0% found this document useful (0 votes)

216 views1,827 pages

SM 1058 EN

Uploaded by

Polished All

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

0% found this document useful (0 votes)

216 views1,827 pages

SM 1058 EN

Uploaded by

Polished All

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

You are on page 1/ 1827

Copyright ©

SERVICE MANUAL
Lep 84512399 EN

CX470C Tier 4
Crawler Excavator

Issue date September 2011

CRAWLER EXCAVATORS
CX470C TIER 4
SERVICE MANUAL

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

Lep 84512399 EN Copyright © 2011 CNH France S.A.

September 2011 Printed in France
Copyright ©

TABLE OF CONTENTS
DIVISION/SECTION SECTION N°

Main Unit-side Trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4023H

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

Lep 84512399 EN Issued 2011-09

TABLE OF CONTENTS
DIVISION/SECTION SECTION N°

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

Structure and Operation Explanation of Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8030B
Structure and Operation Explanation of Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8030C
Structure and Operation Explanation of Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8030D
5 Stack Solenoid Valve Operation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8030E
Structure and Operation Explanation of Upper Pilot Valve (remote control valve) . . . . . . . . . . . . . . . . . 8030F
Structure and Operation Explanation of Travel Pilot Valve (remote control valve). . . . . . . . . . . . . . . . . . 8030G
Structure and Operation Explanation of Cushion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8030H
9 UPPERSTRUCTURE
Removal and Installation of Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9002
Removal and Installation of Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9003A
Removal and Installation of Bucket Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9003B
Removal and Installation of Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9003C
Removal and Installation of Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9003D
Removal and Installation of Operator’s Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9004
Removal and Installation of Cab Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9005A
Removal and Installation of Wiper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9005B
Removal and Installation of Wiper Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9005C
Removal and Installation of Wiper Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9005D
Removal and Installation of Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9005E
Removal and Installation of Cab Front Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9005F
Window Lock Adjustment Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9005G
Cab Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9005H
Air Conditioner Overall Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9006
Assembly and Disassembly of Air Conditioner Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9007
Removal and Installation of Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9009
Removal and Installation of Condenser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9010
Removal and Installation of Receiver Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9011
Air Conditioning Gas Vacuum and Filling Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9015
10 LARGE SIZE SCHEMATICS
Large size hydraulic schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84499648EN
Large size electrical schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84499647EN

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

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

All data given in this manual is subject to production variations. Dimensions and weights are provided with
approximate values and the machine fitting shown in the illustrations may not correspond with standard
models. For precise information on specific machine models and versions, please contact your CASE
dealer.

Reproduction or tranlation, even partial, is prohibited without written authorization from CNH France SA
Company.

Lep 84512399 EN Copyright © 2011 CNH France S.A.

September 2011 Printed in France
Copyright ©

Lep 84512399 EN Issued 2011-09

Section

1001

Safety, general information and standard torque data

84512399 EN - September 2011

CONTENTS

GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Bolt and Nut Tightening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

1001-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

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

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

84512399 EN - September 2011

1001-3
Copyright ©
Safety, general information and standard torque data

Safety

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

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

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

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

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

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

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

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

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

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

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

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

84512399 EN - September 2011

1001-4
Copyright ©
Safety, general information and standard torque data

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

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

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

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

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

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

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

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

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

84512399 EN - September 2011

1001-5
Copyright ©
Safety, general information and standard torque data

Bolt and Nut Tightening

• Tighten alternating between left and right and top and bottom so that uniform tightening force is applied.

• If Loctite was used on a removed bolt (there is something white sticking to the bolt when it is removed), clean the
old Loctite off with cleaning fluid, dry the bolt, then apply 2 - 3 drops of Loctite to the thread section of the bolt.
Torque table

Bolt nominal diameter (size) M6 M8 M10 M12 M14 M16 M18 M20
Wrench [mm] 10 13 17 19 22 24 27 30
Hexagon bolt Tightening [N ・ 156. 196. 294.
6.9 19.6 39.2 58.8 98.1
torque m] 9 1 2
Hexagon Wrench [mm] 5 6 8 10 12 14 14 17
socket head Tightening [N ・ 117. 176. 245. 343.
bolt 8.8 21.6 42.1 78.5
torque m] 7 5 2 2

Bolt nominal diameter (size) M6 M8 M10 M12 M14 M16 M18 M20
Wrench [in] 0.394 0.512 0.669 0.748 0.866 0.945 1.063 1.181
Hexagon bolt Tightening
[lbf・ft] 5.090 14.459 28.917 43.376 72.367 115.743 144.661 217.028
torque
Hexagon Wrench [in] 0.197 0.236 0.315 0.394 0.472 0.551 0.551 0.669
socket head Tightening
[lbf・ft] 6.492 15.934 217.028 57.909 86.826 130.202 180.881 253.175
bolt torque

84512399 EN - September 2011

1001-6
Copyright ©

Section

1002A

Specifications

84512399 EN - September 2011

CONTENTS

Overall（CX470C） . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Main Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Main Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Upper Side Work System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Operating Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Swing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Travel Lower Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hydraulic Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hydraulic Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Control Valve, Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Capacities, Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Coolant and Oil Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hydraulic Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

1002A-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

1002A-2 PRINTED IN FRANCE
Copyright ©
Specifications

Overall（CX470C）
Main Data
CX470C
CX470C CX470C
CX470C MASS Excavator
Model name Retractable Side- MASS Excavator
Fixed Sideframe (Retractable Side-
frame (Fixed Sideframe)
frame)
Operating weight 47800 kg 49300 kg 48200 kg 49700 kg
Engine output 270 kW/2000 min-1

Performance
CX470C
CX470C CX470C
CX470C MASS Excavator
Retractable Side- MASS Excavator
Fixed Sideframe (Retractable Side-
frame (Fixed Sideframe)
frame)
Standard weight 26.5 kN 37.1 kN 38.8 kN
Swing speed 9.1 min-1
Low speed 3.2 km/h
Travel speed
High speed 5.3 km/h
Maximum pulling force 340 kN
Grade ability 70 ％ ( 35°)
82 kPa 84 kPa 83 kPa 85 kPa
(600 mm grouser (600 mm grouser (600 mm grouser (600mm grouser
shoe) shoe) shoe) shoe)
67 kPa 69 kPa 67 kPa 69 kPa
Ground pressure (750 mm grouser (750 mm grouser (750 mm grouser (750 mm grouser
shoe) shoe) shoe) shoe)
56 kPa 58 kPa 57 kPa 58 kPa
(900 mm grouser (900 mm grouser (900 mm grouser (900 mm grouser
shoe) shoe) shoe) shoe)

Main Unit Dimensions

CX470C CX470C
CX470C
CX470C MASS Excavator MASS Excavator
Retractable
Fixed Sideframe (Fixed Side- (Retractable
Sideframe
frame) Sideframe)
Main unit length 6445 mm
3700 mm 3700 mm
(maximum track (maximum track
Main unit width 3560 mm retraction for 3560 mm retraction for
transport transport
= 3200 mm) = 3200 mm)
Upper swing body width 3060 mm (3590 mm with catwalk)
Cab width 1000 mm
Main unit height 3440 mm 3590 mm 3440 mm 3590 mm
Swing radius (rear end) 3730 mm
Swing body rear end distance 3720 mm
Swing body rear section bottom
1330 mm 1480 mm 1330 mm 1480 mm
height
Distance between tumblers 4400 mm
Overall track length 5450 mm
3490 mm 3490 mm
(maximum track (maximum track
Overall track width 3350 mm retraction for 3350 mm retraction for
transpor transport
= 2990 mm) = 2990 mm)
84512399 EN - September 2011
1002A-3
Copyright ©
Specifications

CX470C CX470C
CX470C
CX470C MASS Excavator MASS Excavator
Retractable
Fixed Sideframe (Fixed Side- (Retractable
Sideframe
frame) Sideframe)
2890 mm 2890 mm
(maximum track (maximum track
Distance between tracks 2750 mm retraction for 2750 mm retraction for
transport transport
= 2390 mm) = 2390 mm)
Track shoe width 600 mm (option 750 mm, 900 mm)
540 mm 740 mm 540 mm 740 mm
Minimum ground clearance (to bottom of (to bottom of (to bottom of (to bottom of
lower frame) lower frame) lower frame) lower frame)

84512399 EN - September 2011

1002A-4
Copyright ©
Specifications

Engine
CX470C Fixed Sideframe /
CX470C Retractable (Sideframe) /
CX470C MASS Excavator (Fixed Sideframe) /
CX470C MASS Excavator (Retractable Sideframe)
Name ISUZU 6UZ1X diesel engine
4-cycle, water cooled, overhead camshaft type
Model Common rail system (electronic control), cooled EGR, with turbocharger,
DPD system
Number of cylinders - bore x stroke 6 - D120 mm x 145 mm
Total stroke volume 9.839 L
Maximum torque 1435 N•m/1500 min-1
Starter 24 V 5.5 kW Reduction type
Charging generator 24 V 50 A AC type
Battery 12 V 128 Ah/5 HR x 2

Cooling System
CX470C Fixed Sideframe /
CX470C Retractable (Sideframe) /
CX470C MASS Excavator (Fixed Sideframe) /
CX470C MASS Excavator (Retractable Sideframe)
Fan type D1016 mm, 6 blades, suction
Radiator
Fin type Wavy
Fin pitch 1.75 mm
Oil cooler
Fin type Wavy
Fin pitch 1.75 mm
Inter cooler
Fin type Triangular straight
Fin pitch 2.0 mm
Fuel cooler
Fin type Wavy
Fin pitch 2.25 mm

Upper Side Work System

CX470C
CX470C
MASS Ex-
MASS Ex-
cavator
CX470C CX470C cavator
(Re-
Fixed Sideframe Retractable Sideframe (Fixed
tractable
Side-
Side-
frame)
frame)
Model Backhoe attachment
Components, dimensions, working di-
mensions
Heaped 3.0 m3
Standard bucket capacity Heaped 2.00 m3 (leveled 1.47 m3)
(leveled 2.2 m3)
Bucket width 1530 mm 2020 mm
Bucket width with side cutter 1640 mm -
2910 kg
Bucket weight with side cutter 1920 kg
(no side cutter)
Boom length 6980 mm 6550 mm
Standard Standard
Short Short Short
Arm type (HD) (HD)
(2.53 m) (2.53 m) (2.53 m)
(3.38 m) (3.38 m)
Arm length 3380 mm 2530 mm 3380 mm 2530 mm 2530 mm
84512399 EN - September 2011
1002A-5
Copyright ©
Specifications

CX470C
CX470C
MASS Ex-
MASS Ex-
cavator
CX470C CX470C cavator
(Re-
Fixed Sideframe Retractable Sideframe (Fixed
tractable
Side-
Side-
frame)
frame)
Bucket radius 1840 mm 1850 mm
Bucket wrist angle 176° 161°
Maximum digging radius 12000 mm 11230 mm 12000 mm 11230 mm 10810 mm
Maximum digging radius at ground
11770 mm 10990 mm 11740 mm 10950 mm 10560 mm 10520 mm
line
Maximum digging depth 7720 mm 6870 mm 7570 mm 6720 mm 6490 mm 6340 mm
Maximum vertical straight wall dig-
6570 mm 5670 mm 6420 mm 5520 mm 4920 mm 4770 mm
ging depth
Maximum digging height 11140 mm 10820 mm 11290 mm 10970 mm 10520 mm 10670 mm
Maximum dump height 7740 mm 7420 mm 7890 mm 7570 mm 7180 mm 7340 mm
Minimum swing radius at front 4990 mm 5140 mm 4990 mm 5130 mm 4800 mm 4800 mm
Height for minimum swing radius
9250 mm 9320 mm 9400 mm 9470 mm 9050 mm 9200 mm
at front

Operating Device
CX470C Fixed Sideframe /
CX470C Retractable Sideframe /
CX470C MASS Excavator (Fixed Sideframe) /
CX470C MASS Excavator (Retractable Sideframe)
Operator's seat
Position Left side
Adjustable forward and back and up and down, reclining
Structure
mechanism, with seat suspension
Sealed steel type, all reinforced glass, ROPS, with sun-
Cab
roof
Levers and pedals
For travel use Lever and pedal type (hydraulic pilot type) × 2
For operating machine use Lever type (hydraulic pilot type) × 2
Instruments and switches
Work mode switchover 3 modes (SP/H/A)
Travel mode switchover Low-speed/high-speed switch type
One-touch idle Knob switch type
Engine emergency stop Switch type
Monitor device
Machine status display (TFT color liquid crystal)
Message display
Work mode select status SP/H/A
Instruments
Fuel gauge
Engine coolant temperature gauge
Hydraulic oil temperature gauge
Hour meter
Rear view camera monitor
Warning display and warning alarm * has warning alarm
Overheat (*) Battery charge (*) Electrical system abnormality (*) Refill fuel (*)
Engine oil pressure (*) Refill coolant (*) Engine pre-heat Warm up Air cleaner (*)
Anti-theft device triggered Engine system abnormality (*) Engine emergency stop (*)
Illumination equipment
Right front tool
Working light 24 V 70 W × 1
box front surface:
Cab top: 24 V 70 W × 2
Boom side: 24 V 70 W × 2
84512399 EN - September 2011
1002A-6
Copyright ©
Specifications

CX470C Fixed Sideframe /

CX470C Retractable Sideframe /
CX470C MASS Excavator (Fixed Sideframe) /
CX470C MASS Excavator (Retractable Sideframe)
Interior light 4 V 10 W × 1
Horn Electric horn × 2
Wiper with intermittent function, window washer, air con-
Other ditioner, rear view mirrors (left and right)
1 each

Swing Units
CX470C Fixed Sideframe /
CX470C Retractable Sideframe /
CX470C MASS Excavator (Fixed Sideframe) /
CX470C MASS Excavator (Retractable Sideframe)
Swing circle Swing bearing type (with inner gear)
Swing hydraulic motor Fixed displacement piston motor x 1
Reduction gear Planetary gear 2-stage reduction gear
Swing parking brake Mechanical lock (operational lever linkage type)

Travel Lower Body

84512399 EN - September 2011

1002A-9
Copyright ©
Specifications

84512399 EN - September 2011

1002A-10
Copyright ©

Section

1002B

Main Equipment Table

84512399 EN - September 2011

CONTENTS

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

Lower Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Travel Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Take-up Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Recoil Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Upper Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Swing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine-related . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Air Cleaner (double element) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Control-related . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Solenoid Valve (5 stack) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Remote Control Valve (left/right, travel operations) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Remote Control Valve for Left/Right Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Remote Control Valve for Travel Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Remote Control Valve Characteristic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Operation Remote Control Valve Control Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Travel Remote Control Valve Control Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cushion Valve (heat circuit, with shuttle valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Center Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Backhoe Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

1002B-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

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

Main Equipment Table

Lower Component
Travel Unit
Manufacturer Nabtesco Corporation
Motor type Variable displacement piston motor
Automatic 2-speed switchover with parking brake
Intake amount 290.7/170.1 cm3/rev
Operating pressure 34.3 MPa
Operating flow 360.4 L/min
Brake torque 71 kN·m min. (including reduction gear)
Relief valve set pressure 35.8 - 37.8 MPa
Automatic 2-speed switchover
26.5 MPa
pressure
Reduction gear
Reduction gear type Planetary gear 2-stage reduction gear
Reduction ratio 60.652
Dry weight 613 kg

Take-up Roller
Weight 251 kg

Upper Roller
Weight 43.8 kg

Lower Roller
Weight 82.3 kg

Recoil Spring
Item Weight (kg) Q'ty
Yoke 66.8 1
Sems B M16 × 50 0.5 4
Threaded rod 66.5 1
Groove height N M76 3.3 1
SP pin 10 × 100 0.1 1
Recoil spring 140.9 1
Grease cylinder assembly 62.2 1
Sems B M16 × 70 0.3 2
Assembly (Total) 340.6
Mounting length of spring 740 mm

84512399 EN - September 2011

1002B-3
Copyright ©
Main Equipment Table

Shoe
Weight or Q'ty
600 grouser 2585 kg
Link 1 set
Shoe 50
Bolt 200
Nut 200
750 grouser 2930 kg
Link 1 set
Shoe 50
Bolt 200
Nut 200
900 grouser 3280 kg
Link 1 set
Shoe 50
Bolt 200
Nut 200

84512399 EN - September 2011

1002B-4
Copyright ©
Main Equipment Table

Upper Component
Swing Unit
Swing motor assembly
Swing motor
Manufacturer Hyest Corporation
Motor type Fixed displacement piston motor
With parking brake
Intake amount 250 cm3/rev
Operating pressure 29.4 MPa
Operating flow 360 L/min
Mechanical brake torque 1288 N·m min.
Brake off pressure 2.9 MPa max.
Relief valve set pressure 29.4 MPa
Swing reduction gear
Reduction gear type Planetary gear 2-stage reduction gear
Reduction ratio 27.143
Dry weight 531 kg
Turntable bearing
No. of teeth 92
Weight 656 kg
Counterweight
Weight 10000 kg

84512399 EN - September 2011

1002B-5
Copyright ©
Main Equipment Table

Engine-related
Engine
Engine model name Isuzu 6UZ1X diesel engine
4-cycle, water-cooled, overhead camshaft type, common rail system (elec-
Engine type tronic control), cooled EGR, with turbocharger (variable displacement type),
DPD system
No. of cylinders - bore - stroke 6 - D120 mm - 145 mm
Total displacement 9.839 L
Compression ratio 17.5
Rated output 270 kW/2000 min-1
Maximum torque 1435 N·m/about 1500 min-1
Fuel consumption ratio 205.4 - 232.6 g/kW·h at 2000 min-1
Engine dry weight About 960 kg
Engine dimension L 1235 - W 1180 - H 1308 mm
Cooling fan D1016 mm - suction type - 6 vanes, plastic and steel
Hydraulic motor fan draive system
Pulley ratio -
Charging generator 24 V 50 A AC type
Starter motor 24 V 5.5 kW reduction type
Coolant capacity 22.5 L
Oil pan capacity Max: 36 L Min: 25 L (not including oil filter)
Direction of rotation Right (viewed from fan side)
Compliant with JISD 0006-2000.

DPD
Manufacturer Isuzu Motors, Ltd.
Weight 55 kg

Air Cleaner (double element)

Manufacturer Nippon Donaldson, Ltd.
Element (outer)
Element (inner)
Weight 17 kg

Radiator
Manufacturer T.Rad Co.,Ltd.
Oil cooler Weight 42.0 kg
Oil volume 18.5 L
Radiator Weight 34.5 kg
Coolant capacity 18.6 L
Air cooler Weight 30.0 kg
Capacity -
Fuel cooler Weight 6.0 kg
Capacity 2.1 L
Total weight 291 kg

84512399 EN - September 2011

1002B-6
Copyright ©
Main Equipment Table

Hydraulic Device
Hydraulic Pump
Manufacturer Kawasaki Precision Machinery Ltd.
Main pump
Pump type Double variable displacement piston pump
Displacement capacity 182 × 2 cm3/rev
Operating pressure Rated 31.4 MPa
Maxi-
34.3 MPa
mum
Input revolution speed 2000 min-1
Maximum discharge flow 364 × 2 L/min (at Pd = 2.0 MPa. 2000 min-1)
359 × 2 L/min (at Pd = 8.0 MPa. 2000 min-1)
Pilot pump
Pump type Gear pump
Displacement capacity 15 cm3/rev
Operating pressure 3.9 MPa
Maximum discharge flow 30 L/min (at 2000 min-1)
Control method Hydraulic simultaneous constant output control
Maximum flow adjustment control through external commands (negative
control)
Maximum flow adjustment control through external command milli-amp
(negative control, front side)
Setting horsepower adjustment control through external command milli-
amp
Dry weight 230 kg

84512399 EN - September 2011

1002B-7
Copyright ©
Main Equipment Table

Control-related
Control Valve
Manufacturer KYB Corporation
Maximum flow 364 L/min (at 2000 min-1)
Overload set pressure 24.5 MPa boom down
36.3 MPa
Main relief set pressure 31.4 MPa
(at boosting) 34.3 MPa
Foot relief set pressure 3.38 MPa
Function Straight travel circuit
Boom-up/arm 2 pumps internal flow
Boom and arm load holding circuit
Boom-down regenerative circuit
Bucket-close regenerative circuit
Arm-in forced regenerative circuit
Swing priority variable orifice
2 pumps flow (internal flow merging)
Weight 424 kg

Solenoid Valve (5 stack)

Manufacturer Yuken Kogyo Co., Ltd.
Valve specifications
Maximum flow P → B 25 L/min Other 5 L/min
Rated pressure 4.5 MPa
Port size G3/8 P.T.B. port
G1/4 C1, C2, C3, C4, C5 ports
Solenoid specifications
Operating voltage DC 20 - 32 V
Power consumption 17 W max.
Weight 6.7 kg

84512399 EN - September 2011

1002B-8
Copyright ©
Main Equipment Table

Remote Control Valve (left/right, travel operations)

Remote Control Valve for Left/Right Operations
Manufacturer Kawasaki Precision Machinery Ltd.
Operating pressure 3.92 MPa
Secondary pressure 0.49 - 2.89 MPa primary short type
Operating 1, 3 port 19°
2, 4 port 25°
Weight 1.9 kg

Remote Control Valve for Travel Operations

Manufacturer Kawasaki Precision Machinery Ltd.
Operating pressure 3.92 MPa
Secondary pressure 0.49 - 2.89 MPa primary short type
Operating angle 12.4°
Weight 5.5 kg

Remote Control Valve Characteristic Diagram

Operation Remote Control Valve Control Diagram
Ports 1, 3

Secondary pressure [MPa]

Push rod stroke [mm]

Operating angle [deg.]

Secondary pressure
1

84512399 EN - September 2011

1002B-9
Copyright ©
Main Equipment Table

Ports 2, 4

Secondary pressure [MPa]

Push rod stroke [mm]

Operating angle [deg.]

Secondary pressure
1

Travel Remote Control Valve Control Diagram

Secondary pressure [MPa]

Push rod stroke [mm]

Pedal operating angle [deg.]

Secondary pressure
1
84512399 EN - September 2011
1002B-10
Copyright ©
Main Equipment Table

Cushion Valve (heat circuit, with shuttle valve)

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

Center Joint
Operating pressure High-pressure passage (ABCD) 34.3 MPa
Drain port (T) 1.0 MPa
Pilot port (P) 3.9 MPa
Flow High-pressure passage (ABCD) 360 L/min
Drain port (T) 40 L/min
Pilot port (P) 31 L/min
Port A Forward right G1
Port B Forward left G1
Port C Backward right G1
Port D Backward left G1
Port T Drain port G1/2
Port P Pilot port G1/4
Weight 55.5 kg

Backhoe Attachment
Cylinder
Boom Cylinder
Cylinder bore D170 mm
Rod diameter D115 mm
Maximum retracted length 2230 mm
Stroke 1550 mm
Weight 400 kg

Arm Cylinder
Cylinder bore D200 mm
Rod diameter D140 mm
Maximum retracted length 2588 mm
Stroke 1820 mm
Weight 695 kg

Bucket cylinder
Cylinder bore D165 mm
Rod diameter D115 mm
Maximum retracted length 1972 mm
Stroke 1285 mm
Weight 390 kg

84512399 EN - September 2011

1002B-11
Copyright ©
Main Equipment Table

84512399 EN - September 2011

1002B-12
Copyright ©

Section

1002C

Main Unit Weight

84512399 EN - September 2011

CONTENTS

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

Divided Weight (standard specifications) CX470C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Stand Alone Part Weight （CX470C） . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Shoe Weight (per side) CX470C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Arm Weight （CX470C） . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

1002C-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

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

Main Unit Weight

Divided Weight (standard specifications) CX470C

Weight
Code Component name
(kg)
A Operating weight 47800
Upper component (including counterweight and turntable
B 20910
bearing)
C Counterweight 9200
D Lower component (with grouser shoe) 16480
E Main unit weight 37500
F Attachments 10370
G Boom (including cylinders) 5610
H Arm (including cylinders and linkage) 2720

* The weights displayed are approximate weights.

84512399 EN - September 2011
1002C-3
Copyright ©
Main Unit Weight

Stand Alone Part Weight （CX470C）

Weight
Component name
(kg)
1 Travel unit 756
2 Take-up roller 251
3 Upper roller 44
4 Lower roller 82
5 Swing unit 568
6 Turntable bearing 656
7 Engine 1157
8 Radiator 406
9 Hydraulic pump 270
10 Fuel tank 282
11 Hydraulic oil tank 235
12 Control valve 457
13 Center joint 59
14 Boom 3531

Shoe Weight (per side) CX470C

Weight
Component name
(kg)
1 600mm grouser shoe 2585
2 750mm grouser shoe 2930
3 900mm grouser shoe 3280

Arm Weight （CX470C）

Component name Weight (kg)
1 Standard arm 1741
2 Short Arm 1529

84512399 EN - September 2011

1002C-4
Copyright ©

Section

1002D

Maintenance Standards

84512399 EN - September 2011

CONTENTS

Drive Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Take-up Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Track Shoe (grouser shoe) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Attachment (backhoe) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1. Boom and Swing Frame Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2. Boom Cylinder and Swing Frame Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3. Boom and Boom Cylinder Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4. Boom and Arm Cylinder Installation Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5. Boom and Arm Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6. Arm and Arm Cylinder Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7. Arm and Bucket Cylinder Installation Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
8. Arm and Arm Link Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
9. Bucket and Bucket Link Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
10. Bucket Link and Bucket Cylinder Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
11. Bucket and Arm Installation Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Inspection Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
For Drive Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
For Take-up Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
For Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
For Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

1002D-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

1002D-2 PRINTED IN FRANCE
Copyright ©
Maintenance Standards

Drive Sprocket

* See the gauge list for measurement gauges.

Measured di- Standard Usage limit

Part name Code Judgment Solution
mensions (mm) value (mm) (mm)
a Acceptable/
90 80
Unacceptable
Acceptable/
b D D773.6 D763.6
Unacceptable
c Acceptable/
D D867.5 D857.5
Unacceptable Cladding by welding
Drive sprocket
Acceptable/ or replacement
d D D847.3 -
Unacceptable
e Acceptable/
43.4 48.4
Unacceptable
p - Acceptable/
228.6
Unacceptable

84512399 EN - September 2011

1002D-3
Copyright ©
Maintenance Standards

Take-up Roller

* See the gauge list for measurement gauges.

Measured di- Standard Usage limit

Part name Code Judgment Solution
mensions (mm) value (mm) (mm)
a - Acceptable/
D D676
Unacceptable
Acceptable/ Cladding by welding
Take-up roller b 22.5 25.5
Unacceptable or replacement
c Acceptable/
102 100
Unacceptable
Acceptable/
Shaft d D D95 D94 Replacement
Unacceptable
Acceptable/
d D D95 D96
Unacceptable
Bushing Replacement
e Acceptable/
100 99
Unacceptable
Acceptable/
Hub f 15 14.6 Replacement
Unacceptable

84512399 EN - September 2011

1002D-4
Copyright ©
Maintenance Standards

Upper Roller

* See the gauge list for measurement gauges.

Measurement di- Standard Usage

Part name Code mensions value limit Judgment Solution
(mm) (mm) (mm)
a Acceptable/
D D150 D138
Unacceptable
- Acceptable/ Cladding by welding
Carrier roller b 15
Unacceptable or replacement
c - Acceptable/
104
Unacceptable
Acceptable/
Shaft d D D65 D64 Replacement
Unacceptable
Acceptable/
Bushing d D D65 D66 Replacement
Unacceptable
e Acceptable/
Bushing 69 68 Replacement
Unacceptable
Acceptable/
Thrust plate f 9 8.5 Replacement
Unacceptable
g - Acceptable/
Cover 15 Replacement
Unacceptable

84512399 EN - September 2011

1002D-5
Copyright ©
Maintenance Standards

Lower Roller

* See the gauge list for measurement gauges.

Measured di- Standard Usage limit

Part name Code Judgment Solution
mensions (mm) value (mm) (mm)
a Acceptable/
D D200 D188
Unacceptable
Acceptable/ Cladding by welding
Track roller b 25 20
Unacceptable or replacement
Acceptable/
d 223 231
Unacceptable
e Acceptable/
Shaft D D85 D84 Replacement
Unacceptable
e Acceptable/
D D85 D86
Unacceptable
Bushing Replacement
Acceptable/
f D93 D92
Unacceptable
g Acceptable/
Collar 24.5 24.0 Replacement
Unacceptable

84512399 EN - September 2011

1002D-6
Copyright ©
Maintenance Standards

Track Shoe (grouser shoe)

Measured di- Standard Usage limit

Part name Code Judgment Solution
mensions (mm) value (mm) (mm)
a Acceptable/
Shoe plate 52 32 Replacement
Unacceptable
Acceptable/ Cladding by welding
Link b 129 123
Unacceptable or replacement
c Acceptable/
D D73.33 D69.33
Unacceptable
Master bushing Replacement
- Acceptable/
d D D48.8
Unacceptable
e - Acceptable/
Master pin D D48.3 Replacement
Unacceptable

84512399 EN - September 2011

1002D-7
Copyright ©
Maintenance Standards

Measured di- Standard Usage limit

Part name Code Judgment Solution
mensions (mm) value (mm) (mm)
Acceptable/
f 228.6 232.7
Link pitch Unacceptable
Replacement
4 linked sections Acceptable/
f' 914.4 934.4
Unacceptable
Acceptable/
c' D D73.33 D69.33
Unacceptable
Track bushing Replacement
- Acceptable/
d' D D48.8
Unacceptable
- Acceptable/
Track pin e' D D48.5 Replacement
Unacceptable

84512399 EN - September 2011

1002D-8
Copyright ©
Maintenance Standards

Attachment (backhoe)

1. Boom and Swing Frame Installation Section

84512399 EN - September 2011

1002D-9
Copyright ©
Maintenance Standards

1002D-20
Copyright ©
Maintenance Standards

Inspection Gauge
For Drive Sprocket

84512399 EN - September 2011

1002D-21
Copyright ©
Maintenance Standards

For Take-up Roller

84512399 EN - September 2011

1002D-22
Copyright ©
Maintenance Standards

For Upper Roller

84512399 EN - September 2011

1002D-23
Copyright ©
Maintenance Standards

For Lower Roller

84512399 EN - September 2011

1002D-24
Copyright ©

Section

1002E

Bolt Size and Torque Table

84512399 EN - September 2011

CONTENTS

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

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

1002E-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

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

Special Torque Settings

Bolt nominal Tightening
Code Retightening location Wrench
diameter torque [N•m]
1* Travel motor M24 36 mm 900 - 1051
2* Drive sprocket M24 36 mm 900 - 1051
3* Take-up roller M16 24 mm 267 - 312
4* Upper roller M20 30 mm 521 - 608
5* Lower roller M24 36 mm 902 - 1049
6* Track guard M24 36 mm 902 - 1049
7 Shoe M24 36 mm 1236 - 1510
8 Counterweight M33 50 mm 1862 - 2058
9* Turntable bearing M24 36 mm 952 - 1050
10* Swing unit M24 36 mm 952 - 1050
11* Mount M27 41 mm 843 - 980
12* Engine Front bracket M10 17 mm 64 - 73
13* Rear bracket M16 24 mm 245 - 274
14* Radiator M16 24 mm 147 - 176
15* Flange M12 19 mm 88 - 108
Hydraulic pump 17 mm
16* Pump M20 hexagon 367 - 496
socket head
17* Hydraulic oil tank M16 24 mm 226 - 265
18* Fuel tank M16 24 mm 226 - 265
19* Control valve M20 30 mm 333 - 392
20* Lock bar M16 24 mm 267 - 312
Center joint
21* Joint M12 19 mm 109 - 127
22 Cab M16 24 mm 149 - 173
23 Battery M10 17 mm 20 - 29

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

The tightening for bolts and nuts not otherwise specified in the table above is as follows.

Bolt nominal diameter (size) M6 M8 M10 M12 M14 M16 M18 M20
Wrench [mm] 10 13 17 19 22 24 27 30
Hexagon bolt Tightening
[N･m] 6.9 19.6 39.2 58.8 98.1 157.0 196.0 294.0
torque
Wrench [mm] 5 6 8 10 12 14 14 17
Hexagon socket
head bolt Tightening
[N･m] 8.8 21.6 42.1 78.4 117.6 176.4 245.0 343.0
torque

84512399 EN - September 2011

1002E-3
Copyright ©
Bolt Size and Torque Table

84512399 EN - September 2011

Short Arm (2.53 m)
Note: 1. Numbers are subject to change without notice due to design change or other reason.
Note: 2. The diagrams give values that include the shoe lug height (a) (26 mm).

1-8521-0077-0 380300003 Oil seal remover

5-8840-2626-0 380001722 Installer; Bridge guide

1-8522-0057-0 380300004 Oil seal setting tool

5-8840-2826-0 380002601 Fuel Injector Remover

5-8840-0019-0 380002602 Sliding Hammer

84512399 EN - September 2011

1003-21
Copyright ©
List of special tools

Illustration Isuzu Reference CASE Tool Number Description

1-8522–1082-0 380300006 Piston setting tool

1-8522-1034-0 380002634 Thermostat seal ring installer

1-8521-0067-0 380300002 Thermostat seal remover

8980131700 380002630 Main filter wrench

5-8840-0266-0 380300009 Angle gauge

5-8840-2625-0 380300013 Installer; Valve guide oil seal

5-8840-2628-00 380300014 Remover/Installer; Valve guide

1-8531-7019-0 380002635 Compression gauge adapter

1–8521–0051–0 380300001 Crankshaft gear puller

84512399 EN - September 2011

1003-22
Copyright ©
List of special tools

Illustration Isuzu Reference CASE Tool Number Description

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

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

Section

1004

FLUIDS AND LUBRICANTS

84512399 EN - September 2011

CONTENTS

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

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

1004-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

1004-2 PRINTED IN FRANCE
Copyright ©
FLUIDS AND LUBRICANTS

Lubricants must have the correct properties for each application.

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

HYDRAULIC FLUID
CASE/AKCELA hydraulic fluid is specially designed for high pressure applications and for the CASE hydraulic system.
The type of fluid to be used depends on the ambient temperature.
ENGINE OIL
The "CASE Tutela LE ENGINE OIL" is recommended for
your engine. This oil ensures correct lubrication of your
engine in all working conditions.
If the "CASE Tutela LE ENGINE OIL" cannot be obtained,
use the oil corresponding to one of the following cate-
gories:
API CJ-4.
ACEA E6.
FUEL
IMPORTANT:
The fuel must conform to Interim Tier 4/Stage 3B Ex- EPA regulation ultra low sulfur fuel only.
haust Gas Control Regulations.
Use grade number 2-D (S15) fuel. Important:
Using other types of fuel may lead to stalled engine out-
put or deterioration in fuel economy. IMPORTANT:
During cold weather (lower than -7℃), it is temporarily If a serious problem occurs when other fuels are used,
acceptable to use a mixture of No. 1-D (S15) and No. the warranty is invalidated.
2-D (S15). Using a non-recommended fuel may lead to damage of
Consult the fuel supplier or the CASE dealer. the fuel injection pump, injector, DPD, and other fuel
If the temperature drops below the fuel cloud point, out- supply systems or to the engine.
put deficiency or engine start problems may occur due CASE assumes no responsibility for these damages.
to wax crystals. Note that the warranty will not be applied for these dam-
Conditions applicable to diesel fuel ages.
It is recommended that the following safety information
The diesel fuel used must: be considered in order to prevent damage to the engine
fuel supply system.
- be free from dust particles, even minute ones,
- have the proper viscosity, - Some fuel suppliers mix old engine oil and diesel fuel.
- have a high cetane number,
Makers of larger engine permit the use of this kind of
- present great fluidity at low temperatures,
fuel.
- have low sulphur content,
However, do not use diesel fuel contaminated with en-
- have very little residual carbon.
gine oil in customer's engines.
Not only will this fuel damage the engine, it may also
RECOMMENDED CONDITIONS have a negative impact on the exhaust gas purification
THAT CAN BE APPLIED TO function.
Before using diesel fuel, confirm with the supplier
DIESEL FUEL whether the fuel complies with the above specifications.
- JIS (Japanese Industrial Standards): No. 2 IMPORTANT:
- DIN (Deutsche Industrie Normen): DIN 51601 Consult the supplier or the CASE dealer regarding ap-
- SAE-J-313C: SAE (Society of Automotive Engineers) propriate use of fuel additives.
based on No. 2-D (S15) Do not use fuel oil or gasoline as these may damage the
- BS (British Standards) based on BS/2869-1970: Class engine.
A-1
- EN 590 (less than 10 ppm sulfur) IMPORTANT:
- Or fuel specified by the country using these standards In order to prevent condensation during cold weather, fill
and this machine the fuel tank to full after the completing the day's work.

84512399 EN - September 2011

Items to prepare
• Wrenches (7 mm, 8 mm, 13 mm, 17 mm, 19 mm, 36
mm)
• Box wrench (46 mm)
• Shackle (with the required lifting capacity) x 2
• Wire ropes (with the required breaking load)
• Liftcrane (with the required lifting capacity)
• Marking pen
• Cap 7. Use a wrench (8 mm) to loosen the hose band (1)
• Plug on the inter cooler, and then remove the hose (2).
• Waste oil can
• Rag • Use caps to cover the lines and hoses to prevent
• Cleaning fluid the entry of water, dust or dirt.
• Wood planks, etc.

84512399 EN - September 2011

2000-3
Copyright ©
Removal and Installation of Engine Assembly

8. Remove the hose band (1), and then remove the Tightening torque for bolt installation: 19.6 - 24.5
heater hose (2). N•m
Attach caps or plugs to the engine and hoses to
prevent any entry of water, dust or dirt.

11. Use a wrench (19 mm) to remove the 11 bolts (1),

and then remove the under cover (2).
• Use caution when removing as the parts are
heavy.
Tightening torque for bolt installation: 63.7 - 73.5
N・m

9. Use a wrench (7 mm) to loosen the hose band (1)

of the radiator, and then remove the lower hose (2).
• Use caps to cover the radiator and hoses to pre-
vent the entry of water, dust or dirt. 12. Prepare the waste oil can (1).
• Before removing the radiator hoses, completely • Drain the engine oil before removing the engine
drain the coolant. oil hose.

10. Use a wrench (13 mm) to loosen the line bolts (1) in 13. Use a wrench (36 mm) to remove the 2 engine oil
2 locations, and then remove the 2 lines (2) and (3) remote hoses (1).
from the compressor.
• Mark the engine and hoses so that the connectors
• Always remove the low-pressure (suction side) match at the time of assembly.
line (2) first. • Attach caps or plugs to the engine and hoses to
• Attach caps or plugs to the compressor and lines prevent any entry of water, dust or dirt.
to prevent any entry of water, dust or dirt.

84512399 EN - September 2011

28. Use a box wrench (46 mm) to remove the 4 bolts 29. Use the wire rope (1) and liftcrane to lift the engine
(1) from the mount. main unit.
Tightening torque for bolt installation: 843.4 - 980.7 Thoroughly check that the location is safe before
N・m lowering the engine on wood planks, etc.

84512399 EN - September 2011

• Wrenches (12 mm)

• Screwdriver
• Pliers
• Marking pen
• Cap
• Plug
• Rag
• Cleaning fluid
• Drip pan

84512399 EN - September 2011

2001-3
Copyright ©
Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
2. Use a wrench (12 mm) to remove the 4 bolts (1), Removal and Installation of Engine
and then remove the fuel cooler (2).
Inter Cooler
CAUTION
• Be sure to stop the engine before beginning
work.
• As the fuel hose will be removed, strictly pro-
hibit open flames.

Items to prepare
• Wrenches (8 mm, 13 mm)
• Flathead screwdriver
• Cap
• Rag
• Cleaning fluid

Removal of Inter Cooler

1. Remove the fuel cooler.(For details, see "Removal
and Installation of Fuel Cooler".)
Use a wrench (13 mm) to remove the 4 bolts (1), and
then remove the bracket (2) from the fuel cooler.

Installation of Fuel Cooler

Perform the reverse of the removal procedure.
After connecting the hoses, carefully check for any fuel
leaks.
When installing the bolts, tighten them to the specified 2. Use a wrench (8 mm) or flathead screwdriver to
torque. loosen the hose bands (1) in the 2 locations, and
If the torque is not specified for a bolt or other part, see then remove the 2 hoses (2) and (3).
the "Standard Torque Data for Cap Screws and Nuts". Use caps to cover the inter cooler and hoses to pre-
vent the entry of water, dust or dirt.

84512399 EN - September 2011

2001-4
Copyright ©
Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
3. Use a wrench (13 mm) to remove the 4 bolts (1), Installation of Inter Cooler
and then remove the inter cooler (2).
To install, perform the reverse of the removal procedure.
Check for any air leaks.
Tighten bolts being installed to the specified torque.
For bolts for which the torque is not specified, see "Stan-
dard Torque Data for Cap Screws and Nuts".

84512399 EN - September 2011

2001-5
Copyright ©
Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
Removal and Installation of Removal of Radiator
Radiator 1. Use a wrench (19 mm) to remove the 5 bolts (1),
and then remove the under cover (2).
Job code 10406AO10

WARNING
• Do not remove the radiator cap when the ra-
diator coolant temperature is high. Hot liquid
could spray out.

CAUTION
• Be sure to release hydraulic pressure before
beginning work.
• Be sure to stop the engine before beginning
work.
• Be sure to inspect the wire rope and other
lifting equipment before beginning work. 2. Install the drain hose (1), and then prepare the drain
• Do not stand or pass under the suspended tank (2).
load.

Items to prepare
• Wrenches (7 mm, 8 mm, 13 mm, 19 mm)
• Box wrench (17 mm)
• Pliers
• Shackles (with the required lifting capacity) × 2
• Wire rope (with the required breaking load)
• Liftcrane (with the required lifting capacity)
• Cap
• Plug
• Drain tank
• Drain hose
• Rag
• Cleaning fluid
• Wood planks, etc.

84512399 EN - September 2011

2001-6
Copyright ©
Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
3. To make it easier to drain the coolant, remove the 6. Use a wrench (19 mm) to remove the 11 bolts (1),
radiator cap (1). and then remove the brackets (2) (3).

4. Loosen the drain plug (1), and then drain the 7. Use a wrench (19 mm) to remove the 7 bolts (1),
coolant. and then remove the brackets (2) (3).

5. Use a wrench (8 mm) to loosen the hose band (1), 8. Use a wrench (7 mm) to loosen the hose band (1),
and then remove the hose (2). and then remove the upper hose (2) and lower hose
• Tightening torque for band (1) installation: 8.8 - (3) from the radiator.
9.8 N·m • Use caps to cover the radiator and hoses to pre-
vent any entry of water, dust or dirt.
• Tightening torque for band (1) installation: 4.9 -
5.9 N·m

84512399 EN - September 2011

2001-7
Copyright ©
Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
10. Loosen the hose band (2), and then remove the
hose (1) from the radiator cap.
• Install caps or plugs to the hoses to prevent any
entry of water, dust or dirt.

11. Use a wrench (13 mm) to remove the 4 bolts (1).

9. Install the 2 shackles (11) to the eyebolts, and then

use the wire rope (12) and liftcrane to lift the oil
cooler main unit.

84512399 EN - September 2011

2001-13
Copyright ©
Removal and installation of the fuel cooler engine inter-cooler
radiator and oil cooler
Installation of oil cooler For bolts for which the torque is not specified, see "Stan-
dard Torque Data for Cap Screws and Nuts".
To install, perform the reverse of the removal procedure.
Tighten bolts being installed to the specified torque.

84512399 EN - September 2011

2001-14
Copyright ©

Section

2004

Removal and Installation of Turbocharger assembly

84512399 EN - September 2011

CONTENTS

Turbocharger assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Turbocharger assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

2004-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

2004-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Turbocharger assembly

Turbocharger assembly Removal 1) Disconnect the harness connector from the

MAF sensor.
1. Battery ground cable disconnect 2) Remove the inlet duct from the air duct.
1) Disengage the battery ground cable from the 3) Remove the air duct from the turbocharger
battery. assembly.

2. Coolant drain

WARNING
• Do not loosen the radiator cap when the
coolant is hot.
• Steam and boiling water may burst out
and cause burns, so make sure that the
engine has cooled off.

1) Drain the coolant from the radiator.

CAUTION
• After draining the coolant, tighten
the drain plug.
1 Inlet duct
2) Drain the coolant from the engine assembly. 2 Air duct
ANNOTATION: 3 MAF sensor
4 Air hose
• Loosen the drain plug on the cylinder block
side.
5. Turbocharger feed oil pipe removal
1) Remove the clip from the turbocharger feed
oil pipe.
2) Remove the turbocharger feed oil pipe from
the turbocharger assembly.
3) Remove the turbocharger feed oil pipe from
the oil cooler assembly.
6. Oil return pipe removal
1) Disengage the oil return pipe from the tur-
bocharger assembly.
2) Remove the oil return pipe from the cylinder
block.
7. Water feed pipe removal
1) Disengage the water feed pipe from the tur-
1 Drain plug bocharger assembly.
2) Remove the water feed pipe from the oil
3. Ventilation hose disconnect cooler.
1) Disengage the ventilation hose from the air 8. Water return pipe removal
breather.
1) Disengage the water return pipe from the tur-
4. Air duct removal bocharger assembly.

84512399 EN - September 2011

2004-3
Copyright ©
Removal and Installation of Turbocharger assembly

2) Remove the water return pipe from the ther- Turbocharger assembly
mostat housing.
Installation
1. Turbocharger assembly installation
1) Replenish the engine oil with the turbocharger
assembly.
ANNOTATION:
• Apply about 1 cc of engine oil to the oil path
to lubricate the turbine bearing portion.
2) Install the gasket to the exhaust manifold.
3) Temporarily tighten the turbocharger assem-
bly to the exhaust manifold.
4) Install the exhaust pipe adapter to the tur-
bocharger.
ANNOTATION:
1 Water return pipe
2 Oil return pipe • Assemble the gasket on the exhaust pipe
adapter.
3 Feed oil pipe
4 Water feed pipe CAUTION

9. Turbocharger assembly removal • Make sure to conduct assembly

so that the gasket surface with a
1) Remove the turbocharger assembly from the yellow marking is visible when the
exhaust manifold. gasket is installed to the exhaust
2) Remove the gasket from exhaust manifold. pipe adapter.
• When installing the gasket, be care-
ful not to deform it.
• Make sure to install new gaskets.
Prohibit their reuse.

ANNOTATION:
• Tighten the 3 bolts from the top of the
bracket tightened together with the exhaust
manifold.
• Tighten it to the turbocharger using a
V-band.

CAUTION
• Confirm that there are no pieces of
gasket inside the duct before as-
1 Turbocharger sembly.
2 Exhaust manifold • Insert securely until it touches the
3 Gasket duct.

Tightening torque: 8 N・m {0.8 kgf・m / 71

CAUTION lb・in} V-band
• Put a seal on every part to prevent
foreign materials from getting into
the turbocharger.

84512399 EN - September 2011

2004-4
Copyright ©
Removal and Installation of Turbocharger assembly

1 Exhaust pipe adapter 4. Turbocharger feed oil pipe installation

2 Gasket
1) Temporarily tighten the turbocharger feed oil
3 Turbocharger pipe onto the turbocharger assembly.
4 V-band 2) Temporarily tighten the turbocharger feed oil
pipe onto the oil cooler assembly.
ANNOTATION: 3) Securely tighten the turbocharger feed oil pipe
• Tighten the flange nuts in order starting with onto the turbocharger assembly.
the one at the turbine inlet and secure them Tightening torque: 34 N・m {3.5 kgf・m / 25
with double nuts. lb・ft}
4) Securely tighten the turbocharger feed oil pipe
Tightening torque: 45 N・m {4.6 kgf・m / 33 onto the oil cooler assembly.
lb・ft} Tightening torque: 34 N・m {3.5 kgf・m / 25
lb・ft}

1 Turbocharger
2 Exhaust manifold
3 Gasket 1 Water return pipe
2 Oil return pipe
2. Water return pipe installation 3 Oil feed pipe
1) Install the water return pipe to the cylinder 4 Water feed pipe
head.
Tightening torque: 41 N・m {4.2 kgf・m / 30
lb・ft} 5. Oil return pipe installation
2) Connect the water return pipe to the tur- 1) Install the O-ring to the oil return pipe.
bocharger assembly.
Tightening torque: 50 N・m {5.1 kgf・m / 37 ANNOTATION:
lb・ft}
• Install them on both ends of the oil return
3. Water feed pipe installation pipe.
1) Install the water feed pipe to the cylinder 2) Temporarily tighten the oil return pipe onto the
block. turbocharger assembly.
Tightening torque: 41 N・m {4.2 kgf・m / 30 3) Temporarily tighten the oil return pipe onto the
lb・ft} cylinder block.
2) Connect the water feed pipe to the tur- 4) Securely tighten the oil return pipe onto the
bocharger assembly. turbocharger assembly.
Tightening torque: 50 N・m {5.1 kgf・m / 37 Tightening torque: 22 N・m {2.2 kgf・m / 16
lb・ft} lb・ft}

84512399 EN - September 2011

2004-5
Copyright ©
Removal and Installation of Turbocharger assembly

5) Securely tighten the oil return pipe onto the Tightening torque
cylinder block. Parts Tightening torque
Tightening torque: 44 N・m {4.5 kgf・m / 32 Clip ： 8 N・m {0.8 kgf・m / 71 lb・in}
lb・ft} M10 bolt ： 44 N・m {4.5 kgf・m / 32 lb・ft}

3) Install the MAF sensor to the air duct.

Tightening torque: 1.5 N・m {0.2 kgf・m / 13
lb・in}

2005

Removal and Installation of EGR valve

84512399 EN - September 2011

CONTENTS

EGR valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

EGR valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

2005-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

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

EGR valve Removal 4) Remove the water return pipe from the EGR
cooler.
1. Battery ground cable disconnect
1) Disengage the battery ground cable from the
battery.
2. Coolant drain

WARNING
• Do not loosen the radiator cap when the
coolant is hot.
• Steam and boiling water may burst out
and cause burns, so make sure that the
engine has cooled off.

1) Drain the coolant from the radiator.

CAUTION
1 EGR cooler water hose
• After draining the coolant, tighten 2 Water return pipe
the drain plug. 3 Air leak pipe

2) Drain the coolant from the engine assembly. 5) Remove the EGR cooler A from the EGR
cooler duct A and the EGR cooler D.
ANNOTATION: 6) Remove the EGR cooler B from the EGR
• Loosen the drain plug on the cylinder block cooler duct B and the EGR cooler C.
side. 7) Remove the EGR cooler duct A from the ex-
haust manifold and the bracket.
8) Remove the EGR cooler duct B from the ex-
haust manifold and the bracket.
9) Remove the bracket from the cylinder head.
10) Remove the EGR cooler D from the EGR
valve duct.
11) Remove the EGR cooler C from the EGR
valve duct.
12) Remove the EGR valve duct from the EGR
valve.

1 Drain plug

3. EGR cooler removal

1) Disconnect the air leak pipe from the engine
assembly.
2) Disconnect the water charge pipe from the
EGR cooler duct.
3) Disconnect the EGR cooler water hose from
the EGR cooler.
1 EGR cooler duct B
2 EGR cooler B
3 EGR cooler C
4 EGR valve duct
5 EGR cooler D
6 EGR cooler A
7 EGR cooler duct A

4. EGR valve removal

1) Disconnect the connector from the EGR
valve.
84512399 EN - September 2011
2005-3
Copyright ©
Removal and Installation of EGR valve

2) Remove the EGR valve from the EGR mixing EGR valve Installation
chamber.
3) Remove the lead valve from the EGR mixing 1. EGR valve installation
chamber. 1) Install the lead valve to the EGR mixing cham-
ber.
Tightening torque: 10 N・m {1.0 kgf・m / 89
lb・in}
2) Install the gasket to the EGR mixing chamber.
3) Install the EGR valve to the EGR mixing
chamber.
Tightening torque: 44 N・m {4.5 kgf・m / 32
lb・ft}

1 EGR valve A
2 EGR mixing chamber
3 EGR valve B

1 EGR valve
2 EGR mixing chamber
3 EGR valve

2. EGR cooler installation

1) Temporarily tighten the EGR valve duct to the
EGR valve.
ANNOTATION:
• Temporarily tighten with the gasket inserted.
Temporary tightening torque: 5 N ・ m {0.5
kgf・m / 44 lb・in}

84512399 EN - September 2011

2005-4
Copyright ©
Removal and Installation of EGR valve

2) Install the bracket to the cylinder head. 4) Install the bracket to the cylinder head.
Tightening torque: 97 N・m {9.9 kgf・m / 72 Tightening torque: 97 N・m {9.9 kgf・m / 72
lb・ft} Engine front side lb・ft} Engine front side
Tightening torque: 44 N・m {4.5 kgf・m / 32
ANNOTATION:
lb・ft} Engine rear side
• The rear side bracket should be tightened
together with the exhaust manifold.

Engine front side EGR cooler

1
bracket
Engine rear side EGR cooler
2
bracket 1 Engine rear side bracket
2 Engine front side bracket
3) Temporarily tighten the EGR cooler to the
EGR
valve duct. 5) Temporarily tighten the EGR duct to the ex-
ANNOTATION: haust manifold.

• Temporarily tighten with the gasket inserted. ANNOTATION:

• Install the air removal pipe faicing it towards • Temporarily tighten with the gasket inserted.
the front side.
Temporary tightening torque: 5 N ・ m {0.5
Temporary tightening torque: 5 N ・ m {0.5 kgf・m / 44 lb・in}
kgf・m / 44 lb・in} 6) Temporarily tighten the EGR cooler to the
EGR duct.
ANNOTATION:
• Temporarily tighten with the gasket inserted.
• Refer to the diagram for the direction of the
water pipe.

1 EGR cooler D
2 EGR valve duct
3 EGR cooler C

1 EGR cooler B
2 EGR cooler A
3 EGR duct A
4 EGR duct B
84512399 EN - September 2011
2005-5
Copyright ©
Removal and Installation of EGR valve

ANNOTATION: 9) Securely tighten the EGR cooler to the EGR

duct.
• Procedure for complete tightening Tightening torque: 50 N・m {5.1 kgf・m / 37
CAUTION lb・ft} 3 in the diagram
10) Temporarily tighten the EGR duct to the ex-
• Make sure to follow the installation haust manifold.
procedure. Tightening torque: 50 N・m {5.1 kgf・m / 37
Otherwise, a gas leak or excessive lb・ft} 4 in the diagram
stress may occur causing parts 11) Securely tighten the EGR valve duct to the
damage. EGR valve.
Tightening torque: 44 N・m {4.5 kgf・m / 32
7) Securely tighten the EGR cooler to the EGR lb・ft} 5 in the diagram
valve duct. 12) Securely tighten the EGR valve duct to the
EGR mixing chamber.
ANNOTATION: Tightening torque: 44 N・m {4.5 kgf・m / 32
• Completely tighten the EGR cooler C and lb・ft} 6 in the diagram
the EGR cooler D to the EGR valve duct. 13) Securely tighten the EGR cooler to the EGR
cooler bracket.
Tightening torque: 50 N・m {5.1 kgf・m / 37 Tightening torque: 50 N・m {5.1 kgf・m / 37
lb・ft} 1 in the diagram lb・ft} 7 in the diagram
8) Securely tighten the EGR cooler to the EGR 14) Completely tighten the EGR duct to the
cooler. bracket.
ANNOTATION: Tightening torque: 50 N・m {5.1 kgf・m / 37
lb・ft} 8 in the diagram
• Tighten the connections between the EGR
cooler A and the EGR cooler C and between
the EGR cooler B and the EGR cooler D at
the respective specified torque.
Tightening torque: 50 N・m {5.1 kgf・m / 37
lb・ft} 2 in the diagram

84512399 EN - September 2011

2005-6
Copyright ©
Removal and Installation of EGR valve

15) Install the water return pipe to the EGR cooler. 4) Tighten the plug using the wrench.
16) Install EGR cooler water hose to EGR cooler.
ANNOTATION:
17) Install the water charge pipe to the EGR duct.
18) Install the air leak pipe to the engine assembly. • Apply Loctite 271.
Tightening torque: 15 N・m {1.5 kgf・m / 11
lb・ft}
5) Replenish the coolant with the radiator.

1 EGR cooler water pipe

2 Water return pipe
3 Air leak pipe

3. Coolant filling 1 Plug

1) Replenish the coolant with the radiator.
2) Loosen the plug using the wrench. 4. Battery ground cable connect
3) Replenish the coolant with the radiator. 1) Connect the battery ground cable to the bat-
tery.
CAUTION
• Be careful not to let coolant over-
flow splash on the exhaust system
parts.
• Coolant overflow should be wiped
off.

84512399 EN - September 2011

2005-7
Copyright ©
Removal and Installation of EGR valve

84512399 EN - September 2011

2005-8
Copyright ©

Section

2006

Removal and Installation of Engine Hood

84512399 EN - September 2011

CONTENTS

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

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

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

2006-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

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

CAUTION Removal of Engine Hood

• Be sure to stop the engine before beginning 1. Open the engine hood, and then remove the Mat-
work. suba pin (1) and the flat washer (2).
• Do not perform this operation in strong wind.
• Be sure to inspect the nylon sling and other
lifting equipment before beginning work.
• Do not stand or pass under the suspended
load.

Items to prepare
• Wrench (19 mm)
• Nylon sling (with the required breaking load)
• Liftcrane (with the required lifting capacity)

2007-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

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

WARNING 2. Use a wrench (24 mm) to remove the 4 bolts (1),

and then remove the muffler (2).
• The engine is extremely hot just after stop-
ping. Wait for it to sufficiently cool before be-
ginning work.

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

Items to prepare
• Wrench (19 mm, 24 mm)
• Cap
• Rag
• Cleaning fluid

Removal of Muffler Installation of Muffler

1. Use a wrench (19 mm) to loosen the 4 nuts (1), and To Installation perform the reverse of the removal proce-
then remove the 4 bolts (2). dure.
• Use caps to cover the lines to prevent any entry After installation, check for any leaks or vibration.
of water, dust or dirt. Tighten bolts being installed to the specified torque.
• Tightening torque for bolt (2) installation: 85.0 N・ For bolts for which the torque is not specified, see "Stan-
m dard Torque Data for Cap Screws and Nuts".

84512399 EN - September 2011

2007-3
Copyright ©
Removal and Installation of Muffler

84512399 EN - September 2011

2007-4
Copyright ©

Section

2401

Primary specifications

84512399 EN - September 2011

CONTENTS

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

2401-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

2401-2 PRINTED IN FRANCE
Copyright ©
Primary specifications

1. Primary specifications Engine main specifications

Item Engine model 6UZ1

Type Diesel/4-cycle/water-cooled, inline 6-cylinder OHC
Cylinder bore x stroke 120 mm {4.72 in} x 145 mm {5.71 in}
Displacement 9.839 L ｛600.38 cu・in｝
Compression ratio 17.5
Compression pressure ： 2746 kPa { 28 kgf/cm2 }
Shape of the combustion chamber Direct injection type
Cylinder liner type Dry liner or tight fit type
Maximum output ： 270 kW { 367 ps }
Maximum torque ： 1435 N・m { 146 kgf・m }
1235 mm {48.62 in} x 1149 mm {45.24 in} x 1314 {51.73
Dimensions length x width x height
in}
Dry weight ： 940 kg { 2072 lb }
Fuel injection timing ： 2.5 °
Fuel injection order 1, 5, 3, 6, 2, 4
Idling rotation speed ： 875 to 925 r/min
Intake ： 0.2 mm { 0.0079 in }
Valve clearance
Exhaust ： 0.5 mm { 0.0197 in }
Opening/closing timing of intake valve Open ： 22 °
Opening/closing timing of intake valve Close ： 30 °
Opening/closing timing of exhaust valve Open ： 48.5 °
Opening/closing timing of exhaust valve Close ： 23.5 °
Ignition type Compression ignition
Lubricating system
Oil pump type Gear type
Oil filter type Full-flow bypass integrated type x 2
Engine oil level ： 30 to 41 L { 8 to 11 US gal / 7 to 9 Imp.gal }
Oil pan capacity ： 25 to 36 L { 7 to 10 US gal / 5 to 8 Imp.gal }
Oil cooling type Water-cooled multiple-disc type: 6 levels
Cooling system
Cooling type Water cooling
Volume of coolant in engine ： 22.5 L { 6 US gal / 5 Imp.gal }
Water pump type V belt drive spiral type
Thermostat type Wax type
Fuel system
Injection pump type Electronic control common rail type
Governor type Electronic type
Timer type Electronic type
Injection nozzle type Porous type 8 holes, inner diameter φ 0.14 mm
Turbocharger type RHG7V {IHI}

Cleaning system main specifications

Item Specifications
Pulley ratio 1.3
Thermostat Wax pellet type
Open valve temperature ： 80 to 84 ℃ { 176 to 183 °F }
Full-open temperature ： 95 ℃ { 203 °F } /11 mm (0.43 in)

Electrical system main specifications

Generator
Item Specifications
Manufacturer name Mitsubishi Electric Corporation
Isuzu part number 1-81200-603-5
Manufacturer type A004TU6285
Nominal output 24 V - 50 A
84512399 EN - September 2011
2401-3
Copyright ©
Primary specifications

Generator
Rated speed ： 5000 r/min
Regulator type IC type
： 28 to 29 V /5000 r/min, Load: 5 A or below, measured
Regulated voltage
between L and E
： more than 42 A 2500 r/min
Output characteristics Voltage 27 V
： more than 50 A 5000 r/min
Mass ： 9.6 kg { 21 lb }

84512399 EN - September 2011

2401-4
Copyright ©

Section

2415

Removal and Installation of Cylinder head cover

84512399 EN - September 2011

CONTENTS

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

Cylinder head cover Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal and Installation of Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cylinder head assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cylinder head assembly Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cylinder head assembly Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Cylinder head assembly installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Cylinder head assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

2415-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

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

Cylinder head cover Removal 1 Drain plug

1. Coolant drain 2. EGR cooler water hose removal

WARNING 1) Remove the EGR cooler water hose from the
EGR cooler.
• Do not loosen the radiator cap when the
coolant is hot. 3. Ventilation hose disconnect
• Steam and boiling water may burst out
and cause burns, so make sure that the 1) Disengage the ventilation hose from the air
engine has cooled off. breather.
4. Cylinder head cover removal
1) Drain the coolant from the radiator.
1) Remove the cylinder head cover from the
CAUTION camshaft carrier.
2) Remove the gasket from the cylinder head
• After draining the coolant, tighten cover.
the drain plug.

2) Drain the coolant from the engine assembly.

ANNOTATION:
• Loosen the drain plug on the cylinder block
side.

1 Cylinder head cover

2 Gasket

84512399 EN - September 2011

2415-3
Copyright ©
Removal and Installation of Cylinder head cover

Cylinder head cover Installation 4. Coolant filling

1. Cylinder head cover installation 1) Replenish the coolant with the radiator.
2) Loosen the plug using the wrench.
1) Install the gasket to the cylinder head cover. 3) Replenish the coolant with the radiator.
CAUTION CAUTION
• If the gasket has looseness or a • Be careful not to let coolant over-
slant, repair it before installation. flow splash on the exhaust system
parts.
2) Install the cylinder head cover to the camshaft • Coolant overflow should be wiped
carrier. off.
Tightening torque: 15 N・m {1.5 kgf・m / 11
lb・ft} 4) Tighten the plug using the wrench.
ANNOTATION:
• Apply Loctite 271.
Tightening torque: 15 N・m {1.5 kgf・m / 11
lb・ft}
5) Replenish the coolant with the radiator.

1 Cylinder head cover

2 Gasket

2. Ventilation hose connect

1) Connect the ventilation hose to the air
breather.
1 Plug
3. EGR cooler water hose installation
1) Install the EGR cooler water hose to the EGR
cooler.

84512399 EN - September 2011

2415-4
Copyright ©
Removal and Installation of Cylinder head cover

Removal and Installation of ANNOTATION:

Cylinder head • Before removing, place a mark with paint at
the installation position of the harness clip.
Cylinder head assembly Removal • Disconnect the connectors from every sen-
sor and device.
1. Battery ground cable disconnect
1) Disengage the battery ground cable from the Sensor, device Parts
battery. EGR motor EGR valve
Upper left side of the fly-
2. Coolant drain CKP sensor
wheel housing
WARNING Fuel pressure sensor Common rail
CMP sensor Fuel supply pump
• Do not loosen the radiator cap when the Fuel temperature sensor Fuel supply pump
coolant is hot. PCV Fuel supply pump
• Steam and boiling water may burst out Boost sensor Inlet duct
and cause burns, so make sure that the Boost temperature sen-
engine has cooled off. Inlet duct
sor
Solenoid valve Injector
1) Drain the coolant from the radiator.
Engine coolant tempera-
Thermostat housing
CAUTION ture sensor
Left side of the cylinder
• After draining the coolant, tighten Oil pressure sensor
block
the drain plug. Intake throttle position Between the inlet duct
sensor and the intake duct
2) Drain the coolant from the engine assembly. VGS actuator Turbocharger
ANNOTATION: MAF sensor Inlet duct
• Loosen the drain plug on the cylinder block
side. ANNOTATION:
• When disconnecting the harness connector
from the intake throttle valve, pull the lock
control section to release the lock.

3. Engine oil drain

1) Remove the drain plug from the oil pan.
ANNOTATION:
1 Lock control section
• Drain engine oil into the drain pan. 2 Lock release
2) Install the drain plug to the oil pan. 3 Lock
Tightening torque: 70 N・m {7.1 kgf・m / 52 lb・ft}
5. Air leak pipe removal
CAUTION 1) Remove the air leak pipe from the engine as-
sembly.
• Be careful not to forget to tighten the
drain plug. 6. EGR cooler removal
1) Disconnect the air leak pipe from the engine
4. Engine harness removal
assembly.
1) Disconnect the engine harness from the con- 2) Disconnect the water charge pipe from the
nector. EGR cooler duct.

84512399 EN - September 2011

2415-5
Copyright ©
Removal and Installation of Cylinder head cover

3) Disconnect the EGR cooler water hose from 7. EGR valve removal
the EGR cooler.
1) Disconnect the connector from the EGR
4) Remove the water return pipe from the EGR
valve.
cooler.
2) Remove the EGR valve from the EGR mixing
chamber.
3) Remove the lead valve from the EGR mixing
chamber.

1 EGR cooler water hose

2 Water return pipe
3 Air leak pipe
1 EGR valve A
2 EGR mixing chamber
5) Remove the EGR cooler A from the EGR 3 EGR valve B
cooler duct A and the EGR cooler D.
6) Remove the EGR cooler B from the EGR 8. Intake throttle valve removal
cooler duct B and the EGR cooler C.
7) Remove the EGR cooler duct A from the ex- 1) Remove the intake duct from the intake throt-
haust manifold and the bracket. tle valve.
8) Remove the EGR cooler duct B from the ex- 2) Remove the intake throttle valve from the inlet
haust manifold and the bracket. duct.
9) Remove the bracket from the cylinder head. 3) Remove the O-ring from the intake throttle
10) Remove the EGR cooler D from the EGR valve.
valve duct. 9. Inlet duct removal
11) Remove the EGR cooler C from the EGR
valve duct. 1) Remove the inlet duct from the EGR mixing
12) Remove the EGR valve duct from the EGR chamber.
valve. 2) Install the O-ring to the inlet duct.
ANNOTATION:
• Do not remove the boost sensor unless nec-
essary.
10. EGR mixing chamber removal
1) Remove the EGR mixing chamber from the
inlet cover.

1 EGR cooler duct B

2 EGR cooler B
3 EGR cooler C
4 EGR valve duct
5 EGR cooler D
6 EGR cooler A
7 EGR cooler duct A
84512399 EN - September 2011
2415-6
Copyright ©
Removal and Installation of Cylinder head cover

2) Remove the O-ring from the EGR mixing 14. 14. Fuel pipe removal
chamber.
1) 1. Remove the fuel pipe from the fuel filter.
ANNOTATION:
• Seal the inlet cover opening to prevent for-
eign material from entering.

1 Fuel pipe
2 Fuel leak-off pipe
3 Fuel pipe
1 EGR mixing chamber 4 Fuel feed pipe
2 Intake duct 5 Fuel suction pipe
3 Intake throttle valve
4 Inlet duct
5 Boost sensor 15. Fuel filter removal
1) Remove the fuel filter from the cylinder head
11. Ventilation hose removal assembly.
1) Disconnect the ventilation hose from the cylin- • It varies depending on the machine.
der head cover.
2) Disconnect the ventilation hose from the air 16. Injection pipe removal
duct. 1) Remove the injection pipe from the injector
12. Fuel leak-off pipe removal and the common rail assembly.
1) 1. Disengage the fuel leak-off pipe from the CAUTION
cylinder head.
2) Disengage the fuel leak-off pipe from the fuel • Do not reuse the removed injection
filter bracket. pipe.
3) Disengage the fuel leak-off pipe from the com- • Be careful to prevent dust and dirt
mon rail assembly. from attaching to the sleeve nut.
4) Disconnect the fuel leak-off pipe from the fuel • Seal the opening of the pipe instal-
supply pump. lation section of the common rail to
5) Remove the fuel leak-off pipe from the prevent dirt, etc. from attaching to
bracket. it.
13. Fuel feed pipe removal 17. Turbocharger feed oil pipe removal
1) Remove the clip from the fuel feed pipe. 1) 1. Remove the clip from the turbocharger feed
2) Remove the fuel feed pipe from the fuel filter. oil pipe.
2) Remove the turbocharger feed oil pipe from
the turbocharger assembly.
3) Remove the turbocharger feed oil pipe from
the oil cooler assembly.
18. Oil return pipe removal
1) Disengage the oil return pipe from the tur-
bocharger assembly.
2) Remove the oil return pipe from the cylinder
block.
19. Water feed pipe removal
1) Disengage the water feed pipe from the tur-
bocharger assembly.
84512399 EN - September 2011
2415-7
Copyright ©
Removal and Installation of Cylinder head cover

2) Remove the water feed pipe from the oil 22. Cylinder head cover removal
cooler.
1) Remove the cylinder head cover from the
20. Water return pipe removal camshaft carrier.
2) Remove the gasket from the cylinder head
1) Disengage the water return pipe from the tur-
cover.
bocharger assembly.
2) Remove the water return pipe from the ther-
mostat housing.

1 Cylinder head cover

2 Gasket

23. Glow plug removal

1 Water return pipe
2 Oil return pipe 1) Remove the glow plug connector from the
3 Feed oil pipe glow plug.
4 Water feed pipe 2) Remove the glow plug from the cylinder head
assembly.
24. Injector harness removal
21. Turbocharger assembly removal 1) Remove the harness from the injector.
1) Remove the turbocharger assembly from the
exhaust manifold. CAUTION
2) Remove the gasket from exhaust manifold. • In this state, the injector ID code
plate may come off.
Therefore, avoid mix-up with other
injector ID code plates.

1 Turbocharger
2 Exhaust manifold
3 Gasket

CAUTION
• Put a seal on every part to prevent
foreign materials from getting into
the turbocharger.

84512399 EN - September 2011

2415-8
Copyright ©
Removal and Installation of Cylinder head cover

2) Remove the bolts from the injector harness. CAUTION

• Before lowering the cylinder head,
remove the injector because its tip
will protrude from the bottom sur-
face of the cylinder head.
• Do not remove the ID code plate
from the injector.
• When pulling out the injector, make
sure that the sleeve does not come
off together while working on it.
• Attach a number tag to the removed
injector.

3) Remove the injector harness from the

camshaft carrier.
ANNOTATION:
• Disconnect the injector harness from the
junction connector.
25. Injector leak-off pipe removal
1) Remove the injector leak-off pipe from the
cylinder head assembly and the injector.
2) Remove the gasket from the injector leak-off
pipe.

CAUTION
1 Clamp
• Do not reuse the gasket. 2 Bolt
3 Injector
4 O-ring

ANNOTATION:
• If the injector is difficult to pull out, use the
fuel injector remover and a sliding hammer.

26. Injector removal

1) Remove the clamp from the cylinder head as-
sembly.
2) Remove the injector from the cylinder head
assembly.
Special tool: injector remover (refer to
section 1003)

84512399 EN - September 2011

2415-9
Copyright ©
Removal and Installation of Cylinder head cover

1) Measure the clearance using the feeler

gauge.
ANNOTATION:
• Measure the camshaft clearance in the axis
direction.

Camshaft clearance in the axis direction

: 0.085 to 0.170 mm {0.0033 to
Standard value
0.0067 in}
Limit : 0.25 mm {0.0098 in}

30. Camshaft removal

1) Remove the cam holder from the camshaft
Special tool: sliding hammer (refer to carrier.
section 1003)
3) Remove the gasket from the sleeve. ANNOTATION:
• Evenly loosen them on both sides to remove
CAUTION them.
• Do not reuse the gasket. 2) Remove the camshaft from the camshaft car-
rier.
27. Rocker arm shaft removal
1) Remove the rocker arm shaft from the
camshaft carrier.
ANNOTATION:
• Evenly loosen the rocker arm shaft installa-
tion bolts on both ends to remove them.

31. Camshaft carrier removal

1) Remove the camshaft carrier from the cylinder
head assembly.

28. Bridge removal

1) Remove the bridge from the bridge guide.
ANNOTATION:
• Store the removed bridges in numerical or-
der.
29. Camshaft measurement

84512399 EN - September 2011

2415-10
Copyright ©
Removal and Installation of Cylinder head cover

32. Thermostat housing removal 1) Loosen the head bolts with a wrench.
1) Remove the thermostat housing from the ANNOTATION:
cylinder head.
• Loosen the M10 bolts in the numerical order
indicated in the diagram.
2) Loosen the head bolts with a wrench.
ANNOTATION:
• Evenly loosen the M15 bolts in the order of
arrows indicated in the diagram.

1 Gasket
2 Bracket
3 Water outlet pipe
4 Thermostat housing
5 Bracket

33. Cylinder head assembly removal

3) Remove the cylinder head assembly from the

cylinder block.
4) Remove the cylinder head gasket from the
cylinder block.

CAUTION
• Do not reuse the cylinder head gas-
ket.

ANNOTATION:
• Inspect for water leaks or exhaust gas leaks
during removal.

84512399 EN - September 2011

2415-11
Copyright ©
Removal and Installation of Cylinder head cover

Cylinder head assembly Disassembly 3. Idle gear C removal

1. Camshaft carrier disassembly 1) Remove the idle gear cover from the cylinder
head assembly.
1) 1Remove the oil seal from the camshaft car- 2) Remove the idle gear shaft from the cylinder
rier. head assembly.
ANNOTATION: 3) Remove the idle gear C from the cylinder head
assembly.
• Remove them starting with the inside of the
carrier and ending with the outside.

4. Inlet cover removal

1) Remove the inlet cover from the cylinder head
2. Idle gear C measurement
assembly.
1) 1Measure the clearance using the feeler 2) Remove the gasket from the inlet cover.
gauge.

Clearance of idle gear C in the axis direction

: 0.135 - 0.190 mm {0.005315 -
Standard value
0.007480 in}
Limit : 0.30 mm {0.01181 in}

5. Exhaust manifold removal

1) Remove the exhaust manifold from the cylin-
der head assembly.
ANNOTATION:
• At the same time, remove the bracket and
the distance tube.

84512399 EN - September 2011

2415-12
Copyright ©
Removal and Installation of Cylinder head cover

2) Remove the gasket from the cylinder head as- Special tool: valve spring replacer (refer
sembly. to section 1003)

2) Remove the special tool from the cylinder

1 Bracket head assembly.
2 Exhaust manifold 3) Remove the spring seat from the cylinder
3 - head assembly.
4) Remove the valve spring from the cylinder
4 Gasket
head assembly.
3) Disassemble the exhaust manifold. 7. Inlet valve removal
4) Remove the seal ring from the exhaust mani-
fold. 1) Remove the inlet valve from the cylinder head
assembly.
6. Valve spring removal
ANNOTATION:
1) Remove the split collar from the spring seat
using the special tool. • Store the removed valves with a number tag
attached to them.
ANNOTATION:
8. Exhaust valve removal
• Compress the valve springs using a valve
spring compressor, and then remove the 1) Remove the exhaust valve from the cylinder
split collars. head assembly.
ANNOTATION:
• Store the removed valves with a number tag
attached to them.
9. Valve guide removal
1) Remove the valve stem oil seal from the valve
guide.

84512399 EN - September 2011

2415-13
Copyright ©
Removal and Installation of Cylinder head cover

2) Remove the spring seat from the cylinder

head assembly.

10. Bridge guide removal

1) Remove the bridge guide from the cylinder
head assembly.
ANNOTATION:
• Electrically weld a nut to the bridge guide
and remove the bridge guide with a sliding
hammer.

3) Remove the valve guide from the cylinder

head assembly using the special tool.
ANNOTATION:
• Remove the valve guide using the valve
guide replacer.
11. Valve seat insert removal
1) Heat the valve seat insert with the gas burner.
ANNOTATION:
• Heat the inner surface of the valve seat in-
sert at 2 locations.
Heating temperature: 600 - 700 °C {1112.1 -
1292.0 °F}
2) Remove the valve seat insert from the cylinder
head assembly using the workr.
ANNOTATION:
• Start work after allowing it to cool naturally
for about 5 minutes.
Special tool: valve guide replacer (refer
CAUTION
to section 1003)
• Avoid sudden cooling.

84512399 EN - September 2011

2415-14
Copyright ©
Removal and Installation of Cylinder head cover

Cylinder head assembly Reassembly

1. Injector sleeve installation
1) Apply the engine oil to the O-ring.
2) Install the O-ring to the injector sleeve.

CAUTION
• Install the red O-ring on the upper
side and black O-ring on the lower
side of the injector sleeve groove,
respectively.

3) Apply thread locking adhesive to the injector

sleeve.
12. Injector sleeve removal ANNOTATION:
1) Remove the injector sleeve from the cylinder • Apply Loctite 290 to the lower part, outer
head assembly. circumference, and the contact seat surface
ANNOTATION: of the injector sleeve.

• Place a rod on the injector sleeve and tap it 4) Install the injector sleeve to the cylinder head
with a hammer from the bottom surface of assembly.
the cylinder head to remove the sleeve.

2. Valve seat insert installation

1) Install the valve seat insert to the cylinder
head assembly.
ANNOTATION:
• Firmly press-fit it with a press.
CAUTION
• Carefully remove rust and carbon
on the installation surface of the
valve seat insert before press-fit-
ting.

84512399 EN - September 2011

2415-15
Copyright ©
Removal and Installation of Cylinder head cover

4. Valve guide installation

1) Apply the engine oil to the valve guide.
2) Install the valve guide to the cylinder head
assembly using the special tool.
ANNOTATION:
• Install the valve guide using the valve guide
replacer.

CAUTION
• When installing, refer to the ta-
ble below to keep the protrusion
amount of the valve guide within
the standard value.
3. Bridge guide installation
1) Apply the engine oil to the bridge guide.
2) Install the bridge guide to the cylinder head
assembly using the special tool.
ANNOTATION:
• Drive in the bridge guide using the bridge
guide setting tool.

Special tool: valve guide replacer (refer

to section 1003)

Special tool: bridge guide setting tool

(refer to section 1003)

Amount of the bridge guide protrusion

: 43.0 - 44.0 mm {1.6929 -
Standard value
1.7323 in}

Amount of the valve guide protrusion

Parts Standard value
IN side : 23.5 - 24.5 mm {0.9252 - 0.9646
EX side in}

3) Install the spring seat to the cylinder head as-

sembly.
4) Apply engine oil to the valve stem oil seal.
5) Install the valve stem oil seal to the valve
guide using the special tool.
ANNOTATION:

84512399 EN - September 2011

2415-16
Copyright ©
Removal and Installation of Cylinder head cover

• Press-fit using the valve stem oil seal in- 5. Inlet valve installation
staller.
1) Apply engine oil to the valve stem oil seal.
CAUTION 2) Install the inlet valve to the cylinder head as-
sembly.
• Refer to the following table for the
specified values of the press-fitting ANNOTATION:
depth. • Insert the inlet valve into the front side of the
valve insertion opening.

Special tool: valve stem seal installer

(refer to section 1003) 6. Exhaust valve installation
1) Apply engine oil to the valve stem oil seal.
2) Install the exhaust valve to the cylinder head
Valve stem oil seal press-fitting depth assembly.
Parts Specified value
Position 4 indi- ANNOTATION:
cated in the dia- : 26.3 mm {1.0354 in} • Insert the exhaust valve into the rear side of
gram below the valve insertion opening.

7. Valve spring installation

1) Install the valve spring to the cylinder head
assembly.
1 Valve stem oil seal
2 Valve guide CAUTION
3 Spring seat
• Install the inlet valve spring with
Valve stem oil seal press-fitting the narrowpitch, painted side on
4
depth the bottom.

ANNOTATION:
CAUTION
• Make sure that no spring comes off
or no seal is deformed after press-
fitting.

84512399 EN - September 2011

2415-17
Copyright ©
Removal and Installation of Cylinder head cover

• The exhaust valve spring has no direction-

ality.
2) Install the spring seat to the cylinder head as-
sembly.

4) Remove the special tool from the cylinder

head assembly.
ANNOTATION:
• After removing the special tool, lightly tap
the top of the valve stem to stabilize the split
collar.
8. Exhaust manifold installation
1) Install the seal ring to the exhaust manifold.
ANNOTATION:
• Shift the joint positions by 120 degrees for
installation.

CAUTION
• Pay attention to the directionality of
the seal ring.

3) Install the split collar to the spring seat using

the special tool.
ANNOTATION:
• Compress the valve springs using the valve
spring compressor, and then install the split
collars.

2) Install the gasket to the cylinder head assem-

bly.

CAUTION
• Install it with the molybdenum coat-
ing facing the outside and the pro-
truding portion on the lower right
side.

Special tool: valve spring replacer (refer 3) Install the exhaust manifold to the cylinder
to section 1003) head assembly.
ANNOTATION:
• Refer to the diagram below to collectively
tighten the bracket.

84512399 EN - September 2011

2415-18
Copyright ©
Removal and Installation of Cylinder head cover

3) Install the idle gear shaft to the cylinder head

assembly.
ANNOTATION:
• Align the oil pin with the oil hole position of
the cylinder head and install.
4) Apply the disulfide molybdenum grease to the
bolt.
ANNOTATION:
• Apply molybdenum disulfide to the threaded
portion and seat surface of the idle gear in-
stallation bolt.
5) Install the bolt to idle gear C.
Tightening torque: 80 N・m {8.2 kgf・m / 59
1 Bracket lb・ft}
2 Exhaust manifold ANNOTATION:
3 -
• Confirm that the gear rotates smoothly.
4 Gasket
CAUTION

ANNOTATION: • Be careful not to damage the gear

because it protrudes from the cylin-
• Tighten each flange in the order of 3rd, 4th, der head.
2nd, 5th, 1st, and 6th cylinder.
Tightening torque: 54 N・m {5.5 kgf・m / 40 6) Apply the engine oil to the O-ring.
lb・ft} 7) Install the O-ring to the idle gear cover.
8) Install the idle gear cover to the cylinder head
9. Inlet cover installation assembly.
Tightening torque: 22 N・m {2.2 kgf・m / 16
1) Install the gasket to the inlet cover.
lb・ft}
CAUTION
• Be sure they do not fall off.

2) Install the inlet cover to the cylinder head as-

sembly.
ightening torque: 45 N・m {4.6 kgf・m / 33
lb・ft}

11. Camshaft carrier reassembly

1) Apply engine oil to the oil seal.
2) Install the oil seal to the camshaft carrier using
the special tool.
ANNOTATION:
• Tap in the oil seal using the oil seal installer.
10. Idle gear C installation CAUTION
1) Apply the engine oil to the idle gear shaft.
• Make sure the oil seal does not
2) Align the idle gear C with the cylinder head slant.
assembly.

84512399 EN - September 2011

2415-19
Copyright ©
Removal and Installation of Cylinder head cover

Cylinder head assembly installation

1. Cylinder head assembly installation
1) Clean the cylinder block using the scraper.
ANNOTATION:
• Carefully clean the cylinder block top sur-
face and the cylinder head bottom surface,
being careful not to damage them.
2) Apply the liquid gasket to the cylinder block.

Special tool: oil seal installer (refer to

section 1003)

1 Cylinder block top surface

Flywheel housing installation
2
section
3 Liquid gasket application area

Guidelines for liquid gasket application

Parts to be Liquid gasket
Method of use
applied used
Application thick-
Permatex sil- ness: 2 mm
Position 3 in
icone foam (0.0787 in)
the diagram
gasket No.6 Application width:
5 mm (0.1969 in)

CAUTION
• Strictly conform to the specifica-
tions for thickness and width of the
liquid gasket application.
• After applying liquid gasket,
promptly install the cylinder head.

3) Align the cylinder head gasket with the cylin-

der block.

CAUTION
• Use a new cylinder head gasket.

4) Align the cylinder head assembly with the

cylinder block.
ANNOTATION:
• Carefully align the knock pin positions.
84512399 EN - September 2011
2415-20
Copyright ©
Removal and Installation of Cylinder head cover

CAUTION 5) Apply disulfide molybdenum grease to the

head bolts.
• Confirm engagement of the idle ANNOTATION:
gears.
• Apply disulfide molybdenum to the seat sur-
face and the threaded portion.
6) Tighten the head bolt using the torque wrench.
ANNOTATION:
• Tightening order of the head bolts

ANNOTATION: 8) Tighten the head bolt using the special tool.

• Tighten bolts 1 through 26 shown in the di-
agram in numerical order.
Tightening torque: 98 N・m {10.0 kgf・m / 72
lb・ft}
7) Tighten the head bolt using the torque wrench.
ANNOTATION:
• Tighten bolts 1 through 26 shown in the di-
agram in numerical order.
Tightening torque: 196 N・m {20.0 kgf・m /
145 lb・ft}

Special tool: angle gauge (refer to section

1003)
ANNOTATION:
• Tighten bolts 1 through 26 shown in the di-
agram in numerical order.
Tightening angle: 60 - 90 °

84512399 EN - September 2011

2415-21
Copyright ©
Removal and Installation of Cylinder head cover

9) Tighten the head bolt using the torque wrench. Tightening torque: 44 N・m {4.5 kgf・m / 32
lb・ft}
ANNOTATION:
• Tighten bolts 27 through 29 shown in the
diagram in numerical order.
Tightening torque: 38 N・m {3.9 kgf・m / 28
lb・ft}
10) Tighten the head bolt using the torque wrench.
ANNOTATION:
• Tighten bolts 1 through 26 shown in the di-
agram in numerical order.
• Confirm that the bolts are tightened to the
torque or higher as described below.
Tightening torque: 230 N・m {23.5 kgf・m /
170 lb・ft}

CAUTION 1 Gasket
2 Bracket
• Be careful not to drop foreign mate- 3 Water outlet pipe
rials into the timing gear hole.
4 Thermostat housing
ANNOTATION: 5 Bracket

• The cylinder head installation bolts should 3. Camshaft carrier installation

not be reused exceeding 2 times.
1) Install the gasket to the camshaft carrier.
2. Thermostat housing installation
ANNOTATION:
1) Install the thermostat housing to the cylinder
head assembly. • Firmly push the bulging section of the gas-
ket into the groove of the carrier.
ANNOTATION:
CAUTION
• Insert the gasket, and insert the thermostat
housing into the water pump assembly to • If the gasket edge is not aligned
install it. with the groove center and is slant-
ing, push the gasket sideways with
CAUTION your fingertip so that the gasket
• Assemble the thermostat housing edge position is correctly aligned
after assembling the water pump with the groove center before in-
assembly and cylinder head assem- stalling the gasket.
bly.
2) Temporarily tighten the camshaft carrier onto
ANNOTATION: the cylinder head assembly.

• A small amount of ThreeBond 1521 can also ANNOTATION:

be applied to the gasket. • Temporarily tighten the bolts in the numeri-
cal order indicated in the diagram.
• Tightening order

3) Securely tighten the camshaft carrier onto the ANNOTATION:

cylinder head assembly.
84512399 EN - September 2011
2415-22
Copyright ©
Removal and Installation of Cylinder head cover

• Securely tighten them in the numerical order CAUTION

indicated in the diagram.
Tightening torque: 22 N・m {2.2 kgf・m / 16 • In tightening, if attached oil is
found, thoroughly remove oil from
lb・ft} M8 bolt
each seat surface and threaded
Tightening torque: 44 N・m {4.5 kgf・m / 32
portion of the bolt, camshaft car-
lb・ft} M10 bolt
rier, and cam holder.
CAUTION
6) Align the cam holder with the camshaft carrier.
• Confirm and retighten the bolts 1 to
5, because the torque at which they CAUTION
were initially tightened may have re-
duced. • Confirm the identification code and
front mark of the cam holder.
4. Camshaft installation
7) Temporarily tighten the cam holder onto the
1) Align 1st cylinder to the compression top dead camshaft carrier.
center.
ANNOTATION:
ANNOTATION:
• Temporarily tighten the bolts in the numeri-
• Rotate the crankshaft positively and align cal order indicated in the diagram.
the marking of the flywheel with the pointer. • Tightening order

2) Apply engine oil to the camshaft carrier. 8) Securely tighten the cam holder onto the
ANNOTATION: camshaft carrier.

• Apply on the journal, holder, and No.7 jour- ANNOTATION:

nal thrust sections. • Securely tighten them in the numerical order
3) Place the camshaft on the camshaft carrier. indicated in the diagram.
4) Align the alignment mark with the camshaft Tightening torque: 53 N・m {5.4 kgf・m / 39
carrier. lb・ft}

CAUTION
• After tightening the cam holder,
confirm the alignment mark of the
camshaft gear again.

5. Bridge installation
1) Apply the engine oil to the bridge guide.
2) Loosen the adjust screw using the wrench.

CAUTION
• Be sure the adjust screw does not
loosen too much because it may fall
5) Apply engine oil to the cam holder. off of the bridge.
ANNOTATION:
• Apply it on the cam holder journal surface.

84512399 EN - September 2011

2415-23
Copyright ©
Removal and Installation of Cylinder head cover

3) Install the bridge to the bridge guide. 6) Loosen the adjust screw using the special
tool.
CAUTION
ANNOTATION:
• Install it in the same position as it
was removed. • Completely loosen the adjust screw on the
bridge side.

6. Rocker arm shaft installation Special tool: valve clearance adjust nut
wrench (refer to section 1003)
1) Apply engine oil to the camshaft.
2) Apply the engine oil to the bridge. CAUTION
3) Temporarily tighten the rocker arm shaft onto
the camshaft carrier. • Make sure the adjust screw on the
bridge side is not loosened too
ANNOTATION: much because it may fall off.
• Temporarily tighten the bolts in the numeri-
cal order indicated in the diagram.
• Tightening order

1 Adjust nut wrench

7) Adjust the valve clearance to the standard

1 Front mark
value using a feeler gauge.

4) Securely tighten the rocker arm shaft onto the

1 Feeler gauge 4 Bridge

2 Rocker arm 5 Adjust screw on the bridge side
Adjust screw on the rocker arm 6 Camshaft
3
side

Cylinder No. 1 2 3 4 5 6
Arrangement of
Condition IN EXH IN EXH IN EXH IN EXH IN EXH IN EXH
valve
When the #1 cylinder
is set at the compres- Yes Yes Yes Yes Yes Yes
Valve to be ad- sion top dead center
justed When the #6 cylinder
is set at the compres- Yes Yes Yes Yes Yes Yes
sion top dead center

ANNOTATION: ANNOTATION:
• Tighten the adjust screw on the rocker arm • Confirm that there is no old gasket remain-
side and adjust it to the standard value. ing in the sleeve.
2) Apply the disulfide molybdenum grease to the
Valve clearance - at cold condition bolt.
Inlet valve : 0.2 mm {0.0079 in}
ANNOTATION:
Exhaust valve : 0.5 mm {0.0197 in}
• Apply on the seat surface and threaded por-
tion of the clamp tightening bolt.
ANNOTATION:
3) Install the injector to the cylinder head assem-
• In the case of inlet adjustment, insert the 0.2 bly.
mm feeler gauge between the rocker arm
and the camshaft. CAUTION
• In the case of exhaust side adjustment, in-
sert a 0.5 mm feeler gauge between the • Carefully remove carbon from in-
rocker arm and the camshaft. side the sleeve.
• Secure the adjust screw on the rocker arm • Do not remove the ID code plate
side with the lock nut. from the injector.

Tightening torque: 34 N・m {3.5 kgf・m / 25 4) Temporarily tighten the injection pipe to the
lb・ft} injector.
ANNOTATION: 5) Install the clamp to the cylinder head assem-
bly.
• Lightly tighten the adjust screw on the Tightening torque: 26 N・m {2.7 kgf・m / 19
bridge with a feeler gauge inserted. lb・ft}
• Confirm that the tip of the adjust screw
touches the end of the bridge shaft and that
movement of the feeler gauge has become
stiff.
• Slightly loosen the adjust screw on the
bridge so that movement of the feeler gauge
becomes appropriate.
• Secure the adjust screw on the bridge side
with the lock nut.
Tightening torque: 22 N・m {2.2 kgf・m / 16
lb・ft}
ANNOTATION:
• Turn the crankshaft one rotation to adjust
the remaining valves.
7. Injector installation 1 Clamp
1) Install the gasket to injector. 2 Bolt
3 Injector
CAUTION 4 O-ring
• Use a new gasket.
8. Injector leak-off pipe installation
84512399 EN - September 2011
2415-25
Copyright ©
Removal and Installation of Cylinder head cover

1) Install the gasket to the injector leak-off pipe. 2) Install the bolt to the injector harness.
Tightening torque: 22 N・m {2.2 kgf・m / 16
CAUTION lb・ft}
• Use a new gasket.

2) Install the injector leak-off pipe to the cylinder

head assembly.

Injector leak-off pipe tightening torque

The num-
ber indi-
Bolt size cated in Tightening torque
the dia-
gram
: 15 N・m {1.5 kgf・
M8 eyebolt 2
m / 11 lb・ft}
M12 eye- : 34 N・m {3.5 kgf・
3 3) Install the harness to the injector.
bolt m / 25 lb・ft}
Tightening torque: 2 N・m {0.2 kgf・m / 18
lb・in}

CAUTION
• Strictly conform to the specified
torque to avoid over-tightening of
nuts, which may cause damage.

1 Injector leak-off pipe

2 M8 eyebolt
3 M12 eyebolt

9. Injector harness installation

1) Install the injector harness to the camshaft 10. Glow plug installation
carrier.
1) Install the glow plug to the cylinder head as-
ANNOTATION: sembly.
• Make sure to lock the connector on the har- Tightening torque: 20 N・m {2.0 kgf・m / 15
ness. lb・ft}
2) Install the glow plug connector to the glow
plug.
11. Cylinder head cover installation
1) Install the gasket to the cylinder head cover.

CAUTION
• If the gasket has looseness or a
slant, repair it before installation.

84512399 EN - September 2011

2415-26
Copyright ©
Removal and Installation of Cylinder head cover

2) Install the cylinder head cover to the camshaft CAUTION

carrier.
Tightening torque: 15 N・m {1.5 kgf・m / 11 • Confirm that there are no pieces of
lb・ft} gasket inside the duct before as-
sembly.
• Insert securely until it touches the
duct.

Tightening torque: 8 N・m {0.8 kgf・m / 71

lb・in} V-band

1 Cylinder head cover

2 Gasket

12. Turbocharger assembly installation

1) Replenish the engine oil with the turbocharger
assembly. 1 Exhaust pipe adapter
ANNOTATION: 2 Gasket
3 Turbocharger
• Apply about 1 cc of engine oil to the oil path 4 V-band
to lubricate the turbine bearing portion.
2) Install the gasket to the exhaust manifold. ANNOTATION:
3) Temporarily tighten the turbocharger assem-
bly to the exhaust manifold. • Tighten the flange nuts in order starting with
4) Install the exhaust pipe adapter to the tur- the one at the turbine inlet and secure them
bocharger. with double nuts.
ANNOTATION: Tightening torque: 45 N・m {4.6 kgf・m / 33
lb・ft}
• Assemble the gasket on the exhaust pipe
adapter.

CAUTION
• Make sure to conduct assembly
so that the gasket surface with a
yellow marking is visible when the
gasket is installed to the exhaust
pipe adapter.
• When installing the gasket, be care-
ful not to deform it.
• Make sure to install new gaskets.
Prohibit their reuse.

ANNOTATION:
• Tighten the 3 bolts from the top of the 1 Turbocharger
bracket tightened together with the exhaust 2 Exhaust manifold
manifold.
3 Gasket
• Tighten it to the turbocharger using a
V-band.
13. Water feed pipe installation
1) Install the water feed pipe to the cylinder
block.
Tightening torque: 41 N・m {4.2 kgf・m / 30
lb・ft}
84512399 EN - September 2011
2415-27
Copyright ©
Removal and Installation of Cylinder head cover

2) Connect the water feed pipe to the tur- 4) Securely tighten the oil return pipe onto the
bocharger assembly. turbocharger assembly.
Tightening torque: 50 N・m {5.1 kgf・m / 37 Tightening torque: 22 N・m {2.2 kgf・m / 16
lb・ft} lb・ft}
5) Securely tighten the oil return pipe onto the
14. Water return pipe installation cylinder block.
1) Install the water return pipe to the cylinder Tightening torque: 44 N・m {4.5 kgf・m / 32
head. lb・ft}
Tightening torque: 41 N・m {4.2 kgf・m / 30
lb・ft}
2) Connect the water return pipe to the tur-
bocharger
assembly.
Tightening torque: 50 N・m {5.1 kgf・m / 37
lb・ft}
15. Turbocharger feed oil pipe installation
1) Temporarily tighten the turbocharger feed oil
pipe onto the turbocharger assembly.
2) Temporarily tighten the turbocharger feed oil
pipe onto the oil cooler assembly.
3) Securely tighten the turbocharger feed oil pipe
onto the turbocharger assembly.
Tightening torque: 34 N・m {3.5 kgf・m / 25
lb・ft}
4) Securely tighten the turbocharger feed oil pipe
onto the oil cooler assembly.
Tightening torque: 34 N・m {3.5 kgf・m / 25
lb・ft}

1 Turbocharger assembly
2 Water return pipe
3 Water feed pipe
4 Oil return pipe
1 Water return pipe 5 Oil feed pipe
2 Oil return pipe
3 Oil feed pipe 17. Air duct installation
4 Water feed pipe
1) Install the air duct to the turbocharger assem-
bly.
16. Oil return pipe installation 2) Install the inlet duct to the turbocharger as-
1) Install the O-ring to the oil return pipe. sembly.
ANNOTATION: ANNOTATION:
• Install them on both ends of the oil return • Insert the rubber hose all the way in until it
pipe. hits the deepest part.
• Place the clip at the lower side and tighten
2) Temporarily tighten the oil return pipe onto the it horizontally.
turbocharger assembly.
3) Temporarily tighten the oil return pipe onto the
cylinder block. Tightening torque
Parts Tightening torque
Clip : 8 N・m {0.8 kgf・m / 71 lb・in}
M10 bolt : 44 N・m {4.5 kgf・m / 32 lb・ft}
84512399 EN - September 2011
2415-28
Copyright ©
Removal and Installation of Cylinder head cover

3) Install the MAF sensor to the air duct. 2) Install the clip to the injection pipe.
Tightening torque: 1.5 N・m {0.2 kgf・m / 13 Tightening torque: 9 N・m {0.9 kgf・m / 80
lb・in} lb・in}

CAUTION
• If the rubber is cracked or damaged,
do not reuse it.

1 Inlet duct
2 Air duct
3 MAF sensor
4 Air hose
1 Injection pipe
18. Injection pipe installation 2 Bracket
1) Install the injection pipe to the injector and 3 Common rail assembly
common rail assembly.
19. Fuel filter installation
CAUTION
1) Install the fuel filter to the cylinder head as-
• Use new injection pipes. sembly.
ANNOTATION:
ANNOTATION:
• It varies depending on the machine.
• Alternately tighten the injection pipe sleeve
nuts on the injector side and the common 20. Fuel pipe installation
rail side in a few steps.
1) Securely tighten the fuel pipe onto the fuel
Tightening torque: 44 N・m {4.5 kgf・m / 32 filter.
lb・ft} Tightening torque: 50 N・m {5.1 kgf・m / 37
lb・ft}
2) Install the clip to the fuel feed pipe.
Tightening torque: 9 N・m {0.9 kgf・m / 80
lb・in}

84512399 EN - September 2011

2415-29
Copyright ©
Removal and Installation of Cylinder head cover

21. Fuel feed pipe installation 1) Install the O-ring to EGR mixing chamber.
2) Install the EGR mixing chamber to the inlet
1) Securely tighten the fuel feed pipe onto the
cover.
fuel
Tightening torque: 44 N・m {4.5 kgf・m / 32
filter.
lb・ft}
Tightening torque: 50 N・m {5.1 kgf・m / 37
lb・ft}

25. Inlet duct installation

1) Install the O-ring to the inlet duct.
1 Fuel pipe 2) Install the inlet duct to the EGR mixing cham-
2 Fuel leak-off pipe ber.
3 Fuel pipe Tightening torque: 45 N・m {4.6 kgf・m / 33
4 Fuel feed pipe lb・ft}
5 Fuel suction pipe
26. Intake throttle valve installation
22. Fuel leak-off pipe installation 1) Install the O-ring to the intake throttle valve.
2) Install the intake throttle valve to the inlet duct.
1) Temporarily tighten the fuel leak-off pipe to the 3) Install the intake duct to the intake throttle
common rail assembly. valve.
2) Temporarily tighten the fuel leak-off pipe to the Tightening torque: 22 N・m {2.2 kgf・m / 16
fuel supply pump. lb・ft}
3) Temporarily tighten the fuel leak-off pipe to the
cylinder head and fuel filter bracket.
4) Temporarily tighten the fuel leak-off pipe to the
pipe bracket.
5) Securely tighten the fuel leak-off pipe to the
fuel supply pump.
Tightening torque: 17 N・m {1.7 kgf・m / 13
lb・ft}
6) Securely tighten the fuel leak-off pipe to the
common rail assembly.
Tightening torque: 20 N・m {2.0 kgf・m / 15
lb・ft}
7) Completely tighten the fuel leak-off pipe to the
cylinder head.
Tightening torque: 41 N・m {4.2 kgf・m / 30
lb・ft}
8) Completely tighten the fuel leak-off pipe to the
fuel filter bracket. 1 EGR mixing chamber
Tightening torque: 41 N・m {4.2 kgf・m / 30 2 Intake duct
lb・ft} 3 Intake throttle valve
9) Completely tighten the fuel leak-off pipe to the 4 Inlet duct
pipe bracket. 5 Boost sensor
Tightening torque: 41 N・m {4.2 kgf・m / 30
lb・ft}
27. EGR valve installation
23. Ventilation hose installation
1) Install the lead valve to the EGR mixing cham-
1) Connect the ventilation hose to the air duct.
ber.
2) Connect the ventilation hose to the cylinder
Tightening torque: 10 N・m {1.0 kgf・m / 89
head cover.
lb・in}
24. EGR mixing chamber installation 2) Install the gasket to the EGR mixing chamber.
84512399 EN - September 2011
2415-30
Copyright ©
Removal and Installation of Cylinder head cover

3) Install the EGR valve to the EGR mixing 2) Install the bracket to the cylinder head.
chamber. Tightening torque: 97 N・m {9.9 kgf・m / 72
Tightening torque: 44 N・m {4.5 kgf・m / 32 lb・ft} Engine front side
lb・ft} Tightening torque: 44 N・m {4.5 kgf・m / 32
lb・ft} Engine rear side

1 EGR valve
2 EGR mixing chamber Engine front side EGR cooler
1
3 EGR valve bracket
Engine rear side EGR cooler
2
28. EGR cooler installation bracket

1) Temporarily tighten the EGR valve duct to the 3) Temporarily tighten the EGR cooler to the
EGR valve. EGR valve duct.
ANNOTATION: ANNOTATION:
• Temporarily tighten with the gasket inserted. • Temporarily tighten with the gasket inserted.
• Install the air removal pipe faicing it towards
Temporary tightening torque: 5 N ・ m {0.5 the front side.
kgf・m / 44 lb・in}
Temporary tightening torque: 5 N ・ m {0.5
kgf・m / 44 lb・in}

1 EGR cooler D
2 EGR valve duct
3 EGR cooler C

84512399 EN - September 2011

2415-31
Copyright ©
Removal and Installation of Cylinder head cover

4) Install the bracket to the cylinder head. 1 EGR cooler B

Tightening torque: 97 N・m {9.9 kgf・m / 72 2 EGR cooler A
lb・ft} Engine front side 3 EGR duct A
ANNOTATION: 4 EGR duct B

• The rear side bracket should be tightened

together with the exhaust manifold. ANNOTATION:
• Procedure for complete tightening
CAUTION
• Make sure to follow the installation
procedure.
Otherwise, a gas leak or excessive
stress may occur causing parts
damage.

7) Securely tighten the EGR cooler to the EGR

valve duct.
ANNOTATION:
• Completely tighten the EGR cooler C and
the EGR cooler D to the EGR valve duct.
1 Engine rear side bracket Tightening torque: 50 N・m {5.1 kgf・m / 37
2 Engine front side bracket lb・ft} 1 in the diagram
8) Securely tighten the EGR cooler to the EGR
5) Temporarily tighten the EGR duct to the ex- cooler.
haust manifold.
ANNOTATION:
ANNOTATION:
• Tighten the connections between the EGR
• Temporarily tighten with the gasket inserted. cooler A and the EGR cooler C and between
Temporary tightening torque: 5 N ・ m {0.5 the EGR cooler B and the EGR cooler D at
kgf・m / 44 lb・in} the respective specified torque.
6) Temporarily tighten the EGR cooler to the Tightening torque: 50 N・m {5.1 kgf・m / 37
EGR duct. lb・ft} 2 in the diagram
ANNOTATION: 9) Securely tighten the EGR cooler to the EGR
duct.
• Temporarily tighten with the gasket inserted. Tightening torque: 50 N・m {5.1 kgf・m / 37
• Refer to the diagram for the direction of the lb・ft} 3 in the diagram
water pipe. 10) Temporarily tighten the EGR duct to the ex-
haust manifold.
Tightening torque: 50 N・m {5.1 kgf・m / 37
lb・ft} 4 in the diagram
11) Securely tighten the EGR valve duct to the
EGR valve.
Tightening torque: 44 N・m {4.5 kgf・m / 32
lb・ft} 5 in the diagram
12) Securely tighten the EGR valve duct to the
EGR mixing chamber.
Tightening torque: 44 N・m {4.5 kgf・m / 32
lb・ft} 6 in the diagram
13) Securely tighten the EGR cooler to the EGR
cooler bracket.
Tightening torque: 50 N・m {5.1 kgf・m / 37
lb・ft} 7 in the diagram

84512399 EN - September 2011

2415-32
Copyright ©
Removal and Installation of Cylinder head cover

14) Completely tighten the EGR duct to the

bracket.
Tightening torque: 50 N・m {5.1 kgf・m / 37
lb・ft} 8 in the diagram

15) Install the water return pipe to the EGR cooler. 2) Connect the extension harness to the connec-
16) Install EGR cooler water hose to EGR cooler. tor.
17) Install the water charge pipe to the EGR duct.
ANNOTATION:
18) Install the air leak pipe to the engine assembly.
• Connect connectors to every sensor and de-
vice.
• Align the clip positions marked at removal.

Sensor, device Parts

EGR motor EGR valve
Upper left side of the fly-
CKP sensor
wheel housing
Fuel pressure sensor Common rail
CMP sensor Fuel supply pump
Fuel temperature sensor Fuel supply pump
PCV Fuel supply pump
Boost sensor Inlet duct
Boost temperature sen-
Inlet duct
sor
1 EGR cooler water pipe Solenoid valve Injector
2 Water return pipe Engine coolant tempera-
3 Air leak pipe Thermostat housing
ture sensor
Left side of the cylinder
Oil pressure sensor
29. Air leak pipe installation block
Intake throttle position Between the inlet duct
1) Install the air leak pipe to the engine assembly. sensor and the intake duct
30. Engine harness installation VGS actuator Turbocharger
1) Install the engine harness to the engine as-
sembly. ANNOTATION:
84512399 EN - September 2011
2415-33
Copyright ©
Removal and Installation of Cylinder head cover

• When connecting the harness connector to 5) Replenish the coolant with the radiator.
the intake throttle valve, push in the lock
control section and lock it.

1 Plug

1 Lock control section 33. Fuel air bleed

2 Lock release
3 Lock CAUTION
• To prevent engine failure, be sure to per-
31. Engine oil filling form air removal after the installation or
1) Replenish the engine with engine oil. removal of fuel system parts.
ANNOTATION:
• Make sure that the oil drain plug has been
tightened before refilling engine oil.
32. Coolant filling
1) Replenish the coolant with the radiator.
2) Loosen the plug using the wrench.
3) Replenish the coolant with the radiator.

CAUTION
• Be careful not to let coolant over-
flow splash on the exhaust system
parts.
• Coolant overflow should be wiped
off.
1 Priming pump
4) Tighten the plug using the wrench. 2 Plug
ANNOTATION: 3 Drain plug
4 Case
• Apply Loctite 271. 5 Fuel filter element
Tightening torque: 15 N・m {1.5 kgf・m / 11
lb・ft} 1) Prepare the pan.
2) Loosen the plug using the wrench.
ANNOTATION:
• Start with the fuel filter that is nearest to the
fuel tank.
3) Operate the priming pump.
ANNOTATION:
• Bleed the air from the fuel filter and fix the
priming pump.
4) Tighten the plug using the wrench.
5) Operate the priming pump.
ANNOTATION:
84512399 EN - September 2011
2415-34
Copyright ©
Removal and Installation of Cylinder head cover

• Repeat the operation 10 times or more until Cylinder head assembly Inspection
fuel is filled.
• Wait for about 1 minute after operating the 1. Idle gear shaft inspection
priming pump. 1) Measure clearance using a micrometer.
6) Tighten the plug using the wrench. ANNOTATION:
ANNOTATION: • Measure the outer diameter of the idle gear
• Remove the air in the fuel filter. shaft and the inner diameter of the bushing.

CAUTION Outer diameter of the idle gear shaft

Standard value : 38 mm {1.4961 in}
• Continue air removal work until no
air comes out. Limit : 37.85 mm {1.4902 in}

7) Loosen the plug using the wrench. Clearance between the shaft and the bushing
: 0.020 - 0.066 mm {0.0008 -
ANNOTATION: Standard value
0.0026 in}
• Loosen the plug of the fuel supply pump. Limit : 0.12 mm {0.0047 in}
8) Operate the priming pump.
ANNOTATION:
• Operate the priming pump until no air bub-
bles come out.
9) Tighten the plug using the wrench.
ANNOTATION:
• Tighten the plug of the fuel supply pump.
CAUTION
• Do not over-tighten the plug.

10) Operate the priming pump.

ANNOTATION: ANNOTATION:

• Operate the priming pump until it becomes • Conduct visual inspections at the same time
heavy. as the measurements.

34. Battery ground cable connect 2. Valve spring inspection

1) Connect the battery ground cable to the bat- CAUTION

tery.
• Refer to the following diagram and table
to conduct inspection and measurement
of the valve spring.

Valve spring perpendicularity measurement

Measur-
ing instru- Parts Measured value
ments
Standard : 3.85 mm
Inlet value {0.1516 in}
side : 4.5 mm
Limit
{0.1772 in}
Square
Standard : 4.11 mm
Exhaust value {0.1618 in}
side : 4.8 mm
Limit
{0.1890 in}

84512399 EN - September 2011

2415-35
Copyright ©
Removal and Installation of Cylinder head cover

3. Inlet valve inspection

84512399 EN - September 2011

CONTENTS

Cylinder block Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Cylinder block installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Cylinder block Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

2425-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

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

Cylinder block Removal 4. Oil level gauge guide tube removal

1. Battery ground cable disconnect 1) Remove the oil level gauge guide tube from
the cylinder block.
1) Disengage the battery ground cable from the
battery. CAUTION
2. Coolant drain • Be careful not to damage the
O-ring.
WARNING
• Do not loosen the radiator cap when the 5. Generator work belt removal
coolant is hot. 1) Remove the generator work belt from the pul-
• Steam and boiling water may burst out ley.
and cause burns, so make sure that the
engine has cooled off. ANNOTATION:
• Loosen the lock nut and penetration bolt,
1) Drain the coolant from the radiator. and then loosen the adjust bolt to remove
the generator work belt.
CAUTION
• After draining the coolant, tighten
the drain plug.

2) Drain the coolant from the engine assembly.

ANNOTATION:
• Loosen the drain plug on the cylinder block
side.

1 Lock nut
2 Adjust bolt
3 Generator
4 Penetration bolt

6. Generator removal
1) Remove the generator from the bracket.
7. Generator bracket removal
1 Drain plug
1) Remove the generator bracket from the cylin-
3. Engine oil drain der block.
2) Remove the adjust plate from the cylinder
1) Remove the drain plug from the oil pan.
block.
ANNOTATION:
8. Starter assembly removal
• Drain engine oil into the drain pan.
2) Install the drain plug to the oil pan.
Tightening torque: 70 N・m {7.1 kgf・m / 52
lb・ft}

CAUTION
• Be careful not to forget to tighten
the drain plug.

84512399 EN - September 2011

2425-3
Copyright ©
Removal and Installation of Cylinder block

1) Remove the starter assembly from the fly-

wheel housing.
ANNOTATION:
• Remove the collectively tightened starter
ground cables together.

1 Lock control section

2 Lock release
3 Lock

10. Air leak pipe removal

Earth cable collective tighten- 1) Remove the air leak pipe from the engine as-
1
ing position sembly.
11. EGR cooler removal
9. Engine harness removal 1) Disconnect the air leak pipe from the engine
1) Disconnect the engine harness from the con- assembly.
nector. 2) Disconnect the water charge pipe from the
EGR cooler duct.
ANNOTATION: 3) Disconnect the EGR cooler water hose from
• Before removing, place a mark with paint at the EGR cooler.
the installation position of the harness clip. 4) Remove the water return pipe from the EGR
• Disconnect the connectors from every sen- cooler.
sor and device.

Sensor, device Parts

EGR motor EGR valve
Upper left side of the fly-
CKP sensor
wheel housing
Fuel pressure sensor Common rail
CMP sensor Fuel supply pump
Fuel temperature sensor Fuel supply pump
PCV Fuel supply pump
Boost sensor Inlet duct
Boost temperature sen-
Inlet duct
sor
Solenoid valve Injector
Engine coolant tempera-
Thermostat housing 1 EGR cooler water hose
ture sensor
Left side of the cylinder 2 Water return pipe
Oil pressure sensor 3 Air leak pipe
block
Intake throttle position Between the inlet duct
sensor and the intake duct
5) Remove the EGR cooler A from the EGR
VGS actuator Turbocharger cooler duct A and the EGR cooler D.
MAF sensor Inlet duct 6) Remove the EGR cooler B from the EGR
cooler duct B and the EGR cooler C.
ANNOTATION: 7) Remove the EGR cooler duct A from the ex-
haust manifold and the bracket.
• When disconnecting the harness connector 8) Remove the EGR cooler duct B from the ex-
from the intake throttle valve, pull the lock haust manifold and the bracket.
control section to release the lock. 9) Remove the bracket from the cylinder head.
84512399 EN - September 2011
2425-4
Copyright ©
Removal and Installation of Cylinder block

10) Remove the EGR cooler D from the EGR 3) Remove the O-ring from the intake throttle
valve duct. valve.
11) Remove the EGR cooler C from the EGR
14. Inlet duct removal
valve duct.
12) Remove the EGR valve duct from the EGR 1) Remove the inlet duct from the EGR mixing
valve. chamber.
2) Install the O-ring to the inlet duct.
ANNOTATION:
• Do not remove the boost sensor unless nec-
essary.
15. EGR mixing chamber removal
1) Remove the EGR mixing chamber from the
inlet cover.
2) Remove the O-ring from the EGR mixing
chamber.
ANNOTATION:
• Seal the inlet cover opening to prevent for-
eign material from entering.
1 EGR cooler duct B
2 EGR cooler B
3 EGR cooler C
4 EGR valve duct
5 EGR cooler D
6 EGR cooler A
7 EGR cooler duct A

12. EGR valve removal

1) Disconnect the connector from the EGR
valve.
2) Remove the EGR valve from the EGR mixing
chamber.
3) Remove the lead valve from the EGR mixing
chamber. 1 EGR mixing chamber
2 Intake duct
3 Intake throttle valve
4 Inlet duct
5 Boost sensor

16. Ventilation hose removal

1) Disconnect the ventilation hose from the cylin-
der head cover.
2) Disconnect the ventilation hose from the air
duct.
17. Fuel suction pipe removal
1) Remove the fuel suction pipe from the fuel
supply pump.
1 EGR valve A
2 EGR mixing chamber 18. Fuel leak-off pipe removal
3 EGR valve B 1) Disengage the fuel leak-off pipe from the cylin-
der head.
2) Disengage the fuel leak-off pipe from the fuel
13. Intake throttle valve removal
filter bracket.
1) Remove the intake duct from the intake throt- 3) Disengage the fuel leak-off pipe from the com-
tle valve. mon rail assembly.
2) Remove the intake throttle valve from the inlet 4) Disconnect the fuel leak-off pipe from the fuel
duct. supply pump.
84512399 EN - September 2011
2425-5
Copyright ©
Removal and Installation of Cylinder block

5) Remove the fuel leak-off pipe from the 24. Common rail assembly removal
bracket.
1) Remove the common rail assembly from the
19. Fuel feed pipe removal bracket.
2) Remove the common rail bracket from the
1) Remove the clip from the fuel feed pipe.
cylinder block.
2) Remove the fuel feed pipe from the fuel filter.
3) Remove the fuel feed pipe from the fuel supply
pump.
20. Fuel pipe removal
1) Disconnect the fuel pipe from the common rail
assembly.
2) Remove the fuel pipe from the fuel supply
pump.
21. Fuel pipe removal
1) Remove the fuel pipe from the fuel filter.
2) Remove the fuel pipe from the fuel supply
pump.

1 Injection pipe
2 Bracket
3 Common rail assembly

CAUTION
• Seal every fuel opening to prevent
foreign matter from getting inside.

25. Supply pump coupling assembly disconnect

1) Align 1st cylinder to the compression top dead
center.

1 Fuel pipe
2 Fuel leak-off pipe
3 Fuel pipe
4 Fuel feed pipe
5 Fuel suction pipe

22. Fuel filter removal

1) Remove the fuel filter from the cylinder head
assembly.
ANNOTATION:
It varies depending on the machine.
23. Injection pipe removal
1) Remove the injection pipe from the injector
and the common rail assembly.

84512399 EN - September 2011

2425-6
Copyright ©
Removal and Installation of Cylinder block

2) Remove bolts from the supply pump coupling 28. Air duct removal
assembly.
1) Disconnect the harness connector from the
ANNOTATION: MAF sensor.
2) Remove the inlet duct from the air duct.
• Remove the coupling cotter bolt and the 3) Remove the air duct from the turbocharger
coupling half bolt. assembly.

1 Fuel supply pump 1 Inlet duct

2 Marked line 2 Air duct
3 Coupling cotter bolt 3 MAF sensor
4 Bearing case 4 Air hose
5 Coupling half bolt
6 Coupling bolt 29. Turbocharger feed oil pipe removal
26. Fuel supply pump removal 1) Remove the clip from the turbocharger feed
oil pipe.
1) Remove the oil feed pipe from the fuel supply 2) Remove the turbocharger feed oil pipe from
pump. the turbocharger assembly.
2) Remove the oil return pipe from the fuel sup- 3) Remove the turbocharger feed oil pipe from
ply pump. the oil cooler assembly.
3) Remove the fuel supply pump from the
bracket. 30. Oil return pipe removal
1) Disengage the oil return pipe from the tur-
bocharger assembly.
2) Remove the oil return pipe from the cylinder
block.
31. Water feed pipe removal
1) Disengage the water feed pipe from the tur-
bocharger assembly.
2) Remove the water feed pipe from the oil
cooler.
32. Water return pipe removal
1) Disengage the water return pipe from the tur-
bocharger assembly.
27. Bearing case assembly removal
1) Remove the bearing case assembly from the
cylinder block.

84512399 EN - September 2011

2425-7
Copyright ©
Removal and Installation of Cylinder block

2) Remove the water return pipe from the ther- ANNOTATION:

mostat housing.
• Remove it if it is installed to the engine.
• Varies depending on the machine.
1) Remove the oil filter from the bracket.
2) Remove the bracket from the oil cooler as-
sembly.
35. Oil cooler assembly removal
1) Disconnect the water hose from the oil cooler
assembly.
ANNOTATION:
• Disconnect all hoses connected to the oil
cooler assembly.
2) Disconnect the water pipe from the oil cooler
assembly.
1 Water return pipe
2 Oil return pipe
3 Feed oil pipe
4 Water feed pipe

33. Turbocharger assembly removal

1) Remove the turbocharger assembly from the
exhaust manifold.
2) Remove the gasket from exhaust manifold.

1 EGR cooler water pipe

3) Remove the oil cooler from the cylinder block.

1 Turbocharger
2 Exhaust manifold
3 Gasket

CAUTION
• Put a seal on every part to prevent
foreign materials from getting into
the turbocharger. 36. Cylinder head cover removal
1) Remove the cylinder head cover from the
34. Oil filter removal camshaft carrier.

84512399 EN - September 2011

2425-8
Copyright ©
Removal and Installation of Cylinder block

2) Remove the gasket from the cylinder head 2) Remove the bolts from the injector harness.
cover.

3) Remove the injector harness from the

camshaft carrier.
1 Cylinder head cover ANNOTATION:
2 Gasket
• Disconnect the injector harness from the
junction connector.
37. Glow plug removal 39. Injector leak-off pipe removal
1) Remove the glow plug connector from the 1) Remove the injector leak-off pipe from the
glow plug. cylinder head assembly and the injector.
2) Remove the glow plug from the cylinder head 2) Remove the gasket from the injector leak-off
assembly. pipe.
38. Injector harness removal CAUTION
1) Remove the harness from the injector.
• Do not reuse the gasket.
CAUTION
• In this state, the injector ID code
plate may come off.
Therefore, avoid mix-up with other
injector ID code plates.

40. Injector removal

1) Remove the clamp from the cylinder head as-
sembly.
2) Remove the injector from the cylinder head
assembly.

84512399 EN - September 2011

2425-9
Copyright ©
Removal and Installation of Cylinder block

CAUTION
• Before lowering the cylinder head,
remove the injector because its tip
will protrude from the bottom sur-
face of the cylinder head.
• Do not remove the ID code plate
from the injector.
• When pulling out the injector, make
sure that the sleeve does not come
off together while working on it.
• Attach a number tag to the removed
injector.

Special tool: sliding hammer (refer to

section 1003)
3) Remove the gasket from the sleeve.

CAUTION
• Do not reuse the gasket.

41. Rocker arm shaft removal

1) Remove the rocker arm shaft from the
camshaft carrier.
ANNOTATION:
• Evenly loosen the rocker arm shaft installa-
tion bolts on both ends to remove them.
1 Clamp
2 Bolt
3 Injector
4 O-ring

ANNOTATION:
• If the injector is difficult to pull out, use the
fuel injector remover and a sliding hammer.

42. Bridge removal

1) Remove the bridge from the bridge guide.
ANNOTATION:
• Store the removed bridges in numerical or-
der.
43. Camshaft measurement
Special tool: injector remover (refer to
section 1003)

84512399 EN - September 2011

2425-10
Copyright ©
Removal and Installation of Cylinder block

1) Measure the clearance using the feeler 46. Thermostat housing removal
gauge.
1) Remove the thermostat housing from the
ANNOTATION: cylinder head.
• Measure the camshaft clearance in the axis
direction.

Camshaft clearance in the axis direction

: 0.085 - 0.170 mm {0.0033 -
Standard value
0.0067 in}
Limit : 0.25 mm {0.0098 in}

44. Camshaft removal

1) Remove the cam holder from the camshaft
carrier.
ANNOTATION:
• Evenly loosen them on both sides to remove
them.
1 Gasket
2) Remove the camshaft from the camshaft car- 2 Bracket
rier. 3 Water outlet pipe
4 Thermostat housing
5 Bracket

47. Water pump assembly removal

1) Remove the water pump assembly from the
cylinder block.

45. Camshaft carrier removal

1) Remove the camshaft carrier from the cylinder
head assembly.

48. Cylinder head assembly removal

1) Loosen the head bolts with a wrench.
ANNOTATION:
• Loosen the M10 bolts in the numerical order
indicated in the diagram.

84512399 EN - September 2011

2425-11
Copyright ©
Removal and Installation of Cylinder block

2) Loosen the head bolts with a wrench.

ANNOTATION:
• Evenly loosen the M15 bolts in the order of
arrows indicated in the diagram.

3) Remove the cylinder head assembly from the 50. Oil pump assembly removal
cylinder block.
1) Measure backlash using a dial gauge.
4) Remove the cylinder head gasket from the
cylinder block. ANNOTATION:
CAUTION • Measure the backlash of the oil pump gear
and the crankshaft gear.
• Do not reuse the cylinder head gas-
ket.
Gear backlash
ANNOTATION:
Standard value : 0.15 mm {0.0059 in}
• Inspect for water leaks or exhaust gas leaks Limit : 0.20 mm {0.0079 in}
during removal.

49. Oil pan removal

2) Remove the oil pump assembly from the cylin-
1) Remove the oil pan from the cylinder block. der block.

84512399 EN - September 2011

2425-12
Copyright ©
Removal and Installation of Cylinder block

51. CKP sensor removal ANNOTATION:

1) Remove the CKP sensor from the flywheel • If the slinger of the remover is easy to come
housing. off, the outer circumference of the jig can be
tightened using a clip band to improve the
workability.

CAUTION
• Be careful not to damage the fly-
wheel housing and crankshaft.

54. Flywheel housing removal

1) Remove the idle gear cover from flywheel
housing.
2) Remove the idle gear from flywheel housing.
ANNOTATION:
• Remove the idle gear D from the flywheel
housing.
1 CKP sensor
3) Remove the flywheel housing from the cylin-
52. Flywheel removal der block.

1) Remove the flywheel from the crankshaft. ANNOTATION:

53. Crankshaft rear oil seal removal • Remove it by tapping it with a wooden ham-
mer.
1) Remove the crankshaft rear oil seal from the
flywheel housing using the special tool. 55. Piston removal
1) Clean the cylinder block using the scraper.
ANNOTATION:
• Remove carbon from the top of the cylinder
liner using a scraper.

CAUTION
• Be careful not to damage the cylin-
der liner.

Special tool: oil seal remover (refer to

section 1003)

84512399 EN - September 2011

2425-13
Copyright ©
Removal and Installation of Cylinder block

2) Remove connecting rod bearing cap from 1) Remove the crankshaft pulley from the crank-
connecting rod assembly. shaft.

CAUTION
• Be careful not to scratch the seal
surface or not to apply excessive
force to the water pump body when
removing it.

3) Remove the piston from the cylinder block.

ANNOTATION:
• Set the piston to be removed at the com-
pression top dead center and push out the
bottom end of the connecting rod with a
hammer handle, etc.
57. Front cover removal
1) Remove the front cover from the cylinder
block.
58. Crankshaft measurement
1) Measure the clearance using the feeler
gauge.
ANNOTATION:
• Insert a feeler gauge in the No. 7 bearing
cap position and measure the clearance in
the axis direction.

Measuring the clearance in the crankshaft axis

CAUTION direction
: 0.100 - 0.285 mm {0.0039 -
• Be careful to prevent the connect- Standard value
0.0112 in}
ing rod from interfering with the
Limit : 0.30 mm {0.0118 in}
cylinder liner.
• Be careful not to damage the oil jet.
• Temporarily assemble the removed
cap and bearing on the connecting
rod as a set so that they are not
mixed up.

56. Crankshaft pulley removal

CAUTION
• Replace the thrust bearing if the
measured value exceeds the limit.

84512399 EN - September 2011

2425-14
Copyright ©
Removal and Installation of Cylinder block

59. Crankshaft removal 3) Remove the crankshaft from the cylinder

block.
1) Remove the bolts from the cylinder block.
ANNOTATION:
ANNOTATION:
• When removing, hoist the crankshaft hor-
• Loosen and remove the bolts in the numer- izontally to avoid interference with nearby
ical order indicated in the diagram below.
parts.

4) Remove the bearing from the crankcase.

1 Replacer hole
ANNOTATION:
ANNOTATION: • Mark the installation positions of the bearing
using tags.
• Insert the removed bolt into the replacer
hole. 5) Remove the bearing from the cylinder block.
2) Remove the crankcase from the cylinder ANNOTATION:
block.
• Mark the installation positions of the bearing
CAUTION using tags.

• When removing, hoist the

crankcase horizontally to avoid
interference with nearby parts.
• Be careful not to drop the thrust
bearing.

CAUTION
• Be careful not to damage the sliding
portion of the crankshaft bearing.
• Be careful not to drop the bearing.

84512399 EN - September 2011

2425-15
Copyright ©
Removal and Installation of Cylinder block

Cylinder block installation ANNOTATION:

1. Crankshaft installation • Confirm that the crankshaft bearing has no

oil hole.
CAUTION 5) Install the crankshaft bearing to the cylinder
• When replacing the crankshaft bearing, block.
select the crankshaft bearing following
the procedure below. CAUTION
• Pay full attention as an improper selec- • When installing, confirm that the
tion of the crankshaft bearing may cause bearing grade is appropriate for the
oil pressure reduction or seizure to oc- installation position.
cur.
ANNOTATION:
1) Check marking of the cylinder block.
• Confirm that the crankshaft bearing has an
ANNOTATION: oil hole.
• The marking on the cylinder block indicates
the cylinder block grade.
• Markings are provided in the order of jour-
nals No.7 to No.1 starting on the rear side.

6) Apply the engine oil to the crankshaft bearing.

ANNOTATION:
• Apply engine oil to the sliding surface.
2) Select the crankshaft bearing. 7) Align the crankshaft with the cylinder block.
ANNOTATION: ANNOTATION:
• Refer to the crankshaft bearing selection ta- • Carefully align them holding the crankshaft
ble. horizontally.

Crankshaft bearing selection table

Parts Grade selection Supplement
Marking on the
Cylinder block right side and
1 2 3
grade rear top of the
cylinder block
Colored on
BR the center side
Bearing grade BL K BL U
N surface of the
bearing

3) Dry the crankshaft bearing using an air spray

gun. 8) Apply engine oil to the thrust bearing.
4) Install the crankshaft bearing to the
crankcase.

CAUTION
• When installing, confirm that the
bearing grade is appropriate for the
installation position.

84512399 EN - September 2011

2425-16
Copyright ©
Removal and Installation of Cylinder block

9) Install the thrust bearing to the cylinder block. 11) Install the thrust bearing to the crankcase.
ANNOTATION: ANNOTATION:
• Install on both ends of the No.7 journal sec- • Install it aligned with the knock pin with the
tion with the oil groove facing outside oil groove facing outside.

1 Thrust bearing 1 Oil groove

2 Oil groove
12) Apply the engine oil to the crankshaft.
13) Apply engine oil to the bearing.
10) Apply the liquid gasket to the cylinder block. 14) Align the crankcase with the cylinder block.
ANNOTATION:
CAUTION
• Apply liquid gasket while referring to the fol-
lowing table and diagram. • If there is a gap with the cylinder
block, start it all over again.
Guidelines for applying liquid gasket on the cylin- 15) Apply the disulfide molybdenum grease to the
der block bottom surface bolt.
Liquid gasket
Parts FMD127 ANNOTATION:
used
: more than 4 mm • Apply on the seat surface and threaded por-
Position 1 indi- Application {more width than tion of the crankcase installation bolt.
cate d in the di- 0.1575 in}
agram below Application : more than 0.3 mm 16) Install the bolt to the crankcase.
thickness {more than 0.0118 in} ANNOTATION:
• Tighten the M15 bolts in the numerical order
indicated in the diagram.
Tightening torque: 54 N・m {5.5 kgf・m / 40
lb・ft}

1 Liquid gasket application area

CAUTION
ANNOTATION:
• After applying liquid gasket,
promptly install the crankcase. • Tighten by an angle between 90 and 120
degrees with an angle wrench.
84512399 EN - September 2011
2425-17
Copyright ©
Removal and Installation of Cylinder block

• Tighten the M10 bolts in the numerical order 1) Apply the engine oil to the crankshaft front oil
indicated in the diagram. seal.
Tightening torque: 55 N・m {5.6 kgf・m / 41 ANNOTATION:
lb・ft}
17) Turn the crankshaft. • Apply lightly to the outer circumference of
the oil seal.
ANNOTATION:
2) Install the crankshaft front oil seal to the front
• Confirm that the crankshaft rotates cover using the special tool.
smoothly.
ANNOTATION:
Rotation torque: less than 15 N・m {less than
1.5 kgf・m / less than 11 lb・ft} • Install the oil seal and the slinger at the
same time using the oil seal setting tool.
18) Inspect the piston oil jet.
ANNOTATION:
• Confirm that the piston oil jet is not de-
formed.

Special tool: oil seal setting tool (refer to

section 1003)

2. Front cover installation

1) Apply the liquid gasket to the front cover.
ANNOTATION:
• Refer to the diagram below to apply Three-
Bond 1201.

Liquid gasket application sur-

1
face

2) Install the front cover to the cylinder block.

Tightening torque: 44 N・m {4.5 kgf・m / 32
lb・ft}
3. Crankshaft front oil seal installation
84512399 EN - September 2011
2425-18
Copyright ©
Removal and Installation of Cylinder block

CAUTION 5. Piston installation

1) Dry the connecting rod bearing using an air
• Install the oil seal and slinger at the splay gun.
same time without disassembling
2) Install the connecting rod bearing to the con-
them.
necting rod.
ANNOTATION: ANNOTATION:
• Thoroughly wipe off oil that flows out after • Keep the connecting rod bearing installation
fitting the oil seal. surface dry before installation.
• When installing the oil seal, refer to the table • Confirm that yellow paint is on the connect-
below for the specified installation locations ing rod bearing lower side.
classified by color.
3) Apply the engine oil to the connecting rod
bearing.
Crankshaft oil seal identification color
ANNOTATION:
Front-side slinger Silver
Rear-side slinger Gray • Apply to the sliding surface of the connect-
ing rod bearing.

CAUTION
• If flaws are found on the crankshaft,
apply ThreeBond 1207C to the area
shown in the diagram below.

1 Sliding surface

4) Apply the engine oil to the cylinder liner.

4. Crankshaft pulley installation

1) Apply the engine oil to the bolt.
2) Apply engine oil to the washer.
3) Install the crankshaft pulley to the crankshaft.
ANNOTATION:
• Tighten the bolts in diagonal order.
Tightening torque: 200 N・m {20.4 kgf・m /
148 lb・ft}

84512399 EN - September 2011

2425-19
Copyright ©
Removal and Installation of Cylinder block

5) Align the crankshaft to the compression top

dead center.
ANNOTATION:
• Set the crank pin of the cylinder in which the
piston is to be assembled to the top dead
center.

Special tool: Piston setting tool (refer to

section 1003)

6) Apply the engine oil to the piston.

WARNING
• Apply to the piston, piston ring, and
piston pin.

7) Turn the piston ring.

ANNOTATION:
• Avoid placing the piston ring joints in a lat-
eral pressure direction, instead adjust them CAUTION
to be 90 degrees apart from each other.
• When using the piston installer,
firmly attach it to the cylinder block.
• When inserting the piston, be care-
ful not to damage the crank pin and
oil jet.
• When inserting the piston, insert
the crank pin at the top dead cen-
ter of each cylinder.

9) Install the connecting rod assembly to the

crankshaft.
ANNOTATION:
• Align the connecting rod marking with the
cap marking.
• Install so that the marking faces the exhaust
8) Install the piston to the cylinder block using the side.
special tool.
10) Apply the engine oil to the bolt.
ANNOTATION:
• Apply on the seat surface and threaded por-
tion of the connecting rod cap installation
bolt.
11) Install the connecting rod bearing cap to the
connecting rod.
ANNOTATION:
• Tighten the bolts on both sides.

84512399 EN - September 2011

2425-20
Copyright ©
Removal and Installation of Cylinder block

CAUTION ANNOTATION:
• Refer to the diagram below to apply Three-
• When tightening the connecting Bond 1201.
rod cap, conduct work with the
crank pin at the bottom dead posi-
tion of each cylinder.

Tightening torque: 58 N・m {5.9 kgf・m / 43

lb・ft}

1 Idle gear D hole

2 Apply liquid gasket.

CAUTION
ANNOTATION:
• Make sure the hole and groove por-
• Tighten the right side bolt 60 degrees with tion of idle gear D are not blocked
an angle wrench. by the liquid gasket at the hole.
• Tighten the left side bolt 120 degrees with • Install it within 5 minutes after ap-
an angle wrench. plying liquid gasket.
• Tighten the right side bolt 60 degrees with
an angle wrench. 2) Install the flywheel housing to the cylinder
12) Turn the crankshaft. block.

ANNOTATION: Flywheel housing tightening torque

• Confirm that the crankshaft rotates Bolts to be
Tightening torque
smoothly. used
M12 : 78 N・m {8.0 kgf・m / 58 lb・ft}
13) Inspect the piston oil jet.
M8 : 25 N・m {2.5 kgf・m / 18 lb・ft}
ANNOTATION:
• Confirm that the piston oil jet is not de-
formed.

1 M12
2 M12
6. Flywheel housing installation 3 M12
1) Apply liquid gasket to the flywheel housing. 4 M12

84512399 EN - September 2011

2425-21
Copyright ©
Removal and Installation of Cylinder block

5 M12
6 M8

3) Apply engine oil to the bushing.

4) Apply the engine oil to the idle gear shaft.
ANNOTATION:
• Apply to the inner surface of the idle gear
bushing and outer circumference of the idle
gear shaft.
5) Install idle gear shaft to idle gear.
6) Apply the disulfide molybdenum grease to the
bolt.
ANNOTATION:
• Apply on the seat surface and threaded por- 1 Idle gear D
tion of the idle gear installation bolt. 2 Idle gear shaft
3 Thrust collar
7) Install the idle gear to the flywheel housing.
Tightening torque: 154 N・m {15.7 kgf・m /
8) Install the O-ring to the idle gear cover.
114 lb・ft}
9) Apply grease to the flywheel housing.
ANNOTATION:
ANNOTATION:
• Tighten the bolt via the thrust collar.
• Apply Besco L2 grease to the O-ring con-
CAUTION tact surface on the flywheel housing over
the entire circumference with a width of 5
• Because of oil lubrication, install mm {0.1969 in}.
the shaft as its notch portion faces
upward, and install the thrust collar 10) Install the idle gear cover to the flywheel hous-
to fit its painted portion in the range ing.
of diagram. Tightening torque: 22 N・m {2.2 kgf・m / 16
lb・ft}

1 Paint sections 1 O-ring

2 45°
3 Notch section 7. Crankshaft rear oil seal installation
4 Idle gear shaft 1) Apply the engine oil to the crankshaft rear oil
5 Thrust collar seal.
ANNOTATION:
• Apply lightly to the outer circumference of
the oil seal.
2) Install the crankshaft rear oil seal to the fly-
wheel housing using the special tool.
ANNOTATION:
• Install the oil seal and slinger at the same
time without disassembling them.
84512399 EN - September 2011
2425-22
Copyright ©
Removal and Installation of Cylinder block

Crankshaft oil seal identification color

Front-side slinger Silver
Rear-side slinger Gray

CAUTION
• If flaws are found on the crankshaft, ap-
ply ThreeBond 1207C to the area shown
in the diagram.

Special tool: oil seal setting tool (refer to

section 1003)

8. Flywheel installation
1) Apply the disulfide molybdenum grease to the
bolt.
ANNOTATION:
• Apply disulfide molybdenum to the threaded
portion of the tightening bolts and the seat
surface.
2) Install the flywheel to the crankshaft.
ANNOTATION:
• Tighten in the numerical order indicated in
the diagram.

1st time : 79 N・m {8.1 kgf・m / 58 lb・ft}

2nd time : 60 ° Angle method
3rd time : 30 ° Angle method

CAUTION
• The angle tolerance for tightening
by the angle method must be within
ANNOTATION: 90 - 120 degrees.
• Thoroughly wipe off oil that flows out after fitting ANNOTATION:
the oil seal.
• When installing the oil seal, refer to the table for • Confirm that the bolts are tightened at a
the specified installation locations with classifica- torque of 245 N ・ m {25 kgf ・ m / 181 lb ・
tion by colors. ft} or more in the tightening direction.

84512399 EN - September 2011

2425-23
Copyright ©
Removal and Installation of Cylinder block

9. CKP sensor installation 3) Install the O-ring to the oil strainer.

4) Apply the engine oil to the O-ring.
1) Install the CKP sensor to the flywheel housing.
5) Install the oil strainer to the oil pump assembly.
Tightening torque: 8 N・m {0.8 kgf・m / 71
Tightening torque： 22 N・m { 2.2 kgf・m /
lb・in}
16 lb・ft }
11. Oil pan installation
1) Apply the liquid gasket to the cylinder block.
ANNOTATION:
• Apply Sealend 242 or ThreeBond 1207C
to the joints of the cylinder block, flywheel
housing, and front cover with the thickness
of about 2 mm {0.0787 in} and width of about
3 mm {0.1181 in}.

CAUTION
• Clean the surface before applying
the gasket.

1 CKP sensor

10. Oil pump assembly installation

CAUTION
• Install the oil pipe and the oil strainer af-
ter installing the oil pump assembly.

1) Install the oil pump assembly to the cylinder

block.
Tightening torque: 22 N・m {2.2 kgf・m / 16
lb・ft} M8
Tightening torque: 38 N・m {3.9 kgf・m / 28
lb・ft} M10 2) Install the oil pan to the cylinder block.
2) Install the oil pipe to the oil pump assembly.
ANNOTATION:
ANNOTATION:
• Install the oil pan gasket with the identifica-
• Apply the engine oil to the O-ring. tion text "OIL PAN SIDE" or silicone coated
surface facing the oil pan.
CAUTION • Install the plate with the white paint facing
outside.
• All bolts must be temporarily tight-
ened, and after being confirmed • Tighten the oil pan in the order of the num-
bers and arrows shown in the diagram.
that they are seated,
they must be tightened to the spec- Tightening torque: 19 N・m {1.9 kgf・m / 168
ified torque. lb・in}

Tightening torque: 22 N・m {2.2 kgf・m / 16

lb・ft}
84512399 EN - September 2011
2425-24
Copyright ©
Removal and Installation of Cylinder block

Guidelines for liquid gasket application

Parts to be Liquid gasket
Method of use
applied used
Application thick-
ness: 2 mm
Position 3 in Permatex silicone (0.0787 in)
the diagram foam gasket No.6
Application width:
5 mm (0.1969 in)

CAUTION
• Strictly conform to the specifica-
tions for thickness and width of the
liquid gasket application.
• After applying liquid gasket,
CAUTION promptly install the cylinder head.

• The oil pan must be re-tightened 3) Align the cylinder head gasket with the cylin-
for several bolts because loosening der block.
torque will occur.
• Note that the oil pan gasket has CAUTION
front and back sides.
• Use a new cylinder head gasket.
12. Cylinder head assembly installation
4) Align the cylinder head assembly with the
1) Clean the cylinder block using the scraper. cylinder block.
ANNOTATION: ANNOTATION:
• Carefully clean the cylinder block top sur- • Carefully align the knock pin positions.
face and the cylinder head bottom surface,
being careful not to damage them. CAUTION
2) Apply the liquid gasket to the cylinder block. • Confirm engagement of the idle
gears.

1 Cylinder block top surface

5) Apply disulfide molybdenum grease to the
Flywheel housing installation head bolts.
2
section
3 Liquid gasket application area ANNOTATION:
• Apply disulfide molybdenum to the seat sur-
face and the threaded portion.
6) Tighten the head bolt using the torque wrench.
ANNOTATION:
• Tightening order of the head bolts

84512399 EN - September 2011

2425-25
Copyright ©
Removal and Installation of Cylinder block

ANNOTATION: • Confirm that the bolts are tightened to the

torque or higher as described below.
• Tighten bolts 1 through 26 shown in the di-
agram in numerical order. Tightening torque: 230 N・m {23.5 kgf・m /
170 lb・ft}
Tightening torque: 98 N・m {10.0 kgf・m / 72
lb・ft} CAUTION
7) Tighten the head bolt using the torque wrench.
• Be careful not to drop foreign mate-
ANNOTATION: rials into the timing gear hole.
• Tighten bolts 1 through 26 shown in the di-
agram in numerical order. ANNOTATION:
Tightening torque: 196 N・m {20.0 kgf・m / • The cylinder head installation bolts should
145 lb・ft} not be reused exceeding 2 times.
8) Tighten the head bolt using the special tool.
13. Water pump assembly installation
1) Install the O-ring to the water pump assembly.
2) Install the water pump assembly to the cylin-
der block.
ANNOTATION:
• Use the stud bolts as a guide to prevent
displacement of the gasket.

CAUTION
• Clean the installation surface of the
gasket, and install the gasket so
that it is not displaced.

Tightening torque: 38 N・m {3.9 kgf・m / 28 lb・ft}

Special tool: angle gauge (refer to section
1003)
ANNOTATION:
• Tighten bolts 1 through 26 shown in the di-
agram in numerical order.
Tightening angle: 60 - 90 °
9) Tighten the head bolt using the torque wrench.
ANNOTATION:
• Tighten bolts 27 through 29 shown in the
diagram in numerical order.
Tightening torque: 38 N・m {3.9 kgf・m / 28
lb・ft}
10) Tighten the head bolt using the torque wrench. 14. Thermostat housing installation
ANNOTATION: 1) Install the thermostat housing to the cylinder
head assembly.
• Tighten bolts 1 through 26 shown in the di-
agram in numerical order. ANNOTATION:
84512399 EN - September 2011
2425-26
Copyright ©
Removal and Installation of Cylinder block

• Insert the gasket, and insert the thermostat 1 Gasket

housing into the water pump assembly to 2 Bracket
install it. 3 Water outlet pipe
4 Thermostat housing
CAUTION
5 Bracket
• Assemble the thermostat housing
after assembling the water pump
assembly and cylinder head assem- 15. Camshaft carrier installation
bly. 1) Install the gasket to the camshaft carrier.
ANNOTATION: ANNOTATION:

• A small amount of ThreeBond 1521 can also • Firmly push the bulging section of the gas-
be applied to the gasket. ket into the groove of the carrier.
Tightening torque： 44 N・m { 4.5 kgf・m / 32 lb・ CAUTION
ft }
• If the gasket edge is not aligned
with the groove center and is slant-
ing, push the gasket sideways with
your fingertip so that the gasket
edge position is correctly aligned
with the groove center before in-
stalling the gasket.

2) Temporarily tighten the camshaft carrier onto

the cylinder head assembly.
ANNOTATION:
• Temporarily tighten the bolts in the numeri-
cal order indicated in the diagram.
• Tightening order

3) Securely tighten the camshaft carrier onto the CAUTION

cylinder head assembly.
• Confirm and retighten the bolts 1 to
ANNOTATION: 5, because the torque at which they
• Securely tighten them in the numerical order were initially tightened may have re-
indicated in the diagram. duced.
Tightening torque: 22 N・m {2.2 kgf・m / 16 16. Camshaft installation
lb・ft} M8 bolt
Tightening torque: 44 N・m {4.5 kgf・m / 32
lb・ft} M10 bolt

84512399 EN - September 2011

2425-27
Copyright ©
Removal and Installation of Cylinder block

1) Align 1st cylinder to the compression top dead 6) Align the cam holder with the camshaft carrier.
center.
CAUTION
ANNOTATION:
• Confirm the identification code and
• Rotate the crankshaft positively and align front mark of the cam holder.
the marking of the flywheel with the pointer.
7) Temporarily tighten the cam holder onto the
camshaft carrier.
ANNOTATION:
• Temporarily tighten the bolts in the numeri-
cal order indicated in the diagram.
• Tightening order

2) Apply engine oil to the camshaft carrier.

ANNOTATION:
• Apply on the journal, holder, and No.7 jour-
nal thrust sections.
3) Place the camshaft on the camshaft carrier.
4) Align the alignment mark with the camshaft
carrier. 8) Securely tighten the cam holder onto the
camshaft carrier.
ANNOTATION:
• Securely tighten them in the numerical order
indicated in the diagram.
Tightening torque: 53 N・m {5.4 kgf・m / 39
lb・ft}

CAUTION
• After tightening the cam holder,
confirm the alignment mark of the
camshaft gear again.

17. Bridge installation

5) Apply engine oil to the cam holder.
1) Apply the engine oil to the bridge guide.
ANNOTATION: 2) Loosen the adjust screw using the wrench.
• Apply it on the cam holder journal surface.
CAUTION
CAUTION
• Be sure the adjust screw does not
• In tightening, if attached oil is loosen too much because it may fall
found, thoroughly remove oil from off of the bridge.
each seat surface and threaded
portion of the bolt, camshaft car- 3) Install the bridge to the bridge guide.
rier, and cam holder.
CAUTION
• Install it in the same position as it
was removed.

84512399 EN - September 2011

2425-28
Copyright ©
Removal and Installation of Cylinder block

18. Rocker arm shaft installation Special tool: valve clearance adjust nut
1) Apply engine oil to the camshaft. wrench (refer to section 1003)
2) Apply the engine oil to the bridge.
3) Temporarily tighten the rocker arm shaft onto CAUTION
the camshaft carrier. • Make sure the adjust screw on the
ANNOTATION: bridge side is not loosened too
much because it may fall off.
• Temporarily tighten the bolts in the numeri-
cal order indicated in the diagram.
• Tightening order

1 Adjust nut wrench

7) Adjust the valve clearance to the standard

1 Front mark
value using a feeler gauge.

4) Securely tighten the rocker arm shaft onto the

camshaft carrier.
ANNOTATION:
• Securely tighten them in the numerical order
indicated in the diagram.
Tightening torque: 90 N・m {9.2 kgf・m / 66
lb・ft}
5) Loosen the adjust screw using the wrench.
ANNOTATION:
• Completely loosen the adjust screw on the
rocker arm side.
6) Loosen the adjust screw using the special
tool. 1 Feeler gauge
2 Rocker arm
ANNOTATION: Adjust screw on the rocker arm
3
• Completely loosen the adjust screw on the side
bridge side. 4 Bridge
84512399 EN - September 2011
2425-29
Copyright ©
Removal and Installation of Cylinder block

5 Adjust screw on the bridge side

6 Camshaft

Cylinder No. 1 2 3 4 5 6
Arrangement
Condition IN EXH IN EXH IN EXH IN EXH IN EXH IN EXH
of valves
When the #1
cylinder is set
at the com- yes yes yes yes yes yes
pression top
Valve to be dead center
adjusted When the #6
cylinder is set
at the com- yes yes yes yes yes yes
pression top
dead center

ANNOTATION: CAUTION
• Tighten the adjust screw on the rocker arm • Use a new gasket.
side and adjust it to the standard value.
ANNOTATION:
Valve clearance - at cold condition • Confirm that there is no old gasket remain-
Inlet valve : 0.2 mm {0.0079 in} ing in the sleeve.
Exhaust valve : 0.5 mm {0.0197 in}
2) Apply the disulfide molybdenum grease to the
bolt.
ANNOTATION: ANNOTATION:
• In the case of inlet adjustment, insert the 0.2 • Apply on the seat surface and threaded por-
mm feeler gauge between the rocker arm tion of the clamp tightening bolt.
and the camshaft.
3) Install the injector to the cylinder head assem-
• In the case of exhaust side adjustment, in-
sert a 0.5 mm feeler gauge between the bly.
rocker arm and the camshaft.
CAUTION
• Secure the adjust screw on the rocker arm
side with the lock nut. • Carefully remove carbon from in-
side the sleeve.
Tightening torque: 34 N・m {3.5 kgf・m / 25
lb・ft} • Do not remove the ID code plate
from the injector.
ANNOTATION:
4) Temporarily tighten the injection pipe to the
• Lightly tighten the adjust screw on the
injector.
bridge with a feeler gauge inserted.
5) Install the clamp to the cylinder head assem-
• Confirm that the tip of the adjust screw
bly.
touches the end of the bridge shaft and that
Tightening torque: 26 N・m {2.7 kgf・m / 19
movement of the feeler gauge has become
lb・ft}
stiff.
• Slightly loosen the adjust screw on the
bridge so that movement of the feeler gauge
becomes appropriate.
• Secure the adjust screw on the bridge side
with the lock nut.
Tightening torque: 22 N・m {2.2 kgf・m / 16
lb・ft}
ANNOTATION:
• Turn the crankshaft one rotation to adjust
the remaining valves.
19. Injector installation
1) Install the gasket to injector.
84512399 EN - September 2011
2425-30
Copyright ©
Removal and Installation of Cylinder block

1 Clamp 2) Install the bolt to the injector harness.

2 Bolt Tightening torque: 22 N・m {2.2 kgf・m / 16
3 Injector lb・ft}
4 O-ring

20. Injector leak-off pipe installation

1) Install the gasket to the injector leak-off pipe.

CAUTION
• Use a new gasket.

2) Install the injector leak-off pipe to the cylinder

head assembly.

Injector leak-off pipe tightening torque

The number
Bolt size indicated in Tightening torque 3) Install the harness to the injector.
the diagram Tightening torque: 2 N・m {0.2 kgf・m / 18
: 15 N・m {1.5 kgf・ lb・in}
M8 eyebolt 2
m / 11 lb・ft}
: 34 N・m {3.5 kgf・ CAUTION
M12 eyebolt 3
m / 25 lb・ft} • Strictly conform to the specified
torque to avoid over-tightening of
nuts, which may cause damage.

1 Injector leak-off pipe

2 M8 eyebolt 22. Glow plug installation
3 M12 eyebolt
1) Install the glow plug to the cylinder head as-
sembly.
21. Injector harness installation Tightening torque: 20 N・m {2.0 kgf・m / 15
1) Install the injector harness to the camshaft lb・ft}
carrier. 2) Install the glow plug connector to the glow
plug.
ANNOTATION:
23. Cylinder head cover installation
• Make sure to lock the connector on the har-
ness. 1) Install the gasket to the cylinder head cover.

CAUTION
• If the gasket has looseness or a
slant, repair it before installation.

2) Install the cylinder head cover to the camshaft

carrier.
Tightening torque: 15 N・m {1.5 kgf・m / 11
lb・ft}

84512399 EN - September 2011

2425-31
Copyright ©
Removal and Installation of Cylinder block

4) Connect the water pipe to the oil cooler.

Tightening torque: 32 N・m {3.3 kgf・m / 24
1 Cylinder head cover lb・ft} Eyebolt
2 Gasket 5) Connect the water hose to the oil cooler.
25. Oil filter installation
24. Oil cooler assembly installation ANNOTATION:
1) Install the O-ring to the oil cooler. • Install it if necessary.
2) Install the gasket to the oil cooler. • Varies depending on the machine.
1) Install the bracket to the oil cooler assembly.
2) Install the oil filter to the bracket.
26. Turbocharger assembly installation
1) Replenish the engine oil with the turbocharger
assembly.
ANNOTATION:
• Apply about 1 cc of engine oil to the oil path
to lubricate the turbine bearing portion.
2) Install the gasket to the exhaust manifold.
3) Temporarily tighten the turbocharger assem-
bly to the exhaust manifold.
4) Install the exhaust pipe adapter to the tur-
bocharger.
1 Gasket ANNOTATION:
2 O-ring
3 O-ring • Assemble the gasket on the exhaust pipe
adapter.

CAUTION
CAUTION
• Make sure to conduct assembly
• When pushing the gasket, com- so that the gasket surface with a
pletely push the protruding portion yellow marking is visible when the
of the stopper into the groove. gasket is installed to the exhaust
• Do not use cement to prevent pipe adapter.
debonding. • When installing the gasket, be care-
ful not to deform it.
3) Install the oil cooler to the cylinder block. • Make sure to install new gaskets.
Prohibit their reuse.
ANNOTATION:
• Clean the installation surface of the oil ANNOTATION:
cooler and cylinder block.
• Tighten the installation bolts outward from • Tighten the 3 bolts from the top of the
the center. bracket tightened together with the exhaust
manifold.
Tightening torque: 50 N・m {5.1 kgf・m / 37 • Tighten it to the turbocharger using a
lb・ft} V-band.

84512399 EN - September 2011

2425-32
Copyright ©
Removal and Installation of Cylinder block

CAUTION 1 Turbocharger
2 Exhaust manifold
• Confirm that there are no pieces of 3 Gasket
gasket inside the duct before as-
sembly. 27. Water return pipe installation
• Insert securely until it touches the
duct. 1) Install the water return pipe to the cylinder
head.
Tightening torque: 8 N・m {0.8 kgf・m / 71 lb・in} Tightening torque: 41 N・m {4.2 kgf・m / 30
V-band lb・ft}
2) Connect the water return pipe to the tur-
bocharger assembly.
Tightening torque: 50 N・m {5.1 kgf・m / 37
lb・ft}
28. Water feed pipe installation
1) Install the water feed pipe to the cylinder
block.
Tightening torque: 41 N・m {4.2 kgf・m / 30
lb・ft}
2) Connect the water feed pipe to the tur-
bocharger assembly.
Tightening torque: 50 N・m {5.1 kgf・m / 37
lb・ft}
29. Oil return pipe installation
1 Exhaust pipe adapter 1) Install the O-ring to the oil return pipe.
2 Gasket
ANNOTATION:
3 Turbocharger
4 V-band • Install them on both ends of the oil return
pipe.
ANNOTATION:
2) Temporarily tighten the oil return pipe onto the
• Tighten the flange nuts in order starting with the turbocharger assembly.
one at the turbine inlet and secure them with dou- 3) Temporarily tighten the oil return pipe onto the
ble nuts. cylinder block.
4) Securely tighten the oil return pipe onto the
Tightening torque: 45 N・m {4.6 kgf・m / 33 lb・ft}
turbocharger assembly.
Tightening torque: 22 N・m {2.2 kgf・m / 16
lb・ft}
5) Securely tighten the oil return pipe onto the
cylinder block.
Tightening torque: 44 N・m {4.5 kgf・m / 32
lb・ft}

84512399 EN - September 2011

2425-33
Copyright ©
Removal and Installation of Cylinder block

1 Water return pipe

2 Oil return pipe
3 Oil feed pipe
4 Water feed pipe

31. Air duct installation

1) Install the air duct to the turbocharger assem-
bly.
2) Install the inlet duct to the turbocharger as-
sembly.
ANNOTATION:
• Insert the rubber hose all the way in until it
hits the deepest part.
1 Turbocharger assembly • Place the clip at the lower side and tighten
it horizontally.
2 Water return pipe
3 Water feed pipe
4 Oil return pipe Tightening torque
5 Oil feed pipe Parts Tightening torque
Clip : 8 N・m {0.8 kgf・m / 71 lb・in}
30. Turbocharger feed oil pipe installation M10 bolt : 44 N・m {4.5 kgf・m / 32 lb・ft}

1) Temporarily tighten the turbocharger feed oil

pipe onto the turbocharger assembly. 3) Install the MAF sensor to the air duct.
2) Temporarily tighten the turbocharger feed oil Tightening torque: 1.5 N・m {0.2 kgf・m / 13
pipe onto the oil cooler assembly. lb・in}
3) Securely tighten the turbocharger feed oil pipe
onto the turbocharger assembly.
Tightening torque: 34 N・m {3.5 kgf・m / 25
lb・ft}
4) Securely tighten the turbocharger feed oil pipe
onto the oil cooler assembly.
Tightening torque: 34 N・m {3.5 kgf・m / 25
lb・ft}

1 Inlet duct
2 Air duct
3 MAF sensor
4 Air hose
84512399 EN - September 2011
2425-34
Copyright ©
Removal and Installation of Cylinder block

32. Bearing case assembly installation

1) Align 1st cylinder to the compression top dead
center.
ANNOTATION:
• Align the T/C marking line of the flywheel to
the pointer so that it is set for the top dead
center on the 1st cylinder.

1 Bearing case
2 White paint
3 Projection
4 Key

33. Fuel supply pump installation

1) Install the fuel supply pump to the bracket.
2) Install the key to the shaft. ANNOTATION:
ANNOTATION: • Move the injection pump coupling assembly
• Firmly press-fit the key onto the bearing towards the bearing case in advance.
case shaft. • Loosen the coupling cotter bolt and coupling
half bolt to some extent to keep them from
3) Install the O-ring to the bearing case. shaking loose.
CAUTION CAUTION
• Be careful not to allow disulfide • Note that tightening when it is in
molybdenum to adhere to the shaft a very loose condition will cause
taper section. damage to the coupling.

4) Install the bearing case to the cylinder block. ANNOTATION:

ANNOTATION: • Refer to the figure and tighten them in diag-
onal order.
• Align the white paint at the tip of the bearing
case gear tooth with the protrusion of the Tightening torque: 57 N・m {5.8 kgf・m / 42
bearing case and install the bearing case to lb・ft}
the cylinder block.
• Fix the bearing case with 2 bolts and 2 nuts.
Tightening torque: 86 N・m {8.8 kgf・m / 63
lb・ft}

34. Supply pump coupling assembly connect

84512399 EN - September 2011

2425-35
Copyright ©
Removal and Installation of Cylinder block

1) Align 1st cylinder to the compression top dead 3) Install the bolts to the supply pump coupling
center. assembly.
ANNOTATION: ANNOTATION:
• Align the T/C marking line of the flywheel to • Refer to the diagram to install the 2 coupling
the pointer so that it is set for the top dead bolts.
center on the 1st cylinder.
Tightening torque: 91 N・m {9.3 kgf・m / 67
lb・ft}

2) Align the fuel supply pump with the supply

pump coupling assembly.
ANNOTATION: 1 Coupling bolt
• Refer to the diagram to align the markings
on the pump and the flange. 4) Install the special tool to the supply pump cou-
pling assembly.
ANNOTATION:
• Install so that its indent section contacts the
coupling half bolt.

1 Fuel supply pump

2 Marked line
3 Coupling flange

1 Coupling cotter bolt

2 Coupling half bolt
3 Indent section
4 Coupling setting tool
5 Stamping line

5) Temporarily tighten the bolt onto the supply

pump coupling assembly.
ANNOTATION:
• Insert a flat-blade screwdriver between the
coupling and the bearing case.
• Temporarily tighten the cotter bolt with the
coupling laminate attached to the special
tool.
84512399 EN - September 2011
2425-36
Copyright ©
Removal and Installation of Cylinder block

CAUTION
• Be careful not to damage the oil
seal of the bearing case with the
screwdriver.

6) Remove the special tool from the supply pump

coupling assembly.
ANNOTATION:
• Remove the special tool after confirming
that they are firmly attached.
7) Securely tighten the bolt onto the supply pump
coupling assembly.

CAUTION 1 Oil return pipe

2 Oil feed pipe
• Confirm that the laminate of the
coupling has no bending before
securely tightening the cotter bolt. 35. Common rail assembly installation
1) Install the common rail bracket to the cylinder
Tightening torque: 91 N・m {9.3 kgf・m / 67 block.
lb・ft} Tightening torque: 44 N・m {4.5 kgf・m / 32
8) Securely tighten the bolt onto the supply pump lb・ft}
coupling assembly. 2) Install the common rail assembly to the
ANNOTATION: bracket.
Tightening torque: 44 N・m {4.5 kgf・m / 32
• Securely tighten the coupling half bolt. lb・ft}
Tightening torque: 91 N・m {9.3 kgf・m / 67 36. Injection pipe installation
lb・ft}
1) Install the injection pipe to the injector and
CAUTION common rail assembly.
• After completely tightening each CAUTION
bolt, confirm that the marking lines
are aligned. • Use new injection pipes.

9) Install the oil feed pipe to the fuel supply ANNOTATION:

pump. • Alternately tighten the injection pipe sleeve
nuts on the injector side and the common
Oil feed pipe tightening torque rail side in a few steps.
Parts Tightening torque
Tightening torque: 44 N・m {4.5 kgf・m / 32
Fuel supply
: 10 N・m {1.0 kgf・m / 89 lb・in} lb・ft}
pump side
2) Install the clip to the injection pipe.
Cylinder block- Tightening torque: 9 N・m {0.9 kgf・m / 80
: 20 N・m {2.0 kgf・m / 15 lb・ft}
side lb・in}
10) Install the oil return pipe to the fuel supply CAUTION
pump.
• If the rubber is cracked or damaged,
Oil return pipe tightening torque do not reuse it.
Parts Tightening torque
Fuel supply
: 17 N・m {1.7 kgf・m / 13 lb・ft}
pump
Cylinder block
: 41 N・m {4.2 kgf・m / 30 lb・ft}
side

84512399 EN - September 2011

2425-37
Copyright ©
Removal and Installation of Cylinder block

39. Fuel pipe installation

1) Temporarily tighten the fuel pipe to the fuel
supply pump and the fuel filter.

CAUTION
• Use new fuel pipes.

2) Securely tighten the fuel pipe onto the fuel

supply pump.
Tightening torque: 17 N・m {1.7 kgf・m / 13
lb・ft} Fuel temperature sensor adapter
3) Securely tighten the fuel pipe onto the fuel
filter.
Tightening torque: 50 N・m {5.1 kgf・m / 37
lb・ft}
1 Injection pipe 4) Install the clip to the fuel feed pipe.
2 Bracket Tightening torque: 9 N・m {0.9 kgf・m / 80
3 Common rail assembly lb・in}
37. Fuel filter installation 40. Fuel pipe installation
1) Install the fuel filter to the cylinder head as- 1) Temporarily tighten the fuel pipe onto the com-
sembly. mon rail assembly and the fuel supply pump.
2) Securely tighten the fuel pipe onto the com-
ANNOTATION: mon rail assembly and the fuel supply pump.
• It varies depending on the machine. Tightening torque: 44 N・m {4.5 kgf・m / 32
lb・ft} Sleeve nut
38. Fuel feed pipe installation Tightening torque: 9 N・m {0.9 kgf・m / 80
1) Temporarily tighten the fuel field pipe to the lb・in} Clip
fuel supply pump and the fuel filter. 41. Fuel leak-off pipe installation
2) Securely tighten the fuel feed pipe onto the
fuel supply pump. 1) Temporarily tighten the fuel leak-off pipe to the
Tightening torque: 17 N・m {1.7 kgf・m / 13 common rail assembly.
lb・ft} 2) Temporarily tighten the fuel leak-off pipe to the
3) Securely tighten the fuel feed pipe onto the fuel supply pump.
fuel filter. 3) Temporarily tighten the fuel leak-off pipe to the
Tightening torque: 50 N・m {5.1 kgf・m / 37 cylinder head and fuel filter bracket.
lb・ft} 4) Temporarily tighten the fuel leak-off pipe to the
pipe bracket.
5) Securely tighten the fuel leak-off pipe to the
fuel supply pump.
Tightening torque: 17 N・m {1.7 kgf・m / 13
lb・ft}
6) Securely tighten the fuel leak-off pipe to the
common rail assembly.
Tightening torque: 20 N・m {2.0 kgf・m / 15
lb・ft}
7) Completely tighten the fuel leak-off pipe to the
cylinder head.
Tightening torque: 41 N・m {4.2 kgf・m / 30
lb・ft}
8) Completely tighten the fuel leak-off pipe to the
fuel filter bracket.
Tightening torque: 41 N・m {4.2 kgf・m / 30
lb・ft}
1 Fuel pipe 9) Completely tighten the fuel leak-off pipe to the
2 Fuel leak-off pipe pipe bracket.
3 Fuel pipe Tightening torque: 41 N・m {4.2 kgf・m / 30
4 Fuel feed pipe lb・ft}
5 Fuel suction pipe

84512399 EN - September 2011

2425-38
Copyright ©
Removal and Installation of Cylinder block

42. Fuel suction pipe installation 1 EGR mixing chamber

2 Intake duct
1) Install the fuel suction pipe to the fuel supply
pump. 3 Intake throttle valve
Tightening torque: 17 N・m {1.8 kgf・m / 13 4 Inlet duct
lb・ft} Eyebolt 5 Boost sensor
Tightening torque: 9 N・m {0.9 kgf・m / 80
lb・in} Clip
47. EGR valve installation
43. Ventilation hose installation
1) Install the lead valve to the EGR mixing cham-
1) Connect the ventilation hose to the air duct. ber.
2) Connect the ventilation hose to the cylinder Tightening torque: 10 N・m {1.0 kgf・m / 89
head cover. lb・in}
44. EGR mixing chamber installation 2) Install the gasket to the EGR mixing chamber.
3) Install the EGR valve to the EGR mixing
1) Install the O-ring to EGR mixing chamber. chamber.
2) Install the EGR mixing chamber to the inlet Tightening torque: 44 N・m {4.5 kgf・m / 32
cover. lb・ft}
Tightening torque: 44 N・m {4.5 kgf・m / 32
lb・ft}

45. Inlet duct installation 1 EGR valve

1) Install the O-ring to the inlet duct. 2 EGR mixing chamber
2) Install the inlet duct to the EGR mixing cham- 3 EGR valve
ber.
Tightening torque: 45 N・m {4.6 kgf・m / 33
lb・ft} 48. EGR cooler installation
46. Intake throttle valve installation 1) Temporarily tighten the EGR valve duct to the
1) Install the O-ring to the intake throttle valve. EGR valve.
2) Install the intake throttle valve to the inlet duct. ANNOTATION:
3) Install the intake duct to the intake throttle
valve. • Temporarily tighten with the gasket inserted.
Tightening torque: 22 N・m {2.2 kgf・m / 16 Temporary Tightening torque: 5 N ・ m {0.5
lb・ft} kgf・m / 44 lb・in}

84512399 EN - September 2011

2425-39
Copyright ©
Removal and Installation of Cylinder block

Engine front side EGR cooler

1
bracket
Engine rear side EGR cooler
2
bracket 1 Engine rear side bracket
2 Engine front side bracket
3) Temporarily tighten the EGR cooler to the
EGR valve duct.
ANNOTATION: 5) Temporarily tighten the EGR duct to the ex-
haust manifold.
• Temporarily tighten with the gasket inserted.
• Install the air removal pipe faicing it towards ANNOTATION:
the front side. • Temporarily tighten with the gasket inserted.
Temporary Tightening torque: 5 N ・ m {0.5 Temporary Tightening torque: 5 N ・ m {0.5
kgf・m / 44 lb・in} kgf・m / 44 lb・in}
6) Temporarily tighten the EGR cooler to the
EGR duct.
ANNOTATION:
• Temporarily tighten with the gasket inserted.
• Refer to the diagram for the direction of the
water pipe.

1 EGR cooler D
2 EGR valve duct
3 EGR cooler C

1 EGR cooler B
2 EGR cooler A
3 EGR duct A
4 EGR duct B
84512399 EN - September 2011
2425-40
Copyright ©
Removal and Installation of Cylinder block

ANNOTATION: 9) Securely tighten the EGR cooler to the EGR

84512399 EN - September 2011

2425-41
Copyright ©
Removal and Installation of Cylinder block

15) Install the water return pipe to the EGR cooler. • Align the clip positions marked at removal.
16) Install EGR cooler water hose to EGR cooler.
17) Install the water charge pipe to the EGR duct. Sensor, device Parts
18) Install the air leak pipe to the engine assembly. EGR motor EGR valve
Upper left side of the fly-
CKP sensor
wheel housing
Fuel pressure sensor Common rail
CMP sensor Fuel supply pump
Fuel temperature sensor Fuel supply pump
PCV Fuel supply pump
Boost sensor Inlet duct
Boost temperature sen-
Inlet duct
sor
Solenoid valve Injector
Engine coolant tempera-
Thermostat housing
ture sensor
Left side of the cylinder
Oil pressure sensor
block
Intake throttle position Between the inlet duct
1 EGR cooler water pipe sensor and the intake duct
2 Water return pipe VGS actuator Turbocharger
3 Air leak pipe

49. Air leak pipe installation ANNOTATION:

1) Install the air leak pipe to the engine assembly. • When connecting the harness connector to
the intake throttle valve, push in the lock
50. Starter assembly installation control section and lock it.
1) Install the starter assembly to the flywheel
housing.
Tightening torque: 137 N・m {14.0 kgf・m /
101 lb・ft}
ANNOTATION:
• Tighten it together with the earth cable.

1 Lock control section

2 Lock release
3 Lock

52. Generator bracket installation

1) Install the generator bracket to the cylinder
Earth cable collective tighten- block.
1 Tightening torque: 97 N・m {9.9 kgf・m / 72
ing position
lb・ft} M12bolt
Tightening torque: 50 N・m {5.1 kgf・m / 37
51. Engine harness installation lb・ft} M10 bolt
1) Install the engine harness to the engine as- 2) Temporarily tighten the adjust plate onto the
sembly. cylinder block.
2) Connect the extension harness to the connec- 53. Generator installation
tor.
1) Install the generator to the bracket.
ANNOTATION:
ANNOTATION:
• Connect connectors to every sensor and de-
vice. • Temporarily tighten all the installation bolts.
84512399 EN - September 2011
2425-42
Copyright ©
Removal and Installation of Cylinder block

54. Generator work belt installation 56. Oil level gauge guide tube installation
1) Install the generator work belt to the pulley. 1) Apply the engine oil to the O-ring.
2) Install the oil level gauge guide tube to the
CAUTION cylinder block.
• Confirm that the generator work 57. Engine oil filling
belt is securely inside each of the
pulley grooves. 1) Replenish the engine with engine oil.
ANNOTATION:
55. Generator work belt adjustment
• Make sure that the oil drain plug has been
1) Turn the adjust bolt. tightened before refilling engine oil.
ANNOTATION: 58. Coolant filling
• Conduct adjustment so that the amount of 1) Replenish the coolant with the radiator.
belt flex that occurs when the belt is pressed 2) Loosen the plug using the wrench.
at the location indicated by the arrow in 3) Replenish the coolant with the radiator.
the diagram with the specified pressure
matches the standard value. CAUTION
Standard: 98.0 N {10.0 kg / 22 lb} • Be careful not to let coolant over-
Specified value: 6.0 - 7.0 mm {0.2362 - 0.2756 flow splash on the exhaust system
in} Joint type parts.
Specified value: 12.0 - 13.0 mm {0.4724 - • Coolant overflow should be wiped
0.5118 in} Split type off.

4) Tighten the plug using the wrench.

ANNOTATION:
• Apply Loctite 271.
Tightening torque: 15 N・m {1.5 kgf・m / 11
lb・ft}
5) Replenish the coolant with the radiator.

1 Crankshaft pulley
2 Generator
3 Water pump pulley

CAUTION
• Crank the engine for approximately
5 rotations and readjust the belt
tension to the standard value.

2) Securely tighten the adjust plate onto the 1 Plug

cylinder block.
Tightening torque: 50 N・m {5.1 kgf・m / 37
lb・ft} 59. Fuel air bleed
3) Tighten the penetration bolt with a wrench.
Tightening torque: 157 N・m {16.0 kgf・m / CAUTION
116 lb・ft}
• To prevent engine failure, be sure to per-
4) Tighten the lock nut with a wrench. form air removal after the installation or
Tightening torque: 93 N・m {9.5 kgf・m / 69 removal of fuel system parts.
lb・ft}

84512399 EN - September 2011

2425-43
Copyright ©
Removal and Installation of Cylinder block

• Wait for about 1 minute after operating the

priming pump.
6) Tighten the plug using the wrench.
ANNOTATION:
• Remove the air in the fuel filter.
CAUTION
• Continue air removal work until no
air comes out.

7) Loosen the plug using the wrench.

ANNOTATION:

1 Priming pump • Loosen the plug of the fuel supply pump.

2 Plug 8) Operate the priming pump.
3 Drain plug
ANNOTATION:
4 Case
5 Fuel filter element • Operate the priming pump until no air bub-
bles come out.
1) Prepare the pan. 9) Tighten the plug using the wrench.
2) Loosen the plug using the wrench.
ANNOTATION:
ANNOTATION:
• Tighten the plug of the fuel supply pump.
• Start with the fuel filter that is nearest to the
fuel tank. CAUTION
3) Operate the priming pump. • Do not over-tighten the plug.
ANNOTATION:
10) Operate the priming pump.
• Bleed the air from the fuel filter and fix the
priming pump. ANNOTATION:
4) Tighten the plug using the wrench. • Operate the priming pump until it becomes
5) Operate the priming pump. heavy.
ANNOTATION: 60. Battery ground cable connect
• Repeat the operation 10 times or more until 1) Connect the battery ground cable to the bat-
fuel is filled. tery.

84512399 EN - September 2011

2425-44
Copyright ©
Removal and Installation of Cylinder block

Cylinder block Inspection • Inspect the cylinder block while referring to

the following table, as necessary.
1. Cylinder block inspection
1) Measure the cylinder block using a feeler Cylinder block inspection
gauge. Inspection lo- Inspection
Supplement
cations method
ANNOTATION:
Water pas- Corrosion and
• Measure the amount of deformation using a sage, oil pas- clogging in- -
simple straight ruler and feeler gauge. sage spection
Crack inspec-
: 490 kPa {5 kgf/
Amount of deformation of the cylinder block tion
Water jacket cm2 / 71 psi} For 3
top surface Water pres-
minutes
Limit : 0.20 mm {0.0079 in} sure tester
Crack and
Dye penetrant
Block surface damage in-
check
spection

1 Feeler gauge

2) Inspect the crankcase using dye penetrant

check. 2. Piston oil jet inspection
ANNOTATION: 1) Inspect the piston oil jet.
• Inspect the crankcase for cracks and dam- ANNOTATION:
age.
• Inspect the piston oil jet for bending and the
oil hole for clogging.

ANNOTATION:

84512399 EN - September 2011

2425-45
Copyright ©
Removal and Installation of Cylinder block

84512399 EN - September 2011

2425-46
Copyright ©

Section

2445

Lubrication System

84512399 EN - September 2011

CONTENTS

Removal and Installation of Oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Oil pan Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Oil pan Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal and Installation of Oil level switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Oil level switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Oil level switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal and Installation of Oil pump assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Oil pump assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Oil pump assembly Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Oil pump assembly Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Oil pump assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Oil pump assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine oil Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

2445-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

2445-2 PRINTED IN FRANCE
Copyright ©
Lubrication System

Removal and Installation of Oil pan Oil pan Installation

1. Oil pan installation
Oil pan Removal
1) Apply the liquid gasket to the cylinder block.
1. Engine oil drain
ANNOTATION:
1) Remove the drain plug from the oil pan.
• Apply Sealend 242 or ThreeBond 1207C
ANNOTATION: to the joints of the cylinder block, flywheel
• Drain engine oil into the drain pan. housing, and front cover with the thickness
of about 2 mm {0.0787 in} and width of about
2) Install the drain plug to the oil pan. 3 mm {0.1181 in}.
Tightening torque: 70 N・m {7.1 kgf・m / 52
lb・ft} CAUTION
CAUTION • Clean the surface before applying
the gasket.
• Be careful not to forget to tighten
the drain plug.

2. Oil pan removal

1) Remove the oil pan from the cylinder block.

2) Install the oil pan to the cylinder block.

ANNOTATION:
• Install the oil pan gasket with the identifica-
tion text “OIL PAN SIDE” or silicone coated
surface facing the oil pan.
• Install the plate with the white paint facing
outside.
• Tighten the oil pan in the order of the num-
bers and arrows shown in the diagram.
Tightening torque: 19 N・m {1.9 kgf・m / 168
lb・in}

84512399 EN - September 2011

2445-3
Copyright ©
Lubrication System

CAUTION Removal and Installation of Oil

• The oil pan must be re-tightened level switch
for several bolts because loosening
torque will occur. Oil level switch Removal
• Note that the oil pan gasket has 1. Engine oil drain
front and back sides.
1) Remove the drain plug from the oil pan.
2. Engine oil filling
ANNOTATION:
1) Replenish the engine with engine oil.
• Drain engine oil into the drain pan.
ANNOTATION:
2) Install the drain plug to the oil pan.
• Make sure that the oil drain plug has been Tightening torque: 70 N・m {7.1 kgf・m / 52
tightened before refilling engine oil. lb・ft}

CAUTION
• Be careful not to forget to tighten
the drain plug.

2. Oil level switch removal

1) Disengage the harness connector from the oil
level switch.
2) Remove the oil level switch from the oil pan.

1 O-ring
2 Oil level switch
3 Spacer

84512399 EN - September 2011

2445-4
Copyright ©
Lubrication System

Oil level switch Installation Removal and Installation of Oil

1. Oil level switch installation pump assembly
1) Install the oil level switch to the oil pan.
Tightening torque: 10 N・m {1.0 kgf・m / 87 Oil pump assembly Removal
lb・in} 1. Engine oil drain
2) Connect the harness connector to the oil level
switch. 1) Remove the drain plug from the oil pan.
ANNOTATION:
• Drain engine oil into the drain pan.
2) Install the drain plug to the oil pan.
Tightening torque: 70 N・m {7.1 kgf・m / 52
lb・ft}

CAUTION
• Be careful not to forget to tighten
the drain plug.

2. Oil pan removal

1) Remove the oil pan from the cylinder block.
3. Oil pump assembly removal
1 O-ring
2 Oil level switch 1) Measure backlash using a dial gauge.
3 Spacer ANNOTATION:
• Measure the backlash of the oil pump gear
2. Engine oil filling and the crankshaft gear.
1) Replenish the engine with engine oil.
Gear backlash
ANNOTATION:
Standard value ： 0.15 mm {0.0059 in}
• Make sure that the oil drain plug has been Limit ： 0.20 mm {0.0079 in}
tightened before refilling engine oil.

2) Remove the oil pump assembly from the cylin-

der block.

84512399 EN - September 2011

2445-5
Copyright ©
Lubrication System

Oil pump assembly Disassembly Oil pump assembly Reassembly

1. Oil pump assembly disassembly 1. Oil pump assembly reassembly
1) Remove the oil strainer from the oil pump. 1) Apply the engine oil to the driven gear.
2) Remove the oil pipe from the oil pump. 2) Install the driven gear to the oil pump body.
3) Remove the oil pump cover from the oil pump
body.
4) Remove the driven gear from the oil pump
body.

1 Driven gear

3) Install the oil pump cover to the oil pump body.

Tightening torque: 19 N・m {1.9 kgf・m / 14
lb・ft}

CAUTION
• Before installing the cover, fill up
the gear cavities with clean engine
oil.

ANNOTATION:
• Filling engine oil is important to prevent oil
pressure lag when starting the engine.
4) Install the oil pipe to the oil pump.
ANNOTATION:
• Apply liquid gasket to the two O-ring
grooves, and install the O-rings.
Tightening torque: 22 N・m {2.2 kgf・m / 16
lb・ft}

CAUTION
• Install the oil pipe after installing
the oil pump.

5) Install the oil strainer to the oil pump.

84512399 EN - September 2011

2445-6
Copyright ©
Lubrication System

Oil pump assembly Installation

1. Oil pump assembly installation

CAUTION
• Install the oil pipe and the oil strainer af-
ter installing the oil pump assembly.

1) Install the oil pump assembly to the cylinder

block.
Tightening torque: 22 N・m {2.2 kgf・m / 16
lb・ft} M8
Tightening torque: 38 N・m {3.9 kgf・m / 28
lb・ft} M10
2) Install the oil pipe to the oil pump assembly. 2) Install the oil pan to the cylinder block.
ANNOTATION: ANNOTATION:
• Apply the engine oil to the O-ring. • Install the oil pan gasket with the identifica-
tion text "OIL PAN SIDE" or silicone coated
CAUTION surface facing the oil pan.
• All bolts must be temporarily tight- • Install the plate with the white paint facing
ened, and after being confirmed outside.
that they are seated, they must be • Tighten the oil pan in the order of the num-
tightened to the specified torque. bers and arrows shown in the diagram.
Tightening torque: 19 N・m {1.9 kgf・m / 168
Tightening torque: 22 N・m {2.2 kgf・m / 16 lb・in}
lb・ft}

3) Install the O-ring to the oil strainer. CAUTION

4) Apply the engine oil to the O-ring.
5) Install the oil strainer to the oil pump assembly. • The oil pan must be re-tightened
Tightening torque: 22 N・m {2.2 kgf・m / 16 for several bolts because loosening
lb・ft} torque will occur.
• Note that the oil pan gasket has
2. Oil pan installation front and back sides.
1) Apply the liquid gasket to the cylinder block.
3. Engine oil filling
ANNOTATION:
1) Replenish the engine with engine oil.
• Apply Sealend 242 or ThreeBond 1207C
to the joints of the cylinder block, flywheel ANNOTATION:
housing, and front cover with the thickness • Make sure that the oil drain plug has been
of about 2 mm {0.0787 in} and width of about tightened before refilling engine oil.
3 mm {0.1181 in}.

CAUTION
• Clean the surface before applying
the gasket.

84512399 EN - September 2011

2445-7
Copyright ©
Lubrication System

Oil pump assembly Inspection Engine oil Inspection

1. Oil pump assembly inspection 1. Engine oil inspection
1) Inspect the backlash.
CAUTION
ANNOTATION:
• The engine should be in a horizontal po-
• Measure the backlash of the oil pump work sition.
gear and the crankshaft gear. • Wait at least 5 minutes before starting the
• Measure the backlash before removing the engine and after stopping the engine.
oil pump assembly.
1) Remove the oil level gauge from the oil level
Gear backlash gauge guide tube.
Standard value ： 0.15 mm {0.0059 in}
ANNOTATION:
Limit value ： 0.20 mm {0.0079 in}
• Wipe off the engine oil remaining on the oil
2) Measure the clearance using the feeler level gauge.
gauge. 2) Install the oil level gauge to the oil level gauge
ANNOTATION: guide tube.
3) Remove the oil level gauge from the oil level
• Measure the clearance between the oil gauge guide tube.
pump body and the gear.n 4) Inspect the engine oil.
Specified value: 0.100 - 0.196 mm {0.0039 - ANNOTATION:
0.0077 in}
• Check the engine oil remaining on the oil
level gauge to inspect the engine oil level.

1 MAX
2 MIN
3 Acceptable oil amount
4 Requires replenishment

84512399 EN - September 2011

2445-8
Copyright ©

Section

2455

Cooling System

84512399 EN - September 2011

CONTENTS

Removal and Installation of Water pump assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Water pump assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Water pump assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Water pump assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal and Installation of Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Thermostat Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Thermostat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Thermostat Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Coolant Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Removal and Installation of Overheat switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Overheat switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Overheat switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

2455-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

2455-2 PRINTED IN FRANCE
Copyright ©
Cooling System

Removal and Installation of Water 3) Disconnect the EGR cooler water hose from
the EGR cooler.
pump assembly 4) Remove the water return pipe from the EGR
cooler.
Water pump assembly Removal
1. Battery ground cable disconnect
1) Disengage the battery ground cable from the
battery.
2. Coolant drain

WARNING
• Do not loosen the radiator cap when the
coolant is hot.
• Steam and boiling water may burst out
and cause burns, so make sure that the
engine has cooled off.

1) Drain the coolant from the radiator.

1 EGR cooler water hose
CAUTION 2 Water return pipe
3 Air leak pipe
• After draining the coolant, tighten
the drain plug.
5) Remove the EGR cooler B from the EGR
2) Drain the coolant from the engine assembly. cooler duct B and the EGR cooler C.
6) Remove the EGR cooler duct A from the ex-
ANNOTATION: haust manifold and the bracket.
7) Remove the EGR cooler duct B from the ex-
• Loosen the drain plug on the cylinder block
side. haust manifold and the bracket.
8) Remove the bracket from the cylinder head.
9) Remove the EGR cooler D from the EGR
valve duct.
10) Remove the EGR cooler C from the EGR
valve duct.
11) Remove the EGR valve duct from the EGR
valve.

1 Drain plug

3. EGR cooler removal

1) Disconnect the air leak pipe from the engine
assembly.
2) Disconnect the water charge pipe from the
EGR cooler duct. 1 EGR cooler duct B

84512399 EN - September 2011

2455-3
Copyright ©
Cooling System

4. Thermostat housing removal 7. Water pump assembly removal

1) Remove the thermostat housing from the 1) Remove the water pump assembly from the
cylinder head. cylinder block.

1 Gasket
2 Bracket
3 Water outlet pipe
4 Thermostat housing
5 Bracket

5. Generator work belt removal

1) Remove the generator work belt from the pul-
ley.
ANNOTATION:
• Loosen the lock nut and penetration bolt,
and then loosen the adjust bolt to remove
the generator work belt.

1 Lock nut
2 Adjust bolt
3 Generator
4 Penetration bolt

6. Generator removal
1) Remove the generator from the bracket.

84512399 EN - September 2011

2455-4
Copyright ©
Cooling System

Water pump assembly Installation • A small amount of ThreeBond 1521 can also
be applied to the gasket.
1. Water pump assembly installation
Tightening torque: 44 N・m {4.5 kgf・m / 32
1) Install the O-ring to the water pump assembly. lb・ft}
2) Install the water pump assembly to the cylin-
der block.
ANNOTATION:
• Use the stud bolts as a guide to prevent
displacement of the gasket.

CAUTION
• Clean the installation surface of the
gasket, and install the gasket so
that it is not displaced.

Tightening torque: 38 N・m {3.9 kgf・m / 28

lb・ft}

1 Gasket
2 Bracket
3 Water outlet pipe
4 Thermostat housing
5 Bracket

3. EGR cooler installation

1) Temporarily tighten the EGR valve duct to the
EGR valve.
ANNOTATION:
• Temporarily tighten with the gasket inserted.
2. Thermostat housing installation Temporary tightening torque: 5 N ・ m {0.5
1) Install the thermostat housing to the cylinder kgf・m / 44 lb・in}
head assembly.
ANNOTATION:
• Insert the gasket, and insert the thermostat
housing into the water pump assembly to
install it.

CAUTION
• Assemble the thermostat housing
after assembling the water pump
assembly and cylinder head assem-
bly.

ANNOTATION:

84512399 EN - September 2011

2455-5
Copyright ©
Cooling System

Engine front side EGR cooler

1
bracket
Engine rear side EGR cooler
2
bracket 1 Engine rear side bracket
2 Engine front side bracket
3) Temporarily tighten the EGR cooler to the
EGR valve duct.
ANNOTATION: 5) Temporarily tighten the EGR duct to the ex-
haust manifold.
• Temporarily tighten with the gasket inserted.
• Install the air removal pipe faicing it towards ANNOTATION:
the front side. • Temporarily tighten with the gasket inserted.
Temporary tightening torque: 5 N ・ m {0.5 Temporary tightening torque: 5 N ・ m {0.5
kgf・m / 44 lb・in} kgf・m / 44 lb・in}
6) Temporarily tighten the EGR cooler to the
EGR duct.
ANNOTATION:
• Temporarily tighten with the gasket inserted.
• Refer to the diagram for the direction of the
water pipe.

1 EGR cooler D
2 EGR valve duct
3 EGR cooler C

1 EGR cooler B
2 EGR cooler A
3 EGR duct A
4 EGR duct B
84512399 EN - September 2011
2455-6
Copyright ©
Cooling System

ANNOTATION: 9) Securely tighten the EGR cooler to the EGR

duct.
• Procedure for complete tightening Tightening torque: 50 N・m {5.1 kgf・m / 37
CAUTION lb・ft} 3 in the diagram
10) Temporarily tighten the EGR duct to the ex-
• Make sure to follow the installation haust manifold.
procedure. Tightening torque: 50 N・m {5.1 kgf・m / 37
lb・ft} 4 in the diagram
Otherwise, a gas leak or excessive stress may 11) Securely tighten the EGR valve duct to the
occur causing parts damage. EGR valve.
7) Securely tighten the EGR cooler to the EGR Tightening torque: 44 N・m {4.5 kgf・m / 32
valve duct. lb・ft} 5 in the diagram
12) Securely tighten the EGR valve duct to the
ANNOTATION: EGR mixing chamber.
• Completely tighten the EGR cooler C and Tightening torque: 44 N・m {4.5 kgf・m / 32
the EGR cooler D to the EGR valve duct. lb・ft} 6 in the diagram
13) Securely tighten the EGR cooler to the EGR
Tightening torque: 50 N・m {5.1 kgf・m / 37 cooler bracket.
lb・ft} 1 in the diagram Tightening torque: 50 N・m {5.1 kgf・m / 37
8) Securely tighten the EGR cooler to the EGR lb・ft} 7 in the diagram
cooler. 14) Completely tighten the EGR duct to the
ANNOTATION: bracket.
Tightening torque: 50 N・m {5.1 kgf・m / 37
• Tighten the connections between the EGR lb・ft} 8 in the diagram
cooler A and the EGR cooler C and between
the EGR cooler B and the EGR cooler D at
the respective specified torque.
Tightening torque: 50 N・m {5.1 kgf・m / 37
lb・ft} 2 in the diagram

0.0020 in}
Thermostat
ANNOTATION:
• Measure the interference of the impeller and Thermostat Removal
water pump pulley. 1. Battery ground cable disconnect
Specified value: 0.048 - 0.082 mm {0.0019 - 1) Disengage the battery ground cable from the
0.0032 in} battery.
2. Coolant drain

WARNING
• Do not loosen the radiator cap when the
coolant is hot.
• Steam and boiling water may burst out
and cause burns, so make sure that the
engine has cooled off.

1) Drain the coolant from the radiator.

CAUTION
• After draining the coolant, tighten
4. Water pump bearing inspection the drain plug.

1) Inspect the bearing. 2) Drain the coolant from the engine assembly.
ANNOTATION: ANNOTATION:
• Check to see from the ball clearance to the • Loosen the drain plug on the cylinder block
lace for scratching or flaking (full circumfer- side.
ence).
• Inspect the ball and race for any abnormal
looseness.
• Check if you can feel anything unusual in
your hand when rotating the bearing.

1 Drain plug

3. EGR cooler removal

1) Disconnect the air leak pipe from the engine
assembly.
2) Disconnect the water charge pipe from the
EGR cooler duct.
3) Disconnect the EGR cooler water hose from
the EGR cooler.

84512399 EN - September 2011

2455-10
Copyright ©
Cooling System

4) Remove the water return pipe from the EGR 4. Thermostat housing removal
cooler.
1) Remove the thermostat housing from the
cylinder head.

1 EGR cooler water hose

2 Water return pipe
1 Gasket
3 Air leak pipe
2 Bracket
5) Remove the EGR cooler A from the EGR 3 Water outlet pipe
cooler duct A and the EGR cooler D. 4 Thermostat housing
6) Remove the EGR cooler B from the EGR 5 Bracket
cooler duct B and the EGR cooler C.
7) Remove the EGR cooler duct A from the ex- 5. Thermostat removal
haust manifold and the bracket.
8) Remove the EGR cooler duct B from the ex- 1) Remove the spacer from the thermostat hous-
haust manifold and the bracket. ing.
9) Remove the bracket from the cylinder head. 2) Remove the thermostat from the thermostat
10) Remove the EGR cooler D from the EGR housing.
valve duct. 3) Remove the thermostat seal ring from the
11) Remove the EGR cooler C from the EGR thermostat housing using a special tool.
valve duct. ANNOTATION:
12) Remove the EGR valve duct from the EGR
valve. • Remove the thermostat seal ring using the
thermostat seal remover.

1 EGR cooler duct B Special tool: thermostat seal remover

2 EGR cooler B (refer to section 1003)
3 EGR cooler C
4 EGR valve duct
5 EGR cooler D
6 EGR cooler A
7 EGR cooler duct A

84512399 EN - September 2011

2455-11
Copyright ©
Cooling System

Thermostat Installation
1. Thermostat installation
1) Install the thermostat seal ring to the thermo-
stat housing using a special tool.
ANNOTATION:
• Using the seal ring setting tool, install the
thermostat seal ring with the lip section fac-
ing the front.

1 Thermostat housing
2 Gasket
3 Thermostat seal ring
4 Thermostat
5 Spacer

Special tool: Thermostat seal ring Installer

(refer to section 1003)
2) Install the thermostat to the thermostat hous-
ing.

CAUTION
• Install the thermostat while being
careful not to damage the thermo-
stat seal ring.

1 Thermostat housing
2 Gasket
3 Thermostat seal ring
4 Thermostat
5 Spacer

2. Thermostat housing installation

1) Install the thermostat housing to the cylinder
head assembly.
ANNOTATION:
84512399 EN - September 2011
2455-12
Copyright ©
Cooling System

• Insert the gasket, and insert the thermostat 2) Install the bracket to the cylinder head.
housing into the water pump assembly to Tightening torque: 97 N・m {9.9 kgf・m / 72
install it. lb・ft} Engine front side
Tightening torque: 44 N・m {4.5 kgf・m / 32
CAUTION lb・ft} Engine rear side
• Assemble the thermostat housing
after assembling the water pump
assembly and cylinder head assem-
bly.

ANNOTATION:
• A small amount of ThreeBond 1521 can also
be applied to the gasket.
Tightening torque: 44 N・m {4.5 kgf・m / 32
lb・ft}

Engine front side EGR cooler

1
bracket
Engine rear side EGR cooler
2
bracket

3) Temporarily tighten the EGR cooler to the

EGR valve duct.
ANNOTATION:
• Temporarily tighten with the gasket inserted.
• Install the air removal pipe faicing it towards
the front side.
1 Gasket
Temporary tightening torque: 5 N ・ m {0.5
2 Bracket kgf・m / 44 lb・in}
3 Water outlet pipe
4 Thermostat housing
5 Bracket

3. EGR cooler installation

1) Temporarily tighten the EGR valve duct to the
EGR valve.
ANNOTATION:
• Temporarily tighten with the gasket inserted.
Temporary tightening torque: 5 N ・ m {0.5
kgf・m / 44 lb・in}

2455-15
Copyright ©
Cooling System

5) Replenish the coolant with the radiator. Thermostat Inspection

1. Thermostat inspection
1) Inspect the thermostat.
ANNOTATION:
• Shake the thermostat pellet section to in-
spect for looseness and damages in the
caulking sections.

1 Plug

5. Battery ground cable connect

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

ANNOTATION:
• Place the thermostat in water, and gradually
raise the water temperature to inspect the
opening temperature, full open temperature
and lift amount.

Opening tempera-
80 - 84 °C {176 - 183 °F}
ture:
full open Temper-
95 °C {203 °F}
ature:
Lift amount: 11 mm {0.4331 in}

ANNOTATION:
• Since the heat capacity is high for wax type
thermostats, there is a slight difference in
valve operations for the fluctuations of water
temperature.

CAUTION
• Place a wood piece on the bottom of
the container so that the thermostat
is not directly heated, or suspend
the thermostat.
• Constantly stir the hot water so that
there is no difference in tempera-
ture.

84512399 EN - September 2011

2455-16
Copyright ©
Cooling System

Coolant Inspection
1. Coolant inspection

WARNING
• If the coolant temperature is high, do not
perform the inspection.
• When removing the cap, be careful as the
coolant will burst out if the coolant tem-
perature is high.

1) Inspect the concentration.

ANNOTATION:
• Use the specified LLC by diluting with tap
water to the appropriate concentration.

LLC
Region where the machine is oper- con-
ated. centra-
tion
Regions where the low-
General speci-
est temperature is (-12) : 30％
fications
°C
Regions where the low-
Cold region
est temperature is (-30) : 50％
specifications
°C

CAUTION
• With LLC concentration of 30％％ or
below, the ability to prevent rust de-
creases.
• With LLC concentration of 60％％ or
above, it may cause an overheat.
• If the LLC is used at any other con-
centration than the one specified,
the anti-freezing performance may
decrease, and freezing may result.
• Be sure to use long life coolant
which is specified or recommended
by Isuzu.

84512399 EN - September 2011

2455-17
Copyright ©
Cooling System

Radiator cap operating pressure

: 61.8 to 71.6 kPa {0.63
Positive
- 0.73 kgf/cm2 / 9 to 10
Standard pressure
psi}
value
Negative : 4.9 kPa {0.05 kgf/cm2 /
pressure 1 psi}

SPE-
CIFIC
GRAV-
ITY

TEMPERATURE (°C)
ANNOTATION:
Coolant density (％) • Replace the sub-tank cap if the open valve
pressure is not at the standard value.
4) Inspect coolant using a radiator cap tester.
ANNOTATION:

Frozen tem- Frozen tem- • Inspect the sections listed in the table for
perature perature coolant leakage using a radiator cap tester.
(°C) (°F) Inspection pressure: 88 kPa {0.90 kgf/cm2 /
12.8 psi}

Radiator
Water pump
Radiator upper hose
Coolant leakage in- Radiator lower hose
2) Inspect the cap.
spection sections Heater hose
ANNOTATION: Water pipe
• Inspect the condition of the negative pres- Water rubber hose
sure valve located at the center of the radi- Sub-tank
ator cap valve seat side.
• If the valve seat is not operating smoothly
because of rust, filth, etc., clean or replace
the radiator cap.
3) Inspect the cap using a radiator cap tester.
ANNOTATION:
• Inspect the open valve pressure of the radi-
ator cap using a radiator cap tester.

84512399 EN - September 2011

2455-18
Copyright ©
Cooling System

Removal and Installation of Overheat switch Installation

Overheat switch 1. Overheat switch installation
1) Install the overheat switch to the water outlet
Overheat switch Removal pipe.
1. Overheat switch removal ANNOTATION:
1) Disconnect the harness connector from the • Apply Loctite 271.
overheat switch.
2) Remove the overheat switch from the water Tightening torque: 20 N・m {2 kgf・m / 14
outlet pipe. lb・ft}
2) Connect the harness connector to the over-
heat switch.

1 Overheat switch
2 Oil pressure sensor
1 Overheat switch
2 Oil pressure sensor

84512399 EN - September 2011

2455-19
Copyright ©
Cooling System

84512399 EN - September 2011

2455-20
Copyright ©

Section

2465

Removal and Installation of Exhaust Manifold

84512399 EN - September 2011

CONTENTS

Exhaust manifold Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Exhaust manifold Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Exhaust manifold Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

2465-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

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

Exhaust manifold Removal Exhaust manifold Installation

1. Remove the exhaust manifold from the cylinder 1. Install the seal ring to the exhaust manifold.
head assembly.
ANNOTATION:
ANNOTATION:
• Shift the joint positions by 120 degrees for instal-
• At the same time, remove the bracket and the lation.
distance tube.
CAUTION
2. Remove the gasket from the cylinder head assem-
bly. • Pay attention to the directionality of the
seal ring.

1 Bracket 2. Install the gasket to the cylinder head assembly.

2 Exhaust manifold
3 - CAUTION
4 Gasket
• Install it with the molybdenum coating
facing the outside and the protruding
3. Disassemble the exhaust manifold. portion on the lower right side.
4. Remove the seal ring from the exhaust manifold.
3. Install the exhaust manifold to the cylinder head as-
sembly.
ANNOTATION:
• Refer to the diagram below to collectively tighten
the bracket.

1 Bracket
2 Exhaust manifold
3 -
4 Gasket

ANNOTATION:
• Tighten each flange in the order of 3rd, 4th, 2nd,
5th, 1st, and 6th cylinder.
84512399 EN - September 2011
2465-3
Copyright ©
Removal and Installation of Exhaust Manifold

Tightening torque： 54 N・m { 5.5 kgf・m / 40 lb・ Exhaust manifold Inspection

ft }
1. Exhaust manifold Inspection
1) Inspect the exhaust manifold.
ANNOTATION:
• Inspect the exhaust manifold for cracks.
2) Align the simple straight ruler to the cylinder
head assembly.
3) Measure the clearance using the feeler
gauge.
ANNOTATION:
• Flatness of the exhaust manifold
Limit： 0.5 mm ｛0.0197 in｝
Specified value： 0.3 mm ｛0.0118 in｝

CAUTION
• Replace the exhaust manifold if flat-
ness is above the limit value.

84512399 EN - September 2011

2465-4
Copyright ©

Section

2470

Disassembly, Removal and Installation of DPD assembly

84512399 EN - September 2011

CONTENTS

DPD assembly Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

DPD assembly Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DPD assembly Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

2470-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

2470-2 PRINTED IN FRANCE
Copyright ©
Disassembly, Removal and Installation of DPD assembly

DPD assembly Disassembly 2) Disengage the harness connector from the

exhaust differential pressure sensor.
1. Exhaust differential pressure sensor safety Informa- 3) Remove the exhaust differential pressure sen-
tion sor from the DPD assembly.
CAUTION CAUTION
• Do not use a tool which causes vibra- • Remove the exhaust differential
tions such as an impact wrench when in- pressure sensor with the attached
stalling and removing the exhaust differ- bracket.
ential pressure sensor.
• Do not reuse the exhaust differential
pressure sensor which has been sub-
jected to shock such as being dropped.
• Install or remove the exhaust differen-
tial pressure sensor together with the
bracket.
• Be sure not to loosen the 4 screws in-
stalled on the exhaust differential pres-
sure sensor.
• Replace the exhaust differential pres-
sure sensorif the 4 screws installed on
the DPD differential pressure sensor
have been loosened.

Exhaust differential pressure

1
sensor

3. Exhaust gas temperature sensor safety Information

CAUTION
• Before removing, be sure to check the
DPD pressure difference, status, and in-
spection/ maintenance contents using a
scan tool.
• Do not reuse an exhaust gas tempera-
1 Screw ture sensor which has been subjected to
shock such as being dropped.
2. Exhaust differential pressure sensor removal
4. Exhaust gas temperature sensor removal
CAUTION
1) Disengage the harness connector from the
• Before performing work, be sure to exhaust gas temperature sensor.
check the exhaust differential pressure
ANNOTATION:
sensor precautions.
• To prevent incorrect assembling, make an
1) Disengage the differential pressure hose from alignment mark on the connector before dis-
the exhaust differential pressure sensor. connecting.

84512399 EN - September 2011

2470-3
Copyright ©
Disassembly, Removal and Installation of DPD assembly

2) Remove the exhaust gas temperature sensor 3) Remove the differential pressure pipe from
from the DPD assembly. the DPD assembly.

Exhaust gas temperature sen- 1 Differential pressure pipe

1
sor 1
Exhaust gas temperature sen- 4) Remove the oxidation catalyst assembly from
2 the filter assembly.
sor 2
5) Remove the filter assembly from the exhaust
5. DPD assembly disassembly silencer assembly.

1) Loosen the differential pressure pipe using the

wrench.
2) Remove the clip from the differential pressure
pipe.

1 Oxidation catalyst assembly

2 Filter assembly
3 Exhaust silencer assembly

84512399 EN - September 2011

2470-4
Copyright ©
Disassembly, Removal and Installation of DPD assembly

DPD assembly Reassembly 6) Temporarily tighten the clip to the differential

pressure pipe.
1. DPD assembly reassembly 7) Securely tighten the clip to the differential
pressure pipe.
CAUTION Tightening torque: torque: 10 N・m {1.0 kgf・
• Do not reuse gaskets, bolts, and nuts. m / 89 lb・in}
8) Securely tighten the differential pressure pipe
1) Temporarily tighten the filter assembly to the to the DPD assembly.
exhaust silencer assembly. Tightening torque: torque: 35 N・m {3.6 kgf・
m / 26 lb・ft} pipe sleeve nut
ANNOTATION:
• Tighten together with the bracket.
2) Temporarily tighten the oxidation catalyst as-
sembly to the filter assembly.
ANNOTATION:
• Tighten together with the bracket.
• Place the DPD assembly tightened tem-
porarily on a flat surface to determine the
position so that the bracket installation area
is horizontal.
3) Securely tighten the filter assembly to the ex-
haust silencer assembly.
Tightening torque: torque: 29 N・m {3.0 kgf・
m / 21 lb・ft}
4) Securely tighten the oxidation catalyst assem- 1 Differential pressure pipe
bly to the filter assembly.
Tightening torque: torque: 29 N・m {3.0 kgf・ 9) Install the bracket to the DPD assembly.
m / 21 lb・ft} Tightening torque: torque: 25 N・m {2.5 kgf・
m / 18 lb・ft}
2. Exhaust gas temperature sensor installation

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

5) Temporarily tighten the differential pressure 1) Temporarily tighten the exhaust gas tempera-
pipe to the DPD assembly. ture sensor to the DPD assembly.

CAUTION CAUTION
• Remove the old anti-seize lubricant • To avoid damaging the sensor in-
on the sleeve nut. stallation sections due to sensor
• Apply the anti-seize lubricant on the incorrect assembly, tighten it by
threaded portion of the sleeve nut. hand.
• Apply Never-Seez High Tempera-
ture Stainless Grade: 5-87411-039-0 ANNOTATION:
anti-seize lubricant, manufactured
by Bostik in the United states. • Exhaust gas temperature sensor identifica-
tion
84512399 EN - September 2011
2470-5
Copyright ©
Disassembly, Removal and Installation of DPD assembly

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

Exhaust gas temperature sen-

1
sor 1
Exhaust gas temperature sen-
2
sor 2 1 Screw

ANNOTATION:
• Start the engine after assembling each part, 4. Exhaust differential pressure sensor installation
and check for gas leaks from each joint and
for vibration. CAUTION
3. Exhaust differential pressure sensor safety Informa- • Before performing work, be sure to
tion check the exhaust differential pressure
sensor precautions.

1) Install the exhaust differential pressure sensor

to the DPD assembly.
2) Connect the harness connector to the exhaust
differential pressure sensor.
3) Connect the differential pressure hose to the
exhaust differential pressure sensor.

CAUTION
• Be careful not to mistake the con-
necting position of the differential
pressure hose.
• Since the differential pressure sen-
sor may malfunction if exhaust gas
leaks from the joint sections, con-
firm that there is no exhaust gas
leakage after the engine starts.

84512399 EN - September 2011

2470-6
Copyright ©
Disassembly, Removal and Installation of DPD assembly

DPD assembly Inspection

1. Filter assembly inspection
1) Inspect the filter assembly.
ANNOTATION:
• Inspect the filter for erosion, crack, damage,
or clogging.
• Replace the filter assembly if light passes
through when shining light from the other
side of the filter.

Exhaust differential pressure

4. Use a wrench (19 mm) to remove the 2 bolts (2) 5. Use a wrench (19 mm) to remove the 6 bolts (1) and
from the fuel tank front cover (tank) (1), and then then remove the handle (2).
remove the cover (tank).

84512399 EN - September 2011

3001-4
Copyright ©
Removal and Installation of Fuel Tank

6. Use a wrench (19 mm) to remove the 7 bolts (1), • Depending on the machine, there may be height
and then remove the under cover (2) (3). adjustment shims between the tank and the
Tightening torque for bolt installation: 63.7 - 73.5 frame. Do not lose them.
N·m • Also, mark or write down the locations where they
are and how many.
• Tightening torque for bolt installation: 233.0 -
276.0 N·m

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

hose (2).
• Mark the fuel tank and hose so that the connec-
tors match at the time of assembly. 10. Use a wrench (19 mm) to remove the 4 bolts (1),
• Attach caps or plugs to the fuel tank and hose to and then remove the side covers (tank) (2).
prevent any entry of water, dust or dirt.

11. Install the 4 eyebolts (M12) (1) on top of the fuel

tank.
8. Remove the connector (1).
• Fully tighten the eyebolts, and then loosen them
by a half turn.

9. Use a wrench (24 mm) to remove the 6 bolts (1) and

6 spacers (2) from the bottom of the fuel tank.

84512399 EN - September 2011

3001-5
Copyright ©
Removal and Installation of Fuel Tank

12. Install the 4 shackles (1) on the eyebolts, then use Installation of fuel tank
the wire ropes (2) and liftcrane to lift the fuel tank.
Thoroughly check that the location is safe before To install, perform the reverse of the removal procedure.
lowering the fuel tank (3) on wood planks. Tighten bolts being installed to the specified torque.
For bolts for which the torque is not specified, see "Stan-
dard Torque Data for Cap Screws and Nuts".
Finally, carefully check for any fuel leaks.

84512399 EN - September 2011

3001-6
Copyright ©

Section

3004A

Removal and Installation of Fuel supply pump

84512399 EN - September 2011

CONTENTS

Fuel supply pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Fuel supply pump Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

3004A-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

3004A-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Fuel supply pump

Fuel supply pump Removal 4) Remove the water return pipe from the EGR
cooler.
1. Fuel safety Information

CAUTION
• Fuel leakage can cause a fire, so wipe
away any leaked fuel after completing the
work and inspection, and make sure to
confirm that no fuel leak is found after
starting the engine.

2. Battery ground cable disconnect

1) Disengage the battery ground cable from the
battery.
3. Coolant drain

WARNING
1 EGR cooler water hose
• Do not loosen the radiator cap when the 2 Water return pipe
coolant is hot.
3 Air leak pipe
• Steam and boiling water may burst out
and cause burns, so make sure that the
engine has cooled off.
5) Remove the EGR cooler A from the EGR
cooler duct A and the EGR cooler D.
1) Drain the coolant from the radiator. 6) Remove the EGR cooler B from the EGR
cooler duct B and the EGR cooler C.
CAUTION
7) Remove the EGR cooler duct A from the ex-
• After draining the coolant, tighten haust manifold and the bracket.
the drain plug. 8) Remove the EGR cooler duct B from the ex-
haust manifold and the bracket.
2) Drain the coolant from the engine assembly. 9) Remove the bracket from the cylinder head.
10) Remove the EGR cooler D from the EGR
ANNOTATION: valve duct.
• Loosen the drain plug on the cylinder block 11) Remove the EGR cooler C from the EGR
side. valve duct.
12) Remove the EGR valve duct from the EGR
valve.

1 Drain plug
1 EGR cooler duct B
2 EGR cooler B
3 EGR cooler C
4. EGR cooler removal 4 EGR valve duct
1) Disconnect the air leak pipe from the engine 5 EGR cooler D
assembly. 6 EGR cooler A
2) Disconnect the water charge pipe from the 7 EGR cooler duct A
EGR cooler duct.
3) Disconnect the EGR cooler water hose from
the EGR cooler. 5. EGR valve removal
84512399 EN - September 2011
3004A-3
Copyright ©
Removal and Installation of Fuel supply pump

1) Disconnect the connector from the EGR 2) Remove the O-ring from the EGR mixing
valve. chamber.
2) Remove the EGR valve from the EGR mixing
ANNOTATION:
chamber.
3) Remove the lead valve from the EGR mixing • Seal the inlet cover opening to prevent for-
chamber. eign material from entering.

1 EGR valve A
2 EGR mixing chamber 1 EGR mixing chamber
3 EGR valve B 2 Intake duct
3 Intake throttle valve
6. Intake throttle valve removal 4 Inlet duct
5 Boost sensor
1) Remove the intake duct from the intake throt-
tle valve.
2) Remove the intake throttle valve from the inlet 9. Ventilation hose removal
duct.
1) Disconnect the ventilation hose from the cylin-
3) Remove the O-ring from the intake throttle
der head cover.
valve.
2) Disconnect the ventilation hose from the air
7. Inlet duct removal duct.
1) Remove the inlet duct from the EGR mixing 10. Fuel pipe removal
chamber.
1) Disconnect the fuel pipe from the common rail
2) Install the O-ring to the inlet duct.
assembly.
ANNOTATION: 2) Remove the fuel pipe from the fuel supply
pump.
• Do not remove the boost sensor unless nec-
essary. 11. Fuel suction pipe removal
8. EGR mixing chamber removal 1) Remove the fuel suction pipe from the fuel
supply pump.
1) Remove the EGR mixing chamber from the
inlet cover. 12. Fuel leak-off pipe removal
1) Disengage the fuel leak-off pipe from the cylin-
der head.
2) Disengage the fuel leak-off pipe from the fuel
filter bracket.
3) Disengage the fuel leak-off pipe from the com-
mon rail assembly.
4) Disconnect the fuel leak-off pipe from the fuel
supply pump.
5) Remove the fuel leak-off pipe from the
bracket.
13. Fuel feed pipe removal
1) Remove the clip from the fuel feed pipe.
2) Remove the fuel feed pipe from the fuel filter.
3) Remove the fuel feed pipe from the fuel supply
pump.
14. Fuel pipe removal
84512399 EN - September 2011
3004A-4
Copyright ©
Removal and Installation of Fuel supply pump

1) Remove the fuel pipe from the fuel filter. 2) Remove bolts from the supply pump coupling
2) Remove the fuel pipe from the fuel supply assembly.
pump.
ANNOTATION:
• Remove the coupling cotter bolt and the
coupling half bolt.

1 Fuel pipe
2 Fuel leak-off pipe
3 Fuel pipe
4 Fuel feed pipe 1 Fuel supply pump
5 Fuel suction pipe 2 Marked line
3 Coupling cotter bolt
15. Supply pump coupling assembly disconnect 4 Bearing case
5 Coupling half bolt
1) Align 1st cylinder to the compression top dead
center. 6 Coupling bolt

16. Fuel supply pump removal

1) Remove the oil feed pipe from the fuel supply
pump.
2) Remove the oil return pipe from the fuel sup-
ply pump.
3) Remove the fuel supply pump from the
bracket.

84512399 EN - September 2011

3004A-5
Copyright ©
Removal and Installation of Fuel supply pump

Fuel supply pump Installation 1) Align 1st cylinder to the compression top dead
center.
1. Fuel safety Information
ANNOTATION:
CAUTION • Align the T/C marking line of the flywheel to
• Fuel leakage can cause a fire, so wipe the pointer so that it is set for the top dead
away any leaked fuel after completing the center on the 1st cylinder.
work and inspection, and make sure to
confirm that no fuel leak is found after
starting the engine.

2. Fuel supply pump installation

1) Install the fuel supply pump to the bracket.
ANNOTATION:
• Move the injection pump coupling assembly
towards the bearing case in advance.
• Loosen the coupling cotter bolt and coupling
half bolt to some extent to keep them from
shaking loose.

CAUTION 2) Align the fuel supply pump with the supply

• Note that tightening when it is in pump coupling assembly.
a very loose condition will cause ANNOTATION:
damage to the coupling.
• Refer to the diagram to align the markings
ANNOTATION: on the pump and the flange.

• Refer to the figure and tighten them in diag-

onal order.
Tightening torque: 57 N・m {5.8 kgf・m / 42
lb・ft}

1 Fuel supply pump

2 Marked line
3 Coupling flange

3. Supply pump coupling assembly connect

84512399 EN - September 2011

3004A-6
Copyright ©
Removal and Installation of Fuel supply pump

3) Install the bolts to the supply pump coupling • Temporarily tighten the cotter bolt with the
assembly. coupling laminate attached to the special
tool.
ANNOTATION:
• Refer to the diagram to install the 2 coupling CAUTION
bolts.
• Be careful not to damage the oil
Tightening torque: 91 N・m {9.3 kgf・m / 67 seal of the bearing case with the
lb・ft} screwdriver.

6) Remove the special tool from the supply pump

coupling assembly.
ANNOTATION:
• Remove the special tool after confirming
that they are firmly attached.
7) Securely tighten the bolt onto the supply pump
coupling assembly.

CAUTION
• Confirm that the laminate of the
coupling has no bending before
securely tightening the cotter bolt.

Tightening torque: 91 N・m {9.3 kgf・m / 67

1 Coupling bolt lb・ft}
8) Securely tighten the bolt onto the supply pump
coupling assembly.
4) Install the special tool to the supply pump cou-
pling assembly. ANNOTATION:
ANNOTATION: • Securely tighten the coupling half bolt.
• Install so that its indent section contacts the Tightening torque: 91 N・m {9.3 kgf・m / 67
coupling half bolt. lb・ft}

CAUTION
• After completely tightening each
bolt, confirm that the marking lines
are aligned.

9) Install the oil feed pipe to the fuel supply

pump.

Oil feed pipe tightening torque

Parts Tightening torque
: 10 N・m {1.0 kgf・m /
Fuel supply pump side
89 lb・in}
: 20 N・m {2.0 kgf・m /
Cylinder block side
15 lb・ft}
1 Coupling cotter bolt
2 Coupling half bolt
3 Indent section 10) Install the oil return pipe to the fuel supply
4 Coupling setting tool pump.
5 Stamping line

5) Temporarily tighten the bolt onto the supply Oil return pipe tightening torque
pump coupling assembly. Parts Tightening torque
: 17 N・m {1.7 kgf・m /
ANNOTATION: Fuel supply pump
13 lb・ft}
• Insert a flat-blade screwdriver between the : 41 N・m {4.2 kgf・m /
Cylinder block side
coupling and the bearing case. 30 lb・ft}
84512399 EN - September 2011
3004A-7
Copyright ©
Removal and Installation of Fuel supply pump

3) Securely tighten the fuel feed pipe onto the

fuel filter.
Tightening torque: 50 N・m {5.1 kgf・m / 37
lb・ft}

1 Oil return pipe

2 Oil feed pipe

4. Fuel pipe installation

1 Fuel pipe
1) Temporarily tighten the fuel pipe to the fuel
2 Fuel leak-off pipe
supply pump and the fuel filter.
3 Fuel pipe
CAUTION 4 Fuel feed pipe
5 Fuel suction pipe
• Use new fuel pipes.
6. Fuel leak-off pipe installation
2) Securely tighten the fuel pipe onto the fuel
supply pump. 1) Temporarily tighten the fuel leak-off pipe to the
Tightening torque: 17 N・m {1.7 kgf・m / 13 common rail assembly.
lb・ft} Fuel temperature sensor adapter 2) Temporarily tighten the fuel leak-off pipe to the
3) Securely tighten the fuel pipe onto the fuel fuel supply pump.
filter. 3) Temporarily tighten the fuel leak-off pipe to the
Tightening torque: 50 N・m {5.1 kgf・m / 37 cylinder head and fuel filter bracket.
lb・ft} 4) Temporarily tighten the fuel leak-off pipe to the
4) Install the clip to the fuel feed pipe. pipe bracket.
Tightening torque: 9 N・m {0.9 kgf・m / 80 5) Securely tighten the fuel leak-off pipe to the
lb・in} fuel supply pump.
Tightening torque: 17 N・m {1.7 kgf・m / 13
5. Fuel feed pipe installation lb・ft}
1) Temporarily tighten the fuel field pipe to the 6) Securely tighten the fuel leak-off pipe to the
fuel supply pump and the fuel filter. common rail assembly.
2) Securely tighten the fuel feed pipe onto the Tightening torque: 20 N・m {2.0 kgf・m / 15
fuel supply pump. lb・ft}
Tightening torque: 17 N・m {1.7 kgf・m / 13 7) Completely tighten the fuel leak-off pipe to the
lb・ft} cylinder head.
Tightening torque: 41 N・m {4.2 kgf・m / 30
lb・ft}
8) Completely tighten the fuel leak-off pipe to the
fuel filter bracket.
Tightening torque: 41 N・m {4.2 kgf・m / 30
lb・ft}
9) Completely tighten the fuel leak-off pipe to the
pipe bracket.
Tightening torque: 41 N・m {4.2 kgf・m / 30
lb・ft}
7. Fuel pipe installation
1) Temporarily tighten the fuel pipe onto the com-
mon rail assembly and the fuel supply pump.

84512399 EN - September 2011

3004A-8
Copyright ©
Removal and Installation of Fuel supply pump

2) Securely tighten the fuel pipe onto the com- 3) Install the intake duct to the intake throttle
mon rail assembly and the fuel supply pump. valve.
Tightening torque: 44 N・m {4.5 kgf・m / 32 Tightening torque: 22 N・m {2.2 kgf・m / 16
lb・ft} Sleeve nut lb・ft}
Tightening torque: 9 N・m {0.9 kgf・m / 80
lb・in} Clip
8. Fuel suction pipe installation
1) Install the fuel suction pipe to the fuel supply
pump.
Tightening torque: 17 N・m {1.8 kgf・m / 13
lb・ft} Eyebolt
Tightening torque: 9 N・m {0.9 kgf・m / 80
lb・in} Clip
9. Ventilation hose installation
1) Connect the ventilation hose to the air duct.
2) Connect the ventilation hose to the cylinder
head cover.
10. EGR mixing chamber installation 1 EGR mixing chamber
1) Install the O-ring to EGR mixing chamber. 2 Intake duct
2) Install the EGR mixing chamber to the inlet 3 Intake throttle valve
cover. 4 Inlet duct
Tightening torque: 44 N・m {4.5 kgf・m / 32 5 Boost sensor
lb・ft}
13. EGR valve installation
1) Install the lead valve to the EGR mixing cham-
ber.
Tightening torque: 10 N・m {1.0 kgf・m / 89
lb・in}
2) Install the gasket to the EGR mixing chamber.
3) Install the EGR valve to the EGR mixing
chamber.
Tightening torque: 44 N・m {4.5 kgf・m / 32
lb・ft}

11. Inlet duct installation

1) Install the O-ring to the inlet duct.
2) Install the inlet duct to the EGR mixing cham-
ber.
Tightening torque: 45 N・m {4.6 kgf・m / 33
lb・ft}
12. Intake throttle valve installation
1) Install the O-ring to the intake throttle valve.
2) Install the intake throttle valve to the inlet duct.
1 EGR valve
2 EGR mixing chamber
3 EGR valve
4
5

84512399 EN - September 2011

3004A-9
Copyright ©
Removal and Installation of Fuel supply pump

14. EGR cooler installation

1) Temporarily tighten the EGR valve duct to the
EGR valve.
ANNOTATION:
• Temporarily tighten with the gasket inserted.
Temporary tightening torque: 5 N ・ m {0.5
kgf・m / 44 lb・in}

1 EGR cooler D
2 EGR valve duct
3 EGR cooler C

4) Install the bracket to the cylinder head.

Tightening torque: 97 N・m {9.9 kgf・m / 72
lb・ft} Engine front side

2) Install the bracket to the cylinder head. ANNOTATION:

Tightening torque: 97 N・m {9.9 kgf・m / 72 • The rear side bracket should be tightened
lb・ft} Engine front side together with the exhaust manifold.
Tightening torque: 44 N・m {4.5 kgf・m / 32
lb・ft} Engine rear side

1 Engine rear side bracket

Engine front side EGR cooler 2 Engine front side bracket
1
bracket
Engine rear side EGR cooler 5) Temporarily tighten the EGR duct to the ex-
2 haust manifold.
bracket
ANNOTATION:
3) Temporarily tighten the EGR cooler to the
EGR valve duct. • Temporarily tighten with the gasket inserted.
ANNOTATION: Temporary tightening torque: 5 N ・ m {0.5
kgf・m / 44 lb・in}
• Temporarily tighten with the gasket inserted. 6) Temporarily tighten the EGR cooler to the
• Install the air removal pipe faicing it towards EGR duct.
the front side.
ANNOTATION:
Temporary tightening torque: 5 N ・ m {0.5
kgf・m / 44 lb・in} • Temporarily tighten with the gasket inserted.

84512399 EN - September 2011

3004A-10
Copyright ©
Removal and Installation of Fuel supply pump

• Refer to the diagram for the direction of the 7) Securely tighten the EGR cooler to the EGR
water pipe. valve duct.
ANNOTATION:
• Completely tighten the EGR cooler C and
the EGR cooler D to the EGR valve duct.
Tightening torque: 50 N・m {5.1 kgf・m / 37
lb・ft} 1 in the diagram
8) Securely tighten the EGR cooler to the EGR
cooler.
ANNOTATION:
• Tighten the connections between the EGR
cooler A and the EGR cooler C and between
the EGR cooler B and the EGR cooler D at
the respective specified torque.
Tightening torque: 50 N・m {5.1 kgf・m / 37
1 EGR cooler B lb・ft} 2 in the diagram
2 EGR cooler A 9) Securely tighten the EGR cooler to the EGR
3 EGR duct A duct.
4 EGR duct B Tightening torque: 50 N・m {5.1 kgf・m / 37
lb・ft} 3 in the diagram
10) Temporarily tighten the EGR duct to the ex-
ANNOTATION: haust manifold.
• Procedure for complete tightening Tightening torque: 50 N・m {5.1 kgf・m / 37
lb・ft} 4 in the diagram
CAUTION 11) Securely tighten the EGR valve duct to the
EGR valve.
• Make sure to follow the installation Tightening torque: 44 N・m {4.5 kgf・m / 32
procedure. lb・ft} 5 in the diagram
12) Securely tighten the EGR valve duct to the
Otherwise, a gas leak or excessive stress may EGR mixing chamber.
occur causing parts damage. Tightening torque: 44 N・m {4.5 kgf・m / 32
lb・ft} 6 in the diagram
13) Securely tighten the EGR cooler to the EGR
cooler bracket.
Tightening torque: 50 N・m {5.1 kgf・m / 37
lb・ft} 7 in the diagram

84512399 EN - September 2011

3004A-11
Copyright ©
Removal and Installation of Fuel supply pump

14) Completely tighten the EGR duct to the

bracket.
Tightening torque: 50 N・m {5.1 kgf・m / 37
lb・ft} 8 in the diagram

15) Install the water return pipe to the EGR cooler. 15. Coolant filling
16) Install EGR cooler water hose to EGR cooler.
1) Replenish the coolant with the radiator.
17) Install the water charge pipe to the EGR duct.
2) Loosen the plug using the wrench.
18) Install the air leak pipe to the engine assembly.
3) Replenish the coolant with the radiator.

CAUTION
• Be careful not to let coolant over-
flow splash on the exhaust system
parts.
• Coolant overflow should be wiped
off.

4) Tighten the plug using the wrench.

ANNOTATION:
• Apply Loctite 271.
Tightening torque: 15 N・m {1.5 kgf・m / 11
lb・ft}
1 EGR cooler water pipe
2 Water return pipe
3 Air leak pipe

84512399 EN - September 2011

3004A-12
Copyright ©
Removal and Installation of Fuel supply pump

5) Replenish the coolant with the radiator. 3) Operate the priming pump.
ANNOTATION:
• Bleed the air from the fuel filter and fix the
priming pump.
4) Tighten the plug using the wrench.
5) Operate the priming pump.
ANNOTATION:
• Repeat the operation 10 times or more until
fuel is filled.
• Wait for about 1 minute after operating the
priming pump.
6) Tighten the plug using the wrench.
ANNOTATION:
1 Plug • Remove the air in the fuel filter.
16. Fuel air bleed CAUTION
CAUTION • Continue air removal work until no
air comes out.
• To prevent engine failure, be sure to per-
form air removal after the installation or 7) Loosen the plug using the wrench.
removal of fuel system parts.
ANNOTATION:
• Loosen the plug of the fuel supply pump.
8) Operate the priming pump.
ANNOTATION:
• Operate the priming pump until no air bub-
bles come out.
9) Tighten the plug using the wrench.
ANNOTATION:
• Tighten the plug of the fuel supply pump.
CAUTION
• Do not over-tighten the plug.
1 Priming pump
10) Operate the priming pump.
2 Plug
3 Drain plug ANNOTATION:
4 Case
• Operate the priming pump until it becomes
5 Fuel filter element heavy.
1) Prepare the pan. 17. Battery ground cable connect
2) Loosen the plug using the wrench. 1) Connect the battery ground cable to the bat-
ANNOTATION: tery.
• Start with the fuel filter that is nearest to the
fuel tank.

84512399 EN - September 2011

3004A-13
Copyright ©
Removal and Installation of Fuel supply pump

84512399 EN - September 2011

3004A-14
Copyright ©

Section

3004B

Removal and Installation of Common rail assembly

84512399 EN - September 2011

CONTENTS

Common rail assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Common rail assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

3004B-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

3004B-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Common rail assembly

Common rail assembly Removal 2) Remove the O-ring from the EGR mixing
chamber.
1. Fuel safety Information
ANNOTATION:
CAUTION • Seal the inlet cover opening to prevent for-
• Fuel leakage can cause a fire, so wipe eign material from entering.
away any leaked fuel after completing the
work and inspection, and make sure to
confirm that no fuel leak is found after
starting the engine.

2. Common rail assembly safety Information

CAUTION
• Add a cleaning fluid to a steam cleaner
and thoroughly clean the sensor and
common rail areas.
• Completely remove the moisture by
blowing air.
• Start the work after confirming that
foreign matter has been completely re-
moved.
1 EGR mixing chamber
• After replacing any sensor, use the scan
tool to clear the trouble code and confirm 2 Intake duct
that the sensor is operating properly. 3 Intake throttle valve
4 Inlet duct
3. Battery ground cable disconnect 5 Boost sensor
1) Disengage the battery ground cable from the 7. Fuel pipe removal
battery.
1) Disconnect the fuel pipe from the common rail
4. Intake throttle valve removal assembly.
1) Remove the intake duct from the intake throt- 2) Remove the fuel pipe from the fuel supply
tle valve. pump.
2) Remove the intake throttle valve from the inlet 8. Fuel leak-off pipe removal
duct.
3) Remove the O-ring from the intake throttle 1) Disengage the fuel leak-off pipe from the com-
valve. mon rail assembly.
5. Inlet duct removal 9. Injection pipe removal
1) Remove the inlet duct from the EGR mixing 1) Remove the injection pipe from the injector
chamber. and the common rail assembly.
2) Install the O-ring to the inlet duct.
CAUTION
ANNOTATION:
• Do not reuse the removed injection
• Do not remove the boost sensor unless nec- pipe.
essary. • Be careful to prevent dust and dirt
6. EGR mixing chamber removal from attaching to the sleeve nut.
• Seal the opening of the pipe instal-
1) Remove the EGR mixing chamber from the lation section of the common rail to
inlet cover. prevent dirt, from attaching to it.

10. Common rail assembly removal

1) Remove the common rail assembly from the
bracket.

84512399 EN - September 2011

3004B-3
Copyright ©
Removal and Installation of Common rail assembly

2) Remove the common rail bracket from the Common rail assembly Installation
cylinder block.
1. Fuel safety Information

CAUTION
• Fuel leakage can cause a fire, so wipe
away any leaked fuel after completing the
work and inspection, and make sure to
confirm that no fuel leak is found after
starting the engine.

2. Common rail assembly installation

1) Install the common rail bracket to the cylinder
block.
Tightening torque: 44 N・m {4.5 kgf・m / 32
lb・ft}
2) Install the common rail assembly to the
1 Injection pipe bracket.
2 Bracket Tightening torque: 44 N・m {4.5 kgf・m / 32
3 Common rail assembly lb・ft}
3. Injection pipe installation
CAUTION 1) Install the injection pipe to the injector and
common rail assembly.
• Seal every fuel opening to prevent
foreign matter from getting inside. CAUTION
• Use new injection pipes.

ANNOTATION:
• Alternately tighten the injection pipe sleeve
nuts on the injector side and the common
rail side in a few steps.
Tightening torque: 44 N・m {4.5 kgf・m / 32
lb・ft}
2) Install the clip to the injection pipe.
Tightening torque: 9 N・m {0.9 kgf・m / 80
lb・in}

CAUTION
• If the rubber is cracked or damaged,
do not reuse it.

1 Injection pipe
2 Bracket
3 Common rail assembly

84512399 EN - September 2011

3004B-4
Copyright ©
Removal and Installation of Common rail assembly

4. Fuel pipe installation 3) Install the intake duct to the intake throttle
valve.
1) Temporarily tighten the fuel pipe onto the com- Tightening torque: 22 N・m {2.2 kgf・m / 16
mon rail assembly and the fuel supply pump. lb・ft}
2) Securely tighten the fuel pipe onto the com-
mon rail assembly and the fuel supply pump.
Tightening torque: 44 N・m {4.5 kgf・m / 32
lb・ft} Sleeve nut
Tightening torque: 9 N・m {0.9 kgf・m / 80
lb・in} Clip
5. Fuel leak-off pipe installation
1) Temporarily tighten the fuel leak-off pipe to the
common rail assembly.
2) Securely tighten the fuel leak-off pipe to the
common rail assembly.
Tightening torque: 20 N・m {2.0 kgf・m / 15
lb・ft}
6. EGR mixing chamber installation
1) Install the O-ring to EGR mixing chamber.
2) Install the EGR mixing chamber to the inlet 1 EGR mixing chamber
cover. 2 Intake duct
Tightening torque: 44 N・m {4.5 kgf・m / 32 3 Intake throttle valve
lb・ft} 4 Inlet duct
5 Boost sensor

9. Fuel air bleed

CAUTION
• To prevent engine failure, be sure to per-
form air removal after the installation or
removal of fuel system parts.

7. Inlet duct installation

1) Install the O-ring to the inlet duct.
2) Install the inlet duct to the EGR mixing cham-
ber.
Tightening torque: 45 N・m {4.6 kgf・m / 33
lb・ft}
8. Intake throttle valve installation
1) Install the O-ring to the intake throttle valve.
2) Install the intake throttle valve to the inlet duct.

1 Priming pump
2 Plug
3 Drain plug
4 Case
5 Fuel filter element

1) Prepare the pan.

2) Loosen the plug using the wrench.
ANNOTATION:
• Start with the fuel filter that is nearest to the
fuel tank.
84512399 EN - September 2011
3004B-5
Copyright ©
Removal and Installation of Common rail assembly

3) Operate the priming pump. 8) Operate the priming pump.

ANNOTATION: ANNOTATION:
• Bleed the air from the fuel filter and fix the • Operate the priming pump until no air bub-
priming pump. bles come out.
4) Tighten the plug using the wrench. 9) Tighten the plug using the wrench.
5) Operate the priming pump.
ANNOTATION:
ANNOTATION:
• Tighten the plug of the fuel supply pump.
• Repeat the operation 10 times or more until
fuel is filled. CAUTION
• Wait for about 1 minute after operating the
priming pump. • Do not over-tighten the plug.

6) Tighten the plug using the wrench. 10) Operate the priming pump.
ANNOTATION: ANNOTATION:
• Remove the air in the fuel filter. • Operate the priming pump until it becomes
heavy.
CAUTION
10. Battery ground cable connect
• Continue air removal work until no
air comes out. 1) Connect the battery ground cable to the bat-
tery.
7) Loosen the plug using the wrench.
ANNOTATION:
• Loosen the plug of the fuel supply pump.

84512399 EN - September 2011

3004B-6
Copyright ©

Section

3005

Removal and Installation of Injector

84512399 EN - September 2011

CONTENTS

Injector Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Injector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

3005-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

3005-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Injector

Injector Removal 3) Disconnect the EGR cooler water hose from

the EGR cooler.
1. Fuel safety Information 4) Remove the water return pipe from the EGR
cooler.
CAUTION
• Fuel leakage can cause a fire, so wipe
away any leaked fuel after completing the
work and inspection, and make sure to
confirm that no fuel leak is found after
starting the engine.

2. Battery ground cable disconnect

1) Disengage the battery ground cable from the
battery.
3. Coolant drain

WARNING
• Do not loosen the radiator cap when the
coolant is hot. 1 EGR cooler water hose
• Steam and boiling water may burst out 2 Water return pipe
and cause burns, so make sure that the 3 Air leak pipe
engine has cooled off.
5) Remove the EGR cooler A from the EGR
1) Drain the coolant from the radiator. cooler duct A and the EGR cooler D.
6) Remove the EGR cooler B from the EGR
CAUTION
cooler duct B and the EGR cooler C.
• After draining the coolant, tighten 7) Remove the EGR cooler duct A from the ex-
the drain plug. haust manifold and the bracket.
8) Remove the EGR cooler duct B from the ex-
2) Drain the coolant from the engine assembly. haust manifold and the bracket.
9) Remove the bracket from the cylinder head.
ANNOTATION: 10) Remove the EGR cooler D from the EGR
• Loosen the drain plug on the cylinder block valve duct.
side. 11) Remove the EGR cooler C from the EGR
valve duct.
12) Remove the EGR valve duct from the EGR
valve.

1 Drain plug

4. Air leak pipe removal 1 EGR cooler duct B

2 EGR cooler B
1) Remove the air leak pipe from the engine as- 3 EGR cooler C
sembly. 4 EGR valve duct
5. EGR cooler removal 5 EGR cooler D
1) Disconnect the air leak pipe from the engine 6 EGR cooler A
assembly. 7 EGR cooler duct A
2) Disconnect the water charge pipe from the
EGR cooler duct. 6. EGR valve removal
84512399 EN - September 2011
3005-3
Copyright ©
Removal and Installation of Injector

1) Disconnect the connector from the EGR 2) Remove the gasket from the cylinder head
valve. cover.
2) Remove the EGR valve from the EGR mixing
chamber.
3) Remove the lead valve from the EGR mixing
chamber.

1 Cylinder head cover

2 Gasket

10. Injector harness removal

1 EGR valve A
1) Remove the harness from the injector.
2 EGR mixing chamber
3 EGR valve B CAUTION

7. Ventilation hose removal • In this state, the injector ID code

plate may come Therefore, avoid
1) Disconnect the ventilation hose from the cylin- mix-up with other injector ID code
der head cover. plates.
2) Disconnect the ventilation hose from the air
duct.
8. Injection pipe removal
1) Remove the injection pipe from the injector
and the common rail assembly.

CAUTION
• Do not reuse the removed injection
pipe.
• Be careful to prevent dust and dirt
from attaching to the sleeve nut.
• Seal the opening of the pipe instal-
lation section of the common rail to
prevent dirt, from attaching to it.
2) Remove the bolts from the injector harness.
9. Cylinder head cover removal
1) Remove the cylinder head cover from the
camshaft carrier.

84512399 EN - September 2011

3005-4
Copyright ©
Removal and Installation of Injector

3) Remove the injector harness from the

camshaft carrier.
ANNOTATION:
• Disconnect the injector harness from the
junction connector.
11. Injector leak-off pipe removal
1) Remove the injector leak-off pipe from the
cylinder head assembly and the injector.
2) Remove the gasket from the injector leak-off
pipe.

CAUTION
• Do not reuse the gasket.
1 Clamp
2 Bolt
3 Injector
4 O-ring

ANNOTATION:
• If the injector is difficult to pull out, use the
fuel injector remover and a sliding hammer.

12. Injector removal

1) Remove the clamp from the cylinder head as-
sembly.
2) Remove the injector from the cylinder head
assembly.

CAUTION
• Before lowering the cylinder head,
remove the injector because its tip Special tool: injector remover (refer to
will protrude from the bottom sur- section 1003)
face of the cylinder head.
• Do not remove the ID code plate
from the injector.
• When pulling out the injector, make
sure that the sleeve does not come
off together while working on it.
• Attach a number tag to the removed
injector.

Special tool: sliding hammer (refer to

section 1003)
3) Remove the gasket from the sleeve.

CAUTION
• Do not reuse the gasket.
84512399 EN - September 2011
3005-5
Copyright ©
Removal and Installation of Injector

Injector Installation 5) Install the clamp to the cylinder head assem-

bly.
1. Fuel safety Information Tightening torque: 26 N・m {2.7 kgf・m / 19
lb・ft}
CAUTION
• Fuel leakage can cause a fire, so wipe
away any leaked fuel after completing the
work and inspection, and make sure to
confirm that no fuel leak is found after
starting the engine.

2. Injector installation
1) Install the gasket to injector.

CAUTION
• Use a new gasket.

ANNOTATION:
• Confirm that there is no old gasket remain- 1 Clamp
ing in the sleeve. 2 Bolt
2) Apply the disulfide molybdenum grease to the 3 Injector
bolt. 4 O-ring
ANNOTATION:
3. Injector leak-off pipe installation
• Apply on the seat surface and threaded por-
tion of the clamp tightening bolt. 1) Install the gasket to the injector leak-off pipe.
3) Install the injector to the cylinder head assem- CAUTION
bly.
• Use a new gasket.
CAUTION
2) Install the injector leak-off pipe to the cylinder
• Carefully remove carbon from in- head assembly.
side the sleeve.
• Do not remove the ID code plate
from the injector. Injector leak-off pipe tightening torque
The number
Bolt
4) Temporarily tighten the injection pipe to the indicated in Tightening torque
size
injector. the diagram
M8 eye- : 15 N・m {1.5 kgf・m
2
bolt / 11 lb・ft}
M12 : 34 N・m {3.5 kgf・m
3
eyebolt / 25 lb・ft}

1 Injector leak-off pipe

2 M8 eyebolt
3 M12 eyebolt
84512399 EN - September 2011
3005-6
Copyright ©
Removal and Installation of Injector

4. Injector harness installation 5. Cylinder head cover installation

1) Install the injector harness to the camshaft 1) Install the gasket to the cylinder head cover.
carrier.
CAUTION
ANNOTATION:
• If the gasket has looseness or a
• Make sure to lock the connector on the har- slant, repair it before installation.
ness.
2) Install the bolt to the injector harness. 2) Install the cylinder head cover to the camshaft
Tightening torque: 22 N・m {2.2 kgf・m / 16 carrier.
lb・ft} Tightening torque: 15 N・m {1.5 kgf・m / 11
lb・ft}

3) Install the harness to the injector.

Tightening torque: 2 N・m {0.2 kgf・m / 18
lb・in} 1 Cylinder head cover
2 Gasket
CAUTION
• Strictly conform to the specified 6. Injection pipe installation
torque to avoid over-tightening of
nuts, which may cause damage. 1) Install the injection pipe to the injector and
common rail assembly.

CAUTION
• Use new injection pipes.

ANNOTATION:
• Alternately tighten the injection pipe sleeve
nuts on the injector side and the common
rail side in a few steps.
Tightening torque: 44 N・m {4.5 kgf・m / 32
lb・ft}

84512399 EN - September 2011

3005-7
Copyright ©
Removal and Installation of Injector

2) Install the clip to the injection pipe. 9. EGR cooler installation

Tightening torque: 9 N・m {0.9 kgf・m / 80
1) Temporarily tighten the EGR valve duct to the
lb・in}
EGR valve.
CAUTION ANNOTATION:
• If the rubber is cracked or damaged, • Temporarily tighten with the gasket inserted.
do not reuse it.
Temporary tightening torque: 5 N ・ m {0.5
kgf・m / 44 lb・in}

2) Install the bracket to the cylinder head.

1 Injection pipe Tightening torque: 97 N・m {9.9 kgf・m / 72
2 Bracket lb・ft} Engine front side
3 Common rail assembly Tightening torque: 44 N・m {4.5 kgf・m / 32
lb・ft} Engine rear side
7. Ventilation hose installation
1) Connect the ventilation hose to the air duct.
2) Connect the ventilation hose to the cylinder
head cover.
8. EGR valve installation
1) Install the lead valve to the EGR mixing cham-
ber.
Tightening torque: 10 N・m {1.0 kgf・m / 89
lb・in}
2) Install the gasket to the EGR mixing chamber.
3) Install the EGR valve to the EGR mixing
chamber.
Tightening torque: 44 N・m {4.5 kgf・m / 32
lb・ft}
Engine front side EGR cooler
1
bracket
Engine rear side EGR cooler
2
bracket

3) Temporarily tighten the EGR cooler to the

EGR valve duct.
ANNOTATION:
• Temporarily tighten with the gasket inserted.
• Install the air removal pipe faicing it towards
the front side.
Temporary tightening torque: 5 N ・ m {0.5
kgf・m / 44 lb・in}

1 EGR valve
2 EGR mixing chamber
3 EGR valve
84512399 EN - September 2011
3005-8
Copyright ©
Removal and Installation of Injector

1 EGR cooler D 1 EGR cooler B

2 EGR valve duct 2 EGR cooler A
3 EGR cooler C 3 EGR duct A
4 EGR duct B
4) Install the bracket to the cylinder head.
Tightening torque: 97 N・m {9.9 kgf・m / 72
lb・ft} Engine front side ANNOTATION:
ANNOTATION: • Procedure for complete tightening
• The rear side bracket should be tightened CAUTION
together with the exhaust manifold.
• Make sure to follow the installation
procedure.

Otherwise, a gas leak or excessive stress may

occur causing parts damage.
7) Securely tighten the EGR cooler to the EGR
valve duct.
ANNOTATION:
• Completely tighten the EGR cooler C and
the EGR cooler D to the EGR valve duct.
Tightening torque: 50 N・m {5.1 kgf・m / 37
lb・ft} 1 in the diagram
8) Securely tighten the EGR cooler to the EGR
cooler.
ANNOTATION:
1 Engine rear side bracket
• Tighten the connections between the EGR
2 Engine front side bracket cooler A and the EGR cooler C and between
the EGR cooler B and the EGR cooler D at
the respective specified torque.
5) Temporarily tighten the EGR duct to the ex-
haust manifold. Tightening torque: 50 N・m {5.1 kgf・m / 37
lb・ft} 2 in the diagram
ANNOTATION: 9) Securely tighten the EGR cooler to the EGR
• Temporarily tighten with the gasket inserted. duct.
Tightening torque: 50 N・m {5.1 kgf・m / 37
Temporary tightening torque: 5 N ・ m {0.5 lb・ft} 3 in the diagram
kgf・m / 44 lb・in} 10) Temporarily tighten the EGR duct to the ex-
6) Temporarily tighten the EGR cooler to the haust manifold.
EGR duct. Tightening torque: 50 N・m {5.1 kgf・m / 37
ANNOTATION: lb・ft} 4 in the diagram
11) Securely tighten the EGR valve duct to the
• Temporarily tighten with the gasket inserted. EGR valve.
• Refer to the diagram for the direction of the Tightening torque: 44 N・m {4.5 kgf・m / 32
water pipe. lb・ft} 5 in the diagram
84512399 EN - September 2011
3005-9
Copyright ©
Removal and Installation of Injector

12) Securely tighten the EGR valve duct to the 14) Completely tighten the EGR duct to the
EGR mixing chamber. bracket.
Tightening torque: 44 N・m {4.5 kgf・m / 32 Tightening torque: 50 N・m {5.1 kgf・m / 37
lb・ft} 6 in the diagram lb・ft} 8 in the diagram
13) Securely tighten the EGR cooler to the EGR
cooler bracket.
Tightening torque: 50 N・m {5.1 kgf・m / 37
lb・ft} 7 in the diagram

15) Install the water return pipe to the EGR cooler. 10. Air leak pipe installation
16) Install EGR cooler water hose to EGR cooler.
1) Install the air leak pipe to the engine assembly.
17) Install the water charge pipe to the EGR duct.
18) Install the air leak pipe to the engine assembly. 11. Coolant filling
1) Replenish the coolant with the radiator.
2) Loosen the plug using the wrench.
3) Replenish the coolant with the radiator.

CAUTION
• Be careful not to let coolant over-
flow splash on the exhaust system
parts.
• Coolant overflow should be wiped
off.

4) Tighten the plug using the wrench.

ANNOTATION:
• Apply Loctite 271.
1 EGR cooler water pipe
Tightening torque: 15 N・m {1.5 kgf・m / 11
2 Water return pipe
lb・ft}
3 Air leak pipe

84512399 EN - September 2011

3005-10
Copyright ©
Removal and Installation of Injector

5) Replenish the coolant with the radiator. 3) Operate the priming pump.
ANNOTATION:
• Bleed the air from the fuel filter and fix the
priming pump.
4) Tighten the plug using the wrench.
5) Operate the priming pump.
ANNOTATION:
• Repeat the operation 10 times or more until
fuel is filled.
• Wait for about 1 minute after operating the
priming pump.
6) Tighten the plug using the wrench.
ANNOTATION:
1 Plug • Remove the air in the fuel filter.
12. Fuel air bleed CAUTION
CAUTION • Continue air removal work until no
air comes out.
• To prevent engine failure, be sure to per-
form air removal after the installation or 7) Loosen the plug using the wrench.
removal of fuel system parts.
ANNOTATION:
• Loosen the plug of the fuel supply pump.
8) Operate the priming pump.
ANNOTATION:
• Operate the priming pump until no air bub-
bles come out.
9) Tighten the plug using the wrench.
ANNOTATION:
• Tighten the plug of the fuel supply pump.
CAUTION
• Do not over-tighten the plug.
1 Priming pump
10) Operate the priming pump.
2 Plug
3 Drain plug ANNOTATION:
4 Case
• Operate the priming pump until it becomes
5 Fuel filter element heavy.
1) Prepare the pan. 13. Battery ground cable connect
2) Loosen the plug using the wrench. 1) Connect the battery ground cable to the bat-
ANNOTATION: tery.
• Start with the fuel filter that is nearest to the
fuel tank.

84512399 EN - September 2011

3005-11
Copyright ©
Removal and Installation of Injector

84512399 EN - September 2011

3005-12
Copyright ©

Section

4001A

Electrical and Engine Basic Functions

84512399 EN - September 2011

CONTENTS

Monitor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Coolant Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Oil Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Monitor Display Dimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Eco Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DPD Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Diagnostic Trouble Code Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fuel Economy Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Neutral Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine Start/Stop Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Idling Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Auto Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
One-touch Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Auto Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Idling Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Idle up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Travel Speed Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Swing Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Static Horsepower Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Working Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Radio Mute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Engine Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Travel Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Back/Side View Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Swing Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Operability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Swing Speed Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Pressure Boost Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Free Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Energy saving / Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Pump Standby Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Swing Relief Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Boom Down Energy Save. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Auto Energy Save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Overload Reduction Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
End Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Breaker Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Crusher Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Anti-theft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Immobilizer Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

4001A-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

4001A-2 PRINTED IN FRANCE
Copyright ©
Electrical and Engine Basic Functions

Monitor Control

84512399 EN - September 2011

4001A-3
Copyright ©
Electrical and Engine Basic Functions

Coolant Temperature Gauge

Purpose
Displays the coolant temperature using a meter and bar graph.(Coolant temperature check)

1 Coolant temperature gauge 3 Computer A 5 Coolant temperature sensor

2 Monitor 4 ECM 6 Engine

a Bar graph display

b Meter display

Operation explanation
1. When the key is turned ON, the coolant temperature meter indicates the current coolant temperature range.
2. When the camera screen select switch is pressed to switch to the camera screen, the coolant temperature bar
graph is displayed on the left side.
3. The meter and bar graph are not displayed if coolant temperature sensor trouble is detected.
Remarks
The coolant temperature ranges are shown in the table below.

Meter indicator angle

Temperature [°C]
[deg.]
Lower than 50 0 - 15
50 15
77 58
82 66
97 90
100 118
102 137
105 165

84512399 EN - September 2011

4001A-4
Copyright ©
Electrical and Engine Basic Functions

Oil Temperature Gauge

Purpose
Displays the oil temperature on a meter.(Oil temperature check)

1 Oil temperature gauge 3 Computer A 5 Oil temperature sensor

2 Monitor 4 Hydraulic oil tank 6 Hydraulic pump

a Meter display

Operation explanation
1. When the key is turned ON, the oil temperature meter indicates the current oil temperature range.
2. When the camera screen select switch is pressed to switch to the camera screen, the oil temperature meter is
not displayed.
3. The meter is not displayed if oil temperature sensor trouble is detected.
Remarks
The oil temperature ranges are shown in the table below.

Meter indicator angle

Temperature [°C]
[deg.]
Lower than 25 0 - 15
25 15
45 42
60 63
80 90
88 123
92 140
95 153
97 161
98 165

84512399 EN - September 2011

4001A-5
Copyright ©
Electrical and Engine Basic Functions

Monitor Display Dimming

Purpose
Adjusts the brightness of the backlight through operation that is linked to the working light and solar radiation sensor.

1 Monitor 3 Solar radiation sensor 5 Working light relay

2 Computer A 4 Working light switch

a Dimming level automatic adjustment using the solar radiation

sensor
b Working light-linked dimming using the working light relay

Operation explanation
1. When the operator turns the key ON, the monitor screen brightness is set to "brightness (day)".
2. When the operator turns the working light ON, the monitor screen brightness is set to "brightness (night)" (=
working light-linked dimming).
• When working light-linked dimming is set to OFF on the rear screen, instead of using "brightness (night)" to
adjust the monitor screen brightness when the working light is ON, the brightness is judged using the solar
radiation sensor (= dimming level automatic adjustment).
• The brightness when the working light is OFF is set to "brightness (day)" regardless of whether working light-
linked dimming is set to ON or OFF.
3. The operator can set "brightness (day)" or "brightness (night)" in the menu screen.
• The screen brightness setting is stored inside the monitor, so the setting is saved even if a computer is re-
placed.

84512399 EN - September 2011

4001A-6
Copyright ©
Electrical and Engine Basic Functions

Eco Gauge
Purpose
Displays on the monitor whether energy-saving operation is being performed.(Eco function)

1 Eco gauge
2 Monitor
3 Computer A

Operation explanation
1. The eco gauge is displayed on the monitor.
2. The eco-saving performance is judged in levels from 0 to 9.(The higher the number, the better the eco perfor-
mance.)
In SP mode, the maximum is 4.
In H mode, the maximum is 6.
In A mode, the maximum is 8.
In low idle, the maximum is 9.

84512399 EN - September 2011

4001A-7
Copyright ©
Electrical and Engine Basic Functions

DPD Gauge
Purpose
Displays an icon and bar graph on the monitor during DPD regeneration.

1 DPD gauge
2 Monitor
3 Computer A

Operation explanation
1. DPD bar graph display conditions
1) The DPD clogging level is displayed on the DPD bar graph during normal operation.(5-level display)
When 5 white lamps are displayed, it indicates that the tank is full.
2) The regeneration progress is displayed on the DPD bar graph during DPD regeneration (5-level display).
The white lamps go off one by one, and when all have gone off, regeneration is complete.
2. DPD amber lamp display condition
1) The amber lamp turns on and flashes during manual DPD regeneration.
3. DPD green lamp display condition
1) The green lamp turns on and flashes during automatic DPD regeneration.

84512399 EN - September 2011

4001A-8
Copyright ©
Electrical and Engine Basic Functions

Diagnostic Trouble Code Indicator

Purpose
Displays a diagnostic trouble code (DTC) on the monitor when trouble occurs. (Makes troubleshooting easier)

1 Diagnostic trouble code

2 Monitor
3 Computer A

Operation explanation
1. If trouble occurs, the "!" symbol and the diagnostic trouble code (DTC) are displayed in the top right of the
monitor.
• When multiple cases of trouble occur, they are displayed in turn at 5-second intervals.
• At the same time, "ELEC. PROBLEM" and "CHECK ENGINE" are displayed.
• Up to 8 items can be displayed.
2. When the trouble is repaired, the diagnostic trouble code (DTC) goes off.

84512399 EN - September 2011

4001A-9
Copyright ©
Electrical and Engine Basic Functions

Clock
Purpose
Displays the time on the monitor.
Operation explanation
• The time is always displayed on the monitor.
• The clock continues to operate, without display, when the key is turned OFF. (Because it uses power from the
battery)

Fuel Economy Gauge

Purpose
Displays the fuel economy on the monitor.

1 Fuel economy gauge

2 Monitor
3 Computer A

Operation explanation
1. The fuel economy gauge is displayed on the monitor after the key is turned ON.
2. When trouble occurs, the fuel economy gauge goes off and the diagnostic trouble code is displayed.
3. When the trouble is recovered from, the diagnostic trouble code goes off and the fuel economy gauge is dis-
played again.

84512399 EN - September 2011

4001A-10
Copyright ©
Electrical and Engine Basic Functions

Basic Operation
Neutral Start
Purpose
The engine will not start with the gate lever lifted.(It will not crank.)
This prevents accidental operation if the operation lever is touched when the engine is started.
Configuration

1 Key switch 4 Starter cut relay 7 Starter relay

2 Gate lock limit switch 5 Lever lock solenoid 8 Neutral start relay
3 Starter motor 6 Battery relay 9 ECM

Operation explanation
1. Lower the gate lever.
2. The starter cut relay is excited and the excitation to the safety relay is cut off.
3. Engine cranking is prohibited.
4. If the gate lever is then raised, cranking is enabled.

84512399 EN - September 2011

4001A-11
Copyright ©
Electrical and Engine Basic Functions

Engine Start/Stop Control

Purpose
Engine starting and stopping

1 Computer A 3 Crank sensor 5 Speed

2 Cam sensor 4 ECM 6 Engine

Operation explanation
1. Start the engine.
2. When the engine speed rises to 500 min-1 or higher, engine start is judged.
3. Stop the engine.
4. When the engine speed drops to less than 200 min-1, engine stop is judged.

a Start c 200 min-1

b 500 min-1 d Stop

84512399 EN - September 2011

4001A-12
Copyright ©
Electrical and Engine Basic Functions

Preheating
Purpose
Before cranking, the insides of the engine cylinders are automatically heated to improve starting.(Warm-up opera-
tion)

1 Key switch 3 ECM 5 Coolant temperature sensor

2 Computer A 4 Engine

Operation explanation
1. Turn the key ON.
2. When the key is turned ON, the pre-glow time is calculated based on the current coolant temperature. At the
same time, the glow relay is excited and the glow lamp is turned on.
3. After pre-glow is completed, the glow lamp goes off and the operator is prompted to begin cranking.
4. Perform cranking to start the engine.
5. When engine start and cranking stop are recognized, the after-glow time is calculated from the current coolant
temperature.

84512399 EN - September 2011

4001A-13
Copyright ©
Electrical and Engine Basic Functions

Throttle
Purpose
Indicates the target engine speed.

1 Monitor 3 Throttle volume 5 Engine

2 Computer A 4 ECM

b 3 min. e SP mode h Low idle
c 3 min. f 1500 min-1

3. End conditions for auto warm up

Auto warm up is ended and operation shifts to idling start under the following conditions.
1) Coolant temperature is 50°C or more.
2) The one-touch idle switch is pressed.
3) The entire auto warm up process has ended (after 14 min.).
4) An operation lever is operated (upper, swing, travel, option 1, option 2 pressure sensor is ON).

84512399 EN - September 2011

4001A-18
Copyright ©
Electrical and Engine Basic Functions

Idling Stop
Purpose
Automatically stops the engine after a certain time has passed. (Energy saving)

1 Monitor 3 Engine 5 One-touch idle switch

2 Computer A 4 Idle stop relay 6 Throttle volume

Operation explanation
1. Operation conditions for idle stop mode
Idle stop operates after performance of 1 through 3.
1) The auto idle stop switch is pressed, switching on the idle stop mode.
2) If the gate lever is raised, the engine speed is less than 1200 min-1, and the throttle volume, auto idle
switch and one-touch idle switch are not operated for a continuous period of 15 sec., an alarm displays
on the monitor screen and a buzzer sounds.
3) After another 3 min., the idle stop relay turns ON and the engine stops.
* To restart, the key is switched OFF, and cranking is performed to start the engine.
* If a restart is not performed, the key is to be switched OFF.
2. Operations conditions for idle stop and auto idle mode
Idling stop operates after performance of 1 through 4.
1) The auto idle stop switch is pressed, switching on the idle stop mode.
2) If the operation lever is not operated for a continuous period of 5 sec., the engine speed is reduced to
1200 min-1. (The upper, swing, travel, option 1, and option 2 pressure sensor are OFF for a continuous
period of 5 sec.)
3) If the throttle volume, auto idle switch and one-touch idle switch are not operated for a continuous period
of 3 min., an alarm displays on the monitor screen and a buzzer sounds.
4) After another 3 min., the idle stop relay turns ON and the engine stops.
* To restart, the key is switched OFF, and cranking is performed to start the engine.
* If a restart is not performed, the key is to be switched OFF.

84512399 EN - September 2011

4001A-19
Copyright ©
Electrical and Engine Basic Functions

Idle up
Purpose
Raises the engine speed and maintains mechanical speed.

1 Throttle volume 3 Pressure sensor (travel) 5 Engine

2 Computer A 4 ECM

a Engine speed

1. Operation conditions for idle up

Operation starts when all the conditions below are satisfied.
1) Travel operation is performed. (Travel pressure sensor ON)
2. End conditions for idle up
Operation ends under the following conditions.
1) The work mode is a mode other than SP mode.
2) A travel operation is not performed.

84512399 EN - September 2011

4001A-20
Copyright ©
Electrical and Engine Basic Functions

Travel Speed Selection

Purpose
The travel motor tilting angle is changed by switching the travel speed between low speed and high speed with the
switch. (Travel speed switchover)

Travel 2-speed switchover so-

1 Computer A 3 Travel motor 5
lenoid
Travel 2-speed switchover so-
2 4 Monitor
lenoid

Operation explanation
1. When the key is turned ON, the travel 2-speed switchover solenoid turns OFF, and the travel mode icon on the
monitor goes to low speed.
2. When the travel speed switchover switch is pressed, the travel 2-switchover solenoid turns ON, and the travel
mode icon on the monitor goes to high speed.
3. When the travel speed switchover switch is pressed again, the travel 2-speed switchover solenoid turns OFF,
and the travel mode icon on the monitor goes to low speed.
* Even when the travel 2-speed switchover solenoid is ON, the tilting angle will automatically switch over to low
speed due to a travel motor function if the travel motor drive pressure becomes high.
However, the travel 2-speed switchover solenoid is ON.

84512399 EN - September 2011

4001A-21
Copyright ©
Electrical and Engine Basic Functions

Swing Brake
Purpose
The swing brake is turned OFF when either the upper or swing is operating. (Operational ability is increased)

1 Computer A 3 Pressure sensor (swing) 5 Swing brake

2 Pressure sensor (upper) 4 Swing brake solenoid valve

1. Operation conditions for swing brake

Operation starts under the following conditions.
1) An upper operation is not being performed. (Upper pressure sensor OFF)
* The swing brake is applied 1 sec. after the upper pressure sensor turns OFF.
2) A swing operation is not being performed. (Swing pressure sensor OFF)
* The swing brake is applied 5 sec. after the swing pressure sensor turns OFF.
2. End conditions for swing brake
Operation ends under the following conditions.
1) An upper operation is performed. (Upper pressure sensor ON)
2) A swing operation is performed. (Swing pressure sensor ON)

84512399 EN - September 2011

4001A-22
Copyright ©
Electrical and Engine Basic Functions

Static Horsepower Control

Purpose
Monitor the engine actual speed and the engine target speed and set the appropriate amount of horsepower. (En-
gine stop prevention, energy saving)

1 Hydraulic pump 4 ECM 7 Pressure sensor (travel)

Horsepower control propor-
2 5 Engine
tional valve
3 Computer A 6 Engine speed sensor

a Engine target speed

b Discharge volume fluctuation

Operation Explanation
1. The minimum milli-amp and maximum milli-amp is selected from the milli-amp set for each engine speed.
2. When the engine actual speed falls 30/min or more below the target engine speed, the milli-amp is gradually
lowered to the minimum.
3. When the engine actual speed is not 30/min or more below the target engine speed, the milli-amp is gradually
raised to the maximum.
4. When the engine speed is at a low speed, the milli-amp decreases.
5. When the engine speed is increasing after being at a low speed, the milli-amp increases.

84512399 EN - September 2011

4001A-23
Copyright ©
Electrical and Engine Basic Functions

Accessories
Working Light
Purpose
Press the working light switch to turn the working light on.(To improve visibility during night work.)

1 Monitor 3 Working light relay

2 Computer A 4 Working light switch

Operation explanation
1. When the key is turned ON, the working light is OFF.
2. When the working light switch is pressed, the working light relay turns ON, and the working light icon on the
monitor turns ON.
The boom light and cab light turn on.
3. When the working light switch is pressed again, the working light relay turns OFF, and the working light icon on
the monitor turns OFF.
The boom light and cab light turn off.

84512399 EN - September 2011

4001A-24
Copyright ©
Electrical and Engine Basic Functions

4001A-28
Copyright ©
Electrical and Engine Basic Functions

Back/Side View Monitor

Purpose
Displays an image on the monitor from the camera that is installed on the shovel.(Improves rear visibility. Improves
safety)

1 Monitor 3 Camera select switch 5 Side camera

2 Camera screen switch 4 Rear camera

a Options

Operation explanation
1. When the key is turned ON, the camera screen can be viewed by pressing the camera screen switch.
• Each time the camera screen switch is pressed, the screen alternates between the work screen and the
camera screen.
• In the camera screen, only the minimum required icons and gauges are displayed.
2. When the camera select switch is pressed in the camera screen, the screen display can be selected in the
order of rear → side → rear + side → rear.
• To perform camera selection, camera ON must be set in the camera setting screen.
• The camera select switch is enabled when multiple cameras are set.
The switch does not respond if there is only 1 rear camera.
3. If image interruption due to camera trouble (disconnection, etc.) is detected, the camera screen turns black
and ERROR is displayed.
* When the camera select switch is pressed in the work screen, the trip meter select switch function is activated.
* The camera screen switch is disabled if no cameras are mounted.

84512399 EN - September 2011

4001A-29
Copyright ©
Electrical and Engine Basic Functions

Swing Lock
Purpose
Turns the swing brake ON.

1 Monitor 4 Travel speed select switch 7 Swing brake

2 Working light switch 5 Computer A
3 Auto idle switch 6 Swing brake solenoid

Operation explanation
1. Operation conditions for swing lock
1) Hold down the travel speed select switch, working light switch and auto idle switch at the same time for
3 sec.
* When the swing lock is ON and the key is OFF.Then, when the key is turned ON again, the swing lock stays
ON.
* When the swing lock and free swing are both ON, the swing lock is prioritized.
* When the swing lock is ON, the swing lock icon is displayed on the monitor.
* Even when an attachment operation or swing operation is performed while swing is ON, swing lock ON is
prioritized.(Be careful because if the swing operation is performed in this condition, the swing brake plate will
be dragged.)
2. End conditions for swing lock
1) While the swing lock is ON, hold down the travel speed select switch, working light switch and auto idle
switch at the same time for 3 sec.

84512399 EN - September 2011

4001A-30
Copyright ©
Electrical and Engine Basic Functions

Operability
Swing Speed Limit
Purpose
When the pump flow rises during a swing operation, the swing speed increases.
To prevent this, control of the pump flow is performed.(Swing speed control)

1 Computer A 5 Pressure sensor (N1) 9 Regulator

P1 flow control proportional
2 Throttle volume 6 Pressure sensor (N2) 10
valve
3 Pressure sensor (travel) 7 Pressure sensor (P1)
4 Pressure switch (option 1) 8 Pressure sensor (P2)

a Arm (1) d Option 1 g Boom (1)

b Boom (2) e Travel (left) h Bucket
c Swing f Arm (2) i Travel (right)

Operation explanation
1. Operation conditions for swing speed limit control
Control is executed when all the conditions below are satisfied.
1) Independent swing operation (swing pressure sensor ON)
2) When travel or option operations are not being performed (travel and option pressure sensors OFF)
3) Work mode is SP or H mode(except CX350C/CX370C/350X3)
2. Swing speed limit end conditions
The operation ends under the following conditions.
1) Ends immediately after a travel or option operation is performed (travel or option pressure sensor ON).
2) Ends gradually after an attachment operation is performed (upper pressure sensor ON).

84512399 EN - September 2011

4001A-31
Copyright ©
Electrical and Engine Basic Functions

Pressure Boost Control

Purpose
Raises the relief pressure.(Increases the digging force)

1 Computer A 6 Pressure sensor (option 2) 11 P2 pressure sensor

2 Engine 7 Control valve 12 Pump
3 Pressure sensor (upper) 8 Main relief valve 13 Monitor
4 Pressure sensor (travel) 9 Pressure boost solenoid 14 Regulator
5 Pressure sensor (option 1) 10 P1 pressure sensor 15 ECM

a Pressure boost icon

b Engine load ratio

84512399 EN - September 2011

4001A-32
Copyright ©
Electrical and Engine Basic Functions

Operation explanation
1. Operation conditions for pressure boost control (SP or H mode)
The operation starts when all the following conditions are satisfied.
1) When high-load work is being performed (P1 or P2 is high pressure, upper pressure sensor ON, swing
pressure sensor OFF)
2) When the work mode is SP or H mode.
2. End conditions for pressure boost control (SP or H mode)
The operation ends under the following conditions.
1) When 8 sec. or longer elapses after starting the pressure boost (pressure boost time expires)
* When the pressure boost time expires, pressure boost is not performed again unless the operation lever
is returned one time to neutral.
2) When an attachment operation is not performed (upper pressure sensor OFF)
3) When a travel or option operation is performed (travel or option pressure sensor ON)
* Pressure boost is not performed to protect the travel and option circuits.
3. Operation conditions for pressure boost control (A mode)
When the work mode is A mode, pressure boost is performed for the lifting work.
* When a travel or option operation is performed in A mode, the pressure boost is continued.
4. Time chart (when work mode = SP or H)

a Pressure boost solenoid valve d Icon g Less than 8 sec.

e Pressure sensor (travel) and/or
b High-load work
pressure sensor (option)
c Pressure sensor (upper) f 8 sec.

84512399 EN - September 2011

4001A-33
Copyright ©
Electrical and Engine Basic Functions

Free Swing
Purpose
Prevents swinging of the suspended load while swinging is stopped during lifting work.

1 Free swing（Locker switch） 3 Monitor 5 Swing motor

2 Computer A 4 Free swing solenoid valve 6 Control valve

a Free swing icon

Operation explanation
1. Operation conditions for free swing
1) When the free swing switch is pressed.
* The free swing is disabled during a swing lock.
* The free swing icon is displayed on the monitor.
2. End conditions for free swing
1) When the free swing switch is pressed during free swing.

84512399 EN - September 2011

4001A-34
Copyright ©
Electrical and Engine Basic Functions

Energy saving / Noise

Pump Standby Pressure Control
Purpose
Reduces the pump load during non-operation.(Reduces the fuel consumption)
The control methods are the following 2.
1. The negative control relief pressure is varied and the negative control pressure is lowered to reduce the pump
load.
2. The pump discharge volume is set to the minimum flow.

1 Computer A 5 Pressure sensor (swing) 9 Pump 2

P1 flow control proportional
2 Control valve 6 Pressure sensor (travel) 10
valve
Negative control foot relief
3 Power save solenoid 7
valve
4 Pressure sensor (upper) 8 Pump 1
84512399 EN - September 2011
4001A-35
Copyright ©
Electrical and Engine Basic Functions

Operation explanation
1. Operation conditions for pump standby
1) When an attachment, travel or swing operation is not being performed.(Upper, travel and swing pressure
sensors OFF)
2. End conditions for pump standby
1) When an attachment operation is performed.(Upper pressure sensor ON)
2) When a travel operation is performed.(Travel pressure sensor ON)
3) When a swing operation is performed.(Swing pressure sensor ON)
3. Operation for trouble
If an abnormality occurs in the upper, swing or travel pressure sensors, the P1 flow control proportional valve,
or the power save solenoid valve, the system judges that a machine operation is in progress.

84512399 EN - September 2011

4001A-36
Copyright ©
Electrical and Engine Basic Functions

Swing Relief Cut

Purpose
When independent swing operation is running, the pump flow is reduced, and the excess oil ejected from the swing
motor relief valve is eliminated.

1 Computer A 4 Pressure sensor (option 1) 7 Pressure sensor (P2)

2 Oil temperature sensor 5 Pressure sensor (N2) 8 Regulator
P1 flow control proportional
3 Pressure sensor (travel) 6 Pressure sensor (P1) 9
valve

a Arm (1) d Option 1 g Boom (1)

End Attachment
Breaker Mode
Purpose
Maximum flow and maximum pressure settings can be set for each breaker used for up to 5 breakers.(Available for
models with an electromagnetic proportional relief valve only.)
Operation explanation
1. The mode is switched from one mode to the next in the sequence normal mode → breaker mode → crusher
mode → normal mode each time the attachment select switch is pressed.
The maximum flow for the mode that has been switched to will display on the indicator for 2 sec.
* In the default state, there is only 1 breaker mode, but more can be added in the flow setting screen.
2. The breaker can be used when breaker mode is selected.
* Set the maximum flow and maximum pressure in the flow setting screen first.
* If 2 pumps flow is necessary at the set flow volume, 2 pumps flow will be used.
3. The suitability of the flow volume to the breaker will be judged.
If the acceptable flow volume has been exceeded, the message “CHECK FLOW RATE” will display.
* This message only displays during breaker operation. The display ends if operation is stopped.
4. The next time the key is switched OFF and then ON again, the machine will be set to the last attachment mode
that was selected.

Crusher Mode
Purpose
Maximum flow and maximum pressure settings can be set for each crusher used for up to 5 crushers.(Available for
models with an electromagnetic proportional relief valve only.)
Operation explanation
1. The mode is switched from one mode to the next in the sequence normal mode → breaker mode → crusher
mode → normal mode each time the attachment select switch is pressed.
The maximum flow for the mode that has been switched to will display on the indicator for 2 sec.
* In the default state, there is only 1 crusher mode, but more can be added in the flow setting screen.
2. The crusher can be used when crusher mode is selected.
* Set the maximum flow and maximum pressure in the flow setting screen first.
* If 2 pumps flow is necessary at the set flow volume, 2 pumps flow will be used.
3. When an arm in + crusher operation is performed, milli-amp control will be performed so that the arm-in oper-
ation will not be performed with 2 pumps flow.
* This is to prevent crusher operation from being stopped.
4. The next time the key is switched OFF and then ON again, the machine will be set to the last attachment mode
that was selected.

84512399 EN - September 2011

4001A-41
Copyright ©
Electrical and Engine Basic Functions

Maintenance
Anti-theft
Password
Purpose
Locks the machine if is operated without authorization. (Anti-theft)
Operation explanation
1. When the anti-theft function is ON, turn the key ON.
2. Enter the correct password at the password input screen.
* If an incorrect password is input, "ERROR" is displayed and the buzzer buzzes.
If the correct password is then input, the lock is released.
3. The machine lock is released and the normal screen is displayed.
* If the “ERROR” message is ignored and the engine is started, the machine will lock.
Machine lock conditions
• The engine speed is fixed at low idle.
• The swing brake cannot be released.
• The travel alarm buzzes continuously.
* In addition, if the operator tries to operate the machine in the machine lock state, the engine will be stopped.
Machine operation judgment conditions
• The P1 or P2 pressure rises to 5 MPa or higher.
• The engine load ratio is 50 % or higher for 2 sec. cumulative.
• The upper, travel, P1, or P2 pressure sensor is removed.
Immobilizer Key
Purpose
Prevents starting of the engine with keys other than the designated key. (Anti-theft)
Operation explanation
• When the key is switched ON, the immobilizer computer performs verification of the key.
• If the key is verified as the designated key, cranking is performed.
• If the key is not verified as the designated key, cranking is not performed.
* At this time, cranking will not be performed even if the key is turned up to ST.

84512399 EN - September 2011

4001A-42
Copyright ©

Section

4001B

Service Support

84512399 EN - September 2011

CONTENTS

Service Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Screen Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Screen Display List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHECK Screen List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MACHINE STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FAULT HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
WORK HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ENGINE HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
HYDRAULIC HISTORY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
PART NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SETUP Screen List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
MACHINE SELECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

4001B-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

4001B-2 PRINTED IN FRANCE
Copyright ©
Service Support

Service Support
Screen Operations
Screen Display List

1 Travel speed select switch 3 Menu screen display switch 5 Wiper switch
2 Attachment select switch 4 Working light switch 6 Auto idling switch

84512399 EN - September 2011

4001B-3
Copyright ©
Service Support

CHECK Screen List check sensor and switch input/output states, as well as
the angle, load ratio and work radius, etc. at the applied
In CHECK mode, in addition to the machine status (milli- machine (liftcrane specifications machine, lifting magnet
amp, oil pressures, temperatures, etc.), it is possible to machine).

1 Section MACHINE STATUS

1. Engine and pump
For the CHECK mode section types and their contents,
see the separate sheet.

By pressing and on the monitor,

MACHINE STATUS, FAULT HISTORY, etc. can be
selected.
Detailed data for the selected item can be seen by press-

ing .

ENGINE SPEED min-1 Engine speed

ENGINE LOAD
% Engine load ratio
RATIO
Pump 1; Discharge
P1 PRESS. MPa
pressure
Pump 2; Discharge
P2 PRESS. MPa
pressure
Pump 1; Negative
N1 PRESS. MPa
control pressure
Pump 2; Negative
N2 PRESS. MPa
control pressure
Horsepower control
P.SOL;PUMP-
mA proportional valve;
POWER
Actual milli-amp
Flow milli-amp pro-
P.SOL;PUMP-
mA portional valve; Ac-
FLOW
tual milli-amp
SOL;POWER-
on/off Power save solenoid
SAVE

84512399 EN - September 2011

4001B-4
Copyright ©
Service Support

2. Temperature and pressure 3. Pressure and solenoid

BOOST PRESS. kPa Boost pressure UPPER PILOT

MPa Upper pilot pressure
BAROMETRIC PRESS.
kPa Barometric pressure SWING PILOT
PRESS. MPa Swing pilot pressure
BOOST TEMP. °C Boost temperature PRESS.
Suction air tempera- TRAVEL PILOT
AIR INLET TEMP. °C MPa Travel pilot pressure
ture PRESS.
FUEL TEMP. °C Fuel temperature OPT.LINE
on/off 1st option operation
MANIFOLD IN- PRESS SW.
°C Manifold temperature 2ND OPT.LINE
NER TEMP. on/off 2nd option operation
COOLANT TEMP. °C Coolant temperature PRESS SW.
HYD.OIL TEMP. °C Oil temperature TRAVEL ALARM
on/off Travel alarm
OUT.
POWER SAVE
on/off Power save solenoid
SOL.
SWING BRAKE
on/off Swing brake solenoid
SOL.
FREE SWING
on/off Free swing solenoid
SOL.

OFFSET ANGLE deg Offset angle
ARM ANGLE deg Arm angle
WORKING RA- m Work radius
DIUS
LIFTING HEIGHT m Work height
HEIGHT LIMIT m Hanging limit height
LIFTING LOAD kg Hanging load
RATED LOAD kg Rated load
WARNING
on/off Liftcrane buzzer
BUZZER OUT
84512399 EN - September 2011
4001B-8
Copyright ©
Service Support

11. Safety distances 13. GPS information

To switch to a page from 1 to 15, press the monitor

BOOM ANGLE deg Boom angle
OFFSET ANGLE deg Offset angle
ARM ANGLE deg Arm angle switch while the MACHINE STATUS screen
P.SOL;BOOM-UP % Boom-up solenoid is displayed and select the desired page.
P.SOL;OFFSET-
% Offset solenoid
LEFT
P.SOL;ARM-
mA Arm-in solenoid
CLOSE
SAFETY DIS- m Safety distance
TANCE(TOP) (side)
SAFETY DIS- m Safety distance
TANCE(SIDE) (front)

12. Hanging load

BOOM BOTTOM Boom bottom pres-

MPa
PRESS. sure
BOOM ROD
MPa Boom rod pressure
PRESS.
WORKING RA- m Work radius
DIUS
LIFTING LOAD kg Hanging load
RATED LOAD kg Rated load
TOTAL MOMENT kg.m Total moment
Attachment indepen-
ATT.MOMENT kg.m
dent moment

84512399 EN - September 2011

4001B-9
Copyright ©
Service Support

FAULT HISTORY 3 Initial occurrence time

4 Final occurrence time
1. With FAULT HISTORY, the contents for the trouble
currently occurring and a log of trouble that has oc-
curred in the past can be checked. • Diagnostic trouble codes that occur display in
"DTC-1" - "DTC-4".
•
The cursor is moved with the and
switches. (The cursor moves between "DTC-1"
and "DTC-4".)
• The information for the diagnostic trouble code for
the location under the cursor is displayed with the
items from "STATUS" to "LAST HOUR".
• Up to 30 diagnostic trouble codes can be dis-
played.
To switch to a page from 1 to 6, press the monitor

switch while the FAULT HISTORY screen

is displayed and select the desired page.
1 Displayed/Not displayed
2 Occurrence count

84512399 EN - September 2011

4001B-10
Copyright ©
Service Support

WORK HISTORY
Operation times for mechanical parts, electrical parts,
etc., and operation counts for switches can be displayed.

1. Machine main unit 2. Work mode

KEY-ON TIME hour Key ON time SP-MODE OPERA- SP mode operation

hour
Engine operation TION TIME time
ENGINE-RUN TIME hour
time H-MODE OPERA- H mode operation
hour
OPERATION TIME hour Operation time TION TIME time
UPPER OPERA- A-MODE OPERA- A mode operation
hour Upper operation time hour
TION TIME TION TIME time
SWING OPERATION - - -
hour Swing operation time POWER-BOOST Boosted pressure
TIME hour
TRAVEL OPERA- TIME time
hour Travel operation time AUTO IDLE TIME hour Auto idle time
TION TIME
INDEPENDENT Independent travel ONE-TOUCH-IDLE
hour hour One-touch idle time
TRAVEL TIME operation time TIME
Lo-SPEED TRAVEL 1st speed travel oper-
hour
TIME ation time
Hi-SPEED TRAVEL 2nd speed travel op-
hour
TIME eration time

84512399 EN - September 2011

4001B-11
Copyright ©
Service Support

3. End attachment 5. Electrical part

BREAKER OPERATION Breaker operation WIPER-INT. OPER-

hour hour Wiper (INT) time
TIME time ATION TIME
CRUSHER OPERA- Crusher operation WIPER-CNT. OPER-
hour hour Wiper (CNT) time
TION TIME time ATION TIME
OPT.1 PUMP OPERA- 1st option opera- WASHER OPERA- Washer operation
hour hour
TION TIME tion time TION TIME time
OPT.2 PUMP OPERA- 2nd option opera- WORKING LAMP Working light ON
hour hour
TION TIME tion time ON TIME time
2ND OPT. OPERATION 2 pumps flow op- RADIO MUTE TIME hour Radio mute time
hour DISPLAY-MODE1 No camera screen
TIME eration time hour
CRANE OPERATION Liftcrane opera- TIME selection time
hour DISPLAY-MODE2 Camera screen dis-
TIME tion time hour
MAGNET OPERATION Lifting magnet op- TIME play 1 selection time
hour DISPLAY-MODE3 Camera screen dis-
TIME eration time hour
TIME play 2 selection time

4. Electrical part

KEY-ON COUNT hour Key ON count

ENGINE-START
hour Engine ON count
COUNT
IDLE SHUT Front window open
hour
DOWN COUNT count
WINDOW OPEN
hour Door open count
TIME
WINDOW OPEN
10 times Idle stop time
COUNT
DOOR OPEN Front window open
hour
TIME time
DOOR OPEN
10 times Door open time
COUNT
84512399 EN - September 2011
4001B-12
Copyright ©
Service Support

6. Air conditioner 7. Air conditioner

A/C OPERATION AC power supply Maximum cooling op-

hour COOL-MAX TIME hour
TIME ON time eration time
A/C BLOWER-Lo AC blower Lo set- T1 TARGET TEMP T1 Target tempera-
hour hour
TIME ting time ＜ T2 TIME ture T ＜ T2 time
A/C BLOWER-M1 AC blower M1 set- T2 TARGET TEMP T2 Target tempera-
hour hour
TIME ting time ＜ T3 TIME ture T ＜ T3 time
A/C BLOWER-M2 AC blower M2 set- T3 TARGET TEMP T3 Target tempera-
hour hour
TIME ting time ＜ T4 TIME ture T ＜ T4 time
A/C BLOWER-M3 AC blower M3 set- Maximum heating
hour HOT-MAX TIME hour
TIME ting time operation time
A/C BLOWER-M4 AC blower M4 set- RECIRC.AIR MAX- Maximum inside air
hour ℃
TIME ting time TEMP. temperature
A/C BLOWER-Hi AC blower Hi set- RECIRC.AIR MIN- Minimum inside air
hour ℃
TIME ting time TEMP. temperature
MAG.CLUTCH RE- Electromagnetic INTAKE AIR MAX- Maximum outside air
hour ℃
LAY ON TIME clutch ON time TEMP. temperature
CLUTCH RELAY ON Electromagnetic INTAKE AIR MIN- Minimum outside air
10 times ℃
COUNT clutch ON count TEMP. temperature

To switch to a page from 1 to 7, press the monitor switch

while the WORK HISTORY screen is displayed

and select the desired page.

84512399 EN - September 2011

4001B-13
Copyright ©
Service Support

ENGINE HISTORY
The engine speed, coolant temperature, fuel tempera-
ture, and suction air temperature distributions, etc. can
be displayed.

1. Actual speed distribution 2. Water temperature distribution

ROTATION ＜ R1 hour S 1025 TEMP. ＜ T1 hour T ＜ 77

R1 REV. SPEED ＜ T1 TEMP. ＜ T2 hour 77 T ＜ 82
hour 1025 S ＜ 1225
R2 T2 TEMP. ＜ T3 hour 82 T ＜ 97
R2 REV. SPEED ＜ T3 TEMP. ＜ T4 hour 97 T ＜ 100
hour 1225 S ＜ 1425
R3 T4 TEMP. ＜ T5 hour 100 T ＜ 103
R3 REV. SPEED ＜ T5 TEMP. ＜ T6 hour 103 T ＜ 105
hour 1425 S ＜ 1625
R4 T6 TEMP. hour 105 T
R4 REV. SPEED ＜ - - -
hour 1625 S ＜ 1825
R5 Maximum temper-
R5 REV. SPEED ＜ TEMP. MAX ℃
hour 1825 S ＜ 2025 ature
R6
R6 REV. SPEED hour 2025 S

84512399 EN - September 2011

4001B-14
Copyright ©
Service Support

3. Fuel temperature distribution 5. Boost temperature distribution

TEMP. ＜ T1 hour T ＜ 40 TEMP. ＜ T1 hour T＜0

T1 TEMP. ＜ T2 hour 40 T ＜ 50 T1 TEMP. ＜ T2 hour 0 T ＜ 20
T2 TEMP. ＜ T3 hour 50 T ＜ 60 T2 TEMP. ＜ T3 hour 20 T ＜ 40
T3 TEMP. ＜ T4 hour 60 T ＜ 70 T3 TEMP. ＜ T4 hour 40 T ＜ 60
T4 TEMP. ＜ T5 hour 70 T ＜ 80 T4 TEMP. ＜ T5 hour 60 T ＜ 80
T5 TEMP. ＜ T6 hour 80 T ＜ 90 T5 TEMP. ＜ T6 hour 80 T ＜ 100
T6 TEMP. hour 90 T T6 TEMP. hour 100 T
- - - - - -
Maximum temper- Maximum temper-
TEMP. MAX ℃ TEMP. MAX ℃
ature ature

6. Suction air temperature distribution

4. Suction air temperature distribution

PRESS. ＜ P1 hour P ＜ 100

TEMP. ＜ T1 hour T ＜ -20 P1 PRESS. ＜ P2 hour 100 P ＜ 140
T1 TEMP. ＜ T2 hour -20 T ＜ 0 P2 PRESS. ＜ P3 hour 140 P ＜ 180
T2 TEMP. ＜ T3 hour 0 T ＜ 15 P3 PRESS. ＜ P4 hour 180 P ＜ 220
T3 TEMP. ＜ T4 hour 15 T ＜ 30 P4 PRESS. ＜ P5 hour 220 P ＜ 260
T4 TEMP. ＜ T5 hour 30 T ＜ 45 P5 PRESS. ＜ P6 hour 260 P ＜ 300
T5 TEMP. ＜ T6 hour 45 T ＜ 60 P6 PRESS. hour 300 P
T6 TEMP. hour 60 T Maximum pres-
PRESS. MAX kPa
- - - sure
Maximum temper- Minimum pres-
TEMP. MAX ℃ PRESS. MIN kPa
ature sure

84512399 EN - September 2011

4001B-15
Copyright ©
Service Support

7. Oil pressure distribution 9. Load ratio distribution

PRESS. ＜ P1 hour P＜0 RATIO ＜ R1 hour R＜ 30

P1 PRESS. ＜ P2 hour 0 P ＜ 150 R1 RATIO ＜ R2 hour 30 R ＜ 40
P2 PRESS. ＜ P3 hour 150 P ＜ 300 R2 RATIO ＜ R3 hour 40 R ＜ 50
P3 PRESS. ＜ P4 hour 300 P ＜ 450 R3 RATIO ＜ R4 hour 50 R ＜ 60
P4 PRESS. ＜ P5 hour 450 P ＜ 600 R4 RATIO ＜ R5 hour 60 R ＜ 70
P5 PRESS. ＜ P6 hour 600 P ＜ 750 R5 RATIO ＜ R6 hour 70 R ＜ 80
P6 PRESS. hour 750 P R6 RATIO hour 80 R
Maximum pres-
PRESS. MAX kPa
sure 10. SP mode load ratio distribution
Minimum pres-
PRESS. MIN kPa
sure

8. Boost pressure distribution

RATIO ＜ R1 hour R ＜ 30
R1 RATIO ＜ R2 hour 30 R ＜ 40
R2 RATIO ＜ R3 hour 40 R ＜ 50
R3 RATIO ＜ R4 hour 50 R＜60
PRESS. ＜ P1 hour P＜0 R4 RATIO ＜ R5 hour 60 R ＜ 70
P1 PRESS. ＜ P2 hour 0 P ＜ 150 R5 RATIO ＜ R6 hour 70 R ＜ 80
P2 PRESS. ＜ P3 hour 150 P ＜ 300 R6 RATIO hour 80 R
P3 PRESS. ＜ P4 hour 300 P＜450
P4 PRESS. ＜ P5 hour 450 P ＜ 600
P5 PRESS. ＜ P6 hour 600 P ＜ 750
P6 PRESS. hour 750 P
Maximum pres-
PRESS. MAX kPa
sure
Minimum pres-
PRESS. MIN kPa
sure

84512399 EN - September 2011

4001B-16
Copyright ©
Service Support

11. H mode load ratio distribution 13. DOC temperature distribution

RATIO ＜ R1 hour R ＜ 30 TEMP. ＜ T1 hour T ＜ 200

R1 RATIO ＜ R2 hour 30 R ＜ 40 T1 TEMP. ＜ T2 hour 200 T ＜ 300
R2 RATIO ＜ R3 hour 40 R ＜ 50 T2 TEMP. ＜ T3 hour 300 T ＜ 400
R3 RATIO ＜ R4 hour 50 R ＜ 60 T3 TEMP. ＜ T4 hour 400 T ＜ 500
R4 RATIO ＜ R5 hour 60 R ＜ 70 T4 TEMP. ＜ T5 hour 500 T ＜ 600
R5 RATIO ＜ R6 hour 70 R ＜ 80 T5 TEMP. ＜ T6 hour 600 T ＜ 700
R6 RATIO hour 80 R T6 TEMP. hour 700 T
- - -
12. Fuel density distribution Maximum temper-
TEMP. MAX ℃
ature

14. DPD temperature distribution

DENSITY ＜ D1 hour D＜ D1
D1 DENSITY ＜ D2 hour D1 D ＜ D2
D2 DENSITY ＜ D3 hour D2 D ＜ D3
TEMP. ＜ T1 hour T ＜ 200
D3 DENSITY ＜ D4 hour D3 D ＜ D4
T1 TEMP. ＜ T2 hour 200 T ＜ 300
D4 DENSITY ＜ D5 hour D4 D ＜ D5
T2 TEMP. ＜ T3 hour 300 T ＜ 400
D5 DENSITY ＜ D6 hour D5 D ＜ D6
T3 TEMP. ＜ T4 hour 400 T ＜ 500
D6 DENSITY hour D6 D
T4 TEMP. ＜ T5 hour 500 T ＜ 600
T5 TEMP. ＜ T6 hour 600 T ＜ 700
T6 TEMP. hour 700 T
- - -
Maximum temper-
TEMP. MAX ℃
ature

84512399 EN - September 2011

4001B-17
Copyright ©
Service Support

15. Supply pump inlet pressure distribution 17. DPD differential pressure distribution

PRESS. ＜ P1 hour P ＜ -40 PRESS. ＜ P1 hour P＜0

P1 PRESS. ＜ P2 hour -40 P ＜ -30 P1 PRESS. ＜ P2 hour 0 P＜5
P2 PRESS. ＜ P3 hour -30 P ＜ -20 P2 PRESS. ＜ P3 hour 5 P ＜ 10
P3 PRESS. ＜ P4 hour -20 P ＜ -10 P3 PRESS. ＜ P4 hour 10 P ＜ 15
P4 PRESS. ＜ P5 hour -10 P ＜ 0 P4 PRESS. ＜ P5 hour 15 P ＜ 20
P5 PRESS. ＜ P6 hour 0 P ＜ 10 P5 PRESS. ＜ P6 hour 20 P ＜ 25
P6 PRESS. hour 10 P P6 PRESS. hour 25 P
Maximum pres- Maximum pres-
PRESS. MAX kPa PRESS. MAX kPa
sure sure
Minimum pres- Minimum pres-
PRESS. MIN kPa PRESS. MIN kPa
sure sure

16. Hot shutdown 18. DPD regeneration count

ITEM-1 - - ITEM-1 - -
ITEM-2 - - ITEM-2 - -
ITEM-3 - - ITEM-3 - -
ITEM-4 - - ITEM-4 - -
ITEM-5 - - ITEM-5 - -
ITEM-6 - - ITEM-6 - -
ITEM-7 - - ITEM-7 - -
ITEM-8 - - ITEM-8 - -
ITEM-9 - - ITEM-9 - -

To switch to a page from 1 to 18, press the monitor switch

while the ENGINE HISTORY screen is displayed

and select the desired page.

84512399 EN - September 2011

4001B-18
Copyright ©
Service Support

HYDRAULIC HISTORY
The P1 and P2 pilot pressure can be displayed.

1. P1 pressure 2. P2 pressure

PRESS. ＜ P1 hour P＜ 10 PRESS. ＜ P1 hour P ＜ 10

P1 PRESS. ＜ P2 hour 10 P＜ 15 P1 PRESS. ＜ P2 hour 10 P ＜ 15
P2 PRESS. ＜ P3 hour 15 P＜ 20 P2 PRESS. ＜ P3 hour 15 P ＜ 20
P3 PRESS. ＜ P4 hour 20 P＜ 25 P3 PRESS. ＜ P4 hour 20 P ＜ 25
P4 PRESS. ＜ P5 hour 25 P＜ 30 P4 PRESS. ＜ P5 hour 25 P ＜ 30
P5 PRESS. ＜ P6 hour 30 P＜ 35 P5 PRESS. ＜ P6 hour 30 P ＜ 35
P6 PRESS. hour 35 P P6 PRESS. hour 35 P

84512399 EN - September 2011

4001B-19
Copyright ©
Service Support

3. N1 pressure 5. P1 + P2 pressure

PRESS. ＜ P1 hour P＜ 1.0

P1 PRESS. ＜ P2 hour 1.0 P ＜ 1.5 PRESS. ＜ P1 hour P＜ 20
P2 PRESS. ＜ P3 hour 1.5 P ＜ 2.0 P1 PRESS. ＜ P2 hour 20 P＜ 30
P3 PRESS. ＜ P4 hour 2.0 P ＜ 2.5 P2 PRESS. ＜ P3 hour 30 P＜ 40
P4 PRESS. ＜ P5 hour 2.5 P ＜ 3.0 P3 PRESS. ＜ P4 hour 40 P＜ 50
P5 PRESS. ＜ P6 hour 3.0 P ＜ 3.5 P4 PRESS. ＜ P5 hour 50 P＜ 60
P6 PRESS. hour 3.5 P P5 PRESS. ＜ P6 hour 60 P＜ 70
P6 PRESS. hour 70 P
4. N2 pressure

6. Operation count

PRESS. ＜ P1 hour P＜ 1.0

P1 PRESS. ＜ P2 hour 1.0 P ＜ 1.5
P2 PRESS. ＜ P3 hour 1.5 P ＜ 2.0
P3 PRESS. ＜ P4 hour 2.0 P ＜ 2.5 UPPER PILOT Upper operation
1000 times
P4 PRESS. ＜ P5 hour 2.5 P ＜ 3.0 PRESS count
P5 PRESS. ＜ P6 hour 3.0 P ＜ 3.5 SWING PILOT Swing operation
1000 times
P6 PRESS. hour 3.5 P PRESS count
TRAVEL PILOT Travel operation
1000 times
PRESS count
ARM-CLOSE PI- Arm-in operation
1000 times
LOT PRESS. count
OPT.LINE 1st option opera-
1000 times
PRESS SW. tion count
2ND OPT.LINE 2nd option opera-
1000 times
PRESS SW. tion count
POWER BOOST Pressure boost
1000 times
SOL. operation count
SWING BRAKE Swing operation
1000 times
SOL. count
POWER-SAVE Power save oper-
1000 times
TIME ation count
84512399 EN - September 2011
4001B-20
Copyright ©
Service Support

7. Oil temperature distribution PART NUMBER

The software version for computers A, B, C can be dis-
played.

TEMP. ＜ T1 hour T ＜ 45
T1 TEMP. ＜ T2 hour 45 T ＜ 60
T2 TEMP. ＜ T3 hour 60 T ＜ 80
T3 TEMP. ＜ T4 hour 80 T ＜ 88
T4 TEMP. ＜ T5 hour 88 T ＜ 95
T5 TEMP. ＜ T6 hour 95 T ＜ 98
T6 TEMP. hour 98 T
- - -
Maximum tempera-
TEMP. MAX ℃
ture

To switch to a page from 1 to 7, press the monitor switch

while the HYDRAULIC HISTORY screen is dis-

played and select the desired page.

SETUP Screen List

The model selection, work mode speed, etc. can be
changed.

84512399 EN - September 2011

4001B-21
Copyright ©
Service Support

By pressing "Wiper switch" (5) and "Auto idling switch" MACHINE SELECT
(6) on the monitor, MACHINE SELECT, PARAMETERS,
etc. can be selected. Machine data information, etc. are registered.
Detailed data for the selected item can be seen by press-
ing "Working light switch" (4).

MACHINE 0 Japanese
Fix the selection. 1 English
TERRITORY 2 Thai
3 Chinese
0 JAPAN 4 German
1 NA 5 French
2 - 6 Italian
3 EU 7 Spanish
4 IHI 8 Portuguese
5 TURK 9 Dutch
6 CHINA 10 Danish
11 Norwegian
12 Swedish
BRAND
13 Finnish
14 Turkish
0 SUMITOMO 15 Arabic
1 LBX 16 Malay
2 CASE 17 Indonesian
3 IHI 18 Russian
19 Canadian French
LANGUAGE 20 Pictographs only

84512399 EN - September 2011

4001B-22
Copyright ©
Service Support

PARAMETERS 3. Work mode engine speed

The work mode speed and pump milli-amps can be set.
1. Engine

ITEM-1 min-1 SP mode speed

ITEM-2 min-1 H mode speed
ITEM-3 min-1 A mode speed
ITEM-1 min-1 Auto idling speed ITEM-4 min-1 Idling speed
ITEM-2 ms*100 Auto idle time
Transient load minimum milli- 4. Energy save
ITEM-3 mA
amp (normally 50 mA)
Semi-transient load minimum
ITEM-4 mA
milli-amp
Eco gauge update period (nor-
ITEM-5 ms*100
mally 1000 ms)

2. Work mode milli-amp

Speed change amount during

ITEM-1 min-1
boom-down swing operation
ITEM-2 - -
Semi-auto idling speed change
ITEM-3 min-1
amount
ITEM-4 - -
ITEM-5 - -
ITEM-1 mA SP mode milli-amp (Hi) - -
ITEM-6
ITEM-2 mA SP mode milli-amp (Low)
ITEM-7 mA Speed limit milli-amp
ITEM-3 mA H mode milli-amp (Hi)
ITEM-4 mA H mode milli-amp (Low)
ITEM-5 mA A mode milli-amp (Hi)
ITEM-6 mA A mode milli-amp (Low)
ITEM-7 mA Minimum milli-amp

4001C-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

4001C-2 PRINTED IN FRANCE
Copyright ©
Function, Structure, Operation

Function, Structure, Operation

1. Engine number

1 Engine number stamping

84512399 EN - September 2011

4001C-3
Copyright ©
Function, Structure, Operation

2. Function, Structure, Operation

1) Engine structural diagram

84512399 EN - September 2011

4001C-4
Copyright ©
Function, Structure, Operation

84512399 EN - September 2011

4001C-5
Copyright ©
Function, Structure, Operation

2) Fuel system
Fuel system diagram

1 Injector 3 Fuel tank 5 Supply pump

2 Fuel filter 4 Pre-fuel filter 6 Common rail

CAUTION
• Since the high-precision fuel system has been adopted, take care to prevent any foreign
matter from entering the fuel system.
• Do not disassemble the supply pump, common rail, or injector.

84512399 EN - September 2011

4001C-6
Copyright ©
Function, Structure, Operation

Common rail

1 Pressure limiter
2 Pressure sensor
3 Flow damper

84512399 EN - September 2011

4001C-7
Copyright ©
Function, Structure, Operation

Fuel supply pump

3) Cooling system
The cooling system is a forced-circulation system, and its main components are the water pump, thermostat
and radiator.
It cools the inside of the engine, oil cooler, EGR gas, etc.

1 Sub-tank 4 Oil cooler 7 Radiator

2 Air leak pipe 5 Thermostat
3 EGR cooler 6 Water pump

84512399 EN - September 2011

1 Drive gear 3 Spring 5 Driven gear

2 Drive gear shaft 4 Relief valve

84512399 EN - September 2011

4001C-15
Copyright ©
Function, Structure, Operation

5) Induction system
Turbocharger structural diagram

1 VGS actuator 3 Turbine housing 5 Compressor housing

2 VGS device 4 Bearing housing

84512399 EN - September 2011

4001C-16
Copyright ©
Function, Structure, Operation

4001C-19
Copyright ©
Function, Structure, Operation

8) Electrical system
Charging system
The main components of the charging system are the battery, generator, and battery discharge indicator
light circuit.
Generator is a self-rectifier type with a regulator built in.
Generator
The generator is a brushless type.
The main components are the roller, stator, rectifier assembly, front bracket, rear bracket, IC regulator,
bearing, pulley, etc.
The moving parts are the roller and pulley.
The field coil is fixed to the rear bracket.
6 main diodes and 2 additional diodes are used to change the three-phase alternating current generated
in the stator coil to a direct current.
3 out of the 6 main diodes are referred to as positive diode, and the rest is referred to as negative diode.
In addition, 3 small diodes that are referred to as a triodiode are used to supply the field current.
This generator has 3 terminals comprised of the Bterminal (direct current output terminal), L-terminal and
R-terminal.
Since the L-terminal is connected to the field coil, it works as an input terminal for the initial excitation
current along with the R-terminal, until the generator starts generating power.
Also, it functions as an output terminal (current capacity is 1 A).
When the L-terminal voltage reaches the battery voltage, the charge light turns off.
Since both bearings are sealed, periodic lubrications are not required.
The IC regulator cannot be disassembled, so it should be handled as an assembly.

1 Rear bracket 5 Stator 9 Front bracket

2 IC regulator 6 Rotor 10 Field coil assembly
3 Bearing 7 Bearing
4 Rectifier 8 Pulley

84512399 EN - September 2011

84512399 EN - September 2011

4001C-24
Copyright ©
Function, Structure, Operation

High altitude correction

The ECM calculates the current altitude using the signals from the barometric pressure sensor.
According to the conditions such as the current altitude, the fuel amount is corrected properly.

Fuel flow limit (mm3/st)

Barometric pressure kPa (psi)

*1 Highland

84512399 EN - September 2011

4001C-25
Copyright ©
Function, Structure, Operation

Control during overheat

To protect the engine, restriction on fuel flow is started when the engine coolant temperature exceeds
98°C {208°F}.
When the engine coolant temperature increases further, the fuel flow is also restricted further.
When the temperature reaches 110°C {230°F}, a DTC is detected and a failure is recorded in the ECM.
When the temperature is near 120°C {248°F}, the fuel flow is restricted to a certain level.
The setting varies depending on the machine manufacturer.
The machine is designed to issue an alarm from 105°C {221°F}.
By reducing the load applied to the machine upon alarm issuance, it is possible to avoid the operation
condition with fuel flow restriction.

Fuel flow

Water temperature

*1 Warning indication DTC set

If the ECM is equipped with an emergency stop function by a high engine coolant temperature, it stops
the engine when the temperature has reached 105°C {221 °F}.

Fuel flow

Water temperature

*1 Engine emergency stop

84512399 EN - September 2011

4001C-26
Copyright ©
Function, Structure, Operation

4001C-36
Copyright ©
Function, Structure, Operation

EGR control
The ECM controls the EGR valve lift amount by operating the motor according to the engine status such
as the engine rpm and engine load.
The valve lift amount is detected by the EGR position sensor.
Darker portions in the figure represent large valve lift amounts and the darkest portion represents the lift
amount of nearly 100％.

Accelerator position

Engine speed

*1 No idle EGR

84512399 EN - September 2011

4001C-37
Copyright ©
Function, Structure, Operation

EGR system schematic diagram

1 Outlet port of coolant 7 Boost temperature sensor *13 ECM

84512399 EN - September 2011

4001C-38
Copyright ©
Function, Structure, Operation

EGR and turbine noise

Some engines may generate high frequency noise due to the turbine rotation.
This high frequency noise can be muted by using an appropriate silencer.
For some OEMs where use in residential areas is not assumed, the silencer for muting the high frequency
noise may be omitted from the specifications, leaving the noise.
The high frequency noise tends to become lower while controlling the EGR and louder when EGR control
is not provided.

*1 Without EGR
*2 With EGR

84512399 EN - September 2011

4001C-39
Copyright ©
Function, Structure, Operation

Turbocharger control
This is the system that secures the optimal boost pressure and air flow amount in accordance with all of
the engine operating conditions by adjusting the opening angle of the nozzle vane inside the turbocharger.
The ECM sends the target nozzle opening angle to the turbo control unit through CAN communication to
control the boost pressure and the air flow amount properly in accordance with the engine load conditions
based on information such as the engine rpm, accelerator opening angle, boost pressure, etc.
The turbo control unit drives the turbo actuator based on the information received from the ECM, and
properly adjusts the nozzle vane opening angle through the control rod.

1 Engine control module (ECM) 3 Turbo actuator *5 Turbo position sensor

*2 Turbo control unit *4 Turbo motor

84512399 EN - September 2011

4001C-40
Copyright ©
Function, Structure, Operation

Turbo actuator activation

The actuator is activated based on the signal from the turbo control unit to move the nozzle control rod.
The nozzle vane is opened and closed depending on the movement of the nozzle control rod.

1 Exhaust gas inlet 3 Control rod 5 Turbine wheel

2 Actuator 4 Exhaust gas outlet 6 Nozzle vane

84512399 EN - September 2011

4001C-41
Copyright ©
Function, Structure, Operation

Engine operation control

There are the following 4 types of operation control instructions, and the selection varies depending on
each specification.
Voltage input by APS, 1 - 4 V
Accelerator opening angle instruction given through
CAN communication control, 0 - 100％, RPM instruction
RPM instruction given through mode map switch control,
RPM instruction and change instruction given by APS
Increase and decrease instruction for each rotation given by idle switch
Mode map switch
The mode map switch has 6 rotation control mode types of H, S, L, B, I and LM.
The rotation settings are H > S > L > B, I > LM.
For H, S, L and B, the rotation speed can be decreased by the APS,but any change cannot be made from
the APS for I and LM.

When the regulation mode switch input is present in addition to the mode map switch, the following 2
types of control methods are available.

*1 Directed speed

84512399 EN - September 2011

4001C-42
Copyright ©
Function, Structure, Operation

*1 Directed speed

H, S, L and B of the mode map switch change as follows depending on the APS input.

Meaning of mode map switch and each mode In the APS, a change toward the engine rpm decrease
direction can be made from each mode point.
The specified engine rpm for H, S, L and B are determined depending on the calibration of the ECM.

84512399 EN - September 2011

4001C-43
Copyright ©
Function, Structure, Operation

CAN communication
When a CAN controller does not exist on the machine.

*1 Diagnostic scan tool

*2 MCX
*3 ECM
*4 LCD
*5 TCM
*6 Shift control

When a CAN controller exists on the machine.

*1 Diagnostic scan tool

*2 MCX
*3 ECM
*4 TCM
*5 Shift Control

84512399 EN - September 2011

4001C-44
Copyright ©
Function, Structure, Operation

1 Accelerator position sensor 5 Idle down switch *9 Reguration mode switch

*2 Engine stop switch *6 Mode map switch 0 *10 Load advance switch
*3 Idling selector switch *7 Mode map switch 1
*4 Idle up switch *8 Mode map switch 2

Mode map switch control

External switch
Operation mode Control
MAP0 MAP1 MAP2
OFF OFF OFF
H OFF ON ON Basic operations
ON ON ON
S ON OFF OFF Maximum revolution speed control #1
L OFF ON OFF Maximum revolution speed control #2
I OFF OFF ON Fixed rotational operation #1
B ON ON OFF Maximum revolution speed control #3
LM ON OFF ON Fixed rotational operation #2

84512399 EN - September 2011

4001C-45
Copyright ©
Function, Structure, Operation

I, LM and H modes

*1 Regulation mode switch

*2 Idle speed
*3 Max. speed

H, S, L, and B modes

*1 Idle speed
*2 Max. speed

4001C-56
Copyright ©
Function, Structure, Operation

PCV
The PCV is installed on the supply pump portion, and controls the fuel force-feed to the common rail.
The ECM controls the fuel discharge amount by regulating the energizing time to the PCV.

84512399 EN - September 2011

IMT sensor
The IMT sensor is a variable resistor installed on the intake manifold, and measures the intake tempera-
ture of the intake manifold.
When the sensor is cold, the sensor resistance is high.
When the intake temperature rises, the sensor resistance decreases.
For low sensor resistance, the ECM detects a low voltage of the signal circuit.

Pin No. Pin name Connection

61 PG-POWER GND
62 PG-POWER GND
63 PG-POWER GND
64 PG-POWER GND
65 PG-POWER GND
84512399 EN - September 2011
4001C-81
Copyright ©
Function, Structure, Operation

66 PG-POWER GND
67 PS-+B Power source
68 SP-5V1 Accelerator position sensor power source
69 SP-5V2 Barometric pressure sensor power source
70 SP-5V3 Exhaust differential pressure sensor, fuel filter pressure sensor power source
71 - -
72 CC-KW2000 Data link connector
(CC- -
73
BOOTRX)
74 - -
75 - -
76 - -
77 - -
78 - -
79 IA-THE1 Exhaust gas temperature sensor 1 signal
80 IA-THE2 Exhaust gas temperature sensor 2 signal
81 IA-IAT IAT sensor signal
82 IA-MAF MAF sensor signal
83 IA-FIPRESS Fuel filter pressure sensor signal
84 IA-EXHP Exhaust differential pressure sensor signal
85 IA-ACCEL1 Accelerator position sensor 1 signal
86 IA-ACCEL2 Accelerator position sensor 2 signal
87 IA-BARO Barometric pressure sensor signal
88 CC-ISOCAN-L ISO CAN-Low
89 PS-+B Power source
90 SG-5VRT1 Accelerator position sensor GND
91 - -
92 - -
93 - -
94 - -
(CC- -
95
BOOTTX)
96 (MOD1) -
97 PG-SIGN GND
98 - -
99 IS-SWLO2 -
100 IS-START Starter switch start signal
101 IS-LOAD Load advance switch signal
102 IS-REG Regulation mode switch signal
103 IS-AC Air cleaner switch
104 IS-IDLMNL Idling control change switch signal
105 IS-MDMAP0 Mode map switch 0 signal
106 IS-IDLUP Idling control switch Up signal
107 IS-MDMAP1 Mode map switch 1 signal
108 IS-MDMAP2 Mode map switch 2 signal
109 IS-IDLDWN Idling control switch Down signal
CC-ISO-
110 ISO CAN-High
CAN-H
111 PS-+B Power source
Exhaust differential pressure sensor, fuel filter pressure sensor, exhaust gas tempera-
112 SG-5VRT3
ture sensor 1, exhaust gas temperature sensor 2 GND
113 SG-12VRT MAF sensor GND
114 OS-MAINR ECM main relay
115 SG-SLD1 Accelerator position sensor shield
116 - -
117 SP-12V MAF sensor power source
118 - -
119 PG-SIGN GND
120 - -

84512399 EN - September 2011

4001C-82
Copyright ©
Function, Structure, Operation

121 IS-ENGSTP Engine stop switch signal

122 IS-DPDREG DPD switch
123 OS-OVRL Engine overrun light
124 OS-OILPL Engine oil pressure light
125 OS-BOOSTL Boost temperature sensor pilot light
126 OS-OVHL Overheat light
127 OS-OPL1 -
128 OS-OPL1 Tachometer
129 OS-DPDREG DPD regeneration light
130 OS-DIAGL Monitor
131 OS-EGRTL EGR gas temperature light
132 CC-CAN-L CAN-Low
133 PS-+B Power source
134 IS-IGKEY Starter switch ON signal
135 SG-5VRT2 Barometric pressure sensor GND
136 OS-MAINR ECM main relay signal
137 PG-CASE GND
138 - -
139 PS-MAFBAT Dropping resistor
140 IS-SWHI1 -
141 IS-DIAG Diagnostic switch signal
142 IS-MEMCL Memory clear switch signal
143 IS-DGSEL Diagnostic switch signal
144 IS-SWHI2 -
145 OS-GLOWL Glow light
146 OS-OPL2 -
OS-FI-
147 Fuel filter clogging light
PRESSL
148 OS-THLL Fuel temperature light
149 OS-DPDSL DPD light
150 OS-HOUR Hour meter relay
151 - -
152 OS-STARTR Starter cut relay
153 OS-GLOWR Glow relay
154 CC-CAN-H CAN-High

84512399 EN - September 2011

4001C-83
Copyright ©
Function, Structure, Operation

84512399 EN - September 2011

4001C-84
Copyright ©

Section

4001E

Symptom

84512399 EN - September 2011

CONTENTS

Frequent DPD regeneration by manual regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Long DPD regeneration time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine start failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine stalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine hunching, rough idling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Excessive white smoke in the exhaust gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Excessive black smoke in the exhaust gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Abnormal noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Large fuel consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Large oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Insufficient engine output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

4001E-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

4001E-2 PRINTED IN FRANCE
Copyright ©
Symptom

Frequent DPD regeneration by Inspect the hose and pipe of the exhaust differ-
ential pressure sensor for clogging, collapsing, or
manual regeneration twisting.
Inspect the exhaust differential pressure sensor
1. DPD system manual regeneration frequently de-
for incorrect installation.
scription of Symptom
Inspect the exhaust differential pressure sensor
The DPD manual regeneration indicator light comes
for damage.
on, and the manual regeneration is frequently re-
Inspect the exhaust differential pressure sensor
quested.
for contamination and foreign materials which in-
Or, it is requested more frequently than before.
terfere with its inlet.
ANNOTATION: Check the exhaust differential pressure sensor for
abnormalities and operation delay with the scan
• Automatic regeneration cannot be performed fre- tool data display exhaust differential pressure.
quently Check the exhaust temperature sensor at vari-
Depending on the manufacturer of the machine, ous temperatures, and inspect for the possibility
the indication may not be displayed. of sensor abnormalities.
2. DPD system manual regeneration frequently diag- Check the MAF sensor for abnormalities and op-
nostics eration delay with the scan tool data display MAF.
Check the boost pressure and atmospheric pres-
• Preliminary inspection sure when the starter switch is ON and the engine
Inspect the fuel quality. is not started.
Inspect the engine oil level and quality. It is normal if both data displays are within 7.0 kPa
Inspect whether the odometer is functioning prop- {0.07 kgf / cm2 / 1.0 psi}.
erly. • Inspection of the air intake system
If excessive amount of black smoke is observed, Inspect the air cleaner and air intake duct for clog-
inspect the black smoke. ging, holes, and leakage.
Inspect for excessive ash accumulation inside the Inspect whether a condition exists where the flow
DPD filter. in the turbocharger inlet duct is restricted.
Check the scan tool data list. Inspect the intake throttle valve for anchoring.
Check the service technical report. Inspect the inside of the intake manifold for clog-
Check the ECM carry part number. ging or air leaks.
Check operator's operating habits and conditions. Inspect the air intake system for modification.
Recommend the owner voluntarily carry out re- Inspect the MAF sensor for contamination and
generation as necessary. damage.
Check whether the idling time is too long under Inspect the turbocharger turbine wheel, shaft, or
normal operating conditions. compressor wheel for wear and damage.
Check whether operating at lower speed has • Inspection of the exhaust system
been frequent under normal operating conditions. Check for any condition that restricts the flow of
Check whether the vehicle runs on a long downhill the exhaust system.
under normal operating conditions. Check for absence or damage of the exhaust sys-
Check whether the idling time is too long in DPD tem gasket.
regeneration. Check for exhaust gas leak from exhaust pipe,
Check whether operating at lower speed has gasket, DPD, exhaust temperature sensor, or ex-
been frequent in DPD regeneration. haust differential pressure sensor hose or pipe.
Check whether PTO is activated frequently and Inspect the exhaust system for modification.
for a long period of time in DPD regeneration. Inspect for excessive ash accumulation inside the
Check whether the engine operating time is short DPD filter.
in DPD regeneration. Inspect the DPD filter for damages, cracks, melt
Check whether switching accelerator ON/OFF is or excessive accumulation.
frequent in DPD regeneration. Inspect the oxidation catalyst for damages,
• Inspection of the sensor cracks, melt or excessive accumulation.
Inspect the hose and pipe of the exhaust differen- If any excessive white smoke is observed in the
tial pressure sensor for incorrect piping or if they regeneration process, oxidation catalyst may be
came off. deteriorated or damaged.
{The hose of the exhaust differential pressure
sensor has a specified installation direction}

84512399 EN - September 2011

84512399 EN - September 2011

4001E-7
Copyright ©
Symptom

Engine hunching, rough idling Layout of the fuel filter, pre-filter, and electro-
magnetic pump constituting a structure that may
1. Engine hunching, rough idling description of Symp- cause air stagnant.
tom Isuzu genuine pre-filter has no air bleeding plug.
The engine has variable engine idling, or has Therefore, check whether it is placed so that no
change in idling revolution speed. air stagnant occurs.
In a severe case, the engine or the actual unit may Fuel leaks and damage or dents on pipes in the
vibrate. fuel system.
In either case, the engine stall may occur if the Abnormalities in intake system parts
symptom gets worse. Abnormalities in exhaust system parts
2. Engine hunching, rough idling diagnostics • Diagnostic aids
Abnormalities in the fuel system such as running
• Preliminary inspection
Before using this section, perform the functional out of fuel, fuel freezing, air intrusion in the fuel
inspection and the OBD system check to check piping, filter abnormalities, piping abnormalities,
all of the following items. poor fuel quality, and fuel tank abnormalities Ab-
The ECM and monitor are operating properly. normalities in the intake system such as clogging
DTC check. of the filter and intake piping abnormalities Sup-
The scan tool data is in the normal range of oper- ply pump abnormalities and fuel feeding without
ation values. pressure
Check the machine condition to locate the indi- Abnormalities in the input circuit system related to
cated symptom. switches
Check with the customer whether the customer is Abnormalities in the sensor input circuit system
using the specified engine oil and fuel. related to the accelerator position sensor, harness
and engine coolant temperature sensor
• Visual inspection
Careful visual inspection is required for certain Abnormalities in the accelerator position sensor
symptom procedures. system
This can lead to correcting a problem without fur- Abnormalities in the engine body including
ther inspections, saving valuable time. seizure, insufficient compression pressure, and
The inspection covers the following items. other mechanical failures
Dirt and clogging of the fuel filter. Failure related to equipment on the actual ma-
Poor connector connections. chine side such as the oil pressure pump
Low battery terminal voltage. Effect of the post-installed electronic components
Proper connections, tightening, and disconnec- such as wireless devices, lamps, etc.
tion of wiring. Poor connector connections, abnormalities in har-
Branching the ECM power source for the com- ness such as friction and bending, separation of a
mercial accessory power source. wire from the harness and short circuits with other
Whether the ECM ground is clean and securely circuits.
installed in the correct location. Perform inspections with functional diagnosis,
Cracks, and twists in the pipes and hoses re- and confirm the operation and control of each
lated to fuel, air, and oil, and correct connections part.
thereof. Repair if an abnormality is found.
Extensively check for any leaks or blockage.
Fuel leaks and damage or dents on pipes in the
fuel system.

84512399 EN - September 2011

4001E-8
Copyright ©
Symptom

Excessive white smoke in the Excessive black smoke in the

exhaust gas exhaust gas
1. Excessive white smoke in the exhaust gas descrip- 1. Excessive black smoke in the exhaust gas descrip-
tion of Symptom tion of Symptom
Excessive white smoke when driving. Excessive black smoke when driving.
2. Excessive white smoke in the exhaust gas diagnos- 2. Excessive black smoke in the exhaust gas diagnos-
tics tics
• Preliminary inspection • Preliminary inspection
Before using this section, perform the functional Before using this section, perform the functional
inspection and OBD system check to check all of inspection and OBD system check to check all of
the following. the following.
The ECM and monitor are operating correctly. The ECM and monitor are operating correctly.
DTC check. DTC check.
The scan tool data is within the normal operating The scan tool data is within the normal operating
range. range.
Check the condition of the machine, and locate Check the condition of the machine, and locate
the appropriate symptom. the appropriate symptom.
Check with the customers whether they are using Check with the customers whether they are using
the specified engine oil and fuel. the specified engine oil and fuel.
• Visual inspection • Visual inspection
Careful visual inspection is required for several Careful visual inspection is required for several
symptom procedures. symptom procedures.
This can lead to fixing a problem without further This can lead to fixing a problem without further
inspections, and can save valuable time. inspections, and can save valuable time.
The inspection includes the following. The inspection includes the following.
Whether there is an improper connection of injec- Whether there is grime or clogging in the air
tor connectors. cleaner element.
Proper wiring connections, tightening, and dis- Proper wiring connections, tightening, and dis-
connection. connection.
Whether the power source of any commercial ac- Whether the power source of any commercial ac-
cessories is being taken divergingly from the ECM cessories is being taken divergingly from the ECM
power source. power source.
Whether the ECM ground is free of dirt, etc. and Whether the ECM ground is free of dirt, etc. and
securely installed in the correct location. securely installed in the correct location.
Proper connections, cracks, and twists in the Proper connections, cracks, and twists in the
pipes and hoses related to fuel, air, and oil. pipes and hoses related to fuel, air, and oil.
Extensively check for any leaks or blockage. Extensively check for any leaks or blockage.
Whether there are any fuel leaks, pipe damage, Whether there are any fuel leaks, pipe damage,
or dents in the fuel system. or dents in the fuel system.
Abnormalities of the air intake system parts Abnormalities of the air intake system parts
Abnormalities of the exhaust system parts Abnormalities of the exhaust system parts
• Diagnostic aids • Diagnostic aids
Fuel quality when using a product with a low Fuel quality when using a product other than
cetane number or a product other than those those specified, etc.
specified Air intake system abnormalities such as filter clog-
Use of low-viscosity fuel such as kerosene may ging, air intake piping abnormalities, etc.
result in abnormal wear on the seat area of the Abnormalities of the EGR control system Abnor-
injector and cause abnormal spray and white malities of the exhaust system such as exhaust
smoke. pipe abnormalities, etc.
In such cases, replacement of the injector is re- Water temperature sensor malfunction
quired. Boost sensor failure
Since the replacement of the injector due to the Engine body failure such as insufficient compres-
use of low-viscosity fuel such as kerosene is at sion pressure, piston related failure, turbocharger
the customer's expense, instruct the customer not failure, and raised oil, etc.
to use low-viscosity fuel such as kerosene.
Idling for a long time
Failure of the engine coolant temperature sensor,
fuel temperature sensor, IAT sensor, boost sensor
failure, or barometric pressure sensor
Engine body failure such as insufficient compres-
sion pressure, piston related failure, turbocharger
failure, and raised oil or sucked down oil, etc.
ECM failure
84512399 EN - September 2011
4001E-9
Copyright ©
Symptom

Abnormal noise Large fuel consumption

1. Abnormal noise description of Symptom 1. Large fuel consumption description of Symptom
Engine combustion noise is abnormal. Fuel consumption is significantly larger than indi-
2. Abnormal noise diagnostics cated in the manual of the machine.
2. Large fuel consumption diagnostics
• Preliminary inspection
Before using this section, perform the functional • Preliminary inspection
inspection and OBD system check to check all of Before using this section, perform the functional
the following. inspection and the OBD system check to check
Refer to the manual of the machine and inspect all of the following items.
the abnormal noise. Confirm the guideline for fuel consumption (A)
The ECM and monitor are operating correctly. provided by the machine manufacturer because
DTC check. fuel consumption significantly varies depending
The scan tool data is within the normal operating on how the machine is operated.
range. Guideline for fuel consumption (L {qts}/hour)
Check the condition of the machine, and locate Check the actual fuel consumption (B).
the appropriate symptom. If the actual fuel consumption (L {qts}/hour)
Check with the customers whether they are using B is larger than A, refer to the machine instruction
the specified engine oil and fuel. manual to check the actual machine settings.
• Visual inspection Check the machine for excessive loads.
Careful visual inspection is required for several Refer to the inspection and maintenance list in the
symptom procedures. instruction manual to conduct inspections corre-
This can lead to fixing a problem without further sponding to operation time of the machine.
inspections, and can save valuable time. As for the machine with its operation time exceed-
The inspection includes the following. ing 3,000 hours, refer to the machine instruction
Proper wiring connections, tightening, and dis- manual to conduct inspection.
connection The ECM and monitor are operating properly.
Whether the ECM ground is free of dirt, etc. and DTC check.
securely installed in the correct location. Check the machine condition to locate the indi-
Proper connections, cracks, and twists in the cated symptom.
pipes and hoses related to fuel, air, and oil. Check with the customer whether the customer is
Extensively check for any leaks or blockage. using the specified engine oil and fuel.
Whether there are any fuel leaks, pipe damage, Check that periodic maintenance including engine
or dents in the fuel system. oil change, air cleaner filter, fuel filter, etc. has
Abnormalities of the air intake system parts been conducted.
Abnormalities of the exhaust system parts • Visual inspection
• Diagnostic aids Careful visual inspection is required for certain
Fuel system abnormalities such as fuel running symptom procedures.
out, fuel freezing, mixture of air into the fuel pip- This can lead to correcting a problem without fur-
ing, filter abnormalities, piping abnormalities, fuel ther inspections, saving valuable time.
quality, fuel tank, etc. The inspection covers the following items.
Air intake system abnormalities such as EGR Proper connections, tightening, and disconnec-
valve abnormalities, etc. tion of wiring.
Abnormalities of the injector, no fuel injection Whether the ECM ground is clean and securely
Engine body abnormalities such as seizure, insuf- installed in the correct location.
ficient compression pressure, and other mechan- Cracks, and twists in the pipes and hoses re-
ical failures, etc. lated to fuel, air, and oil, and correct connections
Failure related to the machine equipment such as thereof.
the oil pressure pump, etc. Extensively check for any leaks or blockage.
ECM failure Fuel leaks and damage or dents on pipes in the
Inspect the connector for connection failures and fuel system.
the harness for abnormalities such as abrasions, Abnormalities in intake system parts
bending, etc. Abnormalities in exhaust system parts
Inspect that the wires inside the harness are sepa- • Diagnostic aids
rate and have not caused a short circuit with other Abnormalities in the fuel system such as fuel out,
circuits. fuel freezing, air contained in the fuel piping, ab-
Perform inspections for functional diagnosis, and normalities in the filter, abnormalities in the piping,
confirm the operation, control of each part, etc. poor fuel quality, abnormalities in the fuel tank
Repair if abnormalities are found. Abnormalities in the intake system such as those
in the EGR valve, etc.
Abnormalities in the injector such as excessive
fuel injection

84512399 EN - September 2011

4001E-10
Copyright ©
Symptom

4001F-9
Copyright ©
Functional Inspection

Maintenance precautions

84512399 EN - September 2011

CONTENTS

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

4001G-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

4001G-2 PRINTED IN FRANCE
Copyright ©
Maintenance precautions

1. Maintenance precautions damaged due to foreign matter accidentally

intruded.
1) Precautions on maintenance
For this reason, extreme care must be taken
To prevent damaging the engine and to en- to prevent any foreign matter from entering.
sure the reliability of engine performance, When performing maintenance on the fuel
be careful of the following points when per- system, take extreme care to prevent any
forming engine maintenance. foreign matter from entering the system.

4004

Removal and Installation of Starter Motor

84512399 EN - September 2011

CONTENTS

Removal of Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

4004-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

4004-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Starter Motor

Job code 55201AE50 Removal of Starter Motor

1. Use a wrench (17 mm) to remove the bolt (1), and
WARNING then remove the battery cable (2) on the negative
side.
• Do not use open flames and do not allow
sparks near the battery. • When removing the terminal and harness, secure
them so that they do not interfere with the frame.
CAUTION Also, cover with a rubber cap to protect against
sparks.
• Be sure to stop the engine before beginning
work.

Items to prepare
• Wrenches (8 mm, 14 mm, 17 mm, 19 mm)
• Rag
• Cleaning fluid

2. Use a wrench (19 mm) to remove the 10 bolts (3),

and then remove the under cover (4).
Tightening torque for bolt installation: 63.7 - 73.5
N·m

3. Use a wrench (8 mm) to remove the nut (5), then

remove the wiring (6).

84512399 EN - September 2011

4004-3
Copyright ©
Removal and Installation of Starter Motor

4. Use a wrench (8 mm) to remove the bolt (7), and Installation of Starter Motor
then remove the wiring (8).
Tighten bolts and nuts to the specified torque.
For bolts for which the torque is not specified, see "Stan-
dard Torque Data for Cap Screws and Nuts".

5. Use a wrench (14 mm) to remove the bolt (10), and

then remove the wiring on the ground side (9).

6. Use a wrench (17 mm) to remove the 2 nuts (11),

then remove the starter motor (12).
Tightening torque for nut installation: 82.4 N·m

84512399 EN - September 2011

4004-4
Copyright ©

Section

4005

Removal and Installation of Alternator

84512399 EN - September 2011

CONTENTS

Removal of Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

4005-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

4005-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Alternator

WARNING Removal of Alternator

• Do not use open flames and do not allow 1. Remove the fan belt.(For details, see "Removal and
sparks near the battery. Installation of Fan Belt".)
2. Use a wrench (17 mm) to remove the bolt (1), and
then remove the battery cable (2) on the negative
CAUTION side.
• Be sure to stop the engine before beginning • When removing the terminal and harness, secure
work. them so that they do not interfere with the frame.
• Also, cover with a rubber cap to protect against
Items to prepare sparks.
• Wrenches (10 mm, 17 mm, 20 mm)
• Rag
• Cleaning fluid

3. Remove the connector (1).

4. Remove the cap (1), use the wrench (10 mm) to

remove the nut (2), and then remove the wiring (3).

84512399 EN - September 2011

4005-3
Copyright ©
Removal and Installation of Alternator

5. Use a wrench (20 mm) to remove the bolt (1), and Installation of Alternator
then remove the alternator (2).
Tightening torque for bolt installation：40 N•m To install, perform the reverse of the removal procedure.

84512399 EN - September 2011

4005-4
Copyright ©

Section

4008

Preheating System

84512399 EN - September 2011

CONTENTS

Removal and Installation of Glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Glow plug Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Glow plug Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Glow plug Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

4008-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

4008-2 PRINTED IN FRANCE
Copyright ©
Preheating System

Removal and Installation of Glow 4) Remove the water return pipe from the EGR
cooler.
plug
Glow plug Removal
1. Battery ground cable disconnect
1) Disengage the battery ground cable from the
battery.
2. Coolant drain

WARNING
• Do not loosen the radiator cap when the
coolant is hot.
• Steam and boiling water may burst out
and cause burns, so make sure that the
engine has cooled off.
1 EGR cooler water hose
1) Drain the coolant from the radiator. 2 Water return pipe
3 Air leak pipe
CAUTION
5) Remove the EGR cooler A from the EGR
• After draining the coolant, tighten cooler duct A and the EGR cooler D.
the drain plug. 6) Remove the EGR cooler B from the EGR
cooler duct B and the EGR cooler C.
2) Drain the coolant from the engine assembly. 7) Remove the EGR cooler duct A from the ex-
ANNOTATION: haust manifold and the bracket.
8) Remove the EGR cooler duct B from the ex-
• Loosen the drain plug on the cylinder block haust manifold and the bracket.
side. 9) Remove the bracket from the cylinder head.
10) Remove the EGR cooler D from the EGR
valve duct.
11) Remove the EGR cooler C from the EGR
valve duct.
12) Remove the EGR valve duct from the EGR
valve.

1 Drain plug

3. EGR cooler removal

1) Disconnect the air leak pipe from the engine
assembly.
2) Disconnect the water charge pipe from the 1 EGR cooler duct B
EGR cooler duct.
2 EGR cooler B
3) Disconnect the EGR cooler water hose from
the EGR cooler. 3 EGR cooler C
4 EGR valve duct
5 EGR cooler D
6 EGR cooler A
7 EGR cooler duct A

4. Ventilation hose removal

1) Disconnect the ventilation hose from the cylin-
der head cover.
84512399 EN - September 2011
4008-3
Copyright ©
Preheating System

2) Disconnect the ventilation hose from the air Glow plug Installation
duct.
1. Glow plug installation
5. Glow plug removal
1) Install the glow plug to the cylinder head as-
1) Remove the glow plug connector from the sembly.
glow plug. Tightening torque： 20 N・m {2.0 kgf・m / 15
2) Remove the glow plug from the cylinder head lb・ft}
assembly. 2) Install the glow plug connector to the glow
plug.
2. Ventilation hose installation
1) Connect the ventilation hose to the air duct.
2) Connect the ventilation hose to the cylinder
head cover.
3. EGR cooler installation
1) Temporarily tighten the EGR valve duct to the
EGR valve.
ANNOTATION:
• Temporarily tighten with the gasket inserted.
Temporary tightening torque: 5 N ・ m {0.5
kgf・m / 44 lb・in}

2) Install the bracket to the cylinder head.

Tightening torque： 97 N・m {9.9 kgf・m / 72
lb・ft} Engine front side
Tightening torque： 44 N・m {4.5 kgf・m / 32
lb・ft} Engine rear side

Engine front side EGR cooler

1
bracket
Engine rear side EGR cooler
2
bracket

84512399 EN - September 2011

4008-4
Copyright ©
Preheating System

3) Temporarily tighten the EGR cooler to the 6) Temporarily tighten the EGR cooler to the
EGR valve duct. EGR duct.
ANNOTATION: ANNOTATION:
• Temporarily tighten with the gasket inserted. • Temporarily tighten with the gasket inserted.
• Install the air removal pipe faicing it towards • Refer to the diagram for the direction of the
the front side. water pipe.
Temporary tightening torque： 5 N・m {0.5
kgf・m / 44 lb・in}

1 EGR cooler B
1 EGR cooler D 2 EGR cooler A
2 EGR valve duct 3 EGR duct A
3 EGR cooler C 4 EGR duct B

4) Install the bracket to the cylinder head.

Tightening torque： 97 N・m {9.9 kgf・m / 72 ANNOTATION:
lb・ft} Engine front side • Procedure for complete tightening
ANNOTATION:
CAUTION
• The rear side bracket should be tightened
together with the exhaust manifold. • Make sure to follow the installation
procedure.

Otherwise, a gas leak or excessive stress may

84512399 EN - September 2011

4008-5
Copyright ©
Preheating System

10) Temporarily tighten the EGR duct to the ex- 13) Securely tighten the EGR cooler to the EGR
haust manifold. cooler bracket.
Tightening torque： 50 N・m {5.1 kgf・m / 37 Tightening torque： 50 N・m {5.1 kgf・m / 37
lb・ft} 4 in the diagram lb・ft} 7 in the diagram
11) Securely tighten the EGR valve duct to the 14) Completely tighten the EGR duct to the
EGR valve. bracket.
Tightening torque： 44 N・m {4.5 kgf・m / 32 Tightening torque： 50 N・m {5.1 kgf・m / 37
lb・ft} 5 in the diagram lb・ft} 8 in the diagram
12) Securely tighten the EGR valve duct to the
EGR mixing chamber.
Tightening torque： 44 N・m {4.5 kgf・m / 32
lb・ft} 6 in the diagram

15) Install the water return pipe to the EGR cooler. 18) Install the air leak pipe to the engine assembly.
16) Install EGR cooler water hose to EGR cooler.
17) Install the water charge pipe to the EGR duct.

1 EGR cooler water pipe

2 Water return pipe
3 Air leak pipe

4. Coolant filling
84512399 EN - September 2011
4008-6
Copyright ©
Preheating System

1) Replenish the coolant with the radiator. Glow plug Inspection

2) Loosen the plug using the wrench.
3) Replenish the coolant with the radiator. 1. Glow plug inspection
1) Measure the resistance using the circuit
CAUTION tester.
• Be careful not to let coolant over- Values： about 4.3 Ω At room temperature
flow splash on the exhaust system
parts. CAUTION
• Coolant overflow should be wiped • If the value is not within the stan-
off. dard value, replace the glow plug.
• Use a set of 6 glow plugs from the
4) Tighten the plug using the wrench. same manufacturer.
ANNOTATION:
• Apply Loctite 271.
Tightening torque： 15 N・m {1.5 kgf・m / 11
lb・ft}
5) Replenish the coolant with the radiator.

1 Plug

5. Battery ground cable connect

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

84512399 EN - September 2011

4008-7
Copyright ©
Preheating System

84512399 EN - September 2011

4008-8
Copyright ©

Section

4020A

Electrical Equipment Layout Diagram

84512399 EN - September 2011

CONTENTS

Electrical Equipment Layout Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Main Unit Left Side Layout Diagram (radiator chamber) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine Section Layout Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Main Unit Right Side Layout Diagram (pump chamber) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Main Unit Center Section Layout Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cab Layout Diagram 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cab Layout Diagram 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Layout Around Operator Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Stand Alone Parts Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

4020A-1 PRINTED IN FRANCE
Copyright ©

4020A-7
Copyright ©
Electrical Equipment Layout Diagram

Main Unit Right Side Layout Diagram (pump chamber)

84512399 EN - September 2011

4020A-8
Copyright ©
Electrical Equipment Layout Diagram

1 Flow control proportional valve 5 5 Stack Solenoid Valve 9 Swing brake

Removal and Installation of
2 N2 pressure sensor 6 10 Lever lock
Counterweight
3 Oil temperature sensor 7 2-stage relief
4 Charge fuel pump 8 2-stage travel

84512399 EN - September 2011

4020A-9
Copyright ©
Electrical Equipment Layout Diagram

Main Unit Center Section Layout Diagram

Name Shape Circuit Remarks

Sumitomo
Vacuum sen-
part No. ；
sor
KHH10330

Isuzu part
Glow plug No. ； 894390-
7775

EGR valve ac-

cessory
EGR motor
EGR valve
EGR position
Isuzu part
sensor
No. ； 898001-
1910

Common rail
accessory
Common rail
Common rail
pressure sen-
Isuzu part
sor
No. ； 897306-
0632

84512399 EN - September 2011

4020A-22
Copyright ©
Electrical Equipment Layout Diagram

Name Shape Circuit Remarks

Isuzu part
Cam angle
No. ； 898014-
sensor
8310

Isuzu part
Crank angle
No. ； 897306-
sensor
1131

Isuzu part
Oil pressure
No. ； 897600-
sensor
4340

Isuzu part
Boost pressure
No. ； 180220-
sensor
0140

Isuzu part
Boost temper-
No. ； 81246-
ature sensor
8300

84512399 EN - September 2011

4020A-23
Copyright ©
Electrical Equipment Layout Diagram

Name Shape Circuit Remarks

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

2 stack sole- Sumitomo

noid valve part No. ；
(pedal type) KHJ14000

P1 flow control Sumitomo

proportional part No. ；
valve LJ016060

Horsepower
Sumitomo part
control propor-
No.；LJ00684
tional valve

Sumitomo
Free swing
part No. ；
switch
KHR16140

84512399 EN - September 2011

84512399 EN - September 2011

4020A-32
Copyright ©
Electrical Equipment Layout Diagram

Name Shape Circuit Remarks

Sumitomo
Air conditioner
part No. ；
unit
KHR27160

Limit switch Sumitomo

(front window) part No. ；
(door) KHN26000

Sumitomo
Wiper con-
part No. ；
troller
KHN3392

Sumitomo
Wiper motor part No. ；
KHN25780

84512399 EN - September 2011

4020A-33
Copyright ©
Electrical Equipment Layout Diagram

Name Shape Circuit Remarks

Sumitomo
Solar radiation
part No. ；
sensor
KHR10540

Sumitomo
Receiver dryer
part No. ；
(switch)
KHR13590

Air conditioner
Sumitomo
compressor
part No. ；
(magnetic
KHR3197
clutch)

Motor actuator
(air mix)
(mode) (inside/
outside air)

EVA sensor

84512399 EN - September 2011

4020A-34
Copyright ©
Electrical Equipment Layout Diagram

Name Shape Circuit Remarks

Interior tem-
perature sen-
sor

Relay
(compressor)
(blower OFF)

Blower motor

Blower amp

84512399 EN - September 2011

4020A-35
Copyright ©
Electrical Equipment Layout Diagram

Name Shape Circuit Remarks

Sumitomo
Air conditioner
part No. ；
switch panel
KHR27250

Sumitomo
Travel alarm
part No. ；
switch
KHR15850

Sumitomo
Horn volume
part No. ；
switch
KHR28540

Engine emer- Sumitomo

gency stop part No. ；
switch KHR28530

84512399 EN - September 2011

4020A-36
Copyright ©
Electrical Equipment Layout Diagram

Name Shape Circuit Remarks

3 stack propor-
tional valve Sumitomo
(boom up, part No.;
arm in, bucket KHJ23870
close)

Fuel filter sen- Sumitomo

sor part No.;
(Isuzu) KHH13230

DPD exhaust
Isuzu part No.;
gas pressure
897360-3682
differential
Sumitomo
pressure sen-
part No.;
sor
KHH13330
(Isuzu)

Isuzu part No.;

DPD tempera-
898004-3300
ture sensor
Sumitomo
(Isuzu) (cen-
part No.;
ter)
KHH13360

Isuzu part No.;

DPD tempera-
898004-3290
ture sensor
Sumitomo
(Isuzu)
part No.;
(front)
KHH13350

84512399 EN - September 2011

4020A-37
Copyright ©
Electrical Equipment Layout Diagram

Name Shape Circuit Remarks

Isuzu part No.;

Turbo com- 898077-1181
puter Sumitomo
(Isuzu) part No.;
KBH13650

EGR manifold Isuzu part No.;

temperature -
sensor Sumitomo part
(Isuzu) No.; -

Sumitomo part
VGS TURBO
No.; -

84512399 EN - September 2011

4020A-38
Copyright ©

Section

4020B

Connection Connector Pin Layout

84512399 EN - September 2011

CONTENTS

Computer A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

4020B-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

4020B-2 PRINTED IN FRANCE
Copyright ©
Connection Connector Pin Layout

Computer A

4020C-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

4020C-2 PRINTED IN FRANCE
Copyright ©
Sequence Circuit Diagram

84512399 EN - September 2011

4020C-8
Copyright ©
Sequence Circuit Diagram

ECM

84512399 EN - September 2011

4020C-9
Copyright ©
Sequence Circuit Diagram

Monitor

84512399 EN - September 2011

4020C-10
Copyright ©
Sequence Circuit Diagram

Air Conditioner

84512399 EN - September 2011

4020C-11
Copyright ©
Sequence Circuit Diagram

Lever Lock

Horn

84512399 EN - September 2011

4020C-12
Copyright ©
Sequence Circuit Diagram

Working lights

84512399 EN - September 2011

4020C-13
Copyright ©
Sequence Circuit Diagram

Option

84512399 EN - September 2011

4020C-14
Copyright ©
Sequence Circuit Diagram

Other

84512399 EN - September 2011

4020C-15
Copyright ©
Sequence Circuit Diagram

Electrical Symbol List

Symbol Name Symbol Name

Fuse Variable solenoid valve

Diode Resistor

LED Variable resistor

Toggle switch "a" contact Variable resistor

Push switch "a" contact Alarm

Limit switch "a" contact Buzzer

Limit switch "b" contact Horn

Relay coil Motor

Relay contact "a" contact Solar radiation sensor

84512399 EN - September 2011

4020C-16
Copyright ©
Sequence Circuit Diagram

Symbol Name Symbol Name

Relay contact "b" contact Speaker

Solenoid valve Lamp

84512399 EN - September 2011

4020C-17
Copyright ©
Sequence Circuit Diagram

84512399 EN - September 2011

4020C-18
Copyright ©

Section

4021

Engine-side DTC List

84512399 EN - September 2011

CONTENTS

Engine-side DTC List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

4021-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

4021-2 PRINTED IN FRANCE
Copyright ©
Engine-side DTC List

Engine-side DTC List

DTC code Description
P0016 Abnormally correlation between crankshaft position and camshaft position
P0045 Turbocharger boost pressure control system abnormality
P0087 Fuel rail system pressure low pressure error
P0088 Fuel rail system pressure high pressure error
P0089 Fuel rail pressure regulator characteristics error
P0091 Fuel rail pressure regulator control system low input
P0092 Fuel rail pressure regulator control system high input
P0093 Fuel system leak detection
P0102 Mass air flow sensor system law input
P0103 Mass air flow sensor system high input
P0112 Intake temperature sensor system low input
P0113 Intake temperature sensor system high input
P0117 Engine coolant temperature sensor system low input
P0118 Engine coolant temperature sensor system high input
P0122 Throttle sensor system low input
P0123 Throttle sensor system high input
P0182 Fuel temperature sensor system low input
P0183 Fuel temperature sensor system high input
P0192 Fuel rail pressure sensor system low input
P0193 Fuel rail pressure sensor system high input
P0201 Injector first cylinder system error
P0202 Injector second cylinder system error
P0203 Injector third cylinder system error
P0204 Injector fourth cylinder system error
P0205 Injector fifth cylinder system error
P0206 Injector sixth cylinder system error
P0217 Engine coolant high temperature error
P0219 Engine high rpm error
P0234 Turbocharger high boost pressure state
P0299 Turbocharger low boost pressure state
P0237 Boost sensor circuit low input
P0238 Boost sensor circuit high input
P0335 Crankshaft position sensor system error
P0336 Crankshaft position sensor system characteristics error
P0340 Camshaft position sensor system error
P0341 Camshaft position sensor characteristics error
P0404 EGR1 control system error
P0409 EGR1 position sensor system error
P041C IMT sensor system high input
P041D IMT sensor system low input
P0426 Pre-filtered exhaust gas high temperature error
P0427 Exhaust temperature sensor 1 system low input
P0428 Exhaust temperature sensor 1 system high input
P042B Exhaust gas high temperature error before oxidation catalyst
P042C Exhaust temperature sensor 2 system low input
P042D Exhaust temperature sensor 2 system high input
P0522 Oil pressure sensor system low input
P0523 Oil pressure sensor system high input
P0560 System voltage error
P0563 System voltage high input
P0601 Control module memory checksum error
P0602 Control module program error
P0604 Control module RAM error
P0606 Control module processing device error
P060B Control module A/D converter processing system characteristics error
P0638 Throttle actuator control system characteristics error
84512399 EN - September 2011
4021-3
Copyright ©
Engine-side DTC List

DTC code Description

P0641 Sensor voltage system error
P0650 MIL control system error
P0651 Sensor voltage system error
P0685 ECM main relay control system low input
P0687 ECM main relay control system high input
P0697 Sensor voltage system error
P1093 Fuel rail pressure low pressure error
P1112 Boost temperature sensor system low input
P1113 Boost temperature sensor system high input
P1261 Injector group 1 voltage control system error
P1262 Injector group 2 voltage control system error
P1293 Fuel filter pressure sensor system low input
P1294 Fuel filter pressure sensor system high input
P1404 EGR close position characteristics error
P1455 DPD restriction 2
P1471 DPD regeneration error
P1621 Control module EEPROM error
P1655 Sensor voltage system error
P1669 DPD light control system error
P2122 Pedal position sensor 1 system low input
P2123 Pedal position sensor 1 system high input
P2127 Pedal position sensor 2 system low input
P2128 Pedal position sensor 2 system high input
P2146 Injector group 1 supplied voltage system error
P2149 Injector group 2 supplied voltage system error
P2228 Atmospheric pressure sensor system low input
P2229 Atmospheric pressure sensor system high input
P242F DPD restriction
P2452 DPD differential pressure sensor system error
P2453 DPD differential pressure sensor system characteristics error
P2454 DPD differential pressure sensor system low input
P2455 DPD differential pressure sensor system high input
P2456 DPD differential pressure sensor learning position error
P2458 DPD regeneration time error
U0001 CAN bus communication error
U0073 Control module communication error
U0101 TCM communication error
U0110 Turbocharger control module communication error
U0411 Turbocharger control module signal error

84512399 EN - September 2011

4021-4
Copyright ©

Section

4022

Main Unit-side DTC List

84512399 EN - September 2011

CONTENTS

Main Unit-side DTC List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

4022-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

4022-2 PRINTED IN FRANCE
Copyright ©
Main Unit-side DTC List

Main Unit-side DTC List

DTC Trouble mode

7000 P1 Pressure Sensor Signal Abnormality
7001 P2 Pressure Sensor Signal Abnormality
7002 N1 Pressure Sensor Signal Abnormality
7003 N2 Pressure Sensor Signal Abnormality
7004 Overload Pressure Sensor Signal Abnormality
7005 Bottom Pressure Sensor Signal Abnormality
7006 Rod Pressure Sensor Signal Abnormality
7020 Upper Pressure Sensor Signal Abnormality
7021 Swing Pressure Sensor Signal Abnormality
7022 Travel Pressure Sensor Signal Abnormality
7023 Arm-in Pressure Sensor Signal Abnormality
7040 Fuel Level Sensor Signal Abnormality
7041 Oil Temperature Sensor Signal Abnormality
7045 Monitor Thermistor Signal Abnormality
7060 Boom Angle Sensor Signal Abnormality
7061 Arm Angle Sensor Signal Abnormality
7063 Return Filter Clogging Pressure Switch Signal Abnormality
7065 Boom-up Pilot Pressure Sensor Signal Abnormality
7066 Bucket-close Pilot Pressure Sensor Signal Abnormality
7200 Swing Brake Solenoid Signal Abnormality
7201 Travel High-speed Solenoid Signal Abnormality
7202 Pressure Boost Solenoid Signal Abnormality
7203 Travel Alarm Buzzer Signal Abnormality
7204 Power Save Solenoid Signal Abnormality
7205 Feed Pump Relay Signal Abnormality
7206 Option Line Switchover Solenoid Signal Abnormality
7207 Free Swing Solenoid Signal Abnormality
7210 Liftcrane Buzzer Signal Abnormality
7211 Rotating Light Relay and Bucket Lock Signal Abnormality
7240 Pump Horsepower Proportional Valve Signal Abnormality
7241 P1 Flow Control Proportional Valve Signal Abnormality
7242 Fan Proportional Valve Signal Abnormality
7246 2 Pumps Flow Solenoid Signal Abnormality
7247 Boom-down Proportional Valve Signal Abnormality
7248 Arm-in Proportional Valve Signal Abnormality
7250 Option Relief Pressure Proportional Valve Signal Abnormality
7251 Battery Control Relay Signal Abnormality
7252 Idle Stop Relay Signal Abnormality
7253 DPD Regeneration Request Output Signal Abnormality
7400 Abnormally High Coolant Temperature (105℃ or higher)
7401 Abnormally High Coolant Temperature (110℃ or higher)
7402 Abnormally High Coolant Temperature (120℃ or higher)
7404 Abnormally High Oil Temperature (95℃ or higher)
7405 Boost temperature is abnormally high ( 80 ℃ or more )
7406 Boost temperature is abnormally high ( 90 ℃ or more)
7420 Abnormally Low Alternator Voltage
7421 Coolant Level Reduction
7422 Abnormally Low Engine Oil Pressure
7423 Air Cleaner Clogging
7424 Return Filter Clogging (breaker specifications)
7425 Fuel Density Error Signal Abnormality
7600 CAN Bus Abnormality
7601 Monitor Communication Abnormality
7602 ECM Communication Abnormality
7603 Computer B Communication Abnormality
84512399 EN - September 2011
4022-3
Copyright ©
Main Unit-side DTC List

DTC Trouble mode

7605 ECM Mismatch
7606 EEPROM Data Abnormality
7607 Computer C Communication Abnormality

84512399 EN - September 2011

4022-4
Copyright ©

Section

1 ON 3 Tens digit *5 Hundreds digit

*2 Goes off *4 Units digit

t1 Approx. 0.3 sec t3 Approx. 1.2 sec

t2 Approx. 0.6 sec t4 Approx. 2.4 sec

DTC indicated by monitor blinking display Check the customer complaint by compar-
The current and past DTCs are both dis- ing to another machine that is operating
played while the engine is being stopped. properly.
While the engine is in operation, the light is However, depending on the condition, it
turned on only when a current DTC exists. may be an intermittent.
Using the trouble display monitor to read the Before returning the machine, check the
DTC complaint under the conditions given by the
When a DTC occurs, the DTC can be dis- customer.
played on the trouble display monitor of the Reinvestigate the complaint.
machine. If you cannot adequately detect or confirm
Using the scan tool to read the DTC the complaint, it is necessary to perform
The DTC can be read using the trouble di- the diagnosis again, and reconfirm the com-
agnosis scan tool. plaint.
As stated above in "Intermittent", the com-
ANNOTATION:
plaint may be an intermittent or normal con-
• For the work procedure, refer to the man- dition.
ual of the trouble diagnosis scan tool. Repair and confirm.
Perform the repair when the cause has been
When the DTC is recorded confirmed.
Perform repairs accurately according to the Confirm that the vehicle is operating cor-
specified DTC chart. rectly, and that the symptom has been cor-
When no DTC is present rected.
Select a symptom from diagnosis by symp- This includes the confirmation test per-
tom. formed on the machine or other methods
Complete the repair according to the diag- to confirm that the complaint has been re-
nostic procedure. solved.
It is also possible to perform the inspection Confirm by testing under the conditions
by referring to the functional diagnosis. given by the customer.
When an appropriate symptom is not found When a DTC is diagnosed, confirm that the
Examine the complaint in detail. failure has been repaired by reproducing the
Create a diagnosis plan. condition that appeared when the DTC was
Utilize the schematics and operation princi- set while checking the scan tool data.
ples.
If you can obtain repair history for similar 7) Check after repair
cases, request technical assistance.
Check repair on actual machine
Combine technical knowledge and effective
When an repair has been performed for the
utilization of available service information.
electronic control system, it is necessary to
Intermittent
confirm that the repair is appropriate after
A failure condition that does not necessar-
repairing the actual machine.
ily always appear is referred to as "intermit-
If this check is not adequate, the monitor
tent".
may turn on again while returning the actual
Check the DTC information and the data
unit to the customer, or drivability problems
display.
may occur.
Evaluate the symptoms and conditions re-
For intermittents in particular, it is neces-
ported by the customer.
sary to perform the check by reproducing
Use a check sheet or other method to con-
the conditions of the customer complaint.
firm the circuit or electronic system compo-
Confirmation of machine repairs
nents.
It is effective to use the OBD system check
When no trouble is detected
for confirming machine repairs.
This status indicates that the machine is de-
After the repair is completed, the person
termined as operating properly.
who performed the machine diagnosis
The condition given by the customer may be
should review either the DTC that was diag-
normal.
nosed or scan tool data, or both, and record
it.
Clear the DTC.
84512399 EN - September 2011
4023B-8
Copyright ©
Introduction to the trouble diagnosis

Operate the machine based on the scan tool The implementation of these steps is ex-
data. tremely important when checking the repair
Check the DTC status information of the status with the OBD system check.
specific DTC that was diagnosed until the Neglecting to implement these steps may
diagnosis tests related to that DTC are per- result in unnecessary repairs.
formed by the control unit.
8) Final check item list

No. Item Purpose Method

Clear the previous DTCs.
Keep the engine idling to sufficiently warm it up,
1 DTC check Checking the DTC display after repair then perform a racing operation with the engine
rpm raised up to the No Load Max., and secure
the test conditions.
Confirm that the idling speed after warming up
Idling speed
To check whether the idling control is op- the engine is constant with no load applied.
2 check after warm-
erating normally. If a problem is detected, refer to Idling Unstable
ing up the engine
in Diagnosis by Symptom.
Monitor the scan tool data list, and check the
Check whether the engine control and
Confirm the scan values using the typical value sheet.
3 communication status are normal or ab-
tool data list. Check the typical values of the scan tool data
normal during the normal state.
list.
After warming up the engine, confirm that the
Re-startability To check whether the starting control is cranking time is 5 seconds or less when restart-
4
check normal. ing the vehicle, and that the engine revolution is
stable after starting.
Check whether turning electromagnetic trans-
When electromagnetic transmitters such mitters such as a transceiver ON and OFF
Check powerful
as a transceiver have been added to the cause the idling engine rpm to change.
5 electromagnetic
vehicle, confirm that no interfering waves If you discover a problem, let the customer know
transmitters
are being emitted. that they need to change the installation location
and output of the electromagnetic transmitter.

Supplementary information regarding the CAUTION

check for powerful electromagnetic transmit-
ters • Follow the steps when performing
If a problem is found with this item, notify the the OBD system checks to confirm
customer as necessary. the repair.
• Failure to follow these steps may
• Install antennas to a position distant from result in performing unnecessary
electronic control systems on the machine repair works.
such as the control unit sensor.
• Review the scan tool data relating
• Install antenna cords at least 20 cm away to the DTC that was diagnosed and
from the electronic systems on the machine, make a record.
such as the control unit sensor.
• Clear the DTC.
• Do not wire other cables together with an- • Operate the machine while check-
tenna cords. ing the related scan tool data.
Also, place antenna cords as far away from
other wiring as possible.
9) DTC clearing method
• Make sure to install retrofitted equipment in
accordance with each installation manual. Clearing DTC
• Do not install high-output mobile communi- If an error occurs in the system and the
cation devices. DTC is recorded in the ECM, that DTC is
not deleted from the memory even when
the malfunctioning part is repaired, so use
the following measures to execute a forced
deletion.
Using the scan tool to delete the DTC
If the trouble diagnosis scan tool is con-
nected, you can delete codes by performing
turning off of the trouble diagnosis scan tool.
Clearing by ECM
A DTC recorded in the ECM is erased if
the same DTC has not been satisfied for 40
consecutive ignition cycles.
84512399 EN - September 2011
4023B-9
Copyright ©
Introduction to the trouble diagnosis

Trouble diagnosis scan tool Engine replacement mode

This tool is effective for diagnosing electri- This should be used when changing back
cal failures in the engine control system and to the old ECM part number which requires
performing system checks. hardware changes such as addition of ma-
If you connect the SAE 16/19 adapter to chine wiring is performed along with engine
the DLC installed in the machine, it per- replacement, etc.
forms communication with the control units ECM replacement
of the machine, and enables various diag- When replacing the ECM within the same
noses and tests to be performed. model, data can be uploaded from the cur-
Functions of the trouble diagnosis scan tool. rent ECM to a failure diagnosis scan tool
Data display and then downloaded to the new ECM af-
Snapshot ter replacement.
Programming Factory shipment settings
Actuator test Based on the engine serial number, data
such as ECM injector QR code can be
CAUTION downloaded to ECM.
Actuator test
• When conditions such as the The injector test, fuel injection test, rail pres-
running state of the machine or
sure test, glow plug test, and EGR control
the engine, water temperature,
test are performed to inspect the operation
switches and gear position are
and function of each target component.
not met, or when a DTC has been
detected, each test may possibly CAUTION
not operate.
• When conditions such as the
ECM reflash running state of the machine or
The ECM can be updated by overwriting the the engine, water temperature,
control program using the most up-to-date switches and gear position are
control data issued every 3 months. not met, or when a DTC has been
Normal reflash detected, each test may possibly
The ECM is reflashed by automatically not operate.
searching for the ECM part number com-
patible with the part number currently re- HTML manual display
flashed. Links with DTC to display the manual along
Forced reflash with the failure diagnosis procedure.
The ECM is reflashed by specifying an arbi- Reading saved data
trary ECM part number. Read in the saved snapshot data to display
In this case, a password dedicated for reproduction.
forced reflash is necessary.
Campaign reflash CAUTION
The ECM is reflashed by selecting the part
number during a campaign carried out by • When using the trouble diagnosis
scan tool, refer to the separate in-
the manufacturer.
struction manual for the trouble
Rewriting the injector QR code
diagnosis scan tool.
The injector QR code that is required when
replacing the injector can be rewritten.
This allows fuel compensation to be per-
formed on each injector to optimize the en-
gine condition.

84512399 EN - September 2011

4023B-10
Copyright ©

Section

4023D

Engine Control System

84512399 EN - September 2011

CONTENTS

Removal and Installation of Fuel filter pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Fuel filter pressure sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel filter pressure sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal and Installation of Engine coolant temperature sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine coolant temperature sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine coolant temperature sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine coolant temperature sensor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal and Installation of CKP sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CKP sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CKP sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CKP sensor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal and Installation of CMP sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CMP sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CMP sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CMP sensor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal and Installation of Oil pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Oil pressure sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Oil pressure sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal and Installation of Boost sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Boost sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Boost sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal and Installation of Boost temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Boost temperature sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Boost temperature sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal and Installation of IMT sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
IMT sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
IMT sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal and Installation of Exhaust differential pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Exhaust differential pressure sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Exhaust differential pressure sensor Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Exhaust differential pressure sensor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal and Installation of Exhaust gas temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Exhaust gas temperature sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Exhaust gas temperature sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Exhaust gas temperature sensor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

4023D-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

4023D-2 PRINTED IN FRANCE
Copyright ©
Engine Control System

Removal and Installation of Fuel Fuel filter pressure sensor Installation

filter pressure sensor 1. Fuel filter pressure sensor installation
1) Install the fuel filter pressure sensor to the fuel
Fuel filter pressure sensor Removal filter.
1. Fuel filter pressure sensor removal
CAUTION
1) Disengage the harness connector from the
fuel filter pressure sensor. • After cleaning the threaded portion
2) Remove the fuel filter pressure sensor from of the fuel filter body, install it.
the fuel filter.
Tightening torque: 24 N・m {2.4 kgf・m / 18
lb・ft}

1 Fuel filter pressure sensor

2) Start the engine.

ANNOTATION:
• Check that there is no fuel leaks.
• Confirm that DTC has not been detected.

84512399 EN - September 2011

4023D-3
Copyright ©
Engine Control System

Removal and Installation of Engine 2) Remove the engine coolant temperature sen-
sor from the thermostat housing.
coolant temperature sensor
Engine coolant temperature sensor
Removal
1. Battery ground cable disconnect
1) Disengage the battery ground cable from the
battery.
2. Coolant drain

WARNING
• Do not loosen the radiator cap when the
coolant is hot.
• Steam and boiling water may burst out
and cause burns, so make sure that the
engine has cooled off. 1 Thermostat housing
Engine coolant temperature
2
1) Drain the coolant from the radiator. sensor

CAUTION
• After draining the coolant, tighten
the drain plug.

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

84512399 EN - September 2011

4023D-10
Copyright ©
Engine Control System

Boost temperature sensor Installation Removal and Installation of IMT

1. Boost temperature sensor installation sensor
1) Install the boost temperature sensor to the in-
let duct. IMT sensor Removal
Tightening torque: 14 N・m {1.4 kgf・m / 120 1. IMT sensor removal
lb・in}
2) Connect the harness connector to the boost 1) Disconnect the harness connector from the
temperature sensor. IMT sensor.
2) Remove the IMT sensor from the inlet cover.

1 Inlet duct 1 Inlet duct

2 IMT sensor 2 IMT sensor
3 Boost temperature sensor 3 Boost temperature sensor

84512399 EN - September 2011

4023D-11
Copyright ©
Engine Control System

IMT sensor Installation Removal and Installation of

1. IMT sensor installation Exhaust differential pressure
1) Install the IMT sensor to the inlet cover. sensor
Tightening torque: 20 N・m {2.0 kgf・m / 14
lb・ft} Exhaust differential pressure sensor
2) Connect the harness connector to the IMT
sensor. Removal
1. Battery ground cable disconnect
1) Disengage the battery ground cable from the
battery.
2. Exhaust differential pressure sensor safety Informa-
tion

CAUTION
• Do not use a tool which causes vibra-
tions such as an impact wrench when in-
stalling and removing the exhaust differ-
ential pressure sensor.
• Do not reuse the exhaust differential
pressure sensor which has been sub-
jected to shock such as being dropped.
1 Inlet duct • Install or remove the exhaust differen-
2 IMT sensor tial pressure sensor together with the
3 Boost temperature sensor bracket.
• Be sure not to loosen the 4 screws in-
stalled on the exhaust differential pres-
sure sensor.
• Replace the exhaust differential pres-
sure sensorif the 4 screws installed on
the DPD differential pressure sensor
have been loosened.

1 Screw

3. Exhaust differential pressure sensor removal

CAUTION
• Before performing work, be sure to
check the exhaust differential pressure
sensor precautions.

1) Disengage the differential pressure hose from

the exhaust differential pressure sensor.
2) Disengage the harness connector from the
exhaust differential pressure sensor.
84512399 EN - September 2011
4023D-12
Copyright ©
Engine Control System

3) Remove the exhaust differential pressure sen- Exhaust differential pressure sensor
sor from the DPD assembly. Installation
CAUTION 1. Exhaust differential pressure sensor safety Informa-
tion
• Remove the exhaust differential
pressure sensor with the attached CAUTION
bracket.
• Do not use a tool which causes vibra-
tions such as an impact wrench when in-
stalling and removing the exhaust differ-
ential pressure sensor.
• Do not reuse the exhaust differential
pressure sensor which has been sub-
jected to shock such as being dropped.
• Install or remove the exhaust differen-
tial pressure sensor together with the
bracket.
• Be sure not to loosen the 4 screws in-
stalled on the exhaust differential pres-
sure sensor.
• Replace the exhaust differential pres-
sure sensorif the 4 screws installed on
the DPD differential pressure sensor
have been loosened.
Exhaust differential pressure
1
sensor

1 Screw

2. Exhaust differential pressure sensor installation

CAUTION
• Before performing work, be sure to
check the exhaust differential pressure
sensor precautions.

1) Install the exhaust differential pressure sensor

to the DPD assembly.
2) Connect the harness connector to the exhaust
differential pressure sensor.
3) Connect the differential pressure hose to the
exhaust differential pressure sensor.

84512399 EN - September 2011

4023D-13
Copyright ©
Engine Control System

CAUTION Exhaust differential pressure sensor

Inspection
• Be careful not to mistake the con-
necting position of the differential 1. Exhaust differential pressure sensor inspection
pressure hose.
• Since the differential pressure sen- CAUTION
sor may malfunction if exhaust gas
leaks from the joint sections, con- • Perform 0-point correction when replac-
ing the exhaust differential pressure sen-
firm that there is no exhaust gas
sor.
leakage after the engine starts.
• Perform 0-point correction when the ex-
haust differential pressure sensor is at
room temperature.
• Do not perform 0-point correction within
two hours after regenerating DPD.

ANNOTATION:
• 0-point correction
1) Turn OFF the starter switch.
2) Turn ON the starter switch.

4023D-16
Copyright ©

Section

84512399 EN - September 2011

4023G-24
Copyright ©
Engine-side Trouble

DTC P0602 (Flash Code 154) DTC P0604 (Flash Code 153)
Control Module Programming Internal Control Module Random
Error Access Memory (RAM) Error
1. DTC P0602 description of DTC 1. DTC P0604 description of DTC
The EEPROM inside the ECM records the injector This diagnosis applies to the microprocessor inside
ID code information. the ECM.
When the ECM has detected that the injector ID 2. DTC P0604 condition for setting the DTC
code is not programmed in the EEPROM or found The battery voltage is 16 V or higher.
an error in the programmed injector ID code, it sets The ECM detects an abnormality in the internal
DTC. RAM.
2. DTC P0602 condition for setting the DTC 3. DTC P0604 action taken when the DTC sets
The starter switch is ON. Failure is indicated in the monitor on the machine,
Either of the following conditions is met. or the monitor is turned on.
The ECM detects that no injector ID code is pro-
ANNOTATION:
grammed.
The ECM detects an error in the programmed injec- • Depending on the manufacturer of the machine,
tor ID code. the failure indication may not be shown.
3. DTC P0602 action taken when the DTC sets
When it has been detected for 2 consecutive times, Stop the engine.
the failure is displayed on the monitor of the ma- Limit the fuel flow.
chine or the monitor illuminates.
ANNOTATION:
• Depending on the manufacturer of the machine,
the failure indication may not be shown.

84512399 EN - September 2011

4023G-25
Copyright ©
Engine-side Trouble

DTC P0606 (Flash Code 51) DTC P0638 (Flash Code

ECM/PCM Processor 61) Throttle Actuator Control
1. DTC P0606 description of DTC Range/Performance
This diagnosis applies to the microprocessor inside
the ECM. 1. DTC P0638 description of DTC
2. DTC P0606 condition for setting the DTC The ECM opens/closes the intake throttle valve by
The battery voltage is 16 V or higher. controlling the intake throttle solenoid depending
The starter switch is ON. upon the engine operating status.
The internal sub CPU detects an abnormality in the The intake throttle valve opening angle is detected
main CPU. by the position sensor and transmitted to the ECM.
3. DTC P0606 action taken when the DTC sets If the ECM detects that the actual and desired open-
Failure is indicated in the monitor on the machine, ing angles of the intake throttle valve are different
or the monitor is turned on. during execution of an ON command for the intake
throttle solenoid, the DTC is set.
ANNOTATION: 2. DTC P0638 condition for setting the DTC
DTCs P0122 and P0123 are not set.
• Depending on the manufacturer of the machine, The battery voltage is between 18 and 32 V.
the failure indication may not be shown.
The starter switch is ON.
Upon returning to the CPU The desired intake throttle opening angle is con-
Limit the fuel injection amount. stant.
Limit the fuel flow. The intake throttle solenoid has been commanded
Limit the maximum engine rpm to 1700 r/min. ON.
Stop the EGR control. The ECM detects that the difference between the
Stop the DPD regeneration. actual and desired opening angles of the intake
throttle has been 40 ％ or more for 5 seconds or
longer.
3. DTC P0638 action taken when the DTC sets
Failure is indicated in the monitor on the machine,
or the monitor is turned on.
ANNOTATION:
• Depending on the manufacturer of the machine,
the failure indication may not be shown.
Limit the fuel injection amount.
Stop the EGR control.
Stop the DPD regeneration.

84512399 EN - September 2011

4023G-26
Copyright ©
Engine-side Trouble

DTC P0641 (Flash Code 55) DTC P0651 (Flash Code 56)
Sensor Reference Voltage 1 Sensor Reference Voltage 2
Circuit Circuit
1. DTC P0641 description of DTC 1. DTC P0651 description of DTC
The ECM supplies 5 V power to the following sen- The ECM supplies 5 V power to the following sen-
sors via power supply circuit 1. sors through 5 V power supply circuit 2.
Accelerator position sensor Barometric pressure sensor
The ECM also supplies 5 V power to the following The ECM also supplies 5 V power to the following
sensors via power supply circuit 5. sensors via 5 V power supply circuit 6.
IAT sensor CMP sensor
CKP sensor Boost temperature sensor
Fuel pressure sensor 5 V power supply circuits 2 and 6 are independent
5 V power supply circuits 1 and 5 are independent of each other outside the ECM, but they share a bus
of each other outside the ECM, but they share a bus inside
inside the ECM. the ECM.
Therefore, the entire 5 V power supply circuits 1 and Therefore, the entire 5 V power supply circuits 2 and
5 may be affected by short circuit of either of the 6 may be affected by short circuit of either of the
sensor 5 V power supply circuits. sensor 5 V power supply circuits.
The ECM monitors the voltage of the 5 V power The ECM monitors the voltage of the 5 V power
supply circuits 1 and 5, and sets DTC when the supply circuits 2 and 6, and sets DTC when the
ECM has detected that the voltage is abnormally ECM has detected that the voltage is abnormally
low or high. low or high.
2. DTC P0641 condition for setting the DTC 2. DTC P0651 condition for setting the DTC
DTC P060B is not set. DTC P060B is not set.
The battery voltage is between 16 and 32 V. The battery voltage is between 16 and 32 V.
The starter switch is ON. The starter switch is ON.
The ECM detects that voltage of 5 V power supply The ECM detects that voltage of 5 V power supply
circuit circuit 2 or 6 has been 4.5 V or lower or 5.5 V or
1 and 5 has been 4.5 V or lower or 5.5 V or higher higher for 0.4 seconds or longer.
for 0.4 seconds or longer. 3. DTC P0651 action taken when the DTC sets
3. DTC P0641 action taken when the DTC sets Failure is indicated in the monitor on the machine,
Failure is indicated in the monitor on the machine, or the monitor is turned on.
or the monitor is turned on.
ANNOTATION:
ANNOTATION:
• Depending on the manufacturer of the machine,
• Depending on the manufacturer of the machine, the failure indication may not be shown.
the failure indication may not be shown.
Limit the fuel injection amount.
Limit the fuel injection amount. Stop the DPD regeneration.
Stop the EGR control.
Stop the DPD regeneration.

84512399 EN - September 2011

4023G-27
Copyright ©
Engine-side Trouble

DTC P0685 (Flash Code 416) DTC P0687 (Flash Code 416)
ECM/PCM Power Relay Control ECM/PCM Power Relay Control
Circuit/Open Circuit High
1. DTC P0685 description of DTC 1. DTC P0687 description of DTC
When the ECM receives an starter switch ON sig- When the ECM receives an starter switch ON sig-
nal, the ECM main relay is energized to feed the nal, the ECM main relay is energized to feed the
battery power to the ECM through the relay switch battery power to the ECM through the relay switch
side. side.
When the starter switch is OFF, the ECM main re- When the starter switch is OFF, the ECM main re-
lay is de-energized after a certain length of time lay is de-energized after a certain length of time
passed. passed.
If the ECM has detected a low voltage with the relay If the ECM has detected that the ECM is ON when
voltage supply circuit when the ON command has the OFF command has been executed for the ECM
been executed for the ECM main relay, it sets DTC. main relay, it sets DTC.
2. DTC P0685 condition for setting the DTC 2. DTC P0687 condition for setting the DTC
The battery voltage is between 18 and 32 V. The starter switch is OFF.
The starter switch is ON. The ECM detects that the relay has been ON for 5
The ECM detects a low voltage status of 1 V or seconds when the ECM commands the relay OFF.
lower in the ECM main relay voltage supply circuit 3. DTC P0687 action taken when the DTC sets
for 3 seconds when the relay is commanded ON. Failure is indicated in the monitor on the machine,
3. DTC P0685 action taken when the DTC sets or the monitor is turned on.
Failure is indicated in the monitor on the machine,
or the monitor is turned on. ANNOTATION:

4023G-41
Copyright ©
Engine-side Trouble

DTC P060B (Flash Code 36) DTC P242F (Flash Code 131)
Internal Control Module A/D DPD Restriction
Processing Performance 1. DTC P242F description of DTC
The ECM detects PM accumulation failures from the
1. DTC P060B description of DTC exhaust differential pressure sensor located near
This diagnosis applies to the microprocessor inside the DPD itself.
the ECM. When it is reached to a certain amount of PM accu-
2. DTC P060B condition for setting the DTC mulations or a certain length of operating time, the
When the ECM has detected an abnormality of the automatic regeneration of the DPD filter starts.
internal A/D converter. If the automatic regeneration cannot be completed
3. DTC P060B action taken when the DTC sets for some reason, the manual regeneration is re-
Failure is indicated in the monitor on the machine, quested to the operator by blinking the DPD manual
or the monitor is turned on. regeneration indicator light.
ANNOTATION: When the ECM detects that DPD differential pres-
sure is not within a predetermined range, this DTC
• Depending on the manufacturer of the machine, is set.
the failure indication may not be shown. 2. DTC P242F condition for setting the DTC
Limit the fuel injection amount. The starter switch is ON.
Stop the EGR control. The exhaust differential pressure has been above
Stop the DPD regeneration. the calculated differential pressure range for 30 sec-
onds or longer.
3. DTC P242F action taken when the DTC sets
Failure is indicated in the monitor on the machine,
or the monitor is turned on.
ANNOTATION:
• Depending on the manufacturer of the machine,
the failure indication may not be shown.
Limit the fuel injection amount.
Stop the EGR control.
Stop the DPD regeneration.

84512399 EN - September 2011

4023G-42
Copyright ©

Section

4023H

Main Unit-side Trouble

84512399 EN - September 2011

CONTENTS

Main Unit-side Trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Diagnostic Trouble Code: 7000 P1 Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Diagnostic Trouble Code: 7001 P2 Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Diagnostic Trouble Code: 7002 N1 Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Diagnostic Trouble Code: 7003 N2 Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Diagnostic Trouble Code: 7004 Overload Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Diagnostic Trouble Code: 7005 Bottom Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Diagnostic Trouble Code: 7006 Rod Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Diagnostic Trouble Code: 7020 Upper Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Diagnostic Trouble Code: 7021 Swing Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Diagnostic Trouble Code: 7022 Travel Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Diagnostic Trouble Code: 7023 Arm-in Pressure Sensor Signal Abnormality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Diagnostic Trouble Code: 7040 Fuel Level Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Diagnostic Trouble Code: 7041 Oil Temperature Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Diagnostic Trouble Code: 7045 Monitor Thermistor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Diagnostic Trouble Code: 7060 Boom Angle Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Diagnostic Trouble Code: 7061 Arm Angle Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Diagnostic Trouble Code: 7063 Return Filter Clogging Pressure Switch Signal Abnormality. . . . . . . . . . . . . . . . . . 34
(Breaker specifications). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
(Other than breaker specifications) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Diagnostic Trouble Code: 7065 Boom-up Pilot Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . 36
Diagnostic Trouble Code: 7067 Bucket-close Pilot Pressure Sensor Signal Abnormality. . . . . . . . . . . . . . . . . . . . . 38
Diagnostic Trouble Code: 7200 Swing Brake Solenoid Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Diagnostic Trouble Code: 7201 Travel High-speed Solenoid Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Diagnostic Trouble Code: 7202 Pressure Boost Solenoid Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Diagnostic Trouble Code: 7203 Travel Alarm Buzzer Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Diagnostic Trouble Code: 7204 Power Save Solenoid Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Diagnostic Trouble Code: 7205 Feed Pump Relay Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Diagnostic Trouble Code: 7206 Option Line Switchover Solenoid Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . 54
Diagnostic Trouble Code: 7207 Free Swing Solenoid Signal Abnormality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Diagnostic Trouble Code: 7210 Liftcrane Buzzer Signal Abnormality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Diagnostic Trouble Code: 7211 Rotating Light Relay and Bucket Lock Signal Abnormality . . . . . . . . . . . . . . . . . . . 58
Diagnostic Trouble Code: 7240 Pump Horsepower Proportional Valve Signal Abnormality . . . . . . . . . . . . . . . . . . . 59
Diagnostic Trouble Code: 7241 P1 Flow Control Proportional Valve Signal Abnormality . . . . . . . . . . . . . . . . . . . . . 61
Diagnostic Trouble Code: 7242 Fan Proportional Valve Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Diagnostic Trouble Code: 7246 2 Pumps Flow Solenoid Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Diagnostic Trouble Code: 7247 Boom-down Proportional Valve Signal Abnormality. . . . . . . . . . . . . . . . . . . . . . . . . 66
Diagnostic Trouble Code: 7248 Arm-in Proportional Valve Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Diagnostic Trouble Code: 7250 Option Relief Pressure Proportional Valve Signal Abnormality . . . . . . . . . . . . . . . 70
Diagnostic Trouble Code: 7251 Battery Control Relay Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Diagnostic Trouble Code: 7252 Idle Stop Relay Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Diagnostic Trouble Code: 7253 DPD Regeneration Request Output Signal Abnormality. . . . . . . . . . . . . . . . . . . . . 75
Diagnostic Trouble Code: 7400 Abnormally High Coolant Temperature (105°C or higher) . . . . . . . . . . . . . . . . . . . 77
Diagnostic Trouble Code: 7401 Abnormally High Coolant Temperature (110°C or higher). . . . . . . . . . . . . . . . . . . . 77
Diagnostic Trouble Code: 7402 Abnormally High Coolant Temperature (120°C or higher) . . . . . . . . . . . . . . . . . . . 77
Diagnostic Trouble Code: 7404 Abnormally High Oil Temperature (95°C or higher) . . . . . . . . . . . . . . . . . . . . . . . . . 78

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

4023H-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011

4023H-14
Copyright ©
Main Unit-side Trouble

Diagnostic Trouble Code: 7006 Rod Pressure Sensor Signal Abnormality

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7006 is displayed. Go to Step 2
Is diagnostic trouble code: 7006 displayed?
1. Inspect the connection status of each
connector.
2 2. Check whether diagnostic trouble code: Go to Step 3
7006 is displayed.
Is diagnostic trouble code: 7006 displayed?
1. Check the rod pressure sensor voltage
on the service support screen. 4.75 V or When 0.25 V or
3 Go to Step 4
higher lower, go to Step 7
Is it 4.75 V or higher?
Inspect for shorts to the power supply
1. Turn the key switch OFF and disconnect
CN. CR10.
W414 or W415 har-
2. Turn the key switch ON.
4 About 5 V Go to Step 5 ness defect (short).
3. Measure the voltage between the
Replace
ground and terminal 1 of the CN. CR10
harness side.
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. CR10 4.75 V or L435 harness defect
5 harness side. Go to Step 6
lower (short). Replace
Is it 4.75 V or lower?
1. Measure the voltage between the
ground and terminal 3 of the CN. CR10 0.25 V or Computer B defect. BW454 or BW455
6 harness side. harness defect
lower Replace
(short). Replace
Is it 0.25 V or lower?
Inspect the rod pressure sensor.
1. Turn the key switch OFF.
2. Disconnect CN. CR10.
About 10 Rod pressure sensor
7 3. Measure the resistance between termi- Go to Step 8
kΩ defect. Replace
nals 1 and 3 of the CN. CR10 rod pres-
sure sensor side.
Is it about 10 kΩ?
Inspect for shorts to ground and disconnec-
tions.
1. Inspect for continuity between the
ground and terminal 1 of the CN. CR10 W414, W415, or
8 harness side. L435 harness defect Go to Step 9
2. Inspect for continuity between the (short). Replace
ground and terminal 2 of the CN. CR10
harness side.
Is there continuity?
1. Inspect for continuity between the BW454 or BW455
ground and terminal 3 of the CN. CR10 harness defect (dis-
9 harness side. Go to Step 10
connection). Repair
Is there continuity? or replace

84512399 EN - September 2011

4023H-15
Copyright ©
Main Unit-side Trouble

Abnormality
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7023 is displayed. Go to Step 2
Is diagnostic trouble code: 7023 displayed?
1. Inspect the connection status of each
connector.
2 2. Check whether diagnostic trouble code: Go to Step 3
7023 is displayed.
Is diagnostic trouble code: 7023 displayed?
1. Check the arm-in pressure sensor volt-
age on the service support screen. 4.75 V or When 0.25 V or
3 Go to Step 4
higher lower, go to Step 7
Is it 4.75 V or higher?
Inspect for shorts to the power supply
1. Turn the key switch OFF and disconnect
CN. D54.
2. Turn the key switch ON.
3. Measure the voltage between the About 5 V WL430 harness de-
4 Go to Step 5
ground and terminal 1 of the CN. D54 fect (short). Replace
harness side.
-
Is it about 5 V?
1. 1. Measure the voltage between the
ground and terminal 2 of the CN. D54
harness side. 4.75 V or YG445 harness de-
5 Go to Step 6
lower fect (short). Replace
-
Is it 4.75 V or lower?
1. 1. Measure the voltage between the
ground and terminal 3 of the CN. D54
harness side. 0.25 V or Computer B defect. BL450 harness de-
6
lower Replace fect (short). Replace
-
Is it 0.25 V or lower?
1. Inspect the arm-in pressure sensor.
2. Turn the key switch OFF.
3. Disconnect CN. D54.
7 4. Measure the resistance between termi- About 10 Go to Step 8 Arm-in pressure sen-
nals 1 and 3 of the CN. D54 arm-in pres- kΩ sor defect. Replace
sure sensor side.
Is it about 10 kΩ?
Inspect for shorts to ground and disconnec-
tions.
1. Inspect for continuity between the
ground and terminal 1 of the CN. D54 WL430 or YG445
8 harness side. harness defect Go to Step 9
2. Inspect for continuity between the (short). Replace
ground and terminal 2 of the CN. D54
harness side.
Is there continuity?
1. Inspect for continuity between the
ground and terminal 3 of the CN. D54 BL450 harness de-
9 harness side. Go to Step 10 fect (disconnection).
Repair or replace
Is there continuity?
84512399 EN - September 2011
4023H-23
Copyright ©
Main Unit-side Trouble

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Measure the voltage between the WL430 harness de-
10 ground and terminal 1 of the CN. D54 About 5 V Go to Step 11 fect (disconnection).
harness side. Repair or replace
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. D54 0.25 V or Computer B defect. YG445 harness de-
11 harness side. fect (disconnection).
higher Replace
Repair or replace
Is it 0.25 V or higher?

84512399 EN - September 2011

4023H-24
Copyright ©
Main Unit-side Trouble

Diagnostic Trouble Code: 7040 Fuel Level Sensor Signal Abnormality

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7040 is displayed. Go to Step 2
Is diagnostic trouble code: 7040 displayed?
1. Inspect the connection status of each
connector and ground.
2 2. Check whether diagnostic trouble code: Go to Step 3
7040 is displayed.
Is diagnostic trouble code: 7040 displayed?
1. Check the fuel level sensor resistance
on the service support screen. 100 Ω or When 2 Ω or lower,
3 Go to Step 4
higher go to Step 7
Is it 100 Ω or higher?
Inspect for disconnection.
1. Turn the key switch OFF and disconnect
CN. D57.
2. Measure the resistance between termi- Fuel level sensor de-
4 Go to Step 5
nals 1 and 2 of the CN. D57 fuel level fect. Replace
sensor side.(See the Float position and
resistance table.)
Is it the standard value?
1. Inspect for continuity between the BG660 or BG601
ground and terminal 1 of the CN. D57 harness defect (dis-
5 harness side. Go to Step 6
connection). Repair
Is there continuity? or replace
1. Turn the key switch ON.
2. Measure the voltage between the GL492 harness de-
ground and terminal 2 of the CN. D57 About 5 V Computer A defect.
6 fect (disconnection).
harness side. Replace
Repair or replace
Is it about 5 V?
Inspect for shorts.
1. Turn the key switch OFF.
2. Connect CN. D57.
GL492 harness de-
7 3. Inspect for continuity between the Go to Step 8
fect (short). Replace
ground and terminal 2 of the CN. D57
harness side.
Is there continuity?
1. Turn the key switch ON.
2. Measure the voltage between the BG660 or BG601
ground and terminal 1 of the CN. D57 0 V Computer A defect.
8 harness defect
harness side. Replace
(short). Replace
Is it 0 V?

84512399 EN - September 2011

4023H-25
Copyright ©
Main Unit-side Trouble

1 COMPUTER A
2 FUEL LEVEL SENSOR

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7060 is displayed. Go to Step 2
Is diagnostic trouble code: 7060 displayed?
1. Inspect the connection status of each
connector.
2 2. Check whether diagnostic trouble code: Go to Step 3
7060 is displayed.
Is diagnostic trouble code: 7060 displayed?
1. Check the boom angle sensor voltage
on the service support screen. 4.8 V or When 0.2 V or lower,
3 Go to Step 4
higher go to Step 7
Is it 4.8 V or higher?
Inspect for shorts to the power supply
1. Turn the key switch OFF and disconnect
CN. CR11.
W414 or W416 har-
2. Turn the key switch ON.
4 About 5 V Go to Step 5 ness defect (short).
3. Measure the voltage between the
Replace
ground and terminal 3 of the CN. CR11
harness side.
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. CR11 4.8 V or Lg436 harness de-
5 harness side. Go to Step 6
lower fect (short). Replace
Is it 4.8 V or lower?
1. Measure the voltage between the
ground and terminal 1 of the CN. CR11 0.2 V BW454 or BW456
or Computer B defect.
6 harness side. harness defect
lower Replace
(short). Replace
Is it 0.2 V or lower?
Inspect the boom angle sensor.
1. Turn the key switch OFF.
2. Disconnect CN. CR11.
About 10 Boom angle sensor
7 3. Measure the resistance between termi- Go to Step 8
kΩ defect. Replace
nals 1 and 3 of the CN. CR11 boom an-
gle sensor side.
Is it about 10 kΩ?
Inspect for shorts to ground and disconnec-
tions.
1. Inspect for continuity between the
ground and terminal 3 of the CN. CR11 W414, W416, or
8 harness side. Lg436 harness de- Go to Step 9
2. Inspect for continuity between the fect (short). Replace
ground and terminal 2 of the CN. CR11
harness side.
Is there continuity?
1. Inspect for continuity between the BW454 or BW456
ground and terminal 1 of the CN. CR11 harness defect (dis-
9 harness side. Go to Step 10
connection). Repair
Is there continuity? or replace

84512399 EN - September 2011

4023H-30
Copyright ©
Main Unit-side Trouble

Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Measure the voltage between the W414 or W416 har-
ground and terminal 3 of the CN. CR11 About 5 V ness defect (discon-
10 Go to Step 11
harness side. nection). Repair or
replace
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. CR11 0.2 V Lg436 harness de-
or Computer B defect.
11 harness side. fect (disconnection).
higher Replace
Repair or replace
Is it 0.2 V or higher?

Abnormality
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7065 is displayed. Go to Step 2
Is diagnostic trouble code: 7065 displayed?
1. Inspect the connection status of each
connector.
2 2. Check whether diagnostic trouble code: Go to Step 3
7065 is displayed.
Is diagnostic trouble code: 7065 displayed?
1. Check the boom-up pilot pressure sen-
sor voltage on the service support 4.75 V or When 0.25 V or
3 screen. Go to Step 4
higher lower, go to Step 7
Is it 4.75 V or higher?
Inspect for shorts to the power supply
1. Turn the key switch OFF and disconnect
CN. D53.
WL432 or WL430
2. Turn the key switch ON.
4 About 5 V Go to Step 5 harness defect
3. Measure the voltage between the
(short). Replace
ground and terminal 1 of the CN. D53
harness side.
Is it about 5 V?
1. Measure the voltage between the
ground and terminal 2 of the CN. D53 4.75 V or GW444 harness de-
5 harness side. Go to Step 6
lower fect (short). Replace
Is it 4.75 V or lower?
1. Measure the voltage between the
ground and terminal 3 of the CN. D53 0.25 V or Computer B defect. BL452 or BL450 har-
6 harness side. ness defect (short).
lower Replace
Replace
Is it 0.25 V or lower?
1. Inspect the boom-up pilot pressure sen-
sor.
2. Turn the key switch OFF.
3. Disconnect CN. D53. Boom-up pilot pres-
About 10
7 4. Measure the resistance between termi- kΩ Go to Step 8 sure sensor defect.
nals 1 and 3 of the CN. D53 boom-up Replace
pilot pressure sensor side.
Is it about 10 kΩ?
Inspect for shorts to ground and disconnec-
tions.
1. Inspect for continuity between the
ground and terminal 1 of the CN. D53 WL432, WL430, or
8 harness side. GW444 harness de- Go to Step 9
2. Inspect for continuity between the fect (short). Replace
ground and terminal 2 of the CN. D53
harness side.
Is there continuity?
1. Inspect for continuity between the BL452 or BL450 har-
ground and terminal 3 of the CN. D53 ness defect (discon-
9 harness side. Go to Step 10
nection). Repair or
Is there continuity? replace

84512399 EN - September 2011

PRESS. SENSOR (PILOT

3 8 POWER SAVE 13 FUSIBLE LINK FUSE BOX
SWING)
PRESS. SENSOR (PILOT UP-
4 9 RELAY BATTERY 14 KEY SWITCH
PER)
PRESS. SENSOR (PILOT
5 10 BATTERY (24 V) 15 COMPUTER B
TRAVEL)

4023H-57
Copyright ©
Main Unit-side Trouble

Diagnostic Trouble Code: 7211 Rotating Light Relay and Bucket Lock
Signal Abnormality
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7211 is displayed. Go to Step 2
Is diagnostic trouble code: 7211 displayed?
1. Inspect the connection status of each
connector.
2. Inspect the fusible link F1 (65 A) fuse
2 and fuse box F21 (10 A) fuse to see if Go to Step 3
either is blown.
Are 1 and 2 above both OK?
Inspect the rotating light relay.
1. Turn the key switch OFF and disconnect
CN. 19.
Rotating light relay
3 2. Inspect for continuity between terminals Go to Step 4
defect. Replace
1 and 2 of the CN. 19 rotating light relay
side.
Is there continuity?
Inspect for shorts.
1. Install CN. 19. VW858, GW226,
2. Inspect for continuity between the GW227, R106, or
4 Go to Step 5
ground and terminal 1 of the CN. 19 R105 harness defect
harness side. (short). Replace
Is there continuity?
Inspect for disconnection.
VW816, VW817,
1. Turn the key switch ON. GW227, GW226,
2. Inspect for continuity between the Computer B defect. GW225, R106, or
5
ground and terminal 1 of the CN. 19 Replace R105 harness defect
harness side. (disconnection). Re-
pair or replace
Is there continuity?

84512399 EN - September 2011

4023H-58
Copyright ©
Main Unit-side Trouble

Diagnostic Trouble Code: 7240 Pump Horsepower Proportional Valve

Signal Abnormality
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7240 is displayed. Go to Step 2
Is diagnostic trouble code: 7240 displayed?
1. Inspect the connection status of each
connector.
2 2. Check whether diagnostic trouble code: Go to Step 3
7240 is displayed.
Is diagnostic trouble code: 7240 displayed?
1. Reset the diagnostic trouble code on the
service support DIAG screen.
3 2. Check whether diagnostic trouble code: Go to Step 4 Go to Step 5
7240 is displayed.
Is diagnostic trouble code: 7240 displayed?
Inspect for shorts.
1. Turn the key switch OFF and disconnect
CN. D39.
Y900 harness defect Computer A defect.
4 2. Inspect for continuity between the
(short). Replace Replace
ground and terminal 1 of the CN. D39
harness side.
Is there continuity?
Inspect the pump horsepower proportional
valve.
1. Turn the key switch OFF.
Pump horsepower
2. Disconnect CN. D39.
5 Go to Step 6 proportional valve
3. Inspect for continuity between terminals
defect. Replace
1 and 2 of the CN. D39 pump horse-
power proportional valve side.
Is there continuity?
Inspect for disconnection.
YR940 harness de-
1. Disconnect CN. A56.
fect (disconnection)
2. Inspect for continuity between terminal
6 Go to Step 7 between CN. D39
1 of the CN. D39 female side and termi-
and CN. A56. Repair
nal 1 of the CN. A56 male side.
or replace
Is there continuity?
BY901 harness de-
Inspect for continuity between terminal 2 of
fect (disconnection)
the CN. D39 female side and terminal 9 of
7 Go to Step 8 between CN. D39
the CN. A56 male side.
and CN. A56. Repair
Is there continuity?
or replace
1. Disconnect CN. A4. Y900 harness defect
2. Inspect for continuity between terminal (disconnection) be-
8 1 of the CN. A56 male side and terminal Go to Step 9 tween CN. A56 and
3 of the CN. A4 female side. CN. A4. Repair or re-
Is there continuity? place
1. Inspect for continuity between terminal BY901 harness de-
9 of the CN. A56 male side and terminal fect (disconnection)
Computer A defect.
9 6 of the CN. A4 female side. between CN. A56
Replace
and CN. A4. Repair
Is there continuity? or replace

84512399 EN - September 2011

4023H-59
Copyright ©
Main Unit-side Trouble

PRESS. SENSOR (PILOT UP-

1 COMPUTER A 4 7 ENGINE COMPUTER
PER)
2 PRESS. SENSOR (P1) 5 CRANK ANGLE SENSOR
3 PRESS. SENSOR (P2) 6 PUMP POWER

a CAN COMMUNICATION

84512399 EN - September 2011

4023H-60
Copyright ©
Main Unit-side Trouble

Diagnostic Trouble Code: 7241 P1 Flow Control Proportional Valve

Signal Abnormality
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7241 is displayed. Go to Step 2
Is diagnostic trouble code: 7241 displayed?
1. Inspect the connection status of each
connector.
2 2. Check whether diagnostic trouble code: Go to Step 3
7241 is displayed.
Is diagnostic trouble code: 7241 displayed?
1. Reset the diagnostic trouble code on the
service support DIAG screen.
3 2. Check whether diagnostic trouble code: Go to Step 4 Go to Step 5
7241 is displayed.
Is diagnostic trouble code: 7241 displayed?
Inspect for shorts.
1. Turn the key switch OFF and disconnect
CN. D40.
L904 harness defect Computer A defect.
4 2. Inspect for continuity between the
(short). Replace Replace
ground and terminal 1 of the CN. D40
harness side.
Is there continuity?
Inspect the P1 flow control proportional
valve.
1. Turn the key switch OFF.
P1 flow control pro-
2. Disconnect CN. D40.
5 Go to Step 6 portional valve de-
3. Inspect for continuity between terminals
fect. Replace
1 and 2 of the CN. D40 flow control
proportional valve side.
Is there continuity?
Inspect for disconnection.
Y904 harness defect
1. Disconnect CN. A56.
(disconnection) be-
2. Inspect for continuity between terminal
6 Go to Step 7 tween CN. D40 and
1 of the CN. D40 male side and terminal
CN. A56. Repair or
3 of the CN. A56 female side.
replace
Is there continuity?
BL905 harness de-
Inspect for continuity between terminal 2 of
fect (disconnection)
the CN. D40 male side and terminal 11 of the
7 Go to Step 8 between CN. D40
CN. A56 female side.
and CN. A56. Repair
Is there continuity?
or replace
1. Disconnect CN. A3. Y904 harness defect
2. Inspect for continuity between terminal (disconnection) be-
8 3 of the CN. A56 male side and terminal Go to Step 9 tween CN. A56 and
2 of the CN. A3 female side. CN. A3. Repair or re-
Is there continuity? place
BL905 harness de-
Inspect for continuity between terminal 11 of
fect (disconnection)
the CN. A56 male side and terminal 5 of the Computer A defect.
9 between CN. A56
CN. A3 female side. Replace
and CN. A3. Repair
Is there continuity?
or replace

84512399 EN - September 2011

4023H-61
Copyright ©
Main Unit-side Trouble

PRESS. SENSOR (PILOT

1 CONTROLLER A
2 BOOM DOWN

84512399 EN - September 2011

4023H-67
Copyright ©
Main Unit-side Trouble

Diagnostic Trouble Code: 7248 Arm-in Proportional Valve Signal

Abnormality
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7248 is displayed. Go to Step 2
Is diagnostic trouble code: 7248 displayed?
1. Inspect the connection status of each
connector.
2 2. Check whether diagnostic trouble code: Go to Step 3
7248 is displayed.
Is diagnostic trouble code: 7248 displayed?
1. Reset the diagnostic trouble code on the
service support DIAG screen.
3 2. Check whether diagnostic trouble code: Go to Step 4 Go to Step 5.
7248 is displayed.
Is diagnostic trouble code: 7248 displayed?
Inspect for shorts.
1. Turn the key switch OFF and disconnect
CN. D42.
G906 harness defect Computer B defect.
4 2. Inspect for continuity between the
(short). Replace Replace
ground and terminal 1 of the CN. D42
harness side.
Is there continuity?
Inspect the arm-in proportional valve.
1. Turn the key switch OFF.
2. Disconnect CN. D42. Arm-in proportional
5 3. Inspect for continuity between terminals Go to Step 6 valve defect. Re-
1 and 2 of the CN. D42 arm-in propor- place
tional valve side.
Is there continuity?
Inspect for disconnection.
G906 harness defect
1. Disconnect CN. A56.
(disconnection) be-
2. Inspect for continuity between terminal
6 Go to Step 7 tween CN. A56 and
1 of the CN. D42 female side and termi-
CN. D42. Repair or
nal 4 of the CN. A56 female side.
replace
Is there continuity?
GB907 harness de-
Inspect for continuity between terminal 2 of
fect (disconnection)
the CN. D42 female side and terminal 12 of
7 Go to Step 8 between CN. A56
the CN. A56 female side.
and CN. D42. Repair
Is there continuity?
or replace
1. Disconnect CN. A7. G906 harness defect
2. Inspect for continuity between terminal (disconnection) be-
8 4 of the CN. A56 male side and terminal Go to Step 9 tween CN. A56 and
3 of the CN. A7 female side. CN. A7. Repair or re-
Is there continuity? place
GB907 harness de-
Inspect for continuity between terminal 12 of
fect (disconnection)
the CN. A56 male side and terminal 6 of the Computer B defect.
9 between CN. A56
CN. A7 female side. Replace
and CN. A7. Repair
Is there continuity?
or replace

84512399 EN - September 2011

4023H-68
Copyright ©
Main Unit-side Trouble

1 CONTROLLER B
2 ARM CLOSE

84512399 EN - September 2011

4023H-69
Copyright ©
Main Unit-side Trouble

Diagnostic Trouble Code: 7250 Option Relief Pressure Proportional

Valve Signal Abnormality
Standard
Step Action Yes No
value
1. Turn the key switch ON.
2. Check whether diagnostic trouble code:
1 7250 is displayed. Go to Step 2
Is diagnostic trouble code: 7250 displayed?
1. Inspect the connection status of each
connector.
2 2. Check whether diagnostic trouble code: Go to Step 3
7250 is displayed.
Is diagnostic trouble code: 7250 displayed?
1. Reset the diagnostic trouble code on the
service support DIAG screen.
3 2. Check whether diagnostic trouble code: Go to Step 4 Go to Step 5
7250 is displayed.
Is diagnostic trouble code: 7250 displayed?
Inspect for shorts.
1. Turn the key switch OFF and disconnect
CN. D44-1.
V910 harness defect Computer B defect.
4 2. Inspect for continuity between the
(short). Replace Replace
ground and terminal 1 of the CN. D44-1
harness side.
Is there continuity?
Inspect the option relief pressure propor-
tional valve.
1. Turn the key switch OFF.
Option relief pressure
2. Disconnect CN. D44-1.
5 Go to Step 6 proportional valve
3. Inspect for continuity between terminals
defect. Replace
1 and 2 of the CN. D44-1 option relief
pressure proportional valve side.
Is there continuity?
Inspect for disconnection.
V910 harness defect
1. Disconnect CN. D44.
(disconnection) be-
2. Inspect for continuity between terminal
6 Go to Step 7 tween CN. D44-1 and
1 of the CN. D44-1 female side and ter-
CN. D44. Repair or
minal 1 of the CN. D44 male side.
replace
Is there continuity?
1. Inspect for continuity between terminal VG911 harness de-
2 of the CN. D44-1 female side and ter- fect (disconnection)
7 minal 2 of the CN. D44 male side. Go to Step 8 between CN. D44-1
and CN. D44. Repair
Is there continuity? or replace
1. Disconnect CN. A7. V910 harness defect
2. Inspect for continuity between terminal (disconnection) be-
1 of the CN. D44 female side and termi- tween CN. D44 and
8 Go to Step 9
nal 2 of the CN. A7 female side. CN. A7. Repair or re-
place
Is there continuity?
1. Inspect for continuity between terminal VG911 harness de-
2 of the CN. D44 female side and termi- fect (disconnection)
Computer B defect.
9 nal 5 of the CN. A7 female side. between CN. D44
Replace
and CN. A7. Repair
Is there continuity? or replace

84512399 EN - September 2011

1 COMPUTER A
2 HYD. OIL TEMP SENSOR

Section

4023K

Data Reference Values

84512399 EN - September 2011

CONTENTS

Non-operational P rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

4023K-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

4023K-2 PRINTED IN FRANCE
Copyright ©
Data Reference Values

The purpose of data list is for checking the status of the whether the vehicle data is temporarily or always differ-
machine and each equipment. ent from the reference values.
This data is used in trouble diagnosis by comparing the This display menu is subject to change without notice.
each machine data with standard values, and checking
Non-operational P rotation
Idling speed reference value
Data display items Unit This varies depending on the conditions of the ma-
chine.
Battery voltage V 22 - 30
Target engine rpm RPM 800
Engine rpm RPM 895 - 905
Throttle accelerator switch position sensor 1
V 0.0
(APP1)
Throttle accelerator switch position sensor 2
V 0.0
(APP2)
Throttle accelerator switch position (APP) ％ 0
Fuel rail pressure sensor V 1.8
Fuel rail pressurefeedback Feedback mode
Coolant temperature sensor V 0.5 - 0.8
Coolant temperature °C 65 - 78
Intake air temperature sensor V 0.9 - 4.1
Intake air temperature °C (-10) - 40
Fuel temperature sensor V 2.3
Fuel temperature °C 20
Barometric pressure sensor V Approx. 2
Barometric pressure kPa Approx. 100
Boost temperature sensor voltage V 4.4
Boost pressure sensor kPa Approx. 100
1st cylinder fuel correction amount mm3/st (-3) - 3 or less
2nd cylinder fuel correction amount mm3/st (-3) - 3 or less
3rd cylinder fuel correction amount mm3/st (-3) - 3 or less
4th cylinder fuel correction amount mm3/st (-3) - 3 or less
5th cylinder fuel correction amount mm3/st (-3) - 3 or less
6th cylinder fuel correction amount mm3/st (-3) - 3 or less
Engine mode Fuel mode
EGR valve 1 drive duty ％ 0
ON/OF- Any one among 1, 2 and 3 is polarity-inverted (Exam-
EGR position 1
F ple: 1 = ON, 2 = ON, 3 = OFF)
ON/OF- Any one among 1, 2 and 3 is polarity-inverted (Exam-
EGR position 2
F ple: 1 = ON, 2 = ON, 3 = OFF)
ON/OF- Any one among 1, 2 and 3 is polarity-inverted (Exam-
EGR position 3
F ple: 1 = ON, 2 = ON, 3 = OFF)
ON/OF-
Ignition switch ON
F
ON/OF-
Starter switch OFF
F
ON/OF- OFF
Glow relay
F ON immediately after the starter switch is turned ON
Fuel delivery rate data 1 - Depending on the machine
Fuel delivery rate data 2 - Depending on the machine
Fuel delivery rate data 3 - Depending on the machine

84512399 EN - September 2011

4023K-3
Copyright ©
Data Reference Values

84512399 EN - September 2011

4023K-4
Copyright ©

Section

4040

Electrical Wiring Diagram

CN. A50 Cab main harness: A (2-pin) CN. D49 Pressure sensor: Swing (3-pin)
CN. A51 Cab main harness: B (8-pin) CN. D50 Pressure sensor: Upper (3-pin)
CN. A52 Cab main harness: C (8-pin) CN. D51 Pressure sensor: Travel (3-pin)
CN. A53 Cab main harness: D (14-pin) CN. D52 Pressure sensor: HBCV (3-pin)
CN. A54 Cab main harness: E (22-pin) CN. D53 Pressure sensor: Boom (3-pin)

84512399 EN - July 2011

4040-7
Copyright ©

Electrical Wiring Diagram

Engine and Pump

84512399 EN - July 2011

4040-8
Copyright ©

Electrical Wiring Diagram

ANNOTATION: *CN.D8 Engine harness; D (20-pin) CN.D48 Pressure sensor N2 (3-pin)
*CN.D9 Engine harness; H (1-pin) CN.D56 Sensor; Oil temperature (2-pin)
1. When assembling the ground terminals marked with a ※, it should be confirmed that the frame seating surface is not
coated. CN.D12 Starter motor: S CN.D59 SV; Lever lock (2-pin) ID tape: Blue
If the surface is coated, assembly should be performed after removing the coating.(2 places) CN.D13 Alternator: B Electrical wiring color: Red CN.D60 SV; Swing brake (2-pin) ID tape: White
2. Clean the terminal of the connectors marked with a * using cleaning agent (36) before mating, and then coat with an CN.D14 Alternator: L/R (2-pin) CN.D61 SV; 2-stage travel (2-pin) ID tape: Red
anti-rust agent (37). CN.D15 Alternator: E Electrical wiring color: Black CN.D62 SV; 2-stage relief (2-pin) ID tape: Yellow
3. The clamp positions of the electrical wiring that comes out from connectors should be adjusted so that the wiring does CN.D16 Alternator ground CN.D63 SV; CTWT removal (2-pin) ID tape: Green
not form sharp rounded shapes. (R = 10 mm or more) CN.D32 Pressure sensor; Exhaust gas (3-pin) CN.D78 Aircon compressor (1-pin)
CN.D33 Temperature sensor; Exhaust CSF (2-pin)
a Marking position; Align white tape of harness.

Engine harness (attached to en- KTR12031 (Wire harness frame

*1 Round terminal M5 *4 *7
gine main unit) main)
Starter motor (attached to engine
*2 Round terminal M8 *5 *8 KHR26690 (battery starter cable)
main unit)
Engine ground (attached to en-
*3 Aircon compressor *6
gine main unit)

Code Part name Q'ty

84512399 EN - July 2011

4040-12
Copyright ©

Electrical Wiring Diagram

Electrical Wiring Diagram

84512399 EN - July 2011

4040-16
Copyright ©

Section

5001A

Removal and Installation of Shoe Assembly

84512399 EN - September 2011

CONTENTS

Removal of Shoe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Shoe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

5001A-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

5001A-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Shoe Assembly

Job code 48100AD07 2. Use a box wrench (19 mm) to loosen the check
valve (1) to release grease, and then loosen the
track shoe tension.
WARNING Do not loosen the check valve all at once.
Loosen it slowly while monitoring the grease output
• When loosening the grease cylinder check
valve, loosen it a little at a time. and shoe loosening.
Use a rag to catch grease that trickles out of the
• The pressure inside the cylinder is very high,
so there is the danger of grease being ex- check valve.
pelled and the plug flying off. If the check valve is loosened too much at this time,
The check valve adjustment procedure it may fly off. Be careful not to work in front of the
should not be done in front of the check check valve.
valve.
• Do not get under the main unit when it is
jacked up.
Make sure to place the main unit on crossties
to prevent falling.

CAUTION
• Make sure to stop the engine for loosening
shoes and when removing master pins.

Items to prepare
• Wrench (19 mm)
• Box wrench (19 mm)
• Hammer
• Wood planks, etc.
• Striking jig
• Crowbar
• Rag
• Lifting equipment (with the required breaking load)
• Liftcrane (with the required lifting capacity)

Removal of Shoe Assembly

1. Rotate the shoe and align it so that the master pin
(1) is next to the idler.

3. Use a wrench (19 mm) to remove the bolt (1), and

then remove the check valve (2) and stopper (3).
• If the check valve (2) is removed, it is easier to
loosen the track shoe tension.

4. Straighten out the S-pin (2) attached to the master

pin (1) by striking one side of it with a hammer, and
use a crowbar, etc. to remove it.

84512399 EN - September 2011

5001A-3
Copyright ©
Removal and Installation of Shoe Assembly

6. Remove the track shoe (1).

At this time, place a wood plank (2) under the bot-
tom track shoe (1) so that it does not fall.

7. Start the engine, raise the lower side frame of the

track shoe removal side about 20 cm, slowly set the
travel lever to backwards, and move the track shoe
(1) to remove it from the lower frame.

5. Use a hammer (2) and striking rod (3) to push the

master pin (1) out.

84512399 EN - September 2011

5001A-4
Copyright ©
Removal and Installation of Shoe Assembly

Installation of Shoe Assembly 3. Wrap the edge of the track shoe (1) onto the take-up
roller (2).
1. Raise the lower side frame about 20 cm. Place a wood plank (3) on the ground and lift the
Lift the track shoe (1) and align it with the sprocket bottom-side link to align the position where the mas-
(2). ter pin is inserted.
Pay attention to the backwards and forward direc-
tion of the track shoe.

4. Insert the master pin (1).

Insert the S-pin (2) and bend it so that it cannot slip
out.

2. Slowly set the travel lever to forward and feed the 5. Tighten the check valve (1).
track shoe to the take-up roller side as shown in the While monitoring the track shoe tension, inject
diagram. grease into the grease cylinder.
In the middle of this procedure when the track shoe
passes the upper roller, use a crowbar, etc. to lift
the track shoe while it is being fed.
Lower the lower side frame after the shoe has
reached position A shown in the diagram.

84512399 EN - September 2011

5001A-5
Copyright ©
Removal and Installation of Shoe Assembly

6. To adjust the track shoe tension, raise the lower 7. Adjust the tension so that the distance indicated
side frame with a wood plank (1) or other device as with A between the frame bottom (1) of the center
shown in the diagram. area of the lower side frame and the lowest hanging
part of the top of the shoe plate (2) is 340 - 360 mm.

84512399 EN - September 2011

5001A-6
Copyright ©

Section

5001B

Removal and Installation of Shoe Plate

84512399 EN - September 2011

CONTENTS

Removal of Shoe Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Shoe Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

5001B-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

5001B-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Shoe Plate

Job code 48100AB14 Installation of Shoe Plate

1. Install the shoe plate (1).
CAUTION
• Be sure to stop the engine before beginning
work.

Items to prepare
• Box wrench (32 mm)
• Grease
• Rag
• Cleaning fluid

Removal of Shoe Plate

1. Use a box wrench (32 mm) to remove the 4 shoe
bolts (1).
2. Use a box wrench (32 mm) to install the 4 shoe bolts
(1).
Bolt (1) tightening torque: 1236 - 1510 N・m

2. Remove the shoe plate (1).

84512399 EN - September 2011

5001B-3
Copyright ©
Removal and Installation of Shoe Plate

84512399 EN - September 2011

5001B-4
Copyright ©

Section

5003A

Removal and Installation of Upper Roller

84512399 EN - September 2011

CONTENTS

Removal of Upper Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

5003A-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

5003A-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Upper Roller

Job code 48138AB21 2. Use a jack (3) to lift the top of the shoe, and then
insert wood planks (4) to separate the shoe (2) and
upper roller (1) by about 10 mm.
WARNING
• When loosening the check valve, loosen it a
little at a time and stop when any grease ap-
pears.
The pressure inside the cylinder is very high,
so there is the danger of grease being ex-
pelled and the plug flying off if the check
valve is loosened too much.
The check valve adjustment procedure
should not be done in front of the check
valve.

CAUTION
• Be sure to stop the engine before beginning 3. Use a box wrench (30 mm) to remove the 4 bolts
work.
(2), and then remove the upper roller (1).
Items to prepare
• Box wrenches (19 mm, 30 mm)
• Jack (That meets the lifting weight.)
• Rag
• Cleaning fluid
• Wood planks, etc.

Removal of Upper Roller

1. Use a box wrench (19 mm) to loosen the grease
cylinder check valve (1), then loosen the shoe ten-
sion.
• Grease drains out, so provide rag (2) close to the
drain port.
Do not loosen the check valve all at once.
Loosen it slowly while monitoring the grease out-
put and shoe loosening.

84512399 EN - September 2011

5003A-3
Copyright ©
Removal and Installation of Upper Roller

Installation of Upper Roller 4. To adjust the track shoe tension, raise the lower side
frame as shown in the diagram.
1. Use a jack (2) to lift the top of the shoe (1), and then Place a wood plank (1) under the lower frame to
insert wood planks (3). prevent falling.

2. Use a box wrench (30 mm) to install the 2 bolts (4), 5. Adjust the tension so that the distance indicated
and then install the upper roller (1). with A between the frame bottom (1) of the center
area of the lower side frame and the lowest hanging
• Apply Loctite.
part of the top of the shoe plate (2) is 360 - 380 mm.
• Bolt (2) tightening torque: 521 - 608 N・m

3. Tighten the check valve (1).

While monitoring the track shoe tension, inject
grease into the grease cylinder.

84512399 EN - September 2011

5003A-4
Copyright ©

Section

5003B

Assembly and Disassembly of Upper Roller

84512399 EN - September 2011

CONTENTS

Configuration Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Jig Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

5003B-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

5003B-2 PRINTED IN FRANCE
Copyright ©
Assembly and Disassembly of Upper Roller

Job code 48138AC30

CAUTION
• To ensure safe operations, wear protective
devices before beginning work and follow all
precautions.
• When removing devices or positioning de-
vices at the time of installation, use a removal
jig and a hammer or steel rod.
• Follow the precautions below when suspend-
ing the load.
• The liftcrane must be operated by a qualified
operator.
• Do not stand or pass under the suspended
load.
• Check the weight of the roller to determine
whether it can be carried by hand or whether
a liftcrane must be used.
• Fix the roller to a level surface so it does not
roll.
• Be sure to repair any parts damaged during
disassembly, and prepare replacement parts
in advance.
• If any parts are significantly rusted or dirty,
clean them before disassembling.
• Any foreign matter entering the equipment
during assembly can create a malfunction.
Therefore, after thoroughly cleaning the
equipment with cleaning oil, air blow the
equipment, and assemble in a clean location.
• When assembling touching parts, be sure to
coat them with new hydraulic oil.
• As a rule, replace all O-rings and other seal
parts with new parts.
<General cautions>
• Be careful not to drop precision parts or let
bump them with other parts during work.
• Do not forcefully open or hit parts in an effort
to speed up operations. Pay careful attention
and proceed slowly so as not to damage any
parts, create any oil leaks, or compromise the
efficiency of the equipment, etc.
• Disassembled parts can easily rust or collect
dust. Therefore, immediately after disassem-
bling parts, take precautions to prevent the
parts from rusting or collecting dust.

Items to prepare
• Hexagon wrench (6 mm)
• Hammer
• Wrenches (17 mm)
• Box wrench (17 mm)
• Screwdriver
• Engine oil (Shell Rimula Oil #30)
• Specialty jigs
• Pressing machine
• Loctite 262
• Special fiber cloth (Kimwipe)
• Marking pen
• Micrometer caliper
• Caliper

84512399 EN - September 2011

5003B-3
Copyright ©
Assembly and Disassembly of Upper Roller

Configuration Diagram

Code Part name Code Part name

1 Cover 7 Bushing
2 O-ring 8 Shaft
3 Plug 9 Bushing
4 Hexagon bolt 10 Roller
5 Loctite 11 Floating seal
6 Thrust plate 12 Bracket

84512399 EN - September 2011

5003B-4
Copyright ©
Assembly and Disassembly of Upper Roller

Dimension Diagram

*1 Press fit length

84512399 EN - September 2011

5003B-5
Copyright ©
Assembly and Disassembly of Upper Roller

Jig Dimension Diagram

A Bushing removal jig B2 For bushing press-fit jig (9)

B1 For bushing press-fit jig (7) C Floating seal installation jig

84512399 EN - September 2011

5003B-6
Copyright ©
Assembly and Disassembly of Upper Roller

Disassembly Procedures 4. Use a box wrench (17 mm) to remove the 3 bolts (1)
inside the roller, and then remove the thrust plate
1. Stand the roller vertically and use a hexagon (2).
wrench (6 mm) (1) to remove the plug (2).
• The plug is coated with seal nylon, which comes
off when the plug is removed. To reuse the plug,
using seal tape is necessary.

5. Lift the roller (1) and remove the shaft (2).

2. Face down the part of the roller from which the

plug was removed and empty the oil from within the
roller.
• It may take a few hours to completely empty the
oil.
• Place an oil pan (1) under the roller to catch the
oil.

6. Remove the floating seal (2) on the roller (1).

Check whether the sliding surface has rusted or is
damaged.

3. Use a wrench (17 mm) to remove the 3 bolts (2)

from the cover (1), and then remove the cover.

84512399 EN - September 2011

5003B-7
Copyright ©
Assembly and Disassembly of Upper Roller

5003B-11
Copyright ©
Assembly and Disassembly of Upper Roller

84512399 EN - September 2011

5003B-12
Copyright ©

Section

5003C

Removal and Installation of Lower Roller

84512399 EN - September 2011

CONTENTS

Removal of Lower Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

5003C-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

5003D-2 PRINTED IN FRANCE
Copyright ©
Assembly and Disassembly of Lower Roller

CAUTION
• To ensure safe operations, wear protective
devices before beginning work and follow all
precautions.
• When removing devices or positioning de-
vices at the time of installation, use a removal
jig and a hammer or steel rod.
• Follow the precautions below when suspend-
ing the load.
• The liftcrane must be operated by a qualified
operator.
• Do not stand or pass under the suspended
load.
• Check the weight of the roller to determine
whether it can be carried by hand or whether
a liftcrane must be used.
• Fix the roller to a level surface so it does not
roll.
• Be sure to repair any parts damaged during
disassembly, and prepare replacement parts
in advance.
• If any parts are significantly rusted or dirty,
clean them before disassembling.
• Any foreign matter entering the equipment
during assembly can create a malfunction.
Therefore, after thoroughly cleaning the
equipment with cleaning oil, air blow the
equipment, and assemble in a clean location.
• When assembling sliding parts, be sure to
coat them with new hydraulic oil.
• As a rule, replace all O-rings and other seal
parts with new parts.
<General cautions>
• Be careful not to drop precision parts or let
bump them with other parts during work.
• Do not forcefully open or hit parts in an effort
to speed up operations.
Pay careful attention and proceed slowly so
as not to damage any parts, create any oil
leaks, or compromise the efficiency of the
equipment, etc.
• Disassembled parts can easily rust or collect
dust.
Therefore, immediately after disassembling
parts, take precautions to prevent the parts
from rusting or collecting dust.

5003D-6
Copyright ©
Assembly and Disassembly of Lower Roller

Disassembly Procedures
1. Stand the roller vertically and use a hexagon
wrench (6 mm) (1) to remove the plug (2).
• The plug is coated with seal nylon, which comes
off when the plug is removed.
To reuse the plug, using seal tape is necessary.

4. Use pliers (2) to remove the pushed out wire clip (1).

2. Face down the part of the roller from which the

plug was removed and empty the oil from within the
roller.
• It may take a few hours to completely empty the
oil.
• Place an oil pan (1) underneath to catch the oil.
• Securely fasten so that the roller does not fall
over. 5. Use a gear puller (2) to remove the collar (1).
If the collar is difficult to remove, hook the collar on
the bolt and catch the puller on that part.
• If the collar has rusted or is difficult to remove due
to an accumulation of debris, subject it to a shock,
for example by hitting it with a hammer, to make
it easier to move.
• When hitting it with a hammer, be careful not to
dent it.

3. Tap another wire (2) with the hammer (3) from the
outside to push out the wire clip that is already in
the roller.
• Place the roller horizontally and secure it so it
does not roll before doing this work.
• The wire in the roller is very securely fixed, so
prepare several wire clips.
Also be sure to coat with lubricant.

84512399 EN - September 2011

5003D-7
Copyright ©
Assembly and Disassembly of Lower Roller

6. Check whether the surface of the floating seal (2) 8. Remove the O-ring (2) on the shaft (1).
sliding against the removed collar (1) has rusted or
is damaged. • The O-ring cannot be reused.
Replace it with new part.
Also make sure the O-ring (3) on the seal ring (4) is
not twisted.
• The O-ring cannot be reused.
Replace it with new part.

9. Remove the shaft (1).

7. Remove the floating seal (1) on the roller.

As described in step 6, check whether the sliding
surface has rusted or is damaged.
Also make sure the O-ring is not twisted.

10. As described in step 7, remove the floating seal (1)

on the opposite side.

84512399 EN - September 2011

5003D-8
Copyright ©
Assembly and Disassembly of Lower Roller

11. Use a caliper (6), micrometer caliper (5), and cylin- Assembly Procedures
der gauge (7) to measure the roller (with bushing)
(1), collars (2) (3), and shaft (4) for wear and defor- 1. Clean all parts by immersing them in cleaning fluid
mation. (1).
• Select a clean location.
• Place a rubber plate or cloth on the work platform
so as not to damage the parts.

2. After cleaning the parts, air blow them to remove

any remaining cleaning fluid or debris.

12. When replacing a bushing, insert jig A (3) into the

bushing (1), and use a cylindrical object (such as a
shaft) (2) to push from the top.
The bushing comes off.
3. If the bushing (2) was removed during disassembly,
put it into the roller (1).
Restraining from above using jig B (3), push in with
the pressing machine (4).
Invert the roller and insert the bushing on the oppo-
site side in the same manner.

84512399 EN - September 2011

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

5004-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

5004-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Drive Sprocket

WARNING 2. Slowly rotate the shoe so that the shoe joint section
(1) is aligned as in the diagram on the right.
• When loosening the check valve, loosen it a Place wood planks (2) under the shoe and return
little at a time and stop when any grease ap- the bucket to its original position.
pears. Perform air bleeding for the hydraulic line.
The pressure inside the cylinder is very high, For details, see Air Bleed Procedures.
so there is the danger of grease being ex-
pelled and the plug flying off if the check
valve is loosened too much.

CAUTION
• Before removing the shoes, be sure to bleed
off any air in the hydraulic circuits.
• Be sure to inspect the wire rope and other
lifting equipment before beginning work.
• Do not stand or pass under the suspended
load.

Items to prepare
• Box wrench (19 mm)
• Wrenches (19 mm, 30 mm)
• Hammer (to remove the master pin)
• Striking jig (to remove the master pin)
• Liftcrane (with the required lifting capacity)
• Wire rope (with the required breaking load)
• Loctite #262
• Wood plank
• Rag
• Cleaning fluid

Removal of Drive Sprocket

1. Allow the bucket (1) to touch the ground so as to
elevate the shoe (2) of the side to be removed as in
the diagram on the right.

84512399 EN - September 2011

5004-3
Copyright ©
Removal and Installation of Drive Sprocket

3. Use a box wrench (19 mm) to rotate the grease 5. Place a striking jig (2) against the master pin (1) and
cylinder check valve (1) and loosen the shoe ten- hit it with a hammer (3) to push the master pin out.
sion.
• Grease will flow out, so have rag ready.
If the check valve is loosened too much at this
time, it may fly off. Be careful not to work in front
of the check valve.
Tightening torque for installation: 49.0 - 68.6 N・m

6. Open the shoe (1) to the rear.

7. Use a wrench (36 mm) to remove the 24 bolts (1).

Tightening torque for installation: 900 - 1051 N·m

4. Pull out the S-pin (1) from the rear of the joint sec-
tion.

84512399 EN - September 2011

5004-4
Copyright ©
Removal and Installation of Drive Sprocket

8. Lift the drive sprocket (2) with the wire rope (1), and
remove the drive sprocket from the travel motor (3).

84512399 EN - September 2011

5004-5
Copyright ©
Removal and Installation of Drive Sprocket

Installation of Sprocket
To install, perform the reverse of the removal procedure.

84512399 EN - September 2011

5004-6
Copyright ©

Section

5005A

Removal and Installation of Take-up Roller

84512399 EN - September 2011

CONTENTS

Removal of Take-up Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Take-up Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

5005A-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

5005A-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Take-up Roller

WARNING 3. Install the lifting equipment (4) on the take-up roller

(1) and recoil spring assembly (3) and hang them
• When loosening the grease cylinder check from the side frame (2) with the liftcrane.
valve, loosen it a little at a time.
• The pressure inside the cylinder is very high,
so there is a danger of grease being expelled
and the plug flying off.
The check valve adjustment procedure
should not be done in front of the check
valve.
• Do not get under the machine when the main
unit is jacked up.
• Make sure to place the main unit on wood
planks or the like to prevent falling.
• Align the shoe assembly feed location and
stop the engine except when working.

Items to prepare
4. Place the take-up roller (1) and recoil spring assem-
• Wrench (24 mm) bly (2) onto wood planks (4) as in the diagram.
• Hammer Use a wrench (24 mm) to remove the take-up roller
• Lifting equipment bolt (3) and separate the roller and the recoil spring
• Loctite #262 assembly.
• Striking jig
• Liftcrane
• Crowbar
• Wood planks, etc.
• Rag

Removal of Take-up Roller

1. Remove the shoe assembly.
See the "Removal and Installation of Shoe Assem-
bly".
2. Use a crowbar (3) to pull off the take-up roller (1)
and recoil spring assembly from the side frame (2).

84512399 EN - September 2011

5005A-3
Copyright ©
Removal and Installation of Take-up Roller

Installation of Take-up Roller 2. Install the lifting equipment (4) on the take-up roller
(1) and recoil spring assembly (3) as in the diagram,
1. Place the take-up roller (1) and recoil spring assem- lift them up with the liftcrane, and insert them into
bly (2) onto wood planks (4) as in the diagram. Use the side frame (2).
a wrench (24 mm) to fasten the take-up roller (1) Push in with the crowbar until the recoil spring as-
and recoil spring assembly (2) with the bolt (3). sembly contacts the grease cylinder.
At this time, be sure to coat the bolt with Loctite
#262.
Installation bolt tightening torque: 267 - 312 N·m

3. Install the shoe assembly.

For details on installation, see the "Removal and
Installation of Shoe Assembly" procedure.

84512399 EN - September 2011

5005A-4
Copyright ©

Section

5005B

Assembly and Disassembly of Take-up Roller

84512399 EN - September 2011

CONTENTS

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

5005B-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

5005B-2 PRINTED IN FRANCE
Copyright ©
Assembly and Disassembly of Take-up Roller

CAUTION • Seal tape

• Oil pan (drip pan)
• To ensure safe operations, wear protective • Water container for inspection
devices before beginning work and follow all
precautions.
• When removing devices or positioning de-
vices at the time of installation, use a removal
jig and a hammer or steel rod.
• Follow the precautions below when suspend-
ing the load.
• The liftcrane must be operated by a quali-
fied operator.
• Do not stand or pass under the suspended
load.
• Check the weight of the roller to deter-
mine whether it can be carried by hand or
whether a liftcrane must be used.
• Fix the roller to a level surface so it does not
roll.
• Be sure to repair any parts damaged during
disassembly, and prepare replacement parts
in advance.
• If any parts are significantly rusted or dirty,
clean them before disassembling.
• Any foreign matter entering the equipment
during assembly can create a malfunction.
Therefore, after thoroughly cleaning the
equipment with cleaning oil, air blow the
equipment, and assemble in a clean location.
• When assembling sliding (5) parts, be sure to
coat them with new hydraulic oil.
• As a rule, replace all O-rings and other seal
parts with new parts.
• The take-up roller is a heavy object and re-
quires at least 2 workers to handle.
<General cautions>
• Be careful not to drop precision parts or let
bump them with other parts during work.
• Do not forcefully open or hit parts in an effort
to speed up operations. Pay careful attention
and proceed slowly so as not to damage any
parts, create any oil leaks, or compromise the
efficiency of the equipment, etc.
• Disassembled parts can easily rust or collect
dust. Therefore, immediately after disassem-
bling parts, take precautions to prevent the
parts from rusting or collecting dust.

5005B-6
Copyright ©
Assembly and Disassembly of Take-up Roller

Disassembly Procedures 4. After removing the O-ring (2) on the shaft (1), pull
the shaft (1) out from the roller (3).
1. After cleaning the roller with kerosene, use the
hexagon wrench (1) to remove the plug (2) from • The O-ring cannot be reused. Replace it with new
the hub (3). part.

• The plug is coated with seal nylon, which comes

off when the plug is removed.
Seal tape is necessary for reusing.

5. Remove the pin hub (2) from the hub (1).

Next, after removing the hub (1) from the shaft (3),
remove the O-ring (4) from the shaft (3).

2. Face down the part of the roller from which the

plug was removed and empty the oil from within the
roller.
• It may take a few hours to completely empty the
oil.
• Place an oil pan (1) underneath to catch the oil.

6. Remove the floating seals (2) from the hub (1).

3. Remove the pin hub (2) from the hub (1), and re-
move the hub (1) from the shaft (3).
• Only remove on one side.

84512399 EN - September 2011

5005B-7
Copyright ©
Assembly and Disassembly of Take-up Roller

7. Remove the floating seals (2) from the roller (1). 9. When replacing the bushing (1), remove it by plac-
ing a striking rod (2) against the end surface and
striking that with a hammer (3) uniformly left and
right as in the diagram.
• Do not disassemble the bushing (1) unless it has
become unusable due to wear, etc.
• Be careful not to scratch the inside of the roller
when striking the end of the bushing.

8. Use a micrometer caliper (4), cylinder gauge (5),

and caliper (6) to measure the roller (with bushing)
(1), hub (2), and shaft (3) for wear and deformation.
Replace with new parts as necessary.

10. Invert the roller (1), use jig A (2) to push up against
the bushing (3), and press with a rod-shaped object
(4) (such as a shaft). The bushing comes off.

84512399 EN - September 2011

5005B-8
Copyright ©
Assembly and Disassembly of Take-up Roller

Assembly Procedures 4. Use the jigs (1) (2) attached to the pressing machine
to install the bushing (3).
1. Clean all parts. Use the pressing machine to press from the oppo-
site side.
• Find a clean location.
Next, use a special fiber cloth to remove all dust and
• Place a rubber plate or cloth on the work platform
so as not to damage the parts. debris.
• In order to clean off adhered matter that forms
sharp points and causes scratches, immerse
parts in cleaning fluid (1) until dirt and grease
float to the top.

5. Install the floating seal (2) to the hub (1).

Use jig C (3) to press it into position.

2. After cleaning the parts, air blow them to remove

any remaining cleaning fluid or debris.
• If the parts are to be left as is for a long time after
drying them, apply engine oil.

6. Use jig C (3) to install the floating seal (2) to the

Section

5005C

Removal and Installation of Grease Cylinder

84512399 EN - September 2011

CONTENTS

Removal of grease cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of grease cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

5005C-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

5005C-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Grease Cylinder

5005D-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

5005D-2 PRINTED IN FRANCE
Copyright ©
Assembly and Disassembly of Grease Cylinder

CAUTION
• To ensure safe operations, wear protective
gear before beginning work and follow all
precautions.
• When removing devices or positioning de-
vices at the time of installation, use a removal
jig and a hammer or steel rod.
• Follow the precautions below when suspend-
ing the load.
• The liftcrane must be operated by a quali-
fied operator.
• Do not stand or pass under the suspended
load.
• Check the weight of the grease cylinder to
determine whether it can be carried by hand
or whether a liftcrane must be used.
• Be sure to repair any parts damaged during
disassembly, and prepare replacement parts
in advance.
• If any parts are significantly rusted or dirty,
clean them before disassembling.
• Any foreign matter entering the equipment
during assembly can create a malfunction.
Therefore, after thoroughly cleaning the
equipment with cleaning oil, air blow the
equipment, and assemble in a clean location.
• When assembling sliding parts, be sure to
coat them with new hydraulic oil.
• As a rule, replace all O-rings and other seal
parts with new parts.
<General cautions>
• Be careful not to drop precision parts or let
bump them with other parts during work.
• Do not forcefully open or hit parts in an
effort to speed up operations. Pay care-
ful attention and proceed slowly so as not
to deform any parts, create any oil leaks,
or compromise the efficiency of the equip-
ment, etc.
• Disassembled parts can easily rust or col-
lect dust. Therefore, immediately after dis-
assembling parts, take precautions to pre-
vent the parts from rusting or collecting
dust.

5005D-7
Copyright ©
Assembly and Disassembly of Grease Cylinder

Assembly Procedures 4. Use the jig (A) and hammer (C) to install the dust
seal (2) on the grease cylinder (1).
1. Place parts in a rough cleaning container filled with Apply grease to the lip section of the dust seal (2).
kerosene to clean off any adhered matter that can Use a new dust seal (2).
form sharp points and cause scratches.
• Immerse in kerosene until dust, grease, and other
adhered matter comes off and floats to the sur-
face.
2. Place parts in a finish cleaning container filled with
kerosene and clean while gently moving the parts.
After cleaning, wipe away the kerosene with a clean
rag.
• Place the parts in a location free of dust and mois-
ture and use compressed air to dry the parts. After
drying, coat parts with engine oil.
3. Install the U-packing (1) coated with grease onto the
piston rod (2), and then install the snap ring (3).
• Use a new U-packing (1).
• Be careful that the U-packing (1) faces correctly.

6001-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Travel Motor

WARNING 3. Place wood planks (2) under the shoe and return
the bucket to its original position.
• When loosening the check valve, loosen it a 4. Perform air bleeding for the hydraulic line.
little at a time and stop when any grease ap- For details, see "Air Bleed Procedures" under Main-
pears. tenance in the Service Text.
The pressure inside the cylinder is very high,
so there is the danger of grease being ex-
pelled and the plug flying off if the check
valve is loosened too much.

Items to prepare
• Box wrenches (19 mm, 36 mm)
• Wrenches (19 mm, 27 mm, 30 mm, 41 mm)
• Hammer (to remove the master pin)
• Striking jig (to remove the master pin)
• Liftcrane (with the required lifting capacity)
• Wire rope (with the required breaking load)
• Loctite #262
• Wood planks, etc.
• Rag
• Cleaning fluid

Removal of Travel Motor

1. Allow the bucket (1) to touch the ground so as to
elevate the shoe (2) of the side to be removed as in
the diagram.

2. Slowly rotate the shoe so that the shoe joint section

(1) is aligned as in the diagram.

84512399 EN - September 2011

6001-3
Copyright ©
Removal and Installation of Travel Motor

5. Use a box wrench (19 mm) to rotate the grease 7. Place a striking jig (2) against the master pin (1) and
cylinder check valve (1) and loosen the shoe ten- hit it with a hammer (3) to push the master pin out.
sion.
• Grease will flow out, so have rag ready.
If the check valve is loosened too much at this
time, it may fly off.
Be careful not to work in front of the check valve.

8. Open the shoe (1) to the rear.

9. Use a wrench (19 mm) to remove the 4 bolts (1),

then remove the cover (2).

6. Pull out the S-pin (1) from the rear of the joint sec-
tion.

84512399 EN - September 2011

6001-4
Copyright ©
Removal and Installation of Travel Motor

10. Use wrenches (27 mm for drain hose, 41 mm for 12. Attach the wire rope (1) to the travel motor (2) as in
high-pressure hose) to remove the drain hose (1) the diagram.
and 2 high-pressure hoses (2). Adjust the wire rope so that it is located at the center
of mass and lift it with the liftcrane so that it is slightly
• Be sure to use plugs on the removed drain and tensed.
high-pressure hoses.

13. Use a box wrench (36 mm) to remove all 27 bolts

11. Use a wrench (19 mm) to remove the pilot hose (1) (1).
and a wrench (27 mm) to remove the elbow (2).

14. Remove the travel motor (1).

84512399 EN - September 2011

6001-5
Copyright ©
Removal and Installation of Travel Motor

Installation of Travel Motor 3. Use a wrench (27 mm) to remove the elbow (2) and
a wrench (19 mm) to install the pilot hose (1).
1. Attach the travel motor to the lower frame as in the
diagram.
• Be careful of the installation angles.

4. Use wrenches (27 mm for drain hose, 36 mm for

high-pressure hose) to install the drain hose (1) and
high-pressure hoses (2).
2. Apply Loctite #262 to the installation bolt (1)
threaded sections and temporarily tighten them.
Tighten top and bottom alternately to the specified
torque so that an even tightening force acts on op-
posing corners as shown in the diagram below.
Installation bolt tightening torque: 900 - 1051 N・m

5. Use a wrench (19 mm) to install the cover (2) with

the 4 bolts (1).
Installation bolt tightening torque: 63.7 - 73.5 N･m

84512399 EN - September 2011

6001-6
Copyright ©
Removal and Installation of Travel Motor

6. Wrap the shoe (1). 9. When adjusting the track shoe tension, raise the
lower side frame as shown in the diagram.
Place a wood plank (1) under the lower frame to
prevent falling.
Adjust the tension so that the distance indicated
with A between the frame bottom (2) of the center
area of the lower side frame and the lowest hanging
part of the top of the shoe plate (3) is 360 - 380 mm.

7. Insert the master pin (1).

Insert the S-pin (2) and bend it so that it cannot slip
out.

8. Tighten the check valve (1).

While monitoring the track shoe tension, inject
grease into the grease cylinder.

84512399 EN - September 2011

6001-7
Copyright ©
Removal and Installation of Travel Motor

84512399 EN - September 2011

6001-8
Copyright ©

Section

6002

Assembly and Disassembly of Travel Motor

84512399 EN - September 2011

CONTENTS

Tools for Assembly and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Standard tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Secondary materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special Tool (jig) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Measurement device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Motor Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Precautions before motor disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disassembly procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal of supplied valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Disassembly of motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Disassembly of overload relief valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Reduction gear disassembly procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Disassembly preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Disassembly procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation to receiving platform of reduction gear (unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Removal of reduction gear cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Removal of carrier 1 assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Removal of carrier 2 assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Removal of housing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Disassembly of housing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Removal of floating seal from motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Disassembly of carrier 1 assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Disassembly of carrier 2 assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Maintenance standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Motor parts maintenance standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Reduction gear parts maintenance standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Inspection prior to reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Thrust washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Floating seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Parts maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Assembly of motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Precautions before Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Assembly procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Motor Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Motor assembly procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Assembly of the carrier 2 assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Assembly of the carrier 1 assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Installation of bearing and floating seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Assembly of the housing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Determining the thickness of the angular bearing shim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Installation of housing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Installation of carrier 2 assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Installation of carrier 1 assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Cover attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

6002-1 PRINTED IN FRANCE
Copyright ©

Gear oil filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Initial pre-conditioning operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Drain charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Performing initial operation (pre-conditioning operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
General cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Causes of troubles and countermeasures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Structural diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Travel motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Reduction gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

6002-2 PRINTED IN FRANCE
Copyright ©
Assembly and Disassembly of Travel Motor

Tools for Assembly and Disassembly

Use the tools indicated below for assembly and disassembly of the motor.

84512399 EN - September 2011

6002-3
Copyright ©
Assembly and Disassembly of Travel Motor

Standard tools
Secondary materials
Standardized
Secondary materials No. Type and dimen-
No. Part used with
name Manufacturer sions
name
1 Seal tape
242 4, 25
2 Adhesive Loctite
515 24
GL-4#90 equiva-
3 Gear oil
lent
ISO VG46 equiva-
4 Hydraulic oil
lent
5 Grease Lithium series
No.2 equivalent
6 White kerosene
oil
7 Liquid packing ThreeBond 1211
For sliding sur-
8 Lapping plate
face repair
For sliding sur-
9 Lapping agent #1000
face repair
10 Copper plate
11 Tube brush For cleaning
12 Bamboo brush For cleaning
13 Oil pan For receiving oil
14 Plastic container For filling grease
15 Rag
16 Color check 9, 10, 11, 15, 16, 17, 18, 22, 23

Special Tool (jig)

Usage target
No. Tool name Type and dimensions
part
1 Gear (bearing) puller 10, 51

2 Holder fittings (2) 13, 51

3 Rear cover guide pins (2) 1, 24

84512399 EN - September 2011

6002-4
Copyright ©
Assembly and Disassembly of Travel Motor

Usage target
No. Tool name Type and dimensions
part

4 Brake piston removal jig (2) 21

5 Shim thickness adjustment jig 52

6 Oil seal insertion jig 3

7 Rear bearing insertion jig 51

84512399 EN - September 2011

6002-5
Copyright ©
Assembly and Disassembly of Travel Motor

Usage target
No. Tool name Type and dimensions
part

8 Brake piston insertion jig 21

Piston and shoe measurement

9 12, 18
jig

84512399 EN - September 2011

6002-6
Copyright ©
Assembly and Disassembly of Travel Motor

Hexagon socket head bolt M6 x

d
100
t 10 mm or longer
When the rear cover bolts are
*1
used as is
D1 2-20 notch
10 - Plain flat washer with
D2
rounded finish 18 mm

84512399 EN - September 2011

6002-7
Copyright ©
Assembly and Disassembly of Travel Motor

Measurement device
No. Tool name Specifications Part used with
1 Dial gauge
2 Micrometer caliper
3 Micro depth gauge 0 - 15 mm (JIS B7544)
4 Caliper 0 - 150 mm (JIS B7507: 1997)

84512399 EN - September 2011

6002-8
Copyright ©
Assembly and Disassembly of Travel Motor

Motor Disassembly Procedures 5. When removing lines connected to the motor, hy-
draulic oil from inside the lines will spray out.
Precautions before motor disassembly For this reason, remove these lines only after re-
moving pressure from inside the lines and prepar-
Begin motor disassembly only after thoroughly reading ing an oil pan.
the precautions below. To prevent injuries due to the motor falling when
1. When performing disassembly, always wear protec- transporting it by lifting the motor with a liftcrane,
tive devices such as a helmet, goggles and safety lift the machine with the eyebolts (a) mounted in the
shoes. positions indicated in the diagram below.
2. Use the specified tools when performing disassem- 6. The motor is filled with hydraulic oil.
bly. Before disassembling the motor, prepare an oil pan
3. Remove all lines connected to the motor and re- and drain the hydraulic oil from the motor.
move the motor from the mother machine only after 7. To prevent injuries during disassembly, prepare a
making sure that the machine is on a level surface waist-high, stable work platform to perform work on.
and there are no external forces acting on rotating 8. The motor comprises high-precision parts.
parts so that the mother machine does not operate For this reason, foreign matter adhering to parts can
uncontrollably when the motor is removed. be damaging.
4. To prevent foreign matter from entering the lines Motor disassembly should be done in an inside
and motor when removing the motor from the space without dust, and mud and dirt should be
mother machine, sufficiently clean off mud and dirt prevented from adhering to parts.
adhered around the motor before removing lines 9. The motor comprises high-precision parts.
connected to the motor. For this reason, dents and scratches on part sur-
faces can be damaging.
Be very careful when handling parts during disas-
sembly and do not create any dents or scratching.
10. To prevent personal injury and damage to parts dur-
ing disassembly, do not force disassembly of parts
which are especially tight to disassemble.

Motor lifting positions

Tightening torque
Dimen-
Code Part name Tightening torque (N•m)
sions
415.8 - 340.2 N・m
(4) Hexagon socket head bolt M18 x 110
(Loctite #242 coating)
75.5 - 61.7 N・m
(25) Hexagon socket head bolt M10 x 30
(Loctite #242 coating)
(26) Hexagon socket head plug G3/4 161.7 - 132.3 N・m
(29) Plug M42 441 - 461
(35) Pilot valve plug G3/8 49.0 - 58.8
(38) Plug G1/4 26.46 - 32.34
(42) Plug G1/8 16.17 - 13.23
(56) Hexagon socket head bolt M18 356.4 - 291.6
(57) Overload relief valve M27 98.1 - 118
(60) Plug G1/2 107.91 - 88.29

84512399 EN - September 2011

6002-9
Copyright ©
Assembly and Disassembly of Travel Motor

Disassembly procedure However, the motor cannot be disassembled if the over-

load relief valve (56) is not removed first.
Removal of supplied valves
CAUTION
Remove the supplied valves before disassembling the
motor parts. Perform the disassembly procedure after the
• It is recommended not to remove any supplied valves motor has reached its normal temperature, oth-
other than those required for disassembly. erwise burns can occur.

Removal of supplied valves parts, make sure that the assembly direction does
not go in the opposite left-right direction.
1. Remove the M42 plug (28) and O-ring (29).
• Adhesive is applied to the thread sections to fix
2. Remove the spring (27), spring receiver (26), and the spool assembly (25), so no further disassem-
spool assembly (25). bly is possible.
• Make reference marks on the spool assembly (25) 3. Remove the plug (41), O-ring (42), orifice spring
and rear cover (23), and when reassembling the (40), and orifice (39).

84512399 EN - September 2011

6002-10
Copyright ©
Assembly and Disassembly of Travel Motor

4. Remove the overload relief valve (56). 6. Remove the coupling (57).
• When removing the overload relief valve (56), the CAUTION
valve seat (56-3) can easily come off, so be care-
ful not to let it fall inside the rear cover (23), and Be very careful not to get hands stuck between
check that it is not lost. parts or drop the carried parts on feet.
5. Loosen the pilot valve plug (34), and remove the
O-ring (35), spring (33), spring receiver (32), pilot
valve spool (30), and pin (31).

84512399 EN - September 2011

6002-11
Copyright ©
Assembly and Disassembly of Travel Motor

Disassembly of motor 5. Remove the valve plate (53) while making sure that
the cylinder block (12) does not come off.
1. Place the motor shaft horizontally and pull it out
while leaving the 2 vertically-opposite hexagon • Make reference marks on the valve plate (53) and
socket head bolts M18 x 50 (55) in place. rear cover (23), and when reassembling the parts,
2. Install guide pins (a) at the 2 vertically-opposite lo- be sure not to reverse the front and rear.
cations. (Purpose: This prevents the rear cover
from falling when removed and acts as a guide dur-
ing assembly.)
3. Slowly loosen the remaining 2 hexagon socket head
bolts M18 x 50 (55) at the same time.
4. Remove the rear cover (23) and brake spring (54)
while making sure that the cylinder block (12) does
not come out together with the rear cover (23).

CAUTION
Be very careful not to get hands stuck be-
tween parts or drop the carried parts on
feet.

• Be careful not to drop the valve plate (53), brake

spring (54), rear bearing (50) outer race, shim
(51), or O-rings (49) (46) (48).
• There is a shim (51) under the rear bearing (50)
outer race.
Be very careful not to lose this during disassem-
bly.

Removal of rear cover

b Air feed source (left side hole)

6. Using the removed hexagon socket head bolt M18 x

50 (55), press the holder fitting so as not to scratch
the sliding surface of the cylinder block (12), and let
the rear bearing (50) inner race come out.
• Insert a rubber plate between the sliding surface
and the holder fitting so as not to scratch the slid-
ing surface of the cylinder block (12).

84512399 EN - September 2011

6002-12
Copyright ©
Assembly and Disassembly of Travel Motor

7. Attach the gear (bearing) puller to the rear bearing • The piston and shoe are caulked and cannot be
(50) inner race and remove it. disassembled.

Removal of rear bearing Casing matching surface enlargement

8. While holding the brake piston (20) with the hand,
fill compressed air from the brake release oil hole
(c) and push out.

CAUTION
Be very careful as the air pressure can
cause the brake piston (20) to fly off.

• When using a removal jig, install the removal jig to

the M6 taps (2 locations) on the end of the brake
piston (20), and pull out the brake piston (20).
9. Insert a rod that will not scratch the cylinder block
(12) (such as rolled-up cylindrical paper) into the
piston (17) hole, and make a reference mark on
the outer circumference of the cylinder block (12)
for reference.
10. Remove the rotary group (cylinder block (12), piston
assembly (17), shoe retainer (16), spherical joint
(15), spring receiver (14), and cylinder spring (13)).

CAUTION
Be very careful not to get hands stuck be-
tween parts or drop the carried parts on
feet.

11. Remove the separator plate (18) and friction plate

(19).
12. Remove the 9 piston assemblies (17), shoe retainer
(16), and spherical joint (15) from the rotary group
at the same time.
13. Remove the spring receiver (14) and cylinder spring Removal of cylinder block
(13) from the cylinder block (12). [Tip]
• With the piston assembly (17) and shoe retainer The preceding described how to disassemble the
(16) removed, align the alignment mark (e) and motor unit, but the disassembly is also the same
the reference mark (d) and insert them into the if it comes with a reduction gear.
cylinder block (12). Disassembling a motor with a reduction gear may
The purpose is to house the pistons into the same be easier because the shaft does not swing as
holes before disassembly when reassembling. much.
• Be careful not to scratch each of the sliding sur- 14. Remove the shoe plate (11).
faces.
If the sliding surface is scratched, the part cannot
be reused.

84512399 EN - September 2011

6002-13
Copyright ©
Assembly and Disassembly of Travel Motor

15. Do not remove the tilting piston assemblies (5), (6).If

these parts must be removed, hold the tilting piston
(5) with the hand and fill air from the tilting path hole
(f) and push out the parts.

CAUTION
Be very careful as the air pressure can
cause the tilting piston (5) to fly off.

16. The shaft (8) can be pulled out.

17. When replacing the front bearing (9), remove the
inner race from the shaft (8) with the bearing puller,
and replace with a new bearing.
• When replacing parts related to the tightening
margin of the bearing, such as the bearings (9)
(50), shaft (8), casing (1), and rear cover (23), the
thickness of the shim (51) needs to be adjusted.
Correctly measure the shim gap when the shim
is lightly positioned, replace with a shim (51) that
matches the gap, and adjust the bearing gap to 0
- 0.1 mm.
A separate jig or other tool is needed to determine
the jig thickness.
Contact us for details.
• Do not remove the pivot (10).
If removing the part, make a reference mark on
the area aligned with the shoe plate (11).
• Do not remove the oil seal (3).
If the part is removed, always replace with a new
part. Removal of shoe plate
If removing the oil seal, remove the retaining ring 18. Determining the thickness of the taper roller bearing
(4), and then remove the oil seal (3). shim (51)

Casing matching surface enlargement

84512399 EN - September 2011

6002-14
Copyright ©
Assembly and Disassembly of Travel Motor

Disassembly of overload relief valve

• The overload relief valve (56) is an important part in
terms of performance and safety.
Because resetting the pressure of this part is ex-
tremely difficult, the overload relief valve assembly
should be replaced without disassembling if a problem
occurs.

• The valve seat (56-3) fits into the socket (56-1) internal
hole by a clearance fit and can easily come off, so
when removing the overload relief valve (56) from the
rear cover (23), be careful not to drop or lose the valve
seat (56-3).When installing the overload relief valve
(56) to the rear cover, apply grease (g) to the fitting
section and install in a way that the valve seat (56-3)
does not come off.

Determining the shim thickness

• This needs to be performed when replacing the
motor casing (1), rear cover (23), shaft (8), or
bearings (9) (50).
1) Measure dimension E in the assembled con-
dition indicated in the above diagram.
• Be careful not to allow the shaft (8) to fall.
2) Measure dimension F on the rear cover side.
• Use the average of the measurements of
the 4 orthogonally intersecting points on the
circumference.
3) When the thickness of the used shim (51) is Valve seat fitting section
"S," gap "Y" is as follows.
Y = F - (E + S)
4) In the case of this motor, select 1 or 2 shims
(51) so that gap Y is 0 - 0.1 mm.

84512399 EN - September 2011

6002-15
Copyright ©
Assembly and Disassembly of Travel Motor

Reduction gear disassembly Disassembly procedure

procedures Installation to receiving platform of reduction
gear (unit)
Disassembly preparations
1. Remove 3 hexagon socket head bolts M12 × 30
1. The unit removed from the actual machine is dirty (28) screwed into the cover (27) at approximately
with dirt and debris. the same distance apart, and instead, install and
Clean the exterior of the unit and let it dry. suspend the M12 eyebolts, and install the receiving
platform with the cover in the raised position and the
CAUTION
CAUTION
Perform the disassembly procedure after
the reduction gear has sufficiently cooled • Be very careful not to get hands stuck be-
down, otherwise burns can occur. tween parts or drop the suspended parts
on feet.
2. Loosen the drain and the feed plug G3/4 (29) to • Lift the part in a horizontal position.
drain the gear oil inside the reduction gear.

CAUTION
When the gear oil is still hot, the pressure
inside can cause the oil to spray out.

3. Make reference marks (h) to the outside of each

alignment surface so that the part can be assem-
bled in its original form.

84512399 EN - September 2011

6002-16
Copyright ©
Assembly and Disassembly of Travel Motor

Removal of reduction gear cover 2. The contact surfaces of the cover (27) and ring gear
(3) are coated with sealant, so place a metal pin
1. Remove the remaining hexagon socket head bolts
against the projected part of the cover and use a
M12 × 30 (28).
hammer to strike it obliquely upward to remove the
cover.

CAUTION
Be very careful not to get hands stuck be-
tween parts or drop the suspended parts
on feet.

Removal of carrier 1 assembly 3. Remove the sun gear 1 (25).

1. Remove the thrust plate (26). CAUTION
2. Install 3 M10 eyebolts on the carrier 1 (19), then
remove the carrier 1 assemblies (19, 20, 21, 22, 23, Be very careful not to get hands stuck be-
24). tween gears.
CAUTION
• Be very careful not to get hands stuck be-
tween parts or drop the suspended parts
on feet.
• Lift the part in a horizontal position.

84512399 EN - September 2011

6002-17
Copyright ©
Assembly and Disassembly of Travel Motor

Removal of carrier 2 assembly 2. Install 3 M10 eyebolts on carrier 2 (11), then remove
the carrier 2 assemblies (11, 12, 14, 15, 16, 17).
1. Remove the sun gear 2 (18).
CAUTION
CAUTION
• Be very careful not to get hands stuck be-
Be very careful not to get hands stuck between parts or drop the suspended parts
tween gears. on feet.
• Lift the part in a horizontal position.

Removal of housing assembly hexagon socket head bolt M20 × 120 (4)) while lift-
ing it in a horizontal position.
1. Remove the support ring (10).
CAUTION
• Be very careful not to get hands stuck be-
tween parts or drop the suspended parts
on feet.
• Lift the part in a horizontal position.

2. Place a screwdriver or other tool on the divided sur-

face of the lock washer (9) and strike the tool with a
hammer to remove the lock washer (9).

3. Install 3 M12 eyebolts into the M12 threaded holes

on the ring gear (3) at approximately the same dis-
tance apart, and remove the housing assembly (ring
gear (3), housing (1), bearing (2), floating seal (7),

84512399 EN - September 2011

6002-18
Copyright ©
Assembly and Disassembly of Travel Motor

Removal of housing assembly

84512399 EN - September 2011

6002-19
Copyright ©
Assembly and Disassembly of Travel Motor

Disassembly of housing assembly Disassembly of housing assembly

2. Remove the floating seal (7) from the seal cover (5).
1. Install 3 M24 eyebolts into the M24 threaded holes
3. Remove the hexagon socket head bolts M10 x 25
on the housing (1) at approximately the same dis-
(6), then remove the seal cover (5) from the housing
tance apart, and place it on the receiving platform
(1).
with the ring gear (3) in the lowered position and the
4. Remove the hexagon socket head bolts M20 x 120
housing (1) in the raised position.
(4) while leaving 2 diagonally opposite bolts.
Make reference marks to the outer circumference of
5. With the remaining 2 hexagon socket head bolts
the housing and ring gear.
M20 x 120 (4) loosened, tap the heads of the bolts
CAUTION with a hammer to easily remove the ring gear (3)
from the housing (1).
• Be very careful not to get hands stuck be-
tween parts or drop the suspended parts CAUTION
on feet.
Be very careful not to get hands stuck be-
• Lift the part in a horizontal position.
tween parts or drop the suspended parts
• Make the receiving platform 300 mm high
or more. on feet.

Removal of floating seal

• Be careful not to scratch the sliding surface of the
floating seal (7) and its O-ring.
• The bearing (2) outer race and housing (1) inner
diameter form a very tight fit.
Do not disassemble this unless it is necessary to
replace the bearing (2).
When removing the bearing (2) from the housing
(1), replace with a new part instead of reusing the
part.

84512399 EN - September 2011

6002-20
Copyright ©
Assembly and Disassembly of Travel Motor

Removal of floating seal from motor 3. Remove the thrust washer 1 (21), planetary gear 1
(20), and needle bearing (22) from the carrier 1 (19).
1. Remove the floating seal (7) on the motor.
Disassembly of carrier 1 assembly CAUTION

• When reusing the carrier pin 1 (23), place codes on Be very careful not to get hands stuck be-
the carrier 1 (19) hole and carrier pin 1 (23) so that the tween the gear and carrier.
parts can be reassembled in the same combination as
before disassembly, and store the parts. 4. Pull out the spring pin 6 × 36 (24) from the carrier
pin 1 (23).
1. Push the spring pin 6 × 36 (24) into the carrier pin
1 (23). • When replacing the carrier pin 1 (23) or planetary
gear 1 (20), be sure to replace with 1 set of 3 parts.

2. Remove the carrier pin 1 (23) from the carrier 1 (19).

84512399 EN - September 2011

6002-21
Copyright ©
Assembly and Disassembly of Travel Motor

Disassembly of carrier 2 assembly 3. Remove the thrust washer 2 (13), planetary gear 2
(12), and needle bearing (14) from the carrier 2 (11).
• When reusing the carrier pin 2 (15), place codes on
the carrier 2 (11) hole and carrier pin 2 (15) so that the CAUTION
parts can be reassembled in the same combination as
before disassembly, and store the parts. Be very careful not to get hands stuck be-
tween the gear and carrier.
1. Push the spring pin 10 × 63 (16) into the carrier pin
2 (15).
4. Pull out the spring pin 10 × 63 (16) from the carrier
pin 2 (15).
• When replacing the carrier pin 2 (15) or planetary
gear 2 (12), be sure to replace with a set of 3 parts.

2. Remove the carrier pin 2 (15) from the carrier 2 (11).

84512399 EN - September 2011

6002-22
Copyright ©
Assembly and Disassembly of Travel Motor

Maintenance standards
Motor parts maintenance standards
The reference values indicating whether or not a part can be reused are indicated using the measurement values at
the time a part is disassembled.
However, this is a general reference, and when determining whether a part should be replaced, priority is given to
performance prior to disassembly, the purpose of disassembly and the expected remaining life of the part if there is
any damage or discoloration that significantly affects the part appearance.
Measurement item and measurement method
1. Sliding surfaces: cylinder block, valve plate, and shoe plate
Judgment criteria and solution
• Use a surface roughness gauge to measure the roughness of the sliding surfaces of these parts.

Part name and inspection Permissible

Standard value Solution
item limit value
Surface roughness
• Cylinder block 0.4 Zμ or lower 3.0 Zμ or lower Repair or replace.
• Valve plate
• Shoe plate

• Perform common lapping to correct the surface roughness of the cylinder block and valve plate. (Lapping
material #1200)
• Use a hardness gauge to measure the hardness of the shoe plate sliding surface.

Part name and inspection Permissible

Standard value Solution
item limit value
Shoe plate
HS78 or higher HS74 Replacement
• Sliding surface hardness

2. Clearance of piston and cylinder block

Judgment criteria and solution
• Use a micrometer caliper to measure the piston outer diameter and cylinder bore inner diameter at least 3
locations in the longitudinal direction.
Maximum outer diameter value (piston) = d maximum
Minimum outer diameter value (piston) = d minimum
Minimum inner diameter value (cylinder bore) = D minimum
Maximum inner diameter value (cylinder bore) = D maximum

Measurement locations

84512399 EN - September 2011

6002-23
Copyright ©
Assembly and Disassembly of Travel Motor

Part name and inspection Permissible

Standard value Solution
item limit value
Piston outer diameter d
0.01 mm 0.05 mm
maximum - d minimum
Cylinder bore inner diame-
Replace the piston or cylinder block.
ter D maximum - D mini- 0.01 mm 0.022 mm
mum
Clearance D - d 0.037 - 0.047 mm 0.065 mm

• Piston replacement should be performed 9 pistons at a time.

3. Piston and shoe backlash
Judgment criteria and solution
• Use a measurement jig to press the shoe on the surface plate, pull out the pistons in an upward direction, and
measure the piston and shoe backlash δ.
(See "Caulking section backlash" and "Measuring backlash".)

Part name and inspection Permissible

Standard value Solution
item limit value
Piston and shoe backlash 0 - 0.1 mm 0.3 mm Replace piston.

Caulking section backlash Measuring backlash Measurement jig

1 Dial gauge 3 Jig *5 Surface plate

*2 Piston *4 Shoe *6 Magnet

4. Parking brake force

Judgment criteria and solution
• After completing assembly, tighten the torque of the output shaft end with a torque wrench, and measure the
torque when starting rotation.
84512399 EN - September 2011
6002-24
Copyright ©
Assembly and Disassembly of Travel Motor

Part name and inspection Permissible

Standard value Solution
item limit value
• Separator plate
Parking brake torque 1171 N・m 1055 N・m • Friction plate
• Spring Replace all.

Guidelines for replacing the friction plates and partner plates

To measure the brake torque, the motor must be separated to a single unit.
It is extremely difficult to separate the motor by removing it from the mother machine or disassembling the
reduction gear.
Use the following method to determine whether to replace these parts when inspecting the parts during main-
tenance.
Replacement guidelines
Measure the pack length of the 6 friction plates and 7 separator plates, and if the value is less than the permis-
sible value indicated below, replace all friction plates, separator plates, and springs.

Reference value: 33.04 mm (nominal dimensions in the diagram)

Permissible value: 31.5 mm

1. Apply grease to the oil seal (3) outer circumference
Precautions before Motor Assembly and casing (1) inner circumference, then use an in-
Begin motor assembly only after thoroughly reading the sertion jig (a) to tap the oil seal (3) into the casing
precautions below. (1) evenly so that it does not fall down.
2. Use a retaining ring (4) to fasten the oil seal (3).
1. When performing assembly, always wear protec- 3. Insert the front bearing (9) outer race into the casing
tive devices such as a helmet, goggles and safety (1). (Clearance fit)
shoes. Press fit the inner race into the shaft (8). (Tight fit)
2. Use the specified tools when performing assembly.
3. To prevent injuries during disassembly, prepare a • Heating the inner race to 100°C or lower provides
waist-high, stable work platform to perform work on. for easier press fitting.
4. The motor comprises high-precision parts.
For this reason, foreign matter adhering to parts can CAUTION
be damaging. Use caution to prevent burns.
Motor assembly should be done in an inside space
without dust, and mud and dirt should be prevented 4. Install the shaft (8) into the casing (1).
from adhering to parts. Apply grease to the surface contacting the oil seal
5. The motor comprises high-precision parts. (3).
For this reason, dents and scratching on part sur- 5. Install the tilting piston sets (5), (6), and (7).
faces can be damaging.
Be very careful when handling parts during assem- • Insert the tilting piston (5) so that it is not tilted.
bly and do not create any dents or scratching. • When installing the tilting piston (5), apply grease
6. Be sure to repair any damage discovered during to the seal parts and insert the piston carefully so
disassembly and prepare replacement parts before as not to cut anything.
beginning assembly.
6. Install the pivot (10).
7. Remove metal fragments and foreign matters from
Install it to the side matching the reference mark on
all parts and check that there are no burrs or dents
the shoe plate (11).
on parts before beginning assembly.
When operated for a long period of time, install it
If there are burrs or dents, use a whetstone to re-
in the direction in which the slide imprints of the
move them.
spherical section match the contact imprints of the
8. When performing assembly, apply clean hydraulic
shoe plate (11).
oil to each sliding and rotating sections before as-
sembly.
9. Thoroughly degrease areas where Loctite and liquid
packing is used and remove oil and water before
assembly.
10. Replace all seal parts such as O-rings and backup
rings with new parts.
11. Be careful not to damage O-rings and backup rings
during assembly.
When assembling O-rings and backup rings, apply
a small amount of grease for assembly.
12. It is recommended that petroleum jelly or grease be
used to prevent parts from falling during assembly.
13. Tighten the bolts and other fastening sections to the
tightening torque.
Tightening torque should be controlled with a torque
wrench.
14. After assembly is complete, plug all ports leading
into the motor to prevent dirt from entering.

Assembly procedure
Perform assembly by observing the precautions listed in
"Precautions before motor disassembly" and following
the procedure indicated below.

84512399 EN - September 2011

6002-28
Copyright ©
Assembly and Disassembly of Travel Motor

Installation of oil seal 8. After subassembling the piston assembly (17), shoe
retainer (16), spherical joint (15), spring receiver
(14), cylinder spring (13), and cylinder block (12),
insert the entire subassembly into the shaft (8).

CAUTION
Be very careful not to get hands stuck be-
tween parts or drop the carried parts on
feet.

• The piston assembly (17) must be inserted into

the same holes of the cylinder block (12) used
before disassembly.

Installation of shoe plate

7. Thoroughly grease the 3 spherical sections of the
shoe plate (11) before installation.

Installation of piston assembly

9. Use a specialty insertion jig (A1, A2) to insert the
rear bearing (50) inner race into the shaft (8).
10. Alternately install all of the separator plates (18) and
friction plates (19) in turn.
The separator plate (18) should be the first and last
parts.
11. Use an insertion jig (B) to insert the brake piston (20)
installed with D-rings (21) and (22) in the casing (1).
• Apply grease to the D-rings (21) and (22).
• Use the insertion jig to make sure the brake piston
(20) is inserted evenly.
The brake piston is equipped with 2 large and
small D-rings (21) and (22).
First, the large-diameter D-ring (22) is inserted
into the hole, then the small-diameter D-ring (21)
is inserted.

84512399 EN - September 2011

6002-29
Copyright ©
Assembly and Disassembly of Travel Motor

The insertion condition of the small-diameter 14. Insert the rear cover (23) into the casing (1) accord-
D-ring (21) cannot be visually checked, so do not ing to the guide pins (f), then tighten with hexagon
forcefully insert this D-ring. socket head bolts M18 x 50 mm (55) at 2 verti-
This can cause chipping by the casing (1) hole. cally-opposite locations so that the rear cover is in-
stalled in a parallel orientation. After tightening the
bolts, tighten with hexagon socket head bolts M18
x 50 mm (55) at the locations excluding the 2 loca-
tions with installed guide pins.
After tightening the bolts, remove the guide pins
and tighten the remaining 2 locations with hexagon
socket head bolts M18 x 50 mm (55).

CAUTION
Be very careful not to get hands stuck be-
tween parts or drop the carried parts on
feet.

Installation of brake piston

b Rear bearing insertion jig A1

c Brake piston insertion jig B
10 - Plain flat washer with
d
rounded finish 18 mm
e Plastic hammer A2

• The shim must be adjusted when replacing parts

related to the shim adjustment.
Perform the assembly after determining the shim
thickness in advance by using the procedure Installation of rear cover
in "Determining the thickness of the taper roller
bearing shim (51)" in "Disassembly procedures". • If the outer race of the rear bearing (50) is re-
moved, do not forget to install the shim (51).
12. Install guide pins at 2 vertically-opposite locations Check whether the O-rings (46), (48), (49) are
on the casing (1). installed to the rear cover (23).
13. Install the valve plate (53) in the rear cover (23)
• The tightening torque for the hexagon socket
according to the reference mark made at the time of head bolts M18 x 50 mm (55) is 291.6 - 356.4
disassembly, then mount the shim (51), rear bearing N・m.
(50) outer race, brake spring (54), and O-rings (49),
(46), (48). 15. Install the coupling (57).

84512399 EN - September 2011

6002-30
Copyright ©
Assembly and Disassembly of Travel Motor

16. Install the spring (33), spring receiver (32), pilot • The valve seat (56-3) is fit with a clearance fit,
valve spool (30), and pin (31) in the rear cover (23), so during installation, install the valve seat after
then tighten with the pilot valve plug (34) with the making sure that it will not come off by applying
O-ring (35) installed. grease to the fitting sections so that the valve seat
does not fall off or become lost.
• The tightening torque for the overload relief valve
(56) is 98.1 - 118 N･m.
18. Install the orifice (39) and orifice spring (40) in the
rear cover (23), then tighten with the plug (41) with
the O-ring (42) installed.
• The tightening torque for the plug (41) is 14.7 N・
m.
• When using a new orifice (39), adjust the seat
section.
(With a hammer, tap the orifice installed to the rear
cover.)
19. Insert the spool assembly (25) into the rear cover
(23) according to the reference mark made at the
time of disassembly, then install the spring receiver
(26) and spring (27) in that order.
• The spool assembly (25) is directional, so insert it
in the correct direction.
20. Tighten the M42 plug (28) with the O-ring (29) in-
stalled.
• The tightening torque for M42 plug (28) is 441 -
446 N・m.

Installation of supplied valve

• The tightening torque for the pilot valve plug (34)
is 49.0 - 58.8 N･m.
17. Install the overload relief valve (56).

84512399 EN - September 2011

6002-31
Copyright ©
Assembly and Disassembly of Travel Motor

Motor assembly procedure • For the direction of inserting the spring pin and
the caulking method, see "Spring pin and caulking
Assembly of the carrier 2 assembly details".
1. Insert the spacer (17), planetary gear 2 (12), bear-
ing (14), and C retaining ring for the hole (13) into
carrier 2 (11).

CAUTION
Be very careful not to get hands stuck be-
tween the gear and carrier.

2. Align the carrier pin 2 (15) with the spring pin hole
and insert it into the carrier 2 (11).

Spring pin and caulking details

The spring pin opening section

*1
must be as in the diagram.
2 locations opposing each
*2 other at 180° must be caulked
as in the diagram.
The 0.5 mm spring pin must be
*3
hidden by the "caulking".
Sink the spring pin tip 1.0 to 2.0
*4
3. Insert the spring pin 10 x 63 (16) into the carrier pin mm.
2 (11) and carrier pin 2 (15). (Hammer it 1 - 2 mm
deeper than the striking surface.) a Pinion side

4. Caulk at 2 opposing 180° locations.

84512399 EN - September 2011

6002-32
Copyright ©
Assembly and Disassembly of Travel Motor

Determining the angular bearing shim

thickness
Installation of housing assembly
1. Place the motor shaft upwards on the work platform,
then place the shim (8) selected by item e) (Deter-
mining the thickness of the angular bearing shim)
on the end surface of the bearing insertion part of
the motor casing.

CAUTION
• Be very careful not to get hands stuck be-
tween parts or drop the suspended parts
on feet.
• Lift the part in a horizontal position.

2. Install 3 M12 eyebolts on the ring gear (3) and sus-

pend the ring gear. Slowly lower it vertically while
aligning it with the motor core and insert the bear-
ings (2) that have been installed in the inner diam-
eter of the housing (1) into the motor.
Use a pressing machine to press the inner race
parts of the bearings (2) with the press (*3) and in-
sert them completely to the bottom.

CAUTION
• Be very careful not to get hands stuck be-
tween parts or drop the suspended parts
on feet.
• Lift the part in a horizontal position.
Press fitting of the housing assembly

84512399 EN - September 2011

6002-36
Copyright ©
Assembly and Disassembly of Travel Motor

3. Insert the lock washer (9) into the groove while Installation of carrier 2 assembly
pressing the flange part of the housing (1).
1. Insert 3 M10 eyebolts in the carrier 2 assembly, lift
it up, insert the carrier 2 assembly into the ring gear
(3) so that the 3 planetary 2 (12) are at the posi-
tion indicated in "carrier 2 installation direction" and
have the gears mesh with the spline of the motor
casing.

4. Insert the support ring (10) into the outside of the

lock washer (9).

Installation of the carrier 2 assembly

CAUTION
• Be very careful not to get hands stuck be-
tween parts or drop the suspended parts
on feet.
• Lift the part in a horizontal position.

2. Insert the sun gear 2 (18).

CAUTION
Be very careful not to get hands stuck be-
tween gears.

• The carrier 2 assembly is assembled at the posi-

tion indicated in "carrier 2 installation direction" to
improve oil lubrication, so be sure to observe this
procedure.

Carrier 2 installation direction

*4 Carrier 2
*5 Notching V into carrier 2
*6 Motor port

84512399 EN - September 2011

6002-37
Copyright ©
Assembly and Disassembly of Travel Motor

Installation of carrier 1 assembly 3. Install the thrust plate (26) on the carrier 1 (19).
1. Install 3 M10 eyebolts in the carrier 1 assembly, lift it • Face the sharp edge toward the cover (27) side.
up, insert into the ring gear (3), turn planetary gear
1 (20) by hand to align the position, and mesh with
sun gear 2 (18).

CAUTION
• Be very careful not to get hands stuck be-
tween parts or drop the suspended parts
on feet.
• Lift the part in a horizontal position.

2. After making sure that the coupling (See the motor

parts Operator's Manual.) is at the end of the motor
shaft, insert the sun gear 1 (25).

CAUTION
Be very careful not to get hands stuck be-
tween gears.

Thrust plate installation direction

*7 Reduction gear cover

Installation of carrier 1 assembly *8 Sharp edge

84512399 EN - September 2011

6002-38
Copyright ©
Assembly and Disassembly of Travel Motor

Cover attachment 2. Coat the 25 hexagon socket head bolts M12 x 30

mm (28) with Loctite #242, then tighten the bolts to
• The gear oil can be filled before installing the cover the tightening torque of 88.3 - 107.9 N・m.
(27).
• For details on applying Loctite #242 to the bolts,
1. Coat the cover (27) surface that matches with the
see "Method of applying Loctite #242".
ring gear (3) with Loctite #515 (*9), then install the
cover (27) on the ring gear (3).

CAUTION
Be very careful not to get hands stuck be-
tween parts or drop the suspended parts
on feet.

Applying Loctite to the cover end surface

Gear oil filling
1. Fill with gear oil (SAE90, API GL-4 or GL-5, 15 liters)
from the filling port G3/4.
2. Install the plug G3/4 (29) in the cover (27) to a tight-
ening torque of 132.4 - 161.8 N・m.

84512399 EN - September 2011

6002-39
Copyright ©
Assembly and Disassembly of Travel Motor

Initial pre-conditioning operation

Drain charge
After disassembly and assembly, completely fill the case of the motor casing with hydraulic oil.
This motor has 2 drain ports (G1/2). Perform air bleeding from the port on the side without a line (top side).
Performing initial operation (pre-conditioning operation)
Perform a pre-conditioning operation for about 5 min. at the motor tilting 1st speed and engine low idle, and check
for abnormalities, such as abnormal noise or external leaks.
Troubleshooting
See the troubleshooting section below to perform checking, countermeasures and to solve problems when any kind
of problem occurs in the motor during operation.
General cautions
Think before attempting to fix a problem.
Determine the nature of the abnormality before beginning work, and think whether this same kind of problem has
occurred before.
Also, reconfirm whether the motor is the source of the problem.
Be careful about dust and dirt.
The cause of wear is very often dust and dirt. So take measures to prevent dust or dirt from entering the parts during
disassembly.
Parts handling
Handle parts carefully, be especially careful with the drive section, and do not scratch the sliding sections.
Seals handling
Do not damage the seat surfaces of O-rings while performing work.
Also, it is recommended that O-rings be replaced with new ones during disassembly.

Causes of troubles and countermeasures

Parking brake operation problem Inspect and repair or replace the
The brake does not operate. a) Wear on the friction plate brake piston, friction plate, and
b) Broken spring spring(s).
Spool operation defect
a) Sticking of the spool and main unit
The reverse brake works. b) Sticking of the check valve or debris is Repair or replace.
caught in the check valve
c) Orifice hole is clogged.

Oil leak

Symptom Cause Countermeasure

1. Retighten to the specified
1. Bolt and plug loosening
torque.
Oil leak
2. Gouging of O-ring(s) 2. Replace the O-ring.
3. Leak inside gear casing 3. Replace the oil seal(s).

11 Shoe plate 31 Pin 51 Shim
12 Cylinder block 32 Spring receiver 52 Parallel pin
13 Cylinder spring 33 Spring 53 Valve plate
14 Spring receiver 34 Pilot valve plug G3/8 54 Brake spring
Hexagon socket head bolt
15 Spherical joint 35 O-ring 1B P14 55
M18 x 50
16 Shoe retainer 36 Joint 56 Overload valve
17 Piston assembly 37 G1/4 plug 57 Coupling
18 Separator plate 38 O-ring 1B P11 58 C retainer ring 40 for hole
19 Friction plate 39 Orifice 59 G1/2 plug
20 Brake piston 40 Orifice spring (brake valve) 60 O-ring 1B P18

84512399 EN - September 2011

6002-44
Copyright ©
Assembly and Disassembly of Travel Motor

Reduction gear

Diagram 2 Reduction gear structural diagram

Code Part name Code Part name Code Part name

1 Housing 11 Carrier 2 21 Thrust washer 1
Needle bearing FBNP-
2 Bearing 280BA40GS 12 Planetary 2 22
406040
3 Ring gear 13 C stop ring 120 for hole 23 Carrier pin 1
Hexagon socket head bolt
4 14 Bearing 22213EAE4 24 Spring pin 6 x 36
M20 x 120
5 Seal cover 15 Carrier pin 2 25 Sun gear 1
Hexagon socket head bolt
6 16 Spring pin 10 x 63 26 Thrust plate
M10 x 25
7 Floating seal 368 17 Spacer 27 Cover
Hexagon socket head bolt
8 Shim 18 Sun gear 2 28
M12 x 30

84512399 EN - September 2011

6002-45
Copyright ©
Assembly and Disassembly of Travel Motor

Code Part name Code Part name Code Part name

9 Lock washer 19 Carrier 1 29 Plug G (PF) 3/4
10 Support ring 20 Planetary 1 30 O-ring 1B P24

84512399 EN - September 2011

6002-46
Copyright ©

Section

6003

Removal and Installation of Swing Unit

84512399 EN - September 2011

CONTENTS

Removal of Swing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Swing Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

6003-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

6003-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Swing Unit

Job code 35352AL08 Removal of Swing Unit

1. Use a hexagon wrench (5 mm) to remove the 4 bolts
WARNING (1), and then remove the air breather (2) on the
hydraulic oil tank.
• Be sure to release hydraulic pressure before Tightening torque for bolt installation: 2.94 - 4.90
beginning work.
N・m

CAUTION
• Be sure to stop the engine before beginning
work.
• Be sure to inspect the wire rope and other
lifting equipment before beginning work.
• Do not stand or pass under the suspended
load.
• When removing this product from the equip-
ment it is mounted on, stop that equipment
system and wait for the surface temperature
of this product to fall to about 40 °C or below
before removing it.
Working on this product while it is still hot
can cause burns. 2. Attach the specialty adapter (1) to the area where
Additionally, always bleed out the pressure the air breather was removed, and set the vacuum
before removing any line from this product. pump.
Removing a pressurized line can result in oil Create negative pressure in the hydraulic oil tank
spraying out and causing injury or oil leak. using the vacuum pump (2).

Items to prepare
• Wrenches (14 mm, 19 mm, 27 mm, 36 mm, 41 mm)
• Hexagon wrenches (5 mm, 8 mm, 17 mm)
• Box wrench (36 mm)
• Pliers
• Hammer
• Grease
• Specialty adapter for vacuum pump connection
• Vacuum pump (vacuum pump power supply)
• Extension cable
• Wire rope (with the required breaking load)
• Marking pen
• Caps
• Plugs
3. Use a wrench (19 mm) to remove the 6 bolts (1),
• Liftcrane (with the required lifting capacity)
and then remove the center cover (2).
• Rag
• Cleaning fluid
• Wood planks, etc.

4. Use a hexagon wrench (8 mm) to remove the 8

hexagon bolts, and then remove the hoses (1) and
(2).
Next, use a wrench (41 mm) to remove the hose (3),
use a wrench (36 mm) to remove the hoses (4) and
(5).

84512399 EN - September 2011

6003-3
Copyright ©
Removal and Installation of Swing Unit

• Mark the swing motor and hoses so that the con- 7. Use a box wrench (36 mm) to remove the 12 bolts
nectors can be matched during assembly. (1) from the swing unit.
• Attach caps or plugs to the swing motor and hoses Tightening torque for bolt installation: 900 - 1050
to prevent any entry of water, dust or dirt. N・m
• Clean the swing motor and hoses by spraying
them with a parts cleaner to prevent scratching
and prevent dirt from accumulating on the con-
nectors.

8. Wrap the wire rope (1) around the swing motor and
lift it with a liftcrane.
• A knock pin (2) is driven into the installation sec-
tion of the swing unit. Apply lubricating oil to the
5. Use a wrench (19 mm) to remove the 3 bolts (1), knock pin and pull it out together with the main unit
and then remove the under cover (2). of the swing motor while hitting with a hammer.

6. Use a wrench (13 mm) to remove the bolt (3) on the

6004-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

6004-2 PRINTED IN FRANCE
Copyright ©
Assembly and Disassembly of Swing Unit

Job code 35352AF10 Disassembly

1. Making a reference mark on the unit matching sur-
CAUTION face
It is useful to place a reference mark (*1) on the
1. Read and understand the contents of this matching surface of the housing (1) and ring gear
Maintenance Manual before performing (2) with paint, etc.
disassembly, reassembly, inspection, re-
pair, or other such work of this product.
2. Handle this product according to the sep-
arate "Usage Precautions".
3. When removing this product from the
equipment it is mounted on, stop that
equipment system and wait for the surface
temperature of this product to fall to about
40 °C or below before removing it.
Working on this product while it is still hot
can cause burns.
Additionally, always bleed out the pressure
before removing any line from this prod-
uct.
Removing a pressurized line can result in
oil spraying out and causing injury or oil 2. Removal of level gauge assembly
leak. Remove the level gauge assembly (3) and cap (4)
4. Use the specialty tools and measurement (27 mm hexagon diameter).
instruments for disassembly, reassembly,
inspection, and repair, etc. of this product.
Using an inappropriate tool may result in
injury or product damage.
5. Be careful of parts falling when performing
disassembly, reassembly, inspection or re-
pair, etc. of this product.
This may result in injury or parts damage.
6. Do not directly touch with bare hands the
machined edges or threaded sections of
parts during disassembly, reassembly, in-
spection, or repair etc. of this product.
This may result in injury.
7. Check performance after reassembly.
Do not resume use unless performance is
fully recovered.
Use may result in damage to product.
8. The cautions (mark !) listed in this Main-
tenance Manual do not cover all possible
dangers.
Always think of safety first during disas-
sembly, inspection, reassembly, repair, or
other such work.

84512399 EN - September 2011

6004-3
Copyright ©
Assembly and Disassembly of Swing Unit

3. Gear oil draining 5. Removal of motor

Loosen the drain hose (*2) end plug, and then drain Use the hexagon wrench (17 mm) to loosen and
the gear oil. remove the 12 hexagon socket head bolts (6).
Use the make-up port (G1) to raise the motor and
• Gear oil cannot be reused. remove it.
• Liquid packing has been applied to the matching
surfaces of the housing (7) and ring gear (8), so
use the notch sections (*3) in the diagram to re-
move the motor.

5 Reduction gear

4. Removal of hose
Remove the drain hose (*2).

5 Reduction gear

This completes the disassembly.

84512399 EN - September 2011

6004-4
Copyright ©
Assembly and Disassembly of Swing Unit

Assembly Install a plug in the female side of the hose, and

install a hose (*3) in the drain port on the side of the
1. Application of liquid packing gear case (5).
After cleaning and degreasing the reduction gear Fill with gear oil (6 L) from the housing (3) gear oil
ring gear (1) and the motor housing matching sur- fill port.
faces, apply liquid packing (ThreeBond Co.,Ltd.
"1215" gray or the equivalent) as shown in the
diagram on the right (*1).

2. Motor installation
Lift the motor and gently install it in the reduction
gear, and use the hexagon wrench (17 mm) to
tighten the hexagon socket head bolts (2) to the
tightening torque of 568 - 649 N・m.
• Align the housing (3) and ring gear (4) according
to the reference mark (*2) made before disassem-
bly.

4. Installation of level gauge assembly

Install the cap (6) (27 mm hexagon diameter) into
the housing by tightening it to a torque of 98 N・m,
and insert the level gauge assembly (7).

3. Gear oil filling

84512399 EN - September 2011

6004-5
Copyright ©
Assembly and Disassembly of Swing Unit

5. Grease-up
Remove the plug (8) (5 mm hexagon socket diam-
eter) from the gear case (5) and inject grease (1 L)
from the grease fill port (9).
• When injecting grease, there is the possibility of
the reduction gear oil seal being damaged by in-
ternal pressure, so remove the air bleed port plug
before injecting grease.
Tighten the plug to the gear case to a tightening
torque of 20 N・m.
After injecting grease, install the grease hose in
the grease fill port.

This completes the assembly.

84512399 EN - September 2011

6004-6
Copyright ©

Section

8001A

Overall view

84512399 EN - September 2011

CONTENTS

Overall view. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PUMP CHAMBER HYDRAULIC EQUIPMENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SWING BODY CENTER SECTION HYDRAULIC EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
HOUSING LEFT SIDE HYDRAULIC EQUIPMENT LAYOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
LAYOUT OF HYDRAULIC EQUIPMENT IN CAB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

8001A-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

8001A-2 PRINTED IN FRANCE
Copyright ©
Overall view

This page is intentionally left blank

84512399 EN - September 2011

8001A-3
Copyright ©
Overall view

Overall view

84512399 EN - September 2011

8001A-4
Copyright ©
Overall view

1 Housing left side 3 Pomp chamber 5 Fuel tank

2 Swing body center section 4 Hydrauric oil tank

84512399 EN - September 2011

8001A-5
Copyright ©
Overall view

PUMP CHAMBER HYDRAULIC EQUIPMENT LAYOUT

HOUSING LEFT SIDE HYDRAULIC EQUIPMENT LAYOUT

84512399 EN - September 2011

Hydraulic Pump (standard model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5 Stack Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 Stack Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Remote Control Valves (upper, travel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Remote Control Valves (left-right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Remote Control Valve (travel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Cushion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Direction Valve/Relief Valve (electromagnetic proportional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Direction Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Relief Valve (electromagnetic proportional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Manifold Under Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Manifold (accumulator section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

8001B-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

8001B-2 PRINTED IN FRANCE
Copyright ©
Port Diagram

Hydraulic Pump (standard model)

84512399 EN - September 2011

8001B-3
Copyright ©
Port Diagram

Port Port name Port size

SAE
A1, A2 Discharge port
6000psi 1
SAE
B1 Suction port
2000psi 3
Dr Drain port G3/4-23
Proportional valve primary
P1 G1/4-13
pressure port
Psv Servo assist port G1/4-15
Pi1 Negative control port G1/4-13
Pi2 Negative control port G1/4-15
a1, a2, a4, a5 Gauge port G1/4-15
A3 Gear pump discharge port G1/2-19
B3 Gear pump suction port G3/4-20.5
a3 Gauge port G1/4-14
Dr3 Gear pump drain port G3/8-15
A4 Gear pump discharge port G1/2-16
B4 Gear pump suction port G1-21

84512399 EN - September 2011

8001B-4
Copyright ©
Port Diagram

Control Valve
Relief Valve

Detailed diagram of main relief valve adjustment

1 Boom up 5 Arm out 9 Standard lock nut

2 Arm in 6 Bucket open 10 Pressure boost lock nut
3 Boom down 7 Main a (normal use) 11 Pressure boost adjusting screw
Standard pressure adjusting
4 Bucket close 8 Main b (pressure boost) 12
screw

84512399 EN - September 2011

8001B-5
Copyright ©
Port Diagram

Port Port size Port name Port Port size Port name
SAE
P1 Pressure line pb6 G1/4 Right travel forward pilot line
6000psi 1
SAE
A1 Left travel (backward) line pb7 G1/4 Boom1-down pilot line
5000psi 1
SAE
B1 Left travel (forward) line pb8 G1/4 Bucket-open pilot line
5000psi 1
SAE
A2 Swing right line pb9 G1/4 Arm2-out pilot line
5000psi 1
SAE
B2 Swing left line PT G1/4 Travel signal
5000psi 1
SAE
A4 Option line PA G1/4 Upper signal
5000psi 1
SAE
B4 Option line pr1 G1/4 Main pressure
5000psi 1
SAE
A5 Arm-in line pr2 G1/4 Main pressure
6000psi 1
84512399 EN - September 2011
8001B-6
Copyright ©
Port Diagram

Port Port size Port name Port Port size Port name
SAE
B5 Arm-out line PP G1/4 Pilot pressure
5000psi 1
T1 Return line DR1 G1/4 Drain
pb1 G1/4 Left travel forward pilot line T3 G1/4 Swing motor make up
pb2 G1/4 Left swing pilot line T5 G1/4 Bypass filter
pb3 G1/4 Boom2-down pilot line pc1 G1/4 Arm load holding
Swing priority (for arm opera-
pb4 G1/4 Option line pc4 G1/4
tion)
pb5 G1/4 Arm1-out pilot line

Port Port size Port name Port Port size Port name
SAE
P2 Pressure line pa6 G1/4 Right travel backward pilot line
5000psi 1
SAE
A6 Right travel (backward) line pa7 G1/4 Boom1-up pilot line
5000psi 1
84512399 EN - September 2011
8001B-7
Copyright ©
Port Diagram

Port Port size Port name Port Port size Port name
SAE
B6 Right travel (forward) line pa8 G1/4 Bucket-close line
5000psi 1
SAE
A7 Boom-up line pa9 G1/4 Arm2-in pilot line
5000psi 1
SAE
B7 Boom-down line ps1 G1/4 Negative control line
6000psi 1
SAE
A8 Bucket-close line ps2 G1/4 Negative control line
5000psi 1
SAE
B8 Bucket-open line PH G1/4 Pressure boost signal port
5000psi 1
T2 Return line DR2 G1/4 Drain
pa1 G1/4 Left travel backward pilot line T6 G1/4 Heat circuit line
pa2 G1/4 Right swing pilot line pc2 G1/4 Boom load holding
pa3 G1/4 Boom2-up pilot line pc5 G1/4 Boom up priority
pa4 G1/4 Option line pa10 G1/4 Backup confluence line
pa5 G1/4 Arm1-in pilot line

84512399 EN - September 2011

8001B-8
Copyright ©
Port Diagram

5 Stack Solenoid Valve

Port Port size

C2 G1/4
C3 G1/4
C1 G1/4

View from bottom

1 Bucket close 1

2 Boom down 2

3 Bucket open 3

4 Boom up 4

P Pressure P

T Return T

84512399 EN - September 2011

8001B-12
Copyright ©
Port Diagram

Remote Control Valve (travel)

Port Port name Port size

1 Backward left G1/4
2 Forward left G1/4
3 Backward right G1/4
4 Forward right G1/4
P Pressure G1/4
T Return G1/4

84512399 EN - September 2011

8001B-13
Copyright ©
Port Diagram

Cushion Valve

Port Port name Port size Port Port name Port size
E, F Boom up G3/8 I, J Swing right G3/8
G, H Boom down G3/8 Q Swing pressure sensor signal G1/4
O, P Bucket open G3/8 U - G1/4
M, N Bucket close G3/8 S Swing priority orifice switch G1/4
C, D Arm out G3/8 V - G1/4
A, B Arm in G3/8 T Return (drain line) G1/4
K, L Swing left G3/8 R Heat circuit G1/4

84512399 EN - September 2011

8001B-14
Copyright ©
Port Diagram

Direction Valve/Relief Valve (electromagnetic proportional)

Direction Valve

Port Port size Port Port size Port Port size

A G1 T1 G1 PP G1/4
B G1 T2 G3/4 DR G1/4

84512399 EN - September 2011

8001B-15
Copyright ©
Port Diagram

Relief Valve (electromagnetic proportional)

Port Port size Port Port size

A G1 C G3/4
B G1 T G3/4

84512399 EN - September 2011

8001B-16
Copyright ©
Port Diagram

HBCV

B port opening side

Port Port size Remarks

SAE 6000psi 1 Arm HBCV
A
SAE J6000psi 1 Boom HBCV
SAE 6000psi 1 Arm HBCV
B
SAE J6000psi 1 Boom HBCV
C G1/4
DR G3/8
PL G1/4

84512399 EN - September 2011

8001B-17
Copyright ©
Port Diagram

Manifold Under Cab

Port Port size Port Port size Port Port size

P1 G3/8 P5 G1/4 T4 G1/4
P2 G3/8 T1 G3/8 T5 G1/4
P3 G3/8 T2 G3/8
P4 G1/4 T3 G3/8

84512399 EN - September 2011

8001B-18
Copyright ©
Port Diagram

Manifold (accumulator section)

Port Port size

P G1/2
P1 G1/4
P2 G1/4
P3 G1/2
P0 G3/8

84512399 EN - September 2011

8001B-19
Copyright ©
Port Diagram

Manifold

Port Port size

D1 G3/8
D2 G3/8
D3 G3/8
D6 G1/4
T G1/2
T1 G3/8
D7 G1/4
D8 G1/4
D9 G1/4

84512399 EN - September 2011

8001D-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

8001D-2 PRINTED IN FRANCE
Copyright ©
Pressure Measurement and Adjustment Procedures

Procedures for Pressure

Measurement from the Monitor
Display
Monitor and switch panel

1 Liquid crystal monitor 3 Design panel

2 Switch panel 4 Diffuser

Pressure Measurement Method

The P1, P2, N1, and N2 pressure can be measured from the monitor display. (The pilot pressure cannot be mea-
sured.)
Operating Method
1. If both the travel speed select switch and the attachement select switch on the switch panel are held down, the
display switches to the service support screen.
2. CHECK the select service support screen.
3. MACHINE STATUS the select service support screen.
4. The respective pressures are displayed "P1" (P1 pump main pressure), "P2" (P2 pump main pressure), "N1" (N1
negative control pressure), and "N2" (N2 negative control pressure) columns.
* MENU switch is held down the display returns to the normal screen.

*1 Pressure boost lock nut

*2 Pressure boost adjusting screw
*3 Standard lock nut
Standard pressure adjusting
*4
screw

84512399 EN - September 2011

8001D-8
Copyright ©
Pressure Measurement and Adjustment Procedures

Pressure Measurement 3. Main unit installation

Put the main unit on solid, level ground, put the
Preparations bucket cylinder at its open stroke end, the arm cylin-
der at its out stroke end, lower the boom, and touch
1. Items to prepare
the arm top to the ground.
For 10 MPa (for pilot and negative
1 ） Pres- control pressure measurement)
sure gauge For 60 MPa (for main pressure mea-
surement)
Wrench (closed wrench) 17 mm
2）Tool
Hexagon wrench 6 mm
Rag
3）Others
Cleaning fluid

4. Ignition key
Switch OFF the ignition key (1), check that the en-
gine has stopped, then switch the ignition key ON
again. (Do not start the engine.)

2. Monitor check
Use the service check to check the no-load engine
maximum speed and the SP mode pump input milli-
amp.

Engine max. SP mode milli-amp

2000 min-1 600 mA (during operation)

5. Oil temperature check

Use the service check to check the hydraulic oil tem-
perature.

Oil temperature 45 - 55 °C

If the oil temperature is low, raise the oil temperature

according to the warm-up operation procedure in
the operator's manual.

6. Bleeding pressure from inside circuits

84512399 EN - September 2011
8001D-9
Copyright ©
Pressure Measurement and Adjustment Procedures

Flip the gate lock lever (1) forward, then turn the 7. Bleeding pressure from inside the hydraulic oil tank
upper operation lever (2) about 10 times to bleed Press the air breather button (1) on top of the hy-
out the pressure. draulic oil tank to release the pressure inside the
tank.

3 Gate lever 8. Side door opening and closing

Open the side door (1).
Move the travel lever (1) back and forth about 5 At this time, be sure to use the lock (2).
times to bleed out the pressure.

This completes the preparations.

84512399 EN - September 2011

8001D-10
Copyright ©
Pressure Measurement and Adjustment Procedures

Pressure Measurement
Main Pressure Measurement
1. Pressure gauge installation
Remove the pressure sensor (a1) (a2) installed
on the hydraulic pump (1) and install the pressure
gauge.

a1: Can be measured a2: Can be measured

Travel left Travel right
Option Bucket
Swing
Arm 1 pump flow Arm 2 pumps flow
Boom 2 pumps flow Boom 1 pump flow Install the pressure gauge (2) on the adapter (1) and
fasten it.

Pressure gauge
for 60 MPa G1/4
Port size

Install the adapter (2) on the gauge port (1).

84512399 EN - September 2011

8001D-11
Copyright ©
Pressure Measurement and Adjustment Procedures

A.Attachment pressure measurement

Example: Arm-out pressure measurement
Measure with the following operations.

Engine speed 2000 min-1

Work mode SP mode
Lever operation Arm-out relief
Oil temperature 45 - 55°C
1 pump: P1 port
Measuring port
2 pumps: P2 port
Boosted pressure: 34.3 MPa
Set pressure
Standard: 31.4 MPa

a Arm-out relief

When the attachment operates, since the pressure boost operates automatically, the pressure resulting from the pres-
sure boost setting can be checked for about 8 sec.
After 8 sec.or more, the standard set pressure can be checked.
Measure relieving each cylinder with the arm out/in, the bucket open/close, and the boom up.

Lever operation Arm out Arm in Bucket open Bucket close Boom up Boom down
Engine speed 2000 min-1
Work mode SP mode
Oil temperature 45 - 55°C
1 pump flow measuring port P1 P1 P2 P2 P2 P2
2 pumps flow measuring port P2 P2 No No P1 P1
Pressure boost 34.3 MPa 24.5 MPa
Standard pressure 31.3 MPa 24.5 MPa

84512399 EN - September 2011

Engine speed 2000 min-1

Work mode SP mode
Oil temperature 45 - 55°C
Measuring port a3 port
Set pressure 3.92 MPa

84512399 EN - September 2011

8001D-15
Copyright ©
Pressure Measurement and Adjustment Procedures

Negative Control Pressure

Measurement
Pressure gauge installation
Remove the pump N1 pressure sensor (1) or N2 pres-
sure sensor (2) connector (3), and then remove the pres-
sure sensor.(N1, N2: pressure port) (The pressure sen-
sor location becomes the measuring port.)

Install the adapter (1) of the pressure gauge at the port Measure the negative control pressure for each opera-
where the N1 or N2 pressure sensor was removed and tion.
install the pressure gauge (2).

84512399 EN - September 2011

8001D-16
Copyright ©
Pressure Measurement and Adjustment Procedures

Pressure gauge Engine speed 2000 min-1

for 10 MPa G1/4
Port size Work mode SP mode
Oil temperature 45 - 55°C
P1 pump side: N1 port
Measuring port
P2 pump side: N2 port
Set pressure 3.92 MPa max.

84512399 EN - September 2011

8001D-17
Copyright ©
Pressure Measurement and Adjustment Procedures

Pressure Adjustment Boosted pressure:37.3

Measurement pressure MPa
Main Pressure Adjustment Standard:34.3 MPa
Boosted pressure:28.4
Main relief pressure adjustment Pressure per rotation of MPa/rotation
adjusting screw Standard:21.3 MPa/ro-
tation
Engine speed 2000 min-1
Before adjusting, remove the pilot hose for the pressure
Work mode SP mode
boost signal (2) connected to the main relief valve (1),
Lever operation Arm-in relief then insert the plug (3) into the hose side.
Oil temperature 45 - 55°C The procedures for boosted pressure and standard
Measuring port P1 port pressure are different.

4 Control valve
5 Wrench (19 mm)

84512399 EN - September 2011

8001D-18
Copyright ©
Pressure Measurement and Adjustment Procedures

Pressure measurement and adjustment 2. After tightening until the adjusting screw stops
preparation work turning, tighten the pressure boost lock nut (1).
Pressure is adjusted with control valves.
The following preparations are required for adjusting
with control valves.
1. Engine hood opening and closing
Pull the engine hood lock release lever (2) to re-
lease the lock.
Open the engine hood (1).
At this time, always check that the lock is locked.

3. Start the engine and run it at maximum rotation.

4. Move the arm lever to the in side, set the relief
state, and hold.
5. Loosen the pressure boost lock nut (32 mm) (1)
and adjust the set pressure with the adjusting
screw (27 mm) (2).
• When lower than the set pressure, tighten.

2. Cover removal
Remove the 11 bolts (1), then remove the cover (2)
(3).

• When higher than the set pressure, first lower

below the set pressure, then adjust on the tight-
ening side.
6. After adjustment, fasten the adjusting screw with
a wrench (27 mm), then tighten the lock nut.
For boosted pressure 7. After locking, check the pressure on the boosted
1. Loosen the standard lock nut (24 mm) (1) and pressure side.
tighten the adjusting screw (21 mm) (2). Repeat [1] - [6] until the set pressure is correctly ad-
Fasten with a wrench (27 mm) so that the pres- justed.
sure boost adjusting screw does not turn. For standard pressure

84512399 EN - September 2011

8001D-19
Copyright ©
Pressure Measurement and Adjustment Procedures

1. Loosen the standard lock nut (24 mm) (1). Overload relief pressure adjustment

Engine speed 2000 min-1

Work mode SP mode
Oil temperature 45 - 55°C
Measuring port P1/P2 port
Boom down: 27.4
Measurement pressure MPa
Others: 39.2 MPa
Pressure per rotation of adjust-
21.2 MPa/rotation
ing screw

Since the overload relief pressure is set higher than the

main relief pressure, it is necessary to provisionally set
the main relief pressure higher than the overload relief
2. Loosen the adjusting screw (1), lower below the pressure. (Except for boom down)
set pressure, then adjust on the tightening side.

3. After adjustment, tighten the lock nut while fasten-

ing the adjusting screw (1) with a wrench (2).

4. After locking, check the pressure.

Repeat [1], [2], and [3] until the set pressure is cor-
rectly adjusted.
Stop the engine.

84512399 EN - September 2011

8001D-20
Copyright ©
Pressure Measurement and Adjustment Procedures

1 Control valve
2 Boom down
3 Bucket close
4 Boom up
5 Arm-out
6 Bucket open

Main relief pressure provisional setting

• Using the main pressure adjustment procedure for
reference, temporarily set the boosted pressure and
standard pressure to at least 39.2 MPa.
* For boom down (1), since the overload set pres-
sure is lower than the main relief set pressure,
there is no need to temporarily set the main relief
Pressure adjustment
pressure.
84512399 EN - September 2011
8001D-21
Copyright ©
Pressure Measurement and Adjustment Procedures

Example: Arm-out (1) overload relief adjustment 2. After adjustment, lock the lock nut (1).

3. After adjusting the overload relief pressure, adjust

1. Loosen the lock nut (1) with the wrench (2) and the boosted pressure and standard pressure to
adjust by turning the adjusting screw (3) with the their normal values referencing the main pressure
hexagon wrench (4). adjustment procedure.
• When lower than the set pressure, tighten. * For the position of each overload relief, see the
• When higher than the set pressure, first loosen "Control Valve Relief Locations".
to a pressure lower than the set pressure, then
adjust on the tightening side.

84512399 EN - September 2011

8001D-22
Copyright ©
Pressure Measurement and Adjustment Procedures

Swing relief pressure adjustment 3. After adjustment, lock the lock nut (1).

Engine speed 2000 min-1

Work mode SP mode
Oil temperature 45 - 55°C
Measuring port P1 port
Measurement pressure 30.4 MPa
Pressure per rotation of adjust-
11.6 MPa/rotation
ing screw

1. Using the swing pressure measurement procedure

for reference, lock the swing, and check the swing
pressure.
2. Use a wrench (1) to loosen the lock nut (2) and
adjust by turning the adjusting screw (3).
• When lower than the set pressure, tighten.
• When higher than the set pressure, first loosen
to a pressure lower than the set pressure, then
adjust on the tightening side.

84512399 EN - September 2011

8001D-23
Copyright ©
Pressure Measurement and Adjustment Procedures

Pilot Pressure Adjustment

1. Install the pressure gauge (1).
While holding the plug with a wrench (24 mm) (2),
adjust with a hexagon wrench (6 mm) (3).

Engine speed 1900 min-1

Lever operation Neutral
Measuring port P3
Set pressure 3.92 MPa

84512399 EN - September 2011

8001D-24
Copyright ©

Section

8001E

Hydraulic Pump Flow Measurement Procedures

84512399 EN - September 2011

CONTENTS

Hydraulic Pump Flow Measurement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Items to Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Work Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Flow Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

8001E-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

8001E-2 PRINTED IN FRANCE
Copyright ©
Hydraulic Pump Flow Measurement Procedures

Hydraulic Pump Flow Measurement Procedures

Preparations
Role (worker 1: work supervisor, pressure ad-
Workers 3
justment)
Role (worker 2: operator)
Role (worker 3: flow, pressure measurement,
recording)

Items to Prepare

1 Vacuum pump and power supply 6 Extension cable 11 Pen

Hydraulic oil tank lid (for vacuum
2 Flow meter 7 12 Cleaning fluid
pump)
3 Pressure gauge (60 MPa x 2) 8 Adapter (flange type) 13 Rag
84512399 EN - September 2011
8001E-3
Copyright ©
Hydraulic Pump Flow Measurement Procedures

Hydraulic hose (for flow mea-

4 Hexagon wrench (6 mm, 10 mm) 9
surement)
Wrenches (17, 19, 24, 27 x 2, 32,
5 10 Recording sheet
36 x 2)

84512399 EN - September 2011

8001E-4
Copyright ©
Hydraulic Pump Flow Measurement Procedures

Work Preparations 5. Install the vacuum pump (1) on the hydraulic oil tank
lid.
1. Check that the main unit is in its work posture (arm-
vertical).
2. Bleed out the pressure. (See the details on Bleed-
ing Pressure in the Pressure Measurement and Ad-
justment Procedures.)
* Perform a swing prevention check.

6. After setting the vacuum pump (1) as in the diagram

on the right, switch on the power.(If the cable is too
short, use an extension cable.)

3. Use a wrench (17 mm) to remove the feed port

cover (1).

7. Use a hexagon wrench (1) (10 mm) to remove the

split flanges (2) and hydraulic hose (3). (This sec-
tion explains flow measurement at the P2 pump.)

4. Use the bolts removed in 3. to install the hydraulic

oil tank lid (for vacuum pump) (1).

4 Bolt

84512399 EN - September 2011

8001E-5
Copyright ©
Hydraulic Pump Flow Measurement Procedures

8. Use the split flange (2) to install the adaptor (flange * When connecting, always check the connection
type (3)) on the tip of the hydraulic hose (1) removed positions.
in 7.. * Always have the metering valve (7) fully open.
Remove the vavuum pump and re-install the hy-
draulic oil tank the same way it was.
Install pressure gauges on P1 and P2.(See "Main
Pressure Measurement".)
Open the engine hood.(See "Main Pressure Adjust-
ment".)

4 Hydraulic hose

9. Install the adaptor (1) at the position from which the

hydraulic hose was removed.
If necessary, install an "elbow adaptor" (3) on the
(prepared) hydraulic hose (2) connected to the flow
meter IN side.

10. Install the hydraulic hose (3) on the flow meter (1) 11. Remove the cover.
IN side(2), then fasten with the spanner. 12. Remove the pilot hose for the boosted pressure sig-
Install the (prepared) hydraulic hose (5) on the flow nal, then plug the hose side. (See "Main Relief
meter (1) OUT side (4), then fasten with the span- Pressure Adjustment".)
ner.
Installs the adapter (6) to have instralled in opposite This completes the preparation for flow measurement.
in 8..

84512399 EN - September 2011

8001E-6
Copyright ©
Hydraulic Pump Flow Measurement Procedures

Flow Measurement 5. Worker 2 lowers the arm-out port relief. (Min: 24

MPa P1+P2)
1. Measure the flow. 6. Start of flow measurement
When measuring the flow, position the workers as 7. The arm-out relief operation is carried out.
in the diagram on the right. 8. Data measured in units of 2.0 MPa (P1+P2)
(Worker 1 (1): Work supervisor, pressure adjust-
ment) * The measurement is carried out from 24.0 - 76.0
(Worker 2 (2): Operator) MPa and ends when the maximum pressure is
(Worker 3 (3): Flow, pressure measurement, reached.
recording) 9. Remove the flow meter.
* Because the maximum limit of the flow meter
pressure gauge is exceeded starting from 40
MPa.
10. Reset the arm-in port relief valve to normal pres-
sure.(For details on this adjustment, see "Pressure
Adjustment".)
11. Remove the pressure gauges etc. and put every-
thing back to normal.
This completes the work.

2. At the signal from the work supervisor, the operator

starts the engine.
3. Check the hydraulic oil temperature on the monitor.
(50 °C)
Check that the engine rotation and pump milli-amp
is normal.
4. The operator signals the arm-out relief operation to
worker 1.

1 Lock nut 17 mm
2 Hexagon wrench 6 mm

1 Ignition key

84512399 EN - September 2011

8001E-7
Copyright ©
Hydraulic Pump Flow Measurement Procedures

84512399 EN - September 2011

8001E-8
Copyright ©

Section

8001F

Drain Volume Measurement Procedures

84512399 EN - September 2011

CONTENTS

Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Travel Motor Drain Volume Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Swing Motor Drain Volume Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

8001F-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

8001F-2 PRINTED IN FRANCE
Copyright ©
Drain Volume Measurement Procedures

Preparations 4. Use a wrench to remove the drain hose (5). (Always

install a cap on the removed drain hose (5).)
Measuring conditions

Engine speed 1900 min-1

Mode SP mode
Oil temperature About 50°C

* Be careful.
The drain volume varies greatly with the oil tempera-
ture.

Travel Motor Drain Volume

Measurement
1. Allow the bucket (2) to touch the ground so as to 5. Install the extension hose for measurement (1) on
elevate one shoe crawler (1) as in the diagram on the side of the motor from which the drain hose was
the right. removed.

2. Remove the bolts (2), then remove the cover (1). 6. Prepare a waste oil can (1) and measuring con-
tainer (2) and set them as in the diagram on the
right.

3. Always lay a rag (2) underneath before removing

the drain hose (1).

84512399 EN - September 2011

8001F-3
Copyright ©
Drain Volume Measurement Procedures

7. Catch the stopper (1) between the sprocket section Forward Backward
and the frame and lock the travel motor. 1st 2nd 1st 2nd
speed speed speed speed
Right
Left

* Measure at least 3 times each for left, right, for-

ward, and backward.

8. In SP mode at medium speed, relieve the travel op-

eration, and move the extension hose to the mea-
suring container (1) at the same time the motor
starts. (At starting, start measurement with a stop
watch (3).)
9. After 30 sec., move the extension hose to the waste
oil can (1).
10. Measure the volume of oil in the measuring con-
tainer (2) as the drain volume for 30 sec. a 30 seconds

84512399 EN - September 2011

8001F-4
Copyright ©
Drain Volume Measurement Procedures

Swing Motor Drain Volume 5. After 60 sec., move the extension hose (3) to the
waste oil can (4).
Measurement 6. Measure the volume of oil in the measuring con-
tainer (1) as the drain volume for 60 sec.
1. Remove the 2 drain hoses (1) and put plugs in the
Measure at least 3 times each for left and right.
hose side of each. (wrench size: 36 mm, clamp 36
mm (hose side))
Right Left

2. Install the extension hose (1) for measuring the

drain volume on one side of the T nipple.
Install the hose facing in a direction that makes
measurement easy and install a plug (2) on the
other side.

3. Prepare a waste oil receiver and measuring con-

tainer (1) and set them as in the diagram on the
right.
For details on the method for locking the swing mo- a 60 seconds
tor, see "Swing relief pressure adjustment".
4. In SP mode, relieve the swing operation and move
the extension hose to the measuring container (1)
at the same time the motor starts.(At starting, start
measurement with a stop watch (2).)

84512399 EN - September 2011

8001F-5
Copyright ©
Drain Volume Measurement Procedures

84512399 EN - September 2011

8001F-6
Copyright ©

Section

8001G

Air Bleed Procedure

84512399 EN - September 2011

CONTENTS

Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Boom Cylinder HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Arm Cylinder HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

8001G-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

8001G-2 PRINTED IN FRANCE
Copyright ©
Air Bleed Procedure

CAUTION
Always bleed off any air in the hydraulic cir-
cuits after replacing the hydraulic oil, repairing
or replacing hydraulic equipment, or removing
hydraulic pipes.

Air bleed procedure mode (when bleeding, follow the procedure be-
low.)
Hydraulic
Cylinder air Swing motor Travel motor
pump air Check
bleeding air bleeding air bleeding
bleeding
Hydraulic oil or hydraulic pump re-
placement

der too.
4. Check boom operations.
If there is a delay in the operation response, bleed
the air again with the same procedure.

84512399 EN - September 2011

8001G-7
Copyright ©
Air Bleed Procedure

2 Hose mouthpiece

84512399 EN - September 2011

8001G-8
Copyright ©

Section

8002-4
Copyright ©
Removal and Installation of Hydraulic Oil Tank

14. Connect the 2 eyebolts (M12) (1) to the top of the

hydraulic oil tank, and then use the shackles (2),
wire rope (3) and liftcrane to lift the hydraulic oil tank
(4).
• When lifting, be careful that the level gauge (5)
does not interfere with the frame at the side of the
hydraulic oil tank.
• Fully tighten the eyebolts, and then loosen them
by a half turn.

13. Use a wrench (19 mm) to remove the 3 bolts (1),

and then remove the side covers (tank) (2).

8003-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

8003-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Hydraulic Pump

WARNING 2. Use a wrench (27 mm) to remove the hose (1), use
a wrench (19 mm) to remove the 2 hoses (2), use
• Be sure to release hydraulic pressure before a wrench (22 mm) to remove the hose (3), use a
beginning work. wrench (17 mm) to remove the 2 bolts (4) and 2
washers, and then remove the pilot filter (5).
CAUTION • Remove the 5 stack solenoid. (For details, see
"Removal and Installation of 5 Stack Solenoid".)
• Be sure to stop the engine before beginning
work.
• Be sure to inspect the wire rope and other
lifting equipment before beginning work.
• Do not stand or pass under the suspended
load.

Items to prepare
• Wrenches (17 mm, 19 mm, 22 mm, 27 mm, 36 mm,
41 mm)
• Hexagon wrenches (10 mm, 14 mm)
• Nylon sling (with the required breaking load)
• Liftcrane (with the required lifting capacity)
• Marking pen
• Caps
• Plugs 3. Use a wrench (19 mm) to remove the 18 bolts (1),
• Rag and then remove the 3 covers (2) (3) (4).
• Cleaning fluid
• Wood planks, etc. • Remove the muffler. (For details, see "Removal
and Installation of Muffler".)
Removal of Hydraulic Pump
1. Use a wrench (19 mm) to remove the 6 bolts (1),
and then remove the under cover (2).

4. Remove the hoses and connectors that are con-

nected to the pump.
• Use a hexagon wrench (10 mm) to remove the 8
hose bolts (1), and remove the pressure hose (2).
• Remove the engine hood. • Use a wrench (41 mm) to remove the drain hose
For details, see "Removal and Installation of En- (5).
gine Hood". • Use a wrench (27 mm) to remove the drain hose
• Remove the side door (right). (For details, see (4).
"Removal and Installation of Side Door".) • Use a wrench (27 mm) to remove the pilot hose
(5).
• Use a wrench (36 mm) to remove the suction hose
(6).
• Remove the connector (7).
• Use a wrench (19 mm) to remove the hydraulic
pilot hoses (8).
• Use a hexagon wrench (14 mm) to remove the 4
suction line bolts (9) and remove the suction line
(10).
• Mark the pump and hoses so that the connectors
match at the time of assembly.

84512399 EN - September 2011

8003-3
Copyright ©
Removal and Installation of Hydraulic Pump

• Attach caps or plugs to the pump and hoses to 6. Use a wrench (19 mm) to remove the 12 bolts (1)
prevent any entry of water, dust or dirt. from the pump.
• Clean the pump and hoses by spraying with a
parts cleaner to prevent scratches and prevent
dirt from accumulating on the connectors.

7. Use a liftcrane and the nylon sling (1) to pull the

pump out from the shaft and lift the pump.

8. Thoroughly check that the location is safe before

placing the pump on the wood plank (1).

5. Secure the pump with a liftcrane and nylon sling (1) • Thoroughly secure the pump so that it does not
so that it does not fall during removal and installation fall over.
operations.

84512399 EN - September 2011

8003-4
Copyright ©
Removal and Installation of Hydraulic Pump

Installation of Hydraulic Pump • Use a hexagon wrench (14 mm) to install the suc-
tion line bolts (1), and install the suction line (2).
• When installing the bolts, tighten them to the specified • Use a wrench (19 mm) to install the hydraulic pilot
torque. hoses (3).
If the torque is not specified for a bolt, see the "Stan- • Install the connectors (4).
dard Torque Data for Cap Screws and Nuts". • Use a wrench (41 mm) to install the suction hose
• Fill the pump case with hydraulic oil from the drain port (5).
so that no air remains in the pump case. • Use a wrench (27 mm) to install the pilot hose (6).
Additionally, when there is a 2nd option gear pump, • Use a wrench (27 mm) to install the drain hose
bleed off air from the air bleed port on the top surface (7).
of the power take-off case. • Use a wrench (36 mm) to install the drain hose
1. Use a liftcrane and nylon sling (1) to secure the (8).
pump. • Use a hexagon wrench (10 mm) to install the 8
hose bolts (9), and install the pressure hose (10).
• For details, see "Removal and Installation of Muf-
fler".

2. Use a liftcrane and nylon sling (1) to lift the pump

and lower it inside the housing.

3. Use a wrench (19 mm) to install the 12 pump bolts

Removal of Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

8004-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

8004-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Control Valve

Job code 35359AB10 2. After opening the engine hood, use a wrench (19
mm) to remove the 11 bolts (1), then remove the
top cover (2) (3).
WARNING
• Keep away from fire.
• Be sure to release hydraulic pressure before
beginning work.

Items to prepare 3. Use a wrench (19 mm) to remove the 2 bolts (1),
• Wrenches (7 mm, 19 mm, 22 mm, 30 mm) and then remove the bracket (2).
• Hexagon wrenches (8 mm, 10 mm, 12 mm)
• Wire cutters
• Eyebolts (M12 x 2)
• Shackle (with the required lifting capacity) x 2
• Wire rope (with the required lifting capacity)
• Liftcrane (with the required lifting capacity)
• Marking pen
• Cap
• Plug
• Rag
• Cleaning fluid
• Wood planks, etc.

Removal of Control Valve

1. Extend the attachment and bring in contact with the 4. Use a wrench (19 mm) to remove the 3 bolts (2),
ground. and then remove the under cover (1).
• Drain the oil from the hydraulic oil tank.
(For details, see "Draining Oil from Hydraulic Oil
Tank")

84512399 EN - September 2011

8004-3
Copyright ©
Removal and Installation of Control Valve

5. Remove the connectors (1) (2) from the pressure

sensor.

6. Use a wrench (7 mm) to remove the hose band (1),

and then remove the low-pressure hose (2) (3).

8. Use a wrench (30 mm) to remove the 4 bolts (1)

from the control valve.
7. Use wrenches (19 mm, 22 mm) and hexagon
wrenches (8 mm, 10 mm, 12 mm) to remove the
control valve lines and hoses.
• Mark the lines and hoses so that the connectors
match at the time of assembly.
• Use caps or plugs to cover the lines and hoses to
prevent any entry of water, dust or dirt.
• Clean the lines by spraying with a parts cleaner to
prevent scratches and prevent dirt from accumu-
lating on the connectors.

9. Install the 2 eyebolts (1) (M12) on the control valve.

84512399 EN - September 2011

8004-4
Copyright ©
Removal and Installation of Control Valve

10. Install the shackles (2) on the eyebolts, then use the 2. Install the shackles (2) on the eyebolts, then use the
liftcrane and wire ropes (3) to lift the control valve liftcrane and wire ropes (3) to lift the control valve
(1). (1) in such a way that it does not interfere with the
housing, engine parts and pipes.

11. Place the control valve (1) on wood planks (2).

3. Use a wrench (30 mm) to install the 4 bolts (1) for
the control valve.
Bolt (1) tightening torque: 333 - 392 N·m

Installation of Control Valve

1. Install the 2 eyebolts (1) (M12) on the control valve.

84512399 EN - September 2011

8004-5
Copyright ©
Removal and Installation of Control Valve

4. Use wrenches (19 mm, 22 mm) and hexagon 6. Install the connectors (1) (2) on the pressure sensor.
wrenches (8 mm, 10 mm, 12 mm) to install the
control valve lines and hoses.

7. Use a wrench (19 mm) to install the 3 bolts (2), and

then install the under cover (1).
Bolt (1) tightening torque: 63.7 - 73.5 N・m

84512399 EN - September 2011

CONTENTS

Removal of Bucket Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Bucket Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

8005A-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

8005A-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Bucket Cylinder

Job code 35738AA10 Removal of Bucket Cylinder

• Remove the bucket. (For details, see "Removal and
CAUTION Installation of Bucket".)
• Remove the bucket link. (For details, see "Removal
• Stop the machine on a level location with and Installation of Bucket Link".)
good footing.
• Be sure to stop the engine before beginning 1. Bring the arm (1) top in contact with the ground.
work. Retract the bucket cylinder rod.
• When working together with others, always
be sure to exchange signals and pay ade-
quate attention to safety.
• Always wear protective devices (protective
eyewear and safety shoes, etc.) when work-
ing with a hammer.
• Be sure to inspect the nylon sling and other
lifting equipment before beginning work.
• Do not stand or pass under the suspended
load.

Items to prepare
• Wrenches (30 mm)
• Hexagon wrench (8 mm)
• Hammer 2. Tie the cylinder rod with wire (1) so that it cannot
• Striking rod come out.
• Liftcrane (with the required lifting capacity)
• Nylon sling (with the required lifting capacity)
• Grease
• Rag
• Cleaning fluid
• Crosstie
• Wire

3. Turn the key switch (1) OFF and stop the engine.

84512399 EN - September 2011

8005A-3
Copyright ©
Removal and Installation of Bucket Cylinder

4. Switch the key switch ON again, and then turn the Remove the hose (1) in the same way.
control lever (1) about 10 times to bleed out any
pressure. • Use caps or plugs to cover the hoses and lines to
prevent any entry of water, dust or dirt.
NOTE: • Clean the hoses and lines by spraying them with
Do not operate the bucket at this time. a parts cleaner to prevent scratches and prevent
dirt from accumulating on the connectors.

5. Move the travel lever (1) back and forth about 5

times to bleed off the pressure.
Return the key switch to OFF.

8. Use a liftcrane and nylon sling (2) to secure the

6. Press the air breather button (1) on top of the hy- bucket cylinder (1).
draulic oil tank to release the pressure inside the
tank. • Wrap the nylon sling to the inside of the line so
that it is not crushed.

7. Use a hexagon wrench (8 mm) to remove the 4

hexagon socket head bolts (3) of the hose (2), and
then remove the 2 split flanges (4) and O-ring (5).

84512399 EN - September 2011

8005A-4
Copyright ©
Removal and Installation of Bucket Cylinder

9. Use a wrench (30 mm) to remove the bolt (1) and

spacer (2).

10. Use a hammer (2) and striking rod (3) to push the
pin (1) out.
• When removing the pin, be careful not to damage
the installed O-rings or dust seals.

11. Lift the bucket cylinder (1) and then place it on the
crosstie.

84512399 EN - September 2011

8005A-5
Copyright ©
Removal and Installation of Bucket Cylinder

Installation of Bucket Cylinder 4. Align the bucket cylinder (1) with the arm and use a
hammer (3) to push in the pin (2).
• Tighten lines and bolts being installed to the specified
torque. • If a pin is hard to insert, the cylinder is tilted.
• When the torque is not specified, check the "Bolt Size • When inserting the pin, be careful not to damage
and Torque Table". the installed O-rings or dust seals.

1. Clean each pin and pin hole.

5. Use a wrench (30 mm) to install the bolt (1) and

spacer (2).
2. Tie the cylinder rod with wire (1) so that it cannot
come out.

6. After setting the O-ring (5) on the line side, install

3. Use a liftcrane and nylon sling (2) to lift the bucket the hose (2) with the 2 split flanges (4) and the 4
cylinder (1). hexagon socket head bolts (3).

• Wrap the nylon sling to the inside of the line so • Install the hose (1) with the same procedure.
that it is not crushed. • The O-rings cannot be reused.
Replace them with new parts.
• Install the bucket link. (For details, see "Removal
and Installation of Bucket Link".)
• Install the bucket. (For details, see "Removal and
Installation of Bucket".)

84512399 EN - September 2011

8005A-6
Copyright ©
Removal and Installation of Bucket Cylinder

84512399 EN - September 2011

8005A-7
Copyright ©
Removal and Installation of Bucket Cylinder

84512399 EN - September 2011

8005A-8
Copyright ©

Section

8005B

Removal and Installation of Arm Cylinder

84512399 EN - September 2011

CONTENTS

Removal of Arm Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Arm Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

8005B-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

8005B-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Arm Cylinder

Job code 35737AA10 Removal of Arm Cylinder

1. Use a liftcrane and nylon sling (1) to secure the arm
CAUTION cylinder (2).
• Stop the machine on a level location with
good footing.
• Be sure to stop the engine before beginning
work.
• When working together with others, always
be sure to exchange signals and pay ade-
quate attention to safety.
• Always wear protective devices (protective
eyewear and safety shoes, etc.) when work-
ing with a hammer.
• Be sure to inspect the nylon sling and other
lifting equipment before beginning work.
• Do not stand or pass under the suspended
load.
2. Use a wrench (30 mm) to remove the bolt (1) and
Items to prepare spacer (2).
• Wrenches (30 mm)
• Hexagon wrench (12 mm)
• Nylon sling (with the required lifting capacity)
• Liftcrane (with the required lifting capacity)
• Cap
• Plug
• Hammer
• Striking rod
• Grease
• Rag
• Cleaning fluid
• Crosstie
• Wire

3. Use a hammer (2) and striking rod (3) to remove the

pin (1).
Be careful. The arm and arm cylinder rod may come
out of place at this time.

84512399 EN - September 2011

8005B-3
Copyright ©
Removal and Installation of Arm Cylinder

4. Start the engine, move the arm out at idle, and re-
tract the arm cylinder (1) rod.

7. Move the travel lever (1) back and forth about 5

times to bleed off the pressure.
5. Tie the cylinder rod with wire (1) so that it cannot
come out.

8. Switch the key switch OFF.

9. Press the air breather button (1) on top of the hy-
6. Switch the key switch (1) OFF to stop the engine. draulic oil tank to release the pressure inside the
Switch the key switch ON again, then turn the con- tank.
trol lever (2) about 10 times to bleed off any pres-
sure.
Switch the key switch OFF.

10. Use a hexagon wrench (12 mm) to remove the 4

hexagon socket head bolts (1) of the hose (2), and
then remove the 2 split flanges (5) and O-ring (4).
• Remove the hose (3) with the same procedure.
• Use caps or plugs to cover the hoses and lines to
prevent any entry of water, dust or dirt.
• Clean the hoses and lines by spraying them with
a parts cleaner to prevent scratches and prevent
dirt from accumulating on the connectors.

84512399 EN - September 2011

8005B-4
Copyright ©
Removal and Installation of Arm Cylinder

• If a pin is hard to remove, there is a load on the

pin.
• When removing the pin, be careful not to damage
the installed O-rings or dust seals.

11. Use a wrench (19 mm) to remove the grease hose

(1).
• Use caps or plugs to prevent any entry of water,
dust or dirt.
14. Lift the arm cylinder (1), and then place it on the
crosstie.

12. Use a wrench (30 mm) to remove the bolt (1) and
spacer (2).

13. Use a hammer (2) and striking rod (3) to push the
pin (1) out.

84512399 EN - September 2011

8005B-5
Copyright ©
Removal and Installation of Arm Cylinder

Installation of Arm Cylinder • If a pin is hard to insert, there is a load on the pin.
• When inserting the pin, be careful not to damage
• Tighten lines and bolts being installed to the specified the installed dust seals.
torque.
• When the torque is not specified, check the "Bolt Size
and Torque Table".
1. Clean each pin and pin hole.

5. Use a wrench (30 mm) to install the bolt (1) and

spacer (2).

2. Tie the cylinder rod with wire (1) so that it cannot

come out.

6. Use a wrench (19 mm) to attach the grease hose

(1).

3. Use a liftcrane and nylon sling (2) to lift the arm

cylinder (1).
• Wrap the nylon sling to the inside of the line so
that it is not crushed.

7. After setting the O-ring (4) on the line side, install

the hose (2) with the 2 split flanges (5) and the 4
hexagon socket head bolts (1).
• Install the hose (3) with the same procedure.
• The O-rings cannot be reused.
Replace them with new parts.
4. Align the arm cylinder with the boom and use a ham- Tightening torque for installation: 85.2 - 101.2 N·m
mer (2) to push in the pin (1).

84512399 EN - September 2011

8005B-6
Copyright ©
Removal and Installation of Arm Cylinder

9. Align the arm cylinder (1) with the arm pin hole and
use a hammer (3) to insert the pin (2).
Be careful. The arm and arm cylinder rod may come
out of place at this time.

8. Start the engine, move the arm in at idle, and extend

the arm cylinder (1) rod.

10. Use a wrench (30 mm) to tighten the bolt (1) and
spacer (2).
• Grease up.

84512399 EN - September 2011

8005B-7
Copyright ©
Removal and Installation of Arm Cylinder

84512399 EN - September 2011

8005B-8
Copyright ©

Section

8005C

Removal and Installation of Boom Cylinder

84512399 EN - September 2011

CONTENTS

Removal of Boom Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Boom Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

8005C-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

8005C-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Boom Cylinder

Job code 35736AA10 2. Use a wrench (19 mm) to remove the grease hoses
on the left and right sides (1).
CAUTION • Use caps or plugs to prevent any entry of water,
dust or dirt.
• Stop the machine on a level location with
good footing.
• Be sure to stop the engine before beginning
work.
• When working together with others, always
be sure to exchange signals and pay ade-
quate attention to safety.
• Always wear protective devices (protective
eyewear and safety shoes, etc.) when work-
ing with a hammer.
• Be sure to inspect the nylon sling and other
lifting equipment before beginning work.
• Do not stand or pass under the suspended
load.

Items to prepare 3. Use 2 wrenches (36 mm) to remove the 2 double

nuts (1) and bolt (2), and then remove the fastening
• Wrenches (19 mm, 30 mm, 36 mm)
ring (3).
• Hexagon wrench (8 mm)
Also, remove the cab side in the same way.
• Crowbar
• Wire rope (with the required lifting capacity)
• Liftcrane (with the required lifting capacity)
• Nylon sling
• Marking pen
• Cap
• Plug
• Hammer
• Striking rod
• Grease
• Rag
• Cleaning fluid
• Crosstie
• Wire

Removal of Boom Cylinder 4. Use a hammer (2) and striking rod (3) to push the
pin (1) out.
• When removing only the boom cylinder, put the attach-
ments in the temporary decommissioning posture. Start the engine, lower the boom at idle, and retract
the boom cylinder (right) (left) rods.
• When removing as far as the boom, first remove the
bucket, bucket link, bucket cylinder, arm, arm cylinder
according to their respective removal and installation
procedures.
Bring the boom top in contact with the ground.
1. Use a liftcrane and nylon sling (1) to secure the
boom cylinders (right) (left) (2) (3).

84512399 EN - September 2011

8005C-3
Copyright ©
Removal and Installation of Boom Cylinder

5. Tie the cylinder rods on the left and right sides with 8. Move the travel lever (1) back and forth about 5
wire (1) so that they cannot come out. times to bleed off the pressure.
• Switch the key switch OFF.

Removal and Installation of Center Joint

84512399 EN - September 2011

CONTENTS

Removal of Center Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Center Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

8006-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

8006-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Center Joint

CAUTION 2. Attach the specialty adapter (1) to the area where

the air breather is removed, and set the vacuum
• Be sure to stop the engine before beginning pump (2).
work. Create negative pressure in the hydraulic oil tank
• Be sure to inspect the wire rope and other using the vacuum pump.
lifting equipment before beginning work.
• Do not stand or pass under the suspended
load.

Items to prepare
• Wrenches (19 mm, 27 mm, 41 mm)
• Hexagon wrenches (5 mm, 8 mm)
• Box wrench (19 mm)
• Specialty adapter for vacuum pump connection
• Vacuum pump (vacuum pump power supply)
• Extension cable
• Marking pen
• Cap
• Plug
• Wire rope (with the required breaking load) 3. Use a box wrench (19 mm) to remove the 8 bolts
• Liftcrane (with the required lifting capacity) (1), and then remove the lower under covers (2).
• Wood planks, etc.
• Rag
• Cleaning fluid

Removal of Center Joint

1. Use a hexagon wrench (5 mm) to remove the 4 bolts
(1), and then remove the air breather (2) on the
hydraulic oil tank.
Tightening torque for bolt installation: 2.94 - 4.90
N•m

4. Prepare a waste oil can (1) to receive the oil that

84512399 EN - September 2011

8007A-4
Copyright ©
Removal and Installation of Travel Remote Control Valve

4. Use a wrench (19 mm) to install the 6 hoses (1). 7. Use a hexagon wrench (8 mm) to install the 2 bolts
Tightening torque: 25.4 - 31.4 N・m/44.0 - 54.0 N・ (2) on both the left and right sides, then install the
m left and right travel pedals (1).

5. Use a wrench (19 mm) to install the 6 bolts (2) and 8. Install the floor mat (1).
install the under cover (1).

6. Use a hexagon wrench (8 mm) to install the 2 bolts

(2) on both the left and right sides of the lever, then
install the levers (1).

84512399 EN - September 2011

8007A-5
Copyright ©
Removal and Installation of Travel Remote Control Valve

84512399 EN - September 2011

8007A-6
Copyright ©

Section

8007B

Removal and Installation of Operation Remote Control Valve

84512399 EN - September 2011

CONTENTS

Removal of Operation Remote Control Valve (left side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Operation Remote Control Valve (left side). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal of Operation Remote Control Valve (right side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation of Operation Remote Control Valve (right side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

8007B-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

8007B-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Operation Remote Control Valve

Job code 35355AA12 3. Use a hexagon wrench (5 mm) to remove the 2 bolts
(2), and remove the grip (1) of the gate lock lever.
WARNING
• Be sure to release hydraulic pressure before
beginning work.

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

Items to prepare
• Wrenches (19 mm, 22 mm)
• Box wrench (10 mm)
• Hexagon wrench (5 mm)
• Phillips screwdriver 4. Use the Phillips screwdriver to remove the 2 screws
• Marking pen (1) of the console top cover.
• Cap
• Plug
• Rag
• Cleaning fluid

Removal of Operation Remote

Control Valve (left side)
1. Roll up the boot (1) of the control lever and use
the Phillips screwdriver or box wrench (10 mm) to
remove the 2 bolts (2) of the console top cover.

5. Remove the 3 connectors (2) and remove the con-

sole top cover (1).

2. Use the Phillips screwdriver to remove the 2 screws

(2), and then remove the handle of the tilt lever (1).

84512399 EN - September 2011

8007B-3
Copyright ©
Removal and Installation of Operation Remote Control Valve

6. Use the Phillips screwdriver or box wrench (10 mm) 9. Roll back the hose cover (1).
to remove the 5 bolts (2), then remove the cover (1).

10. Use a wrench (22 mm) to remove the 6 hoses (1).

7. Roll up the boot (1) of the control lever, remove the
connector (2) of the horn switch, and cut the wire • Mark the joystick remote control valve and hoses
so that the connectors match at the time of as-
band (3).
sembly.
• Use caps and plugs to cover the joystick remote
control valve and hoses to prevent any entry of
water, dust or dirt.
• Clean the joystick remote control valve and hoses
by spraying them with a parts cleaner to prevent
scratches and prevent dirt from accumulating on
the connectors.

8. While securing the nut (2) with a wrench (22 mm),

use a wrench (19 mm) to remove the lock nut (3)
and remove the control lever (1).

11. Use the hexagon wrench (5 mm) to remove the 3

bolts (1) and 3 washers (2).

84512399 EN - September 2011

8007B-4
Copyright ©
Removal and Installation of Operation Remote Control Valve

12. Remove the joystick remote control valve (1). Installation of Operation Remote
Control Valve (left side)
1. Clean all the parts with a rag.

2. Install the joystick remote control valve (1).

3. Use the hexagon wrench (5 mm) to install the 3 bolts

(1) and 3 washers (2).

4. Use a wrench (22 mm) to install the 6 hoses (1).

• P port
Hose adapter tightening torque: 25.4 - 31.4 N·m
Hydraulic hose tightening torque: 44 - 54 N·m
• T port, 1 - 4 ports
Hose adapter, hydraulic hose tightening torque:
44 - 54 N·m

84512399 EN - September 2011

8007B-5
Copyright ©
Removal and Installation of Operation Remote Control Valve

8. Use the Phillips screwdriver or box wrench (10 mm)

to install the 5 bolts (2), then install the cover (1).

5. Put the hose cover (1) in place.

9. Install the 3 connectors (2) and install the console

top cover (1).

6. While securing the nut (2) with a wrench (22 mm),

use a wrench (19 mm) to install the lock nut (3) and
install the control lever (1).
10. Use the Phillips screwdriver to install the 2 screws
(1) of the console top cover.

7. Install the horn switch connector (2), bundle with the

wire band (3), then cover the control lever boot (1).

84512399 EN - September 2011

8007B-6
Copyright ©
Removal and Installation of Operation Remote Control Valve

11. Use a hexagon wrench (5 mm) to install the 2 bolts Removal of Operation Remote
(2), and install the grip (1) of the gate lock lever.
Control Valve (right side)
1. Roll up the boot (1) of the control lever and use
the Phillips screwdriver or box wrench (10 mm) to
remove the 2 bolts (2) of the console top cover.

12. Use the Phillips screwdriver to install the 2 screws

(2), then install the handle of the tilt lever (1).

2. Use the Phillips screwdriver to remove the 2 screws

(2), and then remove the handle of the tilt lever (1).

13. Use the Phillips screwdriver or box wrench (10 mm)

to install the 2 bolts (2) for the console top cover and
cover the control lever boot (1).

3. Use the Phillips screwdriver to remove the 2 screws

(1) of the console top cover.

84512399 EN - September 2011

8007B-7
Copyright ©
Removal and Installation of Operation Remote Control Valve

4. Remove the 3 connectors (2) and remove the con- 7. While securing the nut (2) with a wrench (22 mm),
sole top cover (1). use a wrench (19 mm) to remove the lock nut (3)
and remove the control lever (1).

5. Use the Phillips screwdriver or box wrench (10 mm)

to remove the 5 bolts (2), then remove the cover (1). 8. Roll back the hose cover (1).

6. Roll up the boot (1) of the control lever, remove the 9. Use a wrench (22 mm) to remove the 6 hoses (1).
connector (2) of the horn switch, and cut the wire
band (3). • Mark the joystick remote control valve and hoses
so that the connectors match at the time of as-
sembly.
• Use caps and plugs to cover the joystick remote
control valve and hoses to prevent any entry of
water, dust or dirt.
• Clean the joystick remote control valve and hoses
by spraying them with a parts cleaner to prevent
scratches and prevent dirt from accumulating on
the connectors.

84512399 EN - September 2011

8007B-8
Copyright ©
Removal and Installation of Operation Remote Control Valve

10. Use the hexagon wrench (5 mm) to remove the 3 Installation of Operation Remote
bolts (1) and 3 washers (2).
Control Valve (right side)
1. Clean all the parts with a rag.

11. Remove the joystick remote control valve (1).

2. Install the joystick remote control valve (1).

3. Use the hexagon wrench (5 mm) to install the 3 bolts

(1) and 3 washers (2).

4. Use a wrench (22 mm) to install the 6 hoses (1).

• P port
Hose adapter tightening torque: 25.4 - 31.4 N·m
Hydraulic hose tightening torque: 44 - 54 N·m
• T port, 1 - 4 ports
Hose adapter, hydraulic hose tightening torque:
41 - 54 N·m

84512399 EN - September 2011

8007B-9
Copyright ©
Removal and Installation of Operation Remote Control Valve

8. Use the Phillips screwdriver or box wrench (10 mm)

to install the 5 bolts (2), then install the cover (1).

5. Put the hose cover (1) in place.

9. Install the 3 connectors (2) and install the console

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

8007C-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of 5 Stack Solenoid

Job code 35350AL06 3. Remove the 5 connectors (1).

WARNING
• Be sure to release hydraulic pressure before
beginning work.

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

Items to prepare
• Wrenches (13 mm, 17 mm, 19 mm, 22 mm)
Wrenches (0.512 in, 0.669 in, 0.748 in, 0.866 in)
• Hexagon wrench (5 mm) 4. Use wrenches (19 mm, 22 mm) to remove the hoses
Hexagon wrench (0.197 in) (1) (2) (3).
• Marking pen • Mark the solenoid valve and hose so that the con-
• Cap nector matches at the time of assembly.
• Plug • Use a cap or a plug to cover the solenoid valve
• Rag and hose to prevent any entry of water, dust or
• Cleaning fluid dirt.
• Clean the solenoid valve and hose by spraying
Removal of 5 Stack Solenoid Valve them with a parts cleaner to prevent scratches
and prevent dirt from accumulating on the con-
1. Attach the specialty adapter (1) to the area where
nector.
the air breather is removed, and set the vacuum
pump (2).
Create negative pressure in the hydraulic oil tank
using the vacuum pump.

5. Use a wrench (22 mm) to remove the hoses (1) (2)

(3).
• Mark the solenoid valve and hose so that the con-
2. Use a wrench (13 mm) to remove the 2 cover bolts nector matches at the time of assembly.
(1) and then remove the cover (2). • Use a cap or a plug to cover the solenoid valve
and hose to prevent any entry of water, dust or
dirt.
• Clean the solenoid valve and hose by spraying
them with a parts cleaner to prevent scratches
and prevent dirt from accumulating on the con-
nector.

84512399 EN - September 2011

8007C-3
Copyright ©
Removal and Installation of 5 Stack Solenoid

Installation of 5 Stack Solenoid

Valve
1. Use a wrench (17 mm) to install the 2 bolts (2), and
then install the 5 stack solenoid valve (1).

6. Use a wrench (17 mm) to remove the 2 bolts (2),

and then remove the 5 stack solenoid valve (1).

2. Use a wrench (22 mm) to install the hoses (1) (2)

(3).

3. Use wrenches (19 mm, 22 mm) to install the hoses

(1) (2) (3).

• The hose connections are as follows.

84512399 EN - September 2011

8007C-4
Copyright ©
Removal and Installation of 5 Stack Solenoid

4. Install the 5 connectors (1).

Connect the connectors with the matching color ID
tape.

5. Use a wrench (13 mm) to install the 2 cover bolts

(1), and then install the cover (2).

6. Use a hexagon wrench (5 mm) to tighten the 4 bolts

(1), and then install the air breather (2) on the hy-
draulic oil tank.
• Bolt (1) tightening torque: 2.94 - 4.9 N·m

1 Assembly hose
2 Solenoid valve

*1 Code
Solenoid valve (left side) de-
*2
tails
Solenoid valve (right side) de-
*3
tails

84512399 EN - September 2011

8007C-5
Copyright ©
Removal and Installation of 5 Stack Solenoid

84512399 EN - September 2011

8007C-6
Copyright ©

Section

8007D

Removal and Installation of Cushion Valve

84512399 EN - September 2011

CONTENTS

Removal of Cushion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Cushion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

8007D-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

8007D-2 PRINTED IN FRANCE
Copyright ©
Removal and Installation of Cushion Valve

Job code 35350AF50 2. Use a wrench (19 mm) to remove the 4 bolts (2),
and then remove the under cover (1).
WARNING
• Be sure to release hydraulic pressure before
beginning work.

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

Items to prepare
• Wrenches (17 mm, 19 mm, 22 mm)
• Hexagon wrench (5 mm)
• Marking pen
• Cap 3. Prepare the waste oil can (1).
• Plug
• Waste oil can
• Rag
• Cleaning fluid

Removal of Cushion Valve

1. Attach the specialty adapter (1) to the area where
the air breather is removed, and set the vacuum
pump (2).
Create negative pressure in the hydraulic oil tank
using the vacuum pump.

4. Remove the sensor (1).

Use wrenches (19 mm, 22 mm) to remove the hoses
connected to the ports.
• Mark the cushion valve, hoses and lines so that
the connectors match at the time of assembly.
• Use caps or plugs to cover the cushion valve,
hoses and lines to prevent any entry of water, dust
or dirt.
• Clean the cushion valve, hoses and lines by
spraying them with a parts cleaner to prevent
scratches and prevent dirt from accumulating on
the connectors.

84512399 EN - September 2011

8007D-3
Copyright ©
Removal and Installation of Cushion Valve

5. Use a wrench (17 mm) to remove the 4 bolts (1)

on the cushion valve bottom, and then remove the
cushion valve.

*1 Use 22 mm wrench
*2 Use 19 mm wrench

84512399 EN - September 2011

8007D-4
Copyright ©
Removal and Installation of Cushion Valve

Installation of Cushion Valve

1. Use a wrench (17 mm) to tighten the 4 bolts (1)
on the cushion valve bottom, and then install the
cushion valve.

2. Install the sensor (1).

Use wrenches (19 mm, 22 mm) to connect the
hoses to the nipples and elbows on the ports.

*1 Use 22 mm wrench
*2 Use 19 mm wrench

• The hose connections are as follows.

84512399 EN - September 2011

11. Lightly strike the shaft end sections of the drive

shafts (111) (113) with a plastic hammer, etc. to re-
move the drive shafts from the swash plate support
board.

84512399 EN - September 2011

8008-4
Copyright ©
Procedures for Assembly and Disassembly of Hydraulic Pump
Main Unit
12. Remove the valve plates (313) (314) from the valve Assembly Procedures
block (312).
The assembly procedure is the reverse of the disassem-
• These can also be removed in Step 6. bly procedure. However, follow the precautions below.
1. Be sure to repair any parts damaged during disas-
sembly, and prepare replacement parts in advance.
2. Thoroughly clean all parts with cleaning oil and air
blow them before assembly.
3. Be sure to apply clean hydraulic oil to sliding parts
and bearings before assembly.
4. As a rule, replace all O-rings, oil seals, and other
seal parts with new parts.
5. Use a torque wrench to tighten all installation bolts
and plugs to the torque specified in "Maintenance
Standards."
6. Be careful not to mix up the pump parts for the front
and rear.
7. Install the swash plate support board (251) on the
13. If necessary, remove the stopper (L) (534), stopper pump casing (271) by lightly striking it with a ham-
(S) (535), servo piston (532), and tilting pin (531) mer.
from the pump casing (271), and remove the nee- • If the servo pistons, tilting pin, stoppers (L), and
dle bearing (124) and 1st gear (116) from the valve stoppers (S) have been removed, install these
block (312). parts on the pump casings in advance.
• To avoid damaging the head of the tilting pin, use • To avoid damaging the heads of the tilting pins
a jig when removing it. and the feedback pins, use a jig when tightening
• Loctite has been applied to the section where the the servo pistons and tilting pins. Also be sure to
tilting pin and the servo piston are bonded, so be apply Loctite (moderate strength) to the threaded
careful not to damage the servo piston. sections.
• Try to avoid removing the needle bearings unless
they are at the end of their service life.
• Do not loosen the hexagon nuts of the valve block
or swash plate support board. This changes the
flow setting.

8010

Pump Main Unit Maintenance Standards

84512399 EN - September 2011

CONTENTS

Replacement standards for worn parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Standards for repairing cylinders, valve plates, and swash plates (shoe plates) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overall View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Attached diagram 1. pump assembly cross-section diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Drive Shaft Front Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Drive Shaft Rear Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Part Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Procedures for Assembly and Disassembly of Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disassembly preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disassembly procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

8010-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

8010-2 PRINTED IN FRANCE
Copyright ©
Pump Main Unit Maintenance Standards

Replacement standards for worn parts

If wear on any part exceeds the standard values below, replace or readjust that part.
If, however, the appearance of the part shows significant damage, replace that part.

Recom-
Reference mended
Part name and inspection item dimen- replace- Solution
sions ment
value
Piston and cylinder bore clearance (D - d) 0.038 mm 0.065 mm Replace piston or cylinder.
Piston and shoe caulking section backlash (δ) 0 - 0.1 mm 0.3 mm Replace piston and shoe assembly.
Shoe thickness (t) 5.4 mm 5.0 mm Replace piston and shoe assembly.
Free height of cylinder spring (L) 40.9 mm 40.1 mm Replace cylinder spring.
Assembled height of holder plate and spherical Replace holder plate or spherical
23.8 mm 22.8 mm
bushing (H - h) bushing.
Cylinder opening diameter(spline in cylinder) Replace cylinder and spherical bush-
35.17 mm 35.57 mm
Spherical bushing spline ing.

Clearance between the piston and cylinder bore : D-d Free height of cylinder spring : L

Loseness of piston, shoe, and caulking : δ Combined height of pressure plate and spherical bush :
Thickness of shoe : t H-h

Standards for repairing cylinders, valve plates, and swash plates (shoe
plates)
Valve plate (sliding section)
Surface roughness re-
Swash plate (shoe plate 3-Z
quiring repair
section)
Cylinder Standard surface rough-
0.4 Z or lower (lapping)
Surface roughness ness (repair value)

84512399 EN - September 2011

8010-3
Copyright ©
Pump Main Unit Maintenance Standards

Tightening torque
Tighten-
Part name Size ing torque Tool name (mm)
(N•m)
M5 6.9 B=4
M6 11.8 5
M8 29.4 6
M10 56.9 8
Hexagon socket head bolt M12 98.1 10
M14 156.9 12
M16 235.4 14
M18 333.4 14
M20 431.5 17
R 1/16 6.9 4
Rc plug R 1/8 10.3 5
NOTE: R 1/4 17.2 6
Wrap seal tape around the plug 1.5 - 2 times R 3/8 34.3 8
R 1/2 49.0 10 Hexagon
G1/4 29.4 6 wrench
G1/2 98.1 10
G3/4 147.1 14
PO plug
G1 186.3 17
G1 1/4 264.8 17
G1 1/2 274.6 17

Overall View
Attached diagram 1. pump assembly cross-section diagram

Drive shaft front side Drive shaft rear side

84512399 EN - September 2011

8010-4
Copyright ©
Pump Main Unit Maintenance Standards

Drive Shaft Front Side

84512399 EN - September 2011

8010-5
Copyright ©
Pump Main Unit Maintenance Standards

Drive Shaft Rear Side

*1 Spool
*2 Feedback lever

4. Install the feedback lever (611), and insert the pin

(874) in alignment with the pin hole on the feedback
lever.
• This is easier to assemble by inserting the pin into
the feedback lever to a small degree in advance.
• Be careful to assemble the feedback levers in the
correct direction.

8. Insert the adjusting plug (615), and install the lock-

ing ring.
• Be careful to insert the fulcrum plug and adjusting
plug into the correct openings.
84512399 EN - September 2011
8010-12
Copyright ©
Pump Main Unit Maintenance Standards

• At this time, check that the backlash from the 11. Install the spring seating (644), pilot spring (646),
movement of the feedback lever is not too great and adjusting ring (645) into the pilot hole, and in-
and that the feedback lever does not catch on stall the spring seating (624), inner spring (626), and
anything. outer spring (625) into the compensation hole.
9. Install the return spring (654) and spring seating • Be careful to install the spring seating in the cor-
(653) into the spool hole, and install the stop ring rect direction.
(814).

12. Assemble the cover (C) (629) set with the adjusting
10. Assemble the set spring (655) into the spool hole, screw (628), adjusting ring (C) (627), lock nut (630),
assemble the compensation piston (621) and piston hexagon nuts (801, 802), and the hexagon socket
case (622) into the compensation hole, install the head locking screw (924), and tighten the hexagon
pilot cover (641), and tighten the hexagon socket socket head bolts (438).
head bolts (436, 438).

This completes the assembly.

84512399 EN - September 2011

8010-13
Copyright ©
Pump Main Unit Maintenance Standards

84512399 EN - September 2011

8010-14
Copyright ©

Section

8011

Procedures for Assembly and Disassembly of Control Valve

84512399 EN - September 2011

CONTENTS

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cautions for disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal of long cap and pull out of main spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disassembly of arm 1 parallel-tandem spool, neutral cut spool section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly of arm regeneration release valve section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly of load check valve section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly of antidrift valve section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly of relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly of option section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly of straight travel signal control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly of other plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly of add-on section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disassembly of valve housing union bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cautions for assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cautions for O-Ring handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cautions for spool handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Adhesive application method (for male thread section and female thread section of parts requiring adhesion)8
Procedure for assembly of sub-assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assembly of spool assembly (main spool) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assembly of arm 1 parallel-tandem spool assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assembly of neutral cut spool assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assembly of antidrift valve assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Procedure for assembly of control valve main unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly of relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly of load check valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly of antidrift valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assembly of option section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assembly of arm regeneration release valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assembly of arm 1 parallel-tandem spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assembly of neutral cut spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembly of main spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembly of straight travel signal control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembly of add-on section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assembly of other plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Internal structure diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Part list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Procedures for assembly and disassembly of main relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Procedures for assembly and disassembly of overload relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Procedures for assembly and disassembly of low-pressure relief valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Procedures for assembly and disassembly of add-on main relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Relief valve adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

8011-1 PRINTED IN FRANCE
Copyright ©

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Troubles and countermeasures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

8011-2 PRINTED IN FRANCE
Copyright ©
Procedures for Assembly and Disassembly of Control Valve

Disassembly
Cautions for disassembly
1. On level ground, bring all the operating machines into contact with the ground.
When doing this, have the main machine in a horizontal position.
Check that the machine is in such a state that it will not travel or swing on its own.
Then stop the engine and bleed out the pressure from each actuator.

CAUTION
Do not replace a valve assembly or disassemble a valve with pressure remaining in the system.
This would be dangerous.
High-pressure oil might spray out or parts might suddenly come out.
For disassembly, bring the bucket to the ground and adequately bleed out any pressure in the cir-
cuits.

2. Bleed the air pressure from the tank.

3. Clean well around the location to be disassembled and keep foreign matter from getting into the valve during
disassembly.
4. Identify disassembled parts with shipping tags to show their position for re-assembly.
5. Do not reuse any disassembled seals (O-rings, backup rings).
Replace them with new ones.
6. The spool was selected to fit with the valve housing and sleeve, so do not replace the spool.

Disassembly procedure
Removal of long cap and pull out of main spool
1. Loosen the hexagon socket head bolts (74) (8 mm hexagon socket diameter) for the 9 caps (8) and the 1 cap
(9), and remove them.
When pulling out the spool only, do not loosen the M6 screws on the plate except for the 4 hexagon socket head
bolts (75) and the 1 hexagon socket head bolt (94) fastening the plate assemblies.
2. Loosen and remove the plugs (91) (19 mm hexagon diameter) attached to the ports as necessary.
3. Remove the O-rings (7) (1 in each section) from the plate assemblies (10) and (11).
4. Pull out each spool from the valve housing still in the sub-assembly state.

CAUTION
1) When pulling out the spool, be careful not to cause any dents or scratches.
2) 2Identify each spool with a shipping tag so that there will be no mistake about their positions
when they are re-assembled.

5. Loosen and remove the hexagon socket head bolts (75) (8 mm hexagon socket diameter) and hexagon socket
head bolts (94) (5 mm hexagon socket diameter) those fastens the plate assemblies (10), (11), (28) and (29) to
the housing.
Remove the plate assemblies still in the assembly state.
Do not disassemble them.
6. Loosen and remove the plugs (91) (19 mm hexagon socket diameter) as necessary.
7. Remove the O-rings (7) and (41) from the valve housings (1) and (13).
8. Disassembly of spool assembly

84512399 EN - September 2011

8011-3
Copyright ©
Procedures for Assembly and Disassembly of Control Valve

CAUTION
1) In order to avoid damaging the outer edge of the spool, sandwich the spool with wooden blocks
(as in the diagram on the right) and fasten with a vise before starting the work.
2) Since adhesive is applied to the spool end thread section, heat up the outer edge of the spool
thread section to break down the adhesive.
3) Heat so that the spool heating temperature is 200 - 250℃ ℃.
Heat until the spool end loosens easily immediately after the heating.
4) If overheating occurs, replace the spring with a new one. (Wooden blocks for spool assembly/
disassembly)

(Wooden blocks for spool assembly/disassembly)

1) Loosen the spool assembly (2) - (6) and (14) - (17) spool ends (8 mm hexagon socket diameter) and dis-
assemble the spring seat and spring.
2) The spools in spool assemblies (3), (4), (6) and (14) have poppets, springs, plugs, and filters in the spools,
but do not disassemble them unless necessary.
When disassembly is required, heat up the outer edge of the spool to break down the adhesive on the
thread section, then remove the plug.
When assembling, always replace O-rings and backup rings with new ones.

Disassembly of arm 1 parallel-tandem spool, neutral cut spool section

1. Loosen and remove the hexagon socket head bolts (78) (5 mm hexagon socket diameter) for the caps (18) and
(86).
2. Remove the O-ring (23) from the cap (18).
Remove the O-rings (65) from the housing (1).
3. Pull out the spools (19) and (84) from the valve housing still in the sub-assembly state.
4. Disassembly of spool assembly

CAUTION
1) In order to avoid damaging the outer edge of the spool, sandwich the spool with wooden blocks
for assemble (as in the diagram) and fasten with a vise before starting the work.
2) Since adhesive is applied to the spool end thread section, heat up the outer edge of the spool
thread section to break down the adhesive.
3) Heat so that the spool heating temperature is 200 - 250℃ ℃.
Heat until the spool end loosens easily immediately after the heating.
4) If overheating occurs, replace the spring with a new one.

1) Loosen the spool (19) spool end (22) (5 mm hexagon socket diameter) and disassemble the spring seat
(20) and spring (21).

Disassembly of arm regeneration release valve section

Sub-parts in the assembly are expressed as [main number - sub-number].

84512399 EN - September 2011

8011-4
Copyright ©
Procedures for Assembly and Disassembly of Control Valve

CAUTION
1. When removing the plug, pressure left within can make parts fly out dangerously.
2. Slowly loosen the plug to check that there is no resistance due to residual pressure, then disassem-
ble.

1. Loosen and remove the plug (24) (32 mm hexagon diameter) and remove the O-ring (25).
2. Remove the spring (26) and spool (27-1) from the sleeve (27-2).
3. Pull out the sleeve (27-2) from the valve housing.
4. Remove the piston (27-3), O-ring (30), and backup ring (31) from the sleeve (27-2).

Disassembly of load check valve section

1. Loosen and remove the hexagon socket head bolts (75) (4 in each section, 8 mm hexagon socket diameter) for
the flanges (37) (6 locations) and (61) (1 location).
Only (61) has a different shape from the others, so keep it separate from (37).
2. Remove the spring (35), poppets (34) and (51) and O-ring (36) from the valve housing.
Remove the arm 2 (E-E cross section) poppet (59), spring (60), and sleeve (58).
3. Loosen and remove the hexagon socket head bolts (75) (8 mm hexagon socket diameter) for the flanges (52) (2
locations) .
4. Remove the spacer (53) from the valve housing and remove the O-ring (54) and backup ring (55) from the spacer
(53).
5. Remove the spring (35) and poppet (34) from the valve housing.
6. Loosen and remove the plug (72) (8 mm hexagon socket diameter). (D-D cross section)
7. Remove the spring (33) and poppet (32) from the valve housing.
8. Loosen and remove the plug (72) (8 mm hexagon socket diameter). (D-D cross section)
9. Remove the spacer (57), spring (33), and poppet (32) from the valve housing.
10. Loosen and remove the plug assembly (92) (36 mm hexagon diameter). (P4 section, cross section H-H )
11. Loosen and remove the hexagon socket head bolts (74) (4 locations, 8 mm hexagon socket diameter) for the
flange (43) .
12. Remove the spring (45), poppet (44), and O-ring (36) from the valve housing.
13. Loosen and remove the plug (46) (27 mm hexagon diameter) and remove the O-ring (47). (H-H cross section)
14. Remove the spring (48) and poppet (49) from the valve housing.

Disassembly of antidrift valve section

Sub-parts in the assembly are expressed as [main number - sub-number].

CAUTION
1. When removing the antidrift valve assembly, pressure left within can make seals and other parts fly
out dangerously.
2. Slowly loosen the hexagon socket head bolt to check that there is no resistance due to residual
pressure, then disassemble.

1. Loosen and remove the hexagon socket head bolts (74) (4 in each section, 8 mm hexagon socket diameter) for
the 2 antidrift valve assemblies (67).
2. Remove the O-rings (36) and (41) from the valve housing.
3. Remove the spring (39) and poppet (38) from the valve housing.
4. Disassembly of antidrift valve assembly

CAUTION
1) If parts inside the antidrift valve are disassembled with the antidrift valve installed in the valve
housing, pressure left within can make parts fly out dangerously.
2) Slowly loosen the plug assembly (67-12) to check that there is no resistance due to residual
pressure, then disassemble.

1) Loosen and remove the plug assembly (67-14) (38 mm hexagon diameter) and remove the O-ring.
2) Remove the piston (67-3), spool (67-4), and spring (67-6).
84512399 EN - September 2011
8011-5
Copyright ©
Procedures for Assembly and Disassembly of Control Valve

3) Loosen and remove the plug (67-14) (12 mm hexagon diameter).

4) Remove the sleeve (67-5) and poppet (67-2) from the body and remove the O-rings (67-8) and (67-9),
backup rings (67-10) and (67-11) from the outer edge of the sleeve.
5) Remove the spring seat (67-13) and spring (67-7) from deep in the hole.

84512399 EN - September 2011

8011-6
Copyright ©
Procedures for Assembly and Disassembly of Control Valve

Disassembly of relief valve

CAUTION
1. When removing the relief valve, loosen and remove the main unit installation section plug.
2. Do not loosen the set pressure adjustment plug or lock nut.
3. Doing so would be dangerous because the set pressure changes if the set pressure adjustment plug
turns.

1. Loosen and remove the overload relief valve (69) (32 mm hexagon diameter).
2. Loosen and remove the main relief valve (68) (32 mm hexagon diameter).
3. Loosen and remove the 2 relief valve assemblies (70) (32 mm hexagon diameter).
Remove the O-rings (70-5) and (70-8).

Disassembly of option section

1. Loosen and remove the hexagon socket head bolts (75) (8 mm hexagon socket diameter) for the 2 caps (88),
and remove the O-rings (89).
2. Loosen and remove the 2 plug assemblies (93) (24 mm hexagon diameter), and remove the O-rings and backup
rings.

Disassembly of straight travel signal control valve

1. Remove the hexagon socket head bolts (83) (5 mm hexagon socket diameter) and remove the body assembly
(42).
2. Loosen and remove the plug assembly (42-5) (5 mm hexagon socket diameter) and remove the O-ring.
3. Pull out the spools (42-2) and (42-3) and spring (42-4).
4. Loosen the orifice plug (42-7) (36 mm hexagon diameter) and remove it from the body (42-1).

Disassembly of other plugs

1. Loosen and remove the plug assembly (71) (10 mm hexagon socket diameter) and remove the O-ring.
2. Loosen and remove the plug assembly (72) (8 mm hexagon socket diameter) and remove the O-ring.
3. Loosen and remove the orifice plug (40) (5 mm hexagon socket diameter). (D-D cross section)
4. Loosen and remove the plug assembly (92) (36 mm hexagon diameter) and remove the O-ring.
5. Loosen and remove the plug assembly (73) (6 mm hexagon socket diameter) and remove the O-ring.

Disassembly of add-on section

1. Loosen and remove the 4 hexagon nuts (97) (22 mm hexagon diameter).
2. Remove the outlet housing (95).
Execute Steps [3] - [5] below as necessary.
3. Remove the spool section assembly (98) and remove the matching surface O-rings (98-10) and (98-11).
4. Remove the inlet section assembly (99) and remove the matching surface O-rings (99-3) and (99-4).
5. Remove the spool section assembly (111) and remove the matching surface O-rings (110-10) and (110-11).
6. Remove the main unit body matching surface O-rings (56) and (64).
7. Loosen the tie rod (96) and remove it from the main unit valve housing (1).
(Use a pipe wrench.)

CAUTION
When removing the add-on section, be careful not to cause any dents, scratches, or the like on
matching surfaces.
Any dents, scratches, or the like on matching surfaces have a danger of allowing oil to leak from
those surfaces and causing malfunction.
Also, be careful not to let any foreign matter enter the oil path.
Such foreign matter has a danger of the spool sticking due to biting of the spool sliding section or
a load check seat defect making the actuator run wild or stop disabled.

Disassembly of valve housing union bolt

CAUTION
1. Do not disassemble the union bolt (77) unless necessary.
2. If such disassembly is necessary, place the main unit on a flat table to do the work.
3. Prepare the replacement O-rings (65) and (66).

84512399 EN - September 2011

8011-7
Copyright ©
Procedures for Assembly and Disassembly of Control Valve

1. Loosen and remove the 8 hexagon socket head bolts (77) (14 mm hexagon socket diameter).
Tightening torque: 166 - 177 N•m
2. Remove the valve housing matching surface O-rings (65) and (66).

Cleaning
Completely clean all the disassembled parts with clean mineral oil.
Dry with compressed air and place each part on clean paper or vinyl for inspection.
Inspection
Inspect all surfaces of each part for burrs, scratches, gouges, and other defects.
1. Inspect the valve housing load check seat surface for scratches, gouges, and also for debris, dents, rust.
Repair any minor scratches with an oilstone.
2. Check that there are no scratches, dents, etc. on the outer edge of the spool.
Repair any small scratches with an oilstone.
3. Sliding parts must all move easily.
Also, all grooves and paths must be free of foreign matter.
4. If a spring is broken or extremely deformed or worn, replace it.
5. If relief valve operation is poor, inspect according to "Troubles and countermeasures Relief valve".
6. Replace all O-rings and backup rings from disassembled parts.
7. After removing caps or plugs, check for any paint fragments around the body opening or plug seating surface. (If
paint fragments were to get inside the valve, they could jam up or clog up the valve, resulting in operation defects
and oil leaks.)

Cautions for assembly

Cautions for O-Ring handling
1. Do not use any O-ring with a molding defect or damage caused by handling.
2. Apply enough grease or hydraulic oil to the O-ring and the section where it is mounted so that it can be mounted
smoothly.
3. Do not stretch an O-ring so far that this causes permanent deformation.
4. When assembling an O-ring, be careful not to roll the O-ring into place.(If an O-ring is mounted twisted, it is
difficult for it to naturally recover to its normal state and that twist causes oil leaks.)
Cautions for spool handling
1. Excessive torque on thread sections causes spool operation defects, so always tighten to just the specified torque.
2. Be careful to assemble all spools, springs, and spool ends in the same combinations as before disassembly.
Adhesive application method (for male thread section and female thread section of parts
requiring adhesion)
1. Cleaning (degreasing)
Either use vapor degreasing with acetate, ether or clean with an alkali cleaning agent.
2. Drying
Dry the surface to be glued, either by blowing clean air on it or letting it dry naturally.
Inadequate drying reduces the effectiveness of the adhesive.
3. Applying the adhesive
Apply a small amount of adhesive (equivalent to Loctite #638) to the first 2 - 3 threads at the entrance of the spool
female threads.
At this time, install being careful that the application section does not touch the spring seat.

CAUTION
Do not use "Loctite Primer T" hardening accelerator.
It causes insufficient adhesion strength.

4. Adhesive hardening time

In order to ensure the hardening of the adhesive, after fastening the spool end, leave the part out in the air for
the following period of time.
- Ambient temperature around 22℃: 8 hr. or longer
- Ambient temperature around 40℃: 3 hr. or longer
- Ambient temperature around 5℃: 24 hr. or longer

84512399 EN - September 2011

8011-8
Copyright ©
Procedures for Assembly and Disassembly of Control Valve

CAUTION
If the parts are not left out in the air for the above period, adequate adhesive strength may not be
achieved.

Procedure for assembly of sub-assembly

CAUTION
Before starting the assembling, check the quantity of each part, the installation location, the required
tools, etc.

Assembly of spool assembly (main spool)

1. Apply adhesive to the thread sections of the spools (2) - (6), (14) - (17) and assemble the spring seat, spring,
and spool end.
2. Sandwich the spool with the wooden blocks (the same ones used for disassembly), fasten in place with a vise,
then tighten the spool ends to the specified torque.
Tightening torque: 20 - 22 N•m
3. For spools (3), (4), and (14), insert the poppets and springs from the end opposite from the spool end, then apply
adhesive to the thread sections of the plugs with the O-rings and backup rings mounted, and tighten.
Also, for spool (5), the plug with filter is mounted at this location.
Tightening torque: 10 - 12 N•m

CAUTION
1) Be careful not to apply so much adhesive that it drips into the spool.
2) Be careful not to tighten any spool end with excessive torque.
Excessive torque there would deteriorate spool operation.
3) There are 2 types of spring.
Be careful to assemble each in its correct location. (only boom 2 different)

Assembly of arm 1 parallel-tandem spool assembly

1. Apply adhesive to the thread sections of the spool (19) and assemble the spring seat (20), spring (21), and spool
end (22).
2. Sandwich the spool with the wooden blocks (the same ones used for disassembly), fasten in place with a vise,
then tighten the spool ends to the specified torque.
Tightening torque: 19 - 22 N•m

Assembly of neutral cut spool assembly

1. Apply adhesive to the thread sections of the spool (84-1) and assemble the spring seat (84-2), spring (84-3), and
spring end (84-4).
2. Sandwich the spool with the wooden blocks (the same ones used for disassembly), fasten in place with a vise,
then tighten the spool ends to the specified torque.
Tightening torque: 19 - 22 N•m

CAUTION
1) Be careful not to apply so much adhesive that it drips into the spool.
2) Be careful not to tighten any spool end with excessive torque.

84512399 EN - September 2011

8011-9
Copyright ©
Procedures for Assembly and Disassembly of Control Valve

Assembly of antidrift valve assembly

1. Assemble the O-rings (67-8) and (67-9) and backup rings (67-10) and (67-11) into the grooves on the outer edge
of the sleeve (67-5).

CAUTION
1) Be careful to assemble O-rings and backup rings in the correct locations.
2) If they are assembled backwards, there is a danger of an O-ring being damaged and the drop
of the actuator from its own weight increasing.

2. Insert the poppet (67-2) and spool (67-4) in the sleeve hole.
Be careful to assemble the spool in the correct direction.
3. Install the spring seat (67-13) at the small-diameter section at the tip of the poppet, mount on the spring (67-7),
and insert into the body (67-1) together with the sleeve.

CAUTION
Apply grease to the poppet seat so that the spring and spring seat can be installed correctly on the
poppet seat.

4. Screw the plug (67-14) into the body (67-1) and tighten it.
Tightening torque: 78 - 88 N•m
5. Assemble the spring (67-6) and piston (67-3) on the plug (67-14).
6. Tighten the plug assembly (67-12) with O-ring mounted to the body (67-1).
Tightening torque: 147 - 157 N•m

Procedure for assembly of control valve main unit

Assembly of relief valve
CAUTION
1. When installing the relief valve, be sure to tighten the main unit installation section plug.
2. Do not tighten the set pressure adjustment plug or lock nut.
3. Doing so would be dangerous because the set pressure changes if the set pressure adjustment plug
turns.

1. Screw in and tighten the main relief valve (68).

Tightening torque: 78 - 88 N•m
2. Screw in and tighten the 6 overload relief valves (69) at each section.
Tightening torque: 78 - 88 N•m
3. Screw in and tighten the 2 relief valve assemblies with O-rings mounted (70).
Tightening torque: 103 - 113 N•m

Assembly of load check valve

1. Mount the O-rings (36) in the arm 1 section (E-E cross section), Boom 1 and 2 sections (F-F cross sections),
swing section, and bucket section (G-G cross sections) and assemble the poppets (34) and springs (35).
Mount the flanges (37) and tighten with the hexagon socket head bolts (75).
Tightening torque: 58 - 64 N•m
For the arm 2 section (E-E cross section), assemble the sleeve (58), poppet (59) and spring (60), mount the
flange (61), and tighten with the hexagon socket head bolts (75).
Tightening torque: 58 - 64 N•m
2. Mount the O-ring (36) in the travel section (I-I cross section) and assemble the poppet (51) and spring (35).
Tighten the flange (37) with the hexagon socket head bolt (75).
Tightening torque: 58 - 64 N•m
3. Assemble the poppet (34) and spring (35) on the common check section (J-J cross section), then insert the
spacers (53) with the O-ring (54) and backup ring (55) mounted.
84512399 EN - September 2011
8011-10
Copyright ©
Procedures for Assembly and Disassembly of Control Valve

Tighten the flange (52) with the hexagon socket head bolt (75).
Tightening torque: 39 - 44 N•m

CAUTION
1) Be careful to assemble O-rings and backup rings in the correct locations.
2) If they are assembled backwards, there is a danger of an O-ring being damaged and causing
external leaks.

4. Mount the O-ring (36) in the option section (H-H cross section) and assemble the poppet (44) and spring (45).
Mount the flange (43) and tighten with the hexagon socket head bolts (74).
Tightening torque: 58 - 64 N•m
5. Assemble the poppet (49) and spring (48) in the travel section (H-H cross section).
Screw in and tighten the plug (46) with O-ring (47) mounted.
Tightening torque: 107 - 117 N•m
6. Assemble the poppet (32) and spring (33) in the arm 1 parallel-tandem section (D-D cross section).
Screw in and tighten the plug assembly (72) with O-ring mounted.
Tightening torque: 73 - 79 N•m
7. Assemble the poppet (32), spring (33), and spacer (57) in the arm 2 parallel-tandem section (D-D cross section).
Screw in and tighten the plug assembly (72) with O-ring mounted.
Tightening torque: 73 - 79 N•m

Assembly of antidrift valve

1. Mount the O-rings (36) and (41) on the antidrift valve installation surfaces in the arm 1 section (E-E cross section)
and boom 1 section (F-F cross section).
2. Assemble the poppet (38) and spring (39).
3. Install the 2 antidrift valve assemblies (67) and tighten with the hexagon socket head bolts (74).
Tightening torque: 39 - 44 N•m

Assembly of option section

1. Install the 2 caps (88) with O-rings (89) mounted and tighten with the hexagon socket head bolts (75).
Tightening torque: 58 - 64 N•m
2. Screw in and tighten the 2 plug assemblies (93) with O-rings and backup rings mounted.
Tightening torque: 78 - 88 N•m

Assembly of arm regeneration release valve

1. Mount the O-ring (30) and 2 backup rings (31) in the sleeve (27-2).
2. Assemble the piston (27-3) and spool (27-1) in the sleeve and insert into the valve housing.
3. Put the spring (26) into the plug (24) with O-ring (25) mounted, then screw into the valve housing and tighten.
Tightening torque: 103 - 113 N•m

Assembly of arm 1 parallel-tandem spool

1. Assemble the spool (19) in the sub-assembly state into the valve housing.

CAUTION
After inserting the spool, slide it to check for any sticky or rough feeling.

2. Mount the cap (18) with O-ring mounted (23) and tighten with the hexagon socket head bolt (78).
Tightening torque: 8.8 - 10.8 N•m

84512399 EN - September 2011

8011-11
Copyright ©
Procedures for Assembly and Disassembly of Control Valve

Assembly of neutral cut spool

1. Assemble the spool assembly (84) into the valve housing.

CAUTION
After inserting the spool, slide it to check for any sticky or rough feeling.

2. Mount the O-ring (65) into the housing and tighten the cap (86) with the hexagon socket head bolt (78).
Tightening torque: 8.8 - 10.8 N•m

Assembly of main spool

1. Mount the O-rings (7) and (41) on the valve housing cap matching surface.
2. Assemble the spool assemblies (2) - (6), (14) - (17) in the sub-assembly state into the same location as before
disassembly.

CAUTION
1) Line up the spool straight with the opening and insert it slowly.
2) After inserting the spool, slide it to check for any sticky or rough feeling.
3) If a spool is left inserted that feels sticky or rough, there is a danger of a spool operation defect.

3. Install the plate assemblies (28) and (29) and tighten the hexagon socket head bolts in the order (75), (94).
Be careful not to apply excessive tightening torque to (94).
Tightening torque:
(75) 39 - 44 N•m
(94) 8.8 - 10.8 N•m
4. Install the plate assemblies (10) and (11), and tighten with the hexagon socket head bolts (75).
Tightening torque: 39 - 44 N•m
5. Install the caps (8) and (9), and tighten with the hexagon socket head bolts (74).
Tightening torque: 39 - 44 N•m
6. Screw in the plug assembly (110) with O-ring mounted into the option section (H-H cross section) short cap and
tighten it.
Tightening torque: 19 - 22 N•m
7. Screw in the plugs (91) with O-rings (90) mounted into the option section (H-H cross section) and straight travel
section (I-I cross section) long caps and tighten them.
Tightening torque: 19 - 22 N•m

CAUTION
1) Be careful not to apply excessive torque when tightening a plug to a cap.
2) Applying excessive torque could crush the cap threads.

Assembly of straight travel signal control valve

1. Screw the orifice plug (42-7) (36 mm hexagon diameter) into the body (42-1) and tighten it.
Tightening torque: 3.0 - 3.8 N・m
2. Being careful about the insertion orientation, assemble the spools (42-2) and (42-3) and spring (42-4).
3. Tighten the plug assembly (42-5) (5 mm hexagon socket diameter) with O-ring mounted to the body.
Tightening torque: 13.5 - 16.5 N・m
4. Install the body assembly (42) with the hexagon socket head bolts (83) (5 mm hexagon socket diameter).
Tightening torque: 8.8 - 10.8 N・m

Assembly of add-on section

1. Screw the tie rod (96) into the main unit valve housing (1).
2. Install the main unit body matching surface O-rings (56) and (64).
Execute Steps [1] - [3] below as necessary.
84512399 EN - September 2011
8011-12
Copyright ©
Procedures for Assembly and Disassembly of Control Valve

1) Remove the spool section assembly (111) and remove the matching surface O-rings (110-10) and (110-11).
2) Remove the inlet section assembly (99) and remove the matching surface O-rings (99-3) and (99-4).
3) Remove the spool section assembly (98) and remove the matching surface O-rings (98-10) and (98-11).
4) Install the outlet housing (95).
5) Tighten the 4 hexagon nuts (97) (22 mm hexagon diameter).

84512399 EN - September 2011

8011-13
Copyright ©
Procedures for Assembly and Disassembly of Control Valve

Assembly of other plugs

1. Screw in and tighten the plug assembly (71) with O-ring mounted.
Tightening torque: 116 - 128 N・m
2. Screw in and tighten the plug assembly (72) with O-ring mounted.
Tightening torque: 39 - 44 N・m
3. Screw in and tighten the orifice plug (40).
ightening torque: 14 - 18 N・m
4. Screw in and tighten the plug assembly (92) with O-ring mounted.
Tightening torque: 205 - 227 N・m
5. Screw in and tighten the plug assembly (72) with O-ring mounted.
Tightening torque: 73 - 79 N・m
6. Screw in and tighten the plug assembly (73) with O-ring mounted.
Tightening torque: 31 - 41 N・m

84512399 EN - September 2011

8011-14
Copyright ©
Procedures for Assembly and Disassembly of Control Valve

Internal structure diagram

1 SWING 3 BUCKET *5 OUT ⇔ IN

*2 OPEN ⇔ CLOSE *4 ARM 1 *6 ARM 2
84512399 EN - September 2011
8011-24
Copyright ©
Procedures for Assembly and Disassembly of Control Valve

Part list
Code Part name Q'ty Code Part name Q'ty
1 Valve housing 1 48 Spring 1
2 Spool assembly 1 49 Poppet 1
3 Spool assembly 1 51 Poppet 1
4 Spool assembly 1 52 Flange 2
5 Spool assembly 2 53 Spacer 2
6 Spool assembly 1 54 O-ring 2
7 O-ring 20 55 Backup ring 2
8 Cap 9 56 O-ring 1
9 Cap 1 57 Spacer 1
10 Plate assembly 1 58 Sleeve 1
11 Plate assembly 1 59 Poppet 1
13 Valve housing 1 60 Spring 1
14 Spool assembly 1 61 Flange 1
15 Spool assembly 1 64 O-ring 3
16 Spool assembly 1 65 O-ring 14
17 Spool assembly 1 66 O-ring 12
18 Cap 1 67 Antidrift valve assembly 2
19 Spool 1 68 Relief valve kit 1
20 Spring seat 2 69-1 Relief valve kit 5
21 Spring 1 69-2 Relief valve kit 1
22 Spool end 1 70 Relief valve assembly 2
23 O-ring 1 71 Plug assembly 3
24 Plug 1 72 Plug assembly 10
25 O-ring 1 73 Plug assembly 3
26 Spring 1 74 Socket head bolt 32
27 Spool assembly 1 75 Socket head bolt 66
28 Plate assembly 1 77 Socket head bolt 8
29 Plate assembly 1 78 Socket head bolt 4
30 O-ring 1 79 Name plate 1
31 Backup ring 2 80 Drive screw 2
32 Poppet 2 82 Metal plug 5
33 Spring 2 83 Socket head bolt 4
34 Poppet 7 84 Spool assembly 1
35 Spring 8 86 Cap 1
36 O-ring 10 88 Cap 2
37 Flange 6 89 O-ring 2
38 Poppet 2 90 O-ring 2
39 Spring 2 91 Plug 2
40 Orifice plug 1 92 Plug assembly 2
41 O-ring 27 93 Plug assembly 2
42 Body assembly 1 94 Socket head bolt 2
43 Flange 1 95 Outlet housing 1
44 Poppet 1 96 Tie rod 4
45 Spring 1 97 Nut 4
46 Plug 1 110 Plug assembly 1
47 O-ring 1

84512399 EN - September 2011

8011-25
Copyright ©
Procedures for Assembly and Disassembly of Control Valve

Relief valve
Procedures for assembly and disassembly of main relief valve

1 Plug (32 mm hexagon diameter) 5 O-ring 9 1-1/16-12UN-2A

2 O-ring 6 Plug (27 mm hexagon diameter) 10 Piston
Hexagon nut
3 O-ring 7 11 PF1/4 JIS O-ring type
(30 mm hexagon diameter)
Hexagon nut
4 8 Plug (27 mm hexagon diameter)
(36 mm hexagon diameter)

1. Disassembly
This part is replaced as an assembly.
When replacing, loosen the plug (1) (32 mm diameter) with a wrench and remove the O-ring (2).
If oil leaks from the nut (4) (36 mm hexagon diameter), loosen the nut (4) (36 mm hexagon diameter) and the
plug (1) (32 mm hexagon diameter), and replace the O-ring (3).
If oil leaks from the nut (7) (30 mm hexagon diameter), loosen the nut (7) (30 mm hexagon diameter) and the
plug (8) (27 mm hexagon diameter), and replace the O-ring (5).
2. Assembly
Carefully check to make sure there is no debris, paint fragments around the thread sections of the plugs (1) (32
mm hexagon diameter), (6) (27 mm hexagon diameter), (8) (27 mm hexagon diameter) and nuts (4) (36 mm
hexagon diameter), (7) (30 mm hexagon diameter) and assemble the new O-rings.
Also clean the valve housing relief valve installation section well, install the relief valve, and tighten the plug (1)
(32 mm hexagon diameter).
Tightening torque: 78 - 88 N・m
When the plug has been disassembled, adjust the pressure according to the Main relief valve item in 5).
Procedures for assembly and disassembly of overload relief valve

Lock nut (17 mm hexagon diam-

1 Cap 5 Poppet 9
eter)
Adjuster (6 mm hexagon diame-
2 O-ring 6 Spring 10
ter)
84512399 EN - September 2011
8011-26
Copyright ©
Procedures for Assembly and Disassembly of Control Valve

3 Adjuster kit section 7 1-1/16-12UN-2A

Cap (31.75 mm hexagon diame-
4 O-ring 8
ter)

1. Disassembly
This part is replaced as an assembly.
When replacing, loosen the cap (1) (31.75 mm hexagon diameter) with a wrench and remove the O-ring (2).
Also, if oil leaks from the adjuster kit section, loosen the adjuster kit and replace the O-ring (4).

CAUTION
Be careful disassembling the adjuster kit.
The spring may make parts fly out and the poppet could be lost.

2. Assembly
Check carefully that there is no debris, paint fragments around the thread section of the cap and assemble a new
O-ring (2).
Also clean the valve housing relief valve installation section well, install the relief valve, and tighten the cap (1)
(31.75 mm hexagon diameter).
Tightening torque: 78 - 88 N・m
When the adjuster kit has been disassembled, clean around the thread sections well and adjust the pressure
according to the Overload relief valve item in 5).
Procedures for assembly and disassembly of low-pressure relief valve

1 Plug 5 O-ring 9 PF1/4

2 Poppet 6 Piston 10 PF3/4
3 Plug 7 Plug 11 1 3/16-12UN-2A
4 Spring 8 O-ring

1. Disassembly
Fasten the assembly with a vise, loosen the plug, and remove the piston (6), spring (4), and poppet (2).
Then loosen the plug and take out the O-rings (5) and (8) from each part.
2. Assembly
Check carefully that there is no debris, paint fragments around the thread section of the plug and assemble a
new O-ring.
Install new O-rings (5) and (8) on the plug and install the plug.
Assemble the poppet (2), spring (4), and piston (6) and screw in and tighten the plug.
Tightening torque: 103 - 113 N・m
Also clean the valve housing relief valve installation section well and tighten the relief assembly plug (1) (36 mm
hexagon diameter).
Tightening torque: 103 - 113 N・m

84512399 EN - September 2011

8011-27
Copyright ©
Procedures for Assembly and Disassembly of Control Valve

Procedures for assembly and disassembly of add-on main relief valve

Lock nut (17 mm hexagon diam-

1 Plug (32 mm hexagon diameter) 5 Poppet 9
eter)
Adjuster (6 mm hexagon diame-
2 O-ring 6 Spring 10
ter)
3 Adjuster kit section 7 1-5/16-12UN-2A
4 O-ring 8 Plug (24 mm hexagon diameter)

1. Disassembly
This part is replaced as an assembly.
When replacing, loosen the plug (1) (32 mm hexagon diameter) with a wrench and remove the O-ring (2).
Also, if oil leaks from the adjuster kit section, loosen the adjuster kit and replace the O-ring (4).

CAUTION
Be careful disassembling the adjuster kit.
The spring may make parts fly out and the poppet could be lost.

2. Assembly
Check carefully that there is no debris, paint fragments around the thread section of the plug and assemble a
new O-ring (2).
Also clean the valve housing relief installation section well, install the relief valve, and tighten the plug.
Tightening torque: 59 - 69 N•m
When the adjuster kit has been disassembled, clean around the thread sections well and adjust the pressure
according to the Add-on main relief valve item in 5).
Relief valve adjustment
CAUTION
This part is neither disassembled nor adjusted. (It is replaced as an assembly.)
Therefore, be aware that proper operation is not guaranteed if pressure is adjusted.

Installation
1. Be careful that the line does not apply excessive force to the valve.
2. Tighten all the bolts the same.
3. Be careful.
Welding close to a valve can damage its seal due to excess heat and sputter.
4. In order to keep out debris, do not remove the cap for a port until it is time to work on the line.
Operation
1. Check that the hydraulic circuits and hydraulic oil are clean, then gradually raise the pressure (inch the operating
machine in low idle) and check that no oil leaks to the outside.
2. For the oil, use hydraulic oil with an aniline point of 82 - 113°C.
3. Do not raise the relief valve above the specified set pressure.
4. Set a difference of at least 2.0 MPa between the set pressure for the main relief valve and for the overload relief
valve.
84512399 EN - September 2011
8011-28
Copyright ©
Procedures for Assembly and Disassembly of Control Valve

5. Warm up the machine adequately before starting the actual work.

Pay attention to the following points in order to avoid sticking due to spool heat shock particularly when starting
up with the hydraulic oil temperature or valve temperature low.
• Do not operate the main relief valve and overload relief valve right too suddenly after each other.
Raise the temperature of each section uniformly and operate in such a way that the hydraulic oil circulates
within each actuator.
• Fine operations and compound operations generate heat locally due to throttling of individual sections, so do
not suddenly perform these operations with the machine still at low temperature.
Troubles and countermeasures
Control valves overall

Trouble content Conceivable cause Countermeasure

Eliminate the section that is providing re-
1.The oil temperature is abnormally high.
sistance to the oil flow in the line.
Replace the hydraulic oil and at the same
2.Dirty hydraulic oil
time, clean the circuits.
3.Line port joint tightened too much Check the torque.
4.The valve housing was warped during
Loosen the installation bolts and check.
installation.
Attach a pressure gauge to the pump and
The spool does not move 5.The pressure is too high. the cylinder port and check the pressure.
through its stroke.
6.The spool is bent. Replace the spool as an assembly.
7.Return spring damage Replace the damaged part.
8.The spring or cap is out of place. Loosen the cap, center it, then tighten it.
9.The temperature distribution within the
Warm up the circuits as a whole.
valve is not uniform.
10.Debris is clogging inside the valve. Remove (flush out) the debris.
Inspect for the pilot valve and pilot relief
11.Pilot pressure insufficient
pressure.
1.Oil leak from cylinder Check the cylinder seal section.
2.Oil from the spool is bypassing. Check for spool damage.
Clean the valve housing seat section and
3.Oil leak from overload relief valve
relief valve seat section.
Disassemble the antidrift valve and clean
the seat section for each part.
The load cannot be held. If a seat section is damaged, replace the
poppet or lap the poppet and seat sec-
4.Oil leak from antidrift valve tion.
If the antidrift valve spool is abnormal,
since the spool and the sleeve are mat-
ing parts, replace them both at the same
time.
1.There is debris jammed in the load
When the spool is switched check valve. Disassemble and clean the check valve.
from the neutral to the raise
2.The check valve poppet or seat section Replace the poppet or lap the poppet and
position, the load falls.
is damaged. seat section.

Relief valve

Trouble content Conceivable cause Countermeasure

1.Either the main poppet, sleeve, or
pilot poppet is stuck open or there is
Pressure does not rise at all.
debris jammed in the valve seat sec-
tion.
1.The pilot poppet seat section is Replace the relief valve.
The relief pressure is unstable. damaged.
2.The piston or main poppet is stuck.
1.Seat section worn by debris
The relief pressure is wrong. Set the pressure again, then tighten
2.The lock nut and adjuster are loose.
the lock nut to the specified torque.
84512399 EN - September 2011
8011-29
Copyright ©
Procedures for Assembly and Disassembly of Control Valve

Trouble content Conceivable cause Countermeasure

1.Relief valve seat section damage
Replace the relief valve.
2.Each part is stuck due to debris.
Oil leak
Replace the adjuster or installation
3.An O-ring is worn.
section O-ring.

Hydraulic system overall

Trouble content Conceivable cause Countermeasure

Check the pressure or replace the
1.Pump trouble
pump.
2.Relief valve trouble Replace the relief valve.
3.Cylinder trouble Repair or replace.
4.Pump load pressure is high. Check the circuit pressure.
The hydraulic system is not working
5.There is a crack in the valve. Replace the valve as an assembly.
properly or is not working at all.
6.The spool does not move through its
Check the spool movement.
full stroke.
7.The tank oil level is too low. Fill the hydraulic oil.
8.The filter in the circuit is clogged. Clean or replace the filter.
9.The circuit line is throttled. Check the line.

84512399 EN - September 2011

8011-30
Copyright ©

Section

8012

Procedures for Operation/Assembly and Disassembly of

Hydraulic Cylinder

84512399 EN - September 2011

CONTENTS

Specifications and structure diagram (including the assembly diagram and parts table) . . . . . . . . . . . . . . . . . . . . . . 3
Basic functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Function of Each Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cylinder Head Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pipe assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Precautions for Installing the Cylinder on the Machine Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Usage Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Maintenance and Inspection Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Maintenance Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Trouble Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Storage Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Storing Parts Individually (In principle, store indoors.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
When Mounted on Vehicle Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Recommended Anti-rust Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Assembly and Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
General Work Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Inspection after Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Required Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
General Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Wrench assembly (U1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Piston Ring Expander . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Bushing Tool Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Piston Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Disassembly of piston assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Disassembly of Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Assembly of Piston Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Assembly of Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Piston Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Structural Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Boom cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Arm Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Bucket Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

8012-1 PRINTED IN FRANCE
Copyright ©

84512399 EN - September 2011 Copyright © 2011 CNH FRANCE S.A.

8012-2 PRINTED IN FRANCE
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder
Specifications and structure diagram (including the assembly diagram
and parts table)
In this manual, explanation is done using a product with a representative structure for a construction machine hydraulic
cylinder.
Tighten bolts being installed to the specified torque.
Basic functions
Hydraulic cylinders are a type of hydraulic actuator.
A hydraulic cylinder converts the energy of pressure supplied from the hydraulic pump into a large force of linear
motion. By operating the hydraulic pressure direction switchover valve, one can switch the direction of operation
between extension and retraction.
This linear motion with large force and the switchover of the operation direction are the basic functions.
Function of Each Location
This manual explains the functions of each section of the cylinder using a product with a typical structure.
There may be some slight differences with the product being used, but the functions are the same.
Cylinder Head Assembly
The cylinder head assembly has the function of bearing the piston rod (2) by the bushing (4) press fit into the inner
diameter of the cylinder head (3).
The seal system of the inner diameter of the cylinder head prevents oil from leaking to the outside and prevents foreign
matter from getting into the cylinder.
The cylinder head assembly also has the function of supplying and discharging high-pressure oil from inside the
cylinder tube to the retraction side port.

1 Cylinder tube 5 Snap ring 9 Snap ring

2 Piston rod 6 Buffer ring 10 Collar
3 Cylinder head 7 Rod packing
4 Bushing 8 Dust seal

• Bushing
The bushing is press fit to the inside surface of the cylinder head (3) and touches the piston rod (2).
Together with the slide rings (18) (19) on the outer circumference of the piston, the bushing divides the lateral load
applied to the cylinder and moves linearly relative to the piston rod.
Furthermore, it supports one end of the piston rod and has the function of minimizing eccentricity which has a
negative impact on the sealing.
• Buffer ring/Rod packing
The buffer ring (6), together with the rod packing (7), prevents cylinder oil leakage from the rod section to the outside.
• Dust seal
The dust seal (9) is positioned in the opening where the piston rod (2) comes out from and goes into the cylinder
and prevents dust and water from getting into the cylinder from the outside.
It also has the function of wiping off any mud sticking to the surface of the piston rod as the piston rod moves.

84512399 EN - September 2011

8012-3
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder
Piston Assembly
The piston assembly has the function of transmitting the propulsion of the cylinder. A seal ring (16) is mounted on the
center of the piston (15) to prevent the flow of pressure oil from either the left or right chamber to the other chamber.
There are slide rings (18) (19) mounted at each end of the seal ring. They have the function of a bearing to receive
the cylinder lateral load.

1 Cylinder tube 15 Piston 19 Nut

2 Piston rod 16 Seal ring 20 Locking screw
13 Cushion ring 17 Slide ring 21 Steel ball
14 Cushion seal 18 Slide ring

Use caution with the direction

a of the cut surfaces during in-
stallation
b Face the "slit" to the piston side.

• Seal ring and backup ring

The seal ring (16) is positioned at the center of the piston (15) and uses the tension force of the O-ring to seal the
ring-shaped gap between the piston and the cylinder tube (1) and form chambers with a high-pressure side and a
low-pressure side with the piston as the boundary. The backup ring (17) has the function of suppressing extrusion
of the seal ring into the gap between the piston and the cylinder tube when the pressure operates and of improving
durability.
• Slide ring
Slide rings are positioned at both ends of the seal ring (16) and contact the inside surface of the cylinder tube (1).
Together with the bushing (4) positioned on the inside surface of the cylinder head (3), the slide ring divides the
lateral load applied to the cylinder and moves linearly relative to the inside surface of the cylinder tube.
Furthermore, it supports one end of the piston rod (2) and has the functions of minimizing eccentricity, which has a
negative impact on the sealing, and buries and captures any impurities trapped between the cylinder tube and the
slide rings (18) (19).
• Cushion ring
When the cylinder is fully extended, the cylinder head (3) and the cushion ring (13) fit together. When it is fully
retracted, the cylinder bottom and the cushion ring fit together. In both cases, this forms a ring-shaped gap and
squeezes the oil to reduce the cylinder collision speed at full extension or full retraction and thus soften the impact.
84512399 EN - September 2011
8012-4
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder
Pipe assembly
The pipe assembly is mounted on the extension side and retraction side ports of the cylinder tube assembly. It has the
function of supplying and discharging high-pressure oil by connecting with the hydraulic circuits of the machine body.

24 Pipe assembly
25 Pipe assembly

84512399 EN - September 2011

8012-5
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder
Handling Precautions
Precautions for Installing the Cylinder on the Machine Body
• When installing the cylinder on the machine body or removing it from the machine body, secure the piston rod at
the fully retracted position, check safety, and suspend.

CAUTION
Never suspend the cylinder from the line section. This would not only pose the danger of falling but
could also damage the cylinder.
Use a band to secure the piston rod in the fully retracted state.
If the piston rod is not in the fully retracted state, it could be easily damaged. This could create the
need for repair or make the piston rod unusable.
Also, not securing the piston rod is dangerous because the piston rod might fly out unexpectedly.

• Do not weld after the cylinder has been mounted on the machine body.
CAUTION
Electric welding on the cylinder or even at a position separated from the cylinder can generate a spark
within the cylinder and damage parts.
This could cause extensive damage, making it necessary to replace parts or replace the cylinder.

• When painting the machine body, mask the piston rod and wiper ring.
CAUTION
If the cylinder is operated with paint sticking to the piston rod surface and the wiper ring, the wiper
ring does not function adequately, greatly interfering with cylinder functions. For example, dirt and
paint from the outside may get into the cylinder easily and damage seal parts and cause an oil leak.

• Clean the cylinder before installing it.

84512399 EN - September 2011

8012-6
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder
Usage Cautions
• Use under the determined conditions.
CAUTION
Use of hydraulic oil other than that specified can cause rapid deterioration of and damage to seal parts.
If the relief valve is set to a value higher than that on the assembly diagram, there is a danger of this
leading to cylinder damage.
General sealing materials cannot handle high ambient temperature (about 100℃ ℃ or higher) or low am-
bient temperature (-20℃ ℃ or lower), so the cylinder would be damaged if used at such temperatures.
Such temperatures require special seal materials, so check if the cylinder being used complies with
this requirement.
The number one cause of cylinder trouble is oil leaks due to piston rod scratches.
Operate very carefully to avoid scratching.
If the piston rod is scratched, handle this according to "Trouble Diagnostics".

• Warm up the equipment adequately before work.

CAUTION
After the cylinder has been stopped for a long time, the seal parts inside the cylinder are stuck to the
metal of sliding surfaces, so do not suddenly pressurize or operate such a cylinder.
A new cylinder or one that has been left unused for a long time has much air built up inside, so it does
not operate smoothly.
Also, if the cylinder is suddenly operated or pressurized without bleeding out the air, the adiabatic
compression of the air generates high temperatures, which may burn and carbonize seal parts, leading
to a drastically reduced functionality.
Before starting work, always warm up the cylinder by moving slowly through a few full strokes under
no load to bleed off any air in the cylinder.

• For stopping the machine temporarily or storing it, always have the machine in a safely secure posture.
CAUTION
When extended, the cylinder cannot hold a load for a long time in a fixed position.
This is because the cylinder is extended and retracted by very minor oil leaks from hydraulic circuits
and from inside the cylinder and changes in the volume of the hydraulic oil due to oil temperature
variation.
This results in the danger of machine moving unexpectedly, which can lead to serious accidents.
For stopping the machine temporarily or storing it, always have the machine in a safely secure posi-
tion.

84512399 EN - September 2011

8012-7
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder
Maintenance and Inspection Cautions
• Always carry out daily maintenance inspections.
CAUTION
The most important point for realizing the cylinder functions for a longer time is "daily maintenance
inspections".
In order to ensure adequate functioning, execute "Maintenance Inspection and Service".
Constantly clean off any mud, water, dust, oil or grease stuck to the piston rod and keep the piston
rod in a clean state.
However, do not use water or the like to clean the wiper ring section and seal section. Wipe with a rag.
When leaving the machine unused for a week or longer, apply anti-rust oil to the surface of the piston
rod in order to prevent rusting.

• Use genuine parts for replacement parts.

CAUTION
If replacement parts are used that are not genuine parts, adequate functioning cannot be attained.
Always use genuine parts.
Specialty jigs have been produced so that assembly work and disassembly work can be done safely
and quickly, so order them.

8012-11
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder
Item Symptom Related part Cause Countermeasure and solution
1. As a rule, replace the rod packing
too at the same time.
2. Abnormally high pressure is often
Backup ring The part is greatly deformed. the cause.
The check items for this are the
same as those given above for
packing heel section extrusion.
There is foreign matter caught
Remove the foreign matter.
in the lip.
Wiper ring The lip is damaged.
There is other abnormal dam- Replace.
age.
Piston rod sliding
1 There is major wear of the
section oil leak
bushing and the gap with the
piston rod exceeds the limit on Replace.
Bearing part inner diameter wear in "Usage
(bushing) Limits".
1. Replace.
There are large scratches on a
2. Inspect the piston rod sliding sur-
sliding surface.
faces for scratches and rust.
1. Remove the scratches or rust
with a whetstone.
A seal mounting section has
Cylinder head 2. If the repair does not solve the
scratches and rust.
problem, replace the cylinder
head.
1. Remove the foreign matter.
2. If the O-ring is damaged, replace
it.
3. Tube interior surface inspection:
If there are any scratches or rust,
use a whetstone to make the sur-
There is foreign matter caught face smooth.
O-ring in the inner or outer diameter. 4. Cylinder head O-ring groove in-
There is damage to the O-ring. spection: Same as above
5. Backup ring inspection: If the
backup ring is deformed or ex-
truded, replace it.
Check the above and replace the
O-ring.
The part is deformed or ex-
Backup ring Replace together with the O-ring.
truded.
1. Disassemble the cylinder head
Cylinder head and inspect the O-ring and
2 matching section backup ring.
oil leak If there is damage, replace.
2. Check the tube and cylinder head
Cylinder
A part is loose. threads for damage and if there is
head
any damage, replace.
3. When the inspection is complete,
tighten to the specified torque.
See "Assembly Procedures".
4. Stop rotation.
There is looseness, stretching Replace all the bolts and tighten to the
Bolt
or breakage. specified torque.
1. Replace with a new one.
2. Oil leaks at matching sections
may be caused by abnormally
high pressure (including cush-
Cylinder tube There is abnormal swelling.
ion pressure), so if the tube is
swollen or deformed, replace it
with a new one.
Also inspect the circuit pressure.

84512399 EN - September 2011

8012-12
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder
Item Symptom Related part Cause Countermeasure and solution
CAUTION
Replace with a new one.
Pipe and cylinder
Pipe and cylinder There are cracks on the weld- The crack progresses and ultimately
tube welding sec-
tube ing section. the part fractures.
tion oil leak
A fracture is extremely dangerous, so
if a crack is seen, quickly stop work
3 and replace that part.
Welding over a crack is ineffective.
Tighten to the specified torque ac-
Line fastening bolt is loose.
cording to the work procedure.
Oil leak from cylin- The line is bent. Replace with a new one.
der line connec- Pipe assembly 1. Use a whetstone to make the sur-
tion section There are scratches on a con- face smooth.
tact surface. 2. If the oil leak does not stop, re-
place.
1. Replace with a new one.
The bending is large and ex-
2. There may also be damage to
ceeds the stipulated bend
Piston rod seals and sliding parts, so inspect
warp.
Cylinder tube them.
(Bend warp: See "Mainte-
If there is any abnormality, re-
nance Standards".)
place.
Operation defect Replace with a new one.
Movement is not Cylinder tube There are dents. Inspect the seal and sliding parts the
smooth. same as above.
1. Replace with a new one.
Abnormal wear of sliding parts
Inspect the seal and sliding parts
Piston rod and damage
the same as above.
Cylinder tube Foreign matter caught at the
2. Remove the foreign matter.
Sliding part piston section or the cylinder
Inspect the seal and sliding parts
head sliding section
the same as above.
Replace with a new one.
There are scratches, wear, or
Piston seal Also inspect the cylinder tube interior
other damage.
4 surfaces.
1. Use honing or a whetstone to
eliminate the scratches and rust
and make the surface smooth.
Internal oil leak There are scratches and rust
Cylinder tube If the scratches cover too large an
The piston rod ex- on interior surface.
area to be repaired, replace the
tends and retracts cylinder tube with a new one.
on its own and 2. Replace with a new piston seal.
drops abnormally
1. Tighten to the specified torque.
during operation.
See "Assembly Procedures".
Also, the stipu-
2. The piston rod thread section
lated speed is not
could be stretched.
output. Piston nut Tightening is insufficient.
Measure the diameter where the
rod and piston fit together and if
this area is tapered, replace the
piston rod assembly.
Inspect the amount of valve leakage
Valves Leak from valve.
and perform maintenance.

84512399 EN - September 2011

8012-13
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder
Item Symptom Related part Cause Countermeasure and solution
Bleed out the air.
1. Cylinder with no air bleeding
Bleed out the air by moving the
cylinder back and forth at few
times at low pressure and low
speed.
2. Cylinder with air bleeding (air
breather)
After securing the machine so
Operation is un- There is air remaining in the that the cylinder does not move,
Air
steady. cylinder. bleed the air from the air breather.

HINT
The cylinder may extend or retract
somewhat when the cylinder stops
suddenly.
This phenomenon occurs due to the
4 compressibility of the hydraulic oil.
This occurs particularly easily for
cylinders with long strokes.
The impact is high
when switching The gap between the installa- Measure the pin and pin bushing di-
Pin bushing
over between ex- tion section and the pin bushing mensions and replace any part that
Pin
tension and re- is enlarged. exceeds its specified dimension.
traction.
The oil or grease feed is inade-
Cylinder sliding Apply oil or grease.
Pin bushing quate.
operations make
Pin There is seizing at matching Replace with a new part and apply oil
sounds.
section. or grease.
CAUTION
The hydraulic oil expands and contracts with changes in temperature and pressure.
This causes the cylinder to extend and retract too, so it can be mistaken for an internal oil leak.
For internal oil leaks, always check the temperature and pressure under the same conditions.

84512399 EN - September 2011

8012-14
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder
Storage Standards
When a hydraulic cylinder is shipped from the plant, every measure is taken, but in order to prevent trouble during
storage and to extend the product service life, pay attention to the following items.
Storing Parts Individually (In principle, store indoors.)
• Store parts off the floor and do not store in any location with high temperature and humidity, corrosive gas or liquids.
• Before shipment, we operate the cylinder with hydraulic oil to which a fixed quantity of vaporizing anti-rust agent
has been added (in order to prevent rust within the cylinder), carry out the pre-shipping inspection, retract the pis-
ton rod with ultra-dry air (condensation point -35℃ or lower) (in order to prevent condensation due to temperature
difference), and then put caps on the ports and line joints before shipping the cylinder.
• Any product that has been in storage in our product warehouse longer than the standard storage period is disas-
sembled and inspected before being shipped.
Therefore, do not store or leave a cylinder unused with a cap removed or with the remaining oil in the cylinder
drained.

Storage for 6 month or longer

Storage for 1 month or longer Storage for 1 year or longer
(3 months for cylinder alone)
Clean any dust from the cylinder, Operate the cylinder back and forth
Since there is a danger of packings
and then apply anti-rust oil to the with clear hydraulic oil, and then pour
deterioration, disassemble, inspect,
1 pin bushings, flange sections, pis- anti-rust oil into the cylinder and store
and replace packings.
ton rod, and other sections that in compliance with the items on the
Also, check for rust inside the cylinder.
rust easily. left for storage of 1 month.
If a cylinder that has been stored for
If the cylinder cannot be operated, a long time is used as is, oil may leak
2 -
seal in anti-rust oil. due to temporary running-in defects of
seals.
3 When storing, be extremely careful not to let parts drop, let them collide with anything, or let anything strike them.

When Mounted on Vehicle Body

1. Operate the cylinder at least once per month.
2. Retract the cylinder so that as much as possible outside air does not touch the piston rod and apply anti-rust oil
at least once per month to the exposed part of the piston rod.
3. Handle carefully to absolutely avoid scratching the piston rod.
4. When putting the cylinder into an environment where rust occurs particularly easily, for example due to exposure
to sea breezes during export, always apply anti-rust oil to the piston rod and as much as possible protect with
polyethylene sheets or VCI paper (vaporizing anti-rust paper).
5. Anti-rust oil and other solvents can have negative impacts on seals, so select anti-rust oil carefully and as much
as possible keep it off dust seals etc.(For details on anti-rust oil to select, see "Recommended Anti-rust Oil".)

Recommended Anti-rust Oil

Vaporizing anti-rust oil
a. Ferro Gard #1009 (from USC Limited)
b. Knuckle Oil #105S (from Parker Industries, Inc.)
For inside cylinder For both a. and b., add 3 - 5 % of the hydraulic oil.
By volume,
Ferro Gard: 5/100
Knuckle Oil: 3/100
For piston rod Anti-rust P-1300 (from the Nippon Oil Corporation)
For machine worked sur-
faces other than parts with Select from JIS K 2246 (anti-rust oil) NP-1 through NP-6.
oil sealed in

84512399 EN - September 2011

8012-15
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder
Assembly and Disassembly Procedures
Preparations
Prepare the Following before Starting Disassembly:
1. Work platform preparation
Prepare a sufficiently spacious, solid and stable work surface so that parts will not fall or move during work.
2. Tool and materials preparation
Prepare the tools and materials shown on the following pages.

General Work Precautions

1. Thoroughly clean any dirt or mud from the outside walls of the cylinder before starting disassembly.
2. Each part has been manufactured with a high degree of precision, so be careful not to let parts bump each other
or fall when handling them.
3. If parts are struck or pried off with excessive force during work because they are tight, this may cause burrs or
damage which causing reduction in performance or oil leaking.
Perform work carefully and thoroughly.
4. If a cylinder is left disassembled, humidity and dirt can cause rust on parts.
If a pause in the work is unavoidable, be careful to prevent rust and keep off dust.

Maintenance Standards
Replace sliding parts and seal parts as follows.
1. Bushing
When 1/4 of the circumference is worn brown over the entire length.
2. Seals and slide rings
Replace with new parts when the cylinder is disassembled.
3. Pin bushing
When there is severe seizing.
4. Piston rod
When the piston rod is bent 0.5 mm/1 m or more.

84512399 EN - September 2011

8012-16
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder
Inspection after Assembly
Dimension inspec-
Check the maximum retracted length and stroke as instructed on the diagram.
tion
Pressure with- Check for looseness, permanent deformation, and external leaks when the test pressure in-
stand inspection structed on the diagram is applied to each stroke end for at least 3 min.
Check the amount of oil leak at the rod section.
• Judgment value for rod section oil leak amount
Move the piston rod back and forth 20 times with the oil at a temperature from 20℃ to 40℃,
then judge by the state of the oil ring formed on the rod surface. If the oil ring is in a broken
down A state, this is judged to be trouble. See "Trouble Diagnostics" for information on how
to solve this.

External leak in-

spection

Oil leak amount unit: ml/10 min.

Inner diameter Oil leak Inner diameter Oil leak Inner diameter Oil leak
mm amount mm amount mm amount
Internal leak in- 32 0.4 100 4.0 160 10.0
spection 40 0.6 125 5.6 180 12.6
50 1.0 140 6.0 200 15.6
63 1.6 220 20.0
80 2.3 250 22.0

1 Oil ring

a Acceptable
b Not acceptable

84512399 EN - September 2011

8012-17
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder
Required Tool
General Tool

No. Tool name Q'ty

Screwdriver (flathead screw-

1 1
driver)

2 Hexagon wrench 1 set

3 Vise 1

4 Wrench (for piston nuts) 1 set

5 Punch 1

6 Torque wrench 1 set

84512399 EN - September 2011

8012-18
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder
No. Tool name Q'ty

7 Hammer (plastic hammer) 1

8 Monkey wrench 1

9 Scoop 1 set

84512399 EN - September 2011

8012-19
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder
Wrench assembly (U1)
Part number: KRV10620
Application: Use for removal and installation of screw-type piston.

Component parts
No. Part name Q'ty Remarks
1 Arm 1 Each drive 3/4"
2 Arm 1
3 Center pin 1
4 Pin 2 Diameter 1/4", 5/16"
5 Set screw 2

Adjustment
2" (50.8 mm) - 6" (152.4 mm)
Usage example

•
• Arm cylinder Tightening torque: 58.85 - 73.55 N·m
• Bucket cylinder
• Check that the top of the plunger has slight back-
lash.

a 2-D10 notch hole

5. Set the cushion plunger (10) on the piston rod, in-
stall the 12 balls (9), and then secure with the cap 3) Use a punch (*3) to caulk the threaded section
(8). at 4 locations.

8012-29
Copyright ©
Procedures for Operation/Assembly and Disassembly of
Hydraulic Cylinder
Location of the slit is shown in
*1 Hole 1 place *6 *11 Type-A
the drawing
*2 Stake 2 places after tightening *7 From bottom pin center *12 With plastic cap
Welding bead height must be
Manufacturing No. stamping
*3 Width across flats *8 *13 under the port face of the cylin-
position
der cap
*4 Outer surface knurl finished *9 130 mm or more (both sides) *14 Drill thru
*5 Cushion stroke *10 Effective thread depth *15 Port detail(push,pull)

L1 Retracted 2230 mm
L2 Stroke 1550 mm

CONTENTS

Procedures for Assembly and Disassembly of Operation Remote Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Required Tools and Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Causes of Trouble and Countermeasures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

8013-2 PRINTED IN FRANCE
Copyright ©
Procedures for Assembly and Disassembly of Operation Remote
Control Valve
Procedures for Assembly and Disassembly of Operation Remote Control
Valve
Job code 35355AA18

CAUTION
• To ensure safe operations, wear protective devices before beginning work and follow all precautions.
• Be sure to repair any parts damaged during disassembly, and prepare replacement parts in advance.
• If any parts are significantly rusted or dirty, clean them before disassembling.
• Any foreign matter entering the equipment during assembly can create a malfunction. Therefore, after
thoroughly cleaning the equipment with cleaning oil, air blow the equipment, and assemble in a clean
location.
• When assembling sliding parts, be sure to coat them with new hydraulic oil.
• As a rule, replace all O-rings and other seal parts with new parts.
General cautions
• Be careful not to drop precision parts or let bump them with other parts during work.
• Do not forcefully open or hit parts in an effort to speed up operations.
Pay careful attention and proceed slowly so as not to damage any parts, create any oil leaks, or com-
promise the efficiency of the equipment, etc.
• Disassembled parts can easily rust or collect dust. Therefore, immediately after disassembling parts,
take precautions to prevent the parts from rusting or collecting dust.

Items to prepare
Maintenance Procedures
Required Tools and Tightening Torque
Tightening
Dimension
Tools Part No. Part name Screw size torque
(mm)
(N·m)
Adjusting
22 312 M14 63.7 - 73.5
Wrench nut
32 302 Disk M14
Special jig 24 301 Joint M14 44.2 - 50.0

Other
• Vapor corrosion inhibitor
• White kerosene
• Heat-resistant grease
• Sandpaper (#1000, #2000)
• Whetstone
• Vise
• Screwdriver
• Torque wrench

84512399 EN - September 2011

8013-3
Copyright ©
Procedures for Assembly and Disassembly of Operation Remote
Control Valve
Maintenance Standards
Maintenance in-
Standard Remarks
spection item
When handle is in neutral 1000 cc/min or more
Conditions
During operation 2000 cc/min or more
Leak amount Primary pressure 2.94 MPa
If either condition occurs, replace the remote
Oil viscosity 23 mm2/S
control valve as one unit.
When wear on the sliding sections exceeds
The same approximate conditions as those
wear on the non-sliding sections by 10 μm or
Spool listed above for leak amount are expected when
more, replace the remote control valve as one
the condition on the left occurs.
unit.
If the end section is worn by 1 mm or more, perform replacement.

Push rod

Replace the operation section disk (302) and

Operation section Make adjustments if the backlash is due to
joint section (301) if there is backlash of 2 mm
backlash looseness in the tightening sections.
or more due to wear.
If abnormal noise, hunting, or a drop in primary
pressure occurs and the problem cannot be re-
Operation stability solved with "Causes of Trouble and Counter-
measures", replace the remote control valve as
a unit.

NOTE:
It is desirable for seal materials such as O-rings to be replaced with each disassembly, but it is acceptable to reuse
these after it is confirmed that they are not damaged.

84512399 EN - September 2011

8013-4
Copyright ©
Procedures for Assembly and Disassembly of Operation Remote
Control Valve
Disassembly Procedures 4. If the return springs are strong, the plate (2), plugs,
and push rods (3) will rise at the same time the joint
1. Use copper plate (or lead plate) to secure the re- (1) is loosened, so be careful of parts flying off when
mote control valve in a vise, then remove the bel- removing the joint.
lows (1).
• Be careful not to tear the bellows.

5. Remove the plate (1).

2. Use a wrench on the bolt width of the adjusting nut

(1) and disk (2) to loosen them, then remove the
adjusting nut and disk.

6. If the return springs are weak, the plugs (1) will re-
main in the casing due to the sliding resistance of
the O-rings, so use a flathead screwdriver to re-
move it.
3. Use a jig (1) to remove the joint. • Use the groove in the outer circumference of the
plugs and remove them while making sure they
are not damaged by an unbalanced load.
• Use caution as plugs may fly off when they are
being removed due to the return springs.

84512399 EN - September 2011

8013-5
Copyright ©
Procedures for Assembly and Disassembly of Operation Remote
Control Valve
7. Remove the push rods (1), plugs (2), pressure re- 10. Remove push rods (2) from the plugs (1).
ducing valve assembly, and the return springs (3)
from the casing.
• Record the relation of parts to the casing hole po-
sitions through marking, etc.

11. Remove the O-rings (2) from the plugs (1).

• The O-ring cannot be reused.
Replace it with new part.

8. For disassembly of pressure reducing valve, press

in the spring seating (1), move the spring seating
to the side while bending the secondary pressure
spring (2), and remove the spring from the spools
(3) by passing through the larger hole.
• Do not press in the spring seating by 6 mm or
more.

12. Remove the seal (1).

Use a small flathead screwdriver, etc. to remove
seals.
• The seal cannot be reused.
Replace it with new part.

9. Separate the spool (1), spring seating (2), sec-

ondary pressure spring (3), and washer (4).
• Be careful not to scratch the surface of the spools.
• Handle as an assembly until assembly is per-
formed.

13. Cleaning parts

Clean all parts by placing them in a rough cleaning
container filled with white kerosene. (rough clean-
ing)
Clean each part by placing it in a finish cleaning
container filled with white kerosene, and thoroughly
clean each part, including the interior, while slowly
rotating the part. (finish cleaning)
Use a clean rag to thoroughly remove any white
kerosene stuck to parts.
84512399 EN - September 2011
8013-6
Copyright ©
Procedures for Assembly and Disassembly of Operation Remote
Control Valve
• Scratching can easily occur if cleaning of a part Assembly Procedures
is begun just after parts are immersed in white
kerosene, so let each part sit in white kerosene 1. Insert washer (4), secondary pressure spring (3)
until debris and grease sufficiently loosen from the and spring seating (2) onto each of the spool (1) in
surface of the part and float to the surface. that order.
• If the white kerosene is dirty, this will encourage
damage to parts and result in reduced perfor-
mance after reassembly. Thoroughly manage the
level of cleanliness of the white kerosene.
• Do not dry parts with compressed air, as this will
damage parts and cause rust to form due to de-
bris and moisture being dispersed into the atmos-
phere.
Preventing rust on parts
Apply an anti-rust agent to each part.
• Rust will form on parts if they are left as is af-
ter cleaning, and this will cause reduced perfor-
mance of functions after reassembly.
2. Press in the spring seating (1) and move it to the
side while bending the secondary pressure spring
(2) to pass the seating over the larger hole and in-
stall it on each of the spools.
• Do not press in the spring seating by 6 mm or
more.

3. Install the return springs (1) in the casing (2).

Install the pressure reducing valve assembly (3) in
the casing (2).
• Install them in the positions they were in before
disassembly.

84512399 EN - September 2011

8013-7
Copyright ©
Procedures for Assembly and Disassembly of Operation Remote
Control Valve
4. Install O-rings (2) on the plugs (1). 6. Install push rods (1) into the plugs (2).
• Apply hydraulic oil to surface of the push rod.

5. Install seal (1) on the plug (2).

• Install so that the seal lips are as shown in the 7. Install the plug assembly (1) in the casing (2).
diagram below. If the return spring is weak, it will be stopped by the
sliding resistance of the O-ring.
• Be careful not to scratch the casing hole by forcing
in the spool.

3 Push rod
8. If the return spring is strong, use the plate (1) to
install all 4 plug assemblies at the same time and
a Hydraulic oil application temporarily tighten them with the joint (2).
• Be careful of the plug assemblies and plate flying
off.

84512399 EN - September 2011

8013-8
Copyright ©
Procedures for Assembly and Disassembly of Operation Remote
Control Valve
9. Install the plate (1). • Tightening torque: 63.7 - 73.5 N·m
• During tightening, do not move the disk position.

10. Use a jig, and tighten the joint (1) to the casing (2)
to the specified torque. 13. Apply grease to the rotating section of the joint and
Tightening torque: 44.2 - 50.0 N·m to the top of the push rods (1).

11. Install the disk (1) onto the joint (2). 14. Install the bellows (1).
• Screw the disk in until it is equally touching each • Be careful not to tear the bellows.
of the 4 push rods (3). • Inject vapor corrosion inhibitor into each port, and
Secondary pressure will cause faulty operation of then place plugs in the ports.
the machine if the disk is screwed in too much,
so pay attention to adjustment of the tightening
position.

12. Install the adjusting nut, use a wrench on the bolt

width of the disk (1) to secure it, and tighten the
adjusting nut to the specified torque.

84512399 EN - September 2011

8013-9
Copyright ©
Procedures for Assembly and Disassembly of Operation Remote
Control Valve
Causes of Trouble and Countermeasures
It is not easy to discover trouble locations.
A few problems that may sometimes occur are listed in the table below.
Repairs are difficult, so refer to the possible causes and solutions in the table.
The table below shows general symptoms, suggested causes, and also solutions.
However, the cause of machine problems are often not rooted in just a single part. Problems are often due to the
relationship of one part with another.
Also keep in mind that solutions other than those listed in the table may sometimes be necessary.
The numbers in parentheses after the part names are the codes indicated in "Attached diagram 1 Remote control
valve assembly cross-section diagram".
The table below does not include all possible causes and countermeasures.
Further investigation of problems and causes should be done by an experienced and qualified repair person, as nec-
essary.

Symptom Cause Solution

1. Insufficient primary pressure 1. Maintain primary pressure.
2. Secondary pressure spring (241) is bro- 2. Replace it with new part.
Secondary pressure is ken or worn. 3. Replace the remote control valve as one
not rising. 3. The gap between spool (201) and the unit.
casing (101) is abnormally large. 4. Assemble and disassemble and/or re-
4. There is backlash in the handle section. place the handle section.
1. Repair the sticking sections.
1. Sliding parts are sticking.
Secondary pressure is 2. Return directly to the oil tank.
2. Tank line pressure is variable.
unstable. 3. Perform operation several times and let
3. Air is getting into lines.
out air.
Secondary pressure is 1. Tank line pressure is high. 1. Return directly to the oil tank.
high. 2. Sliding parts are sticking. 2. Repair the sticking sections.

84512399 EN - September 2011

Attached diagram 1. Remote control valve assembly cross-section diagram

a c Grease application to rotating sliding sections. Be

Grease application to top
careful with the installation direction.
Secondary pressure adjustment shim
b Design central value d Hydraulic symbol
t = 0.4 1 shim

Code Part name Q'ty Code Part name Q'ty

101 Casing 1 217 Washer 4
151 Plate 1 221-1 Return spring (port 1) 1
201 Spool 4 221-2 Return spring (port 3) 1
211 Plug 4 221-3 Return spring (ports 2, 4) 2
212-1 Push rod (ports 1, 3) 2 241-1 Secondary pressure spring (ports 1, 3) 2
212-2 Push rod (ports 2, 4) 2 241-2 Secondary pressure spring (ports 2, 4) 2
213 Seal 4 301 Joint 1
214 O-ring 4 302 Disk 1
84512399 EN - September 2011
8013-11
Copyright ©
Procedures for Assembly and Disassembly of Operation Remote
Control Valve
Code Part name Q'ty Code Part name Q'ty
216-1 Spring seating (ports 1, 3) 2 312 Adjusting nut 1
216-2 Spring seating (ports 2, 4) 2 501 Bellows 1

Tightening torque
Tightening
Code Screw size
torque
301 M14 44.2 - 50.0 N·m
302
M14 63.7 - 73.5 N·m
312

Detailed diagram of jig main unit (1) and (2) are inserted by tightening. Attached diagram 2. Jig main unit

1 (1) Material: SCM415 (N) carburized 3 (Bolt width)

Hole H6 + 0.13
*2 (2) Material: S45C *4
Shaft n6 + 0.028
84512399 EN - September 2011
8013-12
Copyright ©
Procedures for Assembly and Disassembly of Operation Remote
Control Valve

Detailed diagram of bushing

Joint installation state Material: SCM415 (N) carburized
Quantity: 2
Attached diagram 3. Joint disassembly jig

c Bushing

84512399 EN - September 2011

Section

8014

Procedures for Assembly and Disassembly of Travel

Remote Control Valve

84512399 EN - September 2011

CONTENTS

Procedures for Assembly and Disassembly of Travel Remote Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Causes of Trouble and Countermeasures and Cross-section Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

8014-2 PRINTED IN FRANCE
Copyright ©
Procedures for Assembly and Disassembly of Travel Remote
Control Valve
Procedures for Assembly and Disassembly of Travel Remote Control
Valve
Job code 35356AK20

CAUTION
• To ensure safe operations, wear protective devices before beginning work and follow all precautions.
• When removing devices or positioning devices at the time of installation, use a removal jig and a ham-
mer or steel rod.
• Follow the precautions below when suspending the load.
• The liftcrane must be operated by a qualified operator.
• Do not stand or pass under the suspended load.
• Check the weight of the load to determine whether it can be carried by hand or whether a liftcrane
must be used.
• Be sure to repair any parts damaged during disassembly, and prepare replacement parts in advance.
• If any parts are significantly rusted or dirty, clean them before disassembling.
• Any foreign matter entering the equipment during assembly can create a malfunction.
Therefore, after thoroughly cleaning the equipment with cleaning oil, air blow the equipment, and as-
semble in a clean location.
• When assembling sliding parts, be sure to coat them with new hydraulic oil.
• As a rule, replace all O-rings and other seal parts with new parts.
General cautions
• Be careful not to drop precision parts or let bump them with other parts during work.
• Do not forcefully open or hit parts in an effort to speed up operations.
Pay careful attention and proceed slowly so as not to damage any parts, create any oil leaks, or
compromise the efficiency of the equipment, etc.
• Disassembled parts can easily rust or collect dust.
Therefore, immediately after disassembling parts, take precautions to prevent the parts from rusting
or collecting dust.

Items to prepare
• Wrench
• Screwdriver
• Specialty jigs
• Vise
• Loctite 262
• Special fiber cloth (Kimwipe)
• White kerosene

84512399 EN - September 2011

8014-3
Copyright ©
Procedures for Assembly and Disassembly of Travel Remote
Control Valve
Maintenance Procedures
Disassembly Procedures 4. Remove the cams (1) as an assembly with the lock-
ing screws and lock nuts left attached.
1. Use a shock plate to secure the remote control valve Record the positions of the cams in relation to the
in a vise, then remove the bellows (1) from the cover covers (2).
(2).
• Be careful when removing, as the push rods (3)
• Be careful not to tear the bellows. may fly off.

2. Use a hexagon wrench (1) on the hexagon socket 5. Use a hexagon wrench (1) on the hexagon socket
head locking screws to loosen them. head bolts to loosen and remove them.
Be careful, as application of Loctite #241 makes the
loosening torque high.

6. Remove the cover (1).

3. Place a round rod (D8 mm or less) against one end • Record the positions of the covers in relation to
of the cam shafts (1) and lightly strike it with a ham- the casings (4).
mer to remove the shafts. Be careful when removing, as the push rods (2) or
plugs (3) may fly off due to the damping springs.
(The plugs are only kept in the casing by the slid-
ing resistance of the O-rings.)

84512399 EN - September 2011

8014-4
Copyright ©
Procedures for Assembly and Disassembly of Travel Remote
Control Valve
7. Remove push rods (2) from the plugs (1). 10. Remove the damping springs (2) (3) from the casing
Record the positions of the plugs in relation to the (1).
push rods. Record the positions of the damping springs in re-
Be careful not to scratch the surface of the push lation to the casing holes.
rods.
Be careful when removing, as the plugs may fly off.

11. Remove the spring seating (2) from the casings (1).

8. Remove the plugs (1) with the grease caps and • Record the positions of the spring seating in rela-
tion to the casing holes.
NHU packings left attached.
Record the positions of the plugs in relation to the
casing holes.
Be careful when removing parts, as the pistons (3)
may fly off due to the damping springs (2).

12. Use a magnet, etc. to remove steel balls (1).

Be careful not to lose the steel balls.

9. Remove the pistons (1).

Record the positions of the pistons in relation to the
casing holes.

84512399 EN - September 2011

8014-5
Copyright ©
Procedures for Assembly and Disassembly of Travel Remote
Control Valve
13. Use the hexagon wrench to remove the hexagon 16. Remove the return spring (1) from the casing (2).
socket head bolts (1).

17. Lay the covers (1) on their sides on a level surface,

14. Remove the damper casing (1) and remove the place special tool 1 against the bushings, and re-
O-rings (4) (3) from the casing. move the bushings by lightly striking them with a
hammer.
• Record the positions of the damper casing in re-
lation to the casing (2).
• Be careful when removing parts, as the pressure
reducing valve assembly may fly off due to the
return springs.

18. Secure each cam assembly (1) in a vise, use a

wrench to loosen the lock nuts (2), and remove the
lock nuts and locking screws (3).
• As neutral adjustment of locking screws is neces-
sary during assembly, handle them as part of the
15. Remove the pressure reducing valve assembly (1)
cam assembly as long as replacement of locking
from the casing (2).
screws is not necessary.
• Record the positions of these parts in relation to
the casing holes.

84512399 EN - September 2011

8014-6
Copyright ©
Procedures for Assembly and Disassembly of Travel Remote
Control Valve
19. For disassembly of the pressure reducing valve as- 22. Remove the NHU packings (2) from the plugs (1).
semblies, place the bottom end of the spools (1) Use a small flathead screwdriver, etc. to remove.
perpendicular on a level work platform, lower the
spring seating (2), and use the end of a small flat- • Be careful not to scratch the inner surface of the
plugs.
head screwdriver to remove the 2 half-circle wash-
ers 1 (3).
Be careful not to scratch the surface of the spool.
Do not press in the spring seating by 4 mm or more.

8014-9
Copyright ©
Procedures for Assembly and Disassembly of Travel Remote
Control Valve
10. Install the pistons (1).
• Install them in the positions they were in before
disassembly.

13. Install grease cups (2) into the plugs (1).

11. Install O-rings (2) on the plugs (1).

Symptom Cause Solution

1. Insufficient primary pressure 1. Maintain primary pressure.
2. Secondary pressure spring (324) is worn. 2. Replace it with new part.
Secondary pressure is
3. The gap between spool and the casing is 3. Replace spool and casing assembly.
not rising.
abnormally large. 4. Disassemble and assemble or re-
4. There is backlash in the operation section. place operation section parts.
1. Repair the sticking sections.
1. Sliding parts are sticking.
Secondary pressure is 2. Return directly to the oil tank.
2. Tank line pressure is variable.
unstable. 3. Perform operation several times and
3. Air is getting into lines.
let out air.
Secondary pressure is 1. Tank line pressure is high. 1. Return directly to the oil tank.
high. 2. Sliding parts are sticking. 2. Repair the sticking sections.
1. Perform operation several times and
1. Air is gathering in the piston chamber.
let out air.
2. Sliding parts are sticking.
2. Repair the sticking sections.
3. Damping springs (336) (337) are worn.
3. Replace it with new part.
4. The gap between piston (224) and the cas-
Damping is not working. 4. Replace piston and casing assem-
ing is abnormally large.
bly.
5. There are check valve operation problems.
5. Disassemble and adjust the check
6. The piston metering hole is abnormally
valve section.
large.
6. Replace piston.
1. Sliding parts are sticking. 1. Repair the sticking sections.
Damping torque is high.
2. Piston metering hole is clogged. 2. Repair or replace piston.

84512399 EN - September 2011

Hydraulic symbols Cross section B-B

Attached diagram 1. Remote control valve assembly cross-section diagram

84512399 EN - September 2011

8014-15
Copyright ©
Procedures for Assembly and Disassembly of Travel Remote
Control Valve
ANNOTATION:
Since hydraulic equipment is crucial to safety, we cannot guarantee performance and functions if disassembly and
reassembly are performed.

Code Part name Q'ty Code Part name Q'ty

101 Casing 1 271 Hexagon socket head bolt 2
102 Casing (damper) 1 301 Spool 4
201 Cover 2 311 Spring seating 4
202 Plug 4 313 Washer 3 4
203 Grease cup 4 324 Spring 4
210 NHU packing 4 335 Spring 4
211 O-ring 2 336 Spring 4
212 O-ring 4 337 Spring 4
213 O-ring 4 412 Bushing 4
214 Push rod 4 413 Camshaft 2
245 Washer 1 8 420 Cam 2
Hexagon socket head locking
217 Washer 2 4 423 2
screw
218 Spring seating 4 471 Locking screw 4
220 Hexagon socket head bolt 2 472 Lock nut 4
224 Piston 2D085 4 501 Bellows 2
225 Steel ball 2

Tightening torque list

Code Screw size Tightening torque
220 M6 7.8 - 9.8 N·m
271 M12 45.2 - 64.8 N·m
423 M6 5.9 - 7.9 N·m (Loctite coating)
472 M10 29.9 - 36.7 N·m

a Grease application to top

Filling of grease cup with
b
grease

Attached diagram 2. Jig dimension diagram

1 Bushing removal jig

c Center hole possible (D2 or

less)

84512399 EN - September 2011

Section

8016

Assembly and Disassembly of Cushion Valve

84512399 EN - September 2011

CONTENTS

Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Reverse Operation Spool Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Check Plunger Section with Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Shuttle Valve Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Reverse Operation Spool Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Check Plunger Section with Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Shuttle Valve Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Written Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1. Insert the check plungers (1). 1. Insert the steel balls (1).

CAUTION • Assemble the seat (2) with the O-ring (3) attached
and the plug (4) with the O-ring (5) attached.
The check plungers have similar shapes, • Tightening torque: 39.2 - 49.0 N・m
so be careful to insert each one in its cor-
rect position.

• Insert the springs (2) and assemble the plugs (4)

with the O-rings (3) attached.
• Tightening torque: 29.4 - 31.4 N・m

Diagram 8

Diagram 7

84512399 EN - September 2011

Written Materials
1. Check plunger table

Metering orifice diame-

Part No. Name Remarks
ter (D)
65301-11705 Check plunger 0.5
65301-11706 Check plunger 0.6
65301-11707 Check plunger 0.7
65301-11708 Check plunger 0.8
65301-11709 Check plunger 0.9
65301-11710 Check plunger 1.0
65301-11711 Check plunger 1.1
65301-11712 Check plunger 1.2
65301-11713 Check plunger 1.3
65301-11714 Check plunger 1.4
65301-11715 Check plunger 1.5

2. Cushion valve assembly diagram

External shape diagram

84512399 EN - September 2011

Cross section X - Cross section Y -

Cross section V -
Cross-section diagram

Code Part name Code Part name Code Part name

1 Body 9 Check plunger 17 Seat
2 Spool 10 Check plunger 18 O-ring
3 Spring 11 Check plunger 19 Plug
4 Plug 12 Check plunger 20 O-ring
5 O-ring 13 Spring 21 Name plate
6 Cap screw 14 Plug 22 Drive screw
7 O-ring 15 O-ring 23 Plug
8 Plug 16 Steel ball 24 Plug

84512399 EN - September 2011

Section

8017A

Removal and Installation of Arm HBCV

84512399 EN - September 2011

CONTENTS

Removal of Arm HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Arm HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CAUTION 2. Use a hexagon wrench (10 mm) to remove the 4

hexagon socket head bolts (1), and then remove the
• Stop the machine in the temporary decom- line (2) and O-ring (3).
missioning posture on a level location with
good footing. • Use caps or plugs to cover the HBCV and line to
prevent any entry of water, dust or dirt.
• Be sure to stop the engine before beginning
work. • Clean the HBCV and line by spraying them with
a parts cleaner to prevent scratches and prevent
• When working together with others, always dirt from accumulating on the connectors.
be sure to exchange signals and pay ade-
quate attention to safety.
• Be sure to release hydraulic pressure before
beginning work.

Items to prepare
• Wrench (19 mm, 22 mm)
• Hexagon wrench (10 mm)
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid

Removal of Arm HBCV

3. Use a hexagon wrench (10 mm) to remove the 4
1. Use a wrench (19 mm , 22 mm) to remove the line hexagon socket head bolts (1), and then remove the
(1) (2) and (3). arm HBCV (2) and O-ring (3).
• Mark the HBCV and hoses so that the connectors
match at the time of assembly.
• Use caps or plugs to cover the line and HBCV to
prevent any entry of water, dust or dirt.
• Clean the line and HBCV by spraying them with
a parts cleaner to prevent scratches and prevent
dirt from accumulating on the connectors.

84512399 EN - September 2011

Installation of Arm HBCV 2. Set the O-ring (3) on the line (2), and then install
with 4 hexagon socket head bolts (1).
1. Set the O-ring (3) on the arm HBCV (2), and then
install with 4 hexagon socket head bolts (1). • The O-ring cannot be reused.
Replace with a new part.
• The O-ring cannot be reused.
Replace with a new part. Tightening torque: 74.9 - 109.9 N・m

Tightening torque: 74.9 - 109.9 N・m

3. Install the line assemblies (1) (2) and (3).

• Install at the position where the HBCV and hoses
are marked so that the connectors match at the
time of assembly.

84512399 EN - September 2011

Section

8017B

Removal and Installation of Boom HBCV

84512399 EN - September 2011

CONTENTS

Removal of Boom HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

84512399 EN - September 2011

Jig Dimension Diagram

Axle removal jig

a Axle removal jig Hexagon socket head bolt (7)

*4
M10 x 25
M16 - M20 full threaded bolt Backing plate
*1 Axle (1) outer diameter - about
L = 370 - 420 mm *5
*2 M16 - M20 female thread 5 mm
t = about 5 mm
Cover (9) installation dimen-
*3
sions

Removal jig (for O-ring and

Disassembly Procedures 3. Use a hexagon wrench (6 mm) to remove the 4

hexagon socket head bolts (7), and then remove the
1. Use a hexagon wrench (8 mm) to remove the 4 thrust plate (6).
hexagon socket head bolts (10), and then remove
the cover (9).

4. Use the axle removal jig (a) to push out the axle (1)
from the rotor (3).
2. Remove the O-ring (8).
• Do not strike it with the hammer at this time.

84512399 EN - September 2011

5. Use the removal jig (b) or the like to remove the Assembly Procedures
V-ring (2) from the axle (1).
1. Place parts in a rough cleaning container filled with
kerosene to clean off any adhered matter that can
form sharp points and cause scratches.
• Immerse in kerosene until dust, grease, and other
adhered matter comes off and floats to the sur-
face.

6. Use the removal jig (b) or the like to remove the

O-ring (4) and packing rings (5) from the rotor (3).

2. Place parts in a finish cleaning container filled with

kerosene and clean while gently moving the parts.
After cleaning, wipe away the kerosene with a clean
rag.
• Place the parts in a location free of dust and mois-
ture and use compressed air to dry the parts. After
drying, coat parts with engine oil.
• Polish away burrs, barbs, and scratches with a
whetstone.

84512399 EN - September 2011

3. Use cleaning fluid or compressed air to clean the 5. After installing the O-ring and packing rings, use the
rotor (3). mirror to check for any parts that are sticking out or
After cleaning, check inside the rotor and in the are twisted. Also, check for installation mistakes.
groove sections for burrs, barbs and scratches and After checking, coat with grease. After coating with
for scratches caused by striking. grease, check again for any parts sticking out,etc.

4. Check the quantity of packing rings (5) and O-ring 6. Install the V-ring (2) on the axle (1) and coat suffi-
(4). Coat with grease and install in the sequence ciently with grease. Be careful that no water or dirt
below. gets into the grease.
• Set one packing ring (5) in each of the 7 grooves • Use a new V-ring (2).
from the 2nd groove on the axle insertion side to
the thrust plate side.
• Set the O-ring (4) in the front-most groove on the
axle insertion side.
• Use new packing rings (5) and a new O-ring (4).

7. Install the axle (1) on the rotor (3).

• Set in a way that the V-ring (2) will not be cut or
damaged.

84512399 EN - September 2011

8. Using a hexagon wrench (6 mm), coat the hexagon 10. Using a hexagon wrench (8 mm), coat the hexagon
socket head bolts (7) with Loctite, install the thrust socket head bolts (10) with Loctite #262, install the
plate (6) on the axle (1), and tighten to the specified cover (9) on the rotor (3), and tighten to the specified
tightening torque. tightening torque.
Installation bolt tightening torque: 31.4 - 37.3 N•m Installation bolt tightening torque: 62.7 - 72.5 N•m

9. Install the O-ring (8) on the rotor (3). This completes the assembly.
• Use new O-ring (8).

84512399 EN - September 2011

Section

8019

Assembly and Disassembly of Swing Motor

84512399 EN - September 2011

CONTENTS

Causes of Trouble and Solutions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Maintenance Standard Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Swing Motor Internal Structural Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Job code 35352AF10

CAUTION
1. Read and understand the contents of this
maintenance manual before performing
disassembly, reassembly, inspection, re-
pair, or other such work of this product.
2. Handle this product according to the sep-
arate "Usage Precautions".
3. When removing this product from the
equipment it is mounted on, stop that
equipment system and wait for the surface
temperature of this product to fall to about
40 °C or below before removing it.
Working on this product while it is still hot
can cause burns.
Additionally, always bleed out the pressure
before removing any line from this prod-
uct.
Removing a pressurized line can result in
oil spraying out and causing injury or oil
leak.
4. Use the specialty tools and measurement
instruments for disassembly, reassembly,
inspection, and repair, etc. of this product.
Using an inappropriate tool may result in
injury or product damage.
5. Be careful of parts falling when performing
disassembly, reassembly, inspection or re-
pair, etc. of this product.
This may result in injury or parts damage.
6. Do not directly touch with bare hands the
machined edges or threaded sections of
parts during disassembly, reassembly, in-
spection, or repair etc. of this product.
This may result in injury.
7. Check performance after reassembly.
Do not resume use unless performance is
fully recovered.
Using this product at a sub-par perfor-
mance level may result in product damage.
8. The cautions (mark !) listed in this main-
tenance manual do not cover all possible
dangers.
Always think of safety first during disas-
sembly, inspection, reassembly, repair, or
other such work.

84512399 EN - September 2011

Causes of Trouble and Solutions

This list consists of actions to be taken when an abnormality is sensed or there are problems with functions during
use of the hydraulic motor. Additionally, details concerning disassembly inspection and reassembly are listed after
this, but sufficient caution should be exercised in handling during these actions so as to prevent scratching of sliding
parts of the motor.
1. General cautions
This list consists of actions to be taken when an abnormality is sensed during use of the hydraulic motor.
General cautions are listed below.
1) Think before attempting to fix a problem.
Determine the nature of the abnormality before beginning work and think whether this same kind of problem
has occurred before.
Also, reconfirm whether the motor is the source of the problem.
2) Be careful about dust and dirt.
The cause of wear is very often dust and dirt. So be careful that dust and dirt do not get into parts during
disassembly.
3) Parts handling
Parts are manufactured with a high degree of precision, so be careful not to scratch them during handling.
4) Do not damage O-rings or gasket surfaces while performing work. Also, it is recommended that O-rings
are replaced for new ones during disassembly.
2. Investigating abnormalities in the motor main unit
It is very difficult to search for the source of troubles in the hydraulic circuits. Inspect the following items and
thoroughly investigate whether the motor is the source of troubles.
1) Inspecting oil within the casing
Remove the drain plug and inspect the hydraulic oil within the casing. If a large amount of metal particles
come out at the same time as oil, it is very likely that there is damage with parts within the motor.
2) Existence of abnormal noise
Check whether abnormal noise is coming from the motor main unit.
3) Measure pressure for each part.
Do not perform disassembly inspection carelessly. Measure pressure for each part and look for abnormal-
ities in each area.
4) Measure the amount of oil drained from the motor.
1) Operation is normal if about 6 L/min or less of oil drains from the motor when pressure oil is applied
after the swing is locked.
2) 2 L/min or less of drained oil at constant swing is normal.
3. Trouble conditions and countermeasures
1) Hydraulic motor does not rotate.

Symptom Cause Solution

1) Incorrect setting of the circuit safety 1) Reset safety valve correctly.
valve 2) Disassemble and inspect.
2) Operation problems with relief
valve 1) Repair or replace sticking
Pressure does not
section.
rise.
1) Plunger sticking 2) Disassemble and clean.
2) Clogged plunger orifice
3) Check seating sections and replace
3) Plunger seating problem scratched part.
1) Eliminate load.
1) Overload
2) Inspect and repair piston/shoe,
2) Seizing of driving part
cylinder/valve plate, etc.
3) No release pressure acting on the
3) Inspect and repair circuit.
Pressure rises. brake
4) Disassemble and inspect.
4) Piston sticking to the brake
5) Disassemble and inspect.
5) Spool for brake release sticking
6) Disassemble and inspect. Replace
6) Friction plate seizing
seizing part.

84512399 EN - September 2011

2) Rotation direction is reversed.

Symptom Cause Solution

1) Check the rotation direction and as-
Reversed rotation di- 1) Motor rotation direction reversed.
semble correctly.
rection 2) Input and output for line reversed.
2) Correct line configurations.

3) Motor speed is not reaching the set value.

Maintenance Standard Table

Replacement standards for worn parts
If wear on any part exceeds the standard values below, replace or readjust.
However, parts should be replaced regardless of these standards if they appear to be extremely damaged based on
appearance.

Inspection and Standard value

Measurement Repair, solution proce-
Part name measurement loca- (permissible
device dure
tion limit value)
Shoe sliding surface Surface rough- Repair with sandpaper
0.8 S
roughness ness gauge lapping.
Shoe sliding surface Micrometer
0.45 mm or higher Replace with a new part.
groove depth caliper
Piston assembly (10) Piston and shoe
spherical coupling 0.4 mm max. Dial gauge Replace with a new part.
section backlash
There is almost no wear. If there is any scratching or seizing,
Piston bore
replace it with new part.
Surface rough-
Cam plate (6) Surface roughness 0.8 S Lap
ness gauge
End surface rough- Surface rough-
0.4 S Lap
ness ness gauge
Cylinder (9)
There is almost no wear. If there are any scratching or seizing,
Piston hole
replace the motor.
Surface rough-
Balance plate (27) Surface roughness 0.8 S Lap
ness gauge
Micrometer
Gaps between pis-
Piston assembly (10) caliper
ton bore and cylinder 0.04 mm max. Replace motor.
Cylinder (9) Air micrometer
hole
caliper

Part name Inspection and maintenance standards

Even with normal use, bearings need to be replaced with new parts
Tapered roller bearing (4) every 3000 hr. of use.
Needle bearing (28) Also, make sure to replace them with new parts even within the 3000
hr. limit during reassembly after disassembly.
If there is scratching on lip, replace it with new part.
Also, even with normal use without any leaks, replace them with new
Oil seal (3) parts every 3000 hr. of use.
Also, make sure to replace the O-rings with new ones even within the
3000 hr. limit during reassembly after disassembly.
If there is any scratching on O-ring, replace it with new part.
Also, even with normal use without any leaking, replace the O-rings
O-ring (14)(15)(21)(30)(34)(38)(40)(44) with new ones every 3000 hr. of use.
Also, make sure to replace the O-rings with new ones even within the
3000 hr. limit during reassembly after disassembly.
When reassembling after disassembly, always replace them with new
Backup rings (37)(41)
parts.

84512399 EN - September 2011

Disassembly 2. Use a hexagon wrench (17 mm) to loosen the

hexagon socket head bolts (22) and (32), place the
• Wrap the wire rope around the outer circumference of motor with the output shaft facing down, and then
the motor, lift the motor with a liftcrane, and clean with lift up and remove the cover (24).
white kerosene.
After cleaning, dry the motor using compressed air.
• To prevent foreign matter from entering the motor,
mask each port with tape, etc.
Also clean off adhered dirt and dust.
1. Use the wrenches (27 mm, 46 mm) to remove the
relief assemblies (31), level gauge (43), and cap
(45), and use the hexagon wrenches (10 mm, 14
mm) to remove the cap (33), spring (36), check (39),
and bypass valve assembly (42).
• When reassembling the disassembled relief as-
semblies (31), cap (35), spring (36), check (39),
and bypass valve assembly (42), make sure to
install them in their original locations.

3. Remove the retaining ring (29) with the mark-off pin,

and remove the needle bearing (28) inner race and
balance plate (27).
Next, take out the pistons (23) from the balance
plate (27).
• Be careful not to scratch the sliding surface of the
balance plate (27) or apply a great deal of force
and cause deformation.
• The attachment direction of the balance plate (27)
in relation to the cover (24) is set, so place a mark
to confirm the attachment direction with the cover
(24) during reassembly.

84512399 EN - September 2011

5. Remove the bushings (19) with the teflon rings (17)

attached and the disc springs (18) from the cover
(24).

4. Remove the O-ring (15) from the cover (24).

6. Take out the brake springs (16) from the brake pis-
ton (13).

84512399 EN - September 2011

7. First, use the tap holes (M6) provided on the piston 8. Remove the friction plates (11) and partner plates
and use a monkey wrench (*2) to remove the piston (12).
(13) from the housing (5). This is done because the
tightening margin of the O-rings (14) and (15) cre-
ates sliding surface resistance and makes removal
difficult.
Next, remove the O-ring (14) from the housing (5)
and the O-ring (15) from the piston (13).
• Place the metal blocks (*3) outside the housing
inner diameter (*4).

9. Grasp the end of the cylinder (9) by hand and re-

move the cylinder assembly from the housing (5).
• Oil on the cylinder (9) makes it easy for it to slide,
so be careful not to let it fall.
• The tapered roller bearing (4) outer race and oil
seal (3) should be left within the housing (5).
• The "A" end surface of the cylinder (9) is the slid-
ing surface, so cover this surface with a soft rag,
etc. to prevent scratching.
• Place reference marks or numbers on the cylinder
(9) piston holes and piston assemblies (10) so that
during reassembly, piston assemblies are placed
in the same holes they were in at disassembly.

84512399 EN - September 2011

Clean and degrease the housing (5) oil seal instal- Install the tapered roller bearing (4) outer race on
lation section. the housing (5).
Next, degrease the oil seal (3) outer circumference,
apply liquid packing (ThreeBond #1211 white or the • Be careful to install the tapered roller bearing
outer race in the correct direction.
equivalent), and use press-fit jig 2 (*6) to install it on
the housing (5).
• Be careful to install the oil seal in the correct di-
rection.

a Cylinder assembly installation

side
b Cylinder output shaft side

a Bearing side
b Output shaft side

84512399 EN - September 2011

10. Mount the O-rings (14) (15) on housing (5).

8. Align the cylinder (9) with the drive shaft spline and • If grease is applied to the O-ring, it will not break
insert into the housing. easily when inserting the brake piston.

9. Installation of friction plate and partner plate

Install the friction plates (11) and partner plates (12).
• Apply hydraulic oil to both sides of each of these
plates.

84512399 EN - September 2011

11. Install the brake piston (13) into the housing.

• The piston (13) is stiff during assembly.
Therefore, make the entire piston level and use
the jig 3.

a V groove
b Circle groove
c Ports A and B side
d Relief side
12. Install the brake springs (16) into the brake piston
(13). • Sufficiently apply grease to the pistons (23) and
the cover (24) parallel pin (26) (for stopping bal-
ance plate rotation), and attach to the cover side
of the balance plate.

13. Installation of balance plate

Install the bushings (19) with the disc springs (18)
and teflon rings (17) attached into the bushing holes
on the cover (24).
Install the balance plate (27) with the pistons (23)
installed in the cover (24).
• Be careful to install in the correct direction accord-
ing to the marks made on the balance plate (27)
and cover (24) before disassembly.

1 Tapered roller bearing

2 Oil seal
3 Brake piston

84512399 EN - September 2011

Swing Motor Internal Structural

Diagram

84512399 EN - September 2011

Code Part name Q'ty Code Part name Q'ty

1 Retaining ring 1 24 Cover 1
2 Inner race 1 25 Parallel pin 2
3 Oil seal 1 26 Parallel pin 1
4 Tapered roller bearing 1 27 Balance plate 1
5 Housing 1 28 Needle bearing 1
6 Cam plate 1 29 Retaining ring 1
7 Return plate 1 30 O-ring 2
8 Receiving spring 1 31 Relief assembly 2
9 Cylinder 1 Hexagon socket head
32 7
10 Piston assembly 9 bolt
11 Friction plate 4 33 Cap 2
12 Partner plate 4 34 O-ring 5
13 Piston 1 35 Cap 2
14 O-ring 1 36 Spring 2
15 O-ring 2 37 Backup ring 2
16 Spring 19 38 O-ring 2
17 Teflon ring 4 39 Check valve 2
18 Conical spring 4 40 O-ring 2
19 Bushing 4 41 Backup ring 2
20 Cap 2 42 Bypass valve assembly 2
21 O-ring 2 43 Level gauge assembly 1
Hexagon socket head 44 O-ring 1
22 1
bolt 45 Cap 1
23 Piston 2

84512399 EN - September 2011

Section

8020A

Explanation of Hydraulic Circuit and Operations (standard

model)

84512399 EN - July 2011

CONTENTS Boom-down Tilting Prevention Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

When the key is switched ON, the swing brake solenoid valve is switched by the electrical signal from computer A.
The swing motor P port oil goes from the 5 stack solenoid valve C2 port through the swing brake solenoid, and returns to the
hydraulic oil tank to hold the swing parking brake.

84512399 EN - July 2011

Explanation of Hydraulic Circuit and Operations (standard model)

Swing Parking Circuit (brake release)

84512399 EN - July 2011

Explanation of Hydraulic Circuit and Operations (standard model)

Pressure line Pilot tank line
Tank line Electric line
Pilot pressure line

1 Swing motor 7 Swing 13 Control valve

2 Cushion valve 8 Lever lock 14 Upper pilot pressure sensor
3 Right swing 9 Swing brake 15 Hydraulic pump
4 Left swing 10 5 stack solenoid valve 16 Oil cooler
5 Swing pilot pressure sensor 11 Console lever lock switch
6 Remote control valve (arm, swing) 12 Computer A

When the engine is started and the swing lever is in neutral, the swing brake solenoid valve comes ON (24 V input), the
pressure to the swing motor P port is cut, and the swing parking brake works.
When the lever operation raises the reading to 0.5 MPa or higher at the pressure sensor in the swing pilot line, the output
from computer A to the swing brake solenoid valve goes OFF, the swing motor P port pressure rises, the swing parking brake
is released, and swing becomes possible.
As an example, this section explains the right swing operation.
By carrying out the right swing operation on the remote control valve, the pilot pressure oil is fed to the control valve pa2 port
via the shuttle valve and switches the swing spool to the right swing side.
At the same time, computer A detects the swing pilot pressure sensor signal, judges that there is a swing operation, the
electrical signal output from computer A goes OFF, and the swing brake solenoid valve is switched.
The pilot pressure oil is fed to the swing motor P port from the swing brake solenoid valve C2 port to release the swing parking
brake.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the parallel oil path to the swing
spool.
Switching the spool lets the oil flow into the swing motor B port and the right swing operation is carried out.
The pressurized oil from the swing motor A port goes through the swing spool and returns to the hydraulic oil tank.
When this is followed by an attachment operation, the pilot pressure is detected by the control valve PA port pressure sensor
and the swing parking brake continues to be released.
After the swing operation ends, if about 5 sec.pass with no upper operation, the swing brake solenoid valve output from
computer A comes ON and the swing parking brake works again.
After the swing ends, if this is followed by an upper operation or there is an upper operation within about 5 sec., when about
1 sec. passes after the end of the upper operation, the swing parking brake works again.
The swing parking brake is also released for independent upper operations and when about 1 sec. passes after the end of
the upper operation, the swing parking brake works again.

Swing pilot pressure Upper pilot pressure Swing brake solenoid Swing motor mechan-
Key switch
sensor sensor valve ical brake
OFF 0 MPa 0 MPa OFF ON
ON 0 MPa 0 MPa ON ON
ON 0.5 MPa以上 0 MPa OFF OFF
ON 0 MPa 0.5 MPa min. OFF OFF
ON 0.5 MPa min. 0.5 MPa min. OFF OFF

Pilot pressure sensor judgment standard

Operation is judged when at 0.5 MPa or above.
Non-operation is judged when at 0.3 MPa or below.

84512399 EN - July 2011

Explanation of Hydraulic Circuit and Operations (standard model)

Swing Parking Circuit (machine stop)

84512399 EN - July 2011

Explanation of Hydraulic Circuit and Operations (standard model)

Pressure line Pilot tank line
Tank line Electric line
Pilot pressure line

Pressure line Pilot tank line
Tank line Electric line
Pilot pressure line

When an attachment is operated, this circuit boosts the control valve main relief set pressure from 31.4 MPa to 34.3 MPa
according to the engine load ratio and hydraulic load pressure, then ends the pressure boost after 8 sec.
As an example, this section explains bucket-close operations.
By moving the remote control valve to the bucket-close side, the pilot pressure oil is fed via the cushion valve to the control
valve pb8 port and switches the bucket spool to the close side.
At the same time, the pressurized oil separated from the pilot internal oil path is detected and the upper pilot pressure sensor
output signal is input to computer A, which judges that there is upper operation.
Furthermore, computer A judges that there is a boost in the main pump P1 and P2 pressure, outputs the ON (24 V) signal to
the boost relief solenoid, switches the valve, and the pilot pressure oil is fed to the control valve main relief valve PH port to
hold the boost relief set pressure for 8 sec.

84512399 EN - July 2011

Explanation of Hydraulic Circuit and Operations (standard model)

84512399 EN - July 2011

Section

8020B

Explanation of Hydraulic Circuit and Operations (option)

84512399 EN - July 2011

CONTENTS Double-acting Circuit (hydraulic fork) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Multi-purpose Circuit (breaker circuit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Multi-purpose Circuit (2 pumps flow crusher) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Option Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2nd Option Circuit (hydraulic rotation fork) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Breaker Circuit (independent operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 Lever lock 7 Monitor display 12 Hydraulic pump
3 5 stack solenoid valve 8 Computer A 13 Control valve blade
4 Console lever lock switch 9 Hydraulic rotation fork
5 2nd option remote control valve 10 Radiator

As an example, this section explains the case in which the hydraulic rotation fork attachment is used.
By operating the 2nd option remote control valve to the right swing side, the pilot pressure oil is fed to the 2nd option control
valve pb1 port.
The 4th hydraulic pump A4 discharge oil is fed to the 2nd option control valve P port, goes through the 2nd option spool and
flows to the hydraulic rotation fork to operate to the right swing side.
At this time, the 2nd option pilot pressure switch signal is detected and the auto idle function is released.
The return oil from the hydraulic rotation fork goes through the 2nd option spool and returns to the hydraulic oil tank.
The oil in the 2nd option drain line returns to the hydraulic oil tank without going through the control valve.

84512399 EN - July 2011

Explanation of Hydraulic Circuit and Operations (option)

This page is intentionally left blank

84512399 EN - July 2011

Section

8030A

Structure and Operation Explanation of Hydraulic Pump

84512399 EN - September 2011

CONTENTS

Structure and operation explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Hydraulic Pump Internal Structure Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overall view. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Drive shaft front side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Drive shaft rear side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Part table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Gear pump internal structure diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Structure and Operation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Structure and operation explanation

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

84512399 EN - September 2011

Hydraulic Pump Internal Structure

Diagram
Overall view

Drive shaft front side Drive shaft rear side

Drive shaft front side

84512399 EN - September 2011

Drive shaft rear side

84512399 EN - September 2011

Part table
Adhesion agent (ThreeBond Tightening torque
a Co., Ltd. No. 1305N) applica- c Right rotation valve plate e Flange socket (4-M10 × 1.5):
tion 33 N•m
Oil seal outer circumference Tightening torque
b Lubricant (Sealub L101) coat- d Left rotation valve plate f Hexagon bolt (3-M6 × 1.0): 12
ing N•m

Component part no. (q'ty) or

Code Part name Q'ty
type
ZX15LHRZ2-07A-
04 Gear pump 1set
VZX15LHRZ2-07A-V
011 Piston subassembly 2set 151 (9PC), 152 (9PC)
013 Cylinder subassembly (R) 1set 141 (1PC), 313 (1PC)
014 Cylinder subassembly (L) 1set 141 (1PC), 314 (1PC)
030 Swash plate subassembly 2set 212 (1PC), 214 (1PC)
541 (1PC), 543 (1PC), 545
041 Check valve 1 subassembly 2set
(1PC)
541 (1PC), 544 (1PC), 545
042 Check valve 2 subassembly 2set
(1PC)
Electromagnetic proportional
079 pressure reducing valve, cas- 1set KDRDE5KR-V3-V
ing subassembly
530 Tilting pin subassembly 2set 531 (1PC), 548 (1PC)

Code Part name Q'ty Code Part name Q'ty

111 Drive shaft (F) 1 492 Insert plug 12
113 Drive shaft (R) 1 531 Tilting pin 2
114 1st gear 1 532 Servo piston 2
123 Cylinder roller bearing 2 534 Stopper (L) 2
124 Needle roller bearing 2 535 Stopper (S) 2
127 Bearing spacer 4 541 Seat 4
141 Cylinder block 2 543 Stopper 1 2
151 Piston 18 544 Stopper 2 2
152 Shoe 18 545 Steel ball 4
153 Holder plate 2 548 Feedback pin 2
156 Spherical bushing 2 702 O-ring 2
157 Cylinder spring 18 710 O-ring 1
211 Shoe plate 2 714 O-ring 1
212 Swash plate 2 717 O-ring 2
214 Tilting bushing 2 724 O-ring 16
251 Swash plate support board 2 725 O-ring 6
261 Seal cover (F) 1 728 O-ring 4
271 Pump casing 2 732 O-ring 2
312 Valve block 1 774 Oil seal 1
313 Valve plate (R) 1 789 Backup ring 2
314 Valve plate (L) 1 792 Backup ring 2
326 Cover 1 808 Hexagon nut 2
401 Hexagon socket head bolt 8 824 Stop ring 2
406 Hexagon socket head bolt 4 885 Valve plate pin 2
414 Hexagon socket head bolt 4 886 Spring pin 4
466 VP plug 2 901 Eyebolt 2
Hexagon socket head stop
467 VP plug 2 953 2
screw
468 VP plug 4 954 Stop screw 2
490 Insert plug 27 981 Nameplate 1
492 Insert plug 12 983 Driving tack 2

84512399 EN - September 2011

Gear Pump
Gear pump internal structure diagram

Hydraulic circuit

a Front case side c To main pump

b Gear case side

*1 (2PLACES)

Component part No. (q'ty) or

Code Part name Q'ty
type
307 (1PC), 308 (1PC), 351
350 Gear case subassembly 1set (1PC), 353 (1PC), 354 (1PC),
361 (1PC), 887 (2PC)
84512399 EN - September 2011
8030A-7
Copyright ©
Structure and Operation Explanation of Hydraulic Pump

Code Part name Q'ty Code Part name Q'ty

307 Poppet 1 433 Flange socket 2
308 Seat 1 434 Flange socket 2
309 Ring 1 435 Flange socket 4
310 Spring 1 466 VP plug 1
311 Adjusting screw 1 700 Angle ring 1
312 Lock nut 1 710 O-ring 1
351 Gear case 1 725 O-ring 1
353 Drive gear 1 732 O-ring 1
354 Driven gear 1 850 Locking ring 1
355 Filter 1 887 Pin 2
361 Front case 1

Structure and Operation Explanation

Structure
The casing comprises the front case (361) and gear case (351). Inside the casing the drive gear (353), driven gear
(354) pair and the relief valve for setting the discharge pressure are installed.
The relief valve comprises the filter (355), poppet (307), seat (308), spring (310), ring (309), adjusting screw (311),
and lock nut (312).
In order to prevent oil leaking to the outside, an angle ring (700) and O-ring (710) are mounted on the front case (361).
Operation
Oil suctioned in from suction port B3 is discharged from discharge port A3 by the drive and driven gears.
The discharge oil is held at the set pressure of 3.9 MPa by the relief valve.
Unnecessary discharge oil is drained from the drain port via the relief valve.

84512399 EN - September 2011

Section

8030B

Structure and Operation Explanation of Travel Motor

84512399 EN - September 2011

CONTENTS

Travel motor operation explanation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Summary explanation of component parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Rotary group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Variable Capacity Mechanism Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overload Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Brake Valve Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Motor operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Parking Brake Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Operation of Variable Capacity Mechanism Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Overload Relief Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Brake Valve Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Travel motor operation explanation

Structure

Diagram 1 Travel motor structural diagram

Code Part name Code Part name Code Part name

1 Casing 21 D-ring (small diameter) 41 G1/8 plug
2 NPT 1/16 plug 22 D-ring (large diameter) 42 O-ring 1B P8
3 Oil seal 23 Rear cover 43 Check valve
Circle R retaining ring
4 24 NPT 1/16 plug (mec) 44 Check valve spring
IRTW68
5 Tilting piston 25 Spool assembly 45 M6 orifice (D0.6)
6 Tilting piston seal 26 Spring receiver 46 O-ring 1B P12.5
7 Steel ball 27 Spring 47 M6 orifice (D0.8)
8 Shaft 28 M42 plug 48 O-ring 1B P15
9 Bearing HR32209J 29 O-ring 1B G40 49 O-ring 215.57 x 2.62
84512399 EN - September 2011
8030B-3
Copyright ©
Structure and Operation Explanation of Travel Motor

Code Part name Code Part name Code Part name

10 Pivot 30 Pilot spool 50 Bearing HR32207C
11 Shoe plate 31 Pin 51 Shim
12 Cylinder block 32 Spring receiver 52 Parallel pin
13 Cylinder spring 33 Spring 53 Valve plate
14 Spring receiver 34 Pilot valve plug G3/8 54 Brake spring
Hexagon socket head bolt
15 Spherical joint 35 O-ring 1B P14 55
M18 x 50
16 Shoe retainer 36 Joint 56 Overload valve
17 Piston assembly 37 G1/4 plug 57 Coupling
18 Separator plate 38 O-ring 1B P11 58 C retainer ring 40 for hole
19 Friction plate 39 Orifice 59 G1/2 plug
20 Brake piston 40 Orifice spring (brake valve) 60 O-ring 1B P18

Summary explanation of component parts

The motor is made up of the following main components.
• Rotary group producing rotational force
• Parking brake that prevents self-travel when the machine is parked
• Variable mechanism section that switches the motor capacity between high and low
• Overload relief valve installed to the rear cover
• Brake valve section (counter balance valve) that plays a critical role in controlling the hydraulic circuits

Rotary group
The cylinder block (12) is fit into the teeth grooves on the spline of the shaft (8), which is supported at both ends by
the bearings (9), (50). This cylinder block (12) is pressed against the rear cover (23) together with the valve plate (53)
by the cylinder spring (13).
The nine piston assemblies (17) slide along the surface of the shoe plate (11) while moving in and out of the cylinder
block (12). There are static pressure bearings at the end surface of the piston assembly (17) shoe to reduce the sliding
resistance. The spring force of the cylinder spring (13) is transmitted through the spring receiver (14), spherical joint
(15), and shoe retainer (16) to press the end surface of the piston assembly (17) against the shoe plate (11) so that
the piston moves without separating from the surface of the shoe plate (11).
Parking Brake
A separator plate (18) and friction plate (19) are fit into the spline groove around the outer edge of the cylinder block
(12) in an alternating pattern and are pressed against the casing (1) by the 14 brake springs (54) via the brake piston
(20).
Variable Capacity Mechanism Section
This section comprises the pivot (10), which is fit into the 2 semispherical indentations on the shoe plate (11) and
support the shoe plate (11), the tilting piston (5), which revolves the shoe plate (11) around the pivot (10), the tilting
stopper (1-1), which supports this revolution at the determined position, the pilot valve section, which brings the pres-
sure oil to the tilting piston (5) according to the external command, and the 3 check valves (43), which take out and
send to the pilot valve section the highest of the 3 pressures among the external command pilot pressure, the motor
inlet pressure, and the motor outlet pressure.

84512399 EN - September 2011

Overload Relief Valve

This comprises the socket (56-1), which holds the valve seat (56-3) that seats metal to the motor rear cover (23)
internal hole section and which screws it into the rear cover (23) to secure it, the valve (56-2), which is contacted
to the valve seat (56-3) by the adjusting spring (56-9) and which is fit into the socket (56-1) internal hole, the linking
piston (56-4), which is inserted into the valve internal hole and serves as the oil path to the pilot section body (56-6),
the piston (56-7), which is inserted into the pilot section body (56-6) and is pressed against the lid (56-5), and the
spring adjusting shims (56-8).

Diagram 2 Overload relief valve structural diagram

Diagram 5
As in Diagram 5 (a), this high-pressure oil operates on each piston during 180°, with the Y-Y line connecting the piston
top dead center and bottom dead center as the boundary, and generates force of .

Diagram 12 When the counter balance is operating

84512399 EN - September 2011

1 Spring
2 Pilot chamber
3 Check valve with orifice

84512399 EN - September 2011

Section

8030C

Structure and Operation Explanation of Swing Motor

84512399 EN - September 2011

CONTENTS

Swing Motor Operation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Hydraulic motor operation explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Mechanical brake operation explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Make-up valve operation explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Relief valve operation explanation (relief valve internal structure diagram) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Bypass valve operation explanation (bypass valve internal structure diagram) . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Swing motor internal diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Swing Motor Operation

Explanation
Hydraulic motor operation explanation
The pressurized oil fed by the pump through the control valve or the like enters from the A port (or B port) on the cover
(29) and is discharged from the B port (or A port).
Also, the oil that has leaked from the sliding sections and the gap returns to the hydraulic tank from the drain port "a"
on the cover (29).
The pressurized oil fed to the A port is fed to the cylinder (27) piston hole "f" through path "b" in the cover (29), path "c"
the bushing (15) section in the cover (29), balance plate (24) path "d" that has a crescent shaped port that switches
between feed and discharge every 180・of one rotation of the motor, and the cylinder (27) path "e".
The pressurized oil operates on the piston assemblies (8) and the piston assemblies (8) are pressed against the cam
plate (5) via the shoe section.
The cam plate (5) shoe sliding surface has a constant angle slope, so the piston assembly (8) pressing force created
by the action of the pressurized oil is converted into force making the shoe slide on the swash plate.
The piston assembly (8) shoe spherical section is coupled as a free joint, so the force of the shoe sliding on the swash
plate is transmitted to the motor output shaft section as rotation force via the piston assemblies (8) and the cylinder
assembly (27).
In this way, each piston assembly (8) receives pressurized oil in the stroke from the slope surface top dead center to
bottom dead center, converts this hydraulic pressure force to rotation force, rotates the cylinder assembly (27), and
discharges oil in the stroke from the bottom dead center to the top dead center.
The discharge path is the reverse of the above pressurized oil feed path and the oil is discharged from the B port.
In this way, the hydraulic motor operates. The hydraulic motor output torque is determined by the hydraulic pressure
force and speed is determined by the feed oil volume.

84512399 EN - September 2011

Mechanical brake operation explanation

The friction plate (9) is spline coupled with the exterior circumference section of the cylinder assembly (27).
Also, the partner plate (10) is coupled with the housing (28).
When the mechanical brake release chamber pressure is zero, the brake piston (11) presses the friction plate (9) and
partner plate (10) with the force of the spring (14) to lock rotation of the cylinder assembly (27) (output shaft).
On the other hand, when the oil pressurized to 2.9 - 4.9 MPa operates on the brake release chamber, the brake piston
(11) wins out over the spring force, the piston stroke proceeds until the cover (29) end, a gap is generated between
the friction plate (9) and partner plate (10), and the mechanical brake is released.
Make-up valve operation explanation
1. Half brake state (state in which the relief valve (31) is not operating)
After the swing body is accelerated, when it is decelerated by the control valve with the half lever, the oil feed
volume from the pump to the A port drops, but if the swing body was rotating at relatively high speed, the pressure
comes close to negative at the "c" section due to the motor pump operation, so oil supply becomes necessary.
However, if the B port pressure is lower than the operating pressure of the relief valve (31), all the oil flowing into
the "c" section from the A port is drained to the control valve via the B port, so with just the quantity of oil from
the control valve, the quantity of oil is insufficient for what is absolutely required at the "c" section. (Because the
valve is at the half lever position, the quantity of oil from the pump is restricted.)
In order to prevent this, the make-up check valve (39) is set up to make up the quantity of the oil shortfall to the
"c" section from the make-up port.
2. When the brake operates (state in which the relief valve (31) is operating)
In the state in 1., if the lever is sharply operated to neutral, the quantity of oil fed from the pump to the A port
becomes zero, but the swing body rotates due to inertial force.
In this case, the B port side relief valve (31) operates, the oil blown out in relief passes through oil paths "g" and
"h", pushes open the A port side make-up check valve (39), and is fed to oil paths "b" and "c", but the quantity of
this oil falls short by the quantity of oil that leaked to the motor case drain. In order to prevent this, the make-up
check valve (39) is opened from the make-up port to replenish paths "b" and "c" and prevent cavitation.

84512399 EN - September 2011

Relief valve operation explanation (relief valve internal structure diagram)

1. Starting
For the pressurized oil fed to the A port by the operation of the control valve, constant rotation is not reached be-
cause the swing body inertial force is large and part of the oil passes through the relief valve (31) which operates
as a safety valve, passes through oil paths "g" and "h", pushes open the B port side check valve (39), and flows
out to the B port.
The A port oil resists the force of the spring (48), pushes open the poppet (47), passes through the path "g" from
between the seat (46) and the poppet (47), and flows out to the path "h".
2. Braking (cushion)
When the control valve is returned to neutral, the motor discharge oil return path is closed.
Immediately after this operation, the motor rotates with a large inertial force and pump operation is caused, which
tries to suction in the oil from the A port and discharge it from the B port, but because the control valve return
path is closed, the B port pressure rises.
The B port pressure that rises pushes open the poppet (47) resisting the force of the spring (48), so it pushes up
the make-up check valve (39) via the oil paths "g" and "h", the oil flows into the path "c", and through this process,
the swing body inertial force is absorbed and the swing body comes to a stop.
Also, in the above pressure rise process, the high-pressure oil flowing into the poppet (47) front chamber, in that
pressure rise process, flows through the poppet (47) outer circumference orifice "j", through the piston (52) center
section small hole path, enters the piston chamber, and moves the piston (52) to the position where it contacts
the end of the sleeve (51).
During this time, because the poppet (47) is already pushed open, the cushion relief action operates at first with
somewhat low pressure and after a slight time, rises to the regulation pressure.
This 2-stage operation reduces the shock of motor starting and stopping.

External adjustment shockless relief internal structure diagram

84512399 EN - September 2011

2) Signal, straight travel signal control valve, plate assembly [Fig. 3]

There are 2 signals, (a) and (b) below. The pilot signal for each spool for which a lever is operated is used
to generate the pressure that is output.
The straight travel signal control valve integrates each signal pressure and controls straight travel spool
switchover. Also, the plate assembly has a function for picking up the pilot pressures with the built-in shuttle.
1) Travel signal (PT)
The highest of the pilot pressures applied to the travel section 1 (pa1, pb1) and travel section 6 (pa6,
pb6) is selected and output to the PT port.
Therefore, when the travel spool is in the neutral position (no-load pilot pressure), no pressure is
generated at the PT port.
2) Front signal (PA)
The highest of the pilot pressures (pa2 - 9 and pb2 - 9) applied to sections 2 - 9 that use the pressurized
oil from the P1 and P2 pumps, except for the travel sections, is selected and output to the PA port.
(Note 1)
Therefore, when all the spools are in the neutral position (no-load pilot pressure), no pressure is gen-
erated at the PA port.
<Note 1>
When an add-on (main pump add-on) is used through the feed from P2, the branches for the add-on pilot
signals par1 and pbr1 are connected to the respective main unit valves, prs1 and prs2 ports, and thus
incorporated in the front signal PA selection area.
Be careful. If the above line connection is not done, the PA pressure will not rise through add-on selection.
Also, when using 2 main pump add-ons, set the circuit so that the maximum of the add-on pilot pressures
(par1 and 2, pbr1 and 2) can be taken out as desired and connect to either prs1 or prs2.

84512399 EN - September 2011

Straight travel signal control

Bucket close (regeneration)

1 Neutral state 3 Swing

2 Switching state 4 Bucket

a (Section 3)
b (Section 7)

84512399 EN - September 2011

2) Open [Fig. 8]
When the bucket spool is switched by pressurizing from the bucket (section 7) pilot port Pa7, the
neutral path (R1) is closed. The oil fed from the P2 port flows through the parallel path (R3),
the load check valve (S7-2), path (S7-1), and the spool neck section, and into the A7 port.
The return oil returns to the tank path (Ta) from the B7 port through the spool neck section.

For an arm-in operation, after the return oil from the A5 port passes through the notch (a), it divides
into 2 paths:
1. The return oil returns to the tank path (Ta) through the fixed orifice (d) in the regeneration control
valve, path (e), and the variable orifice (f).
2. The return oil passes through the fixed orifice (b) in the arm 1 spool, the regeneration check (c),
and the fixed orifice (i), then merges into the bridge path (S5-1).
Here, when the bridge path (S5-1) pressure goes higher due to the port B5 load pressure, the regen-
eration control valve spool (h) is pressed through the regeneration control valve piston (g), and the
variable orifice (f) section opening surface area increases, so the quantity of oil returning to the tank
path (Ta) increases.
On the other hand, the quantity of oil regenerated in the B5 port decreases.
Though this variable mechanism, both the regeneration ratio for low loads is secured and reduction
in the return back pressure for high loads is established.

Arm in (variable regeneration)

Regeneration control valve

1
(variable)
2 Arm 1

a (Section 5)

84512399 EN - September 2011

4) Arm out (2 pumps flow) [Fig. 15]

When the arm 1 spool is switched by pressurizing from the arm 1 (section 5) pilot port Pa5, the oil fed
from the P1 port flows from the neutral path (L1) through the load check valve (S5-2), path (S5-1),
and the spool neck section and into the A5 port.
When the arm 2 spool is switched by pressurizing from the arm 2 (section 9) pilot port Pa9, the oil fed
from the P2 port flows from the neutral path (R1) through the load check valve (S9-2) and path (S9-1),
merges into the arm 1 section path (S5-1) and heads toward the A5 port through the arm 1 spool neck
section. The return oil from the B5 port returns to the tank path (Ta) through the spool neck section.

Arm out (2 pumps flow)

1 Arm 1
2 Arm 2

a (Section 5)
b (Section 9)

84512399 EN - September 2011

7) Arm parallel orifice [Fig. 16]

Metering by the spool is installed in the arm 1 parallel path of this valve to control the quantity of oil fed to
arm 1 for compound operations.
The oil fed from the arm 1 (Section 5) parallel path (L3) pushes open the poppet (S5-3) and passes through
the variable metering spool orifice (Lc8), then is connected to path (L5).
Here, the quantity metered by the orifice (Lc8) is adjusted by pressurizing the pilot port (Pbu).

For boom up (for Pbu pressur-

1 Low-pressure relief valve (L) 3
ization)
2 Pbu signal path 4 For neutral

84512399 EN - September 2011

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

84512399 EN - September 2011

2) Overload relief valve [Fig. 18]

There is an overload relief valve at the boom 1, arm 1, bucket, and add-on cylinder ports to prevent
any abnormal rise in actuator pressure, for example due to an external force.
This relief valve is also equipped with a function for preventing cavitation (suction function) by taking
in oil from the tank when the cylinder port pressure becomes negative pressure.

a Suction function Operating

84512399 EN - September 2011

3. Compound operation
1) Travel compound operation [Fig. 19, Fig. 20]
Under the conditions below when the travel left/right and the front system are operated at the same time,
the straight travel spool is switched, and the straight travel characteristic is maintained.
1 When the front is operated during travel left/right simultaneous operation (forward, backward, or pivot
turn)
2 When the left/right are operated simultaneously during front system operation
Front system operation is not affected by the switchover section or quantity of switchovers.
1) Signal circuit [Fig. 19]
(A) When the [Travel 1] side lever is operated, the pressure branched off from the valve main unit
pilot port passes through the filter and the shuttle, then switches the switchover valve [V1].
(B) When the [Travel 2] side lever is operated, the pressure branched off from the valve main unit
pilot port passes through the filter and the shuttle, then if the switchover valve [V1] is switched, it
switches the switchover valve [V2] through the path. On the other hand, if the switchover valve [V1]
is in the neutral state, the path is cut off by the switchover valve [V1]. Therefore, if both (A) and (B)
are established at the same time, the straight travel spool internal path (Pst) is connected to PA.
Also, if either (A) or (B) are established, the travel signal (PT) pressure rises.
(C) If at least one of the front systems is switched, the highest pressure of all the pilot pressures
in the front system is selected and is connected to the front signal port (PA). Therefore, if (A), (B),
and (C) are established at the same time, the straight travel spool switchover quantity is determined
proportional to the front signal (PA) pressure through the internal straight travel signal path (Pst).
[Fig. 19] shows the example of a case of travel left/right forward + boom up.

84512399 EN - September 2011

Straight travel signal control

1 5 Boom 9 Option
valve
2 Travel 1 6 Arm 10 Add-on (main pump)
Main unit housing section (op-
3 Travel 2 7 Bucket 11
tion)
4 Plate assembly 8 Swing

a Advance d Down g Right

b Reverse e Close h Left
c Up f Open

84512399 EN - September 2011

3) Overload relief valve intake operation

1) This relief valve has a built-in anti-void unit that supplies oil if cavitation occurs at the cylinder port
"HP".
When the cylinder port "HP" pressure is lower than the low-pressure side "LP", the sleeve (K) is
opened by the surface area difference between (A) and (B). Oil enters the cylinder port "HP" from the
low-pressure side "LP" to prevent cavitation.

6. Neutral cut spool [Fig. 21]

This valve is equipped as standard with a neutral cut spool in the P2 side housing neutral path (R1) minimum
flow (low-pressure relief valve upstream).
When the pcc port is pressurized and the neutral cut spool is switched, the path through the orifice [Lc7] to
low-pressure relief is cut off and output to the outside from the P3 port becomes possible.

1 Low-pressure relief valve (R)

84512399 EN - September 2011

7. Plate assembly [Fig. 22]

This valve is equipped with a plate assembly hermetically sealed with a gasket piling a plate on the housing side
surface.
The shuttle is built into the inside and this valve has a function for selecting and controlling the spool pilot pressure.
Also, in order to protect the shuttle section from contamination from the outside, a filter is mounted between the
plates.
When removing, do not loosen the screws shown in the diagrams and be careful that internal parts are not dis-
persed.

[Short cap side] [Long cap side]

1 Subassembly screw

84512399 EN - September 2011

8. Straight travel signal control valve [Fig. 19, Fig. 23]

This valve integrates the pilot pressure for the spool of the front system and travel selected with each plate as-
sembly and is used to switch the straight travel spool.
When the Travel 1 pilot pressure is pressurized, the spool [V1] is switched.
When the Travel 2 pilot pressure is pressurized at the same time, the spool [V2] can be switched.
Here, when the front system pilot pressure [PA] is pressurized, the PA pressure flows into Pst and is led to the
straight travel spool pilot chamber and the spool is switched.

a Travel 2
b Travel 1

84512399 EN - September 2011

Straight travel signal control

1 5 Boom 9 Option
valve
2 Travel 1 6 Arm 10 Add-on (main pump)
Main unit housing section (op-
3 Travel 2 7 Bucket 11
tion)
4 Plate assembly 8 Swing

a Advance d Close g Left

b Reverse e Open
c Up f Right

84512399 EN - September 2011

9. Add-on [Fig. 24, Fig. 25]

1) Add-on main relief valve
The oil fed from the Pr port is led to the main relief valve. The Pr pump maximum pressure is regulated by
the operation of the main relief valve.

a Advance d Close g Left

b Reverse e Open
c Up f Right

2) Spool section
When the spool is pressurized from the add-on (Section 10) pilot port par1 (pbr1) and switched, the neutral
path [Pg] is closed. The oil fed from the Pg port flows from the parallel path [Rg] through the load check
valve [S10-1], the path [S10-2], and the spool neck section, and into the AR1 (BR1) port.
The return oil returns to the tank path [Ta] from the BR1 (AR1) through the spool neck section.

84512399 EN - September 2011

3) Low-pressure relief valve operation [Fig. 26, Fig. 27]

1) Signal pressure generation (when pin1 (pin2) port pressurized)
The oil fed from the pump port (P1 (P2)) flows through the neutral path (L1 (R1)), then flows from the
low-pressure relief path (L2 (R2)) through the orifice (Lc1 (Rc1)) and out into the tank path (Ta).
At this time, the pressure generated in path (L2 (R2)) by the orifice (Lc1 (Rc1)) is led to the low-
pressure relief signal port (Ps1 (Ps2)).
When the (L2 (R2)) upstream main spool operates, the oil flowing through (L2 (R2)) is reduced, so
the (Ps1 (Ps2)) signal pressure becomes lower.

2) Relief operation
When excess oil flows in path (L2 (R2)), the poppet is operated by the pressure generated in path (L2
(R2)) by the orifice (Lc1 (Rc1)).
Through this poppet operation, the oil flows from the path, through the notch hole path, and out to the
tank path [Ta]. This prevents the generation of excess pressure at the low-pressure relief signal port.

4) Add-on main relief valve

1) Add-on main relief valve operation
This relief valve is incorporated between the neutral path "HP" and the tank path "LP". The oil passes
through the metering hole of the main poppet [1] and charges the interior space [C].
Also, the sleeve [2] and the main poppet [1] seat securely operating on the different surface areas "A"
and "B".

84512399 EN - September 2011

2) When the neutral path "HP" pressure reaches the set pilot spring force, the pilot poppet [3] opens.
The oil flows around the pilot poppet [3], passes from the notch hole [E] and through the ring-shaped
gap [D] and is led to the tank path "LP".

3) Because the pilot poppet [3] has opened, the interior space [C] pressure drops and the main poppet
[1] opens, so the "HP" oil flows directly into the path "LP".

84512399 EN - September 2011

Section

8030E

5 Stack Solenoid Valve Operation Explanation

84512399 EN - September 2011

CONTENTS

External Shape Diagram and Component Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Operation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

External Shape Diagram and Component Parts

This valve is made up of the body and the electromagnetic switchover valve.

Normal closed type solenoid; SP, S1, S3 Normal open type solenoid; S2 4-port type solenoid; S4

1 Electromagnetic switchover valve

2 Body

84512399 EN - September 2011

Operation Explanation

Hydraulic circuit diagram

The pressure oil fed from the P port feeds pressure oil to the C1 - C5 ports according to the excitation or non-excitation
of electromagnetic switchover valves S1 - S4 resulting from exciting electromagnetic switchover valve SP.

Electromagnetic switchover valves S1, S3 → Oil passing through when valve excited
Electromagnetic switchover valve S2 → Oil passing through when valve not excited
Electromagnetic switchover valve S4 → Oil passing to C5 when valve excited Oil passing to
C4 when valve not excited

84512399 EN - September 2011

Section

8030F

Structure and Operation Explanation of Upper Pilot Valve

(remote control valve)

84512399 EN - September 2011

CONTENTS

Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Structural Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

8030F-2 PRINTED IN FRANCE
Copyright ©
Structure and Operation Explanation of Upper Pilot Valve
(remote control valve)
Structure
The structure of the remote control valve is as shown in the Structural Diagram. There is a longitudinal axial hole in
the casing and the pressure reduction valve is installed in it.
The pressure reduction valve comprises the spool (201), secondary pressure setting spring (241), return spring (221),
spring seating (216), and washer 2 (217). The secondary pressure setting spring (241) is set so that the secondary
pressure calculation is 0.5 - 1 MPa (depending on the model). The spool (201) is pressed against the push rod (212)
by the return spring (221).
When the push rod (212) is pushed down by tilting the handle or another operation, the spring seating goes down at
the same time and the secondary pressure setting spring (241) setting is changed.
The casing (101) has the oil inlet (primary pressure) port P and the outlet (tank) port T and, furthermore, the secondary
pressure is taken out from the ports 1, 2, 3, 4.
Function
1. Basic functions
The remote control valve is for controlling the control valve spool stroke quantity, direction, etc. This is done by
operating the pilot valve output pressure on the control valve spool end section.
In order to satisfy this function, the remote control valve is made up of the following elements.
1) Inlet port (P) to which the oil is fed from the hydraulic pump
2) Multiple output ports (1, 2, 3, 4) for operating the feed pressure from the inlet port on the control valve spool
end
3) Tank port (T) required for controlling the above output pressure
4) Spool connecting the output port to the inlet port or tank port
5) Mechanical means including a spring operating on the above spool in order to control the output pressure
2. Main part functions
The function of the spool (201) is to switch the oil path either to have the hydraulic pressure fed from the hydraulic
pump received by the P port and lead the P port pressure oil to the output ports (1, 2, 3, 4) or to lead the output
port pressure oil to the T port. The output pressure operating on this spool (201) is determined by the secondary
pressure setting spring (241).
In order to change the deflection quantity of the secondary pressure setting spring (241), the push rod (212) is
inserted into the plug (211) in such a way that it can slide.
The return spring (221) operates on the casing (101) and spring seating (216) and operates to return the push
rod (212) in the displacement zero direction regardless of the output pressure and makes the spool (201) neutral
return reliable. It also has the effect of a counter-force spring for giving an operator an appropriate operation feel.

Operation
Operation of the remote control valve is explained based on the hydraulic circuit diagram (Diagram 1) and operation
explanation diagrams (Diagram 2 - Diagram 4).
Diagram 1 is a typical usage example for the remote control valve.

84512399 EN - September 2011

Diagram 1 Remote control valve usage example

1 Pilot valve 3 Main pump 5 Hydraulic motor

2 Pilot pump 4 Control valve 6 Hydraulic cylinder

(remote control valve))

84512399 EN - September 2011

CONTENTS

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pressure Reduction Valve Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operating Section Damping Mechanism Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Structural Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

8030G-2 PRINTED IN FRANCE
Copyright ©
Structure and Operation Explanation of Travel Pilot Valve
(remote control valve))
Operation
The remote control valve with built-in damper (hereinafter, remote control valve with damper) is a remote control valve
that incorporates into the remote control valve main unit a damping function for preventing the man-machine system
hunting (lever hunting) phenomenon.
Operation of the remote control valve with damper is divided into the Pressure Reduction Valve Section and the Op-
eration Section Damping Mechanism Section. The explanations in these 2 sections are based on the hydraulic circuit
diagram, assembly cross-section diagram, and damping operation explanation diagram below. The diagram below is
a typical usage example for the remote control valve.

Hydraulic circuit diagram

101 Casing 1 271 Hexagon socket head bolt 271
151 Plug 2 301 Spool 301
201 Cover 2 311 Spring seating 311
202 Plug 4 313 Washer 3 313
203 Grease cup 4 324 Spring 324
210 NHU packing 4 335 Spring 335
212 O-ring 4 336 Spring 336
214 Push rod 4 337 Spring 337
215 Washer 1 8 412 Bushing 412
217 Washer 2 4 413 Camshaft 413
218 Spring seating 4 420 Cam 420
221 Locking ring 4 423 Hexagon socket head locking screw 423
223 Bushing 4 471 Locking screw 471
84512399 EN - September 2011
8030G-7
Copyright ©
Structure and Operation Explanation of Travel Pilot Valve
(remote control valve))
Code Part name Q'ty Code Part name Q'ty
224 Piston 2D085 4 472 Lock nut 472
225 Steel ball 12 501 Bellows 501

84512399 EN - September 2011

Section

8030H

Structure and Operation Explanation of Cushion Valve

84512399 EN - September 2011

CONTENTS

Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Structure
This valve is made up of a shuttle valve section and cushion valve section with heat circuit.
The cushion valve with a heat circuit is connected between the hydraulic shovel car control valve and the pilot oper-
ation valve to reduce body shaking (cushion function) caused by emergency stop operations by the operator.
This valve is also equipped with a circuit with which the operator can deliberately disable the cushion function for
reverse operations.
The shuttle valve selects the high-pressure signal pressure from 2 signal pressure systems.
This valve has 2 circuits.

*1 Arm
*2 Boom

84512399 EN - September 2011

Operation Explanation
1. Normal operation
The pressure oil fed from the pilot operation valve to the A port (or C, E, or G port) pushes up the check plunger
and is sent to the B port (or D, F, or H port).
The pressure oil that has passed through the B port operates on the control valve spool and operates the actuator.
The oil pushed out from the control valve spool passes through the D port (or B, F, or H port) and flows out to the
T port.

84512399 EN - September 2011

2. Cushion operation
When the pressure oil fed from the pilot operation valve to the A port (or C, E, or G port) is closed by the pilot
operation valve, the pressure oil that has operated on the control valve spool is pushed back to the B port (or the
D, F, or H port) by the return spring on the spool.
The returned oil passes through the check plunger metering orifice, is sent to the A port (or the C, E, or G port),
and is drained from the pilot operation valve.
At this time, by passing through the metering orifice, the pressurized oil holds down the control valve spool speed,
which prevents the sudden stopping of the actuator and reduces shaking of the body. (Cushion function)

84512399 EN - September 2011

3. Reverse operation
When the pressure oil fed from the pilot operation valve to the A port (or C, E, or G port) is switched to the C port
(or A, E, or G port), the pressure oil that has operated on the control valve spool is pushed back to the B port.
Because the pushed back oil flows out to the T port without passing through the check plunger metering orifice,
it does not hold down the control valve spool speed, so the cushion function does not work.

84512399 EN - September 2011

4. Heat circuit
When the pilot operation valve is in the neutral position, the oil fed to the R port passes through the inside of the
reverse operation spool and flows out to the T port, which heats up the inside of the valve.
When pressure oil is being fed from the pilot operation valve to the A port (or C, E, or G port), the oil fed to the
R port flows out to the C port (or A, E, or G port) and heats up the circuit to the pilot operation valve and inside
the valve.

5. Shuttle valve
The steel ball is pressed from the higher of the pressures between the I and J ports and the K and L ports to the
lower of these pressures. Through this process, high-pressure oil is fed to the S port or the Q port.
In the same way, oil of the higher pressure between the M and N ports and the O and P ports is fed to the U port.

84512399 EN - September 2011

Section

9002

Removal and Installation of Counterweight

84512399 EN - September 2011

CONTENTS

Removal of Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CAUTION 4. Use the wire ropes and liftcrane to lift and remove
the counterweight.
• Be sure to stop the engine before beginning
work. • Move the counterweight about 50 cm to the rear
while lifting it so that it does not interfere with the
• Be sure to inspect the wire rope and other housing, engine parts and pipes.
lifting equipment before beginning work.
• Do not stand or pass under the suspended
load.
• Thoroughly secure the removed counter-
weight with the wire ropes and liftcrane so
that it does not fall over.

Items to prepare
• Box wrench (50 mm)
• Balance lifting device
• Shackles (with the required lifting capacity) x 4
• Wire rope (with the required breaking load) x 4
• Liftcrane (with the required lifting capacity)
• Wood planks, etc.
• Rag
• Cleaning fluid

Removal of Counterweight
1. Remove the following before beginning work.。
• Engine hood, gas damper and lock stay
• Rear view camera and electrical parts bracket
2. Install the shackles (1), and then use the wire ropes
(2) and liftcrane to secure the counterweight so that
it does not fall during removal and installation oper-
ations.

3. Use a box wrench (50 mm) to remove the 4 bolts

(1) at the bottom section of the counterweight.

84512399 EN - September 2011

5. Thoroughly check that the location is safe before Installation of Counterweight

lowering the counterweight on wood planks (1).
1. Install the shackles (1), and then use the wire ropes
• Thoroughly secure the counterweight with the (2) and liftcrane to secure the counterweight so that
wire ropes and liftcrane so that it does not fall it does not fall during removal and installation oper-
over. ations.

2. Use the wire ropes and liftcrane to lift and install the
counterweight.
• Suspend the counterweight so that it does not in-
terfere with the housing, engine parts and pipes.

3. Coat the threaded section of the bolt (1) with Loctite,

and use a box wrench (50 mm) to fasten the coun-
terweight using the 4 bolts (1) and 4 high-strength
washers (2) at the bottom section of the counter-
weight.
Tightening torque: 1862 - 2058 N·m

4. Install the following after finishing work.

• Engine hood, gas damper and lock stay
• Rear view camera and electrical parts bracket

Section

9003B

Removal and Installation of Bucket Link

84512399 EN - September 2011

CONTENTS

Removal of Bucket Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Bucket Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CAUTION 2. Use 2 wrenches (36 mm) to remove the double nuts

(1), and then pull out the bolts (2) (3).
• Stop the machine on a level location with
good footing.
• Be sure to stop the engine before beginning
work.
• When working together with others, always
be sure to exchange signals and pay ade-
quate attention to safety.
• Always wear protective gear (protective eye-
wear and safety shoes, etc.) when working
with a hammer.

Items to prepare
• 2 wrenches (36 mm)
• Hammer
• Striking rod 3. Use a hammer (3) and striking rod (4) to push the
• Grease pin (2) out and remove the bucket link (1).
• Rag
• Cleaning fluid

Removal of Bucket Link

• Remove the bucket. (For details, see "Removal and
Installation of Bucket".)
1. Place the bucket link (1) parallel to the ground.

4. Use a hammer (4) and striking rod (5) to push the

pin (3) out and remove the arm links (1) (2).
• When removing the pin, be careful not to damage
the installed O-rings or dust seals.

84512399 EN - September 2011

Installation of Bucket Link 3. Place the bucket link (1) parallel to the ground.
Use a hammer (3) to push in the pin (2) and install
1. Clean each pin and pin hole. the bucket link (1).

9003D

Removal and Installation of Boom

84512399 EN - September 2011

CONTENTS

Removal of Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Job code 39105AB10 1. Bring the boom (1) top in contact with the ground.

CAUTION
• Stop the machine on a level location with
good footing.
• Be sure to stop the engine before beginning
work.
• When working together with others, always
be sure to exchange signals and pay ade-
quate attention to safety.
• Always wear protective devices (protective
eyewear and safety shoes, etc.) when work-
ing with a hammer.
• Be sure to inspect the nylon sling and other
lifting equipment before beginning work.
2. Use a wrench (19 mm) to remove the grease hoses
• Do not stand or pass under the suspended on the left and right sides (1).
load.
• Use caps or plugs to prevent any entry of water,
Items to prepare dust or dirt.
• Wrenches (10 mm、19 mm、22 mm、30 mm、36
mm、41 mm)
• Hexagon wrench (12 mm)
• Slide hammer (24 mm)
• Nylon sling (with the required lifting capacity)
• Liftcrane (with the required lifting capacity)
• Marking pen
• Cap
• Plug
• Rag
• Striking rod
• Cleaning fluid
• Wood piece
• Square wooden pieces
• Wire 3. Use a wrench (36 mm) to remove the double nuts
(1) and bolt (2), and then remove the fastening ring
Removal of Boom (3).
Also, remove the cab side in the same way.
• Remove the bucket. (For details, see "Removal and
Installation of Bucket".)
• Remove the bucket link. (For details, see "Removal
and Installation of Bucket Link".)
• Remove the bucket cylinder. (For details, see "Re-
moval and Installation of Bucket Cylinder".)
• Remove the arm cylinder. (For details, see "Removal
and Installation of Arm Cylinder".)
• Remove the arm. (For details, see "Removal and In-
stallation of Arm".)
• This section explains the procedure for when attaching
the boom cylinder to the frame.
When removing the boom cylinder too, see "Removal
and Installation of Boom Cylinder".

84512399 EN - September 2011

4. Use a hammer (2) and striking rod (3) to push the 7. Secure the base of the boom cylinder with the wood
pin (1) out. piece (1).
Use a liftcrane and nylon slings (4) to hold the boom
cylinders (right) (left) so that they does not fall.

8. Lower the boom cylinders (right) (left) and let them

rest on the wood piece (1).
5. Start the engine, lower the boom at idle, and retract
the boom cylinder (1) (2) rod. • Remove the cab side boom cylinder from the
boom in the same way.

6. Tie the cylinder rods on the left and right sides with
wire (1) so that they cannot come out. 9. Install the pin (1) removed in Step 4.
Use a wrench (36 mm) to tighten the bolt (3) with
the 2 double nuts (2), and then install the fastening
ring (4).
Also, install the cab side in the same way.

10. Use wrenches (41 mm) to remove the hoses (1),

(2), (3).
Use a hexagon wrench (12 mm) to remove the
4 hexagon socket head bolts (5) and the 2 split
flanges (6), and then remove the hose (4).
• Mark the hoses and lines so that the connectors
match at the time of assembly.

84512399 EN - September 2011

• Use caps or plugs to cover the hoses and lines to 12. Use a wrench (30 mm) to remove the bolt (1) and
prevent any entry of water, dust or dirt. washer (2).
• Clean the hoses and lines by spraying them with
a parts cleaner to prevent scratches and prevent
dirt from accumulating on the connectors.

13. Use a slide hammer (1) (24 mm) to remove the pin
(2).

11. Wrap nylon slings (1) around the pins on the left and
right sides installed in Step 9 and secure with the
liftcrane.

14. Back up the machine and remove the boom (1).

84512399 EN - September 2011

Installation of Boom 4. Tie the cylinder rods on the left and right sides with
wire (1) so that they cannot come out.
• This section explains the procedure for when not in-
stalling the boom cylinder.
• Tighten bolts being installed to the specified torque.
• When the torque is not specified, check the "Bolt Size
and Torque Table".
1. Clean each pin and pin hole.

5. Align the boom with the swing frame pin hole and
use a slide hammer (1) (24 mm) to tighten the pin
(2).
• When inserting pins, be careful not to damage the
dust seals.
• If the insertion of a shim is possible according to
2. Install the pin (1). the tolerance adjust the shim.
Use a wrench (36 mm) to tighten the bolt (3) with
the 2 double nuts (2), and then install the fastening
ring (4).
Also, install the cab side in the same way.

6. Use a wrench (30 mm) to tighten the bolt (1) and

washer (2).
• Grease up.
3. Wrap the nylon slings (1) around pins on the left and
right sides installed in Step 2 and secure with the
liftcrane.

84512399 EN - September 2011

7. Use a wrench (41 mm) to install the hoses (1) (2) 10. Use a wrench (36 mm) to attach the double nuts (1)
(3). and bolt (2), and install the fastening ring (3).
After setting the O-ring (4) on the line side, install Also, install the cab side in the same way.
the hose (4) with the 2 split flanges (6) and the 4
hexagon socket head bolts (5).
• The O-ring cannot be reused.
Replace them with new parts.

11. Use a wrench (19 mm) to attach the grease hoses

on the right and left sides (1).

8. Start the engine, raise the boom at idle, and extend

the boom cylinder (1) (2) rod.

12. Bring the boom (1) top in contact with the ground.
• When installing the boom cylinder too, see "Re-
moval and Installation of Boom Cylinder".
• Install the arm. (For details, see "Removal and
9. Use a hammer (2) to push in the pin (1). Installation of Arm".)
Use a liftcrane and nylon slings (3) to hold the boom • Install the arm cylinder. (For details, see "Re-
cylinders (right) (left) so that they does not fall. moval and Installation of Arm Cylinder".)
• Install the bucket cylinder. (For details, see "Re-
moval and Installation of Bucket Cylinder".)
• Install the bucket link. (For details, see "Removal
and Installation of Bucket Link".)
• Install the bucket. (For details, see "Removal and
Installation of Bucket".)

84512399 EN - September 2011

Section

9004

Removal and Installation of Operator's Seat

84512399 EN - September 2011

CONTENTS

Removal of Operator's Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Operator's Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Job code 90120AD17 3. Use a wrench (13 mm) to remove the 2 bolts (1)
from the rear of the seat.
Items to prepare Tightening torque for bolt (1) installation: 19.6 N·m

• Wrench (13 mm)

Removal of Operator's Seat

1. Pull the slide lever (1) to slide the seat (2) to the
rear.
Use a wrench (13 mm) to remove the 2 bolts (3)
from the front of the seat.
Tightening torque for bolt (3) installation: 19.6 N·m

4. Remove the operator's seat (1).

2. Pull the slide lever (1) to slide the seat forward, and
then pull the reclining lever (2) to fold the seatback
forward.

84512399 EN - September 2011

Installation of Cab Assembly Tighten bolts being installed to the specified torque.
If the torque is not specified, see the "Tightening Torque"
To install, perform the reverse of the removal procedure. section.

84512399 EN - September 2011

Section

9005B

Removal and Installation of Wiper

84512399 EN - September 2011

9005D

Removal and Installation of Wiper Motor

84512399 EN - September 2011

CONTENTS

Removal of Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Job code 55518AZ46 3. Use a Phillips screwdriver or box wrench (10 mm)
to remove the 2 bolts (1), use a hexagon wrench (5
Items to prepare mm) to remove the 3 bolts (2) and 3 washers (3),
and then remove the front upper trim assembly (4).
• Hexagon wrench (5 mm) Tightening torque for bolt (1) installation: 5.9 - 7.8
• Wrenches (10 mm, 17 mm) N·m
• Box wrench (10 mm)
• Flathead screwdriver (longnose pliers)
• Phillips screwdriver

Removal of Wiper Motor

1. Use a Phillips screwdriver or box wrench (10 mm)
to remove the 2 bolts (1), and then remove the side
front lower trim (2).
Tightening torque for bolt (1) installation: 5.9 - 7.8
N·m

4. Use a wrench (17 mm) to remove the 1 nut (1), and

then remove the wiper arm (2).
Tightening torque for installation: 12 - 16 N·m

2. Use a flathead screwdriver or longnose pliers to re-

move the clip pins (1), and then remove ducts B (2).

5. Use a wrench (17 mm) to remove the 1 nut (1).

Tightening torque for installation: 11 - 13 N·m

84512399 EN - September 2011

6. Use a box wrench (10 mm) to remove the 4 bolts Installation of Wiper Motor
(1), and then remove the wiper motor assembly (2).
To install, perform the reverse of the removal procedure.
• Be careful about the wiper link and wiper arm installa-
tion location.
• Check the wiper arm wipe location and stop location.
• When installing the bolts, tighten them to the specified
torque.
If the torque is not specified for an installation bolt, see
the "Tightening Torque" section.

84512399 EN - September 2011

Section

9005E

Removal and Installation of Monitor

84512399 EN - September 2011

CONTENTS

Removal of Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Job code 55640AO14 3. Remove the connector (1).

Items to prepare
• Wrench (10 mm)

Removal of Monitor
1. Use a Phillips screwdriver or box wrench (10 mm)
to remove the 2 bolts (1), and then remove the side
front lower trim (2).
• Bolt (1) tightening torque: 5.9 - 7.8 N·m

4. Use a wrench (10 mm) to remove the 4 bolts (2),

and then remove the monitor (1).

2. Use a Phillips screwdriver or box wrench (10 mm)

to remove the 2 bolts (1), use a hexagon wrench (5
mm) to remove the 3 bolts (2) and 3 washers (3),
and then remove the front upper trim assembly (4).
• Bolt (1) tightening torque: 5.9 - 7.8 N·m
Installation of Monitor
To install, perform the reverse of the removal procedure.
Tighten bolts being installed to the specified torque.
For the tightening torques of the installation bolts, see
the "Tightening Torque" section.

84512399 EN - September 2011

Section

9005F

Removal and Installation of Cab Front Glass

84512399 EN - September 2011

CONTENTS

Removal of Cab Front Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of Cab Front Glass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Job code 90156AL10 3. Use a wrench (10 mm) to remove the 3 bolts (1)
each, and then remove the brackets (2) (3).
Tightening torque for bolt (1) installation: 880 - 1270
CAUTION N·cm
Reinforced glass is used for the front win-
dow.
Be extremely careful not to damage it when
touching it during removal or installation.

Items to prepare
• Wrench (10 mm)
• Phillips screwdriver
• Rag
• Cleaning fluid

Removal of Cab Front Glass

1. Use a Phillips screwdriver to remove the 8 clips (2),
and then remove the cover (1). 4. Remove the covers (1) (2) for the bracket.

2. Use a Phillips screwdriver to remove the screw 5. Use a wrench (10 mm) to remove the 3 bolts (1),
(1), and then install the removed screw (1) into the and then remove the front glass left lower bracket
screw hole (2). (2).
Tightening torque for bolt (1) installation: 880 - 1270
• The assist spring is locked. N·cm

84512399 EN - September 2011

6. Use a wrench (10 mm) to remove the 3 bolts (1), Installation of Cab Front Glass
and then remove the front glass right lower bracket
(2). To install, perform the reverse of the removal procedure.
Tightening torque for bolt (1) installation: 880 - 1270 Tighten bolts being installed to the specified torque.
N·cm If the torque is not specified, see the "Tightening Torque"
section.

7. Remove the cab front glass (1).

84512399 EN - September 2011

Section

9005G

Window Lock Adjustment Procedures

9005H

Monitor display Heater hose (Eng.Out) i
console harness.
b Trim side; Front (Right) f Cooler hose (Suction) j Wire harness (Console)
c Trim side; Front (Left) g Cooler hose (Liquid) k Floor
d Heater hose (Eng.Return) h Cover; Top (Console left)

84512399 EN - September 2011

Equipment Layout Diagram

84512399 EN - September 2011

Code Part name Code Part name Code Part name

Motor actuator (refresh/recir-
1 Motor actuator (mode) 4 7 Blower amp
culate switch)
2 Compressor relay 5 Interior temperature sensor 8 Motor actuator (air mix)
3 Blower OFF relay 6 Blower motor 9 Evaporator sensor

84512399 EN - September 2011

Circuit Diagram
Air Conditioner Circuit Diagram

84512399 EN - September 2011

Analog Signal:0 - 5 V are applied

GND

P W B R Y G L Br Lg O Sb V
Light Sky
Pink White Black Red Yellow Green Blue Brown Orange Violet
green blue

Code Part name Code Part name Code Part name

1 Main key switch 7 Compressor 13 Inside air sensor
2 A/C main power supply 8 Blower OFF relay 14 Motor actuator (air mix)
Power supply for compres-
3 9 Blower motor 15 Motor actuator (mode)
sor clutch
Motor actuator (refresh/re-
4 Power supply for controller 10 Blower amp 16
circulate switch)
5 Sunlight sensor 11 Compressor relay 17 CAN signal
Pressure switch (receiver Control panel (TKS-
6 12 Evaporator sensor 18
dryer) CP208C0)

NOTE:
• Wire diameters that are not indicated are 0.5.
• Broken lines indicate wiring on the vehicle side.
• Codes displayed on the connectors indicate the code colors seen from the connection ports of the connectors.

84512399 EN - September 2011

Explanation of Functions
Explanation of Control
Back-up function
Even when air conditioner operation is stopped (switched OFF) with the vehicle main key power supply or operation
panel ON/OFF switch, the set temperature and all the other setting states are stored in memory, so the next time air
conditioner operation starts, it goes into the same state as before it was stopped.
When the vehicle main key power supply is cut off, the data is backed up by storing it in the internal EEPROM.
However, if the main key power supply is cut off within 0.5 sec. of switch input, that switch input is not stored into
memory.
Also, the data read out from EEPROM when the power is switched ON is judged to see if it is within the valid range.
If data outside the valid range was written into memory, for example due to noise, then operation starts from the default
setting values to avoid abnormal operation.
Fahrenheit temperature display
To switch, hold down both the temperature setting UP and DOWN switches for 5 sec.
The display toggles between Celsius and Fahrenheit display each time the switches are both held down for 5 sec.
The Fahrenheit display is a 2-digit integer and below the decimal point is not used, so "F" is displayed.
However, in case of trouble, this display takes priority.
When this display is switched, the new status is backed up in memory, so even if the main key power supply is
switched OFF, the display status is retained.
Internal calculations are all done in Celsius.
Only the operation panel display is in Fahrenheit.
Therefore, the display may differ slightly from the exact Fahrenheit temperature.
Below is shown the Fahrenheit temperature and the corresponding Celsius temperature used in internal processing.

CAUTION
These specifications are written with Celsius as the standard.
Therefore, if the temperature is displayed in Fahrenheit, convert the temperature to centigrade by using
the table below.

Fahrenheit dis- Interior recognition set temper-

play [°F] ature (Celsius) [°C]
63 18.0
64 18.5
65 19.0
：：
77 25.0
：：
91 32.0

Air Mix Motor Actuator Control

1. Summary explanation
The provisional target degree of opening is determined from the target blow temperature and the current blow
mode, various restrictions are applied, and the target degree of opening is calculated.
Then drive is output to move the motor actuator position to the target degree of opening.
Below are the details.
2. Heater unit hysteresis correction operation (motor actuator one-direction stop)
After the actuator moves to the target degree of opening, it returns to the specified position.
However, if the target degree of opening is less than 0°, the actuator is treated as having reached the target
degree of opening when it reaches 0°, then it moves to the specified position. (A stop in the fully-open direction
is used as the reference.)
3. Motor actuator operation priority order
The operation priority for this motor actuator is No. 1.
This means that if the target degree of opening for this motor actuator changes and operation becomes necessary,
even if some other motor actuator is operating, that other motor operation is paused, and this motor actuator
operates.
4. Motor actuator retry control
Even when there are no changes to the target values after the target is attained, if the difference between the
current value and the target value once every 5 min. is equal to or greater than the operation start angle, the
motor actuator is operated.

84512399 EN - September 2011

Blow Mode Motor Actuator Control

1. Summary explanation
The blow mode is switched by rotating the diffuser switching damper with the motor actuator.
There are 2 types of control: auto and manual.
2. Auto control
When AUTO blow mode is set, the blow mode changes to auto control.
During auto control, the diffuser is switched according to the target blow temperature
Auto control continues until operation of the blow mode select switch is recognized.

1 Target blow temperature 3 MODE 2 VENT *5 MODE 4 FOOT

*2 Blow mode *4 MODE 3 B/L

3. Manual control
1) When operation of the blow mode select switch is recognized, the blow mode motor actuator is driven to
attain the output shaft angle below and the display is switched too.
Each time operation of the switch is recognized, the display switches MODE 1 → MODE 2 → MODE 3 →
MODE 4 → MODE 1 →...
However, if this switch is pressed during auto control, auto control is ended and the diffuser is fixed at its
current position.
2) MODE 5 in the table below only occurs when operation of the DEF select switch is recognized.
After that, when operation of the blow mode select switch is recognized, the blow mode becomes the one
that was in effect just before operation of the DEF select switch was recognized.
Also, even if the DEF switch is pressed again during this mode, the mode is not canceled.

MODE MODE MODE MODE MODE

Blow mode
1 2 3 4 5
Blow mode motor actuator degree of opening 90° 67° 48° 26° 0°
FACE VENT B/L FOOT DEF

Panel display

4. Blow mode control priority order

The priority order for auto control and manual control is as follows.

Priority order Control

1 Manual control
2 Auto control

84512399 EN - September 2011

Refresh/Recirculate Switch Motor Actuator Control

1. Recirculate mode
In refresh mode, when it is recognized that the refresh/recirculate select switch on the operation panel has been
closed, the system goes into recirculate mode.At this time, the display switches to recirculate and the motor
actuator operates to the refresh angle (damper angle) of 0°.
2. Refresh mode
In recirculate mode, when it is recognized that the refresh/recirculate select switch on the operation panel has
been closed, the system goes into refresh mode. At this time, the display switches to refresh and the refresh/
recirculate switch motor actuator operates to the refresh angle.
1) Refresh mode I
When blow mode control is manual and is set to B/L or FOOT, the set temperature is set to 32 °C (HOTMAX),
and air flow control is manual and is set to Hi, the refresh angle (damper angle) operates to 67°.
2) Refresh mode II
When in a mode other than refresh mode I, the refresh angle (damper angle) operates to 30°.
3. Operation stop judgment
1) The operating motor actuator stops when the current position comes within the target position range.
2) The stopped motor actuator operates when the current position goes beyond the target position range.

Refresh/recirculate mode and refresh/recirculate display

Refresh/recirculate mode Recirculate Outside air

Panel display

84512399 EN - September 2011

Blower Amp Control

1. Summary explanation
The air flow is controlled by outputting to the blower amp connected in series with the blower motor.
The air flow is switched by varying the analog voltage output by changing the PWM output duty ratio and increas-
ing or decreasing the blower motor speed.
There are 2 types of air flow control: auto air flow control and manual air flow control.
Also, in auto air flow control, the air flow is restricted by the cold blast prevention control etc.
2. Manual air flow control
Each time it is recognized that the air flow UP switch has been closed, the air flow is fixed to the next higher level
of air flow from Lo → M1 → M2 → M3 → M4 → Hi.
When Hi is already displayed, the air flow is not changed.
In the same way, each time it is recognized that the air flow DOWN switch has been closed, the air flow is fixed
to the next lower level of air flow from Hi → M4 → M3 → M2 → M1 → Lo.
When Lo is already displayed, the air flow is not changed.
The same is true when air flow control is switched from auto to manual. For example, when AUTO M1 is dis-
played, if it is recognized that the air flow DOWN switch has been closed, the display becomes Lo and AUTO is
no longer displayed.
Also, the change speed for air flow output switchover is the same as discussed for auto below.

Relationship between air flow and display during manual operation

Lo Hi
Air flow (minimum air M1 M2 M3 M4 (maximum air
flow) flow)
Blower air
40 % 46 % 54 % 64 % 80 % 100 %
flow %

Display

3. Auto air flow control

When it is recognized that the AUTO switch has been closed, the air flow is controlled automatically and AUTO
is displayed.
1) During auto air flow control, the air flow is set according to the target blowing temperature as shown in the
diagram below.
2) Auto air flow control continues until closing of either the air flow UP or air flow DOWN switch is recognized.
3) The auto air flow amount calculation results are continuous, not divided into levels.
4) When it is recognized that the AUTO switch has been closed, the display becomes as in the table below
according to the results of the auto air flow amount calculation.
5) The normal auto air flow output change is roughly 5 V/sec.
6) Auto air flow control is restricted by the cold blast prevention control described in (4), which is the next item.

84512399 EN - September 2011

1 Target blow temperature 4 M4 *7 M1

*2 Auto air flow *5 M3 *8 Lo
*3 Hi *6 M2

Relationship between air flow and target blow temperature

Display refreshing and air flow output correspondence table

Current display Item Target % (about)
Lo display Output range changed to M1 When 44 % or higher
Output range changed to Lo When 40 % or lower
M1 display
Output range changed to M2 When 52 % or higher
Output range changed to M1 When 48 % or lower
M2 display
Output range changed to M3 When 61 % or higher
Output range changed to M2 When 57 % or lower
M3 display
Output range changed to M4 When 74 % or higher
Output range changed to M3 When 70 % or lower
M4 display
Output range changed to Hi When 88 % or higher
Hi display Output range changed to M4 When 84 % or lower

4. Cold blast prevention control

The air flow is restricted according to the value of the coolant temperature data and other parameters sent from
the vehicle side via CAN communication.
The air flow restriction has 2 levels - air flow 0 and air flow Lo. Whether or not to use the restriction is determined
from the judgment results.
1) Conditions under which cold blast prevention control is used
1) Auto air flow
2) When set temperature - inside air sensor temperature 11.
3) When the coolant temperature signal from vehicle is the less than 30 °C signal or the 30 °C or higher
but less than 45 °C signal
Under the condition above, the inside air sensor temperature is the value immediately after the vehicle main
key power supply is switched ON and AUTO and Tset are according to the current switch states.
Therefore, when the AUTO switch is pressed after the air flow has been set manually, if the coolant tem-
perature is within the cold blast prevention range, the air flow is restricted.
In the same way, even if the set temperature is changed, if the conditions are met, the air flow is restricted.
While cold blast prevention control is being executed, the display corresponds to the restricted air flow.
2) Air flow 0 control
When the coolant temperature signal from vehicle is the less than 30 °C, the air flow is set to 0.
This continues until a coolant temperature signal of 30°C or higher is received.
Once a coolant temperature signal of 30 °C or higher is received and these conditions are no longer met,
air flow 0 is ended.
3) Air flow Lo control
When the coolant temperature signal from vehicle is the 30 °C or higher but less than 45 °C signal, the air
flow is set to Lo.
This continues until a coolant temperature signal of 45 °C or higher is received.
Also, the same as for [2], this shift is irreversible.
Once a coolant temperature signal of 45 °C or higher is received, control is normal.
5. Blower air flow control when mode motor actuator angle switched
When the mode motor actuator is operated with the blower air flow at M1 or higher, the mode motor actuator is
operated with the blower air flow first set to Lo.
After the end of operation, the original blower air flow returns.
Changes to the blower output at this time are the same as normal auto air flow control.
However, the blower display is not changed during control.

84512399 EN - September 2011

6. Air flow control priority order

The priority order for auto air flow control, manual air flow control, and cold blast prevention control is as follows.

Priority or-
Control
der
Blower air flow control when mode motor actuator angle
1
switched
2 Manual air flow control
3 COOLMAX control
4 Cold blast prevention control
5 HOTMAX control
6 Auto air flow control

84512399 EN - September 2011

Compressor Clutch Control

1. Summary explanation
The compressor clutch is controlled by the power to the clutch coil being switched ON/OFF by an external relay.
This control is executed by thermo operation and the fletching prevention function.
Thermo operation has control mode 1 and control mode 2. These modes are applied according to the blow mode
and other conditions.
However, for blower air flow 0, the compressor clutch is switched OFF.
The operation temperature does not include the thermistor variation.
2. Thermo operation (AC switch ON)
1) Control mode switchover
• When the blow mode is B/L and the target blow temperature is as in the diagram below, control mode 2
is used.
As the diagram shows, there is hysteresis between control modes 1 and 2.
• Other than the above is all control mode 1.

*1 Target blow temperature

*2 Control mode 1
*3 Control mode 2

3. Fletching prevention function

1) Operation conditions
After the end of initial operation, if 4 - 5 min. continue with the air flow M3 or higher and the compressor
clutch not coming ON even once, the compressor clutch is switched ON one time.
This control is cleared by the vehicle main key power supply being switched OFF and this control starts
again when this power supply is switched ON again.
2) This control takes priority over all other control.
4. AUTO switch link function
When operation of the AUTO switch is recognized, compressor clutch control comes ON and AUTO is displayed.
1) Compressor clutch control is the same control as for the AC switch being switched ON.
2) When it is recognized that the AC switch has been switched OFF, the AUTO display goes out.
Even when it is recognized that the AC switch has been switched ON again, AUTO is not displayed.
However, at this time, if the main key power supply is switched OFF, then ON again, since the AC ON, air flow
AUTO, and blow mode AUTO conditions are all met, AUTO is displayed.

84512399 EN - September 2011

COOLMAX Control and HOTMAX Control

1. When the set temperature is 18.0 °C [COOLMAX] (or 18.E)
1) The air mix motor actuator is set to the 0° limiter position (fully closed).
2) For auto air flow control, the air flow is set to Hi.
3) For AUTO blow mode control, the blow mode is set to VENT.
2. When the set temperature is 32.0 °C [HOTMAX] (or 32.E)
1) The air mix motor actuator is set to the 90° limiter position (fully open).
2) For auto air flow control, the air flow is set to M4.
3) For AUTO blow mode control, the blow mode is set to FOOT.
Abnormality Detection and Control after Abnormality Detected
1. Summary explanation
If there is an abnormality in a motor actuator drive line or sensor computer input circuit, the abnormality is detected
and control after detection is performed as described below.
In all cases, abnormality control does not end once abnormality has been detected and the location is returned
to normal.
Trouble control is only ended when the vehicle main key power supply is switched OFF or when air conditioner
operation is stopped with the ON/OFF switch on the operation panel.
However, motor actuator restriction is only ended by switching OFF the main key power supply.
2. Trouble in a motor actuator and its input/output circuits
1) Disconnection detection
After the main key power supply is switched ON, if a motor actuator potentio-meter line is disconnected or
shorted, the display in the table below for that motor actuator is carried out and that motor actuator is not
driven until the main key power supply is switched OFF, then ON again.

Abnormality location Abnormality display

HL. E is displayed on the set temperature display LCD.
Air mix motor actuator
See the diagram below.
Blow mode motor actuator The passenger icon display flashes.
Refresh/recirculate switch motor actuator The refresh/recirculate mark flashes.

84512399 EN - September 2011

2) Motor lock detection

If the output shaft rotation angle of a motor actuator does not reach the target value within 15 sec., locking
is detected, output to that motor is stopped, and the abnormality is displayed on the computer according to
the abnormality location.

Abnormality location Abnormality display

3. Trouble in a sensor or its input/output circuits (disconnection or short)

1) Disconnection or short in the inside air sensor or its input/output circuits
1) Operator compartment temperature control end
• The operator compartment temperature control (all control related to target blow temperature) is
stopped and the air mix degree of opening is directly adjusted according to the temperature adjust-
ment switch input.
• Accompanying this, the operation panel set temperature display changes as in the diagram below.

* is a value between 0 - 9, and each time the DOWN switch is closed, this value decreases by 1; each
time the UP switch is closed, this value increases by 1.

* value Motor actuator degree of opening (°)

0 0°
1-8 * value × 10°
9 90°

2) Auto air flow control end

• The air flow is temporarily fixed at the setting that was in effect when the inside air sensor abnor-
mality was detected.
• The AUTO display is set flashing.
• After this, the air flow is switched by the manual air flow switch.
3) AUTO blow mode control end
• The blow mode is temporarily fixed at the setting that was in effect when the inside air sensor ab-
normality was detected.
• The AUTO display is set flashing.
• After this, the blow mode is switched by the manual blow mode switch.
4) Air mix damper degree of opening display priority
• Even if the trouble shown by one of the items below occurs during inside air sensor trouble, E is not
displayed in the * section below the decimal point and the air mix damper degree of opening display
is given priority.
• HL. E is only displayed for air mix motor actuator trouble.
84512399 EN - September 2011
9006-22
Copyright ©
Air Conditioner Overall Diagram

5) Thermo operation control mode fixed

• Switching of the control mode according to the blow mode and target blow temperature is stopped
and the control mode is fixed at control mode 1.
2) Disconnection or short in evaporator sensor or its input/output circuits
1) Compressor control is not executed and the compressor clutch is always OFF.
2) E is displayed in the first fraction position of the set temperature display LCD.
See the diagram below. (The temperature setting is in 1 °C steps.)
However, E is not displayed for inside air sensor trouble.
3) The AC mark flashes.
Disconnection or short in evaporator sensor or its input/output circuits

*1 The AC mark flashes

*2 E is not displayed

3) Disconnection or short in solar radiation sensor or its input/output circuits

1) The solar radiation compensation data is set to 0.
2) E is not displayed in the first fraction position of the set temperature display LCD as it is for other
sensors.
4) Coolant temperature signal trouble
Cold blast prevention control does not work and normal control is used.
4. CAN communication abnormality processing
1) Recovery from bus off
1) Initial retry processing: 5 msec.
2) Re-retry processing: every 1 sec.
Bus off retry processing is performed at the above rate.
2) Receiving data abnormality
1) Definition: The data field is outside the prescribed range regardless of whether the receiving data is
operating normally or abnormally.
2) Processing: In the case of the former, all data that time are discarded and the previous data are
retained.
In the case of the latter, data is discarded only for those items determined to be abnormal.
3) Communication interruption abnormality
1) Interruption judgment
Monitor Display: When normal reception is not possible 1 sec. or more since the previous normal
reception
Engine: When normal reception is not possible 10 sec. or more since the previous normal reception
2) Internal use data: Shift to alternate data (processing)
3) Sending process: Continue
4) Recover: As soon as valid data is received
4) Alternate data (processing)
＜Sending mode: ENGINE ECU＞
84512399 EN - September 2011
9006-23
Copyright ©
Air Conditioner Overall Diagram

1) Outside air data abnormality

Perform estimated outside air control.
* However, once there is a shift to estimated outside air, estimated outside air control continues until
the ignition is switched OFF.
2) Coolant temperature data abnormality
Control the internal coolant temperature data to 45 °C (the temperature at which to avoid cold air
prevention control).
＜Sending mode: MONITOR DISPLAY ECU＞
1) Open window signal data abnormality
Perform control with the internal open window data closed.
2) Open door signal data abnormality
Perform control with the internal open door data closed.
5) Alternate data (processing) up to initial normal reception
＜Send node: ENGINE ECU＞
1) Outside air data abnormality
Within 5 sec. after ignition is turned on: No data
After 5 sec. after ignition is turned on: Perform estimated outside air control.
2) Coolant temperature data abnormality
Within 5 sec. after ignition is turned on: Perform control at 30 °C (the temperature at which to control
cold air prevention)
After 5 sec. after ignition is turned on: Perform control at 45 °C (the temperature at which to avoid
cold air prevention control)
＜Send node: MONITOR DISPLAY ECU)＞
1) Open window signal data abnormality
Perform control with the internal open window data closed.
2) Open door signal data abnormality
Perform control with the internal open door data closed.

84512399 EN - September 2011

Monitor Mode
1. Summary explanation
Monitor mode is a mode for understanding abnormalities in the operation panel itself or in other control.
The system goes into monitor mode when there is the special switch input below on the operation panel.
2. Starting monitor mode
When the air conditioner is operating with basic control, if the operation panel ON/OFF switch closed path con-
tinues for 1 sec. while the refresh/recirculate select switch closed path is ongoing, monitor mode is started.
3. Monitor contents
1) LCD segment diagnosis
When monitor mode is entered, the target LCD lights up for 1 sec.
An LCD with trouble does not light up.
2) Sensor diagnosis
The detection value (AD value or °C) for each sensor is displayed.
3) Coolant temperature signal recognition value
This displays the reception status for the coolant temperature signal sent from the vehicle.
4. Display contents in monitor mode
In monitor mode, the data (detection value for each sensor, coolant temperature signal recognition, etc.) is dis-
played in the 3-digit of the 7-segment display for the temperature setting.
The data displayed is selected with the blower UP/DOWN switches and AUTO switch.
The blower UP/DOWN switches move the display on the dedicated monitor mode 7-segment display through 16
displays, 0 - F, and the corresponding data is displayed.(Table A)
Hexadecimal data display and decimal data display can be selected with the AUTO switch. Only for the coolant
temperature signal recognition value, the value detected immediately before entry into monitor mode is displayed.
The difference between hexadecimal data and decimal data is indicated by the 3rd-digit of the 7-segment display
for the temperature setting. For hexadecimal data, "H" is displayed there and for decimal data, numbers (0 - 9)
are displayed there.
1) Hexadecimal display
AD values 00H - FFH are displayed.
When the AD value corresponds to that in Table B (or Table C for the solar radiation sensor), this indicates
a disconnection or short.
In the hexadecimal display, when the value of a sensor changes in monitor mode, the hexadecimal display
changes with it.

If the display before entering monitor mode was , the error judgment value is displayed. (In
other words, the detected value before the abnormality was detected) In the same way, if the display be-

fore entering monitor mode was , the display becomes **.E and the error judgment value is
displayed.
2) Decimal display
Decimal display is used from -99.9 °C to 99.9 °C.
Also, the "-" minus display is displayed on the left side of the 3 digit segment.
5. Air conditioner operation in monitor mode
When the system enters monitor mode, all output (operation) through control is stopped and until monitor mode
is ended, operations and settings of basic control through all the switches are not possible.
6. Ending monitor mode
In monitor mode, if the operation panel ON/OFF switch closed path continues for 1 sec. while the refresh/recir-
culate select switch closed path is ongoing, monitor mode is ended and the system returns to the basic control
state.
The same also occurs if the vehicle main key power supply is switched OFF.

Exclusively for monitor

mode Display contents
7 seg
0 Inside air sensor temperature data
1 Evaporator sensor temperature data
2 Solar radiation compensation data
3 Outside air data
4 -

84512399 EN - September 2011

Exclusively for monitor

mode Display contents
7 seg
Coolant temperature signal status data
30°C or higher
C Abnormal Lower than 30°C 45°C or higher
Lower than 45°C
4 1 2 3
5-F Data (sensor diagnosis etc.)

Sensor Discon-
Short
name nection
Inside air
F6H 0CH
sensor
Evaporator
F6H 0CH
sensor

Sensor
5 V short Ground short
name
Solar radia-
D5H 0CH
tion sensor

84512399 EN - September 2011

Door Switch Control

1. Summary explanation
This control adds a restriction to air conditioner operation with the door switch or front window switch. Its purpose
is to prevent overheating of the vehicle main unit.
Concretely, it suppresses condenser heating and controls in a way restricted in order to obtain a feeling of comfort.
2. Door switch/front window switch signal
Due to data sent from CAN communication.
Message ID: 0x18FF1028
Sending mode: Monitor Display
Send cycle: 10 ms
Data: Open door signal and open window signal data
Data judgment: Set with continuous 5 times of the same data for 20 ms cycle sampling
3. Control restricted by door switch/front window switch
1) Starting restricted control
When either the door or front window is open continuously for 1 sec. or longer, it is recognized that the
switch is open.
At the count of 60 sec., the buzzer buzzes the same way as for switch input to tell the operator that restricted
control is starting and that control starts.
2) Restricted control
1) For both auto and manual blow mode control
Regardless of being selected in either auto or manual blow mode, unless the blow mode is FACE, the
following air flow restriction is executed. (If the blow mode is FACE, the air flow is not restricted.)
Ⅰ. If the target blow temperature ＜ 20 °C, the air flow upper limit is set to M1.
Ⅱ. If the target blow temperature 25 °C, the air flow restriction in I is ended.
2) When the current blow mode control is AUTO
Auto control with the AUTO blow mode VENT changed to FACE is used.
3) When the current blow mode control is manual selection
Only if the blow mode is VENT immediately after the open switch is recognized, that mode is changed
to FACE.
After this, all the blow modes can be selected with manual operation.
3) Ending the restriction
When both the door and front window are closed continuously for 1 sec. or longer, it is recognized that the
switches are closed.
After a count of 1 sec., the buzzer buzzes the same way as for switch input to tell the operator that restricted
control has been ended.
When the restricted control is ended, the restriction on the air flow discussed in 1. above and the change
from VENT to FACE in 3. are ended and control returns to normal.
However, if the blow mode has been manually selected, even if the mode was changed from VENT to FACE
by the above restriction, it does not return to VENT when the restricted control is ended.

84512399 EN - September 2011

Inside Air Filter Clogging Detection Control

1. Summary explanation
This control recognizes the blower current with the dedicated shunt resistor voltage input, judges from that value
whether or not the A/C unit inside air filter is clogged and if it judges that that filter is clogged, it issues a warning
to encourage the operator to replace the filter.
2. Filter detection control
1) Starting detection control (detection timing)
5 sec. after the end of initial operation, if the air conditioner is operating and the cold blast prevention con-
ditions are not present, this control is started. Also, this control is executed every 50 hours of air conditioner
(blower) operation. However, during a temporary filter clog or filter clog, it is executed every time.
2) Detection method
Cooling / heating is judged from the operation mode and in this way the air mix motor actuator target position
is determined. Also, the mode motor actuator target value is set to FOOT, the blower air flow target value
is set to M1, and output is made to attain the target values. When all the target values are attained, the
blower current from the shunt resistor voltage is recognized, and the filter clog is judged by comparing this
current with the default current value.

(cooling / heating judgment)

When the operation mode is FACE or VENT, : Cooling (COOLMAX)
When FOOT or DEF : Heating (HOTMAX)
When B/L: Final inside air temperature If < 22 ºC, heating
When B/L: Final inside air temperature If ≥ 22 ºC, cooling
(detection current threshold)
Relative to the default current value For cooling : 0.35 - 0.39 A min.

For heating : 0.48 - 0.54 A min.

If the value is below this three times in a row, it is judged that there is a clog.
(default current value)
Current found in the initialization operation described below.

3) Clog warning
(buzzer)
The buzzer buzzes intermittently at 1 Hz for 10 sec.
(display)
"FIL" is displayed on the 7-segment display for the set temperature for 10 sec. Other marks go out.
However, if there is any switch input, the "FIL" display is ended immediately.
4) Alarm reset
If a reset detection value is recognized during the clog state, the clog state is reset.
The reset detection value is 50 % of the clog detection threshold.
5) ON/OFF switching
This function is switched ON/OFF by pressing the [Refresh / Recirculate], [MODE], and [DEF] switches
at the same time. The factory setting for this function is OFF. This function does not come ON until the
initialization operation discussed below is executed.
(buzzer)
When operation of this switch is recognized, there is the normal switch input sound.
(display)
ON or OFF is displayed on the set temperature 7-segment display, whichever is the state after switching.
Other marks go out.
6) Initialization operation
When the [Refresh / Recirculate] and [DEF] switches are pressed at the same time, the default current
value is detected and all the data for filter detection is initialized. Before executing this operation, make
sure that the air conditioner unit (with a new inside air filter installed), ducts, and grilles (with all grilles fully
open) are all installed in their normal states on the vehicle. If initialization is carried out in any other state,
there is a danger of the clog detection judgment control making an incorrect judgment. Immediately after
replacing the inside air filter with a new one, execute the initialization operation.
(buzzer)
When operation of the switch is recognized, the buzzer buzzes with the normal switch input sound. When
the detection ends, the buzzer buzzes for 3 sec.
7) Detection processing avoidance
84512399 EN - September 2011
9006-28
Copyright ©
Air Conditioner Overall Diagram

• When the inside / outside air damper is not at the recirculate position immediately before the current value
is read
• When the power supply voltage is not in the tolerance range for the voltage during the initialization oper-
ation
• Trouble in any of the motor actuators

84512399 EN - September 2011

Actuator Inspection
Air Mix Motor Actuator Inspection
• Structural diagram

Air mix damper operation defect

↓
See the chart.
↓
Specifying the trouble location

1 Control panel 3 Connector 1

2 Air mix motor actuator 4 Connector 9

• Chart

Standard
Step Action Yes No
value
Press the temperature setting
switches and set to COOLMAX
1 (18.0 °C). Go to Step 2 Go to Step 3
Does the actuator operate at
all?
2 Is an error displayed? Go to Step 6 Damper lock or link defect
Press the temperature setting
switches and set to HOTMAX
3 (32.0 °C). Go to Step 2 Go to Step 4
Does the actuator operate at
all?
4 Is an error displayed? Go to Step 5 Control panel defect
Is there continuity in harness
Actuator defect or damper
5 between the actuator and con- Harness defect
lock or link defect
trol panel?
Remove the actuator connec-
tor (9).
About 4.7
6 Is the resistance between L/Y Go to Step 7 Actuator defect
KΩ
and B/L of the actuator about
4.7 KΩ?
Is there continuity between the
7 G/L and L/Y and between G/L Control panel defect Actuator defect
and B/L of the actuator?

Set temperature Air mix motor actuator position

COOLMAX (18 °C) 0°
HOTMAX (32 °C) 90°

84512399 EN - September 2011

Refresh/Recirculate Switch Motor Actuator Inspection

• Structural diagram

Inside/outside air mix damper op-

eration defect
↓
See the chart.
↓
Specifying the trouble location

1 Control panel 3 Connector 1

2 Refresh/recirculate motor actuator 4 Connector 11

• Chart

Standard
Step Action Yes No
value
Press the refresh/recirculate
1 switch. Does the actuator operate Go to Step 2 Go to Step 3
at all?
2 Is an error displayed? Go to Step 5 Damper lock or link defect
3 Is an error displayed? Go to Step 4 Control panel defect
Is there continuity in harness be-
Actuator defect or damper
4 tween the actuator and control Harness defect
lock or link defect
panel?
Remove the actuator connector
(11). About 4.7
5 Go to Step 6 Actuator defect
Is the resistance between L/Y and KΩ
B/L of the actuator about 4.7 KΩ?
Is there continuity between the L/G
6 and L/Y and between L/G and B/L Control panel defect Actuator defect
of the actuator?

84512399 EN - September 2011

Mode Motor Actuator Inspection

• Structural diagram

Mode damper operation defect

↓
See the chart.
↓
Specifying the trouble location

1 Control panel 3 Connector 1

2 Mode motor actuator 4 Connector 10

• Chart

Standard
Step Action Yes No
value
Press the mode select switch.
1 Go to Step 4 Go to Step 2
Does the actuator operate at all?
2 Is an error displayed? Go to Step 3 Control panel defect
Is there continuity in harness be-
Actuator defect or damper
3 tween the actuator and control Harness defect
lock or link defect
panel?
4 Is an error displayed? Go to Step 5 Damper lock or link defect
Remove the actuator connector
(10). About 4.7
5 Go to Step 6 Actuator defect
Is the resistance between L/Y and KΩ
B/L of the actuator about 4.7 KΩ?
Is there continuity between the Y/L
6 and L/Y and between Y/L and B/L Control panel defect Actuator defect
of the actuator?

Blow mode MODE 1 MODE 2 MODE 3 MODE 4 MODE 5

Blow mode motor actuator degree of open-
90° 67° 48° 26° 0°
ing
FACE VENT B/L FOOT DEF

Panel display

84512399 EN - September 2011

Self-diagnosis Function with Panel Display

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

a This segment is displayed only in the monitor mode

below.
b Error is displayed on the 3-digit 7-segment display.

84512399 EN - September 2011

Explanation of Abnormality Display

Motor Actuator Abnormality
1. HL. E displayed on 3-digit 7-segment display.

Check the air mix damper motor actuator for a harness disconnection or disconnected
connector.
This is also displayed when locked due to air mix motor actuator abnormality and link
abnormality.

flashes.

Check the blow mode damper motor actuator for a harness disconnection or discon-
nected connector.

flashes.

Check the refresh/recirculate damper motor actuator for a harness disconnection or

disconnected connector.

CAUTION
The above display and flashing is displayed on the 3-digit 7-segment display when trouble occurs with
the panel ON/OFF switch ON status.
After trouble occurs, when the panel ON/OFF switch is switched ON, the function is displayed.
After trouble is resolved, the abnormality display and flashing are not ended until the main switch is
switched OFF → ON.

Monitor Mode Display Operating Method

1 Refresh/recirculate select switch

2 Blower switch UP/DOWN switch
3 ON/OFF switch

1. Hold down the refresh/recirculate select switch and the ON/OFF switch at the same time for 1 sec. or longer.
2. Press the AUTO switch.
(All the 7 segments light up for 1 sec., then the system enters monitor mode.)
3. Numbers 0 - 9 or letters A - F are displayed in the 2nd and 3rd digit of the 3-digit 7-segment display.
"H" is displayed in the 1st-digit.
4. The display of 0 - 2 on the dedicated 7-segment display is carried out with the blower UP/DOWN switches. The
necessary sensor is selected from the table below.

7-segment display table dedicated to monitor

0 Inside air sensor
1 Evaporator sensor
2 Solar radiation sensor

(Display other than the above (3 - 9, B - F) is not

used during service.)

5. To end the monitor display, either hold down the refresh/recirculate select switch and the ON/OFF switch at the
same time for 1 sec. again or longer or switch the vehicle main switch OFF.

CAUTION
1. During monitor mode, operations and settings of basic control through all the switches are not pos-
sible until the air conditioner control operation is stopped and monitor mode ended.
2. During monitor mode, even if a sensor is repaired, the abnormality display is recorded in memory,
and until the ON/OFF switch is switched OFF, then ON again, the abnormality display is not ended.

84512399 EN - September 2011

Display Contents in Monitor Mode

See the dedicated monitor 7-segment display table and 3-digit 7-segment table.
1. Display example 1

The dedicated monitor 7-segment display is 0 (indicates the inside air sensor
state).
From the 3-digit 7-segment table 3F → The sensor is normal.
→ The inside air sensor is normal.

2. Display example 2

The dedicated monitor 7-segment display is 1 (indicates the evaporator sensor

state).
From the 3-digit 7-segment table 0C → The sensor is disconnected.
→ The evaporator sensor is disconnected.

3. Display example 3

The dedicated monitor 7-segment display is 2 (indicates the solar radiation sen-
sor state).
From the 3-digit 7-segment table D5 → The sensor is shorted on the 5 V side.
→ The solar radiation sensor is shorted.

3-digit 7-segment table

84512399 EN - September 2011

a Solar radiation sensor short g Solar radiation sensor 5 V side

2nd-digit of 7-segment display d
OCH2 display short D5H2 display
Inside air sensor disconnection e Inside air sensor short F6H0
b 3rd-digit of 7-segment display h
OCH0 display display
c Evaporator sensor disconnec- Evaporator sensor short F6H1
f Sensors normal i
tion OCH1 display display

Air conditioner troubleshooting

The blow temperature does not go down.
* M/A means motor actuator.

Standard
Step Action Yes No
value
• The air mix motor actuator
connector is disconnected
or has a contact defect.
When the AUTO switch or AC • Air mix motor actuator de-
switch is pressed, HL. E is dis- fect
1 Go to Step 2
played in the panel set temper- • Main harness continuity
ature display section. defect
Inspect and repair or re-
place part.
HL. * is displayed on the panel
set temperature display sec-
2 Go to Step 3 Go to Step 4
tion.
* is No. 0 to 9.

84512399 EN - September 2011

Standard
Step Action Yes No
value
• Inside air sensor or har-
ness disconnection or
• Inside air sensor and short
evaporator sensor simul-
The inside air sensor con-
taneous disconnection or •
nector is disconnected or
3 The panel snow mark flashes. short
has a contact defect.
• Computer breakdown
See the Monitor Mode sec-
See the Monitor Mode sec-
tion too.
tion too.
Inspect and repair or re-
place part.
• The evaporator sensor
connector is disconnected
or there is a contact de-
fect.
• Evaporator sensor simul-
4 The panel snow mark flashes. taneous disconnection or Go to Step 5
short
See the Monitor Mode sec-
tion too.
Inspect and repair or re-
place part.
When the set temperature is
18.0 and the blow mode is set
5 18.0 ﾟC Go to Step 6 Go to Step 7
to vent mode, the blow temper-
ature drops.
Inspect the duct or eliminate Computer breakdown or in-
Cool air is flowing into the in-
6 the cause of the cool air inside air sensor defect
side air sensor section.
filtration. Inspect and replace.
Switch compressor clutch
ON/OFF and inspect and
The air mix damper is at the repair the power supply cir-
7 Go to Step 8
COOLMAX position. cuit.
See the cooling cycle trou-
bleshooting.
If motor actuator operation
• Inspect, repair, or replace
stops midway, remove the
Motor actuator breakdown the motor actuator lever
cause or correct the problem, 1.5 kgf or link section.
8 or computer breakdown
and then measure the operat- less
Replacement • Clean the lever link sec-
ing force. tion, then apply grease.
Is it 1.5 kgf or less?

The blow temperature does not go up.

84512399 EN - September 2011

Standard
Step Action Yes No
value
• The air mix motor actuator
connector is disconnected
or has a contact defect.
HL. E is displayed on the panel • Air mix motor actuator de-
1 set temperature display sec- fect Go to Step 2
tion. • Main harness continuity
defect
Inspect and repair or re-
place part.
• Inside air sensor or har-
ness disconnection or
short
HL. * is displayed on the panel • The inside air sensor con-
set temperature display sec- nector is disconnected or
2 has a contact defect. Go to Step 3
tion.
* is No. 0 to 9. See the Monitor Mode sec-
tion too.
Inspect and repair or re-
place part.
When the set temperature is
32.0 and the blow mode is set
3 32.0 ﾟC Go to Step 4 Go to Step 5
to foot mode, the blow temper-
ature rises.
Inspect the duct or eliminate Computer breakdown or in-
Warm air is flowing into the in-
4 the cause of the warm air side air sensor defect
side air sensor section.
infiltration. Inspect and replace.
The air mix damper is at the Inspect the warm coolant
5 Go to Step 6
HOTMAX position. lines.
If motor actuator operation
• Inspect motor actuator
stops midway, remove the
Motor actuator breakdown lever link section.
cause or correct the problem, 1.5 kgf or Repair or replace.
6 or controller breakdown
and then measure the operat- less
Replacement • Clean the lever link sec-
ing force. tion, then apply grease.
Is it 1.5 kgf or less?

The blower motor does not rotate.

Standard
Step Action Yes No
value
With the flow set to HI, battery
voltage is applied to the termi-
1 Replace the blower motor. Go to Step 2
nals (+ and -) of the blower mo-
tor. (Note: 1)
The battery voltage is applied
between the blower motor (+)
2 Go to Step 3 Go to Step 5
power supply red/blue and the
body.
Voltage of about 10 V is ap-
3 plied between the blower amp About 10 V Go to Step 4 Replace computer.
brown/yellow line and ground.
Remove the blower amp and
refer to the section on Blower
Eliminate the cause of the
Amp Inspection. Is there any Inspect and repair the wire
4 trouble, then replace the
abnormality? harness.
blower amp.
No abnormality → Yes
Abnormality → No
Inspect the blower motor relay.
When the blower motor relay
Inspect, repair, or replace
5 white/red and blue/red are di- Go to Step 6
the wire harness.
rectly connected, the blower
motor rotates. (Note: 2)
84512399 EN - September 2011
9006-41
Copyright ©
Air Conditioner Overall Diagram

Standard
Step Action Yes No
value
The battery voltage is applied
Inspect, repair, or replace
6 between the blower motor relay Go to Step 7
the wire harness.
white/red and the body.
When the blower motor re-
Inspect or repair the wire
lay purple/white is dropped to
7 harness or replace the com- Replace the relay.
ground, the blower motor ro-
puter.
tates.

NOTE:
1. Measure with the connector connected.
2. For the sake of safety, have the air conditioner, vehicle key, and light switches all OFF when working with direct
connections in place.
The blower motor speed does not change.
Part 1

Step Action Yes No

• Inside air sensor or harness
disconnection or short
• The inside air sensor connec-
HL. * is displayed on the panel set tor is disconnected or has a
contact defect. Replace the blower amp or
1 temperature display section.
computer.
* is No. 0 to 9. See the Monitor Mode section
too.
Inspect and repair or replace
part.

Part 2

Step Action Yes No

Does the blower motor fail to change
1 speed when the mode is other than Go to Step 2 See Part 1.
FACE?
While operating under restric-
2 Is the door or front window open? tive control by door switch or See Part 1.
front window switch.

The magnetic clutch does not engage.

Step Action Yes No

The snow mark flashes and E is
When the AUTO switch or AC switch
1 Go to Step 2 displayed on the panel display
is pressed, the snow mark lights up.
section.
Clutch defect. Replace the
2 Voltage is applied to the clutch. Go to Step 3
compressor.
Pressure switch defect or
coolant pressure abnormally
Voltage is applied between the har-
3 high or low Go to Step 4
ness and pressure switch.
See the cooling cycle trou-
bleshooting.
Voltage is applied between the vehicle
4 side harness connector blue/red and Go to Step 5 Inspect the clutch fuse.
ground (black).
Is there trouble in the air conditioner
5 Replace computer. Replace the harness.
harness?

Refresh/recirculate mode does not switch

Step Action Yes No

The refresh/recirculate motor
actuator connector is discon-
The refresh/recirculate mode display
nected, there is a contact de-
1 on the operation panel LCD display Go to Step 2
fect, or there is trouble with the
section is flashing.
motor actuator or the main har-
ness.
There is foreign matter on the refresh/
recirculate motor actuator lever sec- Remove the foreign matter or
2 Replace the motor actuator.
tion or the motor actuator lever sec- replace the part.
tion is broken.

The mode is not switched.

4-pole relays are used for the blower OFF relay and compressor relay.
Blower OFF relay
This relay receives the signal from the control amp and switches the blower OFF relay ON.
When the blower OFF relay is switched ON, the power supply voltage is fed to the blower motor via the blower amp
and the blower motor is started.
Compressor relay
The compressor relay is switched ON/OFF by the control amp compressor control.
Relay inspection contents
1. Relay
2. Coil resistor: 320Ω
3. Specification voltage: DC 20 - 30 V
4. Be careful. The coil side of this relay must be installed with the poles facing correctly.
5. Inspection: Inspect for continuity between 3 and 4 under the conditions below.

20 - 30 V applied between term8inals 1 and 2 : Continuity

No voltage applied between terminals 1 and 2 : No continuity

84512399 EN - September 2011

Air Mix Actuator

CAUTION
The air conditioning system voltage specifications are 24 V, but the motor actuator has 12 V specifica-
tions.

The air mix actuator is installed at the center of the air conditioner unit contained behind the link cover. It opens and
closes the air mix damper via the link.
Built into the air mix actuator is the potentio-meter which switches linked with the actuator shaft.
When the target air mix door position is determined by the temperature control switch, the control unit reads in the
potentio-meter position in the actuator and determines whether the motor turns forward or reverse.
The contacts move linked with the motor. When the contacts move open or the control unit output signal goes OFF,
the motor stops.

Control panel Motor actuator

1 M/A 1 3 GND 5 5 VDC

2 M/A 2 4 Potentio-meter

Terminal
Direction of rotation 1 2
Clockwise (forward) + -
Counter-clockwise (reverse) - +

84512399 EN - September 2011

Refresh/Recirculate Actuator

CAUTION
The air conditioning system voltage specifications are 24 V, but the motor actuator has 12 V specifica-
tions.

The refresh/recirculate switch actuator is installed on the blower intake unit. It opens and closes the refresh/recirculate
door via the link.
Built into the refresh/recirculate switch actuator is the potentio-meter that switches linked with the actuator shaft.
When the refresh/recirculate door position is determined by the refresh/recirculate switch on the control panel, the
control unit reads in the signal of the potentio-meter in the actuator and determines whether the motor turns forward
or reverse.
The position detection switch also rotates linked with the motor and stops the refresh/recirculate door at the set po-
sition.

84512399 EN - September 2011

Blow Mode Actuator

CAUTION
The air conditioning system voltage specifications are 24 V, but the motor actuator has 12 V specifica-
tions.

The blow mode actuator is installed at the center of the air conditioner unit contained behind the link cover. It opens
and closes the mode door via the link.
Built into the blow mode actuator is the potentio-meter which switches linked with the actuator shaft.
When blow mode is determined by the temperature control switch, the control unit reads in the potentio-meter position
in the actuator and determines whether the motor turns forward or in reverse.
The contacts move linked with the motor. When the contacts move open or the control unit output signal goes OFF,
the motor stops.

84512399 EN - September 2011

Evaporator Sensor
In order to prevent the evaporator from freezing, the evaporator blow temperature is detected and the compressor
ON/OFF is controlled.

• Evaporator sensor inspection method (specifications value)

Disconnect the evaporator sensor from the main harness and measure the resistance between the sensor side
connector terminals using the tester.

Resistance between When the sensor section detection temperature is 0 °C : 7.2 kΩ

terminals When the sensor section detection temperature is 25 °C : 2.2 kΩ

84512399 EN - September 2011

Dual Pressure Switch

• The dual pressure switch is installed on the receiver dryer.

When there is pressure trouble in the coolant high-pressure side line (abnormally high pressure or abnormally low
pressure), the dual pressure switch contacts open up to cut off the compressor power and protect the cooling cycle.

Dual pressure switch specifications

1 (Low-pressure side)
2 (High-pressure side)

Replacement of Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Replacement of Blower Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal of Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal of Heat Case Right/Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Replacement of Evaporator and Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation of Evaporator Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Replacement of Motor Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

CAUTION 2. Remove the filter cover (1) and inside air filter (2).
• Remove the 4 Phillips screws (3) and remove the
• Be sure to stop the engine before beginning intake case (4).
work.
Screw size
Phillips screws (3): M5 x 16 (T1)
CAUTION
• When replacing the evaporator, re-supply
and check the compressor oil quantity.

Removal of Blower Unit

1. Remove the connectors connected to the refresh/
recirculate motor actuator connector (1), blower mo-
tor connector (2), inside air sensor connector (3),
evaporator sensor connector (4) and relay connec-
tor (5).

84512399 EN - September 2011

Replacement of Blower Motor Replacement of Blower Amp

CAUTION CAUTION
Do not remove the fan from the blower motor. Never disassemble the blower amp.
Removing with the power on can suddenly in-
1. Remove the cooling hose (2) from the air condi- crease the blower amp temperature, damaging
tioner unit (1). the part.
Also, touching the surface could cause burns.
• Remove the 3 Phillips screws (3) and remove the
blower motor (4). 1. Remove the connector (1) from the blower amp (2).
Screw size
Phillips screws (3): M5 x 14 • Remove the 2 Phillips screws (3) and remove the
blower amp (2).
• The installation procedure is the reverse of the Screw size
removal procedure. Phillips screws (3): M4 x 16
• The installation procedure is the reverse of the
removal procedure.

Removal of Heater Core

CAUTION
Remove while being careful not to apply exces-
sive force to the pipe.

1. Drain the coolant.

• Remove the 4 Phillips screws (1) and remove the
link cover (2).
Screw size
Phillips screws (1): M5 x 16
• Remove the mode actuator connector (3), and re-
move the heater core (4).
• The installation procedure is the reverse of the
removal procedure.

84512399 EN - September 2011

Removal of Heat Case Right/Left Replacement of Evaporator and

CAUTION Expansion Valve
At this time, perform work with the heater core CAUTION
removed from the heater case.
The evaporator sensor cord is sandwiched in Be careful of the O-rings getting caught, etc.
the groove of the HVAC unit, so carefully check when installing the expansion valve.
it and remove it while making sure not to dam- The evaporator sensor cord is sandwiched in
age it. the groove of the HVAC unit, so carefully check
it and remove it while making sure not to dam-
age it.
1. Remove the 10 Phillips screws (1) and remove the
heater case right (2) and heater case left (3).
Screw size 1. Turn the HVAC unit upside down and place it on a
Phillips screws (1): M4 x 16 stand.
• Remove the 4 Phillips screws (1) and remove the
drain case (2).
• Remove the 1 Phillips screw (1) and remove the
evaporator pipe stay (3).
• Remove the evaporator sensor connector (4), and
remove the evaporator (5).

2. Use a hexagon wrench (4 mm) to remove the 2

hexagon socket head bolts (1), and then remove the
expansion valve (2).
• Install O-rings (3) on the new evaporator (4) (1 NF
O-ring 5/8 and 1 NF O-ring 1/2).
Bolt (1) tightening torque: 6.9 N·m

84512399 EN - September 2011

Installation of Evaporator Sensor Make sure to install the harness holder (1) and thermis-
tor holder (2) in the original position of the evaporator (4)
CAUTION as shown in the diagram.

Be careful that the sensor cord does not get • Install the evaporator sensor (3) end and thermistor
squeezed in the case when the case is assem- holder (2) as shown in the diagram.
bled.

a Thermistor holder position Replacement of Motor Actuator

b 20 mm
c 73 mm 1. Replacement of mode motor actuator
d 9th row Remove the link cover.
e 27th row Remove the connector (2) from the motor actuator
(1).
Remove the 3 Phillips screws (3) securing the mo-
tor actuator (1), remove the rod (4) attached to the
motor actuator (1) from the rod hole on the mode
cam, and then install the new motor actuator (1).
The installation procedure is the reverse of the re-
moval procedure.

Screw size
Phillips screws (3): M4 x 16 (T1)

84512399 EN - September 2011

2. Replacement of air mix motor actuator 3. Replacement of refresh/recirculate motor actuator

Remove the link cover. Remove the link cover.
Remove the connector (2) from the motor actuator Remove the connector (2) from the motor actuator
(1). (1).
Remove the 3 Phillips screws (3) securing the mo- Remove the 3 Phillips screws (3) securing the motor
tor actuator (1), remove the rod (4) attached to the actuator (1), remove the lever pin (4) attached to
motor actuator (1) from the rod hole on the damper the motor actuator (1) from the slot hole, and then
lever, and then install the new motor actuator (1). install the new motor actuator (1). The installation
The installation procedure is the reverse of the re- procedure is the reverse of the removal procedure.
moval procedure. Screw size
Screw size Phillips screws (3): M4 x 16 (T1)
Phillips screws (3): M4 x 16 (T1)

84512399 EN - September 2011

Section

9009

Removal and Installation of Compressor

84512399 EN - September 2011

CONTENTS

Removal of Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Job code 50200AA26 • Always remove the low-pressure side line (2) first.
• Attach caps or plugs to the compressor and lines
to prevent any entry of water, dust or dirt.
WARNING Tightening torque for bolt installation: 19.6 - 24.5
N·m
• Be careful when loosening the lines. The air
conditioner circuit is filled with high-pressure
gas, so there is the danger of gas splaying
out.

CAUTION
• Be sure to stop the engine before beginning
work.
• When removing and installing the compres-
sor, check the compressor oil quantity.

Items to prepare
• Wrench (13 mm)
• Box wrench (13 mm)
• Rag 3. Use a wrench (13 mm) to remove the 4 bolts (1),
• Cleaning fluid and then remove the compressor (2).
Tightening torque for bolt installation: 19.6 - 29.4
Removal of Compressor N·m

1. Remove the connector (1).

2. Use a box wrench (13 mm) to loosen the bolts (1)

on the lines in the 2 locations, and then remove the
2 lines (2) (3).

84512399 EN - September 2011

Installation of Compressor 2. Check the compressor oil quantity.

The compressor contains 135 cc of oil.
1. To install, perform the reverse of the removal pro- The oil quantity being low will cause compressor
cedure. seizing and a reduction in durability. The oil quantity
When installing the bolts, tighten them to the spec- being high will cause a reduction in cooling capabil-
ified torque. ities.
Make sure to check the oil quantity and adjust if
needed.
Measure the oil quantity of the removed compres-
sor. Only this oil quantity is necessary, so subtract
this quantity from 135 cc to determine the amount by
which the oil quantity of the new compressor should
be reduced.
Example)
If the remaining oil quantity of the removed com-
pressor is 30 cc:
Remove 135 cc - 30 cc = 105 cc from the new com-
pressor to be installed.
Resupply oil: SP-10 or SP-20 (P.A.G. oil)
3. Perform air conditioner gas charging.
For details, see "Gas Filling Procedures".

84512399 EN - September 2011

Section

9010

Removal and Installation of Condenser

84512399 EN - September 2011

CONTENTS

Removal of Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Job code 50200AK72 mm) to loosen and remove the sleeve nut of the
high-pressure side line (2).
CAUTION • Attach caps or plugs to the condenser and line to
prevent any entry of water, dust or dirt.
• Be careful when loosening the lines. The air • Clean the lines by spraying with a parts cleaner to
conditioner circuit is filled with high-pressure prevent scratches and prevent dirt from accumu-
gas, so there is the danger of gas splaying lating on the connectors.
out. Tightening torque for line (1) installation: 19.6 -
24.5 N·m
CAUTION
• Be sure to stop the engine before beginning
work.

CAUTION
• When removing and installing the condenser,
resupply and check the compressor oil quan-
tity.

Items to prepare
• Wrenches (10 mm, 13 mm, 19 mm)
• Cap
• Plug
3. Use a wrench (13 mm) to remove the 4 bolts (1),
• Rag
and then remove the condenser (2).
• Cleaning fluid
• Bolt (1) tightening torque: 17.7 - 21.6 N·m
Removal of Condenser
1. Use a wrench (17 mm) to press the lower line on
the condenser side (1), and then use a wrench (19
mm) to loosen and remove the sleeve nut of the
low-pressure side line (2).
• Always remove the low-pressure side line first.
• Attach caps or plugs to the condenser and line to
prevent any entry of water, dust or dirt.
• Clean the lines by spraying with a parts cleaner to
prevent scratches and prevent dirt from accumu-
lating on the connectors.
Tightening torque for line (1) installation: 11.8 -
14.7 N·m

2. Use a wrench (22 mm) to press the upper line on

the condenser side (1), and then use a wrench (24

84512399 EN - September 2011

Installation of condenser 2. Make sure to resupply and check the compressor

oil quantity.
1. To install, perform the reverse of the removal pro- The compressor contains 135 cc of oil.
cedure. The oil quantity being low will cause compressor
Tighten lines and bolts to the specified torque. seizing and a reduction in durability. The oil quantity
For bolts for which the torque is not specified, check being high will cause a reduction in cooling capabil-
"Bolt Size and Torque Table" in the explanation in ities.
the materials. Make sure to check the oil quantity and adjust if
needed.
Resupply quantity: 40 cc
Resupply oil: SP-10 or SP-20 (P.A.G. oil)
3. Perform air conditioner gas charging.
For details, see "Procedures for Gas Filling".

84512399 EN - September 2011

Section

9011

Removal and Installation of Receiver Dryer

84512399 EN - September 2011

CONTENTS

Removal of Receiver Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of receiver dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Job code 50200AN92

WARNING
• Be careful when loosening the lines. The air
conditioner circuit is filled with high-pressure
gas, so there is the danger of gas splaying
out.

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

CAUTION * When connecting the hoses, be sure not to mis-

• When replacing the receiver dryer, resupply take the IN and OUT sides.
and check the compressor oil quantity.

Items to prepare
• Wrenches (10 mm, 19 mm)
• Cap
• Plug
• Rag
• Cleaning fluid

Removal of Receiver Dryer

1. Open the rear left side door.
Remove the connector (1).

IN: Hose from the condenser

*1
outlet (LIQUID1 hose)
OUT: Hose that goes to the
*2 air conditioner unit (LIQUID2
hose)

3. Use a wrench (10 mm) to remove the 2 bolt (1), and

then remove the receiver dryer (2).

2. Use a wrench (10 mm) to remove the 2 bolts (2)

from the line (1).
• Install caps or plugs to the receiver dryer and line
to prevent any entry of water, dust or dirt.
• Clean the receiver dryer and line by spraying them
with a parts cleaner to prevent scratches and pre-
vent dirt from accumulating on the connectors.
• Bolt (2) tightening torque: 7.8 - 11.8 N·m

84512399 EN - September 2011

Installation of receiver dryer 2. Check the compressor oil quantity.

The compressor contains 135 cc of oil.
1. To install, perform the reverse of the removal pro- The oil quantity being low will cause compressor
cedure. seizing and a reduction in durability. The oil quantity
Tighten lines and bolts being installed to the speci- being high will cause a reduction in cooling capabil-
fied torque. ities.
For bolts for which the torque is not specified, check Make sure to check the oil quantity and adjust if
"Bolt Size and Torque Table" in the explanation in needed.
the materials. Resupply quantity: 20 cc
Resupply oil: SP-10 or SP-20 (P.A.G. oil)
3. Perform air conditioner gas charging.
For details, see "Gas Filling Procedures".

84512399 EN - September 2011

Section

9015

Work Precautions

84512399 EN - September 2011

CONTENTS

Work Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Work Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Air Conditioner Refrigerant "Vacuum Operation" and "Gas Filling Operation". . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operation Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Filling Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Charging Hose Connection Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Gauge Manifold Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Vacuuming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Gas Filling Operation, High-pressure Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Gas Filling Operation, Low-pressure Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Work Precautions
WARNING
• Refrigerant gas filling involves handling dangerous high-pressure gas, so make sure that a experi-
enced and qualified worker with the procedure performs this operation.
• Always wear protective eyewear.
• Gas entering the eyes may cause blindness.
• Refrigerant in the liquid state is very cold (about -26 °C), so be very careful during handling.
• Refrigerant coming in contact with skin may cause frostbite.

Always use R134a refrigerant.

• Storage
Keep service cans (hereinafter, cans) with refrigerant in them at 40 °C or below.
The insides of the cans are highly pressurized and filled with refrigerant, so if the temperature rises there is the
danger of internal pressure rising sharply and an explosion occurring.
Never store in direct sunlight, in a closed vehicle, or near open flames.
Be careful not to drop cans or have them collide with other objects.
• Filling operation
When cans are heated in order to fill them with refrigerant, make sure that the service can valve and gauge manifold
low-pressure valve are open and heat with water at 40 °C or below.
Direct heating or heating to 40 °C or higher may cause explosions, so use caution.
If refrigerant filling is done after the engine is started, never open the gauge manifold high-pressure valve.
This is very dangerous, as the high-pressure gas will flow in the opposite direction and may cause a can or charging
hose explosion.
Be careful not to allow the entry of dust or dirt into the air conditioner circuit.
Air, moisture and dirt are very bad for the cooling cycle.
Perform work quickly and accurately, and be especially careful to prevent the entry of foreign matter.
Be careful not to overfill with gas.

84512399 EN - September 2011

Work Procedures
Air Conditioner Refrigerant "Vacuum Operation" and "Gas Filling Operation".
1. The "vacuum operation" consists of eliminating moisture in the air conditioner circuit.
If there is any moisture left inside the air conditioner circuit, various problems may occur during operation such
as freezing in the small hole of the expansion valve causing the circuit to clog and rust developing in the circuit.
For this reason, perform vacuuming before filling the circuit with refrigerant. This operation consists of eliminating
moisture inside the circuit through boiling and evaporation.
2. The "gas filling operation" consists of filling the circuit with refrigerant after the vacuum operation.
Gas filling does not only affect the cooling capabilities of the air conditioner, it also affects the life of the parts
which make up the circuit.
Severely overfilling the circuit will cause pressure inside the circuit to be abnormally high, and this will cause
reductions in the cooling ability of the air conditioner.
Additionally, if pressure is extremely low, the circulation of lubricating oil within the compressor will be poor and
this will cause seizing with sliding parts of the compressor.
Because the gas filling operation itself involves handling high-pressure gas, performing the operation using an
incorrect procedure is very dangerous.
Follow the operation and observe all precautions indicated in this text to correctly perform refrigerant filling.

Operation Chart
Vacuuming start 30 min. or longer (750 mmHg or less)
↓
Vacuuming stop Let sit for 5 min.
Vacuuming
↓
operation
Gauge display abnormality (connectors check and
Airtightness check
repair)
↓
Fill with refrigerant gas up to a gauge pressure of
Refrigerant filling
0.098 MPa.
Refrigerant fill- ↓
ing operation Gas leak check
↓
Refrigerant filling

84512399 EN - September 2011

Tools
No. Part name Q'ty Shape Application

1 Gauge manifold 1

Red: high-pressure
side
Blue: low-pressure
2 Charging hose 3
side
Yellow: vacuum
pump side

3 Quick joint 1

4 Quick joint 1 Low-pressure side

5 T joint 1 For service can valve

6 Service can valve 2 For service can

Vacuum pump
7 1 For vacuum pump
adapter

84512399 EN - September 2011

Filling Procedures
CAUTION
• Because gauge manifold specifications such as hose color are different depending on the manufac-
turer, read the operator's manual for the gauge manifold to be used for details.

Charging Hose Connection Positions

High-pressure side (DIS) ser-

1 3 Air conditioner compressor 5 Receiver dryer
vice valve
Low-pressure side (SUC) ser-
2 4 Condenser 6 Air conditioner unit
vice valve

Gauge Manifold Connection

1. Close the high-pressure valve (HI) (12) and low-pressure valve (LO) (11) of the gauge manifold (13).
2. Connect the charging hoses (red and blue) to the service valve.
Red hose (14): Gauge manifold high-pressure side (HI) → compressor high-pressure side (DIS) service valve (1)
Blue hose (15): Gauge manifold low-pressure side (LO) → compressor low-pressure side (SUC) service valve
(2)
Push in the connections for the high-pressure and low-pressure sides until a "click" is heard to make sure they
are secure and in the correct position.
3. Connect the charging hose (yellow) (7) to the vacuum pump (8).

84512399 EN - September 2011

9 Low-pressure gauge
10 High-pressure gauge

84512399 EN - September 2011

Vacuuming
1. Open the high-pressure valve (HI) (12) and low-pressure valve (LO) (11) of the gauge manifold (13).
2. Turn the vacuum pump (8) switch on and vacuum for at least 30 min.
3. After the prescribed vacuuming time has elapsed (degree of vacuuming achieved: -750 mmHg or less), close
the gauge manifold (13) high-pressure valve (12) and low-pressure valve (11).
4. Next, turn the vacuum pump (8) switch off.
5. Perform a check of air-tightness.
Let the gauge manifold (13) sit for at least 5 min. with the high-pressure valve (12) and low-pressure valve (11)
closed, and check that the gauge indicator does not go back to 0.
If the gauge indicator starts to swing back to 0, this indicates there is a leak. Tighten the line connections, perform
vacuuming again, and check to see if there is still a leak.

84512399 EN - September 2011

Gas Filling Operation, High-pressure Side

First, prepare the regulation amount of refrigerant, then start the filling operation from the high-pressure side.
1. After repeating vacuuming, switch the charging hose (yellow) (7) of the gauge manifold (13) from the vacuum
pump to the service can (16).
2. Air purging
Open the valve for the service can (17). (However, keep the gauge manifold high-pressure and low-pressure
valves closed.)
Next, press the air purge valve (18) of the side service port on the gauge manifold low-pressure side with a
screwdriver to discharge the air inside the charging hose using the refrigerant pressure. (Complete after the
swooshing sound stops.)
3. Open the high-pressure valve (12) of the gauge manifold (13), and fill with coolant. (Fill with refrigerant gas up
to a gauge pressure of 0.098 MPa.)
After filling, close the gauge manifold high-pressure valve and valve for the service can (17).
Never operate the compressor. (This is very dangerous, as the refrigerant will flow in the opposite direction and
may cause a service can or hose explosion.)
4. Gas leak check
Check for gas leaks in the cycle using the gas leak tester.
If there are leaks, eliminate them through tightening.
Always use the tester for R134a.

84512399 EN - September 2011

Gas Filling Operation, Low-pressure Side

CAUTION
• Never open the gauge manifold high-pressure valve.
• Never tip over the service can. This may cause damage to the compressor.

After finishing the high-pressure side filling operation, perform the operation for the low-pressure side.
1. Check that the high-pressure valve (12) and low-pressure valve (11) of the gauge manifold (13) and the valve for
the service can (17) are closed.
2. Start the engine, increase speed to 1400 - 1600 min-1, and completely open the cab door and window.
3. Turn the air conditioner switch on, move the fan switch to the maximum position, and move the temperature
adjustment switch to the maximum cooling position.
4. During filling, set the degree of discharge for the compressor at 1.37 - 1.57 MPa.
5. Open the low-pressure valve (11) of the gauge manifold (13) and valve for the service can (17), and fill with the
regulation amount of refrigerant until the air bubbles in the receiver sight glass (19) are gone.

• Judging the amount of refrigerant from the receiver dryer sight glass
After the AC is turned ON, a few air
When the amount is bubbles are visible. The glass then be-
correct comes transparent and turns to a pale,
milky-white color.

When overfilling oc- After the AC is turned ON, no air bubbles

curred at all are visible.

When filling was in- After the AC is turned ON, air bubbles are
sufficient seen continuously.

(Total gas filling amount: 950 - 1050 g)

6. After refrigerant filling is complete, close the low-pressure valve (11) of the gauge manifold (13) and the valve for
the service can (17), and stop the engine.
84512399 EN - September 2011
9015-10
Copyright ©
Work Precautions

• If the air conditioner is operated with very little refrigerant (R134a), this will have a damaging effect on the
compressor.
• If the air conditioner is filled with too much refrigerant (overcharge), this will actually cause insufficient cooling
and there is the danger of pressure in the circuit becoming abnormally high.
Be sure to use an appropriate amount of refrigerant.
• Never open the gauge manifold high-pressure valve (12).
• Never invert the service can. (Gas is suctioned in liquid form, so this may cause damage to the compressor
valve.)
7. After refrigerant filling and inspection, remove the gauge manifold and hoses.
Quickly remove the low-pressure side charge hose (blue) (15) from the low-pressure side (SUC) service valve.
Do not do anything on the high-pressure side until the high-pressure gauge indicator falls to 0.98 MPa or below.
After confirming that the indicator has fallen below this point, quickly remove the high-pressure side charge hose
(red) (14) from the high-pressure side (DIS) service valve.

84512399 EN - September 2011

A= MAIN RELIEF (STANDARD) - 31.4 MPa / 314 bar / 4556 psi 1 HYDRAULIC RESERVOIR
A= MAIN RELIEF (BOOST) - 34.3 MPa / 343 bar / 4977 psi 2 BREATHER

* B= BOOM RAISING PORT SECONDARY RELIEF - 36.3 MPa / 363 bar / 5267 psi 4 BY-PASS VALVE

65 B1/B2 = RELIEF ON BOOM HBCV - 37.0 MPa / 370 bar / 5369 psi
5
6
SCREEN FILTER
RETURN FILTER
39.2 MPa
30 L/min 30 * 21 D MA MB D 21 26 25
C=
D=
BOOM LOWERING PORT SECONDARY RELIEF
DIPPER OUT PORT SECONDARY RELIEF
- 24.5 MPa / 245 bar / 3556 psi
- 36.3 MPa / 363 bar / 5267 psi
9
10
HYDRAULIC PUMP (OPTIONAL)
MAIN HYDRAULIC PUMP
φ3.0 D1 = RELIEF ON DIPPER HBCV - 39.2 MPa / 392 bar / 5688 psi 15 MAIN CONTROL VALVE
43
D9 LEFT J I D1 P2 37.0 MPa B45 37.0 MPa E= DIPPER IN PORT SECONDARY RELIEF - 36.3 MPa / 363 bar / 5267 psi
16 HYDRAULIC SWIVEL
P T A MU B RIGHT 23 23 30 L / min 30 L/min
F= BUCKET OPEN PORT SECONDARY RELIEF - 36.3 MPa / 363 bar / 5267 psi
21 TRAVEL MOTOR

Y18 *
22 SWING MOTOR
T1
35.8～37.8MPa 35.8～37.8MPa B1 C2 C2
B2 G= BUCKET CLOSE PORT SECONDARY RELIEF - 36.3 MPa / 363 bar / 5267 psi 23 TRAVEL MOTOR BRAKE
VA VB at 50 L ／min E E H= PILOT PRESSURE RELIEF - 3.92 MPa / 39.2 bar / 569 psi 24 SWING REDUCTION GEARS
at 50 L ／min

REG

REG
A 25 RIGHT BOOM CYLINDER
GA 29.3MPa
GB I= RIGHT-HAND SWING PORT SECONDARY RELIEF - 29.3 MPa / 293 bar / 4251 psi
26 LEFT BOOM CYLINDER
at 100 L/min T2 Pi VB VA J= LEFT-HAND SWING PORT SECONDARY RELIEF - 29.3 MPa / 293 bar / 4251 psi 27 DIPPER CYLINDER
K2 K1/K2 = TRAVEL REVERSE PORT SECONDARY RELIEF - ------ MPa / ----- bar / ------ psi 28 BUCKET CYLINDER

22 K1 L1/L2 = TRAVEL FORWARD PORT SECONDARY RELIEF - ------ MPa / ----- bar / ------ psi 29 BOOM SAFETY VALVE
30 DIPPER SAFETY VALVE
Dr
106 P1 N1/N2 = NEGATIVE CONTROL RELIEF - 2.55 MPa / 25.5 bar / 370 psi
31 DIPPER LOAD HOLDING VALVE
O/P = SECONDARY RELIEF (2eme OPTION) - 22.6 MPa / 226 bar / 3279 psi
27 107 107 29 Pi1 Pi1
Q= RELIEF VALVE BLOCK COUNTERWEIGHT - 27.4 MPa / 274 bar / 3976 psi
32
33
BOOM LOAD HOLDING VALVE
COUNTERWEIGHT DIPPER CYLINDER
T T
28 R= MAIN RELIEF (2eme OPTION) - 20.6 MPa / 206 bar / 2989psi 34 COUNTERWEIGHT CYLINDER
42 OIL COOLER
W1/W2 CRUSHER OPTION PORT SECONDARY RELIEF - ------ MPa / ----- bar / ------ psi
250.0 cm 3／rev P MB MA P 43 RETURN MANIFOLD
D C V2 V2 W4 = BREAKER OPTION SECONDARY RELIEF VALVE - ------ MPa / ----- bar / ------ psi
B A 44 OIL COOLER BY-PASS VALVE
Au L1 Pi Dr
16 L2 Z= MAIN RELIEF VALVE FAN - 24.5 MPa / 245 bar / 3555 psi 45 NON-RETURN CHECK VALVE
BACKWARD L.H BACKWARD R.H 51 ACCUMULATOR
FORWARD L.H 133 FORWARD R.H 53 BOOM & BUCKET CONTROL LEVER
C1 54 SWING & DIPPER CONTROL LEVER
29
P
24
42
* 72 55
57
TRAVEL CONTROL PEDAL
BOOM & DIPPER CONTROL SHOCK ABSORBER
58 PILOT AND RETURN SYSTEM MANIFOLD
OPTION
59 FILTER

FOR CTWT FOR ARM(CTWT) BREAKER 60 PILOT SYSTEM MANIFOLD

ON 65 CALIBRATED ORIFICE
i＝27.143 33 φ100-φ55-200 33 34 φ190-φ95-385 71 SECOND OPTION CONTROL VALVE
MIN.L 600 MIN.L 915
Z=92 0.18 MPa
26.10 psi 44 45 72 CONTROL PEDAL (OPTIONAL)
53 73 SECOND OPTION CONTROL VALVE
Z=16 1.8 bar
4 76 HAMMER/CRUSHER SELECTOR
15 B43 0.5 MPa
162 82 PILOT CIRCUIT FILTER
72.5 psi A 83 SHUT-OFF VALVE (OPTIONAL)
15
pa9
15
pb8
15
pb3
164 5 bar
84 160 C2 C1 84 T- SHUTTLE BLOCK (OPTIONAL)
ps1 T6 T3 T1 pc5 T2 T4 T5 ps2

71 * SECOND OPTION
A B C
A1
132
B P T A
71
85
86
PILOT FILTER
PILOT FILTER BY-PASS VALVE
T
A2 90 HYDRAULIC BREAKER VERSION, PLUG
Y61 Y60 Y59 43 DR1′
85 106 ANTI PENDULUM VALVE
D6 3.38MPa 3.38MPa
at 61 L/min
N2 171 15 Y67 107 TWO STAGE TRAVEL VALVE
at 61 L/min B1
DR1 31 pa10 Y15 Y14 Y13 Y12 15 pa4 108 STRAIGHT TRAVEL VALVE
pb4 110 ARM REGENERATION VALVE
T pc1 N1 D SOL.A A B SOL.B SOL.A A B SOL.B ON 1.2 MPa

* B28 174.0 psi A1 120 HYDRAULIC PUMP FOR COOLING HYDRAULIC CIRCUIT
STD 12 bar 121 COOLING HYDRAULIC MOTOR

C1 C2
P1 P2 P3
B5 OUT
43 42 71 OFF 0.8 MPa
116.0 psi Y68 B2 132 HAMMER/CRUSHER 2 SOLENOID VALVE BANK
W1 W2 B9
D8 P 8 bar 133 5 SOLENOID VALVE BANK
85
*B94 * 132
B P T A 57 A5 P T P T
* 85 ON 1.2 MPa 134 2 SOLENOID VALVE BANK (SECOND OPTION)
174.0 psi
N 133 IN OUT IN ARM(2) A2
84 156 MANIFOLD
12 bar P ARM(1) 172 171
OFF 0.8 MPa
B83 57 pb5 A9
T
157 BREAKER OPTION PORT SECONDARY RELIEF
73 116.0 psi D 172 Q 58 158 SHUT-OFF VALVE (OPTIONAL)
Pa1 8 bar T 159 2 SOLENOID VALVE BANK (OPTION 1)
36.3MPa
73 110 at 20 L/min IN OUT
43
D1
27.5MPa 160 2 SOLENOID VALVE BANK
57 83 at 45 L ／min SINGLE ACTING CIRCUIT
Pb1 73 73 OPTION < KNOB SWITCH TYPE > 161 2 SOLENOID VALVE BANK (OPTION 1)
E 58
* 85
B FOR MULTI-PURPOSE+3WAY VALVE MULTI-PURPOSE + 3WAY VALVE
Pb1 Pa1 pb9 57 P1 162 1 SOLENOID VALVE BANK
FOR DOUBLE ACTING CIRCUIT
* 134 A2 A1 pa5
V B T 133 15
pb4
15
pa4
84 * 160
163
164
STRAIGHT LINE TRAVEL PEDAL
BOOM / ARM / BUCKET PRESS. PROPORTIONAL SOLENOID VALVE
2-STAGE TRAVEL LEVER LOCK 166 SHUTTLE VALVE BLOCK
pc4 164
156 83
57
S F G pa9
A
16 C1
Y4 Y2 A2 A1 A2 A1 171 DOUBLE ACTING SOLENOID VALVE
B4 BREAKER ON Pi
CLOSE B8
* 85
172 RELIEF VALVE
71
76 A4 B22 SWING PILOT PRESSURE SWITCH
P 83
3 OPTION BREAKER OPEN CLOSE OPEN A8 BUCKET B26 UPPER PILOT PRESSURE SENSOR
G
pb8 164 P 164 B27 TRAVEL PILOT PRESSURE SENSOR
P pb4
161 159 72 B P3 G G B28 SECOND OPTION PILOT CIRCUIT 1 PRESSURE SWITCH
pa8 2-STAGE RELIEF
Y25 Y26 A2 A2 B 57
15 C3 Y77 P P B40 PUMP PRESSURE SENSOR (NEGA-CONT.2)
T
pa4
36.3MPa
at 20 L/min
P
PH
Y5 CTWT REMOVAL B42 PUMP PRESSURE SENSOR (P1)
SECOND OPTION 161 159 72
Y23 Y24 Y27 Y9 B43 PUMP PRESSURE SENSOR (NEGA-CONT.1)
A1 A1 A DR2′ T T
72 90 C4 OPTION
B44 PUMP PRESSURE SENSOR (P2) (BLUE BAND)
DR2
B84
* 159
B45 OVERLOAD INDICATOR PRESSURE SWITCH
T A3 B C 32 B83 PRESS. SENSOR (PILOT ARM CLOSE)
pc2
BOOM(2) 36.3MPa 24.5MPa B84 PRESS. SENSOR (PILOT BUCKET CLOSE)
B3 C5 71 163
UP at 20 L/min at 20 L/min C2 SWING BRAKE B85 PRESS. SENSOR (PILOT BOOM UP)
134 164 UP A7
Y3 T P

G C pb3 BOOM(1) B94 PRESS.SWITCH (1ST OPTION)

S71 PRESSURE SWITCH FILTER INDICATOR (BREAKER OPTION)
DOWN B7 Y2 PILOT PRESSURE SOLENOID VALVE (BLUE BAND)
UP DOWN Y3 SWING BRAKE SOLENOID VALVE (WHITE BAND)
72 OPTION (NA) < KNOB SWITCH TYPE > DOUBLE ACTING CIRCUIT (NA)
P pb7 Y4 2 STAGE TRAVEL SOLENOID VALVE (RED BAND)
57 pa3 15 15
F B85 pb4 pa4
Y5
Y7
POWER-UP SOLENOID VALVE (YELLOW BAND)
MAIN PUMP POWER PROPORTIONAL SOLENOID
B2 LEFT
RIGHT
pa7
FORWARD B6 * 161
A2 A1 * 162 Y9
Y11
OPTION 2 SPEED SOLENOID VALVE (BLUE TAPE)
MAIN PUMP FLOW PROPORTIONAL SOLENOID
57
* 85
132 A2 RIGHT LEFT
SWING BACKWARD FORWARD BACKWARD A6 H Y12 COUNTERWEIGHT RAISING SOLENOID VALVE
T
57 pb2 φ2.5 TRAVEL(R)
163 158 Y13 COUNTERWEIGHT LOWERING SOLENOID VALVE
55 L pb6 166
158 T
A
Y14 COUNTERWEIGHT ARM RAISING SOLENOID VALVE
TRAVEL(L) TRAVEL(R) S1 84 Y15 COUNTERWEIGHT ARM LOWERING SOLENOID VALVE
57 pa2
φ2.5
73 G
P Y18 FREE SWING SOLENOID VALVE (NA)
BACKWARD

BACKWARD
FORWARD

FORWARD

J pa6 B1 P
166 Y23 OPT.1 KNOB (R) -R SOLENOID VALVE (BLUE TAPE)
1 PEDAL TRAVEL TRAVEL(L) B1 FORWARD S3
P i2 73 Y23 Y24 Y24 OPT.1 KNOB (R) -L SOLENOID VALVE (RED TAPE)
FORWARD BACKWARD A1 BACKWARD STRAIGHT A1
T Y9 Y25 OPT.2 KNOB (L) -R SOLENOID VALVE (BLUE TAPE)
BACKWARD OPTION Y26 OPT.2 KNOB (L) -L SOLENOID VALVE (RED TAPE)
pb1 FORWARD TRAVEL Y27 OPTION SELECT SOLENOID VALVE (RED TAPE)
166 45 71 163
T2 T P Y31 COOLING HYDRAULIC MOTOR SOLENOID VALVE
S2
166 pa1 156 Y32 PROPORTIONAL SOLENOID FOR COOLING HYDRAULIC MOTOR
S4 108 LOW FLOW CIRCUIT
157 Y59 BOOM DOWN PROPORTIONAL SOLENOID VALVE (NO TAPE)
pr1 A B44 Y60 ARM CLOSE PROPORTIONAL SOLENOID VALVE (RED TAPE)
15 Y61 BUCKET CLOSE PROPORTIONAL SOLENOID VALVE (BLUE TAPE)
C2 C1 P T B4
Y67 OPTION SELECT SOLENOID VALVE (BLUE TAPE)
1 P T 2 1 2 3 4 31.4MPa at 340 L ／min 15 Y68 OPTION 2 SPEED SOLENOID VALVE (RED TAPE)
83
*
34.3MPa at 315 L ／min B4 Y77 COUNTERWEIGHT REMOVAL SOLENOID VALVE (GREEN TAPE)
pr2
B42 83
P1 PT PP PA PH P3
15 W4
P2 A4
ON 1.2 MPa OFF 0.8 MPa
B27 ON 2.0 MPa OFF 1.4 MPa B26 174.0 psi 116.0 psi
15
A4 SINGLE ACTING CIRCUIT 157 83
290.1 psi 203.0 psi 12 bar 8 bar DOUBLE ACTING CIRCUIT (NA)
A4 B2 A3 A2 B1 A1
20 bar 14 bar W4 15
B4

85 83 LEGEND
P1 PUMP
133 51 GAS PRESSURE
C3
166
S4 S3 S2 S1 1.5MPa 60 15 3 2
15 15 15 15 CAPACITY A4 P2 PUMP
pa1 pa6 pb1 pb6 P3 320cm3 84 1 MULTI-PURPOSE + 3WAY VALVE
β75 ≧17
82
121
P0 P T PILOT SYSTEM PUMP
76
0.02 MPa A1 P sv a 4 A2
P4 P5 T4 T5 159 161
0.29 psi
0.2 bar 83 RETURN TO RESERVOIR
T T 10
159 160 162
Y7 171 42
G P P 0.15 MPa
21.75 psi P S71 LEAK-OFF RETURN
1.5 bar
P3 P2 P1 T3 T2 T1 (FRONT) a1 a2 (REAR)
58 P1 P2 Y11 29 171
ON 0.1MPa
14.5 psi
133 T T 1 bar SUPPLY CIRCUIT
B
158 158 Pi1 a7 a8 OFF 0.08MPa 2
54 86 11.6 psi
0.8 bar
85 10μ PILOT SYSTEM CIRCUIT
73 Y31 42
85 53 57 59 15 15 164 15
B1 A1 Pi2
31μ
15 15
pa2 pb2 P2 pa8 121 COMPONENT BOUNDARY
P T P T 15 15 15 OPEN
pa3 pb7 CLOSE
pa5 pb5 pc4 121 0.004 MPa
T T1 0.58 psi 0.07 MPa
RIGHT LEFT Tc 1 bar 10.15 psi
IN OUT UP DOWN HOSE
FAN D1 0.7 bar
B D R F H J S L N U P O 24.5MPa
23.5MPa
at 100 L/min B40 D2
T
at 10 L/min 40 cm 3
P1 40cm 3 ／rev 182cm 3／rev 182cm3／rev D3
／rev A3 0.127 MPa
PIPING CONNECTION
15cm ／rev
3
D6 10 18.42 psi

ARM SWING BOOM BUCKET

P Z M PILOT 3.92MPa a3
D7
1.27 bar

IN OUT LEFT RIGHT DOWN UP OPEN CLOSE P ISUZU PUMP 568.4 psi D8 150MESH 5 PIPING CROSS-OVER
6UZ1X 39.2 bar D9
2 4 3 1 2 4 3 1
270kW B1 B3 Dr3
at2000min 28 COMPONENT ITEM NO.
－1

A C V T E G I Q K M O
Tc
120 Dr
20.6MPa 33.3cm 3
／rev 133
85 85 15 R at 65 L/min A4 H T
15 pb9 6 4 COMPONENT NUMBER
pc5 1 15 43
Y32 DR1' 1 58
Pa1 P T Pb1 71 134 B4 9
ON 0.5 MPa B A2 P5
72.5 psi 71 134 CONNECTION ITEM NO.

*
5 bar A A1
OFF 0.3 MPa 15 Y18
43.5 psi
3 bar pa10 T -- OPTIONAL ITEM NO.
B22 STD

CX470C EXCAVATOR - HYDRAULIC SCHEMATIC

BOX FUSE(ATTACHMENT FOR CAB MAIN HARNESS)

8R 105 8R 105 2 8R 105
5RW 103 5RW 103 1 5RW 103
F34 F41 F42 F43 F45

3R 105d

3R 105b
3R 105e

3R 105c

3R 105a
180,215,242,250,260,267
400,410,411,412,413,414,415,416,419,420,430,444,445,446,450,490,492,532,534,535,538,559,660,800,801,802,803,805,0806,807,812,813,818,900,901,902,903,904,905,906,907,908,909,910,911

5RW 020
DIESEL ENGINE

(CN.A50
YAZAKI
1
2
FUSIBLE LINK FUSE FUSIBLE LINK FUSIBLE LINK
(F20)

(F17)

(F16)

(F15)

(F14)

(F13)

(F12)

(F10)

58L
(F19)

(F18)

(F11)
10 9 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 BACK UP CONT FUSE BOX SAFTY RL

(F4)
(F9)

(F8)

(F7)

(F6)

(F5)

(F3)

(F2)

(F1)
20 19 18 17 16 15 14 13 12 11 20 19 18 17 16 15 14 13 12 11 ALTERNATOR

15A

10A

20A

15A
50A 15A 65A 60A
10A

15A

10A

15A

10A

15A

15A
1 1 1 1 8B 797 E 24V 50A

CIGAR LIGHTER 10A

SUMITOMO SUMITOMO 2
(CN.A41) (CN.A42) 2 2 2 YAZAKI M6
YAZAKI YAZAKI YAZAKI

WIPER / WASHER
BLOWER MOTOR
YAZAKI M8 (CN.D15)

TRAVEL ALARM

(BOOM,HOUSE)
1 2 3 1 2 3 1 2 3

COMPRESSOR
REFUEL PUMP

2
1

1
2
58L 58L 58L

CONTROLLER

CONTROLLER
1.25BG 600 8 2BG 600 CN-A

2
1
AIRCON UNIT

LEVER LOCK
CONVERTOR

KEY SWITCH
4 5 6 4 5 6 4 5 6 (CN.D23) (CN.D26) (CN.D25) (CN.D24) IC

SOLENOID
1.25B 700 2B 700 YAZAKI

SEAT SUS
7

BACK UP
REGULATOR

BEACON

12
13
14
15
16
17
18
19
20

12
13
14
15
16
17
18
19
20
11

11
AIRCON

AIRCON
OPTION

ENGINE

1
2
3
4
5
6
7
8
9

1
2
3
4
5
6

6
5
4
3
2
1

1
2
3
4
5
6
YAZAKI YAZAKI YAZAKI (CN.D16)
SPARE

SPARE

(GATE)
DC/DC

HORN
6

LAMP

LAMP
(CAB)

5RW 103
5RW 102

8R 105
8R 104

5R 002
5R 003
M M M

GPS

1.25W 107
1.25W 106
(CN.A38) (CN.A39) (CN.A40) 5

PG 41b

PG 41d

PG 41g
PG 41h

BG 630
BG 637
BG 640
G2

PG 41a

PG 41c

PG 41e
P 40b

P 40d

P 40g
P 40h
P 40a

P 40c

P 40e

RL 160
RL 161
RL 162
RL 163
RL 164

PG 41f

PG 41i
PG 41j
P 40f

P 40i
P 40j

1.25W 109
1.25W 108
1.25W 107
1.25Y 870 1.25Y 870

1.25WR 141
1.25WR 142
1.25WR 145
1.25WR 146
1.25WR 147
1.25WR 148

1.25W 112

1.25W 110
1.25G 510 0.75R R

1.25W 111
0.85G 502
0.85G 503
0.85G 504
0.85G 505
0.85G 506

1.25BG 600
1.25BG 601
1.25BG 602
0.85BG 603
1.25BG 609
1.25BG 610
0.85BG 620

1.25B 700
0.85B 701
0.85B 702
1.25B 703
0.85B 704
0.85B 720
4 1
WB 245
WL 260

2W 250

GR 180
LgW 190
VR 230

RL 160
0.85GW 215
WL 267 WL 267

1.25WR 235

1.25RW 140
1.25W 205

0.85VW 170
1.25Br 515 0.75L L

0.85OR 225

1.25LW 200

0.85R 130
3 2

1.25RB 150
0.85YR 220
0.85LR 240

1.25GrR 195
0.85BrR 210
WL 266
WL 267

0.85GW 216
0.85GW 215 2 0.85GW 215

0.85YR 221

0.85LR 242

(CN.D14)
SWP
YAZAKI
B 749 2W 250 1 2W 250

1 2
0.85B 708
RL 166 0.85G 507 K7

(CN.D17)

(CN.D19)

(CN.D18)
1 2 3 4
5 6 7 8

YAZAKI

YAZAKI
0.5μF

(CN.A51)
8R 030 B

YAZAKI
108,109,110 YAZAKI M6

58M
G1 RELAY BATTERY
(CN.D13)
A1 601,602,603,701,702,703
STARTER MOTOR
CONTROLLER A 503,504,505,515,520,521,530,536,537,539,558,804,808,809
K63 (CN.A09) K64 (CN.A13) K65 (CN.A11) K66 (CN.A12) K67 (CN.A10) (CN.A14) K68 (CN.A15) K34 60R 100 60R 101 60R 001 B
M
RELAY RELAY RELAY RELAY RELAY RELAY RELAY
M8 M8 YAZAKI M10
M1

10 11 12 13 14 15 16 17 18 19 20
6 7 8 9
Y1
POWER 24V 1.25W 108 V 097 (CN.D21) 5Y 004 S

0.85BG 660
1 1
ECM KEY ON BATTERY RL IDLE STOP DPF NEUTRAL START STARTER CUT M10 M10 M10 M10
12 1.25W 108a VG 098 2 M4 YAZAKI YAZAKI M5

7 8 9 10 11 12 13 14
4 5 6

(CN.D11)
58Y
YAZAKI
- + - +
(CN.D12)

(CN.C21)
SDL
YAZAKI
POWER 24V 11 G 099 3 (CN.D20)

6 5 4 3
2

1
24V 5.0kw
VR 595 M4

(CN.C3)
YAZAKI
22 4

(CN.A44)
P1

60B 799
YAZAKI

2
1
SDL
GND_2 2 1.25BG 601 Br 596 5 5L 021 1 5BW

1.25WR 511
1.25G 501
1 2 3 4 5

SDL
GLOW PLUG

1 2 3

B
13 1.25BG 601a BG 612 6 1 4 2 1

YR 882a
LR 881a
GND_3 0.85B 701 MONITOR DISPLAY 12V 12V

14 13 12 11
(CN.D9)
SWP
YAZAKI
5 5

7 6 5 4
R1
YAZAKI

10 9 8

3 2 1
1
16 0.85B 701a 3 M8 CN-A
GND BZ. BATT. 0.85RL 161 0.85RL 161 0.85RL 161 RL 161 SUMITOMO (CN.D22)
9 1 1 1
VGS TURBO

3
1
2
5
4

3
1
2
5
4
20 IGN 2 1.25W 111 2 1.25W 111 1.25W 111 2 1.25W 111 1.25W 107 1 1.25W 107 0.85B 751
GND_A 10 D-IN8 ALTERNATOR 4 0.85BrW 519 4 0.85BrW 519 0.85BrW 519 3 0.85BrW 519 0.85G 501 2 1.25G 501 0.75GR 389 1 0.75GR 5
U
P4 M

0.85GW 303
P 040b P 040b 0.85LR 881 LR 881 0.85WR 511 1.25WR 511 0.75Y 390 0.75YR

1.25WR 141

1.25WR 146
1.25WR 147

1.25WR 145
1.25RW 140

0.85W 112
0.85W 113

0.85W 114
0.85W 115
0.85WR 511
CAN H

0.85G 501

0.85O 804

0.85GR 845
0.85B 704

0.85B 705

0.85B 706
21 5 5 4 3 2 6

0.85YR 370

0.85LR 890

0.85LR 891

0.85LR 890

0.85Y 011

0.85LR 373
0.85YL 808
0.85LgR 500

0.85LY 824

0.85GrR 012
0.85BrR 010
SOL SWING BRAKE 6 W 800 H1 CAN L 6 PG 041b 6 PG 041b 0.85YR 882 5 YR 882 0.85Br 515 4 1.25Br 515 0.75WR 391 3 0.75LR 7
V
W
SOL 2 STAGE TRAVEL 4 L 801 CAN GND 18 18 V 809 6 V 809 0.85GrR 012 5 0.85GrR 012 0.75R 357 8 0.75R 4 VCC
SOL 2 STAGE RELIEFE 7 Y 802
LCD DISPLAY
TxD (RS232C) 8 WL 061b 8 WL 061b P 040b 7 P 040b 373 0.85RY 840 6 0.85RY 840 K69 0.75W 358 5 LW 1 U M23

(CN.E1)
DL090
SUMITOMO
(CN.D30)
CN-A
YAZAKI

5 6 7 8
1 2 3 4
CPU RELAY GLOW 1 2 RELAY STARTER
Br 803 W 060b W 060b PG 041b PG 041b 303
K2 0.75G 359 Br V
FREE SWING 3 TFT FULL COLOR RxD (RS232C) 9 9 8 7 6 2

508
509
118
10 11 12 13 14 15 16 17 18 19 20
5 6 7 8 9

SUMITOMO

1
RL BATTERY 8 0.85O 804 GND (RS232C) 19 BL 064b 19 BL 064b WL 061b 9 WL 061b 142 8 0.85B 779 MT090 0.75L 360 7 L 3 W

517
519

1
2
SOL OPT 2 SPEED 14 YR 805 5V-OUT PGM_WRITE 3 V 097 3 V 097 W 060b 10 W 060b 140 370 (CN.D82) 1 5R 003 0.75B 361 9 0.75B 8 GND
SOL OPT SELECT 15 LY 806 PGM_WRITE SW 12 VG 098 12 VG 098 BL 064b 11 BL 064b 804,808 301 5RW 020 1 1 5L 021 2 5Y 004 0.75BW 693b 4 0.75BW

(CN.D28)
SWP
YAZAKI
070MIULTI

TRAVEL ALARM 18 WL 807 RESET 7 G 099 7 G 099 WB 949 12 WB 949 500 501 10
(CN.C1)

2 3
4 5 6 7 8

0.85B 776
INTAKE THROTTLE

1 2
0.85GrR 013
AMP

RL DPF 17 0.85YL 808 8V-OUT CAMERA + 10 R 960 10 R 960 BW 950 13 BW 950 112 511 0.75BR 392 12 BL

(CN.A52)
YAZAKI
DC-MOTOR
P10
1 2 3 4

SIG WASHER 19 V 809 CAMERA GND 11 B 961 11 B 961 1.25BG 610 14 1.25BG 610 515 515 0.85G 509 1 0.75GR 393 13 G

(CN.D27)
SDL

1 2
YAZAKI
(CN.D31)
YAZAKI
A/D-IN THERMO SN 010 012 0.85L 372 0.85GrR 012 0.75P 326 VW BL

1
13 13 2 1 11 2

1
M

CN-A

58
SWITCH PANEL
AGND 14 14 840 840 0.85B 750 2 14 G 1

1 2 3 4 5
(CN.E2)
AMP
PUMP POWER (OUT) 3 0.85Y 900 SCL (12C) 16 16 845 6

9 10 11 12 13 14 15 16 17 18
5 6 7 8
S11 M24

(CN.D29)
CN-A
YAZAKI
PUMP POWER (RTN) 6 0.85BY 901 SDA (12C) 17 17 824 L 5 Vcc
WIPER
BOOM DOWN (OUT) 0.85O 902 GND 1.25BG 611 1.25BG 611 VW OUT

2
1
1 15 15 3
S12

(CN.A45)
BOOM DOWN (RTN) 4 0.85BO 903 GND 20 1.25BG 610 20 1.25BG 610 704 508,372 LW 4 GND

YAZAKI

16 15 14 13
12 11 10 9
(CN.D8)
SWP
YAZAKI

8 7 6 5
4 3 2 1
WASHER
P1 FLOW (OUT) 0.85L 904
K36 K35 K5 K3 K11

SDL
2
S10

1 2 3 4

(CN.D38)
MT090
SUMITOMO
P1 FLOW (RTN) 5 0.85BL 905 1.25W 119 1

520
521
RELAY RELAY RELAY RELAY RELAY RELAY RELAY EGR VALVE A

BG 613
BG 614
W.LAMP
K37 K10

1 2
SHLD GND 8 CAMERA 1 SIG 1 Y 962 1 Y 962 1.25G 754 2
S2 SPEAKER: R SPEAKER: L ROOM LAMP BEACON HORN LAMP:CAB LAMP:UPPER

0.85WR 512
W 963 W 963 0.75WR 386 0.75WR

0.85Br 516
7 CAMERA 1 GND 11 11 5 5
U
S-G BOOT_CNT 11 WR 062
TRAVEL MODE
CAMERA 2 SIG 2 YB 967 2 YB 967 0.85BrR 210 1 0.85BrR 210
(CN.A21) (CN.A22) (CN.A20) (CN.A19) (CN.A16) (CN.A18) (CN.A17)
M20 0.75WB 387 6 0.75WB 6 M
FWE 12 WR 063 S4 CAMERA 2 GND 12 WB 968 12 WB 968 0.85YR 220 2 0.85YR 220 M8 FUEL PUMP 0.75WL 388 7 0.75WL 7
V
W
IDLE MODE

0.75RY 890

189,835
LM MAG SW 9 YR 541 CAMERA 3 SIG 3 YR 972 3 YR 972 0.85WR 282 3 0.85WR 282 0.75RG 356 8 0.75LW 8 GND
S86 YAZAKI
M25

(CN.D37)
58W
YAZAKI
1
2
O 542 WR 973 WR 973 0.85WY 829 0.85WV 829 1.25W 118 2BY 0.75GB 353 0.75GB U
M
LM MODE 10 CAMERA 3 GND 13 13 4 (CN.D81) SOLENOID VALVE 1 1 1

(CN.E3)
DL090
SUMITOMO
DPF CLEAN

1 2

5 6 7 8
1 2 3 4
D-IN1 F-WINDOW SW 4 O 590 4 O 590 1.25GR 875 5 1.25GR 875 1.25G 753 2 2B 0.75GW 354 2 0.75GW 2 V
S87 1 4 2 LEVER 24V
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20

(CN.D59)
SWP
YAZAKI
D-IN2 MUTE SW 5 YL 591 5 YL 591 VG 822 6 VG 822 5 0.75RY 890 1 0.75R 0.75GR 355 3 0.75GY 3 W
ATT SELECT (SP)

1 2
TXD 4 PW 055 D-IN3 CAMERA SW 6 V 592 6 V 592 WG 823 7 WG 823 3 0.75B 752 2 0.75B LOCK 0.75RW 352 4 0.75L 4 VCC
RXD 12 PL 056 S88 D-IN4 DOOR SW 7 OL 593 7 OL 593 LY 824 8 0.85LY 824 SUMITOMO (BLUE TAPE) (Y2) 0.75RY 367 13
040MIULTI

EGR

3
1
2
5
4

3
1
2
5
4
MENU 1 2
RS232C_TXD 3 W 060a D-IN5 ONE TIME WIPER 8 YG 594 8 YG 594 LG 825 9 LG 825 0.75BW 368 14
(CN.C2)

S89 SUMITOMO SWING VALVE B

(CN.D60)
SWP
YAZAKI
AMP

RS232C_RXD 10 WL 061a D-IN6 SPARE1 9 VR 595 9 VR 595 OR 826 10 OR 826 0.75R 181 1 0.75R 1.25Y 871 1 1.25Y 871 1 0.85R 0.75L 369 15
MT090 24V (See page 2/2) CRANK ANG (MRE) SENSOR

WG 831

WG 823
G 888

OR 826

LW 841
LgW 190
LgW 191
(S2)

LG 825

LG 832

LG 842

LR 880
RL 164

RL 165
DIAPLAY SEL

1 2
0.85GW 216
0.85GW 217
RS232C_GND BL 064a D-IN7 SPARE2 Br 596 Br 596 G 888 G 888 0.75W 800 0.75B 1.25B 758 1.25B 758 0.85B 0.75BY 366

1.25GR 875

1.25LW 200
1.25LW 201
0.85R 885
2 10 10 11 2 2 2 16

0.85RB 292

0.85RB 293

0.85RB 290
(CN.A30)

0.85Y 980

0.85YB 984

1.25Y 870
0.85LB 985
0.85L 981
BRAKE

1.25GrR 195
1.25GrR 196
GND 5 S90 D-OUT1 WIPER-INT 14 GR 820 14 GR 820 YL 591 12 YL 591 (WHITE TAPE) (Y3) 70W 0.75YB 363 9 1 Vcc

(CN.E5)
YAZAKI
TRIP/CAMERA
B49

1 2 3
GND 13 D-OUT2 WIPER-CNT 15 Lg 821 15 Lg 821 V 592 13 0.75WG 364 10 3 OUT(PULSE)

(CN.D66)
SWP
YAZAKI

(CN.G2)
CN-A
YAZAKI
LR 881
2STAGE LAMP

(CN.D61)
SWP
YAZAKI
P 040c VG 822 VG 822 YG 594 YG 594 GR 180 0.75GR 180 0.75R 182 0.75R
E2 0.75Y 365 GND
CAN_H 6 D-OUT3 RL FUEL PUMP 16 16 14 1 1 11 2

1 2
(S1)

2
1
(BOOM)

1 2
CAN_L 14 PG 041c D-OUT4 RL LAMP 17 WG 823 17 WG 823 0.85YB 984 15 0.85YB 984 833 W 800 2 0.75W 800 0.75L 801 2 0.75B TRAVEL 0.75WB 362 12
+5V_OUT 11 D-OUT5 RL IDLE STOP 18 LY 824 18 LY 824 0.85LB 985 16 0.85LB 985 164,190,195,200,216 L 801 3 0.75L 801 (RED TAPE) (Y4)
FREQUENCY_IN 1 D-OUT6 RL MUTE 19 LG 825 19 LG 825 0.85BY 982 17 0.85BY 982 Y 802 4 0.75Y 802
2STAGE LAMP COMMON RAIL PRESS. SENSOR

(CN.D62)
SWP
YAZAKI
FREQUENCY_GND 9 D-OUT7 RL ROOM LAMP 20 OR 826 20 OR 826 0.85BL 983 18 0.85BL 983 829,834,850,851,852,853,880,882,885,943 Br 803 5 0.85Br 803 0.75R 183 1 0.75R 1.25Y 870 1 0.85R
(S3) 24V (HOUSE)

1 2
AVcc 7 0.85Y 408 11 WB 949 G 812 6 0.75Y 802 2 0.75B RELIEFE 1.25B 757 2 0.85B 1
70W
(Y5)

(CN.E6)
AMP
0.85Lg 813 B52

1 2 3
L 530 BW 950 Lg 813 0.75W 310 VW
SW_1 IDLE SW 15 22 7
E1 1 2

(CN.D65)
CN-A
YAZAKI
(YELLOW TAPE)
VG 531 WL 807 0.85WL 807 0.75R 311 GrB
SW_2 ANTI-THEFT 16
S1 8 6 3

2
1
R3 S51 CTWT

(CN.D63)
SWP
YAZAKI
12 13 14 15 16 17 18 19 20 21 22

SUNLOAD SENSOR
1 2 3 4 5 6 7 8 9 10 11

SW_3 RESERVE TANK 8 GrR 532 VG 822 9 0.85VG 822 0.75R 184 1 0.75R 0.75G 312 15 WB
(S4)
7 8 9 10 11 12 13

1 2
4 5 6

0.85R 130 1 0.85R 130 KEY SWITCH LR 880 10 0.85LR 880 0.75G 835 2 0.75B REMOVAL 0.75B 690b 11 0.75B
1 WB 949 0.85RB 290 2 0.85RB 290
CONNECTION YR 882 11 0.85YR 882 (GREEN TAPE) (Y77) 0.85WL 807 1 B TRAVEL 12
A4 B61 TO CAMERA 3 THROTTLE VOL. LIMIT SWITCH OFF ACC ALARM H2 BOOST PRESS. SENSOR
(CN.C6)

SN HYD.TEMP 2 0.85YB 490 2 BW 950 0.85VW 170 3 0.85VW 170 0.85WV 829 12 0.85WV 829 0.85GW 215 2 R 0.75W 313 5 L
(BLUE TAPE) B G1 G2 ACC M ST
AMP

(GATE) 24V,107dB
(CN.C4)
YAZAKI
1 2 3

0.85GL 492
X28 0.85LgR 500 0.85LgR 500
ON 0.85R 885 0.85R 885 0.75L 314 LW 0.75RW

(CN.D69)
SWP
YAZAKI
SN FUEL LEVEL 15 4 13 10 1
1.0Ⅲ

(CN.E7)
SUMITOMO
HEAT Y18

1 2 3
0.85Y 410 R 970 0.85BrR 010 0.85BrR 010 0.85GW 943 0.85GW 943 0.75G 315 Br 0.75L

1 2
SN_P P1 21 WIPER 1 5 14 SOLENOID VALVE 17 2
ST
B47

R 189
SN_P P2 9 0.85L 411 CONTROLER B 971 2 0.85RY 840 6 0.85RY 840 OFF 0.85LR 242 15 0.75BW 691b 14 0.75BW 0.75RL 3
(CN.C5)

(CN.C20)
1 2

FREE

(CN.D64)
SWP
YAZAKI
1 2
3 4
0.85Lg 412 YR 972 0.85GR 845 0.85GR 845 0.75R 187 0.75R 2W 250

YAZAKI
SN_P N1 22 3 7
ACC 16 1 1 16
AMP
040

SWP

362
REFUEL PUMP

1 2
SN_P N2 10 0.85G 413 WIPER SW.IN (INT) 11 GR 820 WR 973 4 0.85G 507 8 0.85G 507 17 0.85Br 803 2 0.75B SWING 0.85VG 822 3 0.75RW 319 29 0.75RW
ON (See page 2/2)

Br 834
SN_P SWING 23 0.85GR 414 WIPER SW.IN (CNT) 12 Lg 821 0.85B 720 9 0.85B 720 18 2B 764 2 0.75GW 320 24 0.75L

10 11 12 13 14 15 16 17 18 19 20
5 6 7 8 9
(NO TAPE)

(CN.D58)
SWP
YAZAKI
ST OIL PRESS. SENSOR

5 6 7 8
1 2 3 4
0.85B
0.85Y
0.85L
0.85V 415 WASHER SW. IN V 809 0.85BG 620 0.85BG 620 0.75RG 321 0.75RL

(CN.D76)
58W
YAZAKI
SN_P UPPER 12 13 10 19 19
TO CAMERA 2
0.85YG 416 POWER (24V) IN 0.85BrR 210 RELAY LEVER LOCK 0.75WB

1 2
SN_P TRAVEL 24 1 20 18 1
(RED TAPE)
K70

(CN.E8)
SUMITOMO
3
ROOM LAMP 3 2 1 1 2

366
5 6 7 8 9 10
1 2
E4 X29 HYD FAN&CTWT REMOVAL
B21

1 2 3
WASHER CONT. (+) 0.85WY 829 0.75WB 322 0.75WB 0.75LY

(CN.B6)
MT090
SUMITOMO
13 2 30 2

(CN.A46)
SDL
YAZAKI
YAZAKI

(CN.A55)
(CN.C8)

1
2
3
YAZAKI
1 2

1
2

YAZAKI
YAZAKI (CN.D85F)

(CN.D68)
MT090
SUMITOMO
0.85LY 418 WASHER CONT. (-) R 965 0.75GR 180 0.85WV 830 0.75YB 323 0.75LY 0.75BY

1 2
SN_ANG THROTTLE 25 3 24V,10W 1 SDL 1 2 3 1 1 25 3
090

SWP

SDL
4
2
5
3
6
1

1 2
SN_P OVER LOAD 26 0.85Gr 419 WINDOW CONTROL 9 B 966 2 (CN.B2) 4 5 6 0.75R 181 2 0.85B 756 2 0.75BY 324 20 0.75BY
(CN.B3) 4 0.75RY 890

1 2 3 4
3 4
(CN.C19)
OFF

1 2
3 4
(CN.C22)

0.85G 503 REV. SIG. 0.85G 485 G 888 G 888 YB 967 0.75R 182

0.85VW 170
KEY ON

0.85BO 428
YAZAKI
7 7 2 1 3 3 21

0.85Y 408
YAZAKI

0.85RY 840
BG 771

0.85LY 418
YAZAKI

5 FUEL TEMP. SENSOR

1
2

SWP
CN-A

SW GATE LEVER 0.85RY 520 STOP SIG. 0.85L 486 Y 843 Y 843 WB 968 0.85RY 844 CN-A 0.75R 183 0.75YG 342 0.75YG

0.85R 130
20 1 2 4 2 4 31

0.85RB 290
DOOR

0.85LgR 500
0.85BrR 010
2 G 831
(CN.B1) WASHER 0.75YG t℃

(CN.E9)
ECO-J
AMP
1
BATTERY CHARGE 8 0.85Br 515 WINDOW LIMIT SW. 4 ON L 530 1 0.85L 530 0.85GR 845 1 0.75R 184 5 1 R 189 0.75BW 336 22 0.75BY
B3

1 2
0.85W 400 WIPER MOTOR (CW) 0.85LR 827 YG 594 0.85YG 594 0.75R 185 0.75BR 344 0.75BR 0.75LW 2
AVcc 11 8
5 2 6 3 0.85RY 840 9
TO CAMERA 1
0.85BO 428 WIPER MOTOR (CCW) 0.85LB 828 G 850 0.85G 850 0.85WV 829 0.75G 345 0.75RL
AGND 1 6 LIMIT SW (NO TAPE) 3 7 1
M 13
(CN.C9)
YAZAKI

M4
1 2
3 4

SUMITOMO
0.85BW 420 GND 1.25B 710
X30 O 851 0.85O 851 0.75R 187 0.85B 755

1 4 2
AGND 14 10 (DOOR) 4 8 2 23 BOOST TEMP. SENSOR
24V

5
3
LW 533 R 960 LW 841 0.85LW 841 0.75WR 306 0.75WR
S53
SW AIR CLEANER 16 1 5 7

(CN.D67)
CN-A
YAZAKI

(CN.E10)
PACKARD
t℃

188
0.75BR
P-SW OPT1 3 VY 534
M3 1 OL 593 2 OL 593 B 961 2 YL 591 6 0.85YL 591 KNOB (RIGHT) RADIO AM/FM STEREO
P15 0.75Y 307 2 0.75GY
1
B51

2
1

1 2
24V,2A 0.75RL 2
(CN.C18)
1 2 3
4 5 6

S16
1 2
3 4

P-SW OPT2 GY 535 Y 843 Y 843 Y 962 GL 852 0.85GL 852 0.85Y 900 0.75Y 900
YAZAKI

17 2 4 3 7 1 26
(CN.C7)
YAZAKI
CN-A

SWP

WIPER MOTOR
SW FREE SWING GW 536 BG 613 BG 613 W 963 OL 853 0.85OL 853
P3 0.85O 902 0.85O 902
B2 0.75R 340 0.75RB
(CN.C23)

4 3 1 4 8 IDLE SW 2 3
YAZAKI

BUCK UP
HYD.OIL TEMP SENSOR HORN LOW
1
2
3

WG 537 0.85L 530 L 0.85L 904 0.75L 904 0.85LR 880 0.75R FUEL FILTER
CN-A

SW HBCV/TRVL ALM 18 3 6 3 8
(LEFT) 0.75BY 2

GND
S11

4 5 6 7 8
1

ACC
B92

(CN.A47)
SDL
YAZAKI

R(+)
L(+)
YL 538 0.85LR 0.85LR 827 0.85BG 625 L 0.85G 906 0.85G 906 0.75YB 490 t℃ 0.75GW 335 0.75GY

R(-)
SENSOR

L(-)
SW FILTER IND 5 1 7 4 2 YAZAKI (CN.D70) 27
24V,370Hz 0.75GY
LB 539 M 0.85LB 0.85LB 828 DOOR OPEN:CLOSE 0.85YG 594 Y WIPER 0.85W 908 0.85W 908 0.75BW 491 0.85B 760 0.75G
3
B88

(CN.D36)
PACKARD
SW ENG STOP 19 3 4 5 1 4
111dB
U1
DOOR CLOSE:OPEN 0.75WL 1

4 5 6 7 8
1
2 3
0.85BG 626 Y 0.85V 910
S31

(CN.B4)
62C
YAZAKI

(CN.D56)
SWP
YAZAKI

1 2
6 2 5 6 28

GrR
YAZAKI (CN.D71)

OW
(CN.C10)

3
1 2
3 4

Gr
YAZAKI

G
R

B
0.85G 0.85G 485
H4 0.85G 850 G 0.75WL 334

1 2
4 3 7 32
1ST.ACT
0.85L 0.85L 486
SPEAKER (R)
RL 167 0.85B 723 G X8 R5

2 3
6
DC/DC(24V/12V) 8 S/V(R) 8
FUEL LEVEL SENSOR EGR INTAKE TEMP. SENSOR
HORN HIGH

1
2
3
4
5
6
7
8
9
0.85B 5 1.25B 711 1 0.85BY 982 3 0.85BY 982 RL 162 1 RL 162 0.85O 851 1 O 0.85BY 901 9 0.75BY 901 0.85YR 882
CONVERTER

(CN.E11)
YAZAKI
(RIGHT) 0.75WR t℃
S32 1
(CN.C24)

R
B93 B86
YAZAKI

2 0.85YB 984 1 0.85YB 984 0.85YR 221 2 0.85YR 221 0.85B 724 2 O 0.85BO 903 10 0.85BO 903 0.85GL 492 2 0.75Y YAZAKI (CN.D72)
1
2

(CN.D7)
NMW
MITSUBISHI
0.85RB 291

1.25B 728
0.85Y 980
0.85L 981

RL 162

0.85BY 982
0.85BL 983

1 2
24V,370Hz

32
27
22
17
14
10
0.75GY

5
CN-A

24V 1 2 3 4 2
4 0.85BL 983 24V IN (MAIN) 6 0.85OR 225 GW 536 3 0.85GW 536 1ST.ACT 0.85BL 905 11 0.75BL 905 0.85BG 660 1 0.75B 0.85B 761

31 30 29 28
26 25 24 23
21 20 19 18

13
9 8 7 6
4 3 2 1
5 6 7 8 9 111dB
0.85LB 985 24V IN (BACKUP) RL 163 WG 537 0.85WG 537 S/V(L) 0.85GB 907 0.85GB 907

(CN.D57)
SWP
YAZAKI
2 2 4 12 YAZAKI(CN.D73)
YAZAKI

16 15
12 11
A13 GND 0.85B 708 YL 558 0.85YL 558 0.85YL 818 0.85YL 818 WATER TEMP. SENSOR

1 2
5 5 PA 13
ACC

(CN.E12)
SUMITOMO
SOCKET H5 SPEAKER (L)
12V OUT(BACKUP) 3 0.85RY 280 YB 570 6 0.85YB 570 KNOB (LEFT) (CN.B13) 14
PRESS. SENSOR (P1) B42 0.75RB 1 t℃
B1

1 2
CONTROLLER B

(CN.D74)
SWP
YAZAKI
12V OUT(MAIN) 0.85WR 281 V 571 0.85V 571
S15 0.85WB 909 0.85WB 909 0.85R 885

3
1 7 15 1 BEACON X2 0.75BY 2

1 2
X15 0.85B 712
12V
0.85WR 282 1 0.85BL 983 GND 4 0.85BW 709 Br 834 8 0.85Br 834
HORN
P2
0.85VG 911 16 0.75W 400 1 0.85B 762 2 0.75R

(CN.D45)
ECO-J
AMP
M8 YAZAKI 3
(CN.C25)

L
YAZAKI

1 2 3
POWER 24V 1 1.25W 109 YAZAKI YAZAKI 2 0.85LB 985 SHUT OFF 7 LG 842 9 0.85LG 842 0.85LW 841 6 L 17 0.75Y 410 2
1
2

(CN.B22)
S69
CN-A

1.25W 109a (CN.C16) (CN.C15) 0.85Y 980 0.85Y 980 0.85B 725 L 0.85RY 280 0.75BW 420 OVER HEAT SW.

9 10 11 12 13 14 15 16 17 18
5 6 7 8
12 10 7 18 3
YAZAKI(CN.B14) DUAL SWITCH M4
RADIO
X36
POWER 24V 0.85L 981 0.85L 981 0.85YL 591 Y 0.85WR 281 ISUZU(CN.E19)
X35
11 11 4
CIGAR LIGHTER MUTE YAZAKI(CN.B15) (RECIVER DRYER) S52 CAM ANG (MRE) SENSOR

4 5 6 7 8
1
0.85BY 982 0.85BY 982 0.85BG 627 Y 0.85BW 709

(CN.B5)
62C
YAZAKI
22 12 5
24V,5A S33 YAZAKI(CN.B16)
B44
4 5 6 7
2 3

(CN.A56)

(CN.D77)
090
SUMITOMO
GND_2 2 1.25BG 602 0.85BL 983 13 0.85BL 983 0.85GL 852 3 G 0.85GW 943 2 1 Vcc

YAZAKI
(CN.A28)

(CN.E13)
SUMITOMO
LIMIT SW 12V OUTPUT PRESS. SENSOR (P2)
YAZAKI

2ND.ACT
E51

1 2

1 2 3
1.25BG 602a 0.85B 713 0.85YR 220 0.85RY 280 0.85RY 280 0.85B 726 G

2 3
1.25W 944 OUT(PULSE)

SDL
13
(WINDOW)
14 8
(FOR RADIO)
1 3
B87

1 2 3 4
S/V(R)
PA

P-G
1

GND_3 5 0.85B 702 YAZAKI YAZAKI YAZAKI (CN.A30F) 0.85WR 281 15 0.85WR 281 0.85OL 853 1 O 0.75W 401 1 2 GND
X6

(CN.D46)
ECO-J
AMP
(CN.C14) (CN.C13)
S34

1 2 3
16 0.85B 702a O 590 6 O 590 0.85BW 709 16 0.85BW 709 0.85B 727 2 O 0.75L 411 2
S54

(CN.B17)
SWP
YAZAKI
N-G GND 9 BG 614 3 BG 614 17 2ND.ACT 0.75BW 421 3
HORN VOL.SW MAGNET CLUTCH
Y8 SUPPLY PUMP PCV1

1 2
9 10 11 12 13 14 15 16 17 18
1 2 3 4

20 YAZAKI( CN.A31F) 2 18 S/V(L) AIR SUSPENSION (COMPRESSOR)

(CN.D78)
SWP
YAZAKI
9 10
L-G

(CN.E14)
MT090
SUMITOMO
GND_A 10 6 3 5 2
Y33

1
B43
(CN.A49)
SDL
YAZAKI

WINDOW OPEN:CLOSE

1 2
5 2
M
1.25GR 875 0.85YR 221 1.25R 0.85W 400 0.75W 400 1.25W 944 1.25G
A-G
21
6
S70 4
7
1
8
WINDOW CLOSE:OPEN
1
4 1.25B 714 0.85B 720
1
2 1.25B 0.85BW 420
1
2 0.75BW 420 PRESS. SENSOR (N1)
1 1

4 0.85Y 410 3 0.75Y 410 0.85W 402 1 0.75R 316 17 Y

5 6 7 8

(CN.D47)
ECO-J
AMP
E3
10

SUPPLY PUMP PCV2

1
2
3
4
5
6
7
8
9

CARLING

(CN.B18)
MT090
SUMITOMO

1 2 3
SOL POWER SAVE 7 G 812 YAZAKI (CN.A26F) 0.85YR 222 1 0.85L 411 4 0.75L 411 0.85Lg 412 2 0.75L 317 18 T
VC2 24V

1 2

(CN.E15)
MT090
SUMITOMO
SOL FAN REVERSE 3 Lg 813 (CN.C12) 0.85R 1.25GR 875 0.85B 721 2 0.85Lg 412 5 0.85Lg 412 0.85BW 422 3 0.75G 318 19 OB 2
24V
1 2 3
4 5 6

PUMP
Y34
(CN.C11)
YAZAKI

1 2
8 0.85LR 881 0.85W 1.25B 714 0.85G 413 6 0.75G 413 0.75BL 692b 15 0.75BW 1
LAMP 70W
CN-A

PUMP

(CN.D39)
SWP
YAZAKI
0.85YR 882 VR 230 VR 230 0.85GR 414 0.85GR 414 0.75Y 900 0.75RG 394 0.75RW
S9 S85
14 1 7 1 16
(CAB) YAZAKI (CN.A27F)
B40 Y7

1 2
15 1.25WR 235 2 1.25WR 235 0.85V 415 8 0.85V 415 0.75BY 901 2 POWER 0.75RW 396 20 0.75WB
18 0.85LR 240 3 0.85LR 240 0.85YG 416 9 0.85YG 416 PRESS. SENSOR (N2) 11
INJ1 (#1)
ENG STOP BEACON<EU>

(CN.E16)
MT090
SUMITOMO
0.85YL 818 1.25WR 148 0.85WR 148 0.85Gr 419 0.85Gr 419 0.75W 403 1.25R 374 1.25W
BUCKET CLOSE (PWM) 17
E3 MEMORY CLEAR 4 10 1 5 5 1
Y63

(CN.D48)
ECO-J
AMP
X23

1 2
1 2 3
19 YAZAKI (CN.A28F) BG 635 0.85LG 302 5 0.85LG 302 0.85WL 430 11 0.85WL 430 0.75G 413 2 1.25G 375 1 1.25L 1 2
YAZAKI (CN.A37M) P1

(CN.D40)
ECO-J
AMP
0.85R 1.25GR 876 BrY 084 LB 539 6 0.85LB 539 0.85BL 450 12 0.85BL 450 0.75BW 423 3 0.75L 904 1 1.25Y 376 7 1.25WR
IMMOBILIZER
X9
24V YAZAKI (CN.A37F)
Y11

1 2
VG 531 0.85W 1.25B 715 0.85Y 408 7 0.85Y 408 9 10 9 10 0.85GW 444 13 0.85GW 444 0.75BL 905 2 FLOW 1.25L 377 3 1.25GR 3
0.85G 906 BG 637
YAZAKI (CN.A33F) LAMP 70W 0.85LY 418 0.85LY 418 0.85VG 445 0.85VG 445 1.25R 378 1.25WR INJ5 (#2)
ARM CLOSE (OUT) 3 8 6 3 6 3 14 6
(CAB) DIAG SW PRESS. SENSOR

10
YAZAKI (CN.A33M) YAZAKI (CN.A29F)

1
2
3
4
5
6
7
8
9

1
2
3
4
5
6
7
8
9
X24
5 2 5 2
B22

(CN.E17)
MT090
SUMITOMO
ARM CLOSE (RTN) 6 0.85GB 907 M8 M8 BG 634 0.85BO 428 9 0.85BO 428 0.85LR 446 15 0.85LR 446 1.25Br 379 2 1.25LW 6 1
(PILOT SWING)
YAZAKI (CN.A36M) 4 1 4 1
Y69

1 2
FAN SPEED (OUT) 1 0.85W 908 PB 083 P 040g 10 P 040g 7 8 7 8 0.85YB 490 16 0.75YB 490 1.25R 149 12 0.75RL 2 2
TO CONTROLLER C YAZAKI (CN.A36F)

0.85WR 148
0.85WB 909 YAZAKI YAZAKI PG 041g PG 041g 0.85GL 492 0.85GL 492 0.85W 404 1.25B 380 1.25RB

0.85BG 620
0.85LG 302
FAN SPEED (RTN)

0.85LB 539

0.85B 722
4 11 17 1 14

0.85LG 842

(CN.D49)
ECO-J
AMP
(CN.C17) (CN.C32) CARLING CARLING PROPORTIONAL S/V

1 2 3
OPT PRESS (OUT) 2 0.85V 910 1.25W 110 1 WB 949 12 WB 949 VC2 VC2 0.85BG 660 18 0.85BG 660 0.85GR 414 2 1.25BW 381 10 1.25GB
X25 A BG 631 1 BG 631 BOOM INJ3 (#3)

(CN.D41)
SWP
YAZAKI
OPT PRESS (RTN) 5 0.85VG 911 WL 266 2 BW 950 13 BW 950 (CN.B7) (CN.B10) GrR 532 19 0.85GrR 532 0.85BW 424 3 0.85O 902 1 1.25L 382 8 1.25R
B RL 166 2 RL 166 SOL3
Y59

1 2

(CN.E18)
MT090
SUMITOMO
(CN.E20)
YAZAKI
SHLD GND 8 0.85G 505 3 0.85GW 943 14 0.85GW 943 LW 533 20 0.85LW 533 0.85BO 903 2 UP 1.25RL 383 4 1.25LY 1
C P 040 3 P 040h
Y65

1 2
2 3
1 5 6
7 0.85RY 521 4 YL 538 21 0.85YL 538 1.25R 380 13 1.25RB 2
X5
EST CONNECTOR A

PRESS. SENSOR (NO TAPE)

PG 041 PG 041h
B26
1 2 3

D 4
7 8 9 10 11 12 13 14

S-G BOOT_CNT 11 YR 067 YB 570 5 LB 559 22 LB 559 1.25RB 385 9 1.25LR

(PILOT UPPER)
3 2 1
14 13 12 11 10 9 8 7

PL 081 PL 081 ARM

F A B
(CN.52)
HD10
DEUTSCH

E 5

(CN.D42)
SWP
YAZAKI
YR 068 V 571 0.85G 906
(CN.A48)
SDL
YAZAKI

FWE
G

12 6 1
F 6 S22 SOL2
Y60 INJ2 (#5)

6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22

1 2
P 040e 0.85W 405 0.85GB 907
H

SW_IN12 9 7 1 2 CLOSE

(CN.D50)
ECO-J
AMP
(CN.A23)

(CN.D10)
D
SUMITOMO

(CN.E19)
MT090
SUMITOMO
YAZAKI

1 2 3
PG 041e 0.85V 415

20 19 18 17
16 15 14 13
12 11 10 9
SW_IN13 10 8 OVER LOAD WARNING <EU>
S13 2 1

8 7 6 5
4 3 2 1
CAN FREE SWING <NA> (RED TAPE)
4 5 6

Y64
SDL

1 2
YR 541 P 040j 0.85BW 425

(CN.E21)
YAZAKI
9 3 2
X31
6 5 4

YAZAKI (CN.A34F) LED

(CN.A26)
SDL
YAZAKI

J BUCKET
3 4 5 6
1

(CN.D43)
SWP
YAZAKI
O 542 PG 041j 0.75R 185

10 8 13
10 1

9 4
(CN.A54)
YAZAKI (CN.A35F) SOL1
Y61

YAZAKI

1 2
TXD 4 PL 056 LG 833 11 0.85YL 818 2 CLOSE
PRESS. SENSOR INJ6 (#4)

SDL
B27

5 6 7 8 9 10
3 4
RXD PW 055

1 2 3 4 5
2

12 12 9 10 9 10 (BLUE TAPE)
A/C PANEL (PILOT TRAVEL)
EST CONNECTOR B

7 8 9 10 11 12
6 5 4 3 2 1

(CN.E20)
MT090
SUMITOMO
RS232C_TXD 3 Y 065a 1.25B 703 13 6 3 6 3 8 1

(CN.A57)
OPT POWER &
10

YAZAKI
Y70
DEUTSCH

1
2
3
4
5
6
7
8
9

1
2
3
4
5
6
7
8
9
5 2 5 2
X26 X3

1 2
(CN.A25)

RS232C_RXD 10 YL 066a 1.25BG 603 14 1.25B 749 1 0.85W 406 1 4 2

A/C UNIT

SDL

(CN.D51)
ECO-J
AMP
YAZAKI (CN.A32M) 4 1 4 1 HYDRAULIC MOTOR (FAN)

1 2
M27

1 2 3

(CN.H1)
DEUTSCH
RS232C_GND 2 BY 069 1.25W 205 2 TRAVEL ALARM <NA> 0.85YG 416 2
(See page 2/2) 7 8 7 8
DT

YAZAKI (CN.A32F)

(CN.H0)
58X
X4 (Y32)
0.85WG 537

0.85GW 536
GND P 040i 0.85BW 426
0.85BG 623

0.85BG 622

1 2
5 3 3 10

0.85YR 223
0.85Br 834

3 4
1 2
CARLING CARLING INJ4 (#6)
GND 13 WB 245 1 TO GPS UNIT 4 BG 633
S28 VC2 VC2 WL 260 1

(CN.E21)
MT090
SUMITOMO
CAN_H 6 P 040d W 060a 7 Y 065b 2 5 BG 632 (CN.B11) (CN.B9) LY 806 2 1.25WR 944 1 13 1
X27 Y66

0.85BW 429

1 2
0.85Gr 419
PG 041d WL 061a YL 066b 1.25RB 150 V 050 YR 805 0.85W 908 1.25BW 945

0.85W 409
CAN_L 14 12 3 1 6 3 1 2 9 2
16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1

WR 062 BG 636 0.85G 506 PL 080 RL 167 VY 534 0.85BW 909

+5V_OUT 11 4 4 2 7
X32 13 4 2
CONNECTOR
DIAGNOSTIC

FREQUENCY_IN BL 064a 0.85Br 517 0.85G 507 GY 535 0.85R 188

(CN.A27)
DIAG
AMP

1 11 3 8 5 5 3 2 1 3
OPTION EXSHAUST PRESS
8 7 6 5 4
3
(CN.A24)
SDL
YAZAKI

FREQUENCY_GND 9 Y 065a 1 W 060b 4 9 2 P 040k G 850 6 YAZAKI 0.85Lg 813 4 1.25RW 258 1 R
PRESS. SENSOR SENSOR
TO DRM LINE
B45

2
3
1
YL 066a WL 061b PG 041k (FOR FAN REVERSE) O 851 SDL 1.25Br 813 Y
4 3 2 1

AVcc 7 3 5 10 8 7 2
(See (CN.D52) (HBCV)
(CN.A29)

X33
YAZAKI

YR 067
2 1

SW_1 15 6 6 P 040f 11 PG 041i 3 0.85Y 085 GL 852 8 0.75WB 331 1

(CN.H22)
58X

(CN.D32)
SUMITOMO
YAZAKI (CN.B24)
1 2 3
7 8 9 10 11 12 13

60B 798
page 2/2)
SDL

B89

1 2 3
BY 069 BL 064b PG 041f PB 082 0.85BG 629 (FOR CRANE) OL 853 1.25W 405 G 831 0.75P 332
(Y31)
SW_2 16 8 7 12 1 9 1 1 2

1 2
(CN.B23)
PA
YAZAKI

YAZAKI (CN.B25)

(CN.G6)
ECO-J
AMP
10 9

1 2 3
SW_3 8 9 8 1.25B 740 13 4 (NOT USED) 3 6 BG 640 10 1.25Gr 425 2 0.85OG 832 2 0.75BW 333 3 M10
5 14 VG 051 6 2 5 10 9 1.25BW 445 3

(CN.D84)
MT090
SUMITOMO
WL 267
LEVEL SWITCH
10

S55
4 5 6

3 6
4
5
6
1
2
3
7
8
9

1
2
3
4
5
6
7
8
9

10 15 9 1 4

1 2
M8 8 7 2 5 (RESERVE TANK) EXSHAUST TEMP
2 BG 630 2 16 10 1 4
SENSOR (CNT)
B90

(CN.D79)
SWP
YAZAKI
CARLING 8 7 1.25WR 142 1.25WR 142 0.85GrR 532
0.85BG 624

0.85BG 621

15 11 1 2
0.85V 571
0.85YB 570

0.85YL 558

YAZAKI(CN.A43) VC2
S64 CARLING

1 2
0.85YR 370 0.85YR 370 0.85BG 651 0.75Y 346 t℃

(CN.D33)
YAZAKI
21 12 (CN.B12) 2 1 1
VC2 PRESS. SENSOR
0.85BG 628 0.85LR 373 0.85LR 373 B83 0.75BW 347

2 1
9 7 (CN.B8) 3 2
0.85Y 301 0.85BrR 301
(PILOT ARM CLOSE)
22 4
040a,041a

10 0.85LG 302 5 0.85LG 302 0.85WL 430 1 S62

(CN.D54)
ECO-J
AMP
PRESS. SWITCH EXSHAUST TEMP
640

302

1 2 3
SN_P BOOM UP 23 0.85GW 444 0.85GW 303 6 0.85GW 303 0.85VG 445 2
(AIR CLEANER) SENSOR (FNT)
SN_P ARM CLOSE 12 0.85VG 445 P 040a 7 P 040 0.85BL 450 3 B91

(CN.D80)
SWP
YAZAKI
t℃

(CN.D34)
YAZAKI
0.85WR 149

SN_P BCKT CLOSE 24 0.85LR 446 PG 041a 8 PG 041 0.85LW 533 2 1.25Y 0.75R 348 1

1 2

2 1
13 V 050 9 V 050b 0.85BG 650 1 1.25Y 0.75BW 349 2
25 VG 051 10 VG 051b
PRESS. SENSOR
(PILOT BUCKET CLOSE)
B84 267,559
VG 051b
V 050b

26 PB 082 11 PB 082 771,835

CTWT REMOVAL

(CN.D86)
SWP
5 6 7 8
1 2 3 4
SW KEY ON 7 0.85G 504 A V 050 G 351 345 PL 080 12 PL 080 0.85WL 431 1
S71 (OPTION)

(CN.D55)
ECO-J
AMP
PRESS. SWICH AIR INTAKE SENSOR 1
DEUTSCH

B95
336

1 2 3
120ohm

20 C 0.75W 313 366 BrY 084 13 BrY 084 0.85LR 446 2

(CN.D4)

1.25R 149 (FILTER INDICATOR) MASS & TEMP 2 (See page 2/2)
C

334

8 B VG 051 0.75G 315 362 14 0.85BL 451 3 B 772 3

(CN.D81)
SWP
YAZAKI
0.85WL 430 0.85BG 652 1.25B BrR 350 t℃

0.85BG 680
1.25B 780
AVcc 11 1 2 BG 771 4
7 8 9 10 11 12 13 14
4 5 6

1 2
0.85BW 693a

0.85BW 691a

Caterpillar 305e - Mini Hyd Excavator - Service Manual - PDF Download
No ratings yet
Caterpillar 305e - Mini Hyd Excavator - Service Manual - PDF Download
31 pages
OM936 en Schulung
67% (3)
OM936 en Schulung
88 pages
Pin3 Electrical Schematics - Hyperlinked
No ratings yet
Pin3 Electrical Schematics - Hyperlinked
72 pages
Komatsu PC200-8, PC200LC-8, PC220-8, PC220LC-8 Electrical
100% (5)
Komatsu PC200-8, PC200LC-8, PC220-8, PC220LC-8 Electrical
7 pages
Compact Wheeled Excavators: Product Range
No ratings yet
Compact Wheeled Excavators: Product Range
16 pages
Case 130c Manual
No ratings yet
Case 130c Manual
1,993 pages
Komatsu PW168-11E1 H68051-UP Shop Manual VENBM75000
100% (1)
Komatsu PW168-11E1 H68051-UP Shop Manual VENBM75000
58 pages
Uenbm00451 HB365LC NLC-3 1910
No ratings yet
Uenbm00451 HB365LC NLC-3 1910
3,080 pages
R125lcr-9a R125lcrd-9a Demo PDF
100% (1)
R125lcr-9a R125lcrd-9a Demo PDF
37 pages
Sen06892-04 083754
No ratings yet
Sen06892-04 083754
4,844 pages
Manual Excavadora CX460 Tier Dos.
No ratings yet
Manual Excavadora CX460 Tier Dos.
578 pages
Hyundai HL960 Workshop Manuel
No ratings yet
Hyundai HL960 Workshop Manuel
622 pages
PC600-8 K50001 Uen00128-01 0609
No ratings yet
PC600-8 K50001 Uen00128-01 0609
986 pages
PC490 11
No ratings yet
PC490 11
2,898 pages
Crawler Hydraulic Excavator: Sany Heavy Machinery Limited
No ratings yet
Crawler Hydraulic Excavator: Sany Heavy Machinery Limited
681 pages
Sales Manual +ZX250 - 290LC-5B 【完成版】
No ratings yet
Sales Manual +ZX250 - 290LC-5B 【完成版】
96 pages
Group 2 Electrical Circuit (1/2) : HL7407 1WIRG1
No ratings yet
Group 2 Electrical Circuit (1/2) : HL7407 1WIRG1
19 pages
Jurnal Alat Berat
No ratings yet
Jurnal Alat Berat
10 pages
New Holland E45B SR, E50B SR, E55B Mini Excavator Service Repair Manual
No ratings yet
New Holland E45B SR, E50B SR, E55B Mini Excavator Service Repair Manual
21 pages
John Deere 300D Articulated Dump Truck 2
No ratings yet
John Deere 300D Articulated Dump Truck 2
1,348 pages
Troubleshooting EX1200 7
No ratings yet
Troubleshooting EX1200 7
509 pages
ZX200 4H (T1GR E 00) Service Manual
100% (1)
ZX200 4H (T1GR E 00) Service Manual
218 pages
Wenbm00230 Pc45mr-5e0 Pc55mr-5e0
No ratings yet
Wenbm00230 Pc45mr-5e0 Pc55mr-5e0
1,266 pages
Shop Wa600 8e0
No ratings yet
Shop Wa600 8e0
4,184 pages
Bager New Holand E50
No ratings yet
Bager New Holand E50
559 pages
Adaptadores para Conectores Deutsch
No ratings yet
Adaptadores para Conectores Deutsch
2 pages
Case CX145CSR Operator Manual
No ratings yet
Case CX145CSR Operator Manual
306 pages
View All Callouts: Function Isolation Tools
No ratings yet
View All Callouts: Function Isolation Tools
9 pages
TTNFC EN 00 - Circuit
No ratings yet
TTNFC EN 00 - Circuit
18 pages
Powerful and Productive: Superb Profitability
No ratings yet
Powerful and Productive: Superb Profitability
8 pages
Hydraulic Diagram, With Option Components: Service Information
No ratings yet
Hydraulic Diagram, With Option Components: Service Information
4 pages
Operación Sistema Hyd. 345C
No ratings yet
Operación Sistema Hyd. 345C
160 pages
Service Manual: Skid-Steer Loader
No ratings yet
Service Manual: Skid-Steer Loader
1,082 pages
BSM 00840345EN 000 00.orig
100% (1)
BSM 00840345EN 000 00.orig
1,024 pages
CLG922E III Service Manual201503001-En
No ratings yet
CLG922E III Service Manual201503001-En
981 pages
SM-New Holland T5030, T5040, T5050, T5060, T5070 Tractor 4
No ratings yet
SM-New Holland T5030, T5040, T5050, T5060, T5070 Tractor 4
1,752 pages
2510 Cruz-Crane Carrier Mounted Serv. Man.
No ratings yet
2510 Cruz-Crane Carrier Mounted Serv. Man.
173 pages
6015B Manual de Operación y Mtto
No ratings yet
6015B Manual de Operación y Mtto
236 pages
LGB BFC 00000
No ratings yet
LGB BFC 00000
264 pages
Todeu90 en 00 (20231222)
No ratings yet
Todeu90 en 00 (20231222)
269 pages
Komatsu PC33E-6 Shop Manual SEN06975-04
No ratings yet
Komatsu PC33E-6 Shop Manual SEN06975-04
175 pages
Sb60 08 Electrical
100% (1)
Sb60 08 Electrical
39 pages
SM BC972,1172 RB 101 570 80 Up 00891488.d08
No ratings yet
SM BC972,1172 RB 101 570 80 Up 00891488.d08
798 pages
Schéma Hy 277B 02
No ratings yet
Schéma Hy 277B 02
2 pages
Manual XEF250,+XEF450,+XXF250,+XXF450
No ratings yet
Manual XEF250,+XEF450,+XXF250,+XXF450
145 pages
Kubota SSV65 WSM Manual
No ratings yet
Kubota SSV65 WSM Manual
544 pages
Procedure Manual For Visual Machine Check (PC200-7, 8)
No ratings yet
Procedure Manual For Visual Machine Check (PC200-7, 8)
25 pages
Komatsu PC58MR-5E0 Shop Manual WENBM00240
No ratings yet
Komatsu PC58MR-5E0 Shop Manual WENBM00240
318 pages
Repuestos 336d 336dl - PDF Versión 1
No ratings yet
Repuestos 336d 336dl - PDF Versión 1
912 pages
Uen R 65410001
No ratings yet
Uen R 65410001
40 pages
Cecgu S5 SM DX 420LC-7K 950106-02922 C en PDF
No ratings yet
Cecgu S5 SM DX 420LC-7K 950106-02922 C en PDF
520 pages
SM 327B-330B Multi-Simple en
No ratings yet
SM 327B-330B Multi-Simple en
1,400 pages
325L MERI G Hydraulic and Electronic Systems Checking Procedures
No ratings yet
325L MERI G Hydraulic and Electronic Systems Checking Procedures
77 pages
973C 3RZ PDF
No ratings yet
973C 3RZ PDF
2 pages
Workshop Manual Zx68usr
No ratings yet
Workshop Manual Zx68usr
378 pages
Linked PDF
No ratings yet
Linked PDF
60 pages
ZE550EK-10-11Z-Technical Specifications
No ratings yet
ZE550EK-10-11Z-Technical Specifications
8 pages
R55 9
No ratings yet
R55 9
476 pages
DG743 PDF
No ratings yet
DG743 PDF
977 pages
LeeBoy Gear Box 360 Service Manual 01 2014
No ratings yet
LeeBoy Gear Box 360 Service Manual 01 2014
64 pages
Section 2 Drawbar Circle and Moldboard
No ratings yet
Section 2 Drawbar Circle and Moldboard
38 pages
Case Y487
No ratings yet
Case Y487
22 pages
SM - CX300C Tier 4 - EN
No ratings yet
SM - CX300C Tier 4 - EN
2,011 pages
SM CX15b CX18B EN
No ratings yet
SM CX15b CX18B EN
607 pages
Sm Cx40b-Cx50b En
No ratings yet
Sm Cx40b-Cx50b En
780 pages
SM - CX330 Tier3 - CX350 Tier3 - EN
100% (1)
SM - CX330 Tier3 - CX350 Tier3 - EN
650 pages
SM - TX130-30 - TX130-33 - EN
No ratings yet
SM - TX130-30 - TX130-33 - EN
415 pages
E Technical Training Mk2.0
No ratings yet
E Technical Training Mk2.0
100 pages
SM - TX130 - 170 Tier3 - EN
No ratings yet
SM - TX130 - 170 Tier3 - EN
419 pages
SM TX130-TX140-TX170 EN
No ratings yet
SM TX130-TX140-TX170 EN
501 pages
SM - CX240B SL - EN
No ratings yet
SM - CX240B SL - EN
119 pages
Service Manual: (Tier 2) Crawler Dozer
100% (1)
Service Manual: (Tier 2) Crawler Dozer
425 pages
SM 1045 EN
100% (1)
SM 1045 EN
338 pages
SM 1047 EN
100% (1)
SM 1047 EN
354 pages
Spirit: Instructions
No ratings yet
Spirit: Instructions
126 pages
50-7088 SM Power Train - Chassis
No ratings yet
50-7088 SM Power Train - Chassis
98 pages
Seed Hawk: Instructions
No ratings yet
Seed Hawk: Instructions
122 pages
C35943 PowerShuttle FC English
No ratings yet
C35943 PowerShuttle FC English
11 pages
547638en 1.0.0 1600325824
No ratings yet
547638en 1.0.0 1600325824
126 pages
TD300 900
No ratings yet
TD300 900
102 pages
Service and Parts Manual: Serial Number Range 13400001 - Up
No ratings yet
Service and Parts Manual: Serial Number Range 13400001 - Up
244 pages
93079-SCH-A92.6 Mec
No ratings yet
93079-SCH-A92.6 Mec
126 pages
Mr547792en 12 01 01 PDF
No ratings yet
Mr547792en 12 01 01 PDF
534 pages
CEADX20601
No ratings yet
CEADX20601
249 pages
547309en 1.0.0 PDF
No ratings yet
547309en 1.0.0 PDF
114 pages
Mr547792en 12 01 01 PDF
No ratings yet
Mr547792en 12 01 01 PDF
534 pages
Experiment 1 Group 1
No ratings yet
Experiment 1 Group 1
7 pages
Tutorial - Risk Management in (Bio) Pharmaceutical and Device Industry
No ratings yet
Tutorial - Risk Management in (Bio) Pharmaceutical and Device Industry
63 pages
Intra Report
No ratings yet
Intra Report
73 pages
Demag
No ratings yet
Demag
1 page
Holiday Homework XII 2025-26
No ratings yet
Holiday Homework XII 2025-26
2 pages
Customer Churn Prediction Using Machine Learning Algorithms
No ratings yet
Customer Churn Prediction Using Machine Learning Algorithms
5 pages
Reactor Project Ammonia Synthesis
100% (1)
Reactor Project Ammonia Synthesis
21 pages
OBLG. Appelgren Engstr M - Mothers in Same Sex Relationships Striving For Equal Parenthood
No ratings yet
OBLG. Appelgren Engstr M - Mothers in Same Sex Relationships Striving For Equal Parenthood
10 pages
Igbt Hmi Wincc Manual
No ratings yet
Igbt Hmi Wincc Manual
119 pages
GSA Report Qena
No ratings yet
GSA Report Qena
4 pages
Alfa Laval T6: Gasketed Plate-And-Frame Heat Exchanger For A Wide Range of Applications
No ratings yet
Alfa Laval T6: Gasketed Plate-And-Frame Heat Exchanger For A Wide Range of Applications
2 pages
Eduvos Brochure 2023
No ratings yet
Eduvos Brochure 2023
23 pages
Topic 11: Control Management: What Is Controlling?
No ratings yet
Topic 11: Control Management: What Is Controlling?
4 pages
Each Section Takes The Same Amount of Time To Travel: Physical Science Kepler's Laws Worksheet
No ratings yet
Each Section Takes The Same Amount of Time To Travel: Physical Science Kepler's Laws Worksheet
2 pages
Sistem Persamaan Linier 3 Variabel
No ratings yet
Sistem Persamaan Linier 3 Variabel
8 pages
Enrichment
No ratings yet
Enrichment
2 pages
Columbian Exchange DBQ
100% (1)
Columbian Exchange DBQ
12 pages
Force and Stress
No ratings yet
Force and Stress
8 pages
Narrative Report On Critical Content
No ratings yet
Narrative Report On Critical Content
2 pages
Gerador de Solda Trailblazer 302D
No ratings yet
Gerador de Solda Trailblazer 302D
81 pages
Ee 307
No ratings yet
Ee 307
6 pages
Learning Deep Learning Theory and Practice of Neural Networks Computer Vision Natural Language Processing and Transformers Using TensorFlow 1st Edition Magnus Ekman Instant Download
100% (2)
Learning Deep Learning Theory and Practice of Neural Networks Computer Vision Natural Language Processing and Transformers Using TensorFlow 1st Edition Magnus Ekman Instant Download
44 pages
BENZ - Text - v12 - 06 - Es - Bloc de Notas
No ratings yet
BENZ - Text - v12 - 06 - Es - Bloc de Notas
7 pages
Innovation and Leadership Presentation
No ratings yet
Innovation and Leadership Presentation
26 pages
A VLSI Architecture For Signed Multipliers
No ratings yet
A VLSI Architecture For Signed Multipliers
4 pages
Recruitment and Selection Process in IT Industries - A Case Study
No ratings yet
Recruitment and Selection Process in IT Industries - A Case Study
23 pages
Paper 2 Prep 2
No ratings yet
Paper 2 Prep 2
2 pages
Wireless Plotter (Mini CNC Plotter + Bluetooth) - 6 Steps (With Pictures) - Instructables
No ratings yet
Wireless Plotter (Mini CNC Plotter + Bluetooth) - 6 Steps (With Pictures) - Instructables
5 pages
CCPilot XL - Technical Manual - For CCpilot XL 3.0
No ratings yet
CCPilot XL - Technical Manual - For CCpilot XL 3.0
31 pages