SERVICE TRAINING

SK130HDL
SK130-8 YP09-200001~
LX08-T0101~

Customer Support Department

KOBELCO INTERNATIONAL (S) CO., LTD

Book
Bookcode:
code:2014-02-KISCO-SK130-8- Trg Text
2014-01-KISCO-SK130HDL-TrgText
MACHINE SPECIFICATION ［2. SPECIFICATIONS］

2.1 NAME OF COMPONENTS

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MACHINE SPECIFICATION ［2. SPECIFICATIONS］

2.5 SPECIFICATIONS AND PERFORMANCE

2.5.1 SPEED AND CLIMBING CAPABILITY

Item / Model SK140LC-8 SK130-8 SK130L-8

1
Swing speed : min- {rpm} 11 {11}
Travel speed (1-speed/2-speed) : km/h

２
3.4 / 5.6 (2.1 / 3.5) 3.0 / 5.3 (1.8 / 3.3)
(mile/h)
Gradeability : % (degree) 70 (35)

2.5.2 ENGINE

Engine model MITSUBISHI D04FR-74KW

Water-cooled, 4 cycle 4 cylinder direct injection type diesel
Type
engine with inter cooler turbo-charger
4 - 102 dia. mm X 130 mm
Number of cylinders-BoreXStroke
(4.02 in X 5.12 in)
Total displacement 4.249 L (259.27 cu-in)
Net 69.2 kW (94 PS) / 2,000 min-1 (ISO 9249)
Rated output / Engine speed
Net 74 kW (101 PS) / 2,000 min-1 (ISO 14396)
Net 359 N-m (265 lbf-ft)/ 1,600 min-1 (ISO 9249)
Maximum torque / Engine speed
Net 375 N-m (277 lbf-ft)/ 1,600 min-1 (ISO 14396)
Starter 24 V / 5.0kW
Alternator 24 V / 50A

2.5.3 HYDRAULIC COMPONENTS

Hydraulic pump Variable displacement axial piston pump X 2 + gear pump X 1

Hydraulic motor (swing) Axial piston motor X 1
Variable displacement axial piston motor X 2
Hydraulic motor (travel)
(with counterbalance valve)
Control valve 8-spool control valve X 1
Cylinder
Double action cylinder
(Boom, Arm, Bucket)
Oil cooler Air-cooled type

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 ［2. SPECIFICATIONS］
MACHINE SPECIFICATION

2.5.4 WEIGHT

SK140LC-8 Unit : kg (lbs)

Fully equipped weight 13,000 (28,665)
Upper structure 6,550 (14,440)
Lower machinery
4,275 (9,430)
(500mm grouser shoe)
Attachment [STD]
4.68m (15 ft-4in) Boom+2.38m (7ft-10in) Arm 2,347 (5,175)
+0.50m3 (0.65cu-yd) Bucket
Attachment
4.68m (15 ft-4in) Boom+2.38m (7ft-10in) Arm 2,367 (5,220)
+0.57m3 (0.75cu-yd) Bucket

SK130-8 Unit : kg (lbs)

Fully equipped weight 12,800 (28,220)
Upper structure 6,550 (14,440)
Lower machinery
4,445 (9,800)
(500mm grouser shoe)
Attachment [STD]
4.68m (15 ft-4in) Boom+2.38m (7ft-10in) Arm 2,347 (5,175)
+0.50m3 (0.65cu-yd) Bucket
Attachment
4.68m (15 ft-4in) Boom+2.38m (7ft-10in) Arm 2,367 (5,220)
+0.57m3 (0.75cu-yd) Bucket

SK130L-8 Unit : kg (lbs)

Fully equipped weight 14,700 (32,410)
Upper structure 5,320 (11,730)
Lower machinery
7,070 (15,590)
(900mm grouser shoe)
Attachment [STD]
4.68m (15 ft-4in) Boom+2.38m (7ft-10in) Arm 2,322 (5,120)
+0.45m3 (0.59cu-yd) Bucket

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MACHINE SPECIFICATION ［2. SPECIFICATIONS］

2.6 TYPE OF CRAWLER

２
Use 500mm (19.7") grouser shoes on rough ground (areas covered with rocks and gravel). If you drive
or excavate with other shoes, this may cause shoe bending, shoe bolt looseness, and track assembly
(link, roller, etc.)

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［2. SPECIFICATIONS］
MACHINE SPECIFICATION
2.7 TYPE OF BUCKET

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MACHINE SPECIFICATION ［2. SPECIFICATIONS］

2.8 COMBINATIONS OF ATTACHMENT

２
When the only 2.38m (7ft-10in) arm is using, do not turn the bucket back to front to use as a shovel.

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［2. SPECIFICATIONS］
MACHINE SPECIFICATION
2.9 ENGINE SPECIFICATION

2.9.1 SPECIFICATIONS

Applicable machine SK140LC-8 / SK130-8 / SK130L-8

Engine model MITSUBISHI D04FR-74KW
Water-cooled, 4 cycle 4 cylinder direct injection type diesel
Type
engine with inter cooler turbo-charger
Number of cylinderXBoreXStroke mm (in) 4 X 102 X 130 (4.02 X 5.12)
Total displacement cc (cu-in) 4,249 (259.27)
Compression ratio 17.8
Net 69.2 (94) at 2,000 (ISO 9249)
Rated output kW (PS) at min-1
Net 74 (101) at 2,000 (ISO 14396)
N-m (lb-ft) at Net 359 (265) at 1,600 (ISO 9249)
Maximum torque
min-1 Net 375 (277) at 1,600 (ISO 14396)
High idling min-1 2,220 ~ 2,260
Low idling min-1 995 ~ 1,035
Injection starting pressure MPa (psi) -
Start/Full open
Thermostat action 344 (160) / 358 (185)
K (degrees F)
Firing order 1 - 3 - 4 - 2
Starter capacity V X kW 24 X 5.0
Generator capacity (Alternator) V X A 24 X 50
600 dia (23.6") X suction type 6 fans, V-belt drive, pulley
Cooling fan drive method
ratio Crank / Fan= 0.9
Full level 17.5 (4.62)
Engine oil quantity L (gal) Low level 14.5 (3.83)
Total 18.5 (4.89)
Dry weight kg (lbs) 395 (871)
Fuel consumption ratio
g/kW-h (g/ps-h) 233 (171)
(At rated output)
Allowable inclination Front / Rear and Right / Left : 35 degrees
Dimension (LXWXH) mm (in) 911 X 719 X 940 (35.9in X 28.3in X 37.0in)
Rotating direction Counterclockwise seeing from flywheel side

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MACHINE SPECIFICATION ［2. SPECIFICATIONS］

2.9.2 ENGINE CHARACTERISTIC CURVE

Condition to be measured: The net value is indicated, measuring without cooling fan.

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［13. MAINTENANCE STANDARD AND TEST PROCEDURE］

Issue Date of Issue Applicable Machines Remarks

S5YP1301E01
First Edition July, 2009 SK140LC-8 : YP09-05001~
(SE Asia)
S5YP1301E02
SK140LC-8 : YP09-05001~
(SE Asia)
Revision January, 2010 SK130-8 : LP09-20001~
(NZL)
SK130L-8 : LX07-11001~
(Thailand)

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PROCEDURE
13.2 PERFORMANCE INSPECTION STANDARD TABLE

Unless otherwise specified, measure it on "H" mode.

13.2.1 STANDARD VALUE TABLE

13

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MAINTENANCE STANDARD
STANDARD ANDAND TEST PROCEDURE］
TESTING PROCEDURE

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MAINTENANCE STANDARD AND TESTINGSTANDARD AND TEST PROCEDURE］
PROCEDURE

13.3 MEASUREMENT OF ENGINE SPEED

13.3.1 MEASUREMENT OF ENGINE SPEED

(1) Warming up of engine
Start engine to raise the coolant temperature of engine to 60 to 90C degrees (140 to 194F degrees)
at surface of radiator upper tank.
The E/G coolant tem-perature gauge is used to measure. The range in white color shows the
temperature of approx. 65 to 105 C degrees (149 to 221F degrees), so confirm that the pointer
indicates the temperature within the white range.

(2) Engine speed measured value through service diagnosis (See below Fig.)
1. Turn "ON" the starter switch with the buzzer stop switch pressed.
2. A program No. and an actual engine revolution are displayed as the No.2 Item.
3. The screen advances like No.2, No.3....each time the "Wiper switch" on the gauge cluster is
pushed.
4. The screen returns like No.45, No.44....each time the "Washer switch" is pushed. 13
5. The display does not disappear unless the starter switch is turned to"OFF".

Service diagnosis for E/G speed measuring

(Example)

Switch for E/G speed indication

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［13. MAINTENANCE
MAINTENANCE STANDARD
STANDARD ANDAND TEST PROCEDURE］
TESTING PROCEDURE
13.4 MEASUREMENT OF HYDRAULIC PRESSURE

13.4.1 PREPARING TO MEASURE HYDRAULIC PRESSURE

(1) Hydraulic equipment
6.9 MPa (1000psi) pressure gauge: 1unit
49 MPa (7100psi) pressure gauge: 2 units
Pressure measuring equipment and instrument for analysis: 1 set
(2) Measuring cleanliness of hydraulic oil

After releasing air in the hydraulic oil tank, open the cover and sample oil in the hydraulic tank, and
measure with the instrument for analysis. If the measured value is higher than the standard value,
replace the return filter or change the hydraulic oil.

13.4.2 PLACE TO INSTALL PRESSURE GAUGE

(1) Main circuit
After releasing the pressure in hydraulic oil
tank and system, replace plugs PF1/4 of
main pump gauge ports (a1) (a2) with plugs
for pressure measurement, and attach
pressure gauge 49 MPa (7100 psi).
(2) Pilot circuit
Replace pilot gauge plug (a3) with plug
PF1/4 for pressure measurement, and
attach pressure gauge 6.9 MPa (1000 psi).

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PROCEDURE

13.4.3 PRESSURE ADJUSTMENT POSITION

(1) Main control valve

13

Relief valve position on main control valve

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MAINTENANCE STANDARD
STANDARD AND
AND TEST PROCEDURE］
TESTING PROCEDURE
(2) Pilot relief valve
The pilot relief valve PR1 is located on the gear pump that is attached to the main pump.

Pilot relief valve position

(3) Swing over load relief

The swing motor is equipped with plugs PA,PB for pressure measurement, but the measurement is
carried out using gauge ports (a1) and (a2). (See "Gauge port on main pump" Fig.)

Swing over load relief position

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MAINTENANCE STANDARD AND TESTINGSTANDARD AND TEST PROCEDURE］
PROCEDURE

13.4.4 PROCEDURE FOR ADJUSTING RELIEF VALVE

(1) Pilot relief valve
Adjust it with adjust screw (311).
Tools: Spanner: 24 mm,
Tightening torque : 29.4 N-m (22 lbf-ft)
Tools: Allen wrench: 6 mm

Pilot relief valve

(2)Main relief valve

(Common for travel and ATT sections)
Loosen lock nut (7) and adjust the pressure with adjust screw (6).
Tightening torque : 27~31 N-m (20~23 lbf-ft)
Tools: Spanner: 19 mm, Adjust screw
Tools: Allen wrench: 4 mm
13

Main relief valve (Travel section, ATT

common section)

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MAINTENANCE STANDARD
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AND TEST PROCEDURE］
TESTING PROCEDURE
(3) Over load relief valve
(Boom, bucket, arm sections)
Loosen lock nut (1) and adjust it with adjust screw (2).
Tools: Spanner: 22 mm,
Tightening torque : 27.4~31.4 N-m (20~23 lbf-ft)
Tools: Allen wrench: 6 mm

Over load relief valve (Boom, bucket, arm

sections)

(4) Over load relief valve (Swing)

When the pressure adjustment is required, loosen lock nut (1) and adjust the pressure with cap (2).
Tools: Spanner: 30, 38 mm,
Tightening torque: 118 N-m (87 lbf-ft)
Tools: Allen wrench: 12 mm

Swing over load relief valve

(5) Travel over load relief valve

This valve was adjusted by manufacturer and
shipped. Do not replace the parts except O-ring.
Loosen cap (205) and adjust the pressure with
shim (213).
Tools: Allen wrench: 10 mm Travel over load relief valve

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MAINTENANCE STANDARD AND TESTINGSTANDARD AND TEST PROCEDURE］
PROCEDURE

13.5 MEASURING TRAVEL PERFORMANCES

13.5.1 TRAVEL SPEED

(1) Purposes
Measure the travel sprocket revolution and
confirm the performances between the
hydraulic pump and the travel motor of the
travel drive system.

(2) Conditions
Hydraulic oil temperature;
45 to 55C degrees (113 to 131F degrees)
Crawler on the right and left sides are One side lifted position
tensioned evenly.

(3) Preparation
Attach the reflection panel with a magnet to the
travel motor cover.
Swing the swing frame through 90C degrees as
shown in upper right Fig. and make the
crawler on one side take off the ground, using
the attachment.

Adhering position of reflection panel 13

(4) Measurement
Engine revolution; Hi idle
2-speed travel switch; 1st speed and 2nd speed
Measuring points; Right and left
Method, example 1;
Measure revolution with a stroboscope
Method, example 2;
Measure the revolutions per minute visually.

13.5.2 DEVIATION OF TRAVEL

(1) Purpose
Measure the amount of deviation at 20 (66 t)
travel and confirm the horizontal balance
between the hydraulic pump and the travel
motor of the travel drive system.

(2) Condition
Hydraulic oil temperature;
Travel position
45 to 55C degrees (113 to 131F degrees)
RH and LH crawler are tensioned evenly.
Firm, level ground
Engine revolution; Hi idle

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MAINTENANCE STANDARD
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TESTING PROCEDURE
(3) Preparation
1.
Straight course more than 30 m (108 ft)
2.
Travel position in which the bottom of the
bucket is lifted by about 30 cm (1 ft).
Measuring method

(4) Measurement
1.
Measure the max. deviation distance of the
circular arc in the 20 m (66 ft) length, excluding
the preliminary run of 3 to 5 m (10 to 16 ft).
2.
Operate the travel lever at the same time.

13.5.3 PERFORMANCES OF PARKING BRAKE

(1) Purpose
Confirm that the parking brake holds a
stopped condition of the machine in a no-load
travel position and on a 15 degree slope.

(2) Condition
A slope with (Approx. 15 deg) gradient and a
stopped condition in a no-load travel position

(3) Preparation
Place an angle meter on the shoe plate and Parking brake operating position
confirm that it makes an angle more than 15
degree.
Hang a perpendicular in parallel with the guide
frame rib on the track frame and put a mark
(matching mark) on the shoe plate.

(4) Measurement
Five minutes after the engine stops, measure
the movement distance of the matching mark.

Method of measurement

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MAINTENANCE STANDARD AND TESTINGSTANDARD AND TEST PROCEDURE］
PROCEDURE

13.5.4 DRAIN RATE OF TRAVEL MOTOR

(1) Purpose
To measure the drain rate of the travel motor
and to confirm the performances of the travel
motor.

(2) Conditions
Hydraulic oil temperature;
45 to 55C degrees (113 to 131F degrees)
Engine revolution; Hi idle Location of stopper applied to travel sprocket

(3) Preparation
1.
Place a stopper under the RH and LH travel
sprockets.
2.
Stop the engine and release pressure from the
hydraulic circuit.
3.
Connect a hose with the drain port of the travel
motor and take drain in a container.

Method of measuring the drain rate of travel

motor
13
(4) Measurement ; at Travel Lock
1.
Start the engine and relieve pressure at the
full stroke of the travel lever.
2.
Measure the drain rate for 30 seconds of
relieving.

Unless you observe the rotary force direction at travel lock, rib "A" may be broken by stopper "B" in
some cases. (See Upper right Fig.)

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MAINTENANCE STANDARD
STANDARD AND
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TESTING PROCEDURE

13.6 MEASURING SWING PERFORMANCES

13.6.1 SWING SPEED

(1) Purpose
Measure the swing time and confirm the
performances between the hydraulic pump
and the swing motor of the swing drive
system.
(2) Conditions
Hydraulic oil temperature;
45 to 55C degrees (113 to 131F degrees)
Firm, level ground
Engine revolution; Hi idle
(3) Preparation
Swing speed measuring position (at the min.
Put the bucket empty and extend the
reach)
boom, arm and bucket cylinder fully.
And the machine becomes a position of
minimum reach.
(4) Measurement
Swing the machine by bringing the swing
lever to its full stroke. Measure the time
required to make two turns after one turn
of preliminary run and calculate the time
required for one turn.

13.6.2 PERFORMANCE OF SWING BRAKE

(1) Purpose
Confirm the braking torque performances by the swing relief valve.

(2) Conditions
Hydraulic oil temperature;
45 to 55C degrees (113 to 131F degrees)
Firm, level ground
Engine revolution; Hi idle

(3) Preparation
1.
Put the bucket empty, retract the arm cylinder
fully and extend the bucket cylinders fully. And
move the boom so that the arm top pin is
positioned at same height with boom foot pin.
Swing brake performance measuring position
2.
Put a matching mark on the outer
circumference of the swing bearing of the upper
frame side and of the track frame side. Place
two poles (flags) on the front and back of the
extended line of the matching mark.

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MAINTENANCE STANDARD AND TESTINGSTANDARD AND TEST PROCEDURE］
PROCEDURE
(4) Measurement
1.
When operating in regular swing speed, by
shifting lever to neutral position at pole position
the swing operation stops.
2.
Calculate the swing drift angle by the following
equation, after the upper swing body stops,
using the amount of deflection (m) of the
matching marks on the swing race and the
length (m) of the circumference of the swing
race:

13.6.3 PERFORMANCE OF SWING PARKING BRAKE

(1) Purpose
To confirm the mechanical performances of the
swing parking brake that is fitted to the inside
of the swing motor.

(2) Conditions
On a slope of 15 degree incline. 13
Stop the machine at right angles with the slope.
Put the bucket empty, retract the arm cylinder Swing parking brake performance measuring
fully and extend the bucket cylinder fully. And position
move the boom so that the arm top pin is
positioned at same height with boom foot pin.

(3) Preparation
Put the angle meter on the shoe plate and
make sure that the angle is more than 15
degree.
Put a matching mark on the outer race side
and on the inner race side.

Measuring position of swing parking brake

performances

(4) Measurement
When five minutes has passed after the
engine stops, measure the length of the
movement of the matching marks.

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MAINTENANCE STANDARD
STANDARD AND
AND TEST PROCEDURE］
TESTING PROCEDURE

13.6.4 DRAIN RATE OF SWING MOTOR

(1) Purpose
Measure the drain rate of the swing motor and
confirm the performances of the swing motor.

(2) Conditions
Hydraulic oil temperature; 45 to 55C degrees
(113 to 131F degrees)
Firm, level ground
Engine revolution; Hi idle

(3) Preparation
1.
Stop the engine.
2.
Release pressure from inside the hydraulic
circuit.
3.
Disconnect the swing motor drain hose from
its end returning to the hydraulic oil tank and
take oil in a container.
4.
Put a plug to the tank side.

(4) Measurement; at Swing Lock

1.
Start the engine and put the side faces of
bucket against the inside of the right or left
shoe plates.
2.
Relieve the swing motor at full stroke of the
swing motion.
3.
Collect the amount of drained oil in a
container for 30 seconds.

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PROCEDURE

13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES

13.7.1 OPERATING TIME OF CYLINDERS

(1) Purpose
Measure the operating time of the boom, arm
and bucket and confirm the performances
between the hydraulic pump and the cylinder
of the attachment drive system.

Measuring position for bucket digging and

dump

(2) Condition
Hydraulic oil temperature; 45 to 55C degrees
(113 to 131F degrees)
Engine revolution; Hi idle
Operating time excluding the cushion stroke

Measuring position for boom up and down

motions

(3) Preparation
Firm level ground with the bucket empty 13
(4) Measurement1; Boom up and down
With the boom operating lever at full stroke,
measure the required operating time of the
bucket between the ground surface and its Measuring position for arm in and out
highest position. motions

Measurement 2; Arm in and out, bucket

digging and dump
In a position in which the tooth of the bucket
rises to a level of about 30 cm (1ft) above
ground, measure the full stroke operating time
required with the arm and bucket operating
levers at full stroke.

When lowering the boom, allow the bucket onto a soft ground or cushioning such as rubber tires ;
never put the bucket against concrete or other solid material.

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MAINTENANCE STANDARD
STANDARD AND
AND TEST PROCEDURE］
TESTING PROCEDURE

13.7.2 OIL TIGHTNESS OF CYLINDERS

(1) Purpose
Confirm that the cylinder oil tight by checking the moving length of the cylinder rods.
(2) Condition
Hydraulic oil temperature; 45 to 55C degrees (113 to 131F degrees)
Firm, level ground
After cylinders are replaced, bleed off air from the cylinders, before checking for oil tightness.
Retract the arm cylinder rod 50 mm (2 in) from stroke end so that the piston does not match a
same range of the cushioning mechanism.
(3) Preparation
Put the bucket empty. Extend the arm cylinder rod 50mm (2in) from the most retracted position.
And extend the bucket cylinders fully. Then hold the boom so that the arm top pin is positioned at
same height with boom foot pin.
(4) Measurement
Measure the items five minutes after the engine is turned off.

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PROCEDURE
13.8 MEASURING PERFORMANCES OF SWING BEARING

(1) Purpose
Measure the gap between the lower frame and
the bottom face of the swing bearing and
estimate the degree of wear of the swing
bearing.

(2) Condition
Firm, level ground
The swing bearing mounting bolts are not
loosened. How to measure the axial play of swing
The swing bearing is lubricated well, not making bearing
abnormal sound during turning.

(3) Preparation
1.
Install a dial indicator to the magnetic base and
fix it to the lower frame.
2.
Direct the upper swing body and the lower
frame toward the travel direction, bring the
Measuring position 1
probe of the dial indicator in contact with the
bottom surface of the outer race on the swing
body side and set the reading at zero. 13
(4) Measurement 1 (Measuring position 1 and 2)
1.
Measure the displacement of the outer race in
the axial direction in position 1 [The arm at 90
degrees to 110 degrees and the crawler front is
lifted by attachment about 30cm (1ft)] and in
Measuring position 2
position 2, using a dial indicator.

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TESTING PROCEDURE
(5) Measurement 2 (Measuring position 3)
1.
Retract the arm cylinder fully and extend the
bucket cylinder fully. And move the boom so
that the arm top pin is positioned at same
height with boom foot pin. Then swing the
Measuring position 2
bucket right and left by man power. But in this
case, the gap of the attachment is included.

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MECHATRO CONTROLLER TUNING STANDARD AND TEST PROCEDURE］

13.9 MECHATRO CONTROLLER

13.9.1 ENGINE CONTROL INPUT / OUTPUT

INPUT / OUTPUT

13.9.2 ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (A-B-C

ADJUSTMENT)
13.9.2.1 PURPOSE OF THE ADJUSTMENT 13
There are 2 kinds of adjustment of mechatro controller as shown below; every adjustment is an
essential function to ensure performance of machine.

(1) Adjustment of pump ("B" adjustment)

This adjustment is performed to correct the output variation by coordinating the output hydraulic
pressure with engine rated output.
(2) Adjustment of unloading valve ("C" adjustment)
This adjustment is performed to correct the open variation of unloading valve to improve the
operability further.

13.9.2.2 IN CASES WHERE THE ADJUSTMENT OF MECHATRO CONTROLLER IS REQUIRED;

When the following parts are replaced or repaired, carry out the adjustment without fail.

(1) Mechatro controller

(2) Engine or engine controller
(3) Hydraulic pump or hydraulic pump proportional valve
(4) Unloading proportional valve, spool of unloading valve

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MECHATRO STANDARD
CONTROLLER AND TEST PROCEDURE］
TUNING
13.9.2.3 PREPARATION
(1) Raise the oil temperature to about 50C degrees (122F degrees) to warm up the engine.
(2) Turn the air-con OFF.
(3) Turn the starter key switch OFF to stop the engine.
When the mechatro controller was replaced, the following error code is displayed because the
adjustment data is not entered.
A215, A225, A015, A025, A035
As the error codes other than those shown above may suggest failures of machine, repair the
machine into the ordinary operating condition according to Error Code List.

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［13. TUNING
MECHATRO CONTROLLER
13.9.2.4 ADJUSTING PROCEDURE

Gauge cluster

(1) Adjustment of engine ("B" adjustment)

Procedure
1.
Turn starter key switch ON keeping the work
mode selector switch on the gauge cluster
pressed, and hold it for 5 to 10 seconds, and
then release it. (If the engine is started, the 13
following indication is not displayed. Therefore
do not start the engine.)

2.
Keep buzzer stop switch on gauge cluster
pressed for 5 seconds and release it and the
screen for selecting adjustment is displayed.
When adjustment data is not entered in
mechatro controller, "READY" is indicated. If the
adjustment operation is once performed, "FIN" is
indicated.
And the lever lock solenoid is automatically
released, disabling all operations.

3.
Press selector switch on gauge cluster to
display "START ENG".
"Engine SPEED", P1, P2 "PUMP PRESSURE"
and "STEP" (acceleration command voltage) are
indicated.

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TUNING
4.
The adjustment automatically shifts from engine
to pump, the speed shifts from LOW idling to
HIGH idling. And "MEMORY PUMP" is
displayed. And the unloading proportional valve
and pump proportional valve actuate,
accordingly the loading of pump is increased.
The "ENGINE SPEED", P1, P2 "PUMP
PRESSURE" and P1, P2 pump
"PROPO-VALVE" current (command value) are
indicated.

5.
After detection of the engine rated speed, the
adjustment of pump is automatically completed.
And "FINISH PUMP" is displayed.
(Press the buzzer stop switch on gauge cluster
while this display is appeared and the
adjustment is completed. The unloading
adjustment required later is not performed, and
default value is written.)

(2) Adjustment of unloading valve ("C" adjustment)

Procedure
1.
The adjustment shifts from pump to unloading,
and the unloading valve actuates, accordingly
the pump pressure is detected. And "MEMORY
UNLOAD" is displayed.
The "ENGINE SPEED", P1, P2 "PUMP
PRESSURE" and P1, P2 "PROPO-VALVE"
voltage (command value) are indicated.

2.
When the unloading valve operates to the
specified value, the adjustment of unloading
proportional valve is automatically terminated.
And "FINISH UNLOAD" is displayed.
The speed is shifted to the speed
corresponding to acceleration potentiometer.
The adjusting current value is indicated on the
display of current of P1, P2 unloading
proportional valves. The adjusting range is
usually 520 to 635 mA.

Stop the engine. (The adjusted data is

automatically stored.)

13-26
 ［13. MAINTENANCE
MECHATRO CONTROLLER TUNING STANDARD AND TEST PROCEDURE］

(3) Corrective actions taken when the adjustment can not be performed;

1.
In cases where the adjustment of pump can not
be performed; And "ERROR PUMP" is
displayed.
Judging condition 1:
P1 and P2 average pump pressure at the time
when the adjustment is completed is 25MPa or
less.
Judging condition 2:
The adjustment does not complete although
the pump proportional valve current reaches to
the specified value.

The P1 and P2 pump pressures usually

increase to 33~38MPa.
When the pressure does not increase;

a. Identify the reason why the pressure does not increase,

-Check that the relief valve operates normally.
-Check that the hydraulic circuit is free from leak of pressure.
-Check that the pressure sensor functions normally.
And so on.
b. Identify the reason why the actual flow rate does not increase,
-Check that the pump proportional valve operates normally. 13
-Check that the pump regulator operates normally.
And so on.

13-27
［13. MAINTENANCE
MECHATRO STANDARD
CONTROLLER AND TEST PROCEDURE］
TUNING
2.
In cases where unloading valve can not be
performed; And "ERROR UNLOAD" is displayed.
Judging condition 1:
The pump pressure does not increase up to the
pressure in the range of the specified
adjustment. Or the increased pressure is held
as it is.
Judging condition 2:
Pressure sensor of either P1 pump or P2 pump
is failed.

Normally the pump pressures of P1 and p2

pumps gradually increase to 10 to 25 MPa.
(It may be affected by operating oil
temperature.)

When the pump pressure does not increase;

a. Identify the reason why the pressure does not increase,

-Check that the relief valve operates normally.
-Check that the hydraulic circuit is free from leak of pressure.
-Check that the pressure sensor functions normally.
And so on.

13-28
 MAINTENANCE STANDARD AND TEST PROCEDURE］
［13. TUNING
MECHATRO CONTROLLER
(4) Other precautions:

1.
In the event of a failure, there is case where the adjustment may not be performed normally.
First serve the machine, and perform the adjustment work.
2.
In the condition where large load is constantly applied to engine, the adjustment could not be
performed normally.

(5) When the adjustment of unloading valve only is performed; ("C" adjustment)

In the event where only unloading valve and unloading proportional valve are replaced, perform the
adjustment of unloading valve only.

Procedure
1.
Turn starter switch ON keeping the work mode
selector switch on the gauge cluster pressed,
and hold it for 5 to 10 seconds, and then
release it.
(If the engine is started, the following indication
is not displayed. Therefore do not start the
engine.)

2.
Keep buzzer stop switch on gauge cluster 13
pressed for 5 seconds and release it and the
screen for selection of adjustment type is
displayed. And "ADJUST" is displayed.
When adjustment data is not entered in
mechatro controller, "READY" is indicated. If the
adjustment operation is once performed, "FIN" is
indicated.
And the lever lock solenoid is automatically
released, disabling all operations.

3.
Change the adjusting items with washer switch
(▲) and wiper switch (▼), and select
"ADJUST UNLOAD". (See Fig. "Gauge cluster")
Like the output adjustment, when adjustment
data is not entered in mechatro controller,
"READY" is indicated. If the adjustment
operation is once performed, "FIN" is indicated.

4.
Press selector switch on gauge cluster to
display "START ENG".
"ENGINE SPEED", P1, P2 "PUMP PRESSURE"
and "STEP" (acceleration command voltage) are
indicated.

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 ［13. MAINTENANCE
MECHATRO STANDARD
CONTROLLER AND TEST PROCEDURE］
TUNING
5.
After starting engine, press selector switch on
gauge cluster and "MEMORY UNLOAD" is
indicated, the engine speed is automatically
increased and the adjustment of unloading valve
is performed.
"ENGINE SPEED", P1, P2 "PUMP PRESSURE"
and "PROPO-VALVE" (acceleration command
current) are indicated.

6.
When the unloading proportional valve operates
to the specified value, the adjustment of
unloading proportional valve automatically
completes. "FINISH UNLOAD" is indicated.
The speed is shifted to the speed
corresponding to acceleration potentiometer.
The value of adjusting current is indicated on
the display of current of P1 and P2 unloading
proportional valves. The adjusting range is
usually 520 to 635 mA.

Stop the engine. (The adjusted data is

automatically stored.)

13-30
［21. MECHATRO
MECHATRO CONTROLLER］
CONTROLLER
21.1 SUMMARY OF MECHATRO CONTROL SYSTEM

21.1.1 MECHATRO CONTROL SYSTEM IN GENERAL

21-4
MECHATRO CONTROLLER ［21. MECHATRO CONTROLLER］

21

21-5
［21. MECHATRO
MECHATRO CONTROLLER］
CONTROLLER

21.1.2 UNLOAD VALVE CONTROL

(1) On starting any one of operations, the control pilot secondary pressure switches spools and
enters in respective low pressure sensors.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro
controller processes pilot signal and outputs command according to the input voltage to each
unload pressure proportional valve.
(3) Each unload pressure proportional valves output pilot secondary pressure according to the
command output by mechatro controller and switches each unload spools.
(4) With this operation, the bleed opening according to lever manipulated movement is obtained,
consequently the pump pressure which is used to actuate each actuators are delivered and
makes each actuator start operating.

21-6
MECHATRO CONTROLLER ［21. MECHATRO CONTROLLER］

21.1.3 POSITIVE CONTROL & P-Q CONTROL

21

21-7
［21. MECHATRO
MECHATRO CONTROLLER］
CONTROLLER
(1) Positive control
1. On starting any one of operations, pilot secondary pressure switches each spool and is input to
each low pressure sensor.
2. The output voltage of low pressure sensor is input to mechatro controller and the mechatro
controller processes pilot signal and outputs command according to the input voltage to each
unload pressure proportional valve.
3. Each pump proportional valve outputs pilot secondary pressure according to the command output
by mechatro controller and changes the tilting angle of each pump and controls the delivery rate.
4. With this operation, the delivery rate according to lever manipulated movement is fed to the
actuator, and consequently the working speed according to the lever manipulated movement will be
obtained.

(2) P-Q control

(1) The output voltage of high pressure sensor provided on each pump line is input to mechatro
controller and the mechatro controller processes pilot signal and operates the command according
to the input voltage (load pressure).
(2) The lower value between command values calculated by positive control and operated value
found by P-Q control {operated value found in item 1)} is selected and is output to each pump
proportional valve as command value.
(3) Each pump proportional valve outputs pilot secondary pressure according to the command output
by mechatro controller and changes tilting angle of each pump and controls the delivery rate.
(4) With this operation, the delivery rate according to lever manipulated movement is fed to actuator
and consequently working speed will be obtained according to lever movement.

21-8
MECHATRO CONTROLLER ［21. MECHATRO CONTROLLER］

21.1.4 BOOM UP CONFLUX CONTROL

21

21-9
 ［21. MECHATRO
MECHATRO CONTROLLER］
CONTROLLER
(1) On starting boom up operation, boom up operating pilot pressure switches boom spool and boom
up conflux spool and is input to low pressure sensor.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro
controller processes pilot signal and outputs command according to the input voltage to P1 and P2
proportional valves and P1 and P2 unload proportional valves.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the
command output by mechatro controller and changes P1 and P2 pump delivery rate and switches
P1 and P2 unload pressure control valve.
(4) With original hydraulic pressure command, boom main spool and boom up conflux spool are
switched, and also with the command by mechatro controller, P1 and P2 pumps and P1 and P2
unload valves are switched and consequently the delivery oil on P1 pump side confluxes delivery
oil on P2 pump side during boom up operation.

21-10
PRESSURE RELEASE ［21. MECHATRO CONTROLLER］

21.1.11 PRESSURE RELEASE CONTROL

21

21-21
 ［21. MECHATRO
PRESSURE CONTROLLER］
RELEASE
(1) Change mechatro controller to "PRESSURE DRAINING MODE" by operating switch on gauge
cluster.
For detail of changing mode method, refer to "How to switch to "Pressure release mode"" on item
22.11.1.
(2) Once mechatro controller decides it as pressure release control, regardless of each input signal
(operating pilot, accel potentiometer, etc.) the mechatro controller;
1.Outputs minimum tilt angle command to P1, P2 pump proportional valves and fixes P1, P2 pump
to minimum tilt angle.
2.Outputs command of pressure release and outputs command of pressure release control to
ECU and fixes engine speed to pressure release control speed.
3.Outputs maximum command to P1 and P2 unload valves and each pilot secondary pressure
fixes P1 and P2 unload valves to the maximum opening.
(3) Mechatro controller senses output voltage from the main pump high pressure sensor, decides the
pump pressure and displays "DRAINING HYD. PRESS" or "FAIL DRAIN HYD. PRESS" on gauge
cluster.
(4) Each pump delivery oil is unloaded to tank passage enabling for the remained pressure (trapped
pressure) to be released by operating each control lever and switching spool with the unload valve
opened.

21-22
 ［21. MECHATRO CONTROLLER］

21.1.12 N&B SWITCH CONTROL (OPTION)

21

21-23
［21. MECHATRO CONTROLLER］

(1) Nibbler circuit

1. Select nibbler mode through select switch.
2. Nibbler display appears on gauge cluster.
3. The return oil from the nibbler passes through selector valve and option spool and led to tank
line of main control valve.
4. When selecting nibbler mode through select switch, the breaker pressure sensor has not function
to output.
It is in normal when there is no output from sensor in nibbler mode, and in cases of other than
above, error display is output to gauge cluster.

(2) Breaker circuit

1. Select breaker mode through select switch.
2. Breaker display appears on gauge cluster.
3. The return oil from the breaker passes through selector valve and directly returns into hydraulic oil
tank.
4. When selecting breaker mode through select switch, the breaker pressure sensor outputs signal.
It is in normal when there is an output from sensor in breaker mode, and in cases of other than
above, error display is output to gauge cluster.

21-24
 ［21. MECHATRO CONTROLLER］

21.1.13 OPTION CONFLUX CONTROL (OPTION)

21

21-25
［21. MECHATRO CONTROLLER］

(1) Select the Conflux with the aid of Conflux/Single switch.

(2) On starting option operation, option operating pilot pressure switches option spool and is input to
low pressure sensor.
(3) The output voltage of low pressure sensor is input to mechatro controller and the mechatro
controller processes pilot signal and outputs command according to the input voltage to P1 and P2
pump proportional valves, P1 and P2 unload pressure proportional valves and travel straight
proportional valve.
(4) Each proportional valves output pilot proportional valve secondary pressure according to the
command output by mechatro controller and changes P1 and P2 pump delivery rate and switches
P1 and P2 unload valves and travel straight valve of the control valve.
(5) The parallel passage on P2 side is connected to P1 port because of the travel straight valve
switched and P1 pump delivery oil confluxes P2 pump delivery oil because of the P2 unload valve
switched.

21-26
 ［21. MECHATRO CONTROLLER］

21.2 MECHATRO CONTROLLER

21.2.1 SUMMARY OF MULTI DISPLAY

Electro-hydraulic conversion information is displayed on the multi display of the gauge cluster.

(1) Controls

21

(2) Gauge cluster

21-27
WORK MECHATRO
［21. MODE CONTROLLER］
SETTING
(3) Screen selection by work mode select switch
The mode after the engine starting is always the start from "S" mode.
The work mode is switched in order of "S" -> "H" each time the work mode select switch is pressed.
Select proper work mode shown below according to the work condition and the purpose.
For the selected work mode, refer to the table shown below.

・ S mode: For standard excavating work

・ H mode: For heavy duty excavating work

S mode
"S mode" is suitable for standard digging and
loading works and is in saving fuel consumption
and is in good balance to the workload.

H mode
"H mode" is suitable for heavy duty digging
work which gives priority to the workload at
the high speed.

21-28
MAINTENANCE SETTING ［21. MECHATRO CONTROLLER］

(4) Screen selection by attachment mode select switch (SE Asia : Option)
This switch is used for switching the attachment
mode.
The screen is changed from "Digging" to
"Nibbler" to "Breaker" each time the attachment
mode switch (3) is turned to respective position.
Depending on the attachment employed, select
the applicable mode from "Digging", Nibbler",
and "Breaker".
Before the working, confirm whether
appropriate attachment had been selected.

21

21-29
［21. MECHATROSETTING
MAINTENANCE CONTROLLER］

(5) Pump flow rate adjustment (Nibbler mode / Breaker mode)

According to some kind of attachment, it is required to change the flow rate for service circuit. Change
the flow rate in accordance with the procedure mentioned below.
In this machine, last set flow rate has been stored and the initial flow rate is 130L/min. The
adjustment (increase or decrease) of flow rate is changeable by 10L/min step.

1: Screen Change Switch

2: Buzzer Stop Switch
3: Work Mode Select Switch
4: Washer Switch
5: Wiper Switch
6: Travel Speed Select Switch
7: Auto Accel Switch
8: Select Switch
9: Attachment Mode Select Switch
(SE Asia : Option)

1. Turn starter key switch on and display main screen (a).

2. The screen is changed from "Digging" to "Nibbler" to "Breaker" each time the attachment mode
select switch (9) is turned when the main screen (a) is displayed.
3. Turn the switch (9) to "B", and "Nibbler mode" screen is displayed. Or turn the switch (9) to "A",
and "Breaker mode” screen is displayed.
4. When the nibbler/breaker select screen (b) or (c) is displayed, press the select switch (8) and the
value of flow rate reverses to black, and the screen is changed to (d). To increase flow, press the
up arrow (4) (washer switch), or to decrease flow, press the down arrow (5) (washer switch).
5. Select the desired setting value and then press select switch (8) and the flow rate is set to the
desired value.

21-30
MAINTENANCE SETTING ［21. MECHATRO CONTROLLER］

(6) MAINTENANCE SCREEN DISPLAYS

This screen displays the remaining time to the
end of recommended replacement/change
interval specified for filter/oil.

After turning starter key switch ON or starting

engine, the screen is changed in order of "Time
for engine oil change" --> "Time for fuel filter
replacement" --> "Time for hydraulic oil filter
change" --> "Time for hydraulic oil change" -->
"Main screen" each time the screen change
switch (2) is pressed.
With this menu, the time range to the
recommended change time for the filter and oil
in use can be identified.
21

For the initial set value of recommenced replacement/change time, see the following table.

Replacement interval
Item Default
Engine oil 500 Hr
Fuel filter 500 Hr
Hydraulic oil filter 1,000 Hr
Hydraulic oil 2,000 Hr

This menu is available for confirmation of the following items.

The maintenance screen changes each time the screen change switch is pressed.

1.
Remaining time display to the engine oil change
This display shows the remaining time to the
coming engine oil change.

2.
Remaining time display to the coming fuel filter
replacement
This display shows the remaining time to the

21-31
［21. MECHATROSETTING
MAINTENANCE CONTROLLER］

coming engine fuel filter replacement.

3.
Remaining time display to the coming hydraulic
oil filter replacement
This display shows the remaining time to the
coming hydraulic oil filter replacement.

4.
Remaining time display to the coming hydraulic
oil change
This display shows the remaining time to the
coming hydraulic oil change.

-The display automatically changes to the main screen, if switch is not operated for 30 seconds.
-For the setting procedure of maintenance time to be performed to the coming oil change in each
type and filter replacement, see the 21.2.6 SET PROCEDURE OF MAINTENANCE SCHEDULE.

21-32
SELF DIAGNOSIS ［21. MECHATRO CONTROLLER］

(7) Gauge cluster display

After key is switched on and logo mark display disappears, screen for operator is displayed on multi
screen. The display functions of multi display are explained below.

1. Display function for operator:

Screen usually displayed during operation
1.1 Clock display function:
Current time is displayed.
1.2 Self-diagnosis display :
When abnormality is detected on mechatro system like sensor, proportional valve, etc., this displays
error code.
1.3 Warning display:
When machine was thrown into dangerous state, or was failed, displays warning contents with the
symbol and statement.

21

Error codes were stored as trouble history, and displayed on the monitor by the trouble history display
function.

1.4 Machine condition display :

Displays machine operating condition.

2. Display function for maintenance:

Displays remaining time up to replacement/change of following items.
(1) Engine oil (2) Fuel filter (3) Hydraulic oil filter (4) Hydraulic oil

3. Failure history display function:

Stores abnormality occurred on mechatro system in the past and displays in order of recent occurrence.

21-33
 MECHATRO CONTROLLER］
［21. DIAGNOSIS
SELF
4. Mechatro adjustment display:
Displays procedure for adjustment of mechatro system like output adjustment and unload adjustment,
etc.

5. Service diagnosis display :

Displays information like pressure sensor sensed value, proportional valve command, etc. output by
mechatro controller

6. Failure diagnosis mode display function:

Specifies failed section automatically for failures which are not detected by self diagnosis and displays
the results.

21-34
SELF DIAGNOSIS ［21. MECHATRO CONTROLLER］

21.2.2 SELF DIAGNOSIS DISPLAY

(1) Outline
This function identifies abnormality of control I/O signal like pressure, proportional valve, etc. during
machine operation through self diagnosis. The failed items are displayed on multi display of gauge
cluster. For connector No. and pin No., refer to the section "C-1 Mechatro controller" explained later.
Electric circuit diagram or harness is available to identify wire No. and wire color.

(2) I/O configuration

(3) Self diagnosis display items

As-displayed clock (Usually main screen). When error occurred, specifies failed section and the failure
type with the aid of error code.

21

21-35
 MECHATRO CONTROLLER］
［21. DIAGNOSIS
SELF

21-36
SELF DIAGNOSIS ［21. MECHATRO CONTROLLER］

21

21-37
［21. MECHATRO
SERVICE CONTROLLER］
DIAGNOSIS

21.2.3 SERVICE DIAGNOSIS DISPLAY FUNCTION

The current service diagnosis is displayed on multi display based on the data received from mechatro
controller. This section explains the operating procedure and examples of each screen. The values in
display changes according to the conditions like engine speed, attachment position, etc.

(1) Service diagnosis display screen operating procedure

1. Turn starter switch ON keeping buzzer stop switch pressed.

Buzzer stop switch

2. After logo mark is displayed, the screen changes in service diagnosis mode.
The service diagnosis screen "Mode No.1", "Screen No.1" is displayed first.
The service diagnosis is classified into three modes, 1, 2, and 3, and the present mode is displayed in
"Screen No.1".
The screen number each mode can display differs. The screen number displayed by each mode is as
follows.

・ Mode No.1 : Screen No.1 to No.30

・ Mode No.2 : Screen No.1, Screen No.31 to No.40
・ Mode No.3 : Screen No.1, Screen No.41 to No.50

3. The screen changes each time each switch is pressed from now on.

Washer switch
Screen gains by 1 in order.
(No.2-->No.3-->No.4-->...)

Wiper switch
Screen loses by 1 in order.
(No.24-->No.23-->No.22-->...)

Auto idling switch

Service diagnosis number advances from No.1
to No.3, and then returns to No.1.
(No.1 No.2 No.3 No.1 ...)

Travel 1, 2 speed switch

Service diagnosis number advances from No.3
to No.1, and then returns to No.3.
(No.3-->No.2-->No.1-->No.3-->...)

4. Turn key switch OFF and the display of service diagnosis mode is closed.

21-38
SERVICE DIAGNOSIS ［21. MECHATRO CONTROLLER］

(2) Service diagnosis display screen (Example)

The service diagnosis display screen list is shown below. The conditions for display are H mode,
engine low speed and lever to neutral position.)

1) Service diagnosis mode No.1

21

21-39
［21. MECHATRO
SERVICE CONTROLLER］
DIAGNOSIS

21-40
SERVICE DIAGNOSIS ［21. MECHATRO CONTROLLER］

2) Service diagnosis mode No.2

21

21-41
［21. MECHATRO
SERVICE CONTROLLER］
DIAGNOSIS
3) Service diagnosis mode No.3

21-42
SERVICE DIAGNOSIS ［21. MECHATRO CONTROLLER］

(3) Service diagnosis data list

Preface and precaution
The following is the data decided as normal status after service diagnosis for every operation. Use
these data to decide normal/abnormal status.

・ The values in following display are reference values with standard attachment attached machine.
・ The value of pressure sensor is calculated taking variation into accounts. When compared to
performance check reference criteria, measure it with the aid of calibrated measuring instrument.
・ The current of proportional valve is not the measured value, but command value. The measured
value should be confirmed by the value in the displayed value for each proportional valve.
・ The current value of pump proportional valve is reference value because it varies according to
pump pressure and adjusted torque value.
・ The value in display during operation shows the value in steady state, rather than, at start of
operation.
・ Check on machine after sufficiently warming up machine.
・ The value in display may differ according to software version. Contact our dealer/distributor.

Operation No.1: No operation Operation No.2: No operation

H mode Hi idle S mode Hi idle
No.32 ARM, SWING No.32 ARM, SWING
C-1 P1-PRES 0.2~1.5 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 0.2~1.5 M C-2 P2-PRES 0.2~1.5 M
E-1 P1-PSV 350 mA E-1 P1-PSV 350 mA
E-2 P2-PSV 350 mA E-2 P2-PSV 350 mA
D-1 P1-UL(BPC) 750 mA D-1 P1-UL(BPC) 750 mA
D-2 P2-UL(BPC) 750 mA D-2 P2-UL(BPC) 750 mA 21
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
D-6 ARM-IN-2 750 mA D-6 ARM-IN-2 750 mA
B-3 ARM OUT 0.0 M B-3 ARM OUT 0.0 M
B-4 ARM IN 0.0 M B-4 ARM IN 0.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 0.0 M B-7 SWING 0.0 M
G-3 ENG SPEED 1970~2030 G-3 ENG SPEED 1870~1930
POWER SHIFT 0 mA POWER SHIFT 0 mA

Operation No.3: Operation No.4:

Boom up in full lever operation & relief Boom up in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.31 BOOM No.31 BOOM
C-1 P1-PRES 32.0~35.8 M C-1 P1-PRES 11.0~16.0 M
C-2 P2-PRES 32.0~35.8 M C-2 P2-PRES 11.0~16.0 M
E-1 P1-PSV 385~495 mA E-1 P1-PSV 560~750 mA
E-2 P2-PSV 385~495 mA E-2 P2-PSV 450~550 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
B-1 BOOM RAISE 3.0 M B-1 BOOM RAISE 3.0 M
B-2 BOOM LOWER 0.0 M B-2 BOOM LOWER 0.0 M
G-3 ENG SPEED 1970~2030 G-3 ENG SPEED 1970~2030
POWER SHIFT 0 mA POWER SHIFT 0 mA

21-43
 ［21. MECHATRO
SERVICE CONTROLLER］
DIAGNOSIS
Operation No.5:
Boom down in full lever operation & in operation
H mode Hi idle
No.31 BOOM
C-1 P1-PRES 12.5~16.0 M
C-2 P2-PRES 0.2~1.5 M
E-1 P1-PSV 549 mA
E-2 P2-PSV 350 mA
D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 750 mA
B-1 BOOM RAISE 0.0 M
B-2 BOOM LOWER 3.0 M
G-3 ENG SPEED 1970~2030
POWER SHIFT 0 mA

Operation No.6: Operation No.7:

Arm-in in full lever operation & relief Arm-in in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.32 ARM, SWING No.32 ARM, SWING
C-1 P1-PRES 32.0~35.8 M C-1 P1-PRES 12.0~16.5 M
C-2 P2-PRES 32.0~35.8 M C-2 P2-PRES 12.0~16.5 M
E-1 P1-PSV 385~495 mA E-1 P1-PSV 550~700 mA
E-2 P2-PSV 385~495 mA E-2 P2-PSV 550~750 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
D-6 ARM-IN-2 200 mA D-6 ARM-IN-2 370 mA
B-3 ARM OUT 0.0 M B-3 ARM OUT 0.0 M
B-4 ARM IN 3.0 M B-4 ARM IN 3.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 0.0 M B-7 SWING 0.0 M
G-3 ENG SPEED 1970~2030 G-3 ENG SPEED 1970~2030
POWER SHIFT 0 mA POWER SHIFT 0 mA

21-44
SERVICE DIAGNOSIS ［21. MECHATRO CONTROLLER］

Operation No.8: Operation No.9:

Arm-out in full lever operation & relief Arm-out in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.32 ARM, SWING No.32 ARM, SWING
C-1 P1-PRES 32.0~35.8 M C-1 P1-PRES 12.0~18.0 M
C-2 P2-PRES 32.0~35.8 M C-2 P2-PRES 12.0~18.0 M
E-1 P1-PSV 385~495 mA E-1 P1-PSV 606~750 mA
E-2 P2-PSV 385~495 mA E-2 P2-PSV 606~750 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
D-6 ARM-IN-2 750 mA D-6 ARM-IN-2 750 mA
B-3 ARM OUT 3.0 M B-3 ARM OUT 3.0 M
B-4 ARM IN 0.0 M B-4 ARM IN 0.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 0.0 M B-7 SWING 0.0 M
G-3 ENG SPEED 1970~2030 G-3 ENG SPEED 1970~2030
POWER SHIFT 0 mA POWER SHIFT 0 mA

* Measure the values after a lapse of 5 * Measure the values after a lapse of 5
minutes or after release of low temperature minutes or after release of low temperature
mode mode

Operation No.10: Operation No.11:

Swing in full lever operation & relief Swing in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.32 ARM, SWING No.32 ARM, SWING 21
C-1 P1-PRES 0.2~1.5 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 28.0~35.8 M C-2 P2-PRES 8.0~13.0 M
E-1 P1-PSV 350 mA E-1 P1-PSV 350 mA
E-2 P2-PSV 500~610 mA E-2 P2-PSV 642 mA
D-1 P1-UL(BPC) 750 mA D-1 P1-UL(BPC) 750 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
D-6 ARM-IN-2 750 mA D-6 ARM-IN-2 750 mA
B-3 ARM OUT 0.0 M B-3 ARM OUT 0.0 M
B-4 ARM IN 0.0 M B-4 ARM IN 0.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 3.0 M B-7 SWING 3.0 M
G-3 ENG SPEED 1970~2030 G-3 ENG SPEED 1970~2030
POWER SHIFT 0 mA POWER SHIFT 0 mA

21-45
［21. MECHATRO
SERVICE CONTROLLER］
DIAGNOSIS

Operation No.12: Operation No.13:

Bucket digging in full lever operation & relief Bucket digging in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.33 BUCKET No.33 BUCKET
C-1 P1-PRES 32.0~35.8 M C-1 P1-PRES 4.0~8.0 M
C-2 P2-PRES 0.2~1.5 M C-2 P2-PRES 0.2~1.5 M
E-1 P1-PSV 500~610 mA E-1 P1-PSV 750 mA
E-2 P2-PSV 350 mA E-2 P2-PSV 350 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
B-5 BUCKET DIG 3.0 M B-5 BUCKET DIG 3.0 M
B-6 BUCKET DUMP 0.0 M B-6 BUCKET DUMP 0.0 M
G-3 ENG SPEED 1970~2030 G-3 ENG SPEED 1970~2030
POWER SHIFT 0 mA POWER SHIFT 0 mA

Operation No.14: Operation No.15:

Bucket dump in full lever operation & relief Bucket dump in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.33 BUCKET No.33 BUCKET
C-1 P1-PRES 32.0~35.8 M C-1 P1-PRES 6.0~15.0 M
C-2 P2-PRES 0.2~1.5 M C-2 P2-PRES 0.2~1.5 M
E-1 P1-PSV 500~610 mA E-1 P1-PSV 650 mA
E-2 P2-PSV 350 mA E-2 P2-PSV 350 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
B-5 BUCKET DIG 0.0 M B-5 BUCKET DIG 0.0 M
B-6 BUCKET DUMP 3.0 M B-6 BUCKET DUMP 3.0 M
G-3 ENG SPEED 1970~2030 G-3 ENG SPEED 1970~2030
POWER SHIFT 0 mA POWER SHIFT 0 mA

21-46
SERVICE DIAGNOSIS ［21. MECHATRO CONTROLLER］

Operation No.16: Operation No.17:

P2 side option in full lever operation & relief P2 side option in full lever operation & relief
Nibbler mode Hi idle Breaker mode Hi idle
No.35 OPT No.35 OPT
C-1 P1-PRES 22.5~26.0 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 22.5~26.0 M C-2 P2-PRES 22.5~26.0 M
E-1 P1-PSV 480~590 mA E-1 P1-PSV 500 mA
E-2 P2-PSV 480~590 mA E-2 P2-PSV 665~750 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 750 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 720 mA D-3 S-TRAVEL 350 mA
E-3 OPT RELIEF 0 mA E-3 OPT RELIEF 0 mA
B-16 P1 OPT 0.0 M B-16 P1 OPT 0.0 M
B-17 P2 OPT 2.0~2.6 M B-17 P2 OPT 2.0~2.6 M
F-4 OPT SELECT NIB F-4 OPT SELECT BRK
DOUBLE FLOW SW. ON DOUBLE FLOW SW. OFF
G-3 ENG SPEED 1970~2030 G-3 ENG SPEED 1970~2030
POWER SHIFT 0 mA POWER SHIFT 0 mA

* Conflux switch is ON. Relief set pressure is * Conflux switch is OFF. Relief set pressure is
value of shipping. value of shipping.

Operation No.18: Operation No.19 :

Travel right in full lever operation & travel idling Travel left in full lever operation & travel idling
H mode Hi idle H mode Hi idle
No.34 TRAVEL No.34 TRAVLE
C-1 P1-PRES 5.0~12.0 M C-1 P1-PRES 0.2~1.5 M 21
C-2 P2-PRES 0.2~1.5 M C-2 P2-PRES 5.0~12.0 M
E-1 P1-PSV 750 mA E-1 P1-PSV 350 mA
E-2 P2-PSV 350 mA E-2 P2-PSV 750 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 750 mA
D-2 P2-UL(BPC) 750 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
B-9 TRAVEL(R) 2.0~2.5 M B-9 TRAVEL(R) 0.0 M
B-10 TRAVEL(L) 0.0 M B-10 TRAVEL(L) 2.0~2.5 M
Pi-P1 0.0 M Pi-P1 0.0 M
Pi-P2 0.0 M Pi-P2 0.0 M
G-3 ENG SPEED 1970~2030 G-3 ENG SPEED 1970~2030
POWER SHIFT 0 mA POWER SHIFT 0 mA

21-47
 ［48.
MECHATRO- TROUBLE TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)］
DIAGNOSIS
48.1 TROUBLE DIAGNOSIS MODE

The trouble diagnosis mode is used to automatically specify the failed sections for the troubles which
can not be detected by auto diagnosis function (the trouble can be specified by error code) like
disconnection, abnormal output.

(1) Function
There are two types of trouble diagnosis mode.

1. Trouble diagnosis mode 1: Used to diagnose unload system, pump system, travel straight system
and engine system.
2. Trouble diagnosis mode 2: Used to diagnose pilot system.
In any mode, with the attachment not operated, both selector valve and proportional valve are
automatically actuated, the sensor detects the machine condition and the mechatro controller
identifies the normal condition or failed condition of the system.

48

48-3
 ［48. TROUBLESHOOTING
MECHATRO- (TROUBLE DIAGNOSIS MODE)］
TROUBLE DIAGNOSIS
(2) How to use and flow chart
The operation is performed through gauge cluster.
No.1 Select service adjustment select screen.
(Switch starter key on while pressing buzzer stop switch and press select switch three times while
pressing buzzer stop switch on the service diagnosis screen No.1.)
No.2 Select Trouble diagnosis mode
(Move the cursor to the desired position with screen change switch "▲▼", and press the select
switch.)
No.3 Select either "DIAG MODE 1" or "DIAG MODE 2"
(Move the cursor to the desired position with screen change switch "▲▼", and press the select
switch.)
No.4 Go ahead the operation according to the instructions on the screen of cluster gauge.

48-4
 ［48.
MECHATRO- TROUBLE TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)］
DIAGNOSIS

Failure diagnosis Mode-1/Diagnosis item

No. Display Contents of diagnosis
Is normal pressure generated in the condition that the flow rate at P1 side is minimum
1 1 P1 UNLOAD
and the unloading valve is in the emergency position?
Is normal pressure generated in the condition that the minimum flow rate is relieved at
2 2 P1 UNLOAD
P1 side?
Is normal pressure generated in the condition that the unload valve is fully opened,
3 3 P1 UNLOAD
and P1 side flow rate is minimum?
Is normal pressure generated in the condition that the unload valve is in emergency
4 1 P2 UNLOAD
position, and P2 side flow rate is minimum?
Is normal pressure generated in the condition that the minimum flow rate is relieved at
5 2 P2 UNLOAD
P2 side?
Is normal pressure generated in the condition that the unload valve is fully opened,
6 3 P2 UNLOAD
and P2 side flow rate is minimum?
Is normal pressure generated in the condition that the flow rate at P1 side is
7 1 P1 PUMP
emergency and the unloading valve is in the emergency position?
Is normal pressure generated in the condition that the unload valve is emergency, and
8 2 P1 PUMP
P1 side flow rate is minimum?

9 3 P1 PUMP
Is normal pressure generated in the condition that the unload valve is in emergency
position, and P1 side flow rate is maximum?
48
Is normal pressure generated in the condition that the flow rate at P2 side is
10 1 P2 PUMP
emergency and the unloading valve is in the emergency position?
Is normal pressure generated in the condition that the unload valve is emergency, and
11 2 P2 PUMP
P2 side flow rate is minimum?
Is normal pressure generated in the condition that the unload valve is in emergency
12 3 P2 PUMP
position, and P2 side flow rate is maximum?

48-5
［48. TROUBLESHOOTING
MECHATRO- (TROUBLE DIAGNOSIS MODE)］
TROUBLE DIAGNOSIS
Failure diagnosis Mode-1/Diagnosis and item
No. Display Contents of diagnosis
Is normal pressure generated in the condition that P1 side flow rate is minimum,
13 1 TRAVEL-S
unload valve is emergency position and travel straight is stroked fully?
Is normal pressure generated in the condition that P2 side flow rate is minimum,
14 2 TRAVEL-S
unload valve is emergency position and travel straight is stroked fully?
Is rated engine speed obtained in the condition that P1 side flow rate increases little
15 1 P1 ENGINE
by little when P1 side flow rate is relieved?
Is rated engine speed obtained in the condition that P2 side flow rate increases little
16 2 P2 ENGINE
by little when P2 side flow rate is relieved?

Failure diagnosis Mode-1/Diagnosis and Remedy

Diagnosis (Display) Possible cause Remedy
Check each pressure sensor by
Disconnection of pressure sensor, Short
SENSOR CHECK NG service diagnosis and replace it if
circuit, Abnormal output
necessary
Secondary pressure is excessive high
against the command Check P1 unload proportional valve
P1 UN-LOAD PSV NG
Secondary pressure is excessive low and replace it if necessary
against the command
Stuck at full-stroke side Check P1 unload spool and replace it
P1 UN-LOAD SPOOL NG
Stuck at neutral side if necessary

Secondary pressure is excessive high

against the command Check P2 unload proportional valve
P2 UN-LOAD PSV NG
Secondary pressure is excessive low and replace it if necessary
against the command
Stuck at full-stroke side Check P2 unload spool and replace it
P2 UN-LOAD SPOOL NG
Stuck at neutral side if necessary

Stuck at closing side Check P1 by-pass cut valve and

P1 B-P CUT NG
Stuck at neutral side replace it if necessary

Stuck at closing side Check P2 by-pass cut valve and

P2 B-P CUT NG
Stuck at neutral side replace it if necessary

Secondary pressure is excessive high

against the command Check P1 pump proportional valve
P1 PUMP PSV NG
Secondary pressure is excessive low and replace it if necessary
against the command
Delivery rate is excessive large against the Check P1 pump regulator and
command replace it if necessary.
P1 PUMP NG
Delivery rate is excessive small against the Check P1 pump and replace it if
command necessary.

Secondary pressure is excessive high

against the command Check P2 pump proportional valve
P2 PUMP PSV NG
Secondary pressure is excessive low and replace it if necessary
against the command
Delivery rate is excessive large against the Check P2 pump regulator and
command replace it if necessary.
P2 PUMP NG
Delivery rate is excessive small against the Check P2 pump and replace it if
command necessary.

48-6
 ［48.
MECHATRO- TROUBLE TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)］
DIAGNOSIS
Failure diagnosis Mode-1/Diagnosis and Remedy
Diagnosis (Display) Possible cause Remedy
Secondary pressure is excessive high
against the command Check travel straight proportional
S-TRAVEL PSV NG
Secondary pressure is excessive low valve and replace it if necessary
against the command
Stuck at full-stroke side Check travel straight spool and
S-TRAVEL SPOOL NG
Stuck at neutral side replace it if necessary

PUMP 1 PRESS. Check P1 high pressure sensor and

Pressure is recognized lower than it is
SENSOR NG replace it if necessary
PUMP 2 PRESS. Check P2 high pressure sensor and
Pressure is recognized lower than it is
SENSOR NG replace it if necessary
Set pressure decreases Check main relief valve and replace it
MAIN RELIEF NG
Set pressure increases if necessary

Check engine and replace it if

ENGINE NG Output is lowered
necessary
Check engine speed sensor and
E/G R SENSOR NG Characteristics is misaligned
replace it if necessary

48

48-7
［21. MECHATRO
TROUBLE CONTROLLER］
HISTORY

21.2.4 TROUBLE HISTORY DIAGNOSIS

The items of error detected by mechatro controller self diagnosis function are stored in mechatro
controller as one of history. And the errors are able to be indicated on the multi display.
The warning content is stored partially in "Travel history screen".
The error code for self diagnosis is stored.

(1) How to display

1. Turn starter switch on.

2. Press buzzer stop switch for 10 seconds continuously 5 times and the trouble history screen is
displayed.

3. Transmit trouble history data (One or many) and hour meter to gauge cluster.
-Hour meter and 4 failure data are displayed on screen.
-In case of more than 4 failure data, 4 data is displayed at a time for 10 seconds by turns.
4. Paging (Up and down)
-Press washer switch (UP), and the item moves upward.
-Press wiper switch (DOWN), and the item moves downward.
5. Turn starter switch off, and the display is disappeared.

(2) How to delete contents of trouble history

1. Display trouble history screen.
2. Press work mode change switch and buzzer stop switch simultaneously for 10 seconds or more.
3. When "NO ERROR" is displayed, the deletion is completed.
4. Turn starter switch off.

All the stored items are erased. It is impossible to erase data partially.

21-48
TROUBLE DIAGNOSIS ［21. MECHATRO CONTROLLER］

21.2.5 TROUBLE DIAGNOSIS MODE

The recent control system includes many electrical systems and it makes troubleshooting very difficult.
The failure diagnosis mode is used to automatically specify the failed sections for the failures which
can not be detected through the use of self diagnosis function (the failure can be specified through the
use of error code) like disconnection and abnormal output. This is useful to save the time for
troubleshooting.

(1) Function
There are two types of trouble diagnosis mode.

1. Trouble diagnosis mode 1: Used to diagnose unload system, pump system, travel straight system
and engine system.
2. Trouble diagnosis mode 2: Used to diagnose pilot system.
In any mode, with the attachment not moved, both directional valve and proportional valve are
automatically actuated, the sensor detects the machine status and the mechatro controller
identifies the normal condition or failed condition of the system.

For details of how to use, refer to "Chapter 48 TROUBLESHOOTING TROUBLE DIAGNOSIS MODE".

21

21-49
［21. MECHATRO
MONITOR CONTROLLER］
SETTING

21.2.6 SET PROCEDURE OF MAINTENANCE SCHEDULE

This machine is equipped with multi-display
which allows confirmation of remaining time to
the coming replacement/change time of engine
oil, fuel filter, hydraulic oil filter and hydraulic
oil, therefore when the remaining time reaches
to Zero (0), replace or change engine oil, fuel
filter, hydraulic filter, hydraulic oil, etc. and
perform the initial setting by the following order.

Interval of replacement of parts is mentioned below.

-Engine oil: 250 Hr
-Fuel filter: 500 Hr
-Hydraulic filter: 1,000 Hr
-Hydraulic oil: 2,000 Hr

1. After displaying the display for setting by pressing the display change switch, set the respective
maintenance time for fuel filter, hydraulic oil filter and hydraulic oil while repeating the procedure 2 to 5.
2. The engine oil change time is displayed on the multi-display by 500 hours as a warning, but the
buzzer does not sound.

21-50
MONITOR SETTING ［21. MECHATRO CONTROLLER］

21.2.7 ADJUSTING PROCEDURE OF DISPLAY

(1) For operator
2) Clock Adjustment Switches

21

1. Turn starter key switch on and display main screen (a) for operator, and then press select switch
(8) and display "SWITCH STATUS CLOCK/CONTRAST" select screen (b).
2. In operations of FEED UP (4) and FEED DOWN (5), move cursor to "CLOCK/CONTRAST"
screen (c) and then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen
(d) is displayed.
3. In operations of FEED UP (4) and FEED DOWN (5), move cursor to "ADJUST CLOCK" and then
press select switch (8) and the "ADJUST CLOCK" screen (e) is displayed.
4. Select any of "Y-M-D-H-M" in operation of FEED UP (4) and FEED DOWN (5) and vary the
values in operations of FEED UP (4) and FEED DOWN (5).
5. After adjustment, press select switch (8) and the adjusted values are stored as memory and time
setting is completed, and then the screen returns to main screen (a).

21-51
［21. MECHATRO
MONITOR CONTROLLER］
SETTING
2) Contrast Adjustment Switches

1. Turn starter key switch on and display main screen (a), and press select switch (8) and display
"SWITCH STATUS CLOCK CONTRAST" select screen (b).
2. In operations of FEED UP (4) and FEED DOWN (5), move cursor to "SWITCH STATUS CLOCK
CONTRAST" screen (c) and then press select switch (8) and the "ADJUST CLOCK ADJ
CONTRAST" screen (d) is displayed.
3. In operations of FEED UP (4) and FEED DOWN (5), move cursor to "ADJUST CLOCK ADJ
CONTRAST" and then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST"
screen (e) is displayed.
4. Press select switch (8) and the "ADJ CONTRAST 55555" screen (f) is displayed.
5. Vary the values by pressing the desired figure in operations of FEED UP (4) and FEED DOWN
(5).
The available setting range is in 9 steps from "11111" to "99999".
[Example] 11111 (faint) --> 99999 (clear) * The initial set value is 55555.
6. Press select switch (8) and the adjusted values are stored as a memory and the contrast
adjustment is completed, and then the screen returns to main screen (a).

21-52
MONITOR SETTING ［21. MECHATRO CONTROLLER］

(2) Function for service

Following items are provided for adjustment of service function.

Item CONTENTS
Language Language selection
Rise-up wiper Wiper control change (When cab is changed)
P1 option pressure sensor ON/OFF of self diagnosis for P1 option pressure sensor
P2 option pressure sensor ON/OFF of self diagnosis for P2 option pressure sensor
Swing alarm ON/OFF of swing alarm (ON/OFF of adjustment for user)
Left pedal for rotation of Does left rotation pedal use?
option attachment (Unload valve does not actuate because P4 pump is equipped in EU.)
Setting of optional Optional flow rate limitation, relief pressure limitation, combination of return selector
equipment adjustment.
Engine speed ON/OFF of engine rpm display
Auto acceleration Adjustment the type of the engine speed of auto deceleration runs up abruptly.
Change of starter mode Change of start mode
Low temperature mode Low temperature mode release
forcible release
Cylinders calibration Injection adjust mode of engine
Pressure release For pressure release

21

21-53
［21. MECHATRO
MECHATRO CONTROLLER］
CONTROLLER

21.2.8 MECHATRO CONTROL EQUIPMENT

(1) C-1 Mechatro controller
1) Outside view

2) List of connectors

21-54
MECHATRO CONTROLLER ［21. MECHATRO CONTROLLER］

21

21-55
［21. MECHATRO
MECHATRO CONTROLLER］
CONTROLLER

21-56
MECHATRO CONTROLLER ［21. MECHATRO CONTROLLER］

21

21-57
［21. MECHATRO
MECHATRO CONTROLLER］
CONTROLLER

21-58
CLUSTER GAUGE ［21. MECHATRO CONTROLLER］

(2) Gauge cluster (symbol C-2)

1) General view

2) Connector CN-600 (Harness side)

No. Item name Wire color No. Item name Wire color
Gauge cluster --> Mechatro
GND source (+24V Battery direct
1 controller (RS232C White 5 Yellow / Black
connection)
communication)
Mechatro controller --> Gauge
2
cluster (RS232C communication)
Red 6 GND Black 21
3 Reserved - 7 Source (+24V starter switch ON) White
4 Reserved - 8 GND (RS232C communication) Black

3) Function
a. It processes signals by communication between the gauge cluster and the mechatro controller,
displays them in lamps, displays them in LCDs and actuates the buzzer.
b. It outputs coolant temperature signals, fuel level signals and panel switch signals to the mechatro
controller through the communication port.

4) Summary of display and drive item

No. Item Remarks
1 Monitar display LCD dot 120X168
2 Gauge display (Coolant temp., Fuel level) Stepping motor
3 -
4 Buzzer Piezo-electricity type
5 Screen change switch
6 Buzzer stop switch
7 Work mode select switch
8 Back light LED

21-59
 ［21. &MECHATRO
FUSE CONTROLLER］
RELAY BOX
(3) Relay & fuse box (symbol E-1)
1) General view

21-60
ELECTRICAL SYSTEM ［21. MECHATRO CONTROLLER］

2) Circuit diagram

21

21-61
 ［21. MECHATRO
ELECTRICAL CONTROLLER］
SYSTEM

21-62
ELECTRICAL SYSTEM ［21. MECHATRO CONTROLLER］

21

21-63
 ［21. MECHATRO
PRESSURE CONTROLLER］
SENSOR INSPECTION AND MEASUREMENT
(4) High pressure sensor : LS52S00015P1

(5) Low pressure sensor : LC52S00019P1

21-64
HYDRAULIC SYSTEM ［22. HYDRAULIC SYSTEM］

22.2.1 STANDARD
A. SK140LC-8, SK130-8

22

22-5
HYDRAULIC SYSTEM
［22. HYDRAULIC SYSTEM］

B. SK130L-8

22-6
HYDRAULIC SYSTEM ［22. HYDRAULIC SYSTEM］

22.2.2 N&B SPECIFICATION (OPTION)

22

22-7
HYDRAULIC SYSTEM
［22. HYDRAULIC SYSTEM］

22.3 COLOR CODING STANDARD 22.4 NEUTRAL CIRCUIT (2) Principle: spool sleeve is closed.
The current command I to the pump's solenoid
FOR HYDRAULIC CIRCUITS
This section describes the following. proportional valve controls the delivery rate of the 22.4.4 PUMP P-Q CURVE CONTROL
Blue pump. OPERATION
(1) Bypass cut valve and unload valve control (3) Operation: (1) Type:
Feed, drain circuit
(2) Safety lock lever and pilot circuit Electrical flow control type variable pump
less than 0.44 MPa (64 psi)
(3) Pump positive flow control 1. Flow rate rise operation (Eg. P1 pump) (2) Principle:
Green
(4) Pump P-Q (Pressure-Quantity) curve control By operating any of control levers, the operating Perform an operation of the value from pump high
Return, make up circuit, secondary pressure of pilot valve rises, and the pressure sensor to P-Q curve control value, and
0.44~0.59 MPa (64~86 psi) 22.4.1 OPERATION OF BY-PASS CUT rising pressure is transformed to the rise of output send a command to the pump solenoid
Purple VALVE AND UNLOADING VALVE voltage corresponding to the pressure input by the proportional valve.
Secondary pilot pressure, HOUSED IN CONTROL VALVE low pressure sensor. Mechatro controller (3) Operation:
(including proportional vlave) (1) By-pass cut valve signal-processes this change of voltage, resulting The pump high pressure sensor converts the
On starting engine, P1 and P2 unloading in rise of command current value I to the pump pressure to the output voltage corresponding to
0.59~5 MPa (86~725 psi)
proportional valves (PSV-D, PSV-B) output proportional solenoid valve and consequently the the pump delivery pressure.
Red
secondary pressure according to the command pump flow rate rises. This is called "Positive The mechatro controller converts the voltage
Primary pilot pressure,
output by mechatro controller, and this pressure Control System". output by the high pressure sensor to the P-Q
(including proportional vlave) exerts on PBp1 and PBp2 ports, and As the pump command current value rises, the curve control value. On the other hand, select the
5 MPa (725 psi) consequently the by-pass cut spool is switched secondary pressure of proportional solenoid valve pump positive control command current value from
Orange to CLOSE side. also rises. On the regulator attached on the the low pressure sensor in lower order, and the
Main pump drive pressure, The by-pass cut spool is usually held on CLOSE pump, the spool (652) through piston (643) is values are output to respective pump proportional
side after the engine started. And it is switched to pushed leftward, and stops at the position where valve as a command current.
5~34.3 MPa (725~4970 psi)
OPEN side only when failure occurred on pump being in proportion to the force of pilot spring With this operation, the pump power is controlled
Blue tone
proportional valve and mechatro controller. (646). so as not to be exceed the engine power,
At valve operation
(2) Unloading valve The tank port connected to the large bore of therefore engine dose not stall.
Red valve On starting engine, like by-pass cut valve, the servo piston (532) opens, and the piston moves
When solenoid proportional valve (reducing) is secondary pressures output by P1 and P2 leftward by delivery pressure P1 of the small bore
operating unloading proportional valves (PSV-D, PSV-B) resulting in the increase of tilt angle (α).
Red solenoid exert on PCb and PCa ports, consequently the The servo piston and spool (652) are connected
In active and exciting P1 and P2 unloading valves are switched to to feedback lever (611). Therefore when servo
Displaying the flow circuit and standby circuit when OPEN side. piston moves leftward, the spool (652) also moves
operating. rightward by means of feedback lever. With this
Regarding the electrical symbols in this manual, refer to 22.4.2 SAFETY LOCK LEVER AND PILOT movement, the opening of spool sleeve closes
the electric circuit diagram. CIRCUIT gradually, and the servo piston stops at the
(1) Purpose: position the opening closed completely.
To protect attachment from unexpected 2. Flow rate reduction operation
movement for safety. As the current value I of mechtro controller
(2) Principle: reduces, the secondary pressure of solenoid
Cut pressure source of pilot valve for operation. proportional valve reduces, and spool (652) is
(3) Operation: moved rightward by the force of pilot spring (646).
If the safety lock lever (red) is pushed forward With the movement of spool, the delivery pressure
after the engine starts, the limit switch (SW-11) P1 usually flows into the large bore of piston
is turned on. The timer relay is actuated one through the spool.
second later which causes the solenoid (SV-4) of The delivery pressure P1 flows in the small bore
the solenoid valve block (13) to be energized of servo piston, but the servo piston moves
and makes the pilot operating circuit to stand by. rightward due to the difference of area, resulting
in the reduction of tilt angle. Similarly, when the
22.4.3 PUMP POSITIVE FLOW CONTROL servo piston moves rightward, the spool (652) is
(1) Type: moved leftward by the feedback lever.
Electric flow controlled variable displacement pump. The operation is maintained until the opening of

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SYSTEM

22.5 TRAVEL CIRCUIT switches the unloading spool in CLOSE side.

This section describes the following. 22.5.2 2-SPEED TRAVEL SOLENOID

COMMAND CIRCUIT AND AUTO 1st
(1) Travel forward pilot simultaneous operation circuit SPEED RETURN FUNCTION
(2) 2 speed travel solenoid command circuit and (1) Purpose:
auto 1-speed return function Change travel motor speed with switch.
(3) Travel main circuit (2) Principle:
(4) Travel motor function If the switch is turned, an electric signal is
issued. It excites the 2-speed travel solenoid
22.5.1 TRAVEL FORWARD PILOT which in turn converts the primary pilot pressure
SIMULTANEOUS OPERATION and the self pressure to a tilting angle of the
CIRCUIT variable displacement motor.
(1) Purpose: (3) Operation:
Light operating force and shockless operation If the rabbit marked switch on the gauge cluster
(2) Mechatronics: is pressed, the solenoid (SV-3) of the
proportional valve block (13) is excited and
1. If the travel lever with damping mechanism is changes the proportional valve. Then the
operated for travel right, left and forward solenoid command pressure is issued from port
motions, the secondary pilot proportional pressure A3, enters the P port of the travel motor (4),
comes out of the 3, 1 ports of P/V (10). The opens the oil passage to the 2nd speed select
higher of the pressures is selected, comes out of piston, and causes the motor to run in the 2nd
the 6, 5 ports and acts upon the low pressure speed tilting mode by its self pressure. However,
sensors (SE-9) (SE-10). when the main circuit pressure rises above 27.3
2. The pilot secondary pressure flows to PBr and MPa (3960 psi), the motor's self pressure pushes
PBL ports of the control valve (2), moves the the 2nd speed select piston back to the 1st
travel spool, and switches the main circuit. speed.
3. The low pressure sensor output voltage is input
into mechatro controller. The mechatro controller 22.5.3 TRAVEL MAIN CIRCUIT
performs signal processing and outputs current (1) Operation:
corresponding to the increase of flow rate to P1 The delivery oil from Pump A1 and A2 ports by
pump proportional valve (PSV-P1) and P2 pump changing the travel spool with the operation of
proportional valve (PSV-P2), and at the same time travel pilot flows in each A,B port on the left
the command current is output to P1 unloading side of travel motor (4) through C,D ports of
valve (PSV-D) and P2 unloading valve (PSV-B). swivel joint (8) from AL, AR ports of C/V, and
4. The secondary pressures output by P1 pump rotates the travel motor.
proportional valve (PSV-P1) and P2 pump
proportional valve (PSV-P2) exert on pump 22.5.4 TRAVEL MOTOR FUNCTION
regulator, actuating the pump on the delivery (1) Function:
flow rate increase side.
5. The secondary pressure delivered in P1 unloading 1. Prevents the motor from over running on a slope.
valve (PSV-D) and P2 unloading valve (PSV-B) 2. Check valve that prevents cavitation of the
is fed to PBp1, Pcb, PBp2 and PCa ports hydraulic motor.
provided in control valve (2). 3. Shockless relief valve and anti cavitation valve
The secondary pressure from proportional valve when inertia force stops.
which has exerted on PBp1 and PBp2 ports holds 4. High/Low 2 step speed change mechanism and
the by-pass cut spool on CLOSE side, like the auto 1st speed return at high load.
operation in the lever neutral position. 5. Travel parking brake.
The secondary pressure from proportional valve
which has exerted on PCb and PCa ports

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22.6 BUCKET CIRCUIT <When lever is set to neutral position>

In the event where the sensor does not receive
This section describes the following. signal for 4 seconds or more even though the
acceleration dial is set to MAX position, the
(1) Bucket digging pilot circuit engine speed should be raised to 1000 rpm.
(2) Auto accel operation <When lever is operated>
(3) Flow control in the work mode When the pressure 0.6 MPa (87 psi) is input to
low pressure sensor in STD specification (travel,
22.6.1 PILOT CIRCUIT FOR BUCKET bucket, swing, arm), proportional voltage from
DIGGING low pressure sensor inputs in mechatro
(1) Mechatronics: controller, and then the engine speed returns to
the dial set position corresponding to the lever
1. When the operation for bucket digging is operation.
performed, the pilot proportional secondary
pressure is delivered through port 1 of the right 22.6.3 STAND-BY CURRENT CONSTANT
pilot V (9), flows to PAc port, and acts on the CONTROL
low pressure sensor (SE-1), and at the same time (1) Principle:
the bucket spool is switched. When the engine speed is intermediate speed or
2. The voltage output by low pressure sensor lower, command current value to have the pump
inputs in mechatro controller. The mechatro delivery rate constant is output.
controller performs signal processing and outputs (2) Operation:
current corresponding to the increase of pump Even if the engine speed specified by acceleration
flow rate to pump proportional valves (PSV-P1) on potentiometer is low speed, as the delivery rate
the P1 pump sides, and at the same time the corresponds to the intermediate speed, the
command current is output to P1 unloading valve actuator moves earlier than the movement
(PSV-D). equivalent to the control lever angle rate in light
In the following pages, the relation of operation of load operation.
low pressure sensor to both the increase of pump
flow rate and unloading proportional valve is the
same. Therefore the explanation is omitted.
3. The secondary pressure output by P1 pump
proportional valve (PSV-P1) exerts on pump
regulator, actuating the pump onto the delivery
flow increase side.
4. The secondary pressure delivered in P1 unloading
valve (PSV-D) is led to PBp1 and PCb ports
provided in control valve (2).
The secondary pressure from proportional valve
which has exerted on PBp1 ports holds the
by-pass cut spool on CLOSE side, like the
operation in the lever neutral position.
The secondary pressure from proportional valve
which has exerted on PCb ports switches the
unloading spool in CLOSE side.

22.6.2 AUTO ACCELERATION OPERATION

(1) Principle:
Auto acceleration actuates according to signals
from low pressure sensor.
(2) Operation:

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22.7 BOOM CIRCUIT into tank circuit through boom spool from C/V (2)
Bb port.
This section describes the boom raise conflux
operation.

(1) Boom up pilot circuit

(2) Boom up 2 pumps conflux main circuit in C/V

22.7.1 BOOM RAISE PILOT CIRCUIT

(1) Operation:

1. If boom up operation is performed, the

secondary pilot proportional pressure from the
right pilot valve (9) gets out of port 3 and acts
upon the low pressure sensor (SE-3). At the
same time, the pressure acts upon the PAb and
PB1 ports.
2. The secondary pressure which enters the PAb
port of C/V (2) shifts the boom spool. The
secondary pressure which enters the PB1 port
shifts the boom conflux spool.

22.7.2 BOOM UP 2 PUMPS CONFLUX

MAIN CIRCUIT IN C/V
(1) Purpose:
Boom up speed up
(2) Principle:
Confluxing oil from 2 pumps
(3) Operation:

1. The oil delivered through A1 port of P1 pump

flows into C/V (2) P1 port, and branches into
bypass circuit and parallel circuit. Since P1
unloading valve is closed, the boom spool is
moved and bypass circuit is closed, the oil
opens load check valve LCb through parallel
circuit and flows into boom spool.
2. Then the oil passes through boom spool, opens
lock valve of boom lock valve CRb, and is led
into H side of boom cylinder through C/V (2) Ab
port.
3. Meanwhile, the oil delivered from the A2 port of
the P2 pump enters the P2 port of C/V (2) and
due to shut off the P2 unloading valve, the oil
then passes through the parallel circuit and via
the restrictor on the circumference of the boom
conflux spool, pushes the load check valve CCb
open from the boom conflux circuit, and combines
the oil delivered by the P1 pump internally.
4. The return oil from boom cylinder R side flows

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This section describes boom lower operation. 22.7.5 CONSTANT RECIRCULATION

(1) Boom down pilot circuit FUNCTION OF BOOM DOWN MAIN
(2) Prevention of natural fall by lock valve and CIRCUIT
actuation at lowering (1) Purpose:
(3) Constant recirculation function of boom down main Prevention of cavitation during boom lowering
circuit motion.
(2) Principle:
22.7.3 BOOM DOWN PILOT CIRCUIT The oil returning from the boom cylinder head (H)
(1) Operation: is recirculated to the rod (R).
(3) Operation:
1. If the boom down operation is performed, the When the oil is supplied to the boom cylinder
secondary pilot proportional pressure comes out of rod (R) side during boom down operation, the
porta4 of the right pilot valve (9) and acts upon boom moves faster than it should do in some
the low pressure sensor (SE-4). cases by the self weight of the attachment.
At the same time, the pressure acts upon the On that occasion, the circuit pressure on the rod
PBb port of C/V (2). (R) side is on the negative side.
2. The voltage output of the low pressure sensor The oil supplied to the boom cylinder rod (R)
(SE-4) enters the mechatro controller and flows into the A1 port of the P1 pump and the
processed in it. P1 port of C/V. The oil then passes through the
3. Then, the proportionl secondary pressure fed into boom spool and goes out of the Bb port.
C/V (2) PBb port and branches off in two lines On that occasion, the oil returning from the head
and switches boom spool and releases boom lock (H) goes through the recirculation path in the
valve. boom spool, pushes the check valve in the spool
open, is recirculated to the Bb port and is
22.7.4 PREVENTION OF NATURAL FALL supplied to the rod (R). When the (R) pressure
BY LOCK VALVE AND ACTUATION is larger than the head (H) pressure, the check
AT LOWERING valve in spool closes.
(1) Purpose: Thereupon, the recirculation is stopped.
Prevention of natural fall when the lever is neutral.
(2) Principle:
The oil is prevented from returning to the boom
spool by the poppet seat of the boom lock valve.
(3) Operation:
In the boom down action, the selector valve is
changed over by the secondary proportional
pressure of PBb port. Then the poppet spring
chamber of the lock valve CRb gets through the
drain line (Dr) and makes the lock valve poppet
open.
When the boom lever is at neutral, the drain line
on the lock valve CRb poppet spring chamber is
closed which causes the poppet closed.
The result is that the oil returning from the boom
cylinder head (H) to the boom spool is held and
makes the leak from the boom spool zero.
Thus the boom cylinder is prevented from
making a natural fall.

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22.8 SWING CIRCUIT 22.8.3 SWING MAIN CIRCUIT

(1) Operation:
This section describes the following operations. The oil delivered from the A2 port of the P2
(1) Swing left pilot circuit pump enters the P2 port of C/V (2) and is
(2) Swing auto parking brake branched off into the bypass line and the parallel
(3) Swing main circuit circuit. However, since the bypass line is closed
(4) Swing motor circuit as the swing spool is shifted, the oil pushes the
load check valve LCs open through the parallel
22.8.1 PILOT CIRCUIT FOR LEFT SWING circuit, enters the B port of the swing motor via
(1) Operation: the As port of C/V (2), and rotates the swing
motor counterclockwise.
1. When the left swing operation is performed, the
pilot proportional secondary pressure is delivered 22.8.4 SWING MOTOR CIRCUIT
through port (5) of left pilot V (9), and the (1) Anti cavitation circuit at swing deceleration
secondary pressure acts on PAs port of C/V (2), (2) Shockless relief valve that prevents the swing
and simultaneously flows out from Pss port of motor from being reversed.
C/V and acts on low pressure sensor (SE-5).
2. The voltage output by the low pressure sensor is
input in the mechatro controller, and is
signal-processed.
3. Then, the secondary pressure led into PAs port of
C/V (2) switches the swing spool.

22.8.2 SWING AUTO PARKING BRAKE

(1) Purpose:
Swing lock in neutral position and parking
(2) Principle:
Release mechanical brake only when required to
operate swing and arm in.
(3) Operation:

1. The swing parking system excites the swing

parking SOL (SV-1) usually if the key switch is
turned on and works by the action of the
mechanical brake.
2. The mechanical brake is released if the swing
parking solenoid is de-excited only when the
secondary operating pressure in the swing and
arm in actions acts upon any of the low
pressure sensors (SE-5, 7).
3. The swing parking solenoid (SV-1) is excited five
seconds after the pressure of the swing low
pressure sensors (SE-5) is reduced to zero. In
the case of arm in operation, the swing parking
solenoid (SV-1) is excited the moment the
pressure of the arm in low pressure sensor
(SE-7) is reduced to zero. This causes the
mechanical brake to operate.

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22.9 ARM CIRCUIT section and travel right tandem path. Then
because arm 2 spool was switched, the delivery
This section describes the following operations. oil opens load check valve LCAT2, goes through
arm 2 spool, and confluences with P2 pump
(1) Arm in, light-load operating pilot circuit delivery oil in the valve section, and then is
(2) Arm in, light-load variable normal recirculation flowed into arm cylinder head (H) side through Aa
main circuit / internal conflux main circuit port of C/V (2).
3. The return oil from arm cylinder (R) side flows in
22.9.1 ARM IN, LIGHT-LOAD Ba port of C/V (2) and passes through the Ba
OPERATING PILOT CIRCUIT port because the arm lock valve CRa is open,
(1) Purpose: and is flowed into arm 2 spool through arm 1
Speed-up and Anticavitation when the arm is at spool.
light loaded. 4. Because arm 2 spool is switched to normal
(2) Principle: recirculation position, causing restriction of
The oil returning from the arm cylinder rod (R) is passage to tank, the return oil from arm cylinder
recirculated variably to the head (H) at arm 2 (R) side flows into arm cylinder (H) side.
spool in C/V. -Because, at light load, the pressure in cylinder
(3) Operation: rod (R) side is higher than that in the head (H)
side, it opens the check valve housed-in arm 2
1. When the arm in operation is performed, the spool and is recirculated in the head (H) side,
secondary pilot proportional pressure gets out of resulting in the speed up of arm-in operation at
port 7 of the left pilot valve (9) and acts upon the light load.
low pressure sensor (SE-7). 5. Cavitations prevention control in arm-in operation
At the same time, the pressure is branched off Command current is output to arm 2 solenoid
in two flows, acts upon the PAa1 port and the proportional valve by signal processing of E/G
PLc2 port, changes over the arm spool and the speed and arm-in pilot pressure, accordingly the
arm lock valve CRa. releases. arm 2 spool is switched to neutral (cavitations
2. The output voltage by the low pressure sensor is prevention) position, resulting in cavitations
input into mechatro controller, and is pilot prevention.
signal-processed, and is output to P1, P2 pump
proportional valve (PSV-P1), (PSV-P2) and arm 2 Position of arm 2 spool
inverse proportional valve (PSV-A).
3. The secondary pressure from pilot proportional
valve, which is reduced by arm 2 inverse
proportional valve (PSV-A) switches arm 2 spool.

22.9.2 ARM-IN, LIGHT-LOAD VARIABLE

NORMAL RECIRCULATION,
INTERNAL CONFLUX MAIN CIRCUIT
(1) Operation:
Reference:
1. The P2 pump delivery oil flows in travel left In light-load arm-in operation (normal recirculation,
section through P2 port of C/V (2) and is conflux), when the attachment to which the circuit in
branched off in by-pass circuit and parallel P1 pump side is applied is operated, the meter-in
circuit, but because arm 1 spool is switched, the path of arm 2 spool is closed, resulting in single flow
delivery oil which goes through parallel circuit operation.
opens load check valve LCa and is flowed into
arm 1 spool.
2. On the other hand, P1 pump delivery oil flows in
P1 port of C/V (2), and the flows in travel straight

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 ［22. HYDRAULIC
HYDRAULIC SYSTEM］
SYSTEM

This section describes the following operations. valve, but because the arm lock valve is open,
the return oil goes through arm lock valve CRa
(3) Arm in, heavy load operating pilot circuit and flows in arm 2 spool.
(recirculation cut) 4. The return oil returns directly into tank circuit
(4) Arm in, heavy load operating sequence confluxed because arm 2 spool is switched to recirculation
main circuit cut position.

22.9.3 ARM IN, HEAVY LOAD Position of arm 2 spool

OPERATING PILOT CIRCUIT
(1) Operation:

1. In arm-in operation, when the heavy loading is

applied to arm and the P2 pump pressure
increases to the set pressure, the voltage output
by P2 pump pressure sensor (SE-23) is converted
to signal (signal processing) by mechatro
controller, consequently the current of arm 2
solenoid proportional valve is controlled according
to the load pressure and the arm variable
recirculation is cut.
When the recirculation is cut, internal confluence
is held similarly to that in light load operation.
2. Left pilot valve actuation due to arm-in operation
is equivalent to that at light load operation.

22.9.4 ARM IN, HEAVY LOAD

OPERATING RECIRCULATION CUT
MAIN CIRCUIT
(1) Purpose:
Power up for arm in operation
(2) Principle:
Cut the recirculation and reduce rod pressure.
(3) Operation:

1. P2 pump delivery oil flows in the travel left

section through P2 port of C/V (2) and branched
off in by-pass circuit and parallel circuit.
Consequently the arm spool is switched and
pushes and opens load check valve LCa through
parallel circuit, and flows in the arm spool.
2. On the other hand, P1 pump delivery oil flows in
P1 port of C/V (2), and flow in travel right
tandem passage through travel straight section.
Then because arm 2 spool was switched, the
delivery oil opens load check valve LCAT2, and
confluences with P2 pump delivery oil in the valve
section, and is flowed into arm cylinder head (H)
side through Aa port of C/V(2).
3. The return oil from arm cylinder (R) side flows in
Ba port of C/V(2) and is flowed to arm lock

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This section describes the following operations. weight of the arm and bucket.
(5) Arm out pilot circuit (2) Principle:
(6) Arm out 2 pumps conflux main circuit Complete seat of the return circuit against the
(7) Natural fall protection with arm lock valve arm spool of the arm cylinder (R) side circuit.
(3) Operation:
22.9.5 ARM OUT PILOT CIRCUIT
(1) Operation: 1. When the secondary pressure for arm operation
disappears and the arm cylinder stops, the
1. When the arm out operation is performed, the pressure on the rod (R) side passes through the
secondary pilot proportional pressure gets out of selector of the lock valve from the Ba port of C/V
port 8 of the left pilot valve (9), and acts upon (2), acts the back pressure on the lock valve CRa
the low pressure sensor (SE-8). At the same and seats the lock valve.
time, the oil is branched off in two flows and act 2. Since the oil flow into the arm spool from the
upon the PBa1 and PBa2 ports of C/V (2). lock valve is shut off completely, natural fall of
2. The operating proportional secondary pressure the arm due to oil leaks through the arm spool is
flowed in Pba1 port of C/V (2) switches the arm prevented.
1 spool.
3. Then, the operating secondary pressure flowed in
PBa2 port of C/V (2) switches the arm 2 spool
valve.

22.9.6 ARM OUT 2 PUMPS CONFLUX

MAIN CIRCUIT
(1) Purpose:
Arm out operation speed up.
(2) Principle:
The oil delivered by the P1 pump is confluxed
with that delivered by the P2 pump in C/V (2).
(3) Operation:

1. P1 pump delivery oil opens load check valve

(LCAT2) by switching arm 2 spool and confluxes
with P2 pump delivery oil just short of the arm
lock valve.
2. And, P2 pump delivery oil flows through arm 1
spool and confluences with P1 delivery oil,
opens lock valve of arm lock valve CRa with
free flow and is flowed into arm cylinder rod (R)
side through Ba port of C/V(2).
3. On the other hand, the return oil from arm
cylinder (H) side flows in Aa port, and returns into
tank circuit through arm 1 spool and arm 2 spool.
The return line which does not pass through
boost check valve is used for this return circuit
to reduce the pressure loss.

22.9.7 NATURAL FALL PROTECTION

WITH ARM LOCK VALVE
(1) Purpose:
To prevent the arm from falling naturally by the

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22.10 COMBINED CIRCUIT P2 pump flows in left travel spool to travel

leftward.
This section describes only the difference in combined The delivery oil flowed into travel straight spool of
operation. P2 pump flows in right travel spool because the
travel straight spool is shifted and exerts on the
(1) Boom up / travel, pilot circuit right travel operation.
(2) Boom up / travel, main circit (In travel straight operation, P2 pump delivery oil
exerts on travel operation.)
22.10.1 BOOM UP / TRAVEL, PILOT 4. However, a portion of the flow is led to the
CIRCUIT travel straight spool notch restriction. The speed
(1) Operation: of attachments like travel, boom, etc. is adjusted
<Operation: Different point of pilot circuit from by the circuit of restriction.
independent operation >

1. The mechatro controller outputs command current

to travel straight solenoid proportional valve
(PSV-C) after signal processing, and the solenoid
valve outputs secondary pressure and acts on
PTb port of C/V (2).
2. Then the pressure of PTb port switches the travel
straight valve.

22.10.2 BOOM UP / TRAVEL, MAIN

CIRCUIT
(1) Purpose:
To insure straight travel movement during travel
operation even if the attachment is operated.
(2) Principle:
The travel action and the attachment action are
actuated by separate pumps.
(3) Operation:

1. P1 pump delivery oil flows through P1 port of

C/V(2) and branches off in P1 parallel circuit and
travel straight spool.
P2 pump delivery oil flows through P2 port of
C/V(2) and branches off in P2 tandem circuit
and travel straight spool.
2. The delivery oil flowed into P1 parallel circuit of
P1 pump opens check valve CT1 and LCb and
flows in boom spool, which exerts on boom up
operation.
The delivery oil flowed into travel straight spool of
P1 pump opens check valve CT2 because the
travel straight spool is shifted, and flows in boom
conflux spool and exerts on boom up operation
with the internal oil conflux.
(In travel straight operation, P1 pump delivery oil
exerts on swing operation of attachment.)
3. The delivery oil flowed into P2 tandem circuit of

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In this section, the independent operation is omitted This operation is called "Swing Priority Circuit".
and describes difference in combined operation.
(3) Swing / Arm in light load, pilot circuit Position of arm 2 spool
(4) Swing / Arm in, swing priority main circuit

22.10.3 SWING / ARM IN LIGHT LOAD,

PILOT CIRCUIT
(1) Operation:

1. On operating swing (left) and arm in motions

simultaneously, mechatro controller outputs
command current to travel straight solenoid
proportional valve (PSV-C) and arm 2 solenoid
inverse proportional valve (PSV-A) according to
signal processing, and this proportional valve
outputs secondary pressure, which acts on PTb
port and PAa2 port of C/V(2).
2. PTb port pressure switches the travel straight
spool 2 steps, and the PAa2 port pressure
switches the arm 2 spool to the forced
recirculation position.

22.10.4 SWING / ARM IN, SWING

PRIORITY MAIN CIRCUIT
(1) Purpose:
Stable swing speed.
(2) Principle:
Raise the oil pressure flowing to arm cylinder,
and give a priority of the delivery of P2 pump to
swing operation.
(3) Operation:

1. The swing main circuit operates with P2 pump

flow. But on P2 pump circuit side, the flow goes
to the swing circuit and arm circuit
simultaneously because the swing circuit and
arm circuit are parallel. Then since the return oil
from arm cylinder rod (R) side is restricted in the
arm 2 spool because the arm 2 spool is switched
to forced recirculation position, the pressure of
return oil is raised, causing the rise of circuit
pressure on the arm cylinder head (H) side.
2. At the same time meter-in of arm 2 spool closes
and arm in conflux is therefore cancelled, and
delivery oil from P2 pump and P1 pump are
combined in the parallel circuit on P2 pump side
because the travel straight spool was switched.
The conflux oil of P1 and P2 delivery oil in high
pressure flows in swing side taking priority over
all others.

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HYDRAULIC SYSTEM ［22. HYDRAULIC SYSTEM］

22.2.1 STANDARD
A. SK140LC-8, SK130-8

22

22-5
［22. HYDRAULIC
HYDRAULIC SYSTEM］
SYSTEM

22.11 PRESSURE DRAINING 2. Unloading proportional valves (PSV-D, PSV-B)

output secondary pressure and the secondary
This section describes the following operations. pressure flows in PCb, PCa ports of C/V(2) and
switches the P1, P2 unloading valves to OPEN
(1) Pressure drain (releasing) pilot circuit position.
(2) Pressure drain (releasing) main circuit
22.11.2 PRESSURE RELEASE MAIN
22.11.1 PRESSURE RELIEVING PILOT CIRCUIT
CIRCUIT
(1) Purpose:
To release the pressure in main circuit for piping
repair works. When the hydraulic pressure releasing is performed,
(2) Principle: make sure to place bucket on the ground.
After the mode is switched to "Pressure Relief
Mode" with switch on gauge cluster, mechatro (1) Operation:
controller outputs the following commands. When the operating lever is shifted to neutral
during engine running, "DRAINING HYD.
1. Minimum tilting command value to pump PRESS." is displayed on the gauge cluster while
proportional valve (PSV-P1, PSV-P2). the mode switch is changed to pressure relieving
2. Output "Pressure relief control speed command mode. In this time the intermittent buzzer sounds
value" at ECU. (Electric system) continuously. When right and left operating levers
3. Stand-by command value to P1, P2 unloading are operated 4 or 5 times to their full stroke,
proportional valves pressure is relieved.
After draining pressure is completed, turn off the
How to switch to "Pressure release mode" starter key and buzzer sound stops. If the pump
1. Select the service diagnosis mode. pressure is determined to be more than 1 MPa
(Keeping pressing of the "BUZZER STOP (145 psi) by the output value of the high pressure
SWITCH" on gauge cluster, turn the starter key sensor or the high pressure sensors (SE-22,23)
on.) are broken, "FAIL DRAIN HYD. PRESS" is
2. Select the service adjustment mode 1. displayed and the buzzer sounds continuously. In
(Under the condition that "Screen No.1" of that case, also the buzzer is not stopped unless
"Service diagnosis mode 1" is indicated, keeping the engine key is turned to OFF. Repeat the
pressing of the "BUZZER STOP SWITCH", press pressure releasing procedure once again.
the "SELECT SWITCH" 3 times. When (2) Hydraulics :
"LANGUAGE/LOGO", "ADJUSTING MODE 1" Unload spool is switched to open position, and
and "PRESET BY FACTORY" are displayed, the oil delivered by each pump is unloaded to the
press [▲] or [▼] switch, and highlight tank passage.
"ADJUSTING MODE 1", and then press "Selector If the spools are switched by pilot operation, the
Switch" again.) remaining pressure from the actuators may be
3. When "ADJUSTING MODE 1" screen is displayed, relieved to the tank circuit, i.e. the main circuit
press [▲] or [▼] switch, and "DRAIN HYD. pressure may be released.
OFF" screen appears.
4. Press "Selector Switch" and highlight "OFF", and
press [▲] switch to change to "DRAIN HYD. ON",
and then press "Selector Switch" again.

(3) Operation:

1. Pump proportional valve reduces the pump flow

rate to the minimum.

22-30
HYDRAULIC SYSTEM ［22. HYDRAULIC SYSTEM］

22

PRESSURE DRAIN (RELEASE) CIRCUIT : At pressure release mode.

22-31
ELECTRICAL SYSTEM ［23. ELECTRICAL SYSTEM］

23.1 ELECTRIC CIRCUIT DIAGRAM

23

23-3
ELECTRICAL SYSTEM
［23. ELECTRICAL SYSTEM］

23-4
ELECTRICAL SYSTEM ［23. ELECTRICAL SYSTEM］

23

23-5
 ［23. ELECTRICAL
ELECTRICAL SYSTEM］
SYSTEM

23-6
ELECTRICAL SYSTEM ［23. ELECTRICAL SYSTEM］

23

23-7
［23. ELECTRICAL
ELECTRICAL SYSTEM］
SYSTEM

23-8
ELECTRICAL SYSTEM ［23. ELECTRICAL SYSTEM］

23

23-9
 ［23. ELECTRICAL
ELECTRICAL SYSTEM］
SYSTEM

23.2 ELECTRICAL EQUIPMENT &

HARNESS

23-10
ELECTRICAL SYSTEM ［23. ELECTRICAL SYSTEM］

23.3 HARNESS

23.3.1 HARNESS LIST

23

23-11
ELECTRICAL SYSTEM
［23. ELECTRICAL SYSTEM］

23.3.2 INSTRUMENT PANEL ASSY

23-12
ELECTRICAL SYSTEM ［23. ELECTRICAL SYSTEM］

23.3.3 CONTROLLER INSTALL

23

23-13
 ［23. ELECTRICAL
ELECTRICAL SYSTEM］
SYSTEM

23.3.4 OPERATOR'S CONTROL (SWITCH

INSTALL)

23-14
ELECTRICAL SYSTEM ［23. ELECTRICAL SYSTEM］

23.3.5 UPPER ELECTRIC ASSY

23

23-15
 ［23. ELECTRICAL
ELECTRICAL SYSTEM］
SYSTEM

23.3.6 UPPER HARNESS ASSY (1/6)

23-16
ELECTRICAL SYSTEM ［23. ELECTRICAL SYSTEM］

23.3.6 UPPER HARNESS ASSY (2/6)

23

23-17
 ［23. ELECTRICAL
ELECTRICAL SYSTEM］
SYSTEM

23.3.6 UPPER HARNESS ASSY (3/6)

23-18
ELECTRICAL SYSTEM ［23. ELECTRICAL SYSTEM］

23.3.6 UPPER HARNESS ASSY (4/6)

23

23-19
［23. ELECTRICAL
ELECTRICAL SYSTEM］
SYSTEM

23.3.6 UPPER HARNESS ASSY (5/6)

23-20
ELECTRICAL SYSTEM ［23. ELECTRICAL SYSTEM］

23.3.6 UPPER HARNESS ASSY (6/6)

23

23-21
ELECTRICAL SYSTEM ［23. ELECTRICAL SYSTEM］

23.3.7 UPPER HARNESS ASSY (FLOOR)

(1/3)

23

23-33
 ［23. ELECTRICAL
ELECTRICAL SYSTEM］
SYSTEM

23.3.7 UPPER HARNESS ASSY (FLOOR) (2/3)

23-34
ELECTRICAL SYSTEM ［23. ELECTRICAL SYSTEM］

23.3.7 UPPER HARNESS ASSY (FLOOR) (3/3)

23

23-35
 ［23. ELECTRICAL
ELECTRICAL SYSTEM］
SYSTEM

23.3.8 ENGINE HARNESS ASSY

23.3.8.4 ENGINE SUB CABLE : YY16E01010P1

23-42
ELECTRICAL SYSTEM ［23. ELECTRICAL SYSTEM］

23.3.9 CAB INSTALL

23.3.9.1-1 CAB ASSY : YN02C00131F1

23

23-43
 ［23. ELECTRICAL
ELECTRICAL SYSTEM］
SYSTEM

23.3.9.1-49 HARNESS : YN02C03098P1

23.3.10 WASHER TANK ASSY

23-44
ELECTRICAL SYSTEM ［23. ELECTRICAL SYSTEM］

23.3.11 CAB HARNESS ASSY

23

23-45
HYDRAULIC COMPONENTS ASSY ［24. COMPONENTS SYSTEM］

24.1 HYDRAULIC COMPONENTS

24.1.1 HYDRAULIC PUMP - REGULATOR

24.1.1.1 SUMMARY
(1) Outside view and Hydraulic port

24

Hydraulic pump - regulator

24-3
 ［24. COMPONENTS
HYDRAULIC SYSTEM］ASSY
COMPONENTS
(2) Hydraulic circuit diagram

Hydraulic circuit diagram of pump

(3) Specifications

24-4
HYDRAULIC COMPONENTS ASSY ［24. COMPONENTS SYSTEM］

24.1.1.2 HYDRAULIC PUMP

24.1.1.2.1 CONSTRUCTION
(1) Main pump

24

24-5
 ［24. COMPONENTS
HYDRAULIC SYSTEM］ASSY
COMPONENTS
(2) Gear pump (For pilot)

No. Parts Q'TY No. Parts Q'TY

307 Poppet 1 433 Flange socket; M8X40 2
308 Seat 1 434 Flange socket; M8X55 2
309 Ring 1 435 Flange socket; M8X20 4
310 Spring 1 466 VP plug ; PF1/4 1
311 Adjust screw 1 700 Ring 1
312 Lock nut ; M14X1.5 1 710 O-ring 1
351 Gear case 1 725 O-ring ; 1B P11 1
353 Drive gear 1 732 O-ring ; 1B P16 1
354 Driven gear 1 850 Locking ring 1
355 Filter 1 887 Pin 2
361 Front case 1

24-6
HYDRAULIC COMPONENTS ASSY ［24. COMPONENTS SYSTEM］

(3) PTO gear case (OPT.)

No. Parts Q'TY No. Parts Q'TY

115 Idle shaft 1 435 Flange socket; M10X20 4
117 2nd gear 1 468 VP plug; PF3/4 1
118 3rd gear 1 710 O-ring; 1B G80 1
125 Ball bearing 2 711 O-ring; 1B G85 1
126 Roller bearing 1 728 O-ring; 1B P24 1
128 Bearing spacer 2 825 Snap ring 1
262 Cover 2 826 Snap ring 1
326 Gear case 1 885 Sprig pin 1
414 Capscrew; M10X20 4 886 Pin 2

24

24-7
［24. COMPONENTS SYSTEM］

24.1.1.2.2 OPERATION
The pump assy is equipped with two pumps
arranged on the same axis that are connected
with gear (116) and distribute the rotating power
to the gear trains on a different axis. Thus the
engine rotation is transmitted to front shaft (111)
that drives the two pumps and, at the same
time, drives the auxiliary pump (OPT) arranged
on another shaft.
The pump assy consists largely of the rotary
group, the main part of the pump that makes
rotary on; the swash plate group that changes
the delivery rate; the valve block group that
selects between oil suction and delivery and the
PTO group (OPT) that transmits the drive power
to the auxiliary pump.

Construction of hydraulic pump

(1) Rotary group

The rotary group consists of shaft(111) (113), cylinder block (141), piston (151), shoe (152), plate
(153), spherical bushing (156), bearing spacer (127), and cylinder spring (157).
The shaft is supported by bearings (123) and (124) at its both ends. The shoe, which is caulked to
the piston, forms a spherical joint and relieves it of thrust force that is generated by load pressure.
Further, the piston is provided with a pocket so it moves lightly on shoe plate (211), taking hydraulic
balance.
The sub group of the piston-shoe is pressed against the shoe plate by the cylinder spring, via the
retainer plate and the spherical bushing, so that it moves smoothly over the shoe plate. The cylinder
block (141) is also pressed against valve plate (314) by the action of cylinder spring (157).

Rotary group

24-8
HYDRAULIC COMPONENTS ASSY ［24. COMPONENTS SYSTEM］

(2) Swash plate group

The swash plate group consists of swash plate
(212), shoe plate (211), swash plate support
(251), lock pin (255), set spring (256), tilting
bushing (214), tilting pin (531), and servo piston
(532). The swash plate is the cylindrical part
that is formed on the opposite side of the
shoe sliding surface and is supported by the
swash plate support.
The hydraulic force controlled by the regulator
flows into the hydraulic chamber that is
provided on both sides of the servo piston. This
moves the servo piston to the right and left.
The result is that the swash plate swings on Swash plate group
the swash plate support via the spherical part
of the tilting pin and changes the tilting angle
(a).

(3) Valve block group

The valve block group consists of valve block
(312), valve plates (313 or 314), and spring
pin (886). The valve plates having two
crescent-shaped ports are installed to valve
block (312) to feed oil and recycle it from
cylinder block (141). The oil switched over by
the valve plate is connected with the external
pipe by way of the valve block.

Valve block group

24

24-9
 ［24. COMPONENTS
HYDRAULIC SYSTEM］ASSY
COMPONENTS
(4) PTO group (OPT)
The PTO group is composed of 1st gear
(116), 2nd gear (117) and 3rd gear (118). The
2nd and the 3rd gear are supported by
bearings (125) and (126) respectively and
installed to the valve block.
Now, if the shaft is driven by the engine, the
cylinder block rotates together by the spline
linkage. If the swash plate is inclined, the
pistons arranged in the cylinder block make
reciprocating motion with respect to the
cylinder while rotating with the cylinder block.
If we keep an eye on a single piston, it
makes a motion away from the valve plate (oil
suction process) in the first 180?and a motion
toward the valve plate (oil delivery process) in PTO group
the remaining 180?. If the swash plate is not
inclined (zero tilting angle), the piston does not
stroke i.e. delivers no oil.
The shaft rotation is taken up by the 1st gear
(116) and transmitted to the 2nd gear (117) and
the 3rd gear (118), in that order, to drive the
gear pump that is linked to the 3rd gear.

24-10
 ［24. COMPONENTS
HYDRAULIC SYSTEM］ASSY
COMPONENTS
24.1.1.3 REGULATOR
24.1.1.3.1 CONSTRUCTION

24-12
HYDRAULIC COMPONENTS ASSY ［24. COMPONENTS SYSTEM］

24

24-13
 ［24. COMPONENTS
HYDRAULIC SYSTEM］ASSY
COMPONENTS
24.1.1.3.2 OPERATION
(1) Control function
Control function ...... Electric flow control.
-Positive flow control.

(2) Summary
The regulator KR76-0E13-V for the in-line type axial piston pump K7V series is composed of the
control mechanism as mentioned below:

1. Electric flow control and positive flow control

The tilting angle of the pump (delivery rate) is controlled by controlling the current command
value of the solenoid proportional reducing valve attached to the regulator. The regulator makes
positive flow control (positive control) that increases the delivery rate as the secondary pressure
of the solenoid proportional reducing valve rises. Since this function permits the output power of
the pump to be varied, it is possible to attain optimum power according to the operating
condition. Also, since the pump delivers only the necessary oil flow, the machine does not
consume excessive power.

24-14
HYDRAULIC COMPONENTS ASSY ［24. COMPONENTS SYSTEM］

(3) Explanation of operation

1. 1. Flow rate electrical control
The pump delivery rate is controlled
according to the command current value
corresponding to the movement of control
devices. This relation is shown in right
figure.
2. Flow increasing action
As the command current I rises, the
secondary pressure of solenoid
proportional reducing valve (079) increases.
This causes spool (652) to move via pilot
piston (643) and stops where the hydraulic
pressure pushing the spool rightwards
balances with the action of pilot spring
(646).

If the spool (652) moves, port CL opens to the tank port. This causes the pressure of the large
diameter part of servo piston (532) to go away. This causes the servo piston (532) to the left by
delivery pressure P1 of the small diameter part, resulting in an increase in the tilting angle.
Feedback lever(611) is linked with the servo piston and sleeve(651). As the servo piston moves to
the left, the feedback lever rotates on point A which causes the sleeve to the right. As the servo
piston moves to the right, the feedback lever rotates on point A to move the sleeve to the right. The
result is that the opening of the spool sleeve begins to close gradually and the servo piston settles
down when the opening of the spool sleeve closes completely.

3. Flow decrease function

As the command current I decreases, the secondary pressure of the solenoid proportional valve
decreases. This causes the spool to move to the left.
When the spool(652) has moved, delivery pressure P1 reaches port CL via spool and is admitted
to the large diameter chamber of the servo piston. Delivery pressure P1 is admitted to the small
diameter part of the servo piston at all times. The servo piston moves rightward by areal
difference to decrease tilting angle. As the servo piston moves to the right, the feedback lever
rotates on point A to move the sleeve to the left. The sleeve keeps moving till the opening of
the spool sleeve closes and settles down when the spool sleeve closes completely.

24

24-15
［24. COMPONENTS
HYDRAULIC SYSTEM］ASSY
COMPONENTS

Regulator operation

24-16
HYDRAULIC COMPONENTS ASSY ［24. COMPONENTS SYSTEM］

24.1.1.3.3 ADJUSTING THE REGULATOR

The regulator may be adjusted in terms of maximum flow, minimum flow, horsepower (at emergency
mode control) control characteristics, flow control characteristics using the adjust screw.

(1) Adjusting the maximum flow (See Fig. "24.1.1.2 HYDRAULIC PUMP")
Adjust the maximum flow by loosening nut (808) and by tightening set screw (954) (or loosening it).
Tightening set screw (954) decreases the delivery rate, as indicated in right Fig.
Only the maximum flow varies, but other control characteristics remain unchanged.

Adjusting the max. delivery flow

(2) Adjusting the minimum flow (See Fig. "24.1.1.2 HYDRAULIC PUMP")
Adjust the minimum flow by loosening nut (808) and by tightening socket screw (953) (or loosening
it). Tightening socket screw increases the delivery rate, as indicated in right Fig.
Other control characteristics remain unchanged in the same way as maximum flow adjustment, care
should be used of the fact that overtightening may increase a required power at the maximum
delivery pressure (at relieving action).

Adjusting the min. delivery flow

24

24-17
［24. COMPONENTS
HYDRAULIC SYSTEM］ASSY
COMPONENTS
(3) Adjusting the flow control characteristics (See Fig. "24.1.1.3 REGULATOR")
Adjust them by loosening nut (801) and socket bolt (924) (or loosening it). Socket bolt causes the
control chart to move to the right as shown in right Fig.

Adjusting the flow control characteristics

24-18
HYDRAULIC COMPONENTS ASSY ［24. COMPONENTS SYSTEM］

24.1.1.3.4CAUSES OF FAULT RESULTING FROM REGULATOR

When trouble due to this regulator occurs, disassemble and inspect it referring to "Chapter UPPER
STRUCTURE"

(1) When the engine is overloaded,

Load every unit of pump, and check on pumps on the right and left sides for possible damages. When
pumps on both sides are failed, check on them for the following failures 1), 2). When pump on the
one side is failed, start checking from para. 3).

1. Check that the power shift command current I is normal.

2. The power shift pressure is high.
-Check the dither of amp.
-Replace solenoid proportional reducing valve.
3. Stick of spool (652) and sleeve (651)
-Disassemble and clean it.
4. Stick of pilot piston (643)
-Disassemble and clean it.

(2) The max. flow rate is not delivered.

1. Check that secondary pressure of solenoid proportional reducing valve is normal.
2. Stick of pilot piston (643)
-Disassemble and clean it.
3. Stick of spool (652) and sleeve (651)
-Disassemble and clean it.

Note : When the damage of part is severe, replace the part with new one.

24

24-19
［24. COMPONENTS
HYDRAULIC SYSTEM］ASSY
COMPONENTS
24.1.1.4 CONTROL CURVE OF PUMP

24-20
 ［24. COMPONENTS
HYDRAULIC SYSTEM］
COMPONENTS ASSY

24.1.2 CONTROL VALVE

24.1.2.1 SPECIFICATIONS
24.1.2.1.1 OUTSIDE VIEW

Outside view

24-22
［24. COMPONENTS
HYDRAULIC SYSTEM］ASSY
COMPONENTS
24.1.2.1.3SPECIFICATIONS
Item Specifications
Model KMX13YD/B44004
Maximum flow rate [L/min (gal/min)] 130 (34) X 2
Maximum set pressure [MPa (psi)] 37.8 (5480) (Pump port)/ 39.7 (5760) (Actuator port)
Main relief valve set pressure [MPa (psi)] Std 34.3 (4970) [at 30 X 2L/min (8 X 2gal/min)]
Overload relief valve set pressure [MPa (psi)] 37.8 (5480) [at 30L/min (8gal/min)]

24-24
HYDRAULIC COMPONENTS ASSY ［24. COMPONENTS SYSTEM］

24.1.2.2 CONSTRUCTION AND OPERATION

24.1.2.2.1 CONSTRUCTION
(1) Control valve

24

Section (1/6)

24-25
 ［24. COMPONENTS
HYDRAULIC SYSTEM］ASSY
COMPONENTS

Section (2/6)

24-26
HYDRAULIC COMPONENTS ASSY ［24. COMPONENTS SYSTEM］

24

Section (3/6)

24-27
［24. COMPONENTS
HYDRAULIC SYSTEM］ASSY
COMPONENTS

Section (4/6)

24-28
HYDRAULIC COMPONENTS ASSY ［24. COMPONENTS SYSTEM］

24

Section (5/6)

24-29
［24. COMPONENTS
HYDRAULIC SYSTEM］ASSY
COMPONENTS

Section (6/6)

24-30
［24. COMPONENTS
HYDRAULIC SYSTEM］ASSY
COMPONENTS
(2) Main relief valve (601)

Main relief valve

Tightening torque Tightening torque

No. NAME Q'TY No. NAME Q'TY
N-m (lbf-ft) N-m (lbf-ft)
69~78 (51~58) 103 Plug ; M27 1 541 Seat 1
121 C-ring 1 561 O-ring 1
122 Spacer 1 562 Back up ring 1
123 C-ring 1 611 Poppet 1
124 Filter stopper 1 612 Spring seat 1
125 Filter 1 621 Spring 1
163 O-ring 1 651 Adjust screw 1
512 Plunger 1 661 O-ring 1
521 Spring 1 28~31 (21~23) 671 Lock nut ; M14 1

24-32
HYDRAULIC COMPONENTS ASSY ［24. COMPONENTS SYSTEM］

(3) Over load relief valve (602,606)

Over load relief valve

Tightening torque Tightening torque

No. NAME Q'TY No. NAME Q'TY
N-m (lbf-ft) N-m (lbf-ft)
69 to 78 (51 to 58) 101 Body; M27 1 541 Seat 1
69 to 78 (51 to 58) 102 Plug; M27 1 561 O-ring 1
161 O-ring 1 562 Backup ring 1
162 O-ring 1 563 O-ring 1
123 C-ring 1 564 Backup ring 1
124 Filter stopper 1 611 Poppet 1
125 Filter 1 612 Spring seat 1
301 Piston 1 621 Spring 1
511 Plunger 1 651 Adjust screw 1
521 Spring 1 661 O-ring 1
522 Spring 1 28 to 31 (21 to 23) 671 Lock nut; M14 1

24

24-33
 ［24. COMPONENTS
HYDRAULIC SYSTEM］ASSY
COMPONENTS
(4) Arm 2 spool (308)

Arm 2 spool

Tightening
Tightening torque
torque No. NAME Q'TY No. NAME Q'TY
N-m (lbf-ft)
N-m (lbf-ft)
308 Spool 1 18~20 (13~15) Loctite #638 350 Plug 1
317 Plunger 2 18~20 (13~15) Loctite #638 351 Plug 1
340 Spring 2 361 O-ring 2
371 Buckup ring 2

(5) Boom spool (301)

Boom spool

Tightening
Tightening torque
torque No. NAME Q'TY No. NAME Q'TY
N-m (lbf-ft)
N-m (lbf-ft)
301 Spool 1 18~20 (13~15) Loctite #638 350 Plug 1
317 Plunger 1 361 O-ring 1
340 Spring 1 371 Buckup ring 1

24-34
HYDRAULIC COMPONENTS ASSY ［24. COMPONENTS SYSTEM］

(6) Lock valve selector (211)

Lock valve selector

Tightening torque Tightening torque

No. NAME Q'TY No. NAME Q'TY
N-m (lbf-ft) N-m (lbf-ft)
101 Casing 1 10 to 14 (7.4 to 10.3) 171 Socket bolt 3
161 O-ring 4 49 to 59 (36 to 44) 201 Plug 1
164 O-ring 1 321 Spring 1
166 O-ring 1 511 Spool 1
167 O-ring 1 541 Sleeve 1

24

24-35
［24. COMPONENTS
HYDRAULIC SYSTEM］ASSY
COMPONENTS
(7) Bypass cut valve (605)

Bypass cut valve

Tightening torque Tightening torque

No. NAME Q'TY No. NAME Q'TY
N-m (lbf-ft) N-m (lbf-ft)
98 to 120 (72 to 89) 101 Plug 1 301 Plunger 1
102 O-ring 1 302 Spring 1
201 Poppet 1 69 to 78 (51 to 58) 401 Plug 1
202 Spring 1 402 O-ring 1

24-36
HYDRAULIC COMPONENTS ASSY ［24. COMPONENTS SYSTEM］

(8) Swing shuttle valve cover (204)

Swing shuttle valve cover

Tightening torque Tightening torque

No. NAME Q'TY No. NAME Q'TY
N-m (lbf-ft) N-m (lbf-ft)
166 O-ring 1 542 Seat 1
202 Cover 1 25 to 29 (18 to 21) 554 Plug 1
541 Steel ball 1 7.9 to 9.8 (5.9 to 7.2) 555 Plug 1

24

24-37
［24. COMPONENTS
HYDRAULIC SYSTEM］ASSY
COMPONENTS
24.1.2.2.2 HYDRAULIC CIRCUIT DIAGRAM

Hydraulic circuit diagram

24-38
HYDRAULIC COMPONENTS ASSY ［24. COMPONENTS SYSTEM］

24.1.2.2.3 OPERATION
(1) In neutral position
The hydraulic oil delivered by hydraulic pump P1 enters port P1 of control valve, and passes through
unloading valve P1 (309), low pressure circuit (D) and boost check valve (517), and returns to the
hydraulic tank through tank port T1. And when the operation of unloading valve is impossible due to
failure of electric control system, because the by-pass cut valve (605) located on the downstream of
center by-pass passage (52) opens, the hydraulic oil through hydraulic pump P1 port passes through
travel straight spool (307), and then flows though the center by-pass passage (52) which passes
through travel right, boom, bucket and arm 2 and the by-pass cut valve (605) on P1 side, and flows
into low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank
through tank port T1.
The hydraulic oil delivered by hydraulic pump P2 passes through unloading valve P2 (310), low
pressure circuit (D) and boost check valve (517) and returns to the hydraulic tank through tank port T1
similarly to the hydraulic oil from hydraulic pump P1. And when the operation of unloading valve is
impossible, because the by-pass cut valve (605) located on the downstream of center by-pass passage
(55) opens, the hydraulic oil through hydraulic pump P2 port passes through main passage, and then
flows though the center by-pass passage (55) which passes through travel left, swing, arm 1 and
option and the by-pass cut valve (605) on P2 side, and flows into low pressure circuit (D) and boost
check valve (517), and then returns to the hydraulic tank through tank port T1.

In neutral position

24

24-39
HYDRAULIC COMPONENTS ASSY ［24. COMPONENTS SYSTEM］

(5) Arm operation

1. In arm out operation
When arm out operation is performed, the pilot pressure enters ports PBa1 and arm 1 spool (302)
moves rightward against the force of springs (321) (322). Simultaneously the secondary pressure of
solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310).
And the pilot pressure also enters PBa2, and arm 2 spool (308) is switched against the force of
springs (325) (326) and the secondary pressure of solenoid proportional valve [X1] acts on port PCb
and switches unload spool (309).
The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens
load check valve LCa (511), and flows into AR chamber through between the perimeter of arm 1 spool
(302) and casing through U-shaped passage.
In the meantime, the hydraulic oil delivered by hydraulic pump P1 flows through center by-pass
passage (52) and pushes and opens load check valve LCAT2 (511) and enters U-shaped passage,
and pushes and opens load check valve LCAP2 (515) provided with orifice, and flows into U-shaped
passage. And then the hydraulic oil flows through between the perimeter of arm 2 spool (308) and
casing, and enters AR chamber through casing inside passage (RR) and confluences the hydraulic oil
from hydraulic pump P2 side.
The conflux hydraulic oil opens lock valve poppet CRa (514) and is supplied to arm cylinder rod side
(R).
In the meantime, the return oil from arm cylinder head side (H) flows through between the perimeter of
arm 1 spool (302) and casing and passes though low pressure circuit (D) and casing inside passage
(HH) and then flows into low pressure circuit (D) through between the perimeter of arm 2 spool (308)
and casing.
The return oil in low pressure circuit (D) returns to hydraulic tank through tank port T1 passing through
boost check valve (517).

24
In arm out operation

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2. In arm in operation (At light load: arm recirculation function)
When arm in operation is performed, the pilot pressure enters ports PAa1 and PLc2, and arm 1
spool (302) moves rightward against the force of springs (321) (322). Simultaneously the secondary
pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310). At
the same time, since the spool of lock valve selector (211) is switched, the spring chamber of lock
valve poppet CRa (514) is connected to the drain circuit and the retention of poppet (514) is released.
And the pilot pressure enters PAa2 through solenoid proportional valve [XR], and arm2 spool (308)
moves rightward against the force of springs (325) (326) and the secondary pressure of solenoid
proportional valve [X1] acts on port PCb and switches unloading spools (309). But in light load
operation, because the solenoid proportional valve [XR] actuates and arm 2 spool (308) stays in the
position of circuit (I).
The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens
load check valve LCa (511), and flows into port (Aa) through between the perimeter of arm 1 spool
(302) and casing through U-shaped passage. In the meantime, the hydraulic oil delivered by hydraulic
pump P1 flows through center by-pass passage (52) and pushes and opens load check valve LCAT2
(511) and enters U-shaped passage, and also the oil from parallel passage (53) pushes and opens
load check valve LCAP2 (515) provided with orifice and flows into U-shaped passage. And then the
hydraulic oil flows through between the perimeter of arm 2 spool (308) and casing from U-shaped
passage and enters port (Aa) through casing inside passage (HH) and confluences the hydraulic oil
from hydraulic pump P2 side.
The conflux hydraulic oil is supplied to arm cylinder head side (H) through port (Aa).
In the meantime, the return oil from arm cylinder rod side (R) enters the control valve through port
(Ba). Because the retention of lock valve poppet CRa (514) which is located on this side of arm 1
spool (302) is released, the return oil pushes and opens lock valve poppet CRa (514) and enters AR
chamber. The return oil in AR chamber flows through between perimeter of arm 1 spool (302) and
casing, and flows through low pressure circuit (D) and boost check valve (517). And finally, the oil
returns to hydraulic oil tank through tank port T1. The return oil in AR chamber is led to arm 2 spool
(308) through casing inside passage (RR), but because arm 2 spool (308) does not connect to low
pressure passage (D) at circuit (I), the entire flow rate flows into arm 1 spool (302).
Further more, the return oil from chamber AR passes through the perimeter of arm 1 spool (302) and
casing, and flows through casing inside passage (RH) and is led to the inside of arm 2 spool (308)
through circular notch (a) of arm 2 spool (308). In light load operation, since the return oil contains
higher pressure than that of arm cylinder head side (H) with the self weight of arm, etc. the hydraulic
oil inside of arm 2 spool (308) passes through check valve (317) and flows into casing inside
passage (HH) and the supplied to arm cylinder head side (H) again. (Arm recirculation function)
And a part of the return oil which was led to arm 2 spool (308) passes through check valve (319),
and flows through boost check valve (517) through low pressure circuit (D) and returns to the hydraulic
tank through tank port T1.

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In arm in operation (At light load: arm recirculation function)

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3. In arm in operation (In heavy load operation)
The arm recirculation function is effective in actuating arm cylinder quickly in light load operation, but
in heavy load operation (work required large power); the function causes the power loss. This control
valve selects the presence of recirculation function in light and heavy load operation with solenoid
proportional valve [XR]. (Variable recirculation function)
The flow path of hydraulic oil in heavy load operation, the path on the supply side to arm cylinder is
the same as that in light load operation, differs from that of return oil. In heavy load operation,
solenoid proportional valve [XR] actuates and arm 2 spool (308) is positioned to circuit (II). The return
oil from arm cylinder rod side (R) enters the control valve through port (Ba). Because the retention of
lock valve poppet CRa (514) which is located on this side of arm 1 spool (302) is released, the
return oil pushes and opens lock valve poppet CRa (514) and enters AR chamber. The return oil in
AR chamber flows through between perimeter of arm 1 spool (302) and casing, and flows through
low pressure circuit (D) and boost check valve (517). And finally, the oil returns to hydraulic oil tank
through tank port T1. The return oil in AR chamber is led to arm 2 spool (308) through arm 1 spool
(302) and casing inside passage (RR). But because arm 2 spool (308) is connected to low pressure
passage (D) at circuit (II), the return oil passes through between the perimeter of arm 2 spool (308)
and casing and flows through boost check valve (517) through low pressure (D) and returns to the
hydraulic tank through tank port T1.
The return oil from AR chamber passes through between the perimeter of arm 1 spool (302) and
casing and flows through casing inside passage (RH) and then is led to the inside of arm 2 spool
(308) through circular notch (a) of arm 2 spool (308). In heavy load operation, since the pressure on
arm cylinder head side (H) is higher than the rod side, the hydraulic oil in arm 2 spool (308) does not
flow into casing inside passage (HH), but flows through check valve (319) and passes through boost
check valve (517) through low pressure (D) and returns to the hydraulic tank through port T1.

In arm in operation (In heavy load operation)

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(7) Spool actuation for operation in option
This spool is used to control the attachment in option like Nibbler (Crusher), etc.
Where the pilot pressure acts on port PAo on operating the attachment in option, the pilot pressure
enters ports PAo, and option spool (311) moves against the force of springs (329) (330), and
simultaneously the secondary pressure of solenoid proportional valve [X2] acts on port PCa and
switches unloading spool (310).
The hydraulic oil delivered by hydraulic pump P2 flows through parallel passage (56) and pushes and
opens load check valve LCo (511), and flows through between the perimeter of option spool (311)
and casing through U-shaped passage and is supplied to actuator for attachment through port (Ao).
In the meantime, the return oil from actuator for attachment swing passes through between the
perimeter of option spool (311) and casing through port (Bo) and flows through low pressure circuit (D)
and boost check valve (517), and then returns to the hydraulic tank through tank port T1.
The operation where the pilot pressure acts on PBo port is the same as the above.
* The oil passage is branched toward the end side of control valve at the mid course from option
spool (311) to port Ao, but when N&B (Nibbler and Breaker) selector valve is provided on the end
side of control valve, this oil passage is used as passage to connect to N&B selector valve.

Spool actuation for operation in option

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(8) Lock valve operation

The lock valve is housed in between each port of the control valve connected to arm cylinder rod side
(R) and arm cylinder head side (H) and the arm spool and boom spool, and reduces the leaking due
to holding pressure caused by each cylinder.

1. At boom spool neutral position (Arm spool makes the same operation.)
When boom spool (301) is set to neutral position, spool (511) of lock valve selector is held on the
left side as shown in the figure. At this position, passages Sa and Sb are connected each other at the
inside of bushing (541) and on the perimeter of spool (511). Therefore in spring chamber (RH) of
lock valve poppet, the holding pressure receiving from boom cylinder head side (H) passes from
passage Sa to bushing (541) spool (511) and is connected through passage Sb, consequently the
lock valve poppet (514) is kept pressed the lower side as shown in the below Fig. and restricts the
leaking to the minimum.

Lock valve operation (At boom spool neutral position)

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(10) Boost check valve, By-pass check valve

1. Boost check valve
The boost check valve is located between low pressure passage (D) and tank port T1 and generates
boost pressure necessary for the low pressure passage.

a. In normal operation
The hydraulic oil from low pressure passage (D) moves the boost check valve (517) upward
against the force of spring (527), and returns to the hydraulic tank through tank port T1. At this
time, the pressure generated by spring (527) is used as the boost pressure for the low pressure
passage.

Boost check valve operation

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2. By-pass check valve
Even if the pressure at tank port T1 goes up due to the sudden change of return flow rate, the
by-pass check valve actuates and prevents the pressure at tank port T1 from going up higher than the
specified pressure, and consequently the oil cooler and filter located between tank port T1 and the
hydraulic tank are protected from possible damage.
When the pressure at tank port T1 goes up to the pressure added by spring (528), by-pass check
valve (518) is pushed and opens against the force of spring (528), and the hydraulic oil in tank port
T1 directly returns to the hydraulic tank through tank port T2.

By-pass check valve operation

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24.1.3 PILOT VALVE (ATT)

24.1.3.1 OUTLINE
(1) Outside view

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24.1.3.2 CONSTRUCTION

Pilot valve (ATT)

Tightening torque Tightening torque

No. NAME Q'TY No. NAME Q'TY
N-m (lbf-ft) N-m (lbf-ft)
101 Casing 1 *218-1 Seat 2
151 Plate 1 *218-2 Seat 2
201-1 Spool 2 221 Spring 4
201-2 Spool 2 241-1 Spring 2
211 Plug 4 241-2 Spring 2
212 Push rod 4 *246 Spring 4
213 Seal 4 47.1 (34.7) 301 Joint: M14 1
214 O-ring: 1B P20 4 302 Circular plate 1
216-1 Spring seat 2 68.6 (50.6) 312 Adjust nut: M14 1
216-2 Spring seat 2 501 Boots 1
217 Washer 2 (Shim) 4

Note) The parts marked * may not be equipped depending on valve type.

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24.1.4 PILOT VALVE (TRAVEL)

24.1.4.1 OUTLINE
(1) Outside view

(2) Specifications

(3) Performance characteristics

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24.1.5 SWING MOTOR UNIT

24.1.5.1 SPECIFICATION
(1) General view

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(2) Specifications
Swing motor unit part No. YY15V00016F1
Type M2X63CHB-13A-36/285-60
Part No. YY15V00018F1
Displacement cm3 (in3) / rev 60 (3.66)
Rated pressure MPa (psi) 28.0 (4060)
Hydraulic motor
Braking torque N-m (lbf-ft) 314 (232)
Release pressure MPa (psi) 2.3 (334)
Relief set pressure MPa (psi) 28.0 (4060) at 110L/min (29 gal/min)
Weight kg (lbs) 29 (64)
Type RG06D19J2
Part No. YY32W00004F1
Gear oil SAE#90~#140 (API class GL-3~4
Lubicate oil
grade)
Reduction unit
Lubicate oil volume L (gal) 1.65 (0.44)
Grease Extreme pressure lithum base #2 grease
Grease volume cm3 (in3) 500 (30.5)
Weight kg (lbs) 79 (174)
Total weight kg (lbs) 113 (249)

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24.1.5.2 CONSTRUCTION
(1) Swing motor

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(2) Anti-reaction valve

Tightening
torque No. Parts Q'ty
N-m (lbf-ft)
101 Casing 1
9 (6.6) 151 Plug : NPTF1/16 4
161 O-ring : 1B P22 2
29 (21) 171 Socket bolt : M8X60 6
29 (21) 401 Swing reactionless valve : M22 2
401-1 O-ring : 1B P20 2
401-2 Back-up ring 2

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(3) Swing reduction unit

Tightening torque Tightening torque Q'T

No. NAME Q'TY No. NAME
N-m (lbf-ft) N-m (lbf-ft) Y
102 Casing 1 402 Roller bearing 1
201 Pinion shaft 1 403 Needle bearing 3
202 Ring gear 1 98 (72) 602 Socket bolt : M12X100 8
203 No.2 planetary gear 4 603 Socket bolt : M12X135 2
204 No.2 sun gear 1 801 Oil seal 1
210 No.1 planetary gear 3 910 Spring pin 4
211 No.1 sun gear 1 911 Retaining ring 3
230 No.2 spider 1 912 Retaining ring 1
231 No.1 spider 1 913 Retaining ring 1

24
282 No.2 pin 4 915 Seal 1
283 No.1 pin 3 65 (48) 920 Adapter : PT1/2 1
285 Side plate t=1 7 108 (80) 921 Hose : PF1/2 1
286 Thrust washer t=2 1 108 (80) 922 Plug : PF1/2 1
287 Side plate t=2 3 925 relief fitting 1
401 Roller bearing 1 926 Grease nipple : PT1/4 1

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24.1.6 TRAVEL MOTOR

24.1.6.1 SPECIFICATIONS
24.1.6.1.1 General view

Travel motor (with reduction unit and brake valve)

24.1.6.1.2SPECIFICATIONS

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24.1.6.2 CONSTRUCTION
(1) Outline

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(2) Hydraulic motor

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(3) Reduction unit

No. Parts Q'TY No. Parts Q'TY

1 Hub 1 16 Parallel pin (1) 3
2 Spindle 1 17 Parallel pin (2) 3
3 Spider (1) 1 22 Lock washer 2
4 Sun gear (1) 1 23 Shim 1
5 Planetary gear (1) 3 24 Bearing 2
6 Pin (1) 3 27 Needle bearing 3
7 Spider (2) 1 28 Needle bearing 3
8 Sun gear (2) 1 29 Floating seal 2
9 Planetary gear (2) 3 30 Plug 3
10 Pin (2) 3 31 O-ring 3
11 Thrust washer (1) 6 32 O-ring 1
12 Thrust washer (2) 6 33 O-ring 2
13 Thrust plate 1 34 Parallel pin 2
14 Cover 1 35 Socket bolt 12
15 Coupling 1 36 Snap ring 1

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24.1.6.3 OPERATING DESCRIPTION

24.1.6.3.1REDUCTION GEAR
(1) Function
This reduction gear unit is composed of two stage planetary gear mechanism. The reduction gear
reduces the high speed of hydraulic motor and converts it low-speed, high-torque rotation.

(2) Operating Description

The rotation of hydraulic motor shaft is
transmitted to sun gear (4) of the first stage
which is linked with shaft (102) in spline.
At that time, the hub (1) is rotated by the
rotation of the planetary gears (5). The hub (1)
rotation is transmitted to carrier (3) which
connected to planetary gears (5), and that
causes sun gear (6) rotation of the second
stage.
The rotation of sun gear (6) is transmitted to
the hub via three planetary gears (7) of the
second stage.
The generated rotation of reduction gear is
output rotation.

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24.1.6.3.2 Reduction unit
(1) Function
1. Hydraulic Motor
This hydraulic motor is a swash plate type axial piston motor, converting the hydraulic force from
the pump to rotary motion.
2. Brake Valve
a. Controls inertia when stopping the hydraulic motor, in order to provide smooth stopping.
b. Prevents runaway rotation when the hydraulic motor is rotated by external force.
This is done by preventing hydraulic cavitation.
c. Prevents the generation of abnormally high pressure when the hydraulic motor is stopped
suddenly.
3. Parking Brake
The parking brake prevents the hydraulic motor from being rotated by external force while stopped.
A friction plate type mechanism is used, constructed so as to form one unit with the hydraulic
motor.
4. High-Low 2-Speed Switching Mechanism
Switches the hydraulic motor between high speed rotation with low torque, and low speed rotation
with high torque.

(2) Operating Principles and Description

1. Hydraulic Motor
Hydraulic fluid fed from the hydraulic pump
enters the GM motor through the rear
flange (101), passes through the brake
valve and timing plate (109) and enters
the cylinder block (104). This hydraulic
fluid is fed only into one side of a line
connecting the upper and lower dead points
(Y1-Y2) of the piston stroke (105). The
hydraulic fluid pushes each of the pistons
(105), creating force F(=PXA). This force
operates on the oblique surface of the
swash plate (103). Force F is separated
into components F2 and F3 according to
the angle θ of the oblique surface. Of the
two components, the radial component force
F3 generates torque (=F3Xri). The sum of
the torque T(= (F3Xri) of each of the
pistons (105) is the rotary force of the
hydraulic motor. This rotary force passes
through the pistons (105) and rotates the
cylinder block (104) and the shaft (102).

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2. Brake Valve

a. Operation (Brake released)

The pressure oil is led to through port (A),
opens valve (327), and led to port (C) on
the section side of hydraulic motor to rotate
hydraulic motor.
At the same time, the pressure oil enters
chamber (a) through orifice (329), and
exerts on the end of spool (323) to
generate the force. Then the force of spring
(328) slides the spool (323) placed on the
neutral position leftward.
The sliding of spool (323) forms the space
(passage) between spool (323) and rear
flange (301) with spool groove.
This passage is connected to port (D) and
port (B) of the return circuit of the hydraulic
motor, and the returns oil returns to tank
side, enabling hydraulic motor to rotate.
Then, the sliding of spool (323) leads
pressure oil to port (E). The pressure oil
led to port (E) moves piston (112) of
parking brake, and releases parking
braking force. (For details, refer to item
"Parking brake".)
If pressurized oil is supplied from port (B),
the movements of spool (323) and valve
(327) are reversed so that the hydraulic
motor is rotated reversely.

b. Self-traveling
While machine is being operated, as the
travel speed is increased due to steep
slope, the oil flow rate of the hydraulic
motor is higher than the supply flow rate of
the hydraulic oil pump.
The rotation of the hydraulic motor in this
case is called a self-traveling. (Overrun)
While self-traveling, the pressure is
lowered similar to the stopping condition.
Then brake valve is moved similar to the
stopping condition, throttles passage in the 24
return side of hydraulic motor, and generate
backing pressure.
In addition, the force of inertia decreases
the revolution of hydraulic motor to
revolution having a balance with the
supply flow rate of pump.

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c. Stop / Stall (Braking Operation)
If pressurized oil supply through the port
(A) is suspended while traveling, the
hydraulic force to push up the spool (323)
is lost, and the spool (323) which is slid
to left side, tries to return to the neutral
position due to the spring (328) force. At
that time, through the oil in the chamber
(a) tries to flow out to the port (A) side
through the orifice (329), its flow is
restricted and some back pressure is
generated by the throttle effect in the orifice
(329) controlling the return speed of the
spool (323). At the same time, the
hydraulic motor tries to rotate with its inertia
force even though the pressurized oil is
suspended, and the return oil from the
hydraulic motor tries to return to the port
(B) side from the port (D) through the
passages on spool groove and rear flange
(301).
When the spool (323) entirely return to
neutral position, the passage on the
hydraulic motor of the oil return side is
completely closed by the spool (323), and
the hydraulic motor ceases its rotation.
While machine working, the brake valve
smoothly stops rotation of-the hydraulic
motor which tries to rotate with its inertia
force, by means of throttling the return
side passage of the hydraulic motor,
generating back pressure due to shape of
the spool groove and controlling the return
speed of the spool.
On the other hand, when braking is
operated, the hydraulic motor tries to
rotate with its inertia force and to intake
oil with its pumping function. However,
because the intake side is closed its
passage with the spool (323), the oil supply
is suspended. This causes cavitation in
the hydraulic motor. To prevent the
cavitation, the valve (327) is operated by
very slight negative pressure to open the
passages of port (A) side and intake port
(C) of the hydraulic motor.
And when pressurized oil is supplied
through the port (B), each motion of the
mentioned parts above becomes
symmetrical right and left to stop the
hydraulic motor.

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3. High-Low 2-Speed Switching Mechanism

a. Low Speed
When the pilot pressure is not supplied
through the port (P), the valve (363) is
pushed up to the upper position due to
the spring (366) force and pressurized oil
through the port (A) or (B), the
pressurized oil is cut off at port (C), and oil
in the chamber (W) is released into the
drain (motor case) through the valve (363).
Accordingly, the tilt angle of the swash
plate (103) becomes the maximum 1
resulting the maximum stroke volume and
low speed rotation of the hydraulic motor.

b. High Speed
When the pilot pressure is supplied
through the port (D), it defeats the spring
(366) force and pressurized oil through the
port (A) or (B) to push down the valve
(363) to lower position, the pressurized oil
at the port (C) is led to the chamber (P)
through the valve (363), and the piston
(161) pushes the swash plate (103) up to
the plane X and maintain it at its position.
At that time, the tilt angle of the swash
plate becomes the minimum 2 resulting
the minimum stroke volume and high speed
rotation of the hydraulic motor.

c. Automatic shifting to low speed during

high speed operation
If the load is increased while high speed
operation, the oil pressure at the port (A)
or (B) is also increased. And when the oil
pressure reaches to specified pressure, it
excesses the pilot pressure, and the valve
(363) is pushed up to upper position, and
oil in the chamber (W) is released into the
drain (motor case) through the valve (363).
At that time, the swash plate (103) gets
touch with the plane Y of spindle, and the 24
tilt angle of swash plate (103) becomes
the maximum 1 and is maintained at its
position resulting low speed rotation.

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24.1.7 TRAVEL MOTOR (FOR "L" SPEC.)

24.1.7.1 SPECIFICATIONS
(1) Appearance

Travel motor (With reduction unit and brake valve)

(2) Specifications
Parts No. YV15V00005F1
Item
Type GM28VL-B-57/100-5
Revolution [rpm] 43.5/25.2
Reduction unit Lube oil Gear oil SAE #90 GL4
Oil level [L (gal)] 4.7 (1.24)
Max. displacement [cc/rev (cu-in/rev)] 56.5/99.6 (3.45/6.1)
Max revoiution [rpm] 2437/1411
Hydraulic motor
System pressure [kgf/cm2(psi)] 350 (5000)
2-speed changeover pressure [kgf/cm2(psi)] 51 (725)
Braking torque [Kgf-m (lbf-ft)] 26 (188)
Parking brake
2
Release pressure [kgf/cm (psi)] 11 (157)
24
Total weight [kg (lbs)] 271 (480)

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24.1.7.2 CONSTRUCTION
(1) Outline

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24.1.7.3 EXPLANATION OF FUNCTION
24.1.7.3.1 REDUCTION UNIT
(1) Function
This reduction unit is equipped with spur gears (Hereinafter referred as 1st reduction gear section)
and differential gears (Hereinafter referred as 2nd reduction gear section), reduces the high rotation
speed from the Hydraulic motor, converts it to low speed large torque and rotates hub (1) (Casing.)

(2) Explanation of function

1. 1st reduction gear section
The rotation of hydraulic motor shaft is transmitted to input gear (6) which is linked with shaft
(102) in spline.
Then, the rotation speed of three spur gears (7) which are engaged with input gear is reduced.
Also, the reduction rate of 1st reduction gear section is as follows.

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2. 2nd reduction gear section

a.Three spur gears are engaged with
crankshaft respectively to transmit the
power from the 1st reduction gear section
to 2nd reduction gear section.
The eccentric bodies of crankshaft a and
b revolve eccentrically (revolution) while
rotating on its axis by rotating crankshaft.
Also, these eccentric bodies a and b and
RV gears "A" (4) and "B" (5) transmit only
the eccentric revolution.
And RV gears A and B revolve in the
same direction and number of revolutions
as spur gear and crankshaft.
b.Teeth number ZR of RV gears A and B
is always engaged with ZP pins (17)
rotating and changing the mesh part in
order, by eccentrically revolving RV gears A
and B.
By eccentrically revolving RV gears A and
B one turn, the pin revolves in the same
direction of eccentrical revolution in the
portion of difference between number of
teeth ZR and number of pins ZP [(ZP-ZR) /
ZP].
This revolution of pin is transmitted to
hub, producing output rotation of reduction
unit.
At this point, the speed ratio of 2nd
reduction gear section is as follows.

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 ［24. COMPONENTS
HYDRAULIC SYSTEM］
COMPONENTS ASSY
24.1.7.3.2 HYDRAULIC MOTOR SECTION (BRAKE VALVE, HIGH AND LOW SPEED CHANGE
MECHANISM)
(1) Function
1. Hydraulic motor is referred to as a swash plate type axial piston motor which converts the
pressure oil power fed by pump into rotary motion.
2. Brake valve
a.Travel motor controls the force of rotational inertia of the body to brake and stop the rotation
smoothly.
b.Check valve function to prevent hydraulic motor from cavitation.
c.Surge cut valve function to control braking power of hydraulic motor, and anti-cavitation valve
function to prevent cavitation.
3. High and low speed change mechanism
The function of selector valve and control piston switches the tilting angle of swash plate. As a
result of the switching, travel motor has high speed low torque motion and low speed high torque
motion.
4. Parking brake
The parking brake is used to the prevent machine from running away or slipping while parking on
a slope using the friction plate type brake mechanism, and is installed on the hydraulic motor.

24-96
HYDRAULIC COMPONENTS ASSY ［24. COMPONENTS SYSTEM］

4. High and low speed change mechanism

a.At low speed

In case the travel 2-speed select pilot pressure
is not supplied from port (P), valve (363) is
pushed up by the action of spring (366) and
the hydraulic pressure from port (A) or (B). This
shuts off the pressure of (C) and the oil in the
S chamber is released to the drain (motor
casing) via the valve (363). The result is that
the swash plate (103) takes the max. tilting
angle θ1 which in turn maximizes the piston
stroke volume, making the hydraulic motor run
at low speed.

b.At high speed

In case the travel 2-speed select pilot pressure
51 kgf/cm2 (725 psi) is supplied from port (P),
valve (363) is pushed down, overcoming the
action of spring (366) and the pressure from
port (A) or (B). The pressurized oil at port (C)
is admitted to chamber S via valve (363).
Piston(161) is pushed till swash plate (103)
hits the surface X and is held.
On that occasion, the swash plate (103) takes
the min. tilting angle θ2 which in turn minimizes
the piston stroke volume to make the hydraulic
motor run at high speed.

c.Automatic selection of low speed during high

speed operation :
The pressure at port (A) or (B) increases as
the load of the hydraulic motor increase during
high speed operation, and when the pressure
arrives at 280 kgf/cm2 (3990 psi), it overcomes
the pilot pressure [51 kgf/cm2 (725 psi)] at port
(P).
Valve (363) is then pushed upward. The oil in
the S chamber is released to the drain (motor
casing) via valve (363).
On that occasion, swash plate (103) hits the
surface Y of the spindle and takes the max.
tilting angle θ1 . The angle is held to make the 24
hydraulic motor run at low speed.

24-101
HYDRAULIC COMPONENTS ASSY ［24. COMPONENTS SYSTEM］

24.1.8 SWIVEL JOINT

24.1.8.1 GENERAL VIEW

General view of swivel joint

24.1.8.2 SPECIFICATIONS
Item Specifications
Assy parts No. YN55V00053F1
Working pressure 34.3 MPa (4970 psi)
High pressure ports
Max. impact pressure 51.5 MPa (7470 psi)
A, B, C, D
Rated flow 255 L/min (67 gal/min)
Low pressure ports Working pressure 0.5 MPa (73 psi)
E Rated flow 50 L/min (13 gal/min)
Low pressure ports Working pressure 5 MPa (725 psi)
H, I Rated flow 30 L/min (8 gal/min)
Revolution speed 15 min-1 (15 rpm)
24
A, B, C, D (Body) PF1
A, B, C, D (Stem) PF3/4
Ports size
E PF1/2
F PF1/4
Length: L 368 mm (14.5")
Weight 25 kg (245 lbs)

24-103
 ［24. COMPONENTS
HYDRAULIC SYSTEM］
COMPONENTS ASSY
24.1.8.3 CONSTRUCTION

Construction

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

1 Body 1 7 O-ring(G95 1A) 1
2 Stem 1 8 Capscrew (M8X20) 2
3 Thrust plate 1 9 Capscrew (M8X30) 3
4 Cover 1 12 Plug 1
5 Seal 5 13 O-ring 1
6 Seal 1

24.1.8.4 FUNCTION
The swivel joint consists mainly of body (1) and stem (2) that rotate mutually, thrust plate (3)
preventing both components from falling off, cover (4) closing one side of body (1), seal (5) that
partitions off the circuits and seal assy (6) and O-ring (7) that prevent external leaks. Four ports for
the travel main circuits are provided on body (1) and stem (2). Further, four oil passing grooves are
arranged in the inner surface of body (1), with seal (5) fixed above and below the circumferential
groove. The body (1) and the stem (2) rotate mutually. The oil flowing in from body (1) or stem (2)
keeps on flowing to stem (2) or body (1) past the circumferential groove between body (1) and stem
(2) ; the oil flow is never shut off because of rotation. Further, an oil groove for lubrication that
connects with the drain port is provided, in order to prevent the body (1) from seizure with the stem
(2). This construction keeps on connecting the circuits between the swing bodies by means of a swivel
joint.

24-104
HYDRAULIC COMPONENTS ASSY ［24. COMPONENTS SYSTEM］

24.1.9 CYLINDER
24.1.9.1 SPECIFICATIONS
(1) General View

General view of cylinder

(2) Specifications
Unit : mm (ft-in)
Center
Part No. of Cylinder bore/ distance of pins Dry weight
Use Stroke Cushion
cylinder assy Rod Dia. Full extend B / kg (lbs)
Full retract A
100 dia./ 70 dia. 2,648 / 1,556 With cushion on
Boom YY01V00053F1 1092 (3-7) 101 (223)
(3.94" / 2.76") (8-8.3 / 5-1.3) rod side
115 dia./ 80 dia. 1120 2,835 / 1,715 With cushion on
Arm YY01V00054F1 148 (326)
(4.53" / 3.15") (3-8.1) (9-3.6 / 5-7.5) both sides
95 dia./ 65 dia. 903 2,293 / 1,390 With cushion on
Bucket YY01V00055F1 98 (216)
(3.74" / 2.56") (2-11.6) (7-6.3 / 4-6.7) rod side

24

24-105
 ［24. COMPONENTS
HYDRAULIC SYSTEM］
COMPONENTS ASSY
24.1.9.2 CONSTRUCTION AND FUNCTION
24.1.9.2.1 Construction
(1) Boom cylinder

Construction of boom cylinder

P/No: YY01V00053F1
No. PARTS Q'TY No. PARTS Q'TY No. PARTS Q'TY
1 CYLINDER TUBE 1 10 BACKUP RING 1 19 DUST RING 1
2 PIN BUSHING 1 11 DUST WIPER 1 20 O-RING 1
3 PISTON ROD 1 12 O-RING: 1B G95 1 21 BACKUP RING 2
4 PIN BUSHING 1 13 BACKUP RING 1 22 PISTON NUT 1
5 ROD COVER 1 14 O-RING: 1B G100 1 23 SETSCREW: M8X16 1
6 BUSHING 1 15 CUSHION RING 1 24 SOCKET BOLT: M14 10
7 RETAINING RING 1 16 PISTON 1 25 WIPER PIN 2
8 BUFFER SEAL 1 17 SLIPPER SEAL 1 26 WIPER PIN 2
9 U-PACKING 1 18 WEAR RING 2

24-106
HYDRAULIC COMPONENTS ASSY ［24. COMPONENTS SYSTEM］

(2) Arm cylinder

Construction of arm cylinder

P/No: YY01V00054F1
No. PARTS Q'TY No. PARTS Q'TY No. PARTS Q'TY
1 CYLINDER TUBE 1 12 O-RING : 1B G110 1 23 SET SCREW : M8 1
2 PIN BUSHING 2 13 BACK-UP RING 1 24 CUSHION PLUNGER 1
3 PISTON ROD 1 14 O-RING : 1B G115 1 25 STOP RING 1
4 PIN BUSHING 2 15 CUSHION RING 1 26 SOCKET BOLT : M16 10
5 ROD COVER 1 16 PISTON 1 27 CHECK VALVE 1
6 BUSHING 1 17 SLIPPER SEAL 1 28 SPRING 1
7 RETAINING RING 1 18 WEAR RING 2 29 SPRING SUPPORT 1
8 BUFFER SEAL 1 19 DUST RING 2 30 O-RING : 1B P14 1
9 U-PACKING 1 20 O-RING 1 31 PLUG : PT3/8 1
10 BACK-UP RING 1 21 BACK-UP RING 2 32 WIPER RING 4
11 DUST WIPER 1 22 PISTON NUT 1

24

24-107
［24. COMPONENTS
HYDRAULIC SYSTEM］ASSY
COMPONENTS
(3) Bucket cylinder

Construction of bucket cylinder

P/No: YY01V00055F1
No. PARTS Q'TY No. PARTS Q'TY No. PARTS Q'TY
1 CYLINDER TUBE 1 10 BACKUP RING 1 19 DUST RING 2
2 PIN BUSHING 1 11 DUST WIPER 1 20 O-RING 1
3 PISTON ROD 1 12 O-RING: 1B G90 1 21 BACKUP RING 2
4 PIN BUSHING 1 13 BACKUP RING 1 22 PISTON NUT 1
5 ROD COVER 1 14 O-RING: 1B G95 1 23 SETSCREW: M8X16 1
6 BUSHING 1 15 CUSHION RING 1 24 SOCKET BOLT: M14 8
7 RETAINING RING 1 16 PISTON 1 25 WIPER PIN 2
8 BUFFER SEAL 1 17 SLIPPER SEAL 1 26 WIPER PIN 2
9 U-PACKING 1 18 WEAR RING 2

24-108
HYDRAULIC COMPONENTS ASSY ［24. COMPONENTS SYSTEM］

Hydraulic cylinder construction (See Fig. 24.1.8.2 CONSTRUCTION AND FUNCTION)

By construction the hydraulic cylinder consists mainly of cylinder tube assy (1), piston rod assy (3) that
takes out the motion of pistons reciprocating in the cylinder tube assy, and rod cover (5) that serves
as both a lid and a guide. Cylinder tube assy (1) is equipped with a piston mount (clevis) that
connects piston rod assy (3) with other parts.
In addition to these main components, slipper seal (17) and ware ring (18) are located between,
cylinder tube assy (1) and piston rod assy (3) ; buffer seal (8), rod packing (9) and dust seal (11)
are located between piston rod assy (3) and rod cover (5) ; and an O-ring and a back-up ring are
placed between cylinder tube assy (1) and rod cover (5).

24.1.9.2.2 OPERATION
If pressurized oil is fed alternatively to the oil inlet and outlet provided in the cylinder, force acts on
the piston which in turn causes the piston rod (3) to extend and retract.

(1) Operation of cylinder with cushion

1. Cushion on rod side
The cushion mechanism is provided to prevent
the generation of shock when the moving speed
of piston (16) is not reduced and strikes rod
cover (5).
An oil in chamber "A" returns to the tank by
passing through paths "B" and "C" at a fixed
flow rate in a intermediate stroke state (right
Fig.) of pressing bottom side. Next, in a state Cushion mechanism on the rod side
of just before stroke end (right Fig.), cushion
ring (15) plunges into path "B".
At this time, an oil in chamber "A" passes
clearance "D" and mouth gap "C", an oil flow
volume returning to tank suddenly drops and
the piston part movement slows down.

Rod side cushion Cushioning action on the rod side

24

24-109
［24. COMPONENTS
HYDRAULIC SYSTEM］ASSY
COMPONENTS
2. Cushion on head side
This construction is similar to the one of
cushion on rod side. In a state of intermediate
stroke pressing rod side, an oil in chamber "A"
returns to tank by passing through paths "B"
and "C" at a fixed flow rate.
Next, in a state of just before stroke end,
plunger plunges into path "B". At this time, an
oil in chamber "A" path clearance "D" and
restricted path "C", an oil flow volume returning
to tank suddenly drops and the piston part
movement slows down.

Cushioning action on the head side

24-110
The New MHI Engine –
compact, fuel saving and
powerful Engine.
ENGINE
GENERAL ASSY

1. External view

Oil filler
Exhaust manifold
Front hanger Turbocharger
Thermostat

Fan Rear hanger

Front Rear

Alternator

Crankshaft pulley
Starter
Belt
Oil pan

Engine left view

Inlet manifold
Breather
Oil level gauge
Air heater

Oil filter Water pump

Rear Front

Common rail

Fuel pump

Flywheel housing Oil pump

Flywheel

Engine right view

1-2
ENGINE ASSY GENERAL

2. System flow diagrams

2.1 Fuel system - flow diagram

Injector

Common rail

Fuel pump

To fuel tank

From fuel tank

Fuel system - flow diagram

2.2 Lubrication system - flow diagram

Tappet Turbocharger Valve mechanism

Piston
Camshaft

Piston cooling nozzle

Oil filter

Main gallery
Oil cooler
Timing gear
Relief valve

Oil pump
Crankshaft
Oil strainer
Safety valve

Lubrication system - flow diagram

1-3
 GENERAL ASSY
ENGINE

2.3 Cooling system - flow diagram

Outlet

Thermostat
Cylinder head
Bypass pipe

Inlet
Oil cooler Water pump
Water jacket

Cooling system - flow diagram

2.4 Inlet and exhaust system - flow diagram

Inlet
Exhaust Turbocharger

Muffler

Cylinder

Inlet and exhaust system - flow diagram

1-4
ENGINE ASSY GENERAL

2.5 Electrical system - wiring diagram

Injector power supply

Air heater relay
Inlet manifold pressure sensor

Water temperature sensor

Common rail

Common rail pressure sensor

Speed/timing sensor
(Camshaft side)
Speed/timing sensor
(Crankshaft side)
High pressure pump

High pressure pump

Engine oil pressure switch solenoid sensor (MPROP)

Connector

Electronic control unit

Electrical system - wiring diagram

1-5
ENGINE
GENERALASSY

3. Engine serial number location

The engine serial number is stamped on the side of the
crankcase.

Engine serial number

Stamp location of engine serial number

1-6
ENGINE ASSY GENERAL

4. Main specifications
Table 1-1 Main specifications (1 / 3)
Engine model D04FR-TAA
Type Water cooled, 4 cycle diesel engine, turbocharged
No. of cylinders - arrangement 4 cylinder in-line
Combustion system Direct injection
Valve mechanism Overhead
Cylinder bore × stroke 102 × 130 mm [4.02 × 5.12 in.]
Displacement 4.249 L [259 cu. in.]

Main Compression ratio 17.8

specification Fuel Diesel fuel
Firing order 1-3-4-2
Direction of rotation Counterclockwise when viewed from flywheel side
Length 911 mm [35.87 in.]
Dimensions
(varies depending on the Width 719 mm [28.3 in.]
specifications)
Height 940 mm [37.0 in.]
Dry weight Approx. 395 kg [870.8 lbs]
Cylinder sleeve Type Dry
Compression rings: 2
Piston ring Number of rings
Oil ring (w/expander): 1
Open BTDC 15°
Inlet valve
Valve timing Close ABDC 45°
Basic engine (when warm) Open BBDC 49°
Exhaust valve
Close ATDC 15°

Internal EGR Open ATDC 21°

Exhaust valve
valve timing Close BBDC 55°
Starting system Starter
Starting aid system Air heater
Type Common rail fuel injection system
Fuel
Model number CP1H
system
Manufacturer Bosch Corporation

1-7
GENERAL ASSY
ENGINE
Table 1-1 Main specifications (2 / 3)
Engine model D04FR-TAA
Forced circulation type
Lubricating method
(pressure feed by oil pump)
Standard API classification CF-4 or above class
Engine oil
Engine oil capacity Engine total: approx. 17.5 L [4.62 US gallons]
Type Gear type oil pump
Oil pump 40 L [10.57 US gallons]/min
Delivery capacity
Lubrication (at pump rotation of 1800 min-1)
system Type Piston valve type
Relief valve 0.35 ± 0.05 MPa
Valve opening pressure
{3.5 ± 0.5 kgf/cm²} [50 ± 7 psi]
Oil cooler Type Water-cooled, multi-plate type
Oil filter Type Cartridge type paper element
1.1 MPa
Safety valve Opening pressure
{11 kgf/cm²} [157 psi]
Cooling method Water-cooled, forced circulation
Coolant capacity (Engine water jacket) 6 L [1.6 US gallons] approx.
Type Centrifugal
Water pump 133 L [35 US gallons]/min
Discharge capacity
(at pump rotation of 1800 min-1)
Cooling
Water pump pulley Speed ratio Varies depending on the specifications
system
Fan belt Type Ribbed belt
Fan Type ø600 mm [23.62 in.]
Type Wax type
Thermostat Valve opening
71 ± 2°C [160 ± 3.6°F]
temperature
Inlet and Model number TD04HL
exhaust Turbocharger
system Qty 1

Control ECU Model number EDC16UC40

system (Electronic Control Unit) Manufacturer Bosch Corporation

1-8
ENGINE ASSY GENERAL

Table 1-1 Main specifications (3 / 3)

Engine model D04FR-TAA
Manufacturer Nikko Electric Industry
Type 0-24000-0188
Pinion meshing type Pinion shift
Output 24V - 5kW
Qty 1
Ring gear and pinion ratio 10/127
Voltage 23V
Starter No-load
Current 85A or below
characteristics
Speed 3300 min-1 or more
Voltage 9V
Load
Current 1400A or below
characteristics
Torque 88.26 N·m {9.0 kgf·m} [65 lbf·ft] or above
Minimam operating
16V or below
Electrical voltage
system Minimam holding voltage 8V or below
Manufacturer Nikko Electric Industry
Model number 0-35000-4838
Output 24V - 50A
Rated speed 5000 min-1
Direction of rotation Clockwise when viewed from pulley side
Alternator
Drive system PK type, V ribbed, 12 ribs
Ground system One conductor (-) side
Regulated voltage 28.5V ± 1V
Temperature range
-30 to +100°C [-22 to +212°F]
tolarance
Type Electric heater
Air heater
Capacity 2.1kW
Heater relay Fuse capacity 127A

1-9
ENGINE
GENERAL ASSY

5. Tips on disassembling and reassem-

bling
This service manual specifies the recommended procedures
to be followed when servicing Mitsubishi engines. The
manual also specifies the special tools that are required for
the work, and the basic safety precautions to follow when
working.
Note that this manual does not exhaustively cover potential
hazards that could occur during maintenance, inspection and
service work of engine.
When working on an engine, follow the relevant directions
given in this manual and observe the following instructions:

5.1 Disassembling
(1) Use correct tools and instruments. Serious injury or
damage to the engine will result from using the wrong
tools and instruments.
(2) Use an overhaul stand or work bench if necessary, and
follow the disassembling procedures described in this
manual.
(3) Keep the engine parts in order of removal to prevent
losing them.
(4) Pay attention to assembling marks. Put your marks on
the parts, if necessary, to ensure correct reassembling.
(5) Carefully check each part for defects during
disassembling or cleaning. Do not miss symptoms
which can not be detected after disassembling or
cleaning.
(6) When lifting or carrying heavy parts, exercise utmost
caution to ensure safety. Pay attention to balance of
heavy parts when handling. (Get help, and use jacks,
chain blocks and guide bolts as necessary.)

5.2 Reassembling
(1) Wash all engine parts, except such parts as oil seals, O-
rings and rubber sheets, in cleaning oil and dry them
with compressed air.
(2) Use correct tools and instruments.
(3) Use only high-quality lubricating oils and greases of
appropriate types. Be sure to apply oil, grease or
adhesive to the part wherever specified.
(4) Use a torque wrench to tighten parts correctly when
their tightening torques are specified.
Refer to "Tightening torque table."
(5) Replace all gaskets and packings with new ones unless
specified otherwise. Apply adhesive if necessary. Use
only the proper amount of adhesive.

1-10
ENGINE ASSY
SERVICE DATA

1. Maintenance service data

1.1 General
Table 2-1 Maintenance service data table - General Unit: mm [in.]
Inspection point Nominal Standard Limit Remark
-1 -1
Maximum rotation speed 2240 min ± 10 min
-1
Minimum rotation speed 1015 min ± 20 min-1
When oil and water tem-
2.9 MPa 2.6 MPa
-1 peratures
Compression pressure (at 300 min ) {30 kgf/cm²} {27 kgf/cm²}
at 20 to 30°C
[427 psi] {[384 psi]
[68 to 86 °F]
0.2 to 0.4 MPa 0.15 MPa
Rated speed {2 to 4 kgf/cm²} {1.5 kgf/cm²}
[28.4 to 56.9 psi] [21.3 psi] Oil temperature
Lubricating
at 70 to 90 °C
oil pressure 0.1 MPa 0.05 MPa [158 to 194 °F]
Low idling {1 kgf/cm²} {0.5 kgf/cm²}
[14.2 psi] [7.1 psi]
Open BTDC 15°
Inlet
Close ABDC 45° ±3°
Valve timing
Open BBDC 49° (crank angle)
Exhaust
Close ATDC 15°

Internal EGR Open ATDC 21°

Exhaust
valve timing Close BBDC 55°

Valve clearance Inlet 0.25 [0.0098]

(when cold) Exhaust 0.40 [0.0157]
Deflection when the belt
forcefully pressed with a
7 to 9 thumb
Fan belt deflection
[0.276 to 0.354] New fan belt standard
value 4 to 6
[0.158 to 0.236]

2-2
ENGINE ASSY SERVICE DATA

1.2 Basic engine

Table 2-2 Maintenance service data table - Basic engine (1 / 4) Unit: mm [in.]
Inspection point Nominal Standard Limit Remark
Reface minimum as possible.
Total grinding thickness of
Crankcase Flatness of top surface 0.05 [0.0020] or less 0.20 [0.008] crankcase top and cylinder
head bottom is 0.2 [0.008]
max.
ø 102 102.010 to 102.045 102.700 If limit (102.200 [4.0236]) is
Inside diameter
[4.02] [4.0161 to 4.0175] [4.0433] exceeded, use oversize
Cylinder sleeve, and hone to +0.010 to
Circularity 0.01 [0.0004] or less
sleeve +0.045 [0.0004 to 0.0018].
Use oversize piston and pis-
Cylindricality 0.015 [0.0006] or less
ton ring.
If the measured value
exceeds the standard and is
less than the limit, replace
Clearance between main bearing and 0.050 to 0.118 0.200
bearing.
crank journal [0.0020 to 0.0046] [0.0079]
Main If the limit is exceeded, grind
bearing the crank journal, and use
undersize bearing.
Replace thrust plate. The
Width of thrust journals 0.100 to 0.264 (0.300
limit value means a play in
(Thrust clearance) [0.0039 to 0.0104] [0.0118])
the direction of thrust.
ø 22 22.000 to 22.021 22.100 Repair limit:
Inside diameter
[0.87] [0.8661 to 0.8670] [0.8701] 102.200 [4.0236]
Tappet
hole Replace tappet if diameter of
Clearance between tappet and tappet 0.035 to 0.086 0.120
tappet hole is +0.10 [0.0039]
hole [0.0014 to 0.0034] [0.0047]
or less.
Front 0.04 to 0.09 0.15
Clearance between Middle [0.0016 to 0.0035] [0.0059]
Camshaft Replace bushing.
bushing and cam-
bushing 0.04 to 0.119 0.15 (Ream if necessary.)
shaft journal Rear
[0.0016 to 0.0047] [0.0059]
Reface minimum as possible.
Total grinding thickness of
Cylinder Distortion of bottom surface 0.05 [0.0020] or less 0.20 [0.008] crankcase top and cylinder
head head bottom is 0.2 [0.008]
max.
Compressed thickness of gasket 1.7 [0.07] ±0.05 [0.0020]
7.940 to 7.955 7.900
Inlet
Valve stem ø8 [0.3126 to 0.3132] [0.3110]
outside diameter [0.315] 7.920 to 7.940 7.850
Exhaust
[0.3118 to 0.3126] [0.3091]
Valve
and 0.055 to 0.085 0.150
Clearance between Inlet
valve [0.0022 to 0.0033] [0.0059]
guide valve stem
and guide 0.070 to 0.105 0.200
Exhaust
[0.0028 to 0.0041] [0.0079]
17 17.2 to 17.4
Valve guide mounting dimension
[0.669] [0.6772 to 0.6850]

2-3
ENGINE ASSY
SERVICE DATA

Table 2-2 Maintenance service data table - Basic engine (2 / 4) Unit: mm [in.]
Inspection point Nominal Standard Limit Remark
Inlet
Valve seat angle 30°
Exhaust
0.4 0.3 to 0.5 1.1
Inlet Seat width
[0.016] [0.0118 to 0.0197] [0.0433]
Valve sinkage
0.5 0.4 to 0.6 1.1
Exhaust
Valve seat [0.020] [0.0157 to 0.0236] [0.0433]
Inlet Valve Valve
1.4 1.2 to 1.6 1.8 Valve sinkage margin
Seat width
Exhaust [0.055] [0.0472 to 0.0630] [0.071] seat angle

Refacing permissi-
Valve margin 2.13 [0.084] 2.13 [0.084] ble up to 1.2
[0.047]
Free length 56.40 [2.221] 55.00 [2.165]

θ = 2.0°or less
Δ = 2.0 [0.079]
Perpendicularity below Δ = 2.0 [0.079]
at the end Lf
Valve Lf = 56.4 [2.221]
spring

44.0 [1.732]/
44.0 [1.732]/207 N
222.7 to 246.1 N
Set length/set load {21.2 kgf}
{22.7 to 25.1 kgf}
[153.3 lbf]
[164.2 to 181.5 lbf]
ø 20 20.011 to 20.094
Rocker bushing inside diameter
[0.79] [0.7878 to 0.7911]
Rocker ø 20 19.966 to 19.984
Rocker shaft outside diameter
arm [0.79] [0.7861 to 0.7868]
Clearance between rocker bushing 0.027 to 0.128 0.150
and shaft [0.0011 to 0.0050] [0.0059]
Push rod Runout Below 0.4 [0.016] 0.4 [0.016] TIR

2-4
ENGINE ASSY SERVICE DATA

Table 2-2 Maintenance service data table - Basic engine (3 / 4) Unit: mm [in.]
Inspection point Nominal Standard Limit Remark
0.04 0.10
Runout TIR
[0.0016] or less [0.0039]
If the diameter is the limit or
more, replace bearing.
ø 90 89.95 to 89.97 89.85 If the diameter is less than
Crank journal outside diameter
[3.54] [3.5413 to 3.5421] [3.5374] the limit, grind the journal
and use undersize bearing.
Service limit: 89.10 [3.5079]
ø 65 64.945 to 64.965 64.800
Crankpin outside diameter
[2.56] [2.5569 to 2.5577] [2.5512]
Distance between centers of journal
65 [2.56] ± 0.05 [± 0.002]
and crankpin
Pin maximum defec-
Crank- Parallelism between journal and
tion: 0.01 [0.0004] or
shaft crankpin
less
Roundness of journals and crankpins 0.01 0.03
(diameter difference) [0.0004] or less [0.0012]
Cylindericity of journals and crank-
0.01 0.03
pins
[0.0004] or less [0.0012]
(diameter difference)
Fillet radius of journal R3 [0.12] ± 0.2 [± 0.008]
Fillet radius of pin R4 [0.16] ± 0.2 [± 0.008]
If end play is less than the
limit, replace thrust plates.
0.100 to 0.264 0.300
End play If end play exceeds the limit,
[0.0039 to 0.0104] [0.0118]
replace with oversize thrust
plates.
101.915 to 101.945 101.730
STD
[4.0124 to 4.0136] [4.0051]
Outside diameter 0.25 [0.0098]/ ø 102 102.165 to 102.195 101.980
(at piston skirt) OS [4.02] [4.0222 to 4.0234] [4.0150]
0.50 [0.0197]/ 102.415 to 102.445 102.230
OS [4.0321 to 4.0333] [4.0248]
Bearing clearance check.
Gasket compressed
Protrusion from crankcase 0.8 [0.031]
(installed) thickness:
1.7 ± 0.05 [0.067 ± 0.0020]
Piston Clearance between piston pin hole 0.005 to 0.021 0.050
and piston pin [0.0002 to 0.0008] [0.0020]
Weight difference in one engine 5.0 g [0.2 oz.] or less
No.1
0.08 to 0.12 0.200
compression
[0.0031 to 0.0047] [0.0079]
ring
Clearance between
No.2
piston ring and 0.08 to 0.12 0.150
compression
ring groove [0.0031 to 0.0047] [0.0059]
ring
0.025 to 0.065 0.150
Oil ring
[0.0010 to 0.0026] [0.0059]
Compression 0.30 to 0.45
Piston rings [0.0118 to 0.0177] 1.50
End gap
ring 0.30 to 0.50 [0.0591]
Oil ring
[0.0118 to 0.0197]

2-5
ENGINE ASSY
SERVICE DATA

Table 2-2 Maintenance service data table - Basic engine (4 / 4) Unit: mm [in.]
Inspection point Nominal Standard Limit Remark
ø 34 33.991 to 33.997
Outside diameter
[1.34] [1.3382 to 1.3385]
Clearance between pin and connect- 0.023 to 0.054 0.080
Piston pin
ing rod bushing [0.0009 to 0.0021] [0.0031]
ø 34 34.020 to 34.045
Inside diameter of bushing
[1.34] [1.3394 to 1.3404]
0.05/100 0.150
Bend and twist
[0.0020/3.94] or less [0.0059]
Clearance between crankpin and con- 0.035 to 0.100 0.200
Connect- necting rod bearing [0.0014 to 0.0039] [0.0079]
ing rod
0.15 to 0.35 0.50 Replace connecting rod bear-
End play
[0.0059 to 0.0138] [0.0197] ings.
Weight difference in one engine 10 g [0.4 oz.] or less
Flatness 0.15 [0.0059] or less 0.5 [0.0197]
Flywheel
Runout 0.15 [0.0059] or less 0.5 [0.0197]
TIR
0.10
Runout 0.04 [0.0016] or less Repair using a press, or
[0.0039]
replace.
Major axis
+0.1 Major axis - minor
46.911 -0.3 Major axis - minor axis
Inlet axis = 6.189
[1.8469
+0.004 = 6.689 [0.2633]
-0.012 [0.2437] Major axis
]
Cam lift Minor
Major axis axis
+0.1 Major axis - minor
Camshaft 46.256 -0.3 Major axis - minor axis
Exhaust axis = 5.729
[1.8211
+0.004
-0.012
= 6.229 [0.2452]
[0.2256]
]
Front ø 54 53.94 to 53.96 53.90
Middle [2.13] [2.1236 to 2.1244] [2.1220]
Journal diameter
ø 53 52.94 to 52.96 52.90
Rear
[2.09] [2.0842 to 2.0850] [2.0827]
0.10 to 0.25 0.30
End play Replace thrust plate.
[0.0039 to 0.0098] [0.0118]
Clearance between idler bushing and 0.009 to 0.050
0.100 [0.0039] Replace bushing.
shaft [0.0004 to 0.0020]
0.05 to 0.20 0.35
Idler Idler gear end play Replace thrust plate.
[0.0020 to 0.0079] [0.0138]
Interference between shaft and crank- 35 -0.016 to -0.035
case hole [1.38] [-0.0006 to -0.0138]
Between crankshaft gear 0.053 to 0.154 0.25
and idler gear [0.0021 to 0.0061] [0.0098]
Between camshaft gear 0.049 to 0.160 0.25
Timing and idler gear [0.0019 to 0.0063] [0.0098]
gear Replace gear.
backlash Between injection pump idler gear 0.050 to 0.228 0.25
and idler gear [0.0020 to 0.0090] [0.0098]
Between injection pump idler gear 0.044 to 0.163 0.25
and injection pump gear [0.0017 to 0.0064] [0.0098]

2-6
ENGINE ASSY SERVICE DATA

1.3 Lubrication system

Table 2-3 Maintenance service data table - Lubrication system Unit: mm [in.]
Inspection point Nominal Standard Limit Remark
Backlash between the oil pump idler gear and 0.051 to 0.197 0.35
the idler gear [0.0020 to 0.0078] [0.0138]
Replace gear.
Backlash between the oil pump idler gear and 0.049 to 0.166 0.35
Oil pump
the oil pump drive gear [0.0019 to 0.0065] [0.0138]
0.10 to 0.27
Oil pump idler gear end play
[0.0039 to 0.0106]
0.35 ± 0.05 MPa
Relief valve Valve opening pressure {3.5 ± 0.5 kgf/cm²}
[49.8 ± 7.1 psi]
1.1 MPa
Safety valve Valve opening pressure {11 kgf/cm²}
[157 psi]

1.4 Cooling system

Table 2-4 Maintenance service data table - Cooling system
Inspection point Nominal Standard Limit Remark
Temperature at which valve starts open- 71 ± 2°C
ing [160 ± 3.6°F]
Thermostat
Temperature at which valve lift is 10 85°C
[0.039], minimum [185°F]

1.5 Inlet and exhaust system

Table 2-5 Maintenance service data table - Inlet and exhaust system Unit: mm [in.]
Inspection point Nominal Standard Limit Remarks
Distortion of exhaust manifold Below 0.2 [0.008]

1.6 Electrical system

Table 2-6 Maintenance service data table - Electrical system Unit: mm [in.]
Inspection point Nominal Standard Limit Remark
0.06
Armature shaft runout TIR
[0.0024]
0.10
Runout
[0.0039]
Commutator
0.7 to 0.9 0.2
Undercut depth
Starter [0.028 to 0.035] [0.008]
17 to 18 10
Brush length
[0.67 to 0.71] [0.39]
21.56 to 27.44 N 21.56 N
Tension of brush springs {2.2 to 2.8 kgf} {2.2 kgf}
[15.9 to 20.3 lbf] [15.9 lbf]
Alternator Adjusting voltage 27.5 to 29.5V at 25°C [77°F]

2-7
ENGINE ASSY DETERMINATION OF OVERHAUL

2. Testing compression pressure

CAUTION
Compression gage
(a) Measure all cylinders for compression pressure. P/N:33391-02100
Do not measure only one cylinder and make
assumption about the other cylinders as it will lead
Gage adapter
to a wrong conclusion. P/N:32G91-00500
(b) Compression pressure varies depending on the
engine speed. When measuring the compression
pressure, be sure to measure the engine speed as
well.
(c) It is important to regularly check the compression
pressure so that you can tell the change with time.
Testing compression pressure
(1) Disconnect the harness connector from the injector
solenoid connector.
(2) Disconnect the harness connector from the MPROP
connector on the fuel pump.
(3) Select a cylinder, and remove the injector in the
cylinder. (Each cylinder is tested one at a time.)
(4) Install a gauge adapter in the same location that the
injector was mounted, and install a compression gauge
to the gauge adapter.
(5) Start the engine using starter. With the engine running
at specified speed, read the compression gauge.
(6) If the measured value is at the limit or below, overhaul
the engine.

Item Standard Limit

Engine speed 300 min-1 -
2.6 MPa
2.9 MPa
{27 kgf/cm²}
Compression pressure {30kgf/cm²}
[384 psi]
[427 psi]
or more

4-3
ENGINE ASSY - FUEL SYSTEM
Fuel system

1. Environment of fuel system service 2. Removing fuel system

To maintain the cleanliness when installing, removing,
inspecting and repairing the fuel system of this engine, WARNING
(a) Keep flame or heat away from the fuel system
observe the following instructions.
before conducting the removal work. It could be
• Clean the engine before conducting the fuel system
cause a fire.
service.
(b) Wipe off any spilled fuel. Spilled fuel could cause a
• Cover the electrical parts and connectors to protect
fire.
the parts, and to prevent the electric leakage and
(c) Do not conduct the work right after the engine stop-
short-circuit.
ping. There are high pressure fuel remaining inside
• Cleaning and drying the fuel system using com-
the fuel system parts such as the fuel pump, com-
pressed air must be done before disassembling the
mon rail and injectors.
fuel system to prevent dust from entering the fuel
(d) Cut the fuel supply from the fuel tank before con-
injection pipes.
ducting the work.
• To keep the parts from contaminants, seal the open-
ings with plugs as soon as the fuel system parts are
CAUTION
removed.
(a) Cover or plug any inlet and outlet openings to pre-
• Disassembling and reassembling work of fuel sys-
vent dust from entering fuel system.
tem parts must be done on the work table that has
(b) If maintenance of the fuel pump, common rail and
stainless-steel table top.
injectors that are not instructed in this manual are
• Always use clean tools when working on the fuel sys-
required, do not conduct the maintenance by your-
tem. After working, clean the tools.
self. For fuel pump, common rail, and injector, have
• When the ventilator is installed in the working area,
a specialized maintenance shop do the mainte-
install the filter to the ventilator. Do not use the elec-
nance work.
tric fan at the working area.
(c) When the contaminant entered in the fuel system,
• Do not wear the fuzzy cloths. Wear clean cloths at
clean inside of the fuel system with clean fuel oil.
the working area. Wear hat to prevent hair falling. Do
not use the hand cream or equivalent. Use the rub-
ber glove for precise manufacture if necessary.

8-2
 Fuel system
ENGINE ASSY - FUEL SYSTEM

2.1 Removing fuel system (Part 1)

Replace: Sealing washer 8

B
O-ring
Gasket
Leak off hose 6

10
2
3
4 1
5 11
16
A
18 14
17 D
15 7 9
B
C 13

C
21

22

12

23
19
D

A 20

FUEL SYSTEM
Removing fuel systemPARTS
(Part 1)
Removing sequence

1 Pipe clamp 9 Fuel pipe 17 Nozzle ground

2 No.1 injection pipe 10 Bracket 18 Injector
3 No.2 injection pipe 11 Bolt 19 Fuel pump nut
4 No.3 injection pipe 12 Hose clamp 20 Fuel pump flange, fuel pump
5 No.4 injection pipe 13 Fuel hose 21 Head assembly
6 Leak off hose 14 Fuel return pipe 22 Fuel filter element
7 Fuel hose 15 Common rail 23 Water sedimenter
8 Pipe clamp 16 Hexagon bolt

8-3
 Fuel systemASSY - FUEL SYSTEM
ENGINE

2.2 Removing fuel system (Part 2)

1
2

Removing fuel system (Part 2)

Removing sequence

1 Fuel pump nut 3 Bolt 5 Fuel pump idler gear, bearing

2 Fuel pump gear 4 Fuel pump

8-4
ENGINE ASSY - FUEL SYSTEM Fuel system

3. Replacing fuel pump, fuel pump gear and fuel pump idler gear
3.1 Removing fuel pump and fuel pump gear

CAUTION
Be careful not to damage the fuel metering unit
Put a mating mark
(MPROP) when removing the fuel pump and fuel
pump gear.
(1) Remove the harness connector.
(2) Disconnect the fuel pipes and hoses from the fuel
pump.
(3) Remove the inspection cover for the fuel pump idler Fuel pump Idler gear
idler gear
gear and idler gear.
(4) Put a mating mark on the fuel pump idler gear and idler
gear with white paint. Removing fuel pump
(5) Remove the fuel pump together with the fuel pump
flange from the timing gear case.
(6) Install the baffle jig that is included in the HPP gear
remove kit (32G91-01010) to the fuel pump flange as
shown in the illustration.
(7) Put a mating mark on the fuel pump idler gear and fuel
pump gear with white paint. Baffle
(8) Remove the fuel pump gear mounting nut.
(9) Install the fuel pump gear puller, that is included in the
HPP gear remove kit (32G91-01010), to the fuel pump Fuel pump
gear. Install the one arm of the gear puller to the body
of the gear puller. Insert the installed arm into the Removing fuel pump gear (1)
clearance between the fuel pump gear and fuel pump
flange, and hook the fuel pump gear. Also insert the
Arm of
other arm of gear puller into the clearance, and hook the
gear puller
fuel pump gear. After hook the fuel pump gear, install
the other arm to the body of gear puller. Body of
gear puller
(10)Tighten the jack bolt of gear puller to the specified
torque and remove the fuel pump gear.
(11)Remove the fuel pump from the fuel pump flange.
Jack bolt
CAUTION Tightening torque Fuel pump
(a) Fuel pump gear could come off suddenly. Be care- 10 N·m {0.1 kgf·m}
ful when removing the fuel pump gear with gear
puller. Removing fuel pump gear (2)
(b) When the replacement of the fuel pump idler gear
and/or the bearing is required, replace the fuel
pump flange and fuel pump idler gear as assem-
bly.

8-5
ENGINE ASSY - FUEL SYSTEM
Fuel system

3.2 Installing fuel pump and fuel pump gear

(1) Apply grease to the O ring of fuel pump shaft.
(2) Install the fuel pump into the fuel pump flange.
(3) Install the woodruff key into the fuel pump shaft.

CAUTION
Make sure that the top face of the woodruff key is par-
allelized with the fuel pump shaft when it is installed. If
it is not parallelized, it will be hard to pull out on next
removal.
(4) Install the fuel pump gear with aligning the position of
woodruff key into the fuel pump shaft. Then, mating Installing fuel pump
mark of fuel pump gear and fuel pump gear must be
aligned.
(5) Install the O ring on the fuel pump flange.
(6) With aligning the mating mark of fuel pump idler gear
and idler gear, install the fuel pump flange together
with the fuel pump to the timing gear case.
(7) Install the inspection cover for the fuel pump idler gear
and idler gear to the timing gear case.
(8) Connect the harness connector.
(9) Install the fuel pipes and hoses, and tighten it to the
specified torque.

8-6
ENGINE ASSY - FUEL SYSTEM Fuel system

4. Disassembling and inspecting fuel pump

4.1 Inspecting fuel pump
Inspect the fuel pump for following items shown in the illustration after removed from the engine. If defects of parts are found,
replace it with new one.

1 Damage of key groove

and thread
Damage of
mating surface
5

Damage of connector
and terminal
Damage of 2 3
mating surface
Damage of mating surface
and thread

Inspecting fuel pump

1 Fuel backflow connector 3 Fuel outlet connector 5 Eccentric drive shaft

2 Fuel inlet connctor 4 Fuel metering unit (MPROP)

CAUTION
When replacing the fuel pump parts, operate the engine at low idle for 10 minutes after replacement and make sure
no leakage are found. After that, operate the engine again at rated speed for 3 minutes and make sure no leakage
are found.

CAUTION
When replacing the fuel pump parts, put the red or white mark (ø5mm circle) on the new parts to notify the replace-
ment.

8-7
ENGINE ASSY - FUEL SYSTEM
Fuel system

4.2 Disassembling fuel pump

4.2.1 Preparation of disassembling fuel pump Fuel backflow Rubber cap
connector 31A61-01800
(1) Seal the fuel backflow connector, fuel inlet connector
and fuel oultet connctor with plugs. Fuel
(2) Clean the fuel pump with commercial cleaning agent metering
and dry it with compressed air. unit
Fuel inlet
connector
CAUTION Plug
When cleaning the fuel pump, be careful not to allow 31G61-08600
the cleaning agent entering the connector of fuel
Plug Fuel outlet connector
metering unit. 31G61-08700

Preparation of disassembling fuel pump

4.2.2 Removing feed pump

(1) Remove the four Torx screws, and remove the feed
pump from the pump housing carefully. Feed pump
Note: Remove dust from the feed pump mating surface of
the pump housing if there it is.

Torx screw

Removing feed pump

4.2.3 Removing fuel metering unit

(1) Remove the three Torx screws, and remove the fuel
metering unit from the pump housing carefully.
Flat gasket
(2) Remove the flat gasket.
Note: (a) Be careful not to damage the pump housing when Connector
removing the flat gasket.
(b) Do not touch inside of the fuel metering unit
connector.
(c) Do not allow water and oil entering the fuel
Fuel metering unit
metering unit connector.
Torx screw
(d) Remove dust from the fuel metering unit mating
surface of the pump housing if there it is. Removing fuel metering unit

8-8
ENGINE ASSY - FUEL SYSTEM Fuel system

4.2.4 Removing overflow valve

(1) Remove the oveflow valve.
Note: Remove dust from the overflow valve mating surface
of the pump housing if there it is.

CAUTION
Be careful not to damage the fuel metering unit con-
nector when removing the overflow valve.

Overflow valve

Removing overflow valve

4.3 Reassembling fuel pump

4.3.1 Installing feed pump
Feed pump
Note: Make sure no dust and damage are found on the feed Shaft hole
pump mating surface of the pump housing.
(1) Apply grease to the seal ring evenly.
(2) Install the seal ring into the ring groove of the feed
pump.
(3) Using the flat blade screwdriver, aling the shaft hole
Seal ring
position as shown in the illustration.
(4) Install the feed pump with aligning the shaft and shaft Shaft
hole.
(5) Tighten the Torx screw in the numerical order as shown Installing feed pump (1)
in the illustration by folloing steps.
a. Tighten by hand.
b. Tighten to 2 ± 1 N·m
c. Tighten to 8 ± 0.5 N·m

Installing feed pump (2)

8-9
ENGINE ASSY - FUEL SYSTEM
Fuel system

4.3.2 Installing fuel metering unit

(1) Apply grease to the O ring, and install the O ing into the
ring groove of fuel metering unit. Flat gasket
Note: (a) Do not install the O ring to wrong position.
(b) Be careful not to damage the O ring when Connector
installing it.
Note: Make sure no dust and damage are found on the fuel
metering unit mating surface of pump housing. Torx screw
(2) Install the flat gasket to the fuel metering unit. Tightening torque
Fuel metering unit 6.5 ± 0.5 N·m
(3) With aligning the thread holes, install the fuel metering {0.65 ± 0.05 kgf·m}
unit together with the flat gasket into the pump housing. [4.8 ± 0.4 lbf·ft]

(4) Tighten the Torx screw to the specified torque. Installing fuel metering unit

4.3.3 Installing overflow valve

Note: Make sure no dust and damage are found on the
overflow valve mating surface of pump housing.
(1) Apply clean oil to the O ring thinly.
(2) Install the overflow valve into the pump housing. Then,
be careful not to damage the O ring.
(3) Tighten the overflow valve to the specified torque.
Note: If the O ring is damaged, replace it.
Overflow valve
Tightening torque
20 ± 1.5 N·m {2.0 ± 0.15 kgf·m} [15 ± 1 lbf·ft]

Installing overflow valve

4.3.4 Replacing O ring of overflow valve

(1) Remove the O ring.
(2) Insert the new O ring into the mouting sleeve.
Mounting
(3) Insert the overflow valve into the mouting sleeve to
sleeve
install the O ring to the ring groove. 32G61-08800

O ring
Overflow valve

Replacing O ring

8-10
ENGINE ASSY - FUEL SYSTEM Fuel system

5. Disassembling and inspecting common rail

5.1 Inspecting common rail assembly
Inspect the common rail assembly for following items shown in the illustration after removed from the engine. If defects of rail
pressure sensor are found, replace it with new one. If defects of any other parts are found, replace the common rail assembly
with new one.

Damage of mating surface

and thread
4
1

Damage of
mating surface

Damage of connector
3 and terminal

Damage of mating surface

and thread

Inspecting common rail assembly

1 Fuel inlet connctor 3 Fuel backflow connector

2 Fuel outlet connector 4 Rail pressure sensor

CAUTION
When replacing the common rail assembly parts, operate the engine at low idle for 10 minutes after replacement
and make sure no leakage are found. After that, operate the engine again at rated speed for 3 minutes and make
sure no leakage are found.

CAUTION
When replacing the common rail assembly parts, put the red or white mark (ø5mm circle) on the new parts to notify
the replacement.

8-11
 Fuel system
ENGINE ASSY - FUEL SYSTEM
5.2 Disassembling common rail assembly
5.2.1 Preparation of disassembling common rail
Rail sensor connector
assembly
Fuel inlet connector
(1) Seal the four of fuel outlet connectors, rail pressure (Plug 32G61-09300)
sensor connector, fuel backflow connector and fuel
Fuel outlet connector (4)
inlet connector with plugs. (Plug 32G61-09300)
(2) Clean the common rail with commercial cleaning agent
and dry it with compressed air.
Fuel backflow connector
CAUTION
(Plug 32G61-09400)
When cleaning the common rail, be careful not to allow
the cleaning agent entering the connector of rail pres-
Preparation of disassembling common rail assembly
sure sensor.

5.2.2 Removing rail pressure sensor

(1) Remove the rail pressure sensor.
Note: (a) Do not touch inside of the rail pressure sensor Rail pressure sensor
connector.
(b) Do not allow water and oil entering the rail
pressure sensor connector.
(c) Remove dust and burr from the rail pressure
sensor mating surface of common rail if there it
is. If burr or damage that cannot remove are
found, replace the common rail assembly with a
new one.
Removing rail pressure sensor

5.2.3 Removing pressure limiting valve

(1) Remove the pressure limiting valve.
Note: (a) Remove dust and burr from the pressure limiting
valve mating surface of common rail if there it is.
(b) Be careful not to allow peeled paint entering the
common rail.

Pressure limiting valve

Removing pressure limiting valve

8-12
ENGINE ASSY - FUEL SYSTEM Fuel system

5.3 Reassembling common rail assembly

5.3.1 Installing rail pressure sensor Rail pressure sensor
(1) Apply clean oil thinly to the mating surface and thread Tightening torque
of rail pressure sensor. 95 ± 5 N·m {9.7 ± 0.5 kgf·m}
[70 ± 4 lbf·ft]
Note: (a) Do not apply grease.
(b) Be careful not to allow the peeled paint entering
the common rail.
(2) Install the rail pressure sensor, and tighten it to the
specified torque.

Installing rail pressure sensor

5.3.2 Installing pressure limiting valve

(1) Apply clean oil thinly to the mating surface, O ring and Pressure limiting valve
thread of pressure limiting valve. Tightening torque
Note: (a) Do not apply grease. 100 ± 5 N·m {10.2 ± 0.5 kgf·m}
[74 ± 4 lbf·ft]
(b) Be careful not to allow the peeled paint entering
the common rail.
(2) Install the pressure limiting valve, and tighten it to the
specified torque.

Installing pressure limiting valve

8-13
ENGINE ASSY - FUEL SYSTEM
Fuel system

6. Installing fuel system

6.1 Installing fuel system (Part 1)

19 ± 2 N·m
{1.9 ± 0.2 kgf·m}
[13.7 ± 1.4 lbf·ft]

70 ± 5 N·m
{7.1 ± 0.5 kgf·m}
[51.4 ± 3.6 lbf·ft]

Installing fuel system (Part 1)

8-14
ENGINE ASSY - FUEL SYSTEM Fuel system

6.2 Installing fuel system (Part 2)

Replace: Sealing washer 25 ± 3 N·m B

O-ring {2.5 ± 0.3 kgf·m}
Gasket [18 ± 2.2 lbf·ft]
Leak off hose 20 ± 2 N·m
{2 ± 0.2 kgf·m}
[14.5 ± 1.4 lbf·ft]
30 ± 3 N·m
{3.1 ± 0.3 kgf·m}
[22.4 ± 2.2 lbf·ft]

A
D
25 ± 3 N·m B
{2.5 ± 0.3 kgf·m}
[18 ± 2.2 lbf·ft] C

C
20 ± 2 N·m
{2 ± 0.2 kgf·m}
[14.5 ± 1.4 lbf·ft]

25 +2.5
0 N·m
{2.5 +0.25
0 kgf·m}
+1.8
[18 0 lbf·ft]

Installing fuel system (Part 2)

8-15
ENGINE ASSY
COOLING - COOLING SYSTEM
SYSTEM

1. Removing cooling system

Replace
5

Crack, water leakage, damage

Replace
4

2 3

Crack, wear

Removing cooling system

Removing sequence

1 Fan 3 Belt 5 Thermostat assembly

2 Spacer 4 Water pump assembly

10-2
ENGINE ASSY - COOLING SYSTEM COOLING SYSTEM

2. Inspecting cooling system

2.1 Inspecting water pump for smooth rotation
Check to make sure that the impeller and shaft of water
pump rotate smoothly without noise and irregularities. If
faulty, replace the water pump assembly.

2.2 Inspecting thermostat

CAUTION
Be careful of burns or a fire when measuring tempera-
ture, as it involves a high-temperature and open flame.
To test the thermostat operation, immerse the thermostat in a
container filled with water. Heat the water, while measuring
the water temperature. Record the temperature at the
conditions shown in the table below. If the temperatures are
not within the standard range, replace the thermostat.
Note: (a) Stir the water in the container with a stick to
ensure uniform temperature distribution.
Inspecting thermostat
(b) Before installing the thermostat, be sure to check
the valve opening temperature stamped on the
thermostat valve side face.

Item Standard
Temperature at which valve starts 71 ± 2°C
opening [160 ± 3.6°F]
Temperature at which valve lift
85°C [185°F]
becomes 10 mm [0.39 in.] or more.

Note: When assembling, orient the thermostat with its air

breed hole faced upward.

10-3
ENGINE ASSY
COOLING - COOLING SYSTEM
SYSTEM

3. Installing cooling system

Replace

Crack, water leakage, damage

Replace

Water pump mounting bolt

M8 × 1.25
17 ± 2.9 N·m {1.7 ± 0.3kgf·m} [12.5 ± 2 lbf·ft]
Water pump mounting bolt
Crack, wear (together with gear case)
M8 × 1.25
19 ± 2 N·m {1.9 ± 0.2 kgf·m} [13.7 ± 1.4 lbf·ft]
M10 × 1.25
35 ± 3 N·m {3.6 ± 0.3 kgf·m} [25.3 ± 2.2 lbf·ft]
Fan and water pump pulley mounting bolt
M10 × 1.5, 49 ± 5 N·m {5 ± 0.5kgf·m} [36.2 ± 3.6 lbf·ft]

Installing cooling system

10-4
ENGINE ASSY - ELECTRICAL COMPONENT - STARTER ELECTRICAL SYSTEM

2. Disassembling, inspecting and reassembling electrical system

2.1 Disassembling and inspecting starter

11
12
4
14
Open or short circuit

25
18
15
16
17 Damage, wear

13
23 Damage, wear
24
22
Damage, wear
3 21
19 Replace

20 Function of
overrunning clutch
2
6
1 Replace
5
Wear
Damage, wear
7

Replace Brush dust accumulation,

8
local wear, rust,
Replace
deterioration, insulation

Open or short circuit

9

Open or short circuit,

10 ground, damage, wear

Disassembling and inspecting starter

Disassembling sequence

1 Clip ring 10 Armature 19 E ring

2 Pinion stopper, pinion, spring 11 Cover 20 Over runnning clutch
3 Bolt 12 Packing 21 Internal gear
4 Magnetic switch 13 Planetary gear 22 Plate
5 Screw 14 Ball 23 Gear shaft
6 Through bolt 15 Packing 24 Front bracket
7 Rear bracket 16 Plate 25 Safety relay
8 Brush holder 17 Spring
9 Yoke assembly 18 Shift lever

12-5
ENGINE ASSY - ELECTRICAL COMPONENT - ALTERNATOR
ELECTRICAL SYSTEM

2.4 Disassembling and inspecting alternator

4 5
6
3
3
11 Crack, damage

Rotation
10

9
12
7
17
Coil open circuit, ground
3

14

8 13

Rotation
22 Short or open circuit

16 20

18 19

23
15
Crack, damage
21

2 1

Disassembling and inspecting alternator

Disassembling sequence

1 Screw 9 Retainer 17 Stator coil

2 Cover 10 Front bearing 18 Holder
3 Through bolt 11 Front bracket 19 Regulator
4 Nut, spring washer, plain washer 12 Collar 20 Terminal B
5 Pulley 13 Rear bearing 21 Condensor
6 Fan 14 Rotor 22 Rectifier
7 Collar 15 Screw 23 Rear bracket
8 Screw 16 Field coil

12-19
 ELECTRICAL SYSTEM
ENGINE ASSY - ELECTRICAL COMPONENT - ALTERNATOR

2.8 Performance test of alternator

Measure the adjusting voltage and output current with wiring as schematic bellow.

Terminal B SW1 SW2

+
V R
- CL (24V 3W)
L

Terminal R Terminal L
Terminal E

Electric schematic of IC regulator built-in alternator performace test

2.8.1 Measuring regulator adjusting voltage 2.8.2 Measuring output current

(1) Close the SW1, and operate the alternator at 1500min -1 Close the SW1 and SW2. Measure the maximaum output
for 5 to 10 minutes until the ammeter indicates 6 A or current with a variable resistor operating the alternator at
less. 5000min-1 and keeping the indication of voltmeter at 27 V.
(2) Make sure that ammeter indicates 2 to 6 A or less, then It is normal that the measured output current is 50A or
operate the alternator at 3000 to 4000min-1. more.
If the indication of voltmeter is within the standard
CAUTION
value, the adjusting voltage of the alternator is normal.
(a) Do not disconnect the battery when operating the
(3) If the indication of ammeter is 6 A or more, charge the
alternator.
battery for a while or replace the battery with fully
(b) Do not connect the terminal L when the charge
charged one.
lamp （24V, 3W）is not used. The terminal L and
If the indication of voltmeter is out of the standard
circuit B must not be connected. It causes damege
value, replace the regulator with new one.
of diode.

Item Standard
Adjusting voltage 27.5 to 29.5 V (at 25°C [77°F])

12-29
ENGINE ASSY
ELECTRICAL - COMMON RAIL COMPONENT - ECU
SYSTEM

3.3 Replacing ECU

3.3.1 Removing ECU
(1) Make sure that the ignition switch is in the OFF
position.
(2) Uplift the lever of the connector, and pull out the
connector. Then, do not pull the harness. Pull out the
connector with holding the connector.
Note: (a) Do not forget to uplift the lever before pulling out
the connector. Do not pull the connector forcedly.
(b) Be careful for the removed connector not to
contact with other parts.
(3) Remove the ECU mouting bolts. Replacing ECU（1）
(4) Remove the ECU.

3.3.2 Installing ECU

(1) Make sure that the Q-Rank number attached on the new
ECU is same as the number attached on the previous
ECU.
Note: If the ECU which has different Q-Rank number is
installed, it causes the excess and deficiency of the
engine power.
(2) Install the ECU and tighten the ECU mouting bolts to
specified torque.
(3) Push the connector into the ECU securely, and push Replacing ECU（2）
down the lever to lock. After connecting, check the
connector for excessive play.

3.3.3 Test operation after replacing ECU

(1) Turn the ignition switch to ON position. If the diagnosis
code is not displayed on the monitor for 2 to 3 minutes,
start the engine and operate the engine in low idle.
(2) Inspect that the diagnosis code is displayed on the
monitor. Inspect the engine for noise, odor and
vibration.

12-32
ENGINE ASSY - COMMON RAIL COMPONENT - SENSORS ELECTRICAL SYSTEM

3.4 Installing sensors

Inlet manifold pressure sensor

19.6 ± 2 N·m
Pick up {2 ± 0.2 kgf·m} ̪ Apply sealing tape to the thread.
30 ± 3 N·m [14 ± 1.4 lbf·ft]
{3 ± 0.3 kgf·m} Water temperature sensor
[22 ± 2.2 lbf·ft] 7.5 ± 0.5 N·m
{0.75 ± 0.05 kgf·m}
[5.5 ± 0.36 lbf·ft]

Speed/timing sensor
Speed/timing sensor (camshaft side)
(crankshaft side) 8 ± 1 N·m
8 ± 1 N·m {0.8 ± 0.1 kgf·m}
{0.8 ± 0.1 kgf·m} [6 ± 0.7 lbf·ft]
[6 ± 0.7 lbf·ft]

Oil pressure switch

10 ± 2 N·m
{1 ± 0.2 kgf·m}
[7.2 ± 1.4 lbf·ft]

Installing sensors

12-33
ENGINE ASSY - TROUBLE SHOOTING
TROUBLESHOOTING

1. Troubleshooting by diagnosis codes

1.1 Outline of control system
This engine is controlled by electronic control unit (ECU).
The engine has the control parts and the sensors that
monitors the engine operation.
The ECU monitors the engine operation using the inputs
from various sensors, and controls the injectors and the fuel
injection pump.
This control system can provide appropriate engine control
for operating condition.

1.2 Diagnosis codes

When the ECU detects the abnormal engine operation
receiving signal input from the sensors, the ECU generates
an error code which is called a diagnosis code.
The diagnosis code includes the one which warns the
critical failure, and also the one which warns the light fault.
The diagnosis code can be seen by connecting the scan
tester（32G91-00600, 32G91-00600）to the ECU directly. It
also can be seen on the monitor if the monitor is located on
the vehicle.

14-2
ENGINE ASSY - TROUBLE SHOOTING TROUBLESHOOTING

1.3 Connecting scan tester and ECU

To see the diagnosis code, connect the scan tester to the Scan tester
Scan tester (32G91-00811)
ECU.
connector
1.3.1 Scan tester (32G91-00800) SCANTOOL EOBD

INSPECTION
DIAGNOSTIC

(1) Turn the ignition switch to OFF position. SETUP

(2) When the power (24 V) from ECU is supplied to the OBD/OBDII/EOBD Scentool

ESC

service connector, connect the scan tester (32G91-

00811) connector and service connector directly. When
the power (24 V) from ECU is not supplied to the Service connector
service connector, use a interconnect cable. Connect a
extension harness connector A with a scan tester
connector, and extension harness connector B with a Connecting scan tester and ECU
service connector. Then, the power is supplied from a (32G91-00800, when the power is supplied from ECU)
cigarette.
Service Scan tester
(3) Turn the ignition switch to ON position. Extension harness
connector (32G91-00811)
1.3.2 Scan tester (32G91-00600) connector B
(1) Turn the ignition switch to OFF position. SCANTOOL EOBD

INSPECTION
DIAGNOSTIC
SETUP

(2) Connect the scan tester connector to the service

Scan OBD/OBDII/EOBD Scentool

connector which is located on the vehicle. Extension

ESC

tester
Cigarette plug harness
(3) Turn the ignition switch to ON position. connector
connector A

1.4 When ECU does not respond Connect to the cigarette

on the vehicle
If the scan tester does not display with connecting to the Interconnect cable
service connector, following conditions can be concerned. (32G91-00812)

• The harness and/or the connector between the service Connecting scan tester and ECU
connector and the ECU are faulty. (32G91-00800, when the power is not supplied from
ECU)
• The ECU is faulty.
At first, inspect the harness and connectors between the
Scan tester
service connector and the ECU. For the inspection, refer to Service connector (32G91-00600)
"Inspecting wiring"(14-36). Scan tester mastertech

If the harness and the connectors are not faulty, replace the connector
ECU. For the replacement of ECU, refer to "Replacing
ECU"(12-32).

CAUTION
The engine may operate even if the ECU does not Interface
Vetronix

respond with the scan tester. In this case, it is possible

that there are faults on the CAN circuit (communica-
tion circuit connecting the ECU and vehicle control Connecting scan tester and ECU
unit) inside the ECU. Do not operate the engine except (32G91-00600)
emergency situation, replace the ECU.

14-3
ENGINE ASSY - TROUBLE SHOOTING
TROUBLESHOOTING

2. Scan tester (32G91-00800, main unit: 32G91-00811, interconnect cable: 32G91-

00812)

SCANTOOL EOBD

EOBD SCANTOOL DIAGNOSTIC

INSPECTION
DIAGNOSTIC INSPECTIONS
SETUP
MEASURE
FAULT CODES
䣅䣑䣏䣏䣗䣐䣋䣅䣃䣖䣋䣑䣐
䣃䣰䣶䣫䣲䣱䣮䣮䣷䣶䣫䣱䣰
OBD/OBDII/EOBD Scantool

ESC
ESC pour quitter CE AND PUSH OK . .

Connection screen DIAGNOSTIC menu

SCANTOOL EOBD

INSPECTIONS
DIAGNOSTIC
SETUP

CE AND PUSH OK . .

Main menu

Scan tester

Scan tester (32G91-00811)

2.1 Basic operation of scan tester
• Press UP key and DOWN key to move the cursor up and OBD/OBDII/EOBD Scantool ESC key
down.
UP key
• When the page number is displayed on the upper right of ESC
the screen, turn the page to use RIGHT key and LEFT
LEFT key ENTER key
key.
• Press ESC key to return to the previous screen.
• Press ENTER key to execute the selected menu. RIGHT key

DOWN key

Key operation

14-4
ENGINE ASSY - TROUBLE SHOOTING TROUBLESHOOTING

2.2 Connecting the connector

(1) Make sure that the ignition key is OFF position. EOBD SCANTOOL
(2) When the power (24 V) from ECU is supplied to the
service connector, connect the scan tester (32G91-
00811) connector and service connector directly. When
the power (24 V) from ECU is not supplied to the 䎦䎲䎰䎰䎸䎱䎬䎦䎤䎷䎬䎲䎱
service connector, use a interconnect cable. Then, the 䎤䏑䏗䏌䏓䏒䏏䏏䏘䏗䏌䏒䏑
power is supplied from a cigarette. For more
information, refer to "Connecting scan tester and
ECU"(14-3). ESC pour quitter
(3) Turn the ignition key to ON position.
(4) The Connection screen is displayed, and then the main Connection screen
menu is displayed.

SCANTOOL EOBD

INSPECTIONS
DIAGNOSTIC
SETUP

CE AND PUSH OK . .

Main menu screen

14-5
ENGINE ASSY - TROUBLE SHOOTING
TROUBLESHOOTING

2.3 Diagnostic
Using the scan tester, you can check the diagnostic codes
SCANTOOL EOBD
that are occurring presently or occurred in the past, and the
engine status when having trouble with the engine.
(1) Select DIAGNOSTIC from the main menu screen and INSPECTIONS
press ENTER key. (INSPECTIONS and SETUP are not DIAGNOSTIC
used.) SETUP

CE AND PUSH OK . .

Main menu screen

(2) The DIAGNOSTIC menu is displayed.
Note: If ECU is not support the OBD tool, it takes few
DIAGNOSTIC
minutes to display the DIAGNOSTIC menu. Then,
the "ECU does not respond..." message is displayed. INSPECTIONS
MEASURE
FAULT CODES

CE AND PUSH OK . .

DIAGNOSTIC menu screen

14-6
ENGINE ASSY - TROUBLE SHOOTING TROUBLESHOOTING

2.3.1 Checking engine status

(1) Select MEASURE from the DIAGNOSTIC menu and
DIAGNOSTIC
press ENTER key. The MEASURE menu is displayed.
(2) Select INTERNAL MEASURES from the MEASURE INSPECTIONS
MEASURE
menu, and press ENTER key.
FAULT CODES
(3) Each engine status is displayed. Turn the page to use
RIGHT or LEFT key.

Engine status displays 01/03

Screen display (The val- Description (The values CE AND PUSH OK . .
ues are an example) are an example)
Number of codes stored in DIAGNOSTIC menu screen
Number of diagnosis codes
this module
3
3 code(s)
MEASURE
MI commanded ON by the
Warning
module INTERNAL MEASURES
None
NO
OXYGEN SENSORS
Calculated load value Engine torque NO CONTINU TEST
0.0% 0.0%
Engine coolant temperature
Water temperature 19 ℃
19 ℃
Intake manifold absolute
pressure
Boost pressure CE AND PUSH OK . .
1438hPa (Abs)
143kPa Abs
MEASURE menu screen
Engine status displays 02/03
Screen display (The val- Description (The values
INTERNAL MEASURES 01 03
ues are an example) are an example)
Number of codes s. .
Engine speed Engine revolutions 3 code(s)
0 rpm 0 rpm MI commanded ON b . .
NO
Gazol pressure Rail pressure Calculated load v . .
59040 kPa Mano 590400 hPa 0.0 %
Engine coolant te . .
Number of warm-ups since 19 °C
diagnostic trouble codes Q-rank Intake manifold a . .
cleared 4 101 kPa Abs .
4 Number of codes

Barometric pressure Barometrical pressure

100 kPa 1003 hPa Engine status screen

Control module voltage Battery voltage

Note: The full text of the item that has been selected with
24.007 V 24.007 V
the cursor is displayed at the bottom of screen.
Engine status displays 03/03
Screen display (The val- Description (The values
ues are an example) are an example)
Accelerator (D)
Accelerator pedal position D 82.3%
82.3 % (CAN communication sig-
nal)
Accelerator (A)
Accelerator pedal position E
82.3%
82.3%
(Analog signal)

14-7
ENGINE ASSY - TROUBLE SHOOTING
TROUBLESHOOTING

2.3.2 Checking diagnosis codes

(1) Select FAULT CODES from the DIAGNOSTIC menu
DIAGNOSTIC
and press ENTER key. The FAULT CODES menu is
displayed. INSPECTIONS
MEASURE
FAULT CODES

CE AND PUSH OK . .

DIAGNOSTIC menu screen

(2) Select ACTIVE FAULT CODES from the FAULT
CODES menu and press ENTER key.
FAULT CODES
STORED FAULT CODES
FREEZED FRAME
ACTIVE FAULT CODES
ERASE FAULT CODES

CE AND PUSH OK . .

FAULT CODES menu screen

(3) The registered diagnosis codes are displayed.

ACTIVE FAULTS
P0543
P060D
P060E

CE AND PUSH OK . .

ACTIVE FAULTS screen

(4) Select the code which you want to confirm the content
and press ENTER key. The content of diagnosis code is
ACTIVE FAULTS
displayed. (Unregistered content in the scan tester is not
P0543
displayed.) P0543 Intake Air H
eater A Circuit Op
en

543 Intake Air H

Contents screen

14-8
ENGINE ASSY - TROUBLE SHOOTING TROUBLESHOOTING

2.3.3 Checking freeze data

(1) Select FAULT CODES from the DIAGNOSTIC menu
DIAGNOSTIC
and ENTER key. The FAULT CODES menu is
displayed. INSPECTIONS
MEASURE
FAULT CODES

CE AND PUSH OK . .

DIAGNOSTIC menu screen

(2) Select FREEZED FRAME from the FAULT CODES
menu and press ENTER key. The FREEZED FRAME
FAULT CODES
menu is displayed.
STORED FAULT CODES
FREEZED FRAME
ACTIVE FAULT CODES
ERASE FAULT CODES

CE AND PUSH OK . .

FAULT CODES menu screen

(3) Select READ FREEZED FRAME from the FREEZED
FRAME menu and press ENTER key.
Freezed frame
SERIAL NUM : 000
READ FREEZED FRAME

CE AND PUSH OK . .

FREEZED FRAME menu screen

(4) The FREEZE DATA is displayed. The FREEZE DATA
is a backup data saving the engine status screen of when 01
TRAMES FIXES 02
the diagnosis code is generated. The most important
Fault code that c . .
code in the fault codes that ECU recognizes is P060E
displayed. Turn the page to use RIGHT or LEFT key. Calculated load v . .
0.0 %
Engine coolant te . .
66 °C
Intake manifold a . .
100 kPa Abs .
Engine speed
0 rpm
Fault code that

FREEZED FRAME displaying screen

14-9
ENGINE ASSY - TROUBLE SHOOTING
TROUBLESHOOTING

2.3.4 Clearing diagnosis codes

(1) Select FAULT CODES from the DIAGNOSTIC menu
DIAGNOSTIC
and press ENTER key. The FAULT CODES menu is
displayed. INSPECTIONS
MEASURE
FAULT CODES

CE AND PUSH OK . .

DIAGNOSTIC menu screen

(2) Select ERASE FAULT CODES from the FAULT
CODES menu.
FAULT CODES
STORED FAULT CODES
FREEZED FRAME
ACTIVE FAULT CODES
ERASE FAULT CODES

CE AND PUSH OK . .

FAULT CODES menu screen

(3) Press ENTER key to delete the diagnosis code.

FAULT CODES
STORED FAULT CODES
FREEZED FRAME
INITIALIZATION
ACTIVE FAULT
DONECODES
S
ERASE FAULT CODES

CE AND PUSH OK . .

Clear DIAG screen

14-10
ENGINE ASSY - TROUBLE SHOOTING TROUBLESHOOTING

3. Scan tester (32G91-00600)

mastertech

Startup screen OBD ΤFUNCTION MENU

YES NO ENTER

F1 F2 F3
HELP
1 2 3

F4 F5 F6
RCV
4 5 6
FUNCTION MENU OBD ΤTEST MENU
F7 F8 F9
SEND
7 8 9

F0 ON
EXIT 㧖 0 #
OFF

Vetronix

Scan tester

SELECT PROGRAM

Scan tester (32G91-00600)

3.1 Operation of scan tester (9) The menu screen of OBD Ⅱ FUNCTIONS is
Use scan tester to check the engine status and the diagnosis displayed.
codes. (10)Press EXIT key to return the previous screen.
3.1.1 Basic operation of scan tester (11)With pressing ON key, press EXIT key to turn off the
(1) Make sure that ignition key is OFF position. scan tester.
(2) Connect the scan tester to the service connector on the (12)Turn the ignition key to OFF position to turn off the
vehicle. ECU.
(3) Turn the ignition key to ON position to energize the
ECU.
(4) Press ON key located on the lower right section of scan
tester to energize the scan tester. When the scan tester is
energized, startup screen is displayed.
(5) Press ENTER key.
(6) FUNCTION MENU is displayed. Select SCAN TEST
and press ENTER key.
(7) SELECT PROGRAM is displayed. Select GLOBAL
OBD Ⅱ and press ENTER key.
(8) OBD Ⅱ TEST MENU is displayed. Select OBD Ⅱ
FUNCTIONS and press ENTER key.

14-11
 TROUBLESHOOTING
ENGINE ASSY - TROUBLE SHOOTING

3.2 Check engine status

(1) Select DATA LIST from the OBD Ⅱ FUNCTIONS
mastertech
menu and press ENTER key.
(2) Select All Data from the PARAMETER SELECTION
menu and press ENTER key.
(3) The engine status is displayed. Check the engine status.

Engine status displays

Vetronix

ECU ID $10
ENGINE SPD Engine speed (rpm)
ECT(°) Water temperature (°C)
Parameter selection screen
Engine load (%)
ENGINE LOAD
(rate against maximum fuel injection)
MAP Boost pressure (kPa(abs)) mastertech

Error status (ON-OFF)

MIL STATUS
(Existence of diagnosis codes)
STORED DTCs Number of diagnosis codes
FRP(G) Rail pressure (MPa)
WARM-UPS Q-rank (1-8)
Vetronix

BARO Barometrical pressure (PaA)

CTRL MOD(V) Battery voltage (V)
APP-D CAN accelerator (%) Engine status screen
APP-E Analog accelerator (%)

14-12
ENGINE ASSY - TROUBLE SHOOTING TROUBLESHOOTING

3.3 Screen of DTC Menu

(1) Select DTCs from the OBD Ⅱ FUNCTIONS menu and
mastertech
press ENTER key.
(2) DTC MENU is displayed.

Vetronix

DTC menu screen

3.3.1 Check diagnosis codes
(1) Select Confirmed DTCs from DTC MENU and press
mastertech
ENTER key.
(2) The diagnosis codes are displayed. The diagnosis codes
are displayed in the order of generating. To display the
previous generated codes, press down key.

Vetronix

Diagnosis code screen

3.3.2 Check freeze data
(1) Select Freeze Data from DTC MENU and press
mastertech
ENTER key.
(2) The FREEZE DATA is displayed. The FREEZE DATA
is a backup data saving the engine status screen of when
the diagnosis code is generated.

Vetronix

Freeze data screen

3.3.3 Clear diagnosis codes
(1) Select Clear Diag Info from DTC MENU and press
mastertech
ENTER key.
(2) The confirmation screen is displayed. Press YES key,
and press ENTER key to delete the diagnosis codes.
However, the diagnosis codes cannot be deleted until
the recovery is completed.

Vetronix

Clear DIAG screen

14-13
 TROUBLESHOOTING
ENGINE ASSY - TROUBLE SHOOTING
4. Diagnosis code cross reference
The P code shown in the table below is displayed by connecting the scan tester to the service connector.
The vehicle side code is displayed on the vehicle monitor. Check the corresponding codes by following chart.
For the detail and treatment of diagnosis codes, refer to "Troubleshooting reference chart".
Note: The word "DBV" in the table is an abbreviation of pressure limiting valve.

Table 14-1 Diagnosis code cross reference (2 / 4)

Table 14-1 Diagnosis code cross reference (1 / 4)
J1939 Vehicle
J1939 Vehicle P
P Item code side
Item code side code
code (DTC) code
(DTC) code
Shut off
Discrepancy between P0215 1110-2 1110-4
P0016 228-3 228-1 pass test
crank and cam signal
Shut off
Backup control using P0215 1110-12 1110-8
P0021 635-3 635-1 pass test
cam side signal
MPROP power stage
P0089 DBV valve opening 2041-3 2041-1 P0230 2001-3 2001-1
short-circuit to battery
P0089 DBV kick off 2042-4 2042-2 MPROP power stage
P0231 2002-4 2002-2
P0090 DBV closed sticking 2043-2 2043-4 short-circuit to ground

P0091 DBV pressure is too low 2045-4 2045-2 MPROP power stage open
P0252 2000-2 2000-4
circuit
P0092 DBV pressure is too high 2044-3 2044-1
MPROP power stage over-
P0117 Water temperature sensor 110-4 110-2 P0252 2000-12 2000-8
load
P0118 Water temperature sensor 110-3 110-1 Inlet manifold pressure
P0235 102-12 102-8
sensor
Accelerator signal
P0121 383-12 383-8
diagnosis Inlet manifold pressure
P0237 102-4 102-2
sensor
P0122 Accelerator sensor 1 29-4 29-2
Inlet manifold pressure
P0123 Accelerator sensor 1 29-3 29-1 P0238 102-3 102-1
sensor
Rail pressure governor
P0191 2013-3 2013-1 P0261 Injector No.1 657-2 657-4
deviation
P0262 Injector No.1 657-3 657-1
Rail pressure governor
P0191 2014-3 2014-1
deviation P0263 Injector No.1 657-12 657-8
Rail pressure governor P0264 Injector No.2 659-2 659-4
P0191 2015-3 2015-1
deviation
P0265 Injector No.2 659-3 659-1
P0192 Rail pressure SRC 2011-4 2011-2
P0266 Injector No.2 659-12 659-8
P0193 Rail pressure SRC 2011-3 2011-1
P0267 Injector No.3 661-2 661-4
Rail pressure sensor
P0192 2012-4 2012-2 P0268 Injector No.3 661-3 661-1
offset monitoring
Rail pressure sensor P0269 Injector No.3 661-12 661-8
P0193 2012-3 2012-1
offset monitoring P0270 Injector No.4 663-2 663-4
P0194 Rail pressure governor 2016-3 2016-1 P0271 Injector No.4 663-3 663-1
P0194 Rail pressure governor 2017-3 2017-1 P0272 Injector No.4 663-12 663-8
P0201 Injector No.1 658-2 658-4 Speed/timing sensor
P0336 637-4 637-2
P0202 Injector No.2 660-2 660-4 (crankshaft side)

P0203 Injector No.3 662-2 662-4 Speed/timing sensor

P0339 637-3 637-1
(crankshaft side)
P0204 Injector No.4 664-2 664-4
Speed/timing sensor
P0341 636-4 636-2
Shut off (camshaft side)
P0215 1110-4 1110-2
pass test
Speed/timing sensor
P0344 636-3 636-1
(camshaft side)

14-14
ENGINE ASSY - TROUBLE SHOOTING TROUBLESHOOTING

Table 14-1 Diagnosis code cross reference (3 / 4) Table 14-1 Diagnosis code cross reference (4 / 4)
J1939 Vehicle J1939 Vehicle
P P
Item code side Item code side
code code
(DTC) code (DTC) code
Air heater relay P060B ADC monitoring 2008-4 2008-2
P0540 677-12 677-8
power stage
P060B ADC monitoring 2008-2 2008-4
Air heater relay
P0541 677-4 677-2 P060B ADC monitoring 2008-12 2008-8
power stage
P060D CAN accelerator 91-2 91-4
Air heater relay
P0542 677-3 677-1
power stage P060E APPREQ message time out 1674-2 1674-4
Air heater relay P061C Engine speed 2005-3 2005-1
P0543 677-2 677-4
power stage
Injector
P062D 651-12 651-8
Power supply unit voltage drive bank 1
P0562 1543-4 1543-2
too low
Injector
P062E 653-12 653-8
Power supply unit voltage drive bank 2
P0563 1542-3 1542-1
too high
P062F EEPROM 1235-4 1235-2
P0600 CAN transmitting time out 2028-2 2028-4
P062F EEPROM 1235-2 1235-4
P0600 CAN (A) pass off 1671-3 1671-1
P062F EEPROM 1235-12 1235-8
P0600 CAN (C) pass off 1673-3 1673-1
P0933 Oil pressure switch 19-12 19-8
P0606 SPI communication error 1231-3 1231-1
P0933 Oil pressure switch 100-12 100-8
P0606 Super vision 1484-12 1484-8
Injector
P2047 652-2 652-4
P0607 Recovery occurred 1668-12 1668-8 drive bank 1
P0607 Recovery occurred 1670-12 1670-8 Injector
P2048 651-4 651-2
drive bank 1
P0607 SPI watch dog error 2010-12 2010-8
Injector
P0611 Injector IC 655-3 655-1 P2049 651-3 651-1
drive bank 1
P0611 Injector IC 655-4 655-2
Injector
P2050 654-2 654-4
P0611 Injector IC 655-2 655-4 drive bank 2
P0611 Injector IC 655-12 655-8 Injector
P2051 653-4 653-2
drive bank 2
P0611 Injector IC 656-3 656-1
Injector
P0611 Injector IC 656-4 656-2 P2052 653-3 653-1
drive bank 2
P0611 Injector IC 656-2 656-4
Atmospheric pressure sen-
P2228 108-4 108-2
P0611 Injector IC 656-12 656-8 sor

Sensor supply voltage Atmospheric pressure sen-

P0642 1079-4 1079-2 P2229 108-3 108-1
monitoring 1 sor

Sensor supply voltage

P0643 1079-3 1079-1
monitoring 1
Sensor supply voltage
P0652 1080-4 1080-2
monitoring 2
Sensor supply voltage
P0653 1080-3 1080-1
monitoring 2
Sensor supply voltage
P0698 620-4 620-2
monitoring 3
Sensor supply voltage
P0699 620-3 620-1
monitoring 3
P060A TPU monitoring 2009-12 2009-8
P060B ADC monitoring 2008-3 2008-1

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 TROUBLESHOOTING
ENGINE ASSY - TROUBLE SHOOTING
5. Troubleshooting reference chart
5.1 Troubleshooting with diagnosis code
Note: The diagnosis codes which has * mark in the "Recovery" column recovers when the cause of fault has deleted and the
engine has restarted.

P0016 : Discrepancy between speed/timing sensor P0117 : Water temperature sensor

(crankshaft side/camshaft side) signal Vehicle side code : 110-2
Vehicle side code : 228-1 Faulty part Water temperature sensor
Speed/timing sensor The ECU detects a faulty operation of
Faulty part
(crankshaft side/camshaft side) the water temperature sensor (open cir-
Detail
The ECU detects a discrepancy between cuit, short circuit). The input voltage
Detail speed/timing sensor (crankshaft side/ falls below the limiting value.
camshaft side) signal. Recovery *
Recovery * When engine is operated, the ECU con-
The ECU controls the engine using trols the engine as overheated
speed/timing sensor (crankshaft side) with fixing the temperature 120°C
Control signal. Control (warm mode). When starting the engine,
The ECU limits the maximum power of the ECU controls the engine with fixing
the engine. the water temperature -20°C (cold
mode).
Power limit The maximum power is limited to 50%.
When the water temperature is 100°C or
Inspection Contact a Mitsubishi dealer. Power limit above, the ECU controls the engine as
overheated.
P0021 : Backup control using camshaft side signal
Water temperature sensor, and wiring of
Vehicle side code : 635-1 Inspection
water temperature sensor.
Speed/timing sensor
Faulty part
(crankshaft side) P0118 : Water temperature sensor
The engine is operating without speed/ Vehicle side code : 110-1
timing sensor (crankshaft side) signal. Faulty part Water temperature sensor
Detail
The ECU controls the engine using cam-
shaft side signal only. The input voltage exceeds the limiting
Detail
value.
Recovery *
Recovery *
The ECU limits the maximum power of
Control When engine is operated, the ECU con-
the engine.
trols the engine as overheated
Power limit The maximum power is limited to 50%. with fixing the temperature 120°C
Speed/timing sensor (crankshaft side) Control (warm mode). When starting the engine,
Inspection and wiring of speed/timing sensor the ECU controls the engine with fixing
(crankshaft side). the water temperature -20°C (cold
mode).
When the water temperature is 100°C or
Power limit above, the ECU controls the engine as
overheated.
Water temperature sensor, and wiring of
Inspection
water temperature sensor.

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 TROUBLESHOOTING
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P0121 : Accelerator signal diagnosis P0191 : Rail pressure governor deviation

Vehicle side code : 383-8 Vehicle side code : 2013-1
Accelerator signal (CAN signal, analog Faulty part Common rail
Faulty part
signal)
The rail pressure control is abnormal.
Detail
The ECU compares the CAN signal and The target pressure is not achieved.
Detail analog signal, and detects a discrepancy
Recovery *
between them.
The ECU limits the maximum power of
When a discrepancy is deleted, it recov- Control
Recovery the engine.
ers automatically.
Power limit The maximum power is limited to 75%.
Control The ECU warns to the operator.
Inspection Damage on the common rail.
Power limit -
Inspection CAN signal and analog signal wiring.
Vehicle side code : 2014-1
P0122 : Accelerator sensor 1
Faulty part Common rail
Vehicle side code : 29-2
The rail pressure control is abnormal.
Faulty part Accelerator signal (analog signal)
Detail The target pressure is not achieved even
The ECU detects a faulty analog signal fully pressured by fuel pump.
Detail input from vehicle controller. The input
Recovery *
voltage falls below the limiting value.
Control Engine stop
When the input voltage recovers to the
Recovery specified value, it recovers automati- Power limit -
cally.
Inspection Damage on the common rail.
When operating by CAN signal, the
ECU warns to the operator. When oper- P0192 : Rail pressure sensor offset monitoring
Control ating by analog signal, the ECU warns
Vehicle side code : 2012-2
to the operator and the engine operation
switches to the redundancy operation. Faulty part Rail pressure sensor
Power limit - The input voltage falls below the limit-
Detail
ing value.
Inspection Accelerator signal (analog signal)
Recovery *
P0123 : Accelerator sensor 1 Accelerator opening ratio is fixed to
Vehicle side code : 29-1 Control
12%.
Faulty part Accelerator signal (analog signal) Power limit -
The ECU detects a faulty analog signal Rail pressure sensor, and wiring of rail
Detail input from vehicle controller. The input Inspection
pressure sensor.
voltage exceeds the limiting value.
When the input voltage recovers to the
Recovery specified value, it recovers automati-
cally.
When operating by CAN signal, the
ECU warns to the operator. When oper-
Control ating by analog signal, the ECU warns
to the operator and the engine operation
switches to the redundancy operation.
Power limit -
Inspection Accelerator signal (analog signal)

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 TROUBLESHOOTING
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P0193 : Rail pressure sensor offset monitoring P0202 : Injector No.2

Vehicle side code : 2012-1 Vehicle side code : 660-4
Faulty part Rail pressure sensor Faulty part Injector No.2
The input voltage exceeds the limiting The ECU detects an open circuit of the
Detail Detail
value. injector and/or injector harness.
Recovery * Recovery *
Accelerator opening ratio is fixed to The engine keeps operating if only one
Control
12%. Control injector is faulty. The engine stops if
two or more injectors are faulty.
Power limit -
There is no specific control by the ECU,
Rail pressure sensor, and wiring of rail Power limit
Inspection but the engine power decreases.
pressure sensor.
Inspection Injector, and wiring of injector.
P0194 : Rail pressure governor
Vehicle side code : 2016-1 P0203 : Injector No.3
Vehicle side code : 662-4
Faulty part Common rail
Faulty part Injector No.3
The rail pressure falls below the limiting
Detail
value. The ECU detects an open circuit of the
Detail
injector and/or injector harness.
Recovery *
Recovery *
Control Engine stop
The engine keeps operating if only one
Power limit -
Control injector is faulty. The engine stops if two
Inspection Damage on the common rail. or more injectors are faulty.
There is no specific control by the ECU,
P0201 : Injector No.1 Power limit
but the engine power decreases.
Vehicle side code : 658-4
Inspection Injector, and wiring of injector.
Faulty part Injector No.1
The ECU detects an open circuit of the P0204 : Injector No.4
Detail
injector and/or injector harness. Vehicle side code : 664-4
Recovery * Faulty part Injector No.4
The engine keeps operating if only one The ECU detects an open circuit of the
Detail
Control injector is faulty. The engine stops if two injector and/or injector harness.
or more injectors are faulty.
Recovery *
There is no specific control by the ECU,
Power limit The engine keeps operating if only one
but the engine power decreases.
Control injector is faulty. The engine stops if two
Inspection Injector, and wiring of injector. or more injectors are faulty.
There is no specific control by the ECU,
Power limit
but the engine power decreases.
Inspection Injector, and wiring of injector.

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ENGINE ASSY - TROUBLE SHOOTING TROUBLESHOOTING

P0215 : Shut off pass test P0235 : Inlet manifold pressure sensor
Vehicle side code : 1110-2 Vehicle side code : 102-8
Faulty part ECU Inlet manifold pressure sensor power
Faulty part
supply line
The emergency injection stop circuit
Detail does not operate. The shut-off by watch The ECU detects an open circuit or short
Detail
dog is disabled. circuit of the sensor power supply (5V).
Recovery * Recovery *
Control The ECU warns to the operator. The ECU controls the engine fixing the
Control value to the backup data.(Approx. 1013
Power limit -
hpa)
Inspection Contact a Mitsubishi dealer.
Power limit The maximum power is limited to 75%.
Inlet manifold pressure sensor power
Inspection
Vehicle side code : 1110-4 supply line wiring

Faulty part ECU P0237 : Inlet manifold pressure sensor

The emergency injection stop circuit Vehicle side code : 102-2
Detail does not operate. The shut off by high
Faulty part Inlet manifold pressure sensor
voltage monitoring is disabled.
The ECU detects the faulty operation of
Recovery *
the inlet manifold pressure sensor (open
Control The ECU warns to the operator. Detail circuit, short circuit, characteristic
fault). The input voltage falls below the
Power limit - limiting value.
Inspection Contact a Mitsubishi dealer. Recovery *
The ECU controls the engine using the
Control
backup data.
Vehicle side code : 1110-8
Power limit The maximum power is limited to 75%.
Faulty part ECU
Inlet manifold pressure sensor, and wir-
The emergency injection stop circuit Inspection
ing of inlet manifold pressure sensor.
Detail does not operate. The shut off by low
voltage monitoring is disabled.
P0238 : Inlet manifold pressure sensor
Recovery * Vehicle side code : 102-1
Control The ECU warns to the operator. Faulty part Inlet manifold pressure sensor
Power limit - The input voltage exceeds the limiting
Detail
Inspection Contact a Mitsubishi dealer. value.
Recovery *
P0231 : MPROP power stage short-circuit to ground
The ECU controls the engine using the
Vehicle side code : 2002-2 Control
backup data.
Faulty part MPROP
Power limit The maximum power is limited to 75%.
The ECU detects a short circuit on the
Detail Inlet manifold pressure sensor, and wir-
ground line of the MPROP harness. Inspection
ing of inlet manifold pressure sensor.
Recovery *
Accelerator opening ratio is fixed to
Control
12%.
Power limit -
Inspection MPROP, and wiring of MPROP.

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 TROUBLESHOOTING
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P0261 : Injector No.1 P0265 : Injector No.2

Vehicle side code : 657-4 Vehicle side code : 659-1
Faulty part Injector No.1 Faulty part Injector No.2
The ECU detects a short circuit of the The injector is faulty. The low side is a
Detail
injector and/or injector harness. There short circuit to the battery (+).
Detail
are short circuits on the high side and
Recovery *
low side.
Control Engine stop
Recovery *
Power limit -
Control Engine stop
Inspection Injector, and wiring of injector.
Power limit -
Inspection Injector, and wiring of injector. P0266 : Injector No.2
Vehicle side code : 659-8
P0262 : Injector No.1
Faulty part Injector No.2
Vehicle side code : 657-1
Unclassifiable error in the injector and/
Faulty part Injector No.1
Detail or the injector harness. The injector is
The injector is faulty. The low side is a disabled.
Detail
short circuit to the battery (+).
Recovery *
Recovery *
Control Engine stop
Control Engine stop
Power limit -
Power limit -
Inspection Injector, and wiring of injector.
Inspection Injector, and wiring of injector.
P0267 : Injector No.3
P0263 : Injector No.1 Vehicle side code : 661-4
Vehicle side code : 657-8
Faulty part Injector No.3
Faulty part Injector No.1
The ECU detects a short circuit of the
Unclassifiable error in the injector and/ injector and/or injector harness. There
Detail
Detail or the injector harness. The injector is are short circuits on the high side and
disabled. low side.
Recovery * Recovery *
Control Engine stop Control Engine stop
Power limit - Power limit -
Inspection Injector, and wiring of injector. Inspection Injector, and wiring of injector.

P0264 : Injector No.2 P0268 : Injector No.3

Vehicle side code : 659-4 Vehicle side code : 661-1
Faulty part Injector No.2 Faulty part Injector No.3
The ECU detects a short circuit of the The injector is faulty. The low side is a
Detail
injector and/or injector harness. There short circuit to the battery (+).
Detail
are short circuits on the high side and
Recovery *
low side.
Control Engine stop
Recovery *
Power limit -
Control Engine stop
Inspection Injector, and wiring of injector.
Power limit -
Inspection Injector, and wiring of injector.

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ENGINE ASSY - TROUBLE SHOOTING TROUBLESHOOTING

P0269 : Injector No.3 P0336 : Speed/timing sensor (crankshaft side)

Vehicle side code : 661-8 Vehicle side code : 637-2
Faulty part Injector No.3 Speed/timing sensor
Faulty part
(crankshaft side)
Unclassifiable error in the injector and/
Detail or the injector harness. The injector is The ECU detects the fault of speed/tim-
disabled. ing sensor (crankshaft side)(open cir-
Detail cuit, short circuit, tooth breakage). The
Recovery *
number of crank pulse and/or crank
Control Engine stop pulse position are faulty.

Power limit - Recovery *

Inspection Injector, and wiring of injector. The ECU controls the engine using the
Control speed/timing sensor (camshaft side) sig-
P0270 : Injector No.4 nal.
Vehicle side code : 663-4 The maximum power is limited to 50%
Power limit
only when starting the engine.
Faulty part Injector No.4
Speed/timing sensor (crankshaft side),
The ECU detects a short circuit of the
Inspection and wiring of speed/timing sensor
injector and/or injector harness. There
Detail (crankshaft side).
are short circuits on the high side and
low side.
P0339 : Speed/timing sensor (crankshaft side)
Recovery * Vehicle side code : 637-1
Control Engine stop Speed/timing sensor
Faulty part
Power limit - (crankshaft side)

Inspection Injector, and wiring of injector. The speed/timing sensor (crankshaft

Detail side) is faulty. The ECU is not receiving
P0271 : Injector No.4 the crank pulse.
Vehicle side code : 663-1 Recovery *
Faulty part Injector No.4 The ECU controls the engine using the
Control speed/timing sensor (camshaft side) sig-
The injector is faulty. The low side is a
Detail nal.
short circuit to the battery (+).
The maximum power is limited to 50%
Recovery * Power limit
only when starting the engine.
Control Engine stop
Speed/timing sensor (crankshaft side),
Power limit - Inspection and wiring of speed/timing sensor
(crankshaft side).
Inspection Injector, and wiring of injector.

P0272 : Injector No.4

Vehicle side code : 663-8
Faulty part Injector No.4
Unclassifiable error in the injector and/
Detail or the injector harness. The injector is
disabled.
Recovery *
Control Engine stop
Power limit -
Inspection Injector, and wiring of injector.

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 TROUBLESHOOTING
ENGINE ASSY - TROUBLE SHOOTING

P0341 : Speed/timing sensor (camshaft side) P0541 : Air heater relay power stage
Vehicle side code : 636-2 Vehicle side code : 677-2
Speed/timing sensor Faulty part Air heater relay
Faulty part
(camshaft side)
The air heater relay and/or connecting
Detail
The ECU detects the fault of speed/tim- harness are short circuits to the ground.
ing sensor (camshaft side) (open circuit,
Recovery *
Detail short circuit, tooth breakage). The num-
ber of cam pulse and/or cam pulse posi- The air heater is disabled. The ECU
tion are faulty. Control
warns to the operator.
Recovery * Power limit -
The ECU controls the engine using Inspection Air heater relay, and wiring of air heater.
Control speed/timing sensor (crankshaft side)
signal. The ECU warns to the operator. P0542 : Air heater relay power stage
Power limit - Vehicle side code : 677-1
Speed/timing sensor (camshaft side), Faulty part Air heater relay
Inspection and wiring of speed/timing sensor (cam-
The air heater relay is faulty. The air
shaft side).
Detail heater relay is a short circuit to the bat-
tery.
P0344 : Speed/timing sensor (camshaft side)
Vehicle side code : 636-1 Recovery *

Speed/timing sensor The air heater is disabled. The ECU

Faulty part Control
(camshaft side) warns to the operator.

The speed/timing sensor (camshaft side) Power limit -

Detail is faulty. The ECU is not receiving the Inspection Air heater relay, and wiring of air heater.
cam pulse.
Recovery * P0543 : Air heater relay power stage
Vehicle side code : 677-4
The ECU controls the engine using
Control speed/timing sensor (crankshaft side) Faulty part Air heater relay
signal. The ECU warns to the operator.
The ECU detects an open circuit of air
Detail
Power limit - heater relay and/or connecting harness.
Speed/timing sensor (camshaft side), Recovery *
Inspection and wiring of speed/timing sensor (cam-
The air heater is disabled. The ECU
shaft side). Control
warns to the operator.
P0540 : Air heater relay power stage Power limit -
Vehicle side code : 677-8 Inspection Air heater relay, and wiring of air heater.
Faulty part Air heater relay
P0562 : Power supply unit voltage too low
The ECU detects an overload of air
Detail Vehicle side code : 1543-2
heater relay and/or connecting harness.
Faulty part ECU
Recovery *
The voltage of the power supply unit
The air heater is disabled. The ECU
Control Detail inside the ECU falls below the limiting
warns to the operator.
value.
Power limit -
Recovery *
Inspection Air heater relay, and wiring of air heater.
Control Engine stop
Power limit -
Inspection Replace the ECU.

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ENGINE ASSY - TROUBLE SHOOTING TROUBLESHOOTING

P0563 : Power supply unit voltage too high P0600 : CAN (C) pass off
Vehicle side code : 1542-1 Vehicle side code : 1673-1
Faulty part ECU Faulty part CAN communication line
The voltage of the power supply unit The CAN communication is faulty. The
Detail
Detail inside the ECU exceeds the limiting ECU detects the CAN (C) pass off.
value.
Recovery *
Recovery *
The ECU uses the analog signal for
Control Engine stop Control backup control. The ECU warns to the
operator.
Power limit -
Power limit -
Inspection Replace the ECU.
Inspection CAN communication line, and ECU.
P0600 : CAN transmitting time out
Vehicle side code : 2028-4 P0606 : SPI communication error
Vehicle side code : 1231-1
Faulty part CAN communication line
Faulty part ECU
The CAN message cannot be transmit-
Detail
ted. There are serial communication errors
Detail
between CPU and other IC.
Recovery *
Recovery *
The ECU uses the analog signal for
Control
backup control. Control Engine stop
Power limit - Power limit -
Inspection CAN communication line, and ECU. Inspection Replace the ECU.

P0600 : CAN (A) pass off P0606 : Super vision

Vehicle side code : 1671-1 Vehicle side code : 1484-8
Faulty part CAN communication line Faulty part ECU
The CAN communication is faulty. The The ECU detects an abnormality by
Detail
Detail ECU detects an open circuit or short cir- using self-diagnosis function.
cuit of CAN line.
Recovery *
Recovery *
Control Engine stop
The ECU uses the analog signal for
Power limit -
Control backup control. The ECU warns to the
operator. Inspection Replace the ECU.
Power limit -
P0607 : Recovery occurred
Inspection CAN communication line, and ECU. Vehicle side code : 1668-8
Faulty part ECU
The recovery occurred by the fault of the
Detail
ECU.
Recovery *
Control The ECU warns to the operator.
Power limit -
Inspection -

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 TROUBLESHOOTING
ENGINE ASSY - TROUBLE SHOOTING

Vehicle side code : 1670-8 Vehicle side code : 655-4

Faulty part ECU Faulty part ECU
The recovery occurred by the fault of the The injector control IC inside the ECU
Detail Detail
ECU. is faulty.
Recovery * Recovery *
Control The ECU warns to the operator. Control Engine stop
Power limit - Power limit -
Inspection - Inspection Replace the ECU.

P0607 : SPI watch dog error

Vehicle side code : 2010-8 Vehicle side code : 655-8
Faulty part ECU Faulty part ECU
The ECU detects an abnormality by The injector control IC inside the ECU
Detail
Detail using self-diagnosis function. Watch dog is faulty.
error.
Recovery *
Recovery occurs. It recovers automati-
Control Engine stop
cally if an error occurs three times in
Recovery two seconds. The engine stops if an Power limit -
error occurs four times or more in two
seconds. Inspection Replace the ECU.

Control Engine stop

Power limit - Vehicle side code : 656-1

Inspection Replace the ECU. Faulty part ECU

The injector control IC inside the ECU
P0611 : Injector IC Detail
is faulty.
Vehicle side code : 655-1
Recovery *
Faulty part ECU
Control Engine stop
The injector control IC inside the ECU
Detail Power limit -
is faulty.
Recovery * Inspection Replace the ECU.

Control Engine stop

Power limit - Vehicle side code : 656-2

Inspection Replace the ECU. Faulty part ECU

The injector control IC inside the ECU
Detail
is faulty.
Vehicle side code : 655-2
Recovery *
Faulty part ECU
Control Engine stop
The injector control IC inside the ECU
Detail Power limit -
is faulty.
Recovery * Inspection Replace the ECU.

Control Engine stop

Power limit -
Inspection Replace the ECU.

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ENGINE ASSY - TROUBLE SHOOTING TROUBLESHOOTING

P0652 : Sensor supply voltage monitoring 2

Vehicle side code : 656-4 Vehicle side code : 1080-2
Faulty part ECU Faulty part ECU
The injector control IC inside the ECU The 5V power supply to the inlet mani-
Detail
is faulty. fold pressure sensor is faulty. The sup-
Detail
ply voltage falls below the limiting
Recovery *
value.
Control Engine stop
Recovery *
Power limit -
The ECU controls the engine using the
Control
Inspection Replace the ECU. backup data.
Power limit The maximum power is limited to 75%.

Vehicle side code : 656-8 Inspection Replace the ECU.

Faulty part ECU P0653 : Sensor supply voltage monitoring 2

The injector control IC inside the ECU Vehicle side code : 1080-1
Detail
is faulty.
Faulty part ECU
Recovery *
The 5V power supply to the inlet mani-
Control Engine stop Detail fold pressure sensor is faulty. The sup-
ply voltage exceeds the limiting value.
Power limit -
Recovery *
Inspection Replace the ECU.
The ECU controls the engine using the
Control
P0642 : Sensor supply voltage monitoring 1 backup data.
Vehicle side code : 1079-2 Power limit The maximum power is limited to 75%.
Faulty part ECU Inspection Replace the ECU.
The 5V power supply to the PTO accel-
Detail erator signal is faulty. The supply volt- P0698 : Sensor supply voltage monitoring 3
age falls below the limiting value. Vehicle side code : 620-2

Recovery * Faulty part ECU

Control The ECU warns to the operator. The 5V power supply to the rail pressure
Detail sensor is faulty. The supply voltage falls
Power limit - below the limiting value.
Inspection Replace the ECU. Recovery *

P0643 : Sensor supply voltage monitoring 1 Control The ECU warns to the operator.
Vehicle side code : 1079-1 Power limit -
Faulty part ECU Inspection Replace the ECU.
The 5V power supply to the PTO accel-
Detail erator signal is faulty. The supply volt-
age exceeds the limiting value.
Recovery *
Control The ECU warns to the operator.
Power limit -
Inspection Replace the ECU.

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 TROUBLESHOOTING
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P0699 : Sensor supply voltage monitoring 3

Vehicle side code : 620-1 Vehicle side code : 2008-2
Faulty part ECU Faulty part ECU
The 5V power supply to the rail pressure The AD converter inside the ECU is
Detail sensor is faulty. The supply voltage Detail faulty. The standard voltage falls below
exceeds the limiting value. the limiting value.
Recovery * Recovery occurs. It recovers automati-
cally if an error occurs three times in two
Control The ECU warns to the operator.
Recovery seconds. The engine stops if an error
Power limit - occurs four times or more in two sec-
onds.
Inspection Replace the ECU.
Control Engine stop
P060A : TPU monitoring Power limit -
Vehicle side code : 2009-8
Inspection Replace the ECU.
Faulty part ECU
The ECU detects a fault of rotating pulse
Detail Vehicle side code : 2008-4
arithmetic circuit inside the ECU.
Recovery occurs. It recovers automati- Faulty part ECU
cally if an error occurs three times in
The AD converter inside the ECU is
Recovery two seconds. The engine stops if an
Detail faulty. The ECU detects the conversion
error occurs four times or more in two
error by using a test pulse.
seconds.
Recovery occurs. It recovers automati-
Control Engine stop
cally if an error occurs three times in
Power limit - Recovery two seconds. The engine stops if an
error occurs four times or more in two
Inspection Replace the ECU. seconds.

P060B : ADC monitoring Control Engine stop

Vehicle side code : 2008-1 Power limit -
Faulty part ECU Inspection Replace the ECU.
The AD converter inside the ECU is
Detail faulty. The standard voltage exceeds the
limiting value. Vehicle side code : 2008-8
Recovery occurs. It recovers automati- Faulty part ECU
cally if an error occurs three times in
The AD converter inside the ECU is
Recovery two seconds. The engine stops if an Detail
faulty. The conversion time is abnormal.
error occurs four times or more in two
seconds. Recovery occurs. It recovers automati-
cally if an error occurs three times in
Control Engine stop
Recovery two seconds. The engine stops if an
Power limit - error occurs four times or more in two
seconds.
Inspection Replace the ECU.
Control Engine stop
Power limit -
Inspection Replace the ECU.

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ENGINE ASSY - TROUBLE SHOOTING TROUBLESHOOTING

P060D : CAN accelerator P062D : Injector drive bank 1

Vehicle side code : 91-4 Vehicle side code : 651-8
Faulty part ECU communication circuit Faulty part ECU
The ECU detects a fault of accelerator The ECU detects the short circuit of the
Detail
Detail opening (APPREQ) receiving from injector drive circuit inside the ECU.
CAN.
Recovery *
Recovery *
Control Engine stop
The ECU uses the analog signal for
Power limit -
Control backup control. The ECU warns to the
operator. Inspection Replace the ECU.
Power limit -
P062E : Injector drive bank 2
Inspection CAN communication circuit Vehicle side code : 653-8

P060E : APPREQ message time out Faulty part ECU

Vehicle side code : 1674-4 The ECU detects the short circuit of the
Detail
injector drive circuit inside the ECU.
Faulty part ECU communication circuit
Recovery *
The ECU cannot receive the accelerator
Detail
opening (APPREQ) signal. Control Engine stop
Recovery * Power limit -
The ECU uses the analog signal for Inspection Replace the ECU.
Control backup control. The ECU warns to the
operator. P062F : EEPROM
Power limit - Vehicle side code : 1235-2

Inspection CAN communication circuit Faulty part ECU

The ECU detects a read-write error of
P061C : Engine speed Detail the data memory bank inside the ECU.
Vehicle side code : 2005-1 The ECU cannot read the data.
Faulty part ECU Recovery *
The ECU is faulty. The engine speed Control The ECU warns to the operator.
Detail
data is faulty.
Power limit -
Recovery occurs. It recovers automati-
cally if an error occurs three times in Inspection Replace the ECU.
Recovery two seconds. The engine stops if an
error occurs four times or more in two
seconds. Vehicle side code : 1235-4
Control The ECU warns to the operator. Faulty part ECU
Power limit - The ECU detects a read-write error of
the data memory bank inside the ECU.
Inspection Replace the ECU. Detail
The ECU cannot write to the data mem-
ory.
Recovery *
Control The ECU warns to the operator.
Power limit -
Inspection Replace the ECU.

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 TROUBLESHOOTING
ENGINE ASSY - TROUBLE SHOOTING

P2047 : Injector drive bank 1

Vehicle side code : 1235-8 Vehicle side code : 652-4
Faulty part ECU Faulty part ECU
The ECU detects a read-write error of The ECU detects an open circuit of the
Detail
Detail the data memory bank inside the ECU. injector drive circuit inside the ECU.
The ECU is using the substitute data.
Recovery *
Recovery *
Control Engine stop
Control The ECU warns to the operator.
Power limit -
Power limit -
Inspection Replace the ECU.
Inspection Replace the ECU.
P2048 : Injector drive bank 1
P0933 : Oil pressure switch Vehicle side code : 651-2
Vehicle side code : 19-8
Faulty part ECU
Faulty part Oil pressure switch
The ECU detects a short circuit of the
Detail
The oil pressure switch remains OFF injector drive circuit inside the ECU.
Detail position even the engine speed reaches
Recovery *
500min-1.
Control Engine stop
Recovery *
Power limit -
Control The ECU keeps the engine low idling.
Inspection Replace the ECU.
Power limit -
Oil pressure switch, and wiring of oil P2049 : Injector drive bank 1
Inspection
pressure switch. Vehicle side code : 651-1
Faulty part ECU
Vehicle side code : 100-8 The ECU detects a short circuit of the
Detail
injector drive circuit inside the ECU.
Faulty part Oil pressure switch
Recovery *
The oil pressure switch remains OFF
position for 30 second after engine start- Control Engine stop
Detail
ing. The oil pressure switch remains
Power limit -
OFF position during engine operation.
Inspection Replace the ECU.
Recovery *
Control Engine stop P2050 : Injector drive bank 2
Power limit - Vehicle side code : 654-4

Oil pressure switch, and wiring of oil Faulty part ECU

Inspection
pressure switch. The ECU detects an open circuit of the
Detail
injector drive circuit inside the ECU.
Recovery *
Control Engine stop
Power limit -
Inspection Replace the ECU.

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ENGINE ASSY - TROUBLE SHOOTING TROUBLESHOOTING

P2051 : Injector drive bank 2 P2229 : Atmospheric pressure sensor

Vehicle side code : 653-2 Vehicle side code : 108-1
Faulty part ECU Faulty part ECU
The ECU detects a short circuit of the The ECU detects a faulty operation of
Detail
injector drive circuit inside the ECU. the atmospheric pressure sensor (open
Detail circuit, short circuit, characteristic
Recovery *
fault). The input voltage exceeds the
Control Engine stop limiting value.

Power limit - Recovery *

Inspection Replace the ECU. The ECU controls the engine fixing the
Control
value to the backup data.
P2052 : Injector drive bank 2 Power limit The maximum power is limited to 75%.
Vehicle side code : 653-1
Inspection Replace the ECU.
Faulty part ECU
The ECU detects a short circuit of the
Detail
injector drive circuit inside the ECU.
Recovery *
Control Engine stop
Power limit -
Inspection Replace the ECU.

P2228 : Atmospheric pressure sensor

Vehicle side code : 108-2
Faulty part ECU
The ECU detects a faulty operation of
the atmospheric pressure sensor (open
Detail circuit, short circuit, characteristic
fault). The input voltage falls below the
limiting value.
Recovery *
The ECU controls the engine fixing the
Control
value to the backup data.
Power limit The maximum power is limited to 75%.
Inspection Replace the ECU.

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 TROUBLESHOOTING
ENGINE ASSY - TROUBLE SHOOTING

5.2 Related diagnosis code

There are diagnosis codes which are caused by other diagnosis codes, for example, the diagnosis code generated by the fault of
the common rail causes the diagnosis code related to the DBV (pressure limiting valve). These codes can be recovered by
eliminating the fault of the causal diagnosis code.
Causal diagnosis code in the following table must be checked when Related diagnosis code is generated.
Related diagnosis code can be recovered by eliminating the fault of Causal diagnosis code.
Also Related diagnosis code B can be generated by Related diagnosis code A. In this case, Causal diagnosis code and Related
diagnosis code A must be checked.

Table 14-2 Related diagnosis code (1 / 2)

Causal diagnosis Related diagnosis Related diagnosis
Cause A Cause B Remark
code code A code B
There is an open cir-
cuit on the MPROP.
P0089 The MPROP is fully
Vehicle side code : opened and the com-
- - -
P0252 2041-1 mon rail receives
Vehicle side code : DBV opening excessive pressure.
2000-4 The DBV will be
MPROP open circuit opened.
P0089 P0090
The ECU clears P0089
Vehicle side code : MPROP was fully Vehicle side code : The DBV does not
when P0090 is gener-
2042-2 opened for 2 seconds. 2043-4 open.
ated.
DBV kick off DBV closed sticking
There is an overload
on the MPROP. The
P0089 MPROP is fully
Vehicle side code : opened and the com-
- - -
P0252 2041-1 mon rail receives
Vehicle side code : DBV opening excessive pressure.
2000-8 The DBV will be
MPROP overload opened.
P0089 P0090
The ECU clears P0089
Vehicle side code : MPROP was fully Vehicle side code : The DBV does not
when P0090 is gener-
2042-2 opened for 2 seconds. 2043-4 open.
ated.
DBV kick off DBV closed sticking
There is a short circuit
on the MPROP. The
P0089 MPROP is fully
Vehicle side code : opened and the com-
P0230 - - -
2041-1 mon rail receives
Vehicle side code : DBV opening excessive pressure.
2001-1 The DBV will be
MPROP power stage opened.
short circuit to battery
P0089 P0090
The ECU clears P0089
Vehicle side code : MPROP was fully Vehicle side code : The DBV does not
when P0090 is gener-
2042-2 opened for 2 seconds. 2043-4 open.
ated.
DBV kick off DBV closed sticking
The pressure in the
P0089 common rail keeps The ECU clears
Vehicle side code : exceeding the limiting P0089(2042-2) when
- -
P0089 2041-1 value, the engine P0089(2041-1) is gen-
Vehicle side code : DBV opening operation switches to erated.
2042-2 the limp home mode.
DBV kick off P0090
The ECU clears P0089
Vehicle side code : The DBV does not
- - when P0090 is gener-
2043-4 open.
ated.
DBV closed sticking

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ENGINE ASSY - TROUBLE SHOOTING TROUBLESHOOTING

Table 14-2 Related diagnosis code (2 / 2)

Causal diagnosis Related diagnosis Related diagnosis
Cause A Cause B Remark
code code A code B
The pressure in the
P0089 common rail keeps
Vehicle side code : exceeding the limiting
P0191 - - -
2041-1 value, the engine
Vehicle side code : DBV opening operation switches to
2015-1 the limp home mode.
Rail pressure gover-
nor deviation P0089 P0090
The ECU clears P0089
Vehicle side code : MPROP was fully Vehicle side code : The DBV does not
when P0090 is gener-
2042-2 opened for 2 seconds. 2043-4 open.
ated.
DBV kick off DBV closed sticking
The pressure in the
P0089 common rail keeps
If DBV does not open,
Vehicle side code : exceeding the limiting
- - the ECU generates
P0194 2041-1 value, the engine
P0090, not 0089.
Vehicle side code : DBV opening operation switches to
2017-1 the limp home mode.
Rail pressure governor P0089 P0090
The ECU clears P0089
Vehicle side code : MPROP was fully Vehicle side code : The DBV does not
when P0090 is gener-
2042-2 opened for 2 seconds. 2043-4 open.
ated.
DBV kick off DBV closed sticking
An error is detected
by SRC. The ECU
cannot control the
P0192 P0089 engine by feedback
In this case, P0192 and
Vehicle side code : Vehicle side code : from the common rail
- - P0089 are generated at
2011-2 2041-1 pressure sensor. The
the same time.
Rail pressure SRC DBV opening DBV will be opened.
The ECU controls the
engine using backup
data.
An error is detected
by SRC. The ECU
cannot control the
P0193 P0089 engine by feedback
In this case, P0192 and
Vehicle side code : Vehicle side code : from the common rail
- - P0089 are generated at
2011-1 2041-1 pressure sensor. The
the same time.
Rail pressure SRC DBV opening DBV will be opened.
The ECU controls the
engine using backup
data.
After the ECU deter-
P0091 mined that DBV has
Vehicle side code : been opened, the
P0091 is not gener-
2045-2 common rail pressure - -
ated separately.
DBV pressure is too exceeds the limiting
P0089 high value during backup
Vehicle side code : operation.
2041-1 After the ECU deter-
DBV opening P0092 mined that DBV has
Vehicle side code : been opened, the
P0092 is not gener-
2044-1 common rail pressure - -
ated separately.
DBV pressure is too exceeds the limiting
high value during backup
operation.

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 TROUBLESHOOTING
ENGINE ASSY - TROUBLE SHOOTING

P0089 : DBV valve opening P0092 : DBV pressure is too high.

Vehicle side code : 2041-1 Vehicle side code : 2044-1
Faulty part DBV Faulty part DBV
Detail The DBV is opening. The DBV pressure is abnormal. (too
Detail
high)
Recovery *
Recovery *
Accelerator opening ratio is fixed to
Control
12%. Control Engine stop
Power limit - Power limit -
Inspection Contact a Mitsubishi dealer. Inspection Contact a Mitsubishi dealer.

P0089 : DBV kick off P0191 : Rail pressure governor deviation

Vehicle side code : 2042-2 Vehicle side code : 2015-1
Faulty part DBV Faulty part Common rail
Pressure shock requested The rail pressure control is abnormal.
Detail Detail
to apply limp home mode. The pressure exceeds the target value.
Recovery * Recovery *
Accelerator opening ratio is fixed to Accelerator opening ratio is fixed to
Control Control
12%. 12%.
Power limit - Power limit -
Inspection Contact a Mitsubishi dealer. Inspection Damage on the common rail.

P0090 : DBV closed sticking P0192 : Rail pressure sensor SRC (Signal Range
Vehicle side code : 2043-4 Check)
Faulty part DBV Vehicle side code : 2011-2

The DBV does not open. Closed stick- Faulty part Rail pressure sensor
Detail
ing. The ECU detects an open or short circuit
Recovery * of rail pressure sensor and/or sensor har-
Detail
ness. The input voltage falls below the
Control Engine stop limiting value.
Power limit - Recovery *
Inspection Contact a Mitsubishi dealer. Accelerator opening ratio is fixed to
Control
12%.
P0091 : DBV pressure is too low
Power limit -
Vehicle side code : 2045-2
Rail pressure sensor, and wiring of rail
Faulty part DBV Inspection
pressure sensor.
The DBV pressure is abnormal. (too
Detail
low)
Recovery *
Control Engine stop
Power limit -
Inspection Contact a Mitsubishi dealer.

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ENGINE ASSY - TROUBLE SHOOTING TROUBLESHOOTING

P0193 : Rail pressure sensor SRC (Signal Range P0252 : MPROP power stage overload
Check) Vehicle side code : 2000-8
Vehicle side code : 2011-1 Faulty part MPROP
Faulty part Rail pressure sensor The ECU detects an overload of
Detail
The input voltage exceeds the limiting MPROP and/or MPROP harness.
Detail
value. Recovery *
Recovery * Accelerator opening ratio is fixed to
Control
Accelerator opening ratio is fixed to 12%.
Control
12%. Power limit -
Power limit - Inspection MPROP, and wiring of MPROP.
Rail pressure sensor, and wiring of rail
Inspection
pressure sensor.

P0194 : Rail pressure governor

Vehicle side code : 2017-1
Faulty part Common rail
The rail pressure exceeds the limiting
Detail
value.
Recovery *
Accelerator opening ratio is fixed to
Control
12%.
Power limit -
Inspection Damage on the common rail.

P0230 : MPROP power stage short-circuit to battery

Vehicle side code : 2001-1
Faulty part MPROP
The ECU detects a short circuit on the
Detail
battery line of the MPROP harness.
Recovery *
Accelerator opening ratio is fixed to
Control
12%.
Power limit -
Inspection MPROP, and wiring of MPROP.

P0252 : MPROP power stage open circuit

Vehicle side code : 2000-4
Faulty part MPROP
The ECU detects an open circuit of the
Detail
MPROP and/or MPROP harness.
Recovery *
Accelerator opening ratio is fixed to
Control
12%.
Power limit -
Inspection MPROP, and wiring of MPROP.

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 TROUBLESHOOTING
ENGINE ASSY - TROUBLE SHOOTING
6. Inspecting sensors
6.1 Speed/timing sensor (crank, cam)
Measure the resistance between terminal A - B.
Standard value : 860±86Ω
If measured value is out of standard, replace the sensor with
a new one.
C B A

Speed/timing sensor
(crank, cam)
6.2 Inlet manifold pressure sensor
With applying pressure using an air compressor, measure
the voltage between terminal B - C.
Standard value
C A
• at 0 MPa {0 kgf/cm²} : 0.5V
• at 0.34 MPa {3.5 kgf/cm²} : 4.5V
If measured value is out of standard, replace the sensor with
a new one. B

Air compressor

Inspecting inlet manifold pressure sensor (1)

0.5
Air pressure MPa

0.4
0.3
0.2
0.1
0

0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5

Output voltage Vdc

Inspecting inlet manifold pressure sensor (2)

6.3 Water temperature sensor
Put the water temperature sensor to the container filled with
water, measure the output resistance between terminal 1 - 2.
Standard value
• 20°C : 2.38 ～ 2.63kΩ
• 80°C : 0.30 ～ 0.36kΩ
If the sensor is an open circuit, its resistance is infinity. If
measured value is out of standard, replace the sensor with a
new one. 1 2

Inspecting water temperature sensor

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ENGINE ASSY - TROUBLE SHOOTING TROUBLESHOOTING

6.4 Engine oil pressure switch

Apply 50±10 kPa {0.5±0.1 kgf/cm²} [7.11±1.42 psi]
pressure to the sensor using an air compressor.
Check that the micro switch is in ON position. Air compressor
If the switch is not operate, replace the engine oil pressure 50 ± 10 kPa
switch with a new one. {0.5 ± 0.1 kgf/cm²}
[7.11 ± 1.42 psi]
On-Off differences
30 kPa
{0.3 kgf/cm²}
[4.27 psi]

Inspecting oil pressure switch

6.5 Common rail pressure sensor
Apply 5V between terminal A - C, and measure the voltage
at terminal B.
Standard value : Approx. 0.5V
If measured value is out of standard, replace the common
A B C
rail with a new one.

Inspecting common rail pressure sensor

6.6 Injector solenoid
Measure the resistance between terminal 1 - 2.
Standard（at 20 to 70°C [68 to 158 °F]）: 0.215 to 0.295 Ω
If measured value is out of standard, replace the injector
with a new one.

2 1

Inspecting injector solenoid

6.7 High pressure pump solenoid sensor
(MPROP)
Measure the resistance between terminal 1 - 2.
Standard （at 20°C [68 °F]）: 2.6 to 3.15 Ω
If measured value is out of standard, replace the fuel pump
with a new one.

2 1

Inspecting high pressure pump solenoid sensor

(MPROP)

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ENGINE ASSY - TROUBLE SHOOTING
TROUBLESHOOTING

7. Inspecting wiring
7.1 Inspecting connector and harness
When the ECU generates the diagnosis code for the sensors,
the ECU and the relays, check the wiring that connects these
parts.
The looseness of the harness connection and/or poor
connection of connector may cause the electrical faults. In
these cases, reconnecting the connector and/or the repairing
the harness deletes the fault. Inspect the wiring connecting
to the sensor which causes diagnosis code.

7.1.1 Inspecting the intermittent fault

Wiggle the harness and connector in order to reproduce the Inspecting intermittent fault
intermittent fault.
If the diagnosis code is generated, reset the ECU and repeat
the above procedure. If the intermittent fault exists, replace
the connector and harness.
Ensure locking
7.1.2 Inspecting connectors
(1) Disconnect the connector and inspect the connector for
moisture and wear.
(2) Inspect that the terminals are correctly located in the
connector. Inspect that the terminals are not lost.
Inspect that the terminals does not rattle.
(3) Inspect that the locking wedge works correctly. Inspecting connector

7.1.3 Inspecting harness

(1) Inspect harness visually for wear, nicks and cuts.
Especially the part which is exposed to the engine must
be inspected. Nick
(2) Inspect the harness for pinch point caused by cramp.

7.1.4 Inspect open circuit and short circuit

(1) Remove the connector from either end of the harness. Pinch point
Measure the resistance between both ends of the
harness using tester. If measured value is between 0.1～
0.3 Ω, it is normal. If measured value is not in this Inspecting harness
range, it is an open circuit.
(2) Remove the connector from either end of the harness.
Measure the resistance between all terminals in the
connector. If measured value is 100kΩ or more, it is
normal. If measured value is 100kΩ or less, it is a short
circuit.

Inspecting open circuit and short circuit

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ENGINE ASSY - TROUBLE SHOOTING TROUBLESHOOTING

7.2 Pin location of the ECU connector and extension harness connector
The wirings of the sensors, the injectors and the fuel pump are connected to the ECU through the extension harness connector.
Inspect the pin of the ECU connector and extension harness connector when inspecting the wiring of the sensors, the injectors
and the fuel pump.

ECU terminal A ECU terminal K

46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
5 6
31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

1‫ޓ‬Injector 3, + 1‫ޓ‬ECU power supply, +㧔1㧕

2‫ޓ‬Injector 2, + 2‫ޓ‬ECU ground, -㧔1㧕
7‫ޓ‬Speed/timing sensor (crankshaft side), shield 3‫ޓ‬ECU power supply, +㧔2㧕
8‫ޓ‬Rail pressure sensor, ground 4‫ޓ‬ECU ground, -㧔2㧕
10‫ޓ‬Speed/timing sensor (camshaft side) 5‫ޓ‬ECU power supply, +㧔3㧕
12‫ޓ‬Speed/timing sensor (crankshaft side) 6‫ޓ‬ECU ground, -㧔3㧕
14‫ޓ‬Inlet manifold pressure sensor, power supply 9‫ޓ‬Accelerator㧔1㧕
15‫ޓ‬Heater relay 12‫ޓ‬PTO accelerator, ground
16‫ޓ‬Injector 1, 23‫ޓ‬PTO accelerator, power supply
17‫ޓ‬Injector 4, 25‫ޓ‬K-LINE
19‫ޓ‬MPROP, + 28‫ޓ‬Ignition switch
20‫ޓ‬Speed/timing sensor (camshaft side), shield 36‫ޓ‬PTO accelerator
23‫ޓ‬Inlet manifold pressure sensor, ground 41‫ޓ‬Signal, ground
24‫ޓ‬Heater relay, power supply 54‫ޓ‬Oil pressure switch
26‫ޓ‬Rail pressure sensor, power supply 61‫ޓ‬CAN-L1
27‫ޓ‬Speed/timing sensor (crankshaft side) 62‫ޓ‬CAN-H1
31‫ޓ‬Injector 2, - 72‫ޓ‬Main relay
33‫ޓ‬Injector 4, - 73‫ޓ‬24V power supply
40‫ޓ‬Inlet manifold pressure sensor
41‫ޓ‬Water temperature sensor, ground
43‫ޓ‬Rail pressure sensor
46‫ޓ‬Injector 3, -
47‫ޓ‬Injector 1, -
49‫ޓ‬MPROP, - Point of view
50‫ޓ‬Speed/timing sensor (camshaft side)
58‫ޓ‬Water temperature sensor

Pin location of ECU connector

14-37
 TROUBLESHOOTING
ENGINE ASSY - TROUBLE SHOOTING

Extension harness connector, 16 terminals Extension harness connector, 12 terminals

4 3 2 1
4 3 2 1
8 7 6 5
8 7 6 5
12 11 10 9
12 11 10 9
16 15 14 13

1ࠉSpeed/timing sensor (camshaft side), power supply 1ࠉInjector 1, +

2ࠉSpeed/timing sensor (camshaft side) 2ࠉInjector 1, -
3ࠉSpeed/timing sensor (camshaft side), shieldࠉ 3ࠉInjector 4, +
5ࠉSpeed/timing sensor (crankshaft side), power supply 4ࠉInjector 4, -
6ࠉSpeed/timing sensor (crankshaft side) 5ࠉInjector 3, +
7ࠉSpeed/timing sensor (crankshaft side), shield 6ࠉInjector 3, -
8ࠉMPROP, - 7ࠉInjector 2, +
9ࠉRail pressure sensor, power supply 8ࠉInjector 2, -
10ࠉRail pressure sensor 9ࠉWater temperature sensor
11ࠉRail pressure sensor, ground 10ࠉWater temperature sensor, ground
12ࠉMPROP, + 11ࠉOil pressure switch
13ࠉInlet manifold pressure sensor, power supply 12ࠉOil pressure switch
14ࠉInlet manifold pressure sensorࠉ
16ࠉInlet manifold pressure sensor, ground

Point of view for 16 terminals Connector location Point of view for 12 terminals

Pin location of extension harness connector

14-38
MACHINE MAINTENANCE ［4. MAINTENANCE］

4.3 LUBRICANT, FUEL & COOLANT SPECIFICATIONS

The following chart provides information on the specification of oils, grease, fuels and coolant to be
used in various climates and working conditions.

4-11
173
MACHINE MAINTENANCE ［4. MAINTENANCE］

4.4 USE OF BIO-DEGRADABLE OILS

When using Bio-degradable Oil (BIO OIL), refer to the following information.

A. Recommended Oil
Maker Mobil
Brand MOBIL EAL Envirosyn 46H

B. Precaution for the Use of Oil

1. When filling the former machine in which mineral oil is charged with BIO oil, try to flush the
machine three times.
The mineral oil will be left in the circuit of the machine without flushing, resulting in the reduction
of effect of biodegradation ability.
2. When you use BIO OIL, slewing and travel parking brake performance will be reduced because
of lower friction factor of BIO OIL compared to that of mineral oil.

C. Flushing Procedure
1. Drain mineral oil from the hydraulic tank completely.
2. Drain mineral oil from the cylinder completely.
3. Fill hydraulic oil tank with new BIO oil.
4. After starting engine, move every cylinder 10 strokes respectively.

４
The abrupt operation may cause burning of seal because of trapped air in the cylinder.
Try to operate first 4 strokes slowly at engine low idling to charge hydraulic oil in the entire cylinder.

5. Idle travel motor right and left for about 3 minutes.

6. Repeat swing operation 10 rotations.
7. Drain BIO oil from hydraulic tank completely.
8. Drain BIO oil from each cylinder completely.
9. Fill hydraulic tank with new BIO oil. Similarly, repeat the procedure 4. to 9. two times.
10. For hydraulic oil in final condition, analyze the hydraulic oil and be sure of amount of remaining
mineral oil.

D. Bio Oil Change Interval

The BIO oil change interval is 2,000 hours.
For the changing procedure, refer to the section "4.17.B Change Hydraulic Oil".

4-13
174
［4. MAINTENANCE］
MACHINE MAINTENANCE
4.5 MAINTENANCE PARTS

A. Filters & Elements, and Bucket

Replace parts, such as filters and elements, during the periodical maintenance or before the service
life.
The machine can be used economically if the parts are changed properly and timely.
When you place an order of parts, confirm the parts number on parts manual.

System Part Number Parts Name Q'ty Replacement Interval

Return filter element kit After 50 hours (first change)
YN52V01016R610 1
(STD. Breaker) Every 1000 hours (from 2nd change)
(ZD11G19000) (O-ring) 1 (Breaker specification : Every 250 hours)
Hydraulic oil tank
YN50V00025F1 Suction strainer 1
Every 2000 hours
(ZD11G20000) (O-ring) 1
Air breather YN57V00010S002 Element 1 Every 1000 hours
After 6 times of cleaning or one
YY11P00008S003 Element (Outer) 1
year whichever comes first.
Air cleaner For machines equipped with W (double)
YY11P00008S002 Element (Inner) 1 element the inner element must be
replaced together with the outer element.

After 50 hours (first change)

Engine oil filter VA34240-11101 Cartridge 1
Every 250 hours
Fuel filter (Main) VA32G62-00100 Cartridge 1 Every 500 hours
Fuel third filter VA34362-04100 Cartridge 1 Every 1000 hours
Fuel pre-filter YN21P01068R100 Element kit 1 Every 500 hours
YN50V01015P3 Air-con filter (Outer) 1 Every 10 times cleanings
Air conditioner When heavy clogging of filter occurs,
YN50V01014P1 Air-con filter (Inner) 1 clean or replace.

Pilot line filter YN50V00020F1 Line filter 1 Every 2000 hours (Cleaning)
Radiator YN05P00010S006 Radiator cap 1 Every 1000 hours
2412N278D11 Side cutter (R.H) 1
2412N278D21 Side cutter (L.H) 1

Bucket (STD) ZS13C20050 Bolt 8

When required
(0.45 m3) ZN13C20016 Nut 8
2412U16F1 Tooth assy (Outer side) 2
2412U112F1 Tooth assy (Inner side) 3
Internal battery for
communication YN22E00469S001 Battery 1 Every 1 year
controller

- Items enclosed in parenthesis ( ) are the parts to be changed at the same time.
- The internal battery for communication controller should be replaced in once a year. When
replacement is required, ask us or our authorized dealer/distributor to replace the battery.

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［4. MAINTENANCE］
MACHINE MAINTENANCE
4.9 INSPECTION & MAINTENANCE CHART

Follow the chart below for recommended intervals of regular inspection and maintenance procedures.
Perform inspection and maintenance according to the calendar time or operation time shown by the
hour meter, whichever comes first.
See the inspection and maintenance procedure mentioned below for details.

See "4.3 LUBRICANT, FUEL & COOLANT SPECIFICATIONS" for detail specification for lubricant,
coolant, fuel and etc.
LLC: KOBELCO genuine antifreeze/coolant.

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When the machine works at dusty site, clean the filter and the core of radiator often. Clean the filter
and core depending on their dirt.

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MACHINE MAINTENANCE

-Contact our dealer/distributor for checking and adjustment shown by asterisk *2.
-*1-Break-in (After first 50, 100, 500 Hours) Inspection & Maintenance Required.

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MACHINE MAINTENANCE

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 ［4. MAINTENANCE］
MACHINE MAINTENANCE
D. Track Tension

-Support lower frame with suitable blocks.

-Before inspecting and greasing, completely wash and remove the mud and dusts attaching to the
truck.

1. Operate swing, arm, bucket and boom

controls until machine is set up as shown
in.
2. In center of track, measure the distance
between the bottom of frame rails and
surface of shoe.
3. Perform steps 1 and 2 on right track.
4. To increase track tension, set machine as
shown in figure and with grease gun inject
extreme pressure No.2 grease into idler
adjustment grease nipple (1) until proper
tension is reached. Perform this procedure
on both tracks.

Slack:
Proper Tension (A):
270 to 300 mm (7.9 to 11.8 inches)

After injecting grease, operate the travel control forward and reverse for the track being adjusted. This
will balance the tension between the idler and the sprocket. Then remeasure as shown in figure.

5. To decrease track tension, set machine up

as shown in figure.

6. Carefully loosen the adjusting grease

nipple (1) to allow grease to escape.
7. Tighten grease nipple (1), measure track
tension as shown in figure.
Tightening torque:
49 to 69 N-m (36.6 to 51.4 lbf-ft)
8. If necessary, perform steps 5 through 7
on other track.

Grease in track tensioning mechanism is under extreme pressure and can penetrate skin causing
severe injury. Keep face and body away from grease nipple area. Never loosen grease nipple more
than one complete turn. If grease does not release after one turn of the nipple, call an authorized
KOBELCO service dealer for assistance.

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 ［3. MACHINE
MACHINE OPERATION］
MAINTENANCE
E. Machine Operation in Water

Be careful not to immerse the slewing bearing, slewing pinion and swivel joint into the water or mud.
If the machine is operated in water or mud, the slewing bearing and others may be worn abnormally.
If water or mud comes up to the slewing bearing level, put grease in slewing bearing unit the old
grease comes out. If water or mud goes higher than the upper frame level, contact the
dealer/distributor for cleaning or repair.

1. Where a bottom is flat and water flow is

slow, the machine may be operated in a
water-depth (A) to the center of upper roller.
2. Make sure careful operation of machine in
water. Use the bucket to check for stability
of the riverbed. Do not operate the machine
in water that is deeper than depth (A).
3. On soft ground or mud the machine may
sink slowly. Make sure constantly of
undercarriage condition and depth of water.
4. After machine operation in seawater,
thoroughly wash the machine to remove
salt.
5. Using grease gun and inject grease into
the part immersed to water until grease
comes out.

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 ［4. MAINTENANCE］
MACHINE MAINTENANCE
B. Refilling engine oil
1. Make sure that the engine oil drain plug is
closed.
2. Remove the oil pan with specified engine
oil to the specified.
3. Fill the engine oil pan with specified
engine oil to the specified level.

Fill it with specified engine oil through oil filler cap (1) referring to the section "4.3 LUBRICANT,
FUEL & COOLANT SPECIFICATIONS" in Chapter 4.

4. Check the oil level in the oil pan as follows: Pull out the oil level gauge (2), and wipe it with a
cloth.
5. Insert the oil level gauge fully into the oil level gauge guide, then pull the gauge out again. The
oil level should be between the H and L marks on the oil level gauge. If the oil level is low, add
engine oil of the specified type.
6. Check the oil pan and other parts for oil leakage. Repair any oil leakage found.
7. Shut off the fuel supply and crank the engine for about 10 seconds or less using the starters, and
wait for about 1 minute.
8. Perform the above cranking operation again to cir culate oil in the engine.
9. Check the oil level with the oil level gauge (2) again, and add oil to the specified level.

To crank the engine, shut off the fuel supply to the engine and operate the starters.

C. Replacing the oil filter

Do not use any oil filter that has dents, as the filter may be damaged during operation, resulting in a
fuel leakage and possible fire.

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To avoid damage to the filter, do not use a filter wrench. Tighten the filter by hand.

1. Clean around the oil filter (1).

2. Place a drip pan under the oil filter.
3. Loosen the oil filter drain cock (2) and
drain oil from the oil filter.
4. Using a filter wrench, remove oil filter.
Filter wrench of parts number :
YW01T01014P1

5. Thoroughly wipe off oil on the mounting

surface of oil filter with a cloth.
6. Check the new oil filter for proper seating
of gasket.
7. Apply clean engine oil to gasket on the
new oil filter.
8. Install the new filter. Turn the filter until
the gasket comes into contact with the filter

４
head then tighten an extra three quarters
turn by hand.
Filter wrench of parts number :
YW01T01014P1

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B. Bleeding the fuel system

If air vent plugs, the thread portion of the bracket, or sealing washers are damaged, replace them with
new ones.

４
1. Loosen the air vent plug (1) on the fuel
filter intake for the left bank cylinder about
1.5 turns.
2. Turn the priming pump cap (2)
counterclockwise to unlock, and priming
the fuel filter
3. When the fuel from the air vent plug
becomes free from air bubbles, stop priming
and tighten the air vent plug (1) to the
specified torque.
4. After completing the air bleeding from the
fuel filter, move the priming pump cap (2)
in and out 36 times continuously. Or
continue the air bleeding work until the air
level in the transparent fuel filter cup (3)
rises and disappears.
5. Start the engine and push the priming
pump cap (2) back into place. And turn it
to the right to tighten.

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K. Cleaning or Replacement of Radiator Cap

To avoid being burned, be careful when removing the radiator cap. Coolant is under high pressure
when hot.
-Do not remove the radiator cap when the system is hot.
-Allow enough time for the machine to cool down before removing the radiator cap.

A loose radiator cap will let hot steam and coolant escape from the cooling system. Allow the radiator
cap/cooling system enough time to cool before tightening the loose cap.

1. After the radiator cap/cooling system has

cooled so it can be touched with a bore
hand, slowly loosen the cap (1) to release
the pressure.
After all pressure is released, remove the
radiator cap.
2. Inspect locations A through C for debris
and damage to the cap (1). Use a clean
cloth to wipe the cap (1) clean. Replace
the cap if necessary.

４
Inspection locations:
A. Contact surface between the negative
pressure valve (2) and gasket (5)
B. Both surfaces of the pressure valve (3)
and gasket (5)
C. Both surfaces of the external lid (4)
and gasket (6)
Radiator cap (1)
3. Securely tighten the cap (1).

If grooves are worn into the surface of the gasket after years of use, steam will escape and pressure
cannot be maintained. Replace the worn gasket with a new one.

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4.18 MACHINE STORAGE

A. Machine Storage
The following procedure applies when the machine is to be stored for a month or more.

1. Perform all inspection and maintenance procedures as previously described in this section.
2. Thoroughly clean the machine, inspect for damaged or worn parts and components and replace
or repair all damaged or worn parts.
3. Completely fill fuel tank with fresh, clean fuel to aid in preventing condensation of moisture inside
the fuel tank.
4. Move machine to an indoor location for storage.
5. Operate bucket and arm completely "IN" extending cylinders. Then lower boom until attachment is
resting on the floor.
6. Coat cylinder rods with a heavy coat of grease to prevent corrosion during storage.
7. Remove batteries and store in a well ventilated, warm area.

Protect CPU and all electrical components from water and steam when cleaning the machine.

４
B. Care During Storage
1. Every 30 days during storage, it will be necessary to start and run the machine to circulate the
fluids through the systems. Before starting clean cylinder rods and after running re-grease cylinder
rods.

Run and operate machine for approximately 1 hour to allow all fluids to circulate well and reach
normal operating temperatures.

C. Strage Up After
1. Perform all Inspection and maintenance procedures as described in this section before bringing
machine out of storage for normal operation.
2. Remove drain plugs from travel motor and slewing gear reduction units to drain off any moisture
which may have accumulated during storage.
3. Carefully and closely inspect all hydraulic hoses after long periods of storage for signs of
deterioration. Replace all hoses showing these signs.

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