350X2 Manual de Servicio

Contents SH330
Contents
Contents
Main Body Section
Specifications
Overall
1. Main Data
2. Performance
3. Main Unit Dimensions
4. Engine
5. Cooling System
6. Upper Side Work System
7. Operating Device
8. Swing Units
9. Travel Lower Body
Hydraulic Equipment
1. Hydraulic Device
2. Control Valve, Cylinder
Capacities, Filters
1. Coolant and Oil Capacities
2. Hydraulic Oil Filters
3. Fuel Filter
Lifting Capacity
Precautions for lifting loads with the hydraulic excavator
Lifting Capacities (Standard Arm)
Lifting Capacities (Short Arm)
Lifting Capacities (Long Arm)
Overall View
Overall View (350X2)
1. Standard Arm (3.25 m)
2. Short Arm (2.63 m)
3. Long Arm (4.04 m)
Work Range Diagram

Work Range Diagram (350X2)
1. Standard Arm (3.25 m)
2. Short Arm (2.63 m)
3. Long Arm (4.04 m)
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Contents
Summary Section
Main Equipment Table
Lower Component
1. Travel Unit
2. Take-up Roller
3. Upper Roller
4. Lower Roller
5. Recoil Spring
6. Shoe
Upper Component
1. Swing Unit
Engine-related
1. Engine
2. Muffler
3. Air Cleaner (double element)
4. Radiator
Hydraulic Device
1. Hydraulic Pump
2. Pump P-Q Diagram
Control-related
1. Control Valve
2. Solenoid Valve (5 stack)
3. Remote Control Valve (left/right, travel operations)
4. Remote Control Valve Characteristic Diagram
5. Cushion Valve (heat circuit, with shuttle valve)
6. Selector Valve (option)
7. Center Joint
Backhoe Attachment
1. Cylinder
2. Attachments
Equipment Layout Diagram

Main Equipment Layout
Consumable Part Layout
Standard Machine Option List

List of Optional Components
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Contents
Hydraulics Section
Hydraulic Equipment Layout
Overall View
Pump Chamber Hydraulic Equipment Layout
Swing Body Center Section Hydraulic Equipment Layout
Housing Left Side Hydraulic Equipment Layout
Layout of Hydraulic Equipment in Cab
Port Diagram
Pump
1. Hydraulic Pump (standard model)
Valves
1. Control Valve
2. 5 Stack Solenoid Valve
4. Remote Control Valves (upper, travel)
5. Cushion Valve
6. 4-way Multi-valve
8. Direction Valve/Shut-off Valve
9. HBCV (Option)
Manifolds
1. Manifold Under Cab
2. Manifold (accumulator section)
3. Manifold (hydraulic oil tank section)
Motors
1. Swing Motor
2. Travel Motor
3. Center Joint
Pilot Hose Connection Diagram

Pilot P and T Lines
Pilot Control Line
Pilot Control Line (2-way selector valve)
Function List
Function Table
Explanation of New Functions
1. Swing Relief Cut-off Control
2. Swing Speed Limit Control
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Contents
3. Negative Control Power Save Control
4. Option Line Flow Adjustment Control
5. Multi Purpose Circuit (breaker ⇔ crusher) One-touch Switching Control
6. Bucket-close Regenerative Circuit
Explanation of Hydraulic Circuit and Operations (standard model)

Travel Circuit
Travel low-speed circuit
Travel high-speed circuit
Straight travel circuit
Swing Circuit
Swing speed limit control circuit
Swing relief cut-off control circuit
Swing priority circuit
Swing brake circuit
Swing parking circuit (lever in neutral)
Swing parking circuit (brake release)
Swing parking circuit (machine stop)
Boom Circuit
Boom-up circuit (independent operation)
Boom-up circuit (compound boom-up + arm-in)
Boom-down regenerative circuit
Boom-down tilting prevention circuit
Boom-down load holding valve circuit
Arm Circuit
Arm-out circuit
Arm-in forced regenerative circuit
Arm-in load holding valve circuit
Bucket Circuit
Bucket-open circuit
Bucket-close regenerative circuit
Negative Control Circuit
Negative control circuit (power save solenoid OFF)
Negative control power save circuit (power save solenoid ON)
Negative control circuit (bucket close, power save solenoid OFF)
Other Circuits
Cushion circuit (arm-out operation)
Cushion circuit (arm-out operation stopped)
Cushion circuit (arm-out → arm-in operation)
Heat circuit (lever in neutral)
Auto pressure boost circuit (bucket close)
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Contents
Explanation of Hydraulic Circuit and Operations (option)
Option Circuits
Breaker circuit (independent operation)
Double-acting circuit (hydraulic fork)
Multi-purpose circuit (breaker Q control)
Multi-purpose circuit (2 pumps flow crusher)
2nd option circuit (hydraulic rotation fork)
Main Equipment Structure and Operation Explanation

Pump
1. Hydraulic Pump
2. Regulator
3. Gear Pump
Motor
1. Travel Motor
2. Swing Motor
Valve
1. Control Valve
2. 5 Stack Solenoid Valve Operation Explanation
3. Upper Pilot Valve (remote control valve)
4. Travel Pilot Valve (remote control valve)
5. Cushion Valve
6. Selector Valve (4-way)
7. Direction Valve (3-direction)
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Contents
Electrics Section
Work Mode Select Switch
The Throttle Volume and Work Mode Select Switch are Linked!!
Computer connection method
Monitor changes
Pilot pressure switch changed to pressure sensor
Pump Electromagnetic Proportional Valve
1. Horsepower Control Proportional Valve
2. P1 Flow Control Proportional Valve
System Control for Energy Saving
1. Reduced Fuel Consumption Through Transient Load Reduction Control
2. Reduced Fuel Consumption Through Swing Relief Cut Control
3. Reduced Fuel Consumption Through Power Save Control
Swing Speed Limit Control
Electrical Equipment Layout Diagram

Overall View
1. Main Unit Left Side Layout Diagram (radiator chamber)
2. Engine Section Layout Diagram
3. Main Unit Right Side Layout Diagram (pump chamber)
4. Main Unit Center Section Layout Diagram
5. Cab Layout Diagram 1
6. Layout Around Operator’s Seat
Stand Alone Parts Diagram
Main Equipment Structural Diagrams

Connection Connector Pin Layout
1. Computer A
2. Monitor
Electrical Circuit Diagram

Overall View
1. Sequence Circuit Diagram
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Contents
Block Diagram
1. Computer A
2. Computer S
3. ECM
4. Monitor Display
5. Air Conditioner
6. Lever Lock
7. Horn
8. Working Light
9. Option
10. Other
11. Electrical Symbol List
Electrical Connector Wiring Diagram

Wire Harness
1. Main Frame Harness
Cab
1. Cab Main Harness
2. Cab Sub Harness
3. In Cab
4. Engine Harness
Console
1. Console Right Harness
2. Console Left Harness
Electrical Parts and Wiring Assembly Diagram

Main Frame
Cab
Explanation of Functions and Operations

Explanation of Electrical Functions
Engine Speed Control
1. Throttle Control
2. Idling Control (auto/one-touch)
3. Idling Start
4. Auto Warm-up
Engine Start/Stop Control
1. Engine Start/Stop Judgment
2. Power-cut Delay
3. Engine Emergency Stop
4. Neutral Start
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Contents
Pump Control
1. Work Mode Control
2. Pump Horsepower Boost Control
3. Pump Horsepower Cut Control
4. Power Save Control
Swing
1. Swing Brake
2. Swing Free Swing (option for North America)
3. Swing Lock (for maintenance)
4. Swing Relief Cut
5. Swing Speed Limit
Travel
1. Travel Speed Switchover
2. Travel Alarm
Valve Control
1. Lever Lock
2. Solenoid Sticking Prevention
3. Pressure Boost Control
Monitor Control
1. Bar Graph (coolant temperature gauge, oil temperature gauge, fuel gauge)
Accessories
1. Horn
2. Working Light
3. Wiper and Washer
4. Room Lamp
5. Radio Mute
Other
1. Anti-theft
2. Battery Save Function
3. Alternator Power Generation Detection
4. Overload Warning
Options
1. Option line control
2. Option Line Control
3. Feed Pump Automatic Stop
4. Return Filter Clogging Detected
5. Beacon
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Contents
Service Support
Screen Operations
1. Screen Shift
Screen Display List
1. CHK (status display) Screen List
2. DIAG (trouble diagnosis) Screen
3. HR (usage log) Screen List
4. CFG (setting change) Screen
5. CAL (troubleshooting support) Screen
6. Check the Monitor Switch (self-diagnosis function)
7. Option Flow Setting
8. Anti-theft Setting
9. Model Setting
10. Engine Information Screen
Screen Display Details
1. Message Display List
Abnormality Display
1. Diagnostic Trouble Code Display
2. Main Unit Diagnostic Trouble Code List
3. Diagnostic Trouble Code (monitor display)
4. Sensor Trouble Operation Table
5. EPF (Engine Protection Feature)
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Contents
Engine Section
Engine Summary
Main Data Table
Overall Appearance Diagram
Sensor and Auxiliary Equipment Layout (left)
Sensor and Auxiliary Equipment Layout (rear)
Engine System Diagram
Fuel System Diagram
Detailed Parts Diagrams
1. ECM (engine control module)
2. Supply Pump/SCV (suction control valve)
3. Common Rail/Flow Damper
4. Common Rail Pressure Sensor/Pressure Limiter
5. Injector
6. Engine Coolant Temperature Sensor
7. Engine Oil Pressure Sensor
8. Cam Position Sensor (CMP sensor)
9. Crank Position Sensor (CKP sensor)
10. Atmospheric Pressure Sensor
11. Suction Air Temperature Sensor
12. Boost Pressure Sensor
13. Boost Temperature Sensor
14. Charge Fuel Pump
15. EGR Cooler
16. Lead Valve (check valve)
17. EGR Valve
Engine Control Summary
Explanation of Engine Terms

Function Explanation Table
Explanation of Engine Structure

Technology for Exhaust Gases
1. Common Rail System
2. Multi Stage Fuel Injection (multiple injection)
3. Inter Cooler
4. EGR (exhaust gas recirculation)
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Contents
Explanation of Engine Operation
Fuel Unit
1. Common Rail System Summary
2. Change Points for Injection Method (governor, common rail)
3. Explanation of Injector Operation
4. Explanation of Supply Pump Operation
5. Supply Pump Disassembly Diagram
6. Explanation of Flow Damper Operation
7. Pressure Limiter
8. Cautions for Maintenance
Explanation of Engine Control
1. Fuel Injection Quantity Correction
2. Starting Q Correction
3. Preheat Control (QOS: quick on start)
4. Atmospheric Pressure Correction (high altitude correction)
5. Control for Overheating
6. Control for Boost Temperature Rise
7. Control for Engine Oil Pressure Drop
8. Start Control (coolant temperature monitoring)
9. Long Cranking Control
10. Starting Control for Reduced Number of Cylinders
11. Normal Stop (key switch OFF operation)
Engine Maintenance Standards

Engine Information Screen
1. Purpose
2. How to Go to This Screen
3. Engine Start Restriction
4. Screen
Monitor Operating Method
1. View Mode
2. Edit Mode
Engine Information
(Q resistance, QR code, engine serial number) Copying Method
Rewriting Injector QR Codes
When Replacing Computer A at the Same Time
Engine Information Acquisition Timing
Redoing Engine Information Acquisition
Abnormality Display
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Contents
Engine Equipment Table
Exhaust Gas 3rd Engine Accessory Electrical Parts Interchangeability (Isuzu part number)
Exhaust Gas Regulations

Features of Materials Subject to Exhaust Gas Regulation
Exhaust Gas Regulation Values
Cautions for Fuel Used

Engine Fuel and Maintenance of Fuel Filters
1. Fuel to be applied
2. Maintenance of fuel filters
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Contents
Air Conditioner Section
Layout Diagram
Air Conditioner Overall Diagram
1. Frame
2. Cab
Circuit Diagram
Air Conditioner Circuit Diagram
Explanation of Functions
Explanation of Control
1. Air Mix Motor Actuator Control
2. Blow Mode Motor Actuator Control
3. Refresh / Recirculate Switch Motor Actuator Control
4. Blower Amp Control
5. Compressor Clutch Control
6. COOLMAX Control and HOTMAX Control
7. Trouble Detection and Control after Trouble Detected
8. Monitor Mode
9. Door Switch Control
10. Inside Air Filter Clogging Detection Control
Actuator Inspection
Air Mix Motor Actuator Inspection
Refresh / Recirculate Motor Actuator Inspection
Mode Motor Actuator Inspection
Self-diagnosis Function with Panel Display

Abnormality Display and Self-check Procedures
1. Abnormality Display Position
2. Explanation of Abnormality Display
3. Explanation of Monitor Mode
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Contents
Part Function and OK/NG Judgment
Control Panel and Control Unit
Blower Amp
Relay
Air Mix Actuator
Refresh / Recirculate Actuator
Blow Mode Actuator
Evaporator Sensor
Dual Pressure Switch
Solar Radiation Sensor
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Contents
New Machine Performance Section
New Machine Performance Judgment Table
Performance Judgment Check Sheet
Performance Measurement Entry Table
Measurement Method and Main Unit Posture

Engine Speed
Pressure in Each Section
Cylinder Falling Amount
Attachment Speed
Swing Speed
Swing (180°) Brake Angle
Travel Speed
Off Travel Amount
Travel Sprocket Speed
Shoe Tension Amount
Swing Ball Race Bearing Movement Amount and Bucket Tip Movement Amount
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Contents
Maintenance Section
Pressure Measurement and Adjustment Procedures
Procedures for Pressure Measurement from the Monitor Display
1. Pressure Measurement Method
2. Operating Method
Procedures for Measuring Hydraulic Oil Temperature from the Monitor Display
1. Hydraulic Oil Temperature Measurement Method
2. Operating Method
Procedures for Pressure Measurement by Installing Pressure Gauge
1. Preparations
2. Items to Prepare
Pressure Measuring Ports
Control Valve
1. Location of Relief Valves
Pressure Measurement Preparations
1. Main Pressure Measurement
2. Pilot Pressure Measurement
3. Negative Control Pressure Measurement
Pressure Adjustment
1. Main Pressure Adjustment
2. Pilot Pressure Adjustment
Hydraulic Pump Flow Measurement Procedures

Preparations
1. Items to Prepare
Work Preparations
Flow Measurement
Drain Volume Measurement Procedures

Preparations
Travel Motor Drain Volume Measurement
Swing Motor Drain Volume Measurement
Air Bleed Procedure

Hydraulic Pump
Travel Motor
Swing Motor
HBCV (Option)
1. Boom Cylinder HBCV
2. Arm Cylinder HBCV
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Contents
Electricity Measurement Procedures
Measurement Equipment
Measurement Tools
Measurement Method
1. Hydraulic Pump Electromagnetic Proportional Valve
3. Oil Temperature Sensor
4. Pressure Sensor
Procedures for Replacing Consumable Parts

Air Conditioner Belt and Fan Belt Replacement
1. Air Conditioner Belt Replacement
2. Fan Belt Replacement
Fuel Filter Replacement
1. Filter Replacement
2. Air Bleeding
Engine Oil Filter and Engine Oil Replacement
1. Engine Oil Replacement
2. Engine Oil Filter Replacement
Radiator Coolant Replacement
Air Cleaner Cleaning and Replacement
Hydraulic Oil Filter Replacement
1. Return Filter Replacement
2. Suction Filter Replacement
3. Air Breather Element Replacement
4. Pilot Oil Filter Replacement
5. Hydraulic Oil Replacement
Others
1. Coolant Filling
2. Washer Fluid Filling
Periodic Maintenance Procedures

Maintenance Every 250 Hours
1. Battery Inspection and Replacement
Maintenance after First 250 Hours for New Machine
/ Every 1000 Hours from Then on
1. Swing Reduction Gear Oil Replacement
2. Gear Oil Filling
Replace the Flange Packing at the Bottom of the Fuel Tank
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Contents
Bolt Size and Torque Table
Bolt and Nut Tightening
Retightening Torque Table
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Contents
Data Section
Main Unit Weight
Divided Weight (standard specifications)
Stand Alone Part Weight
Shoe Weight (per side)
Arm Weight
Bucket Weight
Interchangeability
Interchangeability
1. Main Part Interchangeability Table (350X2)
Attachment Installation Dimensions

Attachment Dimensions
Paint Colors
Paint Colors
Unit Conversion Ratio

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NOTES:
Specifications SH330
Main Unit
Specifications
Overall
1. Main Data
Model name 350X2
Operating weight 79145 lb (35900 kg)
Engine output 271 HP/2000 RPM (202 kW/2000 min-1)
Bucket capacity Bucket less
2. Performance
350X2
Standard weight 18.0 kN
Swing speed 9.8 min-1
Low speed 2.17 mph (3.5 km/h)
Travel speed
High speed 3.4 mph (5.5 km/h)
Maximum pulling force 59574 lbf (265 kN)
Grade ability 70 % (35°)
8.4 PSI (58 kPa)
27.6 in (700 mm) grouser shoe
7.25 PSI (50 kPa)
Ground pressure
6.8 PSI (47 kPa)
3. Main Unit Dimensions

350X2
Main unit length 232.6 in (5910 mm)
Main unit width 125.9 in (3200 mm)
Upper swing body width 118.8 in (3020 mm)
Cab width 39.3 in (1000 mm)
Main unit height 123.2 in (3130 mm)
Swing radius (rear end) 135.8 in (3450 mm)
Swing body rear end distance 134.6 in (3420 mm)
Swing body rear section bottom height 47.6 in (1210 mm)
Distance between tumblers 159 in (4040 mm)
Overall track length 196 in (4980 mm)
Overall track width 125.9 in (3200 mm)
Distance between tracks 102.3 in (2600 mm)
Track shoe width 31.4 in (800 mm) (option 27.5 in (700 mm), 33.4 in (850 mm))
Minimum ground clearance 18.8 in (480 mm) (to bottom of lower frame)
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Specifications
4. Engine
350X2
Name Isuzu 6HK1X diesel engine
4-cycle, water cooled, overhead camshaft, vertical in-line, direct injection
Model
type (electronic control), with turbocharger
Number of cylinders - bore x stroke 6 - φ 4.5 in (115 mm) x 4.9 in (125 mm)
Total stroke volume 0.04 Gal. (0.15 L)
Maximum torque 796.5 lb•ft (1080 N•m)/1500 rpm.
Fuel consumption ratio 234.6 g/kW•h max.
Starter 24 V 5.0 kW Reduction type
Charging generator 24 V 50 A AC type
Battery 12 V 128 Ah/5 HR x2
5. Cooling System
350X2
Fan type φ33.4 in (850 mm) x 6 Intake
Radiator
Fin type Wavy
Fin pitch 0.07 in (2.0 mm)
Oil cooler
Fin type Wavy
Inter cooler
Fin type Triangular straight
Fuel cooler
Fin type Wavy
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Specifications
6. Upper Side Work System
350X2
Model Backhoe attachment
Components, dimensions, working
dimensions
Standard bucket capacity Heaped 1.40 m3 (leveled 1.04 m3)
Bucket width 51.1 in (1300 mm)
Bucket width with side cutter 55.5 in (1440 mm)
Bucket weight with side cutter 79146 lb (1150 kg)
Boom length 253.9 in (6450 mm)
Standard (STD) Long Short
Arm type
(3.25 m) (4.04 m) (2.63 m)
Arm length 127.9 in (3250 mm) 159 in (4040 mm) 103.5 (2630 mm)
Bucket radius 66.1 in (1680 mm)
Bucket wrist angle 173°
Maximum digging radius 440 in (11170 mm) 469 in (11900 mm) 420 in (10670 mm)
Maximum digging radius at
432 in (10980 mm) 461 in (11720 mm) 412 in (10470 mm)
ground line
Maximum digging depth 289 in (7340 mm) 320 in (8140 mm) 265 in (6730 mm)
Maximum vertical straight wall
250 in (6350 mm) 281 in (7150 mm) 235 in (5970 mm)
digging depth
Maximum digging height 408 in (10370 mm) 420 in (10670 mm) 406 in (10320 mm)
Maximum dump height 285 in (7230 mm) 297 in (7540 mm) 280 in (7140 mm)
Minimum swing radius at front 177 in (4500 mm) 180 in (4560 mm) 182 in (4630 mm)
Height for minimum swing radius
334 in (8480 mm) 334 in (8490 mm) 336 in (8540 mm)
at front
7. Operating Device
350X2
Operator's seat
Position Left side
Adjustable forward and back and up and down, reclining mechanism, with
Structure
seat suspension
Cab Sealed steel type, all reinforced glass
Levers and pedals
For travel use Lever and pedal type (hydraulic pilot type) x2
For operating machine use Lever type (hydraulic pilot type) x2
Instruments and switches
Work mode select switch 3 modes (SP/H/A)
Travel mode select switch Low-speed / high-speed switch type
One-touch idle Knob switch type
Engine emergency stop Switch type
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Specifications
350X2
Monitor device
Machine status display (full dot
liquid crystal)
　 Work mode select status SP/H/A
Instrument (full dot liquid crystal ex-
cept for hour meter)
Fuel gauge Bar graph indicator
Engine coolant temperature
Bar graph indicator
gauge
Hydraulic oil temperature gauge Bar graph indicator
Hour meter Digital type
Machine status and warnings (full dot liquid crystal and warning alarm)　 * has warning alarm
Overheat * Battery charge * Electrical system abnormality *
Refill fuel * Engine oil pressure * Refill coolant *
Engine pre-heat Auto Warm-up Air cleaner *
Anti-theft device triggered Engine system abnormality * Engine emergency stop *
Illumination equipment
Working light Cab top: 24 V 70 W x1
Boom up: 24 V 70 W x1
Interior light 4V 10 W x1
Horn Electric horn　 x2
Wiper with intermittent function, window washer, air conditioner, clock, rear
Other
view mirrors (left and right)　 1 each
8. Swing Units
350X2
Swing circle Swing bearing type (with inner gear)
Swing hydraulic motor Fixed displacement piston motor x1
Reduction gear Planetary gear 2-stage reduction gear
Swing parking brake Mechanical lock (operational lever linkage type)
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Specifications
9. Travel Lower Body
350X2
Travel hydraulic motor Variable displacement piston motor　 x 2
Reduction gear Planetary gear 3-stage reduction gear
Travel brake Hydraulic lock
Parking brake Mechanical lock (travel lever linkage type)
Track shoe
Model Assembly-type triple grouser shoe
Number of shoes (per side) 48
Shoe width 24 in (600 mm) (option 31.4 in (800 mm))
Grouser height 1.4 in (36 mm)
Link pitch 8.5 in (216 mm)
Roller
Number of upper rollers (per side) x 2
Number of lower rollers (per side) x 8
Track belt tension adjuster Grease cylinder type (with cushion spring)
Hydraulic Equipment
1. Hydraulic Device
350X2
Hydraulic pump drive type Direct engine link (no transmission)
Hydraulic pump
Model Double variable displacement piston pump x1
Gear pump　 x1
Discharge volume Piston pump 2 x 76.6 gpm (290 L/min)
Gear pump 7.9 gpm (30 L/min)
Pump control method Simultaneous output full-horsepower control
Set pressure of main relief valve 4975 PSI (34.3 MPa) (5410 PSI (37.3 MPa) for boost)
Set pressure of overload relief 3974 PSI (27.4 MPa) (boom down)
valve 5685 PSI (39.2 MPa) (other)
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Specifications
2. Control Valve, Cylinder
350X2
Control valve
Quadruple spool
Model One-piece type　 x 1
Quintuple spool
Operating method Hydraulic pilot type: travel, swing, and operating machine
Cylinder Number of cylinders x tube bore - rod diameter - stroke
Boom cylinder 2 x φ6 in - φ4 in - 59 in (φ145 mm - φ100 mm - 1495 mm)
Arm cylinder 1 x φ7 in - φ5 in - 69 in (φ170 mm - φ120 mm - 1748 mm)
Bucket cylinder 1 x φ6 in - φ4 in - 48 in (φ150 mm - φ105 mm - 1210 mm)
Capacities, Filters
1. Coolant and Oil Capacities
350X2
Coolant 7.9 Gal (30 L)
Fuel 152.6 Gal (578 L)
Engine lubricating oil 10 Gal (38 L)
Travel reduction gear lubricating oil
2.9 Gal (11 L)
(one side)
Swing reduction gear lubricating oil 1.5 Gal (6 L)
Hydraulic oil 92.4 Gal (350 L)
Hydraulic oil tank regulation amount 46.2 Gal (175 L)
2. Hydraulic Oil Filters

350X2
Suction filter (inside tank) 105 μm
Return filter (inside tank) 6 μm
Pilot line filter (inside housing) 8 μm
3. Fuel Filter
350X2
Main filter 4 μm
Pre-filter 10 μm
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Lifting Capacity SH330
Lifting Capacity
Lifting Capacity
Precautions for lifting loads with the hydraulic excavator
Discuss the procedures in advance
1. Operators and those who handle rigging must be trained for those specific pur-
poses.
2. Use a sling that is sturdy enough. Also, use a device designed to prevent loads
from falling.
Take measures to ensure safe operation

1. Specify signals to be used for lifting 2. Work on a level surface. (Working on 3. If you are on a slope, level out the
loads and designate a signal person a slope can cause the machine to footing before starting to work.
for the entire course of operation. overturn and fall.)
4. Do not allow anyone to be under the 5. Do not lift a load exceeding the rated 6. The wire ropes and the chains for rig-
suspended load or at other danger- capacity. (The machine can overturn ging must be sturdy enough and be
ous areas. and jeopardize the safety of workers.) free of disfigurement and corrosion.
Use wire ropes with safety factor 6 or greater.

Use lifting chains with safety factor 5 or greater.
Caution
[1] The operators must be trained specifically.
[2] The weight of the loads and the rigging equipment combined must not exceed the maximum load
value.
[3] During the crane operations, lower the engine speed (mode A) and keep working at low engine speed.
[4] Be extra careful while carrying out the swing operations. Move the machine slowly.
[5] Do not leave the cab while you are suspending a load.
[6] Do not travel any distance while you are suspending a load.
[7] Sling the load in such a manner that the wire rope and the ring do not get detached from the hook.
[8] If the bucket hook, or the rigging equipment gets damaged during operation, stop the procedure
and make necessary repairs.
[9] Please contact our authorized service shops when you wish to have hooks attached to your
bucket.
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Lifting Capacity
Lifting Capacities (Standard Arm)
Type of machine: 350X2 L: 10.67 ft (3.25 m) Arm length
Arm: Standard arm R: Reach from swing center
Shoe: 800 Grouser shoe H: Bucket hook height
Bucket: 1.83 yd3 (1.4 m3) W: Lifting capacity
We: Frontal rating load
Ws: Lateral rating load
Rating load at height point H and

MAX:
at maximum working reach
(Maximum working reach: 33.929 ft) (Units; Ib)

Max.
R 30 ft 25 ft 20 ft 15 ft 10 ft
H W R (ft)
We 9250 * 26.75
30 ft
Ws 9250 * 26.75
We 8650 * 30.68
25 ft
Ws 8650 * 30.68
We 8450 * 33.23 16150 *
20 ft
Ws 8450 * 33.23 15350
We 8500 * 34.75 15950 * 17450 * 19700 *
15 ft
Ws 8100 34.75 10650 14850 19700 *
We 8800 * 35.39 16450 19300 * 23150 * 31300 * 48800 *
10 ft
Ws 7600 35.39 10300 14100 20250 31300 * 48800 *
We 9400 * 35.21 16050 21100 * 26700 * 38800 * 18950 *
5 ft
Ws 7500 35.21 9900 13400 18900 29100 18950 *
We 10300 * 34.20 15700 20900 29100 * 41000 * 25100 *
0 ft
Ws 7750 34.20 9600 12800 17900 27550 25100 *
We 11750 * 32.25 15500 20500 29200 40750 * 32400 *
-5 ft
Ws 8550 32.25 9400 12450 17400 27150 32400 *
We 14250 * 29.16 20450 28700 * 38750 * 45550 *
-10 ft
Ws 10150 29.16 12350 17350 27350 45550 *
We 13800 * 24.38 18500 * 25400 * 34050 * 47600 *
-15 ft
Ws 13800 24.38 12700 17650 27850 47600 *
We 16900 * 24800 * 33750 *
-20 ft
Ws 16900 * 24800 * 33750 *
*Hydraulic pressure factor: 87.0%. Without asterisk: Stability factor: 75.0%
SST-02-02-007LX 8
2
Lifting Capacity
Lifting Capacities (Short Arm)
Arm: Short arm R: Reach from swing center

MAX:
(Maximum working reach: 32.286 ft) (Units; Ib)

Max.
R 30 ft 25 ft 20 ft 15 ft 10 ft
H W R (ft)
We 13200 * 24.39
30 ft
Ws 13200 * 24.39
We 12250 * 28.72
25 ft
Ws 11900 28.72
We 11850 * 31.45 17600 *
20 ft
Ws 9800 31.45 14900
We 11850 * 33.07 18700 * 21450 *
15 ft
Ws 8700 33.07 14450 20950 *
We 12150 * 33.75 16200 20300 * 24650 * 33400 *
10 ft
Ws 8150 33.75 10050 13750 19650 30600
We 12800 * 33.56 15850 21250 27800 * 38450 *
5 ft
Ws 8050 33.56 9750 13100 18400 28150
We 13800 32.48 15600 20700 29400 * 40700 *
0 ft
Ws 8400 32.48 9500 12600 17550 27000
We 15350 30.41 20400 29050 39950 * 32400 *
-5 ft
Ws 9350 30.41 12350 17200 27150 32400 *
We 15350 * 27.06 20500 27650 * 36900 * 47550 *
-10 ft
Ws 11450 27.06 12400 17350 27450 47550 *
We 22950 * 30800 * 41450 *
-15 ft
Ws 17850 28050 41450 *
9 SST-02-02-007LX
3
Lifting Capacity
Lifting Capacities (Long Arm)
Arm: Long arm R: Reach from swing center

MAX:
(Maximum working reach:36.314 ft) (Units; Ib)

Max.
R 35 ft 30 ft 25 ft 20 ft 15 ft 10 ft
H W R (ft)
We 7300 * 29.96
30 ft
Ws 7300 * 29.96
We 6850 * 33.46
25 ft
Ws 6850 * 33.46
We 6700 * 35.78 12550 *
20 ft
Ws 6700 * 35.78 11100
We 6750 * 37.18 14600 * 15550 *
15 ft
Ws 6750 * 37.18 10850 15150 *
We 7000 * 37.78 8550 * 15650 * 17550 * 20650 *
10 ft
Ws 6700 37.78 7700 10400 14400 20350 *
We 7450 * 37.61 10800 * 16100 19600 * 24400 * 34700 * 31600 *
5 ft
Ws 6550 37.61 7450 9950 13500 19250 30000 31600 *
We 8150 * 36.67 10050 * 15600 20900 27650 * 39550 * 26600 *
0 ft
Ws 6750 36.67 7250 9500 12750 18000 27750 26600 *
We 9250 * 34.89 15300 20350 29050 40500 * 32300 *
-5 ft
Ws 7300 34.89 9200 12250 17200 26700 32300 *
We 11050 * 32.09 15200 20100 28750 39600 * 40200 *
-10 ft
Ws 8400 32.09 9100 12050 16900 26600 40200 *
We 14100 * 27.93 20250 27050 * 36550 * 52550 *
-15 ft
Ws 10750 27.93 12150 17050 27000 52550 *
We 22000 * 30000 * 42300 *
-20 ft
Ws 17650 27700 42300 *
SST-02-02-007LX 10
4
Overall View SH330
Main Unit
Overall View
Overall View (350X2)
1. Standard Arm 3.55 yd (3.25 m)
Note: 1. Numbers are subject to change without notice due to design change or other reason.
Note: 2. The diagrams give values that include the shoe lug height 1.4 in (36 mm).
2. Short Arm 2.88 yd (2.63 m)

11 SST-02-03-012LX
1
Overall View
3. Long Arm 4.4 yd (4.04 m)
SST-02-03-012LX 12
2
Work Range Diagram SH330
Main Unit
Work Range Diagram

Work Range Diagram (350X2)
1. Standard Arm 3.55 yd (3.25 m)
Note: 2. The diagrams give values that exclude the shoe lug height 1.4 in (36 mm).
33 SST-02-04-012LX
1
Work Range Diagram
2. Short Arm 2.88 yd (2.63 m)
SST-02-04-012LX 34
2
Work Range Diagram
3. Long Arm 4.4 yd (4.04 m)
35 SST-02-04-012LX
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NOTES:
Main Equipment Table SH330
Summary

Lower Component
1. Travel Unit
350X2
Sumitomo part No. KSA10220
Manufacturer Nabtesco Corporation
Motor type Variable displacement piston motor
Automatic 2-speed switchover with parking brake
Intake amount 290.7/170.1 cm3/rev
Operating pressure 4975 PSI (34.3 MPa)
Operating flow 77.3 gpm (292.5 L)/min
Brake torque 34946 lbf•ft (47.38 kN•min.) (including reduction gear)
Relief valve set pressure 5192 - 5482 PSI (35.8 - 37.8 MPa)
Automatic 2-speed switchover pres-
3843 PSI (26.5 MPa)
sure
Reduction gear
Reduction gear type Planetary gear 2-stage reduction gear
Reduction ratio 40.467
Dry weight 860 lb (390 kg)
2. Take-up Roller
350X2
Weight 364 lb (165.0 kg)
3. Upper Roller
350X2
Sumitomo part No. KBA1141
4. Lower Roller
350X2
1 SST-03-01-013LX
1
5. Recoil Spring
350X2
Item Sumitomo part No. Weight lb (kg)
Yoke KSA1065 88 (39.8)
Sems B M16 × 50 105R016Y050R 1 (0.5)
Threaded rod KSA1066 111 (50.3)
Groove height N M64 165R064HSN 4 (1.9)
SP pin 10 × 100 338W100Z100B 0.2 (0.1)
Recoil spring KSA1310 263 (119.4)
Grease cylinder assembly KSA0832 91 (41.3)
Sems B M16 × 65 105R016Y065R 0.7 (0.3)
Assembly Total 560 (254)
Mounting length of spring 31 in (779 mm)
6. Shoe
350X2
Sumitomo part No. Weight or quantity
600 grouser KSA10450 4888 lb (2217 kg)
Link KSA10460 1 set
Shoe KSA1106 × 48
Bolt KSA1107 × 192
Nut KSA1108 × 192
800 grouser KSA10480 5774 lb (2619 kg)
Link KSA10460 1 set
Shoe KSA1167 × 48
Bolt KSA1107 × 192
Nut KSA1108 × 192
SST-03-01-013LX 2
2
Upper Component
1. Swing Unit
350X2
Swing motor assembly
Sumitomo part No. KSC10140
Swing motor
Manufacturer Kawasaki Precision Machinery Ltd.
Motor type Fixed displacement piston motor
With parking brake
Intake amount 180.1 cm3/rev
Operating pressure 4409 PSI (30.4 MPa)
Operating flow 76.6 gpm (290 L/min)
Mechanical brake torque 746 lbf•ft (1010.8 N•m min.)
Brake off pressure 450 PSI (3.1 MPa) max.
Relief valve set pressure 4409 PSI (30.4 MPa)
Swing reduction gear
Reduction gear type Planetary gear 2-stage reduction gear
Reduction ratio 27.143
Dry weight 959 lb (435 kg)
Turntable bearing
Sumitomo part No. KSB10070
Number of teeth 92
Weight 1190 lb (540 kg)
Counterweight
Sumitomo part No. KSB12490
3 SST-03-01-013LX
3
Engine-related
1. Engine
350X2
Sumitomo part No. KSH1027
Engine model name Isuzu 6HK1X diesel engine
4-cycle, water cooled, overhead camshaft, vertical in-line, direct injection
Engine type
type (electronic control)
Number of cylinders - bore - stroke 6 - φ4.5 in - 4.9 in (115 mm - 125 mm)
Total displacement 475 cu•in (7.79 L)
Compression ratio 17.5
Rated output 270 HP (202 kW)/2000 min)
Maximum torque 796.5 lbf•ft (1080 N•m) about 1500 rpm
Fuel consumption ratio 234.6（221± 13.6) g/kW•h max.
Engine dry weight About 1410.95 lb (640 kg)
Engine dimension L 53.4 - W 39.1 - H 45.7 in (1357 x 995 x 1162.5 mm)
Oil pan All direction 35º, inclinable
Cooling fan 33.4 in (φ850 mm) - suction type - 6 vanes, plastic
With bell mouth-type fan guide
Pulley ratio 0.80 (reduction)
Charging generator 24 V 50 A AC type
Starter motor 24 V 5 kW reduction type
Coolant capacity 3.8 Gal (14.5 L)
Oil pan capacity Max: 10 gpm (38 L/ min): 7.3 Gal (28 L) (not including oil filter)
Direction of rotation Right (as seen from fan)
Compliant with JISD 0006-2000.
SST-03-01-013LX 4
4
2. Muffler
350X2
Manufacturer Sankei Giken Kogyo Co., Ltd.
Type φ74.7 × 206 Gal (283 × 780 L)
3. Air Cleaner (double element)

350X2
Manufacturer Nippon Donaldson, Ltd.
Element (outer) KSH0933
Element (inner) KSH0932
Weight 29.9 lb (13.6 kg)
4. Radiator
350X2
Manufacturer T.Rad Co., Ltd.
Oil cooler Weight 74.9 lb (34.0 kg)
Oil capacity 4.2 Gal (16.0 L)
Radiator Weight 46.5 lb (21.1 kg)
Coolant capacity 2.4 Gal (9.4 L)
Air cooler Weight 43.8 lb (19.9 kg)
Capacity -
Fuel cooler Weight 2.6 lb (1.2 kg)
Capacity 0.1 Gal (0.44 L)
Total weight 308.6 lb (140 kg)
5 SST-03-01-013LX
5
Hydraulic Device
1. Hydraulic Pump
350X2
Sumitomo part No. KSJ12240
Main pump
Pump type Double variable displacement piston pump
Displacement capacity 150 × 2 cm3/rev
Operating pressure Rated 4974.7 PSI (34.3 MPa)
Maximum 5409 PSI (37.3 MPa)
Input revolution speed 1930 rpm
Maximum discharge flow 76.6 × .5 gpm (290 × 2 L/min) (at 1930 rpm)
Pilot pump
Pump type Gear pump
Displacement capacity 15 cm3/rev
Operating pressure 568.5 PSI (3.92 MPa)
Maximum discharge flow 7.6 gpm (29 L/min) (at 1930 rpm)
Control method Hydraulic simultaneous constant output control
Maximum flow adjustment control through external commands (neg-
ative control)
Setting horsepower adjustment control through external command
milli-amp
Dry weight 414.4 lb (188 kg)
SST-03-01-013LX 6
6
2. Pump P-Q Diagram
7 SST-03-01-013LX
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Control-related
1. Control Valve
350X2
Sumitomo part No. KSJ12250
Manufacturer KYB Corporation
Maximum flow 77.2 gpm (292.5 L/min) (at 1950 rpm)
Overload set pressure 3974 PSI (27.4 MPa) boom down
5685.4 PSI (39.2 MPa) other
Main relief set pressure 4974.7 PSI (34.3 MPa)
(at boosting) 5409.9 PSI (37.3 MPa)
Foot relief set pressure 369.8 PSI (2.55 MPa)
Function Straight travel circuit
Boom-up/arm 2 pumps internal flow
Boom and arm load holding circuit
Bucket-close Regenerative circuit
Swing priority variable orifice (for arm operation)
2 pumps flow
Variable foot relief
Weight 425.4 lb (193 kg)

350X2
Sumitomo part No. KHJ14520
Manufacturer Yuken Kogyo Co., Ltd.
Valve specifications
P → B 6.6 gpm (25 L/min) other 1.3
Maximum flow
gpm (5 L/min)
Rated pressure 652.6 PSI (4.5 MPa)
Port size P, T, B, port G3/8
C1, C2, C3, C4, C5 ports G1/4
Solenoid specifications
Operating voltage 20 - 32 V DC
Power consumption 17 W max.
SST-03-01-013LX 8
8
3. Remote Control Valve (left/right, travel operations)
(1) Valve for left/right operations
350X2
Secondary pressure 92.8 - 355.3 PSI (0.64 - 2.45 MPa) primary short type
Operating angle 1, 3 ports 19°
2, 4 ports 25°
(2) Valve for travel operation

350X2
Sumitomo part No. KRJ5803
Secondary pressure 92.8 - 355.3 PSI (0.64 - 2.45 MPa) primary short type
Operating angle 12.4°
9 SST-03-01-013LX
9
4. Remote Control Valve Characteristic Diagram
(1) Operation remote control valve control diagram
(2) Travel remote control valve control diagram
SST-03-01-013LX 10
10
5. Cushion Valve (heat circuit, with shuttle valve)
350X2
Sumitomo part No. KBJ12430
Manufacturer Yanagisawa Seiki MFG. Co., Ltd.
Port size G3/8 (A - P ports)
G1/4 (R - V ports)
6. Selector Valve (option)

350X2
2-way
Manufacturer Nishina Industrial Co., Ltd.
Rated flow 6.6 gpm (25 L/min)
Operating method I: ISO
S: Sumitomo (old)
Port size G3/8
7. Center Joint
350X2
Operating pressure High-pressure passage (ABCD) 4974 PSI (34.3 MPa)
Drain port (T) 145 PSI (1.0 MPa)
Pilot port (P) 565 PSI (3.9 MPa)
Flow High-pressure passage (ABCD) 95 gpm (360 L/min)
Drain port (T) 11 gpm (40 L/min)
Pilot port (P) 8 gpm (31 L/min)
Port A Forward right G1
Port B Forward left G1
Port C Backward right G1
Port D Backward left G1
Port T Drain port G1/2
Port P Pilot port G1/4
Weight 106.7 kg
11 SST-03-01-013LX
11
Backhoe Attachment
1. Cylinder
Boom cylinder 350X2
Sumitomo part No. KSV1925 (right)
Sumitomo part No. KSV1926 (left)
Manufacturer ZENOAH
Cylinder bore φ5.7 in (145 mm)
Rod diameter φ3.9 in (100 mm)
Maximum retracted length 82.2 in (2090 mm)
Stroke 58.8 in (1495 mm)
Arm cylinder 350X2

Sumitomo part No. KSV1927
Manufacturer ZENOAH
Bucket cylinder 350X2

Sumitomo part No. KSV1928
Manufacturer ZENOAH
SST-03-01-013LX 12
12
2. Attachments
(1) Normal bucket type
● Standard bucket
◎ General digging (specific gravity 2.0 ton/m3 max.)
○ Light digging (specific gravity 1.6 ton/m3 max.)
△ For loading only (specific gravity 1.2 ton/m3 max.)

× Do not use
Bucket capacity (m3) 1.15 STD 1.4 STD 1.4 HD 1.6 STD 1.8 STD
Number of claws 4 5 5 5 5
48.5 (1233) 56.4 (1435) 56 (1424) 62 (1575) 68.2 (1733)
Width in (mm)
43.3 (1100） 51.2 (1302) 51.5 (1310) 56.7 (1442) 62.9 (1600)
Long arm 4.4 yd (4.04 m) × ○ ○ × ×
Standard arm 3.6 yd (3.25 m) ◎ ● ◎ ○ ×
Short arm 2.9 yd (2.63 m) ◎ ◎ ◎ ● ○
Ultra-short arm 2.4 yd (2.21 m) ◎ ◎ ◎ ◎ ●
The figures in ( ) are dimensions excluding the side cutter.
(2) HD bucket type

● Standard bucket
◎ General digging (specific gravity 2.0 ton/m3 max.)
○ Light digging (specific gravity 1.6 ton/m3 max.)
△ For loading only (specific gravity 1.2 ton/m3 max.)

× Do not use
Bucket capacity (m3) 1.4 HD 1.6 HD

Number of claws 5 5
56 (1424) 61 (1564)
Width in. (mm)
51.5 (1310) 57 (1450)
Standard arm 127.9 in (3.25 m) ● ◎
Short arm 103.5 in (2.63 m) ◎ ●
The figures in ( ) are dimensions excluding the side cutter.
13 SST-03-01-013LX
13
NOTES:
Equipment Layout Diagram SH330
Summary Section

Main Equipment Layout
1 Engine 8 Front idler 15 Boom cylinder

2 Radiator 9 Bucket 16 Travel motor
3 Control valve 10 Arm 17 Tool box
4 Boom 11 Hydraulic pump 18 Bucket cylinder
5 Battery 12 Hydraulic oil tank 19 Air Conditioner condenser
6 Air cleaner 13 Fuel tank
7 Swing motor 14 Arm cylinder
14 SST-03-02-008EN
1
Consumable Part Layout
1 Fuel tank 6 Hydraulic oil tank 11 Air conditioner outside air filter
2 Pilot filter 7 Return filter 12 Washer tank
3 Fuel prefilter 8 Tank air breather 13 Battery
4 Engine oil filter 9 Suction filter 14 Reserve tank
5 Fuel filter 10 Air cleaner
SST-03-02-008EN 15
2
Standard Machine Option List SH200
Summary

List of Optional Components
◎ : Standard ● : Option
Models
350X2 Remarks
Spec.
700G shoe ●
800G shoe ◎
850G shoe ●
LC lower ◎
Lower under cover ◎
Center guard (single) -
Center guard (double) ◎
Travel alarm ●
DC-DC converter ◎
Feed pump ● KIT
Rear view mirror (forward right) ◎
Rear view mirror (cab) ◎
Front guard, mesh (lower)
(with cab seating) ● KIT
Front guard, mesh (full)

(with cab seating) ●
OPG Level 1 (with cab seating) ●

OPG Level 2 (with cab seating) ●
Top guard, FOPS Level 2 ●
Head guard, FOPS Level 2 ●
Rain deflector ●
Sunroof polycarbonate ●
Cab top light ●
KAB seat (air suspension) ◎
Air suspension seat ●
Quick change (2-way) ●
Breaker circuit (pedal) ● + Strengthened bucket linkage
Breaker circuit (SW) ● + Strengthened bucket linkage
Shuttle circuit + Strengthened bucket linkage, boom & arm
(thumb line tube, 2 pumps flow) ● with reinforcement
+ Strengthened bucket linkage, boom & arm
Multi-purpose circuit (pedal) ● with reinforcement
Multi-purpose circuit (SW) ● with reinforcement
Multi-purpose + 2nd option (pedal) ● with reinforcement
Semi-E.M.S. ◎
16 SST-03-03-012LX
1
◎ : Standard ● : Option
Models
350X2 Remarks
Spec.
Arm reinforcement plate ● KIT

No bucket ◎
LLC (55 %) ◎
GPS ◎
SST-03-03-012LX 17
2
Hydraulic Equipment Layout SH330
Hydraulics Section

Overall View
1 Left side housing

2 Swing body center section
3 Pump chamber
4 Hydraulic oil tank
5 Fuel tank
1 SST-04-01-011EN
1
Pump Chamber Hydraulic Equipment Layout
1 Hydraulic pump 7 P1 pressure sensor

2 Accumulator 8 Pilot pump
3 Pilot filter 9 N2 sensor
4 5 stack solenoid valve Horsepower control electromagnetic
10
5 N1 sensor proportional valve
6 P2 pressure sensor 11 Hydraulic oil temperature sensor
SST-04-01-011EN 2
2
Swing Body Center Section Hydraulic Equipment Layout
1 Swing motor
2 Center joint
3 Control valve
3 SST-04-01-011EN
3
Housing Left Side Hydraulic Equipment Layout
1 Cushion valve (with heat circuit)

2 Swing pilot pressure sensor
3 4-way selector valve installation seating
4 4-way selector valve
5 Oil cooler
SST-04-01-011EN 4
4
Layout of Hydraulic Equipment in Cab
1 Travel remote control valve

2 Upper operation remote control valve
5 SST-04-01-011EN
5
NOTES:
Port Diagram SH200
Port Diagram
Port Diagram
Pump
1. Hydraulic Pump (standard model)
Port Port name Port size

A1, A2 Discharge port SAE 6000psi 1
B1 Suction port SAE 2500psi 3
Dr Drain port G3/4-23
Proportional valve primary
P1 G1/4-13
pressure port
P2 P2 port G1/4-13
Psv Servo assist port G1/4-15
Pi1, Pi2 Negative control port G1/4-13
a1, a2,
a4, a5, Gauge port G1/4-15
a6
A3 Gear pump discharge port G1/2-19
B3 Gear pump suction port G3/4-20.5
a3 Gauge port G1/4-14
Dr3 Drain port (gear pump) G3/8-15
6 SST-04-06-012EN
1
Port Diagram
Valves
1. Control Valve
(1) Relief valve
Detailed diagram of main relief valve adjustment
1 Boom up
2 Arm in
3 Boom down
4 Bucket close
5 Arm out
6 Bucket open
7 Main a (normal use)
8 Main b (pressure boost)
9 Standard lock nut
10 Pressure boost lock nut
11 Pressure boost adjusting screw
12 Standard pressure adjusting screw
SST-04-06-012EN 7
2
Port Diagram
Port Port size Port name Port Port size Port name
P1 SAE 6000psi 1 Pressure line pb3 G1/4 Left swing pilot line
A1 SAE 5000psi 1 Left travel (forward) line pb4 G1/4 Boom 2-down drain line
B1 SAE 5000psi 1 Left travel (backward) line pb5 G1/4 Arm 1 in pilot line
A2 SAE 5000psi 1 Option line pb7 G1/4 Bucket-close pilot line
B2 SAE 5000psi 1 Option line pb8 G1/4 Boom 1-down pilot line
A3 SAE 5000psi 1 Swing right line pb9 G1/4 Arm 2-in pilot line
B3 SAE 5000psi 1 Swing left line Pn1 G1/4 Negative control power save signal
A5 SAE 5000psi 1 Arm-out line Pn2 G1/4 Negative control power save signal
B5 SAE 5000psi 1 Arm-in line PH G1/4 Pressure boost signal port
T1 Return line Ps1 G1/4 Negative control line
pb1 G1/4 Left travel backward pilot line T8 G1/4 Heat circuit line
pb6 G1/4 Right travel backward pilot line pb2 G1/4 Option line
8 SST-04-06-012EN
3
Port Diagram
Port Port size Port name Port Port size Port name
P2 SAE 6000psi 1 Pressure line pa7 G1/4 Bucket-open pilot line
A6 SAE 5000psi 1 Right travel (forward) line pa3 G1/4 Right swing pilot line
B6 SAE 5000psi 1 Right travel (backward) line pa8 G1/4 Boom 1-up pilot line
A7 SAE 5000psi 1 Bucket-open line pa4 G1/4 Boom 2-up pilot line
B7 SAE 5000psi 1 Bucket-close line pa9 G1/4 Arm 2-out pilot line
A8 SAE 5000psi 1 Boom-up line pa5 G1/4 Arm 1-out pilot line
B8 SAE 5000psi 1 Boom-down line PA G1/4 Upper signal
T2 Return line PT G1/4 Travel signal
pa1 G1/4 Left travel forward pilot line Ps2 G1/4 Negative control line
pa6 G1/4 Right travel forward pilot line Pbu G1/4 Swing priority variable orifice switch signal
DR3 G1/4 Straight travel drain line Pa2 G1/4 Option line
SST-04-06-012EN 9
4
Port Diagram
Port Port size

C2 G1/4
C3 G1/4
C1 G1/4
Port Port size

B G3/8
T G3/8
View from bottom
Port Port size

C5 G1/4
C4 G1/4
P G3/8
1 Power save
2 Lever lock
3 Swing lock
4 Pressure boost
5 Travel high speed
10 SST-04-06-012EN
5
Port Diagram
B port side A port side
Port Port size

A1 G1/4
B1 G1/4
A2 G1/4
B2 G1/4
T G1/4
SST-04-06-012EN 11
6
Port Diagram
4. Remote Control Valves (upper, travel)
(1) Remote control valves (left-right)
Right side Left side
Right side Port name Left side Port name Port size
1 Bucket close 1 Swing right G3/8
2 Boom down 2 Arm in G3/8
3 Bucket open 3 Swing left G3/8
4 Boom up 4 Arm out G3/8
P Pressure P Pressure G1/4
T Return T Return G3/8
(2) Remote control valve (travel)

1 Backward left G1/4
2 Forward left G1/4
3 Backward right G1/4
4 Forward right G1/4
P Pressure G1/4
T Return G1/4
12 SST-04-06-012EN
7
Port Diagram
5. Cushion Valve
1 Arm in
2 Boom up
3 Swing right
4 Bucket close
5 Heat circuit line
6 Arm out
7 Boom down
8 Swing left
9 Bucket open
10 Pressure sensor (swing)
11 Swing priority switching pilot line
12 Drain line

E, F Boom up G3/8
G, H Boom down G3/8
O, P Bucket open G3/8
M, N Bucket close G3/8
C, D Arm out G3/8
A, B Arm in G3/8
K, L Swing left G3/8
I, J Swing right G3/8
Q Swing pressure sensor signal G1/4
U - G1/4
S Swing priority orifice switch G1/4
V - G1/4
T Return G1/4
R Heat circuit G1/4
SST-04-06-012EN 13
8
Port Diagram
Port Port name *ISO type Port size

A Right remote control valve side port/boom up G1/4
C Right remote control valve side port/boom down G1/4
D Right remote control valve side port/bucket open G1/4
B Right remote control valve side port/bucket close G1/4
E Left remote control valve side port/arm out G1/4
G Left remote control valve side port/arm in G1/4
H Left remote control valve side port/swing left G1/4
F Left remote control valve side port/swing right G1/4
1 Cushion valve side port G1/4
14 SST-04-06-012EN
9
Port Diagram
Remote control valve side Cushion valve side
Port Port name *ISO type Port size

A Remote control valve side/swing-left port G3/8
B Remote control valve side/arm-in port G3/8
C Remote control valve side/swing-right port G3/8
D Remote control valve side/arm-out port G3/8
SST-04-06-012EN 15
10
Port Diagram
8. Direction Valve/Shut-off Valve
(1) Direction valve
Port Port size

A G1
B G1
T1 G1
T2 G3/4
PP G1/4
(2) Shut-off valve DR G1/4
Port Port size

A G1
B G1
T G3/4
PP G1/4
DR G1/4
16 SST-04-06-012EN
11
Port Diagram
9. HBCV (Option)
B port opening side
Port Port size Remarks

SAE 6000psi 1 Arm HBCV
A
SAE J6000psi 1 Boom HBCV
SAE 6000psi 1 Arm HBCV
B
SAE J6000psi 1 Boom HBCV
C G1/4
DR G3/8
PL G1/4
SST-04-06-012EN 17
12
Port Diagram
Manifolds
1. Manifold Under Cab
Port Port size
P1 G3/8
P2 G3/8
P3 G3/8
P4 G1/4
P5 G1/4
T1 G3/8
T2 G3/8
T3 G3/8
T4 G1/4
T5 G1/4
2. Manifold (accumulator section)
Port Port size

P G1/2
P1 G1/4
P2 G1/4
P3 G1/2
P0 G3/8
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13
Port Diagram
3. Manifold (hydraulic oil tank section)
Port Port size

D1 G3/8
D2 G1/4
D3 G1/4
D6 G1/4
T G1/2
T1 G3/8
D7 G3/8
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14
Port Diagram
Motors
1. Swing Motor

M Make up G1
DB Drain G1/2
PG Brake release G1/4
A Right swing -
B Left swing -
PA, PB Pressure measurement G1/4
Dr Gear oil drain port PT3/8
SGr Grease-up port PT1/8
20 SST-04-06-012EN
15
Port Diagram
2. Travel Motor

D1, D2 Drain port G1/2
P Pilot port G1/4
MA, MB Pressure detection port G1/4
VA, VB Main port G1
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16
Port Diagram
3. Center Joint

A' Forward right (connected to travel motor) G1
B' Forward left (connected to travel motor) G1
C' Backward right (connected to travel motor) G1
D' Backward left (connected to travel motor) G1
P' Pilot port (connected to travel motor) G1/4
T Drain port G1/2
A Forward right (connected to control valve) 500psi 1
B Forward left (connected to control valve) 500psi 1
C Backward right (connected to control valve) 500psi 1
D Backward left (connected to control valve) 500psi 1
P Pilot port (connected to control valve) G1/4
22 SST-04-06-012EN
17
Pilot Hose Connection Diagram SH700
Hydraulics Section

Pilot P and T Lines
SST-04-07-013EN 23
1
a Travel line Code Part name Q'ty

b Platform (left) ASSY hose
1 1
c Swing frame (abrasion-proof rubber hose)
d Center Joint 2 ASSY hose (flexible nylon hose) 1
e Swing frame 3 ASSY hose (Nylon hose) 1
f Hydraulic Pump 4 ASSY hose (Nylon hose) 1
g House frame 5 Hydraulic hose 1
h Cushion Valve 6 ASSY hose (Nylon hose) 1
i Platform (left) 7 Hydraulic hose 1
j Sump tank 8 Nylon hose 1
k Control Valve 9 Nylon hose 1
l Indicator line 10 Nylon hose 1
m Control line
n Pressure line bracket
24 SST-04-07-013EN
2
Pilot Control Line
SST-04-07-013EN 25
3
Code Part name Q'ty

1 ASSY hose (rubber hose) 1
3 ASSY hose (Nylon hose) 1
4 ASSY hose (flexible nylon hose) 1
5 Nylon hose 1
a Floor 6 Nylon hose 1
b Platform (left) 7 ASSY hose (Nylon hose) 1
c Control Valve 8 Hydraulic hose 1
d Adapter hose (pilot P&T) 9 Line filter G1/4 (OR) x G1/4 1
e Pressure sensor Q 10 ASSY hose (flexible nylon hose) 1
f Pressure sensor PA,PT 11 ASSY hose (flexible nylon hose) 1
26 SST-04-07-013EN
4
SST-04-07-013EN 27
5
Code Part name Q'ty

4 ASSY hose (flexible nylon hose) 1
5 Nylon hose 1
6 Nylon hose 1
7 ASSY hose (nylon hose) 1
a Floor 8 Hydraulic hose 1
b Platform (left) 9 ASSY tube (flare) 1
c Control Valve 10 ASSY tube (flare) 1
d Adapter hose (pilot P&T) 11 ASSY tube (flare) 1
e Pressure sensor Q 12 ASSY tube (flare) 1
f Pressure sensor PA,PT 13 Line filter G1/4 (OR) x G1/4 1
28 SST-04-07-013EN
6
SST-04-07-013EN 29
7
Code Part name Q'ty

4 ASSY hose (flexibleNylon hose) 1
5 Nylon hose 1
6 Nylon hose 1
8 Hydraulic hose 1
9 ASSY tube (flare) 1
a Floor 15 ASSY tube (flare) 1
b Platform (left) 16 ASSY tube (flare) 2
c Control Valve 17 ASSY tube (flare) 1
d Hose adapter (pilot P&T) 18 Line finter G1/4 (OR) x G1/4 1
e Pressure sensor PA,PT 19 ASSY tube (flare) 1
f Pressure sensor Q 20 ASSY tube (flare) 1
30 SST-04-07-013EN
8
NOTES:
Function List SH330
Hydraulics Section
Function List
Function Table
◎ : New function △ : Changed function
Operation
Operation Explanation of functions
explanation
Travel circuit
Low-speed circuit Sets the travel motor 2-stage tilting angle to a large angle to set low speed. page 40
Sets the travel motor 2-stage tilting angle to a small angle to set high speed.
The speed is automatically switched to low speed according to the load pressure
High-speed circuit on the travel motor. page 42
In order to prevent hunting at high speed, if the travel pressure becomes 3741.9
PSI (25.8 MPa) or higher, the speed is set to low speed.
Straight travel
When there is an attachment or swing operation during traveling, travel is held
circuit page 44
straight without curving.
(△)
Swing circuit
In order to increase the cylinder bore and attachment speed, the pump maxi-
Swing speed limit
mum flow was increased, but in order to not increase the swing speed, when
control circuit page 46
swing is operated alone, the pump flow is restricted with the proportional valve
(◎)
installed on the swing pump (front side).
For swing single operation, if swing is started with a sharp lever operation, the
pump flow is reduced with the proportional valve installed on the swing pump
Swing relief
(front side).
cut-off control
Normally, this control eliminates the excess oil discharged from the swing relief page 48
circuit
valve and reduces the horsepower consumption.
(◎)
When the swing speed rises, the pump discharge pressure falls, so the pump
flow is increased gradually while it is detected with the sensor.
1. Swing pushing is obtained by the swing priority variable orifice built into the
Swing priority control valve.
page 50
circuit 2. The swing priority variable orifice also works to secure the arm flow for bed
metering.
Swing brake Suctions in the oil from the make-up line in order to prevent cavitation when
page 52
circuit swing stops.
1. When the swing lever is in neutral, swing parking works and is held at 100%.
2. When there is a swing lever or attachment operation, swing parking is
Swing parking released.
circuit 3. Swing parking works about 5 sec. after the swing lever is put into neutral. page 54
(△) 4. When an attachment operation is stopped, if there is no swing operation, the
swing parking circuit works about 1 sec. later.
5. When the engine is stopped, swing parking works.
Vibration The reversal prevention valve attached to the swing motor reduces backlashes
backlash -
that occur when the swing stops.
Boom circuit
1. Single
The flow is merged internally by switching the boom (1) and (2) spool to raise
the speed.
Boom-up circuit page 60
2. Compound
The swing priority variable orifice spool is switched to make movement in
arm-in compound operation smooth.
Boom-down Regeneration within the boom (1) spool is used to increase speed and prevent
page 64
regenerative circuit cavitation.
31 SST-04-03-008EN
1
Function List
◎ : New function △ : Changed function
Operation
Operation Explanation of functions
explanation
Boom-down tilting
High pressure is suppressed with the bleed-off circuit and tilting is mitigated. page 66
prevention circuit
1. By releasing the load hold valve built into the control valve, boom speed
Boom-down load becomes faster.
page 68
hold valve circuit 2. Boom-down pilot pressure enables boom-down operation by releasing the
load holding valve.
Arm circuit
The flow is merged internally by switching the arm (1) and (2) spool to raise the
Arm-out circuit page 70
speed.
Arm-in forced The speed for compound operation is raised by the forced regeneration release
page 72
regenerative circuit valve in the control valve.
1. Load holding valve integrated in the control valve reduces natural drop on the
Arm-in load hold arm-in side.
page 74
valve circuit 2. Arm-in pilot pressure enables arm-in operation by releasing the load holding
valve.
Bucket circuit
Bucket-close
regenerative Regeneration within the bucket spool is used to increase speed and prevent cav-
circuit page 78
itation.
(◎)
Negative control circuit
Negative control In the non-operation state, this circuit switches the negative control relief valve
power save circuit set pressure to reduce the pump discharge force and further reduce horsepower page 80
(◎) consumption.
Negative control For no-load operation, this circuit sets the hydraulic pump discharge volume to
page 82
circuit minimum to reduce horsepower consumption.
Others
Softens the shock through the work of the cushion valve with heat circuit.
Cushion circuit This circuit is attached to the boom and arm pilot lines. There is no soft / hard page 86
switch. (Inline is disused by the tuning）
Auto pressure Boosts the main relief pressure from 4974.7 - 5337.3 PSI (34.3 - 36.8 MPa)
page 94
boost circuit according to the engine load ratio and circuit pressure.
Option circuits
The main control valve has an option section as standard so that it can support a
Breaker circuit page 96
breaker, crusher or other special attachment.
Option flow
It is possible to set the flow for the breaker, crusher, or other special attachment
adjustment -
application by just operating a switch in the cab. Maximum of 5 applications.
(◎)
Multi purpose
It is possible to switch the circuit between the breaker and the crusher by just
circuit switch -
operating a switch in the cab.
(◎)
2nd option circuit Option valve can be added to the top section of the control valve and a 2nd
-
(◎) option line can be installed easily.
SST-04-03-008EN 32
2
Function List
1. Swing Relief Cut-off Control
[1] Model 3B circuit
• When a swing starts, almost all the oil is discharged from the swing relief valve.
1 Foot relief valve

2 Negative control signal
33 SST-04-03-008EN
3
Function List
[2] Model 5 circuit
• When a swing starts, the flow is reduced with the front side proportional valve and the excess oil
is eliminated.
1 Foot relief valve

SST-04-03-008EN 34
4
Function List
2. Swing Speed Limit Control
• The maximum pump flow has been increased, but because it is desired to maintain the current
state of the swing speed, the front side proportional valve is used to hold down the flow for swing
single operation.

2 Foot relief valve
3 Negative control orifice
4 Swing motor
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5
Function List
3. Negative Control Power Save Control
[1] Model 3B negative control circuit
• Control such that the discharge flow decreases as the negative control pressure increases.
1 Foot relief valve 3 Negative control pressure

2 Negative control orifice 4 Servo assist pressure
[2] Model 5 negative control circuit

This circuit uses the power save function.
• The negative control relief was made variable to lower the negative control pressure.
SST-04-03-008EN 36
6
Function List
4. Option Line Flow Adjustment Control
• This control adjusts the set flow to match the breaker, crusher, or other application.
1 Negative control signal 2 Foot relief valve 3 Negative control orifice
37 SST-04-03-008EN
7
Function List
5. Multi Purpose Circuit (breaker ⇔ crusher) One-touch Switching Control

• This control makes it easy to switch the circuit with a rocker switch in the cab.
1 Option line select switch 5 Pilot switchover

2 3 positions 6 Crusher
3 Computer A 7 Breaker
4 3-direction valve 8 Option line switchover solenoid
SST-04-03-008EN 38
8
Function List
6. Bucket-close Regenerative Circuit
This circuit speeds up bucket closing.
Bucket-close regenerative circuit used.
1 Bucket cylinder
3 Hydraulic pump
39 SST-04-03-008EN
9
Explanation of Hydraulic Circuit and Operations (standard model) SH330
Hydraulic

Travel Circuit
Travel low-speed circuit
As an example, this section explains the forward travel operation.
The travel motor 2-stage tilting angle is a large angle side.Even if the travel switchover is set to the
high-speed side, switching the key switch OFF and then ON again always returns the system to this
state.
By operating the travel remote control valve to the forward side, the pilot pressure oil is fed to the
control valve pa1 port and switches the left travel spool to the forward side.
At the same time, the oil is also fed to the pa6 port to switch the right travel spool to the forward side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and the discharge oil from
hydraulic pump A2 enters the control valve P2 port. Each flows to the respective travel motor and
causes forward travel through the left and right travel spools being switched.
The return oil from the travel motor goes through the left and right travel spools and returns to the
hydraulic oil tank.
The travel high-speed solenoid valve goes OFF, the travel motor P port oil connects with the tank
line, and the travel motor tilting angle moves to the large tilting side.
Pressure line
Tank line
Pilot pressure line
Pilot tank line
Electric line
1 Travel motor 10 Console lever lock switch

2 Travel high-speed select switch 11 Hydraulic pump
3 Computer A 12 Travel remote control valve
4 Control valve 13 Check valve
5 Travel (left) 14 Oil cooler
6 Travel (right) 15 Backward left
7 Travel high speed 16 Forward left
8 Lever lock 17 Backward right
9 5 stack solenoid valve 18 Forward right
SST-04-04-010EN 40
1
41 SST-04-04-010EN
2
Travel Circuit
Travel high-speed circuit
As an example, this section explains the forward travel operation.
Sets the travel motor 2-stage tilting angle to a small angle to set high speed. The travel motor has an
automatic switchover function that switches the speed to low speed according to the load pressure
on the travel motor only during high-speed travel conditions.
At the same time, the oil is also fed to the pa6 port to switch the right travel spool to the forward side.
The return oil from the travel motor goes through the left and right travel spools and returns to the
hydraulic oil tank.
Electrical signals are sent to the computer A by operation of the travel high-speed select switch and
the computer A sends electrical signals to the travel high-speed solenoid valve. Due to the switching
of the travel high-speed solenoid valve, the pilot pressure 565.6 PSI (3.9 MPa) from the C1 port
enters the left and right travel motor P ports through the center joint and sets the travel motor tilting
angle to a small angle to raise the speed.
Pressure line
Tank line
Pilot pressure line
Pilot tank line
Electric line
1 Travel motor 10 Console lever lock switch

2 Travel high-speed select switch 11 Hydraulic pump
3 Computer A 12 Travel remote control valve
5 Travel (left) 14 Oil cooler
6 Travel (right) 15 Backward left
7 Travel high speed 16 Forward left
8 Lever lock 17 Backward right
9 5 stack solenoid valve 18 Forward right
SST-04-04-010EN 42
3
43 SST-04-04-010EN
4
Travel Circuit
Straight travel circuit
As an example, this section explains simultaneous forward travel and boom-up operations.
In the same way, oil is also fed to the pa6 port to switch the right travel spool to the forward side.
Furthermore, the right forward travel pilot pressure oil separated internally from the control valve
pa6 port switches the straight travel signal (right). On the other hand, the travel pilot pressure oil
separated internally from the pa1 port switches the straight travel signal (left) via the straight travel
signal (right).
If a boom-up operation is carried out during travel, the pilot pressure oil is fed via the cushion valve
to the control valve pa4 port and switches the boom (1) and (2) spools to the up side.
The upper (boom, arm, bucket, swing, option) pilot pressure oil separated internally from the control
valve pa4 port is fed to the straight travel valve via the straight travel signal (left) and the straight
travel spool is switched.
The amount of switching of the straight travel spool varies with the upper pilot pressure.
(Because the pilot pressure is low for slight upper operation, the amount of switching of the straight
travel spool is slight to prevent sharp reduction in the travel speed.)
Through the straight travel valve being switched, it is possible for the control valve P1 pressurized oil
to drive the left and right travel motors and for the control valve P2 pressurized oil to drive the boom.
Because the left and right motors are driven by 1 pump, the left and right motors have the same
pressure and straight travel is possible. Furthermore, the P2 excess pressurized oil is fed to the
travel side via the check valve with travel merge orifice to minimize the drop in speed.
The same operations are carried out when travel and an upper actuator other than for the boom are
operated simultaneously.
Pressure line
Tank line
Pilot pressure line
Pilot tank line
Electric line
1 Travel motor 10 Straight travel signal (left) 19 Boom cylinder

2 Boom (up) 11 Straight travel signal (right) 20 Travel remote control valve
3 Boom (down) 12 Travel high-speed select switch 21 Check valve
4 Cushion valve 13 Computer A 22 Oil cooler
5 Remote control valve (boom, bucket) 14 Travel high speed 23 Backward left
6 Control valve 15 Lever lock 24 Forward left
7 Travel (left) 16 5 stack solenoid valve 25 Forward right
8 Travel (right) 17 Console lever lock switch 26 Backward right
9 Straight travel valve 18 Hydraulic pump
SST-04-04-010EN 44
5
45 SST-04-04-010EN
6
Swing Circuit
Swing speed limit control circuit
This control is for suppressing increases in the swing speed accompanying increased pump flow.
(Only in SP mode)
For independent swing operation, due to the swing pilot pressure sensor and P1 pressure sensor
input electric signal, the computer A outputs a signal to the P1 flow control proportional valve.
The discharge oil from the hydraulic pump A3 is fed to the P1 flow control proportional valve.
The hydraulic pump A1 side discharge flow is reduced to 73.9 gpm (280 L/min) by the signal output
from the computer A to the P1 flow control proportional valve.
[1] Conditions under which the swing speed limit control is entered
• Independent full-lever swing operation
• Travel non-operation
• Work mode SP
[2] Conditions under which the swing speed limit control is ended
• Upper operation other than boom down
→ Gradual end (to reduce shock)
• Travel operation
→ Immediate end (to avoid off travel)
• Option operation
Pressure line
Tank line
Pilot pressure line
Pilot tank line
Electric line
1 Swing motor 13 Swing brake

2 Swing 14 5 stack solenoid valve
3 Cushion valve 15 Console lever lock switch
4 Right swing 16 N1 negative control pressure sensor
5 Left swing 17 P1 pressure sensor
6 Swing pilot pressure sensor 18 P1 flow control proportional valve
7 Remote control valve (arm, swing) 19 Hydraulic pump
8 Control valve 20 Horsepower control proportional valve
9 Travel pilot pressure sensor 21 P2 pressure sensor
10 Upper pilot pressure sensor 22 Check valve
11 Computer A 23 Oil cooler
12 Lever lock
SST-04-04-010EN 46
7
47 SST-04-04-010EN
8
Swing Circuit
Swing relief cut-off control circuit
This control aims for an energy-saving effect by controlling the pump in such a way as to minimize
the excess oil drained from the swing motor relief valve for the starting pressure boost for a indepen-
dent sharp swing operation.
When a swing operation starts, due to the swing pilot pressure sensor and P1 pressure sensor input
electrical signals, computer A outputs a signal to the hydraulic pump P1 flow control proportional
valve.
The discharge oil from the hydraulic pump A3 is fed to the P1 flow control proportional valve.
The output signal from computer A to the P1 flow control proportional valve controls the pilot pres-
sure to reduce the hydraulic pump A1 side discharge flow. Also, the input signal from hydraulic
pump P1 pressure sensor controls the pilot pressure to gradually increase the discharge flow.
[1] Swing relief cut-off control is executed when all the conditions below are satisfied.
• Travel non-operation
• Sharp independent swing operation or swing + boom-down operation
[2] Swing relief cut-off control ends when a condition below is satisfied.
• When swing operation is stopped
• Travel, boom-up, arm-out/in, or bucket-open/close operation
Pressure line
Tank line
Pilot pressure line
Pilot tank line
Electric line
1 Swing motor 13 Swing brake

2 Swing 14 5 stack solenoid valve
3 Cushion valve 15 Console lever lock switch
4 Right swing 16 N1 negative control pressure sensor
5 Left swing 17 P1 pressure sensor
6 Swing pilot pressure sensor 18 P1 flow control proportional valve
8 Control valve 20 Horsepower control proportional valve
10 Upper pilot pressure sensor 22 Check valve
11 Computer A 23 Oil cooler
12 Lever lock
SST-04-04-010EN 48
9
49 SST-04-04-010EN
10
Swing Circuit
Swing priority circuit
The swing pilot pressure is fed to the Pc3' port via the shuttle valve and holds the swing priority vari-
able orifice to the right side. By metering the parallel circuit, for arm and swing simultaneous opera-
tion, the swing pressure is boosted to secure the swing force for pressing digging.
As an example, this section explains the right-swing and arm-in operation.
By moving the remote control valve to the right swing side, the pilot pressure oil is fed via the shuttle
valve to the control valve pa3 port and switches the spool to the right swing side.
At this time, by moving the remote control valve to the arm-in side, the pilot pressure oil is fed via the
cushion valve to the control valve pb5 port and switches the spool to the arm-in side.
At the same time, the pilot pressure oil from the shuttle valve S port is fed to the control valve Pc3'
port to move the swing priority variable orifice to the right side and hold it.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the paral-
lel oil path to the swing spool. Switching the spool lets the oil flow into the swing motor B port and
the right swing operation is carried out.
The discharge oil from hydraulic pump A2 enters the control valve P2 port, is fed from the parallel oil
path to the arm (2) spool and merges upstream of the arm (1) spool. Switching the spool lets the oil
flow into the arm cylinder bottom and the arm-in operation is carried out.
When the right swing and arm-in operations are carried out at the same time, the swing priority vari-
able orifice on the control valve P1 port parallel oil path moves and narrows, so the pressure is
boosted to secure the swing force for pressing digging.
Pressure line
Tank line
Pilot pressure line
Pilot tank line
Electric line
1 Swing motor 15 Arm cylinder

2 Arm (in) 16 Arm (1)
3 Arm (out) 17 Swing
4 Right swing 18 Arm load holding valve spool
5 Left swing 19 Arm load holding valve check valve
6 Cushion valve 20 Regeneration release valve
7 Swing pilot pressure sensor 21 Control valve
8 Shuttle valve 22 Swing priority variable orifice
9 Computer A 23 Arm (2)
10 Remote control valve (arm, swing) 24 Upper pilot pressure sensor
11 Lever lock 25 Hydraulic pump
12 Swing brake 26 Check valve
13 5 stack solenoid valve 27 Oil cooler
14 Console lever lock switch
SST-04-04-010EN 50
11
51 SST-04-04-010EN
12
Swing Circuit
Swing brake circuit
As an example, this section explains the brake circuit operation after the end of a right swing opera-
tion.
When the remote control valve is returned to neutral from a right swing operation, the pilot pressure
oil is cut off and the control valve swing spool returns to neutral.
The pressurized oil fed to the swing motor A port from the control valve A3 port is cut. At the same
time, the destination location is eliminated for the pressurized oil flowing from the swing motor B port
to the control valve B3 port, so the pressure rises to the swing motor relief valve set pressure. The
pressure generated here becomes a brake force and stops the motor.
When the swing is stopped, the swing motor continues to rotate for a while due to inertial force.In
order to make up the shortfall in the oil volume, oil is supplied from the make-up line connected to
the swing motor M port from the control valve T3 port to open the make-up check valve and oil is
suctioned in to prevent cavitation.
Pressure line
Tank line
Pilot pressure line
Pilot tank line
Electric line
1 Swing motor 9 Lever lock

2 Cushion valve 10 Swing brake
3 Right swing 11 5 stack solenoid valve
4 Left swing 12 Console lever lock switch
5 Swing pilot pressure sensor 13 Computer A
6 Remote control valve (arm, swing) 14 Control valve
7 Hydraulic pump 15 Oil cooler
8 Check valve 16 Upper pilot pressure sensor
SST-04-04-010EN 52
13
53 SST-04-04-010EN
14
Swing Circuit
Swing parking circuit (lever in neutral)
When the key is switched ON, the swing brake solenoid valve is switched by the electrical signal
from computer A.
The swing motor PR port oil goes from the 5 stack solenoid valve C2 port through the swing brake
solenoid, and returns to the hydraulic oil tank to hold the swing parking brake.
Pressure line
Tank line
Pilot pressure line
Pilot tank line
Electric line

8 Oil cooler 16 Hydraulic pump
SST-04-04-010EN 54
15
55 SST-04-04-010EN
16
Swing Circuit
Swing parking circuit (brake release)
When the engine is started and the swing lever is in neutral, the swing brake solenoid valve comes
ON (24 V input), the pressure to the swing motor PR port is cut, and the swing parking brake works.
When the lever operation raises the reading to 72.5 PSI (0.5 MPa) or higher at the pressure sensor in
the swing pilot line, the output from computer A to the swing brake solenoid valve goes OFF, the
swing motor PR port pressure rises, the swing parking brake is released, and swing becomes possi-
ble.
As an example, this section explains the right swing operation.
By carrying out the right swing operation on the remote control valve, the pilot pressure oil is fed to
the control valve pa3 port via the shuttle valve and switches the swing spool to the right swing side.
At the same time, computer A detects the swing pilot pressure sensor signal, judges that there is a
swing operation, the electrical signal output from computer A goes OFF, and the swing brake sole-
noid valve is switched.The pilot pressure oil is fed to the swing motor PR port from the swing brake
solenoid valve C2 port to release the swing parking brake.
lel oil path to the swing spool. Switching the spool lets the oil flow into the swing motor A port and
the right swing operation is carried out.
The pressurized oil from the swing motor B port goes through the swing spool and returns to the
hydraulic oil tank.
When this is followed by an attachment operation, the pilot pressure is detected by the control valve
PA port pressure sensor and the swing parking brake continues to be released.
After the swing operation ends, if about 5 sec. pass with no upper operation, the swing brake sole-
noid valve output from computer A comes ON and the swing parking brake works again.
After the swing ends, if this is followed by an upper operation or there is an upper operation within
about 5 sec., when about 1 sec. passes after the end of the upper operation, the swing parking
brake works again.
The swing parking brake is also released for independent upper operations and when about 1 sec.
passes after the end of the upper operation, the swing parking brake works again.
Swing pilot pressure Upper pilot pressure Swing brake Swing motor
Key switch
sensor sensor solenoid valve mechanical brake
OFF 0 PSI (0 MPa) 0 PSI (0 MPa) OFF ON
ON 0 PSI (0 MPa) 0 PSI (0 MPa) ON ON
ON 72.5 PSI (0.5 MPa) min 0 PSI (0 MPa) OFF OFF
ON 0 PSI (0 MPa) 72.5 PSI (0.5 MPa) min OFF OFF
ON 72.5 PSI (0.5 MPa) min 72.5 PSI (0.5 MPa) min OFF OFF
Pilot pressure sensor judgment standard
Operation is judged when at 72.5 PSI (0.5 MPa) or above.
Non-operation is judged when at 43.5 PSI (0.3 MPa) or below.
Pressure line 1 Swing motor 10 5 stack solenoid valve

Tank line 2 Cushion valve 11 Console lever lock switch
Pilot pressure line 3 Right swing 12 Computer A
Pilot tank line 4 Left swing 13 Control valve
Electric line 5 Swing pilot pressure sensor 14 Upper pilot pressure sensor
7 Swing 16 Check valve
8 Lever lock 17 Oil cooler
9 Swing brake
SST-04-04-010EN 56
17
57 SST-04-04-010EN
18
Swing Circuit
Swing parking circuit (machine stop)
When the machine is stopped (the key is switched OFF), the swing motor PR port oil goes from the
swing brake solenoid C2 port through the lever lock solenoid and returns to the hydraulic oil tank,
holding the swing parking brake hold status.
Pressure line
Tank line
Pilot pressure line
Pilot tank line
Electric line

SST-04-04-010EN 58
19
59 SST-04-04-010EN
20
Boom Circuit
Boom-up circuit (independent operation)
By operating the remote control valve to the boom-up side, the pilot pressure oil is fed via the cush-
ion valve to the control valve pa4 port and the boom (2) spool is switched. At the same time, the pilot
pressure oil from the pa4 port separated in the internal path is fed to the boom (1) pilot port and
switches the boom (1) spool to the up side.
path to the boom (2) spool and merges downstream of the boom (1) spool. The discharge oil from
hydraulic pump A2 is fed to the boom (1) spool via the parallel oil path, merges with the discharge oil
from boom (2), flows through the boom load holding valve check valve and into the boom cylinder
bottom side and the boom-up operation is carried out.
The boom cylinder rod side return oil goes through the boom (1) spool and returns into the hydraulic
oil tank.
Pressure line
Tank line
Pilot pressure line
Pilot tank line
Electric line
1 Cushion valve 12 Boom cylinder

2 Boom (up) 13 Travel pilot pressure sensor
3 Boom (down) 14 Upper pilot pressure sensor
4 Boom (2) 15 Console lever lock switch
5 Remote control valve (boom, bucket) 16 Monitor display
6 Lever lock 17 Computer A
7 Boost pressure relief 18 P1 pressure sensor
8 5 stack solenoid valve 19 P2 pressure sensor
9 Control valve 20 Hydraulic pump
10 Boom load holding valve check valve 21 Check valve
11 Boom (1) 22 Oil cooler
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Boom Circuit
Boom-up circuit (compound boom-up + arm-in)
As an example, this section explains the boom-up + arm-in compound operation (leveling work).
For leveling work, the boom-up pilot pressure oil is fed to the pbu port, the swing priority variable ori-
fice is moved to the left side and the restriction on the flow to the arm is released to smooth the arm
movement.
By operating the remote control valve to the boom-up side and arm-in side, the pilot pressure oil is
fed via the cushion valve to the control valve pa4 port and pb5 port and switches the boom (1) and
arm (1) spools. At the same time, pressurized oil separated from the boom (1) side pilot internal
path is fed from the pa8 port to the pbu port and the swing priority variable orifice spool is switched
to the left side.
lel oil path to the boom (2) and arm (1) spools. Because the swing priority variable orifice spool in
the parallel oil path is moved, the restriction on flow to the arm is released and the oil flows through
the arm (1) spool and into the arm cylinder bottom side. This makes arm-in operation movement
smooth.
The arm cylinder rod side return oil goes through the load holding valve check valve and the arm (1)
spool and returns to the hydraulic oil tank.
lel oil path to the boom (1) spool. Switching the spool lets the oil flow through the boom load holding
valve check valve and into the boom cylinder bottom side and the boom-up operation is carried out.
When the circuit has an HBCV, the discharge oil from hydraulic pump A2 enters the control valve P2
port and is fed from the parallel oil path to the boom (1) spool.
Switching the spool lets the oil flow through the boom load holding valve check valve and HBCV
check valve and into the boom cylinder bottom side and the boom-up operation is carried out.
The boom cylinder rod side return oil goes through the boom (1) spool and returns to the hydraulic
oil tank.
Pressure line
Tank line
Pilot pressure line
Pilot tank line
Electric line
1 Arm cylinder 12 Arm (1) 23 Travel pilot pressure sensor

2 Arm (in) 13 Boom (2) 24 Upper pilot pressure sensor
3 Arm (out) 14 Arm load holding valve spool 25 Console lever lock switch
4 Boom (up) 15 Load holding valve check valve 26 Monitor display
5 Boom (down) 16 Regeneration release valve 27 Computer A
6 Cushion valve 17 Control valve 28 P1 pressure sensor
7 Remote control valve (boom, bucket) 18 Swing priority variable orifice 29 P2 pressure sensor
8 Remote control valve (arm, swing) 19 Arm (2) 30 Hydraulic pump
9 Lever lock 20 Boom load holding valve check valve 31 Check valve
10 Boost pressure relief 21 Boom (1) 32 Oil cooler
11 5 stack solenoid valve 22 Boom cylinder
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Boom Circuit
By moving the remote control valve to the boom-down side, the pilot pressure oil is fed via the cush-
ion valve to the control valve pb8 port and switches the boom (1) spool to the down side.
lel oil path to the boom (1) spool. Switching the spool lets the oil flow into the boom cylinder rod side
and the boom-down operation is carried out.
The pilot pressure oil from the pb8 port separated in the internal path is fed to the load holding valve
spool and moves the spool to the left. In this way, the load holding valve check valve spring chamber
oil is connected to the tank line through the load holding valve spool, the spring chamber pressure
drops, and the load holding valve check valve is opened.
When the circuit has an HBCV, the pilot pressure oil separated in the internal path operates on the
HBCV PL port and switches the spool. This opens the HBCV check valve. The boom cylinder bot-
tom side pressurized oil goes through the load holding valve check valve (passes through the HBCV
check valve and goes through the load holding valve check valve when the circuit has an HBCV)
and is metered by the boom (1) spool regeneration orifice. Through this, the return oil pushes open
the check valve in the spool and is regenerated on the cylinder rod side. The lower the cylinder rod
side load pressure, the greater the volume of regeneration. When the cylinder rod side load pres-
sure becomes high, the check valve is closed and the cylinder bottom return oil goes through the
boom spool (1) without regeneration and returns to the hydraulic oil tank.
Because the circuit is configured in such a way that, even if the boom (1) spool is at full stroke, neg-
ative control pressure is generated by the center bypass bleed-off oil path and the pump does not
discharge full flow, the shortfall is made up for with regeneration and engine output can be used
effectively.
Pressure line
Tank line
Pilot pressure line
Pilot tank line
Electric line
1 Load holding valve check valve 9 Boom (down) 17 Boom cylinder

2 Check valve 10 Remote control valve (boom, bucket) 18 Boom (1)
3 Oil cooler 11 Lever lock 19 Travel pilot pressure sensor
4 P1 pressure sensor 12 Boost pressure relief 20 Upper pilot pressure sensor
5 Orifice 13 5 stack solenoid valve 21 Console lever lock switch
6 Bleed-off 14 Control valve 22 Monitor display
7 Cushion valve 15 P2 pressure sensor 23 Computer A
8 Boom (up) 16 Hydraulic pump
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Boom Circuit
Boom-down tilting prevention circuit
By operating the remote control valve all the way to the boom-down side at once, even if the boom
spool goes its full stroke, negative control pressure is generated by the center bypass bleed-off oil
path and the circuit is such that the hydraulic pump does not discharge full flow, so the generation of
high pressure is restrained and main unit tilt is reduced. Since the shortfall in the oil volume is com-
pensated by the regenerative circuit, the engine output can be used effectively.
Pressure line
Tank line
Pilot pressure line
Pilot tank line
Electric line
1 Load holding valve check valve 12 Control valve

2 Check valve 13 P2 pressure sensor
4 Bleed-off 15 Boom cylinder
5 Cushion valve 16 Boom (1)
8 Remote control valve (boom, bucket) 19 Console lever lock switch
9 Lever lock 20 Monitor display
10 Boost pressure relief 21 Computer A
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Boom Circuit
Boom-down load holding valve circuit
When the remote control valve boom operation lever is in neutral, the oil at the boom cylinder bot-
tom side is sealed by the load holding valve check valve, reducing internal leakage from the main
spool and reducing the natural drop of the boom.
By moving the remote control valve to the boom-down side, the pilot pressure oil is fed via the cush-
ion valve to the control valve pb8 port and switches the boom spool to the down side.
lel oil path to the boom (1). Switching the spool lets the oil flow into the boom cylinder bottom side
and the boom-down operation is carried out.
spool and moves the spool to the left. In this way, the load holding valve check valve spring chamber
oil is connected to the tank line through the load holding valve spool, the spring chamber pressure
drops, and the load holding valve check valve is opened.
The boom cylinder bottom side pressurized oil goes through the load holding valve check valve and
the boom (1) spool and returns to the hydraulic oil tank.
Pressure line
Tank line
Pilot pressure line
Pilot tank line
Electric line
1 Boom load holding valve check valve 12 Oil cooler

2 Load holding valve spool 13 Boom cylinder
3 Cushion valve 14 Boom (1)
6 Remote control valve (boom, bucket) 17 Console lever lock switch
8 Boost pressure relief 19 Computer A
10 Control valve 21 P2 pressure sensor
11 Check valve 22 Hydraulic pump
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Arm Circuit
Arm-out circuit
By moving the remote control valve to the arm-out side, the pilot pressure oil is fed via the cushion
valve to the control valve pa5 port and pa9 port and switches the arm (1) and (2) spools to the out
side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the center
bypass oil path to the arm (1) spool. The discharge oil from hydraulic pump A2 enters the control
valve P2 port, flows from the center bypass oil path and through the arm (2) spool front arm merge
oil path and merges upstream of the arm (1) spool.
Switching the arm spool lets the oil flow through the load holding valve check valve and into the arm
cylinder rod side, carrying out the arm-out operation.
When the circuit has an HBCV, switching the arm spool lets the oil flow through the load holding
valve check valve to push open the arm cylinder HBCV check valve and flow into the rod side, carry-
ing out the arm-out operation.
The arm cylinder bottom side return oil goes through the arm (1) and (2) spools and returns to the
hydraulic oil tank.
Pressure line
Tank line
Pilot pressure line
Pilot tank line
Electric line
1 Arm cylinder 13 Travel pilot pressure sensor

2 Arm (in) 14 Upper pilot pressure sensor
3 Arm (out) 15 Console lever lock switch
4 Cushion valve 16 Monitor display
5 Remote control valve (arm, swing) 17 Computer A
6 Lever lock 18 P1 pressure sensor
8 5 stack solenoid valve 20 Hydraulic pump
10 Load holding valve check valve 22 Oil cooler
11 Arm (1) 23 Arm HBCV check valve
12 Arm (2) 24 Arm HBCV
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Arm Circuit
By moving the remote control valve to the arm-in side, the pilot pressure oil is fed via the cushion
valve to the control valve pb5 port and pb9 port and switches the arm (1) and (2) spools to the in
side.
Switching the arm spool lets the oil flow into the arm cylinder bottom side and the arm-in operation
is carried out.
spool and moves the spool to the right. In this way, the load holding valve check valve spring cham-
ber oil is connected to the tank line through the load holding valve spool, the spring chamber pres-
sure drops, and the load holding valve check valve is opened.
The arm cylinder rod side pressurized oil goes through the load holding valve check valve and the
arm (1) spool and is metered by the forced regeneration release valve.Through this, the return oil
pushes open the check valve in the arm (1) spool and is forcibly regenerated on the cylinder bottom
side, securing the arm speed for leveling work etc. When the cylinder bottom load pressure
becomes high, the forced regeneration release valve is switched to the large metering side and the
opening becomes larger. Through this, the check valve in the spool is closed and the cylinder rod
side return oil returns to the hydraulic oil tank via the arm spool (1) and forced regeneration release
valve without being regenerated.
Pressure line
Tank line
Pilot pressure line
Pilot tank line
Electric line
1 Load holding valve spool 10 Cushion valve 19 Travel pilot pressure sensor
2 Load holding valve check valve 11 Remote control valve (arm, swing) 20 Upper pilot pressure sensor
3 Oil cooler 12 Lever lock 21 Console lever lock switch
4 Regeneration check valve 13 Boost pressure relief 22 Monitor display
5 Metering large 14 5 stack solenoid valve 23 Computer A
6 Metering small 15 Control valve 24 P1 pressure sensor
7 Forced regeneration release valve 16 Arm cylinder 25 P2 pressure sensor
8 Arm (in) 17 Arm (1) 26 Hydraulic pump
9 Arm (out) 18 Arm (2) 27 Check valve
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Arm Circuit
Arm-in load holding valve circuit
When the remote control valve arm operation lever is in neutral, the oil at the arm cylinder rod side is
sealed by the load holding valve check valve, reducing internal leakage from the main spool and
reducing the natural drop of the arm.
By moving the remote control valve to the arm-in side, the pilot pressure oil is fed via the cushion
valve to the control valve pb5 port and pb9 port and switches the arm (1) and (2) spools to the in
side.
Switching the arm spool lets the oil flow into the arm cylinder bottom side and the arm-in operation
is carried out.
spool and moves the spool to the right. In this way, the load holding valve check valve spring cham-
ber oil is connected to the tank line through the load holding valve spool, the spring chamber pres-
sure drops, and the load holding valve check valve is opened.
The arm cylinder rod side pressurized oil goes through the load holding valve check valve and the
arm (1) spool and returns to the hydraulic oil tank.
Pressure line
Tank line
Pilot pressure line
Pilot tank line
Electric line
1 Load holding valve spool 13 Arm (1)

2 Load holding valve check valve 14 Arm (2)
3 Oil cooler 15 Travel pilot pressure sensor
4 Arm (in) 16 Upper pilot pressure sensor
6 Cushion valve 18 Monitor display
7 Remote control valve (arm, swing) 19 Computer A
12 Arm cylinder
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Bucket Circuit
Bucket-open circuit
By moving the remote control valve to the bucket-open side, the pilot pressure oil is fed via the cush-
ion valve to the control valve pa7 port and switches the bucket spool to the open side.
lel oil path to the bucket spool. Switching the spool lets the oil flow into the bucket cylinder rod side
and the bucket-open operation is carried out.
The bucket cylinder bottom side pressurized oil goes through the bucket spool and returns to the
hydraulic oil tank.
Pressure line
Tank line
Pilot pressure line
Pilot tank line
Electric line
1 Cushion valve 11 Travel pilot pressure sensor

2 Bucket (close) 12 Upper pilot pressure sensor
3 Bucket (open) 13 Console lever lock switch
9 Bucket 19 Check valve
10 Bucket cylinder 20 Oil cooler
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Bucket Circuit
Bucket-close regenerative circuit
By moving the remote control valve to the bucket-close side, the pilot pressure oil is fed via the cush-
ion valve to the control valve pb7 port and switches the bucket spool to the close side.
lel oil path to the bucket spool. Switching the spool lets the oil flow into the bucket cylinder bottom
and the bucket-close operation is carried out.
The bucket cylinder rod side pressurized oil is metered by the bucket spool regeneration ori-
fice.Through this, the return oil pushes open the check valve in the spool and is regenerated on the
cylinder bottom side. The lower the cylinder rod side load pressure, the greater the volume of regen-
eration. When the cylinder rod side load pressure becomes high, the check valve is closed and the
cylinder bottom side return oil goes through the bucket spool without regeneration and returns to the
hydraulic oil tank.
Pressure line
Tank line
Pilot pressure line
Pilot tank line
Electric line
1 Regeneration check valve 12 Bucket

2 Oil cooler 13 Bucket cylinder
3 Orifice 14 Travel pilot pressure sensor
4 Cushion valve 15 Upper pilot pressure sensor
5 Bucket (close) 16 Console lever lock switch
6 Bucket (open) 17 Monitor display
7 Remote control valve (boom, bucket) 18 Computer A
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Negative control circuit (power save solenoid OFF)
When the remote control valve operation lever is set to neutral, the discharge oil from hydraulic
pumps A1 and A2 goes from the control valve P1 and P2 ports through the center bypass oil path,
and through the downstream negative control variable relief, and returns to the hydraulic oil tank.
The discharged oil from pilot pump A3 enters the 5 stack solenoid valve P port, flows through the
power save solenoid valve, is fed to the control valve Pn1 and Pn2 ports, and holds the P1 and P2
negative control relief at the set pressure of 369.8 PSI (2.55 MPa).
The negative control pressure oil separated from the center bypass oil path is fed from the Ps1 and
Ps2 ports to the hydraulic pump Pi1 and Pi2 ports, moves the pump tilting to the minimum flow side,
and the pump discharge flow is reduced.
Pressure line
Tank line
Pilot pressure line
Pilot tank line
Electric line
1 P1 negative control relief 11 N1 negative control pressure sensor

2 P2 negative control relief 12 P1 pressure sensor
4 Travel pilot pressure sensor 14 N2 negative control pressure sensor
5 Upper pilot pressure sensor 15 Horsepower control proportional valve
6 Computer A 16 P1 flow control proportional valve
7 Console lever lock switch 17 Hydraulic pump
8 Lever lock 18 Check valve
9 Power save 19 Oil cooler
10 5 stack solenoid valve
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Negative control power save circuit (power save solenoid ON)
The purpose of this control is to reduce fuel consumption during standby by reducing the back pres-
sure for the negative control signal.
When the remote control valve operation lever is set to neutral, the non-operation state signal enters
the computer A from the travel pilot pressure sensor and the upper pilot pressure sensor installed on
the control valve PT port and PA port. After about 1 sec., the power save solenoid valve is excited
and switched ON by the signal output from computer A, and the oil path is switched.
The pressurized oil from the control valve negative control relief Pn1 and Pn2 ports goes through
the power save solenoid valve and returns to the hydraulic oil tank.
Therefore, the negative control relief set pressure is switched to low pressure to further reduce the
A1 and A2 pump discharge pressure.
With the system running this way, the negative control signal is cut off and the P1 and P2 pump dis-
charge volume increases.
The discharge oil from pilot pump A3 enters the 5 stack solenoid valve P port, flows through the
power save solenoid valve, is fed to the hydraulic pump P2 port from the C5 port, moves the A2 side
pump tilting to the minimum flow side, and this reduces the discharge flow.
At the same time, the discharge oil from the pilot pump A3 is fed to the hydraulic pump P1 port by
the signal from computer A to the P1 flow restriction proportional valve, moves the A1 side pump tilt-
ing to the minimum flow side, and this reduces the discharge flow.
Pressure line
Tank line
Pilot pressure line
Pilot tank line
Electric line

3 Upper pilot pressure sensor 12 N2 negative control pressure sensor
4 Computer A 13 Horsepower control proportional valve
5 Console lever lock switch 14 P1 flow control proportional valve
6 Lever lock 15 Hydraulic pump
7 Power save 16 Check valve
8 5 stack solenoid valve 17 Oil cooler
9 N1 negative control pressure sensor
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Negative control circuit (bucket close, power save solenoid OFF)
As an example, this section explains the bucket-close operations.
The discharge oil from the hydraulic pump A2 enters the control valve P2 port, is fed to the bucket
spool, flows into the bucket cylinder bottom side because of the spool switching and the bucket-
close operation is carried out.
At the same time, the upper pilot pressure sensor signal is detected and through the signal output
from computer A to switch OFF the power save solenoid valve, pilot pressure oil enters the negative
control relief, and the pressure becomes the set pressure of 369.8 PSI (2.55 MPa).
Because the bucket spool switches and the pressurized oil on the center bypass downstream side is
cut off, the Pi2 pump negative control pressure oil from the Ps2 port is eliminated, the pump tilting
moves to the increase side, and the flow is increased.
Also, the command milli-amp to the P1 flow control proportional valve is lowered and the pressur-
ized oil from the hydraulic pump A3 is cut off, but the negative control pressurized oil is fed from the
control valve Ps1 port to the Pi1 port, moves the pump tilting to the minimum flow side, and the
hydraulic pump A1 discharge volume is reduced.
Pressure line
Tank line
Pilot pressure line
Pilot tank line
Electric line
1 Control valve 12 Power save

2 Travel pilot pressure sensor 13 5 stack solenoid valve
3 Upper pilot pressure sensor 14 P1 pressure sensor
4 Cushion valve 15 P2 pressure sensor
5 Bucket (close) 16 N1 negative control pressure sensor
6 Bucket (open) 17 N2 negative control pressure sensor
7 Bucket cylinder 18 P1 flow control proportional valve
8 Computer A 19 Hydraulic pump
9 Remote control valve (boom, bucket) 20 Check valve
10 Console lever lock switch 21 Oil cooler
11 Lever lock
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Other Circuits
As examples, this section explains the cases when an arm-out operation is carried out, when an arm-
out operation is stopped, and when an arm-out operation is followed by an arm-in operation.
Cushion circuit (arm-out operation)
When a remote control valve arm-out operation is carried out, the pilot pressure oil enters from the
remote control valve 2 port into the cushion valve, pushes up the internal check valve, and is fed to
the control valve pa5 and pa9 ports.
At the same time, the cushion valve cushion spool is switched to the left.
The arm-in side oil pushed out from the control valve pb9 and pb5 ports passes from the cushion
valve B port through the cushion spool switched to the left and returns to the hydraulic oil tank.
At this time, the warmed oil from the return line enters the remote control valve through the cushion
spool from the cushion valve R port and returns to the hydraulic oil tank, so heat performance is
improved.
Pressure line
Tank line
Pilot pressure line
Pilot tank line
Electric line
1 Arm (in) 9 5 stack solenoid valve

2 Arm (out) 10 Control valve
3 Cushion spool 11 Arm (1)
4 Orifice 12 Arm (2)
5 Check valve 13 Console lever lock switch
6 Cushion valve 14 Hydraulic pump
7 Remote control valve (arm, swing) 15 Check valve
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Other Circuits
Cushion circuit (arm-out operation stopped)
When the remote control valve arm-out operation is returned to neutral, the oil pushed out from the
control valve pa5 and pa9 ports flows to the cushion valve D port through the cushion orifice and
returns from the remote control valve to the hydraulic oil tank.
Through this orifice, the arm spool moves to the neutral position without returning sharply, so the
cushioning is improved.
Pressure line
Tank line
Pilot pressure line
Pilot tank line
Electric line
1 Arm (in) 9 Control valve

2 Arm (out) 10 Arm (1)
4 Orifice 12 Console lever lock switch
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Other Circuits
Cushion circuit (arm-out → arm-in operation)
When the lever is operating all at once from an arm-out operation to an arm-in operation (arm rat-
tling operation), the pilot pressure oil is fed from the remote control valve 2 port into the cushion
valve A port, pushes up the internal check valve, and reaches the control valve pb5 port and pb9
port.
At the same time, the cushion valve cushion spool is switched to the right.
At this time, the oil pushed out from the pa5 and pa9 ports does not pass through the cushion ori-
fice, but passes through the cushion spool that has been switched to the right and returns to the
hydraulic oil tank, so response is improved.
Pressure line
Tank line
Pilot pressure line
Pilot tank line
Electric line

2 Arm (out) 10 Arm (1)
4 Orifice 12 Console lever lock switch
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Other Circuits
Heat circuit (lever in neutral)
The pilot line is equipped with a heat circuit to prevent response delay at low temperatures.
When the remote control valve operation lever is set to neutral, the discharge oil from hydraulic
pumps A1 and A2 goes from the control valve P1 and P2 ports through the center bypass oil path,
and returns to the hydraulic oil tank.
The pressurized oil from the control valve T8 port is fed to the cushion valve R port and returns
through the cushion spool to the hydraulic oil tank.
By circulating the oil inside the cushion spool, the temperature of the oil in the cushion valve is
raised to improve heat performance.
Pressure line
Tank line
Pilot pressure line
Pilot tank line
Electric line

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Other Circuits
Auto pressure boost circuit (bucket close)
When an attachment is operated, this circuit boosts the control valve main relief set pressure from
4974.7 PSI (34.3 MPa) to 5409.9 PSI (37.3 MPa) according to the engine load ratio and hydraulic load
pressure, then ends the pressure boost after 8 sec.
As an example, this section explains bucket-close operations.
At the same time, the output signal from the upper pilot pressure sensor that detected the pressur-
ized oil separated from the pilot internal path is input to computer A, which judges that there is upper
operation. Furthermore, computer A judges that there is a boost in the main pump P1 and P2 pres-
sure, outputs the ON (24 V) signal to the pressure boost relief solenoid, switches the valve, and the
pilot pressure oil is fed to the control valve main relief valve PH port to hold the pressure boost relief
set pressure for 8 sec.
There is no boost for the option circuit and during travel operation.
Pressure line
Tank line
Pilot pressure line
Pilot tank line
Electric line
1 Cushion valve 11 Upper pilot pressure sensor

2 Bucket (close) 12 Console lever lock switch
3 Bucket (open) 13 Digging force incresed
9 Bucket 19 Check valve
10 Bucket cylinder 20 Oil cooler
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Explanation of Hydraulic Circuit and Operations (option) SH200
Hydraulic

Option Circuits
Breaker circuit (independent operation)
By operating the option remote control valve to the breaker side, the pilot pressure oil is fed to the
control valve pa2 port and switches the option spool.
The discharge oil from hydraulic pump A1 is fed from the control valve P1 port through the parallel
oil path and fed to the option spool. Switching the spool lets the oil flow from the relief valve A port
through the B port and into the breaker.
The breaker set pressure is set by this relief valve.
At this time, the option pilot pressure switch signal is detected, the P1 flow control proportional valve
is controlled by the output signals from the computer A to adjust the discharge flow.
The return oil from the breaker goes through the manifold and returns to the hydraulic oil tank.
Because the breaker operating flow can be set to 5 levels on the service support screen of the mon-
itor display with the ON signal from the breaker switch in the cab, the optimum operating flow can be
selected.
Pressure line
Tank line
Pilot pressure line
Pilot tank line
Electric line
1 Control valve 12 Console lever lock switch

2 Manifold 13 Lever lock
3 Relief valve 14 5 stack solenoid valve
4 Breaker 15 P1 pressure sensor
6 Upper pilot pressure sensor 17 N1 negative control pressure sensor
7 Computer A 18 N2 negative control pressure sensor
8 Monitor display 19 P1 flow control proportional valve
9 Breaker switch 20 Hydraulic pump
10 Option remote control valve 21 Check valve
11 Option pilot pressure switch 22 Oil cooler
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Double-acting circuit (hydraulic fork)
As an example, this section explains the case in which the hydraulic fork attachment is used.
By operating the option remote control valve to the fork close side, the pilot pressure oil is fed to the
control valve pa2 port and switches the option spool to the close side.
path to the option spool, flows into the hydraulic fork because of the option spool switching and
operates to the close side.
At this time, the option pilot pressure switch signal is detected and the auto idle function is released.
The return oil from the hydraulic fork goes through the option spool and returns to the hydraulic oil
tank.
Pressure line
Tank line
Pilot pressure line
Pilot tank line
Electric line
1 Control valve 8 5 stack solenoid valve

2 Hydraulic fork 9 Console lever lock switch
3 Travel pilot pressure sensor 10 Hydraulic pump
4 Upper pilot pressure sensor 11 Option remote control valve
5 Monitor display 12 Option pilot pressure switch
6 Computer A 13 Check valve
7 Lever Lock 14 Oil cooler
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Multi-purpose circuit (breaker Q control)
When the switch in the cab is flipped to the breaker side, the ON signal (24 V) is output from the
computer A to the option switchover solenoid valve to switch the valve.
The pilot pressure oil flows from the option switchover solenoid valve B1 port to the A1 port and is
fed to the 3-direction valve PP port and shut-off valve PP port and each valve is switched.
Always switch the 2 pumps flow select switch to the 1 pump side.
By operating the option remote control valve to the breaker side, the pilot pressure oil is fed to the
control valve pa2 port and switches the option spool.
oil path and fed to the option spool. Switching the spool lets the oil flow from the shut-off valve A port
through the B port and into the breaker.
The breaker set pressure is set by the relief valve built into the shut-off valve.
The return oil from the breaker returns from the 3-direction valve A1 port through the T1 port and to
the hydraulic oil tank.
Because the breaker operating flow can be set to 5 levels on the service support screen of the mon-
itor display, the optimum operating flow can be selected.
Pressure line
Tank line
Pilot pressure line
Pilot tank line
Electric line
1 Control valve 12 Lever lock

2 3-direction valve 13 5 stack solenoid valve
3 Shut-off valve 14 Horsepower control proportional valve
4 Breaker 15 P1 pressure sensor
5 Option remote control valve 16 P2 pressure sensor
6 Option pilot pressure switch 17 N1 negative control pressure sensor
7 Multi-purpose circuit switch 18 N2 negative control pressure sensor
8 Computer A 19 P1 flow control proportional valve
9 Monitor display 20 Hydraulic pump
10 Option switchover solenoid valve 21 Check valve
11 Console lever lock switch 22 Oil cooler
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Multi-purpose circuit (2 pumps flow crusher)
When the 2 pumps flow select switch in the cab is flipped to the 2 pumps flow side, the ON signal
(24 V) is output from the computer A to the 2 pumps flow solenoid valve to switch the valve.
When the multi-purpose circuit switch is flipped to the crusher side, the crusher circuit is formed
without outputting a signal from the computer A to the option switchover solenoid valve and without
switching the valve.
At this time, the pilot signal does not go to the 3-direction valve or to the shut-off valve and the 3-
direction valve forms the A ⇔ B circuit.
By operating the option remote control valve to the crusher close side, the pilot pressure oil is fed to
the control valve pa2 port and switches the option spool.
At the same time, the pilot pressure oil flows from the solenoid valve for 2 pumps flow B2 port to the
A2 port and is fed to the control valve pcc port and the control valve neutral cut valve is switched.
The discharge oil from hydraulic pump A2 enters the control valve P2 port and goes through the
center bypass oil path and since the neutral cut valve has closed the port to the tank, the oil goes
from the P3 port via the P4 port and merges on the upstream side of the option spool.
oil path and fed to the option spool. Switching the spool lets the oil flow from the shut-off valve A port
through the B port and into the crusher.
The return oil from the crusher returns from the 3-direction valve A port through the B port and the
option spool and returns to the hydraulic oil tank.
Because the crusher operating flow can be set to 5 levels on the service support screen of the mon-
itor display, the optimum operating flow can be selected.
Pressure line
Tank line
Pilot pressure line
Pilot tank line
Electric line
1 3-direction valve 10 Monitor display 19 5 stack solenoid valve

2 Shut-off valve 11 Computer A 20 Console lever lock switch
3 Crusher 12 Multi-purpose circuit switch 21 Horsepower control proportional valve
4 Option switchover solenoid valve 13 2 pumps flow select switch 22 P1 pressure sensor
5 2 pumps flow solenoid valve 14 Control valve 23 P2 pressure sensor
6 Option remote control valve 15 Neutral cut valve 24 N1 negative control pressure sensor
7 Check valve 16 Travel pilot pressure sensor 25 N2 negative control pressure sensor
8 Oil cooler 17 Upper pilot pressure sensor 26 P1 flow control proportional valve
9 Option pilot pressure switch 18 Lever lock 27 Hydraulic pump
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103 SST-04-05-009EN
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2nd option circuit (hydraulic rotation fork)
As an example, this section explains the case in which the hydraulic rotation fork attachment is
used.
By operating the 2nd option remote control valve to the right swing side, the pilot pressure oil is fed
to the control valve par2 port.
The 4th hydraulic pump OUT discharge oil is fed to the control valve Pr port, goes through the 2nd
option spool and flows to the hydraulic rotation fork to operate to the right swing side.
At this time, the 2nd option pilot pressure switch signal is detected and the auto idle function is
released.
The return oil from the hydraulic rotation fork goes through the 2nd option spool and returns to the
hydraulic oil tank.
The oil in the 2nd option drain line returns to the hydraulic oil tank without going through the control
valve.
Pressure line
Tank line
Pilot pressure line
Pilot tank line
Electric line
1 Control valve 9 Oil cooler

2 Travel pilot pressure sensor 10 Hydraulic rotation fork
3 Upper pilot pressure sensor 11 2nd option pilot pressure switch
5 5 stack solenoid valve 13 Computer A
6 Console lever lock switch 14 4th pump
7 2nd option remote control valve 15 Hydraulic pump
8 Check valve
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105 SST-04-05-009EN
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NOTES:
Main Equipment Structure and Operation Explanation SH330
Hydraulic

Pump
1. Hydraulic Pump
(1) Structure and operation explanation
This pump has a structure in which 2 pumps are coupled by the 1st gear (116) and the 2 pumps
can be driven at the same time through the rotation of the power source being transmitted to the
drive shaft F (111) on the front side. The oil suction and discharge port are located in the connec-
tion section of the 2 pumps (specifically, the valve block (312)), and the suction port is used in
common by the front pump and rear pump. Pump structure and operation principles are the same
for the front and rear pumps. The front pump is explained below.
The pump can be roughly divided into the rotary group, which is the main part of the pump that
performs rotation, the swash plate group, which changes the discharge flow, and the valve cover
group, which switches between oil suction and discharge.
The rotary group is made up of the drive shaft F (111), cylinder block (141), piston shoes (151),
(152), holder plate (153), spherical bushing (156), and cylinder spring (157). The drive shaft is
supported at both ends with bearings (123), (124). Along with being caulked to the piston to form
a spherical joint, the shoe has a pocket section for balancing the hydraulic pressure in order to
reduce the thrust force generated by the load pressure and allow the shoe to slide lightly on the
shoe plate (211). The piston shoe sub-group is pressed against the shoe plate by the cylinder
spring via the holder plate and spherical bushing so that it can slide smoothly on the shoe plate.
Also, the cylinder block is pressed against the valve plate (314) by the cylinder spring in the same
way.
The swash plate group comprises the swash plate (212), shoe plate (211), swash plate support
board (251), tilting bushing (214), tilting pin (531), and servo piston (532). The swash plate is
supported by the swash plate support board at the cylindrically shaped section formed by the
opposite side of the shoe sliding surface. By leading the hydraulic pressure force controlled by
the regulator into the hydraulic pressure chambers on both sides of the servo piston, the servo
piston moves left and right. This moves the swash plate on the swash plate support board via the
tilting pin spherical section and changes the tilting angle (α).
The valve cover group comprises the valve block (312), valve plates (313), (314), and valve plate
pin (885). The valve plate, which has 2 oval-shaped ports, is installed on the valve block. Its func-
tion is to feed oil to the cylinder block and recover it from the cylinder block. The oil switched by
the valve plate is connected through the valve block to the outside lines.
Now when the drive shaft is driven by the power source (motor, engine, etc.), the cylinder block is
also rotated at the same time via the spline coupling. When the swash plate tilts, the piston
located at the center of the cylinder block moves reciprocally relative to the cylinder while turning
with the cylinder block.
Therefore, if just one piston is looked at, during one cylinder block rotation the piston moves away
from the valve plate (oil intake stroke) for 180° and then moves toward the valve plate (oil dis-
charge stroke) for the remaining 180°. When the swash plate tilting angle is 0°, the piston does
not move through a stroke and oil is not discharged.
106 SST-04-02-009EN
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(2) Hydraulic pump internal structure diagram
Overall View
Drive shaft front side Drive shaft rear side

Drive shaft front side
SST-04-02-009EN 107
2
Parts table
Code Part name Qty Component part No. (q'ty) or model Code Part name Qty Code Part name Qty
111 Drive shaft (F) 1 531 Tilting pin 2
04 Gear pump 1 set ZX15LHRZ2-07A-V
113 Drive shaft (R) 1 532 Servo piston 2
011 Piston subassembly 2 set 151 (9PC), 152 (9PC)
114 1st gear 1 534 Stopper (L) 2
013 Cylinder subassembly (R) 1 set 141 (1PC), 313 (1PC)
123 Roller bearing 2 535 Stopper (S) 2
014 Cylinder subassembly (L) 1 set 141 (1PC), 314 (1PC) 124 Needle roller bearing 2 541 Seat 4
030 Swash plate subassembly 2 set 212 (1PC), 214 (1PC) 127 Bearing spacer 4 543 Stopper 1 2
041 Check valve 1 subassembly 2 set 541 (1PC), 543 (1PC), 545 (1PC) 141 Cylinder block 2 544 Stopper 2 2
042 Check valve 2 subassembly 2 set 541 (1PC), 544 (1PC), 545 (1PC) 151 Piston 18 545 Steel ball 4
Electromagnetic proportional 152 Shoe 18 548 Feedback pin 2
079 pressure reducing valve, cas- 1 set KDRDE5KR-V3-V 153 Holder plate 2 702 O-ring 2
ing subassembly
156 Spherical bushing 2 710 O-ring 1
530 Tilting pin subassembly 2 set 531 (1PC), 548 (1PC)
157 Cylinder spring 18 714 O-ring 1
Adhesion agent 211 Shoe plate 2 717 O-ring 2
1 (ThreeBond Co., Ltd. No. 130SN) application 212 Swash plate 2 724 O-ring 16
Oil seal outer circumference Lubricating agent 214 Tilting bushing 2 725 O-ring 6
2 (Sealub L101) application 251 Swash plate support board 2 728 O-ring 4
3 Right rotation valve plate 261 Seal cover (F) 1 732 O-ring 2
4 Left rotation valve plate 271 Pump casing 2 774 Oil seal 1
5 Tightening torque Flange socket 312 Valve block 1 789 Backup ring 2
(4-M10 × 1.5): 24.3 lbf•ft. (33 N•m)
313 Valve plate (R) 1 792 Backup ring 2
6 Tightening torque Hexagon bolt 314 Valve plate (L) 1 808 Hexagon nut 2
(3-M6 × 1.0): 8.8 lbf•ft (12 N•m)
326 Cover 1 824 Stop ring 2
401 Hexagon socket head bolt 8 885 Valve plate pin 2
406 Hexagon socket head bolt 4 886 Spring pin 4
414 Hexagon socket head bolt 4 901 Eyebolt 2
466 VP plug 2 953 Hexagon socket head stop screw 2
467 VP plug 2 954 Stop screw 2
468 VP plug 4 981 Nameplate 1
490 Insert plug 27 983 Driving tack 2
492 Insert plug 12
Drive shaft rear side
108 SST-04-02-009EN
3
2. Regulator
(1) Regulator operation explanation
[1] Flow control
• Operation explanation (See the regulator operation explanation diagram.)
1) Flow control
The pump discharge flow is controlled as desired with the pilot pressure Pi as in the dia-
gram below.
1. Flow reduction operation
When the pilot pressure Pi increases,
the pilot piston (643) moves to the
right and stops at the location where
the pilot spring (646) force and
hydraulic pressure balance each
other. The pin (875) fixed to lever 2
(613) fits into the grooved section of
the pilot piston (643), so, through the
movement of the pilot piston (643),
lever 2 rotates with the B section (fastened by the fulcrum plug (614) and pin (876)) as
the fulcrum. The pin (897) fixed to the feedback lever (611) projects into the large open-
ing (C section) of lever 2 (613), so as lever 2 (613) rotates, the pin (897) moves to the
right. The pin (548) fixed to the tilting pin (531) that shakes the swash plate (212) is
bonded to the two-side width section (D section) of the feedback lever (611). Therefore,
as the pin (897) moves, the feedback lever (611) rotates with D section as the fulcrum.
Since the spool (652) is linked to the feedback lever (611) via the pin (874), the spool
(652) moves to the right.
When the spool (652) moves, the discharge pressure Pd1 is led to the servo piston
large-diameter chamber via the spool and CI port. The discharge pressure Pd1 is
always led to the servo piston small-diameter chamber. As a result, the servo piston is
moved to the right due to the surface area difference and reduces the flow.
When the servo piston (532) moves to the right, the D section also moves to the right.
The return spring (654) is mounted on the spool (652). Since force pulling the spool to
the left is always operating, the pin (897) is pressed into the large opening (C section) of
lever 2 (613). Therefore, accompanying the D section movement, the feedback lever
(611) rotates around the C section as the fulcrum and the spool (652) moves to the left.
This movement causes the open section between the sleeve (651) and the spool (652)
to begin to close, and the servo piston (532) stops at the point the open section fully
closes.
2. Flow increase operation
When the pilot pressure Pi decreases, the pilot piston (643) is moved to the left by the
pilot spring (646) force and lever 2 (613) rotates with the B section as the fulcrum. The
pin (897) is pressed in the large opening (C section) of lever 2 (613) by the return spring
(654) via the spool (652), pin (874), and feedback lever (611), so accompanying rotation
of lever 2 (613), the feedback lever (611) rotates with the D section as the fulcrum and
the spool (652) moves to the left.
When the spool (652) moves, the CI port opens to the tank port, so the pressure in the
large-diameter chamber of the servo piston drains out, the servo piston (532) is moved
to the left by the discharge pressure Pd1 of the small-diameter section and the flow
increases.
Accompanying the movement of the servo piston (532), the D section moves to the left,
the feedback lever (611) rotates with the C section as the fulcrum and the spool (652)
moves to the right. This operation continues until the open section between the spool
(652) and sleeve (651) closes, and then the servo piston stops at the point the open
section fully closes.
SST-04-02-009EN 109
4
3. High-pressure selection function
The pilot pressure Pi, which serves as the flow control signal, is the pressure for which
high pressure is selected from among multiple command pressures via the shuttle valve
subassembly (050).
KR3K-9Y04-HV selects the higher pressure from Pi1 or the proportional valve 2nd
pressure and KR3K-9X04-HV selects the higher pressure from Pi2 or the external com-
mand pressure P2.
[2] Horsepower control
1) Horsepower control
As the load pressure increases, the pump tilting angle decreases and the overload of the
engine is prevented as in the diagram below. Since this regulator uses the simultaneous
full-horsepower control method, the tilting angles (displacement volumes) of the 2 pumps
are controlled to be the same value as in the following equation.
Tin = Pd1 × q/2 π + Pd2 × q/2 π = (Pd1 + Pd2) × q/2 π
(q: Displacement volume)
Horsepower control is the same as flow control and is briefly explained below.
(For detailed operation of each part, see the Flow control section.)
1. Overload prevention operation
When the self pump discharge pres-
sure Pd1 or the counterpart pump dis-
charge pressure Pd2 rises, since Pd1
and Pd2 operate on the stepped sec-
tion of the compensation piston (621),
the compensation rod (623) is pressed
to the right and moves to the location
where the force of the outer spring
(625) and inner spring (626) balance
out the hydraulic pressure force. The
movement of the compensation rod
(623) is transmitted to lever 1 (612) through the pin (875) and lever 1 (612) rotates
around the pin (876) (E section) fastened to the casing (601). The pin (897) fixed to the
feedback lever (611) projects into the large opening (F section) of lever 1 (612), so as
lever 1 (612) rotates, the feedback lever (611) rotates with the D section as the fulcrum
and the spool (652) moves to the right.
When the spool (652) moves, the discharge pressure Pd1 is led to the large-diameter
section of the servo piston via the CI port, the servo piston (532) is moved to the right,
and the pump discharge flow is decreased to prevent overload of the power source.
The servo piston (532) movement is transmitted to the feedback lever (611) via the D
section. The feedback lever (611) rotates with the F section as the fulcrum and the
spool (652) moves to the left. The spool (652) moves until the open section between the
spool (652) and sleeve (651) closes, and then the servo piston stops at the point the
open section fully closes.
2. Flow return operation
If the self pump discharge pressure Pd1 or the counterpart pressure pump discharge
pressure Pd2 decreases, the compensation rod (623) is pressed back by the outer
spring (625) and the inner spring (626) and lever 1 (612) rotates about the E section.
Accompanying the lever 1 (612) rotation, the feedback lever (611) rotates around the D
section as the fulcrum and the spool (652) moves to the left. Because of this, the CI port
opens to the tank port, the servo piston large-diameter section pressure drains off, the
servo piston (532) moves to the left and the pump discharge flow increases.
The movement of the servo piston (532) is transmitted to the spool (652) by the feed-
back mechanism, and this operation continues until the open section between the spool
(652) and the sleeve (651) closes.
110 SST-04-02-009EN
5
[3] Low tilting (low flow) command priority mechanism
As above, the flow control and the horsepower control tilting command is transmitted to the
feedback lever (611) and spool (652) via the large opening (C and F sections) of lever 1
(612) and lever 2 (613), but since the C and F sections have a structure in which a pin (φ5)
projects into a large hole (φ9), the pin (897) only contacts the lever that makes the tilting
smaller and the φ9 hole for the lever on the side that has the larger tilting command state
does not contact the pin (897), but is free. This type of mechanical selection method gives
priority to flow control and horsepower control commands with low tilting.
[4] Power shift control (decreased horsepower control)
Use the power shift pressure Pf to arbitrarily control the pump set horsepower as in the dia-
gram below.
When the power shift pressure Pf increases, the compensation rod (623) is moved to the
right via the pin (898) and the compensation piston (621), so the pump tilting angle is
reduced and the horsepower setting is reduced in the same way as was explained for the
operation to prevent overload. By contrast, as the power shift pressure Pf decreases, the
horsepower setting increases.
SST-04-02-009EN 111
6
(2) Regulator operation explanation diagram
KR3K-9Y04-HV KR3K-9X04-HV
Hydraulic circuit diagram Hydraulic circuit diagram

Front side Rear side
1 CI port
112 SST-04-02-009EN
7
(3) Front side regulator internal structure diagrams
Hydraulic circuit
SST-04-02-009EN 113
8
1 Front side regulator

2 Rear side regulator
Code Part name Qty Component part No. (qty) or model

050 Shuttle valve subassembly 1 set 545 (1PC), 546 (1PC), 547 (1PC)
Electromagnetic proportional
079 1 set KDRDE5K-31/30C50-102
pressure reducing valve
Code Part name Qty Code Part name Qty

- Regulator subassembly 1 651 Sleeve 1
412 Hexagon socket head bolt 2 652 Spool 1
413 Hexagon socket head bolt 2 653 Spring seating 1
418 Hexagon socket head bolt 2 654 Return spring 1
436 Hexagon socket head bolt 4 655 Set spring 1
438 Hexagon socket head bolt 8 656 Blind cover 1
466 VP plug 1 708 O-ring 1
496 Insert plug 12 724 O-ring 9
545 Steel ball 1 725 O-ring 1
546 Seat 1 1 727 O-ring 1
547 Seat 2 1 728 O-ring 1
601 Casing 1 730 O-ring 1
611 Feedback lever 1 732 O-ring 1
612 Lever 1 1 733 O-ring 1
613 Lever 2 1 734 O-ring 1
614 Fulcrum plug 1 735 O-ring 1
615 Adjusting plug 1 753 O-ring 1
621 Compensation piston 1 755 O-ring 3
622 Piston case 1 756 O-ring 1
623 Compensation rod 1 763 O-ring 1
624 Spring seating (C) 1 801 Hexagon nut 1
625 Outer spring 1 802 Hexagon nut 1
626 Inner spring 1 814 Stop ring 1
627 Adjusting ring (C) 1 836 Stop ring 1
628 Adjusting screw (C) 1 858 Locking ring 2
629 Cover (C) 1 874 Pin 1
630 Lock nut 1 875 Pin 2
631 Pf sleeve 1 876 Pin 2
641 Pilot cover 1 887 Pin 1
643 Pilot piston 1 897 Pin 1
644 Spring seating (Q) 1 898 Pin 1
645 Adjusting ring (Q) 1 924 Hexagon socket head stop screw 1
646 Pilot spring 1
114 SST-04-02-009EN
9
(4) Rear side regulator internal structure diagram
Hydraulic circuit
SST-04-02-009EN 115
10

050 Shuttle valve subassembly 1 set 545 (1PC), 546 (1PC), 547 (1PC)

- Regulator subassembly 1 651 Sleeve 1
412 Hexagon socket head bolt 2 652 Spool 1
413 Hexagon socket head bolt 2 653 Spring seating 1
436 Hexagon socket head bolt 4 654 Return spring 1
438 Hexagon socket head bolt 8 655 Set spring 1
466 VP plug 1 656 Blind cover 1
496 Insert plug 6 722 O-ring 3
545 Steel ball 1 724 O-ring 9
546 Seat 1 1 725 O-ring 1
547 Seat 2 1 727 O-ring 1
601 Casing 1 728 O-ring 1
611 Feedback lever 1 730 O-ring 1
612 Lever 1 1 732 O-ring 1
613 Lever 2 1 733 O-ring 1
614 Fulcrum plug 1 734 O-ring 1
615 Adjusting plug 1 735 O-ring 1
621 Compensation piston 1 753 O-ring 1
622 Piston case 1 755 O-ring 3
623 Compensation rod 1 756 O-ring 1
624 Spring seating (C) 1 763 O-ring 1
625 Outer spring 1 801 Hexagon nut 1
626 Inner spring 1 802 Hexagon nut 1
627 Adjusting ring (C) 1 814 Stop ring 1
628 Adjusting screw (C) 1 836 Stop ring 1
629 Cover (C) 1 858 Locking ring 2
630 Lock nut 1 874 Pin 1
631 Pf sleeve 1 875 Pin 2
641 Pilot cover 1 876 Pin 2
643 Pilot piston 1 887 Pin 1
644 Spring seating (Q) 1 897 Pin 1
645 Adjusting ring (Q) 1 898 Pin 1
646 Pilot spring 1 924 Hexagon socket head stop screw 1
116 SST-04-02-009EN
11
3. Gear Pump
(1) Gear pump internal structure diagram
1 Front case side

2 Gear case side
3 To main pump

Gear case 307 (1PC), 308 (1PC), 351 (1PC),
350 1 set
subassembly 353 (1PC), 354 (1PC), 361 (1PC), 887 (2PC)
Hydraulic circuit

307 Poppet 1 433 Flange socket 2
308 Seat 1 434 Flange socket 2
309 Ring 1 435 Flange socket 4
310 Spring 1 466 VP plug 1
311 Adjusting screw 1 700 Angle ring 1
312 Lock nut 1 710 O-ring 1
351 Gear case 1 725 O-ring 1
353 Drive gear 1 732 O-ring 1
354 Driven gear 1 850 Locking ring 1
355 Filter 1 887 Pin 2
361 Front case 1
SST-04-02-009EN 117
12
(2) Structure and operation explanation
Structure
The casing comprises the front case (361) and gear case (351). Inside the casing the drive gear
(353), driven gear (354) pair and the relief valve for setting the discharge pressure are installed.
The relief valve comprises the filter (355), poppet (307), seat (308), spring (310), ring (309),
adjusting screw (311), and lock nut (312).
In order to prevent oil leaking to the outside, an angle ring (700) and O-ring (710) are mounted on
the front case (361).
Operation
Oil suctioned in from suction port B3 is discharged from discharge port A3 by the drive and driven
gears.
The discharge oil is held at the set pressure of 565.6 PSI (3.9 MPa) by the relief valve.
Unnecessary discharge oil is drained from the drain port via the relief valve.
118 SST-04-02-009EN
13
Motor
1. Travel Motor
(1) Travel motor operation explanation
Structure
Diagram 1 Travel motor structural diagram
Code Part name Code Part name Code Part name

1 Casing 23 D-ring (large bore) 45 Check valve spring
2 NPT1/16 plug 24 Rear cover 46 M6 orifice (φ0.6)
3 Oil seal 25 NPT1/16 plug (mec) 47 O-ring 1B P12.5
4 Circle R retaining ring IRTW68 26 Spool assembly 48 M6 orifice (φ0.8)
5 Expansion plug 27 Spring receiver 49 O-ring 1B P15
6 Tilting piston 28 Spring 50 O-ring 215.57 × 2.62
7 Tilting piston seal 29 M42 plug 51 Bearing HR32207C
8 Steel ball 30 O-ring 1B G40 52 Shim
9 Shaft 31 Pilot spool 53 Parallel pin
10 Bearing HR32209J 32 Pin 54 Valve plate
11 Pivot 33 Spring receiver 55 Brake spring
12 Shoe plate 34 Spring 56 Hexagon socket head bolt M18 × 50
13 Cylinder block 35 Pilot valve plug G3/8 57 Overload valve
14 Cylinder spring 36 O-ring 1B P14 58 Coupling
15 Spring receiver 37 Joint 59 C retaining ring 40 for hole
16 Spherical joint 38 G1/4 plug 60 G1/2 plug
17 Shoe retainer 39 O-ring 1B P11 61 O-ring 1B P18
18 Piston assembly 40 Orifice (break valve)
19 Separator plate 41 Orifice spring (break valve)
20 Friction plate 42 G1/8 plug
21 Brake piston 43 O-ring 1B P8
22 D-ring (small bore) 44 Check valve
SST-04-02-009EN 119
14
Component parts summary explanation
The motor comprises the main parts listed below.
• Rotary group that produces rotation force
• Parking brake for preventing self-travel during parking
• Variable mechanism section for switching the motor capacity between high and low
• Overload relief valve installed in the rear cover
• Brake valve section (counterbalance valve) that plays a critical role in controlling the hydraulic
circuits
1) Rotary group
The cylinder block (13) is fit into the teeth grooves on the spline of the shaft (9), which is sup-
ported at both ends by the bearings (10), (51). This cylinder block (13) is pressed against the
rear cover (24) together with the valve plate (54) by the cylinder spring (14).
The 9 piston assemblies (18) slide along the surface of the shoe plate (12) while moving in and
out of the cylinder block (13).There are hydrostatic bearings at both ends of the piston assem-
bly (18), and to reduce the sliding resistance as well as make the piston move without separat-
ing from the surface of the shoe plate (12), the force of the cylinder spring (14) is transmitted
through the spring receiver (15), spherical joint (16), and shoe retainer (17) to press both ends
of the piston assembly (18) against the shoe plate (12).
2) Parking brake
7 separator plates (19) and 6 friction plates (20) are fit into the spline groove around the outer
edge of the cylinder block (13) in an alternating pattern and are pressed against the casing (1)
by the 14 brake springs (55) via the brake piston (21).
3) Variable capacity mechanism section
This section comprises the pivot (11), which is fit into the 2 semispherical indentations on the
shoe plate (12) and supports the shoe plate (12), the tilting piston (6), which tilts the shoe plate
(12) around the pivot (11), the tilting stopper (1-1), which supports tilting at the determined
position, the pilot valve section, which brings pressurized oil to the tilting piston (6) according to
external commands, and 3 check valves (44), which extract the highest pressure out of either
the external command pilot pressure, the motor inlet pressure, and the motor outlet pressure,
and send the pressurized oil to the pilot valve section.
120 SST-04-02-009EN
15
4) Overload Relief Valve
This comprises the socket (57-1), which holds the valve seat (57-3) which seats metal to the
motor rear cover (24) internal hole section and screws the valve seat (57-3) into the rear cover
(24) to fasten it, the valve (57-2), which is contacted to the valve seat (57-3) by the adjusting
spring (57-9) and which is fit into the socket (57-1) internal hole, the linking piston (57-4), which
is inserted into the valve internal hole and serves as the oil path to the pilot section body (57-6),
the piston (57-7), which is inserted into the pilot section body (57-6) and is pressed against the
lid (57-5), and the spring adjusting shim (57-8).
Diagram 2 Overload relief valve structural diagram

Code Part name Code Part name
57-1 Socket 57-8 Shim
57-2 Valve 57-9 Adjusting spring
57-3 Valve seat 57-10 O-ring 1B P7
57-4 Linking piston 57-11 Backup ring T2 P7
57-5 Lid 57-12 O-ring 1B G25
57-6 Pilot section body 57-13 Backup ring T2 G25
57-7 Piston
SST-04-02-009EN 121
16
5) Brake valve section
Spool switchover pressure: 85.5 - 137.7 PSI (0.59 - 0.95 MPa)
Check valve cracking pressure: 2.1 PSI (0.015 MPa)
Diagram 3 Brake valve section

a Check valve
[1] Spool
Through switchover of this spool (26), shut-off of discharge oil of the hydraulic motor and
metering is automatically performed, and the effects of holding, acceleration, stopping and
counterbalance operations can be applied to the hydraulic motor.
[2] Check valve (built into spool)
At the same time this serves as the feed oil path for the hydraulic motor, it also fulfills the dis-
charge oil lock function.
Accordingly, at the same time it is the suction valve for the hydraulic motor, it serves as the
holding valve.
122 SST-04-02-009EN
17
Function
Discharge Direction of rotation (view
Inflow port
port from rear cover side)
VB VA Right (clockwise)
VA VB Left (counter-clockwise)
1 VA port
2 VB port
Diagram 4 Port positions

1) Motor operation
The high-pressure oil sent from the hydraulic pump enters from the inflow ports (VA, VB), flows
through the break valve section, rear cover (24), and valve plate (54), and is led into the cylin-
der block (13).
The table shows the inflow port, the discharge port, and the direction of rotation of the output
shaft.
(a) (b)
Diagram 5
This high-pressure oil, as shown in diagram 5(a), operates on all the pistons in a 180° area with
the Y-Y line connecting the piston top dead center and bottom dead center representing the
boundary and is produced.
This force F1 becomes a thrust force F2 and radial forces F31 - F34 (or F35) due to the shoe
plate (12), which has a tilting angle of α.(See diagram 5 (b).) These radial forces operate as
the rotation force on the Y-Y shaft and generate a torque of.
(When high pressure operates on 5 pistons, r5/F35 is added.)

This torque is transmitted to the shaft (9) spline via the cylinder block (13) and is transmitted to
the shaft (9).
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2) Parking brake operation
The parking brake is released when high hydraulic pressure selected by the counterbalance
section installed in the rear cover operates on the brake piston (21). Brake torque is constantly
being produced if no pressure is operating.
This brake torque is generated by the force of friction between the separator plate (19) coupled
by the casing (1) and spline and the friction plate (20) coupled with the cylinder block (13) by
the spline.
When pressure is not operating on the brake piston section, the brake piston (21) is pressed by
the brake spring (55) and the brake piston (21) sandwiches the friction plate (20) and separator
plate (19) against the casing (1).
This sandwiching force generates friction force between the friction plate (20) and the separator
plate (19), which serves as brake torque that constrains the shaft (9) in addition to the cylinder
block (13).
Diagram 6 Parking brake section
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3) Operation of variable capacity mechanism section
Diagram 7 Operation of variable capacity mechanism section

b High-speed travel command line (external pilot)
a To counterbalance valve (brake valve)
c Force application point
Diagram 7 shows a model of the variable capacity mechanism section.
When pressure overcoming the spring (34) enters the high-speed travel command line PA, the
spring (34) is compressed, the spool (31) moves to the right, the P and C ports are connected,
the highest of the 3 pressures - motor pressure MA, motor pressure MB, and the high-speed
travel command line pressure - is selected by the check valve (44), and the tilting piston (6) is
pressed. Therefore, the shoe plate (12) tilts as shown by the broken line with the line (L) con-
necting the 2 pivots (11) as the axis center and when the tilting stops at the point where it con-
tacts the tilting stopper (1-1), it holds that state.
As a result, the amount of the piston (18) coming in and out is reduced and the motor capacity
becomes small, so the motor rotates at high speed without increasing the amount of oil sent
from the hydraulic pump. For this machine, the capacity is about 1.71 time more.
On the other hand, when the high-speed travel command line PA pressure disappears, the
spool (31) is returned to the left by the spring (34), the oil that had been pressing against the
tilting piston (6) passes through the orifice (46) and is released to the tank, and the force press-
ing against the piston disappears.
Here, there are 9 pistons (18) distributed uniformly on the shoe plate (12) and they press
against the shoe plate (12). The force application point for the total force of these 9 pistons is
positioned about at the center of the shoe plate (12) as in the diagram and the pivots (11) are at
a position S away from the center, so a rotation force that is equal to S multiplied by the piston
pressing force returns the motor to its original state and the motor switches to low-speed travel.
Also, when the engine power is exceeded, for example when steering or climbing a steep hill at
high speed, in order to prevent the engine stalling, when the engine load exceeds the stipulated
value, the motor is automatically switched to low-speed.
When the hydraulic pump pressure (VA or VB) is led to the PB port of diagram 7, this pressure
operates on the pin (32). When the stipulated pressure is exceeded, the spool (31) is returned
to the left by the reaction force of the pin (32), the oil that had been pressing against the tilting
piston (6) is released to the tank, and the shoe plate (12) tilts to configure the high-capacity
motor so that operation becomes low-speed travel.
When this pressure falls to or below the stipulated pressure, the spool (31) moves to the right
and operation becomes high-speed travel.
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4) Overload relief valve operation
There are 2 overload relief valves that are arranged in a cross-over fashion and operate in the
following way.
[1] When the hydraulic motor is stopped, in order to prevent load inertia, the brake pressure
generated on the motor discharge side is held to no greater than a certain value.
[2] In order to get sharp acceleration with driving at the stipulated set pressure when starting
the hydraulic motor and to attenuate the brake shock when stopping, what is called boost
attenuation operation is carried out. The pressure generated is held at low pressure for a
short time and the reduction gear, travel crawler sprocket section, etc. mesh smoothly, then
the circuit pressure is held at the stipulated set pressure.
When the A port pressure for the overload relief valve rises when the hydraulic motor starts,
this pressure is applied to the effective diameter section seating to the valve seat (57-3) of the
valve (57-2) and it is also applied to the linking piston (57-4) of the valve interior through the
small hole in the valve (57-2). The A port pressure rises and the valve (57-2) resists the adjust-
ing spring (57-9) with the surface area difference between the valve seat effective diameter
section and the linking piston hole diameter section and sets the stipulated set pressure.
When the hydraulic motor brakes, the piston (57-7) in the rear section is on the left side due to
the drive pressure and when the A port pressure rises, it is also applied to the piston (57-7)
through the small hole in the valve and the small hole in the linking piston (57-4) and moves the
piston to the right side until it contacts the lid (57-5).
During this time, the valve (57-2) resists the adjusting spring (57-9) and holds the A port pres-
sure to a comparatively low and releases oil to the B port.
After the piston (57-7) contacts the lid (57-5), operation is the same as when the motor starts.
Diagram 8 Overload relief valve operation

a From the A port
b To the B port
c Small hole
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5) Brake valve operation
a) Hold state (See diagram 9.)
In the switchover valve neutral state, the VA and VB ports are connected to the tank and the
spool (26) is held in a central position by springs at both ends. Accordingly, because the VA →
MA, VB → MB paths are closed, the MA and MB ports that connect to the hydraulic motor on
either side are both in the closed state.
Also, because the parking brake release path is connected to the tank, the parking brake is in
the operation state and rotation of the hydraulic motor is mechanically stopped by the brake
spring force.
When an external force operates on the hydraulic motor, motor rotation is normally stopped by
the parking brake.
The parking brake will slide when torque higher than the parking brake force occurs, but hold-
ing pressure occurs in the MA or MB port side and rotation is held to a very small amount by
this holding pressure.
Also, when a small amount of rotation occurs with the hydraulic motor, high-pressure oil
escapes from the closed circuit and cavitation tends to form in the low-pressure side of the
closed circuit. The check valve built into the spool operates in order to prevent this cavitation,
a VA → MA or VB → MB path is formed, and an oil volume equal to the leaked volume is filled
into the closed circuit from the tank.
Diagram 9 Hold state

1 Spring
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22
b) Acceleration operation (See diagram 10.)
When the VA port connects to the hydraulic pump and the VB port connects to the tank
through switching of the switchover valve, pressurized oil from the hydraulic pump pushes up
the check valve within the spool from the VA port, this oil is fed to the hydraulic motor from the
MA port, and this makes the hydraulic motor rotate.
Also, pressurized oil is fed to the pilot chamber on the VA port side, and the spool (26) which
overcomes the spring force on the VB port side moves to the left. If this occurs, along with the
MB → VB return path being formed, pressurized oil is fed to the parking brake release line and
the parking brake is released. Accordingly, the hydraulic motor rotates.
If the inertial load of the hydraulic motor is large, pressure required for acceleration is achieved
with the overload relief valve set pressure and the hydraulic motor increases the rotation
speed while relieving pressurized oil.
As the rotation of the hydraulic motor increases, the relief volume decreases and a constant
speed is eventually achieved.
Diagram 10 Acceleration operation

1 Spring
2 Pilot chamber
128 SST-04-02-009EN
23
c) Stop operation (See diagram 11.)
When the switchover valve is returned to the neutral position, oil sending is cut off, and the VA
and VB ports are connected to the tank during rotation of the hydraulic motor, pressure in the
pilot chambers on both ends of the spool becomes equal and the spool (26) is returned to the
neutral position through spring force.
This causes the MB → VB path to close. However, the inertial force of the load will force rota-
tion of the hydraulic motor to continue. Pump operation occurs in the hydraulic motor and
hydraulic oil continues to be discharged into the MB port, but pressure increases because this
path is cut off. The overload relief valve operates and, as this happens, the speed of the
hydraulic motor gradually decreases and the motor eventually stops.
Also, the parking brake release pressure is slowly reduced because it is metered. The brake
eventually reaches the operation state and rotation of the hydraulic motor mechanically stops.
Diagram 11 Stop operation

1 Spring
2 Pilot chamber
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24
d) Counterbalance operation (diagram 12)
When the speed of the rotation hydraulic motor is reduced by load inertia, a counterbalance
operation is necessary.
If the hydraulic oil being fed to the VB port from the hydraulic pump is gradually decreased, the
hydraulic motor will rotate at a speed that is at or above the speed determined by the oil feed
volume due to inertial force. As a result, the pressure in the pilot chamber of the VB port side
is decreased and the spool (26) is pushed in the neutral direction to the left side by the spring
(28).
Accordingly, because the surface area of the MA → VA path is reduced and path resistance
increases, pressure on the MA side increases and the hydraulic motor is affected by brake
operation.
If the motor rotation speed falls to or below the speed determined by the oil feed volume, pres-
sure in the pilot chamber on the VB port side increases, the spool (26) moves to the right,
brake operation is reduced in order to increase the surface area of the MA → VA path, and the
rotation speed of the hydraulic motor is controlled to a speed that is equivalent to the oil feed
volume.
In order to perform stable counterbalance operations, orifices (40) are installed on the pilot
chambers on both ends in order to provide a damping effect on the spool (26).
The parking brake is released while the spool (26) is performing a pressure adjustment opera-
tion.
Diagram 12 Counterbalance operation

1 Spring
2 Pilot chamber
3 Check valve with orifice
130 SST-04-02-009EN
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2. Swing Motor
(1) Swing motor operation explanation
1) Hydraulic motor section
As the diagram below shows, when the high-pressure oil passes through the valve plate (1)
intake-side port (a) and flows into the cylinder, the hydraulic pressure operates on the piston
and a force F is generated in the axial direction. This force F is divided into 2 vectors, a force F1
perpendicular to the swash plate (3) via the shoe (2) and a force F2 perpendicular to the shaft.
This force F2 is transmitted to the cylinder block (4) via the piston, generating a rotational cou-
ple around the output shaft.
9 pistons are arrayed in the cylinder block. Rotation torque is transmitted sequentially to the
output shaft by multiple pistons linked with the high-pressure oil intake-side port.
When the oil in and out directions are reversed, the rotation of the output shaft also reverses.
The theoretical output torque T lbf•ft [N•m] is given by the following equation.
1 Piston
2 Drive shaft
Figure 1 Motor section operation explanation diagram

2) Valve casing section
[1] Anti-cavitation check valve section
Because the system using this type of motor does not have a valve with a counter-balance
function, the motor sometimes rotates more than the quantity of oil fed.
In order to prevent cavitation due to insufficient oil, there is a check valve to take in the oil
shortfall.
1 M port
Figure 2 Hydraulic circuit diagram 2 Control valve
SST-04-02-009EN 131
26
3) Brake section
The cylinder (111) is coupled with the drive shaft (101) by the gear. Also, the separator plate
(743) is constrained for circumferential rotation by the arc groove cut into the casing (301).
When the friction plate (742) that is gear coupled to the cylinder outer circumference section is
pressed to the casing (301) by the brake spring (712) via the separator (743) and the brake pis-
ton (702), friction force is generated between the friction plate and casing and between the sep-
arator plate and the brake piston. The drive shaft is constrained and braked by this friction
force.
On the other hand, when brake release pressure is applied to the oil chamber formed between
the brake piston and the casing and the hydraulic pressure wins out over the spring force, the
brake piston moves, the force pressing the friction plate against the casing disappears, and the
brake is released.
Spring
Hydraulic pressure
101
111
712
702
301
742
743
Figure 3 Brake operation diagram

1 Oil chamber
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4) Relief valve operation explanation (Relief valve model: KRD22EK10)
[1] Operation explanation for when the relief valve is pressurized
In the case where the P port is pressurized with the tank pressure,
the P and R ports are initially at the tank pressure and the valve status is as shown in dia-
gram 4 (1).
At the pressure where there is balance between the hydraulic pressure determined by the
product of the pressure P and the pressurized area A1 of the plunger (301) on the one hand
and the hydraulic pressure determined by the product of the spring (321) load FSP and
plunger (301) pressurized area A2 and the g chamber pressure Pg on the other, the relief
valve starts to operate.
After that, the g chamber pressure rises and the piston (302) starts its stroke. Accompanying
this movement, the load on the spring (321) increases.
Through the operation above, the relief pressure P is increased from P1 to Ps in the pres-
sure boost time t1.
This process is explained below in terms of the relationship between the movement state of
the parts in diagrams 4-(2) - (4) and the relief pressure.
1) State shown in diagram 4-(2)
When the relief valve P port is pressurized, pressure is generated in the g chamber via the
orifice m in the plunger (301).
When the hydraulic pressure operating on the plunger (301) increases and reaches the
pressure at which it balances the spring (321) load FSP, the relief valve carries out the
relief operation at pressure P1.
The relationship at this time is expressed by the following equation.
P1 × A1 = FSP1 + Pg1 × A2FSP1: Initial set load for the spring (321)
The g chamber pressure operates on pressurized areas A3 and A4 of the piston (302).
When this hydraulic pressure becomes larger than the load on the spring (321), the piston
starts to move to the left.
At this time, the oil in the h chamber formed between the piston and the adjusting plug
(401) is discharged into the g chamber via the orifice n set up on the piston (302) while the
piston moves to the left, so the h chamber functions as a damping chamber.
Through this, the spring load gradually increases until the piston reaches the adjusting
plug end section and the relief pressure P rises smoothly.
When the piston (302) reaches the adjusting plug (401) end section, it does not move far-
ther to the left, so the constant relief state is reached and the relief pressure is held at P2.
Through the processes (1) - (4) above, the relief pressure varies as in diagram 5.
[2] Operation explanation for when the relief valve is depressurized
In the case where the P port pressure falls,
the P port pressure and the g chamber pressure fall together to the tank pressure when the
pressurization of the P port ends. Through this, the plunger (301) which was open moves to
the left and is placed in the seat (401). At the same time, the piston (302) also is moved to
the right by the spring (321) and returns to the state in diagram 4-(1).
SST-04-02-009EN 133
28
Figure 4 Relief valve operation explanation diagram

1 Orifice m 5 A1 pressurized area
2 Spring (321) 6 Plunger (301)
3 Chamber h 7 Orifice n
4 Piston (302) 8 g chamber
Diagram 5 Pressure boost characteristics
134 SST-04-02-009EN
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(2) Swing motor internal diagram
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30
Code Part name Qty

Reverse prevention valve sub-
052 1 set
assembly
100 Casing 1
151 ROH plug 2
161 O-ring 2
162 O-ring 2
163 O-ring 2
171 Hexagon socket head bolt 4
400 Reverse prevention valve 2 set
400-1 O-ring 2
400-2 Backup ring 2
Code Part name Qty

051 Relief valve 2 set
051-1 O-ring 2
10 Piston subassembly 1 set
101 Drive shaft 1
111 Cylinder 1
114 Plate spring 1
121 Piston 9
122 Shoe 9
123 Holder plate 1
124 Shoe plate 1
131 Valve plate B 1
20 Valve casing H2 subassembly 1 set
301 Casing JA1 1
303 Valve casing H2 1
351 Plunger H2 2
355 Spring H2 2
390 Nameplate 1
391 Driving tack 2
443 Roller bearing 1
444 Roller bearing 1
451 Pin 2
469 ROMH plug 2
472 O-ring 1
488 O-ring 2
491 Oil seal 1
702 Brake piston 1
706 O-ring 1
707 O-ring 1
712 Brake spring 18
742 Friction plate 2
743 Separator plate 4
984 Masking plug 1 set
994 Insert plug 1
a Identification mark
136 SST-04-02-009EN
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NOTES:
Valve
1. Control Valve
Basic configuration
This valve is based on the main unit housing which combines the P1 side housing and P2 side
housing with the rear surfaces against each other and has a configuration that makes it possible
to mount the inlet, add-on section, and outlet on the P2 side housing top.
(1) Operation
[1] When all spools in neutral
1) Neutral path [Fig. 1, Fig. 2]
1. When Pn1 and Pn2 ports are pressurized
The oil fed from the P1 port enters the tank path (Ta) from the neutral path (L1) through
the low-pressure relief orifice (Lc1) and returns to T1 - T8 ports.
The oil fed from the P2 port enters the tank path (Ta) from the neutral path (R1) through
the low-pressure relief orifice (Rc1) and returns to the T1 - T8 ports.
The pressure in the pressure chambers (L2) and (R2) upstream from the low-pressure
relief valve is led into the pump from the ps1 and ps2 ports and controls the P1 and P2
pump discharge volume.
Also, if excess oil flows into the neutral path (L1), the poppet opens to provide low-pres-
sure relief. This prevents the ps1 and ps2 port pressures from becoming abnormally
high.
2. When Pn1 and Pn2 ports are not pressurized
In this case, the low-pressure relief poppets open at lower pressure than in (a).
Therefore, the oil fed from the P1 port enters the tank path (Ta) from the neutral path
(L1) primarily through the low-pressure relief valve discharge port (L3) and returns to
the T1 - T8 ports.
Also, the oil fed from the P2 port enters the tank path (Ta) from the neutral path (R1) pri-
marily through the low-pressure relief valve discharge port (R3) and returns to the T1 -
T8 ports.
137 SST-04-02-009EN
32
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33
1 Low-pressure relief valve (L) 6 Travel 11 Arm 2

2 Arm 1 7 Outlet 12 Boom 1
3 Boom 2 8 Attachment 2 13 Bucket
4 Swing 9 Inlet 14 Straight travel
5 Option 10 Attachment 1 15 Low-pressure relief valve (R)
139 SST-04-02-009EN
34
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35
1 Variable arm regeneration orifice 6 Travel 11 Boom 1

2 Arm 1 7 Attachment 2 12 Bucket
3 Boom 2 8 Attachment 1 13 Travel
4 Swing 9 Neutral cut 14 Straight travel
5 Option 10 Arm 2
141 SST-04-02-009EN
36
2) Signal, straight travel signal control valve, plate assembly [Fig. 3]
There are 2 signals, (a) and (b) below. The pilot signal for each spool for which a lever is
operated is used to generate the pressure that is output.
The straight travel signal control valve integrates each signal pressure and controls
straight travel spool switchover. Also, the plate assembly has a function for picking up the
pilot pressures with the built-in shuttle.
1. Travel signal (PT)
The highest of the pilot pressures applied to the travel section 1 (pa1, pb1) and travel
section 6 (pa6, pb6) is selected and output to the PT port.
Therefore, when the travel spool is in the neutral position (no-load pilot pressure), no
pressure is generated at the PT port.
SST-04-02-009EN 142
37
2. Front signal (PA)
The highest of the pilot pressures (pa2 - 9 and pb2 - 9) applied to sections 2 - 9 that use
the pressurized oil from the P1 and P2 pumps, except for the travel sections, is selected
and output to the PA port. (Note 1)
Therefore, when all the spools are in the neutral position (no-load pilot pressure), no
pressure is generated at the PA port.
Note: 1
When an add-on (main pump add-on) is used through the feed from P2, the branches for
the add-on pilot signals par1 and pbr1 are connected to the respective main unit valves,
prs1 and prs2 ports, and thus incorporated in the front signal PA selection area.
Be careful. If the above line connection is not done, the PA pressure will not rise through
add-on selection.
Also, when using 2 main pump add-ons, set the circuit so that maximum of the add-on pilot
pressures (par1 and 2, pbr1 and 2) can be taken out as desired and connect to either prs1
or prs2.
1 Straight travel signal control valve 6 Arm

2 Travel 7 Bucket
3 Main unit housing section (option) 8 Swing
4 Plate assembly 9 Option
5 Boom 10 Add-on (main pump)
143 SST-04-02-009EN
38
[2] Independent operation
1) Travel spool switchover [Fig. 4 and Fig. 5]
When a travel spool is switched by pressurizing from the travel (section 1) pilot port Pb1
(Pa1), the oil fed from the P1 port flows from the neutral path (L1) through the spool neck
section and into the B1 (A1) port. The return oil returns to the tank path (Ta) from the A1
(B1) port through the spool neck section.
When a travel spool is switched by pressurizing from the travel (section 6) pilot port Pb6
(Pa6), the oil fed from the P2 port flows from the neutral path (R1) through the spool neck
section or path (S6-1) and into the B6 (A6) port.
When only travel is operated, the parallel path (R3) and the path (S6-1) have the same
pressure, so the poppet (S6-2) does not open. The return oil returns to the tank path (Ta)
from the A6 (B6) port through the spool neck section.
SST-04-02-009EN 144
39
1 Switching state
2 Neutral state
3 Option
4 Travel
1 Switching state
2 Neutral state
3 Travel
4 Straight travel
145 SST-04-02-009EN
40
2) Option spool switchover [Fig. 4]
When the option spool is switched by pressurizing from the option (section 2) pilot port
Pb2 (Pa2), the neutral path (L1) is closed. The oil fed from the P1 port flows from the par-
allel path (L3) through the load check valve (S2-2), path (S2-1), and the spool neck sec-
tion, and into the B2 (A2) port.
The return oil returns to the tank path (Ta) from the A2 (B2) through the spool neck section.
Also, when oil is fed from the P4 port, it passes through the inside of the load check valve
(S2-2) and merges with path (S2-1).
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41
1 Switching state
2 Neutral state
3 Option
4 Travel
1 Switching state
2 Neutral state
3 Travel
4 Straight travel
147 SST-04-02-009EN
42
3) Swing spool switchover [Fig. 6]
When the swing spool is switched by pressurizing from the swing (section 3) pilot port Pb3
(Pa3), the neutral path (L1) is closed. The oil fed from the P1 port flows from the parallel
path (L3) through the load check valve (S3-2), path (S3-1), and the spool neck section,
and into the B3 (A3) port.
The return oil returns to the tank path (Ta) from the A3 (B3) through the spool neck section.
1 Switching state 3 Swing

2 Neutral state 4 Bucket
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43
4) Bucket spool switchover [Fig. 7 and Fig. 8]
1. Close (regeneration) [Fig. 7]
When the bucket spool is switched by pressurizing from the bucket (section 7) pilot port
Pb7, the neutral path (R1) is closed. The oil fed from the P2 port flows through the par-
allel path (R3), the load check valve (S7-2), path (S7-1), and the spool neck section,
and into the B7 port.
At the same time, the return oil from the A7 port returns to the tank path (Ta).
After part of the return oil pushes open the poppet (S7-3) inside the bucket spool, it
merges into the B7 port to prevent cylinder head side cavitation.
This is also accompanied by cylinder speed increases and P2 port pressure reductions
depending on the port pressure conditions.
Bucket close (regeneration)
1 Neutral state 3 Swing

2 Switching state 4 Bucket
149 SST-04-02-009EN
44
2. Open [Fig. 8]
When the bucket spool is switched by pressurizing from the bucket (section 7) pilot port
Pa7, the neutral path (R1) is closed. The oil fed from the P2 port flows through the par-
allel path (R3),
the load check valve (S7-2), path (S7-1), and the spool neck section, and into the A7
port.
The return oil returns to the tank path (Ta) from the B7 port through the spool neck sec-
tion.
Bucket open
1 Neutral state 3 Swing

2 Switching state 4 Bucket
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45
5) Boom spool switchover [Fig. 9, Fig. 10, and Fig. 11]
1. Neutral [Fig. 9]
This valve mounts an anti-drift valve on the boom 1 cylinder head (A8) side.
In neutral, the poppet (AD1) is reliably seated by the pressure of the A8 port itself led
through path (AD2) and the spool (AD3) into the spring chamber (AD4) to cut off the
return oil from the A8 port.
Neutral
1 Boom 2
2 Boom 1
151 SST-04-02-009EN
46
2. Boom up (2 pumps flow) [Fig. 10]
When the boom 1 spool is switched by pressurizing from the boom 1 (section 8) pilot
port Pa8, the neutral path (R1) is closed. The oil fed from the P2 port flows through the
parallel path (R3), the load check valve (S8-2), and the spool neck section and into the
A8 port.
port Pa4, the neutral path (L1) is closed. The oil fed from the P1 port flows through the
parallel path (L3), the load check valve (S4-2), the spool neck section, and path (4) and
merges into the A8 port. The return oil returns to the tank path (Ta) from the B8 port
through the spool neck section.
Up (2 pumps flow)
1 Boom 2
2 Boom 1
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47
3. Boom down (regeneration) [Fig. 11]
port pb8, the neutral path (R1) is closed. The oil fed from the P2 port flows through the
parallel path (R3), the load check valve (S8-2), and the spool neck section and into the
B8 port.
The pilot pressure applied to pb8 at this time moves the anti-drift valve spool (AD3)
through the path built into the housing at the same time that the spool is switched and
reduces the pressure of the spring chamber (AD4) to open the poppet (AD1).
Through this movement, the cutoff of the A8 port is released before the spool is
switched.
After that, the return oil from the A8 port returns to the tank path (Ta).
Part of the return oil pushes open the poppet (S8-3) inside the boom 1 spool, passes
through path (S8-1), and merges into the B8 port to prevent cylinder rod side cavitation.
This is also accompanied by cylinder speed increases and P2 port pressure reductions
depending on the port pressure conditions.
Down (regeneration)
1 Boom 2
2 Boom 1
153 SST-04-02-009EN
48
6) Arm spool switchover [Fig. 12 - 15]
1. Neutral [Fig.12]
This valve mounts an anti-drift valve on the arm 1 cylinder rod side.
In neutral, the poppet (AD1) is led through path (AD2) and the spool (AD3) into the
spring chamber (AD4). It is reliably seated by the pressure of the A5 port itself to cut off
the return oil from the A5 port.
Neutral
1 Arm 1
2 Arm 2
SST-04-02-009EN 154
49
2. Arm in (2 pumps flow) [Fig. 13]
When the arm 1 spool is switched by pressurizing from the arm 1 (section 5) pilot port
Pb5, the oil fed from the P1 port flows from the neutral path (L1) through the load check
valve (S5-2), path (S5-1), and the spool neck section and into the B5 port. When the
arm 2 spool is switched by pressurizing from the arm 2 (section 9) pilot port Pb9, the oil
fed from the P2 port flows from the neutral path (R1) through the load check valve (S9-
2), path (S9-1), the spool neck section, and path (6) and merges into the B5 port.
The pilot pressure applied to pb5 at this time moves the anti-drift valve spool (AD3)
through the path built into the housing at the same time that the spool is switched and
reduces the pressure of the spring chamber (AD4) to open the poppet (AD1). Through
this movement, the cutoff of the A5 port is released before the spool is switched.
After that, the return oil from the A5 port splits into the flow through the regeneration
check valve in the spool that is regenerated at the B5 port and the flow returning to the
tank path (Ta) through the regeneration control valve.
(For details on the regeneration function, see the regeneration valve operation explana-
tion in next section 3).)
Arm in (2 pumps flow)
1 Arm 1
2 Arm 2
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3. Arm in (variable regeneration) [Fig. 14]
For an arm-in operation, after the return oil from the A5 port passes through the notch
(a), it divides into 2 paths:
1. The return oil returns to the tank path (Ta) through the fixed orifice (d) in the regener-
ation control valve, path (e), and the variable orifice (f).
2. The return oil passes through the fixed orifice (b) in the arm 1 spool, the regenera-
tion check valve (c), and the fixed orifice (i), then merges into the bridge path (S5-1).
Here, when the bridge path (S5-1) pressure goes higher due to the port B5 load pres-
sure, the regeneration control valve spool (h) is pressed through the regeneration con-
trol valve piston (g), and the variable orifice (f) section opening surface area increases,
so the quantity of oil returning to the tank path (Ta) increases.
On the other hand, the quantity of oil regenerated in the B5 port decreases.
Though this variable mechanism, both the regeneration ratio for low loads is secured
and reduction in the return back pressure for high loads is established.
Arm in (variable regeneration)
1 Regeneration control valve (variable)

2 Arm 1
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4. Arm out (2 pumps flow) [Fig. 15]
Pa5, the oil fed from the P1 port flows from the neutral path (L1) through the load check
valve (S5-2), path (S5-1), and the spool neck section and into the A5 port.
Pa9, the oil fed from the P2 port flows from the neutral path (R1) through the load check
valve (S9-2) and path (S9-1), merges into the arm 1 section path (S5-1) and heads
toward the A5 port through the arm 1 spool neck section. The return oil from the B5 port
returns to the tank path (Ta) through the spool neck section.
Arm out (2 pumps flow)
1 Arm 1
2 Arm 2
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7) Arm parallel orifice [Fig. 16]
Metering by the spool is installed in the arm 1 parallel path of this valve to control the quan-
tity of oil fed to arm 1 for compound operations.
The oil fed from the arm 1 (Section 5) parallel path (L3) pushes open the poppet (S5-3)
and passes through the variable metering spool orifice (Lc8), then is connected to path
(L5).
Here, the quantity metered by the orifice (Lc8) is adjusted by pressurizing the pilot port
(Pbu).
1 Low-pressure relief valve (L) 3 For boom up (for Pbu pressurization)

2 Pbu signal path 4 For neutral
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8) Relief valve
1. Main relief valve [Fig. 17]
The oil fed from the P1 port passes through the poppet (LP) and the oil fed from the P2
port passes through the poppet (RP) and path (3) and is led to the main relief valve.
The maximum pressure of the P1 and P2 side pumps is controlled by the operation of
the main relief valve.
2. Overload relief valve [Fig. 18]

There is an overload relief valve at the boom 1, arm 1, bucket, and add-on cylinder
ports to prevent any abnormal rise in actuator pressure, for example due to an external
force.
This relief valve is also equipped with a function for preventing cavitation (suction func-
tion) by taking in oil from the tank when the cylinder port pressure becomes negative
pressure.
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[3] Compound operation
1) Travel compound operation [Fig. 19, Fig. 20]
Under the conditions below when the travel left/right and the front system are operated at
the same time, the straight travel spool is switched, and the straight travel characteristic is
maintained.
1 When the front is operated during travel left/right simultaneous operation (forward,
backward, or pivot turn)
2 When the left/right are operated simultaneously during front system operation
Front system operation is not affected by the switchover section or quantity of switchovers.
1. Signal circuit [Fig. 19]
(A)When the [Travel 1] side lever is operated, the pressure branched off from the valve
main unit pilot port passes through the filter and the shuttle, then switches the
switchover valve [V1].
(B)When the [Travel 2] side lever is operated, the pressure branched off from the valve
main unit pilot port passes through the filter and the shuttle, then if the switchover
valve [V1] is switched, it switches the switchover valve [V2] through the path. On the
other hand, if the switchover valve [V1] is in the neutral state, the path is cut off by
the switchover valve [V1]. Therefore, if both (A) and (B) are established at the same
time, the straight travel spool internal path (Pst) is conducted to PA. Also, if either (A)
or (B) are established, the travel signal (PT) pressure rises.
(C)If at least one of the front systems is switched, the highest pressure of all the pilot
pressures in the front system is selected and is conducted to the front signal port
(PA). Therefore, if (A), (B), and (C) are established at the same time, the straight
travel spool switchover quantity is determined proportional to the front signal (PA)
pressure through the internal straight travel signal path (Pst). [Fig. 19] shows the
example of a case of travel left/right forward + boom up.
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1 Straight travel signal control valve 5 Boom 9 Option

2 Travel 1 6 Arm 10 Add-on (main pump)
3 Travel 2 7 Bucket 11 Main unit housing section (option)
4 Plate assembly 8 Swing
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2. Main unit circuit [Fig. 20]
When the straight travel spool is switched, the oil fed from the P1 port flows from the
neutral path (L1) to travel (section 1) and at the same time passes through path (2), the
straight travel spool neck section, and the neutral path (R1) and into travel (section 6)
and feeding to travel left and right becomes possible.
On the other hand, when the oil fed from the P2 port flows to the parallel path (R3), at
the same time it passes through the straight travel spool neck section and path (1) and
into the parallel path (L3), so it becomes possible to feed oil to the entire front system.
When the front system is switched during travel and that pressure becomes higher than
the load pressure on travel (section 6), part of the oil fed from the P2 port pushes up the
poppet (S6-2) from the parallel path (R3) and the oil flows through the orifice at the pop-
pet tip and merges into path (S6-1).
This softens the shock on the machine body of the sharp drop in speed caused by the
switchover to 1 pump travel.
As described above, because travel (sections 1 and 6) operates with the oil fed from the
P1 port and operations other than travel are operated with oil fed from the P2 port,
travel curving is prevented and straight travel characteristics are maintained during
compound operations.
1 Switching state 3 Straight travel

2 Travel 4 Travel
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[4] Anti-drift valve
The anti-drift valve is mounted on the arm rod (boom head) side cylinder port to prevent the
arm (boom) cylinder from dropping naturally.
Also, the release signal operates led by the internal path from the pilot signal.
(The arm side (A5) is shown as a typical example.)
1) Neutral (A5 port hold)
1. The A5 port hold pressure passes from path (a) through path (b), through path (c), and
is conducted to the poppet (1) spring chamber (d).
2. Therefore, the A5 port pressurized oil is cut off by the seat section (S1) and the seat
section (S2).
1 Main spool
2) Release signal application

1. When the pi port is pressurized, the piston (2) moves and the spool (3) operates.
2. Furthermore, the spool (3) operates the poppet (4).
3. Then, the operation of the poppet (4) cuts off the conduction between the A5 port and
the spring chamber (d).
1 Main spool
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3) Ending hold state
1. When the piston (2) operates further, the spring chamber (d) passes from path (c)
through path (e) and is conducted to the drain chamber [DR] through the (T2) section.
2. The spring chamber (d) pressure becomes the drain pressure and the main poppet (1)
operates.
1 Main spool
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[5] Relief valve
1) Main relief valve operation
1. This relief valve is incorporated between the neutral path "HP" and the low-pressure
path "LP". The oil passes through the metering hole of the main poppet (C) and charges
the interior space (D). The sleeve (E) and the main poppet (C) operating on the different
surface areas [A] and [B] are seated securely.
2. When the neutral path "HP" pressure reaches the set pilot poppet spring force, the pilot
poppet (F) opens. The oil flows around the poppet, passes through the notch hole (G),
and is led to the low-pressure path "LP".
3. Because the pilot poppet has opened, the (D) pressure drops and the main poppet (C)
opens, so the oil flows directly into the path "LP".
"Boosted pressure operation"

When pressure is applied to the pilot port "PH", the piston (H) is moved to the set posi-
tion by the plug (I). Because of this, the pilot spring force rises and the "HP" pressure
rises.
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2) Overload relief valve operation
1. This relief valve is incorporated between the cylinder port "HP" and the low-pressure
path "LP". The oil passes through the metering hole of the piston (C) and charges the
interior space (G). The sleeve (K) and the main poppet (D) operating on the different
surface areas [A] and [B] are seated securely.
2. When the cylinder port "HP" pressure reaches the set pilot poppet spring force, the pilot
poppet (E) opens. The oil flows around the poppet, passes through the notch hole (H),
and is led to the low-pressure path "LP".
3. Because the pilot poppet (E) has opened, oil flow is generated through the orifice (I) of
the piston (C), a pressure difference is generated between the path "HP" and the rear
side of the piston (C), and the piston (C) moves and is seated with the poppet (E).
4. The flow of oil from the path "HP" to the rear side of the poppet (D) is only through the
ring-shaped gap between the poppet (D) and the piston (C) and through the orifice (F),
so the pressure difference increases.
Because of this, the poppet (D) opens and the oil flows directly into the path "LP".
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3) Overload relief valve intake operation
1. This relief valve has a built-in anti-void unit that supplies oil if cavitation occurs at the
cylinder port "HP".
When the cylinder port "HP" pressure is lower than the low-pressure side "LP", the
sleeve (K) is opened by the surface area difference between (A) and (B). Oil enters the
cylinder port "HP" from the low-pressure side "LP" to prevent cavitation.
[6] Neutral cut spool [Fig. 21]

This valve is equipped as standard with a neutral cut spool in the P2 side housing neutral
path (R1) minimum flow (low-pressure relief valve upstream).
When the pcc port is pressurized and the neutral cut spool is switched, the path through the
orifice [Lc7] to low-pressure relief is cut off and output to the outside from the P3 port
becomes possible.
1 Low-pressure relief valve (R)
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[7] Plate assembly [Fig. 22]
This valve is equipped with a plate assembly hermetically sealed with a gasket piling a plate
on the housing side surface.
The shuttle is built into the inside and this valve has a function for selecting and controlling
the spool pilot pressure.
Also, in order to protect the shuttle section from contamination from the outside, a filter is
mounted between the plates.
When removing, do not loosen the screws shown in the diagrams and be careful that inter-
nal parts are not dispersed.
[Long cap side] [Short cap side]

1 Subassembly screw
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[8] Straight travel signal control valve [Fig. 19, Fig. 23]
This valve integrates the pilot pressure for the spool of the front system and travel selected
with each plate assembly and is used to switch the straight travel spool.
When the Travel 1 pilot pressure is pressurized, the spool [V1] is switched.
When the Travel 2 pilot pressure is pressurized at the same time, the spool [V2] can be
switched.
Here, when the front system pilot pressure [PA] is pressurized, the PA pressure flows into
Pst and is led to the straight travel spool pilot chamber and the spool is switched.
1 Straight travel signal control valve 5 Boom 9 Option

2 Travel 1 6 Arm 10 Add-on (main pump)
3 Travel 2 7 Bucket 11 Main unit housing section (option)
4 Plate assembly 8 Swing
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[9] Add-on [Fig. 24, Fig. 25]
1) Add-on main relief valve
The oil fed from the Pr port is led to the main relief valve. The Pr pump maximum pressure
is regulated by the operation of the main relief valve.
2) Spool section
When the spool is pressurized from the add-on (Section 10) pilot port par1 (pbr1) and
switched, the neutral path [Pg] is closed. The oil fed from the Pg port flows from the paral-
lel path [Rg] through the load check valve [S10-1], the path [S10-2], and the spool neck
section, and into the AR1 (BR1) port.
The return oil returns to the tank path [Ta] from the BR1 (AR1) through the spool neck sec-
tion.
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3) Low-pressure relief valve operation [Fig. 26, Fig. 27]
1. Signal pressure generation (when pin1 (pin2) port pressurized)
The oil fed from the pump port (P1 (P2)) flows through the neutral path (L1 (R1)), then
flows from the low-pressure relief path (L2 (R2)) through the orifice (Lc1 (Rc1)) and out
into the tank path (Ta).
At this time, the pressure generated in path (L2 (R2)) by the orifice (Lc1 (Rc1)) is led to
the low-pressure relief signal port (Ps1 (Ps2)).
When the (L2 (R2)) upstream main spool operates, the oil flowing through (L2 (R2)) is
reduced, so the (Ps1 (Ps2)) signal pressure becomes lower.
2. Relief operation
When excess oil flows in path (L2 (R2)), the poppet is operated by the pressure gener-
ated in path (L2 (R2)) by the orifice (Lc1 (Rc1)).
Through this poppet operation, the oil flows from the path, through the notch hole path,
and out to the tank path [Ta]. This prevents the generation of excess pressure at the
low-pressure relief signal port.
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4) Add-on main relief valve
1. Add-on main relief valve operation
This relief valve is incorporated between the neutral path "HP" and the tank path "LP".
The oil passes through the metering hole of the main poppet [1] and charges the inte-
rior space [C].
Also, the sleeve [2] and the main poppet [1] operating on the different surface areas "A"
and "B" are seated securely.
2. When the neutral path "HP" pressure reaches the set pilot spring force, the pilot poppet
[3] opens.
The oil flows around the pilot poppet [3], passes from the notch hole [E] and through the
ring-shaped gap [D] and is led to the tank path "LP".
3. Because the pilot poppet [3] has opened, the interior space [C] pressure drops and the
main poppet [1] opens, so the "HP" oil flows directly into the path "LP".
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2. 5 Stack Solenoid Valve Operation Explanation
(1) External shape diagram and component parts
This valve is made up of the body and the electromagnetic switchover valve.
Normal closed-type solenoid: SP, S1, S3 Normal open type solenoid: S2 4 port-type solenoid: S4
1 Electromagnetic switchover valve
2 Body
(2) Operation explanation
Hydraulic circuit diagram

The pressurized oil fed from the P port feeds pressurized oil to the C1 - C5 ports according to the
excitation or non-excitation of electromagnetic switchover valves S1 - S4 resulting from exciting
electromagnetic switchover valve SP.
Electromagnetic switchover valves S1 and S3 → Oil passing through when valve excited
Electromagnetic switchover valve S2 → Oil passing through when valve not excited
Oil passing to C5 when valve excited
Electromagnetic switchover valve S4 → Oil passing to C4 when valve not excited
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3. Upper Pilot Valve (remote control valve)
(1) Structure
The structure of the remote control valve is as shown in the assembly cross-section diagram
(page 178). There is a longitudinal axial hole in the casing and the pressure reduction valve is
installed in it.
The pressure reduction valve comprises the spool (201), secondary pressure setting spring
(241), return spring (221), spring seating (216), and washer 2 (217). The secondary pressure
setting spring (241) is set so that the secondary pressure calculation is 72.5 PSI - 145 PSI (0.5-1
MPa) (depending on the model). The spool (201) is pressed against the push rod (212) by the
return spring (221).
When the push rod (212) is pushed down by tilting the handle or another operation, the spring
seating goes down at the same time and the secondary pressure setting spring (241) setting is
changed.
The casing (101) has the oil inlet (primary pressure) port P and the outlet (tank) port T and, fur-
thermore, the secondary pressure is taken out from the ports 1, 2, 3, and 4.
(2) Function
[1] Basic functions
The remote control valve is for controlling the control valve spool stroke quantity, direction,
etc. This is done by operating the pilot valve output pressure on the control valve spool end
section.
In order to satisfy this function, the remote control valve is made up of the following ele-
ments.
1) Inlet port (P) to which the oil is fed from the hydraulic pump
2) Multiple output ports (1, 2, 3, 4) for operating the feed pressure from the inlet port on the
control valve spool end
3) Tank port (T) required for controlling the above output pressure
4) Spool connecting the output port to the inlet port or tank port
5) Mechanical means including a spring operating on the above spool in order to control the
output pressure
[2] Main part functions
The function of the spool (201) is to switch the oil path either to have the hydraulic pressure
fed from the hydraulic pump received by the P port and lead the P port pressurized oil to the
output ports (1, 2, 3, and 4) or to lead the output port pressurized oil to the T port. The out-
put pressure operating on this spool (201) is determined by the secondary pressure setting
spring (241).
In order to change the deflection quantity of the secondary pressure setting spring (241), the
push rod (212) is inserted into the plug (211) in such a way that it can slide.
The return spring (221) operates on the casing (101) and spring seating (216) and operates
to return the push rod (212) in the displacement zero direction regardless of the output pres-
sure and makes the spool (201) neutral return reliable. It also has the effect of a counter-
force spring for giving an operator an appropriate operation feel.
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(3) Operation
Operation of the remote control valve is explained based on the hydraulic circuit diagram (dia-
gram 1) and operation explanation diagrams (diagram 2 - diagram 4). Diagram 1 is a typical
usage example for the remote control valve.
Diagram 1 Remote control valve usage example

1 Pilot valve 4 Control valve
2 Pilot pump 5 Hydraulic motor
3 Main pump 6 Hydraulic cylinder
[1] When the handle is in neutral (See diagram 2.)

The force of the secondary pressure setting spring (241) that determines the remote control
valve output pressure does not operate on the spool (201). Therefore, the spool (201) is
pushed up by the return spring (221) (spring seating (216)) and the output ports (2 and 4)
are connected with the T port. Therefore, the output pressure is the same as the tank pres-
sure.
Diagram 2 When the handle is in neutral
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[2] When the handle is tilted (See diagram 3.)
When the handle is tiled and the push rod (212) is moved through a stroke, the (spring seat-
ing (216)) spool (201) moves down and the oil fed from the pilot pump flows out to the ports
(2 and 4) through the P port and the ports (2 and 4) and pressure is generated.
Diagram 3 When the handle is tilted

[3] When the handle is held (See diagram 4.)
When the handle is tilted and the pressure of the ports (2 and 4) rises to a pressure equiva-
lent to the set spring force (241), the hydraulic pressure and the spring force are in balance.
When the ports (2 and 4) pressure becomes higher than the set pressure, the ports (2 and
4) and the P port close and the ports (2 and 4) and the T port open. When the ports (2 and
4) pressure becomes lower than the set pressure, the ports (2 and 4) and the P port open
and the ports (2 and 4) and the T port close, so the secondary pressure is held constant.
Diagram 4 When the handle is held

(secondary pressure at or above set pressure)
1 T port
2 P port
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[4] Operation in area in which the handle tilt is large (depends on the model)
For certain models, when the handle is flipped down beyond a certain angle, the spool top
end section touches the push rod bore bottom section and the output pressure goes into the
state of still being connected with the P port pressure.
Furthermore, with the structure in which the spring seating and spring are installed inside
the push rod, when the handle is flipped down beyond a certain angle, the push rod bore
bottom section and the spring touch. That spring force changes the 2nd pressure gradient
and after that the push rod bore bottom section and the spring seating top end section
touch, and the output pressure remains connected to the P port.
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72
(4) Structural diagram
Code Part name Q'ty Code Part name Q'ty

101 Casing 1 217 Washer 2 4
151 Plate 1 221-1 Spring (port 1) 1
201 Spool 4 221-2 Spring (port 3) 1
211 Plug 4 221-3 Spring 2
212-1 Push rod 2 241-1 Spring 2
212-2 Push rod 2 241-2 Spring 2
213 Seal 4 301 Joint 1
214 O-ring 4 302 Disk 1
216-1 Spring seating 1 2 312 Adjusting nut 1
216-2 Spring seating 1 2 501 Bellows 1
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4. Travel Pilot Valve (remote control valve)
(1) Operation
The remote control valve with built-in damper (referred to below as remove control valve with
damper) is a remote control valve with a damping function for preventing the man-machine sys-
tem hunting (lever hunting) phenomenon installed in the remote control valve main unit.
Operation of the remote control valve with damper is divided into the 4.-(1)-1) Pressure reduction
valve section and the 4.-(1)-2) Operation section damping mechanism section. The explanations
in these 2 sections are based on the hydraulic pressure circuit diagram, assembly section dia-
gram, and damping operation explanation diagram below. The diagram below is a typical usage
example for the remote control valve.
Hydraulic circuit diagram

1 Remote control valve 4 Control valve
2 Pilot pump 5 Hydraulic motor
3 Main pump 6 Hydraulic cylinder
1) Pressure reduction valve section

[1] For the neutral state
The spool (301) is pushed up by the return spring (335) via the spring seating (311) and
washer 1 (215) and is in the neutral position shown in the assembly cross-section diagram.
Therefore, since the output port is connected only to port T by the spool switching function,
the pressure at output ports 1 and 2 is the same as the pressure at port T.
[2] When the remote control valve operation section is tilted from the neutral state
In the assembly cross-section diagram, when the cam (420) is rotated clockwise, the port 1
side push rod (214) is pushed down, the spool moves down via washer 1, the spring seating,
the secondary pressure setting spring (324), washer 2 (217), and washer 3 (313), the port P
and port 1 are connected, and the oil fed from the pilot pump flows to port 1 and generates
pressure.
When the port 1 pressure rises to the pressure equivalent to the secondary pressure setting
spring force that has been set by tilting the operation section, the hydraulic pressure on the
spool and the spring force come into balance and the port 1 output pressure is held con-
stant. The port 2 spool stays in the neutral state and the oil from the control valve is dis-
charged via port T.
Some specifications are of the type that near the maximum angle of the operation section, a
push rod directly touches the spool top section and forcibly pushes in the spool to connect
port P and the output port so that they have the same pressure.
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74
2) Operating section damping mechanism section
[1] For the neutral state
The push rod is pushed up by the damping springs (333 and 337) via the piston (224) and is
in the position shown in the assembly cross-section diagram.
[2] When the operation section is tilted from the neutral state (See Damping operation explana-
tion diagram (1).)
In the assembly cross-section diagram, when the cam is rotated clockwise, the port 1-side
push rod is pushed down and the piston moves down.
At this time, the oil in the damping piston chamber is discharged from the piston metering
hole and the pressure generated at this time generates damping force.
On the other hand, the port 2-side push rod is moved up by the damping spring via the pis-
ton.
At this time, the tank chamber oil is suctioned in through the 3 ball check sections made up
of bushings (223) and steel balls (225) and into the damping piston chamber. The oil outside
the piston chamber drains out from the path that leads from the casing top end section to
port T.
[3] When the operation section is tilted back from a full tilt (See Damping operation explanation
diagram (2).)
In the assembly cross-section diagram, after the cam is fully tilted clockwise then rotated
counter-clockwise, the port 2 push rod is pushed down and the piston moves down.
At this time, as described above, the oil in the damping piston chamber is discharged from
the piston metering hole and the pressure generated at this time generates damping force.
On the other hand, the port 1 push rod is moved up by the return spring (335) and the damp-
ing spring.
At this time, the tank chamber oil is suctioned in through the 3 ball check sections made up
of bushings and steel balls and into the damping piston chamber. Also, the oil outside the
piston chamber drains out from the path that leads from the casing top end section to the
tank port.
In other words, the structure is such that damping force works for either tilt operation, from
the neutral position to the full tilt position or from the full tilt position to the neutral position.
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Damping operation explanation diagram
[1] Operation when lever is moved through its stroke from the neutral position
1 Push rod
2 Orifice
3 Piston
4 Piston chamber
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[2] Lever stroke state and operation when lever is moved back
5 Oil
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(2) Structural diagram

101 Casing 1 271 Hexagon socket head bolt 2
151 Plug 2 301 Spool 4
201 Cover 2 311 Spring seating 4
202 Plug 4 313 Washer 3 4
203 Grease cup 4 324 Spring 4
210 NHU packing 4 335 Spring 4
212 O-ring 4 336 Spring 4
214 Push rod 4 337 Spring 4
215 Washer 1 8 412 Bushing 4
217 Washer 2 4 413 Camshaft 2
218 Spring seating 4 420 Cam 2
221 Locking ring 4 423 Hexagon socket head locking screw 2
223 Bushing 4 471 Locking screw 4
224 Piston 2D085 4 472 Lock nut 4
225 Steel ball 12 501 Bellows 2
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5. Cushion Valve
[1] Valve summary
This valve is made up of a shuttle valve section and cushion valve section with a heat circuit.
The cushion valve with a heat circuit is connected between the hydraulic shovel control valve and
the pilot operation valve to reduce body shaking (cushion function) caused by emergency stop
operations by the operator.
This valve is also equipped with a circuit with which the operator can deliberately disable the
cushion function for reverse operations.
The shuttle valve selects the high-pressure signal pressure from 2 signal pressure systems. This
valve has 2 circuits.
Diagram 1 External shape diagram
Diagram 2 Hydraulic system diagram
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[2] Operation explanation
1) Normal operation
The pressurized oil fed from the A port (or C, E, or G port) pushes up the check plunger and is
sent to the B port (or D, F, or H port). The pressurized oil that has passed through the B port
operates on the control valve spool and operates the actuator. The oil pushed out from the con-
trol valve spool passes through the D port (or B, F, or H port) and flows out to the T port.
Diagram 3
2) Cushion operation
When the pressurized oil fed from the pilot operation valve to the A port (or C, E, or G port) is
closed by the pilot operation valve, the pressurized oil that has operated on the control valve
spool is pushed back to the B port (or the D, F, or H port) by the return spring on the spool. The
returned oil passes through the check plunger metering orifice, is sent to the A port (or the C, E,
or G port), and is drained from the pilot operation valve. At this time, by passing through the
metering orifice, the pressurized oil holds down the control valve spool speed and reduces
shaking of the body. (Cushion function)
Diagram 4
SST-04-02-009EN 185
80
3) Reverse operation
When the pressurized oil fed from the pilot operation valve to the A port (or C, E, or G port) is
switched to the C port (or A, E, or G port), the pressurized oil that has operated on the control
valve spool is pushed back to the B port. Because the pushed back oil flows out to the T port
without passing through the check plunger metering orifice, it does not hold down the control
valve spool speed, so the cushion function does not work.
Diagram 5
4) Heat circuit
When the pilot operation valve is in the neutral position, the oil fed to the R port passes through
the inside of the reverse operation spool, flows out to the T port, and heats up the inside of the
valve.
When pressurized oil is being fed from the pilot operation valve to the A port (or C, E, or G
port), the oil fed to the R port flows out to the C port (or A, E, or G port) and heats up the circuit
to the pilot operation valve and inside the valve.
Diagram 6 Diagram 7
186 SST-04-02-009EN
81
5) Shuttle valve
In the pressure between the I and J ports and the pressure between the K and L ports, the steel
ball is pressed from the high pressure to the low pressure. Through this process, the high-pres-
sure oil is fed to the S port or the Q port. In the same way, oil is fed to the U port at the higher of
the pressures between the M and N ports and between the O and P ports.
Diagram 8 Diagram 9
SST-04-02-009EN 187
82
6. Selector Valve (4-way)
(1) Structure
Circuit diagram
Operation, work
A Right valve, retraction 1 Boom, up
B Right valve, left side 2 Bucket, digging
C Right valve, push out 3 Boom, down
D Right valve, right side 4 Bucket, dirt removal
E Left valve, push out 5 Swing, right
F Left valve, right side 6 Arm, digging
G Left valve, pull in 7 Swing, left
H Left valve, left side 8 Arm, dirt removal
Circuit combination table

Type I: Type S: Type M: Type K:
ISO Old Sumitomo Old Mitsubishi Old Kobelco
A-1 A-1 A-8 A-6
B-2 B-2 B-7 B-7
C-3 C-3 C-6 C-8
D-4 D-4 D-5 D-5
E-8 E-5 E-3 E-3
F-5 F-6 F-2 F-2
G-6 G-7 G-1 G-1
H-7 H-8 H-4 H-4
188 SST-04-02-009EN
83
Diagram 1 Valve structure

1 Name plate 9 Cover 17 Steel ball
2 Pin 10 Lever 18 Oil seal
3 Spring 11 Plug with flange 19 O-ring
4 Knob 12 Hexagon socket head bolt 20 O-ring
5 Cover 13 Hexagon socket head bolt 21 O-ring
6 Spring 14 Rivet screw 22 Hexagon socket head plug
7 Casing 15 Spring pin
8 Shaft 16 Spring pin
SST-04-02-009EN 189
84
This valve is a rotation type switch valve.
By connecting a line between the hydraulic shovel work remote control valve and the main con-
trol valve and changing the lever (10) to the position for each type (rotating the shaft (8)), the
valve circuit has been changed and the operation type changed to that in Diagram 2.
For details on the valve structure (circuit diagram), see Diagram 1.
Diagram 2 Operation method by type
190 SST-04-02-009EN
85
(3) Development diagram
SST-04-02-009EN 191
86
7. Direction Valve (3-direction)
(1) Structure
Z-Z section
Circuit diagram
Diagram 1
1 Cover 5 Body 9 Hexagon socket head bolt
2 Name plate 6 Cover 10 Hexagon socket head bolt
3 Spool 7 Spring 11 Rivet screw
4 Spring 8 Hexagon socket head bolt 12 O-ring
192 SST-04-02-009EN
87
This valve switches the direction with the pilot pressure.
[1] When the spool is in neutral (PP port no load) Double-acting circuit,
2 pumps flow circuit selected
When the pilot pressure is not fed to the PP port, the spool (3) is held in the neutral position
by the spring (4) and (7). The A port and the B port are conducting and pressurized oil from
the T1 and T2 ports is cut off by the spool (3). (See diagram 2.)
Diagram 2
[2] When the spool operates (PP port pressurized) Breaker circuit selected
When pressure is fed to the PP port, force [F] (PP port pressure × spool cross-sectional
area) works on the spool (3) in the left direction. When F becomes larger than the set load of
springs (4) and (7), the spool (3) moves to the left and the A port is conducted to the T1 and
T2 ports.
Also, at this time, the pressurized oil at the B port is cut off by the spool (3). (See diagram 3.)
Diagram 3
SST-04-02-009EN 193
88
NOTES:
Explanation of New Functions SH200
Electrical

Work Mode Select Switch
The Throttle Volume and Work Mode Select Switch are Linked!!
1 SST-05-00-008EN
1
[1] Flow of throttle control
With Model 3B, the throttle volume signal is connected directly to the ECU and only the work
mode signal instruction is sent from the main unit computer. With Model 5, the throttle volume
signal first goes to computer A, then the target engine speed instruction is sent from computer A
to the ECM.
1 Throttle volume
2 Computer A
3 CAN communication
4 Engine
5 UART communication
6 Monitor
[2] Pump horsepower control for each mode

If a throttle volume signal is input to computer A, computer A judges the work mode according to
the degree of opening of the throttle volume and controls milli-amp for pump horsepower control
proportional valve to match the work mode.
SST-05-00-008EN 2
2
* = When the target engine speed is 1300 min-1 or less, milli-amp for pump horsepower control proportional
Control milli-amp
valve is 50 mA.
Volume position (detent position) 1 2 3 4-8 9 - 15
Work mode (upper) SP H A
-1) 1900 1800 1700 1699 - 1300 1299 - 900
Engine speed (min
SH330-5 Milli-amp for pump horsepower control

500 500 500 380 50
proportional valve (mA)
Pressure boost Auto Auto Normal
1 Computer A 5 P2 pressure sensor

2 Throttle volume 6 N1 pressure sensor
3 Hydraulic pump 7 N2 pressure sensor
4 P1 pressure sensor 8 Pump horsepower control proportional valve
3 SST-05-00-008EN
3
Computer connection method
[1] Computers and the ECM are connected with CAN communication.
[2] The monitor and computers are connected with serial communication (UART).
1 Monitor
2 Computer A
3 Computer S
1) Computer A ............. Main unit side computer (standard)

2) Computer S ............. Remote support computer (standard)
3) ECM ........................ Engine computer
SST-05-00-008EN 4
4
Monitor changes
1 Horn volume select switch

2 Travel speed select switch
3 Auto idle switch
[1] LCD backlight color change (green → white); no change in number or size of LCD dots
[2] Mounted switch changes
Switch name Model 3B Model 5 Details

Work mode Yes Eliminated Throttle volume link mode switching
Auto mode Yes Eliminated Throttle volume link mode switching
Travel mode Yes Yes
Wiper Yes Yes
Washer Yes Yes
Working Light Yes Yes
Swing lock Yes Eliminated
Emergency stop Yes Eliminated Changed to rocker switch
Buzzer stop Yes Eliminated Buzzer changed to auto off
Auto idle No Yes Dedicated switch added
Horn volume No Yes Newly added
[3] Major increase in LCD brightness (Model 3B: 6 cd minimum → Model 5: 220 cd type)
(The increased brightness creates glare at night, so a light reduction function linked to working
light output was added.)
5 SST-05-00-008EN
5
[4] External switch input ports added (5 ports)
1 Monitor
2 Computer A
Purpose
Sending the above switch states to the computer A makes it possible to check the operation of
each switch on the service support check screen. Also, since the cumulative operation time for
each switch is stored in the computer A, the time that the front window was open or closed and
the usage log of each option line can be checked on the service support HR screen.
SST-05-00-008EN 6
6
[5] Output port (wiper, washer, working light, horn volume switchover) control method change
Purpose
Passing the switch states through the computer A makes the following possible.
1) Checking operation of each switch on the service support CHK screen
2) Checking the usage log for each operation on the service support HR screen
Judging communication abnormalities
7 SST-05-00-008EN
Pilot pressure switch changed to pressure sensor
No. Model 3B Model 5 Change details
1 Upper pressure switch Upper pressure sensor Switch to sensor
2 Travel pressure switch Travel pressure sensor Switch to sensor
3 Swing pressure switch Swing pressure sensor Switch to sensor
Parts change
4 P1 pressure sensor P1 pressure sensor
(not interchangeable with Model 3B)
Parts change
5 P2 pressure sensor P2 pressure sensor
Parts change
6 N1 pressure sensor N1 pressure sensor
7 None N2 pressure sensor Newly added
8 Option pressure switch Option pressure switch No change
[1] Configuration
Pilot pressure sensor and switch sensing points
1 Computer A 6 1st option lever 11 Travel (right) lever

2 Bucket lever 7 Upper pressure sensor 12 2nd option lever
3 Arm lever　 8 Swing pressure sensor 13 Travel pressure sensor
4 Boom lever 9 1st option pressure switch 14 2nd option pressure switch
5 Swing lever 10 Travel (left) lever
SST-05-00-008EN
8
[2] Pilot pressure sensor characteristics
Relationship between pilot pressure and voltage (rated 725.1 PSI (5 MPa))
[3] Sensor ON/OFF criterion
Option pressure
Upper sensor Swing sensor Travel sensor
switch
ON 72.5 PSI (0.5 MPa) 72.5 PSI (0.5 MPa) 72.5 PSI (0.5 MPa) 72.5 PSI (0.5 MPa)
OFF 43.5 PSI (0.5 MPa) 43.5 PSI (0.5 MPa) 43.5 PSI (0.5 MPa) 43.5 PSI (0.5 MPa)
[4] Sensor trouble criterion
When 0.25 V < Voltage < 4.75 V, normal; otherwise abnormal
[5] New functions through switch to sensor

Changing the pilot pressure switch to a sensor makes it possible to judge sharp operation of the
operation lever.
Judgment method
When the time to reach the Pu [MPa] pressure is t1 [s] or t2 [s],
the shorter time until Pu [MPa] is reached, the more sharp the operation.
Therefore, operation is sharper with t1 [s] than with t2 [s].
With Model 5 machines, the sharp operation judgment standards ⊿ Pu [MPa] and ⊿ T [s] are set
in the computer A, and if a ⊿Pu[MPa] pressure boost occurs during ⊿T[s], sharp operation judg-
ment is made.
Also, sharp load is judged in the same way using the main pressure sensor.
9 SST-05-00-008EN
9
Pump Electromagnetic Proportional Valve
2 electromagnetic proportional valves are mounted on the main pump.
[1] Horsepower control proportional valve
[2] P1 flow control proportional valve (newly added)
1 Computer A
2 Hydraulic pump
3 P1 flow control proportional valve
4 P1 pressure sensor
6 N1 pressure sensor
8 Horsepower control proportional valve
1. Horsepower Control Proportional Valve

Controls overall flow for the P1 and P2 pumps
Applications
1) Pump horsepower boost control
2) Pump horsepower cut control
Control
Control milli-amp: 50 mA min. .................... 500 mA max.
Milli-amp increase → Pump flow increase
Milli-amp decrease → Pump flow decrease
2. P1 Flow Control Proportional Valve
Control of the flow for the P1 pump
Applications
1) Swing relief cut control
2) Swing speed limit control
3) Power save control
4) Option flow control
Control
Control milli-amp: 50 mA min. .................... 740 mA max.
Milli-amp increase → Pump flow decrease
Milli-amp decrease → Pump flow increase
* In order to detect disconnections, the minimum value for the control milli-amp is set to 50 mA.
At 0 mA, computer A judges that the line is disconnected.
SST-05-00-008EN 10
10
System Control for Energy Saving
Fuel consumption is reduced 8 % through the use of three new hydraulic pressure control systems.
[1] Transient load reduction control (5 % reduction)
[2] Swing relief cut control (2 % reduction)
[3] Power save control (1 % reduction)
1. Reduced Fuel Consumption Through Transient Load Reduction Control
When the lever is operated sharply or there is a sharp high load, the pump control delay reduces the
engine speed.
At this time, the engine side control increases the fuel injection quantity to restore the speed to the
target engine speed, so fuel consumption increases. By using transient load reduction control, when
these conditions occur, the pump torque is reduced to minimize the drop in engine speed and
reduce fuel consumption.
(1) Transient load reduction control
When the conditions below occur, the milli-amp to the pump horsepower control proportional
valve is first lowered to the minimum to reduce the pump torque, then the horsepower is con-
trolled by gradually raising the milli-amps while watching the difference between the actual
engine speed and the target speed and thus reducing the increase in fuel injection quantity.
Conditions
1) Sharp lever operation
Judged from sharp rise in the pressure at the upper pressure sensor
2) Operation for high loads and sharp loads
Judged from sharp rise in the pressure at the P1 or P2 pump pressure sensor
11 SST-05-00-008EN
11
2. Reduced Fuel Consumption Through Swing Relief Cut Control
Model 3B swing line
• When the swing starts, high pressure is required, but not flow.On Model 3B, almost all the oil flows
from the swing relief to the tank when the swing begins to start, so energy is consumed need-
lessly.
1 Swing motor
Model 5 swing line

[1] Swing relief cut used
Purpose
The swing relief cut control provides relief when the pressure is boosted for the start of the swing
due to sharp swing operation and the drained off excess oil is held to the lowest amount possible.
This provides an energy-saving effect.
Operation
For sharp swing operation, when the swing starts, the P1 pump discharge volume is reduced and
only the necessary amount of oil is flowed. When the constant swing is reached, flow is neces-
sary, so the P1 pump discharge volume is increased.
1 Computer A 3 Discharge increased

2 Discharge decreased 4 P1 flow control valve
Caution
The P1 flow control proportional valve Milli-amp (high) ⇒ P1 pump flow (low)
Milli-amp (low) ⇒ P1 pump flow (high)
SST-05-00-008EN 12
12
Control contents
When the conditions below are all met, computer A judges that this is swing relief cut control,
increases the milli-amp to the P1 flow control proportional valve, and reduces the P1 flow.
After that, while checking the P1 pump discharge pressure, it gradually reduces the output milli-
amp to the P1 flow control valve and raises the P1 pump flow to the constant swing speed.
Conditions
1) Sharp swing operation .......... Judged from the swing pilot pressure sensor pressure rise state
2) Within 1 sec. after start of swing
3) Attachment non-operation ..... Non-operation of attachments is judged from the N2 negative
control pressure and P1 pressure sensor.
4) Travel non-operation ............. Travel pressure sensor OFF
5) Option line non-operation ...... Option pressure sensor OFF
1 Computer A 9 Option 17 Upper pressure sensor

2 Swing remote control valve 10 Travel (left) 18 P1 pressure sensor
3 Swing motor 11 Arm (2) 19 P2 pressure sensor
4 Swing pressure sensor 12 Boom (1) 20 Hydraulic pump
5 Option pressure switch 13 Bucket 21 N1 pressure sensor
6 Arm (1) 14 Travel (right) 22 N2 pressure sensor
7 Boom (2) 15 Straight travel 23 Discharge increased/decreased
8 Swing 16 Travel pressure sensor 24 P1 flow control proportional valve
13 SST-05-00-008EN
13
3. Reduced Fuel Consumption Through Power Save Control
Negative control circuit change
[1] Model 3B negative control circuit
Control such that the discharge flow decreases as the negative control pressure increases.
1 Arm (1) 7 Boom (1)

2 Boom (2) 8 Bucket
3 Swing 9 Travel (right)
4 Option 10 Straight travel
5 Travel (left) 11 Discharge decreased
6 Arm (2)
SST-05-00-008EN 14
14
[2] Model 5 negative control circuit
Power save control used
Purpose
By making the negative control relief variable and lowering the negative control pressure, a fur-
ther energy-saving effect is obtained.
1 Computer A 10 Travel (left) 19 Discharge decreased

2 P1 flow control proportional valve 11 Arm (2) 20 Travel 2nd speed
3 Power save solenoid valve 12 Boom (1) 21 Pressure boost
4 Swing pressure sensor 13 Bucket 22 Swing Brake
5 Negative control relief 14 Travel (right) 23 Lever Lock
6 Arm (1) 15 Straight travel 24 Power save
7 Boom (2) 16 Travel pressure sensor 25 5 stack solenoid valve
8 Swing 17 Upper pressure sensor
15 SST-05-00-008EN
15
Swing Speed Limit Control
Purpose
Since the maximum pump flow has been increased compared to Model 3, the swing speed at
maximum pump flow is too fast.
For the sake of improved swing operability and energy-saving effects, the maximum swing speed
is held down to the same speed as for Model 3B.
(SH330-5 P1 maximum discharge volume held down from 285 L/min ⇒ 280 L/min; control only
for SP mode)
Operation
When the conditions below are all met, the output milli-amp to the P1 flow control valve is set to
the maximum of 370 mA and the P1 pump flow is held down.
Conditions
1) Swing single full lever operation … Judged from the N1 and N2 negative control pressure sen-
sors and P1 and P2 pressure sensors
2) Travel non-operation …Travel pressure sensor OFF
3) The work mode is SP mode.
SST-05-00-008EN 16
16
End conditions
1) Travel operation ⇒ immediate end (to prevent off travel)
2) Other attachment operation ⇒ gradual end (to reduce shock)
3) Option circuit operation
1 Computer A 9 Option 17 Upper pressure sensor

2 Swing remote control valve 10 Travel (left) 18 P1 pressure sensor
3 Swing motor 11 Arm (2) 19 P2 pressure sensor
4 Swing pressure sensor 12 Boom (1) 20 Hydraulic pump
5 Option pressure switch 13 Bucket 21 N1 pressure sensor
6 Arm (1) 14 Travel (right) 22 N2 pressure sensor
7 Boom (2) 15 Straight travel 23 Discharge increased/decreased
8 Swing 16 Travel pressure sensor 24 P1 flow control proportional valve
Flow from swing start to constant-speed swing (SP mode)
Swing lever operation ⇒ Judged to be swing relief cut condition ⇒ Increased milli-amp to P1 flow
control proportional valve ⇒ P1pump flow reduced ⇒ Milli-amp gradually decreased while
watching swing pressure fall status ⇒ P1 pump flow increased ⇒ Judged to be speed limit con-
dition ⇒ P1 pump milli-amp fixed to 370 mA
17 SST-05-00-008EN
17
Electrical Equipment Layout Diagram SH330
Electrics Section

Overall View
1 Main unit left side (radiator chamber)

2 Engine
3 Main unit right side (pump chamber)
4 Main unit center section
5 In Cab
18 SST-05-01-009EN
1
1. Main Unit Left Side Layout Diagram (radiator chamber)
Shuttle valve back diagram
Location of fuses
1 Air cleaner sensor 6 Fuse: ECM20A (F4) 11 Battery relay

2 Suction air temperature sensor 7 Fuse: computer 20A (F5) 12 Receiver dryer sensor
3 Fusible link 65A (F1) 8 Fuse: GPS15A (F6) 13 Battery
4 Fusible link 60A (F2) 9 Swing pilot pressure sensor
5 Fuse: key 15A (F3) 10 Safety relay
SST-05-01-009EN 19
2
2. Engine Section Layout Diagram
1 Engine coolant temperature sensor 7 Starter motor

2 Boost pressure sensor 8 Engine hydraulic pressure sensor
3 Overheat switch 9 Suction control valve
4 Common rail pressure sensor 10 Fuel temperature sensor
5 EGR valve 11 Cam position sensor
6 Boost temperature sensor 12 Crank position sensor
20 SST-05-01-009EN
3
3. Main Unit Right Side Layout Diagram (pump chamber)
1 Charge fuel pump 8 Boosted pressure

2 P1 pressure sensor 9 Travel high speed
3 P2 pressure sensor 10 N1 pressure sensor
4 5 stack solenoid valve 11 P1 flow control proportional valve
5 Power save 12 Horsepower control proportional valve
6 Lever lock 13 N2 pressure sensor
7 Swing lock 14 Oil temperature sensor
SST-05-01-009EN 21
4
4. Main Unit Center Section Layout Diagram
1 Upper pressure sensor

2 Travel pressure sensor
22 SST-05-01-009EN
5
5. Cab Layout Diagram 1
1 Air conditioner solar radiation sensor 7 Monitor display 13 Air conditioner control panel
2 Clock 8 12 V socket 14 Emergency stop switch
3 Cigar lighter 9 Wiper motor 15 Rocker switch
4 Knob 10 Radio 16 Gate lock limit switch
5 Wiper controller 11 Throttle volume
6 Rocker switches (4) 12 Key cylinder
SST-05-01-009EN 23
6
Location of fuses Location of relays
No. Part name No. Part name No. Name

F7 BACK UP RADIO, ROOM LAMP 10A F17 FUEL FEED PUMP 20A R1 Main relay
F8 ENGINE PRE-HEAT 30A F18 CLOCK BACK MONITOR 10A R2 Glow relay
F9 OPTION LINE 10A F19 CIGAR LIGHTER KAB SEAT 15A R3 Lamp relay
F10 AIR-CONDITIONER UNIT 5A F20 DC CONVERTER 10A R4 Lamp relay (CAB)
F11 AIR-CONDITIONER BLOWER 15A F21 TRAVEL ALARM BEACON 10A R5 Horn relay L
F12 AIR-CONDITIONER COMPRESSOR 5A F22 SPARE (CRANE) 15A R6 Horn relay R
F13 SOLENOID 10A F23 ELEC. FUEL PUMP 10A R7 Speaker relay R
F14 WIPER WASHER 15A F24 LAMP (SPARE) 15A R8 Speaker relay L
F15 HORN 10A F25 LOCK LEVER (GATE) 10A R9 Room lamp relay
F16 LAMP (BOOM, HOUSE) 15A F26 LAMP (CAB) 15A R10 Beacon relay
R11 Starter cut relay
1 Computer A 6 TECH II service connector

2 Relay 7 EST service connector
3 ECM (engine control module) 8 Computer A service connector
4 Fuse box 9 Computer S service connector
5 Atmospheric pressure sensor
24 SST-05-01-009EN
7
6. Layout Around Operator’s Seat
Right console
Left console
1 Cup holder
2 Key switch
3 Rocker switch space
4 AM/FM radio
5 Tilt lever
6 Throttle volume
7 Ashtray
8 Air conditioner control panel
9 Gate lever
10 Emergency stop switch
SST-05-01-009EN 25
8
Stand Alone Parts Diagram
Name Shape Circuit Remarks
Model
； DC24 V specifications
Isuzu Part No.
Safety relay
； 182553-0391
Part No.
； AEH0017
Model
； For +24 V DC
Battery relay
Part No.
； KHR1241
Model
； 5.0 kW-24 V
Starter motor
Isuzu Part No.
； 898001-9150
Model
； 50 A-24 V
Alternator
Isuzu Part No.
； 897375-0171
Model
； 130E41R
Battery
Part No.
； KHR3944
Part No.
Washer motor
； KHR2261 (tank + motor)
26 SST-05-01-009EN
9
Model
Fusible link ； 65 A
(F1) Part No.
； KHR1592
Model
Fusible link ； 50 A
(F2) Part No.
； KHR3850
Fuse box Model

(F3, F4, F5, ； 7224-8511（20 A）
F6) 7224-8512（15 A）
Model
Throttle vol- ； RA30Y2 30SKB1KΩK
ume Part No.
； KHR2751
Model
； DC24 V
Starter switch
Part No.
； KHR3077
SST-05-01-009EN 27
10
Fuel level sen- Part No.

sor ； KHR10670
Model
Charge fuel ； DC24 V
pump Part No.
； KHH10460
Reserve tank Part No.

limit switch ； KHH0221
Vacuum sen- Part No.

sor ； KHH10330
28 SST-05-01-009EN
11
Isuzu Part No.

Glow plug
； 894390-7775
EGR motor EGR valve accessory EGR valve

EGR position Isuzu Part No.
sensor ； 898001-1910
Common rail Common rail accessory

pressure sen- Isuzu Part No.
sor ； 897306-0632
Cam position Isuzu Part No.

sensor ； 898014-8310
Crank position Isuzu Part No.

sensor ； 897306-1131
Oil pressure Isuzu Part No.

sensor ； 897600-4340
SST-05-01-009EN 29
12
Boost pres- Isuzu Part No.

sure sensor ； 180220-0140
Boost tempera- Isuzu Part No.

ture sensor ； 81246-8300
Supply pump accessory part

Fuel tempera- Supply pump
ture sensor Isuzu Part No.
； 897306-0448
Supply pump accessory part

Suction con- Supply pump
trol valve Isuzu Part No.
； 897306-0448
Isuzu Part No.

Injector
； 897329-7032
Isuzu Part No.

Suction air ； 812146-8300
temperature
sensor Part No.
； KHH0535
30 SST-05-01-009EN
13
Engine cool- Isuzu Part No.

ant tempera-
ture sensor ； 897170-3270
Isuzu Part No.

Atmospheric ； 897217-7780
pressure sen-
sor Part No.
； KHH0536
Part No.
Computer A
； KHR10024
Model
； DC24 V
Relay
Part No.
； KHR3802
DC-DC con- Part No.

verter ； KHR2447
Alarm (feed Part No.

pump) ； KHR4024
SST-05-01-009EN 31
14
Part No.
Feed pump
； KHR12840
Feed pump Part No.

switch ； KHR11520
Model
Lamp ； 24 V 70 W
(front right
Part No.
house)
； KHR2475
Model
； 24 V 70 W
Lamp (boom)
Part No.
； KHR0957
Model
； 24 V 70 W
Lamp (cab top)
Part No.
； KHR16240
32 SST-05-01-009EN
15
Part No.
Speaker (R)
； CAP2284
Model
； SK-0023-001-N0-KK
Monitor display
Part No.
； KHR10051
Model
Pressure
； 50.0 MPa
sensor
Part No.
(P1) (P2)
； KHR10290
Pressure Model
sensor
； 5.0 MPa
(N1) (N2)
(swing) (upper) Part No.
(travel) ； KHR10300
Pressure Model
switch ； 0.49 MPa
(option) Part No.
(2nd option) ； KHR10820
SST-05-01-009EN 33
16
Pressure Part No.

switch (filter) ； KHR14470
5 stack sole- Part No.

noid valve ； KHJ14520
2 stack sole-
noid valve Part No.
(knob switch ； KHJ14780
type)
2 stack sole-
Part No.
noid valve
(pedal type) ； KHJ14000
P1 flow control
Part No.
proportional
valve ； TIP0002128
34 SST-05-01-009EN
17
Horsepower
Part No.
control propor-
tional valve ； LJ00684
Free swing Part No.

switch ； KHR16140
Model
； KAB 555
KAB seat
Part No.
； KHN12810
Free swing Part No.

solenoid ； KHJ0659
Hydraulic oil
Part No.
temperature
sensor ； KHR2433
SST-05-01-009EN 35
18
Part No.
Clock
； KHR10060
Model
Knob right ； with 2 switches
(with one-
touch switch) Part No.
； KHJ14460
Knob right Model

(with one- ； with 4 switches
touch switch) Part No.
(short type) ； KHJ16140
Knob left Model

(with horn ； with 2 switches
switch and Part No.
radio mute) ； KHJ14450
Knob left Model

(with horn ； with 4 switches
switch and
Part No.
radio mute)
(short type) ； KHJ16150
36 SST-05-01-009EN
19
Part No.
Travel alarm ； KHR3852
Basic frequency；2560 Hz
Part No.
Horn (low) ； KHR2427
Part No.
Horn (high) ； KHR2428
Wiring Systems Part No.

； 6098-0017
Diode 6098-0061
Part No.
； KHP1796
Lever lock limit Part No.

switch ； KHR14930
SST-05-01-009EN 37
20
Model
； AM/FM ST
Radio （12/24 V）
Part No.
； KHR15550
Model
Lamp ； 24 V 10 W
(room lamp) Part No.
； KHN2714
Model
Accessory ； DC12 V
socket Part No.
； KHR2501
Model
Cigar lighter ； DC24 V
24 V Part No.
； KHR11210
Air conditioner Part No.

unit ； KHR13320
38 SST-05-01-009EN
21
Limit switch
Part No.
(front window)
(door) ； KHR2950
Wiper control- Part No.

ler ； KHN3392
Part No.
Wiper motor
； KHN16020
Solar radiation Part No.

sensor ； KHR10540
Receiver dryer Part No.

(switch) ； KHR13590
SST-05-01-009EN 39
22
Air conditioner
compressor Part No.
(magnetic ； KHR3197
clutch)
Motor actuator
(air mix)
Part No.
(mode)
(refresh / recir- ； KHR13610
culate)
Part No.
EVA sensor
； KHR13670
Interior tem-
Part No.
perature sen-
sor ； KHR13790
Relay (com-
Part No.
pressor)
(blower OFF) ； KHR2836
40 SST-05-01-009EN
23
Part No.
Blower motor
； KHR2845
Part No.
Blower amp
； KHR13730
Air conditioner Part No.

switch panel ； KHR12510
Option select
switch Part No.
(breaker / ； KHR14450
crusher)
Option select
Part No.
switch
(breaker) ； KHR14060
SST-05-01-009EN 41
24
Option select
Part No.
switch
(crusher) ； KHR15020
2 pumps flow Part No.

select switch ； KHR14460
Emergency Part No.

stop switch ； KHR14050
42 SST-05-01-009EN
25
Main Equipment Structural Diagrams SH200
Electrics Section

Connection Connector Pin Layout
1. Computer A
43 RST-05-02-001E
1
2. Monitor
RST-05-02-001E 44
2
Electrical Circuit Diagram SH290
Electrical

Overall View
1. Sequence Circuit Diagram
SST-05-03-010EN 45
1
97
Injector #1
121 W350
L352
119
Injector #2
B356
114
Injector #3
G354
117
R351
Injector #4
116
R357
R351 115
Injector #5
120 Y353
Injector #6
118 P355
46 SST-05-03-010EN
2
Block Diagram
1. Computer A
SST-05-03-010EN 47
3
2. Computer S
48 SST-05-03-010EN
4
3. ECM
KEY S/W ECM G372

LgR530 LR336 24 L371
ST M 107
Glow relay G370 CKP sensor
LgR338 BrR339 BW689
R2 10 108
R11
GrR009 BrR009 GrR010 GrR337 W373
46
L374 CMP sensor
98
BL687
100
Main relay
BG608 YR332 87 W307
R1 21
YR333 L317 Common rail
40 82
L318
pressure sensor
90
F4 R1
RG125 WR330 G327
2 101
WR331 5
94 GB363 U
Engine stop S / W 93 GW364 EGR position sensor
V
RG126 LG340 92 GR365
47 W
111 WR360 U
DIAGNOSTIC Connector 103 WB361 V M EGR valve motor
CN51 WL362
110 W
BG691 DIAG S/W PB083 PB082 WB303

52 80
CN55 Y313
67 Oil pressure sensor
BG692 MEMORY CLEAR BrY084 79
BY323
32
RG316 BY
84 Coolant temperature sensor
83 YG315 BY
Fuel temperature sensor
RW304
95
91 L314 Boost
Computer A pressure sensor
GW324
109
GR312 RL
P040 P042 74
CNC2-6 18 Boost temperature sensor
PG041 PG043 RW368
CNC2-14 37 105
113 RW369 SCV (suction control valve)
89 RG366
97 RG367
Injector #1
121 W350
L352
119
Injector #2
B356
114
Injector #3
G354
117
BARO
(atmospheric pressure) Injector #4
sensor 116 R351
W300 R357
61 R351 115
116
YL310
71 Injector #5
G320 120 Y353

60
Injector #6
Suction air temperature
sensor 118 P355
G321 L311
72
B770
1
B771
3
B772
4
BG670
43
BG671
62
BG672
81
SST-05-03-010EN 49
5
4. Monitor Display
50 SST-05-03-010EN
6
5. Air Conditioner
SST-05-03-010EN 51
7
6. Lever Lock
7. Horn
52 SST-05-03-010EN
8
8. Working Light
9. Option
SST-05-03-010EN 53
9
10.Other
54 SST-05-03-010EN
10
11.Electrical Symbol List
Symbol Name Symbol Name
Fuse Variable solenoid valve
Diode Resistor
LED Variable resistor
Toggle switch "a" contact Variable resistor
Push switch "a" contact Alarm

A
Limit switch "a" contact Buzzer

B
Limit switch "b" contact Horn

H
R Relay coil M Motor
R
Relay contact "a" contact Solar radiation sensor
R Relay contact "b" contact Speaker
Solenoid valve Lamp
SST-05-03-010EN 55
11
Electrical Connector Wiring Diagram SH330
Electrics Section

Wire Harness
1. Main Frame Harness
SST-05-04-012EN 56
1
57 SST-05-04-012EN
2
1 Eng. cont. c-2 11 Fix connector (CN.155F) with red tape.
2 Eng. cont. c-1 12 Fix connector (CN.124F) with red tape.
3 WhiteHITE tape 13 Fix connector (CN.T4M) with red tape.
4 Red tape 14 Fix connector (CN.150F) with red tape.
5 Blue tape 15 Fix connector (CN.133F) with red tape.
6 Yellow tape 16 Fix connector (CN.148F) with red tape.
7 Green tape 17 Fix connector (CN.T6F) with red tape.
8 Position of label 18 Fix connector (CN.137F) with red tape.
9 Horn (right) 19 Fix connector (CN.126F) with red tape.
10 Horn (left)
CN.100 Battery relay CN.146F Boom lamp harness

CN.101 Battery relay(IGN) CN.147F Washer motor
CN.102 Battery relay(IGN) CN.148F Washer diode
CN.103 Battery relay (coil) CN.149F Travel alarm
CN.104 Battery relay (coil) CN.150F Beacon harness
CN.109 Starter motor: C CN.155F Fuel pump harness
CN.111 Alternator: BWasher motor CN.105M Battery relay GND
CN.112 Alternator: E CN.108M Safety relay: C
CN.139 Air-cleaner sensor CN.A0F Eng. cont. C-1
CN.106F Safety relay: S,R,E CN.A1F Eng. cont. C-2
CN.107F Safety relay: B CN.A3F Engine harness: B
CN.110F Alternator: L,R CN.A4F Engine harness: C
CN.113F Proportionals/v: power CN.A5F Engine harness: D
CN.114F Proportional s/v: flow CN.A7F Intake air temp.
CN.115F Pressure sensor: P1 CN.A2M Engine harness: A
CN.116F Pressure sensor: P2 CN.A6M Engine harness: E
CN.117F Pressure sensor: N1 CN.B1F Cab main harness: A
CN.118F Pressure sensor: N2 CN.B2F Cab main harness: B
CN.119F Swing pressure sensor CN.B3F Cab main harness: C
CN.120F Upper pressure sensor CN.B4F Cab main harness: D
CN.121F Travel pressure sensor CN.B5F Cab main harness: E
CN.124F Over load harness CN.B6F Cab main harness: F
CN.125F Oil temp. sensor CN.D12F Reciever drier
CN.126F Joint connector CN.D13F Aircon compressor
CN.127F Lock lever SOL. V CN.F1M Fusible link 65 A
CN.128F Swing brake SOL. V CN.F2M Fusible link 60 A
CN.129F 2 stage travel SOL. V CN.F3F Fuse: KEY
CN.130F 2 stage relief SOL. V CN.F4F Fuse: ECM
CN.131F Power save SOL. V CN.F5F Fuse: CONT.
CN.133F Free swing harness CN.F6F Fuse: GPS
CN.134F Filter indcator CN.T4M Lubricator
CN.135F Fuel level sensor CN.T5F Condenser fan
CN.136F Elec. fuel pump CN.T6F Condenser fan diode
CN.137F Elec. fuel pump diode CN.G1 GND G1
CN.138F Reserve tank CN.G2 GND G2
CN.144F House lamp CN.G3 Alternator GND
SST-05-04-012EN 58
3
Cab
1. Cab Main Harness
SST-05-04-012EN 59
4
60 SST-05-04-012EN
5
1 Yellow tape 11 Fix connector (CN.79F) with red tape.
2 White tape 12 Fix connector (CN.21F) with red tape.
3 Red tape 13 Fix connector (CN.23F) with red tape.
4 Blue tape 14 Fix connector (CN.9F) with red tape.
5 Position of label Fix pin terminal of circuit no. 481 & 632 with red
15
tape.
6 Hour meter
Connect pin terminal of circuit no. 524 & 525 and
7 Fuse box KHR16012 16
fix with red tape.
8 Immobilizer SW
9 Fix connector (CN.80F) with yellow tape.
10 Fix connector (CN.24F) With red tape.
CN.1F Cab harness: A CN.79F Diode

CN.9F Crane harness CN.80F GPS unit
CN.10F Main relay CN.4M Cab harness: A
CN.11F Glow relay CN.5M Cab harness: B
CN.12F Lamp relay CN.7M Console (R) harness: A
CN.13F Lamp CAB relay CN.8M Console (R) harness: B
CN.14F Horn L relay CN.A8F Swing baro sensor
CN.15F Horn R relay CN.B1M Frame main harness: A
CN.16F Spk. R relay CN.B2M Frame main harness: B
CN.17F Spk. L relay CN.B3M Frame main harness: C
CN.18F Room lamp relay CN.B4M Frame main harness: D
CN.19F Beacon relay CN.B5M Frame main harness: E
CN.22F Dc converter CN.B6M Frame main harness: F
CN.24F Joint connector CN.B7M Option line harness
CN.25F GNDConnector CN.C1F Controller CN-1
CN.20F Starter cut relay CN.C2F Controller CN-2
CN.21F Back monitor CN.C3F Controller CN-3
CN.23F Option power CN.C4F Controller CN-4
SST-05-04-012EN 61
6
2. Cab Sub Harness
SST-05-04-012EN 62
7
1 Blue tape CN2F Cab harness: B CN51F Diag. connector

2 White tape CN4F Cab main harness: A CN52F ESTConnector: A
3 Red tape CN5F Cab main harness: B CN53M ESTConnector: B
4 Position of label CN6F Console (L) harness CN54F GPS jumper harness
5 Diag. switch CN50M J1939Connector CN54M GPS service connector
6 Memory clear
7 Fix connector (CN.50M) with red tape.
63 SST-05-04-012EN
8
3. In Cab
SST-05-04-012EN 64
9
1 White marking
2 Yellow tape
3 Blue tape
Part number entry The two ends must
4
be pasted on with tape.
65 SST-05-04-012EN
10
4. Engine Harness
1 2 3 4
0.75 1.25 1.25
G/B R R
5 6 7 8
0.75 0.75
L/R L/Y
H95
H94
1 2 3 4
0.75 1.25 1.25
L W W
5 6 7 8
1
5 0.75 0.75
B/W L/W G/R 1 2 3 4
0.75 0.75 0.75 0.75
L G/Y G/W G/B
H1 5 6 7 8
0.75 0.75 0.75 0.75
L/W W/L W/B W/R
E80
1 2
0.75 0.75
B/Y R/B
3 1 2 3
0.75 0.75 0.75 0.75
R R/L L R/W E93
1 2
0.75 0.75
E90 B/Y Y/G
E75
1 2
0.75 0.75
R/L B/R
E163
E164 1 2
0.75 0.75
R/W R/B
1
0.75 E161
G
1 2 3
0.5 0.5 0.5
L/W Br L
1 2 3
0.75 0.5 0.5
E113 B/W V/W Y
E112
1 2
1 2 3 0.5 0.5
0.75 0.75 0.75
B/Y L/Y W/B
E76 Y V /W
E98
1 Water sensor
2 Common rail sensor
3 Glow plug
1 2 3 4
4 Overheat switch
0.5 0.5 0.75 0.5
Y V/W B Y
5 6 7 8 5 Injector 1(#1. 2. 3)
0.5 0.75 0.75 0.75
V/W B/W R/B R/W
4 3 2 1 9 10 11 12 6 Injector 2(#4. 5. 6)
1.25 1.25 0.75 0.75 0.75 0.5
W R W/B L/Y B/Y L
3 2 1 4 3 2 1 8 7 6 5 13 14 15 16 7 Boost pressure sOil pressure sensorensor
0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.5 0.5 0.75 0.75
Y/G R/W R/B G/Y G/W G/B L L/R L/Y L/W Br L/W B/R L
6 5 4 8 7 6 5 12 11 10 9 17 18 19 20
1
5 8 Oil pressure sensor
0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 B/W
G R W/L W/B W/R G/R G/B R/L
9 Boost temperature sensor
H6 H8 H12 H20 H22
10 Crank position sensor
11 Fuel temperature sensor
12 EGR valve
13 SCV
14 Cam angle sensor (G)
SST-05-04-012EN 66
11
Console
1. Console Right Harness
1 Fix connector (CN.44F) with red tape. CN.7F Cab main harness: A
2 White tape CN.8F Cab main harness: B
3 Fix connector (CN.43F) with red tape. CN.34F Starter switch
4 Position of label CN.35M Throttle volume
CN.36F Radio
CN.37F Knob (right) switch
CN.39F Crane switch
CN.43F KAB seat
CN.44F Diode
2. Console Left Harness
1 White tape CN.6M Cab harness

2 Position of labelPosition of label CN.26F Air Conditioner unit: A
3 Red tape CN.27F Air Conditioner unit: B
CN.28F Air Conditioner panel: A
CN.29F Air Conditioner panel: B
CN.30F Limit switch
CN.31F Engine stop SW
CN.32F Knob (left) switch
67 SST-05-04-012EN
12
Electrical Parts and Wiring Assembly Diagram SH330
Electrical

Main Frame
SST-05-05-012EN 68
1
69 SST-05-05-012EN
2
Code Part name Q'ty CN. 106 Safety relay S, R, E: 3-pin
1 Working light 24 V × 70 W 1 CN. 107 Safety relay B: 1-pin
2 Horn; Electric (low) 1 CN. 108 Safety relay C: 1-pin
3 Horn; Electric (high) 1 CN. 110 Alternator L, R: 2-pin
4 Terminal cap M5 × 3.8 1 CN. 113 Pump electromagnetic proportional valve: 2-pin
5 Wire harness; Frame (Main) 1 CN. 114 Pump proportional valve: 2-pin
6 Pressure sensor 725.1 PSI (5 MPa) 5 CN. 115 Pressure sensor P1: 3-pin (no ID tape)
7 Battery 180G51 with terminal 2 CN. 116 Pressure sensor P2: 3-pin (yellow ID tape)
8 Terminal cap (black) 1 CN. 117 Pressure sensor: 3-pin
9 Battery cable; Ground 1 CN. 118 Pressure sensor: 3-pin
10 Terminal cap (red) 2 CN. 119 Pressure sensor: 3-pin
11 Battery cable; Bridge 1 CN. 120 Pressure sensor: 3-pin (blue ID tape)
12 Terminal cap (red) 1 CN. 121 Pressure sensor: 3-pin (red ID tape)
13 Battery cable; B+ (Relay) 1 CN. 125 Oil temperature sensor: 2-pin
14 Battery cable; Relay (Starter) 1 CN. 127 Lock lever SOL. V: 2-pin (yellow ID tape)
15 Pressure sensor 7251.8 PSI (50 MPa) 2 CN. 128 Swing brake SOL. V: 2-pin (white ID tape)
16 Thermo-sensor 1 CN. 129 2-stage travel SOL. V: 2-pin (red ID tape)
17 Travel alarm 1 CN. 130 2-stage relief SOL. V: 2-pin (yellow ID tape)
18 Working light 1 CN. 131 Power save SOL. V: 2-pin (green ID tape)
19 Terminal cap M4 × 2.0 2 CN. 134 Filter indicator: 2-pin
20 Battery relay 1 CN. 135 Fuel sensor: 2-pin
21 Terminal cap 2 CN. 136 Electromagnetic fuel pump: 2-pin
22 Fuse; High current (Model A3) 1 CN. 138 Reserve tank: 2-pin
23 Fuse (fusible link) 1 CN. 139 Vacuum sensor: 2-pin
24 Ground wire; Floor 1 CN. 144 Housing lamp: 2-pin
25 Terminal cap M6 × 5.3 1 Boom light: 2-pin
26 Wire harness; Light (Main frame) 1 CN. 145 (The connector should be fastened with an
M6 clamp with a band (S).)
1 Fuel tank CN. 146 Boom light harness: 2-pin
2 Sump tank CN. 147 Washer motor: 2-pin
3 Round terminal M8; Ground G2 CN. 149 Travel alarm: 2-pin
4 Window washer tank CN. A0 Engine controller C-1: 81-pin
5 Reserve tank CN. A1 Engine controller C-2: 40-pin
6 Condenser (with electric fan) CN. A2 Engine harness A: 20-pin
7 Dryer receiver CN. A3 Engine harness B: 12-pin
8 Round terminal M8; Alternator ground CN. A4 Engine harness C: 8-pin
9 Swing frame CN. A5 Engine harness D: 6-pin
10 Wire color: red stripe on yellow background CN. A6 Engine harness E: 1-pin
11 Wire color: red stripe on blue background CN. A7 Suction air temperature sensor: 2-pin
12 Wire color: black CN. B1 Cab main harness A: 2-pin
13 Fuel sensor CN. B2 Cab main harness B: 8-pin
14 Engine support; Front CN. B3 Cab main harness C: 18-pin
15 C starter motor (round terminal M5) CN. B4 Cab main harness D: 22-pin
16 Engine ground (attached to engine main unit) CN. B5 Cab main harness E: 20-pin
17 Alternator (attached to engine main unit) CN. B6 Cab main harness F: 14-pin
18 Inlet pipe bracket (air cleaner) Battery relay ground: 1-pin
19 Platform (L) CN. C0 (The connector should be fastened with an
M8 clamp with a band (S).)
20 AEH0017 safety relay (attached to engine main unit)
CN. D12 Receiver dryer: 2-pin
21 Wire color: white stripe on red background
CN. D13 Air conditioner compressor: 1-pin
Wire color: red
CN. F1 Fusible link: 2-pin
22 Wire color: red stripe on blue background
Wire color: red stripe on green background CN. F2 Fusible link: 2-pin (yellow ID tape)
23 Wire color: red stripe on white background CN. F3 Key fuse: 2-pin (no ID tape)
24 Wire color: red stripe on light green background CN. F4 ECM fuse: 2-pin (red ID tape)
25 Engine controller CN. F5 CONT fuse: 2-pin (blue ID tape)
26 Round terminal M6; Alternator B (wire color: red) CN. F6 GPS fuse: 2-pin (yellow ID tape)
27 CN. T5 Condenser fan: 2-pin
Round terminal M5; Alternator E (wire color: black)
28 Hydraulic pump
29 Air conditioner compressor
30 Starter motor (attached to engine main unit)
SST-05-05-012EN 70
3
Cab
SST-05-05-012EN 71
4
Code Part name Q'ty
1 Automatic lighter 1
2 Cap; Blind (rocker switch) 7
3 Wire harness; Cab (Sub) 1
4 Wire harness; Cab (Main) 1
5 Relay; Changeover (24 V) 10
6 Antenna code 1
7 Wire harness; Console (right) 1
8 Wire harness; Short console (right) 1
9 Wire harness; Console (left) 1
10 Wire harness; Short console (left) 1
11 Car radio; AM/FM ST (12/24 V) JPN 1
12 Switch; Starter (assembly) 1
13 Ground wire; Cab 1
14 Switch; Rocker (E. STOP) 1
15 Bracket; Harness 1
16 Bracket; Radio 2
1 Trim; Front (upper)

2 Trim; Side (upper)
3 Frame main harness
4 Clock
5 Monitor display
6 Wiper motor (cab accessory)
7 Wiper controller (cab accessory)
8 Cover; Top (Console right)
9 Cover; Top (Console left)
10 Air conditioner panel
11 Atmospheric pressure sensor (engine accessory)
12 Engine controller (engine accessory)
13 Operators cab
14 Floor
15 Knob (memory clear) white ID tape
16 Knob (diagnostic switch) red ID tape
17 Fuse box (cab main harness accessory)
72 SST-05-05-012EN
5
CN. 1 Cab harness A: 14-pin
CN. 2 Cab harness B: 18-pin
CN. 3 Right console harness A; 18-pin
CN. 4 Right console harness B; 10-pin
CN. 5 Cab sub-harness A: 22-pin
CN. 6 Cab sub-harness B: 18-pin
CN. 7 Left console harness: 22-pin
CN. 8 Liftcrane harness: 14-pin
CN. 10 GND connector: 6-pin
CN. 11 DC converter: 7-pin
CN. A8 Atmospheric pressure sensor: 3-pin
CN. B1 Frame main harness A: 2-pin
CN. B2 Frame main harness B: 8-pin
CN. B3 Frame main harness C: 18-pin
CN. B4 Frame main harness D: 22-pin
CN. B5 Frame main harness E: 20-pin
CN. B6 Frame main harness F: 14-pin
CN. B7 Option line harness: 10-pin
CN. C1 Computer CN-1: 26-pin
CN. L1 Limit switch: 2-pin
CN. L2 Left knob switch: 8-pin
CN. L3 Engine stop SW: 10-pin
CN. Q2 Diagnostic: 16-pin
CN. Q3 EST connector: 12-pin
CN. Q4 Maintenance connector: 12-pin
CN. R1 Starter switch: 6-pin
CN. R2 Right knob switch: 8-pin
CN. R3 Throttle volume: 3-pin
CN. R5 Rocker switch 1: 10-pin
CN. R6 Rocker switch 2: 10-pin
CN. R7 KAB seat: 2-pin (fastened with red tape)
CN. T1 Air conditioner unit A: 10-pin
CN. T2 Air conditioner unit B: 18-pin
CN. T3 Air conditioner panel A: 14-pin
CN. T4 Air conditioner panel B: 22-pin
CN. Q1 J1939: 3-pin (fastened with red tape)
CN. R4 Radio: 9-pin
RL. 01 Main
RL. 02 Glow (white marking)
RL. 03 Lamp 1
RL. 04 Lamp 2 (white marking)
RL. 05 Horn L
RL. 06 Horn R (white marking)
RL. 07 Speaker R
RL. 08 Speaker L (white marking)
RL. 09 Room lamp
RL. 10 Beacon (white marking)
SST-05-05-012EN 73
6
Explanation of Functions and Operations SH200
Electrical

Explanation of Electrical Functions
Item Control Contents
The engine speed, work mode, and boosted
1. Throttle Control
pressure state are switched by the throttle volume.
Engine Speed 2. Idling Control (auto/one-touch) With auto/one-touch switchover function

Control 3. Idling Start Runs the engine at low idle speed when it starts up.
If the coolant temperature is low, warm-up operation
4. Auto Warm-up
is executed automatically when the engine starts
1. Engine Start/Stop Judgment Judgment based on engine speed from ECM
When key ON → OFF, 4-second delay; when engine

2. Power-cut Delay
Engine Start/ running → OFF, 7-second delay
Stop Control When the emergency stop switch is pressed, the
ECM recognizes this and stops the engine.
4. Neutral Start Engine start load (cell not turning) when lever locked.
Linked with the throttle, the SP/H/A mode is switched
over and the pump horsepower is controlled.
Controls pump horsepower milli-amp in accordance
with the work mode selected.
The milli-amp for pump horsepower control
Pump Control proportional valve is reduced by the transient load
control, engine stall prevention control, and PID
control conditions.
The negative control relief pressure for non-
4. Power Save Control operation is varied and the negative control pressure
is lowered to reduce the pump load.
When the upper and swing are not operated, the
1. Swing Brake swing brake is operated automatically and during
travelling too.
Swing Free Swing (option for North
2. Swing option for North America
America)
There is a swing lock function (for servicing) with
Swing 3. Swing Lock (for maintenance)
monitor operations.
When a swing starts, the flow is reduced with the
4. Swing Relief Cut front side proportional valve and the excess oil is
eliminated.
The front side flow is controlled to suppress the
speed rise due to increased pump flow.
1. Travel Speed Switchover Travel speed low-speed/high-speed switchover
Travel
2. Travel Alarm Buzzer sounded (for 10 sec.) during travel
Operation is not possible unless the gate lever is
1. Lever Lock
raised.
When key ON, solenoid switched ON/OFF for 0.25
Valve Control sec.
The computer automatically raises the pressure from
3. Pressure Boost Control 4975 PSI (34.3 MPa) to 5337 PSI (36.8 MPa) when
necessary.
74 SST-05-06-009EN
1
Item Control Contents
Bar Graph (coolant temperature
Bar graph display of coolant temperature, oil
1. gauge, oil temperature gauge, fuel
temperature, and fuel level on monitor
Monitor Control gauge)
Output port control method change, liftcrane and
2. Monitor Function
option screen added to display screens, etc.
Switching between 1 or 2 horns with horn volume
1. Horn
select switch
Right housing and boom light illumination (option
2. Working Light
setting for 2 lights at top of cab)
Wiper with rise-up used (intermittent, continuous,
Accessories 3. Wiper and Washer
washer). Same one used as for Model 3
The room lamp lights up when the door is opened
4. Room Lamp and lights up for exactly 30 sec. from when the door
is opened with the key OFF.
5. Radio Mute Mute switch setting on the knob
1. Anti-theft Anti-theft set with password input to monitor

When the key is ON, no output to travel switchover,
2. Battery Save Function boost, power save, bucket lock, option switchover
Other and free swing solenoid valve.
Alternator Power Generation Detec- Alternator L terminal voltage judged with 10 V
3.
tion comparator
4. Overload Warning Only mounted on machines for Europe.
Switchover crusher ⇔ breaker with just rocker switch

in cab
There are 5 flow settings each for the breaker and
crusher, for a total of 10 settings.
Feed pump automatic stop. Full tank detected by fuel
Options 3. Feed Pump Automatic Stop
level sensor and the pump stopped automatically
Warning issued when return filter clogged (only for
breaker specifications)
5. Beacon Standard for Europe, Japan liftcrane specifications
6. DC-DC converter Convert 24 V into 12 V.
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Engine Speed Control
1. Throttle Control
(1) Throttle display
[1] Configuration
1 Monitor 3 Engine
2 Computer A 4 Throttle volume
[2] Summary
The throttle volume voltage signal is first input to computer A. Computer A converts the
voltage signal to a target speed and sends it to the ECM via CAN communication.
At the same time, computer A sends the throttle display data to the monitor.
(2) Throttle volume position detection

[1] Configuration
1 Throttle volume
2 Computer A
3 Potentio-meter
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[2] Structure
The detent and notches provide a click feel. (15 notches; Notch 1 is the "SP mode" position.)
[3] Characteristic
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[4] Potentio-meter characteristic
[5] Throttle volume degree of opening calculation

The throttle volume degree of opening (%) that can be checked on the CHK screen is
calculated with the standard below.
100 % … When the detent is in the 1 + position
0% … When the detent is in the 15 - position
Therefore, even if the detent is in the 1 position (SP), this does not necessarily mean that the
degree of opening is 100 %.
In the same way, even if the detent is in the 15 position, the degree of opening is not
necessarily 0 %.
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[6] List table
For the angle, voltage, and degree of opening for each detent position, see the following table.
Detent Angle [deg] Voltage [V] Degree of opening [%]
1+ 131.2 4.86 100.0
1 128.7 4.77 98.0
1- 126.2 4.67 96.1
2+ 109.6 4.06 83.0
2 107.1 3.97 81.1
2- 104.6 3.87 79.1
3+ 95.2 3.53 71.7
3 92.7 3.43 69.8
3- 90.2 3.34 67.8
4+ 88.0 3.26 66.1
4 85.5 3.17 64.1
4- 83.0 3.07 62.2
5+ 80.8 2.99 60.4
5 78.3 2.90 58.5
5- 75.8 2.81 56.5
6+ 73.6 2.73 54.8
6 71.1 2.63 52.8
6- 68.6 2.54 50.9
7+ 66.4 2.46 49.1
7 63.9 2.37 47.2
7- 61.4 2.27 45.2
8+ 59.2 2.19 43.5
8 56.7 2.10 41.5
8- 54.2 2.01 39.6
9+ 52.0 1.93 37.8
9 49.5 1.83 35.9
9- 47.0 1.74 33.9
10+ 44.8 1.66 32.2
10 42.3 1.57 30.2
10- 39.8 1.47 28.3
11+ 37.6 1.39 26.5
11 35.1 1.30 24.6
11- 32.6 1.21 22.6
12+ 30.4 1.13 20.9
12 27.9 1.03 18.9
12- 25.4 0.94 17.0
13+ 23.2 0.86 15.2
13 20.7 0.77 13.3
13- 18.2 0.67 11.3
14+ 16.0 0.59 9.6
14 13.5 0.50 7.6
14- 11.0 0.41 5.7
15+ 8.8 0.33 3.9
15 6.3 0.23 2.0
15- 3.8 0.14 0.0
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2. Idling Control (auto/one-touch)
1 Monitor display 5 One-touch idle switch 9 Pressure sensor (upper)

2 Computer A 6 Throttle volume 10 Pressure sensor (swing)
3 Engine 7 1st option pressure switch 11 Pressure sensor (travel)
4 Coolant temperature sensor 8 2nd option pressure switch
Operation explanation
[1] Auto/one-touch switchover function
The operator can switch between one-touch and auto by pressing the auto idle switch on the
monitor in the diagram below.
When auto idle is ON, the LED at the side of the switch lights up.
1 Auto idle switch
[2] Auto idle control

1) When auto idle is set, if the lever is left continuously unoperated for 5 sec., the engine speed
automatically becomes the auto idling speed (1200 rpm).
* This 5-second setting for auto idle operation is the default setting value. This setting can be
changed to from 1 - 30 sec. with service support operations.
2) When the lever is operated, the engine speed is automatically returned to the engine speed set
for the throttle volume.
3) Even with auto idle set, it is possible to move to auto idle or return from auto idle by pressing
the knob switch (one-touch idle switch) on the right operation lever.
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[3] One-touch idle control
When auto idle is not set, regardless of lever operation, it is possible to move to auto idle or
return from auto idle by pressing the knob switch (one-touch idle switch) on the right operation
lever.
The idling speed for one-touch idle control is 900 rpm .
[4] Idling speed
1) Auto idling speed 1200 rpm
2) One-touch idling speed 900 rpm
3) Low idling speed 900 rpm
The speeds above are the default values. They can be set to from 900 - 1600 rpm with service
support operation. (See monitor operation procedures.) However, the settings are based on the
following conditions.
Low idle speed = One-touch idle speed ≦ Auto-idle speed
(The one-touch idle speed and auto-idle speed settings can be changed.)
3. Idling Start
[1] When the engine starts, the engine speed becomes the low idle speed regardless of the throttle
position.
[2] When the low idle speed is changed, the engine speed is controlled at this new speed.
[3] During an idling start, the "idling icon" is displayed at the top left of the monitor.
No message is displayed.
1 Idling icon
[4] An idling start is ended in the following cases and control becomes normal.
1) When the one-touch idle switch is pressed
2) When the throttle volume is operated
3) When the operation lever is operated (upper, travel, swing pressure sensor ON)
[5] Back-up operation
1) Sensor trouble
If trouble occurs in a sensor (upper, travel, swing), idling start is ended.
2) Throttle volume trouble
Even if the throttle volume is operated, the idling start is not ended. Also, even if the idling start
is ended with some other method, the throttle cannot be adjusted.
3) One-touch idle switch trouble
Even if the switch is pressed, the idling start is not ended.
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4. Auto Warm-up
If the coolant temperature is low when the engine starts up, warm-up operation is executed,
automatically raising the engine speed in steps.
[1] Auto warm up is used if the coolant temperature is lower than 122º F (50º C) when the engine
starts.
[2] If the coolant temperature is 122º F (50º C) or higher, auto warm up is not used and an "idling
start" is executed.
[3] Operation
The engine speed is raised in steps from low idle speed up to 1900 rpm as shown below.
When the low idle speed is changed, the engine speed starts from the newly set speed.
The warm-up time is the same, 14 min.
When the coolant temperature reaches 122º F (50º C), the engine speed falls immediately to low
idle. (Idling start)
[4] Monitor display

During auto warm up, the "auto warm up icon" is displayed at the top left of the monitor.
1 Auto warm up icon
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[5] In the cases below, auto warm up is ended and operation shifts to "idling start".
1) When the coolant temperature reaches 122º F (50º C)
2) When the one-touch idle switch is pressed
3) When the entire auto warm up process ends (after 14 min.)
[6] In the cases below, auto warm up is ended and operation shifts to the engine speed for the
throttle position.
1) When the lever is operated (as detected by a pressure sensor)
2) When the throttle volume is operated
[7] Back-up operation
1) Sensor trouble
If trouble occurs in a sensor (upper, travel, swing, coolant temperature sensor), auto warm up is
not operated. Also, even trouble occurs in a sensor partway through a warm up, the warm up is
ended and operation shifts to normal control.
2) One-touch idle switch trouble
Even if the switch is pressed, auto warm up is not ended.
3) Throttle volume trouble
Even if the throttle volume is operated, the auto warm up is not ended.
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Engine Start/Stop Control
[1] Configuration
1 Computer A
2 Cam sensor
3 Crank sensor
[2] Summary
Engine start and stop is judged based on the engine speed sent from the ECM with CAN
communication.
[3] Judgment values
Start 500 rpm, stop 200 rpm
☆ ) Concerning hysteresis: For Model 3B, judged at 500 rpm with no hysteresis
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2. Power-cut Delay
[1] Configuration (fuses etc. omitted)
1 Computer A 5 Load A
2 Key switch 6 Power supply
3 Battery relay 7 Key switch signal
4 Battery 8 Battery relay hold
[2] Summary
After the key is switched OFF, after the battery relay is held for a certain period, the power supply
is cut off.
[3] Purpose
1) This secures time after the key is switched OFF for data to be written in the EEPROM in the
ECM and computer A.
2) This waits until the engine completely stops to avoid load dumping.
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[4] Operation
1) When the key is ON, the battery relay is held by the battery relay hold output (OUT1) from the
ECM and the key switch.
2) After the key is switched OFF, the battery relay is only held by the ECM.
3) After it detects the key going OFF through the key switch signal input (IN1), the ECM starts the
count down.
4) After a certain time has passed, the ECM stops output to the battery relay and the battery relay
goes OFF.
At the same time, the power supply to electrical parts, including the ECM and computer A is
cut. (Except the backup power supply)
5) The time from the key being switched OFF until the power supply goes OFF (the delay time)
depends on whether or not the engine was started.
* After the key is switched ON, if the key is switched OFF without the engine being started =
about 4 sec.
* If the key is switched OFF after the engine was started = about 7 sec.
[5] Differences from Model 3B
With Model 3B, the main unit side computer (called computer A in Model 5) held the battery relay.
With Model 5, the ECM bears this responsibility. (Engine manufacturer requirement)
Function for stopping the engine in an emergency
When the emergency stop switch on top of the left console is pressed, the engine is stopped
regardless of the key switch position.
1 Monitor display
2 Computer A
3 Engine
4 Engine emergency stop switch
[1] Circuit
1) When the emergency stop switch is pressed, a 24 V signal enters the ECM input port.
2) When the 1) signal enters, the ECM controls the injector, suction control valve, and EGR valve
to stop the engine.
3) The emergency stop switch signal also enters computer A, and computer A sends the engine
stop command to the ECM with CAN communication.
4) At the same time, computer A sends the emergency stop display and buzzer instructions to the
monitor with serial communication.
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[2] Display and warning
1) When the emergency stop switch is switched ON, the "ENGINE STOP" message is displayed
on the monitor.
2) Even if there is another message, the "ENGINE STOP" message is displayed with priority for 5
sec. after the switch is switched ON.
3) At the same time as 1), the buzzer in the monitor buzzes intermittently at 1 Hz.
4) If any kind of trouble is detected during the 1 Hz intermittent buzzing of 3), after the 5-second
continuous buzzing, which is the trouble warning, the buzzing returns to the 1 Hz intermittent
buzzing.
5) Even if the buzzing continues after the switch ON/OFF message display (for 5 sec.), the
message display is not extended.
6) The above message display and buzzer operate whether the engine is running or stopped.
[3] An emergency stop takes priority over any other control and stops the engine.
* The engine stops even during lifting magnet suction, elevator cab rising, and fan reverse
operation (large machine only).
[4] When an emergency stop is made, it is not recorded in the trouble log.
[5] The engine can be cranked with the emergency stop switch ON, but the engine will not start.
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4. Neutral Start
[1] Purpose and summary
The engine will not start with the gate lever lifted. (It will not crank.)
This prevents accidental operation if the operation lever is accidentally bumped into when the
engine is started.
[2] Configuration
1 Key switch 5 Starter cut relay

2 Gate lock limit switch 6 Lever lock solenoid
3 Starter motor 7 Battery relay
4 Safety relay
[3] Operation
When the gate lever is raised (and the limit switch comes ON), the starter cut relay is excited, the
excitation to the safety relay is cut off, and the engine does not crank. At this time, nothing in
particular is displayed on the monitor.
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Pump Control
Purpose
Work mode control enables the operator to select the work mode to match the work contents, for
example emphasizing speed, emphasizing fuel economy, etc.
At the same time, the engine speed is adjusted. (throttle adjustment)
1 Monitor
2 Computer A
3 Engine
4 Throttle volume
5 Pump horsepower control proportional valve
6 Pressure boost solenoid
Operation
[1] Manual switchover (main mode)
The operator can select 1 of the following work modes by turning the throttle volume.
For the correspondence between the throttle volume detents and the work modes, see the
attached table.
Mode Aim Display Monitor buzzer
The buzzer buzzes twice

① SP mode Speed emphasis
when this is selected.
Balances speed and fuel The buzzer buzzes once

② H mode
economy when this is selected.
③ A mode Fuel economy emphasis No buzzing
[2] Automatic switchover (submode)

Each of the three main modes that can be selected manually has two submodes (high and low).
These submodes are switched automatically based on the sensor input values.
* For the high and low milli-amp, see the explanation in 2. Pump Horsepower Boost Control on the
next page.
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Purpose
Controls pump horsepower according to the work mode (engine speed).
Control milli-amp
Work mode SP H A
Engine speed (rpm) 1900 1800 1700 1699 - 1300 1299 - 900
Milli-amp for pump horsepower
500 500 500 380 50
control proportional valve (mA)
Operation
[1] Controls milli-amp to the pump horsepower control proportional valve according to the selected
work mode (engine speed).
[2] Increase/decrease control of milli-amp is not performed according to load variation.
[3] When SP mode is selected, the engine rotation increases to 2050 rpm if low-speed (1st speed)
travel is performed.
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Purpose
The pump milli-amp is controlled in order to prevent black smoke during excess loads and engine
speed drops and in order to improve energy saving.
The control methods are the following 3.
[1] Overload reduction control
[2] Engine stalling prevention control
[3] PID control
1 Computer A
2 Pump
3 Engine
6 Pump horsepower control proportional valve
(1) Overload reduction control

When the engine is overloaded, the milli-amp to the pump horsepower proportional valve first
drops to 50 mA.
After that, the milli-amp is gradually raised while watching the difference between the actual
engine speed and the target engine speed.
Overload reduction control is executed in all work modes.
• The engine is judged to be overloaded when the following conditions are met.
1) Sharp lever operation
When there is lever operation, this is judged from the upper pressure sensor pressure rise
state.
2) Operation for high loads and sharp loads
Judged from the P1 or P2 pressure sensor and from the pump main pressure boost state
(2) Engine stalling prevention control
When the target engine speed is 1300 rpm or less, the milli-amp is 50 mA.
(3) PID control
When the engine actual speed falls 30 rpm or more below the target engine speed, the milli-amp
is gradually lowered.
When the difference between the actual engine speed and the target engine speed falls below 30
rpm, the milli-amp rises to the target milli-amp for each mode.
Backup control
If trouble occurs in a pressure sensor (P1, P2, upper), the overload restriction control is not
carried out.
If trouble occurs in the pump horsepower control proportional valve, the output from the computer
A stops.
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4. Power Save Control
Purpose
When no lever is operated, the pump load is reduced with the control below to reduce fuel
consumption.
The control methods are the following 2.
[1] The negative control relief pressure is varied and the negative control pressure is lowered to
reduce the pump load.
[2] The pump discharge volume is set to the minimum flow.
1 Computer A
2 Control valve
3 Power save solenoid
4 Upper pressure sensor
5 Swing pressure sensor
6 Travel pressure sensor
7 Negative control foot relief valve
8 Pump 1
9 Pump 2
10 P1 flow control proportional valve
[1] Normal operation
If more than 1 sec. passes with all the sensor signals to the computer A OFF (upper, travel, and
swing pressure), the computer A judges that no lever is being operated and outputs to the P1
flow control proportional valve and the power save solenoid valve.
1) P1 pump discharge volume reduced
1. The milli-amp for P1 flow volume proportional valve is increased from 50 mA to 740 mA.
2. The P1 pump swash plate is switched to the minimum tilting and the discharge volume is set
to its minimum.
2) P2 pump discharge volume reduced
1. When the power save solenoid valve is switched, the pilot source pressure is fed to the P2
pump negative control port via the solenoid valve.
2. The P2 pump swash plate is switched to the minimum tilting and the discharge volume is set
to its minimum.
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3) Negative control pressure reduction
1. When the power save solenoid valve is switched, the negative control foot relief valve spring
chamber is linked with the tank line and the negative control foot relief valve setting pressure
drops from 435 PSI (3 MPa) to 145 PSI (1 MPa).
2. By reducing the negative control relief pressure, the pressure within the circuit is reduced,
and the horsepower used by the pump is reduced. This saves energy.
[2] Operation when the engine is stopped with the key ON.
When the engine stops, the battery save function works and there is no output to the P1 flow
control proportional valve or the power save solenoid valve.
[3] Operation for trouble
If an abnormality occurs on either the input side (upper, swing, travel pressure sensors) or the
output side (P1 flow control proportional valve, power save solenoid valve), the system treats this
as operation being underway and control is fixed to the following.
Milli-amp to the P1 flow volume valve … 50 mA, the power save solenoid valve is always OFF.
Caution
During a trouble, even if the abnormality is ended, trouble mode does not end until the key is
switched OFF.
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Swing
1. Swing Brake
[1] Configuration
1 Horn volume select switch 8 Swing brake solenoid

2 Computer A 9 Accumulator
3 Engine 10 Swing motor
4 Working light switch 11 Swing Brake
5 Auto idle switch 12 Free swing solenoid
6 Upper pressure sensor 13 Free swing switch (momentary)
7 Swing pressure sensor
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[2] Braking through upper operation
When the upper pressure sensor is ON, the brake goes OFF. 1 sec. after the upper pressure
sensor goes OFF, the brake comes ON.
[3] Braking control through swing operation
When the swing pressure sensor is ON, the swing brake goes OFF (swing brake solenoid =
OFF). 5 sec. after the swing pressure sensor goes OFF, the swing brake comes ON (swing brake
solenoid = ON).
[4] Swing lock with key OFF
When the key is OFF (during power-cut delay), the swing brake comes ON unconditionally.
2. Swing Free Swing (option for North America)

[1] Free swing switchover
When the free swing switch is pressed, the free swing mode is switched ON ⇔ OFF. When the
(momentary) key is OFF, always start with free swing OFF. (Previous data reset)
[2] Free swing control
When free swing is ON, the free swing solenoid is ON and the swing brake solenoid is OFF.
[3] Mode display
When free swing is ON, the icon in the diagram below is displayed on the monitor.
[4] Battery save
While the engine is stopped with the key ON, if free swing is switched ON, the icon is displayed,
but the free swing solenoid does not come ON. It does come ON after the engine starts.
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3. Swing Lock (for maintenance)
Purpose
This is used for measuring the swing relief pressure and other maintenance tasks.
[1] Swing lock switching
In order to prevent accidental operation under certain special circumstances, sometimes the
swing brake need to be left ON all the time. (Swing lock) At this time, the swing lock can be
switched ON/OFF by holding down the "horn volume select switch", the "working light switch",
and the "auto idle switch" at the same time for 3 sec.
Additionally, turn the key OFF with the swing lock ON, have the swing lock ON when the key is
turned ON again. (The previous data is held.)
[2] Swing lock control
When the swing lock is ON, even if the upper or the swing is operated, the swing brake keep
working. Be particularly careful about swing operation because the swing brake plate is dragged.
(The swing pilot pressure is not shut off. This is no more than a simple swing lock.)
[3] Competition with free swing
If the swing lock is used, even if free swing is ON, the swing brake solenoid comes ON and the
free swing solenoid goes OFF. (Swing lock priority)
[4] Mode display
When swing lock is ON, the icon in the diagram below is displayed on the monitor.
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[5] Time chart (free swing and swing lock)
[6] Trouble mode

If trouble occurs in an input (upper/swing pressure sensor), communication (CAN), or output
(swing brake solenoid/free swing solenoid), the system goes into trouble mode. In trouble mode,
the swing brake solenoid is OFF and the free swing solenoid is OFF. Even if the trouble is
recovered from, this does not recover the system from trouble mode.
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4. Swing Relief Cut
Purpose
When independent swing operation is running, the pump flow is reduced, and the excess oil ejected
from the swing motor relief valve is eliminated.
1 Computer A 8 Boom (2) 15 Travel (right)

2 Throttle volume 9 Swing 16 P1 pressure sensor
3 Travel pressure sensor 10 Option 1 17 P2 pressure sensor
4 1st option pressure switch 11 Travel (left) 18 Regulator
5 N1 pressure sensor 12 Arm (2) 19 P1 flow control proportional valve
6 N2 pressure sensor 13 Boom (1)
7 Arm (1) 14 Bucket
[1] Operation conditions for swing relief cut control
The swing relief cut control provides relief when the pressure is boosted for the start of the swing
due to sharp swing operation and the drained off excess oil is held to the lowest amount possible.
The purpose is to provide an energy saving effect.
Control is executed when all the conditions below are satisfied.
1) Sharp swing operation … When the swing lever is operated, this is judged from the swing pilot
pressure sensor pressure rise.
2) Within 1 sec. after start of swing
3) Travel non-operation … Travel pressure sensor OFF
4) Attachments other than boom down non-operation
… Non-operation of attachments is judged from the N2 negative control pressure and P1
pressure sensor
5) Option line non-operation … Option pressure sensor OFF
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[2] Control contents
For the swing relief cut operation, after the milli-amp to the P1 flow control proportional valve is
increased and the P1 flow is reduced, while checking the P1 pump discharge pressure, the
system gradually reduces the output milli-amp to the P1 flow control valve and raises the P1
pump flow to the constant swing speed.
• Swing relief cut control flow
Independent swing + sharp operation judged ⇒ Swing relief cut operation ⇒ Milli-amp to P1 flow
control proportional valve increased ⇒ P1 pump flow reduced ⇒ Milli-amp gradually decreased
while watching swing pressure fall status ⇒ P1 pump flow increased
Caution
P1 flow control proportional valve: milli-amp (high) ⇒ P1 pump flow (low); milli-amp (low) ⇒ P1
pump flow (high)
[3] Swing relief cut end conditions
1) When swing operation is stopped
2) Travel ON
3) Boom up, arm out/in, bucket open/close
4) Boom-down sharp operation
5) Boom-down pressure boost
Purpose
With the increase in the pump maximum flow, the swing speed at maximum flow is too fast.
Therefore, the P1 pump flow is controlled to suppress the speed rise. (Control only in SP mode)
P1 maximum discharge volume held down from 75 Gal (285 L/min) to 74 Gal (280 L/min) for
independent swing operation
1 Computer A 8 Boom (2) 15 Travel (right)

2 Throttle volume 9 Swing 16 P1 pressure sensor
3 Travel pressure sensor 10 Option 1 17 P2 pressure sensor
4 1st option pressure switch 11 Travel (left) 18 Regulator
5 N1 pressure sensor 12 Arm (2) 19 P1 flow control proportional valve
6 N2 pressure sensor 13 Boom (1)
7 Arm (1) 14 Bucket
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[1] Operation conditions for swing speed limit control
Control is executed when all the conditions below are satisfied.
1) Swing single full lever operation … Judged from the N1 and N2 negative control pressure
sensors and P1 and P2 pressure sensors
2) Travel non-operation … Travel pressure sensor OFF
3) The work mode is SP mode.
[2] Control contents
The output milli-amp to the P1 flow control valve is set to the maximum of 370 mA and the P1
pump flow is held down to 74 gpm (280 L/min).
[3] Swing speed limit end conditions
1) Travel operation ⇒ Immediate end (to prevent off travel)
2) Other attachment operation ⇒ Gradual end (to reduce shock)
3) Option circuit operation
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Travel
1. Travel Speed Switchover
The travel motor tilting angle is changed by switching the travel speed between low speed and high
speed with the switch.
However, in high-speed mode, if the drive pressure becomes high due to the functioning of the travel
motor itself, the tilting angle is automatically switched to low speed.
After that, when the drive pressure becomes low, the slope automatically returns to high speed.
1 Computer A
2 Engine
3 Travel high-speed select switch
4 Travel motor
5 Travel high-speed solenoid
6 Key switch
[1] Operation
1) When the key is ON, the speed becomes low speed. The previous travel mode is reset.
(If the service support operation is changed, it is possible to hold the previous data.)
2) Each time the travel high-speed switch is pressed, the speed is switched between low speed
and high speed. During high speed, the LED at the top left of the switch lights up.
3) While the engine is stopped with the key ON, if the travel high-speed switch is pressed, the
solenoid does not operate. The LED lights up.
(To prevent the battery being run down)
4) In high-speed mode, the tilting angle is automatically switched between low speed and high
speed by the travel motor drive pressure.
However, the electrical control remains at high speed, the high-speed LED remains lit, and the
solenoid remains ON.
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[2] Trouble mode
If an abnormality occurs in communication (serial/CAN) or computer A solenoid output, the
speed is fixed to low speed. (The travel high-speed solenoid comes OFF.)
2. Travel Alarm
[1] Configuration
1 Computer A Travel alarm mode select switch

3
2 Travel pressure sensor (alternator)
[2] Travel alarm (automatic stop)

When the travel pressure sensor comes ON due to travel operation, the travel alarm starts 1 Hz
continuous buzzing. This buzzing automatically stops after 10 sec.
[3] Travel alarm (continuous buzzing)
When the travel alarm mode select switch is switched ON, the buzzer buzzes continuously during
travel. (Function for North America only)
[4] Signals when key is ON
After the key is switched ON, the travel alarm sounds for 0.4 sec. as a signal.
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[5] Time chart
[6] Trouble mode

If trouble occurs in the travel pressure sensor, the machine goes into trouble mode and the travel
alarm is always OFF.
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Valve Control
1. Lever Lock
1 Gate lock limit switch 3 Lever lock solenoid

2 Starter cut relay 4 Battery relay
When the battery relay is excited by the key being switched ON, the power enters the lever lock limit
switch. When the gate lever is raised, the lever lock switch (limit switch) comes ON and the lever
lock solenoid is operated. (For details on neutral start control, see Neutral Start in Explanation of
Functions and Operations.)
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[1] Target solenoid
• Travel high-speed switchover solenoid
• Pressure boost solenoid
• Option switchover solenoid
• Fan reverse solenoid (only for models with hydraulic drive fan)
• Free swing solenoid
• Bucket lock solenoid (only liftcrane specification machines)
* Because the swing brake, power save solenoid, and electromagnetic proportional solenoid go
ON and OFF frequently in regular work, they are not subject to control.
[2] Operation
When key ON, switched ON/OFF for 0.25 sec.
After that, control is normal control. Control ends before the engine starts, so the machine does
not operate accidentally.
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3. Pressure Boost Control
[1] Configuration
1 Computer A 6 2nd option line pressure switch 11 P2 pressure sensor

2 Engine 7 Control valve 12 Pump 1
3 Upper pressure sensor 8 Main relief valve 13 Pump 2
4 Travel pressure sensor 9 Pressure boost solenoid 14 Regulator
5 Option line pressure switch 10 P1 pressure sensor
[2] During upper operation (upper pressure sensor = ON), the next time the high-load conditions are
met, the pressure boost solenoid valve on the 5 stack solenoid valve comes ON, and the main
relief valve pressure rises from 4975 PSI (34.3 MPa) to 5337 PSI (36.8 MPa).
Conditions
When the engine load ratio rises and the P1 or P2 pump pressure is boosted.
[3] Auto pressure boost (ended by time restriction)
When the work mode is SP or H, the pressure boost continues a maximum of 8 sec., then is
automatically ended (pressure boost solenoid = OFF). When the work mode is AUTO, this time
restriction is eliminated and the pressure boost is always available.
[4] Auto pressure boost (ended by operation stop)
Even before the time limit for auto pressure boost, if the upper pressure sensor goes OFF, the
boost is ended.
[5] Boost prohibition
During travel (travel pressure sensor = ON) or the breaker is in use (option line pressure switch =
ON and
breaker mode), the boost is not used. (Actuator protection)
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[6] Auto pressure boost setting
Auto pressure boost ON/OFF and enabling/disabling of pressure boost during breaker operation
can be set with service support operations.
[7] During boosting, the monitor displays an icon.
[8] Time chart (when work mode = SP or H)
[9] Trouble mode

If trouble occurs in an input (upper pressure sensor/travel pressure sensor), output (pressure
boost solenoid) or communication (CAN), the system goes into trouble mode. In trouble mode,
the pressure boost solenoid is fixed to OFF.
* Even if trouble occurs in UART communication, the system does not go into trouble mode.
* Trouble in the (2nd) option line pressure switch cannot be detected.
[10] Recovery from trouble mode
Even if the trouble is recovered from, trouble mode continues.
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Monitor Control
1. Bar Graph (coolant temperature gauge, oil temperature gauge, fuel gauge)
(1) Coolant temperature gauge
[1] Configuration
1 Coolant temperature gauge 3 Computer A

2 Monitor 4 Coolant temperature sensor
[2] Operation summary

The ECM reads the coolant temperature from the coolant temperature sensor installed on
the engine and send to computer A through CAN communication. After computer A receives
the coolant temperature, it judges the gauge level, and sends the display data to the monitor
with UART communication.
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[3] Gauge and coolant temperature
The gauge level is judged based on the diagram below.
[4] Preventing flickering

When the temperature moves up or down near the gauge level fluctuation threshold (for
example 124º F (5º C)), the gauge goes on and off repeatedly causing flickering. In order to
prevent that, the gauge level is judged using the temperature (judgment coolant
temperature) after the following processing.
• Judgment coolant temperature = Average of the coolant temperatures obtained the past 32
times
• Coolant temperature obtained period = 1 sec.
• Bar graph update period = 32 sec. (updates when the 32nd coolant temperature obtained)
[5] Trouble mode
If trouble occurs in the coolant temperature sensor or CAN bus, the bar graph itself is not
displayed.
1) If there is a short, the bar graph display is immediately ended.
2) For a disconnection, the display goes off 3 min. after the engine starts.
If trouble occurs in UART communication (computer A → monitor), the display is fixed at the
last state sent.
When the trouble is recovered from, the display returns to normal.
For a disconnection, when the key is switched OFF more than 3 min. after the engine starts,
then ON again, the display is recovered.
☆ ) Coolant temperature obtained during trouble

If a meaningless coolant temperature were obtained and the processing in [4] carried out,
display upon recovery would be strange. In order to prevent this, the coolant temperature
is not obtained during a coolant temperature sensor or CAN bus trouble.
[6] Message display
When the gauge level reaches 8, "OVERHEAT" is displayed on the monitor and the buzzer
buzzes.
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(2) Oil temperature gauge
[1] Configuration
1 Oil temperature gauge 4 Hydraulic oil tank

2 Monitor 5 Oil temperature sensor
3 Computer A
Computer A reads the oil temperature from the oil temperature sensor installed in the
hydraulic oil tank outlet suction pipe and judges the gauge level. The gauge level is sent to
the monitor with UART communication.
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[3] Gauge and oil temperature
The gauge level is judged based on the diagram below.

When the temperature moves up or down near the gauge level fluctuation threshold (for
example 77º F (25º C)), the gauge goes on and off repeatedly causing flickering. In order to
prevent that, the gauge level is judged using the temperature (judgment oil temperature)
after the following processing.
• Judgment oil temperature = Average of the oil temperatures obtained the past 32 times
• Oil temperature obtained period = 1 sec.
• Bar graph update period = 32 sec. (updates when the 32nd oil temperature obtained)
[5] Trouble mode
If trouble occurs in the oil temperature sensor, the bar graph itself is not displayed. (only for
trouble due to short)
If trouble occurs in UART communication (send: computer A → monitor), the display is fixed
at the last state sent.
☆ ) Oil temperature obtained during trouble

If a meaningless oil temperature were obtained and the processing in [4] carried out,
display upon recovery would be strange. In order to prevent this, the oil temperature is not
obtained during an oil temperature sensor trouble.
[6] Message display
When the gauge level reaches 8, "OVERHEAT" is displayed on the monitor and the buzzer
buzzes.
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(3) Fuel gauge
[1] Configuration
1 Monitor 3 Fuel tank

2 Computer A 4 Fuel sensor

Computer A reads the fuel level from the fuel sensor installed in the fuel tank and judges the
gauge level.
The gauge level is sent to the monitor with UART communication.
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[3] Relationship between gauge level and lever angle
R: Lever angle percentage [%]

Gauge level and fuel level [L]
1 2 3 4 5 6 7 8
(R ≦ 0 %) (R < 22 %) (R < 38 %) (R < 52 %) (R < 67 %) (R < 82 %) (R < 100 %) (R ≧ 100 %)
- 37.8 - 98.0 - 156.3 - 213.1 - 275.7 - 335.5 - 395.6 - 407.5
[4] Message display
When the gauge level reaches 1, "LOW FUEL" is displayed on the monitor and the buzzer
buzzes. (See "Message Display List".)
When the fuel surface in the tank shakes and the fuel sensor lever angle moves up or down
near the gauge level fluctuation threshold (for example 7%), the gauge goes on and off
repeatedly causing flickering.
In order to prevent that, the gauge level is judged using the lever angle (judgment lever
angle) after the following processing.
• Lever angle obtained period = 1 sec.
• Bar graph update period = 5 sec.
• The judgment value when the bar graph is updated = Average lever angle over the past 20
sec.
[6] Trouble mode
If trouble occurs in the fuel sensor, the bar graph itself is not displayed.
If trouble occurs in UART communication, the display is fixed at the last state sent.
(Send: Computer A → Monitor)
[7] Lever angle obtained during trouble
If lever angle were obtained and the processing in [5] carried out, display upon recovery
would not be normal.
In order to prevent this, the lever angle is not obtained during a fuel sensor trouble.
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Accessories
1. Horn
Basic operation
[1] When the horn switch is pressed, the horn is driven via a relay.
[2] When the volume select switch is switched ON, the LED indicator lights up and only the horn (L)
sounds. (horn volume down)
The volume select switch state is retained even when the key is switched OFF. (The previous
data is held.)
[3] Communication with computer A
When this switch is pressed, the signal is first sent to the computer A and processed.
Then, the drive command is sent to the monitor and the monitor drives the horn (R) relay.
[4] Trouble mode
If there is an error in UART communication, the monitor goes into trouble mode.
In trouble mode, the monitor carries out the operation in [2] on its own without receiving
commands from the computer A.
However, the previous data is not held. (The monitor always starts up with normal volume.)
When the error is recovered from, trouble mode ends too and the monitor returns to normal
mode.
1 Monitor panel 6 Horn (L) relay

2 Horn volume select switch (with LED indicator) 7 Horn (R) relay
3 Horn switch 8 Horn (R)
4 Computer A 9 Horn (L)
5 Key switch
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2. Working Light
Basic operation
[1] When turning the key to ON, always start with the working light OFF. (Previous data reset)
[2] Each time the working light switch is pressed, the working light is switched between ON and OFF.
(momentary)
When this light is ON, the LED indicator lights up.
[3] Communication with computer A
When the working light switch is pressed, the signal is first sent to the computer A and
processed.
Then, the light command is sent to the monitor and the monitor drives the relay.
[4] Trouble mode
If there is an abnormality occurs in UART communication, the monitor goes into trouble mode.
In trouble mode, the monitor carries out the operation in [2] on its own rather than commands
from the computer A.
When the communication abnormality is recovered from, trouble mode is exited and the monitor
returns to normal mode.
1 Monitor panel 6 Working light relay (cab)

2 Working light switch (with LED indicator) 7 Working light (boom)
3 Computer A 8 Working light (tool etc.)
4 Key switch 9 Working light (cab top)
5 Working light relay (upper)
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3. Wiper and Washer
[1] Configuration
1 Monitor panel 4 Monitor 7 Key switch

2 Washer switch 5 Front window limit SW 8 Wiper motor
3 Wiper switch (with LED indicator) 6 Computer A 9 Washer motor
[2] Wiper basic operation

When the wiper switch is pressed, it switches to the next state in the order: intermittent operation
→ continuous operation → OFF → intermittent. In intermittent operation, the I LED is lit and in
continuous operation, the II LED lights up. (When the wipers are OFF, both are OFF.) When
turning the key ON, always start from OFF. (Previous data reset)
[3] Washer basic operation
While the washer is pressed, the washer operates.
[4] Wiper linked with washer
While the washer switch is pressed, after 0.5 sec., the washer starts
to operate linked with the wipers.
When the washer switch is released, the washer stops, and after 2
wipes, the wipers stop too.
1) Auto rise up
Even during wiper operation, if the key is turned OFF, the wipers
are automatically stopped and retracted. 1 Wiper switch
2) Overload prevention
If the blades are locked, the monitor output is stopped.
[5] Front window open detection
If the front window is opened while the wipers or washer are operating, it is stopped.
The operations of [2] and [3] are not carried out while the front window is open.
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[6] Wiper controller duty
The wiper controller is responsible for [2] - [4]. [5] is provided by the monitor/controller detecting
the front window being open and the output to the wiper controller being switched OFF.
[7] Computer A duty
Computer A receives switch signals from the monitor through UART communication (wiper
switch, washer switch, front window limit switch).
This signal is processed by computer A and the 3 ports that control the wiper controller (WIPER
(INT), WIPER (CNT), and WASHER) are controlled as in the following time chart.
[8] Time chart
1) During washer operation, wiper operations are handled automatically by the wiper controller
even if there is no output to WIPER (INT) or WIPER (CNT).
2) Wiper stop by front window open detection
3) Washer-linked wiper stop by front window open detection
[9] Trouble mode
If there is an error in UART communication, the monitor cannot receive drive commands from
computer A.At this time, the monitor goes into trouble mode and independently executes the
same control as in [8].
When the UART communication abnormality is recovered from, the monitor recovers from trouble
mode and follows the drive commands from computer A.
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4. Room Lamp
[1] Configuration
1 Key switch 4 Room lamp

2 Clock unit 5 Door limit switch
3 Room lamp relay
• The clock unit is not connected with computer A or B and controls the room lamp relay on its
own.
• For the connection destination, see "Air Conditioner".
• The clock unit is connected to the backup power supply and continues to operate even if the key
is switched OFF.
[2] Door link
When the room lamp switch is set to the DOOR position, the lamp lights when the door is open
and goes out when the door is closed.
[3] Auto lamp off
In [2], in order to prevent the battery from being run down, the room lamp goes out 30 sec. after
the door is opened. However, this function only works when the key switch is OFF. If it is ACC or
ON, auto lamp off does not work. (Because even if the room lamp relay is OFF, power is supplied
from ACC.)
The only purpose of this auto lamp off function is to prevent the battery from being run down if the
door is left open with the key OFF.
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[4] Time chart
The time chart shows how the function in [3] works. The room lamp switch is set to DOOR.
0）Door linked room lamp

1）Even after the door is closed, the room lamp relay is ON for 30 sec.
2）30 sec. is counted from the last time the door was opened.
3）After 30 sec., the lamp goes off automatically.
4）Auto lamp off does not work if the key switch is ON or ACC.
5）When the key is switched OFF, the lamp goes out. (after power-cut delay)
[5] Trouble mode
Since the clock unit does not have a trouble detection function for either input (IN1) or output
(OUT1), it does not go into trouble mode.
[6] Time chart
This shows the operation when the room lamp switch is ON.
1) If the key is OFF, the lamp goes out automatically after 30 sec.
2) Auto lamp off does not work if the key switch is ON or ACC.
3) Power-cut delay
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5. Radio Mute
[1] Configuration
1 Mute switch (knob) 4 Speaker (L) relay 7 Speaker (R)

2 Clock unit 5 Speaker (R) relay
3 Radio 6 Speaker (L)
[2] Summary and purpose

The radio volume can be switched ON/OFF with one-touch control by switching the speaker (L
and R) signal lines on and off with a relay.
[3] Operation
Each time the mute switch on the knob is pressed, the radio volume is switched between ON ⇔
OFF. (momentary)
When the key is switched ON, the radio always starts with mute off (normal radio volume).
(Previous data reset)
[4] Battery save
In order to prevent the battery from being run down, when the key is at ACC (accessory), the
radio is always set to mute off (normal radio volume).
[5] Time chart
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Other
1. Anti-theft
(1) Anti-theft control
If the anti-theft password does not match (anti-theft is not ended), the machine operation is
controlled.
1 Computer A 4 P2 pressure sensor 7 Swing brake solenoid

2 Engine 5 Travel pressure sensor 8 Travel alarm
3 P1 pressure sensor 6 Upper pressure sensor
[1] If the engine is started without shutting off the anti-theft device, the machine is controlled.
1) The engine speed is fixed at low idle.
2) The swing brake cannot be released. (Solenoid operation is not possible.)
3) The travel alarm buzzes continuously.
[2] In the state in [1], if any of the following operations is executed, the engine is forced to stop.
1) Upper or travel operation (Detected by the corresponding sensor)
2) The P1 or P2 pressure rises to 725 PSI (5 MPa) or higher.
3) The engine load ratio is 50 % or higher for 2 sec. cumulative.
4) The upper, travel, P1, or P2 pressure sensor is removed.
[3] Even in the state in [1], the anti-theft control can be ended by inputting the correct password.
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2. Battery Save Function
[1] Summary and purpose
In order to prevent the battery from being run down when the key is ON and the engine is
stopped, solenoid and proportional valve output is suppressed.
[2] Operation
See the table below.
Control target Operation when the engine is stopped with the key ON
Travel high-speed Fixed to OFF (low speed) whether the travel speed select switch ON or OFF.
switchover solenoid However, the LED at the side of the switch is linked with the switch.
Power save solenoid Fixed to OFF (power save OFF)
Fixed to OFF (free swing OFF) whether the free swing switch ON or OFF.
Free swing solenoid
However, the free swing icon on the monitor is linked with the switch.
Fixed at OFF (crusher side) regardless of whether the breaker/crusher mode
Option return line
switch is ON or OFF.
switchover solenoid
However, the attachment icon on the monitor is linked with the switch.
Pressure boost Fixed to OFF (no boost) regardless of the work mode (throttle volume position).
solenoid However, the status icon on the monitor is linked with the throttle.
0 mA, so the standby milli-amp for detecting disconnections of 50 mA does not
Pump horsepower
flow.
proportional valve
Disconnections are only detected after the engine has started.
Pump flow proportional
Same as above
valve
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3. Alternator Power Generation Detection
[1] Configuration (fuses etc. omitted)
1 Computer A 3 Battery relay

2 Key switch 4 Alternator
[2] Separated from battery voltage

When the battery relay is closed, by looking not at the B terminal, where the battery voltage is
applied, but rather to the independent L terminal, defects in the alternator alone are detected.
(The battery voltage is monitored by the ECM. (IN2))
[3] Operation
Alternator L terminal output voltage judged with 10 V comparator
ON when L terminal voltage ≧ 10 V
OFF when L terminal voltage < 10 V * The threshold value of 10 V has a tolerance of ± 1 V.
[4] Power generation defect judgment
If the 10 V comparator input is OFF even though the engine is running, it is judged that there is a
power generation defect. For details on the judgment conditions, see the "Main Unit Diagnostic
Trouble Code List".
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4. Overload Warning
[1] Configuration
1 Overload warning switch (alternate) 4 Boom cylinder bottom pressure sensor

2 Monitor panel 5 Boom
3 Computer A 6 Boom cylinder
[2] This function is only mounted on machines for Europe.

[3] Warning judgment
When the overload warning switch is ON, the overload warning is switched ON/OFF according to
the following conditions.
ON: (Boom cylinder bottom pressure ≧ set pressure) for continuously for 1 sec.
OFF: (Boom cylinder bottom pressure ≦ set pressure - 290 PSI (2 MPa)) for continuously for 1
sec.
* For the set pressure for each model, see "Overload set pressure".
* The set pressure can be changed with CFG.
[4] Operation when warning judgment ON
The "OVERLOAD" message is displayed on the monitor and the buzzer buzzes continuously.
This message is handled as an "alert". For details, see "Message Display List".
[5] Ending the warning
To end a warning that has been issued, either switch the overload warning switch OFF or operate
the attachment in such a way that the judgment in [2] goes OFF.
Be aware that there is no buzzer stop switch like the one in Model 3B.
[6] Trouble mode
If trouble occurs in the boom cylinder bottom pressure sensor, this function goes into trouble
mode and the warning judgment is fixed to OFF.
Even if the trouble is recovered from, trouble mode continues until the key is switched OFF.
[7] Trouble judgment
The boom cylinder bottom pressure sensor trouble judgment is made after the overload warning
switch has come ON once.
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[8] Time chart
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Options
[1] Configuration
[Multi-purpose circuit with 2nd option line]
1 Monitor panel 7 4th pump 13 1st option pedal

2 Breaker mode switch 8 Control valve 14 1st option pressure switch
3 Option select switch 9 3-direction valve 15 1st option switch (L)
4 Crusher mode switch 10 Shut-off valve 16 1st option switch (R)
5 2 pumps flow switch 11 Solenoid valve for 2 pumps flow
6 2nd option control valve 12 Option switchover solenoid valve
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Option select switch switchover (breaker mode ⇔ crusher mode)
Operation
When the option select switch is set to the breaker mode switch side, the option switchover
solenoid valve is operated and the and the shut-off valve and 3-direction valve are switched.
When the switch is switched to crusher mode, the option switchover solenoid valve goes OFF.
1 2nd option pedal

2 2nd option switch (L)
3 2nd option switch (R)
2 pumps flow select switch (1 pump ⇔ 2 pumps)

Operation
When the 2 pumps flow switch is switched ON, the solenoid valve for 2 pumps flow switches to 2
pumps flow.
Difference between pedal type and knob switch type
For the pedal type, solenoid valve for 2 pumps flow hydraulic pressure source is the secondary
pressure via the option 1 pedal shuttle, but for the knob switch type, the solenoid valve for 2
pumps flow hydraulic pressure source comes directly from the gear pump.
Therefore, when the 2 pumps flow switch is switched ON, operation becomes always 2 pumps
flow.
In order to prevent this, whereas for the pedal type the ground treatment for the 2 pumps flow
switch is to ground directly,
with the knob switch type, it is set so that the switch is not grounded unless one or the other of
the option switches is ON.
* Be careful with Model 5, as the shuttle valve is built into the option 1 pedal remote control
valve.
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Mode switchover
When the breaker mode switch/crusher mode switch is pressed, the option line mode changes as
follows.
* The factory setting is that only breaker 1 mode and crusher 1 mode can be selected.
* With settings on the service screen, the number of modes can be increased to 5 each for the
breaker and for the crusher, for a total of 10.
[2] For [1], the following icons are displayed according to each mode.
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[1] Configuration
[Multi-purpose circuit with 2nd option line (pedal type)]
1 Computer A 8 Arm (2) 15 Option pressure switch

2 N2 pressure sensor 9 Boom (1) 16 2nd option pedal
3 Arm (1) 10 Bucket 17 2nd option pressure switch
4 Boom (2) 11 Travel (right) 18 Pressure boost solenoid
5 Swing 12 Swing pressure sensor 19 P1 pump
6 Option 1 13 Travel pressure sensor 20 P2 pump
7 Travel (left) 14 Option pedal 21 P1 flow control proportional valve
* There are 2 operating methods: the pedal type and the knob switch type. With either type,
when the pedal or knob switch is operated, the switch input port (IN3, IN4 = IN4, IN5 of
"Option select and operating method") is the same. (In other words, there is no need to be
aware of the difference in operating method.)
• The explanation below uses the pedal method.
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[2] Option line operation control
The table below shows the control for operation of the independent option and compound
operation.
Option line mode Breaker Crusher 2nd option

1st option pressure switch 1st option pressure switch 2nd option pressure switch
… ON … ON … ON
Operation (IN3 is ground) (IN3 is ground) (IN4 is ground)
Independent Compound Independent Compound Independent Compound
Boost cut Yes Yes No
Flow restriction Yes Yes No No function (4th pump)
Engine speed/milli-
amp for pump
According to the command for the work mode selected with the throttle
horsepower control
proportional valve
• The flow is not cut for compound crusher operation. (to secure speed for compound operation)
• Since the breaker often works while the machine is jacked up with the boom (compound
operation), the flow is cut even for compound work. (the same as the engine reduction for the
current breaker)
• The pressure boost is cut when Option 1 and Option 2 are operated at the same time. (boost cut
priority)
• The engine speed and milli-amp for pump horsepower control proportional valve are according to
the work mode currently selected with the throttle.
(cannot be forced to change to another mode only for breaker/crusher.）
[3] Option 1 independent operation judgment conditions
When all the conditions below are satisfied, it is judged that this is independent operation.
Conditions
1st option pressure switch … ON Swing pressure sensor … OFF
Travel pressure sensor … OFF N2 pressure sensor ≧ 348 PSI (2.4 MPa)
[4] Flow cut
The maximum flow during option line operation is restricted by the option line selected in "Option
line selection and 2 pumps flow".
Also, be careful about the fact that since the flow set for the option line is the flow for SP mode,
when used in H/A mode,
the flow is slightly less than the display.
When neither the breaker or crusher mode is selected (normal mode), the minimum flow amount
(50 L/min) is produced when the pedal is pressed. (For prevention of damage to attachments)
[5] Trouble mode
If a trouble occurs in input (swing pressure sensor, travel pressure sensor, N2 pressure sensor)
or output (pressure boost solenoid, flow proportional valve),
the machine goes into trouble mode and
• Output command to pressure boost solenoid = fixed to OFF
• Output command to flow proportional valve = fixed to OFF
Mode continues until the key is switched OFF.
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3. Feed Pump Automatic Stop
[1] Configuration
1 Computer A 4 Fuel tank 7 Feed stop relay

2 Feed switch 5 Oil feed start relay 8 Full tank detection buzzer
3 Fuel sensor 6 Oil feed pump made by Jabsco 9 Engine
1) Feed pump main unit accessory (original) switch

This must be fixed ON beforehand in order to use this function.
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[2] Operating method
1) With the engine stopped and the key ON, if the feed switch is flipped down to the Auto side, the
fuel feed starts.
2) When the tank is full, the fuel feed stops automatically and the buzzer buzzes to announce that.
3) Returning the feed switch to the center stops the buzzer.
4) To feed more fuel
Press the feed switch manual side. The fuel is fed while the switch is pressed.
[3] Computer A control targets
Input = Fuel sensor (0 - 100 %), engine state (running/stopped)
Output = Feed stop relay
[4] System state (when relay OFF)
When the feed switch is set to the Auto side, the start relay comes ON and the pump operates.
[5] System state (when relay ON)
When the feed switch is set to the Auto side, the start relay goes OFF, and the pump does not
operate. Also, the buzzer buzzes.
[6] Feed stop relay control (while engine running and key ON)
Always ON (no feed)
[7] Feed stop relay control (while engine stopped and key ON)
OFF (auto feed enabled) when (fuel level < 94 % continuously for 3 sec.)
ON (auto feed disabled) when (fuel level ≧ 94 % continuously for 3 sec.)
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[8] Time chart
1) Even if the level falls below 94 %, no fuel can be fed as the engine is running.
2) Stopped, so fuel can be fed.
3) Fuel feed is not possible unless the key is switched ON.
4) If the engine is started during fuel feeding, the fuel feed stops.
5) When the operator forgets and leaves the switch switched to the Auto side, the pump operates
during the power-cut delay. (When fuel level under 98 %)
6) Power-cut delay
[9] Trouble mode
If trouble occurs in an input (fuel sensor), output (feed stop relay) or communication (CAN), the
system goes into trouble mode and the feed stop relay is fixed to OFF. Be careful. In trouble
mode, even if the feed switch is set to Auto, the fuel feed is not stopped.
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[1] Configuration
1 Computer A
2 Return filter clog pressure switch
4 Return filter
[2] Return filter clog pressure switch specifications
[3] Detection cancellation when breaker used

When the breaker is used, the return oil pressure pulse is intense, so clog detection is not
attempted.
[4] Detection cancellation when oil temperature low
When the oil temperature is less than 158º F (30º C), its viscosity rises and filter pressure
damage increases, so clog detection is not attempted.
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[5] Solution for machines with no breaker setting
Machines with no breaker setting in accordance with [3].
(= Machines with no return filter clog pressure switch) Even with these machines, filter clogs
would be detected. In order to prevent this, a special connector is set that is always shorted.
1 Computer A
[6] Disconnection detection

When the key is ON, if IN1 was OFF before the engine was started, the situation is judged to be
a disconnection abnormality.
5. Beacon
[1] Configuration
1 Beacon switch (alternate)

2 Computer A
3 Beacon
[2] Destination
This function is for Europe.
[3] Operation
The beacon is driven via the beacon relay linked with the beacon switch.
This function is not mediated by the computer A.
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NOTES:
Service Support SH330
Electrical
Service Support
Screen Operations
1. Screen Shift
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Service Support
[1] Operation for shifting to service support screen
1) If both the travel high-speed switch and the horn volume select switch on the switch
panel are held down for 3 sec., the display switches to the service support screen.
2) If both the travel high-speed switch and the horn volume select switch on the switch
panel are held down again for 1 sec., the display returns to the normal screen.
[2] Service support screen switching operation
1 Mode 3 Page
2 Section
1) Mode switchover; switching with travel high-speed switch

2) Section switch; switching with horn volume select switch
3) Page switchover; forward with light switch and back with washer switch
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Service Support
Screen Display List
1. CHK (status display) Screen List
In CHK mode, in addition to the machine status (milli-amp, oil pressures, temperatures, etc.), it is
possible to check sensor and switch input/output states, as well as the angle, load ratio and work
radius, etc. at the applied machine (liftcrane specifications machine, lifting magnet machine).
1 Section
2 Page
For the CHK mode section types and their contents, see the separate sheet.
* From the CHK mode screen, if the washer switch and the light switch are held down for 3
≦ R ≦ R sec., the display shifts to the model selection screen.
MAIN
[1] Engine and pump
Eng : Engine speed
Power : Actual milli-amp for horsepower control proportional valve
Flow : Actual milli-amp for flow control proportional valve
P1 : Pump 1 Discharge pressure
N1 : Pump 1 Negative control pressure
[2] Temperature and pressure

Coolnt : Radiator coolant temperature
HydOil : Hydraulic oil temperature
FuelT : Fuel temperature
Baro : Atmospheric pressure
EngOil : Engine oil pressure
BstT : Boost temperature
Air : Suction air temperature
[3] Load and boost

Eng : Engine speed
Load : Load ratio
BstP : Boost pressure
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[4] Load and milli-amp for horsepower control proportional valve
Eng : Engine speed
Load : Load ratio
[5] Target and actual milli-amp for horsepower control proportional valve
Eng : Engine speed
Load : Load ratio
-4- : ＊
tEng : Target engine speed
ThVol : Throttle volume degree of opening
Target milli-amp for horsepower control
tPower :
proportional valve
[6] Target and actual milli-amp for flow control proportional valve
Eng : Engine speed
Flow : Actual milli-amp for flow control proportional valve
N1 : Pump １ Negative control pressure
Swg : Swing pilot pressure
Target milli-amp for flow control proportional
tFlow :
valve
[7] Target and actual milli-amp for hydraulic fan proportional valve
Eng : Engine speed
Fan : Actual milli-amp for hydraulic fan proportional valve
HydOil : Hydraulic oil temperature
FuelT : Fuel temperature
tFan : Target milli-amp for hydraulic fan proportional valve
[8] Pilot pressure

Cyl (B) : Boom bottom pressure
Upr : Upper pilot pressure
Swg : Swing pilot pressure
Trv : Travel pilot pressure
AmCls : Arm-in pilot pressure
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[9] Input/output and pressure for hydraulic circuit
Hydraulic circuit input/output state ( ○ =OFF, ● =ON)
1 Pressure sensor; Arm in 5 Solenoid; Free swing/beacon 9 Relay; Travel alarm

2 Pressure sensor; Travel 6 Solenoid; Travel high-speed switchover 10 Solenoid; Fan reverse (large machine only)
3 Pressure sensor; Swing 7 Solenoid; Pressure boost 11 Solenoid; Option line switchover
4 Pressure sensor; Upper 8 Solenoid; Swing brake 12 Solenoid; Power save
[10] Input/output for electrical circuit

Eng : Engine speed
Batt : Battery voltage
FuelLv : Fuel level
Electric circuit input/output state ( ○ =OFF, ● =ON)
1 Switch; Anti-theft 6 Glow signal

2 Battery charge 7 Engine stop due to trouble
3 Switch; Key 8 Low idle restriction due to trouble
A/C coolant temperature sending Restriction on milli-amp for horsepower
4
mode (1: Low/2: Medium/3: High) 9 control proportional valve due to trou-
5 Relay; Feed pump automatic stop ble
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MNT
[1] Computer S information
* The longitude and latitude are displayed when the continuous

GPS position measurement time is 5 min. or longer.
* UTC is global standard time. Japan is +9 hr. from UTC.

Example:
If the time is May 28, 2006, 03:14:32 UTC, the time in
Japan is May 28, 2006, 12:14:32.
If the time is May 27, 2006, 20:14:32 UTC, the time in
Japan is May 28, 2006, 05:14:32.
* Displayed after the completion of GPS position
measurement.
* For 3D position measurement, the altitude can be
measured.
* GCC is a land station. 130 is the GCC for Japan. (122 is
South Korea.)
GPS continuous position measurement time
1
(For example, 5 min. 30 sec. of continuous position measurement)
2 Computer S part number bottom 4-digit display (Example, KHR14401)
Inside the ○ latitude, 0 = North latitude, 1 = South latitude
3
(Example, 35 degrees 47.83 min. north latitude)
Inside the ○ longitude, 0 = Longitude east, 1 = Longitude west
4
(Example, 140 degrees 41.32 min. longitude east)
GPS position measurement status Default setting send status
0 = GPS not yet operating, 0 = Waiting for default settings send
1 = GPS measuring, 1 = Waiting due to sending currently
2 = 2D measurement status, being prohibited
5 3 = 3D measurement status, 7 2 = Resending default settings
8 = GPS module abnormality, 3 = Default settings send complete,
9 = GPS antenna abnormality sending prohibited
4 = Default settings send complete,
sending permitted
Satellite communications status BLANK
0 = No satellite supplement,
6 1 = Satellite supplement, 8
9 = Satellite communication abnormal-
ity
UTC 10 Altitude (Example: 2047 in (52 m))
(Example: May 28, 2006, 03:14:32) 11 Send GCC number
9
The time in Japan is May 28, 2006,
12:14:32. 12 Data acquisition GCC number
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Event send setting

The default state is fuel volume warning, anti-theft operation warning event send prohibited.
These can be changed to enabled with signals from the web server. When this signal is received, No. 4 becomes the display below.
Anti-theft operation Anti-theft operation

warning warning
Fuel volume warning
(without position infor- (with position informa-
mation) tion)
0028 Prohibited Prohibited Prohibited
0156 Enabled Prohibited Prohibited
0220 Enabled Enabled Prohibited
0188 Enabled Prohibited Enabled
0092 Prohibited Enabled Prohibited
0060 Prohibited Prohibited Enabled
Engine start enable setting

1
0 = Prohibited, 1 = Enabled
Send destination count
2 * The send destination is the server, so it is
fixed at 1.
Time until next sending
3 (Example: 3 hr. 24 min. more until the next
sending)
4 Send wait message count (Example: 2)
Q1200 status
0 = Waiting
5 1 = Sending
4 = Receiving
5 = Receiving complete
Send distribution setting
6 0248 = STD
0252 = Liftcrane specifications
Event send setting
7
0028 = Default
Send prohibition setting
8 0 = Sending default settings
128 = Default settings send complete
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H/W-A
[1] Digital input/output
Input/output state ( ○ =OFF, ● =ON)
1 Solenoid; Power save 9 Relay; Feed pump 17 Switch; Pressure (Option)

2 Solenoid; Pressure boost 10 Switch; Clog (Air cleaner) 18 Switch; Fan reverse
3 Solenoid; Travel high-speed switchover 11 Switch; Level (Coolant) 19 Switch; Clog (Return filter)
4 Solenoid; Swing brake 12 Switch; Anti-theft 20 Alternator
5 Buzzer; Travel alarm 13 Switch; One-touch idle 21 Switch; Engine emergency stop
6 Solenoid; Option line switchover 14 Switch; Travel alarm/overload 22 Switch; Key
7 Solenoid; Free swing 15 Switch; Free swing
8 Solenoid; Fan reverse 16 Switch; Pressure (2nd option)
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[2] Digital output/output monitor
1 Solenoid; Power save 4 Solenoid; Swing brake 7 Solenoid; Free swing

2 Solenoid; Pressure boost 5 Buzzer; Travel alarm 8 Solenoid; Fan reverse
3 Solenoid; Travel high-speed switchover 6 Solenoid; Option line switchover 9 Relay; Feed pump
[3] Potentio-meter voltage

Pot1 : Sensor pressure P1
Pot2 : Sensor pressure P2
Pot3 : Sensor pressure N1
Pot4 : Sensor pressure N2
Pot5 : Sensor pressure Swing
Pot6 : Sensor pressure Upper
Pot7 : Sensor pressure Travel
[4] Potentio-meter and sensor voltage (resistance)

Pot8 : Sensor pressure Arm in
Pot9 : Sensor throttle
Pot10 : Sensor pressure Overload
Sn1 : Sensor temperature Hydraulic oil
Sn2 : Sensor level Fuel
Sn1 : Sensor temperature Hydraulic oil
Sn2 : Sensor level Fuel
[5] PWM data

PWM# : PWM channel number
actcur : Actual milli-amp for horsepower control proportional valve
tgtcur : Target milli-amp for horsepower control proportional valve
duty : Duty
freq : Frequency
volt : Voltage
Overcurrent detection status
ovc :
(+: Overcurrent/-: Normal)
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[6] PWM data
actcur : Actual milli-amp for hydraulic fan proportional valve
tgtcur : Target milli-amp for hydraulic fan proportional valve
duty : Duty
freq : Frequency
volt : Voltage
ovc :
[7] PWM data

actcur : Actual milli-amp for flow control proportional valve
tgtcur : Target milli-amp for flow control proportional valve
duty : Duty
freq : Frequency
volt : Voltage
Overcurrent detection status (+: Overcurrent/-:
ovc :
Normal)
[8] Frequency and communication

FreqIn : Frequency input
CAN : CAN reception state
UART : UART reception state
RS232 : RS232C communication state
-5- : ＊
-6- : ＊
-7- : ＊
Input/output state ( ● =receiving)
1 Computer S reception state

2 Computer B reception state
3 ECM reception state
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H/W-B
[1] Computer B digital input/output
1 Solenoid; Lever lock 4 Switch; Liftcrane mode 7 Switch; Lifting magnet mode
2 Rotating light and bucket lock 5 Switch; Liftcrane (Display switching) 8 Switch; Interference (Shut-off release)
3 Buzzer; Liftcrane 6 Switch; Interference (Temporary end)
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[2] Digital output/output monitor
1 Solenoid; Lever lock

2 Rotating light and bucket lock
3 Buzzer; Liftcrane
[3] Potentio-meter voltage

Pot1 : Sensor; Angle (Boom)
Pot2 : Sensor; Angle (Arm)
Pot3 : Sensor; Angle (Offset)
Pot4 : Sensor; Pressure (Bottom)
Pot5 : Sensor; Pressure (Rod)
Pot6 : ＊
Pot7 : ＊
[4] Potentio-meter and sensor voltage (resistance)

Pot8 : ＊
Pot9 : ＊
Pot10 : ＊
Sn1 : ＊
Sn2 : ＊
Sn1 : ＊
Sn2 : ＊
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[5] PWM data
actcur : Actual milli-amp for boom proportional valve
tgtcur : Target milli-amp for boom proportional valve
duty : Duty
freq : Frequency
volt : Voltage
ovc :
[6] PWM data

actcur : Actual milli-amp for offset proportional valve
tgtcur : Target milli-amp for offset proportional valve
duty : Duty
freq : Frequency
volt : Voltage
ovc :
[7] PWM data

actcur : Actual milli-amp for arm proportional valve
tgtcur : Target milli-amp for arm proportional valve
duty : Duty
freq : Frequency
volt : Voltage
ovc :
[8] Frequency and communication

FreqIn : Frequency input
CAN : CAN reception state
UART : UART communication state
RS232 : RS232C communication state
-5- : ＊
-6- : ＊
-7- : ＊
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H/W-M
[1] Monitor
1 Working light 7 Switch; Travel high-speed select 13 Switch; Washer

2 Motor washer 8 Switch; Auto idle select 14 Switch; Reserve
3 Wiper CNT 9 Switch; Horn volume select 15 Switch; 2 pumps flow
4 Wiper INT 10 Switch; Breaker select 16 Switch; Crusher select
5 Relay horn volume switchover 11 Switch; Limit front window
6 Switch; Working light 12 Switch; Wiper
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2. DIAG (trouble diagnosis) Screen
[1] In diagnosis mode, the contents for the trouble currently occurring and a log of trouble that has
occurred in the past can be checked.
1 Status occurrence count 4 Diagnostic trouble code

2 Initial occurrence time 5 Cursor movement
3 Final occurrence time
• In "DTC-1" - "DTC-4", the last diagnostic trouble codes that occurred are displayed starting with
the most recent one.
1) The cursor is moved with the wiper switch and auto idle switch . (The cursor moves
between "DTC-1" and "DTC-4".)
* There is no "section" in diagnosis mode.
• The information for the diagnostic trouble code for the location under the cursor is displayed in
the order "St/Oc", "1st", "Last".
• The ○ mark displayed at the left most of "St/Oc" shows whether or not the trouble is currently
occurring.
The black circle ● means the trouble is currently occurring.
The clear circle ○ means the trouble is not occurring now, but has occurred in the past.
• "1st" indicates the time at which this trouble occurred the first time and "last" indicates the time at
which this trouble occurred the last time.
[2] For details on the "Diagnostic trouble codes" that can be read in diagnosis mode and their
contents, see the Main Unit Diagnostic Trouble Code List below.
(1) Screen
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[1] Displays the status at the cursor and the occurrence count.
[Status]
Displays whether the diagnostic trouble code under the cursor is current or from the past.
For ● , the trouble is current or continuing.
For ○ , the status is normal or recovered. (The trouble is not occurring now, but has
occurred in the past.)
[Occurrence count]
The number of times that diagnostic trouble code under the cursor has occurred
[2] Displays the time at which the trouble under the cursor first occurred
[3] Displays the time at which the trouble under the cursor last occurred
[4] Diagnostic trouble code

The troubles are sorted with the last one to occur at the top of the list.
Displayed when the whether the diagnostic trouble code under the cursor is ① - ③ .
Maximum display count

4 codes per page × 16 pages = 64 diagnostic trouble codes are displayed. From the 65th
code onward, the oldest code is erased. However, even though these codes are not
displayed, the data is retained.
(2) Operation
[1] Cursor up/down
Up operation............. Wiper switch
Down operation ........ Auto idle switch
[2] Page forward/back
Forward operation .... Light switch
Back operation ......... Washer switch
(3) Reset
If the washer switch and the light switch are held down for 10 sec., the trouble log is
reset.
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3. HR (usage log) Screen List
Operation times for mechanical parts, electrical parts, etc., operation counts for switches and
solenoids, as well as pressure distributions, etc. can be displayed.
1 Section
2 Page
(1) MAIN
[1] Main unit operation time
KeyOn : Computer A power supply ON time
EngOn : Alternator power generation time
Work : Machine operation time (upper ON or travel ON)
Upr : Upper operation time
Swg : Swing operation time
Trv : Travel operation time
TrSolo : Independent travel operation time
[2] Electrical parts operation time

WpInt : Wiper (intermittent) Operation time
WpCnt : Wiper (continuous) Operation time
Wsh : Washer Operation time
WLight : Working light ON time
HornLo : Horn volume low time
DrOpn : ＊
WinOpn : Front window open time
[3] Idle time

1 : Auto idle time
2 : One-touch idle time
3 : Boosted pressure time
4 : Low-speed travel time
5 : High-speed travel time
6 : ＊
7 : ＊
[4] Pressure switch operation count

1 : Upper pressure sensor ON count × 1000
2 : Swing pressure sensor ON count × 1000
3 : Travel pressure sensor ON count × 1000
4 : Arm-in pressure switch ON count × 1000
5 : 1st option pressure switch ON count × 1000
6 : 2nd option pressure switch ON count × 1000
7 : ＊
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[5] Operation switch operation count
1 : Key ON count × 10
2 : Engine start count × 10
3 : Front window open count × 10
4 : ＊
5 : Pressure boost solenoid ON count × 1000
6 : Swing brake solenoid ON count × 1000
7 : Power save solenoid ON count × 1000
[6] Work mode

1 : Mode usage time SP-hi
2 : Mode usage time SP-lo
3 : Mode usage time H-hi
4 : Mode usage time H-lo
5 : Mode usage time A1-hi
6 : Mode usage time A1-lo
7 : Mode usage time, other than above
[7] Breaker usage time

1 : Breaker 1 operation time
6 : Breaker 1-5 operation time
7 : ＊
[8] Crusher usage time

1 : Crusher 1 operation time
6 : Crusher 1-5 operation time
7 : ＊
[9] P1 pressure (P) distribution

1 : P < 1450 PSI Time
2 : 1450 PSI ≦ P < 2180 PSI Time
3 : 2180 PSI ≦P < 2900 PSI Time
4 : 2900 PSI ≦P < 3630 PSI Time
5 : 3630 PSI ≦ P < 4350 PSI Time
6 : 4350 PSI ≦P < 5080 PSI Time
7 : 5080 PSI ≦ P Time
[10] P2 pressure (P) distribution

1 : P < 1450 PSI Time
2 : 1450 PSI ≦ P < 2180 PSI Time
3 : 2180 PSI ≦ P < 2900 PSI Time
4 : 2900 PSI ≦ P < 3630 PSI Time
5 : 3630 PSI ≦ P < 4350 PSI Time
6 : 4350 PSI ≦ P < 5080 PSI Time
7 : 5080 PSI ≦ P Time
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[11] N1 pressure (P) distribution
1 : P < 1450 PSI Time
2 : 1450 PSI ≦ P < 2180 PSI Time
3 : 2180 PSI ≦ P < 2900 PSI Time
4 : 2900 PSI ≦ P < 3630 PSI Time
5 : 3630 PSI ≦ P < 4350 PSI Time
6 : 4350 PSI ≦ P < 5080 PSI Time
7 : 5080 PSI ≦ P Time
[12] N2 pressure (P) distribution

1 : P < 1450 PSI Time
2 : 1450 PSI ≦ P < 2180 PSI Time
3 : 2180 PSI ≦ P < 2900 PSI Time
4 : 2900 PSI ≦ P < 3630 PSI Time
5 : 3630 PSI ≦ P < 4350 PSI Time
6 : 4350 PSI ≦ P < 5080 PSI Time
7 : 5080 PSI ≦ P Time
[13] P1 + P2 pressure (P) distribution

1 : P < 2900 PSI Time
2 : 2900 PSI ≦ P < 4350 PSI Time
3 : 4350 PSI ≦ P < 5800 PSI Time
4 : 5800 PSI ≦ P < 7250 PSI Time
5 : 7250 PSI ≦ P < 8700 PSI Time
6 : 8700 PSI ≦ P < 10150 PSI Time
7 : 10150 PSI ≦ P Time
[14] Oil temperature (T) distribution

1 : T < 113 °
F Time (bar graph 1st and 2nd gradations)
2 : 113 °
F ≦ T < 140 °
F Time (bar graph 3rd gradation)
3 : 140 °
F ≦ T < 176 °
F Time (bar graph 4 th gradation)
4 : 176 °
F ≦ T < 190 °
5 : 190 °
F ≦ T < 203 °
6 : 203 °
F ≦ T < 208 °
7 : 208 °
F≦T Time (bar graph 8th gradation)
(2) ENG
[1] Oil temperature/coolant temperature/pressure maximum values
(measured 10 min. after engine started)
Coolnt : Radiator coolant maximum temperature
HydOil : Hydraulic oil maximum temperature
FuelT : Fuel maximum temperature
Air : Suction air maximum temperature
BstT : Boost maximum temperature
BstP : Boost maximum pressure
EngOil : Engine oil minimum pressure
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[2] Engine actual speed (S) distribution
1 : S < 1025 rpm Time
2 : 1025 rpm ≦ S < 1225 rpm Time
3 : 1225 rpm ≦ S < 1425 rpm Time
4 : 1425 rpm ≦ S < 1625 rpm Time
5 : 1625 rpm ≦ S < 1825 rpm Time
6 : 1825 rpm ≦ S < 2025 rpm Time
7 : 2025 rpm ≦ S Time
[3] Coolant temperature (T) distribution

1 : T < 171 °
F Time (bar graph 1st and 2nd gradations)
2 : 171 °
F ≦ T < 180 °
3 : 180 °
F ≦ T < 207 °
4 : 207 °
F ≦ T < 212 °
5 : 212 °
F ≦ T < 217 °
6 : 217 °
F ≦ T < 221 °
7 : 221 °
F≦ T Time (bar graph 8th gradation)
[4] Fuel temperature (T) distribution

1 : T < 104 °
F Time
2 : 104 °
F ≦ T < 122 °
F Time
3 : 122 °
F ≦ T < 140 °
F Time
4 : 140 °
F ≦ T < 158 °
F Time
5 : 158 °
F ≦ T < 176 °
F Time
6 : 176 °
F ≦ T < 194 °
F Time
7 : 194 °
F≦ T Time
[5] Suction air temperature (T) distribution

1 : T < -4 °
F Time
2 : -4 °
F≦ T < 32 °
F Time
3 : 32 °
F≦ T < 59 °
F Time
4 : 59 °
F≦ T < 86 °
F Time
5 : 86 °
F≦ T < 113 °
F Time
6 : 113 °
F ≦ T < 140 °
F Time
7 : 140 °
F≦ T Time
[6] Boost temperature (T) distribution

1 : T < 122 °
F Time
2 : 122 °
F ≦ T < 176 °
F Time
3 : 176 °
F ≦ T < 230 °
F Time
4 : 230 °
F ≦ T < 284 °
F Time
5 : 284 °
F ≦ T < 338 °
F Time
6 : 338 °
F ≦ T < 392 °
F Time
7 : 392 °
F≦ T Time
[7] Atmospheric pressure (P) distribution

1 : P < 600 hPa Time
2 : 600 hPa ≦ P < 690 hPa Time
3 : 690 hPa ≦ P < 780 hPa Time
4 : 780 hPa ≦ P < 870 hPa Time
5 : 870 hPa ≦ P < 960 hPa Time
6 : 960 hPa ≦ P < 1050 hPa Time
7 : 1050 hPa ≦ P Time
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[8] Engine oil pressure (P) distribution
1 : P < 0 PSI Time
2 : 0 PSI ≦ P < 21.7 PSI Time
3 : 21.7 PSI ≦ P < 43.5 PSI Time
4 : 43.5 PSI ≦ P < 65.2 PSI Time
5 : 65.2 PSI ≦ P < 87 PSI Time
6 : 87 PSI ≦ P < 108.7 PSI Time
7 : 108.7 PSI ≦ P Time
[9] Boost pressure (P) distribution

1 : P < 21.7 PSI Time
2 : 21.7 PSI ≦ P < 26.1 PSI Time
3 : 26.1 PSI ≦ P < 30.4 PSI Time
4 : 30.4 PSI ≦ P < 34.8 PSI Time
5 : 34.8 PSI ≦ P < 39.1 PSI Time
6 : 39.1 PSI ≦ P < 43.5 PSI Time
7 : 43.5 PSI ≦ P Time
[10] Load ratio (R) distribution

1 : R < 30 % Time
2 : 30 % ≦ R < 40 % Time
3 : 40 % ≦ R < 50 % Time
4 : 50 % ≦ R < 60 % Time
5 : 60 % ≦ R < 70 % Time
6 : 70 % ≦ R < 80 % Time
7 : 80 % ≦ R Time
[11] Load ratio (R) distribution for SP mode

1 : R < 30 % Time
2 : 30 % ≦ R < 40 % Time
3 : 40 % ≦ R < 50 % Time
4 : 50 % ≦ R < 60 % Time
5 : 60 % ≦ R < 70 % Time
6 : 70 % ≦ R < 80 % Time
7 : 80 % ≦ R Time
[12] Load ratio (R) distribution for H mode

1 : R < 30 % Time
2 : 30 % ≦ R < 40 % Time
3 : 40 % ≦ R < 50 % Time
4 : 50 % ≦ R < 60 % Time
5 : 60 % ≦ R < 70 % Time
6 : 70 % ≦ R < 80 % Time
7 : 80 % ≦ R Time
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4. CFG (setting change) Screen
• Hold down the auto idle switch for 1 sec. The cursor is displayed and the value starts to
flash.
• The flashing value can be changed with the washer switch /working light switch .
• When the travel high-speed switch is pressed, value is finalized and the change is reflected in
the actual machine.
• When the horn volume select switch is pressed, the change is cancelled.
(1) Operation
[1] View mode (screen switching operation)

1) Switching to edit mode
Press and hold down the auto idle switch
for 1 sec.
The cursor will display when switching to
edit mode is done.
2) Page forward/back
Forward operation ...... Light switch
Back operation ...........Washer switch
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[2] Edit mode (setting change operation)
1) Cursor up/down
Up operation ......... Wiper switch
Down operation .... Auto idle switch
2) Numeric value increase/decrease
Increase value ...... Light switch
Decrease value ..... Washer switch
3) Enter
Enters the set contents.
4) Cancel
Cancels the set contents.
When 3) or 4) is executed, this exits edit mode and shifts the mode to view mode.
(The cursor disappears.)
[3] Reset
If the washer switch and the light switch are held down for 10 sec., the setting
contents are reset and all settings return to their default values.
(2) Screen
[1] MAIN 1
Item name Explanation Setting range Default value

LowIdl Low idling speed Min speed - Auto-idle speed 1000
AtIdl1 Auto idling shift time 1 - 30 5
AtIdl2 Auto idling speed Low idling speed - 1500 1200
PrUp1 Auto pressure boost yes/no +: YES, -: NO ＋
Auto pressure boost for option line
PrUp2 +: YES, -: NO -
usage yes/no
PwrAj Transient load minimum milli-amp 50 - 400 300
-7- High altitude correction milli-amp 0 - 250 0
* PwrAj is the previous high altitude mode.
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[2] MAIN 2

TrSpd Travel speed previous data held yes/no +: YES, -: NO -
TrAlm1 Travel alarm buzzing yes/no +: YES, -: NO ＋
TrAlm2 Travel alarm automatic stop time 1 - 30 10
CoolDn
EPF EPF (Engine Protection Feature) yes/no +: YES, -: NO ＋
Unit Display unit 0: MPa, 1: PSI, 2: kgf/cm2 0
-7-
F}, kgf/cm2 = {kgf/cm2, ºC}

* Display units … MPa = {MPa, ºC}, PSI = {psi, °
[3] MAIN 3

Spd1
Spd2
OvLd Pressure at which alarm starts
MntMsg "SERVICE DUE" display yes/no +: YES, -: NO ＋
Cycle "SERVICE DUE" display range 0 - 5000 500
Remain Time until next "SERVICE DUE" display 0 - 5000 500
-7- New harness yes/no +: YES, -: NO ＋
* OvLd is an option for Europe.
* -7- indicates replacement of the battery charge and engine emergency stop ports
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5. CAL (troubleshooting support) Screen
(1) Operation
[1] View mode (screen switching operation)

1) Switching to edit mode
Press and hold down the auto idle switch
for 1 sec.
The cursor will display when switching to
edit mode is done.
2) Page forward/back
Forward operation .....Light switch
Back operation ...........Washer switch
[2] Edit mode (setting change operation)
1) Cursor up/down
Up operation ......... Wiper switch
Down operation .... Auto idle switch
2) Numeric value increase/decrease
Increase value ...... Light switch
Decrease value ..... Washer switch
3) Enter
Enters the set contents.
4) Cancel
Use the travel high-speed select switch or horn volume select switch to cancel.
Exits edit mode and returns to view mode. (The cursor disappears.)
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(2) Screen
[1] Engine pump override 1

tEng Target engine speed 500 - max. speed Low idle
tPower 50 - 740 50
proportional valve
Target milli-amp for flow control propor-
tFlow 50 - 740 50
tional valve
P1 P1 pressure - -
P2 P2 pressure - -
N1 N1 pressure - -
N2 N2 pressure - -
[2] Engine pump override 2

tEng Target engine speed 500 - max. speed Low idle
tPower 50 - 740 50
proportional valve
Target milli-amp for flow control propor-
tFlow 50 - 740 50
tional valve
P1+P2 P1+P2 pressure - -
Eng Actual engine speed - -
Actual milli-amp for horsepower control
Power - -
proportional valve
Actual milli-amp for flow control propor-
Flow - -
tional valve
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[3] Hydraulic pressure drive fan override

Eng Actual engine speed - -
Coolnt Coolant temperature - -
Target milli-amp for hydraulic fan pro-
tFan - -
portional valve
HydOil Oil temperature - -
FuelT Fuel temperature - -
BstT Boost temperature - -
Actual milli-amp for hydraulic fan pro-
Fan - -
portional valve
6. Check the Monitor Switch (self-diagnosis function)

[1] After the key is switched ON, the "LBX" logo screen is displayed on the monitor.
At this time, the display can be switched to the monitor switch check screen by pressing the one-
touch idle switch 5 times.
The switch contents are as follows.
SW1 Front window limit switch

SW2 Breaker mode switch
SW3 Crusher mode switch
SW4 2 pumps flow mode switch
SW5 Not used
WIPER SW Wiper switch
WASHER SW Washer switch
W. LAMP SW Working light switch
T. MODE SW Travel high-speed select switch
A. IDLE SW Auto idle switch
HORN VOL. SW Horn volume select switch
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[2] Configuration
1 Switch panel 4 Breaker mode switch

2 2 pumps flow switch 5 Crusher mode switch
3 Front window limit switch 6 Monitor
[3] Differences from CHK screen [CHK|H/W-M|1]

Monitor main unit input/output can also be checked on the CHK screen. However, for the CHK
screen,
1) after the switch input is sent to computer A with communication,
2) the switch input is processed by computer A and
3) the results are sent to the monitor as screen data
and displayed. On the monitor switch check screen, the switch input recognized by the monitor
itself is displayed directly on the screen (without involving communication or computer A), so it is
possible to diagnose purely the switches themselves.
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7. Option Flow Setting
[1] When 3 sec. have passed, the logo screen shifts to the user screen.
With the user screen being displayed, if either the "breaker" or "crusher" rocker switch on the
right panel is held down for 3 sec., the "option flow setting screen" is displayed on the monitor.
[2] Flow setting

1) Press the breaker or crusher mode switch to select the mode to set the flow for.
1 Flow increase 3 Crusher mode (1 - 5) switchover

2 Flow decrease 4 Breaker mode (1 - 5) switchover
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2) The flow setting for the selected mode is selected by pressing the wiper switch or auto idle
select switch .
The flow setting can be set to 10 levels from level 1 - level 10.
Caution
The set flow is the flow value when SP mode is selected.
Be careful. If run with the engine speed reduced, the actual flow is not the flow displayed.
Unit Model 5
1 pump flow (flow level 1) gpm 75
2 pumps flow (flow level 1) gpm 150
[3] There is no need to do anything to finalize the setting. End by leaving this screen or switching
OFF the key.
The factory settings for each mode are as follows.
There are no 4 or 5 settings for the breaker or crusher. Just a hyphen is displayed for these
settings.
Mode Flow display

Breaker circuit 1/Crusher 1 Level 3 flow
Breaker circuit 4/Crusher 4 ---- (Not used)
Breaker circuit 5/Crusher 5
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8. Anti-theft Setting
[1] Anti-theft setting and password registration
1) Enabling the anti-theft function
With the key OFF, connect the anti-theft knob terminal.
When the male and female knob terminals are connected on the cab main harness in the rear
cover, the anti-theft function is enabled. The factory setting is for these knob terminals to be
disconnected.
2) Setting the password

When the knob terminals are connected, then the key switched ON, the following screen is
displayed.
Enter any 4-digit number made up of the numbers 1 - 9.
(If all 4 digits are not input, "ERROR" is displayed.)
Input by using the monitor switches as follows.
1. When the Enter button is pressed, the password is stored into memory and display
returns to the normal screen.
1 Enter 3 Numeric value increase/decrease

2 Cursor movement
3) Changing the password

If the password has been forgotten or if a password change is desired, the password is cleared
if the knob terminal in [1]-1) is disconnected and the key switched ON. To re-input the
password, repeat the procedure in [1].
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[2] Anti-theft function operation
1) Enabling the anti-theft function
1. If the key is switched twice in a row ON → OFF → ON → OFF with the engine stopped, the
anti-theft function is switched ON.
(All the key switching operations must be done within 2 sec.）
2. When the anti-theft comes ON, the monitor buzzes and the "key" icon is displayed.
(Once the anti-theft is switched ON, this icon is displayed while the power is OFF.)
3. The next time the key is switched ON, the anti-theft operates and the password input screen
is displayed.
Input the password made up of 4 digits 0 - 9.
Input by using the monitor switches below.
If an incorrect number is input, "ERROR" is displayed and the buzzer buzzes.
The key must be switched OFF, then ON again before the password can be re-input.
1 Enter 3 Numeric value increase/decrease

2 Cursor movement
2) Disabling the anti-theft function

1. If the engine is stopped by switching OFF the key, the anti-theft function does not operate.
2. To disable the anti-theft function, disconnect the anti-theft knob terminals VG (purple/green)
and BG (black/green). The registered password is canceled.
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9. Model Setting
[1] If the model selection has not been completed, immediately after the key is switched ON, the
"Model select screen" is displayed.
1 Cursor 3 Computer B; Part number

2 Computer A; Part number 4 Error display section
1) For the "CONT.A:" item, the part number for computer A is automatically displayed.
2) In the same way, if computer B is connected (for the liftcrane specifications or interference
prevention specifications), the part number for computer B is automatically displayed for the
"CONT.B:" item.
3) A "?" displays for items in which input is required.
a) MACHINE ： Model (SH120-5, SH150-5, SH180-5, SH200-5, SH240-5, SH290-5, SH330-5)
b) TERRITORY ： Destination ( 0: Domestic, general export, 1:LBX, 2:CASE NA, 3:CASE EU, 4: IHI )
( 00: Japanese, 01: English, 02: Thai, 03: Chinese, 04: German,
05: French, 06: Italian, 07: Spanish, 08: Portuguese, 09: Dutch,
c) LANGUAGE ： Language
10: Danish, 11: Norwegian, 12: Swedish, 13: Finnish, 14: Turkish,
15: Arabic, 16: Malay, 17: Indonesian, 18: Icon)
d) SPEC ： Main unit specifications (Input 0)
e) ATT.No. ： Attachment specifications (input 0)
0: No liftcrane
f) CRANE ： 1: With liftcrane
0: No interference prevention function

g) A.INTF ： 1: With interference prevention function
4) Input operating method

Input by using the monitor switches as follows.
* When the model select screen is displayed on the monitor, the normal monitor switch
functions do not work.
1 Enter button
2 Numeric value change
3 Cursor movement
When the throttle volume position or all the input is complete, press " " (enter button). (The
throttle volume must always be at the "H" mode position.)
If the input value is inappropriate (*), "CONT. A.ERR" is displayed.
* When there is still an item left with "?" displayed or the combination of model, destination,
specification, and the like is inappropriate
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5) On the model setting screen, the ECM part number is automatically checked.
If the input model and the ECM part number do not correspond, "ECM ERR" is displayed.
6) Even after the model selection is complete, it is possible to change just the LANGUAGE,
CRANE, or ATT. No. setting without one of the half resets or all resets listed below.
7) Half reset
On the model select screen, if the washer switch and the light switch are held down for
3 sec., data in the table below is erased.
8) All reset
On the model select screen, if the washer switch and the light switch are held down for
10 sec., data in the table below is erased.
Difference between all reset and half reset
Reset ....................................... ○
Do not reset ................................. ×
Reset when model information has changed ..... △
Half reset All reset
Model information (*1) ○ ○
Control data (*2) ○ ○
Computer A memory information Usage log (*3) × ○
Trouble log (*4) × ○
Engine information (*5) × ○
Angle sensor compensation
value △ ○
Computer B memory information
Liftcrane/interference preven-
tion usage log △ ○
Computer S memory information Transmission information (*6) × ○

*1 Contents displayed on model selection screen
*2 Contents displayed on CFG screen
*3 Contents displayed on HR screen
*4 Contents displayed on DIAG screen
*5 Contents displayed on engine service screen
*6 When transmission information is reset, transmission with the G@NAV server is restarted from
the initial send.
In this case, transmission with the G@NAV server cannot be done until a send permission signal
is sent from the control center.
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10.Engine Information Screen
[1] Purpose
It has been made possible to copy the engine information (Q adjustment, QR code, engine serial
number) stored in the ECM to the new ECM when the ECM and injector are replaced.
[2] How to go to this screen
See the service support screen operations.
[3] Engine start restriction
When this screen is displayed, the engine cannot be started.
[4] Screen
The engine information held in computer A can be checked as follows.
1) Pages 1 - 6: Injector cylinder 1 - 6 QR codes
1 Page
2 24-digit QR code
3 Error code
Indicates the display mode.
4 Currently displays the information in
computer A.
2) Page 7: Q resistance data
1 3-digit Q resistance data
3) Page 8: Engine serial number
1 6-digit engine serial number
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4) ECM part number
1 ECM part number
[5] Operating method

See the Engine Maintenance Standards.
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Screen Display Details
1. Message Display List
Message
Display Display ON timing Display OFF timing
type
None
LOW OIL
Warning When the "Engine oil pressure abnormally low" trouble occurs Does not go off while the key is
PRESS.
ON.
When the "ECM mismatch" trouble occurs None

CHECK
Warning Does not go off while the key is
ENGINE Also, when a diagnostic trouble code is sent from the ECM ON.
When any of the troubles below occur
"Sensor; Pressure (P1)", "Sensor: Pressure (P2)", "Sensor; Pressure (N1)",
"Sensor; Pressure (N2)", "Sensor; Pressure (Overload)", "Sensor; Pressure
(Bottom)", "Sensor; Pressure (Rod)", "Sensor; Pressure (Upper)", "Sensor;
Pressure (Swing)", "Sensor; Pressure (Travel)"
"Sensor; Fuel level", "Sensor; Oil temperature",
"Sensor; Angle (Boom)", "Sensor; Angle (Arm)", "Sensor; Angle (Offset)",
"Pressure switch; Return filter clog"
"Solenoid; Swing brake", "Solenoid; Travel high-speed", "Solenoid; Power
save" None
ELEC. PROB- "Relay; Feed pump automatic stop", "Solenoid; Option return circuit", "Sole- Does not go off while the key is
Warning
LEM (*1) noid; Free swing" ON.
"Solenoid; Fan reverse", "Air conditioner signal output", "Buzzer; Liftcrane"
"Rotating light and solenoid; Bucket lock", "Solenoid; Lever lock"
"Proportional valve; Pump horsepower", "Proportional valve; Pump flow"
"Proportional valve; Fan",
"Proportional valve; Boom", "Proportional valve; Offset", "Proportional
valve; Arm",
"Communication monitor", "Communication ECM", "Communication com-
puter B", "Communication computer S",
"CAN bus"
When all the troubles below are
When any of the troubles below occur recovered from "Abnormally high
OVER HEAT Warning
"Abnormally high coolant temperature 1", "Abnormally high oil temperature" coolant temperature 1", "Abnor-
mally high oil temperature"
LOW COOL- None Does not go off while the
Warning When the "Coolant level low" trouble occurs
ANT key is ON.
None
ALTERNATOR Warning When the "Abnormally low alternator voltage" trouble occurs Does not go off while the key is
ON.
CHECK None
HYD.OIL Warning When the "Return filter clogged" trouble occurs Does not go off while the key is
FILTER ON.
None
AIR FILTER Warning When the "Air cleaner clogged" trouble occurs Does not go off while the key is
ON.
When the "Abnormally high boost
BOOST
Warning When the "Abnormally high boost temperature 1" trouble occurs temperature 1" trouble is recov-
TEMP.HIGH
ered from
When the "Fuel level low" trouble
LOW FUEL Warning When the "Fuel level drop" trouble occurs
is recovered from
SWITCH TO When the conditions on the left
Alert When the breaker mode is ON and 2 pumps flow is ON
1-PUMP are no longer met
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Message
Display Display ON timing Display OFF timing
type
When the conditions on the left
ENGINE STOP Alert When the engine emergency stop switch is ON
are no longer met
ENG. IDLING Icon During one-touch idling or auto idling
are no longer met
POWER UP Icon During auto pressure boost
are no longer met
ENG. PRE When the conditions on the left
Icon When power ON to glow plug
HEAT are no longer met
AUTO WARM When the conditions on the left
Icon During auto warm up
UP are no longer met
After 1 min. after the key was
SERVICE DUE Status When the key is ON and the hour meter has reached the regulation time
switched ON
(*1) Even if one of the following troubles occurs, "ELEC. PROBLEM" is not issued.
"BZ travel alarm", "Monitor thermistor", "Air conditioner coolant signal output"
Message type
[1] Status ...........Message only
[2] Alert ..............The intermittent warning continues to sound at 1-second intervals.
[3] Warning ........The continuous warning sounds for just 5 sec.
[4] Icon ...............Icon only
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Abnormality Display
1. Diagnostic Trouble Code Display
[1] Purpose and summary
When a trouble occurs, the diagnostic trouble code (DTC) is displayed on the user screen.
This enables the operator to verbally communicate the trouble to the service engineer.
[2] Screen
Displayed with the ! mark next to the work mode followed by a 4-digit number.
If there is no trouble, nothing at all is displayed.
[3] Trouble display

The "ELEC. PROBLEM" or "CHECK ENGINE" message is displayed.
When trouble occurs, the corresponding diagnostic trouble code is displayed. If the message
makes clear the trouble location, the location is not displayed elsewhere.
For details, see the "Main Unit Diagnostic Trouble Code List". All the diagnostic trouble codes
sent from the ECM are subject to display.
[4] Displayed trouble status
Only current and ongoing troubles are displayed. Troubles that have been recovered from are not
displayed.
[5] Multiple trouble display
When multiple troubles occur, they are displayed in turn at 5-second intervals.
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2. Main Unit Diagnostic Trouble Code List
(1) Electrical troubles (input) [7000-7199]
Diagnostic
Occurrence judgment Recovery judgment
trouble code
Trouble location Trouble mode Judgment timing Prerequisites
Dis-
DTC Conditions Conditions
play
Ground short/dis-
Sensor; Immediately after key Voltage ≦ 0.25 V
connection 7000 ○ None 0.25 V < Voltage < 4.75 V
Pressure (P1) switched ON
Power supply short Voltage ≧ 4.75 V
Ground short/dis-
Pressure (P2) switched ON
Ground short/dis-
Pressure (N1) switched ON
Ground short/dis-
Pressure (N2) switched ON
Sensor; Ground short/dis-
Immediately after key EU selected as Voltage ≦ 0.25 V
Pressure connection 7004 ○ 0.25 V < Voltage < 4.75 V
switched ON destination
(Overload) Power supply short Voltage ≧ 4.75 V
Sensor; Ground short/dis-
Immediately after key Voltage ≦ 0.25 V
Pressure connection 7005 ○ Liftcrane selected 0.25 V < Voltage < 4.75 V
switched ON
(Bottom) Power supply short Voltage ≧ 4.75 V
Ground short/dis-
connection 7006 ○ Liftcrane selected 0.25 V < Voltage < 4.75 V
Pressure (Rod) switched ON
Ground short/dis-
Pressure (Upper) switched ON
Ground short/dis-
Pressure (Swing) switched ON
Ground short/dis-
Pressure (Travel) switched ON
Sensor; Disconnection Immediately after key Resistance ≧ 100 Ω
7040 ○ None 2 Ω < Resistance < 100 Ω
Fuel level Short switched ON Resistance ≦ 2 Ω
3 min. after engine Resistance ≧
Disconnection 111 Ω < Resistance
Sensor; start 67200Ω(Voltage ≧ 4.93 V )
Oil temperature
7041 ○ None < 67200 Ω
Immediately after key Resistance ≦ (0.5 V < Voltage < 4.93 V)
Short
switched ON 111Ω(Voltage ≦ 0.5 V )
Monitor; Disconnection Immediately after key Trouble bit received from No trouble bit received from
7045 × None
Thermistor (*1) Short switched ON monitor monitor
Ground short/dis- Liftcrane or inter-
connection 7060 ○ ference prevention 0.2 V < Voltage < 4.8 V
Angle (Boom) switched ON
Power supply short selected Voltage ≧ 4.8 V
Angle (Arm) switched ON
Angle (Offset) switched ON
From immediately
Pressure switch;
Return filter clog
Disconnection 7063 ○ after key switched ON None Pressure switch = OFF Pressure switch = ON
until engine starts
(*1) Even if trouble occurs, the "ELEC. PROBLEM" message is not displayed.
For items for which × is displayed, the "ELEC. PROBLEM" message is not displayed. Also, there
is no DTC display on the user screen.
However, the DTC is recorded on the service (DIAG) screen.
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(2) Electrical troubles (output) [7200-7399]
Diagnostic
trouble code
Dis-
play
Solenoid; Disconnection Immediately after key
7200 ○ switched ON
None Output ≠ Output monitor Output = output monitor
Swing brake Short
Solenoid; Disconnection
Immediately after key
Travel 7201 ○ switched ON
high-speed Short

Pressure boost Short
BZ; Disconnection Immediately after key

Travel alarm (*1) Short
7203 ×
switched ON

Power save
Short
REL; Disconnection Immediately after key
Feed pump stop Short
Solenoid; Disconnection
Option return cir- 7206 ○ switched ON
cuit Short

Free swing
Short
Fan reverse
Short
Air conditioner Disconnection
coolant Immediately after key
7209 × None Output ≠ Output monitor Output = output monitor
temperature sig- Short switched ON
nal output (*1)
Disconnection Immediately after key
BZ; Liftcrane 7210 ○ switched ON
Short
REL; Disconnection
Rotating light 7211 ○ switched ON
and bucket lock Short
Gate lock
Short
Proportional Disconnection After engine start Milli-amp ≦ 30 mA
valve;
Pump
7240 ○ Immediately after key None 30 mA < Milli-amp < 3 A
Short
switched ON Milli-amp ≧ 3 A
horsepower
valve; 7241 ○ Immediately after key None 30 mA < Milli-amp < 3 A
Pump flow Short Milli-amp ≧ 3 A
switched ON
Fan Short Milli-amp ≧ 3 A
switched ON
Boom Short
switched ON Milli-amp ≧ 3 A

Arm Short Milli-amp ≧ 3 A
switched ON
Disconnection After engine start Milli-amp ≦ 30 mA
Proportional
valve; Offset
7245 ○ Immediately after key None 30 mA < Milli-amp < 3 A
Short Milli-amp ≧ 3 A
switched ON
(*1) Even if trouble occurs, the "ELEC. PROBLEM" message is not displayed.
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(3) Mechanical troubles [7400-7599]
Diagnostic
trouble code
Dis-
play
Abnormally high Coolant tempera- Coolant temperature ≥ 221 °F Coolant temperature < 221 °F
temperature 1
7400 ○ ture sensor (105 °C) (105 °C)
= Normal
Abnormally high Coolant temperature ≥ 230 °F Coolant temperature < 221 °F
Coolant 7402 ○ 1 min. after engine CAN communica- (105 °C)
temperature 2 (110 °C)
temperature start tion = Normal
Abnormally high ECM 5 V power Coolant temperature ≥ 248 °F Coolant temperature < 248 °F
temperature 3
7403 ○ supply voltage = (120 °C) (120 °C)
Normal
Abnormally high 1 min. after engine Oil temperature Oil temperature ≥ 208 °F Oil temperature < 208 °F
Oil temperature
temperature
7404 ○ start sensor = Normal (98 °C) (98 °C)
Boost temperature
sensor = Normal,
CAN communica-
Abnormally high Boost temperature ≥ 176 °F Boost temperature ≤ 158 °F
temperature 1
7405 ○ tion = Normal,
(80 °C) (70 °C)
Boost 1 min. after engine ECM 5 V power
temperature start supply voltage =
Normal
Abnormally high Boost temperature ≤ 194 °
F Boost temperature < 194 °
F
temperature 2
7406 ○ (90 °C) (90 °C)
Alternator Abnormally low 10 sec. after engine
7420 ○ None Generated voltage ≤ 10 V Generated voltage > 10 V
voltage voltage start
Coolant level Drop 7421 ○ switched ON
None Level switch = ON Level switch = OFF
Oil pressure sen-

sor = Normal,
CAN communica-
Engine oil pres- Abnormally low 30 sec. after engine Pressure ≤ 5.8 PSI Pressure > 5.8 PSI
sure pressure
7422 ○ start
tion = Normal,
(0.03 MPa) (0.03 MPa)
ECM 5 V power
supply voltage =
Normal
10 sec. after engine
Air cleaner Clog 7423 ○ start
None Vacuum switch = ON Vacuum switch = OFF
Return filter pres-

10 sec. after engine
Return filter Clog 7424 ○ start
sure switch Pressure switch = OFF Pressure switch = ON
= Normal
(4) Communication abnormality [7600-7799]

Diagnostic
trouble code
Dis-
play
Immediately after key When the occurrence
CAN bus Bus abnormality 7600 ○ switched ON
None Bus off or error passive
conditions are not met
Reception Packets not coming from When the occurrence
Communication abnormality Immediately after key monitor conditions are not met
monitor
None
Transmission Reception from monitor When the occurrence
abnormality Defective packet received conditions are not met
Communication Immediately after key Messages not coming from When the occurrence condi-
ECM
Time out 7602 ○ switched ON
None
ECM tions are not met
Communication Immediately after key Messages not coming from When the occurrence
computer S
None
computer S conditions are not met
Liftcrane or inter-
Communication Immediately after key Messages not coming from When the occurrence
computer B
ference prevention
computer B conditions are not met
selected
10 sec. after engine Model selection None
ECM Mismatch 7605 ○ start completed Model ≠ ECM calibration No. No recovery
Previously stored checksum Previously stored checksum
EEPROM Data abnormality 7606 × None ≠ Current calculated = Current calculated
switched ON
checksum checksum
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3. Diagnostic Trouble Code (monitor display)
Diagnostic Main symptoms Patterns for
Trouble Diagnostic trouble code
trouble when trouble Back-up function Conceivable cause recovery
content display conditions
code occurs from trouble
The ratio for the fuel flow
command signal to the
SCV is 33 % or less. Fuel system clogged, line (hose)
Differential pressure blocked
send amount is 1.19 Charge fuel pump defect
(discharge defect)
Engine vibration, lb/in3/s 2800 mm3/s Wiring defect (short) between
idle instability, drop or longer. When any Multi-injection stop
ECM and common rail pressure
No pump pressure 1093 of output power, of the above occurs Target common rail sensor 1
send (2nd stage) rev-up defect, black and the condition pressure upper limit Injector defect
smoke, engine below At 1200 rpm or 11600 PSI (80 MPa)
Supply pump defect
stalling higher, actual rail Common rail pressure sensor
pressure is 4350 PSI defect (common rail)
(30 MPa) or more Pressure limiter defect (common
below the target rail rail)
pressure for 5 sec. or
longer.
Boost Wiring defect (disconnection,

The boost temperature short, high resistance) between
temperature sen- Nothing in particu- sensor voltage is 0.1 V ECM and boost temperature
sor abnormality 1112 No backup *2
(abnormally low lar or lower for 4 sec. or sensor
longer. Boost temperature sensor defect
voltage)
ECM internal defect
Wiring defect (disconnection,
Boost temperature The boost temperature short, high resistance) between
sensor abnormality Nothing in particu- sensor voltage is 4.95 V ECM and boost temperature
(abnormally high 1113 lar or higher for 4 sec. or No backup sensor *2
voltage) longer. Boost temperature sensor defect
ECM internal defect
Drop of output
power Wiring defect (short) between
If the coolant tem- The coolant temperature ECM and engine coolant sensor
perature exceeds is higher than Engine cooling system trouble
Overheat 1173 No backup 2
226.4 ºF (108 º C) 248 ° F (120 ºC) ＜ for 5 (radiator clog or the like)
during overheating, sec. or longer. Engine coolant level too low
the fuel flow is Engine coolant sensor defect
restricted.
Engine vibration,
idling instability, Injector monitor inputs No 1, 4 injector harness defect
Injection nozzle drop of output Common 1 stop
for all common 1 system (disconnection, short)
common 1 drive 1261 power (No. 1, 4 cylinder stop) 1
system abnormality Possibility of rev-up No signal for 3 sec. or EGR stop Injector defect
longer ECM defect
defect, engine
stalling
Engine vibration,
idling instability, Injector monitor inputs No 2, 3 injector harness defect
Injection nozzle drop of output for all common 2 system Common 2 stop (disconnection, short)
common 2 drive 1262 power (No. 2, 3 cylinder stop) 1
No signal for 3 sec. or Injector defect
system abnormality Possibility of rev-up longer EGR stop ECM internal defect
defect, engine
stalling
No fault during No change when error Wiring defect (disconnection,
CMP sensor out of engine rotation, but No correct CMP sensor occurs (shift to crank short, high resistance) between
phase 1345 when it is stopped pulse in crank gap posi- sensor) ECM and CMP sensor 1
once, it cannot be tion However, engine can- Camshaft gear installation defect
restarted. not be restarted. Flywheel installation defect
Main relay input power Wiring defect (disconnection,

short, high resistance) between
supply voltage 1 V or ECM and main relay
Engine starting dif- lower for 2 sec. or longer
Main relay system 1625 ficulty, power sup- Even when the main No backup
2
abnormality short, high resistance) with fusible
ply not cut off relay coil OFF command
link main relay
is issued, the relay does Main relay defect
not cut off within 5 sec.
ECM internal defect
Analog sensor system
default processing
(sensors operating with
A/D Drop of output Analog/digital conver- default values, because
conversion abnor- 1630 conversion not possible) ECM internal defect 2
mality power, black smoke sion not possible Multi-injection stop
Target common rail
pressure upper limit
(11600 PSI) (80 MPa)
5 V power supply 2 Black smoke at Key switch power supply EGR control stop Power supply circuit wiring defect
voltage abnormal- high altitudes, voltage 5.5 V or higher Default value setting (short) between ECM and atmo-
ity (atmospheric 1632 11.6 PSI (0.08 MPA) 2
insufficient output or 4.5 V or lower for 0.5 spheric pressure sensor
pressure sensor at low altitudes sec. or longer (equivalent to 2734 yd ECM internal defect
power supply) (2500 m))
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5 V power supply 3 Key switch power supply Power supply circuit wiring defect
voltage abnormal- Poor starting and
ity (engine hydrau- 1633 black smoke at low voltage 5.5 V or higher Control using default (short) between ECM and oil 2
or 4.5 V or lower for 0.5 values pressure sensor
lic pressure temperatures sec. or longer ECM internal defect
sensor)
5 V power supply 4 Key switch power supply Power supply circuit wiring defect
voltage abnormality 1634 Black smoke voltage 5.5 V or higher Control using default (short) between ECM and boost 2
(boost pressure or 4.5 V or lower for 0.5 values pressure sensor
sensor) sec. or longer ECM internal defect
5 V power supply 5
voltage abnormal- Possibility of poor
Key switch power supply Power supply circuit wiring defect
ity (common rail engine rev-up, drop voltage 5.5 V or higher Control using default (short) between ECM and com-
pressure 1635 of output power, or 4.5 V or lower for 0.5 values mon rail pressure sensor 2
sensor, EGR posi- back smoke,
tion engine stalling sec. or longer ECM internal defect
sensor)
Engine rotation that Wiring defect (disconnection,

CAN bus Engine speed down computer A sends with Engine speed down to
abnormality 2104 to 1500 rpm. CAN stops for 1 sec. or 1500 rpm. ECM and computer A 2
ECM internal defect
longer. Computer A internal defect
Control from actual
machine side stops Wiring defect (disconnection,
working because Engine rotation that
CAN time-out CAN communica- computer A sends with Engine speed down to
2106 ECM and computer A 2
abnormality tion become impos- CAN stops for 2 sec. or 1500 rpm.
ECM internal defect
sible. The engine longer.
Computer A internal defect
speed drops to
1500 rpm.
Fuel system clogged (element),
line (hose), etc. blocked
Possibility of engine Wiring defect (short) between
No pump pressure vibration, idle insta- Actual rail pressure of Multi-injection stop ECM and common rail pressure
bility, drop of out- Target common rail sensor
send 0087 put power, black
2180 PSI (15 MPa) or
pressure upper limit Injector defect
1
(fuel leak) smoke, excess
lower for 3 sec. or longer 11600 PSI (80 MPa) Common rail pressure sensor
output defect
Supply pump defect
Pressure limiter defect
1st stage
Rail pressure exceeds
26825 PSI (185 MPa)
for 5 sec. or longer,
common rail pressure Fuel system line (hose), etc.
sensor voltage is 3.9 V blocked
Abnormal common Engine vibration, or higher
Multi-injection stop
Air in fuel system (check hose
rail pressure idle instability, drop Target common rail
(1st stage, 2nd 0088
2nd stage connection.) 1
of output power, 1st stage established,
pressure upper limit
Common rail pressure sensor
stage) rev-up defect rail pressure exceeds
11600 PSI (80 MPa)
defect
26825 PSI (185 MPa) Supply pump defect
for 5 sec. or longer,
common rail pressure
sensor voltage is 4 V or
higher
Common rail pressure sensor
Common rail pres- Engine vibration, Actual rail pressure Multi-injection stop defect
5800 PSI (40 MPa) or
sure abnormality idle instability, drop Target common rail Supply pump defect
(pump sending too 0089 more above the target 1
of output power, pressure upper limit ECM, SCV, common rail pressure
much pressure) rev-up defect rail pressure for 5 sec. 11600 PSI (80 MPa) sensor connector connection
or longer
defect
When the SCV drive
milli-amp exceeds the
rated milli-amp for 2 sec. Multi-injection stop
SCV defect
SCV drive system Black smoke and or longer Target common rail
disconnection, + B 0090 When the difference short, high resistance) between 2
excess output pressure upper limit
short, GND short between the target and 11600 PSI (80 MPa) ECM and SCV
actual milli-amp ECM internal defect
exceeds the rated milli-
amp for 2 sec. or longer
Atmospheric pres- Black smoke at The atmospheric pres- EGR control stop short, high resistance) between
Default value setting ECM and atmospheric pressure
sure sensor high altitudes, sure sensor voltage is
abnormality (abnor- 0107 insufficient output 0.5 V or lower for 5 sec. 11.6 PSI (0.08 MPa) sensor 2
mally low voltage) at low altitudes or longer. (equivalent to 2734 yd Atmospheric pressure sensor
(2500 m)) defect
ECM internal defect
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Atmospheric pres- Black smoke at The atmospheric pres- EGR control stop ECM and atmospheric pressure
sure sensor abnor- high altitudes, sure sensor voltage is Default value setting
mality (abnormally 0108 insufficient output 3.8 V or higher for 4 sec. 11.6 PSI (equivalent to sensor
Atmospheric pressure sensor
2
high voltage) at low altitudes or longer. 2734 yd (2500 m)) defect
ECM internal defect
EGR control stop Wiring defect (short) between
Suction air temper- Possibility of white The suction air tempera- Default value setting ECM and suction air temperature
ature sensor abnor- smoke when start- ture sensor voltage is Starting: 14 ° F sensor
mality 0112 *2
(abnormally low ing at low tempera- 0.1 V or lower for 4 sec. (-10 ºC) Suction air temperature sensor
voltage)
tures or longer. Running: 77 ° F defect
(25 ºC) ECM internal defect
EGR control stop Wiring defect (disconnection,

Suction air temper- Possibility of white The suction air tempera- Default value setting short, high resistance) between
ature sensor abnor- ECM and suction air temperature
smoke when start- ture sensor voltage is Starting: 14 ° F
mality 0113 ing at low tempera- 4.95 V or higher for 4 (-10 ºC) sensor *2
(abnormally high Suction air temperature sensor
voltage) tures sec. or longer. Running: 77 ° F defect
(25 ºC) ECM internal defect
Engine coolant EGR control stop
temperature sen- Poor starting at low The coolant temperature Default value setting Wiring defect (short) between
temperatures, black sensor voltage is 0.1 V Starting: -4 ºF (-20 ºC) ECM and engine coolant sensor
sor abnormality 0117 smoke, drop of out- or lower for 4 sec. or *2
Engine coolant sensor defect
(abnormally low
put power longer. Running:176 ° F ECM internal defect
voltage) (80 ºC)
Engine coolant EGR control stop, Wiring defect (disconnection,
Increase in noise, The coolant temperature default value setting
temperature sen- short, high resistance) between
white smoke at low sensor voltage is 4.85 V Starting: -4 ºF (-20 ºC)
sor abnormality 0118 ECM and engine coolant sensor *2
temperatures, or higher for 4 sec. or
(abnormally high rough idling longer. Running:176 ° F Engine coolant sensor defect
voltage) (80 ºC) ECM internal defect
Fuel temperature The fuel temperature Default value setting Wiring defect (short) between
sensor abnormality 0182 Nothing in sensor voltage is 0.1 V Starting: -4 ºF (-20 ºC) ECM and fuel temperature sensor
Fuel temperature sensor (supply *2
(abnormally low particular or lower for 4 sec. or Running: 158 ºF
voltage) longer. (70 ºC) pump) defect
ECM internal defect
Fuel temperature The fuel temperature Default value setting short, high resistance) between
sensor abnormality 0183 Nothing in sensor voltage is 4.85 V Starting: -4 F (-20 ºC) ECM and fuel temperature sensor
*2
(abnormally high particular or lower for 4 sec. or Running:158 ºF Fuel temperature sensor (supply
voltage) longer. (70 ºC) pump) defect
ECM internal defect
Common rail pres- Wiring defect (disconnection,
sure The common rail pres-
sensor Engine rev-up Default value setting ECM and common rail
0192 sure sensor voltage is 2
abnormality defect, hunting 0.7 V or lower.
11600 PSI (80 MPa) Common rail pressure sensor
(abnormally low defect (common rail)
voltage) ECM internal defect
Common rail pres- short, high resistance) between
sure Possibility of drop The common rail pres-
Default value setting ECM and common rail
sensor abnormality 0193 of output power and sure sensor voltage is 11600 PSI (80 MPa) Common rail pressure sensor 2
(abnormally high engine stalling 4.5 V or higher. defect (common rail)
voltage)
ECM internal defect
No. 1 cylinder injector ECM and No. 1 injector
High engine vibra- drive circuit disconnec- intermediate connector
Injection nozzle #1 tion, idle instability, tion/short detected No. 1 cylinder injection No. 1 injector terminal looseness
drive system dis- 0201 drop of output No. 1 cylinder injector stop Wiring defect (disconnection, high 1
connection power, rev-up monitor input EGR control stop resistance) between No. 1 injector
defect No signal for 2.4 sec. or intermediate connector and No. 1
longer injector terminal
No. 1 injector defect
ECM internal defect
No. 2 cylinder injector ECM and No. 2 injector intermedi-
High engine vibra- drive circuit disconnec- ate connector
drive system 0202 drop of output No. 2 cylinder injector stop Wiring defect (disconnection, high 1
disconnection power, rev-up monitor input EGR control stop resistance) between No. 2 injector
ECM internal defect
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ECM internal defect
ECM internal defect
ECM internal defect
No. 6 cylinder injector short, high resistance) between
ECM and No. 6 injector intermedi-
High engine vibra- drive circuit ate connector
disconnection/short
Injection nozzle #6 tion, idle instability, No. 6 cylinder injection No. 6 injector terminal looseness
drive system 0206 drop of output detected
stop Wiring defect (disconnection, high 1
disconnection power, rev-up No. 6 cylinder injector
monitor input EGR control stop resistance) between No. 6 injector
defect intermediate connector and No. 4
No signal for 2.5 sec. or
injector terminal
longer
ECM internal defect
Faulty engine main unit (common
rail, supply pump, injector)
The engine speed is Injection quantity It is necessary to check whether
Overrun 0219 Drop of output the set speed of 2000 restriction or not there is another diagnostic 2
power rpm or higher for 1 sec. When the speed drops, trouble code.
or longer. the restriction is ended. Mechanical engine trouble (turbo
damaged, engine oil mixed in)
ECM internal defect
Boost pressure The boost pressure sen- short, high resistance) between
sensor abnormality Nothing in particu- sor voltage is 0.1 V or Default value setting
(abnormally low 0237 lar lower for 3 sec. or 21.7 PSI (0.15 MPa) ECM and boost pressure sensor
Boost pressure sensor defect
2
voltage) longer. ECM internal defect
Boost pressure The boost pressure sen- Wiring defect (disconnection,

sensor abnormality 0238 Black smoke sor voltage is 4.9 V or Default value setting ECM and boost pressure sensor 2
(abnormally high higher for 3 sec. or 21.7 PSI (0.15 MPa) Boost pressure sensor defect
voltage) longer.
ECM internal defect
Possibility of drop
of output power,
white smoke, Wiring defect (disconnection,
Crank position
(CKP) sensor engine vibration When the CMP sensor short, high resistance) between
0335 Possibility of engine There is a CMP signal, is normal, cam ECM and CKP sensor 1
abnormality stalling (when the but not a CKP signal. standard control CKP sensor defect
(no signal)
CMP sensor is ECM internal defect
normal, restarting
is possible.)
Possibility of drop
of output power,
white smoke, Wiring defect (short) between
Crank position engine vibration When the CMP sensor ECM and CKP sensor
(CKP) sensor CKP signal pulses do
abnormality (signal 0336
Possibility of engine is normal, cam CKP sensor defect 1
stalling (when the not match standard control Flywheel ring gear tooth missing
abnormality) CMP sensor is nor- ECM internal defect
mal, restarting is
possible.)
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While engine turning: Wiring defect (disconnection,
No fault during When the CKP sensor is short, high resistance) between
Cam position engine rotation, but normal, crank standard ECM and CMP sensor
(CMP) sensor There is a CKP signal,
abnormality 0340 when it is stopped but not a CMP signal. After engine stop: CMP sensor defect 1
once, it cannot be Restart is impossible Faulty cam gear
(no signal) restarted. due to inability to Supply pump defect
discriminate cylinders ECM internal defect
While engine turning: Wiring defect (short) between
No fault during When the CKP sensor is
Cam position When excess cam ECM and CMP sensor
(CMP) sensor engine rotation, but pulses detected or normal, crank standard CMP sensor defect
abnormality (signal 0341 when it is stopped Insufficient cam pulses After engine stop: Faulty camshaft gear 1
abnormality) once, it cannot be detected Restart is impossible Supply pump defect
restarted. due to inability to
ECM internal defect
discriminate cylinders
The glow relay drive short, high resistance) between
instruction signal and fuse and glow relay
Glow relay Low-temperature glow relay monitor Wiring defect (disconnection,
0380 No backup 1
abnormality starting defect signal (line 339 in e short, high resistance) between
lectrical circuit diagram) ECM and glow relay
are different. Glow relay defect
ECM internal defect
Signal inputs from EGR short, high resistance) between
EGR position Nothing in position sensor U, V, EGR valve all-close ECM and EGR position sensor
sensor 0487 2
abnormality particular and W all ON or all OFF command EGR valve (position sensor)
for 3 sec. or longer defect
ECM internal defect
When the difference Wiring defect (disconnection,
between the target valve short, high resistance) between
EGR valve control 0488 Nothing in lift and the actual posi- EGR valve all-close ECM and EGR motor 2
abnormality particular
tion is larger than 20 % command EGR valve defect
for 10 sec. or longer ECM internal defect
Oil pressure sensor The oil pressure sensor Wiring defect (short) between
abnormality Nothing in ECM and oil pressure sensor
voltage is 0.1 V or lower No backup 2
(abnormally low 0522 particular for 4 sec. or longer. Oil pressure sensor defect
voltage) ECM internal defect
Oil pressure sensor The oil pressure sensor Wiring defect (disconnection,
abnormality Nothing in voltage is 4.85 V or
(abnormally high 0523 particular higher for 4 sec. or No backup ECM and oil pressure sensor 2
voltage) longer. Oil pressure sensor defect
ECM internal defect
ROM abnormality ROM abnormality
(ECM internal com- 0601 Engine stop detected No backup (engine stop) ECM internal defect 2
ponent part) Reflash failure
EEPROM abnor-
mality (ECM inter- Nothing in EEPROM abnormality
nal component 0603 particular detected No backup ECM internal defect 2
part)
The CPU monitoring IC
detects faulty main
CPUs for 100 msec. Multi-injection stop
CPU Drop of output after the key is switched Injection quantity
abnormality ON.
(ECM internal 0606 power, starting not The RUN-SUB pulse
restriction ECM internal defect 2
possible The SUB-CPU stopped
component part) (signal between CPU the CPU.
and SUB-CPU) was
unchanging for 20 msec.
or longer.
The RUN-SUB pulse
(signal between CPU
Abnormality with IC 0606 Drop of output and SUB-CPU) was Injection quantity restric- ECM internal defect 2
monitoring CPU power tion
unchanging for 20 msec.
or longer.
Engine vibration,
idling instability,
ECM terminal, ECM ground
Charge circuit 1 drop of output When the ECU charge Common 1 stop (No. 1,
0611 power circuit bank 1 voltage is 4 cylinder stop) terminal defect (disconnection, 2
abnormality Possibility of rev-up low for 1.5 sec. or longer EGR stop high resistance)
ECM internal defect
defect, engine
stalling
Engine vibration,
idling instability, ECM terminal, ECM ground
Charge circuit 2 drop of output When the ECU charge Common 2 stop (No. 2, terminal defect (disconnection,
0612 power circuit bank 2 voltage is 3 cylinder stop) 2
abnormality high resistance)
Possibility of rev-up low for 1.5 sec. or longer EGR stop ECM internal defect
defect, engine
stalling
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Fuel system line (hose), etc.
blocked
Air in fuel system (check hose
When the pressure lim- connection.)
iter is open or when the Pressure limiter defect
Pressure 1095 Drop of output common rail pressure Injection quantity Common rail pressure sensor 1
limiter open power, hunting exceeds 29000 PSI restriction defect
(200 MPa) for 1 sec. or Wiring defect (short) between
longer ECM and common rail pressure
sensor
Supply pump defect
ECM internal defect
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Note:
[1] Patterns for recovery from trouble
Trouble recovery can be roughly divided into 2 types.
Sometimes, one more cycle is required after the cycle below for the diagnostic trouble code
displayed on the monitor screen by the actual machine to go out.
Pattern 1:
In the cycle in which the diagnostic trouble code was detected, even if the machine recovers to
normal (including intermittent problems), the diagnostic trouble code does not disappear from
the monitor screen and backup mode does not recover to normal mode. After the key is
switched OFF, when the engine is restarted, the trouble judgment is made and if it is judged
that the status is normal,
Time chart
Name
1 Diagnostic trouble code detection
2 Repair and inspection
3 Recovery to normal
Pattern 2:
If the machine recovers to normal (including intermittent problems) in the cycle in which the
diagnostic trouble code was detected, the diagnostic trouble code disappears from the
monitor screen and backup mode recovers to normal mode.
• generally, the trouble judgment ends immediately and if it is judged that the status is normal,
the diagnostic trouble code disappears and operation recovers to normal.
• For a temperature sensor or the like in the section marked *, trouble judgment takes 3 - 10
min. and if it is judged that the status is normal, the diagnostic trouble code disappears and
operation recovers to normal.
Time chart
Name
1 Diagnostic trouble code detection
2 Recovery to normal
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4. Sensor Trouble Operation Table
• The table below shows the operations when there is trouble with a sensor (current, recovered
from, ongoing).
• '*' indicates that it is not related to (not affected by) that trouble.
Input Coolant
Upper Swing Travel P1 pres- P2 pres- N1 pres- N2 pres- Oil tem-
tempera- Fuel sen-
pressure pressure pressure sure sen- sure sen- sure sen- sure sen- perature
Output and function ture sensor
sensor sensor sensor sor sor sor sor sensor
sor
Trouble contin-
0 PSI 0 PSI 0 PSI 0 PSI 0 PSI 0 PSI 0 PSI -40 °
F 417 °F 0%
uation (-40 ºC) (214 ºC)
Backup value
Input Input Input Input Input Input Input Input Input Input
Recovery
value value value value value value value value value value
Backup Backup Backup

value value value
Auto idle
control control control ＊＊＊＊＊＊＊
(*1) (*1) (*1)

value value value
Idling start
Engine target (*2) (*2) (*2)

speed Backup Backup Backup
value value value
Auto warm-up
(*3) (*3) (*3)

value value value
Idle up
(*4) (*4) (*4)
Fixed to Fixed to Fixed to Fixed to

Engine Anti-theft
ON (*21) ＊ ON (*21) ON (*21) ON (*21) ＊＊＊＊＊
Stop command
Static horse-
power control ＊＊＊＊＊＊＊＊＊＊

Dynamic
value value value
horsepower
control ＊＊ control control ＊＊＊＊＊
control
Milli-amp for (*5) (*5) (*5)
pump horse-
Backup
power control Travel
value
proportional horsepower ＊＊ control ＊＊＊＊＊＊＊
valve boost
(*6)
Arm-in horse-
power boost ＊＊＊＊＊＊＊＊＊＊
Engine stall
prevention ＊＊＊＊＊＊＊＊＊＊
Fixed to Fixed to Fixed to Fixed to Fixed to Fixed to Fixed to

Relief cut 50 mA 50 mA 50 mA 50 mA 50 mA 50 mA 50 mA ＊＊＊
(*7) (*7) (*7) (*7) (*7) (*7) (*7)

Pump flow pro-
portional valve
Speed limit 50 mA 50 mA 50 mA 50 mA 50 mA 50 mA 50 mA ＊＊＊
(*8) (*8) (*8) (*8) (*8) (*8) (*8)

Power save 50 mA 50 mA 50 mA 50 mA 50 mA 50 mA 50 mA ＊＊＊
(*9) (*9) (*9) (*9) (*9) (*9) (*9)

Power save value value value
solenoid
Power save
(*9) (*9) (*9)
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Input Coolant
Upper Swing Travel P1 pres- P2 pres- N1 pres- N2 pres- Oil tem-
tempera- Fuel sen-
pressure pressure pressure sure sen- sure sen- sure sen- sure sen- perature
Output and function ture sensor
sensor sensor sensor sor sor sor sor sensor
sor
Trouble contin-
0 PSI 0 PSI 0 PSI 0 PSI 0 PSI 0 PSI 0 PSI -40 °
F 417 °F 0%
uation (-40 ºC) (214 ºC)
Backup value
Input Input Input Input Input Input Input Input Input Input
Recovery
value value value value value value value value value value

Fixed to
Auto pressure value value value
boost control ＊ OFF
control control ＊＊＊＊＊
(*12)
(*10) (*11) (*11)
Pressure boost Fixed to

Continuous
solenoid
pressure boost ＊＊ OFF ＊＊＊＊＊＊＊
(*12)
Fixed to
Pressure boost
cut ＊＊ OFF ＊＊＊＊＊＊＊
(*12)
Fixed to Fixed to
Auto brake OFF OFF ＊＊＊＊＊＊＊＊
(*13) (*13)
Swing brake
Fixed to Fixed to
solenoid Swing lock
ON (*14) ON (*14) ＊＊＊＊＊＊＊＊
Fixed to Fixed to
Anti-theft
ON (*15) ON (*15) ＊＊＊＊＊＊＊＊
Backup
value
Travel alarm ＊＊ control ＊＊＊＊＊＊＊
Travel alarm (*16)
Key ON alarm ＊＊＊＊＊＊＊＊＊＊
Anti-theft ＊＊＊＊＊＊＊＊＊＊
Coolant tem- Not dis-
Coolant tem-
perature gauge
perature dis- ＊＊＊＊＊＊＊＊ played ＊
play (*17)
Not dis-
Oil tempera- Oil tempera-
ture gauge ture display ＊＊＊＊＊＊＊ played ＊＊
(*18)
Not dis-
Fuel level dis-
Fuel gauge
play ＊＊＊＊＊＊＊＊＊ played
(*19)
Backup
Cold blast pre- value
Air conditioner
vention ＊＊＊＊＊＊＊＊ control ＊
(*20)
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―Symptom―
(*1) Idle cannot be ended. Idles even during work.
(*2) Idle cannot be ended.
(*3) Auto warm up cannot be ended.
(*4) Idle speed cannot be raised.
(*5) Dynamic horsepower control (for transient loads) is not possible.
(*6) No horsepower boost even for travel.
(*7) No swing relief cut. (deterioration in fuel economy)
(*8) No swing speed limit. (Excessive swing speed)
(*9) No power save. (deterioration in fuel economy)
(*10) Auto pressure boost stops. (Constant pressure boost for A mode is executed.)
(*11) Auto pressure boost is not carried out for a pump load on only one side.
(*12) Pressure boost is always OFF.
(*13) Swing brake is always OFF.
(*14) During a swing lock, held ON even if there is trouble.
(*15) During swinging with anti-theft prevention, held ON even if there is trouble.
(*16) Travel alarm does not sound. (key ON alarm sounds)
(*17) Coolant temperature gauge is not displayed. (Goes out)
(*18) Oil temperature gauge is not displayed. (Goes out)
(*19) Fuel gauge is not displayed. (Goes out)
(*20) Air flow maximum
(*21) The engine cannot be started if the password has not been input.
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5. EPF (Engine Protection Feature)
This feature controls the engine speed or stopping when the coolant temperature rises, the boost
temperature rises, or the oil pressure drops.
―Trouble state―
Recovered = State in which trouble recovered from during the key ON cycle
in which the key was switched OFF, then ON again with the previous trouble
underway (or continuing)
―Speed restriction control―
0: None
1: Backup speed
2: Low idle
3: Stop (restart possible, low idle)
4: Stop (restart not possible)
Speed restriction
Explanation
control
Trouble
Coolant 0: None -
underway
temperature
over 221 °F Recovered 0: None -
(105 ºC)
Ongoing 0: None -
Trouble The engine goes to low idle at a coolant temperature of 230 °
F
2: Low idle
underway (1.6 °
C) or higher.
Coolant When the coolant temperature falls to 221 °
F (105 ºC) or less, the
temperature Recovered 0: None
system recovers and controls returns to normal.
over 230 °F
(110 ºC) When the key is switched ON again and the engine starts, for the
time (1 min.) until judgment starts, the engine speed is restricted
Ongoing 2: Low idle
to low idle. After that, the status moves to trouble underway or
recovered based on the judgment results.
The engine stops at a coolant temperature of 248 ° F (120 ºC) or
Trouble 4: Stop higher. The engine cannot be restarted until the key is turned to
underway (restart possible) ON again or the coolant temperature falls to 248 °F (1.7 ºC) or
less.
Coolant When the coolant temperature falls to 248 ° F (120 ºC) or less, the
temperature system recovers and the degree of restriction due to the coolant
over 248 °F
Recovered 0: None temperature being over 248 ° F (120 ºC) goes to 0. (Normal
(120 ºC) control) However, if the restriction due to the coolant temperature
being over 230 °
F (110 ºC) is not 0, that restriction is applied.
When the key is switched ON again and the engine starts, for the
Ongoing 2: Low idle
Trouble The engine goes to low idle at a boost temperature of 176 °
F
2: Low idle
underway (80 ºC) or higher.
Boost When the boost temperature falls to 158 °F (70 ºC) or less, the
temperature Recovered 0: None
system recovers and controls returns to normal.
over 176 °F
(80 ºC)
Ongoing 2: Low idle
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Speed restriction
Explanation
control
Engine stop. The engine cannot be restarted until either the key is
Trouble 4: Stop
switched ON again or the boost temperature recovers to the
underway (restart possible)
normal level.
When the boost temperature falls to 194 ° F (90 ºC) or less, the
Boost degree of restriction due to the boost temperature being over
temperature Recovered 0: None 194 °F (90 ºC) goes to 0. (Normal control) However, if the degree
over 194 °F of restriction due to the boost temperature being over 176 ° F
(90 ºC) (80 ºC) is not 0, that degree of restriction is applied.
Ongoing 2: Low idle
Engine stop. The engine cannot be restarted until the key is
Trouble 4: Stop switched ON again. Recovery cannot be judged until the engine is
underway (restart possible) restarted, so the system does not move from trouble underway to
be recovered.
Engine oil The engine oil pressure recovers to 5800 PSI (40 MPa) or higher
Recovered 0: None
pressure drop and control returns to normal.
time (30 sec.) until judgment starts, the engine speed is restricted
Ongoing 2: Low idle
recovered based on the judgment.
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Engine Summary SH330
Engine
Engine Summary
Main Data Table
350X2 (exhaust gas 3rd regulation)
Engine model name - Isuzu 6HK1
4-cycle, water-cooled, overhead camshaft, vertical in-line, direct
Type -
injection type
Dry weight lb (kg) 1411 (640)
Displacement cu in. (cc) 475.3 (7790)
Number of cylinders - bore ×
in. (mm) 6 - 4.5 x 4.9 (115 × 125)
stroke
Compression ratio - 17.5
hp(kW)/
Rated output 270 (202)/2000
rpm
lbf-ft (Nm)/ 797 (1080)/
Maximum torque
rpm 1500
No-load maximum speed rpm 2050
No-load minimum speed
rpm 900
(idling)
Rated fuel consumption ratio g/kW•hr 221 max.
Fuel unit - HP4 model common rail from Denso Corp.
Control device - ECM made by Transtron Inc.
Cooling fan - 6N suction φ850 plastic
Bell mouth-type fan guide - Yes
Fan belt - Drive by 1 V-rib belt (3-in-1 type)
Alternator - 50 A-24 V made by Mitsubishi Electric Corp.
Starter - 5.0 kW-24 V made by Mitsubishi Electric Corp.
Turbo - RHG6 model made by IHI
Preheat unit - QOS-II
Inter cooler - Yes
Fuel cooler - Yes
Charge fuel pump - Yes
Fuel filter - 4 μ main unit remote type with water separator function
Fuel prefilter - 10 μ main unit remote type with water separator function
Oil filter - Remote type
Oil pan capacity L 28.0 - 38.0 (not including remote oil filter)
Oil pan drain cock - Yes
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Engine Summary
Overall Appearance Diagram
1 Engine oil fill port 6 EGR cooler

2 Air breather 7 Bell mouth-type fan guide
3 Alternator 8 Starter pump
4 Turbo 9 Supply pump (SCV)
5 EGR valve 10 Common rail
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Engine Summary
Sensor and Auxiliary Equipment Layout (left)
1 Overheat switch 6 Common rail pressure sensor

2 Coolant temperature sensor 7 Crank position sensor
3 Boost pressure sensor 8 Engine oil pressure sensor
4 Boost temperature sensor 9 Suction control valve
5 ERG valve 10 Fuel temperature sensor
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Engine Summary
Sensor and Auxiliary Equipment Layout (rear)
1 Cam position sensor
Engine System Diagram
1 Air cleaner 7 Turbine side 13 Muffler

2 Fuel cooler 8 Engine 14 Fuel main filter
3 Inter cooler 9 Injector 15 Fuel tank
4 Radiator 10 Common rail 16 Fuel prefilter
5 Turbo 11 Supply pump 17 Charge fuel pump
6 Compressor side 12 EGR cooler
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Engine Summary
Fuel System Diagram
Sensors (accelerator, boost pressure, engine coolant temperature)
1 Charge fuel pump 6 Flow damper 11 Cam position sensor

2 Fuel main filter 7 Fuel prefilter 12 Crank position sensor
3 Common rail pressure sensor 8 Supply pump 13 Injector
4 Common rail 9 Fuel cooler
5 Pressure limiter 10 Fuel tank
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Engine Summary
Detailed Parts Diagrams
1. ECM (engine control module)
3 roles of the ECM

[1] The ECM constantly monitors information sent from the various sensors and controls the power
train systems.
[2] The ECM executes system function diagnosis, detects problems in system operation, issues
trouble warnings to the operator and stores the diagnostic trouble code into memory.
The diagnostic trouble code identifies the area in which the problem occurred and supports
repair work by the service engineer.
[3] The ECM puts out 5 V and other voltages to supply power to the various sensors and switches.
The ECM controls output circuits by controlling ground or power supply circuits via one device or
another.
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Engine Summary
2. Supply Pump/SCV (suction control valve)

2 SCV (suction control valve)
3 Feed pipe
[1] Supply pump

The supply pump uses the force of the engine rotation to raise the fuel pressure and send fuel to
the common rail. The SCV, fuel temperature sensor, and feed pump are installed on the supply
pump.
[2] SCV (suction control valve)
The SCV is installed on the supply pump and controls the sending of fuel to the common rail
(discharge volume). The ECM controls the electrified time to the SCV and controls the fuel
discharge volume.
3. Common Rail/Flow Damper
1 Common rail
2 Flow damper
[1] Common rail

The common rail receives the fuel from the supply pump, holds the common rail (fuel) pressure,
and distributes the fuel to each cylinder.The common rail pressure sensor, flow damper, and
pressure limiter are installed on the common rail.
[2] Flow damper
The flow dampers are installed on the discharge port of each injector of the common rail. They
suppress pressure pulses in the common rail and prevent excess fuel injection from the injectors.
When a flow damper operates, the fuel supply to the injector stops.
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Engine Summary
4. Common Rail Pressure Sensor/Pressure Limiter
1 Pressure limiter
2 Common rail pressure sensor
[1] Common rail pressure sensor

This sensor sends the pressure inside the common rail to the ECM as a voltage signal. From the
signal sent, the ECM calculates the actual common rail pressure (fuel pressure) and uses this for
fuel injection control.
[2] Pressure limiter
If the pressure in the common rail becomes abnormally high, the pressure limiter relieves the
pressure by returning excess fuel to the tank.
5. Injector
The injectors are installed on the cylinder head sections. They are controlled from the ECM and
inject fuel.The injector drive voltage is boosted (to 118 V) inside the ECM and applied to the
injectors. By controlling the injector electrified time, the ECM controls the fuel injection, injection
timing, etc.
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Engine Summary
6. Engine Coolant Temperature Sensor
The engine coolant temperature sensor is installed on the engine block. The resistance of its
thermistor varies with the temperature.
The resistance is low when the engine coolant temperature is high and high when the coolant
temperature is low. From the ECM voltage variation, the ECM calculates the engine coolant
temperature and uses this for fuel injection control etc.
7. Engine Oil Pressure Sensor
The engine oil pressure sensor is installed near the cylinder block starter motor. It detects the
engine oil pressure, converts this pressure into an electrical signal, and sends that signal to the
ECM.
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Engine Summary
8. Cam Position Sensor (CMP sensor)
This sensor sends a signal to the ECM when the engine camshaft cam section passes this sensor.
The ECM identifies the cylinders through this sensor input, determines the crank angle, and uses
this information to control the fuel injection and to calculate the engine speed.
Also, it provides a back-up function in case of trouble in the CKP sensor. There is no change in
behavior while the engine is running even if there is trouble in the CMP sensor system. However, it
will be difficult to restart the engine after it has been stopped.
9. Crank Position Sensor (CKP sensor)
This sensor sends a signal to the ECM when the projection section of the engine flywheel passes
this sensor.
The ECM uses this sensor input in the calculation of engine speed.
In case of trouble in the CKP sensor, the CMP sensor provides a back-up function.
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Engine Summary
10.Atmospheric Pressure Sensor
The atmospheric pressure sensor is installed in the cab. The ECM converts the atmospheric
pressure into an electric signal and calculates the atmospheric pressure from this voltage signal and
corrects the fuel injection quantity according to the atmospheric pressure.
11.Suction Air Temperature Sensor
The suction air temperature sensor is installed midway through the suction air duct. It detects the
suction air temperature in order to optimize the fuel injection quantity.
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Engine Summary
12.Boost Pressure Sensor
The boost pressure sensor uses a pressure hose between the boost pressure sensor and intake
pipe to detect the boost (suction air pressure), converts this pressure into an electrical signal, and
sends that signal to the ECM.
13.Boost Temperature Sensor
The boost temperature sensor is installed on the upstream side of the EGR valve of the intake
manifold.
This sensor is the thermistor type. The internal resistance of the sensor changes with the
temperature.
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Engine Summary
14.Charge Fuel Pump
Converting the fuel filter and pre-filter to remote operation increased the distance from the fuel tank
to the feed pump.
Therefore, it was newly added to assist in drawing the fuel from the tank and to make it easy to
bleed out air during maintenance.
The pump always operates when the key switch is ON.
15.EGR Cooler
1 Coolant inlet
2 Coolant path (outside of exhaust gas path)
3 Exhaust gas path
The cooled EGR (cooling system installed in the path) uses the engine coolant to cool exhaust gas
at high temperature (about 1292 ºF (700 ºC)) to a lower temperature (about 392 ºF (200 ºC)) in
order to further drop the combustion temperature and reduce NOx.
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Engine Summary
16.Lead Valve (check valve)
The lead valve is installed between the EGR valve outlet and the inlet manifold. It suppresses EGR
gas back flow and allows the EGR gas to only flow in one direction.
17.EGR Valve
The operation of the EGR valve (lift amount) is controlled by signals from the ECM.
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Engine Summary
Engine Control Summary
Electronic control fuel injection system (common rail type)
This is a system in which the engine speed, engine load, and other information (signals from many
sensors) are acquired from the engine control module (ECM) and based on that information, the ECM
sends electrical signals to the supply pump, injectors, etc. to appropriately control the fuel injection
quantity and timing for each cylinder.
Injection quantity control
To provide the optimum injection quantity, the ECM controls the injectors based mainly on the engine
speed and the instructed speed from computer A and controls the fuel injection quantity.
Injection pressure control
The injection pressure is controlled by controlling the fuel pressure in the common rail. The appropriate
pressure in the common rail is calculated from the engine speed and fuel injection quantity and by
controlling the supply pump, the appropriate quantity of fuel is discharged and the pressure sent to the
common rail is controlled.
Injection timing control
Instead of a timer function, the injectors are controlled primarily by calculating the appropriate fuel
injection timing from the engine speed, injection quantity, etc.
Injection ratio control
In order to improve the combustion in the cylinder, at first only a small amount of fuel is injected (pre-
injection), the fuel is ignited, then once the fuel has ignited, a second injection (main injection) is
carried out. This injection timing and quantity control is effected by controlling the injectors.
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Explanation of Engine Terms SH200
Engine Section

Function Explanation Table
Name Function
Receives the high-pressure fuel sent under pressure from the supply
1 Common rail pump, holds the fuel pressure, and distributes the fuel to each
injector.
Pressure limiter Operates to allow pressure within the common rail to escape if the
2
(common rail component part) pressure in the common rail becomes abnormally high.
Installed on the discharge port of each injector. Suppress pressure
Flow damper
3 pulses in the common rail and prevent fuel supply to the injectors
(common rail component part)
when there is line damage.
Common rail pressure sensor Detects the pressure inside the common rail, converts it to a voltage,
4
(common rail component part) and sends that voltage to the ECM.
5 Injector Controlled by the ECM and injects the fuel.
Raise the fuel pressure and send it under pressure to the common rail
6 Supply pump
by using the force of the engine rotation.
Controls the fuel pressure (discharge volume) sent to the common
SCV (suction control valve) rail.
7
(supply pump component part) The ECM controls the electrified time to the SCV to increase or
decrease the volume of fuel discharged.
Fuel temperature sensor Detects the fuel temperature and sends it to the ECM.
8
(supply pump component part) Used for supply pump control etc.
Recirculates part of the exhaust gas in the intake manifold and mixes
9 EGR the EGR gas with the suction air to reduce the combustion
temperature and reduce NOx.
The EGR valve operation (open and close) timing and the lift amount
EGR valve
10 are controlled by signals from the ECM. (The valve lift amount is
(EGR position sensor)
detected by the EGR position sensor)
11 EGR cooler Cools the high-temperature EGR gas by using the engine coolant.
Increases the amount of EGR by suppressing back flow of the EGR
12 Lead valve
gas and letting it flow only in one direction.
ECM Constantly monitors the information from each sensor and controls
13
(engine control module) the engine system.
Determines the glow time according to the engine coolant
QOS temperature, operates the glow relay, and makes starting at low
14
(quick on start system) temperatures easy and also reduces white smoke and noise
immediately after the engine starts.
This sensor sends a signal to the ECM when the projection section of
the engine flywheel passes this sensor.
CKP sensor
15 The ECM uses this sensor input in the calculation of engine speed.
(crank position sensor)
In case of trouble in the CKP sensor, the CMP sensor provides a
back-up function.
Detects the engine oil pressure and sends it to the ECM.
16 Oil pressure sensor
Used for oil pressure drop alarms etc.
Detects the engine coolant temperature and sends it to the ECM.
17 Engine coolant temperature sensor
Used for fuel injection control, QOS control, etc.
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Name Function
This sensor sends a signal to the ECM when the engine camshaft
cam section passes this sensor.
The ECM identifies the cylinders through this sensor input,
determines the crank angle, and uses this information to control the
CMP sensor fuel injection and to calculate the engine speed.
18
(cam position sensor) Also, it provides a back-up function in case of trouble in the CKP
sensor.
There is no change in behavior while the engine is running even if
there is trouble in the CMP sensor system. However, it will be difficult
to restart the engine after it has been stopped.
Detects the atmospheric pressure and sends it to the ECM. The
19 Atmospheric pressure sensor
injection quantity is corrected according to the atmospheric pressure.
Detects the suction air temperature and sends it to the ECM.
20 Suction air temperature sensor
Optimizes the fuel injection quantity.
Detects the boost (suction air pressure) inside the intake pipe and
21 Boost pressure sensor sends it to the ECM. Used to control fuel injection with the boost
pressure.
Detects the boost temperature and sends it to the ECM. Used for fuel
22 Boost temperature sensor
injection control etc.
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2
Explanation of Engine Structure SH330
Engine

Technology for Exhaust Gases
1. Common Rail System
1 Fuel tank
2 High-pressure pump
3 Common rail
4 Injector
5 Electronic control system
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2. Multi Stage Fuel Injection (multiple injection)
Injection
start
With conventional models, there is the no-injection state, but with common rail models, pre-injection
is started and ignition starts.
Ignition
Conventional models start injection at this point in time, but common rail models have already
ignited with pre-injection and now start the 2nd injection (main injection).
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2
Combustion
Common rail models divide the high-pressure fuel injection over many times to make it possible to
create a uniform, complete combustion state in the combustion chamber and also to reduce the
engine noise and vibration.
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3. Inter Cooler
By cooling intake air that has reached a high temperature due to turbo-charging, the air density rises and the
charging efficiency rises.
This raises the engine fuel efficiency and improves fuel efficiency (CO/CO2 reduction) and also has the effect of
lowering the combustion temperature that reduces NOx.
1 Inter cooler
2 Radiator
3 Oil cooler
4 Fuel cooler
5 Engine
Air cooled and brought to high-density
6
(to engine)
7 Outside air
8 Suction air
9 Exhaust gas
Air that has been compressed and
10
become hot
11 Turbo charger
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4. EGR (exhaust gas recirculation)
1 EGR cooler 6 Boost pressure sensor

2 Lead valve 7 Suction air temperature sensor
3 EGR valve 8 Engine speed
4 EGR position sensor 9 Engine coolant temperature
5 Boost temperature sensor 10 Engine load
EGR (exhaust gas recirculation)
EGR system is an abbreviation for "exhaust gas recirculation" system. The EGR system recirculates
part of the exhaust gas in the intake manifold and mixes inactive gases with the suction air to reduce
the combustion temperature and suppress the generation of nitrogen oxides (NOx). The EGR quan-
tity is controlled by the operation (opening and closing) of the EGR valve, which is installed between
the exhaust manifold and the intake manifold.
The ERG quantity is determined from the engine speed and engine load ratio (fuel injection quan-
tity) and the EGR amount is controlled. A cooling system (EGR cooler) is installed in the EGR gas
path to cool the high-temperature EGR gas with this EGR cooler. This cooled EGR gas is mixed with
new air intake to make the combustion temperature lower than with normal EGR, which contributes
to the reduction of NOx. (Cooled EGR)
Furthermore, a lead valve is used in the EGR system to suppress EGR gas back flow and allow the
EGR gas to only flow in one direction.
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The ECM operates the motor according to such engine states as the speed and load and controls
the EGR valve lift amount.
The valve lift amount is detected by the EGR position sensor.The sections shown in darker color in
the diagram have a larger valve lift amount. The darkest color indicates a lift amount near 100 %.
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6
Explanation of Engine Operation SH200
Engine

Fuel Unit
1. Common Rail System Summary
The common rail system pressurizes the fuel to high pressure and injects the fuel mist widely into
the cylinder to increase the surface of contact with the air and improve the combustion state.
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Relationship between ECM and sensor actuators
1 Throttle volume (computer A) 5 Injector

2 Crankshaft position sensor 6 Common rail pressure sensor
3 Camshaft position sensor 7 Supply pump
4 Other sensors 8 EGR valve
2. Change Points for Injection Method (governor, common rail)

Inline type Common rail system
System
Injection quan-
Pump (governor) ECM, injector
tity adjustment
Injection timing
Pump (timer) ECM, injector
adjustment
Pressure boost Pump Supply pump
Distribution
Pump Common rail
method
Injection pres- According to engine speed and injection quan-
Supply pump (SCV)
sure adjustment tity
1 Pipe 5 Nozzle
2 Timer 6 Common rail
3 Supply pump 7 Injector
4 Governor
SST-06-04-010EN 25
2
3. Explanation of Injector Operation
(1) When there is no signal from the ECM (state before injection)
The outer valve (1) in the injector is pushed down by the force of the spring A (6) and seals the
fuel into the control chamber (8).
The hydraulic piston (4) and spring B (9) are pushed down by the fuel in the control chamber (8)
and the nozzle (10) is in the closed state.
No signal
1 Outer valve
2 Orifice 1
3 Orifice 2
4 Hydraulic piston
5 Solenoid
6 Spring A
7 Inner valve
8 Control chamber
9 Spring B
10 Nozzle
a Common rail
b Return
(2) When there is a signal from the ECM

When the signal from the ECM passes power through the injector solenoid (5), the outer valve (1)
compresses spring A (6) and moves up.
The outer valve (1) opening allows the fuel in the control chamber (8) to return to the tank via the
return line.
Signal input
1 Outer valve
2 Orifice 1
3 Orifice 2
4 Hydraulic piston
5 Solenoid
6 Spring A
7 Inner valve
8 Control chamber
9 Spring B
10 Nozzle
11 Valve open
a Common rail
b Return
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(3) Injection start state
Fuel in the control chamber (8) flowing into the return line creates a pressure difference between
the control chamber (8) side and the hydraulic piston (4) and nozzle (10), which causes the noz-
zle (10) to open and fuel to be injected.
Injection start
1 Outer valve
2 Orifice 1
3 Orifice 2
4 Hydraulic piston
5 Solenoid
6 Spring A
7 Inner valve
8 Control chamber
9 Spring B
10 Nozzle
a Common rail
b Return
(4) When the signal from the ECM is cut off

Because the power to the injector solenoid (5) is cut off, the outer valve (1) is pushed back down
by the force of the spring A (6) and the outer valve (1) closes the return line path.
Signal stop
1 Outer valve
2 Orifice 1
3 Orifice 2
4 Hydraulic piston
5 Solenoid
6 Spring A
7 Inner valve
8 Control chamber
9 Spring B
10 Nozzle
11 Valve close
a Common rail
b Return
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4
(5) Injection stop state (injection end)
Because the fuel is sealed into the return line, the control chamber (8) is filled with fuel again.
The hydraulic piston (4) and the spring B (9) are compressed down by the filled fuel and the noz-
zle (10) is closed.
This ends the injection.
Injection stop
1 Outer valve
2 Orifice 1
3 Orifice 2
4 Hydraulic piston
5 Solenoid
6 Spring A
7 Inner valve
8 Control chamber
9 Spring B
10 Nozzle
a Common rail
b Return
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4. Explanation of Supply Pump Operation
The drive shaft is driven by the force of engine rotation.
The feed pump is turned by the power of the drive shaft and draws up fuel from the fuel tank.
The fuel pressurized by the feed pump has feed pressure pulse stabilized by the adjusting valve.
Part of this fuel remains at the suction control valve to lubricate the plunger and cam and is returned
to the fuel tank via the overflow.
The signal from the ECM is input to the suction control valve and the opening stroke varies accord-
ing to the quantity of power passed through.
The quantity of fuel corresponding to the stroke is sent to the suction valve under pressure and is
compressed to high pressure at the plunger.
The fuel raised to high pressure at the plunger is sent under pressure from the delivery valve to the
common rail.
The fuel temporarily built up in the common rail is distributed to the injectors for each cylinder.
1 Fuel tank 8 Return spring 15 Injector

2 Fuel filter 9 Plunger 16 Drive shaft
3 Suction 10 Suction valve 17 Suction pressure
4 Fuel inlet 11 Delivery valve 18 Feed pressure
5 Feed pump 12 Overflow 19 High pressure
6 Adjusting valve 13 Return 20 Return pressure
7 Suction control valve 14 Common rail
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5. Supply Pump Disassembly Diagram
1 SCV (suction control valve) 5 Plunger

2 Eccentric cam 6 Suction valve
3 Feed pump 7 Delivery valve
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1 Fuel temperature sensor 5 Filter

2 Camshaft 6 SCV (suction control valve)
3 Cam ring 7 Feed pump
4 Pump body 8 Adjusting valve
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6. Explanation of Flow Damper Operation
Internal structure diagram
Common rail side Injector side
1 Piston 3 Spring
2 Ball
[1] When engine is stopped

1 Piston 3 Spring
2 Ball
When the engine is stopped, the ball and piston are pressed to the common rail side by the ten-
sion of the spring.
[2] When engine starts (damping)
1 Piston 3 Spring
2 Ball
When the engine starts, the fuel pressure from the common rail side is applied and the piston
and ball move to the injector side.
The fuel pulses (damping) are absorbed by the spring.
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[3] Faulty fuel outflow
1 Piston 3 Spring
2 Ball 4 Adhering
When there is faulty fuel outflow from the injection pipe etc. on the injector side, the injector side
pressure drops drastically, so the piston and ball are pushed out by the pressure difference with
the common rail side to seal the flow damper with the ball and prevent fuel inflow from the com-
mon rail side.
7. Pressure Limiter
When the pressure within the common rail reaches 29008 PSI (200 MPa), for the sake of safety, the
pressure limiter opens and returns fuel to the tank.
When the pressure drops to 4351 PSI (30 MPa), the valve closes to return operation to normal.
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8. Cautions for Maintenance
(1) Cautions concerning fuel used
With common rail engines, the supply pump and injector are lubricated by the fuel running
through them.
Therefore, if any fuel other than diesel is used, this leads to engine trouble, so use of non-speci-
fied fuel is strictly prohibited.
Please be aware that troubles resulting from use are "not covered by the warranty".
Specified fuel
JIS No. 2 diesel, JIS No. 3 diesel, special No. 3 diesel
The parts of the fuel system (injector internal part etc.) and the holes and gaps that form the fuel
path are made with extremely high precision.
Therefore, they are extremely sensitive to foreign matter. Foreign matter in the fuel path can dam-
age it, so use great care to keep out foreign matter.
[1] Clean and care for the fuel line and its surroundings before starting maintenance.
[2] Those working on the fuel line must have hands clean of dirt and dust. Wearing gloves while
working is strictly prohibited.
[3] After removing fuel hoses and fuel pipes, always seal the hoses and pipes by covering the
open sections with plastic bags or the like.
[4] When replacing parts, do not open the packing for the new parts until it is time to install
them.
[5] Do not reuse any gaskets or O-rings. Replace them with new ones.
• Do not reuse fuel system high-pressure lines or injector pipes. If they are removed, replace
them with new parts.
• Do not replace a pressure limiter, fuel temperature sensor or flow damper alone. If there is
any problem, replace the common rail assembly and all the fuel lines.
1 Injector pipe 4 Common rail pressure sensor

2 Flow damper 5 Pressure limiter
3 Common rail
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The SCV and fuel temperature sensor are installed on the supply pump main unit and cannot be
individually replaced.
Always replace the supply pump assembly.

2 SCV (suction control valve)
Judging individual cylinders as OK or not by starting up the engine and loosening the injection
pipes is strictly prohibited when there is engine trouble. (Never do this. The high-pressure fuel
sprays out dangerously.)
1 Injector pipe
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Be careful. High voltage of 118 V or higher is applied to the injectors. Disconnect the battery
cable ground before replacing injectors.
1 Injector
2 Injector harness
3 Injector nut
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Explanation of Engine Control
1. Fuel Injection Quantity Correction
The ECM calculates the basic injection quantity with the throttle volume, boost sensor, CKP sensor,
CMP sensor, and other signals.
According to the common rail pressure, engine coolant temperature, and other conditions at this
time, the ECM controls the SCV and controls the injector electrified time to attain optimum injection
timing and correct the injection quantity.
2. Starting Q Correction
The engine starting Q correction is terminated at the idling speed +α rpm (+ α depends on the
coolant temperature.)
Also, below the system recognition engine speed (30 rpm), the ECM cannot recognize engine rota-
tion, so starting Q correction and engine starting become impossible.
* Minimum engine starting speed is 60 rpm
3. Preheat Control (QOS: quick on start)
The ECM determines the glow time (pre-glow, glow, and after-glow) according to the engine coolant
temperature and makes the glow relay operate.
The QOS system makes starting at low temperatures easier and reduces white smoke and noise
immediately after starting.
When the key is switched ON, the ECM detects the coolant temperature with the signal from the
engine coolant sensor and varies the glow time to always obtain the optimum starting conditions.
Also, the after-glow function makes it possible to stabilize the idling rotation immediately after start-
ing.
Also, if there is trouble in the engine coolant temperature sensor system, control assumes a fixed
coolant temperature of -4 ºF (-20 ºC) for engine starting and 176 ºF (80 ºC) for running.
Also, EGR control stops. Thermostat valve opening temperature is 180 ºF (82 ºC).
4. Atmospheric Pressure Correction (high altitude correction)
The ECM calculates the current altitude from the atmospheric pressure sensor signals.
The ECM controls the SCV and controls the injector electrified time to attain optimum fuel flow
according to the altitude and other conditions at the time.
Also, if there is sensor trouble, control assumes a fixed atmospheric pressure of 12 PSI (80 kPa)
(equivalent to an altitude of 6562 ft (2000 m)) and stops EGR control too.
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5. Control for Overheating
When the engine overheats, in order to protect the engine, if the engine coolant temperature
exceeds 212 ºF (100 ºC), fuel flow restriction is started.
If the temperature rises further, the fuel flow is further restricted.
If engine coolant temperature rises to 248 ºF (120 ºC), the engine is stopped.
The protection function is started 1 min. after the engine starts. (In order to detect a stable coolant
temperature)
Setting Judgment time Engine control Recovery condition

212 ºF
- -
(100 ºC) ECM: Reduced fuel injection quantity
221 ºF 8th on coolant tem- Computer A: Normal
(105 ºC) perature gradation 7th or lower on coolant tem-
230 ºF ECM: Reduced fuel injection quantity perature gradation
5 sec.
(110 ºC) Computer A: Idling
248 ºF ECM: Reduced fuel injection quantity Key switched ON after engine
5 sec.
(120 ºC) Computer A: Engine stopped stopped
* The protection function does not work if any of the error codes below occurs.
0117 (coolant temperature sensor abnormally low voltage)
0118 (coolant temperature sensor abnormally high voltage)
2104 (CAN bus abnormality)
2106 (CAN time-out abnormality)
0090 (CAN communication error)
Overheat protection through Q control
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6. Control for Boost Temperature Rise
If the boost temperature exceeds 176 ºF (80 ºC), fuel flow restriction is started.
If temperature rises to 194 ºF (90 ºC), the engine is stopped.
The protection function is started 1 min. after the engine starts. (In order to detect a stable boost
temperature)

176 ºF ECM: Normal State of 158 ºF (70 ºC) or less continue
5 sec.
(80 ºC) Computer A: Idling control for 30 sec.
194 ºF ECM: Normal
5 sec. Key switched ON after engine stopped
(90 ºC) Computer A: Engine stop control
1112 (boost temperature sensor abnormally low voltage)
1113 (boost temperature sensor abnormally high voltage)
2104 (CAN bus abnormality)
7. Control for Engine Oil Pressure Drop

If the engine oil pressure drops, the engine is stopped to prevent engine damage.
The protection function is started 30 sec. after the engine starts. (In order to detect a stable engine
oil pressure)

6 PSI ECM: Normal
5 sec. Key switched ON after engine stopped
(40 kPa) Computer A: Engine stop control
0522 (oil pressure sensor abnormally low voltage)
0523 (oil pressure sensor abnormally high voltage)
2104 (faulty CAN bus)
1633 (5 V power supply 3 voltage abnormality/sensor power supply)
8. Start Control (coolant temperature monitoring)

[1] Purpose
When the coolant temperature is 32 ºF (0 ºC) or lower, fuel injection is controlled according to the
coolant temperature for stable engine starting at low temperatures.
SST-06-04-010EN 39
16
9. Long Cranking Control
[1] Purpose
For the purpose of reducing black smoke when starting the engine and as backup in case ade-
quate starting Q (fuel injection) is not obtained, for example due to injector wear, after the stipu-
lated time after the start of cranking, the starting Q is raised the stipulated amount to improve
startability.
ST-Q Standard starting Q

UP-Q Starting Q after increase
NL-Q Q for no load
10.Starting Control for Reduced Number of Cylinders

When the fact that there is a stopped injector is detected with trouble diagnosis (when an error code
is detected), for the purpose of emergency escape, the fuel injection quantity is corrected to secure
engine startability.
[1] The injection quantity for the troubled injector is allocated to the normal injectors. (The total injec-
tion quantity is made the same.)
* The injector correction factors are as follows.
Number of effective cylinders 6 5 4 3 2 1 0

Correction factor 1.0 1.2 1.5 2.0 1.0 1.0 1.0
Caution:
No control if there is trouble in injectors for 3 or more cylinders.
No control if an injector has a mechanical trouble.
11.Normal Stop (key switch OFF operation)

[1] The key switch is set OFF.
[2] When the ECM recognizes that the key is OFF, [3] - [5] are carried out at the same time.
[3] Injector injection quantity calculation stop
[4] Suction control valve (SCV) full close instruction
[5] EGR valve full close instruction, EGR valve initial correction
[6] When the operations in [3] - [5] end, the trouble log etc. are written to the EEPROM in the ECM.
[7] The main relay is switched OFF and the power feed to the ECM is switched OFF.
40 SST-06-04-010EN
17
12.Engine Start/Stop Judgment
Engine start and stop is judged based on the engine speed sent from the ECM with CAN communi-
cation.
Judgment values Start: 500 rpm
Stop: 200 rpm
Configuration diagram
1 Computer A
SST-06-04-010EN 41
18
Engine Maintenance Standards SH200
Engine

Engine Information Screen
1. Purpose
It has been made possible to copy the engine information (Q resistance, QR code, engine serial
number) stored in the ECM to the new ECM when the ECM and injector are replaced.
2. How to Go to This Screen
See the service support operation procedure.
3. Engine Start Restriction
When this screen is displayed, the engine cannot be started.
4. Screen
The engine information held in computer A can be checked as follows.
The information inside the ECM is checked by changing the display mode with the method shown in
"When Replacing Computer A at the Same Time".
[1] Pages 1 - 6: Injector cylinder 1 - 6 QR codes
1 Page
2 24-digit QR code
Indicates the display mode.
3 Currently displays the information in
computer A.
4 Error code
[2] Page 7: Q resistance data
1 3-digit Q resistance data
42 SST-06-06-007EN
1
[3] Page 8: Engine serial number
1 6-digit engine serial number
SST-06-06-007EN 43
2
Monitor Operating Method
1. View Mode
Display mode
(switching between information in computer A
/ information in ECM)
Each time this switch is pressed, the second
line of each page is switched as follows.
Page
(Mode displaying information in
computer A)
(Mode displaying information in
ECM)
Hold down for 1 sec. to shift to edit mode
(Only valid while QR code is displayed and when in "AA AA" mode.)
Be careful. Shifting to edit mode will not be done when in "EE EE" mode.
Hold down for 3
seconds to start copying the engine information.
(for details, see "Engine Information Copying Method".)
2. Edit Mode
* Can only be shifted to during QR code display.
Cancel editing and exit edit mode

Value increased
Cursor movement
Value decreased
Start the QR code writing and exit edit mode
(For details, see "Rewriting Injector QR Codes".)
44 SST-06-06-007EN
3
Engine Information (Q resistance, QR code, engine serial number) Copying Method
If the ECM is replaced with a new one for any reason, the engine information is copied with the proce-
dure below.
[1] Arrange for a service ECM.
Engine information can only be copied to a service ECM.
[2] Connect the service ECM and check the following.
1) The old ECM information must still be in computer A.
2) The ECM must match the model.
3) No display for EEPROM abnormality on computer A or EEPROM abnormality on ECM.
[3] Go to the engine information screen, then hold down for 3 sec. The buzzer buzzes and the
copy starts.
* The display may be any page (1 - 8) and either display mode (computer A or ECM).
When held for 3 sec,

the buzzer buzzes.
During copying, the display is as below. During writing, the error code 99 is displayed.
Wait about 10 sec.
When the copy ends normally, the error code 00 is displayed.
When the copy ends abnormally, the error code is displayed.
Example: Starting copying from the Q resistance screen
Error code
Normal
Message interruption
Message internal trouble
Outside instruction
value constant
Engine running
Faulty EEPROM
Writing
[4] When the copy ends normally, check that the information has been rewritten by switching the key
switch OFF → ON once.
SST-06-06-007EN 45
4
Rewriting Injector QR Codes
When an injector is replaced, input and write the QR codes with the following procedure.
[1] Arrange for the replacement injector.
Input the part below from the character array written on the injector.
QR code
QR code
Injector ASM
Input section
24 digits
Input the QR codes one at a time.

Engine information screen pages 1 - 6 correspond to the injectors with those numbers. (See the
diagram below.)
1 Engine front
2 Engine rear
3 Injector No.
[2] Hold down for 1 sec. to shift to edit mode.
Hold down for 1 sec.
46 SST-06-06-007EN
5
[3] Cursor is displayed
Cursor displayed
[4] Move the cursor with and raise and lower values with to
input the QR codes written on the injector.
Value increased
Cursor movement / decreased
Error code
Normal
Message interruption
Message internal trouble
Outside instruction value constant
Engine running
Cursor only moves Writing
as far as here
[5] When the QR code input is complete, press .

The buzzer buzzes once and the writing starts.
The error code 99 (writing) is displayed. When the copy ends normally, the error code 00 is dis-
played.
When the copy ends abnormally, the error code is displayed. (To cancel input, press .)
[6] Switch OFF the key switch, then ON again and check the QR codes have been rewritten.
SST-06-06-007EN 47
6
When Replacing Computer A at the Same Time
If the ECM and computer A have trouble at the same time and the engine information inside the ECM
cannot be used, restore the engine information with the procedure below.
[1] Rather than a service ECM, arrange for an ECM with the engine information already written into
it and use that as the replacement.
* An ECM with the engine information already written into it means one into which the Q resis-
tance data has been written with EMPS.
[2] Input the injector QR codes 1 at a time. (With the procedure in the preceding item)
Engine Information Acquisition Timing

The engine information is acquired only the first time the key is switched ON after factory assembly.
Redoing Engine Information Acquisition
To re-acquire the engine information, hold down + on the engine information screen
for 10 sec.
Abnormality Display
If the engine information cannot be displayed correctly due to an ECM time-out, CAN communication
abnormality, or EEPROM abnormality, the display is all Fs.
[1] Display for EEPROM abnormality on ECM, CAN communication abnormality, or ECM time-out
48 SST-06-06-007EN
7
Engine Equipment Table SH330
Engine
Engine Equipment Table

Exhaust Gas 3rd Engine Accessory Electrical Parts Interchangeability (Isuzu part number)
Engine model 4J 4H 6H 6U 6W
Supply pump 897381-5551 897306-0448 115603-5081 898013-9100 897603-4140
Common rail 898011-8880 897306-0632 897323-0190 897603-1211
Injector 898011-6040 897329-7032 897603-4152 115300-4360
Starter 898045-0270 898001-9150 181100-4142 181100-4322 181100-3413
Alternator 898018-2040 897375-0171 181200-6032 181200-5304
EGR valve 897381-5602 898001-1910 116110-0173
Crank position sensor 897312-1081 897306-1131 897306-1131
Cam position sensor 897312-1081 898014-8310 Supply pump accessory part
Coolant temperature sensor 897363-9360 897170-3270 897363-9360
Fuel temperature sensor Supply pump accessory part 897224-9930
Suction air temperature sen-
812146-8300
sor
Boost temperature sensor 812146-8300
Boost pressure sensor 809373-2691 180220-0140
Common rail pressure sensor Common rail accessory part
Oil pressure sensor 897600-4340
Atmospheric pressure sensor 897217-7780
Glow plug 894390-7775 182513-0443
Caution
[1] For 4J, the crank position sensor and the cam position sensor have the same part number.
[2] The 6U/6W cam position sensor is a supply pump accessory part.
[3] The coolant temperature sensor part number is different for the 4H/6H and the 4J/6U/6W.
[4] Part numbers are subject to change without notice, so confirm part numbers on the engine parts
table.
49 SST-06-07-006EN
1
NOTES:
Exhaust Gas Regulations SH200
Engine Section

Features of Materials Subject to Exhaust Gas Regulation
Exhaust Gas Regulation Values
50 RST-06-08-002E
1
[Example of method for meeting exhaust gas 3rd regulations]

In order to simultaneously reduce both NOx and PM, which have a trade-off relationship, more
complex fuel injection is required. Therefore, fuel injection is now completely electronically
controlled.
Common rail engine (high pressure injection / multiple injection / injection ratio control)
In addition, depending on the engine size, it may be necessary to change from 2 to 4 valves, install
an inter cooler, and use EGR (exhaust gas recombustion).
* With the Model 5 SPACE5, all these systems are used.
RST-06-08-002E 51
2
Cautions for Fuel Used SH200
Engine Section

Engine Fuel and Maintenance of Fuel Filters
In order to meet the emission control regulation of 3rd-stage, the engine components have been made
precisely and they are to be used under high-pressure conditions.
Therefore, the specified fuel must be used for the engine.
As a matter of course, not only the guarantee will not be given for the use of a fuel other than the spec-
ified but also it may invite a serious breakdown.
In addition, since suitable specifications for the fuel filter elements have been established for this
engine, use of the genuine filter is essential.
The following describes the specifications and the requirements of the fuel to be applied, and mainte-
nance of the fuel and the fuel elements.
1. Fuel to be applied
Selection of fuel
Following conditions must be met for the diesel engines, that is the one;
[1] In which no dust even fine one is mixed
[2] With proper viscosity
[3] With high cetane rating
[4] With good flow properties in lower temperature
[5] With not much sulfur content
[6] With less content of carbon residue
(1) Applicable standards for diesel fuel
Applicable Standard Recommendation
JIS (Japanese Industrial Standard) No.2
DIN (Deutsche Industrie Normen) DIN 51601
SAE (Society of Automotive Engineers)
No. 2-D
Based on SAE-J-313C
BS (British Standard)
Class A-1
Based on BS/2869-1970
If a standard applied to the fuel for the diesel engine is stipulated in your country, check the
standard for details.
(2) Requirements for diesel fuel
Although conditions required for the diesel fuel are illustrated above, there are other require-
ments exerting a big influence on its service durability and service life.
Be sure to observe the following requirements for selecting fuel.
Sulfur content 2500 ppm or less
HFRR* (460 μm) or less
Water content 0.05 wt% or less
* HFRR (High-Frequency Reciprocating Rig.): An index showing lubricating properties of the
fuel.
52 RST-06-09-004E
1
Sulfur content reacts to moisture to change into sulfuric acid after combustion.
Use of a fuel containing much sulfur content allows it to accelerate internal corrosion and
wear.
In addition, much sulfur content quickens deterioration of engine oil allowing its cleaning dis-
persive property to be worse which results in acceleration of wear of sliding portions.
HFRR is an index that indicates lubricating property of a fuel.
Large value of the index means poor lubrication so that seizure of the machine components
may result if such a fuel is used.
Since a fuel with high HFRR value also has lower viscosity, it can easily be leaked out.
If the fuel is mixed with the engine oil, the oil is diluted to deteriorate its lubricating property
resulting in acceleration of wear.
Water content allows inside of the fuel tank to rust which in turn blocking the fuel line and the
fuel filter.
This may also cause wear and seizure of the machine components.
If atmospheric temperature goes below the freezing point, moisture content in the fuel forms
fine particle of ice allowing the fuel line to be clogged.
Obtain table of analysis for the fuel you are using from the fuel supplier to confirm that it
meets the criteria described above.
Important
If a fuel which does not meet the specifications and the requirements for the diesel engine,
function and performance of the engine will not be delivered.
In addition, never use such a fuel because a breakdown of the engine or an accident may be
invited.
Guarantee will not be given to a breakdown caused by the use of a improper fuel.
Some fuels are used with engine oil or additives mixed together with diesel engine fuel.
In this case, do not use these fuels because damage to the engine may result as the fuel
has been contaminated.
It is natural that the emission control regulation of 3rd-stage will not be cleared in case
where a fuel that does not meet the specifications and the requirements is used.
Use the specified fuel for compliance of the exhaust gas control.
Important
It you use diesel fuel which contains much sulfur content more than 2500 ppm, be sure to
follow the items below for the engine oil selection and maintenance of engine parts.
Guarantee will not be given to breakdowns caused by not to follow these items.
[1] Selection of engine oil
Use API grade CF-4 or JASO grade DH-1.
[2] Exchange the engine oil and engine oil filter element by periodical interval below.
Engine oil Every 250 hour of use
Engine oil filter element Every 250 hour of use
[3] Inspect and exchange the EGR parts and fuel injector parts of engine by periodical interval
below.
EGR (*) parts Every 3000 hour of use
Fuel injector parts Every 3000 hour of use
* EGR : Exhaust Gas Recircultion
For the detail of inspection and replacement for the above engine parts, please contact
your nearest Service factory outlet.
[4] In addition above if the value of HFRR or water content in the fuel you use is more then limi-
tation in above table of this manual, please also contact your nearest Service factory outlet.
RST-06-09-004E 53
2
2. Maintenance of fuel filters
Be sure to use the genuine fuel filters.
The fuel injection system is precisely constructed and the genuine filter employs finer mesh than
conventional filters to improve protection of machine equipment.
If a filter with coarse mesh is used, foreign object passing through the filter enters into the engine
so that machine equipment can wear out in a short period of time.
Important
If a fuel filter other than the genuine filter is used, guaranty will not be applied to a fault caused by
the use of a wrong filter.
Two kinds of fuel filter, the pre-filter and the main filter, are mounted on the machine.
Be sure to use the genuine fuel filters and replace them at a periodic intervals.
Replacement criteria
Every 250 hour of use Every 500 hour of use
Pre-filter {
Main filter {
Since the pre-filter also has a function of water separation, discharge water and sediment when
the float reaches lower part of the filter elements.
Time to replace filters may be advanced according to properties of the fuel being supplied.
Running the engine with the fuel filter blocked may cause the engine to be stopped due to establish-
ment of engine error code.
If much foreign objects are found in the fuel, carry out earlier inspection and regular replacement
of the filters.
If dust or water get mixed with the fuel, It may cause the engine trouble and an accident.
Therefore, take measures to prevent dust or water from being entered in the fuel tank when supply-
ing fuel.
When supplying fuel directly from a fuel drum can, leave the drum as it stands for a long period of
time to supply clean fuel standing above a precipitate.
If it is hard to leave the drum for a long period of time, install a fuel strainer and a water separator
before the fuel tank of the machine to supply clean fuel.
Water drain cock is provided on the bottom side of the fuel tank.
Drain water before starting the engine every morning.
In addition, remove the cover under the tank once a year to clean up inside of the tank.
54 RST-06-09-004E
3
Layout Diagram SH200
Air Conditioner
Layout Diagram
Air Conditioner Overall Diagram
1. Frame
SST-07-01-007EN 1
1
Layout Diagram
Code Part name Q'ty

1 Cooler hose (liquid 2) 1
2 Cooler hose (suction) 1
3 Rubber hose 16 × 5600 2
4 Cooler hose (discharge) 1
5 Compressor; Air conditioner 1
6 Slide shaft 1
7 Tension pulley (with cover) 1
8 Air condenser 1
9 Dryer receiver (D60.5) 1
10 Cooler hose (liquid 1) 1
11 Bracket receiver (D60.5) 1
12 V belt B-45.5 1
1 Air conditioner unit

2 Engine
3 Heater (eng. return)
4 White marking
5 Heater (eng. outlet)
6 Heater (unit outlet)
7 Heater (unit inlet)
Must be connected with the air condi-
8
tioner unit
White marking Must be connected
9
with the air conditioner unit.
* in the diagram indicates a clamp posi-
tion. Figures indicate hose lengths.
2 SST-07-01-007EN
2
Layout Diagram
2. Cab
SST-07-01-007EN 3
3
Layout Diagram
Code Part name Q'ty

1 Face grille 1
2 Control panel 1
3 Duct; FACE-B 1
4 Duct; FACE-C 1
5 Duct; H and C box 1
6 Box; Hot and cool 1
7 Duct; VENT (Right) 1
8 Duct; VENT (Left) 1
9 Box; Rear 1
10 Duct; Suction (Fresh) 1
11 Air conditioner unit 1
12 Duct; FOOT 1
13 Duct; DEF-C 1
14 Duct; DEF-B 1
15 Face grille 6
16 Drain hose 2
17 Air filter 1
18 Box; Bracket (left) 1
1 Duct
2 Trim; Side (Front upper)
Sensor; Air conditioner
3
(Solar radiation)
4 Duct; DEF-A
5 Duct; FACE-A
6 Trim; Side (Front lower)
7 Cover; Top (Console left)
Console must be connected with the
8
harness.
9 Harness; Wire (Console left)
10 Duct: suction
11 Filter; Inside air
12 Cooler hose
13 Heater hose
14 Duct; Flange
15 Cab; Operator
16 Filter case
17 Seal; Cushion
18 Grommet; Rubber
19 Floor
4 SST-07-01-007EN
4
Layout Diagram
1 Motor actuator (mode)

2 Compressor relay
3 Blower OFF relay
Motor actuator
4
(refresh/recirculate switch)
5 Interior temperature sensor
6 Blower motor
7 Blower amp
8 Motor actuator (air mix)
9 Evaporator sensor
SST-07-01-007EN 5
5
Circuit Diagram SH200
Air Conditioner
Circuit Diagram
Air Conditioner Circuit Diagram
SST-07-02-005EN
1
Circuit Diagram
P W B R Y G L Br Lg O Sb V
Pink White Black Red Yellow Green Blue Brown Light green Orange Sky blue Purple
(Note)
1) Wire diameters that are not indicated are 0.5.
2) Broken lines indicate wiring on the vehicle side.
3) Codes displayed on the connectors indicate the code colors seen from the connection ports of the connectors.
7 SST-07-02-005EN
2
Explanation of Functions SH200
Explanation of Control
Back-up function
Even when air conditioner operation is stopped (switched OFF) with the ignition key power supply or
operation panel ON/OFF switch, the set temperature and all the other setting states are stored in mem-
ory, so the next time air conditioner operation starts, it goes into the same state as before it was
stopped.
When the ignition key power supply is cut off, the data is backed up by storing it in the internal
EEPROM. However, if the main key power supply is cut off within 0.5 s of switch input, that switch input
is not stored into memory. Also, the data read out from EEPROM when the power is switched ON is
judged to see if it is within the valid range. If data outside the valid range was written into memory, for
example due to noise, then operation starts from the default settings to avoid abnormal operation.
Fahrenheit temperature display
To switch, hold down both the temperature setting UP and DOWN switches for 5 s. The display toggles
between Celsius and Fahrenheit display each time the switches are both held down for 5 s.
The Fahrenheit display is a two-digit integer and below the decimal point is not used, so °F" is dis-
played. However, in case of trouble, this display takes priority.
When this display is switched, the new status is backed up in memory, so even if the main key power
supply is switched OFF, the display status is retained. Internal calculations are all done in Celsius. Only
the operation panel display is in Fahrenheit. Therefore, the display may differ slightly from the exact
Fahrenheit temperature.
Below is shown the Fahrenheit temperature and the corresponding Celsius temperature used in inter-
nal processing.
Caution
These specifications are written with Celsius as the standard. Therefore, if the temperature is displayed
in Fahrenheit, convert the temperature to centigrade by using the table below.
Fahrenheit and Celsius correspondence

Interior recognition set
Fahrenheit display [°F]
temperature (Celsius) [°C]
63 18.0
64 18.5
65 19.0
: :
77 25.0
: :
91 32.0
8 RST-07-03-001E
1
1. Air Mix Motor Actuator Control
[1] Summary explanation
The provisional target degree of opening is determined from the target blow temperature and the
current blow mode, various restrictions are applied, and the target degree of opening is calcu-
lated. Then drive is output to move the motor actuator position to the target degree of opening.
Below are the details.
[2] Restrictions on operation angle according to the blow mode
When the blow mode motor actuator is in the B/L, FOOT, or DEF position, it is prohibited for this
motor actuator degree of opening to be less than 20°
[3] Heater unit hysteresis correction operation (motor actuator one-direction stop)
After the actuator moves to the target degree of opening, it returns to the specified position. How-
ever, if the target degree of opening is less than 0°, the actuator is treated as having reached the
target degree of opening when it reaches 0°, then it moves to the specified position.
(A stop in the fully-open direction is used as the standard.)
[4] Operation start / stop judgment
1) The operating motor actuator stops when the current position comes within the target position.
2) The stopped motor actuator operates when the current position goes beyond the target posi-
tion.
[5] Motor actuator operation priority order
The operation priority for this motor actuator is No.1. This means that if the target degree of
opening for this motor actuator changes and operation becomes necessary, even if some other
motor actuator is operating, that other motor operation is paused, and this motor actuator oper-
ates.
2. Blow Mode Motor Actuator Control

The blow mode is switched by rotating the diffuser switching damper with the motor actuator.
There are two types of control: auto and manual.
[2] Auto control
When the AUTO blow mode signal is recognized, the blow mode changes to auto control. During
auto control, the diffuser is switched according to the target blow temperature Auto control contin-
ues until operation of the blow mode select switch is recognized.
RST-07-03-001E 9
2
[3] Manual control
1) When operation of the blow mode select switch is recognized, the motor actuators are driven to
attain the output shaft angle below and the display is switched too. Each time operation of the
switch is recognized, the display switches MODE1 → MODE2 → MODE3 → MODE4 →
MODE1→ ... However, if this switch is pressed during auto control, auto control is ended and
the diffuser is fixed at its current position.
2) MODE5 in the table below only occurs when operation of the DEF select switch is recognized.
After that, when operation of the blow mode select switch is recognized, the blow mode
becomes the one that was in effect just before operation of the DEF switch was recognized.
Blow mode and display and motor actuator angle
Blow mode MODE 1 MODE 2 MODE 3 MODE 4 MODE 5
Blow mode motor actuator
90° 65.5° 46.5° 26.6° 0°
degree of opening
Panel display
[4] Mode unit hysteresis correction operation (motor actuator one-direction stop)
After the actuator moves to the target degree of opening a, it returns to the specified position.
However, if a is less than 0°, the actuator is treated as having reached the target degree of open-
ing a when it reaches 0°, then it moves to the specified position.
(A stop in the VENT or FACE direction is used as the standard.)
[5] Operation start / stop judgment
1) The operating motor actuator stops when the current position comes within the target position.
2) The stopped motor actuator operates when the current position goes beyond the target posi-
tion.
[6] Blow mode control priority order
The priority order for auto control and manual control is as follows.
Control priority order
Priority order Control
1 Manual control
2 Auto control
3. Refresh / Recirculate Switch Motor Actuator Control

[1] Recirculate mode
In refresh mode, when it is recognized that the refresh / recirculate switch on the operation panel
has been closed, the system goes into recirculate mode. At this time, the display switches to
recirculate and the refresh / recirculate switch motor actuator operates to the recirculate angle.
[2] Refresh mode
In recirculate mode, when it is recognized that the recirculate / refresh select switch on the oper-
ation panel has been closed, the system goes into refresh mode. At this time, the display
switches to refresh and the refresh / recirculate switch motor actuator operates to the refresh
angle.
10 RST-07-03-001E
3
[3] Operation stop judgment
When one of the limiters is detected, operation stops.
Refresh / recirculate mode and refresh / recirculate display and motor actuator angle
Refresh / recirculate mode Recirculate Refresh
Refresh / recirculate motor actuator degree of opening 0° 90°
Panel display
4. Blower Amp Control

The air flow is controlled by outputting to the blower amp connected in series with the blower
motor. The air flow is switched by varying the analog voltage output by changing the PWM output
duty ratio and increasing or decreasing the blower motor speed.
There are two types of air flow control: auto air flow control and manual air flow control. Also, in
auto air flow control, the air flow is restricted by the cold blast prevention control etc.
Auto air flow control has no levels and manual control has four levels.
[2] Manual air flow control
Each time it is recognized that the air flow UP switch has been closed,
Lo → M1 → M2 → Hi
the air flow is fixed to the next higher level of air flow. When Hi is already displayed, the air flow is
not changed.
In the same way, each time it is recognized that the air flow DOWN switch has been closed,
Hi → M2 → M1 → Lo
the air flow is fixed to the next lower level of air flow. When Lo is already displayed, the air flow is
not changed.
The same is true when air flow control is switched from auto to manual. For example, when
AUTO M1 is displayed, if it is recognized that the air flow DOWN switch has been closed, the dis-
play becomes Lo and AUTO is no longer displayed.
Also, the change speed for air flow output switchover is the same as discussed for auto below.
Relationship between air flow and PWM output
Air flow Display Target % (approx.)
Hi (maximum air flow) 100 %
M2 75 %
M1 59 %
Lo (minimum air flow) 40 %
RST-07-03-001E 11
4
[3] Auto air flow control
When it is recognized that the AUTO switch has been closed, the air flow is controlled automati-
cally and AUTO is displayed.
1) During auto air flow control, the air flow is set according to the target blowing temperature as in
Figure 3.
2) Auto air flow control continues until closing of either the air flow UP or air flow DOWN switch is
recognized.
3) The auto air flow amount calculation results are continuous, not divided into levels.
4) When it is recognized that the AUTO switch has been closed, the display becomes as in Table
10 according to the results of the auto air flow amount calculation.
5) The normal auto air flow output change is roughly 5 V/s.
6) Auto air flow control is restricted by the cold blast prevention control described in [4], which is
the next item.
Relationship between air flow and target blow temperature
Display refreshing and air flow output correspondence table

Current display Item Target % (approx.)
Lo display Output range changed to M1 When 53 % or higher
Output range changed to Lo When 46 % or lower
M1 display
Output range changed to M2 When 70 % or higher
Output range changed to M1 When 64 % or lower
M2 display
Output range changed to Hi When 92 % or higher
Hi display Output range changed to M2 When 83 % or lower
12 RST-07-03-001E
5
[4] Cold blast prevention control
The air flow is restricted according to the value of the coolant temperature and other parameters
sent from the vehicle side. The air flow restriction has two levels - air flow 0 and air flow Lo.
Whether or not to use the restriction is determined from the judgment results.
1) Conditions under which cold blast prevention control is used
1. Auto air flow
2. When set temperature - inside air sensor temperature ≥ 11
3. When the coolant temperature signal from vehicle is the less than 95 °F (35 °C) signal or the
95 °F (35 °C) or higher but less than 113 °F (45 °C) signal
Under the condition above, the inside air sensor temperature is the value immediately after the
ignition key power is switched ON and AUTO and Test are according to the current switch
states. Therefore, when the AUTO switch is pressed after the air flow has been set manually, if
the coolant temperature is within the cold blast prevention range, the air flow is restricted. In the
same way, even if the set temperature is changed, if the conditions are met, the air flow is
restricted.
While cold blast prevention control is being executed, the display corresponds to the restricted
air flow.
2) Air flow 0 control
When the coolant temperature signal from vehicle is the less than 95 ºF (35 °C) signal, the air
flow is set to 0. This continues until a coolant temperature signal of 86 ºF (30 °C) or higher is
received. Once a coolant temperature signal of 86 °F (30 °C) or higher is received and these
conditions are no longer met, air flow 0 is ended.
3) Air flow Lo control
When the coolant temperature signal from vehicle is the 95 °F (35 °C) or higher but less than
113 °F (45 °C) signal, the air flow is set to Lo. This continues until a coolant temperature signal
of 113 ºF (45 °C) or higher is received. Also, the same as for 2), this shift is irreversible. Once a
coolant temperature signal of 113 ºF (45 °C) or higher is received, control is normal.
Coolant temperature signal sent from the vehicle (one cycle)
* Finalized by the same waveform for three cycles. However, for the first combustion after the ignition
switch is switched ON, judged with the latest one cycle.
* The default state for the coolant temperature signal when the ignition is switched ON is 113 °F (45 °C)
or higher.
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6
[5] Air flow control priority order
The priority order for auto air flow control, manual air flow control, and cold blast prevention con-
trol is as follows.
Control priority order
Priority order Control
Blower air flow control when mode motor actuator angle
1
switched
2 Manual air flow control
3 COOLMAX control
4 Cold blast prevention control
5 HOTMAX control
6 Auto air flow control
5. Compressor Clutch Control

The compressor clutch is controlled by the power to the clutch coil being switched ON/OFF by an
external relay. This control is executed by thermo operation, the condensation prevention func-
tion, and the fletching prevention function. Thermo operation has control mode 1 and control
mode 2. These modes are applied according to the blow mode and other conditions. However, for
blower air flow 0, the compressor clutch is switched OFF. The operation temperature does not
include the thermistor variation.
[2] Thermo operation (AC switch ON)
1) Control mode switchover
• When the blow mode is B/L and the target blow temperature is as in the figure below, control
mode 2 is used.
As the figure shows, there is hysteresis between control modes 1 and 2.
• Other than the above is all control mode 1.
Relationship between control mode and target blow temperature for B/L
2) Control mode 1
• OFF temperature: 41 ± 34 °F (5 ± 1 °C)
When this temperature or lower is detected, the compressor clutch is switched OFF.
(It is kept OFF until a temperature at or above the ON temperature is detected.)
• ON temperature: OFF temperature + 36 ± 33 °F (2 ± 0.5 °C)
When this temperature or higher is detected, the compressor clutch is switched ON.
(It is kept ON until a temperature at or below the OFF temperature is detected.)
3) Control mode 2
• OFF temperature: 41 ± 34 °F (5 ± 1 °C)
• ON temperature: OFF temperature + 36 ± 33 °F (2 ± 0.5 °C)
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[3] Condensation prevention function
1) Timer set temperature: 46 ± 36 °F (8 ± 2 °C)
When this temperature or lower is detected, the timer is set and starts counting.(It is not reset
until a temperature at or above the timer cancel temperature is detected.)
2) Timer cancel temperature: Timer set temperature + 34 ± 34 °F (1 ± 1 °C)
When this temperature or higher is detected, the timer is reset.
3) Count-up time: 10 ± 1 minutes
When the timer count reaches this time, the compressor clutch is switched OFF. After this,
when the timer recovery temperature or higher is detected, the compressor clutch is switched
ON and timer setting is prohibited.
4) Timer recovery temperature: Timer set temperature + 36 ± 34 °F (2 ± 1 °C)
When this temperature or higher is detected, the compressor clutch is switched ON and timer
setting is permitted.
[4] Fletching prevention function
1) Operation conditions
After the end of initial operation, if 5 ± 1 minutes continue with the air flow M2 or higher and the
compressor clutch not coming ON even once, the compressor clutch is switched ON one time.
This control is cleared by the ignition key power being switched OFF and this control starts
again when this power supply is switched ON again.
Compressor clutch ON time: 1 ± 0.6 s
2) This control takes priority over all other control.
[5] AUTO switch link function
When operation of the AUTO switch is recognized, compressor clutch control comes ON and
AUTO is displayed.
1) Compressor clutch control is the same control as for the AC switch being switched ON.
2) When it is recognized that the AC switch has been switched OFF, the AUTO display goes out.
Even when it is recognized that the AC switch has been switched ON again, AUTO is not dis-
played.
However, at this time, if the main key power is switched OFF, then ON again, since the AC ON, air
flow AUTO, and blow mode AUTO conditions are all met, AUTO is displayed.
6. COOLMAX Control and HOTMAX Control

[1] When the set temperature is 64 °F (18 °C) [COOLMAX] (or 18. E)
1) The air mix motor actuator is set to the 0° limiter position (fully closed).
2) For auto air flow control, the air flow is set to Hi.
3) For AUTO blow mode control, the blow mode is set to VENT.
[2] When the set temperature is 90 °F (32 °C) [HOTMAX]
1) The air mix motor actuator is set to the 90 ° limiter position (fully open).
2) For auto air flow control, the air flow is set to M2.
3) For auto blow mode control, the blow mode is set to FOOT.
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8
7. Trouble Detection and Control after Trouble Detected
If there is trouble in a motor actuator drive line or sensor controller input circuit, the trouble is
detected and control from then on changed as described below.
In any of these cases, once trouble has been detected, even when that location is returned to
normal, trouble control is not ended. Trouble control is only ended when the ignition key power
supply is switched OFF or when air conditioner operation is stopped with the ON/OFF switch on
the operation panel. However, motor actuator restriction is only ended by switching OFF the main
key power supply.
[2] Trouble in a motor actuator and its input / output circuits
1) Disconnection detection
Immediately after the main key power supply is switched ON, if a motor actuator potentio-meter
line is disconnected or shorted, the display in the table below for that motor actuator is carried
out and that motor actuator is not driven until the main key power is switched OFF, then ON
again.
Disconnection detection display
Trouble location Trouble display
HL.E is displayed on the set temperature display
Air mix motor actuator
LCD.(See the figure below.)
Blow mode motor actuator The passenger icon display flashes.
Refresh / recirculate motor actuator Potentio-meter line not used
2) Motor lock detection

If the output shaft rotation angle for a motor actuator does not reach its target value within 15 s,
this is treated as lock detection, output to that motor is stopped, and trouble is displayed on the
controller according to the trouble location.
Motor lock detection display
Trouble location Operation panel trouble display
HL.E is displayed on the set temperature display
Air mix motor actuator
LCD.(See the figure below.)
Blow mode motor actuator The passenger icon display flashes.
Refresh / recirculate switch motor actu-
The refresh / recirculate mark flashes.
ator
16 RST-07-03-001E
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[3] Trouble in a sensor or its input / output circuits (disconnection or short)
1) Disconnection or short in the inside air sensor or its input / output circuits
1. Operator compartment temperature control end
• All control related to the operator compartment temperature (target blow temperature) is
stopped and the air mix degree of opening is directly adjusted according to the tempera-
ture adjustment switch input.
• Accompanying this, the operation panel set temperature display changes as in the figure
below.
* is a value from 0 to 9. Each time the DOWN switch is closed, this value decreases by 1.
Each time the UP switch is closed, this value increases by 1.
For any blow mode other than FACE or VENT, the minimum value is set to 1.
Display and control for inside air sensor trouble
* value Motor actuator degree of opening (°)
0 0°
1 to 8 * value x 10 °
9 90 °
2. Auto air flow control end
• The air flow is temporarily fixed at that in effect when the inside air temperature sensor
trouble was detected.
• The AUTO display is set flashing.
• After this, the air flow is switched by the manual air flow switch.
3. AUTO blow mode control end
• The blow mode is temporarily fixed at that in effect when the inside air temperature sen-
sor trouble was detected.
• The AUTO display is set flashing.
• After this, the blow mode is switched by the manual blow mode switch.
4. Air mix damper degree of opening display priority
• Even if the trouble shown by one of the items below occurs during inside air sensor trou-
ble, E is not displayed in the * section below the decimal point and the air mix damper
degree of opening display is given priority.
• HL.E is only displayed for air mix motor actuator trouble.
5. Thermo operation control mode fixed
• Switching of the control mode according to the blow mode and target blow temperature is
stopped and the control mode is fixed at control mode 1.
2) Disconnection or short in evaporator sensor or its input / output circuits
1. Compressor control is not executed and the compressor clutch is always OFF. However,
fletching prevention control is executed.
2. E is displayed in the first fraction position of the set temperature display LCD.
(See the figure below.) (The temperature setting is in 34 °F (1 °C) steps.)
However, E is not displayed for inside air sensor trouble.
RST-07-03-001E 17
10
3. The AC mark flashes.
3) Disconnection or short in solar radiation sensor or its input / output circuits

1. The solar radiation compensation data is set to 0.
2. E is not displayed in the first fraction position of the set temperature display LCD as it is for
other sensors.
4) Coolant temperature signal trouble
Cold blast prevention control does not work and normal control is used.
8. Monitor Mode
Monitor mode is a mode for understanding trouble in the controller itself or in other control. The
system goes into monitor mode when there is the special switch input below on the operation
panel.
[2] Starting monitor mode
When the air conditioner is operating with basic control, if the operation panel ON/OFF switch
closed path continues for 1 s while the refresh / recirculate switch closed path is ongoing, monitor
mode is started.
[3] Monitor contents
1) LCD segment diagnosis
When monitor mode is entered, the target LCD lights up for 1 s. An LCD with trouble does not
light up.
2) Sensor diagnosis
The detection value (AD value or °F (°C)) for each sensor is displayed.
3) Coolant temperature signal recognition value
This displays the reception status for the coolant temperature signal sent from the vehicle.
[4] Monitor contents
1) LCD segment diagnosis
When monitor mode is entered, the target LCD lights up for 1 s. An LCD with trouble does not
light up.
2) Sensor diagnosis
The detection value ºF (°C) for each sensor is displayed.
[5] Display contents in monitor mode
In monitor mode, the data (detection value for each sensor, coolant temperature signal recogni-
tion, etc.) is displayed in the 3 digits of the 7-segment display for the temperature setting. The
data displayed is selected with the blower UP/DOWN switches and AUTO switch. The blower UP/
DOWN switches move the display on the dedicated monitor mode 7-segment display through 16
displays, 0 to F, and the corresponding data is displayed.(Table A on next page) Hexadecimal
data display and decimal data display can be selected with the AUTO switch. Only for the coolant
temperature signal recognition value, the value detected immediately before entry into monitor
mode is displayed.
The difference between hexadecimal data and decimal data is indicated by the 3 digit of the 7-
segment display. For hexadecimal data, "H" is displayed there and for decimal data, numbers (0
to 9) are displayed there.
18 RST-07-03-001E
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1) Hexadecimal display
AD values 00H through FFH are displayed. When the AD value corresponds to that in Table B
on the next page (or Table C for the solar radiation sensor), this indicates a disconnection or
short. In the hexadecimal display, when the value of a sensor changes in monitor mode, the
hexadecimal display changes with it. If the display before entering monitor mode was
, the error judgment value is displayed.(In other words, the value detected before the
trouble was detected) In the same way, if the display before entering monitor mode was
, the display becomes **.E and the error judgment value is displayed.
2) Decimal display
From -148 °F (-99.9 °C) to 212 °F (99.9 °C) is decimal display. Also, the "-" minus display dis-
plays the arrow mark for FOOT mode.
[6] Air conditioner operation in monitor mode
When the system enters monitor mode, all output (operation) through control is stopped and until
monitor mode is ended, operations and settings of basic control through all the switches are not
possible.
[7] Ending monitor mode
In monitor mode, if the operation panel ON/OFF switch closed path continues for 1 s while the
refresh / recirculate switch closed path is ongoing, monitor mode is ended and the system
returns to the basic control state. The same also occurs if the ignition key power supply is
switched OFF.
Table A
Dedicated monitor mode
Display contents
7-segment display
0 Inside air sensor temperature data
1 Evaporator sensor temperature data
2 Solar radiation compensation data
Coolant temperature signal status data
86 °F (30 °C) or
Lower than 86 °F higher and lower 113 °F
C Trouble
(30 °C) than 113 °F (45 °C) or higher
(45 °C)
4 1 2 3
3 to 9 and B to F Data (sensor diagnosis etc.)
Table B
Sensor name Short Disconnection
Inside air sensor F6H 0CH
Evaporator sensor F6H 0CH
Table C
Sensor name 5 V short Ground short
Solar radiation sensor C7H 0CH
RST-07-03-001E 19
12
9. Door Switch Control
This control adds a restriction to air conditioner operation with the door switch or front window
switch. Its purpose is to prevent overheating of the ignition unit. Concretely, it suppresses con-
denser heating and controls in a way restricted in order to obtain a feeling of comfort.
[2] Door switch / front window switch signal
The signal input into the controller is as follows for both the door and front window switches.
1) When door / front window open
When contact closed. In other words, the control controller input is at ground level.
2) When door / front window closed
When contact open. Pulled up to 5 VDC inside the control controller
[3] Control restricted by door switch / front window switch
1) Starting restricted control
When either the door or front window is open continuously for 1 s or longer, it is recognized that
the switch is open. At the count of 60 s, the buzzer buzzes the same way as for switch input to
tell the operator that restricted control is starting and that control starts.
2) Restricted control
1. For both auto and manual blow mode control
Even if auto or manual blow mode is selected, unless the blow mode is FACE, the following
air flow restriction is executed.(If the blow mode is FACE, the air flow is not restricted.)
I. If the target blow temperature < 68 °F (20 °C), the air flow upper limit is set to M1.
II. If the target blow temperature ≥ 77 °F (25 °C), the air flow restriction in I is ended.
2. When the current blow mode control is AUTO
Auto control with the AUTO blow mode VENT changed to FACE is used.
3. When the current blow mode control is manual selection
Only if the blow mode is VENT immediately after the open switch is recognized, that mode is
changed to FACE. After this, all the blow modes can be selected with manual operation.
3) Ending the restriction
When both the door and front window are closed continuously for 1 s or longer, it is recognized
that the switches are closed. After a count of 1 s, the buzzer buzzes the same way as for switch
input to tell the operator that restricted control has been ended.
When the restricted control is ended, the restriction on the air flow discussed in 1. above and
the change from VENT to FACE in 3. are ended and control returns to normal. However, if the
blow mode has been manually selected, even if the mode was changed from VENT to FACE by
the above restriction, it does not return to VENT when the restricted control is ended.
10.Inside Air Filter Clogging Detection Control

This control recognizes the blower current with the dedicated shunt resistor voltage input, judges
from that value whether or not the AC unit inside air filter is clogged and if it judges that filter is
clogged, it issues a warning to encourage the operator to replace the filter.
[2] Filter detection control
1) Starting detection control (detection timing)
5 s after the end of initial operation, if the air conditioner is operating and the cold blast preven-
tion conditions are not present, this control is started. Also, this control is executed every 50
hours of air conditioner (blower) operation. However, during a temporary filter clog or filter clog,
it is executed every time.
2) Detection method
Cooling / heating is judged from the operation mode and in this way the air mix motor actuator
target position is determined. Also, the mode motor actuator target value is set to FOOT, the
blower air flow target value is set to M1, and output is made to attain the target values. When all
20 RST-07-03-001E
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the target values are attained, the blower current from the shunt resistor voltage is recognized,
and the filter clog is judged by comparing this current with the default current value.
(Cooling / heating judgment)
When the operation mode is FACE or VENT, : Cooling (COOLMAX)
When FOOT or DEF : Heating (HOTMAX)
When B/L: Final inside air temperature If < 72 ºF (22 °C), heating
When B/L: Final inside air temperature If ≥ 72 ºF (22 °C), cooling
(Detection current threshold)
Relative to the default current value For cooling : 0.37 ± 0.02 A min.
For heating : 0.51 ± 0.03 A min.
If the value is below this three times in a row, it is judged that there is a clog.
(Default current value)
Current found in the initialization operation described below.
3) Clog warning
(Buzzer)
The buzzer buzzes intermittently at 1 Hz for 10 s.
(Display)
"FIL" is displayed on the 7-segment display for the set temperature for 10 s. Other marks go
out.
However, if there is any switch input, the "FIL" display is ended immediately.
4) Alarm reset
If a reset detection value is recognized during the clog state, the clog state is reset.
The reset detection value is 50% of the clog detection threshold.
5) ON/OFF switching
This function is switched ON/OFF by pressing the [Refresh / Recirculate], [MODE], and [DEF]
switches at the same time. The factory setting for this function is OFF. This function does not
come ON until the initialization operation discussed below is executed.
(Buzzer)
When operation of this switch is recognized, there is the normal switch input sound.
(Display)
ON or OFF is displayed on the set temperature 7-segment display, whichever is the state
after switching. Other marks go out.
6) Initialization operation
When the [Refresh / Recirculate] and [DEF] switches are pressed at the same time, the default
current value is detected and all the data for filter detection is initialized. Before executing this
operation, make sure that the air conditioner unit (with a new inside air filter installed), ducts,
and grilles (with all grilles fully open) are all installed in their normal states on the vehicle. If ini-
tialization is carried out in any other state, there is a danger of the clog detection judgment con-
trol making an incorrect judgment. Immediately after replacing the inside air filter with a new
one, execute the initialization operation.
(Buzzer)
When operation of the switch is recognized, the buzzer buzzes with the normal switch input
sound. When the detection ends, the buzzer buzzes for 3 s.
7) Detection processing avoidance
• When the inside / outside air damper is not at the recirculate position immediately before the
current value is read
• When the power supply voltage is not in the tolerance range for the voltage during the initial-
ization operation
• Trouble in any of the motor actuators
RST-07-03-001E 21
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Actuator Inspection SH200
Actuator Inspection
Air Mix Motor Actuator Inspection
1 Control amp
2 Air mix motor actuator
3 Connector 1
4 Connector 9
22 RST-07-04-003E
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Actuator Inspection
•Chart
RST-07-04-003E 23
2
Actuator Inspection
Refresh / Recirculate Motor Actuator Inspection
1 Control amp
2 Refresh/recirculate motor actuator
3 Connector 1
4 Connector 2
5 Connector 11
24 RST-07-04-003E
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Actuator Inspection
•Chart
RST-07-04-003E 25
4
Actuator Inspection
Mode Motor Actuator Inspection
1 Control amp
2 Mode motor actuator
3 Connector 1
4 Connector 10
26 RST-07-04-003E
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Actuator Inspection
•Chart
RST-07-04-003E 27
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Self-diagnosis Function with Panel Display SH200

Abnormality Display and Self-check Procedures
Motor actuator and sensor abnormalities can be checked on the panel display.
1. Abnormality Display Position
2. Explanation of Abnormality Display

(1) Motor actuator abnormality
[1] HL.E displayed on 3-digit 7-segment display.
Check the air mix damper motor actuator for a

harness disconnection or disconnected con-
nector.
[2] MODE flashes.
Check the blow mode damper motor actuator

for a harness disconnection or disconnected
connector.
[3] The R/F flashes.
Check the refresh/recirculate damper motor

actuator for a harness disconnection or discon-
nected connector.
Caution
With the panel ON/OFF switch ON, the
above display and flashing does not func-
tion even if a harness disconnection or dis-
connected connector occurs.
After trouble occurs, when the panel ON/
OFF switch is switched ON, the function is
displayed.
After trouble is resolved, the abnormality
display and flashing are not ended until the
main switch is switched OFF → ON.
28 RST-07-05-002EN
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(2) Sensor abnormality
[1] HL.* displayed on 3-digit 7-segment display
Check the inside air sensor and check its harness

for disconnections, shorts, or connector connection
defects.
[2] **.E and the mark flashing are flashing on the 3-digit 7-segment display. (** displays the
set temperature value at that time still remaining.)
Check the evaporator sensor and check its harness

for disconnections, shorts, or connector connection
defects.
Caution
The display in [1] and [2] above is displayed on the 3-digit 7-segment display when trouble
occurs with the panel ON/OFF switch ON status.
After the trouble section is repaired, end the abnormality display by switching the panel
ON/OFF switch OFF → ON.
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2
3. Explanation of Monitor Mode
2. (2) When sensor trouble is displayed, the sensor status (disconnection, short) can be checked in
monitor mode.
(1) Monitor mode display position
(2) Monitor mode display operating method
1 Refresh/recirculate select switch

2 Blower switch UP/DOWN switch
3 ON/OFF switch
[1] Hold down the refresh/recirculate select switch and the ON/OFF switch at the same time for
1 sec. or longer.
[2] Press the AUTO switch.
(All the 7 segments light up for 1 sec., then the system enters monitor mode.)
[3] Numbers 0 - 9 or letters A - F are displayed in the 2nd and 3rd digit of the 3-digit 7-segment
display.
"H" is displayed in the 1st-digit.
[4] The display of 0 - 2 on the dedicated 7-segment display is carried out with the blower UP/
DOWN switches. The necessary sensor is selected from the table below.
[5] The display of 0 - 2 on the dedicated 7-segment display is carried out with the blower UP/
DOWN switches. The necessary sensor is selected from the table below.
[6] To end the monitor display, either hold down the refresh/recirculate select switch and the
ON/OFF switch at the same time for 1 sec. or longer or switch the vehicle main switch OFF.
Caution
1. During monitor mode, operations and settings of basic control through all the switches
are not possible until the air conditioner control operation is stopped and monitor
mode ended.
2. During monitor mode, even if a sensor is repaired, the abnormality display is recorded
in memory, and until the ON/OFF switch is switched OFF, then ON again, the abnormal-
ity display is not ended.
30 RST-07-05-002EN
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(3) Display contents in monitor mode
See the dedicated monitor 7-segment display table and 3-digit 7-segment table.
[1] Display example 1
The dedicated monitor 7-segment display is 0 (indi-

cates the inside air sensor state).
From the 3-digit 7-segment table 3F → The sensor
is normal.
→ The inside air sensor is normal.

cates the evaporator sensor state).
From the 3-digit 7-segment table 00 → The sensor
is disconnected.
→ The evaporator sensor is disconnected.

cates the solar radiation sensor state).
From the 3-digit 7-segment table FF → The sensor
is shorted.
→ The solar radiation sensor is shorted.
3-digit 7-segment table
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38 RST-07-05-002EN
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Part Function and OK/NG Judgment SH200

Control Panel and Control Unit
The control panel and control unit are formed into one piece. The operation of its built-in microcom-
puter compares, operates on, and processes the sensor input signals and control panel switch input
signals, switches the output side actuators (refresh / recirculate switching, air mix) and comprehen-
sively controls the fan motor and compressor.
It is equipped with self-diagnosis functions to make trouble diagnosis easier. (For details see the con-
trol specifications.)
Blower Amp
The blower amp receives the control signals from the control unit and changes the speed of the blower
motor.
Normal
Terminal number
Conductance
1 2 3
+ - Conductance (4.7 kΩ ± 5 %)
- + No conductance
Tester
Conductance
+ -
(diode parallel forward direction)
[1] Remove the blower amp connector.

[2] Check the conductance between the blower amp side
terminals.
* The installation position is on the left side of the air conditioner unit.
39 RST-07-06-002E
1
Relay
4-pole relays are used for the blower OFF relay and compres-
sor relay.
Blower OFF relay
This relay receives the signal from the control amp and
switches the blower OFF relay ON.
When the blower OFF relay is switched ON, the power supply
voltage is fed to the blower motor via the blower amp and the
blower motor is started.
Compressor relay
The compressor relay is switched ON/OFF by the control amp
compressor control;
Relay inspection contents
[1] Relay
[2] Coil resistor: 320 Ω
[3] Specification voltage: 20 - 30 V DC
[4] Be careful. The coil side of this relay must be installed with the poles facing correctly.
[5] Inspection: Inspect the conductance between 3 and 4 under the conditions below.
20 - 30 V applied between Terminals 1 and 2 : Conductance
No voltage applied between Terminals 1 and 2 : No conductance
Air Mix Actuator

The air mix actuator is installed at the center of the air condi-
tioner unit. It opens and closes the air mix damper via the link.
Built into the air mix actuator is the potentio-meter which var-
ies linked with the actuator shaft.
When the target air mix door position is determined by the temperature control switch, the control unit
reads in the potentio-meter position in the actuator and determines whether the motor turns forward or
reverse.The contacts move linked with the motor. When the contacts move open or the target potentio-
meter position is reached, the control unit output signal goes OFF and the motor stops.
(See "Air Mix Motor Actuator Inspection".)
Refresh / Recirculate Actuator

The refresh / recirculate switch actuator is installed on the
blower intake unit. It opens and closes the refresh / recircu-
late damper via the link.
Built into the refresh / recirculate switch actuator is the posi-
tion detection switch that changes linked with the actuator
shaft.
When the refresh / recirculate damper position is determined by the refresh / recirculate switch on the
control panel, the control unit reads in the signal of the position detection switch in the actuator and
determines whether the motor turns forward or reverse.The contact moves linked with the motor and
when the contact reaches the position detection switch and separates, the motor stops.
(See "Refresh / Recirculate Motor Actuator Inspection".)
RST-07-06-002E 40
2
Blow Mode Actuator
The blow mode actuator is installed on the back surface of the
air conditioner unit. It opens and closes the blow damper via
the link.
Built into the blow mode actuator is the potentio-meter which
varies linked with the actuator shaft.
When the blow mode position is determined by the temperature control switch, the control unit reads in
the potentio-meter position in the actuator and determines whether the motor turns forward or
reverse.The contacts move linked with the motor. When the contacts move open or the target potentio-
meter position is reached, the control unit output signal goes OFF and the motor stops.
(See "Mode Motor Actuator Inspection".)
Evaporator Sensor
In order to prevent the evaporator freezing, the evaporator blow temperature is detected and the com-
pressor ON/OFF controlled.
• Evaporator sensor inspection method
(specifications value)
Disconnect the evaporator connector from the main har-
ness and measure the resistance between the sensor side
connector terminals using the tester.
When the sensor section detec-
Resistance : 7.2 kΩ
tion temperature is 32 ºF (0 ºC )
between
terminals When the sensor section detection
: 2.2 kΩ
temperature is 77 ºF (25 ºC)
Dual Pressure Switch

The dual pressure switch is installed on the receiver dryer.
When there is pressure trouble in the coolant high-pressure
side line (abnormally high pressure or abnormally low pres-
sure), the dual pressure switch contacts open up to cut off the
compressor power and protect the cooling cycle.
• Simple inspection method for dual pressure switch
[1] With the cooling cycle stopped, disconnect the connec-
tor from the switch and check the conductance between
the switch side connector terminals using the tester.If
there is conductance, the switch is normal.(When the
outside air temperature is 32 ºF (0 ºC) or higher)
[2] Connect the gauge manifold high-pressure side hose to
the high-pressure side charge port. With the cooling
cycle operating, the condenser front surface is covered
with the plate top and the high-pressure rises.If the
compressor stops around 455 PSI (3.14 MPa), the
switch is normal.
[3] With the coolant removed, check the conductance
between the switch side connector terminals using the
tester.If there is no conductance, the switch is normal.
41 RST-07-06-002E
3
Solar Radiation Sensor
This is the air conditioner solar radiation correct sensor. It detects the strength of sunlight with a photo-
diode, converts it into current and sends that to the control panel.
• Solar radiation sensor inspection method
Disconnect the solar radiation sensor connector from the
harness and measure the resistance between the sensor
side connector terminals using the tester's voltage mea-
surement mode.
The voltage must be different when light is striking the pho-
toreceiver section and when it is not.(The voltage is 0 V
when absolutely no light is striking the photoreceiver.)
Caution
Always measure with the tester in voltage measurement mode (V mode).
Measuring with the tester in resistance mode (Ω mode) would destroy the sensor.
RST-07-06-002E 42
4
NOTES:
New Machine Performance Judgment Table SH200

Performance Judgment Check Sheet
Checked, S Measured, A Adjusted
Inspection item Check Remarks Inspection item Check Remarks

Water and oil amount inspection Engine inspection
1. Radiator coolant amount 1. Engine speed
2. Engine oil amount Idling rpm
3. Hydraulic oil amount No-load maximum rpm
Pre-conditioning operation inspection 2. Engine rotation condition
1. Engine start/stop ① During idling
2. Air bleeding implementation (as
② No load
required)
3. Operation check for each section 3. Engine exhaust gas color
4. Oil leak inspection 4. Engine noise, vibration
Hydraulic oil cleanliness inspection 5. Engine Stop
Electrical system inspection
① Key switch OFF
1. Model selection check
② Emergency stop switch
2. Monitor display check
Hydraulic equipment inspection
3. Throttle volume function check
Pressure at each section check
1.
4. One-touch/auto idle function check (separate sheet)
5. Lever lock function check 2. Noise check for each section
6. Neutral start function check Natural drop for each cylinder
3.
(separate sheet)
7. Travel high-speed function check
Operation speed for each cylinder
8. Horn volume switching function check 4.
(separate sheet)
9. Travel alarm function check (as
5. Swing speed (separate sheet) required)
10. Power-cut delay function
Swing brake performance
6.
11. Accessory operation check (separate sheet)
① Radio ② Air conditioner 7. Swing status and noise
③ Wiper ④ Horn 8. Travel speed (separate sheet)

9. Turn
⑤ Working light ⑥ Room lamp
10. Travel status and noise
⑦ Clock ⑧ Hour meter
Operability inspection
⑨ Backlight
1. Operation state for each lever
Shoe tension status
Other
1. Oil leak inspection for each section
Rubber hose lines oil leak inspec-
2.
tion
3. Bolt and nut loosening, falling off
4. Cab inspection
5. Cylinder inspection
1 RST-08-01-001EN
1
Performance Measurement Entry Table
Measurement date
Model name: Serial No. Measurer
Date
Hour meter: Attachment Arm m3Bucket Remarks
Idling rotation rpm
1 Engine speed
No-load maximum speed rpm
Relief name Operation Measurement pressure
Standard PSI (MPa)
Check the pressure at Main relief
Pressure
each section PSI (MPa)
boost
2 (and measure as nec-
essary). Left and
Swing relief PSI (MPa)
right
Pilot relief ― PSI (MPa)
For the measurement and adjustment methods, see the hydraulic measurement adjustment procedures.
Boom cylinder in (mm)
Natural fall distance Arm cylinder in (mm)
3 for each cylinder
(in 10 min.) Bucket cylinder (open) in (mm)
Overall (for 10 min.) in (mm)
1 rotations 2 rotations 3 rotations Total Average
Up
Boom
Down
Operating speed for
4 each cylinder Open
(sec.) Arm
Close
Open
Bucket
Close
Swing speed
5 Left swing
(sec./rotation)
Right swing
6 Swing 180° neutral brake flow angle (degrees)

7 Travel speed (sec./6 meters) Front
Rear
Low front
Drive sprocket speed
8 Low rear
(sec./10 rotations)
High front
High rear
Turntable bearing movement Left and right in (mm)
9
distance Up and down in (mm)
Shoe extension distance from the side frame bottom surface to
10 in (mm)
the shoe top surface
11 Travel turning amount in (mm)
12 Travel motor leakage amount gpm (L/min)
13 Swing motor leakage amount gpm (L/min)
14 Bucket tip movement amount in (mm)
RST-08-01-001EN 2
2
Measurement Method and Main Unit Posture SH330
New Machine Performance Section

Engine Speed
Measurement method
[1] No load operation mode at high idle:
SP mode, H mode and A mode speed
[2] Operation mode at low idle: SP mode speed
Main unit posture: bucket on ground
Pressure in Each Section

Measurement method
[1] Engine high idle
[2] Oil temperature is 113 ºF - 131 ºF (45 ºC - 55 ºC)
[3] Travelling and swing is measured between the counter bal-
ance and motor.
[4] Measure the main relief pressure before adjusting the over-
load pressure, and then measure the overload pressure after
the main pressure has been increased to a level as high or
higher than the overload pressure. Return the main pressure
to regulation pressure after measurement.
Main unit posture: operate each attachment in the travel pos-
ture.
Cylinder Falling Amount

Measurement method
[1] Have oil flow into each cylinder before measurement with the oil at 113 ºF - 131 ºF (45 ºC - 55 ºC)
(Record the oil temperature before and after measurement)
[2] Make the height of the boom foot pin and the bucket pin the same.
The arm cylinder is fully retracted, and the bucket cylinder is fully opened.
[3] Engine is stopped.
[4] After 10 min., measure the extension amount and retraction amount of the boom, arm, and
bucket cylinder rod.
[5] Along with measuring the movement amount of the cylinders after 10 min., measure the tip dis-
placement.
Main unit posture
3 SST-08-03-005EN
1
Attachment Speed
Measurement method
[2] Oil temperature is 113 ºF - 131 ºF (45 ºC - 55 ºC).
[3] No load
Main unit posture
Boom cylinder
With the arm fully out and the bucket fully opened,
measure the operation time it takes the boom
cyclinder to go from fully upwards to the ground
and also from the ground to fully upwards
[Note] When the boom is lowered, make sure not
to directly hit the concrete (place tires on
the ground).
Arm cylinder
With the arm cylinder fully out and the arm hori-
zontal to the ground, measure the operation time it
takes the arm cylinder to do a full stroke with
bucket cylinder fully out
Bucket cylinder
Measure the operation time for a full stroke at the
maximum radius.
SST-08-03-005EN 4
2
Swing Speed
Measurement method
[3] No load
[4] The time required for the next rotation after one rotation
Main unit posture
Swing (180°) Brake Angle

Measurement method
[3] No load
[4] Swing 180°and measure the flow angle after neutral braking
Main unit posture: same as the above
Travel Speed
Measurement method
[1] Engine high idle and oil temperature is 113 ºF - 131 ºF (45 ºC - 55 ºC) with no load.
[2] Measure the required time to travel 19.7 ft (6 m) after a 13.1 - 16.4 ft (4 - 5 m) running start. If
the off travel distance is 3.3 ft (1 m) or more, however, use the off travel distance as a reference
value to correct the off travel, then measure the travel speed again.
[3] Travelling should be done on concrete.
[4] Conduct both high-speed and low-speed travelling.
5 SST-08-03-005EN
3
Off Travel Amount
Measurement method
[1] Engine high idle and oil temperature is 113 ºF - 131 ºF (45 ºC - 55 ºC) with no load.
[2] Measure the required time to travel 65.6 ft (20 m) after a 13.1 - 16.4 ft (4 - 5 m) running start.
[3] Shoe tension amount should be standard.
[4] Measure for both forward and backward traveling.
[5] Measure for both high-speed and low-speed traveling.
Main unit posture: same as with travel speed measurement.
Travel Sprocket Speed

Measurement method
[2] Oil temperature is 113 ºF - 131 ºF (45 ºC - 55 ºC) .
[3] Raise a shoe, and after achieving a constant speed, measure the
time required for the sprocket to rotate 10 times both forwards
and backwards.
[4] Measure for both high-speed and low-speed traveling.
Main unit posture: 90°swing, shoe raised.
Shoe Tension Amount
Measurement method
[1] Raise the shoe and, at the central position of the track, measure the gap between the underside
of lower side frame and the topside of the shoe plate.
[2] Measure for both the left and right sides.
SST-08-03-005EN 6
4
Swing Ball Race Bearing Movement Amount and Bucket Tip Movement Amount
Measurement method
A) Up and down direction measurement
[1] Measure the up and down movement amount at two locations in front of and behind the ball
race.
[2] Move the arm cylinder out and close the bucket cylinder, and move the bottom surface of the
bucket 11.8 in (30 cm) above the ground. Attach a dial gauge to the lowering section as shown
in the figure below and do zero point adjustment.
[3] Jack up the main unit and measure the amount of movement with the dial gauge.
* Jack up the main body until the swinging of the dial gauge becomes constant.
Main unit posture
B) Left and right direction measurement

[1] Measure the left to right movement amount at the front side of the ball race and the left to right
movement amount of the bucket tip.
[2] The arm cylinder and bucket cylinder are in the open position, apply 66 - 88 lbf (294.2 - 392.3 N)
of force to one side, and zero point adjustment is done for these conditions.
[3] 66 - 88 lbf (294.2 - 392.3 N) of force is applied to the opposite side and the left to right movement
is measured.
Main unit posture
7 SST-08-03-005EN
5
NOTES:
Pressure Measurement and Adjustment Procedures SH330
Maintenance

Procedures for Pressure Measurement from the Monitor Display
■ Monitor and switch panel
1 Liquid crystal monitor 4 Design panel

2 Switch panel 5 Installation bracket
3 Hour meter
1. Pressure Measurement Method

The P1, P2, N1, and N2 pressure can be measured from the monitor display.
(The pilot pressure cannot be measured.)
2. Operating Method
[1] If both the travel mode select switch and the horn volume select switch on the switch panel are
held down for 3 sec., the display switches to the service support screen.
[2] The respective pressures are displayed in the service support screen's "P1" (P1 pump main
pressure), "P2" (P2 pump main pressure), "N1" (N1 negative control pressure), and "N2" (N2
negative control pressure) columns.
* If both the travel mode select switch and the horn volume select switch on the switch panel are
held down again for 1 sec., the display returns to the normal screen.
(A) Normal screen (B) Service support screen
1 SST-09-01-009F
1
Procedures for Measuring Hydraulic Oil Temperature from the Monitor Display
1. Hydraulic Oil Temperature Measurement Method
The hydraulic oil temperature can be measured from the monitor display.
2. Operating Method
[1] If both the travel mode select switch and the horn volume select switch on the switch panel are
held down for 3 sec., the display switches to the service support screen.
[2] With the travel mode select switch (mode switch), set the mode to "CHK".
[3] With the horn volume select switch (section switch), set the section to the "MAIN" section.
[4] With the light switch (page +), switch to page "2".
[5] The hydraulic oil temperature is displayed in the "Hydoil" column.
Page switch operation
1 Section 5 Page (-)

2 Mode 6 Page (+)
3 Page 7 Mode switchover
4 Section switch 8 Hydraulic oil temperature ( ℃ )
SST-09-01-009F 2
2
Procedures for Pressure Measurement by Installing Pressure Gauge
1. Preparations
Workers 2 Role (worker 1: work supervisor, pressure adjustment)
Role (worker 2: operator)
2. Items to Prepare
Vacuum pump power supply

1 5 Wrenches (17, 19, 24, 27 × 2, 32, 36 × 2) 9 Recording sheet
(for vacuum pump)
2 Pressure gauge (10 MPa-1) 6 Rag 10 Pen
3 Pressure gauge (60 MPa-2) 7 Extension cable 11 Cleaning fluid
4 Hexagon wrench (8 mm, 6 mm) 8 Hydraulic oil tank lid (vacuum pump)
3 SST-09-01-009F
3
Pressure Measuring Ports
There are the following 3 ports for pressure measurement.
• Main pressure: pressure ports (P1, P2)
• Negative control pressure: pressure ports (N1, N2)
• Pilot pressure: pressure port (P3)
Main pressure
Pilot pressure
Pressure port: Measuring with P3
1 Pump 4 Pressure port: N1

2 Pressure port: P2 5 Pressure port: N2
3 Pressure port: P1 6 Pressure port: P3
SST-09-01-009F 4
4
Control Valve
1. Location of Relief Valves
Tool Pressure per
rotation of
Set pressure Measuring
Position adjusting
Lock nut Adjusting screw PSI (MPa) port
screw PSI
(MPa)
Main Hexagon diameter Hexagon diameter
a 4931 (34.3) 3089 (21.3) Monitor P1
(normal use) (27 mm) (27 mm)
1
Main Hexagon diameter Hexagon diameter
b 5410 (37.3) 4119 (28.4) Monitor P1
(boosted pressure) (32 mm) 27 mm
2 Boom up 5685 (39.2) 3075 (21.2) Monitor P2
3 Boom down 3974 (27.4) 3075 (21.2) Monitor P2
4 Arm in Hexagon diameter 5685 (39.2) 3075 (21.2) Monitor P1

Arm out 17 mm Hexagon diameter 5685 (39.2) 3075 (21.2) Monitor P1
5
(6 mm)
6 Bucket close 5685 (39.2) 3075 (21.2) Monitor P2
7 Bucket open 5685 (39.2) 3075 (21.2) Monitor P2

Hexagon diameter
8 Pilot 569 (3.92) 290 (2.0)
24 mm
Detailed diagram of main relief valve adjustment

1 Pressure boost lock nut
2 Pressure boost adjusting screw
3 Standard pressure adjusting screw
4 Standard lock nut
5 SST-09-01-009F
5
Pressure Measurement Preparations
[1] Items to prepare
1) Pressure gauge For 1450 PSI (10 MPa) (for pilot
and negative control pressure
measurement)
For 8702 PSI (60 MPa)
(for main pressure
measurement)
2) Tool Wrench (closed wrench) 17 mm
Hexagon wrench 6 mm
3) Others Rag
Cleaning fluid
[2] Monitor check
Use the service check to check the no-load
engine maximum speed and the SP mode
pump input milli-amp.
Engine max. SP mode milli-amp

1900 rpm 500 mA (during operation)
[3] Main unit installation

Put the main unit on solid, level ground, put the
bucket cylinder at its open stroke end, the arm
cylinder at its out stroke end, lower the boom,
and touch the arm top to the ground.
[4] Ignition key

Switch OFF the ignition key (1), check that the
engine has stopped, then switch the ignition key
ON again. (Do not start the engine.)
SST-09-01-009F 6
6
[5] Oil temperature check
Use the service check to check the hydraulic oil
temperature.
Oil temperature 113 - 131 ºF (45 - 55 ºC)

If the oil temperature is low, raise the oil temper-
ature according to the warm-up operation pro-
cedure in the operator's manual.
[6] Bleeding pressure from inside circuits

Flip the gate lock lever (2) forward, then turn the
upper operation lever (3) about 10 times to
bleed out the pressure.
4 Gate lever
Move the travel lever (5) back and forth about 5

times to bleed out the pressure.
[7] Bleeding pressure from inside the hydraulic oil

tank
Press the air breather button (6) on top of the
hydraulic oil tank to release the pressure inside
the tank.
7 SST-09-01-009F
7
[8] Side door opening and closing
Open the side door (7). At this time, be sure to
use the lock (8).
This completes the preparations.
SST-09-01-009F 8
8
1. Main Pressure Measurement
[1] Pressure gauge installation
Remove the pressure sensor and install the
pressure gauge.
a1: Can be measured a2: Can be measured

Travel left Travel right
Option Bucket
Swing
Arm 1 pump flow Arm 2 pumps flow
Boom 2 pumps flow Boom 1 pump flow
1 Pump
Remove the pressure sensor.
2 Gauge port
Install the adapter (3).
Install the pressure gauge (4) on the adapter

and fasten it.
Pressure gauge for 8702 PSI (60 MPa)

Port size G1/4
9 SST-09-01-009F
9
A Attachment pressure measurement
Example: Arm-out pressure measurement
　　 Measure with the following operations.
Engine speed 1900 rpm

Work mode SP mode
Lever operation Arm-out relief
1 pump: P1 port
Measuring port
2 pumps: P2 port
Boosted pressure:
5410 PSI (37.3 MPa)
Set pressure
Standard:
5 Arm-out relief
4975 PSI (34.3 MPa)
When the attachment operates, since the pressure boost operates automatically, the pressure
resulting from the pressure boost setting can be checked for about 8 sec. After 8 sec. or more,
the standard set pressure can be checked.
Measure relieving each cylinder with the arm out/in, the bucket open/close, and the boom up.
Bucket Bucket Boom

Lever operation Arm out Arm in Boom up
open close down
Work mode SP mode
1 pump flow measuring
P1 P1 P2 P2 P2 P2
port
2 pumps flow measuring
P2 P2 No No P1 P1
port
5410 PSI 5410 PSI 5410 PSI 5410 PSI 5410 PSI 3974 PSI
Pressure boost
(37.3MPa) (37.3MPa) (37.3MPa) (37.3MPa) (37.3MPa) (27.4MPa)
4975 PSI 4975 PSI 4975 PSI 4975 PSI 4975 PSI 3974 PSI
Standard pressure
(34.3MPa) (34.3MPa) (34.3MPa) (34.3MPa) (34.3MPa) (27.4MPa)
Boom-down pressure measurement

For pressure measurement with the boom
down, put the arm cylinder at its out stroke
end, open the bucket, put the bucket tip on the
ground, carry out the boom-down operation,
and measure.
6 Boom-down relief
SST-09-01-009F 10
10
B Travel pressure measurement
[1] Install the stopper (5) on the crawler sprocket
section (6) and lock the travel motor.
[2] Measure with the following operations.

Work mode SP mode (1st speed)
Lever operation Travel relief
Left travel: P1 port
Measuring port
Right travel: P2 port
Set pressure 4975 PSI (34.3 MPa)
C Swing pressure measurement

[1] Set the swing lock with the monitor.

Work mode SP mode
Lever operation Swing relief
Measuring port P1 port
[3] After the end of pressure measurement,

release the swing lock with the monitor.
Swing lock switching
In order to prevent accidental operation under certain special circumstances, sometimes the
swing brake need to be left ON all the time.(Swing lock) At this time, the swing lock can be
switched ON/OFF by holding down the "horn volume select switch", the "working light switch",
and the "auto idle switch" at the same time for 2 sec. Additionally, turn the key OFF with the
swing lock ON, have the swing lock ON when the key is turned ON again. (The previous data is
held.)
11 SST-09-01-009F
11
D Option line pressure measurement
[1] Close the option line stop valve (7).
[2] With the option operation select switch in the

cab, switch to the option line to measure.
(Breaker, double-acting)

Work mode SP mode
Pedal operation Option relief
1 pump: P2 port
Measuring port
2 pumps: P1 port
Set pressure * 4264 PSI (29.4 MPa)
* Adjust the set pressure to match the specifications of the attachment used.
Factory pressure settings
Breaker circuit: 426 PSI (2.94 MPa)
Double-acting, multi-purpose (crusher) circuit: 2582 PSI (17.8 MPa)
SST-09-01-009F 12
12
2. Pilot Pressure Measurement
(1) Pressure gauge installation
Remove the plug with the wrench (8) to install a
pressure gauge at the pump pressure measur-
ing port (P3).
Install the adapter (9).
Install the pressure gauge (10) and measure the

pressure.

Work mode SP mode

Port size G1/4
13 SST-09-01-009F
13
3. Negative Control Pressure Measurement
(1) Pressure gauge installation
Remove the pump N1 or N2 pressure sensor connector (11), and remove the pressure sensor.
(N1, N2: pressure port)
(The pressure sensor location becomes the measurement port.)
Install the pressure gauge at the port from which the N1 or N2 pressure sensor was removed.

Port size G1/4
12 Adapter
13 Ratchet
SST-09-01-009F 14
14
Measure the negative control pressure for each operation.
14 Pressure gauge
Work mode SP mode
P1 pump side: N1 port
Measuring port
P2 pump side: N2 port
566 PSI
Set pressure
(3.9 MPa max.)
15 SST-09-01-009F
15
Pressure Adjustment
1. Main Pressure Adjustment
■ Pressure measurement and adjustment prepa-
ration work
Pressure is adjusted with control valves.
The following preparations are required for
adjusting with control valves.
[1] Engine hood opening and closing
Pull the engine hood lock release lever (2) to
release the lock.
Open the engine hood (1).

At this time, always check that the lock (3) is
locked.
[2] Cover removal

Remove the 6 bolts (4), then remove the
cover (5).
SST-09-01-009F 16
16
(1) Main relief pressure adjustment
k) After locking, check the pressure.
Repeat h), i), and j) until the set pres-
Work mode SP mode sure is correctly adjusted.
Lever operation Arm-in relief l) Stop the engine.
Boosted pressure: 5410 PSI
Measurement (37.3 MPa)
pressure
Standard: 4975 PSI (34.3 MPa)
Boosted pressure:
Pressure per 4119 PSI (28.4 MPa)/rotation
rotation of adjust-
ing screw Standard:
3089 PSI (21.3 MPa)/rotation
Before adjusting, remove the pilot hose for the
pressure boost signal (10) connected to the
main relief valve (7), then insert the plug (8) into
the hose side. The procedures for boosted pres-
sure and standard pressure are different.
For boosted pressure
a) Loosen the standard lock nut (27 mm) (14) and
tighten the adjusting screw (27 mm) (13). Fas-
ten with a wrench (27 mm) so that the pressure
boost adjusting screw does not turn.
b) After tightening until the adjusting screw stops
turning, tighten the lock nut (11).
c) Start the engine and run it at maximum rotation.
d) Move the arm lever to the in side, set the relief
state, and hold.
e) Loosen the pressure boost lock nut (32 mm)
(11) and adjust the set pressure with the adjust-
ing screw (27 mm) (12).
• When lower than the set pressure, tighten.
• When higher than the set pressure, first lower
below the set pressure, then adjust on the tight-
ening side.
f) After adjustment, fasten the adjusting screw with
a wrench (27 mm), then tighten the lock nut.
g) After locking, check the pressure on the boosted
pressure side.
Repeat a) - f) until the set pressure is correctly 6 Control valve
adjusted. 9 Wrench (19 mm)
For standard pressure
h) Loosen the standard lock nut (27 mm) (14).
i) Loosen the adjusting screw (13), lower below the
set pressure, then adjust on the tightening side.
j) After adjustment, tighten the lock nut while fas-
tening the adjusting screw (13) with a wrench
(9).
17 SST-09-01-009F
17
(2) Overload relief pressure adjustment
Work mode SP mode
Measuring port P1/P2 port
Boom down: 3974 PSI
(27.4 MPa)
Measurement pressure
Others: 5685 PSI
(39.2 MPa)
Pressure per rotation of 3075 PSI
adjusting screw (21.2 MPa)/rotation
Since the overload relief pressure is set higher
than the main relief pressure, it is necessary to
provisionally set the main relief pressure higher
than the overload relief pressure. (Except for
boom down)
Main relief pressure provisional setting
• Using the main pressure adjustment proce-
dure for reference, temporarily set the
boosted pressure and standard pressure to
at least 5685 PSI (39.2 MPa.)
* For boom down (19), since the overload set
pressure is lower than the main relief set
pressure, there is no need to temporarily set
the main relief pressure.
Pressure adjustment
Example: Arm-out (17) overload relief adjust-
ment
[1] Loosen the lock nut (21) with the wrench (23)
and adjust by turning the adjusting screw
(22) with the hexagon wrench (24).
• When higher than the set pressure, first
loosen to a pressure lower than the set pres-
sure, then adjust on the tightening side.
[2] After adjustment, lock the lock nut (21).
[3] After adjusting the overload relief pressure,
adjust the boosted pressure and standard
pressure to their normal values referencing
the main pressure adjustment procedure.
* For the position of each overload relief,
see the "Control Valve Relief Locations".
15 Control valve
16 Boom up
18 Bucket open
20 Bucket close
SST-09-01-009F 18
18
(3) Swing relief pressure adjustment
Work mode SP mode
Measurement pressure 4409 PSI (30.4 MPa)
Pressure per rotation of 1682 PSI
adjusting screw (11.6 MPa)/rotation
Swing pressure
[1] Using the swing pressure measurement pro-
cedure for reference, lock the swing, and
check the swing pressure.
[2] Loosen the lock nut (25) and adjust by turn-
ing the adjusting screw (24).
• When higher than the set pressure, first
loosen to a pressure lower than the set pres-
sure, then adjust on the tightening side.
[3] After adjustment, lock the lock nut (25).
26 Wrench
19 SST-09-01-009F
19
2. Pilot Pressure Adjustment
(1) Pressure measurement
a) Install the pressure gauge (28).
b) While holding the plug with a wrench (24 mm)
(26), adjust with a hexagon wrench (6 mm)
(27).

Lever operation Neutral
Measuring port P3
SST-09-01-009F 20
20
Hydraulic Pump Flow Measurement Procedures SH330
Maintenance

Preparations
Workers 3 Role (worker 1: work supervisor, pressure adjustment)
Role (worker 2: operator)
Role (worker 3: flow, pressure measurement, recording)
1. Items to Prepare
1 Vacuum pump 8 Adapter (flange type)

2 Flow meter 9 Hydraulic hose (for flow measurement)
3 Pressure gauge 8702 PSI (60 MPa × 2) 10 Recording sheet
4 Hexagon wrench (6 mm, 10 mm) 11 Pen
5 Wrenches (17, 19, 24, 27 × 2, 32, 36 × 2) 12 Cleaning fluid
6 Extension cable 13 Rag
7 Hydraulic oil tank lid (for vacuum pump)
21 SST-09-02-006EN
1
Work Preparations
[1] Check that the main unit is in its work posture
(arm-vertical).
[2] Bleed out the pressure. (See the details on
Bleeding Pressure in the Pressure Measure-
ment and Adjustment Procedures.)
* Perform a swing prevention check.
[3] Use a wrench (17 mm) to remove the feed port

cover (1).
[4] Use the bolts removed in [3] to install the

hydraulic oil tank lid (for vacuum pump) (2).
[5] Install the vacuum pump (3) on the hydraulic oil

tank lid.
SST-09-02-006EN 22
2
[6] After setting the vacuum pump (3) as in the dia-
gram on the right, switch on the power.
(If the cable is too short, use an extension
cable.)
[7] Use a hexagon wrench (7) (10 mm) to remove

the split flanges (4) and hydraulic hose (6).
(This section explains flow measurement at the
P2 pump.)
5 Bolt
23 SST-09-02-006EN
3
a Procedure 9 - 12 8 Elbow adapter 13 Hydraulic hose (OUT)

b Procedure 13 - 15 9 Adapter 14 Hydraulic hose
c Procedure 8 10 Hydraulic hose (IN) 15 Split flange
11 Flow meter 16 Adapter (flange type)
12 Orifice
[8] Use the split flange to install the adapter [14] Install the (prepared) hydraulic hose on the
(flange type) on the tip of the hydraulic hose flow meter OUT side, then fasten with the
removed in [7]. wrench.
[9] Install the adapter at the position from * When connecting, always check the con-
which the hydraulic hose was removed. nection positions.
* Always have the orifice fully open.
[10] When the parts are set as in the diagram
above, remove the plug. [15] Install pressure gauges on P1 and P2.
(See "Main Pressure Measurement".)
[11] Use the wrench to connect the adapter
installed on the pump in [9]. [16] Remove the vacuum pump and re-install
the hydraulic oil tank the same way it was.
[12] If necessary, install an "elbow adapter" on
the (prepared) hydraulic hose connected to [17] Open the engine hood.
the flow meter IN side. (See "Main Pressure Adjustment".)
[13] Install the hydraulic hose on the flow meter [18] Remove the cover.
IN side, then fasten with the wrench. [19] Remove the pilot hose for the pressure
boost signal, then plug the hose side.
(See "Main relief pressure adjustment".)
This completes the preparation for flow measure-
ment.
SST-09-02-006EN 24
4
Flow Measurement
[1] Measure the flow.
When measuring the flow, position the workers
as in the diagram on the right.
(Worker 1: Work supervisor, pressure adjust-
ment)
(Worker 2: Operator)
(Worker 3: Flow, pressure measurement,
recording)
[2] At the signal from the work supervisor, the oper-

ator starts the engine.
[3] Check the hydraulic oil temperature on the mon-
itor. 122 ºF (50 ºC)
Check that the engine rotation and pump milli-
amp is normal.
[4] The operator signals the arm-out relief opera-
tion to worker 1.
4 Ignition key
[5] Worker 2 lowers the arm-out port relief. (Min:

3480 PSI (24 MPa) P1+P2)
[6] Start of flow measurement
[7] The arm-out relief operation is carried out.
[8] Data measured in units of 290 PSI (2.0 MPa)
(P1+P2)
* The measurement is carried out from
3481 - 11023 PSI (24.0 - 76.0 MPa) and
ends when the maximum pressure is
reached.
[9] Remove the flow meter.
* Because the maximum limit of the flow meter pres-
sure gauge is exceeded starting from 5802 PSI
(40 MPa.)
[10] Reset the arm-in port relief valve to normal pressure.
(For details on this adjustment, see "Pressure
Adjustment".)
[11] Remove the pressure gauges etc. and put every-
thing back to normal. This completes the work. 5 Lock nut 17 mm
6 Hexagon wrench 6 mm
25 SST-09-02-006EN
5
Drain Volume Measurement Procedures SH330
Maintenance

Preparations
Measuring conditions
1st speed 1900 rpm

Engine speed
2nd speed 2050 rpm
Mode SP mode
Oil temperature About 122 ºF (50 ºC)
* Be careful. The drain volume varies greatly with the oil temperature.
Travel Motor Drain Volume Measurement

[1] Allow the bucket (2) to touch the ground so as to
elevate one shoe crawler (1) as in the diagram
on the right.
[2] Remove the bolts (4), then remove the cover

(3).
[3] Always lay a rag (6) underneath before remov-

ing the drain hose (5).
[4] Use a wrench to remove the drain hose (5).
(Always install a cap on the removed drain hose
(5).)
26 SST-09-03-008EN
1
[5] Install the extension hose for measurement (7)
on the side of the motor from which the drain
hose was removed.
[6] Prepare a waste oil can (8) and measuring con-

tainer (9) and set them as in the diagram on the
right.
[7] Catch the stopper (10) between the sprocket

section and the frame and lock the travel motor.
SST-09-03-008EN 27
2
[8] In SP mode at medium speed, relieve the travel
operation, and move the extension hose to the
measuring container (9) at the same time the
motor starts.
(At starting, start measurement with a stop
watch (11).)
[9] After 30 sec., move the extension hose to the
waste oil can (8).
[10] Measure the volume of oil in the measuring con-
tainer (9) as the drain volume for 30 sec.
Forward Backward
1st 2nd 1st 2nd
speed speed speed speed
Right
Left
* Measure at least 3 times each for left, right,
forward, and backward.
28 SST-09-03-008EN
3
Swing Motor Drain Volume Measurement
[1] Remove the 2 drain hoses (1) and put plugs in
the hose side of each.
(wrench size: 27 mm, clamp 22 mm (hose side))
[2] Install the extension hose (3) for measuring the

drain volume on one side of the T nipple. Install
the hose facing in a direction that makes mea-
surement easy and install a plug (2) on the
other side.
[3] Prepare a waste oil receiver and measuring

container (5) and set them as in the diagram on
the right.
For details on the method for locking the swing
motor, see "Swing relief pressure adjustment".
[4] In SP mode, relieve the swing operation and
move the extension hose to the measuring con-
tainer (5) at the same time the motor starts.
(At starting, start measurement with a stop
watch (4).)
[5] After 60 sec., move the extension hose to the
waste oil can (6).
[6] Measure the volume of oil in the measuring con-
tainer (5) as the drain volume for 60 sec.
Measure at least 3 times each for left and right.
Right Left
SST-09-03-008EN 29
4
Air Bleed Procedure SH330
Maintenance Section
Air Bleed Procedure

Always bleed off any air in the hydraulic circuits after replacing the hydraulic oil, repairing or
Caution replacing hydraulic equipment, or removing hydraulic pipes.
* Failure to completely bleed off all the air can reduce the service life of hydraulic equipment and
lead to damage.
Hydraulic Pump
[1] Loosen the air bleed plug (1) and check that oil
oozes from the air bleed port (2).
[2] If oil does not ooze out, remove the air bleed
plug (1), and fill hydraulic oil (3) from the air
bleed port (2) into the pump case.
[3] Temporarily tighten the air bleed plug (1).
[4] Run the engine at low idle, slightly loosen the air
bleed port, and run until oil oozes from the air
bleed port (2) section.
[5] Completely tighten the air bleed plug (1).
30 SST-09-04-009EN
1
Air Bleed Procedure
Travel Motor
[1] Remove the bolts (2), then remove the cover
(1).
[2] Remove the hose (3) of drain port and elbow

(4).
[3] Pour in of hydraulic oil (5) from the air bleed

port.
[4] When inside the motor is filled with hydraulic oil,
tighten the elbow and hose.
[5] Start the engine and execute a slow travel oper-
ation.
[6] Repeatedly travelling forward and backward
bleeds off the air.
SST-09-04-009EN
2
Air Bleed Procedure
Swing Motor
[1] Run the engine at low idle, loosen the tee (1) of
drain hose (3), and check that oil oozes from the
air bleed port section (2).
* Do not execute a swing operation.
[2] If oil does not ooze out, stop the engine for now,
remove the tee (1) of drain hose (3), and fill
hydraulic oil (4) into the motor case.
[3] Temporarily tighten the tee (1) of drain hose (3).
[4] Run the engine at low idle, slightly loosen the
tee (1) of drain hose, and run until oil oozes
from the port section (2).
[5] Completely tighten the tee (1) of drain hose.
[6] With the engine at low idle, slowly swing evenly
left and right at least 2 rotations.
Check
After the air bleeding is complete, stop the engine for at least 5 minutes to allow any air bubbles in
the hydraulic oil tank to dissipate.
32 SST-09-04-009EN
3
Air Bleed Procedure
HBCV (Option)
The HBCV air bleeding work requires 2 workers: an operator and an air bleed worker.
Caution Decide the signals beforehand and work safely.
Set the main unit so that the arm HBCV is at the highest position. (See the figure below)
1. Boom Cylinder HBCV
[1] Start the engine and lower the boom without
jacking up the main unit.
[2] at the position in the figure.
[3] Foaming hydraulic oil comes out from the hose
mouthpiece section.
When foaming hydraulic oil stops coming out,
tighten the hose mouthpiece (1).
[4] Execute steps [2] and [3] for the opposite side
boom cylinder too.
[5] Check boom operations. If there is a delay in the
operation response, bleed the air again with the
same procedure.
2. Arm Cylinder HBCV

For arm-in operations, bleed the air from the arm
cylinder HBCV using the same procedure as for
boom cylinder HBCV air bleeding.
1 hose mouthpiece
SST-09-04-009EN 3
4
Electricity Measurement Procedures SH330
Maintenance

Measurement Equipment
[1] Hydraulic pump electromagnetic proportional valve (horsepower, flow)
[2] Solenoid valve
[3] Oil temperature sensor
[4] Pressure sensor
[5] Fuel sensor
[6] Atmospheric pressure sensor
[7] Suction air temperature sensor
[8] Glow plug
[9] Fuel feed pump
[10] EGR
[11] Injector
[12] Other sensors included on the engine
34 SST-09-10-002EN
1
Measurement Tools
[1] Tester
[2] Service connector kit
Models 1 - 3 common kit part number: KG0HP202-00
Old part -1/-2 -3 -3B -5
No. Part number Name
number series series series series
1 KHP11810 WDB0055-1 Throttle motor (12P) ● - - -
2 KHP11820 WDB0055-2 Throttle motor (12P) (main harness side) ● - - -
3 KHP11830 WDB0055-3 Stop motor (6P) ● ● - -
4 KHP11840 WDB0055-4 Stop motor (6P) (main harness side) ● ● - -
5 KHP11850 WDB0055-5 Solenoid valve (2P) ● ● ● ●

Hydraulic pump electromagnetic proportional valve 1 (2P)
6 KHP11860 WDB0055-6
(main harness side) ● ● ● ●
7 KHP11870 WDB0055-7 Hydraulic pump electromagnetic proportional valve 2 (2P) ● ● ● ●

8 KHP11880 WDB0055-8 Pressure switch (2P) ● ● ● ●
9 KHP11890 WDB0055-9 Pressure switch (2P) (main harness side) ● ● ● ●
10 KHP11900 WDB0055-10 Receiver dryer (2P) ● ● ● ●
11 KHP11910 WDB0055-11 Oil filter switch (1P) ● - - -
12 KHP11920 WDB0055-12 Oil filter switch (1P) (main harness side) ● - - -
13 KHP1576 Backup sensor (2P) 120 - 290 - ● - -
14 KHP1732 Backup sensor (2P) 330 - 460 - ● - -
15 KHP11930 Backup sensor (3P) 800 - ● - -
16 KHP1578 Engine governor A (8P) - ● - -
17 KHP1579 Engine governor B (6P) - ● - -
18 KHP1579 Engine governor B (3P) - ● - -
19 KHP1575 Oil temperature sensor (2P) - ● ● ●

20 KHP1577 Pressure sensor (3P) - ● ● -
21 KHP11020 Atmospheric pressure sensor/pressure sensor (3P) - - ● ●

22 KHP11030 Suction air temperature sensor (2P) - - ● ●
23 KHP11060 Glow (1P) - - ● ●
24 KHP11070 Fuel pump (6P) - - ● ●
25 KHP11080 EGR (8P) - - ● ●
26 KHP11090 Injector (12P) - - ● ●
27 KHP11100 Sensor (20P) - - ● ●
28 KHP11970 Breaker ECM main harness assembly - - ● ●
29 KHP11040 Fan motor proportional valve (2P) 460 - 800 - - ● -
30 KHP11050 Fan motor reverse valve (2P) 460 - 800 - - ● -
31 KHP13650 Fuel sensor/solenoid valve (2P) - - - ●

32 KHP13660 Angle sensor (3P) (liftcrane specifications) - - - ●
33 KHP13670 Fuel feed pump (2P) - - - ●
34 KHP13680 Fuel pump harness (3P) - - - ●
35 KHP13690 Fuel pump (2P) - - - ●
36 KHP13700 Air conditioner compressor (1P) - - - ●
37 KHP13710 Engine sensor (20P) - - - ●
38 KHP13720 Engine EGR (8P) - - - ●
SST-09-10-002 35
2
Model 3B additional kit part number: KG0HP203-00
-1/-2 -3 -3B
No. Part number Q'ty Name
series series series
1 KHP11020 1 Atmospheric pressure sensor (3P) - - ●

2 KHP11030 1 Suction air temperature sensor (2P) - - ●
3 KHP11060 1 Glow (1P) - - ●
4 KHP11070 1 Fuel pump (6P) - - ●
5 KHP11080 1 EGR (8P) - - ●
6 KHP11090 1 Injector (12P) - - ●
7 KHP11100 1 Sensor (20P) - - ●
8 KHP11970 1 Breaker ECM main harness assembly - - ●
9 KHP11040 1 Fan motor proportional valve (2P) 460 - 800 - - ●
10 KHP11050 1 Fan motor reverse valve (2P) 460 - 800 - - ●
[3] Service connector

1) Solenoid valve
Part number : KHP11850
Old part number : WDB0055-5
• Solenoid valve
• Fuel sensor
2) Hydraulic pump electromagnetic proportional valve (main harness side)

3) Hydraulic pump electromagnetic proportional valve

36 SST-09-10-002
3
4) Pressure switch
5) Pressure switch (main harness side)

6) Receiver dryer
7) Oil temperature sensor

8) Atmospheric pressure sensor

SST-09-10-002 37
4
9) Suction air temperature sensor
10) Glow
11) Fuel pump

38 SST-09-10-002
5
12) EGR
13) Injector
SST-09-10-002 39
6
14) Sensor
40 SST-09-10-002
7
15) Breaker ECM main harness assembly
Component parts
Part number Part name Q'ty

KHP11980 Wire harness (for ECM to knob) 1
KHP11990 Wire harness (for main harness to knob) 1
KHP12000 Wire harness (for joint knob) 3
1. Wire harness (for ECM to knob)

SST-09-10-002 41
8
2. Wire harness (for main harness to knob)
3. Wire harness (for joint knob)

42 SST-09-10-002
9
16) Solenoid valve and fuel sensor
17) Angle sensor (3P) (liftcrane specifications)

18) Fuel feed pump (2P)

19) Fuel pump harness (3P)

SST-09-10-002 43
10
20) Fuel pump (2P)
21) Air conditioner compressor (1P)

22) Engine sensor (20P)

44 SST-09-10-002
11
23) Engine EGR (8P)
SST-09-10-002 45
12
Measurement Method
1. Hydraulic Pump Electromagnetic Proportional Valve
Specified connectors
KHP11860
KHP11870
• Remove the connector of the electromagnetic

proportional valve (horsepower, P1 flow) con-
nected to the hydraulic pump.
• Connect 2P service connectors in between the

removed connectors.
• Be careful at this time that the knob terminals do
not make the lines intersect.
• For the tester connections, check that the har-

ness from the operator's seat side is brown/black
(service connector side is the same color), and
connect the red tester terminal to the operator's
seat side and the black tester terminal to the
hydraulic pump side.
• After connection is completed, start the engine
and check the milli-amp of each mode at the max-
imum rotation.
*= When the target engine speed is 1300 rpm or less, milli-amp for
Control milli-amp
pump horsepower control proportional valve is 50 mA.
Work mode (upper) SP H A
Engine speed (rpm) 1900 1800 1700 1699 - 1300 1299 - 900
Milli-amp for pump horsepower
SH330-5 500 500 500 380 50
control proportional valve (mA)
46 SST-09-10-002
13
Specified connectors
KHP13650
• Remove the 1 connector attached to the solenoid
valve to be measured.

2 For swing brake (white)
3 For pressure boost (yellow)
4 For travel 2nd speed (red)
5 For power save (green)
6 For lever lock (blue)
• There are 5 solenoid valves that are attached, but

the application of each location is as explained in
the diagram on the right.(view from front)
Color bands are attached to the connector sec-
tions.
Functions are different for each color, so use cau-
tion when measuring.

removed connectors.(solenoid valve side only)
• For the tester connections, connect the red and

black terminals to the service connector knob ter-
minals.
• After connection is complete, check the resis-
tance.
Resistance 40 Ω (at 68 ºF (20 ºC))
* The resistance value changes to a slight degree
due to temperature.
SST-09-10-002 47
14
3. Oil Temperature Sensor
Specification connector
KHP1575
• Remove the oil temperature sensor.
• Connect 2P service connectors to the removed
sensors.
• or the tester connections, connect the red and
black terminals to the service connector knob ter-
minals.
• After connection is complete, slowly raise the
temperature and check the resistance.
Resistance value for each temperature Unit: kΩ

Oil temperature Oil temperature sensor
68 ºF (20 ºC) 2.45
86 ºF (30 ºC) 1.66
104 ºF (40 ºC) 1.15
122 ºF (50 ºC) 0.81
140 ºF (60 ºC) 0.58
158 ºF (70 ºC) 0.43
176 ºF (80 ºC) 0.32
48 SST-09-10-002
15
4. Pressure Sensor
Specification connector
KHP11020
Remove the connector of the pressure sensor connected to the hydraulic pump.
Pump pressure sensor side

removed connectors.
• For the tester connections, connect the red termi-
nal to the service connector knob terminals WY
(white/yellow).Connect the black terminal to the
ground.
• After connection is complete, turn the key switch
ON and check the voltage.
For engine-side sensor OK/NG judgment, see the engine troubleshooting manual.
SST-09-10-002 49
16
Pressure sensor voltage
Pressure and voltage
[1] P1, P2 pressure sensors [2] Negative control pressure sensor
Pressure PSI Pressure PSI
Voltage (V) Voltage (V)
(MPa) (MPa)
7252 (50) 4.5 725 (5.0) 4.5
6338 (43.7) 4 634 (4.37) 4
5439 (37.5) 3 544 (3.75) 3
3626 (25.0) 2 363 (2.5) 2
2538 (17.5) 1 181 (1.25) 1
0 0.5 0 0.5
50 SST-09-10-002
17
Procedures for Replacing Consumable Parts SH330
Maintenance Section

Air Conditioner Belt and Fan Belt Replacement
If the belt is loose, battery charging defects, engine overheating, and rapid belt wear occur.
1. Air Conditioner Belt Replacement
[1] Use a box wrench (19 mm) to remove the bolts,
then remove the bottom cover (1).
[2] The air conditioner belt (3) is at the position in

the figure on the right.
[3] Use a box wrench (14 mm) (5) to remove the

nut (2).
51 SST-09-05-009EN
1
tension bolt (4).
[5] Remove the air conditioner belt (7) from the ten-
sion pulley (6) and replace it.
Tension adjustment
After replacing the air conditioner belt, it is neces-
sary to adjust the belt tension.
[1] Use a box wrench (14 mm) (5) to tighten the
tension bolt (4).
[2] Adjust the belt so that when the center section
of the belt is pressed with a finger, it deflects
about 1 cm. (See the figure on the right.)
[3] Securely fasten the nut (8).
SST-09-05-009EN 52
2
2. Fan Belt Replacement
[1] Remove the air conditioner belt.
(See "Air Conditioner Belt Replacement".)
[2] Use a wrench (14 mm) to remove the bolt (1).
[3] Use a wrench (14 mm) to remove the bolt (1).

[4] Remove the bracket (2).
[5] Remove the fan guard (3).
53 SST-09-05-009EN
3
[6] Use box wrench (17 mm) to loosen the alterna-
tor lower installation bolts (7).
• The lower installation bolts (7) is loosend while
holding the nut (6) by the wrench and the span-
ner (17 mm), etc.
[7] Use a box wrench (17 mm) (4) to loosen the nut
(9), then free the adjust plate (8) of alternater.
[8] Use a box wrench (17 mm) (4) to loosen the

alternator (5) tension bolt (10).
[9] Remove the fan belt from the alternator (5).
SST-09-05-009EN 54
4
[10] While slowly turning the fan (11), pass the fan
belt (12) over the five one at a time and remove
it.
Tension adjustment
After replacing the fan belt, it is necessary to adjust
the belt tension.
[1] Use a box wrench (17 mm) (4) to tighten the
alternator (5) tension bolt (10).
[2] Adjust the fan belt (12) so that when the center
section of the belt is pressed with a finger, it
deflects about .3 in (1 cm.)
[3] Securely fasten the nut (9).
[4] The lower instllation bolt (7) is firmly tightened
with the box wrench (17 mm) (4).
• The lower instrallation bolt (7) is tightend while
holding the nut (6) by the wrench and the span-
ner (17 mm), etc.
55 SST-09-05-009EN
5
Fuel Filter Replacement
1. Filter Replacement
(1) Main filter
When replacing the fuel filter, always bleed the air.
[1] Tighten the fuel line (1) stop valve (2).
[2] Use a wrench (10 mm) (3) to loosen the air

bleed plug (4).
[3] Loosen the cap (5) at the bottom and drain
out any remaining fuel.
* Put a waste oil case (6) underneath.
[4] Remove the filter cover (8) with the special

filter wrench (7).
SST-09-05-009EN 56
6
[5] Remove the element (9) and replace it.
[6] Open the fuel line stop valve.
(2) Pre-filter
[1] Close the fuel line (1) stop valve (2).
[2] Use a wrench (10 mm) to loosen the air

bleed plug (5).
[3] Loosen the cap (3) at the bottom and drain
out any remaining fuel.
6 Wrench
57 SST-09-05-009EN
7
[4] Remove the pre-filter cover (8) with the
special filter wrench (8).
[5] Remove the element (10) and replace it.
9 O-ring
[6] Open the fuel line stop valve.
SST-09-05-009EN 58
8
2. Air Bleeding
If air gets into the fuel system, this can cause difficulty starting and poor engine condition. When the
fuel tank has been emptied, water drained from the fuel, the element replaced, or other such work
carried out, always bleed the air.
[1] Install the air bleed hose (1) at the position in
the figure on the right.
[2] Use a wrench (10 mm) (2) to loosen the air
bleed plug (3).
[3] When the filter case priming pump is turned in

the direction of the arrow, the knob (4) pops out.
[4] Press the knob a few times.

When fuel appears inside the filter case, gently
tighten the air bleed plug for now. Press the
knob a few times with the plug and knob as they
are.
Finally, hold the knob pressed in and slightly
loosen the air bleed plug.
Fuel oozes out from the hose like bubbles.
[5] Repeat the operation in [4] until no more bub-
bles appear.
[6] Tighten the air bleed plug, then turn the knob
and lock it.
59 SST-09-05-009EN
9
Engine Oil Filter and Engine Oil Replacement
If the engine oil is severely dirty or deteriorated, replace it quickly even if it is not yet time for
Caution periodic replacement.
1. Engine Oil Replacement

[1] Open the engine hood.
[2] Remove the engine oil cap (1).
[3] Put a waste oil can (2) underneath the engine

oil drain port.
[4] Remove the bottom cover (3).
4 Bolt
SST-09-05-009EN 60
10
[5] Remove the drain plug (5).
[6] Install the drain plug (6) with hose and screw it
in.
The valve is pressed automatically and the oil is
drained.
[7] After draining the oil, securely install the drain
plug.
2. Engine Oil Filter Replacement

[1] Remove the engine oil filter cover with the spe-
cial filter wrench (1).
[2] Replace the engine oil filter (2).
[3] When installing the engine oil filter (2), check
that the O-ring is not damaged, then install.
Also, if the O-ring is replaced, apply oil to it
before installing it.
61 SST-09-05-009EN
11
[4] Fill engine oil (3) from the feed port at the top.
[5] Check on the oil gauge (4) that the oil volume is
correct.
[6] Start the engine and let it idle for a few minutes.
During this idling, check for oil leaking.
[7] Stop the engine, wait about 20 minutes, then
inspect the oil volume again.
If the oil volume is correct now, the oil change is
OK.
If the oil is low, fill more.
SST-09-05-009EN 62
12
Radiator Coolant Replacement
[1] Open the engine hood.
[2] Remove the radiator cap (1).
[3] Use a box wrench (19 mm) to remove the bolts,

then remove the bottom cover (2).
[4] Turn the drain cock (3) to the left and drain the
coolant.
[5] Return the drain cock (3) to its original position,
fill the radiator with hot water up to the radiator
port, then run the engine slightly faster than
idling.
Run for about 10 minutes to raise the water tem-
perature to 176 ºF (80 ºC), then drain the water.
[6] Fill the radiator with coolant (4) up to the radia-

tor port.
Run the engine for about 10 minutes, then ade-
quately bleed the air from the cooling system.
[7] Stop the engine and check the coolant level.
If the coolant level is low, fill in more.
63 SST-09-05-009EN
13
Air Cleaner Cleaning and Replacement
[1] Open the door (1).
[2] Release the 4 locks (2), then remove the cover

(3).
[3] Remove the air cleaner (outer) (4).
SST-09-05-009EN 64
14
[4] Use a compressed air gun (5) to blow out from
the inside of the air cleaner (outer) (6) and clean
it.
[5] Remove the air cleaner (inner) (7) and replace

it.
This air cleaner cannot be cleaned. Always
replace it.
65 SST-09-05-009EN
15
Hydraulic Oil Filter Replacement
・ When replacing the hydraulic oil, be careful to keep dirt, water, sand, and all other foreign
matter out of the tank.
・ When replacing the hydraulic oil, always replace the filter and element with new ones.
・ When using with a hydraulic breaker mounted, the deterioration of the hydraulic oil is more
Caution
severe than for normal excavation work, so maintain the hydraulic oil frequently enough.
・ Manage the hydraulic oil (by checking samples for contamination and deterioration) every
1000 hour per engine running time. ”We recommend the Sumitomo Oil Analysis System
(Oiltech).”
Put the main unit into the posture for transport or ship-
ping.
1. Return Filter Replacement

[1] Press the rubber cap at the breather section on
the top of the hydraulic oil tank to bleed off the
pressure in the tank.
[2] Use a wrench (17 mm) to remove the bolts (1),
then remove the cover (2).
(There is an O-ring (6) on the rear.)
[3] Take the spring (3), valve (4), and return filter
(5) out from the tank.
[4] Replace the return filter.
[5] If the O-ring (6) on the rear of the cover is worn
or damaged, replace it.
[6] The installation procedure is the reverse of the
removal procedure.
SST-09-05-009EN 66
16
2. Suction Filter Replacement
[1] Press the rubber cap at the breather section on
the top of the hydraulic oil tank to bleed off the
pressure in the tank.
then remove the feed port cover (2).
(There is an O-ring (3) on the rear.)
[3] Remove the suction strainer (4).

[4] Replace the suction strainer (4) with a new one.
[5] If the O-ring is worn or damaged, replace it.

removal procedure.
* When installing the feed port cover (2), align
it with the position in the figure on the right,
then install it.
a Align
67 SST-09-05-009EN
17
3. Air Breather Element Replacement
[1] Press the rubber cap (1) at the breather section
on the top of the hydraulic oil tank to bleed off
the pressure in the tank.
[2] Remove the rubber cup (1).
[3] Use a wrench (19 mm) to remove the hexagon
nut (2).
[4] Remove the cover (3).

[5] Replace the filter element (4) with a new one.
removal procedure.
4. Pilot Oil Filter Replacement

[1] Use a filter wrench (1) or the like to remove the
pilot oil filter cover.
[2] Replace the pilot oil filter (2).
[3] When installing the pilot oil filter (2), check that
the O-ring is not damaged, then install.
Also, if the O-ring is replaced, apply oil to it
before installing it.
SST-09-05-009EN 68
18
5. Hydraulic Oil Replacement
[1] Rotate the main unit slightly before replacing
the hydraulic oil. (Enough to make the work
easy)

then remove the feed port cover (2).
[3] Insert the feed pump into the feed port (3).
69 SST-09-05-009EN
19
[4] Prepare a can (4) to drain the hydraulic oil into.
[5] Use a box wrench (19 mm) to loosen the bolt

(6), and remove the under cover (5).

drain plug (8).
SST-09-05-009EN 70
20
[7] Drain the waste oil into the drain can (9).
[8] After draining the waste oil, securely install the
drain plug.
Hydraulic oil filling

[1] Fill with the feed pump (10) as in the figure on
the right.
[2] Check that the hydraulic oil comes to the correct
position on the level gauge (11).
71 SST-09-05-009EN
21
Others
1. Coolant Filling
Remove the reserve tank (1) cap and pour in cool-
ant (2).
2. Washer Fluid Filling

Remove the washer tank (1) cap and pour in
washer fluid (2).
SST-09-05-009EN 72
22
Periodic Maintenance Procedures SH330
Maintenance Section

Maintenance Every 250 Hours
1. Battery Inspection and Replacement
Check the color from the battery cover inspec-
tion window.
Green : OK
Black : Charge (Charge the battery.)
White : Replace (Replace the battery.)
■ Battery replacement can

[1] Remove the 2 screws (2), then remove the
battery cover (1).
[2] Remove the 2 cables (4) connected to the
battery terminals, then replace the battery (3)
with a new one.
73 SST-09-07-009EN
1
Maintenance after First 250 Hours for New Machine / Every 1000 Hours from Then on
1. Swing Reduction Gear Oil Replacement
and remove the under cover(1).
[2] Prepare a waste oil can (3).
[3] Remove the level gauge (4).
SST-09-07-009EN 74
2
[4] Use a wrench (22 mm) (5) to remove the drain
plug (6) and drain off the oil.
[5] After oil draining is complete, tighten the drain
plug (6).
2. Gear Oil Filling

[1] Remove the level gauge (2), fill the stipulated a
mount of gear oil from the gauge port.
[2] After about 10 minutes, check the oil volume
with the level gauge.
3 Stipulated volume of oil
75 SST-09-07-009EN
3
Replace the Flange Packing at the Bottom of the Fuel Tank
[1] Whenever the fuel tank bottom cover (1) is removed, for example for cleaning the fuel tank,
replace the packing (2).
[2] When installing the packing (2), apply liquid packing. (See the figure below)
• Replacement parts
Part name Part number

Joint seat packing KSH0503
Liquid packing 1104 KTC0075
3 Liquid packing must be applied.
SST-09-07-009EN 76
4
Bolt Size and Torque Table SH330
Maintenance

Bolt and Nut Tightening
• Tighten alternating between left and right and top and bottom so that uniform tightening force is
applied.
456C
• For bolts at critical locations, apply engine oil to the threads for a uniform tightening force without
catching on the thread peaks.
• For bolts and nuts at critical locations and at locations that cannot be inspected from the outside,
use wire, cotter pins, folded washers, or the like to securely prevent turning.
• If Loctite was used on a removed bolt (there is something white sticking to the bolt when it is
removed), clean the old Loctite off with cleaning fluid, dry the bolt, then apply 2 - 3 drops of Loctite to
the thread section of the bolt.
Bolt and nut retightening [after 1st 50 hr. for new machine] [every 250 hr.]
• Tighten and retighten bolts and nuts in each section according to the table. Also before and after
day-to-day work, inspect for loose or fallen out bolts and nuts. Retighten any that are loose and
replace any that have come out.
• Inspect and retighten after the first 50 hr. for a new machine and every 250 hr. after that.
77 SST-09-08-008EN
1
Retightening Torque Table
Bolt nominal Tightening torque [lbf•ft
Code Retightening location Wrench
diameter (N•m)]
1 Travel motor M24 36 mm 664 - 775 (900 - 1051)
2 Drive sprocket M20 30 mm 384 - 448 (521 - 608)
3 Take-up roller M16 24 mm 197 - 230 (267 - 312)
4 Upper roller M20 30 mm 384 - 448 (521 - 608)
5 Lower roller M24 36 mm 665 - 774 (902 - 1049)
6 Track guard M24 36 mm 665 - 774 (902 - 1049)

7 Shoe M24 32 mm 912 - 1114 (1236 - 1510)
8 Counterweight M33 50 mm 1243 - 1960 (1685 - 1960)
9 Turntable bearing M24 36 mm 664 - 775 (900 - 1050)
10 Swing unit M24 36 mm 664 - 775 (900 - 1050)
11 Mount M20 30 mm 213 - 249 (289 - 337)
12 Engine Front bracket M10 17 mm 47 - 54 (64 - 73)
13 Rear bracket M12 19 mm 80 - 94 (109 - 127)
14 Radiator M16 24 mm 108 - 130 (147 - 176)
15 Flange M10 17 mm 47 - 54 (64 - 73)

Hydraulic pump 17 mm
16 Pump M20 270 - 366 (367 - 496)
hexagon socket head
17 Hydraulic oil tank M16 24 mm 171 - 204 (233 - 276)
18 Fuel tank M16 24 mm 171 - 204 (233 - 276)
19 Control valve M16 24 mm 197 - 230 (267 - 312)
20 Lock bar M16 24 mm 197 - 230 (267 - 312)

Center joint
21 Joint M12 19 mm 40 - 47 (54 - 64)
M16 24 mm 58 - 59 (78 - 80)
22 Cab
M10 17 mm 26 - 31 (35 - 42)
23 Battery M10 17 mm 15 - 21 (20 - 29)
Caution: For items marked with ○ , always apply Loctite #262 or the equivalent and tighten to the
specified torque.
The tightening torque in kgf•m is determined with N•m ÷ 9.8.
The tightening for bolts and nuts not otherwise specified in the table above is as follows.
Bolt nominal diameter (size) M6 M8 M10 M12 M14 M16 M18 M20
Wrench [mm] 10 13 17 19 22 24 27 30
Hexagon bolt Tightening 5 14 29 43 72 115 145 217
[lbf•ft N•m]
torque (6.9) (19.6) (39.2) (58.8) (98.1) (156.9) (196.1) (294.2)
Wrench [mm] 5 6 8 10 12 14 14 17
Hexagon socket
head bolt Tightening 6.4 16 31 58 87 130 181 253
[lbf•ft N•m]
torque (8.8) (21.6) (42.1) (78.5) (118) (176.5) (245.2) (343.2)
SST-09-08-008EN 78
2
79 SST-09-08-008EN
3
SST-09-08-008EN 80
4
81 SST-09-08-008EN
5
NOTES:
Main Unit Weight SH330
Data
Main Unit Weight

Divided Weight (standard specifications)
Weight lb (kg)
Symbol Component name 350X2
A Operating weight 79146 (35900)
B Upper component (including counterweight and turntable bearing) 33113 (5020)
C Counterweight 16314 (7400)
D Lower component (with grouser shoe) 28925 (13120)
E Main unit weight 64088 (29070)
F Attachments 14903 (6760)
G Boom (including cylinders) 8466 (3840)
H Arm (including cylinders and linkage) 3858 (1750)
* The weights displayed are approximate weights.
1 SST-11-01-012LX
1
Main Unit Weight
Stand Alone Part Weight Weight lb (kg)
Component name 350X2
1 Travel unit 1113 (505)
2 Take-up roller 363 (165)
3 Upper roller 97 (44)
4 Lower roller 137 (62)
5 Swing unit 1047 (475)
6 Turntable bearing 1301 (590)
7 Engine 1543 (700)
8 Radiator 366 (166)
9 Hydraulic pump 619 (281)
10 Fuel tank 531 (241)
11 Hydraulic oil tank 445 (202)
12 Control valve 425 (193)
13 Center joint 128 (58)
14 Boom 5842 (650)
Shoe Weight (per side) Weight lb (kg)

Component name 350X2
1 700 mm grouser shoe 5467 (2480)
2 800 mm grouser shoe 5798 (2630)
3 850 mm grouser shoe 6063 (2750)
Arm Weight Weight lb (kg)

Component name CX350B
1 Standard arm 2436 (1105)
2 Short arm 2359 (1070)
3 Ultra-short arm 2172 (985)
4 Long arm 3174 (1440)
SST-11-01-012LX 2
2
Main Unit Weight
Bucket Weight
Weight lb (kg)
Bucket capacity (m3) Weight lb (kg) L1 in (mm) L2 in (mm)

1 1.15 2306 (1046) 43 (1100) 49 (1233)
2 1.4 2577 (1169) 51 (1302) 56 (1435)
3 1.4 HD 3303 (1498) 52 (1310) 56 (1424)
4 1.6 2732 (1239) 57 (1442) 62 (1575)
5 1.8 2901 (1316) 63 (1600) 68 (1733)
Weight lb (kg)
Bucket capacity (m3) Weight lb (kg) L1 in (mm) L2 in (mm)

1 1.4 HD 3303 (1498) 52 (1310) 56 (1424)
2 1.6 HD 3468 (1573) 57 (1450) 62 (1564)
Bucket shape
Hoe bucket
3 SST-11-01-012LX
3
Interchangeability SH330
Data
Interchangeability
Interchangeability
1. Main Part Interchangeability Table (350X2)
Inter-
Position Part name 330LX change- 350X2 Remarks
ability
A Travel motor KSA10220 ←○→ KSA10220
Shoe (800 mm) KSA10480 ←○→ KSA10480
Lower roller KSA1068 ←○→ KSA1068
Upper roller KBA1141 ←○→ KBA1141
Lower-related
Take-up roller KSA1307 ←○→ KSA1307
Recoil spring KSA1310 ←○→ KSA1310
Drive sprocket KSA1061 ←○→ KSA1061
Center joint KSA1305 ←○→ KSA1305
B Counterweight KSB0861 ←×→ KSB12490 Shape change
Turntable bearing KSB10070 ←○→ KSB10070
C Swing motor KSC0247 ←×→ KSC10070 Manufacturer change
Swing reduction gear KSC0252 ←×→ KSC10080 Along with motor change
H Engine KSH1027 ←○→ KSH1027 Output change
Radiator/oil cooler KSH1028 ←○→ KSH1028
Air cleaner KSH0895 ←○→ KSH0895
Muffler KSH0948 ←○→ KSH0948
Fuel tank KSH0903 ←×→ KSH10270 Shape change
J Hydraulic pump KSJ2851 ←×→ KSJ12240 Specifications change
Control valve KSJ3106 ←×→ KSJ12250 Specifications change
Upper-related
Remote control valve KHJ12030
(operating machine) KHJ13290 ←○→ KHJ13290 Specifications change
Remote control valve

(travel)
KNJ2557 ←○→ KRJ5803 Manufacturer change
Hydraulic oil tank KSJ11130 ←×→ KSJ12260 Shape change

N Cab KHN10020 ←×→ KHN16482 Structure change
Operator's seat KHN3470 ←×→ KHN11470 Suspension change
Console box KHN3237 ←×→ KHN12211 Design alteration
R Computer KHR2688 ←×→ KHR10026 Specifications change
Monitor display KHR3825 ←×→ KHR10051 Design alteration
Air conditioner unit - - Only main unit interchangeable
V Boom KSV13810 ←×→ KSV15490 Line seating differs
Arm KSV1934 ←×→ KSV15530 Line seating differs
Bucket link KSV12210 ←○→ KSV12210
KSV1450 KSV1450
Attachment-
Arm link
KSV1451 ←○→ KSV1451
related KSV1925 KSV1925
Boom cylinder
KSV1926 ←○→ KSV1926
Arm cylinder KSV1927 ←○→ KSV1927
Bucket cylinder KSV1928 ←○→ KSV1928
Pin and bushing - ←○→ -
The parts numbers are for reference. When arranging for parts, check with the parts
manual.
4 SST-11-02-012LX
1
Attachment Installation Dimensions SH200
Data

Attachment Dimensions
Arm boss
1 Maximum retracted length stroke
Standard arm
Position
A B C D E F G H I J1 J2 K1 K2
Dimension 128 37 21 11 10 11 35 8 7 4 4 16 15
in (mm) (3240) (952) (535) (286) (265) (270) (895) (210) (170) (90) (90) (400) (375)
Bucket cylinder
Position
Maximum retracted length Stroke Cylinder top width
Dimension in
74 (1870) 48 (1210) 5 (120)
(mm)
Bucket link
Arm
Bucket Bucket link
Position link
L1 L2 M1 M2 N O P Q R S T U1 U2
Dimension in 24 25 16 16 4 21 28 27 16 5 15 4 4
(mm) (611) (632) (401) (401) (90) (535) (710) (675) (400) (121) (375) (90) (105)
5 SST-11-04-010EN
1
Bucket pin
Bucket pin
Bucket and arm Bucket and bucket link
Position
connection section connection section
V W X Y V W X Y
Dimension in 4 4 25 1 4 4 23 1
(mm) (90) (90) (638) (25) (90) (90) (591) (25)
SST-11-04-010EN 6
2
Paint Colors SH330
Data
Paint Colors
Paint Colors
Sumitomo No. MUNSELL No.
1 Red F-222 9.03R 3.5 / 12.5
2 Granite gray S-148 6.71Y 7.1 / 0.8
3 Black S-141 9.0YR 3.3 / 0.1
Paint location Color Sumitomo No. Paint part number

• The upper of machine
(except cabin, engine, muffler, exhaust pipe, house door,
engine hood. Frame duct. Front cover, tank cover, elec- KHN1444
Granite gray S-148
tric parts, plastics) (urethane)
• Rev. frame (front side)
KHN1444
• Attachment Red F-222 (urethane)
• Inside of house KHP1193
MS37 gray N-300
• Rev. frame (expect front and lower side) (one coat)
KHN1444
• Upper under cover MS37 gray N-300
(urethane)
Granite gray S-148
• Outside of cabin - (melamine)
Black S-141
• Inside of cabin Granite gray S-148 - (melamine)
• Flames of front window, cab hand rail Black S-141 - (melamine)
KHP1193
• Inside of cab, floor, bracket trim MS37 gray N-300
(one coat)
• The lower of machine KHN1189
Rev. frame (lower side) Black S-141
(acrylic paint)
Include of turntable bearing
KHN1189
• Rev. frame (under engine&inside) MS37 gray N-300
(acrylic paint)
KHP1193
• Lower under cover MS37 gray N-300
(one coat)
Ceramic Coating KHP1200
• Tail pipe Black
(KK) (baking)
KHP1200
• House door, side cover, top cover Granite gray S-148 (baking)
KHP1445
• Engine hood Black S-141
(baking)
• Hand rail Black S-141 Powder coating
• House cover, tool box Black S-141 KHP1445 (baked)
7 SST-11-05-012LX
1
Unit Conversion Ratio SH200

― (x) →
Weight unit SI unit
← (÷) ―
Kgf 9.807 N
lbf 4.448 N
Kgf •cm 0.0981 N•m
lbf•ft 1.356 N•m
lbf•in 0.113 N•m
Kgf/cm2 0.0981 MPa

atm 0.1013 MPa
lbf•in2 0.0069 MPa

mmHg 133.3 Pa
inHg 3386 Pa
Kgf •m/s 0.00981 kW
lbf•ft/s 0.00136 kW
PS 0.7355 kW
HP 0.746 kW
Kgf •m 9.807 J
Kcal 4186 J
Kgf•s/cm2 98067 Pa•s

cP 0.001 Pa•s
P 0.1 Pa•s
cSt 1 x 10-6 m2/s
St 0.0001 m2/s
8 RST-11-06-001EN
1
Contents SH330-5
Contents
Contents
Engine Section
Engine Oil ................................................................................................................... 1
Removal and Installation of Engine Oil Filter Element................................................ 4
Fuel Filter.................................................................................................................... 5
Charge Fuel Pump Filter ............................................................................................ 9
Removal and Installation of Fan Belt ........................................................................ 11
Removal and Installation of Air Conditioner Belt ...................................................... 14
Assembly and Disassembly

Removal and Installation of Engine Hood................................................................. 15
Removal and Installation of Engine Assembly.......................................................... 17
Removal and Installation of Alternator...................................................................... 30
Removal and Installation of Supply Pump ................................................................ 32
Removal and Installation of Common Rail................................................................ 42
Removal and Installation of Injector.......................................................................... 44
Removal and Installation of Muffler .......................................................................... 56
Removal and Installation of Turbo Charger .............................................................. 58
Removal and Installation of EGR Cooler and EGR Valve......................................... 62
Removal and Installation of Engine Sensors ............................................................ 66
Removal and Installation of Fuel Cooler................................................................... 68
Removal and Installation of Engine Inter Cooler ...................................................... 69

Removal and Installation of Compressor.................................................................... 1
Removal and Installation of Condenser...................................................................... 3
Removal and Installation of Receiver Dryer ............................................................... 6
Assembly and Disassembly of Unit ............................................................................ 8
Gas Filling Procedures

Work Precautions ..................................................................................................... 13
Work Procedures ...................................................................................................... 14
Filling Procedures ..................................................................................................... 16
Maintenance Section
Electrical Equipment Judgment Procedures
Electricity Measurement Procedures.......................................................................... 1
Maintenance Standards
Check Sheet ............................................................................................................... 3
1 SSM-00-00-004EN
1
Contents
Assembly and Disassembly Section
Track Shoe
Removal and Installation of Shoe Assembly .............................................................. 1
Removal and Installation of Shoe Plate...................................................................... 6
Travel Unit
Removal and Installation of Travel Motor.................................................................... 7
Assembly and Disassembly of Travel Motor ............................................................. 15
Take-up Roller
Removal and Installation of Take-up Roller .............................................................. 63
Assembly and Disassembly of Take-up Roller.......................................................... 66
Upper Roller
Removal and Installation of Upper Roller ................................................................. 76
Assembly and Disassembly of Upper Roller............................................................. 79
Lower Roller
Removal and Installation of Lower Roller ................................................................. 90
Assembly and Disassembly of Lower Roller............................................................. 93
Swing Unit
Removal and Installation of Swing Unit .................................................................. 103
Assembly and Disassembly of Swing Unit.............................................................. 108
Assembly and Disassembly of Swing Motor........................................................... 114
Assembly and Disassembly of Swing Reduction Gear........................................... 134
Planetary Carrier No.1 Assembly Diagram............................................................. 155
Planetary Carrier No.2 Assembly Diagram............................................................. 155
Center Joint
Removal and Installation of Center Joint ................................................................ 156
Counterweight
Removal and Installation of Counterweight ............................................................ 161
Hydraulic Pump
Removal and Installation of Hydraulic Pump .......................................................... 163
Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit............. 171
Pump Main Unit Maintenance Standards ............................................................... 179
Procedures for Assembly and Disassembly of Regulator....................................... 190
Remote Control Valve

Removal and Installation of Operation Remote Control Valve................................ 199
Procedures for Assembly and Disassembly of Operation Remote Control Valve... 208
Removal and Installation of Travel Remote Control Valve ...................................... 221
Procedures for Assembly and Disassembly of Travel Remote Control Valve ......... 224
SSM-00-00-004EN 2
2
Contents
Control Valve
Removal and Installation of Control Valve .............................................................. 244
Procedures for Assembly and Disassembly of Control Valve ................................. 250
Other Valves
Removal and Installation of 5 Stack Solenoid ........................................................ 276
Removal and Installation of Cushion Valve............................................................. 280
Assembly and Disassembly of Cushion Valve ........................................................ 284
Radiator and Oil Cooler

Removal and Installation of Radiator...................................................................... 291
Removal and Installation of Oil Cooler .........................................................................
Tank
Removal and Installation of Hydraulic Oil Tank....................................................... 304
Removal and Installation of Fuel Tank..........................................................................
Attachments
Removal and Installation of Bucket......................................................................... 316
Removal and Installation of Bucket Link .......................................................................
Removal and Installation of Bucket Cylinder ................................................................
Removal and Installation of Arm Cylinder.....................................................................
Removal and Installation of Arm...................................................................................
Removal and Installation of Boom Cylinder..................................................................
Removal and Installation of Boom ................................................................................
Removal and Installation of Arm HBCV........................................................................
Removal and Installation of Boom HBCV .....................................................................
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder ..............
Lights
Removal and Installation of Boom Light ................................................................. 376
Removal and Installation of Tool Box Light ...................................................................
Procedures for Removal and Installation of Cab Inner and Outer Parts
Removal and Installation of Cab Assembly ............................................................ 378
Removal and Installation of Operator's Seat ................................................................
Removal and Installation of Wiper ................................................................................
Removal and Installation of Wiper Controller ...............................................................
Removal and Installation of Wiper Motor......................................................................
Removal and Installation of Monitor .............................................................................
Removal and Installation of Cab Front Glass ...............................................................
Window Lock Adjustment Procedures ..........................................................................
3 SSM-00-00-004EN
3
Contents
Hydraulic Equipment-related Parts
Accumulator............................................................................................................ 399
Suction Filter.................................................................................................................
Return Filter..................................................................................................................
Pilot Filter......................................................................................................................
Other
Removal and Installation of Side Door ................................................................... 405
Draining Oil from Hydraulic Oil Tank.............................................................................
SSM-00-00-004EN 4
4
Procedures for Replacing Consumable Parts SH330-5
Engine

Engine Oil
Warning ・ Keep away from fire.
Caution ・ Be sure to stop the engine before beginning work.
Items to prepare
• Wrench (19 mm)
• Specialty plug (drainer plug)
• Waste oil can
• Rag
• Cleaning fluid
1. Engine Oil Draining
[1] Use a wrench (19 mm) to loosen the 2 bolts (1),
and then move the under cover (2) in the direc-
tion of the arrow.
[2] Remove the drain cap (3).

• The diagram on the right has the cover removed
so that the layout can be understood.
1 SSM-06-10-004EN
1
[3] Prepare the waste oil can (4).
[4] When the drainer plug (5) is screwed in, engine
oil will drain.
2. Engine Oil Filling

[1] Remove the drainer plug used for draining oil.
[2] Attach the drain cock cap removed when oil was
drained.
[3] Fill at the feed port (2) with new engine oil. Next,
wait about 15 min. for the oil to completely travel
down to the oil pan, remove the oil level gauge
(1), and wipe the tip of the gauge off with a rag
before fully inserting the gauge again.
[4] Gently pull out the oil level gauge (1). If oil is
adhered to the area between the "upper limit
(3)" and "lower limit (4)", this indicates the oil
volume is correct (5).
SSM-06-10-004EN 2
2
3. Inspection After Engine Oil and Element Replacement
Oil leak inspection
[1] Start the engine.
Slowly raise the rotation from idling rotation.
[2] Check the oil pan drain cock and each installation section of the oil filter for oil leaks.
Rechecking the engine oil volume
Stop the engine and wait 10 - 20 min. to recheck the engine oil volume. If the volume is low, fill up
with oil to the stipulated level.
The oil level will decrease due to engine oil entering the oil filter and oil path when the engine is
started.
Refill with oil if the oil level is low.
3 SSM-06-10-004EN
3
Removal and Installation of Engine Oil Filter Element
Items to prepare
• Filter wrench
• Rag
• Cleaning fluid
1. Removal of Oil Filter Element
[1] Use a filter wrench (1) to remove the oil filter
element (2).
2. Installation of Oil Filter Element

Use the following procedure to install a new car-
tridge.
[1] Apply a thin layer of engine oil to the cartridge
gasket.
[2] After the cartridge is screwed in and the gasket
is touching the seal surface, use the filter
wrench to tighten the cartridge 1 rotation.
SSM-06-10-004EN 4
4
Fuel Filter
・ When the fuel tank has been emptied, water drained from the fuel, the filter or element
Caution replaced, or other such work carried out, always bleed the air.
・ Be sure to stop the engine before beginning work.
Items to prepare
• Wrench (10 mm)
• Filter wrench
• Waste oil can
• Rag
• Cleaning fluid
[1] Tighten the cock (1).

[3] Use a wrench (10 mm) to loosen the air bleed
plug (3).
5 SSM-06-10-004EN
5
[5] Drain the fuel.
SSM-06-10-004EN 6
6
[6] Use the filter wrench (5) to remove the cover
(6).
[7] Replace the element (7) and O-ring (8).

The O-ring cannot be reused. Always replace it
with a new one.
[8] After replacing the filter, use the filter wrench (5)
to attach the cover (6).
7 SSM-06-10-004EN
7
plug (3).
[10] When the filter case priming pump (9) is turned
in the direction of the arrow, the knob pops out.
[11] Move the priming pump in and out until the fuel
filter is filled with fuel (more than 10 times).
When fuel appears inside the filter case, lightly
tighten the air bleed plug (3). Press the knob a
few times in this state.
Finally, hold the knob pressed in and slightly
loosen the air bleed plug.
Fuel oozes out from the hose (10) like bubbles.
[12] Repeat the operation in [11] until no more bub-
bles appear.
[13] Tighten the air bleed plug, and then turn the
knob and lock it.
SSM-06-10-004EN 8
8
Charge Fuel Pump Filter
Items to prepare
• Box wrench (19 mm)
• Wrench (10 mm)
• Pliers
• Cap
• Rag
• Cleaning fluid
[1] Use a box wrench (19 mm) to remove the 2

bolts (1) and washer (2), and then remove the
cover (3).
[2] Remove the connector (4).
9 SSM-06-10-004EN
9
[3] Use pliers or another tool to loosen the hose
bands (5), and then remove the hoses (6) and
(7).
• Use caps to cover the charge fuel pump filter
and hoses to prevent the entry of water, dust or
dirt.
[4] Use a wrench (10 mm) to remove the 2 installa-

tion bolts (8), and then turn the filter cover (9) to
the left and remove the element (10).
SSM-06-10-004EN 10
10
Removal and Installation of Fan Belt
Items to prepare
• Wrenches (14 mm, 17 mm)
• Rag
• Cleaning fluid
[1] Remove the air conditioner belt.

(For details, see "Removal and Installation of Air
Conditioner Belt".)
[2] Use a wrench (14 mm) to remove the 3 bolts
(1).
[3] Use a wrench (14 mm) to remove the bolt (3),

and then remove the bracket (4).
11 SSM-06-10-004EN
11
[5] Use a wrench (17 mm) to loosen the nut (5).
[6] Use a wrench (17 mm) to loosen the tension

bolt (6).
SSM-06-10-004EN 12
12
[7] Use a wrench (17 mm) to remove the nut (5),
and then remove the tension bolt (6).
[8] Pass the fan belt (7) over each of the fans and
remove it.
13 SSM-06-10-004EN
13
Removal and Installation of Air Conditioner Belt
Items to prepare
• Wrench (19 mm)
• Rag
• Cleaning fluid

(2), and then remove the under cover (1).
[2] Use a box wrench (14 mm) to loosen the nut (3).
[3] Use a box wrench (14 mm) to loosen the ten-

sion bolt (4), and then remove the air condi-
tioner belt (5).
SSM-06-10-004EN 14
14
Assembly and Disassembly SH330-5
Engine

Removal and Installation of Engine Hood
・ Do not perform this operation in strong wind.
Caution ・ Be sure to inspect the nylon sling and other lifting equipment before beginning work.
・ Do not stand or pass under the suspended load.
Items to prepare
• Wrench (19 mm)
• Nylon sling (with the required breaking load)
• Liftcrane (with the required lifting capacity)
[1] Open the engine hood, and then remove the
Matsuba pin (1) and the flat washer (2).
[2] Pull out the lock arm (4) from the engine hood
(3).
15 SSM-06-11-004EN
1
[3] After closing the engine hood, use a wrench (19

mm) to remove the 9 bolts (5) from the engine
hood.
[4] Wrap the nylon sling (6) around the engine

hood, and then use the liftcrane to lift the engine
hood (7).
SSM-06-11-004EN 16
2
Removal and Installation of Engine Assembly
・ Keep away from fire.
・ Be sure to release hydraulic pressure before beginning work.
Warning ・ The air conditioner circuit is filled with high-pressure gas, so there is the danger of gas spray-
ing out when loosening lines.
・ Do not use open flames and do not allow sparks near the battery.

Caution ・ Be sure to inspect the wire rope and other lifting equipment before beginning work.
Items to prepare
• Wrenches (7 mm, 8 mm, 13 mm, 14 mm, 17 mm, 19 mm, 36 mm)
• Shackle (with the required lifting capacity) × 2
• Wire ropes (with the required breaking load)
• Marking pen
• Cap
• Plug
• Waste oil can
• Rag
• Cleaning fluid
• Wood planks, etc.
[1] Drain the engine oil.

(For details, see "Engine Oil".)
[2] Drain the coolant from the radiator.
(For details, see "Removal and Installation of
Radiator".)
[3] Remove the engine hood.
Engine Hood".)
[4] Remove the hydraulic pump.
Hydraulic Pump".)
(1).
17 SSM-06-11-004EN
3
(2), and then remove the bracket (3).
[8] Use a wrench (19 mm) to remove the 4 bolts,

and then remove the fan guide rubber (5).
SSM-06-11-004EN 18
4
[9] Use a wrench (8 mm) to loosen the hose band
(6) on the radiator, and then remove the upper
hose (7).

(6) on the radiator, and then remove the lower
hose (8).
• Use caps to cover the radiator and hoses to pre-
vent the entry of water, dust or dirt.
• Before removing the radiator hoses, completely
drain the coolant.
[11] Use a wrench (13 mm) to loosen the line bolts

(9) in 2 locations, and then remove the 2 lines
(10) and (11) from the compressor.
• Always remove the low-pressure (suction side)
line (10) first.
• Attach caps or plugs to the compressor and
lines to prevent any entry of water, dust or dirt.
19 SSM-06-11-004EN
5
(12) on the inter cooler, and then remove the
hose (13).
• Use caps to cover the lines and hoses to pre-

• Use caution when removing as the parts are
heavy.

• Drain the engine oil before removing the engine
oil hose.
SSM-06-11-004EN 20
6
[15] Use a wrench (36 mm) to remove the 2 engine
oil remote hoses (17).
• Mark the engine and hoses so that the connec-
tors match at the time of assembly.
• Attach caps or plugs to the engine and hoses to
prevent any entry of water, dust or dirt.
• Clean the engine and hoses by spraying them
with a parts cleaner to prevent scratches and
prevent dirt from accumulating on the connec-
tors.

and then remove the battery cable (19) on the
negative side.
• When removing the terminal and harness,
secure them so that they do not interfere with
the frame.
Also, cover with a rubber cap to protect against
sparks.

21 SSM-06-11-004EN
7
[18] Use a wrench (8 mm) to remove the 2 nuts (22),
and then remove the wiring (23) from the starter
motor.
[19] Remove the hose band (24), and then remove

the fuel hose (25).
[20] Remove the hose band (26), and then remove

the fuel hose (27).
SSM-06-11-004EN 22
8
(28), and then remove the box cover (29).
[22] Remove the connectors (30) in the box.

• Wrap the removed connectors in plastic after
tying them together to prevent any entry of
water, dust or dirt.

(31), and then remove the heater hose (32).
23 SSM-06-11-004EN
9
(33), and then remove the heater hose (34).

(35), and then remove the radiator hose (36).
vent any entry of water, dust or dirt.

(37), and then remove the air hose (38).
SSM-06-11-004EN 24
10
(39), and then remove the air hose (40).
[28] Remove the connectors (41) from the alternator.
[29] Remove the cap (42), use the wrench (10 mm)
to remove the nut (44), and then remove the
alternator wiring (43).
25 SSM-06-11-004EN
11
[30] Install the 2 shackles (45), and then use the
wire rope (46) and liftcrane to secure the engine
main unit.

bolts (47) from the mount.
SSM-06-11-004EN 26
12
[32] Use the wire rope (48) and liftcrane to lift the
engine main unit.
[33] Thoroughly check that the location is safe
before lowering the engine on wood planks, etc.
[34] To install the engine, perform the reverse of the removal procedure.
After installing the engine, resupply coolant and engine oil, perform fuel line air bleeding, and per-
form filling for the air conditioner gas.
For details, see the individual explanations for each procedure.
[35] Run the engine at no-load idling and check for any water or oil leaks.
[36] Attach the hydraulic pump, covers, and counterweight.
For details, see the individual explanations for each procedure.
27 SSM-06-11-004EN
13
Removal and Installation of Starter Motor
Warning ・ Do not use open flames and do not allow sparks near the battery.
Items to prepare
• Wrenches (8 mm, 14 mm, 17 mm, 19 mm)
• Rag
• Cleaning fluid

negative side.
the frame.
sparks.

SSM-06-11-004EN 28
14
and then remove the wiring (6).

and then remove the wiring on the ground side
(8).

and then remove the starter motor (10).
[6] To install, perform the reverse of the removal

procedure.
Mount nut tightening torque: 82.4 N•m
29 SSM-06-11-004EN
15
Removal and Installation of Alternator
Warning ・ Do not use open flames and do not allow sparks near the battery.
Items to prepare
• Wrenches (10 mm, 17 mm, 20 mm)
• Rag
• Cleaning fluid
[1] Remove the fan belt.

Fan Belt".)
negative side.
the frame.
sparks.
SSM-06-11-004EN 30
16
[4] Remove the cap (5), use the wrench (10 mm) to
remove the nut (6), and then remove the wiring
(4).

and then remove the alternator (8).
[6] To install, perform the reverse of the removal

procedure.
Adjust the fan belt according to the tension
adjustment procedures.
31 SSM-06-11-004EN
17
Removal and Installation of Supply Pump
Warning ・ Be sure to release hydraulic pressure before beginning work.
Each part of the fuel system is a high-precision part.

Caution Damage may result if foreign matter, etc. enters the fuel system, so use extreme caution when
handling these parts.
When high-pressure lines in the fuel system are removed, replace them with new lines.
Replace gaskets or O-rings with new ones.
Warning Fuel leaks may cause fires. Thoroughly wipe off fuel after work is completed, and carefully
check for any leaks after starting the engine.
Items to prepare
• Wrenches (10 mm, 14 mm, 17 mm, 19 mm, 22 mm)
• Gear puller
• Cap
• Plug
• Rag
• Cleaning fluid
1. Removal of Supply Pump
and then remove the hole cover (2).
[2] Turn the crankshaft in the correct rotation direc-

tion and align the reference mark of the 1st or
4th cylinder with the compression top dead cen-
ter position.
SSM-06-11-004EN 32
18
[3] Use a wrench (19 mm) to remove the sleeve nut
(3), and then remove the injection pipe (4).
• Use caps and plugs to cover the lines to prevent
any entry of water, dust or dirt.
• Clean the line by spraying with a parts cleaner
to prevent scratches and prevent dirt from accu-
mulating on the connectors.
[4] Remove the fuel hose (5).

[5] Use a wrench (14 mm) to remove the 3 eyebolts

(6), and then remove the leak-off pipe (7).
33 SSM-06-11-004EN
19
[6] Remove the connectors (8) and (9).
[7] Use a wrench (22 mm) to remove the eyebolt
(10) on the fuel pipe (11).

[9] Use a wrench (17 mm) to remove the bolts (13)
and (14).
[10] Remove the supply pump assembly (15).
• Use caps and plugs to prevent any entry of
• Clean the assembly by spraying it with a parts
cleaner to prevent scratches and prevent dirt
from accumulating on the connectors.
[11] Remove the nut securing the supply pump gear

(18) and use the gear puller (17) to remove the
gear from the supply pump assembly (19).
SSM-06-11-004EN 34
20
[12] Remove the 3 bolts (21), and then remove the
supply pump (22) from the bracket (20). Also
remove the O-ring (23) at the same time.
35 SSM-06-11-004EN
21
2. Installation of Supply Pump
[1] Install the O-ring (2) on the supply pump (1).
Install the pump on the bracket (3) and tighten
the 3 bolts (4) to the specified torque.
Tightening torque: 19 N•m
[2] Align the key of the supply pump shaft with the
gear (5), install the gear, and tighten the nut (6)
to the specified torque.
SSM-06-11-004EN 36
22
[3] A reference mark circle has been stamped onto
the end face surface of the gear.
Paint the upper part of the gear tooth just above
the stamped "0" mark white.
This paint is very important for checking the cor-
rect position.
37 SSM-06-11-004EN
23
[4] Install the O-ring (7) on the supply pump
assembly (8).
Align the supply pump gear position with the ref-
erence mark (0 mark) on the gear end face sur-
face and the slit on the pump bracket side.
Install the supply pump assembly on the engine
so that the alignment position is correct.
Temporarily tighten the bolts (10) and (11) and
the nut (9).
SSM-06-11-004EN 38
24
[5] When looking from the plug hole, check that the
gear tooth with the white paint reference mark
(0 mark) and white paint is at the center of the
hole and in the position shown in the diagram.
If alignment is not correct, adjust the gear posi-
tion again and install the pump on it.
Temporarily tighten bolts (10) and (11) and nut
(9) to the specified torque.
Tightening torque
Nut: 50 N•m
Bolt: 76 N•m
[6] Install the hole cover (13) in the plug hole.

Tighten the bolt (12) to the specified torque.
39 SSM-06-11-004EN
25
[7] Connect the connectors (14) and (15).
Install the line (17) with the eyebolt (16).
[8] Install the leak-off pipe (18) with the 3 eyebolts

(19).
• Be careful not to allow entry of any water, dust
or dirt.
Always replace seals.
SSM-06-11-004EN 40
26
[9] Install the fuel hose (20).
or dirt.
[10] Install the injection pipe (22). This injection pipe

cannot be reused, so always replace it with a
new one.
Tighten the sleeve nut (21).
or dirt.
41 SSM-06-11-004EN
27
Removal and Installation of Common Rail
Items to prepare
• Marking pen
• Cap
• Plug
• Rag
• Cleaning fluid
See Removal and Installation of Supply Pump for procedures for removal and installation of the oil level
gauge pipe, intake hose, manifold, etc.
[2] Use a wrench (14 mm) to remove the 3 eyebolts

(2) and (3) on the leak-off pipe (4), and then
remove the leak-off pipe.
SSM-06-11-004EN 42
28
and then remove the fuel pipe (5).
[4] Use a wrench (17 mm) to remove each sleeve
nut (6) in the 6 locations.
• Replace the removed line in the same way as
the common rail.

and nuts (9).
[6] Remove the common rail (10).
[7] To install the common rail, perform the reverse of the removal procedure.
High-pressure lines that have been removed cannot be reused.
Always replace them with new ones.
43 SSM-06-11-004EN
29
Removal and Installation of Injector
Warning Do not use open flames and do not allow sparks near the battery.
Warning Injector wiring is high voltage wiring, so make sure to remove the battery.
Caution ・ Be careful not to drop any removed parts inside the engine.
Items to prepare
• Pliers
• Marking pen
• Torx wrench (T40)
• Cap
• Plug
• Waste oil can
• Rag
• Cleaning fluid
1. Removal of Injector
Removal and installation of the No. 1 injector is explained here as a representative example. Use
the same procedure for other cylinder injectors.
Be extremely careful when handling injectors. The nozzle tips are especially delicate. Hitting the
nozzles or wiping them with a rag may cause the hole to clog. Also, injector wiring use high voltage,
so make sure to remove the battery terminals before beginning work.
High-pressure lines, seals, and packing that have been removed cannot be reused, so always
replace them with new parts.
negative side.
the frame.
sparks.
SSM-06-11-004EN 44
30
(3), and then remove the step (4).
[3] Use pliers to loosen the hose band, and then

remove the blow-by hose (5).
• Use caps and plugs to cover the hoses and
[4] Remove the connectors (6) in the 2 locations.
45 SSM-06-11-004EN
31
(7) on the cylinder head cover (8), and then
remove the cylinder head cover.
SSM-06-11-004EN 46
32
[7] Use a wrench (7 mm) to remove the 2 nuts (11)
at each of the 6 injector terminal locations.
[8] Use a wrench (14 mm) to loosen the 4 bolts
(10), and then remove the harness bracket (12).
• When removing the nuts, loosen them equally a
little bit a time to simultaneously remove them.
47 SSM-06-11-004EN
33
[9] Use wrenches (12 mm, 17 mm) to remove the 7
bolts (13) and (14) and the 7 gaskets (15) and
(16), and then remove the nozzle leak-off pipe
(17).
[10] Use a wrench (10 mm) to remove the bolt (18)

on the line clamp (21).
(19) of the injector-side line.
(20) of the common rail-side line.
SSM-06-11-004EN 48
34
[13] Use a Torx wrench (T40) to remove the bolt (22)
on the injector clamp (24).
[14] Remove the injector (23).
[15] Use the injector remover (26) when it is difficult

to remove the injector (27).
Install the injector remover on the injector line
connection section. Also connect the sliding
hammer (25) and then remove the injector.
1) Sliding hammer
Isuzu part No.: 5-8840-0019-0
2) Injector remover
Isuzu part No.: 5-8840-2826
49 SSM-06-11-004EN
35
2. Installation of Injector
[1] Record the "QR code" (2) that appears on the
top of the QR plate (1) of the replacement injec-
tor (3).
The "QR code" is different for each injector, so
match the cylinder to be installed with the injec-
tor and record the code.
[2] Always replace the gasket (5) and O-ring (7).

Apply Molybdenum to the threaded section of
the bolt (4) on the injector clamp (6) and seating
surface.
Install the injector (3) on the cylinder head. As
shown in the diagram, insert the injector by
pressing it in with the clamp. Temporarily tighten
the bolt on the injector clamp.
SSM-06-11-004EN 50
36
[3] Apply a small amount of engine oil to the out-
side surface of the injector-side sleeve nut (10).
Install the line.
Carefully tighten each of the sleeve nuts (9) and
(10) until the line is touching the common rail
and injector.
Tighten the bolt (8) on the line clamp (11) to the
specified torque.
Fully tighten the bolt (4) on the injector clamp to
the specified torque.
Tighten the line sleeve nuts to the specified
torque.
51 SSM-06-11-004EN
37
[4] Install the nozzle leak-off pipe (16) with the bolts
(12) and (13).
Replace the gaskets (14) and (15).
Tighten each of the lines to the specified torque.
SSM-06-11-004EN 52
38
[5] Secure the harness bracket (19) with the bolts
(17).
Secure the bolts in sequence from the inside to
the outside.
[6] Install the injector terminal nuts (18) on each
injector.
Tighten to the specified torque.
Be careful not to tighten the nuts too much.
Tightening all at once with a ratchet wrench,
etc. may cause damage to the terminal stud.
[7] Connect the injector harness connector (20).
53 SSM-06-11-004EN
39
[8] Install the head gasket (24) on the cylinder head
cover (23) and tighten with each of the bolts
(21) and nuts (22).
Tighten in the order shown in the diagram.
Specified torque: 13 N•m
[9] Connect the connectors (25).
[10] Install the blow-by hose (26).
SSM-06-11-004EN 54
40
[11] Install the negative-side battery cable (28) ter-
minal.
Be careful of shorts with the terminal and har-
ness.
27 Bolt
[12] When replacing an injector (3) with a new one, make sure to enter the QR code of the replaced
injector into the ECM.
[13] See the Service Text for this procedure.
55 SSM-06-11-004EN
41
Removal and Installation of Muffler
・ The engine is extremely hot just after stopping. Wait for it to sufficiently cool before beginning
Warning work.
Items to prepare
• Wrench (14 mm)
• Cap
• Rag
• Cleaning fluid
1. Removal of Muffler
[1] Use a wrench (14 mm) to loosen the nut (2) to
remove the 2 bolts (1), remove the seal clamp
from the exhaust pipe, and then remove the line.
• Use caps to cover the lines to prevent any entry
of water, dust or dirt.
[2] Use a wrench (14 mm) to remove the 2 nuts (3).
SSM-06-11-004EN 56
42
[3] Remove the U-bolts (4), and then remove the
muffler (5).
2. Installation of Muffler
Perform the reverse of the removal procedure.
After installation, check for any leaks or vibration.
57 SSM-06-11-004EN
43
Removal and Installation of Turbo Charger
The engine is extremely hot just after stopping.
Warning Wait for them to sufficiently cool before beginning work.
Items to prepare
• Cap
• Plug
• Rag
• Cleaning fluid
1. Removal of Turbo Charger
The engine oil line and coolant line will be removed, so either drain the engine oil and coolant
beforehand or use caps on the ends of the lines to prevent leaking.
(1), and then remove the intake hose (2).
• Use caps to cover the turbo charger and hoses
to prevent any entry of water, dust or dirt.

(3), and then remove the hose (4).
• Use caps to cover the turbo charger and hoses
SSM-06-11-004EN 58
44
[3] Use a wrench (14 mm) to remove the eyebolt
(5), and then remove the oil feed pipe (6).
• Use caps and plugs to cover the turbo charger
and oil feed pipe to prevent any entry of water,
dust or dirt.
• When removing the oil feed pipe, take care not
to damage or lose the packing.

(7), and then remove the oil return pipe (8).
Use caps and plugs to cover the turbo charger
and oil return pipe to prevent any entry of water,
dust or dirt.

and then remove the turbo charger (10).
59 SSM-06-11-004EN
45
[6] Use a wrench (13 mm) to remove the 8 nuts
(11), and then remove the line (12) from the
turbo charger main unit.
SSM-06-11-004EN 60
46
2. Installation of Turbo Charger
To install, perform the reverse of the removal procedure. During installation, replace each gasket
and the packing with new ones.
Make sure to check the engine oil and coolant levels and resupply as necessary.
Each of the installation tightening torque values are indicated below.
Check carefully for exhaust leaks, water leaks, and oil leaks.
1 Oil feed pipe -

2 Exhaust manifold -
3 Turbo charger assembly 52 N•m
4 Exhaust adapter 32.4 N•m
5 Oil return pipe 17.6 N•m
61 SSM-06-11-004EN
47
Removal and Installation of EGR Cooler and EGR Valve
The engine is extremely hot just after stopping.
Warning Wait for them to sufficiently cool before beginning work.

Caution ・ Be sure to drain coolant before beginning work.
Items to prepare
• Wrench (12 mm)
• Pliers
• Cap
• Plug
• Rag
• Cleaning fluid
1. Removal of EGR Cooler and EGR Valve
(1).
SSM-06-11-004EN 62
48
(2).

and (4).
63 SSM-06-11-004EN
49
[4] Use pliers to loosen the hose band (5) to
remove the hose (6), and then remove the EGR
cooler (7).
• Use caps and plugs to cover the lines and
hoses to prevent any entry of water, dust or dirt.
[5] Use a wrench (12 mm) to remove the nuts (9),

and then separate the manifold (8) and the EGR
cooler (7).

Use a wrench (12 mm) to remove the bolts (11),
and then remove the EGR valve (12).
SSM-06-11-004EN 64
50
2. Installation of EGR Cooler and EGR Valve
To install, perform the reverse of the removal procedure. During installation, replace gaskets with
new ones.
Check that there is sufficient coolant and resupply as necessary. Each of the installation tightening
torque values are indicated below.
Check carefully for exhaust leaks and water leaks.
65 SSM-06-11-004EN
51
Removal and Installation of Engine Sensors
Sensor name Bolt or nut Tool size Remarks
1 Engine coolant temperature sensor Lock nut × 1 Wrench (19 mm)
Bolt × 2 Wrench (10 mm)
2 Boost pressure sensor
Clip × 1 Pliers
Lock nut × 1 Wrench (22 mm)
3 Overheat switch
Wiring fastener nut Wrench (7 mm)
4 Common rail pressure sensor Lock nut × 1 Wrench (27 mm)
Installation screw
5 EGR valve DC motor Phillips screwdriver
×4
Tightening torque:
6 Boost temperature sensor Lock nut Wrench (19 mm)
82.4 N•m
7 Starter motor Installation nut × 2 Wrench (17 mm)
8 Engine hydraulic pressure sensor Lock nut × 1 Wrench (27 mm)
Hexagon wrench
9 Suction control valve Installation bolt × 2
(5 mm)
10 Fuel temperature sensor Lock nut × 1 Wrench (19 mm)
11 Cam position sensor Installation bolt × 1 Wrench (10 mm)
12 Crank position sensor Installation bolt Wrench (10 mm)
SSM-06-11-004EN 66
52
67 SSM-06-11-004EN
53
Removal and Installation of Fuel Cooler
Caution ・ As the fuel hose will be removed, strictly prohibit open flames.
Items to prepare
• Wrench (12 mm)
• Screwdriver
• Pliers
• Marking pen
• Cap
• Plug
• Rag
• Cleaning fluid
• Drip pan
1. Removal of Fuel Cooler
[1] Mark the fuel cooler (5) and hoses (1) and (2)
so that the connectors match at the time of
assembly.
• Use pliers to loosen the hose bands (3) and (4),
and then remove the hoses.
• Fuel will spill out, so place a drip pan directly
below the area.
• Attach caps or plugs to the fuel cooler and

(6), and then remove the fuel cooler (5).
2. Installation of Fuel Cooler

[1] After connecting the hoses, carefully check for any fuel leaks.
SSM-06-11-004EN 68
54
Removal and Installation of Engine Inter Cooler
Caution ・ As the fuel hose will be removed, strictly prohibit open flames.
Items to prepare
• Flathead screwdriver
• Wire cutters
• Cap
• Rag
• Cleaning fluid
1. Removal of Inter Cooler
[1] Remove the fuel cooler.
Fuel Cooler".)
(1), and then remove the bracket (2) from the
fuel cooler.
[3] Use a wrench (8 mm) or flathead screwdriver to

loosen the hose bands (3) in the 2 locations,
and then remove the 2 hoses (4) and (5).
• Use caps to cover the inter cooler and hoses to
prevent the entry of water, dust or dirt.
69 SSM-06-11-004EN
55
(6), and then remove the inter cooler (7).
2. Installation of Inter Cooler

Check for any air leaks.
SSM-06-11-004EN 70
56
Assembly and Disassembly SH330-5
Air Conditioner

Removal and Installation of Compressor
・ Be careful when loosening the lines. The air conditioner circuit is filled with high-pressure
Warning gas, so there is the danger of gas splaying out.

Caution ・ When removing and installing the compressor, check the compressor oil quantity.
Items to prepare
• Wrench (13 mm)
• Rag
• Cleaning fluid
1. Removal of compressor
[2] Use a box wrench (13 mm) to loosen the bolts

(2) on the lines in the 2 locations, and then
remove the 2 lines (3) and (4).
• Always remove the low-pressure side line (3)
first.
• Attach caps or plugs to the compressor and
1 SSM-07-07-004EN
1
(5), and then remove the compressor (6).
2. Installation of compressor
[1] The installation procedure is the reverse of the removal procedure.
Compressor installation bolt tightening torque: 19.6 - 29.4 N•m
[2] Check the compressor oil quantity.
The compressor contains 135 cc of oil.
The oil quantity being low will cause compressor seizing and a reduction in durability. The oil
quantity being high will cause a reduction in cooling capabilities.
Make sure to check the oil quantity and adjust if needed.
Measure the oil quantity of the removed compressor. Only this oil quantity is necessary, so sub-
tract this quantity from 135 cc to determine the amount by which the oil quantity of the new com-
pressor should be reduced.
Example)
If the remaining oil quantity of the removed compressor is 30 cc:
Remove 135 cc - 30 cc = 105 cc from the new compressor to be installed.
Resupply oil: SP-10 or SP-20 (P.A.G. oil)
[3] Perform air conditioner gas charging.
For details, see "Gas Filling Procedures".
SSM-07-07-004EN 2
2
Removal and Installation of Condenser
Caution ・ When removing and installing the condenser, resupply and check the compressor oil quantity.
Items to prepare
• Cap
• Plug
• Rag
• Cleaning fluid
1. Removal of condenser
[1] After opening the engine hood (1), use a

wrench (19 mm) to remove the top covers (2)
and (3).
5)

and then remove the center bar (5).
3 SSM-07-07-004EN
3
[4] Use a wrench (17 mm) to press the lower line
on the condenser side (7), and then use a
wrench (19 mm) to loosen and remove the
sleeve nut of the low-pressure side line (6).
• Always remove the low-pressure side line first.
• Attach caps or plugs to the condenser and line
[5] Use a wrench (22 mm) to press the upper line

on the condenser side (9), and then use a
wrench (22 mm) to loosen and remove the
sleeve nut of the high-pressure side line (8).
• The "H" cap indicates the high-pressure side
line.
• Attach caps or plugs to the condenser and line

(10), and then remove the condenser (11).
SSM-07-07-004EN 4
4
2. Installation of condenser
[1] To install, perform the reverse of the removal procedure.
High-pressure side line tightening torque: 19.6 - 24.5 N•m, Low-pressure side line tightening
torque: 11.8 - 14.7 N•m
[2] Make sure to resupply and check the compressor oil quantity.
Resupply quantity: 40 cc
For details, see "Procedures for Gas Filling".
5 SSM-07-07-004EN
5
Removal and Installation of Receiver Dryer
Caution ・ When replacing the receiver dryer, resupply and check the compressor oil quantity.
Items to prepare
• Cap
• Plug
• Rag
• Cleaning fluid
1. Removal of receiver dryer
(1), and then remove the stay (2).
(1), and then remove the top cover (3).
SSM-07-07-004EN 6
6
[4] Use a wrench (10 mm) to remove the 2 bolts (5)
from the line (6).
• Attach caps or plugs to the receiver dryer and
line to prevent any entry of water, dust or dirt.
• Clean the receiver dryer and line by spraying
them with a parts cleaner to prevent scratches
and prevent dirt from accumulating on the
connectors.
[5] Use a wrench (10 mm) to remove the 1 bolt (7),

and then remove the receiver dryer (8).
2. Installation of receiver dryer

[1] To install, perform the reverse of the removal procedure.
Receiver dryer installation bolt tightening torque: 19.6 - 24.5 N•m
[2] Check the compressor oil quantity.
Resupply quantity: 20 cc
For details, see "Procedures for Gas Filling".
7 SSM-07-07-004EN
7
Assembly and Disassembly of Unit
Caution ・ When replacing the evaporator, resupply and check the compressor oil quantity.
1. Removal of blower unit

[1] Remove the connectors connected
to the refresh/recirculate motor
actuator, blower motor, blower con-
troller, and inside air sensor, and
also the harness installed on the
blower case.
[2] Remove the inside air filter (8) from

the intake duct (12), and remove the
3 T4 × 14 (T1) Phillips screws (16)
to remove the intake duct.
[3] Remove the filter clog sensor (11)
along with the nylon clip (17) from
the intake case (13).
[4] Remove the 4 T5 × 14 (T1) Phillips
screws (14) and remove the intake
case (13).
[5] Remove the 3 T5 × 14 (T1) Phillips
screws (18) and separate the blower
case (10) and air conditioner unit.
1 Evaporator sensor connector

2 Blower controller connector
3 Blower motor connector
4 Harness
5 Filter clog sensor
6 Refresh/recirculate motor actuator connector
7 Inside air sensor connector
9 Unit
15 Inside air sensor
SSM-07-07-004EN 8
8
2. Replacement of blower motor
[1] Remove the coolant hose (4) connecting the
blower motor (5) and the blower case (6).
[2] Remove the 3 N5 × 16 (W) Phillips screws (3)
installed at the bottom of the blower unit case
and remove the blower motor (5).
removal procedure.
Do not remove the fan from the
Caution blower motor.
3. Replacement of blower controller
[1] Remove the 2 T4 × 14 (T1) Phillips screws (2)
installed at the bottom of the blower case and
remove the blower controller (1).
[2] The installation procedure for the new blower
controller (1) is the reverse of the removal pro-
cedure.
Never disassemble the blower con-
Caution troller.
4. Removal of heater core
[1] Drain the coolant.
[2] Remove the 1 N5 × 16 (T2) Phillips screw (2),
and remove the pipe clamp (3) fixing the heater
core (4) to the unit (1) to remove the heater core
from the unit.
removal procedure.
9 SSM-07-07-004EN
9
5. Removal of air conditioner unit case front, rear and bottom
[1] Remove the mode motor actuator (4) and evap-
orator sensor connector.
[2] Remove the mode rod (1) from the rod holder
installed on the mode motor actuator (4) lever
MAL 1 (3).
[3] Remove the 3 N4 × 30 (T1) Phillips screws (6)
and remove the mode motor actuator (4)
installed on the bottom (5) and rear (7) of the
unit case.
[4] Remove the 11 N5 × 16 (T2) Phillips screws (8)

and remove the bottom (5) and front (12) of the
unit case.
While being careful not to let the evaporator
sensor cord get caught by the case, pull the
front of the unit case upwards to remove it.
At this time, perform work with the
Caution heater core removed from the unit
case.
2 Rod holder
9 Evaporator sensor
10 Expansion valve
11 Evaporator
SSM-07-07-004EN 10
10
6. Replacement of evaporator and expansion valve
[1] Remove the evaporator assembly from the bot-
tom of the case with the case heat insulating
material and expansion valve attached to the
evaporator.
[2] After removing the case heat insulating material
from the top and bottom of the evaporator
assembly, remove the evaporator sensor (1) as
one piece with the sensor holder.
[3] Use a hexagon wrench (4 mm) to remove the 2
M5 × 40 hexagon socket head bolts (2), and
remove the expansion valve (3) from the evapo-
rator (5).
[4] Install O-rings (4) on the new evaporator (5) (1
NF O-ring 5/8 and 1 NF O-ring 1/2).
(Tightening torque 6.9 N•m)
Be careful of the O-rings getting
Caution caught, etc. when installing the
expansion valve.
7. Installation of evaporator sensor

[1] Make sure to install the evaporator sensor (1) in
the original position of the evaporator (2), as in
the diagram.
Be careful that the sensor cord does
Caution not get squeezed in the case when
the case is assembled.
11 SSM-07-07-004EN
11
8. Replacement of motor actuator
[1] Replacement of mode motor actuator
Remove the connector connected to the motor
actuator (4).
Remove the mode rod (1) connecting the motor
actuator and mode cam from the rod holder (2).
Remove the 3 N4 × 30 (T1) Phillips screws (6)
that are used to install the motor actuator,
remove the motor actuator from the unit with the
rod holder and lever MAL 1 (3) attached to the
actuator, remove the rod holder and lever MAL 1
from the motor actuator, and then install the
new motor actuator. The installation procedure
is the reverse of the removal procedure.
[2] Replacement of air mix motor actuator
actuator (11).
Remove the AM rod (9) connecting the motor
actuator and lever AM (8) from the rod holder
(10).
that are used to install the motor actuator,
rod holder and lever MAL 1 (12) attached to the
actuator, remove the rod holder and lever MAL 1
from the motor actuator, and then install the
5 Unit case bottom
7 Unit case rear
[3] Replacement of refresh/recirculate motor actua-

tor
actuator (15).
that are used to install the motor actuator and
lever MAL 2 (14) attached. Remove the lever
MAL 2 from the motor actuator and install the
SSM-07-07-004EN 12
12
Gas Filling Procedures SH330-5
Air Conditioner

Work Precautions
・ Refrigerant gas filling involves handling dangerous high-pressure gas, so make sure that a
experienced and qualified worker with the procedure performs this operation.
・ Always wear protective eyewear.
Warning ・ Gas entering the eyes may cause blindness.
・ Refrigerant in the liquid state is very cold (about -26 ℃ , so be very careful during handling.
・ Refrigerant coming in contact with skin may cause frostbite.
Always use R134a refrigerant.

• Storage
Keep service cans (hereinafter, cans) with refrigerant in them at 40 ℃ or below.
The insides of the cans are highly pressurized and filled with refrigerant, so if the temperature rises
there is the danger of internal pressure rising sharply and an explosion occurring.
Never store in direct sunlight, in a closed vehicle, or near open flames.
Be careful not to drop cans or have them collide with other objects.
• Filling operation
When cans are heated in order to fill them with refrigerant, make sure that the service can valve and
gauge manifold low-pressure valve are open and heat with water at 40 ℃ or below.
Direct heating or heating to 40 ℃ or higher may cause explosions, so use caution.
If refrigerant filling is done after the engine is started, never open the gauge manifold high-pressure
valve.
This is very dangerous, as the high-pressure gas will flow in the opposite direction and may cause a
can or charging hose explosion.
Be careful not to allow the entry of dust or dirt into the air conditioner circuit.
Air, moisture and dirt are very bad for the cooling cycle.
Perform work quickly and accurately, and be especially careful to prevent the entry of foreign matter.
Be careful not to overfill with gas.
13 SSM-07-08-004EN
1
Work Procedures
1. Air conditioner refrigerant filling is divided into the "vacuum operation" and "gas filling oper-
ation".
[1] The "vacuum operation" consists of eliminating moisture in the air conditioner circuit.
If there is any moisture left inside the air conditioner circuit, various problems may occur during
operation such as freezing in the small hole of the expansion valve causing the circuit to clog and
rust developing in the circuit.
For this reason, perform vacuuming before filling the circuit with refrigerant. This operation con-
sists of eliminating moisture inside the circuit through boiling and evaporation.
[2] The "gas filling operation" consists of filling the circuit with refrigerant after the vacuum operation.
Gas filling does not only affect the cooling capabilities of the air conditioner, it also affects the life
of the parts which make up the circuit.
Severely overfilling the circuit will cause pressure inside the circuit to be abnormally high, and
this will cause reductions in the cooling ability of the air conditioner.
Additionally, if pressure is extremely low, the circulation of lubricating oil within the compressor
will be poor and this will cause seizing with sliding parts of the compressor.
Because the gas filling operation itself involves handling high-pressure gas, performing the oper-
ation using an incorrect procedure is very dangerous.
Follow the operation and observe all precautions indicated in this text to correctly perform refrig-
erant filling.
2. Operation chart
SSM-07-08-004EN 14
2
3. Tools
No. Part name Q'ty Shape Application
1 Gauge manifold 1
Red: high-pressure side

2 Charging hose 3 Blue: low-pressure side
Yellow: vacuum pump side
3 Quick joint 1
4 Quick joint 1 Low-pressure side
5 T joint 1 For service can valve
6 Service can valve 2 For service can
7 Vacuum pump adapter 1 For vacuum pump
15 SSM-07-08-004EN
3
Filling Procedures
・ Because gauge manifold specifications such as hose color are different depending on the
Caution manufacturer, read the Operator's Manual for the gauge manifold to be used for details.
1. Charging hose connection positions
1 High-pressure side (DIS) service valve

2 Low-pressure side (SUC) service valve
3 Air conditioner compressor
4 Condenser
5 Receiver dryer
6 Air conditioner unit
SSM-07-08-004EN 16
4
2. Gauge manifold connection
[1] Close the high-pressure valve (HI) (8) and low-pressure valve (LO) (7) of the gauge manifold (9).
[2] Connect the charging hoses (red and blue) to the service valve.
Red hose (10): Gauge manifold high-pressure side (HI) → compressor high-pressure side (DIS)
service valve (1)
Blue hose (11): Gauge manifold low-pressure side (LO) → compressor low-pressure side (SUC)
service valve (2)
Push in the connections for the high-pressure and low-pressure sides until a "click" is heard to
make sure they are secure and in the correct position.
[3] Connect the charging hose (yellow) (3) to the vacuum pump (4).
5 Low-pressure gauge
6 High-pressure gauge
17 SSM-07-08-004EN
5
3. Vacuuming
[1] Open the high-pressure valve (HI) (8) and low-
pressure valve (LO) (7) of the gauge manifold
(9).
[2] Turn the vacuum pump (4) switch on and vac-
uum for at least 30 min.
[3] After the prescribed vacuuming time has
elapsed (degree of vacuuming achieved: -750
mmHg or less), close the gauge manifold (9)
high-pressure valve (8) and low-pressure valve
(7).
[4] Next, turn the vacuum pump (4) switch off.
[5] Perform a check of air-tightness.
Let the gauge manifold (1) sit for at least 5 min.
with the high-pressure valve (3) and low-pres-
sure valve (2) closed, and check that the gauge
indicator does not go back to 0.
If the gauge indicator starts to swing back to 0,
this indicates there is a leak. Tighten the line
connections, perform vacuuming again, and
check to see if there is still a leak.
4. Gas filling operation, high-pressure side
First, start the filling operation from the high-pressure side.
[1] After repeating vacuuming, switch the charging
hose (yellow) (3) of the gauge manifold (9) from
the vacuum pump to the service can (12).
[2] Air purging
Open the valve for the service can (13). (How-
ever, keep the gauge manifold high-pressure
and low-pressure valves closed.) Next, press
the air purge valve (14) of the side service port
on the gauge manifold low-pressure side with a
screwdriver to discharge the air inside the
charging hose using the refrigerant pressure.
(Complete after the swooshing sound stops.)
[3] Open the high-pressure valve (8) of the gauge
manifold (9), and fill with coolant.
(Fill with refrigerant gas up to a gauge pressure
of 0.098 MPa.)
After filling, close the gauge manifold high-pres-
sure valve and valve for the service can (13).
Never operate the compressor. (This is very
dangerous, as the refrigerant will flow in the
opposite direction and may cause a service can
or hose explosion.)
[4] Gas leak check
Check for gas leaks in the cycle using the gas
leak tester.
If there are leaks, eliminate them through tight-
ening.
Always use the tester for R134a.
SSM-07-08-004EN 18
6
5. Gas filling operation, low-pressure side
・ Never open the gauge manifold high-pressure valve.
Caution ・ Never tip over the service can. This may cause damage to the compressor.
After finishing the high-pressure side filling operation, perform the operation for the low-pressure
side.
[1] Check that the high-pressure valve (8) and low-
pressure valve (7) of the gauge manifold (9) and
the valve for the service can (13) are closed.
[2] Start the engine, increase speed to 1500 ± 100
min.-1, and completely open the cab door and
window.
[3] Turn the air conditioner switch on, move the fan
switch to the maximum position, and move the
temperature adjustment switch to the maximum
cooling position.
[4] During filling, set the degree of discharge for the
compressor at 1.37 - 1.57 MPa.
[5] Open the low-pressure valve (7) of the gauge
manifold (9) and valve for the service can (13),
and fill with refrigerant until the air bubbles in
the receiver sight glass (15) are gone.
・ Judging the amount of refrigerant from the receiver dryer sight glass
After the AC is turned ON, a few air bub-
When the amount is bles are visible. The glass then becomes
correct transparent and turns to a pale, milky-
white color.
When overfilling After the AC is turned ON, no air bubbles

occurred at all are visible.
When filling was After the AC is turned ON, air bubbles

insufficient are seen continuously.
(Total gas filling amount: 950 ± 50 g)
19 SSM-07-08-004EN
7
[6] After refrigerant filling is complete, close the low-pressure valve (7) of the gauge manifold (9) and
the valve for the service can (13), and stop the engine.
• If the air conditioner is operated with very little refrigerant (R134a), this will have a damaging
effect on the compressor.
• If the air conditioner is filled with too much refrigerant (overcharge), this will actually cause insuf-
ficient cooling and there is the danger of pressure in the circuit becoming abnormally high.
Be sure to use an appropriate amount of refrigerant.
• Never open the gauge manifold high-pressure valve (8).
• Never invert the service can.
(Gas is suctioned in liquid form, so this may cause damage to the compressor valve.)
[7] After refrigerant filling and inspection, remove the gauge manifold and hoses.
Quickly remove the low-pressure side charge hose (blue) (11) from the low-pressure side (SUC)
service valve.
Do not do anything on the high-pressure side until the high-pressure gauge indicator falls to 0.98
MPa or below.
After confirming that the indicator has fallen below this point, quickly remove the high-pressure
side charge hose (red) (10) from the high-pressure side (DIS) service valve.
SSM-07-08-004EN 20
8
Electrical Equipment Judgment Procedures SH330-5

Items to prepare
• Service connector
• Tester
[1] Use service connector (female) (1) and service
connector (male) (2) for voltage measurement.
[2] Remove the connector (3) in which voltage is to

be measured.
[3] Connect the service connector (female) (1) to

the removed connector, and attach the tester (4)
to measure voltage.
1 SSM-09-13-004EN
1
[4] Also attach the service connector (male) (2) to
the removed connector on the opposite side
and measure voltage with the tester (4).
SSM-09-13-004EN 2
2
Maintenance Standards SH330-5
Maintenance
Check Sheet
1. Drive Sprocket
* See the gauge list for measurement gauges.

* Use the maintenance standard table for judgment.
Measured
Standard
dimen- Usage
Part name Code value Judgment Solution
sions limit (mm)
(mm)
(mm)
Acceptable/
a 83 73
Unacceptable
Acceptable/
b φ φ660.7 φ649.2
Unacceptable
Acceptable/
c φ φ748 φ738
Unacceptable Cladding by welding or
Drive sprocket
Acceptable/ replacement
d φ φ732.5 -
Unacceptable
Acceptable/
e 40 45
Unacceptable
Acceptable/
p 215.9 -
Unacceptable
3 SSM-09-14-004EN
1
2. Take-up roller

Measured
Standard
dimen- Usage
sions limit (mm)
(mm)
(mm)
Acceptable/
a φ φ560 φ550
Unacceptable
Acceptable/ Cladding by welding or
Take-up roller b 22.5 -
Unacceptable replacement
Acceptable/
c 102 92
Unacceptable
Acceptable/
Shaft d φ φ85 φ84 Replacement
Unacceptable
Acceptable/
d φ φ85 φ86
Unacceptable
Bushing Replacement
Acceptable/
e 82 81
Unacceptable
Acceptable/
Hub f 24 23.6 Replacement
Unacceptable
SSM-09-14-004EN 4
2
3. Upper roller

Measured
Standard
dimen- Usage
sions limit (mm)
(mm)
(mm)
Acceptable/
a φ φ150 φ140
Unacceptable
Carrier roller b 15 -
Acceptable/
c 104 -
Unacceptable
Acceptable/
Shaft d φ φ65 φ64 Replacement
Unacceptable
Acceptable/
Bushing d φ φ65 φ66 Replacement
Unacceptable
Acceptable/
Bushing e 69 68 Replacement
Unacceptable
Acceptable/
Thrust plate f 9 8.5 Replacement
Unacceptable
Acceptable/
Cover g 15 - Replacement
Unacceptable
5 SSM-09-14-004EN
3
4. Lower roller

Measured
Standard
dimen- Usage
sions limit (mm)
(mm)
(mm)
Acceptable/
a φ φ180 φ170
Unacceptable
Track roller b 25 20
Acceptable/
d 216 224
Unacceptable
Acceptable/
Shaft e φ φ75 φ74 Replacement
Unacceptable
Acceptable/
e φ φ75 φ76
Unacceptable
Bushing Replacement
Acceptable/
f φ82 φ81
Unacceptable
Acceptable/
Collar g 17.5 17.0 Replacement
Unacceptable
SSM-09-14-004EN 6
4
5. Track shoe (grouser shoe)
Measured Standard Usage

dimensions (mm) limit (mm)
(mm)
Acceptable/
Shoe plate a 49 34
Unacceptable Replacement
Link b 129 124
Acceptable/
c φ φ71 φ67 Unacceptable
Master bushing Replacement
Acceptable/
d φ φ47 -
Unacceptable
Acceptable/
Master pin e φ φ46.83 - Unacceptable Replacement
Acceptable/
f 215.9 220.2
Unacceptable
Link pitch Replacement
Acceptable/
f' 863.6 880.8 Unacceptable
Acceptable/
c' φ φ71 φ67 Unacceptable
Track bushing Replacement
Acceptable/
d' φ φ47 -
Unacceptable
Acceptable/
Track pin e' φ φ47 -
7 SSM-09-14-004EN
5
6. Attachment (backhoe)

① Boom and swing frame installation section
Measured Standard Usage limit
Part name Code Judgment Solution
dimensions (mm) value (mm) (mm)
Acceptable/
Swing frame a 860 868
Unacceptable －
Acceptable/
Boom b 857 855 Replacement
Unacceptable
Shim adjust- Acceptable/
Clearance c (a - b) 3.0 - 5.5 Adjust with shims
ment Unacceptable
Acceptable/
Pin d φ φ110 φ109 Unacceptable
Replacement
Acceptable/
Bushing (boom) e φ φ110 φ111.5 Unacceptable
Replacement
② Boom cylinder and swing frame installation section
Part name Code Measured Standard Usage limit Judgment Solution

dimensions (mm) value (mm) (mm)
A c c e p t a bl e /
Swing frame a 131 137
Unacceptable －
Boom cylinder A c c e p t a bl e /
b 130 127 Replacement
(foot section) Unacceptable
Clearance c (a - b) 1.0 - 3.5 Shim adjust- Acceptable/ Adjust with shims
ment Unacceptable
Acceptable/
Replacement
Bushing (boom Acceptable/
cylinder) e φ φ90 φ91.5 Unacceptable
Replacement
SSM-09-14-004EN 8
6

③ Boom and boom cylinder installation section

dimensions (mm) (mm)
(mm)
Boom cylinder (top Acceptable/
a 123 120 Replacement
section) Unacceptable
Acceptable/
Boom b 669 665 Unacceptable Replacement
Clearance c 2.0 - 3.0 ment Unacceptable Adjust with shims
Acceptable/
Replacement
Bushing (boom cyl- Acceptable/
inder)
e φ φ110 φ111.5 Unacceptable Replacement
④ Boom and arm cylinder installation section

Standard
Measured Usage limit
(mm)
Acceptable/
Boom a 146 152 Unacceptable Replacement
Boom cylinder (foot Acceptable/
b 145 143 Replacement
ment Unacceptable
Acceptable/
Replacement
Bushing (arm cylin- Acceptable/
der) e φ φ100 φ101.5 Unacceptable
Replacement
9 SSM-09-14-004EN
7

⑤ Boom and arm installation section
Measured
Standard
dimen- Usage
sions limit (mm)
(mm)
(mm)
Acceptable/
Boom a 392 395 Replacement
Unacceptable
Acceptable/
Arm b 387.7 389 Replacement
Unacceptable
Shim
Acceptable/
Clearance c (a - b) 4.3 - 4.9 adjust- Adjust with shims
Unacceptable
ment
Acceptable/
Pin d φ φ115 φ114 Replacement
Unacceptable
Acceptable/
Bushing (arm) e φ φ115 φ116.5 Replacement
Unacceptable
Acceptable/
Boom f φ φ115 φ116.5 Replacement
Unacceptable
Acceptable/
Boom g 89 87 Replacement
Unacceptable
SSM-09-14-004EN 10
8

⑥ Arm and arm cylinder installation section

(mm)
Acceptable/
Arm a 146 151
Arm cylinder (top Acceptable/
b 145 143
section) Unacceptable Replacement
Clearance c (a - b) 0.5 - 2.5
ment Unacceptable Adjust with shims
Acceptable/
Pin d φ φ100 φ99 Unacceptable Replacement
Bushing (arm cylin- Acceptable/
der)
⑦ Arm and bucket cylinder installation section
Standard
(mm)
A c c e p t a bl e / Replacement
Arm a 146 152
Unacceptable
Bucket cylinder A c c e p t a bl e / Replacement
b 145 143
(foot section) Unacceptable
Clearance c (a - b) 1.0 - 2.5
ment Unacceptable Adjust with shims
Acceptable/
Pin d φ φ95 φ94 Unacceptable Replacement
Bushing (bucket Acceptable/
cylinder)
11 SSM-09-14-004EN
9

⑧ Arm and arm link installation section
Standard
(mm)
Acceptable/
Arm link a 50 47 Replacement
Unacceptable
Acceptable/
Arm b 375 371 Replacement
Unacceptable
Clearance c 1.0 - 1.5 Adjust with shims
ment Unacceptable
Acceptable/
Replacement
Acceptable/
Bushing (arm) e φ φ85 φ86.5 Unacceptable
Replacement
⑨ Bucket and bucket link installation section

Standard
(mm)
Acceptable/
Bucket a 401 406 Replacement
Unacceptable
Acceptable/
Bucket link b 400 397 Replacement
Unacceptable
Clearance c(a-b) 1.0 - 3.5 Shim adjust- Acceptable/ Adjust with shims
ment Unacceptable
Acceptable/
Replacement
link)
e φ φ90 φ91.5 Unacceptable
Replacement
SSM-09-14-004EN 12
10

⑩ Bucket link and bucket cylinder installation section
Standard
(mm)
Acceptable/
Arm link a 50 48 Replacement
Unacceptable
Acceptable/
Bucket link b 375 371 Replacement
Unacceptable
Clearance c 1.0 - 1.5 Adjust with shims
ment Unacceptable
Acceptable/
Bucket link d 121 123 Replacement
Unacceptable
Bucket cylinder (top Acceptable/
e 120 118 Replacement
Clearance f (d - e) 1.0 - 2.0 Adjust with shims
ment Unacceptable
Acceptable/
Pin g φ φ105 φ104 Replacement
Unacceptable
h φ φ105 φ106.5 Replacement
link) Unacceptable
i φ φ105 φ106.5 Replacement
cylinder) Unacceptable
13 SSM-09-14-004EN
11

⑪ Bucket and arm installation section
Standard
(mm)
Acceptable/
Bucket a 401 406 Replacement
Unacceptable
Acceptable/
Arm b 400 397 Replacement
Unacceptable
ment Unacceptable
Acceptable/
Bushing (bucket) d 16 10 Replacement
Unacceptable
Acceptable/
Pin e φ φ90 φ89 Replacement
Unacceptable
Acceptable/
Bushing (arm) f φ φ90 φ91.5 Replacement
Unacceptable
Acceptable/
Bushing (bucket) g φ φ90 φ91.5 Replacement
Unacceptable
SSM-09-14-004EN 14
12
Track Shoe SH330-5
Track Shoe
Track Shoe
Removal and Installation of Shoe Assembly
・ When loosening the grease cylinder check valve, loosen it a little bit at a time.
・ The pressure inside the cylinder is very high, so there is the danger of grease being expelled
and the plug flying off. The check valve adjustment procedure should not be done in front of
Warning the check valve.
・ Do not get under the main unit when it is jacked up.
Make sure to place the main unit on crossties to prevent falling.
Caution ・ Make sure to stop the engine for loosening shoes and when removing master pins.
Items to prepare
• Wrench (19 mm)
• Hammer
• Striking jig
• Crowbar
• Rag
• Lifting equipment (with the required breaking load)
1. Removal of Shoe Assembly
[1] Rotate the shoe and align it so that the master
pin (1) is next to the idler.
[2] Use a box wrench (19 mm) to loosen the check

valve (2) to release grease, and then loosen the
track shoe tension.
Do not loosen the check valve all at once.
Loosen it slowly while monitoring the grease
output and shoe loosening.
Use a rag to catch grease that trickles out of the
check valve.
If the check valve is loosened too much at this
time, it may fly off. Be careful not to work in front
of the check valve.
1 SSM-13-01-004EN
1
Track Shoe
and then remove the check valve stopper (4).
• If the check valve is removed, it is easier to
loosen the track shoe tension.
[4] Straighten out the S-pin (5) attached to the

master pin by striking one side of it with a ham-
mer, and use a crowbar, etc. to remove it.
[5] Use a hammer (6) and striking rod (7) to push

the master pin (1) out.
[6] Remove the track shoe (8).

At this time, place a wood plank (9) under the
bottom track shoe so that it does not fall.
SSM-13-01-004EN 2
2
Track Shoe
[7] Start the engine, raise the lower side frame of
the track shoe removal side about 20 cm, slowly
set the travel lever to backwards, and move the
track shoe to remove it from the lower frame.
3 SSM-13-01-004EN
3
Track Shoe
2. Installation of Shoe Assembly
[1] Raise the lower side frame about 20 cm.
Lift the track shoe (1) and align it with the
sprocket (2).
Pay attention to the backwards and forward
direction of the track shoe.
[2] Slowly set the travel lever to forward and feed

the track shoe to the take-up roller side as
shown in the diagram.
In the middle of this procedure when the track
shoe passes the upper roller, use a crowbar,
etc. to lift the track shoe while it is being fed.
Lower the lower side frame after the shoe has
reached position A shown in the diagram.
[3] Wrap the edge of the track shoe (4) onto the
take-up roller (3).
Place a wood plank (5) on the ground and lift
the bottom-side link to align the position where
the master pin is inserted.
[4] Insert the master pin (7).

Insert the S-pin (6) and bend it so that it cannot
slip out.
SSM-13-01-004EN 4
4
Track Shoe
[5] Tighten the check valve (8).
While monitoring the track shoe tension, inject
grease into the grease cylinder.
[6] To adjust the track shoe tension, raise the lower

side frame as shown in the diagram.
Adjust the tension so that the distance indicated
with A between the frame bottom (9) of the cen-
ter area of the lower side frame and the lowest
hanging part of the top of the shoe plate (10) is
340 - 360 mm.
5 SSM-13-01-004EN
5
Track Shoe
Removal and Installation of Shoe Plate
Items to prepare
• Grease
• Rag
• Cleaning fluid

shoe bolts (1), and then remove the shoe plate
(2).
SSM-13-01-004EN 6
6
Travel Unit SH330-5
Travel Unit
Removal and Installation of Travel Motor
・ When loosening the check valve, loosen it a little at a time and stop when any grease
Warning appears. The pressure inside the cylinder is very high, so there is the danger of grease being
expelled and the plug flying off if the check valve is loosened too much.
・ Before removing the shoes, be sure to bleed off any air in the hydraulic circuits.
Items to prepare
• Box wrenches (19 mm, 36 mm)
• Hammer (to remove the master pin)
• Striking jig (to remove the master pin)
• Wire rope (with the required breaking load)
• Loctite #262
• Rag
• Cleaning fluid
1. Removal of Travel Motor
[1] Allow the bucket (1) to touch the ground so as to
elevate the side with the shoe (2) to be removed
as in the diagram on the right.
[2] Slowly rotate the shoe so that the shoe joint

section (3) is aligned as in the diagram on the
right.
[3] Place wood planks (4) under the shoe and
return the bucket to its original position.
[4] Perform air bleeding for the hydraulic line.
For details, see Air Bleed Procedures.
7 SSM-13-02-004EN
1
Travel Unit
[5] Use a box wrench (19 mm) to rotate the grease
cylinder check valve (5) and loosen the shoe
tension.
• Grease will flow out, so have rags ready. If the
check valve is loosened too much at this time, it
may fly off. Be careful not to work in front of the
check valve.
[6] Pull out the S-pin (6) from the rear of the joint
section.
[7] Place a striking jig (9) against the master pin (7)
and hit it with a hammer (8) to push the master
pin out.
SSM-13-02-004EN 8
2
Travel Unit
[8] Open the shoe (2) to the rear.

(10), and then remove the cover (11).
[10] Use wrenches (27 mm for drain hose, 41 mm for

high-pressure hose) to remove the drain hose
(13) and 3 high-pressure hoses (12).
• Be sure to use plugs on the removed drain and
high-pressure hoses.
9 SSM-13-02-004EN
3
Travel Unit
[11] Use a wrench (19 mm) to remove the pilot hose
(15) and a wrench (27 mm) to remove the elbow
(14).
[12] Attach the wire rope (17) to the travel motor (16)
as in the diagram.
Adjust the wire rope so that it is located at the
center of mass and lift it with the liftcrane so that
it is slightly tensed.
[13] Use a box wrench (36 mm) to remove all 18

bolts (18).
SSM-13-02-004EN 10
4
Travel Unit
[14] Remove the travel motor (16).
11 SSM-13-02-004EN
5
Travel Unit
2. Installation of Travel Motor
[1] Attach the travel motor to the lower frame as in
the diagram.
• Be careful of the installation angles.
[2] Apply Loctite #262 to the installation bolt (2)

threaded sections and temporarily tighten them.
Tighten top and bottom alternately to the speci-
fied torque so that an even tightening force acts
on opposing corners as shown in the diagram
below.
[3] Use a wrench (27 mm) to remove the elbow (3)

and a wrench (19 mm) to install the pilot hose
(4).
SSM-13-02-004EN 12
6
Travel Unit
[4] Use wrenches (27 mm for drain hose, 36 mm for
high-pressure hose) to install the drain hose (6)
and high-pressure hoses (5).

(7), and then install the cover (8).
[6] Wrap the shoe (9).
13 SSM-13-02-004EN
7
Travel Unit
[7] Insert the master pin (11).
Insert the S-pin (10) and bend it so that it can-
not slip out.

[9] When adjusting the track shoe tension, raise the

lower side frame as shown in the diagram.
Place a wood plank (13) under the lower frame
to prevent falling.
with A between the frame bottom (14) of the
center area of the lower side frame and the low-
est hanging part of the top of the shoe plate (15)
is 340 - 360 mm.
SSM-13-02-004EN 14
8
Travel Unit
Assembly and Disassembly of Travel Motor
1. To Ensure Safe Use
Please follow these precautions.

When transporting the motor with a liftcrane, do not use the tap on top of the base plate to sus-
pend the motor.
The motor falling may cause personal injury or damage the machine.
When disassembling the motor for transport, installation or maintenance inspection, make sure
to wear a helmet, protective shoes, gloves and safety goggles.
When there is little hydraulic oil in the hydraulic tank and the oil surface is near the inlet port or
there is no hydraulic oil, do not run the motor.
The motor will take in air and may run out of control, which could cause personal injury or dam-
age the machine.
Warning
Do not operate the motor when there is no hydraulic oil in the lines.
The motor will take in air and may run out of control, which could cause personal injury or dam-
age the machine.
For 1 hr. after operating the motor, do not remove the plugs for the oil fill, oil drain and oil check
ports for reduction gear lubrication oil.
Hot lubricating oil may spray out and cause burns.
Hot lubricating oil spraying out and entering the eyes may cause blindness.
15 SSM-13-02-004EN
9
Travel Unit

When pressure is applied inside the lines, do not remove the motor pressure detection port
plug or the drain port plug.
Pressurized oil spraying out and entering the eyes may cause blindness.
When removing plugs, always let out the pressure inside the lines.
Do not remove the reduction gear cover with the motor left installed in the machine main unit.
Fingers or hands may get caught in gears and this could result in injury.
Warning
Do not disassemble the motor with the motor left installed in the machine main unit.
The machine may run out of control, which could result in personal injury.
For motor disassembly, be sure to remove the motor from the machine main unit.
Do not remove the spool of the double counter balance valve with the motor left installed in the
machine main unit.
The motor may run out of control, which could cause personal injury or damage the machine.
SSM-13-02-004EN 16
10
Travel Unit

Do not tamper with the relief valve adjuster.
The set pressure of the relief valve may change and cause the motor to run out of control,
which could cause personal injury or damage the machine.
Warning
17 SSM-13-02-004EN
11
Travel Unit

Do not operate the motor at settings beyond its specified range.
This could cause damage to the machine.
Do not touch the motor for 1 hr. after operation.
The surface of the motor is very hot due to operation. Touching the surface could cause burns.
Do not suddenly remove the plugs for the oil fill, oil drain and oil check ports on the reduction gear.
A plug may fly off and cause injury.
Align the port positions with the specified positions and slowly loosen the plug for each port,
starting with oil fill port on top, to release air inside the reduction gear.
Caution
When handling lines, make sure to confirm the input and output flow of the hydraulic oil and the
motor rotation direction.
It is extremely dangerous if the motor rotates in the opposite direction.
Do not use hydraulic oil other than the type specified.

Doing so could cause damage to the machine.
SSM-13-02-004EN 18
12
Travel Unit

Do not use reduction gear lubricating oil other than the type specified.
Doing so could cause damage to the machine.
Do not let foreign matter into the motor.
This will damage the machine.
Caution Perform motor maintenance and inspection after the motor has cooled down.
19 SSM-13-02-004EN
13
Travel Unit
2. Tools for Assembly and Disassembly
Use the tools indicated below for assembly and disassembly of the motor.
(1) Standard tools
The necessary standard tools for assembly and disassembly of this motor are indicated in Table 1.
1) Required tools for motor
Tool name Specifications
Hexagon wrench Bolt width 5, 6, 8, 10, 14 mm
Pliers for snap rings φ32 - φ58, φ60 - φ80 for hole
Plastic hammer 1
Screwdriver Flathead (medium-sized) 2
Torque wrench For 98.1 N•m, 324 N•m, and 441 N•m
Gear (bearing) puller Maximum diameter of 75 mm and maximum width of 45 mm (e.g., GP75 made by Asahi Tools) of removed item
Other Seal tape, cleaning oil (white kerosene), grease, hydraulic oil, rag, compressed air
Table 1
SSM-13-02-004EN 20
14
Travel Unit
2) Required tools for reduction gear
Tool name Specifications
Hexagon wrench Bolt width 8, 14 mm
Torque wrench For 490 N•m
Receiving platform
Micro depth gauge 0 - 15 mm

Caliper 0 - 150 mm
For inserting spring pins (14, 21)
Pin
φ5.5 × 80 φ9.5 × 60
Eyebolt M10, M20 (3 bolts each)
For inserting angular bearing and installing lock washers
Pressing machine
(3-ton press capacity)
Cleaning oil (white kerosene), solvent, gear oil, grease, Loctite #242 and #515,
Other
rag, etc.
Table 1
21 SSM-13-02-004EN
15
Travel Unit
(2) Secondary materials
The necessary secondary materials for assembly and disassembly of this motor are indicated in
Table 2.
Table 2. Secondary materials
Secondary mate- Standardized number

No. Type and dimensions Part used with
rials name Manufacturer name
1 Seal tape
2 Adhesive Loctite 271
3 Gear oil GL-4#90 equivalent
4 Hydraulic oil ISO VG46 equivalent
5 Grease Lithium-series
6 White kerosene No.2 equivalent oil
7 Liquid packing ThreeBond 1211
8 Lapping plate For sliding surface repair
9 Lapping agent #1000 For sliding surface repair
10 Copper plate
11 Tube brush For cleaning
12 Bamboo brush For cleaning
13 Oil pan For receiving oil
14 Plastic container For filling grease
15 Rag
(3) Special tools

The necessary special tools for assembly and disassembly of this motor are indicated in Table 3.
Table 3. Special tools
Standardized number Type and dimen-

No. Tool name Part used with
Manufacturer name sions
1 Pulley remover
2 Bearing press-fit jig
3 Bearing press-fit jig
4 Floating seal mounting jig
5 Rod
6 Angular bearing press-fit jig
7 Shim thickness adjustment jig
8 Rod
10 Thrust plate selection jig
11 Oil seal press-fit jig
12 Brake piston positioning jig
13 Snap ring removal jig
14 Poppet seat removal jig
SSM-13-02-004EN 22
16
Travel Unit
(4) Measurement device
The necessary measurement devices for assembly of this motor are indicated in Table 4.
Table 4. Measurement devices
Standardized number Type and

No. Tool name Part used with
Manufacturer name dimensions
1 Dial gauge JIS B7503
2 Micrometer caliper JIS B7502
23 SSM-13-02-004EN
17
Travel Unit
3. Disassembly of Motor
(1) Precautions before motor disassembly
Begin motor disassembly only after thoroughly reading the precautions below.
[1] When performing disassembly, always wear protective devices such as a helmet, goggles
and safety shoes.
[2] Use the specified tools when performing disassembly.
[3] Remove all lines connected to the motor and remove the motor from the mother machine
only after making sure that the machine is on a level surface and there are no external forces
acting on rotating parts so that the mother machine does not operate uncontrollably when
the motor is removed.
[4] To prevent foreign matter from entering the lines and motor when removing the motor from
the mother machine, sufficiently clean off mud and dirt adhered around the motor before
removing lines connected to the motor.
[5] When removing lines connected to the motor, hydraulic oil from inside the lines will spray
out. For this reason, remove these lines only after removing pressure from inside the lines
and preparing an oil pan. To prevent injuries due to the motor falling when transporting it by
lifting the motor with a liftcrane, lift the machine with the eyebolts mounted in the positions
indicated in the diagram below.
[6] The motor is filled with hydraulic oil. Before disassembling the motor, prepare an oil pan and
drain the hydraulic oil from the motor.
[7] To prevent injuries during disassembly, prepare a waist-high, stable work platform to perform
work on.
[8] The motor comprises high-precision parts. For this reason, foreign matter adhering to parts
can be damaging. Motor disassembly should be done in an inside space without dust, and
mud and dirt should be prevented from adhering to parts.
[9] The motor comprises high-precision parts. For this reason, dents and scratching on part sur-
faces can be damaging. Be very careful when handling parts during disassembly and do not
create any dents or scratching.
[10] To prevent personal injury and damage to parts during disassembly, do not force disassem-
bly of parts which are especially tight to disassemble.
Motor lifting positions
SSM-13-02-004EN 24
18
Travel Unit
(2) Tightening torque
Table 5 indicates tightening torque for each fastening section.
Table 5. Tightening torque for each section
Code Part name Dimensions Tightening torque (N•m)

378± 37.8 N•m
(4) Hexagon socket head bolt M18 × 110
(Loctite #242 coating)
68.6±6.9 N•m
(25) Hexagon socket head bolt M10 × 30
(Loctite #242 coating)
(26) Hexagon socket head plug G3/4 147± 14.7 N•m
(29) Plug M42 441 - 461
(35) Pilot valve plug G3/8 49.0 - 58.8
(38) Plug G1/4 29.4
(42) Plug G1/8 14.7
(56) Hexagon socket head bolt M18 324 ± 32.4
(57) Overload relief valve M27 98.1 - 118
(60) Plug G1/2 98.1
25 SSM-13-02-004EN
19
Travel Unit
(3) Disassembly procedure
1) Disassembly of motor
Perform disassembly by observing the safety precautions listed in "1. To Ensure Safe Use" and
following the procedure indicated below.
a) Removal of supplied valves
Remove the supplied valves before disassembling the motor parts.
• It is recommended not to remove any supplied valves other than those required for disassembly.
However, the motor cannot be disassembled if the overload relief valve (57) is not removed
first.
Perform the disassembly procedure after the motor has reached its normal temperature, other-
Caution wise burns can occur.
Removal of supplied valves

[1] Remove the M42 plug (29) and O-ring (30).
[2] Remove the spring (28), spring receiver (27), and spool assembly (26).
• Make reference marks on the spool assembly (26) and rear cover (24), and when reas-
sembling the parts, make sure that the assembly direction does not go in the opposite
left-right direction.
• Adhesive is applied to the thread sections to fix the spool assembly (26), so no further
disassembly is possible.
[3] Remove the plug (42), O-ring (43), orifice spring (41), and orifice (40).
[4] Remove the overload relief valve (57).
• When removing the overload relief valve (57), the valve seat (57-3) can easily come off,
so be careful not to let it fall inside the rear cover (24), and check that it is not lost.
[5] Loosen the pilot valve plug (35), and remove the O-ring (36), spring (34), spring receiver
(33), pilot valve spool (31), and pin (32).
[6] Remove the coupling (58).
Caution Be very careful not to get hands stuck between parts or drop the carried parts on feet.
SSM-13-02-004EN 26
20
Travel Unit
b) Disassembly of motor
[1] Place the motor shaft horizontally and
pull it out while leaving the 2 vertically-
opposite hexagon socket head bolts
M18 × 50 (56) in place.
[2] Install guide pins at the 2 vertically-
opposite locations.
(Purpose: This prevents the rear cover
from falling when removed and acts as a
guide during assembly.)
[3] Slowly loosen the remaining 2 hexagon
socket head bolts M18 × 50 (56) at the
same time.
[4] Remove the rear cover (24) and brake
spring (55) while making sure that the
cylinder block (13) does not come out
together with the rear cover (24).
Be very careful not to get hands stuck

Caution between parts or drop the carried parts
on feet.
• Be careful not to drop the valve plate
(54), brake spring (55), rear bearing (51)
outer race, shim (52), and O-rings (50),
(47), (49).
• There is a shim (52) under the rear
bearing (51) outer race. Be very careful
not to lose this during disassembly.
[5] Remove the valve plate (54) while mak-
ing sure that the cylinder block (13) does
not come off.
• Make reference marks on the valve
plate (54) and rear cover (24), and when
reassembling the parts, be sure not to
reverse the front and rear.
[6] Using the removed hexagon socket
head bolt M18 × 50 (56), press the
holder fitting so as not to scratch the
sliding surface of the cylinder block (13),
and let the rear bearing (51) inner race
come out.
• Insert a rubber plate between the sliding
surface and the holder fitting so as not
to scratch the sliding surface of the cyl-
inder block (13).
[7] Attach the gear (bearing) puller to the
rear bearing (51) inner race and remove
it.
Removal of rear bearing
27 SSM-13-02-004EN
21
Travel Unit
[8] While holding the brake piston (21) with
the hand, fill compressed air from the
brake release oil hole and push out.
Be very careful as the air pressure can

Caution cause the brake piston (21) to fly off.
• When using a removal jig, install the
removal jig to the M6 taps (2 locations)
on the end of the brake piston (21), and
pull out the brake piston (21).
[9] Insert a rod that will not scratch the cyl-
inder block (13) (such as rolled-up cylin-
drical paper) into the piston (18) hole,
and make a reference mark on the outer
circumference of the cylinder block (13)
for reference.
[10] Remove the rotary group (cylinder block
(13), piston assembly (18), shoe retainer
(17), spherical joint (16), spring receiver
(15), and cylinder spring (14)).

on feet.
[11] Remove the separator plate (19) and
friction plate (20).
[12] Remove the 9 piston assemblies (18),
shoe retainer (17), and spherical joint
(16) from the rotary group at the same
time.
[13] Remove the spring receiver (15) and
cylinder spring (14) from the cylinder
block (13).
• With the piston assembly (18) and shoe
retainer (17) removed, align the align-
ment mark and the reference mark and
insert them into the cylinder block (13).
The purpose is to house the pistons into
the same holes before disassembly
when reassembling.
• Be careful not to scratch each of the
sliding surfaces. If the sliding surface is
scratched, the part cannot be reused.
• The piston and shoe are caulked and
cannot be disassembled.
[Tip]
The preceding described how to disassemble the motor unit, but the disassembly is also
the same if it comes with a reduction gear. Disassembling a motor with a reduction gear
may be easier because the shaft does not swing as much.
SSM-13-02-004EN 28
22
Travel Unit
[14] Remove the shoe plate (12).
[15] Do not remove the tilting piston assemblies (6), (7), (8). If these parts must be removed,
hold the tilting piston (6) with the hand and fill air from the tilting path hole and push out
the parts.
Caution Be very careful as the air pressure can cause the tilting piston (6) to fly off.
[16] The shaft (9) can be pulled out.

[17] When replacing the front bearing (10),
remove the inner race from the shaft (9)
with the bearing puller, and replace with
a new bearing.
• When replacing parts related to the
clearance of the bearing, such as the
bearings (10) and (51), shaft (9), casing
(1), and rear cover (24), the thickness of
the shim (52) needs to be adjusted. Cor-
rectly measure the shim gap when the
shim is lightly positioned, replace with a
shim (52) that matches the gap, and
adjust the bearing gap to 0 - 0.1 mm.
(See page 24.)
A separate jig or other tool is needed to
determine the jig thickness.
Contact us for details.
• Do not remove the pivot (11). If remov-
ing the part, make a reference mark on
the area aligned with the shoe plate
(12).
• Do not remove the oil seal (3). If the part
is removed, always replace with a new
part.
If removing the oil seal, remove the
retaining ring (4), and then remove the
oil seal (3).
29 SSM-13-02-004EN
23
Travel Unit
[18] Determining the thickness of the taper roller bearing shim (52)
Determining the shim thickness

• This needs to be performed when replacing the motor casing (1), rear cover (24), shaft
(9), or bearings (10), (51).
1) Measure dimension E in the assembled condition indicated in the above diagram.
• Be careful not to allow the shaft (9) to fall.
2) Measure dimension F on the rear cover side.
• Use the average of the measurements of the 4 orthogonally intersecting points on the
circumference.
3) When the thickness of the used shim (52) is "S," gap "Y" is as follows.
Y = F - (E + S)
4) In the case of this motor, select 1 or 2 shims (52) so that gap Y is 0 - 0.1 mm.
SSM-13-02-004EN 30
24
Travel Unit
c) Disassembly of overload relief valve
• The overload relief valve (57) is an important part in terms of performance and safety.
Because resetting the pressure of this part is extremely difficult, the overload relief valve
assembly should be replaced without disassembling if a problem occurs.
• The valve seat (57-3) fits into the socket (57-1) internal hole by a clearance fit and can easily come
off, so when removing the overload relief valve (57) from the rear cover (24), be careful not to drop
or lose the valve seat (57-3). When installing the overload relief valve (57) to the rear cover, apply
grease to the bonding section and install in a way that the valve seat (57-3) does not come off.
Valve seat bonding section
31 SSM-13-02-004EN
25
Travel Unit
2) Reduction gear disassembly procedures
a) Disassembly preparations
[1] The unit removed from the actual machine is dirty with dirt and debris.
Clean the exterior of the unit and let it dry.
Perform the disassembly procedure after the reduction gear has sufficiently cooled down, oth-
Caution erwise burns can occur.
[2] Loosen the drain and the feed plug G3/4 (26) to drain the gear oil inside the reduction
gear.
Caution When the gear oil is still hot, the pressure inside can cause the oil to spray out.
[3] Make reference marks to the outside of each alignment surface so that the part can be
assembled in its original form.
b) Installation to receiving platform of reduction gear (unit)
[1] Remove 3 hexagon socket head bolts
M10 × 30 (25) screwed into the cover
(24) at approximately the same distance
apart, and instead, install and suspend
the M10 eyebolts, and install the receiv-
ing platform with the cover in the raised
position and the motor in the lowered
position.
・ Be very careful not to get hands stuck

between parts or drop the suspended
Caution parts on feet.
・ Lift the part in a horizontal position.
SSM-13-02-004EN 32
26
Travel Unit
c) Removal of reduction gear cover
[1] Remove the remaining hexagon socket
head bolts M10 × 30 (25).
[2] The contact surfaces of the cover (24)

and ring gear (3) are coated with seal-
ant, so place a metal pin against the
projected part of the cover and use a
hammer to strike it obliquely upward to
remove the cover.

Caution between parts or drop the suspended
parts on feet.
33 SSM-13-02-004EN
27
Travel Unit
d) Removal of carrier 1 assembly
[1] Remove the thrust plate (23).
[2] Install 3 M10 eyebolts to the carrier 1
(16), and then remove the carrier 1
assembly (16, 17, 18, 19, 20, 21).

[3] Remove the sun gear 1 (22).

Caution between gears.
e) Removal of carrier 2 assembly

[1] Remove the sun gear 2 (15).

[2] Install 3 M10 eyebolts to the carrier 2
(9), and then remove the carrier 2
assembly (9, 10, 11, 12, 13, 14).

SSM-13-02-004EN 34
28
Travel Unit
f) Removal of housing assembly
[1] Remove the support ring (8).
[2] Place a screwdriver or other tool on the

divided surface of the lock washer (7)
and strike the tool with a hammer to
remove the lock washer (7).
[3] Install 3 M10 eyebolts into the M10

threaded holes on the ring gear (3) at
approximately the same distance apart,
and remove the housing assembly (ring
gear (3), housing (1), bearing (2), float-
ing seal (5), hexagon socket head bolt
M18 × 110 (4)) while lifting it in a hori-
zontal position.

35 SSM-13-02-004EN
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Travel Unit
g) Disassembly of housing assembly
[1] Install 3 M20 eyebolts into the M20
threaded holes on the housing (1) at
approximately the same distance apart,
and place it on the receiving platform
with the ring gear (3) in the lowered
position and the housing (1) in the
raised position.
Make reference marks to the outer cir-
cumference of the housing and ring
gear.

[2] Remove the floating seal (5) from the

housing (1).
[3] Remove the hexagon socket head bolts
M18 × 110 (4) while leaving 2 diagonally
opposite bolts.
[4] With the remaining 2 hexagon socket
head bolts M18×110 (4) loosened, tap
the heads of the bolts with a hammer to
easily remove the ring gear (3) from the
housing (1).

parts on feet.
Removal of floating seal
• Be careful not to scratch the sliding surface of the floating seal (5) and its O-ring.
• The bearing (2) outer race and housing (1) inner diameter form a very tight fit. Do not dis-
assemble this unless it is necessary to replace the bearing (2). When removing the bear-
ing (2) from the housing (1), replace with a new part instead of reusing the part.
h) Removal of floating seal from motor
[1] Remove the floating seal (5) on the motor.
SSM-13-02-004EN 36
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Travel Unit
i) Disassembly of carrier 1 assembly
• When reusing the carrier pin 1 (20), place codes on the carrier 1 (16) hole and carrier pin 1
(20) so that the parts can be reassembled in the same combination as before disassembly,
and store the parts.
[1] Push the spring pin 6 × 36 (21) into the
carrier pin 1 (20).
[2] Remove the carrier pin 1 (20) from the

carrier 1 (16).
37 SSM-13-02-004EN
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Travel Unit
[3] Remove the thrust washer 1 (18), plane-
tary gear 1 (17), and needle bearing
(19) from the carrier 1 (16).

Caution between the gear and carrier.
[4] Pull out the spring pin 6 × 36 (21) from
the carrier pin 1 (20).
• When replacing the carrier pin 1 (20) or
planetary gear 1 (17), be sure to replace
with 1 set of 3 parts.
j) Disassembly of carrier 2 assembly

• When reusing the carrier pin 2 (13), place codes on the carrier 2 (9) hole and carrier pin 2
(13) so that the parts can be reassembled in the same combination as before disassembly,
and store the parts.
[1] Push the spring pin 10 × 50 (14) into the
carrier pin 2 (13).
SSM-13-02-004EN 38
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Travel Unit
[2] Remove the carrier pin 2 (13) from the
carrier 2 (9).
[3] Remove the thrust washer 2 (11), plane-

tary gear 2 (10), and needle bearing
(12) from the carrier 2 (9).

[4] Pull out the spring pin 10 × 50 (14) from
the carrier pin 2 (13).
• When replacing the carrier pin 2 (13) or
planetary gear 2 (10), be sure to replace
with a set of 3 parts.
39 SSM-13-02-004EN
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Travel Unit
4. Maintenance standards
(1) Motor parts maintenance standards
The reference values indicating whether or not a part can be reused are indicated using the mea-
surement values at the time a part is disassembled. However, this is a general reference, and
when determining whether a part should be replaced, priority is given to performance prior to dis-
assembly, the purpose of disassembly and the expected remaining life of the part if there is any
damage or discoloration that significantly affects the part appearance.
Measurement item and measurement method
[1] Sliding surfaces: cylinder block, valve plate, and shoe plate
Judgment criteria and solution
• Use a surface roughness gauge to measure the roughness of the sliding surfaces of these
parts.
Part name and inspection item Reference value Permissible limit value Solution
Surface roughness
・ Cylinder block
0.4 Zμ or lower 3.0 Zμ or lower Repair or replace.
・ Valve plate
・ Shoe plate
Table 1
(Perform common lapping to correct the surface roughness of the cylinder block and valve
plate. (Lapping material #1200))
• Use a hardness gauge to measure the hardness of the shoe plate sliding surface.
Shoe plate
HS78 or higher HS74 Replacement
・ Sliding surface hardness
Table 2
[2] Clearance of piston and cylinder block
• Use a micrometer caliper to measure the
piston outer diameter and cylinder bore
inner diameter at at least 3 locations in the
longitudinal direction.
Maximum outer diameter value (piston) = d maximum
Minimum outer diameter value (piston) = d minimum
Minimum inner diameter value (cylinder
bore) = D minimum
Maximum inner diameter value (cylinder
bore) = D maximum Measurement locations
Piston outer diameter d maxi-
0.01 mm 0.05 mm
mum - d minimum
Replace the piston or
Cylinder bore inner diameter
0.01 mm 0.022 mm cylinder block.
D maximum - D minimum
Clearance D - d 0.037 - 0.047 mm 0.065 mm
Table 3
(Piston replacement should be performed 9 pistons at a time.)
SSM-13-02-004EN 40
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Travel Unit
[3] Piston and shoe backlash
• Use a jig (See "Measurement jig".) to press the shoe on the surface plate, slide the pistons
in an upward direction, and measure the piston and shoe backlash δ. (See "Caulking sec-
tion backlash" and "Measuring backlash".)
Permissible
Part name and inspection item Reference value Solution
limit value
Piston and shoe backlash 0 - 0.1 mm 0.3 mm Replace piston.
Table 4
Caulking section backlash Measuring backlash Measurement jig
41 SSM-13-02-004EN
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Travel Unit
[4] Parking brake force
• After completing assembly, tighten the torque of the output shaft end with a torque wrench,
and measure the torque when starting rotation.
Part name and inspection Permissible

Reference value Solution
item limit value
Replace all parts.
・ Separator plates
Parking brake torque 1171 N•m 1055 N•m
・ Friction plates
・ Springs
Table 5
Guidelines for replacing the friction plates and partner plates
To measure the brake torque, the motor must be separated to a single unit.
It is extremely difficult to separate the motor by removing it from the mother machine or dis-
assembling the reduction gear.
Use the following method to determine whether to replace these parts when inspecting the
parts during maintenance.
(Replacement guidelines)
Measure the pack length of the 6 friction plates and 7 separator plates, and if the value is
less than the permissible value indicated below, replace all friction plates, separator plates,
and springs.
Reference value: 33.04 mm (nominal dimensions in the diagram)
Permissible value: 31.5 mm
[5] Shaft
• Use a roughness gauge to measure the wear on the oil seal contact areas of the shaft.
The parts can be reused with a stepped wear of up to 0.05 mm.
(When replacing the shaft (9), replace the oil seal (3) at the same time.)
[6] Bearing
• Replace the bearings.
Replace the bearings (10) (51) before the hour meter on the mother machine reaches 10000
hr.
(When replacing the bearings (10) (51), replace the inner race and outer race at the same
time. Also, when replacing the shaft (9) or bearings (10) (51), the shim (52) thickness must
be adjusted.)
[7] Spline
• Replace the spline when the spline wear exceeds the permissible limit value.
The parts can be reused with a stepped wear of up to 0.3 mm on the contact surface.
[8] Overload relief valve
• Pressure inspection and adjustments cannot be performed without a speciality test bench.
Replace as a valve assembly every time the hour meter on the mother machine reaches
10000 hr.
SSM-13-02-004EN 42
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Travel Unit
(2) Reduction gear parts maintenance standards
1) Inspection prior to reassembly
a) Thrust washer
[1] Inspect for seizing, abnormal wear, and uneven wear.
[2] Inspect for wear that exceeds the permissible value.
b) Gears
[1] Inspect for pitching or seizing on the tooth surfaces.
[2] Perform a color check for cracks in the tooth base.
c) Bearing
Rotate by hand and inspect for abnormal noise or catching.
d) Floating seal
[1] Inspect for damage on the sliding surfaces and O-rings.
[2] Perform a color check for cracks in the tooth base.
43 SSM-13-02-004EN
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Travel Unit
2) Parts maintenance
The reference values indicating whether or not a part can be reused are indicated below using
the measurement values at the time a part is disassembled. However, this is a general refer-
ence, and when determining whether a part should be replaced, priority is given to perfor-
mance prior to disassembly, the purpose of disassembly and the expected remaining life of the
part if there is any damage or discoloration that significantly affects the part appearance.
Parts with specified maintenance standards
See the above diagram for the corresponding codes.
Permissible limit
Code Item Reference value Solution
value
Smooth with no
Replace using a set of
A Planetary shaft wear abnormal wear or ← 3 parts.
seizing
No pitching of φ1.6
Smooth with no Replacement
Tooth surface and tooth base mm or more, or no
B abnormal wear or (Replace using a set of
condition cracks in the tooth
seizing 3 planetary gears.)
base.
Angular bearing (2) Inner race - 0.08 mm or more Shim adjustment (See
C
thrust gap 0.02 mm or less ← section e) on page 43.)
D Thrust washer 1 (18) thickness 3.5± 0.2 mm Wear of 0.1 mm Replacement
E Thrust washer 2 (11) thickness 5.5± 0.2 mm Wear of 0.1 mm Replacement
F Thrust plate (23) thickness 4.5± 0.16 mm Wear of 0.15 mm Replacement
G Gear oil 2000 operating hr. (hour meter) Replacement
SSM-13-02-004EN 44
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Travel Unit
5. Assembly of motor
(1) Precautions before motor assembly
Begin motor assembly only after thoroughly reading the precautions below.
[1] When performing assembly, always wear protective devices such as a helmet, goggles and
safety shoes.
[2] Use the specified tools when performing assembly.
[3] To prevent injuries during disassembly, prepare a waist-high, stable work platform to perform
work on.
[4] The motor comprises high-precision parts. For this reason, foreign matter adhering to parts
can be damaging. Motor assembly should be done in an inside space without dust, and mud
and dirt should be prevented from adhering to parts.
[5] The motor comprises high-precision parts. For this reason, dents and scratching on part sur-
faces can be damaging. Be very careful when handling parts during assembly and do not
create any dents or scratching.
[6] Be sure to repair any damage discovered during disassembly, and prepare replacement
parts before beginning assembly.
[7] Remove metal fragments and foreign matter from all parts, and check that there are no burrs
or dents on parts before beginning assembly. If there are burrs or dents, use a whetstone to
remove them.
[8] When performing assembly, apply clean hydraulic oil to each sliding and rotating section
before assembly.
[9] Thoroughly degrease areas where Loctite and liquid packing is used, and remove oil and
water before assembly.
[10] Replace all seal parts such as O-rings and backup rings with new parts.
[11] Be careful not to damage O-rings and backup rings during assembly. When assembling O-
rings and backup rings, apply a small amount of grease for assembly.
[12] It is recommended that petroleum jelly or grease be used to prevent parts from falling during
assembly.
[13] Tighten each type of bolt at the fastening sections to the tightening torque indicated in Table
5 in 3. (2). Tightening torque should be controlled with a torque wrench.
[14] After assembly is complete, plug all ports leading into the motor to prevent dirt from entering.
45 SSM-13-02-004EN
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Travel Unit
(2) Assembly procedures
Perform assembly by observing the precautions listed in "(1) Precautions before motor assembly"
and following the procedure indicated below.
1) Reduction gear assembly procedure
a) Assembly of the carrier 2 assembly
[1] Insert the planetary gear 2 (10), needle
bearing (12), and thrust washer 2 (11)
into the carrier 2 (9).

[2] Align the carrier pin 2 (13) with the
spring pin hole and insert it into the car-
rier 2 (9).
[3] Insert the spring pin 10 × 50 (14) into

the carrier pin 2 (9) and carrier pin 2
(13). (Hammer it 1 - 2 mm deeper than
the striking surface.)
[4] Caulk at 2 opposing 180° locations.

• For the direction of inserting the spring
pin and the caulking method, see
"Spring pin and caulking details".
Spring pin and caulking details
SSM-13-02-004EN 46
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Travel Unit
b) Assembly of the carrier 1 assembly
[1] Insert the planetary gear 1 (17), needle
bearing (19), and thrust washer 1 (18)
into the carrier 1 (16).

[2] Align the carrier pin 1 (20) with the
spring pin hole and insert it into the car-
rier 1 (16).
[3] Insert the spring pin 6 × 36 (21) into the

carrier pin 1 (16) and carrier pin 1 (20).
(Hammer it 1 - 2 mm deeper than the
striking surface.)
[4] Caulk at 2 opposing 180° locations.

• For the direction of inserting the spring
pin and the caulking method, see "Dia-
gram 1 Spring pin and caulking details".
47 SSM-13-02-004EN
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Travel Unit
c) Installation of bearing and floating seal
[1] Install the bearings (2) in the inner diam-
eter of the housing (1).
[2] Install the floating seals (5) on the motor
and housing (1).
• Clean the floating seal installation sec-
tion of any oil, dirt, paint, or other foreign
matter.
• Lightly apply gear oil to the sliding sec-
tions of the floating seals (5). (Do not
coat the O-rings with gear oil.)
• Install in such a way that the O-rings do

not become twisted. Check that the
floating seal (5) is correctly installed
between the housing (1) and motor in a
parallel direction, as shown in the dia-
gram. (Use of an insertion jig is recom-
mended.)
SSM-13-02-004EN 48
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Travel Unit
d) Assembly of the housing assembly
[1] Thoroughly coat the housing (1) surface
that matches with the ring gear (3) with
Loctite #515.
[2] Install 3 housing (1) M20 eyebolts and
lift with a wire, and install onto the ring
gear (3) while aligning the reference
marks.

[3] Coat the 25 hexagon socket head bolts
M18 × 110 (4) with Loctite #242, and
tighten the bolts to the tightening torque
of 378 ± 38 N•m.
• For details on applying Loctite #242 to
the bolts, see "Method of applying Loc-
tite #242".
49 SSM-13-02-004EN
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Travel Unit
e) Determining the thickness of the angular bearing shim
• This needs to be performed when replacing the motor (casing), housing (1), (angular) bearing (2), or
lock washer (7). Otherwise use the previous shim (6) as is.
[1] Press the outer races of the 2 bearings (2) into the housing (1).
[2] Press the inner races of the 2 bearings (2) evenly and measure the inner race installation
width (A).
• Before measuring the inner race installation width, rotate the bearings at least 5 times to
stabilize them.
[3] Measure the bearing installation width (B) of the motor casing.
[4] Measure the lock washer groove width (C) of the motor casing.
[5] Measure the lock washer (7) thickness (D).
• Use the average of the measurements of the 4 orthogonally intersecting points on the cir-
cumference. Measure the dimensions with a precision of 0.01 mm.
[6] When the thickness of the used shim (6) is S, gap X is as follows. X = (B + C) - (A + D +
S)
[7] In the case of this unit, select 1 shim so that gap X is -0.08 - 0.02 mm. ((+) indicates a gap
and (-) indicates pressing.)
Determining the angular bearing shim thickness
SSM-13-02-004EN 50
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Travel Unit
f) Installation of housing assembly
[1] Place the motor shaft upwards on the
work platform, and place the shim (6)
selected by item e) (Determining the
thickness of the angular bearing shim) on
page 42 on the end surface of the bear-
ing insertion part of the motor casing.

[2] Install and suspend 3 M10 eyebolts to the
ring gear (3), slowly lower it vertically
while aligning it with the motor core, and
insert the bearings (2) installed in the
inner diameter of the housing (1) into the
motor. Use a pressing machine to press
the inner race parts of the bearings (2),
and insert them completely to the bottom.
Press fitting of the housing assembly
[3] Insert the lock washer (7) into the
groove while pressing the flange part of
the housing (1).
[4] Insert the support ring (8) into the out-

side of the lock washer (7).
51 SSM-13-02-004EN
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Travel Unit
g) Installation of the carrier 2 assembly
[1] Insert the carrier 2 assembly into the
ring gear (3) so that the 3 planetary
gears 2 (10) are at the position indicated
in "carrier 2 installation direction," and
have the gears mesh with the spline of
the motor casing.
Installation of the carrier 2 assembly

[2] Insert the sun gear 2 (15).

• The carrier 2 assembly is assembled at
the position indicated in "carrier 2 instal-
lation direction" to improve oil lubrica-
tion, so be sure to observe this
procedure.
Carrier 2 installation direction

h) Installation of the carrier 1 assembly
[1] Install and suspend 3 M10 eyebolts to
the carrier 1 assembly, insert it into the
ring gear (3), rotate the planetary gear 1
(17) by hand to align it, and then have
the gear mesh with the sun gear 2 (15).

[2] After making sure that the coupling (See
the motor parts Operator's Manual.) is at
the end of the motor shaft, insert the sun
gear 1 (22).
Be very careful not to get hands stuck Installation of the carrier 1 assembly
SSM-13-02-004EN 52
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Travel Unit
[3] Install the thrust plate (23) on the carrier 1 (16).
• Face the sharp edge toward the cover (24) side.
Thrust plate installation direction

i) Cover attachment
• The gear oil can be filled before installing the cover (24).
[1] Coat the cover (24) surface that
matches with the ring gear (3) with Loc-
tite #515, and install the cover (24) on
the ring gear (3).

parts on feet.
[2] Coat the 18 hexagon socket head bolts
M10 × 30 (25) with Loctite #242 sealant, Applying Loctite to the cover end surface
and tighten the bolts to the tightening
torque of 68.6 ± 6.9 N•m.
• For details on applying Loctite #242 to
the bolts, see "Method of applying Loc-
tite #242".
j) Gear oil filling
[1] Fill the gear oil (SAE90, API GL-4 or GL-
5, 9.5 L) into the filling port G3/4.
[2] Install the hexagon socket head plug
G3/4 (26) to the cover (24) at a tighten-
ing torque of 147.1 ± 14.7 N•m.
53 SSM-13-02-004EN
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Travel Unit
2) Motor assembly procedure
[1] Apply grease to the oil seal (3) outer cir-
cumference and casing (1) inner circumfer-
ence, and use a insertion jig to tap the oil
seal (3) into the casing (1) evenly so that it
does not fall down.
[2] Use a retaining ring (4) to fasten the oil seal
(3).
[3] Insert the front bearing (10) outer race into
the casing (1). (Clearance fit)
Press fit the inner race into the shaft (9).
(Tight fit)
• Heating the inner race to 100 ℃ or lower
provides for easier press fitting.
Caution Use caution to prevent burns.
[4] Install the shaft (9) into the casing (1).

Apply grease to the surface contacting the
oil seal (3).
[5] Install the tilting piston set.
• Insert the tilting piston (6) so that it is not
tilted.
• When installing the tilting piston (6), apply
grease to the seal parts and insert the pis-
ton carefully so as not to cut anything.
[6] Install the pivot (11). Install it to the side
matching the reference mark on the shoe
plate (12).
When operated for a long period of time,
install it in the direction in which the slide
imprints of the spherical section match the
contact imprints of the shoe plate (12).
[7] Thoroughly grease the 3 spherical sections
of the shoe plate (12) before installation.
SSM-13-02-004EN 54
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Travel Unit
[8] After sub-assembling piston assembly (18),
shoe retainer (17), spherical joint (16),
spring receiver (15), cylinder spring (14),
and cylinder block (13), insert the entire
assembly into the shaft (9).

on feet.
• The piston assembly (18) must be inserted
into the same holes of the cylinder block
(13) used before disassembly.
[9] Use a specialty insertion jig (A1, A2) to

insert the rear bearing (51) inner race into
the shaft (9).
[10] Alternately install all of the separator plates
(19) and friction plates (20) in turn.
The separator plate (19) should be the first
and last parts.
[11] Use an insertion jig (B) to insert the brake
piston (21) installed with D-rings (22) and
(23) to the casing (1).
• Apply grease to the D-rings (22) and (23).
• Use the insertion jig to make sure the brake
piston (21) is inserted evenly.
The brake piston is equipped with 2 large
and small D-rings (22) and (23). First, the
large-diameter D-ring (23) is inserted into
the hole, and then the small-diameter D-
ring (22) is inserted. The insertion condi-
tion of the small-diameter D-ring (22) can-
not be visually checked, so do not forcefully
insert this D-ring.
This can cause chipping by the casing (1)
hole.
• The shim must be adjusted when replacing parts related to the shim adjustment.
Perform the assembly after determining the shim thickness in advance by using the proce-
dure in "Determining the thickness of the taper roller bearing shim (52)" (page 24) in the dis-
assembly procedure.
55 SSM-13-02-004EN
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Travel Unit
[12] Install guide pins at 2 vertically-opposite
locations on the casing (1).
[13] Install the valve plate (54) to the rear cover
(24) according to the reference mark made
at the time of disassembly, and then mount
the shim (52), rear bearing (51) outer race,
brake spring (55), and O-rings (50), (47),
(49).
[14] Insert the rear cover (24) into the casing (1)
according to the guide pins, and tighten
with hexagon socket head bolts M18 × 50
(56) at 2 vertically-opposite locations so
that the rear cover is installed in a parallel
orientation. After tightening the bolts,
tighten with hexagon socket head bolts
M18 × 50 (56) at the locations excluding
the 2 locations with installed guide pins.
After tightening the bolts, remove the guide
pins and tighten the remaining 2 locations
with hexagon socket head bolts M18 × 50
(56).

on feet.
• If the outer race of the rear bearing (51) is
removed, do not forget to install the shim
(52). Check whether the O-rings (47), (49),
(50) are installed to the rear cover (24).
• The tightening torque for the hexagon
socket head bolts M18 × 50 (56) is 324 ±
32.4 N•m.
[15] Install the coupling (58).
[16] Install the spring (34), spring receiver (33),
pilot valve spool (31), and pin (32) to the
rear cover (24), and tighten with the pilot
valve plug (35) installed with the O-ring
(36).
• The tightening torque for the pilot valve plug (35) is 49.0 - 588 N•m.
[17] Install the overload relief valve (57).
• The valve seat (57-3) is fit with a clearance fit, so during installation, install the valve seat
after making sure that it will not come off by applying grease to the fitting sections so that the
valve seat does not fall off or become lost.
• The tightening torque for the overload relief valve (57) is 98.1 - 118 N•m.
[18] Install the orifice (40) and orifice spring (41) to the rear cover (24), and tighten with the plug
(42) installed with the O-ring (43).
• The tightening torque for the plug (42) is 14.7 N•m.
• When using a new orifice (40), adjust the seat section.
(With a hammer, tap the orifice installed to the rear cover.)
SSM-13-02-004EN 56
50
Travel Unit
[19] Insert the spool assembly (26) to the rear cover (24) according to the the reference mark
made at the time of disassembly, and then install the spring receiver (27) and spring (28) in
order.
• The spool assembly (26) is directional, so insert it in the correct direction.
[20] Tighten the M42 plug (29) installed with the O-ring (30).
• The tightening torque for M42 plug (29) is 441 - 446 N•m.
(3) Initial pre-conditioning operation
a) Drain charge
After disassembly and assembly, completely fill the case of the motor casing with hydraulic oil.
This motor has 2 drain ports (G1/2). Perform air bleeding from the port on the side without a
line (top side).
b) Performing initial operation (pre-conditioning operation)
Perform a pre-conditioning operation for about 5 min. at the motor tilting 1st speed and engine
low idle, and check for abnormalities, such as abnormal noise or external leaks.
57 SSM-13-02-004EN
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Travel Unit
6. Troubleshooting
See the troubleshooting section below to perform checking, countermeasures and to solve prob-
lems when any kind of problem occurs in the motor during operation.
(1) General cautions
1) Think before attempting to fix a problem.
Determine the nature of the abnormality before beginning work, and think whether this same
kind of problem has occurred before.
Also, reconfirm whether the motor is the source of the problem.
2) Be careful about dust and dirt.
The cause of wear is very often dust and dirt. So take measures to prevent dust or dirt from
entering the parts during disassembly.
3) Parts handling
Handle parts carefully, be especially careful with the drive section, and do not scratch the slid-
ing sections.
4) Seals handling
Do not damage the seat surfaces of O-rings while performing work.
Also, it is recommended that O-rings be replaced with new ones during disassembly.
(2) Causes of troubles and countermeasures
1) Hydraulic motor does not operate.
Symptom Cause Countermeasure
No pressure rise Operation problem with internal relief valve Repair or replace the relief valve.
1. The parking brake cannot be released. 1. Check the orifice clog, and
(Orifice of release pressure path is then clean or replace the part.
clogged.)
2. The parking brake cannot be released. 2. Install the spool in the correct
(The spool assembly is inverted.) direction.
3. The friction plate or separator plate of 3. Replace the friction plate or
the parking brake section is sticking. separator plate.
Pressure rises.
4. The brake piston of the parking brake 4. Repair or replace the brake
section is sticking. piston outer diameter.
5. Seizing of sliding sections 5. Inspect and then repair or
replace the sliding parts (pis-
ton, shoe, shoe plate, cylinder
block, valve plate, etc.)
6. Spool operation problem 6. Repair or replace.
SSM-13-02-004EN 58
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Travel Unit
2) Weak startup of the hydraulic motor
The set pressure is normal, but
Spool operation problem
there is a delay in the release of Repair or replace.
(Spool sticking)
the parking brake.
The parking brake is released,
The hydraulic oil viscosity is too high. Raise the oil temperature.
but startup is delayed.
1. The parking brake is not fully released.
(Orifice of release pressure path is 1. Check the orifice clog.
clogged.)
The parking brake is released, 2. Clean the relief valve, and then
but startup is weak. 2. Debris is caught in the relief valve. inspect or replace the seat sur-
face.
3. Inspect and repair or replace
3. Seizing of sliding sections
the sliding parts.
3) Rotation speed does not reach the setting value.

1. Check the pump discharge vol-
1. Insufficient oil flow amount ume and the oil pressure path
Rotation speed does not reach up to the motor.
the setting value. 2. The shoe, cylinder block, or valve plate
2. Inspect and repair or replace
shows signs of wear or serious dam-
the part (s).
age.
4) The brake does not operate.

Parking brake operation problem Inspect and repair or replace the
The brake does not operate. a) Wear on the friction plate brake piston, friction plate, and
b) Broken spring spring(s).
a) Sticking of the spool and main unit
The reverse brake works. b) Sticking of the check valve or debris is Repair or replace.
caught in the check valve
c) Orifice hole is clogged.
5) Oil leak
1. Retighten to the specified
1. Bolt and plug loosening
torque.
Oil leak
2. Gouging of O-ring(s) 2. Replace O-ring(s).
3. Leak inside gear casing 3. Replace the oil seal(s).
6) Cannot shift from high speed to low speed.

Cannot shift from high speed to Inspect and repair or replace the
The pilot valve spool is sticking.
low speed. pilot valve spool.
59 SSM-13-02-004EN
53
Travel Unit
7) Abnormal noise emitted
When braking slowly or braking Spool operation problem
at the same time as operating a Air is remaining in the circuit or valve sec- Air bleeding implementation
circuit other than the motor cir- tion.
cuit, a noise is emitted along
with a strong vibration. Spool sticking Repair or replace.
8) Hunting occurs when lowering the plate.

a) Sticking of the spool and main unit Repair or replace.
Strong hunting occurs during b) Orifice seating problem
inching operation. Interference with parking brake
The springs in the spool end section are Repair or replace.
worn or broken.
SSM-13-02-004EN 60
54
Travel Unit
7. Structural diagram
(1) Travel motor
Diagram 1 Travel motor structural diagram

1 Casing 21 Brake piston 41 Orifice spring (brake valve)
2 NPT 1/16 plug 22 D-ring (small diameter) 42 G1/8 plug
3 Oil seal 23 D-ring (large diameter) 43 O-ring 1B P8
4 Circle R retaining ring IRTW68 24 Rear cover 44 Check valve
5 Expansion plug 25 NPT 1/16 plug (mec) 45 Check valve spring
6 Tilting piston 26 Spool assembly 46 M6 orifice (φ0.6)
7 Tilting piston seal 27 Spring receiver 47 O-ring 1B P12.5
8 Steel ball 28 Spring 48 M6 orifice (φ0.8)
9 Shaft 29 M42 plug 49 O-ring 1B P15
10 Bearing HR32209J 30 O-ring 1B G40 50 O-ring 215.57 × 2.62
11 Pivot 31 Pilot spool 51 Bearing HR32207C
12 Shoe plate 32 Pin 52 Shim
13 Cylinder block 33 Spring receiver 53 Parallel pin
14 Cylinder spring 34 Spring 54 Valve plate
15 Spring receiver 35 Pilot valve plug G3/8 55 Brake spring
16 Spherical joint 36 O-ring 1B P14 56 Hexagon socket head bolt M18 × 50
17 Shoe retainer 37 Joint 57 Overload valve
18 Piston assembly 38 G1/4 plug 58 Coupling
19 Separator plate 39 O-ring 1B P11 59 C retainer ring 40 for hole
20 Friction plate 40 Orifice (brake valve) 60 G1/2 plug
61 O-ring 1B P18
61 SSM-13-02-004EN
55
Travel Unit
(2) Reduction gear
Diagram 2 Reduction gear structural diagram

1 Housing 11 Thrust washer 2 21 Spring pin 6 × 36
2 Bearing 245BA35S1GS 12 Needle bearing FBNP-608660 22 Sun gear 1
3 Ring gear 13 Carrier pin 2 23 Thrust plate
4 Hexagon socket head bolt M18 × 110 14 Spring pin 10 × 50 24 Cover
5 Floating seal 368 15 Sun gear 2 25 Hexagon socket head bolt M10 × 30
6 Shim 16 Carrier 1 26 Plug G (PF) 3/4
7 Lock washer 17 Planetary 1 27 O-ring 1B P24
8 Support ring 18 Thrust washer 1
9 Carrier 2 19 Needle bearing FBNP-406040
10 Planetary 2 20 Carrier pin 1
SSM-13-02-004EN 62
56
Take-up Roller SH330-5
Take-up Roller
Removal and Installation of Take-up Roller
・ When loosening the grease cylinder check valve, loosen it a little at a time.
・ The pressure inside the cylinder is very high, so there is a danger of grease being expelled
and the plug flying off. The check valve adjustment procedure should not be done in front of
Warning the check valve.
・ Do not get under the machine when the main unit is jacked up.
・ Make sure to place the main unit on wood planks or the like to prevent falling.
・ Align the shoe assembly feed location and stop the engine except when working.
Items to prepare
• Wrench (24 mm)
• Hammer
• Lifting equipment
• Loctite #262
• Striking jig
• Liftcrane
• Crowbar
• Rag
1. Removal of Take-up Roller
[1] Remove the shoe assembly.
See the "Removal and Installation of Shoe
Assembly" procedure.
[2] Use a crowbar (3) to pull off the take-up roller
(1) and recoil spring assembly from the side
frame (2).
[3] Install the lifting equipment (5) on the take-up

roller (1) and recoil spring assembly (4) and
hang them from the side frame (2) with the lift-
crane.
5 Lifting equipment
63 SSM-13-03-004EN
1
Take-up Roller
[4] Place the take-up roller (1) and recoil spring
assembly (4) onto wood planks (7) as in the dia-
gram. Use a wrench (24 mm) to remove the
take-up roller bolt (6) and separate the roller
and the recoil spring assembly.
SSM-13-03-004EN 64
2
Take-up Roller
2. Installation of take-up roller
[1] Use a wrench (24 mm) to fasten the take-up
roller (1) and recoil spring assembly (2) with the
bolt (3).
At this time, be sure to coat the bolt with Loctite
#262.
[2] Install the lifting equipment (6) on the take-up

roller and recoil spring assembly (2) as in the
diagram, lift them up with the liftcrane, and
insert them into the side frame (5).
Push in with the crowbar until the recoil spring
assembly contacts the grease cylinder.
4 Wood plank
[3] Install the shoe assembly.

For details on installation, see the "Removal and Installation of Shoe Assembly" procedure.
65 SSM-13-03-004EN
3
Take-up Roller
Assembly and Disassembly of Take-up Roller
・ To ensure safe operations, wear protective devices before beginning work and follow all pre-
cautions.
・ When removing devices or positioning devices at the time of installation, use a removal jig
and a hammer or steel rod.
・ Follow the precautions below when suspending the load.
・ The liftcrane must be operated by a qualified operator.
・ Check the weight of the roller to determine whether it can be carried by hand or whether a
liftcrane must be used.
・ Fix the roller to a level surface so it does not roll.
・ Be sure to repair any parts damaged during disassembly, and prepare replacement parts in
advance.
・ If any parts are significantly rusted or dirty, clean them before disassembling.
Caution
・ Any foreign matter entering the equipment during assembly can create a malfunction. There-
fore, after thoroughly cleaning the equipment with cleaning oil, air blow the equipment, and
assemble in a clean location.
・ When assembling sliding (5) parts, be sure to coat them with new hydraulic oil.
・ As a rule, replace all O-rings and other seal parts with new parts.
・ The take-up roller is a heavy object and requires at least 2 workers to handle.
General cautions
・ Be careful not to drop precision parts or let bump them with other parts during work.
・ Do not forcefully open or hit parts in an effort to speed up operations. Pay careful attention
and proceed with caution so as not to damage any parts, create any oil leaks, or compromise
the efficiency of the equipment.
・ Disassembled parts can easily rust or collect dust. Therefore, immediately after disassem-
bling parts, take precautions to prevent the parts from rusting or collecting dust.
Items to prepare
• Hexagon wrench (6 mm)
• Hammer
• Wire clip
• Pliers
• Gear puller
• Screwdriver
• Engine oil (Shell Rimula Oil #30)
• Specialty jigs
• Pressing machine
• Loctite
• Special fiber cloth (Kimwipe)
• Micrometer caliper
• Caliper
• Cylinder gauge
• Seal tape
• Oil pan (drip pan)
• Water container for inspection
SSM-13-03-004EN 66
4
Take-up Roller
Configuration diagram
Code Part name

1 Take-up roller
2 Wrapping bearing
3 Floating seal
4 O-ring
5 Roller shaft
6 Pin hub
7 Hub (with plug)
8 Plug
9 Hub (without plug)
Dimension diagram
Jig dimension diagram

120 145.5
90 152 142
.5 .5
C0 C0
89
70
85
1.0
40
30 X
19
10
5
20 131
C3
A Bushing removal jig

B Bushing press-fit jig
C Floating seal installation jig
67 SSM-13-03-004EN
5
Take-up Roller
Disassembly procedures
[1] After cleaning the roller with kerosene, use the
hexagon wrench (1) to remove the plug (2) from
the hub (3).
• The plug is coated with seal nylon, which comes
off when the plug is removed. Seal tape is nec-
essary for reusing.
[2] Face down the part of the roller from which the
plug was removed and empty the oil from within
the roller.
• It may take a few hours to completely empty the
oil.
• Place an oil pan (4) underneath to catch the oil.
[3] Remove the pin hub (6) from the hub (3), and
remove the hub (3) from the shaft (5).
• Only remove on one side.
SSM-13-03-004EN 68
6
Take-up Roller
[4] After removing the O-ring (7) on the shaft (8),
pull the shaft (6) out from the roller (9).
• The O-ring cannot be reused. Replace them
with new parts.
[5] Remove the pin hub (6) from the hub (3). Next,
after removing the hub (3) from the shaft (8),
remove the O-ring (7) from the shaft (8).
[6] Remove the floating seals (10) from the hub (3).
[7] Remove the floating seals (10) from the roller

(9).
69 SSM-13-03-004EN
7
Take-up Roller
[8] Use a micrometer caliper (11), cylinder gauge
(12), and caliper (13) to measure the roller (with
bushing) (9), hub (3), and shaft (8) for wear and
deformation. Replace with new parts as neces-
sary.
SSM-13-03-004EN 70
8
Take-up Roller
[9] When replacing the bushing (14), remove it by
placing a striking rod (15) against the end sur-
face and striking that with a hammer (16) uni-
formly left and right as in the diagram.
• Do not disassembly the bushing (14) as long as
use has not yet been made impossible due to
wear, etc.
• Be careful not to scratch the inside of the roller
when striking the end of the bushing.
[10] Invert the roller (9), use jig A (17) to push up

against the bushing (14). Pressing with a rod-
shaped object (18) (shaft can be used) will
make the bushing come off.
71 SSM-13-03-004EN
9
Take-up Roller
Assembly procedures
[1] Clean all parts.
• Find a clean location.
• Place a rubber plate or cloth on the work plat-
form so as not to damage the parts.
• In order to clean off adhered matter that forms
sharp points and causes scratches, immerse
parts in cleaning fluid (1) until dirt and grease
float to the top.
[2] After cleaning the parts, air blow them to

remove any remaining cleaning fluid or debris.
• If the parts are to be left as is for a long time
after drying them, apply engine oil.
[3] If the bushing (3) was removed during disas-

sembly, put it into the roller (2). Use a pressing
machine (4) to press in both the left and right
sides.
[4] Use the jigs (5) and (6) attached to the pressing
machine to attach the bushing (3). Use the
pressing machine to press from the opposite
side. Next, use a special fiber cloth to remove all
dust and debris.
SSM-13-03-004EN 72
10
Take-up Roller
[5] Attach the floating seal (8) to the hub (7). Use
jig C (9) to press it into position.
[6] Use jig C (9) to attach the floating seal (8) to the
roller (2) side.
[7] Use a special fiber cloth to thoroughly wipe the

sliding surface of the floating seal to prevent any
dust or scratches.
[8] Apply engine oil to the floating seals (8) on the

hubs.
73 SSM-13-03-004EN
11
Take-up Roller
[9] After attaching the O-ring (12) to the shaft (11),
attach the shaft to the hub (10) and fasten it with
the pin hub (13).
[10] Attach the shaft (11) to the roller (2).
[11] After attaching the O-ring (12) to the shaft (11),

attach the hub and fasten it with the pin hub
(13).
[12] Inject compressed air (0.2 MPa) from the oil fill
port and immerse in water to check that there
are no leaks.
SSM-13-03-004EN 74
12
Take-up Roller
[13] Fill engine oil (120 cc) into the roller main unit.
• The roller main unit can be very unstable, so
give consideration to securing it.
[14] After filling the oil, use a hexagon wrench (6

mm) to tighten the plug (17) with the nylon seal
applied.
• To reuse a plug, wrap it with seal tape.
75 SSM-13-03-004EN
13
Upper Roller SH330-5
Upper Roller
Removal and Installation of Upper Roller
・ When loosening the check valve, loosen it a little at a time and stop when any grease
appears. The pressure inside the cylinder is very high, so there is the danger of grease being
Warning expelled and the plug flying off if the check valve is loosened too much.
The check valve adjustment procedure should not be done in front of the check valve.
Items to prepare
• Jack (That meets the lifting weight.)
• Rag
• Cleaning fluid
1. Removal of Upper Roller
[1] Use a box wrench (19 mm) to loosen the grease
cylinder check valve (1), then loosen the shoe
tension.
• Grease drains out, so provide rag (2) close to
the drain port.
[2] Use a jack (3) to lift the top of the shoe, and
then insert wood planks (4) to separate the
shoe (5) and upper roller (6) by about 10 mm.
76 SSM-13-04-004EN
1
Upper Roller
bolts (7), and then remove the upper roller (6).
SSM-13-04-004EN
2
Upper Roller
2. Installation of Upper Roller
[1] Perform the reverse of the removal procedure.
Apply Loctite to the bolts and tighten them to the
specified torque.
Installation specified tightening torque: 521 -
608 N 疥
[3] To adjust the track shoe tension, raise the lower

side frame as shown in the diagram.
Place a wood plank (2) under the lower frame to
prevent falling.
with A between the frame bottom (3) of the cen-
ter area of the lower side frame and the lowest
hanging part of the top of the shoe plate (4) is
340 - 360 mm.
78 SSM-13-04-004EN
3
Upper Roller
Assembly and Disassembly of Upper Roller
cautions.
advance.
Caution ・ If any parts are significantly rusted or dirty, clean them before disassembling.
・ When assembling touching parts, be sure to coat them with new hydraulic oil.
General cautions
Items to prepare
• Hammer
• Screwdriver
• Engine oil (Shell Rimula Oil #30)
• Specialty jigs
• Loctite 262
• Marking pen
• Caliper
SSM-13-04-004EN
4
Upper Roller
Configuration Diagram
4, 5
1
2 4, 5
3 6
8
7
Code Part name
1 Cover
10
2 O-ring
9
3 Plug
11
4 Hexagon bolt
12 5 Loctite
6 Thrust plate
7 Bushing
8 Shaft
9 Bushing
10 Roller
11 Floating seal
12 Bracket
Dimension Diagram
11 12
4 5
6 7 8 9 10
Jig Dimension Diagram

B1 Bushing press-fit jig (10)
B2 Bushing press-fit jig (9)
80 SSM-13-04-004EN
5
Upper Roller
Disassembly Procedures
[1] Stand the roller vertically and use a hexagon
wrench (6 mm) (1) to remove the plug (2).
off when the plug is removed. To reuse the plug,
using seal tape is necessary.
the roller.
oil.
• Place an oil pan (3) under the roller to catch the
oil.

from the cover (5), and then remove the cover.
SSM-13-04-004EN
6
Upper Roller
bolts (6) inside the roller, and then remove the
thrust plate (7).
[5] Lift the roller (8) and remove the shaft (9).
[6] Remove the floating seal (10) on the roller.

Check whether the sliding surface has rusted or
is damaged.
82 SSM-13-04-004EN
7
Upper Roller
[7] Remove the floating seal (10) on the shaft (9).
[8] Remove the O-ring (11) on the cover (12) side.

• Check whether the O-ring is twisted. If it is
twisted, replace it with a new one.
[9] Use a micrometer caliper to measure the roller

(with bushing) (8), bracket (14), and shaft (9) for
wear and deformation. Replace with new parts
as necessary.
16 Caliper
17 Micrometer caliper
18 Cylinder gauge
SSM-13-04-004EN
8
Upper Roller
[10] When replacing a bushing (19) and (20), use jig
A (15) to restrain it from the side where the shaft
(9) was removed and press it out with a press-
ing machine (13).
8 Roller
84 SSM-13-04-004EN
9
Upper Roller
Assembly Procedures
[1] Clean all parts.
• Find a clean location.
1 Cleaning fluid


sembly, put it into the roller (5). Face up the
thrust plate installation side, restrain from above
using jig B2 (3), and push in with the pressing
machine (4).
SSM-13-04-004EN
10
Upper Roller
[4] Invert the roller (5) and insert the bushing (6).
Restraining from above using jig B1 (7), push in
with the pressing machine (4).
Push in all the way to the position where jig B1
stops.
[5] Insert the floating seal (8) into the roller (5) and
bracket (10). Use jig C (9) to press the floating
seal into position.
[6] Use a special fiber cloth to wipe the surfaces of

the floating seals so as to increase adhesion
and prevent dust from entering.
86 SSM-13-04-004EN
11
Upper Roller
[7] Apply hydraulic oil to the roller (5).
[8] Attach the shaft (11) to the roller (5).
[9] Use a special fiber cloth to thoroughly wipe the

surface of the thrust plate (12) to prevent any
dust or scratches.
SSM-13-04-004EN
12
Upper Roller
[10] Install the thrust plate (12) with 2 bolts (13).
Degrease the bolts well, apply Loctite (14) to the
bolt openings, and tighten the bolts. After tight-
ening the bolts, mark them (15).
[11] Install the cover (18) with 3 bolts (17). Degrease

the bolts, apply Loctite (14) to the bolt openings,
and tighten the bolts. After tightening the bolts,
mark them (16).
[12] Rotate the roller in the direction of the arrow and

check that it rotates smoothly.
88 SSM-13-04-004EN
13
Upper Roller
are no leaks.
[14] Inject engine oil (50 - 55 cc) into the roller. After
filling the engine oil, use a hexagon wrench (20)
to tighten the plug (21) (coated with seal nylon).
After tightening the bolts, mark them (19).
This completes the assembly.
SSM-13-04-004EN
14
Lower Roller SH330-5
Lower Roller
Removal and Installation of Lower Roller
・ Do not get under the main unit when it is jacked up.
Make sure to place the main unit on wood planks to prevent falling.
Warning ・ When loosening the grease cylinder check valve, loosen it a little at a time and stop when any
grease appears. The pressure inside the cylinder is very high, so there is the danger of
grease being expelled and the plug flying off if the check valve is loosened too much.
Items to prepare
• Rag
• Cleaning fluid
1. Removal of Lower Roller
[1] Use a box wrench (19 mm) to loosen the check
valve (1), and then loosen the shoe tension.
• Grease drains out, so provide rag (2) close to
the drain port.
90 SSM-13-05-004EN
1
Lower Roller
[2] Jack up the side frame on the side where the
roller is being replaced, as shown in the dia-
gram.
Jack up so that the shoe is floating about 5 cm,
and insert wood plank (3) under the lower frame
to prevent falling.
[3] If it is impossible to insert wood plank (3) under

the lower frame, insert wood planks (4) between
the side frame and the link shoe (5) to separate
the link shoe and lower roller (6) by about 15
mm.

bolts (7), and then remove the lower roller (6).
SSM-13-05-004EN
2
Lower Roller
2. Installation of Lower Roller
Apply Loctite to the bolts and tighten them to the
specified torque.
Tightening torque: 902 - 1049 N•m
[3] When adjusting the track shoe tension, raise the

lower side frame as shown in the diagram.
Place a wood plank (2) under the lower frame to
prevent falling.
with A between the lower frame (3) of the center
area of the lower side frame and the lowest
hanging part of the shoe plate (4) is 340 - 360
mm.
92 SSM-13-05-004EN
3
Lower Roller
Assembly and Disassembly of Lower Roller
cautions.
advance.
Caution ・ If any parts are significantly rusted or dirty, clean them before disassembling.
・ When assembling sliding parts, be sure to coat them with new hydraulic oil.
General cautions
Items to prepare
• Hammer
• Wire clip
• Pliers
• Gear puller
• Screwdriver
• Gear oil (Mobile Gear Oil SHC320)
• Specialty jigs
• Loctite
• Caliper
• Cylinder gauge
SSM-13-05-004EN
4
Lower Roller
Configuration Diagram
Part name
1 Roller
2 Shaft
3 Bushing
4 Floating seal
5 O-ring
6 Collar (with plug)
7 Wire clip
8 Plug
9 Collar (without plug)
Dimension diagram
9 1 2 3 4 5 6
Jig dimension diagram

B Bushing press-fit jig
94 SSM-13-05-004EN
5
Lower Roller
Disassembly procedures
[1] Stand the roller vertically and use a hexagon
wrench (6 mm) (1) to remove the plug (2).
off when the plug is removed. To reuse the plug,
using seal tape is necessary.
the roller.
oil.
• Place an oil pan (3) underneath to catch the oil.
• Securely fasten so that the roller does not fall
over.
[3] Remove the wire clip (4). Tap another wire (5)
with the hammer (6) from the outside to push
out the wire clip that is already in the roller.
• Place the roller horizontally and secure it so it
does not roll before doing this work.
• The wire in the roller is very securely fixed, so
prepare several wire clips. Also be sure to coat
with lubricant.
SSM-13-05-004EN
6
Lower Roller
[4] Use pliers (7) to remove the pushed out wire
clip (4).
[5] Use a gear puller (8) to remove the collar (9). If

the collar is difficult to remove, hook the collar
on the bolt and catch the puller on that part.
• If the collar has rusted or is difficult to remove
due to an accumulation of debris, subject it to a
shock, for example by hitting it with a hammer,
to make it easier to move.
• When hitting the collar with a hammer, be care-
ful not to dent it.
[6] Check whether the surface of the floating seal

(10) sliding against the removed collar has
rusted or is damaged. Also check whether the
O-ring (11) is twisted.
• The O-ring cannot be reused. Replace it with
new part.
12 Ring
96 SSM-13-05-004EN
7
Lower Roller
[7] Remove the floating seal (10) on the roller. As
described in step [6] above, check whether the
sliding surface has rusted or is damaged. Also
check whether the O-ring is twisted.
[8] Remove the O-ring (13) on the shaft (14).

• The O-ring cannot be reused. Replace it with
new part.
[9] Remove the shaft (14).
SSM-13-05-004EN
8
Lower Roller
[10] As described in Step [7], remove the floating
seal (10) on the opposite side.
[11] Use a caliper (19), micrometer caliper (20), and

cylinder gauge (21) to measure the roller (with
bushing) (17), collars (9) and (18), and shaft
(14) for wear and deformation. Replace with
new parts as necessary.
[12] When replacing a bushing, insert jig A (15) into

the bushing (16), and use a cylindrical object
(such as a shaft) (14) to push from the top.
The bushing comes off.
98 SSM-13-05-004EN
9
Lower Roller
Assembly procedures
[1] Clean all parts by immersing them in cleaning
fluid (1).
• Select a clean location.


sembly, put it into the roller (5). Restraining from
above using jig B (3), push in with the pressing
machine (4).
Invert the roller and insert the bushing on the
opposite side in the same manner.
SSM-13-05-004EN
10
Lower Roller
[4] Use jig C (8) to push the floating seal (6) into the
collar (7) and roller (5) by hand.
[5] Use a special fiber cloth to wipe the surfaces of

the floating seals so as to increase adhesion
and prevent dust from entering.
[6] Apply gear oil to the floating seals (6) on the col-
lars (7) and (9).
100 SSM-13-05-004EN
11
Lower Roller
[7] Attach O-rings (11) to the shaft (10) and mount
into the roller (5).
[8] Install the collars (7) and (9) on both sides.
[9] Attach the wire clip (12).

• When attaching the wire clip, secure the roller
main unit so that it does not roll.
SSM-13-05-004EN
12
Lower Roller
[10] Turn the main unit and check that the roller
rotates properly.
are no leaks.
[12] Fill gear oil (125 cc) into the roller. Use a hexa-
gon wrench (6 mm) (14) to tighten the plug (13)
with the nylon seal applied.
• Mobile Gear Oil SHC320 is recommended for
use.
• The plug tightening torque is 24.5 N 疥 .
102 SSM-13-05-004EN
13
Swing Unit SH330-5
Swing Unit
Removal and Installation of Swing Unit

・ Be sure to inspect the wire rope and other lifting equipment before beginning work.
・ When removing this product from the equipment it is mounted on, stop that equipment sys-
Caution
tem and wait for the surface temperature of this product to fall to about 40 ℃ or below before
removing it. Working on this product while it is still hot can cause burns. Additionally, always
bleed out the pressure before removing any line from this product. Removing a pressurized
line can result in oil spraying out and causing injury or oil leak.
Items to prepare
• Wrenches (14 mm, 19 mm, 22 mm, 27 mm, 36 mm, 41 mm)
• Hexagon wrenches (5 mm, 8 mm, 17 mm)
• Pliers
• Hammer
• Grease
• Specialty adapter for vacuum pump connection
• Vacuum pump (vacuum pump power supply)
• Extension cable
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid
1. Removal of Swing Unit
bolts (1), and then remove the air breather (2)
on the hydraulic oil tank.
103 SSM-13-06-004EN
1
Swing Unit
[2] Attach the specialty adapter (3) to the area
where the air breather was removed, and set
the vacuum pump.
Create negative pressure in the hydraulic oil
tank using the vacuum pump (4).

(5), and then remove the center cover (6).

hexagon bolts, and then remove the hoses (8)
and (9). Next, use a wrench (41 mm) to remove
the hose (7), use a wrench (36 mm) to remove
the hoses (10) and (11), and use a wrench (22
mm) to remove the hose (12).
• Mark the swing motor and hoses so that the
connectors can be matched during assembly.
• Attach caps or plugs to the swing motor and
• Clean the swing motor and hoses by spraying
them with a parts cleaner to prevent scratching
and prevent dirt from accumulating on the con-
nectors.
SSM-13-06-004EN 104
2
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on the clamp (16) for the hose.

bolts (18) from the swing unit.
17 Drain hose
19 Knock pin
105 SSM-13-06-004EN
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Swing Unit
[8] Wrap the wire rope (20) around the swing motor
and lift it with a liftcrane.
• A knock pin (19) is driven into the installation
section of the swing unit. Apply lubricating oil to
the knock pin and pull it out together with the
main unit of the swing motor while hitting with a
hammer.

before lowering the swing unit on wood planks
(21).
• Thoroughly secure the swing unit so that it does
not fall over.
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2. Installation of Swing Unit
When installing the swing unit, be careful with the position of the knock pin.
The tightening torque for the bolts for installing the swing unit on the swing frame is 900 - 1050
N•m.
[2] Before driving, be sure to fill the inside of the motor casing with hydraulic oil from the drain port
(1).
Thoroughly perform air bleeding from the air bleed port (2).
Use the level gauge (3) to check that gear oil for the reduction gear is filled to the stipulated vol-
ume.
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Swing Unit
Assembly and Disassembly of Swing Unit
1. Read and understand the contents of this Maintenance Manual before performing disas-
sembly, reassembly, inspection, repair, or other such work of this product.
2. Handle this product according to the separate "Usage Precautions".
3. When removing this product from the equipment it is mounted on, stop that equipment sys-
4. Use the specialty tools and measurement instruments for disassembly, reassembly, inspec-
tion, and repair, etc. of this product. Using an inappropriate tool may result in injury or prod-
Caution uct damage.
5. Be careful of parts falling when performing disassembly, reassembly, inspection or repair,
etc. of this product. This may result in injury or parts damage.
6. Do not directly touch with bare hands the machined edges or threaded sections of parts
during disassembly, reassembly, inspection, or repair etc. of this product. This may result in
injury.
7. Check performance after reassembly. Do not resume use unless performance is fully recov-
ered. Use may result in damage to product.
8. The cautions (mark !) listed in this Maintenance Manual do not cover all possible dangers.
Always think of safety first during disassembly, inspection, reassembly, repair, or other such
work.
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Swing Unit
1. Disassembly
[1] Making a reference mark on the unit matching
surface
It is useful to place a reference mark (*1) on the
matching surface of the housing (1) and ring
gear (2) with paint, etc.
[2] Removal of level gauge assembly

Remove the level gauge assembly (3) and cap
(4) (27 mm hexagon diameter).
[3] Gear oil draining

Loosen the drain hose (*2) end plug, and then
drain the gear oil.
• Gear oil cannot be reused.
5 Reduction gear
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[4] Removal of hose
Remove the drain hose (*2).
[5] Removal of motor

Use the hexagon wrench (17 mm) to loosen and
remove the 12 hexagon socket head bolts (6).
Use the make-up port (G1) to raise the motor
and remove it.
• Liquid packing has been applied to the match-
ing surfaces of the housing (7) and ring gear (8),
so use the notch sections (*3) in the diagram on
the right to remove the motor.
5 Reduction gear
This completes the disassembly.
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2. Assembly
[1] Application of liquid packing
After cleaning and degreasing the reduction
gear ring gear (1) and the motor housing match-
ing surfaces, apply liquid packing (ThreeBond
Co.,Ltd. "1215" gray or the equivalent) as shown
in the diagram on the right (*1).
[2] Motor installation

Lift the motor and gently install it in the reduc-
tion gear, and use the hexagon wrench (17 mm)
to tighten the hexagon socket head bolts (2) to
the tightening torque of 568 N•m.
• Align the housing (3) and ring gear (4) accord-
ing to the reference mark (*2) made before dis-
assembly.
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[3] Gear oil filling
Install a plug in the female side of the hose, and
install a hose (*3) in the drain port on the side of
the gear case.
Fill with gear oil (6 L) from the housing (3) gear
oil fill port.
[4] Installation of level gauge assembly

Install the cap (5) (27 mm hexagon diameter)
into the housing by tightening it to a torque of 49
N•m, and insert the level gauge assembly (6).
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[5] Grease-up
Remove the plug (8) (5 mm hexagon socket
diameter) from the gear case (7) and inject
grease (1 L) from the grease fill port.
• When injecting grease, there is the possibility of
the reduction gear oil seal being damaged by
internal pressure, so remove the air bleed port
plug before injecting grease.
Tighten the plug to the gear case to a tightening
torque of 20 N•m.
After injecting grease, install the grease hose in
the grease fill port.
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Swing Unit
Assembly and Disassembly of Swing Motor
Caution uct damage.
injury.
ered. Using this product at a sub-par performance level may result in product damage.
work.
SSM-13-06-004EN 114
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Swing Unit
1. Causes of Trouble and Solutions
This list consists of actions to be taken when an abnormality is sensed or there are problems with
functions during use of the hydraulic motor. Additionally, details concerning disassembly inspection
and reassembly are listed after this, but sufficient caution should be exercised in handling during
these actions so as to prevent scratching of sliding parts of the motor.
[1] General cautions
This list consists of actions to be taken when an abnormality is sensed during use of the hydrau-
lic motor.
General cautions are listed below.
1) Think before attempting to fix a problem.
Determine the nature of the abnormality before beginning work and think whether this same
kind of problem has occurred before.
Also, reconfirm whether the motor is the source of the problem.
2) Be careful about dust and dirt.
The cause of wear is very often dust and dirt. So be careful that dust and dirt do not get into
parts during disassembly.
3) Parts handling
Parts are manufactured with a high degree of precision, so be careful not to scratch them dur-
ing handling.
4) Do not damage O-rings or gasket surfaces while performing work. Also, it is recommended that
O-rings are replaced for new ones during disassembly.
[2] Investigating abnormalities in the motor main unit
It is very difficult to search for the source of troubles in the hydraulic circuits. Inspect the following
items and thoroughly investigate whether the motor is the source of troubles.
1) Inspecting oil within the casing
Remove the drain plug and inspect the hydraulic oil within the casing. If a large amount of metal
particles come out at the same time as oil, it is very likely that there is damage with parts within
the motor.
2) Existence of abnormal noise
Check whether abnormal noise is coming from the motor main unit.
3) Measure pressure for each part.
Do not perform disassembly inspection carelessly. Measure pressure for each part and look for
abnormalities in each area.
4) Measure the amount of oil drained from the motor.
1. Operation is normal if about 30 L/min or less of oil drains from the motor when pressurized
oil is applied after the swing is locked.
2. 2 L/min or less of drained oil at constant swing is normal.
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[3] Trouble conditions and countermeasures
1) Hydraulic motor does not rotate.
Symptom Cause Solution

Pressure does not 1. Incorrect setting of the circuit safety 1. Reset safety valve correctly.
rise. valve 2. Disassemble and inspect.
2. Operation problems with relief valve ① Repair or replace sticking sec-
① Plunger sticking tion(s).
② Clogged plunger orifice ② Disassemble and clean.
3. Plunger seating problem 3. Check seating sections and replace
scratched part(s).
Pressure rises. 1. Overload 1. Eliminate load.
2. Seizing of driving part 2. Inspect and repair piston/shoe, cylin-
3. No release pressure acting on the der/valve plate, etc.
brake 3. Inspect and repair circuit.
4. Piston sticking to the brake 4. Disassemble and inspect.
5. Spool for brake release sticking 5. Disassemble and inspect.
6. Friction plate seizing 6. Disassemble and inspect. Replace
seizing part(s).
2) Rotation direction is reversed.

Reversed rotation 1. Motor rotation direction reversed. 1. Check the rotation direction and
direction 2. Input and output for line reversed. assemble correctly.
2. Correct line configurations.
3) Motor speed is not reaching the set value.

Rotation speed does 1. Insufficient oil flow amount 1. Check the pump discharge volume
not reach the setting 2. High temperature and severe leak of and the circuit up to the motor.
value. oil 2. Lower the temperature of the oil.
3. Wear or damage on each sliding 3. Replace part(s).
section
4) Hydraulic motor does not rotate.

Insufficient braking 1. Wear on the friction plate 1. Disassemble and inspect. Replace
torque 2. Brake piston sticking parts worn beyond the limit.
3. Brake release pressure cannot be 2. Disassemble and inspect.
released. 3. Inspect and repair circuit.
4. Spool for brake release sticking 4. Disassemble and inspect.
5. Damaged friction plate spline 5. Disassemble and inspect. Replace
damaged part(s).
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5) Severe hydraulic motor slipping
Investigate the amount of oil drained from the hydraulic motor. Motor operation is normal if the
amount is 500 cc/min or less.

1. Disassemble and inspect.
Slipping is severe 1. Operation problems with relief valve ① Repair or replace sticking sec-
when an external
① Plunger sticking tion(s).
driving torque acts
on the hydraulic ② Clogged plunger orifice ② Disassemble and clean.
motor. 2. Plunger seating problem 2. Check seating sections and replace
scratched part(s).
6) Oil leak
1) Oil leak from oil seal

Oil leak from oil seal 1. Debris lodged in lip causing scratch- 1. Replace oil seal(s).
ing. 2. Stagger the position(s) of the lip and
2. Shaft scratched or worn shaft(s) or replace it (them).
3. Pressure within the casing becoming 3. Repair any clogged drain line(s).
abnormally high caused oil seal lip to 4. Disassemble and repair.
turn up.
4. Shaft rusted.
2) Oil leak from matching surface

Oil leak from match- 1. O-ring has not been inserted. 1. Insert O-ring(s) and assemble.
ing surface 2. Scratched O-ring 2. Replace part(s).
3. Scratched seal surface 3. Disassemble and repair.
4. Loosened or damaged bolt 4. Tighten to the specified torque or
replace.
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2. Maintenance procedures
[1] Replacement standards for worn parts
If wear on any part exceeds the standard values below, replace or readjust that part.
However, parts should be replaced regardless of these standards if they appear to be extremely
damaged based on appearance.
Table 1. Part replacement standards
Standard Value at which replace-

Item dimensions ment is recommended Solution
(mm) (mm)
Clearances between piston and cylinder Replace the piston(s) or cylin-
0.028 0.058
bore (D-d) der(s).
Piston and shoe caulking section back- Replace the piston and shoe
0 0.3
lash (δ) assemblies.
Replace the piston and shoe
Shoe thickness (t) 5.5 5.3
assemblies.
Friction plate thickness 2.0 1.6 Replace the part(s).
Clearance (D-d) Piston and shoe backlash (δ)
Shoe thickness (t)
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[2] Sliding surface repair standards
If the roughness of the sliding surface in any section exceeds the standard values below, repair or
replace that part.
Table 2. Sliding surface repair standards
Standard surface Surface roughness requiring

Part name
roughness repair
0.8 - Z (Ra = 0.2)
Shoe 3 - Z (Ra = 0.8)
(Lapping)
0.4 - Z (Ra = 0.1)
Shoe plate 3 - Z (Ra = 0.8)
(Lapping)
1.6 - Z (Ra = 0.4)
Cylinder 12.5 - Z (Ra = 3.2)
(Lapping)
0.8 - Z (Ra = 0.2)
Valve plate 6.3 - Z (Ra = 1.6)
(Lapping)
Note:
1) Using lapping, make the degree of surface roughness of each sliding surface equal to or lower
than the standard value.
2) If the plate spring and cylinder spherical surface sliding section are rough, these should be
replaced as a set.
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Swing Unit
3. Disassembly
[1] Wrap the wire rope around the outer circumfer-
ence of the motor, lift the motor with a liftcrane,
and clean with white kerosene. After cleaning,
dry the motor using compressed air.
• To prevent foreign matter from entering the
motor, mask each port with tape, etc. and clean
off adhered dirt and dust.
[2] From the drain plug, drain the oil inside the
housing.
[3] Point the shaft end of the drive shaft downwards
and place a reference mark (*1) on the match-
ing surface of the cover (1) and housing (2) with
paint, etc.
• Select a clean location. Place a rubber plate or
cloth on the work platform so as not to damage
the parts.
[4] Loosen the relief valves (3) and remove them

from the cover (1).
• Be sure to replace the O-rings. The O-rings are
damaged when the relief valves are loosened.
[5] Remove the plug (4) from the cover (1) and take
out the spring and plunger.
Be careful not to scratch the plunger seating
sections.
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[6] Loosen the bolts (5) and remove the cover (1)
from the housing (2).
• The cover will rise up from the housing when
the bolts are removed due to the force of the
brake springs.
[7] Remove the valve plate from the cover.
• Do this carefully so as not to let the valve plate
fall from the cover. (The valve plate may be
attached to the cylinder side.)
• When prying open the matching surface with a
screwdriver, be careful not to scratch the sur-
face.
[8] Take out the brake springs (6) from the brake
piston (7).
[9] Use a jig and remove the brake piston (7) from
the housing (2).
• Apply the tips of the jig to the grooves of the
brake piston, and pull straight up.
[10] Reposition the motor on its side, and remove

the cylinder (8) from the drive shaft. Next,
remove the piston, holder plate, plate spring,
and shoe plate.
• Be careful not to scratch the sliding surfaces of
the cylinder, shoe, etc.
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[11] Remove the friction plate and separator plate
(9) from the housing (2).
[12] Take out the drive shaft (11) and shoe plate
(10).
• The spline will damage the oil seal (12) when
the drive shaft is removed, so wrap the spline
section of the drive shaft with vinyl tape, etc.
(*2).
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[13] Perform the following as necessary. Do not
reuse a removed bearing.
• Use a press to remove the inner race of the
roller bearing (13) from the drive shaft (14).
When using a steel rod to hit the inner race of
the roller bearing, hit the inner race evenly while
being careful not to damage the bearing.
• Using a steel rod, tap from the housing section
side of the oil seal, and pull out the outer race of
the roller bearing from the housing.
• Use a slide hammer bearing puller (*3) to
remove the roller bearing (13) from the cover
(1).
123 SSM-13-06-004EN
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4. Assembly
(1) Preparation before operation
Execute the following preparations before reassembly.
1) Check each part for scratches from use or from disassembly. If there are any scratches,
remove them with a whetstone or sandpaper of the necessary grain, clean with pure cleaning
oil, then dry off with an air blower.
2）Replace seal parts with new ones.
3）Thoroughly clean all parts with cleaning fluid and dry with compressed air.
4）When assembling sliding sections, apply clean hydraulic oil before assembling.
[1] Place the housing on an appropriate plat-
form with the cover on top.
[2] If the roller bearing (1) was removed, shrink
fit the inner race of the roller bearing to the
drive shaft (2).
• Be careful with the direction of the flange of
the roller bearing.
[3] Use a jig to insert the oil seal (4) into the
housing (3).
• Be careful with the direction of the oil seal.
• Apply a thin layer of grease to the oil seal
lip section.
• Be careful to evenly hit it without scratching
the outer circumference.
[4] Use a steel rod to install the outer race of

the roller bearing (1) into the housing (3).
SSM-13-06-004EN 124
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[5] Mount the drive shaft (2) in the housing (3).
• Carefully insert it so as not to scratch the
lip section of the oil seal.
• Wrap vinyl tape, etc. around the shaft
spline section to protect it.
[6] Lay the housing on its side and insert the

shoe plate (5).
• Install with the larger chamfered side of the
shoe plate on the housing side.
• Apply a thin layer of grease to the matching
surface to prevent it from falling out.
[7] Set the plate spring (7) on the holder plate

(6), and then set the pistons (8).
125 SSM-13-06-004EN
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Swing Unit
[8] Install the piston assembly (9) to the cylin-
der (10).
[9] Align the piston assembly (9) and cylinder

(10) with the drive shaft spline and insert
into the housing.
[10] Set the housing down with the oil seal side
facing downwards, and alternately install
separator plates (12) and friction plates
(11) in that order to the housing. Install the
4 separator plates and 3 friction plates.
SSM-13-06-004EN 126
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Swing Unit
[11] Mount the O-ring (13) to the housing.
• If grease is applied to the O-ring, it will not
break easily when inserting the brake pis-
ton.
[12] Install the brake piston (14) into the hous-

ing.
[13] Install the brake springs (15) into the brake

piston (14).
127 SSM-13-06-004EN
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Swing Unit
[14] If the roller bearing (17) was removed, use
a hammer and steel rod to insert it into the
cover (16).
[15] Install the valve plate (18) on the cover

(16).
• Apply a thin layer of grease to the matching
surface (*1) of the valve plate.
[16] Mount the O-ring (19) to the cover.

• Apply grease to the O-ring.
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Swing Unit
[17] Install the cover (16) to the housing and
secure with the bolts (20).
• Be careful with the installation direction of
the valve.
• Make sure that the valve plate does not fall
over.
• Make sure that the brake springs (21) do
not fall over.
[18] Insert the plunger (22) and spring to the

cover (16) and tighten the ROMH plug with
the O-ring.
• Check that the plunger moves smoothly.
[19] Mount the relief valve (23) on the cover

(16).
129 SSM-13-06-004EN
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Swing Unit
[20] Assembly confirmation
Open the input/output ports, apply 3.2 - 4.9
MPa of pilot pressure to the brake release
port to check if the output shaft rotates
smoothly for at least 1 rotation with about
30 - 40 N•m of torque. There is an assem-
bly problem if it does not rotate, so disas-
semble again and adjust it.
• At this time, have the drain port open.
• Check that the set pressure of the relief assembly is at the correct pressure after the hydraulic
motor is installed in the actual machine.
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Swing Unit
Brake piston removal jig
1 Brake piston removal jig

2 Brake piston
3 Casing
131 SSM-13-06-004EN
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Swing Unit
Swing motor internal structural diagram
No. Part name Qty No. Part name Qty No. Part name Qty No. Part name Qty
052 valve assyprevention
Reversal 051 Relief valve 2set 303 Valve casing H2 1 702 Brake piston 1
1set
051-1 O-ring 2 351 Plunger H2 2 706 O-ring 1
100 Casing 1 010 Piston subassy 1set 355 Spring H2 2 707 O-ring 1
151 ROH plug 2 101 Drive shaft 1 390 Name plate 1 712 Brake spring 14
161 O-ring 2 111 Cylinder 1 391 Pin 2 742 Friction plate 3
162 O-ring 2 114 Plate spring 1 401 Hex.socket head bolt 4 743 Separator plate 4
163 O-ring 2 121 Piston 9 443 Roller bearing 1 983 Plug 2set
171 Hex.socket head bolt 4 122 Shoe 9 444 Roller bearing 1 984 Plug 1set
400 Reversal prevention 2set 123 Retainer 1 451 Pin 2 985 Plug 1set
valve
124 Shoe plate 1 469 ROMH plug 2 986 Plug 1set
400-1 O-ring 2
131 Valve plate B 1 472 O-ring 1 994 Plug 1set
400-2 Backup ring 2
020 Valve casing H2 subassy 1set 488 O-ring 2
301 Casing K1 1 491 Oil seal 1
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Relief internal structural diagram
1 Seat
2 Poppet
3 Spring
4 Spring seat
5 Shim
6 Liner
7 Piston
8 Cap
9 Backup ring
10 O-ring
11 Holder
133 SSM-13-06-004EN
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Swing Unit
Assembly and Disassembly of Swing Reduction Gear
Caution uct damage.
injury.
ered. Using this product at a sub-par performance level may result in product damage.
work.
SSM-13-06-004EN 134
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Swing Unit
1. Disassembly
(1) Disassembly of swing reduction gear
[1] Remove the plug (11), and then drain the
gear oil.
[2] Remove all bolts (23).
[3] Use a liftcrane to carefully suspend and
remove the swing motor.
[4] Remove the sun gear No.1 (1) and the

planetary carrier No.1 assembly (3).
135 SSM-13-06-004EN
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Swing Unit
[5] Use 2 lifting taps (M10) of the carrier No.2
(29) to remove the planetary carrier No.2
assembly (4) while lifting gently with a lift-
crane.
[6] Remove the sun gear No.2 (5) remaining
on the shaft.
(2) Disassembly of the planetary carrier No.1 assembly

This part cannot disassembled because it has
been caulked.
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(3) Disassembly of the planetary carrier No.2 assembly
[1] Use a jig to insert the spring pins (33) all
the way to the back of the planetary carrier
No.2 (29).
• Do not forcefully insert the parts, as this
can scratch the inner diameter of the pin
holes of the planetary carrier No.2 (29).
[2] Tap from the casting hole on the bottom of

the planetary carrier No.2 (29) and pull out
the planetary pin No.2 (31).
• Be careful not to drop the planetary gear
No.2 (30) and side plate No.2 (32).
[3] Pull out the spring pin (33) from the spring
hole of the planetary pin No.2 (31).
• When securing the planetary pin No.2 (31)
in a vise, use a rag so as not to scratch the
pin.
[4] Perform steps [1] to [3] for 4 locations.
137 SSM-13-06-004EN
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Swing Unit
(4) Disassembly of the case subassembly
[1] Reverse the case subassembly.
[2] Remove the wire (18).
[3] Use 2 lifting tap holes (M16) on the gear
shaft end section (20) to pull out the shaft
subassembly.
(5) Disassembly of shaft subassembly

This part cannot be disassembled.
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Swing Unit
2. Assembly
(1) Assembly of subassemblies
1) Assembly of the planetary carrier No.1 assembly (3)
• This part cannot reassembled because it has been caulked. Be careful when assembling.
[1] Insert the planetary gear No.1 (26) and 1
side plate No.1 (28) in order into the plane-
tary pin No.1 (27).
[2] Face the surface with the counterbore of
the internal teeth gear of planetary carrier
No.1 (25) upward, and place on top of the
jig.
[3] Face the notch with the planetary pin No.1

(27) flange section toward the side of the
outside of the circumference of the plane-
tary carrier No.1 (25), and press fit the
planetary carrier No.1 assembly. Be careful
not to pinch side plate No.1 (28). After con-
tinuing to apply press-fit force for about 5 or
6 sec. after press fitting, release the press-
fit force and remove the jig. Do not insert by
striking with a hammer or other tool, as this
can cause the inner diameter of the plane-
tary carrier hole to stick, reducing the pin
holding force and resulting in damage.
139 SSM-13-06-004EN
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[4] Invert the planetary carrier No.1 assembly.
Caulk using the following procedure.
Rotate the planetary gear No.1 (26) by
hand and check that there is no rotation
unevenness or catching.
[5] Use a caulking jig (*1) to caulk the plane-

tary pin No.1 (27) end section by opening
the end section.
If linear chips form during caulking, be sure
to remove the chips.
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[6] Rotate the planetary gear No.1 (26) by
hand and check again that there is no rota-
tion unevenness or catching. If there is any
rotation unevenness or catching, reassem-
ble using a new part.
Perform steps [1] - [6] at 3 locations to complete operations.
141 SSM-13-06-004EN
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Swing Unit
2) Assembly of the carrier No.2 subassembly (4)
[1] Slide the planetary gear No.2 (30) and side
plate No.2 (32) from the side of the plane-
tary carrier No.2 (29), and place at the
specified position.
[2] Insert the planetary pin No.2 (31) from the

pin hole on the upper side of planetary car-
rier No.2 (29). Insert while being careful
with the insertion direction of the planetary
pin No.2 (31) and the planetary carrier No.2
(29) spring pin (See 3) Assembly of shaft
subassembly.).
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Swing Unit
[3] Check that the spring pin insertion holes of
the planetary carrier No.2 (29) and plane-
tary pin No.2 (31) match, and then use a jig
to hammer the part while paying attention
to the direction (joint facing upward) and
depth (1 mm) of the spring pin 10 × 40 (33).
After hammering, use a punch to punch at
a position about 1 mm from the spring pin
hole, and then perform caulking by deform-
ing the spring pin hole.
[4] Rotate the planetary gear No.2 (30) by

hand and check that there is no rotation
unevenness or catching. If there is any
rotation unevenness or catching, disas-
semble according to "1. (3) Disassembly of
the planetary carrier No.2 assembly" and
reassemble using this procedure.
When reassembling, assemble using a new
pin for the spring pin 10 × 40 (33). (Using
the spring pin prior to disassembly can
reduce the holding force and result in dam-
age.)
Perform steps [1] - [4] at 4 locations to complete operations.
143 SSM-13-06-004EN
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Swing Unit
3) Assembly of shaft subassembly
This describes how to assemble the subassembly of this part by shrink fitting it.
[1] Use a roller bearing (16) and pipe spacer
(19) to warm up to a temperature about 50
℃ warmer than the outside air. The roller
bearing (16) retainer is made of plastic, so
be careful not to deform the part with
excessive temperature. (Less than the
maximum temperature of 120 ℃ )
[2] Place the gear shaft (20) on the platform

with the 2 end surfaces with tapping facing
up.
[3] Be careful to insert the pipe spacer (15) in
the correct up-down direction.
[4] Remove the roller bearing (16) from the
bearing heater and insert.
SSM-13-06-004EN 144
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[5] When the temperature of the roller bearing
(16) reaches to about the temperature of
the outside air, grease up the inside of the
roller bearing (16).
[6] Be careful to insert the bearing cover (17)
in the correct up-down direction.
[7] Remove the pipe spacer (19) from the
bearing heater, and be careful to insert the
pipe spacer (19) in the correct up-down
direction.
[8] When the temperature of the pipe spacer

(19) reaches to about the temperature of
the outside air invert the pipe spacer,
grease up the inside of the roller bearing
(16), and place additional grease (*1) on
top of the roller bearing (16).
145 SSM-13-06-004EN
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Swing Unit
4) Assembly of the case subassembly
[1] Turn the gear case (8) upside-down (with
the large flange up) and place on a surface
plate.
[2] Use lifting taps (M16, 2 locations) of the
gear shaft (20) to insert the shaft subas-
sembly (1) - 3) into the gear case (8) while
lifting with a liftcrane.
[3] Install the wire (18). If not installed suffi-

ciently, the shaft subassembly (1) - 3) can
come off and result in damage, so make
sure that it is properly installed.
[4] Invert the case subassembly being oper-

ated and place it on the jig.Be careful not to
allow the shaft end section to touch the
ground, as the shaft can fall out.
SSM-13-06-004EN 146
44
Swing Unit
[5] Coat the outer circumference of the oil seal
(12) with liquid packing (13) and press fit
with a jig. Apply a thin coat of grease to the
seal lip section and be careful to press fit
without scratching the lip.
[6] Be careful to insert the pipe spacer (10) in

147 SSM-13-06-004EN
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Swing Unit
[7] Use a jig to press fit the roller bearing (9)
into the gear case (8).
[8] Hammer in the 4 knock pins (7).

[9] Degrease the gear case (8) end surface
and apply the liquid packing (22) evenly.
[10] Install while paying attention to the up-

down orientation of the ring gear (6) and
position of the knock pins (7), and tighten
the jig bolts (M20 × 200 hexagon socket
head bolt) and spacers (outer diameter:
φ27.2, inner diameter: φ21.6, height: 20)
at each of the 3 locations.
SSM-13-06-004EN 148
46
Swing Unit
[11] Screw in the plugs (11) and (14) in the
drain port on the gear case (8) side.
149 SSM-13-06-004EN
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Swing Unit
(2) Assembly of the swing reduction gear
[1] Set the case subassembly (1) - 4) on the
jig.
[2] Use lifting taps (M10, 2 locations) of the
planetary carrier No.2 (29) to install the
case subassembly (1) - 4) while lifting the
planetary carrier No.2 subassembly (4)
with a liftcrane. (Picture 27) If installation is
difficult, rotate the carrier a little to make
installation easier.
[3] Insert the sun gear No.2 (5).
[4] Insert the thrust plate (2) into the grooves

on the sun gear No.2 (5) end surface.
SSM-13-06-004EN 150
48
Swing Unit
[5] Insert the planetary carrier No.1 subas-
sembly (3).
[6] Be careful to insert the sun gear No.1 (1) in

[7] Check that the distance between the end

surfaces of the sun gear No.1 (1) and ring
gear (6) is 1.04 - 3.70 mm (sun gear No.1
(1) is lower than ring gear (6)).
If the distance is less than 1.04 mm
• The gear shaft (20) and roller bearing (16)
are shifted.
• The roller bearing (9) is not inserted all the
way to the back.
• Foreign matter is caught inside.
If the distance is greater than 3.70 mm
• The wire (18) installation is insufficient.
• The ring gear (6) is not tightened all the
way on the gear case (8).
• Foreign matter is caught inside.
These are possible causes, so disassem-
ble and reassemble the part.
151 SSM-13-06-004EN
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Swing Unit
[8] After removing the spacer and jig bolt used
to assemble the case subassembly (1) - 4)
and degreasing the ring gear (6) end sur-
face, apply the liquid packing (22) evenly.
[9] After degreasing the screw section of the

hexagon socket head bolt M20 × 200 (23)
attaching the swing motor, apply the liquid
packing (24) to the screw section, and
tighten to a tightening torque of 568.4 -
649.7 N•m at 12 locations.
[10] Fill with 6 liters of gear oil (viscosity classifi-

cation: GL-4 L or greater).
SSM-13-06-004EN 152
50
Swing Unit
Jig 1
(For assembly of oil seal (70))
Jig 2
(For assembly of pinion shaft (61))
153 SSM-13-06-004EN
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Swing Unit
SH330-5 Swing reduction gear internal structure diagram
Code Part name Code Part name

1 Sun gear No.1 13 Liquid packing
2 Thrust plate 14 Plug with seal nylon
3 Planetary carrier No.1 assembly 15 Pipe spacer
4 Planetary carrier No.2 assembly 16 Roller bearing
5 Sun gear No.2 17 Bearing cover
6 Ring gear 18 Wire
7 Knock pin D16 × 40 19 Pipe spacer
8 Gear case 20 Gear shaft
9 Roller bearing 21 Grease (Lithium-series, consistency number: 2)
10 Pipe spacer 22 Liquid packing
11 Plug with seal nylon 23 Hexagon socket head B M20 × 200
12 Oil seal 24 Liquid packing
SSM-13-06-004EN 154
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Swing Unit
Planetary Carrier No.1 Assembly Diagram
KSC0245X-B00
Planetary Carrier No.2 Assembly Diagram
KSC0246X-B00
155 SSM-13-06-004EN
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Center Joint SH330-5
Center Joint
Removal and Installation of Center Joint
Items to prepare
• Hexagon wrenches (5 mm, 8 mm)
• Specialty adapter for vacuum pump connection
• Vacuum pump (vacuum pump power supply)
• Extension cable
• Marking pen
• Cap
• Plug
• Rag
• Cleaning fluid
1. Removal of center joint
bolts (1), and then remove the air breather (2)
on the hydraulic oil tank.

the vacuum pump (4).
tank using the vacuum pump.
156 SSM-13-07-004EN
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Center Joint
bolts (5), and then remove the lower under cov-
ers (6).
[4] Prepare a waste oil can (7) to receive the oil that
spills out under the center joint.
[5] Use a wrench (41 mm) to remove the travel

hoses (8) and a wrench (27 mm) to remove the
drain hoses (9).
• Mark the center joint and hoses so that the con-
nectors match at the time of assembly.
• Attach caps or plugs to the center joint and
• Clean the center joint and hoses by spraying
nectors.
SSM-13-07-004EN
2
Center Joint
[6] Use a wrench (19 mm) to remove the pilot hose
(10) and a wrench (27 mm) to remove the drain
hose (11).
• Attach caps or plugs to the center joint and
• Clean the center joint and hoses by spraying
nectors.

(12), and then remove the center joint lock bar
(13).
[8] Use a hexagon wrench (8 mm) to remove each

group of 4 hexagon bolts, and then remove the
4 travel hoses (14).
• Mark the hoses so that the connectors can be
matched during assembly.
• Attach caps or plugs to the hoses to prevent any
entry of water, dust or dirt.
• Clean the hoses by spraying them with a parts
cleaner to prevent scratches and prevent dirt
from accumulating on the connectors.
158 SSM-13-07-004EN
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Center Joint
[9] Wrap a wire ropes (15) around the center joint
and suspend it with a liftcrane so that the center
joint does not fall during removal and installation
operations.

(16) from the center joint.
[11] Use the wire rope (15) and liftcrane to lift the
center joint (17).
before lowering the center joint on wood planks.
SSM-13-07-004EN
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Center Joint
2. Installation of center joint
The tightening torque for the center joint bolts
(1) is 109 - 127 N•m.
[2] The tightening torque for the lock bar (2) bolts
(3) is 267 - 312 N•m.
Also, apply Loctite #262 to the bolts.
160 SSM-13-07-004EN
5
Counterweight SH330-5
Counterweight
Removal and Installation of Counterweight
・ Be sure to inspect the wire rope and other lifting equipment before beginning work.
Caution ・ Do not stand or pass under the suspended load.
・ Thoroughly secure the removed counterweight with the wire ropes and liftcrane so that it
does not fall over.
Items to prepare
• Balance lifting device
• Wire rope (with the required breaking load × 4)
• Rag
• Cleaning fluid
1. Removal of counterweight
[1] Install the shackles (1), and then use the wire
ropes (2) and liftcrane to secure the counter-
weight so that it does not fall during removal and
installation operations.

bolts (3) at the bottom section of the counter-
weight.
161 SSM-13-08-004EN
1
Counterweight
[3] Use the wire ropes and liftcrane to lift and
remove the counterweight.
• Move the counterweight about 50 cm to the rear
while lifting it so that it does not interfere with
the housing, engine parts and pipes.

before lowering the counterweight on wood
planks (8).
• Thoroughly secure the counterweight with the
wire ropes and liftcrane so that it does not fall
over.
2. Installation of counterweight
The tightening torque for the counterweight bolts is 1862 - 2058 N•m.
Do not apply oil, etc. to the bolts.
SSM-13-08-004EN 162
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Hydraulic Pump SH330-5
Hydraulic Pump
Removal and Installation of Hydraulic Pump

Items to prepare
• Wrenches (10 mm, 13 mm, 17 mm, 19 mm, 27 mm, 30 mm, 36 mm, 41 mm)
• Nylon sling (with the required breaking load)
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid
1. Removal of hydraulic pump
[2] Remove the engine hood. For the procedure,

see "Removal and Installation of Engine Hood".
[3] Tighten the cock (3).
163 SSM-13-09-004EN
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Hydraulic Pump
plug (5).
SSM-13-09-004EN 164
2
Hydraulic Pump
[7] Drain the fuel.
[8] Loosen the hose bands (8), and then remove

the 2 hoses (7).
(9), and then remove the fuel filter (10).
165 SSM-13-09-004EN
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Hydraulic Pump
[10] Remove the charge fuel pump filter.
For the procedure, see "Charge Fuel Pump Fil-
ter in Procedures for Replacing Consumable
Parts".
plug (12) of the fuel pre-filter (11).
[12] Loosen the cap (13) at the bottom and drain out
any remaining fuel.
[13] Remove the 2 hoses (15).

and then remove the fuel pre-filter (11).
SSM-13-09-004EN 166
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Hydraulic Pump
[15] Remove the engine oil filter hoses (17).
and then remove the engine oil filter (19).
[17] Remove the 3 pilot filter (20) hoses (21).

(22), and then remove the pilot filter (20).

(23), and then remove the 4 covers (24), (25),
(26), and (27).
[20] Use a wrench (19 mm) to remove the bolts, and
then remove the right housing frame (28).
167 SSM-13-09-004EN
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Hydraulic Pump
[21] Remove the hoses and connectors that are con-
nected to the pump.
• Use a hexagon wrench (10 mm) to remove the 8
hose bolts (29), and remove the pressure hoses
(30).
• Use a wrench (41 mm) to remove the drain hose
(31).
• Use a wrench (27 mm) to remove the pilot hose
(32).
• Use a wrench (36 mm) to remove the suction
hose (33).
• Remove the connectors (34).
• Use a wrench (19 mm) to remove the hydraulic
pilot hoses (35).
• Use a hexagon wrench (14 mm) to remove the
suction line bolt and remove the suction line
(36).
• Mark the pump and hoses so that the connec-
• Attach caps or plugs to the pump and hoses to
• Clean the pump and hoses by spraying with a
parts cleaner to prevent scratches and prevent
dirt from accumulating on the connectors.
[22] Secure the pump with a liftcrane and nylon sling
(37) so that it does not fall during removal and
installation operations.
SSM-13-09-004EN 168
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Hydraulic Pump
(38) from the pump.
[24] Use a liftcrane and the nylon sling (39) to pull

the pump out from the shaft and lift the pump.

before lowering the pump on wood planks (40).
• Thoroughly secure the pump so that it does not
fall over.
169 SSM-13-09-004EN
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Hydraulic Pump
2. Installation of hydraulic pump
The tightening torque for the pump bolt (38) is 63.7
- 73.6 N•m.
Fill the pump case with hydraulic oil from the drain
port so that no air remains in the pump case.
Additionally, when there is a 2nd option gear pump,
bleed off air from the air bleed port on the top sur-
face of the power take-off case.
SSM-13-09-004EN 170
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Hydraulic Pump
Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit
1. Tools
The table below shows the tools required for assembly and disassembly of the K3V/K5V pump. The
bolts and plugs may vary by pump type.
Tool name Tools dimensions

Hexagon wrench 4, 5, 6, 8, 14, 17 (B dimension, mm)
Socket wrench, double-head (single-head) wrench 19, 27 mm
Monkey wrench Medium-sized
Screwdriver Flathead screwdriver (medium-sized) × 2
Plastic hammer
Torque wrench With adjustable specified torque tightening
Snap ring pliers For stop ring, TSR-160
Steel rod Key material steel rod, 10 × 8 × 200
Tweezers
Bolt M8, L = about 50
2. Disassembly procedures
When disassembling the pump, read the disassembly procedures all the way to the end before dis-
assembling according to the sequence below.
The numbers in the parentheses after the part names indicate part numbers in the pump structural
diagram.
This manual lists the disassembly procedures for the tandem pump. Perform disassembly using the
type column as reference.
Also, be careful that parts from the front pump and rear pump do not get mixed together.
[1] Select a location for disassembly.
[2] Use cleaning oil to remove any dirt or rust from
the surface of the pump.
[3] Remove the drain port plugs (468) and drain the
oil from the pump casing.
• Remove the plugs from both the front and rear
pumps.
[4] Remove the hexagon socket head bolts (412,
413), and remove the regulator.
• See the manual for the regulator for how to dis-
assemble the regulator.
171 SSM-13-09-004EN
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Hydraulic Pump
[5] Loosen the hexagon socket head bolts (401)
that fasten together the swash plate support
boards (251), pump casings (271), and valve
block (312).
• When a gear pump, etc. is attached to the pump
rear surface, remove the gear pump, etc. first
before performing work.
[6] Face down the pump regulator installation sur-
face horizontally on the work platform, and sep-
arate the pump casing (271) and valve block
(312).
• When placing the regulator with the installation
surface facedown, be sure to place a rubber
plate or similar material on the work platform so
as not to damage the regulator installation sur-
face.
• When separating the pump casings and valve
block, remove the 1st gear at the same time.
[7] Remove the cylinder blocks (141) out from the
pump casings (271) in a straight line in relation
to the drive shafts (111), and remove the pis-
tons (151), holder plates (153), spherical bush-
ings (156), and cylinder springs (157) at the
same time.
• Be careful not to damage the sliding surfaces of
the cylinders, spherical bushings, shoes, and
swash plates.
[8] Remove the hexagon socket head bolts (406)

and remove the seal cover (F) (261).
• Removal can be performed easily by inserting a
bolt into the hole on the seal cover (F) and then
pulling the bolt out.
• The seal cover (F) has an oil seal, so be careful
not to damage the oil seal when removing the
seal cover.
SSM-13-09-004EN 172
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Hydraulic Pump
[9] Tap the installation flange section of the swash
plate support board (251) on the pump casing
side, and separate the swash plate support
board and the pump casing.
[10] Remove the shoe plates (211) and swash plates

(212) from the pump casings (271).
[11] Lightly strike the shaft end sections of the drive

shafts (111, 113) with a plastic hammer, etc. to
remove the drive shafts from the swash plate
support board.
173 SSM-13-09-004EN
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Hydraulic Pump
[12] Remove the valve plates (313, 314) from the
valve block (312).
• These can also be removed in Step [6].
[13] If necessary, remove the stopper (L) (534), stopper (S) (535), servo piston (532), and tilting pin
(531) from the pump casing (271), and remove the needle bearing (124) and 1st gear (116) from
the valve block (312).
• To avoid damaging the heads of the tilting pins, use a jig when removing them.
• Loctite has been applied to the sections where the tilting pins and servo pistons are bonded, so
be careful not to damage the servo pistons.
• Try to avoid removing the needle bearings unless they are at the end of their service life.
• Do not loosen the hexagon nuts of the valve block or swash plate support boards. This changes
the flow volume setting.
SSM-13-09-004EN 174
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Hydraulic Pump
3. Assembly procedures
The assembly procedure is the reverse of the disassembly procedure. However, follow the precau-
tions below.
[1] Be sure to repair any parts damaged during disassembly, and prepare replacement parts in
advance.
[2] Thoroughly clean all parts with cleaning oil and air blow them before assembly.
[3] Be sure to apply clean hydraulic oil to sliding parts and bearings before assembly.
[4] As a rule, replace all O-rings, oil seals, and other seal parts with new parts.
[5] Use a torque wrench to tighten all installation bolts and plugs to the torque specified in "Mainte-
nance Standards."
[6] Be careful not to mix up the pump parts for the front and rear.
[1] Install the swash plate support board (251) on
the pump casing (271) by lightly striking it with a
hammer.
• If the servo pistons, tilting pin, stoppers (L), and
stoppers (S) have been removed, assemble
these parts on the pump casings in advance.
• To avoid damaging the heads of the tilting pins
and the feedback pins, use a jig when tightening
the servo pistons and tilting pins. Also be sure
to apply Loctite (moderate strength) to the
threaded sections.
[2] Face down the regulator installation surface of

the pump casing, insert the tilting bushing of the
swash plate onto the tilting pin (531), and cor-
rectly mount the swash plate (212) and swash
plate support board (251).
• Use the fingertips of both hands to check that
the swash plates move smoothly.
• Coat the swash plates, swash plate support
boards, and all sliding sections with grease for
easier installation of the drive shaft.
175 SSM-13-09-004EN
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Hydraulic Pump
[3] Install the drive shaft (111) with a bearing (123),
bearing spacers (127), and stop ring (824)
attached to the swash plate support board
(251).
• Do not strike the drive shaft with a hammer, etc.
• Lightly strike the outside ring of the bearing with
a plastic hammer to install it, and use a steel
rod, etc. to tightly insert it all the way in.
[4] Attach the seal cover (F) (261) to the pump cas-
ing (271), and secure with the hexagon socket
head bolts (406).
• Apply a thin layer of grease to the oil seal inside
the seal cover (F).
• Be careful not to damage the oil seal when
attaching it.
SSM-13-09-004EN 176
14
Hydraulic Pump
[5] Assemble the piston cylinder subassembly [cyl-
inders (141), pistons (151, 152), holder plates
(153), spherical bushings (156), spacers (158),
cylinder springs (157)], and insert it into the
pump casing in alignment with the phase of the
splines of the spherical bushings and cylinders.
[6] Install into the valve block (312) while aligning

the valve plate (313) with the pin (885).
• Be careful not to mistake the suction and dis-
charge directions of the valve plates.
[7] Install the valve block (312) into the pump cas-
ing (271) and tighten it with the hexagon socket
head bolts (401).
• Assembly is easier when starting with the rear
side pump.
• Install the valve block in the correct direction.
(Install the valve block with the regulator facing
up and the suction flange facing to the right
when looking at the valve block from the front.))
• Insert the 1st gear into the valve block before-
hand and couple it with the drive shaft joint sec-
tion spline.
177 SSM-13-09-004EN
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Hydraulic Pump
[8] Insert the feedback pins of the tilting pins into
the feedback lever of the regulators, install the
regulators, and tighten the hexagon socket head
bolts (412, 413).
• Install the regulator, making sure not to mistake
the front and the rear of the regulator.
[9] Attach the drain port plugs (468) to finish

assembly.
SSM-13-09-004EN 178
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Hydraulic Pump
Pump Main Unit Maintenance Standards
1. Standards for replacing worn parts
If any part exceeds the standard values below and is worn, replace or readjust that part. If, however,
the appearance of the part shows significant damage, replace that part.
Standard dimensions/
Part name and inspection item recommended replace- Solution
ment value
Piston and cylinder bore clearance
0.038/0.065 Replace the piston or cylinder.
(D-d)
Piston, shoes, and caulking section
0 ～ 0.1/0.3 Replace piston and shoe assembly.
backlash (δ)
Shoe thickness (t) 5.4/5.0 Replace piston and shoe assembly.
Free height of cylinder springs (L) 40.9/40.1 Replace cylinder springs.
Assembled height of holder plate
23.8/22.8 Replace holder plate or spherical bushing.
and spherical bushing (H-h)
179 SSM-13-09-004EN
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Hydraulic Pump
2. Standards for repairing cylinders, valve plates, and swash plates (shoe plates)
Valve plate (sliding section) Surface roughness requiring
3-Z
Swash plate (shoe plate section) repair
Cylinder Standard surface roughness
0.4 Z or lower (lapping)
Surface roughness (repair value)
3. Tightening torque
Tightening torque Tool name
Part name Size
(N•m) (mm)
M5 6.9 B=4
M6 11.8 5
M8 29.4 6
M10 56.9 8
Hexagon socket head bolt M12 98.1 10
M14 156.9 12
M16 235.4 14
M18 333.4 14
M20 431.5 17
R 1/16 70 4
R 1/8 105 5
Rc plug
Note: Wrap seal tape around the R 1/4 175 6
Hexagon
plug 1.5 - 2 times
R 3/8 350 8 wrench
R 1/2 500 10
G1/4 300 6
G1/2 1,000 10
G3/4 1,500 14
PO plug
G1 1,900 17
G1 1/4 2,700 17
G1 1/2 2,800 17
SSM-13-09-004EN 180
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Hydraulic Pump
Overall view
Attached diagram 1. pump assembly cross-section diagram
Drive shaft front side Drive shaft rear side
Drive shaft front side
SSM-13-09-004EN
19
Hydraulic Pump
Part table
Code Part name Q'ty Component part no. (quantity) or type Code Part name Q'ty Code Part name Q'ty
04 Gear pump 1 set ZX15LHRZ2-07A-V 111 Drive shaft (F) 1 531 Tilting pin 2
011 Piston subassembly 2 set 151 (9PC), 152 (9PC) 113 Drive shaft (R) 1 532 Servo piston 2
013 Cylinder subassembly (R) 1 set 141 (1PC), 313 (1PC) 114 1 set gear 1 534 Stopper (L) 2
014 Cylinder subassembly (L) 1 set 141 (1PC), 314 (1PC) 123 Cylinder roller bearing 2 535 Stopper (S) 2
030 Swash plate subassembly 2 set 212 (1PC), 214 (1PC) 124 Needle roller bearing 2 541 Seat 4
041 Check valve 1 subassembly 2 set 541 (1PC), 543 (1PC), 545 (1PC) 127 Bearing spacer 4 543 Stopper 1 2
042 Check valve 2 subassembly 2 set 541 (1PC), 544 (1PC), 545 (1PC) 141 Cylinder block 2 544 Stopper 2 2
Electromagnetic proportional 151 Piston 18 545 Steel ball 4
079 pressure reducing valve and 1 set KDRDE5KR-V3-V 152 Shoe 18 548 Feedback pin 2
casing subassembly
153 Holder plate 2 702 O-ring 2
530 Tilting pin subassembly 2 set 531 (1PC), 548 (1PC)
156 Spherical bushing 2 710 O-ring 1
1 Adhesive (ThreeBond No. 130SN) coating 157 Cylinder spring 18 714 O-ring 1
Oil seal outer circumference Lubricant (SEALUB L101) 211 Shoe plate 2 717 O-ring 2
1 coating 212 Swash plate 2 724 O-ring 16
3 Right rotation valve plate 214 Tilting bushing 2 725 O-ring 6
4 Left rotation valve plate 251 Swash plate support board 2 728 O-ring 4
5 Tightening torque Flange socket (4-M10 × 1.5) 33 N•m 261 Seal cover (F) 1 732 O-ring 2
6 Tightening torque Hexagon bolt (3-M6 × 1.0) 12 N•m 271 Pump casing 2 774 Oil seal 1
312 Valve block 1 789 Backup ring 2
313 Valve plate (R) 1 792 Backup ring 2
314 Valve plate (L) 1 808 Hexagon nut 2
326 Cover 1 824 Stop ring 2
401 Hexagon socket head bolt 8 885 Valve plate pin 2
406 Hexagon socket head bolt 4 886 Spring pin 4
414 Hexagon socket head bolt 4 901 Eyebolt 2
466 VP plug 2 Hexagon socket head locking
953 2
screw
467 VP plug 2
954 Locking screw 2
468 VP plug 4
981 Nameplate 1
490 Plug 27
983 Driving tack 2
492 Plug 12
Drive shaft rear side
182 SSM-13-09-004EN
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Hydraulic Pump
4. Operation explanation
[1] Flow control
The pump discharge flow is controlled as desired with the pilot pres-
sure Pi as in the diagram on the right.
1) Flow reduction operation
When the pilot pressure Pi increases, the pilot piston (643) moves
to the right and stops at the location where the pilot spring (646)
force and hydraulic pressure force balance each other.
The pin (875) fixed to lever 2 (613) fits into the crimped groove sec-
tion [A section] of the pilot piston, so lever 2 rotates through the
movement of the pilot piston with point B [fastened by the fulcrum
plug (614) and pins (876)] as the fulcrum. The pin (897) fixed to the
feedback lever (611) projects into the large opening [C section] of lever 2, so as lever 2 rotates,
the pin (897) moves to the right. The pin (548) fixed to the tilting pin (531) that shakes the
swash plate is bonded to the 2-side width section [D section] of the feedback lever. Therefore,
as the pin (897) moves, the feedback lever rotates with section D as the fulcrum. Since the
spool (652) is linked to the feedback lever via the pin (874), the spool moves to the right.
When the spool moves, the discharge pressure P1 is led to the servo piston large-bore cham-
ber via the spool and port. The discharge pressure P1 is always led to the servo piston
small-bore chamber, but the servo piston is moved to the right due to the surface area differ-
ence and the tilting angle is reduced.
When the servo piston moves to the right, point D also moves to the right. The return spring
(654) is mounted on the spool. Since force pulling the spool to the left is always acting, the pin
(897) is pressed into the large opening (C section) of lever 2. Because of this, accompanying
the point D movement, the feedback lever rotates around the point C as the fulcrum and the
spool moves to the left.
This movement causes the open section between the sleeve (651) and the spool (652) to begin
to close, and the servo piston stops at the point the open section fully closes.
2) Flow increase operation
When the pilot pressure Pi decreases, the pilot piston (643) is moved to the left by the pilot
spring (646) force and lever 2 (613) rotates with point B as the fulcrum. The pin (897) is pressed
in the large opening [C section] of lever 2 by the return spring (654) via the spool (652), pin
(874), and feedback lever (611), so accompanying rotation of lever 2, the feedback lever rotates
with point D as the fulcrum and the spool moves to the left.
When the spool moves, the port opens to the tank port, so the pressure in the large-diame-
ter section of the servo piston drains out, the servo piston is moved to the left by the discharge
pressure P1 of the small-diameter section and the flow increases.
Accompanying the movement of the servo piston, point D moves to the left, the feedback lever
rotates with point C as the fulcrum, and the spool moves to the right. This operation continues
until the open section between the spool and sleeve closes, and then the servo piston stops at
the point the open section fully closes.
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Hydraulic Pump
[2] Horsepower control
As in the diagram on the right, the pump tilting angle decreases
when the load pressure increases and overload of the power
source is prevented and overload of the self pump is prevented.
The regulator utilizes a method to control horsepower in which a
hydraulic force that is the sum of the self pump pressure multiplied
by 1.33 and the counterpart pump pressure multiplied by 0.67 is
transmitted as a signal.
Compensation piston surface area
　Self pump pressurized area: counterpart pump pressurized area = 2 : 1
1) Overload prevention operation

When the self pump discharge pressure P1 or the counterpart pump discharge pressure P2
rises, since P1 and P2 act on the stepped section of the compensation piston (621), the com-
pensation rod (623) is pressed to the right and moves to the location where the force of the
outer spring (625) and inner spring (626) balance out the hydraulic pressure force. The move-
ment of the compensation rod is transmitted to lever 1 through the pin (875) and lever 1 rotates
around the pin (876) (point E) fastened to the casing (601). The pin (897) fixed to the feedback
lever (611) projects into the large opening [F section] of lever 1, so as lever 1 rotates, the feed-
back lever rotates with point D as the fulcrum and the spool (652) moves to the right.
When the spool moves, the discharge pressure P1 is led to the large-bore chamber of the servo
piston via the port, the servo piston is moved to the right, and the pump discharge flow is
decreased to prevent overload of the power source.
The servo piston movement is transmitted to the feedback lever via point D. The feedback lever
rotates with point F as the fulcrum and the spool moves to the left. The spool moves until the
open section with the sleeve (651) closes, and then the servo piston stops at the point the open
section closes.
2) Flow return operation
If the self pump discharge pressure P1 or the counterpart pump discharge pressure P2
decreases, the compensation rod (623) is pressed back by the springs (625, 626) and lever 1
rotates about point E. Accompanying the lever 1 rotation, the feedback lever rotates around
point D as the fulcrum and the spool moves to the left. Because of this, the port opens to
the tank port, the servo piston large-diameter section pressure drains off, the servo piston
moves to the left and the pump discharge flow increases.
The movement of the servo piston is transmitted to the spool by the feedback mechanism, and
this operation continues until the open section between the spool and the sleeve closes.
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Hydraulic Pump
[3] Low tilting (low flow) command priority mechanism
As above, the flow control and the horsepower control tilting command is transmitted to the feed-
back lever and spool via the large openings [C and F sections] of lever 1 and lever 2, but since
the C and F sections have a structure in which a pin (φ4) projects into a large hole (φ8), the pin
(897) only contacts the lever that makes the tilting smaller and the φ8 hole for the lever on the
side that has the larger tilting command state is free rather than being in contact with the pin
(897). This type of mechanical selection method gives priority to flow control and horsepower
control commands with low tilting.
[4] Power shift control (decreased horsepower control)
Use the power shift pressure Pf to arbitrarily control the pump set
horsepower as in the diagram on the right. When the power shift
pressure Pf increases, the compensation rod (623) is moved to the
right via the pin (898) and the compensation piston (621), so the
pump tilting angle and the horsepower setting are reduced in the
same way as was explained with the overload prevention operation
of horsepower control. By contrast, as the power shift pressure Pf
decreases, the horsepower setting increases.
5. Regulator adjustment
The adjusting screws on this regulator can be used to adjust the maxi-
mum flow, minimum flow, horsepower control properties, and flow control properties. (Each of the
adjustment amounts is shown in "6. (1) Regulator adjustment amount list".)
[1] Maximum flow adjustment
Loosen the hexagon nut (808) and tighten (or loosen) the locking
screw (954) to adjust the maximum flow. This only changes the max-
imum flow. It does not change the other control properties.
[2] Minimum flow adjustment

Loosen the hexagon nut (808) and tighten (or loosen) the hexagon
socket head locking screw (953) to adjust (or tighten) the minimum
flow. Similar to the maximum flow adjustment, this does not change
other control properties. However, if the hexagon socket head locking
screw is tightened too much, the required power may increase at the
time of maximum discharge pressure (during relief), so adjust this
carefully.
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Hydraulic Pump
[3] Input horsepower adjustment
This regulator uses the simultaneous full-horsepower method. Therefore, when changing the
horsepower setting, adjust the adjusting screw of both the front and rear pumps to the same
amount.
The pressure change value resulting from adjustment is the value when pressure boost is simul-
taneously performed with both pumps.
1) Outer spring adjustment
Loosen the hexagon nut (630) and tighten (or loosen) the adjusting
screw (C) (628) to adjust the outer spring. As the adjusting screw is
tightened, the control diagram shifts to the right as in the diagram
on the right and the input horsepower increases. When the adjust-
ing screw (C) is rotated N times, the inner spring setting also
changes. Therefore, return the adjusting ring (C) (627) by rotating it
N × A times in the opposite direction.
2) Inner spring adjustment

Loosen the hexagon nut (802) and tighten (or loosen) the adjusting
ring (C) (627). As the adjusting screw is tightened, the flow
increases as in the diagram on the right and the input horsepower
increases.
[4] Flow control properties adjustment

Loosen the hexagon nut (801) and tighten (or loosen) the hexagon
socket head locking screw (924) to adjust the flow control properties.
As the hexagon socket head locking screw is tightened, the control
diagram shifts to the right as in the diagram on the right.
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Hydraulic Pump
6. Tables and diagrams
[1] Regulator adjustment amount table
Speed (min-1) 2,030

Adjusting screw (954) tightening amount (rotation) +1/4
Maximum flow adjustment
Flow change volume (L/min) 6.3
Minimum flow adjustment
Outer spring Compensation control start pressure change volume (MPa) 1.75
adjustment Input torque change volume (N•m) 71.6
Input horsepower
A 1.9
adjustment
Inner spring
adjustment
Input torque change volume (N•m) 63.7
Adjusting ring (627) tightening amount (rotation) +1/4
Flow control properties adjustment Flow control start pressure change volume (MPa) 0.15
Flow change (L/min) 16.4
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Hydraulic Pump
[2] Regulator operation explanation diagram
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Hydraulic Pump
[3] Regulator breakdown
189 SSM-13-09-004EN
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Hydraulic Pump
Procedures for Assembly and Disassembly of Regulator
1. Cautions for disassembly
[1] These regulators comprise small precision parts, so disassembly and assembly operations are
somewhat complex. Accordingly, it is recommended that replacement be performed by replacing
the whole assembly as long as there are no special circumstances requiring disassembly. If dis-
assembly is unavoidable, read this entire manual before performing disassembly.
[2] The numbers in the parentheses after the part names indicate codes in the structural diagram.
2. Tools
Tool name Tools dimensions
Hexagon wrench 4, 5, 6 (B dimension, mm)
Socket wrench, double-head (single-
head) wrench
Monkey wrench Small-sized (maximum 36 mm)
Screwdriver
Plastic hammer
Torque wrench
Pliers For stop ring, × 2
Steel rod Diameter φ4 or less, L = 100
Tweezers
Bolt M4, L = about 50
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Hydraulic Pump
[1] Select a location for disassembly.
[2] Use cleaning oil to remove any dirt or rust from
the surface of the regulator.
413), and remove the regulator from the pump
main unit..
• Be careful not to lose the O-rings.
[4] Remove the hexagon socket head bolts (438),

and remove the cover (C) (629).
• The cover (C) is assembled with an adjusting
screw (C) (628), adjusting ring (C) (627), lock
nut (630), hexagon nuts (801, 802), and hexa-
gon socket head locking screw (924). Do not
loosen these screws and nuts. Loosening
causes the adjusted pressure and flow setting
to change.
[5] After removing the cover (C) (629) subassem-

bly, remove the outer spring (625), inner spring
(626), and spring seat (C) (624) from the com-
pensation section, and pull out the adjusting
ring (Q) (645), pilot spring (646), and spring
seat (644) from the pilot section.
• The adjusting ring (Q) (645) can be easily
removed by pulling it out with an M4 bolt.
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Hydraulic Pump
438), and remove the pilot cover (641). When
the pilot cover is removed, remove the set
spring (655) from the pilot section.
[7] Remove the stop ring (814), and remove the

spring seating (653), return spring (654), and
sleeve (651).
• The sleeve (651) is assembled with a retaining
ring (836).
• When removing the stop ring (814), the return
spring (654) will fly out, so be careful not to lose
it.
[8] Remove the locking rings (858), and remove the

fulcrum plug (614) and adjusting plug (615).
• The fulcrum plug (614) and adjusting plug (615)
can be easily removed by pulling them out with
an M6 bolt.
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Hydraulic Pump
[9] Remove lever 2 (613). Do not pull out the pin
(875).
• It can be easily removed by using a pair of twee-
zers.
[10] Pull out the pin (874), and remove the feedback
lever (611).
• Use a fine steel rod to push out the pin (874)
(pin diameter φ4) from above without touching
lever 1 (612).
[11] Remove lever 1 (612). Do not pull out the pin

(875).
[12] Pull out the pilot piston (643) and spool (652).
[13] Pull out the piston case (622), compensation
piston (621), and compensation rod (623) to
complete disassembly of the regulator.
• The piston case (622) can be removed by push-
ing out the compensation rod (623) from the
opposite side of the piston case.
The component parts are small, so be very careful not to lose them.
193 SSM-13-09-004EN
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Hydraulic Pump
The assembly procedure is the reverse of the disassembly procedure. However, follow the precau-
tions below.
[1] Be sure to repair any parts damaged during disassembly, and prepare replacement parts in
advance.
[2] Any foreign matter entering the equipment can create a malfunction. Therefore, after thoroughly
cleaning the equipment with cleaning oil, air blow the equipment, and perform assembly in a
clean location.
[3] Make sure to tighten bolts and plugs of each section to the specified torque.
[4] Be sure to apply clean hydraulic oil to sliding sections before assembly.
[5] As a rule, replace all seals such as O-rings with new parts.
[1] Install the compensation rod (623) into the com-
pensation hole on the casing (601).
[2] Insert the pin press fit in lever 1 (612) into the
groove on the compensation rod, and install
lever 1 on the pin press fit in the casing.
[3] Install the spool (652) and sleeve (651) in the
casing spool hole.
• Check that the spool and sleeve slide smoothly
in the casing without catching.
• Be careful to assemble the spool in the correct
direction.
[4] Install the feedback lever (611), and insert the

pin (874) in alignment with the pin hole on the
feedback lever.
• This is easier to assemble by inserting the pin
into the feedback lever to a small degree in
advance.
• Be careful to assemble the feedback levers in
the correct direction.
[5] Install the pilot piston (643) into the flow control
hole on the casing.
• Check that the pilot piston slides smoothly with-
out catching.
SSM-13-09-004EN 194
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Hydraulic Pump
[6] Insert the pin press fit in lever 2 (613) into the
groove on the pilot piston, and assemble lever
2.
[7] Assemble the fulcrum plug (614) and install the

locking ring (858) so that the pins press fit in the
fulcrum plug are inserted into the pin holes on
lever 2.
[8] Insert the adjusting plug (615), and install the

locking ring.
• Be careful to insert the fulcrum plug and adjust-
ing plug into the correct openings.
• At this time, check that the backlash from the
movement of the feedback lever is not too great
and that the feedback lever does not catch on
anything.
[9] Install the return spring (654) and spring seating
(653) into the spool hole, and install the stop
ring (814).
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Hydraulic Pump
[10] Assemble the set spring (655) into the spool
hole, assemble the compensation piston (621)
and piston case (622) into the compensation
hole, install the pilot cover (641), and tighten the
hexagon socket head bolts (436, 438).
[11] Install the spring seating (644), pilot spring

(646), and adjusting ring (645) into the pilot
hole, and install the spring seating (624), inner
spring (626), and outer spring (625) into the
compensation hole.
• Be careful to install the spring seating in the cor-
rect direction.
[12] Assemble the cover (C) (629) set with the

adjusting screw (628), adjusting ring (C) (627),
lock nut (630), hexagon nuts (801, 802), and the
hexagon socket head locking screw (924), and
tighten the hexagon socket head bolts (438).
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Hydraulic Pump
5. Regulator assembly structural diagram
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Hydraulic Pump
Code Part name Q'ty
496 Plug 5
601 Casing 1
611 Feedback lever 1
612 Lever (1) 1
613 Lever (2) 1
614 Fulcrum plug 1
615 Adjusting plug 1
621 Compensation piston 1
622 Piston case 1
623 Compensation rod 1
624 Spring seating (C) 1
625 Outer spring 1
626 Inner spring 1
627 Adjusting ring (C) 1
628 Adjusting screw (C) 1
629 Cover (C) 1
630 Lock nut 1
631 Pf sleeve 1
641 Pilot cover 1
643 Pilot piston 1
644 Spring seating (Q) 1
645 Adjusting ring (Q) 1
646 Pilot spring 1
651 Sleeve 1
652 Spool 1
653 Spring seating 1
654 Return spring 1
655 Set spring 1
656 Blind cover 1
708 O-ring 1
722 O-ring 3
724 O-ring 9
725 O-ring 1
728 O-ring 1
730 O-ring 1
732 O-ring 1
733 O-ring 1
734 O-ring 1
735 O-ring 1
753 O-ring 2
755 O-ring 2
756 O-ring 1
763 O-ring 1
801 Hexagon nut 1
802 Hexagon nut 1
814 Stop ring 1
836 Retaining ring 1
Tightening torque
858 Locking ring 2
Code Screw size Tightening torque (N•m) 874 Pin 1
412, 413 M8 29 875 Pin 2
436, 438 M6 12 876 Pin 2
496 NPTF1/16 8.8 887 Pin 1
630 M30 × 1.5 160 897 Pin 1
801 M8 16 898 Pin 1
802 M10 19 924 Hexagon socket head locking screw 1
198 SSM-13-09-004EN
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Remote Control Valve SH330-5

Removal and Installation of Operation Remote Control Valve
Items to prepare
• Phillips screwdriver
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid
1. Removal of operation remote control valve (left side)
[1] Roll up the boot (1) of the control lever and use
the Phillips screwdriver or box wrench (10 mm)
to remove the 2 bolts (2) of the console top
cover.
[2] Use the Phillips screwdriver to remove the 2

screws (3), and then remove the handle of the
tilt lever (4).
199 SSM-13-10-004EN
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bolts (5), and remove the grip (6) of the gate
lock lever.

screws (7) of the console top cover.
[5] Remove the 3 connectors (8) and remove the

console top cover (9).
[6] Use the Phillips screwdriver or box wrench (10

mm) to remove the 5 bolts (10).
SSM-13-10-004EN 200
2
[8] Roll up the boot (12) of the control lever, remove
the connector (13) of the horn switch, and cut
the wire band (14).
[9] While securing the nut (15) with a wrench (22

mm), use another wrench (19 mm) to remove
the lock nut (16) and remove the control lever
(17).
[10] Roll back the hose cover (18).
201 SSM-13-10-004EN
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[11] Use a wrench (22 mm) to remove the 6 hoses
(19).
• Mark the joystick remote control valve and
hoses so that the connectors match at the time
of assembly.
• Use caps and plugs to cover the joystick remote
control valve and hoses to prevent any entry of
• Clean the joystick remote control valve and
hoses by spraying them with a parts cleaner to
prevent scratches and prevent dirt from accu-
[12] Use the hexagon wrench (5 mm) to remove the

4 bolts (20).
SSM-13-10-004EN 202
4
[13] Remove the joystick remote control valve (21).
203 SSM-13-10-004EN
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2. Removal of operation remote control valve (right side)
[1] Roll up the boot (1) of the control lever and use
the Phillips screwdriver or box wrench (10 mm)
to remove the 2 bolts (2) of the console top
cover.

screws (3), and then remove the handle of the
tilt lever (4).

screws (5) of the console top cover.
[4] Remove the 3 connectors (6) and remove the

console top cover (7).
SSM-13-10-004EN 204
6
mm) to remove the 5 bolts (8).
[7] Roll up the boot (10) of the control lever, remove

the connector (11) of the horn switch, and cut
the wire band (12).
[8] While securing the nut (13) with a wrench (22

mm), use a wrench (19 mm) to remove the lock
nut (14) and remove the control lever (15).
[9] Roll back the hose cover (16).
205 SSM-13-10-004EN
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(17).
• Mark the joystick remote control valve and
hoses so that the connectors match at the time
of assembly.
• Use caps and plugs to cover the joystick remote
control valve and hoses to prevent any entry of
• Clean the joystick remote control valve and
hoses by spraying them with a parts cleaner to
prevent scratches and prevent dirt from accu-
[11] Use the hexagon wrench (5 mm) to remove the
4 bolts (18) and 4 washers (19).
[12] Remove the joystick remote control valve (20).
SSM-13-10-004EN 206
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3. Installation of operation remote control valve
To install, perform the reverse of the removal procedure.
Be careful not to connect the hydraulic hoses in incorrect locations.
Before installing the hoses, check that the hose adapters are not loose and retighten them to the
specified torque.
P port
Hose adapter tightening torque : 28.4 ± 2.9 N•m
Hydraulic hose tightening torque : 49 ± 4.9 N•m
T port, 1 - 4 ports
Hose adapter, hydraulic hose tightening torque : 49 ± 4.9 N•m
207 SSM-13-10-004EN
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Procedures for Assembly and Disassembly of Operation Remote Control Valve
(1) Required tools and tightening torque
Dimension Tightening
Tool Part number Part name Screw size
(mm) torque (N•m)
22 312 Adjusting nut M14 68.6 ± 4.9
Wrench
32 302 Disk M14
Special jig
(diagram on 24 301 Joint M14 47.1 ± 2.9
page 220)
Other
· Vapor corrosion inhibitor · Sandpaper (#1000, #2000)
· White kerosene · Whetstone
· Heat-resistant grease · Vice
(2) Maintenance standards
Maintenance
Standard Remarks
inspection item
Leak amount When handle is in neutral1000 cc/min or more Conditions
During operation2000 cc/min or more Primary pressure 2.94 MPa
If either condition occurs, replace the remote con- Oil viscosity 23 mm2/s
trol valve as one unit.
Spool When wear on the sliding sections exceeds wear The same approximate condi-
on the non-sliding sections by 10 μm or more, tions as those listed above for
replace the remote control valve as one unit. leak amount are expected when
the condition on the left occurs.
Push rod If the end section is worn by 1 mm or more, perform replacement.
Operation section Replace the operation section disk (302) and joint Make adjustments if the backlash
backlash section (301) if there is backlash of 2 mm or more is due to looseness in the tighten-
due to wear. ing sections.
Operation stability If abnormal noise, hunting, or a drop in primary
pressure occurs and the problem cannot be
resolved with "4. Causes of trouble and counter-
measures", replace the remote control valve as
one unit.
Note:
It is desirable for seal materials such as O-rings to be replaced with each disassembly, but it is
acceptable to reuse these after it is confirmed that they are not damaged.
SSM-13-10-004EN 208
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[1] Preparations
1) Prepare a sufficiently spacious, solid and stable work platform so that parts will not fall or move
during work.
2) Prepare the tools and materials indicated in "1. Maintenance procedures (1) Required tools
and tightening torque".
3) When disassembling the valve, read the disassembly procedures thoroughly before following
the sequence below.
The numbers in the parentheses after the part names indicate codes in "Attached diagram 1.
Remote control valve assembly cross-section diagram".
[2] General work precautions
1) Each part has been manufactured with a high degree of precision, so be careful not to let parts
bump each other or fall when handling them.
2) If parts are struck or pulled with excessive force during work because they are tight, this may
cause burrs or damage which lead to faulty assembly causing reduction in performance or oil
leak. Perform work carefully and thoroughly.
3) Rust may form on parts due to moisture or debris if the valve is left disassembled or if work is
abandoned in the middle of disassembly. If work must be halted, be careful about preventing
rust from forming and dust settling on parts.
[3] Disassembly procedure
1) Clean the remote control valve with white ker-
osene.
• Place plugs in each port.
2) Use copper plate (or lead plate) to secure the
remote control valve in a vise.
3) Remove the bellows (501).
• Be careful not to tear the bellows.
209 SSM-13-10-004EN
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4) Use a wrench on the bolt width of the adjust-
ing nut (312) and disk (302) to loosen them,
and remove the adjusting nut and disk.
SSM-13-10-004EN 210
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5) Use a jig to rotate the joint (301) to the left and
loosen it.
• The diagram shows the jig installed.
• If the return springs (221) are strong, the
plate (151), plugs (211), and push rods
(212) will rise at the same time the joint is
loosened, so be careful of parts flying off
when removing the joint.
6) Remove the plate (151).
7) If the return springs (221) are weak, the plugs

(211) will remain in the casing (101) due to the
sliding resistance of the O-rings (214), so use
a flathead screwdriver to remove them.
• Use the groove in the outer circumference of
the plugs and remove them while making
sure they are not damaged by an unbal-
anced load.
• Use caution as plugs may fly off when they
are being removed due to the return springs.
211 SSM-13-10-004EN
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8) Remove the push rods (212), plugs (211),
pressure reducing valve assemblies and the
return springs (221) from the casing (101).
• Record the relation of parts to the casing
hole positions through marking, etc.
9) For disassembly of pressure reducing valves,

press in the spring seatings, move the spring
seatings (216) to the side while bending the
secondary pressure springs (241), and
remove the springs from the spools (201) by
passing the springs through the larger hole of
the spring seatings.
Next, separate the spools, spring seatings, sec-
ondary pressure springs, and washers (217).
• Be careful not to scratch the surface of the
spools.
• Do not lower the spring seatings by 6 mm or more.
• Handle these parts as assemblies until
assembly of the remote control valve.
10)Remove push rods (212) from the plugs (211).
SSM-13-10-004EN 212
14
11)Remove O-rings (214) and seals (213) from
the plugs (211). Use a small flathead screw-
driver, etc. to remove seals.
• O-rings and seals cannot be reused.
Replace them with new parts.
12)Cleaning parts
1. Clean each part by placing it in a rough cleaning container filled with white kerosene. (rough
cleaning)
2. Clean each part by placing it in a finish cleaning container filled with white kerosene, and
thoroughly clean each part, including the interior, while slowly rotating it. (finish cleaning)
Use a rag to thoroughly remove white kerosene adhered to parts.
• Scratching can easily occur if cleaning of a part is begun just after parts are immersed in
white kerosene, so let each part sit in white kerosene until debris and grease sufficiently
loosen from the surface of the part and float to the surface.
• If the white kerosene is dirty, this will encourage damage to parts and result in reduced
performance after reassembly. Thoroughly manage the level of cleanliness of the white
kerosene.
• Do not dry parts with compressed air, as this will damage parts and cause rust to form
due to debris and moisture being dispersed into the atmosphere.
13)Preventing rust on parts
Apply an anti-rust agent to each part.
• Rust will form on parts if they are left as is after cleaning, and this will cause reduced perfor-
mance of functions after reassemly.
213 SSM-13-10-004EN
15
[1] Preparations
1) As with disassembly, prepare a work platform, tools and materials.
[2] General work precautions
1) Observe the same general work precautions as with disassembly.
2) When performing assembly, remove metal fragments and foreign matter from all parts, and
check that there are no burrs or nicks on parts. If there are burrs or nicks, use a whetstone to
remove them.
3) As a rule, replace all O-rings and backup rings with new parts.
4) When installing O-rings and backup rings, be careful not to damage them. (Apply a thin layer of
grease to ensure smooth installation.)
5) When installing parts, using grease is good for preventing parts from falling.
6) Tighten bolts, etc. to the torque values indicated in "Attached diagram 1. Remote control valve
assembly cross-section diagram" on page 219. Use the torque wrench to measure the tighten-
ing torque.
7) After assembly is complete, place plugs in all of the ports to prevent entry of debris.
[3] Assembly procedures
1) Insert washers (217), secondary pressure
springs (241) and spring seatings (216) onto
each of the spools (201) in that order.
Then, press in the spring seatings and move

them to the side while bending the secondary
pressure springs to pass the seatings over the
larger holes and install them on each of the
spools.
• Do not lower the spring seatings by 6 mm or
more.
SSM-13-10-004EN 214
16
2) Install the return springs (221) in the casing
(101).
Install the pressure reducing valve assemblies
in the casing.
• Install them in the positions they were in
before disassembly.
3) Install O-rings (214) on the plugs (221).
4) Install seals (213) on the plugs (211).

• Install so that the seal lips are as shown in
the diagram below.
*1 Seal
*2 Plug
*3 Push rod
*4 Hydraulic oil application
215 SSM-13-10-004EN
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5) Install push rods (212) into the plugs (211).
• Apply hydraulic oil to surface of the push
rods.
6) Install the plug assemblies into the casing

(101).
If the return springs (221) are weak, they will
be stopped by the sliding resistance of the O-
rings (214).
• Be careful not to scratch the casing holes by
forcing in the spools (201).
If the return springs are strong, use the plate

(151) to install all 4 plug assemblies at the
same time and temporarily tighten them with
the joint (301).
• Be careful of the plug assemblies and plate
flying off.
7) Install the plate (151).

8) Use a jig, and tighten the joint (301) to the
casing (101) to the specified torque.
Tightening torque: 47.1 ± 2.9 N•m
SSM-13-10-004EN 216
18
9) Install the disk (302) onto the joint (301).
• Screw the disk in until it is equally touching
each of the 4 push rods (212).
Secondary pressure will cause faulty opera-
tion of the machine if the disk is screwed in
too much, so pay attention to adjustment of
the tightening position.
10)Install the adjusting nut (312), use a wrench

on the bolt width of the disk (302) to secure it,
and tighten the adjusting nut to the specified
torque.
• During tightening, do not move the disk posi-
tion.
11)Apply grease to the rotating section of the joint

(301) and to the top of the push rods (212).
12)Install the bellows (501).

• Be careful not to tear the bellows.
13)Inject vapor corrosion inhibitor into each port, and then place plugs in the ports.
217 SSM-13-10-004EN
19
4. Causes of trouble and countermeasures
It is not always easy to find where the source of trouble is located. A few problems that may some-
times occur are listed in the table below. Repair of these problems can be difficult, so see the sug-
gested causes and solutions in the table for assistance.
The table below shows general symptoms, suggested causes and also solutions. However, the
cause of machine problems are often not rooted in just a single part. Problems are often due to the
relationship of one part with another. Also keep in mind that solutions other than those listed in the
table may sometimes be necessary.
The table below does not include all possible causes and countermeasures. Accordingly, further
investigation of problems and causes should be done by an experienced and qualified repair per-
son, as necessary.

Secondary pressure is 1. Insufficient primary pressure 1. Maintain primary pressure.
not rising. 2. Secondary pressure spring(s) (241) is 2. Replace it (them) with new
(are) broken or worn. part(s).
3. The gap between spool(s) (201) and the 3. Replace the remote control valve
casing (101) is abnormally large. as one unit.
4. There is backlash in the handle section. 4. Disassemble and assemble and
replace the handle section.
Secondary pressure is 1. Sliding parts are sticking. 1. Repair the sticking sections.
unstable. 2. Tank line pressure is variable. 2. Return directly to the oil tank.
3. Air is getting into lines. 3. Perform operation several times
and let out air.
Secondary pressure is 1. Tank line pressure is high. 1. Return directly to the oil tank.
high. 2. Sliding parts are sticking. 2. Repair the sticking sections.
SSM-13-10-004EN 218
20
Attached diagram 1. Remote control valve assembly cross-section diagram

101 Casing 1 217 Washer 4
151 Plate 1 221-1 Return spring (port 1) 1
201 Spool 4 221-2 Return spring (port 3) 1
211 Plug 4 221-3 Return spring (ports 2, 4) 2
212-1 Push rod (ports 1, 3) 2 241-1 Secondary pressure spring (ports 1, 3) 2
212-2 Push rod (ports 2, 4) 2 241-2 Secondary pressure spring (ports 2, 4) 2
213 Seal 4 301 Joint 1
214 O-ring 4 302 Disk 1
216-1 Spring seating (ports 1, 3) 2 312 Adjusting nut 1
216-2 Spring seating (ports 2, 4) 2 501 Bellows 1
219 SSM-13-10-004EN
21
Attached diagram 2. Joint disassembly jig
SSM-13-10-004EN 220
22
Removal and Installation of Travel Remote Control Valve
Items to prepare
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid
1. Removal of travel remote control valve
[1] Remove the 3 screws (1) on the cover (2) and
remove the cover.
[2] Remove the floor mat (3).
221 SSM-13-10-004EN
23
bolts (4) on both the left and right sides, and
then remove the left and right travel pedals (5).

bolts (6) on both the left and right sides of the
lever, and then remove the levers (7).


(10).
• Mark the valve and hoses so that the connec-
• Attach caps or plugs to the valve and hoses to
• Clean the valve and hoses by spraying with a
parts cleaner to prevent scratches and prevent
dirt from accumulating on the connectors.
SSM-13-10-004EN 222
24
[7] Use a wrench (19 mm) to remove the 2 hose
adapters (11).

bolts (12) on both the left and right sides of the
travel lever .
[9] Pull up the travel remote control valve (13) into

the cab, and then remove the travel remote con-
trol valve.
2. Installation of travel remote control valve

Be careful not to connect the hydraulic hoses in incorrect locations.
Before installing the hoses, check that the hose adapters are not loose and retighten them to the
specified torque.
Hose adapter, hydraulic hose tightening torque: 36.3 ± 2.0 N•m
223 SSM-13-10-004EN
25
Procedures for Assembly and Disassembly of Travel Remote Control Valve
When disassembling the valve, read the disassembly procedures thoroughly before following the
sequence below. The numbers in the parentheses after the part names indicate codes in "Attached
diagram 1. Remote control valve assembly cross-section diagram" on page 242.
(1) Disassembly procedures
1) Preparations
• Prepare a sufficiently spacious, solid and stable work platform so that parts will not fall or
move during work.
• Prepare tools and materials.
2) General work precautions
• Each part has been manufactured with a high degree of precision, so be careful not to let
parts bump each other or fall when handling them.
• If parts are struck or pulled with excessive force during work because they are tight, this may
cause burrs or damage which may then cause reductions in performance or oil leak due to
faulty assembly. Perform work carefully and thoroughly.
• Rust may form on parts due to moisture or debris if the valve is left disassembled or if work is
abandoned in the middle of disassembly. If work must be halted, be careful about preventing
rust from forming and dust settling on parts.
3) Disassembly procedure
[1] Clean the remote control valve with white
kerosene.
• Place plugs in each port.
[2] Use shock plate to secure the remote con-
trol valve in a vise.
• Remove the bellows (501) from the covers
(201) and remove the bellows by pulling
upwards.
4/
[3] Use a hexagon wrench on the hexagon

socket head locking screws (423) to loosen
them.
• Be careful, as application of Loctite #241
makes the loosening torque high.
4/
SSM-13-10-004EN 224
26
[4] Place a round rod (φ8 mm or less) against
one end of the cam shafts (413) and lightly
strike it with a hammer to remove the
shafts.
4/
[5] Remove the cams (420) as an assembly

with the locking screws (471) and lock nuts
(472) left attached.
Record the positions of the cams in relation
to the covers (201).
• Be careful when removing, as the push
rods (214) may fly off.
4/

socket head bolts (271) to loosen and
remove them.
4/
[7] Remove the covers (201).

• Record the positions of the covers in rela-
tion to the casing (101).
• Be careful when removing, as the push
rods (214) or plugs (202) may fly off due to
the damping springs (336) and (337). (The
plugs are only kept in the casing by the
sliding resistance of the O-rings (212).)
4/
225 SSM-13-10-004EN
27
[8] Remove push rods (214) from the plugs
(202).
• Record the positions of the plugs in relation
to the push rods.
push rods.
• Be careful when removing, as plugs may fly
off.
4/
[9] Remove the plugs (202) with the grease

caps (203) and NHU packings (210) left
attached.
Record the positions of the plugs in relation
to the casing holes.
• Be careful when removing, as the pistons
(224) may fly off due to the damping
springs (336) and (337).
4/
[10] Remove the pistons (224).

• Record the positions of the pistons in rela-
tion to the casing holes.
4/
[11] Remove the damping springs (336) and

(337) from the casing (101).
• Record the positions of the damping
springs in relation to the casing holes.
4/
SSM-13-10-004EN 226
28
[12] Remove the spring seatings (218) from the
casing (101).
• Record the position of the spring seatings
in relation to the casing holes.
4/
[13] Use a magnet, etc. to remove steel balls

(225).
• Be careful not to lose steel balls.
4/

socket head bolts (220) to loosen and
remove them.
227 SSM-13-10-004EN
29
[15] Remove the damper casing (102) and
remove the O-rings (211) and (213) from
the casing.
• Record the position of the damper casing in
relation to the casing (101).
• Be careful when removing, as the pressure
reducing valve assembly may fly off due to
the return springs (335).
SSM-13-10-004EN 228
30
[16] Remove the pressure reducing valve
assemblies and return springs (335) from
the casing (101).
• Record the positions of these parts in rela-
tion to the casing holes.
4/
4/
[17] Lay the covers (201) on their sides on a

level surface, place the special tool 1
against the bushings (412), and remove the
bushings by lightly strike them with a ham-
mer.
4/
[18] Secure each cam assembly in a vise, use a

wrench to loosen the lock nuts (472), and
remove the lock nuts and locking screws
(471).
• As neutral adjustment of locking screws is
necessary during assembly, handle them
as part of the cam assembly as long as
replacement of locking screws is not nec-
essary.
4/
229 SSM-13-10-004EN
31
[19] For disassembly of the pressure reducing
valve assemblies, place the bottom end of
the spools (301) perpendicular on a level
work platform, lower the spring seatings
(311), and use the end of a small flathead
screwdriver to remove the 2 half-circle
washers 1 (215).
spools.
• Do not lower the spring seatings by 4 mm
4/
or more.
[20] Separate the spools (301), spring seatings
(311), secondary pressure springs (324),
washers 2 (217), and washers 3 (313).
• Handle as an assembly until assembly is
performed.
• Washers 2 are used for pre-set adjustment
of the secondary pressure springs, so
thickness is different for each spool assem-
bly. Additionally, these are sometimes not
used, so record the status for each assem-
4/
bly.
[21] Remove the grease cups (203) from the
plugs (202).
4/
[22] Remove the NHU packings (210) from the

plugs (202). Use a small flathead screw-
driver, etc. to remove.
• Be careful not to scratch the inner surface
of the plugs.
4/
SSM-13-10-004EN 230
32
[23] Remove the O-rings (212) from the plugs
(202).
4/
[24] Cleaning parts

• Clean each part by placing it in a rough cleaning container filled with white kerosene. (rough
cleaning)
[25] Scratching can easily occur if cleaning of parts is begun just after parts are immersed in
white kerosene, so let each part sit in white kerosene until debris and grease sufficiently
loosen off from the surface of parts and float to the surface.
• If the white kerosene is dirty, this will encourage damage to parts and result in reduced per-
formance after reassembly. Thoroughly manage the level of cleanliness of the white kero-
sene.
• Clean each part by placing it in a finish cleaning container filled with white kerosene, and
thoroughly clean each part, including the interior, while slowly rotating it (finish cleaning).
Use a rag to thoroughly remove white kerosene adhered to parts.
[26] Do not dry parts with compressed air, as this will damage parts and cause rust to form due
to debris and moisture being dispersed into the atmosphere.
[27] Preventing rust on parts
Apply an anti-rust agent to each part.
• Rust will form on parts if they are left as is after cleaning, and this will cause reduced perfor-
mance of functions after reassemly.
231 SSM-13-10-004EN
33
1) Preparations
• As with disassembly, prepare a work platform, tools and materials.
2) General work precautions
• Observe the same general work precautions as with disassembly.
• When performing assembly, remove metal fragments and foreign matter from all parts, and
check that there are no burrs or nicks on parts. If there are burrs or nicks, use a whetstone to
remove them.
• As a rule, replace all O-rings and NHU packings.
• When installing O-rings and NHU packings, be careful not to damage them. (Apply a thin layer
of grease to ensure smooth installation.)
• When installing parts, using grease is good for preventing parts from falling.
• Tighten bolts, etc. to the torque values indicated in the assembly cross-section diagram.
• After assembly is complete, place plugs in all of the ports to prevent entry of debris.
3) Assembly procedures
[1] Install the washers 3 (313), washers 2
(217), secondary pressure springs (324),
and the spring seatings (311) onto each of
spools (301) in that order.
Washers 2 are used for pre-set adjustment
of the secondary pressure springs, so
thickness is different for each spool assem-
bly. Additionally, these are sometimes not
used.
• Check the status recorded during disas-
sembly and attach parts accordingly. 4/
[2] Place the bottom end of the spools (301)

perpendicular on a level work platform,
push the spring seatings (311) down, and
install the 2 half-circle washers 1 (215) onto
the spring seatings in such a way that they
are not on top of each other.
4/
• Install the washers 1 so that the sharp

edge side faces up and the washer catches
the head of the spool.
• Do not lower the spring seatings by 4 mm
or more.
SSM-13-10-004EN 232
34
[3] Install the return springs (335) in the casing
(101).
before disassembly.
4/
[4] Install the pressure reducing valve subas-

semblies assembled in the previous steps
1) and 2) into the casing (101).
before disassembly.
4/
• When installing the pressure reducing

valve subassemblies, be careful not to
strongly strike the casing corners with the
bottom ends of the spools.
[5] Install O-rings (211) and (213) on the cas-

ing.
233 SSM-13-10-004EN
35
[6] Tighten the damper casing (102) and cas-
ing (101) with the hexagon socket head
bolts (220) to the specified torque.
before disassembly.
• Tighten the 2 hexagon socket head bolts
(220) evenly, and tighten the damper cas-
ing (102) in a parallel orientation.
[7] Install the steel balls (225) into the bush-

ings (412).
4/
[8] Install the spring seatings (218) into the

bushings (412).
before disassembly.
4/
[9] Install the damping springs (336) in the

casing (101).
before disassembly.
4/
SSM-13-10-004EN 234
36
[10] Install the damping springs (337) in the
casing (101).
before disassembly.
• Be careful that they do not become entan-
gled with damping springs (336).
4/
[11] Install the pistons (224).

before disassembly.
4/
[12] Install O-rings (212) on the plugs (202).
4/
235 SSM-13-10-004EN
37
[13] Install NHU packings (210) into the plugs
(202).
• When installing the NHU packings, be
careful of the installation direction. (See the
diagram.)
• Before installing NHU packings, apply a
thin layer of grease.
4/
NHU packing
[14] Install grease cups (203) into the plugs

(202).
4/
[15] Install push rods (214) into the plugs (202).

• Before installing push rods, apply hydraulic
oil to the rod surfaces.
• Do not press the rods in strongly, as this
may damage the NHU packing lip sections.
4/
SSM-13-10-004EN 236
38
[16] Install the push rod subassemblies assem-
bled in the previous steps [13], [14], [15],
and [16] into the casing (101).
4/
[17] Use special tool 1 on the covers (201) to

press down the bushings (412), and lightly
strike the bushings with a hammer to press
fit them.
• Be careful that the ends of the bushings do
not stick out from within the cover.
4/
[18] Install the covers (201) on the casing (101).

before disassembly.
• Be careful of the cover rising up due to the
damping springs (336) and (337).
4/
[19] Tighten the hexagon socket head bolts

(271) to the specified torque.
• Be careful that the covers are horizontal.
4/
237 SSM-13-10-004EN
39
[20] Temporarily install the locking screws (471)
and lock nuts (472) on the cams (420).
4/
[21] Install the cams (420) on the covers (201).

before disassembly.
4/
[22] While holding the cams (420), insert the

cam shafts (413) from the outside.
4/
[23] Apply Loctite #241 or the equivalent to the

surfaces of the hexagon socket head lock-
ing screws (423).
4/
SSM-13-10-004EN 238
40
[24] Tighten the hexagon socket head locking
screws (423) to the specified torque.
Tightening torque: 6.9 ± 1 N•m
4/
[25] Adjust the height of the locking screws

(471) so that the top surface of the cams
(420) and the bottom surface of the covers
(201) are parallel, and tighten the lock nuts
(472) to the specified torque after rotating
the cams left and right to check if there is
any neutral backlash.
• Even if the push rods (214) are pressed in
too much by the locking screws, backlash
during neutral will occur. Use caution as 4/
this may cause the sudden movement

when starting the engine.
[26] Tilt the cams (420) and fill the grease cups
(203) of the plugs (202) with grease while
filling grease to the top of the push rods
(214).
• For grease application and filling, use a flat
object made of soft material so as to not
scratch the push rod or plug surfaces.
4/
[27] After mounting the top end of the bellows

(501) on the cams (420), mount the bottom
end into the grooves on the covers (201).
• Before mounting the bottom end of the bel-
lows into the grooves of the covers, spray
anti-rust oil on the parts within the bellows.
4/
239 SSM-13-10-004EN
41
• Be careful that the bellows are properly
mounted in the grooves and not twisted, as
this may reduce anti-rust and anti-moisture
protection.
4/
SSM-13-10-004EN 240
42
2. Causes of trouble and countermeasures
It is not always easy to find where the source of trouble is located. A few problems that may some-
times occur are listed in the table below. Repair of these problems can be difficult, so see the sug-
gested causes and solutions in the table for assistance.
The table below shows general symptoms, suggested causes and also solutions. However, the
cause of machine problems are often not rooted in just a single part. Problems are often due to the
relationship of one part with another. Also keep in mind that solutions other than those listed in the
table may sometimes be necessary.
The table below does not include all possible causes and countermeasures. Accordingly, further
investigation of problems and causes should be done by an experienced and qualified repair per-
son, as necessary.

1. Insufficient primary pressure 1. Maintain primary pressure.
2. Secondary pressure spring(s) (324) is 2. Replace it (them) with new part(s).
(are) worn.
Secondary pressure is
not rising. 3. The gap between spool(s) and the cas- 3. Replace spool(s) and casing assembly.
ing is abnormally large.
4. There is backlash in the operation sec- 4. Disassemble and assemble or replace
tion. operation section parts.
1. Sliding parts are sticking. 1. Repair the sticking sections.
Secondary pressure is 2. Tank line pressure is variable. 2. Return directly to the oil tank.
unstable. 3. Air is getting into lines. 3. Perform operation several times and let
out air.
Secondary pressure is 1. Tank line pressure is high. 1. Return directly to the oil tank.
high. 2. Sliding parts are sticking. 2. Repair the sticking sections.
1. Air is gathering in the piston chamber. 1. Perform operation several times and let
out air.
3. Damping spring(s) (336) and/or (337) 3. Replace it (them) with new part(s).
are worn.
Damping is not work-
ing. 4. The gap between piston(s) (224) and 4. Replace piston(s) and casing assembly.
the casing is abnormally large.
5. There are check valve operation prob- 5. Disassemble and adjust the check valve
lems. section(s).
6. The piston metering hole(s) is (are) 6. Replace piston(s).
abnormally large.
Damping torque is high.
2. Piston metering hole(s) is (are) clogged. 2. Repair or replace piston(s).
241 SSM-13-10-004EN
43
Note
1. Apply anti-rust oil to the inside of the bellows with a spray.
Attached diagram 1. Remote control valve assembly cross-section diagram
Tightening torque list Code Part name Q'ty Code Part name Q'ty
Code Screw size Tightening torque 101 Casing 1 271 Hexagon socket head bolt 2
151 NPTF1/16 6.9 ± 1 N•m 151 Plug 2 301 Spool 4
271 M12 78.5 ± 9.8 N•m 201 Cover 2 311 Spring seating 4
6.9 ±1 N•m 202 Plug 4 313 Washer 3 4
423 M6
(Loctite coating) 203 Grease cup 4 324 Secondary pressure spring 4
472 M10 33.3 ± 3.4 N•m 210 NHU packing 4 335 Return spring 4
212 O-ring 4 336 Damping spring 4
214 Push rod 4 337 Damping spring 4
215 Washer 1 8 412 Bushing 4
217 Washer 2 4 413 Camshaft 2
218 Spring seating 4 420 Cam 2
221 Locking ring 4 423 Hexagon socket head locking screw 2
223 Bushing 4 471 Locking screw 4
224 Piston 4 472 Lock nut 4
225 Steel ball 12 501 Bellows 2
SSM-13-10-004EN 242
44
[1] Special jig 1 (for bushing removal)
[2] Special jig 2 (for locking ring installation)
Attached diagram 2. Jig for assembly and disassembly
243 SSM-13-10-004EN
45
Control Valve SH330-5
Control Valve
Removal and Installation of Control Valve

Items to prepare
• Wire cutters
• Eyebolts (M10 × 2)
• Wire ropes (with the required lifting capacity)
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid
1. Removal of Control Valve
[1] Extend the attachment and bring in contact with
the ground.
[2] Drain the oil from the hydraulic oil tank.

(For details, see "Draining Oil from Hydraulic Oil
Tank")
244 SSM-13-11-004EN
1
Control Valve
[3] After opening the engine hood (1), use a
wrench (19 mm) to remove the bolts (2), and
then remove the top covers (3) and (4).


(7), and then remove the bracket (8).
(9), and then remove the center bar (10).
SSM-13-11-004EN
2
Control Valve
[7] Remove the connectors (11) and (12) from the
pressure sensor.
[8] Use a wrench (7 mm) to remove the hose band

(13), and then remove the low-pressure hose
(14).

and then remove the clamp (16).
246 SSM-13-11-004EN
3
Control Valve
[10] Use wrenches (19 mm, 22 mm) and hexagon
wrenches (8 mm, 10 mm) to remove the control
valve lines and hoses.
• Mark the lines and hoses so that the connectors
match at the time of assembly.
• Use caps or plugs to cover the lines and hoses
• Clean the lines by spraying with a parts cleaner
SSM-13-11-004EN
4
Control Valve
(17) from the control valve.
[12] Install the 2 eyebolts (18) (M10) on the control

valve.
[13] Install the shackles (19) on the eyebolts, then

use the liftcrane and wire ropes (20) to lift the
control valve (21).
248 SSM-13-11-004EN
5
Control Valve
[14] Place the control valve (21) on wood planks
(22).
2. Installation of Control Valve

SSM-13-11-004EN
6
Control Valve
Procedures for Assembly and Disassembly of Control Valve
1. Disassembly
(1) Cautions for disassembly
[1] On level ground, bring all the operating machines into contact with the ground. When doing
this, have the main machine in a horizontal position.
Check that the machine is in such a state that it will not travel or swing on its own.
Then stop the engine and bleed out the pressure from each actuator.
Do not replace a valve assembly or disassemble a valve with pressure remaining in the system.
This would be dangerous. High-pressure oil might spray out or parts might suddenly come out.
Caution For disassembly, bring the bucket to the ground and adequately bleed out any pressure in the
circuits.
[2] Bleed the air pressure from the tank.
[3] Clean well around the location to be disassembled and keep foreign matter from getting into
the valve during disassembly.
[4] Identify disassembled parts with shipping tags to show their position for re-assembly.
[5] Do not reuse any disassembled seals (O-rings, backup rings). Replace them with new ones.
[6] The spool was selected to fit with the valve housing and sleeve, so do not replace the spool.
(2) Disassembly procedure (The reference numbers are from the parts list.)
a) Removal of long cap and pull out of main spool
[1] Loosen the hexagon socket head bolts (74) (8 mm hexagon socket diameter) for the 9
caps (8) and the 1 cap (9), and remove them. When pulling out the spool only, do not
loosen the M6 screws on the plate except for the 4 hexagon socket head bolts (75) and
the 1 hexagon socket head bolt (94) fastening the plate assemblies.
[2] Loosen and remove the plugs (91) (19 mm hexagon diameter) attached to the ports as
necessary.
[3] Remove the O-rings (7) (1 in each section) from the plate assemblies (10) and (11).
[4] Pull out each spool from the valve housing still in the sub-assembly state.
1. When pulling out the spool, be careful not to cause any dents or scratches.
Caution 2. Identify each spool with a shipping tag so that there will be no mistake about their positions
when they are re-assembled.
[5] Loosen and remove the hexagon socket head bolts (75) (8 mm hexagon socket diameter)
and hexagon socket head bolts (94) (5 mm hexagon socket diameter) those fastens the
plate assemblies (10), (11), (28) and (29) to the housing.
Remove the plate assemblies still in the assembly state. Do not disassemble them.
[6] Loosen and remove the plugs (91) (19 mm hexagon socket diameter) as necessary.
[7] Remove the O-rings (7) and (41) from the valve housings (1) and (13).
250 SSM-13-11-004EN
7
Control Valve
[8] Disassembly of spool assembly
1. In order to avoid damaging the outer edge of the spool,

sandwich the spool with wooden blocks (as in the dia-
gram on the right) and fasten with a vise before starting
the work.
2. Since adhesive is applied to the spool end thread section,
heat up the outer edge of the spool thread section to
break down the adhesive.
Caution
3. Heat so that the spool heating temperature is 200 - 250 ℃
. Heat until the spool end loosens easily immediately after
the heating.
4. If overheating occurs, replace the spring with a new one.
(Wooden blocks for spool
assembly/disassembly)
1) Loosen the spool assembly (2) - (6) and (14) - (17) spool ends (8 mm hexagon socket
diameter) and disassemble the spring seat and spring.
2) The spools in spool assemblies (3), (4), (6) and (14) have poppets, springs, plugs, and
filters in the spools, but do not disassemble them unless necessary.
When disassembly is required, heat up the outer edge of the spool to break down the
adhesive on the thread section, then remove the plug. When assembling, always
replace O-rings and backup rings with new ones.
b) Disassembly of arm 1 parallel-tandem spool, neutral cut spool section
for the caps (18) and (86).
[2] Remove the O-ring (23) from the cap (18). Remove the O-rings (65) from the housing (1).
[3] Pull out the spools (19) and (84) from the valve housing still in the sub-assembly state.
[4] Disassembly of spool assembly
1. In order to avoid damaging the outer edge of the spool, sandwich the spool with wooden
blocks for assemble (as in the diagram) and fasten with a vise before starting the work.
2. Since adhesive is applied to the spool end thread section, heat up the outer edge of the
Caution spool thread section to break down the adhesive.
3. Heat so that the spool heating temperature is 200 - 250 ℃ . Heat until the spool end loosens
easily immediately after the heating.
4. If overheating occurs, replace the spring with a new one.
1) Loosen the spool (19) spool end (22) (5 mm hexagon socket diameter) and disassem-
ble the spring seat (20) and spring (21).
c) Disassembly of arm regeneration release valve section (Sub-parts in the assembly are
expressed as [main number - sub-number].)
1. When removing the plug, pressure left within can make parts fly out dangerously.
Caution 2. Slowly loosen the plug to check that there is no resistance due to residual pressure, then
disassemble.
[1] Loosen and remove the plug (24) (32 mm hexagon diameter) and remove the O-ring (25).
[2] Remove the spring (26) and spool (27-1) from the sleeve (27-2).
[3] Pull out the sleeve (27-2) from the valve housing.
[4] Remove the piston (27-3), O-ring (30), and backup ring (31) from the sleeve (27-2).
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d) Disassembly of load check valve section
1. When removing the plug, pressure left within can make parts fly out dangerously.
Caution 2. Slowly loosen the plug to check that there is no resistance due to residual pressure, then
disassemble.
[1] Loosen and remove the hexagon socket head bolts (75) (4 in each section, 8 mm hexa-
gon socket diameter) for the flanges (37) (6 locations) and (61) (1 location). Only (61) has
a different shape from the others, so keep it separate from (37).
[2] Remove the spring (35), poppets (34) and (51) and O-ring (36) from the valve housing.
Remove the arm 2 (E-E cross section) poppet (59), spring (60), and sleeve (58).
for the flanges (52) (2 locations) .
[4] Remove the spacer (53) from the valve housing and remove the O-ring (54) and backup
ring (55) from the spacer (53).
[5] Remove the spring (35) and poppet (34) from the valve housing.
[6] Loosen and remove the plug (72) (8 mm hexagon socket diameter). (D-D cross section)
[8] Loosen and remove the plug (72) (8 mm hexagon socket diameter). (D-D cross section)
[9] Remove the spacer (57), spring (33), and poppet (32) from the valve housing.
[10] Loosen and remove the plug assembly (92) (36 mm hexagon diameter). (P4 section,
cross section H-H )
[11] Loosen and remove the hexagon socket head bolts (74) (4 locations, 8 mm hexagon
socket diameter) for the flange (43) .
[12] Remove the spring (45), poppet (44), and O-ring (36) from the valve housing.
[13] Loosen and remove the plug (46) (27 mm hexagon diameter) and remove the O-ring (47).
(H-H cross section)
e) Disassembly of antidrift valve section (Sub-parts in the assembly are expressed as [main
number - sub-number].)
1. When removing the antidrift valve assembly, pressure left within can make seals and other
parts fly out dangerously.
Caution 2. Slowly loosen the hexagon socket head bolt to check that there is no resistance due to
residual pressure, then disassemble.
[1] Loosen and remove the hexagon socket head bolts (74) (4 in each section, 8 mm hexa-
gon socket diameter) for the 2 antidrift valve assemblies (67).
[2] Remove the O-rings (36) and (41) from the valve housing.
[4] Disassembly of antidrift valve assembly
1. If parts inside the antidrift valve are disassembled with the antidrift valve installed in the
valve housing, pressure left within can make parts fly out dangerously.
Caution 2. Slowly loosen the plug assembly (67-12) to check that there is no resistance due to residual
pressure, then disassemble.
1) Loosen and remove the plug assembly (67-14) (38 mm hexagon diameter) and remove
the O-ring.
2) Remove the piston (67-3), spool (67-4), and spring (67-6).
3) Loosen and remove the plug (67-14) (12 mm hexagon diameter).
4) Remove the sleeve (67-5) and poppet (67-2) from the body and remove the O-rings
(67-8) and (67-9), backup rings (67-10) and (67-11) from the outer edge of the sleeve.
5) Remove the spring seat (67-13) and spring (67-7) from deep in the hole.
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f) Disassembly of relief valve
1. When removing the relief valve, loosen and remove the main unit installation section plug.
2. Do not loosen the set pressure adjustment plug or lock nut.
Caution 3. Doing so would be dangerous because the set pressure changes if the set pressure adjust-
ment plug turns.
[1] Loosen and remove the overload relief valve (69) (32 mm hexagon diameter).
[2] Loosen and remove the main relief valve (68) (32 mm hexagon diameter).
[3] Loosen and remove the 2 relief valve assemblies (70) (32 mm hexagon diameter).
Remove the O-rings (70-5) and (70-8).
g) Disassembly of option section
for the 2 caps (88), and remove the O-rings (89).
[2] Loosen and remove the 2 plug assemblies (93) (24 mm hexagon diameter), and remove
the O-rings and backup rings.
h) Disassembly of straight travel signal control valve
[1] Remove the hexagon socket head bolts (83) (5 mm hexagon socket diameter) and
remove the body assembly (42).
[2] Loosen and remove the plug assembly (42-5) (5 mm hexagon socket diameter) and
remove the O-ring.
[3] Pull out the spools (42-2) and (42-3) and spring (42-4).
[4] Loosen the orifice plug (42-7) (36 mm hexagon diameter) and remove it from the body (42-1).
i) Disassembly of other plugs
[1] Loosen and remove the plug assembly (71) (10 mm hexagon socket diameter) and
remove the O-ring.
[2] Loosen and remove the plug assembly (72) (8 mm hexagon socket diameter) and remove the O-ring.
[3] Loosen and remove the orifice plug (40) (5 mm hexagon socket diameter). (D-D cross section)
[4] Loosen and remove the plug assembly (92) (36 mm hexagon diameter) and remove the
O-ring.
[5] Loosen and remove the plug assembly (73) (6 mm hexagon socket diameter) and remove
the O-ring.
j) Disassembly of add-on section
[1] Loosen and remove the 4 hexagon nuts (97) (22 mm hexagon diameter).
[2] Remove the outlet housing (95).
Execute Steps [3] - [5] below as necessary.
[3] Remove the spool section assembly (98) and remove the matching surface O-rings (98-
10) and (98-11).
[4] Remove the inlet section assembly (99) and remove the matching surface O-rings (99-3)
and (99-4).
[5] Remove the spool section assembly (111) and remove the matching surface O-rings
(110-10) and (110-11).
[6] Remove the main unit body matching surface O-rings (56) and (64).
[7] Loosen the tie rod (96) and remove it from the main unit valve housing (1).
(Use a pipe wrench.)
When removing the add-on section, be careful not to cause any dents, scratches, or the like on
matching surfaces. Any dents, scratches, or the like on matching surfaces have a danger of
allowing oil to leak from those surfaces and causing malfunction.
Caution Also, be careful not to let any foreign matter enter the oil path. Such foreign matter has a dan-
ger of the spool sticking due to biting of the spool sliding section or a load check seat defect
making the actuator run wild or stop disabled.
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k) Disassembly of valve housing union bolt
1. Do not disassemble the union bolt (77) unless necessary.
Caution 2. If such disassembly is necessary, place the main unit on a flat table to do the work.
3. Prepare the replacement O-rings (65) and (66).
[1] Loosen and remove the 8 hexagon socket head bolts (77) (14 mm hexagon socket diam-
eter).
[2] Remove the valve housing matching surface O-rings (65) and (66).
(3) Cleaning
Completely clean all the disassembled parts with clean mineral oil.
Dry with compressed air and place each part on clean paper or vinyl for inspection.
(4) Inspection
Inspect all surfaces of each part for burrs, scratches, gouges, and other defects.
[1] Inspect the valve housing load check seat surface for scratches, gouges, and also for debris,
dents, rust. Repair any minor scratches with an oilstone.
[2] Check that there are no scratches, dents, etc. on the outer edge of the spool.
Repair any small scratches with an oilstone.
[3] Sliding parts must all move easily.
Also, all grooves and paths must be free of foreign matter.
[4] If a spring is broken or extremely deformed or worn, replace it.
[5] If relief valve operation is poor, inspect according to "Troubles and countermeasures Relief
valve".
[6] Replace all O-rings and backup rings from disassembled parts.
[7] After removing caps or plugs, check for any paint fragments around the body opening or
plug seating surface. (If paint fragments were to get inside the valve, they could jam up or
clog up the valve, resulting in operation defects and oil leaks.)
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(5) Assembly
1) Cautions for assembly
a) Cautions for O-Ring handling
[1] Do not use any O-ring with a molding defect or damage caused by handling.
[2] Apply enough grease or hydraulic oil to the O-ring and the section where it is mounted so
that it can be mounted smoothly.
[3] Do not stretch an O-ring so far that this causes permanent deformation.
[4] When assembling an O-ring, be careful not to roll the O-ring into place.
(If an O-ring is mounted twisted, it is difficult for it to naturally recover to its normal state
and that twist causes oil leaks.)
b) Cautions for spool handling
[1] Excessive torque on thread sections causes spool operation defects, so always tighten to
just the specified torque.
[2] Be careful to assemble all spools, springs, and spool ends in the same combinations as
before disassembly.
c) Adhesive application method (for male thread section and female thread section of parts
requiring adhesion)
[1] Cleaning (degreasing)
Either use vapor degreasing with acetate, ether or clean with an alkali cleaning agent.
[2] Drying
Dry the surface to be glued, either by blowing clean air on it or letting it dry naturally.
Inadequate drying reduces the effectiveness of the adhesive.
[3] Applying the adhesive
Apply a small amount of adhesive (equivalent to Loctite #638) to the first 2 - 3 threads at
the entrance of the spool female threads.
At this time, install being careful that the application section does not touch the spring
seat.
Caution Do not use "Loctite Primer T" hardening accelerator. It causes insufficient adhesion strength.
[4] Adhesive hardening time

In order to ensure the hardening of the adhesive, after fastening the spool end, leave the
part out in the air for the following period of time.
- Ambient temperature around 22 ℃ : 8 hr. or longer
If the parts are not left out in the air for the above period, adequate adhesive strength may not
Caution be achieved.
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Control Valve
2) Procedure for assembly of sub-assembly
Before starting the assembling, check the quantity of each part, the installation location, the
Caution required tools, etc.
a) Assembly of spool assembly (main spool)
[1] Apply adhesive to the thread sections of the spools (2) - (6), (14) - (17) and assemble the
spring seat, spring, and spool end.
[2] Sandwich the spool with the wooden blocks (the same ones used for disassembly), fas-
ten in place with a vise, then tighten the spool ends to the specified torque.
[3] For spools (3), (4), and (14), insert the poppets and springs from the end opposite from
the spool end, then apply adhesive to the thread sections of the plugs with the O-rings
and backup rings mounted, and tighten.
Also, for spool (5), the plug with filter is mounted at this location.
1. Be careful not to apply so much adhesive that it drips into the spool.
2. Be careful not to tighten any spool end with excessive torque. Excessive torque there would
Caution deteriorate spool operation.
3. There are 2 types of spring. Be careful to assemble each in its correct location. (only boom
2 different)
b) Assembly of arm 1 parallel-tandem spool assembly
[1] Apply adhesive to the thread sections of the spool (19) and assemble the spring seat
(20), spring (21), and spool end (22).
Caution 2. Be careful not to tighten any spool end with excessive torque. Excessive torque there would
deteriorate spool operation.
c) Assembly of neutral cut spool assembly
[1] Apply adhesive to the thread sections of the spool (84-1) and assemble the spring seat
(84-2), spring (84-3), and spring end (84-4).
Caution 2. Be careful not to tighten any spool end with excessive torque. Excessive torque there would
deteriorate spool operation.
d) Assembly of antidrift valve assembly
[1] Assemble the O-rings (67-8) and (67-9) and backup rings (67-10) and (67-11) into the
grooves on the outer edge of the sleeve (67-5).
1. Be careful to assemble O-rings and backup rings in the correct locations.

Caution 2. If they are assembled backwards, there is a danger of an O-ring being damaged and the
drop of the actuator from its own weight increasing.
[2] Insert the poppet (67-2) and spool (67-4) in the sleeve hole. Be careful to assemble the
spool in the correct direction.
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[3] Install the spring seat (67-13) at the small-diameter section at the tip of the poppet, mount
on the spring (67-7), and insert into the body (67-1) together with the sleeve.
Apply grease to the poppet seat so that the spring and spring seat can be installed correctly on
Caution the poppet seat.
[4] Screw the plug (67-14) into the body (67-1) and tighten it.
[5] Assemble the spring (67-6) and piston (67-3) on the plug (67-14).
[6] Tighten the plug assembly (67-12) with O-ring mounted to the body (67-1).
3) Procedure for assembly of control valve main unit
a) Assembly of relief valve
1. When installing the relief valve, be sure to tighten the main unit installation section plug.
2. Do not tighten the set pressure adjustment plug or lock nut.
Caution 3. Doing so would be dangerous because the set pressure changes if the set pressure adjust-
ment plug turns.
[1] Screw in and tighten the main relief valve (68).
[2] Screw in and tighten the 6 overload relief valves (69) at each section.
[3] Screw in and tighten the 2 relief valve assemblies with O-rings mounted (70).
b) Assembly of load check valve
[1] Mount the O-rings (36) in the arm 1 section (E-E cross section), Boom 1 and 2 sections
(F-F cross sections), swing section, and bucket section (G-G cross sections) and assem-
ble the poppets (34) and springs (35).
Mount the flanges (37) and tighten with the hexagon socket head bolts (75).
[1]For the arm 2 section (E-E cross section), assemble the sleeve (58), poppet (59) and
spring (60), mount the flange (61), and tighten with the hexagon socket head bolts (75).
[2] Mount the O-ring (36) in the travel section (I-I cross section) and assemble the poppet
(51) and spring (35). Tighten the flange (37) with the hexagon socket head bolt (75).
[3] Assemble the poppet (34) and spring (35) on the common check section (J-J cross sec-
tion), then insert the spacers (53) with the O-ring (54) and backup ring (55) mounted.
Tighten the flange (52) with the hexagon socket head bolt (75).
1. Be careful to assemble O-rings and backup rings in the correct locations.

Caution 2. If they are assembled backwards, there is a danger of an O-ring being damaged and caus-
ing external leaks.
[4] Mount the O-ring (36) in the option section (H-H cross section) and assemble the poppet
(44) and spring (45). Mount the flange (43) and tighten with the hexagon socket head
bolts (74).
[5] Assemble the poppet (49) and spring (48) in the travel section (H-H cross section).
Screw in and tighten the plug (46) with O-ring (47) mounted.
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Control Valve
[6] Assemble the poppet (32) and spring (33) in the arm 1 parallel-tandem section (D-D
cross section).
Screw in and tighten the plug assembly (72) with O-ring mounted.
[7] Assemble the poppet (32), spring (33), and spacer (57) in the arm 2 parallel-tandem sec-
tion (D-D cross section).
Screw in and tighten the plug assembly (72) with O-ring mounted.
c) Assembly of antidrift valve
[1] Mount the O-rings (36) and (41) on the antidrift valve installation surfaces in the arm 1
section (E-E cross section) and boom 1 section (F-F cross section).
[2] Assemble the poppet (38) and spring (39).
[3] Install the 2 antidrift valve assemblies (67) and tighten with the hexagon socket head
bolts (74).
d) Assembly of option section
[1] Install the 2 caps (88) with O-rings (89) mounted and tighten with the hexagon socket
head bolts (75).
[2] Screw in and tighten the 2 plug assemblies (93) with O-rings and backup rings mounted.
e) Assembly of arm regeneration release valve
[1] Mount the O-ring (30) and 2 backup rings (31) in the sleeve (27-2).
[2] Assemble the piston (27-3) and spool (27-1) in the sleeve and insert into the valve hous-
ing.
[3] Put the spring (26) into the plug (24) with O-ring (25) mounted, then screw into the valve
housing and tighten.
f) Assembly of arm 1 parallel-tandem spool
[1] Assemble the spool (19) in the sub-assembly state into the valve housing.
Caution After inserting the spool, slide it to check for any sticky or rough feeling.
[2] Mount the cap (18) with O-ring mounted (23) and tighten with the hexagon socket head
bolt (78).
Tightening torque: 8.8 - 10.8 N•m
g) Assembly of neutral cut spool
[1] Assemble the spool assembly (84) into the valve housing.
Caution After inserting the spool, slide it to check for any sticky or rough feeling.
[2] Mount the O-ring (65) into the housing and tighten the cap (86) with the hexagon socket
head bolt (78).
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Control Valve
h) Assembly of main spool
[1] Mount the O-rings (7) and (41) on the valve housing cap matching surface.
[2] Assemble the spool assemblies (2) - (6), (14) - (17) in the sub-assembly state into the
same location as before disassembly.
1. Line up the spool straight with the opening and insert it slowly.
2. After inserting the spool, slide it to check for any sticky or rough feeling.
Caution 3. If a spool is left inserted that feels sticky or rough, there is a danger of a spool operation
defect.
[3] Install the plate assemblies (28) and (29) and tighten the hexagon socket head bolts in
the order (75), (94). Be careful not to apply excessive tightening torque to (94).
Tightening torque: (75) 39 - 44 N•m, (94) 8.8 - 10.8 N•m
[4] Install the plate assemblies (10) and (11), and tighten with the hexagon socket head bolts (75).
[5] Install the caps (8) and (9), and tighten with the hexagon socket head bolts (74).
[6] Screw in the plug assembly (110) with O-ring mounted into the option section (H-H cross
section) short cap and tighten it.
[7] Screw in the plugs (91) with O-rings (90) mounted into the option section (H-H cross sec-
tion) and straight travel section (I-I cross section) long caps and tighten them.
1. Be careful not to apply excessive torque when tightening a plug to a cap.

Caution 2. Applying excessive torque could crush the cap threads.
i) Assembly of straight travel signal control valve
[1] Screw the orifice plug (42-7) (36 mm hexagon diameter) into the body (42-1) and tighten
it.
[2] Being careful about the insertion orientation, assemble the spools (42-2) and (42-3) and
spring (42-4).
[3] Tighten the plug assembly (42-5) (5 mm hexagon socket diameter) with O-ring mounted
to the body.
[4] Install the body assembly (42) with the hexagon socket head bolts (83) (5 mm hexagon
socket diameter).
j) Assembly of add-on section
[1] Screw the tie rod (96) into the main unit valve housing (1).
[2] Install the main unit body matching surface O-rings (56) and (64).
Execute Steps [3] - [5] below as necessary.
[3] Remove the spool section assembly (111) and remove the matching surface O-rings
(110-10) and (110-11).
[4] Remove the inlet section assembly (99) and remove the matching surface O-rings (99-3)
and (99-4).
[5] Remove the spool section assembly (98) and remove the matching surface O-rings (98-
10) and (98-11).
[6] Install the outlet housing (95).
[7] Tighten the 4 hexagon nuts (97) (22 mm hexagon diameter).
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Control Valve
k) Assembly of other plugs
[1] Screw in and tighten the plug assembly (71) with O-ring mounted.
[3] Screw in and tighten the orifice plug (40).
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Control Valve
Internal structure diagram
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Control Valve
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Control Valve
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Control Valve
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Control Valve
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Control Valve
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Control Valve
Part list

1 Valve housing 1 48 Spring 1
2 Spool assembly 1 49 Poppet 1
3 Spool assembly 1 51 Poppet 1
4 Spool assembly 1 52 Flange 2
5 Spool assembly 2 53 Spacer 2
6 Spool assembly 1 54 O-ring 2
7 O-ring 20 55 Backup ring 2
8 Cap 9 56 O-ring 1
9 Cap 1 57 Spacer 1
10 Plate assembly 1 58 Sleeve 1
11 Plate assembly 1 59 Poppet 1
13 Valve housing 1 60 Spring 1
14 Spool assembly 1 61 Flange 1
18 Cap 1 67 Antidrift valve assembly 2
19 Spool 1 68 Relief valve kit 1
20 Spring seat 2 69-1 Relief valve kit 5
21 Spring 1 69-2 Relief valve kit 1
22 Spool end 1 70 Relief valve assembly 2
23 O-ring 1 71 Plug assembly 3
24 Plug 1 72 Plug assembly 10
26 Spring 1 74 Socket head bolt 32
27 Spool assembly 1 75 Socket head bolt 66
28 Plate assembly 1 77 Socket head bolt 8
29 Plate assembly 1 78 Socket head bolt 4
30 O-ring 1 79 Name plate 1
31 Backup ring 2 80 Drive screw 2
32 Poppet 2 82 Metal plug 5
33 Spring 2 83 Socket head bolt 4
34 Poppet 7 84 Spool assembly 1
35 Spring 8 86 Cap 1
36 O-ring 10 88 Cap 2
37 Flange 6 89 O-ring 2
38 Poppet 2 90 O-ring 2
39 Spring 2 91 Plug 2
40 Orifice plug 1 92 Plug assembly 2
42 Body assembly 1 94 Socket head bolt 2
43 Flange 1 95 Outlet housing 1
44 Poppet 1 96 Tie rod 4
45 Spring 1 97 Nut 4
46 Plug 1 110 Plug assembly 1
47 O-ring 1
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Control Valve
(6) Relief valve
1) Procedures for assembly and disassembly of main relief valve
1 Plug (32 mm hexagon diameter) 7 Hexagon nut (30 mm hexagon diameter)

2 O-ring 8 Plug (27 mm hexagon diameter)
3 O-ring 9 1-1/16-12UN-2A
4 Hexagon nut (36 mm hexagon diameter) 10 Piston
5 O-ring 11 PF1/4 JIS O-ring type
6 Plug (27 mm hexagon diameter)
[1] Disassembly
This part is replaced as an assembly.
When replacing, loosen the plug (1) (32 mm diameter) with a wrench and remove the O-ring
(2).
If oil leaks from the nut (4) (36 mm hexagon diameter), loosen the nut (4) (36 mm hexagon
diameter) and the plug (1) (32 mm hexagon diameter), and replace the O-ring (3).
If oil leaks from the nut (7) (30 mm hexagon diameter), loosen the nut (7) (30 mm hexagon
diameter) and the plug (8) (27 mm hexagon diameter), and replace the O-ring (5).
[2] Assembly
Carefully check to make sure there is no debris, paint fragments around the thread sections
of the plugs (1) (32 mm hexagon diameter), (6) (27 mm hexagon diameter), (8) (27 mm
hexagon diameter) and nuts (4) (36 mm hexagon diameter), (7) (30 mm hexagon diameter)
and assemble the new O-rings.
Also clean the valve housing relief valve installation section well, install the relief valve, and
tighten the plug (1) (32 mm hexagon diameter).
[3]When the plug has been disassembled, adjust the pressure according to the Main relief
valve item in 5).
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Control Valve
2) Procedures for assembly and disassembly of overload relief valve
1 Cap 6 Spring
2 O-ring 7 1-1/16-12UN-2A
3 Adjuster kit section 8 Cap (31.75 mm hexagon diameter)
4 O-ring 9 Lock nut (17 mm hexagon diameter)
5 Poppet 10 Adjuster (6 mm hexagon diameter)
[1] Disassembly
When replacing, loosen the cap (1) (31.75 mm hexagon diameter) with a wrench and
remove the O-ring (2).
Also, if oil leaks from the adjuster kit section, loosen the adjuster kit and replace the O-ring
(4).
Be careful disassembling the adjuster kit. The spring may make parts fly out and the poppet
Caution could be lost.
[2] Assembly
Check carefully that there is no debris, paint fragments around the thread section of the cap
and assemble a new O-ring (2).
Also clean the valve housing relief valve installation section well, install the relief valve, and
tighten the cap (1) (31.75 mm hexagon diameter).
[3]When the adjuster kit has been disassembled, clean around the thread sections well and
adjust the pressure according to the Overload relief valve item in 5).
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Control Valve
3) Procedures for assembly and disassembly of low-pressure relief valve
1 Plug 7 Plug
2 Poppet 8 O-ring
3 Plug 9 PF1/4
4 Spring 10 PF3/4
5 O-ring 11 1 3/16-12UN-2A
6 Piston
[1] Disassembly
Fasten the assembly with a vise, loosen the plug, and remove the piston (6), spring (4), and
poppet (2). Then loosen the plug and take out the O-rings (5) and (8) from each part.
[2] Assembly
Check carefully that there is no debris, paint fragments around the thread section of the plug
and assemble a new O-ring. Install new O-rings (5) and (8) on the plug and install the plug.
Assemble the poppet (2), spring (4), and piston (6) and screw in and tighten the plug.
[3]Also clean the valve housing relief valve installation section well and tighten the relief
assembly plug (1) (36 mm hexagon diameter).
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Control Valve
4) Procedures for assembly and disassembly of add-on main relief valve
1 Plug (32 mm hexagon diameter) 6 Spring

2 O-ring 7 1-5/16-12UN-2A
3 Adjuster kit section 8 Plug (24 mm hexagon diameter)
4 O-ring 9 Lock nut (17 mm hexagon diameter)
5 Poppet 10 Adjuster (6 mm hexagon diameter)
[1] Disassembly
When replacing, loosen the plug (1) (32 mm hexagon diameter) with a wrench and remove
the O-ring (2).
Also, if oil leaks from the adjuster kit section, loosen the adjuster kit and replace the O-ring
(4).
Be careful disassembling the adjuster kit. The spring may make parts fly out and the poppet
Caution could be lost.
[2] Assembly
Check carefully that there is no debris, paint fragments around the thread section of the plug
and assemble a new O-ring (2).
Also clean the valve housing relief installation section well, install the relief valve, and tighten
the plug.
[3]When the adjuster kit has been disassembled, clean around the thread sections well and
adjust the pressure according to the Add-on main relief valve item in 5).
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28
Control Valve
5) Relief valve adjustment
This part is neither disassembled nor adjusted. (It is replaced as an assembly.) Therefore, be
Caution aware that proper operation is not guaranteed if pressure is adjusted.
a) Main relief valve
[1] Install an accurate pressure gauge in the entry circuit.
[2] Run the pump at its rated rotation rate.
[3] Switch the control valve spool and read the pressure gauge at the cylinder stroke end.
Switch the spool for the actuator with the overload relief valve set pressure higher than the
Caution main relief valve set pressure.
[4] High-pressure setting (1st stage) (See the diagram on page 268.)
1) Tighten the plug (8) until the piston (10) touches the plug (6) end surface (section
marked *). At this time, the plug (8) (27 mm hexagon diameter) tightening torque must
be 19.6 N•m or less.
However, when tightening the plug (8), be careful that the plug does not turn too. (The A
dimension must be at least 4 mm.)
2) With the plug (6) in the state in [4] 1), tighten and adjust the pressure. (While watching
the pressure gauge, tighten in the plug (6) gradually: 1 turn of the plug raises the pres-
sure 28.4 MPa.)
After setting the pressure, lock with the hexagon nut.
[5] Low-pressure setting (2nd stage)
With the high-pressure set in 4), loosen the plug (8) and adjust the pressure.
(When the plug is loosened, the piston moves to the right in the diagram and the spring
load drops: 21.3 MPa pressure drop per one rotation.)
After setting the pressure, lock with the hexagon nut (7).
[6] Again raise the pressure and check that it reaches the specified pressure.
b) Overload relief valve
If the set pressure is higher than the main relief valve, when adjusting as below, the main relief
valve operates, so the overload relief valve cannot be adjusted. That is why the relief valve is
Caution not disassembled and adjusted but is replaced as an assembly with an assembly that has
already been set.
[2] Turn the adjuster clockwise until the required pressure is obtained.
[3] Reference number 69, total of 6 locations: The pressure rises 21.2 MPa for one rotation
of the adjuster.
[4] When the specified pressure is reached, restrain the adjuster so that it does not turn,
then tighten the lock nut.
272 SSM-13-11-004EN
29
Control Valve
c) Add-on main relief valve
[1] Install an accurate pressure gauge in the entry circuit.
[2] Run the pump at its rated rotation rate.
Switch the spool for the actuator with the overload relief valve set pressure higher than the
Caution main relief valve set pressure.
[4] Turn the adjuster clockwise until the required pressure is obtained.
The pressure rises 17.8 MPa for one rotation of the adjuster.
[5] When the specified pressure is reached, restrain the adjuster so that it does not turn,
then tighten the lock nut.
(7) Installation
[1] Be careful that the line does not apply excessive force to the valve.
[2] Tighten all the bolts the same.
[3] Be careful. Welding close to a valve can damage its seal due to excess heat and sputter.
[4] In order to keep out debris, do not remove the cap for a port until it is time to work on the
line.
(8) Operation
[1] Check that the hydraulic circuits and hydraulic oil are clean, then gradually raise the pres-
sure (inch the operating machine in low idle) and check that no oil leaks to the outside.
[2] For the oil, use hydraulic oil with an aniline point of 82 - 113 ℃ .
[3] Do not raise the relief valve above the specified set pressure.
[4] Set a difference of at least 2.0 MPa between the set pressure for the main relief valve and for
the overload relief valve.
[5] Warm up the machine adequately before starting the actual work.
Pay attention to the following points in order to avoid sticking due to spool heat shock partic-
ularly when starting up with the hydraulic oil temperature or valve temperature low.
• Do not operate the main relief valve and overload relief valve right too suddenly after each
other. Raise the temperature of each section uniformly and operate in such a way that the
hydraulic oil circulates within each actuator.
• Fine operations and compound operations generate heat locally due to throttling of individ-
ual sections, so do not suddenly perform these operations with the machine still at low tem-
perature.
SSM-13-11-004EN
30
Control Valve
(9) Troubles and countermeasures
Control valves overall
Trouble content Conceivable cause Countermeasure

The spool does not 1. The oil temperature is abnormally Eliminate the section that is providing resis-
move through its stroke. high. tance to the oil flow in the line.
2. Dirty hydraulic oil Replace the hydraulic oil and at the same
time, clean the circuits.
3. Line port joint tightened too much Check the torque.
4. The valve housing was warped dur- Loosen the installation bolts and check.
ing installation.
5. The pressure is too high. Attach a pressure gauge to the pump and the
cylinder port and check the pressure.
6. The spool is bent. Replace the spool as an assembly.
7. Return spring damage Replace the damaged part.
8. The spring or cap is out of place. Loosen the cap, center it, then tighten it.
9. The temperature distribution within Warm up the circuits as a whole.
the valve is not uniform.
10. Debris is clogging inside the valve. Remove (flush out) the debris.
11. Pilot pressure insufficient Inspect for the pilot valve and pilot relief pres-
sure.
The load cannot be 1. Oil leak from cylinder Check the cylinder seal section.
held.
2. Oil from the spool is bypassing. Check for spool damage.
3. Oil leak from overload relief valve Clean the valve housing seat section and relief
valve seat section.
4. Oil leak from antidrift valve Disassemble the antidrift valve and clean the
seat section for each part.
If a seat section is damaged, replace the pop-
pet or lap the poppet and seat section.
If the antidrift valve spool is abnormal, since
the spool and the sleeve are mating parts,
replace them both at the same time.
When the spool is 1. There is debris jammed in the load Disassemble and clean the check valve.
switched from the neu- check valve.
tral to the raise position,
2. The check valve poppet or seat sec- Replace the poppet or lap the poppet and seat
the load falls.
tion is damaged. section.
274 SSM-13-11-004EN
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Control Valve
Relief valve

Pressure does not rise 1. Either the main poppet, sleeve, or Replace the relief valve.
at all. pilot poppet is stuck open or there is
debris jammed in the valve seat
section.
The relief pressure is 1. The pilot poppet seat section is
unstable. damaged.
2. The piston or main poppet is stuck.
The relief pressure is 1. Seat section worn by debris
wrong.
2. The lock nut and adjuster are loose. Set the pressure again, then tighten the lock
nut to the specified torque.
Oil leak 1. Relief valve seat section damage Replace the relief valve.
2. Each part is stuck due to debris.
3. An O-ring is worn. Replace the adjuster or installation section O-
ring.
Hydraulic system overall

The hydraulic system is 1. Pump trouble Check the pressure or replace the pump.
not working properly or
2. Relief valve trouble Replace the relief valve.
is not working at all.
3. Cylinder trouble Repair or replace.
4. Pump load pressure is high. Check the circuit pressure.
5. There is a crack in the valve. Replace the valve as an assembly.
6. The spool does not move through Check the spool movement.
its full stroke.
7. The tank oil level is too low. Fill the hydraulic oil.
8. The filter in the circuit is clogged. Clean or replace the filter.
9. The circuit line is throttled. Check the line.
SSM-13-11-004EN
32
Other Valves SH330-5
Other Valves
Removal and Installation of 5 Stack Solenoid
Items to prepare
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid
1. Removal of 5 stack solenoid valve
[2] Use a wrench (13 mm) to remove the 2 cover

bolts (3), and then remove the cover (4).
276 SSM-13-12-004EN
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Other Valves
[3] Remove the 5 connectors (5).
[4] Use wrenches (19 mm, 22 mm) to remove the

hoses (6), (7) and (8).
• Mark the solenoid valve and hoses so that the
connectors match at the time of assembly.
• Use caps or plugs to cover the solenoid valve
and hose to prevent any entry of water, dust or
dirt.
• Clean the solenoid valve and hoses by spraying
nectors.
[5] Use a wrench (22 mm) to remove the hoses (9)

and (10).
and hoses to prevent any entry of water, dust or
dirt.
nectors.
6 Pilot hose (use 22 mm wrench)

10 Drain hose (use 22 mm wrench)
SSM-13-12-004EN
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Other Valves
hoses (11), (12) and (13).
dirt.
nectors.

(14), and then remove the 5 stack solenoid
valve (15).

278 SSM-13-12-004EN
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Other Valves
2. Installation of 5 stack solenoid valve
The hose connections and electrical connector connections are indicated below.
SSM-13-12-004EN
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Other Valves
Removal and Installation of Cushion Valve
Items to prepare
• Marking pen
• Caps
• Plugs
• Waste oil can
• Rag
• Cleaning fluid
1. Removal of cushion valve

280 SSM-13-12-004EN
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Other Valves
SSM-13-12-004EN
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Other Valves
[5] Use wrenches (17 mm, 19 mm, 22 mm) to
remove each hose and line.
• Mark the cushion valve, hoses and lines so that
the connectors match at the time of assembly.
• Use caps or plugs to cover the cushion valve,
hoses and lines to prevent any entry of water,
dust or dirt.
• Clean the cushion valve, hoses and lines by
spraying them with a parts cleaner to prevent
scratches and prevent dirt from accumulating on
the connectors.
6 Pilot hose
7 Line
9 Use 17 mm wrench
10 Use 19 mm wrench
11 Use 22 mm wrench
282 SSM-13-12-004EN
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Other Valves
(12) on the cushion valve bottom, and then
remove the cushion valve.
2. Installation of cushion valve

The connections are as follows.
1 Arm in 7 Boom down

2 Boom up 8 Swing left
3 Swing right 9 Bucket open
4 Bucket close 10 Pressure sensor (swing)
5 Heat circuit line 11 Swing priority switching pilot line
6 Arm out 12 Drain line
SSM-13-12-004EN
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Other Valves
Assembly and Disassembly of Cushion Valve
This valve has a structure that forms small gaps. It is precision processed and the parts are carefully
selected and fit together, so do not disassemble it as much as possible. If assembly and disassem-
bly is unavoidable, pay attention to the following. (Failure to follow these instructions may invalidate
the product warranty.)
[1] Only disassemble in a clean location with minimal dirt.
[2] Use only clean tools and cleaning oil and handle them with care.
[3] Use plugs, caps to cover ports to prevent any entry of dirt and clean the outside of the assembly.
[4] Check the internal structure before starting work, and carefully study the disassembly objective
and scope.
(1) Reverse operation spool section
[1] Remove the plugs (1) and O-rings (2).
[2] Remove the springs (3).
[3] Remove the spools (4) with the cap screws and O-rings assembled in them.
Diagram 1
[4] Use a vise to fasten the spool (4) assemblies taken out in [3].
[Caution] Use a piece of wood (jig) to prevent scratches.
284 SSM-13-12-004EN
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Other Valves
[5] Remove the cap screw (1) and O-ring (2).
3 Spool
4 Piece of wood (jig)
Diagram 2
(2) Check plunger section with throttle

[1] Remove the plugs (1) and O-rings (2).
[2] Remove the springs (3) and remove the check plungers (4).
[Caution] The check plungers have similar shapes, so identify them in such a way that no
one will mix them up with each other.
Diagram 3
SSM-13-12-004EN
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Other Valves
(3) Shuttle valve section
[1] Remove the plugs (1) and O-rings (2) and (3).
[2] Remove the steel balls (4).
Diagram 4
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Other Valves
This valve has a structure that forms small gaps. It is precision processed and the parts are carefully
selected and fit together, so do not disassemble it as much as possible. If assembly and disassem-
bly is unavoidable, pay attention to the following. (Failure to follow these instructions may invalidate
the product warranty.)
[1] Only assemble in a clean location with minimal dirt.
[2] Use only clean tools and cleaning oil and handle them with care.
[3] Clean the disassembled parts and prepared parts.
[4] Study the internal structure before starting the work and prepare the parts required by the disas-
sembly objective and scope.
(1) Reverse operation spool section
[1] Assemble on the spool (3) the cap screw (1) with O-ring (2) attached.
[1][Caution] Use a piece of wood (jig) (4) to prevent scratches.
Diagram 5
[2] Insert the spool assembly (1) assembled in [1] into the body.
[Caution] The spool assembly is symmetrical left/right, so the insertion direction does not matter.
[3] Insert the springs (2) and assemble the plugs (3) with the O-rings (4) attached.
Diagram 6
SSM-13-12-004EN
12
Other Valves
(2) Check plunger section with throttle
[1] Insert the check plungers (1).
[Caution] The check plungers have similar shapes, so be careful to insert each one in its cor-
rect position.
[2] Insert the springs (2) and assemble the plugs (4) with the O-rings (3) attached.
Diagram 7
(3) Shuttle valve section

[1] Insert the steel balls (1).
[2] Assemble the plugs (2) with the O-rings (3) and (4) attached.
Diagram 8
288 SSM-13-12-004EN
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Other Valves
3. Written materials
[1] Check plunger table
Part No. Name Orifice diameter (φ) Remarks

65301-11705 Check plunger 0.5
SSM-13-12-004EN
14
Other Valves
[2] Cushion valve assembly diagram
External shape diagram
Cross-section diagram

1 Body 9 Check plunger 17 Plug
2 Spool 10 Check plunger 18 O-ring
3 Spring 11 Check plunger 19 Name plate
4 Plug 12 Check plunger 20 Drive screw
5 O-ring 13 Spring 21 Plug
6 Cap screw 14 Plug 22 Plug
7 O-ring 15 O-ring
8 Plug 16 Steel ball
290 SSM-13-12-004EN
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Radiator and Oil Cooler SH330-5

Removal and Installation of Radiator
・ Do not remove the radiator cap when the radiator coolant temperature is high. Hot liquid
Warning could spray out.

Items to prepare
• Pliers
• Caps
• Plugs
• Drain tank
• Drain hose
• Rag
• Cleaning fluid
1. Removal of radiator
291 SSM-13-13-004EN
1
[2] Install the drain hose (3), and then prepare the
drain tank (4).
[3] To make it easier to drain the coolant, remove

the radiator cap (5).
[4] Loosen the drain plug (6), and then drain the
coolant.
SSM-13-13-004EN 292
2


(10), and then remove the seal bracket (11).
293 SSM-13-13-004EN
3
bolts (12) from the radiator cover.

(13), and then remove the upper hose (14) and
lower hose (15) from the radiator.
• Use caps to cover the radiator and hoses to pre-
SSM-13-13-004EN 294
4
[10] Remove the drain plug (16), loosen the hose
band (17), and then remove the hose (18).
[11] Loosen the hose band (20), and then remove

the hose (19) from the radiator cap.
• Attach caps or plugs to the hoses to prevent any
entry of water, dust or dirt.

(21).
295 SSM-13-13-004EN
5
[15] Remove the fan guide rubber (25).
SSM-13-13-004EN 296
6
[16] Remove the 2 butterfly bolts (26), and then
remove the front anti-insect net (27).
[17] Install the 2 shackles (28) to the top of the radia-

tor, and then use the wire rope (29) and liftcrane
to lift the radiator.
[18] Lift the radiator together with the radiator cover

(31) until the fixtures (30) at the bottom of the
radiator become disconnected.
297 SSM-13-13-004EN
7
before lowering the radiator on square wooden
pieces.
When laying down the radiator, be careful not to
bend or crush the bottom fixtures (30).
2. Installation of radiator
For details on the method for coolant filling, see the Engine Shop Manual.
Coolant capacity is 30 L.
Finally, check that the level of coolant is correct.
SSM-13-13-004EN 298
8
Removal and Installation of Oil Cooler

Items to prepare
• Pliers
• Screwdriver
• Caps
• Waste oil can
• Rag
• Cleaning fluid
1. Removal of oil cooler
[1] Drain the hydraulic oil from the hydraulic oil
tank.
See "Draining Oil from Hydraulic Oil Tank" for
details of the procedure.
299 SSM-13-13-004EN
9
[4] Remove the 2 butterfly bolts (4), and then

remove the anti-insect net (5).
SSM-13-13-004EN 300
10
upper hexagon socket head bolts (6) and 2
lower bolts (6), and then remove the lines (7)
and (8).
• Use caps to cover the oil cooler and lines to pre-
301 SSM-13-13-004EN
11
(9).
[7] Install the 2 eyebolts (M12) (10) on the top of

the oil cooler.
• Fully tighten the eyebolts, and then loosen them
by a half turn.
SSM-13-13-004EN 302
12
[8] Install the 2 shackles (11) to the eyebolts, and
then use the wire rope (12) and liftcrane to lift
the oil cooler main unit.

before lowering the oil cooler on wood planks,
etc.
2. Installation of oil cooler

303 SSM-13-13-004EN
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Tank SH200-5
Tank
Removal and Installation of Hydraulic Oil Tank
・ Bleed off the pressure in the hydraulic oil tank before beginning work.
Warning ・ The temperature of the hydraulic oil is high immediately after stopping the engine. Wait until
the hydraulic oil temperature has decreased (to 40 ℃ or less) before beginning work.

Items to prepare
• Marking pen
• Caps
• Plugs
• Waste oil can
• Rag
• Cleaning fluid
1. Removal of Hydraulic Oil Tank
[1] Drain the oil from the hydraulic oil tank. (For
details, see "Draining Oil from Hydraulic Oil
Tank".)
304 SSM-13-14-004EN
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Tank
[3] Prepare a waste oil can (3) under the hydraulic
oil tank.

and then remove the seal washer (5).
• Cover the seal washer to prevent the entry of
[5] After closing the engine hood (9), use a wrench

(19 mm) to remove the 9 bolts (6), and then
remove the top covers (7) and (8).
2
Tank
(10), and then remove the drain hoses (11) and
(12).
• Use caps to cover the lines to prevent any entry
of water, dust or dirt.
[7] Use wrenches (19 mm, 22 mm, 27 mm, 36 mm)

to remove the drain hoses (13).
• Mark the hydraulic oil tank and hoses so that
the connectors match at the time of assembly.
• Attach caps or plugs to the hydraulic oil tank
dirt.
• Clean the hydraulic oil tank and hoses by spray-
ing them with a parts cleaner to prevent
scratches and prevent dirt from accumulating on
the connectors.

306 SSM-13-14-004EN
3
Tank
(16), and then remove the top cover (17) from

(18) and 6 spacers (19) from the bottom of the
hydraulic oil tank.
• Depending on the machine, there may be height
adjustment shims between the tank and the
frame. Do not lose them.
Also, mark or write down the locations where
they are and how many.

(20) from the fuel tank front cover (tank) (21),
and then remove the cover (tank).
4
Tank
(22) from the fuel tank side cover, and then
remove the side cover (23).

(24), and then remove the side covers (tank)
(25).
308 SSM-13-14-004EN
5
Tank
[14] Connect the 2 eyebolts (M12) (26) to the top of
the hydraulic oil tank, and then use the shackles
(27), wire rope (28) and liftcrane to lift the
hydraulic oil tank (29).
• When lifting, be careful that the level gauge (30)
does not interfere with the frame at the side of
by a half turn.

before lowering the hydraulic oil tank on wood
planks (31).
• Thoroughly secure the hydraulic oil tank so that
it does not fall down.
2. Installation of Hydraulic Oil Tank

For the tightening torque, check the "Bolt tightening torque list" in the Service Text .
6
Tank
Removal and Installation of Fuel Tank

Items to prepare
• Caps
• Plugs
• Drum can (for draining fuel)
• Rag
• Cleaning fluid
Removal of Fuel Tank
[1] Remove the cap (1) and filter (2).
[2] Drain out all the fuel from the fuel tank into a
drum can.
310 SSM-13-14-004EN
7
Tank

(3), and then remove the top cover (5).

from the fuel tank front cover (tank) (7), and
then remove the cover (tank).
6
8
Tank
and clamps (9), and then remove the handle
(10).

(11) from the fuel tank side cover (12), and then
remove the side cover.
312 SSM-13-14-004EN
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Tank
[9] Loosen the hose band (15), and then remove

the hose (16).
• Mark the fuel tank and hose so that the connec-
• Attach caps or plugs to the fuel tank and hoses
10
Tank
(18) and 6 spacers (19) from the bottom of the
fuel tank.
• Depending on the machine, there may be height
adjustment shims between the tank and the
frame. Do not lose them.
Also, mark or write down the locations where
they are and how many.

(20), and then remove the side covers (tank)
(21).
[13] Install the 4 eyebolts (M12) (22) on top of the

fuel tank.
by a half turn.
314 SSM-13-14-004EN
11
Tank
[14] Connect the 4 shackles (23) to the eyebolts,
then use the wire ropes (24) and liftcrane to lift.
before lowering the fuel tank (25) on wood
planks.
Installation of fuel tank

Finally, carefully check for any fuel leaks.
For the tightening torque, check the "Bolt tightening torque list" in the Service Text .
12
Attachments SH330-5
Attachments
Removal and Installation of Bucket
・ Stop the machine on a level location with good footing.
・ When working together with others, always be sure to exchange signals and pay adequate
Caution attention to safety.
・ Always wear protective devices (protective eyewear and safety shoes, etc.) when working
with a hammer.
Items to prepare
• Hammer
• Striking rod
• Screwdriver
• Grease
• Rag
• Cleaning fluid
1. Removal of bucket
[1] Place the back of the bucket parallel to the
ground.
[2] Remove the bolts and nuts (1), and then remove
the bucket side and boom side pins.
316 SSM-13-15-004EN
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Attachments
the bucket side pin (6) and arm side pin (5) out,
and then remove the bucket (2).
• If a pin is hard to remove, there is a load on the
pin.
Do not force it. Adjust the bucket position.
• When removing the pins, be careful not to dam-
age the installed O-rings or dust seals.
2. Installation of bucket
• Clean each pin and pin hole.
• If a pin is hard to insert, do not force it. Adjust the bucket position.
• When insetting pins, be careful not to damage the O-rings or dust seals.
• As the final step, always grease up.
SSM-13-15-004EN
2
Attachments
Removal and Installation of Bucket Link
Caution attention to safety.
・ Always wear protective devices (protective eyewear and safety shoes, etc.) when working
with a hammer.
Items to prepare
• 2 wrenches (36 mm)
• Hammer
• Striking rod
• Grease
• Rag
• Cleaning fluid
1. Removal of bucket link
[1] Remove the bucket. (For details, see "Removal
and Installation of Bucket".)
[2] Place the bucket link (1) parallel to the ground.
[3] Use 2 wrenches (36 mm) to remove the double

nuts (2), and then pull out the bolts (3) and (4).
318 SSM-13-15-004EN
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Attachments
the pin (7) out and remove the bucket link (8).

the pin (9) out and remove the arm links (10)
and (11).
pin.
SSM-13-15-004EN
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Attachments
2. Installation of bucket link
320 SSM-13-15-004EN
5
Attachments
Removal and Installation of Bucket Cylinder
attention to safety.
Caution ・ Always wear protective devices (protective eyewear and safety shoes, etc.) when working
with a hammer.
・ Be sure to inspect the nylon sling and other lifting equipment before beginning work.
Items to prepare
• Hammer
• Striking rod
• Nylon sling (with the required lifting capacity)
• Grease
• Rag
• Cleaning fluid
• Crossties
• Wire
1. Removal of bucket cylinder
[2] Remove the bucket link. (For details, see
"Removal and Installation of Bucket".)
[3] Bring the arm (1) top in contact with the ground.
Retract the bucket cylinder rod.
[4] Tie the cylinder rod with wire (2) so that it can-
not come out.
SSM-13-15-004EN
6
Attachments
[5] Switch the key switch (3) OFF to stop the
engine. Switch the key switch ON again, and
then turn the control lever (4) about 10 times to
bleed off any pressure.
Note:
Do not operate the bucket at this time.
[6] Move the travel lever (5) back and forth about 5
[7] Return the key switch to OFF.
[8] Press the air breather button (6) on top of the

the tank.
322 SSM-13-15-004EN
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Attachments
[9] Use 2 wrenches (36 mm) to remove the hoses
(7) and (8).
• Use caps or plugs to cover the hoses and lines
• Clean the hoses and lines by spraying them
tors.
[10] Use a liftcrane and nylon sling (9) to secure the

bucket cylinder (10).
• Wrap the nylon sling to the inside of the line so
that it is not crushed.

and washer (12).

the pin (15) out.
pin.
SSM-13-15-004EN
8
Attachments
[13] Lift the bucket cylinder (10) and remove it.
[14] Place the bucket cylinder on crossties.
2. Installation of bucket cylinder

• When inserting pins, be careful not to damage the dust seals.
324 SSM-13-15-004EN
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Attachments
Removal and Installation of Arm Cylinder
with a hammer.
Items to prepare
• Wrench (19 mm)
• Caps
• Plugs
• Hammer
• Striking rod
• Grease
• Rag
• Cleaning fluid
• Crossties
• Wire
1. Removal of arm cylinder
arm cylinder (2).

and washer (4).
SSM-13-15-004EN
10
Attachments
[3] Use a hammer (5) and striking rod (6) to remove
the pin (7). Be careful. The arm and arm cylin-
der rod may come out of place.
[4] Start the engine, move the arm out at idle, and
retract the arm cylinder (2) rod.
not come out.
326 SSM-13-15-004EN
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Attachments
Do not operate the arm at this time.
[8] Switch the key switch OFF.

the tank.
SSM-13-15-004EN
12
Attachments
[10] Use a hexagon wrench (12 mm) to remove the
hexagon bolts, and then remove the hoses (13)
and (14).
tors.
[11] Use a wrench (19 mm) to remove the grease

hose (15).
• Use caps or plugs to prevent any entry of water,
dust or dirt.

and washer (17).
328 SSM-13-15-004EN
13
Attachments
the pin (20) out.
pin.
[14] Lift the arm cylinder (2).

[15] Place the arm cylinder (2) on crossties.
2. Installation of arm cylinder

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Attachments
Removal and Installation of Arm
with a hammer.
Items to prepare
• Wrench (19 mm)
• Hammer
• Striking rod
• Grease
• Rag
• Cleaning fluid
• Crossties
1. Removal of arm
[2] Remove the bucket cylinder. (For details, see
"Removal and Installation of Bucket Cylinder".)
[3] Remove the arm cylinder. (For details, see
"Removal and Installation of Arm Cylinder".)
[4] Bring the arm (1) top in contact with the ground
and use a liftcrane and nylon sling (2) to secure
it.
At this time, insert the arm cylinder pin (3) and
secure with the nylon sling.

and washer (5).
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Attachments
the pin (8) out and remove the arm (9).
pin.
• Be very careful. When the pin is removed, the
arm may fall slightly.
• Be very careful. The arm may fall over to the
side.
[7] Lift the arm.

[8] Place the arm on crossties.
2. Installation of arm
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Attachments
Removal and Installation of Boom Cylinder
with a hammer.
Items to prepare
• Crowbar
• Wire rope (with the required lifting capacity)
• Nylon sling
• Marking pen
• Caps
• Plugs
• Hammer
• Striking rod
• Grease
• Rag
• Cleaning fluid
• Crossties
• Wire
1. Removal of boom cylinder
• When removing only the boom cylinder, put the attachments in the temporary decommissioning
posture.
• When removing as far as the boom, first remove the bucket, bucket cylinder, arm, and arm cylinder
according to their respective removal procedures.
Bring the boom top in contact with the ground.
right boom cylinder (2).
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Attachments
hose (4).
dust or dirt.
[3] Use 2 wrenches (30 mm) to remove the 2 dou-

ble nuts (5) and bolt (6), and then remove the
fastening ring (7).

the pin (10) out.
[5] Start the engine, lower the boom at idle, and
retract the boom cylinder rod.
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Attachments
not come out.

[9] Switch the key switch OFF.
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Attachments
the tank.
[11] Use a wrench (36 mm) to remove the hoses

(16).
• Mark the lines and hoses so that the connectors
tors.

and washer (18).
[13] Use a crowbar to remove the pin (19).
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Attachments
[14] Use a liftcrane and nylon sling (1) to lift the right
boom cylinder (2) and remove it.
[15] Place the right boom cylinder (2) on crossties.
[16] Remove the left boom cylinder (3) with the
same procedure.
2. Installation of boom cylinder

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Attachments
Removal and Installation of Boom
with a hammer.
Items to prepare
• Slide hammer (24 mm)
• Marking pen
• Caps
• Plugs
• Rag
• Striking rod
• Cleaning fluid
• Batten
• Square wooden pieces
• Wire
1. Removal of boom
[2] Remove the bucket cylinder. (For details, see
"Removal and Installation of Bucket Cylinder".)
[3] Remove the arm cylinder. (For details, see
"Removal and Installation of Arm Cylinder".)
[4] Remove the arm. (For details, see "Removal
and Installation of Arm".)
[5] When removing the boom cylinder too, see
"Removal and Installation of Boom".
[6] This section explains the procedure for when
not removing the boom cylinder.
Bring the boom (1) top in contact with the
ground.
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Attachments
hose (2).
dust or dirt.
[8] Use a wrench (30 mm) to remove the double

nuts (3) and bolt (4), and then remove the fas-
tening ring (5).

the pin (8) out.
Use a liftcrane and nylon sling (9) to hold the
boom cylinder so that it does not fall.
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Attachments
not come out.
[11] Secure the base of the boom cylinder with the

batten (11).
[12] Lower the boom cylinder and let it rest on the

batten (11).
[13] Remove the cab side boom cylinder from the
boom in the same way.
[14] Install the pin (8) removed in Step [9].

Use a wrench (30 mm) to install the bolt (4) with
the 2 double nuts (3), and then install the fasten-
ing ring (5).
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Attachments
[15] Wrap the nylon sling (9) around the pin installed
in Step [14] and secure with the liftcrane.
[16] Use wrenches (22 mm, 36 mm, 41 mm) to

remove the hoses (13), (14), (15), (16), (17) and
(18).
• Mark the hoses and lines so that the connectors
tors.
13 Bucket hose (use 36 mm wrench)

14 Bucket hose (use 36 mm wrench)
15 Arm hose (use 36 mm wrench)
16 Arm hose (use 41 mm wrench)
17 2nd option hose (use 22mm wrench)
18 2nd option hose (use 22mm wrench)

and washer (20).
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Attachments
[18] Use a slide hammer (21) (24 mm) to remove the
pin (12).
[19] Back up the machine and remove the boom (1).
2. Installation of boom cylinder

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Attachments
Removal and Installation of Arm HBCV
・ Stop the machine in the temporary decommissioning posture on a level location with good
footing.
Caution ・ When working together with others, always be sure to exchange signals and pay adequate
Items to prepare
• Wrench (22 mm)
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid
1. Removal of arm HBCV
[1] Use a wrench (22 mm) to remove the hoses (1)
and (2).
• Mark the HBCV and hoses so that the connec-
• Use caps or plugs to cover the hoses and
HBCV to prevent any entry of water, dust or dirt.
• Clean the hoses and HBCV by spraying them
tors.

hexagon socket head bolts (3), and then remove
the line (4).
• Use caps or plugs to cover the HBCV and line to
• Clean the HBCV and line by spraying them with
a parts cleaner to prevent scratches and pre-
vent dirt from accumulating on the connectors.
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Attachments
the arm HBCV (6).
2. Installation of arm HBCV

The tightening torque for line installation and HBCV installation is 92.4 ± 17.5 N•m.
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Attachments
Removal and Installation of Boom HBCV
Caution ・ When working together with others, always be sure to exchange signals and pay adequate
Items to prepare
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid
• Crossties
1. Removal of boom HBCV
hoses from the tool box side boom HBCV (1),
(2), (3) and (4).
• Use caps or plugs to cover the HBCV and lines
• Clean the HBCV and lines by spraying them
tors.

the line (6).
tors.

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Attachments
the boom HBCV (8).

hoses (1), (3), (4) and (9) from the cab side
boom HBCV in Step [1].
[5] Use a wrench (27 mm) to remove the boom bot-
tom pressure sensor (10).
tors.
hexagon socket head bolts (11), and then
remove the line (12).
• Use caps or plugs to cover the HBCV and line to
• Clean the HBCV and line by spraying them with
a parts cleaner to prevent scratches and pre-
vent dirt from accumulating on the connectors.

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Attachments
hexagon socket head bolts (13), and then
remove the boom HBCV (14).
2. Installation of arm HBCV

The tightening torque for line installation and HBCV installation is 92.4 ± 17.5 N•m.
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Attachments
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder
1. Specifications and structure diagram (including the assembly diagram and parts table)
In this manual, explanation is done using a product with a representative structure for a construction
machine hydraulic cylinder (KCH-6 model).
For details on the specifications and structure of the product being used, see the delivery diagram
(including the assembly diagram and parts table) given separately.
2. Explanation of functions
(1) Basic functions
Hydraulic cylinders are a type of hydraulic actuator. A hydraulic cylinder converts the energy of
pressure supplied from the hydraulic pump into a large force of linear motion. By operating the
hydraulic pressure direction switchover valve, one can switch the direction of operation between
extension and retraction. This linear motion with large force and the switchover of the operation
direction are the basic functions.
(2) Function of each location
This manual explains the functions of each section of the cylinder using one of our products with
a typical structure. There may be some slight differences with the product being used, but the
functions are the same.
1) Cylinder head assembly
The cylinder head assembly has the function of bearing the piston rod (2) by the bushing (4)
press fit into the inner diameter of the cylinder head (3). The seal system of the inner diameter
of the cylinder head prevents oil from leaking to the outside and prevents foreign matter from
getting into the cylinder. The cylinder head assembly also has the function of supplying and dis-
charging high-pressure oil from inside the cylinder tube to the retraction side port.
1 Cylinder tube 7 U-ring

2 Piston rod 8 Backup ring
3 Cylinder head 9 Wiper ring
4 Bushing 10 O-ring
5 O-ring 11 Backup ring
6 Buffer ring 12 Installation bolt
• Bushing
The bushing is press fit to the inside surface of the cylinder head (3) and touches the piston
rod (2). Together with the slide rings (18) and (19) on the outer circumference of the piston,
the bushing divides the lateral load applied to the cylinder and moves linearly relative to the
piston rod. Furthermore, it supports one end of the piston rod and has the function of minimiz-
ing eccentricity which has a negative impact on the sealing.
• Buffer ring
The buffer ring (6) has the function of buffering the pressure and heat applied on the U-ring (7)
by the hydraulic oil to improve durability.
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Attachments
• U-ring and backup ring
The U-ring (7) seals the pressurized oil within the cylinder. The U-ring also has the function of
forming an appropriate oil film on the surface of the piston rod in order to prevent rust of the
piston rod (2). The backup ring (8) has the function of suppressing extrusion of the U-ring into
the gap between the piston rod and the cylinder head (3) when the pressure operates and of
improving durability.
• Wiper ring
The wiper ring (9) is positioned in the opening where the piston rod (2) comes out from and
goes into the cylinder and prevents dust and water from getting into the cylinder from the out-
side. It also has the function of wiping off any mud sticking to the surface of the piston rod as
the piston rod moves.
2) Piston assembly
The piston assembly has the function of transmitting the propulsion of the cylinder. A seal ring
(16) is mounted on the center of the piston (15) to prevent the flow of pressurized oil from either
the left or right chamber to the other chamber. There are slide rings (18) and (19) mounted at
each end of the seal ring. They have the function of a bearing to receive the cylinder lateral
load.
1 Cylinder tube 19 Slide ring

2 Piston rod 20 Locking screw
13 Cushion ring 21 Steel ball
14 Cushion seal 22 Cushion ring
15 Piston 23 Cushion seal
16 Seal ring 24 Stopper
17 Backup ring 25 Snap ring
18 Slide ring
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For some cylinder sizes, the piston (15) and nut (21) are separate.
1 Cylinder tube 20 Shim

2 Piston rod 21 Nut
13 Cushion ring 22 Locking screw
14 Cushion seal 23 Steel ball
15 Piston 24 Cushion ring
16 Seal ring 25 Cushion seal
17 Backup ring 26 Stopper
18 Slide ring 27 Snap ring
19 Slide ring
Example of parts numbers for separated piston and nut

• Seal ring and backup ring
The seal ring (16) is positioned at the center of the piston (15) and uses the tension force of
the O-ring to seal the ring-shaped gap between the piston and the cylinder tube (1) and form
chambers with a high-pressure side and a low-pressure side with the piston as the boundary.
The backup ring (17) has the function of suppressing extrusion of the seal ring into the gap
between the piston and the cylinder tube when the pressure operates and of improving dura-
bility.
• Slide ring
Slide rings are positioned at both ends of the seal ring (16) and contact the inside surface of
the cylinder tube (1). Together with the bushing (4) positioned on the inside surface of the cyl-
inder head (3), the slide ring divides the lateral load applied to the cylinder and moves linearly
relative to the inside surface of the cylinder tube.
Furthermore, it supports one end of the piston rod (2) and has the functions of minimizing
eccentricity, which has a negative impact on the sealing, and buries and captures any impuri-
ties trapped between the cylinder tube and the slide rings (18) and (19).
• Cushion ring
When the cylinder is fully extended, the cylinder head (3) and the cushion ring (13) fit together.
When it is fully retracted, the cylinder bottom and the cushion ring fit together. In both cases,
this forms a ring-shaped gap and squeezes the oil to reduce the cylinder collision speed at full
extension or full retraction and thus soften the impact.
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Attachments
3) Pipe assembly
The pipe assembly is mounted on the extension side and retraction side ports of the cylinder
tube assembly. It has the function of supplying and discharging high-pressure oil by connecting
with the hydraulic circuits of the machine body.
28 Pipe assembly
29 Pipe assembly
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Attachments
3. Handling precautions
(1) Precautions for installing the cylinder on the machine body
• When installing the cylinder on the machine body or removing it from the machine body, secure
the piston rod at the fully retracted position, check safety, and suspend.
Never suspend the cylinder from the line section. This would not only pose the danger of falling
but could also damage the cylinder.
Use a band to secure the piston rod in the fully retracted state. If the piston rod is not in the fully
Caution retracted state, it could be easily damaged. This could create the need for repair or make the
piston rod unusable. Also, not securing the piston rod is dangerous because the piston rod
might fly out unexpectedly.
• Do not weld after the cylinder has been mounted on the machine body.
Electric welding on the cylinder or even at a position separated from the cylinder can generate
Caution a spark within the cylinder and damage parts. This could cause extensive damage, making it
necessary to replace parts or replace the cylinder.
• When painting the machine body, mask the piston rod and wiper ring.
If the cylinder is operated with paint sticking to the piston rod surface and the wiper ring, the
wiper ring does not function adequately, greatly interfering with cylinder functions. For example,
Caution dirt and paint from the outside may get into the cylinder easily and damage seal parts and
cause an oil leak.
• Clean the cylinder before installing it.

(2) Usage cautions
• Use under the determined conditions.
Use of hydraulic oil other than that specified can cause rapid deterioration of and damage to
seal parts. If the relief valve is set to a value higher than that on the assembly diagram, there is
a danger of this leading to cylinder damage.
General sealing materials cannot handle high ambient temperature (about 100 ℃ or higher) or
low ambient temperature (-20 ℃ or lower), so the cylinder would be damaged if used at such
Caution temperatures. Such temperatures require special seal materials, so check if the cylinder being
used complies with this requirement.
The number one cause of cylinder trouble is oil leaks due to piston rod scratches. Operate very
carefully to avoid scratching.
If the piston rod is scratched, take the measures according to "Trouble diagnostics".
• Warm up the equipment adequately before work.

After the cylinder has been stopped for a long time, the seal parts inside the cylinder are stuck
to the metal of sliding surfaces, so do not suddenly pressurize or operate such a cylinder.
A new cylinder or one that has been left unused for a long time has much air built up inside, so
it does not operate smoothly. Also, if the cylinder is suddenly operated or pressurized without
Caution bleeding out the air, the adiabatic compression of the air generates high temperatures, which
may burn and carbonize seal parts, leading to a drastically reduced functionality.
Before starting work, always warm up the cylinder by moving slowly through a few full strokes
under no load to bleed off any air in the cylinder.
• For stopping the machine temporarily or storing it, always have the machine in a safely secure
posture.
When extended, the cylinder cannot hold a load for a long time in a fixed position. This is
because the cylinder is extended and retracted by very minor oil leaks from hydraulic circuits
and from inside the cylinder and changes in the volume of the hydraulic oil due to oil tempera-
Caution ture variation. This results in the danger of machine moving unexpectedly, which can lead to
serious accidents.
For stopping the machine temporarily or storing it, always have the machine in a safely secure
position.
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Attachments
(3) Maintenance and inspection cautions
• Always carry out daily maintenance inspections.
The most important point for realizing the cylinder functions for a longer time is "daily mainte-
nance inspections". In order to ensure adequate functioning, execute "4. Maintenance inspec-
tion and service".
Caution Constantly clean off any mud, water, dust, oil or grease stuck to the piston rod and keep the
piston rod in a clean state. However, do not use water or the like to clean the wiper ring section
and seal section. Wipe with a rag. When leaving the machine unused for a week or longer,
apply anti-rust oil to the surface of the piston rod in order to prevent rusting.
• Use genuine KYB parts for replacement parts.

If replacement parts are used that are not genuine KYB parts, adequate functioning cannot be
attained. Always use genuine KYB parts.
Caution Specialty jigs have been produced so that assembly work and disassembly work can be done
safely and quickly, so order them.
• Be careful about assembly and disassembly too.

Disassembling a cylinder still installed on the machine body is extremely dangerous because it
can cause unexpected movement of the machine body. Always remove the cylinder from the
machine body before disassembling it.
Caution Assembling with dirty hands can get dirt inside the cylinder and not only reduce the cylinder
service life but also damage other hydraulic equipment. Assemble under clean conditions.
Use the thread part tightening torque indicated in the diagram. If the torque is either too low or
too high, this can cause thread damage.
• Strictly observe the cylinder storage standards.
Caution Execute according to "7. Assembly and disassembly procedures".
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4. Maintenance inspection and service
In order to ensure a hydraulic cylinder functions properly for a long time, periodically carry out main-
tenance inspection and service based on the "Autonomous inspection table". Repair any trouble
locations quickly based on the trouble diagnostics.
For periodic inspection and service, first work to prevent any hazard to operators. Strive to pre-
Caution vent hazards by working with an attitude based on good sense.
Inspection and
Inspection and service detail Daily Monthly Yearly Remarks
service location
Is the cylinder clean
(especially rod sliding sections)? ○
Appearance Is any oil leaking from line installation sections

or other fixed sections? ○
Is there missing or peeling paint, or rust? ○

Is operation smooth and free of abnormal
noise and any other abnormality? ○
Is the responsiveness good? ○

Is any oil leaking from sliding sections? ○
Operation
Are there internal leaks? ○
Is the operating pressure normal? ○
Is the overload relief valve set pressure nor-
mal? ○
Is hydraulic oil dirty or deteriorated? ○

Hydraulic oil Is hydraulic oil replaced periodically? ○
Are filters inspected periodically? ○
Is the supply of grease to pins adequate? ○
Do pin sections have any abnormal noises or
seizing? ○
Section for instal-
lation with main Do pin sections have any backlash or wear? ○
unit Are pin seals normal? ○
Are any installation screws loose or fallen out? ○
Retighten installation screws. ○
Are sliding sections worn? ○
Are sliding sections scratched or dented? ○ When leaving piston
rod sliding sections
Piston rod sec- Is sliding section plating peeling off? ○ exposed for long peri-
tion
Are sliding sections bent? ○ ods, apply anti-rust oil
to the piston rod.
Are there any welding section cracks or dam-
age? ○
Are there any loose bolts or nuts (threaded

parts)? ○
Cylinder tube Retighten threaded installation parts (bolts

and nuts (threaded parts)). ○
section (including
line sections) Are there any welding section cracks or dam-
age? ○
Are there large dents on the tube? ○
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5. Trouble diagnostics
Hydraulic cylinder trouble, countermeasure and solution
It is not easy to discover trouble locations. The table below shows general symptoms, suggested
causes and also solutions.
For repairs, see the suggested causes and solutions in the table.
The cause of machine problems are often not rooted in just a single part. Problems are often due to
the relationship of one part with another. In some cases, solutions are required other than those
given in the table. In such a case, contact with our company to investigate the problem and its cause
further and take appropriate measures.
Item Symptom
Piston rod sliding section oil leak (For determining the values, see "7. (4)
1
Inspection after assembly".)
2 Cylinder head matching section oil leak
3 Pipe and cylinder tube welding section oil leak
4 Operation defect
Item Symptom Related part Symptom Countermeasure and solution

① Remove the scratches with a whetstone to make the
sliding surface smooth (1.5 s or lower). If the oil leak
A sliding surface has continues, the rod scratches may have damaged the
rust and scratches U-ring or other seal, so disassemble and inspect.
that catch on a fin- ② If the scratches or rust cover too large an area to be
Piston rod gernail. repaired with a whetstone, replace the piston rod and
the U-ring, wiper ring, or other seal and the piston
rod bearing part.
① Replate or replace the piston rod.
Plating is peeling off. ② At this time, inspect the seals and piston rod bearing
part as well and replace any that are damaged.
There is foreign mat-
ter caught in the ① Remove the foreign matter.
inner or outer diam- ② If the packing is damaged, replace it.
eter section.
There are scratches
on the inner or outer Replace the part.
Piston rod diameter section.
sliding
1 ① This may be scorching due to adiabatic compression
section oil The lips and groove
leak of air remaining in the cylinder.
section are locally
carbonized ② When operating the cylinder for the first time after
(scorched). replacing a packing, run at low pressure and low
speed to adequately bleed off the air.
Rod packing
(Buffer ring The packing has lost ① Replace the part.
and U-ring) its rubber elasticity ② This may be the end of the packing service life, dete-
and is in tatters. rioration of the hydraulic oil, or high temperature of
the hydraulic oil.
The lip section is a. Replace the hydraulic oil.
defective all the way b. Check the temperature of the hydraulic oil. (The
around. oil temperature should be no higher than 80 ℃ .)
c. Check for local high temperature.
① Replace the part.
There is major extru- ② Abnormally high pressure may be operating on the
sion of the packing packing.
heel section. a. Check the pressure during operation.
b. There may be trouble with the buffer ring section.
Inspect the buffer ring section.
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Attachments
① As a rule, replace the rod packing too at the same
time.
The part is greatly
Backup ring
deformed. ② Abnormally high pressure is often the cause. The
check items for this are the same as those given
above for packing heel section extrusion.
There is foreign mat-
Remove the foreign matter.
ter caught in the lip.
Wiper ring The lip is damaged.
There is other Replace the part.
abnormal damage.
Piston rod
sliding There is major wear
1 of the bushing and
section oil
leak the gap with the pis-
ton rod exceeds the Replace the part.
Bearing part limit on inner diame-
(bushing) ter wear in "7. (9)
Usage limits".
There are large ① Replace the part.
scratches on a slid- ② Inspect the piston rod sliding surfaces for scratches
ing surface. and rust.
A seal mounting ① Remove the scratches or rust with a whetstone.
Cylinder head section has ② If the repair does not solve the problem, replace the
scratches and rust. cylinder head.
① Remove the foreign matter.
② If the O-ring is damaged, replace it.
③ Tube interior surface inspection: If there are any
There is foreign mat- scratches or rust, use a whetstone to make the sur-
ter caught in the face smooth.
O-ring inner or outer diam-
eter. There is dam- ④ Cylinder head O-ring groove inspection: Same as
age to the O-ring. above
⑤ Backup ring inspection: If the backup ring is
deformed or extruded, replace it.
Check the above and replace the O-ring.
The part is
Backup ring deformed or Replace the backup ring together with the O-ring.
Cylinder extruded.
head
2 matching ① Disassemble the cylinder head and inspect the O-
section oil ring and backup ring. If there is damage, replace.
leak ② Check the tube and cylinder head threads for dam-
Cylinder
A part is loose. age and if there is any damage, replace.
head
③ When the inspection is complete, tighten to the spec-
ified torque. See "7. (7) Assembly procedures.
④ Stop rotation.
There is looseness,
Bolt stretching or break- Replace all the bolts and tighten to the specified torque.
age.
① Replace with a new one.
There is abnormal ② Oil leaks at matching sections may be caused by
Cylinder tube abnormally high pressure (including cushion pres-
swelling.
sure), so if the tube is swollen or deformed, replace it
with a new one. Also inspect the circuit pressure.
Replace with a new one.
Pipe and
cylinder Caution (See page 356.)
tube weld- Pipe and cyl- There are cracks on
3 The crack progresses and ultimately the part fractures.
ing sec- inder tube the welding section.
tion oil A fracture is extremely dangerous, so if a crack is seen,
leak quickly stop work and replace that part.
Welding over a crack is ineffective.
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Attachments
Oil leak Line fastening bolt is Tighten to the specified torque according to the work
from cylin- loose. procedure.
der line Pipe assem- The line is bent. Replace with a new one.
3
connec- bly There are scratches
tion sec- ① Use a whetstone to make the surface smooth.
on a contact sur-
tion face. ② If the oil leak does not stop, replace.
The bending is large and
exceeds the stipulated ① Replace with a new one.
Piston rod bend warp. ② There may also be damage to seals and sliding
Cylinder tube (Bend warp: See "7. (3) parts, so inspect them. If there is any abnormality,
Operation Maintenance stan- replace.
defect dards".)
Move- Replace with a new one. Inspect the seal and sliding
Cylinder tube There are dents.
ment is not parts the same as above.
smooth.
Abnormal wear of sliding ① Replace with a new one.
Piston rod parts and damaged pis- Inspect the seal and sliding parts the same as above.
Cylinder tube ton section or foreign
Sliding part matter caught at the cylin- ② Remove the foreign matter.
der head sliding section Inspect the seal and sliding parts the same as above.
There are scratches,
Internal oil Replace with a new one.
Piston seal wear, or other dam-
leak Also inspect the cylinder tube interior surfaces.
age.
The piston
rod extends ① Use honing or a whetstone to eliminate the scratches and rust and
There are scratches
and retracts Cylinder tube make the surface smooth. If the scratches cover too large an area
and rust on interior
on its own to be repaired, replace the cylinder tube with a new one.
surface.
and drops ② Replace with a new piston seal.
abnormally ① Tighten to the specified torque. See "7. (7) Assembly proce-
during opera- dures".
tion. Tightening is insuffi-
Piston nut
cient. ② The piston rod thread section could be stretched. Measure the
Also, the stip- diameter where the rod and piston fit together and if this area is
ulated speed tapered, replace the piston rod assembly.
is not output.
Valves Leak from valve. Inspect the amount of valve leakage and service.
4 Bleed out the air.
a. Cylinder with no air bleeding
Bleed out the air by moving the cylinder back and forth at
few times at low pressure and low speed.
b. Cylinder with air bleeding (air breather)
Operation
There is air remain- After securing the machine so that the cylinder does not
is Air
ing in the cylinder. move, bleed the air from the air breather.
unsteady.
[Tip]
The cylinder extends or retracts somewhat when the cylin-
der stops suddenly. This phenomenon occurs due to the
compressibility of the hydraulic oil. This occurs particularly
easily for cylinders with long strokes.
The impact is
high when The gap between
switching Pin bushing the installation sec- Measure the pin and pin bushing dimensions and
over between Pin tion and the pin replace any part that exceeds its stipulated dimension.
extension bushing is enlarged.
and retrac-
tion.
Cylinder slid- The oil or grease
Apply oil or grease.
ing opera- Pin bushing feed is inadequate.
tions make Pin There is seizing at
sounds. Replace with a new part and apply oil or grease.
matching section.
Caution
The hydraulic oil expands and contracts with changes in temperature and pressure.
This causes the cylinder to extend and retract too, so it can be mistaken for an internal oil leak.
For internal oil leaks, always check the temperature and pressure under the same conditions.
356 SSM-13-15-004EN
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Attachments
6. Storage standards
When a hydraulic cylinder is shipped from the plant, every measure is taken, but in order to prevent
trouble during storage and to extend the product service life, pay attention to the following items.
1) Storing parts individually (In principle, store indoors.)
• Store parts off the floor and do not store in any location with high temperature and humidity,
corrosive gas or liquids.
• Before shipment, we operates the cylinder with hydraulic oil to which a fixed quantity of vapor-
izing anti-rust agent has been added (in order to prevent rust within the cylinder), carries out
the pre-shipping inspection, then retracts the piston rod with ultra-dry air (condensation point -
35 ℃ or lower) (in order to prevent condensation due to temperature difference), and then puts
caps on the ports and line joints before shipping the cylinder.
• Any product that has been storage in our product warehouse longer than the standard storage
period is disassembled and inspected before being shipped. Therefore, do not store or leave a
cylinder unused with a cap removed or with the remaining oil in the cylinder drained.
Storage for 6 months or longer
Storage for 1 month or longer Storage for 1 year or longer
(3 months for cylinder alone)
Operate the cylinder back and
Clean any dust from the cylin- Since there is a danger of pack-
forth with clear hydraulic oil, and
der, and then apply anti-rust ing deterioration, disassemble,
then pour anti-rust oil into the cyl-
① oil to the pin bushings, flange
inder and store in compliance
inspect, and replace packings.
sections, piston rod, and other Also, check for rust inside the cyl-
with the items on the left for stor-
sections that rust easily. inder.
age of 1 month.
If a cylinder that has been stored
If the cylinder cannot be oper- for a long time is used as is, oil
② -
ated, seal in anti-rust oil. may leak due to temporary run-
ning-in defects of seals.
When storing, be extremely careful not to let parts drop, let them collide with anything, or let anything
③ strike them.
2) Mounted on vehicle body

① Operate the cylinder at least once per month
② Retract the cylinder so that as much as possible outside air does not touch the piston rod and apply anti-
rust oil at least once per month to the exposed part of the piston rod.
③ Handle carefully to absolutely avoid scratching the piston rod.
④ When putting the cylinder into an environment where rust occurs particularly easily, for example due to
exposure to sea breezes during export, always apply anti-rust oil to the piston rod and as much as possi-
ble protect with polyethylene sheets or VCI paper (vaporizing anti-rust paper).
⑤ Anti-rust oil and other solvents can have negative impacts on seals, so select anti-rust oil carefully and as
much as possible keep it off dust seals etc. (For details on anti-rust oil to select, see "6.3) Recommended
anti-rust oil".)
3) Recommended anti-rust oil

Vaporizing anti-rust oil
a. Ferro Gard #1009 (from USC Limited)
a. Knuckle Oil #105S (from Parker Industries, Inc.)
For inside cylinder For both a. and b., add 3 - 5 % of the hydraulic oil.
By volume,
Ferro Gard: 5/100
Knuckle Oil: 3/100
For piston rod Anti-rust P-1300 (from the Nippon Oil Corporation)
For machine worked surfaces
other than parts with oil Select from JIS K 2246 (anti-rust oil) NP-1 through NP-6.
sealed in
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Attachments
7. Assembly and disassembly procedures
(1) Preparations.........repare the following before starting disassembly.
[1] Work platform preparation
Prepare a sufficiently spacious, solid and stable work surface so that parts will not fall or
move during work.
[2] Tool and materials preparation
Prepare the tools and materials shown on the following pages.
(2) General work precautions
[1] Thoroughly clean any dirt or mud from the outside walls of the cylinder before starting disas-
sembly.
[2] Each part has been manufactured with a high degree of precision, so be careful not to let
parts bump each other or fall when handling them.
[3] If parts are struck or pried off with excessive force during work because they are tight, this
may cause burrs or damage which causing reduction in performance or oil leaking. Perform
work carefully and thoroughly.
[4] If a cylinder is left disassembled, humidity and dirt can cause rust on parts. If a pause in the
work is unavoidable, be careful to prevent rust and keep off dust.
(3) Maintenance standards
Replace sliding parts and seal parts as follows.
[1] Bushing .........................When 1/4 of the circumference is worn brown over the entire length
[2] Seals and slide rings .....Replace with new parts when the cylinder is disassembled.
[3] Pin bushing....................When there is severe seizing
[4] Piston rod ......................When the piston rod is bent more than 0.5 mm/1 m
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Attachments
(4) Inspection after assembly
Dimension
Check the fully retracted length and stroke as instructed on the diagram.
inspection
Pressure with- Check for looseness, permanent deformation, and external leaks when the test pres-
stand inspection sure instructed on the diagram is applied to each stroke end for at least 3 min.
Check the amount of oil leak at the rod section.
・ Judgment value for rod section oil leak
Move the piston rod back and forth 20 times with the oil at a temperature from 20 ℃
to 40 ℃ , and then judge by the state of the oil ring formed on the rod surface. If the
oil ring is in a broken down A state, this is judged to be trouble.¢5.See "Trouble
diagnostics" for information on how to solve this.
External leak
inspection
Oil leak unit: ml/10 min. (For judgment, see the following page.)
Inner diam- Oil leak Inner diam- Oil leak Inner diam- Oil leak
eter mm amount eter mm amount eter mm amount
32 0.4 160 10.0
Internal leak
inspection 40 0.6 100 4.0 180 12.6
50 1.0 125 5.6 200 15.6
63 1.6 140 6.0 220 20.0
80 2.3 250 22.0
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Attachments
(5) Required tools
1) General tools
No. Tool name Q'ty
1 Screwdriver (flathead screwdriver) 1
2 Hexagon wrench 1 set
3 Vise 1
4 Wrench (for piston nuts) 1 set
5 Punch 1
6 Torque wrench 1 set
7 Hammer (plastic hammer) 1
8 Monkey wrench 1
9 Scoop 1 set
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Attachments
2) Special jig
Cylinder assembly requires the following special jigs.
Jig name Sketch
For bushing removal and

press fitting
For wiper ring press fitting
Seal ring insertion jig
Seal ring calibration jig
For cylinder head insertion
For piston insertion
Consult with our company about jigs.

(The following page has a list of jig part numbers.)
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Attachments
3) Special jigs part number list
[1] Select jigs for the cylinder head according to the rod diameter.
[2] Select jigs for the piston according to the cylinder bore.
Applicable rod diameter Set part No.

65 3006J-56001
70 3007J-06001
75 3007J-56001
80 3,008J-06001
85 3008J-56001
Cylinder head
assembly and disas- 90 3,009J-06001
sembly jig
95 3009J-56001
100 3,010J-06001
105 3010J-56001
110 3,011J-06001
115 3011J-56001
120 3012J-06001
Applicable cylinder bore Set part No.
95 3009J-51001
100 3010J-01001
105 3010J-51001
110 3011J-01001
115 3011J-51001
120 3012J-01001
Seal ring insertion
125 3012J-51001
and calibration jig
130 3013J-01001
135 3013J-51001
140 3014J-01001
145 3014J-51001
150 3015J-01001
160 3016J-01001
170 3017J-01001
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Attachments
(6) Disassembly procedures
1) Drain the oil.
2) Secure the cylinder.
Secure the cylinder in a vertical or horizontal
position. A vertical position makes assembly
and disassembly easier. Secure the cylinder
using the bottom pin hole and stop rotation
and secure the direction of the axis.
(When securing the cylinder, if a line or the
like interferes, remove it.)
3) Removal of cylinder head
Use a hexagon wrench to loosen the cylinder
head tightening bolts and remove them.
Passing a pipe through the hexagon wrench
as in the diagram below makes the work eas-
ier.
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Attachments
4) Pull out the piston rod.
[1] Check that the line caps are removed.
[2] Put the oil pan at the retraction side (cylinder head side) port.
[3] With the piston rod pulled out all the way, slowly pull out the cylinder head and remove it.
[4] Pull out the piston rod together with the cylinder head and place them on crossties.
・ When assembling and disassembling with the cylinder

secured vertically, work paying particular attention to the fol-
lowing points.
In the work of removing the piston rod, the cylinder head may
come out of the cylinder tube ahead of the piston due to fric-
Caution tion with the packing, creating a condition in which there is
space between the cylinder head and the piston.
If the work is done in that state, the cylinder head may sud-
denly slip out and injure the operator. Always work with the
cylinder head touching the piston.
Working in the vertical state
・ When assembling and disassembling with

the cylinder secured horizontally, work pay-
ing particular attention to the following
points.
In the work of removing the piston rod,
Caution there is a danger of the piston rod falling
and damaging parts right after it is
removed.
Work carefully while holding the rod hori-
zontal and in contact with the crossties.
5) Secure the piston rod.

Use the rod head bolt width or pin hole to set
up a rotation stopper.
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Attachments
6) Remove the piston nut.
[1] Remove the locking screw (3).
Locking screw is caulked in with a punch at
2 locations on the outer circumference.
Cut away the caulked sections with a hand
drill (1), and then loosen the locking screw.
[2] Remove the steel ball (2) at the bottom of
the locking screw (3).
[3] Remove the piston nut.

• The piston nut is tightened with the torque
specified in the assembly diagram.
• Loosening a piston nut requires about 1.5
times that torque. Prepare the power
wrench (6) that uses the hydraulic jack (4)
and hydraulic cylinder (5).
* For a one-piece type piston and nut,
apply the wrench to the hexagonal sec-
tion of the piston and loosen the piston
directly.
7) Removal of piston etc.

Remove the piston (9), cushion ring (8), and cylinder head (7) in that order.
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Attachments
8) Retraction side cushion ring disassembly
[1] Remove the piston nut. Disassembly cannot be done with the nut attached.
[2] Remove the snap ring (12). Remove by gently tapping with a plastic hammer in such a way
as to not scratch the piston rod (11) or cushion ring (14).
[3] When the cushion ring (14) is slid to the piston rod thread (11) side, the stopper (split in two)
(15) can be removed.
[4] Remove the cushion ring (14).
[5] The cushion seal (13) has a split opening, so spread the opening wide and remove the cush-
ion seal.
9) Remove the piston seal.

[1] The slide rings (22) and backup ring (20)
can be removed easily by hand.
[2] Stand up a flathead screwdriver (23) as in
the diagram on the right and tap with a
hammer to cut through the seal ring (16),
and then remove the seal ring.
[3] Pull out the O-ring (19) with a scoop.
* The removed seal parts cannot be
reused.
10 Screw
17 Piston
18 Vise
21 Hardwood
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Attachments
10)Disassembly of buffer ring
[1] The buffer ring (27) is mounted in the
groove on the inner diameter of the cylinder
head. When removing this seal, stick in a
sharp tool and lift it up, and then insert a
scoop and take it out.
* The removed seal parts cannot be
reused.
11)Disassembly of U-ring and wiper ring

[1] Use a screwdriver to remove the U-ring (26) and backup ring (25).
[2] The wiper ring (24) is press fit.
Stick a screwdriver straight down into the rubber and tap it to remove the wiper ring.
* The removed seal parts cannot be reused.
12)Removal of O-ring and backup ring
[1] Pull out the O-ring (29) and backup ring
(30) with a scoop.
13)Disassembly of bushing
[1] Raise the snap ring (28) with a screwdriver,
and then remove it from the cylinder head.
[2] For the bushing (33), use the bushing
removal jig (32) as in the diagram on the
right and press out the bushing with a
press.
31 Bushing
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Attachments
14)Removal of pin bushing
[1] Remove the wiper ring (24) from the tube
and piston rod. Remove it by using a
screwdriver in the same manner as for the
cylinder head.
[2] Use the metal block (35) to remove the pin
bushing (37).
34 Press
36 Jig
15)Cleaning and storage

Clean the removed parts with white kerosene, and then apply hydraulic oil, cover the parts, and
store them.
If they are left disassembled, there is a danger of their collecting rust and dust and not being
able to function adequately after they are assembled again.
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Attachments
If a part with peeling paint is assembled, the peeled off paint can get inside the cylinder.
Caution This causes oil leaks, so work being very careful to prevent this.
1) Installation of pin bushing

[1] Use the installation jig to press fit onto the piston rod (4) and into the tube.
(Apply hydraulic oil in advance.)
[2] Use the metal block (5) to install the wiper ring (6).
2) Replacement of seal
[1] When reassembling the cylinder, replace
all the seals.
[2] O-rings
• Clean the mounting groove well, and then
mount the backup ring (7) and O-ring (8).
Foreign matter in the grove section would
cause an oil leak.
• Be careful about the location of the backup
ring.
• Apply grease or hydraulic oil to the backup
ring and O-ring so that they slide easily,
and then assemble them. If they are sliding 1 Press
poorly, O-ring may become twisted during 2 Installation jig
assembly, which causes oil leaks. 3 Pin bushing
9 Cylinder head
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Attachments
3) Assembly of cylinder head assembly
[1] Use the bushing press fit jig (10) to press fit the bushing (11).
Apply hydraulic oil to the inside surface of the cylinder head in advance and after press fit-
ting, check that there is no level difference at the bushing.
[2] Use the wiper ring press fit jig (15) to press fit the wiper ring (16).
[3] Mount the backup ring (18) and U-ring (19) in the U-ring groove (17) in that order.
• Check the assembly direction of the U-ring and mount it carefully so as not to scratch it.
Installing backwards can cause an oil leak.
• After mounting, check that there are no wrinkles or other permanent deformation remaining
in the U-ring.
[4] Mount the buffer ring (20).

Be careful with the attachment directions of the seals.
If the seal is attached backwards, extraordinarily high pressure will be generated between
the seal and the U-ring (19), causing deformation and breakage of the cylinder.
[5] Assemble the bushing retainer snap ring (21).
12 Cylinder head
13 Pressing base
14 Press
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Attachments
4) Assembly of piston assembly
[1] Attach the seal ring (24).
• Attach the back-up ring (23) for one side
and the O-ring (25) on the piston (26) in
advance, place on the press platform, and
use the seal ring insertion jig (22) as in the
diagram to assemble the seal ring.
[2] Correct the seal ring.
• Mount the seal ring (24) and the other
backup ring (23), and then immediately
correct with the seal ring calibration jig (27)
so that the seal ring does not remain
expanded. (Strictly observe this instruc-
tion.)
Since the seal ring is stretched when it is
mounted, if it is not calibrated, "6) Insertion
of piston rod into the tube" is not possible.
[3] Assemble the slide ring.
• Spread the cut section of the slide ring the
minimum with both hands and install from
the axial direction.
If it is spread too wide, it cannot be
mounted.
* Consult with our company about jigs.
5) Assembly of piston rod assembly
[1] Secure the piston rod (31).
[2] Assemble the cylinder head (32) on the pis-
ton rod (31).
Be careful that the wiper ring and U-ring
lips do not catch on the stepped section.
Use the cylinder head insertion jig (30) as
in the diagram on the right to assemble the
cylinder head on the piston rod.
• Apply grease or oil and assemble being
careful not to scratch the packing.
28 Metal block
29 Press
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Attachments
[3] If there is a cushion on the extension side,
assemble the cushion ring (33) and cush-
ion seal (34) with the following procedure.
1) Insert into the groove with the side of the
cushion seal with the slit (*2) facing the
piston side.
2) Assemble with the part of the cushion
ring processed to be flat facing as in the
diagram.
[4] When there is a cushion on the retraction

side
Assemble the cushion ring (39) and cush-
ion seal (38) with the following procedure.
1) Assemble the cushion ring before assem-
bling the piston nut.
The cushion ring cannot be assembled
with the piston nut attached.
2) Mount in the groove with the side of the
cushion seal with the slit (*4) facing the
thread side.
3) Assemble with the part of the cushion
ring processed to be flat facing as in the
diagram below.
4) Insert the stopper (40) into the groove.
Press the cushion ring (39) all the way to *1 Flat surface processing
the stopper and strike in the snap ring *3 Face the slit to the thread side.
(37). Strike gently with a plastic hammer 35 Piston
in such a way as to not scratch the piston 36 Screw
rod (4) or cushion ring.
Make sure that the cushion seal and cushion ring face the correct direction.
If they are installed backwards, the cushion will not be effective.
Caution After installing the cushions, check that the extension and retraction cushion rings move up and
down and left and right.
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Attachments
[5] Tighten the piston nut.
• Always tighten the piston nut to the specified torque given on the assembly diagram.
• If the tightening torque is insufficient, this causes internal leaks, nut looseness, and thread
cutting
• Also, if the tightening torque is excessive, extension side cushion ring swelling and piston
contact surface deformation occur.
• In order to tighten correctly, clean and degrease the piston and nut and piston rod thread
section adequately (with paint thinner) before tightening the nut.
[6] Stop the piston from turning.
• After tightening the piston nut, put in the
steel ball (43), tighten the locking screw
(42) to the specified torque given on the
assembly diagram, and then caulk (41) with
the punch (44) at 2 locations on the outer
circumference.
6) Insertion of piston rod into the tube

[1] Secure the tube (47) vertically or horizon-
tally.
[2] Insert the piston rod (4) into the tube (47).
• If the tube is secured vertically, the piston
rod enters the tube due to its own weight.
• When the piston section is entering the
tube, be careful that the slide rings (46) do
not fall out.
45 Jig (nylon pipe (split in two))

Slide ring (Shift the abutment phase
46
180°rom one ring to the next.)
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Attachments
7) Cylinder head tightening
Align the cylinder head with the position on the assembly diagram, and then tighten the bolts to
the specified torque given on the assembly diagram in the order shown in the diagram below.
Bolt tightening order
8) Installation of line
[1] Check that the O-ring is in the groove correctly.
[2] Tighten the port section bolts to the specified torque given on the assembly diagram.
[3] Tighten the line bands to the torque on the assembly diagram, the same on both sides, so
that no abutment gap occurs.
*5 Tighten the bolts. *8 Normal: OK

*6 Be careful about the O-rings. *9 There is a gap: Not OK
*7 No abutment opening gap *10 Band for securing the line
When installing the cylinder lines and the machine body rubber hoses, nipples, etc., assemble
Caution securing the cylinder line port section with a wrench. If one tightens without securing the port
section, the line may bend, oil may leak, and the machine body may get in the way.
(8) Test operation

[1] In order to fill the inside of the cylinder with oil, after it is installed on the machine body, move
the cylinder through its full stroke slowly 8 times or more. If the cylinder is suddenly moved
from the start, the hydraulic oil may be aerated.
[2] If the cylinder has air bleeding, pressurize so that the air bleed side is the pressure side
(return oil side) and bleed off the air.
[3] Apply oil and grease to the pins at both ends.
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Attachments
(9) Usage limits
Below are the usage limits for the main sliding sections. Use them for reference for maintenance.
• Piston rod outer diameter wear limit
Nominal diameter Minimum outer diameter
Solution
(mm) (mm)
65 - 80 -0.023 Replace or replate.
85 - 120 -0.027 Replace or replate.
• Rod bushing inner diameter wear limit

Nominal diameter Standard inner diameter Maximum inner diameter
Solution
(mm) (mm) (mm)
55 - 75 +0.060 - +0.190 +0.30 Replace the bushing.
80 - 120 +0.060 - +0.195 +0.30 Replace the bushing.
• Piston slide ring thickness wear limit

Nominal diameter
Standard thickness (mm) Minimum thickness (mm) Solution
(mm)
95 - 160 t 2.42 - 2.48 t 2.37 Replace the slide ring.
165 - 250 t 2.92 - 2.98 t 2.87 Replace the slide ring.
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Lights SH330-5
Lights
Removal and Installation of Boom Light
Items to prepare
• Wrench (19 mm)
• Rag
• Cleaning fluid

spring washer (3), and washer (4), and then
remove the boom light (5).
376 SSM-13-16-004EN
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Lights
Removal and Installation of Tool Box Light
Items to prepare
• Wrench (13 mm)
• Rag
• Cleaning fluid
[1] Open the tool box (1).

and then remove the tool box light (4).
SSM-13-16-004EN
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Procedures for Removal and Installation of Cab Inner and Outer Parts SH330-5
Removal and Installation of Cab Assembly
Items to prepare
• Box wrenches (10 mm, 13 mm, 19 mm)
• Eyebolt (M24) × 4
• Chains (wire ropes) (with the required breaking load)
• Lubricating oil
• Rag
• Cleaning fluid
1. Removal of cab assembly
[1] Remove the operator's seat.
Operator's Seat".)
bolts (1) and a box wrench (13 mm) to remove
the 2 bolts (2), and then remove the rear cover
(3).

bolts (4), and then remove the air conditioner
ducts on both sides (5).
378 SSM-13-17-004EN
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[4] Remove the air conditioner ducts (6) and (7) by
pulling them forward.

(8), and then remove the brackets (9).
[6] Remove the air conditioner duct (10).
[7] Remove the radio antenna (11).
SSM-13-17-004EN 379
2
for the ground wire (13) connecting the cab and
frame.
[9] Remove the connectors (14) and (15).
[10] Remove the washer fluid hose (16).

(17) each, and then remove the rear brackets
(right and left) (18) and (19).
380 SSM-13-17-004EN
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[12] Remove the 3 butterfly screws (20), and then
remove the cover (21).
[13] Remove the 2 butterfly screws (22), and then

open the cover (23) of the outside air filter.
[14] Remove the outside air filter (24).

Slide the suction duct connected with the air
conditioner unit in the cab from the duct flange
and remove it.
SSM-13-17-004EN 381
4
[15] Remove the 4 caps (25) from the top of the cab.
[16] Install the 4 eyebolts (M24) (26) in place of the

removed caps.
by a half turn.
[17] Use chains (27) and liftcrane to secure the cab.
382 SSM-13-17-004EN
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[18] Use a Phillips screwdriver to remove the 3
screws (28), and then remove the cover (29).

(30) from the cab.
SSM-13-17-004EN 383
6
[20] Use chains (32) and liftcrane to remove the cab
(31).

before lowering the cab on wood planks (33).
• Thoroughly secure the cab with the chains and
liftcrane so that it does not fall down.
2. Installation of cab assembly

The tightening torque for the cab assembly installation bolts is 157 N•m.
384 SSM-13-17-004EN
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Removal and Installation of Operator's Seat
Items to prepare
• Wrench (13 mm)
1. Removal of operator's seat
[1] Pull the slide lever (1) to slide the seat (2) to the
rear.
from the front of the seat.
[3] Pull the slide lever (1) to slide the seat forward,
and then pull the reclining lever (4) to fold the
seatback forward.

from the rear of the seat.
SSM-13-17-004EN 385
8
[5] Remove the operator's seat (6).
2. Installation of operator's seat

The tightening torque for the seat installation bolts is 19.6 N•m.
386 SSM-13-17-004EN
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Removal and Installation of Wiper
Items to prepare
• Wrench (17 mm)
1. Removal of wiper
and then remove the wiper arm (2).
[2] Use the Phillips screwdriver to remove the

screw (3), and then remove the wiper (4).
2. Installation of wiper
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10
Removal and Installation of Wiper Controller
Items to prepare
• Wrench (10 mm)
• Flathead screwdriver
1. Removal of wiper controller
installation screws (2) for the side upper trim (1).
[2] Lift the side upper trim (1), remove the connec-
tors (3), and then remove the side upper trim.
Some models have no connector.
[3] Use a box wrench (13 mm) to remove the 2 turn

clips (4) and the 4 bolts (5), and then remove
the side rear cover (6).
388 SSM-13-17-004EN
11
mm) to remove the 4 bolts (7), and then remove
the side rear B trim (8).

(9), and then remove the side lower trim (10).

mm) to remove the 4 bolts (11), and then
remove the side rear A trim (12).
SSM-13-17-004EN 389
12
[7] Remove the connector (14) from the wiper con-
troller (13).
[8] Use a flathead screwdriver to slightly bend the 4

installation clips (15), and then remove the
wiper controller (13).
2. Installation of wiper controller

390 SSM-13-17-004EN
13
Removal and Installation of Wiper Motor
Items to prepare
• Flathead screwdriver (longnose pliers)
1. Removal of wiper motor
(1), and then remove the side lower trim (2).
[2] Use a flathead screwdriver or longnose pliers to

remove the clip pins (3), and then remove ducts
B (4).
[3] Use a Phillips screwdriver or box wrench (10

mm) to remove the 3 bolts (5). Use a hexagon
wrench (4 mm) to remove the 3 bolts (6).
Remove the front upper trim assembly (7).
SSM-13-17-004EN 391
14
[4] Lift the front upper trim assembly (7), and then
remove the connector (8).

392 SSM-13-17-004EN
15
and then remove the wiper arm (13).
[8] Use a wrench (17 mm) to remove the 1 nut (14).

bolts (15) and 2 nuts (16), and then remove the
wiper motor assembly (17).
2. Installation of wiper motor

• Be careful about the wiper link and wiper arm installation location.
• Check the wiper arm wipe location and stop location.
SSM-13-17-004EN 393
16
Removal and Installation of Monitor
Items to prepare
• Wrench (10 mm)
on the monitor (2).
[2] Lift the monitor main unit (2), and then remove
the connector (3) underneath.
394 SSM-13-17-004EN
17
Removal and Installation of Cab Front Glass
Reinforced glass is used for the front window.
Caution Be extremely careful not to damage it when touching it during removal or installation.
Items to prepare
• Wrench (10 mm)
• Rag
• Cleaning fluid
each, and then remove the brackets (2) and (3).
[2] Remove the covers (4) and (5) for the bracket.

(6), and then remove the front glass left lower
bracket (7).
SSM-13-17-004EN 395
18
(8), and then remove the front glass right lower
bracket (9).
[5] Move the front glass right upper bracket (11) to

a position where the wire (10) is not pulled on.
[6] Remove the cab front glass (12).
396 SSM-13-17-004EN
19
Window Lock Adjustment Procedures
Items to prepare
• Wrench (10 mm)
• Rag
• Cleaning fluid

(2).
[3] Set the cab front glass (3) in place.
SSM-13-17-004EN 397
20
[4] Use a wrench (10 mm) to retighten the 3 bolts
(2).
398 SSM-13-17-004EN
21
Hydraulic Equipment-related Parts SH330-5

Accumulator
Warning ・ Be sure to release the hydraulic pressure in the circuits.
Items to prepare
• Wrench (30 mm)
• Rag
• Cleaning fluid
[1] Use a wrench (30 mm) to remove the accumula-

tor (1).
399 SSM-13-18-004EN
1
Suction Filter
・ Be careful to keep dirt, water, sand, and all other foreign matter out of the tank.
Caution ・ When replacing the hydraulic oil, always replace with new oil.
Items to prepare
• Wrench (17 mm)
• Rag
• Cleaning fluid

the tank.

(2), and then remove the feed port cover (3).
[3] Drain the oil from the hydraulic oil tank. (For
details, see "Draining Oil from Hydraulic Oil
Tank".)
[4] Remove the O-ring (4).
SSM-13-18-004EN 400
2
[5] Remove the suction filter (5).
[6] Clean the suction filter (5) with pure cleaning

fluid, dry it well, and then inspect it. If there is
any damage on the surface, replace the suction
filter with a new one.
• If the O-ring on the rear of the cover is worn or
damaged, replace it.
• The installation procedure is the reverse of the
removal procedure.
• Always replace the suction filter with a new one
every 5000 hr. and when replacing the hydraulic
oil.
5 Suction filter
401 SSM-13-18-004EN
3
Return Filter
・ Be careful to keep dirt, water, sand, and all other foreign matter out of the tank.
Caution ・ When replacing the hydraulic oil, always replace with new oil.
Items to prepare
• Wrench (17 mm)
• Rag
• Cleaning fluid

the tank.

• There is a spring inside the cover, so restrain
the spring by hand and remove the cover.
SSM-13-18-004EN 402
4
[3] Remove the O-ring (4).
Take the spring (5) and valve (6) out from the
tank.
[4] Take the return filter (7) out from the tank and
replace it.
• If the O-ring on the rear of the cover is worn or
damaged, replace it.
• The installation procedure is the reverse of the
removal procedure.
403 SSM-13-18-004EN
5
Pilot Filter
Warning ・ Be sure to release the hydraulic pressure in the circuits.
Items to prepare
• Wrench (19 mm)
• Rag
• Cleaning fluid
[1] Use a wrench (19 mm) to remove the pilot filter

(1).
SSM-13-18-004EN 404
6
Other SH330-5
Other
Removal and Installation of Side Door
Items to prepare
• Wrench (19 mm)
(1), and then remove the side door (left front)
(2).

(1), and then remove the side door (left rear)
(3).

(1), and then remove the side door (right) (4).
405 SSM-13-19-004EN
1
Other
Draining Oil from Hydraulic Oil Tank
Warning ・ The temperature of the hydraulic oil is high immediately after stopping the engine. Wait until
the hydraulic oil temperature has decreased (to 40 ℃ or less) before beginning work.
Items to prepare
• Feed pump (power source for feed pump)
• Extension cable
• Waste oil tank
• Waste oil can
• Rag
• Cleaning fluid
hydraulic oil tank to bleed off the pressure in the
tank.

(2), and then remove the feed port cover (3).
SSM-13-19-004EN 406
2
Other
[3] Insert the feed pump (4) into the feed port.
[4] Transfer the oil inside the hydraulic oil tank to

the waste oil tank (5).

407 SSM-13-19-004EN
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Other
[6] Prepare a waste oil can (8) under the hydraulic
oil tank.
[7] Use a wrench (36 mm) to remove the drain plug

(9).
[8] Drain any remaining oil that has settled at the

bottom of the hydraulic oil tank.
SSM-13-19-004EN 408
4

350X2 Manual de Servicio

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Contents SH330

Work Range Diagram

Equipment Layout Diagram

Standard Machine Option List

Pilot Hose Connection Diagram

Explanation of Hydraulic Circuit and Operations (standard model)

Main Equipment Structure and Operation Explanation

Electrical Equipment Layout Diagram

Main Equipment Structural Diagrams

Electrical Circuit Diagram

Electrical Connector Wiring Diagram

Electrical Parts and Wiring Assembly Diagram

Explanation of Functions and Operations

Explanation of Engine Terms

Explanation of Engine Structure

Engine Maintenance Standards

Exhaust Gas Regulations

Cautions for Fuel Used

Self-diagnosis Function with Panel Display

Measurement Method and Main Unit Posture

Hydraulic Pump Flow Measurement Procedures

Drain Volume Measurement Procedures

Air Bleed Procedure

Procedures for Replacing Consumable Parts

Periodic Maintenance Procedures

Attachment Installation Dimensions

Unit Conversion Ratio

3. Main Unit Dimensions

2. Hydraulic Oil Filters

Take measures to ensure safe operation

Use wire ropes with safety factor 6 or greater.

We: Frontal rating load

Ws: Lateral rating load

Rating load at height point H and

(Maximum working reach: 33.929 ft) (Units; Ib)

We: Frontal rating load

Ws: Lateral rating load

Rating load at height point H and

(Maximum working reach: 32.286 ft) (Units; Ib)

We: Frontal rating load

Ws: Lateral rating load

Rating load at height point H and

(Maximum working reach:36.314 ft) (Units; Ib)

2. Short Arm 2.88 yd (2.63 m)

Work Range Diagram

Main Equipment Table

3. Air Cleaner (double element)

2. Solenoid Valve (5 stack)

(2) Valve for travel operation

(2) Travel remote control valve control diagram

6. Selector Valve (option)

Arm cylinder 350X2

Bucket cylinder 350X2

◎ General digging (specific gravity 2.0 ton/m3 max.)

○ Light digging (specific gravity 1.6 ton/m3 max.)

△ For loading only (specific gravity 1.2 ton/m3 max.)

(2) HD bucket type

◎ General digging (specific gravity 2.0 ton/m3 max.)

○ Light digging (specific gravity 1.6 ton/m3 max.)