Manual de Serviço SY215-C8

V\ERRN3DJH)ULGD\2FWREHU30
INTRODUCTION
To readers
This manual is edited for the persons who have special techniques and certifications, the purpose of
which is to provide technical information during maintenance and repair of the machine.
x Be sure to read the manual carefully for a clear understanding of product information and service
procedures.
x If you have any comments and suggestions or find out there are mistakes in this manual, please
contact us with the "Service Manual Questionnaire Form" attached at the end of the manual.
(Note: it is not necessary to tear it down, copy is allowed):
Sany Heavy Industry Co., Ltd.
Customer Service Dept.
TEL: 86-0512-57831110
FAX: 86-0512-57831999-6059
Supplementary reference data

Besides this manual, please refer to the following data.
x Operation Manual
x Illustration Parts Manual
x Sany Heavy Industry training materials
Manual structure
This manual consists of three parts: Technical Manual (Operation Principle), Technical Manual
(Trouble Diagnosis) and Handling Manual.
x Technical Manual (Operation Principle) contains:
Required technical data for first and second delivery, the operation and functions for all types of
devices and systems.
x Technical Manual (Trouble Diagnosis) contains:
Required technical data for operation performance tests and trouble diagnosis procedures.
x Handling Manual contains:
Required technical data for maintenance and repair of the machine; tools and devices required
during maintenance and repair; maintenance standards; the procedures for removal/installation
and assembly/disassembly.
Page number
Each page is compiled with a number at the lower part, please read the manual carefully after reading
the contents.
INTRODUCTION - 1 -
Safety warning marks and headline symbols

The following safety warning marks and symbol words in the manual are used to warn the readers that
possible damage may occur to person or machine.
Symbol Item Remark
This is the safety warning mark. This mark indicates the
possibility that the injury will be caused to you.
x Be sure to comply with the safety instructions following the
safety warning mark.
WARNING
x The safety warning mark is also used for calling attention to
the weight of the parts.
x To avoid injury and damage, make sure that proper lifting
techniques and equipments are used when lifting heavy parts.
Indicates a potential hazard which, if not avoided, will result in

CAUTION
injury or even death.
Indicates a hazard which, if not avoided, will result in damage to

IMPORTANCE
the machine.
NOTE Indicates the supplementary technical information.
Measurement unit being used

The international metric unit is used in this manual.
MKSA unit and inch unit are provided in the brackets following the metric unit.
For example: 24.5 MPa (250 kgf/cm2, 3560 psi)
The following table, given for reference, can be used to convert the metric system into other systems.
Convert the Convert the
Units in Need to Units in Need to
Parameter Into Parameter Into
This Multiply This Multiply
Column Column
mm in 0.03937 MPa kgf/cm2 10.197
Length Pressure
mm ft 0.003281 MPa psi 145.0
L US gal 0.2642 kW PS 1.360
Power
Cub (Vol.) L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature qC qF qC × 1.8 + 32
Weight kg lb 2.205 km/h mph 0.6214
Speed
N kgf 0.10197 min-1 rpm 1.0
Force
N lbf 0.2248 Flow L/min US gpm 0.2642
Ngm kgfgm 0.10197 mL/rev cc/rev 1.0
Torque
Ngm lbfgft 0.7375
INTRODUCTION - 2 -
CONTENTS
CONTENTS
CHAPTER 1 GENERAL DESCRIPTION .......................................1
1-1. Precautions for disassembly and assembly..................................... 1
CHAPTER 2 SAFETY ..................................................................17
1
2-1. Safety information.......................................................................... 17
2-2. Operating excavator safely ............................................................ 34
2-3. Safety maintenance instructions.................................................... 48
2-4. Warning signs and illustrations ...................................................... 54
2
CHAPTER 3 UPPER SWING PLATFORM ..................................63
3-1. Driving cab..................................................................................... 63
3-2. Air conditioning system.................................................................. 78
3-3. Removal and installation of balance weight................................... 95
3
3-4. Removal and installation of main frame......................................... 97
3-5. Removal and installation of the pump unit................................... 102
3-6. Removal and installation of main valve ....................................... 129
3-7. Swing unit .................................................................................... 159
4
3-8. Left and right pilot valve............................................................... 200
3-9. Tracking pilot valve ...................................................................... 213
3-10.Removal and installation of solenoid valve................................. 231
CHAPTER 4 UNDER TRACKING CARRIAGE ..........................237 5
4-1. Removal and installation of swing supporting bearing................. 237
4-2. Tracking unit ................................................................................ 244
4-3. Central connector ........................................................................ 279
4-4. Track tensioning mechanism ....................................................... 286 6
4-5. Removal and installation of tensioner pulley ............................... 290
4-6. Sprocket wheel and track roller ................................................... 296
4-7. Track............................................................................................ 304
CHAPTER 5 WORK DEVICES ..................................................313 7
5-1. Removal and installation of work devices.................................... 313
5-2. Removal and installation of cylinder ............................................ 322
INDEX
CHAPTER 6 ENGINE ................................................................343

6-1. Outline ......................................................................................... 343
CONTENTS - 1 -
6-2. Engine ......................................................................................... 360

6-3. Lubrication system....................................................................... 425
6-4. Fuel feed and engine control ....................................................... 448
6-5. Cooling system ............................................................................ 476
6-6. Air intake and exhaust system..................................................... 494
CHAPTER 7 ELECTRICAL SYSTEM........................................ 509
7-1. Engine electrical .......................................................................... 509
7-2. Display......................................................................................... 545
7-3. Controller ..................................................................................... 552
7-4. Radio ........................................................................................... 560
7-5. Battery ......................................................................................... 562
7-6. Key switch ................................................................................... 564
7-7. Fuse box...................................................................................... 567
7-8. Wiper ........................................................................................... 569
7-9. Relay ........................................................................................... 573
7-10.Sensor ........................................................................................ 577
7-11.Installation and removal method of connector terminals ............ 579
CONTENTS - 2 -
GENERAL DESCRIPTION-Precautions for disassembly and assembly
CHAPTER 1 GENERAL DESCRIPTION
CONTENTS
1-1. Precautions for disassembly and assembly
1-1-1. Precautions for disassembly and assembly
1. Cleaning the machine
Clean the machine thoroughly before taking it to the repair factory. If a dirty machine is brought
1
to the workshop, the machine components will be polluted while disassembling/assembling,
leading to the damage of the components and also the low efficiency of care and maintenance.
2. Checking the machine
Understand the disassembly/assembly procedures thoroughly in advance to avoid
disassembling the components incorrectly or resulting in personal injury.
Check and record the following items to avoid the problems appearing in the future. 2
x Machine model, machine serial number and hour meter reading.
x The reasons for disassembly (Symptom, malfunctioning parts and reason).
x Conditions for filter clogged and oil, water or air leakage.
x The amount and condition of lubricant.
x The loose or damaged parts.
3. Preparing cleaning tools and disassembly site 3
Prepare the required tools and disassembly site.
4. Precautions for disassembly
x Set covers or plugs to the removed tube to prevent dirt from entering.
x Before the component is disassembled, clean its outer and place it on the workbench.
x Gear oil in deceleration device will be drained before disassembly.
x Be sure to prepare an appropriate container to catch the draining fluid. 4
x It will be easier for reassembly to use the align mark.
x Be sure to use the specified and special tool, if it is suggested.
x If some components still cannot be removed after the tightening nuts and bolts are
removed, do not try to do it forcibly. Find out the reason and then take appropriate
measures to remove it.
x The removed parts should be arranged in order if necessary, a sign should be marked or 5
hanged up.
x For the universal parts such as nuts and bolts, it's necessary to keep separately according
to the using locations to avoid missing.
x For the removed parts, check if the contact and sliding surfaces are worn abnormally,
conglutinated or damaged.
x Measure and record the wear level and clearance.
6
5. Precautions for assembly
x Be sure to clean all the parts, and check for damage. If so, repair or replace it with a new
one.
x The life of the machine will be shortened due to dirt or adhesion on the contact surfaces or
sliding surfaces. Be careful not to contaminate the contact surfaces or sliding surfaces of
the parts to be assembled. 7
x Once the O-ring, support collar and oil seal are removed, replace them with new ones.
Apply a coat of lubricant before installing.
x Make sure the waterproof and oil proof gasket are clean and dry.
x For the new parts with anti-rust agent on the surface, be sure to wash thoroughly.
INDEX
x Use the align mark when assembling.

x Be sure to use the specified tools to assemble bearing, bush and oil seal.
1

x For the tools used in disassembly/assembly, record the number. After the disassembly has
been finished, check the number of tools to make sure that none of tools is left in
assembled machine.
1-1-2. Bleeding air in hydraulic system

After draining hydraulic oil, replacing fuel suction filter or suction tube, or removing and installing
pump, swing motor, tracking motor or cylinder, be sure to bleed air in hydraulic system by the following
procedures:
When the engine is running, if air enters the hydraulic pump, it will lead to the pump damaged.
When the hydraulic motor is operating, if air enters the motor, it will lead to the motor damaged.
When the cylinder is operating, if air enters the tube, it will lead to the cylinder damaged.
Be sure to bleed air before starting the engine.
1. Bleeding air from the hydraulic pump

x Remove the air bleeding plug on the top of the pump, and add hydraulic oil to the pump
housing.
x After hydraulic oil is added to the pump housing, tighten the plug temporarily. Then, start
the engine with it idling at low speed.
x Loosen the plug slightly to bleed air from the pump housing until the hydraulic oil flows out.
x After bleeding the air, tighten the plug securely.
2. Bleeding air in the tracking motor/swing motor
x After removing the bleeding plug/hose on the tracking motor/swing motor, fill the hydraulic
oil into the motor case.
3. Bleeding air in the hydraulic oil circuit
x After hydraulic oil is filled, start the engine. Leave the machine operating 10 - 15 minutes
under a light load while operating each cylinder, swing motor and tracking motor uniformly.
Start each operation slowly (The cylinder is never allowed to do a full-stroke movement
during the original operation). Air in the pilot circuit will be bled when above operations
have been performed for 5 minutes as pilot circuit has a air bleeding device.
x Rearrange the work devices to check the

hydraulic oil level.
x Stop the engine. Recheck the hydraulic oil
level. If necessary, add the oil.
2
1-1-3. Precautions for float oil seal
CONTENTS
1. Replace the float oil seal with a new one after
A disassembling in general.
If the float oil seal is reused, perform the following
procedures:
(a) Store the seal ring in the way of surface-
matched combination. Insert a piece of thick
paper to protect its surface. 1
(b) Check the sliding surface of the seal ring (A)
B for scratches, dents, corrosion, deformation
or uneven wear.
(c) Check the O-ring (B) for cracks, breaks,
deformation or hardening.
2
2. If it is installed incorrectly, oil leakage and
parts damage will occur. To prevent accidents,
make sure to do as the following:
(a) Wipe off the float oil seal and the packing
installation hole with cleaner. Remove the
mud, rust or oil with a wire brush. Dry the 3
parts thoroughly with compressed air after
Correct cleaning.
(b) Clear the float oil seal and the packing
installation hole. Touch the hole surface, and
Incorrect check for scratches or dents.
(c) Confirm that the O-ring is not twisted, and 4
install it on the seal ring correctly.
(d) After installing the float oil seal, measure the

Correct C Incorrect distance between points (A) and (C) at
points (a) and (b) to check if the packing 5
a a
surface (A) is parallel to the packing
A
installation surface (C) as shown in the
illustration. If the distances are different,
B adjust the O-ring base.
7
b b
a=b a≠b
INDEX
3
1-1-4. Precautions for using nylon sling
1. Observe the following precautions for using

Correct Noose
Installation nylon sling safely.
x Place a gasket (a soft object) on the top of
the cargo to prevent the nylon sling from
touching the top directly. Using a gasket can
avoid nylon sling damage, as well as cargo
sliding.
x The cargo temperature should be less than
100qC (212qF) when lifting. Reduce the load
when the cargo temperature exceeds 100qC
(212qF).
x It's prohibited to lift up the acid and alkali
chemical medicine.
x Be careful not to soak the nylon sling. Or it
may slip easily.
x Use nylon slings with the same length and
width if the number required is more than
one to ensure the cargo balance.
x The clearance between the sling and cargo

Incorrect Noose is not allowed when hanging and loading
Installation cargo (See illustration on the left). Decrease
the weight of the cargo to less than 80% of
the pulling power of the sling.
x Never use the twisty, knotted, connected or
tangled nylon sling.
x Do not place goods on the nylon sling in

twisting or bending state (See illustration on
the left).
x Be careful not to damage the nylon sling
when pulling it out under the cargo. Avoid
hanging a swollen part.
x Do not drag the sling on the ground, or use it
to pull goods with slugs.
Bending Sling x Be careful not to damage the nylon sling in
connecting area when used together with
other hangers (Wire rope and so on) or
auxiliary tools (Lifting ring and so on).
x The nylon sling should be stored indoor
where cannot be affected by high
temperature, sunshine and chemical
medicine.
4
Condition of Damage
CONTENTS
Sewing Line is Broken
If the cargo is hanged with the broken nylon sling, it

will lead to a serious injury. Be sure to check the nylon
Abrasion sling visually before using.
1
Fluff
2
2. Be sure to check the nylon sling visually for
damage as shown on the left before using. If
so, cut it off and throw it away. Even if no
damage on the surface, do not use the sling for
more than 7 years.
3
Layers are Separated
Cut
Abrasion 4
Fluff Vertical Thread is Broken
1-1-5. Meaning of the care and maintenance standard term

"Standard" means
1. Parts size on new machine.
6
2. New components or sets size adjusted as specification.
"Using limit" means

1. The machine cannot complete general operation after out of the standard.
2. Repairing or adjusting cannot be performed after exceeding the limit.
3. Therefore, the appropriate care and maintenance job should be performed before the 7
machine reaches the "using limit" according to the operation efficiency and maintenance
expense.
INDEX
5
1-1-6. Specifications for tightening torque

Bolt Wrench Torque
Number
Explanation Diameter Size
(×) Ngm (kgfgm) (lbfgft)
(mm/in) (mm/in)
Engine absorber mat
mounting bolt (Main 2 18/0.709 27/1.06 382 38.95 281.92
pump side)
Engine absorber mat
2 18/0.709 27/1.06 382 38.95 281.92
mounting bolt (Fan side)
Hydraulic oil tank set bolt 6 16/0.630 24/0.945 279 28.45 205.90
Fuel tank set bolt 6 16/0.630 24/0.945 279 28.45 205.90
Pump unit set bolt 4 20/0.787 30/1.181 664 67.71 490.04
Control valve set bolt 4 12/0.472 18/0.709 137 13.97 101.11
Control valve holder set
3 16/0.630 24/0.945 279 28.45 205.90
bolt
Swing motor set bolt 11 20/0.787 30/1.181 664 67.71 490.04
Battery mounting nut 4 12/0.472 18/0.709 137 13.97 101.11
Driving cab mounting nut 4 16/0.630 24/0.945 279 28.45 205.90
swing supporting bearing
set bolt 32 20/0.787 30/1.181 664 67.71 490.04
(Upper swing platform) 36 20/0.787 30/1.181 664 67.71 490.04
(Under tracking carriage)
Tracking unit set bolt
(Tracking motor 22 16/0.630 24/0.945 279 28.45 205.90
reduction machine) 32 16/0.630 24/0.945 279 28.45 205.90
(Drive wheel)
Sprocket wheel set bolt 8 16/0.630 24/0.945 279 28.45 205.90
Track roller set bolt 56 18/0.709 27/1.06 382 38.95 281.92
Track board bolt 360 18/0.709 27/1.06 382 38.95 281.92
Track protector board set
4 16/0.630 24/0.945 279 28.45 205.90
bolt
Standard elastic
coupling, T-bolt in low- 8 4/0.157 13/0.512 10.3~12.4 1.05~1.26 7.59~9.11
pressure piping
1. Apply lubricant (Such as spindle oil with dissolved zinc oxide) to the bolts and nuts to decrease
their friction coefficients.
2. Make sure that the bolt and nut threads are clean before installing.
3. Apply LOCTITE (Bond) to the threads before installing and tightening the swing supporting
bearing set bolt and track roller set bolt.
6
1-1-7. Torque table
CONTENTS
Tools used are appropriate for the operation.
Temporary use of improper tools and regulations may
endanger safety. Use the tools of correct size when
loosening or tightening nuts and bolts. Otherwise,
1
fastening tools may slip which leads to injury.
Bolt type
Tighten nuts or bolts to specified torque correctly. There are 2 types and different levels for bolts.
Be sure to use the correct bolts and tighten them correctly when installing machine or components.
2
Hexagon Bolt Inner Hexagon Bolt
10.9 8.8 12.9
4
Hexagon Hexagon Bolt Inner Hexagon Bolt
Bolt Bolt Wrench
Wrench
Diameter Level Size Ngm kgfgm lbfgft Ngm kgfgm lbfgft
Size
M6 10.9 10 4 13.2 1.37 9.74 13.2 1.37 9.74
M8 10.9 13 6 31 3.16 22.87 31 3.16 22.87
M10 10.9 17 8 66 6.73 48.7 66 6.73 48.7 5
M12 10.9 19 10 113 11.53 83.39 113 11.53 83.39
M14 10.9 22 12 177 18.06 130.6 177 18.06 130.6
M16 10.9 24 14 279 28.47 205.9 279 28.47 205.9
M18 10.9 27 14 382 38.98 281.9 382 38.98 281.9
M20 10.9 30 17 549 56.02 405.16 549 56.02 405.16 6
M27 10.9 41 19 1320 134.7 974.16 1320 134.7 974.16
M10 12.9 17 6 78 7.96 57.76 78 7.96 57.76
M12 12.9 19 8 137 13.98 101.1 137 13.98 101.1
M16 12.9 24 14 339 34.6 250.18 339 34.6 250.18
M20 12.9 30 17 664 67.75 490 664 67.75 490 7
INDEX
7
The items below are applicable to the fine thread and coarse-pitch thread.
1. Apply lubricant (Zinc white B melts into the spindle oil) to the nuts and bolts to decrease the
friction coefficient. The lubricant is not required for thrust bolt.
2. The torque tolerance is r 10%.
3. Be sure to use the correct-length bolt. If the bolt is too long, it cannot be tightened because the
top of the bolt has touched the bottom of its hole. If the bolt is too short, the tightening force will
be not enough.
4. The torque in the table is only for general purposes. If different torques are given to special
purposes, do not use torques in the table.
5. Make sure that the threads are clean before the nuts and bolts are installed. If there is dirt or
rust, clean it.
Order for tightening bolts

When two bolts or more are tightened, the operation should be alternate to make sure that they are
tightened evenly as shown below.
Tighten Equally up and

Diagonally Tighten Tighten from Center and Diagonal
down Alternately
1 12 9 4 1 6 7 14
6 3
1 and 4
4 5
2 13 8 5 2 3 10 11
2 and 3
Suggestions for divided type flange maintenance

1. Clean and check the seal surface. The packing will leak or wear due to scratches/
roughness. The packing will be extruded due to unevenness. If the problems cannot be
solved, replace parts.
2. Be sure to use the specified O-ring. Check the O-ring for damage. Be careful not to file
the O-ring surface with a file. When the O-ring is placed into the groove, fasten its
position with grease.
3. Tighten the divided type flange slightly, and be

careful to set the opening in the center with it
perpendicular to the oil port. Tighten the bolt
by hand to keep the position of the part.
8
CONTENTS
Incorrect
Be careful not to press the O-ring.
4. After tightening one of the bolts, tighten the

bolt on the diagonal side, as shown in the
3 2
illustration, to ensure an even tightening.
1 4
5. Do not use the pneumatic wrench. Using the pneumatic wrench usually causes that one
3
of the bolts has been tightened completely before others have not been tightened yet,
which leads to the damage of the O-ring and the uneven tightening of the bolts.
Locking for nut and bolt

Correct Incorrect 1. Locking plate
4
Do not reuse the locking plate. It cannot bend twice in

Bend out corners of Do not bend out
edges along the sides round corners the same place.
Correct Correct Incorrect
Bend it in the correct way as shown on the left
illustration. 5
Bend out corners of edges along the sides
2. Cotter pin
6
Correct Correct Incorrect

Do not reuse the cotter pin. Fit the hole in the
direction of tightening the bolt and nut, but not in that
of loosening. 7
Lock it in the correct way as shown on the left

illustration.
INDEX
9

3. Locking the foil strip
Correct Incorrect
Loosen
The foil strip should be penetrated in the direction of
Tighten tightening bolts, but not loosening.
Lock it in the correct way as shown on the left

illustration.
Pipe union
The torque in the table is only for general purposes.

If different torques are given to special purposes, do not use torques in the table.
Pipe union
1 4 3 5 2 Fit the union (1) with the metal seal surface (4) and (5) of
hose (2) to seal the pressure oil. Pipe joint is used to
connect the smaller diameter pipe.
Union Body
1. Do not over tighten the nut (3). If the over force is applied to the metal seal surface (4) and (5),
the joint (1) may be broken. Be sure to tighten the nut (3) according to the specification.
2. Oil leakage will be found at the connections because of the scratches or other damage on the
seal surface (4) and (5). Be careful not to damage the seal surface when connecting/
disconnecting it.
The tightening torque for the camber, concavity tube

union is as follows:
30e
30e
Camber Tube Union Concavity Tube Union
10
Wrench Size mm Wrench Size mm Tightening Torque

Type
CONTENTS
Union Nut Hose union Ngm (kgfgm, lbfgft)
19 19 59(6, 44)
22 22 98(10, 72)
27 27 118(12, 87)
36 36 235(24, 173)
30° camber
41 41 295(30, 218)
50 50 490(50, 361)
60 60 670(68, 494) 1
70 70 980(100, 723)
19 17 44(4.5, 32)
22 19 59(6, 44)
27 22 118(12, 87)
30° concavity
36 30, 32 235(24, 173)
41 36 295(30, 218)
50 46 490(50, 361) 2
O-ring and seal ring connection

7 6 9 The O-ring (6) is fitted with the end surface of union (7)
to seal the high pressure oil.
3
8 10 Hose Union
1. Be sure to replace the O-ring (6) with a new one when reconnecting the pipe.
2. Confirm that the O-ring (6) is installed in the O-ring groove (8) correctly before tightening the nut
(9). If the O-ring (6) is moved when tightening the nut (9), the O-ring (6) will be damaged, leading
to a oil leakage.
5
3. Be careful not to damage the O-ring groove (8) or seal surface (10). The oil leakage will happen
as the O-ring (6) is damaged.
4. If the oil leakage happens as the nut (9) is loose, do not tighten the nut (9) to stop leakage but
replace the O-ring (6) with a new one and check that it is installed surely, and then tighten the
nut (9).
6
Wrench Size mm Wrench Size mm Tightening Torque
Union Nut Hose union Ngm (kgfgm, lbfgft)
19 17 59 (6, 44)
22 19 98 (10, 72)
27 22 118 (12, 87) 7
36 30, 32 235 (24, 173)
41 36 295 (30, 218)
50 46 490 (50, 361)
INDEX
11

Thread connection
PT PF Use different threaded connectors depending on the
30e
thread type and seal requirement.
Always ensure the pitch and thread type (conical

Camber Conical Thread thread or column thread) are correct before connecting
Camber Column Thread thread.
Application of bond
Bond is used to connect between threads. It is simple,
Inner Thread
economical and effective. The bond can prevent threads
becoming flexible. Sometimes connecting threads,
proper bond is used to approach the special
requirements of removal and non-removal.
Outer Thread Before using, please check that the surface of thread is
Clearance
clean, no-dust and no-damage.
Tightening torque for low pressure hose clamp

T- bolt Worm-type The tightening torque for low pressure hose clamp
differs depending on the clamp type.
T-bolt strap holder:
4.4 Ngm (0.45 kgfgm, 3.25 lbfgft)
Worm-type strap holder:
5.9~6.9 Ngm
(0.6~0.7 kgfgm, 4.3~5.1 lbfgft)
12

Hose connection
CONTENTS
Always only use the genuine brand repair fittings of Sany Heavy Industry Co., Ltd when replacing
hoses. If not using the genuine brand hoses, it may lead to oil leakage, hose crack or connection
disengaged, even cause the machine to catch fire.
1
Do not twist the hose when installing it. For the oil
Incorrect Correct pressure is high, the vibration and impact will make hose
leakage, crack or connection disengaged. Be careful of
the sign marked on hose to prevent twist when installing
hoses.
2
If hoses rub each other, it will make the hoses worn,

leading to hoses breaks. Take necessary measures to
Incorrect Correct
3
prevent the hoses from rubbing each other.
Mutual Friction
Incorrect Correct 4
Clamp Clamp
Mutual Friction
5
Be careful not to let the hose touch the operating parts
or sharp objects.
Incorrect Correct
6
Mutual Friction
Clamp
7
INDEX
13
1-1-8. Parts replaced periodically

Always check machine periodically to ensure safety running. In addition, if the parts listed in the table
below are damaged, it may lead to serious risks or a fire. It's difficult to determine the degree of their
aging, fatigue or weakening of parts below only by checking appearance. So replace these parts
depending on the intervals listed in the table below. However, once malfunctions are found in these
parts, be sure to replace them before starting and do not consider intervals' limit.
In addition, check the clamp bands for deformation, cracks or other deterioration symptoms when
replacing hoses, and replace them as necessary.
Always check the hoses below periodically, and replace or tighten the fault parts as required.
Consult your specified dealer for correct replacing methods.
Parts Replaced Periodically Replacing Intervals

Fuel hose (From fuel tank to filter) Every 2 years
Engine Fuel hose (From fuel tank to fuel injection pump) Every 2 years
Oil hose (From filter to engine) Every 2 years
Pump oil inlet hose Every 2 years
Pump oil outlet hose Every 2 years
Mainframe
Swing hose Every 2 years
Pilot hose Every 2 years
Hydraulic system
Boom cylinder piping
Every 2 years
hose
Work devices Arm cylinder piping hose Every 2 years
Bucket cylinder piping
Every 2 years
hose
Be sure to replace the grommet such as O-ring and gasket when replacing hoses.
14
1-1-9. Paint
CONTENTS
Paint
Surface to be Painted Paint Colors
Swing platform main surface Sany yellow finishing coat SYC-001
Inner surface Sany yellow primer SYC-001
Work devices Sany half matte coat SYC-001
Track (Under tracking carriage) Sany black finishing coat SYC-003 1
Driving cab outside Sany black finishing coat SYC-003
Rear view mirror lever Sany black finishing coat SYC-003
Base board Sany black finishing coat SYC-003
Armrest Sany black finishing coat SYC-003
Operating lever Sany black finishing coat SYC-003
2
Outside of Driving Cab Outside of Driving Cab
Top cover of Machine

3
Main Surface of Swing Platform Armrest Main Surface of Swing Platform

Armrest
4
Work Devices
Track (Under Tracking Carriage)
7
INDEX
15

Record
16
SAFETY-Safety information
CHAPTER 2 SAFETY
CONTENTS
2-1. Safety information
2-1-1. Identifying safety symbol
(a) This is the symbol of "BE CAREFUL".

1
(b) You should be aware that this symbol is used to
remind a risk of personal injury when you see it on
the excavator or in this manual.
(c) Observe the advised precautions and safety
operation methods.
2
2-1-2. Understanding signal words

x The words that used to indicate hazard level such as "DANGER", "WARNING" or "NOTICE" are
3
used along with on the safety signs of the excavator.
"DANGER" refers to a case that there is a direct risk. If ignored, it may cause serious injuries or
even death. The safety signs are set near a specific hazardous location. 4
"WARNING" refers to a case that there is a potential risk. If ignored, may cause serious injuries or
even death. The safety signs are set near a specific hazardous location. 5
"CAUTION" refers to a case that there is a potential risk. If ignored, it may cause minor or moderate
injuries. The general precautions are listed on the safety signs of "NOTICE". In this manual,
"CAUTION" is also used to remind you to take notice to the safety instructions. 6
To avoid the confusion of machine protection and personal safety instructions, the signal word
"IMPORTMENCE" is used to indicate a case that may cause machine damage.
7
It is used to provide additional instructions on individual important information.

INDEX
17
2-1-3. Observing safety regulations
(a) Carefully read all the safety signs on the excavator

and observe them as well as all the contents
concerning safety in this manual.
(b) Install, maintain and replace the safety signs when
necessary.
(c) If the safety signs or this manual is damaged or
lost, order replacement parts from the appointed
dealer and the Sany Heavy Industry as the same
way of ordering other replacement parts (It is
necessary to clearly state the excavator models
and serial numbers).
(d) Learn to operate the excavator and its controllers
correctly and safely.
(e) Only the trained and qualified specialists are
allowed to operate the excavator.
(f) Excavator should be operated in an appropriate
environment.
(g) Any unauthorized modifications on the excavator
may have an impact on its functions and (or) safety
as well as its life.
(h) The safety instructions in Chapter "SAFETY" is the
basic safety regulations of the excavator.
However, these related safety instructions cannot
involve all the dangerous cases that you might
encounter. If you have any questions, first contact
your appointed dealer or the Sany Heavy Industry
service engineer before operating and maintaining
the excavator.
1. Understanding safety equipments
(a) Make sure that all the protectors and covers are in appropriate positions. If the protectors
and covers are damaged, have them repaired immediately.
(b) Understanding how to use the safety devices and use them correctly.
(c) Do not remove any safety devices and keep them in a good operating state.
2. Keeping excavator clean

(a) If the electrical system ingress water, it will
cause machine failures or malfunctions. Do
not flush the electrical system (sensors,
connectors) with water or steam.
(b) If the excavator is attached with mud or oil
when inspecting or maintaining, there may
be a risk of personal slipping or falling, or a
risk that the dirt enters into one's eyes.
Therefore, always keep the excavator clean.
18
3. Keeping driving cab clean
CONTENTS
(a) Make sure to remove the mud and oil attached on your shoes before entering the driving
cab. If you operate the pedal with mud or oil attached on your shoes, your feet will be
slippery, which could cause serious accidents.
(b) Do not leave any parts or tools around the driving cab.
(c) Do not attach the ambulacra to the window glass. The ambulacra may act as a magnifier,
which could cause a fire.
(d) Do not use mobile phone in the driving cab when driving or operating the excavator.
1
(e) Do not bring dangerous articles (Such as flammable or explosive items) to the driving cab.
4. Leaving operating seat in locking state

(a) Before the operator standing from the seat
(Such as opening or closing the front
window or the roof window, removing or 2
Lock State installing the end window or adjusting the
seat), lower the work devices to the ground,
firmly turn the safety lock lever to the lock
position, and then turn the engine off. If the
lever is not locked, the excavator may move
3
suddenly when you touch the lever
accidentally, resulting in serious injuries or
machine damage.
(b) Always lower the work devices to the ground

when leaving the excavator, firmly turn the 4
safety lock lever to the lock position, and
then turn the engine off. Remove the key
and place it in the specified position after
locking all the equipments with it.
5. Provisions for emergency

Make provision against fire or accident:
(a) Prepare first aid kits or fire extinguishers in
the surrounding area. 6
(b) Carefully read and understand the
instructions pasted on the fire extinguishers
for using it properly.
(c) Set down an emergency countermeasure
guide against fire and accidents. 7
(d) Paste the phone numbers of doctors,
ambulances, hospitals and fire brigades at
the side of the phone.
INDEX
19
6. Wearing protective articles
(a) Wear tight-fitting clothes and safety supplies that appropriate for working.
You may need the following safety supplies:

x Hard helmet
x Safety shoes
x Safety glasses, protective goggle or face shield
x Hard gloves
x Audition protection
x Reflective vest
x Rain-proof
x Respirators or filtering masks
(b) Always properly wear the work clothes and safety supplies, do not expect a fluke.
(c) Avoid wearing loose clothes, jewelries or other items that may hooked on the operating
lever or other components.
(d) The operator must be absorbed for operating the excavator safely. Do not listen to the
radio or music earphones when operating.
7. Hearing protection
(a) Your audition will be harmed or lost if you
stay in intensity noise for a long period of
time.
(b) Wear an appropriate audition protection
such as earphones to avoid harmful or
offensive intensity noise.
8. Checking excavator
(a) To avoid personal injuries, check around the
excavator carefully before starting the
excavator everyday or per shift starting.
(b) Always check all the items described in the
chapter of "Inspections before starting" when
checking around the excavator carefully.
20
9. Using armrest and ladder
CONTENTS
Always observe this precaution to ensure safety!
(a) Falling is one of the major causes that

resulting in personal injuries. 1
(b) Always keep a three-point contact with the

pedal and armrest and face to the excavator
when getting on or off the excavator.
(c) Do not use any levers and driving cab doors 3
as the armrest.
(d) Never jumping on or off the excavator, and
do not get on or off a moving excavator.
7
INDEX
21
(e) While operating the excavator, please notice
that the platform, pedal and armrest are
slippery.
(f) Mud, oil and water on pedal, armrest and
shoes should be removed at any time.
10. Adjusting seat

(a) It is easy to cause the operator to be
fatigued if the seat position is inappropriate,
resulting in an operating false.
(b) The seat position should be readjusted when
exchanging the excavator operators every
time.
(c) When the operator sits with his back against
the seatback, he should be able to fully
depress the pedal and operate the operating
lever correctly. If not, move the seat back
and forth to adjust again.
11. Fastening the belt

(a) If the excavator involves in a rollover
accident, the operator may be injured or be
thrown away from the driving cab as well as
being squashed by the overturning
excavator, which lead to an accident causing
serious injuries or even death.
(b) Carefully check the belt, buckle and mounts
before operating the excavator. Replace the
belt or its components before operating the
excavator if you find any damage or wear.
22
(c) Always sit on the operating seat and fasten
CONTENTS
the belt while the excavator is running to
maximally reduce the possibility of injuries
due to an accident.
(d) Regardless of its status, the belt is preferred
to be replaced every three years.
12. Do not allow people to stay on the excavator
Do not allow people except the driver to stay on the excavator as there is a risk of falling or 1
causing serious injuries.
13. Windshield washer fluid
Wash the windshield with alcohol based washer fluid. Do not use the methanol based washer
fluid, doing so may cause eyes irritation.
14. Driving cab window glass
2
(a) There may be a risk that the work devices come into contact with the body of operator
directly if the driving cab glass on the work devices side is broken, so stop operating
immediately and replace the glass.
(b) If the plexiglass-made (polycarbonate) roof window is broken, it will crack and lose the
protection function; if the roof window has been damaged by the falling stones or cracked,
replace it with a new one.
3
15. Ensuring a good vision
(a) To ensure safe operation or tracking, check for people or obstacles around the excavator
and the situations in the work place.
(b) Turn on the working lights and headlights installed on the excavator when working in a
dark place. Set a supplementary lighting in the working area when necessary.
(c) Stop operating if you cannot get a good vision such as when it is fogging, snowing, raining 4
or there is dust.
16. Investigating work site beforehand

(a) There is a possibility that the excavator rolls
over when working by grooves or curbs,
which may lead to an accident causing 5
serious injuries or even death.
(b) Investigating the landforms and surface
conditions beforehand of the work site to
prevent the excavator from rolling over, or
even the surface, material piles or bank 6
collapse.
(c) Formulate a working plan and use the
excavator that is suitable for working or work
site.
(d) Strengthening the ground surface, grooves
7
side and curbs according to needs to
maintain a reasonable distance between the
excavator and the grooves side or curbs.
(e) A signal worker is assigned to command
INDEX
according to needs when working on slopes

or curbs.
23
(f) Always strengthen the ground surface
before working when the groundsill is soft.
(g) Use extreme caution when working on the
frozen ground. Because the groundsill will
become soft and slippery as the increasing
of the environment temperature.
17. Preventing from falling stones and rubbles

(a) Make sure that the driving cab is equipped
with falling objects protection net when
working at the place that there are falling
stones or rubbles.
(b) Always wear helmet and protective glasses.
18. Sending signals for multimachine work

In the case of multimachine work, designate a
signal worker to organize the working by using the
uniform signals for all operators and make sure
that all the operators obey the command of this
signal worker.
24
19. Signals and gestures of signal worker
CONTENTS
(a) Set signs on curbs or soft ground. If your cannot get a good vision, designate a signal
worker to command when necessary. Operators should pay extreme attention to signs and
obey the command of signal worker.
(b) Signals can only be sent by just one signal worker.
(c) Make sure that all the operators have understood all the signals and gestures before
working.
20. Keeping away from rotating components 1

(a) It could result in a serious injury if you are
caught up in the rotating components.
(b) Be extremely cautious that your hands, feet,
clothes, jewelry and hair are not caught up in
it when working near the rotating 2
components.
21. Preventing ports from being thrown out

If you do not observe the following precautions,
3
serious injuries, blindness or even death will be
resulted in when the grease in the track adjuster is
under high pressure.
(a) Do not remove the grease nozzles or valve
components.
(b) Always keep your body and face far away 4
from the valve body as the parts may be
thrown out.
(c) The tracking decelerator is under pressure.
(d) Always keeping your body and face away
from the air discharge cock to avoid injuries, 5
because the parts may be thrown out.
(e) Always releasing the air discharge cock
gradually after the gear oil has cooled down
to release pressure, because the gear oil is
hot.
6
22. Preventing from falling objects, splashes and
invaders
(a) According to the operating state, install
necessary protectors to protect the operator
in a dangerous work site where the falling 7
objects, splashes and invaders may hit or
enter the driving cab.
(b) Install the front protector and stick
transparent glass paper on the front window
INDEX
when removing or crashing.

(c) Install FOPS (Falling Object Protection
System) and front protector and stick
25
transparent glass paper on the front window
when working in the mine or quarry that has
a risk of falling stones.
(d) Close the front window when performing the
above operations. In addition, make sure
that other people are out of the falling risk
area and maintain a reasonable safety
distance.
(e) Descriptions above are intended for typical
working condition, you may need to install
other protectors according to the operating
state of the work site. Contact with the Sany
Heavy Industry dealer beforehand.
23. Preventing from burns

(a) Sprayed hot fluid:
x The engine coolant is hot and under
pressure after the excavator is
operated. There are hot waters and
steams in the hot water pipes of
engine, radiator and air conditioning.
In the event that these sprayed hot
water or steams come into contact with
your skin, a serious burn will be
resulted in.
x Do not open the radiator cap when the

engine is still hot. When opening the
cap, turn the cap slowly first and
remove the cap after the pressure has
been released completely.
x Make sure that the pressure has been
released before removing the cap as
the hydraulic oil tank is pressurized.
(b) Hot fluid and surface:

x Engine oil, gear oil and hydraulic oil
will become hot during operation. The
engine, hoses, lines and other parts
will also become hot. Therefore, start
to inspect and maintain after the oil
and components have cooled down.
26
24. Storing spare parts safely
CONTENTS
(a) The stored spare parts such as buckets,
hydraulic hammers and sweep blades are
likely to fall down, which leads to an accident
causing serious injuries or even death.
(b) Safely store the spare parts and appliances
to prevent them from falling down. Keep
children and other irrelevant people away 1
from the storage area.
25. Caution for high pressure fluid

(a) Serious injuries, blindness or even death will
be resulted in as the sprayed diesel or 2
hydraulic oil under pressure comes into
contact with the skin or eyes. Therefore,
always release the pressure before
removing hydraulic or other lines to avoid
these risks.
(b) Tighten all the connectors before 3
pressurizing.
(c) Be careful that preventing your hands and
body from contacting with the high pressure
fluid when checking for any leaks with the
pasteboard. Well wear the face shield or 4
protective goggle to protect your eyes.
(d) Seek immediate professional surgeon
attention if an accident occurs. Any fluid that
shot into the skin must be removed within
several hours, failing to do so may cause
5
gangrene.
26. Preventing from fire

(a) Check for oil leakage 6
x It may cause fire as the leakage of
fuel, hydraulic oil and grease.
x To avoid oil leakage, check if the
clamps are missing or loose, the hoses
are being twisted, or the hoses, lines
are scraping with each other, the oil 7
cooler is damaged and the oil cooler
flange bolts are loose.
x Tighten, repair or replace any missing,
loose or damaged clamps, lines,
INDEX
hoses, oil coolers and their flange

bolts.
27
x Do not bend or strike the high pressure
lines.
x Never install bent or damaged lines,
pipes or hoses.
(b) Check for short
x Short in circuit will cause fire.
x Clear and tighten all the circuit
connections.
x Check if the cables and wires are
loose, twisted, hard or cracked before
every shift or after operating for 8~10
hours.
x Check if the terminal hoods are lost or
damaged before every shift or after
operating for 8~10 hours.
x Do not operate the excavator if the
cables or wires are loose or twisted.
(c) Removing the flammable items
x The spilled fuel and hydraulic oil,
trashes, grease, chippings and other
flammable items may cause fire.
Checking and clearing the excavator
every day and removing the spilled or
accumulated flammable items in time
to prevent fire.
(d) Checking the key switch
x If the engine cannot be stopped when
a fire occurs, the fire will become
worse that does not in favor of fire
fighting. Always check the key switch
functions before operating the
excavator every day, check if the
engine stops when you turn the key
switch to OFF position after starting
the engine and idling it without load.
(e) Preventing the illuminating apparatus from
explosion
x Using the illuminating apparatus with
explosion protection performance
when inspecting the fuel, oil, battery
fluid, window washer fluid or coolant.
There may be a risk of serious injuries
due to explosion if you do not use this
kind of illuminating apparatus.
x Observe the specifications in this
manual when using the power of the
excavator as an illumination.
(f) Checking the heat insulator
x It may cause fire if the heat insulator is
damaged or lost.
x Always repair or equip with a new heat
insulator before operating the
28
excavator if you find something is
abnormal.
CONTENTS
27. Evacuation when a fire occurs
(a) Exiting from the excavator as follows if a fire
occurs:
x Turn the key switch to OFF position to
stop the engine if time permits.
1
x Use fire extinguishers if time permits.
x Exiting from the excavator
immediately.
(b) If the driving cab or the front window cannot

be opened in an emergency, you can pull the 2
pulling ring and remove the glass to exit from
the driving cab.
28. Be aware of exhaust smoke

x Preventing from choking. The engine
exhaust smoke could result in disease or
even death. 4
If you must operate in buildings, sufficient
ventilation is required. Possibly you can vent
the smoke by using a lengthened exhaust
pipe, or open doors and windows to
introduce sufficient air from outside into the
working area. 5
29. Precautions for welding and polishing

(a) Welding can produce smoke and/or small
sparks.
Make sure that there is a well ventilated and
prepared place when welding. Store the 6
flammable items in a safe place before
welding.
Only specialists are allowed to perform
welding. People other than specialists are
not allowed to weld.
(b) Polishing on the excavator may cause fire. 7
Store the flammable items in a safe place
before polishing.
(c) After welding and polishing are finished,
recheck if there is no unusual phenomena,
INDEX
such as smoking in the welding area.
29
30. Avoid heating near the hydraulic pipelines
The flammable mist spray burns as being heated
near the pressure pipes, causing you and the
onlookers to be burned severely.
x Do not use fusion welding, brazing or torch
near the hydraulic pipelines or other
flammable materials.
x The hydraulic pipelines may be cut at any
moment when the heat exceeds the direct
burning zone. The temporary fire protection
jacket should be set to protect the hoses and
other materials when performing the fusion
welding or brazing.
31. Avoid heating pipelines that contain flammable fluid
(a) Do not perform welding or gas cutting on the pipelines or hoses that contain flammable
fluid.
(b) Thoroughly clear the flammable fluid in it with non-inflammable solvent before welding or
gas cutting the pipelines.
32. Removing paints before welding or heating

(a) The paints will produce harmful gases when
it is heated by fusion welding, brazing or
torch using. You will feel sick if you inhale
these gases.
(b) Preventing the producing of potential
poisonous gases and dusts.
(c) Remove the paints at outside or at a well
ventilated place. Dispose the paints and
solvents correctly.
(d) Remove paints before welding or heating:
x If you want to remove the paints by
using sand papers and abrasive
wheels, you should prevent from
inhaling dusts and wear a qualified
respirator.
x If solvent or paint remover is used, you
should wash the paint remover away
with soap and water before welding,
clear the solvent or paint remover
container and other flammable
materials in the work site, wait at least
15 minutes before welding or heating
to disperse the volatile gases.
30
33. Preventing battery from explosion
CONTENTS
(a) Battery fumes is explosive.
x Keep the spark, lighted match and
flame away from the top of the battery.
x Do not check the battery charging
capacity by placing a metal object over
the terminal. You should use a
voltmeter or densimeter.
1
x Do not charge a frozen battery, or an
explosion may occur. Warm the
battery up to 16qC in advance.
(b) The battery electrolyte is poisonous. If the

battery explodes, the battery electrolyte may
2
spill into your eyes, which may result in
blindness.
(c) Always well wear the protective goggle when

checking the battery specific gravity.
If the sulfuric acid is spilled on your clothes without caution, handling it as follows:
x Flush your skin with clean water.
x Neutralize the acid with soda water or lime water.
x Flush with clean water for 10~15 minutes once more and get medical attention immediately. 6
34. Ventilation in a closed region

To prevent from gas poisoning, always open the
door and windows to ensure sufficient ventilation if
you must start the engine or dispose the fuel,
7
clean oil or paints in a closed area.
INDEX
31
35. Defending against risk of asbestos dust
(a) It will cause lung cancer if you inhale the
asbestos dust in the air. There is a risk of
inhaling the asbestos dust when
demolishing or disposing the industrial
wastes on the work site. Always observe the
following regulations.
(1) You should not clear it with
compressed air but spray water to
reduce the dust when clearing.
(2) If there may be asbestos dusts in the
air, always operate the excavator at
the windward side and all the persons
should use a qualified anti-dust
respirator.
x Do not allow other people to approach
during operating.
x Observe the laws, regulations and
environment standards on the work
site.
(b) Always use genuine Sany Heavy Industry
components as the counterfeit components
may contain asbestos which are not used on
this excavator.
36. Safe disposing of chemicals

Direct contact with harmful chemicals may cause
serious personal injuries. The chemicals used on
this excavator such as lubricants, coolant, painting
and adhesive may be harmful.
x The detail information (including harm to
your body and health, safety regulations and
emergency measures) of the chemicals are
supplied in the Material Safety Data Sheet.
x Verifying with the data sheet before using
harmful chemicals to exactly understand
their dangerousness and know how to
operate safely, and then follow the
regulations to operate by using
recommended tools.
x Ask for the safely using instructions of the
chemicals used on the excavator from the
local appointed dealer and the Sany Heavy
Industry service engineer.
32
37. Disposing wastes correctly
CONTENTS
(a) Inappropriate disposing of the wastes will do
harm to the environment and ecology. The
potential poisonous wastes in the Sany
Heavy Industry equipments include
hydraulic oil, fuel, coolant, refrigerant, filters
and batteries, etc.
x Using a leak proof container when 1
discharging the fluid. Do not use food
or drink containers as it may cause
somebody to drink it for mistake.
x Do not pour any waste fluid onto the

ground, in sewers or any water source. 2
x The earth's atmosphere could be
destroyed if the air conditioning
refrigerant leaks into air. An authorized
air conditioning service center may be
required in the government laws to
recycle and regenerate the air 3
conditioning refrigerant.
(b) Ask the local environment or recycle center
or your appointed dealer for the correct
method for recycling or disposing of the
wastes.
4
2-1-4. Accessory installation
(a) There is an issue of safety or legal restriction when installing the options or accessories.
Therefore, contact your Sany Heavy Industry dealer in advance.
(b) Your Sany Heavy Industry cannot accept any liability on any injuries, accidents or product
malfunctions as the using of unapproved accessories or parts. 5
(c) Read the instructions concerning accessories and the general instructions on accessories in this
manual when installing and using the optional accessories.
1. Accessory combination
(a) The different types and combinations of work devices may result in a risk of hitting the
driving cab or other components of the excavator.
(b) Check if there is a risk of interruption and operate carefully before using an unfamiliar work 6
devices.
2. Unapproved modification
(a) Contact your Sany Heavy Industry dealer before modification. Any modification that
unapproved by Sany will cause a danger.
(b) Your Sany cannot accept any liability on any injuries, accidents or product malfunctions 7
without the approval of Sany.
INDEX
33
SAFETY-Operating excavator safely
2-2. Operating excavator safely
2-2-1. Before starting the engine

1. Inspections before starting the engine
When you begin the daily work, perform the following inspections before starting the engine:
x Wiping off the dust on the surface of the window glass to ensure a good vision.
x Wipe off the dust on the lens' surface of the headlights and the working light and check if
they work effectively.
x Check the coolant level, fuel level and the oil level in the engine pan.
x Check if the air cleaner is blocked and the wire is damaged.
x Adjust the operator seat to a position where it is easier to operate, and check if the seat
belt or the retaining clips are damaged or worn.
x Check if the gauges are working effectively, and inspect the angle of lights and working
lights, and check if all the levers are placed in the neutral position.
x Adjust the rear mirror so that you can just clearly see the rear of the excavator from the
driving seat.
x Check that there is no people or obstacles above, below or around the excavator.
2. Safety regulations for starting the engine
(a) Sound the horn as a warn when starting the engine.
(b) The excavator is only allowed to start and operate while sitting on the seat.
(c) Nobody except the operator is allowed to stay in the excavator.
(d) Do not start the engine by using a way that can cause short in the starting motor circuit,
doing so not only cause a danger, but also can cause excavator damage.
3. Starting the engine in cold weather
(a) A full preheat up is required. The excavator will be slow to respond if it is not fully
preheated before operating the lever, resulting in an accident.
(b) Do not charge the battery or start the engine with different power if the battery electrolyte is
frozen, doing so may cause a risk of battery fire.
(c) Unfreeze the battery electrolyte before charging or starting the engine with different power,
check if the battery electrolyte is frozen or leaking before starting.
4. Safely moving and operating the excavator

(a) Persons around are likely to be hit
x Pay special attention not to hitting the
person around, and confirm the
position of the person around before
moving, swing or operating the
excavator.
x Always keep the tracking alarm and
horn (optional) operating. They can
warn the person around when the
excavator begins to move.
x Designate a signal worker to
command when tracking, swing or
operating the excavator in a narrow
zone. The meanings of the gesture
signals must be identified before
starting the excavator. Do not allow 2
or more signal workers to command at
34

the same time as the signal worker is
unique.
CONTENTS
(b) Operate when sitting on the operating seat
x The engine can be started only when
sitting on the operating seat.
x Never start the engine when standing
on the track or ground.
x Make sure that all the levers are in the 1
neutral position before starting the
engine.
2
Incorrect engine start steps may result in excavator out of control, and lead to serious injuries or
even death.
3
The engine can only be started with the safety lever in the lock position, otherwise, the engine
cannot be started.
(c) Jump-starting
x The battery fumes may explode, which
lead to serious injuries or even death. 4
x If you must start the engine by jump-
starting, always observe the
regulations described in the chapter of
"Engine operation" in the "Instruction
Manual", and it must be performed by
two people. 5
x Never use a frozen battery.
x If you do not observe the correct jump-
starting steps, it will result in battery
explosion or the excavator out of
control.
6
(d) Avoid carrying occupants in the excavator
x Only the operator is allowed to stay in
the excavator.
x The occupant carried in the excavator
can block the operator's vision,
causing unsafe operation.
7
INDEX
35
The occupant in the excavator is easy to be injured, such as being hit by foreign objects or thrown
out from the excavator.
Only one passenger is allowed to carry when the driving cab is equipped with a passenger seat.
2-2-2. After starting the engine

1. The inspection after starting the engine
(a) Move the excavator to a vast area without obstacles when inspecting and operate slowly.
No one is allowed to approach the excavator.
(b) Always fasten the seat belt.
(c) Check if the gauges and equipments are working effectively, and check if the bucket, arm,
boom, tracking system, swing system and steering system are functioning normally.
(d) Inspect if the sound, vibration, heating and gauges of the excavator are abnormal and
check the oil or fuel for leakage.
(e) Have it repaired immediately if find something wrong.
2. Excavator direction
Front In this manual, front, rear, left and right indicate the
Operator Seat tracking direction looking from the driving cab
when the driving cab faces to the front and the
Left Right driving wheels are in the rear pout of the
excavator.
Drive Wheel
Rear
3. Confirming the tracking direction of the

excavator
(a) Confirm the position of the under carriage
before driving the excavator and its
relationship with the operator:
x If the tracking motor is located under
the driving cab, the excavator will
move backwards when you push the
pedal/lever forward.
x When the guide wheel is located under
the driving cab, the excavator will
move forward if you push the pedal/
lever forward.
36

(b) The tracking direction board is attached to
CONTENTS
inside of the excavator's under carriage. The
direction appointed by the arrow of the board
is the exact tracking direction of the
excavator when push the pedal/lever
forward.
The incorrect operation of the tracking pedal/lever will lead to serious injuries or even death.
2
4. Safety regulations of tracking
(a) To prevent the excavator from stalling due to
overloading and avoid the work devices to
be damaged when using the excavator, do
not exceed the maximum permissible load or
3
performance.
20~30 cm (b) When tracking on a level surface, retract the
(8~12 in) work devices and keep a height of 20~30 cm
(8~12 in) away from the ground.
(c) Track slowly and do not turn suddenly when
tracking on a rough road, otherwise, there 4
will be a risk of rollover. The excavator will
be out of balance, or the excavator or its
structure will be damaged when the work
devices hit the ground.
(d) When tracking on a rough road or a slope,
5
turn off (Cancel) the automatic speed-
reducing switch if the excavator is equipped
with automatic speed-reducing system. If the
automatic speed-reducing switch is turned
on, the engine speed will increase, and the
tracking speed will also increase suddenly. 6
(e) Avoid tracking on obstacles as much as

possible, keep the work devices close to the
ground and track at a low speed if the
excavator must track on obstacles. Do not
7
track on obstacles that can cause the
excavator leaning to one side violently.
(f) When tracking or operating, keep a safe
distance with people, buildings and other
INDEX
machines to avoid coming into contact with

them.
37

(g) First check that the strength of the structure
is strong enough to support the weight of the
excavator when passing bridges or
buildings.
(h) When tracking on road, first have it
inspected by the relevant authorities and
observe their guidance.
(i) When operating in tunnels, under bridges or
wires or other height-limited places, operate
it slowly and be careful that the work devices
do not hit anything.
5. Tracking the excavator safely

(a) Confirm the tracking direction and how to
move the pedal or lever before moving the
excavator.
(b) Depress the front part of the tracking pedal
or push the tracking lever forward to move
the excavator towards the direction of the
20~30 cm
(8~12 in) guide wheel. (For correct tracking operation,
please refer to the section of "Driving the
excavator with pedals and levers").
(c) Tracking on a slope may cause excavator
sliding or rollover, which lead to serious
injuries or even death.
(d) Keep the work devices 20~30 cm away
(8~12 in) from the ground when tracking on
a slope. Lower the work devices to the
ground immediately to help stop the
excavator in case of an emergency.
(e) Adjust the driving cab so that it faces the

uphill direction when tracking on an uphill
road. Adjust the driving cab so that it faces
the downhill direction when tracking on a
downhill road.
(f) Always check the ground hardness in front
of the excavator when tracking.
20~30 cm
(8~12 in)
38

(g) When tracking on a uphill road, extend the
CONTENTS
work devices forward to keep the balance,
and track at a low speed while keeping the
work devices 20~30 cm (8~12 in) away from
the ground.
20~30 cm (h) When tracking on a downhill road, slow
(8~12 in) down the engine speed and keep the
tracking lever to the position that 1
approaching "neutral" and track at a low
speed.
(i) Driving up or down on a slope straight is

preferred as turning on a slope or tracking
2
cross the slope is very dangerous.
(j) Do not turn or drive cross a slope. Always

track down to a level surface to adjust the
position of the excavator, and then travel
uphill. 4
(k) You must drive at a low speed when tracking
across the grass, leaves or wet steel plates
as the excavator will slip even though the
slope is very slight.
(l) If the engine stalls when the excavator is
tracking on a slope, set the lever to "neutral" 5
position immediately and restart the engine.
6. Preventing from injuries caused by the loss of

control of the excavator
To prevent the excavator from the loss of 6
control:
(a) Select a level surface as much as possible
when stopping the machine.
(b) Do not stop the machine on a slope.
7
INDEX
39

(c) Lower the bucket and other tools onto the
ground.
(d) Downshift the accelerator control knob to
gear 1.
(e) Running the engine at a low speed for 5

minutes without loading to cool the engine
down.
(f) Stop the engine and remove the key from
the key switch.
(g) Move the safety lever to the lock position as

shown in the illustration.
Lock State
(h) If the excavator must be stopped on a slope,

both sides of the track should be blocked
with stoppers, and lower down the bucket
and then put the bucket teeth into ground.
(i) Positioning the machine to prevent it from
rolling.
(j) Stop the machine at a place where it can
keep a proper distance with other machines.
If you attempt to climb up or hold back a moving machine, it may lead to serious injuries or even
death.
40

7. Avoid accidents when reversing or turning
around
CONTENTS
To avoid an accident when reversing or turning
around:
(a) Look around before reversing or turning
around to confirm that there is no person
around the machine.
(b) Keep the travel alarm and horn (optional) 1
operating.
(c) Pay special attention that no other person

enters into the working area at any moment,
warn other persons with horn or other
2
signals before moving the excavator.
3
(d) Arrange a signal worker to command if your
vision is blocked when reversing and always
keep the signal worker within your field of
vision.
(e) Use the gesture signals that conform to the 4
local regulations when a signal worker is
needed according to the working condition.
(f) Move the excavator only when both the
signal worker and the operator fully
understand the meaning of the signals.
(g) Understand the meaning of the flags, signals 5
and symbols that used in the operation and
confirm the person who is in charge of
sending signal.
(h) Keep the windows, mirrors as well as the
lights clean and undamaged. 6
(i) The visibility will be reduced due to dust, rain
and fog. Slow down the speed and use light
when the visibility is reduced.
7
If someone is standing near the excavator when reversing or turning around the excavator, he/she
will be hit down or squashed by the excavator, leading to serious injuries or even death.
INDEX
41

8. Preventing people from entering the working
area
People are likely to be hit by the rotating work
devices or be squeezed against other objects,
leading to serious injuries or even death.
(a) Keep all the people away from the operating
and excavator rotating areas.
(b) Set a rail at the side or behind the turn-
around radius of the bucket before operating
the excavator to prevent people from
entering into the working area.
9. Never place the bucket above anybody

Never let the bucket pass above anybody or the
truck driving cab when lifting, moving or turning
around. People will be injured seriously or the
excavator may be damaged if the materials in the
bucket fall down or the bucket comes into collision.
10. Preventing from undercutting

(a) To ensure that you can exit from the ditch
when the groundsill collapses, place the
excavator with the tracking motor at back
and the under carriage perpendicular to the
ditch.
(b) Take it easy when the excavator cannot exit
as the groundsill begins to collapse. At this
time, the excavator can be generally
secured by lowering the work devices.
(c) Avoid caverning the soil under the excavator
when digging.
11. Preventing rollover

(a) Do not attempt to jump out from the tilting
excavator, doing so may result in serious or
fatal crush injury.
(b) Do not expect a fluke as the tilting speed of
the excavator is faster than your jumping
speed.
(c) Do fasten the belt.
(d) There is a risk of rollover when operating on
a slope, which may lead to serious injuries or
even death.
42

To prevent rollover:
x
CONTENTS
Pay special attention when operating on a
slope.
x Leveling the working area.
x Lower the bucket to the ground and
put it close to the excavator.
x Slowing down the operating speed to
prevent rollover or slipping.
x Don't change direction when traveling 1
on a slope.
x Never drive cross a slope whose
grade is more than 15 degrees if the
horizontal driving is unavoidable.
x Slow down the turn-around speed
according to situations when turning 2
around with load.
x Caution is advisable when operating on a

frozen surface because the surface will
become soft as the temperature rises,
causing the road difficult to drive on.
3
Upper Platform
4
12. Preventing collapsing
It may result in fringe collapsing or landslide if you
dig from the lower part, leading to serious injuries
or even death.
13. Taking care of the underground facilities

The accidental cut of the underground cables or 6
gas pipes may cause explosion and fire, which
may lead to serious injuries or even death.
(a) Inspect the position symbols of cables, gas
pipes and water pipes or confirm their
positions before digging.
7
(b) Keep a legal minimum distance with cables,
gas pipes and water pipes.
(c) If the fiber optic cables are cut because of
the accident, do not stare at the end of the
INDEX
cables. Otherwise, your eyes may be

damaged seriously.
43

(d) Please contact them if there is "digging
hotline" indicator in your area; or contact the
local public utility company directly and let
them mark all the underground cables and
pipelines.
14. Taking care of the elevated facilities such as

the bridges, etc.
If the work devices or other part of the excavator
hit the elevated facilities (e.g,overbridge), both the
excavator and the elevated facilities will be
damaged and lead to serious injury.
15. Avoiding the power transmission lines

(a) If the excavator or the work devices does not
keep a safe distance with the wires, it may
lead to serious injuries or even death.
(b) When operate near wires, avoid moving any
part of the excavator or load within the
distance of the wire for more than 3 meters
added double length of the wire dielectric.
(c) Verify and observe all the appropriate local
laws.
(d) The possibility that people get an electric
shock will increase on wet ground. Keep the
people around away from the working area.
16. Suspending objects

People around may be hit or squashed by the
falling objects if the suspending objects fall down,
leading to serious injuries or even death.
To prevent an accident:
(a) Always observe all the local laws when the
excavator is used to hoisting operation.
(b) Do not use the damaged chains or cracked
wire cables, lifting eyes or ropes.
(c) Position the excavator before suspending to
place the tracking motor at rear part.
(d) Move objects slowly and carefully, never
move them suddenly.
(e) Keep all the people away from the
suspended objects.
(f) Never move the objects above the top of the
workers.
44

(g) Do not let anyone approach the suspended
CONTENTS
objects before safely and firmly placing the
objects on the attachments or ground.
(h) Never hook the lifting eyes or chains on the
bucket teeth, doing so may cause the bucket
teeth to fall and cause the suspended
objects to fall down.
1
17. Stopping the excavator safely
To prevent an accident:
(a) Stop the machine on the level ground.
(b) Lower the bucket to the ground.
(c) Downshift the accelerator control knob to
2
gear 1.
(d) Run the engine at a low speed for 5 minutes

without load. 3
(e) Turn the switch key to OFF to stop the
engine.
(f) Remove the key from the key switch.
(g) Set the safety lever to the LOCK position as

(h) Close the window, roof window and driving
5
cab door.
Lock State (i) Lock all the service door and box room.
6
18. Disposing of the fluid safely - to prevent a fire
(a) Dispose the fuel carefully as it is very
flammable. An explosion and (or) fire will
occur if the fuel is lighted, causing personal
injuries or even death. 7
(b) Do not refuel when smoking or when there is
an open flame or sparks nearby.
(c) Always stop the engine before refueling.
(d) You should refuel in the open air.
INDEX
(e) All the fuel, most lubricants and some

coolant are flammable.
45

(f) The flammable fluid should be stored in a
place that is far away from the fire hazard.
(g) Do not burn or break the pressure container.
(h) Do not preserve rags with oil as they can be
lighted or burn spontaneously.
19. Safe transportation

(a) The excavator has a risk of rollover if it is
loaded and unloaded with truck or platform
trailer.
x Always observe the local laws when
transporting the excavator on road.
x Provide appropriate truck or trailer for
the excavator transportation.
(b) Pay attention to the following instructions
when loading or unloading the excavator:
x Select a solid and level surface.
x Always use a dock leveler or slope.
x A signal worker is required when

loading or unloading the excavator.
x The automatic speed-reducing switch
must be turned off when loading or
unloading the excavator to avoid the
speed increasing suddenly because of
the sudden operation of the lever.
x Select the low speed mode with the

tracking mode switch. The tracking
speed will be increased automatically
in the fast speed mode.
x Avoid steering when traveling up or
down a slope as it is extremely
dangerous. Drive the excavator back
to the ground or the platform trailer if a
steering is required, and drive up a
slope again after adjusting the
direction.
x Do not operate any other levers except
the tracking lever when driving up or
down a slope.
x Caution is advisable when passing the
interchange of the top of the slope and
the platform as it is projected.
x Prevent injuries caused by the rollover
of the excavator when turning back.
46

x Keep the arm retracted and turn back
slowly to obtain an optimal stability.
CONTENTS
x Fix the frame of the excavator with
chains or ropes. For details, please
refer to the chapter of "Transportation".
20. Lifting objects with a bucket

Safety regulations for lifting objects
(a) Do not lift on a slope, soft surface or other
places that the excavator cannot stand 2
stably.
(b) Use specified wire ropes.
(c) Do not exceed the specified lifting load.
(d) It is very dangerous if the load hit persons or
buildings. Check carefully if the surrounding
area is safe before turning back or steering. 3
(e) Do not start, turn around or stop the

excavator suddenly as the lifting load may
swing.
(f) Do not pull the load aside or toward the 4
excavator.
(g) Do not leave the operator seat when lifting
the load.
7
INDEX
47
SAFETY-Safety maintenance instructions
2-3. Safety maintenance instructions
2-3-1. Perform the safety maintenance

1. To prevent an accident:
(a) Learn about the maintenance procedure before operation.
(b) Keep the operation area clean and dry.
(c) Do not spray water or steam in the driving cab.
(d) When the machine is moving, do not lubricate the machine with oil or perform
maintenance.
(e) Avoid the hand, foot and clothes coming into contact with the rotating component.
2. Before performing maintenance

(a) Stop the machine on the level ground.
(b) Lower the bucket to the ground.
(c) Downshift the accelerator control knob to
gear 1.
(d) Run the engine without load at low speed for

5 minutes.
(e) Turn the key switch to the OFF position to
stop the engine.
(f) Move the control lever several times to
release the pressure in the hydraulic system.
(g) Remove the key from the key switch.
(h) Hang the indicator "PROHBIT OPERATION"

on the control lever.
(i) Pull the pilot control cutting lever to the lock
position.
(j) Cool down the engine.
(k) If the maintenance must be performed when
the engine is running, please keep someone
staying in the excavator.
(l) If the machine must be lifted when
performing the maintenance, the angle
between the boom and the arm should be
kept within 90~110°. Firmly support any
component of the lifted machine.
48

(m) Do not operate under the machine lifted by
CONTENTS
the boom.
(n) Inspect some parts periodically, repair and
replace them as necessary. Refer to the
related contents in "Maintenance" of the
instruction manual.
(o) Keep all the parts in a good operation
condition and install them correctly. 1
(p) Handle the damaged parts in time. Replace
the worn and broken parts. Clear any
accumulated grease, oil and scrap.
(q) Before adjusting the electrical system and
welding on the machine, always disconnect
2
the ground cable of the battery (-) !
3. Warning other people when performing

maintenance on the machine
(a) Accidental movement of the machine can
cause serious personal injury. 3
(b) Before operating on the machine, hang the
indicator "PROHIBIT OPERATION" on the
control level.
(c) The emblem are available from your
designated dealer.
4
4. Keeping the operation area clean and tidy
(a) Do not leave the hammer or other tools in the operation area. Wipe all the grease, oil or
other matters that can easily cause slipping. Keep the operation area clean and tidy for
operating safely.
(b) If the operation area cannot be kept clean and tidy, there is a risk of trapping, slipping and
dropping and injury could be resulted in. 5
(c) Clean the moon roof made of organic glass (Polycarbonate) with plain water. Do not use
any alkali solvent. If benzene, toluene, methanol or other alkali solvent are used, chemical
reaction will occur. For example, the glass will dissolve or decompose, and the
polycarbonate will deteriorate.
5. Two people are needed to perform 6

maintenance while the engine is running
In order to prevent injury, do not perform the
maintenance while the engine is running. If the
maintenance must be performed while the engine
is running, operate when two people are on the
7
spot and follow the regulations below:
(a) Always have one operator sit on the
operation seat and be ready to turn off the
engine at any time. All the operators must
INDEX
keep in touch with each other.
49

(b) Set the safety lock control lever to the lock
position.
(c) When operating near the fan, fan belt and
other whirling components, there is a risk of
Lock State being enmeshed by the components. So
take special care.
(d) Do not touch any control lever. If some
control lever must be operated, send signal
to other people and warn them to transfer to
safe place quickly.
(e) Do not drop or insert the tools and other
objects into the fan or fan belt, or the parts
will be broken or thrown out.
6. Proper tool
(a) Do use proper tools and use them correctly.
(b) If the damaged, inferior, defective and
temporary tools are used or they are used
improperly, serious injury could be resulted
in.
7. Supporting the machine correctly

(a) Never perform the maintenance on the
machine which is not well supported.
(b) Lower the work devices to the ground before
the repair and maintenance of the machine
are performed.
(c) If the machine or the work devices must be
lifted to perform repair or maintenance,
support them firmly. Do use the slag brick,
air core tire or stand to support the machine,
because they could collapse under
continuous load. Do not operate under the
machine supported by only one jack.
8. Accumulator
Accumulator is filled with high pressure nitrogen.
When operating the accumulator, careless
operation may result in explosion and cause
serious injury or damage. So, be sure to observe
the following precautions.
(a) Do not disassemble the accumulator.
(b) Keep the accumulator away from fire or
expose it to the flame.
50

(c) Do not drill, weld or use welding torch on the
CONTENTS
accumulator.
(d) Do not hit or roll the accumulator, or make it
subject to any shock.
(e) When disposing of the accumulator, air must
be bled. Please contact the Sany Heavy
Industry dealer to carry out the operation.
1
9. When using the hammer
When tapping with a hammer, the pin may fly off
and the metal grain may scatter, which could result
in serious injury. Thus, operate according to the
following steps:
2
(a) If tapping solid metal parts, e.g. pin, bucket
teeth, edge or bearing with a hammer, the
shatter scattering may cause injury. Be sure
to wear protective goggle and gloves.
(b) When tapping the pin or bucket teeth, the
shatter may fly off. This may cause injury to 3
the people around. So make sure that there
are no people around the area.
(c) If tapping the pin by force, the pin may fly off.
This may cause injury to the people around.
10. Welding operation 4
The welding operation must be done by qualified welder with proper equipment. When welding,
there is a danger of fire or electric shock. So, unqualified operators are forbidden.
11. Removing battery terminals
When repairing the electrical system or welding, remove the negative (-) terminal of the battery
to prevent electric shock.
5
12. Be careful when adjusting the track tension
with high pressure grease
(a) The grease is pushed into the track tension
adjusting system under high pressure.
(b) If not observe the specified maintenance
Grease Discharge Plug 6
procedures when adjusting, the grease
discharge plug will fly off and cause serious
injury or damage.
(c) When loosening the grease discharge plug
for releasing the track tension, do not loosen
the discharge plug more than one lap and 7
loosen it slowly.
INDEX
51

(d) Keep the face, hand, feet or other parts of
the body away from the grease discharge
plug.
13. Do not remove the bumper spring

The bumper spring assembly which contains a high pressure spring is used to decrease the
force of the tensional pulley. If it is removed incorrectly, the spring will fly off, causing serious
injury or even death. So do not remove the spring.
14. Compressed air

(a) When cleaning with the compressed air, the
grains flying out may result in injury.
(b) When cleaning the filter element or the
radiator with compressed air, be sure to
wear protective goggle, anti-dust respirator,
gloves and other protective articles.
15. Periodical replacement of safety crucial parts

(a) In order to operate the machine safely for a long period, it is necessary to add oil
periodically and perform maintenance. In order to further enhance safety, the components
relating to safety, such as hose, seat belt, etc., must be replaced periodically.
(b) The material of the components will change naturally once exceed the specified time.
Repeated use will result in deterioration, abrasion and damage. Trouble will arise and
cause serious injury or damage. It is difficult to judge how long the components have been
used according to the external inspection or touching when operating, so replace them
periodically.
(c) If any defect is found on the safety crucial parts, replace or repair them even if the
specified time is not due.
16. Replacing the rubber hose periodically
(a) The rubber hose that contains flammable fluid may crack under pressure due to aging and
excessive abrasion. It is difficult to judge the aging and abrasion degree of the rubber hose
only by inspection. So replace the rubber hose periodically.
(b) Failure to check the rubber hose regularly may cause accidents like fire, the fluid ripping
into the skin or the operation devices unit hit the people around, etc and result in burns,
necrosis or other injuries.
17. Safely maintaining the air conditioning

(a) Never get the refrigerant come into contact
with the skin as it will cause frostbite.
(b) Refer to the instructions on the refrigerant
container when maintaining the air
conditioning, and use the refrigerant
correctly. The refrigerant is R134a, do not
52

use other refrigerants, doing so may cause
CONTENTS
the air conditioning system be damaged.
(c) Prevent the refrigerant from releasing into air
by using recycling and circulating system.
(d) Keep away from fire when repairing or

maintaining the air conditioning system.
1
The refrigerant R134a is non-toxic gas under constant temperature, but it will become highly toxic
gas if it comes into contact with fire.
3
18. Before bringing the excavator back to the
owner
After finishing the maintaining or repairing, you
need to confirm:
(a) The function of the excavator should be 4
normal, especially the safety system.
(b) The worn or damaged parts have been
repaired or replaced.
7
INDEX
53
SAFETY-Warning signs and illustrations
2-4. Warning signs and illustrations
2-4-1. Manufacturing plate
Manufacturing Plate
The manufacturing plate is riveted on the inside of the left upper plat form
See above illustration for plates used in domestic market
54
2-4-2. Warning plate position and illustration information
CONTENTS
1. Warning! Excavator operating range
Do not stay in the work area!
Otherwise, there is a risk of being squashed!
2. Warning! Excavator operating range

Do not enter into the operating range of the
2
excavator!
Otherwise, there is a risk of being squashed!
3. Adjusting the tension of the excavator track

Do not exceed one lap when loosening the track,
otherwise, it may cause a risk of being bruising by
the flying regulating valve under high pressure! 4
䄺ਞ WARNING

ौय़ᯊা‫ܕ‬䆌ᢻᵒϔ೜
It is permitted to adjust only 6
one circle when remove press
4. Working direction of the excavator

Warn the exact working direction of the excavator 7
when you operate the tracking lever (pedal) of the
excavator forward.
INDEX
55

Plate position diagram 1
12 13
11
10
8 7 6 5
5. Diesel-oil tank plate

Warn the owner to refill premium diesel-oil of
᷈⊍ㆅ (Diesel-oil tank)
different brand under different ambient
䇋Փ⫼㒃ℷક䋼᷈⊍
3OHDVHXVHWKHSXUHGLHVHORLO temperature!
៪োıe&1RRU1Rıe&
ো៪៪ো1RRU1Rİe&
ᆍ⿃㑺छ&XEDJHDERXWOLWHU
6. Hydraulic oil tank plate

Warn the owner about brand, cleanness and
volume of the hydraulic oil tank when refilling the
hydraulic oil.
⎆य़⊍
Hydraulic Oil
⊍ક˖AW46˗
Quality˖AW46
ᆍ⿃˖㑺239छ˗
Cubage:about 239 liter˗
ᤶ⊍਼ᳳ˖Ꮉ԰ᇣᯊ៪ᑈ˗
Oil change Interval:Opration
for 2000h or one year
56

7. Water releasing direction plate of oil water
separator
CONTENTS
The owner should turn the water releasing valve of
the oil water separator according to the direction
shown in the sign.
8. Warning! Take care of burns!
ॅ䰽DANGER 2
9. Warning! Be careful not to slip or fall down;

Treading or walking is prohibited
7
INDEX
57

10. Warning! Be careful not to be injured by the
belt
STOP
11. Warning! Be careful not to be injured by

rotating objects
ॅ䰽DANGER
58

12. Air cleaner filter element cleaning sign
CONTENTS
⊼ᛣ CAUTION
1.᳈ᤶⒸ㢃ᯊ,䇋㺙㋻Ⓒ㢃Ϟ೎ᅮൿ⠛.
৺߭ᇚᓩ䍋থࡼᴎᤳണ.
2.ぎ⇨Ⓒ㢃ᅝ㺙ᅠ↩ৢ⫼᠟ᑨϡ㛑䕀ࡼ. 1
1.When change filter net,make sure the
net be fixed correctly.
Or the engine will be damaged quickly.
2.Make sure the filter net is firm
after changing.
2
13. Strictly no sitting
14. Sling point of the sling equipments

6
7
INDEX
59
15. Safety lever "UNLOCK/LOCK" sign

15 16 17
16. Operating sign for adjusting seat forward and

back ward
ᓔਃԡ㕂
ADJUST POSITION
䯁䫕ԡ㕂
LOCK POSITION
17. Lubrication and maintenance sign
18. Read the "Instruction Manual"
60
CONTENTS
18,19,20 21 22 23
1
24
19. Warning! Note the high voltage and keep a 3

safe distance to prevent from the risk of
electric shock
20. Warnings for leaving the operator seat

Lower the work devices to the ground and shift the 5
safety lever to the lock position remove the engine
start key before leaving the excavator.
21. Excavator operation options
7
INDEX
61

22. Battery position/voltage/charging state
24V
23. Warning! The plug pin is tightened when the

front upper window is at the "CLOSE/OPEN"
position
24. Emergency exit
62
UPPER SWING PLATFORM - Driving cab
CHAPTER 3 UPPER SWING PLATFORM
CONTENTS
3-1. Driving cab
3-1-1. Removal and installation of driving cab
Removal 1
Firstly, remove the battery's negative (-)
terminal cable
1
1. Remove the interior decoration buttons (1) (×4)
2 on the interior decoration (2) and the set
screws (×4) to remove the interior decoration
(2). 2
3 4 2. Remove the screws (4) (×3) on the air

conditioning cover (3), and the set bolts (×4) of
the air conditioning cover (3) and driving cab; 3
remove the air conditioning cover (3).
: 4 mm (0.16 in)
: 13 mm (0.51 in)
3. Remove the side duct (5), main duct (6) and

new duct (7) on the A/C unit (8).
6
5 7
5
7
INDEX
63

4. Disconnect the wiper motor wire plug (9),
driver cab dome light wire plug (10), A/C
insolation sensor plug (11), display wire plug
(12), radio antenna plug (13), radio horn wire
plug (14) and interior light wire plug (15).
9, 10, 11, 12
13, 14, 15
5. Remove the plastic hose (17) of driver cab rear

washer (16).
16
17
Driving cab weight: 326 kg
6. Install the sling belt to the four lifting eyes on

the top of the driving cab.
64

7. Remove the screws (18) (×3) and bolts 19 (×2)
which connect the floor and driving cab, then
CONTENTS
remove the nuts 20 (×4) that are used to fix the
floor, driving cab and platform.
: 10 mm (0.4 in)
18
: 18 mm (0.7 in)
: 24 mm (0.94 in)
19
1
20
Driving
Cab
19
2
Floor Frame
8. Lift the driving cab carefully and remove it. 3
5
Seat removal
9. Remove the set bolts (22) (×4) of the seat (21).
: 13 mm (0.51 in)
6
21 22
7
INDEX
65
21
22
A/C unit removal

23
28
10. Remove the set bolts (28) (×4) and the controller
24 wire on the electrical mounting rack (23) to
27 remove the electrical mounting rack (23);
remove the screws (26) (×2) on the inside air
duct (25) to remove the inside air duct (25);
25 make sure that the refrigerant has been
26 discharged from the air conditioning system,
then remove the refrigerant fluid pipe (×2) and
hot water pipe (×2) from the A/C unit (24), and
protect the nose piece to prevent pollution;
remove the bolts (27) (×6) on A/C unit (24) to
remove the A/C unit (24).
: 13 mm (0.51 in)
: 6 mm (0.24 in)
66

Installation
CONTENTS
1. Install the refrigerant fluid pipe and hot water
pipe on the A/C unit (24); install the inside air
duct (25) with screws (26) (×2) on the driving
cab base board; install the A/C unit (24) onto
the driving cab base board with bolts (27) (×6);
install the electrical mounting rack (23) onto
the driving cab base board with bolts (28) (×4);
and connect the controller wire properly. 1
: 6 mm (0.24 in)
: 31 Ngm (3.1 kgfgm, 22.32 ftglbf)
: 13 mm (0.51 in)
2
2. Install the seat (21) onto the seat base with
bolts (22) (×4).
21 : 13 mm (0.51 in)
22
5
Driving cab weight: 326 kg
3. Install the sling belt onto the driving cab and 6

lift it up with a crane.
7
INDEX
67

4. Install the set bolts (19) (×2), screws (18) (×3)
and nuts (20) (×4) of the driving cab.
: 10 mm (0.4 in)
: 137 Ngm (13.7 kgfgm, 98.64 ftglbf)
: 18 mm (0.7 in)
: 137 Ngm (13.7 kgfgm, 98.64 ftglbf)
18
: 24 mm (0.94 in)
: 339 Ngm (33.9 kgfgm, 244 ftglbf)
19
20 Driving
Cab
19
Floor Frame
5. Connect the wiper motor wire plug (9), driver

cab dome light wire plug (10), A/C insolation
sensor plug (11), display wire plug (12), radio
antenna plug (13), radio horn wire plug (14)
and interior light wire plug (15).
9, 10, 11, 12
13, 14, 15
68

6. Connect the plastic hose (17) of the driver cab
rear washer (16) securely.
CONTENTS
16
1
17
7. Install the side duct (5), main duct (6) and new
duct (7) on the A/C unit (8). 3
6
5 7
8
5
8. Install the A/C cover (3) with screws (4) (×3)

3 4
and set bolts (×4).
: 4 mm (0.16 in)
6
: 13 mm (0.5 in)
7
INDEX
69

9. Fix the interior decoration (2) onto the driving
cab with set screws (×4), and cover the interior
decoration buttons (1) (×4).
1
2
70
3-1-2. Removal and installation of driving cab glass
CONTENTS
Unit: mm Glass material: toughened glass Thickness: 5
9
8
1
1
6
2
3
4
5
7
INDEX
71

Removal method of glass
9 Removal method of glass 1, 2, 5, 7, 9
1
7 Always pay attention to the sharp edge of the glasses

when removing broken glass or glass with rips, which
2
may result in serious injury. Before removing, stick the
broken glass or glass with rips with adhesive tape or
something similar, and fix it securely to prevent injury.
5 Always have the glass fragments cleaned. Protecting
measures should be taken before removing, and fix
the glass with adhesive tape or something similar,
which will be helpful to safe removal.
1. Remove the resin board, garnish rail, retaining

Driving Cab
block, etc. around the glass.
Glass
Awl 2. Prick a hole in the adhesive with an awl ( or
cutting knife ).
Adhesive
3. Pass a piano wire ( or steel wire ) through the

pricked hole.
Piano Wire
(or Steel Wire)
4. Twist the two ends of the piano wire tightly to

two screwdrivers to pull the piano wire so that
(Outside of Driving Cab) the adhesive between the driving cab and the
Driving Cab
glass can be cut off, then remove the glass
Glass
from driving cab. It requires two or three
persons to finish the job together.
Always cut the intermediate section of the adhesive

between the glass and the driving cab. If the piano
Adhesive wire is hot, it will be snapped easily. Always change
the using position as the adhesive is cut.
(Inside of Driving Cab)
72

Removal method of glass 3
The glass is fastened with weatherstrip, and it can be
CONTENTS
pulled out with strength slowly and directly while
removing.
Removal method of glass 4 and 6

1. Remove the weatherstrip on the window frame
and door inner side.
2. Slowly push out the window frame with strength
from door inside, and remove the window frame, 2
glass 4 and glass 6 integrally.
6 3. Remove the glass 4 and glass 6 with a screwdriver
from the window frame.
4
Weatherstrip
Window
Frame 4
6
Removal method of glass 8

8
1. Remove the stopper (rubber groove) with an
ordinary screwdriver. 6
2. Insert a bamboo chip into A position of the
retaining rubber, and pry the retaining rubber out
along the rim.
3. Patting the glass with palms from the inside of
driving cab to remove it. This work needs to be
finished by two persons.
7
INDEX
73
Retaining Rubber Side

Retaining Glass
Rubber
Inside of cab
A A
Driving Stopper
Cab (Rubber Groove)
Installation method of driving cab glass

9 Installation method of glass 1, 2, 5, 7, 9
1 1. Using cutting knife or something similar, cut
1~2 mm depth off from the residual adhesive
7 on the driving cab side.
2
Be careful not to scratch the paint surfaces of the
driving cab.
5
2. Clean the cutting edge of the driving cab side
adhesive with petroleum solvent.
Driving Cab
Before opening the cap, waggle the base paint 24 for
Awl 1 minute so that it can be mixed fully.
After opening the cap, the base paint 24 should be
Cut 1~2 mm Depth form used as soon as possible and cover the cap
the old adhesive immediately after use. All the solvents should be used
within 3 days after they are opened (two hours
without a cap).
3. Apply primer (Sunrise MSI base paint 24),

apply the base paint to all the cutting locations
Driving Cab of the old adhesive, then wait for 15 minutes
Base Paint 24 until they become dry naturally.
The cut edge of old

adhesive at cab side The base paint should be applied evenly without flaw.
4. Apply alcohol to a clean cloth to wipe the

installing rim of the new glass that is to be
installed.
74
CONTENTS
Before opening the cap, waggle the base paint 24 for
1 minute so that it can be mixed fully. After opening
the cap, the base paint 24 should be used as soon as
possible and cover the cap immediately after use. All
the solvents should be used within 3 days after they
are opened (Two hours without a cap). 1
5. Apply glass base paint (Sunrise MSI base paint

35) to the integral location that need to be
applied with glass adhesive, and wait for 15
minutes until they become dry.
2
8~9 mm
6. Cut the nozzle of the adhesive tube (Sunrise
MSI SR sealant U90 4463876) to be V-type with
a knife.
13~15 mm 7. Remove the seal on the sealant canister end,
Cut tube nozzle
to be V-type and face
then install the V-type nozzle.
its raised side 8. Install the sealant canister into the hand 3
toward adhesive injector gun.
9. The sealant should form even triangle channel
while it is applied to the desired position.
10. The glass will be adsorbed within 5 minutes

after the sealant is applied. 4
Take off seal

Install the glass with retaining block as a match mark
Adhesive Tube onto the driving cab. Press-fit the glass. Before the
adhesive solidifies, clean all the adhesive outside of 5
the installation surface with petroleum solvent.
11. Before the adhesive hardens, hold the glass in

place securely with the tape to prevent it from
Adhesive Should
being out of alignment or peeling off.
Form Even Triangle
6
Hardening time of adhesive (Sunrise MSI SR

adhesive U90 4463876): 8 hours (Only for reference).
Glass
7
INDEX
75

Installation method of glass 3
Insert the glass into the groove from top to bottom
directly, then fix it with sealant securely.
Installation method of glass 4 and glass 6

1. Install the weatherstrip on the window frame and
door inside securely.
2. Install glass 4 and glass 6 into the window frame.
3. Apply special glue to the position (surrounding
areas) where the window frame is to be installed
on the driving cab door.
4. Install the window frame, glass 4 and glass 6 into
the driving cab door integrally on the driving cab
door.
6
Weatherstrip
Window Frame
6
76

Installation method of glass 8
1. The retaining rubber should be installed around
CONTENTS
8
the glass of the driving cab. Stick the joints of the
retaining rubber with adhesive (Standard 366
adhesive or equivalent).
Deteriorating of the rubber will cause the rubber to

1
retract, and be sure to leave longer and then press it
in with hand.
2. After installing the glass assembly to the driving

cab, fill the stopper into the rubber.
2
Retaining Rubber Side
Retaining Glass
Rubber
Inside of cab
A 3
A
Driving Stopper
Cab (Rubber Groove)
7
INDEX
77
SW wiring list
1.25R
7
02 FURM B G1 G2 ACC M ST
B Black 3
3
FL1
8
H
8 FUCD 20A FUM
Br(R) Umber 15A
OFF
60A 8
9 1.25R ACC
0.85W White 2 13
5A
ON
10 RL Red+Blue bar 8
START MRF
UPPER SWING PLATFORM - Air conditioning system
8
2
11 G Green CMB RLCD RLCC RLBM
13 15 13
M
12 0.5BL Black+Blue bar RLCC RLCD RLBM
9 10
GND
REC
FFE
13 0.5R Red+Blue bar 1
Vz
Pt
10 1.25L 15 2RL 1.25RL
16 16 19 25 24 22 26 25
1
14 Yellow D MR
0.5Y FLZ
MCD SPCD M 200W
15 0.5BR Black+Red bar RLSF 5 2 40A
M 11
1.256 10 2G 13 +B 16 19 25 24 26
5
16 0.5BrY Umber+Yellow bar 80W 10 10 BLCM
6 16 19 22 23 1
5
17 0.5BY Black+Yellow bar 1
SW 4 3
6 RLCH ACM
18 Green+White bar BAT BLC 2 12 12
0.5GW 8
19 0.5LO Blue+Orange bar 7 1
ACC
28 15 14 12 13 3 16 27 4 21 20 2 24 25 9 38 26 10
20 0.5PG Pink+Green bar 7 G 12 14 17 18 20 22 21 15 23 27 28 29 30 31 32 32 34 35
D1 9
21 0.5RY Red+Yellow bar RCD RLCH RLCH ECC THAM THW THI THF SSD
40W
22 0.5BW Black+White bar G 4 22
02 02 02 15 15 15
03 15
4 4
23 0.5LgR Light green+Red bar D2 30 31 22 32 15 33 34 35 35 22
CMB
1.25B
1.25B
3
24 SPHL
0.5VW Purple+White bar CM
0.85B
3-2. Air conditioning system
0.50
25 0.5YB Yellow+Black bar 02 02
2B
M M M
06 0.5B
26 0.5WO White+Orange bar 2B 2B
01 02 03
27 0.5PB Pink+Black bar 06 MAM MV1 MV2
Air conditioning circuit diagram
28 0.5VR Purple+Red
29 0.5BG Black+Green bar
30 0.5WY White+Yellow bar AC Air conditioner amplifier EC

M C Compressor clutch M AM A/M servomotor RL BM Blower main relay SP HL High/low pressure switch
31 0.5WR White+Red bar
BAT Power supply FL1 Fuse MB Blower motor RLCC Compressor realy SW Selector
32 0.5BrW Umber+White bar
33 0.5GO Green+Orange bar BLC Adjust speed thermistor FL2 Fuse MCD Condenser motor RLCD Condenser relay THAM Outside air thermistor
34 0.5Sb Light blue
CM Power supply relay
B
FU BM
Blower fuse M RF
Inside and outside air servomotor RL CH
Condenser high speed relay TH F
Anti-frost thermistor
35 0.5OW Orange+White bar
36 1.25V Purple D Diode FUCD Condenser fuse MV1 Air outlet servomotor RLSF Protective relay THI Inside air thermistor
37 1.25RG Red+Green bar FUM Air conditioner main fuse MV2 Front air outlet servomotor SSD THW Water temp. thermistor
D1 Diode 1 Insolation sensor
38 1.25RW Red+Orange bar
39 0.85GL Green+Blue bar D2 Diode 2 G Alternator RCD Condenser resistance SPCD Condenser pressure switch
78
1.

2. Positions of A/C components on the excavator
CONTENTS
2 3
1
4
5 1
C 2
C
A 3
C 6
B
C
4
7
1- Hot Water Guide 2- A/C Compressor 3- Refrigerant Line 4- Condenser 5

5- Reservoir 6- Hot Water Return 7- Refrigeration Unit 8- Duct: A. Outside Air B. Inside Air
Line C. Warm Air/Cool air
3. Fill of compressor oil
Certain amount of oil should be filled into the air conditioning system for lubricating, the compressor oil
is dissolved in the refrigerant and recycled in the whole system, the compressor oil will be retarded in
each component of the air conditioning system when the system is turned off, insufficiently lubricating 6
will be caused if a proper amount of oil could not be supplemented to the system when replacing main
components. The oil capacity that should be supplemented when replacing the main components is
shown in the following table:
Replacing Components
Compressor Condenser Evaporator
7
For details, see the precautions
Fill oil capacity (CC) 40 40
below
ND8# oil (10P, 10PA, 10S serial compressor)
INDEX
Compressor oil type

ND9# oil (TV serial compressor)
79
Replaced Compressor
New Compressor
x The new compressor should be filled with

sufficient oil as the recycling system desired, and
discharge the redundant oil when replacing the
compressor next time.
x Improper amount of compressor oil filling: the
Clear cooling capability will reduce if excessive amount
Unnecessary
Oil
of compressor oil is filled in the air conditioning
(A B) system, and there may be a malfunction in the
A B
compressor if there is insufficient compressor oil
in the system.
x Please keep the cleanness of the pipe union and
the O-seal ring when removing the compressor.
External Paint
4. Installation of compressor assembly and

adjustment of belt
x Installation of line:
When installing the line, connect the line correctly (As
shown in the illustration); the thread should be
connected according to specified torque, and use torque
wrench to connect the lines.
OK NG
1. Avoid using the O-ring that has been used;

2. The tightening torque of the 4 bolts used to fix the
compressor:
24.5 - 29.4 Ngm;
3. Manual inspection: press the center between the
drive pulley and the compressor wheel with a
finger (With a strength approximate to 6 kg (58.5
N), normal pulley will deform for about 5-8 mm)
4. Tension gauge inspection: check the tension of
compressor belt with tension gauge.
New Belt
Belt that has been used
(Belt that has not been used)
637 r 108 N 441 r 88.2 (N)
80

x Compressor test running:
Compressor test running time: the compressor should
CONTENTS
5~8 mm
run more than 10 minutes in idling state when the A/C is
ON.
1. Never increase the speed in the middle of running

when the test running is being performed, and
1
keep the idling speed until the test running is
finished.
2. During test running, the intake temperature of the
COOLING UNIT keeps for more than 15qC
generally, and A/C is kept ON for more than 10
minutes.
2
In winter or when the air conditioning is not used for a

long time (More than 3 months), turn on the air
conditioning periodically and let it run more than 10 3
minutes to prevent the A/C compressor from stuck for
lack of oil.
5. Inspection of condenser fins

Always check if there is any mud, dirt and leaves, etc. on the condenser fins after using for a period of
time; clear it off with compressed air, vapor or water. 4
1. There may be personal danger if human body suffers from impact of compressed air, vapor or
water directly. Be sure to wear safety glasses, mask and safety shoes.
2. To prevent the fins from being damaged, there must be a certain distance between the 5
compressed air nozzle and the fins. Damaged fins may result in leakage or overheating. Check
the fins daily without the limit of maintenance interval in those working places where there is too
much dust.
6. Maintenance of air cleaner

x Air cleaner is installed on the intake side of the 6
inner circulation duct of the A/C refrigeration unit in
the driving cab to purify the air; if the cleaner is
blocked, it will affect the blowing of wind or cause
the wind cannot be blown out; affect the working
performance of the air conditioning directly.
x Clean the air cleaner with compressed air, and use 7
neutral washer fluid if there is grease on the
cleaner or it is too dirty. Dry it thoroughly after
washing and then reuse it. Replace it with a new
one if the blocked air cleaner cannot be cleaned
INDEX
with air or water.
Air Filter Screen
81
The interval of normal cleaning time is 500 hours,

however, the maintenance interval should be
shortened if the air cleaner is used in those places
with too much dust.
7. Evacuation task
x Reason for vacuum extract
The most important precaution for A/C unit installation is that there should not be water in it. The
refrigerant (R134a) used in the air conditioning is dissolvable to water, and malfunctions such as
icing of the expansion valve hole and rust of compressor valve will be caused if there is a little
water left in the unit. Therefore, remove the water in the cooling system as possible before filling
the refrigerant as much. To decrease the residual water amount in the cooling system to the
minimum, there is no better method than vacuum extract to remove the water by boiling and
gasifying it in the unit.
x Vacuum extract essentials
Vacuum extract finish
Vacuum extract start
Air leakage check

Add refrigerant R134a
Air leakage check
Performance test
Add refrigerant
sealing check
75 cm-Hg or more
about more than Wait for 5 Pressure

15 minutes minutes gauge
indication
is normal
Pressure gauge indication is abnormal
Pipe interface is tightened (1) Stop the compressor, refill from the high pressure
Repair the leakage location (2) The compressor is running, fill the refrigerant from the low pressure
x Procedures of vacuum extract:
(a) Connection of manifold gauge

Valve Low Pressure Gauge (1) The high pressure valve (HI) and low
LO HI Above 750 mmHg LO HI pressure valve (LO) of manifold gauge are
ON ON OFF OFF
Low Pressure turned off.
Gauge High Pressure
(2) Connect the inflation hose (red, blue) to the
Gauge
compressor auxiliary valve.
Low Pressure High Pressure Red hoseĂĂhigh pressure side (Mark D)
Valve (ON) Valve (ON) Blue hoseĂĂlow pressure side (Mark S)
Green Red D
Blue
S
Press the compressor auxiliary valve at the side
where there is L-bend on the inflation hose's front
Vacuum Pump Compressor
(Running) end, and the compressor inner valve cannot be
opened when the hose is connected reversely. In
addition, be careful not to connect the high pressure
and low pressure sections reversely.
(3) The inflation hose (green) in the middle of

the manifold gauge is connected onto the
vacuum pump.
82

(b) Vacuum extract
(1) Open the high pressure valve (HI) and low
CONTENTS
pressure valve (LO) of manifold gauge;
(2) Turn on the vacuum pump switch to perform
the evacuation task (About 15 minutes);
(3) Turn off the vacuum pump switch and close
the high and low pressure valves of the
manifold gauge when the gauge's negative
pressure scale (Vacuum level) reaches more 1
than 750 mmHg.
Valve
(c) Seal inspection
Low Pressure (1) Make sure that the pressure reading does
LO HI Place more than 5 minutes Gauge Needle
OFF OFF not return to zero when the high and low
Returns to 0
Low Pressure Gauge pressure valves of manifold gauge are 2
placed for 5 minutes in closing state.
(2) When the needle of the manifold gauge
Needle returns to 0, it indicates that there is a
Returns leakage somewhere, thus the union section
To 0 Tighten tube union of the hose needs a further correction,
perform vacuum extract again after
3
tightening it up until there is no leakage.
(d) Gas leakage inspection
(1) Connect the inflation hose (Green) which
was formerly connected to the vacuum
pump onto the freon tank.
(2) The inflation hose (Green) is connected to 4

Valve the manifold gauge, open the valve for freon
LO HI
OFF OFF hose, then press the air bleeder (Be careful
not to press it by hand directly to prevent
Bleeder Valve
frostbite caused by sprayed refrigerant),
bleed the original air in the inflation hose by
the pressure of refrigerant (Release the air 5
Turn On Freon
Bleed Tank Valve bleeder when the sound of "zi" is heard).
(3) Fill the refrigerant until the low pressure
Inflation Hose reading reaches 1 kgf/cm2, at this time the
(Green) high pressure valve of the manifold gauge is
Blue open, then close it after filling is finished.
R134a
Red (4) For caution, check whether there is a 6
Freon Tank leakage with a gas leak detector in the
To Compressor
cooling system.
7
INDEX
83

(5) Correction (tightening) is needed if there is a
Low pressure gauge leakage somewhere.
Valve reading 1 kg
LO HI 1 kgf/cm2 LO HI
Low Pressure OFF ON OFF OFF
Gauge Reading
1 kgf/cm2
Turn on High
Low Pressure Pressure Valve
Valve (OFF)
D
S
R134a
Freon Tank
Freon Tank Valve (ON) Compressor
8. Filling of refrigerant
x Filling method and amount of the refrigerant:
(1) Verifying the kinds of the refrigerant filled:
HFC-134a;
(2) Refrigerant filling-in tolerance: 900 r 50 g
(For reference);
(3) Filling-in method of refrigerant: it is
prohibited to fill the liquid refrigerant from the
low pressure side. If the operation fails and
needs to be performed again, fill it after the
filled refrigerant is discharged.
Sight Glass x Check the flowing state of the refrigerant in the A/

C recycling system through the sight glass:
(1) Proper amount filling: the bubble can hardly
be seen when the refrigerant is flowing.
When the engine is accelerated from idling
speed to 1500 r/min, the bubbles disappear
Proper amount and refrigerant becomes transparent.
filling (2) Excessive amount filling: no bubble can be
seen when the refrigerant is flowing.
(3) Insufficient amount filling: bubbles can be
seen frequently when the refrigerant is
Insufficient amount flowing.
filling
9. Filling refrigerant operation
After vacuum extract task is finished, fill the refrigerant into the cooling system according to the
essentials below.
84
CONTENTS
Vacuum extract finish
Vacuum extract start
Air leakage check

Add refrigerant R134a
Air leakage check
Performance test
Add refrigerant
sealing check
75 cm-Hg or more
about more than Wait for 5 Pressure

15 minutes minutes gauge
indication
is normal
Pressure gauge indication is abnormal
1
Pipe interface is tightened (1) Stop the compressor, refill from the high pressure
Repair the leakage location (2) The compressor is running, fill the refrigerant from the low pressure
x Fill from the high pressure side

Valve 2
LO HI
(1) Remove the inflation hose (green) of the
OFF OFF (NOTE) manifold gauge from the vacuum pump, then
Refrigerant is
connect it to the freon tank.
discharged
when hiss is heard (2) Open the freon tank valve, press the air
bleeder on the manifold gauge side, and
Bleeder
Turn on Freon bleed the air in the same inflation hose by
Valve
Tank Valve the refrigerant pressure. 3
Loosen the bell
mouth type nut Inflation Hose
(Green)
The refrigerant is discharged accompanying with the
Blue R134a
Red sound of "zi", then release the bleed valve. To prevent
To Compressor Freon Tank frostbite, never press the air bleeder by hand directly. 4
(3) When the engine is stopped, open the high
pressure valve and freon tank valve of the
manifold gauge and fill one and a half tank of
refrigerant (About 600 g).
5
Valve Fill a tank

LO HI (about 600 g) LO HI x Never operate the compressor at this time, once it
OFF ON OFF OFF
(Forbidden) is running, dangers may occur due to crack of
gDo not operate the compressor freon tank and hose caused by refrigerant return.
gDo not turn on the low
pressure valve x Another reason is that the compressor will burn if 6
Low Pressure Turn on the High it is operated without refrigerant. Thus, never
Valve (OFF) Pressure Valve operate the compressor.
D x Do not open the low pressure valve of the
manifold gauge (The compressor will be damaged
S
R134a
due to liquid compression).
Freon Tank Valve (ON)

7
(4) Close the high pressure valve and the freon
tank valve on the manifold gauge.
INDEX
85

x Fill from the low pressure side (supplement fill)
High Pressure
Manifold (1) Firstly, make sure that the high pressure
Valve OFF ON
Gauge valve of the manifold gauge is closed.
(2) Start the engine and open all the doors.
HI (3) Turn on the air conditioning switch;
temperature controlü"The coldest" position.
(NOTE) Start Engine (4) Set the engine speed to 1,300~1,500 rpm.
Opening the high pressure
valve will break the Freon tank, 1300~1500 rpm (5) Open the low pressure valve and freon tank
resulting in serious injury. valve of the manifold gauge to fill the
refrigerant into the reservoir until bubbles
cannot be seen.
OFF
Reading of manifold gauge (for reference):
TEMP
MODE AUTO
High pressure 13~17 kgf/cm2 (When the outside
A/C
temperature is 30qC);
Low pressure 1.5~2 kgf/cm2 (When the outside
Temperature Control Button temperature is 30qC).
Fill until no bubble can be (6) Close the low pressure valve and the freon
seen from the observation glass tank valve of the manifold gauge after the
Valve
LO HI LO HI
filling operation of refrigerant is finished.
Low Pressure
Gauge
ON OFF OFF OFF (7) Using a gas leak detector, check whether
(1.5~2.5 kgf/cm2) High Pressure Gauge there is a leakage carefully.
(13~17 kgf/cm2)
Turn Low High Pressure
Pressure Valve ON Valve (OFF)
Freon Tank (Never turn it on)
Valve (ON) x Never open the high pressure valve (HI) of the
manifold gauge. Once the high pressure valve is
opened, the high pressure gas will flow oppositely,
which will cause crack of the freon tank and
Freon Tank inflation hose and lead to danger (cause serious
(Never invert it) Compressor is running
injury);
x Never invert the freon tank. (In situations when the
engine is started and filled). If the freon tank is
inverted, the liquid refrigerant will be sucked into
the compressor directly leading to liquid
compression, which will damage the valve and
gasket of the compressor. The freon tank should
be placed vertically, and the refrigerant is filled as
gas.
86

(8) Areas where the outside temperature is low
Fill until no bubble can be seen
When the filling of refrigerant cannot be
CONTENTS
from the sight glass
Valve performed because of low temperature
LO HI LO HI outside, put the freon tank in warm under
ON OFF OFF OFF
40qC to increase the pressure of the
Low Pressure refrigerant in the freon tank and then fill.
Valve (ON)
(9) Areas where the outside temperature is high
High Pressure
Freon Tank Oppositely, cooling the compressor with a
Valve (OFF)
Valve (ON) fan when the outside temperature is high will 1
help the filling to be performed smoothly.
Lukewarm below 40°C Compressor is running

(Hot water is forbidden)
2
x Replacing freon tank
Handwheel Replace the new freon tank according to the following
essentials if the refrigerant is exhausted during the
filling.
(a) Close the high pressure valve and low
Inflation hose 3
interface
pressure valve of manifold gauge.
(b) Lift the needle and circular plate of the valve
Needle Valve for freon tank to remove the empty tank.
Bush (c) Install the new freon tank onto the valve.
Circular Plate (d) Remove the air in the inflation hose as the
following methods.
Freon Tank
(1) Tighten the freon tank valve firstly and 4
then release a little;
(2) Open the low pressure valve of the
manifold gauge a little;
(3) Press the air bleeder and the
refrigerant is bled simultaneously,
close the freon tank valve and the low 5
pressure valve of the manifold gauge.
Valve The refrigerant is

LO HI
Slight ON OFF
discharged when a
"hiss" is heard, turn To prevent frostbite, never press the air bleeder by
off the low pressure hand directly. 6
valve immediately
(e) Turn the handle of the freon tank valve to
Slightly loosen the open the freon tank, and continue the filling
freon tank valve
Low operation.
Pressure
Valve 7
Green
Blue
R-134a
Red
to Compressor Freon Tank

INDEX
87

10. Performing malfunction detection with manifold gauge
How to detect the system malfunction with manifold gauge will be introduced in the following
methods:
After the engine is warmed up, read out the pressure value on the manifold gauge in the special
conditions below.
(a) The temperature in the air intake is 30~35qC.
(b) The engine speed is 1,500 r/min.
(c) The speed of the blower is in high position.
(d) The temperature control is set in "the coldest position".
(e) Set in "recirculation" position.
x Refrigeration system under normal state
Measure gauge reading:
Low pressure side 0.15~0.25 MPa (1.5~2.5 kgf/cm2)
High pressure side 1.37~1.57 MPa (14~16 kgf/cm2)
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5 30
{cmHg kgf/cm2} 05 {cmHg kgf/cm2}
0 8 3
-50 8.5 0
0 08
-76 -76 35
085 0
-01 15 -01 35
MPa MPa
R134a
/2 +,
x Water appears in the refrigeration system

Situation: intermittent refrigeration, and no refrigeration at last
88
CONTENTS
04 15 2
03 05
4 15 20
3 5
1
02 06
6 10 25
2 25
7
1
01 07 5 30
8
0
0
-50 8.5 0
3
1
-76 08 -76 35
085 0
-01 15 -01 35
MPa MPa
2
Symptoms occurred in Troubleshooting
Possible Cause Diagnosis
refrigeration system procedure
x The water that enters x Dryer is in
the refrigeration oversaturated state. x Replace the receptor/
x When the system is
system is iced in the x The water which dryer.
operating, sometimes
expansion valve, enters the x Remove the water in
the pressure on the 3
which cause the refrigeration system is the system by
low pressure side is
circulation stopped iced in the expansion extracting
vacuum and
temporarily, however, valve, which will ceaselessly.
sometimes it is
normal operation will prevent the circulation x Fill a proper amount
normal.
be resumed after the of the refrigeration of new refrigerant.
ice melts. system.
x Insufficient cooling 4
Condition: Insufficient cooling
7
INDEX
89
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08 -76 35
-76
085 0
-01 15 -01 35
MPa MPa
Symptoms occurred in
Possible Cause Diagnosis Troubleshooting procedure
refrigeration system
x Check for gas leakage with
x Pressure is lower on leak detector, and repair if
both low and high necessary.
x Gas leakage
pressure sides x Insufficient refrigerant x Fill a proper amount of
occurs in the
x Bubbles can be seen in the system. refrigerant.
refrigeration
through sight glass x Refrigerant leaking. x If the pressure value closes to 0
system.
continuously when connected to gauge,
x Insufficient cooling create vacuum after inspecting
and repairing the system.
x Poor circulation of refrigerant

Condition: Insufficient cooling
04 15 2
03 05
4 15 20
3 5
1
02 06
6 10 25
2 25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08 -76 35
-76
085 0
-01 15 -01 35
MPa MPa

x Pressure is lower on
both low and high
x Refrigerant flow is
pressure sides.
obstructed by the dirt x Reservoir clogged x Replace reservoir
x Frost exists on the
in reservoir
pipe from components
to reservoir.
x No circulation of refrigerant
Condition: No refrigeration (Intermittent refrigeration in some conditions)
90
CONTENTS
04 15 2
03 05
4 15 20
3 5
1
02 06 25
2 6 10 25
7
1
01 07 5 30
8 3
0
0
-50 8.5
08
0 1
-76 -76 35
085 0
-01 15 -01 35
MPa MPa
2
Symptoms occurred in
Possible Cause Diagnosis Troubleshooting procedure
refrigeration system
x Refrigerant flow
x Vacuum indicated on x Check the expansion valve and
is obstructed by
low pressure side, EPR.
the water or dirt
and extremely low x Clear the dirt in the expansion
in refrigerant.
pressure indicated on valve by blowing air. If ineffective,
x Refrigerant flow 3
high pressure side. x No circulation replace the expansion valve.
is obstructed by
x Frost or condensation of refrigerant. x Replace receiver.
gas leakage
is seen on piping on x Evacuate air and fill a proper
around the
both sides of amount of refrigerant. Replace
expansion valve
expansion valve or the expansion valve if gas leaks
thermosensitive
receiver/drier. around thermosensitive pipe.
pipe.
4
x Refrigerant overcharged or insufficient refrigeration of condenser
Condition: insufficient cooling
7
INDEX
91
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08 35
-76 -76
085 0
-01 15 -01
35
MPa MPa

x Clean the condenser.
x Excessive refrigerant
x Check the operating
x Pressure is extremely in the system o
x Excessive refrigerant condition of the fan
high on both low and refrigerant is filled
in the system causes motor.
high pressure sides. excessively.
insufficient cooling x Check the refrigerant
x No bubble can be x Condenser will not
performance. amount if both of the
seen even if the cool efficiently o
x The refrigerator cools first two conditions
engine speed is condenser fins are
insufficiently. are normal. Fill a
decreased. clogged or the fan
proper amount of
motor malfunctions.
refrigerant.
x Air exists in the refrigeration system

Condition: poor cooling
The following conditions will occur on the gauge reading if refrigerant is filled after the refrigeration
system is opened without vacuum extract.
92
CONTENTS
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5 30
8
0
-50 8.5 0
3
1
0 08 -76 35
-76
085 0
-01 15 -01 35
MPa MPa
2
x Pressure is extremely
high on both low and
high pressure sides; x Check whether the
x Air enters the
x The low pressure compressor oil is not
x Air enters the refrigerant system; 3
hose is hot while clean or insufficient;
refrigerant system. x Insufficient vacuum
touching; x Deflate the air and fill
extract.
x Bubbles can be seen new refrigerant.
through the sight
glass.
x Incorrect installation of expansion valve/heat-variable hose defect (The opening is too wide)
Condition: Insufficient cooling 4
04 15 2
03
4
05
15 20
5
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08
-76 -76 35
085 0
-01 15 -01 35
MPa MPa

x Pressure is extremely x Check the installation 7
high on both low and condition of heat-
high pressure sides; x Malfunction in x Excessive refrigerant variable hose;
x Frost or a large expansion valve or in low pressure hose; x Check expansion
amount of incorrect installation x Expansion valve valve if the above
INDEX
condensation on of heat-variable hose opening is too wide. conditions are normal

piping on low and replace it if there
pressure side. is a defect.
93

x Compression failure of compressor
Condition: not cold
04 15 2
03 05
4 15 20
3 5
1
02 06
6 10 25
2 25
7
1 5
01 07 30
0 8 3
-50 8.5 0
0 08 -76 35
-76
085 0
-01 15 - 01 35
MPa MPa

x Pressure is extremely
high on low pressure x Compression failure;
side; x Internal leakage in x The valve leaks or is x Repair or replace
x Pressure is extremely compressor damaged, and the compressor
low on high pressure parts drop.
side.
94
UPPER SWING PLATFORM - Removal and installation of balance weight
3-3. Removal and installation of balance weight
CONTENTS
3-3-1. Removal
Weight of balance weight: 3,900 kg

1
1. Remove the cap (1) from the balance weight.
Install lifting bolt onto balance weight.
1
Lifting bolt specification (B-48: M48, pitch 3.0)

2
2. Install the steel wire rope onto the lifting bolt

Steel Wire Rope with lifting eyes. Tighten the steel wire rope 3
with a crane or an elevator to eliminate slack.
Lifting Bolt
3. Remove the set bolt (2) from the balance

weight. Lift it with a crane or an elevator and
remove the balance weight.
: 41 mm (1.6 in)
5
2 6
7
INDEX
95
UPPER SWING PLATFORM - Removal and installation of balance weight
3-3-2. Installation
1. Lift the balance weight (3) and install it onto

the excavator with a crane.
Install the washer (4) and tighten the set bolt
3
(2) onto the balance weight temporarily.
: 41 mm (1.6 in)
2
4
2. Remove the steel wire rope. Tighten the set

bolt of the balance weight with the super
wrench and torque wrench.
: 41 mm (1.6 in)
: 1323r147 Ngm (135r15 kgfgm, 976r108 lbfgft)
Super Wrench Torque Wrench
3. Remove the lifting bolt. Install the top cap (1)

onto the balance weight.
1
96
UPPER SWING PLATFORM - Removal and installation of main frame
3-4. Removal and installation of main frame
CONTENTS
The liquid sprayed under high pressure can penetrate the skin and cause a serious injury.
To avoid this kind of danger, release pressure before disconnecting the hydraulic pipe or other
pipes.
The hydraulic oil is hot just after the work is finished. The hot hydraulic oil may spray out and cause 1
serious burns. All the repairing work should begin after the hydraulic oil cools.
If the inner pressure is not released at first when removing the hydraulic oil tank top cap, the header
may fly off. Push the air bleed valve on the top of hydraulic tank to release all the residuary
pressure.
Preparation 2
1. Stop the excavator on a solid and flat ground.
2. Stop the engine. Push the air bleed valve on
the top of hydraulic tank to release all the
residual pressure.
3. Remove the header on hydraulic tank, and 3
connect a vacuum pump to maintain negative
pressure in the hydraulic tank. Keep the
vacuum pump running continuously during
operation.
Removal 4
Driving cab weight: 380 kg (838 lb)
1. Remove the driving cab (See "Removal of

driving cab" in this section). 5
: 36 mm (1.42 in), 27 mm (1.06 in), 13 mm (0.51

in)
: 8 mm (0.31 in), 14 mm (0.55 in) 6
2. Remove the balance weight.

(See "Removal of balance weight" in this 7
section. )
: 41 mm (1.6 in)
INDEX
97
Work device weight:

4,025 kg (8873 lb) (SY205C8M)
4,055 kg (8939 lb) (SY215C8M)
3. Remove the work device assembly.

(See "Removal of work device" in this section.)
: 20 mm (0.87 in), 24 mm (0.95 in)
: 8 mm (0.31 in)
4. Remove all the hoses on the central connector
upper side. Then remove the stopper.
: 17 mm (0.67 in), 19 mm (0.75 in), 22 mm (0.87
in), 27 mm (1.06 in), 36 mm (1.42 in)
Upper swing platform: 4,268 kg (9409 lb)
5. Connect the steel wire rope to the rear side of

the frame (Balance weight bracket ) and the
boom bracket. Then tighten the steel wire rope.
If the trundle (1) is used, not only the
adjustment of angle of steel wire rope, but also
the balance of frame will be realized easily.
Rear Side
Never have the rear hanger touch the engine.
Front Side
98

6. Make match marks on the outer gear ring of
the upper swing platform and swing
CONTENTS
supporting bearing.
Loosen and remove the set bolt (2) on swing
supporting bearing.
: 30 mm (1.18 in)
2
1
There are special regulations for installing angle of
the swing supporting bearing. Please refer to this
manual.
7. Use guide sprocket wheel group (1) to adjust

1 the frame and keep its balance, then lift the 2
frame slowly and remove it from under
tracking carriage.
Installation
4
Upper swing platform weight: 4268 kg (9409 lb)
1. Tighten up the steel wire rope on the main

2
frame. Adjust guide sprocket wheel group (1)
to keep the main frame balance.
Lift the main frame with a crane and install it
1 5
on the under tracking carriage.
For lifting method, see Section "Removal".
2. Align match marks on outer gear ring of upper
swing platform and swing supporting bearing.
Install set bolt (2) on swing supporting bearing
and tighten it temporarily. Remove the steel
wire rope, tighten the set bolt on swing 6
supporting bearing to the specified torque.
: 30 mm (1.18 in)
: Swing unit side:
510 Ngm (52 kgfgm, 376.5 lbfgft)
Track side:
7
490 Ngm (50 kgfgm, 362 lbfgft)
3. Connect all the hoses to the central swing
joint.
: 17 mm (0.67 in)
INDEX
: 25 Ngm (2.5 kgfgm, 18.5 lbfgft)

: 19 mm (0.75 in)
99

: 27 mm (1.06 in)
: 93 Ngm (9.5 kgfgm, 69 lbfgft)
: 36 mm (1.42 in)
: 175 Ngm (18 kgfgm, 129 lbfgft)
4. Install the stopper and bolt to the central swing
joint.
: 22 mm (0.87 in)
Driving cab weight: 380 kg (838 lb)
5. Install driving cab (3).

(See "Removal and installation of driving cab
" in this section.)
3
: 13 mm (0.51 in)
: 6 mm (0.24 in)
: 19.5 Ngm (2 kgfgm, 14.5 lbfgft)
: 36 mm (1.42 in)
: 27 mm (1.06 in)
Weight of the balance weight: 3,900 kg
6. Install balance weight (4).

(See "Balance weight" in this section. )
: 41 mm (1.61 in)
4 : 1323r147 Ngm (135r15 kgfgm, 976r108 lbfgft)
Work device weight:

4025 kg (8873 lb) (SY205C8M)
4055 kg (8939 lb) (SY215C8M)
7. Install work device module (5). Then fill

hydraulic oil.
5 (See "Removal and installation of work device"
in this section. )
: 24 mm (0.95 in)
: 8 mm (0.31 in)
: 22 mm (0.87 in)
100

8. Start the engine and place the work device as
shown in the illustration to check the hydraulic
CONTENTS
oil level in the oil tank. Check hydraulic oil
level and check whether there has oil leakage.
7
INDEX
101
UPPER SWING PLATFORM - Removal and installation of the pump unit
3-5. Removal and installation of the pump unit
3-5-1. Removal and installation of the main pump
The liquid sprayed under high pressure can penetrate the skin and cause a serious injury. To avoid
this kind of danger, release pressure before disconnecting the hydraulic pipe or other pipes.
The hydraulic oil is hot just after the work is finished. The hot hydraulic oil may spray out and cause
serious burns. Don't repair until hydraulic oil cooling down.
If the inner pressure is not released at first when removing the hydraulic oil tank header, the header
may fly off. Push the air release valve on the top of hydraulic tank to release all the residual
pressure.
Preparation
2. Stop the engine. Push the air release valve on
the top of the hydraulic oil tank and release the
residual pressure completely.
3. Remove the hydraulic oil tank header. Connect
a vacuum pump to keep negative pressure in
the hydraulic oil tank.
Keep the vacuum pump continuously rotating or drain

the hydraulic oil in the hydraulic oil tank thoroughly.
Removal
1 2 3 4 1. Remove the connector.
Main pump weight: 120 kg
2. Disconnect the hoses (1~4), pipe joint (5),

intermediate flange (6), oil suction steel pipe
(7) and suction hose (8) from the main pump.
: 36 mm
: 8 mm, 10 mm
Do not install the lifting eye bolt on the adjuster with

5 6 7 8 the solenoid valve.
3. Install the lifting eye bolt (M10, pitch 1.5) on the

main pump, then connect it to the crane.
4. Remove the Lifting set bolt of the main pump,
and remove the main pump.
: 17 mm
102

Installation
CONTENTS
1. Install the lifting eye bolt (M10, pitch 1.5) on the main pump, then lift it up with the crane.
2. Insert the propeller shaft of the main pump into the coupling, and install the main pump
with the main pump set screw.
: 17 mm
Engine Screw, Washer End Cover 1

Screw
Screw, Washer
Coupling 2
Lifting Eye Bolt
Main Pump 3
Lifting Eye Bolt
4
3. Connect the joint pipe (1~4), pipe joint (5), intermediate flange (6), oil suction steel pipe
(7) and suction hose (8)
Wrench Size Tightening Torque
Remark
(mm) Ngm kgfgm (37 lbfgft)
: 27 93 9.5 (69) Hose 5
: 36 175 18 (130) Hose
: 10 90 9.2 (67) Bolt
: 17 175 18 (130) Screw
:8 50 5.1 (37) Bolt 6

: 19 29.5 3 (21.5) Hose
Bleed the air in the pump.

7
Be sure to inspect the level of hydraulic oil and check for leakage after assembling.
: 27 mm
INDEX
103
3-5-2. Removal, installation essentials of pump body

1. Tools
Required bolts and inserted pins needed when removing and installing the K3V pump body (see
the following table).
ƻ Mark Indicates
Tool Name and Required Tool Part Name
Specification
Pump Type
PT Hole Inner
Inner PO Pin
K3V K3V K3V K3V Bolt Hexagon
Name B Hexagon (PF
63 112 140 180 (PT Lock
Bolt Screw)
Screw) Screw
2 M4
2,5 M5
3 M6
4 ƻ ƻ ƻ ƻ M5 BP-1/16 M8
Inner hexagon
wrench 5 ƻ ƻ ƻ ƻ M6 BP-1/8 M10
6 ƻ ƻ ƻ ƻ M8 BP-1/4 PO-1/16 M12 M14
8 ƻ ƻ ƻ M10 BP-3/8 PO-3/8 M16 M18
10 M12 BP-1/2 PO-1/2 M20
12 M14
14 ƻ M16M18 BP-3/4 PO-3/4
B
PO111/4
17 ƻ ƻ ƻ M20M22 BP-1
11/2
19 M24M27
21
22 M30 PO-2
19 ƻ ƻ ƻ ƻ M12 M12 VP-1/4
"Torx" wrench
Open spanner 22 VP-3/8
(double ended,
24 ƻ ƻ ƻ M16 M16
single ended)
27 ƻ ƻ ƻ M18 M18 VP-1/2
B
30 ƻ ƻ ƻ M20 M20
36 ƻ ƻ ƻ VP-3/4
41 VP-1
50 VP-1 1/4
55 VP-1 1/2
Monkey wrench ƻ ƻ ƻ ƻ Middle type One
Screwdriver ƻ ƻ ƻ ƻ Middle type slotted screwdriver Two
Hammer ƻ ƻ ƻ ƻ Rubber hammer One
Needle nose
ƻ ƻ ƻ ƻ Used for locking the retainer TSR-160
plier
Brass bar ƻ ƻ ƻ ƻ Forgeable brass bar about 10×8×200
Wrench that can be circumrotated tightly according to
Torque wrench ƻ ƻ ƻ ƻ preset torque
104

2. Removal essentials
When removing the pump, please read the book of removal essentials carefully and remove,
CONTENTS
disassemble successively as the following requirement.
The number in brackets next to the part name indicates the part number in structure
disassembling drawing (attached diagram 1) of the pump.
The repair manual is applicable for the monomer pump and binary pump. Please remove and
disassemble according to requirement in the table of pump type.
Please do not mix parts of various kinds of pump components together when disassembling the
binary pump. 1
7
INDEX
105

3. Disassembly of main pump
413
263
710
049
113
724
719
314 885
124
901 886
534 808
792 702 725
532 954
466
728 468
A 490 886
312/313 312 885
719
271 114
B 124
531 548
717 313
732 490
141
789
535 251
157
886
953 158
401 156
808
153
111 151
152
211
127
B
123
214
127 212
824 A
774
710
261
406
106

4. Disassembly of main pump
CONTENTS
No Contents for Operating Precautions Type
1 Select the removal place. (a) Choose a tidy and clean place.
(b) Lay rubber plate or working cloth,
etc. on the workbench to prevent
the components from being
damaged.
2 Please wipe off the rubbish, rusty stain, etc.
on the pump surface with washer fluid and so 1
on.
3 Take away the oil-bolted cover on the pump (a) Drain the oil from the inserted pin
housing and drain the oil in pump body. port of the front pump and rear
pump for the series pump.
4 Remove the hexagon bolts (412, 413) and (a) For removal of the adjuster,
take away the adjuster. please refer to the repair 2
instruction of adjuster.
5 Loosen the hexagon bolt (401) fixed on the (a) When the back of pump is fixed
whirling supporting table of tilting plate (251), with pump attachment, first 4
pump housing (271), valve body (312). remove the pump attachment
then operate the next step.
6 Put the pump and adjuster on the workbench (a) To avoid destroying the mounting
horizontally with the mounting surface facing surface, the rubber plate must be
downward, remove the pump housing (271) laid on the workbench when the
and valve body (312). mounting surface of adjuster
faces downward.
5
7
INDEX
107

7 Align the drive shaft in the pump housing (a) Prevent the cylinder, spherical All types
(271), take out the cylinder block (141), piston surface bush, rail, sliding surface
(151), clamp plate (153), spherical surface of piston shell from being
bush (156), oil cylinder spring. damaged.
8 Remove the inner hexagon bolt (406), and (a) The cover plate can be easily Size of
remove the seal cover (F) (261). taken out by installing plucking plucking hole
bolt in the plucking hole of the K5V80: M6
seal cover (F). K3V63: M6
(b) Oil seal ring is installed on the
seal cover (F), be careful not to K3V140: M8
damage it while installing and K3V180: M8
removing. K3V280: M8
9 Remove the hexagon bolt (413), and remove

the rear cover plate (263).
10 Tap the flange plate of the supporting table of
tilting plate (251) on the pump side to
separate the pump case from the supporting
table.
11 Remove the tilting plate (212), piston shell
(211) from the pump housing (271).
108
CONTENTS
12 Tap the shaft end surface of propeller shafts
(111, 113) with a plastic hammer, etc. Pull out
the drive shaft from the supporting table of
tilting plate.
2
13 Take out the orifice plates (313, 314) from the (a) When operating Step 6, the orifice All types
valve body (312). plate often falls off.
4
14 If it is necessary, take out the stopper (L) (a) Please use clamp to remove the All types
(534), stopper (S) (535), auxiliary piston tilting pin to prevent the head of
(532), tilting pin (531) from pump body (271), tilting pin from being damaged.
and take out the needle roller bearing (124), (b) As the jogged side of tilting pin
spline connecting shaft (114) from valve body and auxiliary piston is applied
(312). with the hard glue, please do not
damage the auxiliary piston. 5
(c) Do not pull out the needle roller
bearing except for considering the
bearing life.
(d) Do not loosen the hexagon nuts
on valve body and supporting
table of tilting plate, otherwise the
flow setting can be changed. 6
5. Installation of main pump
The installation procedures are the removal procedures in reverse order; please pay attention to
the following items.
(a) Be sure to repair the damaged components when removing, prepare the new component
for replacing beforehand.
(b) Clean the components with washer fluid, blow them clean with air before installing. 7
(c) Moving parts, bearing, etc. must be applied with actuating oil before installing.
(d) Sealing parts such as O-ring, oil seal, etc. should be replaced in principle.
(e) Mounting bolt, inserted pin of each part should be tightened according to the specified
torque in "Repair Standard" with the wrench.
INDEX
(f) Please do not mix the parts of series pump, front and back pumps together.
109

1 Tap the supporting table of tilting plate (251) (a) Before removing the auxiliary All types
into pump housing (271) with the hammer and piston, the tilting pin, the stopper
install it securely. (L), the stopper (S), install them
on the pump housing beforehand.
(b) When tightening the auxiliary
piston and the tilting pin, please
use the clamp to avoid damaging
the top of tilting pin and the
feedback pin. Besides, apply the
part of screw with the hard glue
(middle strength).
2 With the mounting surface of the pump body (a) Confirm if the plate moves flexibly All types
and the adjuster facing downward, install the by the finger tips.
bush in the tilting pin (531) tilting plate, install (b) Apply the lubricant to the swash
the tilting plate (212) correctly in the plate, the supporting table of
supporting table of tilting plate (251). tilting plate, the driving part to
make the installation of propeller
shaft easily.
3 Install the assembled bearing (123), the (a) Do not tap the propeller shaft with All types
bearing retaining plate (127), the drive shaft of the hammer.
blocking ring (824) into the supporting table of (b) Tap the bearing outer race with
tilting plate (251). the rubber hammer, knock it in
drastically with the brass bar.
110
CONTENTS
4 Install the seal cover (F) (261) into the pump (a) Please apply thin lubricant to the All types
housing (271), and secure it with the inner oil seal in the seal cover (F).
hexagon bolt (406). (b) Be careful not to damage the oil
seal.
(c) Install the back cover (263) and
the seal cover (262) of the series
pump according to the same
essentials. 1
5 Install the auxiliary piston cylinder block [the All types 2

cylinder (141), the auxiliary pistons (151,
152), the clamp plate (153), the spherical
surface bush (156), the shim (158), the oil
cylinder spring (157)], align the spherical
surface bush with the cylinder spline shaft,
and insert it in the pump housing.
3
6 Align the valve block (313) with the pin, and (a) Pay attention to the installation
then insert it into the valve body (312). direction of the suction and the
spit of valve block. 5
7
INDEX
111

7 Install the valve body (312) to the pump (a) If the pump body on the rear side
housing (271), and secure it with the inner is installed firstly, the operation
hexagon bolt (401). will become easier.
(b) Pay attention to the installation
direction of the valve body.
x Right whirling pump
(Looking from the input shaft)
vent position:
left (Adjuster position: facing up)
x Left whirling pump
(Looking from the input shaft)
vent position:
right (Adjuster position: facing up)
8 Feedback pin of the tilting pin is clamped in (a) Pay attention to the installation of All types
the feedback pin of the adjuster, install the the adjuster using for front or rear.
adjuster, and secure it with the inner hexagon
bolts (412, 413).
9 The whole operation is finished after the All types

installation of the drain pin hole (467).
112
3-5-3. Pump body, repair standard
CONTENTS
1. Replacing standard of worn component
When the worn degree of component exceeds the following standard, replace or adjust it again.
But the component must be replaced when there is clear outward damage.
Standard Size/Recommended Exchange Value
Name And Item Pump Type Handle
K3V63 K3V112 K3V140 K3V180
1
Clearance
0.028 0.039 0.043 0.0375
between Replace
piston and piston or
cylinder cylinder
inner wall
(D-d)
0.056 0.067 0.070 0.078
2
Clearance 0̚0.1 0̚0.1 0̚0.1 0̚0.1

Replace
between
piston and
piston and
coupling parts.
piston shell ( )
0.3 0.3 0.3 0.35
3
3.9 4.9 5.4 5.4

Replace
Thickness of
piston and
piston shell
coupling parts.
(t)
3.7 4.7 5.0 5.0 4
Free height 31.3 41.1 47.9 40.9

Replace
of cylinder cylinder spring.
spring
(L)
30.2 40.3 47.1 40.1 5
Height of
assembly for 10.5 12.0 13.5 13.5 Replace
press board press board
and spherical and spherical
surface bush surface bush.
(H-h) 9.8 11.0 12.5 12.5 6
7
INDEX
113
D
d
L
Clearance between stopcock and cylinder Free length of oil cylinder spring: L
inwall: D-d
H
h
δ
t
Clearance between the piston and piston shell: G Assembly height of clamp plate and
Thickness of piston shell: t spherical surface bush: H-h
Correcting standard of cylinder, valve block, tilting plate (Piston shell plate)
Cylinder (Sliding part) Correcting the degree of roughness
3-Z (Ra=0.8)
Tilting plate (Piston shell plate) if necessary
Surface finish of inner wall of the Degree of roughness of standard 0.4Z or less (Ra=0.1)
cylinder (Sliding part) wall (Trim value) (Grind)
2. Rotating Torque
Component Name Size Rotating Torque Tool Name
Inner hexagon bolt M5 0.7 B= 4 Inner hexagon
(Material SCM435) M6 1.2 5 wrench
M8 3.0 6
M10 5.8 8
M12 10 10
M14 16 12
M16 24 14
M18 34 14
M20 44 17
PT pin PT1/16 0.7 4 Same as above
(Material S45C) PT1/8 1.05 5
Note: wrap the seal tape PT1/4 1.75 6
1.5~2 circles PT3/8 3.5 8
PT1/2 5.0 10
PF pin PF1/4 3.0 6 Same as above
(Material S45C) PF1/2 10 10
PF3/4 15 14
PF1 19 17
PF11/4 27 17
PF11/2 28 17
114
535 789 732 532 214 548 531 724 702 792 534 901 808 954 717 151 152 211
A
806
953
886
717
261
406
774
B B
111
127
824 04
710
123
212
153
401 251 490 271 156 157 982 468 313 124 710 116 312 113 752 885 314 981 141 271 401
983 728 466 983
A B-B
326 414
546
725
724
325
407
115
7
6
5
4
3
2
1
INDEX CONTENTS
Component Number Component Name Material Remark

983 Rivet 0SK2548 2PCS
981 Nameplate PNPA-2550B 1PCS
954 Lock screw 2953801768 2PCS
953 Inner hexagon nut PSSSM1630 2PCS
901 Lifting eye bolt 0EBM10 2PCS
886 Spring pin 0SPV614 4PCS
885 Valve plate pin PJR812 2PCS
824 Blocking ring 0SR40 2PCS
808 Hexagon nut 0RNM20 2PCS
806 Hexagon nut 0RNM16 2PCS
792 Protector washer 0T2BG35 2PCS
789 Protector washer 0T2BP18 2PCS
774 Oil seal ring P15Z456812F 1PCS
732 O-ring 00RBP18W 2PCS
717 O-ring 00RBG145W 4PCS
548 Feedback pin 2953802202 2PCS
546 Washer 2903370-0919 2PCS
535 Stopper 2953801762 2PCS
534 Stopper 2925110-0318 2PCS
532 Auxiliary piston 2924490-0050 2PCS
531 Pin 2943800517 2PCS
490 End cap PBP116-2403 32PCS
468 VP stopper plug 0VP34 4PCS
466 VP stopper plug 0VP14 2PCS
414 Inner hexagon bolt OSBM1020 4PCS
407 Inner hexagon bolt 0SBM630 3PCS
406 Inner hexagon bolt 0SBM820 4PCS
401 Inner hexagon bolt 2953801767 8PCS
326 Cover 2923150-0860 1PCS
325 Cover 2953802374 1PCS
314 Valve plate 3890L-314N 1PCS
313 Valve plate 3890R-313N 1PCS
312 Valve block 2923370-0080 1PCS
271 Pump housing 2923800807 2PCS
261 Seal housing 2943800572 1PCS
116
Component Number Component Name Material Remark
CONTENTS
Supporting table of tiling
251 2923800809 2PCS
plate
214 Tilting bush P1R2025125 2PCS
212 Tilting plate 2933800813 2PCS
211 Piston supporting shell 68710-00-211 2PCS
157 Oil cylinder spring 2953801769 18PCS
1
156 Spherical surface bush 2924610-0030 2PCS
153 Clamp plate 2924110-0056 2PCS
152 Piston shell 2924330-0341 18PCS
151 Piston 2924530-0441 18PCS
141 Cylinder body 2933800787 2PCS 2
127 Bearing washer 38800-127 4PCS
124 Bearing PAJ503518 2PCS
123 Bearing PNUP308R1CS50 2PCS
116 Gear 2903190-0083 1PCS
113 Drive shaft (R) 2933800883 1PCS 3
111 Drive shaft (F) 2933800982 1PCS
3-5-4. Adjuster for K3V series

1. Note for disassembly
(a) As the components of the adjuster are precise and diminutive, the operation of 4
disassembly and assembly is relatively complicated. It is recommended that the adjuster
assembly be replaced when repairing if there is no special condition. When the
disassembly is unavoidable, please read through the Repair essentials before operating.
(b) The number in the ( ) following the part name indicates the mark of structure diagram
(Page 14, 15).
2. Tools 5
Tool Name Tool Size
Hexagon wrench 4, 5, 6 (B size, mm)
Socket wrench Double ended (Single ended) wrench
Monkey wrench Diminutive (Max. 36 mm)
Screwdriver 6
Plastic hammer
Torque wrench
Needle nose plier Be used for 2 retainers
Brass bar Diameter below I4 mm L=100
7
Tweezer
Bolt M4, L=50 or so
INDEX
117

3. Disassembly essentials
No Contents for Operating Precautions
1 Choose the disassembly place. (a) Choose a tidy clean place.
(b) Lay the rubber plate or the working
cloth, etc. on the workbench to prevent
components from being damaged.
2 Please wipe off the rubbish, rusty stain, etc. on the
pump surface with washer fluid and so on.
3 Take out the hexagon bolts (312, 413), and take out (a) Be careful not to lose the O-seal ring.
the adjuster body from the pump body.
4 Remove the inner hexagon bolt (438), take the cover (a) The cover (C) has been installed with
(C) (629). the adjusting screws (C) (CI), (628,
925), the adjusting wheel (C) (627), the
lock nut (630), the hexagon nut (801)
and the adjusting screw (924). Do not
tweak these screws and nuts. If tweak
them, the set pressure-flow may be
changed.
5 Remove the rear compensation part of the cover (C) (a) Take out the adjusting ring (Q) (645)
(629) to take out the outer ring spring (625), the inner easily with M4 screw.
ring spring (626), the spring seat (C) (624) and pull
out the adjusting ring (Q) (645), guide spring (646),
spring seat (644) from the guide part.
118
CONTENTS
6 Please take out the hexagon bolts (436, 438), remove
the guide cap (641), then take out the set spring (655)
from the guide part.
7 Take out the retainer (814), then remove the spring 2

(a) The sleeve (651) has been installed with
seat (653), the retracting spring (654) and the sleeve the clamp ring (836).
(651). (b) When taking out the retainer (814), the
retracting spring (654) may spring out.
Be careful not to lose it.
4
8 Take out the lock retainer (858), the fulcrum inserted (a) Take out the fulcrum inserted pin (614),
pin (614) and the adjustment inserted pin (615). adjustment inserted pin (615) easily with
M6 screw.
7
INDEX
119

9 Take out the lever (2) (613), but do not pull out the pin (a) The operation process can be simplified
(875). by using the tweezer.
10 Pull out the pin (874), and take out the feedback rod (a) Push out the pin (874) (The pin diameter
block (611). is I4) from up to down with a thin brass
bar. Be careful not to touch the lever.
11 Take out the lever (1) (612), but do not pull out the pin
(875).
12 Pull out the guide piston (643), the sliding block (652).
13 Pull out the piston housing (622), the compensation Do not push out the compensation unit (623)
plug (621), the compensation unit (623). The from the contrary direction of the piston
disassembly operation of adjuster is over. housing (622).
4. Assembly essentials
Assembly is in the reverse order of disassembly. Please pay attention to the following items
when operating.
(a) Be sure to repair the damaged components when removing, prepare the new component
for replacing.
(b) If the components are mixed with foreign material, it can cause the movement poor. Be
sure to clean the components with washer fluid, and blow them clean with air. Assemble
them at a clean and neat place.
(c) Tighten the bolts, the inserted pins of all parts to the specified torque.
(d) Be sure to apply the clean drive grease to the turning part before assembly.
(e) The sealing component such as the O-ring should be replaced with a new one in principle.
120
CONTENTS
1 Install the compensation lever (623) in the
compensation hole of the housing (601).
2 Embed the lever (1) (612) pressed with the brad in the
compensation lever groove, install the lever on the pin
pressed in housing.
3 Install the bush (651) and the sliding block (652) in the (a) The bush, the sliding block cannot be
case sleeve. locked in the adjuster case. Be sure to 1
move smoothly.
(b) Pay attention to the direction of bush.
2
Bush
Feedback Rod Block
4 Install the feedback rod block (611), align the pin hole (a) Inserting the pin a little into the feedback
of feedback rod block and insert the pin (874). rod block beforehand can make the
operation easily.
3
(b) Pay attention to the installation direction
of the feedback rod block.
Rod Block Rod Block (2)
(1) Side Side
Supporting Pin,
Adjusting Pin
Side 4
5 Install the guide shaft (643) into the inside hole of the (a) The guide shaft cannot be locked. Be
case. sure to move smoothly.
6 Embed the pin pressed in the lever (2) (613) into the
groove of the guide piston, then install the lever (2). 5
7
INDEX
121

7 Insert the pin pressed in the fulcrum inserted pin (614)
into the pin hole of lever (2), install the fulcrum
inserted pin and the lock retainer (858).
8 Insert in the adjusting pin (615), and install the set (a) Do not install incorrectly the fulcrum
ring. inserted pin and adjusting inserted pin
hole incorrectly.
(b) At the same time, confirm if the moving
clearance of feedback rod block is too
large or if it is stuck.
9 Install the retracting spring (654), spring seat (653)
into the sleeve hole, then install the retainer (814).
122
CONTENTS
10 Install the set spring (655) in the sleeve hole. Install
the compensation piston (621), piston housing (622),
guide cap (641) in the compensation hole and tighten
them with the inner hexagon bolts (436) (438).
2
11 Install the spring seat (644), the guide spring (646), (a) Pay attention to the installation direction
the adjusting ring (Q) (645) in the guide hole. Install of the spring seat.
the spring seat (624), inner spring (626), outside
spring (625) into the compensation hole.
12 Install the cover (C) (629) assembled with the

adjusting screw (628) (925), the adjusting wheel (C)
(627), the lock nut (630), the hexagon nut (801),
adjusting screw (924) and tighten it with the inner
hexagon bolt (438). All the installation is over. 5
7
INDEX
123
124
B-B
B Oil Pressure Circuit Diagram
496 418 079
Psv A
757 413 646 438

439
438 P2
656
D
a3
D
B 924 B
722
755
543 755 545 541 438 466 730 643 708 644 645 728 801
724 725 E-E
545 755
A-A 541
C 543
734
897 876 874 755 653
655 654 836 651 652 601 624 629 630
A
412 612 858 641 628
615 814 802
C
614 D-D
613
801
611 627 E
A
875 631 753
898 756
732 E
763
733 642 753 727

625 626 887
622 621 623 467
Quant Part Name

Area Part Number Part Name Material Remark
CONTENTS
ity Number
Inner hexagon
C 924 Alloy steel 1 PSSSM820
locating screw
- 898 Pin Bearing steel 1 PJR859 I8.5×10L
- 897 Pin Bearing steel 1 PJR519 I5×19L
- 887 Pin Carbon steel 1 2953801817
1
- 874 Pin Bearing steel 1 PJR411 I4×11.7L
D 858 Clamp ring Tool steel 2 ORR15 JIS B 2804 RR-15
- 836 Retainer Tool steel 1 PWR20 2
D 814 Retainer Tool steel 1 OSR10 JIS B 2804 SR-10
D 802 Hexagon nut Rolled steel 1 2903480 M10
D 801 Hexagon nut Rolled steel 2 ORNM8 JIS B 1181 RN-M8
D 763 O-ring Nitrile rubber 1 OORBG35W JIS B 2401-G35
D 757 O-ring Nitrile rubber 1 OORBP1250W JIS B 2401-P12.5 3
D 756 O-ring Nitrile rubber 1 OORBP26W JIS B 2401-P26
D 733 O-ring Nitrile rubber 1 OORBP20W JIS B 2401-P20 4
5
- 656 Blind plate Cast iron 1 2953802034
6
- 655 Spring Spring steel 1 2953801709
- 654 Retracting spring Spring steel 1 2953801746
- 653 Spring seat Carbon steel 1 2953801707
- 652 Bush Alloy steel 1 2953801706
- 651 Sliding block Alloy steel 1 2903380-0662 7
- 646 Guide spring Spring steel 1 2903340-0654
2933260-
- 645 Adjusting ring (Q) Carbon steel 1
00492
INDEX
- 644 Spring seat (Q) Alloy steel 1 2903270-0855

- 643 Guide piston Alloy steel 1 2924550-0405
- 642 Rod Carbon steel 1 2933420-0160
125
Quant Part Name

Area Part Number Part Name Material Remark
ity Number
- 641 Guide cap Cast iron 1 2923150-0582
- 631 Pf sliding block Cast iron 1 2903380-0270
- 630 Lock nut Rolled steel 1 2953801695
- 629 Cover (C) Cast iron 1 2943800443
- 628 Adjusting bolt (C) Carbon steel 1 2903300-0326
- 627 Adjusting ring (C) Carbon steel 1 2933260-350
- 626 Inner spring Spring steel 1 2953801831
- 625 Outside spring Spring steel 1 2903340-0919
- 624 Spring seat (C) Alloy steel 1 2903270-0854
Compensation
- 623 Alloy steel 1 2926730-0402
unit
- 622 Piston housing Cast iron 1 2953801688
Intracavity
- 621 Alloy steel 1 2953801687
stopcock
Compensation
- 615 Carbon steel 1 2953801686
piston
- 614 Fulcrum pin Carbon steel 1 2953801685
- 613 Lever (2) Alloy steel 1 2925150-0007
- 612 Lever (1) Alloy steel 1 2953801683
Feedback rod
- 611 Alloy steel 1 2953802680
block
- 601 Case Cast iron 1 2923290-0070
- 545 Ball Bearing steel 2 0DW732
- 543 Stopper 1 Alloy steel 2 2933260-0311
- 541 Seat Alloy steel 2 2933180-0414
C 496 End cap Carbon steel 15 PBP116-2403
C 467 End cap Rolled steel 1 2903560-0378 G3/8Xm8
C 466 End cap Rolled steel 1 0VP14 G1/4
Inner hexagon
D 439 Alloy steel 3 OSBM635 JISB 1176 M6-35
screw with hole
Inner hexagon
screw with hole
Inner hexagon
screw with hole
Inner hexagon
screw with hole
Inner hexagon
screw with hole
29070821-
B - Adjuster - 1
4927
126
3-5-5. Disassembly and assembly of pilot pump
CONTENTS
1
2
466 725
307 312 3
435
312 311
700 354 351 4

433
850 6
a3
307 308 355
340 309 434 466 752

710 435 361 353
7
INDEX
127
Number Name Quantity Remark

307 Lift valve 1
308 Grommet 1
309 Retainer 1
310 Spring 1
311 Adjusting bolt 1
312 Lock nut 1
351 Case 1
353 Gear shaft 1
354 Gear shaft 1
355 Filter screen 1
361 Case 1
433 Screw 2
434 Screw 2
435 Screw 4
466 End cap 1 G1/4
700 Grommet 1
710 O-ring 1
725 O-ring 1
732 O-ring 1
850 Retainer 1
Remove and install the pilot pump pipe casting (with pilot pump attachment) with the target torque
value, see the following table:
Number Oil Port Union Target Torque Value Remark
1 G3/4 74 Ngm
2 1/4 oil port 16 Ngm
3 G1/2 53 Ngm
4 M8 17 Ngm
128
UPPER SWING PLATFORM - Removal and installation of main valve
3-6. Removal and installation of main valve
CONTENTS
3-6-1. Removal and installation of operating valve
this kind of danger, release pressure before disconnecting the hydraulic pipe or other pipes. 1
pressure.
2
Preparation
the top of the hydraulic oil tank and release the
residual pressure completely. 3
a vacuum pump to keep negative pressure in
the hydraulic oil tank.
4
Keep the vacuum pump continuously rotating or drain
the hydraulic oil in the hydraulic oil tank thoroughly.
Removal
5
x Attach a tag for the convenience of reinstallment.
x Cover the ports of all disconnected hoses and pipes.
7
INDEX
129
Main Pump A1 Port

Swing Motor B Port Main Pump A2 Port
Screw Screw Return to Oil Tank
Swing Motor A Port Bucket Small Chamber
Arm Main Bucket Main

Chamber Chamber
Boom Small
Arm Small Chamber Chamber
Swing Connector B Port Main Pump Boom Main Chamber

A2 Port Screw
Swing Connector A Port
Swing Connector D Port
Main Pump A1 Port Swing Connector C Port Return to Cooler
Bucket Confluence
130

1. Disconnect all the hoses, pipes and
Right Tracking Boom Arm Bucket connectors from the control valve.
CONTENTS
Spare
: 17 mm
: 19 mm
: 36 mm
: 8 mm 1
: 10 mm
Oil Oulet : 90 Ngm (9.2 kgfgm, 67 lbfgft)
Left Tracking
Boom
2. Remove the set screws (×3) on the control
Swing Swing Priority Boom valve .
: 24 mm 2
Bucket Spare
90 Ngm (9.2 kgfgm, 67 lbfgft)
Arm Boom Boom
Swing Priority Right Tracking

Swing
Arm Control valve weight: 185 kg
Bucket
Confluence 3. Lift up and remove the operating valve from 3
the main valve bracket by the crane.
Arm
Installation
Left Tracking 4
For the wrench dimensions and tightening torque,
refer to the "Removal" above.
Control valve weight: 185 kg 5
1. Install the control valve to the main valve

Control Valve bracket with 3 screws.
2. Connect all the hoses, pipes and connectors to
the control valve.
6
Main Valve Bracket Check the hydraulic oil level after installation. Fill the
oil if needed. Run the engine to check for the oil
leakage of the components.
7
INDEX
131
3-6-2. Removal and installation essentials of operating valve

1. Tools
The table below shows the various bolts and inserted pin required for removing and installing the
valve body.
2. Removal essentials
x Before disassembling, make sure to read the manual of removal essentials carefully and
thoroughly, and remove, disassemble the parts according to the requirements below.
x Attach tags to the installation positions of the valve rod and case to prevent error occurring
during reinstallment.
132
A-A G
CONTENTS
E F
159 C D 159 159
I H
Dr2
N
N
561 A
A J
1
153
273
M M 977
978 H 159
101
103 I
J 2
C D G
E F
I-I 388 325
B-B 324 H-H
974 974 974 391

976 3
976
158
K
601 Main Spill Valve
561 153 4
M-M N-N
L
164 L 104
154
K 102
975
975 975 975 975 5
L-L L1-L1 551 561 521 511 K-K

551
L1
561
155 521 6
511
167
P2
P2
551 561 521 511
7
L1
INDEX
133
203 C-C 203

333
333
331
331
334
334
329
329
328
328
331
331
262
262 166
168
165
165
515
164
521
154
551
561
310
165
301
169
169 202
202
134
CONTENTS
D-D
203 164 154 201
333 336
331 332
334 335 1
329 379
328 370
159
331 332
262 261
602 159 2
166
166
971 165
165 165
209
254 3
511
521
551
561
971 4
165 251
209 165
309 305
264
602 204
166 5
169
202 164 154
7
INDEX
135
E-E
201
379 336
370 332
335 207
332
336
261 332
159 339
602 372
159 374
252 332
261
307
165
165
552
523 561
561 551
516 521
165 511
561
521 551
551 521
561
511
511
551
303 561
165 395
264 261
603 332
204 370
376
339
332
336
207
154 164
136
CONTENTS
F-F
551 551
561 561
356 355
206 206 1
332 332
336 336
335 335
379 379
370 370
332 332 2
261
261
602
602
166
252 3
516
523
513 552
561
522
561 511
521 4
551
561
554
304
5
302
264
264 204
602 6
205 602
7
INDEX
137
G-G
201 203
336 333
332
331
335
337
372
329
374
332 328
331
261
262
166
7 13
392
551
165
561
165
170
156
551
561 156
170
306
561
165
551
264 169
202
204
138
3-6-3. Main valve (Continue)
CONTENTS
Part
Code/Type Name Quantity Remark
Number
Operating valve
A220400000419 1 For SY205C8M
KMX15RA/B45201
101 VZ33170-1616 Valve body A 1
1
102 VZ33170-1613 Valve body B 1
Straight tracking valve
103 V0305152788 1
block
104 V0101238653 Boom priority valve block 1
153 OROH34 End cap 2
2
156 OROH14 Union 2
158 PBP116-2403 End cap 1
159 VZ50101400 End cap 8
3
164 00RBP14 O-ring 5
165 00RBG30 O-ring 17
4
169 00RBG35 O-ring 4
201 VZ40101148 Spring cover 3
202 VZ50103504 Cap (Valve rod) 4
203 VZ40103496 Spring cover 4 5
204 VZ33140-0091 Cap (Valve rod) 4
205 VZ33140-0093 Cap (Valve rod) 1
206 VZ40101152 Cap (Arm) 2
207 VZ33140-0768 Spring cover 2
209 VZ03580-0141 Seal plate 2 6
Swing logical valve control
251 V0507126953 1
valve
252 V9605208996 Holding valve 2
Swing logical valve
254 VZ02360-9470 1
assembly
7
261 VZ50102761H50 O-ring 7
262 VZ50102761H39 O-ring 4
264 00RBG40 O-ring 5
INDEX
273 0SBM825 Inner hexagon screw 40

301 5203320-5163 Tracking valve rod 1
302 5231200-1452 Arm (1) valve rod 1
139
Part
Number
303 5203320-5157 Boom (1) valve rod 1
304 5203320-5159 Bucket valve rod 1
305 5203320-5160 Swing valve rod 1
306 5203320-5156 Arm (2) valve rod 1
307 5203320-5158 Boom (2) valve rod 1
309 5203320-5164 Spare valve rod 1
310 5203320-5162 Tracking valve rod 1
324 VZ03340-0097 Spring 1
325 VZ03340-0098 Spring 1
328 VZ03340-1745 Spring 4
329 VZ03340-1635 Spring 4
331 VZ50103529 Spring seat 8
332 VZ50103142 Spring seat 14
333 VZ50105183 Screw 4
334 VZ50106102 STOPPER 3
335 VZ50101296 STOPPER 5
336 VZ50101297 Screw 7
337 VZ50105182 STOPPER 1
338 VZ33420-0019 STOPPER 1
339 VZ33260-0013 STOPPER 2
355 VZ33330-0028 Piston 1
356 VZ33330-0453 Piston 1
370 VZ03340-1961 Spring 5
372 VZ03340-1964 Spring 2
374 VZ03340-1963 Spring 2
376 VZ03340-0168 Spring 1
379 VZ03340-1962 Spring 4
391 VZ31200-0650 Straight tracking valve rod 1
392 VZ03320-3126 Valve rod 1
395 5203320-5161 Swing priority valve rod 1
511 VZ03610-0026 Lift valve 8
513 VZ03610-0607 Lift valve 1
515 VZ03610-0015 Lift valve 1
516 VZ03610-0028 Lift valve 2
521 VZ50101290 Spring 9
522 VZ03340-0148 Spring 1
523 VZ03340-0294 Spring 2
551 OROMH27 End cap 15
552 VZ03560-0117 End cap 2
140
Part
CONTENTS
Number
Confluence valve
554 VZ03560-0029 1
connector
555 VZ02360-0208 Check valve 1
561 00RBP24 O-ring 20
601 V0306122956 Main safety valve 1
602 V9606259181 By-pass safety valve 7
1
603 V0009227982 By-pass safety valve 1
971 OSBM1020 Inner hexagon screw 8
2
977 PNPA-2550B Nameplate 1
978 OSK2548 Rivet 2
7
INDEX
141

Master pressure relief valve
124 561 611 621 661

123 125 562 663 163 614 613
512 521 121 103 104 664 673 652 671

541 122
Num Quan Num Quan

Part Name Remark Part Name Remark
ber tity ber tity
Torque
103 Screw-in sleeve 1 69~78 Ngm 562 Retainer 1
(51~58 lbfgft)
104 Regulating sleeve 1 611 Poppet head 1
121 C-ring 1 613 Stopper 1
122 Washer 1 614 Piston 1
123 C-ring 1 621 Spring 1
Filter element
124 1 652 Adjusting Screw 1
stopper
125 Filter element 1 661 O-ring 1 P8
163 O-ring 1 P25 663 O-ring 1 P14
512 Plunger 1 664 O-ring 1 P16
Torque
521 Spring 1 671 Lock nut 1 27~31 Ngm
(20~23 lbfgft)
Torque
541 Base stand 1 673 Lock nut 1 27~31 Ngm
(20~23 lbfgft)
561 O-ring 1 P16V
142

Port pressure relief valve
CONTENTS
564 123 125 562
301 563 521 124 561 611 621 661 612
511 522 161 541 101 162 102 651 671
3
Num Quan Num Quan
Part Name Remark Part Name Remark
ber tity ber tity
Torque
101 Valve body 1 69~78 Ngm 541 Base stand 1
(51~58lbfgft)
4
Torque
102 Screw-in sleeve 1 69~78 Ngm 561 O-ring 1 P16V
(51~58 lbfgft)
O-ring 1 P24 562 Retainer 1
162 O-ring 1 P22.4 563 O-ring 1 P16V
123 C-ring 1 564 Retainer 1
5
Filter element
124 1 611 Poppet head 1
stopper
125 Filter element 1 612 Spring seat 1
301 Piston 1 621 Spring 1
511 Plunger 1 651 Adjusting Screw 1 6
521 Spring 1 661 O-ring 1 P8
Torque
522 Spring 1 671 Lock nut 1 27~31 Ngm
(20~23 lbfgft)
7
INDEX
143

Straight tracking valve integrated package
A-A
561 551 521 511 103
B A
601
266
561
251 C C
338 551
325 391
324 B A
154 164 156 163
C-C B-B
103
974 165 391 166 167 357
266 308
561
251
551
338
325
103 159
324
Part Number Name Quantity Remark

103 1
integrated package
154 RO plug 1 Torque 69~78 Ngm (51~58 lbfgft)
156 RO plug 2 Torque 34~39 Ngm (25~29 lbfgft)
159 Plug 8 Torque 5.9~8.8 Ngm (4.4~6.5 lbfgft)
163 O-ring 2 P11
164 O-ring 1 P14
165 O-ring 4 G30
166 O-ring 2 P10
167 O-ring 3 P12
251 Screw-in sleeve 1 Torque 69~78 Ngm (51~58 lbfgft)
266 O-ring 4 G25
308 Installing sequence 1 Torque 69~78 Ngm (51~58 lbfgft)
324 Spring 1
325 Spring 1
338 Stopper 1
357 Pore 2 Torque 15~18 Ngm (11~13 lbfgft)
391 1
rod
511 Poppet head 2
521 Spring 2
551 Plug 3 Torque 147~176 Ngm (108.5~130 lbfgft)
561 O-ring 3 P24
Master pressure relief
601 1 Torque 69~78 Ngm (51~58 lbfgft)
valve
974 Inner hexagon screw 5 M18×1.5-95
144

Installing sequence
CONTENTS
356 347 266 375 376 344 308 267 346 309

376 Spring seat 1
375 Spring 1
356 Screw-in sleeve 1 Torque 69~78 Ngm (51~58 lbfgft) 3
347 Stopper 1
346 Sleeve 1
344 Sleeve 1
309 Piston 1
308 Valve rod 1 4
267 O-ring 1 P10A
266 O-ring 1 P24
Install negative control pressure relief valve

5
632 638 611 621 631

7

611 Poppet head 1
INDEX
621 Spring 1
145

631 Pressure relief pole 1
632 Sleeve 1
638 Filter element 1
Install support arm valve rod
341 338 313 339 349 342 328 314 302 312 358 343 329 359 352

302 Valve rod 1
312 Secondary valve rod 1
313 Piston 1
314 Sleeve (2) 1
328 Spring A1 1
329 Spring A2 1
338 Spring 1
339 C-ring 1
342 Sleeve (1) 1
343 Gasket bolt 1 Torque 9.8~11.8 Ngm (7~66.4 lbfgft)
349 Stopper (1) 1
358 Spring seat 1
359 Spring seat 1
146

Installing main arm valve rod
CONTENTS
1
353 303

303 Valve rod 1 2
353 Plug 1 Torque 59~69 Ngm (44~51 lbfgft)
Installing locking valve
101 162 171 541 511 161 512 201 3
164
301
163

101 Housing 1 6
161 O-ring 1 P22A
162 O-ring 3 P16
163 O-ring 2 P7
164 O-ring 1 P11
171 Inner hexagon bolt 4 M6-50 7
201 Screw-in sleeve 1 Torque 74 Ngm (55 lbfgft)
301 Plug 1 Torque 34~39 Ngm (25~29 lbfgft)
511 Valve rod 1
INDEX
512 Spring 1
541 Bush 1
147
3-6-4. Removal and installation of operating valve

1. General precautions
(a) As all the hydraulic components are subject to accurate machining, it is necessary to select a
very clean ground for removal and installation.
(b) Attention should be paid to prevent dust, sand and the like from entering into the valve when
handling the control valve.
(c) All the ports should be coverd with caps when removing the control valve from the machine.
Before removing the valve, check again if all the caps are well covered, and then clean the
outside. Select a suitable workbench laid with paper or rubber, and perform valve removal
operation on it.
(d) Support the valve body of the control valve carefully when performing operations like handling
and moving. Do not use control lever, exposed valve rod, end cover and other parts as support
in order to prevent damage to the control valve.
(e) A series of tests (including pressure relief characteristic, leakage, flow resistance, etc.) that
should be performed with the hydraulic testing equipment need to be carried out after reinstalling
the removed components. Therefore, never try to remove those parts which cannot be tested or
adjusted even if the removal work is supported technically. Besides, prepare clean washing oil,
hydraulic oil, grease, etc. in advance.
2. Tools
Prepare the following tools in advance before removing the control valve:
Table 11
Tool Name Quantity Size (mm)
File bench 1
Socket wrench 1 piece for each size 27, 30 and 32
Hexagon socket wrench 1 piece for each size 4, 5, 6, 8, 10, 12 and 14
Seal tape 1 hank
Bond #262 1 bottle
Wrench 1 piece 32 (master pressure relief valve)
3. Removal
In the operation instructions, the number in the ( ) following the part name are corresponding with the
part number in the structure diagrams (Diagram 2 to 12).
(a) Place the control valve on the workbench.
Remove the valves on a clean ground, pay attention not to damaging the flange face.
(b) Move out the straight tracking valve integrated

package:
Moving out
Loosen the inner hexagon socket bolt, take out the
straight tracking valve integrated package (103) that are
combined together.
148

Removal
(a) Clamp the case (103) with a vise.
CONTENTS
(b) Remove the screw-in sleeve (251), draw out the springs (324 and 325), stopper (338) and valve
rod (391).
(c) Move out the plug (551), draw out the poppet head (511) and the spring (521).
(d) Move out the master pressure relief valve (601). (The removal of the master pressure relief
valve is as follows. )
Removal of master pressure relief valve:
(a) As the screw-in sleeve (103) and the base stand (541) are fixed by the C-ring (121), draw them 1
out jointly.
(b) Take out the spring (521) and the plunger (512) from the base stand.
(c) Move out the lock nut (671) and the adjusting screw (652) on the regulating sleeve (104) and
take out the stopper (613), piston (614), spring (621) and poppet head (611).
(d) Loosen the lock nut (673) on the screw-in sleeve (103), move out the regulating sleeve (104).
(e) Move out the C-ring (121) and washer (122) on the screw-in sleeve (103). 2
As filter element (125), filter element stopper (124) screw-in sleeve (103) are installed together
through C-ring (123), do not remove them further.
3
Removal of tracking valve rod
(a) Loosen the inner hexagon bolt (273), and move
out the spring cover (203).
(b) Move out the valve rod assembly consisting of the

tracking valve rod (301), springs (328, 329), spring 5
seat (331), stopper (334) and shim bolt (333) from
the case wholly.
Be careful not to damage the case when taking the

6
valve rod assembly out of the case.
(c) Use the vise with mouthing to clamp the tracking

valve rod (301). Move out the shim bolt (333), and
remove the springs (328, 329), spring seat (331)
and stopper (334).
7
INDEX
149

Removal of arm valve rod
out the support arm cap (206).
(b) Move out the valve rod assembly consisting of the

arm valve rod (302), spring (371, 372), spring seat
(332), stopper (335) and shim bolt (336) from the
case wholly.
(c) Use the vise with mouthing to clamp the arm valve
rod (302). Move out the shim bolt (336), and
remove the springs (371, 372), spring seat (332)
and stopper (335).
(d) Do not remove the arm valve rod (302) further unless there is a special problem. If there is a
necessity to make further removal, please operate according to the steps described below:
(1) Clamp the center section of the support arm valve rod (302) by a vise with mouthing, and
move out the plugs (352 and 341) on both ends.
(2) Move out the plugs (352 and 341) on both ends and wholly take out the secondary valve
rod (312) assembly. Move out the piston (341) installed on the plug (313).
(3) Clamp the secondary valve rod (312) by a vise with mouthing, move out spacer stand
(343), and take out the spring (329) and spring seats (358 and 359).
Pay attention not to damaging the secondary valve rod (312).
(4) As the secondary valve rod (312), valve rod-2 (314), spring (328), sleeve-1 (342), stopper
(349) and C-ring (339) are wholly installed, do not remove them further.
Removal of main arm valve rod

out the spring cover (201). Move out the main arm
assembly consisting of the main arm valve rod
(303), springs (371, 372), spring seat (332),
stopper (335) and shim bolt (336) from the case
wholly.
(b) Clamp the plug on one side of the valve rod
assembly with a vise, move out the shim bolt
(336), and remove the springs (371 and 372),
spring seat (332) and stopper (335).
150

(c) Do not remove the main arm secondary valve rod
(303) further unless there is a special problem. If
CONTENTS
there is a necessity to make further removal,
please operate according to the steps described
below.
Clamp the center section of the main arm valve
rod (303) by a vise with mouthing, move out the
plugs (353).
1
Do not swing the vise too tight to prevent the main

arm secondary valve rod (303) from deforming.
Removal of valve cover

2
x Screw off the inner hexagon bolt (273), and
remove the valve rod cap (202).
Moving out port pressure relief valve:

x Moving out
Move the port pressure relief valve (602) out of the
4
case.
5
x Removal
(1) Loosen the screw-in sleeve (102), take the
springs (521 and 522) and seat (541) out of
the valve body (101), and take the piston
(301) and plunger (511) out of the seat
(541). 6
(2) Move out the lock nut (671) and adjusting
screw (651) on the screw-in sleeve (102)
and take out the spring seat (612), spring
(621) and poppet head (611).
7
As the filter element (125), filter element stopper
(124) screw-in sleeve (102) are installed together
through C-ring (123), do not remove them further.
INDEX
151

Moving out locking valve assembly:
Loosen the inner hexagon bolt, and move out the
locking valve assembly (252).
Removal of negative control pressure relief valve:

(a) Move out the plug (551).
(b) Move out the poppet head (611), spring (621) and
pressure relief pole (631).
Removal of check valve:

Move out the plug (551), take out the poppet head (511)
and spring (521).
Removal of case:
(a) Do not remove the connecting bolts between case
A and B unless it is necessary.
(b) The plugs that without explanation in the removal
procedure described above are blind plugs which
can be used in fabrication holes or keeping the
castings tidy, do not remove them unless
absolutely necessary.
152

Check after removal:
Wash all the removed parts thoroughly with clean mineral oil and dry them with compressed air. Then,
CONTENTS
place them on a piece of clean paper or cloth for checking.
(a) Control valve:
(1) Check if there are burr, nick, notch or other defects on the surface of the parts.
(2) Check that the sealing groove of the case and the integrated package are glossy and
without dust, dent or rust.
(3) If dent or damage are on the base stand surface of the case and the integrated package,
restore it by grinding. 1
Note that the abrasive should not be left on the case and the integrated package.
(4) Confirm that all the sliding and matching parts can be moved manually, and there are no 2
foreign matters in all the notches and passages.
(5) If the spring is ruptured or deformed, replace it with a new one.
(6) If the pressure relief valve does not work effectively, repair it according to the procedures
described in removal and installation.
(7) Replace all the packings and O-rings with new ones.
(b) Pressure relief valve:
3
(1) Confirm that the seat surfaces at the end of the poppet head or seat have no defects and
are even contact face.
(2) Confirm that the main poppet head and seat can be slid easily and smoothly manually.
(3) Confirm that there is no nick and the like on the outer surface of the main poppet head or
on the inner surface of the seat.
(4) Confirm that the spring has no fracture, deformation and wear.
(5) Confirm that the pores on the main poppet head and seat are not blocked with foreign 4
matters.
(6) Replace all the O-rings with new ones.
(7) If minor damages are detected in the above checking, restore it by grinding.
(8) If there are abnormal parts, replace them with the corresponding components in the
pressure relief valve.
4. Installation
5
(1) Only literal explanation is provided for installation. Please refer to the diagrams and
pictures in the removal part.
(2) In the instructions, the number in the ( ) following the part name are corresponding with the
part number in the structure diagrams.
(3) Precaution for installing packing
(a) Be careful to prevent manufacturing defects of the packing and the damage during 6
handling.
(b) Apply grease, hydraulic oil and the like to the packing and its assembling part to
ensure sufficient greasing.
(c) Do not stretch the packing excessively to avoid permanent distortion.
(d) Be careful not to position the O-ring by scrolling when assembling it. Besides,
deformed O-rings cannot eliminate distortion by itself after the installation, thus, it 7
can cause oil leakage.
(e) Tighten the lock bolts on each part with torque wrench according to the relevant
tightening torque in the "Service Standard".
INDEX
153

Installation of case:
x Install the O-rings (166 and 165) for case A (101) and case B (102), tighten the bolts (974 and
975) to the specified torque.
Check if there is dust on the mating surface, and make sure that the O-ring is installed in the notch
firmly.
Installation of plug:
x Tighten the plug (159) to the specified torque.
1. Replace the plug with a new one when reinstalling, as the plug (159) is covered with special
coating. However, the PT 1/8 plug purchased from the market can be used as a substitute in
emergency and entangled it with the seal tape. In this case, pay extreme attention not to leaving
the seal tape fragments in the case.
2. The usage of seal tape may cause the control valve work abnormally. Therefore, do not use it as
possible as you can.
Installation of check valve

x Install the poppet heads (511, 513, 515 and 516) and springs (521, 522 and 523). Attach O-ring
(561) to the plugs (551, 552 and 554), and tighten them to the specified torque.
Use the poppet head, spring and plug according to the following combinations.
Poppet Head Spring Plug Note:

511 521 551 10 places for 511
517 521 551 1 places for 517
515 521 551 1 places for 515
516 523 552 1 places for 516
(c) Installation of negative control pressure relief valve:
(1) Install the poppet head (611), spring (621) and pressure relief pole (631) to case A (101).
Install O-ring (561) to the plug (551), and tighten it to the specified torque.
(d) Installation of locking valve set
(1) Install O-ring (163) on the locking valve set (252), and tighten the inner hexagon bolt to the
specified torque.
(e) Installation of port pressure relief valve
(1) Install port pressure relief valve (602) to the case, and tighten it to the specified torque.
[INSTALLATION PROCEDURES OF PORT PRESSURE RELIEF VALVE ARE AS FOLLOWS]
(1) Install O-ring (162 and 561) and retainer (562) to the screw-in sleeve (102). Install the
poppet head (611), spring (621) and O-ring (661) to the spring seat (612). Then, install the
spring seat (612) in screw-in sleeve (102) temporarily, and tighten the adjusting screw
(651) and lock nut (671).
154
CONTENTS
Make sure that the poppet head (611) has been firmly installed to the base stand of the screw-in
sleeve (102).
(2) Set O-ring (563) and retainer (564) to the base stand (541) of plunger (511). After that,
install the plunger (511), piston (301) and springs (521 and 522).
(3) Install the base stand (541) set described in the above 2) to the valve body (101), and
1
tighten the screw-in sleeve (102) set described in the above 1) to the specified torque.
Make sure that the springs (521 and 522) are positioned securely
(4) Tighten the adjusting screw (651) temporarily, as the pressure adjustment should be 2
performed in accordance with the service standard.
(f) Installation of main arm valve rod:
(1) Screw a plug (353) on the valve rod (Main arm) (303).
(2) Clamp the valve rod (Main arm) with a vise, install the spring seat (332), spring (371 and
372) and stopper (335), and tighten the shim bolt (336) to the specified torque.
3
Apply bond #262 to shim bolt (336) before tightening.
(3) Install the valve rod set described above in item ķ and item ĸ to case B (102).
4
Push the valve rod set into case B (102) slowly and carefully. Never push it forcibly.
(g) Installation of ally arm valve rod:

(1) Use a vise with mouthing to clamp the secondary valve rod (support arm) (312). Install the
spring (329) and spring seats (358 and 359), and tighten the shim bolt (343) to the 5
specified torque.

6
(2) Insert the secondary valve rod (Support arm) (312) set into valve rod (Support arm) (302),
pay attention not to inserting in the wrong direction. Make sure that the piston (313) has
been inserted into the plug (341), install the plug and tighten it to the specified torque.
7
Make sure that the secondary valve rod (Support arm) (312) can move easily in the valve rod
(Support arm) (302).
(3) Clamp the plug (341) on one end of the valve rod (Support arm) (302) with a vise, install
INDEX
spring seat (332), springs (371 and 372) and stopper (335), and tighten the shim bolt (336)
to the specified torque.
155
(4) Install the valve rod set described above to case A (101).
Push the valve rod set into case A (101) slowly and carefully. Never push it forcibly.
(h) Installation of tracking valve rod:

(1) Use a vise with mouthing to clamp one end of the tracking valve rod (301). Install the
spring seat (331), springs (328 and 329) and stopper (334), and tighten the shim bolt (333)
to the specified torque.
(2) Insert the valve rod set described above in item ķ into case A (101) and case B (102).
Push the valve rod set into case A (101) and case B (102) slowly and carefully. Never push it
forcibly.
(i) Installation of valve cap:

(1) Install the valve rod cap (202, 204) to the back of the spring end of valve rods (tracking
valve rod, selection valve rod, swing valve rod, support arm - 1 valve rod, main arm - 1
valve rod, bucket valve rod and support arm - 2 valve rod), and tighten the inner hexagon
bolt (273) to the specified torque.
Make sure that O-rings (165 and 264) have been installed.
(2) Install the spring cover (203 and 201) to the spring end of valve rods (tracking valve rod,
selection valve rod, by-pass cutting valve rod, swing valve rod, main arm - 2 valve rod,
bucket valve rod, swing priority main arm valve rod and ally arm - 2 valve rod), and tighten
the inner hexagon bolt (273) to the specified torque.
Make sure that O-rings (261 and 262) have been installed.
(3) Install the support arm cap (206) to the spring end of support arm valve rod and bucket
valve rod, and tighten the inner hexagon bolt (273) to the specified torque.
Make sure that O-rings (261) has been installed.
(4) Insert the piston (355) into the corresponding ally arm cap of the ally arm cap (206), install
O-ring (561) into plug (551) and tighten it to the specified torque.
156

(j) Installation of straight tracking valve integrated package:
(1) Install the O-rings (165, 166,167 and 266) into the straight tracking valve integrated
CONTENTS
package (103), and tighten the inner hexagon bolt (273) to the specified torque.
[THE INSTALLATION PROCEDURES OF STRAIGHT TRACKING VALVE INTEGRATED
PACKAGE ARE AS FOLLOWS]
(a) Clamp the case (103) with a vise.
(b) Install the master pressure relief valve (601) to the case, tighten it to the specified
torque. (The installation procedures of master pressure relief valve is explained
separately. ) 1
(c) Install the poppet head (511) and spring (521), tighten the plug (551) to the specified
torque.
(d) Tighten the throttle ring (357) to the specified torque with hexagon wrench. Install the
O-ring (163) to the plug (156), and tighten it to the specified torque.
(e) Install the piston (309), valve rod (308), sleeve (344), spring seat (376) and spring
(375), be careful not to install them to the wrong direction. Then install the O-ring 2
(266) to the plug (356), and tighten it to the specified torque.
(f) Install the valve rod (391), springs (324 and 325) and stopper (338). Install the O-
ring (266) to the screw-in sleeve (251), and tighten it to the specified torque.
(k) Installation of master pressure relief valve:
(1) Insert the shim (122), C-ring (121), O-rings (163 and 561) and retainer (562) into the
screw-in sleeve (103). 3
(2) Install the piston (614) and O-ring (661) to the stopper (613). Install it to the regulating
sleeve (104) temporarily, and tighten the adjusting screw (652) and lock nut (671).
(3) Install the poppet head (611) and spring (621) to the screw-in sleeve (103) described
above, and install the regulating sleeve (104) installed with O-rings (663 and 664) (step ĸ
above ).
4
Make sure that poppet head (611) has been firmly installed to the seat of screw-in sleeve (103).
(4) Install the plunger (512) and spring (521) to the seat (541).
(5) Install the seat described above in step ĺ to the screw-in sleeve (103) set described
above in step Ĺ and secure it with the C-ring (121). 5
(6) Tighten the adjusting screws (104 and 652) temporarily as the pressure adjustment should
be performed in accordance with the service standard.
7
INDEX
157
3-6-5. Checking of main valve

Num Check
Check Item Technical Requirement Check Method
ber Instrument
Check if there are crackings, air blisters or
Package
obvious polished vestiges on the main Check main valve surface Visual
1 and
valve surface, or oil leakage from the and each contact surface inspection
appearance
contact surface
Surface Check all the PF1/4, PF3/8, PF1 oil ports, Vernier
Check upon the drawings
2 quality and SAE1" and SAE2" flanges, contour size caliper,
provided by Kawasaki
oil port and all the crucial dimensions straight edge
Filter paper,
The pollution level number of solid particles microscope,
Counting method,
for the hydraulic oil being tested should not automatic
3 Cleanliness gravimetric method and
be higher than ISO15/1, or the particle microscope,
pollution index method
pollution level should below 2-4 mmg/100 cc electronic
balance
Clean the valve being
tested, if some places
cannot be wipe up at one
When the main valve is being tested in the time, clean it again when
external leakage checking, no leakage the oil leakage occurs after
Sealing Absorbent
4 should occur at the static seal and rotation. Press and paste
performance paper
the dynamic seal should not the clean absorbent paper
drop oil within 4 hours. onto the static seal part,
then lift down, it should be
oil leakage if the paper is
spotted with oil.
The inner leakage amount should meet the
Inner Machinery Industry Standard JB/T8729.1- Main valve
Check under the JB/
5 leakage 1998 of the People's Republic of China (Not inspection
T8729.2 stipulation
amount greater than 280 ml/min at meso-position console
and 1600 ml/min at reversing position)
The reversing times should not be less than
100 thousand times, the inner leakage
amount should not be greater than 10% of
Check under the JB/ Main valve
the specified value after being tested, the
6 Durability T8729.2 stipulation grade inspection
opening frequency of safety valve should
A console
not be less than 80%, and the parts
should not be worn abnormally or
damaged in other forms.
158
UPPER SWING STRUCTURE - Swing unit
3-7. Swing unit
CONTENTS
3-7-1. Removal and installation of swing reduction machine
Repairing essentials
1. Precautions
This reduction machine is designed for the average life and the fewer number of components.
There is a large number of components which are necessary to be replaced simultaneously in 1
the structure and function when replacing, even though each of the components is supplied
separately. These are already shown in Table 1.1, please pay attention.
2. Inspecting requirement and replacing standard of components
(a) When the dents are appearing in the serrations of the sun gear, the planetary gear and the
gear ring.
(The depth of each dent is I1 mm, and the area is 5% or more) 2
(b) Oil packing
Replace it when its surface is damaged and worn. It is recommended that it must be
replaced when the disintegrating reduction machine is inspected.
(c) Drive shaft supporting bearing (Front)
Do not pull it out from the drive shaft, and observe the following items to inspect.
(1) Check if the mirror surface of the bearing and the ball which can be seen are no 3
clearance or crack.
(2) And confirm it by the following items.
(a) Confirm if the wear powder in the gear oil is excessive.
(b) Confirm if the wear powder attaching between the balls is excessive.
(c) Confirm if you can turn it easily with your hands.
Replace it if it is abnormal after checking. The bearing which is pulled out from 4
one side of the shaft cannot be reused.
(d) Drive shaft bearing (Rear)
Replace them when there is a clearance or a break between the bearing surface and ball.
(e) No.2 planetary gear sliding bearing part
Check if there is a clearance in the circumference direction among the No.2 carrier
assembly, No.2 planetary gear and No.2 pin. 5
Replace it if the clearance is 0.5 or more.
(f) End panel type
Replace it when there is visible damage in No.2 sun gear rotating surface.
(g) Replace them if there is a clearance or damage in the rotating surfaces of No.1 needle
roller bearing and No.1 pin which are supporting the planetary gear.
6
7
INDEX
159

Table 1.1 Part & component list (kit)
Components Which Are Replaced Simultaneously
Symbol 201 401 402 203 230 282 285 910 210 231 283 403
Self-aligning ball-bearing
Self-aligning ball-bearing
No.2 planetary gear
No.1 planetary gear
Needle gauge
No.2 carrier
No.1 carrier
Drive shaft
End panel
Spring pin
No.2 pin
No.1 pin
Name
201 Drive shaft — ƻ ƻ

Self-aligning
Components which need to be replaced
401 Ƹ — Ƹ
ball-bearing
Self-aligning
402 Ƹ Ƹ —
ball-bearing
No.2 planetary
203 — Ƹ ƻ Ƹ ƻ
gear
230 No.2 carrier Ƹ — ƻ Ƹ ƻ
282 No.2 pin Ƹ Ƹ — Ƹ ƻ
285 End panel Ƹ Ƹ ƻ — ƻ
910 Spring pin Ƹ Ƹ ƻ Ƹ —
No.1 planetary
210 — Ƹ Ƹ Ƹ
gear
231 No.1 carrier Ƹ — ƻ Ƹ
283 No.1 pin Ƹ ƻ — Ƹ
403 Needle gauge Ƹ Ƹ Ƹ —
ƻ means the components which must be replaced simultaneously.

Ƹ means the components which are recommended to be replaced simultaneously.
The inner and outer gears of the roller bearing must be replaced simultaneously.
3. Disassembling and assembling requirements

(a) Bolt size and the rotating torque.
Table 1.2 means the bolt size and the rotating torque which are used for the reduction
machine.
The bolt size and rotating torque in Table 1.2
Symbol Name Size Hexagon Width Rotating Torque
602 Inner hexagon bolt M14 Length130 12 mm 157 Ngm
901 Oil drain connector PT1/2 22 mm 65 Ngm
925 Exhaust connector PT1/4 14 mm 22 Ngm
926 Grease fitting PT1/4 14 mm 22 Ngm
(b) Tools
Hexagonal wrench (double side width 12), socket wrench, shifting spannar, double-ended
spanner, hammer, plastic hammer, screwdriver, torque wrench, gear special tools (refer to
Item 1.3.4), liquid sealer (Three Bond No.1104B). The oil grooves which are inserted with
high temperature (80qC ~ 100qC).
(c) Disassembling assembling essentials
Disassemble and assemble it as the sequence shown from the following page.
160
CONTENTS
1. Be careful not to damage the components when disassembling.
2. Check each of the components by following the essentials of Item 1.2 before assembling.
3. Wash each component with the washer fluid and dry it with the compressed air.
4. After stripping off the liquid packing with the chamfering tool while disassembling, degrease it
after precision-made of the surface with the gouge slip.
5. Rotating torque is performed by following the requirements of Item 1.3.1. 1
7
INDEX
161
Operation Precautions
1. The gear oil of the swing mechanism is drained from the oil drain Pour the gear oil to the clean
connector of the excavator. Remove the swing mechanism from the container and check if there is
excavator. Remove the gear motor from the swing mechanism body, wearing powdery material.
please refer to the outside dimension illustration. Put the swing Please refer to the guidebook for
mechanism body on the proper workbench. the oil pressure motor.
2. Loosen the inner hexagon bolt (602), and remove the oil pressure
motor.
3. Remove No.1 sun gear A (211).
4. Remove No.1 carrier as a unit, and take out No.1 planetary gear B
(210), etc. in their original installation state. Each planetary gear and pin will
5. Disassemble No.1 carrier assembly be marked, and make sure that
(a) Remove center pin B (283). the gear and pin are not
(b) Remove No.1 planetary gear B (210) and needle gauge (403). combination misalignment.
(c) Remove the bracket plate E (285) which is in the lower part of the
planetary gear.
(d) Remove the bracket plate F (287)
Do not remove No.1 pin (283) from No.1 carrier B (281) i

there is no abnormality.
6. Remove No.2 sun gear B (204).
7. Remove No.2 carrier assembly.
8. Disintegrate No.2 carrier assembly.
It is unnecessary to disassemble No.2 carrier further when there is no The removed No.2 pin cannot be
special circumstance. Hold it and check the components by following reused.
the requirements of Item 1.2. No.2 carrier which is described above is
recommended being replaced with the mating one as much as possible.
Perform the following requirements if it is necessary to replace some of
the components only.
(a)Take out No.2 pin A (282) which is in the deep side after taking out
If the self-aligning ball-bearing
the spring pin (910).
(402) is left in the case, the shaft
(b)Take out No.2 planetary gear A (203) and side plate B (286) laterally. will fall down from the lower part,
9. Take out gear ring A (202). and be careful not to injury
Insert the slotted screwdriver into the two pulling holes which are on the yourself.
joint surface of the gear motor casing A (102) and gear ring A (202).
Take it out without damaging the joint surface. Impact
10. Take out the retainer (913) from the drive shaft E (201).
11. Put the shaft end on the workbench with the flange supporting, and tap
the center of the shaft with a plastic hammer to pull out the shaft which
is downward.
Do not disassemble it further when there is no special circumstance.
In this state, check the components by following the requirements of
Item 1.2. The drive shaft assembly which is described above is
recommended being replaced with the mating one as much as possible.
Observe the following requirements if it is necessary to replace some of
the components only.
It is not necessary to disassemble as follows if there is no abnormality
in this stage.
12. Use the impact to pull out the bearing packing (915) and the self-
aligning ball-bearing (401) when the drive shaft components are
supported as shown in the right illustration.
13. Take out the oil packing (801) from the gear motor casing (102).
The removed oil packing and

bearing seal ring cannot be
reused.
162
CONTENTS
1. Assembly of the drive shaft assembly Refer to the Item 1.3.4 about the
(a) Insert the bearing seal (915) into the drive shaft (201). clamp.
(b) Apply the inside of the self-aligning ball-bearing (401) with enough As the center of the self-aligning
grease, and press it exactly with the impact. Inner race is tapped in ball-bearing (401) is separated,
the final meshing with the key and ensure that it is rebounded with fill the lubricant in the two sides
the hammer. Then apply enough grease sufficiently as the following before installing the shaft.
illustration.
1
The bearing outer race

sometimes cannot be tapped in
slightly even when it is tilting. Do
not tap it forcibly in this case, tap 2
it after pulling out the bearing
outer race and place it on a level
surface.
Grease
3
2. Place the casing (102) to the level workbench. Use the clamp of Item 1.3.4.
3. Lift vertically by the bolt which is in the shaft end of the drive shaft Install it horizontally to prevent
assembly, and install it into the gear motor casing. Keep the bearing the oil seal ring from being
outer race level fully and tap it in slightly. damaged.
4. Place the shaft side which is downward with the flange supporting in the
gear casing. 4
5. Place the oil seal ring into the case (102). The dimension of the inner race
6. Press in the clamp with the bearing outer race, and press in the inner end surface is controlled from
and outer race of the self-aligning ball-bearing under the impact. the shaft end with the clamp
(Item 1.3.4).
7. Install the retainer (913).
8. Assemble No.2 carrier.
(a) Align the side end plate B (286) with the pin hole.
(b) Place into the planetary gear A (203).
5
(c) Confirm the position of the hole from up to bottom, look for the
corresponding direction which can place the holes of the spring pin
(910) and No.2 carrier to tap No.2 pin A (282) slightly.
7
INDEX
163
9. Apply the liquid sealing material to the contact surface between the
case (102) and the gear ring (202).
10. Check the position of contact mark while placing the gear ring A (202)
in the case A (102), and holding it temporarily with 4 hexagon bolts or
inner hexagon bolts which are M14 with a length of 130. (The rotating
torque is above 157 Ngm.) The plate washer must be installed to the
bolt, and be careful not to damage the contact surface of the motor.
11. Install No.2 carrier into the inside of the gear ring.
12. Install No.2 sun gear A (204).
13. Assemble No.1 carrier assembly [(5) cannot be assembled as it must
be performed with special clamp].
(a)Place No.1 carrier A (231) to the leveling workbench.
(b)Install the middle side plate F (287).
φ2.5
(c)Install the side plate E (285).
(d)Install needle gauge (403) and No.1 planetary gear A (210).
(e)Align the I2.5 oil via hole of No.1 pin A (283) with the center of No.1
carrier (231) and face toward the exterior. (Right illustration) And
then, connect it with a special clamp.
14. Install No.1 carrier assembly.
15. Assemble No.1 sun gear A (211).
16. Remove the temporary tightening bolt, and apply the liquid sealing
material to the oil pressure motor mounting surface of the gear ring A
(202).
17. Install the retainer (912) to the drive shaft of the oil pressure motor, Be careful not to misplace it
hang it down vertically, align splines while installing the oil pressure as there are differences
motor and turning the inner hexagon bolt (602). between the thickness of the
18. Install the swing mechanism to the excavator and connect the oil drain up and down side plates.
rubber tube.
19. Fill the proper gear oil to the fill hole.
164

4. Clamping apparatus
(a) Install the oil packing clamp
CONTENTS
(b) Take out the aligning ball-bearing clamp
1) Oil Packing Clamp 2) Aligning Ball-bearing Clamp

1
φ125
2
176
3
3) Self-aligning Ball-bearing Clamp 146
166
φ10 4
φ160
φ93
φ 156
45
(c) Install the self-aligning ball-bearing clamp 6
7
INDEX
165
122 123 121 030 031 111033706 707 702 472 712 488 469 355 351
985 303
124 162
443 052
A 171
491 161
151
101
A 163
985
444
984
993
114 131
451
301 994 742 743 401 050 051
400 398 399 100 390

391
052
Detailed Illustration of the Exhaust Port

DIMENSION
A B C D
NAME
A. B. M PF3/4 45 30.8 3.5
DB PF3/8 28 18.6 2.5
PA. PB. PF1/4 28 15.6 2.5
PG. SH PF1/4 32 15.6 2.5
Swing Direction
See from the direction of the shaft
Entrance Exit
side
A B Turn right
B A Turn left
166

Spur-gear Parameter Table
CONTENTS
Machining accuracy of the
Types of teeth spur tooth
tooth face
Tools
Module 12 Gear accuracy JIS level 7
Pressure angle 20q Tooth Span 56.807~56.944
thickne
Number of teeth 13 ss Number 3-2
Standard tooth pitch diameter 156 Material SCM420H 1

Rounded carburizing heat
Modification coefficient +0.5 Surface heat treatment
treatment
Gear clearance 0.145~0.290 Surface hardness HRC58~62
Addendum circle diameter 180.3 Effective case hardness HV550
Effective case depth 1.2-1.7 (Tooth bottom)
2
Tubing Exhaust Shape
Dimension Depth Tubing Rotating Torque
Oil Port Name Mark State of Carrying
of the Bolt Ngm kgfgcm
Ć2
Main oil port AB 167 1700 Plastic pin
PF3/4-20 3
Ć1
Oil filling port M 167 1700 Plastic pin
PF3/4-20
Ć1
Pressure detection port PA PB 36 370 Steel pin
2-PF1/4-15
Ć1
Drain oil port DB 74 750 Plastic pin 4
PF3/8-15
Ć1
Brake release port PG 36 370 Plastic pin
PF1/4-12
Ć1
Brake command port SH 36 370 Plastic pin
PF1/4-12
Metering rod L PT1/4-13 22 220 5
Gear oil port supply IP PT3/4-19 98 1000
Gear oil drain out DP PT1/2-22 65 660
Steel pin
Grease filler port GN PT1/4-13 22 220
Exhaust port when filling
AN PT1/4-13 22 220
with the grease 6
7
INDEX
167

Specification Parameter
Type M5×130CHB-10A-12C/260
Capacity 129.2 cm3
Maximun pressure 25.5 MPa 260 kgf/cm2
525 Ngm 53.5 kgfgm
Stoichiometric output torque
(at 260 kgf/cm2)
Oil Pressure Motor
Maximum flow 228 L/min

Maximum speed 1760 min-1
Brake torque 874 Ngm 874 Ngm
Release pressure 3.4 MPa 3.4 MPa
Maximum brake is allowed to release
4.9 MPa 4.9 MPa
torque
Cracking pressure 0.6r0.1 MPa 0.6±0.1 MPa
Delayed time 5+3 sec
Quality (Dry) Actual measurement 52 kg
Model RG10D20E3D
Reduction ratio 20.04
10500 Ngm 10500 Ngm
Reduction Machine
Stoichiometric output torque

(at 260 kgf/cm2)
Speed 87.8 min-1
Lubricant SAE#140 (GL-4)
Quantity of lubricant (Dry) Actual measurement 3.4 L
Suttle weight (Dry) Actual measurement 150.5 kg
Weight 202.5 kg
168
CONTENTS
312 311
925 801 402 390 391 202 230 602
231
1
204
287
211
912
2
283
313 314
3
403
210
201 915 102 401 926 901 913 910 286 203 282 285
4
Tightening torque of bolts and plugs
Tightening Torque
Part Name Bolt Dimension Hexagon Width
Ngm (kgfgcm)
602 M14 157 1600 12
901 PT1/2 65 660 10 5
925 PT1/4 22 220 14
926 PT1/4 22 220 14
Classification Declaration
The components can be purchased for the auxiliary spare parts (Apply any component other than
B
these ones). 6
/ It means the single component which consisting of B (it is not retail).
C It means that the components parts are available.
D Components which supplied first for customers are available.
7
INDEX
169
Serial Number of
Classificati Commodity
Part Number Part Name Number composing the component
on Serial Number
(quantity)
B 50 Oil filler Pipe 1 6326390-0209 313×1 314×1
B 40 Oil dipstick 1 6302500-0205 311×1 312×1
210×3 231×1
B 30 Auxiliary carrier 1 6321120-0216 283×3 285×3
287×1 403×3
Name Serial
Classification Part Number Part Name Material Quantity
Number
C 926 Grease fitting 1 6303560-0787
C 925 Exhaust plug 1 6303560-0786
Synthetic
C 915 Bearing seal 1 6326210-0015
rubber
D 913 Backstop ring Tool steel 1 OSR90 JIS B 2804 SR-90
D 912 Backstop ring Tool steel 1 OSR35 JIS B 2804 SR-35
D 910 Spring pin Tool steel 4 OSPV820 JIS B 2808 I8 L20
Screw ferric Carbon
C 901 1 OBP12U
plug steel
Synthetic
D 801 Oil packing 1 PTC10012513V TC10012513V
rubber
Inner
D 602 Alloy steel 14 OSBM14130 JIS B 1176 M14-130
hexagon bolt
Bearing
/ 403 Needle gauge 3 PBN5045AA
steel
Self-aligning Bearing
D 402 1 P22218RH
ball-bearing steel
Self-aligning Bearing
D 401 1 P22320
ball-bearing steel
C 391 Pin 2 OSK2548
C 390 Nameplate 1 PNPA-2550B
/ 314 Breathing cap Resin 1 6333160-0225
Carbon
/ 313 Oil filler pipe 1 6326390-0208
steel
Carbon
/ 312 Guide 1 6326390-0203
steel
/ 311 Metering rod 1 6302500-0203
/ 287 Carrier F 1 6333360-0968 D1=I42 DO=I86 t=2
C 286 Carrier B 4 6333360-0234 D1=I50 DO=I64 t=1
/ 285 Carrier E 3 6333360-0967 D1=I45 DO=I65 t=2
/ 283 No.1 pin B Alloy steel 3 6303540-0561
Carbon
C 282 No.2 pin A 4 6303540-0106
steel
No.1 support Special
/ 231 1 6324120-0206
B cast iron
170
No.2 support Special

C 230 1 6324120-0046
CONTENTS
A cast iron
No.1 sun gear
C 211 Alloy steel 1 6303190-0123
A
No.1
/ 210 planetary Alloy steel 3 6303190-0631
gear B
No.2 sun gear
C 204
B
Alloy steel 1 6303190-0633 1
No.2
C 203 planetary Alloy steel 4 6303190-0120
gear A
C 202 Gear ring A Alloy steel 1 6303190-0119
Transmission 2
C 201 Alloy steel 1 6324250-0312
shaft E
Gear motor Special
C 102 1 6323310-0144
casing A cast iron
7
INDEX
171

Disassembling and assembling essentials illustration
[FIGURE-1] [FIGURE-2]
172
CONTENTS
1
7
INDEX
173
[FIGUER-9] [FIGUER-10]
174
CONTENTS
1
7
INDEX
175
176
CONTENTS
1
3
[FIGUER-23]
INDEX
177
3-7-2. Removal and installation of swing motor

Disassembly Assembly
1. Tightening torque of bolts
Tightening torque of bolts which used for motor are shown in Table 1. Tighten it carefully by
following Table 1 when assembling.
Table 1 Tightening Torque of Bolts
Tightening Torque Distance Across
Component Symbol Name Screw Dimension
(Ngm) Flat (mm)
Inner hexagon
033 M6 12 5
screw
051 Safety valve M33 177 41
151 End cap PF1/4 36 6
Inner hexagon
171 M8 29 6
screw
400 Swing check valve M22 69 24
Inner hexagon
401 M20 431 17
screw
469 End cap M30 334 14
Oil drain connector PT3/8 74
Oil filling connector PT3/4 167
Oil dipstick PT1/4 22 11.8
314 Breathing cap PF1/2 2.7 \
313 Breathing tube PT3/4 98 24.8
If it is not corresponding to the component symbol above, refer to the cross section illustration.
2. Disassembling assembling tools
The disassembling and assembling tools which are necessary are shown as Pictures 1, 2 and 3.
The models and types of bolts and pins are different when using, prepare the tools after
researching.
Table 2 Wrench and Torque Wrench
Appropriate Symbol
Name Size 2 Sides Extent Tool
Component
Inner hexagon
M20 17 Hexagonal wrench
screw
Pin PF-1/4 6 VP pin Hexagonal wrench
Inner hexagon
M8 6 Hexagonal wrench
screw
Hexagon wrench,
M22 24 Swing check valve
socket wrench
End cap M30 14 RO pin Hexagonal wrench
Inner hexagon
M6 5 Delaying valve Hexagonal wrench
screw
Hexagon wrench,
M33 41 Safety valve
socket wrench
If it is different to the pins or bolts above, please refer to the cross section illustration.
178

Table 3 Others
CONTENTS
Specification
Size
Tools
Plier For lock ring Opening for I52 hole, I60 hole
Screwdriver Slotted middle for 2
Steel bar About 10×8×200 for 1
Hammer 1 plastic hammer, 1 iron hammer 1
Torque adjusting range
x For 100~450 kgfgcm
Torque wrench
Slide hammer bearing removal tool
2
Braking piston removal tool
7
INDEX
179
Brake Piston Removal Clamp
40
40
Two Ends M10
(Effective Thread
Length 20)
100
250
Inner Diameter
2×M10
10
M10
150
210
180

3. Disassembling essentials
(a) Disassemble the motor in the following sequence when disassembling it.
CONTENTS
Disassembling Sequence Precautions
Tie the outside of the motor with wire, lift it up with Seal each inlet with the tape to prevent foreign
1 a crane, and clean it with the washer oil. Dry it with matter from entering the motor, and clean the dirt
the compressed air after cleaning. and dust attached to it.
2 Drain the oil of the case (301) from the drain port.
Tighten the drive shaft (101) to the workbench
which can be disassembled easily with its end Select a clean place. The rubber plate or cloth is 1
3 downward. In this case, make the butting mark on paved on the disassembling workbench to prevent
the companion part of the case (301) and valve the components from being damaged.
casing (303).
Loosen the screw, and remove the delaying valve
4
(031) from the case (301).
There is a great possibility to damage the O-ring if
Loosen the safety valve (051), and remove it from 2
5 loosening the safety valve. It is recommended to
the valve casing (303).
replace the O-ring.
Loosen the swing check valve component (052),
6
and remove it from the valve casing (303).
Remove RO pin (469) from the valve casing (303),
7 Pay attention not to damage the piston socket.
and take out the spring (355) and piston (351).
Loosen the inner hexagon bolt (401), and remove 3
Operate it carefully to prevent the valve plate
the valve casing (303) from the case (301).
falling from the valve casing. (The valve plate is
If removing the bolts with the force of the brake
possible to adhere to the cylinder side. )
8 spring (712), the valve casing will spring from the
Caution is advisable that do not damage the
case.
contact surface when prying it with the screwdriver,
Go on removing the valve plate (131) from the
etc.
valve casing (303).
Pull out the brake spring (712) from the brake 4
9
piston (702).
Pull out the brake piston (702) from the case (301) Pull it vertically using the bolt hole of the brake
10
with tools. piston.
Push rod is easy to be separated when removing
Place the motor horizontally, and pull out the the cylinder, so pay attention to it. In addition,
cylinder (111) from the drive shaft (101). Then pull caution is advisable that do not damage the sliding
11 out the piston (121), clamp plate (123), spherical surface of the cylinder, spherical surface bush, 5
surface bush, gasket F (117) and bearing shell bearing shell, etc.
plate (124) further. Follow Operation 11 to remove the bearing shell
plate if it cannot be removed.
Pull out the friction plate (742), release plate (743)
12
from the case (301).
Oil seal will be damaged by the spline when
13
Pull out the drive shaft (101), bearing shell plate
removing the drive shaft. Therefore, wrap the 6
(124).
spline of drive shaft with plastic tape, etc.
7
INDEX
181

14 Perform the following operations as necessary. Tap the inner race of the cylindrical roller bearing
1. Take out the inner race of cylindrical roller with the steel bar. However, tap it evenly to prevent
bearing from the drive shaft (101) by pressing. the bearing from being damaged.
The removed bearing cannot be reused.
Stamp
Drive Shaft
2. Remove the lock ring with the screwdriver, and

pull out the seal cover (305) from the case
(301).
Install the bolt into the screw hole (M4×0.7) of
the oil seal (491), and take out the oil seal
(491) from the case (301).
3. Tapping the oil seal (491) bracket side with the
pontil, and remove the outer race of the
The removed bearing cannot be reused.
cylindrical roller bearing (443) from the case
(301).
4. Remove the cylindrical bearing (444) from the
valve casing with the slide hammer bearing The removed bearing cannot be reused.
removal tool.
Check if each component is normal after disassembling.
(b) When only replacing the oil seal
Disassembling Sequence Precautions
Remove the lock ring (437) with pliers, and take
1
out the seal cover from the case (301).
Install the bolt into the screw hole (M4×0.7) of the
2 oil seal (491), and take out the oil seal (491) from
the case (301).
Apply a light coat of lubricant to the lip of the oil
seal.
Install the bolt into the screw hole (M4×0.7) of new
Install it carefully to prevent the lip of the oil seal
3 oil seal (491), and then install it to the case (301)
from being damaged.
and drive shaft (101).
Wrap the spline of the shaft with the plastic tape,
etc. to protect.
Place the seal cover (305) in, and install the lock
4
ring (437) to the case (301) with pliers.
182

4. Assembling essentials
Assembling is the opposite of disassembling, but you should pay attention to the following
CONTENTS
precautions.
(a) The parts damaged when disassembling must be repaired, and the replacing components
should be prepared beforehand.
(b) Clean each component with the washer fluid, and then dry it with the compressed air.
(c) After applying clean action oil to the slide part, bearing, etc., and then assemble.
(d) The seal components of the O-ring and oil seal should be replaced in principle.
(e) Tighten the mounting bolts, pins with the torque wrench. Tighten them with the torque 1
wrench of Table 1.
The following is the assembling sequence.
Assembling Sequence Precautions

1 Place the case (301) to the proper workbench, and
place the valve casing (303) side on it. 2
2-1 (This operation is only for removing the cylinder Take care to the collar of the cylindrical roller
roller bearing) Drive shaft (101) heat-presses the bearing.
inner race.
Output Shaft Side
2-2 Heat-press the inner race of the cylindrical roller

bearing in the drive shaft. 4
3 (This operation is only for removing the oil seal) Pay attention to the direction of the oil seal.
Install the lock ring (437) to the case (301), and (Refer to the structure diagram)
place it in the seal cover (305), and insert it into the Apply a light coat of lubricant to the lip of the oil
oil seal (491) with a clamp. seal.
Tap it evenly to avoid damaging the outer
circumference.
5
4 Tap the outer race of the cylindrical roller bearing There is a great possibility to damage the O-ring if
(443) slightly with the steel bar, and install to the loosening the safety valve. It is recommended to
case (301). replace the O-ring.
5 Install the drive shaft (101) to the case (301). Insert it carefully to prevent the lip of the oil seal
from being damaged.
Wrap the spline of the shaft with the plastic tape,
etc. to protect. 6
6 Place the case (301) horizontally, and insert the Install the bigger surface of the bearing shell plate
bearing shell plate. to the case side.
Apply a light coat of lubricant to the contact surface
to prevent it from dropping.
7 Insert the push rod (116) into the cylinder (111). Be careful not to damage the slide part of the
Then place the spherical surface bush (113) with cylinder. 7
gasket F (117) to the cylinder. (Place 2 push rods to each hole)
8 Set the sub pistons (121, 122) on the perss plate
(123).
INDEX
9 Install the sub pistons (121, 122) which are set on It is easy to insert the drive shaft if the phases of
the press plate (123) to the cylinder (111), and spherical surface bush and the spline of the
insert them to the spline of the drive shaft (101) cylinder are matched.
while aligning.
183
Assembling Sequence Precautions

10 Place the case (301) which is downward to the Assemble up and down the 4 cut-out parts of the
seal cover side (305), install them to the case (301) gear to the same phase with the friction plate.
in the sequence of the release plate (743), friction Install the 4 cut-out parts to the positions of the
plate (742). illustration with the release plate.
Install 4 release plates and 3 friction plates.
11 Install the O-ring (706), (707) to the case (301). If applying a light coat of lubricant to the O-ring, the
brake piston is not easy to break when inserting.
12 Install the brake piston (702) to the case (301). There are 4 cut-outs in the brake piston. Assemble
them as the positions in the illustration. (Align the
position of M8 screw with the right illustration)
Screw the M8 hexagon bolt into the brake piston
and tap its top evenly with the plastic hammer
when the brake piston is difficult to enter due to the
resistance of the O-ring.
Brake Piston
2×M8
Reverse Cut-out
13 Install the brake spring (712) to the brake piston Confirm if the spring is already in the counter
(702). boring of the brake piston.
14 (It is only for removing the cylindrical roller bearing) Tap the outside of the outer race evenly until it is
Insert the outer race of the cylindrical bearing (444) stopped at the valve casing step.
into the valve casing (303) while tapping it slightly
with a steel bar.
15 Install the valve plate (131) to the valve casing Apply a light coat of lubricant to the contact surface
(303), and then install the O-ring (472). of the valve plate. (Prevent dropping)
16 Install the valve casing (303) to the case (301), and Pay attention to the installing direction of the valve
tighten it with the inner hexagon bolt. casing. (Refer to the outside dimension illustration)
Be careful not to detach the valve plate.
Be careful not to make the brake spring fall down.
The inner hexagon bolt must be tightened evenly.
17 Insert the piston (351), spring (355) into the valve Make sure that the piston can be moved smoothly.
casing (303), and fix the RO pin (469) with O-ring
(488) to the valve casing (303).
18 Install the safety valve (051) to the valve casing
(303).
19 Install the swing check valve component (052) to Do not leave the O-ring.
the valve casing (303). Install the plate when there is no swing check valve
component.
The above installation is finished.
184

Repairing essentials
CONTENTS
1. Replacing standard of friction components
Each component should be replaced or readjusted if its worn exceeds the following standard.
However, it is not limited within the standard if its appearance is damaged obviously.
Standard Dimension Recommended
Items Handling
(mm) Replacing Value (mm)
Clearance between the
piston and the cylinder Replace the piston or the
0.027 0.052 1
bore. cylinder
(D-d)
Clearance between the
piston and the top of the Replace the piston bearing
0 0.3
bearing shell shell assembly
(G)
Thickness of the bearing 2
Replace the piston bearing
shell 5.5 5.3
shell assembly
(t)
Combination height of the
Replace the clamp plate
clamp plate spherical
5.5 5.0 spherical surface bush as a
surface bush
unit
(H-h) 3
Thickness of the friction
1.8 1.6 Replace
plate
δ
4
t
h H
Clearance between the piston and the top of the Combination height of the clamp plate spherical
bearing shell ( ¥ ) surface bush (H-h) 5
Thickness of the bearing shell (t)
7
INDEX
185

2. Correcting standard of the sliding surface
Please correct or replace the sliding surface of each component when its roughness exceeds
the following standard.
The surface roughness which
Part Name Standard Surface Roughness
needs correcting
0.8-Z (Ra=0.2)
Bearing shell 3-Z (Ra=0.8)
(Grind)
0.4-Z (Ra=0.1)
Bearing shell plate 3-Z (Ra=0.8)
(Grind)
1.6-Z (Ra=0.4)
Cylinder 12.5-Z (Ra=3.2)
(Grind)
0.8-Z (Ra=0.2)
Valve plate 6.3-Z (Ra=1.6)
(Grind)
1. The roughness of each sliding surface should be grinded below the standard roughness.
2. Replace the component as a unit when the sliding part of the clamp plate spherical surface bush
is rough.
186

Disassembling and assembling essentials illustration
CONTENTS
1
7
INDEX
187
188
CONTENTS
1
INDEX
189
190
CONTENTS
1
INDEX
191
192
CONTENTS
1
INDEX
193
194
CONTENTS
1
INDEX
195
196
CONTENTS
1
[FIGUER-43]
INDEX
197

Anti-rebound valve
6 7 B
1 2 3 4 5
1 2 3 4
1. Valve Body
2. Slide Valve (MA side)
3. Spring (MA side)
4. Plug
5. Slide Valve (MB side)
6. Spring (MB side)
7. Plug
7 6 5
Swing
Motor T
MB MA
Swing Control Valve
198

General description
MA The valve reduces the swing shake which is caused by
CONTENTS
c e D4 a D3 the inertia of the swing body, the reactive thrust and rigid
T of the mechanical system and the compressibility of the
hydraulic oil, etc. when the swing stopped. It is effective
to prevent the load of the inner bucket from overflowing
and reduce the circulation time when stopping swinging
(The location performance is very good, and it can be
moved quickly to perform the next task. ) 1
D1 d D2 b f T
2
MB
Notch
Operation
MA 1. When the brake pressure is caused in the oil port
2 3
e MB
3
T x The pressure MB enters the oil chamber d
through the cutout, and valve core (5) will
push the spring (6) to the left by following the
area difference of D1 ˚ D2, and connect MB
with e. When this case occurs, the pressure
MA is lower than the set pressure of spring
(3), so the sliding valve (2) does not move. 4
Due to this reason, the pressure oil is closed
by the sliding valve (2) so that the braking
force can be guarantied.
D1 d D2 T
6 MB 5 5
Notch
2. After stopping the motor

MA x The motor is turning reversely (first
2 3
a
reversion) as the oil port MB causes the
T closing pressure under this circumstance,
6
the reversion pressure is caused by the oil
port MA. The pressure MA enters the oil
chamber a, and so the slide valve (2) will
push the spring (3) to the right, and connect
MA with b. In this case, b will connect with f
through the drill of the valve core (5).
Therefore the reversion pressure of the oil
7
port MA will go to the oil port T to prevent
second reverse turning.
b f T
INDEX
5 MB
199
UPPER SWING STRUCTURE - Left and right pilot valve
3-8. Left and right pilot valve
3-8-1. Removal and installation of right pilot valve
pressure.
Preparation
the top of the hydraulic oil tank to release all
the residual pressure.
Removal
1
1. Loosen the protector (1) and move it upward.
At this time, the set screw (2) of the right pilot
valve (3) and the set screw (4) of the upper
2 cover (5) are exposed.
2. Pry up the rear cover, the set screw (4) of the
4 5
3 upper cover (5) is exposed.
3. Remove the screws (4) (×4), move the upper
4
cover (5) of the right armrest box upward.
Disconnect all the electrical connectors, then
remove the upper cover (5).
4. Remove the screws (2) (×4), and move the right
pilot valve (3) upward.
: 5 mm (0.2 in)
Tag all the removed hoses for convenient reassembly.
200

5. Disconnect the connectors and hoses (6~11).
: 17 mm (0.67 in)
CONTENTS
10 11 : 19 mm (0.75 in)
6
7
8
To prevent the oil pipe from being contaminated, cap
9
all the hoses
1
6. Remove the plug (13) on the wire which leads
to the horn button.
12
7. Remove the screw (14) of the locking lever (12)
14 and right pilot valve (3), and remove the handle
13
(12).
: 8 mm (0.31 in) 2
6- Hose T: (To the PT block oil outlet)

7- Hose P: (To the PT block oil inlet) 3
8- Hose 1: (To the transition block signal
port of the bucket dumping)
port of the boom lifting)
port of the bucket digging)
4
port of the boom lower)
Right Handle Right Handle

P Port 1, 2, 3, 4, T Ports
M14×1.5
5
M14×1.5
PF1/4 PF3/8
7
INDEX
201

Installation
1. Connect the hoses (6~11).
11 6 : 1 mm (0.67 in)
10
7 : 24 Ngm (2.4 kgfgm, 17.28 lbfgft)
8 2. Install the protector (1) to the right pilot valve
9 (3), pass the horn button wire through the
protector (1) and the spare hole on the right
pilot valve (3), then connect the plug (13).
12
Be sure to pass the horn button wire through the
14 13 spare hole on the right pilot valve (3), it will easily be
worn and damaged if passing from outside.
3. Tighten the screw (14) of the locking lever (12)

and right pilot valve (3), and tighten the set
screws (2) (×4) of the right pilot valve (3).
6- Hose T: (To the PT block oil outlet) : 8 mm (0.31 in)
7- Hose P: (To the PT block oil inlet) : 66 Ngm (6.6 kgfgm, 47.52 lbfgft)
8- Hose 1: (To the transition block signal : 5 mm (0.2 in)
port of the bucket dumping) 4. Connect all the electrical connectors, install
9- Hose 2: (To the transition block signal the upper cover (5) to the right armrest box,
port of the boom lifting) and tighten the screws (4) (×4).
5. Install the protector (1).
port of the bucket digging)
port of the boom lower)
After installation, check the oil level. Start the engine
and check for oil leakage.
202
3-8-2. Removal and installation of left pilot valve
CONTENTS
serious burns. Don't repair until hydraulic oil cooling down. 1
pressure.
Preparation
1. Stop the excavator on a solid and flat ground. 2
2. Stop the engine. Loosen the air release valve
on the top of the hydraulic oil tank to release
all the residual pressure.
Removal
1 1. Loosen the protector (1) and move it upward.
At this time, the set screw (2) of the left pilot
valve (3) and the set screw (4) of the upper 4
cover (5) are exposed.
2
2. Pry up the rear cover, the set screw (4) of the
4 Radio upper cover (5) is exposed.
3
3. Remove the screws (4) (×4), move the upper
4 cover (5) of the left armrest box upward. 5
Rear
Cover Disconnect all the electrical connectors, then
5 remove the upper cover (5).
Air Conditioning 4. Remove the screws (2) (×4), and move the left
Panel pilot valve (3) upward.
: 5 mm (0.2 in)
6
Tag all the removed hoses for convenient reassembly.
7
INDEX
203

5. Disconnect the connectors and hoses (6~11)
: 17 mm (0.67 in)
11
: 19 mm (0.75 in)
6
10
7
8
9 To prevent the oil pipe from being contaminated, cap
all the hoses
6. Remove the plug (13) on the wire which leads

to the secondary boosting button.
12
7. Remove the screw (14) of the locking lever (12)
14
and left pilot valve (3), and remove the handle
13
(12).
: 8 mm (0.31 in)
6- Hose T: (To the PT block oil outlet)

7- Hose P: (To the PT block oil inlet)
port of right swing)
port of the arm digging)
port of left swing)
port of the arm dumping)
Right Handle Right Handle

P Port 1, 2, 3, 4, T Ports
M14×1.5
M14×1.5
PF1/4 PF3/8
204

Installation
CONTENTS
1. Connect the hoses (6~11).
11 : 17 mm (0.67 in)
10 6
7 : 24 Ngm (2.4 kgfgm, 17.28 lbfgft)
8 2. Install the protector (1) to the left pilot valve (3),
9 pass the secondary boosting button through
the protector (1) and the spare hole on the left
pilot valve (3), and connect the plug (13). 1
12
Be sure to pass the secondary boosting button
14 13 through the spare hole on the left pilot valve (3), it will
easily be worn and damaged if passing from outside.
2
3. Tighten the screw (14) of the locking lever (12)
and left pilot valve (3), and tighten the set
screws (2) (×4) of the left pilot valve (3).
6- Hose T: (To the PT block oil outlet) : 8 mm (0.31 in)
7- Hose P: (To the PT block oil inlet) : 66 Ngm (6.6 kgfgm, 47.52 lbfgft)
3
8- Hose 1: (To the transition block signal : 5 mm (0.2 in)
port of right swing) 4. Connect all the electrical connectors, install
9- Hose 2: (To the transition block signal the upper cover (5) to the left armrest box, and
port of the arm digging) tighten the screws (4) (×4).
5. Install the protector (1), and cap it with the rear
port of left swing)
cover. 4
port of the arm dumping)

5
7
INDEX
205
3-8-3. Disassembly of left and right pilot valve
1 14
14
2
3
4 15
5 5
6 6
7 7
16
8 8 20
9 17
10
10
19
11 11
18
13
12
1 - Lock Nut (×1) 2 - Adjusting Nut (×1) 3 - Cam Plate (×1) 4 - Joint Union (×1)
5 - O-ring A (×4) 6 - Oil Seal (×4) 7 - O-ring B (×4) 8 - Push Rod (×4)
9 - Clamp Plate (×1) 10 - Spring Guide Bush (×4) 11 - Return Spring (×4) 12 - Spring Washer (×4)
13 - Balance Spring (×4) 14 - Valve Rod (×4) 15 - Case (×1) 16 - O-ring C (×1)
17 - Oil Port End Plate (×1) 18 - Screw (×2) 19 - Washer (×2) 20 - Bush (×1)
206
3-8-4. Disassembly of left and right pilot valve
CONTENTS
The oil seal (6) is made of brass alloy, the case (15) is made of aluminum alloy. They may be
deformed and damaged by excessive force. Therefore, remove and install it carefully.
Valve Rod (14) is opted by the hole of the case (15), so they must be replaced as a set.
Do not remove the lock nut (1) by holding the case (15) with a vise because it could generate great 1
torque on the lock nut.
1. Hold the adjusting nut (2) with a 22 mm open spanner, and remove the clamp nut (1) with
a 26 mm open spanner.
: 22 mm (0.87 in)
: 26 mm (1.0 in) 2
2. Hold the adjusting nut (2) with a vise. Then turn the cam plate (3) with a wrench, and
remove the adjusting nut.
: 32 mm (1.26 in)
3. Hold the flat of the case (15) lightly with a vise. Remove the cam plate (3) from the joint
union (4).
: 32 mm (1.26 in) 3
4. Press the top of the clamp plate (9) firmly with a special tool, and remove the joint union
(4).
5. Remove the clamp plate (9) slowly from the oil

4 6
seal (6), it's suggested removing after
4
releasing the spring force with the special tool.
6. Remove the oil seals (6) (×4) and push rods (8)
(×4) separately.
9
Special Tool
Be careful not to lose O-rings in the oil seal, take 5
them out from the oil seal and store.
7
INDEX
207

7. Remove the spring guide bush (10), return
14 14 spring (11), spring washer (12), balance spring
(13) from the valve rod (14).
Since the valve rod is used with the hole in the case,
carry them properly when removing so that they can
15
be installed to the original oil port.
8. Remove the valve rods (14) (×4) from the case

(15). Pull them out while turning.
The valve rod and case must be replaced as a unit.

20 16
9. Hold the flat of the case (15) lightly with a vise,
and remove the inner hexagon bolts (18) (×2)
17 to remove the oil port end plate (17).
: 6 mm (0.24 in)
19
18 10. Remove the O-ring C (16) and bush (20) from
the case (15).
208
3-8-5. Assembly of left and right pilot valve
CONTENTS
13 14
10
12
15 1
8,9
11
7
16
3,4 2
5,6
2
19
3
1
17
4
21 20 18
1 - Spacer Sleeve (×4) 2 - Shim (Several) 3 - Balance Spring A (×2) 4 - Balance Spring B (×2)
5 - Return Spring A (×2) 6 - Return Spring B (×2) 7 - Snap Spring (×4) 8 - Push Rod A (×2)
9 - Push Rod B (×2) 10 - Spacer Block 11 - Inner Hexagon Bolt (×2) 12 - Cam
13 - Threaded Connector 14 - Joint Union 15 - Oil Seal (×4) 16 - Spring Guide Bush (×4) 5
17 - Valve Rod (×4) 18 - Case 19 - O-ring 20 - Aligning Pin (×2)
21 - O-ring (×2)
The pilot valve is contaminated easily. Keep the parts clean when assembling. 6
1. Insert the thin end of the valve rod (17) into the case (18), then turn the case by pushing
the valve rod.
7
The valve rod and the hole in the case are optional. The valve rod and case must be replaced
together as a unit.
2. Install the spacer sleeve (1), shim (2), balance spring (3) or (4), return spring (5) or (6) to
INDEX
the valve rod (17) which has been installed on the case (18).
209
Install the spring guide bush with the protruding part facing upward.
3. Install the spring guide bush (16) to the return

spring (3) or (4).
Ring Seat 4. Install the snap spring (7) to the ring seat.
7
5. Insert the top of the valve rod (17) into the hole
Ring Seat of the spring special tool, and press the spring
Special Tool from the top of the spring guide bush (16).
Install the snap spring (7) to the top of the
17
valve rod with the ring seat .
Sealing Material
Put a sealing material whose diameter is about 8 mm
(0.3 in) and length is 10 mm (0.4 in) on the oil hole.
And it is not only easy to work, but also the valve rod
will not fall to the bottom when pressing the spring
down.
6. Install the remaining valve rods (17) (×3) to the

case (18) by following the same procedure as
the steps 2~5.
210

7. Install the O-ring (19) and two O-rings (21) to the case (18).
CONTENTS
13 14
10
12
1
8,9
15
11
4
20 18
8. Apply grease to the internal surface of the oil seals (15) (×4), then install the oil seals (×4)
to the spacer block (10) with a bamboo splint.
5
The oil seal will enter the inside most of the hole when operating, so insert the push rods (8), (9) at
first to prevent this happening as shown in the following illustration.
Oil Seal Installation Hole
6
8, 9 Check the installation positions of the push rods.
10
9. Install the push rods (8), (9) to the spacer block
(10). Install the push rods with grooves to the
oil ports #1 and #3 and the push rods without
grooves to the oil ports #2 and #4 separately
when installing . 7
10. Apply grease to the end ball parts of the push
rods (8), (9).
11. Apply grease to the union part of the joint union (14).
INDEX
211

12. Align the position of the aligning pin (20), install the spacer block (10) module to the case
(18) with the inner hexagon bolts (11) (×2).
: 6 mm (0.24 in)
Be sure to tighten the cam.
13. Hold the case (18) carefully with a vise, then install the cam (12) to the joint union (14).
Tighten the joint union so that the clearance between the cam and push rods (8), (9) is
0~0.2 mm.
: 32 mm (1.26 in)
Do not hold the case (18) with a vise, because it could generate great torque on the threaded
connector.
14. Hold the threaded connector (13) with a vise to tighten the joint union (14). Tighten the
cam (12) with a wrench.
: 32 mm (1.26 in)
: 88.2 Ngm (9 kgfgm, 65 lbfgft)
212
UPPER SWING STRUCTURE - Tracking pilot valve
3-9. Tracking pilot valve
CONTENTS
3-9-1. Removal and installation of tracking pilot valve
Removal
1. Loosen the bolts (4) (×2) to remove the pedals (5)
(×2), operating levers (16) and (17).
: 17 mm 1
16 17
4
5
Apply identification marks to all the disconnected
hoses for reassembly.
4
2. Disconnect the connectors and hoses (6~11). 2
5 15 : 19 mm
14
14
13
13
12
Cap each disconnected hose.
12
6
3
7 3. Remove the inner hexagon bolt (14), spring
washer (13) and flat washer (12) to remove the
pilot valve (15).
11 : 8 mm
10
9
8 Installation
M14×1.5
1. Install the pilot valve (15) with the inner hexagon 4
bolt (14), spring washer (13) and flat washer (12).
PF1/4 : 8 mm
Tracking PPC Valves P1, P2, P3, P4, : 49 Ngm (5.0 kgfgm, 36 lbfgft)
P, T Port Connector 2. Connect the hoses (8~11).
: 19 mm
6- Hose: (To the pilot block valve)
7- Hose: (From the pilot block valve) : 29.5 Ngm (3.0 kgfgm, 21.5 lbfgft) 5
8- Hose: (To the signal control valve oil port for right 3. Install the pedal (5), operating levers (16) and (17)
tracking and forward tracking) with the bolt (4).
9- Hose: (To the signal control valve oil port for right : 17 mm
tracking and rearward tracking)
10- Hose: (To the signal control valve oil port for left
tracking and rearward tracking)
11- Hose: (To the signal control valve oil port for right
6
tracking and forward tracking)
7
INDEX
213
26 6 7 1 2 3 31 2 27 24 10 32 30 33 34, 35 8 9
13
4 22
28 11
5 21
29 12 18
23
20
19
14 17
15, 16
28 - Inner Hexagon Bolt

1 - Bolt (×2) 10 - Carrier 19 - Spacer Sleeve (×4)
(×4)
2 - Cover 11 - Oil Seal (×4) 20 - Shim (Several) 29 - Spring Washer (×4)
3 - Pin (×2) 12 - O-ring (×4) 21 - Balance Spring (×4) 30 - Adjusting Bolt (×4)
4 - O-ring (×2) 13 - Bush (×4) 22 - Spring Guide Bush (×4) 31 - Bush (×4)
5 - O-ring (×2) 14 - Case 23 - Push Rod (×4) 32 - Cam (×2)
6 - Absorber (×2) 15 - O-ring 24 - Spring Pin (×2) 33 - Lock Nut (×4)
7 - Rubber Cushion (×2) 16 - Plug 25 - Spring Pin (×2) 34 - Spring Pin (×2)
8 - Inner Hexagon Bolt (×2) 17 - Valve Rod (×4) 26 - Carrier (×2) 35 - Spring Pin (×2)
9 - Spring Washer (×2) 18 - Spring (×4) 27 - Spring Pin (×2)
x Be careful of the installation direction of the spring guide bush (22).

x Install the shims as the same number.
1. Install the valve rod (17) into the module. (×4)

x Insert the spacing ring (19), shim (20), and balance spring (21) into the valve rod in
sequence.
x Press the balance spring down by hand. Install the spring guide bush (22) to the valve rod
with the step end facing downward.
2. Insert the spring (18) into the case (14). (4 places)
Insert the valve rod (17) module into the original oil port.
214

3. Turn and install the valve rod (17) module to the case (14). (4 places)
CONTENTS
4. Install the push rods (23) (×4).
x Install the oil seal (11) to the bush (13).
x Apply grease to the internal surface of the oil seal.
x Install the O-ring (12) to the bush.
x Insert the push rod (23) into the bush.
x Apply grease to the tip of the propulsion.
5. Insert the push rod (23) module to the support (10). (4 places)
1
6. If the bush (31) has been removed from the carrier (10), install it to the carrier using the
special tool as the following procedures below.
The 4 bushes are the same.

2
x Insert the bush into the special tool, and install it to

Special Tool the carrier hole by tapping the tool lightly. Stop
10
tapping when the end of the bush is parallel with
the inner wall.
3
31
x Use the same procedures to install the bush to the

31 opposite side. 4
10
Special Tool
x Install the bush to the closer side as shown in the

31 illustration on the left. Stop tapping when the end
Special Tool
of the bush is parallel with the outside of the
support.
6
Outside of
Support
7
INDEX
215

x Install the bush to the opposite side as shown in
31 10 the illustration on the left.
Special Tool
3 10 32 30 33 34,35 8 9
23
14
7. Install the adjusting bolt (30) to the cam (32). Tighten the bolt by hand, then temporarily
fix it lightly with the lock nut (33). (2 places)
Then adjust the size.
8. Apply grease to the top (the connecting surface of the push rod (23)) of the adjusting bolt
(30). (2 places)
9. Install the O-ring (5) to the pin (3), then install the pin to the carrier (10) of the installed
cam (32). (2 places)
x Be careful of the insertion direction of the spring pin.

x Tap the spring pin until it comes into contact the step in the hole.
216

10. Install the spring pins (34), (35) to the cam (32)
34 35
with the special tool, then tighten the cam and
CONTENTS
Opening Opening
pin (3). Move the spring pin until its opening is
90q. (2 places)
1
11. Rivet the hole edge of the spring pins (34), (35) which are inserted into the cam (32) with
the punch. (2 places)
12. Place the support (10) to the case (14) module, and install it with the inner hexagon bolts
(8) (×2), spring washers (9) (×2).
: 8 mm 2
Do not adjust the adjusting bolt (30) while the top of the push rod (23) is pressed against the
adjusting bolt. The standard distance between the adjusting bolt and push rod is 0~0.2 mm 3
(0~0.008 in).
13. Adjust the adjusting bolt (30) by following the

30 33 32 10 procedures below. (2 places)
: 13 mm
: 4 mm 4
x Loosen the lock nut (33).
A B x Move the cam (32) and check for clearance.
If not, adjust the adjusting bolt by turning it.
x Turn both the left and right sides of the
adjusting bolt alternately in order to keep the
cam horizontal. 5
x Measure the sizes A and B between the left
and right concaved portions of the cam and
the support (10). Adjust the adjusting bolt
accurately so that the left and right
clearance are the same.
x Using a hexagon wrench, tighten the 6
adjusting bolt. Tighten the lock nut to the
specified torque, then tighten the adjusting
bolt.
x After the adjustment is complete, move the
cam and make sure the clearance should be
very small. If no clearance, the push rod is in 7
the state of pressing down, and make an
adjustment again.
INDEX
217
26 6 7 1 2 3 25 27 24 10
4
28
5
29
14. Install the rubber cushion (7) to the pin (3). (2 places)
15. Apply grease to the O-ring (5). (2 places)
x Be careful of the direction of the absorber (6).

x The inside diameter shape of the absorber (6) is the same as fin. If it is pried up, the O-ring (5)
will be damaged.
16. Keep the operating lever facing upward, install the absorber (6) without the spring to the
pin (3) straightly. (2 places)
17. Hold the absorber (6) to the carrier (10) with the inner hexagon bolts (28) (×2) and spring
washers (29) (×2). (2 places)
: 8 mm
18. Apply grease to the O-ring (4), then press it to the tip of the pin (3). (2 places)
For the installation direction of the support, refer to the illustration of the removal section. Be careful
not to make a mistake when installing.
218

19. Install the pin (3) to the support (26), then hold it to the carrier by aligning the inserting
hole of the spring pins (24), (25).
CONTENTS
x Place a pedestal under the carrier. If the carrier (10) receives a reactive force, great force will be
applied to the pin (3) and it will deform.
x The inner wall shape of the spring pin hole on the carrier is the same as the step. Check the
insertion direction of the spring pin. 1
x Check the direction of the spring pin.
20. Place a pedestal under the carrier (26). Using

Riveted the special tool, install the spring pins (24),
Riveted
(25) to the carrier until the spring pin reaches
26 3 the step end. Move the spring pin until the 2
cutout is 90q.
Pedestal 21. Using the punch, rivet the hole edge of the
24, 25
spring pins (24), (25) which are inserted into
the support (26). (2 places) (Refer to the
illustration on the left)
22. Install the pin (3) to another carrier (26) by 3
following the steps 19~21.
23. Install the cover (2) to the carrier (10) with the
bolts (1) (×2).
: 10 mm
: 5 Ngm (0.5 kgfgm, 3.6 lbfgft) 4
24. Apply grease to the contacting areas of the
spring pin (27) and absorber (6). (2 places)
7
INDEX
219
3-9-2. Disassembly and assembly of tracking pilot valve
3 14
15
16
4
5 17
28
6 18 29
7 30
19
8 31
20
9
32
21
10
11 22 33
12 23
13 24
34
25
26 35
36
27 37
38
1 - Rubber Cushion (×2) 11 - Sleeve (×4) 21 - Spring (×4) 31 - Washer 2 (×4)

2 - Inner Hexagon Bolt (×4) 12 - Camshaft (×2) 22 - Spring Seat (×4) 32 - Spring (×4)
3 - Pedal (×2) 13 - Inner HexagonBolt (×2) 23 - Stop Ring (×4) 33 - Slide Valve (×4)
4 - Inner Hexagon Bolt (×4) 14 - House Cover (×2) 24 - Ball (×12) 34 - Housing (×1)
5 - Support (×2) 15 - End Cap (×2) 25 - Support Plate (×4) 35 - Ball (×2)
6 - Corrugated Tube (×2) 16 - Grease Cap (×4) 26 - Push Rod (×4) 36 - Valve Bush (×2)
7 - Tightening Screw (×2) 17 - Seal Washer (×4) 27 - Washer 1 (×8) 37 - O-ring (×2)
8 - Cam (×2) 18 - O-ring (×4) 28 - Spring Seat (×4) 38 - End Cap (×2)
9 - Tightening Screw (×4) 19 - Pin (×4) 29 - Spring (×4)
10 - Lock Nut (×4) 20 - Spring (×4) 30 - Washer 3 (×4)
220

Disassembly of tracking pilot valve
CONTENTS
1. Remove the rubber cushion (1).
2. Hold the housing of the pilot valve with a vise
(34). Loosen the inner hexagon bolt (2) to
remove the pedal (3) from the support (5).
: 8 mm
3. Loosen the inner hexagon bolt (4) to remove
the support (5) from the cam (8). 1
: 8 mm
4. Peel off the lower end of the corrugated tube
(6) from the house cover (14), and remove it
upward.
5. Insert the hexagonal wrench into the 2

tightening screw (7) with inner hexagon hole to
unscrew it.
: 5 mm
3
Apply the locking agent #241, as the unscrew torque
is great, please take care of it.
6. Lift up one end of the camshaft (12) with a

round bar (below I8), and pull it out with a
hammer by tapping lightly. 4
7. Remove the cam (8) with tightening screw (9)

and lock nut (10) as a unit.
6
Record the position relationships with the housing
base.
7
INDEX
221

8. Hold the cam module to the vise, unscrew the
lock nut (10) with a wrench, and then remove
the lock nut (10) and tightening screw (9).
: 16 mm
Since the tightening screw need to be adjusted

uprightly when assembling, so if it is not necessary to
replace the tightening screw, handle it as the cam
assembly later.
9. Unscrew the bolt (13) with inner hexagon hole

gradually.
: 10 mm
x When the elastic force of the return spring (32) is

great, the house cover (14), pin (19) and push rod
(26) will spring while unscrewing the bolt with
inner hexagon hole, and unscrew it gradually and
horizontally with the house cover.
x Remove the pin (19) with a slotted screwdriver as
the motion-resistance force of the O-ring (18)
could leave it in the housing when the elastic force
of the return spring (32) is weak.
x Be carefull to prevent the pin from being damaged
when declining with the outer edge groove of the
pin.
x The pin may fly off when pulling it out because of
the return spring which should be taken care.
10. Remove the house cover (14).
Record the position relationships with the housing.
11. Place the house cover to the flat workbench

laterally, align the sleeve (11) with the special
tool, and tap it lightly with a hammer and pull it
out.
222

12. Remove the pin (19) together with the push rod
(26).
CONTENTS
Record the position relationships with the housing.
13. Pull out the relief valve assembly and the

return spring (32) from the housing.
2
Record the position relationships of the relief valve
assembly and housing hole.
14. For disassembly of the relief valve, first place

the lower end of the slide valve (33) on the flat
workbench vertically, push down the spring
seat (28), then remove 2 half-circle washers 1 5
(27) with the head of a mini slotted
screwdriver.
x Be careful not to scratch the slide valve surface.

x Do not push down the spring seat for more than 4 6
mm.
15. Detach the slide valve (33), spring seat (28),

secondary pressure setting spring (29),
washer 3 (30) and washer 2 (31).
7
x Regard it as an assembly before assembling.

x The washer 2 (31) is used for the preset
INDEX
adjustment of the secondary pressure setting

spring (29), it may not be used since the thickness
of each slide valve assembly is different.
223

16. Pull out the push rod (26) from the pin (19).
Be careful not to scratch the push rod surface.
17. Remove the O-ring (18), seal washer (17) from

the pin (19), remove the seal washer and dust
washer using a mini slotted screwdriver.
Be careful not to scratch the inside surface of the pin.
18. Remove the end cap (15) from the housing

(34).
: 5 mm
224

Assembly of tracking pilot valve
CONTENTS
1
1
2
3
4
5
6 2
7
8
9
10
11 3
13 12
14
16 15 4
26
17 20
21
18 22
19
T 23
27 24
28 25
29 5
32 P
30
35
31
33
36
34 1 2 37 6
38
1 - Rubber Cushion (×2) 9 - Tightening Screw (×4) 17 - Seal Washer (×4) 25 - Support Plate (×4) 33 - Slide Valve (×4)
2 - Inner Hexagon Bolt (×4) 10 - Lock Nut (×4) 18 - O-ring (×4) 26 - Push Rod (×4) 34 - Housing (×1)
3 - Pedal (×2) 11 - Sleeve (×4) 19 - Pin (×4) 27 - Washer 1 (×8) 35 - Ball (×2)
4 - Inner Hexagon Bolt (×4) 12 - Camshaft (×2) 20 - Spring (×4) 28 - Spring Seat (×4) 36 - Valve Bush (×2)
5 - Support (×2) 13 - Inner Hexagon Bolt (×2) 21 - Spring (×4) 29 - Spring (×4) 37 - O-ring (×2)
6 - Corrugated Tube (×2) 14 - House Cover (×2) 22 - Spring Seat (×4) 30 - Washer 3 (×4) 38 - End Cap (×2)
7
7 - Tightening Screw (×2) 15 - End Cap (×2) 23 - Stop Ring (×4) 31 - Washer 2 (×4)
8 - Cam (×2) 16 - Grease Cap (×4) 24 - Ball (×12) 32 - Spring (×4)
INDEX
225

1. Install the washer 2 (31), washer 3 (30), spring
(29), spring seat (28) on the slide valve (33) in
sequence.
2. Place the lower end of the slide valve on the

flat workbench vertically, push down the
spring seat and install 2 washers 1 (27) on it
(Do not overlap).
x The sharp edge side of the washer 1 (27) is facing

upward, keep the head hanging the slide valve
(33) when installing.
x Do not push down the spring seat for more than 4
mm.
Sharp Edge of
Washer 1 Upward
226

3. Install the return spring (32) into the housing.
Then install the relief valve sub-assembly that
CONTENTS
was made as Step 1 and 2 above.
x Install them in previous positions.

x Be careful not to collide the corners of the housing
base forcibly with the lower end of the slide valve
when installing the relief valve sub-assembly.
1
3
Do not collide
4
4. Install the end cap (15) to the housing (34).
: 5 mm
: 6.9 r 1.0 Ngm (70 r 10 kgfgcm)
5. Install the seal washer (17), O-ring (18) into the
pin (19). 5
x Be careful of the direction when installing the seal

washer (17).
x Apply a light coat of grease before installing the
seal washer (17). 6
Seal Washer
7
INDEX
227

6. Install the push rod (26) into the pin (19).
x Apply actuating oil to the surface of the push rod

(26) before installing.
x The edge of the seal washer may be damaged, so
don't insert it forcibly.
7. Install the assembled push rod sub-assembly

(according to Step 4, 5) to the housing base.

weak, hold it by the friction resistance of the O-
ring (18).
great, place the house cover (14) on it, keep the
cover (14) horizontal to be assembled by
tightening it alternately with the inner hexagon bolt
(13). (Operate the No.7 at first)
8. Insert the sleeve (11) into the house cover (14)

with the special tool, and press it in with a
hammer by tapping lightly.
Be careful not to allow the tip of the sleeve to fly off

from the inside house cover.
9. Install the house cover, and tighten the inner

hexagon bolt (13) with the specified torque
wrench.
: 10 mm
: 78.5 r 9.8 Ngm (800 r 100 kgfgcm)
228

10. Temporarily install the tightening screw (9),
lock nut (10) to the cam (8).
CONTENTS
11. Install the cam to the house cover and insert
the camshaft (12) from one end.
12. Apply locking agent #241 or equivalent on the

surface of the tightening screw with inner
hexagon hole, and tighten it to the specified
torque.
: 5 mm 2
241
: 6.9 r 1.0 Ngm (70 r 10 kgfgcm)
13. Adjust the height of the tightening screw (9),

keep the upper surface of the cam and the
lower surface of the house cover parallel, and
make the clearance between it and the push 5
rod to be zero as much as possible, then
tighten the lock nut (10) to the specified
torque.
: 16 mm
: 33.3 r 3.4 Ngm (340 r 35 kgfgcm)
6
Please take care that if the screw is tightened too

much, it will be loosened and shaken when it is set
uprightly.
7
INDEX
229

14. Tilt the cam, and apply grease to the recessed
parts of the push rod top and the pin top.
Do not scratch the surface of the push rod and pin

when applying grease, operate it with a soft blade
shape tool.
15. After inserting the upper end of corrugated

tube (6) into the cam groove, then insert the
lower end into the house cover groove.
x Before inserting the lower end of the corrugated

tube (6) into the house cover groove, apply
antirust oil to the internal components of the tube
(6) by mist spray.
x If the corrugated (6) isn't inserted into the groove
appropriately, it will cause the poor performance
of dustproof and waterproof when twisting, which
should be taken care.
16. Install the support (5) to the cam (8), and

tighten the inner hexagon bolt (4).
: 8 mm
: 33.3 r 3.4 Ngm (340 r 35 kgfgcm)
17. Install the pedal (3) to the support (5), and
tighten the inner hexagon bolt (2).
: 8 mm
: 33.3 r 3.4 Ngm (340 r 35 kgfgcm)
18. Install the rubber cushion (1).
230
UPPER SWING STRUCTURE - Removal and installation of solenoid valve
3-10. Removal and installation of solenoid valve
CONTENTS
serious burns. Don't repair until hydraulic oil cooling down. 1
pressure.
[ Preparation
2
2. Stop the engine. Press the air release valve on
the top of the hydraulic oil tank to release all
the residual press.
a vacuum pump to keep negative pressure in 3
the hydraulic oil bank.
Be sure to keep the vacuum pump running

continuously when the hydraulic system is operating.
4
Removal
14 13 12 11
1. Disconnect each wire harness of the solenoid
valves (1~8).
1
2. Disconnect the pilot tubes (9~14). 5
2 10 3. Remove the bolts (15) (×2) to remove the
3
4 5 solenoid valves.
6
7 8 : 17 mm (0.67 in), 19 mm (0.75 in), 24 mm (0.95
9 in)
: 8 mm (0.31 in)
6
Installation
1. Install the solenoid valve with the bolts (15)
(×2).
2. Connect the pilot tubes (9~14).
7
INDEX
231

3. Connect each wire harness of the solenoid
valves (1~8).
Wrench Size Tightening Torque
Note
(mm) Ngm kgfgm (lbfgft)
Rubber
: 17 25 2.5 (18)
tube
Rubber
: 19 30 3.1 (21.6)
tube
Rubber
: 24 50 5.1 (37)
tube
:8 50 5.1 (37) Bolt
1. Solenoid conversion valve Secondary boosting

2. Solenoid conversion valve Tracking high speed
3. Solenoid conversion valve Boom first 1
4. Solenoid conversion valve Swing first
5. Solenoid conversion valve Bucket confluence
6. Solenoid conversion valve Boom first 2
7. Solenoid conversion valve ppc
12 8. Solenoid conversion valve Swing brake
13 11 9. Hose: to the oil tank
14 10. Hose: to the check valve block
1 11. Hose: to the PT block
2 12. Hose: to the main valve XAas
3
4 10 13. Hose: to the main valve XBp1
5 14. Hose: to the swing motor PG
67 9
8 15 15. Bolt: connect the solenoid valve and main valve
bracket
232
3-10-1. Solenoid conversion valve
CONTENTS
1
3
2
4
5
1
6
7
8
9
10 2
13
11
12 14
15
16 3
17
18
4
1 - Inner Hexagon Screw (×2) 2 - Lock Nut 3 - O-ring 4 - Adjusting Screw 5 - Spring
6 - Solenoid Coil 7 - Spring 8 - O-ring 9 - Diaphragm 10 - Valve Rod
11 - Washer 12 - Spring 13 - O-ring 14 - O-ring 15 - O-ring
16 - Valve Bush 17 - Retainer 18 - Washer
Disassembly of solenoid conversion valve 5

1. Loosen the inner hexagon bolt (1), and remove the solenoid coil (6).
Be careful not to lose the spring (7) installed in the solenoid coil (6) groove when removing the
solenoid coil (6). Do not turn the lock nut (2) and the adjusting screw (4). 6
: 3 mm
2. Pull out the valve rod (10), remove the diaphragm (9), washer (11), and spring (12).
3. Pull out the valve bush (16), remove the O-rings (13), (14), (15), washer (18) and retainer
(17).
7
INDEX
233

Assembly diagram of the solenoid conversion valve
4 2 6 1 8 16 13 14 10 15 18
3,5
9 7 11 12 17
1 - Inner Hexagon Screw (×2) 2 - Lock Nut 3 - O-ring 4 - Adjusting Screw 5 - Spring
6 - Solenoid Coil 7 - Spring 8 - O-ring 9 - Diaphragm 10 - Valve Rod
11 - Washer 12 - Spring 13 - O-ring 14 - O-ring 15 - O-ring
16 - Valve Bush 17 - Retainer 18 - Washer
234
3-10-2. Assembly of proportional solenoid valve
CONTENTS
Apply grease to the O-rings (13), (14), (15), and apply a coat of hydraulic oil to the valve bush (16).
Be sure to align the valve bush oil port with the case oil port when inserting the valve bush. The
valve bush end surface and valve body are in the same position by installing the valve bush.
1
1. Install the washer (18), retainer (17) to the case.
16 Install the O-rings (13), (14), (15) to the valve
15
14 bush (16), and insert them into the case.
13
Be careful not to damage the edge of the valve bush 2

(16) inner diameter when inserting the valve rod (10)
Case module.
Check if the valve rod can slide in and out smoothly
without stuck of 3~5 mm (0.12~0.20 in) after inserted.
Apply hydraulic oil to the valve rod.
3
2. Install the diaphragm (9), washer (11), spring
10 (12) to the valve rod (10), and install it into the
9 valve bush (16).
4
Because the lock nut (2), adjusting screw (4), spring
6
(5) and O-ring (3) are not removed, the assembly is
12
not required. Be careful not to drop the spring (7)
11 Case
when installing the solenoid coil (6).
10
6
3. Install the solenoid coil (6) with the bolts (1)

6 (×2).
: 3 mm
: 29 Ngm (0.3 kgfgm, 2.2 lbfgft) 7
7
INDEX
235
- MEMO -
236
UNDER TRACKING CARRIAGE - Removal and installation of swing supporting bearing
CHAPTER 4 UNDER TRACKING CARRIAGE
CONTENTS
4-1. Removal and installation of swing supporting bearing
Before removing the swing supporting bearing, remove the upper swing platform at first. Refer to
"Removal and installation of main frame" for the removal and installation of the upper swing platform.
The work in this chapter begins with the premise that the upper swing platform has been removed.
1
Removal
Mark
1. Make align mark on the swing supporting
bearing (1) inner race and the track frame (2).
1 2
2. Remove the swing supporting bearing inner

race bolts (3) (×36).
3
: 30 mm (1.18 in)
Swing supporting bearing weight: 302 kg (666 lb)
3 4
3. Install the sling, lift up the swing supporting

bearing (4) and remove it with a crane.
Sling
4
Installation 6
Wipe off the matching surface of the swing supporting
bearing and the frame.
1. Apply Tian Shan sealer 1596 to the mounting
surface of the swing supporting bearing and
the track frame. 7
INDEX
237
Position of Front Side Position of

Aligning Pin Grease Fitting
Position of If the corresponding mark that cannot be aligned, it

Aligning Pin may cause the misplacement of the inner race gear
ring.
2. Lift up the swing supporting bearing with a

crane. Align the track frame and the align mark
on the swing supporting bearing.
3. Install the set bolts (Apply Tian Shan

adhesive-sealant 1277) (3) (×36) to the swing
supporting bearing inner race and tighten
them to the specified torque.
: 30 mm (1.18 in)
4. After the installation of swing supporting

Swing Grease Pinion bearing, fill the grease (Great Wall ü
Supporting Level
Bearing molybdenum disulphide lithium base grease
No.3 or equivalent) into the oil groove until the
pinion of the swing unit immerses in the
grease for more than 5 mm (Fill amount: (13 r 1
5 mm kg).
Grease Groove
238
4-1-1. Disassembly of swing supporting bearing
CONTENTS
1 2 3
4
12 13 14,15,16
9 7 6 5 2
8
17
3
10,11
9
7
6
1 - Outer Race 2 - Seal Ring 3 - Aligning Pin 4 - Plug 5 - Seal Ring

6 - Ball 7 - Inner Race 8 - Grease Fitting (×2) 9 - Supporting 10 - Washer
11 - Pipe Union 12 - Square Union 13 - Square Union 14 - Bolt 15 - Tube Clamp
16 - Washer 17 - Hard Tube 7
Be sure to read through the "Disassembly and assembly precaution" before the disassembly
operation.
INDEX
239

1. Tap the aligning pin (3) of the plug (4) upward
3 from the bottom.
Since the pin (3) is riveted after installation, the part

that is riveted should be rubbed out with a grinder.
2. Take out the plug (4).
4
Screw the bolt into the hole (M8, Pitch: 1.25 mm) of
the plug (4), and then pull out the bolt.
1
2 Swing supporting bearing weight: 302 kg (666 lb)
A
7
3. Install the sling, slightly and horizontally lift up
the outer race of the swing supporting bearing
out of its place with a crane. Remove the seal
ring (2) and (5).
6 5 4. Lift up the outer race (1) with a crane and put
the inner race (7) of the swing bearing on a
wooden block.
5. Turn the outer race (1) while taking out the ball
B (6) and the supporting (9) from the plug hole.
Draw the ball out with the magnetic stripe (A),
and remove the bearing (9) with the steel wire
(B) that has a hook.
9,10 6. Remove the seal ring (2) from the outer race (1)
and remove the seal ring (5) from the inner
race (7) with a scraper.
240
4-1-2. Assembly of swing supporting bearing
CONTENTS
1 2 3
12 13 14,15,16
9 7 6 5 2
8
17
3
10,11
7
6
1 - Outer Race 2 - Seal Ring 3 - Aligning Pin 4 - Plug 5 - Seal Ring

6 - Ball 7 - Inner Race 8 - Grease Fitting (×2) 9 - Supporting 10 - Washer
11 - Pipe Union 12 - Square Union 13 - Square Union 14 - Bolt 15 - Tube Clamp
16 - Washer 17 - Hard Tube 7
INDEX
Always apply grease to the ball (6) and the supporting (9).
241
1. Lift up the outer race horizontally with a crane

and install it on the same shaft with the inner
2 race. Turn the outer race while putting the ball
(6) and the supporting (9) into the hole of the
plug in sequence using a round bar.
2. Tap the plug (4) into the outer race (1) and then
3 tap the pin (3) into the pin hole. Rivet the top of
the pin (3) with a chisel.
1
3. Install the sling on the outer race (4) and lift it
up with a crane. Degrease the groove of the
4 mounting seal ring (2 and 5) throughly. Apply
THREEBOND #1745 to the seal ring (2) and
apply THREEBOND #1735 to the seal ring (5),
and then install the seal ring (2 and 5) in the
groove.
4. Add the grease of 0.35 L (0.092 US gal),
(Albania EP2 grease or equivalent), through
the grease fitting (8), add the grease while
turning the outer race.
Add the grease at two places.
242
4-1-3. Swing supporting clearance measurement
CONTENTS
When measuring the swing supporting clearance on the machine, please follow the procedures
described below:
When measuring, be careful not to put your hands or feet under the under tracking carriage.
1
1. Tighten a magnet type dial indicator to the
2 2
Rotary Table Rotary Table swing supporting outer race (1) or inner race
(2) and touch the end surface of the inner race
1 1
(2) or the other side of the outer race (1) with a
tester probe.
Track Frame Track Frame 2
Set the dial indicator before or behind the machine.

Dial Indicator Dial Indicator
2. Keep the work devices at the maximum

contact pose, and keep the bucket teeth top
3
with the lower part of the turntable at the same
level.
At this time the front of the upper structure falls and

the back rises. 4
3. Set the dial indicator to zero.

4. Keep the arm almost vertical on the ground
and lower the boom until the track board is
lifted to the front of the machine.
5
At this time the front of the upper structure rises and

the back falls.
5. Read the value of the dial indicator under this 6

condition.
The displayed value of the dial indicator is the bearing

clearance.
150 - 200 mm 7
6. Let the machine return to the pose in the item 2
above, and make sure the dial indicator
reading is zero.
INDEX
If the zero is not displayed, repeat the item 3 to 5.
243
UNDER TRACKING CARRIAGE - Tracking unit
4-2. Tracking unit
4-2-1. Removal and installation of tracking unit
pressure.
Preparation
1. Stop the excavator on a solid and flat ground
and lower the bucket to the ground.
2. Stop the engine, and turn the air release valve
on the top of the hydraulic oil tank to release
all the residual pressure.
3. Remove the top cap of the hydraulic oil tank,
connect a vacuum pump and run it
continuously to keep negative pressure in the
hydraulic oil tank.
When operating, run the vacuum pump continuously.

If there is no vacuum pump, operate after draining the
hydraulic oil in the hydraulic oil tank.
Removal
Perform the following procedures when the track has
6 been removed and the end plate has been opened.
1. Remove the hose (3~6).
: 19 mm
: 24.5 r 5 Ngm (2.5 kgfgm, 18 lbfgft)
: 27 mm
5 4 : 74 r 14 Ngm (7.6 kgfgm, 55 lbfgft)
: 36 mm
: 166 r 26 Ngm (17 kgfgm, 122.5 lbfgft)
1 2 3
Cover the removed hose port and line port.
244

2. Prepare to lift up the tracking unit with wire
rope.
CONTENTS
Tracking unit weight: 360 kg (794 lb)
3. Remove the bolt (1) and washer (2), lift up the

tracking unit and remove it with a crane.
: 27 mm
1
: 339 r 30 Ngm (34.6 kgfgm, 250 lbfgft)
Installation
2
Refer to "Removal" for the wrench size and tightening torque.
1. Install the tracking unit with the bolt (1) and washer (2).
2. Reconnect the hoses (3~6) to the tracking unit.
After the installation of the tracking motor, be sure to fill it with the hydraulic oil. The fill amount is
based on that there is oil overflowing from the oil gauge port. After the installation of the tracking
motor or tracking unit, be sure to perform test run in order to avoid motor stuck.
Test run is as follows:
Test run conditions: 4
1. Engine gear position: Minimum speed
2. Tracking mode: Low speed
3. Run time: Above 2 minutes
7
INDEX
245
4-2-2. Tracking motor parts
II
116 115 107 103 149 167 171 132 9 22 23 4 5 12 1

VI II-A 21
II II II II-A II
30
27 35
379 13
V
20
29
8
A 25
139
112
135 33
43
113 7
III
341 15
104 36
VI
109 6
399 102
V
150 3
I-A
2
I-A
355
V
357 A 19
V I I
366 37
V I
34
363
V I
193
398
V 17
397 161
V VII VII
145 110 114 110 151 111 31 108 105 106 162
VI VI VI VI VI VI IV VI VI-A VI-A VII
246
CONTENTS
326 337 327 330 343 357 355
V V V V V V
4
208 42
W
211 328
W V
220 324
W V
209 336
W V 5
217 325
W V
201 323
W W V-A
219 B 301
W V-A
202 206 203 205 204 210
W W W W W W 6
Cross Section A-A
7
INDEX
247
359 380 384 382 383 385 381

V V V V V V V-A
Cross Section C-C
346
V
354
V 358
352 V
398 V
V
368
V
C
Cross Section B-B
Number Code Name Serial Number Quantity Remark

1 1 Case 671B1001-01 1
2 I Bracket assembly 671B1102-05 1
3 I-A Bracket module 671B1132-05 1
4 I-A-2 Bracket 671B1132-05 1
5 I-A-3 Retaining bracket 671B1103-03 1
6 I-19 Screw 671B1019-00 3
7 I-34 Flat pin 671B1034-01 6
248
CONTENTS
8 I-37 Retainer 671B1037-00 3
9 II Sun gear module 671B1104-03 1
Sun gear
10 II-A 671B1204-01 1
assembly
11 II-A-4 Sun gear A 671B1004-01 1
12 II-A-5 Sun gear B 671B1005-01 1
1
13 II-9 Crankshaft 671B1009-01 3
14 II-12 Septa 671B1012-03 6
Needle roller
15 II-22 671B1022-00 6
bearing
Needle roller
16 II-23 671B1023-01 6 2
bearing
17 6 Input gear 671B1006-01 1
Planetary gear
18 III 671B1107-01 1
assembly
19 III-7 Planetary gear 671B1007-01 3
20 8 Cover 671B1008-03 1 3
21 13 Septa 671B1013-02 3
22 15 Connector 50F1024-00 1
23 17 Pin 671B1017-00 24
24 20 Snap ring JIS B 2804-Ai95 3
25 21 Ball-bearing 671B1021-00 2 4
26 25 Snap ring JIS B 2804-WN40 3
27 27 O-ring JIS B2401-P8-90 2
28 29 O-ring JIS B 2401-G230-70 1
29 30 O-ring JIS B 2401-P335-70 1
5
Floating sealing
30 IV KS207-336~368~40.8-B 1
ring module
Floating sealing
31 IV-31 207-27-61331 2
ring
32 33 Plug 610B2021-00 3
33 35 Screw JIS B 1176-M12~30-12.9L 12 6
34 36 Ball JIS B 1501-7/16 1
35 42 Parallel pin 671B2077-01 2
36 43 O-ring JIS B 2401-P18-90 3
End surface flange
37 V 678B4100-02-B 1
module 7
End surface flange
38 V-A 678B4101-02-B 1
body
39 V-A-301 End surface flange 676B4091-03 1
INDEX
40 V-A-323 Valve core 671B4050-01-B 1

41 V-A-381 Piston 682B4081-00-A 1
42 V-A-324 Plug 100A2051-00 2
249

43 V-A-325 Spring seat 140F4052-00-A 2
44 V-A-326 Plug 120F2053-00 2
45 V-A-327 Valve 120F2054-00 2
46 V-A-328 Spring 100A2055-00 2
47 V-A-330 Spring 120F2055-00 2
48 V-A-336 O-ring JIS B 2401-P32-90 2
49 V-A-337 O-ring JIS B 2401-P22A-90 2
50 V-A-346 Plug GM-1/4-K-S 4
51 V-A-352 Plug 512B2021-00 2
52 V-A-354 Plug GDL-1/16-S 8
53 V-A-355 O-ring JIS B 2401-P18-90 1
54 V-A-357 Plug 610B2021-00 2
55 V-A-358 O-ring JIS B 2401-P11-90 2
56 V-A-359 O-ring JIS B 2401-P14-90 2
57 V-A-363 Valve core 671B4069-03 1
58 V-A-366 Spring GA400001-00 1
59 V-A-368 Ball JIS B 1501-3/8 2
60 V-A-379 Filter element 263B2079-01 1
61 V-A-380 Plug 810B2021-00 2
62 V-A-382 Plug 682B4082-00 2
63 V-A-383 O-ring JIS B 2401-P5-90 2
64 V-A-384 O-ring JIS B2401-P8-90 2
65 V-A-385 Ball JIS B 1501-7 2
66 V-A-397 Throttle 671B2079-01 1
67 V-A-398 Plug GM-1/8-S 4
68 V-A-399 Plate 850A0006-00 1
69 341 Parallel pin JIS B 1354-6~14 1
70 343 Screw JIS B 1176-M16~40-12.9 12
Cylinder block
71 VI 671B2205-00 1
plunger module
72 VI-A Plunger module 671B2040-03 1
73 VI-A-105 Plunger 671B2005-02 9
74 VI-A-106 Slipper 671B2006-01 1
75 VI-104 Cylinder block 671B2004-01 1
76 VI-107 Retaining plate 671B2007-00 1
77 VI-108 Thrust ball 671B2008-00 1
78 VI-110 Washer 80W0015-01 2
79 VI-111 Snap ring 671B2011-01 1
80 VI-114 Spring 671B2014-02 1
81 VI-145 Snap ring JIS B 2804-Ai62 1
82 VI-151 Needle roller JIS B 1506-3.5~27.8F 5
250
CONTENTS
83 VII Plunger module 401B2070-00-A 1
84 VII-161 Plunger 401B2071-01-A 1
85 VII-162 Slipper 400B2072-01 1
86 102 Shaft 671B2002-00 1
87 103 Swash plate 671B7203-00-E 1
88 109
Speed regulation
671B2009-01 1
1
plate
89 112 Piston 671B4012-02 1
90 113 Spring 671B4013-00 12
91 115 Brake plate 671B4015-00 2
92 116 Matching plate 120F2016-00 2 2
93 132 Oil seal TCN-38~58~11 1
94 135 O-ring 671B4035-00 1
95 139 O-ring 671B4039-00 1
96 149 Ball-bearing 671B2048-00 1
97 150 Ball bush 671B2049-00 1 3
98 167 Fulcrum 671B2076-02 2
99 171 Parallel pin 671B2077-01 2
100 193 Spring 401B2093-00 1
101 W Valve module 671B3100-03-0A 1
102 W-201 Valve 671B3002-02 1 4
103 W-202 Valve sleeve 671B3003-03 1
104 W-203 Spring seat 671B3004-01 1
105 W-204 Plug 671B3005-00 1
106 W-205 Thin shim 247B3006-00 1
5
107 W-206 Spring 671B3008-01 1
108 W-208 O-ring JIS B 2401-P16-90 1
109 W-209 O-ring JIS B 2401-P22-90 1
110 W-210 O-ring JIS B 2401-P18-90 1
111 W-211 Retainer JIS B 2407-T2-P16 2
6
112 W-217 Retainer JIS B 2401-T2-P22 2
113 W-219 O-ring JIS B 2401-P29-90 1
Plunger sealing
114 W-220 SPG0 7.5-10.5-1.5 1
ring
7
INDEX
251
4-2-3. Removal and installation
Removal procedure
1. Remove the protecting cap (11)
39, 40, 41
Fix the motor on a stable workbench, loosen
the 8 inner hexagon bolts (13) and remove the
O-ring (12) and protecting cap (11) at the same
time. Then, remove the spring seat (10), spring
8 (9) and spring seat (8). Remove the O-ring (41),
9 17
spring (40) and check valve (39).
10
12 : 10 mm
11
13
The protecting cap (11) is ejected by the spring (9).

So pay attention to the following when operating:
x Loosen the inner hexagon bolt (13) evenly.
x Loosen the bolt (13) and the protecting cap (11).
2. Remove the double balanced plunger (3)

Slightly push the end of the plunger (3) and
expose part of the plunger (3) out of the base
(2). Then, grasp the end of the plunger (3) and
turn it to take it out.
The plunger (3) and the base (2) match closely. So

2 pay attention to the following when operating.
3 x If the plunger (3) is stuck halfway and cannot be
taken out, do not take it out forcibly. Or the surface
of the base (2) core and the outer surface of the
plunger (3) may be scratched.
x If it is stuck, please operate as follows: slightly tap
the plunger (3) into the base (2) with a plastic
hammer, and then check that the plunger rotates
smoothly. And turn the plunger again to take it out.
x If unnecessary, please do not remove the plunger
rashly. Incorrect removal may scratch its outer
surface.
252

3. Remove the safety valve assembly (17)
17-3 Loosen the plug (17-6) and remove the safety
CONTENTS
valve assembly (17). At this time, the poppet
valve base (17-3) should be kept in the base
(2).
: 27 mm
1
The safety valve assembly (17) has a certain set
17-6 2 pressure. The set pressure determines the starting
17-15 17-16
and brake power of the motor. So do not perform the
following operations:
x Do not loosen the nut (17-16) and do not damage
17
the set screw (17-15). If the set screw is turned, 2
the set pressure of the safety valve may be
changed and the anticipated performance of the
motor cannot be guaranteed.
x Do not remove the safety valve assembly. Or the
set pressure may be changed and the anticipated
performance of the motor cannot be reached. 3
4. Remove the poppet valve base (17-3)

Remove the poppet valve base (17-3) from the
base (2) using the poppet valve base removal
clamp.
x Do not remove without special reason. 4
2
17-3 5
5. Remove the 2-speed automatic select slide

valve (19)
Loosen the plug (28), (31) and remove the plug
(28), (31) and spring (27). Partially push the
31 end of the slide valve (19) out of the base (2). 6
27 Then grasp the end of the slide valve by hand
and turn it to take out the slide valve (19).
19 7
28
INDEX
253
The slide valve (19) and the base (2) match very
closely. So pay attention to the following when
operating:
x Do not remove the slide valve (19) unless
necessary.
x If the slide valve is stuck halfway, do not pull it out
forcibly. Or the surface of the base (2) core and
the outer surface of the slide valve (19) may be
scratched.
If it is stuck, please handle with the following
methods.
Slightly tap the end surface of the slide valve (19) with
a plastic hammer to place it in the base (2) again.
Then check that it rotates smoothly, and turn the slide
valve by hand to take it out again.
6. Do not remove the pore plate plug (18) unless

necessary.
The pore plates (34), (35), (36) have been
treated for leak and make resistance to loosen.
Do not remove them (See the illustration 1-1
58 and 1-3.)
7. Remove the base (2)
65 2 Loosen the inner hexagon bolt (58) and
remove the base (2).
: 12 mm
When removing the base, pay attention to the

2 following:
x The base is pushed up under the effect of the
66 spring (65). So evenly loosen the cap screw
around it.
x There is a positioning ejection bar (66) between
the base (2) and the body. When removing the
base, let it face the center of the motor shaft
vertically to prevent the ejection bar from being
stuck. If stuck, slightly tap the base (2) with a
plastic hammer to return the ejection bar (66) to its
original position and remove the base.
x When removing the base (2), take out the orifice
plate (68) and the base (2) at the same time.
Since the moving surface of the orifice plate can
be easily scratched, be careful not to drop the
orifice plate (68).
254

8. Remove the orifice plate (68)
68 Remove the orifice plate (68) from the base (2)
CONTENTS
with a slotted screwdriver.
When removing the orifice plate, pay attention to the

following:
x The moving surface of the orifice plate can be 1
easily scratched. If scratched, the anticipated
performance cannot be reached. So be careful not
to scratch it.
2
9. Remove the O-ring, the ejection bar (66) and
65 spring (65). Remove the O-rings (69), (70) and
the ejection bar (66). Then remove the spring
(65).
70 69 66
10. Remove the brake piston (62)

4
Install an air blast nozzle on the oil circuit of
the flange (1) stop braking, and blow air into
the stop braking cylinder inner chamber to
make the brake piston (62) float, then remove
the brake piston. After the removal of the brake
piston (62), remove the disc (60) and the 5
friction plate (61). Then remove the O-ring (63),
(64)from the brake piston.
62 When removing the brake piston, pay attention to the

6
following:
x When blowing air from the parking brake circuit of
the flange (1), prevent the air from leaking.
x When blowing air from the parking brake circuit of
the flange (1) and the pressure of air is high, the
brake piston pops out may injure the operator. So
7
keep the pressure below 3 kgf/cm2 (43 psi) and
hold the brake piston (62) to prevent it from being
popped out.
INDEX
255
62
63
64
60
61
60
61
60
11. Remove the cylinder block (43)

Take out the cylinder block (43) from the flange
(1).
When taking out the cylinder block (43), pay attention

43 to the following:
x Hold the cylinder block by hands and slightly turn
1 it back and forth, then take it out slowly.
x Be careful not to scratch the moving surface
where the cylinder block and orifice plate (68)
contact. Otherwise, the performance cannot be
guaranteed.
x Be careful not to scratch the brake shoe of the
piston assembly (44). Otherwise, the performance
cannot be guaranteed.
12. Remove the cylinder block (43)

(a) Make match marks on the piston assembly
(44) and the cylinder block (43) so that they
can be assembled to their original positions
when reinstalling. Then remove the piston
assembly (44) and the retainer plate (45)
from the cylinder block (43).
43
44
45
256

(b) Make match marks on the piston assembly
(44) and the retainer plate (45) so that they
CONTENTS
can be assembled to their original positions
when reinstalling. Then remove the piston
assembly (44) from the retainer plate (45).
45
1
44
(c) Remove the retainer fixture (46) from the 2

cylinder block (43), then remove the inserted
pin (51) from the cylinder block (43).
51
43
46
4
(d) Fix the cylinder block (43) on a hand press
device and make its action surface face
upward. Remove the snap ring (47), push
47 the retainer with a clamp (50), press and
hold the spring (49) and take out the snap
ring (47) using a snap ring plier.
5
When removing the snap ring (47), be careful not to

injure yourself.
x When the snap ring is overtightened and cannot
43 be taken out using a snap ring plier, if the snap 6
ring plier slips from the snap ring, it may injure the
operator. The remover must be used to remove
the snap ring and make sure that the plier claw is
engaged in the snap ring hole.
7
INDEX
257
50
(e) Remove the retainer (50), spring (49) and
spring seat (48) from the cylinder block (43).
49
48
43
13. Remove the swash plate (52)

Remove it from the flange (1).
When removing the swash plate, pay attention to the

52 following:
x Do not scratch its sliding surface. Otherwise, the
performance cannot be guaranteed.
1
x Sometimes the swash plate (52) may slip off with
the piston assembly (44) and the ball (53)
together. Be careful not to allow them to slip off.
14. Remove the tracking 2 speeds select piston

67 assembly (54) and ball (53)
Remove the piston assembly (54) from the
flange (1). Then take out the spring (67).
Remove the ball (53) from the flange (1).
54
53
Since the ball is difficult to slip off, use the following

1
methods when operating:
x Degrease the ball fixed on the flange (1) with
kerosene or thinner.
x Remove the ball (53) from the flange (1) with a
magnet.
258

15. Remove the shaft (42)
Remove the shaft (42) and the ball-bearing (55)
CONTENTS
from the flange (1).
42
When removing the shaft (42), pay attention to the
55
following:
x Be careful not to damage the spline of the shaft 1
1 (42). Be careful not to scratch the sliding part of
the oil seal (59) on the shaft (42). Otherwise oil will
leak.
16. Drain the lubricant from the reduction gear unit 2

Before removing the reduction unit, install
1 screws in the two diagonal thread hole of the
flange (1) and lift up the reduction unit with a
crane. Remove the two plugs (103), and drain
the lubricant in the reduction unit.
: 12 mm 3
103 103
Before operating, please prepare an oil container.
x Do not lift up the reduction unit too high. The sling
height should be as low as possible and fit for 4
operation. (About as high as your knee)
17. Remove the protector cover (101)

Loosen the bolt (102) and remove it. Then
remove the protector cover (101).
102 : 8 mm 5
78 Use the following methods to remove the protector

101
cover
x There is a water pressure packing unit installed
between the protector cover (101) and the frame 6
(78). So it is hard to take out the protector cover.
Loosen the bolt (102) and tap with a plastic
hammer to remove the top and side of the
protector cover (101).
x Place a slotted screwdriver between the protector
cover (101) and frame (78) and remove the 7
protector cover.
INDEX
259

18. Remove the thrust plate (100)
Remove the thrust plate (100) from the top of
the thrust plate (97).
97
100
19. Remove the drive gear (99)
99
20. Remove the level 1 fixture assembly

Remove the level 1 fixture assembly including
holder A (91), planetary gear A (95), needle
roller bearing (94), inside gear ring (93), thrust
plates (92), (96), (97) and screw (98).
Pay attention to the following when removing:

Level 1 Fixture Assembly
x Be careful not to get your fingers caught.
21. Remove the level 1 holder assembly

Fix the level 1 holder assembly on the plier and
heat up the screw (98) using hair to dry the
machine and loosen it. Remove the screw (98),
98
thrust plate (97), thrust plate (96), planetary
91
92 gear A (95), needle roller bearing (94), inside
93 gear ring (93) and thrust plate (92) from the
94
95 holder B in order.
96
97 : 8 mm
When loosening the screw (98), pay attention to the

following:
x The screw (98) is coated with loctite and it is
difficult to loosen. If loosened forcibly, the screw
may be scratched and cannot be used. So before
loosening, heat it up.
260

22. Remove the center gear B (89)
CONTENTS
89 1
1 23. Remove the planetary gear B (86)

Fix the flange (1), loosen the bolt (88) and
remove it. Then, remove the thrust plate (87),
planetary gear B (86), needle roller bearing
85
(85), inside gear ring (84) and thrust plate (83) 2
in order.
: 17 mm
84 83
86
87
88
When loosening the bolt (88), pay attention to the
3
following:
x The bolt has been applied with loctite. So hold the
flange (1) firmly.
x When loosening, use longer tools as iron pipe,
etc. If not, and loosen it forcibly, that may injure
yourself. 4
24. Remove the holder B (80)

Fix the flange (1), loosen the bolt (82) and
remove it. Holder B (80) is installed together
with the flange (1) using the inserted pin.
80 Install the removal clamp from the motor side
5
and remove the holder B (80) using a press
tool.
: 17 mm
82 When loosening the bolt (82), pay attention to the 6

105
following:
x Apply the screw locking agent to the bolt (82) to
prevent it from being loosened. So hold the flange
(1) firmly.
x Use longer tools as iron pipe, etc. to loosen the
bolt (82). If loosened forcibly, you may be injured. 7
INDEX
261

25. Remove the flange (1) from the frame (78)
Clamp Install a clamp on the end surface of the outer
1 flange of the frame and use a press tool to
push and press the flange (1) to remove it from
the frame.
105
78
26. Remove the floating-ring seal (76)

Push up the outer circumference of the
floating-ring seal using a slotted screwdriver
to remove the seal.
78
27. Storage of parts

The removal operation has been completed
until now. Clean the removed parts completely,
apply thick antirust oil, put them in a plastic
bag and store them in a cool, dark, and dry
place. If stored in a damp circumstance, they
may be eroded even if the antirust oil has been
applied. Keep the parts away from dust.
76
Assembly procedure
<Reduction unit>
1. Install the floating-ring seal (76) into the flange
(1)
1 Confirm the following item about floating-ring
76 seal (76) . Then install the floating-ring seal
(76) into the flange (1) using the floating-ring
seal holder.
Floating-ring Seal Holder
Make sure that there is no dust on the contact surface

of the flange (1) and the floating-ring seal (76).
x Clear the surface of the floating-ring seal (76) on
the flange (1) completely.
x Make sure that there is no dust on the O-ring of
the floating-ring seal (76).
x Degrease the O-ring of the floating-ring seal (76)
completely.
262

2. Install the angular contact thrust bearing (77)
into the frame (78)
CONTENTS
Push the angular contact thrust bearing (77)
into the frame (78) using the extrusion clamp
and press tool.
77
78
77
Angular Thrust Bearing Holder 1
3. Install the floating-ring seal (76) into the frame

(78)
Make sure that the content about the floating-
ring seal (76) listed below is correct. Then
install it into the frame (78) using the floating- 2
Floating-ring ring seal holder.
76 Seal Holder
78 Make sure that there is no dust or foreign objects on

the located position surface of the floating-ring seal in
3
the frame.
x Degrease the located position surface of the
floating-ring seal (76) in the frame (78) completely.
x Make sure that there is no dust or foreign objects
on the floating-ring seal O-ring.
x Degrease the floating-ring seal O-ring completely.
4
4. Install the frame (78) into the flange (1)

Make sure that the following items are correct,
install the frame (78) into the flange (1) using a
crane. Make sure that the floating-ring seal (76)
of the flange (1) and the floating-ring seal (76)
5
of the frame (78) match.
1
78 Make sure that there are no foreign objects on the

moving surface of the seal ring on the floating-ring
seal (76). 6
x Apply the lubricant to the reduction unit or apply
hydraulic oil to all the moving surface of the seal
ring in the floating-ring seal (76).
x When installing the frame (78) into the flange (1),
make sure that axial direction centers align with
each other. 7
INDEX
263

5. Select the shim thickness (79)
80 Select the preload adjusting shim thickness
h
according to the following procedures:
(a) Hold down the inside gear ring end surface
Pressure: 3000 kgf (6600 lbf) of angular thrust bearing (77) using the shim
thickness adjuster at the load of 3000 kgf
jig
(6600 lbf).
(b) At this time, measure the distance H
between the inside gear ring end surface in
the angular thrust bearing and the end
77 surface of the flange (1).
(c) Measure the distance h at the holder (80).
(d) Select and connect the shim combination
1 (79) (T=0.05, 0.1, 0.3, 0.5, 1.0 mm) to make
the thickness reach H-h.
Do not use the used shim (79).

x This step of operation must be performed. If the
preload adjusting has not been achieved, the
reduction unit may be damaged when operating.
x Clean the measured surface completely.
80 6. Install the holder B (80)

Fix the flange (1) and make the inserted pins
79 (105) (×4) vertically on the flange (1). Apply
grease to the shim selected in the step (5) and
105 make it contact with the holder B (80). Make
the pin hole of the holder B (80) match with the
inserted pin and press-fit them using a press
1
tool. Install the washer (81) into the holder B
(80), apply the loctite to the bolt (82) and
tighten it.
79 : 17 mm
80 Tightening torque: 55 kgfgm (400 ftglbs)
Make sure that the inserted pin (105) must be vertical.

105 x The washer (81) matches with a notch to prevent
loosening. Install the notch into the base of the
82 81 holder B (80).
x Clean the thread on the bolt (82) completely, and
apply loctite after degreasing.
x Clean and clear the grease inside the flange (1)
Make sure the assembling
direction of washer (81). thread completely.
See the direction in the right diagram
81
264

7. Install the planetary gear B (86)
Install the thrust plate (83) to the planetary
CONTENTS
78
80 gear B (86). Then, install the needle roller
83 bearing (85) to the planetary gear B (86). At
84
85
86 last, install the inside gear ring (84). Engage
the internal boring diameter of the inside gear
ring (84) with 4 trunnions of the holder B (80)
86 83 85 84 to install the planetary gear B (86).
Place the thrust 1
plate on one side
of the holder
Install the thrust plate (83) to planetary gear B (86) to
make sure the thrust plate (83) locates on one side of
80
Installation Direction of Thrust Plate (83) the holder B (80).
x When the holder B (80) is installed on the 2
planetary gear B (86), engage the internal gear of
the frame (78) with the gear teeth on the planetary
gear B (86).
x Be careful of the installation direction of the
planetary gear B (86).
3
8. Install the thrust plate (87)
Install the planetary gear B (86), and place the
chamfering in the bolt hole of the thrust plate
(87) under the collar of the bolt (88). After the
placement, apply loctite to the thread of the
bolt (88) and tighten it.
4
: 8 mm
Tightening torque: 55 kgfgm (400 ftglbs)
88 87
88
Be careful of the installation direction of the thrust
plate. If the bolt collar is damaged, it may drop. 5
x Clean the thread on the bolt (88) completely, and
Place Chamfering apply loctite after degreasing.
of C2 at Seat Side x Clean the thread in the thread hole of the holder B
(80) completely and degrease it.
87
7
INDEX
265

9. Install the center gear B (89) and make sure
that the center gear B (89) is installed to the
snap ring (90). Then install the center gear B
86
(89) among the 4 planetary gears B (86).
Engage the gear teeth of the planetary gear B (86)

with the gear teeth of the center gear B (89) and
90 89
assemble them together.
10. Install the holder A (91)

Engage the inside gear teeth of the holder A
(91) with the gear teeth of the center gear B
(89) and install the holder A (91) into the center
gear B (89).
91 89
11. Install the planetary gear A (95)

gear A (95). Install the needle roller bearing
(94) to the planetary gear A (95). Install the
92 inside gear ring (93) at last, engage the internal
boring with the 3 trunnions of the holder A (91)
95 and install the planetary gear A (95) to the
holder A (91).
91
94 93 95
Place the drafted side of 92 94 93
thrust plate at the holder Install the thrust plate (92) into the planetary gear A
(91) side (95), and place the drafted side of the thrust plate (92)
91 on one side of the holder A (91).
x When installing the planetary gear A (95) to the
Assembling Direction of the Thrust Plate (92)
holder A (91), engage the inside gear teeth of the
frame (78) with the gear teeth of the planetary
gear A (95).
x Be careful of the assembling direction of the
planetary gear.
266

12. Assemble the drive gear (99)
CONTENTS
95 gear A (95), and then install the thrust plate
96
97 (97). Apply the loctite to the thread of the
screw (98) and tighten it.
99 : 8 mm
Tightening torque: 6.0 kgfgm (43 ftglbs)
98 84 85 86 87 Make the spline of the drive gear (99) face the motor
Place the drafted assembly side, and install the drive gear (99) among 3 1
80 side of the thrust
planetary gears A (95). Then engage the gear teeth of
plate at the holder
(91) side the planetary gear A (95) with the gear teeth of the drive
gear (99).
Assembling Direction of
the Thrust Plate (87)
2
Be careful of the assembling direction of the thrust
plate (96).
x Clean and clear the grease in the thread hole of
the holder A (91) and the screw (98) completely.
13. Install the thrust plate (100) 3

78 Measure the distance between the end surface
97 of the frame (78) and the thrust plate (100)
using the thrust plate select clamp, and install
100 the thrust plate (100) according to the table
listed below.
Unit: mm (in) 4
Shim
Distance (T) Thrust Plate Code
Thickness (t)
1.20~0.67
78 20941-62306 2.3
(0.0472~0.0264)
Measured Distance T 0.66~0.04
20941-62307 2.8
(0.0260~0.0016) 5
97
0.03~-0.16
20941-62308 3.0
100 (0.00122~-0.0063)
-0.174~-0.41
20941-62309 3.2
(-0.00685~-0.0161)
-0.42~-0.80
B0841-23017 3.6 6
(-0.0165~-0.0315)
Align the center hole of the thrust plate (100) and the
protrusion of the drive gear (99) and install them
together. 7
INDEX
267

14. Install the protector cover (101)
78 Clear the foreign objects on the matching
101 surface of the end surface of the frame (78)
102
and the protector cover (101). Install the water
pressure packing unit at the top joint corner on
one side of the matching surface of the
protector cover (101) and the frame (78). Match
the thread hole of the frame (78) and the bolt
hole of the protector cover (101) and place the
protector cover (101) into the frame (78). At
last install the bolt (102) and tighten it.
: 8 mm
Tightening torque: 7.48 kgfgm (54 ftglbs)
15. Install the plug (103)

101 Remove the O-ring (104) from the plug (103)
and install a new O-ring into the plug (103).
Then, install the plug (103) to the oil circuit
104 outlet and inlet, and 3 horizontal ports and
103
tighten it.
: 12 mm
The assembly of the reduction unit has been completed
until now. Next is the assembly of the motor. Refer to
"Motor assembly" for details.
<Motor>
1. Install the oil seal (59)
Make sure that the flange (1) and the oil seal
(59) are installed together. If not, push the oil
Oil Seal seal (59) into the flange (1) using the oil seal
59 Holder holder.
Before installing the oil seal, apply grease to the

internal boring surface (the place where the oil seal is
placed) of the flange (1) the outer diameter of the oil
seal.
x Apply grease to the internal boring edge of the oil
seal (59) and push it in.
x Push the oil seal in vertically. If not vertical, the
outer diameter of the oil seal (59) may be
scratched.
x Be careful not to scratch the internal boring edge
of the oil seal (59) when fixing. If scratched, it may
leak oil and damage the reduction unit interior
when the motor is running.
268

2. Install the plug assembly (54)
54 Place the spring (67) in the hole where the plug
CONTENTS
67
assembly (54) of the flange (1) locates. Then
install the plug assembly (54) to the flange (1).
Install the spring (67) to the hole center.

x Install the plug assembly (54) and make its
1
columnar section face downward.
x Before installing the plug assembly (54), apply
1 grease to the internal boring of the flange (1) and
the outer surface of the plug assembly (54)
columnar section.
x After the installation of the plug assembly (54),
2
make sure that it rotates smoothly.
3. Install the ball (53)

Install the ball (53) to the hole on the spherical
surface of the flange (1).
53
3
Before fastening the ball, apply hydraulic oil to the ball

1 (53) and the internal boring surface on the spherical
surface section of the flange (1).
4. Installation of the shaft (42)

4
42 Push the ball-bearing (55) into the shaft (42)
using the bearing set clamp. Then install the
55 shaft (42) into the flange (1) center.
Bearing Set Clamp
5
Install the ball-bearing (55) vertically.
x After the installation of the shaft (42), make sure
that the shaft rotates smoothly.
5. Install the rotating swash plate (52)

Install the flange (1) and make the inclined 6
plane of the rotating swash plate (52) face
upward.
1
Match the hole on the rear spherical surface of the
rotating swash plate (52) with the ball (53), and then 7
install the rotating swash plate (52).
x Apply hydraulic oil to the ball (53) and install the
rotating swash plate.
x After the installation of the swash plate (52), make
INDEX
sure that it rotates smoothly.
269

6. Install the cylinder block (43)
52
(a) Place the cylinder block (43) on a hand
press device, and make the sliding surface
of the orifice plate (68) upward. Install the
cylinder block (43) and make the inclined
plane of the spring seat (48) face downward.
Then install the spring (49), retainer (50) in
1
sequence to the spring seat (48).
(b) Push it into the upper end surface of the
retainer (50) using a clamp. And fix the snap
ring (47).
47
Sometimes if the snap ring is overtightened and the

snap ring pliers slips off, that may injure people.
When fastening the snap ring, the clamp must be
Clamp
used and make sure that the claw of the snap ring
pliers is engaged in the snap ring hole.
x If the snap ring is difficult to shrink, use a snap
ring pliers of bigger size.
x When pushing in the retainer (50), align the
centers of cylinder block and press tool.
50
49
48
43
270

(c) Place the cylinder block (43) on a
51 workbench, and make the sliding surface
CONTENTS
where the cylinder block and the orifice plate
contact face downward. Insert three inserted
pins (51) into the inclined hole of the cylinder
block (43).
43
1
Before placing the cylinder block (43) on the
workbench, make sure that there is no contamination
on the workbench.
x Be careful not to scratch the sliding surface of the
orifice plate (68) in the cylinder block. Otherwise,
the performance of the motor will decrease and 2
trouble occurs in the motor prematurely.
x Before fixing the inserted pin (51), apply grease in
the pin hole.
(d) Install the retainer fixture (46) on the cylinder

block (43). 3
43 4
46
(e) Install the piston assembly (44) (×9) on the

retainer fixture (45) and make the conical
surface of the retainer plate face downward.
5
45
44
6
(f) Install the piston assembly (44) to the
cylinder block (43).
Before installing the piston assembly (44), apply

43 hydraulic oil in the 9 piston holes which are in the 7
cylinder block (43).
x Before the installation, apply hydraulic oil to the
44
spherical surface of the retainer fixture (46).
INDEX
271

7. Install the cylinder block (43)
Engage the retainer fixture (46) with inside
gear spline of the cylinder block (43) with the
outside gear spline of the shaft (42), and make
43
the sliding surface where the cylinder block
(43) and the orifice plate (68) contact face
1 downward. Then install the cylinder block (43)
into the flange (1).
Be careful not to have the piston assembly (44),

retainer plate (45) and the retainer fixture (46)
dropped from the cylinder block (43) when
assembling.
x Before assembly, apply hydraulic oil to the surface
of the swash plate (52) and the sliding surface of
the piston assembly (44).
8. Install disc (60)

Engage the inside gear teeth of disc (60) and
the outside gear teeth of the cylinder block (43)
and install it to the flange (1). Install the
60 protrusion on the edge of the friction plate (61)
61 to the concave of the flange (1) and install
60
61 them together into the flange (1). Install the
60
disc (60), friction plate (61) in sequence into
the flange (1) with the same method.
The disc (60) is of humid type. Before assembling,

immerse it in the hydraulic oil to make it suck in
enough hydraulic oil.
272

9. Install the brake piston (62)
Install the O-rings (63), (64) to the brake piston
CONTENTS
(62). Then install the brake piston (62) into the
flange (1) and make the side of the brake
62 piston with the bigger diameter side face
downward.
63
64 1
Before fixing the O-rings (63), (64), apply grease to
them at first.
x Align the ejection bar hole on the flange (1) which
contacts with the base (2) and the ejection bar
Positioning hole on the brake piston (62) using positioning
Fixture fixture. Then install the brake piston (62).
2
62 x Before installing the brake piston (62), apply
grease to the outer surface of the brake piston
1 and the internal boring of the flange (1).
x Assemble with the brake piston (62) pushed in
and it cannot be tilted. If installed slantwise,
trouble will occur and the O-ring will be peeled off.
3
31
10. Install the 2 speeds tracking select slide valve
(19)
Install the spring (27) into the slide valve (19).
Then install them together to the base (2). After
29 placing the slide valve (19), make sure that the
27 4
O-ring (29) is putted in the plug (28), and then
install the plug (28) to the base (2) and tighten
it. Then, install the O-ring (29) into the plug
2
(31), install the spring guide (30) and the
19 washer (32), and place the plug (31) in the base
29 (2) and tighten it.
28
: 10 mm 5
Install the slide valve A (19) into the base (2) and
make the nose piece surface of the base (2) face you, 6
put the side of the slide valve A (19) having the spring
(27) on RH side. If the order of installing the slide
valve is reversed, trouble may occur in the slide
valve.
x Apply hydraulic oil to the outer surface of the slide
7
valve before installing.
x After the installation of the slide valve (19), make
sure that it rotates smoothly.
INDEX
273

11. Install the safety valve (17)
Place the poppet valve base (17-3) on the top
of the safety valve (17). Then install the safety
valve (17) into the base (2) and tighten it.
: 27 mm
2
17-17,18 Replace all the O-rings (17-7) before assembly.
17-3 x Make sure that the O-rings (17-7) and the spare
17-7 ring (17-18) are installed into the poppet valve
base (17-3).
17 x Apply grease to the O-ring (17-17) and the spare
ring (17-18) before assembly.
274
4-2-4. Repair and maintenance
CONTENTS
Hydraulic oil
1. Hydraulic oil selection
Use the hydraulic oil whose viscosity is equal to VG32-VG46.
Use the anti-wear hydraulic oil as much as possible.
2. Hydraulic oil inspection and replacement
The replacement timeframe of the hydraulic oil depends on the operation conditions, please
1
replace the hydraulic oil according to the following timeframe and the standard listed in the table
below.
The replacement timeframe of hydraulic oil: 1000 hours or once a year
The replacement standard of the hydraulic oil:
Test Item Replacement Standard 2

Viscosity change r10%
Moisture 10 mg/ml
Insoluble ingredient 0.05%
Color When the change is obvious
3
Lubricant
The interior of the reduction machine is filled with lubricant (gear oil) at the factory, but make sure that
there is gear oil before the motor operates.
1. Gear oil selection

Oil Amount Oil Filler Hole Please use the gear oil SAE#90 added with 4
Test Hole
extreme pressure additive.
2. The replacement timeframe of the gear oil
The first replacement: 500 hours.
The second replacement: 1000 hours or one year.
3. The replacement amount of the gear oil: 5.4 L
(1.43 gal). 5
4. The operation flow of replacing the gear oil
The gear oil used to replace and supplement must
be of the same brand. Do not mix and use the gear
oil of different brands.
Oil Drain Hole (a) The oil amount test hole and oil drain hole
are placed in the vertical direction (Refer to 6
the left illustration).
(b) When replacing the gear oil, drain the used
gear oil after turning and removing the 3
plugs as shown in the illustration below.
When supplementing the gear oil, please
turn and remove the plugs of the oil filler 7
hole and the oil amount test hole.
(c) Please block the oil drain hole before adding
oil, and add the gear oil through the oil filler
hole until there is oil coming out of the oil
INDEX
amount test hole.

(d) Please tighten the plug after making sure
that there is no damage on the O-ring.
275

Maintenance and inspection
Usually, only after confirming each of the following maintenance items, the motor can be operated.
Before maintenance and inspection, please confirm whether there are the following abnormalities:
1. Whether the oil leaks.
2. Whether the bolt is loose.
3. Whether there is abnormal noise.
4. Whether the case temperature increases abnormally.
5. Whether the replacement time of the gear oil meats the requirement.
Do not keep the temperature of the case outer surface more than 80qC when running continuously.
The case temperature is very hot after running. In order to avoid the danger of being burned, please
touch by hand after cooling for a while.
The mating standard of each part of the motor
1. The clearance between the plunger outer

D diameter d and the cylinder block inside
diameter D:
0.005 mm İ (D-d)/2 İ 0.012 mm
Plunger Set
Cylinder Block
276

2. The clearance between the balance valve core
outer diameter d and the valve hole diameter
CONTENTS
D:
0.01 mm İ (D-d)/2 İ 0.02 mm
7
INDEX
277
4-2-5. Tracking offset measurement
1. Adjust the machine to the tracking pose.

45°
With the machine in the tracking pose, fully extend

the bucket and arm cylinder lever and keep the boom
angle at 45q.
2. Track for 10 m and then track for 20 m,

measure the tracking offset.
Measure it when the engine runs at a high speed and

in S mode: install the hydraulic meter while measuring
the output pressure of the pump.
0
20 m Tracking for 10 m
Continuously Tracking
Straightly
Make a Mark Make a mark at the middle of 10 m Make a Mark
Datum Line 0
Middle of 10 m
20 m position
Mark Mark
Measure Offset Distance a Mark
278
UNDER TRACKING CARRIAGE - Central connector
4-3. Central connector
CONTENTS
4-3-1. Removal and installation of central connector
pressure.
2
Preparation
Lower the work devices on the ground.
2. Stall the engine. Push the air release valve on
the top of the hydraulic oil tank to release all 3
the residual pressure.
3. Remove the top cap of the hydraulic oil tank,
connect a vacuum pump and run it
continuously to keep negative pressure in the
hydraulic oil tank.
Run the vacuum pump continuously in the 4
operation.
Removal
1. Attach the labels on the hoses and connectors
of the central connector for reassembling.
Remove all the hoses and connectors from the 5
central connector. Cover all the ports removed.
: 17 mm
: 19 mm
6
: 24 mm
1 2 : 80 Ngm (8.2 kgfgm, 59 lbfgft)
: 27 mm
: 30 mm
: 110 Ngm (11 kgfgm, 81.2 lbfgft) 7
: 32 mm
INDEX
279

2. Remove the set bolt (1) M20.
: 30 mm
: 110 Ngm (11 kgfgm, 81.2 lbfgft)
Central connector weight: 56 kg (123 lb)
3. Remove the set bolt (2) from the central

connector. Lift up and remove the central
connector by a crane.
: 24 mm
Installation
Refer to "Removal" above for the wrench size and tightening torque.
1. Install the central connector with the set bolt (2).

2. Install the set bolt (1) to the central connector.
3. Connect all the hoses of the central connector.
After installation, start the engine. Check each part for leakage.
280
4-3-2. Disassembly of central connector
CONTENTS
10
1,2 3 4 5 6 7 8 9
5
11 12 13
1 - Bolt (×4) 2 - Washer (×4) 3 - Cover 4 - O-ring 5 - Spacer

6 - Shim 7 - Swing Body 8 - Oil Seal (×7) 9 - Dustband 10 - Retainer
11 - Swing Shaft 12 - Plug 1 (×1) 13 - Plug (×4)
6
Read the "Disassembly and assembly precaution" before the disassembly operation.
Central connector weight: 48.978 kg (108 lb)
1. Remove the set bolts (1, 2) from the diagonal of the cover (3). Using the lifting eye bolt 7
M18 (Pitch: 1, Length: 18 mm), lift up the central connector, then fix it on the workbench.
INDEX
Put matching mark on the swing body (7) and swing shaft (11).
281

2. Remove the bolt (1), then remove the cover (3) from swing body (7).
: 24 mm
3. Remove the spacer (5), shim (6), O-ring (4) from the swing body (7).
4. Connect the removal tools to the swing body

(7) with two set bolts (1) on the cover (3).
Special
: 17 mm
Tools
Be careful not to damage the sealed sliding surface of

the swing shaft (11).
5. Remove the swing shaft (11) from the swing

body (7).
It's easy to pry out the oil seal (8) with two pins. Be
careful not to scratch the seal groove when prying.
6. Remove the oil seals (8) (×7) from the swing

body (7).
282
4-3-3. Assembly of central connector
CONTENTS
1
11
7
4
5, 6
5
3 6
10 1, 2
7
1 - Bolt (×4) 2 - Washer (×4) 3 - Cover 4 - O-ring 5 - Spacer
6 - Shim 7 - Swing Body 8 - Oil Seal (×7) 9 - Dustband 10 - Retainer
11 - Swing Shaft 12 - Plug 1 (×1) 13 - Plug 2 (×4)
INDEX
283
Install the dust seal (9) with the lip side facing the swing body (7).
1. Install swing shaft and dust seal (9).

Dust Seal (9) 2. Install the oil seals (8) (×7) into the swing body
(7).
3. Fix the swing shaft (11) on the workbench.
Lip
Install the swing body (7) to the swing shaft
(11) with aligning the matching mark.
Swing Body (7)
The clearance between the swing body (7) and swing

shaft (11) is about 0.1 mm (0.004 in), so the swing
shaft must be inserted straightly and slowly in the
direction of the shaft.
4. Tap the swing body (7) with a nylon hammer to

match it with the swing shaft (11).
5. Install the spacer (5) and shim (6) to the swing
body (7).
6. Install the retainer (10) and O-ring (4) to the
swing shaft (11).
7. Install the cover (3) with 4 bolts and shims (1,
2).
: 17 mm
284
4-3-4. Care and maintenance standard
CONTENTS
Item Allowable Limit (Judgment standard) Measure
1. Worn is more than 0.2 mm (0.008 in) Replace
2. Scratch, worn is oblique Replace
3. Worn is uneven (worn range is less than

Replace
180q)
Oil Seal Worn range is within a half 1
Replace
2
Sliding surface and
Scratch or serious damage Replace
sealing part
1. Scratch or abnormal worn is more than
Sliding surface of Replace
0.1 mm (0.004 in)
case and main shaft,
except sealing part 2. Scratch depth is less than 0.1 mm Repair and burnish
(0.004 in) by oil stone
Swing Body, 3
Swing Shaft 1. Worn depth is more than 0.5 mm (0.02
Replace
in) abnormal worn
2. Scratch depth is less than 0.5 mm (0.02
Sliding surface Repair and burnish
in)
3. Scratch or abnormal worn is less than
Repair and burnish 4
0.5 mm (0.02 in) and can be repaired
1. Worn is more than 0.5 mm (0.02 in) Replace
2. Worn is less than 0.5 mm (0.02 in) Repair and burnish

Cover Sliding surface
3. Scratch or abnormal worn is less than
Repair and burnish
0.5 mm (0.02 in) and can be repaired
5
7
INDEX
285
UNDER TRACKING CARRIAGE - Track tensioning mechanism
4-4. Track tensioning mechanism
4-4-1. Removal and installation of track tensioning mechanism

Before removing and adjusting the track tensioning mechanism, the track must be removed first. For
the removal of the track, refer to the relevant part of the removal/installation.
In this part, the precondition of work procedure startup is the track has been removed.
Removal
l Track tensioning mechanism weight: 135 kg (298 lb)

e m ova
R n
ctio When removing the track, because the spring elastic
dire
force may eject the tensioner pulley and tensioning
mechanism, take necessary precautions to avoid
personal injuries.
1. Using a tommy bar, pry out the tensioner

pulley and tensioning mechanism as a unit
from the track frame with fork arm.
2. Remove the set bolts (1) (×4) and washers (2)
(×4), then remove the tensioner pulley.
: 24 mm (0.95 in)
Installation
at
1. Fix the tensioner pulley on the fork ring of the
e r
gS ne tensioning mechanism with the bolts (1) (×4)
tin n sio
un Te ring and washers (2) (×4).
Mo Sp
tensioner pulley 1 : 24 mm (0.95 in)
2
2. Install the tensioner pulley and the tensioning
mechanism as a unit to the track frame.
286
4-4-2. Disassembly of track tensioning mechanism
CONTENTS
11
1
3
4
6
5 17 1
18
Tensioner Pulley
14 2
16
15
7 13
8
9
10
2
12
3
1 - Fork Ring 2 - Retainer 3 - Nut 4 - Keeper 5 - Bolt

6 - Washer 7 - Shaft 8 - Dustband 9 - Worn Adjusting Blade 10 - Seal Ring
11 - Spring 12 - Cylinder 13 - Oil Cup 14 - Retaining Plate 15 - Bolt
16 - Washer 17 - Bolt 18 - Washer
Read the "Disassembly and assembly precaution" on page 1-1-1 carefully before the removal 4
operation.
1. Remove the loosened oil cup (13) slowly, the
14 grease will overflow from the outlet.
16 : 24 mm (0.95 in)
15
2. Remove the bolt (15) and washer (16). The 5
retaining plate (14) has been removed before.
: 19 mm (0.75 in)
7
13
Track tensioning mechanism weight: 135 kg (298 lb)
6
3. Fix the tensioning mechanism, then pull out
the shaft (7) and other related sets as a unit
from the cylinder (12).
4. Remove the retainer (2), seal ring (10), worn
7 adjusting blade (9) and dustband (8)
8 respectively. 7
9
10
2
12
Because the spring elastic force of the tensioning
INDEX
mechanism is strong, special replacers are needed to

finish the removal and installation, and do not remove
other set of tensioning mechanism.
287
4-4-3. Assemble of track tensioning mechanism
11
1
3
4
6
5 17
18
Tensioner Pulley
14
16
15
7 13
8
9
10
2
12
1 - Fork Ring 2 - Retainer 3 - Nut 4 - Keeper 5 - Bolt
6 - Washer 7 - Shaft 8 - Dustband 9 - Worn Adjusting Blade 10 - Seal Ring
11 - Spring 12 - Cylinder 13 - Oil Cup 14 - Retaining Plate 15 - Bolt
16 - Washer 17 - Bolt 18 - Washer
1. Clean all the parts. After applying the G2 - L1

grease (No.2 lithium base), install the dustband
(8), worn adjusting blade (9), seal ring (10) and
retainer (2) in sequence to the shaft (7).
7
8
9
10 Replace the seal ring (10) before assembling, and
2
replace the worn adjusting blade (9) together if
12
necessary.
12 2. Install the shaft (7) set to the cylinder (12), and

fix the dustband (8).
288

3. Using the bolt (15) and the washer (16), fix the
14 retaining plate (14) on the shaft (7).
CONTENTS
16
: 19 mm (0.75 in)
15
4. Tighten the oil cup (13).
: 24 mm (0.95 in)
7
13 1
7
INDEX
289
UNDER TRACKING CARRIAGE - Removal and installation of tensioner pulley
4-5. Removal and installation of tensioner pulley

Removal
Be sure to remove the track first before removing the
tensioner pulley. For the removal of the track, refer to
l "Removal and installation of track".
ova
Rem tion In this part, the precondition of work procedure start up
c
Dire is the track has been removed.
Tensioner pulley weight: 116 kg (254 lb)

When removing the track, because the spring elastic
force may eject the tensioner pulley and tensioning
mechanism, take necessary precautions to avoid
personal injuries.
1. Using a tommy bar, pry out the tensioner

pulley and tensioning mechanism as a unit
eat er from the track frame with fork arm.
ngS s ion
unti n
Te ring 2. Remove the set bolts (1) (×4), washers (2) (×4)
Mo Sp
Tensioner Pulley 1
on the tensioner pulley.
2 : 24 mm (0.95 in)
Installation
1. The installation procedures of the tensioner
pulley are the removing procedures in reverse
order and pay attention to the following
precautions when installing.
x Clean up the connecting surface between
the tensioner pulley and tensioning
mechanism and the sliding surface of the
track frame, then apply the grease to them.
290
4-5-1. Disassembly of tensioner pulley
CONTENTS
8
9
7
6
1
7
4
5
5
2
2
4
9
1 7 5
6
7
8
6
1 - Tensioner Pulley Body 2 - Sleeve (×2) 3 - Tensioner Pulley Shaft 4 - Plug M16×1.5 5 - O-ring (×2)
6 - Seal Ring (×4) 7 - O-ring (×4) 8 - Support (×2) 9 - Pin (×2)
Read the "Disassembly and assembly precaution" on page 1-1-1 carefully before the removal
operation.
1. Remove the plug (4) from shaft (3) to drain the oil to a container.
7
: 24 mm (0.95 in)
2. Remove the pins (9) from supports at both sides, then remove the supports (8) at both
sides respectively.
: 16 mm (0.63 in)
INDEX
291
Total weight including the tensioner pulley: 116 kg (254 lb)
3. Using a press machine, press out the shaft (3)

2 3 from the sleeve (2) and seal ring (6). Using the
shaft (3), push the sleeve (2), seal ring (6) and
1 O-ring (7) on the opposite side out of the
tensioner pulley (1).
4. Remove the O-ring (5) from the shaft (3).
5. Using a press machine, press out the shaft (3)

from the sleeve (2), seal ring (6) etc. on the
other side.
2 6. Remove all components on the other side.
292
4-5-2. Assembly of tensioner pulley
CONTENTS
6
7
4
5
3
1
5
2 3
2 4
1 7
6
7
8 5
1 - Tensioner Pulley Body 2 - Sleeve (×2) 3 - Tensioner Pulley Shaft 4 - Plug M16×1.5 5 - O-ring (×2) 6
6 - Seal Ring (×4) 7 - O-ring (×4) 8 - Support (×2) 9 - Pin (×2)
1. Install the sleeve (2) to the tensioner pulley

shaft (1) at both sides respectively.
7
2
INDEX
2
1
293
5 2. Install the shaft (3) to the tensioner pulley (1)

with the sleeve (2) installed, and install the O-
rings (5) (×2) to the shaft at both sides. Be
careful not to damage the O-rings.
3
5
6 7 3. Install the O-rings (7) (×2) to the seal rings (6)

5 (×2) respectively, and install them to the shafts
(3) (×2) respectively. Be careful not to damage
the O-rings.
3
5
1
7 6
4. Install the O-rings (7) (×2), seal rings (6) (×2) to

8 the supports (8) (×2) respectively.
9 5. Install the two supports assy to both sides of
7
6 the shaft (3), and adjust the position of the
shaft (3), and fix them with pin (9) respectively.
6. Add lubricant to the shaft (3) via the hole of the
plug (4). Apply sealant to the plug (4). Then
tighten the plug (4).
: 24 mm (0.95 in)
Lubricant: No.18 dual linear gear oil
Oil amount: 70~80 ml (0.018~0.021 gal)
294
CONTENTS
C D
A
B
Unit: mm (in) 2
Standard Allowable Limit Measure
A 85r1 (3.35) [66 (2.60)]
B 164 (6.46) -
C 520 (20.5) [488 (19.21)] Surfacing and burnish
D 560 (22.0) - 3
E 20 (0.79) [25 (0.98)]
7
INDEX
295
UNDER TRACKING CARRIAGE - Sprocket wheel and track roller
4-6. Sprocket wheel and track roller
4-6-1. Removal and installation of sprocket wheel
Removal
Do not loosen the oil cup (1) too fast or excessively as

the high pressure grease in the adjusting cylinder
may be ejected out.
Loosen it carefully and keep each part of your body
and face away from the oil cup (1).
If any block or silt accumulates between drive wheel

and the track, clean it up before loosening the oil cup
(1).
1. Slowly loosen the oil cup (1) counterclockwise

to remove the tension of the track.
: 24 mm (0.95 in)
Place a piece of antiskid cloth between track frame

(4) and hydraulic oil jack to prevent sliding.
2. Jack up the track (2) to a height enough to

remove the sprocket wheel (3).
Antiskid Cloth 4 3
3. Insert a block between the track (2) and the
track frame (4).
4. Remove the set bolts of sprocket wheel.
: 24 mm (0.95 in)
Sprocket wheel weight: 25.5 kg (56.2 lb)
5. Remove the sprocket wheel (3) from the track

frame (4).
296
4 3 Installation
CONTENTS
1. Install the sprocket wheel (3) on the track
frame (4).
: 24 mm (0.95 in)
2. Take the block and hydraulic oil jack away.
3. Install the oil cup (1) of the track tensioning 3

mechanism.
: 24 mm (0.95 in)
1
4
Using block, support the jacked track securely.
4. Jack up the track on the side to be adjusted,

turn in the opposite direction lightly.
5. Inject the grease via the oil cup (1) to make the
track tense. 5
Track Tension Specification 300~335 mm
(A) (11.8~13.19 in)
Sprocket wheel should be replaced as an assembly. 6
6. Fill hydraulic oil via the plug (7) hole of the

6 cover (6), then tighten the plug (7).
Apply the LOCTITE #503 or equivalent sealant to
the plug. 7
7
: 6 mm (0.24 in)
Lubricant: Oil API CD grade SAE 30
Oil amount: 70 mL (0.018 US gal)
INDEX
297
4-6-2. Removal and installation of track roller
Removal
1 4
1. Remove the set bolt (1) of the track roller (4)
after removing the track board (The two track
rollers under each side board can be removed
after removing the board).
: 27 mm
: 30 mm
2. Operate the boom and arm to make the angle

between them reach 90q~110q, then lower the
boom after bucket retraction to support the
machine. Support the machine by placing
spacer block under the frame (2).
90°-110°

may be ejected out and lead to a injury.
Loosen it carefully and keep any part of your body
3. Loosen the oil cup (3) of the track tensioning

mechanism, so that the kept tension of the
track can remove the track roller (4).
: 24 mm
3 Tensioner pulley weight: 40 kg (88 lb)
4. Remove the track roller (4) by a fork truck etc.
298

Installation
CONTENTS
1. Place the track roller (4) under the track by a
fork truck etc. as shown in the illustration.
6
1
2 2. Lower the track frame (2) until there is a slight

gap between the grommet (6) and the track
frame (2).
3. Align the bolt hole and tighten the bolt (1) (Two 3
track rollers need the board installed on each
side, fix the board after installing the track
rollers).
: 27 mm
: 30 mm 4
1
4. Install the oil cup (3) of the track tensioning

3 mechanism.
: 24 mm 5
Using a sleeper, support the jacked track securely.

6
5. Jack up the track on the side to be adjusted,

turn in the opposite direction lightly.
6. Inject the grease via the oil cup (3) to make the
track tense.
7
A Track Tension Specification 300~335 mm
(A) (11.8~13.2 in)
INDEX
299

Removal of track roller
3
2
4 1
5
8
7
6
5
4
3
2
1
1 - Plug (×2) 2 - Grommet (×2) 3 - Pin (×2) 4 - O-ring (×2) 5 - Float Oil Seal (×2)
6 - Bush (×2) 7 - Track Roller 8 - Shaft
Be sure to read through the "Disassembly and assembly precaution" on page 1-1-1 before the
disassembly operation.
2 5 7 5 1. Remove the plug (1) from the grommet (2), to

drain oil.
: 6 mm
5 2. Just remove the pin (3) from one of the

2 grommet (2), then you can remove the shaft (8)
from the removed pin (3) side of the track roller
(7), at this time, remove the pin and grommet
from the other side together.
8 : 14 mm
3. Remove the float oil seal (5) on both sides of
the track roller (7) and grommets (2) (×2).
4. Remove the pin (3) from the shaft (8) set, to

4 2
push out the shaft (8) from the grommet (2).
5. Remove the O-rings (4) (×2) from the shaft (8).
300

6. If replacing the bush (6), press out the bush (6)
using the press machine and special tools.
CONTENTS
6
Assembly of track roller
2 7 6 5 4 3 1
2
1 - Plug (×2) 2 - Grommet (×2) 3 - Pin (×2) 4 - O-ring (×2) 5 - Float Oil Seal (×2)
5
6 - Bush (×2) 7 - Track Roller 8 - Shaft
3 1. Using a press machine, install the bushes (6)

(×2) on the track roller (7) without pressing out
8 the dent on flange surface of the bushes (6),
and apply the grease to the O-ring (4) which is 6
installed to the shaft (8).
2. Install the grommet (2) on one side to the shaft
(8), align the pin hole and fix it with the pin (3),
and pay attention not to damage the O-ring (4).
2 4
7
Apply the grease to the O-ring of the float oil seal,
then install it.
When installing the O-ring, pay attention not to twist
INDEX
the O-ring and install it at a correct angle.

Float oil seals are conjugated, do not to use them with
other oil seals.
301

3. Install the float oil seal (5) to the track roller (7)
7 5
and the grommet (2).
4. Insert the shaft (8) to the track roller (7) and
install the O-ring (4). Install the other grommet
5 2 (2) in the same way, fix it with the pin (3).
5. Add the oil via the plug (1) hole to the grommet
(2). Tighten the plug (1).
Apply adhesive LOCTITE#503 or equivalent to the
plug.
: 6 mm
Oil API CD grade, SAE30
Capacity 260 mL (0.069 US gal)

Sprocket wheel
Unit: mm (in)
A 84(3.31) -
B 150(5.91) - Replace
C 120(4.72) [110(4.33)]
The value inside [ ] is just for reference.
302

Track roller
CONTENTS
D
C A C
B
3
Roller wheel
Unit: mm (in)
A 169.0 (6.65) [193.5 (7.62)] 4
B 218.0 (8.85) -
Surfacing and burnish
C 24.5 (0.96) [12.3 (0.48)]
D 150.0 (5.90) 132 (5.19)
Shaft and bush 5

Unit: mm (in)
Shaft Outside diameter 65 (2.56) [64.2 (2.53)] Replace
Inside diameter 65 (2.56) [66.0 (2.60)]
Bush
Flange thickness 2 (0.079) [1.2 (0.047)] 6
7
INDEX
303
UNDER TRACKING CARRIAGE - Track
4-7. Track
4-7-1. Removal and installation of track
Removal

may be ejected out and lead to a injury.
Loosen it carefully and keep each part of your body
1. Turn the track to place the kingpin (2) on the

2
tensioner pulley (3). Place a wooden block
under the track board (4) to jack up the track
3 board as shown in the illustration.
2. Remove tension of the track.

: 24 mm (0.95 in)
Slowly loosen the oil cup (1) counterclockwise to

remove tension of the track. The grease overflows
from the outlet.
1
When removing the track, tensioner pulley will be

ejected due to powerful spring force.
Especially the powerful spring force always acts on
the thread part of the piston rod. When removing the
track, if piston rod or thread part is damaged, the
metal chips will fly out. Take necessary precautions to
prevent from being injured.
ሹᏺ䔼䫔 3 Џ䔼䫔
304
CONTENTS
Track and kingpin have some differences because of
the difference of the supplier. The kingpin (3) shown
in the illustration is just one of them. If there are some
differences between practicality and the illustration,
refer to the standard based on the practicality. But the
method of removal is approximately the same. 1
3. Remove the kingpin (3).
4. Operate the boom and arm to make the angle

between them reach 90q~110q. Lower the boom
after bucket retraction to jack up the machine, 2
pull out the track. Then place a spacer block
under track frame to support the machine.
90°-110°
5. Turn the machine in the backward direction to

drop down the whole track to the ground.
Installation 5
1. Jack up the machine, place the track under the
track roller to engage the driving gear teeth
Tensioner Drive with one side of the track.
Pulley Wheel Be sure to place the track in a correct direction
Side Side as shown in the illustration.
6
2. Lift up the track and place it on the driving

wheel (8).
7
Track set weight: 1330 kg (2932 lb)

8
INDEX
305
9 3. After jacking up the machine, install the

tracking operating lever on the track side when
operating in the forward direction. Wrap the
track while turning the tracking unit (9).
3 4. When wrapping the connected part of the track

2
link to tensioner pulley (4), lower the machine
and place a wooden block under the track
board (5) to support it (5).
Track and kingpin have some differences because of

4 the difference of the supplier. The kingpin (3) shown
in the illustration is just one of them. If there are some
differences between practicality and the illustration,
refer to the standard based on the practicality. But the
method of installation is approximately the same.
5. Install the kingpin (5) with special tools.
Track Rail Pin 3

Main Rail Pin
306
CONTENTS
Bush Seal
If any of link has been removed from the track, when
Pin reconnecting the links, you must apply the grease
(Daphne Epone SR or equivalent) in the clearance
between pin and bush.
Erect the bush on the plate. Fill the grease into the
bush hole. Insert the pin to the bush while pushing 1
and holding the bush on the plate (make the end of
bush stick together with the plate). Clean extra
grease.
Grease
Grease Grease Install the seal as shown in the illustration.
is is
forbidden forbidden 2
Seal
6. Tighten the oil cup (1) and fill grease to adjust

1 track tension. 3
: 24 mm (0.95 in)
Track bottoming out specification (A):
300~335 mm (11.8~13.19 in)
7
INDEX
307

Link
Measure the length of 4 links
x Kingpin is not included in measured part.
x Measure should be performed in the condition of the track tension.
A
Unit: mm (in)
A 761.8 (29.99) 785.8 (30.94) Surfacing and burnish or
B 105 (4.13) 97 (3.82) replace
308

Track board (There may be some differences between practicality and the illustration because of the
difference of the supplier, refer to the standard based on the practicality)
CONTENTS
C
B
A 1
Unit: mm (in)
Track Board Width 600 mm (23.6 in) Track Board
Standard Allowable Limit Measure 2
A 219 (8.61) -
B 8.5 (0.33) - Surfacing and burnish or
replace
C 26 (1.02) 18.2 (0.72)
Main bush (There may be some differences between practicality and the illustration because of the
difference of the supplier, refer to the standard based on the practicality. The illustration below shows 3
Qingdao Hyundai)
4
C
B
Unit: mm (in)
5
A 128.7 (5.07) -
B 38 (1.50) [41.7 (1.63)]
Replace
C 59 (2.32) [54 (2.13)]
7
INDEX
309

Kingpin (There may be some differences between practicality and the illustration because of the
difference of the supplier, refer to the standard based on the practicality. The illustration below shows
Qingdao Hyundai)
Unit: mm (in)
A 213.2 (8.39) -
Replace
B 37.8 (1.49) [35.4 (1.39)]
Pin (There may be some differences between practicality and the illustration because of the difference
of the supplier, refer to the standard based on the practicality. The illustration below shows Qingdao
Hyundai)
Unit: mm (in)
A 213.2 (8.39) -
Replace
B 38 (1.50) [35 (1.38)]
310

Bush (There may be some differences between practicality and the illustration because of the
difference of the supplier, refer to the standard based on the practicality. The illustration below shows
CONTENTS
Qingdao Hyundai)
C
B
1
Unit: mm (in)
Standard Allowable Limit Measure 2
A 138.5 (5.45) -
B 38 (1.50) [39.7 (1.56)] Replace
C 59 (2.32) [54 (2.13)]
3
7
INDEX
311
- MEMO -
312
WORK DEVICE - Removal and installation of work devices
CHAPTER 5 WORK DEVICES
CONTENTS
5-1. Removal and installation of work devices
pressure. 2
Preparation
1. Park the machine on the flat ground, bucket
forward, arm cylinder retracts completely and
lower the bucket to the ground.
2. Turn off the engine, press air release valve on 3
the top of hydraulic oil tank to release all the
residual pressure.
3. Remove hydraulic oil tank header, connect a
vacuum pump to keep negative pressure in the
hydraulic oil tank.
4
When working, make sure to keep vacuum pump
running continuously.
Air Release Valve (Breath Valve)
6
Removal
1
1. Remove grease hose from boom cylinder
piston rod support connector (1). (left and
Connector right)
: 22 mm (0.87 in)
Boom Cylinder 7
INDEX
313
WORK ATTACHMENTS - Removal and installation of work devices
3 2. Remove nut (4) and bolt (6) from boom

2
cylinder piston rod front end center pin (3),
and then remove stop ring (5), spacer (2), (left
6 Boom Cylinder and right)
: 24 mm (0.95 in)
5 1. When pin (3) cannot be pulled out, start the

4 engine, operate boom operating lever little by
little, align boom cylinder piston rod and pin hole.
2. Spacer (2) (Both 1.5 and 0.8 thicknesses are
available) is used for adjusting the clearance.
Determine the type and quantity according to
presence fitting.
Weight of boom cylinder: 178 Kg (SY205C8M,

SY215C8M)
To prevent the metal chips from flying and cause an
injury when removing the pins with a hammer, it's
necessary to wear protective equipments such as
protective glasses and safety helmet etc.
3. Lift up the boom cylinder on both sides with a

crane, knock center pin (3) out of another with
a stick and hammer from one side until it can
be removed.
4. Put the boom cylinder at a 1 m high
workbench, start the engine, operate boom
operating lever to make boom cylinder retract,
Boom Cylinder as shown in the illustration, tight boom
cylinder piston rod with iron wire, stop the
engine.
Iron Wire
5. Remove boom cylinder.
See "Removal of boom cylinder"
The pin skips out suddenly sometimes, make sure to

avoid the case.
6. Remove the bucket cylinder and arm cylinder

hose (7) and (8), and cover port of hose and
tube removed with cover (it can achieve the
aim by removing inner hexagon bolt of fixing
flange ).
: 8 mm (0.31 in)
314

7. Remove the bolt (9), washer (10) from root of
boom to remove clamp plate (11).
CONTENTS
: 24 mm (0.95 in)
Boom
10 9 Weight of work devices:

12 11 4025 kg (8873 lb) (SY205C8M)
4055 kg (8939 lb) (SY215C8M) 1
8. Lift up the work devices to the crane.

13 Lift up the work devices slowly to tighten each
rope.
9. Turn boom root center pin (12) left and right to
pull it out, then remove spacer (13). 2
(Lift up/lower the work devices to adjust the
position of boom root center pin hole. )
Spacer (13) (Both 1.5 and 0.8 thicknesses are

available) is used for adjusting the clearance. 3
Determine the type and quantity according to
presence fitting.
10. Follow step 8, 9, 10 to remove boom cylinder at

another side.
4
11. After lifting up the work devices, move the
machine backward.
12. Lay the work devices on sleeper.

6
7
INDEX
315

Installation
Weight of work devices:

4025 kg (8873 lb) (SY205C8M)
4055 kg (8939 lb) (SY215C8M)
1. Lift up the work devices with a crane, move the

machine forward, while aligning boom root
center pin hole.
(Lift up/lower the work devices to adjust the boom
root center pin hole. )

necessary to wear protective equipments such as
2. Hammer in boom root center pin (12),

determine the type and quantity used of spacer
(13) in accordance with presence fitting
clearance (0.5 thickness and 0.8 thickness ).
Boom
3. Fix plate (11) with bolt (9), washer (10) to limit
9 center pin (12) turn and prevent it from
10
12 11 dropping.
: 24 mm (0.95 in)
13
4. Remove the cap of hose and tubing. Install the

bucket cylinder hose (7) and arm cylinder hose
(8).
: 8 mm (1.97 in)
Weight of boom cylinder:

178 Kg (SY205C8M, SY215C8M)
316

5. Install boom cylinder.
See "Installation of boom cylinder"
CONTENTS
Boom Cylinder necessary to wear protective equipments such as
protective glasses and safety helmet etc. 1
3 2 6. Lift up boom cylinder with a crane, hammer in

center pin (3) from one side, through which
pass the cylinder at both sides.
6 Boom Cylinder 7. Install stop ring (5), and fix with bolt (6) and nut
(4). 2
: 24 mm (0.95 in)
5
4
Spacer (2) (Both 1.5 and 0.8 thicknesses are 3

Determine the type and quantity according to the
presence fitting.
8. Install grease hose to the boom cylinder piston

1 rod support (1) (left and right). 4
: 22 mm (1.26 in)
Connector : 54 Ngm (5.5 kgfgm, 40 lbfgft)
Boom
Cylinder
7
INDEX
317

9. Add grease at the sides, bottom of boom
Boom cylinder piston rod and root of boom.
Cylinder
Piston
Rod Side
Root of
Boom
Boom Cylinder Piston

Rod Right Side
Arm Cylinder
Bottom Side
Boom Cylinder Piston
Rod Left Side
Boom Root Left Side
Boom Root Right Side
When installing the arm removed from boom, carry

out the following steps.
14 14 10. Fit the spacer (14) into left and right side of
arm, adjust left and right clearance within 1.5
mm (0.06 in).
1. Spacer (14) (Both 1.5 and 0.8 thicknesses are

15 15
Determine the type and quantity according to the
presence fitting.
2. Always replace seal ring (16) in each removal.
11. After installing the arm, add grease through

the oil cup (15) on the protrusions of the
connection between arm and boom.
318
16
CONTENTS
17
When installing the sleeve (17) of work devices, pay
attention to the following problems.
Precautions when pressing the sleeve:

If tap the sleeve in with a hammer, the sleeve will be
Arm damaged, so a press machine should be used.
17 16 1
Precautions when reinforcing the arm:
Welding heat will cause the sleeve leak and weaken the
lubricating performance.
If leakage occurs, replace the sleeve.
After welding, if it leaks because of sleeve heated, the
sleeve must be replaced. 2
Sleeve should be pull out or press in with special tool.
7
INDEX
319
5-1-1. Standard of care and maintenance

Center pin and sleeve
E G
F
C
H
J
D
I K
A
B
unit: mm (in)
Part Name Standard Allowable Limit Measure
Center pin 90(3.54) 89.0(3.50)
A
Sleeve 90(3.54) 91.5(3.60)
Center pin 70(2.76) 69.0(2.72)
Boss (Mainframe) 70(2.76) 71.5(2.81)
B
Sleeve
70(2.76) 71.5(2.81)
(Boom cylinder)
Center pin 80(3.15) 79.0(3.11)
Sleeve
C 80(3.15) 81.5(3.21)
(Boom cylinder)
Boss (Boom) 80(3.15) 81.5(3.21)
Center pin 90(3.54) 89.0(3.50)
D
Sleeve 90(3.54) 91.5(3.60)
Center pin 80(3.15) 79.0(3.11)
Boss (arm) 80(3.15) 81.5(3.21)
E
Sleeve
80(3.15) 81.5(3.21)
(Arm cylinder)
Center pin 80(3.15) 79.0(3.11)
Replace
Boss (boom) 80(3.15) 81.5(3.21)
F
Sleeve
80(3.15) 81.5(3.21)
(Arm cylinder)
Center pin 70(2.76) 69.0(2.72)
Boss (arm) 70(2.76) 71.5(2.81)
G
Sleeve
70(2.76) 71.5(2.81)
(Bucket cylinder)
Center pin 70(2.76) 69.0(2.72)
Sleeve
H 70(2.76) 71.5(2.81)
(Bucket cylinder)
Sleeve 70(2.76) 71.5(2.81)
Center pin 70(2.76) 79.0(3.11)
I
Sleeve 70(2.76) 81.5(3.21)
Center pin 80(3.15) 79.0(3.11)
J
Sleeve 80(3.15) 81.5(3.21)
Center pin 80(3.15) 79.0(3.11)
K
Sleeve 80(3.15) 81.5(3.21)
320
CONTENTS
When replacing the sleeve, always press-fit sleeve with the press machine.
Side teeth (Main size shown as below, unit: mm)
1
144
359 92
133
140
175 9
18
73
2
197
Teeth sleeve
C B 3
D
4
unit: mm (in)
A 219 (8.6) 109 (4.29)
B 80 (3.15) - 5
Replace
C 102 (4.02) -
D 105 (4.13) -
7
INDEX
321
WORK ATTACHMENTS - Removal and installation of cylinder
5-2. Removal and installation of cylinder
pressure.
Preparation
1. Park the machine on the flat ground. Bucket
forward, arm cylinder retracts completely and
lower the bucket to the ground.
2. Turn off the engine. Press air release valve on
the top of hydraulic oil tank to release all the
residual pressure.
Removal of bucket cylinder

1. Insert a block (3) between bucket cylinder (1)
1 and arm (2).
2. After turning off the engine, release all the
3 residual pressure in the hydraulic oil tank by
pressing and holding exhaust valve, then
2 remove cap. Release the pressure in the
3 bucket circuit.
4 5
Before pushing pin (7) out, tighten the connecting rod

with rope to prevent it from dropping.
6
injury when using a hammer, it's necessary to wear
protective equipments such as protective glasses and
safety helmet etc.
7
3. Remove nut (6) and bolt (4). Push pin (7) out.
Remove spacer (5).
322
WORK DEVICE - Removal and installation of cylinder
8 1
4. To prevent bucket cylinder (1) and piston rod
(8) from extending, pass iron wire (9) through
CONTENTS
cylinder piston rod hole and tighten it to the
tube of the bucket cylinder (1).
9
1
5. Tools for installation.
(a) general tools
No. Tool Name Number
1 Screwdriver (Slotted screwdriver) 1 2
2 Hexagon Wrench a set
3 Vise 1
4
4 Wrench (For piston screw cap) a set
5 Punch 1
5
6 Torque wrench a set
7 Hammer (Plastic hammer) 1 6
8 Monkey wrench 1
7
9 Scraper a group
INDEX
323

(b) Special clamp
Special clamp needed for cylinder assembling
Clamp Name Sketch Drawing Note
For bush pulled out and pressed in.
For dustband pressed in

For seal ring rectify
Clamp for Inserting Clamp for Rectificatio
For cylinder insert
For piston insert
For clamp, please consult with CUSTOMER SERVICE DEPT. of the Sany Heavy Industry.
324

Installation of bucket cylinder
CONTENTS
10
11
When pressing bush, if the hammer is used, the bush
12
will be damaged, so press it at first.
13
1
1 To prevent the metal chips from flying and cause an
injury when installing the pin (11) with a hammer, it's
14 necessary to wear protective equipments such as
2
1. Hang the bucket cylinder (1) with crane, align
the pin hole at the side of cylinder tube with
the installation hole of bucket cylinder on the
arm, then insert spacer (10) and install pin
(11).
2. Insert bolt (13) into arm stopper (12) and pin 3

8 1
(11).
After installing the hose, add hydraulic oil to the

specified level, then start the engine and check each 4
connecting part for oil leakage.
9 3. Install two bucket cylinder hoses (12).

4. Remove iron wire (9) from bucket cylinder (1)
piston rod (8).
5
Removal of arm cylinder
1
1. Insert block (3) into the place between arm
cylinder (1) and boom (2).
2 2. After turning off the engine, release all the
residual pressure in the hydraulic oil tank by
pressing and holding exhaust valve, then 6
3 remove cap , to release the pressure in the arm
oil circuit.
7
INDEX
325

3. Connect hose blocks (4, 5) to arm cylinder
3 5
separately from tube nozzle (2) and oil pipe
module (3).
: 50 mm (1.98 in)
1 Cylinder
2 Tube Nozzle
3 Oil Pipe Module
1 2 4 4 Hose
5 Hose
4 4. Remove nut (8) and bolt (10) from pin (5) at the
5
10 side of arm cylinder (1) piston rod.
1

safety helmet etc.
8
5. Knock-out pin (5) and remove spacer (4).
6. To prevent arm cylinder (1) piston rod (6) from

6 1 extending, pass iron wire (7) through cylinder
piston rod hole and tighten it to the tube on the
arm cylinder (1).
326

Installation of arm cylinder
13
CONTENTS
When bush is pressed, if hammer is used, the bush
will be damaged, so to press it at first.
1
1. Tight the rope to the center of arm cylinder (1)
14 gravity, then hang it with crane, align the hole 1
15
at the side of cylinder tube with the installation
16 hole of arm cylinder on the boom.
11 To prevent the metal chips from flying and cause an

injury when using a hammer, it's necessary to wear 2
safety helmet etc.
2. Insert spacer (13), then install center pin (14),

set it on the cylinder mounting with bolt (16)
and clamp plate (15). 3
12
3. Install grease hose (12) and two arm cylinder
(11).
Wait until hydraulic oil is added to specified level, start 4

the engine and check for each connecting part oil
leak.
1 Removal of boom cylinder

1. Remove grease hose (1) from boom cylinder.
5
2. Tight the rope to the boom cylinder (2) and
hang it with crane.

injury when using a hammer, it's necessary to wear 6
safety helmet etc.
3. Remove nut (5), bolt (7) and stop ring (6) from
boom cylinder (2) piston rod, then push out pin
7
(4) and remove spacer (3).
7
4. Place boom cylinder (2) to the support, so
does for another one.
INDEX
6
5 3 4 3 2
327

5. Operate boom operating lever to retract boom
cylinder.
To prevent boom cylinder (2) piston rod from
extending, pass the iron wire through cylinder
piston rod hole, and tighten it to cylinder tube.
6. After turning engine off, release all the residual
pressure in the hydraulic oil tank by pressing
and holding exhaust valve, then remove the
2 cap, release the pressure in the oil circuit.
Installation of boom cylinder.
When bush pressing, if the hammer is used, the bush

Boom Cylinder will be damaged, so press it at first.
1. Tighten the rope to the center of boom cylinder

2 (2) gravity and lift it with crane, align pin hole
at the bottom of boom cylinder with the
installation hole of boom cylinder on the
mainframe.

safety helmet etc.
2. Insert the spacer (11) and pin (9), install the

11 2 bolt (8), tighten the nut (10).
8 3. Install the boom cylinder on the other side in
the same way.
4. Install 4 hoses (12) to two boom cylinders (2).
9
9 10
10 Wait until hydraulic oil is added to specified level, start
12
engine and check each connecting part for oil
leakage.
328
5-2-1. Disassembly of cylinder.
CONTENTS
Disassembly essentials
About 1.5 m
3
Fix Cylinder
Belt for tube

4
( No need to take it off
if replacement is not
necessary
)
5
1. Drain oil
2. Fix cylinder
Please fix the cylinder at vertical and horizontal position. Removal and installation are very easy
in vertical condition.
Please fix using bottom and pin hole.
Please stop rotating and fix axis direction. 6
(In addition, please remove interference such as tubing etc.when fixing. )
3. Removal of cylinder cap.
Please loosen and remove the tightened bolt with hexagon wrench.
Connecting hexagon wrench with guide as shown in the illustration make operation easily.
4. Pull out piston rod.
(a) Make sure that tubing sleeve has been removed. 7
(b) Please prepare the appliance for receiving the oil flowed out from oil hole at the side of
cylinder cap.
(c) Please slowly loosen and pull out the cap of cylinder after pulling out piston rod to longest
position.
INDEX
(d) Please pull out piston rod with the cap of cylinder and put them on the sleeper.
329

Operate in vertical condition
Danger occurs when dropping
x When removing and assembling the cylinder

which is fixed vertically, specially be careful of the
record below before operating.
x When pulling out piston rod, because of the
friction of cylinder cap packing, it will cause the
condition of existing space between cylinder tube
and piston if pull out the piston first.
x If operate in this condition, it will cause the
cylinder cap fast slip off suddenly and lead to the
possibility of operator injured.
x Make sure to operate in the condition that the
cylinder cap can contact with piston.
Operate in horizontal condition

Danger occurs when dropping
x When remove and assemble the cylinder which is

fixed horizontally, specially be careful of the record
below before operating.
Sleeper
x When pulling out the piston rod, there is the
possibility of dropping and leading to objects
damage.
x Please pad the piston rod with sleeper, meanwhile
operate carefully.
5. Fix piston rod

Please stop the rotation by using pin hole on the
head of rod or flat part.
330

6. Removal of piston screw cap
Drill (a) Remove set screw
CONTENTS
Outer circumference of set screw has two
slots which are used for riveting on the
punch.
After removing the riveting part with hand
drill, then loosen and remove set screw.
(b) Remove the ball in the set screw.
Ball
(c) Remove piston screw cap. 1
Piston Screw Cap Piston screw cap is tightened as the torque
specified in the assembly drawing.
Loosen piston screw cap needs 1.5 times
torque.
Please make good preparation of power
wrench used for hydraulic jack and hydraulic 2
cylinder.
Hydraulic Jack
Hydraulic Cylinder
7. Remove parts such as piston etc.

Remove as the order of piston, buffer bearing, cylinder cap.
3
Cylinder Head Damping Bearing
Piston
8. Removal of buffer bearing at retraction side
5
Thread
Piston Rod
Spring Blocking Ring A Groove for Damping Bearing Spacing Ring 7

Damping Seal (Twin piece type)
(a) Remove piston nut. The removal cannot be performed with the nut installed.
(b) Remove sliding ring. It is based on the premise that without damage of piston rod and
INDEX
buffer bearing, remove with the tools such as plastic hammer etc. by knocking at lightly.
(c) Slide buffer bearing towards piston rod screw, spacing ring(twin piece type) drops.
(d) Remove buffer bearing.
(e) There is a jag in cushion seal, remove from the jag.
331

9. Remove piston seal
Seal Ring Sliding Ring (a) Sliding ring and protector retainer can be
removed simply by hand.
Piston
(b) Seal ring as right diagram, straighten the
Vise Wood slotted screwdriver and knock it with
hammer to cut and remove.
(c) Take out O-ring with crowbar.
The removed seal objects cannot be used again.
O-Ring Protector Retainer
O-Ring and Protector

10. Removal of buffer ring
Buffer ring is installed in inner diameter slot of
Dustband cylinder. When removing the buffer ring, tie into
and lift out with sharp tool, then insert scraper to
take it out.
Damping 11. Removal of U-ring and dustband
Protector Ring Sliding Ring
(a) Remove U-ring and protector retainer with
Retainer
U-Ring screwdriver etc.
(b) Dustband is pressed into by special tool,
remove it with screwdriver etc. tied into
rubber by knocking.
12. Removal of bush

Use a Press Machine to Push
(a) Take out spring blocking ring with
Tool screwdriver, remove it from the cylinder cap.
(b) Push the bush out with clamp and press
machine as left diagram.
Bush
Removal Method of Bush
13. Removal of pin bush

Press Machine (a) Remove dustband, cylinder tube and piston
rod with screwdriver etc. so does the case
when together with the cap of cylinder.
(b) Remove pin bush by using heel block.
heel block
14. Clean and management
Wash the removed objects with colorless gas,
manage them after applying work oil and cover
them.
If place them like this after removing, the
possibility of without playing function completely
Clamp may exist after assembling because of scaling,
dust ect.
332

Disassembly of cylinder.
CONTENTS
Boom cylinder/bucket cylinder
1 2 3 4 5 6 7
16
8 9 10 11 12 13 14 15 13 12
19 18 17
3
1 - Piston Rod 2 - Snap Spring 3 - Dust Seal 4 - Seal
5 - Ring 6 - Bush 7 - Snap Spring 8 - Inner Hexagon Bolt (×12)
9 - O-ring 10 - Buffer Ring 11 - O-ring 12 - Piston Ring (×2)
13 - Wearable Ring (×2) 14 - Piston 15 - Seal Ring 16 - Cylinder Tube
17 - Inner Hexagon Bolt (×6) 18 - Washer 19 - Cylinder Head
4
Disassembly of boom and bucket cylinder
The beginning for the disassembly procedure below is based on the premise that both hydraulic
pipeline and pipeline snap have been removed.
1. Lift up the cylinder with crane and put it on the

workbench steadily. Always place the cylinder
5
horizontally, drain hydraulic oil out of cylinder.
2. Extend the piston rod (1) completely. Lift up
the piston end with crane, remove inner
hexagon bolts (8) (×12) from cylinder head (19).
3. Knock with nylon hammer, remove cylinder 6
head (19) from cylinder tube (16).
Always pull the piston rod (1) out straightly to prevent

sliding surface from being damaged.
7
INDEX
333

4. Fix piston rod (1) to workbench, remove inner
hexagon bolt (17) (×6), washer (18) (×6) from
piston (14).
334

Arm Cylinder
CONTENTS
8
1 2 3 4 5 6 7 9 10
2
11 12 13 14
15
22 18 19 21 20 19 18 17 16

9 - Cylinder Head 10 - O-ring 11 - Spring 12 - Stopper 4
13 - Ball 14 - Plunger 15 - Cylinder Tube 16 - Inner Hexagon Bolt (×6)
17 - Washer (×6) 18 - Plastic Ring (×2) 19 - Wearable Ring (×2) 20 - Seal Ring
21 - Piston 22 - Buffer Ring
7
INDEX
335

Disassembly of arm cylinder
The beginning for the disassembly procedure below is based on the premise that both hydraulic
pipeline and pipeline snap have been removed.
1. Lift up the cylinder with crane and put it on the

workbench and fix it , drain hydraulic oil inside
the cylinder.
2. Extend piston rod (1) completely , lift up the
piston rod end with crane, remove inner
hexagon bolts (8) (× 14) from cylinder head (9).
Always pull the piston rod (1) out straightly to prevent

sliding surface from being damaged.
3. Knock with nylon hammer, remove cylinder

head (9) together with piston rod from cylinder
tube (15).
4. Place piston rod (1) on the workbench
horizontally, loosen inner hexagon bolt (16) (×6)
and remove it together with washer (17) (×6) from
piston (21).
336
5-2-2. Assembly of cylinder
CONTENTS
Assembly essentials
When assembling, paint of each part may drop and enter into the inner of cylinder and cause oil
leakage. Be careful extremely to operate.
1
1. Installation of pin bush
(a) Please press it into piston rod and bush by
Press Machine
using installation clamp.
(Pre-apply work oil and prepare)
(b) Install dustband by using back block.
Clamp for Installation 2
Pin Bush
Heel Block
4
Piston Rod
Dustband
Pin Bush
5
2. Replacement for seals

Protector Retainer
(a) When removing cylinder, replace all seals.
O-Ring
(b) For O-ring:
x Install protector retainer and O-ring
Pressure after cleaning mounting groove. If 6
Side there is foreign matter in groove, it
may cause oil leakage.
x Please pay attention to the position of
Cylinder Cap protector retainer.
x Apply grease or work oil to protector
retainer and O-ring, install them in the 7
condition of good slide. When install in
bad slide, O-ring will twist and cause
oil leakage.
INDEX
337

\ 3. Assemble cylinder head assembly
Dustband (a) Please press the bush in by using clamp.
Tool
U-Ring Groove Pre-apply work oil fluid to the inner of the
Use a Press cylinder, check the pressed bush for rids.
Machine (b) Please press the dustband in by using
to push
clamp.
(c) U-ring groove should be installed by the
order of protector retainer, U-ring.
x Please confirm the installation
direction of U-ring, install it in the
Hydraulic
Press Machine
condition of without damage.
x If install reversely, it may cause oil
leakage.
Cylinder
Clamp x After installation, check U-ring for
Head
permanent deforming as wrinkle etc.
(d) Install buffer ring.
x Pay attention to the direction of seal
ring when installing. If install in
Bush
opposite direction, extremely high
Be Pressed pressure will be caused between U-
rings and cause cylinder deform,
damage.
(e) Install spring blocking ring to prevent bush
from dropping.
Use a Press Machine to Push Use a Press Machine to Push 4. Assemble piston assembly
Heel Block (a) Install seal ring.
Please consult with our company for clamp
Protector
Tool Retainer x Pre-install O-ring and one-side buffer
Clamp for bearing and piston, place them on the
Rectification
Clamp
press machine and install seal ring as
right diagram with clamp.
Piston
(b) Rectify seal ring.
Seal Ring O-Ring
x After installing seal ring and another
Protector Retainer
side of protector retainer, rectify seal
ring immediately with rectification
clamp to prevent it from expanding
permanently (seriously obey). Seal
ring was prolonged when installed, if
was not rectified in time, (6. piston rod
is inserted into cylinder tube) cannot
be proceed.
(c) Install sliding ring
x Expand the section surface at the least
limitation with both hands, install it in
the direction of axis.
x If expand too large, the installation
cannot be proceed.
338

5. Assemble piston rod assembly .
(a) Please fix piston rod.
CONTENTS
Clamp for Assembly (b) Assemble cylinder head and piston rod.
x Be careful that the lips of dustband
and U-ring cannot be hung by part with
rids, assemble cylinder cover and
piston rod with clamp as right diagram.
(c) Extending side has buffer occasion, install

Buffer Bearing Piston buffer bearing, cushion seal in the following
Cushion Seal order.
(1) The direction of jag of cushion seal is
installed into the groove which face 2
toward piston side.
(2) Install the flat machining part of buffer
bearing show in the illustration below.
Flat Machining (d) Retraction side has buffer occasion, install
buffer bearing, cushion seal in the following
Groove faces piston side order. 3
(1) Install buffer bearing before installing
Extending Side Damping
piston screw cap. If install screw cap
first, the installation for buffer bearing
Groove faces screw side cannot be proceed.
Thread (2) The direction of jag of cushion seal is
installed into the groove which face 4
Piston Rod toward screw side.
(3) Install the flat machining part of buffer
bearing shown in the illustration below.
(4) Put spacing ring into the groove. After
buffer bearing being pressed
Spring A Groove for Buffer Spacing Rin sufficiently toward spacing ring, install
Blocking Cushion Seal Bearing (Twin Piece
5
spring blocking ring. It is based on the
Ring Type) premise that without damage of piston
Retraction Side Damping rod and buffer bearing, slightly tap with
plastic hammer etc.
6
x Please pay attention to the direction of cushion
seal and buffer bearing when installing.
x Error in installation direction, buffer is invalid.
x After buffer installed, confirm the buffer bearing for
extending, retraction, up, down, left and right
movement. 7
INDEX
339

(e) Tighten the piston screw cap.
x Make sure that piston screw cap is
Rivet Punch tightened as the specified torque
shown in the assembly drawing.
Set Bolt x If the torque is insufficient, it may
cause inner leak, screw cap loosen,
Ball
screw damage. Also, if the torque is
excessive, it may cause buffer bearing
to inflate at the extending side or
deform when contact piston.
x For tightening correctly, after cleaning
and degreasing (banana oil etc.) the
screw part of piston, screw cap and
piston rod, tighten the screw cap.
(f) Fix the piston as the direction of
circumference.
x After tightening piston screw cap, put
the ball into it and tighten set screw as
the specified torque shown in the
assembly drawing of fixing screw, rivet
the 2 parts of outside with punch.
6. Insert piston rod into cylinder tube

(a) Fix the cylinder tube vertically or horizontally.
Clamp (b) Insert piston rod into cylinder tube.
Nylon Tube x When it is vertical, enter the bush by
(Twin piece type) the weight of piston rod itself.
x When the piston enters the bush, be
Sliding Ring careful that the sliding ring does not
(Stagger the drop.
Notch 180°)
7. Tighten the cylinder cap

8 1 Tighten the bolt as the order in the illustration on
4 9 the left and specified torque by comparing the
12 5 position of cylinder cap assembly drawing.
6 11
10 3
2 7
Tighten Order of the Bolts
340
5-2-3. Assembly of cylinder
CONTENTS
Boom, bucket cylinder
Pay attention to the direction of seal ring
7
1
2 3
4 5 6
8 12 13 15 13
1 9 10 12
11 17
14
2
18
19
3
16
1 - Piston Rod 2 - Snap Spring 3 - Dust Seal 4 - Seal Ring

9 - O-ring 10 - Buffer Ring 11 - O-ring 12 - Piston Ring (×2) 4
13 - Wearable Ring (×2) 14 - Piston 15 - Seal Ring 16 - Cylinder Tube
17 - Inner Hexagon Bolt (×6) 18 - Washer (×6) 19 - Cylinder Head
Assembly of boom, bucket cylinder

1. Press bush (6) into cylinder head (19).
5
2. Install snap spring (7), ring (5), seal ring (4), dust seal (3) and snap spring (2) to the
cylinder head (19).
Never install ring, seal ring and dust seal in wrong direction. (Always face one side with groove
toward hydraulic oil port)
6
3. Install O-ring (11), seal ring (15), wearable ring (13) (×2) and piston ring (12) (×2) to piston
(14).
4. Install cylinder head (19) module to piston rod (1).
5. Install buffer ring (10) to piston rod (1). 7
Never install buffer ring in wrong direction. (Always face one end of buffer ring with groove (2 parts)
INDEX
toward piston. )
341

Arm Cylinder
8
1 2 3 4 5 6 7 9 10
11 12 13 14 15
22 18 19 21 20 19 18 17 16

9 - Cylinder Head 10 - O-ring 11 - Spring 12 - Stopper
13 - Ball 14 - Plunger 15 - Cylinder Tube 16 - Inner Hexagon Bolt (×6)
17 - Washer (×6) 18 - Plastic Ring (×2) 19 - Wearable Ring (×2) 20 - Seal Ring
21 - Piston 22 - Buffer Ring
Assembly of arm cylinder

1. Press bush (6) into cylinder head (9).
2. Install snap spring (7), ring (5), seal ring (4), dust seal (3) and snap spring (2) to the
cylinder head (9).
Never install ring, seal ring and dust seal in wrong direction. (Always face one side with groove
toward hydraulic oil port.)
3. Install seal ring (20), wearable ring (19) (×2), plastic ring (18) (×2) into piston (21).
4. Install plunger (14), ball (13), stopper (12) and spring (11) into piston (21).
5. Install cylinder head (9) module to piston rod (1).
6. Install buffer ring (22) to piston rod (1).
Never install buffer ring in wrong direction. (Always face one side of buffer ring with groove (2 parts)
toward piston.)
342
ENGINE - Outline
CHAPTER 6 ENGINE
CONTENTS
6-1. Outline
6-1-1. How to read this chapter

This chapter contains the following parts.
x Specification 1
x Structure and operation principle
x Troubleshooting
x Inspection and adjustment with the engine carried
x Service methods
Inspection and adjustment with the engine carried
x The description of inspection and adjustment procedures of parts and assembly installed on the 2
machine includes specific check and adjustment items. Untight, loose, backlash, cracks,
damage and other phenomenon should be checked whether it is required or not.
Service standard
x The description of inspection procedures of each unit and component mainly focuses on main
points of removal, installation, disassembly, assembly, inspection etc.
3
Inspection
x Inspection items that can be determined as "accept/non-accept" according to the service
standard are described.
x Some items such as routine visual check and cleaning of reused parts are not described, but
must be carried out in actual inspection operations.
CAUTION
4
x Some hazards are described. If not avoided, it will cause major injuries or even death, or
damage the vehicle and overhauling equipments..
Take preventive measures when moving and handling the potential hazardous substances
such as the battery fluid and coolant additives.
Preventive instructions, if do not follow the instructions, it may lead to major injuries or even 5
death.
Preventive instructions, if do not follow the instructions, it may lead to equipments or parts
damage.
Suggestions or additional information for more effective use of equipment or a better
Remark
understanding of the content.
6
Terms and units
x Front and rear
The end facing the flywheel housing and towards the fan is the front.
x Right and left
The left hand side and the right hand side is the left and right respectively, when facing the
flywheel housing.
7
Standard Value
x The standard value size in design means: design size of all parts, the standard clearance
between the two parts during the installation and the standard value of a assembly, that depends
on the situation.
INDEX
Limit Value
x When the value of the part exceeds its limit value, the part cannot be reused due to the reduced
performance and strength, it must be replaced or repaired.
343
ENGINE - Outline
Tightening torque
x Provide the standard tightening torque of nuts and bolts directly.
x If the specific tightening torque value is not provided, refer to the standard tightening torque table
when operating. (Standard tightening torque value depends on the size and material of the
thread.)
x The word "wet" means the part should be tightened in "wet" state. No indication should be
regarded as dry state, tighten the part in accordance with the provided tightening torque.
Unit
x Tightening torque and other parameters are provided by SI * unit, with the metric unit in bracket
{ }. Engine specification, performance curves and the values of other items form formal approval
documents are provided by the metric units only.
*SI: International System of Units
Example: 390Ngm {40kgfgm}
Original Unit (Metric System Unit)

SI Unit (International Unit)
International unit
Name Converting to International unit
{Metric Unit}
Force N {kgf} 9.80665N {1 kgf}
Torque Ngm {kgfgm} 9.80665Ngm {1 kgfgm}
Positive pressure kPa {kgf/cm2} 98.0665kPa {1 kgf/cm2}
Pressure Vacuum kPa {mmHg} 0.133322kPa {1 mmHg}
pressure Pa {mmH2O} 9.80665Pa {1 mmH2O}
Capacity dm3 {L} 1dm3 {1 L}

Energy J {kcal} 4186.05J {1 kcal}
Heat flow W {kcal/h} 1.16279W {1 kcal/h}
Power kW {PS} 0.7355kW {1 PS}
344
ENGINE - Outline
How to read this paper
CONTENTS
Symbol Symbol Title Indicate Part Remark
Parts whose torques are not in
The value is provided in the table.
Ta the standard torque table
If the part have no torque
Tightening torque (However, the standard torque is
provided, see the standard torque
provided if necessary during
table
preparation)
Parts that need to be located
Aligning pin
when installing 1
Non-reusable parts Regarded as non-reusable parts
Parts that need to be applied

Grease type, amount of apply etc.
Lubricants, sealers grease or sealer to when
are provided in the table
assembling or installing
Parts that need special tools Shape and No. are provided in 2
Special tools
during operation. the table
*a Indirect parts Part indirectly indicated
7
INDEX
345
ENGINE - Outline
Indicate Specific Tightening Torque
Rocker Arm, Camshaft Indicate the position of aligning pin
Rocker Arm Shaft, Rocker Arm
7 Ta
6
Lubricant or Sealer
is Needed 5
9
8
Non-reusable Part
Ta
3
2 4
The front of engine
ˆa
ƽDisassembly Order
1ǂAdjusting Screw 7ǂLong Rocker Arm
2ǂRocker Arm Bush 8ǂExhaust Rocker Arm Shaft
3ǂShort Rocker Arm 9ǂIntake Rocker Arm Shaft
4ǂRocker Arm Shaft Spring
5ǂAdjusting Screw ˆa : Camshaft Frame
6ǂRocker Arm Bush ˖: Aligning Pin Installing Hole of Camshaft Frame
˖: Non-reusable Parts
This part
ƽAssembling Order
number is the Assemble in the reverse order of disassembly.
same with the If thread is tightened under the condition
number of DBVUJPO that oil or grease has been applied, it
disassembling indicates as "wet".
Rocker arm classifies into short and long rocker arm, please assemble them by turns.
order. In addition, the assembling order steps of intake and exhaust are different.
Service Standard (Unit: mm)

Part Service Items Standard Value Limit Value Correction Method
2, 6 Clearance between rocker arm bush and rocker
0.01 - 0.08 0.12 Replace
8, 9 arm shaft
3, 7 Radial clearance of rocker arm (Roller part) 0.038 - 0.100 Replace
Tightening Torque (Unit: N·m {kgf·m})

Symbol Tightened Parts Tightening Torque Remark
Ta Lock nut (Adjusting screw tightening degree) 11.2 {1.14} -
Lubricant and/or sealer

Symbol Applied part Type Amout
Inner surface of rocker arm bush Engine oil as required
346
ENGINE - Outline
CONTENTS
Special Tools (Unit: mm)
Symbol Tool Name and Shape No. Function
B B
Removal and installation of
Rocker arm bush remover MH062536 rocker arm bush
A B
φ22 φ24.5 A A
ƹInspection Methodsƹ
1
ƵInspect: radial clearance of rocker arm (cylindrical roller)
gIf measured valve is beyond standard, replace the rocker arm.
Cylindrical Roller Part
Special tool symbol is

the same in this manual
2
Clearance
ƵInspect: clearance between rocker arm bush and rocker arm shaft
gIf measured valve is above standard, replace the bush.
Replacement of rocker arm bush

Press Machine
[Removal]
Rocker Arm 4
Bush
7
INDEX
347
ENGINE - Outline
6-1-2. Engine serial number, name plate
x Engine serial number is inherent, which indicates

Engine Serial Number the production order, the number is required when
the vehicles are registered and checked.
x Engine name plate indicates the following items.

x Engine model
6D34-TLU2E
ENGINE FAMILY:L05.8D3B
e4 97/68FA 2002/88 0076 04
348
ENGINE - Outline
6-1-3. Precautions for repair operation
CONTENTS
x Prepare parts for replacement when installing.
x Oil seals, gaskets, O-rings and other rubber parts;

shim and cotter pins, should be replaced with a
new one of Mitsubishi brand. 2
MITSUBISHI
FUSO
x Visually check all parts for wear, cracks, damage,

deformation, aging, rust, corrosion and poor
rotation, fatigue, blockage or any other possible
defects after disassembling.
4
5
x Put matching marks on connection parts before
disassembly, arrange the removed parts in order,
this will help to avoid installing the parts
incorrectly.
x Do not affect the performance and appearance of
the parts when place the matching marks and 6
inscribed marks.
x After removing the parts from the engine, cover
them to prevent dust.
x Be careful not to mix the numerous parts, similar 7

parts and left/right parts together.
x Arrange the prepared new parts and the original
ones (Removed parts) separately.
INDEX
349
ENGINE - Outline
x Apply the specified oil and grease on clevis
sealing ring, oil seal, boot and bearing before
reassembly.
x Use the specified oil and grease only when check
or replace the new parts. Clear any surplus oil or
grease away with cloth.
x Wear protective goggles when using wheel

machine or electric welding machine. Wear
gloves if necessary, and pay special attention to
safety.
x Pay close attention to the sharp edge or other
things which may hurt your hands.
x Disconnect the battery (-) negative cable to

prevent short circuit before the repair operation for
electrical system.
(-)
x Make sure to set the starter switch and light switch

to the OFF position before disconnecting or
connecting the battery cable.
(Otherwise, semiconductor devices may be
damaged)
x Be careful when operating the sensor, relay and

other components which are vulnerable to heat
and shock.
x Do not remove the cover plate on the electronic
control devices or paint on the control device if not
necessary.
x Pull the connector body and do not pull the wire

when disconnect the connector. Pull the
connector body under the unlock condition when
disconnect the lock connector.
x Insert the connector in the direction indicated by
the arrow in the illustration until a click sound is
heard when connecting the lock connector.
350
ENGINE - Outline
x Cover the electric components to keep them dry
before washing the excavator
CONTENTS
(Using plastic film or equivalent).
Do not let the connector and sensor touch the
water, if touched, immediately wiped it away.
x Check whether the positive (+) and negative (-)

(+) wire are connected correctly, and then gradually
increase the voltage from 0 V, when apply voltage
for testing. Do not apply higher voltage than the
(-)
specified value. Please note that not all the 2
electronic control devices and sensor operate
under 24 V.
Precautions for electric lines operation 3
Do not prick the insulation

wrapper of the wire.
x Be careful not to prick wire wrapper when
checking the circuit with testing probe and
alligator clip. Otherwise, it will speed up corrosion 4
of the circuit especially in the chassis wiring
system.
1. Wire inspection 5
C (a) Check the connection status of the connectors
B
(Circuit continuity status)
B (1) Waterproof connector
x Prepare the testing wire and connector A,
A connect the connector B with testing wire
and connector A in the circuit checked.
6
Connect the connector B with Connect the testing probe C to the testing
B testing wire and connector A. wire side connector and check.
x Do not insert the testing probe C into
waterproof connector wire side, because this
will damage waterproof seal and lead to
corrosion.
7
INDEX
351
ENGINE - Outline
(2) Non-waterproof connectors
C x Insert the testing probe C into connector
wire side and check. As the controller
connector is smaller than any other type
connector, therefore super miniature testing
probe should be used for testing. Do not
insert common testing probe into controller
connector, otherwise, it will cause damage.
B C
(b) Check when the connector is disconnected

(1) Check socket terminal
x Insert the testing probe into the terminal and
check. Do not insert the testing probe into
the terminal by force, as this may lead to
deformation of the connector, causing poor
contact.
(2) Check plug terminal

x Contact the testing probe with the pins
directly and check.
x Be careful not to lead to short-circuit between the

pins by the testing probe.
For the electronic control device connector, short
circuit between the pins may cause the inner
circuit damage of electronic control devices.
x Be careful not to allow the probe to the touch

wrong terminal when checking the continuity
with multimeter.
2. Check the connector

(a) Visual check
x Connector looseness, poor contact.
352
ENGINE - Outline
x The wiring disconnects due to stretching the
terminal side
CONTENTS
1
x The contact pressure between the plug

terminal and socket terminal is low
x The connector terminals come off
x Poor contact due to rusted terminals or
mixed foreign matters. 2
(b) Check the terminals for looseness 3

x If the keeper of the connector terminal is
broken or damaged, the terminals between
plug and socket does not engage together
even if the cases of the connector are
attached. Pull each wire lightly and check
which terminal slips out the connector case. 4
3. Check when the fuse is melted

Battery x Remove the fuse, and measure the
resistance between the ground and the fuse 5
- + 0Ω
loaded side.
Then, turn on the circuit switches connected
to the fuse. If the resistance is 0 between
some switch and the ground, there is a short
Fuse circuit between the switch and the load side.
If the resistance is not 0, the circuit should 6
Loaded Short circuit not be short all the time; The fuse may be
Switch happens blown out by a momentary short.
x The main reasons for short as follows.
x The wire is stuck between the chassis
Loaded parts
x The wire insulation is damaged by 7
friction or heat.
x Moisture exists in the connector or
circuit.
x Human failure (The unit is accidentally
INDEX
short)
353
ENGINE - Outline
Precautions for checking the alternator
x Follow the precautions below when inspecting and
repairing the alternator.
x Do not misconnect the battery terminals.
Otherwise, the diodes and regulator will be
damaged by the high current that flows from
the battery to the alternator.
x Do not disconnect the battery wire when the

engine is running. The impulse voltage will be
generated when the engine is running, which will
damage the diodes and regulator.
x Do not use ohmmeter or high-voltage multimeter

when checking. The diodes and regulator will be
damaged when using the high-voltage multimeter.
x Keep the alternator dry. The inside of the

alternator will be short or damaged if water comes
in.
x Do not operate the alternator when short exists

between B and L. The diode pack will be damaged
if operating with the terminals B and L connected.
354
ENGINE - Outline
x Disconnect the battery positive (+) and negative (-)
cable before charging the battery with rapid
CONTENTS
battery charger. The diodes and regulator may be
damaged during rapid charging, if the battery
cable has not been disconnected.
Intermittent malfunction
x Intermittent malfunction usually occur under some
working conditions. The possible causes of the
intermittent malfunction will be determined easily
2
once the working conditions are confirmed. First,
ask the customer about the driving conditions and
weather conditions at the time the intermittent
malfunction occurred and the malfunction
frequency and symptom. And then, reoccur the
malfunctions according to these information.
Determine the malfunctions are caused by 3
vibration, high temperature or other reasons
according to the conditions at the time the
malfunctions occurred. If it is caused by vibration,
check if the malfunctions will reoccur by checking
the following connector and other parts:
4
x Move the connector up, down, right and left
slowly.
x Move the wire up, down, right, and left
slowly.
x Wiggle the sensor and other electrical
appliance slowly by hand. 5
x Wiggle the wire on the suspension system or
other moving parts.
x The checked connectors and electronic parts
contain the connectors and electronic parts that
should be checked according to diagnostic codes
and/or trouble symptoms, or parts where the 6
malfunction may occur.
7
INDEX
355
ENGINE - Outline
Precautions for electric-arc welding operation
x Do not let the current of the welding machine back flow from the metal part of the machine to the
ground circuit when doing arc welding. Otherwise, the ECU and other parts, wiring in electrical
system may be damaged. In addition, if there are electrical parts near the machine part which is
connected with the electric welding machine negative (-) cable, the damage will be very serious.
x If the current in the electric welding machine back

flow from the battery negative (-) cable, the battery
and other electrical parts connected with battery
will be damaged. Thus, be sure to disconnect the
cable from the battery negative (-) in accordance
with the following order.
x Turn the battery switch to the OFF position.
x Turn the starter switch to the OFF position.
x Disconnect the cable from the battery negative (-).
x Cover the area around if necessary in order to
avoid damage to the machine by welding spark.
x Connect the electric welding machine negative (-)
cable to the nearby area of welded portion.
x Set the electric welding machine current to
appropriate value in accordance with weld type.
356
ENGINE - Outline
6-1-4. Standard tightening torque table
CONTENTS
x Use the specified bolts and nuts, tighten them with the appropriate torque according to the table.
Unless the other regulations are specified.
x The thread and contact surface should be in the dry state.
x Use the bolt specified torque when the strength is different between the nut and bolt (Or stud
bolt).
Hexagon bolt and stud bolt (Unit: Ngm {kgfgm})

1
Strength
4T 7T 8T
Grade
Graphic
Represen
tation
Nominal 2
Diameter (Stud Bolt) (Stud Bolt) (Stud Bolt)
mm
2-3 4-6 5-7
M5 - - -
(0.2-0.3) (0.4-0.6) (0.5-0.7)
4-6 7-10 8-12
M6 - - -
(0.4-0.6) (0.7-1.0) (0.8-1.2)
3
9-13 16-24 19-28
M8 - - -
(0.9-1.3) (1.7-2.5) (2.0-2.9)
18-27 17-25 34-50 32-48 45-60 37-55
M10
(1.8-2.7) (1.8-2.6) (3.5-5.1) (3.3-4.9) (4.5-6.0) (3.8-5.7)
34-50 31-45 70-90 65-85 80-105 75-95
M12
(3.4-5.1) (3.1-4.6) (7.0-9.5) (6.5-8.5) (8.5-11) (7.5-10)
4
60-80 55-75 110-150 100-140 130-170 120-160
M14
(6.0-8.0) (5.5-7.5) (11-15) (11-14) (13-17) (12-16)
90-120 90-110 170-220 160-210 200-260 190-240
M16
(9-12) (9-11) (17-23) (16-21) (20-27) (19-25)
130-170 120-150 250-330 220-290 290-380 250-340
M18
(14-18) (12-16) (25-33) (23-30) (30-39) (26-35) 5
180-240 170-220 340-460 310-410 400-530 360-480
M20
(19-25) (17-22) (35-47) (32-42) (41-55) (37-49)
250-330 230-300 460-620 420-560 540-720 490-650
M22
(25-33) (23-30) (47-63) (43-57) (55-73) (50-67)
320-430 290-380 600-810 540-720 700-940 620-830
M24 6
(33-44) (29-39) (62-83) (55-73) (72-96) (63-85)
7
INDEX
357
ENGINE - Outline
Hexagon Flange Bolts (Unit: Ngm {kgfgm})

Strength
4T 7T 8T
Grade
Graphic
Represen
tation
Nominal
Diameter
mm
4-6 8-12 10-14
M6 - - -
(0.4-0.6) (0.8-1.2) (1.0-1.4)
10-15 19-28 22-33
M8 - - -
(1.0-1.5) (2.0-2.9) (2.3-3.3)
21-31 20-29 45-55 37-54 50-65 50-60
M10
(2.1-3.1) (2.0-3.0) (4.5-5.5) (3.8-5.6) (5.0-6.5) (5.0-6.5)
38-56 35-51 80-105 70-95 90-120 85-110
M12
(3.8-5.5) (3.5-5.2) (8.0-10.5) (7.5-9.5) (9-12) (8.5-11)
Hexagon Nuts (Unit: Ngm {kgfgm})

Strength
4T 6T
Grade
Graphic
Represen
tation 6
Nominal
Diameter Standard Thread Rough Thread Standard Thread Rough Thread
mm
2-3 4-6
M5 - -
(0.2-0.3) (0.4-0.6)
4-6 7-10
M6 - -
(0.4-0.6) (0.7-1.0)
9-13 16-24
M8 - -
(0.9-1.3) (1.7-2.5)
18-27 17-25 34-50 32-48
M10
(1.8-2.7) (1.8-2.6) (3.5-5.1) (3.3-4.9)
34-50 31-45 70-90 65-85
M12
(3.4-5.1) (3.1-4.6) (7.0-9.5) (6.5-8.5)
60-80 55-75 110-150 100-140
M14
(6.0-8.0) (5.5-7.5) (11-15) (11-14)
90-120 90-110 170-220 160-210
M16
(9-12) (9-11) (17-23) (16-21)
130-170 120-150 250-330 220-290
M18
(14-18) (12-16) (25-33) (23-30)
180-240 170-220 340-460 310-410
M20
(19-25) (17-22) (35-47) (32-42)
250-330 230-300 460-620 420-560
M22
(25-33) (23-30) (47-63) (43-57)
320-430 290-380 600-810 540-720
M24
(33-44) (29-39) (62-83) (55-73)
358
ENGINE - Outline
Hexagon Flange Nuts (Unit: Ngm {kgfgm})
CONTENTS
Strength
4T
Grade
Graphic
Represen
tation
Nominal 1
Diameter Standard Thread Rough Thread
mm
4-6
M6 -
(0.4-0.6)
10-15
M8 -
(1.0-1.5)
2
21-31 20-29
M10
(2.1-3.1) (2.0-3.0)
38-56 35-51
M12
(3.8-5.5) (3.5-5.2)
Tightening torque for common connecting nut (Unit: Ngm {kgfgm})

3
Tube
4.76mm 6.35mm 8mm 10mm 12mm 15 mm
Diameter
Tightening
17 {1.7} 25 {2.6} 39 {4.0} 59 {6.0} 88 {9.0} 98 {10}
torque
Tightening torque for common air line nylon pipe (DIN type) (Unit: Ngm {kgfgm}) 4
Nominal Diameter ×
6×1 mm 10×1.25 mm 12×1.5 mm 15×1.5 mm
Wall Thickness
Tightening torque 20+6

0
{2.0+0.6
0
} 34+10
0
{3.5+1.0
0
} 49+10
0
{5.0+1.0
0
} 54+50 {5.5+0.5
0
}
Tightening torque for common air line nylon pipe (SAE type) (Unit: Ngm {kgfgm})
5
Nominal Diameter 1/4in. 3/8 in. 1/2in. 5/8 in.
Tightening torque 13+40 {1.3+0.4

0 } 29+50 {3.0+0.5
0 } 49+5
0
{5.0+0.5
0 } 64+5
0
{6.5+0.5
0 }
7
INDEX
359
ENGINE - Engine
6-2. Engine
6-2-1. Specification
Item Specification
Engine model 6D34TLE2A
Type 6 in line water cooled 4 stroke diesel engine
Combustion
Direct injection type
chamber type
Valve
Overhead valve (OHV) type
mechanism
Maximum output
kW {PS}/rpm 114 {155}/2050
power
Maximum torque Ngm {kgfgm}/rpm 590 {60}/1400
Cylinder bore ×
mm I104×115
stroke
Total
displacement cm3 {L} 5860 {5.860}
Compression
18.2
ratio
360
ENGINE - Engine
6-2-2. Structure and operation principle
CONTENTS
1. Structure diagram
Cylinder Liner
Cylinder Head
Camshaft
Valve Spring
1
Rocker Arm
Flywheel
Rocker Arm Shaft
Push Rod 2
Intake Valve
Lifter
Camshaft Gear 3
Idle Gear
Pump Gear
4
Crankshaft
Exhaust Valve
Crankshaft Gear Piston 5
Connecting Rod
Injection Pump Gear
7
INDEX
361
ENGINE - Engine
2. Valve mechanism
Valve Cover
Rocker Arm Valve Lock Clip
Valve Lever
sealing ring Valve Seat
Adjusting Screw Ex. Spring
In. Spring
Valve Guide
Push Rod Valve
Lifter
Camshaft
x The valve lever sealing ring is installed in the valve in order to control the amount of the lubricant
on the slippery area between the control valve and valve guide.
x Ex. spring and In. spring are variable pitch spring. The two springs have different twist to avoid
engaging together when engine is running.
x Using the adjusting screw to adjust the valve clearance.
3. Cylinder Head Gasket
Dimension distinguishing
1.3 mm 1.35 mm 1.4 mm
“UP” Part NO.
x Select and use the cylinder head shim with suitable thickness for the piston projection.
x The thickness of the shim can be distinguished by the shape of the jag.
362
ENGINE - Engine
4. Water Director
CONTENTS
Cooling Water
x The water director is installed under the cylinder head and direct the direction of the coolant 2
appropriately.
5. Connecting rod
Connecting 3
Rod Bush
Connecting Rod
Connecting Rod Bolt

4
Connecting Rod Upper Bearing Weight Mark
“A”-“E”
Matching Mark
Connecting Rod Lower Bearing Tab
5
Connecting Rod Cover
6. Piston
Part NO. 6
Weight
Enlarged Dimension Mark Front Mark
7
INDEX
363
ENGINE - Engine
7. Timing gear
Idle Gear
Oil Hole
Camshaft Gear
Idle Gear Shaft
Idle Gear Bush
Thrust Plate
2
2
2
Injection Pump Gear
Idle Gear
3
1
3
1
3
1
Pump Gear Crankshaft Gear
x Matching marks ("1", "2", "3") are marked on each gear, in order to install gears correctly.
364
ENGINE - Engine
6-2-3. Troubleshooting
CONTENTS
Abnormal noise from engine
Symptoms
Output power insufficient

Reference
Possible causes 1
The valve clearance is incorrect ƻ ƻ

The cylinder head shim is poor ƻ ƻ
The valve and valve seat are worn or have carbon-
ƻ ƻ 2
deposit
Cylinder head,
The valve spring is fatigue ƻ ƻ
valve mechanism
The rocker arm shaft and carrier are poor ƻ
The lubrication in rocker arm shaft carrier area is
poor ƻ
The valve lifter is worn ƻ

3
The engaged clearance between gears is poor ƻ
Timing gear The lubrication between timing gear peripheral and
idler shaft is poor ƻ
The end play of the camshaft is big ƻ

Camshaft
The camshaft is worn ƻ 4
The piston ring groove is worn or damaged ƻ ƻ
Piston, connecting The piston ring is worn or damaged ƻ ƻ
rod
The piston pin and connecting rod small end are
worn ƻ
The end play of the crankshaft is big ƻ 5

The installation of the crankshaft is not good ƻ
Crankshaft The crankshaft pin and connecting rod bearing are
worn or damaged ƻ
The crankshaft journal and main bearing are worn

or damaged ƻ
6
The injection pump is poor ƻ ƻ
Fuel system The injector spray is poor ƻ ƻ Section 6-4
The air is sucked in the fuel system parts or stuck ƻ
The cooling system function is poor ƻ
Cooling system Section 6-5
The belt is loose or damaged ƻ 7
Air intake and The air cleaner is stuck ƻ ƻ
Section 6-6
exhaust system The muffler is stuck ƻ ƻ
The oil viscosity is not qualified ƻ Section 6-3
INDEX
365
ENGINE - Engine
Abnormal noise from engine

Symptoms
Output power insufficient

Reference
Possible causes
The fuel is not qualified ƻ

The installation of the pipe line and hose is poor ƻ
The alternator or other auxiliary equipments are abnormal or the
installation is poor ƻ
366
ENGINE - Engine
6-2-4. General inspection and adjustment
CONTENTS
Measurement of compression pressure
Service standard
Correction
Area Service Item Standard Value Limit Value
Method
All the cylinders (When 2550 kPa 1960kPa
Inspection
Compression 2000 rpm) {26 kgf/cm2} {20 kgf/cm2} 1
-
pressure Pressure difference 390kPa
- Inspection
between cylinders {Below 4 kgf/cm2}
Special tool
Unit: mm
Area Name and Shape of the Tool No. Function 2
Compression pressure
gauge union
A Measure the
MH061460
compression pressure
M14×1.5
3
A
x The decrease of the compression pressure can be used as a guide to confirm the overhaul
period of the engine.
x Periodically check and always pay attention to the change, learning about the change will help
you diagnose troubles. In addition, if the machine is new or new parts are installed in it, the 4
pressure will be higher because the piston rings and valve bases are in running-in process, the
pressure tends to be normal with the parts worn.
x Check if the engine oil, starter and battery are in normal condition before checking.
x Set the machine to the following state.
(a) Preheat the engine until the engine coolant temperature reaches 75 - 85qC.
(b) Turn off all lights and assist equipments. 5
(c) Turn the speed to the min idling condition.
x Remove the injector of the checked cylinder.

Injector Rag x Cover the mounting hole of the injector with rag.
Mounting x Start the engine by the starter and check if there is
Hole foreign matter on the rag. 6
x It may be the following reasons if there is foreign
matter (Engine oil, coolant) on the rag.
x Only oil on the rag may be caused by the
poor sealing of the piston ring. Therefore,
the piston ring should be checked.
x Adhering of oil and coolant to the rag may be
7
caused by cylinder cracks. Therefore, the
crankshaft case should be replaced.
INDEX
367
ENGINE - Engine
x In case of coolant or engine oil attaching if operate

the engine, the coolant and engine oil may spray
out of the injector mounting hole in high
temperature, which is very dangerous. Never look
into or touch the injector mounting hole when the
engine is running.
x Install a shim and on the injector mounting

20 30
10
0
60
40
50 hole, fix them with a injection nozzle cap and
Shim install compression pressure gauge.
x Start the engine and measure the compression
pressure of all cylinders. Calculate the pressure
differences between cylinders.
Injection
x When the compression pressure and the
Injector Nozzle
Cap differences deviate the limit value, fill some engine
Mounting Hole
oil through the injector mounting oil and measure
the compression pressure again.
x If the compression pressure increases, the
piston ring or cylinder interior surface may
be worn or damaged.
x If it does not increase, the valve may be
stuck or poorly installed or the cylinder head
gasket may be poor.
Inspection and adjustment of valve clearance

Service standard
Unit: mm
Correction
Method
Valve clearance (When the engine is in cold
- 0.4 - Adjustment
state)
Special tool
Area Name and Shape of the Tool No. Function
Adjust the valve

Screwdriver with groove MH060008 clearance
(For engine on board)
368
ENGINE - Engine
Check and adjust the valve clearance as follows when
the engine is in cold state.
CONTENTS
[INSPECTION]
x Remove the rocker arm cover.
x Turn No.1 piston or No.6 piston to the
Needle compression stroke upper dead centre as the
following tips.
x Turn the engine until the mark "1 6" stamped
on the flywheel are aligned with the needle 1
of the flywheel housing inspection window.
x Turn No.1 piston or No.6 piston to the
compression stroke upper dead centre.
If the push rod at the side of rocker arm
adjusting bolt can rotate, at the same time ,
the intake and exhaust valve are closed, and 2
there is clearance between rocker arm and
the end of valve stem the piston is at
compressing top dead center. Based on the
above, turn the engine one more round to
exchange the compressing top dead center
position of No.1 piston and No.6 piston. 3
x When No.1 piston or No.6 piston is in the

Valve Clearance
compression top dead centre, measure the
clearance of valves which are marked O symbol in
the following table.
x When use a thickness gauge to measure, some 4
resistance should be felt when moving the gauge
between the clearance.
If the thickness gauge moves freely in the
clearance, the measured value is not accurate.
Cylinder No. 1 2 3 4 5 6
5
Air exhaust valve
Air exhaust valve
Air exhaust valve
Air exhaust valve
Air exhaust valve
Air exhaust valve

Air intake valve
Air intake valve
Air intake valve
Air intake valve
Air intake valve
Air intake valve
Valve sequence
No.1 6
compressing top ƻ ƻ ƻ - - ƻ ƻ - - ƻ - -
dead centre
No.6
compressing top - - - ƻ ƻ - - ƻ ƻ - ƻ ƻ
dead centre
x If the measured value exceeds the specific value, 7

use the following method to adjust.
INDEX
369
ENGINE - Engine
Adjusting Screw
[ADJUSTMENT]
x When adjusting the clearance, loosen the lock nut
and turn the adjusting screw until the thickness
Lock Nut gauge can slightly move.
x After the adjustment, use a screwdriver to hold the
adjusting screw, and tighten the lock nut to secure
it.
x Use the thickness gauge to check the valve
Valve Clearance clearance again, if the value deviates the specific
value, readjust it.
x When the engine is on-board, it is easier to turn

the adjusting screw with the .
Adjusting
Screw
370
ENGINE - Engine
6-2-5. Cylinder head, valve mechanism
CONTENTS
Ta
3
1
1
4
7 Tb
2
Tb 7
8
6 3
9 4
6
10
*a
P 7
INDEX
371
ENGINE - Engine
x Disassembling order
1. Oiler cap 8. Cylinder head (Refer to the following statement)
2. Insulator 9. Cylinder Head Gasket
3. Rocker arm cover 10. Lifter
4. Rocker arm cover shim *a: Crank case
5. Rocker arm and carrier (Refer to the following : Aligning Pin
statement)
: Non-reusable Part
6. Push rod
7. Cylinder head bolt
x Heating plug and injector protrude from the cylinder head lower side. Take care not to damage these
parts when the cylinder head are placed on the working table.
x Assembling order
The assembling procedures are the disassembling procedures in reverse order.
x Because the cylinder head bolt is fixed on plastic area, replace it if it has been used for 3 times.
Service standard
Unit: mm
Area Service Item Standard Value Limit Value Correction Method
6 Swing of push rod - 0.4 Replacement
Clearance between the lifter
10, *a and the lifter hole of the 0.05-0.09 0.2 Replacement
crankshaft case.
Tightening torque
Unit: Ngm {kgfgm}
Symbol Tightened Part Tightening torque Remark
Ta Bolt (For installing the rocker arm cover) 4.9-6.9 {0.5-0.7} -

x Wet
Tb Cylinder head bolt 147 {15}+90q x It can be reused
for 3 times

Symbol Application Area Type Amount
Thread of the cylinder head bolt
Outside of the lifter Engine oil As required
Both ends of the rush rod
372
ENGINE - Engine
Special tool
CONTENTS
Unit: mm
Area Name and Shape of the Tool No. Function
Assemble the cylinder

Socket Wrench MH061560
head
1
Lifter Puller MH063329 Removal of the lifter

2
Operation before removal

Adjusting Screw
Rocker Preparation: loosen the valve springs 3
Cylinder Arm x If the rocker arms tightly press the valve spring
Head Bolt before loosing the cylinder head bolts, loosen the
adjusting screws of the rocker arms first. It will
avoid parts damage caused by the counterforce of
the valve springs.
Valve Spring 4
Removal method
Removal: cylinder head
x When removing the cylinder head, slowly loosen
1
5
9
13
17
23
25
22
20
14
10
6
2 the bolts in accordance with the numbers shown in 5
the illustration.
3 7 11 15 19 21 24 18 16 12 8 4 Removal: cylinder head gasket
x Do not scratch the cylinder head or crankshaft 6

case when removing the cylinder head gasket.
Removal: lifter
Lifter
INDEX
373
ENGINE - Engine
Inspection method
Check: swing of push rod
x Replace the push rod if the measured value
exceeds the limit value.
Check: clearance between the lifter and the lifter

hole of the crankshaft case.
x If the measured value exceeds the limit value,
replace the poor parts.
Installation method
Dimension Distinguishing Installation: cylinder head gasket
A B x For the cylinder head gasket is selective, observe
C
the following tips to select gasket.
x Measure the piston protrusion value of all
cylinders. (Refer to pistons)
“UP” x The piston protrusion value will change after

replacing the piston and rod etc, be sure to
measure the projection.
x Select the cylinder head gasket the thickness of

which fits for maximum piston protrusion value
Jag from the following table after the measurement. In
addition, the piston protrusion value (even only
one cylinder) exceeds the average protrusion
value by 0.05 mm or more, use the gasket that the
thickness of which is 1 grade higher (AoB, BoC).
Unit: mm
Piston Protrusion Value Cylinder Head Gasket
Thickness
Average piston protrusion
Dimension when
value
tightened
0.546-0.610 A 1.3
0.610-0.674 B 1.35
0.674-0.738 C 1.4
x Distinguish the dimension of the cylinder head

gasket by the jag.
374
ENGINE - Engine
x Install the cylinder head shims on the crankshaft
case in the direction shown in the illustration.
CONTENTS
Installation: cylinder head
Stamped Mark
x Confirm the stamped marks on the bolt head

before installing the cylinder head bolt. (It can be
reused if the stamped marks are no more than 2)
1
The stamped marks indicates the assembly times
on the plastic area of the bolt, replace it if there
are 3 stamped marks (Assembled 3 times).
x Apply 1/2 (75 Ngm {7.5 kgfgm} ) of the specified

torque to temporarily fix the cylinder head bolts as 2
the numbers shown in the illustration.
25 17 9 1 6 16 24 x After temporarily fixing them, apply specified
23 13 3 4 12 20
torque (147 Ngm {15 kgfgm} ) to fix them as the
numbers shown in the illustration, and finally
22 18 15 10 8 2 5 7 11 14 19 23
observe the following tip to fasten them.
: Fasten the rocker arms and the carrier at the 3
same time.
x Left turn the socket seat of to make the

interior springs take effect.
Socket 4
Connecting Rod
Socket
Seat Connecting Rod
(For connection)
x Make the connecting bar touch the surrounding

parts such as rocker arm shaft carrier, injection
Scale pipe etc by the spring force.
(Socket Connecting x Select a clear scale on the socket seat side.
Side) Bar
x Based on that scale, right turn the scale on the
6
socket side 90°(Each scale 5°) to fasten it.
x For the cylinder head bolt can be only used for 3
Scale (Socket
Seat Side) times, before installing it, stamp on the bolt head
to define the used times.
7
x For the cylinder head blot is installed in plastic
area, it is not necessary to fasten it again after the
angle tightening.
INDEX
375
ENGINE - Engine
Rocker arm and carrier
4 5
7
1 10
9
8
6
1. Tightening Bolt 6. Rocker Arm Shaft Spring
2. Rocker Arm Shaft Carrier 7. Adjusting Screw
3. Adjusting Screw 8. Rocker Arm Bush
4. Rocker Arm Bush 9. Exhaust Rocker Arm
5. Air Intake Rocker Arm 10. Rocker Arm Shaft
Non-reusable Part
x Assembling order
Service standard
Unit: mm
Correction
Method
Clearance between the rocker arm bush
4, 8, 10 0.06-0.11 0.2 Replacement
and the rocker arm shaft

Interior surface of the rocker arm bush Engine oil As required
Special tool
Unit: mm
Symbol Name and Shape of the Tool No. Function
Rocker Arm Bush

Remover
Removal and
A B A MH061378 installation of rocker
B arm bush
I19 I21
C
376
ENGINE - Engine
Inspection method
CONTENTS
Inspection: clearance between the rocker arm bush
and the rocker arm shaft
x If the measured value exceeds the limit, replace
the bushing.
Replacement of the rocker arm bush

[REMOVAL]
Bush
3
[INSTALLATION]
x Set the parts as shown in the illustration, align the
oil hole of the rocker arm bush with the oil hole of
Bush the rocker arm.
Bush Notch Bush Torsion x Install until the touches the chamfering of the
(Gap) rocker arm.
Chamfering of x Check the clearance again after installation. 4
Bush Oil Hole
rocker arm x If the measured value is less than the standard
Oil hole of
rocker arm
value, the bush needs to be reamed.
Installation tips
Tightening Bolt Hole
Installation: the rocker arm shaft 5
x Install the rocker arm shaft in the direction as
Front of engine 6
Oil Hole
7
INDEX
377
ENGINE - Engine
Cylinder head
Tc
13
1
10
2
Ta
3
11
Tb 14
4 9
12
5
6
8 16
15
7
20
19
21
18
17
1. Valve Cover 9. Injection Nozzle Cap 17. Intake Valve Seat
2. Valve Lock Clip 10. Injector (See Section 6-4) 18. Exhaust Valve Seat
3. Upper Seat 11. O-ring 19. Water Director
4. Ex. Spring 12. Injection Nozzle Shim 20. Double Ended Stud Bolt
5. In. spring 13. Linking Board 21. Cylinder head
6. Valve Lever Seal 14. Heating plug Non-reusable Part
7. Intake valve 15. Intake Valve Guide
8. Exhaust valve 16. Exhaust Valve Guide
x Assembling order
x The valve lever seal should be replaced when removing the intake valve and exhaust valve.
378
ENGINE - Engine
Service standard
CONTENTS
Unit: mm
Correction
Method
free length 60.84 57.8
installation load
4 Ex. Spring (Installation length of 24.5r1.2kg 20.8kg Replacement
47.25)
1
squareness - 2.5
free length 55.07 52.1
installation load
5 In. spring 9.5r0.45kg 8.1kg Replacement
(Installation length of 40.3)
squareness - 2
2
outer diameter of valve
8.96-8.97 8.85 Replacement
lever
sinking depth in bottom
7 Intake valve 1.0r0.25 - Inspection
surface of cylinder head
valve margin thickness 1.5 1.2 Correction or
valve seat angle 45qr1.5' - replacement 3
Clearance between the intake valve lever
7, 15 0.04-0.06 0.15 Replacement
and intake valve guide
outer diameter of valve
lever
sinking depth in bottom
8 Exhaust valve 1.2r0.25 1.7 Inspection 4
surface of cylinder head
margin thickness 1.5 1.2 Correction or
valve seat angle 45qr1.5' - replacement
Clearance between the exhaust valve lever

8, 16 0.07-0.1 0.2 Replacement
and exhaust valve guide
Correction or 5
17 Intake valve seat width 2r0.2 2.8
replacement
Correction or
18 Exhaust valve seat width 2r0.2 2.8
replacement
Bottom surface Correction or
Below 0.05 0.2
deformation replacement
21 Cylinder head 6
The height from top to
95r0.1 94.6 Replacement
bottom
Tightening torque
Unit: Ngm {kgfgm}
7
Ta Bolt (For installing the injection nozzle cap) 25 {2.5} -
Tb Heating plug 15-20 {1.5-2.0} -
Tc Nut (For installing the linking board) 1.0-1.5 {0.1-0.15} -

INDEX
379
ENGINE - Engine
The sliding area between valve cover and
rocker arm
The lip part of valve lever seal Engine oil As required
The valve lever part
O-ring
Special tool
Unit: mm
Valve Lifter
A MH061668
I42
A
Removing and
installing the valve
lock clip
Valve Lifter Hook MH061679
Valve lever seal

Installation Tool
Installing the valve
A B A B MH061293
lever seal
I28 I9
Rubbing the valve and

Valve Abrasive Tool 30091-07500
valve seat
Valve Guide Remover A
A B Removing the valve

MH061066
guide
I9 I13
A
380
ENGINE - Engine
CONTENTS
Valve Guide
Installation Tool
A B
A B C MH061998 Installing valve guide
I28.5 I15 18
C
Caulking Tool Body 1
A MH061067
I9
Caulking Ring
Installing the valve
B A h seat 2
MH061695
Intake B i <Intake side >
I47.6
side MH061069
<Exhaust side >
Exhau
I40.6
st side
3
Removal method
Removal: valve lock clip
x Remove the valve lock clip when the valve spring
is compressed uniformly so that it does not tilt.
4
x If the valve spring is compressed beyond of
Valve
Lock Clip requirement, the upper seat will contact the valve
lever seal, resulting in damage, please pay
special attention to this.
5
Inspection method
Inspection: intake valve and exhaust valve
1. Outer diameter of valve lever
x If the measured value is below the limit value
or one side wears heavily, replace the valve.
x The valve and valve seat must be ground 6
after replacement.
2. Valve seat angle and valve margin thickness

x If the measured value is above the limit
value, correct or replace the valve. 7
Seat Surface Angle

INDEX
Valve Margin Thickness
381
ENGINE - Engine
Correcting the valve
x The grinding quantity should be controlled to the
minimum limit as far as possible.
x If the valve margin thickness is beyond the limit
value after correcting, replace the valve.
30
x The valve and valve seat should be rubbed after
20
10
correcting.
Inspection: the clearance between valve and valve

guide.
x If the measured value is above the limit value,
Replacement of the valve guide

[REMOVAL]
Valve Guide
[INSTALLATION]
x Install the valve guide until contacts the
cylinder head completely.
Cylinder Head
10 mm
Valve Guide x must be used as the specified insertion

depth of the valve guide is 10 mm.
x Pay attention that the exhaust valve guide is
longer than the intake valve guide.
Inspection: the contact condition of the valve and

valve seat
x Check that the valve and valve guide are normal
Valve Interface
before inspecting.
x Apply minium to the valve interface of the valve
seat evenly.
x Tap the valve on the valve seat and do not turn the
valve when tapping.
382
ENGINE - Engine
x If poor contact exists according to the quantity of
the minum adhering to the valve, correct in
CONTENTS
accordance with the following tips.
Contact
Correcting Measure
Condition
little defect Grinding the valve
Correcting or replacing valve and valve
Serious defect
seat
1
Rubbing of the valve

x Apply a light coat of rubbing cream to the contact
surface of the valve and valve seat evenly.
Lever of the valve
2
Rubbing Cream
x Make sure that there is no rubbing cream
adhering to the lever of the valve.
x Use the mid-fine grit (120-150 Mu) of rubbing
cream at the beginning, at last use the fine grit
(200 Mu or more) of rubbing cream.
x If a little engine oil is mixed in the rubbing cream, it
3
is easy to apply evenly.
x Tap the valve seat with the valve, at the same time
turn it little by little.
x Use light diesel oil or equivalent to wash away the
rubbing cream. 4
x Apply engine oil on the contact surface of the
valve seat, and rub it forcibly.
x Inspect the contact condition of the valve and
valve seat again.
x If the contact condition is still poor, replace the
valve seat. 5
Inspection: valve seat

1. Valve seat width
Valve Seat x If the measured value is above the limit
value, correct or replace the valve seat.
Valve Seat Width 6
x The valve and valve seat should be rubbed
after corrected or replaced.
7
INDEX
383
ENGINE - Engine
2. Valve depression depth of bottom surface of
cylinder head
Valve Seat
x Measure the depression depth with the valve
attached against the valve seat.
x If the measured value is above the limit
value, replace the poor parts.
Depression Depth
Correcting of the valve seat

Depression Depth
Valve x Grind the valve seat with valve seat milling cutter
Seat or valve seat grinder.
Angle x Put a sand paper with about 400 Mu between the
cutter and valve seat after grinding and grind the
Valve valve seat slightly.
Seat x Use the 15q or 75q f cutter to correct the valve until
Valve Seat Width the valve seat width reaches the specified valve.
x Make sure that the depression depth of valve

does not exceed the specified limit value when
grinding.
x The valve and valve seat should be rubbed after

correcting.
Replacement of the valve seat

Valve Seat [REMOVAL]
x The assembly of the valve seat is magnitude of
interference range. Grind the inner surface of the
seat valve to minimize its thickness, then remove it
at room temperature.
0.5-1.0 mm
Part to be grinded
[INSTALLATION]
x Check that the valve seat bore diameter A and B
of cylinder head are as shown in the table below.
Intake side valve seat bore
I46+0.025
0 mm
diameter: A
Exhaust side valve seat bore
I39+0.025
0 mm
diameter: B
A B
x If there is abnormality, replace the cylinder head.
384
ENGINE - Engine
x Soak the valve seat in liquid nitrogen to cool it
sufficiently.
CONTENTS
g
h
x When operating the cooled valve seat, please be
䯔ᑻ
Valve Seat aware of low temperature and frostbite.
x Install the valve seat to cylinder head with

and . At this time, place the chamfering side
1
of on the side of cylinder head.
x Grind the valve after installing the valve seat.
Inspection: deformation of bottom surface of

cylinder head
x If the measured value is above the limit value, 2
grind it with the surface grinding machine. Pay
attention not to deviating the height from top to
bottom of cylinder head from the limit value.
3
x Make sure that the depression depth of valve
does not exceed the specified limit value when
grinding.
Installation method
Installation: water director 4
x Install the water director to cylinder head and
Notch
insert it to the specified depth (4 mm) with its notch
following the direction shown in the illustration.
Installation: valve lever seal ring

x Apply engine oil to the lip part of valve lever seal
ring.
x When installing the valve lever seal ring, make 6
Lip sure that contacts the cylinder head
Valve Lever Seal completely.
Cylinder Head x Check the spring part of valve lever seal ring for
deformation and damage after being inserted, if 7
there is abnormality, replace it with a new one.
Installation: valve lock clip

x Install valve lock clip according to the removal tips.
INDEX
(See page: [REMOVAL: VALVE LOCK CLIP])
385
ENGINE - Engine
6-2-6. Piston, connecting rod and cylinder liner
5
3
1
P Ta
1. Connecting Rod Lower Bearing 3. Connecting Rod Upper Bearing 5. Cylinder Liner
2. Connecting Cap 4. Piston and Connecting Rod : Aligning Pin
(Refer to the following
statement)
x Because the connecting rod bolt is tightened in plastic area, if it has been used for 3 times
judging from the marks, replace the connecting rod bolt.
x Assembling order
386
ENGINE - Engine
Service standard
CONTENTS
Unit: mm
Correction
Method
- Piston protrusion value (Average value) 0.43-0.69 - Inspection
- Connecting rod end play 0.15-0.45 0.6 Inspection
Connecting rod Span in free state - 69.5

1, 3 Replacement 1
bearing Oil clearance 0.04-0.099 0.2
Clearance of piston, connecting rod and
4, 5 0.07-0.11 - Replacement
cylinder liner
Inside diameter I104-104.03 I104.25 Replacing
Cylinder part of with a
5 Roundness Below 0.01 -
crankshaft case oversized
Cylindricity Below 0.03 - one 2
Tightening torque
Unit: Ngm {kgfgm}
x Wet
Nuts (For installing the connecting rod cap) 29 {3}+90qr5q x Reuse it for 3 3
Ta
times

Symbol Application Area Type Consumption
Thread part of bolt
Interior surface of connecting rod bearing
4
Engine oil As required
Outer circumference of piston
Outer circumference of cylinder liner
Special tool
7
INDEX
387
ENGINE - Engine
Unit: mm
Piston Guide Clamp MH061890
Piston Guide Lever MH061658

Installing the piston
and connecting rod
Socket wrench MH061560
Cylinder Liner
Installation Tool
Installing the cylinder
A ME062228
liner
I103
A

Crank Case
Inspection: the piston protrusion value from the top
of crankshaft case
x The piston protrusion value must be inspected, as

it will influence engine performance.
x Turn the piston to the compression stroke upper

dead centre position.
x Make base point A as the point O (Totally 7) and
A measure the protrusion value from point O
(Measure point B. Base point A)
x The piston protrusion valve can be calculated by
measuring the nearest base point A near measure
B point B, then measure 2 positions (12 totally) each
cylinder and calculate average value.
x If the average value exceeds the standard value,
inspect the clearance of each part.
x The thickness of cylinder head should fit the
average value of piston protrusion value. (Refer to
cylinder head)
388
ENGINE - Engine
Inspection: connecting rod end play
x Measure the end play of each connecting rod.
CONTENTS
Inspection method
Inspection: connecting rod bearing span in free
state
2
x Do not expand the bearing by hand.
x If the measured value is below the limit value,

replace the connecting rod upper bearing and
lower in pairs. 3
Inspection: clearance between connecting rod

bearing and crankshaft (Oil clearance)
Upper Bearing
x Install connecting bearing upper and lower to
connecting rod cap and the connecting rod, and
then tighten bolts with torque 29 Ngm {3kgfgm}. 4
x Measure the inside diameter of connecting rod
bearing and the crankshaft pin outer diameter of
crankshaft.
Lower Bearing x If the clearance is above the limit value, replace
the poor parts.
x The crankshaft pin outer diameter of crankshaft
Outer Diameter of the Crank Pin 5
should be corrected to the specified downsized
value when downsizing the bearing. (Refer to
crankshaft)
7
INDEX
389
ENGINE - Engine
Inspection: clearance between the piston and the
Crank Case Cylinder Liner
cylinder part of cylinder liner
Over 20 mm x If the measured value exceeds the standard value,
80 mm take any of the following measures.
A A: crankshaft case side measure position (Parallel
to the axis of crankshaft)
B
B: crankshaft case side measure position
Over 60 mm (Perpendicular to the axis of crankshaft)
C: piston side measure position (Perpendicular to
piston hole)
x If the cylinder part inside diameter of cylinder liner
exceeds the limit value, the cylinder part should be
bored to oversized dimension, and replace piston
72.15 mm and piston ring which fit the cylinder part.
C
x Even though only one of the cylinders is poor, all
cylinders must be bored to the same oversized
dimension.
x If the cylinder part inside diameter of cylinder liner

is within the standard valve, replace the piston and
piston ring.
Set piston oversized dimension
x Oversized dimension value: 0.501.00 mm (2
types)
x Measure the inside diameter of all cylinders,
oversized dimension can be determined based on
the cylinder that has the largest inside diameter.
x Measure the outer diameter of oversized
dimension piston.
x Bore the cylinders according to the standard
clearance value between the piston and cylinder
part.
x In order to avoid deformation due to the increasing

temperature when boring, please follow the orders
below to bore the cylinder.
No.1oNo.5oNo.3oNo.6oNo.2oNo.4
Bore cutting process size (Tolerance: r0.005) =

oversized piston outer diameter (Measured value) +
clearance between the piston and cylinder (Maintaining
basis medium value) - 0.02 mm (Hone allowance)
Hone it after boring, then as the final process size
(Tolerance: r0.005).
Final process size (Tolerance: r0.005) = oversized piston
outer diameter (Measured value) + clearance between the
piston and cylinder (Maintaining reference medium value)
x Honing process surface roughness: 2-4Pm
x Honing intersection angle: 15-25° (Half angle)
390
ENGINE - Engine
x Cylinder inner diameter squareness: 0.05 mm
x Check the clearance between piston and cylinder
CONTENTS
part
Replacement of cylinder liner

[REMOVAL]
x Fix and center the boring machine on the
crankshaft case. Centering should be done on the
lower side of cylinder liner where there exists little 1
uneven wear.
x Bore the cylinder liner to make its thickness reach
0.5 mm.
Cylinder Liner x Insert the tool (The process tool, like screwdriver,
etc.) between crank case and cylinder liner, tap it
lightly while you open the cylinder liner to remove. 2
x Place the circular bead end of tool to crankshaft

case side. Without placing it to crankshaft case
side, scratch will happen.
3
183 mm [INSPECTION]
99 mm Crank Case x Check for scratch of the cylinder liner installing
15 mm
hole of crankshaft case.
x Measure the distance related to the crankshaft
D1 A B
case inside diameters and the cylinder liner outer
D2
diameters at the points shown in the illustration. 4
x If the average value of measured value deviates
D3 from the standard value, bore the crankshaft case
hole to oversized value.
15 mm
Cylinder Liner
5
99 mm
D1
183 mm
B
D2 A
D3 6
[INSTALLATION]
x Press the cylinder liner from chamfering side into
crankshaft case with .
Cylinder Liner
x Hone the cylinder liner after pressing until its
7
inside diameter reaches standard value.
Crank Case
INDEX
391
ENGINE - Engine
Installation method
Lower Bearing Upper Bearing
Tab Installation: connecting rod bearing
Oil Hole x If the lower and upper bearing (With oil hole) are
installed reversely, the engine crankshaft will be
stuck. Please pay more attention.
D A Installation: piston and connecting rod

x Check that the piston ring closed end is in the
specified position.
ĀƸā
A: No.1 Compression Ring closed end
B: No.2 Compression Ring closed end
C: oil ring closed end
D: oil ring support spring corresponding part
" Ƹ ": forward mark on the piston
B C
x Make the piston forward mark " Ƹ " in the front of

ĀƸā the engine.
x Install to piston skirt, and adjust with adjusting
bolt of to match its inside diameter and outer
diameter.
x Remove it from piston after adjusting properly,
then install it to piston ring after applying engine oil
Adjusting Bolt
to the following parts.
x Outer circumference of piston
x inside circumference of
x inside circumference of the crankshaft part
of the crankshaft case
x Match the matching marks of the connecting rod

and connecting rod cap, tighten bolts alternately
Connecting
according to the following orders after installing
Rod Cap
piston and connecting rod.
Matching Mark
x Tighten bolts with torque 29 Ngm {3kgfgm}.
x Tighten bolts further according to the following
order after tightening.
392
ENGINE - Engine
x Turn the sleeve base of left to tighten the
Sleeve spring in socket wrench.
CONTENTS
Connecting Bar
Sleeve
Seat
Connecting Bar
(For connecting)
1
x Adjust the sleeve and apply the build-in spring

Connecting Bar
force to crankshaft by connecting bar (For
(For connecting)
connecting).
x Align any of the scales on the sleeve base with
any of the scales on the sleeve. (Serve as the 2
position of datum 0°.)
x Tighten sleeve following the direction shown in the
Reticle (Sleeve side) illustration and make the reticle reach 90r5°.
Reticle (Sleeve beat side) Each reticle on the sleeve side is equal to 5°.
x Check the following items after installing the
connecting rod cap. 3
x Connecting rod end play
x Protrusion value of the piston
7
INDEX
393
ENGINE - Engine
Piston and connecting rod
5
8
4
7
6
1. No.1 Compression Ring 4. Snap Ring 7. Connecting Rod
2. No.2 Compression Ring 5. Piston Pin 8. Piston
3. Oil Ring 6. Connecting Rod Bush Non-reusable Part
x Do not remove the connecting rod bolt unless it is abnormal.
x Assembling order
Service standard
Unit: mm
Limit Correction
Area Service Item Standard Value
Value Method
No.1 compression ring 0.3-0.45
Piston ring closed end
1-3 No.2 compression ring 0.4-0.55 1.5 Replacement
clearance
Oil ring 0.25-0.45
No.1 compression ring 0.09-0.13 0.2
Clearance between
1-3, 8 piston ring and ring No.2 compression ring 0.06-0.1 Replacement
groove 0.15
Oil ring 0.03-0.06
Clearance between piston pin and connecting rod
5, 6 0.03-0.05 0.1 Replacement
bush
5, 8 Clearance between piston pin and piston 0.007-0.021 0.05 Replacement
Bending - 0.05
7 Connecting rod Replacement
Twisted - 0.1
394
ENGINE - Engine
CONTENTS
Outer circumference of piston pin
Outer circumference of connecting rod bush
Mounting surface of connecting rod bush of
connecting rod
Special tools
1
Unit: mm
Removing and
Piston Ring Tool MH060014
installing piston ring 2
Removing and
Connecting Rod Bush
MH062225 installing connecting
Remover Replacer Set 3
rod bush
Removal method
Removal: piston ring
4
Removal: piston pin

x Tap out piston pin with press stick.
Piston Pin x If piston pin cannot be tapped out easily, put it in
hot water or heat it with heater and then remove it.
6
7
INDEX
395
ENGINE - Engine
Inspection method
Cylinder Section Inspection: piston ring closed end clearance
x Insert piston ring into the cylinder section of
crankshaft case horizontally using piston top.
Piston
Insert into the lower part where there exists little
uneven wear.
x Do not move piston ring when measuring the
closed end clearance.
Piston Ring
replace the complete set of piston rings.
Inspection: clearance between piston ring and

piston ring groove
x Clean all carbon-deposit in the piston ring groove.
x Measure along the circumference of the piston
ring groove.
replace the poor parts. In addition, a complete set
of piston rings should be replaced when replacing
the piston ring.
Inspection: clearance between piston pin and piston

Inspection: clearance between piston pin and

connecting rod bush
replace the bush.
396
ENGINE - Engine
Part and Component of Replacement of connecting rod bush

x Replace the connecting rod bush using .
CONTENTS
Remover Base Board
Spacer A Carrier [REMOVAL]
Spacer B x Remove the connecting rod upper bearing
installed on the connecting rod big end (If
equipped).
x Fix the connecting rod on the base and lock it in
the proper position with carrier and base board.
Nut Base x Install spacer A to the remover following the 1
direction shown in the illustration, then gradually
Remover Press
apply about 49 kN (5000 kgf) pressure until the
connecting rod bush is pressed out.
Spacer A Carrier
Bush
Base Board
2
Base
[INSTALLATION]
Spacer B
Remover x Apply engine oil to the installing position of 3
connecting rod bush and the outer circumference
Bush Oil Hole of bush.
Connecting Rod x Install spacer B to the remover following the
Spacer A
direction shown in the illustration, put to
connecting rod bush and spacer A on it, and fix a
series of parts with nuts. 4
Nut x Align the connecting rod bush with the connecting
oil hole, and then gradually apply about 49 kN
(5000 kgf) pressure using the press machine until
the bush is pressed in proper position.
x Measure the clearance again after installing.
x If the measured value is below the standard value, 5
ream out the bush.
7
INDEX
397
ENGINE - Engine
Inspection: bending and twist of connecting rod
Bending x Install connecting rod to connecting rod aligner.
Install connecting rod upper bearing, piston pin
100 mm and connecting rod cap, in order to keep in step
with the condition that the connecting rod is
installed to crankshaft case. Then tighten the
connecting rod cap nut to the specified torque 69
Connecting Rod Aligner
(Measuring device) Ngm {7kgfgm}.
x Measure bending and twist of connecting rod.
replace the connecting rod.
Twist
100 mm
Connecting Rod Aligner

(Measuring device)
Installation method
ĀƸā Installation: piston and connecting rod
x Make sure that the quality of each cylinder is equal
when replacing connecting rod.
x Apply engine oil to piston pin and install the piston
and connecting rod following the direction shown
in the illustration. " Ƹ ": onward mark
Quality Mark x If piston pin cannot be installed easily, put the
piston in hot water or heat it with piston heater and
then install the pin.
Installation: piston ring

x When installing the piston ring, make the mark
near piston ring closed end upward and set each
“Ƹ” oil ring closed end in the direction shown in the
illustration.
A: No.1 compression ring closed end
A: No.2 compression ring closed end
Company Mark C: oil ring closed end
D: oil ring support spring corresponding part
" Ƹ ": piston forward mark
In addition, the mark only exits on the No.1
compression ring closed and No.2 compression
ring closed end.
398
ENGINE - Engine
6-2-7. Flywheel
CONTENTS
3
P
4
*a 1
5
2
6
Ta
3
1
1. Keeper 4. Flywheel *a: Crank
2. Bearing 5. Engine Speed Sensor : Aligning Pin
3. Gear ring 6. Flywheel Housing 4
x Assembling order
Service standard
Unit: mm

Correction 5
Method
Rubbing surface runout Correction or
4 Flywheel - 0.2
after assembling replacement
Eccentric degree of concave with the Correction or
6 - 0.2
flywheel housing installed replacement
6
Tightening torque
Unit: Ngm {kgfgm}
Symbol Tightened Part Tightening Torque Remark
Ta Bolt (For installing the flywheel) 39 {4.0}+47q Wet
Lubricant and/or sealer 7

Thread part of bolt Engine oil As required
INDEX
399
ENGINE - Engine
Special tools
MH062183
Socket Wrench
Installing the flywheel
Magnetic Base MH062356
Inspection before removal

Inspection: rubbing surface runout with the flywheel
Flywheel
installed
check that the bolt is properly tightened and check
the mounting surface between the flywheel and
the crankshaft. Then correct or replace the
flywheel as necessary.
Removal method
Removal: flywheel
Flywheel x Remove the flywheel by screwing the bolt into
flywheel removing hole.
Removal: gear ring
Removing Hole x Uniformaly heat the gear ring to 200qC with gas
Bolt
burner etc., and remove it from the flywheel.
x Never touch it with hands, as the heated part has

a high temperature.
Installation method
Concave Part Inspection: eccentric degree of concave part with
the flywheel housing installed
x Turning the crankshaft, inspect the eccentric
degree at the area of the flywheel housing shown
in the illustration.
x If eccentric degree exceeds the specified limit
value, reassemble it.
x If eccentric degree still exceeds the specified limit
value after reassembling, replace the
malfunctioning components.
400
ENGINE - Engine
Ring Gear
Installation: gear ring
CONTENTS
x Uniformly heat the gear ring to 200 degree
centigrade by gas burner, etc..
Chamfering x Never touch it with hands, as the heated part has

Side a high temperature.
Flywheel 1
x Install the gear ring with the non-chamfering side
of gear the ring facing the flywheel.
Installation: flywheel
x Tighten the bolt with 39Ngm {4.0kgfgm}, then
tighten it as follows. 2
Socket
Connecting Rod x Turn the socket seat of left to tighten the
Socket spring in socket wrench.
Seat Connecting Rod
(For connection)
x Adjust the socket to apply the build-in spring force

Scale (Socket side) to by the connecting rod (For connecting).
x Align any of the scales on the socket seat with any
of the scales on the socket. (Serve as the position
of datum 0q.) 4
x Turn the socket side scale mark right by 47qr3q
Scale (Socket from the aligned mark and tighten it.
seat side) Each division on the socket seat scales is equal to
Connecting Rod (For connection) 10q
7
INDEX
401
ENGINE - Engine
6-2-8. Timing gear
10
*c
4
*d
5 *b
*a
11
8
Tb
2 *a
9
3 13
12
1
Charmfering
Ta 10
1. Cone 7. Timing Gear Case 13. Key
2. O-ring 8. Thrust Plate *a: Crankshaft Gear
3. Crankshaft Pulley 9. Idle Gear Bush *b: Oil Pump Gear
4. Cap 10. Idle Gear *c: Camshaft Gear
5. O-ring 11. Idle Gear Shaft *d: Injection Pump Gear
6. Front Oil Seal 12. Front Oil Seal Stop Ring Non-reusable Part
x Do not remove the front oil seal unless it is determined to be abnormal.
x Assembling order
402
ENGINE - Engine
Service standard
CONTENTS
Unit: mm
Correction
Method
Crankshaft gear and oil
0.10-0.18 0.3
pump gear
Idle gear and
0.07-0.15 0.3
Clearance crankshaft gear
- Replacement 1
between gears Idle gear and camshaft
0.07-0.17 0.3
gear
Idle gear and injection
0.07-0.17 0.3
pump gear
- End play of idle gear 0.05-0.15 0.3 Replacement
Clearance between idle gear bush and idle 2
9, 11 0.03-0.06 0.1 Replacement
gear shaft
Tightening torque
Unit: Ngm {kgfgm}
Nut (For installing the crankshaft pulley) 490 {50} - 3
Ta
Tb Bolt (For installing the thrust ring) 78 {8} -

O-ring 4
Front oil seal lip part Engine oil As required
Idle gear bush inner surface
Timing gear case mounting surface ThreeBond 1270C As required
Special tools
5
Unit: mm
Idle Gear Bush C

Remover
Removing and
A B C MH062224 installing the idle gear
bush
6
B
I44.5 I49 I45
A
Cone Remover
A MH062496 Removing the cone 7

M44×1.5 A
INDEX
403
ENGINE - Engine
Removal essentials
Cone
Removal: cone
x Install to the shaft and turn it as shown in the
illustration to mesh the cone, then remove the
cone together with .
Inspection: clearance between gears

x Measure the clearance of each pair of gears at 3
places or more.
replace the malfunctioning components.
Inspection: end play of idle gear

replace the malfunctioning parts.
Inspection method
Inspection: clearance between idle gear bush and
idle gear shaft
[INSPECTION]
replace the bush.
Replacement of idle gear bush

[REMOVAL]
Bush
404
ENGINE - Engine
[INSTALLATION]
x Place the idle gear in the direction shown in the
CONTENTS
Chamfering Part illustration.
x Install bush and make touch the chamfering
part of idle gear.
x Measure the clearance again after installing.
Bush
x If the measured value is below the standard value,
ream out the bush.
1
Idle Gear Installation method

Injection Installation: idle gear
Camshaft
Pump Gear x Place No.1 piston and No.4 piston to the top dead
Gear
center.
2
x Align idle gear with the matching marks "1","2","3"
of each gear and install it.
Crankshaft
Gear
Installation: timing gear case 3

Sealer
φ1 mm x Clean the sealer coated surface of timing gear
case and remove the oil or other attachments.
x Apply sealer to the timing gear case continuously
and uniformly, and install the front end plate within
3 minutes. At this time, keep the sealer in the right
position. 4
x Do not start the engine within 1 hour after

Front End Plate installing the timing gear case.
x The sealer must be applied again after the timing
gear case mounting bolt is loosed or removed.
5
Timing Gear Case
7
INDEX
405
ENGINE - Engine
6-2-9. Camshaft
“F”
2
Ta 1
1. Camshaft Gear 4. Camshaft
2. Thrust Plate Non-reusable Part
3. Key
x Do not remove the camshaft gear unless it is determined to be abnormal.
x Assembling order
406
ENGINE - Engine
Service standard
CONTENTS
Unit: mm
- End play of camshaft 0.05-0.22 0.3 Replacement
A maximum of 3 times
Magnitude of interference range of
1, 4 0.03-0.07 - are allowed when
camshaft gear and camshaft
reassembling.
Long 1
diameter:
Intake 47.105
7.195r0.05 6.70
side Short
Difference diameter:
between long Replace 39.910
4 Camshaft diameter and ment Long
short diameter diameter: 2
Exhaust 46.979
7.321r0.05 6.82
side Short
diameter:
39.658
Bending Below 0.02 0.05 Replacement
Tightening torque 3
Unit: Ngm {kgfgm}
Ta Bolt (For installing the camshaft gear) 180 {18} -

The thrust face of the thrust plate
The cam part and journal part of the Engine oil As required
camshaft
5
Inpection: camshaft end play
Removal method
Bolt Removal: camshaft 7
x Before removing the camshaft, release the bolts
through the hole of the camshaft gear first.
INDEX
x Be careful not to damage the camshaft bush when

removing the camshaft.
407
ENGINE - Engine
Removal: camshaft gear
Camshaft Camshaft Gear x The press machine should work on the camshaft
side when removing since the camshaft gear has
been pressed onto the camshaft.
x Use a press machine not a hammer to remove the

camshaft.
Inspection method
Inspection: camshaft gear and camshaft magnitude
of interference range
x If the measured value exceeds the standard value,
Inspection: camshaft
Long
Diameter 1. The difference between long diameter and
Front of
Engine
short diameter of the cam part
x If the measured value exceeds the limit
value, replace the camshaft.
6.5 mm 6.5 mm Short
Diameter
Measuring Measuring
Position Position x Because the cam part of the camshaft is a taper,
measure it at the measuring position shown in the
illustration.
2. Bending
x When measure the bending of the camshaft,
support the both ends of the crankshaft
journal and measure at the central part of
the journal.
x The bending of the camshaft is half reading
of the dial indicator when the camshaft turn
one round.
value, replace the camshaft.
Installation method
Stamped Mark Installation: Camshaft gear
x Check the stamped mark in the center part of the
gear before installing the camshaft gear. Because
the camshaft gear is allowed to be reasembled 3
times at most, so if there are 3 stamped marks on
it, replace the camshaft gear and the camshaft.
408
ENGINE - Engine
x Install the camshaft gear to the camshaft and fix it
“2”
with the key as shown in the illustration.
CONTENTS
Clamp 2
2
Camshaft Gear
Thrust Plate
Key x Apply the pressure to the center part of the
camshaft gear. The camshaft gear will be
damaged if apply the pressure to the gear part.
x After installation, mark a stamped mark in the

1
center of the camshaft gear for the reassembly.
Installation: camshaft
Camshaft Gear x Place No.1 piston and No.4 piston to the top dead
center. Align the matching mark “2” of camshaft
gear and idle gear and install the camshaft. 2
7
INDEX
409
ENGINE - Engine
6-2-10. Crank and crankshaft case
16
15
P
Tb 14
13
1
12
11 b
3 b
8
2
Ta 5
P
10 6
410
ENGINE - Engine
CONTENTS
1. Rear Oil Seal 7. Crank Gear 13. Upper Main Bearing
2. Main Tightening Bolt 8. Key 14. Check valve
3. Side Oil Seal 9. Rear Oil Seal Stop Ring 15. Oil Jet Tube
4. Thrust Plate 10. Crankshaft 16. Crank Case
5. Lower Main Bearing 11. Front End Plate : Aligning Pin
6. Main Bearing Lid 12. Shim Non-reusable Part
x Assembling order
The assembling procedures are the disassembling procedures in reverse order. 1
x Because the main tightening bolt is fixed in the plastic area, if the bolt has been tighted 3 times
according to the marks, replace it.
x Be careful not to tighten the check valve with a torque greater than the specified torque for the 2
improper operation will cause the engine lock.
Service standard
Unit: mm
Correction
Method 3
Replace thrust
- Crank end play 0.10-0.26 0.4
plate
Oil clearance 0.04-0.09 0.15
5, 13 Main bearing Less than Replacement
Span in free state -
82.5
4
Bending Below 0.025 0.05 Replacement
11 Crankshaft Pin part and Circularity Below 0.01 0.03

Correction or
crankshaft
Cylindricity Below 0.006 - replacement
journal part
Correction or
17 Deformation of the crankshaft case roof Below 0.07 0.2
replacement
5
Tightening torque
Unit: Ngm {kgfgm}
x Wet
Main tightening bolt (For installing main
Ta 59 {6}+90q x 3 times at most
bearing lid) 6
are allowed
Tb Check valve 38 {3.9} Wet

The lip part of the rear oil seal 7
The thread part of the main tightening bolt
The inside of the main bearing
The thread part of the check valve
INDEX
Crank case mounting surface of the rear oil

seal ThreeBond 1207C As required
The top and groove of the side oil seal
411
ENGINE - Engine
Special tools
Unit: mm
Installing the main

Socket Wrench MH061560
bearing lid
Bearing Lid Remover
A B Removing the main

MH061083
bearing lid (End part)
I103 M8×1.25 B
A
Removing the
Gear Remover MH061326
crankshaft gear
Installation tool of the

rear oil seal stop ring
Installing the rear oil
A B C MH062677
seal stop ring
C
I103 I100 I15 AB

Inspection: crankshaft end play
replace the thrust plate with an oversize one and
make adjustment.
x Oversize type
+0.15, +0.30, +0.45mm
x If the end play cannot be adjusted fully, replace the
crankshaft.
Removal method
Removal: main bearing lid
x Because there is side oil seal between the main
bearing lid in the end and the crankshaft case,
remove it with .
Main Bearing Lid
412
ENGINE - Engine
Removal: crank gear
CONTENTS
x Do not remove the crankshaft gear by tapping it or
it may be damaged.
Removal: rear oil seal stop ring

x Disengage the rear oil seal stop ring with chisel or
similar tool. Be careful not to damage the
1
crankshaft.
Inspection method
Inspection: main bearing span in the free state
2
x Do not expand the bearing by hand.
x If the measured value is less than the limit value,

replace the upper and lower main bearing.
3
Inspection: clearence between the main bearing and
Upper Bearing the crankshaft
x Install the upper main bearing and lower main
bearing to the crankshaft case and main bearing
lid.
x Tighten the main tightening bolt with a torque of 4
59Ngm {6kgfgm}.
x Measure the inner diameter of the main bearing
and the outer diameter of the crankshaft journal.
Lower Bearing
correct the crankshaft journal to specified small
size. 5
Journal Outer Diameter

6
7
INDEX
413
ENGINE - Engine
Inspection: crankshaft
1. Bending
x When measuring the crankshaft bending,
support NO.1 and No.7 crankshaft journal
first, then measure the center part of NO.4
crankshaft journal.
value, replace the crankshaft.
x The bending of the crankshaft is half reading of

the dial indicator when the camshaft turn one
round.
2. The cylindricity and roundness of the

crankshaft journal and crankshaft pin
value, grind the crankshaft to small size or
replace it.
Correction of crankshaft
C B
Pin Part D
Journal Part
D
x If correct the crankshaft by grinding, replace the
A main bearing with one of the small sizes.
x The distance A between journal part center and

pin part center should keep unchanged.
A: 57.5r0.075 mm
x The crankshaft journal width B and crankshaft pin
part width C should keep unchanged.
B: 35 mm (No.1 crankshaft journal part is 32 mm)
C: 41+0.2
0 mm
x Smooth the round corner D.
D: R4r0.2 mm
x Perform magnetc inspection to check for cracks.
Check the surface hardness (Shore hardness
should be Hs75 or more)
x If there is an abnormality, replace the crankshaft.
414
ENGINE - Engine
Specification of the crankshaft small size
CONTENTS
Unit: mm
Grade of Small Size
0.25 0.50 0.75 1.00
Finish size of the
crankshaft journal outer 77.68-77.70 77.43-77.45 77.18-77.20 76.93-76.95
diameter
Finish size of the pin part
64.69-64.71 64.44-64.46 64.19-64.21 63.94-63.96
1
outer diameter
Circularity Below 0.01
Cylindricity Below 0.006
x When grinding, make sure that the crankshaft and

Grinding Process Finish Machining abrasive wheels turn left by abserving in front of 2
the crankshaft.
x When processing the crankshaft with oil stone or
sand paper, the crankshaft should turn right.
Crank Crank
3
Abrasive Wheel Sand Paper
Inspection: deformation of the crankshaft case top

Measuring Position surface
correct it with surface grinder. 4
x keep the pistion projection within the specified
value when grinding.
5
Installation method
Rear Oil Seal Stop Ring
Installation: rear oil seal stop ring
x Install the rear oil seal stop ring until the
installation tool touches the guide.
6
Guide Installation Tool
Installation: crank gear

Jag Part Key x Heat the crankshaft gear to about 100 qC with gas 7
burner nozzle.
INDEX
Be careful not to be burn.
Crankshaft Gear Crank
415
ENGINE - Engine
x Align the key fixed on the crankshaft with the jag
part of the camshaft gear, and install it by tapping
the gear end surface with plastic hammer.
Installation: main bearing

Lower Bearing Upper Bearing
x Install the main bearing with the tabs inserted into
Oil Hole the grooves.
In additon, the main bearing should be small size if
the crankshaft has been corrected to small size.
Tab Tab Small size type: 0.25, 0.50, 0.75, 1.00mm
x The engine will be stuck if the upper bearing and

lower bearing are assembled reversely because
the upper bearing has oil hole while the lower
bearing doesn't.
Thrust Plate Main Bearing Lid Installation: thrust plate

x Install the thrust plate in the main bearing lid
Oil Groove position which is in the end of the engine to make
the oil groove outside.
: Aligning Pin
Oil Groove
x Be careful not to install the oil groove of the thrust

Oil Groove
plate reversely, which will cause the engine lock.
x Install oversize thrust plate when adjust the

crankshaft end play. In this case, it is OK even the
left size and right size is different, however, the
upper and lower thrust plates must be the same
size.
x Installation: main bearing lid

Stamped Mark
x Before installintg the main tightening bolt, first

check the stamped marks on the tip of the bolt (If
there are no more than 2 stamped marks, you can
use it again.)
x Stamped marks indicates the assembly times in
the plastic area of bolts in the past. If there are 3
stamped marks (Which indicates that they have
been assembled 3 times), replace them with new
bolts.
416
ENGINE - Engine
x Line the protruding number "1"~ "4", mark "R" and
front mark as shown in the illustration and
CONTENTS
install the main bearing lids according to the
Front of number sequence from the front of the engine.
Engine
1
7
F F F F F F F
x Apply engine oil to the main tightening bolt thread

part and the seat surface and tighten them with
Socket torque 59Ngm {6kgfgm}, and then go on tightening
Connecting Rod according to the following essentials.
Socket x Turn the bolt of left to make the inner spring 2
Seat Connecting Rod active.
(For connection)
3
x Adjust the socket and apply the build-in spring
Scale Crank
(Socket seat side)
force to crankshaft by connecting rod (For
Connecting connecting).
Rod (For
x Align any of the scales on the socket seat with any
connection)
of the scales on the socket. (Serve as the position
of datum 0°.)
x Make the aligned position as the benchmark and 4
Scale tighten the socket as shown in the illustration,
(Socket side) making the scale of the socket side at 90° position.
Every scale on the socket seat side is equal to 5°.
x Mark stamped mark after tightening the main
tightening bolt in the plastic area to record the
usage times. 5
Because the bolts are tightened in the plastic area, do

not tighten any more after the tightening above.
6
x Confirm that you can turn the crankshaft by hand
after installation. Inspect the installation of the
main bearing lid if there is an abnormality.
Installation: install the side oil seal

Main Bearing Lid x Fill the mounting groove for the side oil seal of the
main bearing lid with sealer. 7
Sealer
INDEX
417
ENGINE - Engine
x Apply sealer to the top and install the side oil seal
between the main bearing lid and crankshaft case
A B as shown in the illustration.
A: crankshaft side
B: crankshaft case side
Side Oil Seal Top
x Apply sealer to the area shown in the illustration
after installation. Make sure that there is no engine
oil leakage from all the parts.
Sealer
Installation: real oil seal

x Apply engine oil to the lip part of the rear oil seal.
x Clean the oil seal surface.
x Apply the sealer along the line of the rear oil seal
Lip Part
evenly and continuously.
x Install within 3 minutes after applying the sealer.
Keep the sealer in the right position.

Sealer
installing the rear oil seal.
x Apply the sealer again after releasing or removing
the bolts.
2 mm
Line
418
ENGINE - Engine
6-2-11. Camshaft bush
CONTENTS
4
*a 5
3
1
3
1. No.1 Camshaft Bush 4. Seal Housing : Non-reusable Parts
2. No.3 Camshaft Bush 5. No.5 Camshaft Bush
3. No.4 Camshaft Bush *a: Camshaft
4
x Do not remove the camshaft bush, unless it is determined to be abnormal.
x Assembling order
Service standard 5
Unit: mm
Correction
Method
Correction or
The clearence No.1, 5 0.03-0.08 0.15
replacement
1-3, 5, *a between camshaft
bush and camshaft No.1, 4 Correction or 6
0.06-0.11 0.17
replacement

The inside of camshaft bush Engine oil As required
7
INDEX
419
ENGINE - Engine
Special tools
Unit: mm
Camshaft bush Connecting

Rod Remove and install the
installation tool and MH061276
camshaft bush
remover tool
Guide
Splicer
Inspection essentials
Inspection: clearence between camshaft bush and
camshaft
replace the bush.
Replacement of camshaft bush

Parts & components of x Replace the bush with
For No.4 bush, prepare and use the clamp which
Connecting Rod
is used to extend the connecting rod.
Splicer
Guide
Clamp
φ30 mm
φ17.5 mm 50 mm
200 mm
420
ENGINE - Engine
[REMOVAL]
x Remove each bush with the corresponding splicer
CONTENTS
and the connecting rod together.
Connecting Rod Unit: mm
Corresponding Splicer
Bush
A C A B C
No.1 I54.5 41.5 I58.5
Splicer
B No.3 I54.5 26.5 I58 1
No.4 I54.5 26.5 I57.5
No.5 I53 30.5 I57
1. No.1, 3 camshaft bushes

Splicer x When removing the No.1, 3 camshaft 2
bushes, tap them in front of the engine.
Connecting Rod
Bush
No.3 Bush 3
No.1 Bush
2. No.4 camshaft bush

x When removing the No.4 bush, tap it in front
Connecting Rod
of the engine while using the clamp to 5
extend the connecting rod.
Splicer
Clamp
No.4 Bush
6
7
INDEX
421
ENGINE - Engine
x When removing the No.5 bush, remove the
Splicer
seal cover first, then tap the No.5 bush from
the back of the engine.
Connecting Rod
No.5 Bush
Seal Cover
[INSTALLATION]
Connecting Rod x Install each bush with the corresponding splicer,
the connecting rod and the guide bush together.
Unit: mm
Corres-
ponding
Bush Corresponding Splicer
Guide guide
Splicer bush
Outer
A B C D
diameter
Bush A C No.1 I58.5 I54.5 41.5 I58.5 I58.5

No.3 I58 I54.5 26.5 I58 I58
B No.4 I57.75 I54.5 26.5 I57.5 I57.5
D No.5 I57 I53 30.5 I57 I57
422
ENGINE - Engine
x Align the No.4 bush oil hole and the
CONTENTS
Splicer
crankshaftcase oil hole.
x Install the No.4 bush to the crankshaftcase
by tapping in front of the engine until it is
positioned as shown in the illustration.
Clamp Connecting
Rod Guide
No.4 Bush
1
2
Oil Hole

x Align the No.5 bush oil hole and the 3
Splicer
by tapping it from the back of the engine until
Connecting Rod it is positioned as shown in the illustration.
No.5 Connecting Rod 4
Oil Hole
7
INDEX
423
ENGINE - Engine
Guide x Align the No.3 bush oil hole and the
Splicer
by tapping it in front of the engine until it is
positioned as shown in the illustration.
Connecting Rod
No.3 Bush
Oil Hole

Splicer Guide x Align the No.1 bush oil hole and the
by tapping it in front of the engine until it is
Connecting Rod positioned as shown in the illustration.
No.1 Bush
Oil Hole
Installation method
Front of Engine
Seal Cover Installation: seal cover
x Install the seal cover to the crankshaft case with
the specified depth.
2.5 mm
424
ENGINE - Lubrication system
6-3. Lubrication system
CONTENTS
Item Specification
Lubricating method Oil pump type
Oil filter type Spin-on type paper-filter element
Oil cooler type Case-fins type (Multiple) 1
API Class CD, CD/SF, CE,
Type
CE/SF, CF-4
Engine oil
Oil Pan 18 {18}
Amount of oil dm3 {L}
Oil Filter 1 {1}
Adjusting valve opening pressure kPa {kgf/cm2} 440r29 {4.5r0.3} 2
By-pass valve opening pressure kPa {kgf/cm2} 390r29 {4.0r0.3}
MPa {kgf/
Relief valve opening pressure 1.1r0.1 {11r1.0}
cm2}
7
INDEX
425

1. Lubrication system diagram
2 3
14 19 25
4
5 6 7
15 17
26 27
8
23
9 10 16 18 20
11
21
12
A 24
22
13
28
1 main oil passage 11 Relief Valve 21 Push Rod

2 Relief Valve 12 Oil Pump 22 Lifter
3 Engine Oil Pressure Switch 13 Oil Strainer 23 Check Valve
4 Engine Oil By-pass Warning Switch 14 Main Bearing 24 Piston
5 By-pass Valve 15 Connecting Rod Bearing 25 Fuel Injection Pump
6 Full Flow Type Filter Element 16 Connecting Rod Bush 26 Automatic Advancer
7 Shunt Flow Type Filter Element 17 Idler Bush 27 Turbocharger
8 Adjusting Valve 18 Timing Gear Bush 28 Oil Pan
9 By-pass Valve 19 Camshaft Bush
10 Oil Cooler 20 Rocker Arm Bush A: Jet Panel
426

2. Oil pump
CONTENTS
Crankshaft Gear Oil Pump Gear
Oil Pump
2
To Oil Cooler
Relief Valve
3
From Oil Strainer
To Oil Pan
x The gear-type oil pump is driven by the crankshaft with the crankshaft gear and oil pump gear 4
engaged.
x To prevent the oil pressure of the lubrication system from becoming too high, the relief valve
installed on the oil pump will return some of the engine oil to the oil pan when the output
pressure of the oil pump is over the specified range.
7
INDEX
427

3. Oil cooler and oil filter
Bolt Union
Washer
Washer
Union
Washer
Seal Ring
Oil Filter
Filter Seat
(a) By-pass Valve

To Oil Cooler
x The flowing resistance of the oil increases
By-pass Valve when the oil viscosity is too high or the oil
cooler element is blocked. In this case, the
by-pass valve installed on the oil cooler
opens to make the engine oil flow directly
into (not through the oil cooler) the oil filter.
Oil Filter
To Main Oil (b) Adjusting Valve

Distributing x If the oil pressure of the main oil passage is
Passage higher than the specified, the adjusting valve
To Oil Pan Adjusting
Valve opens and makes some of the engine oil
flow into the oil pan to adjust the oil
Oil Filter pressure.
428

(c) Engine oil pressure switch
x If the pressure of the oil that is sent to the
CONTENTS
To Main Oil main oil passage is lower than the specified,
Distributing the electrical contact point which is built in
Engine Oil Passage the engine oil pressure switch closes.
Pressure
x The warning light of the combination meter
Switch
comes on to inform the driver of the
abnormity of the oil pressure.
1
(d) Engine oil by-pass warning switch

Main Oil Distributing Passage x If the oil filter is blocked, the amount of the
engine oil will decrease and cause every
parts of the engine lock. To prevent the lock,
the engine oil by-pass warning switch is 2
installed.
x If the oil filter is blocked, the engine oil by-
pass warning switch makes the oil flow into
Engine Oil By-pass Warning Switch the main oil passage directly but not through
the full flow type filter element. In addition, if
the engine oil by-pass warning switch 3
operates, the warning light comes on to
inform the driver that the oil filter element is
blocked.
(e) Oil Filter
4
To Main Oil Distributing Passage
To Oil Pan
Shunt Flow Type Filter Element

6
Full Flow Type Filter Element
7
By-pass Valve
x Oil filler uses the spin-on paper filter with the by-pass filter and full flow filter integrated.
x The by-pass valve is installed at the bottom of the filter. The valve opens when the
INDEX
element is blocked to prevent the engine form being locked.
429

4. Lubrication for parts
x The engine oil sent to the main oil passage lubricates the following parts.
(a) Main bearing and connecting rod bearing
Main Oil Distributing Passage

Connecting Rod Oil Hole
Main Bearing
Connecting Rod Bearing
Crank Crank Oil Hole
x The big end of the connecting rod (Connecting rod bearing) is lubricated by the oil hole in
the crankshaft. At the same time, the small end of the connecting rod (Connecting rod
bush) is lubricated by the inner oil hole of the rod.
(b) Timing gear
Main Oil Distributing Passage

Camshaft
Thrust Plate Idle Gear Bush
Oil Pipe
Injection Pump Gear
Idle Gear
Camshaft Gear
Bearing Timing Gear Case
Vacuum Pump Idle Gear Bearing Oil Jet Tube
x The oil flows through the interior of the camshaft and idle gear shaft to lubricate the gears.
In addition, the oil jet tube for lubricating the injection pump gear forcibly is installed on the
timing gear case to lubricate the injection pump gear continuously.
430

(c) Valve mechanism
CONTENTS
Rocker Arm Oil Hole
Rocker Arm
Rocker Arm Bush
Rocker Arm Shaft Carrier
1
Rocker Arm Shaft
2
Cylinder Head
Oil Passage Push Rod 3
Crank Case
Lifter
4
To Oil Pan
Camshaft
5
No.1 Camshaft Bush
From Main Oil Distributing Passage

6
x After lubricating the camshaft bush No.1, the oil is sent to the rocker arm shaft through the
oil passage which goes through the crankshaft case and the cylinder head.
x The oil of the rocker arm shaft lubricates the rocker arm bush through the rocker arm shaft
carrier and jets out from the oil hole of the rocker arm.
x After lubricating, the oil goes along the push rod, then returns to the oil pan from the oil
hole of the lifter. 7
INDEX
431

(d) Check valve and oil jet tube
x The oil jet tube is installed under the main oil
Main Oil
Distributing
passage of each cylinder.
Passage Piston x The oil jet tube jets oil towards the inner side
of the piston to cool it.
x The check valve, which can open or close in
the specified oil pressure range, in the oil jet
Oil Jet Tube
tube closes when the engine speed is low to
Check Valve keep the oil amount needed by the parts of
engine lubrication system enough and to
prevent the decrease of the oil pressure.
(e) Turbocharger
Bearing Bush Snap Ring

From Main
Oil Distributing
Passage
Fuel Injection Pump
1 Fuel Injection Pump
2 Governor
3 Bearing Steel
4 Timer
5 Oil Pipe
6 Timing Gear Case
To Oil
Pan
Piston Ring
Piston Ring
Bearing
x The engine oil from the main oil passage is sent to the bearing bush through the oil pipe to
lubricate the interior of the bearing bushing.
x The piston rings installed on the two sides of the turbine working shaft work as oil seals.
(f) Fuel Injection Pump
x The oil from the main oil passage lubricates the

Governor
pump main body by the leading of oil pipe and
lubricates the governor through the automatic
advancer.
Oil Pipe
Automatic
Advancer Fuel Injection Pump
432
CONTENTS
Symptoms
Excessive consumption of the oil (Oil leakage)

1
Possible causes Reference
The oil pressure is low.

Difficult to start
Overheating
2
The oil cooler element is installed

improperly. ƻ ƻ ƻ
The shim is damaged. ƻ ƻ ƻ

The O-Ring is damaged. ƻ ƻ ƻ 3
Oil Cooler
The oil cooler element is blocked. ƻ ƻ
The oil cooler element is damaged. ƻ ƻ ƻ
By-pass valve spring force decreased ƻ
Adjusting valve spring force decreased ƻ
Oil pump malfunction ƻ ƻ 4
Oil pump gear interferes with oil pump case
Oil pump ƻ ƻ
or cover
Relief valve spring force decreased ƻ
Installed improperly ƻ
Oil Filter The oil filter element is blocked. ƻ ƻ 5
The shim is damaged. ƻ
The oil strainer is installed improperly or blocked. ƻ ƻ
The crankshaft front oil seal is poor. ƻ
The crankshaft rear oil seal is poor. ƻ Section 6-2
The timing gear case is installed improperly. ƻ
6
The oil jet tube for cooling the piston is poor. ƻ ƻ
The oil jets into the combustion chamber. ƻ
The oil drops into the combustion chamber. ƻ
The oil viscosity is excessive. ƻ
7
The oil quality is improperly. ƻ
The oil is bad. ƻ
The fuel mixed with the oil. ƻ
INDEX
433

Replacement of oil filter
- Oil Filter
Engine oil (API class CD, CD/SF, CE, Approx.1dm3
CE/SF, CF-4) {1L}
Special tools
Unit: mm
Oil Filter Wrench MH061537 Remove the oil filter
x The spilling engine oil may cause a fire, so you should clean it carefully and throughly.
x Do not spill the oil onto the belt when filling it into the engine. Otherwise, the belt will skid,
decreasing the cooling efficiency.
[REMOVAL]
x Loosen the drain plug and discharge the engine oil
in the filter.
Bleeder Plug
Oil Filter
Drain Plug
434

[INSTALLATION]
Oil Filter
x Clean the oil filter mounting surface of the oil filter
CONTENTS
Seat
seat.
x Apply a light coat of oil to the shim of the oil filter.
Shim Part x Tighten the oil filter seat by hand until it touch the
shim, then turn it 11/8~3/8 and tighten it.
x After installing, start the engine and check whether
Oil Filter
the oil leaks from the shim or not.
Drain Plug
x If abnormal, reinstall the oil filter. 1
x Stop the engine and check if the amount of oil is
as the specified.
x If the amount of oil is insufficient, fill some more.
Replacement of engine oil

Tightening torque 2
Unit: Ngm {kgfgm}
- Drain plug (Oil filter) 9.8r1.96 {1.0r0.2} -
- Drain plug (Oil pan) 34-39 {3.5-4.0} -

- Oil Filter Engine oil (API class CD, CD/SF, CE, 1dm3 {1L}
CE/SF, CF-4)
- Oil Pan 18dm3 {18L}
[DISCHARGE OIL] 5
x Remove the oil filler cap.
x Remove the drain plug and discharge the engine
Bleeder Plug oil.
[CHARGE OIL]
Oil Filter x Tighten the drain plug to the specified torque. Fill
6
new oil to the specified level.
Drain Plug
as the specified.
x If the amount of oil is insufficient, fill some more.
Oil Filler Cap
7
INDEX
Drain Plug
435

Measurement of engine oil
Service standard
Correction
Method
No load, the 49 kPa
revolution speed is 145 kPa {1.5 kgf/cm2}
Oil pressure (When lowest {0.5 kgf/cm2}
- the oil temperature Inspection
is 70-90qC) No load, the 295-490 kPa 195 kPa
revolution speed is
highest {3-5kgf/cm2} {2 kgf/cm2}
Tightening torque
Unit: Ngm {kgfgm}
Sealer
- Engine oil pressure switch 7.8-12 {0.8-1.2} When the
engine is cold

Thread area of the engine oil pressure
- ThreeBond 1215 As required
switch
x Remove the engine oil pressure switch.
x Install the transition joint to the engine oil pressure

Oil Pressure Gauge switch, and then install the oil pressure gauge to
the transition joint.
x Preheat the engine until the oil temperature goes
up to 70-90qC.
x Measure the oil pressure when the no load
revolution speed is lowest and highest.
x If the measured value is lower than the standard
Transition Joint
value, the lubrication system should be checked
throughly.
x After measuring, apply sealer to the thread area of
the engine oil pressure switch and tighten it to the
specified torque.
The engine must be cold when installing the engine

oil pressure switch.
436
6-3-5. Oil pan, oil strainer, oil jet tube
CONTENTS
1 Ta
2 1
Tb
5 2
3
1. Drain Plug 5. Check valve
4
2. Oil Pan 6. Oil Jet Tube
3. Oil Strainer Non-reusable Part
4. O-ring
x Assembling order
5
x If tighten the check valve over the specified torque, the operating malfunction may occur,
causing the engine lock. Therefore, the check valve must be tightened as specified torque.
Tightening torque
6
Unit: Ngm {kgfgm}
Ta Drain plug 69 {7.0} -
Tb Check valve 38 {3.9} Wet

Crank case mounting face of the oil pan ThreeBond 1207C As required
O-ring
INDEX

The thread part of the check valve
437

Installation method
Sealer 2 mm Installation: oil pan
x Clean the sealing face of every parts.
x Apply the sealer to the mounting face of the oil pan
uniformly and continuously as shown in the
illustration.
x Install the oil pan in 3 minutes after applying the
sealer. Be careful not to make the sealer come off.

installing the oil pan. In addition, the sealer must
be apply once again when loosen or remove the
oil pan mounting bolts after installation.
438
6-3-6. Oil pump
CONTENTS
8
*b
2
5
*a
4
3
6
3
1 7 4
1. Pin 5. Oil Pump Cover *a: Drive Gear
2. Valve Seat 6. Driven Gear *b: Crankshaft Gear
3. Relief Valve Spring 7. Gear and Case Non-reusable Part
4. Relief Valve 8. O-ring 5
x Assembling order
Service standard
Unit: mm
Correction 6
Method
The installation load of relief valve
3 spring 225N {23.15kgf} - Replacement
(Installation length 33.4)
1.1r0.1 MPa
4 Relief valve opening pressure - -
{11r0.1 kgf/cm2} 7
The clearance between the oil pump
5, 6 0.04-0.07 0.15 Replacement
cover and the driven gear shaft
The clearance between the oil pump
5, *a 0.04-0.07 0.15 Replacement
cover and the drive gear shaft
INDEX
439
Correction
Method
Clearance between driven gear shaft
6, 7 and gear, clearance between driven 0.04-0.07 0.15 Replacement
gear shaft and case
Droop of each gear and gear and
gear case end face
6, 7, *a Clearance between gear tip and
gear, clearance between gear tip and 0.10-0.19 0.2 Replacement
case
Every sliding areas of the oil pump
O-ring
Inspection method
Gear and Case Drive Gear
Inspection: driven gear, drive gear, gear and case
x Perform the following inspections. If abnormal,
replace the oil pump.
1. Droop of each gear and gear and gear case
end face
Driven Gear
2. Clearance between gear tip and gear,

Drive Gear clearance between gear tip and case
Driven Gear
Gear and Case
Inspection: oil pump cover, driven gear, gear and

case
x Measure the clearance between gear shaft and oil
pump cover, the clearance between gear shaft and
oil pump cover and the clearance between gear
shaft and case.
x If the measured value is greater than the standard
value, replace the malfunctioning components.
440

Installation method
Oil Pump Gap
CONTENTS
Installation: oil pump cover
Pin x Place 2 pins whose outer diameter are 9mm into
the mounting area (On the cross) and align the
gear, case and oil pump cover.
Gear and Case 1
x Install the bolts in the area where there is no pin

Oil Pump Gear and tighten them to the specified torque.
Pin x Take the pins out and tighten the leftover bolts.
x After installation, turn the gear of the oil pump by
hand to make sure the gear rotates smoothly.
2
x If abnormal, remove and install it once again.
Bolt Pin
7
INDEX
441
6-3-7. Oil filter
4 1
a 5
Ta 13 6
7
14
a
15
12
10 9
a Tb
11
1. Oil Hose 7. Drain Plug 13. O-ring
2. Connector 8. Oil Filter 14. O-ring
3. Cap 9. By-pass Warning Switch 15. Oil Filter Junction Accessory
4. Oil Hose 10. O-ring Non-reusable Part
5. Connector 11. Plug
6. Plug 12. Oil Filter Seat
x Assembling order
x To prevent burn, do not touch the oil when the engine is hot.
Tightening torque
Unit: Ngm {kgfgm}
Area Tightened Part Tightening Torque Remark
Ta Drain plug 7.8r2.0 {0.8r0.2} -
Tb Engine oil pressure switch 49r4.9 {5.0r0.5} -
442

CONTENTS
O-ring Engine oil As required
6-3-8. Oil cooler
26
b
18 2
22 Tc
21 17 Tb
24
25 23
3
Tb 19 Ta
20 13 Ta
15 14
4 16
2
12 4
3
Ta 1
6
10
Tb 5 11
9
8
7 Ta
5
6
x Removal order
1. Plug 10. Adjusting Valve 19. Plug
2. O-ring 11. Plug 20. O-ring
3. By-pass Valve Spring 12. Connector 21. Engine Oil Pressure Switch
7
4. By-pass Valve 13. Plug 22. Oil Cooler Element
5. Plug 14. O-ring 23. O-ring
6. O-ring 15. Adjusting Valve Spring 24. Oil Cooler Body
7. Plug 16. Adjusting Valve 25. O-ring
8. O-ring 17. Plug 26. Shim
INDEX
9. Adjusting Valve Spring 18. O-ring Non-reusable Part
443

x Installation order
The installation procedures are the removal procedures in reverse order.
Service standard
Correction
Method
The installation load of by-pass valve
3 spring 49 N {5 kgf} - Replacement
(Installation length: 64)
The installation load of adjusting
9, 15 valve spring 49 N {5 kgf} - Replacement
Air leak of oil cooler element
21 (Keep the air under the pressure 980 0 cm3 {0 mL} - Replacement
kPa {10 kgf/cm2} for 15 seconds)
Tightening torque
Unit: Ngm {kgfgm}
Nut (For the installation of oil cooler filter
element)
Plug (For the installation of adjusting
Ta 19.5r5 {2.0r0.5} -
valve spring)
Plug (For the installation of by-pass
valve spring)
Tb Plug 34.5r5 {3.5r0.5} -
Tc Engine oil pressure switch 7.8-12 {0.8-1.2} Sealer

ThreeBond 1215 As required
switch
Inspection method
Inspect: oil cooler element
x Using a plug, block the outlet of the cooler
element. Connect a hose to the engine oil inlet and
Plug put the oil cooler element into the water trough.
x Apply air pressure 980 kPa (10 kgf/cm2) to the
hose side for 15 seconds and check if there is any
air leakage from any part of the element.
x If there is an air leakage, replace the oil cooler
element.
444
6-3-9. Oil cooler, oil filter
CONTENTS
17 5 Ta
6
Tb
3 13 7
1
8
4 2
10 11 12
Ta
9 16 15
Ta 14 3
Td
Tc
Te 1
5
x Removal order
1. Drain Plug 7. Adjusting Valve Spring 13. Engine oil pressure switch
2. Oil Filter 8. Adjusting Valve 14. Engine oil by-pass warning switch
3. Oil Cooler Element 9. Plug 15. Drain Plug
4. Shim 10. O-ring 16. Oil Cooler Body
5. Plug 11. By-pass Valve Spring 17. Shim
6
6. O-ring 12. By-pass Valve Non-reusable Part
7
INDEX
445

Service standard
Correction
Method
Air leak of oil cooler element
3 (Keep the air under pressure 980 0 cm3 {0 mL} - Replacement
kPa {10 kgf/cm2} for 15 seconds)
The installation load of adjusting
7 valve spring 49 N {5 kgf} - Replacement
The installation load of by-pass valve
11 spring 49 N {5 kgf} - Replacement
Tightening torque
Unit: Ngm {kgfgm}
Nut (For the installation of oil cooler filter
element)
Plug (For the installation of adjusting
Ta 19.5r5 {2.0r0.5} -
valve spring)
Plug (For the installation of by-pass
valve spring)
Sealer
Tb Engine oil pressure switch 7.8-12 {0.8-1.2} When the
engine is cold
Tc Engine oil by-pass warning switch 12-18 {1.2-1.9} -
Td Drain plug (Oil cooler side) 25r4.9 {2.5r0.5} -
Te Drain plug (Oil filter side) 9.8r1.96 {1.0r0.2} -

Oil filter shim
O-ring
switch
Special tools
Oil Filter Wrench MH061590 Remove the oil filter
446

Removal method
CONTENTS
Removal: oil filter
Inspection method
Inspection: oil cooler element
x Using a plug, block the outlet of the cooler
element. Connect a hose to the engine oil inlet and
Plug 2
put the oil cooler element into the water trough.
x Apply air pressure 980 kPa (10 kgf/cm2) to the
hose side for 15 seconds and check if there is an
air leakage from any part of the element.
x If there is an air leakage, replace the oil cooler
element.
3
Installation method
Installation: oil cooler
x Clean the oil filter mounting surface of the oil
cooler.
x Apply a light coat of oil to the shim of the oil filter.
x Tighten the oil filter until the shim touches the oil
4
cooler, then turn it 3/4 and tighten it.
Shim Part
x After installing, start the engine and check whether
the oil leaks from the shim or not.
x If abnormal, reinstall the oil filter.
as the specified. 5
x If the amount of engine oil is insufficient, fill some
more.
7
INDEX
447
ENGINE - Fuel feed and engine control
6-4. Fuel feed and engine control
Item Specification
Manufacturer Bosch
Main body model A
Fuel injection Model RSV

Governor
pump Type Mechanical full traveling governor
Advancer model SCDM
Supply pump model KS
Manufacturer Bosch
Injector
Type Hole type spring
Fuel filter Type Filter type

Fuel system (Flow of the fuel)
Fuel Return Hose Fuel Filter Injection Pipe
Injector
Injection Pump
Spill Valve
Fuel Suction Pipe Fuel Return

Pipe
Supply Pump
Fuel Tank
x The fuel in the oil tank are pumped out by the supply pump which is driven by the drive shaft of
the fuel injection pump. And then the impurities in the fuel are filtrated by the fuel filter.
x The filtrated oil becomes high pressure fuel through the fuel injection pump. And then the high
pressure fuel is injected into the combustion chamber.
x The leftover fuel in the injector flows back through the fuel return hose and the fuel return pipe to
the fuel tank.
x If the fuel pressure in the fuel injection pump is over the specified, the spill valve opens to let the
fuel return to the fuel tank.
448

Fuel tank
CONTENTS
5
11
10
1
13
12
2
1
4
7
6
9
8
20 5
16
Rotating Floor
19 2
17
18 3 15
4 14
6
1- Fuel Tank 2- Seat 3- Tube 4- Plug 5- Cover

6- Sensor 7- O-Ring 8- Bolt 9- Washer 10- Director
11- Cover 12- Float 13- Strainer Filter element 14- Elbow 15- Tube
7
16- Grommet 17- Bolt 18- Bolt 19- Washer 20- 1.0 mm Shim
INDEX
Keep the fuel tank far from the fire to prevent it from burning and exploding.
Keep the removed parts clean, and wash the dirty parts in the diesel oil.
449

Fuel tank accessory pipe line
8
9 7
5
10
Primary Strainer
Secondary
To Engine
Strainer
12
Fuel Tank To Engine
12 10
11 6
2
5 1
3 31 13
34
27 26 27 5
4
26
25 5
15
33 2
20
32 28
21
16
5 23 18
19 17
3 24 14 30
29
22
6
5 22
1
4
1- Hose 2- Hose 3- Hose 4- Hose 5- Clamp Band

6- Clip 7- Union 8- Bolt 9- Grommet 10- Union
11- Bolt 12- Grommet 13- Strap 14- Bracket 15- Clip
16- Bolt 17- Washer 18- Clip 19- Sleeve 20- Bolt
21- Washer 22- Clip 23- Bolt 24- Washer 25- Clip
26- Bolt 27- Washer 28- Bracket 29- Bolt 30- Washer
31- Clip 32- Bolt 33- Washer 34- Hose Clamp
Check the hose for broken and corrosion. Replace if necessary.

To prevent the oil leakage, please pay attention to the sealing performance when assembling.
450

Fuel filter
CONTENTS
To Fuel Injection Pump Fuel Filter Cap
From Fuel Tank
2
Fuel Filter
3
x The impurities in the fuel are cleared away by the element of the fuel filter.
x The manual pump is designed and installed on the fuel filter cap which is used for bleeding air.
7
INDEX
451

Fuel injection pump
Delivery Valve Holder
Delivery Valve Spring
Delivery Valve
Plunger Boot
Control Small Gear
Plunger
Control Link
Control Sleeve
Plunger Spring
Lifter
Camshaft
The fuel injection pump is equipped with the unit which can send high pressure fuel to the injector and
control the volume of the fuel.
Fuel Intake &

1. Fuel press-delivery
Exhaust Hole
Spiral Groove
Plunger Boot
Plunger
Lifter
Camshaft
Press-delivery Press-delivery
Suction
Start End
The spiral groove meets the fuel in the intake &

exhaust hole while the plunger raising. Then the
Fuel Intake & fuel is exhausted through the fuel intake & exhaust
Exhaust Hole Stroke hole. The extra fuel cannot be delivered by raising
Spiral Groove the plunger.
In addition, the stroke passed by the plunger when
delivering the fuel is called effective stroke.
Plunger
452

2. Injection volume adjustment structure
Fuel Intake & When control the injection volume according to the
CONTENTS
Exhaust Hole Spiral Groove load of the engine, turn some angle of the plunger,
Control change the meeting position of the fuel intake &
Link exhaust hole and the spiral groove during the
raising of the plunger, consequently, the volume
can be controlled by controlling the effective
stroke. Every plunger occludes one control link
Plunger and turns the same amount of angle. 1
3. Outlet valve
Delivery Valve Spring Suction Stroke The fuel compressed by the plunger can be
injected when opening the outlet valve, then
plunger delivering ends. The outlet valve returns to
the original position by the effect of the outlet valve 2
springs. The fuel channel can be interrupted in this
Delivery
Valve way, preventing the countercurrent of the fuel. In
Press-delivery Start Injection Press-delivery End Suction addition, the outlet valve sucks fuel during suction
(Suction Start) End
stroke downward, leading the remain pressure
between outlet valve and injector descend
immediately. The suction is beneficial to clear the 3
fuel in the injector, preventing oil draining after
injection.
4. Spill valve
Ball
The function of the spill valve is: the ball is pushed
upward when fuel pressure in the fuel injection 4
pump reached to some extent, then the fuel
returns to the fuel tank from injection pump. Fuel
temperature and temperature distribution in the
fuel injection pump can be stabilized in this way,
providing constant fuel volume to the cylinders.
5
7
INDEX
453

Governor
Governor Case Strut Rod Shaft Guide Rod

Tensioner Lever
Starting Spring
Control Link
Shackle
Whirling Arm
Governor Cover
Camshaft
Floating Lever
Governor Spring
Idle Sub-spring
Control Spring
Adjusting Bar
Location Lever
Flyweight
Full Load Limited Bolt
With centrifugal force of the flyweight, the governor not only can control the max speed and min speed
of the full-speed governor, but also control automatically the running in any speed area.
454

Supply pump
CONTENTS
Start Filling Pump
1
To Fuel Filter
Inlet Check Valve

Outlet Check Valve
Supply Pump Case 2
Mesh Filter
From Fuel Tank
Supply pump is driven by the camshaft of the fuel injection pump. The fuel pump can be sent upward
by hand by starting the filling pump when the injection pump stops. Especially, it is used when
bleeding. 4
The mesh filter can filter the big impurity in the fuel which is sucked from the fuel tank, preventing the
inner clog of the injection pump. The mesh filter should be washed with light oil periodically.
When sucking
The camshaft of the fuel injection pump pushes the push
rod. Fuel in the oil chamber opens the outlet check valve
after being compressed. Most of the pushed fuel will be 5
Oil Chamber
Outlet Check sucked by the pressure chamber from the lower part of
Valve Pressure the piston.
Push Rod Chamber
Camshaft
6
When delivering
Oil Chamber
Inlet Check The piston can be pushed back by the piston spring
Valve force when the camshaft cannot push the cam upward
after rotating. Then the fuel will be delivered to the fuel
Piston Spring
Outlet Check filter through the pressure chamber.
Piston 7
Valve The outlet check valve closes while the inlet check valve
Camshaft opens. Then the fuel is sucked into the oil chamber.
Pressure
Chamber
INDEX
455

When stopping
The piston cannot be back by virtue of the piston spring
force when the pressure in the pressure chamber
Piston Spring exceeds the specified value. The function of the pump
Piston stopped immediately, preventing the pressure inside the
Pressure fuel filter exceeding the need.
Chamber
Automatic advancer
Automatic advancer is a mechanical timer and is a kind of fixture which can change the injection time
automatically according to the engine speed.
It is installed to the camshaft of the fuel injection pump with round nuts and driven by the crankshaft of
air compressor through driving disc.
Advancer Spring Adjusting Shim
Advancer Case Flyweight Seat
Flyweight
Flange
456

Injector
CONTENTS
x When the fuel pressure from the fuel injection
From Fuel Injection Pump pump (Pressure in the injection pipe) exceeds the
springs force, the needle valve will raise during the
To Fuel Tank preset stroke only and inject from the injector.
Injection Nozzle Grommet
Spring 2
Injection Nozzle
Needle Valve
7
INDEX
457
The operation force of the accelerator pedal is too heavy

Symptoms
The engine cannot reach the highest speed

The engine stops immediately after starting
The engine idling speed is not stable
Warning light-illuminate-extinguish
The max engine speed is too high
The engine output is insufficient
The engine output is not stable
Reference
The fuel supply is insufficient

The engine is difficult to start
The engine cannot start
The engine cannot stop

The engine knocks
Possible Causes
Poor fuel injection pump ƻ ƻ ƻ ƻ ƻ ƻ ƻ ƻ ƻ ƻ *
Fuel
Injection Poor installation ƻ ƻ ƻ ƻ
Pump
Poor spill valve operation ƻ ƻ ƻ ƻ ƻ *
Needle valve sticking ƻ
Opening pressure is too
low ƻ ƻ
Spray-hole is clogged ƻ ƻ ƻ ƻ ƻ
Poor injector air tightness ƻ ƻ ƻ ƻ ƻ
Injector Opening pressure is too
high ƻ
Spring is broken ƻ ƻ
Poor needle valve sliding ƻ
Poor opening pressure ƻ
Spring force is decreased ƻ
Fuel filter is clogged ƻ ƻ ƻ ƻ
No oil in fuel tank ƻ
Fuel pipe blockage or union leakage ƻ
Air or moisture in fuel system ƻ ƻ ƻ ƻ
Use of inferior fuel ƻ ƻ ƻ ƻ
Poor adjustment of the
accelerator pedal stopper ƻ ƻ
bolt
Poor installation of the
Engine accelerator control cable ƻ
Control
Poor sliding of the
accelerator control cable ƻ
Poor accelerator position

sensor ƻ
458
The operation force of the accelerator pedal is too heavy

Symptoms
CONTENTS
The engine cannot reach the highest speed
The engine stops immediately after starting
The engine idling speed is not stable
Warning light-illuminate-extinguish
The max engine speed is too high
1

The engine output is not stable
Reference
The fuel supply is insufficient

The engine cannot start
The engine cannot stop

The engine knocks
2
Possible Causes
Fuel pipe or hose crack ƻ
Oil viscosity is not as specified ƻ ƻ Section 6-3
3
Wrong valve clearance ƻ ƻ
Cylinder head gasket damage ƻ ƻ
Valve or valve seat wear or carbon-
deposit ƻ ƻ
Valve spring weak ƻ ƻ Section 6-2

4
Piston ring wear or damage ƻ ƻ
Piston ring groove wear or damage ƻ
Part of the piston and crankshaft case
cylinder wear ƻ ƻ
Poor function of the cooling unit ƻ ƻ Section 6-5

5
Starter switch malfunction ƻ
Section 6-7
Fuse broken ƻ ƻ ƻ
*: Contact Bosch Service Center for repair.
7
INDEX
459

Inspection and adjustment of injection timing
1. Service standard
Correction
Method
- Injection timing (Before top dead center) 14q - Adjustment
2. Tightening torque
Unit: Ngm {kgfgm}
- Connecting pipe nuts 24 {2.5} -
- Lock plate 3.4-4.9 {0.35-0.5} -
- Delivery valve holder 39-44 {4.0-4.5} -
- Nut (For installing injection pump) 29-39 {3.0-4.0} -
3. Special tool
Unit: Ngm {kgfgm}
Extension joint rod

Inspection and
A
MH061099 adjustment of
14 injection timing
[INSPECTION]
Injection Pipe x Remove injection pipe, lock plate, delivery valve
holder, spacing collar, outlet valve spring and oil
Delivery Valve Holder outlet valve from the No.1 cylinder of the fuel
injection pump.
Spacing Collar Lock Plate
x Install delivery valve holder after removing all the
Delivery Valve Spring parts.
Delivery Valve
x Put the removed parts in the light oil, preventing

them from dirt.
460

x Install the prepared injection pipe to No.1 cylinder.
Injection Pipe
Make the other end of the injection pipe
CONTENTS
downward, so the flow state can be seen clearly.
x Turn the crankshaft more than 180 degrees
clockwise by hand, setting No.1 cylinder 30
degrees away from the compressing TDC (Top
dead center).
x Deliver the fuel by starting the filling pump, making

Injection Pipe the fuel flow from the injection pipe while turning
the engine clockwise by hand.
2
x The engine locating rod on the top of the governor
must be set in the engine starting position.
Engine Locating Rod
Start Filling Pump
x When the fuel discharge from the injection pipe is 3

going to be interrupted, go on turning the engine
Needle by hand slowly. Stop turning when the discharge
stops fully.
x Check that the needle is away from about 1q to the
injection timing reticle.
4
x When the injection timing deviates from the

standard value, adjust it according to the following
tips. 5
[ADJUSTMENT]
x Release the mounting nuts of the fuel injection
B pump.
A: 4 (Flange part)
A B: 1
6
x Aim at the needle and operate the fuel injection

Fuel Injection Pump pump to adjust the injection timing.
x Tighten the nuts to the specified torque and
measure the injection timing again.
7
Needle
INDEX
461

x Lean the fuel injection pump to the crankshaft
case side C when the injection timing is slow.
C
D x Lean the fuel injection pump away from the
crankshaft case to the D side when the injection
Fuel Injection Pump timing is quick.
x Install outlet valve, oil outlet valve spring, spacing

Injection Pipe Delivery Valve collar, delivery valve holder, lock plate and
Holder injection pipe when make sure that the injection
timing is the standard value.
x Tighten the parts to the specified torque.
Lock Plate
Bleeding air in the fuel system

Unit: Ngm {kgfgm}
- Plug 9.8r2.0 {1.0r0.2} -
Plug x Release the plug of the fuel filter.
x Turn the handle of the start filling pump

counterclockwise, making the hand outside.
x Operate the handle of the start filling pump up and
down to deliver the fuel.
Start Filling Pump
x If there is no bubble in the fuel which leaks from
the fuel filter plug, then tighten the plug to the
specified torque.
462

x Operate the start filling pump up and down 5 to 6
times and fix it by tightening the handle clockwise.
CONTENTS
x After bleeding, clear the spilled fuel away and then
Start Filling Pump start the engine. Make sure that there is no
leakage.
Replace fuel filter

1. Lubricant and/or sealer

- The shim part of the fuel filter Engine oil As required 2
x The inferior fuel filter will lead to fuel leakage and fire, so you should use high quality filter.
x To prevent the malfunction caused by the abnormal injection, make sure that there is no tiny
impurity in the fuel filter or the fuel pipe. 3
x Clean the mounting surface of the fuel filter cap.

x Apply a light coat of the engine oil to the contact
surface of the fuel filter cap evenly.
x Tighten the fuel filter cap until it touches the
Fuel Filter Cap contact surface of the fuel filter. Turn 3/4 to 1
Contact Surface
4
round again to tighten it under this condition.
x Start the engine and make sure that there is no
leakage between the unions of the fuel filter.
x Reinstall fuel filter if there is abnormality.
7
INDEX
463
6-4-5. Fuel filter

<Spin-on>
4 Tb
Ta
1
3
1 Ta
Disassembling order
1. Jointed Bolt 5. O-ring
2. Fuel Pipe 6. Fuel Filter Cap
3. Fuel Filter Element Non-reusable Part
4. Plug
Assembling order
Unit: Ngm {kgfgm}
Ta Jointed Bolt 34 {3.5) -
Tb Plug 9.8r2.0 {1.0r0.2} -

The shim part of the fuel filter
O-ring
464

3. Special tool
CONTENTS
Filter wrench
A
A Removal of the fuel
MH061509
filter
90.2
1
Removal method
Removal: Fuel filter
3
Installation method
Installation: Fuel filter
Fuel Filter Cap

Contact Surface x The inferior fuel filter will lead to fuel leakage and
4
fire, so you should use high quality filter.
x To prevent the malfunction caused by the
abnormal injection, make sure that there is no tiny
impurity in the fuel filter or the fuel pipe.
x Clean the mounting surface of the fuel filter cap.

x Apply a light coat of the engine oil to the contact 5
surface of the fuel filter cap evenly.
x Tighten the fuel filter cap until it touches the
contact surface of the fuel filter. Turn 3/4 to 1
round again to tighten it under this condition.
x Start the engine and make sure that there is no
leakage between the unions of the fuel filter. 6
x Reinstall fuel filter if there is abnormality.
7
INDEX
465

<Spin-on>Primary strainer filter
3
2
1. Drain Valve 5. Element
2. Bleeder Plug 6. Seal
3. Cup Set 7. Filter Block
4. Seal
x Assembling order
x The spilled fuel may lead to a fire, so you should clear it.
x The fuel burns easily, keep it away from the fire and the heat source.
Tightening torque
Unit: Ngm {lbs.in}
Tightened Part Tightening Torque
Filter block 10.2r1.1 {90r10}
Cup set 10.2r1.1 {90r10}
Bleeder plug 0.3r0.1 {3r1}
Drain valve 1.1r0.2 {10r2}
466
6-4-6. <Spin-on> Secondary strainer filter
CONTENTS
3
10
8
9 1
5
2
2
1
3
1. Water Valve Screw 6. Seal End Cap Set
2. Seal Ring 7. Seal Ring
3. Joint Screw 8. Oil Through Screw
4. Case 9. Washer 4
5. Element 10. Filter Block
x Assembling order
5
x The spilled fuel may lead to a fire, so you should clear it.
x The fuel burns easily, keep it away from the fire and the heat source.
Unit: Ngm {lbs.in}
6
Tightened Part Tightening Torque
Filter block 10.2r1.1 {90r10}
Drain valve 1.1r0.2 {10r2}

7

INDEX
467
6-4-7. Fuel injection pump
Te
7
16
Td 8
14
10 9 Ta
11
15
13
17 12 Ta
1 Ta
6 Tc
5
2
*a
3 Tb
Removal order
1. Jointed Bolt 8. Air Pipe 15. Pump Carrier
2. Fuel Apply Pipe 9. Jointed Bolt 16. Fuel Injection Pump
3. Jointed Bolt 10. Fuel Apply Pipe 17. O-ring
4. Fuel Apply Pipe 11. Fuel Scavenge Hose
5. Jointed Bolt 12. Spill Valve *a: Front Case
6. Oil Pipe 13. Connector Non-reusable Part
7. Jointed Bolt 14. Injection Pipe
x The fuel burns easily. Keep it away from the fire and the heat source.
x The spilled fuel may lead to a fire, so you should clear it carefully.
x It will have a bad impact on the engine performance if there is tiny impurity in the fuel injection
pump, the mounting part should be covered after the removal of the pipe and hose. In addition,
clean the joint bolts and shim with light oil, preventing them from foreign matter or impurity.
x Contact the BOSCH service station to repair the fuel injection pump.
468

Installation order
CONTENTS
1. Service standard
Correction
Method
255 kPa Replace-
12 Spill valve -
{2.6 kgf/cm2} ment
1
Unit: Ngm {kgfgm}
Jointed bolt (For installing fuel apply pipe)
Ta 20-29 {2.1-3.0} -
Spill valve
2
Tb Jointed bolt (For installing fuel apply pipe) 20-25 {2.1-2.6} -
Tc Jointed bolt (For installing oil pipe) 10-13 {1.0-1.3} -
Td Injection Pipe 24 {2.5} -
Te Jointed bolt (When installing air pipe) 12-15 {1.2-1.5} - 3

4. Special tool 4
Unit: mm
Socket wrench
Removal and 5
A A 31391-14100 installation of fuel
12 injection pump
Removal method 6
Removal: fuel injection pump
7
INDEX
469

Installation method
16 Installation: fuel injection pump
Needle x Set the engine No.1 cylinder piston at the top dead
center of the compression stroke. Consequently,
aim the reticle of the engine flywheel at the needle
1.6.
x If the push rod of the No.1 cylinder inlet and outlet
valve do not stick up, the No.1 cylinder will be at
the compression top dead center. If the inlet valve
and outlet valve are propped up by push rob, then
turn the crankshaft 360°.
x Align the matching mark of the advancer case with

the gear jag of the fuel injection pump.
Jag
Matching Mark
x Insert the guild pin of the advancer case into the

guild hole of the front end plate, then align the
gear of the fuel injection pump with the slip gear
and push it forward.
Guide Pin
Guide Hole
x Make sure whether the gear jag of the fuel

injection pump aligns with the matching mark of
Jag the advancer case or not, then insert it into the fuel
injection pump. Turn the gear jag in the direction
Matching
indicated by the arrow in the illustration to lock it.
Mark
Installation: injection pipe

x Check the damage and dent of the pipe and seat
surface of the connector part.
Tube x Attach the pipe to the seat surface of the
Seat Surface
Seat connector part uniformly, and do not temporarily fix
Surface it forcibly.
x After temporarily fixture, tighten it to the specified
Connector
torque.
Part
470
6-4-8. Injector
CONTENTS
2
12 1
1 Ta
11
13 10
14 Ta
9
5
2
3 6
7
8
4 Tb
Disassembling order
1. Injection Pipe 7. Needle Valve 13. O-ring
2. Fuel Leak Pipe 8. Injection Nozzle 14. Injection Nozzle Shim
3. Injection Nozzle Cap 9. Pressure Pin
4
4. Set Nut 10. Spring Non-reusable Part
5. Injection Nozzle Grommet 11. Adjusting Gasket
6. Straight Pin 12. Injection Nozzle Seat
Assembling order
5
x The fuel burns easily. Keep it away from the fire and the heat source.
x The spilled fuel may lead to a fire, so you should clear it carefully.
x The removal, installation and adjustment of the injector can be operated only after clearing the
carbon deposits on it. Injection pressure spray state and leakage must be checked before
removal. Please do not remove it if there is no abnormality.
x The needle valve of the inflator injector and the position of the injection nozzle cannot be
changed. 7
INDEX
471

1. Service standard
Unit: mm
Correction
Method
- Injection pressure 21.6 MPa {220 kgf/cm2} - Adjustment
- Valve stroke 0.29 - Adjustment
Unit: Ngm {kgfgm}
Injection pipe connecting pipe nuts
Ta 25 {2.5} -
Bolt (For installing the injection nozzle cap)
Tb Set nut 34r5 {3.5r0.5} -
3. Special tool
Unit: mm
Injector cleaning tool ƾ 105789-0010 Injector disposure
ƾ : Bosch Parts Number

Inspect: injector
x Install the injector to the injector tester and then
check the following items.
x Operate the lever of the injector tester before

inspection, pull out the air bolts after spraying 2 to
3 times.
1. Opening pressure inspection

x Press the level on the injector tester at the
Injector Tester speed of 1 to 2s every stroke, after the
pressure gauge needle raising slowly,
measure the value when shaking intensely.
x If the measured value exceeds the specified
value, you should disassemble the injector
and adjust it after disposure.
x If abnormality still exist after adjusting,
replace the injector.
x Do not touch the aerosol sprayed from the

injector.
472

2. Injection state inspection
x Turn the level of the injector tester at the
CONTENTS
speed of 1 to 2s every stroke and spray
continually.
A: 5 spray-holes spray evenly (In good
condition)
B: even and symmetry (In good condition)
C: dissymmetry (In bad condition)
A B C D E F D: Forking during the spraying (In bad 1
condition)
E: poor spraying (In bad condition)
F: ladder like spray (In bad condition)
x Do not touch the aerosol sprayed from the 2

injector.
x Make sure there is no leakage after

spraying.
x If there is abnormality, disassemble the
injector and recheck after washing. 3
x If abnormality still exist after rechecking,
3. Oil seal, leakage of all parts

x Make the pressure inside the injector is 1960
kPa (20 kgf/cm2) lower than the specified 4
needle valve opening pressure and keep this
pressure. Make sure there is no oil leakage
from the top of the nozzle within 10s.
x If there is abnormality, disassemble the
injector and recheck it after washing.
x If there is abnormality after inspection, 5
Disassembling method
Sliding Part Disassembling: injector
6
x Do not touch the sliding part of the needle valve,
please wash with washer fluid (Light oil, and so
on) in case of touching.
x The match between the removed needle valve
and the inflator of the injection nozzle cannot be
changed. 7
INDEX
473

Disposure method
Cleaning Rod
Disposure: injector
x After cleaning the needle valve and injection
nozzle with washer fluid (Light oil, and so on),
dispose the carbon deposits adhered to them with
following the way listed below.
x Carbon deposits on the top of the needle valve
can be disposed with cleaning rods.
x Do not dispose them with wire brush and hard

metal and so on.
x Carbon deposits on the spray-hole of the injection

Needle Cleaner nozzle can be disposed by turning around again
and again along the spray-hole with needle
cleaner.
Cleaning needle diameter: less than or equal to
0.23mm
x The seat surface of the injection nozzle can be

Cleaning Scraper
disposed with cleaning scraper.
x Dispose the burned hard carbon deposit with
carbon deposit remover.
Inspection method
Inspect: injector
x Reinstall the needle valve and injection nozzle
after cleaning them with washer fluid (light oil, and
Needle Valve so on).
x Pull out 1/3 part of the needle valve and inspect if
Injection Nozzle it can drop by its weight. (Inspect for several times
by turning.)
x If the needle cannot drop, then inspect several
times again after cleaning it up. Reinstall the
needle and injection nozzle if there is abnormality.
474
CONTENTS
x Injection nozzle, straight pin, needle valve and
injection nozzle grommet should be placed with
injection nozzle repair set when replacing the
nozzle.
x Pre-lift should be adjusted after replacing the
injection nozzle, making the opening pressure is
1
the standard value.
Adjustment method
Adjustment: injector
x Clean all the parts with washer fluid (light oil, and
so on) before adjustment and clear the dirt and
2
impurity away.
x Do not touch the sliding part of the needle valve.
x The installation state of the parts to the injection 3

nozzle is shown in the illustration.
x Tighten the set nuts to the specified torque.
x Install the injector to the injector tester and
measure the opening pressure.
4
x Do not touch the aerosol sprayed from the
Adjusting Gasket injector.
Spring
Needle Valve
replace and adjust the adjusting gasket.
Injection Nozzle
5
6
Installation method
Installation: injection pipe
x Check for the damage and dent of the pipe and
Tube
Seat Surface seat surface of the connector part.
Seat Surface x Attach the pipe to the seat surface of the
connector part uniformly, and do not temporarily fix
7
Connector Part it forcibly.
x After temporarily fixture, tighten it to the specified
torque.
INDEX
475
ENGINE - Cooling system
6-5. Cooling system
Item Specification
Cooling type Forced water circulation cooling type
Water pump type Belt transmission whirling type
Thermostat type Core wax at the bottom-bypass (With jiggle valve)
Cooler capacity (Engine body) dm3 9.5 {9.5}

{L}

1. Cooling system (Coolant flow chart)
Radiator
At High Cylinder Head

Thermostat Set Temperature
At Low
Temperature
Cylinder
Water Pump
476

2. Thermostat
CONTENTS
To Radiator
Thermostat Cover
2
Thermostat
Thermostat Case From Cylinder Head
3
To Water Pump
x Thermostat adopts bottom bypass, and its core is filled with wax. This wax core thermostat
utilizes the volume change of the wax while it melts as the temperature rises. The valve opens
and closes while the coolant temperature changes, the movement of the valve adjusts the
amount of coolant which flows to radiator and water pump bypass side), so as to control the 4
coolant temperature.
7
INDEX
477

3. Water pump
Water Pump Case

Bearing
Flange
Combination Seal
Water Pump Shaft
Snap Ring Impeller

Spacing Collar
Drain Hole
x The water pump has a drain hole, which prevents the coolant from coming into the bearing due
to the combination seal abnormality.
478
CONTENTS
Symptoms
The coolant consumption is too fast

Overheat (Insufficient cooling)
Reference
1
Abnormal noise
Overcool
Possible Causes
Loose or broken ƻ ƻ 2
Belt Too tight ƻ
Belt is oily ƻ
Poor installation of water pump ƻ ƻ
Poor shim ƻ ƻ
Poor bearing ƻ ƻ 3
Water Pump Poor impeller ƻ
Poor combination seal ƻ ƻ
The matching between water pump shaft and flange or
impeller looses ƻ ƻ
The housing is not installed properly. ƻ ƻ 4

Poor shim ƻ ƻ
The opening temperature of the valve is too high, and
Thermostat the valve is normally closed. ƻ
The opening temperature of the valve is too low, and

the valve is normally open. ƻ
5
Coolant temperature sensor leakage ƻ ƻ
Core blockage ƻ
Radiator
Core cracked or sealing off ƻ ƻ
Poor installation of the oil cooler ƻ ƻ
Oil Cooler Section 12
Poor shim ƻ ƻ 6
Poor installation of the cylinder head ƻ ƻ
Cylinder Head Section 11
Poor shim ƻ ƻ
poor pressure cover ƻ
Coolant insufficient or cloudy ƻ
Coolant passage dirty or blocked ƻ 7
Poor installation of the hoses ƻ ƻ
Ambient temperature low ƻ
Intercooler Core attached with foreign matter ƻ
INDEX
479

1. Inspection and adjustment for belt tension
x The belt should not be oily. It may slip if it's oily, which decreases the cooling effect.
Inspection and service standard

Unit:mm
- Belt tension 10-15 - Adjustment
Special tool
Belt tension
Belt tension meter MH062345
measurement
[INSPECTION]
x Apply 98N {10kgf} force to the middle of the belt as
A shown in the illustration to measure the belt
deflection.
C
Deflection A: alternator pulley
B: crankshaft pulley
Belt C: water pump pulley
B
x Position the O-ring (Small) of the at the point

O-ring (Small)
98N {10kgf} (Pushing force) of the vernier.
x Position the O-ring (Big) of the at the point
Vernier (the specified maximum value of the belt
deflection) of the vernier.
O-ring (Big)
Vernier
480

x Position at the middle of the belt as shown in
the illustration, press and push it until the part
CONTENTS
O-ring
Flange indicated by the arrow touches the O ring.
x Measure the belt tension.

Deflection x If the measured value is above the standard value,
adjust the belt according to the following
essentials.
2
[ADJUSTMENT] 3
Adjusting Bolt x Loosen the alternator nut, adjust the belt tension
with the adjusting bolt.
Belt x Tighten the nut after adjusting.
4
x Excessive belt tension may damage the belt and
related bearing.
Nut
2. Check for the belt crack and damage
x Visually check for the belt for crack and damage. 5

x Replace the belt if abnormal.
Belt
6
7
INDEX
481
Belt Condition Residual Life (For reference)
More than or equal to the distance which travels from the date (New vehicle
purchasing date or belt-replacing date) to inspection date.
Goffer
Half of the distance which travels from the date (New vehicle purchasing date or
belt-replacing date) to inspection date.
Surface Crack
A quarter of the distance which travels from the date (New vehicle purchasing
date or belt-replacing date) to inspection date.
Crack to Bottom Sealer
Crack to Core Wire

Life span
482

3. Change coolant and clean cooling system
CONTENTS
Tightening torque
Unit: Ngm {kgfgm}
- Crank case drain valve 98 {10} -
x If the radiator has been used for a long time without cleaning, the rust deposit will cause
overheat of the cooling system, so the cooling system should be cleaned regularly. 1
Drain coolant
x Before draining the coolant, unscrew the pressure

cover to reduce the pressure in the cooling
system. In addition, drain the coolant in the
storage tank. 2
x Do not drain the coolant before cooling down

completely to prevent getting burned.
Crank Case x When the coolant is hot, it may spray out if you
Pressure Cover Drain Valve 3
open the pressure cover. When open the pressure
cover, cover it with a piece of rag etc. and unscrew
it slowly to reduce pressure, then open it
completely.
Cleaning tips
x Do not use hard water while cleaning, use soft water that obtains the following properties to
prevent scale and rust.
Total hardness ................................... below 300ppm
Sulfate SO-4 ...................................... below 100ppm
6
Chloride Cl- ........................................ below 100ppm
Total Insoluble solid content ............. below 500ppm
pH...................................................... 6-8
x Keep the coolant cycling in the radiator at about 90 degrees and the thermostat valve open.
x To raise the coolant temperature rapidly, cover the front of the radiator with a paper board or 7
equivalent.
x The radiator may leak after cleaning if a lot of rust exists in it, so perform a leakage test carefully
after cleaning the cooling system.
x The cleaning procedures of cooling system varies according to the following different conditions.
INDEX
483
• Normal condition • When the coolant is seriously dirty • When the radiator is blocked
Method of cleaning the radiator with washer (Radipet 7)

Clean with water
Drain the coolant
Mix the water and radiator (Radipet 7) with 5-10

washer and 100 water
(Operation
procedure) Add the mixture to the radiator
Allow the engine to idle for 30 minutes while the

water temperature is at 90ºC
DBVUJPO
• The cooling system with coolant added may
be damaged if the engine runs for over 1 hour.
Observe the cleaning procedures strictly.
Drain the coolant
Add the water (Hot water is preferable) to the radiator
Allow the engine to idle for 10 minutes while

the water temperature is at 90ºC
Drain the water
If the drained water is clear, the cleaning work can be finished

If the drained water is still dirty, repeat the steps above
DBVUJPO
• Add coolant as soon as possible after cleaning
the cooling system with cleaner.
• To prevent coolant freeze and cooling system
corrosion, add FUSO diesel long effect coolant
in the coolant according to specified proportion
(Refer to operating manual for operating points).
x Diesel long effect coolant burns easily, keep it away from heat source and flame.
x If diesel long effect coolant gets in your eyes accidentally, wash them with water immediately
and go to a doctor for a treatment.
484

4. Air bleeding in cooling system
x Remove the pressure cover, idle the engine with the coolant temperature at 90qC and bleed all
CONTENTS
the air in the cooling system.
x Add coolant to the storage tank if necessary after bleeding the cooling system.
5. Check for air leakage
x Corrosion in the cooling system will accelerate if the coolant is mixed with air and waste gas.
Therefore perform inspection of the following items.
x Remove the pressure cover.
1
x Check that the coolant is cool before loosening the pressure cover. The coolant may spray out
from the filling opening if it is hot.
2
x Start the engine to raise the coolant temperature
to about 90 degrees.
x If bubbles appear continuously in the coolant
under this condition, there are air or waste gas in
Bubbles
the coolant.
x If there is air in the coolant, it is possible that the
3
cylinder head bolt, water pump set bolt or hose
connection are loose, or the hose is broken.
x If there is waste gas in the coolant, it is possible
that the cylinder head shim is broken or the
cylinder head is cracked.
7
INDEX
485
6-5-5. Radiator, oil cooler, intercooler
1
10
11
2
7
6
5
3 9 4
x Removal order
1. Pressure Cover 5. Protector 9. Lower Bracket
2. Fan Shroud 6. Grommet 10. Radiator
3. Intercooler 7. Upper Bracket 11. Frame
4. Bracket 8. Oil Cooler
Service standard
Correction
Method
Opening pressure of the pressure 49r9.8kPa
1 - Replacement
cover {0.5r0.1kgf/cm2}
Intercooler air leak
3 0 cm3 {0 mL} - Replacement
(Air pressure: 150kPa {1.5kgf/cm2})
Oil cooler air leak
(Air pressure: 1.5MPa {15kgf/cm2})
Radiator air leak
(Air pressure: 100kPa {1.0kgf/cm2})
486

Inspection method
CONTENTS
Inspection: intercooler air leak
x Plug one air opening of the intercooler that is
Cap submerged in the water groove and apply
specified air pressure to the other opening.
x If there is air leak, replace the intercooler.
Inspection: oil cooler air leak

x Plug one opening of the oil cooler that is
submerged in the water groove, apply specified air 2
pressure to the other opening.
x If there is air leak, replace the oil cooler.
Cap
Inspection: radiator air leak

Radiator Cap Gauge
x Install hose, radiator cap gauge and plug on the
Plug Hose
radiator water tank.
x Screw plugs on the lower water tank and
submerge them in the water groove. 4
x Using radiator cap gauge, apply specified air
pressure and check for air leak.
x If there is air leak, replace the radiator assembly.
Plug
Inspection: pressure cover 5

Opening pressure
x If the measured value is above the standard,
replace the pressure cover.
6
Pressure Cover
7
INDEX
487
6-5-6. Cooling fan and belt
*a
5
2
1
x Removal order
1. Cooling Fan 4. Fan Coupling
2. Fan Spacer 5. Water Pump Pulley
3. Belt *a: Water Pump
x There are 2 belts installed, replace them together to prevent the belt tension difference.
x The belt should not be oily. It may slip if it's oily, which may decrease cooling effect.
488
6-5-7. Water pump
CONTENTS
8
7
6
5 1
4 Tb
10 1
11
3 9
2 12 2
1. Impeller 6. Bearing 11. Water Pump Housing
2. Flange 7. Washer 12. O-ring 4
3. Snap Ring 8. Water Pump Shaft
4. Bearing 9. Combination Seal Non-reusable Part
5. Spacing Collar 10. Grease nozzle
x Assembling order
The assembling procedures are the disassembling procedures in reverse order except for the
following procedures. 5
12o8o7o6o5o4o11o3o9o10
Service standard
Unit: mm
Limit
Area Service Item Standard Value Correction Method
Value 6
Magnitude of interference
Reassemble twice at
1, 8 range of impeller and water 0.03-0.06 -
most
pump shaft
Magnitude of interference
Reassemble twice at
2, 8 range of flange and water pump 0.03-0.08 -
most
shaft
7
Tightening torque
Unit: Ngm {kgfgm}
INDEX
Ta Nut (For installing fuel injection pump) 24 {2.4} -
Tb Grease nozzle 12.3r2.4 {1.3r0.25} -
489

lubricant and/or sealer
Bearing filling Nolybdenum disulphide lithium base As required
Inject grease through the grease
[NLGI No.2(Lithium Soap Base)] 60g
grease nozzle
Outer edge of the
combination seal
Special tool
Unit: mm
Impeller conical die

A B Removal of the
MH061417
impeller conical die
I48 I10
A
Removal method
Removal: impeller
Removal: flange
Gear Conical Die
Inspection method
Inspection: magnitude of interference range of
impeller and water pump shaft
replace the malfunction part.
x Even if the measured value complies with the

standard, reassemble can be performed twice at
most.
490

Inspection: magnitude of interference range of
flange and water pump shaft
CONTENTS
Flange x If the measured value is above the standard value,
replace the malfunction part.
x Even if the measured value complies with the

Water Pump Shaft standard, value reassemble can be performed
1
twice at most.
Installation method
Installation: flange
2
x Before installing the flange, it is necessary to
check the stamped mark as shown in the
Stamped Mark illustration. It is reusable if there is only 1 stamped
mark. Additionally, a stamped mark should be
stamped for this disassembly and assembly.
x Stamped mark indicates the number of 3
disassembly and reassembly times of the flange
before. If there are 2 marks (2 times of
disassemblies and assemblies before), replace
the flange.
x Using a press machine, apply pressure to the 4

Water Pump water pump shaft.
Shaft x Install the flange until it touches the bearing.
Flange x The water pump housing will be damaged if the

flange is installed without using a clamp. 5
Clamp
Above φ20 mm
φ40 mm
Installation: impeller
x Before installing the impeller, it is necessary to

check the stamped mark as shown in the
illustration. It is reusable if there is only 1 stamped
mark. Additionally, a stamped mark should be
Stamped Mark
stamped for this disassembly and assembly.
7
x Stamped mark indicates the number of
disassembly and reassembly times of the impeller
before. If there are 2 marks (2 times of
disassemblies and assemblies before), replace
INDEX
the impeller.
491

x Use the flange side end surface of the water pump
Clamp
Impeller shaft as the loading surface.
21.34 mm x Using a press machine, apply loading to the
impeller end surface to install it and adjust
dimension between the water pump housing end
End Surface surface and the impeller end surface as shown in
Water Pump of the Water
Shaft Pump Case
the illustration.
Inspection after assembly

Inspection: turning of flange
x Turn the flange by hand to check that it turns
smoothly without blockage.
x If the flange cannot turn smoothly, disassemble
the water pump and check again.
Flange
6-5-8. Thermostat
Sealer
2
Ta 4
7
8
5 Ta
9
10 11
6 Ta
1. Thermostat Cover 8. Shim
2. Shim 9. O-ring
3. Thermostat 10. By-pass Pipe
4. Coolant Temperature Sensor 11. O-ring
5. Coolant Temperature Sensor
: Aligning Pin
6. Faucet
7. Thermostat Cover Non-reusable Part
492

x Assembling order
CONTENTS
x Keep the O-ring free from the oil. The O-ring will expand and cause water leakage if it is oily.
Service standard
Unit: mm 1
Correction
Method
Valve opening
76.5r2 - Replacement
3 Thermostat temperature
Valve lift/temperature more than 10/95qC - Replacement
2
Tightening torque
Unit: Ngm {kgfgm}
Coolant temperature sensor
Ta 20-26 {2.1-2.7} Locking agent
Faucet 3
O-ring Soapy water As required
Coolant temperature sensor

Loctite 575 As required 4
Faucet
Inspection method
Inspection: thermostat
Stirring Stick
Water x Using a stick to stir the water to ensure even water
Temperature temperature in the container and do the following 5
Steel Wire
Gauge inspections at the same time.
replace the thermostat.
1. Valve opening temperature
Heat Source x Fix the thermostat with steel wire to keep it
Valve Lifting away from the heat source. 6
x Water is heated gradually to reach the
temperature which can open the valve.
x Keep the state for 5 minutes, and check that
the valve opens.
x Check that the valve is fully closed when the
water temperature drops to 65qC. 7
2. Valve lift
x Make the water temperature be above the
valve fully open temperature a little and keep
INDEX
the valve open for 5 minutes, then measure

the valve lift.
493
ENGINE - Air intake and exhaust system
6-6. Air intake and exhaust system
Item Specification
Air cleaner element type Paper filter element
Dust indicator type Electric type
Type TE06
Turbocharger
Manufacturer Mitsubishi Heavy Industries

1. Air cleaner
Vacuum Valve Air Cleaner
x Air cleaner adopts double filter element.

x Air cleaner is equipped with vacuum valve.
x When the engine speed is lower than the specified speed, the vacuum valve will vibrate because
the change of the negative voltage, and discharge the accumulated water and dust
automatically.
494

2. Turbocharger
CONTENTS
Lining Thrust Ring Turbine Rear Plate
Thrust Bearing Bearing Bush Piston Ring
Compressor Turbine Casing 1

Housing
2
Shaft and Turbine
Working Wheel
Compressor
Working Wheel
4
Thrust Liner Oil Battle Plate Bearing
7
INDEX
495
Symptoms
Abnormal noise or vibration in air intake/exhaust system

The engine output power is insufficient
Reference
White smoke is exhausted.

Black smoke is exhausted.
Too much oil consumption

Possible Causes
Air cleaner Air cleaner element is blocked ƻ ƻ ƻ ƻ
Bearing damage ƻ ƻ ƻ
Carbon-deposit in the turbocharger
working wheel ƻ ƻ
Turbocharger working wheel is stuck in

the turbocharger case. ƻ ƻ ƻ
Bending shaft ƻ ƻ ƻ
Turbo-
Turbocharger working wheel damage ƻ ƻ ƻ
charger
Turbochar- Assembly Compressor working wheels are stuck in
ger the compressor case. ƻ ƻ ƻ
Compressor working wheels damage ƻ ƻ ƻ

Parts cannot slide because of the
blockage of the lubricant pipes and jointed ƻ ƻ ƻ
bolts.
Seal damage because of oil return pipe ƻ ƻ
Poor installation of the compressor case ƻ ƻ ƻ ƻ
Poor installation of the turbocharger case ƻ ƻ
Deformation of the exhaust pipe and muffler ƻ ƻ
Poor installation of the exhaust pipe and muffler ƻ ƻ
Valve clearance is improper ƻ
Cylinder head shim damage ƻ
The valve and valve seat are worn or have carbon-deposit ƻ
Section 6-2
Valve spring elastic force is decreased ƻ
The piston ring is worn or damaged ƻ ƻ
The piston ring groove is worn or damaged ƻ ƻ
Poor function of the cooling unit ƻ Section 6-5
496
Symptoms
CONTENTS
Abnormal noise or vibration in air intake/exhaust system
The engine output power is insufficient
1
Reference
White smoke is exhausted.

Black smoke is exhausted.
Too much oil consumption

2
Possible Causes
Too much engine oil ƻ Section 6-3 3
The main moving part is stuck ƻ ƻ Section 6-2
Too much or uneven fuel injection ƻ Section 6-4
7
INDEX
497
6-6-4. Air cleaner
1 7
2 6
x Removal order
1. Dust Indicator 6. Inner Element
2. Splicer 7. O-ring
3. Vacuum Valve 8. Body
4. Cap Non-reusable Part
5. Outer Element
x Do not remove the inner element except replacement.

x Do not clean inner element.
Service standard
Correction
Method
Dust indicator displays vacuum
1 6.23r0.57kPa {47r4.3mmHg} - Replacement
negative pressure
Cleaning tips
Cleaning: outer element
x Blow the element with compressed air which is
lower than 685kPa {7kgf/cm2} from inner side
outward.
x Blow along the element flexure part with
compressed air again and again until the element
becomes clean.
498
CONTENTS
x About the cleaning time, refer to the usage
instruction. The frequency of the cleaning will
lead the element wear and make the dust and
foreign matter sucked into the engine.
x Do not clear dust away by tapping the element or
flapping it on the other object.
1
x Do not blow the element with compressed air from
outside inward.
Inspection method
Inspection: outer element
x Put the light in the inside of the outer element. 2
x If the filter is worn or thin or the seal part between
the element and the case contact surface is worn,
replace the element.
In addition, if there is moist lampblack and carbon-
deposit on the element, replace the element even
if the cycle of replacement has not reached. 3
Inspection: dust indicator displays vacuum negative
21
pressure
x Apply negative voltage to the dust indicator slowly
and measure the negative voltage between
terminal 1 and 2 when in continuity.
x If the measured value exceeds the standard value, 4
replace the dust indicator.
7
INDEX
499
6-6-5. Turbocharger
4
2
Ta
Tb
11 5
3
1
*a
13
Ta
6 14
Tc
7
9
15
12 8
Tb
10
x Removal order
1. Air Hose 7. Shim 13. Oil Deliver Pipe
2. Intake Pipe 8. Oil Return Pipe 14. Turbocharger (Refer to the
3. Air Hose 9. Shim following statement)
4. Turbocharger Cap 10. O-ring 15. Shim
5. Spacing Collar 11. Jointed Bolt *a: Intake Pipe
6. Exhaust Pipe 12. Jointed Bolt : Non-reusable Parts
Tightening torque
Unit: Ngm {kgfgm}
Ta Clamp 4.9 {0.5} -
Tb Jointed bolt (For installing oil deliver pipe) 21 {2.2} -
Tc Nuts (For installing turbocharger) 41 {4.2} -

Fill in the turbocharger
O-ring
500

Installation method
Oil Hole Turbocharger
CONTENTS
Installation: turbocharger
x Fill proper amount of engine oil into the oil hole
before installing turbocharger to make sure that
the inner parts can run smoothly.
1
1. Turbocharger
2
Ta
1
3
4
5 4
1. Coupling 5. O-ring
2. Turbine Casing 6. Turbocharger Assembly
5
3. Snap Ring
4. Compressor Case : Non-reusable Parts
x Assembling order
x Because turbocharger assembly is non-removable parts. Therefore, replace the turbocharger if

the turbocharger working wheel and compressor working wheel have damage or cannot run
smoothly.
7
INDEX
501

Service standard
Unit: mm
Limit Correction
Area Service Item Standard Value
Value Method
Clearance in the rotation shaft
direction
Turbocharger
Turbo-
Clearance in the working wheel 0.40-0.53 0.58 Replacement
6 charger
right angle side
Assembly
direction of the Compressor
rotation shaft working wheel 0.55-0.66 0.72 Replacement
side
Tightening torque
Unit: Ngm {kgfgm}
Ta Nuts (For installing coupling) 8-9 {0.8-0.9} Wet
lubricant and/or sealer

Nolybdenum disulphide
lithium base grease
Thread part of bolt As required
[NLGI No.2(Lithium Soap
Base)]
Matching Mark Operation before removal

Compressor
Housing
Matching mark
Turbocharger
x Mark matching mark on coupling turbine casing
Assembly
compressor case or turbocharger assembly.
Turbine Casing
Coupling
Removal method
Removal: turbine casing
x Tap the surface around the turbine casing with a
rubber hammer slightly, be careful not to damage it.
x Because the vane of the turbocharger assembly is

easily bent. Therefore, be careful not to touch the
turbine casing.
502

Removal: compressor case
x Tap the surface around the compressor case with
CONTENTS
a rubber hammer slightly, be careful not to
damage it.
x Because the vane of the turbocharger assembly is

easily bent. Therefore, be careful not to touch
1
compressor case.
Operation after removal

Cleaning
x Visually check the state of the removed parts
before cleaning, make sure that there is no 2
ablation or scratch which are difficult to discover.
Solvent
Replace the parts if there is an abnormality.
x Soak the removed parts into the noninflammable
dissolvant (The dissolvant is 5-10 folds weaker
than the oil cleaning from NEW HOPE company
after dilution.), dry it with compressed air after 3
taking them out.
In addition, if there is foreign matter adhered to
them, operate after clearing them away with
plastic scraper or scrubbing brush.
4
x Do not soak turbocharger assembly into the
dissolvant. If it is soaked in the dissolvant, the O-
ring in the turbocharger assembly will expand and
may cause turbocharger damage.
x Soak the parts in the dissolvant again.
x Dry it with compressed air. 5
Inspection method
Inspection: turbocharger assembly
x Check the following items, replace turbocharger
assembly if the measured value exceeds the
specified value. 6
1. End play of the shaft and turbine working
wheel
7
INDEX
503

2. Clearance in the right angle direction of the
<Turbine Working Wheel Side> rotation shaft
<Compressor Working Wheel Side>
Installation method
Conical Surface
Installation: snap ring
x Insert the snap ring into the compressor case,
making conical surface face upward.
Snap Ring
x Hold the snap ring when installing, preventing it
from flying out.
Compressor Case
Operation after removal

Inspection: the rotation of the turbocharger
assembly
x Rotate the wheels of the turbocharger assembly to
make sure that it can work smoothly.
x Repair after removal if there is an abnormality.
504
6-6-6. Intake manifold
CONTENTS
3
Ta
2
4 2
Ta
3
1
x Removal order
1. Air Pipe 4. Shim
4
2. Air Hose
3. Intake Manifold Non-reusable Part
Tightening torque
5
Unit: Ngm {kgfgm}
Ta Clamp 4.9 {0.5} -
7
INDEX
505
6-6-7. Exhaust manifold
Ta
Folded Part of the Grommet
1. Exhaust Manifold Non-reusable Part
2. Shim
x Assembling order
Tightening torque
Unit: Ngm {kgfgm}
Ta Nuts (For installing exhaust manifold) 41-54 {4.2-5.5} -
506
6-6-8. Exhaust pipe and muffler
CONTENTS
5
6
1
4
3
*a
2
2
3
7
x Disassembling order 4
1. Heat Shield 6. Muffler
2. Exhaust Pipe 7. Muffler Bracket
3. Shim *a: Turbocharger
4. Clamp Non-reusable Part
5. Muffler Clamp
5
7
INDEX
507
- MEMO -
508
ELECTRICAL SYSTEM - Engine electrical
CHAPTER 7 ELECTRICAL SYSTEM
CONTENTS
7-1. Engine electrical
1. Alternator
Item Specification 1
Manufactory Mitsubishi Electric & Electronics, Inc.
Type Built-in adjuster type alternator
Model A4TU7686
Output V-A 24-50
2
2. Starter, pre-heating
Item Specification
Manufactory Mitsubishi Electric & Electronics, Inc.
Model M008T87171
Output V-kW 24-5.0 3
Starter
Reduction gear unit Planetary gear
Magnetic switch
V 16 or less
operation voltage
Model U001T37072
Field current V-A 24-2.3
4
Power on V 16 or less
Starter relay
Power off V 4 or less
Allowable rupturing
A 200
current
Model Sheath model
Heating plug
5
Rated voltage
V-A 11-130
current
Model U001T31383
Field current V-A 24-2.3
Turn-on voltage V 16 or less
Heating plug 6
Cut off voltage V 4 or less
relay
Allowable rupturing
A 200
current
Thermal fuse
A 127
capacity
7
INDEX
509
7-1-2. Structure and operating principle

Starter
Magnetic Switch
Ball Lever
Terminal B Terminal S Starter Relay Brush Spring Front Carrier
Brush
Terminal M Brush Seat Spring
Rear Carrier Pinion

Retainer
Rear Bearing
Pinion
E-ring Front Bearing
Yoke Iron
Terminal SW Cap
Armature Washer
Overdrive Clutch
Rubber Grommet
Gear Shaft
Terminal L Planetary Gear
Internal Gear
The starter uses the planetary gear as reduction gear

unit.
Planetary Gear
510

Alternator
CONTENTS
Terminal E
Terminal P
Terminal B
1
Terminal R Terminal L
Stator
3
Rotor Fan
Rectifier
Neutral Emitting Diode
Pulley
Rear Bearing
4
Front Bearing
5
Adjuster
Rear Carrier Magnetic Coil Front Carrier
7
INDEX
511
7-1-3. Wiring diagram

1. Alternator with neutral emitting diode
Terminal P
Neutral Emitting Terminal B
Neutral Point Diode
Stator Coil
Terminal L
Terminal R
Magnetic
Terminal E
Coil
Neutral Emitting Diode
IC Adjuster
(a) Feature
x The alternator is the same as multipurpose alternator except adding the neutral emitting
diode.
x Via these neutral emitting diodes, the alternator will provide greater DC output power than
the alternator without neutral emitting diode when the alternator is operating at a high
speed.
Voltage waveform of neutral point when running at a high speed

(V) Voltage waveform of neutral point when running at a low speed
28 Output Voltage
14 Average voltage of neutral point

(1/2 of output voltage)
0 Ground Potential
Voltage
Rotating Angle
512

(b) Neutral point voltage variations and neutral emitting diode operating principle
x The potential of neutral point changes up and down depending on neutral point DC voltage
CONTENTS
(1/2 of output voltage), the neutral point as shown in the illustration.
x Neutral point voltage will increase to greater than output voltage (28 V) and decrease to
lower than ground voltage (0 V) when the alternator is operating at a high speed. To adjust
these over voltage and lower voltage (shaded area in the illustration), the current from the
over voltage is picked up and is applied to DC output by the neutral emitting diode.
The voltage and potential of the neutral emitting diode operate as follows.
x When the voltage range of neutral point is from 0 to 28 V, other 6 diodes are operating. 1
The neutral emitting diode does not operate.
Terminal P
Positive Direction Emitting Terminal B
Diode (+) 2
Terminal L
Terminal R
3
Magnetic
Terminal E
Coil
IC Adjuster
4
(c) When the voltage of neutral point exceeds 28 V

x Positive direction emitting diode (+) increases extra output provided by each electrical
equipment to DC output.
Terminal P
Terminal B
6
Terminal L
Terminal R
Magnetic
Terminal E
Coil
7
IC Adjuster
Negative Direction Emitting Diode (-)

INDEX
513

(d) When the voltage of neutral point drops below 0 V
x Negative direction emitting diode (-) provides output via other 3 diodes from neutral point.
Thermostat
Combination Meter Switch
Water Temp. Sensor
Starter
Oil Pressure Switch
M Alternator
M
B E B P Oil By-pass Pipe
L R
S Warning Switch
Starter Relay
S Indicator
B L
SW
Relay Starter Switch

OFF
S E L R P R1
AC
START
B R1 AC BR C
Safety Relay
Indicator
Heating Plug Relay
Main Power Source Relay
Display
+
-
Battery
+
-
Heating Plug
514
CONTENTS
Power source, charging
Symptom
When the engine is in stop condition and the starting switch

is turned to ON, the charge warning light does not come on
Alternator is normal, while the battery over-discharges

1
Battery is normal, while it over-discharges

Reference
Battery fluid decreases too fast

2
Battery is overheated
3
Possible Cause
Connection trouble, wiring broken, ground trouble of the connector ƻ ƻ

Fuse is blown out ƻ ƻ ƻ
Belt loose ƻ ƻ Section 6-5
Belt damaged ƻ ƻ Section 6-5
4
Battery malfunction ƻ ƻ
Stator coil is open ƻ
Stator coil and iron core are short ƻ
Magnetic coil is open ƻ
Alternator 5
Rectifier malfunction ƻ
Adjuster malfunction ƻ ƻ ƻ
Line malfunction ƻ
Combination meter malfunction ƻ
7
INDEX
515

Engine starts, warms up, stops
Symptom Starter
operates,
while
engine
does not
start
Pinion engages with gear ring, while it does not rotate

Flywheel rotates, while engine does not start
Pinion does not engage with gear ring
Reference
Engine operation condition is poor

Warming up is impossible
Starter does not operate
Engine does not stop

Possible Cause
Connection trouble, wiring broken, ground trouble of the
connector ƻ ƻ ƻ ƻ ƻ
Fuse is blown out ƻ ƻ

Low battery charging ƻ ƻ
Magnetic switch contactor is stuck or burned ƻ
Magnetic switch coil is open ƻ
Starter
Overdrive clutch malfunction ƻ ƻ
Pinion worn or damaged ƻ
Starter relay malfunction ƻ ƻ
Starter switch malfunction ƻ ƻ ƻ
Flywheel gear ring worn or damaged ƻ Section 6-2
Water temp. sensor malfunction ƻ ƻ
Heating plug is poor ƻ ƻ
Heating plug relay is poor ƻ ƻ
Connecting sheet is poorly connected ƻ ƻ
516
7-1-5. Switch
CONTENTS
#024 Thermostat switch
2
x Place the switch in a container filled with oil.
1
x Make the oil temperature increase to specified
value and churn up the oil.
x Measure the body temperature between 1 and 2
respectively.
1
Standard Value 105 r 2q

replace the switch.
(Refer to Section 6-5)
#044 Checking the engine oil pressure switch 2

Body x Use the following procedures to check the switch,
1
if any malfunction is found, replace it. (Refer to
Section 6-3)
1. Check without air pressure
x Make sure that there is continuity between
terminal 1 and body. 3
Working Pressure Stamped
2. Check with air pressure
NO. Print Position
x Apply air pressure into the switch gradually
from 0 kPa {0 kgf/cm2}.
x Measure air pressure value the moment that
the continuity between terminal 1 and body
is not detected, check if this value is as 4
standard.
Standard Value
(Operation Pressure) 50 r 10 kPa {0.5 r 0.1 kgf/cm2}
7
INDEX
517
7-1-6. Dust display, heating plug
#757 Checking the dust display

x Use the following procedures to check the dust
display, if any malfunction is found, replace it.
x When the air pressure is not applied to the dust
display, make sure that there is no continuity
between terminal 1 and 2.
x When the negative pressure 6.23 r 0.57 kPa {635 r
58 mm H2O} is applied to the dust display, make sure
(+) 2 1 (-)
that there is no continuity between terminal 1 and 2.
(Refer to Section 6-6)
#764 Checking the heating plug

x Measure the heating plug as shown in the
illustration.
Standard Value
About 3.8 : (reference value)
(At Normal Temperature)

replace the heating plug. (Refer to Section 6-2)
518
7-1-7. Starter
CONTENTS
Starter 1
Terminal B
2
Terminal S
Starter Relay 3
4
x Disconnect the negative (-) battery cable, insulate the cable and negative (-) terminal with
insulting tape before removing the starter.
x It is dangerous if the negative (-) cable is not disconnected as the terminal B always has battery
voltage.
7
INDEX
519
b 24
b 25
26 21
22
28
23
27 18
d 19
20 7
b
8
29
30 5
31 10
6
11
3 9
2
17 12
1 14
b
4 15
b 16 13
Terminal S 5
28
27
28 d
x Disassembling sequence
1. Blocking Ring 12. Brush (+) 23. E-ring
2. Pinion Retainer 13. Yoke Iron 24. Gear Shaft
3. Pinion 14. Rear Bearing 25. Washer
4. Spring 15. Washer 26. Internal Gear
5. Magnetic Switch 16. Armature 27. Overdrive Clutch
6. Adjusting Shim 17. Ball 28. Lever
7. Rear Carrier 18. Cap 29. Front Bearing
8. Taper Washer 19. Rubber Grommet 30. Oil Seal
9. Brush Spring 20. Planetary Gear 31. Front Carrier
10. Brush (-) 21. Rubber Grommet
11. Brush Seat 22. Steel Sheet
x If there is no obvious damage, do not remove the bearing.

x When removing the armature assembly, the ball may come out together with it, take care not to
lose the ball.
x When only disassembling the motor for checking, e.g. when checking brush and related parts, it
is unnecessary to remove the pinion.
x Before disassembling any other parts, always remove the pinion.
520

x Assembly sequence
The installation procedures are the disassembling procedures in reverse order.
CONTENTS
x When replacing the magnetic switch, the pinion clearance must be adjusted.
x If no abnormality is found with the rubber grommet, it could be used again.
Service standard
Unit: mm
Correction
Method
1
- Pinion clearance 0.5-2.0 - Adjust
Current Below 85 A -
No-load
- Apply 23 V Above 3750 Trim or replace
performance Speed -
rpm
29.2-39.4 N
9 Brush spring pressure 20 N {2 kgf} Replace 2
{3-4 kgf}
10, 12 Brush length 18 11 Replace
Segment outer diameter 32 31.4
Replace
Segment runout - 0.1 or more
16
Mica flake depression depth between wedge
0.5-0.8 0.2 or less Trim or replace
segments 3
Amount
Symbol Using Area Kind
of Usage
Contact surface of magnetic switch
lever 4
Taper washer
Mp grease As
Sliding surface between gear shaft [NLGI No.2 (lithium soap base)] required
assembly and overdrive clutch
Sliding surface between lever and
overdrive clutch
Sliding surface between armature
5
assembly and gear shaft assembly
Ball As
Molykote AG650
Teeth of planetary gear and internal required
gear
Washer 6
Mp grease [NLGI No.2 (lithium soap base)] or As
Oil seal
oil seal accessory grease required
Multemp OA-171 As
Spline part of overdrive clutch
(Kyodo Yushi Co., Ltd.) required
7
INDEX
521

Special tool
Symbol Tool Name and Shape Parts No. Purpose
Bearing removal and

installation tool A B
MH063596 Removal and
A: Bearing removal and A: MH063614 installation of front
installation tool B: MH063619 bearing
B: Bearing installation
tool
Task before removing

Rear Carrier
Matching mark: rear carrier and yoke iron
Matching Mark
Yoke Iron
Disassembly method
Front Carrier Lever Pinion
Disassembly: pinion
Blocking
Magnetic Switch x To remove the pinion, the current must be applied
Ring
to starter to eject the pinion.
x When the starter is energized, the pinion will eject

and rotate. Take care not to touch it by hand.
x The magnetic switch may become very hot when
checking. Take care when touching it.
S
B P H
M
x Energizing time of traction coil P must be less

than 10 seconds, energizing time of holding coil H
must be less than 30 seconds, if they exceed
specified time, the two coils may overheat or blow
out.
x To eject the pinion, make sure that the starter is
energized and its parts are in correct position. If
the starter is not energized and the pinion is
moved out by the traction lever, front carrier or
lever may be damaged due to the impact of
blocking ring when removing the blocking ring.
x When the starter is energized, there will be a great
current (100 A or more). Use enhanced cable or
similar thick cable when checking, also, make
sure that all connections are credible.
522

x Connect the starter as shown in the illustration.
Terminal S
CONTENTS
Terminal M
Pinion
Cable 1
x Perform the following operations when the starter

Direct Current Power Source
is energized. Therefore, the whole removal
process of the pinion must be completed in 30
Switch 1
S seconds.
Switch 2 P H
B
x Turn the switch 1 and 2 to ON to apply the 2
M
current to starter. The pinion will eject and
rotate.
x After the pinion starts to rotate, turn the switch 2 to 3

-
OFF quickly (within 5 seconds) to stop the rotation
+
of the pinion.
Switch 1
S
Switch 2 B P H
M
x When switch 1 and 2 are turned to ON, traction

4
coil P and holding coil H are energized. The circuit
is connected so that there is no voltage on starter
terminal B, so the current flows to traction coil to
rotate the pinion. To prevent the traction coil from
being blown out, turn the switch 2 to OFF quickly
(within 5 seconds) after the pinion starts to rotate.
5
Pinion Retainer x Place the tube-shaped tool on the pinion retainer.

x Strike the tube-shaped tool with hand hammer
Pinion
Blocking Ring lightly, remove the blocking ring from ring groove
of the pinion retainer.
x Remove the blocking ring and pinion.
x Turn the switch 1 to OFF, cut the power source of 6
the starter.
Ring Groove
Tube-shaped Tool
Tube-shaped Tool
x When the power source of the starter is cut, this
unit will attempt to pull the pinion in. As a result,
7
the blocking ring may slide into the ring groove of
the pinion retainer. If so, energize the starter
again, perform the removal process of the pinion
once more.
INDEX
523
Yoke Iron and Brush Seat Disassembly: yoke iron and brush seat
Segment x Use following procedures to remove the yoke iron
Brush Spring and brush seat to prevent segment of armature
Brush assembly from being damaged by the brush.
x Lift up the brush to keep it away from the
segment, then press the brush spring firmly
and hold the brush.
Armature
x Hold part A of each brush spring, pull up the

Brush Brush (+) brush.
x Support the brush with brush spring at the
A
position shown in the illustration.
x Remove the yoke iron and brush seat
assembly.
Brush (-)
Brush Spring Yoke Iron and
Brush Seat
Disassembly: gear shaft and internal gear

Gear Shaft and Internal Gear
x Remove the E-ring, then remove the gear shaft
and internal gear from the overdrive clutch.
If the gear shaft and internal gear cannot be
Overdrive Clutch removed because the spline part via which the
gear shaft connect with internal parts of the
overdrive clutch is too tight, perform following
operations.
E-ring x Press the gear shaft firmly facing the
overdrive clutch.
x Rotate the gear shaft about 1/8 round, change
Overdrive Clutch Gear Shaft the position of the spline part.
Spline Part
Disassembly: front bearing

Static Load: 1 ton
-A
Front Bearing
524

Check method
CONTENTS
Check: magnetic switch
x Use following procedures to check. If any
malfunction is found, replace the switch.
1. Coil open circuit test

x Check whether there is continuity between
Terminal S terminal S and M.
1
Terminal M
2
x Check whether there is continuity between
terminal M and body.
Body
Terminal M
2. Contact points fusion test

x Check whether there is continuous between 4
terminal B and M.
Terminal B
Terminal M
3. Continuity test between contacts

x Push in the end of the magnetic switch to
Terminal B close the internal contact points. Then check
if there is continuity between terminal B and 6
M.
Terminal M
7
INDEX
525

Check: brush spring pressure
x Using a new brush, measure the force necessary
for separating each brush spring from the brush.
x If the measured values are lower than specified
limit value, replace the brush spring.
Brush Spring
Brush
Check: brush (-)

1. Brush length
x If the brush (-) length is shorter than limit
Brush Length value, it must be replaced.
Always replace the brush (-) together with the brush

seat.
2. Contact surface between armature segment

and brush
x If any of the contact surface between brush
and segment is rough or wears unevenly,
correct it with sand paper (#300-500).
Check: brush seat

x Thoroughly clean brush seat (+) and seat plate(-),
then check if there is no continuity between them.
x If there is continuity, there is a short circuit and the
brush seat must be replaced.
Brush Seat Seat Plate
Check: yoke iron

Brush (+) 1. Coil open circuit test
x Check if there is continuity between cable
and brush (+).
Yoke Iron x If not, there is an open circuit, the yoke iron
or brush (+) must be replaced.
Cable
526

2. Coil ground test
Brush (+) x Check if there is no continuity between yoke
CONTENTS
iron and brush (+).
x If there is continuity, the coil is grounded.
Yoke Iron
The insulation should be checked, if it
cannot be repaired, replace the yoke iron
and brush (+).
1
x The coil may energize the yoke iron leading to the
earth because of stack of prills which are worn
from the brush or armature.
Check: brush (+)

2
1. Brush length
x If the brush (+) length is shorter than limit
Brush Length value, it must be replaced.
2. Contact surface between armature segment
and brush
x If any of the contact surface between brush 3
and segment is rough or wears unevenly,
correct it with sand paper (#300-#500).
Check: armature
1. Coil short circuit test
Steel Bar x Hold the steel bar so that it and the armature 4
are parallel.
Armature Tester x Rotate the armature slowly by hand.
x If the steel bar vibrates or is pulled to the
armature, there is a short circuit in coil and
the armature must be replaced.
5
2. Coil ground test
x Check if there is no continuity between
segment and armature core (or shaft).
x If there is continuity, the coil is grounded and
the armature must be replaced.
6
Segment Armature Core Shaft
7
INDEX
527

3. Segment outer diameter
x If the measured value is smaller than
specified value, replace the armature.
4. Segment runout
x If the reading is greater than specified limit
value, the armature segment should be
corrected to make sure the outer diameter is
within specified range.
5. Segment appearance
x If the appearance is rough or wears as
steps, correct it with sand paper (#300-
Segment
#500).
x After the appearance is corrected, check run
out range of the segment.
6. Depression depth between segment blocks

x If the measured value is smaller than
specified limit value, the armature should be
corrected or replaced.
x To correct the armature, rub the depression
Shown in the
part as shown in the illustration.
illustration
Depression Depth
x If the wear on the depression part is as

shown in the illustration, the armature should
be corrected or replaced.
ƻ : qualified
h : unqualified
Check: overdrive clutch

If any malfunction is found in following checks, replace
the overdrive clutch.
x Rotate the shaft in direction B, check if it rotates
smoothly.
x Rotate the shaft in direction A, check if it is locked.
A
B Shaft
528
Static Load: 1 ton

Installation method
CONTENTS
Installation: front bearing
x Press-fit the front bearing with -A and -B.
-A
Front Bearing -B
x After press-fitting, rivet slot on the front bearing

Dynamic Load: 3 ton with claws of -A.
-A
2
x Avoid re-rivet at riveted place.
Claw Claw
Front Bearing
Installation: yoke iron and brush seat 3

x The installation procedures are the removal
procedures in reverse order.
(See "Disassembly: yoke iron and brush seat")
Installation: taper washer

Rear Carrier
Taper Washer x Install the taper washer on the rear carrier in the 4
direction shown in the illustration.
Installation: magnetic switch

Magnetic Switch x Align terminal S as shown in the illustration, install
Terminal S
the magnetic switch on the lever.
6
Lever
7
INDEX
529

Installation: pinion
Overdrive Clutch
Pinion x When installing the pinion, it is not necessary to
Pinion Retainer energize the starter.
Blocking Ring x Install the pinion retainer and pinion on the
overdrive clutch in the direction as shown in
the illustration.
x Install the blocking ring into the ring groove
Ring Groove of the overdrive clutch.
x Pull the pinion forcibly, install the blocking ring into

Pinion Retainer
Blocking Ring the ring groove of the pinion retainer securely.
Pinion
Ring Groove
Check after installing

Magnetic Switch Pinion Check: performance and pinion clearance
x After assembling the starter, check by energizing
it.
x When the starter is energized, the pinion will eject

and rotate. Take care not to touch it by hand.
x The magnetic switch assembly may become very
hot when checking. Take care when touching it.
S
B P H
M
x Energizing time of traction coil P must be less

than 10 seconds, Energizing time of holding coil H
must be less than 30 seconds. If it exceeds
specified time, the coils may be overheated or
blown out.
x When the starter is energized, there will be a great
current (100 A or more), use enhanced cable or
similar thick cable when checking. Also, make
sure that all connections are credible.
530

1. Performance test
CONTENTS
Terminal B
Terminal S Pinion x Set the voltage at 23 V direct current.
Terminal M
x The voltage applied cannot be more than 24 V.
x Perform following operations when the starter is

energized. Therefore, the whole test (including the
1
Ammeter Voltmeter Direct Current Power Source measurement of current which flow through the
A V + -
starter and the measurement of starter speed)
Switch must be completed in 30 seconds.
S
P H
x Turn the switch which provides current to the
B
M starter to ON. The pinion will eject and
rotate. 2

-
3
+
Switch 1 x When the switch is turned to ON, both the traction

S
Switch 2 B P H coil P and holding coil H are energized. When
M direct current power source provides a strong
current which flows from terminal B to terminal M,
the current provided to traction coil P is cut; only
holding coil H is energized. To prevent holding coil 4
from being blown out, all operations should be
completed in 30 seconds.
x Measure the current and the starter speed.

Irradiate the pinion by stroboscopic
instrument to measure the speed. 5
x Turn the switch to OFF, cut the power source
of starter.
x If the measured value is greater than specified
value, disassemble and check the starter again.
2. Pinion clearance 6
Terminal S
Terminal M
Pinion
Cable
INDEX
531

x Perform following operations when the starter is
energized. Therefore, the whole measurement
process of the pinion clearance must be
Switch 1
S completed in 30 seconds.
Switch 2 B P H
M
x Turn the switch 1 and 2 to ON to provide
power to starter. The pinion will eject and
rotate.
x After the pinion starts to rotate, turn the
switch 2 to OFF quickly (within 5 seconds) to
stop the rotation of the pinion.
x When switch 1 and 2 are turned to ON, both the

traction coil P and holding coil H are energized.
The circuit is connected so that there is no voltage
on starter terminal B, so the current is applied to
traction coil to rotate the pinion. To prevent the
traction coil from being blown out, turn the switch
2 to OFF quickly (within 5 seconds) after the
pinion starts to rotate.
x Pull out the end of overdrive clutch, then

Pinion Clearance push it in lightly to measure the amount of
axial movement, namely, pinion clearance.
x Turn the switch 1 to OFF, cut the power
source of the starter.
x If measured value exceeds specified value,
replace the lever.
Overdrive Clutch
532
7-1-8. Alternator
CONTENTS
To view A
Terminal E 2 4
Terminal P
A
Terminal B
5
1
Terminal L
4 Terminal R
3
1
x Removal sequence
1. Adjusting bolt 4. Alternator
2. Adjusting shaft 5. Adjusting plate
3. Belt *a: Alternator Carrier
4
x Be sure to disconnect the negative (-) battery cable and insulate the cable and negative (-)
battery terminal with insulting tape before removing the alternator.
x There is battery voltage on terminal B consistently, so keeping the connection of the negative (-) 5
cable is dangerous.
x Installation sequence
x Adjust the tension of belt. (Refer to section 6-5)
Service standard 6
Standard Correction
Area Service Item Limit Value
Value Method
When the speed
Above 24 A -
is 1500 rpm
Alternator output current
When the speed Trim or
(* When the alternator is hot Above 38 A - 7
is 2500 rpm replace
4 and output voltage is 27 V)
When the speed
Above 45 A -
is 5000 rpm
Adjusting voltage of adjuster (When the speed is
28.5 ± 0.5 V - Replace
INDEX
5000 rpm and the load is 5 A)
* Hot: the state of alternator after it operates at a speed of 5000 rpm and under the biggest output load
for 30 minutes in normal ambient temperature.
533

Service method
Check: alternator
x There are two methods of check: simple check performed with engine load and detailed check
performed on the tester after being removed from the engine.
x When any malfunction is found in simple check, the alternator should be checked,
disassembled, serviced detailedly.
1. Alternator output current

Ammeter Voltmeter
(a) Simple check
A x Connect the meter with the alternator as
Switch
x To prevent possible injury, always disconnect the

negative battery terminal and insulate it with
Terminal Terminal B
insulting tape before connecting the wires. There
is battery voltage on terminal B consistently when
the negative (-) battery terminal is connected.
x When connecting with the switch, the diameter of
the cable in use should be the same as or greater
than that of the chassis wiring connected with
terminal B.
x Turn the switch on, make sure that the

voltmeter indicates the battery voltage.
x Start the engine.
x Immediately turn on the switches of all the
vehicle lights.
x The engine accelerates to the speed as
shown below, and measure output current of
the alternator.
About 2500 rpm
x If the measured value is 70% or more of
rated output current, the alternator is normal.
Alternator rated output
Alternator Voltage Output Current
50 A 24 V 50 A
534

(b) Detailed check (bench test)
Voltmeter Direct Current
Ammeter x Connect the alternator as shown in the
CONTENTS
Power Source
+ -
illustration.
(+)
(-)
Switch A x Use wires which have enough thickness for

connection, and each connector should be
Switch B tightened securely.
1
E
B: terminal B
Loaded Resistance E: terminal E
(Changeable Resistance) L: terminal L
B R: terminal R
x Increase the loaded resistance to maximum
L 2
Driving Motor of Alternator value (There is almost no load current).
R Alternator x Turn switch A and B to ON.
x Adjust the loaded resistance, the alternator
operates at a speed of 5000 rpm for 30
minutes to achieve current shown below.
Alternator rated current
Current 3
about 45 A
x Measure the alternator current at each

specified speed.
x If measured value exceeds standard value,
disassemble and check the alternator. 4
2. Adjuster adjusting voltage

Direct Current
Ammeter Power Source Voltmeter (a) Simple check
A V
x Connect the meter with the alternator as
Terminal 5
B
Switch
x To prevent possible personal injury, always
disconnect the negative battery terminal and
Terminal insulate it with insulting tape before connecting
the wires. There is battery voltage on terminal B
consistently when the negative (-) battery terminal 6
is connected.
x When connecting with the switch, the diameter of
the cable in use should be the same as or greater
than that of the chassis wiring connected with
terminal B.
7
x Turn the switches of lights, heaters, etc. off
so that there is no electrical load when
checking.
x Turn the switch on, then start the engine.
INDEX
x If the output current is below 5 A when the

engine speed is 2500 rpm, measure the
voltage of terminal B at this time.
535

When the output current is above 5 A, the
battery is charged, so the measured value
will be lower a bit.
At this time, the battery will be charged until
the current drops below 5 A or replace it with
a battery that is fully charged.
check it again on the tester.
3. Detailed check (bench test)

Direct Current x Connect the alternator as shown in the
Ammeter Voltmeter Power Source illustration.
+ -
B: terminal B
(-)
E: terminal E
(+)
Switch L: terminal L
R: terminal R
x Set the direct current power source at 24 V.
x Turn the switch to ON.
E Alternator x The alternator should operate at a low
speed.
Driving Motor x Increase the alternator speed to 5000 rpm,
B of Alternator and measure the voltage (adjusting voltage)
at this speed. At the same time, always
L make sure that the current is 10 A or lower
when the speed is 5000 rpm.
R x If measured value exceeds standard value,
perform the following operations:
x If it exceeds standard value: replace
the adjuster.
x If it is lower than standard value: check
related parts of the alternator before
replacing the adjuster.
536
CONTENTS
3
4
5
6
7
2
1
1
Ta
12
3
10
11
8
4
x Disassembly sequence
1. Pulley and fan 7. Front carrier
2. Spacing collar 8. Magnetic coil
3. Rear bearing 9. Stator
4. Rotor 10. Adjuster
5. Cap 11. Rectifier
6. Front bearing 12. Rear carrier
5
x Do not remove the front and rear bearing, stator unless they are damaged.
x Assembly sequence
The installation procedures are the disassembling procedures in reverse order.
Service standard
Correction
6
Method
Magnetic coil resistance (when
8 6.1-7.1 : - Replace
the temperature is 20°)
Tightening torque
Unit: Ngm {kgfgm} 7
Symbol Tightened Parts Tightening Torque For Reference
Ta Nut (for installation of pulley) 132-162 {13-17} -

INDEX
537
Rear Carrier
Disassembly method
Stator Front Carrier Disassembly: rotor and front carrier
x Remove the bolts for installing the front and rear
carriers.
Flathead Driver
x Insert the screw driver between front carrier and
stator.
x Pry up the rotor and front carrier assembly with
screw driver so that they are separated from the
Bolt stator and rear carrier.
x Take care not to insert the screw driver too deep,

as this may lead to damage to the stator coil and a
short circuit may occurs.
Coil
Disassembly: pulley
Nut x Hold the rotor with pliers, remove the pulley after
Pulley Claw disconnecting the nut.
Pliers
Rotor
x Clamp the rotor in the bench vise, always clamp
the supporting part of the core claw. If clamping
the core claw, this may cause damage.
Supporting Part Supporting Part
Disassembly: magnetic coil

x Remove screw A (2 places).
Screw B
x If screw B is removed firstly, the weight of

magnetic coil may be loaded on the part
connected with the adjuster, while the adjuster is
held with screw A, so the connecting part will be
Screw A damaged. Only remove screw A firstly to avoid
this condition.
x Remove screw B (3 places).

Magnetic Coil
x When screw B is removed firstly, the magnetic coil

will drop because of its own weight. Hold the
magnetic coil by hand.
x Remove the magnetic coil.
538
CONTENTS
x Do not remove the magnetic coil forcibly. Or the
part connected with the adjuster may be hooked
by the stator coil.
Disassembly: stator
Cable
x Disconnect the cable of stator from the rectifier. 1
The cable is welded to the diode of rectifier at 4
points.
x The soldered point should be hot-opened as

Diode quickly as possible (within 5 seconds), or the 2
Rectifier Stator
diode will be damaged easily due to heat.
Check method
Check: magnetic coil
x Measure the resistance between each magnetic
coil terminal. 3
replace the magnetic coil.
4
Check: stator
x Perform following checks. If any malfunction is
found, replace the stator.
1. Continuity condition between each cable
x Check if there is continuity between each
stator cable. 5
x If there is no continuity, the cable is already
broken.
2. Continuity condition between each cable and

core 6
x Check if there is no continuity between cable
and core.
x If there is continuity, there is a short circuit to
the cable.
7
INDEX
539

Check: rectifier
E x Check if the diodes in the rectifier operate
properly. If any malfunction is found, replace the
A rectifier.
B
C F If the resistance is infinite in the two cases, there is
an open circuit on the diode.
D
If the resistance closes to 0 : in the two cases,
there is a short circuit on the diode.
G
A, B, C, D: the cable connecting area of the stator
coil
B F E, G: radiating area
E
F: adjuster connecting area
x Alternately test it two times using the positive rod
and negative rod of the tester when checking.
x When checking it with tester, the current which
flows through the rectifier is less than usual
current. Therefore, the resistance value indicated
A D
C G by the tester may be incorrect.
Also, the lesser the tester range is adjusted, the
greater the incorrect indicating value becomes.
So the tester should be adjusted to the maximum
range position as mush as possible.
Installation method
Installation: stator
x Install the stator in the reverse order of
disassembly.
(See "Disassembly: stator")
540
7-1-9. Pre-heating system
CONTENTS
x Turn the starter switch to OFF.
x Connect the check light with the heating plug.
Check Light x When the check light does not come on, check the
heating plug.
x If there is any abnormality, replace the heating
plug.
1
Heating Plug
7-1-10. Safety relay

2
x Measure the output voltage of each safety relay
terminal.
Safety Relay
Terminal P 3
Terminal R
Terminal L
Terminal E Terminal S
Service standard
4
When the engine is Replace the alternator or
Below 1 V -
stopped wiring
Output voltage of When the engine is
terminal P running Check and replace the
12-16 V -
(more than 600 rpm in wiring
an idle condition)
Output voltage of When the engine is Check and replace the 5
about 24 V -
terminal R running wiring
x When the voltage is
close to the battery
-
When the engine is voltage, replace the
Output voltage of
started Below 1 V - safety relay.
terminal S
(in rotating condition) x When the voltage is 6
0 V, check and
replace each part.
x Replace
x When the voltage is
Below 5 V
Output voltage of When the engine is close to the battery
(but it is not 0 -
terminal L running voltage, check and
V)
replace the 7
alternator or wiring.
INDEX
541
Alternator
E B P
L R
To Heating Plug Relay
To Starter Relay Terminal L

Starter Switch
OFF
Voltmeter
S E L R P (+) R1
AC
(-) START
Safety Relay B R1 AC BR C
Ground
+
-
Battery
+
-
1. Check output voltage of terminal P

x Measure the voltage between terminal P of safety relay and ground, if measured value
exceeds standard value, check each part of alternator or wiring, if there is any abnormality,
x Start the engine, measure the voltage when the engine is in an idle condition (more than
600 rpm). When the measured value is 0 V, because there is a short circuit on the wiring
connected with terminal P, check the wiring or connecting parts of connector. If there is any
abnormality, replace the poor parts.
Alternator
E B P
L R

Starter Switch
OFF
Voltmeter
S E L R P (+) R1
AC
(-) START
Ground
+
-
Battery
+
-
542

2. Check output voltage of terminal R
x Measure the voltage when the start switch is turned to ON. If measured value deviates
CONTENTS
standard value, check each part of wiring; if there is any abnormality, replace the poor
parts.
Alternator
E B P 1
L R

Starter Switch
OFF
Voltmeter
S E L R P (+) R1 2
AC
(-) START
Ground
+ 3
-
Battery
+
-
7
INDEX
543

3. Check output voltage of terminal S
x Turn the starter switch to START position, measure the voltage between terminal S and
ground in starting condition.
x If measured value exceeds standard value, check each part, if there is any abnormality,
x Start the engine and keep it in an idle condition (more than 600 rpm).
x Measure the voltage of terminal P, if measured value exceeds standard value, replace the
alternator.
x Make sure that the indicator light does not come on in idle condition. When the indicator
light comes on while the voltage of terminal P is normal, replace the safety relay.
Alternator
E B P
L R

Starter Switch
OFF
Voltmeter
(+) S E L R P (+) R1
Voltmeter AC
(-) (-) START
Ground Ground
Indicator
+
-
+
-

Battery
4. Check output voltage of terminal L

x Measure the voltage when the starter switch is turned to ON, if measured value exceeds
standard value, replace the safety relay.
When measured value is close to battery voltage, check the alternator or wiring, if there is
any abnormality, replace the poor parts.
544
ELECTRICAL SYSTEM - Display
7-2. Display
CONTENTS
7-2-1. Parameter specification:
Display: TFT-color display, 5.6 inch, 320×240 Pixel, 16 digit color, 400 cd/m2,
contrast > 400
Central processing unit: 16 digits Siemens C167CR-LM series, 20 MHz
Memory: 1 MB memory [BIOS], 2 MB memory, 512 kB SRAM, EEPROM series 32
kB, 1 SD memory slot 1
Digital potentiometer: the rotating encoder with pressure input, increasing by 30 for every circle
Power: Maximum 8-60 VDC, switch calibration instrument, no confluence and
with polarity protection, maximum closing current 100 PA
Audio convertor: at least it is a piezoelectric audio convertor, 80 dBA
Clock: time damping for two circles
Operating temperature: -25° - +65qC 2
Protecting level: IP6K5
Vibrating frequency: 0.35 mm/beat [10-59 Hz] and 5 g/axis [60-300 Hz]
Impulse: 30 g/11 ms, 10 times/axis
High frequency immunity: at least 100 V/m
High frequency launch: the same standard as that of the ISO/CD 14982 and 75/322/EEC
Echo-sounder : r15 kV air voltage 3
Tool pulse: the same standard as that of ISO 7637 -2, -3 (Pulses 1, 2, 3a, 3b, a, b)
7
INDEX
545
7-2-2. Structures, functions and operations
Main components of operating screen

1. Warning indicator.
x when the controller detects any trouble and
1
submits, this indicator turns red . And it turns
off in normal condition.
2 2. Screen displaying area.
x This area displays the content as requried.
3. Operation keys
x Here the functions of the five keys are
indicated by the above icons. Functions vary
3 according to different screens.
4. Function keys
x Keys of Up, Down, Left, Right, ESC, ENTER
F1 F2 F3 F4 F5 4 are used to set password, select item and
ESC Enter
switch screen. Functions vary according to
5 different screens.
5. ENCODER
x This knob can be turned left and right to
adjust value; the knob can also be pressed it
serves as Enter key in some screens;
Functions vary according to different
screens.
Main screen function:

1. Two gauge outfits
x The above one is water temperature gauge
with a range of 0~120qC.
Sany Heavy Machinary Hydraulic Excavator The below one is a fuel gauge with a range
of 0~100%.
V
2. Working mode is displayed on the top left
corner
C H
x There are four modes as S, H, L, B. Default
mode is S mode while B is smash hammer
mode.
E F
x Press F1 to switch working modes.
12345 : 12 12 12 : 12 : 12
6 Lo 3. Accelerator gear is displayed on the top right

x Turn accelerator knob clockwise with gear
F1 F2 F3 F4 F5 changing from 1 to 11.
ESC Enter
4. Working hours is displayed on the lower left
corner.
5. Current system time is displayed on the lower
right corner.
6. Idle/full - speed switch
x When idle, icon is a white tortoise with blue
background. When full speeding, icon is a
white rabbit with red background.
x Press F2 to switch between idle and full
speed.
546

7. High-low speed switch during tracking
x Low speed condition icon is white "LO" with
CONTENTS
blue backgroud and high speed condition
icon is white "HI" with red background.
Everytime the excavator is started, the
system is in low speed condition icon.
x Press F3 to switch between high and low
speed during tracking.
8. Trouble confirmation 1
x When trouble occurs, it will be indicated by
the acousto-optic warning and trouble
codes, and press this key if you want to stop
warning; trouble indicating acousto-optic will
disappear in 5 seconds automatically. If
trouble stays all the time, trouble code will 2
not disappear.
x Press F4 to perform trouble confirmation.
9. Press F5 to perform information inquiry
Password enter screen

3
1. Password enter screen will appear when
performing information inquiry, system
settings and item settings.
Information Inquiry 2. Password input operation
x Press F1 to adjust corresponding value with
Please Input Information Inquiry Password: cycling range of 1~9. 4
x Press F2 to switch input positions which
0 0 0 0 0 cyclingly change from left to right.
x Press F3 to confirm the password. After
inputting password, press this key to confirm
whether the input is right. If it is right, enter
the corresponding screen. If not, password
5
incorrect hint will appear and stays on the
F1 F2 F3 F4 F5
current screen.
ESC Enter
7
INDEX
547

Accelerator mechanism inquiry screen
1. Accelerator gear inquiry
x To inquiry the accelerator gear in the current
working condition, turn accelerator knob
Accelerator Mechanism Signal clockwise with the gear changing from 1 to
11.
Accelerator Gear N: 12 2. Engine speed inquiry
Engine Speed rpm: 1234
x Inquiry the engine speed in current working
condition. When the accelerator is fully
Gear Position V: 1.23
depressed, the speed is about 2250 rpm.
Accelerator Position V: 1.23
3. Gear position inquiry
4. Accelerator position query
x Inquiry the feedback voltage corresponding
to the accelerator position. Feedback
F1 F2 F3 F4 F5
voltage is about 3.6 V when the accelerator
ESC Enter
is fully depressed.
Pilot pressure signal inquiry screen

x Inquiry pilot pressure signal of every movement of
boom lifting, boom lower, arm digging, arm
dumping, bucket digging, bucket dumping, swing,
Pilot Pressure Signal-2 left tracking, right tracking in current working
condition.
x Press F1 or direction keys below to switch relevant
Bucket Digging Kg: 123
pressure signal inquiry.
Bucket Dumping Kg: 123
Swing Signal Kg: 123
Left Tracking Kg: 123
Right Tracking Kg: 123
F1 F2 F3 F4 F5
ESC Enter
548

Information inquiry screen
CONTENTS
1. This screen is an entry switching to
information options to inquiry.
2. Options switch
Information List x Press F1 to switch from up to down; or turn
ENCODER knob to switch options, and press
Running Information Inquiry this knob can enter corresponding options for
Machine Configuration Inquiry details. 1
Trouble Information Inquiry
Accelerator Mounting Assistance 3. Information hint
System Language Selection
x There is a line of small green words which
introduces the selected option briefly on the
Parameter of Engine, Main Pump and Main Valve During Running top of the key indicator icons in the current
screen.
4. System function settings 2
x
F1 F2 F3 F4 F5
Press F5 to enter system function settings.
ESC Enter
x Function keys below can select the listed
items.
3
System setting screen
x The six functions have their own passwords
separately. Inputting the password will enter
corresponding setting item.
System Settings x Protection parameter settings and protection
touching settings are spare extension connector 4
System Clock Calibration
which is temporarily not used.
Working Time Calibration x Display parameter setting screen adjusts display
Machine Configuration Calibration brightness and other parameters.
Protection Parameter Settings
Protection Release Settings
x Press F1, F2 or the function keys below to switch
Display Parameter the items to be adjusted.
5
F1 F2 F3 F4 F5
ESC Enter
7
INDEX
549

System clock calibration screen
1. Displaying content
x Current time (green) displays current display
system time.
System Clock Catibration x Calibration time (yellow) displays the time
that the user is to calibrate.
Current Time:
2. Time adjustment
1234 · 12 · 12 12 : 12 : 12
x The key ENCODER is used to adjust time and can
Calibration Time: move among the adjusted data when the frame of
1234 · 12 · 12 12 : 12 : 12
data is greg.
x To adjust a certain data, press key ENCODER. At
Hint: please use knob to calibrate system time! this time, the frame of data turns purple, and the
data can be adjusted by turning ENCODER.
3. Time calibration confirmation
F1 F2 F3 F4 F5
x Use F1 to confirm that time calibration is
ESC Enter
completed. After pressing this key, the
calibration time takes effect immediately.
x After the setting is completed, make sure that the

complete vehicle power must be cut off once in
normal condition.
Working time calibration screen

1. Displaying content
x Current working time record (green)
indicates current working accumulated time.
Working Time Calibration x Calibrating working time (yellow), white
value indicates calibrating working time; H
Current Working Time:
indicates the hour number, M indicates the
12345 h 12 m minute number. Record minimum interval is
1 minute.
Calibrating Working Time:
12345 h 12 m 2. Calibrating result confirmation
x The method of adjusting the value is the
Hint: please use knob to calibrate working time!
same as that of adjusting in system clock
calibration screen.
x Using F1 to complete calibrating result
F1 F2 F3 F4 F5
confirmation.
ESC Enter
x After calibrating is completed, make sure that the

complete vehicle power is cut off once in normal
conditon. The power off condition should last
more than 1 minute to memorize the set data
normally.
550
7-2-3. Removal and installation
CONTENTS
Removal
1. Disconnect the display connectors.
x Before removing, turn the key switch to OFF

position. 1
Display Display Display 2

Set Plate Connectors
2. Remove 3 mounting bolts and remove the set

Mounting Set Plate plate and display set from mounting bracket.
Bracket
3. Loosen set nut and remove the display from 3
Screw installing panel.
Display
Installation
Display The installation procedures are the removal procedures
Connectors
Bolt in reverse order.
4
5
7-2-4. Connector mode and wiring
12 GND 0 +12V 29 7
12 11 10 9 8 7
6
1 CAN+ CAN- 6
1 2 3 4 5 6
Wire Socket Terminal

Display Junction Terminal Model: TOUCH DT06-12S
7
INDEX
551
ELECTRICAL SYSTEM - Controller
7-3. Controller
7-3-1. Structure
Operating Panel Controller Pilot Valve Driving Cab
Tracking Tracking Speed Adjusting Motor

Boom lowers Position Setting
after lifting Arm forward
or retract
RPM Bucket digs
Swing Spare
or dumps
H S L B
MIN MAX
Operation position
of using power
KC Controller Input Pressure Sensor

H/S/L/B
Cancel automatic idling
Switch tracking speed
Output
Abnormal
Main Control Valve

Tracking speed
Swing priority
Arm (1)
Bucket confluence
Boom priority
Boom (1)
KC
Controller
Pump proportioning Arm
Control the pressure-relief solenoid Pump
reclining of P2
rear pump Tracking
Control the
reclining of P1
front pump Tracking
Pressure
Sensor
CAN information transfer path
Magnetic Pulse Swing

Generator
Actual speed
of engine Speed adjusting
Boom (2)
motor
Actual speed
adjusting Potentiometer
Arm (1)
Control motor Engine speed

Motor adjusting
H S L ESS Engine
Compartment
RPM
Power Source UP DOWN MODE SET Fuel, water

DC24V (battery) temperature and others
552
7-3-2. Installation and removal
CONTENTS
Removal
House Cover 1. Remove the house cover and air conditioning
cover plate.
x Before removing, turn the key switch to OFF 1

position.
Controller Connectors 2. Remove controller connectors CN-615 and CN-

CN-615 616
2
᥻ࠊ఼
Controller
Controller Connectors
CN-616
Connectors No. Body Wire Harness 3
Relay Wire Harness Relay 3. Remove assist-controller installing panel

Assist-controller Installing Panel x Remove the mounting bolt. Remove assist-
controller, relay and relay wire harness as
well as assist-controller installing panel.
4
Assist-controller
Mounting Bolt
4. Remove four controller mounting screws, and 5

Assist-controller Installing Panel Controller
remove the controller from installing panel.
Installation
x The installation procedures are the removal
procedures in reverse order.
6
Controller Installing Panel
Controller Set Screw
7
INDEX
553
7-3-3. Connector and wiring
Controller Junction Terminal A1 Controller Junction Terminal A2
4 5 116 115 114

42 24 B07 B05 B06 RXL TXL 108B 507 509 6 89 703 702 607 82
0 0
43 B08 B07 B04 RXH TXH 108A 506 500 511 510a 25 97 90
3 118 117
62 B02 B01 CAN+ CAN- 50 00 00 502 202 207 204 200 508 44 105 MT+ 603 602 604 608 98
0 42 42
113 MT- 106
81 B01 B03 B02 CAN- CAN+ 50 50 00 501 203 206 205 208 201 63
121 120 119
1 2
Wire Socket Terminal A1 Wire Socket Terminal A2

Wire Cable Markers CN-615F Wire Cable Markers CN-616F
Model: Bosch AMP1473244 Model: Bosch AMP1473252
554
7-3-4. Trouble diagnosis and protection motion
CONTENTS
x Detecting abnormality/protection motion list
On-off Times
Abnormal Content (Abnormality Cause Motion
code)
The out of control of CPU is
detected by WDT. The reason
Disconnect drive circuit power,
CPU trouble - may be environment temperature 1
CPU restarts
above standard and foreign noise,
etc.
Do not start until correct
Memory trouble (RAM) On
When the power is on, FROM handling
check or RAM verify check, Stop the drive of motor and
Memory trouble detection is abnormal.
11 solenoid coil and do connect
(FROM)
the power again
2
Motor current is Detect that the motor load pipe Stop motor driving at the time
abnormal line is abnormal. When the power of detection. Do turn the power
(Above 1.8 A) is on, current below 0.1 A or on again.
above 1.8 A lasts 2 seconds. Stop
Motor current is the current output by driving
abnormal 12 protection circuit action. Open 3
(Below 0.1 A) circuit and ground short circuit. Only when the alarm output
Limit the rotation of the motor. condition is normal, the alarm
resets automatically.
Motor connection is Detect that motor connection is
abnormal abnormal. Open circuit and
(Open and short) ground short circuit.
Detect that the motor pauses.
Stop motor driving at the time 4
Position deviation is above 5%
of detection and the alarm
Motor motion pauses 13 when the power is turned on for
automatically resets when the
30 seconds. Motor is hitched or
condition is normal.
hooked, etc.
When the voltage below minimum Return to automatic idle
tracking limit position voltage (0.8 position at the time of
Motor preforms badly
14 V) or above maximum tracking detection and the alarm 5
within motion range
limit position voltage (4.2 V) lasts automatically resets when
100 msec. condition is normal.
Stop the drive of motor and
Power voltage is
15 Power voltage is above 36 V. solenoid coil and do connect
abnormal
the power again
Stop the drive of motor, 6
Inner temperature It lasts 10 seconds when the
solenoid coil. The alarm
of the controller is 16 controller inner temperature is
automatically resets when the
abnormal above 80qC or below -30qC.
Detect that the power output of Only when the alarm output
Sensor power is
17 the sensor is abnormal. Short condition is normal, the alarm
abnormal
circuit or overcurrent. resets automatically.
Communication of the Response communication from Only when the alarm output 7
operating panel 18 control panel controller stops for 5 condition is normal, the alarm
controller is abnormal consecutive times. resets automatically.
Only when the alarm output
Spare battery Detect that spare battery voltage
19 condition is normal, the alarm
INDEX
voltage is too low is abnormal.

Simulation quantity inputs (Open and short)
555
On-off Times
code)
Front pump output
AIN0 20
pressure
Rear pump output
AIN1 21
pressure
Arm retraction pilot
AIN2 22
valve pressure
Arm forward pilot valve
AIN3 23
pressure
Boomlifting pilot valve
AIN4 24
pressure
Only alarm outputs
Boom-lower pilot valve The voltage out of 0.25 ~ 4.75 V
AIN5 25 and automatically resets when
pressure continues for 200 msec or more.
Bucket digging pilot
AIN6 26
valve pressure
Bucket dumping pilot
AIN7 27
valve pressure
Swing pilot valve
AIN8 28
pressure
Left tracking pilot valve
AIN9 29
pressure
Right tracking pilot
AIN10 30
valve pressure
Return to automatic idle
position at the time of
detection. Do not detect when
Motor setting The voltage out of 0.25 ~ 4.75 V
AIN11 31 performing memory operation.
potentiometer continues for 200 msec or more.
And the alarm resets
automatically in normal
condition
Stop the motor driving at the
Motor built-in The voltage out of 0.25 ~ 4.75 V time of detection. And the
AIN12 32
potentiometer continues for 200 msec or more. alarm resets automatically in
normal condition
Spare pilot valve The voltage out of 0.25 ~ 4.75 V
AIN13 33 condition is normal, the alarm
pressure continues for 200 msec or more.
AIN14 34
AIN15 35
AIN16 36
The voltage out of 0.25 ~ 4.75 V
Oil temperature sensor AIN17 37 condition is normal, the alarm
continues for 200 msec or more.
AIN18 38
Water temperature
AIN19 39 No abnormality is detected.
sensitive resistance
Fuel meter AIN20 40
Puls input is abnormal
556
On-off Times
CONTENTS
code)
CPU detects that engine speed is
too slow. The speed is blow 100
Engine speed PLS0 41 condition is normal, the alarm
rpm. Speed sensor is open and
short.
PLS1 42
PLS2 43
1
The Current Proportioning Solenoid Coil is abnormal (Excessive current)
Front pump PSOL+0 50
Rear pump PSOL+1 51
Swing priority PSOL+2 52
Detect that the loaded circuit of 2
Bucket confluence PSOL+3 53 the proportioning solenoid coil is
Stop the motor driving at the
abnormal. The current above 1.8
Boom priority (1) PSOL+4 54 time of detection and do turn
A lasts 1 second. Deviation
on the power again.
Boom priority (2) PSOL+5 55 current occurs on the drive
protection circuit. Open and short.
PSOL+6 56
PSOL+7 57
3
PSOL+8 58
7
INDEX
557
On-off Times
code)
The Current Proportioning Solenoid Coil is Abnormal (Current is not enough)
Front pump PSOL+0 50
Rear pump PSOL+1 51
Swing priority PSOL+2 52 Detect that the loaded circuit of
the proportioning solenoid coil is
Bucket confluence PSOL+3 53
abnormal. Deviation current Only alarm outputs
Boom priority (1) PSOL+4 54 above 0.1 A lasts 1 second. and alarm automatically resets
Deviation current occurs on the when condition is normal.
Boom priority (2) PSOL+5 55
drive protection circuit. Open and
PSOL+6 56 short circuit.
PSOL+7 57
PSOL+8 58
ON/OFF solenoid coil connecting is abnormal (Open and short)
Switch the tracking
SOLO-1 60
speed
SOL2-3 61
Detect that ON/OFF solenoid coil Only alarm outputs
SOL4-5 62 connecting is abnormal. Open and alarm automatically resets
SOL6-7 63 and short circuit. when condition is normal
SOL8-9 64
SOL10-11 65
Power
Source
LED
LED
(Prepared by customer)
13 mA
558
CONTENTS
1. In normal condition, the LED will be off after turning on the power for 3 seconds.
2. In normal condition, the LED turns on and off repeatedly according to the specified times (at an
interval of 0.5 second) and then turns off for 1.5 seconds. In other cases, the LED turns on and
off repeatedly according to the specified times (at an interval of 0.5 second) and then turns off
for 4 seconds.
(For example) When abnormal code is 34 the LED turns on and off repeatedly for 3 times and
1
then turns off for 1.5 seconds, and it turns on and off repeatedly for 4 times and then turns off for
4 seconds.
3. All abnormal codes detected are output in sequence.
7
INDEX
559
Radio Antenna
Black one is audio left sound output -
ELECTRICAL SYSTEM - Radio
White one is audio left sound output +
Head Unit Rear Panel

Gray Black one is audio right sound output -
Gray one is audio right sound output +
Black one is ground wire
Power source, ground,

and audio output
Yellow one is BATT power source
Red one is ACC igniter
White one is audio left sound input

Audio input
7-4-1. Structure
Main structure
Red one is audio left sound input
7-4. Radio
Wiring
560
2.
1.
ELECTRICAL SYSTEM - Radio
CONTENTS
Removal
Armrest Box
1. Remove armrest box cover.
Cover
Turn off the power before removing.

1
Radio
2. Remove radio connectors CN-003F
Connector CN-003F Driving Cab Wire 3
3. Remove four mounting screws and washers,

remove radio receiver and radio mounting
Armrest bracket from armrest box.
Box
4. Remove four set screws and washers and
remove radio receiver from the mounting 4
bracket.
Radio
Radio Mounting Washer
Bracket Screw
Installation 5
x The installation procedures are the removal procedures in reverse order.
7-4-3. Connector mode and wiring
1 2 3 6
1 2 3 20b R+ L+
0 20b R- L-
4 5 6 7
4 5 6 7
Wire Socket Terminal 7

Radio Wiring Terminal
Model: TOUCH DJ7072-3-21
INDEX
561
ELECTRICAL SYSTEM - Battery
7-5. Battery
7-5-1. Structure
B A
2
10 J C
11
6 E
D
F
8 7 5 9 4 3 1
1 - Spin-on End Post 2 - Charged State Indicate Densimeter 3 - Heat-sealing Top Cover
4 - Polypropylene Housing 5 - Centre Ear-pole 6 - Forging Grid
7 - Active Material Paste 8 - "Pocket" Panel 9 - Polar Group
10 - Liquid-gas Separator 11 - Center BPCU Bus
x Before removing, turn the key switch to OFF position.

x Do not remove the charged state densimeter. If it is loose, forcibly tighten it clockwise with
proper tool.
1. Removing battery ground cable

Battery Battery
Set Bolt x Lift the waterproof cap, loosen the set bolt,
Terminal Ground Cable
and remove the battery terminals from the
post.
VART
A
x Battery gas may cause explosion. Keep the

Battery
㪘 ⬉ ∴
‫ ܡ‬㓈 ᡸ
1$1*(
)5((%
$77(5< battery away from the spark and flame.
0$,17(
562
ELECTRICAL SYSTEM - Battery

2. Remove the battery connecting wire and
Battery Connecting Wire
battery breaker wire.
CONTENTS
VARTA
VARTA
Battery Battery Breaker Wire 1
3. Remove the 4 mounting bolts and the shim,

Battery then remove the battery box from the base
board and take out the battery.
VAR
2
TA
TA
VAR
Mounting Bolt Shim Battery Box
Installation
4
x The installation procedures are the removal procedures in reverse order.
7-5-3. Replacement
There are two 12 V batteries with negative terminals (-) grounded. If one battery in the 24 V system
fails while the other functions, the failed one should be replaced with one of the same kind. According
to different batteries, charging speed differs. This difference may make either one fail to function due 5
to overload.
Apply geoline to the battery terminals to avoid erosion when installation.

6
7
INDEX
563
ELECTRICAL SYSTEM - Key switch
7-6. Key switch
7-6-1. Structure
23 22 20 18 17 15 13 12,11 28 6 10,9,8,7
SANY
SANY
25,24 21 1 14 19 16 26 5 4,3,2
27
4 5 6
1 2 3
1 - Case Body 2 - Key 3 - Key Ring 4 - Key Knob

5 - Nut 6 - Cylinder 7 - End Cap 8 - Shutter
9 - Shutter Pin 10 - Shutter Spring 11 - Turn-Table 12 - Turn-Table Spring
13 - Plug 14 - Swing Body 15 - Spring Cover 16 - Reset Spring
17 - Ball 18 - Ball Spring 19 - Contact Points SPR-B 20 - Contact Points A
21 - Terminal Blocks 22 - Contact Points SPR-A 23 - Contact Points B 24 - Terminal
25 - Bolt 26 - O-ring 27 - Wiring Harness assembly 28 -Washer
564
CONTENTS
Removal
21
67$5
7 0$
;
1. Remove the lock screw and the armrest box
cover.
2))
&.
/2
0,1
Key Switch Armrest Box Cover Lock Screw
2. Remove the two lock screws, and remove the

Lock Screw Armrest Box Cover
installing panel and key switch from the
armrest box cover. 2
Disconnect the key switch connectors before

removal.
3
Mounting Panel Key Switch

4
3. Remove the nut and remove the key switch
from installing panel.
Key Switch Installing Panel Nut
7
INDEX
565
7-6-3. Key switch inner principle and wiring

Inner principle
On-off Condition
Gear Battery Battery Electrical Accessory Glow Plug
(B) Relay (BR) (ACC) Starting Relay
(R1) (R2)
3B
OFF
1B
2B
Wiring
1 B BR ACC 3 1 22 13 3
4 R1 R2 C 6 4 16 11 6
Wire Plug Terminal

Key Switch Wiring Terminal Sheath Model: YAZAKI 7123-7464-30
Sheath Model: YAZAKI 7222-7464-30
566
ELECTRICAL SYSTEM - Fuse box
7-7. Fuse box
CONTENTS
Removal
House Cover 1. Remove the house cover.
2
2. Remove the tightening bolt to remove the rear
Rear House Cover Fuse Box Cover house cover together with the fuse box.
4
Tightening Bolt
3. Remove the tightening bolt to remove the fuse

Fuse Box Wire
box with fuse wire harness from rear plate.
Tightening
Bolt 5
Rear Plate
6
7
INDEX
567
ELECTRICAL SYSTEM - Fuse box
7-7-2. Fuse box fuse function and ampere value
Ampere Value
Number Number
5A 20A
F2 F1
F4 15A 5A F3
F5 5A 10A F7
F6 F9
10A 5A
F8 F14
F10 20A 10A
F11 5A
F15
20A
F16
F17 15A
10A
10A
F2 - Charge Indicator
F1 - Startup Circuit F3 - Horn Circuit F4 - Working Light
Light
F5 - Wiper, Washer F6 - Audio F7 - Cab Light F8 - Air Conditioning
F9 - Service Light F10 - Display F11 - Controller F14 - Assist-controller
F15 - Cigarette
F16 - Solenoid Valve Set F17 - Headlight
Lighter
When replacing the fuse, make sure to install a fuse with correct ampere value to avoid damage to
the electric system due to overload.
568
ELECTRICAL SYSTEM - Wiper
7-8. Wiper
CONTENTS
7-8-1. Main structure and principle
Main components
Wiper Blade
Rotating Mechanism
Wiper Arm
3
Wiper Motor
Connector
Mounting Bracket
4
7
INDEX
569

Inner principle chart
Green Wire
(Low Speed)
Yellow Wire
(Reset)
Blue Wire
( High Speed)
Red Wire
(Power Source +)
Black Wire
(Power Source -)
570
CONTENTS
Removal
Inner 1. Remove the inner garnishclip to remove the
Garnish inner garnish.
Clip
Inner
Garnish
1
2. Remove motion mechanism and motor

Remove the tightening bolt to remove the wiper
motor and motion mechanism from the driving 2
Tightening cab.
Bolt
Motion
3
Mechanism
Wiper
Motor
Lock Bolt
3. Remove swing and blade

Loosen the set nut and remove the wiper arm and 5
blade from the driving cab.
Wiper Arm
6
Protector
Cover
Set Nut
Driving Cab 7
Installation
INDEX
571
7-8-3. Adjustment of wiper arm angle
x Before the wiper reaches the mechanical stopper,

the wiper arm should stop motion.
Mechanical x If the wiper arm continues to move when the blade
Stopper reaches the mechanical stopper or the wiper arm
has stopped moving when the blade does not
reach the mechanical stopper, adjust the wiper
Blade moving angle to avoid wiper being burnt.
x The adjusting method is to loosen the lock nut,
and adjust the swing working angle LH and RH
Wiper Arm according to the reality to make sure that the wiper
motor just stops working when the wiper blade
reaches the mechanical stopper.
Set Nut
572
ELECTRICAL SYSTEM - Relay
7-9. Relay
CONTENTS
7-9-1. Engine relay
1. Inspecion of starter relay

S
x Perform the check of continuity condition
and motion, if any malfunction is found,
replace the relay. 1
B
S
B SW L
AA2A
1 SW (-)
2 L (-)
2
2. Inspection of main power relay
1 (+)
2 (-) replace the relay.
3 4
Battery (+) Side Terminal
3 4
4
1 (+)
2 (-)
3. Heating plug relay

5 (-) x Perform the check of continuity condition
replace the relay.
1
5 1 2 3 4
6
(-) (+)
2 4 (+)
Fuse 3
7
INDEX
573

4. Safety relay
Measure the resistance between terminal 2 and 3.
Standard Value About 200 :

(P) 6
3 (R) replace the relay.
5
(E) 4 2 (L)
1 (S)
7-9-2. Other load relays

1. Functions and positions
Relay Wire Harness

Starting Control Relay Horn Relay
Pilot Control Relay

Headlight Relay
Stopping Relay
Secondary
Boosting Relay Working Light
Relay
Mounting Panel
574
Relay Wire Harness 2. Installation and removal

Mounting Panel x Removal
CONTENTS
(1) Pull out the relay from the relay socket.
(2) Disassemble set screw, and remove the
relay socket and relay mire harness from the
installing panel.
x Installation
The installation procedures are the removal
procedures in reverse order. 1
Relay Socket Set Screw Relay

2
7
INDEX
575

3. Relay connector and wiring
1 4 2
Relay Wiring Terminal
Relay Model: HELLA 4RD 007 903-027
Secondary
Horn Relay Working Light Relay Pilot Control Relay Boosting Relay Starting Control Relay Stopping Relay Headlight Relay
K5 K6 K10 K11 K3 K7 K8
32 34 12 65 70
0 31 0 33 0 606105 51 0 105 0 63 13 0 72
B A
23 24 27 50 11 64 71
Wire Socket Terminal

Relay Socket Model: Relay Socket Sheath 8JA003526-00
576
ELECTRICAL SYSTEM - Sensor
7-10. Sensor
CONTENTS
1. Inspection of water temperature sensor
1 x Put the sensor into a container with oil.
x Increase the oil temperature to the specified
value, stir the fuel at the same time.
Body
x Measure the resistance of terminal 1 and the
body respectively.
1
50 r 0.2qC 80 r 10 :
56.3 :
60qC
(reference value)
29.5 :
80qC
Standard (reference value)
Value 16.5 : 2
100qC
(reference value)
106 r 0.3qC 14.3 r 1.0 :
10 :
120qC
(reference value)
x If the measure value is beyond the standard 3

value, replace the sensor. (Refer to Section
6-5)
2. Inspection of engine speed sensor

x Measure resistance between terminal 1 and
2.
4
Standard value (At 25qC) 2.3 r 0.2 k:
x If the measure value is beyond the standard

value, replace the sensor.
2 1
5
If the tightening torque of the engine speed sensor is
not enough, the sensor will not output signal. The
engine speed sensor must be tightened to the
specified torque. (Refer to Section 6-2)
3. Inspection of pressure sensor 6

Pressure Connector Body Connector
x Input voltage: 4.75~5.25 VDC
x Output voltage: 0.5~4.5 V
x Inspect pressure range: 0~50 BAR
Terminal A Terminal B
7
Terminal C
INDEX
577
ELECTRICAL SYSTEM - Sensor

4. Inspection of fuel level sensor
x Swing the buoy up and down, and measure
Buoy the swing angle of the lever effective radius,
that is, the swing angle between the buoy
and the swing point should be 105°.
Lever x Swing the buoy up and down and the vertical
distance between the upper position and
lower position should be 500 mm.
x Move the buoy to the upper position, and
Terminal R measure the resistance between sensor R
Case
terminal and ground using multimeter, and
resistance should be Ru İ 9.6 :.
Connector
x Move the buoy to the lower position, and
measure the resistance between sensor R
terminal and the ground using multimeter,
and the resistance should be Ru ı 86 :.
578
ELECTRICAL SYSTEM - Installation and removal method of connector terminals
7-11. Installation and removal method of connector terminals
CONTENTS
Terminal installation
1. Tightly hold the wire position about 25 mm rear
of the terminal pressed parts.
2. Hold the connector, and have the seal ring on

its rear end face you directly.
2
3. Insert the depressed terminal vertically to seal

hole end. Pull the wire lightly in opposite
direction to confirm whether the terminal is
locked up.
4
5
Terminal removal
1. Make the rear part of the connector face you,
and choose the removal tool corresponding to
wiring to enclose the wire.
2. Push the removal tool into the connector along

the wire, and make it open the terminal lock
shoulder and reach the terminal plange part. 7
INDEX
579
ELECTRICAL SYSTEM - Installation and removal method of connector terminals

3. Pull the removal tool outwards and take out the
terminal together with the wire.
580
INDEX
CONTENTS
A D
Accessory installation .............................. 33 Disassembly and assembly of
Adjuster for K3V series.......................... 117 pilot pump .......................................... 127
Adjustment of wiper arm angle .............. 572 Disassembly and assembly of tracking pilot
Air cleaner ............................................. 498 valve .................................................. 220 1
Air conditioning system............................ 78 Disassembly of central connector ......... 281
Air intake and exhaust system............... 494 Disassembly of cylinder......................... 329
Alternator ............................................... 533 Disassembly of left and right pilot
Assemble of track tensioning valve .................................................. 206
mechanism......................................... 288 Disassembly of left and right pilot
2
Assembly of central connector .............. 283 valve .................................................. 207
Assembly of cylinder.............................. 337 Disassembly of swing supporting
Assembly of cylinder.............................. 341 bearing ............................................... 239
Assembly of left and right pilot valve ..... 209 Disassembly of tensioner pulley............ 291
Assembly of proportional Disassembly of track tensioning
solenoid valve .................................... 235 mechanism ........................................ 287 3
Assembly of swing supporting Display .................................................. 545
bearing ............................................... 241 Driving cab .............................................. 63
Assembly of tensioner pulley................. 293 Dust display, heating plug ..................... 518
B E 4
Battery ................................................... 562 Engine electrical .................................... 509
Engine relay .......................................... 573
C Engine serial number, name plate ........ 348
Camshaft bush ...................................... 419 Engine ................................................... 360
Camshaft ............................................... 406 Exhaust manifold................................... 506
5
Care and maintenance standard ........... 285 Exhaust pipe and muffler ...................... 507
Care and maintenance standard ........... 295
Care and maintenance standard ........... 302 F
Care and maintenance standard ........... 308 Flywheel ................................................ 399
Central connector .................................. 279 Fuel feed and engine control................. 448
Checking of main valve ......................... 158 Fuel filter ............................................... 464 6
Connector and wiring............................. 554 Fuel injection pump ............................... 468
Connector mode and wiring................... 551 Fuse box fuse function and ampere
Connector mode and wiring................... 561 value .................................................. 568
Controller ............................................... 552 Fuse box ............................................... 567
Cooling fan and belt............................... 488 7
Cooling system ...................................... 476 G
Crank and crankshaft case.................... 410 General inspection and adjustment....... 367
Cylinder head, valve mechanism........... 371 General inspection and adjustment....... 434
General inspection and adjustment....... 460
INDEX
General inspection and adjustment....... 480
581
H Precautions for disassembly and

assembly ................................................ 1
How to read this chapter ........................343
Precautions for repair operation ............ 349
I Pre-heating system................................ 541
Pump body, repair standard .................. 113
Identifying safety symbol..........................17
Injector ...................................................471 R
Installation and removal method of
Radiator, oil cooler, intercooler .............. 486
connector terminals ............................579
Radio ..................................................... 560
Installation and removal .........................553
Relay ..................................................... 573
Removal and installation
essentials of operating valve .............. 132
balance weight ..................................... 95
Installation................................................96
central connector................................ 279
Intake manifold.......................................505
Removal and installation of cylinder ...... 322
K Removal and installation of
driving cab glass .................................. 71
Key switch inner principle and wiring .....566
Key switch..............................................564
driving cab ............................................ 63
L Removal and installation of
left pilot valve ..................................... 203
Left and right pilot valve .........................200
Lubrication system .................................425
main frame ........................................... 97
M Removal and installation of
main valve ......................................... 129
Main structure and principle...................569 Removal and installation of
Main valve (Continue) ............................139
operating valve ................................... 129
O
operating valve ................................... 148
Oil cooler................................................443 Removal and installation of
Oil cooler, oil filter ..................................445 right pilot valve ................................... 200
Oil filter...................................................442 Removal and installation of
Oil pan, oil strainer, oil jet tube...............437 solenoid valve .................................... 231
Oil pump.................................................439 Removal and installation of
Operating excavator safely ......................34 sprocket wheel ................................... 296
Other load relays....................................574 Removal and installation of
Outline....................................................343 swing motor ........................................ 178
P
swing reduction machine.................... 159
Parameter specification: ........................545 Removal and installation of
Parts replaced periodically.......................14 swing supporting bearing ................... 237
Piston, connecting rod and Removal and installation of
cylinder liner .......................................386 tensioner pulley .................................. 290
Precautions for disassembly and Removal and installation of
assembly ................................................1 the main pump ................................... 102
582
Removal and installation of Structures, functions and operations..... 546
CONTENTS
the pump unit ..................................... 102 Swing supporting clearance
Removal and installation of measurement ..................................... 243
track roller .......................................... 298 Swing unit.............................................. 159
Removal and installation of Switch.................................................... 517
track tensioning mechanism............... 286 <Spin-on> Secondary strainer filter....... 467
Removal and installation of track........... 304
Removal and installation of T 1
tracking pilot valve.............................. 213 Thermostat ............................................ 492
Removal and installation of Timing gear ........................................... 402
tracking unit........................................ 244 Track tensioning mechanism................. 286
Removal and installation of Track ..................................................... 304
work devices ...................................... 313 Tracking motor parts ............................. 246 2
Removal and installation ....................... 252 Tracking offset measurement................ 278
Removal and installation ....................... 551 Tracking pilot valve ............................... 213
Removal .................................................. 95 Tracking unit.......................................... 244
Removal, installation essentials of Trouble diagnosis and
pump body ......................................... 104 protection motion ............................... 555
Repair and maintenance ....................... 275 Troubleshooting .................................... 365 3
Replacement ......................................... 563 Troubleshooting .................................... 433
Troubleshooting .................................... 458
S Troubleshooting .................................... 479
Safety information.................................... 17 Troubleshooting .................................... 496
Safety maintenance instructions.............. 48 Troubleshooting .................................... 515 4
Safety relay............................................ 541 Turbocharger......................................... 500
Sensor ................................................... 577
Solenoid conversion valve..................... 233 U
Specification ......................................... 360 Understanding signal words .................... 17
Specification ......................................... 448
W 5
Specification ......................................... 494
Specification .......................................... 425 Warning signs and illustrations................ 54
Specification .......................................... 476 Water pump........................................... 489
Specification .......................................... 509 Wiper ..................................................... 569
Sprocket wheel and track roller ............. 296 Wiring diagram ...................................... 512
Standard of care and maintenance ....... 320 6
Standard tightening torque table ........... 357
Starter.................................................... 519
Structure and operating principle........... 510
Structure and operation principle........... 361
Structure and operation principle........... 426 7
Structure ................................................ 552
INDEX
Structure ................................................ 560

Structure ................................................ 562
Structure ................................................ 564
583
V\BIXOX$IP3DJH)ULGD\2FWREHU30
ELECTRICAL SYSTEM ATTACHED DIAGRAM
ELECTRICAL SCHEMATIC DIAGRAM
20
21
22 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
F2 F13 F3 F4 F5 F6 F7 F8 F9 F16 F17 F10 F11 F15 F14
2 SO 10A
5A 22 160A 5A 15A 5A 10A 20A 5A 10A 10A 5A 20A 15A 10A
F1 13
PO ̾̿̀ 30 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
20A 25
10 16 24 70
1 23 S4
ST ON SB1 S2 S3 S4 28 S5
3 19̾ 17 ̿ 15 27
S1 26 38
KB 20b
63
4 SQ1 SB2
20 29 42 49 43
21 X1
16 11 13 1 5
64 31 7 8
20 K7 3
105 35H 37
M1 2 4 33 72
B HLR 18 1 2 3 4 5 6
21 65 35L 105 209
KH K5 K6 K6
S
61 1 3 1 3 1 3 1 3
35L S6 57 62 63 61 60
K3 B+ B
14 36 K10 K11
GB1 1 L E A+ P2 2 5 2 5 2 5 2 5
3 P1 E D4 1 3 1 3
R P 17 34 M3 71
5 2 32
L+ R+ 2 4 2 5
S B 10 H5
L SW 4J D3 R0 HLY
12 H4 YC
1 L- R- 606 605
M2 D5
KB D2 R P
D1 S L E A1
2 A7
H1 H2 H3 D6 H1 H2
HA1 HA2 D7 D8
12a
Electrical Air Conditioning Display Controller Cigarette GPS

Working Light Secondary
Starting Starting Charging Generator Stopping Shut-down Pre-heating Pre- Pre-heating Electro- Outside Sun Load Service Pilot Operation Power Power Lighter Power
Battery Starter Battery Relay Horn Wiper Washer Audio Cab Light Pilot Solenoid Button Boosting Front Dome Light Supply Supply Power Supply
Relay Key Switch Indicator Safety Relay Relay Solenoid Valve Switch heater Indicator Rotary Table Boom magnetic Air Sensor Sensor Light Lever
Solenoid Supply
Working Light Working Light Clutch
Boom Boom Bucket High Speed Swing Front Pump Rear Pump Hydraulic Oil
+24V 24V_GND NC Propor- Proportioning Accelerator Motor Temperature CANHO CANLO CANSO TXDO RXDO GND FWE MENTE
Priority -1 Priority -2 Confluence Driving Priority tioning Valve Valve Sensor
42
C1
0 42
KCM-SETTOOLS
0
C2
MT+ MT- 2
B1 B2 B3 B4 B5 B6 B7 B8
A3 A6 A5 A2 A4 A8 Y5 Y6 R=240ohm
M A
3
D9 D10
602 603 604 607 608 609 702 703 MT+ MT- 511
A2-118/119/120/121 A1-4/5 A1-1/2/3 A2-114/115/116/117 A2-100 A2-101 A2-99 A2-82 A2-98 NC A2-88 A2-89 A2-105 A2-113 A1-31 A1-61 A1-81 A1-79 A1-62 A1-80 A1-41 A1-23 A1-22 A1-24 A1-42 A1-43
A1-60 29
CAN+ 3 8
A1-77 OPUS46 0
10
KCM Controller A1-78
CAN-
4 Screen 12 0
A1-58 9 80
Clock 22
A1-49 A1-67 A1-71 A1-52 A1-69 A1-50 A1-70 A1-51 A1-68 A1-33 A1-72 A1-53 A1-56/74/75 A1-54/55/73 A1-14 A1-32 A1-34 A1-15 A1-48 NC A1-11 A1-30 A1-38 A1-19 Power
Supply 0
200 201 202 203 204 205 206 207 208 500 501 502 50 00 520 521 506 507 508 106 509 510 108A 108B
RV1 RV2 RV3 RV10 RV9 RV5 RV7 RV6
Arm Dumping Arm Digging Bucket Dump- Bucket Digg- Boom Lifting Boom Lower Swing Spare Front Pump Rear Pump Accelerator Motor Oil High Water Fuel Coolant
Left Tracking Right Tracking
Pressure Pressure ing Pressure ing Pressure Pressure Pressure Pressure Pressure Main Main SV_VCC SV_GND Spare Diesel Flywheel Sensor
Pressure Sensor Pressure Sensor Knob Position Pressure Temperature Position Temperature
Sensor Sensor Sensor Sensor Sensor Sensor Sensor Sensor Pressure Pressure
585
DRIVING CAB WIRE
To Fuse Box CN-402F

300 DT06-12S
1 27 28 38 70 22 0 6 CN-213F
12 26 25 24 23 20b 10 7
1 2 50
282080-1 60 61
CN-001F
CN-002M 1 2 100 1000 4 23 24 70 1

27
282104-1 0 35L
8 31 33 72 71 5 To Relay Wire CN-302M
1 3 Connector SWP16FB-M/C
50 12 105 209 0 9
36 35H 25 CN-214F
To Wiper Power Supply 16 11 13 18 13

10
50
282105-1
9
CN-212M
200 150 1 2
1 50 506 00 35L 4 50 6 18 57 00 506 50 1
31 23 To Body Wire CN-612F
8 17 18 70 72 5 7 17 14 13 10 12 DT04-12P
SB1: Horn Button
CN-215M
282080-1
To Control Switch Wire CN-513M
200
CN-201F
50
Connector DT06-8S
3 CN-202F
Wire Diameter Specification Parameter:
300 800 300 800 T-202 70 1.5mm2 White
0 0 Y10-10
Wire Diameter: 10mm2
2
21 2.5mm 2
White 71 1.5mm White
T-201
250
Y10-10 20 2.5mm 2
White 38 1.5mm2 White
Wire Diameter: 10mm2 15 1.5mm2 White 34 1.5mm2 White
2
13 1.5mm 2
White 27 1.5mm White
1 25 33 35H 36 37 0 6 To Control Switch Wire CN-512M To Air Conditioning 12 2.5mm2 White 24 1.5mm2 White
DT06-12S 7123-1720 58-S 12PF 11 2.5mm 2
White 22 2.5mm 2
White
12 24 22 14 13 11 10 7 CN-203F CN-207F
Wire NO. Wire Diameter Wire Color Wire NO. Wire Diameter Wire Color
2 5 7 8
62 60 / 38 38
700
63 61 0 / 57 / /
1 2 3 1 2
To Washer Motor
3 4 6 1 0 37 282080-1
20b R+ L+ To Radio Receiver Panel
200
Seven-wire Socket Sheath DJ7072-3-21 CN-211F
CN-003F
200
9 0 20b R- L-
4 5 6 7 300 50
SB2: Secondary 1 2 1 2
1 2 0 26 0 37 282104
Boosting Button 150
282080-1 209 27 ToH4: Cab Light Diode Socket
500
CN-204F 282080-1 282080

50
D5: Diode IN5408
300
1 2 CN-208F 1 2
SQ1: Pilot Switch 150
282104-1 105 27 62 63
800 300 500 500 1400
CN-205M
To Outside Air Sensor
500
300
9 0 7283-7028
50
ǂǂ090ǂ2PF
ǂǂCN-210M
PVC Pipe
50
1 2
0 71
R- R+ L- L+
AR1: Dome Light T-203 0 28 T-204
To Radio Receiver Horn
282080-1
282080-1 282080-1
CN-209F To Service Light
CN-004F CN-005F
Terminal UT1-3
586
FUSE BLOCK WIRE
5 2 3
Fuse Box
PF021-00000
PF021-00000 Fuse Box Cover
F1 F3 F7 F9 F14
20A 5A 10A 5A 10A
20 20 20 20 20 70 15mm2 Yellow
and Green
0 2mm2 Yellow
22 23 26 28 43 and Green
21 2mm2 White
1 2 3 4 5 6 7 8 9 10
20 2mm2 White
11 12 13 14 15 16 17 18 19 20
43 1.5mm2 White
21 21 21 21 21 21 21 21 21 21
42 2mm2 White
42
10 24 25 20b 38 29 49 27 70 29 1.5mm2 White
42
5A 15A 5A 10A 20A 5A 20A 15A 10A 10A 27 1.5mm2 White
F2 F4 F5 F6 F8 F10 F11 F15 F16 F17 26 1.5mm2 White

25 1.5mm2 White
23 1.5mm2 White
20b 1.5mm2 White
Wire Wire Wire
1 4
200
No. Diameter Color
10ǃFuse Box Cover, Side Label
8
Fuse Box Cover Label
F1 F3 F7 F9
Startup Circuit
Horn Circuit
Cab Light
Service Light
150 150 To Body Wire CN-161M
33
6 0 22 70 38 28 27 1 4 42 29 10 22 1
DT04-8P
7 10 20b 23 24 25 26 12 5 20 20 21 21 8 CN-402M
50
F2 F4 F5 F6 F8 F10 F11 F15 F16 F17
Charging Indicator
Working Light
Wiper Washer
Display Screen
Controller
Cigarette Lighter
Solenoid Valve Set
Dome Light
Audio
Air Conditioning
To Driving Cab Wire CN-213F 1 2
500 To GPS Power Supply
DT04-12P
33
CN-401M 0 43 282080-1
CN-404F
80
100
700 1 2
To Cigarette Lighter
0 49 282104-1
CN-405F
587
CONTROL SWITCH WIRE

SO: Key Switch
F-501
22
Connector Y2-5
100
F-502
Connector Y2-5 13
F-503
11
Connector Y2-5
F-500
16
Connector Y2-5
2 5
F-504 10
2 200 100 1 3
To Control Knob Switch
F-505 14 51 506 00 CN-501M
HLR: Charging Indicator

2
150
F-201 17
2
100 S2: Working Light Switch
24 33
F-202 0 DJ7041-3.5-20
50 CN-502F
HLY: Pre-heating Indicator

20
100 S3: Wiper Switch
35H 35H
DJ7081-3.5-20
25 36 35L CN-504F
20
100 S4: Washer Switch

25 37
DJ7041-3.5-20
CN-506F
20
100 S1: Pre-heating Switch

16 18
DJ7041-3.5-20
CN-510F Wire Diameter Specification Parameter :
20
37 1.5mm2 White 71 2mm2 White

100 S5: Dome Light Switch 36 1.5mm 2
White 70 2mm 2
White
70 72
DJ7041-3.5-20 35 1.5mm2 White 22 2mm2 White
CN-508F 25 1.5mm2 White 16 2mm2 White
To Driving Cab Wire CN-203F 11 2mm2 White 13 1.5mm2 White
200
DT 04-12P Wire Wire Wire Wire Wire Wire

6 7 No. Diameter Color No. Diameter Color
CN-512M
6 0 37 36 35H 33 25 1 80 80 8 17 18 70 72 5 To Driving Cab Wire CN-202F

Connector DT04-8P
7 10 11 13 14 22 24 12 1 51 506 00 35L 4 CN-513M
588
BODY WIRE
200 RV1: Left Tracking Pressure Sensor
00 50
Connector 12078090
CN-120F
200
40
200 00 50 RV2: Right Tracking Pressure Sensor
Connector 12078090
201 CN-121F 150 1 2
VAB: NC
Connector 174 352-2
40
609 0
CN-137F Engine Terminal B
RV3: Arm Dumping 100
200 00 50 Terminal Y10-10
40
Pressure Sensor 1 2 21
Connector 12078090 VA7: Pilot Pressure Sensor Wire Diameter 8mm2
202 CN-122F 606 Connector 174 352-2 T107
0
CN-136F
40
150 Engine Terminal L/R
40
300 RV4: Drum Pressure Sensor 1 2 VA6: Boom Priority -2- 14 10 7323-6224-30
00 50 Connector 12078090 Proportioning Valve CN-800F
H3: Boom Working Light RH CN-123F 603 0 Connector 174 352-2
208
282080-1 CN-135F 100 Engine Terminal P
40
CN-105F
40
1 2 VA5: Bucket Confluence 47 Connector 735075
300 RV5: Bucket Digging 100 Temperature Sensor
1 2 Proportioning Valve F-107
200 00 50 604 0 510 Connector 735075
Pressure Sensor Connector 174 352-2
0 34 Connector 12078090 CN-134F 400 Oil Pressure Sensor F-108
205
40
CN-124F 1 2 508 Connector 735075
VA4: Swing Priority
F-106
40
1 2 200 Proportioning Valve 50 Water Temperature Too High-ground
608 0
50
RV6: Boom Lower Connector 174 352-2
200 00 50 0 Terminal Y4-4
0 34 Pressure Sensor CN-133F 400 150
T-113
Connector 12078090
40
1 2 VA3: Boom Priority -1-
207 CN-125F
H2: Boom Working Light LH Proportioning Valve Water Temperature Too High-Signal Tower
282080-1 602 0 106 Terminal Y4-4
40
Connector 174 352-2
CN-104F T-114
3200
RV7: Boom Lifting Pressure Sensor CN-132F
200
40
00 50 1 2 200
Connector 12078090 VA2: High Speed R0: Pre-heating Resistance Wire
CN-126F Tracking 17 Wire Diameter: 8mm2
206 607 0
Solenoid 174 352-2 T-111 Terminal Y8-4
CN-131F
80
Y10-12
40
1 2 T-112
To Fuse To Fuse To Battery Wire Diameter: 10mm2 1200 To Accelerator Motor
RV9: Bucket Dumping VA1: Secondary
Terminal Terminal Ground Cable 2 1
200 00 50 3 MT- 507 50 1 7323-7414-40
H2ǃH3 Boom Working Light Pressure Sensor 605 0 Boosting
Y10-6 Y10-6 Y10-10 Connector 12078090 Solenoid 174 352-2 0 6 MT+ 00 4 Terminal 7116-1471
34 0 282104-1 204 CN-131F
T-109 T-108 T-110 CN-127F CN-130F
400
CN-103M 50
50
Wire Diameter: Wire Diameter: Wire Diameter: 1 2
To Hydraulic Oil
40
1 2 300 Ground wire Terminal To Starting Motor
700
8mm2 8mm2 10mm2 RV9: Fuel Tank Oil Level 0 605 V6 Connector 282080-1(4) 1 2
Connector X01FGY-M/C 800 Temperature Sensor TerminalY10-10
200 RV10: Arm Digging 1 2
CN-101F 00 50 100 2 1 511 42 282080-1 511 42 0 Wire Diameter: 10mm2
Pressure Sensor 0 606 V7
16 21 0 1 2 CN-113M
H2ǃH3 Boom Working Light Connector 12078090 1 2
T-115
203
50
509 0 34 282080-1 CN-128F 0 607 400
V8 Engine Flywheel Sensor
40
2K/1/4 W 100
150
CN-106F 1 2 Connector: 282104-1(4) 108B 108A Pilot Connector 7323-1424-40 T106: To Starting Motor
200 1 3 RV8: Spare 0 609 V5 Diode: IN5408(4) Wire Diameter 8mm2
1000
CN-125F 21
Pressure Sensor
800
Terminal Y10-10
50
600
450
00 500 50 282105-1 T-116

250
250
750
CN-129F 800 300
700 1200 100 100 700 200 400 400 100 1 2
To Starting Motor
12a 12
282080-1
1 2Y6: Rear Pump
470 800 CN-111F
200
200
200
200
600 Proportioning 150 1 2

100
1100
200
200
0 103 Solenoid 174 352-2

CN-114F 12a 12 282080-1
700
P2: Air Conditioning Clogged 1 2 300 CN-112F
1 2 282080-1
600
32 32 F-105 703 0
13 0 21 20 0 34 400
500
10
00
Wire Diameter: Wire Diameter: Wire Diameter: Wire Diameter: CN-102F F-104 F-103 1 2 2 1
1.5mm2 1.5mm2 10mm2 5mm2 282080-1 Connector Connector
T-101 T-102 T-103 T-104 702 0 12 12a 282104-1
Terminal Y4-2.5 Terminal Y4-2.5 Terminal Y10-10 Terminal Y5-10 H1: Rotary Table 735075 735075 200 1 51 506 00 57 18 6 To Driving Cab Wire CN-215M 300 200
To KB To KB To KB To KB Light HA1: Horn HA2: Horn DT06-12S Y5: Diode 6A10
CN-612F Y5: Front Pump Proportioning
12 10 13 14 16 17 7 Solenoid 174 352-2
50
CN-113F
To Safety Relay 1 0 10 12a 47 4 500 100 100

DT04-08P 1 2 To Relay Wire CN-301F 1 0 22 63 64 4
100 To CAN Display Signal Wire S1
CN-613M Core 16 ?? Plug Sheath HSWP16M6Y-M
8 14 5 CAN+ CAN- 282104-1 CN-160M YC: Compressor Clutch
Wire Diameter: 10mm2 1 50 00 3 1 50 00 3
50
CN-711M 8 65 5 1300-4393
T-125 500 500
1 3 501 2 502 2 T-107
0 To CAN Display
To KH: Pre-heating Control Relay 150 0 29 22 Power Wire Shut-down Solenoid
To Driving Cab Ground RV1: Front Main RV2: Rear Main
Terminal Y10-6 100 282105-1 DT06-BS
16 Terminal Y16-10
50
T-117 Wire Diameter: 8mm2 CN-710M 1 606 34 32 4 Pressure Sensor Pressure Sensor CN-801F
150 Connector 6189-0131 Connector 6189-0131
Wire Diameter: 8mm2 CN-115F CN-116F
T-11B Terminal Y10-6 17 5 605 65 12 0 8
700
KH: Pre-heating Relay Control Wire 1 2 100 100 22 2mm2 White
9 63 64 50 51 12
50
282104-1 0 18 2 Yellow
CN-109M 00 1.25mm and Green
13 16
700 Yellow
400 0 10mm2 and Green
50
1 22 10 29 42 4 To Fuse Wire CN-402M Red

0 1.25mm2
Connector DT06-8S and Green
8 21 21 20 20 5 CN-161F
34 1.5mm2 White
100
50 Calibration Data Wire 29
4 B04 B03 B02 B01 1 14 1.5mm2 White 1.5mm2 White
Connector 715-3755-60
8 B08 B07 B06 B05 5 CN-158F 13 1.5mm2 White 12a 1.5mm2 White
To Controller Socket No.A2 21 2mm2 White 47 1.5mm2 White

40 Pin AMP 1473252 Calibration Power Supply
1000 To Controller Socket No.A1 20 2mm2 White 2mm2 White
CN-615F 2 0 42 1 Connector 715-3755-60 42
B1 Pin AMP 1473244
CN-159F
CN-616F 17 10mm2 White 12 1.5mm2 White
116 115 114
400
4 5 16 10mm2 White 10 1.5mm2 White

89 703 702 607 82
0 0
24 B07 B05 B06 RXL TXL 108B 507 509 6 Wire Wire Wire Wire Wire Wire
42
97 90 No. Diameter Color No. Diameter Color
250 300 43 B08 B07 B04 RXH TXH 108A 506 500 511 510a 25
118 117
3
105 MT+ 603 602 604 608 98
62 B02 B01 CAN+ CAN- 50 00 00 502 202 207 204 200 508 44
42 42
113 MT- 106
0
50
81 B01 B03 B02 CAN- CAN+ 50 50 00 501 203 206 205 208 201 63
121 120 119
1 2
1 2 2 1
282080-1 0 511 511 0
CN-157F
240 Ω/1/4 W
589
RELAY WIRE
4 32 34 606 1
8 0 12 65 5 To Body Wire CN-160M

Connector SWP16FGY-M/C
12 51 50 64 63 9 CN-301F
16 13
Secondary Dome Light

Horn Headlight Pilot Valve Boosting Valve Starting Control Stopping Relay Relay
K5 K6 K10 K11 K3 K7 K8
200
32 34 12 65 70
1 2 300 300 50
606 105 51 63
A B 0 31 0 33 0 0 105 0 13 0 72
B A
To GPS
Connector 23 24 27 50 11 64 71
282104-1
200
150
CN-303F
2
50
1 2 1 2 1 2 1 2
1 70 27 24 23 4
0 13 0 65 0 18 51 50
To Driving Cab Wire Diameter Specification Parameter :
5 71 72 33 31 8 Wire CN-214F D2 D3 D4 D4
16 Core Black 3 Connector 282080-1(4)
25 1.5mm2 White 65 1.5mm2 White
9 0 105 12 Plug Sheath
24 1.5mm 2
White 57 1.5mm 2
White
HSWP16MB-M 2 1 2 1 2 1 2 1
13 18 13 11 16 CN-302M 18 1.5mm 2 White 38 1.5mm 2 White 70 1.5mm2 White
13 1.5mm2 White 34 1.5mm2 White 71 1.5mm2
White
4 Connector 282104-1(4)
Resistance R=5.1K 12 1.5mm2 White 32 1.5mm2 White 64 1.5mm2 White
5 11 1.5mm2 White 27 1.5mm2 White 63 1.5mm2 White
6 5
Wire Wire Wire Wire Wire Wire Wire Wire Wire
No. Diameter Color No. Diameter Color No. Diameter Color
590
V\BHQGIP3DJH)ULGD\2FWREHU30
SERVICE MANUAL REVISION SHEET
Sany Heavy Industry Co., Ltd.

Customer Service Dep.
fax: 0512-57831999-6059
Service Manual Questionnaire Form
Company Name:
Model:
Name: Published Number:
ǂ(At the bottom left corner of original book cover)
Date:
Page:
Fax: ǂ(At the center of the lower part of each page. If there
ǂare two or more places need to be revised, please ǂ
ǂwrite them down in the suggestion column).
Your comments/suggestions:
ǂ(Attach photos of malfunction location or schematic diagrams
ǂif necessary.)
ǂIf there is no much space, please add pages by yourself.
Reply:
(Copy the table is allowed)
591

Manual de Serviço SY215-C8

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What are the three parts that the manual is divided into?

What are the three parts that the manual is divided into?

What safety symbols are used in the manual and what do they indicate?

What safety symbols are used in the manual and what do they indicate?

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Supplementary reference data

Safety warning marks and headline symbols

Indicates a potential hazard which, if not avoided, will result in

Indicates a hazard which, if not avoided, will result in damage to

NOTE Indicates the supplementary technical information.

Measurement unit being used

CHAPTER 6 ENGINE ................................................................343

6-2. Engine ......................................................................................... 360

GENERAL DESCRIPTION-Precautions for disassembly and assembly

CHAPTER 1 GENERAL DESCRIPTION

x Use the align mark when assembling.

GENERAL DESCRIPTION-Precautions for disassembly and assembly

1-1-2. Bleeding air in hydraulic system

1. Bleeding air from the hydraulic pump

x Rearrange the work devices to check the

GENERAL DESCRIPTION-Precautions for disassembly and assembly

1-1-3. Precautions for float oil seal

(d) After installing the float oil seal, measure the

GENERAL DESCRIPTION-Precautions for disassembly and assembly

1-1-4. Precautions for using nylon sling

1. Observe the following precautions for using

x The clearance between the sling and cargo

x Do not place goods on the nylon sling in

GENERAL DESCRIPTION-Precautions for disassembly and assembly

If the cargo is hanged with the broken nylon sling, it

1-1-5. Meaning of the care and maintenance standard term

"Using limit" means

GENERAL DESCRIPTION-Precautions for disassembly and assembly

1-1-6. Specifications for tightening torque

GENERAL DESCRIPTION-Precautions for disassembly and assembly

1-1-7. Torque table

Hexagon Bolt Inner Hexagon Bolt

10.9 8.8 12.9

GENERAL DESCRIPTION-Precautions for disassembly and assembly

Order for tightening bolts

Tighten Equally up and

Suggestions for divided type flange maintenance

3. Tighten the divided type flange slightly, and be

GENERAL DESCRIPTION-Precautions for disassembly and assembly

4. After tightening one of the bolts, tighten the

Locking for nut and bolt

Do not reuse the locking plate. It cannot bend twice in

Bend out corners of edges along the sides

Correct Correct Incorrect

Lock it in the correct way as shown on the left

GENERAL DESCRIPTION-Precautions for disassembly and assembly

Lock it in the correct way as shown on the left

The torque in the table is only for general purposes.

The tightening torque for the camber, concavity tube

Camber Tube Union Concavity Tube Union

GENERAL DESCRIPTION-Precautions for disassembly and assembly

Wrench Size mm Wrench Size mm Tightening Torque

O-ring and seal ring connection

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