinder block. cylinder block.
3) Remove the fuel supply pump from the timing
gear case. ANNOTATION:

ANNOTATION: • Remove the common rail bracket at the

same time.
• When removing the fuel supply pump, do
not hold the high pressure pipe of the pump
instead of the handle.

1 Common rail bracket

2 Common rail

48. Crankshaft pulley Removal

1 Fuel supply pump 1) Remove the crankshaft pulley from the crank-
2 Supply pump bracket shaft.
3 Stud bolt
CAUTION
• Do not reuse the crankshaft pulley
4) Remove the O-ring from the fuel supply pump. bolt or washer.

ANNOTATION:
• When fastening, remove using the removal
bolt hole of the crankshaft pulley.

1 Fuel supply pump

2 O-ring
3 High pressure pipe
1 Removal bolt hole

47. Common rail assembly Removal ANNOTATION:

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Removal and Installation of Cylinder Block

• Remove using a removal bolt with a diame- 50. Gear case cover removal
ter of 5 mm {0.1969 in}, a pitch of 0.8, and a
1) Remove the cover from the gear case cover.
stem length of 20 mm {0.7874 in} or more.

CAUTION
• Take care as removing the pulley
forcibly by not using a removal bolt
may cause the oil seal to break and
fuel to leak.

49. Vacuum pump assembly removal

1) Remove the brackets from the gear case and
the vacuum pump.
ANNOTATION:
• Remove the fan shroud bracket left and fan
shroud stay.
Power steering pump hole
1
cover

2) Remove the gear case cover from the gear

case.

1 Fan shroud bracket (LH)

2 Fan shroud stay

2) Disconnect the vacuum hose from the vac-

uum pump.
3) Remove the oil feed pipe from the vacuum 51. Crank gear removal
pump and cylinder block.
4) Remove the vacuum pump from the gear case 1) Install the bolt to idle gear A.
cover. ANNOTATION:
• Install an M6 bolt to idle gear A and fasten it
while aligning the position of the sub gear.

1 Vacuum hose
2 Oil feed pipe
3 Gear case cover 2) Remove the crank gear from the crankshaft.
4 Vacuum pump 52. Idle gear A Removal

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Removal and Installation of Cylinder Block

1) Remove the idle gear A from the idle gear A • Install bolt 1 in the diagram to the inside
shaft. of timing gear case and bolt 2 from the
crankcase side.
ANNOTATION:
• Remove idle gear A, idle gear A flange, and CAUTION
idle gear A shaft.
• Do not forget to remove the bolt.

2) Remove the gasket from the cylinder block.

55. Flywheel Removal
1) Fasten special tool to flywheel housing.
ANNOTATION:
• Install the crankshaft stopper to the flywheel
housing starter installation section and en-
sure the crankshaft does not rotate.

53. Oil pump assembly Removal

1) Remove the oil pump assembly from the tim-
ing gear case.

Special tool: crankshaft stopper (refer to

section 1003)

CAUTION
• Verify that the stopper is installed
and securely bites into the ring
gear.
54. Timing gear case removal
2) Remove the flywheel from the crankshaft.
1) Remove the timing gear case from the cylin-
ANNOTATION:
der block.
• Gradually loosen the flywheel mounting
bolts in the order shown in the diagram
while making sure that the flywheel does
not rotate.
• Loosen all bolts, then remove the stopper
and the flywheel.

1 Bolt
2 Bolt

ANNOTATION: 56. Flywheel housing Removal

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Removal and Installation of Cylinder Block

1) Remove the flywheel housing from the ANNOTATION:

crankcase.
• Use a slinger puller to remove.
ANNOTATION:
• Loosen the bolt indicated with arrows using
a tool while holding down the nut on the
opposite side.

Special tool: rear oil seal remover (refer

to section 1003)

1 Flywheel housing

57. Oil seal retainer removal

1) Remove the oil seal retainer from the cylinder
block and crankcase.
ANNOTATION:
• Remove the retainer with the oil seal on.

59. Oil pan Removal

1) Remove the oil pan from the crankcase.

58. Crankshaft rear oil seal Removal

1) Remove the crankshaft rear oil seal from the
oil seal retainer.
2) Remove the slinger from the crankshaft using
special tool. 60. Crankcase removal

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Removal and Installation of Cylinder Block

1) Remove the crankcase from the cylinder 3) Clean the cylinder liner using a scraper.
block.
ANNOTATION:
• Remove carbon from the top of the cylinder
bore using a scraper.

1 Crankcase
2 O-ring
4) Remove the piston from the cylinder block.
CAUTION ANNOTATION:
• Do not damage the O-ring. • Pull out the piston and connecting rod to the
cylinder head side.
61. Piston Removal
CAUTION
1) Remove the connecting rod bearing cap from
the connecting rod. • When pushing out the connecting
2) Remove the connecting rod bearing from the rod, be careful not to damage the oil
connecting rod bearing cap. jet or cylinder block.
ANNOTATION:
62. CKP sensor removal
• Organize the removed bearings by the cylin- 1) Disconnect the harness connector from the
ders using tags, etc.
CKP sensor.
2) Remove the CKP sensor from the cylinder
block.

CAUTION
• The CKP sensor is sensitive to
shock, so do not throw or drop it.

1 Pressure limiter
2 Fuel pressure sensor
3 CKP sensor
4 Oil pressure sensor

63. Crankshaft Removal

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Removal and Installation of Cylinder Block

1) Remove the bearing cap bolt from the cylinder CAUTION

block.
ANNOTATION: • Make sure to slightly lift the crank
angle sensor rotor when laying the
• Gradually loosen the bolts in the order of the crankshaft.
numbers indicated in the diagram. • Do not hit nor drop crank angle sen-
sor rotors.
• Do not reuse crank angle sensor ro-
tors that have been hit or dropped.

4) Remove the thrust bearing from the cylinder

block.
5) Remove the crankshaft bearing from the cylin-
der block.
ANNOTATION:
• Remove the crankshaft upper bearing.
• The removed crankshaft upper bearing
should be lined in the order of the number.
64. Oil jet pipe removal
2) Remove the crankshaft bearing from the bear-
ing cap. 1) Remove the oil jet pipe from the cylinder
block.
ANNOTATION:
• Remove the crankshaft lower bearing.
• The removed crankshaft lower bearing
should be lined in the order of the number.
3) Remove the crankshaft from the cylinder
block.

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Removal and Installation of Cylinder Block

Installation of Cylinder Block

1. Oil jet pipe installation
1) Install the oil jet pipe to the cylinder block.
ANNOTATION:
• Align the oil jet pipe knock pin with the cylin-
der block pin hole and tighten the M8 bolt,
M6 bolt, and check valve.
Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft} M8 bolt
Tightening torque: 8 N・m {0.8 kgf・m / 5.90
lbf・ft} M6 bolt
Tightening torque: 30 N・m {3.1 kgf・m / 22 3) Select the crankshaft bearing.
lb・ft} Check valve ANNOTATION:
CAUTION • Carefully consider the inner diameter grade
of the cylinder block journal and the diame-
• Be careful not to deform or damage ter grade of the crankshaft journal when se-
the oil jet nozzle. lecting and installing a new bearing.
• The grade of the crankshaft bearing housing
(1, 2, or 3) is marked on the rear right of the
cylinder block.

2. Crankshaft Installation
1) Install the crankshaft bearing to the cylinder
block.
ANNOTATION: 1 No.1
• Install the crank shaft upper bearing to the 2 No.2
cylinder block. 3 No.3
4 No.4
2) Apply the engine oil to the crankshaft bearing.
5 No.5
ANNOTATION:
• Apply to the crankshaft upper bearing. ANNOTATION:
CAUTION • The crankshaft grade mark is marked on the
side of the crank arm.
• Do not apply oil to the cylinder
block bearing installation surface
or the outer circumference of the
bearing.
• When replacing the crankshaft
bearing, select the grade by refer-
ring to the following.

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Removal and Installation of Cylinder Block

1 No.1
2 No.2
3 No.3
4 No.4
5 No.5

CAUTION
• Be careful not to mistake the bear-
ing shapes when installing.

1 Lot number
2 Size code

Cylinder block journal housing Crank shaft journal

Bearing size code
Grade Inner diameter Grade Outer diameter
： 69.927 to 69.932 mm
1 or - 4
{2.7530 to 2.7532 in}
： 73.992 to 74.000 mm ： 69.922 to 69.927 mm
1 2 or -- 4
{2.9131 to 2.9134 in} {2.7528 to 2.7530 in}
： 69.917 to 69.922 mm
3 or --- 5
{2.7526 to 2.7528 in}
： 69.927 to 69.932 mm
1 or - 2
{2.7530 to 2.7532 in}
： 73.983 to 73.991 mm ： 69.922 to 69.927 mm
2 2 or -- 3
{2.9127 to 2.9130 in} {2.7528 to 2.7530 in}
： 69.917 to 69.922 mm
3 or --- 4
{2.7526 to 2.7528 in}
： 69.927 to 69.932 mm
1 or - 1
{2.7530 to 2.7532 in}
： 73.975 to 73.982 mm ： 69.922 to 69.927 mm
3 2 or -- 2
{2.9124 to 2.9127 in} {2.7528 to 2.7530 in}
： 69.917 to 69.922 mm
3 or --- 2
{2.7526 to 2.7528 in}

4) Apply the engine oil to the crankshaft. 6) Install the thrust bearing to the cylinder block.
ANNOTATION: ANNOTATION:
• Apply to the crankshaft journal section. • Install the thrust bearing to the front side
and rear side of the cylinder block 3 journal
5) Install the crankshaft to the cylinder block.
section.
ANNOTATION: • At this time, it is acceptable to use grease
to adhere the thrust bearing upper to the
• Carefully install the crankshaft. cylinder block.
• However, wipe away any excess grease.
CAUTION
• Install so that the oil groove of the
thrust bearing touches the crank-
shaft.

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Removal and Installation of Cylinder Block

7) Install the crankshaft bearing to the bearing

cap. ANNOTATION:

ANNOTATION: • After temporarily tightening the bolts, tighten

them to the specified torque in the order
• Install the crankshaft lower bearing. shown in the diagram.
Tightening torque: 166 N・m {16.9 kgf・m /
122 lb・ft}
ANNOTATION:
• Check that the crankshaft rotates smoothly
each time you tighten the bearing cap at one
location.

8) Apply engine oil to the bearing cap bolt.

ANNOTATION:
• Apply engine oil to the threaded portion and
seat surface.
9) Install the bearing cap to the cylinder block.

3. CKP sensor installation

1) Install the CKP sensor to the cylinder block.
Tightening torque: 5 N・m {0.5 kgf・m / 3.69
lbf・ft}

ANNOTATION:
• Face the bearing cap arrow to the engine
front side, and install in the order of num-
bers.

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2) Install the connector to the CKP sensor. CAUTION

• Firmly attach the piston installer to
the cylinder block when pushing in
the piston.
• If the adherence is inadequate, the
ring can be damaged when pushed.
• When pushing the piston, be care-
ful not to touch the oil jet against
the connecting rod.
• When inserting the piston and con-
necting rod, push the crank pin in
at the top dead center of each cylin-
der.
• Be careful not to damage the inner
surface of the cylinder block when
inserting the piston.
1 Pressure limiter
2 Fuel pressure sensor
3 CKP sensor
4 Oil pressure sensor

4. Piston Installation
1) Apply the engine oil to the piston.
ANNOTATION:
• Thoroughly apply to the piston side surface.
2) Apply the engine oil to the piston ring.
ANNOTATION:
3) Install the connecting rod bearing to the con-
• Thoroughly apply to the piston ring and ring necting rod bearing cap.
groove. 4) Apply the engine oil to the connecting rod
• Alternately shift the piston ring joint to (1) bearing.
in the diagram for the No.1 ring, (2) for the 5) Install the connecting rod bearing cap to the
No.2 ring, and (3) for the No.3 ring. connecting rod.
• Face the piston front mark towards the front,
and insert the piston into the cylinder block ANNOTATION:
using an installer. • Align the cap and the connecting rod num-
ber markings and install the cap.

6) Apply the engine oil to the bolt.

1 No.1 compression ring
2 No.2 compression ring ANNOTATION:
3 Oil ring • Apply it to the threaded portion of the tight-
4 Expander ening bolts and seat surface.

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7) Tighten the bolt using a torque wrench.

ANNOTATION:
• Tighten the bolt in the order shown in the
diagram.
Tightening torque: 29.4 N・m {3.0 kgf・m /
22 lb・ft}
8) Tighten the bolt using special tool.
ANNOTATION:
• Tighten at the specified angle in the order
shown in the diagram.

5. Crankcase installation
1) Apply the engine oil to the O-ring.
2) Install the O-ring to the crankcase.

Special tool: angle gauge (refer to section

1003)
specified angle: 45 °

1 Crankcase
2 O-ring

3) Apply the liquid gasket to the crankcase.

ANNOTATION:
• As shown in the diagram, apply ThreeBond
1207B or equivalent liquid gasket.

CAUTION
CAUTION
• Apply the appropriate amount of
• Perform tightening of the connect- liquid gasket so that it does not
ing rod bearing cap at the lower protrude into the oil path indicated
dead center of each cylinder. with arrows.
ANNOTATION:
• Confirm that the crankshaft turns smoothly.

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Removal and Installation of Cylinder Block

2.0 - 3.0 mm {0.0787 - 0.1181

1
in}
4.0 - 5.0 mm {0.1575 - 0.1969
2
in}

4) Install the crankcase to the cylinder block.

CAUTION
• Install within five minutes of apply-
ing liquid gasket.

Tightening torque: 25 N・m {2.5 kgf・m / 18 lb・ft}

6. Oil pan Installation
8. Crankshaft rear oil seal Installation
1) Install the oil pan to the crankcase.
Tightening torque: 25 N・m {2.5 kgf・m / 18 1) Install the slinger to the oil seal.
lb・ft}
ANNOTATION:
• Use a rear oil seal installer.

7. Oil seal retainer installation

1) Install the oil seal retainer to the crankcase. Special tool: oil seal installer kit (refer to
ANNOTATION: section 1003)
2) Install the crankshaft rear oil seal to the
• As shown in the diagram, apply ThreeBond adapter.
1207B or equivalent liquid gasket,assemble
within five minutes, and tighten to the spec- ANNOTATION:
ified torque. • Assemble and firmly fit the slinger and rear
Tightening torque: 25 N・m {2.5 kgf・m / 18 oil seal.
lb・ft}
CAUTION
• Do not reuse the crankshaft rear oil
seal.

1 2 - 2.5 mm {0.0787 - 0.0984 in}

2 2 - 2.5 mm {0.0787 - 0.0984 in}

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Removal and Installation of Cylinder Block

1 Crankshaft • Install the flywheel housing and tighten to

2 Slinger the specified torque.
3 Crankshaft rear oil seal • Loosen Bolt 4 using a tool while holding
4 Sleeve down the nut on the opposite side.
5 Adapter Tightening torque: 51 N・m {5.2 kgf・m / 38
Bolt, M12 x 1.75, L=55 mm lb・ft} Bolt 1
6
{2.1654 in} Tightening torque: 82 N・m {8.4 kgf・m / 60
7 Bolt lb・ft} Bolt 2
Tightening torque: 97 N・m {9.9 kgf・m / 72
lb・ft} Bolt 3
ANNOTATION: Tightening torque: 51 N・m {5.2 kgf・m / 38
• Insert the oil seal and slinger to the outer lb・ft} Bolt 4
periphery of the adapter.
3) Install the adapter to the crankshaft.
ANNOTATION:
• Install the adapter to the rear end section of
the crankshaft.
4) Install the sleeve to the adapter.
ANNOTATION:
• Insert the sleeve into the adapter section
and tighten the adapter using an M12 x 1.75,
L=55mm {2.1654 in} bolt until it touches the
sleeve.
• After installing the oil seal, confirm that the
length from the end surface of the crank- 10. Flywheel Installation
shaft to the end surface of the oil seal is 1) Apply the engine oil to the bolt.
within the specified range.
ANNOTATION:
specified value: 12.2 - 12.8 mm {0.4803 -
0.5039 in} • Apply to the threaded portion.
2) Install the flywheel to the crankshaft.
ANNOTATION:
• Install a washer and bolt to the flywheel.
3) Install special tool to flywheel housing.

Length from the end surface of

1 the crankshaft to the end sur-
face of the oil seal
2 Oil seal end surface
3 End surface of the crankshaft
Special tool: crankshaft stopper (refer to
section 1003)
9. Flywheel housing Installation
ANNOTATION:
1) Install the flywheel housing to the crankcase.
• Install the crankshaft stopper to the flywheel
ANNOTATION: housing starter installation section.

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Removal and Installation of Cylinder Block

4) Tighten the bolt using a torque wrench. • Apply ThreeBond 1207B to the area indi-
cated in the diagram.
ANNOTATION:
• Install the gasket to the cylinder block.
• Tighten to the specified torque in the order
shown in the diagram.
Tightening torque: 59 N・m {6.0 kgf・m / 44
lb・ft}

1 Liquid gasket application area

5) Tighten the bolt using special tool. 3) Install the timing gear case to the cylinder
block.
ANNOTATION:
ANNOTATION:
• Use an angle gauge to tighten in the order
shown in the diagram. • Align the positions of the dowel pin and bolt
and install the timing gear case.

CAUTION
• Be careful not to forget the tighten-
ing the bolt indicated by the arrow.

Special tool: angle gauge (refer to section

1003)
specified angle: 60 - 90 °

1 Timing gear case

2 Bolt L = 16 mm {0.6299 in}
3 Bolt L = 20 mm {0.7874 in}
4 Bolt L = 35 mm {1.3780 in}
5 Bolt L = 45 mm {1.7717 in}
6 Bolt L = 60 mm {2.3622 in}

Tightening torque: 25 N・m {2.5 kgf・m / 18

lb・ft}
11. Timing gear case installation 12. Oil pump assembly Installation
1) Apply liquid gasket to the gasket. 1) Install the oil pump assembly to the timing
2) Apply the liquid gasket to the cylinder block. gear case.
ANNOTATION: ANNOTATION:

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Removal and Installation of Cylinder Block

• Apply engine oil to the pump gear and pump

case and tighten to the specified torque.
Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft}

ANNOTATION:
• Verify that the pump gear rotates smoothly.
13. Idle gear A Installation
1) Install idle gear A to idle gear A shaft.
ANNOTATION:
• Align the cylinder body side oil hole and the
idle gear A shaft oil hole to install.
• Install the flange with the front mark facing
up and towards you. 14. Crank gear installation
1) Install the crank gear to the crankshaft.
ANNOTATION:
• Install by aligning with the alignment mark
for the idle gear.
2) Remove the bolt from idle gear A.
ANNOTATION:
• Remove the M6 sub gear fixing bolt from idle
gear A.

1 Front mark
2 Cylinder body side oil hole
3 Idle gear shaft oil hole

ANNOTATION:
• Install by aligning with the alignment mark
for the idle gear.
• Apply engine oil to the tooth surface of the
idle gear.
• Apply oil to the threaded portion of the bolt
and seat surface and temporarily tighten. 1 M6 bolt for sub gear fixing

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Removal and Installation of Cylinder Block

15. Idle gear installation 17. Vacuum pump assembly installation

1) Install idle gear A to idle gear A shaft. 1) Install the vacuum pump to the gear case
Tightening torque: 32 N・m {3.3 kgf・m / 24 cover.
lb・ft}
CAUTION
• Apply engine oil to the O-ring.

2) Remove the brackets from the gear case and

the vacuum pump.
ANNOTATION:
• Install the fan shroud bracket left and fan
shroud stay.
Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft}

1 Idle gear A bolt

16. Gear case cover installation

1) Apply liquid gasket to the timing gear case.
ANNOTATION:
• Apply liquid gasket, ThreeBond 1207B to
the area shown in the diagram.

1 Fan shroud bracket (LH)

2 Fan shroud stay

3) Install the oil feed pipe to the vacuum pump

and cylinder block.
Tightening torque: 12 N・m {1.2 kgf・m / 8.85
lbf・ft}
4) Connect the vacuum hose to the vacuum
pump.

1 Liquid gasket application area

2) Install the gasket to the gear case cover.

3) Install the gear case cover to the timing gear
case.
Tightening torque: 8 N・m {0.8 kgf・m / 5.90
lbf・ft}

1 Vacuum hose
2 Oil feed pipe
3 Gear case cover
4 Vacuum pump

18. Crankshaft pulley Installation

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Removal and Installation of Cylinder Block

CAUTION
• Do not reuse the crankshaft pulley bolt
or washer.

1) Apply the engine oil to the bolt.

ANNOTATION:
• Apply engine oil to the threaded portion and
seat surface of the bolt.
2) Install the crankshaft pulley to the crankshaft.
ANNOTATION:
• Tighten at the specified torque in the order
of the numbers in the diagram.
Tightening torque: 30 N・m {3.1 kgf・m / 22 1 Common rail bracket
lb・ft} 2 Common rail assembly
3) Tighten the bolt using special tool.
specified angle: 180 °
ANNOTATION: ANNOTATION:

• Tighten again at the specified angle in the • Tighten bolts in the order shown in the dia-
order shown in the diagram. gram.
specified angle: 60 °

CAUTION
• The total rotational angle for the
2nd and 3rd times will be between
240˚ and 270˚.

Tightening torque: 25 N・m {2.5 kgf・m / 18

lb・ft}
20. Fuel supply pump installation
1) Install the O-ring to the fuel supply pump.
ANNOTATION:
• Apply soapy water to the O-ring and install
19. Common rail assembly Installation the O-ring to the supply pump.
1) Install the common rail assembly to the cylin- 2) Install the fuel supply pump to the timing gear
der block. case.

CAUTION CAUTION
• When installing the common rail as- • When installing the fuel supply
sembly, do not clutch and raise up pump, do not hold the high pres-
the pressure sensor. sure pipe of the pump as a handle.
• Take care not to damage the con- • Ensure the O-ring does not pro-
nector unit of the pressure sensor. trude.

ANNOTATION: ANNOTATION:
• Install the common rail bracket at the same • Confirm that the supply pump camshaft key
time. is at a horizontal position on the right side.

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7) Connect the harness connector to the fuel

supply pump.
ANNOTATION:
• Connect the harness connector of the suc-
tion control valve and fuel temperature sen-
sor.

Tightening torque: 25 N・m {2.5 kgf・m / 18

lb・ft}
3) Temporarily tighten the supply pump bracket
to the gear case.
4) Temporarily tighten the supply pump bracket
to the cylinder block.
5) Securely tighten the supply pump bracket to
the gear case.
Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft} Fuel temperature sensor con-
1
6) Securely tighten the supply pump bracket to nector
the cylinder block. 2 Suction control valve
Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft} 21. Supply pump gear installation
1) Install the supply pump gear to the fuel supply
pump.
ANNOTATION:
• Install by aligning with the alignment mark
for the idle gear.

1 Fuel supply pump

2 Supply pump bracket
3 Stud bolt

22. Sprocket installation

1) Install the sprocket to the supply pump gear.
ANNOTATION:
• Align the alignment mark of the supply pump
sprocket and the yellow plate of the timing
chain.
• Align the dowel pin of the supply pump gear
and the notch of the supply pump sprocket,
and install the supply pump sprocket.

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Removal and Installation of Cylinder Block

2) Turn the nut.

ANNOTATION:
• Tighten the supply pump shaft nut with your
hand.

1 Alignment mark

24. Leak-off pipe installation

1) Install the fuel leak-off pipe to the fuel supply
pump and common rail assembly.
1 Idle gear alignment mark ANNOTATION:
2 Blue plate
3 Sprocket alignment mark • Also install the hose at the same time.
4 Yellow plate CAUTION
• Do not reuse the gasket.
23. Supply pump gear nut installation
1) Securely tighten the nut to the sprocket.
ANNOTATION:
• Tighten the supply pump shaft nut to the
specified torque.
Tightening torque: 130 N・m {13.3 kgf・m /
96 lb・ft}

1 Leak-off pipe, hose

Tightening torque: 10.3 N・m {1.1 kgf・m /

7.598 lbf・ft} Eyebolt
25. Fuel pipe Installation
1) Temporarily tighten the fuel pipe to the com-
mon rail assembly.
1 Supply pump shaft nut CAUTION
• Do not reuse the fuel pipe.
2) Turn the crankshaft pulley.
ANNOTATION: 2) Temporarily tighten the fuel pipe to the fuel
supply pump.
• Turn the crankshaft pulley 720º to make the 3) Securely tighten the fuel pipe to the common
chain tension even. rail assembly.
• Align the alignment marks of the camshaft Tightening torque: 44 N・m {4.5 kgf・m / 32
and the camshaft bearing cap. lb・ft} Sleeve nut

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4) Temporarily tighten the fuel pipe to the fuel • Only the tightening torque of bolt 1 in the
supply pump. diagram is different.
Tightening torque: 44 N・m {4.5 kgf・m / 32
lb・ft} Sleeve nut

1 Bolt
1 Fuel pipe
28. Starter motor installation
26. Water pump assembly installation 1) Install the starter motor to the flywheel hous-
ing.
1) Install the water pump to the timing gear case.
ANNOTATION:
ANNOTATION:
• Install the earth cable at the same time.
• Install a new gasket by aligning with the front
cover stud. Tightening torque: 97 N・m {9.9 kgf・m / 72
• Install the water pump by aligning with the lb・ft}
front cover stud.
• Tighten the installation bolt and nut to their
specified torque.
Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft}

2) Connect the S-terminal to the starter motor.

3) Connect the B-terminal to the starter motor.
29. Cylinder head gasket preparation
1) Select the cylinder head gasket.
ANNOTATION:
27. Oil cooler assembly installation
1) Install the oil cooler to the cylinder block. • Select the grade for the cylinder head gas-
ket by measuring the protrusion amount of
CAUTION the piston head.
• Remove the water deposit on the top sur-
• Do not reuse the gasket. face of the cylinder block, and the carbon
from the piston head.
Tightening torque: 27 N・m {2.8 kgf・m / 20
2) Measure the piston using a dial gauge.
lb・ft} Bolt 1 in the diagram
Tightening torque: 25 N・m {2.5 kgf・m / 18 ANNOTATION:
lb・ft} Other than the above
• Measure the protruding amount of piston
ANNOTATION: head.

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Removal and Installation of Cylinder Block

1 Measurement location
2 Measurement location
3 Measurement location
4 Measurement location

3) Calculate the average value from the mea-

sured value.
ANNOTATION:
• Select the required grade of cylinder head
gasket using the average measured value.

Protrusion
CAUTION Gasket Gasket thick-
amount of the
grade ness
• Make sure that the measuring point piston
is as close to the cylinder block as ： 0.087 to 0.117
： 0.95 mm
possible. A mm {0.0034 to
{0.0374 in}
• The difference in protrusion 0.0046 in}
amounts between pistons should ： 0.117 to 0.167
： 1.00 mm
not exceed the specified value. B mm {0.0046 to
{0.0394 in}
• Disassemble and reassemble if the 0.0066 in}
protrusion amount of each piston ： 0.167 to 0.217
is outside of the specified value ： 1.05 mm
C mm {0.0066 to
range. {0.0413 in}
0.0085 in}

specified value: 0.05 mm {0.0020 in} or less

1 Gasket A
1 Measurement location 2 Gasket B
2 Measurement location 3 Gasket C
3 Measurement location 4 Grade identification location
4 Measurement location

30. Cylinder head gasket installation

1) Install the dowel pin to the cylinder block.
ANNOTATION:
• Install only when the dowel pin has been
removed from the cylinder block.
2) Apply the liquid gasket to the cylinder block.
ANNOTATION:
• As shown in the diagram, apply ThreeBond
1207B to the aligning surface of the gear
case.
• Use the same grade for the gear case gas-
ket as the cylinder head gasket.
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Removal and Installation of Cylinder Block

3) Install the cylinder head gasket to the cylinder

block.

CAUTION
• Install the cylinder head gasket and
gear case gasket within five min-
utes of applying liquid gasket.

Special tool: angle gauge (refer to section

1003)
Tightening torque: 70 N・m {7.1 kgf・m / 52
lb・ft} 1st time
Tightening torque: 70 N・m {7.1 kgf・m / 52
lb・ft} 2nd time
specified angle: 60 - 75 ° 3rd time
specified angle: 60 - 75 ° 4th time

1 2 - 3 mm {0.0787 - 0.1181 in}

2 3 - 4 mm {0.1181 - 0.1575 in}

31. Cylinder head assembly Installation

1) Install the cylinder head assembly to the cylin-
der block.
ANNOTATION:
• Gently place the cylinder head while align-
ing with the cylinder block dowel.

CAUTION
3) Install the bolt to the timing gear case.
• When installing, be careful not to 4) Install the nut to the timing gear case.
damage the cylinder head gasket.
ANNOTATION:
2) Apply engine oil to the head bolt. • Tighten at the specified torque in the order
of the numbers in the diagram.
CAUTION
Tightening torque: 25 N・m {2.5 kgf・m / 18
• Use a new head bolt. lb・ft}
ANNOTATION:
• Apply engine oil to the threaded portion of
the head bolt and seat surface.
• Tighten the head bolts in the order shown
in the diagram using a torque wrench and
angle gauge.

32. Rocker arm shaft assembly installation

1) Apply the engine oil to the bolt.

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Removal and Installation of Cylinder Block

Compression top dead center

Exhaust rocker arm shaft as- 1
1 alignment position
sembly
2 Inlet rocker arm shaft assembly
2) Install the timing chain to the sprocket.
33. Timing chain guide installation 35. Idle gear D installation
1) Install the timing chain guide to the cylinder 1) Apply engine oil to the shaft.
head.
Tightening torque: 25 N・m {2.5 kgf・m / 18 ANNOTATION:
lb・ft}
• Apply to the front and inner surfaces of the
shaft, as well as to the threaded portion and
seat surface of the bolt.
2) Install idle gear D to the cylinder head.
Tightening torque: 59 N・m {6.0 kgf・m / 44
lb・ft}

ANNOTATION:
• Install the timing chain tension lever.
34. Timing chain installation

Shaft front surface and inner

1
surface
Threaded portion of the bolt
2
and seat surface.

ANNOTATION:
• Align the two timing alignment marks as in-
dicated in the diagram.
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Removal and Installation of Cylinder Block

1) Connect the hook to the pin.

ANNOTATION:
• Push down the latch of the timing chain
tensioner, insert the plunger, and hang the
hook to the pin.

1 Timing mark
2 Alignment mark
3 Plate, blue
4 Plate, yellow

36. Timing chain lever pivot installation

CAUTION
• Do not reuse the gasket.

Tightening torque: 10 N・m {1.0 kgf・m / 7.38

lbf・ft}

37. Timing chain tensioner installation

1 Timing chain tensioner

2 Gasket
3 Nut

CAUTION
• Turn the protruding section of the
gasket downward to install.

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Removal and Installation of Cylinder Block

3) Disconnect the hook from the pin.

ANNOTATION:
• Lightly push the area indicated with an ar-
row in the diagram.
• The hook of the tensioner opens, the
plunger pushes the tension lever, and the
chain is pulled.

ANNOTATION:
• Confirm that the alignment marks of the
camshaft bearing cap and the camshaft are
aligned.

38. Camshaft Installation

1 Alignment mark

4) Apply the engine oil to the bolt.

1 Exhaust camshaft gear

2 Inlet camshaft gear
3 Idle gear D

3) Install the camshaft bearing cap to the cylinder

head.
ANNOTATION:
• Apply engine oil to the journal section of the
cylinder head.
• Face the bearing cap front mark to the en- 5) Remove the bolt from the camshaft gear.
gine front side, and assemble in numbered
order to the cylinder head. ANNOTATION:
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Removal and Installation of Cylinder Block

• Remove the M5 bolt of the camshaft gear.

Special tool: valve clearance adjust nut

wrench (refer to section 1003)
ANNOTATION:
ANNOTATION:
• After rotating the crankshaft 720˚, the marks
on the collared end of the crankshaft and • Use the adjust nut wrench to loosen each
that of the bearing cap should align. adjust screw of the rocker arm.

1 Exhaust camshaft gear 1 Driver

2 Inlet camshaft gear 2 Ring spanner
3 Idle gear D 3 Adjust nut wrench

39. Baffle plate installation 2) Align 1st cylinder to the compression top dead
center.
1) Install the baffle plate to the cylinder head.
Tightening torque: 10 N・m {1.0 kgf・m / 7.38 ANNOTATION:
lbf・ft} • Rotate the crankshaft in the forward direc-
tion to align the No.1 cylinder piston to com-
pression top dead center.

1 Baffle plate

40. Rocker arm adjustment Compression top dead center

1
1) Loosen the adjust screw using special tool. alignment position
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Removal and Installation of Cylinder Block

3) Adjust the valve clearance to specified value 5) Adjust the valve clearance to specified value
using a feeler gauge. using a feeler gauge.
ANNOTATION: ANNOTATION:
• Insert a feeler gauge between the rocker • Insert a feeler gauge between the rocker
arm roller and cam and tighten the rocker arm roller and cam and tighten the rocker
arm adjust screw. arm adjust screw.
• Adjust the valve clearance if a circle is
specified value: 0.15 mm {0.0059 in} marked on the diagram when the No.1
4) Align the No.4 cylinder to compression top cylinder is at the compression top dead
dead center. center, or when an X is marked on the
ANNOTATION: diagram when the No.4 cylinder is at the
compression top dead center.
• Rotate the crankshaft 360˚ from compres-
sion top dead center of the No.1 cylinder
and align the No.4 cylinder to compression
top dead center.

Valve ar-
Inlet Exhaust Inlet Exhaust Inlet Exhaust Inlet Exhaust
rangement
No.1 cylinder
compression ○ ○ ○ ○
top dead cen-
ter
No.4 cylinder
compression × × × ×
top dead cen-
ter

specified value: 0.15 mm {0.0059 in} 41. Glow plug Installation

CAUTION 1) Install the glow plug to the cylinder head as-

sembly.
• Make sure to adjust while cool. Tightening torque: 18 N・m {1.8 kgf・m / 13
lb・ft}
6) Tighten the bolt using special tool.
CAUTION
ANNOTATION:
• Do not exceed specifications when
• When the movement of the thickness gauge tightening as over-tightening may
becomes stiff, secure the adjust screw nut result in breakage.
of the rocker arm.
Tightening torque: 18 N・m {1.8 kgf・m / 13
lb・ft}

42. Glow plug connector installation

1) Install the glow plug connector to the glow
plug.
1 Cam: exhaust side
2 Cam: intake side ANNOTATION:
3 Roller: intake side • Install the glow plug connector to the glow
4 Roller: exhaust side plugs of the No.1, No.3 and No.4 cylinders.
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Removal and Installation of Cylinder Block

CAUTION 1 Injector
2 Injector clamp bolt
• Install the glow plug connector so 3 Injector clamp
that there is no interference with the
cylinder head.
CAUTION
Tightening torque: 1.8 N・m {0.2 kgf・m /
• Do not reuse the clip, injector gas-
1.328 lbf・ft} ket, or O-ring.
43. Injector Installation
4) Temporarily tighten the injector to the cylinder
1) Install the injector gasket to the injector. head.
ANNOTATION: ANNOTATION:
• Push in until your hand stops. • Install and temporarily tighten the injector,
• Do not forcibly push the injector gasket in as injector clamp, and clamp bolt to the cylinder
it will be pushed in to the end during clamp head.
tightening.
• When installing the injector to the cylinder
2) Install the O-ring to the injector. head, confirm that the injector gasket is in-
stalled to the injector.
ANNOTATION:
CAUTION
• When installing the O-ring, be careful not to
cause damage by applying engine oil to it. • If the injector has been replaced,
record the injector ID code of the
new injector.
• Record the 24 figures of the injector
ID plate.

1 Injector
2 Leak-off pipe
3 Clip
4 O-ring
5 Injector gasket 1 Injector ID code
2 Injector
3) Install the clamp to the injector.
44. Injection pipe Installation
ANNOTATION:
• Apply engine oil to the threaded portion and CAUTION
seat surface of the injector clamp bolt. • If the high pressure pipe of the fuel sys-
tem has been removed, make sure to re-
place with a new part.
• Reuse may cause the seal surface to be
damaged and fuel to leak.

1) Temporarily tighten the injection pipe to the

injector and common rail assembly.
ANNOTATION:
• Apply engine oil to the threaded portion of
the sleeve nut on the injector side of the
injection pipe and the O-ring of the injector.
• When installing, do not damage the injector
sleeve gasket.
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Removal and Installation of Cylinder Block

• Using an open-end wrench, lightly tighten

the sleeve nut on the common rail side until
it is firmly attached.
• Tighten the sleeve nuts on the injector side
until they can no longer be turned by hand.
2) Securely tighten the injector to the cylinder
head.
ANNOTATION:
• Tighten the injector clamp bolt to the speci-
fied torque.
Tightening torque: 26 N・m {2.7 kgf・m / 19
lb・ft}
3) Securely tighten the injection pipe to the injec-
tor. 1 Liquid gasket
2 2 - 2.5 mm {0.0787 - 0.0984 in}
ANNOTATION:
3 2 - 2.5 mm {0.0787 - 0.0984 in}
• Tighten the sleeve nut on the injector side
of the injection pipe to the specified torque. 2) Install the timing chain upper cover to the
Tightening torque: 30 N・m {3.1 kgf・m / 22 cylinder head.
lb・ft} ANNOTATION:
4) Securely tighten the injection pipe to the com-
mon rail assembly. • Apply Loctite 262 to the threaded portion on
the cylinder head side.
ANNOTATION:
Tightening torque: 25 N・m {2.5 kgf・m / 18
• Tighten the sleeve nut on the common rail lb・ft}
side of the injection pipe to the specified
torque.
Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft}
Tightening torque: 7.8 N・m {0.8 kgf・m /
5.754 lbf・ft} Clamp nut

1 Timing chain upper cover

2 Fan shroud bracket
3 Fan shroud stay

46. Timing chain lower cover installation

1 Injection pipe 1) Apply liquid gasket to the timing chain lower

cover.
2 Clamp
ANNOTATION:
45. Timing chain upper cover installation • Apply ThreeBond 1207B.
1) Apply liquid gasket to the timing chain upper CAUTION
cover.
• Install the cover within five minutes
ANNOTATION: of applying liquid gasket.
• Apply ThreeBond 1207B.
CAUTION
• Install the cover within five minutes
of applying liquid gasket.

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Removal and Installation of Cylinder Block

1) Install the turbocharger control solenoid to the

inlet manifold.
ANNOTATION:
• Install the bracket together with the tur-
bocharger assembly control solenoid.
Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft} Bolt
Tightening torque: 15 N・m {1.5 kgf・m / 11
lb・ft} Nut
2) Connect the vacuum hose to the turbocharger
control solenoid.

CAUTION
• Insert the hose until it stops.
1 Liquid gasket
2 2 - 2.5 mm {0.0787 - 0.0984 in} 3) Connect the harness connector to the tur-
3 2 - 2.5 mm {0.0787 - 0.0984 in} bocharger control solenoid.

CAUTION
2) Install the timing chain lower cover to the gear • Install the harness and hose clip to
case cover. their original locations.
Tightening torque: 10 N・m {1.0 kgf・m / 7.38
lbf・ft}

1 Turbocharger control solenoid

2 IMT sensor
3 Boost sensor
1 Timing chain upper cover
4 Boost temperature sensor
2 CMP sensor
3 Timing chain lower cover 49. Intake throttle valve Installation
1) Install the gasket to the inlet manifold.
2) Install the intake throttle valve to the inlet man-
47. Oil level gauge guide tube Installation ifold.
1) Apply the engine oil to the O-ring. ANNOTATION:
2) Install the oil level gauge guide tube to the
crankcase. • Install with the adapter pipe as a unit.
Tightening torque: 25 N・m {2.5 kgf・m / 18
Tightening torque: 10 N・m {1.0 kgf・m / 7.38
lb・ft} Oil cooler side
lbf・ft}
Tightening torque: 51 N・m {5.2 kgf・m / 38
3) Connect the harness connector to the intake
lb・ft} Cylinder head side
throttle valve.
3) Install the oil level gauge to the oil level gauge
guide tube. ANNOTATION:
48. Turbocharger control solenoid installation • Press the red claw to lock.

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Removal and Installation of Cylinder Block

50. Water intake pipe installation • Assemble so that the gasket ear portion is
on the engine rear side.
1) Install the O-ring to the water intake pipe.
ANNOTATION:
• Apply soapy water to the O-ring.
2) Install the water intake pipe to the cylinder
block.

CAUTION
• Be careful so as not to pinch the
O-ring during installation.

1 Gasket ear portion

ANNOTATION:
• Assemble the washer and nut as indicated
in the diagram and temporarily tighten.

1 Water intake pipe

Tightening torque: 25 N・m {2.5 kgf・m / 18

lb・ft}

CAUTION
• Assembling the oil cooler and water
inlet pipe with their installation sur-
faces tilted will cause the coolant to
leak.
1 Stud
2 Washer
3 Nut

ANNOTATION:
• Tighten to the specified torque in the order
shown in the diagram.
Tightening torque: 52 N・m {5.3 kgf・m / 38
lb・ft}

1 Water bypass pipe

2 Gasket
3 Oil cooler

51. Exhaust manifold Installation

1) Install the exhaust manifold to the cylinder
head.
ANNOTATION:
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Removal and Installation of Cylinder Block

2) Install the exhaust manifold bracket to the ex- 3) Connect the water feed pipe to the tur-
haust manifold and the oil cooler assembly. bocharger assembly.
Tightening torque: 27 N・m {2.8 kgf・m / 20 Tightening torque: 35 N・m {3.6 kgf・m / 26
lb・ft} lb・ft}
4) Install the oil feed pipe to the oil cooler assem-
bly.
5) Connect the oil feed pipe to the turbocharger
assembly.
Tightening torque: 23 N・m {2.3 kgf・m / 17
lb・ft} Eyebolt

1 Exhaust manifold
2 Exhaust manifold bracket

52. Turbocharger assembly Installation

1) Install the turbocharger assembly to the ex-
haust manifold.
1 Oil feed pipe
Tightening torque: 35 N・m {3.6 kgf・m / 26
lb・ft}
6) Install the oil return pipe to the crankcase.
CAUTION Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft}
• Do not hold the actuator rod. 7) Connect the oil return pipe to the turbocharger
assembly.
ANNOTATION: Tightening torque: 10 N・m {1.0 kgf・m / 7.38
• Fill with 0.5 cc of engine oil from the fuel lbf・ft}
filler.

1 Oil return pipe

1 Turbocharger assembly
8) Connect the vacuum hose to the turbocharger
2) Install the water feed pipe to the oil cooler.
assembly.
Tightening torque: 41 N・m {4.2 kgf・m / 30
lb・ft} 53. EGR water pipe installation

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Removal and Installation of Cylinder Block

1) Install the EGR water pipe to the oil cooler. 2) Securely tighten the EGR cooler to the ex-
haust manifold and cylinder head assembly.
ANNOTATION:
• Install the pipe clip installation bolt. ANNOTATION:

Tightening torque: 10 N・m {1.0 kgf・m / 7.38 • Securely tighten them to the specified
lbf・ft} torque in the order of the numbers shown
in the diagram.
Tightening torque: 27 N・m {2.8 kgf・m / 20
lb・ft}

1 EGR water pipe

54. EGR cooler Installation

55. Water pipe installation
1) Temporarily tighten the EGR cooler to the ex-
haust manifold and cylinder head assembly. 1) Install the water pipe to the engine assembly.
Tightening torque: 25 N・m {2.5 kgf・m / 18
ANNOTATION: lb・ft} M8 bolt
• Install the gasket and EGR cooler, and tem- Tightening torque: 10 N・m {1.0 kgf・m / 7.38
porarily tighten them in the order specified lbf・ft} M6
in the diagram.

1 M8 bolt
ANNOTATION:
56. Generator Installation
• Do not hold the water pipe section when
installing the EGR cooler. 1) Install the generator to the generator bracket.
ANNOTATION:
• Install the generator to the bracket and ad-
just plate, and temporarily tighten the instal-
lation nut.

CAUTION
• Tighten the generator after adjust-
ing the work belt.

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Removal and Installation of Cylinder Block

2) Connect the harness to the generator. 3.0 - 5.0 mm {0.1181 - 0.1969

1
in}
ANNOTATION:
3.0 - 5.0 mm {0.1181 - 0.1969
2
• Connect the harness connector and B-ter- in}
minal cable.
57. PCV hose installation 59. Cylinder head cover Installation
1) Install the PCV hose to the engine assembly. 1) Install the cylinder head cover to the cylinder
Tightening torque: 25 N・m {2.5 kgf・m / 18 head.
lb・ft} Clamp Tightening torque: 10 N・m {1.0 kgf・m / 7.38
lbf・ft}
58. Cam end gasket installation 2) Connect the PCV hose to the cylinder head
1) Install the cam end gasket to the cylinder cover.
head. 60. Fuel hose installation
ANNOTATION: 1) Install the nozzle leak off pipe to the injector.
• Apply liquid gasket, ThreeBond 1207B to ANNOTATION:
the area 2 indicated in the diagram with a
width of 2.0 - 3.0 mm {0.0787 - 0.1181 in} • If the nozzle leak off hose has been re-
and install to the cylinder head. moved, install with the clip knob facing the
exhaust side as shown in the diagram.

1 Cam end gasket 2) Connect the harness connector to the injector.

2 Liquid gasket application area
3 Bead width

ANNOTATION:
• Apply liquid gasket, ThreeBond 1207B as
shown in the diagram.

1 Nozzle leak off pipe

2 Injector harness

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Removal and Installation of Cylinder Block

3) Install the cover to the cylinder head cover. 63. Fan shroud installation
1) Install the fan shroud to the bracket.
ANNOTATION:
• Install the fan shroud and fan guard.
Tightening torque: 51 N・m {5.2 kgf・m / 38
lb・ft}

1 Cover

61. Cooling fan Installation

1) Install the fan pulley to the water pump assem-
bly.
Tightening torque: 10 N・m {1.0 kgf・m / 7.38
lbf・ft} 64. Cooling fan belt Adjustment
2) Install the cooling fan belt to the fan pulley.
1) Adjust the cooling fan belt.
ANNOTATION:
ANNOTATION:
• Install the spacer at the same time.
• Loosen the adjust plate lock bolt and the
Tightening torque: 25 N・m {2.5 kgf・m / 18 mounting bolt at the bottom side of the gen-
lb・ft} erator.
• Turn the adjust bolt to adjust the belt.
• Press the specified position on the belt with
the specified load to inspect the amount of
belt flex.
load: 98 N {10 kg / 22 lb}

Amount of deflection
： 4.2 to 5.0 mm {0.1654 to
New
0.1969 in}
When adjusting ： 6.6 to 7.4 mm {0.2598 to
the tension 0.2913 in}

ANNOTATION:
1 Cooling fan • Verify whether precise tension has been set
2 Spacer using a sonic tension meter.
3 Fan pulley
4 Bolt Frequency of vibrations
New ： 220 to 244 Hz
62. Fan shroud installation When adjusting
： 182 to 206 Hz
1) Install the fan shroud to the bracket. the tension

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Removal and Installation of Cylinder Block

67. Fuel Air bleed

2445-2 PRINTED IN FRANCE
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Lubrication System

Removal and Installation of Oil 1) Remove the fan shroud from the bracket.
Pan and Crank Case ANNOTATION:
• Remove the fan shroud and fan guard as a
Removal of Oil Pan and Crank Case unit.
1. Battery ground cable Disconnect
1) Disconnect the battery ground cable from the
battery.
2. Coolant Drain
1) Drain coolant from the radiator.

CAUTION
• Do not loosen or remove the radia-
tor cap when the coolant is hot.
• Steam and boiling water can burst
out, possibly causing burns or heat
related injuries.
• When opening the radiator cap, 5. Cooling fan Removal
place a thick cloth over the cap
when the coolant is cooled, and 1) Remove the cooling fan from the fan pulley.
turn it gradually to release the pres- ANNOTATION:
sure before opening it.
• Remove the spacer at the same time.
ANNOTATION:
• Loosen the water drain plug on the rear right
side of the engine, as well as the radiator
drain plug.
• Completely drain the coolant.
• After completely draining the coolant, se-
curely tighten the drain plug.
3. Engine oil Drain
1) Drain the engine oil from the oil pan.
ANNOTATION:
• After draining the oil, tighten the drain plug
to the specified torque.
Tightening torque: 78 N・m {8.0 kgf・m / 58 1 Cooling fan
lb・ft} Drain plug 2 Spacer
Tightening torque: 70 N・m {7.1 kgf・m / 52 3 Fan pulley
lb・ft} Drain cock
4 Bolt
CAUTION
6. Cooling fan belt Removal
• Do not forget to tighten ｔhe drain 1) Remove the cooling fan belt from the pulley.
plug or drain cock.
ANNOTATION:
4. Fan shroud removal
• Loosen the nuts fastening the bolts.
• Loosen the generator adjust bolt to remove
the belt.

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Lubrication System

3) Remove the nozzle leak off pipe from the in-

jector.

1 Adjust bolt
2 Lock nut
3 Bolt 1 Nozzle leak off pipe
4 Nut 2 Injector harness connector

7. PCV hose removal CAUTION

1) Disconnect the PCV hose from the cylinder
• Do not reuse the leak-off pipe clip.
head cover.
2) Remove the PCV hose from the engine as-
sembly.
ANNOTATION:
• Remove the clamp.
8. Fuel hose removal
1) Remove the cover from the cylinder head
cover.

1 Clip

9. Cylinder head cover Removal

1) Remove the cylinder head cover from the
cylinder head.

CAUTION
• Do not damage the lip section of the
1 Cover oil seal with the connector of the
injector.
2) Remove the harness connector from the in-
jector. ANNOTATION:

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Lubrication System

• Shift the head cover to the left side of the 1) Remove the water pipe from the engine as-
engine and lift upwards to remove. sembly.

10. Cam end gasket removal

1) Remove the cam end gasket from the cylinder 1 Water pipe
head.
ANNOTATION:
ANNOTATION:
• Clean any liquid gasket remaining on the
cylinder head. • Because the plastic pipe is easily damaged
during hose removal, do not remove from
the side of the plastic pipe if possible.
13. EGR cooler Removal
1) Remove the EGR cooler from the exhaust
manifold and cylinder head assembly.
ANNOTATION:
• Remove the IN side and OUT side of the
rubber hose for the water pipe and remove
the EGR cooler and gasket.

CAUTION
• Do not hold the water pipe section
when removing the EGR cooler.
1 Cam end gasket

11. Generator Removal

1) Disconnect the harness from the generator.
ANNOTATION:
• Disconnect the harness connector and
B-terminal cable.
2) Remove the generator from the generator
bracket.
ANNOTATION:
• Remove the nuts at 2 locations, pull out the
bolts, and remove the generator.
12. Water pipe removal
1 EGR cooler

ANNOTATION:
• Because the plastic pipe is easily damaged
during hose removal, do not remove from
the side of the plastic pipe if possible.
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Lubrication System

14. Turbocharger assembly Removal 7) Remove the turbocharger assembly from the
exhaust manifold.
1) Remove the return hose from the water pipe.

1 Turbocharger assembly
1 Water pipe
ANNOTATION:
2) Remove the water feed pipe from the oil • Remove both the water feed hose and the
cooler assembly. water drain hose.
3) Disconnect the oil feed pipe from the tur-
bocharger assembly. CAUTION
4) Remove the oil feed pipe from the oil cooler
assembly. • Do not hold the actuator rod.

1 Oil feed pipe

5) Disconnect the oil return pipe from the tur-

bocharger assembly.
6) Remove the oil return pipe from the
crankcase.

1 Exhaust manifold
2 Exhaust manifold bracket

1 Fuel pipe

CAUTION
• Do not reuse the fuel pipe.

21. Leak-off pipe removal

1) Remove the fuel leak-off pipe from the fuel
supply pump and common rail assembly.
ANNOTATION:
• Do not reuse the gasket.

1 Turbocharger control solenoid

2 IMT sensor
3 Boost sensor
4 Boost temperature sensor

18. Oil level gauge guide tube Removal

1) Remove the oil level gauge from the oil level
gauge guide tube.
2) Remove the oil level gauge guide tube from
the crankcase.
19. Injector safety information

20. Fuel pipe Removal

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Lubrication System

1) Remove the injection pipe from the injector 24. Timing chain upper cover removal
and the common rail assembly.
1) Remove the timing chain upper cover from the
CAUTION cylinder head.

• Do not reuse the injection pipe.

1 Timing chain upper cover

2 Fan shroud bracket
1 Injection pipe
3 Fan shroud stay
2 Clip

23. Timing chain lower cover removal 25. Water intake pipe removal
1) Remove the timing chain lower cover from the 1) Disconnect the water intake pipe from the oil
gear case cover. cooler.

CAUTION
• Do not reuse the gasket or O-ring.

2) Remove the water intake pipe from the cylin-

der block.

1 Timing chain upper cover

2 CMP sensor
3 Timing chain lower cover

1 Water intake pipe

26. Injector Removal

1) Remove the injector from the cylinder head
assembly.
2) Remove the injector gasket from the injector.
3) Remove the O-ring from the injector.

CAUTION
• Do not reuse the clip, injector gas-
ket, or O-ring.

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28. Glow plug Removal

1) Remove the glow plug from the cylinder head
assembly.

1 Baffle plate

1 Injector ID code 30. Camshaft Removal

• The marking indicates the installation posi- 32. Timing chain lever pivot removal
tion.
1) Remove the timing chain lever pivot from the
timing gear case.

31. Timing chain tensioner removal

1) Remove the timing chain tensioner from the
cylinder head.

1 Bolt
2 Washer
3 Idle gear D
1 Timing chain tensioner 4 Idle gear shaft
2 Gasket
3 Nut 34. Timing chain removal

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Lubrication System

1 Nut
2 Bolt

3) Loosen the bolt using a wrench.

4) Remove the cylinder head from the cylinder

CAUTION
37. Cylinder head assembly Removal
• Do not reuse the gasket.
1) Remove the bolt from the timing gear case.

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Lubrication System

1 EGR water pipe

40. Oil cooler assembly removal 43. Supply pump gear nut removal
1) Oil cooler assembly removal 1) Fasten special tool to flywheel housing.
ANNOTATION:
• Install the crankshaft stopper to the flywheel
housing starter installation section and en-
sure the crankshaft does not rotate.

41. Starter motor removal

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Lubrication System

2) Turn the nut. 1) Check alignment mark of the supply pump

gear.
ANNOTATION:
• Loosen the nut of the supply pump gear.

2) Remove the supply pump gear from the fuel

supply pump.
ANNOTATION:
1 Supply pump gear nut
• Remove the supply pump gear using a gear
44. Sprocket removal puller.

1) Remove the nut from the sprocket.

2) Remove the sprocket from the supply pump
gear.

46. Fuel supply pump removal

1) Disconnect the harness connector from the
fuel supply pump.

1 Timing chain tension lever pivot ANNOTATION:

2 Sprocket • Disconnect the harness connector of the
3 Nut suction control valve and fuel temperature
sensor.
ANNOTATION:
• After removing the sprocket, move the tim-
ing chain upward.

Fuel temperature sensor con-

1
nector
45. Supply pump gear removal 2 Suction control valve connector
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Lubrication System

2) Remove the supply pump bracket from the 1) Remove the common rail assembly from the
cylinder block. cylinder block.
3) Remove the fuel supply pump from the timing
gear case. ANNOTATION:

ANNOTATION: • Remove the common rail bracket at the

same time.
• When removing the fuel supply pump, do
not hold the high pressure pipe of the pump
instead of the handle.

1 Common rail bracket

2 Common rail

48. Crankshaft pulley Removal

ANNOTATION:
• When fastening, remove using the removal
bolt hole of the crankshaft pulley.

1 Fuel supply pump

2 O-ring
3 High pressure pipe
1 Removal bolt hole

47. Common rail assembly Removal ANNOTATION:

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Lubrication System

CAUTION
• Take care as removing the pulley
forcibly by not using a removal bolt
may cause the oil seal to break and
fuel to leak.

49. Vacuum pump assembly removal

1) Remove the brackets from the gear case and
the vacuum pump.
ANNOTATION:
• Remove the fan shroud bracket left and fan
shroud stay.
Power steering pump hole
1
cover

2) Remove the gear case cover from the gear

case.

1 Fan shroud bracket (LH)

2 Fan shroud stay

2) Disconnect the vacuum hose from the vac-

1 Vacuum hose
2 Oil feed pipe
3 Gear case cover 2) Remove the crank gear from the crankshaft.
4 Vacuum pump 52. Idle gear A Removal

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Lubrication System

2) Remove the gasket from the cylinder block.

53. Oil pump assembly Removal

1) Remove the oil pump assembly from the tim-
ing gear case.

Special tool: crankshaft stopper (refer to

section 1003)

1 Bolt
2 Bolt

ANNOTATION: 56. Flywheel housing Removal

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Lubrication System

1) Remove the flywheel housing from the ANNOTATION:

crankcase.
• Use a slinger puller to remove.
ANNOTATION:
• Loosen the bolt indicated with arrows using
a tool while holding down the nut on the
opposite side.

Special tool: rear oil seal remover (refer

to section 1003)

1 Flywheel housing

57. Oil seal retainer removal

1) Remove the oil seal retainer from the cylinder
block and crankcase.
ANNOTATION:
• Remove the retainer with the oil seal on.

59. Oil pan Removal

1) Remove the oil pan from the crankcase.

58. Crankshaft rear oil seal Removal

1) Remove the crankshaft rear oil seal from the
oil seal retainer.
2) Remove the slinger from the crankshaft using
special tool. 60. Crankcase removal

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Lubrication System

1) Remove the crankcase from the cylinder Disassembly of Oil Pan and Crank
block. Case
1. Crankcase disassembly
1) Remove the oil strainer from the crankcase.

CAUTION
• Do not reuse the gasket.

1 Crankcase
2 O-ring

CAUTION
• Do not damage the O-ring.

1 Oil strainer
2 Bolt
3 Gasket
4 Crankcase

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Lubrication System

Assembly of Oil Pan and Crank Case Installation of Oil Pan and Crank Case
1. Crankcase reassembly 1. Crankcase installation
1) Apply engine oil to the gasket. 1) Apply the engine oil to the O-ring.
2) Install the gasket to the oil strainer. 2) Install the O-ring to the crankcase.
3) Install the oil strainer to the crankcase.
Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft}

1 Crankcase
2 O-ring

1 Oil strainer 3) Apply the liquid gasket to the crankcase.

2 Bolt
3 Gasket ANNOTATION:
4 Crankcase • As shown in the diagram, apply ThreeBond
1207B or equivalent liquid gasket.

CAUTION
• Apply the appropriate amount of
liquid gasket so that it does not
protrude into the oil path indicated
with arrows.

2.0 - 3.0 mm {0.0787 - 0.1181

1
in}
4.0 - 5.0 mm {0.1575 - 0.1969
2
in}

4) Install the crankcase to the cylinder block.

CAUTION
• Install within five minutes of apply-
ing liquid gasket.

Tightening torque: 25 N・m {2.5 kgf・m / 18

lb・ft}
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2. Oil pan Installation 1) Install the flywheel housing to the crankcase.

1) Install the oil pan to the crankcase. ANNOTATION:
Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft} • Install the flywheel housing and tighten to
the specified torque.
• Loosen Bolt 4 using a tool while holding
down the nut on the opposite side.
Tightening torque: 51 N・m {5.2 kgf・m / 38
lb・ft} Bolt 1
Tightening torque: 82 N・m {8.4 kgf・m / 60
lb・ft} Bolt 2
Tightening torque: 97 N・m {9.9 kgf・m / 72
lb・ft} Bolt 3
Tightening torque: 51 N・m {5.2 kgf・m / 38
lb・ft} Bolt 4

3. Oil seal retainer installation

1) Install the oil seal retainer to the crankcase.
ANNOTATION:
• As shown in the diagram, apply ThreeBond
1207B or equivalent liquid gasket,assemble
within five minutes, and tighten to the spec-
ified torque.
Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft}
5. Crankshaft rear oil seal Installation
1) Install the slinger to the oil seal.
ANNOTATION:
• Use a rear oil seal installer.

1 2 - 2.5 mm {0.0787 - 0.0984 in}

2 2 - 2.5 mm {0.0787 - 0.0984 in}

Special tool: oil seal installer kit (refer to

section 1003)
2) Install the crankshaft rear oil seal to the
adapter.
ANNOTATION:
• Assemble and firmly fit the slinger and rear
oil seal.

CAUTION
• Do not reuse the crankshaft rear oil
seal.

4. Flywheel housing Installation

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Lubrication System

Length from the end surface of

1 the crankshaft to the end sur-
face of the oil seal
2 Oil seal end surface
3 End surface of the crankshaft

6. Flywheel Installation
1) Apply the engine oil to the bolt.
ANNOTATION:
• Apply to the threaded portion.
2) Install the flywheel to the crankshaft.

1 Crankshaft ANNOTATION:
2 Slinger • Install a washer and bolt to the flywheel.
3 Crankshaft rear oil seal
3) Install special tool to flywheel housing.
4 Sleeve
5 Adapter
Bolt, M12 x 1.75, L=55 mm
6
{2.1654 in}
7 Bolt

ANNOTATION:
• Insert the oil seal and slinger to the outer
periphery of the adapter.
3) Install the adapter to the crankshaft.
ANNOTATION:
• Install the adapter to the rear end section of
the crankshaft.
Special tool: crankshaft stopper (refer to
4) Install the sleeve to the adapter. section 1003)
ANNOTATION: ANNOTATION:
• Insert the sleeve into the adapter section • Install the crankshaft stopper to the flywheel
and tighten the adapter using an M12 x 1.75, housing starter installation section.
L=55mm {2.1654 in} bolt until it touches the
sleeve. 4) Tighten the bolt using a torque wrench.
• After installing the oil seal, confirm that the ANNOTATION:
length from the end surface of the crank-
shaft to the end surface of the oil seal is • Tighten to the specified torque in the order
within the specified range. shown in the diagram.
specified value: 12.2 - 12.8 mm {0.4803 - Tightening torque: 59 N・m {6.0 kgf・m / 44
0.5039 in} lb・ft}

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5) Tighten the bolt using special tool.

ANNOTATION:
• Use an angle gauge to tighten in the order
shown in the diagram.
specified angle: 60 - 90 °

1 Timing gear case

2 Bolt L = 16 mm {0.6299 in}
3 Bolt L = 20 mm {0.7874 in}
4 Bolt L = 35 mm {1.3780 in}
5 Bolt L = 45 mm {1.7717 in}
6 Bolt L = 60 mm {2.3622 in}
7. Timing gear case installation
1) Apply liquid gasket to the gasket. Tightening torque: 25 N・m {2.5 kgf・m / 18
2) Apply the liquid gasket to the cylinder block. lb・ft}

ANNOTATION: 8. Oil pump assembly Installation

1) Install the oil pump assembly to the timing
• Apply ThreeBond 1207B to the area indi-
cated in the diagram. gear case.
• Install the gasket to the cylinder block. ANNOTATION:
• Apply engine oil to the pump gear and pump
case and tighten to the specified torque.
Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft}

1 Liquid gasket application area

3) Install the timing gear case to the cylinder

block. ANNOTATION:
ANNOTATION:
• Verify that the pump gear rotates smoothly.
• Align the positions of the dowel pin and bolt 9. Idle gear A Installation
and install the timing gear case.
1) Install idle gear A to idle gear A shaft.
CAUTION
ANNOTATION:
• Be careful not to forget the tighten-
ing the bolt indicated by the arrow. • Align the cylinder body side oil hole and the
idle gear A shaft oil hole to install.

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• Install the flange with the front mark facing 10. Crank gear installation
up and towards you.
1) Install the crank gear to the crankshaft.
ANNOTATION:
• Install by aligning with the alignment mark
for the idle gear.
2) Remove the bolt from idle gear A.
ANNOTATION:
• Remove the M6 sub gear fixing bolt from idle
gear A.

1 Front mark
2 Cylinder body side oil hole
3 Idle gear shaft oil hole

11. Idle gear installation

1) Install idle gear A to idle gear A shaft.
Tightening torque: 32 N・m {3.3 kgf・m / 24
lb・ft}

1 Idle gear A bolt

12. Gear case cover installation

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1) Apply liquid gasket to the timing gear case. 2) Remove the brackets from the gear case and
the vacuum pump.
ANNOTATION:
ANNOTATION:
• Apply liquid gasket, ThreeBond 1207B to
the area shown in the diagram. • Install the fan shroud bracket left and fan
shroud stay.
Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft}

1 Liquid gasket application area

2) Install the gasket to the gear case cover.

3) Install the gear case cover to the timing gear 1 Fan shroud bracket (LH)
case. 2 Fan shroud stay
Tightening torque: 8 N・m {0.8 kgf・m / 5.90
lbf・ft} 3) Install the oil feed pipe to the vacuum pump
and cylinder block.
Tightening torque: 12 N・m {1.2 kgf・m / 8.85
lbf・ft}
4) Connect the vacuum hose to the vacuum
pump.

13. Vacuum pump assembly installation

1) Install the vacuum pump to the gear case
cover.

CAUTION
• Apply engine oil to the O-ring. 1 Vacuum hose
2 Oil feed pipe
3 Gear case cover
4 Vacuum pump

14. Crankshaft pulley Installation

CAUTION
• Do not reuse the crankshaft pulley bolt
or washer.

1) Apply the engine oil to the bolt.

ANNOTATION:
• Apply engine oil to the threaded portion and
seat surface of the bolt.
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Lubrication System

2) Install the crankshaft pulley to the crankshaft.

ANNOTATION:
• Tighten at the specified torque in the order
of the numbers in the diagram.
Tightening torque: 30 N・m {3.1 kgf・m / 22
lb・ft}
3) Tighten the bolt using special tool.
specified angle: 180 °
ANNOTATION:
• Tighten again at the specified angle in the
order shown in the diagram.
specified angle: 60 °
1 Common rail bracket
CAUTION 2 Common rail assembly
• The total rotational angle for the ANNOTATION:
2nd and 3rd times will be between
240˚ and 270˚. • Tighten bolts in the order shown in the dia-
gram.

15. Common rail assembly Installation Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft}
1) Install the common rail assembly to the cylin-
der block. 16. Fuel supply pump installation

CAUTION 1) Install the O-ring to the fuel supply pump.

ANNOTATION:
• When installing the common rail as-
sembly, do not clutch and raise up • Apply soapy water to the O-ring and install
the pressure sensor. the O-ring to the supply pump.
• Take care not to damage the con-
nector unit of the pressure sensor. 2) Install the fuel supply pump to the timing gear
case.
ANNOTATION: CAUTION
• Install the common rail bracket at the same
time. • When installing the fuel supply
pump, do not hold the high pres-
sure pipe of the pump as a handle.
• Ensure the O-ring does not pro-
trude.

ANNOTATION:
• Confirm that the supply pump camshaft key
is at a horizontal position on the right side.

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7) Connect the harness connector to the fuel

supply pump.
ANNOTATION:
• Connect the harness connector of the suc-
tion control valve and fuel temperature sen-
sor.

Tightening torque: 25 N・m {2.5 kgf・m / 18

lb・ft}
3) Temporarily tighten the supply pump bracket
to the gear case.
4) Temporarily tighten the supply pump bracket
to the cylinder block.
5) Securely tighten the supply pump bracket to
the gear case.
Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft} Fuel temperature sensor con-
1
6) Securely tighten the supply pump bracket to nector
the cylinder block. 2 Suction control valve
Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft} 17. Supply pump gear installation
1) Install the supply pump gear to the fuel supply
pump.
ANNOTATION:
• Install by aligning with the alignment mark
for the idle gear.

1 Fuel supply pump

2 Supply pump bracket
3 Stud bolt

18. Sprocket installation

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Lubrication System

2) Turn the nut. 2) Turn the crankshaft pulley.

ANNOTATION: ANNOTATION:
• Tighten the supply pump shaft nut with your • Turn the crankshaft pulley 720º to make the
hand. chain tension even.
• Align the alignment marks of the camshaft
and the camshaft bearing cap.

1 Idle gear alignment mark

2 Blue plate
3 Sprocket alignment mark 1 Alignment mark
4 Yellow plate
20. Water pump assembly installation
19. Supply pump gear nut installation 1) Install the water pump to the timing gear case.
1) Securely tighten the nut to the sprocket. ANNOTATION:
ANNOTATION: • Install a new gasket by aligning with the front
cover stud.
• Tighten the supply pump shaft nut to the • Install the water pump by aligning with the
specified torque. front cover stud.
Tightening torque: 130 N・m {13.3 kgf・m / • Tighten the installation bolt and nut to their
96 lb・ft} specified torque.
Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft}

1 Supply pump shaft nut

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21. EGR water pipe installation 23. Starter motor installation

1) Install the EGR water pipe to the oil cooler. 1) Install the starter motor to the flywheel hous-
ing.
ANNOTATION:
• Install the pipe clip installation bolt. ANNOTATION:

Tightening torque: 10 N・m {1.0 kgf・m / 7.38 • Install the earth cable at the same time.
lbf・ft} Tightening torque: 97 N・m {9.9 kgf・m / 72
lb・ft}

1 EGR water pipe 2) Connect the S-terminal to the starter motor.

3) Connect the B-terminal to the starter motor.
22. Oil cooler assembly installation
24. Cylinder head gasket preparation
1) Install the oil cooler to the cylinder block.
1) Select the cylinder head gasket.
CAUTION ANNOTATION:
• Do not reuse the gasket. • Select the grade for the cylinder head gas-
ket by measuring the protrusion amount of
Tightening torque: 27 N・m {2.8 kgf・m / 20 the piston head.
lb・ft} Bolt 1 in the diagram • Remove the water deposit on the top sur-
Tightening torque: 25 N・m {2.5 kgf・m / 18 face of the cylinder block, and the carbon
lb・ft} Other than the above from the piston head.
ANNOTATION: 2) Measure the piston using a dial gauge.
• Only the tightening torque of bolt 1 in the ANNOTATION:
diagram is different.
• Measure the protruding amount of piston
head.

1 Bolt

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Lubrication System

CAUTION 3) Calculate the average value from the mea-

sured value.
• Make sure that the measuring point ANNOTATION:
is as close to the cylinder block as
possible. • Select the required grade of cylinder head
• The difference in protrusion gasket using the average measured value.
amounts between pistons should
not exceed the specified value. Protrusion
• Disassemble and reassemble if the Gasket Gasket thick-
amount of the
protrusion amount of each piston grade ness
piston
is outside of the specified value ： 0.087 to 0.117
range. ： 0.95 mm
A mm {0.0034 to
{0.0374 in}
0.0046 in}
specified value: 0.05 mm {0.0020 in} or less ： 0.117 to 0.167
： 1.00 mm
B mm {0.0046 to
{0.0394 in}
0.0066 in}
： 0.167 to 0.217
： 1.05 mm
C mm {0.0066 to
{0.0413 in}
0.0085 in}

1 Measurement location
2 Measurement location
3 Measurement location
4 Measurement location

1 Gasket A
2 Gasket B
3 Gasket C
4 Grade identification location

25. Cylinder head gasket installation

1) Install the dowel pin to the cylinder block.
ANNOTATION:
• Install only when the dowel pin has been
removed from the cylinder block.
2) Apply the liquid gasket to the cylinder block.
1 Measurement location ANNOTATION:
2 Measurement location
• As shown in the diagram, apply ThreeBond
3 Measurement location 1207B to the aligning surface of the gear
4 Measurement location case.

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Lubrication System

• Use the same grade for the gear case gas-

ket as the cylinder head gasket.
3) Install the cylinder head gasket to the cylinder
block.

CAUTION
• Install the cylinder head gasket and
gear case gasket within five min-
utes of applying liquid gasket.

Special tool: angle gauge (refer to section

1 2 - 3 mm {0.0787 - 0.1181 in}

2 3 - 4 mm {0.1181 - 0.1575 in}

26. Cylinder head assembly Installation

1) Install the cylinder head assembly to the cylin-
der block.
ANNOTATION:
• Gently place the cylinder head while align-
ing with the cylinder block dowel. 3) Install the bolt to the timing gear case.
4) Install the nut to the timing gear case.
CAUTION
ANNOTATION:
• When installing, be careful not to
damage the cylinder head gasket. • Tighten at the specified torque in the order
of the numbers in the diagram.
2) Apply engine oil to the head bolt. Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft}
CAUTION
• Use a new head bolt.

ANNOTATION:
• Apply engine oil to the threaded portion of
the head bolt and seat surface.
• Tighten the head bolts in the order shown
in the diagram using a torque wrench and
angle gauge.

27. Rocker arm shaft assembly installation

1) Apply the engine oil to the bolt.

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Lubrication System

Compression top dead center

Exhaust rocker arm shaft as- 1
1 alignment position
sembly
2 Inlet rocker arm shaft assembly
2) Install the timing chain to the sprocket.
28. Timing chain guide installation 30. Idle gear D installation
1) Install the timing chain guide to the cylinder 1) Apply engine oil to the shaft.
head.
Tightening torque: 25 N・m {2.5 kgf・m / 18 ANNOTATION:
lb・ft}
• Apply to the front and inner surfaces of the
shaft, as well as to the threaded portion and
seat surface of the bolt.
2) Install idle gear D to the cylinder head.
Tightening torque: 59 N・m {6.0 kgf・m / 44
lb・ft}

ANNOTATION:
• Install the timing chain tension lever.
29. Timing chain installation

Shaft front surface and inner

1
surface
Threaded portion of the bolt
2
and seat surface.

ANNOTATION:
• Align the two timing alignment marks as in-
dicated in the diagram.
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1) Connect the hook to the pin.

ANNOTATION:
• Push down the latch of the timing chain
tensioner, insert the plunger, and hang the
hook to the pin.

1 Timing mark
2 Alignment mark
3 Plate, blue
4 Plate, yellow

31. Timing chain lever pivot installation

CAUTION
• Do not reuse the gasket.

Tightening torque: 10 N・m {1.0 kgf・m / 7.38

lbf・ft}

32. Timing chain tensioner installation

1 Timing chain tensioner

2 Gasket
3 Nut

CAUTION
• Turn the protruding section of the
gasket downward to install.

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3) Disconnect the hook from the pin.

ANNOTATION:
• Lightly push the area indicated with an ar-
row in the diagram.
• The hook of the tensioner opens, the
plunger pushes the tension lever, and the
chain is pulled.

ANNOTATION:
• Confirm that the alignment marks of the
camshaft bearing cap and the camshaft are
aligned.

33. Camshaft Installation

1 Alignment mark

4) Apply the engine oil to the bolt.

1 Exhaust camshaft gear

2 Inlet camshaft gear
3 Idle gear D

3) Install the camshaft bearing cap to the cylinder

• Remove the M5 bolt of the camshaft gear.

1 Exhaust camshaft gear

2 Inlet camshaft gear
3 Idle gear D

34. Rocker arm adjustment Compression top dead center

1
1) Loosen the adjust screw using special tool. alignment position

3) Adjust the valve clearance to specified value

ANNOTATION: cylinder is at the compression top dead

Valve ar-
Inlet Exhaust Inlet Exhaust Inlet Exhaust Inlet Exhaust
rangement
No.1 cylinder
compression ○ ○ ○ ○
top dead cen-
ter
No.4 cylinder
compression × × × ×
top dead cen-
ter

specified value: 0.15 mm {0.0059 in} 1) Install the glow plug to the cylinder head as-
sembly.
CAUTION Tightening torque: 18 N・m {1.8 kgf・m / 13
lb・ft}
• Make sure to adjust while cool.
CAUTION
6) Tighten the bolt using special tool.
• Do not exceed specifications when
ANNOTATION: tightening as over-tightening may
• When the movement of the thickness gauge result in breakage.
becomes stiff, secure the adjust screw nut
of the rocker arm.
Tightening torque: 18 N・m {1.8 kgf・m / 13
lb・ft}

36. Glow plug connector installation

1) Install the glow plug connector to the glow
plug.
ANNOTATION:
1 Cam: exhaust side
2 Cam: intake side • Install the glow plug connector to the glow
3 Roller: intake side plugs of the No.1, No.3 and No.4 cylinders.
4 Roller: exhaust side
CAUTION

35. Glow plug Installation • Install the glow plug connector so

that there is no interference with the
cylinder head.

Tightening torque: 1.8 N・m {0.2 kgf・m /

1.328 lbf・ft}
37. Injector Installation
1) Install the injector gasket to the injector.
ANNOTATION:
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Lubrication System

• Push in until your hand stops. • Install and temporarily tighten the injector,
• Do not forcibly push the injector gasket in as injector clamp, and clamp bolt to the cylinder
it will be pushed in to the end during clamp head.
tightening. • When installing the injector to the cylinder
head, confirm that the injector gasket is in-
2) Install the O-ring to the injector. stalled to the injector.
ANNOTATION:
CAUTION
• When installing the O-ring, be careful not to
cause damage by applying engine oil to it. • If the injector has been replaced,
record the injector ID code of the
new injector.
• Record the 24 figures of the injector
ID plate.

1 Injector
2 Leak-off pipe
3 Clip
4 O-ring
5 Injector gasket 1 Injector ID code
2 Injector
3) Install the clamp to the injector.
38. Injection pipe Installation
ANNOTATION:
CAUTION
• Apply engine oil to the threaded portion and
seat surface of the injector clamp bolt. • If the high pressure pipe of the fuel sys-
tem has been removed, make sure to re-
place with a new part.
• Reuse may cause the seal surface to be
damaged and fuel to leak.

1) Temporarily tighten the injection pipe to the

CAUTION 2) Securely tighten the injector to the cylinder

head.
• Do not reuse the clip, injector gas-
ANNOTATION:
ket, or O-ring.
• Tighten the injector clamp bolt to the speci-
4) Temporarily tighten the injector to the cylinder fied torque.
head.
Tightening torque: 26 N・m {2.7 kgf・m / 19
ANNOTATION: lb・ft}
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3) Securely tighten the injection pipe to the injec- 1 Liquid gasket

tor. 2 2 - 2.5 mm {0.0787 - 0.0984 in}
ANNOTATION: 3 2 - 2.5 mm {0.0787 - 0.0984 in}

• Tighten the sleeve nut on the injector side

of the injection pipe to the specified torque. 2) Install the timing chain upper cover to the
cylinder head.
Tightening torque: 30 N・m {3.1 kgf・m / 22
lb・ft} ANNOTATION:
4) Securely tighten the injection pipe to the com-
• Apply Loctite 262 to the threaded portion on
mon rail assembly. the cylinder head side.
ANNOTATION: Tightening torque: 25 N・m {2.5 kgf・m / 18
• Tighten the sleeve nut on the common rail lb・ft}
side of the injection pipe to the specified
torque.
Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft}
Tightening torque: 7.8 N・m {0.8 kgf・m /
5.754 lbf・ft} Clamp nut

1 Timing chain upper cover

2 Fan shroud bracket
3 Fan shroud stay

40. Timing chain lower cover installation

1 Injection pipe 1) Apply liquid gasket to the timing chain lower
2 Clamp cover.
ANNOTATION:
39. Timing chain upper cover installation
• Apply ThreeBond 1207B.
1) Apply liquid gasket to the timing chain upper
cover. CAUTION
ANNOTATION: • Install the cover within five minutes
of applying liquid gasket.
• Apply ThreeBond 1207B.
CAUTION
• Install the cover within five minutes
of applying liquid gasket.

1 Liquid gasket
2 2 - 2.5 mm {0.0787 - 0.0984 in}
3 2 - 2.5 mm {0.0787 - 0.0984 in}
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Lubrication System

2) Install the timing chain lower cover to the gear 3) Install the oil level gauge to the oil level gauge
case cover. guide tube.
Tightening torque: 10 N・m {1.0 kgf・m / 7.38
43. Turbocharger control solenoid installation
lbf・ft}
1) Install the turbocharger control solenoid to the
inlet manifold.
ANNOTATION:
• Install the bracket together with the tur-
bocharger assembly control solenoid.
Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft} Bolt
Tightening torque: 15 N・m {1.5 kgf・m / 11
lb・ft} Nut
2) Connect the vacuum hose to the turbocharger
control solenoid.

CAUTION
• Insert the hose until it stops.
1 Timing chain upper cover
2 CMP sensor 3) Connect the harness connector to the tur-
3 Timing chain lower cover bocharger control solenoid.

CAUTION
41. Leak-off pipe installation
• Install the harness and hose clip to
1) Install the fuel leak-off pipe to the fuel supply their original locations.
pump and common rail assembly.
ANNOTATION:
• Also install the hose at the same time.
CAUTION
• Do not reuse the gasket.

1 Turbocharger control solenoid

2 IMT sensor
3 Boost sensor
4 Boost temperature sensor

44. Intake throttle valve Installation

1 Leak-off pipe, hose 1) Install the gasket to the inlet manifold.
2) Install the intake throttle valve to the inlet man-
ifold.
Tightening torque: 10.3 N・m {1.1 kgf・m /
7.598 lbf・ft} Eyebolt ANNOTATION:
42. Oil level gauge guide tube Installation • Install with the adapter pipe as a unit.
1) Apply the engine oil to the O-ring. Tightening torque: 10 N・m {1.0 kgf・m / 7.38
2) Install the oil level gauge guide tube to the lbf・ft}
crankcase. 3) Connect the harness connector to the intake
Tightening torque: 25 N・m {2.5 kgf・m / 18 throttle valve.
lb・ft} Oil cooler side
ANNOTATION:
Tightening torque: 51 N・m {5.2 kgf・m / 38
lb・ft} Cylinder head side • Press the red claw to lock.
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Lubrication System

45. Water intake pipe installation • Assemble so that the gasket ear portion is
on the engine rear side.
1) Install the O-ring to the water intake pipe.
ANNOTATION:
• Apply soapy water to the O-ring.
2) Install the water intake pipe to the cylinder
block.

CAUTION
• Be careful so as not to pinch the
O-ring during installation.

1 Gasket ear portion

ANNOTATION:
• Assemble the washer and nut as indicated
in the diagram and temporarily tighten.

1 Water intake pipe

Tightening torque: 25 N・m {2.5 kgf・m / 18

lb・ft}

CAUTION
• Assembling the oil cooler and water
inlet pipe with their installation sur-
faces tilted will cause the coolant to
leak.
1 Stud
2 Washer
3 Nut

ANNOTATION:
• Tighten to the specified torque in the order
shown in the diagram.
Tightening torque: 52 N・m {5.3 kgf・m / 38
lb・ft}

1 Water bypass pipe

2 Gasket
3 Oil cooler

46. Exhaust manifold Installation

1) Install the exhaust manifold to the cylinder
head.
ANNOTATION:
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Lubrication System

2) Install the exhaust manifold bracket to the ex- 4) Install the oil feed pipe to the oil cooler assem-
haust manifold and the oil cooler assembly. bly.
Tightening torque: 27 N・m {2.8 kgf・m / 20 5) Connect the oil feed pipe to the turbocharger
lb・ft} assembly.
Tightening torque: 23 N・m {2.3 kgf・m / 17
lb・ft} Eyebolt

1 Exhaust manifold
2 Exhaust manifold bracket
1 Oil feed pipe
47. Turbocharger assembly Installation
1) Install the turbocharger assembly to the ex- 6) Install the oil return pipe to the crankcase.
haust manifold. Tightening torque: 25 N・m {2.5 kgf・m / 18
Tightening torque: 35 N・m {3.6 kgf・m / 26 lb・ft}
lb・ft} 7) Connect the oil return pipe to the turbocharger
assembly.
CAUTION Tightening torque: 10 N・m {1.0 kgf・m / 7.38
• Do not hold the actuator rod. lbf・ft}

ANNOTATION:
• Fill with 0.5 cc of engine oil from the fuel
filler.

1 Oil return pipe

8) Connect the vacuum hose to the turbocharger

assembly.
1 Turbocharger assembly 48. EGR cooler Installation
2) Install the water feed pipe to the oil cooler. 1) Temporarily tighten the EGR cooler to the ex-
Tightening torque: 41 N・m {4.2 kgf・m / 30 haust manifold and cylinder head assembly.
lb・ft}
ANNOTATION:
3) Connect the water feed pipe to the tur-
bocharger assembly. • Install the gasket and EGR cooler, and tem-
Tightening torque: 35 N・m {3.6 kgf・m / 26 porarily tighten them in the order specified
lb・ft} in the diagram.

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Lubrication System

49. Water pipe installation

1) Install the water pipe to the engine assembly.
Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft} M8 bolt
Tightening torque: 10 N・m {1.0 kgf・m / 7.38
lbf・ft} M6

ANNOTATION:
• Do not hold the water pipe section when
installing the EGR cooler.
2) Securely tighten the EGR cooler to the ex-
haust manifold and cylinder head assembly.
ANNOTATION:
1 M8 bolt
• Securely tighten them to the specified
torque in the order of the numbers shown 50. Generator Installation
in the diagram.
1) Install the generator to the generator bracket.
Tightening torque: 27 N・m {2.8 kgf・m / 20
lb・ft} ANNOTATION:
• Install the generator to the bracket and ad-
just plate, and temporarily tighten the instal-
lation nut.

CAUTION
• Tighten the generator after adjust-
ing the work belt.

2) Connect the harness to the generator.

ANNOTATION:
• Connect the harness connector and B-ter-
minal cable.
51. PCV hose installation
1) Install the PCV hose to the engine assembly.
Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft} Clamp
52. Cam end gasket installation
1) Install the cam end gasket to the cylinder
head.
ANNOTATION:
• Apply liquid gasket, ThreeBond 1207B to
the area 2 indicated in the diagram with a
width of 2.0 - 3.0 mm {0.0787 - 0.1181 in}
and install to the cylinder head.

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Lubrication System

1) Install the nozzle leak off pipe to the injector.

ANNOTATION:
• If the nozzle leak off hose has been re-
moved, install with the clip knob facing the
exhaust side as shown in the diagram.

1 Cam end gasket

2 Liquid gasket application area
3 Bead width

ANNOTATION:
2) Connect the harness connector to the injector.
• Apply liquid gasket, ThreeBond 1207B as
shown in the diagram.

1 Nozzle leak off pipe

3.0 - 5.0 mm {0.1181 - 0.1969 2 Injector harness
1
in}
3.0 - 5.0 mm {0.1181 - 0.1969
2 3) Install the cover to the cylinder head cover.
in}

53. Cylinder head cover Installation

1) Install the cylinder head cover to the cylinder
head.
Tightening torque: 10 N・m {1.0 kgf・m / 7.38
lbf・ft}
2) Connect the PCV hose to the cylinder head
cover.
54. Fuel hose installation

1 Cover

55. Cooling fan belt Installation

1) Install the cooling fan belt to the pulley.
56. Cooling fan Installation
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Lubrication System

1) Install the cooling fan belt to the fan pulley. Amount of deflection
： 4.2 to 5.0 mm {0.1654 to
ANNOTATION: New
0.1969 in}
• Install the spacer at the same time. When adjusting ： 6.6 to 7.4 mm {0.2598 to
the tension 0.2913 in}
Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft}
ANNOTATION:
• Verify whether precise tension has been set
using a sonic tension meter.

Frequency of vibrations
New ： 220 to 244 Hz
When adjusting
： 182 to 206 Hz
the tension

1 Cooling fan
2 Spacer
3 Fan pulley
4 Bolt

57. Fan shroud installation

1) Install the fan shroud to the bracket.
ANNOTATION:
1 Crankshaft pulley
• Install the fan shroud and fan guard. 2 Installation bolt
Tightening torque: 51 N・m {5.2 kgf・m / 38 3 Generator
lb・ft} 4 Adjust bolt
5 Lock nut
6 Fan pulley
Inspection position for belt flex
7
amount

CAUTION
• Always take care to set the correct
tension as belt service life may be
shortened or the belt squeaking
may occur if tension is inadequate.

ANNOTATION:

58. Cooling fan belt Adjustment • After adjustment, tighten the adjust plate
lock bolt and mounting bolt at the bottom
1) Adjust the cooling fan belt. side of the generator to the specified torque.
ANNOTATION: Tightening torque: 51 N・m {5.2 kgf・m / 38
lb・ft} M10 bolt, M10 nut
• Loosen the adjust plate lock bolt and the Tightening torque: 25 N・m {2.5 kgf・m / 18
mounting bolt at the bottom side of the gen- lb・ft} M8 bolt, M8 nut
erator.
• Turn the adjust bolt to adjust the belt. ANNOTATION:
• Press the specified position on the belt with
the specified load to inspect the amount of • When installing a new belt, initial elongation
of the belt occurs.
belt flex.
• Adjust the belt according to the adjustment
load: 98 N {10 kg / 22 lb} method below in order to settle the belt in
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Lubrication System

the pulley groove when installing a new belt 7) Close the plug.
or when readjusting the belt tension.
ANNOTATION:
• Follow the specified method to adjust the
belt tension. • Sufficiently tighten the air bleeding plug to
• Start and idle the engine for 5 minutes or the fuel filter.
more to settle the belt.
• Stop the engine and readjust the belt ten- CAUTION
sion to the specified value.
• Tighten the air removal plug and
59. Engine oil filling then completely wipe away any ex-
cess fuel in the vicinity.
1) Replenish the engine with engine oil.
ANNOTATION: 8) Operate the priming pump.
• Recheck the tightening of the oil pan drain ANNOTATION:
plug.
• Push the priming pump 10 times to 15 times
60. Coolant filling to feed fuel into the supply pump.
1) Replenish the radiator assembly with coolant. • or less, after starting the engine
9) Start the engine and put it into an idling state.
61. Fuel Air bleed
ANNOTATION:
ANNOTATION:
• Idle for 5 seconds.
• Before starting the engine
1) Prepare the pan. CAUTION
ANNOTATION: • Do not rev the engine.
• Place an appropriate pan under the fuel fil-
ter. 10) Adjust the engine speed.

2) Turn the plug. ANNOTATION:

ANNOTATION: • Slowly increase the engine speed and main-

tain for 3 seconds.
• Sufficiently loosen the air removal plug. • After completion of the above operation, op-
erate at maximum revolutions on the side
3) Operate the priming pump.
of the machine and repeat the operation
ANNOTATION: of revving to the maximum speed multiple
times.
• Operate the priming pump 20 times or more
until fuel spills out around the plug. CAUTION
4) Close the plug. • If air removal operations are insuf-
5) Operate the priming pump. ficient, due to the possibility of en-
ANNOTATION: gine trouble, make sure to follow all
procedures.
• Operate the priming pump 10 times or more
until it is completely filled with fuel. 62. Battery ground cable Connect
• Wait for approximately 1 minute after oper-
ating the priming pump. 1) Connect the battery ground cable to the bat-
tery.
6) Drain air from the fuel filter assembly.
ANNOTATION:
• Sufficiently loosen the air removal plug.

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Lubrication System

Removal and Installation of Oil 1) Remove the cooling fan from the fan pulley.
Pump Assembly ANNOTATION:
• Remove the spacer at the same time.
Removal of Oil Pump Assembly
1. Battery ground cable Disconnect
1) Disconnect the battery ground cable from the
battery.
2. Coolant Drain
1) Drain coolant from the radiator.

CAUTION
• Do not loosen or remove the radia-
tor cap when the coolant is hot.
• Steam and boiling water can burst
out, possibly causing burns or heat
related injuries.
• When opening the radiator cap, 1 Cooling fan
place a thick cloth over the cap 2 Spacer
when the coolant is cooled, and 3 Fan pulley
turn it gradually to release the pres- 4 Bolt
sure before opening it.
5. Fan shroud removal
ANNOTATION:
1) Remove the fan shroud from the bracket.
• Loosen the water drain plug on the rear right
side of the engine, as well as the radiator ANNOTATION:
drain plug. • Remove the fan shroud and fan guard as a
• Completely drain the coolant. unit.
• After completely draining the coolant, se-
curely tighten the drain plug.
3. Engine oil Drain
1) Drain the engine oil from the oil pan.
ANNOTATION:
• After draining the oil, tighten the drain plug
to the specified torque.
Tightening torque: 78 N・m {8.0 kgf・m / 58
lb・ft} Drain plug
Tightening torque: 70 N・m {7.1 kgf・m / 52
lb・ft} Drain cock

CAUTION
6. Cooling fan belt Removal
• Do not forget to tighten ｔhe drain 1) Remove the cooling fan belt from the pulley.
plug or drain cock.
ANNOTATION:
4. Cooling fan Removal
• Loosen the nuts fastening the bolts.
• Loosen the generator adjust bolt to remove
the belt.

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Lubrication System

1) Fasten special tool to flywheel housing.

ANNOTATION:
• Install to the flywheel housing starter instal-
lation section and ensure that the crankshaft
does not rotate.

1 Adjust bolt
2 Lock nut
3 Bolt
4 Nut

7. Starter motor removal Special tool: crankshaft stopper (refer to

section 1003)
1) Disconnect the earth cable from the starter
motor. 9. Crankshaft pulley Removal
2) Disconnect the S-terminal from the starter mo-
tor. 1) Remove the crankshaft pulley from the crank-
3) Disconnect the B-terminal from the starter mo- shaft.
tor.
CAUTION
4) Remove the starter motor from the flywheel
housing. • Do not reuse the crankshaft pulley
bolt or washer.

ANNOTATION:
• When fastening, remove using the removal
bolt hole of the crankshaft pulley.

8. Crankshaft pulley preparation

1 Removal bolt hole

ANNOTATION:
• Remove using a removal bolt with a diame-
ter of 5 mm {0.1969 in}, a pitch of 0.8, and a
stem length of 20 mm {0.7874 in} or more.

CAUTION
• Take care as removing the pulley
forcibly by not using a removal bolt
may cause the oil seal to break and
fuel to leak.

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Lubrication System

10. Vacuum pump assembly removal 1) Remove the cover from the gear case cover.
1) Remove the brackets from the gear case and
the vacuum pump.
ANNOTATION:
• Remove the fan shroud bracket left and fan
shroud stay.

Power steering pump hole

1
cover

2) Remove the gear case cover from the gear

case.

1 Fan shroud bracket (LH)

2 Fan shroud stay

2) Disconnect the vacuum hose from the vac-

uum pump.
3) Remove the oil feed pipe from the vacuum
pump and cylinder block.
4) Remove the vacuum pump from the gear case
cover.

12. Crank gear removal

1) Install the bolt to idle gear A.
ANNOTATION:
• Install an M6 bolt to idle gear A and fasten it
while aligning the position of the sub gear.

1 Vacuum hose
2 Oil feed pipe
3 Gear case cover
4 Vacuum pump

11. Gear case cover removal

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Lubrication System

2) Remove the crank gear from the crankshaft. Installation of Oil Pump Assembly
13. Oil pump assembly Removal 1. Oil pump assembly Installation
1) Remove the oil pump assembly from the tim- 1) Install the oil pump assembly to the timing
ing gear case. gear case.
ANNOTATION:
• Apply engine oil to the pump gear and pump
case and tighten to the specified torque.
Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft}

ANNOTATION:
• Verify that the pump gear rotates smoothly.
2. Crank gear installation
1) Install the crank gear to the crankshaft.
ANNOTATION:
• Install by aligning with the alignment mark
for the idle gear.
2) Remove the bolt from idle gear A.
ANNOTATION:
• Remove the M6 sub gear fixing bolt from idle
gear A.

1 M6 bolt for sub gear fixing

3. Gear case cover installation

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Lubrication System

1 Liquid gasket application area

2) Install the gasket to the gear case cover.

4. Vacuum pump assembly installation

1) Install the vacuum pump to the gear case
cover.

CAUTION
• Apply engine oil to the O-ring. 1 Vacuum hose
2 Oil feed pipe
3 Gear case cover
4 Vacuum pump

5. Crankshaft pulley Installation

CAUTION
• Do not reuse the crankshaft pulley bolt
or washer.

1) Apply the engine oil to the bolt.

ANNOTATION:
• Apply engine oil to the threaded portion and
seat surface of the bolt.
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Lubrication System

2) Install the crankshaft pulley to the crankshaft. 8. Cooling fan Installation

ANNOTATION: 1) Install the cooling fan belt to the fan pulley.
• Tighten at the specified torque in the order ANNOTATION:
of the numbers in the diagram.
• Install the spacer at the same time.
Tightening torque: 30 N・m {3.1 kgf・m / 22
Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft}
lb・ft}
3) Tighten the bolt using special tool.
specified angle: 180 °
ANNOTATION:
• Tighten again at the specified angle in the
order shown in the diagram.
specified angle: 60 °

CAUTION
• The total rotational angle for the
2nd and 3rd times will be between
240˚ and 270˚.

1 Cooling fan
2 Spacer
3 Fan pulley
4 Bolt

9. Fan shroud installation

1) Install the fan shroud to the bracket.
ANNOTATION:
• Install the fan shroud and fan guard.
6. Starter motor installation Tightening torque: 51 N・m {5.2 kgf・m / 38
1) Install the starter motor to the flywheel hous- lb・ft}
ing.
ANNOTATION:
• Install the earth cable at the same time.
Tightening torque: 97 N・m {9.9 kgf・m / 72
lb・ft}

10. Cooling fan belt Adjustment

1) Adjust the cooling fan belt.
ANNOTATION:
• Loosen the adjust plate lock bolt and the
mounting bolt at the bottom side of the gen-
2) Connect the S-terminal to the starter motor. erator.
3) Connect the B-terminal to the starter motor. • Turn the adjust bolt to adjust the belt.
7. Cooling fan belt Installation • Press the specified position on the belt with
the specified load to inspect the amount of
1) Install the cooling fan belt to the pulley. belt flex.

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Lubrication System

load: 98 N {10 kg / 22 lb} CAUTION

• Always take care to set the correct
Amount of deflection
tension as belt service life may be
： 4.2 to 5.0 mm {0.1654 to shortened or the belt squeaking
New
0.1969 in} may occur if tension is inadequate.
When adjusting ： 6.6 to 7.4 mm {0.2598 to
the tension 0.2913 in} ANNOTATION:
• After adjustment, tighten the adjust plate
ANNOTATION: lock bolt and mounting bolt at the bottom
side of the generator to the specified torque.
• Verify whether precise tension has been set
using a sonic tension meter. Tightening torque: 51 N・m {5.2 kgf・m / 38
lb・ft} M10 bolt, M10 nut
Frequency of vibrations Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft} M8 bolt, M8 nut
New ： 220 to 244 Hz
When adjusting ANNOTATION:
： 182 to 206 Hz
the tension
• When installing a new belt, initial elongation
of the belt occurs.
• Adjust the belt according to the adjustment
method below in order to settle the belt in
the pulley groove when installing a new belt
or when readjusting the belt tension.
• Follow the specified method to adjust the
belt tension.
• Start and idle the engine for 5 minutes or
more to settle the belt.
• Stop the engine and readjust the belt ten-
sion to the specified value.
11. Engine oil filling
1) Replenish the engine with engine oil.
ANNOTATION:

1 Crankshaft pulley • Recheck the tightening of the oil pan drain

plug.
2 Installation bolt
3 Generator 12. Coolant filling
4 Adjust bolt 1) Replenish the radiator assembly with coolant.
5 Lock nut
6 Fan pulley 13. Battery ground cable Connect
Inspection position for belt flex 1) Connect the battery ground cable to the bat-
7
amount tery.

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Lubrication System

Removal of Water Pump Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Water Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal and Installation of Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal of Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation of Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection of Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspection of Cooling Fan Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

2455-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

2455-2 PRINTED IN FRANCE
Copyright ©
Cooling System

Removal and Installation of Water 4. Fan shroud removal

Pump Assembly 1) Remove the fan shroud from the bracket.
ANNOTATION:
Removal of Water Pump Assembly
• Remove the fan shroud and fan guard as a
1. Battery ground cable Disconnect unit.
1) Disconnect the battery ground cable from the
battery.
2. Coolant Drain
1) Drain coolant from the radiator.

CAUTION
• Do not loosen or remove the radia-
tor cap when the coolant is hot.
• Steam and boiling water can burst
out, possibly causing burns or heat
related injuries.
• When opening the radiator cap,
place a thick cloth over the cap
when the coolant is cooled, and 5. Cooling fan Removal
turn it gradually to release the pres- 1) Remove the cooling fan from the fan pulley.
sure before opening it.
ANNOTATION:
ANNOTATION:
• Remove the spacer at the same time.
• Loosen the water drain plug on the rear right 2) Remove the fan pulley from the water pump
side of the engine, as well as the radiator assembly.
drain plug.
• Completely drain the coolant.
• After completely draining the coolant, se-
curely tighten the drain plug.
3. Cooling fan belt Removal
1) Remove the cooling fan belt from the pulley.
ANNOTATION:
• Loosen the nuts fastening the bolts.
• Loosen the generator adjust bolt to remove
the belt.

1 Cooling fan
2 Spacer
3 Fan pulley
4 Bolt

6. Water pump assembly removal

1) Remove the water pump from the timing gear
case.
ANNOTATION:
1 Adjust bolt
• Remove the water pump installation nut and
2 Lock nut bolt.
3 Bolt • Remove the water pump assembly and gas-
4 Nut ket.

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Cooling System

Installation of Water Pump Assembly

1. Water pump assembly installation
1) Install the water pump to the timing gear case.
ANNOTATION:
• Install a new gasket by aligning with the front
cover stud.
• Install the water pump by aligning with the
front cover stud.
• Tighten the installation bolt and nut to their
specified torque.
Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft}

2. Cooling fan Installation

1) Install the fan pulley to the water pump assem-
bly.
Tightening torque: 10 N・m {1.0 kgf・m / 7.38
lbf・ft}
2) Install the cooling fan belt to the fan pulley.
ANNOTATION:
• Install the spacer at the same time.
Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft}

1 Cooling fan
2 Spacer
3 Fan pulley
4 Bolt

3. Cooling fan belt Installation

1) Install the cooling fan belt to the pulley.
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Cooling System

4. Fan shroud installation

1) Install the fan shroud to the bracket.
ANNOTATION:
• Install the fan shroud and fan guard.
Tightening torque: 51 N・m {5.2 kgf・m / 38
lb・ft}

1 Crankshaft pulley
2 Installation bolt
3 Generator
4 Adjust bolt
5 Lock nut
6 Fan pulley
Inspection position for belt flex
7
5. Cooling fan belt Adjustment amount

1) Adjust the cooling fan belt. CAUTION

ANNOTATION:
• Always take care to set the correct
• Loosen the adjust plate lock bolt and the tension as belt service life may be
mounting bolt at the bottom side of the gen- shortened or the belt squeaking
erator. may occur if tension is inadequate.
• Turn the adjust bolt to adjust the belt.
• Press the specified position on the belt with ANNOTATION:
the specified load to inspect the amount of
belt flex. • After adjustment, tighten the adjust plate
lock bolt and mounting bolt at the bottom
load: 98 N {10 kg / 22 lb} side of the generator to the specified torque.
Tightening torque: 51 N・m {5.2 kgf・m / 38
Amount of deflection lb・ft} M10 bolt, M10 nut
： 4.2 to 5.0 mm {0.1654 to Tightening torque: 25 N・m {2.5 kgf・m / 18
New
0.1969 in} lb・ft} M8 bolt, M8 nut
When adjusting ： 6.6 to 7.4 mm {0.2598 to
the tension 0.2913 in} ANNOTATION:
• When installing a new belt, initial elongation
ANNOTATION: of the belt occurs.
• Adjust the belt according to the adjustment
• Verify whether precise tension has been set method below in order to settle the belt in
using a sonic tension meter. the pulley groove when installing a new belt
or when readjusting the belt tension.
Frequency of vibrations • Follow the specified method to adjust the
New ： 220 to 244 Hz belt tension.
When adjusting • Start and idle the engine for 5 minutes or
： 182 to 206 Hz
the tension more to settle the belt.
• Stop the engine and readjust the belt ten-
sion to the specified value.
6. Coolant filling
1) Replenish the radiator assembly with coolant.
7. Battery ground cable Connect
1) Connect the battery ground cable to the bat-
tery.

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Cooling System

Inspection Removal and Installation of

1. Water pump assembly Inspection Thermostat
1) Inspect the water pump assembly.
Removal of Thermostat
ANNOTATION:
1. Battery ground cable Disconnect
• Cracks and damage on the water pump
body 1) Disconnect the battery ground cable from the
• Cracks and corrosion on the impeller battery.
• Water leak from the seal unit 2. Coolant Drain
CAUTION 1) Drain coolant from the radiator.
• If any abnormality is found in the CAUTION
inspection, replace the water pump
assembly. • Do not loosen or remove the radia-
tor cap when the coolant is hot.
2) Inspect the bearing unit. • Steam and boiling water can burst
out, possibly causing burns or heat
ANNOTATION: related injuries.
• Rotate the fan while pushing the fan center • When opening the radiator cap,
to the radius direction and inspect for any place a thick cloth over the cap
significant looseness or abnormal sounds. when the coolant is cooled, and
turn it gradually to release the pres-
CAUTION sure before opening it.

• If any abnormality is found in the ANNOTATION:

inspection, replace the water pump
assembly. • Loosen the water drain plug on the rear right
side of the engine, as well as the radiator
drain plug.
• Completely drain the coolant.
• After completely draining the coolant, se-
curely tighten the drain plug.
3. Water outlet pipe removal
1) Disconnect the radiator upper hose from the
water outlet pipe.
2) Remove the water outlet pipe from the cylin-
der head assembly.
4. Thermostat Removal
1) Remove the thermostat from the cylinder
head assembly.
2) Remove the gasket from the thermostat.

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Cooling System

Installation of Thermostat Inspection

1. Thermostat Installation 1. Thermostat Inspection
1) Install the thermostat to the cylinder head as- 1) Inspect the thermostat.
sembly.
ANNOTATION:
ANNOTATION: • Put the thermostat in water and raise the
• Install the jiggle valve to face the engine water temperature while thoroughly stirring.
front side. • Measure the temperature both when the
valve starts opening and after it is fully
opened.
: 85 °C {185 °F} Open valve temperature
: 100 °C {212 °F} Full-open temperature
: 10 mm {0.3937 in} Amount of valve lift

1 Thermostat
2 Jiggle valve

2. Water outlet pipe installation

1) Install the water outlet pipe to the cylinder
head assembly.
Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft}
2) Connect the radiator upper hose to the water
outlet pipe.
3. Coolant filling
1) Replenish the radiator assembly with coolant.
4. Battery ground cable Connect
1) Connect the battery ground cable to the bat-
tery.

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Cooling System

Inspection of Coolant 3) Measure the specific gravity using a hydrom-

eter.
1. Coolant Inspection engine coolant temperature: 0 to 50 °C {32 -
122 °F} When inspecting
WARNING
ANNOTATION:
• If the coolant temperature is high, do not
perform the inspection. • Use a container that is deeper than the
• When removing the cap, be careful as the length of the hydrometer.
coolant will burst out if the coolant tem-
perature is high.

CAUTION
• Be sure to use long life coolant which is
specified or recommended by Isuzu.
• Using at an unspecified concentration
may result in freezing due to decreased
anti-freezing performance.
• Use a coolant concentration appropriate
for the usage environment.
• Before using, dilute the specified long
life coolant to the specified concentra-
tion with soft tap water.
1 Radiator
LLC 2 Hydrometer
con-
Area where the equipment is used
centra- 4) Measure the temperature using a thermome-
tion ter.
General area; Area where the lowest engine coolant temperature: 0 to 50 °C {32 -
: 30 ％ 122 °F} When inspecting
temperature is higher than (-12) degrees.
Cold area; Area where the lowest tem- 5) Calculate the concentration from the mea-
: 50 ％ sured value.
perature is (-30) degrees.
Area where the lowest temperature drop
: 55 ％
to (-30) degrees.

1) Inspect the radiator reverse tank.

ANNOTATION:
• If coolant level is MIN or less, add it until it
reaches MAX.

CAUTION SPECIFIC
• When adding coolant, use coolant GRAVITY
appropriate for the usage environ-
ment.

volume of coolant: 6 L {1 Imp.gal} Engine only

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2465-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Exhaust Manifold

Removal of Exhaust Manifold 1) Remove the EGR cooler from the exhaust
manifold and cylinder head assembly.
1. Battery ground cable Disconnect
ANNOTATION:
1) Disconnect the battery ground cable from the
battery. • Remove the IN side and OUT side of the
rubber hose for the water pipe and remove
2. Coolant Drain the EGR cooler and gasket.
1) Drain coolant from the radiator. CAUTION
CAUTION • Do not hold the water pipe section
when removing the EGR cooler.
• Do not loosen or remove the radia-
tor cap when the coolant is hot.
• Steam and boiling water can burst
out, possibly causing burns or heat
related injuries.
• When opening the radiator cap,
place a thick cloth over the cap
when the coolant is cooled, and
turn it gradually to release the pres-
sure before opening it.

1) Remove the water pipe from the engine as- • Because the plastic pipe is easily damaged
sembly. during hose removal, do not remove from
the side of the plastic pipe if possible.
5. Turbocharger assembly Removal
1) Remove the return hose from the water pipe.

1 Water pipe

ANNOTATION:
• Because the plastic pipe is easily damaged 1 Water pipe
during hose removal, do not remove from
the side of the plastic pipe if possible.
2) Remove the water feed pipe from the oil
4. EGR cooler Removal cooler assembly.

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Removal and Installation of Exhaust Manifold

3) Disconnect the oil feed pipe from the tur- 1 Turbocharger assembly
bocharger assembly.
4) Remove the oil feed pipe from the oil cooler ANNOTATION:
assembly.
• Remove both the water feed hose and the
water drain hose.

CAUTION
• Do not hold the actuator rod.

ANNOTATION:
• Do not reuse the gasket.
6. Exhaust manifold Removal
1) Remove the exhaust manifold bracket from
the exhaust manifold and the oil cooler as-
sembly.
2) Remove the exhaust manifold from the cylin-
1 Oil feed pipe der head.

5) Disconnect the oil return pipe from the tur-

bocharger assembly.
6) Remove the oil return pipe from the
crankcase.

1 Exhaust manifold
2 Exhaust manifold bracket

ANNOTATION:

1 Oil return pipe • Do not reuse the gasket.

7) Remove the turbocharger assembly from the

exhaust manifold.

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Removal and Installation of Exhaust Manifold

Installation of Exhaust Manifold

1. Exhaust manifold Installation
1) Install the exhaust manifold to the cylinder
head.
ANNOTATION:
• Assemble so that the gasket ear portion is
on the engine rear side.

2) Install the exhaust manifold bracket to the ex-

haust manifold and the oil cooler assembly.
Tightening torque: 27 N・m {2.8 kgf・m / 20
lb・ft}

1 Gasket ear portion

ANNOTATION:
• Assemble the washer and nut as indicated
in the diagram and temporarily tighten.

1 Exhaust manifold
2 Exhaust manifold bracket

2. Turbocharger assembly Installation

1) Install the turbocharger assembly to the ex-
haust manifold.
Tightening torque: 35 N・m {3.6 kgf・m / 26
lb・ft}

CAUTION
• Do not hold the actuator rod.
1 Stud
2 Washer ANNOTATION:
3 Nut • Fill with 0.5 cc of engine oil from the fuel
filler.
ANNOTATION:
• Tighten to the specified torque in the order
shown in the diagram.
Tightening torque: 52 N・m {5.3 kgf・m / 38
lb・ft}

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Removal and Installation of Exhaust Manifold

1 Turbocharger assembly 8) Connect the vacuum hose to the turbocharger

assembly.
2) Install the water feed pipe to the oil cooler.
Tightening torque: 41 N・m {4.2 kgf・m / 30 3. EGR cooler Installation
lb・ft} 1) Temporarily tighten the EGR cooler to the ex-
3) Connect the water feed pipe to the tur- haust manifold and cylinder head assembly.
bocharger assembly.
Tightening torque: 35 N・m {3.6 kgf・m / 26 ANNOTATION:
lb・ft} • Install the gasket and EGR cooler, and tem-
4) Install the oil feed pipe to the oil cooler assem- porarily tighten them in the order specified
bly. in the diagram.
5) Connect the oil feed pipe to the turbocharger
assembly.
Tightening torque: 23 N・m {2.3 kgf・m / 17
lb・ft} Eyebolt

ANNOTATION:
• Do not hold the water pipe section when
installing the EGR cooler.
1 Oil feed pipe 2) Securely tighten the EGR cooler to the ex-
haust manifold and cylinder head assembly.
6) Install the oil return pipe to the crankcase.
Tightening torque: 25 N・m {2.5 kgf・m / 18 ANNOTATION:
lb・ft} • Securely tighten them to the specified
7) Connect the oil return pipe to the turbocharger torque in the order of the numbers shown
assembly. in the diagram.
Tightening torque: 10 N・m {1.0 kgf・m / 7.38
lbf・ft} Tightening torque: 27 N・m {2.8 kgf・m / 20
lb・ft}

1 Oil return pipe

2 Filter assembly
3 Exhaust silencer assembly

1 Bracket
Differential pressure pipe on
2
the filter rear side
Differential pressure pipe on
3
the filter front side

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Disassembly, Removal and Installation of DPD Assembly

Assembly of DPD Assembly CAUTION

1. DPD assembly Reassembly • Remove the old anti-seize lubricant
on the sleeve nut.
CAUTION • Apply the anti-seize lubricant on the
• Do not reuse gaskets, bolts, and nuts. threaded portion of the sleeve nut.
• Apply Never-Seez High Tempera-
1) Temporarily tighten the filter assembly to the ture Stainless Grade: 5-87411-039-0
exhaust silencer assembly. anti-seize lubricant, manufactured
by Bostik in the United States.
ANNOTATION:
6) Temporarily tighten the clip to the differential
• Tighten together with the bracket.
pressure pipe.
2) Temporarily tighten the oxidation catalyst as- 7) Securely tighten the clip to the differential
sembly to the filter assembly. pressure pipe.
Tightening torque: 17 N・m {1.7 kgf・m / 13
ANNOTATION:
lb・ft}
• Tighten together with the bracket. 8) Securely tighten the differential pressure pipe
• For the integrated-type bracket, place the to the DPD assembly.
temporarily tightened DPD assembly on Tightening torque: 35 N・m {3.6 kgf・m / 26
a level surface and position so that the lb・ft} Pipe sleeve nut
bracket mounting surface is level. 9) Install the bracket to the DPD assembly.
• For the separated-type bracket, tighten Tightening torque: 25 N・m {2.5 kgf・m / 18
while referring to the markings made during lb・ft}
removal, etc., to avoid mispositioning.
• For the separated-type bracket, align it to
the position where the level difference of the
mounting face to the machine side of the
bracket is 40 mm {1.5748 in}.
3) Securely tighten the filter assembly to the ex-
haust silencer assembly.
Tightening torque: 29 N・m {3.0 kgf・m / 21
lb・ft}
4) Securely tighten the oxidation catalyst assem-
bly to the filter assembly.
Tightening torque: 29 N・m {3.0 kgf・m / 21
lb・ft}

1 Bracket
Differential pressure pipe on
2
the filter rear side
Differential pressure pipe on
3
the filter front side

2. Exhaust gas temperature sensor Installation

CAUTION
• Do not subject the tip of the exhaust gas
temperature sensor to shock when in-
stalling.
1 Oxidation catalyst assembly • Remove the old anti-seize lubricant on
2 Filter assembly the sleeve nut.
3 Exhaust silencer assembly • Apply the anti-seize lubricant on the
threaded portion of the sleeve nut.
• Apply Never-Seez High Tempera-
5) Temporarily tighten the differential pressure ture Stainless Grade: 5-87411-039-0
pipe to the DPD assembly. anti-seize lubricant, manufactured by
Bostik in the United States.
• Replace the oxidation catalyst assembly
if damage has been found in the sensor
installation section of the oxidation cata-
lyst assembly.

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Disassembly, Removal and Installation of DPD Assembly

1) Temporarily tighten the exhaust gas tempera- 3. Exhaust differential pressure sensor Safety Infor-
ture sensor to the DPD assembly. mation

CAUTION CAUTION
• To avoid damaging the sensor in- • Do not use a tool which causes vibra-
stallation sections due to sensor tions such as an impact wrench when in-
incorrect assembly, tighten it by stalling and removing the DPD differen-
hand. tial pressure sensor.
• Do not reuse a DPD differential pressure
ANNOTATION: sensor which has been subjected to
shock such as being dropped.
• Exhaust gas temperature sensor identifica- • Install or remove the DPD differen-
tion tial pressure sensor together with the
bracket.
Connector • Be sure not to loosen the 4 screws in-
Sensor type Screw size
color stalled on the DPD differential pressure
Exhaust gas tempera- sensor.
M12 x 1.75 Dark gray
ture sensor 2 • Replace the DPD differential pressure
Exhaust gas tempera- sensor if the 4 screws installed on the
M12 x 1.25 Light gray
ture sensor 1 DPD differential pressure sensor have
been loosened.
2) Securely tighten the exhaust gas temperature
sensor to the DPD assembly.
Tightening torque: 30 N・m {3.1 kgf・m / 22
lb・ft}
3) Connect the harness connector to the exhaust
gas temperature sensor.

CAUTION
• Be careful not to twist the harness.

Removal and Installation of Fuel Tank

84592788 EN - March 2012

CONTENTS

Removal of Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

3001-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

3001-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Fuel Tank

WARNING 2. Drain out all the fuel from the fuel tank into a drum
can.
• Keep away from fire. Use the drain cock on the bottom of the tank to drain
out any fuel that does not drain out but remains at
CAUTION the bottom of the tank.

• Be sure to stop the engine before beginning

work.
• Be sure to inspect the wire rope and other
lifting equipment before beginning work.
• Do not stand or pass under the suspended
load.

Items to prepare
• Wrenches [13 mm (0.512 in), 19 mm (0.748 in), 24 mm
(0.945 in)]
• Eyebolts (M12 x 4)
• Shackle (with the required lifting capacity) x 4
• Wire ropes (with the required breaking load) 3. Use a Wrench [19 mm (0.748 in) ] to remove the 6
• Liftcrane (with the required lifting capacity) bolts (1), and then remove the top cover (2).
• Caps
• Plugs
• Drum can (for draining fuel)
• Rag
• Cleaning fluid
• Wood planks

Removal of Fuel Tank

1. Remove the cap (1) and filter (2).

4. Use a Wrench 19 mm (0.748 in) to remove the 2

bolts (2) from the fuel tank front cover (tank) (1),
and then remove the cover (tank).

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Removal and Installation of Fuel Tank

5. Use a wrench 19 mm (0.748 in) to remove the 6 6. Use a wrench 19 mm (0.748 in) to remove the 5
bolts (1) and clamps (2), and then remove the han- bolts (1) from the fuel tank side cover (2), and then
dle (3). remove the side cover.

7. Use a wrench 19 mm (0.748 in) to remove the 5

bolts (1), and then remove the under cover (2).
Tightening torque for bolt installation: 63.7 - 73.5
N·m (46.991 - 54.220 lbf·ft)

8. Loosen the hose band (1), and then remove the

hose (2).
• Mark the fuel tank and hose so that the connec-
tors match at the time of assembly.
• Attach caps or plugs to the fuel tank and hoses to
prevent any entry of water, dust or dirt.

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Removal and Installation of Fuel Tank

11. Use a wrench 19 mm (0.748 in) to remove the 4

bolts (1), and then remove the side covers (tank)
(2).

9. Remove the connector (1), and then remove the bolt

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

3004A-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

3004A-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Fuel Supply Pump

Removal of Fuel Supply Pump 5. Cooling fan Removal

1. Injector safety information 1) Remove the cooling fan from the fan pulley.
ANNOTATION:
CAUTION
• Remove the spacer at the same time.
• Including the inside of the injector, the
holes and gaps that are to be used as
the fuel paths for the fuel system have an
extremely precise finish.
• Because there is the possibility of dam-
age due to foreign material contamina-
tion, cover the cap after removing parts,
etc., to prevent the intrusion of foreign
material.

2. Battery ground cable Disconnect

1) Disconnect the battery ground cable from the
battery.
3. Coolant Drain
1) Drain coolant from the radiator. 1 Cooling fan
2 Spacer
CAUTION
3 Fan pulley
• Do not loosen or remove the radia- 4 Bolt
tor cap when the coolant is hot.
• Steam and boiling water can burst 6. Fuel hose removal
out, possibly causing burns or heat
related injuries. 1) Remove the cover from the cylinder head
• When opening the radiator cap, cover.
place a thick cloth over the cap
when the coolant is cooled, and
turn it gradually to release the pres-
sure before opening it.

ANNOTATION:
• Loosen the water drain plug on the rear right
side of the engine, as well as the radiator
drain plug.
• Completely drain the coolant.
• After completely draining the coolant, se-
curely tighten the drain plug.
4. Fan shroud removal
1) Remove the fan shroud from the bracket. 1 Cover
ANNOTATION:
2) Remove the harness connector from the in-
• Remove the fan shroud and fan guard as a
unit. jector.
3) Remove the nozzle leak off pipe from the in-
jector.

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Removal and Installation of Fuel Supply Pump

8. Cam end gasket removal

1 Nozzle leak off pipe
2 Injector harness connector 1) Remove the cam end gasket from the cylinder
head.

CAUTION ANNOTATION:

• Do not reuse the leak-off pipe clip. • Clean any liquid gasket remaining on the
cylinder head.

1 Clip
1 Cam end gasket
7. Cylinder head cover Removal
1) Remove the cylinder head cover from the
cylinder head. 9. Timing chain upper cover removal
1) Remove the timing chain upper cover from the
CAUTION
cylinder head.
• Do not damage the lip section of the
oil seal with the connector of the
injector.

ANNOTATION:
• Shift the head cover to the left side of the
engine and lift upwards to remove.

1 Timing chain upper cover

2 Fan shroud bracket
3 Fan shroud stay
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Removal and Installation of Fuel Supply Pump

10. Timing chain lower cover removal

1) Remove the timing chain lower cover from the
gear case cover.

Alignment position of 1 cylinder

1
compression top dead center

1 Timing chain upper cover ANNOTATION:

2 CMP sensor • Confirm that the alignment marks of the
3 Timing chain lower cover camshaft bearing cap and the camshaft are
aligned.
11. Starter motor removal
1) Disconnect the earth cable from the starter
motor.
2) Disconnect the S-terminal from the starter mo-
tor.
3) Disconnect the B-terminal from the starter mo-
tor.
4) Remove the starter motor from the flywheel
housing.

1 Alignment mark

13. Supply pump gear nut removal

1) Fasten special tool to flywheel housing.
ANNOTATION:
• Install the crankshaft stopper to the flywheel
housing starter installation section and en-
12. Fuel supply pump preparation sure the crankshaft does not rotate.
1) Turn the crankshaft.
ANNOTATION:
• Rotate the crankshaft in a forward direction
to align the 1 cylinder with the compression
top dead center.

Special tool: crankshaft stopper (refer to

section 1003)
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Removal and Installation of Fuel Supply Pump

CAUTION 15. Timing chain lever pivot removal

1) Remove the timing chain lever pivot from the
• Verify that the stopper is installed timing gear case.
and securely bites into the ring
gear.

2) Turn the nut.

ANNOTATION:
• Loosen the nut of the supply pump gear.

16. Sprocket removal

1) Remove the nut from the sprocket.
2) Remove the sprocket from the supply pump
gear.

1 Supply pump gear nut

14. Timing chain tensioner removal

1) Remove the timing chain tensioner from the
cylinder head.

1 Timing chain tension lever pivot

2 Sprocket
3 Nut

ANNOTATION:
• After removing the sprocket, move the tim-
ing chain upward.

1 Timing chain tensioner

2 Gasket
3 Nut

17. Timing chain removal

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Removal and Installation of Fuel Supply Pump

1) Remove the timing chain from the sprocket. 1) Remove the fuel pipe from the fuel supply
pump and the common rail assembly.
ANNOTATION:
• Remove from the supply pump sprocket.
18. Supply pump gear removal
1) Check alignment mark of the supply pump
gear.

1 Fuel pipe

CAUTION
• Do not reuse the fuel pipe.
2) Remove the supply pump gear from the fuel
supply pump. 20. Leak-off pipe removal
ANNOTATION: 1) Remove the fuel leak-off pipe from the fuel
supply pump and common rail assembly.
• Remove the supply pump gear using a gear
puller. ANNOTATION:
• Do not reuse the gasket.

19. Fuel pipe Removal

1 Leak-off pipe, hose

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Removal and Installation of Fuel Supply Pump

21. Fuel supply pump removal 3) Remove the fuel supply pump from the timing
gear case.
1) Disconnect the harness connector from the
fuel supply pump. ANNOTATION:
ANNOTATION: • When removing the fuel supply pump, do
not hold the high pressure pipe of the pump
• Disconnect the harness connector of the instead of the handle.
suction control valve and fuel temperature
sensor.

1 Fuel supply pump

Fuel temperature sensor con- 2 Supply pump bracket
1 3 Stud bolt
nector
2 Suction control valve connector
4) Remove the O-ring from the fuel supply pump.
2) Remove the supply pump bracket from the
cylinder block.

1 Fuel supply pump

2 O-ring
3 High pressure pipe

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Removal and Installation of Fuel Supply Pump

Installation of Fuel Supply Pump 6) Securely tighten the supply pump bracket to
the cylinder block.
1. Fuel supply pump installation Tightening torque: 25 N・m {2.5 kgf・m / 18
1) Install the O-ring to the fuel supply pump. lb・ft}

ANNOTATION:
• Apply soapy water to the O-ring and install
the O-ring to the supply pump.
2) Install the fuel supply pump to the timing gear
case.

CAUTION
• When installing the fuel supply
pump, do not hold the high pres-
sure pipe of the pump as a handle.
• Ensure the O-ring does not pro-
trude.

ANNOTATION:
1 Fuel supply pump
• Confirm that the supply pump camshaft key 2 Supply pump bracket
is at a horizontal position on the right side. 3 Stud bolt

7) Connect the harness connector to the fuel

supply pump.
ANNOTATION:
• Connect the harness connector of the suc-
tion control valve and fuel temperature sen-
sor.

Tightening torque: 25 N・m {2.5 kgf・m / 18

Fuel temperature sensor con-

1
nector
2 Suction control valve

2. Leak-off pipe installation

1) Install the fuel leak-off pipe to the fuel supply
pump and common rail assembly.
ANNOTATION:
• Also install the hose at the same time.
CAUTION
• Do not reuse the gasket.
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3004A-9
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Removal and Installation of Fuel Supply Pump

1) Install the supply pump gear to the fuel supply

pump.
ANNOTATION:
• Install by aligning with the alignment mark
for the idle gear.

1 Leak-off pipe, hose

Tightening torque: 10.3 N・m {1.1 kgf・m /

7.598 lbf・ft} Eyebolt
5. Timing chain installation
3. Fuel pipe Installation
1) Align No.1cylinder to the compression top
1) Temporarily tighten the fuel pipe to the com- dead center.
mon rail assembly.
ANNOTATION:
CAUTION
• Rotate the crankshaft in the forward direc-
• Do not reuse the fuel pipe. tion to align the No.1 cylinder piston to com-
pression top dead center.
2) Temporarily tighten the fuel pipe to the fuel
supply pump.
3) Securely tighten the fuel pipe to the common
rail assembly.
Tightening torque: 44 N・m {4.5 kgf・m / 32
lb・ft} Sleeve nut
4) Temporarily tighten the fuel pipe to the fuel
supply pump.
Tightening torque: 44 N・m {4.5 kgf・m / 32
lb・ft} Sleeve nut

Compression top dead center

1
alignment position

2) Install the timing chain to the sprocket.

6. Sprocket installation
1) Install the sprocket to the supply pump gear.
ANNOTATION:
• Align the alignment mark of the supply pump
sprocket and the yellow plate of the timing
1 Fuel pipe chain.
• Align the dowel pin of the supply pump gear
and the notch of the supply pump sprocket,
4. Supply pump gear installation and install the supply pump sprocket.

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Removal and Installation of Fuel Supply Pump

2) Turn the nut. 1) Connect the hook to the pin.

ANNOTATION: ANNOTATION:
• Tighten the supply pump shaft nut with your • Push down the latch of the timing chain
hand. tensioner, insert the plunger, and hang the
hook to the pin.

1 Idle gear alignment mark

2 Blue plate 1 Pin
3 Sprocket alignment mark 2 Plunger
4 Yellow plate 3 Latch
4 Hook
7. Timing chain lever pivot installation
1) Install the timing chain lever pivot to the timing 2) Install the timing chain tensioner to the cylin-
chain tension lever. der head.
ANNOTATION: ANNOTATION:
• Check that the timing chain lever moves • Install the gasket, and tighten it to the spec-
smoothly. ified torque.
Tightening torque: 25 N・m {2.5 kgf・m / 18 CAUTION
lb・ft}
• Do not reuse the gasket.

Tightening torque: 10 N・m {1.0 kgf・m / 7.38

lbf・ft}

8. Timing chain tensioner installation

1 Timing chain tensioner

2 Gasket
3 Nut

CAUTION
• Turn the protruding section of the
gasket downward to install.

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Removal and Installation of Fuel Supply Pump

3) Disconnect the hook from the pin. • Turn the crankshaft pulley 720º to make the
chain tension even.
ANNOTATION:
• Align the alignment marks of the camshaft
• Lightly push the area indicated with an ar- and the camshaft bearing cap.
row in the diagram.
• The hook of the tensioner opens, the
plunger pushes the tension lever, and the
chain is pulled.

1 Alignment mark

10. Timing chain lower cover installation

9. Supply pump gear nut installation 1) Apply liquid gasket to the timing chain lower
1) Securely tighten the nut to the sprocket. cover.
ANNOTATION: ANNOTATION:
• Tighten the supply pump shaft nut to the • Apply ThreeBond 1207B.
specified torque.
CAUTION
Tightening torque: 130 N・m {13.3 kgf・m /
96 lb・ft} • Install the cover within five minutes
of applying liquid gasket.

1 Supply pump shaft nut

1 Liquid gasket
2) Turn the crankshaft pulley. 2 2 - 2.5 mm {0.0787 - 0.0984 in}
ANNOTATION: 3 2 - 2.5 mm {0.0787 - 0.0984 in}

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3004A-12
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Removal and Installation of Fuel Supply Pump

2) Install the timing chain lower cover to the gear 2) Install the timing chain upper cover to the
case cover. cylinder head.
Tightening torque: 10 N・m {1.0 kgf・m / 7.38
ANNOTATION:
lbf・ft}
• Apply Loctite 262 to the threaded portion on
the cylinder head side.
Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft}

1 Timing chain upper cover

2 CMP sensor
3 Timing chain lower cover

11. Timing chain upper cover installation

1 Timing chain upper cover
1) Apply liquid gasket to the timing chain upper 2 Fan shroud bracket
cover. 3 Fan shroud stay
ANNOTATION:
• Apply ThreeBond 1207B. 12. Starter motor installation
CAUTION 1) Install the starter motor to the flywheel hous-
ing.
• Install the cover within five minutes
of applying liquid gasket. ANNOTATION:
• Install the earth cable at the same time.
Tightening torque: 97 N・m {9.9 kgf・m / 72
lb・ft}

1 Liquid gasket
2 2
3 2 - 2.5 mm {0.0787 - 0.0984 in} 2) Connect the S-terminal to the starter motor.
3) Connect the B-terminal to the starter motor.
13. Cam end gasket installation
1) Install the cam end gasket to the cylinder
head.
ANNOTATION:
• Apply liquid gasket, ThreeBond 1207B to
the area 2 indicated in the diagram with a
width of 2.0 - 3.0 mm {0.0787 - 0.1181 in}
and install to the cylinder head.
84592788 EN - March 2012
3004A-13
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Removal and Installation of Fuel Supply Pump

1) Install the nozzle leak off pipe to the injector.

ANNOTATION:
• If the nozzle leak off hose has been re-
moved, install with the clip knob facing the
exhaust side as shown in the diagram.

1 Cam end gasket

2 Liquid gasket application area
3 Bead width

2) Connect the harness connector to the injector.

ANNOTATION:
• Apply liquid gasket, ThreeBond 1207B as
shown in the diagram.

1 Nozzle leak off pipe

2 Injector harness

3) Install the cover to the cylinder head cover.

3.0 - 5.0 mm {0.1181 - 0.1969

1
in}
3.0 - 5.0 mm {0.1181 - 0.1969
2
in}

14. Cylinder head cover Installation

1) Install the cylinder head cover to the cylinder
head.
Tightening torque: 10 N・m {1.0 kgf・m / 7.38
lbf・ft}
2) Connect the PCV hose to the cylinder head
cover.
15. Fuel hose installation 1 Cover

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3004A-14
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Removal and Installation of Fuel Supply Pump

16. Cooling fan Installation 2) Turn the plug.

1) Install the cooling fan belt to the fan pulley. ANNOTATION:
ANNOTATION: • Sufficiently loosen the air removal plug.
• Install the spacer at the same time. 3) Operate the priming pump.
Tightening torque: 25 N・m {2.5 kgf・m / 18 ANNOTATION:
lb・ft}
• Operate the priming pump 20 times or more
until fuel spills out around the plug.
4) Close the plug.
5) Operate the priming pump.
ANNOTATION:
• Operate the priming pump 10 times or more
until it is completely filled with fuel.
• Wait for approximately 1 minute after oper-
ating the priming pump.
6) Drain air from the fuel filter assembly.
ANNOTATION:
• Sufficiently loosen the air removal plug.
1 Cooling fan 7) Close the plug.
2 Spacer ANNOTATION:
3 Fan pulley
• Sufficiently tighten the air bleeding plug to
4 Bolt
the fuel filter.

17. Fan shroud installation CAUTION

1) Install the fan shroud to the bracket. • Tighten the air removal plug and
then completely wipe away any ex-
ANNOTATION: cess fuel in the vicinity.
• Install the fan shroud and fan guard.
8) Operate the priming pump.
Tightening torque: 51 N・m {5.2 kgf・m / 38
lb・ft} ANNOTATION:
• Push the priming pump 10 times to 15 times
to feed fuel into the supply pump.
• or less, after starting the engine
9) Start the engine and put it into an idling state.
ANNOTATION:
• Idle for 5 seconds.
CAUTION
• Do not rev the engine.

10) Adjust the engine speed.

ANNOTATION:
18. Coolant filling
• Slowly increase the engine speed and main-
1) Replenish the radiator assembly with coolant. tain for 3 seconds.
19. Fuel Air bleed • After completion of the above operation, op-
erate at maximum revolutions on the side
ANNOTATION: of the machine and repeat the operation
• Before starting the engine of revving to the maximum speed multiple
times.
1) Prepare the pan.
ANNOTATION:
• Place an appropriate pan under the fuel fil-
ter.
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3004A-15
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Removal and Installation of Fuel Supply Pump

CAUTION 21. ECM writing

ANNOTATION:
• If air removal operations are insuf-
ficient, due to the possibility of en- • Idle the engine until it is warmed up in order to
gine trouble, make sure to follow all have the ECM learn the characteristics of the fuel
procedures. supply pump.
• If a DTC for the fuel system is recorded before
20. Battery ground cable Connect completion, clear the DTC and warm up the en-
gine again.
1) Connect the battery ground cable to the bat-
tery.

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Section

3004B

Removal and Installation of Common Rail Assembly

84592788 EN - March 2012

CONTENTS

Removal of Common Rail Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Common Rail Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

3004B-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

3004B-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Common Rail Assembly

Removal of Common Rail 4. Leak-off pipe removal

Assembly 1) Remove the fuel leak-off pipe from the fuel
supply pump and common rail assembly.
1. Injector safety information
ANNOTATION:
CAUTION • Do not reuse the gasket.
• Including the inside of the injector, the
holes and gaps that are to be used as
the fuel paths for the fuel system have an
extremely precise finish.
• Because there is the possibility of dam-
age due to foreign material contamina-
tion, cover the cap after removing parts,
etc., to prevent the intrusion of foreign
material.

2. Battery ground cable Disconnect

1) Disconnect the battery ground cable from the
battery.
3. Fuel pipe Removal
1) Remove the fuel pipe from the fuel supply 1 Leak-off pipe, hose
pump and the common rail assembly.
5. Injection pipe Removal
1) Remove the injection pipe from the injector
and the common rail assembly.

CAUTION
• Do not reuse the injection pipe.

1 Fuel pipe

CAUTION
• Do not reuse the fuel pipe.

1 Injection pipe
2 Clip

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Removal and Installation of Common Rail Assembly

6. Common rail assembly Removal Installation of Common Rail

1) Disconnect the harness connector from the Assembly
fuel pressure sensor.
2) Remove the common rail assembly from the 1. Common rail assembly Installation
cylinder block.
1) Install the common rail assembly to the cylin-
ANNOTATION: der block.
• Simultaneously remove the common rail CAUTION
bracket.
• When installing the common rail as-
sembly, do not clutch and raise up
the pressure sensor.
• Take care not to damage the con-
nector unit of the pressure sensor.

ANNOTATION:
• Install the common rail bracket at the same
time.

1 Common rail bracket

2 Common rail assembly

1 Common rail bracket

2 Common rail assembly

ANNOTATION:
• Tighten bolts in the order shown in the dia-
gram.

Tightening torque: 25 N・m {2.5 kgf・m / 18

lb・ft}

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3004B-4
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Removal and Installation of Common Rail Assembly

2. Injection pipe Installation 1) Install the fuel leak-off pipe to the fuel supply
pump and common rail assembly.
CAUTION
ANNOTATION:
• If the high pressure pipe of the fuel sys-
tem has been removed, make sure to re- • Also install the hose at the same time.
place with a new part.
CAUTION
• Reuse may cause the seal surface to be
damaged and fuel to leak. • Do not reuse the gasket.

1) Temporarily tighten the injection pipe to the

injector and common rail assembly.
ANNOTATION:
• Apply engine oil to the threaded portion of
the sleeve nut on the injector side of the
injection pipe and the O-ring of the injector.
• When installing, do not damage the injector
sleeve gasket.
• Using an open-end wrench, lightly tighten
the sleeve nut on the common rail side until
it is firmly attached.
• Tighten the sleeve nuts on the injector side
until they can no longer be turned by hand.
2) Securely tighten the injection pipe to the injec-
tor. 1 Leak-off pipe, hose
ANNOTATION:
Tightening torque: 10.3 N・m {1.1 kgf・m /
• Tighten the sleeve nut on the injector side 7.598 lbf・ft} Eyebolt
of the injection pipe to the specified torque.
4. Fuel pipe Installation
Tightening torque: 30 N・m {3.1 kgf・m / 22
lb・ft} 1) Temporarily tighten the fuel pipe to the com-
3) Securely tighten the injection pipe to the common rail assembly.
mon rail assembly.
CAUTION
ANNOTATION:
• Do not reuse the fuel pipe.
• Tighten the sleeve nut on the common rail
side of the injection pipe to the specified
2) Temporarily tighten the fuel pipe to the fuel
torque.
supply pump.
Tightening torque: 25 N・m {2.5 kgf・m / 18 3) Securely tighten the fuel pipe to the common
lb・ft} rail assembly.
Tightening torque: 7.8 N・m {0.8 kgf・m / Tightening torque: 44 N・m {4.5 kgf・m / 32
5.754 lbf・ft} Clamp nut lb・ft} Sleeve nut
4) Temporarily tighten the fuel pipe to the fuel
supply pump.
Tightening torque: 44 N・m {4.5 kgf・m / 32
lb・ft} Sleeve nut

1 Injection pipe
2 Clamp

3. Leak-off pipe installation 1 Fuel pipe

84592788 EN - March 2012
3004B-5
Copyright ©
Removal and Installation of Common Rail Assembly

5. Battery ground cable Connect

1) Connect the battery ground cable to the bat-
tery.

84592788 EN - March 2012

3004B-6
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Section

3005

Removal and Installation of Injector

84592788 EN - March 2012

CONTENTS

Removal of Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Injector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

3005-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

3005-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Injector

Removal of Injector 1 Nozzle leak off pipe

2 Injector harness connector
1. Injector safety information

CAUTION CAUTION
• Including the inside of the injector, the • Do not reuse the leak-off pipe clip.
holes and gaps that are to be used as
the fuel paths for the fuel system have an
extremely precise finish.
• Because there is the possibility of dam-
age due to foreign material contamina-
tion, cover the cap after removing parts,
etc., to prevent the intrusion of foreign
material.

2. Battery ground cable Disconnect

1) Disconnect the battery ground cable from the
battery.
3. Fuel hose removal
1) Remove the cover from the cylinder head
cover. 1 Clip

4. Cylinder head cover Removal

1) Remove the cylinder head cover from the
cylinder head.

CAUTION
• Do not damage the lip section of the
oil seal with the connector of the
injector.

ANNOTATION:
• Shift the head cover to the left side of the
engine and lift upwards to remove.
1 Cover

2) Remove the harness connector from the in-

jector.
3) Remove the nozzle leak off pipe from the in-
jector.

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3005-3
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Removal and Installation of Injector

5. Cam end gasket removal

1) Remove the cam end gasket from the cylinder
head.
ANNOTATION:
• Clean any liquid gasket remaining on the
cylinder head.

1 Injector
2 Leak-off pipe
3 Clip
4 O-ring
5 Injector gasket

CAUTION

1 Cam end gasket • The injector ID code identifies the

injectors.
• Do not remove the injector ID codes
6. Injection pipe Removal from the injectors.
• Absolutely never touch the injector
1) Remove the injection pipe from the injector solenoids because that can hinder
and the common rail assembly. their performance or cause dam-
age.
CAUTION • Store the removed injector with the
• Do not reuse the injection pipe. cylinder number on it.
• When the injector has been re-
placed, erase the ID code of the
replaced cylinder number on the
injector ID code label using a black
pen, etc.

1 Injection pipe
2 Clip

7. Injector Removal 1 Injector ID code

2 Injector
1) Remove the injector from the cylinder head
assembly.
2) Remove the injector gasket from the injector.
3) Remove the O-ring from the injector.

3005-8
Copyright ©

Section

4001A

Electrical and Engine Basic Functions

84592788 EN - March 2012

CONTENTS

Monitor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Coolant Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Oil Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Monitor Display Dimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Eco Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DPD Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Diagnostic Trouble Code Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fuel Economy Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Neutral Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine Start/Stop Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Idling Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Auto Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
One-touch Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Auto Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Quick Warm-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Idling Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Idle up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Travel Speed Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Swing Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Static Horsepower Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Working Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Radio Mute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Engine Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Travel Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Back/Side View Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Swing Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Overload Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Operability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Swing Speed Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Pressure Boost Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Energy saving / Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Pump Standby Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Swing Relief Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Stroke Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Boom Down Energy Save. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Auto Energy Save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Overload Reduction Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
End Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Breaker Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Crusher Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Anti-theft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
84592788 EN - March 2012 Copyright © 2011 CNH FRANCE
4001A-1 PRINTED IN FRANCE
Copyright ©

Enabling the anti-theft function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Immobilizer Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Feed Pump Automatic Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Coolant Level Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Hydraulic Oil Filter Clog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Air Filter Clog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Fuel Filter Clog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
DPD Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Automatic Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Manual Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Forced Manual Regeneration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Hydraulic Assist Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

4001A-2 PRINTED IN FRANCE
Copyright ©
Electrical and Engine Basic Functions

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

• The table below shows the correspondence be-

tween the fuel sensor % and the bar graph level.

Lever angle [%] Bar graph level

100 8
83 7
67 6
50 5
33 4
17 3
1 2
0 1

* Currently, the above settings are common to all

models.

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

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Electrical and Engine Basic Functions

Coolant Temperature Gauge

Purpose
Displays the coolant temperature using a meter and bar graph.(Coolant temperature check)

1 Coolant temperature gauge 3 Computer A 5 Coolant temperature sensor

2 Monitor 4 ECM 6 Engine

a Bar graph display

b Meter display

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

Meter indicator angle

Temperature [°C ( °F )] Bar graph level x 3
[deg.]
Lower than 50 ( 122.0 ) 0 - 15 1
50 ( 122.0 ) 15 2
77 ( 170.6 ) 58 3
82 ( 179.6 ) 66 4
97 ( 206.6 ) 90 5
100 ( 212.0 ) 118 6
102 ( 215.6 ) 137 7
105 ( 221.0 ) 165 8

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Electrical and Engine Basic Functions

Oil Temperature Gauge

Purpose
Displays the oil temperature on a meter.(Oil temperature check)

1 Oil temperature gauge 3 Computer A 5 Oil temperature sensor

2 Monitor 4 Hydraulic oil tank 6 Hydraulic pump

a Meter display

Operation explanation
1. When the key is turned ON, the oil temperature meter indicates the current oil temperature range.
2. When the camera screen select switch is pressed to switch to the camera screen, the oil temperature meter is
not displayed.
3. The meter is not displayed if oil temperature sensor trouble is detected.
Remarks
The oil temperature ranges are shown in the table below.

Meter indicator angle

Temperature [°C ( °F )]
[deg.]
Lower than 25 ( 77.0 ) 0 - 15
25 ( 77.0 ) 15
45 ( 113.0 ) 42
60 ( 140.0 ) 63
80 ( 176.0 ) 90
88 ( 190.4 ) 123
92 ( 197.6 ) 140
95 ( 203.0 ) 153
97 ( 206.6 ) 161
98 ( 208.4 ) 165

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Electrical and Engine Basic Functions

Monitor Display Dimming

Purpose
Adjusts the brightness of the backlight through operation that is linked to the working light and solar radiation sensor.

1 Monitor 3 Solar radiation sensor 5 Working light relay

2 Computer A 4 Working light switch

a Dimming level automatic adjustment using the solar radiation

sensor
b Working light-linked dimming using the working light relay

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

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Electrical and Engine Basic Functions

Eco Gauge
Purpose
Displays on the monitor whether energy-saving operation is being performed.(Eco function)

1 Eco gauge
2 Monitor
3 Computer A

Operation explanation
1. The eco gauge is displayed on the monitor.
2. The eco-saving performance is judged in levels from 0 to 9.(The higher the number, the better the eco perfor-
mance.)
In SP mode, the maximum is 4.
In H mode, the maximum is 6.
In A mode, the maximum is 8.
In low idle, the maximum is 9.

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Electrical and Engine Basic Functions

DPD Gauge
Purpose
Displays an icon and bar graph on the monitor during DPD regeneration.

1 DPD gauge
2 Monitor
3 Computer A

Operation explanation
1. DPD bar graph display conditions
1) The DPD clogging level is displayed on the DPD bar graph during normal operation.(5-level display)
When 5 white lamps are displayed, it indicates that the tank is full.
2) The regeneration progress is displayed on the DPD bar graph during DPD regeneration (5-level display).
The white lamps go off one by one, and when all have gone off, regeneration is complete.
2. DPD amber lamp display condition
1) The amber lamp turns on and flashes during manual DPD regeneration.
3. DPD green lamp display condition
1) The green lamp turns on and flashes during automatic DPD regeneration.

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Electrical and Engine Basic Functions

Diagnostic Trouble Code Indicator

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

1 Diagnostic trouble code

2 Monitor
3 Computer A

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

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Electrical and Engine Basic Functions

Clock
Purpose
Displays the time on the monitor.
Operation explanation
• The time is always displayed on the monitor.
• The clock continues to operate, without display, when the key is turned OFF. (Because it uses power from the
battery)

Fuel Economy Gauge

Purpose
Displays the fuel economy on the monitor.

1 Fuel economy gauge

2 Monitor
3 Computer A

Operation explanation
1. The fuel economy gauge is displayed on the monitor after the key is turned ON.
2. When trouble occurs, the fuel economy gauge goes off and the diagnostic trouble code is displayed.
3. When the trouble is recovered from, the diagnostic trouble code goes off and the fuel economy gauge is dis-
played again.

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Electrical and Engine Basic Functions

Basic Operation
Neutral Start
Purpose
The engine will not start with the gate lever lifted.(It will not crank.)
This prevents accidental operation if the operation lever is touched when the engine is started.
Configuration

1 Key switch 4 Starter cut relay 7 Starter relay

2 Gate lock limit switch 5 Lever lock solenoid 8 Neutral start relay
3 Starter motor 6 Battery relay 9 ECM

Operation explanation
1. Lower the gate lever.
2. The starter cut relay is excited and the excitation to the safety relay is cut off.
3. Engine cranking is prohibited.
4. If the gate lever is then raised, cranking is enabled.

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Electrical and Engine Basic Functions

Engine Start/Stop Control

Purpose
Engine starting and stopping

1 Computer A 3 Crank sensor 5 Speed

2 Cam sensor 4 ECM 6 Engine

Operation explanation
1. Start the engine.
2. When the engine speed rises to 500 min-1 ( 500 rpm ) or higher, engine start is judged.
3. Stop the engine.
4. When the engine speed drops to less than 200 min-1 ( 200 rpm ), engine stop is judged.

a Start c 200 min-1 ( 200 rpm )

b 500 min-1 ( 500 rpm ) d Stop

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Electrical and Engine Basic Functions

Preheating
Purpose
Before cranking, the insides of the engine cylinders are automatically heated to improve starting.(Warm-up opera-
tion)

1 Key switch 3 ECM 5 Coolant temperature sensor

2 Computer A 4 Engine

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

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Electrical and Engine Basic Functions

Throttle
Purpose
Indicates the target engine speed.

1 Monitor 3 Throttle volume 5 Engine

2 Computer A 4 ECM

b 3 min. e SP mode h Low idle
c 3 min. f 1500 min-1 ( 1500 rpm )

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

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Electrical and Engine Basic Functions

Travel Speed Selection

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

Travel 2-speed switchover so-

1 Computer A 3 Travel motor 5
lenoid
Travel 2-speed switchover so-
2 4 Monitor
lenoid

Operation explanation
1. When the key is turned ON, the travel 2-speed switchover solenoid turns OFF, and the travel mode icon on the
monitor goes to low speed.
2. When the travel speed switchover switch is pressed, the travel 2-switchover solenoid turns ON, and the travel
mode icon on the monitor goes to high speed.
3. When the travel speed switchover switch is pressed again, the travel 2-speed switchover solenoid turns OFF,
and the travel mode icon on the monitor goes to low speed.
* Even when the travel 2-speed switchover solenoid is ON, the tilting angle will automatically switch over to low
speed due to a travel motor function if the travel motor drive pressure becomes high.
However, the travel 2-speed switchover solenoid is ON.

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Electrical and Engine Basic Functions

Swing Brake
Purpose
The swing brake is turned OFF when either the upper or swing is operating. (Operational ability is increased)

1 Computer A 3 Pressure sensor (swing) 5 Swing brake

2 Pressure sensor (upper) 4 Swing brake solenoid valve

1. Operation conditions for swing brake

Operation starts under the following conditions.
1) An upper operation is not being performed. (Upper pressure sensor OFF)
* The swing brake is applied 1 sec. after the upper pressure sensor turns OFF.
2) A swing operation is not being performed. (Swing pressure sensor OFF)
* The swing brake is applied 5 sec. after the swing pressure sensor turns OFF.
2. End conditions for swing brake
Operation ends under the following conditions.
1) An upper operation is performed. (Upper pressure sensor ON)
2) A swing operation is performed. (Swing pressure sensor ON)

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Electrical and Engine Basic Functions

Static Horsepower Control

Purpose
Monitor the engine actual speed and the engine target speed and set the appropriate amount of horsepower. (En-
gine stop prevention, energy saving)

1 Hydraulic pump 4 ECM 7 Pressure sensor (travel)

Horsepower control propor-
2 5 Engine
tional valve
3 Computer A 6 Engine speed sensor

a Engine target speed

b Discharge volume fluctuation

Operation Explanation
1. The minimum milli-amp and maximum milli-amp is selected from the milli-amp set for each engine speed.
2. When the engine actual speed falls 30/min or more below the target engine speed, the milli-amp is gradually
lowered to the minimum.
3. When the engine actual speed is not 30/min or more below the target engine speed, the milli-amp is gradually
raised to the maximum.
4. When the engine speed is at a low speed, the milli-amp decreases.
5. When the engine speed is increasing after being at a low speed, the milli-amp increases.

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Electrical and Engine Basic Functions

Accessories
Working Light
Purpose
Press the working light switch to turn the working light on.(To improve visibility during night work.)

1 Monitor 3 Working light relay

2 Computer A 4 Working light switch

Operation explanation
1. When the key is turned ON, the working light is OFF.
2. When the working light switch is pressed, the working light relay turns ON, and the working light icon on the
monitor turns ON.
The boom light and cab light turn on.
3. When the working light switch is pressed again, the working light relay turns OFF, and the working light icon on
the monitor turns OFF.
The boom light and cab light turn off.

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Electrical and Engine Basic Functions

4001A-30
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Electrical and Engine Basic Functions

Back/Side View Monitor

Purpose
Displays an image on the monitor from the camera that is installed on the shovel.(Improves rear visibility. Improves
safety)

1 Monitor 3 Camera select switch 5 Side camera

2 Camera screen switch 4 Rear camera

a Options

Operation explanation
1. When the key is turned ON, the camera screen can be viewed by pressing the camera screen switch.
• Each time the camera screen switch is pressed, the screen alternates between the work screen and the
camera screen.
• In the camera screen, only the minimum required icons and gauges are displayed.
2. When the camera select switch is pressed in the camera screen, the screen display can be selected in the
order of rear → side → rear + side → rear.
• To perform camera selection, camera ON must be set in the camera setting screen.
• The camera select switch is enabled when multiple cameras are set.
The switch does not respond if there is only 1 rear camera.
3. If image interruption due to camera trouble (disconnection, etc.) is detected, the camera screen turns black
and ERROR is displayed.
* When the camera select switch is pressed in the work screen, the trip meter select switch function is activated.
* The camera screen switch is disabled if no cameras are mounted.

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Electrical and Engine Basic Functions

Swing Lock
Purpose
Turns the swing brake ON.

1 Monitor 4 Horn volume select switch 7 Swing brake

2 Working light switch 5 Computer A
3 Auto idle switch 6 Swing brake solenoid

Operation explanation
1. Operation conditions for swing lock
1) Hold down the horn volume select switch, working light switch and auto idle switch at the same time for
3 sec.
* When the swing lock is ON and the key is OFF.Then, when the key is turned ON again, the swing lock stays
ON.
* When the swing lock and free swing are both ON, the swing lock is prioritized.
* When the swing lock is ON, the swing lock icon is displayed on the monitor.
* Even when an attachment operation or swing operation is performed while swing is ON, swing lock ON is
prioritized.(Be careful because if the swing operation is performed in this condition, the swing brake plate will
be dragged.)
2. End conditions for swing lock
1) While the swing lock is ON, hold down the horn volume select switch, working light switch and auto idle
switch at the same time for 3 sec.

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Electrical and Engine Basic Functions

Overload Warning
Summary
Overload warning device for lifting work with shovel
If the bottom pressure of the boom cylinder exceeds the stipulated pressure, it is judged that there is a danger of
the machine falling over and the monitor buzzer sounds (overload warning).
Configuration

1 Overload switch 3 Computer B *5 Overload pressure sensor

*2 Color monitor *4 Computer A

Operation explanation
1. When the overload switch is turned ON, the buzzer sound starts and stops according to the conditions below.
When the overload switch is OFF, the buzzer does not sound.
1) Overload warning start: The boom bottom pressure is greater than or equal to the set pressure continu-
ously for 1 sec.
2) Overload warning stop: The boom bottom pressure is less than or equal to the set pressure -2 MPa
(-290.10 psi) continuously for 1 sec.
2. The alarm pattern is a 1-second cycle - ON for 0.5 sec. and OFF for 0.5 sec.

1 Overload switch 3 Monitor buzzer

*2 Boom bottom pressure *4 Set pressure

3. Display: The warning is only given with the monitor buzzer.

The lamps etc. do not illuminate.

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Electrical and Engine Basic Functions

Operability
Swing Speed Limit
Purpose
When the pump flow rises during a swing operation, the swing speed increases.
To prevent this, control of the pump flow is performed.(Swing speed control)

1 Computer A 5 Pressure sensor (N1) 9 Regulator

P1 flow control proportional
2 Throttle volume 6 Pressure sensor (N2) 10
valve
3 Pressure sensor (travel) 7 Pressure sensor (P1)
4 Pressure switch (option 1) 8 Pressure sensor (P2)

a Arm (1) d Option 1 g Boom (1)

b Boom (2) e Travel (left) h Bucket
c Swing f Arm (2) i Travel (right)

Operation explanation
1. Operation conditions for swing speed limit control
Control is executed when all the conditions below are satisfied.
1) Independent swing operation (swing pressure sensor ON)
2) When travel or option operations are not being performed (travel and option pressure sensors OFF)
3) Work mode is SP or H mode(except CX350C/CX370C/350X3)
2. Swing speed limit end conditions
The operation ends under the following conditions.
1) Ends immediately after a travel or option operation is performed (travel or option pressure sensor ON).
2) Ends gradually after an attachment operation is performed (upper pressure sensor ON).

b Boom (2) e Travel (left) h Bucket
c Swing f Arm (2) i Travel (right)

Operation explanation
1. Operation conditions for swing relief cut
The operation starts when all the conditions below are satisfied.
Oil temperature is 30 °C ( 86.0 °F ) or higher
1) When a swing operation is performed. (Swing pressure sensor ON)
2) Within 1 sec. after start of swing
3) When travel or option operations are not being performed.(Travel and option pressure sensors OFF)
2. Swing relief cut end conditions
1) When a swing operation is not being performed.(Swing pressure sensor OFF)
2) When a travel or option operation is performed.(Travel or option pressure sensor ON)

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Electrical and Engine Basic Functions

Stroke Control
Summary
In order to improve fuel efficiency, the pump pressure is lowered by reducing the orifice loss.
A 3-stack proportional valve is used for control.
Arm 2 control
1. In normal operations, flow volume loss is reduced by suppressing the spool opening for Arm 2.
2. In the second half of leveling work, the spool opening is opened to reduce P2-arm bottom pressure loss and to
give priority to the arm for flow volume, thus suppressing flow volume loss.
Configuration
• The larger the proportional valve output current, the more the secondary pressure output is suppressed.

1 P2 pressure sensor 4 Computer B *7 Arm-in pressure sensor

Arm-in reverse proportional
*2 Travel pressure sensor *5 *8 Bucket-close pressure sensor
valve
*3 Computer A *6 Boom-up pressure sensor

Operation explanation
1. The operator operates the shovel.
2. When the system detects the events below, it judges that this is the start of leveling.
• When any of the following conditions is established the instant that arm-in operation becomes full
• Boom-up lever operation is at half lever.
• The boom-up and bucket-close levers are operated at the same time.
3. When the system judges leveling to be starting, it releases the restriction on Arm 2.
4. If the events below occur when the system does not judge leveling to be starting, it releases the restriction
on Arm 2. When that is not the case, it restricts Arm 2.
• Boom-up lever operation is at half lever.
5. The operator stops arm-in full operation or travels.
6. The system restricts Arm 2.
* When Arm 2 is released from the restricted state, it is released gradually as a measure against shock from
the restriction release.
Boom 2 control
In leveling work, the boom spool is pressed back to reduce P1-arm bottom pressure loss and to allow more flow to
the arm and bucket.
Configuration
• When the output current is raised, the force pushing back the spool is increased.

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Electrical and Engine Basic Functions

1 Boom-up proportional valve 4 Computer B *7 Bucket-close pressure sensor

*2 Travel pressure sensor *5 Boom-up pressure sensor
*3 Computer A *6 Arm-in pressure sensor

Operation
1. The operator operates the shovel.
2. When the system detects the events below, it judges that this is the start of leveling.
• When any of the following conditions is established the instant that arm-in operation becomes full
• The boom-up lever operation is at half lever.
• The boom-up and bucket-close levers are operated at the same time.
3. If the system detects any of the events below when the system judges leveling to be starting, it issues the
Boom-2-down proportional valve instruction.
• The boom-up lever operation is at half lever.
• During bucket-close operation
4. When the system does not judge leveling to be starting, it does not issue the Boom-2-down proportional valve
instruction.
5. The operator stops arm-in full operation or travels.
6. The system stops the Boom-2-down proportional valve instruction.
* When the Boom-2-down proportional valve instruction changes, as a measure against vibration, the Boom-
2-down proportional valve command current value is lowered gradually (for both ON→OFF and OFF→ON).
Bucket control
Mostly in the second half of leveling and when collecting dirt and sand during digging, the spool opening is opened
so that a larger volume can flow.
Configuration
The larger the output current, the more the secondary pressure output is suppressed.

Bucket-close reverse propor-

1 Monitor 4 Breaker mode switch *7 Hydraulic oil tank

Breaker/crusher (1st option)
*2 Computer B *5 *8 1st option pressure switch
pedal
*3 Computer A *6 Hydraulic oil filter clog switch

Operation explanation
If clogging occurs in the return filter inside the hydraulic tank, a message is displayed on the monitor giving the
diagnostic trouble code and the warning buzzer sounds. (For breaker, multi-purpose machines only)
1. Configuration: When the clog detection pressure switch goes open, Computer A detects the clog and sends a
command to the monitor.
2. Clog detection: Starts 10 sec. after the engine starts.
When the clog switch contact opens, Computer A detects this.
If the contact point is ON continuously for 1 sec., the return filter is judged to be clogged.
However, detection does not occur in the following cases.
• During breaker operation: Because pulsation is severe (In other words, no warning is issued while the breaker
is operating.)
• When the oil temperature is less than 30 °C (86.0 °F): Because the hydraulic oil viscosity is high and accurate
detection is not possible.
• When the clog detection switch is broken: For details, see the sections below.
3. Warning: When the monitor receives the filter clog command, it carries out the following operation.
• Message: "RETURN FILTER" is displayed.
Even after the coolant level is restored to normal, the "LOW COOLANT" message remains displayed while
the key is ON.
• Diagnostic Trouble Code: "7423" is displayed.
Even after the coolant level is restored to normal, the "LOW COOLANT" message remains displayed while
the key is ON.
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Electrical and Engine Basic Functions

• Monitor buzzer: The buzzer sounds at the same time that the message is displayed and the buzzer automat-
ically stops after 5 sec.
4. Clog switch trouble detection: Before engine starting, the contact point of the clog detection switch should be
closed (B contact point).
However, if the circuit is open (continuously for 1 sec.), it is judged that the clog detection switch is disconnected,
the "Electrical system abnormality" message and diagnostic trouble code "7063" are displayed, and the buzzer
sounds for 5 sec..
5. Time chart:

Switches the DPD gauge from regeneration progress display to accumulated amount display.
Starts the auto idle/idle stop control.
To restart regeneration, after the cause of the stoppage has been eliminated, press the DPD switch.
• If the gate bar limit switch comes OFF (hydraulic operation is disabled), regeneration is stopped.
• During automatic regeneration, if the monitor's DPD switch is pressed, regeneration is stopped.
• If the exhaust gas temperature reaches 400 °C (752.0 °F) or higher, regeneration is stopped.
4. Ending automatic regeneration: The computer receives the automatic regeneration end signal from the ECM
and ends the control.
• Puts out the DPD green lamp.
• Switches the DPD gauge from regeneration progress display to accumulated amount display.
• Puts out the "AUTO DPD RE-GEN" and "CAUTION! HOT EXHAUST" messages.
• Starts the auto idle/idle stop control.

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Electrical and Engine Basic Functions

Manual Regeneration
Summary
If automatic regeneration is incomplete or the amount of accumulated PM is large, the ECM requests manual re-
generation.
The machine cannot be operated during manual regeneration.
The computer controls the regeneration assist load.
Configuration

1 ECM 5 DPD SW *9 DPD Prerss sensor

*2 CONT_A *6 Water Temp. sensor *10 Pump Flow P-S/V
*3 CONT_B *7 DPD(CT) Temp. sensor *11 Boom2 P-S/V
*4 MONITOR *8 DPD(FT) Temp. sensor *12 Lever lock S/V

Operation explanation
1. Requesting manual regeneration: When the manual regeneration request comes from the ECM to the com-
puter, it displays the following items on the monitor.
• Flashes the DPD amber lamp (2-second cycle at first, high-speed 0.6-second cycle afterward)
• Displays the "PUSH DPD SWITCH TO ACTIVATE" message.
2. Manual regeneration start conditions: When the following conditions are all met and the DPD switch is pressed,
the computer sets the engine speed to 1000 min-1 (1000 rpm) and starts manual regeneration.
• The gate bar limit switch is OFF (hydraulic operation is disabled).
• The engine coolant temperature is at least 70 °C (158.0 °F) but less than 100°C (212.0 °F).
• There is no sensor or DPD related abnormality.
• When released, automatically goes to 1000 min-1 (1000 rpm).
3. Start of manual regeneration: If the conditions above are met, Computer A starts the following control.
• Lights the DPD amber lamp.
• Sets off the buzzer for 2 sec..
• Switches the DPD gauge from accumulated amount display to regeneration progress display.
• Displays the "AUTO DPD RE-GEN" and "CAUTION! HOT EXHAUST" messages alternating.
• Computer A drives the DPD relay and sends the DPD regeneration signal to the ECM.
• Stops the auto idle/idle stop control.
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Electrical and Engine Basic Functions

• Starts the hydraulic pressure assist load control (in order to raise the exhaust gas temperature).
4. Stopping manual regeneration: When the operations below are performed, the ECM regeneration prohibition
signal is sent and manual regeneration is stopped.
While regeneration is stopped, the DPD amber lamp flashes.
Displays the "PUSH DPD SWITCH TO ACTIVATE" message.
Switches the DPD gauge from regeneration progress display to accumulated amount display.
Starts the auto idle/idle stop control.
To restart regeneration, after the cause of the stoppage has been eliminated, press the DPD switch.
• If the gate bar limit switch comes ON (hydraulic operation enabled), regeneration is stopped.
• During automatic regeneration, if the monitor's DPD switch is pressed, regeneration is stopped.
• If the exhaust gas temperature reaches 400 °C (752.0 °F) or higher, regeneration is stopped.
• If the hydraulic pressure assist proportional valve breaks down during regeneration
• If the throttle is operated
5. Ending manual regeneration: The computer receives the manual regeneration end signal from the ECM and
ends the control.
• Puts out the DPD amber lamp.
• Switches the DPD gauge from regeneration progress display to accumulated amount display.
• Puts out the "AUTO DPD RE-GEN" and "CAUTION! HOT EXHAUST" messages.
• Starts the auto idle/idle stop control.
6. Regeneration hydraulic pressure load assist: During manual regeneration, puts a load on the pump in order to
raise the exhaust gas temperature.
• Computer A set the pump flow proportional valve to the minimum flow at 740 mA.
• After 1 sec., Computer A sets the boom 2 proportional valve to 600 mA for the maximum load.
• After 1 sec., Computer A sets the pump flow proportional valve to 600 mA.
• After 30 sec., Computer A controls the pump flow proportional valve so that the DPD exhaust gas temperature
(before DOC) is constant at 270 °C (518.0 °F). (Lowers it gradually 50 mA/second. update period 15 sec.,
update width 5 mA)

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Electrical and Engine Basic Functions

Forced Manual Regeneration

Summary
During automatic regeneration, it is possible to interrupt automatic regeneration and switch to manual regeneration.
This can only be executed while automatic regeneration is stopped.
Configuration

1 ECM 5 DPD SW *9 DPD Prerss sensor

*2 CONT_A *6 Water Temp. sensor *10 Pump Flow P-S/V
*3 CONT_B *7 DPD(CT) Temp. sensor *11 Boom2 P-S/V
*4 MONITOR *8 DPD(FT) Temp. sensor *12 Lever lock S/V

4001B

Service Support

84592788 EN - March 2012

CONTENTS

Service Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Screen Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Screen Display List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHECK Screen List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MACHINE STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FAULT HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
WORK HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ENGINE HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
HYDRAULIC HISTORY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
PART NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SETUP Screen List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
MACHINE SELECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Model Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Throttle Volume Default Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Password Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Adjusting the Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Option Flow Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Screen Brightness Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

4001B-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

4001B-2 PRINTED IN FRANCE
Copyright ©
Service Support

Service Support
Screen Operations
Screen Display List

1 Travel speed select switch 3 Menu screen display switch 5 Wiper switch
2 Attachment select switch 4 Working light switch 6 Auto idling switch

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4001B-3
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Service Support

CHECK Screen List check sensor and switch input/output states, as well as
the angle, load ratio and work radius, etc. at the applied
In CHECK mode, in addition to the machine status (milli- machine (liftcrane specifications machine, lifting magnet
amp, oil pressures, temperatures, etc.), it is possible to machine).

1 Section Detailed data for the selected item can be seen by press-

For the CHECK mode section types and their contents,

see the separate sheet.
ing .

By pressing and on the monitor,

MACHINE STATUS, FAULT HISTORY, etc. can be
selected.

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Service Support

MACHINE STATUS 2. Temperature and pressure

1. Engine and pump

kPa ( psi
BOOST PRESS. Boost pressure
)
min-1 ( BAROMETRIC kPa ( psi
ENGINE SPEED Engine speed Barometric pressure
rpm ) PRESS. )
ENGINE LOAD BOOST TEMP. °C ( °F ) Boost temperature
％ Engine load ratio
RATIO
Suction air tempera-
MPa ( Pump 1; Discharge AIR INLET TEMP. °C ( °F )
P1 PRESS. ture
psi ) pressure
FUEL TEMP. °C ( °F ) Fuel temperature
MPa ( Pump 2; Discharge
P2 PRESS. MANIFOLD IN-
psi ) pressure °C ( °F ) Manifold temperature
NER TEMP.
MPa ( Pump 1; Negative
N1 PRESS. COOLANT TEMP. °C ( °F ) Coolant temperature
psi ) control pressure
MPa ( Pump 2; Negative HYD.OIL TEMP. °C ( °F ) Oil temperature
N2 PRESS.
psi ) control pressure
3. Pressure and solenoid
Horsepower control
P.SOL;PUMP-
mA proportional valve;
POWER
Actual milli-amp
Flow milli-amp pro-
P.SOL;PUMP-
mA portional valve; Ac-
FLOW
tual milli-amp
SOL;POWER-
on/off Power save solenoid
SAVE

UPPER PILOT MPa (

Upper pilot pressure
PRESS. psi )
SWING PILOT MPa (
Swing pilot pressure
PRESS. psi )
TRAVEL PILOT MPa (
Travel pilot pressure
PRESS. psi )
OPT.LINE
on/off 1st option operation
PRESS SW.
2ND OPT.LINE
on/off 2nd option operation
PRESS SW.
TRAVEL ALARM
on/off Travel alarm
OUT.
POWER SAVE
on/off Power save solenoid
SOL.
SWING BRAKE
on/off Swing brake solenoid
SOL.
FREE SWING
on/off Free swing solenoid
SOL.
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Service Support

4. Pressure and solenoid 5. Pressure and solenoid

BOOM-UP PILOT MPa ( Boom-up pilot pres- PILOT SW. on/off Pilot switch
PRESS. psi ) sure MPa ( Pump 1; Discharge
P1 PRESS.
ARM-CLOSE PI- MPa ( psi ) pressure
Arm-in pilot pressure
LOT PRESS. psi ) MPa ( Pump 2; Discharge
P2 PRESS.
BUCKET-CLOSE MPa ( Bucket-close pilot psi ) pressure
PILOT PRESS. psi ) pressure MPa ( Pump 1; Negative
N1 PRESS.
P.SOL;BOOM- psi ) control pressure
mA Boom-down solenoid
DOWN MPa ( Pump 2; Negative
N2 PRESS.
P.SOL;BOOM-UP mA Boom-up solenoid psi ) control pressure
P.SOL;ARM- P.SOL;OPT.LINE
mA Arm-in solenoid mA Option line solenoid
CLOSE RELIEF
P.SOL;BUCKET- Bucket-close sole- SOL;OPTION 2 pumps flow sole-
mA on/off
CLOSE noid 2SPEED noid
P.SOL;OFFSET- SOL;OPTION SE- Option selection so-
mA Offset left solenoid on/off
LEFT LECT lenoid
SOL;BUCKET Bucket-open sole- SOL;POWER
on/off on/off Power boost solenoid
OPEN noid BOOST

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Service Support

6. Engine 8. Engine

ENGINE OIL kPa ( psi min-1 (

Engine oil pressure ENGINE SPEED Engine speed
PRESS ) rpm )
COOLANT LLC reserve tank ENGINE LOAD
on/off ％ Engine load ratio
LEVEL SW. level switch RATIO
Air cleaner clog DPD kPa ( psi DPD exhaust gas dif-
AIR FILTER SW. on/off
switch DIFF.PRESS. ) ferential pressure
BATTERY VOLT- EXHAUST TEMP. Exhaust gas temper-
V Battery voltage °C ( °F )
AGE (DOC) ature (DOC)
BATTERY Alternator power EXHAUST TEMP. Exhaust gas temper-
on/off °C ( °F )
CHARGE generation (DPD) ature (DPD)
IDLE SHUT Idling stop relay out- P.SOL;RE-
on/off mA
DOWN OUT put GEN.ASSIST
2SPEED TRAVEL Travel 2nd speed so- Flow milli-amp pro-
P.SOL;PUMP-
SOL lenoid output mA portional valve; Ac-
FLOW
FAN REVERS- Option switchover tual milli-amp
ING SOL solenoid output MPa ( Pump 1; Discharge
P1 PRESS.
psi ) pressure
7. Fuel MPa ( Pump 1; Negative
N1 PRESS.
psi ) control pressure

FUEL DENSITY
g/cm3 Fuel density
(RAW)
FUEL DENSITY
g/cm3 Fuel density
(15°C)
FUEL TEMP. (IN-
°C ( °F ) Fuel temperature
NER TANK)
FUEL SENSOR
％ Fuel sensor
POSITION
REFUEL AUTO- Fuel supply auto-
on/off
STOP OUT matic stop
HYD.OIL FILTER Hydraulic oil filter
on/off
SW. switch
LOCK STATUS1 - -
LOCK STATUS2 - -
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Service Support

9. Engine 11. Safety distances

ENGINE TAR- min-1 ( BOOM ANGLE deg Boom angle

Engine target speed
GET SPEED rpm ) OFFSET ANGLE deg Offset angle
min-1 ( ARM ANGLE deg Arm angle
ENGINE SPEED Engine speed
rpm ) P.SOL;BOOM-UP ％ Boom-up solenoid
ENGINE LOAD P.SOL;OFFSET-
％ Engine load ratio ％ Offset solenoid
RATIO LEFT
FUEL INJEC- P.SOL;ARM-
％ Fuel injection ratio mA Arm-in solenoid
TION LIMIT CLOSE
COMMON RAIL MPa ( Common rail pres- SAFETY DIS- Safety distance
PRESS. psi ) sure m ( ft )
TANCE(TOP) (side)
C.RAIL MPa ( Common rail differ- SAFETY DIS- Safety distance
DIFF.PRESS. psi ) ential pressure m ( ft )
TANCE(SIDE) (front)
SUPPLY-
kPa ( psi Supply pump pres-
PUMP(IN) 12. Hanging load
) sure (IN)
PRESS
TARGET FUEL Target fuel injection
mm3/st
INJECTION quantity
FUEL FLOW L/h

10. Work radius and height

BOOM BOTTOM MPa ( Boom bottom pres-

PRESS. psi ) sure
BOOM ROD MPa (
Boom rod pressure
PRESS. psi )
WORKING RA-
m ( ft ) Work radius
DIUS
BOOM ANGLE deg Boom angle LIFTING LOAD kg ( lb ) Hanging load
OFFSET ANGLE deg Offset angle RATED LOAD kg ( lb ) Rated load
ARM ANGLE deg Arm angle TOTAL MOMENT kg.m Total moment
WORKING RA- Attachment indepen-
m ( ft ) Work radius ATT.MOMENT kg.m
DIUS dent moment
LIFTING HEIGHT m ( ft ) Work height
HEIGHT LIMIT m ( ft ) Hanging limit height
LIFTING LOAD kg ( lb ) Hanging load
RATED LOAD kg ( lb ) Rated load
WARNING
on/off Liftcrane buzzer
BUZZER OUT
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4001B-8
Copyright ©
Service Support

13. GPS information FAULT HISTORY

1. With FAULT HISTORY, the contents for the trouble
currently occurring and a log of trouble that has oc-
curred in the past can be checked.

To switch to a page from 1 to 15, press the monitor

switch while the MACHINE STATUS screen is

displayed and select the desired page.

1 Displayed/Not displayed
2 Occurrence count
3 Initial occurrence time
4 Final occurrence time

• Diagnostic trouble codes that occur display in

"DTC-1" - "DTC-4".
•
The cursor is moved with the and
switches. (The cursor moves between "DTC-1"
and "DTC-4".)
• The information for the diagnostic trouble code for
the location under the cursor is displayed with the
items from "STATUS" to "LAST HOUR".
• Up to 30 diagnostic trouble codes can be dis-
played.
To switch to a page from 1 to 6, press the monitor

switch while the FAULT HISTORY screen

is displayed and select the desired page.

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Service Support

WORK HISTORY
Operation times for mechanical parts, electrical parts,
etc., and operation counts for switches can be displayed.

1. Machine main unit 2. Work mode

KEY-ON TIME hour Key ON time SP-MODE OPERA- SP mode operation

hour
Engine operation TION TIME time
ENGINE-RUN TIME hour
time H-MODE OPERA- H mode operation
hour
OPERATION TIME hour Operation time TION TIME time
UPPER OPERA- A-MODE OPERA- A mode operation
hour Upper operation time hour
TION TIME TION TIME time
SWING OPERATION - - -
hour Swing operation time POWER-BOOST Boosted pressure
TIME hour
TRAVEL OPERA- TIME time
hour Travel operation time AUTO IDLE TIME hour Auto idle time
TION TIME
INDEPENDENT Independent travel ONE-TOUCH-IDLE
hour hour One-touch idle time
TRAVEL TIME operation time TIME
Lo-SPEED TRAVEL 1st speed travel oper-
hour
TIME ation time
Hi-SPEED TRAVEL 2nd speed travel op-
hour
TIME eration time

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Service Support

3. End attachment 5. Electrical part

WIPER-INT. OPER-
BREAKER OPERATION Breaker operation hour Wiper (INT) time
hour ATION TIME
TIME time WIPER-CNT. OPER-
CRUSHER OPERA- Crusher operation hour Wiper (CNT) time
hour ATION TIME
TION TIME time WASHER OPERA- Washer operation
OPT.1 PUMP OPERA- 1st option opera- hour
hour TION TIME time
TION TIME tion time WORKING LAMP Working light ON
OPT.2 PUMP OPERA- 2nd option opera- hour
hour ON TIME time
TION TIME tion time RADIO MUTE TIME hour Radio mute time
2ND OPT. OPERATION 2 pumps flow op- DISPLAY-MODE1 No camera screen
hour hour
TIME eration time TIME selection time
CRANE OPERATION Liftcrane opera- DISPLAY-MODE2 Camera screen dis-
hour hour
TIME tion time TIME play 1 selection time
MAGNET OPERATION Lifting magnet op- DISPLAY-MODE3 Camera screen dis-
hour hour
TIME eration time TIME play 2 selection time

4. Electrical part

KEY-ON COUNT hour Key ON count

ENGINE-START
hour Engine ON count
COUNT
IDLE SHUT Front window open
hour
DOWN COUNT count
WINDOW OPEN
hour Door open count
TIME
WINDOW OPEN
10 times Idle stop time
COUNT
DOOR OPEN Front window open
hour
TIME time
DOOR OPEN
10 times Door open time
COUNT
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Service Support

6. Air conditioner 7. Air conditioner

A/C OPERATION AC power supply Maximum cooling op-

hour COOL-MAX TIME hour
TIME ON time eration time
A/C BLOWER-Lo AC blower Lo set- T1 TARGET TEMP T1 Target tempera-
hour hour
TIME ting time ＜ T2 TIME ture T ＜ T2 time
A/C BLOWER-M1 AC blower M1 set- T2 TARGET TEMP T2 Target tempera-
hour hour
TIME ting time ＜ T3 TIME ture T ＜ T3 time
A/C BLOWER-M2 AC blower M2 set- T3 TARGET TEMP T3 Target tempera-
hour hour
TIME ting time ＜ T4 TIME ture T ＜ T4 time
A/C BLOWER-M3 AC blower M3 set- Maximum heating
hour HOT-MAX TIME hour
TIME ting time operation time
A/C BLOWER-M4 AC blower M4 set- RECIRC.AIR MAX- °C ( Maximum inside air
hour TEMP. °F ) temperature
TIME ting time
A/C BLOWER-Hi AC blower Hi set- RECIRC.AIR MIN- °C ( Minimum inside air
hour TEMP. °F ) temperature
TIME ting time
MAG.CLUTCH RE- Electromagnetic INTAKE AIR MAX- °C ( Maximum outside air
hour TEMP. °F ) temperature
LAY ON TIME clutch ON time
CLUTCH RELAY ON Electromagnetic INTAKE AIR MIN- °C ( Minimum outside air
10 times
COUNT clutch ON count TEMP. °F ) temperature

To switch to a page from 1 to 7, press the monitor switch

while the WORK HISTORY screen is displayed and

select the desired page.

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ENGINE HISTORY
The engine speed, coolant temperature, fuel tempera-
ture, and suction air temperature distributions, etc. can
be displayed.

1. Actual speed distribution 2. Water temperature distribution

ROTATION ＜ R1 hour S 1025 TEMP. ＜ T1 hour T ＜ 77

R1 REV. SPEED ＜ T1 TEMP. ＜ T2 hour 77 T ＜ 82
hour 1025 S ＜ 1225
R2 T2 TEMP. ＜ T3 hour 82 T ＜ 97
R2 REV. SPEED ＜ T3 TEMP. ＜ T4 hour 97 T ＜ 100
hour 1225 S ＜ 1425
R3 T4 TEMP. ＜ T5 hour 100 T ＜ 103
R3 REV. SPEED ＜ T5 TEMP. ＜ T6 hour 103 T ＜ 105
hour 1425 S ＜ 1625
R4 T6 TEMP. hour 105 T
R4 REV. SPEED ＜ - - -
hour 1625 S ＜ 1825
R5 °C ( Maximum temper-
R5 REV. SPEED ＜ TEMP. MAX
hour 1825 S ＜ 2025 °F ) ature
R6
R6 REV. SPEED hour 2025 S

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3. Fuel temperature distribution 5. Boost temperature distribution

TEMP. ＜ T1 hour T ＜ 40 TEMP. ＜ T1 hour T＜0

T1 TEMP. ＜ T2 hour 40 T ＜ 50 T1 TEMP. ＜ T2 hour 0 T ＜ 20
T2 TEMP. ＜ T3 hour 50 T ＜ 60 T2 TEMP. ＜ T3 hour 20 T ＜ 40
T3 TEMP. ＜ T4 hour 60 T ＜ 70 T3 TEMP. ＜ T4 hour 40 T ＜ 60
T4 TEMP. ＜ T5 hour 70 T ＜ 80 T4 TEMP. ＜ T5 hour 60 T ＜ 80
T5 TEMP. ＜ T6 hour 80 T ＜ 90 T5 TEMP. ＜ T6 hour 80 T ＜ 100
T6 TEMP. hour 90 T T6 TEMP. hour 100 T
- - - - - -
°C ( Maximum temper- °C ( Maximum temper-
TEMP. MAX TEMP. MAX
°F ) ature °F ) ature

6. Suction air temperature distribution

4. Suction air temperature distribution

PRESS. ＜ P1 hour P ＜ 100

TEMP. ＜ T1 hour T ＜ -20 P1 PRESS. ＜ P2 hour 100 P ＜ 140
T1 TEMP. ＜ T2 hour -20 T ＜ 0 P2 PRESS. ＜ P3 hour 140 P ＜ 180
T2 TEMP. ＜ T3 hour 0 T ＜ 15 P3 PRESS. ＜ P4 hour 180 P ＜ 220
T3 TEMP. ＜ T4 hour 15 T ＜ 30 P4 PRESS. ＜ P5 hour 220 P ＜ 260
T4 TEMP. ＜ T5 hour 30 T ＜ 45 P5 PRESS. ＜ P6 hour 260 P ＜ 300
T5 TEMP. ＜ T6 hour 45 T ＜ 60 P6 PRESS. hour 300 P
T6 TEMP. hour 60 T kPa ( Maximum pres-
PRESS. MAX
- - - psi ) sure
°C ( Maximum temper- kPa ( Minimum pres-
TEMP. MAX PRESS. MIN
°F ) ature psi ) sure

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7. Oil pressure distribution 9. Load ratio distribution

PRESS. ＜ P1 hour P＜0 RATIO ＜ R1 hour R＜ 30

P1 PRESS. ＜ P2 hour 0 P ＜ 150 R1 RATIO ＜ R2 hour 30 R ＜ 40
P2 PRESS. ＜ P3 hour 150 P ＜ 300 R2 RATIO ＜ R3 hour 40 R ＜ 50
P3 PRESS. ＜ P4 hour 300 P ＜ 450 R3 RATIO ＜ R4 hour 50 R ＜ 60
P4 PRESS. ＜ P5 hour 450 P ＜ 600 R4 RATIO ＜ R5 hour 60 R ＜ 70
P5 PRESS. ＜ P6 hour 600 P ＜ 750 R5 RATIO ＜ R6 hour 70 R ＜ 80
P6 PRESS. hour 750 P R6 RATIO hour 80 R
kPa ( Maximum pres-
PRESS. MAX
psi ) sure 10. SP mode load ratio distribution
kPa ( Minimum pres-
PRESS. MIN
psi ) sure

8. Boost pressure distribution

RATIO ＜ R1 hour R ＜ 30
R1 RATIO ＜ R2 hour 30 R ＜ 40
R2 RATIO ＜ R3 hour 40 R ＜ 50
R3 RATIO ＜ R4 hour 50 R＜60
PRESS. ＜ P1 hour P＜0 R4 RATIO ＜ R5 hour 60 R ＜ 70
P1 PRESS. ＜ P2 hour 0 P ＜ 150 R5 RATIO ＜ R6 hour 70 R ＜ 80
P2 PRESS. ＜ P3 hour 150 P ＜ 300 R6 RATIO hour 80 R
P3 PRESS. ＜ P4 hour 300 P＜450
P4 PRESS. ＜ P5 hour 450 P ＜ 600
P5 PRESS. ＜ P6 hour 600 P ＜ 750
P6 PRESS. hour 750 P
kPa ( Maximum pres-
PRESS. MAX
psi ) sure
kPa ( Minimum pres-
PRESS. MIN
psi ) sure

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11. H mode load ratio distribution 13. DOC temperature distribution

RATIO ＜ R1 hour R ＜ 30 TEMP. ＜ T1 hour T ＜ 200

R1 RATIO ＜ R2 hour 30 R ＜ 40 T1 TEMP. ＜ T2 hour 200 T ＜ 300
R2 RATIO ＜ R3 hour 40 R ＜ 50 T2 TEMP. ＜ T3 hour 300 T ＜ 400
R3 RATIO ＜ R4 hour 50 R ＜ 60 T3 TEMP. ＜ T4 hour 400 T ＜ 500
R4 RATIO ＜ R5 hour 60 R ＜ 70 T4 TEMP. ＜ T5 hour 500 T ＜ 600
R5 RATIO ＜ R6 hour 70 R ＜ 80 T5 TEMP. ＜ T6 hour 600 T ＜ 700
R6 RATIO hour 80 R T6 TEMP. hour 700 T
- - -
12. Fuel density distribution °C ( Maximum temper-
TEMP. MAX
°F ) ature

14. DPD temperature distribution

DENSITY ＜ D1 hour D＜ D1
D1 DENSITY ＜ D2 hour D1 D ＜ D2
D2 DENSITY ＜ D3 hour D2 D ＜ D3
TEMP. ＜ T1 hour T ＜ 200
D3 DENSITY ＜ D4 hour D3 D ＜ D4
T1 TEMP. ＜ T2 hour 200 T ＜ 300
D4 DENSITY ＜ D5 hour D4 D ＜ D5
T2 TEMP. ＜ T3 hour 300 T ＜ 400
D5 DENSITY ＜ D6 hour D5 D ＜ D6
T3 TEMP. ＜ T4 hour 400 T ＜ 500
D6 DENSITY hour D6 D
T4 TEMP. ＜ T5 hour 500 T ＜ 600
T5 TEMP. ＜ T6 hour 600 T ＜ 700
T6 TEMP. hour 700 T
- - -
°C ( Maximum temper-
TEMP. MAX
°F ) ature

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15. Supply pump inlet pressure distribution 17. DPD differential pressure distribution

PRESS. ＜ P1 hour P ＜ -40

P1 PRESS. ＜ P2 hour -40 P ＜ -30 PRESS. ＜ P1 hour P＜0
P2 PRESS. ＜ P3 hour -30 P ＜ -20 P1 PRESS. ＜ P2 hour 0 P＜5
P3 PRESS. ＜ P4 hour -20 P ＜ -10 P2 PRESS. ＜ P3 hour 5 P ＜ 10
P4 PRESS. ＜ P5 hour -10 P ＜ 0 P3 PRESS. ＜ P4 hour 10 P ＜ 15
P5 PRESS. ＜ P6 hour 0 P ＜ 10 P4 PRESS. ＜ P5 hour 15 P ＜ 20
P6 PRESS. hour 10 P P5 PRESS. ＜ P6 hour 20 P ＜ 25
kPa ( Maximum pres- P6 PRESS. hour 25 P
PRESS. MAX
psi ) sure kPa ( Maximum pres-
PRESS. MAX
kPa ( Minimum pres- psi ) sure
PRESS. MIN
psi ) sure kPa ( Minimum pres-
PRESS. MIN
psi ) sure
16. Hot shutdown

18. DPD regeneration count

ITEM-1 - -
ITEM-2 - -
ITEM-3 - -
ITEM-4 - - ITEM-1 - -
ITEM-5 - - ITEM-2 - -
ITEM-6 - - ITEM-3 - -
ITEM-7 - - ITEM-4 - -
ITEM-8 - - ITEM-5 - -
ITEM-9 - - ITEM-6 - -
ITEM-7 - -
ITEM-8 - -
ITEM-9 - -

To switch to a page from 1 to 18, press the monitor switch

while the ENGINE HISTORY screen is displayed and

select the desired page.
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HYDRAULIC HISTORY
The P1 and P2 pilot pressure can be displayed.

1. P1 pressure 2. P2 pressure

PRESS. ＜ P1 hour P＜ 10 PRESS. ＜ P1 hour P ＜ 10

P1 PRESS. ＜ P2 hour 10 P＜ 15 P1 PRESS. ＜ P2 hour 10 P ＜ 15
P2 PRESS. ＜ P3 hour 15 P＜ 20 P2 PRESS. ＜ P3 hour 15 P ＜ 20
P3 PRESS. ＜ P4 hour 20 P＜ 25 P3 PRESS. ＜ P4 hour 20 P ＜ 25
P4 PRESS. ＜ P5 hour 25 P＜ 30 P4 PRESS. ＜ P5 hour 25 P ＜ 30
P5 PRESS. ＜ P6 hour 30 P＜ 35 P5 PRESS. ＜ P6 hour 30 P ＜ 35
P6 PRESS. hour 35 P P6 PRESS. hour 35 P

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3. N1 pressure 5. P1 + P2 pressure

PRESS. ＜ P1 hour P＜ 1.0 PRESS. ＜ P1 hour P＜ 20

P1 PRESS. ＜ P2 hour 1.0 P＜ 1.5 P1 PRESS. ＜ P2 hour 20 P＜ 30
P2 PRESS. ＜ P3 hour 1.5 P＜ 2.0 P2 PRESS. ＜ P3 hour 30 P＜ 40
P3 PRESS. ＜ P4 hour 2.0 P＜ 2.5 P3 PRESS. ＜ P4 hour 40 P＜ 50
P4 PRESS. ＜ P5 hour 2.5 P＜ 3.0 P4 PRESS. ＜ P5 hour 50 P＜ 60
P5 PRESS. ＜ P6 hour 3.0 P＜ 3.5 P5 PRESS. ＜ P6 hour 60 P＜ 70
P6 PRESS. hour 3.5 P P6 PRESS. hour 70 P

4. N2 pressure 6. Operation count

PRESS. ＜ P1 hour P＜ 1.0 UPPER PILOT Upper operation

1000 times
PRESS count
P1 PRESS. ＜ P2 hour 1.0 P＜ 1.5
SWING PILOT Swing operation
P2 PRESS. ＜ P3 hour 1.5 P＜ 2.0 1000 times
PRESS count
P3 PRESS. ＜ P4 hour 2.0 P＜ 2.5
TRAVEL PILOT Travel operation
P4 PRESS. ＜ P5 hour 2.5 P＜ 3.0 1000 times
PRESS count
P5 PRESS. ＜ P6 hour 3.0 P＜ 3.5 ARM-CLOSE PI- Arm-in operation
P6 PRESS. hour 3.5 P 1000 times
LOT PRESS. count
OPT.LINE 1st option opera-
1000 times
PRESS SW. tion count
2ND OPT.LINE 2nd option opera-
1000 times
PRESS SW. tion count
POWER BOOST Pressure boost
1000 times
SOL. operation count
SWING BRAKE Swing operation
1000 times
SOL. count
POWER-SAVE Power save oper-
1000 times
TIME ation count

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7. Oil temperature distribution PART NUMBER

The software version for computers A, B, C can be dis-
played.

TEMP. ＜ T1 hour T ＜ 45
T1 TEMP. ＜ T2 hour 45 T ＜ 60
T2 TEMP. ＜ T3 hour 60 T ＜ 80
T3 TEMP. ＜ T4 hour 80 T ＜ 88
T4 TEMP. ＜ T5 hour 88 T ＜ 95
T5 TEMP. ＜ T6 hour 95 T ＜ 98
T6 TEMP. hour 98 T
- - -
°C ( Maximum tempera-
TEMP. MAX
°F ) ture

To switch to a page from 1 to 7, press the monitor

switch while the HYDRAULIC HISTORY screen is

displayed and select the desired page.

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SETUP Screen List

The model selection, work mode speed, etc. can be
changed.

By pressing "Wiper switch" (5) and "Auto idling switch" Detailed data for the selected item can be seen by press-
(6) on the monitor, MACHINE SELECT, PARAMETERS, ing "Working light switch" (4).
etc. can be selected.

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MACHINE SELECT
Machine data information, etc. are registered.

MACHINE 0 Japanese
Fix the selection. 1 English
TERRITORY 2 Thai
3 Chinese
0 JAPAN 4 German
1 NA 5 French
2 - 6 Italian
3 EU 7 Spanish
4 IHI 8 Portuguese
5 TURK 9 Dutch
6 CHINA 10 Danish
11 Norwegian
12 Swedish
BRAND
13 Finnish
14 Turkish
0 SUMITOMO 15 Arabic
1 LBX 16 Malay
2 CASE 17 Indonesian
3 IHI 18 Russian
19 Canadian French
LANGUAGE 20 Pictographs only

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PARAMETERS 3. Work mode engine speed

The work mode speed and pump milli-amps can be set.
1. Engine

min-1 (
ITEM-1 SP mode speed
rpm )
min-1 (
min-1 ( ITEM-2 H mode speed
ITEM-1 Auto idling speed rpm )
rpm )
ITEM-2 ms*100 Auto idle time min-1 (
ITEM-3 A mode speed
rpm )
Transient load minimum milli-
ITEM-3 mA
amp (normally 50 mA) min-1 (
ITEM-4 Idling speed
rpm )
Semi-transient load minimum
ITEM-4 mA
milli-amp
Eco gauge update period (nor- 4. Energy save
ITEM-5 ms*100
mally 1000 ms)

2. Work mode milli-amp

min-1 ( Speed change amount during

ITEM-1
rpm ) boom-down swing operation
ITEM-1 mA SP mode milli-amp (Hi) ITEM-2 - -
ITEM-2 mA SP mode milli-amp (Low) min-1 ( Semi-auto idling speed change
ITEM-3
ITEM-3 mA H mode milli-amp (Hi) rpm ) amount
ITEM-4 mA H mode milli-amp (Low) ITEM-4 - -
ITEM-5 mA A mode milli-amp (Hi) ITEM-5 - -
ITEM-6 mA A mode milli-amp (Low) ITEM-6 - -
ITEM-7 mA Minimum milli-amp ITEM-7 mA Speed limit milli-amp

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ITEM-1 - -
ITEM-2 - -
ITEM-3 - -
ITEM-4 - -
ITEM-5 - -
ITEM-6 - -
ITEM-7 - -
ITEM-8 - -
ITEM-9 - -

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Setting
Model Select
Summary
The model information is input to set the control parameters specific to the model.
Configuration
• Screen

Operation explanation
Move up and down to move the cursor, left and right to select a model, set the throttle to H mode, and decide with
the menu switch.
• · Reset by holding down the left and right. (The display changes to "?" for all items.)
* From Ver. 1.8.6
Without a reset, only the LANGUAGE and UNIT can be changed.
Other changes always require a complete reset.
Setting items, values and details
Select "SET UP" on the service screen and input the following items.
The setting item values and setting details are given below.
Explanation of item

Pag-
Item name Explanation Remarks
e
MACHINE Model
TERRITORY Destination
BRAND Brand
LANGUAGE Language
1 UNIT Unit 0: {MPa, °C}, 1: {psi, °F}, 2: {kgf/cm2, °C}
-
-
-
-
-
-
OVERLOAD WARNING Load warning
Interference preven-
ANTI INTERFERENCE Not currently supported
tion
ATT. TYPE Attachment type Used for interference prevention·crane·overload warning
2
OPTION LINE Option Line
GENERATOR Lifting magnet Not currently supported
-
-
-

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Pag-
Item name Explanation Remarks
e
-
Currently not supported; used for Computer ST trouble diag-
REMOTE SUPPORT Remote Support
nosis
Fuel abnormality Currently not supported; used for density sensor trouble di-
FMS
warning agnosis
3 RESERVE 1 Free Swing
RESERVE 2 Reserve 2 Not currently supported
RESERVE 3 Reserve 3 Not currently supported
-
-
-

Explanation of number
1. Model (Machine)
Omitted
2. Destination (Territory)

Value Details Remarks

0 JAPAN
Travel alarm continuous buzzing function ON (Cannot be set
1 NA
OFF)
2 - (Skipped number)
3 EU
4 IHI
5 TURK
6 CHINA

3. Brand

Value Details Remarks

Background color = blue, Sumitomo logo displayed after model
0 SUMITOMO
selection completed
Background color = black, LBX logo displayed after model se-
1 LBX
lection completed
Background color = black, CASE logo displayed after model se-
2 CASE
lection completed
3 IHI Not currently supported, background color = ?

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4. Language
• Can be changed with "LANGUAGE" on the menu screen.

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Throttle Volume Default Setting

Summary
Corrects the throttle volume installation error.
Configuration

1 Throttle volume 3 Computer B *5 ECM

*2 Color monitor *4 Computer A *6 ENG

Operation explanation
1. Switch the key ON and select (Select Model). (See Select Model.)
2. Set all the model selection items and set the throttle volume to H mode, then finalize the selections.
3. The system performs the initial adjustment of the throttle volume. (*1)
• The adjustment results are retained in memory even after the key is switched OFF.

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Operation explanation The icon appears for the model setting only with
flow setting.)
1. The operator enters the option line setting screen Other breakers, 2-5, and crushers, 2-5, are not
from the menu. set.
The system cuts away option line switching sole- When an breaker or crusher is selected that has
noid, pump flow not been set, four hyphens (---) are displayed for
proportional valve, option relief pressure propor- the "SET MAX FLOW" and "SET MAX PRES-
tional valve, 2 pumps flow from normal controls SURE".
and sets to setting mode.
• If the maximum flow and maximum pressure
• There are two ways to enter the option line set- have not yet been set, that breaker or crusher
ting screen. cannot be selected with a work screen.
One is from the menu screen. To put it the other way, everything set here can
The other is by holding down the ATT select be selected with a work screen.
switch for one second. Since the X3 has only one ATT selection switch,
When the former method is used, the ATT when the flow volume is set here for all the
when one enters the option line setting screen breakers or crushers, care is required because
is Breaker 1. (However, if a double-acting cir- selecting the target ATT requires pressing the
cuit is selected with the model selection, it is switch a number of times.
Crusher 1.) * When items that had been set are reset, the
When the latter method is used, the display reset items can no longer be selected.
moves to the currently selected ATT and a
switch guide is displayed on the monitor. (Nor- 4. The operator sets the maximum flow from the
mally, this is from Breaker 1. (However, if "SET MAX FLOW" item and sets the maximum
double-acting circuit is selected with the model pressure from the "SET MAX PRESSURE" item.
selection, it is from Crusher 1).)
• As selection options for the maximum flow, the
2. The operator selects the breaker or the crusher system has available 20 levels for the flow vol-
from the "Attachment selection". (When ume, 10 for without 2 pumps flow and 10 for with
multi-purpose circuit is selected with model se- 2 pumps flow.
lection: For a breaker or crusher, "Attachment • However, the maximum flow depends on the
selection" is not displayed and the selection can- model. Even though 20 levels are displayed
not be changed.) for all models, the flow volumes for the levels
For a breaker, the system sets the item immedi- depend on the model. (See (Number table) flow
ately below to "Breaker No." and for a crusher, adjustment levels below.)
"Crusher No.". • When the flow volume is set, if a stand-alone
At the same time, the system switches the option option operation is executed, the flow propor-
line switching solenoid to ON for a breaker or OFF tional valve command current value is output
for a crusher. to achieve that flow volume. (Breaker mode or
3. The operator selects a number from 1 to 5 with crusher mode processing is executed.)
the "Breaker No. (or Crusher No.)" item. • The range in which the maximum pressure can
The system displays the maximum flow and max- be set depends on the model, but for all models,
imum pressure corresponding to that number the settings are made in increments of 0.5 MPa
in the two items immediately below "SET MAX (72.527 psi). (See (Number table) pressure ad-
FLOW" and "SET MAX PRESSURE". justment range below.)
• No maximum pressure can be set that exceeds
• The factory setting is that the maximum flow and the relief valve pressure setting range.
maximum pressure setting are only for Breaker
• When an item that had been set is reset, four
1 and Crusher 1. hyphens (---) are displayed for either the "SET
(* The pressure is not adjusted, so for pressure MAX FLOW" or the "SET MAX PRESSURE"
adjustment model setting, the icon does not ap- and when you exit the options adjustment
pear even if the ATT select switch is pressed.

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screen, the information that had been set is • During adjustment, if any operation other than
reset. breaker (crusher) operation is done, the sys-
• If the pressure adjustment is not selected with tem stops the adjustment, displays "BREAKER
the model selection, the option flow setting ends OPERATING REQUIRED" on the monitor, and
after just setting the maximum flow. waits for operation of the breaker (crusher) in-
• When multi-purpose circuit is selected with dependently.
model selection, when the flow volume for 2
7. The operator continues operating the breaker
pumps flow is set with breaker mode, "CHECK
(crusher).
FLOW RATE" is displayed on the monitor.
The system waits for the pressure to stabilize for
Once that flow volume is decided, the "CHECK
2 sec., then starts the adjustment.
FLOW RATE" display goes out.
The system continues to compare the actual P1
5. When the operator has changed the maximum pressure and the target set pressure and when
flow or maximum pressure, the system redoes the the difference between them is no more than 0.5
option relief pressure proportional valve adjust- MPa (72.527 psi) (*) continuously for at least 5
ment again. sec., it judges the adjustment to be complete.
The system displays "ADJUST PRESSURE" on The system displays "PRESSURE ADJUSTING.
the monitor. COMPLETE" on the monitor and puts out the
6. The operator checks that the work mode is SP "PRESSURE ADJUSTING INCOMPLETE" dis-
and that the oil temperature is 30 °C (86.0 °F) play.
minimum and operates the breaker (crusher).
The system displays "ADJUSTING PRESSURE" • During adjustment, the system updates the op-
tion relief pressure proportional valve current
on the monitor.
every 500 ms in increments of 5 mA.
At the same time, the "PRESSURE SETTING"
and "CURRENT PRESSURE" items are dis- • If the pedal continues to be held down even after
the setting value is finalized, the setting value is
played.
updated every 5 sec..
• When the operator stops the operation, the dis- • If the pressure adjustment does not end within
play returns to "BREAKER OPERATION RE- 30 sec., "PRESSURE ADJUSTING INCOM-
QUIRED". PLETE" is displayed on the monitor.
• When the work mode is not SP, "SET IN
8. When the operator presses the menu switch to
SP-MODE" is displayed instead of "ADJUST-
exit the option line setting screen, the system
ING PRESSURE".
stores the settings into memory.
• During one-touch idle or while the engine is
stopped, "INCREASE ENGINE RPM" is dis- • If the setting screen was entered from the menu
played instead of "ADJUSTING PRESSURE". screen, the display returns to the menu screen.
• When the operator operates in SP mode, if the If the setting screen was entered from the
oil temperature is less than 30 °C (86.0 °F), main screen by holding down the ATT select
"INCREASE OIL TEMP." is displayed instead of switch for 1 sec., the display returns to the main
"ADJUSTING PRESSURE". screen.
At the same time, the "TARGET OIL TEMP." and
"CURRENT OIL TEMP." items are displayed.

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Screen Brightness Setting 2. Working Light ON: The monitor brightness is re-
duced and the display changes automatically to
<Summary> the "Brightness (night)" setting.
Decides the brightness of the backlight through oper- 3. Brightness settings: "Brightness (day)" and
ation that is linked to the working light and solar radi- "Brightness (night)" can be set on the menu
ation sensor. screen.
<Operation explanation> 4. Dimming by solar radiation sensor: When the
The screen brightness can be selected on the menu working light-linked dimming is set OFF on the
screen. menu screen, the dimming level is adjusted au-
Dimming setting can be changed on the service tomatically to the ambient brightness by the solar
screen. radiation sensor.
1. Working Light OFF: Normal (with key ON),
"Brightness (day)" setting

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Section

4001C

Function, Structure, Operation

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CONTENTS

Function, Structure, Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

4001C-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

4001C-2 PRINTED IN FRANCE
Copyright ©
Function, Structure, Operation

Function, Structure, Operation

1. Engine number

1 Engine number stamping

2 Engine model stamping

2. Function, Structure, Operation

1) Description of functions and operations
Engine electronic control
The control provided by the control unit applies to the range from injection to air intake and exhaust in-
cluding fuel injection amount, injection timing, air intake restriction, EGR and idling speed.
Cylinder block
The cylinder block is made of cast iron, and it has the equal center distance for each bore and a high
rigidity, and the center of the crankshaft matches the center of the block.
Piston
The piston is a strut cast thermal flow piston made of aluminum alloy, and the combustion chamber is the
round re-entrant type.
Cylinder head
The cylinder head is made of cast iron, and has four valves per each cylinder. The angle tightening
method has been adopted to the cylinder head bolt to further improve its reliability and durability.
Crankshaft
The crankshaft is not to be polished for reuse, as it has TUFFTRIDE treatment applied. If a problem is
found, replace with a new one.
EGR system
The EGR system is controlled by the engine control module (ECM) according to various data including
the water temperature, engine RPM, and engine load to recirculate the exhaust gas for purification.
The primary components are the EGR valve, EGR cooler, and various sensors.
Connecting rod cap bolt
The angle tightening method has been adopted to the connecting rod cap bolt to further improve its reli-
ability and durability.
Common rail type electronic control injection system
The common rail type electronic control injection system consists of the supply pump that sets the target
pressure of high-pressure fuel to supply the fuel, the common rail that measures the high-pressure fuel
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and the fuel injector that injects the fuel in the form of a fine mist. Each of these are controlled by the
ECM based on various signals to control the injection timing and injection amount in accordance with the
driving condition.
Fuel injector
The fuel injector has adopted the 8-hole nozzle, and adjusts the fuel injection amount and injection timing
by opening or closing the electromagnetic valve on the injector head portion.
The ECM corrects variation in the fuel injection amount from fuel injector to fuel injector in accordance
with the ID code data in the memory. When adjusting the fuel injector, the ID code data must be recorded
in the ECM.
Fuel filter with sedimenter
The fuel filter with sedimenter removes the water by using the difference in the relative density between
diesel oil and water, and notifies the operator through the indicator when it becomes full of water.
Preheat system
The preheat system consists of the ECM, glow relay, glow plug and glow indicator light. The preheat
system is activated when the engine coolant temperature is low to help engine start.
Lubricating system
It uses and oil filter with a full-flow bypass, and cools down the pistons using the water-cooled oil cooler
and the oil jet.
DPD
An integrated DPD oxidation catalyst is installed for reducing exhaust gas.

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2) Fuel system
Fuel system diagram

1 Electromagnetic pump 4 Fuel injector 7 Fuel return pipe

2 Fuel filter 5 Supply pump 8 Pre-fuel filter
3 Common rail 6 Fuel tank

CAUTION
• Since the high-precision fuel system has been adopted, take care to prevent any foreign
matter from entering the fuel system.

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Common rail

1 Fuel pressure sensor

2 Pressure limiter

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Fuel supply pump

1 Fuel temperature sensor 3 High pressure pipe 5 Camshaft nut

2 Suction control valve 4 Camshaft key

CAUTION
• There is a gauze filter assembled inside the union of the fuel supply pump, but the union
should not be removed to prevent any foreign matter from entering.

1 Union
2 Gauze filter
3 Supply pump
4 Strainer
5 Joint bolt

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Injector

1 ID plate
2 Leak pipe
3 2D barcode
4 Fuel inlet
5 O-ring

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Fuel filter

1 Priming pump
2 Plug
3 Case
4 Drain plug

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3) Cooling system
The coolant system is the forced-circulation system, and its main components are the water pump, thermo-
stat and radiator.

1 Thermostat 5 Oil cooler 9 Cooling fan

2 Turbocharger 6 Heater 10 Radiator
3 EGR cooler 7 Cylinder block 11 Radiator reserve tank
4 Cylinder head 8 Water pump

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Water pump
The water pump is a centrifugal impeller type pump and is driven by the engine fan belt.

1 Fan guide 3 Impeller

2 Bearing 4 Seal unit

Thermostat
The thermostat is a wax pellet type. It is a bottom bypass type, and its initial open valve temperature is
85º C {185˚ F}. It is assembled inside the thermostat housing unit.

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4) 4. Lubrication system
A full-flow bypass integrated filter element, water cooling oil cooler, and piston coolant oil jet are adopted
for the lubrication system.

*1 Oil press. switch *9 Oil pan *17 Oil filter ＆ cooler assembly
*2 Oil gallery *10 Camshaft bearing *18 Relief valve
*3 Turbocharger *11 Crankshaft bearing *19 Oil filter
*4 Chain tensioner *12 Connecting rod bearing *20 Oil cooler
*5 Vacuum pump *13 Idler gear shaft *21 Relief valve
*6 Timing chain oil jet *14 Timing gear *22 Oil pump
*7 Rocker arm *15 Regulating valve *23 Relief valve
*8 Oil level switch *16 Piston cooling jet *24 Oil strainer

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5) Exhaust system

Exhaust gas temperature sen-

1 DPD assembly 3
sor 1
Exhaust gas temperature sen- DPD differential pressure sen-
2 4
sor 2 sor

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6) Emission control device

EGR
The EGR system recirculates a part of the exhaust gas to the intake manifold to suppress the emission
of NOx. By controlling the EGR system, high operability and exhaust gas reduction are both achieved.
The control current from the ECM activate the solenoid to control the EGR valve lift amount. The EGR
position sensor detects the actual valve lift amount and the data is used for precise control of the EGR
amount.
The EGR operates when the engine rpm, engine coolant temperature, intake temperature, and atmo-
spheric pressure satisfy certain criteria. Thereafter, the valve opening angle is calculated according to
the engine rpm and the desired fuel injection amount. The calculated valve opening angle is used to
determine the motor work duty and the valve is driven accordingly. The intake throttle valve closes when
the EGR operates to ensure an appropriate internal pressure of the intake manifold.

1 EGR cooler 4 EGR valve 7 Intake throttle valve

2 Coolant outlet 5 ECM
3 Coolant inlet 6 MAF sensor

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7) Electrical system
Charging system
The main components of the charging system are the battery, generator, and battery discharge indicator
light circuit.
Generator is a self-rectifier type with a regulator built in.
Generator
The generator is the brushless type.
The main components are the rotor, stator, rectifier assembly, front bracket, rear bracket, IC regulator,
bearing, pulley, etc.
The moving parts are the rotor and pulley. The field coil is fixed to the rear bracket.
6 main diodes and 2 additional diodes are used to change the three-phase alternating current generated
in the stator coil to a direct current.
3 out of the 6 main diodes are referred to as positive diode, and the rest is referred to as negative diode.
In addition, 3 small diodes that are referred to as trio-diode are used to supply the field current.
This generator has 3 terminals of B terminal (direct current output terminal), L terminal and R terminal.
Since the L terminal is connected to the field coil, it works as an input terminal for the initial excitation
current together with the R terminal until the generator starts generating power.
Also, it functions as an output terminal. (current capacity is 1 A) When the L terminal voltage reaches the
battery voltage, the charge light turns off.
Since the both bearings are sealed, periodic lubrications are not required.
The IC regulator cannot be disassembled, so it should be handled as an assembly.

1 Rectifier 5 Pulley 9 Regulator

2 Field coil 6 Front bracket 10 Bearing
3 Stator 7 Rotor
4 Bearing 8 Rear bracket

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Starter system
The starter is 4 kW and uses a reduction type.
Gear housing and armature end bearing housing are made of aluminum. Brush assembly is a replaceable
type.
Starter circuit is started using a battery.
The battery cable is connected to a large terminal on the starter.
The wiring is connected from the terminal to the engine control switch and the starter relay.
Starter
The starter is an outer gearing mesh method reduction starter adopting the magnetic shift type.
When the starter switch is turned ON, the plunger is drawn in, the contact point of the magnetic switch
closes and the armature rotates. At the same time, the pinion is pushed to the front via the shift lever to
mesh with the ring gear. When the ring gear rotates, the crankshaft is turned to start the engine. After
the engine is started, the plunger returns, the pinion separates from the ring gear, and the armature stops
rotating when the starter switch is turned OFF. When the engine revolution increases faster than the
pinion, the pinion will be caused to turn in reverse, but because the pinion is idling by the one-way clutch
operation, it does not work the armature.
Preheat system
The preheat system has adopted the QOS system glow plug type. Also, the energization control is per-
formed by the ECM.
8) Engine control system
Engine control system overview and implementation
The engine control system is an electronic control system that controls the engine to be always in the
optimal combustion state according to the driving condition, and consists of the electronic control fuel
injection system, EGR, and idling control.
Also, besides controlling the engine, the engine control system has the QOS system, engine RPM sig-
nal output, self-diagnosing function, and CAN communication SAE J1939/21 and SAE J1939/11 system
control functions.

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System control schematic

The specifications vary depending on the machine, so refer to the manual of the machine.

Correction
Engine coolant temperature
correction
Barometric Pressure
a Fuel temperature boost pres-
sure correction
Correction between cylinders
Q-key correction
QR correction

SCV opening time determina-

*1 Throttle position sensor input *8 *15 SCV
tion
Injector coil energizing time
*2 Boost sensor input *9 *16 Supply pump
Timing determination
*3 CKP sensor input *10 CAN communication *17 Fuel tank
*4 CMP sensor input *11 Machine control unit *18 Injector coil
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Water temperature sensor in-

*5 Engine control module (ECM) *12 *19 Injector
put
*6 Basic fuel injection amount *13 Common rail pressure sensor
*7 Correction *14 Common rail

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Fuel injection correction

The ECM calculates the basic injection amount based on the signals from the throttle position sensor,
boost sensor, crankshaft position sensor, camshaft position sensor, etc. At this time, the open or close
timing of the SCV and the energizing time of the injector are controlled based on the conditions such as
the common rail pressure and engine coolant temperature to make optimal corrections to the injection
timing and injection amount.
About initial Q correction
ECM implements the initial Q correction when the initial Q correction is under the specified engine rotation
during engine start. Also, ECM cannot implement the initial about initial Q correction and cannot start the
engine because it does not recognize the engine rotation when it is under the engine rpm the system can
recognize.

Engine speed (r/min)

*1 Idle speed
Starting Q specified engine
*2
speed
*3 Minimum firing engine speed
System realization engine
*4
speed

About high altitude correction

ECM calculates the current altitude using signals from the atmospheric pressure sensor.
According to the conditions such as the current altitude, the fuel amount is corrected properly.

Fuel flow limit (mm3/st)

Barometric pressure kPa (psi)

*1 Highland
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Control during overheat

To protect the engine, restriction on fuel flow is started when the engine coolant temperature exceeds
the preset temperature. When the engine coolant temperature increases further, the fuel flow is also
restricted further. When the temperature reaches a certain temperature, a DTC is detected and a fault is
recorded in the ECM. After a DTC has been detected, when the engine coolant temperature increases
further, the fuel flow is restricted to a certain amount.
The machine is designed to issue an alarm before a DTC is detected. By reducing the load applied to
the actual machine upon alarm issuance, it is possible to avoid the operation condition with fuel flow
restriction.
ANNOTATION:
• The setting varies depending on the actual machine manufacturer.

Fuel flow

Water temperature

*1 Warning indication
*2 DTC set

If the ECM is equipped with an emergency stop function for a high engine coolant temperature, it stops
the engine when the temperature reaches the preset temperature.

Fuel flow

Water temperature

*1 Engine emergency stop

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The injection pressure is controlled by regulating the fuel pressure inside the common rail. The proper
pressure inside the common rail is controlled by calculating from the engine RPM, fuel injection amount,
etc., and the appropriate amount of the fuel is discharged by regulating the supply pump to be force-fed
to the common rail.
Injection timing control
This control is performed by calculating the proper fuel injection timing mainly from the engine RPM or
injection amount in substitution for the timer function to regulate the injector.
Injection rate control
To improve combustion inside the cylinder, only a small amount of the fuel is injected first to be ignited,
and then the second injection is performed when ignition is made. This control for injection timing and
injection amount is performed through regulating the injector.
Maximum fuel injection amount
The maximum fuel injection amount is the amount of fuel injection calculated by adjustment of initial in-
jection amount under certain water temperature, limitation of maximum injection amount for the boost
pressure, and control of injection amount for the high altitude due to the atmospheric pressure.
Inter-cylinder correction
It is not used for this engine.

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System schematic

1 Electromagnetic pump 6 Pressure limiter 11 CMP sensor

2 Fuel filter 7 Injector 12 Fuel tank
3 Supply pump 8 ECM 13 Pre-fuel filter
Various sensors (Throttle,
4 Fuel pressure sensor 9
boost, water temperature, etc.)
5 Common rail 10 CKP sensor

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Fuel system
The fuel is supplied to the supply pump from the fuel tank, and then it is boosted by the pump before
supplied to the common rail. At this time, the fuel amount to be supplied to the common rail is controlled
by regulating the suction control valve based on the signal from the ECM.

1 Electromagnetic pump 4 Common rail 7 Fuel return pipe

2 Fuel filter 5 Fuel injector 8 Pre-fuel filter
3 Supply pump 6 Fuel tank

Fuel filter clog warning function and engine RPM restriction function
When the clogged fuel filter is kept used, the ECM detects DTC P0093, and the output restriction is im-
plemented.
The first stage
In order to notify a filter clogging before DTC P0093 is detected, the first stage alarm is issued when the
output value from the fuel filter pressure sensor falls below the specified threshold value.
The alarm stops when the output value exceeds the threshold value.

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The second stage

The second stage alarm is issued when the output value from the fuel filter pressure sensor falls below
the threshold value even after the first stage alarm occurs. The second stage alarm remains as issued
until the starter switch is turned OFF.
At the same time as the second stage alarm is issued, the target engine speed is reduced gradually at a
constant rate. When the output value from the sensor exceeds the specified threshold value, reduction
of the restricted engine speed is stopped, and the regulation is continued maintaining the restricted en-
gine speed at that time.When the output value from the sensor falls below the threshold value again, the
restricted engine speed is reduced further. When the starter switch is turned OFF and then turned back
ON, the restriction is once cancelled.

1 Supply pump
2 Warning light
3 Monitor
4 Monitor, CAN communication
5 Fuel tank
6 Pre-filter
7 Electromagnetic pump
8 Fuel filter pressure sensor
9 Main filter

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1 Lamp 3 Engine speed (r/min)

*2 Starter SW *4 5 sec.

1 First stage
2 Second stage

Removing air from fuel system

Place an appropriate pan under the air removal plug.
Turn the starter switch ON, and activate the electromagnetic pump.
Loosen the air removal valve of fuel filter thoroughly, and then operate the priming pump 20 times or more
until fuel flows out around the plug.
Tighten the plug, and then operate the priming pump 10 times or more until fuel fills.
Wait for about 1 minute, and then loosen the plug to remove the air in the fuel filter. Repeat at least 3
times until no air flows out from the plug.
Securely tighten each plug, and then wipe out the spilt fuel flow. Operate the priming pump 10 - 15 times
until fuel fills and it is transferred to the engine.

Machine with electromagnetic

1 Pre-fuel filter 3 5 Supply pump
pump
2 Electromagnetic pump 4 Fuel filter 6 Fuel tank

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EGR
The EGR system recirculates a part of the exhaust gas to the intake manifold, and by mixing in inert gas
to the intake air, the combustion temperature is lowered and the generation of NOx is suppressed.
The EGR amount is controlled by opening and closing the EGR valve provided between the exhaust
manifold and intake manifold. The EGR amount is determined from the engine rpm and engine load ratio
and the EGR valve is actuated to control the EGR amount.
By providing the EGR cooler on the path of the EGR gas, high-temperature gas is cooled by the EGR
cooler and then mixed with air to further lower the burning temperature in order to reduce NOx amount.
Further, the EGR system is also equipped with a check valve to prevent the EGR from flowing in the
opposite direction to increase the EGR amount.
EGR control
The ECM controls the EGR valve lift amount by operating the motor according to the engine status in-
cluding the engine speed and engine load. The valve lift amount is detected by the EGR position sensor.
In the diagram, the portion represented with a darker color indicates a larger valve lift amount and the
portion represented with the darkest color indicates that the lift amount is close to the maximum.

Throttle position

Engine speed

1 At low engine speed 5 Nozzle vane 9 Negative pressure, large

2 At high engine speed 6 Narrow gap 10 Nozzle control actuator
3 Wide gap 7 Driving ring
4 Negative pressure, small 8 Nozzle control rod

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Engine operation control

There are the following 4 types of operation control instructions, and the selection varies depending on
each specification.
Voltage input by APS, 1 - 4 V
Throttle opening angle instruction given through CAN communication control, 0 - 100 ％, RPM instruction
RPM instruction given through mode map switch control, RPM instruction and change instruction given
by APS
Increase and decrease instruction for each rotation given by the idle switch
Mode map switch
The mode map switch has 7 rotation control mode types of S1, S2, S3, L1, L2, L3 and L4.
L1, L2, L3 and L4 are the rotation speed restriction mode, and the operation can be performed between
the idling speed and the preset rotation speed by the APS.
S1, S2 and S3 are the fixed rotation mode, and changes cannot be made from the APS.

Meaning of the mode map switch and each mode

As for each mode of L1, L2, L3 and L4, the engine speed can be changed between the idling speed and
the preset rotation speed using the APS.
The preset rotation speeds for L1, L2, L3 and L4 are determined by the calibration of the ECM.

*1 APS input

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Mode map switch control

1 Throttle position sensor 5 Idle down switch *9 Reguration mode switch

*2 Engine stop switch *6 Mode map switch 0 *10 Load advance switch
*3 Idling selector switch *7 Mode map switch 1
*4 Idle up switch *8 Mode map switch 2

Outer switch
Operation mode Control
MAP0 MAP1 MAP2
STD OFF OFF OFF Basic control
S1 ON OFF OFF Fixed rotation control 1
S2 ON ON OFF Fixed rotation control 2
S3 ON ON ON Fixed rotation control 3
L1 OFF ON OFF Maximum rpm restriction control 1
L2 OFF ON ON Maximum rpm restriction control 2
L3 OFF OFF ON Maximum rpm restriction control 3
L4 ON OFF ON Maximum rpm restriction control 4

Throttle position switch

By operating the throttle position switch, the output voltage changes between 1 V and 4 V.

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Voltages between 0.2 V and 1.05 V are recognized as 1 V. When the voltage is lowered below 0.2 V or
raised above 1.05 V, an error is detected.
In addition, if the ECM terminals 85 and 86 are not at the same potential, DTC P2138 is detected.

*1 Throttle pedal position sensor

Throttle position switch, with APS learning control

If the APS learning control is available, for example, when the ignition cycle ends with the throttle position
as 2 V (1), the throttle position learning causes the 2 V status to be recognized as the opening angle 0 ％
and the control range is set to 2 V to 4 V (2).

Idling control
By operating the idling control change switch during the warm-up operation, the minimum idling RPM can
be adjusted. In addition, by operating the idling control change switch, the minimum idling RPM can be
automatically set to the optimum value in accordance with the engine coolant temperature.
ANNOTATION:
• The specifications vary depending on the machine, so availability of functions also differ.
Idling control change switch
By operating the idling control change switch, the idling control functions can be switched.
The idling control switch
By operating idling control switch, the idling RPM can be adjusted.
ANNOTATION:
• As for the installation positions of the idling control change switch and idling control switch, refer to the
manual of the machine.
The engine RPM upper limit varies depending on the engine model, machine specifications and engine
warming-up condition.
Up
While the Up side of the switch is pressed, the engine RPM is increased and the idling RPM can be raised.
Down
While the Down side of the switches is pressed, the engine RPM is decreased and the idling RPM can
be lowered. However, the engine RPM cannot be decreased below the minimum idling RPM.
Control during starter switch OFF state
There are 2 types of controls provided when the starter switch is turned OFF after the idling control switch
is operated, and either one of them is performed depending on the specification.
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The engine RPM adjusted by the idling control switch is recorded in the ECM, and the next operation is
performed with the engine RPM at the time when the starter switch is turned OFF.
The engine RPM adjusted by the idling control switch is not recorded in the ECM, and the next operation
is performed with the default engine RPM.
As for confirmation and questions regarding the specifications, contact an Isuzu service related person.
Idle manual control

1 Starter switch 3 Idle down switch *5 Idle

*2 Idle up switch *4 Engine speed

CAN communication
When CAN controller does not exist on the machine side

*1 Diagnostic scan tool

*2 MCX
*3 ECM
*4 LCD
*5 TCM
*6 Shift Control

When CAN controller exists on the machine side

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*1 Diagnostic scan tool

*2 MCX
*3 ECM
*4 TCM
*5 Shift Control

Engine RPM output to tachometer

The ECM outputs the engine rpm pulse to the tachometer as a tachometer output. The tachometer dis-
plays the engine RPM based on the engine RPM pulse sent from the ECM.

a Output from machine control unit by machine

1 CKP sensor 4 CAN communication *7 Tachometer

*2 Engine speed *5 Control unit on machine side
*3 Engine control module (ECM) *6 Tachometer output

Locations, shapes and existence or nonexistence of components vary depending on the specifications of
the machine.

1 CMP sensor 6 Turbocharger control solenoid 11 Fuel pressure sensor

2 Vacuum sensor 7 Boost temperature sensor 12 CKP sensor
3 Water temperature sensor 8 IMT sensor 13 Oil pressure sensor
4 Overheat switch 9 Boost sensor 14 Fuel temperature sensor
5 Glow plug 10 EGR valve 15 Suction control valve

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Supply pump
The supply pump highly pressurizes the fuel using the engine torque, and force-feeds the fuel to the
common rail. Also, the suction control valve, fuel temperature sensor, feed pump, etc, are installed on
the supply pump.

1 Feed pump
2 Suction control valve
3 Fuel temperature sensor

Suction control valve

The suction control valve is installed on the supply pump portion, and controls the fuel force-feed to the
common rail. The ECM controls the fuel discharge amount by regulating the energizing time to the suction
control valve.

1 Suction control valve

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Fuel temperature sensor

The fuel temperature sensor is installed on the supply pump, and the thermistor changes the resistance
value according to the temperature change. The resistance value becomes lower when the fuel temper-
ature is high, and it becomes higher when the fuel temperature is low. The ECM applies 5 V to the fuel
temperature sensor through the pull-up resistor, and it calculates the fuel temperature from changes in the
voltage and uses it for controlling the supply pump, etc. The voltage becomes lower when the resistance
is lower, and it becomes higher when the resistance is higher.
ANNOTATION:
• Do not replace the fuel temperature sensor.
When an abnormality is found, replace the supply pump assembly.

Common rail
The common rail receives the fuel from the supply pump, retains the fuel pressure and distributes the fuel
to each cylinder. The fuel pressure sensor and the pressure limiter are installed on the common rail.

1 Pressure limiter
2 Fuel pressure sensor
3 Common rail

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Pressure limiter
The pressure limiter is activated when the pressure in the common rail becomes abnormally high to re-
lease the pressure inside the common rail.

1 Pressure limiter

Fuel pressure sensor

The fuel pressure sensor is installed on the common rail, and detects the fuel pressure inside the common
rail to convert into the voltage signal and sends it to the ECM. The voltage becomes higher when the
pressure is higher, and it becomes lower when the pressure is lower. The ECM calculates the actual fuel
pressure from the voltage signal sent from the sensor, and uses it to control the fuel injection, etc.

1 Fuel pressure sensor

Injector
The injector is installed on the cylinder head portion, and is controlled by the ECM to perform fuel injection.
The ECM internally boosts the voltage for driving the injector to apply it to the injector, and uses it for fuel
injection amount control and injection timing control by regulating the energizing time of the injector.

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Engine coolant temperature sensor

Engine coolant temperature sensor is installed on the engine block, and the thermistor changes the re-
sistance value according to the temperature change. The resistance value becomes smaller when the
engine coolant temperature is high, and the value becomes larger when the engine coolant temperature
is low. The ECM applies 5 V to the engine coolant temperature sensor through the pull-up resistor, and
calculates the engine coolant temperature from changes in the voltage. This value is used in various
control mechanisms, such as for fuel injection control. The voltage becomes higher when the resistance
is higher, and it becomes lower when the resistance is lower.

Overheat switch
The overheat switch is installed on the water outlet pipe, and is turned ON when the engine coolant
temperature exceeds 105º C {221˚ F}.

CKP sensor
The CKP sensor is installed behind the fuel filter at the left side behind the cylinder block. The sensor
rotor is fixed to the crankshaft, with 56 notches arranged at 6° intervals and the section without notch at
30°. This section without notch allows the sensor to generate a pulse signal by detecting the top dead
center of the cylinder No. 1. By detecting the section without notch from the CKP sensor and a single
reference protrusion from the CMP sensor, the ECM can determine the compression top dead center of
the cylinder No. 1 and confirm that they are related to each other.

1 CKP sensor
2 Sensor rotor
3 Rotational direction
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CMP sensor
The CMP sensor is installed to the timing chain cover at the front side of the cylinder head. The CMP
sensor detects 5 protrusions per 1 rotation of the engine to generate a pulse signal. The ECM determines
the cylinder and specifies the crank angle using the CMP signal and the CKP signal input from the CKP
sensor, and uses the information for the fuel injection control and calculation of the engine rpm. While this
control is usually performed using the CKP signal, the CMP signal is used instead when the CKP sensor
is faulty.

1 Timing chain sprocket

2 CMP sensor
3 Projection
4 Reference protrusion
5 Rotational direction

Oil pressure sensor

The oil pressure sensor is installed near the starter motor of the cylinder block, and it detects the pressure
of the engine oil to convert into the voltage signal and send it to the ECM.
The voltage becomes higher when the pressure is higher, and it becomes lower when the pressure is
lower.

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Throttle position sensor

The throttle position sensor is installed on the console panel of the machine to supply the voltage signal
which varies in accordance with the throttle volume angle to the ECM. The ECM calculates the throttle
throttle position from the voltage signal, and uses it for fuel injection control and many other controls.
ANNOTATION:
• As for the installation position of the throttle position sensor, refer to the manual of the machine.
Barometric pressure sensor
The barometric pressure sensor is installed on the machine side, and it replaces the barometric pressure
with the voltage signal. The ECM calculates the barometric pressure from the voltage signal, and uses
the atmospheric pressure to correct the fuel injection amount.
ANNOTATION:
• As for the installation position of the atmospheric pressure sensor, refer to the manual of the machine.

EGR position sensor

This sensor is installed inside the EGR valve to detect the EGR valve lift amount.
ANNOTATION:
• Do not disassemble the EGR position sensor. When an abnormality is found, replace the EGR valve
assembly.

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4001C-47
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Function, Structure, Operation

ECM power distribution diagram Some sensors may not be connected to the ECM depending on the
specifications of the machine.
Since some sensors may perform input/output with the ECM depending on the CAN communication, con-
firm the specifications of the machine.

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4001C-54
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Function, Structure, Operation

*1 Throttle pedal position sensor *17 SCV switch *33 Signal ground
*2 BARO sensor *18 Air cleaner switch *34 Power ground
DPD differential pressure sen-
*3 *19 Memory clear switch *35 Monitor
sor
*4 Fuel filter pressure sensor *20 Diagnosis switch *36 Oil pressure lamp
Exhaust temperature sensor 1
*5 *21 MAF sensor *37 Glow plug lamp
(in front of filter)
*6 Exhaust temperature sensor 2 *22 IAT sensor *38 Boost temperature lamp
*7 Engine stop switch *23 CKP sensor *39 Over heat lamp
*8 Idling selector switch *24 Fuel pressure sensor *40 Engine over rum lamp
*9 Idle up switch *25 ECM *41 DPD regenerate lamp
*10 Idle down switch *26 Starter switch (ON) *42 Fuel temperature lamp
*11 Mode map switch 0 *27 Starter switch (START) *43 Fuel filter pressure lamp
*12 Mode map switch 1 *28 Starter switch *44 DPD lamp
*13 Mode map switch 2 *29 Main relay *45 Glow relay
*14 Reguration mode switch *30 Dropping resistor *46 Glow plug
*15 Load advance switch *31 Battery
*16 DPD regeneration switch *32 Case ground

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4001C-55
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Function, Structure, Operation

1 Boost sensor 10 IMT sensor *19 EGR DC motor

*2 EGR position sensor *11 Starter cut relay *20 Intake throttle motor
*3 Intake throttle position sensor *12 Hour mater relay *21 Fuel injector 1 (Cylinder #1)
84592788 EN - March 2012
4001C-56
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Function, Structure, Operation

*4 Fuel temperature sensor *13 Starter *22 Fuel injector 3 (Cylinder #4)
*5 CMP sensor *14 Tacho meter *23 Fuel injector 2 (Cylinder #3)
*6 Vacuum sensor *15 TOOL *24 Fuel injector 4 (Cylinder #2)
*7 Boost temperature sensor *16 OEM unit *25 Suction control valve
*8 Oil pressure sensor *17 Terminator *26 ECM
*9 Water temperature sensor *18 Turbocharger control solenoid

110 CC-ISOCAN-H ISO CAN-High
111 PS-+B Battery power source
DPD differential pressure sensor, fuel filter pressure sensor, exhaust gas tempera-
112 SG-5VRT3
ture sensor 1, exhaust gas temperature sensor 2 GND
113 SG-12VRT MAF sensor GND
114 OS-MAINR ECM main relay control
115 SG-SLD1 Throttle position sensor shield
116 IA-EVRV Vacuum sensor signal
117 SP-12V Mass air flow sensor power source
118 - -
119 PG-SIGN Signal GND
120 - -
121 IS-ENGSTP Engine stop switch signal
122 IS-DPDREG DPD switch
123 OS-OVRL Engine overrun light
124 OS-OILPL Engine oil pressure light
125 OS-BOOSTL Boost temperature sensor pilot light
126 OS-OVHL Overheat light
127 - -
128 OF-TACHO Tachometer
129 OS-DPDREG DPD regeneration light
130 OS-DIAGL Diagnosis light
131 - -
132 CC-CAN-L CAN-Low
133 PS-+B Battery power source
134 IS-IGKEY Starter switch ON signal
135 SG-5VRT2 Barometric pressure sensor GND
136 OS-MAINR ECM main relay control
137 PG-CASE ECM case GND
138 OP-EVRV Turbocharger control solenoid drive
139 PS-MAFBAT Dropping resistor
140 - -
141 IS-DIAG Diagnostic switch signal
142 IS-MEMCL Memory clear switch signal
143 IS-DGSEL Diagnostic switch signal
144 - -
145 OS-GLOWL Glow light
146 - -
147 OS-FIPRESSL Fuel filter clogging light
148 OS-THLL Fuel temperature light
149 OS-DPDSL DPD light
150 OS-HOUR Hour meter relay
151 - -
152 OS-STARTR Starter cut relay
153 OS-GLOWR Glow relay
154 CC-CAN-H CAN-High

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4001C-61
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Function, Structure, Operation

84592788 EN - March 2012

4001C-62
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4001E-6
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Symptom

Engine stalling upper side or have an outlet toward the motion

direction of the machine.
1. Engine stalling Description of Symptom Abnormalities of the air intake system parts
Engine cranks but takes a long time to start. The Abnormalities of the exhaust system parts
engine ultimately operates, or starts but stops soon.
2. Engine stalling Diagnostics
• Preliminary inspection
Before using this section, perform a functional in-
spection and OBD system check to check all of
the following.
Check the machine for excessive load.
The ECM and monitor are operating correctly.
Since CKP sensor failure is not diagnosed until
the 14th crank rotation, crank it for at least 14
seconds at 60 r/min or above.
Check DTC.
CKP sensor DTC may not be detected in case of
failure of the CKP sensor at low engine speed.
In case of intermittent failure, increase the engine
speed to No Load Max to inspect whether DTC(s)
related to the CKP sensor is detected.
The scan tool data is in the normal range of oper-
ation values.
Check the machine status, and locate the appro-
priate symptom.
Check with the customer whether they are using
the specified engine oil and fuel.
Check to see if the fuel is filled.
• Visual inspection
Careful visual inspection is required for several
symptom procedures. This can lead to correct-
ing a problem without further inspections, and can
save valuable time.
The inspection includes the following.
Whether there is improper connection of the con-
nector. Especially for CKP sensor and CMP sen- *1 Pre fuel filter
sor. *2 Electromagnetic pump
Correct wiring connections, tightening, and dis- *3 Fuel filter
connection.
Whether the power of any commercial acces- • Diagnostic aids
sories is being taken from the ECM power. Fuel system abnormalities such as fuel running
Whether the ECM ground is clean and securely out, fuel freezing, mixture of air into the fuel pip-
installed in the correct location. ing, filter abnormalities, piping abnormalities, fuel
Correct connections, cracks, and twists in the quality, fuel tank, etc.
pipes and hoses related to fuel, air or oil. Exten- Air intake system abnormalities such as filter clog-
sively check for any leaks or blockage. ging and air intake piping abnormalities, etc.
Whether there is any fuel leaks or pipe damage in Abnormalities of the supply pump, non-pressure
the fuel system. fuel supply
Whether the structure allows for air deposit due to The ECM determination of the supply pump non-
layout of the fuel filter, pre-filter and electromag- pressure fuel supply DTC will not be detected un-
netic pump. less a condition continues for 3 seconds or more
Check whether they are arranged to prevent in which the engine revolution speed is 900 r/min
air accumulation as Isuzu genuine pre-filters do and the absolute pressure is below 15 MPa {153
not have any plugs for air removal. Also check kgf/cm2 / 2175 psi}. Therefore, the DTC will not
whether the inlet and outlet of the electromagnetic be detected when the engine does not start with
pump have an appropriate layout. Fix layouts non-pressure fuel supply due to supply pump ab-
which have the electromagnetic pump inlet on the normalities.

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4001E-7
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Symptom

a Absolute pressure
b Non-criteria range
c P0093 Criteria range
d Range in P0093 is established
e Engine speed (r/min)

Common rail abnormalities such as degradation

of flow damper and pressure limiter operations
and internal sealing property
Injector failure, i.e. no injection
System down due to malfunctions
Engine unit abnormalities such as seizure, insuffi-
cient compression pressure and other mechanical
failures
a Engine speed (r/min) ACG failure
P0093 Judgment required en- Failure related to machine measurement devices
b such as oil pressure pump
gine speed
Effect of post-installed accessories such as wire-
c Minimum firing engine speed
less devices and lights, etc.
System realization engine ECM failure
d
speed Inspect the connector for connection failures and
the harness for abnormalities such as abrasions
or bends. Inspect that the wire inside the harness
has not caused a short circuit with other circuits.
Perform inspections for functional diagnosis, and
confirm the operation and control of each part.
Repair if abnormalities are found.

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4001E-8
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Symptom

Engine hunting, rough idling

1. Engine hunching, rough idling Description of Symp-
tom
The engine has variable engine idling, or has
change in idling revolution speed. In a severe case,
the engine or the machine may vibrate. In either
case, the engine stall may occur if the symptom
gets worse.
2. Engine hunching, rough idling Diagnostics
• Preliminary inspection
Before using this section, perform the functional
inspection and OBD system check to check all of
the following.
The ECM and monitor are operating correctly.
DTC check.
The scan tool data is within the normal operating
range.
Check the condition of the machine, and locate
the appropriate symptom.
Check with the customers whether they are using
the specified engine oil and fuel.
• Visual inspection
Careful visual inspection is required for several
symptom procedures. This can lead to correct-
ing a problem without further inspections, and can
save valuable time.
The inspection includes the following.
Whether there is improper connection of the con-
nector.
Whether the battery terminal voltage has *1 Pre fuel filter
dropped. *2 Electromagnetic pump
Correct wiring connections, tightening, and dis-
*3 Fuel filter
connection.
Whether the power of any commercial acces-
• Diagnostic aids
sories is being taken from the ECM power. Fuel out, fuel freezing, mixture of air into the fuel
Whether the ECM ground is clean and securely piping, filter defect, pipe defect, fuel quality and
installed in the correct location. failure of fuel system such as fuel tank
Correct connections, cracks, and twists in the Air intake system abnormalities such as clogged
pipes and hoses related to fuel, air or oil. Exten- filter and air intake piping failure
sively check for any leaks or blockage. Supply pump failure; fuel feeding without pres-
Whether there is any fuel leaks or pipe damage in sure
the fuel system. Switch input circuit system abnormalities
Whether the structure allows for air deposit due to Sensor input circuit system abnormalities such
layout of the fuel filter, pre-filter and electromag- as throttle position sensor, harness and engine
netic pump. coolant temperature sensor
Check whether they are arranged to prevent Throttle position sensor system abnormalities
air accumulation as Isuzu genuine pre-filters do Engine unit abnormalities such as seizure, insuffi-
not have any plugs for air removal. Also check cient compression pressure and other mechanical
whether the inlet and outlet of the electromagnetic failures
pump have an appropriate layout. Fix layouts Failure related to machine measurement devices
which have the electromagnetic pump inlet on the such as oil pressure pump
upper side or have an outlet toward the motion Effect of post-installed accessories such as wire-
direction of the machine. less devices and lights, etc.
Whether there are any fuel leaks, pipe damage, Inspect the connector for connection failures and
or dents in the fuel system. the harness for abnormalities such as abrasions
Abnormalities of the air intake system parts or bends. Inspect that the wire inside the harness
Abnormalities of the exhaust system parts has not caused a short circuit with other circuits.
Perform inspections for functional diagnosis, and
confirm the operation and control of each part.
Repair if abnormalities are found.

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4001E-9
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Symptom

Excessive white smoke in the Whether the power of any commercial acces-
sories is being taken from the ECM power.
exhaust gas Whether the ECM ground is clean and securely
installed in the correct location.
1. Excessive white smoke in the exhaust gas Descrip-
Correct connections, cracks, and twists in the
tion of Symptom
pipes and hoses related to fuel, air or oil. Exten-
Excessive white smoke when driving.
sively check for any leaks or blockage.
2. Excessive white smoke in the exhaust gas Diagnos-
Whether there is any fuel leaks or pipe damage in
tics
the fuel system.
• Preliminary inspection Air intake system parts abnormalities
Before using this section, perform the functional Exhaust system parts abnormalities
inspection and OBD system check to check all of • Diagnostic aids
the following. Quality of fuel (use of fuel with low cetane value
The ECM and monitor are operating correctly. other than standard product)
DTC check. If low-viscosity fuel such as kerosene is used,
The scan tool data is within the normal operating white smoke may be generated due to spraying
range. failure caused by abnormal worn on the injector
Check the condition of the machine, and locate seat. In this case, the injector must be replaced.
the appropriate symptom. Since replacement of injector required due to
Check with the customers whether they are using use of low-viscosity fuel such as kerosene will be
the specified engine oil and fuel. charged, instruct customers not to use low-vis-
• Visual inspection cosity fuel such as kerosene.
Careful visual inspection is required for several Long-time idling
symptom procedures. This can lead to correct- Engine coolant temperature sensor, fuel temper-
ing a problem without further inspections, and can ature sensor, IAT sensor, boost sensor and atmo-
save valuable time. spheric sensor malfunction
The inspection includes the following. Engine unit abnormalities such as insufficient
Whether there is improper connection of the injec- compression pressure, piston-related failures,
tor connector. turbocharger, suck down oil and raised oil
Correct wiring connections, tightening, and dis- ECM failure
connection.

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4001E-10
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Symptom

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4001E-15
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Symptom

Engine Output Deficiency Whether the ECM ground is clean and securely
installed in the correct location.
1. Insufficient engine output Description of Symptom Correct connections, cracks, and twists in the
The engine output is lower than expected, the out- pipes and hoses related to fuel, air or oil. Exten-
put does not change when the throttle lever is lifted sively check for any leaks or blockage.
up, the operation is not effective. Whether there is any fuel leaks or pipe damage in
2. Insufficient engine output Diagnostics the fuel system.
Increase of resistance due to failure of air in-
• Preliminary inspection
Before using this section, perform a functional intake system parts, especially dirty or clogged air
spection and OBD system check to check all of cleaner element and collapsing of air intake pipe
the following. Exhaust system parts abnormalities
The ECM and monitor are operating correctly. • Diagnostic aids
Check DTC. Fuel out, fuel freezing, mixture of air into the fuel
The scan tool data is in the normal range of oper- piping, filter defect, pipe defect, fuel quality and
ation values. failure of fuel system such as fuel tank
Check the machine status, and locate the appro- Air intake system abnormalities such as clogged
priate symptom. filter and air intake piping failure
Check with the customer whether they are using Exhaust system abnormalities such as exhaust
the specified engine oil and fuel. pipe failure
Since there are various possible causes of in- Sensor input circuit system abnormalities such as
sufficient output, investigate on the association throttle position sensor and harness failure
between the engine body and the machine thor- Switch input circuit system abnormalities
oughly. Engine unit abnormalities such as compression
Check in which operation the insufficient output pressure, valve clearance, turbocharger, supply
occurs. pump, injector, common rail, and other mechani-
If the symptom of insufficient output contains hes- cal failure, etc.
itation and lug-down, it is associated with control Failure related to machine measurement devices
of the machine, so contact the machine manufac- such as oil pressure pump
turer. Effect of post-installed accessories such as wire-
If a trouble diagnosis scan tool is available, the less devices and lights, etc.
engine output at the rated point can simply be Inspect the connector for connection failures and
checked by checking the boost at the rated point. the harness for abnormalities such as abrasions
or bends. Inspect that the wire inside the harness
• Visual inspection
Careful visual inspection is required for several has not caused a short circuit with other circuits.
symptom procedures. This can lead to correct- Perform inspections for functional diagnosis, and
ing a problem without further inspections, and can confirm the operation and control of each part.
save valuable time. Repair if abnormalities are found.
The inspection includes the following. Decrease of output by fuel flow rate limitations
Whether the air cleaner element is clean and free due to overheating
from clogging. Insufficient output by fuel flow rate limitations for
Correct wiring connections, tightening, and dis- highland driving
connection.
Whether the power of any commercial acces-
sories is being taken from the ECM power.

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4001E-16
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system system
1. EGR control system check Description of Function 1. Glow control system check Description of Function
The ECM controls the EGR valve based on the
engine speed, engine coolant temperature, intake CAUTION
air temperature, fuel injection amount, and atmo-
spheric The EGR valve is driven by the EGR motor, • The specification of QOS circuit is the
same as the starter ECM control specifi-
and the opening angle of the EGR valve is detected
cation and the safety relay specification.
by the EGR position sensor.
2. EGR control system check Inspection
Inspection when there is a possibility that there is The QOS system consists of the ECM, glow relay,
an abnormality in the locations relating to the EGR. glow plug, and QOS indicator If the starter switch is
turned ON while the temperature of engine coolant
1) Check the DTC. is low, the ECM determines the glow time depend-
ing on the engine coolant temperature, and actu-
ANNOTATION:
ates the glow relay and the QOS indicator When a
• If the DTC is detected, inspect the corre- certain period of time has passed, the ECM turns
sponding DTC. OFF the glow relay and the QOS indicator light.
2. Glow control system check Inspection
2) Start the engine and warm it up until the Inspection when there is a possibility that there is
coolant temperature exceeds the specified an abnormality in the locations relating to the QOS
value. system control
Values: 70 °C {158 °F}
3) Check the EGR position display using a trou- 1) Perform the OBD system check.
ble diagnosis scan tool. 2) Check the DTC.
Specified value: (-3) - 3 ％
ANNOTATION:
4) If the EGR position display is outside the spec-
ified value range, perform the actuator test • If DTC P0117, P0118 or P0380 has been
ERG control with a trouble diagnosis scan detected, inspect the applicable DTC.
tool.
5) Execute an Up and Down command to the 3) Turn ON the starter switch.
EGR valve and check the EGR position dis- 4) Check the operation of the QOS indicator
play. light.
Specified value: (-3) - 3 ％ ANNOTATION:
6) Inspect the EGR piping if the EGR position
display is outside the specified value. • The QOS indicator light is turned on when
No damage or gas leaks should be found. the starter switch is turned ON by the light
7) If a problem is found, repair or replace. check function, even if the QOS does not
8) Start the engine and warm it up until the operate.
coolant temperature exceeds the specified • The QOS indicator light goes off within 10
value. seconds.
Values: 70 °C {158 °F} 5) If the QOS indicator light comes on or does
9) Check the EGR position display using a trou- not go off, inspect the circuit.
ble diagnosis scan tool.
Specified value: (-3) - 3 ％ • The fuse should not be meltdown.
10) Replace the EGR valve if the EGR position • There should no open circuit between the
display is outside the specified value. fuse and QOS indicator light.
Refer to “Emission Control Devices EGR • There should no open circuit or short circuit
valve removal”. between the QOS indicator light and ECM.
Refer to “Emission Control Devices EGR • The bulb of the QOS indicator light should
valve installation”. not be blown.
11) When replacing the EGR valve, perform EGR 6) If a problem is found, repair or replace the
learning to the ECM. circuit.
7) Inspect the glow relay.
8) If a problem is found, replace the relay.
9) Remove all glow plugs.
10) Measure the resistance between the glow
plug terminal and GND using the DMM.
Values: 6 Ω At room temperature
ANNOTATION:
• If the reading is outside the specified range,
inspect the corresponding glow plug.

84592788 EN - March 2012

CONTENTS

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

4001G-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

4001G-2 PRINTED IN FRANCE
Copyright ©
Maintenance precautions

1. Maintenance precautions • Be sure to assemble components within 5

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

4004-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Starter Motor

Job code HA8111000 Removal of Starter Motor

1. Use a wrench [17 mm (0.669 in)] to remove the bolt
WARNING (1), and then remove the battery cable (2) on the
negative side.
• Do not use open flames and do not allow Tightening torque for bolt installation: 10.6 - 13.0
sparks near the battery.
N・m (7.820 - 9.589 lbf・ft)

CAUTION • When removing the terminal and harness, secure

them so that they do not interfere with the frame.
• Be sure to stop the engine before beginning Also, cover with a rubber cap to protect against
work. sparks.

Items to prepare
• Wrenches [13 mm (0.512 in), 14 mm (0.551 in), 17 mm
(0.669 in), 19 mm (0.748 in)]
• Rag
• Cleaning fluid

2. Use a wrench [19 mm (0.748 in)] to remove the 4

bolts (1), and then remove the under cover (2).
Tightening torque for bolt installation: 63.7 - 73.5
N・m (46.991 - 54.220 lbf・ft)

3. Use a wrench [13 mm (0.512 in)] to remove the bolt

(1), and then remove the terminal cap (2).
Use a wrench to remove the wiring (3) (4) from the
starter.

4005-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

4005-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Alternator

Job code HAGE01 3. Use a wrench [10 mm (0.394 in)] to remove the bolts
(1).
Remove the connector (2) from the alternator.
WARNING Use a wrench to remove the wiring (3) from the al-
ternator.
• Do not use open flames and do not allow
sparks near the battery.

CAUTION
• Be sure to stop the engine before beginning
work.

Items to prepare
• Wrenches [10 mm (0.394 in), 13 mm (0.512 in), 17 mm
(0.669 in) ]
• Rag
• Cleaning fluid

Removal of Alternator 4. Use a wrench [13 mm (0.512 in)] or [17 mm (0.669

in)] to remove the 2 bolts (1), and then remove the
1. Remove the fan belt. alternator (2).
(For details, see "Removal and Installation of Water Tightening torque for M8 bolt installation: 25 N·m
Pump Assembly".) (18.44 lbf·ft)
2. Use a wrench [17 mm (0.669 in)] to remove the bolt Tightening torque for M10 bolt installation: 51 N·m
(1), and then remove the battery cable (2) on the (37.62 lbf·ft)
negative side.
Tightening torque for bolt installation: 10.6 - 13.0
N·m (7.820 - 9.589 lbf·ft)
• When removing the terminal and harness, secure
them so that they do not interfere with the frame.
Also, cover with a rubber cap to protect against
sparks.

Installation of Alternator
To install, perform the reverse of the removal procedure.
Install according to the installation procedures and
tension adjustment procedures in "Installation of Water
Pump Assembly".

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4005-3
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Removal and Installation of Alternator

84592788 EN - March 2012

4005-4
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Section

4008

Preheating System

84592788 EN - March 2012

CONTENTS

Removal and Installation of Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Removal of Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

4008-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

4008-2 PRINTED IN FRANCE
Copyright ©
Preheating System

Removal and Installation of Glow Installation of Glow Plug

Plug 1. Glow plug Installation
1) Install the glow plug to the cylinder head as-
Removal of Glow Plug sembly.
1. Battery ground cable Disconnect Tightening torque: 18 N・m {1.8 kgf・m / 13
lb・ft}
1) Disconnect the battery ground cable from the
battery. CAUTION
2. Turbocharger control solenoid removal • Do not exceed specifications when
tightening as over-tightening may
1) Disconnect the harness connector from the
result in breakage.
turbocharger control solenoid.
2) Disconnect the vacuum hose from the tur-
bocharger control solenoid.
3) Remove the turbocharger control solenoid
from the inlet manifold.
ANNOTATION:
• Remove together with the bracket.

2. Glow plug connector installation

1) Install the glow plug connector to the glow
plug.
ANNOTATION:
• Install the glow plug connector to the glow
plugs of the No.1, No.3 and No.4 cylinders.
1 Turbocharger control solenoid
2 IMT sensor CAUTION
3 Boost sensor • Install the glow plug connector so
4 Boost temperature sensor that there is no interference with the
cylinder head.
3. Glow plug connector removal
Tightening torque: 1.8 N・m {0.2 kgf・m /
1) Remove the glow plug connector from the
1.328 lbf・ft}
glow plug.
3. Turbocharger control solenoid installation
4. Glow plug Removal
1) Install the turbocharger control solenoid to the
1) Remove the glow plug from the cylinder head
inlet manifold.
assembly.
ANNOTATION:
• Install the bracket together with the tur-
bocharger assembly control solenoid.
Tightening torque: 25 N・m {2.5 kgf・m / 18
lb・ft} Bolt
Tightening torque: 15 N・m {1.5 kgf・m / 11
lb・ft} Nut
2) Connect the vacuum hose to the turbocharger
control solenoid.

CAUTION
• Insert the hose until it stops.

84592788 EN - March 2012

4008-3
Copyright ©
Preheating System

3) Connect the harness connector to the tur- Inspection

bocharger control solenoid.
1. Glow plug Inspection
CAUTION 1) Measure the resistance using a circuit tester.
• Install the harness and hose clip to ANNOTATION:
their original locations.
• Measure the resistance value of the glow
plug.
Values: 6 Ω Room temperature
ANNOTATION:
• Replace the glow plug if the measurements
reveal that the resistance value is not at the
specified value.

CAUTION
• When replacing the glow plug, use
a set of 4 glow plugs made by the
same manufacturer.

1 Turbocharger control solenoid

2 IMT sensor
3 Boost sensor
4 Boost temperature sensor

4. Battery ground cable Connect

1) Connect the battery ground cable to the bat-
tery.

84592788 EN - March 2012

4008-4
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Section

4020A

Electrical Equipment Layout Diagram

84592788 EN - March 2012

4020A-8
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Electrical Equipment Layout Diagram

Actual milli-amp for flow control

1 Magnetic fuel pump 5 Swing brake 9
proportional valve
Horsepower control propor-
2 P1 pressure sensor 6 Lever lock 10
tional valve
3 P2 pressure sensor 7 2-stage relief 11 N2 pressure sensor
4 4 stack solenoid valve 8 2-stage travel 12 Oil temperature sensor

84592788 EN - March 2012

4020A-9
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Electrical Equipment Layout Diagram

Main Unit Center Section Layout Diagram

1 Arm pressure sensor 3 Travel pressure sensor 5 Upper pressure sensor

2 N1 pressure sensor 4 Bucket pressure sensor 6 Boom pressure sensor

84592788 EN - March 2012

4020A-10
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Electrical Equipment Layout Diagram

Cab Layout Diagram 1

84592788 EN - March 2012

4020A-11
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Electrical Equipment Layout Diagram

1 Air conditioner sunlight sensor 6 Rocker switch 11 Air conditioner control panel
2 Monitor display 7 Wiper motor 12 Engine emergency stop switch
3 Knob 8 Radio 13 Rocker switch
4 Cigar lighter 9 Throttle volume 14 Gate lock limit switch
5 Wiper controller 10 Key cylinder

84592788 EN - March 2012

4020A-12
Copyright ©
Electrical Equipment Layout Diagram

*1: EU
*2: NA
*3: LX
Parts without the * mark are common to EU, NA, and LX models.

Name Shape Circuit Remarks

Specification; For +24

VDC
Battery relay
Sumitomo part No.;
KHR1241

Specification; 5.0 kW -24

V
Starter motor
Isuzu part No.; 898045-
0272

Specification; 50 A -24 V
Alternator Isuzu part No.; 898092-
1122

Model; 115D41R
Battery Sumitomo part No.;
KHR3943

Sumitomo part No.;

Washer motor
KHR2261 (tank + motor)

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Electrical Equipment Layout Diagram

sor 4560

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Electrical Equipment Layout Diagram

Name Shape Circuit Remarks

Isuzu part No.; 897217-

MAP sensor
7780

Isuzu part No.; 812146-

MAT sensor
8300

Supply pump accessory

Fuel temperature
Supply pump Isuzu part
sensor
No.; 898023-5810

Supply pump accessory

Suction control
Supply pump Isuzu part
valve
No.; 897381-5555

Isuzu part No.; 898201-

Injector
5640

Suction air tem- Isuzu part No.; 897601-

perature and flow 9670
sensor Sumitomo part No.;
(MAF sensor) KHH13270

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Electrical Equipment Layout Diagram

84592788 EN - March 2012

4020A-23
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Electrical Equipment Layout Diagram

Name Shape Circuit Remarks

Speaker Sumitomo part No.;

(right) (left) KHR3366

Sumitomo part No.;

Monitor display KHR23592 *1,*2
KHR23582 *3

Specification; 50.0 MPa

Pressure sensor
Sumitomo part No.;
(P1) (P2)
KHR10290

Pressure sensor
(N1) (N2) (swing) Specification; 5.0 MPa
(upper) (travel) Sumitomo part No.;
(arm in) (bucket KHR26940
close) (boom up)

Pressure switch Specification; 0.49 MPa

(option) (2nd op- Sumitomo part No.;
tion) KHR21490

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4020A-24
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Electrical Equipment Layout Diagram

Name Shape Circuit Remarks

Pressure switch Sumitomo part No.;

(filter) KHR14470

4 stack solenoid Sumitomo part No.;

valve KHJ15450

2 stack solenoid
Sumitomo part No.;
valve
KHJ14780
(knob switch type)

2 stack solenoid
Sumitomo part No.;
valve
KHJ14000
(pedal type)

P1 flow control Sumitomo part No.;

proportional valve KNJ11851

84592788 EN - March 2012

4020A-25
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Electrical Equipment Layout Diagram

Name Shape Circuit Remarks

Horsepower con-
Sumitomo part No.;
trol proportional
KNJ11851
valve

Model; KAB 555

Sumitomo part No.;
KAB seat
KHN11490 *1,*2
KHN13560 *3

Hydraulic oil tem- Sumitomo part No.;

perature sensor KHR2433

Knob; Right Model; With 4 switches

(with one-touch Sumitomo part No.;
switch) KHJ24640

Knob; Left Model; With 4 switches

(with horn switch Sumitomo part No.;
and radio mute) KHJ24630

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Electrical Equipment Layout Diagram

Name Shape Circuit Remarks

Sumitomo part No.;

KHR3852
Travel alarm
Basic frequency; 2560
Hz

Sumitomo part No.;

Horn (low) KHR21430
Basic frequency; 350 Hz

Sumitomo part No.;

Horn (high) KHR21440
Basic frequency; 415 Hz

Lever lock limit Sumitomo part No.;

switch KHR14930

84592788 EN - March 2012

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Electrical Equipment Layout Diagram

Name Shape Circuit Remarks

Specification; 24 V, 10 W
Lamp
Sumitomo part No.;
(room lamp)
KHN2714

Specification; 12 VDC
Accessory socket Sumitomo part No.;
KHR2501

Specification; 24 VDC
Cigar lighter 24 V Sumitomo part No.;
KHR11210

Air conditioner Sumitomo part No.;

unit KHR2716

Limit switch
Sumitomo part No.;
(front window)
KHR2950
(door)

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Electrical Equipment Layout Diagram

Name Shape Circuit Remarks

Sumitomo part No.;

Wiper controller
KHN3392

Sumitomo part No.;

Wiper motor
KHN25780

Solar radiation Sumitomo part No.;

sensor KHR10540

Receiver dryer Sumitomo part No.;

(switch) KHR13590

Air conditioner
Sumitomo part No.;
compressor
KHR3197
(magnetic clutch)

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Electrical Equipment Layout Diagram

Name Shape Circuit Remarks

4020A-34
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Section

4020B

Connection Connector Pin Layout

84592788 EN - March 2012

CONTENTS

Computer A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

4020B-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

4020B-2 PRINTED IN FRANCE
Copyright ©
Connection Connector Pin Layout

Computer A

4020C-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

4020C-2 PRINTED IN FRANCE
Copyright ©
Sequence Circuit Diagram

Code table

F1
A1 COMPUTER FUSE 10A ; SPARE R3 THROTTLE VOLUME
8
F1 FUSE 15A; FUEL FILLER THERMISTOR INNER TEM-
A2 ENGINE CONTROLLER R4
9 PUMP PERATURE
F2
A4 WIPER CONTROLLER FUSE 10A ; OPTION LINE R5 FUEL SENSOR
0
F3
A6 BLOWER CONTROLLER FUSE BOX R7 RESISTOR (MAF)
4
AIR CONDITIONER CON- F4
A9 FUSIBLE 50A ; LINK BACK UP S1 KEY SWITCH
TROLLER 1
A1 F4 ENGINE EMERGENCY STOP
CONTROLLER B FUSE 15A ; CONT S9
3 2 SWITCH
COOLANT TEMPERATURE F4 FUSIBLE 65A ; LINK FUSE
B1 S11 WIPER SWITCH
SENSOR 3 BOX
HYDRAULIC OIL TEMPERA- F4 FUSIBLE 50A ; LINK SAFETY S1
B2 OVERLOAD SWITCH (EU)
TURE SENSOR 4 RL 3
FUEL TEMPERATURE SEN- S1
B3 G1 BATTERY HORN SWITCH
SOR 5
S1
B5 EVAPORATOR SENSOR G2 ALTERNATOR IDLE SWITCH
6
B2 ENGINE OIL PRESSURE S2 FREE SWING (NA) ; OP-
H1 AUDIBLE WARNING DEVICE
1 SWITCH 2 TIONAL (EU)
B2 SWING PILOT PRESSURE S2
H4 SPEAKER RIGHT TRAVEL ALARM (NA)
2 SWITCH 8
B2 UPPER PILOT PRESSURE S3 OPTION 1 SOLENOID VALVE
H5 SPEAKER LEFT
6 SENSOR 1 SWITCH
B2 TRAVEL PILOT PRESSURE S3 OPTION 1 SOLENOID VALVE
H8 CCD CAMERA
7 SENSOR 2 SWITCH
B2 SECOND OPTION PILOT CIR- S3 OPTION 2 SOLENOID VALVE
H9 ALARM 24V,107dB
8 CUIT 1 PRESSURE SWITCH 3 SWITCH
B4 PUMP PRESSURE SENSOR H1 S3 OPTION 2 SOLENOID VALVE
CAMERA1(REAR)
0 (NEGA-CONT. P2) 0 4 SWITCH
HYDRAULIC FUNCTION
B4 PUMP PRESSURE SENSOR H1 S5
CAMERA2(RIGHT SIDE) CANCELLATION LEVER
2 (P1) 1 1
SWITCH
B4 PUMP PRESSURE SENSOR S5 AIR CONDITIONING COM-
K2 RELAY-GLOW PLUG
3 (NEGA-CONT. P1) 2 PRESSOR CLUTCH SWITCH
B4 PUMP PRESSURE SENSOR S5
K3 RELAY-HORN DOOR LIMIT SWITCH
4 (P2) (BLUE BAND) 3
B4 OVERLOAD INDICATOR S5 FRONT WINDOW LIMIT
K5 RELAY-ROTARY LIGHT
5 PRESSURE SWITCH 4 SWITCH
B4 DOZER BLADE PRESSURE RELAY-AIR CONDITIONER S5 RESERVE TANK LOW
K6
6 SENSOR CONDENSER FAN 5 SWITCH
B4 S6
BOOST PRESSURE SENSOR K7 RELAY BATTERY REFUEL PUMP SWITCH
7 1
RELAY-WORKING LIGHT
B4 AMBIENT AIR (BAROMET- K1 S6
(UPPERSTRUCTURE / AT- AIR CLEANER SENSOR
8 RIC) PRESSURE SENSOR 0 2
TACHMENT)
B4 CRANKSHAFT POSITION RELAY-WORKING LIGHT S6
K11 RADIO MUTE SWITCH
9 SENSOR (CAB) 9
B5 BOOST TEMPERATURE K1 S7
BLOWER OFF RELAY HORN VOLUME SWITCH
1 SENSOR 7 0
PRESSURE SWITCH FILTER
B5 COMMON RAIL PRESSURE K3 S7
REFUEL PUMP RELAY INDICATOR (BREAKER OP-
2 SENSOR 0 1
TION)
B6 K3 S8
SUNLOAD SENSOR REFUEL PUMP STOP RELAY BEACON (EU)
1 1 5
B8 PRESS. SENSOR (PILOT K3 S9
RELAY STARTER CUT OVER HEAT SW
3 ARM CLOSE) 4 1
84592788 EN - March 2012
4020C-3
Copyright ©
Sequence Circuit Diagram

B8 PRESS. SENSOR (PILOT K3 DC-DC (24V-12V) CON-

RELAY ROOM LAMP U1
4 BUCKET CLOSE) 5 VERTER
B8 PRESS. SENSOR (PILOT K3 ROTARY LIGHT CONNEC-
RELAY SPEAKER LEFT X2
5 BOOM UP) 6 TOR
B8 K3 OPTIONAL POWER CON-
EGR INTAKE TEMP. SENSOR RELAY SPEAKER RIGHT X3
6 7 NECTOR
B8 K6 ENGINE TEST POINT CON-
CAM ANG(MRE) SENSOR RELAY ECM X4
7 3 NECTOR
B8 K6 CONTROLLER TEST POINT
FUEL FILTER SENSOR RELAY KEY ON X5
8 4 CONNECTOR
B8 K6 CAB SEAT COMPRESSOR
EXSHAUST PRESS. SENSOR RELAY BATTERY RL X6
9 5 MOTOR CONNECTOR
B9 EXSHAUST TEMP. SEN- K6 ANTI-THEFT SYSTEM CON-
RELAY IDLE STOP X9
0 SOR(CNT) 6 NECTOR
B9 EXSHAUST TEMP. SEN- K6 X1
RELAY DPF ACCESSORY SOCKET
1 SOR(FNT) 7 5
B9 K6 X2
HORN LOW (LEFT) RELAY NEUTRAL START CLEAR MEMORY 1
2 8 3
B9 K6 X2
HORN HIGH (RIGHT) RELAY STARTER CLEAR MEMORY 2
3 9 4
B9 PRESS. SWITCH (1ST OP- K3 X2
RELAY SPEAKER LEFT TO CONTROLLER C
4 TION) 6 5
B9 AIR INTAKE SENSOR MASS K3 X2
RELAY SPEAKER RIGHT EST CONECTOR B
5 & TEMP 7 6
B9 K6 X2
TURBO VACUUM SENSOR RELAY ECM TO GPS UNIT
6 3 7
B9 PRESS. SENSOR(HYD. FIL- K6 X3
RELAY KEY ON CAN
7 TER) 4 1
WORKING LIGHT (UPPER- K6 X3
E1 RELAY BATTERY RL FOR CRANE
STRUCTURE) 5 3
WORKING LIGHT (ATTACH- K6 X3
E2 RELAY IDLE STOP FOR FAN REVERSE
MENT) 6 4
K6 X3
12V OUTPUT(FOR RADIO
E3 WORKING LIGHT (CAB) RELAY DPF
7 6
EU)
K6 PILOT PRESSURE SOLE-
E4 CAB LIGHT RELAY NEUTRAL START Y2
8 NOID VALVE (BLUE BAND)
E5 K6 2 STAGE TRAVEL SOLENOID
CIGAR LIGHTER RELAY STARTER Y4
1 9 VALVE (RED BAND)
E5 POWER-UP SOLENOID
AIR CONDITIONER M1 STARTER MOTOR Y5
2 VALVE (YELLOW BAND)
E6 MAIN PUMP POWER PRO-
BEACON(FOR CRANE) M3 WIPER MOTOR Y7
9 PORTIONAL SOLENOID
AIR CONDITIONER MAGNET
F1 FUSE 15A ; KEY SWITCH M4 WASHER MOTOR Y8
CLUTCH
FUSE 20A ; ENGINE CON- OPTION 2 SPEED SOLENOID
F2 M5 MOTOR (AIR CHANGING) Y9
TROLLER VALVE (BLUE TAPE)
FUSE 10A ; GPS CON- AIR VENT DIRECTION CON- MAIN PUMP FLOW PROPOR-
F3 M6 Y11
TROLLER TROL MOTOR TIONAL SOLENOID
MOTOR ACTUATOR (AIR Y1 FREE SWING SOLENOID
F4 FUSE 10A ; BACK UP M7
MIX) 8 VALVE (NA)
FUSE 10A ; LEVER LOCK Y2 OPT.1 KNOB (R) -R SOLE-
F5 M8 BLOWER MOTOR
(GATE) 3 NOID VALVE (BLUE TAPE)
M1 Y2 OPT.1 KNOB (R) -L SOLE-
F6 FUSE 10A ; SOLENOID FUEL FEED PUMP MOTOR
4 4 NOID VALVE (RED TAPE)
M2 Y2 OPT.2 KNOB (L) -R SOLE-
F7 FUSE 10A ; HORN ELECTRIC FUEL PUMP
0 5 NOID VALVE (BLUE TAPE)
M2 INTAKE THROTTLE DC-MO- Y2 OPT.2 KNOB (L) -L SOLENOID
F8 FUSE 15A ; LAMP (CAB)
4 TOR 6 VALVE (RED TAPE)
FUSE 15A ; LAMP (BOOM, M2 EXHAUST GAS RECIRCULA- Y2 OPTION SELECT SOLENOID
F9
HOUSE) 5 TION VALVE 7 VALVE (RED TAPE)
F1 Y3 SUCTION CONTROL VALVE
FUSE 15A ; SPARE P1 INSTRUMENT PANEL
0 5 (SCV)
84592788 EN - March 2012
4020C-4
Copyright ©
Sequence Circuit Diagram

SWITCH PANEL(LEFT- Y6 OPTION PRESS. PROPOR-

F11 FUSE 15A ; WIPER/WASHER P2
HAND) 2 TIONAL SOLENOID VALVE
F1 FUSE 10A ; TRAVEL ARALM ; SWITCH PANEL (RIGHT- Y6
P3 INJ1 (#1)
2 BEACON HAND) 3
F1 FUSE 10A ; CIGAR LIGHTER ; Y6
P4 MONITOR DISPLAY INJ3 (#4)
3 SEAT SUS 4
F1 FUSE 10A ; DC/DC CONVER- AIR CONDITIONER SWITCH Y6
P6 INJ2 (#3)
4 TOR PANEL 5
F1 FUSE 5A ; AIR CONDITIONER P1 Y6
SWITCH PANEL INJ4 (#2)
5 HEATER UNIT 0 6
F1 FUSE 15A ; AIR CONDI- P1 Y8 SWING BRAKE SOLENOID
RADIO SET (NA)
6 TIONER BLOWER 5 2 VALVE (PINK TAPE)
F1 FUSE 5A; AIR CONDITIONER Y8
R1 GLOW PLUG EVRV TURBO VALVE
7 COMPRESSOR 3

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4020C-5
Copyright ©
Sequence Circuit Diagram

Overall

4020C-12
Copyright ©
Sequence Circuit Diagram

Lever Lock

Horn

Working lights

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4020C-13
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Sequence Circuit Diagram

Option

84592788 EN - March 2012

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Sequence Circuit Diagram

Other

84592788 EN - March 2012

4020C-15
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Sequence Circuit Diagram

Electrical Symbol List

Symbol Name Symbol Name

Fuse Variable solenoid valve

Diode Resistor

LED Variable resistor

Toggle switch "a" contact Variable resistor

Push switch "a" contact Alarm

Limit switch "a" contact Buzzer

Limit switch "b" contact Horn

Relay coil Motor

Relay contact "a" contact Solar radiation sensor

84592788 EN - March 2012

4020C-16
Copyright ©
Sequence Circuit Diagram

Symbol Name Symbol Name

Relay contact "b" contact Speaker

Solenoid valve Lamp

84592788 EN - March 2012

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Sequence Circuit Diagram

84592788 EN - March 2012

4020C-18
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Section

4021

Engine-side DTC List

84592788 EN - March 2012

CONTENTS

Engine-side DTC List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

4021-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

4021-2 PRINTED IN FRANCE
Copyright ©
Engine-side DTC List

Engine-side DTC List

P code
P0016 Crankshaft Position - Camshaft Position Correlation
P0045 Turbocharger Boost Control Solenoid Circuit
P0087 Fuel Rail/System Pressure - Too Low
P0088 Fuel Rail/System Pressure - Too High
P0089 Fuel Pressure Regulator Performance
P0091 Fuel Pressure Regulator Control Circuit Low
P0092 Fuel Pressure Regulator Control Circuit High
P0093 Fuel System Leak Detected
P0102 Mass Air Flow Circuit Low Input
P0103 Mass Air Flow Circuit High Input
P0112 Intake Air Temperature Sensor Circuit Low
P0113 Intake Air Temperature Sensor Circuit High
P0117 Engine Coolant Temperature Sensor Circuit Low
P0118 Engine Coolant Temperature Sensor Circuit High
P0122 Throttle Position Sensor Circuit Low
P0123 Throttle Position Sensor Circuit High
P0182 Fuel Temperature Sensor Circuit Low
P0183 Fuel Temperature Sensor Circuit High
P0192 Fuel Rail Pressure Sensor Circuit Low
P0193 Fuel Rail Pressure Sensor Circuit High
P0201 Injector Circuit - Cylinder 1
P0202 Injector Circuit - Cylinder 2
P0203 Injector Circuit - Cylinder 3
P0204 Injector Circuit - Cylinder 4
P0217 Engine Coolant Over Temperature Condition
P0219 Engine Overspeed Condition
P0234 Turbocharger Overboost Condition
P0237 Turbo Charger Boost Sensor Circuit Low
P0238 Turbo Charger Boost Sensor Circuit High
P0299 Turbocharger Underboost
P0335 Crankshaft Position Sensor Circuit
P0336 Crankshaft Position Sensor Circuit Range/Performance
P0340 Camshaft Position Sensor Circuit
P0404 Exhaust Gas Recirculation 1 Control Circuit Range/Performance
P0409 Exhaust Gas Recirculation 1 Sensor Circuit
P041C Intake Manifold Temperature Sensor Circuit High
P041D Intake Manifold Temperature Sensor Circuit Low
P0426 Catalyst Temperature Sensor Circuit Range/Performance Sensor 1
P0427 Catalyst Temperature Sensor Circuit Low Sensor 1
P0428 Catalyst Temperature Sensor Circuit High Sensor 1
P042B Catalyst Temperature Sensor Circuit Range/Performance Sensor 2
P042C Catalyst Temperature Sensor Circuit Low Sensor 2
P042D Catalyst Temperature Sensor Circuit High Sensor 2
P0522 Oil Pressure Sensor Circuit Low
P0523 Oil Pressure Sensor Circuit High
P0560 System Voltage
P0563 System Voltage High
P0601 Internal Control Module Memory Check Sum Error
P0602 Control Module Programming Error
P0604 Internal Control Module Random Access Memory (RAM)Error
P0606 ECM/PCM Processor
P060B Internal Control Module A/D Processing Performance
P0638 Throttle Actuator Control Range/Performance
P0641 Sensor Reference Voltage 1 Circuit
P0650 Malfunction Indicator Lamp (MIL) Control Circuit
84592788 EN - March 2012
4021-3
Copyright ©
Engine-side DTC List

P code
P0651 Sensor Reference Voltage 2 Circuit
P0685 ECM/PCM Power Relay Control Circuit /Open
P0687 ECM/PCM Power Relay Control Circuit High
P0697 Sensor Reference Voltage 3 Circuit
P1093 Fuel Rail Pressure (FRP)Too Low
P1112 Boost Temperature Sensor Circuit Low
P1113 Boost Temperature Sensor Circuit High
P1261 Injector Positive Voltage Control Circuit Group 1
P1262 Injector Positive Voltage Control Circuit Group 2
P1293 Fuel Filter Pressure Sensor Circuit Low
P1294 Fuel Filter Pressure Sensor Circuit High
P1404 Exhaust Gas Recirculation 1 Closed Position Performance
P1455 PM Over Accumulation
P1471 DPD Insufficient Regeneration
P1621 Control Module Long Term Memory Performance
P1655 Sensor Reference Voltage 4 Circuit
P1669 DPD Lamp Control Circuit
P2122 Pedal Position Sensor 1 Circuit Low Input
P2123 Pedal Position Sensor 1 Circuit High Input
P2127 Pedal Position Sensor 2 Circuit Low Input
P2128 Pedal Position Sensor 2 Circuit High Input
P2138 Pedal Position Sensor 1 -2 Voltage Correlation
P2146 Fuel Injector Group 1 Supply Voltage Circuit
P2149 Fuel Injector Group 2 Supply Voltage Circuit
P2228 Barometric Pressure Circuit Low
P2229 Barometric Pressure Circuit High
P242F DPD Restriction
P2452 DPD Differential Pressure Sensor Circuit
P2453 DPD Differential Pressure Sensor Circuit Range/Performance
P2454 DPD Differential Pressure Sensor Circuit Low
P2455 DPD Differential Pressure Sensor Circuit High
P2456 DPD Differential Pressure Sensor Learned Position
P2458 DPD Regeneration Duration
P2527 Vacuum Pressure Sensor Circuit Low
P2528 Vacuum Pressure Sensor Circuit High
U0001 CAN-Bus Malfunction (ISO-CAN)
U0073 CAN-Bus Malfunction (J1939)
U0101 Lost Communication with TCM

84592788 EN - March 2012

4021-4
Copyright ©

Section

4022

Main Unit-side DTC List

84592788 EN - March 2012

CONTENTS

Main Unit-side DTC List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

4022-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

4022-2 PRINTED IN FRANCE
Copyright ©
Main Unit-side DTC List

Main Unit-side DTC List

DTC Trouble mode

7000 P1 Pressure Sensor Signal Abnormality
7001 P2 Pressure Sensor Signal Abnormality
7002 N1 Pressure Sensor Signal Abnormality
7003 N2 Pressure Sensor Signal Abnormality
7004 Overload Pressure Sensor Signal Abnormality
7005 Bottom Pressure Sensor Signal Abnormality
7006 Rod Pressure Sensor Signal Abnormality
7020 Upper Pressure Sensor Signal Abnormality
7021 Swing Pressure Sensor Signal Abnormality
7022 Travel Pressure Sensor Signal Abnormality
7023 Arm-in Pressure Sensor Signal Abnormality
7040 Fuel Level Sensor Signal Abnormality
7041 Oil Temperature Sensor Signal Abnormality
7045 Monitor Thermistor Signal Abnormality
7060 Boom Angle Sensor Signal Abnormality
7061 Arm Angle Sensor Signal Abnormality
7063 Return Filter Clogging Pressure Switch Signal Abnormality
7065 Boom-up Pilot Pressure Sensor Signal Abnormality
7067 Bucket-close Pilot Pressure Sensor Signal Abnormality
7200 Swing Brake Solenoid Signal Abnormality
7201 Travel High-speed Solenoid Signal Abnormality
7202 Pressure Boost Solenoid Signal Abnormality
7203 Travel Alarm Buzzer Signal Abnormality
7204 Power Save Solenoid Signal Abnormality
7205 Feed Pump Relay Signal Abnormality
7206 Option Line Switchover Solenoid Signal Abnormality
7207 Free Swing Solenoid Signal Abnormality
7210 Liftcrane Buzzer Signal Abnormality
7211 Rotating Light Relay and Bucket Lock Signal Abnormality
7240 Pump Horsepower Proportional Valve Signal Abnormality
7241 P1 Flow Control Proportional Valve Signal Abnormality
7242 Fan Proportional Valve Signal Abnormality
7246 2 Pumps Flow Solenoid Signal Abnormality
7247 Boom-down Proportional Valve Signal Abnormality
7248 Arm-in Proportional Valve Signal Abnormality
7250 Option Relief Pressure Proportional Valve Signal Abnormality
7251 Battery Control Relay Signal Abnormality
7252 Idle Stop Relay Signal Abnormality
7253 DPD Regeneration Request Output Signal Abnormality
7400 Abnormally High Coolant Temperature [ 105 °C ( 221.0 °F )or higher ]
7401 Abnormally High Coolant Temperature [ 110 °C ( 230.0 °F )or higher ]
7402 Abnormally High Coolant Temperature [ 120 °C ( 248.0 °F )or higher ]
7404 Abnormally High Oil Temperature [ 95 °C ( 203.0 °F )or higher ]
7405 Boost temperature is abnormally high [ 80 °C ( 176.0 °F )or more ]
7406 Boost temperature is abnormally high [ 90 °C ( 194.0 °F )or more ]
7420 Abnormally Low Alternator Voltage
7421 Coolant Level Reduction
7422 Abnormally Low Engine Oil Pressure
7423 Air Cleaner Clogging
7424 Return Filter Clogging (breaker specifications)
7425 Fuel Density Error Signal Abnormality
7600 CAN Bus Abnormality
7601 Monitor Communication Abnormality
7602 ECM Communication Abnormality
7603 Computer B Communication Abnormality
84592788 EN - March 2012
4022-3
Copyright ©
Main Unit-side DTC List

DTC Trouble mode

7605 ECM Mismatch
7606 EEPROM Data Abnormality
7607 Computer C Communication Abnormality

84592788 EN - March 2012

4022-4
Copyright ©

Section

4023B-6
Copyright ©
Introduction to the trouble diagnosis

General diagnostic operations of the compo- • Turn the starter switch ON, but the engine
nents monitor off.
To run the engine normally, a general diagno- • Connect the diagnostic switch.
sis of the components is required. For an actual unit with no diagnostic switch,
Input components short the DLC No. 1 and No. 4 or No. 5.
Inspect the input components to see whether • Read the blinking count of the monitor.
an open in the circuit or outside range value • The DTC determines the failure contents
exists. from the diagnostic trouble code list.
Crankshaft position sensor
If the trouble diagnostic scan tool is con-
Camshaft position sensor
nected, the diagnostic codes can be read by
Water temperature sensor
operating the trouble diagnostic scan tool.
Boost sensor
Fuel pressure sensor ANNOTATION:
Accelerator position sensor
Output components • As for the installation position of the monitor,
The output components are inspected to diag- refer to the manual of the actual unit.
nose whether responses to commands from Display code when no DTC is recorded
the control unit are appropriate. Code 1 (indicating the start of code display)
Inspect whether the circuits have disconnec- continues to be displayed.
tions and whether their values are within the Display when a DTC is recorded
range. The recorded trouble codes are displayed 3
Suction control valve times.
Light, Relay control If more than 2 or more trouble codes have
Magnetic valve been recorded, the DTCs will be output in as-
Monitor cending order with each DTC being displayed
6) DTC reading procedure three times.
Reading DTC with monitor After displaying all codes, the codes will be
Current and past DTCs recorded in the ECM displayed again starting with the smallest
can be displayed by connecting the diagnostic code number.
switch and blinking the monitor. This display continues while the diagnosis
• Switch the starter switch ON and check that connector is connected.
the monitor shows an abnormality display.

84592788 EN - March 2012

4023B-7
Copyright ©
Introduction to the trouble diagnosis

a At code "23"
b At code "413"

1 ON 3 Tens digit *5 Hundreds digit

*2 Goes off *4 Units digit

t1 Approx. 0.3 sec t3 Approx. 1.2 sec

t2 Approx. 0.6 sec t4 Approx. 2.4 sec

DTC indicated by monitor blinking display Verify the symptoms and conditions reported
The current and past DTCs are both displayed by the customer.
while the engine is being stopped. Use a check sheet or other method to check
While the engine is in operation, the light is the circuit or electronic system components.
turned on only when a current DTC exists. When no trouble is detected
Using the trouble display monitor to read the This status indicates that the actual unit is de-
DTC termined as operating properly.
When a DTC occurs, the DTC can be dis- The condition reported by the customer may
played on the trouble display monitor of the be normal.
actual unit. Check the customer complaint by comparing
Using the scan tool to read the DTC to other actual unit that is operating properly.
The DTC can be read using the trouble diag- However, depending on the condition, it may
nosis scan tool. be an intermittent.
Before returning the actual unit, check the
ANNOTATION: complaint under the conditions given by the
• For the work procedure, refer to the manual customer.
of the trouble diagnosis scan tool. Investigate the complaint again.
If the complaint cannot be adequately de-
When the DTC is recorded tected or confirmed , it is necessary to perform
Perform repairs accurately according to the the diagnosis again to verify the complaint.
specified DTC chart. As stated above in "Intermittent", the com-
If no DTC is available plaint may be an intermittent or normal con-
Select the symptom from "Diagnosis By dition.
Symptom". Repair and confirm.
Complete the repair according to the diagnos- Perform the repair when the cause has been
tic procedure. confirmed.
It is also possible to perform the inspection by Confirm that the operation is performed
referring to the functional diagnosis. properly, and that the symptom has been
When the appropriate symptom is not found; corrected.
Investigate the complaint in detail. This includes the confirmation test performed
Create a diagnosis plan. on the actual unit or other methods to confirm
Utilize the schematics and operation princi- that the complaint has been resolved.
ples. Confirm by testing under the conditions given
When repair history for similar cases are avail- by the customer.
able, request technical assistance. When a DTC is diagnosed, confirm that the
Combine technical knowledge and effective failure has been repaired by reproducing the
utilization of available service information. condition that appeared when the DTC was
Intermittent set while checking the scan tool data.
A failure condition that does not necessarily
always appear is referred to as intermittent.
Check the DTC information and the data dis-
play.

4023D

Engine Control System

84592788 EN - March 2012

CONTENTS

Removal and Installation of Suction Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Removal of Suction Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Suction Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal and Installation of Fuel filter pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel filter pressure sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel filter pressure sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal and Installation of Engine coolant temperature sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine coolant temperature sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine coolant temperature sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal and Installation of CKP sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CKP sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CKP sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal and Installation of CMP sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CMP sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CMP sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal and Installation of Oil pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Oil pressure sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Oil pressure sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal and Installation of Boost sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Boost sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Boost sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal and Installation of IMT sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
IMT sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
IMT sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal and Installation of Exhaust differential pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Exhaust differential pressure sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Exhaust differential pressure sensor Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Removal and Installation of Exhaust gas temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DPD temperature sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DPD temperature sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

4023D-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

4023D-2 PRINTED IN FRANCE
Copyright ©
Engine Control System

Removal and Installation of 1) Disconnect the harness connector from the

suction control valve.
Suction Control Valve
Removal of Suction Control Valve
1. Suction control valve safety information

CAUTION
• Add cleaning agent to the steam cleaner
and thoroughly clean the sensor and
supply pump areas.
• Completely remove moisture with an air
blower.
• Start work after checking that all foreign
material has been removed.
• After starting the engine, check to be
sure that there is no fuel leaking. 1 Harness connector
• After replacing any valve, use the scan
tool to verify that the trouble code has 2) Remove the suction control valve from the fuel
been cleared and that operation is nor- supply pump.
mal. 3) Remove the O-ring from the fuel supply pump.

2. Injector safety information

CAUTION
• Including the inside of the injector, the
holes and gaps that are to be used as
the fuel paths for the fuel system have an
extremely precise finish.
• Because there is the possibility of dam-
age due to foreign material contamina-
tion, cover the cap after removing parts,
etc., to prevent the intrusion of foreign
material.

3. Battery ground cable Disconnect

1 O-ring
1) Disconnect the battery ground cable from the
battery.
CAUTION
4. Suction control valve Removal
• Do not reuse removed O-rings.

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Engine Control System

Installation of Suction Control Valve Removal and Installation of Fuel

1. Suction control valve Installation filter pressure
1) Install the O-ring to the fuel supply pump.
Fuel filter pressure sensor Removal
ANNOTATION:
1. Fuel filter pressure sensor Removal
• Remove any foreign material on the groove
to prevent it from entering inside the pump. 1) Disconnect the harness connector from the
fuel filter pressure sensor.
2) Remove the fuel filter pressure sensor from
the fuel filter.

1 O-ring

2) Temporarily tighten the suction control valve 1 Fuel filter pressure sensor
to the fuel supply pump.

CAUTION
• When installing, take care so the
O-ring is not pinched.

ANNOTATION:
• Temporarily tighten by hand until the suction
control valve firmly adheres to the supply
pump.
3) Securely tighten the suction control valve to
the fuel supply pump.
Tightening torque: 9 N・m {0.9 kgf・m / 6.64
lbf・ft}
4) Connect the harness connector to the suction
control valve.

1 Harness connector

2. Battery ground cable Connect

1) Connect the battery ground cable to the bat-
tery.
84592788 EN - March 2012
4023D-4
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Engine Control System

Fuel filter pressure sensor Installation Removal and Installation of Engine

1. Fuel filter pressure sensor Installation coolant temperature sensor
1) Install the fuel filter pressure sensor to the fuel
filter. Engine coolant temperature sensor
Removal
CAUTION
1. Battery ground cable Disconnect
• After cleaning the threaded portion
of the fuel filter body, install it. 1) Disconnect the battery ground cable from the
battery.
Tightening torque: 24 N・m {2.4 kgf・m / 18 2. Coolant Drain
lb・ft}
2) Connect the harness connector to the fuel fil- 1) Drain coolant from the radiator.
ter pressure sensor.
CAUTION
• Do not loosen or remove the radia-
tor cap when the coolant is hot.
• Steam and boiling water can burst
out, possibly causing burns or heat
related injuries.
• When opening the radiator cap,
place a thick cloth over the cap
when the coolant is cooled, and
turn it gradually to release the pres-
sure before opening it.

ANNOTATION:
• Loosen the water drain plug on the rear right
side of the engine, as well as the radiator
1 Fuel filter pressure sensor
drain plug.
• Completely drain the coolant.
3) Start the engine. • After completely draining the coolant, se-
ANNOTATION: curely tighten the drain plug.

• Check that there is no fuel leaks. 3. Engine coolant temperature sensor removal
• Confirm that DTC has not yet been de- 1) Disconnect the harness connector from the
tected. engine coolant temperature sensor.
2) Remove the engine coolant temperature sen-
sor from the cylinder head assembly.

Engine coolant temperature

1
sensor

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4023D-5
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Engine Control System

Engine coolant temperature sensor Inspection

Installation 1. Engine coolant temperature sensor inspection
1. Engine coolant temperature sensor installation 1) Inspect the engine coolant temperature sen-
1) Install the engine coolant temperature sensor sor using a circuit tester.
to the cylinder head assembly. ANNOTATION:
ANNOTATION: • Confirm that the resistance value according
to water temperature matches the thermis-
• Apply Loctite 262 to the threaded portion.
tor characteristics.
Tightening torque: 20 N・m {2.0 kgf・m / 15
lb・ft}

GND terminal for engine con-

1
trol
Engine coolant temperature Signal terminal for engine con-
1 2
sensor trol
3 Signal terminal for meters
2. Coolant filling
1) Replenish the radiator assembly with coolant.
3. Battery ground cable Connect
1) Connect the battery ground cable to the bat-
tery.

Resistance
value (KΩ)

Engine coolant temperature (°C)

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4023D-6
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Engine Control System

Removal and Installation of CKP CKP sensor Installation

sensor 1. CKP sensor installation
1) Install the CKP sensor to the cylinder block.
CKP sensor Removal Tightening torque: 5 N・m {0.5 kgf・m / 3.69
1. Battery ground cable Disconnect lbf・ft}

1) Disconnect the battery ground cable from the

battery.
2. CKP sensor removal
1) Disconnect the harness connector from the
CKP sensor.
2) Remove the CKP sensor from the cylinder
block.

CAUTION
• The CKP sensor is sensitive to
shock, so do not throw or drop it.
2) Install the connector to the CKP sensor.

1 Pressure limiter
2 Fuel pressure sensor 1 Pressure limiter
3 CKP sensor 2 Fuel pressure sensor
4 Oil pressure sensor 3 CKP sensor
4 Oil pressure sensor

2. Battery ground cable Connect

1) Connect the battery ground cable to the bat-
tery.

Inspection
1. CKP sensor inspection
1) Inspect the CKP sensor.
ANNOTATION:
• Inspect whether the CKP sensor is securely
installed.
• Inspect the sensor and connector sections
for damage or debris.

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4023D-7
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Engine Control System

Removal and Installation of CMP CMP sensor Installation

sensor 1. CMP sensor installation
1) Install the CMP sensor to the timing chain up-
CMP sensor Removal per cover.
1. Battery ground cable Disconnect Tightening torque: 5 N・m {0.5 kgf・m / 3.69
lbf・ft}
1) Disconnect the battery ground cable from the
battery.
2. CMP sensor removal
1) Remove the CMP sensor from the timing
chain upper cover.

1 CMP sensor
2 O-ring
3 Bolt

2. Battery ground cable Connect

1 CMP sensor 1) Connect the battery ground cable to the bat-
2 O-ring tery.
3 Bolt
Inspection
1. CMP sensor inspection
1) Inspect the CMP sensor.
ANNOTATION:
• Inspect whether the CMP sensor is securely
installed.
• Inspect the sensor and connector sections
for damage or debris.

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4023D-8
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Engine Control System

Removal and Installation of Oil Oil pressure sensor Installation

Removal and Installation of 2. Exhaust differential pressure sensor Removal

Exhaust differential pressure CAUTION
sensor • Before performing work, be sure to
check the DPD differential pressure sen-
Exhaust differential pressure sensor sor precautions.
Removal
1) Disengage the differential pressure hose from
1. Exhaust differential pressure sensor Safety Infor- the exhaust differential pressure sensor.
mation 2) Disengage the harness connector from the
exhaust differential pressure sensor.
CAUTION 3) Remove the exhaust differential pressure sen-
sor from the DPD assembly.
• Do not use a tool which causes vibra-
tions such as an impact wrench when in- CAUTION
stalling and removing the DPD differen-
tial pressure sensor. • Remove the DPD differential pres-
• Do not reuse a DPD differential pressure sure sensor with the attached
sensor which has been subjected to bracket.
shock such as being dropped.
• Install or remove the DPD differen- ANNOTATION:
tial pressure sensor together with the
bracket. • The installation position of the exhaust dif-
• Be sure not to loosen the 4 screws in- ferential pressure sensor varies depending
stalled on the DPD differential pressure on the machine.
sensor.
• Replace the DPD differential pressure
sensor if the 4 screws installed on the
DPD differential pressure sensor have
been loosened.

1 Front mark
To the differential pressure pipe
2
on the filter rear side
To the differential pressure pipe
3
on the filter front side
4 Bracket
1 Screw 5 Not removable

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4023D-13
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Engine Control System

Exhaust differential pressure sensor 1) Install the exhaust differential pressure sensor
Installation to the DPD assembly.
ANNOTATION:
1. Exhaust differential pressure sensor Safety Infor-
mation • The installation position of the exhaust dif-
ferential pressure sensor varies depending
CAUTION on the machine.
• Do not use a tool which causes vibra- 2) Connect the harness connector to the exhaust
tions such as an impact wrench when in- differential pressure sensor.
stalling and removing the DPD differen- 3) Connect the differential pressure hose to the
tial pressure sensor. exhaust differential pressure sensor.
• Do not reuse a DPD differential pressure
sensor which has been subjected to CAUTION
shock such as being dropped.
• Install or remove the DPD differen- • Be careful not to mistake the con-
tial pressure sensor together with the necting position of the differential
bracket. pressure hose.
• Be sure not to loosen the 4 screws in- • Since the differential pressure sen-
stalled on the DPD differential pressure sor may malfunction if exhaust gas
sensor. leaks from the joint sections, con-
firm that there is no exhaust gas
• Replace the DPD differential pressure
sensor if the 4 screws installed on the leakage after the engine starts.
DPD differential pressure sensor have
been loosened.

1 Front mark
To the differential pressure pipe
2
1 Screw on the filter rear side
To the differential pressure pipe
3
2. Exhaust differential pressure sensor Installation on the filter front side
4 Bracket
CAUTION 5 Not removable
• Before performing work, be sure to
check the DPD differential pressure sen-
sor precautions.

84592788 EN - March 2012

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

4023G-2 PRINTED IN FRANCE
Copyright ©
Engine-side Trouble

Engine-side Trouble
DTC U0001 (Flash Code 84) DTC P0016 (Flash Code 16)
CAN-Bus Malfunction (ISO-CAN) Crankshaft Position - Camshaft
1. DTC U0001 diagnostics Position Correlation
1) Turn OFF the starter switch. 1. DTC P0016Priority DTC
2) Disconnect the harness connector from the DTC P0335
ECM. DTC P0336
3) Measure the resistance between the CAN- DTC P0340
High side terminal and CAN-Low side termi- 2. DTC P0016Diagnostics
nal.
1) Inspect the CKP sensor.
ANNOTATION: Refer to "CKP sensor Inspection".
2) If a problem is found, replace the crankshaft
• Measure the resistance between the termi- position sensor.
nals of the ECM harness connector.
Refer to "CKP sensor Removal".
resistance: about 120.0 Ω Refer to "CKP sensor Installation".
4) If the reading is outside the specified range, 3) Inspect the CMP sensor.
inspect the CAN-Low circuit and CAN-High Refer to "CMP sensor Inspection".
circuit between the ECM and the control unit 4) If a problem is found, replace the camshaft
of the machine. position sensor.
Refer to "CMP sensor Removal".
ANNOTATION: Refer to "CMP sensor Installation".
• No short circuit to the battery or ignition 5) Inspect the flywheel.
power is present. ANNOTATION:
• There should be no open circuit or high re-
sistance. • The sensor rotor should not be damaged.
• No short circuit to GND is present. • The ring gear should be installed correctly.
5) If a problem is found, repair the CAN circuit. 6) If a problem is found, repair the flywheel.
6) If the CAN circuit is normal, replace the control 7) Inspect the camshaft gear.
unit of the machine.
ANNOTATION:
7) Connect the harness connector to the ECM.
8) Disconnect the harness connector from the • The camshaft gear should not be damaged.
control unit of the machine. • The camshaft gear should be installed cor-
9) Measure the resistance between the CAN- rectly.
High side terminal and CAN-Low side termi-
nal. 8) If a problem is found, repair the camshaft gear.

ANNOTATION: 3. DTC P0016 Confirm Resolution

1) Clear the DTC using the trouble diagnosis
• Measure the resistance between the termi-
nals of the ECM harness connector. scan tool.
2) Turn OFF the starter switch for 30 seconds or
resistance: about 120.0 Ω longer.
10) If the reading is outside the specified range, 3) Start the engine.
replace the ECM.
11) Set the injector ID code on the ECM. ANNOTATION:
12) Perform the unit difference learning of the fuel • When the engine does not start, crank the
supply pump to the ECM. engine for 10 seconds.
2. DTC U0001 confirm resolution 4) Perform a test-run.
1) Clear the DTC using the trouble diagnosis 5) Use the trouble diagnosis scan tool to confirm
scan tool. that a DTC has not been detected.
2) Turn OFF the starter switch for 30 seconds or
longer.
3) Start the engine.
4) Perform a test-run.
5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.

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Engine-side Trouble

DTC P0045 (Flash Code 33) 15) Start the engine while checking the test light.
16) Stop the engine while checking the test light.
Turbocharger Boost Control 17) Confirm that the test light comes on when the
Solenoid Circuit engine is started, and the test light turns off
when the engine is stopped.
1. DTC P0045 Diagnostics 18) If the test light comes on when the engine
is started and turns off when the engine is
1) Turn OFF the starter switch for 30 seconds or stopped, inspect the harness connector of the
longer. turbocharger control solenoid valve for poor
2) Start the engine. connections.
3) Use a trouble diagnosis scan tool to check if 19) If a problem is found, repair the harness con-
DTC P2527 has been detected. nector.
4) If DTC P2527 has been detected, inspect to 20) If the harness connector is normal, replace the
see if there is a short circuit to the GND with turbocharger control solenoid valve.
the control circuit between the ECM and tur- 21) Inspect the control circuit between the ECM
bocharger control solenoid valve. and turbocharger control solenoid valve.
ANNOTATION: ANNOTATION:
• If the turbocharger control solenoid control • There should be no open circuit or high re-
circuit has been shorted to GND, the tur- sistance.
bocharger control solenoid valve completely • There should be no short to the battery
opens, the vacuum pressure becomes power supply or ignition power supply cir-
higher, and DTC P2527 is detected. cuit.
5) If a problem is found, repair the solenoid con- 22) If a problem is found, repair the control circuit.
trol circuit. 23) If the circuit is normal, inspect the ECM har-
6) Turn OFF the starter switch. ness connector for poor connections.
7) Disconnect the harness connector from the 24) If a problem is found, repair the harness con-
turbocharger control solenoid valve. nector.
8) Connect the test light between the ignition 25) If the harness connector is normal, replace the
power supply circuit of the turbocharger con- ECM.
trol solenoid valve harness connector and nor- 26) Set the injector ID code on the ECM.
mal GND. 27) Perform the learning of the fuel supply pump
9) Turn ON the starter switch. to the ECM.
10) Confirm that the test light comes on.
11) If the test light does not come on, inspect the 2. DTC P0045 Confirm Resolution
ECM main 10 A fuse.
1) Clear the DTC using the trouble diagnosis
12) If a problem is found, replace the fuse.
scan tool.
13) Repair an open circuit or high resistance in
2) Turn OFF the starter switch for 30 seconds or
the ignition power supply circuit between the
longer.
ECM main 10 A fuse and turbocharger control
3) Start the engine.
solenoid valve.
4) Perform a test-run.
14) Connect the test light to the turbocharger con-
5) Use the trouble diagnosis scan tool to confirm
trol solenoid valve harness connector ignition
that a DTC has not been detected.
power supply circuit and control circuit.

84592788 EN - March 2012

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Engine-side Trouble

4023G-29
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Engine-side Trouble

DTC P0238 (Flash Code 32) Turbo DTC P0336 (Flash Code 15)
Charger Boost Sensor Circuit High Crankshaft Position Sensor Circuit
1. DTC P0238 Priority DTC Range/Performance
DTC P1655
2. DTC P0238 Diagnostics 1. DTC P0336 Priority DTC
DTC P0335
1) Turn OFF the starter switch. DTC P0340
2) Disconnect the harness connector from the DTC P0641
boost sensor. 2. DTC P0336 Diagnostics
3) Check the boost pressure sensor display with
the trouble diagnosis scan tool. 1) Inspect the crankshaft position sensor circuit.
Voltage: 0.1 V ANNOTATION:
4) If the reading is more than or equal to the
specified value, inspect the signal circuit be- • It should not be too close to the wiring or
components of the fuel injection device.
tween the ECM and the boost sensor.
• It should not be too close to any electronic
ANNOTATION: device additionally installed.
• It should not be too close to the solenoid and
• No short circuit to the battery or ignition relay.
power is present.
• There should be no short to the 5 V power 2) If a problem is found, repair the crankshaft
supply. position sensor circuit.
3) Turn OFF the starter switch.
5) If a problem is found, repair the signal circuit. 4) Disconnect the harness connector from the
6) Inspect to see if there is an open circuit or ECM.
high resistance in the GND circuit between the 5) Inspect the ECM harness connector for poor
ECM and the boost sensor. connections.
ANNOTATION: 6) If a problem is found, repair the harness con-
nector.
• The boost sensor shares the GND circuit 7) Disconnect the harness connector from the
with other sensors. crankshaft position sensor.
• The DTC set on a sensor which shares this 8) Inspect the crankshaft position sensor har-
circuit may be detected. ness connector for poor connections.
7) If a problem is found, repair the GND circuit. 9) If a problem is found, repair the harness con-
8) Inspect the boost sensor harness connector nector.
for poor connections. 10) Inspect the CKP sensor.
9) If a problem is found, repair the harness con- Refer to "CKP sensor inspection".
nector. 11) If a problem is found, replace the crankshaft
10) If the harness connector is normal, replace the position sensor.
boost sensor. Refer to "CKP sensor Removal".
Refer to "Boost sensor Removal". Refer to "CKP sensor Installation".
Refer to "Boost sensor Installation". 3. DTC P0336 Confirm Resolution
11) Inspect the ECM harness connector for poor
connections. 1) Clear the DTC using the trouble diagnosis
12) If a problem is found, repair the harness con- scan tool.
nector. 2) Turn OFF the starter switch for 30 seconds or
13) If the harness connector is normal, replace the longer.
ECM. 3) Start the engine.
14) Set the injector ID code on the ECM. 4) Perform a test-run.
15) Perform the unit difference learning of the fuel 5) Use the trouble diagnosis scan tool to confirm
supply pump to the ECM. that a DTC has not been detected.
3. DTC P0238 Confirm Resolution
1) Clear the DTC using the trouble diagnosis
scan tool.
2) Turn OFF the starter switch for 30 seconds or
longer.
3) Start the engine.
4) Perform a test-run.
5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.

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Engine-side Trouble

DTC P0340 (Flash Code 14) 16) If a problem is found, repair the signal circuit.
17) Measure the voltage between the 5 V power
Camshaft Position Sensor Circuit supply circuit and GND circuit of the camshaft
position sensor harness connector.
1. DTC P0340 Priority DTC
Voltage: 4.5 V
DTC P0601
18) If the reading is more than or equal to the
DTC P0651
specified value, inspect to see if there is poor
2. DTC P0340 Diagnostics
connection with the camshaft position sensor
1) Turn OFF the starter switch. harness connector.
2) Disconnect the harness connector from the 19) If a problem is found, repair the harness con-
camshaft position sensor. nector.
3) Turn ON the starter switch. 20) If the harness connector is normal, inspect the
4) Measure the voltage between the 5 V camshaft position sensor.
power supply circuit and normal GND of the Refer to "CMP sensor Inspection".
camshaft position sensor harness connector. 21) If a problem is found, replace the camshaft
Voltage: 4.5 V position sensor.
5) If the reading is less than or equal to the Refer to "CMP sensor Removal".
specified value, inspect to see if there is an Refer to "CMP sensor Installation".
open circuit or high resistance with the 5 V 22) Inspect the camshaft gear.
power supply circuit between the ECM and the
ANNOTATION:
camshaft position sensor.
6) If a problem is found, repair the 5 V power • The camshaft gear should not be damaged.
supply circuit. • The camshaft gear should be installed cor-
7) Measure the voltage between the signal cir- rectly.
cuit and normal GND of the camshaft position
sensor harness connector. 23) If a problem is found, repair the camshaft gear.
Voltage: 5.5 V 24) Inspect the GND circuit between the ECM and
8) If the reading is more than or equal to the the camshaft position sensor for an open cir-
specified value, inspect to see if there is a cuit and high resistance.
short circuit to the battery or ignition power ANNOTATION:
supply with the signal circuit between the ECM
and the camshaft position sensor. • The camshaft position sensor shares the
9) If a problem is found, repair the signal circuit. GND circuit with other sensors.
10) Measure the voltage between the signal cir- • The DTC set on a sensor which shares this
cuit of the camshaft position sensor harness circuit may be detected.
connector and a normal GND again. 25) If a problem is found, repair the GND circuit.
Voltage: 4.5 V 26) Inspect the ECM harness connector for poor
11) If the reading is less than or equal to the spec- connections.
ified value, inspect the signal circuit between 27) If a problem is found, repair the harness con-
the ECM and the camshaft position sensor. nector.
ANNOTATION: 28) If the harness connector is normal, replace the
ECM.
• There should be no open circuit or high re- 29) Set the injector ID code on the ECM.
sistance. 30) Perform the unit difference learning of the fuel
• No short circuit to GND is present. supply pump to the ECM.
12) If a problem is found, repair the signal circuit. 3. DTC P0340 Confirm Resolution
13) Connect the test light between the signal cir-
cuit and normal GND of the camshaft position 1) Clear the DTC using the trouble diagnosis
sensor harness connector. scan tool.
14) Measure the voltage between the probe of the 2) Turn OFF the starter switch for 30 seconds or
test light and a normal GND. longer.
Voltage: 4.5 V 3) Start the engine.
15) If the reading is more than or equal to the 4) Perform a test-run.
specified value, inspect to see if there is a 5) Use the trouble diagnosis scan tool to confirm
short circuit to the 5 V power supply circuit that a DTC has not been detected.
with the signal circuit between the ECM and
the camshaft position sensor.

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Engine-side Trouble

4023G-39
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Engine-side Trouble

DTC P0604 (Flash Code 153) DTC P0606 (Flash Code 51)
Internal Control Module Random ECM/PCM Processor
Access Memory (RAM) Error 1. DTC P0606 Diagnostics
1. DTC P0604 Diagnostics 1) Replace the ECM.
2) Set the injector ID code on the ECM.
1) Replace the ECM. 3) Perform the unit difference learning of the fuel
2) Set the injector ID code on the ECM. supply pump to the ECM.
3) Perform the unit difference learning of the fuel
supply pump to the ECM. 2. DTC P0606 Confirm Resolution
2. DTC P0604 Confirm Resolution 1) Clear the DTC using the trouble diagnosis
scan tool.
1) Clear the DTC using the trouble diagnosis 2) Turn OFF the starter switch for 30 seconds or
scan tool. longer.
2) Turn OFF the starter switch for 30 seconds or 3) Start the engine.
longer. 4) Perform a test-run.
3) Start the engine. 5) Use the trouble diagnosis scan tool to confirm
4) Perform a test-run. that a DTC has not been detected.
5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.

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4023G-46
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Engine-side Trouble

27) While keeping the engine rotating at the spec- 46) Inspect the ECM harness connector for poor
ified engine RPM for the specified period of connections.
time, check the pressure gauge. 47) If a problem is found, repair the harness con-
Specified time: 1 min nector.
Rotational speed: 2500 r/min 48) Inspect each circuit for high resistance.
28) Check if the pressure gauge shows a negative 49) If a problem is found, repair the circuit.
pressure value at or above the specified value 50) If the suction control valve harness connector
during inspection. and the ECM harness connector are normal
Value: (-17.0) kPa {5 inHg/(-2) psi} and there is no high resistance in each circuit,
replace the fuel supply pump and the fuel filter.
ANNOTATION: Refer to "Removal of Fuel Supply Pump".
• Fuel clogging is checked with the negative Refer to "Installation of Fuel Supply Pump".
pressure amount in the fuel system. ANNOTATION:
29) If the negative pressure is at or above the
• When replacing the fuel supply pump, it is
specified value, inspect to see if there is dam- required to also replace the fuel filter at the
age or twisting with the fuel system between same time.
the fuel supply pump and the fuel tank.
30) If a problem is found, repair the fuel system. 51) Perform the unit difference learning of the fuel
31) Inspect the fuel tank bent hose. supply pump to the ECM.
32) If a problem is found, repair the bent hose. 52) If the negative pressure is normal, turn OFF
33) Check to see if there is any foreign matter in the starter switch.
the fuel tank or any foreign matter which can 53) Restore the fuel system.
cause fuel clogging. 54) Start the engine.
34) If a problem is found, repair it. 55) Perform the injector stop test with the trouble
35) Replace the fuel filter. diagnosis scan tool.
36) If the negative pressure is at or below the 56) Check to see if any injector does not change
specified value, pinch the fuel hose at a po- the engine RPM when OFF is instructed.
sition as close as possible to the fuel tank, so 57) If any injector does not change the engine
that the fuel does not flow. RPM when OFF is instructed, replace the rel-
evant injector.
ANNOTATION: Refer to "Removal of Injector".
• The fuel pipe can be disconnected and Refer to "Installation of Injector".
clogged with a plug. 58) When the injector has been replaced, set the
injector ID code on the ECM.
37) Start the engine and use the idling control 59) If the engine RPM changes when OFF is in-
switch to increase the RPM to the highest structed to all injectors, replace the pressure
level. limiter valve.
38) Check the pressure gauge. Refer to "Removal of Common Rail Assem-
Value: (-27.0) kPa {8 inHg/(-4) psi} bly".
ANNOTATION: Refer to "Installation of Common Rail Assem-
bly".
• When the pressure gauge is likely to indi-
cate a value exceeding the specified value ANNOTATION:
during inspection, release the fuel being • The pressure limiter valve may be fixed
blocked. open, or the operation pressure may de-
• Air mixture is checked with the negative crease.
pressure amount while the fuel flow is being • Do not replace the pressure limiter valve
blocked. When a problem is found, replace the com-
39) If the specified negative pressure cannot be mon rail assembly.
generated, inspect to see if there is a cut or 3. DTC P1093 Confirm Resolution
crack with the fuel hose.
40) If a problem is found, replace the fuel hose. 1) Clear the DTC using the trouble diagnosis
41) Inspect to see if appropriate clamp is used. scan tool.
42) If a problem is found, replace the clamp with 2) Turn OFF the starter switch for 30 seconds or
an appropriate one. longer.
43) Turn OFF the starter switch. 3) Start the engine.
44) Inspect the suction control valve harness con- 4) Perform a test-run.
nector for poor connections. 5) Use the trouble diagnosis scan tool to confirm
45) If a problem is found, repair the harness con- that a DTC has not been detected.
nector.

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Engine-side Trouble

DTC P1112 (Flash Code 295) DTC P1113 (Flash Code 295)
Boost Temperature Sensor Circuit Boost Temperature Sensor Circuit
Low High
1. DTC P1112 Priority DTC 1. DTC P1113 Priority DTC
DTC P0651 DTC P0651
2. DTC P1112 Diagnostics 2. DTC P1113 Diagnostics
1) Turn OFF the starter switch. 1) Turn OFF the starter switch.
2) Remove the harness connector from the 2) Remove the harness connector from the
boost temperature sensor. boost temperature sensor.
3) Check the boost temperature sensor display 3) Turn ON the starter switch.
with the trouble diagnosis scan tool. 4) Measure the voltage between the boost tem-
Voltage: 4.5 V perature sensor signal circuit and a normal
4) If the reading is more than or equal to the GND.
specified value, replace the boost tempera- Voltage: 5.5 V
ture sensor. 5) If the reading is more than or equal to the
Refer to "Boost sensor Removal". specified value, inspect to see if there is a
Refer to "Boost sensor Installation". short circuit to the battery or ignition power
5) Inspect to see if there is a short circuit to the supply with the signal circuit between the ECM
GND with the signal circuit between the ECM and the boost temperature sensor.
and boost temperature sensor. 6) If a problem is found, repair the signal circuit.
6) If a problem is found, repair the signal circuit. 7) Connect the test cable with fuse between the
7) Inspect the ECM harness connector for poor boost temperature sensor signal circuit and
connections. GND circuit.
8) If a problem is found, repair the harness con- 8) Check the boost temperature sensor display
nector. with the trouble diagnosis scan tool.
9) If the harness connector is normal, replace the Voltage: 0.1 V
ECM. 9) If the reading is less than or equal to the spec-
10) Set the injector ID code on the ECM. ified value, inspect to see if there is a short
11) Perform the unit difference learning of the fuel circuit to the 5 V power supply circuit with the
supply pump to the ECM. signal circuit between the ECM and the boost
temperature sensor.
3. DTC P1112 Confirm Resolution 10) If a problem is found, repair the signal circuit.
1) Clear the DTC using the trouble diagnosis 11) Inspect boost temperature sensor harness
scan tool. connector for poor connections.
2) Turn OFF the starter switch for 30 seconds or 12) If a problem is found, repair the harness con-
longer. nector.
3) Start the engine. 13) If the harness connector is normal, replace the
4) Perform a test-run. boost temperature sensor.
5) Use the trouble diagnosis scan tool to confirm Refer to "Boost sensor Removal".
that a DTC has not been detected. Refer to "Boost sensor Installation".
14) Connect the test cable with fuse between the
boost temperature sensor signal circuit and a
normal GND.
15) Check the boost temperature sensor display
with the trouble diagnosis scan tool.
Voltage: 0.1 V
16) If the reading is less than or equal to the spec-
ified value, inspect to see if there is an open
circuit or high resistance with the GND circuit
between the ECM and the boost temperature
sensor.
ANNOTATION:
• The boost temperature sensor shares the
GND circuit with other sensors.
• The DTC set on a sensor which shares this
circuit may be detected.
17) If a problem is found, repair the GND circuit.
18) Inspect to see if there is an open circuit or
high resistance in the signal circuit between
the ECM and the boost temperature sensor.
19) If a problem is found, repair the signal circuit.
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Engine-side Trouble

20) Inspect the ECM harness connector for poor DTC P1261 (Flash Code 34)
connections.
21) If a problem is found, repair the harness con- Injector Positive Voltage Control
22)
nector.
If the harness connector is normal, replace the
Circuit Group 1
ECM. 1. DTC P1261 Diagnostics
23) Set the injector ID code on the ECM.
24) Perform the unit difference learning of the fuel 1) Replace the ECM.
supply pump to the ECM. 2) Set the injector ID code on the ECM.
3) Perform the unit difference learning of the fuel
3. DTC P1113 Confirm Resolution supply pump to the ECM.
1) Clear the DTC using the trouble diagnosis 2. DTC P1261 Confirm Resolution
scan tool.
2) Turn OFF the starter switch for 30 seconds or 1) Clear the DTC using the trouble diagnosis
longer. scan tool.
3) Start the engine. 2) Turn OFF the starter switch for 30 seconds or
4) Perform a test-run. longer.
3) Start the engine.
ANNOTATION: 4) Perform a test-run.
5) Use the trouble diagnosis scan tool to confirm
• Run the engine for 3 minutes or longer.
that a DTC has not been detected.
5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.

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Engine-side Trouble

DTC P1262 (Flash Code 34) DTC P1293 (Flash Code 221) Fuel
Injector Positive Voltage Control Filter Pressure Sensor Circuit Low
Circuit Group 2 1. DTC P1293 priority DTC
DTC P0697
1. DTC P1262 Diagnostics 2. DTC P1293 diagnostics
1) Replace the ECM. 1) Turn OFF the starter switch.
2) Set the injector ID code on the ECM. 2) Disconnect the harness connector from the
3) Perform the unit difference learning of the fuel fuel filter pressure sensor.
supply pump to the ECM. 3) Turn ON the starter switch.
2. DTC P1262 Confirm Resolution 4) Measure the voltage between the 5 V power
supply circuit of the fuel filter pressure sensor
1) Clear the DTC using the trouble diagnosis harness connector and normal GND.
scan tool. Voltage: 4.5 V
2) Turn OFF the starter switch for 30 seconds or 5) If the reading is less than or equal to the spec-
longer. ified value, inspect to see if there is an open
3) Start the engine. circuit or high resistance with the 5 V power
4) Perform a test-run. supply circuit between the ECM and the fuel
5) Use the trouble diagnosis scan tool to confirm filter pressure sensor.
that a DTC has not been detected.
ANNOTATION:
• The fuel filter pressure sensor shares the 5
V power supply circuit with other sensors.
• The DTC set on a sensor which shares this
circuit may be detected.
6) If a problem is found, repair the 5 V power
supply circuit.
7) Connect the test cable with fuse between the
5 V power supply circuit and signal circuit of
the fuel filter pressure sensor harness con-
nector.
8) Check the fuel filter pressure sensor display
with the trouble diagnosis scan tool.
Voltage: 4.5 V
9) If the reading is more than or equal to the
specified value, inspect to see if there is poor
connection with the fuel filter pressure sensor
harness connector.
10) If a problem is found, repair the harness con-
nector.
11) If the harness connector is normal, replace the
fuel filter pressure sensor.
Refer to "Fuel filter pressure sensor Re-
moval".
Refer to "Fuel filter pressure sensor Installa-
tion".
12) Inspect the signal circuit between the ECM
and the fuel filter pressure sensor.
ANNOTATION:
• There should be no open circuit or high re-
sistance.
• No short circuit to GND is present.
13) If a problem is found, repair the signal circuit.
14) Inspect the ECM harness connector for poor
connections.
15) If a problem is found, repair the harness con-
nector.
16) If the harness connector is normal, replace the
ECM.
17) Set the injector ID code on the ECM.
18) Perform the unit difference learning of the fuel
supply pump to the ECM.
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Engine-side Trouble

3. DTC P1293 confirm Resolution DTC P1294 (Flash Code 221) Fuel
1) Clear the DTC using the trouble diagnosis Filter Pressure Sensor Circuit High
scan tool.
2) Turn OFF the starter switch for 30 seconds or 1. DTC P1294 priority DTC
longer. DTC P0697
3) Start the engine. 2. DTC P1294 diagnostics
4) Perform a test-run.
1) Turn OFF the starter switch.
5) Use the trouble diagnosis scan tool to confirm
2) Disconnect the harness connector from the
that a DTC has not been detected.
fuel filter pressure sensor.
3) Check the fuel filter pressure sensor display
with the trouble diagnosis scan tool.
Voltage: 0.1 V
4) If the reading is more than or equal to the
specified value, inspect the signal circuit be-
tween the ECM and the fuel filter pressure
sensor.
ANNOTATION:
• No short circuit to the battery or ignition
power is present.
• There should be no short to the 5 V power
supply.
5) If a problem is found, repair the signal circuit.
6) Inspect to see if there is an open circuit or
high resistance in the GND circuit between the
ECM and the fuel filter pressure sensor.
ANNOTATION:
• The fuel filter pressure sensor shares the
GND circuit with other sensors.
• The DTC set on a sensor which shares this
circuit may be detected.
7) If a problem is found, repair the GND circuit.
8) Inspect to see if there is poor connection with
the fuel filter pressure sensor harness con-
nector.
9) If a problem is found, repair the harness con-
nector.
10) If the harness connector is normal, replace the
fuel filter pressure sensor.
Refer to "Fuel filter pressure sensor Re-
moval".
Refer to "Fuel filter pressure sensor Installa-
tion".
11) Inspect the ECM harness connector for poor
connections.
12) If a problem is found, repair the harness con-
nector.
13) If the harness connector is normal, replace the
ECM.
14) Set the injector ID code on the ECM.
15) Perform the unit difference learning of the fuel
supply pump to the ECM.
3. DTC P1294 confirm Resolution
1) Clear the DTC using the trouble diagnosis
scan tool.
2) Turn OFF the starter switch for 30 seconds or
longer.
3) Start the engine.
4) Perform a test-run.
5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.
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Engine-side Trouble

DTC P1404 (Flash Code 45) 9) Inspect the ECM harness connector for poor
connections.
Exhaust Gas Recirculation 1 10) If a problem is found, repair the harness con-
Closed Position Performance 11)
nector.
Inspect the EGR valve circuit between the
1. DTC P1404 priority DTC ECM and the EGR valve for an open circuit
DTC P0404 and high resistance.
DTC P0409 12) If a problem is found, repair the EGR valve
2. DTC P1404 diagnostics circuit.
13) Inspect the solenoid circuit between the ECM
1) Remove the EGR valve assembly from the and EGR valve.
engine.
Refer to "EGR valve Removal". ANNOTATION:
2) Inspect the EGR valve.
• No short circuit to GND is present.
ANNOTATION: • No short circuit to the battery or ignition
power is present.
• There should be nothing to limit flow inside
the EGR valve. • There should be no short to other circuits.
• There should be no excessive deposit inside • There should be no short to EGR position
the EGR valve. sensor circuit.
• There should be no bending with the valve 14) If a problem is found, repair the solenoid cir-
shaft or valve itself inside the EGR valve. cuit.
3) If a problem is found, repair or replace the 15) If the circuit is normal, replace the EGR valve.
EGR valve. Refer to "EGR valve Removal".
Refer to "EGR valve Removal". Refer to "EGR valve Installation".
Refer to "EGR valve Installation". 3. DTC P1404 confirm Resolution
4) Turn OFF the starter switch.
5) Disconnect the harness connector from the 1) Clear the DTC using the trouble diagnosis
EGR valve. scan tool.
6) Inspect the EGR valve harness connector for 2) Turn OFF the starter switch for 30 seconds or
poor connections. longer.
7) If a problem is found, repair the harness con- 3) Start the engine.
nector. 4) Perform a test-run.
8) Disconnect the harness connector from the 5) Use the trouble diagnosis scan tool to confirm
ECM. that a DTC has not been detected.

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DTC P2454 (Flash Code 47) 11) If the harness connector is normal, replace the
DPD differential pressure sensor.
DPD Differential Pressure Sensor Refer to "Exhaust differential pressure sensor
Circuit Low Removal".
Refer to "Exhaust differential pressure sensor
1. DTC P2454 Priority DTC Installation".
DTC P0697 12) When the DPD differential pressure sensor
2. DTC P2454 Diagnostics has been replaced, perform the 0-point cor-
rection.
1) Turn OFF the starter switch. Refer to "Exhaust differential pressure sensor
2) Disconnect the harness connector from the Inspection".
DPD differential pressure sensor. 13) If the reading is less than or equal to the spec-
3) Turn ON the starter switch. ified value, inspect the signal circuit between
4) Measure the voltage between the DPD differ- the ECM and the DPD differential pressure
ential pressure sensor 5 V power supply cir- sensor.
cuit and GND.
Voltage: 4.5 V ANNOTATION:
5) If the reading is less than or equal to the spec-
• There should be no open circuit or high re-
ified value, inspect to see if there is an open
sistance.
circuit or high resistance with the 5 V power
• No short circuit to GND is present.
supply circuit between the ECM and the DPD
differential pressure sensor. 14) If a problem is found, repair the signal circuit.
15) Inspect the ECM harness connector for poor
ANNOTATION:
connections.
• The DPD differential pressure sensor 16) If a problem is found, repair the harness con-
shares the 5 V power supply circuit with nector.
other sensors. 17) If the harness connector is normal, replace the
• The DTC set on a sensor which shares this ECM.
circuit may be detected. 18) Set the injector ID code on the ECM.
19) Perform the unit difference learning of the fuel
6) If a problem is found, repair the 5 V power supply pump to the ECM.
supply circuit.
7) Connect the test cable with fuse between the 3. DTC P2454 Confirm Resolution
5 V power supply circuit and signal circuit of
1) Clear the DTC using the trouble diagnosis
the DPD differential pressure sensor.
scan tool.
8) Check the exhaust differential pressure dis-
2) Turn OFF the starter switch for 30 seconds or
play with the trouble diagnosis scan tool.
longer.
Voltage: 4.5 V
3) Start the engine.
9) If the reading is more than or equal to the
4) Perform a test-run.
specified value, inspect to see if there is poor
5) Use the trouble diagnosis scan tool to confirm
connection with the DPD differential pressure
that a DTC has not been detected.
sensor harness connector.
10) If a problem is found, repair the harness con-
nector.

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Engine-side Trouble

DTC P2455 (Flash Code 47) 10) When the DPD differential pressure sensor
has been replaced, perform the 0-point cor-
DPD Differential Pressure Sensor rection.
Circuit High Refer to "Exhaust differential pressure sensor
Inspection".
1. DTC P2455 Priority DTC 11) If the test light does not come on, inspect to
DTC P0697 see if there is an open circuit or high resis-
2. DTC P2455 Diagnostics tance with the GND circuit between the ECM
and the DPD differential pressure sensor.
1) Turn OFF the starter switch.
2) Disconnect the harness connector from the ANNOTATION:
DPD differential pressure sensor.
• The DPD differential pressure sensor
3) Check the exhaust differential pressure dis-
shares the GND circuit with other sensors.
play with the trouble diagnosis scan tool.
• The DTC may be detected on a sensor
Voltage: 0.1 V
which shares this circuit.
4) If the reading is more than or equal to the
specified value, inspect the signal circuit be- 12) If a problem is found, repair the GND circuit.
tween the ECM and the DPD differential pres- 13) Inspect the ECM harness connector for poor
sure sensor. connections.
14) If a problem is found, repair the harness con-
ANNOTATION:
nector.
• No short circuit to the battery or ignition 15) If the harness connector is normal, replace the
power is present. ECM.
• There should be no short to the 5 V power 16) Set the injector ID code on the ECM.
supply. 17) Perform the unit difference learning of the fuel
supply pump to the ECM.
5) If a problem is found, repair the signal circuit.
6) Connect the test light between the GND circuit 3. DTC P2455 Confirm Resolution
and battery power supply of the DPD differen-
1) Clear the DTC using the trouble diagnosis
tial pressure sensor.
scan tool.
7) If the test light comes on, inspect DPD differ-
2) Turn OFF the starter switch for 30 seconds or
ential pressure sensor harness connector for
longer.
poor connections.
3) Start the engine.
8) If a problem is found, repair the harness con-
4) Perform a test-run.
nector.
5) Use the trouble diagnosis scan tool to confirm
9) If the harness connector is normal, replace the
that a DTC has not been detected.
DPD differential pressure sensor.
Refer to "Exhaust differential pressure sensor
Removal".
Refer to "Exhaust differential pressure sensor
Installation".

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4023G-65
Copyright ©
Engine-side Trouble

DTC P2458 (Flash Code 139) 10) Turn ON the starter switch for 30 seconds.
DPD Regeneration Duration ANNOTATION:

1. DTC P2458 Priority DTC • Do not start the engine.

DTC P0426 • This is for the DPD differential pressure sen-
DTC P0427 sor to relearn.
DTC P0428 11) Turn OFF the starter switch for 30 seconds.
DTC P042B 12) Start the engine.
DTC P042C 13) Use the trouble diagnosis scan tool to check
DTC P042D the DPD accumulation status and the DPD
2. DTC P2458 Diagnostics time status, and confirm the corresponding
1) Inspect the DPD differential pressure sensor area from the DPD status table.
hose.
ANNOTATION:
• There should be no incorrect piping or dis-
connection.
2) If a problem is found, repair the hose.
3) Inspect the DPD differential pressure sensor.
ANNOTATION: DPD Ac-
cumulation
• Exhaust differential pressure sensor unit Status
should not be damaged.
• There should be no dirt or foreign matter
blocking the exhaust differential pressure
sensor entrance.
• There should be no detection error or slow
response from the exhaust differential pres-
sure sensor.
DPD Time Status
4) If a problem is found, replace the DPD differ-
ential pressure sensor.
Refer to "Exhaust differential pressure sensor 14) If the situation falls in the area A or B, use
Removal". the trouble diagnosis scan tool to perform the
Refer to "Exhaust differential pressure sensor DPD forced regeneration.
Installation".
5) When the DPD differential pressure sensor ANNOTATION:
has been replaced, perform the 0-point cor-
• When a DTC has been detected, clear it
rection.
using the trouble diagnosis scan tool.
Refer to "Exhaust differential pressure sensor
Inspection". 15) If the situation falls in the area C or D, use
6) Inspect the exhaust system. the trouble diagnosis scan tool to perform the
DPD forced slow regeneration.
ANNOTATION:
ANNOTATION:
• There should be no missing or damage with
the gasket of the exhaust pipe. • When a DTC has been detected, clear it
• There should be no exhaust gas leak from using the trouble diagnosis scan tool.
the exhaust system. • After the DPD forced slow regeneration is
• The exhaust system should not be modified. completed, replace the engine oil.
• There should be no incorrect detection or
slow response from the exhaust gas tem- 16) Use the trouble diagnosis scan tool to confirm
perature sensor. that the exhaust temperature (before the filter)
display is at or below the specified value.
7) If a problem is found, repair or replace the Values: 130 °C {266 °F}
exhaust system. 17) If the reading is more than or equal to the
8) Inspect the engine cooling system for a factor specified value, idle the engine until it falls to
causing overheat. or below the specified value.
Refer to "Inspection of Coolant". 18) Check the exhaust differential pressure data
Refer to "Inspection of Cooling Fan Belt". display when the exhaust temperature (in
Refer to "Thermostat inspection". front of the filter) data display has reached
Inspection of water pump assembly the specified value with the engine revolution
Inspection of radiator increased to the maximum revolution speed
9) If a problem is found, repair the cooling sys- without load.
tem. Values: 150 °C {302 °F}

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4023G-66
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Engine-side Trouble

19) Confirm if the exhaust differential pressure DTC P042B (Flash Code 145)
data display is at or below the specified value.
Values: 2.1 kPa {0.02 kgf/cm2 / 0.3 psi} Catalyst Temperature Sensor
20) If the reading is more than or equal to the
specified value, perform ash removal.
Circuit Range/Performance
Refer to "DPD Assembly inspection". Sensor 2
3. DTC P2458 Confirm Resolution 1. DTC P042B Priority DTC
1) Turn ON the starter switch. DTC P0093
2) Use the trouble diagnosis scan tool to confirm DTC P042C
that a DTC has not been detected. DTC P1093
2. DTC P042B Diagnostics
1) Inspect the exhaust gas temperature sensor
2.
Refer to "Exhaust gas temperature sensor In-
spection".
2) If a problem is found, replace the exhaust gas
temperature sensor 2.
Refer to "DPD temperature sensor Removal".
Refer to "DPD temperature sensor Installa-
tion".
3) Inspect the DPD filter for a damage.
Refer to "DPD Assembly inspection".
4) If a problem is found, replace the DPD filter.
Refer to "Disassembly of DPD Assembly".
Refer to "Assembly of DPD Assembly".
5) Perform the DPD regeneration data reset with
the trouble diagnosis scan tool.
3. DTC P042B Confirm Resolution
1) Clear the DTC using the trouble diagnosis
scan tool.
2) Turn OFF the starter switch for 30 seconds or
longer.
3) Start the engine.
4) Perform a test-run.
5) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.

84592788 EN - March 2012

4023G-67
Copyright ©
Engine-side Trouble

DTC P042C (Flash Code 49) DTC P042D (Flash Code 49)
Catalyst Temperature Sensor Catalyst Temperature Sensor
Circuit Low Sensor 2 Circuit High Sensor 2
1. DTC P042C Priority DTC 1. DTC P042D Priority DTC
DTC P0697 DTC P0697
2. DTC P042C Diagnostics 2. DTC P042D Diagnostics
1) Turn OFF the starter switch. 1) Turn OFF the starter switch.
2) Disconnect the harness connector from the 2) Disconnect the harness connector from the
exhaust gas temperature sensor 2. exhaust gas temperature sensor 2.
3) Check the exhaust temperature sensor (be- 3) Turn ON the starter switch.
fore the oxidation catalyst) display with the 4) Measure the voltage between the exhaust gas
trouble diagnosis scan tool. temperature sensor 2 signal circuit and nor-
Voltage: 4.5 V mal GND.
4) If the reading is more than or equal to the Voltage: 5.5 V
specified value, replace the exhaust gas tem- 5) If the reading is more than or equal to the
perature sensor 2. specified value, inspect to see if there is a
Refer to "DPD temperature sensor Removal". short circuit to the battery or ignition power
Refer to "DPD temperature sensor Installa- supply with the signal circuit between the ECM
tion". and the exhaust gas temperature sensor 2.
5) Inspect to see if there is a short circuit to the 6) If a problem is found, repair the signal circuit.
GND with the signal circuit between the ECM 7) Connect the test cable with fuse between the
and the exhaust gas temperature sensor 2. exhaust gas temperature sensor 2 signal cir-
6) If a problem is found, repair the signal circuit. cuit and GND circuit.
7) Inspect the ECM harness connector for poor 8) Check the exhaust temperature sensor (be-
connections. fore the oxidation catalyst) display with the
8) If a problem is found, repair the harness con- trouble diagnosis scan tool.
nector. Voltage: 0.1 V
9) If the harness connector is normal, replace the 9) If the reading is less than or equal to the spec-
ECM. ified value, inspect to see if there is a short
10) Set the injector ID code on the ECM. circuit to the 5 V power supply circuit with the
11) Perform the unit difference learning of the fuel signal circuit between the ECM and the ex-
supply pump to the ECM. haust gas temperature sensor 2.
10) If a problem is found, repair the signal circuit.
3. DTC P042C Confirm Resolution 11) Inspect to see if there is poor connection with
1) Clear the DTC using the trouble diagnosis the exhaust gas temperature sensor 2 har-
scan tool. ness connector.
2) Turn OFF the starter switch for 30 seconds or 12) If a problem is found, repair the harness con-
longer. nector.
3) Start the engine. 13) If the harness connector is normal, replace the
4) Perform a test-run. exhaust gas temperature sensor 2.
5) Use the trouble diagnosis scan tool to confirm Refer to "DPD temperature sensor Removal".
that a DTC has not been detected. Refer to "DPD temperature sensor Installa-
tion".
14) Connect the test cable with fuse between the
exhaust gas temperature sensor 2 signal cir-
cuit and normal GND.
15) Check the exhaust temperature sensor (be-
fore the oxidation catalyst) display with the
trouble diagnosis scan tool.
Voltage: 0.1 V
16) If the reading is more than or equal to the
specified value, inspect to see if there is an
open circuit or high resistance with the signal
circuit between the ECM and the exhaust gas
temperature sensor 2.
17) If a problem is found, repair the signal circuit.
18) Inspect to see if there is an open circuit or
high resistance in the GND circuit between the
ECM and the exhaust gas temperature sensor
2.
ANNOTATION:

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4023G-68
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Engine-side Trouble

• The exhaust gas temperature sensor 2 DTC P060B (Flash Code 36)
shares the GND circuit with other sensors.
• The DTC may be detected on a sensor Internal Control Module A/D
which shares this circuit. Processing Performance
19) If a problem is found, repair the GND circuit.
1. DTC P060B Diagnostics
20) Inspect the ECM harness connector for poor
connections. 1) Replace the ECM.
21) If a problem is found, repair the harness con- 2) Set the injector ID code on the ECM.
nector. 3) Perform the unit difference learning of the fuel
22) If the harness connector is normal, replace the supply pump to the ECM.
ECM.
23) Set the injector ID code on the ECM. 2. DTC P060B Confirm Resolution
24) Perform the unit difference learning of the fuel 1) Clear the DTC using the trouble diagnosis
supply pump to the ECM. scan tool.
3. DTC P042D Confirm Resolution 2) Turn OFF the starter switch for 30 seconds or
longer.
1) Clear the DTC using the trouble diagnosis 3) Start the engine.
scan tool. 4) Perform a test-run.
2) Turn OFF the starter switch for 30 seconds or 5) Use the trouble diagnosis scan tool to confirm
longer. that a DTC has not been detected.
3) Start the engine, and warm it up until the
coolant temperature reaches the specified
value.
Values: 70 °C {158 °F}
4) Repeatedly rev the engine in neutral to in-
crease the engine rpm while checking the ex-
haust temperature sensor (in front of the oxi-
dation catalyst) display with the trouble diag-
nosis scan tool.
5) Use the trouble diagnosis scan tool to con-
firm that the exhaust temperature sensor (be-
fore the oxidation catalyst) display does not
exceed the specified value.
Voltage: 4.8 V
6) Use the trouble diagnosis scan tool to confirm
that a DTC has not been detected.

84592788 EN - March 2012

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4023H-14
Copyright ©
Main Unit-side Trouble

Diagnostic Trouble Code: 7006 Rod Pressure Sensor Signal Abnormality

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7006 is displayed. Go to Step 2
Is diagnostic trouble code: 7006 displayed?
1. Inspect the connection status of each
connector.
2 2. Check whether diagnostic trouble code: Go to Step 3
7006 is displayed.
Is diagnostic trouble code: 7006 displayed?
1. Check the rod pressure sensor voltage
on the service support screen. 4.75 V or When 0.25 V or
3 Go to Step 4
higher lower, go to Step 7
Is it 4.75 V or higher?
Inspect for shorts to the power supply
1. Turn the key switch OFF and disconnect
CN. CR10.
W414 or W415 har-
2. Turn the key switch ON.
4 About 5 V Go to Step 5 ness defect (short).
3. Measure the voltage between the
Replace
ground and terminal 1 of the CN. CR10
harness side.
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. CR10 4.75 V or L435 harness defect
5 harness side. Go to Step 6
lower (short). Replace
Is it 4.75 V or lower?
1. Measure the voltage between the
ground and terminal 3 of the CN. CR10 0.25 V or Computer B defect. BW454 or BW455
6 harness side. harness defect
lower Replace
(short). Replace
Is it 0.25 V or lower?
Inspect the rod pressure sensor.
1. Turn the key switch OFF.
2. Disconnect CN. CR10.
About 10 Rod pressure sensor
7 3. Measure the resistance between termi- Go to Step 8
kΩ defect. Replace
nals 1 and 3 of the CN. CR10 rod pres-
sure sensor side.
Is it about 10 kΩ?
Inspect for shorts to ground and disconnec-
tions.
1. Inspect for continuity between the
ground and terminal 1 of the CN. CR10 W414, W415, or
8 harness side. L435 harness defect Go to Step 9
2. Inspect for continuity between the (short). Replace
ground and terminal 2 of the CN. CR10
harness side.
Is there continuity?
1. Inspect for continuity between the BW454 or BW455
ground and terminal 3 of the CN. CR10 harness defect (dis-
9 harness side. Go to Step 10
connection). Repair
Is there continuity? or replace

84592788 EN - March 2012

4023H-15
Copyright ©
Main Unit-side Trouble

4023H-25
Copyright ©
Main Unit-side Trouble

1 COMPUTER A
2 FUEL LEVEL SENSOR

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7060 is displayed. Go to Step 2
Is diagnostic trouble code: 7060 displayed?
1. Inspect the connection status of each
connector.
2 2. Check whether diagnostic trouble code: Go to Step 3
7060 is displayed.
Is diagnostic trouble code: 7060 displayed?
1. Check the boom angle sensor voltage
on the service support screen. 4.8 V or When 0.2 V or lower,
3 Go to Step 4
higher go to Step 7
Is it 4.8 V or higher?
Inspect for shorts to the power supply
1. Turn the key switch OFF and disconnect
CN. CR11.
W414 or W416 har-
2. Turn the key switch ON.
4 About 5 V Go to Step 5 ness defect (short).
3. Measure the voltage between the
Replace
ground and terminal 3 of the CN. CR11
harness side.
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. CR11 4.8 V or Lg436 harness de-
5 harness side. Go to Step 6
lower fect (short). Replace
Is it 4.8 V or lower?
1. Measure the voltage between the
ground and terminal 1 of the CN. CR11 0.2 V BW454 or BW456
or Computer B defect.
6 harness side. harness defect
lower Replace
(short). Replace
Is it 0.2 V or lower?
Inspect the boom angle sensor.
1. Turn the key switch OFF.
2. Disconnect CN. CR11.
About 10 Boom angle sensor
7 3. Measure the resistance between termi- Go to Step 8
kΩ defect. Replace
nals 1 and 3 of the CN. CR11 boom an-
gle sensor side.
Is it about 10 kΩ?
Inspect for shorts to ground and disconnec-
tions.
1. Inspect for continuity between the
ground and terminal 3 of the CN. CR11 W414, W416, or
8 harness side. Lg436 harness de- Go to Step 9
2. Inspect for continuity between the fect (short). Replace
ground and terminal 2 of the CN. CR11
harness side.
Is there continuity?
1. Inspect for continuity between the BW454 or BW456
ground and terminal 1 of the CN. CR11 harness defect (dis-
9 harness side. Go to Step 10
connection). Repair
Is there continuity? or replace

84592788 EN - March 2012

4023H-30
Copyright ©
Main Unit-side Trouble

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Measure the voltage between the W414 or W416 har-
ground and terminal 3 of the CN. CR11 About 5 V ness defect (discon-
10 Go to Step 11
harness side. nection). Repair or
replace
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. CR11 0.2 V Lg436 harness de-
or Computer B defect.
11 harness side. fect (disconnection).
higher Replace
Repair or replace
Is it 0.2 V or higher?

Abnormality
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7065 is displayed. Go to Step 2
Is diagnostic trouble code: 7065 displayed?
1. Inspect the connection status of each
connector.
2 2. Check whether diagnostic trouble code: Go to Step 3
7065 is displayed.
Is diagnostic trouble code: 7065 displayed?
1. Check the boom-up pilot pressure sen-
sor voltage on the service support 4.75 V or When 0.25 V or
3 screen. Go to Step 4
higher lower, go to Step 7
Is it 4.75 V or higher?
Inspect for shorts to the power supply
1. Turn the key switch OFF and disconnect
CN. D53.
WL432 or WL430
2. Turn the key switch ON.
4 About 5 V Go to Step 5 harness defect
3. Measure the voltage between the
(short). Replace
ground and terminal 1 of the CN. D53
harness side.
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. D53 4.75 V or GW444 harness de-
5 harness side. Go to Step 6
lower fect (short). Replace
Is it 4.75 V or lower?
1. Measure the voltage between the
ground and terminal 3 of the CN. D53 0.25 V or Computer B defect. BL452 or BL450 har-
6 harness side. ness defect (short).
lower Replace
Replace
Is it 0.25 V or lower?
1. Inspect the boom-up pilot pressure sen-
sor.
2. Turn the key switch OFF.
3. Disconnect CN. D53. Boom-up pilot pres-
About 10
7 4. Measure the resistance between termi- kΩ Go to Step 8 sure sensor defect.
nals 1 and 3 of the CN. D53 boom-up Replace
pilot pressure sensor side.
Is it about 10 kΩ?
Inspect for shorts to ground and disconnec-
tions.
1. Inspect for continuity between the
ground and terminal 1 of the CN. D53 WL432, WL430, or
8 harness side. GW444 harness de- Go to Step 9
2. Inspect for continuity between the fect (short). Replace
ground and terminal 2 of the CN. D53
harness side.
Is there continuity?
1. Inspect for continuity between the BL452 or BL450 har-
ground and terminal 3 of the CN. D53 ness defect (discon-
9 harness side. Go to Step 10
nection). Repair or
Is there continuity? replace

84592788 EN - March 2012

1 COMPUTER A 6 CRANK ANG (MRE) SENSOR 11 RELAY BATTERY

2 ENGINE COMPUTER 7 FUSE CONT 12 FUSIBLE LINK BACK UP
PRESS. SENSOR (PILOT
3 8 POWER SAVE 13 FUSIBLE LINK FUSE BOX
SWING)
PRESS. SENSOR (PILOT UP-
4 9 RELAY BATTERY 14 KEY SWITCH
PER)
PRESS. SENSOR (PILOT
5 10 BATTERY (24 V) 15 COMPUTER B
TRAVEL)

4023H-56
Copyright ©
Main Unit-side Trouble

Diagnostic Trouble Code: 7211 Rotating Light Relay and Bucket Lock
Signal Abnormality
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7211 is displayed. Go to Step 2
Is diagnostic trouble code: 7211 displayed?
1. Inspect the connection status of each
connector.
2. Inspect the fusible link F1 (65 A) fuse
2 and fuse box F21 (10 A) fuse to see if Go to Step 3
either is blown.
Are 1 and 2 above both OK?
Inspect the rotating light relay.
1. Turn the key switch OFF and disconnect
CN. 19.
Rotating light relay
3 2. Inspect for continuity between terminals Go to Step 4
defect. Replace
1 and 2 of the CN. 19 rotating light relay
side.
Is there continuity?
Inspect for shorts.
1. Install CN. 19. VW858, GW226,
2. Inspect for continuity between the GW227, R106, or
4 Go to Step 5
ground and terminal 1 of the CN. 19 R105 harness defect
harness side. (short). Replace
Is there continuity?
Inspect for disconnection.
VW816, VW817,
1. Turn the key switch ON. GW227, GW226,
2. Inspect for continuity between the Computer B defect. GW225, R106, or
5
ground and terminal 1 of the CN. 19 Replace R105 harness defect
harness side. (disconnection). Re-
pair or replace
Is there continuity?

84592788 EN - March 2012

4023H-57
Copyright ©
Main Unit-side Trouble

Diagnostic Trouble Code: 7240 Pump Horsepower Proportional Valve

Signal Abnormality
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7240 is displayed. Go to Step 2
Is diagnostic trouble code: 7240 displayed?
1. Inspect the connection status of each
connector.
2 2. Check whether diagnostic trouble code: Go to Step 3
7240 is displayed.
Is diagnostic trouble code: 7240 displayed?
1. Reset the diagnostic trouble code on the
service support DIAG screen.
3 2. Check whether diagnostic trouble code: Go to Step 4 Go to Step 5
7240 is displayed.
Is diagnostic trouble code: 7240 displayed?
Inspect for shorts.
1. Turn the key switch OFF and disconnect
CN. D39.
Y900 harness defect Computer A defect.
4 2. Inspect for continuity between the
(short). Replace Replace
ground and terminal 1 of the CN. D39
harness side.
Is there continuity?
Inspect the pump horsepower proportional
valve.
1. Turn the key switch OFF.
Pump horsepower
2. Disconnect CN. D39.
5 Go to Step 6 proportional valve
3. Inspect for continuity between terminals
defect. Replace
1 and 2 of the CN. D39 pump horse-
power proportional valve side.
Is there continuity?
Inspect for disconnection.
YR940 harness de-
1. Disconnect CN. A56.
fect (disconnection)
2. Inspect for continuity between terminal
6 Go to Step 7 between CN. D39
1 of the CN. D39 female side and termi-
and CN. A56. Repair
nal 1 of the CN. A56 male side.
or replace
Is there continuity?
BY901 harness de-
Inspect for continuity between terminal 2 of
fect (disconnection)
the CN. D39 female side and terminal 9 of
7 Go to Step 8 between CN. D39
the CN. A56 male side.
and CN. A56. Repair
Is there continuity?
or replace
1. Disconnect CN. A4. Y900 harness defect
2. Inspect for continuity between terminal (disconnection) be-
8 1 of the CN. A56 male side and terminal Go to Step 9 tween CN. A56 and
3 of the CN. A4 female side. CN. A4. Repair or re-
Is there continuity? place
1. Inspect for continuity between terminal BY901 harness de-
9 of the CN. A56 male side and terminal fect (disconnection)
Computer A defect.
9 6 of the CN. A4 female side. between CN. A56
Replace
and CN. A4. Repair
Is there continuity? or replace

84592788 EN - March 2012

4023H-58
Copyright ©
Main Unit-side Trouble

PRESS. SENSOR (PILOT UP-

1 COMPUTER A 4 7 ENGINE COMPUTER
PER)
2 PRESS. SENSOR (P1) 5 CRANK ANGLE SENSOR
3 PRESS. SENSOR (P2) 6 PUMP POWER

a CAN COMMUNICATION

84592788 EN - March 2012

4023H-59
Copyright ©
Main Unit-side Trouble

Diagnostic Trouble Code: 7241 P1 Flow Control Proportional Valve

Signal Abnormality
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7241 is displayed. Go to Step 2
Is diagnostic trouble code: 7241 displayed?
1. Inspect the connection status of each
connector.
2 2. Check whether diagnostic trouble code: Go to Step 3
7241 is displayed.
Is diagnostic trouble code: 7241 displayed?
1. Reset the diagnostic trouble code on the
service support DIAG screen.
3 2. Check whether diagnostic trouble code: Go to Step 4 Go to Step 5
7241 is displayed.
Is diagnostic trouble code: 7241 displayed?
Inspect for shorts.
1. Turn the key switch OFF and disconnect
CN. D40.
L904 harness defect Computer A defect.
4 2. Inspect for continuity between the
(short). Replace Replace
ground and terminal 1 of the CN. D40
harness side.
Is there continuity?
Inspect the P1 flow control proportional
valve.
1. Turn the key switch OFF.
P1 flow control pro-
2. Disconnect CN. D40.
5 Go to Step 6 portional valve de-
3. Inspect for continuity between terminals
fect. Replace
1 and 2 of the CN. D40 flow control
proportional valve side.
Is there continuity?
Inspect for disconnection.
Y904 harness defect
1. Disconnect CN. A56.
(disconnection) be-
2. Inspect for continuity between terminal
6 Go to Step 7 tween CN. D40 and
1 of the CN. D40 male side and terminal
CN. A56. Repair or
3 of the CN. A56 female side.
replace
Is there continuity?
BL905 harness de-
Inspect for continuity between terminal 2 of
fect (disconnection)
the CN. D40 male side and terminal 11 of the
7 Go to Step 8 between CN. D40
CN. A56 female side.
and CN. A56. Repair
Is there continuity?
or replace
1. Disconnect CN. A3. Y904 harness defect
2. Inspect for continuity between terminal (disconnection) be-
8 3 of the CN. A56 male side and terminal Go to Step 9 tween CN. A56 and
2 of the CN. A3 female side. CN. A3. Repair or re-
Is there continuity? place
BL905 harness de-
Inspect for continuity between terminal 11 of
fect (disconnection)
the CN. A56 male side and terminal 5 of the Computer A defect.
9 between CN. A56
CN. A3 female side. Replace
and CN. A3. Repair
Is there continuity?
or replace

84592788 EN - March 2012

4023H-60
Copyright ©
Main Unit-side Trouble

PRESS. SENSOR (PILOT

1 CONTROLLER A
2 BOOM DOWN

84592788 EN - March 2012

4023H-66
Copyright ©
Main Unit-side Trouble

Diagnostic Trouble Code: 7248 Arm-in Proportional Valve Signal

Abnormality
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7248 is displayed. Go to Step 2
Is diagnostic trouble code: 7248 displayed?
1. Inspect the connection status of each
connector.
2 2. Check whether diagnostic trouble code: Go to Step 3
7248 is displayed.
Is diagnostic trouble code: 7248 displayed?
1. Reset the diagnostic trouble code on the
service support DIAG screen.
3 2. Check whether diagnostic trouble code: Go to Step 4 Go to Step 5.
7248 is displayed.
Is diagnostic trouble code: 7248 displayed?
Inspect for shorts.
1. Turn the key switch OFF and disconnect
CN. D42.
G906 harness defect Computer B defect.
4 2. Inspect for continuity between the
(short). Replace Replace
ground and terminal 1 of the CN. D42
harness side.
Is there continuity?
Inspect the arm-in proportional valve.
1. Turn the key switch OFF.
2. Disconnect CN. D42. Arm-in proportional
5 3. Inspect for continuity between terminals Go to Step 6 valve defect. Re-
1 and 2 of the CN. D42 arm-in propor- place
tional valve side.
Is there continuity?
Inspect for disconnection.
G906 harness defect
1. Disconnect CN. A56.
(disconnection) be-
2. Inspect for continuity between terminal
6 Go to Step 7 tween CN. A56 and
1 of the CN. D42 female side and termi-
CN. D42. Repair or
nal 4 of the CN. A56 female side.
replace
Is there continuity?
GB907 harness de-
Inspect for continuity between terminal 2 of
fect (disconnection)
the CN. D42 female side and terminal 12 of
7 Go to Step 8 between CN. A56
the CN. A56 female side.
and CN. D42. Repair
Is there continuity?
or replace
1. Disconnect CN. A7. G906 harness defect
2. Inspect for continuity between terminal (disconnection) be-
8 4 of the CN. A56 male side and terminal Go to Step 9 tween CN. A56 and
3 of the CN. A7 female side. CN. A7. Repair or re-
Is there continuity? place
GB907 harness de-
Inspect for continuity between terminal 12 of
fect (disconnection)
the CN. A56 male side and terminal 6 of the Computer B defect.
9 between CN. A56
CN. A7 female side. Replace
and CN. A7. Repair
Is there continuity?
or replace

84592788 EN - March 2012

4023H-67
Copyright ©
Main Unit-side Trouble

1 CONTROLLER B
2 ARM CLOSE

84592788 EN - March 2012

4023H-68
Copyright ©
Main Unit-side Trouble

Diagnostic Trouble Code: 7250 Option Relief Pressure Proportional

Valve Signal Abnormality
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7250 is displayed. Go to Step 2
Is diagnostic trouble code: 7250 displayed?
1. Inspect the connection status of each
connector.
2 2. Check whether diagnostic trouble code: Go to Step 3
7250 is displayed.
Is diagnostic trouble code: 7250 displayed?
1. Reset the diagnostic trouble code on the
service support DIAG screen.
3 2. Check whether diagnostic trouble code: Go to Step 4 Go to Step 5
7250 is displayed.
Is diagnostic trouble code: 7250 displayed?
Inspect for shorts.
1. Turn the key switch OFF and disconnect
CN. D44-1.
V910 harness defect Computer B defect.
4 2. Inspect for continuity between the
(short). Replace Replace
ground and terminal 1 of the CN. D44-1
harness side.
Is there continuity?
Inspect the option relief pressure propor-
tional valve.
1. Turn the key switch OFF.
Option relief pressure
2. Disconnect CN. D44-1.
5 Go to Step 6 proportional valve
3. Inspect for continuity between terminals
defect. Replace
1 and 2 of the CN. D44-1 option relief
pressure proportional valve side.
Is there continuity?
Inspect for disconnection.
V910 harness defect
1. Disconnect CN. D44.
(disconnection) be-
2. Inspect for continuity between terminal
6 Go to Step 7 tween CN. D44-1 and
1 of the CN. D44-1 female side and ter-
CN. D44. Repair or
minal 1 of the CN. D44 male side.
replace
Is there continuity?
1. Inspect for continuity between terminal VG911 harness de-
2 of the CN. D44-1 female side and ter- fect (disconnection)
7 minal 2 of the CN. D44 male side. Go to Step 8 between CN. D44-1
and CN. D44. Repair
Is there continuity? or replace
1. Disconnect CN. A7. V910 harness defect
2. Inspect for continuity between terminal (disconnection) be-
1 of the CN. D44 female side and termi- tween CN. D44 and
8 Go to Step 9
nal 2 of the CN. A7 female side. CN. A7. Repair or re-
place
Is there continuity?
1. Inspect for continuity between terminal VG911 harness de-
2 of the CN. D44 female side and termi- fect (disconnection)
Computer B defect.
9 nal 5 of the CN. A7 female side. between CN. D44
Replace
and CN. A7. Repair
Is there continuity? or replace

84592788 EN - March 2012

1 COMPUTER A
2 HYD. OIL TEMP SENSOR

84592788 EN - March 2012

4023H-94
Copyright ©

Section

4023K

Data Reference Values

84592788 EN - March 2012

CONTENTS

Non-operational P rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Two pump relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

4023K-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

4023K-2 PRINTED IN FRANCE
Copyright ©
Data Reference Values

Code Part name Q'ty

5001A-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

5001A-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Shoe Assembly

WARNING Removal of Shoe Assembly

• When loosening the grease cylinder check 1. Rotate the shoe and align it so that the master pin
valve, loosen it a little bit at a time. (1) is next to the idler.
• The pressure inside the cylinder is very high,
so there is the danger of grease being ex-
pelled and the plug flying off.
The check valve adjustment procedure
should not be done in front of the check
valve.
• Do not get under the main unit when it is
jacked up.
Make sure to place the main unit on crossties
to prevent falling.

CAUTION
• Make sure to stop the engine for loosening
shoes and when removing master pins. 2. Use a box wrench [ 19 mm ( 0.748 in ) ] to loosen the
check valve (1) to release grease, and then loosen
Items to prepare the track shoe tension.
• Wrenches [ 17 mm ( 0.669 in ), 19 mm ( 0.748 in ) ] WARNING
• Box wrench [ 19 mm ( 0.748 in ) ]
• Hammer • If the check valve (1) is too loose, it may
• Wood planks, etc. fly off.
• Striking jig • Do not place your body in front.
• Crowbar
• Rag Do not loosen the check valve all at once.
• Lifting equipment (with the required breaking load) Loosen it slowly while monitoring the grease output
• Liftcrane (with the required lifting capacity) and shoe loosening.
Use a rag to catch grease that trickles out of the
check valve.

84592788 EN - March 2012

5001A-3
Copyright ©
Removal and Installation of Shoe Assembly

3. Use a wrench [ 17 mm ( 0.669 in ) ] to remove the 6. Remove the track shoe (1).
bolt (1), and then remove the check valve (2) and At this time, support with a wood plank (2) so the
stopper (3). bottom track shoe (1) does not fall.
• If the check valve (2) is removed, it is easier to
loosen the track shoe tension.

7. Start the engine, raise the lower side frame of the

track shoe removal side about 20 cm ( 7.874 in ),
slowly set the travel lever to backwards, and move
4. Put wood planks (1) underneath the track shoe. the track shoe (1) to remove it from the lower frame.
Straighten out the S-pin (3) attached to the master
pin (2) by striking one side of it with a hammer, and
use a crowbar, etc. to remove it.

5. Use a hammer (2) and striking rod (3) to push the

master pin (1) out.

84592788 EN - March 2012

5001A-4
Copyright ©
Removal and Installation of Shoe Assembly

Installation of Shoe Assembly 3. Wrap the edge of the track shoe (1) onto the take-up
roller (2).
1. Raise the lower side frame about 20 cm ( 7.874 in ). Place a wood plank (3) on the ground and lift the
Lift the track shoe (1) and align it with the sprocket bottom-side link to align the position where the mas-
(2). ter pin is inserted.
Pay attention to the backwards and forward direc-
tion of the track shoe.

4. Insert the master pin (1).

Insert the S-pin (2) and bend it so that it cannot slip
out.

2. Slowly set the travel lever to forward and feed the 5. Tighten the check valve (1).
track shoe to the take-up roller side as shown in the While monitoring the track shoe tension, inject
diagram. grease into the grease cylinder.
In the middle of this procedure when the track shoe
passes the upper roller, use a crowbar, etc. to lift
the track shoe while it is being fed.
Lower the lower side frame after the shoe has
reached position A shown in the diagram.

84592788 EN - March 2012

5001A-5
Copyright ©
Removal and Installation of Shoe Assembly

6. To adjust the track shoe tension, raise the lower 7. Adjust the tension so that the distance indicated
side frame with a wood plank (1) as shown in the with A between the frame bottom (1) of the center
diagram. area of the lower side frame and the lowest hanging
part of the top of the shoe plate (2) is 290 - 310 mm
( 11.418 - 12.204 in ).

84592788 EN - March 2012

5001A-6
Copyright ©

Section

5001B

Removal and Installation of Shoe Plate

84592788 EN - March 2012

CONTENTS

Removal of Shoe Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Shoe Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

5001B-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

5001B-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Shoe Plate

CAUTION Installation of Shoe Plate

• Be sure to stop the engine before beginning 1. Install the shoe plate (1).
work.

Items to prepare
• Box wrench [24 mm (0.945 in)]
• Grease
• Rag
• Cleaning fluid

Removal of Shoe Plate

1. Use a box wrench [24 mm (0.945 in)] to remove the
4 shoe bolts (1).

2. Use a box wrench [24 mm (0.945 in)] to install the

4 shoe bolts (1).
Bolt (1) tightening torque: 373 - 451 N・m (275.16
- 332.69 lbf・ft)

2. Remove the shoe plate (1).

84592788 EN - March 2012

5001B-3
Copyright ©
Removal and Installation of Shoe Plate

84592788 EN - March 2012

5001B-4
Copyright ©

Section

5003A

Removal and Installation of Upper Roller

84592788 EN - March 2012

CONTENTS

Removal of Upper Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

5003A-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

5003A-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Upper Roller

Job code 48138AB21 Removal of Upper Roller

1. Use a box wrench [19 mm (0.748 in)] to loosen the
WARNING check valve (1) to release grease, and then loosen
the track shoe tension.
• When loosening the check valve, loosen it a
little at a time and stop when any grease ap- WARNING
pears.
The pressure inside the cylinder is very high, • If the check valve (1) is too loose, it may
so there is the danger of grease being ex- fly off.
pelled and the plug flying off if the check • Do not place your body in front.
valve is loosened too much.
The check valve adjustment procedure Do not loosen the check valve all at once.
should not be done in front of the check Loosen it slowly while monitoring the grease output
valve. and shoe loosening.
Use a rag to catch grease that trickles out of the
CAUTION check valve.

• Be sure to stop the engine before beginning

work.

Items to prepare
• Box wrenches [19 mm (0.748 in), 24 mm (0.945 in)]
• Jack (That meets the lifting weight.)
• Rag
• Cleaning fluid
• Wood planks, etc.

2. Use a jack (3) to lift the top of the shoe, and then
insert wood planks (4) to separate the shoe (2) and
upper roller (1) by about 10 mm (0.394 in).

84592788 EN - March 2012

5003A-3
Copyright ©
Removal and Installation of Upper Roller

3. Use a box wrench [24 mm (0.945 in)] to remove the Installation of Upper Roller
2 bolts (2), and then remove the upper roller (1).
1. Use a jack (2) to lift the top of the shoe (1), and then
insert wood planks (3).

2. Use a box wrench [24 mm (0.945 in)] to install the

upper roller (1) with the 2 bolts (2).
• Apply Loctite.
• Bolt (2) tightening torque: 267 - 312 N·m (196.96
- 230.16 lbf·ft)

3. Tighten the check valve (1).

5003B-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

5003B-2 PRINTED IN FRANCE
Copyright ©
Assembly and Disassembly of Upper Roller

Job code 48138AC30

CAUTION
• To ensure safe operations, wear protective
devices before beginning work and follow all
precautions.
• When removing devices or positioning de-
vices at the time of installation, use a removal
jig and a hammer or steel rod.
• Follow the precautions below when suspend-
ing the load.
• The liftcrane must be operated by a qualified
operator.
• Do not stand or pass under the suspended
load.
• Check the weight of the roller to determine
whether it can be carried by hand or whether
a liftcrane must be used.
• Fix the roller to a level surface so it does not
roll.
• Be sure to repair any parts damaged during
disassembly, and prepare replacement parts
in advance.
• If any parts are significantly rusted or dirty,
clean them before disassembling.
• Any foreign matter entering the equipment
during assembly can create a malfunction.
Therefore, after thoroughly cleaning the
equipment with cleaning oil, air blow the
equipment, and assemble in a clean location.
• When assembling touching parts, be sure to
coat them with new hydraulic oil.
• As a rule, replace all O-rings and other seal
parts with new parts.
<General cautions>
• Be careful not to drop precision parts or let
bump them with other parts during work.
• Do not forcefully open or hit parts in an effort
to speed up operations. Pay careful attention
and proceed slowly so as not to damage any
parts, create any oil leaks, or compromise the
efficiency of the equipment, etc.
• Disassembled parts can easily rust or collect
dust. Therefore, immediately after disassem-
bling parts, take precautions to prevent the
parts from rusting or collecting dust.

Items to prepare
• Hexagon wrench 6 mm ( 0.236 in )
• Hammer
• Wrenches [ 13 mm ( 0.512 in ), 17 mm ( 0.669 in ) ]
• Box wrench [ 17 mm ( 0.669 in ) ]
• Screwdriver
• Engine oil (Shell Rimula Oil #30)
• Specialty jigs
• Pressing machine
• Loctite 262
• Special fiber cloth (Kimwipe)
• Marking pen
• Micrometer caliper
• Caliper

84592788 EN - March 2012

5003B-3
Copyright ©
Assembly and Disassembly of Upper Roller

Configuration Diagram

Part name Part number Q'ty Part name Part number Q'ty
High-strength bolt M10 x 102R010Y016 7 Thrust plate KMA1285 1
1 2
16 N 8 Shaft KMA1277 1
Req- 9 Bushing KMA1270 1
d. a- 1
2 Loctite #262 KRC5007 Roller KMA1276 1
mo- 0
unt 1
3 Cover KMA1278 1 Floating seal KHA0038 1
1
4 Plug with seal nylon KHJ0300 1 1
5 O-ring KRA0232 1 Bracket KMA1279 1
2
High-strength bolt M8 x
6 102R008 4
25

84592788 EN - March 2012

5003B-4
Copyright ©
Assembly and Disassembly of Upper Roller

Dimension Diagram

*1 Press fit length

84592788 EN - March 2012

5003B-5
Copyright ©
Assembly and Disassembly of Upper Roller

Jig Dimension Diagram

A Bushing removal jig

B Bushing press-fit jig (9)
C Floating seal installation jig

84592788 EN - March 2012

5003B-6
Copyright ©
Assembly and Disassembly of Upper Roller

Disassembly Procedures 4. Remove the cover (1).

If the cover is difficult to remove, it is acceptable to
1. Stand the roller vertically and use a hexagon use an air hose (2) with an adapter or to pry it open
wrench [6 mm (0.236 in) ] (1) to remove the plug by inserting a flathead screwdriver into either end of
(2). the cover.
• The plug is coated with seal nylon, which comes • When using compressed air, be careful of flying
off when the plug is removed. To reuse the plug, parts.
using seal tape is necessary.

5. Use a box wrench [17 mm (0.669 in)] to remove the

2. Face down the part of the roller from which the 2 bolts (2) inside the roller, and then remove the
plug was removed and empty the oil from within the thrust plate (1).
roller.
• It may take a few hours to completely empty the
oil.
• Place an oil pan (1) under the roller to catch the
oil.

6. Lift the roller (1) and remove the shaft (2).

3. Use a wrench [13 mm (0.512 in)] to remove the 4

bolts (2) from the cover (1), and then remove the
cover.

7. Remove the floating seal (2) on the roller .

Check whether the sliding surface has rusted or is
damaged. Also make sure the O-ring (3) on the
floating seat (4) is not twisted.
• The O-rings cannot be reused.
Replace them with new parts.
• Replace floating seats that have rust, deforma-
tions with new ones.

84592788 EN - March 2012

5003B-7
Copyright ©
Assembly and Disassembly of Upper Roller

10. Use a micrometer caliper (4), caliper (5), cylinder

gauge (6), to measure the roller (with bushing) (1),
bracket (2), and shaft (3) for wear and deformation.
Replace with new parts as necessary.

8. Remove the floating seal (2) on the shaft (1).

• The shaft and bracket (3) cannot be removed.

9. Remove the O-ring (2) on the cover (1) side.

• Check whether the O-ring is twisted. If it is
twisted, replace it with a new one.
11. When replacing bushings (1), use jig A (3) to re-
strain it from the side where the shaft (2) was re-
moved and press it out with a pressing machine (4).

84592788 EN - March 2012

5003B-8
Copyright ©
Assembly and Disassembly of Upper Roller

Assembly Procedures 4. Insert the floating seal (3) into the roller (1) and
bracket (2).
1. Clean all parts. Use jig C (4) to press it into position.
• Find a clean location.
• Place a rubber plate or cloth on the work platform
so as not to damage the parts.
• In order to clean off adhered matter that forms
sharp points and causes scratches, immerse
parts in cleaning fluid (1) until dirt and grease
float to the top.

5. Use a special fiber cloth to wipe the surfaces of the

floating seals so as to increase adhesion and pre-
vent dust from entering.

2. After cleaning the parts, air blow them to remove

any remaining cleaning fluid or debris.

6. Apply hydraulic oil to the floating seal (1).

3. If the bushing (1) was removed during disassembly,

put it into the roller (2).
Face up the thrust plate installation side, restrain
from above using jig B (3), and push in with the
pressing machine (4).

7. Attach the shaft (2) to the roller (1).

84592788 EN - March 2012

5003B-9
Copyright ©
Assembly and Disassembly of Upper Roller

8. Use a special fiber cloth to thoroughly wipe the sur- 11. Rotate the roller in the direction of the arrow and
face of the thrust plate (1) to prevent any dust or check that it rotates smoothly.
scratches.

12. Inject compressed air [0.2 MPa (29.011 psi) ] from

9. Use a box wrench [17 mm (0.669 in)] to install the the oil fill port and immerse in water to check that
thrust plate (1) with the 2 bolts (2). there are no leaks.
Degrease the bolts well, apply Loctite (3) to the bolt
openings, and tighten the bolts.
After tightening the bolts, mark them (4).
Bolt (2) tightening torque: 62.8 - 72.6 N·m (46.327
- 53.556 lbf·ft)

13. Inject engine oil (50 - 55 cc) into the roller. After
filling the engine oil, use a hexagon wrench (1) to
tighten the plug (2) (coated with seal nylon).
After tightening the bolts, mark them (3).

10. Use a wrench [13 mm (0.512 in)] to install the cover • To reuse a plug, wrap it with seal tape.
(1) with the 4 bolts (2).
Degrease the bolts, apply Loctite (3) to the bolt
openings, and tighten the bolts.
After tightening the bolts, mark them (4).
Bolt (2) tightening torque: 31.4 - 37.2 N·m (23.164
- 27.442 lbf·ft)

This completes the assembly.

84592788 EN - March 2012

5003B-10
Copyright ©

Section

5003C

Removal and Installation of Lower Roller

Section

5003D

Assembly and Disassembly of Lower Roller

84592788 EN - March 2012

CONTENTS

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

5003D-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

5003D-2 PRINTED IN FRANCE
Copyright ©
Assembly and Disassembly of Lower Roller

CAUTION
• To ensure safe operations, wear protective
devices before beginning work and follow all
precautions.
• When removing devices or positioning de-
vices at the time of installation, use a removal
jig and a hammer or steel rod.
• Follow the precautions below when suspend-
ing the load.
• The liftcrane must be operated by a qualified
operator.
• Do not stand or pass under the suspended
load.
• Check the weight of the roller to determine
whether it can be carried by hand or whether
a liftcrane must be used.
• Fix the roller to a level surface so it does not
roll.
• Be sure to repair any parts damaged during
disassembly, and prepare replacement parts
in advance.
• If any parts are significantly rusted or dirty,
clean them before disassembling.
• Any foreign matter entering the equipment
during assembly can create a malfunction.
Therefore, after thoroughly cleaning the
equipment with cleaning oil, air blow the
equipment, and assemble in a clean location.
• When assembling sliding parts, be sure to
coat them with new hydraulic oil.
• As a rule, replace all O-rings and other seal
parts with new parts.
<General cautions>
• Be careful not to drop precision parts or let
bump them with other parts during work.
• Do not forcefully open or hit parts in an effort
to speed up operations.
Pay careful attention and proceed slowly so
as not to damage any parts, create any oil
leaks, or compromise the efficiency of the
equipment, etc.
• Disassembled parts can easily rust or collect
dust.
Therefore, immediately after disassembling
parts, take precautions to prevent the parts
from rusting or collecting dust.

Items to prepare
• Hexagon wrench [6 mm (0.236 in)]
• Hammer
• Wire clip
• Pliers
• Gear puller
• Screwdriver
• Gear oil (Mobile Gear Oil SHC320)
• Specialty jigs
• Pressing machine
• Loctite
• Special fiber cloth (Kimwipe)
• Micrometer caliper
• Caliper
• Cylinder gauge

84592788 EN - March 2012

5003D-3
Copyright ©
Assembly and Disassembly of Lower Roller

Configuration Diagram

Part Part
Part name Q'ty Part name Q'ty
number number
KNA10 KNA07
1 Roller 1 6 Collar (with plug) 1
930 08
KNA07 KHJ030
2 Shaft 1 7 Plug with seal nylon 1
07 0
KNA05 KAA024
3 Bushing 2 8 Wire clip 2
39 8
KMA07 KNA07
4 Floating seal 2 9 Collar (without plug) 1
55 87
BLA238
5 O-ring 1A-G45 2
1

84592788 EN - March 2012

5003D-4
Copyright ©
Assembly and Disassembly of Lower Roller

Dimension Diagram

84592788 EN - March 2012

5003D-5
Copyright ©
Assembly and Disassembly of Lower Roller

Jig Dimension Diagram

A Bushing removal jig

B Bushing press-fit jig
C Floating seal installation jig

84592788 EN - March 2012

5003D-6
Copyright ©
Assembly and Disassembly of Lower Roller

Disassembly Procedures
1. Stand the roller vertically and use a hexagon
wrench [6 mm (0.236 in)] (1) to remove the plug (2).
• The plug is coated with seal nylon, which comes
off when the plug is removed.
To reuse the plug, using seal tape is necessary.

4. Use pliers (2) to remove the pushed out wire clip (1).

2. Face down the part of the roller from which the

plug was removed and empty the oil from within the
roller.
• It may take a few hours to completely empty the
oil.
• Place an oil pan (1) underneath to catch the oil.
• Securely fasten so that the roller does not fall
over. 5. Use a gear puller (2) to remove the collar (1).
If the collar is difficult to remove, hook the collar on
the bolt and catch the puller on that part.
• If the collar has rusted or is difficult to remove due
to an accumulation of debris, subject it to a shock,
for example by hitting it with a hammer, to make
it easier to move.
• When hitting it with a hammer, be careful not to
dent it.

3. Tap another wire (2) with the hammer (3) from the
outside to push out the wire clip that is already in
the roller.
• Place the roller horizontally and secure it so it
does not roll before doing this work.
• The wire in the roller is very securely fixed, so
prepare several wire clips.
Also be sure to coat with lubricant.

84592788 EN - March 2012

5003D-7
Copyright ©
Assembly and Disassembly of Lower Roller

6. Check whether the surface of the floating seal (2) 9. Remove the shaft (1).
sliding against the removed collar has rusted or is
damaged.
Also make sure the O-ring (3) on the floating seat
(4) is not twisted.
• The O-ring cannot be reused.
Replace it with new part.

10. As described in step 7, remove the floating seal (1)

on the opposite side.

7. Remove the floating seal (1) on the roller.

As described in step 6, check whether the sliding
surface has rusted or is damaged.
Also make sure the O-ring is not twisted.

11. Use a caliper (6), micrometer caliper (5), and cylin-

der gauge (7) to measure the roller (with bushing)
(1), collars (2) (3), and shaft (4) for wear and defor-
mation.

8. Remove the O-ring (2) on the shaft (1).

• The O-ring cannot be reused.
Replace it with new part.

84592788 EN - March 2012

5003D-8
Copyright ©
Assembly and Disassembly of Lower Roller

12. When replacing a bushing, insert jig A (3) into the Assembly Procedures
bushing (1), and use a cylindrical object (such as a
shaft) (2) to push from the top. 1. Clean all parts by immersing them in cleaning fluid
The bushing comes off. (1).
• Select a clean location.
• Place a rubber plate or cloth on the work platform
so as not to damage the parts.

2. After cleaning the parts, air blow them to remove

any remaining cleaning fluid or debris.

3. If the bushing (2) was removed during disassembly,

put it into the roller (1).
Restraining from above using jig B (3), push in with
the pressing machine (4).
Invert the roller and insert the bushing on the oppo-
site side in the same manner.

84592788 EN - March 2012

5003D-9
Copyright ©
Assembly and Disassembly of Lower Roller

4. Use jig C (5) to push the floating seal (4) into the 7. Attach O-rings (3) to the shaft (2) and mount into the
collars (2) (3) and roller (1) by hand. roller (1).

Removal and Installation of the Sprocket

84592788 EN - March 2012

CONTENTS

Removal of Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

5004-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

5004-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of the Sprocket

WARNING Removal of Sprocket

• When loosening the check valve, loosen it a 1. Allow the bucket (1) to touch the ground so as to
little at a time and stop when any grease ap- elevate the shoe (2) of the side to be removed as in
pears. the diagram on the right.
The pressure inside the cylinder is very high,
so there is the danger of grease being ex-
pelled and the plug flying off if the check
valve is loosened too much.

CAUTION
• Before removing the shoes, be sure to bleed
off any air in the hydraulic circuits.
• Be sure to inspect the wire rope and other
lifting equipment before beginning work.
• Do not stand or pass under the suspended
load.

Items to prepare 2. Slowly rotate the shoe so that the shoe joint section
(1) is aligned as in the diagram on the right.
• Box wrenches [ 19 mm ( 0.748 in ) ] Place wood plank (2) under the shoe and return the
• Wrenches [ 19 mm ( 0.748 in ), 24 mm ( 0.945 in ) ] bucket to its original position.
• Hammer (to remove the master pin) Perform air bleeding for the hydraulic line.
• Striking jig (to remove the master pin) For details, see Air Bleed Procedures.
• Liftcrane (with the required lifting capacity)
• Wire rope (with the required breaking load)
• Loctite #262
• Wood plank
• Rag
• Cleaning fluid

84592788 EN - March 2012

5004-3
Copyright ©
Removal and Installation of the Sprocket

3. Use a box wrench [19 mm (0.748 in)] to rotate the 5. Place a striking jig (2) against the master pin (1) and
grease cylinder check valve (1) and loosen the shoe hit it with a hammer (3) to push the master pin out.
tension.
• Grease will flow out, so have rag ready.
If the check valve is loosened too much at this
time, it may fly off.
Be careful not to work in front of the check valve.

6. Open the shoe (1) to the rear.

7. Use a wrench [24 mm (0.945 in)] to remove the 15

bolts (1).

4. Pull out the S-pin (1) from the rear of the joint sec-
tion.

84592788 EN - March 2012

CONTENTS

Removal of Take-up Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Take-up Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

5005A-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

5005A-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Take-up Roller

WARNING Removal of Take-up Roller

• When loosening the grease cylinder check 1. Remove the shoe assembly.
valve, loosen it a little at a time. See the "Removal and Installation of Shoe Assem-
• The pressure inside the cylinder is very high, bly".
so there is a danger of grease being expelled 2. Use a crowbar (3) to pull off the take-up roller (1)
and the plug flying off. and recoil spring assembly from the side frame (2).
The check valve adjustment procedure
should not be done in front of the check
valve.
• Do not get under the machine when the main
unit is jacked up.
• Make sure to place the main unit on wood
planks or the like to prevent falling.
• Align the shoe assembly feed location and
stop the engine except when working.

Items to prepare
• Wrench [ 24 mm ( 0.945 in ) ]
• Hammer
• Lifting equipment 3. Lift up the take-up roller (1) and recoil spring assem-
• Loctite #262 bly (3) and hang them from the side frame (2) with
• Striking jig the liftcrane and lifting equipment (4).
• Liftcrane
• Crowbar
• Wood planks, etc.
• Rag

4. Place the take-up roller (1) and recoil spring assem-

bly (2) onto wood planks (4) as in the diagram.
Use a wrench [24 mm (0.945 in)] to remove the
take-up roller bolt (3), and separate the roller (1) and
the recoil spring assembly (2).

84592788 EN - March 2012

5005A-3
Copyright ©
Removal and Installation of Take-up Roller

Installation of Take-up Roller 2. Lift up the take-up roller (1) and recoil spring assem-
bly (3) and insert them into the side frame (2) with
1. Place the take-up roller (1) and recoil spring assem- the liftcrane and lifting equipment (4).
bly (2) onto wood planks (4) as in the diagram. Use Push in with the crowbar until the recoil spring as-
a wrench [24 mm (0.945 in)] to fasten the take-up sembly contacts the grease cylinder.
roller (1) and recoil spring assembly (2) with the bolt
(3).
At this time, be sure to coat the bolt with Loctite
#262.
Installation bolt tightening torque: 267 - 312 N·m
(196.96 - 230.16 lbf·ft)

3. Install the shoe assembly.

For details on installation, see the "Removal and
Installation of Shoe Assembly" procedure.

84592788 EN - March 2012

5005A-4
Copyright ©

Section

5005B

Assembly and Disassembly of Take-up Roller

84592788 EN - March 2012

CONTENTS

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

5005B-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

5005B-2 PRINTED IN FRANCE
Copyright ©
Assembly and Disassembly of Take-up Roller

CAUTION • Seal tape

• Oil pan (drip pan)
• To ensure safe operations, wear protective • Water container for inspection
devices before beginning work and follow all
precautions.
• When removing devices or positioning de-
vices at the time of installation, use a removal
jig and a hammer or steel rod.
• Follow the precautions below when suspend-
ing the load.
• The liftcrane must be operated by a quali-
fied operator.
• Do not stand or pass under the suspended
load.
• Check the weight of the roller to deter-
mine whether it can be carried by hand or
whether a liftcrane must be used.
• Fix the roller to a level surface so it does not
roll.
• Be sure to repair any parts damaged during
disassembly, and prepare replacement parts
in advance.
• If any parts are significantly rusted or dirty,
clean them before disassembling.
• Any foreign matter entering the equipment
during assembly can create a malfunction.
Therefore, after thoroughly cleaning the
equipment with cleaning oil, air blow the
equipment, and assemble in a clean location.
• When assembling sliding parts, be sure to
coat them with new hydraulic oil.
• As a rule, replace all O-rings and other seal
parts with new parts.
• The take-up roller is a heavy object and re-
quires at least 2 workers to handle.
<General cautions>
• Be careful not to drop precision parts or let
bump them with other parts during work.
• Do not forcefully open or hit parts in an effort
to speed up operations. Pay careful attention
and proceed slowly so as not to damage any
parts, create any oil leaks, or compromise the
efficiency of the equipment, etc.
• Disassembled parts can easily rust or collect
dust. Therefore, immediately after disassem-
bling parts, take precautions to prevent the
parts from rusting or collecting dust.

5005B-6
Copyright ©
Assembly and Disassembly of Take-up Roller

Disassembly Procedures 3. Use the hammer (1) and pin removal jig (2) to re-
move the hub pin (4) from the hub (3).
1. After cleaning the roller with kerosene, use the
hexagon wrench (1) to remove the plug (2) from • Securely fasten the roller before doing this work.
the hub (3). • As it is very securely fixed, apply lubricant before
beginning work.
• The plug is coated with seal nylon, which comes
off when the plug is removed. Seal tape is neces-
sary for reusing.

4. Use a gear puller (1), to remove the hub (2).

• If the hub has rusted or is difficult to remove due
to an accumulation of debris, subject it to a shock,
for example by hitting it with a hammer, to make
it easier to move.
• When hitting it with a hammer, be careful not to
dent it.

2. Face down the part of the roller from which the

plug was removed and empty the oil from within the
roller.
• It may take a few hours to completely empty the 5. Check whether the surface of the floating seal (1)
oil. sliding against the removed hub has rusted or is
• Place an oil pan (1) underneath to catch the oil. damaged. Also make sure the O-ring (2) on the
floating seat (3) is not twisted.
• The O-ring cannot be reused. Replace it with new
part.
• Replace floating seats that have rust, deforma-
tions with new ones.

84592788 EN - March 2012

5005B-7
Copyright ©
Assembly and Disassembly of Take-up Roller

7. Remove the O-ring (2) on the shaft (1).

• The O-ring cannot be reused. Replace it with new
part.

8. Remove the hub (1) and shaft (2) on the opposite

side, and secure the shaft (2) in a vise.
As described in steps 3 - 5, remove the hub (1) on
the opposite side and check that the sliding surface
of the floating seat of the floating seal is not rusted
and that the O-ring is not twisted.

6. Remove the floating seal (1) on the roller. As de-

scribed in step 5, check whether the sliding sur-
face has rusted or is damaged. Also make sure the
O-ring is not twisted.

9. As described in step 6, remove the floating seal (1)

on the opposite side.

84592788 EN - March 2012

5005B-8
Copyright ©
Assembly and Disassembly of Take-up Roller

10. Use a micrometer caliper (5), cylinder gauge (4), 11. When replacing the bushing (1), remove it by plac-
and caliper (6) to measure the roller (with bushing) ing a striking rod (2) against the end surface and
(1), hub (2), and shaft (3) for wear and deformation. striking that with a hammer (3) uniformly left and
Replace with new parts as necessary. right as in the diagram.
• Be careful not to scratch the inside of the roller
when striking the end of the bushing.

12. Invert the roller (1), use jig A (4) to push up against
the bushing (2), and press with a rod-shaped object
(3) (such as a shaft). The bushing comes off.

84592788 EN - March 2012

5005B-9
Copyright ©
Assembly and Disassembly of Take-up Roller

Assembly Procedures 4. Use the jigs (2) (3) attached to the pressing machine
to attach the bushing (1). Use the pressing machine
1. Clean all parts. to press from the opposite side. Next, use a special
fiber cloth to remove all dust and debris.
• Find a clean location.
• Place a rubber plate or cloth on the work platform
so as not to damage the parts.
• In order to clean off adhered matter that forms
sharp points and causes scratches, immerse
parts in cleaning fluid (1) until dirt and grease
float to the top.

2. After cleaning the parts, air blow them to remove

any remaining cleaning fluid or debris.
• If the parts are to be left as is for a long time after
drying them, apply engine oil.

5. Attach the floating seal (2) to the hub (1). Use jig C
(3) to press it into position.

3. If the bushing (2) was removed during disassembly,

put it into the roller (1). Use a pressing machine (3)
to press in both the left and right sides.

84592788 EN - March 2012

5005B-10
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Assembly and Disassembly of Take-up Roller

6. Use jig C (3) to attach the floating seal (2) to the 9. After attaching the O-ring (4) to the shaft (1), attach
roller (1) side. the shaft to the hub (2) and fasten it with the hub pin
(3).

7. Use a special fiber cloth to thoroughly wipe the slid-

ing surface of the floating seal to prevent any dust 10. Attach the shaft (2) to the roller (1).
or scratches.

11. Install the opposite side hub (1) on the roller (2) and
8. Apply engine oil to the floating seals (1) on the hubs fasten with the hub pin (3).
(2) (3).

84592788 EN - March 2012

5005B-11
Copyright ©
Assembly and Disassembly of Take-up Roller

12. Inject compressed air [ 0.2 MPa ( 29.011 psi ) ] from 14. After filling the oil, use a hexagon wrench [ 6 mm (
the oil fill port and immerse in water to check that 0.236 in ) ] (2) to tighten the plug (1) with the nylon
there are no leaks. seal applied.
• To reuse a plug, wrap it with seal tape.

13. Fill engine oil (120 cc) into the roller main unit.
• The roller main unit can be very unstable, so be
careful in securing it.

84592788 EN - March 2012

5005B-12
Copyright ©

Section

5005C

Removal and Installation of Grease Cylinder

84592788 EN - March 2012

CONTENTS

Removal of grease cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of grease cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

5005C-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

5005C-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Grease Cylinder

WARNING Removal of grease cylinder

• When loosening the grease cylinder check 1. Remove the shoe assembly.
valve, loosen it a little at a time. See the "Removal and Installation of Shoe Assem-
• The pressure inside the cylinder is very high, bly" procedure.
so there is a danger of grease being expelled 2. Use a crowbar (3) to pull off the take-up roller (1)
and the plug flying off. and recoil spring assembly about 100 mm (3.937
The check valve adjustment procedure in) from the side frame (2).
should not be done in front of the check When removing the grease cylinder, use a wood
valve. plank (4) or the like to prevent the take-up roller (1)
• Do not get under the machine when the main and recoil spring assembly from coming out.
unit is jacked up.
• Make sure to place the main unit on wood
planks or the like to prevent falling.
• Align the shoe assembly feed location and
stop the engine except when working.

Items to prepare
• Wrench [24 mm (0.945 in)]
• Hammer
• Lifting equipment
• Loctite #262
• Striking jig
• Striking jig
• Crowbar 3. Jack up the shoe about 5 cm (1.969 in) and insert
• Wood planks, etc. the wood plank (1) under the lower frame as shown
• Rag in the diagram to prevent falling.

4. Use a wrench [24 mm (0.945 in)] to remove the bolts

(1), and then remove the track guard (3).

84592788 EN - March 2012

5005C-3
Copyright ©
Removal and Installation of Grease Cylinder

5. Install the wire (2) on the grease cylinder assem- Installation of grease cylinder
bly (1), and then lift it with the liftcrane so that it is
slightly tensed. To install, perform the reverse of the removal procedure.
Grease cylinder and track guard installation bolt tighten-
ing torque: 267 - 312 N·m (196.96 - 230.16 lbf·ft)
When installing bolts, coat the threaded sections with
Loctite #262.

6. Use a wrench or box wrench [24 mm (0.945 in)] to

remove the bolt (1) , and then remove the grease
cylinder (3).
Lower the liftcrane as is to lower to under the frame,
and then take out from between the lower rollers.

84592788 EN - March 2012

5005C-4
Copyright ©

Section

5005D

Assembly and Disassembly of Tension Shock Absorber

84592788 EN - March 2012

CONTENTS

Configuration diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Dimension diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Jig dimension diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Assembly procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

5005D-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

5005D-2 PRINTED IN FRANCE
Copyright ©
Assembly and Disassembly of Tension Shock Absorber

CAUTION
• To ensure safe operations, wear protective
devices before beginning work and follow all
precautions.
• When removing devices or positioning de-
vices at the time of installation, use a removal
jig and a hammer or steel rod.
• Follow the precautions below when suspend-
ing the load.
• The liftcrane must be operated by a quali-
fied operator.
• Do not stand or pass under the suspended
load.
• Check the weight of the grease cylinder to
determine whether it can be carried by hand
or whether a liftcrane must be used.
• Be sure to repair any parts damaged during
disassembly, and prepare replacement parts
in advance.
• If any parts are significantly rusted or dirty,
clean them before disassembling.
• Any foreign matter entering the equipment
during assembly can create a malfunction.
Therefore, after thoroughly cleaning the
equipment with cleaning oil, air blow the
equipment, and assemble in a clean location.
• When assembling touching parts, be sure to
coat them with new hydraulic oil.
• As a rule, replace all O-rings and other seal
parts with new parts.
General cautions
• Be careful not to drop precision parts or let
bump them with other parts during work.
• Do not forcefully open or hit parts in an effort
to speed up operations.
Pay careful attention and proceed with cau-
tion so as not to damage any parts, create any
oil leaks, or compromise the efficiency of the
equipment.
• Disassembled parts can easily rust or collect
dust.
Therefore, immediately after disassembling
parts, take precautions to prevent the parts
from rusting or collecting dust.

Items to prepare
• Hammer
• Wrenches [ 19 mm ( 0.748 in ) ]
• Box wrench [ 19 mm ( 0.748 in ) ]
• Screwdriver
• Specialty jigs
• Special fiber cloth (Kimwipe)
• Marking pen

84592788 EN - March 2012

5005D-3
Copyright ©
Assembly and Disassembly of Tension Shock Absorber

Configuration diagram

Code Part name Q'ty Code Part name Q'ty

1 Dust seal 1 6 High-strength bolt 1
2 Piston rod 1 7 Spring washer 1
3 U-packing 1 8 Bracket 1
4 Retaining ring 1 9 Check valve assembly 1
5 Grease cylinder 1

84592788 EN - March 2012

5005D-4
Copyright ©
Assembly and Disassembly of Tension Shock Absorber

Dimension diagram

Jig dimension diagram

84592788 EN - March 2012

5005D-5
Copyright ©
Assembly and Disassembly of Tension Shock Absorber

A Dust seal press-fit jig Disassembly procedures

B Removal jig
1. Clean the grease cylinder with kerosene, remove
the bolt (1) and washer (2), and remove the bracket
(3).
Remove the check valve (5) from the grease cylin-
der (4).

2. Pull out the piston rod (2) from the grease cylinder
(1).

3. Use the removal jig (B) to remove the dust seal (2)
from the grease cylinder (1).

84592788 EN - March 2012

5005D-6
Copyright ©
Assembly and Disassembly of Tension Shock Absorber

4. Remove the retaining ring (2) from the piston rod Assembly procedures
(1), and then use the removal jig (B) to remove the
U-packing (3). 1. Place parts in a rough cleaning container filled with
kerosene to clean off any adhered matter that can
form sharp points and cause scratches.
• Immerse in kerosene until dust, grease, and other
adhered matter comes off and floats to the sur-
face.
2. Place parts in a finish cleaning container filled with
kerosene and clean while gently moving the parts.
After cleaning, wipe away the kerosene with a clean
rag.
• Place the parts in a location free of dust and mois-
ture and use compressed air to dry the parts. After
drying, coat parts with engine oil.
3. Install the U-packing (1) coated with grease onto the
piston rod (2), and then install the retaining ring (3).
• Use a new U-packing (1).
• Be careful that the U-packing (1) faces correctly.

84592788 EN - March 2012

5005D-7
Copyright ©
Assembly and Disassembly of Tension Shock Absorber

4. Use the jig (A) and hammer (C) to install the dust 5. Coat the surface of the piston rod (1) with grease
seal (2) on the grease cylinder (1). and insert into the grease cylinder (2).
Apply grease to the lip section of the dust seal (2).
• Use a new dust seal (2).

6. Tighten the check valve (1) to the grease cylinder

(2) to the specified tightening torque.
Install the bracket (3), and secure it and the spring
washer (4) together with the bolt (5).
Check valve tightening torque: 48.99 - 68.61 N·m
(36.1394 - 50.6128 lbf·ft)

This completes the assembly.

84592788 EN - March 2012

5005D-8
Copyright ©

Section

6001

Removal and Installation of Travel Motor

84592788 EN - March 2012

CONTENTS

Removal of Travel Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

6001-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

6001-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Travel Motor

WARNING Removal of Travel Motor

• When loosening the check valve, loosen it a 1. Allow the bucket (1) to touch the ground so as to
little at a time and stop when any grease ap- elevate the side with the shoe (2) to be removed as
pears. in the diagram.
The pressure inside the cylinder is very high,
so there is the danger of grease being ex-
pelled and the plug flying off if the check
valve is loosened too much.

Items to prepare 2. Slowly rotate the shoe so that the shoe joint section
(3) is aligned as in the diagram.
• Box wrenches [19 mm (0.748 in)] Place wood planks (4) under the shoe and return
• Wrenches [19 mm (0.748 in), 27 mm (1.063 in), 36 mm the bucket to its original position.
(1.417 in)] Perform air bleeding for the hydraulic line.
• Hammer (to remove the master pin) For details, see Air Bleed Procedures.
• Striking jig (to remove the master pin)
• Liftcrane (with the required lifting capacity)
• Wire rope (with the required breaking load)
• Loctite #262
• Wood planks, etc.
• Rag
• Cleaning fluid

84592788 EN - March 2012

6001-3
Copyright ©
Removal and Installation of Travel Motor

3. Use a box wrench [19 mm (0.748 in)] to rotate the 5. Place a striking jig (9) against the master pin (7) and
grease cylinder check valve (5) and loosen the shoe hit it with a hammer (8) to push the master pin out.
tension.
• Grease will flow out, so have rag ready.
If the check valve is loosened too much at this
time, it may fly off. Be careful not to work in front
of the check valve.

6. Open the shoe (2) to the rear.

7. Use a wrench [19 mm (0.748 in) ] to remove the 4

bolts (10), then remove the cover (11).

4. Pull out the S-pin (6) from the rear of the joint sec-
tion.

84592788 EN - March 2012

6001-4
Copyright ©
Removal and Installation of Travel Motor

8. Use wrenches [27 mm (1.063 in) for drain hose, 36 10. Attach the wire rope (17) to the travel motor (16) as
mm (1.417 in) for high-pressure hose ] to remove in the diagram.
the drain hose (13) and 3 high-pressure hoses (12). Adjust the wire rope so that it is located at the center
of mass and lift it with the liftcrane so that it is slightly
• Be sure to use plugs on the removed drain and tensed.
high-pressure hoses.

11. Use a box wrench [24 mm (0.945 in)] to remove all

9. Use a wrench [17 mm (0.669 in)] to remove the pilot 18 bolts (18).
hoses (15) (14) shown in the diagram.

12. Remove the travel motor (16).

84592788 EN - March 2012

6001-5
Copyright ©
Removal and Installation of Travel Motor

Installation of Travel Motor 3. Use a wrench [17 mm (0.669 in)] to remove the el-
bow joint (3) and pilot hose (4) shown in the dia-
1. Attach the travel motor to the lower frame as in the gram.
diagram.
• Be careful of the installation angles.

2. Apply Loctite #262 to the installation bolt (2)

threaded sections and temporarily tighten all 18
bolts.
Use a wrench [24 mm (0.945 in)] to tighten the top
and bottom alternately to the specified torque so
that an even tightening force acts on the opposing
sides.
Tightening torque M16: 267 - 312 N・m (196.97 -
230.15 lbf・ft)

4. Use wrenches [27 mm (1.063 in) for drain hose, 36

mm (1.417 in) for high-pressure hose] to install the
drain hose (6) and high-pressure hose (5).

84592788 EN - March 2012

6001-6
Copyright ©
Removal and Installation of Travel Motor

5. Use a wrench [19 mm (0.748 in)] to install the cover 8. Tighten the check valve (12).
(8) with the 4 bolts (7). While monitoring the track shoe tension, inject
grease into the grease cylinder.

6. Wrap the shoe (9).

9. When adjusting the track shoe tension, raise the
lower side frame as shown in the diagram.
Place a wood plank (13) under the lower frame to
prevent falling.
Adjust the tension so that the distance indicated
with A between the frame bottom (14) of the center
area of the lower side frame and the lowest hang-
ing part of the top of the shoe plate (15) is 290 - 310
mm (11.418 - 12.204 in).

7. Insert the master pin (11).

Insert the S-pin (10) and bend it so that it cannot slip
out.

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Removal and Installation of Travel Motor

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6001-8
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Section

6002

Assembly and Disassembly of Travel Motor

Title num-
Part name Nominal size Bolt width [mm (in)] Tightening torque
ber
127 - 147 N·m
30357 Plug PF1/2 10 (0.394)
(93.69 - 108.44 lbf·ft)
98 - 118 N·m
35 Hexagon socket head bolt M10 (P1.5) 8 (0.315)
(72.30 - 87.04 lbf·ft)
Sleeve (relief valve attach- 353 - 393 N·m
203 PF1/2 24 (0.94 )(socket)
ment) (260.41 - 289.91 lbf·ft)
8.8 - 10.8 N·m
205 Plug PF1/4 6 (0.23 )
(6.492 - 7.967 lbf·ft)
112 - 124 N·m
324 Plug M36 (P1.5) 41 (1.61 )(socket)
(82.63 - 91.47 lbf·ft)
112 - 124 N·m
343 Hexagon socket head bolt M12 (P1.75) 10 (0.394)
(82.63 - 91.47 lbf·ft)
1.96 - 2.94 N·m
352 Plug PF1/8 5 (0.197)
(1.4459 - 2.1688 lbf·ft)
1.96 - 2.94 N·m
354 Hexagon socket head bolt NPTF1/16 4 (0.157)
(1.4459 - 2.1688 lbf·ft)
1.96 - 2.94 N·m
380 Plug PF3/8 8 (0.315)
(1.45 - 2.16 lbf·ft)
34.3 - 39.3 N·m
396 Hexagon socket head bolt PT1/4 6 (0.236)
(25.303 - 28.991 lbf·ft)
195 - 215 N·m
398 Hexagon socket head bolt PT1/8 5 (0.197)
(143.85 - 158.60 lbf·ft)

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Assembly and Disassembly of Travel Motor

Disassembly Procedure 2) Loosen and remove the hexagon socket head

bolts (35).
1. Cleaning of travel motor 3) The matching surfaces of the cover (14) and
1) Attach eyebolts into the M16 threaded holes hub (1) are coated with sealant, so place a
of the spindle (2), and lift the travel motor with metal pin against the projected part of the
a crane and move it to the cleaning tank. cover and strike it sideways and upwards to
remove the cover.
• So that the 2 eyebolts are in opposing posi-
tions, tighten them into the spindle installa- CAUTION
tion M16 threaded holes.
The cover may fly upwards and fall
2) Clean each travel motor part with a vehicle when it is struck sideways and up-
washing brush. wards. Be careful that the cover does
• Dirt enters the gap (floating seal installation not fall on feet or other parts of the
section) between the hub (1) and spindle body.
(2), so clean this area especially thoroughly.
2. Installation of travel motor
1) Install the travel motor on the work platform.
• While aligning the travel motor with the
threaded holes on the spindle (2) and on
the work platform, gently insert the travel
motor into the installation holes on the work
platform.
2) Install the travel motor on the work platform
so that the 2 hexagon socket head bolts are
in opposing positions.

CAUTION
4) Install eyebolts into the PF1/2 ports and lift the
Thoroughly tighten the hexagon socket cover (14) from the hub and move it.
head bolts. If they are not thoroughly
tightened, the travel motor can fall and
cause injury when it is inverted.

3. Lubricating oil draining

1) Turn the travel motor sideways. (Make the
drain port face down.)
2) Loosen the feed port plugs (30), bleed out
pressure inside the reduction gear, and lightly
close the plugs again.
• Lubricating oil may spray out if the inside of
the reduction gear is pressurized when the
drain port plug is loosened.
3) Place a container in front of the drain port, 5. Removal of thrust plate
slowly loosen the drain port plug to remove it, 1) Remove the thrust plate (13).
and drain the lubricating oil.
• Select a container that can hold 2.1 L (0.555
gal) - the amount of lubricating oil within the
reduction gear.
4) If the lubricating oil drains poorly, slowly
loosen and remove the feed port plug.
5) Remove the O-rings (31) from the removed
plugs.
• Do not reuse the removed O-rings (31).
This can cause oil leaks.
4. Removal of cover
1) Invert the travel motor. (reduction gear side
faces up) 6. Removal of 1st stage gears

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Assembly and Disassembly of Travel Motor

1) Hold the sun gear 1 (4) and remove it. 1) Install eyebolts into the 3 lifting M12 tap lo-
cations of carrier 2 (7), and lift and move the
• The sun gear 1 may be slippery due to lubri- carrier 2 assembly with a crane.
cating oil, so be careful not to drop it.
• When lifting the carrier 2 assembly, slowly
lift with the center axis of the hub (1) and
carrier 2 assembly straight so that the inter-
nal teeth of the hub are not scratched by the
end surface of the planetary gears 2 (9).
2) Hold the sun gear 2 (8) and remove it.
• The sun gear 2 may be slippery due to lubri-
cating oil, so be careful not to drop it.

2) Install bolts onto the 3 carrier 1 (3) lifting M12

taps, and lift and move the carrier 1 assembly
with a crane.
• When lifting the carrier 1 assembly, slowly
lift with the center axis of the hub (1) and
carrier 1 assembly straight so that the inter-
nal teeth of the hub are not scratched by the
end surface of the planetary gears 1 (5).
9. Removal of lock washer
1) Use the D14 mm (0.551 in) hole on the hub
(1) and secure the inversion platform.

7. Removal of coupling
1) Remove the coupling (15) from the shaft
(102).
2) Place an object like a flathead screwdriver in
the gap between 2 lock washers (22) and tap
on it sideways and downwards with a hammer
to remove the lock washers.

8. Removal of 2nd stage gears

10. Removal of hub

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Assembly and Disassembly of Travel Motor

1) Remove the hexagon socket head bolt secur- 1) Place a pin punch against the outer race end
ing the hub and inversion platform. surface of the angular ball bearing (24) and
2) Install eyebolts (M10) into the hub and lift the strike the circumference equally in intervals at
hub with a crane. 3 or 4 locations to remove it little by little.

WARNING • The track surface of the angular ball bearing

will become scratched if the inner race is
Hold the hub parallel with the spindle struck and this will make the ball bearing
axis and slowly lift it little by little. unusable, so do not perform removal other
Lifting sideways requires a gre than when the angular ball bearing is to be
k and can result in injuries due to replaced.
workers being struck by lifting equip- The ball bearing will fall from the hub if the
ment. When lifting does not proceed outer race bonding section of the angular
easily, rather than lifting with greater ball bearing is detached from the hub (1), so
force, use a press and confirm safety place a container under the work platform
while lifting. and place a rubber mat on it so that parts
are not scratched.

11. Removal of floating seal 13. Removal of rear flange

1) Place hands on the inner diameter side of the 1) Invert the travel motor. (motor faces up)
floating seals (29) and force it upwards to re-
move it. • The next operation is to make the plugs
easy to remove when the inside of the rear
• The edge of the floating seal can cause cuts flange is disassembled. At this time, loosen
on hands. Wearing gloves for removal is the plugs to a degree so that they can be re-
recommended. Also, if dirt, etc. has gotten moved by hand. When the inside of the rear
inside and adhered to the surface, use an flange is not disassembled, do not loosen
object like a flathead screwdriver and use the plugs.
leverage to remove the dirt.
2) Loosen the 2 plugs (324).
• This operation is to make the plugs easy to
remove when the inside of the rear flange is
disassembled. When the inside of the rear
flange is not disassembled, do not loosen
the plugs.

12. Removal of angular ball bearing

3) Loosen the 2 plugs (380).

4) Loosen the 2 plugs (352).
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Assembly and Disassembly of Travel Motor

5) Loosen the plug (357). 9) Remove the rear flange (301) from the spindle
(2).
• Note:
Hold the rear flange with both hands and
gently lift it directly upwards to remove it.
If the rear flange is pried off with excessive
force or struck in order to remove it, the tim-
ing plate (109) can fall and this can cause
damage.

6) Loosen the 2 relief valve assemblies (201 -

213).

10) Remove the 2 parallel pins (34) from the spin-

dle (2).

7) Remove the 2 relief valve assemblies (201 -

213).
• Do not reuse the removed O-rings (207),
(209), (212) or backup rings (208), (210).

11) Remove the O-ring (32) and the 2 O-rings (33)

from the spindle (2).
• Do not reuse the removed O-rings (32) and
(33).

8) Loosen the 10 hexagon socket head bolts

(343) and remove them from the rear flange
(301).

14. Disassembly of parts mounted on rear flange

1) Place the rear flange (301) on the work plat-
form so that the surface matching with the
spindle (2) faces up.

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Assembly and Disassembly of Travel Motor

2) Remove the rear flange (301) from the timing 1) Remove the 2 plugs (324) from the rear flange
plate (109). (301).
2) Remove the 2 washers (325) and 2 springs
• Stiffness may occur during removal due (328) from the rear flange (301).
to adherence of oil on the surface that
matches with the rear flange (301). By in-
sert a scoop into the casting grooves of the
rear flange (301) side matching surface, the
timing plate (109) can be removed by lightly
lifting it. Do not use sharp tools such as a
screwdriver for insertion into the matching
surface, as these can cause scratches that
can result in oil leaks.

3) Remove the spool (323) from the rear flange

(301).
• Hold the end of the spool (323) and pull it
out because it will slip out and fall if the plug
port on one side of the rear flange (301) is
titled downwards.

3) Remove the ball bearing (150) from the rear

flange (301).

4) Remove the O-rings (336) from the plugs

(324).
• Do not reuse the removed O-rings (336).
4) Remove the parallel pins (341) from the rear
flange (301).

16. Disassembly of 2nd-speed switchover spool

1) Remove the plug (357) from the rear flange
15. Disassembly of brake valve parts within the rear (301).
flange

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Assembly and Disassembly of Travel Motor

2) Remove the plug (357) from the O-ring (359). 3) Remove the rear flange (301) from the piston
(381).
• Do not reuse the removed O-ring (359).

3) Remove the spool (363) and spring (366) from 18. Disassembly of check ball section
the rear flange (301). 1) Remove the 2 plugs (352) from the rear flange
(301).
2) Remove the O-rings (358) from the plugs
(352).
• Do not reuse the removed O-rings (358).

17. Disassembly of piston

1) Remove the 2 plugs (380) from the rear flange
(301).
2) Remove the O-rings (383) from the plugs
(380). 3) Remove the steel balls (353) from the rear
flange (301).
• Do not reuse the removed O-rings (383).
• If the steel ball is difficult to remove, use a
magnet to remove it.

19. Disassembly of parking brake section

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Assembly and Disassembly of Travel Motor

CAUTION 1) Tilt the travel motor 90°.

2) Drain the oil inside the travel motor.
If compressed air is suddenly injected, the 3) Remove the 4 partner plates (116) and 3 fric-
piston (112) can fly from the spindle (2) and tion plates (115).
cause injury, so place a protective cover
over the piston (112).

1) Inject compressed air into the path hole for

the spindle (2) parking brake, and remove the
piston (112) from the spindle (2).

4) Hold the cylinder block (104) with one hand

and rotate it alternately 2 - 3 times to detach
the shoes (106) attached to the swash plate
(103).
• If the cylinder block is removed as is, the
parts attached to the cylinder block (pistons
2) Remove the O-rings (135) and (139) from the (105), shoes) will become detached from
piston (112). the cylinder block and fall inside the spin-
• Do not reuse the removed O-rings (135) and dle (2) because the shoe is attached to the
(139). swash plate.

5) Remove the cylinder block (104) from the

20. Disassembly of hydraulic motor parts shaft (102).
• Oil will spill out when the travel motor is turned
sideways, so place a container under the travel
motor.

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Assembly and Disassembly of Travel Motor

Reference value Permissible limit

Part
Part name Symptom (standard di- value
number
mensions) (judgment value)
• Significant external damage.
(1) Hub • Pitching on ring gear tooth surfaces. _ _
• Abnormal wear due to seizing.
• Significant external damage.
(2) Spindle _ _
• Abnormal wear due to seizing.
(3) and
Carrier assembly • Abnormal wear due to seizing. _ _
(7) etc.
(4) Sun gear 1
• Pitching on tooth surfaces.
(8) Sun gear 2
• Flaking symptoms appearing on rolling _ _
(5) Planetary gear 1 surface of bearing.
(9) Planetary gear 2
• Indentations present.
(24) Ball bearing • Flaking symptoms appearing. _ _
• Uneven wear.
• Scratches on sections that slide against
(301) Rear flange _ _
spools (323), (363) and piston (381).
• Surface in contact with oil seal (132) worn.
(102) Shaft _ _
• Spline worn.
(103) Swash plate • Seizing symptoms present. _ _
• Spline section worn.
• Significant wear on bore inner surface.
(104) Cylinder block _ _
• Scratches or uneven wear on surface that
slides against timing plate (109).
• Gap in axis direction of pistons (105) and
Piston assembly shoes (106). Gap 0.05 mm Gap 0.15 mm
(105) Piston Abnormal wear and uneven wear on shoes
• [0.00197 in] [0.00591 in]
(106) Shoe (106).
• Uneven wear on sections that slide against
shoes (106).
(107) Retainer plate _ _
• Scratches or wear on surface that slides
against thrust ball (108).
• Uneven wear on spherical section that
(108) Thrust ball _ _
slides against the retainer plate (107).
• Seizing symptoms and uneven wear on
(109) Timing plate _ _
sliding surfaces.
• Uneven wear on both end surfaces. Braking torque Braking torque
(115) Friction plate Specified torque not produced.
• 206 N・m [151.96 206 N・m [151.96
(116) Partner plate Seizing symptoms present.
• lbf・ft] or higher lbf・ft] or higher
(112) Piston • Scratches on outer circumference. _ _
• Indentations present.
(149) Flaking symptoms appearing. _ _
Ball bearing •
(150) Wear is present.
•
2-speed piston
assembly • Abnormal wear on outer circumference. _ _
(161)
Piston • Abnormal wear and uneven wear on shoe.
(162)
Shoe

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6002-22
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Assembly and Disassembly of Travel Motor

Reference value Permissible limit

Part
Part name Symptom (standard di- value
number
mensions) (judgment value)
(323) • Uneven wear on outer circumference. _ _
Spool
(363) • Scratches on outer circumference.
(381) Piston • Scratches on outer circumference. _ _

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Assembly and Disassembly of Travel Motor

Motor Assembly Procedures Assembly Procedure

• Remove adhesive remaining in the threaded holes (12
Precautions before Motor Assembly locations) of the hub (1) by removing it from the M10
Begin motor assembly only after thoroughly reading the (P1.5) taps.
precautions below. After this, clean and degrease the threaded holes, and
use air blowing to remove the cleaning fluid.
1. When performing assembly, always wear protective Replace hexagon socket head bolts (35) with new
gear such as a helmet, goggles and safety shoes. parts.
2. Use the specified tools when performing assembly.
3. To prevent injuries during disassembly, prepare a • It is necessary to perform angular ball bearing precom-
waist-high, stable work platform to perform work on. pression adjustment when replacing parts and then
4. The motor comprises high-precision parts. performing reassembly, so confirm whether the follow-
For this reason, foreign matter adhering to parts can ing parts have been replaced before performing as-
be damaging. sembly.
Motor assembly should be done in an inside space Replacement parts in which angular ball bearing pre-
without dust, and mud and dirt should be prevented compression adjustment is
from adhering to parts.
5. The motor comprises high-precision parts. necessary Hub (1),
For this reason, dents and scratching on part sur- spindle (2),
faces can be damaging. angular ball bearings (24)
Be very careful when handling parts during assem-
• When the parts above are replaced and then reassem-
bly and do not create any dents or scratching. bly is performed, make sure that each has had adjust-
6. Be sure to repair any damage discovered during ment performed before performing reassembly. Use
disassembly and prepare replacement parts before sufficient caution, as including a part that has not been
beginning assembly. adjusted in reassembly will cause travel motor opera-
7. Remove metal fragments and foreign matters from tion defects and induce early damage.
all parts and check that there are no burrs or dents
on parts before beginning assembly. 1. Assembly of hub section
If there are burrs or dents, use a whetstone to re-
1) Place the hub (1) on the press work platform
move them.
(B).
8. When performing assembly, apply clean hydraulic
2) Insert the angular ball bearings (24) in the
oil to each sliding and rotating sections before as-
hub, place the primary bearing press-fit jig (C)
sembly.
in the angular ball bearing outer race, and
9. Thoroughly degrease areas where Loctite and liquid
press down with the press (A) to press-fit the
packing is used and remove oil and water before
jig into the hub.
assembly.
3) Turn the hub upside down.
10. Replace all seal parts such as O-rings and backup
4) Press fit the angular ball bearings (24) into the
rings with new parts.
hub in the same way as 2) above.
11. Be careful not to damage O-rings and backup rings
during assembly. • Be careful to install the angular ball bearings
When assembling O-rings and backup rings, apply (24) in the correct direction.
a small amount of grease for assembly.
12. It is recommended that petroleum jelly or grease be
used to prevent parts from falling during assembly.
13. Tighten the bolts and other fastening sections to the
specified tightening torque indicated in "Tightening
Torque".
Tightening torque should be controlled with a torque
wrench.
14. After assembly is complete, plug all ports leading
into the motor to prevent dirt from entering.

5) Coat the O-rings of the floating seals (29) with

grease and install the floating seals in the
floating seal groove of the hub (1).
• When coating the O-rings of the floating seal
with grease, remove the O-rings from the
floating seals to lightly coat the entire cir-
cumference of the O-rings.

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6002-24
Copyright ©
Assembly and Disassembly of Travel Motor

• For assembly of floating seals (29), place 3) Install the spindle (2) on the work platform so
the floating seal installation jig (I) (D), float- that the hexagon socket head bolts are in op-
ing seals (29), floating seal installation jig (II) posing positions.
(E) in that order, and press in until the float-
ing seal installation jig (II) presses against CAUTION
the floating seal installation jig (I). Remove
the floating seal installation jig and check Thoroughly tighten the hexagon socket
that the hub end surface and floating seal head bolts. If they are not thoroughly
surface are within 1 mm (0.039 in) and par- tightened, the travel motor can fall and
allel. cause injury when it is inverted.

2. Assembly of spindle section 3. Precompression adjustment of angular ball bearing

1) Coat the O-rings of the floating seals (29) with • When the hub (1), angular ball bearings (24) or
grease and install the floating seals in the spindle (2) are replaced, perform precompression
floating seal groove of the spindle (2). adjustment. If precompression is not appropriate,
the angular ball bearing can become damaged in
• For assembly of floating seals (29), place a short period of time.
the floating seal installation jig (III) (F), float-
ing seals, floating seal installation jig (II) (E) 1) Temporarily install the lock washers (22) on
in that order, and press in until the float- the spindle (2) and measure the dimensions
ing seal installation jig (II) presses against of X.
the floating seal installation jig (III). Remove 2) Measure installation width Y of the angular
the installation jig and check that the spindle ball bearing.
groove end surface and floating seal surface • Rotate the hub (1) and angular ball bearing
are within 1 mm (0.039 in) and parallel. a number of times and measure the dimen-
sions after rising subsides.

2) Install the 2 eyebolts in the spindle (2) so that

they are in opposing positions.

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Assembly and Disassembly of Travel Motor

3) Subtract dimension Y from X, and select a 3) Use the D14 mm (0.551 in) hole of the hub and
shim (23) from the table below so that the gap tighten the long hexagon socket head bolts to
is + 0.13 to + 0.17 mm (0.00512 - 0.00669 in). the work platform to secure the hub.
4) Place a metal rod against the inner race of the
reduction valve side angular ball bearings (24)
Code T [mm (in)] Code T [mm (in)] and lightly strike it with a hammer to eliminate
A 0.9 (0.0354 in) G 1.5 (0.0591 in) rising of the inner race.
B 1.0 (0.0394 in) H 1.6 (0.0630 in)
C 1.1 (0.0433 in) I 1.7 (0.0669 in)
D 1.2 (0.0472 in) J 1.8 (0.0709 in)
E 1.3 (0.0512 in) K 1.9 (0.0748 in)
F 1.4 (0.0551 in) L 2.0 (0.0787 in)

5) Align the lock washers (22) with the spindle

(2) groove.

4) Install the shim (23) on the spindle (2).

6) Press the lock washers (22) into the jig with

the spindle.
• Thoroughly press the lock washer into the
back of the groove so that it does not inter-
fere with lock washer when carrier 2 (7) is
installed.
4. Installation of hub
7) Remove the long hexagon socket head bolts
1) Install the angular ball bearings (24) on the connecting the hub (1) and work platform.
hub (1). 8) Rotate the hub (1) 2 - 3 times.
2) Make it so that the center axis of the hub (1)
and spindle (2) is straight, slowly lower the • Rotating the hub (1) makes the sliding sur-
hub, and insert the angular ball bearings in- faces of the floating seals (29) fit against the
stalled in the hub into the spindle. hub and prevents pseudo-leaks.

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Assembly and Disassembly of Travel Motor

9) Rotate the work platform and make the motor 5) Coat the sliding sections of the piston assem-
side face upwards. bly parts with hydraulic oil and install into the
piston hole of the spindle (2).
6) Fit the 2 parallel pins (34) in the pin holes of
the spindle (2) rear flange matching surface.

5. Assembly of motor parts within the spindle

1) Press fit the oil seal (132) into the spindle (2)
using the press-fit jig (G) and hammer.
6. Installation of shaft
• When installing the oil seal, coat the oil seal
lip section with lithium grease. Be careful to CAUTION
install the oil seal (132) in the correct direc-
Burns can occur, so use leather gloves
tion.
when performing insertion. Use caution to
2) Install the 2 parallel pins (171) into the spindle prevent burns.
(2) pin holes.
3) Coat the spherical surfaces of the 2 pivots 1) Insert the ball bearing (149) into the heating
(167) with lithium grease to fit them on the tank and heat them for 10 min. at 90 - 110°C
parallel pins (171) attached to the spindle (2). (194.1 - 230.0 °F), place them on the holder
fitting (II) (H) and press fit the shaft (102) with
the press (A).

4) Coat the spring (185) with grease and attach it

in the piston assembly parts (piston (161) and
shoe (162)). 2) Tilt the travel motor 90°.

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Assembly and Disassembly of Travel Motor

3) Fit the shaft into the spindle. 1) Insert the washer (110), spring (114), washer,
and snap ring (145) parts in that order into the
• Be careful to not scratch the lip section of cylinder block (104).
the oil seal (132) fit into the spindle when
fitting the shaft, and slowly and gently fit the
shaft into the spindle. Be careful as damage
to the lip section can cause oil leaks and
induce early damage to the travel motor.

2) Place the cylinder block (104) on the press

work platform.

CAUTION

4) Fit the swash plate (103) into the spindle (2). When attaching the snap ring (145),
be careful as the tip of the pliers can
• Coat the surface that matches with the be misaligned with the snap ring hole
swash plate spindle with grease. Align the and the snap ring can fly out.
swash plate pivot installation holes with the
2 pivots (167) fit into the spindle and fit the • Spring (114) pressing power 1128 N (253.63
swash plate onto the spindle. lbf·ft) or higher
Place a vinyl sheet over the cylinder block
so that the contact surface between the
cylinder block (104) and timing plate (109)
does not get scratched.
3) Place the holder fitting (I) on the washer (110)
and attach the snap ring (145) into the snap
ring groove of the cylinder block using the pli-
ers for snap rings while pressing down on the
holder fitting (I) with the press.

7. Assembly of inside of cylinder block

• Place the sharp side of the snap ring (145) corner
facing the inlet side.
For insertion of the washer (110) that touches the
snap ring, have the side of the washer with sharp
corners face the snap ring side.

(301).
• Thoroughly coat the springs with grease and
secure them so that they do not fall from the
rear flange.

16. Parts tightening

1) Tighten the 10 hexagon socket bolts (343) in
the spindle (2) to the specified torque.
Tightening torque: 86.3 - 117.7 N·m (63.663 -
86.825 lbf·ft)

15. Connection between rear flange and spindle

1) Install the 2 O-rings (32) and (33) in the spin-
dle (2) O-ring grooves.
• Install the O-rings (32) and (33) without ap-
plying grease. If grease is applied for re-
assembly, grease may ooze out from the
matching surface of the rear flange (301)
and spindle (2) during travel motor opera-
tion. This can be mistaken for an oil leak,
so do not apply grease.

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Assembly and Disassembly of Travel Motor

2) Tighten the plugs (324) to the specified 5) Tighten the plug (357) to the specified torque.
torque. Tightening torque: 78.5 - 117.7 N·m (57.909 -
Tightening torque: 401.8 - 480.2 N·m 86.825 lbf·ft)
(296.404 lbf·ft - 354.237 lbf·ft)

17. Attachment of relief valve assembly

3) Tighten the plugs (380) to the specified
torque. 1) Install the 2 relief valve assemblies (201 -
Tightening torque: 48.99 - 68.61 N·m 213).
(36.1394 - 50.6128 lbf·ft)

2) Tighten the 2 relief valve assemblies (201 -

4) Tighten the plugs (352) to the specified 213) to the specified torque.
torque. Tightening torque: 78.5 - 117.7 N·m (57.909 -
Tightening torque: 9.85 - 14.75 N·m (7.2663 - 86.825 lbf·ft)
10.8809 lbf·ft)

18. Attachment of 2nd stage gears

1) Rotate the work platform and make the reduc-
tion gear side face upwards.
2) Attach the sun gear 2 (8) in the carrier 2 (7).
3) Install eyebolts into the 3 lifting M12 tap loca-
tions of carrier 2 (7), and install the carrier 2
assembly with a crane.
• When installing the carrier 2 assembly,
straightly align the center axis of the hub
and carrier 2 assembly so that the internal
84592788 EN - March 2012
6002-33
Copyright ©
Assembly and Disassembly of Travel Motor

teeth of the hub (1) are not scratched by the 1) Install the lifting carrier 1 assembly in the hub
end surface of the planetary gears 2 (9), (1).
and slowly install the carrier 2 assembly.
• When installing the carrier 1 assembly,
straightly align the center axis of the hub
and carrier 2 assembly so that the internal
teeth of the hub (1) are not scratched by the
end surface of the planetary gears 1 (5),
and slowly install the carrier 1 assembly.

• Arrange the planetary gears 2 (9), rear

flange (301) port (J), and 2-speed piston
hole (K) as shown in the diagram.

2) Install the sun gear 1 (4) while aligning it with

the coupling (15) spline position.
• If interference occurs between the spline of
sun gear 1 and the tooth tips of planetary
gears 1 (5) due to the gear positions, slowly
lift the carrier 1 assembly until the connec-
tion of the gear coupling with the sun gear 2
(8) is disconnected and then install sun gear
1 again.

19. Attachment of coupling

1) Attach the coupling (15) in the shaft (102).

3) Install the thrust plate (13) on carrier 1 (3).

20. Attachment of 1st stage gears

21. Assembly of cover

84592788 EN - March 2012

6002-34
Copyright ©
Assembly and Disassembly of Travel Motor

1) Coat the hub (1) surface that matches with the 1) Feed with lubricating oil at the feed port.
cover (14) with Loctite 515 sealant.
• Feed 2.1 L (0.555 gal) of lubricating oil.
• Coat with sealant so that there are no dis-
continuities.

2) Install the plugs (30) into each port and tighten

to the specified torque.
2) Install eyebolts into the PF1/2 ports and place Tightening torque: 78.5 - 117.7 N·m (57.909 -
the the cover (14) on the hub (1) while aligning 86.825 lbf·ft)
it with the bolt hole positions.

Installation of Swing Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

6003-6
Copyright ©

Section

6004

Assembly and Disassembly of Swing Unit

84592788 EN - March 2012

CONTENTS

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Swing Reduction Gear Structure Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

6004-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

6004-2 PRINTED IN FRANCE
Copyright ©
Assembly and Disassembly of Swing Unit

Job code 35352AF10 Disassembly

1. Making a reference mark on the unit matching sur-
CAUTION face
It is useful for reassembly to place a reference mark
1. Read and understand the contents of this (*1) on the matching surface of the housing (1) and
maintenance manual before performing ring gear (2) with paint, etc.
disassembly, reassembly, inspection, re-
pair, or other such work of this product.
2. Handle this product according to the sep-
arate "Usage Precautions".
3. When removing this product from the
equipment it is mounted on, stop that
equipment system and wait for the surface
temperature of this product to fall to about
40 °C ( 104.0 °F ) or below before removing
it.
Working on this product while it is still hot
can cause burns.
Additionally, always bleed out the pressure
before removing any line from this prod-
uct.
2. Removal of level gauge
Removing a pressurized line can result in
Remove the level gauge (1) and cap (2).
oil spraying out and causing injury or oil
leak.
4. Use the specialty tools and measurement
instruments for disassembly, reassembly,
inspection, and repair, etc. of this product.
Using an inappropriate tool may result in
injury or product damage.
5. Be careful of parts falling when performing
disassembly, reassembly, inspection or re-
pair, etc. of this product.
This may result in injury or parts damage.
6. Do not directly touch with bare hands the
machined edges or threaded sections of
parts during disassembly, reassembly, in-
spection, or repair etc. of this product.
This may result in injury. 3. Gear oil draining
7. Check performance after reassembly. Loosen the drain hose (*1) end plug, and then drain
Do not resume use unless performance is the gear oil.
fully recovered. • Gear oil cannot be reused.
Using this product at a sub-par perfor-
mance level may result in product damage.
8. The cautions (mark !) listed in this main-
tenance manual do not cover all possible
dangers.
Always think of safety first during disas-
sembly, inspection, reassembly, repair, or
other such work.

84592788 EN - March 2012

6004-3
Copyright ©
Assembly and Disassembly of Swing Unit

4. Removal of hose Assembly

Remove the drain hose (*1) and grease hose (*2).
1. Motor installation
Lift the housing (3) and softly fit it in the ring gear
(2), and install with hexagon socket head bolts (1)
[hexagon diameter: 10 mm (0.394 in)].
• Align the housing (3) and ring gear (2) according
to the reference mark (*1) made before disassem-
bly.

5. Removal of motor
Remove the 8 hexagon socket head bolts (1)
[hexagon diameter: 10 mm (0.394 in)], and remove
the housing (3) from the ring gear (2).
• Use the make-up port (G3/4) to raise the motor
and remove it.

2. Install the level gauge.

3. Gear oil filling
Install a plug in the female side of the hose, and
install a hose (*1) in the drain port on the side of the
gear case.
Fill with gear oil [2.2 L (0.581 gal)] from the housing
(1) Mu port.
Install the Mu port cap (2).

*1 Reference mark

This completes the disassembly.

84592788 EN - March 2012

6004-4
Copyright ©
Assembly and Disassembly of Swing Unit

4. Grease-up
Remove the plug (2) from the gear case (1) and
inject grease [0.3 L (0.079 gal)] from the grease fill
port.
• When injecting grease, there is the possibility of
the reduction gear oil seal being damaged by in-
ternal pressure, so remove the air bleed port plug
before injecting grease.
Install the plug (2) on the gear case (1).
After injecting grease, install the grease hose in
the grease fill port.

This completes the assembly.

84592788 EN - March 2012

6004-5
Copyright ©
Assembly and Disassembly of Swing Unit

Swing Reduction Gear Structure Diagram

Code Part name Q'ty Code Part name Q'ty

1 Pinion shaft 1 13 Holder 1 assembly 1
2 Plate 1 14 Holder 2 assembly 1
3 Tapered roller bearing 1 15 Shaft 2 3
4 Gear case 1 16 Holder 2 1
5 Plug 1 17 Bushing 2 3
6 Oil seal 1 18 Spur tooth 5 3
7 Tapered roller bearing 1 19 Thrust plate 2 3
8 Collar 2 20 Spring pin 3
9 Ring gear 1 21 Parallel pin 2
10 Spur tooth 4 1 22 Plug 1
11 Hexagon socket head bolt 8 23 Plug 1
12 Sun gear 1

84592788 EN - March 2012

6004-6
Copyright ©

Section

8001A

Overall view

84592788 EN - March 2012

CONTENTS

Overall view. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PUMP CHAMBER HYDRAULIC EQUIPMENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SWING BODY CENTER SECTION HYDRAULIC EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
HOUSING LEFT SIDE HYDRAULIC EQUIPMENT LAYOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
LAYOUT OF HYDRAULIC EQUIPMENT IN CAB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

8001A-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

8001A-2 PRINTED IN FRANCE
Copyright ©
Overall view

This page is intentionally left blank

84592788 EN - March 2012

8001A-3
Copyright ©
Overall view

Overall view

84592788 EN - March 2012

8001A-4
Copyright ©
Overall view

1 Housing left side 3 Pomp chamber 5 Fuel tank

2 Swing body center section 4 Hydrauric oil tank

84592788 EN - March 2012

8001A-5
Copyright ©
Overall view

PUMP CHAMBER HYDRAULIC EQUIPMENT LAYOUT

HOUSING LEFT SIDE HYDRAULIC EQUIPMENT LAYOUT

Cushion valve (with heat cir-

1
cuit)
2 Swing pilot pressure sensor
3 Oil cooler

84592788 EN - March 2012

8001A-10
Copyright ©
Overall view

LAYOUT OF HYDRAULIC EQUIPMENT IN CAB

1 Travel remote control valve

Upper operation remote control
2
valve

84592788 EN - March 2012

8001A-11
Copyright ©
Overall view

84592788 EN - March 2012

8001A-12
Copyright ©

Section

8001B

Port Diagram

84592788 EN - March 2012

CONTENTS

Hydraulic Pump (standard model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 Stack Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Stack Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Remote Control Valves (upper, travel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Remote Control Valves (left-right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Remote Control Valve (travel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cushion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2-way Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Direction Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Shut-off Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Manifold Under Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Manifold (accumulator section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Manifold (hydraulic oil tank section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Center Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

8001B-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

4 Stack Solenoid Valve

Port Port size

C3 G1/4
C1 G1/4

View from bottom

84592788 EN - March 2012

8001B-10
Copyright ©
Port Diagram

Remote Control Valve (travel)

Port Port name Port size

1 Backward left G1/4
2 Forward left G1/4
3 Backward right G1/4
4 Forward right G1/4
P Pressure G1/4
T Return G1/4

84592788 EN - March 2012

8001B-11
Copyright ©
Port Diagram

Cushion Valve

Port Port name Port size Port Port name Port size
E, F Boom up G3/8 I, J Swing right G3/8
G, H Boom down G3/8 Q Swing pressure sensor signal G1/4
O, P Bucket open G3/8 U - G1/4
M, N Bucket close G3/8 S Swing priority orifice switch G1/4
C, D Arm out G3/8 V - G1/4
A, B Arm in G3/8 T Return (drain line) G1/4
K, L Swing left G3/8 R Heat circuit G1/4

84592788 EN - March 2012

8001B-12
Copyright ©
Port Diagram

2-way Selector Valve

Remote control valve side Cushion valve side

Port name Port name

Port Port size Port Port size
* ISO type * ISO type
Remote control valve side/
A G3/8 1 Cushion valve side port G3/8
Boom-up port
Remote control valve side/
B G3/8 2 Cushion valve side port G3/8
arm-in port
Remote control valve side/
C G3/8 3 Cushion valve side port G3/8
Boom-down port
Remote control valve side/arm-
D G3/8 4 Cushion valve side port G3/8
out port

Direction Valve

Port Port size Port Port size Port Port size

A G1 T1 G1 PP G1/4
B G1 T2 G3/4 DR G1/4

84592788 EN - March 2012

8001B-13
Copyright ©
Port Diagram

Shut-off Valve

Port Port size

A G1
B G1
T G3/4
PP G1/4
DR G1/4

84592788 EN - March 2012

8001B-14
Copyright ©
Port Diagram

HBCV

B port opening side

Port Port size Remarks

SAE6000psi 1 Arm HBCV
A Boom
SAE J6000psi 1
HBCV
SAE6000psi 1 Arm HBCV
B Boom
SAE J6000psi 1
HBCV
C G1/4
DR G3/8
PL G1/4

84592788 EN - March 2012

8001B-15
Copyright ©
Port Diagram

Manifold Under Cab

Port Port size Port Port size Port Port size

P1 G3/8 P5 G1/4 T4 G1/4
P2 G3/8 T1 G3/8 T5 G1/4
P3 G3/8 T2 G3/8
P4 G1/4 T3 G3/8

Manifold (accumulator section)

Port Port size Port Port size Port Port size

P G1/2 P2 G1/4 P0 G3/8
P1 G1/4 P3 G1/2

84592788 EN - March 2012

8001B-16
Copyright ©
Port Diagram

Manifold (hydraulic oil tank section)

Port Port size Port Port size Port Port size

D G1/2 D5 G1/4 T1 G3/8
D1 G3/8 D6 G1/4 N2 G1/4
D2 G1/4 T G1/2

84592788 EN - March 2012

8001B-17
Copyright ©
Port Diagram

Swing Motor

Port Port Port

Port Port name Port Port name Port Port name
size size size
Dr Reduction gear oil
Mu Make up G3/4 B Right swing G3/4 Rc3/8
(RG) drain port
GA, Pressure measure- Reduction gear
Dr Drain G3/8 G1/4 SGr Rc1/8
GB ment grease-up port
P Brake release Rc G1/4 Au Air bleed port G1/4
Air bleed port for
A Left swing G3/4 AGr Rc1/4
grease-up

84592788 EN - March 2012

8001B-18
Copyright ©
Port Diagram

Travel Motor

Port Port name Port size

A, B Main port G3/4
D Drain port G1/2
P Pilot port G1/4
P1, P2,
Pressure detection port Rc1/8
P3, P4

84592788 EN - March 2012

8001B-19
Copyright ©
Port Diagram

Center Joint

Port Port name Port size

A, A' Main port (forward right) G3/4
B, B' Main port (forward left) G3/4
C, C' Main port (backward right) G3/4
D, D' Main port (backward left) G3/4
Drain port *E (2 locations), E' (1
E, E' G1/2
location)
Pilot port *F (2 locations), F' (1
F, F' G1/4
location)

84592788 EN - March 2012

8001B-20
Copyright ©

Section

8001C

Pump P-Q Diagram

84592788 EN - March 2012

CONTENTS

Pump P-Q Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

8001C-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

8001C-2 PRINTED IN FRANCE
Copyright ©
Pump P-Q Diagram

Pump P-Q Diagram

Discharge
flow Q [L/m-
in(gpm)]

Discharge pressure Pd [MPa(psi)]

Discharge pressure Pd [Kgf/cm2]

84592788 EN - March 2012

8001C-3
Copyright ©
Pump P-Q Diagram

84592788 EN - March 2012

8001C-4
Copyright ©

Section

8001D

Pressure Measurement and Adjustment Procedures

84592788 EN - March 2012

CONTENTS

Procedures for Pressure Measurement from the Monitor Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Monitor and switch panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pressure Measurement Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operating Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PROCEDURES FOR MEASURING HYDRAULIC OIL TEMPERATURE FROM THE MONITOR DISPLAY . . . . . . 4
Hydraulic Oil Temperature Measurement Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operating Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Procedures for Pressure Measurement by Installing Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Items to Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pressure Measuring Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Structure and Operation Explanation of Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Location of Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pressure Measurement Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pressure Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Main Pressure Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Attachment pressure measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Boom-down pressure measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Travel pressure measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Swing pressure measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Option line pressure measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Pilot Pressure Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pressure gauge installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Negative Control Pressure Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Pressure gauge installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Main Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Pressure measurement and adjustment preparation work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Main relief pressure adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Overload relief pressure adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Swing relief pressure adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Pilot Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

8001D-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

8001D-2 PRINTED IN FRANCE
Copyright ©
Pressure Measurement and Adjustment Procedures

Procedures for Pressure

Measurement from the Monitor
Display
Monitor and switch panel

1 Liquid crystal monitor 3 Design panel

2 Switch panel 4 Diffuser

Pressure Measurement Method

The P1, P2, N1, and N2 pressure can be measured from the monitor display. (The pilot pressure cannot be mea-
sured.)
Operating Method
1. If both the travel speed select switch and the attachement select switch on the switch panel are held down, the
display switches to the service support screen.
2. CHECK the select service support screen.
3. MACHINE STATUS the select service support screen.
4. The respective pressures are displayed "P1" (P1 pump main pressure), "P2" (P2 pump main pressure), "N1" (N1
negative control pressure), and "N2" (N2 negative control pressure) columns.
* MENU switch is held down the display returns to the normal screen.

a Normal screen
b Service support screen

84592788 EN - March 2012

8001D-3
Copyright ©
Pressure Measurement and Adjustment Procedures

PROCEDURES FOR MEASURING HYDRAULIC OIL TEMPERATURE

FROM THE MONITOR DISPLAY
Hydraulic Oil Temperature Measurement Method
The hydraulic oil temperature can be measured from the monitor display.
Operating Method
1. If both the travel speed select switch and the attachement select switch on the switch panel are held down, the
display switches to the service support screen.
2. CHECK the select service support screen.。
3. MACHINE STATUS the select service support screen.
4. The hydraulic oil temperature is displayed in the "Hyd.OIL TEMP" column.

84592788 EN - March 2012

8001D-4
Copyright ©
Pressure Measurement and Adjustment Procedures

Procedures for Pressure Measurement by Installing Pressure Gauge

Preparations

Role (worker 1: work supervisor, pressure

Workers 2
adjustment)
Role (worker 2: operator)

Items to Prepare

Wrenches [17 (0.669) 、 19

Vacuum pump and power sup-
(0.748) 、 24 (0.945) 、 27
1 ply 5 9 Recording sheet
(1.063) x 2 、 32 (1.259) 、 36
(for vacuum pump)
(1.417) x 2]
Pressure gauge [10 MPa-1
2 6 Rag 10 Pen
(1450.54 psi-1)]
Pressure gauge [60 MPa-2
3 7 Extension cable 11 Cleaning fluid
(8703.22 psi-2)]
Hexagon wrench [8 mm (0.315 Hydraulic oil tank lid
4 8
in)、6 mm (0.236 in)] (for vacuum pump)

Pressure Measuring Ports • Negative control pressure: pressure ports (N1, N2)
(N1: Remove the negative control pressure sensor,
There are the following 3 ports for pressure measure- then Install the pressure gauge.)
ment. • Pilot pressure: pressure port (P3)
• Main pressure: pressure ports (P1, P2)
(Remove the Main pressure sensor, then Install the
pressure gauge.)
84592788 EN - March 2012
8001D-5
Copyright ©
Pressure Measurement and Adjustment Procedures

1 Pump 4 Pressure port: N1

2 Pressure port: P2 5 Pressure port: N2
3 Pressure port: P1 6 Pressure port: P3

84592788 EN - March 2012

8001D-6
Copyright ©
Pressure Measurement and Adjustment Procedures

Structure and Operation Explanation of Control Valve

Location of Relief Valves

Tool Pressure per

Set pressure rotation of ad- Measuring
Position Adjusting
Lock nut [MPa(psi)] justing screw port
screw [MPa(psi)]
Hexagon diam- Hexagon diam-
a Main 34.3 21.3
eter 27 mm eter 27 mm Monitor P1
(normal use) (4975.341) (3089.643)
(1.063 in) (1.063 in)
1
Main Hexagon diam- Hexagon diam-
36.3 28.4
b (boosted pres- eter 32 mm eter 27 mm Monitor P1
(5265.448) (4119.524)
sure) (1.259 in) (1.063 in)
38.2 21.2
2 Boom up Monitor P2
(5541.050) (3075.138)
32.3 21.2
3 Boom down Monitor P2
(4685.234) (3075.138)
38.2 21.2
4 Arm in Hexagon diam- Monitor P1
(5541.050) (3075.138)
eter 17 mm
(0.669 in) Hexagon diam- 38.2 21.2
5 Arm out Monitor P1
eter 6 mm (5541.050) (3075.138)
(0.236 in) 38.2 21.2
6 Bucket close Monitor P2
(5541.050) (3075.138)
38.2 21.2
7 Bucket open Monitor P2
(5541.050) (3075.138)
Hexagon diam-
3.92 2.0
8 Pilot eter 24.25 mm
(568.6104) (290.107)
(0.95472 in)

Detailed diagram of main relief valve adjust-

ment
84592788 EN - March 2012
8001D-7
Copyright ©
Pressure Measurement and Adjustment Procedures

*1 Pressure boost lock nut

*2 Pressure boost adjusting screw
Standard pressure adjusting
*3
screw
*4 Standard lock nut

84592788 EN - March 2012

8001D-8
Copyright ©
Pressure Measurement and Adjustment Procedures

Pressure Measurement 3. Main unit installation

Put the main unit on solid, level ground, put the
Preparations bucket cylinder at its open stroke end, the arm cylin-
der at its out stroke end, lower the boom, and touch
1. Items to prepare
the arm top to the ground.
For 10 MPa (1450.54 psi) (for pilot
and negative control pressure mea-
1 ） Pres-
surement)
sure gauge
For 60 MPa (8703.22 psi) (for main
pressure measurement)
Wrench (closed wrench)
2）Tool 17 mm (0.669 in)
Hexagon wrench 6 mm (0.236 in)
Rag
3）Others
Cleaning fluid

4. Ignition key
Switch OFF the ignition key (1), check that the en-
gine has stopped, then switch the ignition key ON
again. (Do not start the engine.)

2. Monitor check
Use the service check to check the no-load engine
maximum speed and the SP mode pump input milli-
amp.

Engine max. SP mode milli-amp

2000 min-1 5. Oil temperature check
600 mA (during operation)
(2000 rpm) Use the service check to check the hydraulic oil tem-
perature.

45 - 55 °C
Oil temperature
(113.0 - 131.0 °F)

If the oil temperature is low, raise the oil temperature

according to the warm-up operation procedure in
the operator's manual.

6. Bleeding pressure from inside circuits

84592788 EN - March 2012
8001D-9
Copyright ©
Pressure Measurement and Adjustment Procedures

Flip the gate lock lever (1) forward, then turn the 7. Bleeding pressure from inside the hydraulic oil tank
upper operation lever (2) about 10 times to bleed Press the air breather button (1) on top of the hy-
out the pressure. draulic oil tank to release the pressure inside the
tank.

3 Gate lever 8. Side door opening and closing

Open the side door (1).
Move the travel lever (1) back and forth about 5 At this time, be sure to use the lock (2).
times to bleed out the pressure.

This completes the preparations.

84592788 EN - March 2012

8001D-10
Copyright ©
Pressure Measurement and Adjustment Procedures

Pressure Measurement Install the pressure gauge (2) on the adapter (1) and
fasten it.
Main Pressure Measurement for 60 MPa
Pressure gauge
1. Pressure gauge installation (8703.22 psi)
Port size
Remove the pressure sensors (a1), (a2) connected G1/4
to the hydraulic pump (1), and install the adapter.

a1: Can be measured a2: Can be measured

Travel left Travel right
Option Bucket
Swing
Arm 1 pump flow Arm 2 pumps flow
Boom 2 pumps flow Boom 1 pump flow

84592788 EN - March 2012

8001D-11
Copyright ©
Pressure Measurement and Adjustment Procedures

Attachment pressure measurement Oil temperature 45 - 55 °C (113.1 - 131.0 °F)

Negative Control Pressure

Measurement
Pressure gauge installation
After removing the N1 pressure port plug (1) or N2 pres-
sure sensor (2), install the adapter.

Install pressure gauge on the adapter, and measure the Engine speed 2000 min-1 (2000 rpm)
negative control pressure for each operation. Work mode SP mode
45 - 55 °C (113.1 - 131.0
Oil temperature
for 10 MPa °F)
Pressure gauge
(1450.54 psi) P1 pump side: N1 port
Port size Measuring port
G1/4 P2 pump side: N2 port
3.92 MPa (568.6104 psi)
Set pressure
max.

84592788 EN - March 2012

8001D-17
Copyright ©
Pressure Measurement and Adjustment Procedures

Pressure Adjustment 1. Loosen the standard lock nut [27 mm (1.063 in )]

(1) and tighten the adjusting screw [27 mm (1.063
Main Pressure Adjustment in)] (2).
Fasten with a wrench [27 mm (1.063 in)] so that
Pressure measurement and adjustment the pressure boost adjusting screw does not turn.
preparation work
Pressure is adjusted with control valves.
The following preparations are required for adjusting
with control valves.
1. Engine hood opening and closing
Unfasten the 2 latches (2) on the engine hood (1)
and open the engine hood (1).Pull the latches (2) to
release the locks.

2. After tightening until the adjusting screw stops

turning, tighten the pressure boost lock nut (1).

2. Cover removal
Remove the 5 bolts (1), then remove the cover (2).

3. Start the engine and run it at maximum rotation.

4. Move the arm lever to the in side, set the relief
state, and hold.
5. Loosen the pressure boost lock nut [32 mm (1.260
in)] (3) and adjust the set pressure with the adjust-
ing screw [27 mm (1.063 in)] (4).
• When lower than the set pressure, tighten.

For boosted pressure

• When higher than the set pressure, first lower

below the set pressure, then adjust on the tight-
ening side.
6. After adjustment, fasten the adjusting screw with
a wrench [27 mm (1.063 in)], then tighten the lock
nut.

84592788 EN - March 2012

8001D-18
Copyright ©
Pressure Measurement and Adjustment Procedures

84592788 EN - March 2012

CONTENTS

Hydraulic Pump Flow Measurement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Items to Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Work Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Flow Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

8001E-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

8001E-2 PRINTED IN FRANCE
Copyright ©
Hydraulic Pump Flow Measurement Procedures

Hydraulic Pump Flow Measurement Procedures

Preparations
Role (worker 1: work supervisor, pressure ad-
Workers 3
justment)
Role (worker 2: operator)
Role (worker 3: flow, pressure measurement,
recording)

Items to Prepare

Vacuum pump and power sup-

1 6 Extension cable 11 Pen
ply
Hydraulic oil tank lid (for vac-
2 Flow meter 7 12 Cleaning fluid
uum pump)
Pressure gauge (60 MPa (
3 8 Adapter (flange type) 13 Rag
8703.22 psi ) x 2)
84592788 EN - March 2012
8001E-3
Copyright ©
Hydraulic Pump Flow Measurement Procedures

Hexagon wrench [ 6 mm ( Hydraulic hose (for flow mea-

4 9
0.236 in ), 10 mm ( 0.394 in ) ] surement)
Wrenches [ 17( 0.669 ), 19(
0.748 ), 24( 0.945 ), 27( 1.063
5 10 Recording sheet
) x 2, 32( 1.260 ), 36( 1.417 ) x
2]

Work Preparations 4. Use the bolts removed in 3. to install the hydraulic

oil tank lid (for vacuum pump) (1).
1. Check that the main unit is in its work posture (arm-
vertical).
2. Bleed out the pressure. (See the details on Bleed-
ing Pressure in the Pressure Measurement and Ad-
justment Procedures.)
* Perform a swing prevention check.

5. Install the vacuum pump (1) on the hydraulic oil tank

lid.

3. Use a wrench [17 mm (0.669 in)] to remove the feed

port cover (1).

6. After setting the vacuum pump (1) as in the diagram

on the right, switch on the power.(If the cable is too
short, use an extension cable.)

84592788 EN - March 2012

8001E-4
Copyright ©
Hydraulic Pump Flow Measurement Procedures

7. Use a hexagon wrench (1) [8 mm (0.315 in) ] to 10. Install the hydraulic hose (3) on the flow meter (1)
remove the split flanges (2) and hydraulic hose (3). IN side(2), then fasten with the spanner.
(This section explains flow measurement at the P2 Install the (prepared) hydraulic hose (5) on the flow
pump.) meter (1) OUT side (4), then fasten with the span-
ner.
Installs the adapter (6) to have instralled in opposite
in 8..
* When connecting, always check the connection
positions.
* Always have the metering valve (7) fully open.
Remove the vavuum pump and re-install the hy-
draulic oil tank the same way it was.
Install pressure gauges on P1 and P2.(See "Main
Pressure Measurement".)
Open the engine hood.(See "Main Pressure Adjust-
ment".)

4 Bolt

8. Use the split flange (2) to install the adaptor (flange

type (3)) on the tip of the hydraulic hose (1) removed
in 7..

4 Hydraulic hose

9. Install the adaptor (1) at the position from which the

hydraulic hose was removed. 11. Remove the cover.
If necessary, install an "elbow adaptor" (3) on the 12. Remove the pilot hose for the boosted pressure sig-
(prepared) hydraulic hose (2) connected to the flow nal, then plug the hose side. (See "Main Relief
meter IN side. Pressure Adjustment".)
This completes the preparation for flow measurement.

84592788 EN - March 2012

8001E-5
Copyright ©
Hydraulic Pump Flow Measurement Procedures

Flow Measurement 5. Worker 2 lowers the arm-out port relief. (Min: 24

MPa ( 3481.29 psi ) P1+P2)
1. Measure the flow. 6. Start of flow measurement
When measuring the flow, position the workers as 7. The arm-out relief operation is carried out.
in the diagram on the right. 8. Data measured in units of 2.0 MPa ( 290.107 psi )
(Worker 1 (1): Work supervisor, pressure adjust- (P1+P2)
ment)
(Worker 2 (2): Operator) * The measurement is carried out from 24.0 - 76.0
(Worker 3 (3): Flow, pressure measurement, MPa ( 3481.288 - 11024.079 psi ) and ends when
recording) the maximum pressure is reached.
9. Remove the flow meter.
* Because the maximum limit of the flow meter
pressure gauge is exceeded starting from 40
MPa ( 5802.15 psi ).
10. Reset the arm-in port relief valve to normal pres-
sure.(For details on this adjustment, see "Pressure
Adjustment".)
11. Remove the pressure gauges etc. and put every-
thing back to normal.
This completes the work.

2. At the signal from the work supervisor, the operator

starts the engine.
3. Check the hydraulic oil temperature on the monitor.
[ 50 °C ( 122.0 °F ) ]
Check that the engine rotation and pump milli-amp
is normal.
4. The operator signals the arm-out relief operation to
worker 1.

1 Lock nut 17 mm ( 0.669 in )

Hexagon wrench 6 mm ( 0.236
2
in )

1 Ignition key

84592788 EN - March 2012

8001E-6
Copyright ©

Section

8001F

Drain Volume Measurement Procedures

84592788 EN - March 2012

CONTENTS

Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Travel Motor Drain Volume Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Swing Motor Drain Volume Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

8001F-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

8001F-2 PRINTED IN FRANCE
Copyright ©
Drain Volume Measurement Procedures

Preparations 3. Always lay a rag (2) underneath before removing

the drain hose (1).
Measuring conditions Use a wrench [ 27 mm ( 1.063 in ) ] to remove the
drain hose (1).(Always install a cap on the removed
drain hose (1).)
Engine speed 2000 min-1 (2000 rpm)
Mode SP mode
Oil temperature About 50°C (122.0 °F)

* Be careful.
The drain volume varies greatly with the oil tempera-
ture.

Travel Motor Drain Volume

Measurement
1. Allow the bucket (2) to touch the ground so as to
elevate one shoe crawler (1) as in the diagram on 4. Install the extension hose for measurement (1) on
the right. the side of the motor from which the drain hose was
removed.

2. Use a wrench [ 19 mm ( 0.748 in ) ] to remove the

bolts (1), then remove the cover (2). 5. Prepare a waste oil can (1) and measuring con-
Tightening torque for bolt installation：63.7 - 73.5 tainer (2) and set them as in the diagram on the
N・m ( 46.991 - 54.220 lbf・ft ) right.

84592788 EN - March 2012

8001F-3
Copyright ©
Drain Volume Measurement Procedures

84592788 EN - March 2012

CONTENTS

Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Boom Cylinder HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Arm Cylinder HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

8001G-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

8001G-2 PRINTED IN FRANCE
Copyright ©
Air Bleed Procedure

CAUTION
Always bleed off any air in the hydraulic cir-
cuits after replacing the hydraulic oil, repairing
or replacing hydraulic equipment, or removing
hydraulic pipes.

Air bleed procedure mode (when bleeding, follow the procedure be-
low.)
Hydraulic
Cylinder air Swing motor Travel motor
pump air Check
bleeding air bleeding air bleeding
bleeding
Hydraulic oil or hydraulic pump re-
placement

Cylinder replacement

Swing motor replacement

Travel motor replacement

* Failure to completely bleed off all the air can reduce

the service life of hydraulic equipment and lead to
damage.

84592788 EN - March 2012

8001G-3
Copyright ©
Air Bleed Procedure

Hydraulic Pump
1. Loosen the air bleed plug (1) and check that oil
oozes from the air bleed port (2)s.
If oil does not ooze out, remove the air bleed plug
(1), and fill hydraulic oil(3) from the air bleed port (2)
into the pump (4) case.
Temporarily tighten the air bleed plug (1).
Run the engine at low idle, slightly loosen the air
bleed port, and run until oil oozes from the air bleed
port (2) section.
Completely tighten the air bleed plug (1).

84592788 EN - March 2012

8001G-4
Copyright ©
Air Bleed Procedure

Travel Motor Swing Motor

1. Remove the bolts (2) , then remove the cover (1). 1. Use a hexagon wrench [8 mm (0.315 in)] to remove
Tightening torque for bolt installation：63.7 - 73.5 the air bleed plug (2) from the air bleed port.
N・m ( 46.991 - 54.220 lbf・ft ) Check that oil oozes from the air bleed port section.
* Do not execute a swing operation.

2. Use a hexagon wrench [ 6 mm ( 0.236 in ) ] (1) to

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

8002-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

8002-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Hydraulic Oil Tank

WARNING Removal of Hydraulic Oil Tank

• Keep away from fire. 1. Press the air breather button (1) on top of the hy-
• Bleed off the pressure in the hydraulic oil draulic oil tank to bleed off the pressure in the tank.
tank before beginning work.
• The temperature of the hydraulic oil is high
immediately after stopping the engine. Wait
until the hydraulic oil temperature has de-
creased (to 40°C (104.0 °F) or less) before
beginning work.

CAUTION
• Be sure to stop the engine before beginning
work.
• Be sure to inspect the wire rope and other
lifting equipment before beginning work.
• Do not stand or pass under the suspended
load. 2. Use a wrench [17 mm (0.669 in)] to remove the 4
bolts (1), and then remove the feed port cover (2).
Items to prepare
• Wrenches [7 mm (0.276 in), 19 mm (0.748 in), 22 mm
(0.866 in), 24 mm (0.945 in), 27 mm (1.063 in)]
• Eyebolts (M12 x 2)
• Shackle (with the required lifting capacity) x 2
• Wire rope (with the required breaking load)
• Liftcrane (with the required lifting capacity)
• Marking pen
• Caps
• Plugs
• Waste oil can
• Rag
• Cleaning fluid
• Wood plank
3. Insert the feed pump (1) into the feed port.

84592788 EN - March 2012

8002-3
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Removal and Installation of Hydraulic Oil Tank

4. Operate the feed pump (1) and transfer the oil inside 7. Use a wrench [7 mm (0.276 in)] to loosen the hose
the hydraulic oil tank to the waste oil tank (2). bands (1), and then remove the hose (2).
• Use caps to cover the hose to prevent any entry
of water, dust or dirt.

5. Use a wrench [19 mm (0.748 in)] to remove the 6

bolts (1), and then remove the under cover (2).
Tightening torque for bolt installation: 63.7 - 73.5
N・m (46.991 - 54.220 lbf・ft) 8. Use a wrench [19 mm (0.748 in)] to remove the 4
bolts (1), and then remove the center cover (2).

6. Prepare a waste oil can (1) under the hydraulic oil

tank. 9. Use a wrench [7 mm (0.276 in)] to loosen the hose
bands (1), and then remove the drain hoses (2) and
(3).
• Use caps to cover the lines to prevent any entry
of water, dust or dirt.

10. Use wrenches [19 mm (0.748 in), 22 mm (0.866 in),

27 mm (1.063 in)] to remove the drain hoses.
• Mark the hydraulic oil tank and hoses so that the
connectors match at the time of assembly.
• Attach caps or plugs to the hydraulic oil tank and
hoses to prevent any entry of water, dust or dirt.
• Clean the hydraulic oil tank and hoses by spray-
ing them with a parts cleaner to prevent scratches

84592788 EN - March 2012

8002-4
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Removal and Installation of Hydraulic Oil Tank

and prevent dirt from accumulating on the con- 11. Cut the hose bands on the tank side, and tie the
nectors. hoses together.

• Be sure to release hydraulic pressure before 1. Use a wrench [19 mm (0.748 in)] to remove the 6
beginning work. bolts (1), and then remove the under cover (2).
• Tightening torque for bolt installation: [63.7 - 73.5
CAUTION N·m (46.991 - 54.220 lbf·ft)]
• Be sure to stop the engine before beginning
work.
• Be sure to inspect the wire rope and other
lifting equipment before beginning work.
• Do not stand or pass under the suspended
load.

8003-7
Copyright ©
Removal and Installation of Hydraulic Pump

84592788 EN - March 2012

8003-8
Copyright ©

Section

8004

Removal and Installation of Control Valve

84592788 EN - March 2012

CONTENTS

Removal of Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

8004-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

8004-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Control Valve

WARNING Removal of Control Valve

• Keep away from fire. 1. Extend the attachment and bring in contact with the
• Be sure to release hydraulic pressure before ground.
beginning work.

Items to prepare
• Wrenches [7 mm (0.276 in), 13 mm (0.512 in), 17 mm
(0.669 in), 19 mm (0.748 in), 22 mm (0.866 in), 24 mm 2. Drain the oil from the hydraulic oil tank.
(0.945 in), 36 mm (0.315 in)] For details, see "Removal and Installation of Hy-
• Hexagon wrenches [6 mm (0.236 in), 8 mm (0.315 in)] draulic Oil Tank".
• Wire cutters 3. Use a wrench [19 mm (0.748 in)] to remove the 4
• Eyebolts (M10 x 2) bolts (1), and then remove the center cover (2).
• Shackle (with the required lifting capacity) x 2
• Wire rope (with the required lifting capacity)
• Liftcrane (with the required lifting capacity)
• Marking pen
• Cap
• Plug
• Rag
• Cleaning fluid
• Wood planks, etc.

4. Use a wrench [19 mm (0.748 in)] to remove the 3

bolts (1), and then remove the under cover (2).
• Tightening torque for bolt installation: 63.7 – 73.5
N·m (46.991 – 54.220 lbf·ft)

5. Cut the wire band (1) at 6 locations, and remove the

6 pressure sensors (2) from the control valve.
• Tightening torque for pressure sensor installation:
[16 - 20 N·m (11.81 - 14.75 lbf·ft)]
Use a wrench [13 mm (0.512 in)] to remove the
bolts (3).
• Tightening torque for bolt installation: [21.6 - 37.2
N·m (15.935 - 27.442 lbf·ft)]

84592788 EN - March 2012

8004-3
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Removal and Installation of Control Valve

7. Use a wrench [17 mm (0.669 in)] to remove the 2

bolts (1), and then remove the hydraulic line (2) from
the control valve.

8. Use a wrench [19 mm (0.748 in)] to remove the 2

bolts (1), and then remove the clamps (2) in 2 loca-
tions.

6. Use a wrench [7 mm (0.276 in)] to loosen the 2 hose

bands (1), and then remove the hydraulic hose (2).
• Tighten the hose bands from the direction of the
arrow.
9. Use a wrench [17 mm (0.669 in)] to remove the 2
bolts (1), and then remove the clamps (2).

10. Use wrenches [19 mm (0.748 in), 22 mm (0.866 in)

36 mm (1.417 in)] and hexagon wrenches [6 mm
(0.236 in), 8 mm (0.315 in)] to remove the control
valve lines and hoses.
• Mark the lines and hoses so that the connectors
match at the time of assembly.
• Use caps or plugs to cover the lines and hoses to
prevent any entry of water, dust or dirt.
• Clean the lines by spraying with a parts cleaner to
prevent scratches and prevent dirt from accumu-
lating on the connectors.

84592788 EN - March 2012

8004-4
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Removal and Installation of Control Valve

13. Install the 2 eyebolts (1) (M12) on the control valve.

14. Install the shackles (1) on the eyebolts, and then

use the liftcrane and wire ropes (2) to lift the control
valve (3).

11. Use a wrench [24 mm (0.945 in)] to remove the 4

bolts (1).
• Tightening torque for bolt installation: [267 – 312 15. Place the control valve (1) on wood planks (2).
N·m (196.96 – 230.16 lbf·ft)]

12. Use a wrench [19 mm (0.748 in)] to remove the 4

bolts (1).

84592788 EN - March 2012

8004-5
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Removal and Installation of Control Valve

Installation of Control Valve • Tighten bolts being installed to the specified

torque.
1. To install, perform the reverse of the removal pro- • For bolts for which the torque is not specified,
cedure. check the "Bolt Size and Torque Table".

84592788 EN - March 2012

8004-6
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Section

8005A

Removal and Installation of Bucket Cylinder

84592788 EN - March 2012

CONTENTS

Removal of Bucket Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Bucket Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

8005A-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

8005A-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Bucket Cylinder

CAUTION Removal of Bucket Cylinder

Items to prepare
2. Use a wrench [19 mm (0.748 in)] to remove the bolt
• Wrenches [19 mm (0.748 in), 36 mm (1.417 in)] (1) and washer (2).
• Nylon sling (with the required lifting capacity)
• Liftcrane (with the required lifting capacity)
• Cap
• Plug
• Hammer
• Striking rod
• Grease
• Rag
• Cleaning fluid
• Crosstie
• Wire

3. Use a hammer (2) and striking rod (3) to remove the

pin (1).
Be careful. The arm and arm cylinder rod may come
out of place at this time.

84592788 EN - March 2012

8005B-3
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Removal and Installation of Arm Cylinder

4. Start the engine, move the arm out at idle, and re- 7. Switch the key switch ON again, and then turn the
tract the arm cylinder (1) rod. control lever (1) about 10 times to bleed out any
pressure.
Do not operate the arm at this time.

5. Tie the cylinder rod with wire (1) so that it cannot

come out.
8. Move the travel lever (1) back and forth about 5
times to bleed off the pressure.
Switch the key switch OFF.

6. Turn the key switch (1) OFF and stop the engine.

9. Press the air breather button (1) on top of the hy-

draulic oil tank to release the pressure inside the
tank.

10. Use wrenches [36 mm (1.417 in)] to remove the

hoses (1)(2).
• Use caps or plugs to cover the hoses and lines to
prevent any entry of water, dust or dirt.
• Clean the hoses and lines by spraying them with
a parts cleaner to prevent scratches and prevent
dirt from accumulating on the connectors.

84592788 EN - March 2012

8005B-4
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Removal and Installation of Arm Cylinder

• If a pin is hard to remove, there is a load on the

pin.
• When removing the pin, be careful not to damage
the installed dust seals.

11. Use a wrench [19 mm (0.748 in)] to remove the

grease hose (1).
• Use caps or plugs to prevent any entry of water,
dust or dirt.
14. Lift the arm cylinder (1) and then place it on the
crosstie.

12. Use a wrench [19 mm (0.748 in)] to remove the bolt

(1) and washer (2).

13. Use a hammer (2) and striking rod (3) to push the
pin (1) out.

84592788 EN - March 2012

8005B-5
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Removal and Installation of Arm Cylinder

Installation of Arm Cylinder

• Tighten lines and bolts being installed to the specified
torque.
• When the torque is not specified, check the "Bolt Size
and Torque Table".
1. Clean each pin and pin hole.

5. Use a wrench [19 mm (0.748 in)] to tighten the bolt

(1) and washer (2).

2. Tie the cylinder rod with wire (1) so that it cannot

come out.

6. Use a wrench [19 mm (0.748 in)] to attach the

grease hose (1).

3. Use a liftcrane and nylon sling (2) to lift the arm

cylinder (1).
• Wrap the nylon sling to the inside of the line so
that it is not crushed.

7. Use a wrench [36 mm (1.417 in)] to install the hoses

(1) (2).

4. Align the arm cylinder with the boom and use a ham-
mer (2) to push in the pin (1).
• If a pin is hard to insert, there is a load on the pin.
• When inserting the pin, be careful not to damage
the installed dust seals.

84592788 EN - March 2012

8005B-6
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Removal and Installation of Arm Cylinder

8. Start the engine, move the arm in at idle, and extend 10. Use a wrench [19 mm (0.748 in)] to tighten the bolt
the arm cylinder (1) rod. (1) and washer (2).
• Grease up.

9. Align the arm cylinder (1) with the arm pin hole and
use a hammer (3) to insert the pin (2).
Be careful. The arm and arm cylinder rod may come
out of place at this time.

84592788 EN - March 2012

8005B-7
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Removal and Installation of Arm Cylinder

84592788 EN - March 2012

8005B-8
Copyright ©

Section

8005C

Removal and Installation of Boom Cylinder

84592788 EN - March 2012

CONTENTS

Removal of Boom Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Boom Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

8005C-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

8005C-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Boom Cylinder

CAUTION Removal of Boom Cylinder

• Stop the machine on a level location with • When removing only the boom cylinder, put the attach-
good footing. ments in the temporary decommissioning posture.
• Be sure to stop the engine before beginning • When removing as far as the boom, first remove the
work. bucket, bucket link, bucket cylinder, arm, arm cylinder
• When working together with others, always according to their respective removal and installation
be sure to exchange signals and pay ade- procedures.
quate attention to safety. Bring the boom top in contact with the ground.
• Always wear protective devices (protective 1. Use a liftcrane and nylon sling (1) to secure the
eyewear and safety shoes, etc.) when work- boom cylinders (right) (left) (2) (3).
ing with a hammer.
• Be sure to inspect the nylon sling and other
lifting equipment before beginning work.
• Do not stand or pass under the suspended
load.

Items to prepare
• Wrenches [19 mm (0.748 in), 24 mm (0.945 in), 36 mm
(1.417 in) ]
• Crowbar
• Wire rope (with the required lifting capacity)
• Liftcrane (with the required lifting capacity)
• Nylon sling
• Marking pen
• Cap 2. Use a wrench [19 mm (0.748 in)] to remove the
• Plug grease hoses on the left and right sides (1).
• Hammer
• Use caps or plugs to prevent any entry of water,
• Striking rod dust or dirt.
• Grease
• Rag
• Cleaning fluid
• Crosstie
• Wire

3. Use 2 wrenches [24 mm (0.945 in)] to remove the

2 double nuts (1) and bolt (2), and then remove the
fastening ring (3).
Also, remove the cab side in the same way.

84592788 EN - March 2012

8005C-3
Copyright ©
Removal and Installation of Boom Cylinder

4. Use a hammer (2) and striking rod (3) to push the 7. Switch the key switch ON again, and then turn the
pin (1) out. control lever (1) about 10 times to bleed out any
Start the engine, lower the boom at idle, and retract pressure.
the boom cylinder (right) (left) rods.

8. Move the travel lever (1) back and forth about 5

5. Tie the cylinder rods on the left and right sides with times to bleed off the pressure.
wire (1) so that they cannot come out.
• Switch the key switch OFF.

6. Turn the key switch (1) OFF and stop the engine.
9. Press the air breather button (1) on top of the hy-
draulic oil tank to release the pressure inside the
tank.

10. Use a wrench [27 mm (1.063 in)] to remove the hose

(1).
Also, remove the cab side in the same way.
• Mark the lines and hoses so that the connectors
match at the time of assembly.
• Use caps or plugs to cover the hoses and lines to
prevent any entry of water, dust or dirt.
• Clean the hoses and lines by spraying them with
a parts cleaner to prevent scratches and prevent
dirt from accumulating on the connectors.

84592788 EN - March 2012

8005C-4
Copyright ©
Removal and Installation of Boom Cylinder

12. Use a crowbar to remove the pin (1).

Also, remove the cab side in the same way.

11. Use a wrench [19 mm (0.748 in)] to remove the bolt

(1) and washer (2).
Also, remove the cab side in the same way. 13. Use a liftcrane and nylon slings (1) to lift the boom
cylinders (right) (left) (2) (3) and remove.
• Place the boom cylinders (right) (left) (2) (3) on
crossties.

84592788 EN - March 2012

8005C-5
Copyright ©
Removal and Installation of Boom Cylinder

Installation of Boom Cylinder 4. Align the boom cylinders (right) (left) with the swing
frame pin holes and use a hammer (2) to push in
• Tighten bolts being installed to the specified torque. the pin (1).
• When the torque is not specified, check the "Bolt Size
and Torque Table". • When inserting the pin, be careful not to damage
the installed dust seals.
1. Clean each pin and pin hole.

5. Use a wrench [19 mm (0.748 in)] to tighten the bolt

2. Tie the cylinder rods on the left and right sides with (1) and washer (2).
wire (1) so that they cannot come out. Also, attach the cab side in the same way.

3. Use a liftcrane and nylon slings (1) to lift the boom 6. Use wrench [36 mm (1.417 in)] to install the hose
cylinders (right) (left) (2) (3). (1).
Also, install the cab side hose in the same way.

84592788 EN - March 2012

8005C-6
Copyright ©
Removal and Installation of Boom Cylinder

7. Start the engine, raise the boom at idle, and extend 9. Use a wrench [19 mm (0.748 in)] to attach the
the boom cylinder (right) (left) (1) (2) rods. grease hoses on the right and left sides (1).
Align the boom cylinder (right) (left) (1) (2) with the
boom pin holes and use a hammer (4) to push in • Grease up.
the pin (3). • When installing as far as the boom, first install
the bucket, bucket link, bucket cylinder, arm, arm
• If the insertion of a shim is possible according to cylinder according to their respective removal and
the tolerance adjust the shim. installation procedures.

8. Use 2 wrenches [24 mm (0.945 in)] to attach the 2

double nuts (1) and bolt (2), and install the fastening
ring (3).
Also, install the cab side in the same way.

84592788 EN - March 2012

8005C-7
Copyright ©
Removal and Installation of Boom Cylinder

84592788 EN - March 2012

8005C-8
Copyright ©

Section

8006

Removal and Installation of Center Joint

84592788 EN - March 2012

CONTENTS

Removal of Center Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Center Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

8006-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

8006-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Center Joint

Job code 35354AA10 Removal of Center Joint

1. Use a hexagon wrench [5 mm (0.197 in)] to remove
CAUTION the 4 bolts (1), and then remove the air breather (2)
on the hydraulic oil tank.
• Be sure to stop the engine before beginning
work.
• Be sure to inspect the wire rope and other
lifting equipment before beginning work.
• Do not stand or pass under the suspended
load.

Items to prepare
• Wrenches [19 mm (0.748 in), 27 mm (1.063 in), 36 mm
(1.417 in)]
• Hexagon wrenches [5 mm (0.197 in)]
• Box wrench [19 mm (0.748 in)]
• Specialty adapter for vacuum pump connection
• Vacuum pump (vacuum pump power supply)
• Extension cable 2. Attach the specialty adapter (1) to the area where
• Marking pen the air breather is removed, and set the vacuum
• Cap pump (2).
• Plug Create negative pressure in the hydraulic oil tank
• Wire rope (with the required breaking load) using the vacuum pump.
• Liftcrane (with the required lifting capacity)
• Wood planks, etc.
• Rag
• Cleaning fluid
• Waste oil can

3. Use a box wrench [19 mm (0.748 in)] to remove the

8 bolts (2), and then remove the lower under covers
(1).

84592788 EN - March 2012

8006-3
Copyright ©
Removal and Installation of Center Joint

4. Prepare a waste oil can (1) to receive the oil that 7. Use a wrench [19 mm (0.748 in)] to remove the 2
spills out under the center joint. bolts (2), and then remove the center joint lock bar
(1).

5. Use a wrench [36 mm (1.417 in)] to remove the

travel hoses (1) and a wrench [ 27 mm ( 1.063 in 8. Use a wrench [36 mm (1.417 in)] to remove the 4
) ] to remove the drain hoses (2). travel hoses (1).
• Mark the center joint and hoses so that the con- • Mark the hoses so that the connectors can be
nectors match at the time of assembly. matched during assembly.
• Attach caps or plugs to the center joint and hoses • Attach caps or plugs to the hoses to prevent any
to prevent any entry of water, dust or dirt. entry of water, dust or dirt.
• Clean the center joint and hoses by spraying them • Clean the hoses by spraying them with a parts
with a parts cleaner to prevent scratches and pre- cleaner to prevent scratches and prevent dirt from
vent dirt from accumulating on the connectors. accumulating on the connectors.

6. Use a wrench [19 mm (0.748 in)] to remove the pilot 9. Wrap wire ropes (1) around the center joint and sus-
hoses (1) and a wrench [ 27 mm ( 1.063 in ) ] to pend it with a liftcrane so that the center joint does
remove the drain hose (2). not fall during removal and installation operations.
• Attach caps or plugs to the center joint and hoses
to prevent any entry of water, dust or dirt.
• Clean the center joint and hoses by spraying them
with a parts cleaner to prevent scratches and pre-
vent dirt from accumulating on the connectors.

84592788 EN - March 2012

8006-4
Copyright ©
Removal and Installation of Center Joint

10. Use a wrench [19 mm (0.748 in)] to remove the 4 Installation of Center Joint
bolts (1) from the center joint.
Tighten bolts being installed to the specified torque.
For bolts for which the torque is not specified, check the
"Bolt Size and Torque Table".
1. Wrap the wire rope (2) around the center joint (1)
and lift it with a liftcrane.

11. Use the wire ropes (2) and liftcrane to lift the center
joint (1).
Thoroughly check that the location is safe before
lowering the center joint on wood planks.

2. Use a wrench [19 mm (0.748 in)] to tighten the 4

bolts (1) for the center joint.
Bolt (1) tightening torque: 109 - 127 N・m (80.41 -
93.69 lbf・ft)
• Apply Loctite #262 to the bolts.

3. Use a wrench [36 mm (1.417 in)] to install the 4

travel hoses (1).

84592788 EN - March 2012

8006-5
Copyright ©
Removal and Installation of Center Joint

4. Use a wrench [19 mm (0.748 in)] to install the 2 bolts 7. Use a box wrench [19 mm (0.748 in)] to install the
(2), then install the center joint lock bar (1). 8 bolts (2) and install the lower under cover (1).
Bolt (2) tightening torque: 88.3 - 107 N・m (65.14
- 78.93 lbf・ft)
• Apply Loctite #262 to the bolts.

8. Use a hexagon wrench [5 mm (0.197 in)] to install

the 4 bolts (1), then install the air breather (2) on the
hydraulic oil tank to the location from which the spe-
cialty adapter for the vacuum pump was removed.
5. Use a wrench [19 mm (0.748 in)] to install the pilot Bolt (1) tightening torque: 2.94 - 4.90 N・m (2.1689
hose (1) and a wrench [27 mm (1.063 in)] to install - 3.6146 lbf・ft)
the drain hose (2).

6. Use a wrench [36 mm (1.417 in)] to install the travel

hoses (1) and a wrench [27 mm (1.063 in)] to install
the drain hoses (2).

84592788 EN - March 2012

8006-6
Copyright ©

Section

8007A

Removal and Installation of Travel Remote Control Valve

84592788 EN - March 2012

CONTENTS

Removal of Travel Remote Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Travel Remote Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

8007A-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

8007A-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Travel Remote Control Valve

Job code 35356AK19 Removal of Travel Remote Control

Valve
WARNING
1. Remove the floor mat (1).
• Be sure to release hydraulic pressure before
beginning work.

CAUTION
• Be sure to stop the engine before beginning
work.

Items to prepare
• Wrench [ 19 mm ( 0.748 in ) ]
• Hexagon wrench [ 8 mm ( 0.315 in ) ]
• Phillips screwdriver
• Marking pen
• Cap
Plug 2. Use a hexagon wrench [8 mm (0.315 in)] to remove
•
Rag the 2 bolts (2) on both the left and right sides, and
•
Cleaning fluid then remove the left and right travel pedals (1).
•

3. Use a hexagon wrench [8 mm (0.315 in)] to remove

the 2 bolts (2) on both the left and right sides of the
lever, and then remove the levers (1).

84592788 EN - March 2012

8007A-3
Copyright ©
Removal and Installation of Travel Remote Control Valve

4. Use a wrench [19 mm (0.748 in)] to remove the 5 6. Use a wrench [19 mm (0.748 in)] to remove the 2
bolts (2), and then remove the under cover (1). hose adapters (1).

5. Use a wrench [19 mm (0.748 in)] to remove the 5 7. Use a hexagon wrench [8 mm (0.315 in)] to remove
hoses (1). the 2 bolts (1) on both the left and right sides of the
travel lever.
• Mark the valve and hoses so that the connectors
match at the time of assembly.
• Install caps or plugs to the valve and hoses to
prevent any entry of water, dust or dirt.
• Clean the valve and hoses by spraying with a
parts cleaner to prevent scratches and prevent
dirt from accumulating on the connectors.

8. Pull up the travel remote control valve (1) into the

cab, and then remove the travel remote control
valve.

84592788 EN - March 2012

8007A-4
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Removal and Installation of Travel Remote Control Valve

Installation of Travel Remote 4. Use a wrench [19 mm (0.748 in)] to install the 6
hoses (1).
Control Valve Tightening torque: 25.4 - 31.4 N·m (18.737 - 23.163
lbf·ft)
Be careful not to connect the hydraulic hoses in incorrect
locations.
Before installing the hoses, check that the hose adapters
are not loose and retighten them to the specified torque.
When the torque is not specified, check the "Bolt Size
and Torque Table".
1. Pull down the travel remote control valve (1) into the
cab, then install the travel remote control valve.

5. Use a wrench [19 mm (0.748 in)] to install the 5 bolts

(2) and install the under cover (1).

2. Use a hexagon wrench [8 mm (0.315 in)] to install

the 2 bolts (1) on both the left and right sides of the
travel lever.

6. Use a hexagon wrench [8 mm (0.315 in)] to install

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

8007B-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

8007B-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Operation Remote Control Valve

Job code 35355AA12 Removal of Operation Remote

Control Valve (left side)
WARNING
1. Roll up the boot (1) of the control lever and use the
• Be sure to release hydraulic pressure before Phillips screwdriver or box wrench [10 mm (0.394
beginning work. in)] to remove the 2 bolts (2) of the console top
cover.
CAUTION
• Be sure to stop the engine before beginning
work.

Items to prepare
• Wrenches [ 19 mm ( 0.748 in ), 22 mm ( 0.866 in )]
• Box wrench [ 10 mm ( 0.394 in ) ]
• Hexagon wrench [ 5 mm ( 0.197 in ) ]
• Phillips screwdriver
• Marking pen
• Cap
• Plug
• Rag 2. Use the Phillips screwdriver to remove the 2 screws
• Cleaning fluid (2), and then remove the handle of the tilt lever (1).

3. Use a hexagon wrench [5 mm (0.197 in)] to remove

the 2 bolts (2), and remove the grip (1) of the gate
lock lever.

84592788 EN - March 2012

8007B-3
Copyright ©
Removal and Installation of Operation Remote Control Valve

4. Use the Phillips screwdriver to remove the 2 screws 7. Roll up the boot (1) of the control lever, remove the
(1) of the console top cover. connector (2) of the horn switch, and cut the wire
band (3).

5. Remove the connectors (2) and remove the console

top cover (1). 8. While securing the nut (2) with a wrench [22 mm
(0.866 in)], use a wrench [19 mm (0.748 in)] to re-
move the lock nut (3) and remove the control lever
(1).

6. Use the Phillips screwdriver or box wrench [10 mm

(0.394 in)] to remove the 5 bolts (2), then remove
the cover (1).
9. Roll back the hose cover (1).

10. Use a wrench [19 mm (0.748 in), 22 mm (0.866 in)]

to remove the 6 hoses (1).
• Mark the joystick remote control valve and hoses
so that the connectors match at the time of as-
sembly.
• Use caps and plugs to cover the joystick remote
control valve and hoses to prevent any entry of
water, dust or dirt.
• Clean the joystick remote control valve and hoses
by spraying them with a parts cleaner to prevent
scratches and prevent dirt from accumulating on
the connectors.

84592788 EN - March 2012

8007B-4
Copyright ©
Removal and Installation of Operation Remote Control Valve

Installation of Operation Remote

Control Valve (left side)
1. Clean all the parts with a rag.

11. Use the hexagon wrench [5 mm (0.197 in) ] to re-

move the 3 bolts (1) and 3 washers (2).

2. Install the joystick remote control valve (1).

12. Remove the joystick remote control valve (1).

3. Use the hexagon wrench [5 mm (0.197 in)] to install

the 3 bolts (1) and 3 washers (2).

4. Use a wrench [19 mm (0.748 in), 22 mm (0.866 in)]

to install the 6 hoses (1).
• P port
Hose adapter tightening torque: 25.4 - 31.4 N·m
(18.738 - 23.163 lbf·ft)
Hydraulic hose tightening torque: 44 - 54 N·m
(32.459 - 39.835 lbf·ft)
When tightening, fasten the hose adapter with the
wrench.
• T port, 1 - 4 ports
Hose adapter, hydraulic hose tightening torque:
44 - 54 N·m (32.459 - 39.835 lbf·ft)

84592788 EN - March 2012

8007B-5
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Removal and Installation of Operation Remote Control Valve

8. Use a Phillips screwdriver or box wrench [10 mm

(0.394 in)] to install the cover (1) with the 5 bolts
(2).

5. Put the hose cover (1) in place.

9. Install the connectors (2) and install the console top

cover (1).

6. After installing the control lever, use a wrench [19

mm (0.748 in)] to install the lock nut (3) while secur-
ing the nut (2) with a wrench [22 mm (0.866 in)].
Lock nut tightening torque: 38.3 - 44.1 N·m (28.254
- 32.532 lbf·ft) 10. Use the Phillips screwdriver to install the 2 screws
(1) of the console top cover.

7. Install the horn switch connector (2), bundle with the

wire band (3), then cover the control lever boot (1).

84592788 EN - March 2012

8007B-6
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Removal and Installation of Operation Remote Control Valve

11. Use a hexagon wrench [5 mm (0.197 in)] to install Removal of Operation Remote
the gate lock lever grip (1) with the 2 bolts (2).
Control Valve (right side)
1. Roll up the boot (1) of the control lever and use the
Phillips screwdriver or box wrench [10 mm (0.394
in)] to remove the 2 bolts (2) of the console top
cover.

12. Use the Phillips screwdriver to install the handle of

the tilt lever (1) with the 2 screws (2).

2. Use the Phillips screwdriver to remove the 2 screws

(2), and then remove the handle of the tilt lever (1).

13. Use the Phillips screwdriver or box wrench [10 mm

(0.394 in) ] to install the 2 bolts (2) for the console
top cover and cover the control lever boot (1).

3. Use the Phillips screwdriver to remove the 2 screws

(1) of the console top cover.

84592788 EN - March 2012

8007B-7
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Removal and Installation of Operation Remote Control Valve

4. Remove the connectors (2) and remove the console 7. While securing the nut (2) with a wrench [22 mm
top cover (1). (0.866 in)], use a wrench [19 mm (0.748 in)] to re-
move the lock nut (3) and remove the control lever
(1).

5. Use the Phillips screwdriver or box wrench [10 mm

(0.394 in)] to remove the 5 bolts (2), then remove
the cover (1). 8. Roll back the hose cover (1).

6. Roll up the boot (1) of the control lever, remove the 9. Use a wrench [19 mm (0.748 in), 22 mm (0.866 in)]
connector (2) of the horn switch, and cut the wire to remove the 6 hoses (1).
band (3).
• Mark the joystick remote control valve and hoses
so that the connectors match at the time of as-
sembly.
• Use caps and plugs to cover the joystick remote
control valve and hoses to prevent any entry of
water, dust or dirt.
• Clean the joystick remote control valve and hoses
by spraying them with a parts cleaner to prevent
scratches and prevent dirt from accumulating on
the connectors.

84592788 EN - March 2012

8007B-8
Copyright ©
Removal and Installation of Operation Remote Control Valve

10. Use the hexagon wrench [5 mm (0.197 in) ] to re- Installation of Operation Remote
move the 3 bolts (1) and 3 washers (2).
Control Valve (right side)
1. Clean all the parts with a rag.

11. Remove the joystick remote control valve (1).

2. Install the joystick remote control valve (1).

3. Use the hexagon wrench [5 mm (0.197 in) ] to install

the 3 bolts (1) and 3 washers (2).

4. Use a wrench [19 mm (0.748 in), 22 mm (0.866 in)]

84592788 EN - March 2012

8007B-9
Copyright ©
Removal and Installation of Operation Remote Control Valve

8. Use a Phillips screwdriver or box wrench [10 mm

(0.394 in)] to install the cover (1) with the 5 bolts
(2).

5. Put the hose cover (1) in place.

9. Install the connectors (2) and install the console top

cover (1).

6. After installing the control lever, use a wrench [19

7. Install the horn switch connector (2), bundle with the

wire band (3), then cover the control lever boot (1).

84592788 EN - March 2012

8007B-10
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Removal and Installation of Operation Remote Control Valve

11. Use the Phillips screwdriver to install the handle of 12. Use the Phillips screwdriver or box wrench [10 mm
the tilt lever (1) with the 2 screws (2). (0.394 in)] to install the 2 bolts (2) for the console
top cover and cover the control lever boot (1).

84592788 EN - March 2012

8007B-11
Copyright ©
Removal and Installation of Operation Remote Control Valve

84592788 EN - March 2012

8007B-12
Copyright ©

Section

8007C

Removal and Installation of 4 Stack Solenoid

84592788 EN - March 2012

CONTENTS

Removal of 4 Stack Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of 4 Stack Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

8007C-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

8007C-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of 4 Stack Solenoid

Job code 35350AL06 Removal of 4 Stack Solenoid Valve

1. Attach the specialty adapter (1) to the area where
WARNING the air breather is removed, and set the vacuum
pump (2).
• Be sure to release hydraulic pressure before Create negative pressure in the hydraulic oil tank
beginning work.
using the vacuum pump.

CAUTION
• Be sure to stop the engine before beginning
work.

Items to prepare
• Wrenches [13 mm (0.512 in), 17 mm (0.669 in), 19 mm
(0.748 in), 22 mm (0.866 in)]
• Marking pen
• Cap
• Plug
• Rag
• Cleaning fluid
2. Use a wrench [13 mm (0.512 in)] to remove the 4
bolts (1), and then remove the cover (2).

3. Remove the 4 connectors (1).

4. Use wrenches [19 mm (0.748 in), 22 mm (0.866 in)]

to remove the hoses (1) (2) (3) (4) (5).
• Mark the solenoid valve and hose so that the con-
nector matches at the time of assembly.
• Use a cap or a plug to cover the solenoid valve
and hose to prevent any entry of water, dust or
dirt.
• Clean the solenoid valve and hose by spraying
them with a parts cleaner to prevent scratches
and prevent dirt from accumulating on the con-
nector.

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8007C-3
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Removal and Installation of 4 Stack Solenoid

Installation of 4 Stack Solenoid

Valve
1. Use a wrench [17 mm (0.669 in)] to install the 2 bolts
(2), then install the 4 stack solenoid valve (1).

5. Use a wrench [19 mm (0.748 in), 22 mm (0.866 in)]

to remove the hoses (1) (2) (3).
• Mark the solenoid valve and hose so that the con-
nector matches at the time of assembly.
• Use a cap or a plug to cover the solenoid valve
and hose to prevent any entry of water, dust or 2. Use wrenches [19 mm (0.748 in), 22 mm (0.866 in)]
dirt. to install the hoses (1) (2) (3).
• Clean the solenoid valve and hose by spraying
them with a parts cleaner to prevent scratches
and prevent dirt from accumulating on the con-
nector.

• The hose connections are as follows.

6. Use a wrench [17 mm (0.669 in)] to remove the

2 bolts (2), and then remove the 4 stack solenoid
valve (1).

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8007C-4
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Removal and Installation of 4 Stack Solenoid

• The electrical connector connection colors are in-

dicated below.

1 Solenoid valve

*1 Hose assembly
*2 Code

3. Use a wrench [19 mm (0.748 in), 22 mm (0.866 in)]

8007D-3
Copyright ©
Removal and Installation of Cushion Valve

4. Use a wrench [17 mm (0.669 in)] to remove the 4

bolts (1) on the cushion valve bottom, and then re-
move the cushion valve.

*2 Use 22 mm (0.866 in) wrench

*3 Use 19 mm (0.748 in) wrench

84592788 EN - March 2012

8007D-4
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Removal and Installation of Cushion Valve

Installation of Cushion Valve

1. Use a wrench [17 mm (0.669 in)] to install the cush-
ion valve, with the 4 bolt (1) on the cushion valve
bottom.

2. Install the sensor (1).

Use wrenches [19 mm (0.748 in), 22 mm (0.866 in)]
to connect the hoses to the nipples and elbows on
the ports.

2 Use 22 mm (0.866 in) wrench

3 Use 19 mm (0.748 in) wrench

• The hose connections are as follows.

84592788 EN - March 2012

8007D-5
Copyright ©
Removal and Installation of Cushion Valve

3 Swing right
4 Bucket close
5 Heat circuit line
6 Arm out
7 Boom down
8 Swing left
9 Bucket open
10 Pressure sensor (swing)
Swing priority switching pilot
11
line
12 Drain line

3. Use a wrench [19 mm (0.748 in)] to install the under

cover (2) with the 8 bolts (1).

4. Use a hexagon wrench [5 mm (0.197 in)] to install

the air breather (2) on the hydraulic oil tank with the
4 bolts (1).
• Bolt (1) tightening torque: 2.94 - 4.9 N・m (2.1689
- 3.6146 lbf・ft)

1 Arm in
2 Boom up

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8007D-6
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Section

8008

Procedures for Assembly and Disassembly of Hydraulic

Pump Main Unit

84592788 EN - March 2012

CONTENTS

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assembly procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

8008-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

8008-2 PRINTED IN FRANCE
Copyright ©
Procedures for Assembly and Disassembly of Hydraulic Pump
Main Unit
Tools Disassembly procedures
The table below shows the tools required for assembly 1. Select a location for disassembly.
and disassembly of the K7V pump.The bolts and plugs
may vary by pump type. • Select a clean location.
• Place a rubber plate or cloth on the work platform
so as not to damage the parts.
Tool name Tool dimensions
4 mm (0.157 in), 5 mm 2. Use cleaning oil to remove any dirt or rust from the
(0.197 in), 6 mm (0.236 in), surface of the regulator.
Hexagon wrench 3. Remove the drain port plugs (468) and drain the oil
8 mm (0.315 in), 10 mm
(0.394 in), 14 mm (0.551 in) from the pump casing (F) (271).
Socket wrench, dou- • Remove the plugs from both the front and rear
19 mm (0.748 in), 24 mm
ble-head (single- pumps.
(0.945 in)
head) wrench
Monkey wrench Medium-sized 4. Remove the hexagon socket head bolts (412, 413),
Flathead screwdriver and remove the regulator.
Screwdriver
(medium size) x 2 • See the manual for the regulator for how to disas-
Plastic hammer semble the regulators.
With adjustable specified
Torque wrench
torque tightening
Snap ring pliers For stop ring, TSR-160
Diameter D4 (0.157 in) or
Steel rod
less, L = 100 (3.937)
Tweezers

5. Place the pump regulator horizontal on the work

platform with the installation surface facedown, and
remove the flange sockets (435) and PTO unit (05).
• When placing the regulator with the installation
surface face down, be sure to place a rubber plate
or similar material on the work platform so as not
to damage the regulator installation surface.
• See the manual for the PTO unit for how to disas-
semble the PTO unit.

84592788 EN - March 2012

8008-3
Copyright ©
Procedures for Assembly and Disassembly of Hydraulic Pump
Main Unit
6. Loosen the flange sockets (435) and remove the 9. Remove the cylinder blocks (141) out from pump
gear pump (04). casing (F) (271) and pump casing (R) (272) in a
straight line in relation to the drive shafts (111, 113),
and remove the piston subassemblies (151, 152),
holder plates (153), spherical bushings (156), and
cylinder springs (157) at the same time.
• Be careful not to damage the sliding surfaces of
the cylinder blocks, spherical bushings, shoes,
and swash plates.

7. Loosen the hexagon socket head bolts (401, 402)

fastening the pump casing (F) (271), the pump cas-
ing (R) (272), and the valve block (312) together.

10. Remove the hexagon socket head bolts (406) and

remove the seal cover (F) (261).
• The seal cover (F) can be easily removed by
inserting a flathead screwdriver into the notch
groove on the seal cover (F) and then pulling the
screwdriver out.
• The seal cover (F) has an oil seal, so be careful
not to damage the oil seal when removing the seal
cover.
8. Separate the pump casing (F) (271), the pump cas-
ing (R) (272), and the valve block (312).
• When separating the pump casings and valve
block, remove the 1st gear (116) at the same
time.

11. Lightly strike the rear end sections of the drive

shafts (111, 113) to remove them from the pump
casings (271, 272).

84592788 EN - March 2012

8008-4
Copyright ©
Procedures for Assembly and Disassembly of Hydraulic Pump
Main Unit
12. Remove the shoe plates (211) and swash plates 14. Remove the valve plates (313, 314) from the valve
(212) from the pump casings (271, 272). block (312).
• These can also be removed in Step 7.

13. Insert the needles into the lock release holes (See
diagram.) on the swash plate support boards
(251), then while restraining the rotation lock 15. If necessary, remove the Q min. plugs (533), stop-
pins (255), rotate the swash plate support boards pers (L) (534), stoppers (S) (535), servo pistons
counter-clockwise, and take them out from the (532), and tilting pins (531) from the pump casings
pump casings. (271, 272), and remove the needle bearings (124)
from the valve block (312).
• When inserting the needles for restraining, be
careful not to mix up the lock release holes and • To avoid damaging the heads of the tilting pins,
small holes (for the oil paths) on the arc of the use a jig when removing them.
swash plate support boards. • Loctite has been applied to the sections where the
• Be careful when taking out the swash plate sup- tilting pins and servo pistons are bonded, so be
port boards. The rotation lock pins and set springs careful not to damage the servo pistons.
may pop out. • Try to avoid removing the needle bearings unless
they are at the end of their service life.
• Do not loosen the hexagon nuts of the valve block
or Q min. plug. This changes the flow volume
setting.

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8008-5
Copyright ©
Procedures for Assembly and Disassembly of Hydraulic Pump
Main Unit
Assembly procedures plates and the shoe plates on the swash plate sup-
port boards (251).
The assembly procedure is the reverse of the disassem-
bly procedure. However, follow the precautions below. • Use the fingertips of both hands to check that the
1) Be sure to repair any parts damaged during disas- swash plates move smoothly.
sembly, and prepare replacement parts in advance. • Apply grease to sliding sections of swash plates
2) Any foreign matter entering the equipment can create and swash plate support boards for easier instal-
a malfunction. Therefore, after thoroughly cleaning the lation of the drive shafts.
equipment with cleaning oil, air blow the equipment, and • Be careful not to damage the sliding surfaces of
perform assembly in a clean location. the shoe plates.
3) Make sure to tighten bolts and plugs of each section
to the specified torque.
4) Be sure to apply clean hydraulic oil to sliding sections
before assembly.
5) As a rule, replace all seals such as O-rings with new
parts.
1. Install the set springs (256) and the rotation lock
pins (255) in the pump casing (F) (271). Next, align
the swash plate support boards (251) with the cen-
tering locations of the pump casings, rotate clock-
wise, then fasten the swash plate support boards
with the rotation lock pins.
• If the servo pistons, tilting pins, stoppers (L), and
stoppers (S), and Q min. plug have been re- 3. Install the drive shafts (111, 113) with cylinder roller
moved, install these parts in the pump casings in bearings (123), bearing spacers (127), and stop
advance. rings (824) set on them to the pump casings (271,
• To avoid damaging the heads of the tilting pins 272).
and the feedback pins, use a jig when tightening
the servo pistons and tilting pins. Also, apply Loc-
tite (medium strength) to the thread sections.

4. Attach the seal cover (F) (261) to the pump casing

(F) (271), and secure the cover with the hexagon
socket head bolts (406).
• Apply a thin layer of grease to the oil seal inside
the seal cover (F).
• Be careful not to damage the oil seal when attach-
ing it.

2. Install the shoe plates (211) on the swash plates

(212). Next fit the swash plate tilting bushings onto
the tilting pins (531) and correctly mount the swash

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8008-6
Copyright ©
Procedures for Assembly and Disassembly of Hydraulic Pump
Main Unit
5. Assemble the piston cylinder subassemblies (cylin- • When installing the pump casings and valve
der blocks (141), piston subassemblies (151, 152), block, install the 1st gear at the same time.
holder plates (153), spherical bushings (156) and
cylinder springs (157)), align the piston subassem-
blies with the spherical bushings and cylinder
splines, and insert them into the pump casings.

8. Tighten the valve block (312) and pump casings

(271, 272) with the hexagon socket head bolts (401,
402).
6. Align the valve plates (313, 314) with the spring pins
(886) and install on the valve block (312).
• Be careful not to mistake the suction and dis-
charge directions of the valve plates.

9. Tighten the flange sockets (435) and install the gear

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

8010-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

8010-2 PRINTED IN FRANCE
Copyright ©
Pump Main Unit Maintenance Standards

Replacement standards for worn parts

If wear on any part exceeds the standard values below, replace or readjust that part.
If, however, the appearance of the part shows significant damage, replace that part.

Recommended
Reference dimen-
Part name and inspection item replacement Solution
sions
value
Piston and cylinder bore clearance (D 0.032 mm (0.001260 0.056 mm
Replace piston or cylinder.
- d) in) (0.002205 in)
Piston and shoe caulking section 0 - 0.1 mm (0 - 0.0039 0.3 mm (0.0118 Replace piston and shoe assem-
backlash (δ) in) in) bly.
3.7 mm (0.1457 Replace piston and shoe assem-
Shoe thickness (t) 3.9 mm (0.1535 in)
in) bly.
40.3 mm (1.5866
Free height of cylinder spring (L) 41.1 mm (1.6181 in) Replace cylinder spring.
in)
Assembled height of holder plate and 15.7 mm (0.6181 Replace holder plate or spherical
17.0 mm (0.6693 in)
spherical bushing (H - h) in) bushing.

Clearance between the piston and cylinder bore : D-d Free height of cylinder spring : L

Loseness of piston, shoe, and caulking : δ Combined height of pressure plate and spherical bush :
Thickness of shoe : t H-h

84592788 EN - March 2012

8010-3
Copyright ©
Pump Main Unit Maintenance Standards

Standards for repairing cylinders, valve plates, and swash plates (shoe
plates)
Valve plate (sliding section)
Surface roughness re-
Swash plate (shoe plate 3-Z
quiring repair
section)
Cylinder Standard surface rough-
0.4 Z or lower (lapping)
Surface roughness ness (repair value)

Tightening torque
Tightening torque
Part name Size Tool name [mm (in)]
[N・・m (lbf・・ft)]
M5 6.9 (5.090) B=4 (0.157)
M6 11.8 (8.705) 5 (0.197)
M8 29.4 (21.688) 6 (0.236)
M10 56.9 (41.974) 8 (0.315)
Hexagon socket head bolt M12 98.1 (72.367) 10 (0.394)
M14 156.9 (115.743) 12 (0.472)
M16 235.4 (173.652) 14 (0.551)
M18 333.4 (245.945) 14 (0.551)
M20 431.5 (318.313) 17 (0.669)
RC 1/16 6.9 (5.090) 4 (0.157)
PT plug RC 1/8 10.3 (7.598) 5 (0.197)
NOTE: RC 1/4 17.2 (12.688) 6 (0.236)
Hexagon wrench
Wrap seal tape around the plug 1.5 - 2 times RC 3/8 34.3 (25.303) 8 (0.315)
RC 1/2 49.0 (36.147) 10 (0.394)
G1/4 29.4 (21.688) 6 (0.236)
G 3/8 74 (54.59) 8 (0.315)
ROH plug
G1/2 98.1 (72.367) 10 (0.394)
G3/4 147.1 (108.514) 14 (0.551)

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Overall View
Attached diagram 1. pump assembly cross-section diagram

Drive shaft front side Drive shaft rear side

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Drive Shaft Front Side

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Drive Shaft Rear Side

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Part Table
Component part No. (Q'ty) or
Code Part name Q'ty
type
04 Gear pump 1 set ZX10L7RZ1-07AV
2
011 Piston subassembly 151 (9PC), 152 (9PC)
sets
013 Cylinder subassembly (R) 1 set 141 (1PC), 313 (1PC)
014 Cylinder subassembly (L) 1 set 141 (1PC), 314 (1PC)
2
030 Swash plate subassembly 212 (1PC), 214 (1PC)
sets
2
530 Tilting pin subassembly 531 (1PC), 548 (1PC)
sets

1 Right rotation valve plate

2 Left rotation valve plate

Code Part name Q'ty Code Part name Q'ty

111 Drive shaft (F) 1 467 ROH plug 2
113 Drive shaft (R) 1 468 ROH plug 4
116 1st gear 1 490 Insert plug 9
123 Cylinder roller bearing 2 531 Tilting pin 2
124 Needle roller bearing 2 532 Servo piston 2
127 Bearing spacer 2 533 Q min. plug 2
141 Cylinder block 2 534 Stopper (L) 2
151 Piston 18 535 Stopper (S) 2
152 Shoe 18 548 Feedback pin 2
153 Holder plate 2 702 O-ring 2
156 Spherical bushing 2 710 O-ring 1
157 Cylinder spring 12 711 O-ring 1
211 Shoe plate 2 717 O-ring 2
212 Swash plate 2 723 O-ring 6
214 Tilting bushing 2 724 O-ring 12
251 Swash plate support board 2 727 O-ring 4
255 Rotation lock pin 2 732 O-ring 4
256 Set spring 2 733 O-ring 2
261 Seal cover (F) 1 774 Oil seal 1
271 Pump casing (F) 1 789 Backup ring 2
272 Pump casing (R) 1 792 Backup ring 2
312 Valve block 1 806 Hexagon nut 2
313 Valve plate (R) 1 808 Hexagon nut 2
314 Valve plate (L) 1 824 Stop ring 2
326 Cover 1 886 Spring pin 4
401 Hexagon socket head bolt 2 901 Eyebolt 2
Hexagon socket head locking
402 Hexagon socket head bolt 2 953 2
screw
406 Hexagon socket head bolt 4 954 Locking screw 2
414 Hexagon socket head bolt 4 981 Nameplate 1
435 Flange socket 4 983 Strike rivet 2
466 ROH plug 2

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Operation explanation
1. Flow control
The pump discharge flow is controlled as desired with the pilot pressure Pi.（See the Pilot pressure Pi）

Discharge volume Q

Pilot pressure Pi

1) When the pilot pressure Pi increases, the pilot piston (643) moves to the right and stops at the location
where the pilot spring (646) force and hydraulic pressure force balance each other.
The pin (875) fixed to lever 2 (613) fits into the crimped groove section [A section] of the pilot piston, so
lever 2 rotates through the movement of the pilot piston with point B [fastened by the fulcrum plug (614)
and pins (876)] as the fulcrum.
The pin (897) fixed to the feedback lever (611) projects into the large opening [C section] of lever 2, so as
lever 2 rotates, the pin (897) moves to the right.
The pin (548) fixed to the tilting pin (531) that shakes the swash plate is bonded to the 2-side width section
[D section] of the feedback lever.
Therefore, as the pin (897) moves, the feedback lever rotates with section D as the fulcrum.
Since the spool (652) is linked to the feedback lever via the pin (874), the spool moves to the right.
When the spool moves, the discharge pressure P1 is led to the servo piston large-bore chamber via the
spool and Cl port.
The discharge pressure P1 is always led to the servo piston small-bore chamber, but the servo piston is
moved to the right due to the surface area difference and the tilting angle is reduced.
When the servo piston moves to the right, point D also moves to the right.
The return spring (654) is mounted on the spool.
Since force pulling the spool to the left is always acting, the pin (897) is pressed into the large opening (C
section) of lever 2.
Because of this, accompanying the point D movement, the feedback lever rotates around the point C as
the fulcrum and the spool moves to the left.
This movement causes the open section between the sleeve (651) and the spool (652) to begin to close,
and the servo piston stops at the point the open section fully closes.
Flow reduction operation
2) Flow increase operation
When the pilot pressure Pi decreases, the pilot piston (643) is moved to the left by the pilot spring (646)
force and lever 2 (613) rotates with point B as the fulcrum.
The pin (897) is pressed in the large opening [C section] of lever 2 by the return spring (654) via the spool
(652), pin (874), and feedback lever (611), so accompanying rotation of lever 2, the feedback lever rotates
with point D as the fulcrum and the spool moves to the left.When the spool moves, the Cl port opens to the
tank port, so the pressure in the large-diameter section of the servo piston drains out, the servo piston is
moved to the left by the discharge pressure P1 of the small-diameter section and the flow increases.
Accompanying the movement of the servo piston, point D moves to the left, the feedback lever rotates with
point C as the fulcrum, and the spool moves to the right.
This operation continues until the open section between the spool and sleeve closes, and then the servo
piston stops at the point the open section fully closes.

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2. Horsepower control

Discharge volume Q

Discharge pressure

As the load pressure increases, the pump tilting angle decreases and the overload of the engine is prevented
as in the above diagram. This regulator uses the simultaneous full-horsepower control method. Therefore, the
tilting angles (displacement volume) of the 2 pumps are controlled to the same value as indicated in the equation
below.
Tin = P1 x q/2π + P2 x q/2π = (P1 + P2) x q/2π
(q: Displacement volume)
Horsepower control is the same as flow control and is briefly explained below.
(For detailed operation of each part, see the Flow control.)
1) Overload prevention operation
When the self pump discharge pressure P1 or the counterpart pump discharge pressure P2 rises, since
P1 and P2 act on the stepped section of the compensation piston (621), the compensation rod (623) is
pressed to the right and moves to the location where the force of the outer spring (625) and inner spring
(626) balance out the hydraulic pressure force.
The movement of the compensation rod is transmitted to lever 1 through the pin (875) and lever 1 rotates
around the pin (876) (point E) fastened to the casing (601).
The pin (897) fixed to the feedback lever (611) projects into the large opening [F section] of lever 1, so as
lever 1 rotates, the feedback lever rotates with point D as the fulcrum and the spool (652) moves to the right.
When the spool moves, the discharge pressure P1 is led to the large-bore chamber of the servo piston via
the Cl port, the servo piston is moved to the right, and the pump discharge flow is decreased to prevent
overload of the power source.
The servo piston movement is transmitted to the feedback lever via point D.
The feedback lever rotates with point F as the fulcrum and the spool moves to the left.
The spool moves until the open section with the sleeve (651) closes, and then the servo piston stops at the
point the open section closes.
2) Flow return operation
If the self pump discharge pressure P1 or the counterpart pump discharge pressure P2 decreases, the
compensation rod (623) is pressed back by the springs (625, 626) and lever 1 rotates about point E.
Accompanying the lever 1 rotation, the feedback lever rotates around point D as the fulcrum and the spool
moves to the left.
Because of this, the Cl port opens to the tank port, the servo piston large-diameter section pressure drains
off, the servo piston moves to the left and the pump discharge flow increases.
The movement of the servo piston is transmitted to the spool by the feedback mechanism, and this operation
continues until the open section between the spool and the sleeve closes.
3. Low tilting (low flow) command priority mechanism
The flow control and the horsepower control tilting command is transmitted to the feedback lever and spool via
the large openings [C and F sections] of lever 1 and lever 2, but since the C and F sections have a structure in
which a pin (D4) projects into a large hole (D8), the pin (897) only contacts the lever that makes the tilting smaller
and the D8 hole for the lever on the side that has the larger tilting command state is free rather than being in
contact with the pin (897).
This type of mechanical selection method gives priority to flow control and horsepower control commands with
low tilting.

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4. Power shift control (decreased horsepower control)

Discharge volume Q

Discharge pressure
（P1 + P2）

Use the power shift pressure Pf to arbitrarily control the pump set horsepower.(See the Discharge pressure (P1
+ P2)）
When the power shift pressure Pf increases, the compensation rod (623) is moved to the right via the pin (898)
and the compensation piston (621), so the pump tilting angle and the horsepower setting are reduced in the same
way as was explained with the overload prevention operation of horsepower control.
By contrast, as the power shift pressure Pf decreases, the horsepower setting increases.

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Regulator adjustment
The adjusting screws on this regulator can be used to adjust the maximum flow, minimum flow, horsepower control
properties, and flow control properties. (Each of the adjustment amounts is shown in "6. (1) Regulator adjustment
amount list".)
1. Maximum flow adjustment

Discharge volume Q

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Procedures for Assembly and Disassembly of Regulator

Tools
Tool name Tools dimensions
4 mm (0.157 in), 5 mm (0.197 in), 6 mm (0.236 in), 8 mm
Hexagon wrench
(0.315 in) (B dimension)
Socket wrench, double-head (single-head) wrench
Monkey wrench Medium size
Screwdriver Medium-sized flathead screwdriver × 2
Plastic hammer
Torque wrench
Pliers For stop ring, x 2
Steel rod Diameter D4 (0.157) or less, L = 100 (3.937)
Tweezers
Bolt M4, L = about 50 (1.968)

Disassembly preparations
1. These regulators comprise small precision parts, so assembly and disassembly operations are somewhat com-
plex.
2. The pressure-flow settings of the front side regulator and the rear side regulator differ, so mark the regulators
when disassembling to differentiate between the drive side and the driven side.
3. When disassembling the regulators, read this disassembly procedure thoroughly before following the sequence
below.
The numbers in parentheses after the part names are the codes indicated in "Diagram 1.
Front-side regulator assembly cross-section diagram" "Diagram 2.
Rear-side regulator assembly cross-section diagram".

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Disassembly procedures and remove the spring seating (653), return spring
(654), and sleeve (651).
1. Select a location for disassembly.
• The sleeve (651) is assembled with retaining ring
• Select a clean location. (836).
• Place a rubber plate or cloth on the work platform • When removing the stop ring (814), the return
so as not to damage the parts. spring (654) flies out, so be careful not to lose this
2. Use cleaning oil to remove any dirt or rust from the part.
surface of the regulator.
3. Remove the hexagon socket head bolts (438) and
remove the cover (C) (629).
• The cover (C) is assembled with adjusting screw
(C) (628), adjusting ring (C) (627), lock nut (630),
hexagon nut (801), and hexagon socket head
locking screw (924). Do not loosen these screws
and nuts. Doing so changes the adjusted pres-
sure-flow setting.

7. Remove the loosening prevention plugs (616) and

remove the fulcrum plug (614) and adjusting plug
(615).
• When removing the loosening prevention plugs,
they may be damaged. (Even if there is no loos-
ening prevention plug, this is not a problem with
function.)

4. After removing the cover (C) (629) subassemblies,

remove the outer spring (625), inner spring (626),
and spring seating (C) (624) from the compensation
section, and pull out the adjusting ring (Q) (645),
pilot spring (646), and spring seating Q (644) from
the pilot section.
• The adjusting ring (Q) (644) can be easily re-
moved by pulling them out with an M4 bolt.

5. Remove the hexagon socket head bolts (436) and

remove the pilot covers A, B (641). Then, remove
the pilot cover ROH plugs (467), then remove the
Pf sleeve (631) and pin (898).
6. Remove the set spring (655) from the pressure ad-
justment section.Then remove the stop ring (814),

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8. Remove the lever (2) (613). Do not pull out the pins 13. For the KR76-9Y2C-V, remove the hexagon socket
(875). head bolt (436) and remove the pilot cover A (641).
Remove the electromagnetic proportional pressure
• These can be easily removed by using a pair of reducing valve (079).
tweezers.
For the KR76-9X2D-V, remove the hexagon socket
head bolt (436) and remove the pilot cover B (641).
Next, remove the hexagon socket head bolts (439)
and remove the valve casing (656). Remove the
electromagnetic proportional pressure reducing
valve (079).
• Be careful not to damage the connector section of
the electromagnetic proportional pressure reduc-
ing valve (079).
This completes the disassembly of the regulator
main units.

CAUTION

9. Pull out the pins (874) and remove the feedback The component parts are small, so be very
lever (611). careful not to lose them.
• Use a fine steel rod to push out the pins (874)
(pin diameter φ5) from above without touching the
lever (1) (612).

10. Remove the lever (1) (612). Do not pull out the pins
(875).
11. Pull out the pilot piston (643) and spool (652).
12. Pull out the piston case (622), compensation piston
(621), and compensation rod (623).
• The piston case (622) can be removed by pushing
out the compensation rod (623) from the opposite
side of the piston case (622).

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Assembly procedures 7. Insert the pins (875) press fit in the lever (2) (613)
into the groove on the pilot piston (643) and install
The assembly procedure is the reverse of the disas- the lever (2) (613).
sembly procedure. However, follow the precautions
below.
1) Be sure to repair any parts damaged during disas-
sembly, and prepare replacement parts in advance.
2) Any foreign matter entering the equipment can cre-
ate a malfunction. Therefore, after thoroughly clean-
ing the equipment with cleaning oil, air blow the equip-
ment, and perform assembly in a clean location.
3) Make sure to tighten bolts and plugs of each section
to the specified torque.
4) Be sure to apply clean hydraulic oil to sliding sec-
tions before assembly.
5) As a rule, replace all seals such as O-rings with new
parts.
1. Select a location for assembly. 8. Install the fulcrum plug (614) so that the pins (875)
press fit in the fulcrum plug (614) are inserted into
• Select a clean location. the pin holes on the lever (2) (613).
• Place a rubber plate or cloth on the work platform
so as not to damage the parts.
2. Install the compensation rod (623) into the compen-
sation hole on the casing (601).
3. Insert the pins (875) press fit in the lever (1) (612)
into the grooves on the compensation rod (623) and
install the lever (1) (612) on the pins (875) press fit
in the casing (601).
4. Install the spool (652) and sleeve (651) into the
pressure adjustment holes on the casing (601).
• Check that the spool (652) and sleeve (651) slide
smoothly in the casing (601) without catching.
• Be careful to assemble the spool (652) in the cor-
rect direction.
9. Install the adjusting plug (615).Install loosening pre-
5. Install the feedback lever (611), and insert the pins vention plugs (616) as necessary.
(874) in alignment with the pin holes on the feed-
back lever (611). • Be careful to insert the fulcrum plug (614) and
adjusting plug (615) into the correct holes.
• Assembly is easier if the pins (874) are inserted • At this time, check that the backlash from the
into the feedback lever (611) in advance. movement of the feedback lever (611) is not too
• Be careful to assemble the feedback lever (611) great and that the feedback levers do not catch
in the correct direction. on anything.
6. Install the pilot piston (643) into the pilot hole on the 10. Install the return spring (654) and spring seating
casing (601). (653) into the sleeve (651) and install the stop ring
(814) in the spool (652).
• Check that the pilot piston (643) slide smoothly
without catching.

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11. Install the set spring (655) into the pressure adjust- 13. Install the spring seating (Q) (644), pilot spring
ment hole and the compensation piston (621) and (646), and adjusting ring (Q) (645) into the pilot
piston case (622) into the compensation holes. holes, and install the spring seating (C) (624),
inner spring (626), and outer spring (625) into the
compensation holes.
• Be careful to install the spring seating (Q) (644)
and the spring seating (C) (624) in the correct di-
rection.

12. Install the Pf sleeve (631), pin (898), and ROH plugs
(467) in each pilot cover (641) and tighten with the
hexagon socket head bolts (436).
Also, for the KR76-9Y2C-V, install the electromag-
netic proportional pressure reducing valve (079) in
the pilot cover A (641); for the KR76-9X2D-V install
the electromagnetic proportional pressure reducing 14. Assemble the cover (C) (629) set with the adjusting
valve (079) in the valve casing (656). screw (C) (628), adjusting screw (Q) (925), adjust-
ing ring (C) (627), lock nut (630), hexagon nut (801),
• Check that the pin (898) moves smoothly. and hexagon socket head locking screw (924), and
• Be careful not to damage the connector section of tighten the hexagon socket head bolts (438).
the electromagnetic proportional pressure reduc-
ing valve (079).

This completes the assembly of the regulator main units.

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Diagram 1. Front-side regulator assembly cross-section diagram

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1 Front side regulator

2 Rear side regulator

Component part No. (q'ty) or

Code Part name Q'ty
type
545 (1PC), 546 (1PC), 547
050 Shuttle valve subassembly 1 set
(1PC)
Electromagnetic proportional
079 1 set KDRDE5K-31/30C50-102
pressure reducing valve

Code Part name Q'ty Code Part name Q'ty

- Regulator subassembly 1 set 641 Pilot cover A 1
412 Hexagon socket head bolt 2 643 Pilot piston 1
413 Hexagon socket head bolt 2 644 Spring seating Q 1
418 Hexagon socket head bolt 2 645 Adjusting ring Q 1
436 Hexagon socket head bolt 1 646 Pilot spring 1
437 Hexagon socket head bolt 4 651 Sleeve 1
438 Hexagon socket head bolt 4 652 Spool 1
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Code Part name Q'ty Code Part name Q'ty

466 ROH plug 1 653 Spring seating 1
467 ROH plug 1 654 Return spring 1
496 Insert plug 15 655 Set spring 1
545 Steel ball 1 708 O-ring 1
546 Seat 1 1 724 O-ring 7
547 Seat 2 1 726 O-ring 2
601 Casing A 1 727 O-ring 1
611 Feedback lever 1 728 O-ring 1
612 Lever (1) 1 730 O-ring 2
613 Lever (2) 1 734 O-ring 1
614 Fulcrum plug 1 753 O-ring 3
615 Adjusting plug 1 755 O-ring 1
616 Loosening prevention plug 2 757 O-ring 1
621 Compensation piston 1 801 Hexagon nut 1
622 Piston case 1 802 Hexagon nut 1
623 Compensation rod 1 814 Stop ring 1
624 Spring seating C 1 836 Locking ring 1
625 Outer spring 1 874 Pin 1
626 Inner spring 1 875 Pin 4
627 Adjusting ring C 1 887 Pin 1
628 Adjusting screw C 1 897 Pin 1
629 Cover C 1 898 Pin 1
Hexagon socket head locking
630 Lock nut 1 924 1
screw
631 Pf sleeve 1

Tightening torque
Tightening
Part No. Screw size torque
N•m (lbf・・ft)
412, 413 M8 29 (21.39)
418 M5 6.9 (5.090)
436, 437,
M6 12 (8.85)
438
466 G1/4 36 (26.56)
467 G3/8 74 (54.59)
496 NPTF 1/16 8.8 (6.492)
614, 615 M14 x 1.5 27 (19.92)
630 M30 x 1.5 160 (118.03)
801 M8 16 (11.80)
802 M10 19 (14.02)

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Diagram 1. Front-side regulator assembly cross-section diagram

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Component part No. (q'ty) or

Code Part name Q'ty
type
Electromagnetic proportional
079 1 set KDRDE5KR-20/40C13-203A
pressure reducing valve

Code Part name Q'ty Code Part name Q'ty

- Regulator subassembly 1 set 644 Spring seating Q 1
412 Hexagon socket head bolt 2 645 Adjusting ring Q 1
413 Hexagon socket head bolt 2 646 Pilot spring 1
437 Hexagon socket head bolt 5 651 Sleeve 1
438 Hexagon socket head bolt 4 652 Spool 1
439 Hexagon socket head bolt 4 653 Spring seating 1
466 ROH plug 1 654 Return spring 1
496 Insert plug 8 655 Set spring 1
601 Casing B 1 656 Valve casing 1
611 Feedback lever 1 708 O-ring 1
612 Lever (1) 1 724 O-ring 7
613 Lever (2) 1 726 O-ring 2
614 Fulcrum plug 1 728 O-ring 1
615 Adjusting plug 1 730 O-ring 2
616 Loosening prevention plug 2 734 O-ring 1
621 Compensation piston 1 753 O-ring 6
622 Piston case 1 755 O-ring 2
623 Compensation rod 1 757 O-ring 1
624 Spring seating C 1 801 Hexagon nut 1
625 Outer spring 1 802 Hexagon nut 1
626 Inner spring 1 814 Stop ring 1
627 Adjusting ring C 1 836 Locking ring 1
628 Adjusting screw C 1 874 Pin 3
629 Cover C 1 875 Pin 2
630 Lock nut 1 887 Pin 1
631 Pf sleeve 1 897 Pin 1
641 Pilot cover B 1 898 Pin 1
Hexagon socket head locking
643 Pilot piston 1 924 1
screw

Tightening torque
Tightening
Part No. Screw size torque
N•m (lbf・・ft)
412, 413 M8 29 (21.39)
418 M5 6.9 (5.090)
437, 438,
M6 12 (8.85)
439
466 G1/4 36 (26.56)
496 NPTF 1/16 8.8 (6.492)
614, 615 M14 x 1.5 27 (19.92)
630 M30 x 1.5 160 (118.03)
801 M8 16 (11.80)
802 M10 19 (14.02)

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Section

8011

Procedures for Assembly and Disassembly of Control Valve

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CONTENTS

Main plunger section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Foot relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Main relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly and pressure setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pressure setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Overload relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Center bypass valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Arm regeneration check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Boom back pressure check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Load hold valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Boom regeneration check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Check valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Swing priority valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Check valve (swing priority path). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Arm regeneration valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Travel signal switchover spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

8011-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

8011-5
Copyright ©
Procedures for Assembly and Disassembly of Control Valve

Foot relief valve

1. Main unit poppet

1) Remove the socket head bolts (1) and remove the cover assembly (2).
• Socket head bolt
Hex socket diameter: 8 mm (0.315 in)
Tightening torque: 50 N・m (36.88 lbf・ft)
• Before installing the cover for reassembly, confirm that there is an O-ring mounted at the cover opening.
2) Remove the spring (3) and poppet (4).

2. Cover section

84592788 EN - March 2012

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Procedures for Assembly and Disassembly of Control Valve

1) Remove the cap (5), spring (6), and poppet (7).

• Cap
Hex socket diameter: 8 mm (0.315 in)
Tightening torque: 50 N・m (36.88 lbf・ft)

• For parts that have been in operation for a long time, the poppet (7) can sometimes not be removed from
the edge of the sleeve seat surface.Do not force disassembly of parts.
2) Remove the cap (10) and remove the piston (9).
• Cap
Hex socket diameter: 10 mm (0.394 in)
Tightening torque: 60 N・m (44.26 lbf・ft)

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Procedures for Assembly and Disassembly of Control Valve

3) Use a pipe with an inner diameter of D6 and an outer diameter of D10 and lightly tap out the sleeve (8) from
the left side.

4) Remove the cap (11), spacer (12), spring (13), and check (14).
• Cap
Hex socket diameter: 5 mm (0.197 in)
Tightening torque: 20 N・m (14.75 lbf・ft)

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Procedures for Assembly and Disassembly of Control Valve

Boom regeneration check

1. Remove the cap (1), spacer (2), spring (3), and check (4).
• Cap
Hex socket diameter: 6 mm (0.236 in)
Tightening torque: 30 N・m (22.13 lbf・ft)

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Procedures for Assembly and Disassembly of Control Valve

Check valve
This section explains check valve disassembly procedures for the locations listed below.To assemble, perform the
reverse of the disassembly procedure.
• During disassembly, manage each part using shipping tags so that they are reassembled properly.

Disassembly is explained with the double check valve that is installed on the AM-1 etc.
1. Remove the cap (1), spring (2), and checks (3) and (4).
• Cap
Hex socket diameter: 12 mm (0.472 in)
Tightening torque: 100 N・m (73.77 lbf・ft)
• Be careful as the orifice diameter of double check cap varies depending on the application.

1. Remove the swing priority valve.

• See the procedure for disassembling the swing priority valve.

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Procedures for Assembly and Disassembly of Control Valve

2. Remove the seat (1), check (2), and spring (3).

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Procedures for Assembly and Disassembly of Control Valve

Arm regeneration valve

1. Remove the cap (1), spring receiver (2), spring (3), and spool (4).
• Cap
Hex diameter: 24 mm (0.945 in)
Tightening torque: 60 N・m (44.26 lbf・ft)
• There may be a piston (6) attached.

2. Remove the sleeve (5) and remove the piston (6).

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Procedures for Assembly and Disassembly of Control Valve

Travel signal switchover spool

1. Remove the cap (1), spring (2), and spool (3).

• Cap
Hex socket diameter: 6 mm (0.236 in)
Tightening torque: 30 N・m (22.13 lbf・ft)

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Section

8012

Procedures for Operation/Assembly and Disassembly of

Hydraulic Cylinder (made by KYB)

84592788 EN - March 2012

CONTENTS

Specifications and Structure Diagram (including the assembly diagram and parts table) . . . . . . . . . . . . . . . . . . . . . . 3
Basic functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Function of Each Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cylinder Head Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pipe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Precautions for Installing the Cylinder on the Machine Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Usage Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Maintenance and Inspection Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Maintenance Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Trouble Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Storage Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Storing Parts Individually (In principle, store indoors.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
When Mounted on Vehicle Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Recommended Anti-rust Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Assembly and Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
General Work Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Inspection after Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Required Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
General Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Special Jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Special Jigs Part Number List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Drain the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Secure the Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Removal of Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Pull out the Piston Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Fasten the Piston Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Remove the Piston Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Removal of Piston etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Disassembly of the Retraction Side Cushion Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Remove the Piston Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Disassembly of the Buffer Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Disassembly of U-ring and Wiper Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Removal of O-ring and Backup Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Disassembly of Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Removal of Pin Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Cleaning and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Test Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Usage Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Structural Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Boom Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Arm Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Bucket Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

8012-1 PRINTED IN FRANCE
Copyright ©

84592788 EN - March 2012 Copyright © 2011 CNH FRANCE

8012-2 PRINTED IN FRANCE
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Specifications and Structure Diagram (including the assembly diagram
and parts table)
In this manual, explanation is done using a product with a representative structure for a construction machine hydraulic
cylinder (KCH-6 model).
For details on the specifications and structure of the product being used, see the attached structural diagram.
Basic functions
Hydraulic cylinders are a type of hydraulic actuator.
A hydraulic cylinder converts the energy of pressure supplied from the hydraulic pump into a large force of linear
motion. By operating the hydraulic pressure direction switchover valve, one can switch the direction of operation
between extension and retraction.
This linear motion with large force and the switchover of the operation direction are the basic functions.
Function of Each Location
This manual explains the functions of each section of the cylinder using one of our products with a typical structure.
There may be some slight differences with the product being used, but the functions are the same.
Cylinder Head Assembly
The cylinder head assembly has the function of bearing the piston rod (2) by the bushing (4) press fit into the inner
diameter of the cylinder head (3). The seal system of the inner diameter of the cylinder head prevents oil from leaking
to the outside and prevents foreign matter from getting into the cylinder. The cylinder head assembly also has the
function of supplying and discharging high-pressure oil from inside the cylinder tube to the retraction side port.

1 Cylinder tube 5 O-ring 9 Wiper ring

2 Piston rod 6 Buffer ring 10 O-ring
3 Cylinder head 7 U-ring 11 Backup ring
4 Bushing 8 Backup ring 12 Installation bolt

• Bushing
The bushing is press fit to the inside surface of the cylinder head (3) and touches the piston rod (2). Together with
the slide rings (18) (19) on the outer circumference of the piston, the bushing divides the lateral load applied to the
cylinder and moves linearly relative to the piston rod. Furthermore, it supports one end of the piston rod and has
the function of minimizing eccentricity which has a negative impact on the sealing.
• Buffer ring
The buffer ring (6) has the function of buffering the pressure and heat applied on the U-ring (7) by the hydraulic oil
to improve durability.
• U-ring and backup ring
The U-ring (7) seals the pressure oil within the cylinder. The U-ring also has the function of forming an appropriate
oil film on the surface of the piston rod in order to prevent rust of the piston rod (2). The backup ring (8) has the
function of suppressing extrusion of the U-ring into the gap between the piston rod and the cylinder head (3) when
the pressure operates and of improving durability.
• Wiper ring
The wiper ring (9) is positioned in the opening where the piston rod (2) comes out from and goes into the cylinder.
This wiper ring (9) prevents dust and water from getting into the cylinder from the outside. It also has the function
of wiping off any mud sticking to the surface of the piston rod as the piston rod moves.

84592788 EN - March 2012

8012-3
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Piston Assembly
The piston assembly has the function of transmitting the propulsion of the cylinder. A seal ring (16) is mounted on the
center of the piston (15) to prevent the flow of pressure oil from either the left or right chamber to the other chamber.
There are slide rings (18) (19) mounted at each end of the seal ring. They have the function of a bearing to receive
the cylinder lateral load.

1 Cylinder tube 16 Seal ring 21 Steel ball

2 Piston rod 17 Backup ring 22 Cushion ring
13 Cushion ring 18 Slide ring 23 Cushion seal
14 Cushion seal 19 Slide ring 24 Stopper
15 Piston 20 Locking screw 25 Snap ring

Use caution with the direction

a of the cut surfaces during in-
stallation
b Face the "slit" to the piston side.

For some cylinder sizes, the piston (15) and nut (21) are separate.

84592788 EN - March 2012

8012-4
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)

1 Cylinder tube 17 Backup ring 23 Steel ball

2 Piston rod 18 Slide ring 24 Cushion ring
13 Cushion ring 19 Slide ring 25 Cushion seal
14 Cushion seal 20 Shim 26 Stopper
15 Piston 21 Nut 27 Snap ring
16 Seal ring 22 Locking screw

Use caution with the direction

a of the cut surfaces during in-
stallation
b Face the "slit" to the piston side.

Example of parts numbers for separated piston and nut

• Seal ring and backup ring
The seal ring (16) is positioned at the center of the piston (15) and uses the tension force of the O-ring to seal the
ring-shaped gap between the piston and the cylinder tube (1) and form chambers with a high-pressure side and a
low-pressure side with the piston as the boundary. The backup ring (17) has the function of suppressing extrusion
of the seal ring into the gap between the piston and the cylinder tube when the pressure operates and of improving
durability.
• Slide ring
Slide rings are positioned at both ends of the seal ring (16) and contact the inside surface of the cylinder tube (1).
Together with the bushing (4) positioned on the inside surface of the cylinder head (3), the slide ring divides the
lateral load applied to the cylinder and moves linearly relative to the inside surface of the cylinder tube.
Furthermore, it supports one end of the piston rod (2) and has the functions of minimizing eccentricity, which has a
negative impact on the sealing, and buries and captures any impurities trapped between the cylinder tube and the
slide rings (18) (19).
• Cushion ring (for separated piston and nut)
When the cylinder is fully extended, the cylinder head (3) and the cushion ring (13) fit together. When it is fully
retracted, the cylinder bottom and the cushion ring fit together. In both cases, this forms a ring-shaped gap and
squeezes the oil to reduce the cylinder collision speed at full extension or full retraction and thus soften the impact.
84592788 EN - March 2012
8012-5
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Pipe Assembly
The pipe assembly is mounted on the extension side and retraction side ports of the cylinder tube assembly. It has the
function of supplying and discharging high-pressure oil by connecting with the hydraulic circuits of the machine body.

28 Pipe assembly
29 Pipe assembly

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Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Handling Precautions
Precautions for Installing the Cylinder on the Machine Body
• When installing the cylinder on the machine body or removing it from the machine body, secure the piston rod at
the fully retracted position, check safety, and suspend.

CAUTION
Never suspend the cylinder from the line section. This would not only pose the danger of falling but
could also damage the cylinder.
Use a band to secure the piston rod in the fully retracted state.
If the piston rod is not in the fully retracted state, it could be easily damaged. This could create the
need for repair or make the piston rod unusable.
Also, not securing the piston rod is dangerous because the piston rod might fly out unexpectedly.

• Do not weld after the cylinder has been mounted on the machine body.
CAUTION
Electric welding on the cylinder or even at a position separated from the cylinder can generate a spark
within the cylinder and damage parts.
This could cause extensive damage, making it necessary to replace parts or replace the cylinder.

• When painting the machine body, mask the piston rod and wiper ring.
CAUTION
If the cylinder is operated with paint sticking to the piston rod surface and the wiper ring, the wiper
ring does not function adequately, greatly interfering with cylinder functions. For example, dirt and
paint from the outside may get into the cylinder easily and damage seal parts and cause an oil leak.

• Clean the cylinder before installing it.

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Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Usage Cautions
• Use under the determined conditions.
CAUTION
Use of hydraulic oil other than that specified can cause rapid deterioration of and damage to seal parts.
If the relief valve is set to a value higher than that on the assembly diagram, there is a danger of this
leading to cylinder damage.
General sealing materials cannot handle high ambient temperature [ about 100°C ( 212.0 °F ) or higher
] or low ambient temperature [ -20°C ( -4.0 °F ) or lower ], so the cylinder would be damaged if used at
such temperatures.
Such temperatures require special seal materials, so check if the cylinder being used complies with
this requirement.
The number one cause of cylinder trouble is oil leaks due to piston rod scratches.
Operate very carefully to avoid scratching.
If the piston rod is scratched, handle this according to "Trouble Diagnostics".

• Warm up the equipment adequately before work.

CAUTION
After the cylinder has been stopped for a long time, the seal parts inside the cylinder are stuck to the
metal of sliding surfaces, so do not suddenly pressurize or operate such a cylinder.
A new cylinder or one that has been left unused for a long time has much air built up inside, so it does
not operate smoothly.
Also, if the cylinder is suddenly operated or pressurized without bleeding out the air, the adiabatic
compression of the air generates high temperatures, which may burn and carbonize seal parts, leading
to a drastically reduced functionality.
Before starting work, always warm up the cylinder by moving slowly through a few full strokes under
no load to bleed off any air in the cylinder.

• For stopping the machine temporarily or storing it, always have the machine in a safely secure posture.
CAUTION
When extended, the cylinder cannot hold a load for a long time in a fixed position.
This is because the cylinder is extended and retracted by very minor oil leaks from hydraulic circuits
and from inside the cylinder and changes in the volume of the hydraulic oil due to oil temperature
variation.
This results in the danger of machine moving unexpectedly, which can lead to serious accidents.
For stopping the machine temporarily or storing it, always have the machine in a safely secure posi-
tion.

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Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Maintenance and Inspection Cautions
• Always carry out daily maintenance inspections.
CAUTION
The most important point for realizing the cylinder functions for a longer time is "daily maintenance
inspections".
In order to ensure adequate functioning, execute "Maintenance Inspection and Service".
Constantly clean off any mud, water, dust, oil or grease stuck to the piston rod and keep the piston
rod in a clean state.
However, do not use water or the like to clean the wiper ring section and seal section. Wipe with a rag.
When leaving the machine unused for a week or longer, apply anti-rust oil to the surface of the piston
rod in order to prevent rusting.

• Use genuine KYB parts for replacement parts.

CAUTION
If replacement parts are used that are not genuine KYB parts, adequate functioning cannot be attained.
Always use genuine KYB parts.
Specialty jigs have been produced so that assembly work and disassembly work can be done safely
and quickly, so order them.

8012-12
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Item Symptom Related part Cause Countermeasure and solution
1. As a rule, replace the rod packing
too at the same time.
2. Abnormally high pressure is often
Backup ring The part is greatly deformed. the cause.
The check items for this are the
same as those given above for
packing heel section extrusion.
There is foreign matter caught
Remove the foreign matter.
in the lip.
Wiper ring The lip is damaged.
There is other abnormal dam- Replace.
age.
Piston rod sliding
1 There is major wear of the
section oil leak
bushing and the gap with the
piston rod exceeds the limit on Replace.
Bearing part inner diameter wear in "Usage
(bushing) Limits".
1. Replace.
There are large scratches on a
2. Inspect the piston rod sliding sur-
sliding surface.
faces for scratches and rust.
1. Remove the scratches or rust
with a whetstone.
A seal mounting section has
Cylinder head 2. If the repair does not solve the
scratches and rust.
problem, replace the cylinder
head.
1. Remove the foreign matter.
2. If the O-ring is damaged, replace
it.
3. Tube interior surface inspection:
If there are any scratches or rust,
use a whetstone to make the sur-
There is foreign matter caught face smooth.
O-ring in the inner or outer diameter. 4. Cylinder head O-ring groove in-
There is damage to the O-ring. spection: Same as above
5. Backup ring inspection: If the
backup ring is deformed or ex-
truded, replace it.
Check the above and replace the
O-ring.
The part is deformed or ex-
Backup ring Replace together with the O-ring.
truded.
1. Disassemble the cylinder head
Cylinder head and inspect the O-ring and
2 matching section backup ring.
oil leak If there is damage, replace.
2. Check the tube and cylinder head
Cylinder
A part is loose. threads for damage and if there is
head
any damage, replace.
3. When the inspection is complete,
tighten to the specified torque.
See "Assembly Procedures".
4. Stop rotation.
There is looseness, stretching Replace all the bolts and tighten to the
Bolt
or breakage. specified torque.
1. Replace with a new one.
2. Oil leaks at matching sections
may be caused by abnormally
high pressure (including cush-
Cylinder tube There is abnormal swelling.
ion pressure), so if the tube is
swollen or deformed, replace it
with a new one.
Also inspect the circuit pressure.

84592788 EN - March 2012

8012-13
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Item Symptom Related part Cause Countermeasure and solution
CAUTION
Replace with a new one.
Pipe and cylinder
Pipe and cylinder There are cracks on the weld- The crack progresses and ultimately
tube welding sec-
tube ing section. the part fractures.
tion oil leak
A fracture is extremely dangerous, so
if a crack is seen, quickly stop work
3 and replace that part.
Welding over a crack is ineffective.
Tighten to the specified torque ac-
Line fastening bolt is loose.
cording to the work procedure.
Oil leak from cylin- The line is bent. Replace with a new one.
der line connec- Pipe assembly 1. Use a whetstone to make the sur-
tion section There are scratches on a con- face smooth.
tact surface. 2. If the oil leak does not stop, re-
place.
1. Replace with a new one.
The bending is large and ex-
2. There may also be damage to
ceeds the stipulated bend
Piston rod seals and sliding parts, so inspect
warp.
Cylinder tube them.
(Bend warp: See "Mainte-
If there is any abnormality, re-
nance Standards".)
place.
Operation defect Replace with a new one.
Movement is not Cylinder tube There are dents. Inspect the seal and sliding parts the
smooth. same as above.
1. Replace with a new one.
Abnormal wear of sliding parts
Inspect the seal and sliding parts
Piston rod and damage
the same as above.
Cylinder tube Foreign matter caught at the
2. Remove the foreign matter.
Sliding part piston section or the cylinder
Inspect the seal and sliding parts
head sliding section
the same as above.
Replace with a new one.
There are scratches, wear, or
Piston seal Also inspect the cylinder tube interior
other damage.
4 surfaces.
1. Use honing or a whetstone to
eliminate the scratches and rust
and make the surface smooth.
Internal oil leak There are scratches and rust
Cylinder tube If the scratches cover too large an
The piston rod ex- on interior surface.
area to be repaired, replace the
tends and retracts cylinder tube with a new one.
on its own and 2. Replace with a new piston seal.
drops abnormally
1. Tighten to the specified torque.
during operation.
See "Assembly Procedures".
Also, the stipu-
2. The piston rod thread section
lated speed is not
could be stretched.
output. Piston nut Tightening is insufficient.
Measure the diameter where the
rod and piston fit together and if
this area is tapered, replace the
piston rod assembly.
Inspect the amount of valve leakage
Valves Leak from valve.
and perform maintenance.

84592788 EN - March 2012

8012-14
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Item Symptom Related part Cause Countermeasure and solution
Bleed out the air.
1. Cylinder with no air bleeding
Bleed out the air by moving the
cylinder back and forth at few
times at low pressure and low
speed.
2. Cylinder with air bleeding (air
breather)
After securing the machine so
Operation is un- There is air remaining in the that the cylinder does not move,
Air
steady. cylinder. bleed the air from the air breather.

HINT
The cylinder may extend or retract
somewhat when the cylinder stops
suddenly.
This phenomenon occurs due to the
4 compressibility of the hydraulic oil.
This occurs particularly easily for
cylinders with long strokes.
The impact is high
when switching The gap between the installa- Measure the pin and pin bushing di-
Pin bushing
over between ex- tion section and the pin bushing mensions and replace any part that
Pin
tension and re- is enlarged. exceeds its specified dimension.
traction.
The oil or grease feed is inade-
Cylinder sliding Apply oil or grease.
Pin bushing quate.
operations make
Pin There is seizing at matching Replace with a new part and apply oil
sounds.
section. or grease.
CAUTION
The hydraulic oil expands and contracts with changes in temperature and pressure.
This causes the cylinder to extend and retract too, so it can be mistaken for an internal oil leak.
For internal oil leaks, always check the temperature and pressure under the same conditions.

84592788 EN - March 2012

8012-15
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Storage Standards
When a hydraulic cylinder is shipped from the plant, every measure is taken, but in order to prevent trouble during
storage and to extend the product service life, pay attention to the following items.
Storing Parts Individually (In principle, store indoors.)
• Store parts off the floor and do not store in any location with high temperature and humidity, corrosive gas or liquids.
• Before shipment, we operate the cylinder with hydraulic oil to which a fixed quantity of vaporizing anti-rust agent
has been added (in order to prevent rust within the cylinder), carry out the pre-shipping inspection, retract the pis-
ton rod with ultra-dry air (condensation point -35 °C ( -31.0 °F) or lower) (in order to prevent condensation due to
temperature difference), and then put caps on the ports and line joints before shipping the cylinder.
• Any product that has been in storage in our product warehouse longer than the standard storage period is disas-
sembled and inspected before being shipped.
Therefore, do not store or leave a cylinder unused with a cap removed or with the remaining oil in the cylinder
drained.

Storage for 6 month or longer

Storage for 1 month or longer Storage for 1 year or longer
(3 months for cylinder alone)
Clean any dust from the cylinder, Operate the cylinder back and forth
Since there is a danger of packings
and then apply anti-rust oil to the with clear hydraulic oil, and then pour
deterioration, disassemble, inspect,
1 pin bushings, flange sections, pis- anti-rust oil into the cylinder and store
and replace packings.
ton rod, and other sections that in compliance with the items on the
Also, check for rust inside the cylinder.
rust easily. left for storage of 1 month.
If a cylinder that has been stored for
If the cylinder cannot be operated, a long time is used as is, oil may leak
2 -
seal in anti-rust oil. due to temporary running-in defects of
seals.
3 When storing, be extremely careful not to let parts drop, let them collide with anything, or let anything strike them.

When Mounted on Vehicle Body

1. Operate the cylinder at least once per month.
2. Retract the cylinder so that as much as possible outside air does not touch the piston rod and apply anti-rust oil
at least once per month to the exposed part of the piston rod.
3. Handle carefully to absolutely avoid scratching the piston rod.
4. When putting the cylinder into an environment where rust occurs particularly easily, for example due to exposure
to sea breezes during export, always apply anti-rust oil to the piston rod and as much as possible protect with
polyethylene sheets or VCI paper (vaporizing anti-rust paper).
5. Anti-rust oil and other solvents can have negative impacts on seals, so select anti-rust oil carefully and as much
as possible keep it off dust seals etc.(For details on anti-rust oil to select, see "Recommended Anti-rust Oil".)

Recommended Anti-rust Oil

Vaporizing anti-rust oil
a. Ferro Gard #1009 (from USC Limited)
b. Knuckle Oil #105S (from Parker Industries, Inc.)
For inside cylinder For both a. and b., add 3 - 5 % of the hydraulic oil.
By volume,
Ferro Gard: 5/100
Knuckle Oil: 3/100
For piston rod Anti-rust P-1300 (from the Nippon Oil Corporation)
For machine worked sur-
faces other than parts with Select from JIS K 2246 (anti-rust oil) NP-1 through NP-6.
oil sealed in

84592788 EN - March 2012

8012-16
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Assembly and Disassembly Procedures
Preparations
Prepare the Following before Starting Disassembly:
1. Work platform preparation
Prepare a sufficiently spacious, solid and stable work surface so that parts will not fall or move during work.
2. Tool and materials preparation
Prepare the tools and materials shown on the following pages.

General Work Precautions

1. Thoroughly clean any dirt or mud from the outside walls of the cylinder before starting disassembly.
2. Each part has been manufactured with a high degree of precision, so be careful not to let parts bump each other
or fall when handling them.
3. If parts are struck or pried off with excessive force during work because they are tight, this may cause burrs or
damage which causing reduction in performance or oil leaking.
Perform work carefully and thoroughly.
4. If a cylinder is left disassembled, humidity and dirt can cause rust on parts.
If a pause in the work is unavoidable, be careful to prevent rust and keep off dust.

Maintenance Standards
Replace sliding parts and seal parts as follows.
1. Bushing
When 1/4 of the circumference is worn brown over the entire length.
2. Seals and slide rings
Replace with new parts when the cylinder is disassembled.
3. Pin bushing
When there is severe seizing.
4. Piston rod
When the piston rod is bent 0.5 mm ( 0.0196 in )/1 m ( 3.280 ft ) or more.

84592788 EN - March 2012

8012-17
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Inspection after Assembly
Dimension in-
Check the maximum retracted length and stroke as instructed on the diagram.
spection
Pressure with-
Check for looseness, permanent deformation, and external leaks when the test pressure in-
stand inspec-
structed on the diagram is applied to each stroke end for at least 3 min.
tion
Check the amount of oil leak at the rod section.
• Judgment value for rod section oil leak amount
Move the piston rod back and forth 20 times with the oil at a temperature from 20 °C - 40 °C
( 68.0 °F - 104.0 °F ), then judge by the state of the oil ring formed on the rod surface. If the
oil ring is in a broken down A state, this is judged to be trouble. See "Trouble Diagnostics" for
information on how to solve this.

External leak
inspection

Oil leak amount unit: ml/10 min.

Inner diameter Oil leak Inner diameter Oil leak Inner diameter Oil leak
mm ( in ) amount mm ( in ) amount mm ( in ) amount
Internal leak 32 ( 1.259 ) 0.4 100 ( 3.937 ) 4.0 160 ( 6.299 ) 10.0
inspection 40 ( 1.574 ) 0.6 125 ( 4.921 ) 5.6 180 ( 7.086 ) 12.6
50 ( 1.968 ) 1.0 140 ( 5.511 ) 6.0 200 ( 7.874 ) 15.6
63 ( 2.480 ) 1.6 220 ( 8.661 ) 20.0
80 ( 3.149 ) 2.3 250 ( 9.842 ) 22.0

1 Oil ring

a Acceptable
b Not acceptable

84592788 EN - March 2012

8012-18
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Required Tool
General Tool

No. Tool name Q'ty

Screwdriver (flathead screw-

1 1
driver)

2 Hexagon wrench 1 set

3 Vise 1

4 Wrench (for piston nuts) 1 set

5 Punch 1

6 Torque wrench 1 set

84592788 EN - March 2012

8012-19
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
No. Tool name Q'ty

7 Hammer (plastic hammer) 1

8 Monkey wrench 1

9 Scoop 1 set

84592788 EN - March 2012

8012-20
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Special Jig
Cylinder assembly requires the following special jigs.

8012-23
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Removal of Cylinder Head Passing a pipe through the hexagon wrench as in the
diagram below makes the work easier.
Use a hexagon wrench to loosen the cylinder head tight-
ening bolts and remove them.

1 About 1.5 m
2 Cylinder secured
Line band (Removal is unnec-
3 essary when replacement is
unnecessary.)

84592788 EN - March 2012

8012-24
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Pull out the Piston Rod CAUTION
1. Check that the line caps are removed.
2. Put the oil pan at the retraction side (cylinder head • When assembling and disassembling
with the cylinder secured horizontally,
side) port.
work paying particular attention to the
3. With the piston rod pulled out all the way, slowly pull
following points.
out the cylinder head and remove it.
In the work of removing the piston rod,
4. Pull out the piston rod together with the cylinder
there is a danger of the piston rod falling
head and place them on crossties.
and damaging parts right after it is re-
CAUTION moved.
Work carefully while holding the rod hor-
• When assembling and disassembling izontal and in contact with the crossties.
with the cylinder secured vertically, work
paying particular attention to the follow-
ing points.
In the work of removing the piston rod,
the cylinder head may come out of the
cylinder tube ahead of the piston due to
friction with the packing, creating a con-
dition in which there is space between
the cylinder head and the piston.
If the work is done in that state, the cylin-
der head may suddenly slip out and in-
jure the operator.
Always work with the cylinder head
touching the piston.
a Crosstie
Working in the horizontal
b
state
c Beware of falling

a Beware of falling

84592788 EN - March 2012

8012-25
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Fasten the Piston Rod
Use the rod head bolt width or pin hole to set up a rota-
tion stopper.

Remove the Piston Nut • Loosening a piston nut requires about 1.5 times
that torque. Prepare the power wrench (6) that
1. Remove the locking screw (3). uses the hydraulic jack (4) and hydraulic cylinder
Locking screw is caulked in with a punch at 2 loca- (5).
tions on the outer circumference.
Cut away the caulked sections with a hand drill (1), * For a one-piece type piston and nut, apply the
and then loosen the locking screw. wrench to the hexagonal section of the piston and
2. Remove the steel ball (2) at the bottom of the locking loosen the piston directly.
screw (3).

3. Remove the piston nut.

• The piston nut is tightened with the torque speci-
fied in the assembly diagram.

84592788 EN - March 2012

8012-26
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Removal of Piston etc.
Remove the piston (9), cushion ring (8), and cylinder
head (7) in that order.

Disassembly of the Retraction Side Cushion

Ring

1. Remove the piston nut. Disassembly cannot be 4. Remove the cushion ring (14).
done with the nut attached. 5. The cushion seal (13) has a split opening, so spread
2. Remove the snap ring (12). Remove by gently tap- the opening wide and remove the cushion seal.
ping with a plastic hammer in such a way as not to
scratch the piston rod (11) or cushion ring (14).
3. When the cushion ring (14) is slid to the piston rod
thread (11) side, the stopper (split in two) (15) can
be removed.

84592788 EN - March 2012

8012-27
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Remove the Piston Seal 3. Pull out the O-ring (19) with a scoop.
1. The slide rings (22) and backup ring (20) can be * The removed seal parts cannot be reused.
removed easily by hand.
2. Stand up a flathead screwdriver (23) as in the di-
agram on the right and tap with a hammer to cut
through the seal ring (16), and then remove the seal
ring.

10 Screw 18 Vise
17 Piston 21 Hardwood

84592788 EN - March 2012

8012-28
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Disassembly of the Buffer Ring
1. The buffer ring (27) is mounted in the groove on the
inner diameter of the cylinder head. When removing
this seal, stick in a sharp tool and lift it up, and then
insert a scoop and take it out.
* The removed seal parts cannot be reused.

Disassembly of U-ring and Wiper Ring Removal of O-ring and Backup Ring
1. Use a screwdriver to remove the U-ring (26) and 1. Pull out the O-ring (29) and backup ring (30) with a
backup ring (25). scoop.
2. The wiper ring (24) is press fit.
Stick a screwdriver straight down into the rubber
and tap it to remove the wiper ring.
* The removed seal parts cannot be reused.

84592788 EN - March 2012

8012-29
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Disassembly of Bushing 2. For the bushing (33), use the bushing removal jig
(32) as in the diagram on the right and press out
1. Raise the snap ring (28) with a screwdriver, and
the bushing with a press.
then remove it from the cylinder head.

31 Bushing a Press with the press.

Solution
[ mm ( in ) ] [ mm ( in ) ] [ mm ( in ) ]
55 - 75 +0.060 - +0.190
+0.30 ( +0.01181 ) Replace the bushing.
( 2.165 - 2.952 ) ( +0.002362 - +0.007480 )
80 - 120 +0.060 - +0.195
+0.30 ( +0.01181 ) Replace the bushing.
( 3.149 - 4.724 ) ( +0.002362 - +0.007677 )

• Piston slide ring thickness wear limit

Nominal diameter Standard thickness Minimum thickness

Solution
[ mm ( in ) ] [ mm ( in ) ] [ mm ( in ) ]
95 - 160 t2.42 - 2.48
t2.37 ( 0.093307 ) Replace the slide ring.
( 3.740 - 6.299 ) ( 0.09528 - 0.09763 )
165 - 250 t2.92 - 2.98
t2.87 ( 0.112992 ) Replace the slide ring.
( 6.496 - 9.842 ) ( 0.114961 - 0.117322 )

84592788 EN - March 2012

8012-33
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Structural Diagram
Boom Cylinder

Manufacturing No. stamping

*1 *3 PT1/4 *5 PT1/8 (A-TYPE)
position for left
Manufacturing No. stamping
*2 *4 Orifice：D1.3 mm (0.051 in) *6 Apply Loctite #242
position for right

Code kg lb
a 102 224.873

Bolt nomi- Bolt nomi-

Code ・m
N・・ft
lbf・ nal diame- Code ・m
N・・ft
lbf・ nal diame-
ter ter
b 226 - 235 166.72 - 173.36 M14 f 662 - 810 488.35 - 597.53 M60
c 29 - 34 21.39 - 25.08 M8 g 1148 - 1402 846.87 - 1034.24 M48
84592788 EN - March 2012
8012-34
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder (made by KYB)
Bolt nomi- Bolt nomi-
Code ・m
N・・ft
lbf・ nal diame- Code ・m
N・・ft
lbf・ nal diame-
ter ter
d 27 - 32 19.92 - 23.61 M10 h 15 11.07 M8
e 54 - 59 39.84 - 43.52 M10 i 27 - 32 19.92 - 23.61 M10

Code mm in Code mm in
L1 92 3.622 L11 D70 D2.756
L2 80 3.15 L12 (158) (6.22)
L3 (6) (0.236) L13 136 5.354
L4 6 0.236 L14 D70 D2.756
L5 (D160) (D6.299) L15 D105 D4.134
L6 82 3.228 L16 D123 D4.843
L7 70 2.756 L17 Stroke: 961 37.835
Maximum re-
L8 (6.25) (0.24606) L18 tracted length: 57.638
1464
L9 6.25 0.24606 L19 50 1.969
L10 R62 R2.441 L20 R65 R2.559

84592788 EN - March 2012

Manufacturing number stamp-

*1 *3 Orifice: D1.8 mm (0.071 in) *5 PT1/4
ing position
*2 P/T1/8 (B-TYPE) *4 Orifice: D1.0 mm (0.039 in) *6 Apply Loctite #242

Code kg lb
a 150 330.695

CONTENTS

Procedures for Assembly and Disassembly of Operation Remote Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Required Tools and Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Causes of Trouble and Countermeasures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

8013-2 PRINTED IN FRANCE
Copyright ©
Procedures for Assembly and Disassembly of Operation Remote
Control Valve
Procedures for Assembly and Disassembly of Operation Remote Control
Valve
Job code 35355AA18

CAUTION
• To ensure safe operations, wear protective devices before beginning work and follow all precautions.
• Be sure to repair any parts damaged during disassembly, and prepare replacement parts in advance.
• If any parts are significantly rusted or dirty, clean them before disassembling.
• Any foreign matter entering the equipment during assembly can create a malfunction. Therefore, after
thoroughly cleaning the equipment with cleaning oil, air blow the equipment, and assemble in a clean
location.
• When assembling sliding parts, be sure to coat them with new hydraulic oil.
• As a rule, replace all O-rings and other seal parts with new parts.
General cautions
• Be careful not to drop precision parts or let bump them with other parts during work.
• Do not forcefully open or hit parts in an effort to speed up operations.
Pay careful attention and proceed slowly so as not to damage any parts, create any oil leaks, or com-
promise the efficiency of the equipment, etc.
• Disassembled parts can easily rust or collect dust. Therefore, immediately after disassembling parts,
take precautions to prevent the parts from rusting or collecting dust.

Items to prepare
Maintenance Procedures
Required Tools and Tightening Torque
Tightening torque
Tools Dimension [ mm ( in ) ] Part No. Part name Screw size
・ft ) ]
[ N·m ( lbf・
63.7 - 73.5
22 ( 0.866 ) 312 Adjusting nut M14
Wrench ( 46.991 - 54.220 )
32 ( 1.260 ) 302 Disk M14
44.2 - 50.0
Special jig 24 ( 0.945 ) 301 Joint M14
( 32.606 - 36.884 )

Other
• Vapor corrosion inhibitor
• White kerosene
• Heat-resistant grease
• Sandpaper (#1000, #2000)
• Whetstone
• Vise
• Screwdriver
• Torque wrench

84592788 EN - March 2012

8013-3
Copyright ©
Procedures for Assembly and Disassembly of Operation Remote
Control Valve
Maintenance Standards
Maintenance in-
Standard Remarks
spection item
When handle is in neutral 1000 cc/min or more
Conditions
During operation 2000 cc/min or more
Leak amount Primary pressure 2.94 MPa ( 426.4578 psi )
If either condition occurs, replace the remote
Oil viscosity 23 mm2/S
control valve as one unit.
When wear on the sliding sections exceeds
The same approximate conditions as those
wear on the non-sliding sections by 10 μm or
Spool listed above for leak amount are expected when
more, replace the remote control valve as one
the condition on the left occurs.
unit.
If the end section is worn by 1 mm ( 0.039 in ) or more, perform replacement.

Push rod

Replace the operation section disk (302) and

Operation section Make adjustments if the backlash is due to
joint section (301) if there is backlash of 2 mm (
backlash looseness in the tightening sections.
0.079 in ) or more due to wear.
If abnormal noise, hunting, or a drop in primary
pressure occurs and the problem cannot be re-
Operation stability solved with "Causes of Trouble and Counter-
measures", replace the remote control valve as
a unit.

NOTE:
It is desirable for seal materials such as O-rings to be replaced with each disassembly, but it is acceptable to reuse
these after it is confirmed that they are not damaged.

84592788 EN - March 2012

8013-4
Copyright ©
Procedures for Assembly and Disassembly of Operation Remote
Control Valve
Disassembly Procedures 4. If the return springs are strong, the plate (2), plugs,
and push rods (3) will rise at the same time the joint
1. Use copper plate (or lead plate) to secure the re- (1) is loosened, so be careful of parts flying off when
mote control valve in a vise, then remove the bel- removing the joint.
lows (1).
• Be careful not to tear the bellows.

5. Remove the plate (1).

2. Use a wrench on the bolt width of the adjusting nut

1. Insert washer (4), secondary pressure spring (3)

and spring seating (2) onto each of the spool (1) in
that order.

5. Install seal (1) on the plug (2).

• Install so that the seal lips are as shown in the
diagram below.
2. Press in the spring seating (1) and move it to the
side while bending the secondary pressure spring
(2) to pass the seating over the larger hole and in-
stall it on each of the spools.
• Do not press in the spring seating by 6 mm ( 0.236
in ) or more.

3 Push rod

a Hydraulic oil application

3. Install the return springs (1) in the casing (2).

Install the pressure reducing valve assembly (3) in
the casing (2).
• Install them in the positions they were in before
disassembly.

84592788 EN - March 2012

8013-8
Copyright ©
Procedures for Assembly and Disassembly of Operation Remote
Control Valve
6. Install push rods (1) into the plugs (2). 9. Install the plate (1).
• Apply hydraulic oil to surface of the push rod.

8014-4
Copyright ©
Procedures for Assembly and Disassembly of Travel Remote
Control Valve
7. Remove push rods (2) from the plugs (1). 10. Remove the damping springs (2) (3) from the casing
Record the positions of the plugs in relation to the (1).
push rods. Record the positions of the damping springs in re-
Be careful not to scratch the surface of the push lation to the casing holes.
rods.
Be careful when removing, as the plugs may fly off.

11. Remove the spring seating (2) from the casings (1).

8. Remove the plugs (1) with the grease caps and • Record the positions of the spring seating in rela-
NHU packings left attached. tion to the casing holes.
Record the positions of the plugs in relation to the
casing holes.
Be careful when removing parts, as the pistons (3)
may fly off due to the damping springs (2).

12. Use a magnet, etc. to remove steel balls (1).

Be careful not to lose the steel balls.

9. Remove the pistons (1).

Record the positions of the pistons in relation to the
casing holes.

84592788 EN - March 2012

8014-5
Copyright ©
Procedures for Assembly and Disassembly of Travel Remote
Control Valve
13. Use the hexagon wrench to remove the hexagon 16. Remove the return spring (1) from the casing (2).
socket head bolts (1).

17. Lay the covers (1) on their sides on a level surface,

14. Remove the damper casing (1) and remove the place special tool 1 against the bushings, and re-
O-rings (4) (3) from the casing. move the bushings by lightly striking them with a
hammer.
• Record the positions of the damper casing in re-
lation to the casing (2).
• Be careful when removing parts, as the pressure
reducing valve assembly may fly off due to the
return springs.

18. Secure each cam assembly (1) in a vise, use a

wrench to loosen the lock nuts (2), and remove the
lock nuts and locking screws (3).
• As neutral adjustment of locking screws is neces-
sary during assembly, handle them as part of the
15. Remove the pressure reducing valve assembly (1)
cam assembly as long as replacement of locking
from the casing (2).
screws is not necessary.
• Record the positions of these parts in relation to
the casing holes.

84592788 EN - March 2012

8014-6
Copyright ©
Procedures for Assembly and Disassembly of Travel Remote
Control Valve
19. For disassembly of the pressure reducing valve as- 22. Remove the NHU packings (2) from the plugs (1).
semblies, place the bottom end of the spools (1) Use a small flathead screwdriver, etc. to remove.
perpendicular on a level work platform, lower the
spring seating (2), and use the end of a small flat- • Be careful not to scratch the inner surface of the
plugs.
head screwdriver to remove the 2 half-circle wash-
ers 1 (3).
Be careful not to scratch the surface of the spool.
Do not press in the spring seating by 4 mm ( 0.157
in ) or more.

23. Remove the O-rings (2) from the plugs (1).

20. Separate the spools (1), spring seating (2), sec-

ondary pressure springs (3), washers 2 (4), and
washers 3 (5).
Handle as an assembly until assembly is performed.
Washers 2 are used for pre-set adjustment of the
secondary pressure springs, so thickness is differ-
ent for each spool assembly. Additionally, these are
sometimes not used, so record the status for each
assembly.

24. Cleaning parts

• Clean all parts by placing them in a rough clean-
ing container filled with white kerosene. (rough
cleaning)
• Scratching can easily occur if cleaning of parts
is begun just after parts are immersed in white
kerosene, so let each part sit in white kerosene
until debris and grease sufficiently loosen off from
the surface of parts and float to the surface.
• If the white kerosene is dirty, this will encourage
damage to parts and result in reduced perfor-
mance after reassembly. Thoroughly manage the
21. Remove the grease cups (2) from the plugs (1). level of cleanliness of the white kerosene.
• Clean each part by placing it in a finish cleaning
container filled with white kerosene, and thor-
oughly clean each part, including the interior,
while slowly rotating it (finish cleaning).
Use a clean rag to thoroughly remove any white
kerosene stuck to parts.
• Do not dry parts with compressed air, as this will
damage parts and cause rust to form due to de-
bris and moisture being dispersed into the atmos-
phere.
• Preventing rust on parts
Apply an anti-rust agent to each part.
Rust will form on parts if they are left as is af-
ter cleaning, and this will cause reduced perfor-
mance of functions after reassembly.

84592788 EN - March 2012

8014-7
Copyright ©
Procedures for Assembly and Disassembly of Travel Remote
Control Valve
Assembly Procedures 3. Install the return springs (1) in the casing (2).

1. Install the washers 3 (5), washers 2 (4), secondary • Install them in the positions they were in before
pressure springs (3), and the spring seating (2) onto disassembly.
each of spools (1) in that order.
Washers 2 are used for pre-set adjustment of the
secondary pressure springs, so thickness is differ-
ent for each spool assembly. Additionally, these are
sometimes not used.
Check the status recorded during disassembly and
attach parts accordingly.

4. Install the pressure reducing valve subassemblies

(1) assembled in steps 1) and 2) above into the cas-
ing (2).
• Install them in the positions they were in before
disassembly.

2. Place the bottom end of the spools (1) perpendicu-

lar on a level work platform, push the spring seating
(2) down, and install the 2 half-circle washers 1 (3)
onto the spring seating in such a way that they are
not on top of each other.

• When installing the pressure reducing valve sub-

assemblies, be careful not to strongly strike the
casing corners (b) with the bottom ends of the
spools.

• Install the washers 1 so that the sharp edge side

(a) faces up and the washer catches the head of
the spool.
Do not press in the spring seating by 4 mm ( 0.157
in ) or more.

84592788 EN - March 2012

8014-8
Copyright ©
Procedures for Assembly and Disassembly of Travel Remote
Control Valve
5. Install O-rings (1) (2) on the casing (3). 8. Install the spring seating (1) into the bushings.
• Install them in the positions they were in before
disassembly.

6. Tighten the damper casing (1) and casing (2) with

the hexagon socket head bolts (3) to the specified
torque.
9. Install the damping springs (2) (3) in the casing (1).
• Install them in the positions they were in before
disassembly. • Install them in the positions they were in before
• Tighten the 2 hexagon socket head bolts (3) disassembly.
evenly, and tighten the damper casing (1) in a
parallel orientation.
• Hexagon socket head bolt (3) tightening torque:
7.8 - 9.8 N·m ( 5.754 - 7.229 lbf・ft )

10. Install the pistons (1).

• Install them in the positions they were in before
disassembly.

7. Install the steel balls (1) into the bushings.

84592788 EN - March 2012

8014-14
Copyright ©
Procedures for Assembly and Disassembly of Travel Remote
Control Valve
ANNOTATION:
Since hydraulic equipment is crucial to safety, we cannot guarantee performance and functions if disassembly and
reassembly are performed.

Code Part name Q'ty Code Part name Q'ty

101 Casing 1 271 Hexagon socket head bolt 2
102 Casing (damper) 1 301 Spool 4
201 Cover 2 311 Spring seating 4
202 Plug 4 313 Washer 3 4
203 Grease cup 4 324 Spring 4
210 NHU packing 4 335 Spring 4
211 O-ring 2 336 Spring 4
212 O-ring 4 337 Spring 4
213 O-ring 4 412 Bushing 4
214 Push rod 4 413 Camshaft 2
245 Washer 1 8 420 Cam 2
Hexagon socket head locking
217 Washer 2 4 423 2
screw
218 Spring seating 4 471 Locking screw 4
220 Hexagon socket head bolt 2 472 Lock nut 4
224 Piston 2D085 4 501 Bellows 2
225 Steel ball 2

Tightening torque list

Code Screw size Tightening torque Code Screw size Tightening torque
5.9 - 7.9 N･m
7.8 - 9.8 N･m
220 M6 423 M6 （ 4.35 - 5.82 lbf・ft ）
( 5.75 - 7.22 lbf・ft )
(Loctite coating)
45.2 - 64.8 N･m 29.9 - 36.7 N･m
271 M12 472 M10
（ 33.34 - 47.80 lbf・ft ） ( 22.06 - 27.07 lbf・ft )

a Grease application to top

Filling of grease cup with
b
grease

Attached diagram 2. Jig dimension diagram

1 Bushing removal jig

c Center hole possible [ D2 (

0.079 ) or less ]

84592788 EN - March 2012

Section

8016

Assembly and Disassembly of Cushion Valve

84592788 EN - March 2012

CONTENTS

Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Reverse Operation Spool Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Check Plunger Section with Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Shuttle Valve Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Reverse Operation Spool Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Check Plunger Section with Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Shuttle Valve Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Written Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Disassembly Procedures
This valve has a structure that forms small gaps. It is precision processed and the parts are carefully selected and fit
together, so do not disassemble it as much as possible.
If assembly and disassembly is unavoidable, pay attention to the following. (The product warranty may be invalidated.)
• Only disassemble in a clean location with minimal dirt.
• Use only clean tools and cleaning oil and handle them with care.
• Use plugs, caps to cover ports to prevent any entry of dirt and clean the outside of the assembly.
• Check the internal structure before starting work, and carefully study the disassembly objective and scope.

Reverse Operation Spool Section Check Plunger Section with Throttle

1. Remove the plugs (1) and O-rings (2). 1. Remove the plugs (1) and O-rings (2).
• Remove the springs (3). • Remove the springs (3) and remove the check
• Remove the spools (4) with the cap screws and plungers (4).
O-rings assembled in them.
CAUTION
The check plungers have similar shapes,
so identify them in such a way that no
one will mix them up with each other.

Diagram 1
2. Fasten the spool (3) assemblies taken out in 1. in a
vise.

CAUTION
Diagram 3
Use a piece of wood (jig) (4) to prevent
scratches.

• Remove the cap screws (1) and O-rings (2).

Diagram 2

84592788 EN - March 2012

Shuttle Valve Section

1. Remove the plugs (1) and O-rings (2) (3).
• Remove the steel balls (4).

Diagram 4

Assembly Procedures
This valve has a structure that forms small gaps.
It is precision processed and the parts are carefully selected and fit together, so do not disassemble it as much as
possible.
If assembly and disassembly is unavoidable, pay attention to the following. (The product warranty may be invalidated.)
• Only assemble in a clean location with minimal dirt.
• Use only clean tools and cleaning oil and handle them with care.
• Clean the disassembled parts and prepared parts.
• Study the internal structure before starting the work and prepare the parts required by the disassembly objective
and scope.

Reverse Operation Spool Section CAUTION

1. Assemble the cap screw (1) with O-ring (2) on the The spool assemblies are symmetrical left/
spool (3). right, so the insertion direction does not
matter.
• Tightening torque: 9.8 - 14.7 N·m ( 7.23 - 10.84
lbf・ft )
• Insert the springs (2) and assemble the plugs (3)
CAUTION with the O-rings (4) attached.
• Tightening torque: 39.2 - 49.0 N·m ( 28.92 - 36.14
Use a piece of wood (jig) (4) to prevent lbf・ft )
scratches.

Diagram 6
Diagram 5
2. Insert the spool assemblies (1) assembled in 1. into
the body.

84592788 EN - March 2012

Check Plunger Section with Throttle Shuttle Valve Section

1. Insert the check plungers (1). 1. Insert the steel balls (1).

CAUTION • Assemble the plugs (2) with the O-rings (3) (4)
attached.
The check plungers have similar shapes, • Tightening torque: 39.2 - 49.0 N ・ m ( 28.92 -
so be careful to insert each one in its cor- 36.14 lbf・ft )
rect position.

• Insert the springs (2) and assemble the plugs (4)

with the O-rings (3) attached.
• Tightening torque: 29.4 - 31.4 N·m ( 21.69 - 23.16
lbf・ft )

Diagram 8

Diagram 7

84592788 EN - March 2012

Written Materials
1. Check plunger table

Metering orifice diame-

Part No. Name Remarks
ter (D)
65301-11705 Check plunger 0.5 ( 0.0197 )
65301-11706 Check plunger 0.6 ( 0.0236 )
65301-11707 Check plunger 0.7 ( 0.0276 )
65301-11708 Check plunger 0.8 ( 0.0315 )
65301-11709 Check plunger 0.9 ( 0.0354 )
65301-11710 Check plunger 1.0 ( 0.0394 )
65301-11711 Check plunger 1.1 ( 0.0433 )
65301-11712 Check plunger 1.2 ( 0.0472 )
65301-11713 Check plunger 1.3 ( 0.0512 )
65301-11714 Check plunger 1.4 ( 0.0551 )
65301-11715 Check plunger 1.5 ( 0.0591 )

2. Cushion valve assembly diagram

External shape diagram

84592788 EN - March 2012

Cross section X - Cross section Y -

Cross section V -
Cross-section diagram

Code Part name Code Part name Code Part name

1 Body 9 Check plunger 17 Seat
2 Spool 10 Check plunger 18 O-ring
3 Spring 11 Check plunger 19 Plug
4 Plug 12 Check plunger 20 O-ring
5 O-ring 13 Spring 21 Name plate
6 Cap screw 14 Plug 22 Drive screw
7 O-ring 15 O-ring 23 Plug
8 Plug 16 Steel ball 24 Plug

84592788 EN - March 2012

Section

8017A

Removal and Installation of Arm HBCV

84592788 EN - March 2012

CONTENTS

Removal of arm HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of arm HBCV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

CAUTION 2. Use a hexagon wrench [8 mm (0.315 in)] to remove

the 4 hexagon socket head bolts (1), and then re-
• Stop the machine in the temporary decom- move the line (2).
missioning posture on a level location with
good footing. • Use caps or plugs to cover the HBCV and line to
prevent any entry of water, dust or dirt.
• Be sure to stop the engine before beginning
work. • Clean the HBCV and line by spraying them with
a parts cleaner to prevent scratches and prevent
• When working together with others, always dirt from accumulating on the connectors.
be sure to exchange signals and pay ade-
quate attention to safety.
• Be sure to release hydraulic pressure before
beginning work.

Items to prepare
• Wrench [19 mm (0.748 in), 22 mm (0.866 in)]
• Hexagon wrench [8 mm (0.315 in)]
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid

Removal of arm HBCV 3. Use a hexagon wrench [8 mm (0.315 in)] to remove

the 4 hexagon socket head bolts (1), and then re-
1. Use a wrench [19 mm (0.748 in), 22 mm (0.866 in)]
move the arm HBCV (2).
to remove the hoses (1) and (2).
• Mark the HBCV and hoses so that the connectors
match at the time of assembly.
• Use caps or plugs to cover the hoses and HBCV
to prevent any entry of water, dust or dirt.
• Clean the hoses and HBCV by spraying them with
a parts cleaner to prevent scratches and prevent
dirt from accumulating on the connectors.

Installation of arm HBCV

To install, perform the reverse of the removal procedure.
The tightening torque for line installation and HBCV in-
stallation is 41.6 - 60.8 N・m ( 30.688 - 44.851 lbf・ft ).

84592788 EN - March 2012

Section

8017B

Removal and Installation of Boom HBCV

84592788 EN - March 2012

CONTENTS

Removal of Boom HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of boom HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CAUTION 2. Use a hexagon wrench [6 mm (0.236 in)] to remove

the 4 hexagon socket head bolts (1), and then re-
• Stop the machine on a level location with move the line (2).
good footing.
• Tightening torque for bolt installation: 21.4 - 31.2
• Be sure to stop the engine before beginning N・m (15.787 - 23.015 lbf・ft)
work.
• Use caps or plugs to cover the HBCV and lines to
• When working together with others, always prevent any entry of water, dust or dirt.
be sure to exchange signals and pay ade-
quate attention to safety. • Clean the HBCV and lines by spraying them with
a parts cleaner to prevent scratches and prevent
• Be sure to release hydraulic pressure before dirt from accumulating on the connectors.
beginning work.

Items to prepare
• Wrench [19 mm (0.748 in), 22 mm (0.866 in), 27 mm
(1.063 in) ]
• Hexagon wrench [6 mm (0.236 in), 8 mm (0.315 in)]
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid
• Crossties

Removal of Boom HBCV

3. Use a hexagon wrench [8 mm (0.315 in)] to remove
1. Use wrenches [19 mm (0.748 in), 22 mm (0.866 in)]
the 4 hexagon socket head bolts (1), and then re-
to remove the hoses from the tool box side boom
move the boom HBCV (2).
HBCV (1), (2), (3) and (4).
• Tightening torque for bolt installation: 41.6 - 60.8
• Mark the HBCV and hoses so that the connectors N・m (30.688 - 44.851 lbf・ft)
match at the time of assembly.
• Use caps or plugs to cover the HBCV and lines to
prevent any entry of water, dust or dirt.
• Clean the HBCV and lines by spraying them with
a parts cleaner to prevent scratches and prevent
dirt from accumulating on the connectors.

4. Use wrenches [19 mm (0.748 in), 22 mm (0.866 in)]

to remove the hoses (1), (2), (3) and (4) from the
cab side boom HBCV in Step 1.
Use a wrench [27 mm (1.063 in)] to remove the
boom bottom pressure sensor (5).
• Tightening torque for boom bottom pressure sen-
sor installation: 82 - 98 N・m (60.49 - 72.29 lbf・
Pilot hose
1 ft)
[use 19 mm (0.748 in) wrench]
• Mark the HBCV and hoses so that the connectors
Drain hose match at the time of assembly.
2
[use 22 mm (0.866 in) wrench]
• Use caps or plugs to cover the HBCV and lines to
Drain hose prevent any entry of water, dust or dirt.
3
[use 22 mm (0.866 in) wrench] • Clean the HBCV and lines by spraying them with
Pilot hose a parts cleaner to prevent scratches and prevent
4
[use 19 mm (0.748in) wrench] dirt from accumulating on the connectors.

84592788 EN - March 2012

6. Use a hexagon wrench [8 mm (0.315 in)] to remove

the 4 hexagon socket head bolts (1), and then re-
Pilot hose move the boom HBCV (2).
1
[use 22 mm (0.866 in) wrench] • Tightening torque for bolt installation: 41.6 - 60.8
Drain hose N・m (30.688 - 44.851 lbf・ft)
2
[use 19 mm (0.748 in) wrench]
Pilot hose
3
[use 19 mm (0.748 in) wrench]
Pilot hose
4
[use 22 mm (0.866 in) wrench]

5. Use a hexagon wrench [6 mm (0.236 in)] to remove

the 4 hexagon socket head bolts (1), and then re-
move the line (2).
• Tightening torque for bolt installation: 21.4 - 31.2
N・m (15.787 - 23.015 lbf・ft)
• Use caps or plugs to cover the HBCV and line to
prevent any entry of water, dust or dirt.
• Clean the HBCV and line by spraying them with
a parts cleaner to prevent scratches and prevent
Installation of boom HBCV
dirt from accumulating on the connectors. To install, perform the reverse of the removal procedure.

84592788 EN - March 2012

Section

8018

Assembly and Disassembly of Center Joint

84592788 EN - March 2012

CONTENTS

CAUTION CAUTION
• The following cautions for hydraulic equip- General cautions
ment should be observed with these parts.
• To ensure safe operations, wear protective • Be careful not to drop precision parts or let
devices for the work and follow all precau- bump them with other parts during work.
tions. • Do not forcefully open or hit parts in an effort
• When removing devices or positioning de- to speed up operations.
vices at the time of installation, use a removal Pay careful attention and proceed slowly so
jig and a hammer or steel rod. as not to damage any parts, create any oil
• Make sure that the jig is used for disassembly leaks, or compromise the efficiency of the
of the axle and rotor. equipment, etc.
• Follow the precautions below when suspend- • Disassembled parts can easily rust or collect
ing the load. dust. Therefore, immediately after disassem-
bling parts, take precautions to prevent the
• The liftcrane must be operated by a quali- parts from rusting or collecting dust.
fied operator. • Make sure that foreign matter such as debris
• Do not stand or pass under the suspended and moisture does not enter.
load. • The work platform used should be solid, sta-
• Check the weight of the load to deter- ble, and sufficiently spacious.
mine whether it can be carried by hand or Also, items should be clean and free of debris
whether a liftcrane must be used. and moisture.
Remove debris and moisture before perform-
• Be sure to repair any parts damaged during
disassembly, and prepare replacement parts ing work.
in advance. • Inspect, remove debris and moisture, and
clean tools and jigs before work.
• If any parts are significantly rusted or dirty,
clean them before disassembling. • Jigs and tools that are appropriate to the con-
tents of work should be used.
• Any foreign matter entering the equipment
during assembly can create a malfunction.
Therefore, after thoroughly cleaning the Items to prepare
equipment with cleaning oil, air blow the • Hexagon wrenches [ 6 mm ( 0.236 in ), 14 mm ( 0.551
equipment, and assemble in a clean location. in ), or 17 mm ( 0.669 in ) ]
• When assembling V-rings, O-rings, and other • Torque wrench
sliding parts, be sure to coat them with new • Socket wrenches [ 6 mm ( 0.236 in ), 14 mm ( 0.551
grease. in ), or 17 mm ( 0.669 in ) ]
• As a rule, replace all O-rings and other seal • Lights
parts with new parts. • Mirror
• Specialty jigs

84592788 EN - March 2012

Configuration Diagram

Code Part name

1 Axle
2 V-ring
3 O-ring
4 Packing ring
5 Hexagon socket head bolt
6 O-ring
7 Cover
8 Thrust plate
9 Rotor
10 Loctite

84592788 EN - March 2012

Dimension Diagram

Maximum gap 10.0 ( 0.394 )

1 Axle 7 Cover *1
Minimum gap 8.5 ( 0.3346 )
Maximum gap 0.7 ( 0.0276 )
2 V-ring 8 Thrust plate *2
Minimum gap 0.3 ( 0.0118 )
2 x M12, screw depth 18 mm (
3 O-ring 9 Rotor *3 0.709 in ), bottom hole depth 23
mm ( 0.906 in )
4 Packing ring 10 Loctite #262 *4 G1/2-A class
5 Hexagon socket head B 11 Company nameplate *5 G1/4-A class
6 O-ring 12 Parker rivet *6 4 x G3/4-A class

Do not coat any processed surfaces marked with a symbol or port processed surfaces.

84592788 EN - March 2012

Jig Dimension Diagram

Axle removal jig

Hexagon socket head bolt (5)

4
1 Axle removal jig M8 x 25
Backing plate
M16 - M20 full threaded bolt Axle (1) outer diameter - about
5
2 L = 370 - 420 mm ( 14.567 - 5 mm ( 0.197 in )
16.535 in ) t = about 5 mm ( 0.197 in )
3 M16 - M20 female thread
Cover (7) installation dimen-
*1
sions

Removal jig (for O-ring and

Disassembly Procedures 4. Use axle removal jig 1 to push out the axle (2) from
the rotor (1).
1. Use a hexagon wrench [ 6 mm ( 0.236 in ) ] to re-
move the 4 hexagon socket head bolts (3) from the • Do not strike it with the hammer at this time.
rotor (1), then remove the cover (2).

5. Use removal jig 1 or the like to remove the V-ring

2. Remove the O-ring (2) from the rotor (1). (2) from the axle (1).

84592788 EN - March 2012

Disassembly 4. Loosening the tightening bolts

1. Removal of relief assembly • Loosen and remove the cover (32) and housing
Use a hexagon wrench on the caps [14 mm (0.551 (26) [12 mm (0.472 in) hexagon diameter].
in) hexagon diameter] to remove the relief assem-
blies (34) installed on the motor main unit.
• When reassembling the disassembled relief as-
semblies (34), make sure to install them in their
original locations.

5. Removal of cover
Place the entire motor with the shaft facing down,
and lift up and remove the cover (32).

2. Removal of make-up and bypass valve assembly

Loosen and remove the caps (39) [14 mm (0.551
in) hexagon diameter] and remove the springs (38)
and checks (37).
• When reassembling disassembled parts, make
sure to install parts in their original locations.

of the piston assemblies (8), and then install
the cam plate (6).

2. Assembly of cylinder assembly

1) Apply grease to the spherical section (section
touching the receiving spring (5)) of the cylin-
der (25) and install the receiving spring (5).

84592788 EN - March 2012

5) Install the tapered roller bearing (3) inner race 3. Installation of oil seal
on the cylinder (25). Coat the outer circumference of the oil seal (2) with
ThreeBond Co.,Ltd. "1211" white and install it with
the seal press-fit jig.
• Coat the oil seal lip part with grease to install it.

6) Lightly coat the installation section of the cylin-

der (25) inner race with Loctite 515 (or 518).

4. Install the tapered roller bearing (3) outer race on

the housing (26).

7) Install the inner race (1) on the cylinder (25).

5. Installation of cylinder assembly

Grasp the end surface of the cylinder (25) by hand
and gently install the cylinder assembly into the
housing (26). At this time, use seal protector on the
cylinder spline section.
• When the cylinder assembly is installed, the
spline shaft of the cylinder will stick out from the
bottom surface of the housing, so place an object
of about 30 - 50 mm (1.182 - 1.968 in) under the
surface.
• Check that the receiving spring (5) is down in the
spot facing section of the return plate (7).

1 Travel motor 12 Boom (down) 23 Forward left

84592788 EN - March 2012

Explanation of Hydraulic Circuit and Operations (standard model)

Swing Circuit
Swing Relief Cut-off Control Circuit

84592788 EN - March 2012

Explanation of Hydraulic Circuit and Operations (standard model)

Pressure line Pilot tank line • Travel, boom-up, arm-out/in, or bucket-open/close operation
Tank line Electric line
Pilot pressure line

a High flow
b Low flow

1 Swing motor 8 Control valve 15 Console lever lock switch

2 Swing 9 Travel pilot pressure sensor 16 Hydraulic pump
3 Cushion valve 10 Upper pilot pressure sensor 17 P1 pressure sensor
4 Right swing 11 Computer A 18 P1 flow control proportional valve
5 Left swing 12 Lever lock 19 Check valve
6 Swing pilot pressure sensor 13 Swing brake 20 Oil cooler
7 Remote control valve (arm, swing) 14 4 stack solenoid valve

2 Cushion valve 8 Oil cooler 14 Control valve
3 Right swing 9 Lever lock 15 Upper pilot pressure sensor
4 Left swing 10 Swing brake 16 Hydraulic pump
5 Swing pilot pressure sensor 11 4 stack solenoid valve 17 Swing
6 Remote control valve (arm, swing) 12 Console lever lock switch

When the engine is started and the swing lever is in neutral, the swing brake solenoid valve comes ON (24 V input), the
pressure to the swing motor P port is cut, and the swing parking brake works.
When the lever operation raises the reading to 0.5 MPa or higher at the pressure sensor in the swing pilot line, the output
from computer A to the swing brake solenoid valve goes OFF, the swing motor P port pressure rises, the swing parking brake
is released, and swing becomes possible.
As an example, this section explains the right swing operation.
By carrying out the right swing operation on the remote control valve, the pilot pressure oil is fed to the control valve 5b2 port
via the shuttle valve and switches the swing spool to the right swing side.
At the same time, computer A detects the swing pilot pressure sensor signal, judges that there is a swing operation, the
electrical signal output from computer A goes OFF, and the swing brake solenoid valve is switched. The pilot pressure oil is
fed to the swing motor P port from the swing brake solenoid valve C2 port to release the swing parking brake.
The discharge oil from hydraulic pump A1 enters the control valve PR (P1) port and is fed from the parallel oil path to the
swing spool. Switching the spool lets the oil flow into the swing motor B port and the right swing operation is carried out.
The pressurized oil from the swing motor A port goes through the swing spool and returns to the hydraulic oil tank.
When this is followed by an attachment operation, the pilot pressure is detected by the control valve Px2 port pressure sensor
and the swing parking brake continues to be released.
After the swing operation ends, if about 5 sec. pass with no upper operation, the swing brake solenoid valve output from
computer A comes ON and the swing parking brake works again.
After the swing ends, if this is followed by an upper operation or there is an upper operation within about 5 sec., when about
1 sec. passes after the end of the upper operation, the swing parking brake works again.
The swing parking brake is also released for independent upper operations and when about 1 sec. passes after the end of
the upper operation, the swing parking brake works again.

Swing brake sole- Swing motor me-

Key switch Swing pilot pressure sensor Upper pilot pressure sensor
noid valve chanical brake
OFF 0 MPa (0 psi) 0 MPa (0 psi) OFF ON
ON 0 MPa (0 psi) 0 MPa (0 psi) ON ON
ON 0.5 MPa (72.527 psi) min. 0 MPa (0 psi) OFF OFF
ON 0 MPa (0 psi) 0.5 MPa (72.527 psi) min. OFF OFF
ON 0.5 MPa (72.527 psi) min. 0.5 MPa (72.527 psi) min. OFF OFF

* Pilot pressure sensor judgment standard

• Operation is judged when at 0.5 MPa (72.527 psi) or above.

84592788 EN - March 2012

Explanation of Hydraulic Circuit and Operations (standard model)

Swing Parking Circuit (machine stop)

84592788 EN - March 2012

Explanation of Hydraulic Circuit and Operations (standard model)

Pressure line Pilot tank line
Tank line Electric line
Pilot pressure line

1 Swing motor 6 Remote control valve (arm, swing) 11 4 stack solenoid valve
2 Cushion valve 7 Hydraulic pump 12 Console lever lock switch
3 Right swing 8 Check valve 13 Computer A
4 Left swing 9 Lever lock 14 Control valve
5 Swing pilot pressure sensor 10 Swing brake 15 Oil cooler

Explanation of Hydraulic Circuit and Operations (standard model)

Explanation of Hydraulic Circuit and Operations (standard model)

Arm-in Forced Regenerative Circuit (with HBCV)

84592788 EN - March 2012

Explanation of Hydraulic Circuit and Operations (standard model)

Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

a To tank line
b Regeneration

1 Arm (in) 9 Console lever lock switch 17 Oil cooler

84592788 EN - March 2012

Explanation of Hydraulic Circuit and Operations (standard model)

Arm-in Load Holding Valve Circuit

84592788 EN - March 2012

Explanation of Hydraulic Circuit and Operations (standard model)

Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

a To tank line

1 Arm (in) 9 Upper pilot pressure sensor 17 Hydraulic pump

2 Arm (out) 10 Console lever lock switch 18 Oil cooler
3 Cushion valve 11 Monitor display 19 Check valve
4 Remote control valve (arm, swing) 12 Computer A 20 P1 pressure sensor
5 Lever lock 13 Load holding valve check valve 21 P2 pressure sensor
6 Boost pressure relief 14 Load holding valve poppet 22 Arm pressure sensor
7 4 stack solenoid valve 15 Forced regeneration release valve
8 Control valve 16 Arm cylinder

When the remote control valve arm operation lever is in neutral, the oil at the arm cylinder rod side is sealed by the load
holding valve check valve, reducing internal leakage from the main spool and reducing the natural drop of the arm.
By moving the remote control valve to the arm-in side, the pilot pressure oil is fed via the cushion valve to the control valve
5b52 port and 4a41 port and switches the arm (1) and (2) spools to the in side.
The discharge oil from hydraulic pump A1 enters the control valve PR (P1) port and is fed from the center bypass oil path
to the arm (1) spool. The discharge oil from hydraulic pump A2 enters the control valve PL (P2) port, flows from the center
bypass oil path and through the arm (2) downstream arm merge oil path and merges downstream of the arm (1) spool.
Switching the arm spool lets the oil flow into the arm cylinder bottom side and the arm-in operation is carried out.
At the same time, the pilot pressure oil from the Ps2 port operates on the load holding valve poppet and the poppet opens.
In this way, the load holding valve check valve spring chamber oil is connected to the tank line through the load holding valve
poppet, the spring chamber pressure drops, and the load holding valve check valve is opened.
The arm cylinder rod side pressurized oil goes through the load holding valve check valve and the arm (1) spool and returns
to the hydraulic oil tank.

84592788 EN - March 2012

Explanation of Hydraulic Circuit and Operations (standard model)

Arm-in Load Holding Valve Circuit (with HBCV)

84592788 EN - March 2012

Explanation of Hydraulic Circuit and Operations (standard model)

Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line

a To tank line

1 Arm (in) 9 Upper pilot pressure sensor 17 Hydraulic pump

2 Arm (out) 10 Console lever lock switch 18 Oil cooler
3 Cushion valve 11 Monitor display 19 Check valve
4 Remote control valve (arm, swing) 12 Computer A 20 P1 pressure sensor
5 Lever lock 13 Load holding valve check valve 21 P2 pressure sensor
6 Boost pressure relief 14 Load holding valve poppet 22 Arm HBCV spool
7 4 stack solenoid valve 15 Forced regeneration release valve 23 Arm HBCV poppet
8 Control valve 16 Arm cylinder 24 Arm pressure sensor

84592788 EN - March 2012

Explanation of Hydraulic Circuit and Operations (standard model)

Negative Control Circuit

84592788 EN - March 2012

Explanation of Hydraulic Circuit and Operations (standard model)

Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line Negative control line

a High flow
b Low flow

1 Control valve 6 4 stack solenoid valve 11 Hydraulic pump

2 Upper pilot pressure sensor 7 Computer A 12 P1 flow control proportional valve
N1 negative control pressure sen-
3 Travel pilot pressure sensor 8 13 Oil cooler
sor
N2 negative control pressure sen-
4 Lever lock 9 14 Check valve
sor
Horsepower control proportional
5 Console lever lock switch 10
valve

When the remote control valve operation lever is set to neutral, the discharge oil from hydraulic pumps A1 and A2 goes from
the control valve PR (P1) and PL (P2) ports through the center bypass oil path, and through the downstream negative control
relief valve, and returns to the hydraulic oil tank.
The negative control pressure oil separated from center bypass oil path is fed from the FR and FL ports to the hydraulic pump
Pi1 and Pi2 ports, moves the pump tilting to the minimum flow side, and the pump discharge flow is reduced.

84592788 EN - March 2012

Explanation of Hydraulic Circuit and Operations (standard model)

Negative control circuit (bucket close, power save solenoid OFF)

84592788 EN - March 2012

Explanation of Hydraulic Circuit and Operations (standard model)

Pressure line Pilot tank line
Tank line Electric line
Pilotpressure line Negative control line

a High flow
b Low flow

1 Control valve 8 Computer A 15 P1 flow control proportional valve

Remote control valve (boom,
2 Travel pilot pressure sensor 9 16 Hydraulic pump
bucket)
3 Upper pilot pressure sensor 10 Console lever lock switch 17 Check valve
4 Cushion valve 11 Lever lock 18 Oil cooler
5 Bucket (close) 12 4 stack solenoid valve 19 Bucket pressure sensor
N1 negative control pressure sen-
6 Bucket (open) 13
sor
N2 negative control pressure sen-
7 Bucket cylinder 14
sor

As an example, this section explains the bucket-close operations.

By moving the remote control valve to the bucket-close side, the pilot pressure oil is fed via the cushion valve to the control
valve 4a3 port and switches the bucket spool to the close side.
The discharge oil from the hydraulic pump A2 enters the control valve PL(P2) port, is fed to the bucket spool, flows into the
bucket cylinder bottom side because of the spool switching and the bucket-close operation is carried out.
Because the bucket spool switches and the pressurized oil on the center bypass downstream side is cut off, the Pi2 pump neg-
ative control pressure oil from the FL port is eliminated, the pump tilting moves to the increase side, and the flow is increased.
Also, the command milli-amp to the P1 flow control proportional valve is lowered and the pressurized oil from the hydraulic
pump A3 is cut off, but the negative control pressure is fed from the control valve FR port to the Pi1 port, moves the pump
tilting to the minimum flow side, and the hydraulic pump A1 discharge volume is reduced.

84592788 EN - March 2012

Explanation of Hydraulic Circuit and Operations (standard model)

Horsepower Boost Circuits

Arm-in Horsepower Boost Circuit

Horsepower control proportional

1 Travel motor 6 Travel mode select switch 11
valve
2 Travel remote control valve 7 Computer A 12 Oil cooler
3 Lever lock 8 Control valve 13 Check valve
4 Console lever lock switch 9 Travel pilot pressure sensor
5 4 stack solenoid valve 10 Hydraulic pump

1 Control valve 6 Console lever lock switch 11 Computer A

2 Stop valve 7 2nd option remote control valve 12 4th pump
3 Upper pilot pressure sensor 8 Hydraulic rotation fork 13 Hydraulic pump
4 Lever lock 9 2nd option pilot pressure switch 14 Check valve
5 4 stack solenoid valve 10 Monitor display 15 Oil cooler

As an example, this section explains the case in which the hydraulic rotation fork attachment is used.
By operating the 2nd option remote control valve to the right swing side, the pilot pressure oil is fed to the control valve 4a5
port.
The 4th hydraulic pump OUT discharge oil is fed to the control valve P3 port, goes through the 2nd option spool and flows to
the hydraulic rotation fork to operate to the right swing side.
The return oil from the hydraulic rotation fork goes through the 2nd option spool and returns to the hydraulic oil tank.
The oil in the 2nd option drain line returns to the hydraulic oil tank without going through the control valve.
2nd option spool port relief valve pressure becomes the hydraulic rotation fork set pressure.

84592788 EN - March 2012

Explanation of Hydraulic Circuit and Operations (option)

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84592788 EN - March 2012

Section

8030A

Structure and Operation Explanation of Hydraulic Pump

84592788 EN - March 2012

CONTENTS

Code Part name Q'ty
type
04 Gear pump 1 set ZX10L7RZ1-07A-V
2
011 Piston subassembly 151 (9PC), 152 (9PC)
sets
013 Cylinder subassembly (R) 1 set 141 (1PC), 313 (1PC)
014 Cylinder subassembly (L) 1 set 141 (1PC), 314 (1PC)
2
030 Swash plate subassembly 212 (1PC), 214 (1PC)
sets
2
530 Tilting pin subassembly 531 (1PC), 548 (1PC)
sets

1 Right rotation valve plate

2 Left rotation valve plate

Code Part name Q'ty Code Part name Q'ty Code Part name Q'ty
111 Drive shaft (F) 1 272 Pump casing (R) 1 710 O-ring 1
113 Drive shaft (R) 1 312 Valve block 1 711 O-ring 1
116 1st gear 1 313 Valve plate (R) 1 717 O-ring 2
123 Cylinder roller bearing 2 314 Valve plate (L) 1 723 O-ring 6
124 Needle roller bearing 2 326 Cover 1 724 O-ring 12
Hexagon socket head
127 Bearing spacer 2 401 2 727 O-ring 4
bolt
Hexagon socket head
141 Cylinder block 2 402 2 732 O-ring 4
bolt
Hexagon socket head
151 Piston 18 406 4 733 O-ring 2
bolt
Hexagon socket head
152 Shoe 18 414 4 774 Oil seal 1
bolt
153 Holder plate 2 466 ROH plug 2 789 Backup ring 2
156 Spherical bushing 2 467 ROH plug 2 792 Backup ring 2
157 Cylinder spring 12 468 ROH plug 4 806 Hexagon nut 2
211 Shoe plate 2 490 Insert plug 9 808 Hexagon nut 2
212 Swash plate 2 531 Tilting pin 2 824 Stop ring 2
214 Tilting bushing 2 532 Servo piston 2 886 Spring pin 4
Swash plate support
251 2 533 Q min. plug 2 901 Eyebolt 2
board
Hexagon socket head
255 Rotation lock pin 2 534 Stopper (L) 2 953 2
stop screw
256 Set spring 2 535 Stopper (S) 2 954 Stop screw 2
261 Seal cover (F) 1 548 Feedback pin 2 981 Nameplate 1
271 Pump casing (F) 1 702 O-ring 2 983 Striking pin 2

84592788 EN - March 2012

Regulator
Regulator Operation Explanation
1. Flow control
• Operation explanation (See the Regulator Operation Explanation Diagram.)
1) Flow control
The pump discharge flow is controlled as desired with the pilot pressure Pi as in the diagram below.

Discharge flow amount Q

Pilot pressure Pi

1) Flow reduction operation

When the pilot pressure Pi increases, the pilot piston (643) moves to the right and stops at the location
where the pilot spring (646) force and hydraulic pressure balance each other. The pin (875) fixed to
lever 2 (613) fits into the grooved section of the pilot piston (643), so, through the movement of the pilot
piston (643), lever 2 rotates with the B section (fastened by the fulcrum plug (614) and pin (876)) as
the fulcrum. The pin (897) fixed to the feedback lever (611) projects into the large opening (C section)
of lever 2 (613), so as lever 2 (613) rotates, the pin (897) moves to the right. The pin (548) fixed to
the tilting pin (531) that shakes the swash plate (212) is bonded to the bolt width section (D section)
of the feedback lever (611). Therefore, as the pin (897) moves, the feedback lever (611) rotates with
D section as the fulcrum. Since the spool (652) is linked to the feedback lever (611) via the pin (874),
the spool (652) moves to the right.
When the spool (652) moves, the discharge pressure Pd1 is led to the servo piston large-diameter
chamber via the spool and CI port. The discharge pressure Pd1 is always led to the servo piston
small-diameter chamber. As a result, the servo piston is moved to the right due to the surface area
difference and reduces the flow.
When the servo piston (532) moves to the right, the D section also moves to the right. The return
spring (654) is mounted on the spool (652). Since force pulling the spool to the left is always operating,
the pin (897) is pressed into the large opening (C section) of lever 2 (613). Therefore, accompanying
the D section movement, the feedback lever (611) rotates around the C section as the fulcrum and
the spool (652) moves to the left. This movement causes the open section between the sleeve (651)
and the spool (652) to begin to close, and the servo piston (532) stops at the point the open section
fully closes.
2) Flow increase operation
When the pilot pressure Pi decreases, the pilot piston (643) is moved to the left by the pilot spring
(646) force and lever 2 (613) rotates with the B section as the fulcrum. The pin (897) is pressed in
the large opening (C section) of lever 2 (613) by the return spring (654) via the spool (652), pin (874),
and feedback lever (611), so accompanying rotation of lever 2 (613), the feedback lever (611) rotates
with the D section as the fulcrum and the spool (652) moves to the left.
When the spool (652) moves, the CI port opens to the tank port, so the pressure in the large-diameter
chamber of the servo piston drains out, the servo piston (532) is moved to the left by the discharge
pressure Pd1 of the small-diameter section and the flow increases.
Accompanying the movement of the servo piston (532), the D section moves to the left, the feedback
lever (611) rotates with the C section as the fulcrum and the spool (652) moves to the right. This
operation continues until the open section between the spool (652) and sleeve (651) closes, and then
the servo piston stops at the point the open section fully closes.

84592788 EN - March 2012

2. Horsepower control
1) Horsepower control
As the load pressure increases, the pump tilting angle decreases and the overload of the engine is pre-
vented as in the diagram below. Since this regulator uses the simultaneous full-horsepower control method,
the tilting angles (displacement volumes) of the 2 pumps are controlled to be the same value as in the fol-
lowing equation.
Tin = Pd1 x q/2π + Pd2 x q/2π = (Pd1 + Pd2) x q/2π
(q: Displacement volume)
Horsepower control is the same as flow control and is briefly explained below.
(See the pages on Flow control for the detailed movement of each part.)

Discharge flow amount Q

Discharge pressure (Pd1 + Pd2)

1) Overload prevention operation

When the self pump discharge pressure Pd1 or the counterpart pump discharge pressure Pd2 rises,
since Pd1 and Pd2 operate on the stepped section of the compensation piston (621), the compen-
sation rod (623) is pressed to the right and moves to the location where the force of the outer spring
(625) and inner spring (626) balance out the hydraulic pressure force. The movement of the compen-
sation rod (623) is transmitted to lever 1 (612) through the pin (875) and lever 1 (612) rotates around
the pin (876) (E section) fastened to the casing (601). The pin (897) fixed to the feedback lever (611)
projects into the large opening (F section) of lever 1 (612), so as lever 1 (612) rotates, the feedback
lever (611) rotates with the D section as the fulcrum and the spool (652) moves to the right.
When the spool (652) moves, the discharge pressure Pd1 is led to the large-diameter section of the
servo piston via the CI port, the servo piston (532) is moved to the right, and the pump discharge flow
is decreased to prevent overload of the power source.
The servo piston (532) movement is transmitted to the feedback lever (611) via the D section. The
feedback lever (611) rotates with the F section as the fulcrum and the spool (652) moves to the left.
The spool (652) moves until the open section between the spool (652) and sleeve (651) closes, and
then the servo piston stops at the point the open section fully closes.
2) Flow return operation
If the self pump discharge pressure Pd1 or the counterpart pressure pump discharge pressure Pd2
decreases, the compensation rod (623) is pressed back by the outer spring (625) and the inner spring
(626) and lever 1 (612) rotates about the E section. Accompanying the lever 1 (612) rotation, the
feedback lever (611) rotates around the D section as the fulcrum and the spool (652) moves to the left.
Because of this, the CI port opens to the tank port, the servo piston large-diameter section pressure
drains off, the servo piston (532) moves to the left and the pump discharge flow increases.
The movement of the servo piston (532) is transmitted to the spool (652) by the feedback mechanism,
and this operation continues until the open section between the spool (652) and the sleeve (651)
closes.
3. Low tilting (low flow) command priority mechanism
As above, the flow control and the horsepower control tilting command is transmitted to the feedback lever (611)
and spool (652) via the large opening (C and F sections) of lever 1 (612) and lever 2 (613), but since the C and F
sections have a structure in which a pin (D5) projects into a large hole (D9), the pin (897) only contacts the lever
that makes the tilting smaller and the D9 hole for the lever on the side that has the larger tilting command state
does not contact the pin (897), but is free. This type of mechanical selection method gives priority to flow control
and horsepower control commands with low tilting.

84592788 EN - March 2012

4. Power shift control (decreased horsepower control)

Use the power shift pressure Pf to arbitrarily control the pump set horsepower as in the diagram below.
When the power shift pressure Pf increases, the compensation rod (623) is moved to the right via the pin (898)
and the compensation piston (621), so the pump tilting angle is reduced and the horsepower setting is reduced
in the same way as was explained for the operation to prevent overload of the horsepower control. By contrast,
as the power shift pressure Pf decreases, the horsepower setting increases.

Discharge flow amount Q

Discharge pressure (Pd1 + Pd2)

84592788 EN - March 2012

Regulator Operation Explanation Diagram

Connected to CI port servo pis-

*1
ton large bore chamber

84592788 EN - March 2012

Front side Rear side

Hydraulic circuit diagram

84592788 EN - March 2012

Front Side Regulator Internal Structure Diagrams

84592788 EN - March 2012

1 Front side regulator

2 Rear side regulator

Component part No. (Q'ty) or

Code Part name Q'ty
type
Shuttle valve 545 (1PC), 546 (1PC), 547
050 1 set
subassembly (1PC)
Electromag-
netic propor-
079 1 set KDRDE5K-31/30C50-102
tional pressure
reducing valve

Code Part name Q'ty Code Part name Q'ty Code Part name Q'ty
- Regulator sub-
1 set 622 Piston case 1 724 O-ring 7
assembly
Hexagon socket
412 2 623 Compensation rod 1 726 O-ring 2
head bolt
Hexagon socket
413 2 624 Spring seating C 1 727 O-ring 1
head bolt
84592788 EN - March 2012
8030A-14
Copyright ©
Structure and Operation Explanation of Hydraulic Pump

Code Part name Q'ty Code Part name Q'ty Code Part name Q'ty
Hexagon socket
418 2 625 Outer spring 1 728 O-ring 1
head bolt
Hexagon socket
436 1 626 Inner spring 1 730 O-ring 2
head bolt
Hexagon socket
437 4 627 Adjusting ring C 1 734 O-ring 1
head bolt
Hexagon socket
438 4 628 Adjusting screw C 1 753 O-ring 3
head bolt
466 ROH plug 1 629 Cover C 1 755 O-ring 1
467 ROH plug 1 630 Lock nut 1 757 O-ring 1
496 Insert plug 15 631 Pf sleeve 1 801 Hexagon nut 1
545 Steel ball 1 641 Pilot cover A 1 802 Hexagon nut 1
546 Seat 1 1 643 Pilot piston 1 814 Stop ring 1
547 Seat 2 1 644 Spring seating Q 1 836 Stop ring 1
601 Casing A 1 645 Adjusting ring Q 1 874 Pin 1
611 Feedback lever 1 646 Pilot spring 1 875 Pin 4
612 Lever (1) 1 651 Sleeve 1 887 Pin 1
613 Lever (2) 1 652 Spool 1 897 Pin 1
614 Fulcrum plug 1 653 Spring seating 1 898 Pin 1
Hexagon socket
615 Adjusting plug 1 654 Return spring 1 924 1
head stop screw
Loosening preven-
616 2 655 Set spring 1
tion plug
621 Compensation piston 1 708 O-ring 1

84592788 EN - March 2012

Rear Side Regulator Internal Structure Diagram

84592788 EN - March 2012

Component part No. (Q'ty) or

Code Part name Q'ty
type
Electromagnetic
proportional pres-
079 1 set KDRDE5KR-20/40C13-203A
sure reducing
valve

Code Part name Q'ty Code Part name Q'ty Code Part name Q'ty
- Regulator sub-
1 set 625 Outer spring 1 724 O-ring 7
assembly
Hexagon socket
412 2 626 Inner spring 1 726 O-ring 2
head bolt
Hexagon socket
413 2 627 Adjusting ring C 1 728 O-ring 1
head bolt
Hexagon socket
437 5 628 Adjusting screw C 1 730 O-ring 2
head bolt
Hexagon socket
438 4 629 Cover C 1 734 O-ring 1
head bolt
Hexagon socket
439 4 630 Lock nut 1 753 O-ring 6
head bolt
466 ROH plug 1 631 Pf sleeve 1 755 O-ring 2
496 Insert plug 8 641 Pilot cover B 1 757 O-ring 1
601 Casing B 1 643 Pilot piston 1 801 Hexagon nut 1
611 Feedback lever 1 644 Spring seating Q 1 802 Hexagon nut 1
612 Lever (1) 1 645 Adjusting ring Q 1 814 Stop ring 1
613 Lever (2) 1 646 Pilot spring 1 836 Stop ring 1
614 Fulcrum plug 1 651 Sleeve 1 874 Pin 3
615 Adjusting plug 1 652 Spool 1 875 Pin 2
Loosening preven-
616 2 653 Spring seating 1 887 Pin 1
tion plug
621 Compensation piston 1 654 Return spring 1 897 Pin 1
622 Piston case 1 655 Set spring 1 898 Pin 1
Hexagon socket
623 Compensation rod 1 656 Valve casing 1 924 1
head stop screw
624 Spring seating C 1 708 O-ring 1

84592788 EN - March 2012

Gear Pump
Gear Pump Internal Structure Diagram

Hydraulic circuit

*1 To main pump

Component part No. (Q'ty) or

Brake valve
• The brake valve's function is to allow for smooth braking and stopping by controlling inertial force from the main unit
that can make the travel motor rotate when the travel motor is stopped.
• Function of check valve for preventing hydraulic motor cavitation
• The valve opens the port for releasing the parking brake during travel motor operation and closes the port when the
travel motor is stopped.
1. During normal operation
When pressurized oil is fed from the A port, the pressurized oil opens the valve (327), enters the C port on the
suction side of the hydraulic motor, and rotates the hydraulic motor.
At the same time, the pressurized oil enters the chamber from the orifice (329) to produce force by acting on the
end surface of the spool (323). The spool is slid from a neutral state to the left by the force of the spring (328).
If the spool is slid, a gap (path) with the rear flange (301) is formed by the spool groove.
Due to this path, oil returns to the tank side through the hydraulic motor D port return path and the B port path,
which allows for the hydraulic motor to rotate.
Additionally, pressurized oil enters the E port through the spool sliding. Pressurized oil that enters the E port
makes the parking brake piston (112) operate to release the parking brake.
(For details, see the "Parking brake" operation explanation on p. 136.)
When pressurized oil is fed from the B port, the left-right movement of the spool and valve are reversed and
reverse rotation occurs.

84592788 EN - March 2012

2. Stopping operation (brake operation)

If the supply of pressurized oil from the A port stops during travelling, the hydraulic pressure pushing the spool
(323) disappears, and the spool returns from the left side to a neutral position due to the force of the spring (328)
acting on the washer (325).
At this time, the oil inside the a chamber passes through the orifice (329) to exit through the A port. However,
narrowing of the orifice produces back pressure and controls the spools return speed.
At the same time, inertial force is rotating the hydraulic motor even though the pressurized oil has stopped. As
a result, the hydraulic motor return oil passes from the D port through the gap (path) between the spool groove
and the rear flange to return to the B port.
When the spool has returned completely to a neutral position, the hydraulic motor return-side path formed by the
spool is cut off and the hydraulic motor stops.
During operation, this brake valve perform metering the hydraulic motor return-side path through controlling the
spool sliding speed and the shape of the spool groove. It also produces back pressure to allow for smooth stop-
ping of the hydraulic motor when inertial force is acting on the motor.
At the same time, when the brake is applied to stop the hydraulic motor, rotation continues and the pump operates
to suction oil even if inertial force is used to stop the supply of pressurized oil.
However, because the path on the suction side is cut off by the spool, oil cannot be resupplied and cavitation will
occur.
At this time, the valve (327) operates with just a small amount of negative pressure being applied, and the oil
path formed by the A port-side circuit and the C port of the motor suction area opens. This prevents the cavitation
effect in the hydraulic motor.
Additionally, when pressurized oil is fed from the B port, left-right operation of each of the aforementioned parts
is reversed and the hydraulic motor stops.

84592788 EN - March 2012

3. Self-travel prevention function

If the hydraulic motor is rotated by an external force during normal operation, self-travel will occur.
For example, this occurs when going down a sharp incline when using as the power shovel travel motor.
The following explains the mechanism for preventing this phenomenon.
The hydraulic motor is being rotated by an external force during normal operation. The pressure of the hydraulic
oil (A port or B port) being fed is reduced.
If the pressure approaches a state where self-travel begins, the spool (323) begins to move to a central neutral
position.
The area of the hydraulic oil path from the D port to the B port of the exit-side of the hydraulic motor is reduced,
according to the amount of movement of the spool.
The flow amount of the hydraulic oil discharged from the D port to the B port is also restricted.
At the same time, the D port pressure (back pressure) is raised.
In this way, by controlling the hydraulic motor exit port flow amount and pressure, the self-travel phenomenon is
prevented.

84592788 EN - March 2012

Parking brake
The parking brake functions to prevent rolling and slipping using a friction plate-type brake mechanism when the
power shovel is parked or stopped on an incline. The parking brake is one component of the hydraulic motor.
1. During travel
If the pressurized oil is fed from the brake valve, this causes the spool of the hydraulic motor brake valve to
operate and the path to the parking brake opens. The pressurized oil is led to the cylinder chamber a comprising
the spindle (2) and piston (112) in the reduction gear section.
If the pressurized oil exceeds 0.76 MPa, the spring (113) force is overcome, and the piston is moved to the rear
flange (301) side. The movement of this piston makes the force pushing on the counterpart plate (116) and friction
plate (115) disappear. Movement of the friction plate embedded in the cylinder block (104) of the hydraulic motor
is free and the brake force going to the cylinder block is released.
2. During stopping
If the pressurized oil from the brake valve is cut off and the pressure within cylinder chamber a falls below 0.76
MPa, the piston is forced to return by the spring force.
This spring force presses the counterpart plate and friction plate, which are free and are being pressed by the
piston, against the spindle. The frictional force produced by the plates being pressed against the spindle stops
the rotational force of the cylinder block and applies 206 N·m of braking torque to the hydraulic motor shaft.
Additionally, this operation is smooth due to oil being controlled in the appropriate oil path.

84592788 EN - March 2012

Relief mechanism
1. Starting
The pressurized oil fed from the pump is led from the A port to the C port.
The C port is connected to the hydraulic motor and the pressurized oil that enters the C port contributes to the
rotational force of the hydraulic motor.
At this time, the valve (202a) inside relief valve "A" does not open due to the action of pressurized oil.
The valve (202b) in relief valve "B" is opened by the pressurized oil from the C port when a prescribed pressure
is exceed and the pressurized oil is led to the D port.
The pressurized oil from the C port passes through the valve (202b) orifice e, the sleeve (203b) orifice f and the
orifice (384), and is led to the chamber y.
The piston (381) moves in the direction of the arrow to the stroke end due to the pressurized oil led to the chamber.
When the piston has moved to the stroke end, the pressure between the valve (202b) orifice e and sleeve (203b)
orifice f increases.
Due to the raised pressure of the pressurized oil, the opening pressure of relief valve "B" exceeds the shovel's
system pressure and the valve (202b) closes.
The C port pressure is raised by the action of relief valve "A" or "B" and this applies rotational force to the motor.

*1 Relief valve

84592788 EN - March 2012

C port pressure during the aforementioned operation

*2 R/V "B" opened

*3 Pressure
*4 Time

However, because the machine is in the stopped position just before this, the valve (202b) of the relief valve "B"
does not open when the piston has reached the stroke end.
For this reason, the pressure acting on the C port is as follows.

*3 Pressure
*4 Time

As explained above, the pressure of the C port during starting changes depending on the position of the pist
* When the pressurized oil fed from the pump is led from the B port to the D port, the operation principle of relief
valves "A" and "B" explained above are switched.
2. During stopping
The hydraulic motor is rotated by a supply of pressurized oil going from the A port to the C port. If the supply of
pressurized oil to the A port is cut off, the counterbalance valve will return to neutral.
If the counterbalance valve returns to neutral, the exit-side D port is cut off and pressure increases in the D port
due to the hydraulic motor only being rotated according to the amount of inertia.
The pressurized oil inside the D port passes through the valve (202a) orifice c, the sleeve (203a) orifice d and
the orifice (384) of relief valve "A" to chamber x.
The piston (381) moves in the direction of the arrow to the stroke end due to the pressurized oil led to chamber x.
While the piston is moving, pressure in chamber x does not rise.
Because of this, the valve (202a) of relief valve "A" is pushed open by the D port pressurized oil and this pres-
surized oil flows from the D port to the low-pressure side C port.
The D port pressure is controlled through relief provided by relief valve "A" and cavitation is prevented through
oil being fed to the C port.
If the piston reaches the stroke end, the pressure between chamber x, the valve (202a) orifice c and the sleeve
(203a) orifice d rises and the valve (202a) closes.
In this case, the relief valve "A" provides relief at a pressure exceeding the shovel's system pressure and stops
the hydraulic motor.
84592788 EN - March 2012
8030B-9
Copyright ©
Structure and Operation Explanation of Travel Motor

1 Column 5 Output *9 Spindle

*2 Planetary gear 2 *6 Carrier *10 Input
*3 Planetary gear 1 *7 Hub (ring gear) *11 Shaft
*4 Sun gear 1 *8 Sun gear 2

84592788 EN - March 2012

Section

8030C

Structure and Operation Explanation of Swing Motor

84592788 EN - March 2012

CONTENTS

Swing Motor Operation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Hydraulic Motor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Valve Casing Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Brake Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Relief Valve Operation Explanation (relief valve model: KRD22EK10). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Swing Motor Internal Structure Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Swing Motor Operation

Explanation
Hydraulic Motor Section
As the diagram below shows, when the high-pressure oil passes through the valve plate (1) inlet-side port (a) and flows
into the cylinder, the hydraulic pressure operates on the piston (5) and a force F is generated in the axial direction.
This force F is divided into 2 vectors, a force F1 perpendicular to the swash plate (3) via the shoe (2) and a force F2
perpendicular to the shaft.
This force F2 is transmitted to the cylinder block (4) via the piston (5), generating a rotational couple around the output
shaft.
9 pistons (5) are arrayed in the cylinder block. Rotation torque is transmitted sequentially to the output shaft (6) by
multiple pistons (5) linked with the high-pressure oil inlet-side port.
When the oil in and out directions are reversed, the rotation of the output shaft (6) also reverses.
The theoretical output torque T [N·m] is given by the following equation.

Diagram 1 Motor section operation explanation diagram

q Compartments per rotation

[cm3]
p Effective pressure difference
[MPa]

1 Low-pressure oil 3 Outlet

*2 High-pressure oil *4 Inlet

84592788 EN - March 2012

84592788 EN - March 2012

Swing Motor Internal Structure Diagram

84592788 EN - March 2012

Code Part name Q'ty Code Part name Q'ty

1 Inner race 1 22 Balance plate 1
2 Oil seal 1 23 Needle bearing 1
3 Tapered roller bearing 1 24 Stop ring 1
4 Level gauge assembly 1 25 Cylinder 1
5 Receiving spring 1 26 Housing 1
6 Cam plate 1 27 Plug 1
7 Return plate 1 28 Cap 2
8 Piston assembly 9 29 Backup ring 2
9 Friction plate 2 30 O-ring 2
10 Partner plate 2 31 O-ring 2
11 O-ring 1 32 Cover 1
12 Piston 1 33 Parallel pin 2
13 O-ring 2 34 Relief assembly 2
14 Spring 16 35 O-ring 4
15 Teflon ring 2 36 Hexagon socket head bolt 4
16 Piston 2 37 Check valve 2
17 Cap 3 38 Spring 2
18 O-ring 3 39 Cap 2
19 Scrowave spring 4 40 Backup ring 2
20 Teflon ring 4 41 Plug 2
21 Bushing 4

84592788 EN - March 2012

Section

8030D

Structure and Operation Explanation of Control Valve

84592788 EN - March 2012

CONTENTS

Structure and Operation Explanation of Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Basic configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Structure and Operation Explanation of Control Valve

Basic configuration
1. Control Valve
Appearance diagram

84592788 EN - March 2012

1 Valve installation tap

84592788 EN - March 2012

Cross-section structural diagram (BKT-side valve)

84592788 EN - March 2012

1 Main plunger section 8 Load holding valve 15 Plug

2 Foot relief valve 9 BM regeneration check valve 16 Bushing
3 Main relief valve 10 Check valve 17 Cover
4 Overload relief valve 11 Check valve 18 Housing
5 Center bypass valve 12 Check valve 19 Steel ball
6 AM regeneration check valve 13 Check valve
7 BM back pressure check valve 14 Check valve

a Ball check within the cover

84592788 EN - March 2012

Cross-section structural diagram (SW-side valve)

84592788 EN - March 2012

1 Main plunger section 7 Check valve 13 O-ring

2 Foot relief valve 8 AM regeneration valve 14 Housing
3 Overload relief valve 9 Check valve 15 Steel ball
4 Load holding valve 10 Check valve 16 Cap
5 Check valve 11 Plug 17 Orifice
6 Swing priority valve 12 Cover 18 Travel signal switchover spool

a Ball check within the cover

84592788 EN - March 2012

Structural Diagram (each section)

[1] Main plunger

Q't- Q't-
Code Name Code Name
y y
1 Plunger 1 6 O-ring 1
2 Spring guide 2 7 Spacer 1
3 Spring 1 8 Spring 1
4 Plunger cap 1 9 Check valve 1
5 Cap 1

a BKT Plunger
b BM-1 Plunger

NOTE:
1.BM-1, BKT plunger: There is a check valve incorporated at one end.

84592788 EN - March 2012

[2] Foot relief valve

Q't- Q't-
Code Name Code Name
y y
1 Poppet 1 4 Sleeve 1
2 O-ring 1 5 O-ring 1
3 Spring 1 6 Cap 1

[3] Main relief valve

Q't- Q't-
Code Name Code Name
y y
1 Sleeve 1 10 Adjusting screw 1
2 Main poppet 1 11 O-ring 1
3 O-ring 1 12 Backup ring 1
4 Pilot poppet 1 13 O-ring 1
5 Spring 1 14 Piston 1
6 Cap 1 15 Pilot seat 1
7 Hexagon nut 1 16 O-ring 1
8 Sleeve 1 17 Spring 1
9 Hexagon nut 1 18 Orifice 1

84592788 EN - March 2012

[4] Overload relief valve (AM, BM, BKT)

Q't- Q't-
Code Name Code Name
y y
1 Sleeve 1 11 Spring 1
2 Pilot seat 1 12 Spring 1
3 O-ring 1 13 O-ring 1
4 Cap 1 14 Backup ring 1
5 Hexagon nut 1 15 Piston 1
6 Adjusting screw 1 16 O-ring 1
7 Spring receiver 1 17 Backup ring 1
8 O-ring 1 18 Main seat 1
9 Spring 1 19 Main poppet 1
10 Pilot poppet 1 20 O-ring 1

[5] Center bypass valve

84592788 EN - March 2012

Q't- Q't-
Code Name Code Name
y y
1 Cap 1 3 Spring 1
2 O-ring 1 4 Spool 1

84592788 EN - March 2012

[6] Arm regeneration check valve

Q't- Q't-
Code Name Code Name
y y
1 Cap 1 3 Spring 1
2 O-ring 1 4 Check valve 1

[7] Boom back pressure check valve

Q't- Q't-
Code Name Code Name
y y
1 Cap 1 3 O-ring 1
2 Spring 1 4 Check valve 1

84592788 EN - March 2012

[8] Load holding valve (AM, BM)

Q't- Q't-
Code Name Code Name
y y
1 Cap 1 11 O-ring 1
2 O-ring 1 12 Cap 1
3 Piston 1 13 Cover 1
4 Backup ring 1 14 O-ring 1
5 O-ring 3 15 Spring 1
6 Sleeve 1 16 Poppet 1
7 Backup ring 1 17 Cap 2
8 O-ring 4 18 Check valve 1
9 Poppet 1 19 Spring 1
10 Spring 1 20 Spacer 1

a Three locations on this surface

84592788 EN - March 2012

[9] Boom regeneration check valve

Q't- Q't-
Code Name Code Name
y y
1 Cap 1 4 Spring 1
2 O-ring 1 5 Check valve 1
3 Spacer 1

[10] Check valve (SW, BM-2, OPT, others)

Q't- Q't-
Code Name Code Name
y y
1 Cap 1 4 Check valve 1
2 Backup ring 1 5 Spring 1
3 O-ring 1

[11] Check valve (different cap orifice diameter) (AM-2)

[12] Check valve (different cap orifice diameter) (BKT)
[13] Check valve (different cap orifice diameter) (BM-1)
[18] Check valve (different cap orifice diameter) (AM-1)

84592788 EN - March 2012

Q't- Q't-
Code Name Code Name
y y
1 Cap 1 5 Check valve 1
2 Backup ring 1 6 Spring 1
3 O-ring 1 7 Check valve 1
4 Nylon tip 1

84592788 EN - March 2012

[14] Check valve (TL)

Q't- Q't-
Code Name Code Name
y y
1 Cap 1 5 Check valve 1
2 Backup ring 1 6 Spring 1
3 O-ring 1 7 O-ring 1
4 Nylon tip 1 8 Cap 1

2. Arm-in and boom (up) operation, swing operation (See diagram 7.)
When a swing operation is performed from an arm-in and boom-up operation (See the previous page.), the
swing plunger switchover pilot pressure pressurizes the swing priority valve Pi2 port.
Spool A switches and the boom-up plunger switchover pilot pressure is blocked.
Therefore, spool B switches, the priority valve path is blocked, and the swing drive pressure is secured.

Arm-in and boom (up) swing operation

84592788 EN - March 2012

Swing priority circuit (diagram 6)

84592788 EN - March 2012

1 Parallel path 3 Spool B 5 Swing priority valve

2 Orifice C 4 Spool A 6 Straight travel switchover valve

a To parallel path

84592788 EN - March 2012

Swing priority circuit (diagram 7)

a From pump port

b Pilot A signal: OFF

84592788 EN - March 2012

Overload Relief Valve

1. Overload operation
1) The pressurized oil from the cylinder port passes through orifice (*2) of piston A and enters chamber (*3).
d1 > d2, so main poppet B is securely seated.

1 Main poppet B 3 Piston A 5 Pilot poppet D

2 Cylinder port 4 Tank path 6 Spring C

2) When the oil pressure reaches the pressure set by spring C, pilot poppet D opens and the oil flows through
horizontal hole (*4), path (*5), and horizontal hole (*6), and into the tank path.

1 Cylinder port 3 Pilot poppet D

2 Tank path 4 Spring C

84592788 EN - March 2012

3) The oil flow is formed, a pressure drop is generated across orifice (*2), and piston A moves to the right
and is seated at the top of pilot poppet D.
The pressurized oil of chamber (*1) passes through orifice (*7) of piston A, horizontal hole (*4), path (*5),
and horizontal hole (*6), and flows into the tank path.

1 Cylinder port 3 Tank path

2 Piston A 4 Pilot poppet D

4) When a pressure drop is generated across orifice (*7) of piston A and chamber (*1) pressure x d2 surface
area becomes greater than chamber (*3) pressure x d1 surface area, main poppet B opens, the cylinder
port pressurized oil flows into the tank path, and the actuator is protected.

1 Main poppet B 3 Piston A

2 Cylinder port 4 Tank path

84592788 EN - March 2012

2. Make-up operation
Because d1 becomes greater than d2, normally the cylinder port pressure is higher than the tank pressure, so
main poppet B is securely seated.
When the cylinder port pressure drops (and approaches negative pressure) and the cylinder port pressure
becomes less than the tank pressure, main poppet B opens after receiving tank pressure proportional to the
difference in surface areas of d1 and d2, the oil flows from the tank path to the cylinder port, and this prevents
cavitation.

1 Main poppet B 3 Tank path

2 Cylinder port

Foot relief valve

1. Because the load on spring C is extremely small, the oil from the center bypass path opens the poppet and
flows into the tank path.[Check valve operation]

1 Poppet 3 Spring C
2 Tank path

a From center bypass path

1 Piston A 3 Poppet B 5 Feed path

2 Check valve C 4 Poppet D 6 Tank path

a To boom bottom
b Pilot signal pressure

84592788 EN - March 2012

Section

8030E

4 Stack Solenoid Valve Operation Explanation

84592788 EN - March 2012

CONTENTS

External Shape Diagram and Component Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Operation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

External Shape Diagram and Component Parts

This valve is made up of the body and the electromagnetic switchover valve.

*1 Normal closed type solenoid; SP, S1, S3

*2 Normal open type solenoid; S2

Electromagnetic switchover
1
valve
2 Body

84592788 EN - March 2012

Operation Explanation

Hydraulic circuit diagram

The pressure oil fed from the P port feeds pressure oil to the C1 - C5 ports according to the excitation or non-excitation
of electromagnetic switchover valves S1 - S4 resulting from exciting electromagnetic switchover valve SP.

Electromagnetic
Oil passing through
switchover valves →
when valve excited
S1, S3
Oil passing through
Electromagnetic → when valve not ex-
switchover valve S2
cited
Oil passing to C5
when valve excited
Electromagnetic → Oil passing to C4
switchover valve S4
when valve not ex-
cited

84592788 EN - March 2012

Section

8030F

Structure and Operation Explanation of Upper Pilot Valve

(remote control valve)

84592788 EN - March 2012

CONTENTS

Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Structural Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

8030F-2 PRINTED IN FRANCE
Copyright ©
Structure and Operation Explanation of Upper Pilot Valve
(remote control valve)
Structure
The structure of the remote control valve is as shown in the Structural Diagram. There is a longitudinal axial hole in
the casing and the pressure reduction valve is installed in it.
The pressure reduction valve comprises the spool (201), secondary pressure setting spring (241), return spring (221),
spring seating (216), and washer 2 (217).
The secondary pressure setting spring (241) is set so that the secondary pressure calculation is 0.5 - 1 MPa ( 72.527
- 145.05 psi ) (depending on the model). The spool (201) is pressed against the push rod (212) by the return spring
(221).
When the push rod (212) is pushed down by tilting the handle or another operation, the spring seating goes down at
the same time and the secondary pressure setting spring (241) setting is changed.
The casing (101) has the oil inlet (primary pressure) port P and the outlet (tank) port T and, furthermore, the secondary
pressure is taken out from the ports 1, 2, 3, 4.
Function
1. Basic functions
The remote control valve is for controlling the control valve spool stroke quantity, direction, etc. This is done by
operating the pilot valve output pressure on the control valve spool end section.
In order to satisfy this function, the remote control valve is made up of the following elements.
1) Inlet port (P) to which the oil is fed from the hydraulic pump
2) Multiple output ports (1, 2, 3, 4) for operating the feed pressure from the inlet port on the control valve spool
end
3) Tank port (T) required for controlling the above output pressure
4) Spool connecting the output port to the inlet port or tank port
5) Mechanical means including a spring operating on the above spool in order to control the output pressure
2. Main part functions
The function of the spool (201) is to switch the oil path either to have the hydraulic pressure fed from the hydraulic
pump received by the P port and lead the P port pressure oil to the output ports (1, 2, 3, 4) or to lead the output
port pressure oil to the T port. The output pressure operating on this spool (201) is determined by the secondary
pressure setting spring (241).
In order to change the deflection quantity of the secondary pressure setting spring (241), the push rod (212) is
inserted into the plug (211) in such a way that it can slide.
The return spring (221) operates on the casing (101) and spring seating (216) and operates to return the push
rod (212) in the displacement zero direction regardless of the output pressure and makes the spool (201) neutral
return reliable. It also has the effect of a counter-force spring for giving an operator an appropriate operation feel.

84592788 EN - March 2012

8030F-3
Copyright ©
Structure and Operation Explanation of Upper Pilot Valve
(remote control valve)
Operation
Operation of the remote control valve is explained based on the hydraulic circuit diagram (Diagram 1) and operation
explanation diagrams (Diagram 2 - Diagram 4).
Diagram 1 is a typical usage example for the remote control valve.

Diagram 1 Remote control valve usage example

1 Pilot valve 3 Main pump 5 Hydraulic motor

2 Pilot pump 4 Control valve 6 Hydraulic cylinder

(remote control valve))

84592788 EN - March 2012

CONTENTS

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pressure Reduction Valve Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operating Section Damping Mechanism Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Structural Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

8030G-2 PRINTED IN FRANCE
Copyright ©
Structure and Operation Explanation of Travel Pilot Valve
(remote control valve))
Operation
The remote control valve with built-in damper (hereinafter, remote control valve with damper) is a remote control valve
that incorporates into the remote control valve main unit a damping function for preventing the man-machine system
hunting (lever hunting) phenomenon.
Operation of the remote control valve with damper is divided into the Pressure Reduction Valve Section and the Op-
eration Section Damping Mechanism Section. The explanations in these 2 sections are based on the hydraulic circuit
diagram, assembly cross-section diagram, and damping operation explanation diagram below. The diagram below is
a typical usage example for the remote control valve.

Hydraulic circuit diagram

101 Casing 1 271 Hexagon socket head bolt 271
151 Plug 2 301 Spool 301
201 Cover 2 311 Spring seating 311
202 Plug 4 313 Washer 3 313
203 Grease cup 4 324 Spring 324
210 NHU packing 4 335 Spring 335
212 O-ring 4 336 Spring 336
214 Push rod 4 337 Spring 337
215 Washer 1 8 412 Bushing 412
217 Washer 2 4 413 Camshaft 413
218 Spring seating 4 420 Cam 420
221 Locking ring 4 423 Hexagon socket head locking screw 423
223 Bushing 4 471 Locking screw 471
84592788 EN - March 2012
8030G-7
Copyright ©
Structure and Operation Explanation of Travel Pilot Valve
(remote control valve))
Code Part name Q'ty Code Part name Q'ty
224 Piston 2D085 4 472 Lock nut 472
225 Steel ball 12 501 Bellows 501

84592788 EN - March 2012

Section

8030H

Structure and Operation Explanation of Cushion Valve

84592788 EN - March 2012

CONTENTS

Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Structure
This valve is made up of a shuttle valve section and cushion valve section with heat circuit.
The cushion valve with a heat circuit is connected between the hydraulic shovel car control valve and the pilot oper-
ation valve to reduce body shaking (cushion function) caused by emergency stop operations by the operator.
This valve is also equipped with a circuit with which the operator can deliberately disable the cushion function for
reverse operations.
The shuttle valve selects the high-pressure signal pressure from 2 signal pressure systems.
This valve has 2 circuits.

*1 Arm
*2 Boom

84592788 EN - March 2012

Operation Explanation
1. Normal operation
The pressure oil fed from the pilot operation valve to the A port (or C, E, or G port) pushes up the check plunger
and is sent to the B port (or D, F, or H port).
The pressure oil that has passed through the B port operates on the control valve spool and operates the actuator.
The oil pushed out from the control valve spool passes through the D port (or B, F, or H port) and flows out to the
T port.

84592788 EN - March 2012

2. Cushion operation
When the pressure oil fed from the pilot operation valve to the A port (or C, E, or G port) is closed by the pilot
operation valve, the pressure oil that has operated on the control valve spool is pushed back to the B port (or the
D, F, or H port) by the return spring on the spool.
The returned oil passes through the check plunger metering orifice, is sent to the A port (or the C, E, or G port),
and is drained from the pilot operation valve.
At this time, by passing through the metering orifice, the pressurized oil holds down the control valve spool speed,
which prevents the sudden stopping of the actuator and reduces shaking of the body. (Cushion function)

84592788 EN - March 2012

3. Reverse operation
When the pressure oil fed from the pilot operation valve to the A port (or C, E, or G port) is switched to the C port
(or A, E, or G port), the pressure oil that has operated on the control valve spool is pushed back to the B port.
Because the pushed back oil flows out to the T port without passing through the check plunger metering orifice,
it does not hold down the control valve spool speed, so the cushion function does not work.

84592788 EN - March 2012

4. Heat circuit
When the pilot operation valve is in the neutral position, the oil fed to the R port passes through the inside of the
reverse operation spool and flows out to the T port, which heats up the inside of the valve.
When pressure oil is being fed from the pilot operation valve to the A port (or C, E, or G port), the oil fed to the
R port flows out to the C port (or A, E, or G port) and heats up the circuit to the pilot operation valve and inside
the valve.

5. Shuttle valve
The steel ball is pressed from the higher of the pressures between the I and J ports and the K and L ports to the
lower of these pressures. Through this process, high-pressure oil is fed to the S port or the Q port.
In the same way, oil of the higher pressure between the M and N ports and the O and P ports is fed to the U port.

84592788 EN - March 2012

Section

9002

Removal and Installation of Counterweight

84592788 EN - March 2012

CONTENTS

Removal of Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

CAUTION Removal of Counterweight

• Be sure to stop the engine before beginning 1. Remove the following before beginning work.。
work.
• Engine hood, gas damper and lock stay
• Be sure to inspect the wire rope and other • Rear view camera and electrical parts bracket
lifting equipment before beginning work.
• Do not stand or pass under the suspended 2. Remove the 2 rubber plugs (2) from the top of the
load. counterweight (1).
• Thoroughly secure the removed counter-
weight with the wire ropes and liftcrane so
that it does not fall over.

Items to prepare
• Box wrench [41 mm (1.614 in)]
• Eyebolt (M35)
• Balance lifting device
• Shackles (with the required lifting capacity) x 4
• Wire rope (with the required breaking load x 4)
• Liftcrane (with the required lifting capacity)
• Wood planks, etc.
• Rag
• Cleaning fluid
3. Install the 2 eyebolts (M35) (1) in place of the re-
moved caps.
• Apply lubricating oil to the eyebolts.
• Fully tighten the eyebolts, and then loosen them
by a half turn.

4. Connect the eyebolts to the shackles (1), and then

use the wire ropes (2) and liftcrane to secure the
counterweight so that it does not fall during removal
and installation operations.

84592788 EN - March 2012

5. Use a box wrench [41 mm (1.614 in)] to remove the 7. Thoroughly check that the location is safe before
4 bolts (1) and spacers (2) on the lower section of lowering the counterweight on wood planks (1).
the counterweight.
• Thoroughly secure the counterweight with the
wire ropes and liftcrane so that it does not fall
over.

3. After inserting the bucket side and arm side pins (2),
use a screwdriver to install the rings (1).
• Grease up.
2. Place the back of the bucket parallel to the ground.
Use a hammer (4) to press in the bucket side pin (3)
and arm side pin (2), and then install the bucket (1).
• If a pin is hard to insert, there is a load on the pin.
Do not force it in. Adjust the bucket installation
position.
• When inserting the pin, be careful not to damage
the installed O-rings or dust seals.

84592788 EN - March 2012

Section

9003B

Removal and Installation of Bucket Link

84592788 EN - March 2012

CONTENTS

Removal of Bucket Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Bucket Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CAUTION Removal of Bucket Link

• Stop the machine on a level location with • Remove the bucket. (For details, see "Removal and
good footing. Installation of Bucket".)
• Be sure to stop the engine before beginning 1. Place the bucket link (1) parallel to the ground.
work.
• When working together with others, always
be sure to exchange signals and pay ade-
quate attention to safety.
• Always wear protective devices (protective
eyewear and safety shoes, etc.) when work-
ing with a hammer.

Items to prepare
• 2 wrenches [24 mm (0.945 in)]
• Hammer
• Striking rod
• Grease
• Rag
• Cleaning fluid 2. Use 2 wrenches [24 mm (0.945 in)] to remove the
double nuts (1), and then pull out the bolts (2) (3).

3. Use a hammer (3) and striking rod (4) to push the

pin (2) out and remove the bucket link (1).

84592788 EN - March 2012

4. Use a hammer (4) and striking rod (5) to push out Installation of Bucket Link
the pin (3) and remove the arm links (1) (2).
1. Clean each pin and pin hole.
• When removing the pin, be careful not to damage
the installed O-rings or dust seals.

2. Use a hammer (4) to push in the pin (1) and install

the arm links (2) (3).
• If a pin is hard to insert, there is a load on the pin.
• When inserting the pin, be careful not to damage
the installed O-rings or dust seals.

3. Place the bucket link (1) parallel to the ground.

Use a hammer (3) to push in the pin (2) and install
the bucket link (1).

4. Use 2 wrenches [24 mm (0.945 in)] to attach the

double nuts (1), and then install the bolts (2) (3).
Install so that the gap between the double nuts (1)
and collars (4) is 1 - 2 mm (0.039 - 0.079 in).
• Grease up.
• Install the bucket. (For details, see "Removal and
Installation of Bucket".)

84592788 EN - March 2012

a 1 - 2 mm (0.039 - 0.079 in)

84592788 EN - March 2012

Section

9003C

Removal and Installation of Arm

84592788 EN - March 2012

CONTENTS

Removal of Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Job code 39121AA10 Removal of Arm

• Remove the bucket. (For details, see "Removal and
CAUTION Installation of Bucket".)
• Remove the bucket link. (For details, see "Removal
• Stop the machine on a level location with and Installation of Bucket Link".)
good footing.
• Remove the bucket cylinder. (For details, see "Re-
• Be sure to stop the engine before beginning moval and Installation of Bucket Cylinder".)
work.
• Remove the arm cylinder. (For details, see "Removal
• When working together with others, always and Installation of Arm Cylinder".)
be sure to exchange signals and pay ade-
quate attention to safety. 1. Bring the arm (1) top in contact with the ground and
• Always wear protective devices (protective use a liftcrane and nylon sling (2) to secure it.
eyewear and safety shoes, etc.) when work- At this time, insert the arm cylinder pin (3) and se-
ing with a hammer. cure with the nylon sling.
• Be sure to inspect the nylon sling and other
lifting equipment before beginning work.
• Do not stand or pass under the suspended
load.

Items to prepare
• Wrench [ 19 mm ( 0.748 in ) ]
• Hammer
• Striking rod
• Nylon sling (with the required lifting capacity)
• Liftcrane (with the required lifting capacity)
• Grease
• Rag
• Cleaning fluid
Crosstie 2. Use a wrench [ 19 mm ( 0.748 in ) ] to remove the
•
bolt (1) and washer (2).

3. Use a hammer (3) and striking rod (4) to push the

pin (2) out and remove the arm (1).
• If a pin is hard to remove, there is a load on the
pin.
• When removing the pin, be careful not to damage
the installed dust seals.
• Be very careful. When the pin is removed, the
arm may fall slightly.
• Be very careful. The arm may fall over to the side.

84592788 EN - March 2012

Installation of Arm
• Tighten bolts being installed to the specified torque.
• When the torque is not specified, check the "Bolt Size
and Torque Table".
1. Clean each pin and pin hole.

4. Lift the arm and then place it on the crosstie.

2. Insert the arm cylinder pin (3) and secure with the
crane and nylon sling (2).

3. Align the arm (1) with the boom and use a hammer
(3) to push in the pin (2) and then install the arm (1).
• If a pin is hard to insert, there is a load on the pin.
• When inserting the pin, be careful not to damage
the installed dust seals.

4. Use a wrench [19 mm (0.748 in)] to tighten the bolt

(1) and washer (2).
• Install the arm cylinder. (For details, see "Re-
moval and Installation of Arm Cylinder".)
• Install the bucket cylinder. (For details, see "Re-
moval and Installation of Bucket Cylinder".)
• Install the bucket link. (For details, see "Removal
and Installation of Bucket Link".)
84592788 EN - March 2012
9003C-4
Copyright ©
Removal and Installation of Arm

• Install the bucket. (For details, see "Removal and

Installation of Bucket".)

84592788 EN - March 2012

Section

9003D

Removal and Installation of Boom

84592788 EN - March 2012

CONTENTS

Removal of Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

CAUTION Removal of Boom

• Stop the machine on a level location with • Remove the bucket. (For details, see "Removal and
good footing. Installation of Bucket".)
• Be sure to stop the engine before beginning • Remove the bucket link. (For details, see "Removal
work. and Installation of Bucket Link".)
• When working together with others, always • Remove the bucket cylinder. (For details, see "Re-
be sure to exchange signals and pay ade- moval and Installation of Bucket Cylinder".)
quate attention to safety. • Remove the arm cylinder. (For details, see "Removal
• Always wear protective devices (protective and Installation of Arm Cylinder".)
eyewear and safety shoes, etc.) when work- • Remove the arm. (For details, see "Removal and In-
ing with a hammer. stallation of Arm".)
• Be sure to inspect the nylon sling and other • This section explains the procedure for when attaching
lifting equipment before beginning work. the boom cylinder to the frame.
• Do not stand or pass under the suspended When removing the boom cylinder too, see "Removal
load. and Installation of Boom Cylinder".
1. Bring the boom (1) top in contact with the ground.
Items to prepare
• Wrenches [10 mm (0.394 in), 19 mm (0.748 in), 24 mm
(0.945 in), 36 mm (1.417 in)]
• Slide hammer [24 mm (0.945 in)]
• Nylon sling (with the required lifting capacity)
• Liftcrane (with the required lifting capacity)
• Marking pen
• Cap
• Plug
• Rag
• Striking rod
• Cleaning fluid
• Wood piece
• Square wooden pieces
• Wire 2. Use a wrench [19 mm (0.748 in)] to remove the
grease hoses on the left and right sides (1).
• Use caps or plugs to prevent any entry of water,
dust or dirt.

84592788 EN - March 2012

3. Use a wrench [24 mm (0.945 in)] to remove the dou- 6. Tie the cylinder rods on the left and right sides with
ble nuts (1) and bolt (2), and then remove the fas- wire (1) so that they cannot come out.
tening ring (3).
Also, remove the cab side in the same way.

7. Use a wrench [10 mm (0.394 in)] to remove the

grease nipple (1), and then secure the base of the
4. Use a hammer (2) and striking rod (3) to push the boom cylinders (right) (left) with the batten (2).
pin (1) out.
Use a liftcrane and nylon slings (4) to hold the boom
cylinders (right) (left) so that they does not fall.

8. Lower the boom cylinders (right) (left) and let them

rest on the batten (1).

5. Start the engine, lower the boom at idle, and retract

the boom cylinder (1) (2) rod.

84592788 EN - March 2012

9. Install the pin (1) removed in Step 4. Bucket hose [use 36 mm (0.417
1
Use a wrench [24 mm (0.945 in)] to tighten the bolt in) wrench]
(3) with the 2 double nuts (2), and then install the Bucket hose [use 36 mm (0.417
fastening ring (4). 2
in) wrench]
Also, install the cab side in the same way. Arm hose [use 36 mm (0.417
3
in) wrench]
Arm hose [use 36 mm (0.417
4
in) wrench]
2nd option hose [use 19 mm
5
(0.748 in) wrench]
2nd option hose [use 19 mm
6
(0.748 in) wrench]

12. Use a wrench [19 mm (0.748 in)] to remove the bolt

(1) and washer (2).

10. Wrap nylon slings (1) around the pins on the left and
right sides installed in Step 9 and secure with the
liftcrane.

13. Use a slide hammer (1) [36 mm (1.417 in)] to re-

move the pin (2).

11. Use wrenches [19 mm (0.748 in), 36 mm (1.417 in)]

to remove the hoses (1), (2), (3), (4), (5) and (6).
• Mark the hoses and lines so that the connectors
match at the time of assembly.
• Use caps and plugs to cover the hoses and lines
to prevent any entry of water, dust or dirt.
• Clean the hoses and line by spraying them with
a parts cleaner to prevent scratches and prevent
dirt from accumulating on the connectors.
14. Back up the machine and remove the boom (1).

84592788 EN - March 2012

Installation of Boom 4. Tie the cylinder rods on the left and right sides with
wire (10) so that they cannot come out.
• This section explains the procedure for when not in-
stalling the boom cylinder.
• Tighten bolts being installed to the specified torque.
• When the torque is not specified, check the "Bolt Size
and Torque Table".
1. Clean each pin and pin hole.

5. Align the boom with the swing frame pin hole and
use a slide hammer (1) [36 mm (1.417 in)] to tighten
the pin (2).
• When inserting pins, be careful not to damage the
dust seals.
• If the insertion of a shim is possible according to
2. Install the pin (1). the tolerance adjust the shim.
Use a wrench [24 mm (0.945 in)] to tighten the bolt
(3) with the 2 double nuts (2), and then install the
fastening ring (4).
Also, install the cab side in the same way.

6. Use a wrench [19 mm (0.748 in)] to tighten the bolt

(1) and washer (2).
• Grease up.
3. Wrap the nylon slings (1) around pins on the left and
right sides installed in Step 2 and secure with the
liftcrane.

84592788 EN - March 2012

7. Use wrenches [19 mm (0.748 in), 36 mm (1.417 in)] 10. Use a wrench [24 mm (0.945 in)] to attach the dou-
to remove the hoses (1), (2), (3), (4), (5) and (6). ble nuts (1) and bolt (2), and install the fastening
ring (3).
Also, install the cab side in the same way.

Bucket hose
1 11. Use a wrench [ 19 mm ( 0.748 in ) ] to attach the
[use 36 mm (0.417 in) wrench]
Bucket hose grease hoses on the right and left sides (1).
2
[use 36 mm (0.417 in) wrench]
Arm hose
3
[use 36 mm (0.417 in) wrench]
Arm hose
4
[use 36 mm (0.417 in) wrench]
2nd option hose
5
[use 19 mm (0.748 in) wrench]
2nd option hose
6
[use 19 mm (0.748 in) wrench]

8. Start the engine, raise the boom at idle, and extend

the boom cylinder (1) (2) rod.

12. Bring the boom (1) top in contact with the ground.
• When installing the boom cylinder too, see "Re-
moval and Installation of Boom Cylinder".
• Install the arm. (For details, see "Removal and
Installation of Arm".)
• Install the arm cylinder. (For details, see "Re-
moval and Installation of Arm Cylinder".)
• Install the bucket cylinder. (For details, see "Re-
moval and Installation of Bucket Cylinder".)
• Install the bucket link. (For details, see "Removal
and Installation of Bucket Link".)
• Install the bucket. (For details, see "Removal and
9. Use a hammer (2) to push in the pin (1). Installation of Bucket".)
Use a liftcrane and nylon slings (3) to hold the boom
cylinders (right) (left) so that they does not fall.

84592788 EN - March 2012

Section

9004

Removal and Installation of Operator's Seat

84592788 EN - March 2012

CONTENTS

Removal of Operator's Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Operator's Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Job code 90120AD17 3. Use a wrench [ 13 mm ( 0.512 in ) ] to remove the 2

bolts (1) from the rear of the seat.
Tightening torque for bolt (1) installation: 19.6 N・
Items to prepare
m ( 14.459 lbf・ft )
• Wrench [ 13 mm ( 0.512 in ) ]

Removal of Operator's Seat

1. Pull the slide lever (1) to slide the seat (2) to the
rear.
Use a wrench [ 13 mm ( 0.512 in ) ] to remove the 2
bolts (3) from the front of the seat.
Tightening torque for bolt (3) installation: 19.6 N・
m ( 14.459 lbf・ft )

4. Remove the operator's seat (1).

2. Pull the slide lever (1) to slide the seat forward, and
then pull the reclining lever (2) to fold the seatback
forward.

Installation of Operator's Seat

To install, perform the reverse of the removal procedure.
Tighten bolts being installed to the specified torque.

84592788 EN - March 2012

Section

9005A

Removal and Installation of Cab Assembly

84592788 EN - March 2012

CONTENTS

Removal of Cab Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Cab Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Job code 90150AA08 Removal of Cab Assembly

• Remove the operator's seat. (For details, see "Re-
CAUTION moval and Installation of Operator's Seat".)
• Be sure to stop the engine before beginning 1. Use a box wrench [13 mm (0.512 in)] to remove the
work. 6 bolts (1), and the
• Be sure to inspect the wire rope and other
lifting equipment before beginning work.
• Do not stand or pass under the suspended
load.

cab bolts (1), and use a wrench [24 mm (0.945 in)]
to remove the 4 nuts (2).

84592788 EN - March 2012

20. Use chains (1) and liftcrane to remove the cab (2). Installation of Cab Assembly
To install, perform the reverse of the removal procedure.
Tighten bolts being installed to the specified torque.
If the torque is not specified, see the "Tightening Torque"
section.

21. Thoroughly check that the location is safe before

lowering the cab on wood planks (1).
• Thoroughly secure the cab with the chains and
liftcrane so that it does not fall down.

Section

9005C

Removal and Installation of Wiper Controller

84592788 EN - March 2012

CONTENTS

Removal of Wiper Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of wiper controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Job code 55518BH01 2. Remove the connector (2) from the wiper controller
(1).
Items to prepare
• Wrench [ 10 mm ( 0.394 in ) ]
• Box wrench [ 10 mm ( 0.394 in ) ]
• Phillips screwdriver
• Flathead screwdriver

Removal of Wiper Controller

1. Use the Phillips screwdriver or box wrench [ 10 mm
( 0.394 in ) ] to remove the 4 bolts (1), and then
remove the side rear B trim (2).

3. Use a flathead screwdriver to slightly bend the 4 in-

stallation clips (1), and then remove the wiper con-
troller (2).

Installation of wiper controller

To install, perform the reverse of the removal procedure.
Tighten bolts being installed to the specified torque.
For bolts for which the torque is not specified, see the
"Tightening Torque" section.

84592788 EN - March 2012

Section

9005D

Removal and Installation of Wiper Motor

84592788 EN - March 2012

CONTENTS

Removal of Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of wiper motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Job code 55518AZ46 3. Use a Phillips screwdriver or box wrench [ 10 mm (

0.394 in ) ] to remove the 2 bolts (1), use a hexagon
wrench [ 5 mm ( 0.197 in ) ] to remove the 3 bolts (2)
Items to prepare
and 3 washers (3), and then remove the front upper
• Hexagon wrench [ 5 mm ( 0.197 in ) ] trim assembly (4).
• Wrenches [ 10 mm ( 0.394 in ), 17 mm ( 0.669 in ) ] Tightening torque for bolt (1) installation: 5.9 - 7.8
• Box wrench [ 10 mm ( 0.394 in ) ] N・m ( 4.352 - 5.754 lbf・ft )
• Flathead screwdriver (longnose pliers)
• Phillips screwdriver

Removal of Wiper Motor

1. Use a Phillips screwdriver or box wrench [ 10 mm
( 0.394 in ) ] to remove the 2 bolts (1), and then
remove the side front lower trim (2).
Tightening torque for bolt (1) installation: 5.9 - 7.8
N・m ( 4.352 - 5.754 lbf・ft )

4. Use a wrench [ 17 mm ( 0.669 in ) ] to remove the 1

nut (1), and then remove the wiper arm (2).
Tightening torque for installation: 12 - 16 N・m (
8.85 - 11.80 lbf・ft )

2. Use a flathead screwdriver or longnose pliers to re-

move the clip pins (1), and then remove ducts B (2).

5. Use a wrench [ 17 mm ( 0.669 in ) ] to remove the

1 nut (1).
Tightening torque for installation: 11 - 13 N・m (
8.11 - 9.58 lbf・ft )

84592788 EN - March 2012

CONTENTS

Removal of Cab Front Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Cab Front Glass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Job code 90156AL10 3. Use a wrench [ 10 mm ( 0.394 in ) ] to remove the

3 bolts (1) each, and then remove the brackets (2)
(3).
CAUTION Tightening torque for bolt (1) installation: 880 - 1270
N・cm ( 77.90 - 112.42 lbf・in )
Reinforced glass is used for the front win-
dow.
Be extremely careful not to damage it when
touching it during removal or installation.

Items to prepare
• Wrench [ 10 mm ( 0.394 in ) ]
• Phillips screwdriver
• Rag
• Cleaning fluid

Removal of Cab Front Glass

1. Use a Phillips screwdriver to remove the 8 clips (2),
and then remove the cover (1). 4. Remove the covers (1) (2) for the bracket.

2. Use a Phillips screwdriver to remove the screw 5. Use a wrench [ 10 mm ( 0.394 in ) ] to remove the 3
(1), and then install the removed screw (1) into the bolts (1), and then remove the front glass left lower
screw hole (2). bracket (2).
Tightening torque for bolt (1) installation: 880 - 1270
• The assist spring is locked.
N・cm ( 77.90 - 112.42 lbf・in )

84592788 EN - March 2012

6. Use a wrench [ 10 mm ( 0.394 in ) ] to remove the 3 Installation of Cab Front Glass

bolts (1), and then remove the front glass right lower
bracket (2). To install, perform the reverse of the removal procedure.
Tightening torque for bolt (1) installation: 880 - 1270 Tighten bolts being installed to the specified torque.
N・cm ( 77.90 - 112.42 lbf・in ) If the torque is not specified, see the "Tightening Torque"
section.

7. Remove the cab front glass (1).

84592788 EN - March 2012

Section

9005G

Window Lock Adjustment Procedures

Q't- Q't- Q't-

Code Part name Code Part name Code Part name
y y y
Bracket receiver
1 Cooler hose (Liquid 2) 1 6 Slide shaft 1 11 1
[D60.5 (2.3819)]
Tension pulley (With
2 Cooler hose (Suction) 1 7 1 12 V belt B55.5 1
cover)
Rubber hose 16
Rubber hose 16 x
3 1 8 Air condenser 1 13 x 2800 (0.629 x 1
2600 (0.63 x 102.362)
110.236)
Cooler hose (Dis- Dryer receiver [D60.5
4 1 9 1
charge) (2.3819)]
Compressor; Air con-
5 1 10 Cooler hose (Liquid 1) 1
ditioner

Explanation of Functions
Explanation of Control
Back-up function
Even when air conditioner operation is stopped (switched OFF) with the vehicle main key power supply or operation
panel ON/OFF switch, the set temperature and all the other setting states are stored in memory, so the next time air
conditioner operation starts, it goes into the same state as before it was stopped.
When the vehicle main key power supply is cut off, the data is backed up by storing it in the internal EEPROM.
However, if the main key power supply is cut off within 0.5 sec. of switch input, that switch input is not stored into
memory.
Also, the data read out from EEPROM when the power is switched ON is judged to see if it is within the valid range.
If data outside the valid range was written into memory, for example due to noise, then operation starts from the default
setting values to avoid abnormal operation.
Fahrenheit temperature display
To switch, hold down both the temperature setting UP and DOWN switches for 5 sec.
The display toggles between Celsius and Fahrenheit display each time the switches are both held down for 5 sec.
The Fahrenheit display is a 2-digit integer and below the decimal point is not used, so "F" is displayed.
However, in case of trouble, this display takes priority.
When this display is switched, the new status is backed up in memory, so even if the main key power supply is
switched OFF, the display status is retained.
Internal calculations are all done in Celsius.
Only the operation panel display is in Fahrenheit.
Therefore, the display may differ slightly from the exact Fahrenheit temperature.
Below is shown the Fahrenheit temperature and the corresponding Celsius temperature used in internal processing.

CAUTION
These specifications are written with Celsius as the standard.
Therefore, if the temperature is displayed in Fahrenheit, convert the temperature to centigrade by using
the table below.

Fahrenheit dis- Interior recognition set temper-

play [°F] ature (Celsius) [°C]
63 18.0
64 18.5
65 19.0
：：
77 25.0
：：
91 32.0

84592788 EN - March 2012

Air Mix Motor Actuator Control

1. Summary explanation
The provisional target degree of opening is determined from the target blow temperature and the current blow
mode, various restrictions are applied, and the target degree of opening is calculated.
Then drive is output to move the motor actuator position to the target degree of opening.
Below are the details.
2. Heater unit hysteresis correction operation (motor actuator one-direction stop)
After the actuator moves to the target degree of opening, it returns to the specified position.
However, if the target degree of opening is less than 0°, the actuator is treated as having reached the target
degree of opening when it reaches 0°, then it moves to the specified position. (A stop in the fully-open direction
is used as the reference.)
3. Motor actuator operation priority order
The operation priority for this motor actuator is No. 1.
This means that if the target degree of opening for this motor actuator changes and operation becomes necessary,
even if some other motor actuator is operating, that other motor operation is paused, and this motor actuator
operates.
4. Motor actuator retry control
Even when there are no changes to the target values after the target is attained, if the difference between the
current value and the target value once every 5 min. is equal to or greater than the operation start angle, the
motor actuator is operated.

84592788 EN - March 2012

Blow Mode Motor Actuator Control

1. Summary explanation
The blow mode is switched by rotating the diffuser switching damper with the motor actuator.
There are 2 types of control: auto and manual.
2. Auto control
When AUTO blow mode is set, the blow mode changes to auto control.
During auto control, the diffuser is switched according to the target blow temperature
Auto control continues until operation of the blow mode select switch is recognized.

1 Target blow temperature 3 MODE 2 VENT *5 MODE 4 FOOT

*2 Blow mode *4 MODE 3 B/L

3. Manual control
1) When operation of the blow mode select switch is recognized, the blow mode motor actuator is driven to
attain the output shaft angle below and the display is switched too.
Each time operation of the switch is recognized, the display switches MODE 1 → MODE 2 → MODE 3 →
MODE 4 → MODE 1 →...
However, if this switch is pressed during auto control, auto control is ended and the diffuser is fixed at its
current position.
2) MODE 5 in the table below only occurs when operation of the DEF select switch is recognized.
After that, when operation of the blow mode select switch is recognized, the blow mode becomes the one
that was in effect just before operation of the DEF select switch was recognized.
Also, even if the DEF switch is pressed again during this mode, the mode is not canceled.

MODE MODE MODE MODE MODE

Blow mode
1 2 3 4 5
Blow mode motor actuator degree of opening 90° 67° 48° 26° 0°
FACE VENT B/L FOOT DEF
Panel display

4. Blow mode control priority order

The priority order for auto control and manual control is as follows.

Priority order Control

1 Manual control
2 Auto control

84592788 EN - March 2012

Refresh/Recirculate Switch Motor Actuator Control

1. Recirculate mode
In refresh mode, when it is recognized that the refresh/recirculate select switch on the operation panel has been
closed, the system goes into recirculate mode.At this time, the display switches to recirculate and the motor
actuator operates to the refresh angle (damper angle) of 0°.
2. Refresh mode
In recirculate mode, when it is recognized that the refresh/recirculate select switch on the operation panel has
been closed, the system goes into refresh mode. At this time, the display switches to refresh and the refresh/
recirculate switch motor actuator operates to the refresh angle.
1) Refresh mode I
When blow mode control is manual and is set to B/L or FOOT, the set temperature is set to 32 °C ( 89.6 °F
) (HOTMAX), and air flow control is manual and is set to Hi, the refresh angle (damper angle) operates to
67°.
2) Refresh mode II
When in a mode other than refresh mode I, the refresh angle (damper angle) operates to 30°.
3. Operation stop judgment
1) The operating motor actuator stops when the current position comes within the target position range.
2) The stopped motor actuator operates when the current position goes beyond the target position range.

Refresh/recirculate mode and refresh/recirculate display

Refresh/recirculate mode Recirculate Outside air

Panel display

84592788 EN - March 2012

Blower Amp Control

1. Summary explanation
The air flow is controlled by outputting to the blower amp connected in series with the blower motor.
The air flow is switched by varying the analog voltage output by changing the PWM output duty ratio and increas-
ing or decreasing the blower motor speed.
There are 2 types of air flow control: auto air flow control and manual air flow control.
Also, in auto air flow control, the air flow is restricted by the cold blast prevention control etc.
2. Manual air flow control
Each time it is recognized that the air flow UP switch has been closed, the air flow is fixed to the next higher level
of air flow from Lo → M1 → M2 → M3 → M4 → Hi.
When Hi is already displayed, the air flow is not changed.
In the same way, each time it is recognized that the air flow DOWN switch has been closed, the air flow is fixed
to the next lower level of air flow from Hi → M4 → M3 → M2 → M1 → Lo.
When Lo is already displayed, the air flow is not changed.
The same is true when air flow control is switched from auto to manual. For example, when AUTO M1 is dis-
played, if it is recognized that the air flow DOWN switch has been closed, the display becomes Lo and AUTO is
no longer displayed.
Also, the change speed for air flow output switchover is the same as discussed for auto below.

Relationship between air flow and display during manual operation

Lo Hi
Air flow (minimum air M1 M2 M3 M4 (maximum air
flow) flow)
Blower air
40 % 46 % 54 % 64 % 80 % 100 %
flow %

Display

3. Auto air flow control

When it is recognized that the AUTO switch has been closed, the air flow is controlled automatically and AUTO
is displayed.
1) During auto air flow control, the air flow is set according to the target blowing temperature as shown in the
diagram below.
2) Auto air flow control continues until closing of either the air flow UP or air flow DOWN switch is recognized.
3) The auto air flow amount calculation results are continuous, not divided into levels.
4) When it is recognized that the AUTO switch has been closed, the display becomes as in the table below
according to the results of the auto air flow amount calculation.
5) The normal auto air flow output change is roughly 5 V/sec.
6) Auto air flow control is restricted by the cold blast prevention control described in (4), which is the next item.

84592788 EN - March 2012

1 Target blow temperature 4 M4 *7 M1

*2 Auto air flow *5 M3 *8 Lo
*3 Hi *6 M2

Relationship between air flow and target blow temperature

Display refreshing and air flow output correspondence table

Current display Item Target % (about)
Lo display Output range changed to M1 When 44 % or higher
Output range changed to Lo When 40 % or lower
M1 display
Output range changed to M2 When 52 % or higher
Output range changed to M1 When 48 % or lower
M2 display
Output range changed to M3 When 61 % or higher
Output range changed to M2 When 57 % or lower
M3 display
Output range changed to M4 When 74 % or higher
Output range changed to M3 When 70 % or lower
M4 display
Output range changed to Hi When 88 % or higher
Hi display Output range changed to M4 When 84 % or lower

4. Cold blast prevention control

The air flow is restricted according to the value of the coolant temperature data and other parameters sent from
the vehicle side via CAN communication.
The air flow restriction has 2 levels - air flow 0 and air flow Lo. Whether or not to use the restriction is determined
from the judgment results.
1) Conditions under which cold blast prevention control is used
1) Auto air flow
2) When set temperature - inside air sensor temperature 11.
3) When the coolant temperature signal from vehicle is the less than 30 °C ( 86.0 °F ) signal or the 30
°C ( 86.0 °F ) or higher but less than 45 °C ( 113.0 °F ) signal
Under the condition above, the inside air sensor temperature is the value immediately after the vehicle main
key power supply is switched ON and AUTO and Tset are according to the current switch states.
Therefore, when the AUTO switch is pressed after the air flow has been set manually, if the coolant tem-
perature is within the cold blast prevention range, the air flow is restricted.
In the same way, even if the set temperature is changed, if the conditions are met, the air flow is restricted.
While cold blast prevention control is being executed, the display corresponds to the restricted air flow.
2) Air flow 0 control
When the coolant temperature signal from vehicle is the less than 30 °C ( 86.0 °F ), the air flow is set to 0.
This continues until a coolant temperature signal of 30°C ( 86.0 °F ) or higher is received.
Once a coolant temperature signal of 30 °C ( 86.0 °F ) or higher is received and these conditions are no
longer met, air flow 0 is ended.
3) Air flow Lo control
When the coolant temperature signal from vehicle is the 30 °C ( 86.0 °F ) or higher but less than 45 °C (
113.0 °F ) signal, the air flow is set to Lo.
This continues until a coolant temperature signal of 45 °C ( 113.0 °F ) or higher is received.
Also, the same as for [2], this shift is irreversible.
Once a coolant temperature signal of 45 °C ( 113.0 °F ) or higher is received, control is normal.
5. Blower air flow control when mode motor actuator angle switched
When the mode motor actuator is operated with the blower air flow at M1 or higher, the mode motor actuator is
operated with the blower air flow first set to Lo.
After the end of operation, the original blower air flow returns.
Changes to the blower output at this time are the same as normal auto air flow control.
However, the blower display is not changed during control.

84592788 EN - March 2012

6. Air flow control priority order

The priority order for auto air flow control, manual air flow control, and cold blast prevention control is as follows.

Priority or-
Control
der
Blower air flow control when mode motor actuator angle
1
switched
2 Manual air flow control
3 COOLMAX control
4 Cold blast prevention control
5 HOTMAX control
6 Auto air flow control

84592788 EN - March 2012

Compressor Clutch Control

1. Summary explanation
The compressor clutch is controlled by the power to the clutch coil being switched ON/OFF by an external relay.
This control is executed by thermo operation and the fletching prevention function.
Thermo operation has control mode 1 and control mode 2. These modes are applied according to the blow mode
and other conditions.
However, for blower air flow 0, the compressor clutch is switched OFF.
The operation temperature does not include the thermistor variation.
2. Thermo operation (AC switch ON)
1) Control mode switchover
• When the blow mode is B/L and the target blow temperature is as in the diagram below, control mode 2
is used.
As the diagram shows, there is hysteresis between control modes 1 and 2.
• Other than the above is all control mode 1.

*1 Target blow temperature

*2 Control mode 1
*3 Control mode 2

3. Fletching prevention function

1) Operation conditions
After the end of initial operation, if 4 - 5 min. continue with the air flow M3 or higher and the compressor
clutch not coming ON even once, the compressor clutch is switched ON one time.
This control is cleared by the vehicle main key power supply being switched OFF and this control starts
again when this power supply is switched ON again.
2) This control takes priority over all other control.
4. AUTO switch link function
When operation of the AUTO switch is recognized, compressor clutch control comes ON and AUTO is displayed.
1) Compressor clutch control is the same control as for the AC switch being switched ON.
2) When it is recognized that the AC switch has been switched OFF, the AUTO display goes out.
Even when it is recognized that the AC switch has been switched ON again, AUTO is not displayed.
However, at this time, if the main key power supply is switched OFF, then ON again, since the AC ON, air flow
AUTO, and blow mode AUTO conditions are all met, AUTO is displayed.

84592788 EN - March 2012

COOLMAX Control and HOTMAX Control

1. When the set temperature is 18.0 °C ( 64.4 °F ) [COOLMAX] (or 18.E)
1) The air mix motor actuator is set to the 0° limiter position (fully closed).
2) For auto air flow control, the air flow is set to Hi.
3) For AUTO blow mode control, the blow mode is set to VENT.
2. When the set temperature is 32.0 °C ( 89.6 °F ) [HOTMAX] (or 32.E)
1) The air mix motor actuator is set to the 90° limiter position (fully open).
2) For auto air flow control, the air flow is set to M4.
3) For AUTO blow mode control, the blow mode is set to FOOT.
Abnormality Detection and Control after Abnormality Detected
1. Summary explanation
If there is an abnormality in a motor actuator drive line or sensor computer input circuit, the abnormality is detected
and control after detection is performed as described below.
In all cases, abnormality control does not end once abnormality has been detected and the location is returned
to normal.
Trouble control is only ended when the vehicle main key power supply is switched OFF or when air conditioner
operation is stopped with the ON/OFF switch on the operation panel.
However, motor actuator restriction is only ended by switching OFF the main key power supply.
2. Trouble in a motor actuator and its input/output circuits
1) Disconnection detection
After the main key power supply is switched ON, if a motor actuator potentio-meter line is disconnected or
shorted, the display in the table below for that motor actuator is carried out and that motor actuator is not
driven until the main key power supply is switched OFF, then ON again.

Abnormality location Abnormality display

HL. E is displayed on the set temperature display LCD.
Air mix motor actuator
See the diagram below.
Blow mode motor actuator The passenger icon display flashes.
Refresh/recirculate switch motor actuator The refresh/recirculate mark flashes.

84592788 EN - March 2012

2) Motor lock detection

If the output shaft rotation angle of a motor actuator does not reach the target value within 15 sec., locking
is detected, output to that motor is stopped, and the abnormality is displayed on the computer according to
the abnormality location.

Abnormality location Abnormality display

3. Trouble in a sensor or its input/output circuits (disconnection or short)

1) Disconnection or short in the inside air sensor or its input/output circuits
1) Operator compartment temperature control end
• The operator compartment temperature control (all control related to target blow temperature) is
stopped and the air mix degree of opening is directly adjusted according to the temperature adjust-
ment switch input.
• Accompanying this, the operation panel set temperature display changes as in the diagram below.

* is a value between 0 - 9, and each time the DOWN switch is closed, this value decreases by 1; each
time the UP switch is closed, this value increases by 1.

* value Motor actuator degree of opening (°)

0 0°
1-8 * value x 10°
9 90°

2) Auto air flow control end

• The air flow is temporarily fixed at the setting that was in effect when the inside air sensor abnor-
mality was detected.
• The AUTO display is set flashing.
• After this, the air flow is switched by the manual air flow switch.
3) AUTO blow mode control end
• The blow mode is temporarily fixed at the setting that was in effect when the inside air sensor ab-
normality was detected.
• The AUTO display is set flashing.
• After this, the blow mode is switched by the manual blow mode switch.
4) Air mix damper degree of opening display priority
• Even if the trouble shown by one of the items below occurs during inside air sensor trouble, E is not
displayed in the * section below the decimal point and the air mix damper degree of opening display
is given priority.
• HL. E is only displayed for air mix motor actuator trouble.
84592788 EN - March 2012
9006-23
Copyright ©
Air Conditioner Overall Diagram

5) Thermo operation control mode fixed

• Switching of the control mode according to the blow mode and target blow temperature is stopped
and the control mode is fixed at control mode 1.
2) Disconnection or short in evaporator sensor or its input/output circuits
1) Compressor control is not executed and the compressor clutch is always OFF.
2) E is displayed in the first fraction position of the set temperature display LCD.
See the diagram below. (The temperature setting is in 1 °C ( 33.8 °F ) steps.)
However, E is not displayed for inside air sensor trouble.
3) The AC mark flashes.
Disconnection or short in evaporator sensor or its input/output circuits

*1 The AC mark flashes

*2 E is not displayed

3) Disconnection or short in solar radiation sensor or its input/output circuits

1) The solar radiation compensation data is set to 0.
2) E is not displayed in the first fraction position of the set temperature display LCD as it is for other
sensors.
4) Coolant temperature signal trouble
Cold blast prevention control does not work and normal control is used.
4. CAN communication abnormality processing
1) Recovery from bus off
1) Initial retry processing: 5 msec.
2) Re-retry processing: every 1 sec.
Bus off retry processing is performed at the above rate.
2) Receiving data abnormality
1) Definition: The data field is outside the prescribed range regardless of whether the receiving data is
operating normally or abnormally.
2) Processing: In the case of the former, all data that time are discarded and the previous data are
retained.
In the case of the latter, data is discarded only for those items determined to be abnormal.
3) Communication interruption abnormality
1) Interruption judgment
Monitor Display: When normal reception is not possible 1 sec. or more since the previous normal
reception
Engine: When normal reception is not possible 10 sec. or more since the previous normal reception
2) Internal use data: Shift to alternate data (processing)
3) Sending process: Continue
4) Recover: As soon as valid data is received
4) Alternate data (processing)
＜Sending mode: ENGINE ECU＞
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9006-24
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Air Conditioner Overall Diagram

1) Outside air data abnormality

Perform estimated outside air control.
* However, once there is a shift to estimated outside air, estimated outside air control continues until
the ignition is switched OFF.
2) Coolant temperature data abnormality
Control the internal coolant temperature data to 45 °C ( 113.0 °F ) (the temperature at which to avoid
cold air prevention control).
＜Sending mode: MONITOR DISPLAY ECU＞
1) Open window signal data abnormality
Perform control with the internal open window data closed.
2) Open door signal data abnormality
Perform control with the internal open door data closed.
5) Alternate data (processing) up to initial normal reception
＜Send node: ENGINE ECU＞
1) Outside air data abnormality
Within 5 sec. after ignition is turned on: No data
After 5 sec. after ignition is turned on: Perform estimated outside air control.
2) Coolant temperature data abnormality
Within 5 sec. after ignition is turned on: Perform control at 30 °C ( 86.0 °F ) (the temperature at
which to control cold air prevention)
After 5 sec. after ignition is turned on: Perform control at 45 °C ( 113.0 °F ) (the temperature at
which to avoid cold air prevention control)
＜Send node: MONITOR DISPLAY ECU＞
1) Open window signal data abnormality
Perform control with the internal open window data closed.
2) Open door signal data abnormality
Perform control with the internal open door data closed.

84592788 EN - March 2012

Monitor Mode
1. Summary explanation
Monitor mode is a mode for understanding abnormalities in the operation panel itself or in other control.
The system goes into monitor mode when there is the special switch input below on the operation panel.
2. Starting monitor mode
When the air conditioner is operating with basic control, if the operation panel ON/OFF switch closed path con-
tinues for 1 sec. while the refresh/recirculate select switch closed path is ongoing, monitor mode is started.
3. Monitor contents
1) LCD segment diagnosis
When monitor mode is entered, the target LCD lights up for 1 sec.
An LCD with trouble does not light up.
2) Sensor diagnosis
The detection value (AD value or °C ( °F )) for each sensor is displayed.
3) Coolant temperature signal recognition value
This displays the reception status for the coolant temperature signal sent from the vehicle.
4. Display contents in monitor mode
In monitor mode, the data (detection value for each sensor, coolant temperature signal recognition, etc.) is dis-
played in the 3-digit of the 7-segment display for the temperature setting.
The data displayed is selected with the blower UP/DOWN switches and AUTO switch.
The blower UP/DOWN switches move the display on the dedicated monitor mode 7-segment display through 16
displays, 0 - F, and the corresponding data is displayed.(Table A)
Hexadecimal data display and decimal data display can be selected with the AUTO switch. Only for the coolant
temperature signal recognition value, the value detected immediately before entry into monitor mode is displayed.
The difference between hexadecimal data and decimal data is indicated by the 3rd-digit of the 7-segment display
for the temperature setting. For hexadecimal data, "H" is displayed there and for decimal data, numbers (0 - 9)
are displayed there.
1) Hexadecimal display
AD values 00H - FFH are displayed.
When the AD value corresponds to that in Table B (or Table C for the solar radiation sensor), this indicates
a disconnection or short.
In the hexadecimal display, when the value of a sensor changes in monitor mode, the hexadecimal display
changes with it.
If the display before entering monitor mode was , the error judgment value is displayed. (In other
words, the detected value before the abnormality was detected) In the same way, if the display before
entering monitor mode was , the display becomes **.E and the error judgment value is displayed.
2) Decimal display
Decimal display is used from -99.9 °C - 99.9 °C ( -147.8 °F - 211.8 °F ).
Also, the "-" minus display is displayed on the left side of the 3 digit segment.
5. Air conditioner operation in monitor mode
When the system enters monitor mode, all output (operation) through control is stopped and until monitor mode
is ended, operations and settings of basic control through all the switches are not possible.
6. Ending monitor mode
In monitor mode, if the operation panel ON/OFF switch closed path continues for 1 sec. while the refresh/recir-
culate select switch closed path is ongoing, monitor mode is ended and the system returns to the basic control
state.
The same also occurs if the vehicle main key power supply is switched OFF.

Exclusively for monitor

mode Display contents
7 seg
0 Inside air sensor temperature data
1 Evaporator sensor temperature data
2 Solar radiation compensation data
3 Outside air data
4 -

84592788 EN - March 2012

Exclusively for monitor

mode Display contents
7 seg
Coolant temperature signal status data
30 °C ( 86.0 °F ) or
Lower than 30°C ( higher 45 °C ( 113.0 °F )
C Abnormal
86.0 °F ) Lower than 45°C ( or higher
113.0 °F )
4 1 2 3
5-F Data (sensor diagnosis etc.)

Sensor Discon-
Short
name nection
Inside air
F6H 0CH
sensor
Evaporator
F6H 0CH
sensor

Sensor
5 V short Ground short
name
Solar radia-
D5H 0CH
tion sensor

84592788 EN - March 2012

Door Switch Control

1. Summary explanation
This control adds a restriction to air conditioner operation with the door switch or front window switch. Its purpose
is to prevent overheating of the vehicle main unit.
Concretely, it suppresses condenser heating and controls in a way restricted in order to obtain a feeling of comfort.
2. Door switch/front window switch signal
Due to data sent from CAN communication.
Message ID: 0x18FF1028
Sending mode: Monitor Display
Send cycle: 10 ms
Data: Open door signal and open window signal data
Data judgment: Set with continuous 5 times of the same data for 20 ms cycle sampling
3. Control restricted by door switch/front window switch
1) Starting restricted control
When either the door or front window is open continuously for 1 sec. or longer, it is recognized that the
switch is open.
At the count of 60 sec., the buzzer buzzes the same way as for switch input to tell the operator that restricted
control is starting and that control starts.
2) Restricted control
1) For both auto and manual blow mode control
Regardless of being selected in either auto or manual blow mode, unless the blow mode is FACE, the
following air flow restriction is executed. (If the blow mode is FACE, the air flow is not restricted.)
Ⅰ. If the target blow temperature ＜ 20 °C ( 68.0 °F ), the air flow upper limit is set to M1.
Ⅱ. If the target blow temperature 25 °C ( 77.0 °F ), the air flow restriction in I is ended.
2) When the current blow mode control is AUTO
Auto control with the AUTO blow mode VENT changed to FACE is used.
3) When the current blow mode control is manual selection
Only if the blow mode is VENT immediately after the open switch is recognized, that mode is changed
to FACE.
After this, all the blow modes can be selected with manual operation.
3) Ending the restriction
When both the door and front window are closed continuously for 1 sec. or longer, it is recognized that the
switches are closed.
After a count of 1 sec., the buzzer buzzes the same way as for switch input to tell the operator that restricted
control has been ended.
When the restricted control is ended, the restriction on the air flow discussed in 1. above and the change
from VENT to FACE in 3. are ended and control returns to normal.
However, if the blow mode has been manually selected, even if the mode was changed from VENT to FACE
by the above restriction, it does not return to VENT when the restricted control is ended.

84592788 EN - March 2012

Inside Air Filter Clogging Detection Control

1. Summary explanation
This control recognizes the blower current with the dedicated shunt resistor voltage input, judges from that value
whether or not the A/C unit inside air filter is clogged and if it judges that that filter is clogged, it issues a warning
to encourage the operator to replace the filter.
2. Filter detection control
1) Starting detection control (detection timing)
5 sec. after the end of initial operation, if the air conditioner is operating and the cold blast prevention con-
ditions are not present, this control is started. Also, this control is executed every 50 hours of air conditioner
(blower) operation. However, during a temporary filter clog or filter clog, it is executed every time.
2) Detection method
Cooling / heating is judged from the operation mode and in this way the air mix motor actuator target position
is determined. Also, the mode motor actuator target value is set to FOOT, the blower air flow target value
is set to M1, and output is made to attain the target values. When all the target values are attained, the
blower current from the shunt resistor voltage is recognized, and the filter clog is judged by comparing this
current with the default current value.

(cooling / heating judgment)

When the operation mode is FACE or VENT, : Cooling (COOLMAX)
When FOOT or DEF : Heating (HOTMAX)
When B/L: Final inside air temperature If < 22 ºC, heating
When B/L: Final inside air temperature If ≥ 22 ºC, cooling
(detection current threshold)
Relative to the default current value For cooling : 0.35 - 0.39 A min.

For heating : 0.48 - 0.54 A min.

If the value is below this three times in a row, it is judged that there is a clog.
(default current value)
Current found in the initialization operation described below.

3) Clog warning
(buzzer)
The buzzer buzzes intermittently at 1 Hz for 10 sec.
(display)
"FIL" is displayed on the 7-segment display for the set temperature for 10 sec. Other marks go out.
However, if there is any switch input, the "FIL" display is ended immediately.
4) Alarm reset
If a reset detection value is recognized during the clog state, the clog state is reset.
The reset detection value is 50 % of the clog detection threshold.
5) ON/OFF switching
This function is switched ON/OFF by pressing the [Refresh / Recirculate], [MODE], and [DEF] switches
at the same time. The factory setting for this function is OFF. This function does not come ON until the
initialization operation discussed below is executed.
(buzzer)
When operation of this switch is recognized, there is the normal switch input sound.
(display)
ON or OFF is displayed on the set temperature 7-segment display, whichever is the state after switching.
Other marks go out.
6) Initialization operation
When the [Refresh / Recirculate] and [DEF] switches are pressed at the same time, the default current
value is detected and all the data for filter detection is initialized. Before executing this operation, make
sure that the air conditioner unit (with a new inside air filter installed), ducts, and grilles (with all grilles fully
open) are all installed in their normal states on the vehicle. If initialization is carried out in any other state,
there is a danger of the clog detection judgment control making an incorrect judgment. Immediately after
replacing the inside air filter with a new one, execute the initialization operation.
(buzzer)
When operation of the switch is recognized, the buzzer buzzes with the normal switch input sound. When
the detection ends, the buzzer buzzes for 3 sec.
7) Detection processing avoidance
84592788 EN - March 2012
9006-29
Copyright ©
Air Conditioner Overall Diagram

• When the inside / outside air damper is not at the recirculate position immediately before the current value
is read
• When the power supply voltage is not in the tolerance range for the voltage during the initialization oper-
ation
• Trouble in any of the motor actuators

84592788 EN - March 2012

Actuator Inspection
Air Mix Motor Actuator Inspection
• Structural diagram

Air mix damper operation defect

↓
See the chart.
↓
Specifying the trouble location

1 Control panel 3 Connector 1

2 Air mix motor actuator 4 Connector 9

• Chart

Standard
Step Action Yes No
value
Press the temperature setting
switches and set to COOLMAX
1 [ 18.0 °C ( 64.4 °F ) ]. Go to Step 2 Go to Step 3
Does the actuator operate at
all?
2 Is an error displayed? Go to Step 6 Damper lock or link defect
Press the temperature setting
switches and set to HOTMAX [
3 32.0 °C ( 89.6 °F ) ]. Go to Step 2 Go to Step 4
Does the actuator operate at
all?
4 Is an error displayed? Go to Step 5 Control panel defect
Is there continuity in harness
Actuator defect or damper
5 between the actuator and con- Harness defect
lock or link defect
trol panel?
Remove the actuator connec-
tor (9).
About 4.7
6 Is the resistance between L/Y Go to Step 7 Actuator defect
KΩ
and B/L of the actuator about
4.7 KΩ?
Is there continuity between the
7 G/L and L/Y and between G/L Control panel defect Actuator defect
and B/L of the actuator?

Set temperature Air mix motor actuator position

COOLMAX [ 18 °C ( 64.4 °F ) ] 0°
HOTMAX [ 32 °C ( 89.6 °F ) ] 90°

84592788 EN - March 2012

Refresh/Recirculate Switch Motor Actuator Inspection

• Structural diagram

Inside/outside air mix damper op-

eration defect
↓
See the chart.
↓
Specifying the trouble location

1 Control panel 3 Connector 1

2 Refresh/recirculate motor actuator 4 Connector 11

• Chart

Standard
Step Action Yes No
value
Press the refresh/recirculate
1 switch. Does the actuator operate Go to Step 2 Go to Step 3
at all?
2 Is an error displayed? Go to Step 5 Damper lock or link defect
3 Is an error displayed? Go to Step 4 Control panel defect
Is there continuity in harness be-
Actuator defect or damper
4 tween the actuator and control Harness defect
lock or link defect
panel?
Remove the actuator connector
(11). About 4.7
5 Go to Step 6 Actuator defect
Is the resistance between L/Y and KΩ
B/L of the actuator about 4.7 KΩ?
Is there continuity between the L/G
6 and L/Y and between L/G and B/L Control panel defect Actuator defect
of the actuator?

84592788 EN - March 2012

Mode Motor Actuator Inspection

• Structural diagram

Mode damper operation defect

↓
See the chart.
↓
Specifying the trouble location

1 Control panel 3 Connector 1

2 Mode motor actuator 4 Connector 10

• Chart

Standard
Step Action Yes No
value
Press the mode select switch.
1 Go to Step 4 Go to Step 2
Does the actuator operate at all?
2 Is an error displayed? Go to Step 3 Control panel defect
Is there continuity in harness be-
Actuator defect or damper
3 tween the actuator and control Harness defect
lock or link defect
panel?
4 Is an error displayed? Go to Step 5 Damper lock or link defect
Remove the actuator connector
(10). About 4.7
5 Go to Step 6 Actuator defect
Is the resistance between L/Y and KΩ
B/L of the actuator about 4.7 KΩ?
Is there continuity between the Y/L
6 and L/Y and between Y/L and B/L Control panel defect Actuator defect
of the actuator?

Blow mode MODE 1 MODE 2 MODE 3 MODE 4 MODE 5

Blow mode motor actuator degree of open-
90° 67° 48° 26° 0°
ing
FACE VENT B/L FOOT DEF
Panel display

84592788 EN - March 2012

Self-diagnosis Function with Panel Display

Abnormality Display and Self-check Procedures
Motor actuator and sensor abnormalities can be checked on the panel display.
Abnormality Display Position

a This segment is displayed only in the monitor mode

below.
b Error is displayed on the 3-digit 7-segment display.

Explanation of Abnormality Display

Motor Actuator Abnormality
1. HL. E displayed on 3-digit 7-segment display.

Check the air mix damper motor actuator for a harness disconnection or disconnected
connector.
This is also displayed when locked due to air mix motor actuator abnormality and link
abnormality.

flashes.

Check the blow mode damper motor actuator for a harness disconnection or discon-
nected connector.

84592788 EN - March 2012

flashes.

Check the refresh/recirculate damper motor actuator for a harness disconnection or

disconnected connector.

CAUTION
The above display and flashing is displayed on the 3-digit 7-segment display when trouble occurs with
the panel ON/OFF switch ON status.
After trouble occurs, when the panel ON/OFF switch is switched ON, the function is displayed.
After trouble is resolved, the abnormality display and flashing are not ended until the main switch is
switched OFF → ON.

Sensor Abnormality
1. HL. * displayed on 3-digit 7-segment display

Check the inside air sensor and check its harness for disconnection, short, or connector
connection defect.

a (* is any number 0 - 9.)

**.E and the mark flashing are flashing on the 3-digit 7-segment display. (** displays the set temperature
value at that time still remaining.)

Check the evaporator sensor and check its harness for disconnections, shorts, or con-
nector connection defects.

CAUTION
The display in 1 and 2 above is displayed on the 3-digit 7-segment display when trouble occurs with the
panel ON/OFF switch ON status.
After the trouble section is repaired, end the abnormality display by switching the panel ON/OFF switch
OFF → ON.

84592788 EN - March 2012

Explanation of Monitor Mode

When sensor abnormality is displayed, the sensor status (disconnection, short) can be checked in monitor mode.
Monitor Mode Display Position

a 3-digit 7-segment
b 7-segment dedicated to monitor display

84592788 EN - March 2012

Monitor Mode Display Operating Method

Refresh/recirculate select
1
switch
Blower switch UP/DOWN
2
switch
3 ON/OFF switch

1. Hold down the refresh/recirculate select switch and the ON/OFF switch at the same time for 1 sec. or longer.
2. Press the AUTO switch.
(All the 7 segments light up for 1 sec., then the system enters monitor mode.)
3. Numbers 0 - 9 or letters A - F are displayed in the 2nd and 3rd digit of the 3-digit 7-segment display.
"H" is displayed in the 1st-digit.
4. The display of 0 - 2 on the dedicated 7-segment display is carried out with the blower UP/DOWN switches. The
necessary sensor is selected from the table below.

7-segment display table dedicated to

monitor
0 Inside air sensor
1 Evaporator sensor
2 Solar radiation sensor

(Display other than the above (3 - 9, B -

F) is not used during service.)

5. To end the monitor display, either hold down the refresh/recirculate select switch and the ON/OFF switch at the
same time for 1 sec. again or longer or switch the vehicle main switch OFF.

CAUTION
1. During monitor mode, operations and settings of basic control through all the switches are not pos-
sible until the air conditioner control operation is stopped and monitor mode ended.
2. During monitor mode, even if a sensor is repaired, the abnormality display is recorded in memory,
and until the ON/OFF switch is switched OFF, then ON again, the abnormality display is not ended.

84592788 EN - March 2012

Display Contents in Monitor Mode

See the dedicated monitor 7-segment display table and 3-digit 7-segment table.
1. Display example 1

The dedicated monitor 7-segment display is 0 (indicates the inside air sensor
state).
From the 3-digit 7-segment table 3F → The sensor is normal.
→ The inside air sensor is normal.

2. Display example 2

The dedicated monitor 7-segment display is 1 (indicates the evaporator sensor

state).
From the 3-digit 7-segment table 0C → The sensor is disconnected.
→ The evaporator sensor is disconnected.

3. Display example 3

The dedicated monitor 7-segment display is 2 (indicates the solar radiation sen-
sor state).
From the 3-digit 7-segment table D5 → The sensor is shorted on the 5 V side.
→ The solar radiation sensor is shorted.

3-digit 7-segment table

84592788 EN - March 2012

a Solar radiation sensor short g Solar radiation sensor 5 V side

2nd-digit of 7-segment display d
OCH2 display short D5H2 display
Inside air sensor disconnection e Inside air sensor short F6H0
b 3rd-digit of 7-segment display h
OCH0 display display
c Evaporator sensor disconnec- Evaporator sensor short F6H1
f Sensors normal i
tion OCH1 display display

Air conditioner troubleshooting

The blow temperature does not go down.
* M/A means motor actuator.

Standard
Step Action Yes No
value
• The air mix motor actuator
connector is disconnected
or has a contact defect.
When the AUTO switch or AC • Air mix motor actuator de-
switch is pressed, HL. E is dis- fect
1 Go to Step 2
played in the panel set temper- • Main harness continuity
ature display section. defect
Inspect and repair or re-
place part.
HL. * is displayed on the panel
set temperature display sec-
2 Go to Step 3 Go to Step 4
tion.
* is No. 0 to 9.

84592788 EN - March 2012

Standard
Step Action Yes No
value
• Inside air sensor or har-
ness disconnection or
• Inside air sensor and short
evaporator sensor simul-
The inside air sensor con-
taneous disconnection or •
nector is disconnected or
3 The panel snow mark flashes. short
has a contact defect.
• Computer breakdown
See the Monitor Mode sec-
See the Monitor Mode sec-
tion too.
tion too.
Inspect and repair or re-
place part.
• The evaporator sensor
connector is disconnected
or there is a contact de-
fect.
• Evaporator sensor simul-
4 The panel snow mark flashes. taneous disconnection or Go to Step 5
short
See the Monitor Mode sec-
tion too.
Inspect and repair or re-
place part.
When the set temperature is
18.0 and the blow mode is set
5 18.0 ﾟC Go to Step 6 Go to Step 7
to vent mode, the blow temper-
ature drops.
Inspect the duct or eliminate Computer breakdown or in-
Cool air is flowing into the in-
6 the cause of the cool air inside air sensor defect
side air sensor section.
filtration. Inspect and replace.
Switch compressor clutch
ON/OFF and inspect and
The air mix damper is at the repair the power supply cir-
7 Go to Step 8
COOLMAX position. cuit.
See the cooling cycle trou-
bleshooting.
If motor actuator operation
• Inspect, repair, or replace
stops midway, remove the
Motor actuator breakdown the motor actuator lever
cause or correct the problem, 1.5 kgf or link section.
8 or computer breakdown
and then measure the operat- less
Replacement • Clean the lever link sec-
ing force. tion, then apply grease.
Is it 1.5 kgf or less?

The blow temperature does not go up.

84592788 EN - March 2012

Standard
Step Action Yes No
value
• The air mix motor actuator
connector is disconnected
or has a contact defect.
HL. E is displayed on the panel • Air mix motor actuator de-
1 set temperature display sec- fect Go to Step 2
tion. • Main harness continuity
defect
Inspect and repair or re-
place part.
• Inside air sensor or har-
ness disconnection or
short
HL. * is displayed on the panel • The inside air sensor con-
set temperature display sec- nector is disconnected or
2 has a contact defect. Go to Step 3
tion.
* is No. 0 to 9. See the Monitor Mode sec-
tion too.
Inspect and repair or re-
place part.
When the set temperature is
32.0 and the blow mode is set
3 32.0 ﾟC Go to Step 4 Go to Step 5
to foot mode, the blow temper-
ature rises.
Inspect the duct or eliminate Computer breakdown or in-
Warm air is flowing into the in-
4 the cause of the warm air side air sensor defect
side air sensor section.
infiltration. Inspect and replace.
The air mix damper is at the Inspect the warm coolant
5 Go to Step 6
HOTMAX position. lines.
If motor actuator operation
• Inspect motor actuator
stops midway, remove the
Motor actuator breakdown lever link section.
cause or correct the problem, 1.5 kgf or Repair or replace.
6 or controller breakdown
and then measure the operat- less
Replacement • Clean the lever link sec-
ing force. tion, then apply grease.
Is it 1.5 kgf or less?

The blower motor does not rotate.

Standard
Step Action Yes No
value
With the flow set to HI, battery
voltage is applied to the termi-
1 Replace the blower motor. Go to Step 2
nals (+ and -) of the blower mo-
tor. (Note: 1)
The battery voltage is applied
between the blower motor (+)
2 Go to Step 3 Go to Step 5
power supply red/blue and the
body.
Voltage of about 10 V is ap-
3 plied between the blower amp About 10 V Go to Step 4 Replace computer.
brown/yellow line and ground.
Remove the blower amp and
refer to the section on Blower
Eliminate the cause of the
Amp Inspection. Is there any Inspect and repair the wire
4 trouble, then replace the
abnormality? harness.
blower amp.
No abnormality → Yes
Abnormality → No
Inspect the blower motor relay.
When the blower motor relay
Inspect, repair, or replace
5 white/red and blue/red are di- Go to Step 6
the wire harness.
rectly connected, the blower
motor rotates. (Note: 2)
84592788 EN - March 2012
9006-41
Copyright ©
Air Conditioner Overall Diagram

Standard
Step Action Yes No
value
The battery voltage is applied
Inspect, repair, or replace
6 between the blower motor relay Go to Step 7
the wire harness.
white/red and the body.
When the blower motor re-
Inspect or repair the wire
lay purple/white is dropped to
7 harness or replace the com- Replace the relay.
ground, the blower motor ro-
puter.
tates.

NOTE:
1. Measure with the connector connected.
2. For the sake of safety, have the air conditioner, vehicle key, and light switches all OFF when working with direct
connections in place.
The blower motor speed does not change.
Part 1

Step Action Yes No

• Inside air sensor or harness
disconnection or short
• The inside air sensor connec-
HL. * is displayed on the panel set tor is disconnected or has a
contact defect. Replace the blower amp or
1 temperature display section.
computer.
* is No. 0 to 9. See the Monitor Mode section
too.
Inspect and repair or replace
part.

Part 2

Step Action Yes No

Does the blower motor fail to change
1 speed when the mode is other than Go to Step 2 See Part 1.
FACE?
While operating under restric-
2 Is the door or front window open? tive control by door switch or See Part 1.
front window switch.

The magnetic clutch does not engage.

Step Action Yes No

The snow mark flashes and E is
When the AUTO switch or AC switch
1 Go to Step 2 displayed on the panel display
is pressed, the snow mark lights up.
section.
Clutch defect. Replace the
2 Voltage is applied to the clutch. Go to Step 3
compressor.
Pressure switch defect or
coolant pressure abnormally
Voltage is applied between the har-
3 high or low Go to Step 4
ness and pressure switch.
See the cooling cycle trou-
bleshooting.
Voltage is applied between the vehicle
4 side harness connector blue/red and Go to Step 5 Inspect the clutch fuse.
ground (black).
Is there trouble in the air conditioner
5 Replace computer. Replace the harness.
harness?

Refresh/recirculate mode does not switch

Step Action Yes No

The refresh/recirculate motor
actuator connector is discon-
The refresh/recirculate mode display
nected, there is a contact de-
1 on the operation panel LCD display Go to Step 2
fect, or there is trouble with the
section is flashing.
motor actuator or the main har-
ness.
There is foreign matter on the refresh/
recirculate motor actuator lever sec- Remove the foreign matter or
2 Replace the motor actuator.
tion or the motor actuator lever sec- replace the part.
tion is broken.

The mode is not switched.

Standard
Step Action Yes No
value
The refresh/recirculate mo-
tor actuator connector is dis-
The passenger icon display on connected, there is a con-
1 the operation panel LCD dis- tact defect, or there is trou- Go to Step 2
play section flashes. ble with the motor actuator
or the main harness.
Inspect or replace.
The motor actuator rod is cor-
2 Go to Step 3 Correction
rectly in place.
A damper lever is correctly in
3 Go to Step 4 Correction
place.
• Foreign matter or break-
age at cam section or
damper shaft section
• Operation defect due to
When the cam with the rod re- soiling with grease or the
2 kgf or like Replace the motor actuator
4 moved is moved by hand, it is
more or computer.
sluggish (2 kgf or more).
• Remove the foreign mat-
ter or replace the part.
• Clean the cam section,
then apply grease.

84592788 EN - March 2012

Part Function and Good/Poor Judgment

Control Panel
Function of each switch

1 Main power switch 4 Air flow select switch 7 Diffuser select switch
Refresh/recirculate select
2 Auto control switch 5 Air conditioner ON/OFF switch 8
switch
3 Temperature control switch 6 Defrost switch

Through the operation of its internal microcomputer, the control panel compares, operates on, and processes the
sensor input signals and control panel switch input signals, switches the output side actuators (refresh/recirculate
switching, mode switching, air mix) and comprehensively controls the fan motor and compressor.
Also, it is equipped with self-diagnosis functions to make trouble diagnosis easier. (For details see the air conditioner
troubleshooting.)

84592788 EN - March 2012

Blower Amp
The power transistor receives the base current from the control unit and changes the speed of the fan motor.
Blower amp inspection
The blower amp can be easily judged by removing the blower amp connector and checking for continuity across
the blower amp terminals.

Terminal No.
Continuity
1 2 3
+ --- - Yes (4.7 kΩ)
Tester - + --- No
+ - --- Yes (diode parallel forward direction)

a Temperature fuse: 132 - 138 °C

( 275.0 - 280.4 °F )

84592788 EN - March 2012

Relay

4-pole relays are used for the blower OFF relay and compressor relay.
Blower OFF relay
This relay receives the signal from the control amp and switches the blower OFF relay ON.
When the blower OFF relay is switched ON, the power supply voltage is fed to the blower motor via the blower amp
and the blower motor is started.
Compressor relay
The compressor relay is switched ON/OFF by the control amp compressor control.
Relay inspection contents
1. Relay
2. Coil resistor: 320Ω
3. Specification voltage: DC 20 - 30 V
4. Be careful. The coil side of this relay must be installed with the poles facing correctly.
5. Inspection: Inspect for continuity between 3 and 4 under the conditions below.

20 - 30 V applied between term8inals 1 and 2 : Continuity

No voltage applied between terminals 1 and 2 : No continuity

84592788 EN - March 2012

Air Mix Actuator

CAUTION
The air conditioning system voltage specifications are 24 V, but the motor actuator has 12 V specifica-
tions.

The air mix actuator is installed at the center of the air conditioner unit contained behind the link cover. It opens and
closes the air mix damper via the link.
Built into the air mix actuator is the potentio-meter which switches linked with the actuator shaft.
When the target air mix door position is determined by the temperature control switch, the control unit reads in the
potentio-meter position in the actuator and determines whether the motor turns forward or reverse.
The contacts move linked with the motor. When the contacts move open or the control unit output signal goes OFF,
the motor stops.

Control panel Motor actuator

1 M/A 1 3 GND 5 5 VDC

2 M/A 2 4 Potentio-meter

Terminal
Direction of rotation 1 2
Clockwise (forward) + -
Counter-clockwise (reverse) - +

84592788 EN - March 2012

Refresh/Recirculate Actuator

CAUTION
The air conditioning system voltage specifications are 24 V, but the motor actuator has 12 V specifica-
tions.

The refresh/recirculate switch actuator is installed on the blower intake unit. It opens and closes the refresh/recirculate
door via the link.
Built into the refresh/recirculate switch actuator is the potentio-meter that switches linked with the actuator shaft.
When the refresh/recirculate door position is determined by the refresh/recirculate switch on the control panel, the
control unit reads in the signal of the potentio-meter in the actuator and determines whether the motor turns forward
or reverse.
The position detection switch also rotates linked with the motor and stops the refresh/recirculate door at the set po-
sition.

84592788 EN - March 2012

Blow Mode Actuator

CAUTION
The air conditioning system voltage specifications are 24 V, but the motor actuator has 12 V specifica-
tions.

The blow mode actuator is installed at the center of the air conditioner unit contained behind the link cover. It opens
and closes the mode door via the link.
Built into the blow mode actuator is the potentio-meter which switches linked with the actuator shaft.
When blow mode is determined by the temperature control switch, the control unit reads in the potentio-meter position
in the actuator and determines whether the motor turns forward or in reverse.
The contacts move linked with the motor. When the contacts move open or the control unit output signal goes OFF,
the motor stops.
Evaporator Sensor
In order to prevent the evaporator from freezing, the evaporator blow temperature is detected and the compressor
ON/OFF is controlled.

• Evaporator sensor inspection method (specifications value)

Disconnect the evaporator sensor from the main harness and measure the resistance between the sensor side
connector terminals using the tester.

Resistance between When the sensor section detection temperature is 0 °C ( 32.0 °F ) : 7.2 kΩ
terminals When the sensor section detection temperature is 25 °C ( 77.0 °F ) : 2.2 kΩ

84592788 EN - March 2012

Dual Pressure Switch

• The dual pressure switch is installed on the receiver dryer.

When there is pressure trouble in the coolant high-pressure side line (abnormally high pressure or abnormally low
pressure), the dual pressure switch contacts open up to cut off the compressor power and protect the cooling cycle.

Dual pressure switch specifications

1 (Low-pressure side)
2 (High-pressure side)

• Simple inspection method for dual pressure switch

1. With the cooling cycle stopped, disconnect the connector from the switch and check the conductance between
the switch side connector terminals using the tester.
If there is conductance, the switch is normal. (When the outside air temperature is 0 °C ( 32.0 °F ) or higher)
2. Connect the gauge manifold high-pressure side hose to the high-pressure side charge port.
With the cooling cycle operating, the condenser front surface is covered with a plate shaped object and the high
pressure rises.
If the compressor stops around 3.14 MPa ( 455.4685 psi ), the switch is normal.
3. With the coolant removed, check the conductance between the switch side connector terminals using the tester.
If there is no conductance, the switch is normal.

84592788 EN - March 2012

Solar Radiation Sensor

This is the air conditioner solar radiation correct sensor. It detects the strength of sunlight with a photodiode, converts
it into milli-amp and sends that to the controller.

• Solar radiation sensor inspection method

Disconnect the solar radiation sensor connector from the harness and measure the voltage between the sensor
side connector terminals using the tester's voltage measurement mode.
The voltage must be different when light is striking the photoreceiver section and when it is not. (The voltage is
about 0 V when absolutely no light is striking the photoreceiver.)

CAUTION
Always measure with the tester in voltage measurement mode (V mode).
Measuring in resistance mode (Ω mode) would destroy the sensor.

Inside Air Sensor

The inside air sensor is installed in the inside air side intake port of the air conditioner unit and switches the tempera-
ture inside the cab to the resistance.
This resistance value is converted into a voltage value in the control panel and processed.
Inside air sensor inspection method
Remove the inside air sensor connector from the main harness and measure the resistance between the sensor
side connector terminals using the tester.
Inside air sensor inspection details (specifications)
Resistance between terminals
For 0 °C ( 32.0 °F ): 7.2 kΩ ± 3％
For 25 °C ( 77.0 °F ): 2.2 kΩ ± 3％

84592788 EN - March 2012

Section

9007

Assembly and Disassembly of Air Conditioner Units

84592788 EN - March 2012

CONTENTS

Removal of Blower Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Replacement of Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replacement of Blower Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal of Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal of Heat Case Right/Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Replacement of Evaporator and Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation of Evaporator Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Replacement of Motor Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

CAUTION Replacement of Blower Motor

• Be sure to stop the engine before beginning CAUTION
work.
Do not remove the fan from the blower motor.
CAUTION
1. Remove the cooling hose (2) from the air condi-
• When replacing the evaporator, re-supply tioner unit (1).
and check the compressor oil quantity.
• Remove the 3 Phillips screws (3) and remove the
blower motor (4).
Removal of Blower Unit Screw size
Phillips screws (3): M5 x 14 ( 0.551 )
1. Remove the connectors connected to the refresh/
recirculate motor actuator connector (1), blower mo- • The installation procedure is the reverse of the
tor connector (2), inside air sensor connector (3), removal procedure.
evaporator sensor connector (4) and relay connec-
tor (5).

2. Remove the filter cover (1) and inside air filter (2).
• Remove the 4 Phillips screws (3) and remove the
intake case (4).
Screw size
Phillips screws (3): M5 x 16 ( 0.630 )(T1)

84592788 EN - March 2012

Replacement of Blower Amp Removal of Heater Core

CAUTION CAUTION
Never disassemble the blower amp. Remove while being careful not to apply exces-
Removing with the power on can suddenly in- sive force to the pipe.
crease the blower amp temperature, damaging
the part. 1. Drain the coolant.
Also, touching the surface could cause burns.
• Remove the 4 Phillips screws (1) and remove the
1. Remove the connector (1) from the blower amp (2). link cover (2).
Screw size
• Remove the 2 Phillips screws (3) and remove the Phillips screws (1): M5 x 16 ( 0.630 )
blower amp (2).
Screw size • Remove the mode actuator connector (3), and re-
Phillips screws (3): M4 x 16 ( 0.630 ) move the heater core (4).

• The installation procedure is the reverse of the • The installation procedure is the reverse of the
removal procedure. removal procedure.

84592788 EN - March 2012

Removal of Heat Case Right/Left Replacement of Evaporator and

CAUTION Expansion Valve
At this time, perform work with the heater core CAUTION
removed from the heater case.
The evaporator sensor cord is sandwiched in Be careful of the O-rings getting caught, etc.
the groove of the HVAC unit, so carefully check when installing the expansion valve.
it and remove it while making sure not to dam- The evaporator sensor cord is sandwiched in
age it. the groove of the HVAC unit, so carefully check
it and remove it while making sure not to dam-
age it.
1. Remove the 10 Phillips screws (1) and remove the
heater case right (2) and heater case left (3).
Screw size 1. Turn the HVAC unit upside down and place it on a
Phillips screws (1): M4 x 16 ( 0.630 ) stand.
• Remove the 4 Phillips screws (1) and remove the
drain case (2).
• Remove the 1 Phillips screw (1) and remove the
evaporator pipe stay (3).
• Remove the evaporator sensor connector (4), and
remove the evaporator (5).

2. Use a hexagon wrench [ 4 mm ( 0.157 in ) ] to re-

move the 2 hexagon socket head bolts (1), and then
remove the expansion valve (2).
• Install O-rings (3) on the new evaporator (4) (1 NF
O-ring 5/8 and 1 NF O-ring 1/2).
Bolt (1) tightening torque: 6.9 N・m ( 5.09 lbf・ft
)

84592788 EN - March 2012

Installation of Evaporator Sensor Replacement of Motor Actuator

CAUTION 1. Replacement of mode motor actuator
Remove the link cover.
Be careful that the sensor cord does not get Remove the connector (2) from the motor actuator
squeezed in the case when the case is assem- (1).
bled. Remove the 3 Phillips screws (3) securing the mo-
tor actuator (1), remove the rod (4) attached to the
Make sure to install the harness holder (1) and thermis- motor actuator (1) from the rod hole on the mode
tor holder (2) in the original position of the evaporator (4) cam, and then install the new motor actuator (1).
as shown in the diagram. The installation procedure is the reverse of the re-
moval procedure.
• Install the evaporator sensor (3) end and thermistor
holder (2) as shown in the diagram.

Screw size
Phillips screws (3): M4 x 16 ( 0.630 ) (T1)
2. Replacement of air mix motor actuator
a Thermistor holder position Remove the link cover.
b 20 mm ( 0.787 in ) Remove the connector (2) from the motor actuator
c 73 mm ( 2.874 in ) (1).
d 9th row Remove the 3 Phillips screws (3) securing the mo-
e 27th row tor actuator (1), remove the rod (4) attached to the
motor actuator (1) from the rod hole on the damper
lever, and then install the new motor actuator (1).
The installation procedure is the reverse of the re-
moval procedure.
Screw size
Phillips screws (3): M4 x 16 ( 0.630 ) (T1)

84592788 EN - March 2012

3. Replacement of refresh/recirculate motor actuator

Remove the link cover.
Remove the connector (2) from the motor actuator
(1).
Remove the 3 Phillips screws (3) securing the motor
actuator (1), remove the lever pin (4) attached to
the motor actuator (1) from the slot hole, and then
install the new motor actuator (1). The installation
procedure is the reverse of the removal procedure.
Screw size
Phillips screws (3): M4 x 16 ( 0.630 ) (T1)

84592788 EN - March 2012

Section

9009

Removal and Installation of Compressor

84592788 EN - March 2012

CONTENTS

Removal of Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Job code 50200AA26 Removal of Compressor

1. Remove the connector (1).
WARNING
• Be careful when loosening the lines. The air
conditioner circuit is filled with high-pressure
gas, so there is the danger of gas splaying
out.

CAUTION
• Be sure to stop the engine before beginning
work.
• When removing and installing the compres-
sor, check the compressor oil quantity.

Items to prepare
2. Use a box wrench [13 mm (0.512 in)] to loosen the
• Wrench [ 13 mm ( 0.512 in ) ] bolts (1) on the lines in the 2 locations, and then
• Box wrench [ 13 mm ( 0.512 in ) ] remove the 2 lines (2) (3).
• Rag
• Cleaning fluid • Always remove the low-pressure side line (2) first.
• Attach caps or plugs to the compressor and lines
to prevent any entry of water, dust or dirt.
Tightening torque for bolt (1) installation: 20 - 25
N・m (14.75 - 18.44 lbf・ft)

3. Use a wrench [13 mm (0.512 in)] to remove the 4

bolts (1), and then remove the compressor (2).
Tightening torque for bolt (1) installation: 19.6 - 29.4
N・m (14.459 - 21.688 lbf・ft)

84592788 EN - March 2012

Installation of Compressor 2. Check the compressor oil quantity.

The compressor contains 135 cc of oil.
1. To install, perform the reverse of the removal pro- The oil quantity being low will cause compressor
cedure. seizing and a reduction in durability. The oil quantity
When installing the bolts, tighten them to the spec- being high will cause a reduction in cooling capabil-
ified torque. ities.
Make sure to check the oil quantity and adjust if
needed.
Measure the oil quantity of the removed compres-
sor. Only this oil quantity is necessary, so subtract
this quantity from 135 cc to determine the amount by
which the oil quantity of the new compressor should
be reduced.
Example)
If the remaining oil quantity of the removed com-
pressor is 30 cc:
Remove 135 cc - 30 cc = 105 cc from the new com-
pressor to be installed.
Resupply oil: SP-10 or SP-20 (P.A.G. oil)
3. Perform air conditioner gas charging.
For details, see "Gas Filling Procedures".

84592788 EN - March 2012

Section

9010

Removal and Installation of Condenser

9011

Removal and Installation of Receiver Dryer

84592788 EN - March 2012

Work Procedures
Air Conditioner Refrigerant "Vacuum Operation" and "Gas Filling Operation".
1. The "vacuum operation" consists of eliminating moisture in the air conditioner circuit.
If there is any moisture left inside the air conditioner circuit, various problems may occur during operation such
as freezing in the small hole of the expansion valve causing the circuit to clog and rust developing in the circuit.
For this reason, perform vacuuming before filling the circuit with refrigerant. This operation consists of eliminating
moisture inside the circuit through boiling and evaporation.
2. The "gas filling operation" consists of filling the circuit with refrigerant after the vacuum operation.
Gas filling does not only affect the cooling capabilities of the air conditioner, it also affects the life of the parts
which make up the circuit.
Severely overfilling the circuit will cause pressure inside the circuit to be abnormally high, and this will cause
reductions in the cooling ability of the air conditioner.
Additionally, if pressure is extremely low, the circulation of lubricating oil within the compressor will be poor and
this will cause seizing with sliding parts of the compressor.
Because the gas filling operation itself involves handling high-pressure gas, performing the operation using an
incorrect procedure is very dangerous.
Follow the operation and observe all precautions indicated in this text to correctly perform refrigerant filling.

Operation Chart
Vacuuming start 30 min. or longer (750 mmHg or less)
↓
Vacuuming Vacuuming stop Let sit for 5 min.
operation ↓
Airtightness check Gauge display abnormality (connectors check and repair)
↓
Refrigerant filling Fill with refrigerant gas up to a gauge pressure of 0.098 MPa ( 14.21525 psi ).
↓
Refrigerant fill-
Gas leak check
ing operation
↓
Refrigerant filling

84592788 EN - March 2012

Tools
No. Part name Q'ty Shape Application

1 Gauge manifold 1

Red: high-pressure
side
Blue: low-pressure
2 Charging hose 3
side
Yellow: vacuum
pump side

3 Quick joint 1

4 Quick joint 1 Low-pressure side

5 T joint 1 For service can valve

6 Service can valve 2 For service can

Vacuum pump
7 1 For vacuum pump
adapter

• Judging the amount of refrigerant from the receiver dryer sight glass
After the AC is turned ON, a few air bubbles are visible.
When the amount is
The glass then becomes transparent and turns to a
correct
pale, milky-white color.

When overfilling oc- After the AC is turned ON, no air bubbles at all are
curred visible.

When filling was in- After the AC is turned ON, air bubbles are seen con-
sufficient tinuously.

(Total gas filling amount: 950 - 1050 g ( 2.094 - 2.314 lb ))

6. After refrigerant filling is complete, close the low-pressure valve (11) of the gauge manifold (13) and the valve for
the service can (17), and stop the engine.
84592788 EN - March 2012
9015-10
Copyright ©
Work Precautions

• If the air conditioner is operated with very little refrigerant (R134a), this will have a damaging effect on the
compressor.
• If the air conditioner is filled with too much refrigerant (overcharge), this will actually cause insufficient cooling
and there is the danger of pressure in the circuit becoming abnormally high.
Be sure to use an appropriate amount of refrigerant.
• Never open the gauge manifold high-pressure valve (12).
• Never invert the service can.
(Gas is suctioned in liquid form, so this may cause damage to the compressor valve.)
7. After refrigerant filling and inspection, remove the gauge manifold and hoses.
Quickly remove the low-pressure side charge hose (blue) (15) from the low-pressure side (SUC) service valve.
Do not do anything on the high-pressure side until the high-pressure gauge indicator falls to 0.98 MPa ( 142.15
psi ) or below.
After confirming that the indicator has fallen below this point, quickly remove the high-pressure side charge hose
(red) (14) from the high-pressure side (DIS) service valve.

84592788 EN - March 2012

9015-11
Copyright ©
Copyright ©
83 * ITEM DESCRIPTION PRESSURE SETTING ITEM DESCRIPTION
SINGLE ACTING CIRCUIT
A= MAIN RELIEF (STANDARD) - 34.3 MPa / 343 bar / 4974 psi 1 HYDRAULIC RESERVOIR
75
26 25 28 T1
A= MAIN RELIEF (BOOST) - 36.3 MPa / 363 bar / 5264 psi
2
4
BREATHER
BY-PASS VALVE
B= BOOM RAISING PORT SECONDARY RELIEF - 38.2 MPa / 382 bar / 5540 psi 5 SCREEN FILTER

22 27
15
B1/B2 = RELIEF ON BOOM HBCV - 00.0 MPa / 000 bar / 0000 psi
6 RETURN FILTER

L1 L2 K2
*
5B4 9 HYDRAULIC PUMP (OPTIONAL)
D P3 P P4 P4 P P3 D 10 MAIN HYDRAULIC PUMP
83
B45 *
C= BOOM LOWERING PORT SECONDARY RELIEF - 32.3 MPa / 323 bar / 4884 psi

* *
15 MAIN CONTROL VALVE
DOUBLE ACTING CIRCUIT
29 29 D= DIPPER OUT PORT SECONDARY RELIEF - 38.2 MPa / 382 bar / 5540 psi 16 HYDRAULIC SWIVEL
P 15 D1 = RELIEF ON DIPPER HBCV - 00.0 MPa / 000 bar / 0000 psi
21 TRAVEL MOTOR
22 SWING MOTOR
5A4
23 TRAVEL MOTOR BRAKE
E= DIPPER IN PORT SECONDARY RELIEF - 38.2 MPa / 382 bar / 5540 psi
25 RIGHT BOOM CYLINDER
(G3) (G3)
Au B2 G1 G1 A A 15 F= BUCKET OPEN PORT SECONDARY RELIEF - 38.2 MPa / 382 bar / 5540 psi 26 LEFT BOOM CYLINDER
Dr

RED

RED
B B 5B4 27 DIPPER CYLINDER
C C G= BUCKET CLOSE PORT SECONDARY RELIEF - 38.2 MPa / 382 bar / 5540 psi
*
28 BUCKET CYLINDER
B B (G3)
B1 23 K1 23 30
G1
B H= PILOT PRESSURE RELIEF - 3.92 MPa / 39.2 bar / 568 psi
29 BOOM SAFETY VALVE
A A C 30 DIPPER SAFETY VALVE
PL PL FOR SINGLE ACTING VALVE I= RIGHT-HAND SWING PORT SECONDARY RELIEF - 27.9 MPa / 279 bar / 4046 psi 31 DIPPER LOAD HOLDING VALVE
27.9MPa 27.9MPa D1 32 BOOM LOAD HOLDING VALVE
at 108L/min at 108L/min A J= LEFT-HAND SWING PORT SECONDARY RELIEF - 27.9 MPa / 279 bar / 4046 psi 42 OIL COOLER
GA GB
15 PL 44 OIL COOLER BY-PASS VALVE

W4 *
DR DR K1/K2 = TRAVEL REVERSE PORT SECONDARY RELIEF - 00.0 MPa / 000 bar / 0000 psi
5b52 45 NO RETURN CHECK VALVE

P2 P1 P1 P2 182 L1/L2 = TRAVEL FORWARD PORT SECONDARY RELIEF - 00.0 MPa / 000 bar / 0000 psi 51 ACCUMULATOR
53 BOOM & BUCKET CONTROL LEVER
A D DR N1/N2 = NEGATIVE CONTROL RELIEF - 2.55 MPa / 25.5 bar / 370 psi 54 SWING & DIPPER CONTROL LEVER
C B
J I 15 1 E F 21
1 90 O/P = SECONDARY RELIEF (2nd OPTION) - 23.5 MPa / 235 bar / 3410 psi
55 TRAVEL CONTROL PEDAL

4A21 D2 21 16 57 BOOM & DIPPER CONTROL SHOCK ABSORBER

R= MAIN RELIEF (2nd OPTION) - 20.6 MPa / 206 bar / 2987 psi 58 PILOT AND RETURN SYSTEM MANIFOLD
LEFT A Mu B RIGHT 59 FILTER
W1/W2 = CRUSHER OPTION PORT SECONDARY RELIEF - 00.0 MPa / 000 bar / 0000 psi 60 PILOT SYSTEM MANIFOLD
65 CALIBRATED ORIFICE
BACKWARD R.H. FORWARD L.H. W4 = BREAKER OPTION SECONDARY RELIEF VALVE - 20.6 MPa / 206 bar / 2987 psi
65 FORWARD R.H. BACKWARD L.H.
71 SECOND OPTION CONTROL VALVE
72 CONTROL PEDAL (OPTIONAL)
73 SECOND OPTION CONTROL VALVE

W1 *
74 SWING PRIORITY BLOCK
2.5 LEGEND 75 HAMMER/CRUSHER SELECTOR
76 HAMMER/CRUSHER SELECTOR
82 PILOT CIRCUIT FILTER
182 P1 PUMP
W2 *
83 SHUT-OFF VALVE (OPTIONAL)
15
5a4 85 PILOT FILTER
P2 PUMP 86 PILOT FILTER BY-PASS VALVE

A R 90
105
HYDRAULIC BREAKER VERSION PLUG
4 ELECTRO VALVE BLOCK

*
P FOR MULTI-PURPOSE + 3WAY VALVE 108 STRAIGHT TRAVEL VALVE
T 20.6MPa at59L/min P3 PILOT SYSTEM PUMP
73 FOR DOUBLE ACTING VALVE 109 SWING PRIORITY VALVE

Y18 134 71 132 HAMMER/CRUSHER 2 SOLENOID VALVE BANK

158 *
134 2 SOLENOID VALVE BANK (SECOND OPTION)
A1 A RETURN TO RESERVOIR
158 SHUT-OFF VALVE (OPTIONAL)
4b5
* 171
1
D6 44 42 134 71 4a5 OPTION (EU) 159 2 SOLENOID VALVE BANK (OPTION 1)

A2 B PEDAL TYPE LEAK-OFF RETURN 160 2 SOLENOID VALVE BANK

O
23.5MPa
74
72 * 161
162
2 SOLENOID VALVE BANK (OPTION 1)
1 SOLENOID VALVE BANK
4A5 at20L/min 109 SUPPLY CIRCUIT 171 SOLENOID VALVE

S71 *
4B5 BREAKER
2 0.20MPa
dr2 Pi1 B43 ON
178 2-WAY SELECTOR VALVE
29.01psi 23.5MPa 182 PORT RELIEF VALVE
2bar at20L/min 10 60 57 10
PILOT SYSTEM CIRCUIT B22 SWING PILOT PRESSURE SWITCH
Pi2 P0 S Pi1 B26 UPPER PILOT PRESSURE SENSOR
P Pi2 15 B27 TRAVEL PILOT PRESSURE SENSOR
76
10 ON 0.1MPa A COMPONENT BOUNDARY B28 SECOND OPTION PILOT CIRCUIT 1 PRESSURE SWITCH
B40 PUMP PRESSURE SENSOR (NEGA-CONT.2)
14.5psi
1bar 29 FL dr1 Ps2
N2 FR
B42 PUMP PRESSURE SENSOR (P1)
105 HOSE B43 PUMP PRESSURE SENSOR (NEGA-CONT.1)
OFF 0.08MPa T DR B44 PUMP PRESSURE SENSOR (P2) (BLUE BAND)
0.03MPa 0.004MPa R3 R1
4.35psi 0.58psi 0.6psi B45 OVERLOAD INDICATOR PRESSURE SWITCH
0.8bar C1 C2 B83 PRESS. SENSOR (PILOT ARM CLOSE)
0.3bar 0.04bar E PIPING CONNECTION B84 PRESS. SENSOR (PILOT BUCKET CLOSE)
B P T A
D1 R2 2.55MPa B85 PRESS. SENSOR (PILOT BOOM UP)
171
T 31 at35L/min
85 * PIPING CROSS-OVER
B94
S71
PRESS.SWITCH (1ST OPTION)
PRESSURE SWITCH FILTER INDICATOR (BREAKER OPTION)
T1 38.2MPa at20L/min 5B5
1 a
N1 38.2MPa at20L/min 5A5
Y2 PILOT PRESSURE SOLENOID VALVE (BLUE BAND)

1 D6 15
a
D6 ck1 28 COMPONENT ITEM NO. Y4
Y5
2 STAGE TRAVEL SOLENOID VALVE (RED BAND)
POWER-UP SOLENOID VALVE (YELLOW BAND)
D 15 58 132 58 15 Y7 MAIN PUMP POWER PROPORTIONAL SOLENOID
ARM(2) 5b4 P5 B2 T5 5a4 COMPONENT NUMBER Y9 OPTION 2 SPEED SOLENOID VALVE (BLUE TAPE)
6 D2 57 30 Y11 MAIN PUMP FLOW PROPORTIONAL SOLENOID
T
T 4b4 OUT ARM(1) D PL
58 Y18 FREE SWING SOLENOID VALVE (NA)
5 150MESH 0.098MPa 4a41 IN B94 P5 Y23 OPT.1 KNOB (R) -R SOLENOID VALVE (BLUE TAPE)
14.21psi N2 OUT 5a5 ON: 0.5MPa / 5bar / 72.5psi Y24 OPT.1 KNOB (R) -L SOLENOID VALVE (RED TAPE)
CONNECTION ITEM NO.
0.98bar B83 OFF: 0.3MPa / 3bar / 43.5psi

*
F IN 5b51 Y25 OPT.2 KNOB (L) -R SOLENOID VALVE (BLUE TAPE)
Y26 OPT.2 KNOB (L) -L SOLENOID VALVE (RED TAPE)
5b52
D5 4A3 38.2MPa at20L/min -- OPTIONAL ITEM NO. Y27 OPTION SELECT SOLENOID VALVE (RED TAPE)
4B3 38.2MPa at20L/min Y59 BOOM DOWN PROPORTIONAL SOLENOID VALVE (NO TAPE)
4 6 G BUCKET 83 76 Y82 SWING BRAKE (PINK TAPE) (S2)
A
Y59
132 *
4b3 OPEN 5B4 A P
4a3 CLOSE
OPTION 5A4 83 75
B
71 * A2 73
4a5
B84 C 5a4 72
BREAKER ON 5b4 A 1
B1 4A2 32.3MPa at112L/min 32 Y25
Y27 4B2 38.2MPa at20L/min 72
T P A1 73
83 B 4b5
15
SECOND OPTION
83 * 76 * 75 *
A1 5a31 ck2
B2 BOOM(1) BOOM(2) PEDAL
4b21 85 C1 C2 SECOND OPTION
UP B
Y9 5a32 Y26
72 4b22 ELECTRIC
C2 5a31 B P T A
4a21 DOWN
PP
A2 29
PL
4a22
5b3
15
85 * T

45 G
* 134 *
4b21 1 15
T 5B2
73 58 58 73
T1
B85 B T
D1 PS2 4a5 P5 T5 4b5 58 58 85
T2 4A1 5A2
T5 P5
A SWING ON: 0.5MPa / 5bar / 72.5psi
B 15 TRAVEL(R) 2-STAGE LEVER OFF: 0.3MPa / 3bar / 43.5psi B28
5A4 4B1 LEFT 5a2
DR 55 4b1 BACKWARD RIGHT
C1 TRAVEL Y4 LOCK Y2
3
5b2
4a1 FORWARD
55
15
4 5B1
P 51
Px2 108 1.5MPa
B A 5B4 TRAVEL(L)
5A1 2-STAGE 217.5psi 82
dr6 FORWARD C3 RELIEF SWING BRAKE C2
DR 5a1 55 Y5 B42 B44 60 P3 15bar
2
B26 A BACKWARD 5b1
8
P0 P
55
R4
T 1 Y82 0.02MPa 86
MULTI-PURPOSE MAIN RELIEF.V 2.9psi
+3 WAY VALVE Px3 34.3MPa at 90L/min
36.3MPa at 85L/min 0.2bar

W4 *
0.15MPa
21.7psi
PP 1.5bar
15
Py PL(P2) dr3 Ps1 Px1 PR(P1) Py P H1 A1 a1 a2 A2 P H2 P1 P2
105 B27 105
162 161 160 159 72 71 134 72 71 134 162 161 160 159 C3 10
P G P G P P G T T T T T T T

(FRONT) (REAR)

P4 P5 T4 T5
B40

15
58 P3 P2 P1 T3 T2 T1 FR a5
OPTION < KNOB SWITCH TYPE > SINGLE ACTING CIRCUIT
55 / MULTI－PURPOSE＋3WAY VALVE
Pi1 Pi2
CLOSE OPEN 15 15
59 pa2 pb2
75 15
54 53 PP pcc
15
85 85 TRAVEL(L) TRAVEL(R) A2 A1 A2 A1
160 *
FL
31 15
P1
P T P T 57
Pi2
BACKWARD FORWARD FORWARD BACKWARD 85 * Y11
IN OUT UP DOWN * 159 P1
M
RIGHT LEFT a4
B D R F H J S L N U P G G
P
ISUZU 4JJ1X Y7
Y23 Y24 58
Y27 Y9 74.9kW/2000min
T 58 T
OPTION T5 P5 Dr1 A3
ARM SWING BOOM BUCKET
IN OUT LEFT RIGHT DOWN UP OPEN CLOSE B1
2 4 3 1 2 4 3 1
178 A C V E T G I Q K M O 1 P 2 4 T 3 B3 a3
OPTION (NA) < KNOB SWITCH TYPE > DOUBLE ACTING CIRCUIT 9 OUT
1 B22
85 85 A 2 D2 15 15
C 4 pa2 pb2 H 3.92MPa / 39.2bar / 568.5psi
D 3 A2 A1 * 162
*
B 1
Y9
15
85 15 15 15
85 Dr2 IN
5b1 5a1 4a1 4b1 T

* 161
15
G P A pcc
P

BOX FUSE(ATTACHMENT FOR CAB MAIN HARNESS)

8R 105 8R 105 2 8R 105
5RW 103 5RW 103 1 5RW 103
F34 F41 F42 F43 F44

3R 105d

3R 105b
3R 105e

3R 105c

3R 105a
180,260,215,250,267
400,410,411,412,413,414,415,416,417,419,420,430,444,445,446,450,490,492,532,533,534,535,538,559,660,800,801,802,803,805,806,807,812,813,818,900,901,902,903,904,905,906,907,908,909,910,911

5RW 020
DIESE
LL ENGINE

YAZAKI
(CN.A50
58L
2
1
FUSIBLE LINK FUSE FUSIBLE LINK FUSIBLE LINK

(F20)
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10

(F19)

(F18)

(F13)
10A

15A
BACK UP CONT FUSE BOX SAFTY RL

(F12)
(F17)

(F16)

(F15)

(F14)
10A
ALTERNATOR

(F11)

20A
5A

(F10)
15A

10A

15A

10A

15A
(F9)

(F8)

(F7)

(F6)

(F5)
11 12 13 14 15 16 17 18 19 20 11 12 13 14 15 16 17 18 19 20

(F4)

(F3)

(F2)

(F1)
50A 1 15A 1 65A 1 50A 1 8B 797 E 24V 50A
SUMITOMO SUMITOMO 2
(CN.A41) (CN.A42) 2 2 2 YAZAKI M6

BLOWER MOTOR
YAZAKI YAZAKI YAZAKI (CN.D15)

WIPER WASHER
YAZAKI

CIGAR LIGHTER

TRAVEL ARALM
M8

(BOOM,HOUSE)
COMPRESSOR
2W 250 REFUEL PUMP
1 2 3 1 2 3 1 2 3

CONTROLLER

CONTROLLER
58L 58L 58L

2
1

1
2
1.25BG 600 2BG 600 CN-A

AIRCON UNIT
8

LEVER LOCK

2
1
CONVERTOR

KEY SWITCH
4 5 6 4 5 6 4 5 6 (CN.D23) (CN.D26) (CN.D25) (CN.D24) IC

GR 180 SOLENOID
1.25B 700 2B 700 YAZAKI

SEAT SUS
7

BACK UP
REGULATOR

BEACON

20
(CN.D16)

AIRCON

12
13
14
15
16
17
18
19

12
13
14
15
16
17
18
19
11

11
OPTION

YAZAKI YAZAKI YAZAKI

1
2
3
4
5
6
7
8
9

1
2
3
4
5
6

6
5
4
3
2
1

1
2
3
4
5
6
ENGINE
WB 245 SPARE

SPARE

(GATE)
DC/DC
6

5RW 103
5RW 102
LgW 190 HORN
LAMP

LAMP
(CAB)

8R 105
8R 104

5R 002
5R 003
M M M

1.25W 107
1.25W 106
GPS
(CN.A38) (CN.A39) (CN.A40) 5
G2

PG 41b

PG 41d

PG 41g
PG 41h

BG 630
BG 637
BG 640
PG 41a

PG 41c

PG 41e
P 40b

P 40d

P 40g
P 40h
P 40a

P 40c

P 40e

RL 160
RL 161
RL 162
RL 163
RL 164

PG 41f

PG 41i
PG 41j
P 40f

P 40i
P 40j

1.25WR 141
1.25WR 142
1.25WR 145
1.25WR 146
1.25WR 147
1.25WR 148
1.25Y 870 1.25Y 870

1.25W 109
1.25W 108
1.25W 107
0.85BG 603

0.85BG 620

1.25W 112

1.25W 110
1.25G 510 0.75R R

0.85G 502
0.85G 503
0.85G 504
0.85G 505
0.85G 506

1.25W 111
1.25BG 600
1.25BG 601
1.25BG 602

1.25BG 609
1.25BG 610

0.85B 701
0.85B 702

0.85B 705
0.85B 720
4 1

1.25B 700

1.25B 703
VR 230

RL 160
0.85VW 170
1.25WR 235
WL 267

1.25RW 140
0.85OR 225
1.25Br 515 0.75L L

1.25LW 200

0.85R 130
1.25RB 150
3 2

0.85LR 240

0.85BrR 210

1.25GrR 195
0.85GW 215

1.25W 205
WL 260
WL 266
WL 267

0.85YR 220

0.85GW 216

0.85W 206
0.85GW 215 0.85GW 215

0.85YR 221
2

(CN.D14)
B 749 2W 250 1 2W 250

YAZAKI
1 2
SWP
0.85B 708
RL 166 0.85G 507 K7

YAZAKI

YAZAKI
(CN.D17)

(CN.D19)

(CN.D18)
1 2 3 4
5 6 7 8
YAZAKI
(CN.A51)
8R 030 B

58M
108,109,110 YAZAKI M6
RELAY BATTERY
601,602,603,701,702,703 G1 (CN.D13)
STARTER MOTOR
CONTROLLER A 503,504,505,515,520,521,530,536,537,539,558,804,808,809,833 RELAY 60R 100 60R 101 60R 001 B
K63 RELAY K64 RELAY K65 RELAY K66 RELAY K67 RELAY NEUTRAL K68 RELAY K34 M8 M8YAZAKI M10
M
ECM KEY ON BATTERY RL IDLE STOP DPF START STARTER CUT (CN.D21)
M1

10 11 12 13 14 15 16 17 18 19 20
6 7 8 9
POWER 24V 1.25W 108 V 097 5Y 004 S

0.85BG 660
1 1 (CN.A09)
A1 1.25W 108a VG 098
(CN.A13) (CN.A11) (CN.A12) (CN.A10) (CN.A14) (CN.A15) M10 M10 M10 M10
M4YAZAKI

705,708,720,749

(CN.D11)
12 2 YAZAKI M4

7 8 9 10 11 12 13 14
4 5 6

YAZAKI
(CN.D12)
- + - + (CN.D20)

6 5 4 3
POWER 24V G 099

58Y
1
11 3 1 2

YAZAKI

1
(CN.C21)
24V 4.0kw

SDL
YAZAKI
22 VR 595 4 M4

(CN.C3)

YAZAKI
P1 YAZAKI

(CN.A44)
SDL

60B 799
SDL
1 4 2 GLOW

2
1
GND_2 2 1.25BG 601 Br 596 5 SWP 5L 021 1 5BW

1.25WR 511
2 3
4 5 6 7 8
2

1.25G 501
1 2 3 4 5
(CN.A58) 5
PLUG

YAZAKI
1.25BG 601a BG 612

(CN.A52)
1 2 3
13 6 3
R1

B
SDL
1

YR 882a
LR 881a
GND_3 0.85B 701 MONITOR DISPLAY 12V 12V

(CN.D9)

14 13 12 11
5

7 6 5 4
SUMITOMO

YAZAKI
YAZAKI

10 9 8

3 21
EVRV TURBO VALVE

SWP
16 0.85B 701a M8 CN-A

1
BZ. (CN.D22)

(CN.E11)
GND 9 BATT. 1 0.85RL 161 1 0.85RL 161 0.85RL 161 1 RL 161 2

YAZAKI
3
1
2
5
4

3
1
2
5
4

1 2
GND_A
20
10 D-IN8 ALTERNATOR
IGN 2
4
1.25W 111
0.85BrW 519
2
4
1.25W 111
0.85BrW 519
1.25W 111
0.85BrW 519
2
3
1.25W 111
0.85BrW 519
1.25W 107
0.85G 501
1
2
1.25W 107
1.25G 501
0.85B 751
0.75GR 398 1 0.75GR
1
Y83
P4

0.85GW 303
0.85BW 704

0.85WR 511
1.25WR 141

0.85W 113

0.85W 114
0.85W 115

1.25WR 146
1.25WR 147

1.25WR 145
P 040b P 040b 0.85LR 881 LR 881 0.85WR 511 1.25WR 511 0.75WR 149 0.75LR

1.25RW 140

0.85GR 845
CAN H

1.25W 112
0.85G 501

0.85O 804
0.85B 705

0.85B 706
0.85YR 370
21 5 5 4 3 3

0.85LR 890

0.85LR 891

0.85LR 890

0.85LR 373
0.85Y 011

0.85Y 011
0.85LgR 500

0.85YL 808

0.85GrR 012
0.85LY 824

0.85BrR 010
TURBO VACUUM
NPN_OUT1 SOL SWING BRAKE 6 W 800 H1 CAN L 6 PG 041b 6 PG 041b 0.85YR 882 5 YR 882 0.85Br 515 4 1.25Br 515 2
SENSOR
NPN_OUT2 SOL 2STAGE TRAVEL 4 L 801 CAN GND 18 18 V 809 6 V 809 0.85GrR 012 5 0.85GrR 012 4
LCD DISPLAY
NPN_OUT3 SOL 2STAGE RELIEFE 7 Y 802 TxD(RS232C) 8 WL 061b 8 WL 065b P 040b 7 P 040b 373 0.85RY 840 6 0.75RY 840 0.75R 362 8 0.75R 1

(CN.E12)
SUMITOMO
CPU RxD(RS232C)
K69

1 2 3
NPN_OUT4 FREE SWING 3 Br 803 TFT FULL COLOR 9 W 060b 9 W 066b PG 041b 8 PG 041b 303 7 0.75W 363 5 0.75LW 2
B96

508
509

(CN.D30)
10 11 12 13 14 15 16 17 18 19 20

118
5 6 7 8 9

GND(RS232C)

YAZAKI
NPN_OUT5 RL BATTERY 8 0.85O 804 19 BL 064b 19 BL 069b WL 065b 9 YL 066b 142 8 0.85B 779 0.75G 364 9 0.75B 3
K2

CN-A
517
519

520
521
RELAY GLOW 1 2 RELAY STARTER
I/O

1
NPN_OUT6 SOL OPT 2SPEED 14 YR 805 5V-OUT PGM_WRITE 3 V 097 3 V 097 W 066b 10 Y 065b 140 370 6
SUMITOMO
NPN_OUT7 SOL OPT SELECT 15 LY 806 PGM_WRITE SW 12 VG 098 12 VG 098 BL 069b 11 BY 069b 804,808 301 MT090 7
070MIULTI
AMP
(CN.C1)

(CN.D82)

1
2
NPN_OUT8 TRAVEL ALARM 18 WL 807 RESET 7 G 099 7 G 099 WB 949 12 WB 949 500 501 1 5R 003 10
NPN_OUT9 RL DPF 17 0.85YL 808 8V-OUT CAMERA+ 10 R 960 10 R 960 BW 950 13 BW 950 112 511 5RW 020 1 1 5L 021 2 5Y 004 0.75BR 392 12 RW INTAKE THROTTLE
DC-MOTOR

(CN.D28)
1 2 3 4

P10

YAZAKI
NPN_OUT10 SIG WASHER 19 V 809 CAMERA GND 11 B 961 11 B 961 1.25BG 610 14 1.25BG 610 515 515 0.75GR 393 13 G

0.85B 776

1 2
0.85GrR 013

SWP
A/D-IN 010 012 0.75P 326 VW RW
M
THERMO SN 13 13 11 2
22 21 20 19 18 17 16 15 14 13 12 040/070HYBRID I/O

840 840 0.85G 509 G

YAZAKI
AGND

YAZAKI
14 14 1 14 1

(CN.D31)

(CN.D27)
AMP

CN-A

1 2

1 2 3 4 5
SWITCH PANEL

58
1

(CN.E2)
PWM_OUT1 PUMP POWER(OUT) 3 0.85Y 900 SCL(12C) 16 16 845 0.85L 372 2 0.85GrR 012 1 6

9 10 11 12 13 14 15 16 17 18
5 6 7 8
S11 M24

10 11 12 13 14 15 16 17 18 19 20

AMP
5 6 7 8 9
PWM_RTN1 PUMP POWER(RTN) 6 0.85BY 901 SDA(12C) 17 17 824 0.85B 750 2 L 5 Vcc
WIPER
PWM_OUT2 BOOM DOWN(OUT) 1 0.85O 902 GND 15 1.25BG 611 15 1.25BG 611 0.85Br 516 2 VW 3 OUT
S12

(CN.D29)
1 2
YAZAKI
BOOM DOWN(RTN)

(CN.A45)
PWM_RTN2 4 0.85BO 903 GND 20 1.25BG 610 20 1.25BG 610 705 0.85WR 512 1 LW 4 GND

YAZAKI
SDL

(CN.D8)

16 15 14 13
12 11 10 9
8 7 6 5
4 3 21
CN-A

YAZAKI
WASHER

YAZAKI
(CN.A55)
P1 FLOW(OUT) 0.85L 904 704
K35 K5 K3 K11

1
PWM_OUT3

2
2
11 10 9 8 7 6 5 4 3 2 1

SDL

SWP
S10

(CN.A30)
SUMITOMO
1 2 3 4
PWM_RTN3 P1 FLOW(RTN) 0.85BL 905 508,372

MT090
5
EGR VALVE

BG 613
BG 614
W.LAMP
SHLD GND CAMERA1 SIG Y 962 Y 962

1 2 3 4
8 1 1
S2 RELAY
K36 RELAY RELAY RELAY RELAY RELAY RELAY
K10

(CN.D38)
SUMITOMO
W 963 W 963 1.25W 119 0.75WR 386 0.75WR
K37
7 CAMERA1 GND 11 11 1 5 5
(CN.A4)

U
M

MT090
TRAVEL MODE SPEAKER:R SPEAKER:L ROOM LAMP BEACON HORN LAMP:CAB LAMP:UPPER

1 2
S-G BOOT_CNT 11 WR 062 CAMERA2 SIG 2 YB 967 2 YB 967 0.85BrR 210 1 0.85BrR 210 1.25G 754 2 0.75WB 387 6 0.75WB 6
WR 062a S4 CAMERA2 GND WB 968 WB 968 0.85YR 220 0.85YR 220
(CN.A21) (CN.A22) (CN.A20) (CN.A19) (CN.A16) (CN.A18) (CN.A17) 0.75WL 388 0.75WL
V
FWE 12 12 12 2 7 7
IDLE MODE W
SW_IN12 LM MAG SW 9 YR 541
S86
CAMERA3 SIG 3 YR 972 3 YR 972 0.85WR 282 3 0.85WR 282 GR 180 1 0.75GR 180
M20 0.75RG 356 8 0.75LW 8 GND
SW_IN13 LM MODE 10 O 542 CAMERA3 GND 13 WR 973 13 WR 973 0.85WY 829 4 0.85WV 829 W 800 2 0.75W 800 FUEL PUMP 0.75GB 353 1 0.75GB 1 U
M25

SUMITOMO
DPF CLEAN 1 4 2

(CN.E3)

1 2 3 4
5 6 7 8
D-IN1 F-WINDOW SW O 590 O 590 1.25GR 875 1.25GR 875 L 801 0.75L 801 0.75GW 354 0.75GW V
4 4 5 3
Y2 2 2

DL090
S87 5

0.85GR 838

(CN.D37)
0.85LR 837
12 11 10 9 8 7

11 12 13 14 15 16 17 18 19 20
1 2 3 4 5 6 7 8 9 10
6 5 4 3 21

M
D-IN2 MUTE SW YL 591 YL 591 VG 822 VG 822 Y 802 0.75Y 802 SOLENOID VALVE 1.25W 118 2BY 0.75GR 355 0.75GY W

YAZAKI
5 5 6 3 4 1 3 3

1 2
58W
ATT SELECT
TXD 4 PW 055 D-IN3 CAMERA SW 6 V 592 6 V 592 WG 823 7 WG 823 Br 803 5 0.85Br 803 1.25G 753 2 2B 0.75RW 352 4 0.75L 4 VCC
(CN.A3)

SUMITOMO
S88

(CN.D59)
LEVER (SP) 24V

YAZAKI
RXD 12 PL 056 D-IN4 DOOR SW 7 OL 593 7 OL 593 LY 824 8 0.85LY 824 G 812 6 0.75RY 840 1 0.75R M8 9
040MIULTI

MENU SUMITOMO

SWP
AMP
(CN.C2)

RS232C_TXD 3 W 060a D-IN5 ONE TIME WIPER 8 YG 594 8 YG 594 LG 825 9 LG 825 Lg 813 7 0.75B 752 2 0.75B 10
LOCK CARNK ANG(MRE)
S89

1 2
MT090 YAZAKI

3
1
2
5
4

3
1
2
5
4
2
1
RS232C_RXD 10 WL 061a D-IN6 SPARE1 9 VR 595 9 VR 595 OR 826 10 OR 826 (CN.A59) WL 807 8 0.85WL 807 (BLUE TAPE) (CN.D81) 11
DISPLAY SEL
Y82 E2 SENSOR
26 25 24 23 22 21 20 19 18 17 16 15 14 16 15 14 13 12 11 10 9
13 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1

RS232C_GND 2 BL 064a D-IN7 SPARE2 10 Br 596 10 Br 596 G 888 11 G 888 VG 822 9 0.85VG 822 LAMP 12
S90 1 2

WG 831

WG 823
OR 826

LW 841
G 888
YR 224

LgW 190
LgW 191
LG 825

LG 832

LG 842
(S2)

YR 224a

LR 880
RL 164

RL 165
SWING (BOOM)

0.85GW 216
0.85GW 217
D-OUT1 WIPER-INT GR 820 GR 820 YL 591 YL 591 LR 880 0.85LR 880 0.75R 181 0.75R Vcc

0.85RB 290

0.85R 885

1.25GR 875

1.25LW 200
1.25LW 201
GND

0.85YB 984
5 14 14 12 10 1 13 1

0.85LB 985
0.85Y 980

0.85L 981

1.25Y 870
1.25GrR 195
1.25GrR 196
TRIP/CAMERA

(CN.E4)
YAZAKI
Lg 821 Lg 821 OUT(PULSE)
B49

1 2 3
(CN.A2)

(CN.D60)
GND 13 D-OUT2 WIPER-CNT 15 15 V 592 13 YR 882 11 0.85YR 882 0.75W 800 2 0.75B BRAKE 14 3

YAZAKI
1 2
CAN_H 6 P 040c D-OUT3 RL FUEL PUMP 16 VG 822 16 VG 822 YG 594 14 YG 594 0.85WV 829 12 0.85WV 829 (PINK TAPE) 1.25Y 871 1 1.25Y 871 1 0.85R 15 2 GND

SWP
24V

LR 881
CAN_L 14 PG 041c D-OUT4 RL LAMP 17 WG 823 17 WG 823 0.85YB 984 15 0.85YB 984 0.85R 885 13 0.85R 885 1.25B 758 2 1.25B 758 2 0.85B 16
+5V_OUT D-OUT5 RL IDLE STOP LY 824 LY 824 0.85LB 985 0.85LB 985 0.85GW 943 0.85GW 943 0.75R 182 0.75R 2STAGE (S1) 70W
11 18 18 16 14 1
FREQUENCY_IN 1 D-OUT6 RL MUTE 19 LG 825 19 LG 825 0.85BY 982 17 0.85BY 982 164,190,195,200,216 0.85W 206 15 0.75L 801 2 0.75B TRAVEL Y4 COMMON RAIL PRESS

(CN.D66)
1 2
SENSOR

(CN.G2)
YAZAKI

YAZAKI
FREQUENCY_GND 9 D-OUT7 RL ROOM LAMP 20 OR 826 20 OR 826 0.85BL 983 18 0.85BL 983 GY 543 16 0.85GY 543 (RED TAPE)

CN-A
1 2
SWP

1
(CN.D61)

2
AVcc 7 0.85Y 408 11 WB 949 290,841,842,980,981 17 1

YAZAKI

(CN.E5)
(S3)

SWP
822,829,834,880,882,885,943 2STAGE

1 2 3
SW_1 L 530 BW 950 0.75R 183 0.75R 0.75W 310 VW
IDLE SW 15 22 18 1 1 2
B52

AMP
E1

1 2 3 4
5 6 7 8
SW_2 ANTI-THEFT 16 VG 531 Br 834 19 0.75Y 802 2 0.75B RELIEFE 0.75R 311 6 GrB 3
(CN.A1)

1 2
YAZAKI
(CN.D58)
SWP
GrR 532 SUNLOAD SENSOR 1.25Y 870 0.85R 0.75G 312 WB
12 13 14 15 16 17 18 19 20 21 22

SW_3 (YELLOW TAPE)

1 2 3 4 5 6 7 8 9 10 11

COOLANT 8 20 1 15
Y5 24V
R3 S51
7 8 9 10 11 12 13

KEY SWITCH 1.25B 757 0.85B 0.75B 690b 0.75B

1 2 3 4 5 6

2 11
WB 949
70W LAMP
1 12
CONNECTION

(CN.D65)
(CN.D62)
(HOUSE)
B61 A OFF ACC BOOST PRESS

YAZAKI

YAZAKI
AMP
(CN.C6)

CN-A
SN_IN1 SN HYD.TEMP 2 0.85YB 490 2 BW 950 0.85R 130 1 0.85R 130 LIMIT SWITCH 1 0.75GR 180 0.75W 313 5 L
THROTTLE VOL.

SWP
B G1 G2 ACC M ST
YAZAKI

SENSOR

1
2
(CN.C4)

SN_IN2 SN FUEL LEVEL 15 0.85GL 492 0.85RB 290 2 0.85RB 290 (GATE) ON 2 0.75R 181 0.75L 314 10 LW
POT_IN1 SN_P P1 21 0.85Y 410 A4 WIPER CCD CAMERA 0.85VW 170 3 0.85VW 170 HEAT 3 0.75R 182 SOLENOID VALVE 0.75G 315 17 Br 0.75RW 1
ST OFF H2

SUMITOMO
(CN.E6)
0.85LgR 500 0.85LgR 500

1 2 3
POT_IN2 SN_P P2 0.85L 411 CONTROLER 0.75R 183 0.75BW 691b 0.75BW 0.75L
9 4 4 14 2
B47
AMP
(CN.C5)

FREE
Y18
1 2

0.85Lg 412 0.85BrR 010 0.85BrR 010 0.75R 187 0.75R 0.85WL 807 B 0.75RL
040

POT_IN3 SN_P N1
POT_IN4 SN_P N2
22
0.85G 413 GR 820 0.85RY 840
5
0.85RY 840
ACC 5
0.85Br 803
1
0.75B 0.85GW 215
1
R 0.75RW 319
16
0.75RW
3
10 WIPER SW.IN(INT) 11 6 6 2 SWING 2 TRAVEL 29
0.85GR 414 Lg 821 0.85GR 845 0.85GR 845 ON 0.75GW 320 0.75L

(CN.D64)

(CN.D69)
POT_IN5 SN_P SWING 23 WIPER SW.IN(CNT) 12 7 7 (NO TAPE) ALARM 24

YAZAKI

YAZAKI
ST OIL PRESS

0.85B
0.85Y
0.85L
A/D

24V,107dB

1 2

1 2
0.85V 415 V 809 0.75R 187 0.75RG 321 0.75RL

SWP

SWP
POT_IN6 SN_P UPPER 12 WASHER SW. IN 13 8 8 19
POT_IN7 SN_P TRAVEL 0.85YG 416 0.85BrR 210 0.85B 720 0.85B 720
SENSOR
24 POWER (24V) IN 1 9 18
3 21 1 2
0.85LR 417 0.85WY 829 0.85BG 620 0.85BG 620 0.75WB 322 0.75WB 0.75WB

SUMITOMO
POT_IN8 SN_P HYD.FILTER 13 WASHER CONT.(+) 2 10 30 1

(CN.B6)
S1 FUEL LEVEL

SUMITOMO
ROOM LAMP YAZAKI

1
2
3

(CN.E7)
MT090
1
2
YAZAKI

1 2 3
1 2 3

1 2
F
0.85LY 418 2W 250 0.75YB 323 0.75LY 0.75LY
POT_IN9 SN_ANG THROTTLE 25 WASHER CONT.(-) 3
E4 SDL 1 25 2
B21
YAZAKI

SENSOR
(CN.C8)

SWP
1 2

4 5 6

4
2
5
3
6
1
(CN.B2)
090

POT_IN10 SN_P OVER LOAD 26 0.85Gr 419 WINDOW CONTROL 9 24V,10W (CN.B3) 0.85VG 822 3 0.75BY 324 20 0.75BY 0.75BY 3

3 4
5 6 7 8 9 10
YAZAKI REFUEL PUMP

0.85VW 170
0.85G 503 0.85G 485 0.85GL 492 0.75Y 2B 764

0.85BO 428
COMP_IN1 KEY ON 7 REV. SIG. 7 2 2 21

0.85RY 840
0.85Y 408
R5

0.85LY 418
YAZAKI
(CN.A46)
CN-A

SDL
YAZAKI

0.85RY 520 0.85L 486 OFF G 888 G 888 0.85RY 844 0.85BG 660 0.75B 0.75YG 342 0.75YG
(CN.C22)

(CN.D76)
COMP_IN2

0.85RB 290
8

0.85R 130
SW GATE LEVER

0.85LgR 500
20 STOP SIG. 2 1 2 (CN.B1) 1 31

0.85BrR 010
CN-A

YAZAKI
2
1

1 2
0.85Br 515 WINDOW LIMIT SW. Y 843 Y 843 0.85GR 845 0.85Y 900 0.75Y 900

58W
COMP_IN3

(CN.D57)
BATTERY CHARGE 8 4 DOOR 1 2 1 1 22

1 2

3
YAZAKI
0.85W 400 0.85LR 827 0.85O 902 0.85O 902 0.75BR 344 0.75BR FUEL TEMP.SENSOR

1 2
SW_IN1

SWP
AVcc 11 WIPER MOTOR(CW) 5 ON 2 9
HYD.OIL TEMP

833

(CN.D68)
SUMITOMO
SW_IN2 0.85BO 428 0.85LB 828 0.85L 904 0.75L 904 0.85WV 830 0.75G 345 0.75RL 0.75YG

(CN.E8)
AGND 1 WIPER MOTOR(CCW) 6 3 SENSOR 1 13 1
U1

MT090

ECO-J
B3

1 2

1 2
AMP
SW_IN3 AGND 14 0.85BW 420 GND 10 1.25B 710 LIMIT SW RL 162 1 RL 162 0.85G 906 4 0.85B 756 2 23 0.75LW 2
YAZAKI
(CN.C9)
1 2
3 4

(DOOR)
SW_IN4 SW AIR CLEANER 16 LW 533
VY 534
0.85YR 221
GW 536
2 0.85YR 221
0.85GW 536
0.85W 908
0.85V 910
5 0.75YB 490
0.75BW 491
2
B2 0.75WR 365
0.75Y 366
7 0.75WR
0.75GY
SW_IN5 P-SW OPT1 3
M3 S53 DC/DC(24V/12V) 3
X36 RADIO AM/FM STEREO P15
6 1
WASHER
2
YAZAKI
1 2 3
4 5 6

SW_IN6 GY 535 OL 593 OL 593 WG 537 0.85WG 537

(CN.D56)
P-SW OPT2 17 1 2 4 7 26
(CN.C7)

CONVERTER
CN-A

24V,2A BOOST TEMP.SENSOR

ECO-J
GW 536 WIPER MOTOR Y 843 Y 843 YL 558 0.85YL 558 0.75R 340 0.75RB

1 2
SW_IN7

AMP
SW FREE SWING 4 2 4 5 8 3
X6
I/O

24V IN (MAIN)
WG 537 BG 613 BG 613 0.85OR 225 YB 570 0.85YB 570 12V OUTPUT 0.85BY 901 0.75BY 901 0.85WV 829
M M4 0.75R 0.75BR
YAZAKI

SW_IN8 SW HBCV/TRVL ALM

(CN.E9)
PACKARD
(CN.C23)

18 3 1 6 6 9 1 8 1
CN-A

BUCK UP
B51

(CN.B17)
(FOR RADIO)
2
3

(CN.D84)
24V IN (BACKUP)
1

1 2
SW_IN9 YL 538 0.85LR 0.85LR 827 RL 163 V 571 0.85V 571 0.85BO 903 0.85BO 903 0.85B 755 0.75RL

YAZAKI
SW FILTER IND 5 1 3 2 7 10 2 27 2

1 2 3
ECO-J
M

1 2
SWP

ACC

GND
24V

AMP
R(+)
YAZAKI(CN.B14)
YAZAKI(CN.B15)
YAZAKI(CN.B16)

L(+)

(CN.D67)
LB 539 0.85LB 0.85LB 828 GND 0.85B 708 Br 834 0.85Br 834 AIR SUSPENSION 0.85BL 905 0.75BL 905 0.85W 407 0.75G

R(-)
SW_IN10 SW ENG STOP

L(-)
19 3 5 8 11 1
B97 4

YAZAKI
CN-A
SW_IN11 6 2 DOOR OPEN:CLOSE 12V OUT(BACKUP) 3 0.85RY 280 LG 842 9 0.85LG 842 0.85GB 907 12 0.85LR 417 2 28

1
2
GY 543

DOOR CLOSE:OPEN 12V OUT(MAIN)

M PRESS. SENSOR
SW_IN12 0.85G 4 0.85G 485 1 0.85WR 281 0.85Y 980 10 0.85Y 980 0.85YR 221 1 1.25R 0.85YL 818 13 0.85BW 427 3 32

GrR
YAZAKI

OW
EGR INTAKE TEMP.SENSOR
(CN.C10)

GR
1 2
3 4

Gr
H4 (HYD.FILTER)

G
R

B
SW_IN13 0.85L 6 0.85L 486 SPEAKER(R) GND 4 0.85BW 709 0.85L 981 11 0.85L 981 0.85B 720 2 1.25B 0.85LR 417 14 0.85LR 417
HORN LOW

(CN.E10)
0.85B 5 1.25B 711 SHUT OFF 7 0.85BY 982 12 0.85BY 982 0.85WB 909 15 0.85LR 880 0.75WR 1
(LEFT)

YAZAKI
PRESS. SENSOR
B86

1
2
3
4
5
6
7
8
9
B92

1 2
1 0.85BY 982 3 0.85BY 982 0.85BL 983 13 0.85BL 983 0.85VG 911 16 (P1) B42 YAZAKI(CN.D70) 0.75GY 2

MITSUBISHI
24V 24V,370Hz

17
14 13
10 9
32 31
27 26
22 21

5 4
YAZAKI
(CN.C24)

24V

(CN.D7)
CN-A

R 2 0.85YB 984 1 0.85YB 984 0.85RY 280 14 0.85RY 280 17 0.85B 760
2

111dB
1

9 10 11 12 13 14 15 16 17 18
5 6 7 8

NMW
1 2 3 4

RL 162
(CN.B18)
SUMITOMO

0.85WR 281
0.85BW 709
0.85BL 983 0.85WR 281 0.85WR 281 0.85YR 222 0.75W 400 YAZAKI(CN.D71)

30 29 28
25 24 23
20 19 18

8 7 6
3 21
0.85RB 291

0.85BY 982
4 15 1 18 1

0.85Y 980

0.85BL 983
1.25B 728
0.85L 981
0.85RY 280
5 6 7 8 9

MT090

16 15
12 11
(CN.D45)
1 2
4 5 6 7
2 3

2 0.85LB 985 0.85BW 709 16 0.85BW 709 0.85B 721 2 0.75Y 410 2
YAZAKI

WATER TEMP.SENSOR

1 2 3
(CN.A28)

ECO-J
ACC YAZAKI

AMP
PA

X15 0.75BW 420

YAZAKI
17 3

(CN.A56)
SOCKET PA

(CN.E11)
SUMITOMO
SDL
HORN HIGH
1.25GR 875

CONTROLLER B H5 (CN.B13)
SPEAKER(L) 18 0.85YR 882 0.75RB 1
B1
1.25B 714

(RIGHT)

1 2
B93

3
BG 614

1 2 3 4
0.85B 712 0.85WR 282 YAZAKI(CN.D72) 0.75BY

9 10 11 12 13 14 15 16 17 18
5 6 7 8
2
12V
O 590

24V,370Hz
(CN.C11)
CN-A PRESS. SENSOR
A13
POWER 24V 1 1.25W 109 YAZAKI YAZAKI 1 0.85BL 983
M8 YAZAKI (P2) B44 0.85B 761
111dB
0.75R 3
YAZAKI

YAZAKI
(CN.C25)

(CN.C16) (CN.C15)
CN-A

12 1.25W 109a L 2 0.85LB 985 (CN.B22) YAZAKI(CN.D73)

2
1

YAZAKI
4 5 6

(CN.A49)
2
6
5
3
1
4

POWER 24V 0.75W 401

SDL
11 1
S13 S28
1 2 3
CIGAR LIGHTER
E51

(CN.D46)
22 0.75L 411 2

1 2 3
ECO-J
24V,5A LIMIT SW
S9 S85 S22
1 2 3 4

AMP
OVER HEAT SW.

(CN.D74)
GND_2 1.25BG 602 0.75BW 421 0.85R 885 M4 ISUZU(CN.E19)
X2
BG 614
O 590

2 (WINDOW) 3 1 BEACON S91

YAZAKI
1.25GR 875
1.25B 714

YAZAKI(CN.A30F)

1 2
SWP
13 1.25BG 602a 0.85B 713 0.85YR 220 0.85B 762 2
TRAVEL ALARM<NA>
P-G GND_3 5 0.85B 702 YAZAKI YAZAKI O 590 0.85W 400 1 0.75W 400
(CN.C14) (CN.C13) ENG STOP BEACON<EU> OVER LOAD<EU> FREE SWING<NA> PRESS. SENSOR CAM ANG(MRE)
N-G
16 0.85B 702a
S54 BG 614
YAZAKI(CN.A31F)
(CN.B7) (CN.B10) (CN.B11) (CN.B9) 0.85BW 420 2 0.75BW 420
(N1) B43 SENSOR

(CN.D75)
GND 9 HORN VOL.SW 0.85Y 410 3 0.75Y 410 0.75R 886 1

YAZAKI
LED BEACON
9 10 E69

1 2
SWP
20 0.85L 411 4 0.75L 411 0.85W 402 1 0.75B 763 2 1 Vcc
(FOR CRANE)

(CN.E12)
SUMITOMO
OFF ON 9 10 WINDOW OPEN:CLOSE 6 3 0.85Lg 412 0.85Lg 412 0.85Lg 412 OUT(PULSE)
L-G

1 2 3
GND_A
B87

(CN.D47)
10 6 3 VR 230 1 VR 230 5 2 3
S70 5 2

1 2 3
ECO-J
5 2 WINDOW CLOSE:OPEN

AMP
21 1.25WR 235 2 0.85WR 235 41 0.85G 413 6 0.75G 413 0.85BW 422 3 2 GND
NPN_OUT1 A-G 6
41 YAZAKI(CN.A26F) 0.85LR 240 3 0.85LR 240 7 8 0.85GR 414 7 0.85GR 414 DUAL SWITCH 0.75R 316 17 Y
(RECIVER DRYER)

(CN.D77)
SUMITOMO
7 8

2
3
4
5
6

2
3

7
8
NPN_OUT2 4 0.85R 1.25GR 875 M8 1.25WR 148 4 0.85WR 148 CARLING 0.85V 415 8 0.85V 415 0.75L 317 18 T
24V PRESS. SENSOR

090
10

LAMP
1
2
3
4
5
6
7
8
9

CARLING VC2
NPN_OUT3 SOL POWER SAVE 7 G 812
Lg 813
VC2 E3 (CAB) 70W
0.85W 1.25B 714 0.85LG 302 5 0.85LG 302 0.85YG 416 9 0.85YG 416
(N2) B40
0.85GW 943 2
S52
0.75G 318 19 OB
SUCTION CONT.VALVE

0.85WR 148

0.85WG 537

0.85GW 536
YAZAKI

0.85BG 620
(CN.C12) LB 539 0.85LB 539 0.85Gr 419 0.85Gr 419 1.25W 944 0.75BL 692b 0.75BW

0.85LG 302

0.85BG 623

0.85BG 622
NPN_OUT4

0.85LB 539

0.85B 722
SOL FAN REVERSE

0.85LG 842

0.85YR 223
3 6 10 1 15

0.85Br 834
YAZAKI(CN.A27F) (CN.C32)

(CN.E13)
SUMITOMO
NPN_OUT5 0.85LR 881 0.85Y 408 0.85Y 408 0.85WL 430 0.85WL 430 0.75W 403

1 2
8 7 11 1 3 2
Y35

MT090
I/O

(CN.D48)

1 2
NPN_OUT6 14 0.85YR 882 0.85LY 418 8 0.85LY 418 0.85BL 450 12 0.85BL 450 0.75G 413 2 7 1

1 2 3
ECO-J

(CN.D78)
YAZAKI(CN.A28F)

AMP
NPN_OUT7 0.85BO 428 0.85BO 428 0.85GW 444 0.85GW 444 0.75BW 423 0.75RG 394 0.75RB

YAZAKI
15 M8 9 13 3 MAGNET CLUTCH 20

SWP
P 040g P 040g

1
NPN_OUT8 18 IMMOBILIZER 0.85R 1.25GR 876 10 0.85VG 445 14 0.85VG 445 (COMPRESSOR) 0.75RW 396 16 0.75RW
LAMP 24V
NPN_OUT9 BUCKET CLOSE (PWM)
NPN_OUT10 SIG CNH GPS
17 0.85YL 818
WL 819
VG 531
BG 637
YAZAKI(CN.A33F) X9 YAZAKI
(CN.C17) E3 (CAB) 70W
0.85W 1.25B 715 MEMORY CLEAR
BG 635
PG 041g
WB 949
11 PG 041g
WB 949
0.85LR 446
0.85YB 490
15 0.85LR 446
0.75YB 490
PRESS. SENSOR 1.25W 944 1.25G
10
INJ1 (#1)
19 12 16 1 11
YAZAKI(CN.A33M) YAZAKI(CN.A29F)
X23
YAZAKI(CN.A37M) (PILOT SWING)
B22 Y8

(CN.E14)
SUMITOMO
BrY 084 BW 950 13 BW 950 0.85GL 492 17 0.85GL 492 1.25B 374 5 1.25BW 1
22 21 20 19 18 17 16 15 14 13 12 040/070HYBRID I/O

YAZAKI(CN.A37F) 10 9

MT090
(FOR CRANE) 10 9
(FOR FAN REVERSE) Y63

1 2
0.85GW 943 14 0.85GW 943 3 6 3 6 0.85BG 660 18 0.85BG 660 0.85W 404 1 1.25W 375 1 1.25L 2
AMP

TO CONTROLLER C
ARM CLOSE(OUT) 0.85G 906 2 5 2 5 X34 GrR 532 0.85GrR 532 0.85GR 414 1.25RB 378 1.25R

(CN.D49)
PWM_OUT1 3 19 2 6
DIAG SW PRESS.SWITCH

1 2 3
10

ECO-J
4
5
6
1
2
3
7
8
9
4

1
2
3
4
5
6
7
8
9
ARM CLOSE(RTN) 0.85GB 907 1.25W 110 BG 634 1 1 4 LW 533 0.85LW 533 0.85BW 424 1.25RL 379 1.25WB
7 8 9 10 11 12 13 14

PWM_RTN1

AMP
4 5 6

6 1 20 3 (BLADE) 2
X24 YAZAKI(CN.A36M) 8 7 8 7 INJ3 (#4)

(CN.D83) 1 2
PWM_OUT2 FAN SPEED(OUT) 1 0.85W 908 WL 266 2 PB 083 YL 538 21 0.85YL 538 1.25Y 376 8 1.25B
YAZAKI(CN.A36F)

YAZAKI
X25 CARLING CARLING

(CN.E15)
SUMITOMO
FAN SPEED(RTN)

SWP
YAZAKI

0.85WB 909 0.85G 505 LB 559 0.85GY 543 1.25L 377 1.25WL
0.85BG 624

0.85BG 621
PWM_RTN2
(CN.A48)

4 3 0.85YB 570

0.85V 571
22 1 4 1

0.85YL 558
X33
SDL

VC2 VC2 PRESS. SENSOR

MT090
B46 Y65

1 2
11 12 13 14 15 16 17 18 19 20 21 22
OPT PRESS(OUT)

6 7 8 9 10
PWM_OUT3 2 0.85V 910 0.85RY 521 4 (CN.B12) (CN.B8) 0.85BG 653 2 1.25B 380 13 1.25LR 2
11 10 9 8 7 6 5 4 3 2 1

A BG 631 1 BG 631 (PILOT UPPER)

1 2 3

PWM_RTN3 OPT PRESS(RTN) 5 0.85VG 911 YB 570 5

X5 RL 166 RL 166 B26 1.25BW 381 9 1.25BR
14 13 12 11 10 9 8 7
3 21

SHLD GND 8 V 571 6 B 2 0.85W 405 1 12

C P 040h 3 P 040h INJ2 (#3)
EST CONNECTOR A

7 P 040e 7 CAN 0.85V 415 2 14

(CN.A8)

YAZAKI
(CN.A54)

(CN.D50)
YAZAKI
(CN.A23)

PG 041h PG 041h

SDL
P 040j D 4

(CN.D10)
S-G

SUMITOMO

(CN.E16)
SUMITOMO
SDL

WR 062b PG 041e 0.85BW 425

1 2 3
BOOT_CNT

16 15 14 13
12 11 10 9
ECO-J

20 19 18 17
11 8

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